Page 2: System
TOYOTA MOTOR CORPORATION reserved. ©2000 TOYOTA MOTOR CORPORATION rights This book may not be repro· duced or copied, in whole or in part, without the i4, 1999 Oi-990714-00 written permission of Toyota Motor Corporation. 14,2000 04-000314-01 First Printing: Jul. Fourth Printing: Mar.
Page 3 CAUTION This manual does not include all the necessary items about repair and service. This manual is made for the purpose of the use for the persons who have special techniques and certifications. In the cases that non-specialized or uncertified technicians perform repair or service only using this manu� al or without proper equipment or tool, that may cause severe injury to you or other people around and also cause damage to your customer's vehicle.
Page 4 NOTE: The scr e en t o ned sect i o ns bel o w i n VOLUME (Pub. RM744U1). l3l!iJ ENGINE MECHANICAL EMISSION CONTROL lffil COOLING 1!!1 LUBRICATION IGNITION ml STARTING I!III CHARGING CLUTCH li!J}3 C56 MANUAL TRANSAXLE li!J}3 C60 MANUAL TRANSAXLE r.:.tJ U240E AUTOMATIC TRANSAXLE...
Page 5: Engine Mechanical
ENGINE MECHANICAL CO! H C ....EM-1 EM-3 COMPRESSI O N ... . VALVE CLEARANCE .. EM-I EM-1 3 I G NI T I O N TI M I N G ... I D LE SPEED .. EM-1 4 EM-1 5 TI M I N G CHAI N ..
Page 6 EM-1 COIHC ENGINE MECHANICAL CO/HC INSPECTION HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. INSTALL CONDITIONS Engine at normal operating temperature Air cleaner installed Air pipes and hoses of air induction system connected {c ) AI! accessories switched OFF All vacuum lines properly connected...
Page 7 EM-2 ENGINE MECHANICAL CO/HC CO/HC concentration does not comply with regulations, lf the troubleshoot in the order given below. • Check heated oxygen sensor operation (See page 01-49). • See the table below for possible causes, and then inspect and correct the applicable causes if neces sary.
Page 8 EM-3 ENGINE MECHANICAL COMPRESSION COMPRESSION INSPECTION HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure_ WARM UP AN D STOP EN GI N E Allow the engine to warm up to normal operating temperature. REMOVE IGN ITION COIL (See page IG-6) REMOVE SPARK PLUGS IN SPECT CYLI N DER COMPRESSION PRESSURE...
Page 9: Valve Clearance
EM -4 VALVE CLEARANCE ENGINE MECHANICAL VALVE CLEARANCE ADJUSTMENT HINT: Inspect and adjust the valve clearance when the engine is cold. REMOVE CYLINDER HEAD COVER (See page EM-18) SET NO. 1 CYLINDER TO TDCICOMPRESSION Turn the crankshaft pulley, and align its groove with the "0"...
Page 10 EM-5 VALVE CLEARANCE ENGINE MECHANICAL ·- Turn the crankshaft 1 revolution {360 " ) and align the mark as above (See procedure in step 2). Check only the valves indicated as shown. Measure the valve clearance (See procedure in step (a)). 2ZZ-GE: A10J66 1ZZ -FE:...
Page 11 EM-6 ENGINE MECHANICAL VALVE CLEARANCE Determine the replacement valve lifter size according to these Formula or Charts: • Using a micrometer, measure the thickness of the removed lifter. • Calculate the thickness of a new lifter so the valve clearance comes within the specified value. T ..
Page 12 VALVE E M-7 CLEARANCE ENGINE MECHANICAL ..Thickness used shim A ..Measured valve clearance . Thickness new shim Intake: N T + (A - 0.20 mm (0.008 in.)) Exhaust: N T+ (A- 0.40 mm (0.016 in.)) • Select a new shim with a thickness as close as possible to the calculated values.
Page 13 � ""> "> O tr ' " -==· 1 ·· 1 - - '"'''T'[-- ��co � -.., ---- · , · :·: -, - ,_,' -· 1ZZ-FE: Valve Lifter Selection Chart {Intake) N NIO. N \i ; :9. � 1 � R � �...
Page 16 VALVf CLEARANCE EM-11 ENGINE MECHANICAL...
Page 17 EM-12 ENGINE MECHANICAL VALVE CLEARANCE 1 ZZ-FE: REINSTALL CAMSHAFT Reinstall the valve lifters (See page EM-61). Align the crankshaft pulley groove with the timing mark "0" of the timing chain cover. Hold the timing chain, and place the intake camshaft and timing sprocket assembly.
Page 18: Ignition Timing
Connect the TOYOTA hand-held tester or scan tool to the DLC3. (b ) Please refer to the TOYOTA hand�held tester or OBD!I scan tool operator's for further details. CONNECT TIMING LIGHT TO ENGINE INSPECT IGNITION TIMING Using a timing light, check the ignition timing.
Page 19: Idle Speed
Connect the TOYOTA hand-held tester or scan (a ) 08011 tool to the DLC3. Please refer to the TOYOTA hand-held tester or OBD!I scan tool operator's manual for further details. INSPECT IDLE SPEED ( a) Race the engine at 2,500 rpm for approx.
Page 20: Timing Chain
EM-15 ENGINE MECHANICAL fiMING CHAIN TIMING CHAIN COMPON ENTS Upper Apr o n S Front Fender • Dr i v e Bel t Upper Radi a t o r Suppor t Seal RH Engi n e U Cover...
Page 21 EM-16 TIMING CHAIN ENGINE MECHANICAL 1ZZ-FE: Cyli n der 8 ad Cover Cham Cover Tunmg J -- ""'' . � Cham V'bration Dumper gle Sensor Plate Cran n � ble par t...
Page 22 EM-17 ENGINE MECtlANICAL TIMING Cl lAIN 2ZZ-GE: No, 1 +Gasket '-,, � Ventilation Pipe Gu ide 0-Ring •...
Page 23 EM-18 ENGINE MECHANICAL TIMING CHAIN REMOVAL REMOVE UPPER FRONT FENDER APRON SEAL AND UPPER RADIATOR SUPPORT SEAL DRAIN ENGINE COOLANT REMOVE RH FRONT WHEEL REMOVE RH ENGINE UNDER COVER REMOVE DRIVE BELT AND GENERATOR (See page CH-7) DISCONNECT PS PUMP FROM ENGINE Disconnect the PS oil pressure switch connector.
Page 24 EM -1 9 � ENGINE MECHANICAl TIMING CHAIN Remove the bolts, 2 seal washers, 2 nuts, cylinder head cover and gasket. 2ZZ-GE: REMOVE CYLINDER HEAD COVER Remove the bolts and No. 2 cylinder head cover. Remove the ignition coils (See page IG-6). Disconnect the 2 PCV hoses from the cylinder head cov...
Page 25 EM-20 ENGINE MECHANICAL TIMING CHAIN 1 1 . REMOVE CRANKSHAFT PULLEY Using SST and nuts (width: in.)), remove (0.25 the pulley bolt. 09213-70010, 0933G-00021 Remove the crankshaft pulley. HINT: If necessary, remove the pulley with SST. 0995G-50012 (09951-{)501 0, 09952-{)501 0, 09953-{)5020,09954-{)5020) DISCONNECT CRANKSHAFT POSITION SENSOR FROM TIMING CHAIN COVER...
Page 26 EM-21 ENGINE MECHANICAL CHAIN TIMING 2ZZ-GE: REMOVE TIMING CHAIN COVER Remove the 1 2 bolts. Using a torx wrench socket (E8), remove the stud bolt. Remove the timing chain cover and 2 gaskets. REMOVE CRANK ANGLE SENSOR PLATE REMOVE CHAIN TENSIONER SLIPPER Remove the bolt and slipper.
Page 27 EM-22 TIMING CHAIN INSPECTION INSPECT TIMING CHAIN AND TIMING SPROCKETS Using a vernier calipers, measure the length of 1 6 link s � with the chain dully stretched. / --� Maximum chain elongation: 1 22.6 mm (4.827 in.) If the elongation is greater than maximum, replace the chain. HINT: Links PC>477G...
Page 28 EM-23 ENGINE MECHANICAL TIMING CHAIN INSPECT CHAIN TENSIONER Check that the plunger moves smoothly when the ratchet pawl is raised with your finger. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.
Page 29 EM-24 ENGINE MECHANICAL REPLACEMENT HINT: There are 2 methods (A and B) to replace the oil seal which are as fol!ows: REPLACE CRANKSHAFT FRONT OIL SEAL If timing chain cover is removed from cylinder block. Using a screwdriver and a hammer, tap out the oil ( 1 ) seal.
Page 30 EM-25 ENGINE MECHANICAL TIMING CHAIN INSTALLATION INSTALL VALVE TIMING CONTROLLER ASSEMBLY AND CAMSHAFT TIMING SPROCKET Apply engine oil in the range from the tip of the intake camshaft to 1 6 mm from that tip. Align the timing mark on the value timing controller as sembly with the knock pin, and install the value timing controller assembly to the cam shaft.
Page 31 EM-26 ENGINE MECHANICAL TIMING CHAIN INSTALL CHAIN VIBRATION DAMPER 1ZZ-FE: Install the damper with the 2 bolts. Torque: 1ZZ-FE 11 N.m (113 kgl.cm, 8 11-lbl) 2ZZ-GE 20.5 N.m (209 kgf.cm, 1 5 11-lbl) AIOJ94 INSTALL TIMING CHAIN AND CRANKSHAFT TIMING SPROCKET Install the timing chain on the crankshaft timing sprocket with the yellow color llnk aligned with the timing mark on...
Page 32 EM-27 ENGINE MECHANICAL TIMING CHAIN Check that the tension between the intake camshaft tim ing sprocket and crankshaft timing sprocket. INSTALL CHAIN TENSIONER SLIPPER Install the slipper with the bolt. Torque: lZZ-FE 18.5 N-m (189 kgf-cm, 14 ft·lbn 2ZZ-GE 20.5 N-m (209 kgf . cm, 15 ft·lbf) Check that the slipper moves is caught on the cylinder head stopper.
Page 33 EM.-28 ENGINE MECHANICAL TIMING CHAIN 1ZZ-FE: Chai n Cover INSTALL TIMING CHAIN COVER AND WATER PUMP Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing Seal Wi d t h Cyl i n der Head Gr o ove chain cover, cylinder head and cylinder block.
Page 34 EM-29 � ENGINE MECHANICAL TIMING CHAIN (d ) Install the timing chain cover, D-ring and water pump with the 1 7 bolts and nut. Uniformly tighten the bolts and nut in several passes. Torque: 1 0 mm head: 9 N.m (92 kgf.cm, 80 in,·lbf) for C 1 3 N.m (133 kgf.cm, 1 0 ft.lbf) for A 1 1 N·m ( 1 1 3 kgf .
Page 35 EM-30 ENGINE MECHANICAL TIMING CHAIN Wi d t h 1. 5 2ZZ-GE: FIPG INSTALL TIMING CHAIN COVER AND WATER PUMP - Seal Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing Gasket chain cover, cylinder head and cylinder block.
Page 36 EM-31 ENGINE MECHANICAL liMING CHAIN Install the timing chain cover, D-ring and water pump with the 1 9 bolts. Uniformly tighten the bolls in several passes. T orque: A: 21 N-m (214 kgf.cm, 15 ft-lbf) B: 1 1 N-m ( 1 1 3 kgf.cm, 8 ft-lbf) C: 9.0 N.m (92 kgf.cm, 80 in ..
Page 37 EM-32 ENGINE MECHANICAL TIMING CHAIN INSTALL CRANKSHAFT POSITION SENSOR Torque: 9.0 N·m (92 kgf.cm, 80 in.·lbf) INSTALL CRANKSHAFT PULLEY SST- Clean the crankshaft pulley inside. Align the pulley set key with the key groove of the pulley, ( b) and slide on the pulley. Using SST and 2 nuts (width: in.), install the (0.25...
Page 38 EM-33 ENGINE MECHANICAL CHAIN TIMING SET CHAIN TENSION Turn tho crankshaft counterclockwise, and disconnect the plunger knock pin from the hook, (b ) Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger. HINT: lf tho plunger does not spring out, press the slipper into the chain tensioner with a screwdriver or your finger so that the hook is released from the knock pin and the plunger springs out.
Page 39 EM-34 ENGINE MECHANICAL TIMlNG CHAIN Install the gasket to the cylinder head coveL HINT. Part must be assembled within minutes of application. Otherwise the material must be remove and reapplied. Instal! the cylinder head cover with the bolts, 2 seal washers and 2 nuts.
Page 40 EM-35 ENGINE MECHANICAL TIMING CHAIN Install the cylinder head cover and wire harness protector with the9 bolts. Uniformly tighten the bolts, in the several passes, in the sequence shown. Torque: 1 0 N.m (100 kgf.cm, 7 ft.tbf) Connect the 2 PCV hoses to the cylinder head cover. Install a new gasket and No.
Page 41: Cylinder Head
EM--3 6 CYLINDER HEAD ENGINE MECHANICAL CYLINDER HEAD Upper Fr o nt Fender Apr o n Seal COMPONENTS +Gasket � :Speci f i e d t o r q ue + Nor r - r e us aoJ e par t...
Page 42 EM--3 7 CYLINDER HEAD ENGINE MECHANICAL 1ZZ-FE: Wi r e Har n ess Pr o t e ct o r I n t a ke Mani f o l d ·· �� ·� l A C Val v e Connect o r <...
Page 43 EM-38 ENGINE MECHANICAL CYLINDER HEAD Upper Heat e d I n sul a t o r No. 2 Cyl i n der Head Cover +Gasket 50{510,37} SparkPi u � I n t a ke Mani f o l d St a y PCV Hose Thr o t t l e Posi t i o n I n t a ke Mani f o l d Sensor Connect o r...
Page 44 EM-39 CYLINDER HEAD ENGINE MECHANICAL � 1ZZ-FE: -- Crankshaft Pos'l!ion...
Page 45 EM-40 CYLINDER HEAD ENGINE MECHANICAL 2ZZ-GE: + D-- r ing...
Page 46 EM-41 HEAD ENGINE MECHANICAL CYLINDEH 2ZZ-GE Rocker No. Shaf t Rocker No · Shaf t Shi m \§L _ eeper e--- -- - Spc ; n g Ret a ; n ec 119--- K Val v e Spr i n g ®--- -- Spr i n g Seat '-"...
Page 47 EM-42 ENGINE MECHANICAL CYLINDER HEAD REMOVAL REMOVE BAITERY REMOVE ECU BOX (See page EM-74) DRAIN ENGINE COOLANT DISCONNECT ENGINE COOLANT RESERVOIR REMOVE AIR CLEANER ASSEMBLY DISCONNECT ACCELERATOR CABLE REMOVE DRIVE BELT AND ALTERNATOR (See page CH-7) REMOVE EXHAUST PIPE (See page EM-74) 1ZZ-FE: REMOVE EXHAUST MANIFOLD Remove the 3 bolts and exhaust manifold stay.
Page 48 EM-43 ENGINE MECHANICAL CYLINDER HEAD 2ZZ-GE: REMOVE EXHAUST MANIFOLD Remove the bolts and exhaust manifold stay. Remove the 5 bolts and upper heat insulator. Remove the bolts, 2 nuts, exhaust manifold and gasket. ( d) Remove the bolts and lower heat insulator. 1 1 .
Page 49 E M-44 CYLINDER HEAD ENGINE MECHANICAl <.:- - 2ZZ-GE: REMOVE INTAKE MANIFOLD Disconnect the EVAP hose for ORVR. Disconnect the brake booster vacuum hose. Remove the bolt and disconnect the No. 1 ventilation pipe and oil dipstick and guide . Remove the 4 bolts, Remove the 2 bolts, nut and stay.
Page 50 EM-45 ENGINE MECHANICAL HEAD CYUNOI:: H REMOVE CYLINDER HEAD Disconnect the upper radiator hoses from the water hose union. Disconnect the heater water hose from the water hose union. Using a 1 0 mm bi-hexagon wrench, uniformly loosen and {c ) remove the 1 0 cylinder head bolts, in several passes, in the sequence shown.
Page 51 -· EM-46 ENGINE MECHANICAl CYLINDER HEAD DISASSEMBLY REMOVE OIL CONTROL VALVE for VVT Remove the bolt and cam timing oi! control valve. REMOVE OIL CONTROL VALVE FILTER Remove the bolt, gasket and oil control valve filter. 2ZZ-GE: REMOVE OIL CONTROL VALVE HOUSING Remove the bolt and oil control valve for VVTL Using SST, remove the oil pressure switch.
Page 52 EM-47 ENGINE MECHANICAL - CYLINDER HEAD Using compressed air and magnetic finger, remove the spring seat by blowing air. HINT: Arrange the valves, valve springs, spring seats, and spring re tainers in the correct order.
Page 53 EM-48 ENGINE MECHANICAL CYLINDER HEAD I N SPECTION CLEAN T O P S U R FACES OF PISTONS A N D CYL INDER BLOCK Turn the crankshaft, and bring each piston to top dead (a ) center (TDC). Using a gasket scraper, remove all the car bon from the piston surface.
Page 54 EM-49 CYLINDER HEAD ENGINE MECHANICAL CLEAN VALVE GUIDE BUSHINGS Using a valve guide bushing brush and solvent, clean all the guide bushings. INSPECT FOR FLATNESS Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder block and the manifolds for war page.
Page 55 EM-50 ENGINE MECHANICAL CYLINDER HEAD INSPECT VALVE STEMS AND GUIDE BUSHINGS Using a caliper gauge, measure the inside diameter of the guide bushing. Bushing inside diameter: 1 ZZ-FE 5.510 - 5.530 mm (0.21 69 - 0.2177 in.) 2ZZ-GE 5.500 - 5.518 mm (0.2165 - 0.2172 ln.) AQ1478 Using a micrometer, measure the diameter of the valve stem.
Page 56 EM-51 ENGINE MECHANICAL CYUNDER HEAD Check the valve head margin thickness. Standard margin thickness: 1.0 mm {0.039 in.) Minimum margin thickness: 0.7 mm (0 . 028 in.) If the margin thickness is less than minimum, replace the valve. EM0131 Check the valve overall length. Standard overall length: Over a l l Lengt h 1ZZ-FE...
Page 57 EM-52 ENGINE MECHANICAL CYLINDER HEAD • If blue appears 360" around the valve seat, the guide and face are concentric. If not, resurface the seat. • Check that the seat contact is in the middle of the valve face with the following width: 1 .
Page 58 - CYUNDER HEAD EM-53 ENGINE MECHANICAL Using vernier calipers, measure the free length of the valve spring. Free length: 1ZZ-FE 45.90 mm (1.8070 in.) 2ZZ-GE Intake 46.4 mm (1.830 in.) Exhaust 46.5 mm (1.831 in.) Using a spring tester, measure the tension of the valve spring at the specified installed length.
Page 59 EM-54 ENGINE MECHANICAL CYUNDEA HEAD INSPECT CAM LOBES Using a micrometer, measure the cam lobe height. Standard cam lobe height: 1ZZ-FE: Intake 44.333 - 44.433 mm (1.7454 - 1.7493 in.) Exhaust 43.761 - 43.861 mm (1 .7229 - 1 .7268 in.) 2ZZ-GE: INTAKE No.
Page 60 EM-55 ENGINE MECHANICAL CYUNDEH HEAD INSPECT CAMSHAFT JOURNAL CLEARANCE Clean the bearing caps and camshaft journals. Place the camshafts on the cylinder head. Lay a strip of Plastigage across each of the camshaft jour nal. Install the bearing caps (See page EM-65). Torque: 1ZZ-FE: No.1 23 N·m (235 kgf .
Page 61 EM-56 CYLINDER ENGINE. MECHANICAL HFAO INSPECT CAMSHAFT THRUST CLEARANCE Install the camshafts. (See page EM-65) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. 1 ZZ-FE: Standard thrust clearance: 0.040 - 0.095 mm (0.0016 - 0.0037 1n.) Maximum thrust clearance: 0.11 mm (0.0043 in.) 2ZZ-GE:...
Page 62 EM-57 CYLINDER HEAD ENGINE MECHANICAL Under the condition of {d), turn the valve timing controller assembly to the advance angel side (the arrow marked direction in the illustration) with your hand. Standard: Must turn HINT: Depending on the air pressure, the valve timing controller as sembly will turn to the advance angle side without applying force by hand.
Page 63 EM-58 ENGINE MECHANICAL - CYLINDER HEAD INSPECT INTAKE MANIFOLD Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.10 mm (0.0039 in.) If warpage is greater than maximum, replace the manifold. MWJB 2 1 .
Page 64 EM-59 ENGINE MECHANICAL CYLINDER HEAD REPLACEMENT REPLACE VALVE GUIDE BUSHINGS Gradually heat the cylinder head to 1 1 1 30 (230 - 266 'F). Using SST and a hammer, tap out the guide bushing. 09201-{)1 055, 0995(}-70010 (09951-{)7100) Using a caliper gauge, measure the bushing bore diame ter of the cylinder head.
Page 65 EM-£0 ENGINE MECHANICAL CYLINDER HEAD 2ZZ-GE: Bushi n g Select the new guide bushing (STD or 0/S 0.05) . If the bushing bore diameter of the cylinder head is greater than size 1 0.506 mm (0.4136 in.}, machine the bushing bore to the fol Use STD lowing dimension: 1 0.488...
Page 66 EM-61 ENGINE MECHANICAL CYUNDER HEAD REASSEMBLY • Thoroughly clean all parts to be assembled. • Before installing the parts, apply fresh engine oil to all slid ing and rotating surfaces. • Replace oil seals with new ones. For Radi a t o r Hose { A ) For Heat e r INSTALL WATER HOSE UNIONS - �...
Page 67 EM-62 ENGINE MECHANICAl CYUNOER HEAD Using a press, press in a new water hose union until there is protruding from the cylinder head. Standard protrusion: A 29 mm (1.14 in.) 66.5 mm (2.618 in.) C 24 mm (0.95 in.} 69.8 mm (2.630 ln.) NOTICE: Avoid pressing a new water hose union in too far by mea...
Page 68 E�3 ENGINE MECHANICAL CYliNDER HEAD Install the valve ( 1 ) , spring (2), valve spring (3), and spring retainer {4). Using SST, compress the valve spring and place the 2 09202-70020 (09202-00020) keepers around the valve stem. Using a plastic-faced hammer and the valve stem (not in use) tip wound with vinyl tape, lightly tap the valve stem tip to ensure a proper fit.
Page 69 EM-64 -� ENGINE MECHANICAL CYLINDER HEAD Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833--00080, THREE BOND 1 344, LOCTITE 242 or equivalent Using SST, install the oil pressure switch. 09816-30010 Torque: 1 3 N·m (130 kgf . cm, 9 fl·lbf) Install the oil control valve for VVTL with the bolt.
Page 70 EM-65 ENGINE MECHANICAL CYUNDER HEAD ''"" "' INSTALLATION HINT: • Thoroughly dean all parts to be assembled. Before installing the parts, apply fresh engine oil to a!! slid ing and rotating surfaces. • Replace aH gaskets and oil seals with new ones. PLACE CYLINDER HEAD ON CYLINDER BLOCK -- �...
Page 71 EM-66 ENGINE MECHANICAL CYLINDER HEAD 2ZZ-GE: Check that the paint mark is not at a 180" angle to the front. Install the bolt holding the water bypass pipe to the cylin der head. Torque: 9.0 N-m (92 kgf.cm, 80 in.·lbf) Connect the upper radiator hose to the water hose unions.
Page 72 EM-67 ENGINE MECHANICAL CYLINDER HEAD 2ZZ-GE: Install and uniformly tighten the 20 bearing cap bolts. After tightening the No. 1 camshaft bearing cap, tighten then in several passes, in the sequence shown. Torque: 18.5 N·m (189 kgf.cm, 14 ft·lbf) CHECK AND ADJUST VALVE CLEARANCE (See page EM-4) INSTALL CAMSHAFT TIMING SPROCKETS AND VALVE TIMING CONTROLLER ASSEMBLY (See page...
Page 73 EM--68 ENGINE MECHANICAL CYLINDER HEAD 1ZZ-FE: CONNECT ENGINE WIRE TO CYLINDER HEAD Connect the 2 clamps of engine wire to the intake man ifold. Connect the 2 ground cables. Connect the oil control valve for VVT connector. Connect the camshaft position sensor connector. (d ) Connect the ECT sensor connector.
Page 74 EM -6 9 � ENGINE MECHANICAl CYLINDER HEAD 2ZZ-GE: INSTALL EXHAUST MANIFOLD Install the lower heat insulator with the 4 bolts. Instal! the exhaust manifold with the 3 b Torque: 20 N-m (204 kg1-cm, 1 5 ft-lbl) -; T ;_ and 2 nuts.
Page 75 EM-70 ENGINE MECHANICAL ENGINE UNIT ENGINE U NIT Upper Fr o nt Fender Apr o n Seal COMPONENTS n- Bat < e < y Cl a mp Upper Radi a t o r Suppor t Sea! ttJ- Bat t e r y Engi n e Hood Bat t e r y Ai r Cl e aner Cap...
Page 76 E M-71 ENGINE UNIT ENGINE MECHANICAL Dr i v e Bel t J/ B Cover Radi a t o r Assembl y ; Speci f i e d t o r q ue...
Page 77 EM-72 ENGINE MECHANICAL ENGINE UNIT Stabilizer Bar Bracket � � � ..Stabilizer Bar � · • Member Suspension Drive Shaft + Gasket ·· .. . \ f� l � - · ._- Fr on t Ex ha us t Pi pe + G as ket ��' 0-R ing...
Page 78 EM-73 Upper Fr o nt Fender Apr o n Seal ENGINE MECHANICAl - ENGINE UNIT � l Z Z�FE: No.2 Cyl i n der Head Cover 2ZZ-GE: No. Cyl i n der Head Cover 1ZZ-FE: Upper Heat e d I n sul a t o r E: RH Engi n e Mount i n I n sul a t o r lA .
Page 79 EM-74 ENGINE MECHANICAL ENGINE UNIT REMOVAL REMOVE BATTERY AND TRAY REMOVE HOOD REMOVE ENGINE UNDER COVERS DRAIN ENGINE COOLANT DRAIN ENGINE OIL DRAIN TRANSAXLE OIL REMOVE BUMPER COVER AND HEAD LIGHT REMOVE AIR CLEANER CAP Disconnect the MAF meter connector. Disconnect the 2 hoses.
Page 80 EM-75 ENGINE MECHANICAl ENGINE UNIT 1 1 . DISCONNECT ENGINE WIRE FROM ENGINE COMPARTMENT RELAY BOX Remove the relay box upper cover. Disconnect the 3 connectors. Disconnect the 7 claws and J/B from the relay box. Disconnect the 3 connectors. Disconnect the engine wire from the relay box.
Page 81 EM-76 ENGINE MECHANICAL ENGINE UNIT MfT: DISCONNECT CLUTCH RELEASE CYLINDER Remove the 3 bolts, and disconnect the brackets from the (a ) transaxle. Remove the 2 bolts, and disconnect the release cylinder from the transaxle. DISCONNECT TRANSAXLE CONTROL CABLE (S) DISCONNECT 2 GROUND CABLES REMOVE DRIVE SHAFT (See page SA-20) 2 1 .
Page 82 EM-77 ENGINE MECHANICAL ENGINE UNIT DISCONNECT PS PUMP Disconnect the PS oi! pressure switch connector. Remove the 2 nuts and through bolts, and disconnect the PS pump from the engine (See page SR-24). HINT: Put aside the pump and suspend it to the cowl with a string. REMOVE STABILIZER BAR BRACKET (See page SA-51 ) DISCONNECT PS GEAR...
Page 83 EM-78 � ENGINE MECHANICAL ENGINE UNIT Install the engine hangers in the correct direction. Engine hanger part No.: 1ZZ-FE Front: 1 2281-22021 Rear: 12281-15040 or 12281-15050 Bolt: 91512-81016 2ZZ-GE Front: 1 2281-<!8600 Rear: 12282-88600 Bolt: 91512-61020 Torque: 38 N·m (388 kgf·cm, 28 fl·lbf) Attach the engine sling device to the engine hangers.
Page 84 EM -7 9 ENGINE MECHANICAL ENGINE UNIT Lower the engine out of vehicle slowly and carefully, and raise the vehicle. HINT: Make sure the engine is clear of all wiring, hoses and cables. Place the engine and transaxlc assembly onto the stand. {e ) 31 .
Page 85 EM--8 0 ENGINE MECHANICAL ENGINE UNIT INSTALLATION ASSEMBLY ENGINE AND TRANSAXLE (C56 MIT: See page MX--<1) (C60 MIT: See page MX--<1) (U240E AfT: See page AX-35) (U341E AfT: See page AX-35) INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN VEHICLE Attach the engine sling device to the engine hangers. Slowly lower the vehicle, and raise the engine into the en- gine compartment.
Page 86 EM-81 ENGINE MECHANICAL ENGINE UNIT INSTALL SUSPENSION MEMBER Install the suspension member with the 9 bolts and 3 nuts. Torque: A 52 N·m (530 kgf.cm, 32 ft.lbf) B 52 N·m (530 kgf.cm, 32 ft·lbf) C 157 N·m (1,600 kgf.cm, 1 1 6 ft.lbf) D 157 N-m (1 ,600 kgf.cm, 1 1 6 ft·lbf) E 39 N·m (400 kgf.cm, 29 ft·lbf) Nut 52 N·m (530 kgf.cm, 32 ft·lbf)
Page 87 EM-82 ·- UNtT ENGINE MECHANICAL 1 1 . INSTALL EXHAUST PIPE Install the 2 gaskets and exhaust pipe. Connect the 2 0-rings. Install the 4 springs and bolts. { c) Torque: 43 N-m (440 kgf-cm, 32 ft-lbf) Connect the 2 heated oxygen sensor. INSTALL DRIVE SHAFT (See page SA-32) CONNECT 2 GROUND CABLES CONNECT TRANSAXLE CONTROL CABLE (S)
Page 88 EM-83 ENGINE MECHANICAL ENGINE UNIT w/ Cruise Control System: INSTALL CRUISE CONTROL ACTUATOR Install the actuator with the 3 bolts. Connect the actuator connector. CONNECT ENGINE WIRE TO ENGINE COMPART MENT RELAY BOX Install the engine wire to the relay box. Connect the 3 connectors.
Page 89 EM-84 ·- ENGINE MECHANICAL E:NGINE UNIT INSTALL AIR CLEANER CASE Connect the 2 hoses to the air cleaner case. Install the air cleaner case with the 2 bolts. Torque: 5.0 N-m (51 kgf . cm, 44 in fbf} Connect the hose to the intake air control valve. Connect the hose to the VSV for canister closed valve (CVC).
Page 90 EM -85 ENGINE MECHANICAL CYLINDER BLOCK CYLINDER B LOCK COMPONENTS 1ZZ-FE: Wat e r Bypass Pi p e +Gasket - - - - - - Oi ! Gui d e and Oi l Di p st i c k Knock Sensor Wat e r I n l e t Oi l Pump :Speci f i e d t o r q ue...
Page 91 EM-86 � ENGINE MECHANICAL BLOCK CYLINDER Water Bypass Pipe + Non�r e usabl e : Specified orque part...
Page 92 EM-<17 ENGINE MECHANICAL CYLINDER BLOCK 1ZZ-FE: / i _-6) + Connect i n g Rod Bushi n g Connect i n g Rod 6\)------- � - - - Connect i n g Rod Beanng - <> - +Snap Ri n g �...
Page 93 EM-88 CYLINDER BLOCK ENGINE MECHANICAL No. 1 Compr e ssi o n Ri n 2ZZ-GE: +Connect i n g Rod Bushi n g No.2 Compr e ssi o n Ri n (})----- T ( S i d e Rai l } Connect i n g Rod , / / Oi l Ri n g { E xpander )
Page 94 EM-89 CYLINDER BLOCK '�'"" DISASSEMBLY Mrr: REMOVE FLYWHEEL AfT: REMOVE DRIVE PLATE INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY REMOVE TIMING CHAIN AND SPROCKETS (See page EM-18) REMOVE ENGINE WIRE REMOVE CYLINDER HEAD (See page EM-42) 1ZZ-FE: REMOVE OIL DIPSTICK AND GUIDE Remove the bolt and oil dipstick and guide.
Page 95 EM-- 9 0 ENGINE MECHANICAL CYUNDEA BLOCK REMOVE OIL FILTER (See page LU 3) REMOVE OIL FILTER UNION Using a 1 2 mm hexagon wrench, remove the oil filter union. AOII$4 REMOVE OIL PAN 1ZZ-FE: Remove the 14 bolts and 2 nuts. Remove the 12 bolts and 4 nuts .
Page 96 EM-91 ENGINE MECHANICAL CYLINDER BLOCK CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while mov ing the connecting rod back and forth. Standard thrust clearance: 0.160 - 0.342 mm (0.0063 - 0.0135 in.) Maximum thrust clearance: 0.342 mm (0.0135 In,) If the thrust clearance is greater than maximum, replace the connecting rod assembly(s).
Page 97 EM-92 CYLINDER BLOCK ENGINE MECHANICAl Lay a strip of Plastigage the crank pin. Install the connecting rod cap with the 2 bolts (See page (g ) EM-106). Torque: 1st: 1ZZ-FE: 20 N·m (204 kgf . cm, 15 ft.lbf) 2ZZ-GE: 30 N·m (306 kgf . cm, 22 ft.lbf) 2nd: Turn extra 90°...
Page 98 EM--93 CYLINDER BLOCK ENGINE MECHANICAL HINT; If replacing a bearing, replace it with one having the same num� ber as marked on the connecting rod. There are 3 sizes of stan· dard bearings, marked 'T, "2� and "3" accordingly. Reference Standard bearing center wall thickness 1ZZ-FE: mm (in_)
Page 99 EM-94 ENGINE MECHANICAL Using a screwdriver, remove the bearing cap sub-assem bly by prying the portions between the cylinder block and bearing cap sub-assembly. Remove the 5 lower main bearings. NOTICE: Be careful not to damage the contact surfaces of the cylin� der block and bearing cap sub-assembly.
Page 100 E M- 9 5 ENGINE MECHANICAl CYLINDER BLOCK 1ZZ-FE: If using a standard bearing, replace it with one having the same number. if the number of the bearing cannot be de termined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crank the total.
Page 101 EM-96 � ENGINE MECHANICAL Reference Item Mark mm (ln_) " 0 " b!ock 52.000 -52.003 (2.0472- 2.0473) Cylinder main iournal lx:m diameter 52.003 - 52.005 {2.0473- 2.0474) " " 52.005 - 52.007 (2.0474 - 2.0475) "3" 52.007 -52 010 (2.0475 - 2.0476) "...
Page 102 EM-97 � ENGINE MECHANICAL BLOCK GYUNDER CHECK FIT BETWEEN PISTON AND PISTON PIN Try to move the piston back and forth on the piston pin. If any movement is fell, replace the piston and pin as a set. REMOVE PISTON RINGS Using a piston ring expander, remove the 2 compression rings.
Page 103 EM-98 CYLINDER BLOCK ENGINE MECHANICAL INSPECTION REMOVE GASKET MATERIAL Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. CLEAN CYLINDER BLOCK Using a soft brush and solvent, thoroughly clean the cylinder block. NOTICE: If the cylinder Is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block, so always wash...
Page 104 EM- 99 CYLINDER BLOCK ENGINE MECHANICAL 5� INSPECT CYLINDER BORE DIAMETER Using a cylinder gauge, measure the cylinder bore diameter at positions A, 8 and C in the thrust and axial directions. Standard diameter: 1ZZ-FE 79.000 - 79.013 mm (3.1102 - 3.1107 in.) 2ZZ-GE 82.000 - 82.013 mm (3.2283 - 3.2289 1n.) Maximum diameter: 1ZZ-FE 79.013 mm (3.1107 in.)
Page 105 EM-100 ENGINE MECHANICAL - CYLINDER BLOCK Using a groove cleaning tool or broken ring, clean the pis ton ring grooves. Using solvent and a brush, thoroughly clean the piston. NOTICE: Do not use a wire brush. INSPECT PISTON OIL CLEARANCE 1 ZZ-FE: Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 25.6 m m {1 .008 in.)
Page 106 EM-101 BLOCK ENGINE MECHANICAL CYLINDER INSPECT PISTON RING END GAP Using a feeler gauge, measure the clearance between new pis ton ring and the wall of the ring groove. Ring groove clearance: 0.030 - 0.070 mm (0.0012 - 0.0028 in.) If the clearance is not as specified, replace the piston.
Page 107 EM-102 ENGINE MECHANICAL CYLINDER BLOCK • Check for twist Maximum twist: 0.05 mm (0.0020 ln.) per 100 mm (3.94 ln.) If twist is greater than maximum, replace the connecting rod as· sembly. iNSPECT PiSTON PIN Oil CLEARANCE Using a caliper gauge, measure the inside diameter of the connecting rod bushing.
Page 108 EM-103 ENGINE MECHANICAL CYLINDER BLOCK INSPECT CONNECTING ROD BOLTS Using a vernier calipers, measure the tension port!on diameter of the bolt. Standard diameter: 6.6- 6.7 mm (0.260 - 0.264 in.) Minimum diameter: 6.4 mm (0.252 in.) If the diameter is less than minimum, replace the bolt. INSPECT CRANKSHAFT FOR CIRCLE RUNOUT Place the crankshaft on V-blocks.
Page 109 EM-104 ENGINE MECHANICAL - CYLINDER BLOCK REPLACEMENT REPLACE CONNECTING ROD BUSHINGS Using SST and a press, press out the bushing. (a ) 09222-30010 Align the oil hoses of a new bushing and the connecting rod. Using SST and a press, press in the bushing. Hol e 09222-30010 Using a pin hole grinder, hone the bushing to obtain the...
Page 110 EM-105 CYLINDER BLOCK ENGINE MECHANICAL Apply MP grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal until its sur face is flush with the rear oil seal retainer edge. 09223-15030, 09950-70010 (09951-{)7100)
Page 111 EM-106 CYLINDER BLOCK ENGINE MECHANICAL ·� " " REASSEMBLY HINT: Thoroughly clean all parts to be assembled. • Before installing the parts, apply fresh engine oil to all slid· ing and rotating surfaces. Replace all gaskets, 0-rings and oil seals with new parts. ASSEMBLE PISTON AND CONNECTING ROD Using a small screwdriver, install a new snap ring at one end of the piston pin hole.
Page 112 EM-107 CYLINDER BLOCK ENGINE MECHANICAL INSTALL PISTON RINGS Code Mark Install the oil ring expander and 2 side rails by hand. No.2 Using a piston ring expander, install the 2 compression rings with the code mark facing upward. Code mark : 1ZZ-FE: T or 2R 2ZZ-GE: T Position the piston rings so that the ring ends are as...
Page 113 EM-108 ENGINE MECHANICAL CYLINDER BLOCK INSTALL THRUST WASHERS Install the 2 thrust washers under the No.3 journal position of the cylinder block with the oil grooves facing outward. PLACE CRANKSHAFT ON CYLINDER BLOCK PLACE BEARING CAP SUB-ASSEMBLY ON CYL INDER BLOCK A01191 (a ) Remove any old packing (F!PG) material and be careful...
Page 114 E M-1 09 ENGINE MECHANICAl CYLINDER BlOCK Apply a light coat of engine oil on the threads and under Install and uniformly tighten the i 0 bearing cap sub-as the bearing cap sub-assembly bolts. sembly bolts, in several passes, in the sequence shown. Torque: 22 N·m (225 kgf .
Page 115 EM-110 ENGINE MECHANICAL CYLINDER BLOCK 1 1 . INSTALL PISTON A N D CONNECTING ROD AS· SEMBLE$ Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. PLACE CONNECTING ROD CAP ON CONNECTING Match the numbered connecting rod cap with the con...
Page 116 EM-111 CYLINDER ENGINE MECHANICAL BLOCK HINT: Wipe seal packing away from the contact surface of the cylinder block assembly and oil seal. 1 ZZ-FE: Install a new gasket and the oil strainer with the 2 nuts and bolt. INSTALL OIL STRAINER Torque: 9.0 N-m (92 kgf.cm, 80 ln.-lbf) 2ZZ-GE: Install the oil pan baffle with the 4 bolts and 2 nuts.
Page 117 EM-1 1 2 CYLINDER BLOCK ENGINE MECHANICAL HINT Avoid applying an excessive amount to the surface. • Parts must be assembled within 3 minutes of ap plication. Otherwise the materia! must be removed and reapplied. Immediately remove nozzle from the tube and rein stall cap.
Page 118 EM-- 1 13 ENGINE MECHANICAL CYLINDER BLOCK 2ZZ-GE: INSTALL VENTILATION CASE Install a new gasket and ventilation case with the 3 bolts. (a ) Torque: 8.5 N-m (87 kgf . cm, 75 in.-lbf) Install the No. 3 ventilation hose and connect the clip. (b ) INSTALL THERMOSTAT (See page C0-11) INSTALL WATER BYPASS PIPE...
Page 119 EM-114 ENGINE MECHANICAL CYLINDER 8LOCK AfT : INSTALL DRIVE PLATE Install the front spacer, drive plate and rear plate on the crankshaft Apply adhesive to 2 or 3 threads of the mounting bolt end. Adhesi v e Adhesive: Part No. 08833-00070, THREE BONO or equivalent Install and uniformly tighten the 8 mounting bolts, in sev·...
Page 120: Exhaust System
EM-115 ENGINE MECHANICAL EXHAUST SYSTEM EXHAUST SYSTEM Heat Insulator Heat I n sul a t o r Heat I n sul a t o r Heat I n sul a t o r 1ZZ-FE: Tailpipe HeatOO Oxygen Seosor 0-Ai n g (8ank1 Sensor2) Heated Oxygen Sensor +Gasket...
Page 121 - MEMO- · - ' -...
Page 122: Emission Control
EMISSION CONTROL EMI S SI O N CONTROL SYSTEM .. EC-1 PARTS LAYOUT AND SCHEMATI C DRAWI N G EC-2 POSI T I V E CRANKCASE VENTI L ATI O N ( P CV) SYSTEM ..... . . EC- -4 EVAPORATI V E EMI S SI O N ( E VAP) CONTROL SYSTEM.
Page 124: Emission Control System
EC-1 � EMISSION CONTROL EMISSION CONTROL SYSTEM EMISSION CONTROL SYSTEM PURPOSE engine ((3) and (4}), to prevent the atmospheric release of blow-by gas-containing HC ( 1 ) and evaporated The emission control systems are installed to reduce the amount of CO, HC and NOx exhausted from the fuel containing HC being released from the fuel tank {2).
Page 125 EC-2 PARTS LAYOUT AND SCHEMATIC Df1AWING EMISSION CONTROL. PARTS LAYOUT AND SCHEMATIC DRAWING LOCATION EVAP Ser v i c e Par t VSV f o r Pr e ssur e Swi t c hi n g Val v e Ai r ! n ! e t Li n e Pur g e Li n e...
Page 126 EC-3 EMISSION CONTROl PARTS LAYOUT AND SCHEMATIC DRAWING DRAWIN G Pur g e Li n e Vapor Pr e ssur e Sensor Vent li n e EVAP Li n e EVAP Ser v i s e Por t VSV f o r Pr e ssur e Fuel Tank Val v e Char c oal Cani s t e r...
Page 127 EC-4 EM!SSfON CONTROL POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM INSPECTION REMOVE PCV VALVE Disconnect the PCV hose from the PCV valve. Remove the PCV valve. INSTALL CLEAN HOSE TO PCV VALVE Cylinder Head INSPECT PCV VALVE OPERATION Blow air into the cylinder head side, and check that air Clean Hose passes through easily.
Page 128 EC-- 5 EVAPORATIVE EMISSION (EVAP} EMISSION CONTROL CONTROL SYSTEM EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM COMPONENTS Heat e d I n sul a t o r VSV Connect o r f o r Pr e ssur e Swi t c hi n g Val v e Non�r e usab! e par t B!)8749...
Page 129 EVAP service port on the purge line. TOYOTA hand-held tester: Forced driving of the VSV for the EVAP. Connect a TOYOTA hand-held tester to the DLC3. { i ) Start the engine. Push the TOYOTA hand-held tester main switch Use the ACTIVE TEST mode on the TOYOTA hand-held tester to operate the VSV for the EVAP.
Page 130 If you have TOYOTA hand-held tester: Conclude forced driving of the VSV for the EVAP. ( 1 ) Stop the engine. Disconnect the TOYOTA hand-held tester from the DLC3. lf you have no TOYOTA hand-held tester: Conclude forced driving of the VSV for the EVAP.
Page 131 EC--1l EMISSION CONTROL Check if the pressure decreases when the fuel tank cap is removed white adding pressure. HINT: If the pressure does not decrease when the filler cap is re moved, then you can conclude that the hose connecting the service port to the fuel tank is blocked, etc.
Page 132 EC-- 9 ·- EMISSION CONTROL LVAPORAl iVE EMISSION ([VAP) CONTnOL SYSl'CM CHECK AIR INLET LINE Disconnect the air inlet line hose from the charcoal canis ter. Check that there is ventilation in the air inlet line. Reconnect the air inlet line hose to the charcoal canister. AI' I n let Line Hose "-- V / '-- ..._- �...
Page 133 EC-10 EMISSION EVAPORATiVE EMISSION CONTROL While holding the purge port and the air drain port closed, blow air ( 1 .76 kPa, 18 gf/cm2, 026 psi) into the EVAP port and check that air does not flow from the air inlet port. Apply vacuum (3.43 kPa, 25.7 mmHg, 1 .0 1 in.Hg) to the purge port, check that the vacuum does not decrease when the air inlet port is closed, and...
Page 134 EG-11 EMISSION CONTROL THREE-WAY CATALYTIC CONVERTER (TWC) SYSTEM THREE-WAY CATALYTIC CONVERTER (TWC} SYSTEM INSPECTION CHECK TWC FOR DENTS OR DAMAGE If any port of the heat insulator is damaged or dented to the extent that contacts the three-way catalytic repair converter, or replace it.
Page 135 - MEMO-...
Page 136 SFI SYSTEM SF - 1 SF- - 6 FUEL PUMP ..FUH PRESSURE REGULATOR . SF�1 5 SF�1 8 I N JECTOR FUEL TANK AND UNE SF-26 SF-29 MASS AI R FLOW ( M AF) METER THROTTLE BODY ..SF-33 SF�O I D LE AI R CONTROL ( l A C) VALVE CAMSHAFT TI M I N G OI L...
Page 138 SF-1 SF! SYSTEM SFI SYSTEM PRECAUTION BEFORE WORKING ON THE FUEL SYSTEM , DIS· CONNECT THE NEGATIVE (-) TERMINAL CABLE FROM THE BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable removed from before the battery.
Page 139 SF-2 SF! SY TEM When installing the battery, be especially careful not to in correctly connect the positive (+) and negative (�) cables. Do not permit parts to receive a severe impact during re moval or installation. Handle all SFI parts carefully, espe cially the ECM.
Page 140 SF-3 SFI SYSTEM Put a container under the connection. Observe these precautions when removing and installing the injector. Never reuse the 0-- r ing. ( 1 ) When placing a new 0-- r ing on the injector, take � care not to damage it in any way. Coat a new 0-ring with spindle oil or gasoline be�...
Page 141 SF-4 SFI SYSTEM Turn SST, align the retainers inside the connector with SST chamfered parts and incert SST into the connector. Hold SST as it at step 4, push the connector to wards SST to put the retainers on SST champfered parts.
Page 142 DLC3. Turn the ignition switch ON and push TOYOTA hand-- h eld tester main switch ON. Select the active test mode on the TOYOTA hand held tester. Please refer to tho TOYOTA hand-held tester oper ator's manual for further details.
Page 143 FUEL PUMP ON-VEHICLE INSPECTION CHECK FUEL PUMP OPERATION Connect the TOYOTA hand-held tester to the DLC3. Turn the ignition switch ON and TOYOTA hand-held tes· ter main switch ON. NOTICE: Do not start the engine. Select the active test mode on the TOYOTA hand-held tester.
Page 144 SF-7 FUEL PUMP Remove the fuel pipe clamp. Disconnect the fuel tube (fuel tube connector) from the fuel pipe. CAUTION: Perform disconnecting operations of the fuel tube connector (quick type) after observing the precau As there is retained pressure in the fuel pipe line, pre- � tions.
Page 145 SF-8 FUEL PUMP Connect the TOYOTA hand-held tester to the DLC3. If you have no TOYOTA hand-held tester, connect the positive (+) lead from the battery to terminal 4 of the connecter, and the negative (-) lead to terminal 5.
Page 146 SF-9 FUEL PUMP INSPECT FUEL PUMP RESISTANCE Using an ohmmeter, measure the resistance between terminals 4 and 5. Resistance: 0.2 - 3.0 n at 20 " C (68 "F) If the resistance is not as specified, replace the fuel pump. INSPECT FUEL PUMP OPERATION Connect the positive (+) lead from the battery to terminal 4 of the connector and the negative (-) terminal 5.
Page 147 SF-10 UEL PUMP COMPONENTS Rear Seat Cushi o n S Vapor Pr e ssur e ensor Tube Joi n t Cl i p No. Fuel Suct i o nS > Fuel Tube � � Em; s s; o n Tube +0-Ri n g Cap ·...
Page 148 SF-11 FUEL PUMP REMOVAL CAUTION: Do not smoke or work near an open flame when working on the fuel pump. REMOVE REAR SEAT CUSHION REMOVE FLOOR SERVICE HOLE COVER DISCONNECT FUEL PUMP & SENDER GAUGE CON· NECTOR AND VAPOR PRESSURE SENSOR CON NECTOR DISCONNECT FUEL TUBE AND EMISSION TUBE Wash away the mud, dust and the likes on the fuel suction...
Page 149 SF-12 � FUEL PUMP DISASSEM B LY Using a small screwdriver, remove the No. 2 fuel suction REMOVE NO. 2 FUEL SUCTION SUPPORT support. Remove the rubber cushion. REMOVE NO. 1 FUEL SUCTION SUPPORT Disconnect the fuel sender gauge connector and earth plate.
Page 150 SF-13 "' FUEL PUMP "" REASSEMBLY INSTALL FUEL PUMP Connect the fuel pump to the fuel filter. INSTALL FUEL PRESSURE REGULATOR Install the Q-ring to the pressure regulator. HINT: Apply a light coat of gasoline to a new Q-ring, and install it to the pressure regulator.
Page 151 Fl)EL SF-14 PUMP INSTALLATION INSTALL FUEL PUMP ASSEMBLY Install the new gasket to the fuel pump assembly. Instal! the fuel pump assembly to the fuel tank. NOTICE: Do not damage the fuel pump filter. Be careful that the arm of the sender gauge should not bent.
Page 152: Fuel Pressure Regulator
SF-1 5 fUEL PRF.SSURE REGULATOR FUEL PRESSURE REGULATOR COMPONENTS Rear Seat Cushi o n Fl o or Ser v i c e Hol e Cover Fuel Pump Sender Gauge Connect o r & No. 1 Fuel Suct i o n Support Tube Joi n t Cl i p Fuel Tube Out l e t...
Page 153 SF-16 FUEL PRESSURE REGULATOR REMOVAL REMOVE FUEL PUMP ASSEMBLY FROM FUEL TANK (5ee page SF-11 ) REMOVE NO. 1 FUEL SUCTION SUPPORT (See page SF-12) REMOVE FUEL PRESSURE REGULATOR Pull out the pressure regulator. Remove the 0-ring from the pressure regulator.
Page 154 � SF-17 NewO�Ri n g FUEl PRESSURE REGULATOR INSTALLATION INSTALL FUEL PRESSURE REGULATOR Install the Q-ring to the pressure regulator. HINT: Apply a light coat of gasoline to a new 0-ring, and instal! it to the pressure regulator. Connect the pressure regulator from the fuel filter_ INSTALL NO.
Page 155 SF-18 lNJECT INJECTOR ON-VEHICLE INSPECTION REMOVE NO. 2 CYLINDER HEAD COVER CHECK OPERATION SOUND FROM EACH INJECTOR Connect the PCV hose to cylinder head cover. With the engine running or cranking, use a sound scope to check that there is normal operating noise in proportion to engine speed.
Page 156 SF-19 INJEC10R COMPONENTS 1ZZ-FE: Fuel Del i v er y Pi p e and Fuel -"--1 Tube Assembl y Spacer �> I n j e ct o r F uel Pi p e Cl a mp • 0 - - R i n g - - - �...
Page 158 SF-21 INJECTOR REMOVAL REMOVE NO. 2 CYLINDER HEAD COVER 1ZZ-FE: REMOVE PCV HOSE DISCONNECT FUEL TUBE Remove the fuel pipe damp_ Disconnect the fuel tube (fuel tube connector) from the (b ) fuel plpe. CAUTION: • Perform disconnecting operations of the fuel tube connector (quick type) after observing the precauM tions.
Page 160 SF-23 � INJECTOR If you have no TOYOTA hand-held tester, connect the positive (+} and negative (-} leads from the battery to the fuel pump connector (See page SF-18). Connect SST (wire) to the injector and battery for 1 5 se...
Page 161 SF-24 INJECTOR I NSTALLATION INSTALL INJECTORS AND DELIVERY PIPES Install the grommet to each injector. Apply a light coat of spindle oil or gasoline to new 0-ring and install them to each injector. NewO-Ri n g Apply a light coat of spindle oil or gasoline on the place where a delivery pipe touches on D-ring.
Page 162 SF-25 INJEC fOH (m) Tighten the 2 bolts holding the delivery pipe to the cylinder head. Torque: 1ZZ-FE: 19 N·m (190 kgf.cm, 1 4 ft.lbf) 2ZZ-GE: 29 N·m (290 kgf.cm, 21 ft.lbf) Tighten the bolt holding the fuel pipe to the cylinder head. Torque: 9 N·m (92 kgf.cm, 7 ft.lbf) CONNECT FUEL TUBE Connect the fuel tube (fuel tube connector) to the fuel...
Page 163 SF-26 FU LTANKANDLINE FUEL TAN K AND LINE PRECAUTION • Always use new gaskets when replacing the fuel tank or component parts. • Apply the proper torque to all parts tightened.
Page 164 SF-27 FUEL TANK AND UNF COMPONENTS Fuel Tank Vent Tube Set Pl a t e Fuel Pump Assembl y �-- +Gasket� No. 2 Fr o nt Fl o or Heat I n sul a t o r Tai l Pi p e Fr o nt Exhaust Pi p e �...
Page 165 SF-28 FUEL TANK AND LINE INSPECTION INSPECT FUEL TANK AND LINE Check the fuel lines for cracks or leakage, and all con nee· tions for deformation. Check the fuel tank for deformation, cracks fuel leakage or tank band looseness. Check the filter neck for damage or fuel leakage. Hose and tube connections are as shown in the illustra- tio n.
Page 166 SF-29 MASS AIR FLOW MAF METER MASS AIR FLOW (MAF) METER COMPONENTS Mass Ai r Fl o w Meter Mass Ai r Flow Meter Connector O... R ing Non-reusabl e part...
Page 167 SF-30 FLOW MAr METER "''" "' REMOVAL Remove the 2 screws, air flow meter and 0-- r ing. REMOVE AIR FLOW METER...
Page 168 SF-31 SFI - MASS AIR FLOW MAF METER INSPECTION INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. Resistance: lenninals Resistance Temperature THA- E2 13.6 - 1 8.4kn -2o·c H"F) THA- E2 2.21 - 2.69 kn 20"C (68"F) THA-E2 0.49 -0.67k!t...
Page 169 SF-32 MASS AIR FLOW !MAFl METER INSTALLATION INSTALL AIR FLOW METER Install the air flow meter and a new 0-- r ing with 2 screws.
Page 170 SF-33 THHOnLE BODY THROTTLE BODY ON-VEHICLE INSPECTION INSPECT THROTTLE BODY Check that the throttle linkage moves smoothly. INSPECT THROTTLE POSITION SENSOR Remove the air cleaner assembly with alr flow meter. Disconnect the throttle position sensor connector. Using an ohmmeter, measure the resistance between each terminal.
Page 171 SF-34 COMPONENTS 1ZZ-FE: � EVAP Water By-pass Pi p e ®"' - llOT/ 16 + Non - reusable part...
Page 172 SF-35 THROTTLE BODY SFI -- 22Z-GE: d Cover N 2 Cyl i n der Hea � ' t h Ai r Fl o w - - - - - - - - Ai r Cl e ane er Hose - �...
Page 173 SF-36 THAOTILE BODY REMOVAL DRAIN ENGINE COOLANT DISCONNECT ACCELERATOR CABLE REMOVE NO. 2 CYLINDER HEAD COVER REMOVE AIR CLEANER HOSE AND CAP WITH MAF METER Disconnect the VSV for EVAP. Disconnect the 2 air hoses from air cleaner cap. Loosen the air cleaner hose clamp bolt. Disconnect the mass air flow meter connector.
Page 174 SF 37 THROTTLE BODY Rem ove the 2 b It o s, 2 nuts and throttle b ody from the in- take manifold. Remove the throttl e body gasket.
Page 175 SF-38 -· THROTTLE BODY INSPECTION 2ZZ-GE: Thr o t t l e Lever INSPECT THROTTLE VALVE Check that there is no clearance between the throttle stop screw and throttle lever when the closed throttle position. 1 ZZ-FE: INSPECT THROTTLE POSITION SENSOR Using an ohmmeter, measure the resistance between each ter...
Page 176 SF-39 THROTTLE BODY I NSTALLATION INSTALL THROTTLE BODY 1 ZZ-FE: Install a new gasket on the intake manifold, as shown in the illustration. 2ZZ-GE: Install a new gasket on the intake manifold, as shown in (c ) the illustration. Install the throttle body with the 2 bolts and 2 nuts. Torque: 1ZZ-FE: 21 N·m (210 kgf.cm, 1 5 ft.lbf) 2ZZ--GE: 22 N.m (220 kgf.cm, 1 6 ft·lbf)
Page 177 SF-40 !DLEAIR CONTROL lAC VALVE IDLE AIR CONTROL (lAC) VALVE Y, y ,v ,., ON-VEHICLE INSPECTION INSPECT lAC VALVE OPERATION Initial conditions; Engine at normal operating temperature Idle speed set correctly Transmission in neutral AJC switch OFF Using SST, connect terminals TC and CG of the DLC3. 09843-1 8020 After engine speed are kept at 900 - 1 ,300 rpm for 5 se- conds, check !hat they return to idle speed.
Page 178 SF-41 SFI -- lOU_ AiR CON fROL lAC' VALVE a� i · -l ---- - Speci f i e d torque...
Page 179 � SF-42 IDLE Aln 'ONH10L lAC VALVE Cyl i n der Head Cover �E VSV for EVAP Air Cleaner Cap wi t h Air Flow �� -:-./ Meter and Air Cl e aner Hose Ai r Fl o w Meter Connector + Gasket PC V Ho se...
Page 180 SF-43 IDLEAIR CONTROL lAG VALVE REMOVAL REMOVE THROTTLE BODY (See page SF-36) REMOVE lAC VALVE Remove the 4 screws. lAC va!ve and gasket B0/121...
Page 181 SF-44 IDLE AIR CONTHOL lAC VALVE INSPECTION INSPECT lAC VALVE OPERATION Check that the lAC valve is half opened. clo se Connect the lAC valve connector to the lAC valve. Disconnect the ECT sensor connector from the ECT sen- sor. Turn the ignition switch ON.
Page 182 SF-45 IDlE A!n CONTROL lAC VALVE I NSTALLATION Installation is i n reverse order of removal (See page SF-43). H INT: Install the lAC valve with a new gasket.
Page 183 SF-46 CAMSHArT TIMING OIL CONTROL VALVE CAMSHAFT TIMING OIL CONTROL 1ZZ-FE: VALVE ON-VEHICLE INSPECTION INSPECT OIL CONTROL VALVE RESISTANCE Remove the No. 2 cylinder head cover. 2ZZ-GE: Disconnect the 2 PCV hoses. Disconnect the oil control valve connector. (c ) Using an ohmmeter, measure the resistance between the terminals.
Page 184 SF---4 7 SFl - MSHAFT TIMING OIL CONIHOL VALVE COMPONENTS 1ZZ-FE: No . 2 Cyl i n der Head Cover - - � - - ;-- ' (}- -Ri n g Oi l Control Val v e - --- -- -- - -- -- -- -- - - � - - - � · - : N·m { kgf·...
Page 186 SF-49 CMiSHAFT TIMING OIL CONTROL VALVE REMOVAL REMOVE NO. 2 CYLINDER HEAD COVER 2ZZ-GE: DISCONNECT 2 PCV HOSES, UPPER FRONT FEND· ER APRONSEAL AND UPPER RAKIATOR SUPPORT SEAL 2ZZ-GE : REMOVE GENERATOR (See page CH-7) 2ZZ-GE: REMOVE NO. 1 VENTILATION PIPE Remove the 2 nuts, bolt and gasket.
Page 187 SF-50 CAMSHAFT TIMING OIL CONTHOL VALVE INSPECTION . . . - · · - - · - · � - - Connect the positive ( +) lead from the battery to terminal 1 and INSPECT CAMSHAFT OIL CONTROL VALVE OPERATION negative {-) lead to terminal 2, and check the movement of the valve.
Page 188 SF-51 CAMSHAFT liMING OJL CONTROL VALVE INSTALLATION Installation is in the reverse order of removal. (See page SF-49)
Page 189 SF-52 -· EFI MA1N RELAY EFI MAIN RELAY INSPECTION REMOVE EFI MAIN RELAY (Marking: EFI) INSPECT EFI MAIN RELAY CONTINUITY Conti n ui t y Using an ohmmeter, check that there is continuity be- Ohmmeter tween terminals 1 and 2. If there is no continuity, replace the relay.
Page 190 SF-53 CIRCUIT OPENING RELAY CIRCUIT OPENING RELAY INSPECTION REMOVE CIRCUIT OPENING RELAY INSPECT CIRCUIT OPENING RELAY CONTINUITY Continui t y Using an ohmmeter, check that there is continuity be Ohmmeter Ohmmeter tween terminals 1 and there is no continuity, replace the relay. Check that there is no continuity between terminals 3 and If there is continuity, replace the relay.
Page 191 SF-54 VSV FOR INTAKE AIR CONTROL VAlVE VSV FOR INTAKE AIR CONTROL VALVE COMPONENTS VSV for EVAP Air Cl e aner Cap �� Air Cl e aner Upper R adiator Support Seal Air Cleaner Case...
Page 192 SF-55 Ohmmel e r VSV FOR INTAKE AIR CONTROL VALVE INSPECTION ContintJity INSPECTVSV Inspect the VSV for open circuit. Using an ohmmeter, check that there is no continuity be" tween the terminals. Resistance: 37 - 44 .Q at 20�C (68.F) If there is no continuity, replace the VSV.
Page 193 SF-56 ·- VSV FOrl EVAPOHATIVE EMISSION (EVAP) VSV FOR EVAPORATIVE EMISSION (EVAP) COMPON ENTS VSV lor EVAP 8()9181...
Page 194 SF-57 VSV FOR EVAPORATIVE EMISSION (EVAP) "'"-' ,, INSPECTION REMOVE VSV Disconnect the EVAP hoses from the VSV. Disconnect the VSV connector, Remove the bolt and VSV. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the terminals.
Page 195 SF-58 VSV FOR CANISTER CLOSED VALVE (CCVl VSV FOR CANISTER CLOSED VALVE {CCV) COMPONENTS Air Cl e aner Hose...
Page 196 SF-59 VSV FOR CANISTER CLOSED VALVE (CCV) INSPECTION REMOVE VSV INSPECT VSV FOR OPEN CIRCUIT [ fi ] Using an ohmmeter, check that there is continuity between the terminals. Resistance: -· 20 'C (68 'F) If there is no continuity, replace the VSV. Ohmmet e r ' h ' No Cont i n ui t y...
Page 197 SF--<;0 VSV FOR PRESSURE SWITCHING VALVE VSV FOR PRESSURE SWITCHING VALVE COMPON ENTS Char c oal Cani s t e r Assembl y ------ ------ +Gasket Tai l Pi p e Speci f i e d t o r q ue + Non-r e usabl e par t...
Page 198 SF-61 VSV FOR PRESSURE SW11CHING VALVE INSPECTION REMOVE VSV Ohmmet e r INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. Resistance: Cont i n ui t y At20 'C(68'F) 37 � 44!1 At 120 ' C (248 'F) 51 -62Ll no continUity, replace the VSV.
Page 199 SF-j;2 ENGINE COOLANTTEMPERATURE (ECTl SENSOrt ENGINE COOLANT TEMPERATURE (ECT) SENSOR COMPONENTS 2ZZ-GE: Head No.2 Cyl i nder Cover Specifi e d torque lW9!BJ Non-reusabl e part...
Page 200 SF -63 ENGINE COOLANT TEMPERATURE {EC!) S!:'NSOH INSPECTION DRAIN ENGINE COOLANT REMOVE N0.2 CYLINDER HEAD COVER REMOVE ECT SENSOR INSPECT ECT SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals 1 (E2) and 2 (THW). Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor.
Page 201 SF-64 VAPOR PRESSURE SENSOR VAPOR P R ESSURE SENSOR ' " " " COMPONENTS Rear Seat Cushi o n Fl o or Ser v i c e Hol e Cover ·-·�"· Vapor Pr e ssur e Sensor Joi n t Clip...
Page 202 SF-65 VAPOR PRESSURE SENSOR INSPECTION vonmete' INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR Disconnect the vapor pressure sensor connector. HINTc Near the fuel tank. Turn the ignition switch ON. (c ) Using a voltmeter, measure the voltage between connec tor terminals 1 and 3 of the wiring harness side.
Page 203: Knock Sensor
SF--66 KNOCK SENS R KNOCK SENSOR COMPONENTS Cl i p 1ZZ-GE: �--- Apr o nSeal ��- - > - - : : ., , No. 2 Cyl i n der � Upper Fr o nt Fender Head Cover Upper Radi a t o r Suppor t Seal �...
Page 204 SF-67 KNOCK SENSOR No. 2 Cyl i n der Head Cover 2ZZ-GE: Upper Fr o nt Fender Apr o n Seal Upper Radi a t o r VSV f o r EVAP Support Seal � Radi a t o r Reser v oi r Cushi o n Ai r Fl a ·...
Page 205 SF-68 KNOCK SENSOR INSPECTION REMOVE THROTTLE BODY (See page SF-36) REMOVE RADIATOR RESERVOIR (See page C0-17) REMOVE INTAKE MANIFOLD (See page EM-42) REMOVE KNOCK SENSOR Disconnect the knock sensor connector. Using SST, remove the knock sensor. 09816-30010 INSPECT KNOCK SENSOR Using an ohmmeter, check that there is continuity between the Ohmmeter terminal and body.
Page 206 SF-69 XYGEN SENSOR HEATED OXY GEN SENSOR COMPONENTS Heat e d Ox ygen Sensor (Bank1 S ensor1)
Page 207 SF-70 HEAT CO XYGEN SENSOR INSPECTION INSPECT HEATER RESISTANCE OF HEATED OXY GEN SENSOR (Bank1 Sensor1) Disconnect the oxygen sensor connector. Using an ohmmeter, measure the resistance between the terminals +B and HT. Resistance: 11 - 1 6 n at 20"C (68 " F) lf the resistance is not as specified, replace the sensor.
Page 208 SF-71 ENGINE CONTROL MODULE (ECM) ENGINE CONTROL MODULE (ECM) COMPONENTS --- -- - - - -- -- --- - - - - ----- --- - -- -...
Page 209 Sf..-72 ENGINE CONTROL MODULE iECMl INSPECTION REMOVE ECM INSPECT ECM (See page Dl-20) REINSTALL ECM...
Page 210: Fuel Cut Rpm
SCAN TOOL Connect the TOYOTA hand-held tester or II scan tool to the DLC3. Please refer to the TOYOTA hand�held tester or ( b) scan tool operator's manual for further details. INSPECT FUEL CUT OFF RPM Increase the engine speed to at least 3,500 rpm.
Page 211 - MEMO -...
Page 212 COOLING COOLANT ..CG-1 C0-4 WATER PUMP THERMOSTAT CG-8 C0-1 2 RADI A TOR . ELECTRI C COOLI N G FAN ....C0-24 C0-31 COOLI N G FAN RELAY ..
Page 213 .--·. ;·.
Page 214 CHECK ENGINE COOlANT lEVEl AT RESERVOIR The engine coolant level should be between the and "FULL" line. "LOW" If low, check for leaks and add 'Toyota Long Life Coolant" or equivalent up to the "FULL" line. CHECK ENGINE COOlANT QUAliTY Remove the reservoir cap. CAUTION: To avoid the danger of being burned, do not remove the reservoir the cap while the engine and radla�...
Page 215 FULL !fne. Use of improper coolants may damage engine cool ing system. Use "Toyota Long Life Coolant'" or equivalent and mix it with plain water according to the manufac tures directions. Use of the coolant which includes more than 50% [freezing protection down to-35 •...
Page 216 C0-3 COOLING COO LAN T NOTICE: • Do not use an alcohol type coolant or plain water alone. • The coolant should be mix with plain water {prefer� ably demineralized water or distilled water). capacity: 1ZZ-FE: Qts, 5.7 1iners (6.0 US 5.0 Imp.
Page 217: Water Pump
C0-4 COOLING WATER PUMP WATER PUMP Upper Fr o nt Fend , e r Apr o n Sea! COMPONENTS � Upper Radi a t o r Suppor t Seat i..- - - - : Speci f i e d t o r q ue +Non-r e usabl e par 1...
Page 218 C0-5 COOLING WATER PUMP REMOVAL REMOVE RH ENGINE UNDER COVER DRAIN ENGINE COOLANT REMOVE DRIVE BELT (See page CH-7) 1ZZ-FE: REMOVE WATER PUMP Remove the 6 bolts, water pump and 0-ring. Clean up the engine coolant from the water chamber room.
Page 219 COOLING WATER PUMP INSPECTION INSPECT WA TER PUMP Visually check the drain hole for coolant leakage. lf leakage is found, replace the water pump. Turn the pulley, and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump.
Page 220 C0-7 COOLING WATER PUMP INSTALLATION 1ZZ-FE: INSTALL WATER PUMP Place a new 0-ring on the timing chain cover. Install the water pump with the 6 bolts. Torque: Bolt A 9.0 N-m (92 kgf.cm, in.-lbf) Bolt B 11 N-m (113 kgf . cm, 8 ft-lbf) Each bolt length is indicated in the illustration.
Page 222 C0-9 COOLING THERMOSTA T REMOVAL HINT: Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat. DRAIN ENGINE COOLANT REMOVE DRIVE BELT AND GENERATOR (See page CH-7) REMOVE WATER INLET AND THERMOSTAT Remove the...
Page 223 C0-10 COOUNG THERMOSTAT INSPECTION INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening tempera ture. Immerse the thermostat in water and gradually heat the water. Check the valve opening temperature. Valve opening temperature: 80.0 - 84.0"C (176 - 183"F) !I the valve opening temperature is not as specified, replace the thermostat Check the valve lift.
Page 224 C0-11 � COOUNG THERMOSTAT INSTALLATION PLACE THERMOSTAT IN CYLINDER BLOCK Install a new gasket to the thermostat Install the thermostat with the jiggle valve upward. HINT: The jiggle valve may be set within 1 0 � of either side of the pre scribed position_ INSTALL WATER INLET Install the water inlet with the...
Page 225 CD-12 COOLING RAD! TOR RADIATOR ON-VEHICLE CLEANING Using water or a steam cleaner, remove any mud or dirt from the radiator core. NOTICE: If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. {i.e. Main tain a distance between the cleaner nozzle and radiator core.)
Page 226 C0-13 COOLING - RADIATOR ON-VEHICLE INSPECTION REMOVE RESERVOIR CAP CAUTION: To avoid the danger of being burned, do not remove the res· ervoir cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. INSPECT RESERVOIR CAP NOTICE: If the reservoir cap has contaminations, always rinse...
Page 227 C0-- 1 4 COOUNG RADIATOR INSPECT COOLING SYSTEM FOR LEAKS Fill the radiator with coolant and attach a radiator cap tes� ter. Warm up the engine. Pump it to 1 1 8 kPa {1 .2 kgf/cm2, 1 7.1 psi), and check that (c ) the pressure does not drop.
Page 228 C0-15 COOLING AAOIArOR Upper Fr o nt Fender Apr o n Seal COMPONENTS · Cool a nt Reser v oi r Engme Upper Radi a t o r Suppor t Seal Cr u i s e Cont r o l Act u at o r Upper Radi a t o r VSV f o r EVAP...
Page 229 C0-16 COOUNG nADIATOR El e ct r i c Cc, o H'1 C Fan Tank DENSO Made + 0-Ri n g Pl a t e Washer Tank 0-Ring Cool e r Pi p e Dr a i n Pl u g Pl a t e Washer Cor e 0-Ring...
Page 230 C0-17 COOLING RADIATOR REMOVAL REMOVE UPPER FRONT FENDER APRON SEAL AND UPPER RADIATOR SUPPORT SEAL DRAIN ENGINE COOLANT REMOVE BUMPER COVER ( S ee page B<J.-4) REMOVE AIR CLEANER REMOVE ENGINE COOLANT RESERVOIR Disconnect the 3 radiator reservoir hoses. (b ) Remove the bolt and engine coolant reservoir.
Page 231 C0-18 COOUNG RADIATOR DISASSEMBLY REMOVE DRAIN PLUG Remove the drain plug. Remove the 0-ring. DENSO Made: . . . ASSEMBLE SST 09230- 0 1 0 1 0 Install the claw to the overhaul handle, inserting it in the " " hole in part as shown in the diagram.
Page 232 C0-19 COOUNG RAOJATOn INSPECTION DENSO Made; INSPECT LOCK PLATE FOR DAMAGE HINT: If the sides of the Jock plate groove are deformed, reas� sembty of the tank wlll be impossible. • Therefore, first correct any deformation with pliers or simi Core lar object.
Page 234 C0-21 COOLING - RADIATOR DENSO Made: CAULK LOCK PLATE Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, fully caulk the lock plate by squeezing the handle until stopped by the stopped plate . 0923CHJ1 0 1 0 lock Plate...
Page 235 CQ-22 � OUNG ATOR INSPECT FOR WATER LEAKS Tighten the drain plug. Install the engine coolant reservoir. Plug the inlet and outlet pipes of the radiator with SST. 09230-01 0 1 0 Using a radiator cap tester, apply pressure t o the radiator. Test pressure: 1 77 (1.8 kgffcm2, 26 psi) Submerge the radiator in water.
Page 236 C0-23 -· COOLING RADIATOR INSTALLATION INSTALL ELECTRIC COOLING FAN RADIATOR Install the cooling fan with the bolts. Torque: 5.0 N.m (51 kgf.cm, 44 in.·lbf) INSTALL RADIATOR ASSEMBLY (a ) Install the lower radiator support bushings. Install the radiator assembly. Install the upper radiator support bushings.
Page 237 C0-24 COOLING ELECTRIC COOLING FAN ELECTRIC COOLING FAN ON-VEHICLE INSPECTION CHECK COOLING FAN OPERATION WITH LOW TEM- PERATURE (Below 83'C (181 'F)) Turn the ignition switch ON. Check that the cooling fan stops. If not, check the cooling fan relay and ECT sensor, and check for a separated connector or severed wire between the cooling fan relay and ECT sensor.
Page 238 C0-25 ·· COOLING ELECTRIC COOLING FAN COMPONENTS Upper Fr o nt Fender pr A on Seal Engi n e Cool a nt Reser v oi r Cr u i s e Cont r o l Act u at o r Upper Radi a t o r Upper Radi a t o r Suppor t Seal Suppor t Ai r Cl e aner Case...
Page 239 co-zs COOLING ELECTRIC COOLING FAN w/ AJC Fan Shr o ud Fan Mot o r Fan Mot o r wlo AJC...
Page 240 C0-27 COOLING ELECTRIC COOLING FAN REMOVAL REMOVE UPPER FRONT FENDER APRON SEAL AND UPPER RADIATOR SUPPORT SEAL DRAIN ENGINE COOLANT REMOVE BUMPER COVER (See BQ-4) page REMOVE RADIATOR UPPER SUPPORT Remove the air cleaner assembly. Remove the engine coolant reservoir. bolts, and disconnect the hood lock.
Page 241 C(}-28 ELECTRIC COOLING DISASSEMBLY REMOVE FAN(S) Remove the nut and fan. REMOVE FAN MOTOR(S) Disconnect the wire and connector holder from the fan shroud. Remove the 3 screws and fan motor.
Page 242 C0-29 COOLING ELECTRIC COOLING F AN REASSEMBLY INSTALL FAN MOTOR(S) Install the fan motor with the 3 screws. •. Torque: 2.55 N·m (26 kgf . cm, 23 in lbl) (b ) Install the wire and connector holder to the fan shroud. INSTALL FAN(S) Install the fan with the nut.
Page 243 C0-30 COOUNG ELECTRIC COOLING FAN INSTALLATION INSTALL COOLING FAN Install the cooling fan with the 2 bolts. Torque: 5.0 N.m (51 kgf .cm, 44 in lbf) Connect the 2 cooling fan connectors. INSTALL RADIATOR UPPER SUPPORT Install the radiator upper support with the 2 bolts. w/ Cruise control system: Instal! the cruise control actuator with the 3 bolts.
Page 244 C0-31 COOLING COOLING FAN RELAY COOLING FAN R ELAY INSPECTION INSPECT NO. 1 COOLING FAN RELAY Remove the relay box cover. (a ) Remove the No. 1 cooling fan relay. (Marking: FAN No. i ) Cont l- I D _ ! ( i ) Inspect the No.
Page 245 C0-32 RElAY COOLING COOLING FAN Inspect the No. 2 cooling fan relay operation. Apply battery positive voltage across terminals 1 { 1 ) and 2. Using an ohmmeter, check that there is no continu {2 ) ity between terminals 3 and 4. If there is continuity, replace the relay.
Page 246 LUBRICATION OI L AND FI L TER ..LU -1 LU-5 OI L PUMP ..OI L NOZZLE ( 2 ZZ- - -G E) . LU-1 4...
Page 248 FilTER LU-1 LUBRICATION OIL AND OIL AND FILTER INSPECTION CHECK ENGINE OIL QUALITY Check the oil for deterioration, entry of water, discoloring or thin· ning. If the quality is visibly poor, replace the oil. f O.Wff<,UUilE fjANQE M4TICII'Aif0 llHORE NEXT Oil (;IIA"GF Oil grade: API grade or SJ, Energy-Conserving or ILSAC multi�...
Page 249 LU-2 Adhesi v e LUBRICA TION OIL AND FILTER Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833-00080, THREE BOND 1 344 , LOCTITE 242 or equivalent Using SST, install the oil pressure switch. 09816-30010 Torque: 1 3 N-m (130 kgf-cm, 9 ft-lbf) START ENGINE AND CHECK FOR LEAKS...
Page 250 LU-3 LUBRICATION OIL AND FILTER ' ' ' "'- "' REPLACEMENT CAUTION: • Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addi· tion, used engine oil contains potentially harmful contaminants which may cause skin cancer.
Page 251 LU-4 OIL AND fiLTER Fill with fresh engine oil. Capacity 1ZZ-FE Drain and refill: wl Oil filter change: 3.7 1iters (3.9 US qts, 3.3 1mp. qts) w/o Oil filter change: 3.5 1iters {3.7 US qts, 3.1 1mp. qts) Dry fill: 4.1 liters (4.3 US qts, 3.6 Imp. qts) 2ZZ--GE wf Oil filter change: 4.4 1iters (4.8 US qts, 4.0 Imp.
Page 252: Oil Pump
LU-5 LUBRICATION PUMP OIL PUMP COMPONENTS Upper Fr o nt Fender Apr o n Seal � PS Oi l Pr e ssur e Dr i v e Bel t Swi t c h Connect o r PS Pump Upper Radi a t o r Suppor t Seal �...
Page 253 LU-8 PUMP BRlCATION Engi ne Mount i n g Br a cket 1ZZ-FE' --�, • PCV Hose � ai n Tensi o nor � � 1 P Per Ti m i n g Chai n Cham V1 b r a t 1 o n Damper Sensor Pl a t e Cr a nkshaf t Ti .
Page 254 LU-7 PUMP LUBRICATION 2ZZ-GE: Fr o nt Oi l Seal e • Cr a nkshaf t Cr a nkshaf t D Chai n Vi b r a t i o n _ . l ( 9 2, 8 0i o . T bi ) ' nk Angl e Sensor Pl a t Cr a nkshaf t Ti m i n g S pr o cke t t o r q ue...
Page 255 LU-8 � LUBRICATION OILPUMP � · - � · Oi l Pump B d Cover � ;::: :, _ Plug 1 ° - - - � -Spr i n g � ::;::, - - - Rel i e f Val v e �...
Page 256 LU-9 LUBRICATION - PUMP REMOVAL DRAIN ENGINE OIL REMOVE TIMING CHAIN AND CRANKSHAFT TIMING SPROCKET (See pages EM-18) REMOVE OIL PUMP Remove the bolts, oil pump and gasket .
Page 257 LU-10 LUBRICATION PUMP DISASSEMBLY REMOVE RELIEF VALVE Remove the plug, spring and relief valve. REMOVE DRIVE AND DRIVEN ROTORS 1ZZ-FE: Remove the screws, pump body cover, drive and driven rotors. 2ZZ-GE: Remove the 5 screws, pump body cover, drive and driven rotors.
Page 258 LU-11 LUBR!CATION O!L PUMP INSPECTION INSPECT OIL JET Check the oil jet tor damage or clogging. II necessary, replace the oil pump assembly. INSPECT RELIEF VALVE Coat the valve with engine oil and check that it falls smoothly into the valve hole by its own weight. If it does not, replace the relief valve.
Page 259 LU-1 2 PUMP LUBRICATION REASSEMBLY INSTALL DRIVE AND DRIVEN ROTORS Place the drive and driven rotors into pump body with the marks facing the pump body cover side. 1 ZZ-FE: Install the pump body cover with the 3 screws. Torque: 10.5 N-m (107 kgl-cm, 8 fl·lbf) 2ZZ-GE: screws.
Page 260 LU-13 LUBRICATION OIL PUMP INSTALLATION INSTALL OIL PUMP Place a new gasket on the cylinder block, Engage the spline teeth of the oil pump drive rotor with the (b ) large teeth of the crankshaft, and sllde the oH pump. Install the oil pump with the bolts.
Page 262 LU-15 LUBRICATION OIL NOZZLE (2U�GE} REMOVAL REMOVE CRANKSHAFT (See page EM··-El9) REMOVE OIL NOZZLE (WITH RELIEF VALVE) Using a 5 mm hexagon wrench, remove the bolt and oil nozzle.
Page 263 LU-16 OIL NOZZLE (2ZZ--GE) lUBRICATION INSPECTION INSPECT RELIEF VALVE (OIL NOZZLE) Push the valve with a wooden stick to check if it is stuck. If stuck, replace the relief valve<...
Page 264 LU-17 LUBR!CAT!ON OIL NOZZLE (2ZZ--GE) I NSTALLATION INSTALL OIL NOZZLE (WITH RELIEF VALVE) Using a 5 mm hexagon wrench, instal! the oil nozzle witll the bolt. Torque: 9.0 N-m (92 kg!-em, 80 in.-lbf) INSTALL CRANKSHAFT (See page EM-106)
Page 265 - ME M O -...
Page 266 IGNITION I G NI T I O N SYSTEM ..... . J G -1 I G �5 I G NI T I O N COI L CAMSHAFT POSI T I O N SENSOR . I G -8 I G - · 1 1 CRANKSHAFT POSI T I O N SENSOR...
Page 268: Ignition System
JG-1 IGNITION SYSTEM IGNITJON IGNITION SYSTEM ON-VEHICLE INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the tempera� ture of the coils themselves. "Cold" is from -10"C (14 "F) to 50'C (122'F) and "Hot" is from 50'C (122'F) to 100'C (212'F).
Page 269 IG-2 � SYSTEM IGNITION IGNITION !f the spark does not occur, do the test as follows: t h e i CHANGE IT TO NORMAL IGNITION COIL (WITH ------ Replace o n coi l (wi t h i g ni t er). Check IGNITER) AND PERFORM SPARK TEST AGAIN t o i g ni t i o n coi l...
Page 271 IG-4 IGNITION - IGNITION SYSTEM INSPECT CAMSHAFT POSITION SENSOR 1ZZ-FE: Disconnect the camshaft position sensor connector. Using an ohmmeter, measure the resistance between ter minals. Resistance: 835- 1,400 !1 1,060 -1,645 If the resistance is not as specified, replace the camshaft posi tion sensor.
Page 272: Ignition Coil
COIL IGNITION lGNll!ON IGNITION COIL COMPONENTS 2ZZ-GE: N o .2 Cyl i n der Head e N o . 2 Cyl i n der Head Cover 1ZZ-FE·. • }--'it 4 I g ni t i o n Coi l ( w i t h l g ni ! o c ) 9.0 (92, 791n.-lb Speci f i e d t o r q ue...
Page 273 IG-6 IGNITION IGNITION COIL REMOVAL REMOVE NO. 2 CYLINDER HEAD COVER REMOVE IGNITION COILS (WITH IGNITER) FROM SPARK PLUGS Remove the 2 bolts and disconnect the wire harness pro tector. Disconnect the 4 ignition coil connectors. Remove the 4 bolts and pull out the ignition coils {with igniter).
Page 274 IG-7 IGNmON IGNITION COIL I NSTALLATION Installation is in the reverse order of removal (See page IG-6).
Page 276 IG-9 IGNITION CAMSHAfT POSITION SENSOfl REMOVAL REMOVE NO. 2 CYLINDER HEAD COVER 1ZZ-FE: REMOVE CAMSHAFT POSITION SENSOR Disconnect the connector. Torque: 8.8 N·m (90 kgf.cm, 78 in.·lbf) Remove the bolt and camshaft position sensor. 2ZZ-GE: REMOVE CAMSHAFT POSITION SENSOR Disconnect the connector. Remove the 2 bolts and camshaft position sensor.
Page 277 IG-10 � IGNITION CAMSHAFT POSITION SENSOR INSTALLATION Installation Is in the reverse order of removal (See page IG-9).
Page 279 IG-12 �, IGNITION CRANKSHAFT POSITION SENSOR 2ZZ-GE: Upper �ron! Fender Apron Sea! VSV for EVAP Air Filter Oil Dipstick and Oil Guide � Air Cleaner Case Engine Wire · Specified torque + Non-reusable part...
Page 280 IG-13 IGNffiON CRANKSHAFT POSITION SENSOR REMOVAL REMOVE INTAKE MANIFOLD (See page EM-42) REMOVE ENGINE UNDER COVER RH REMOVE CRANKSHAFT POSITION SENSOR Disconnect the crankshaft position sensor connector. Remove the 2 bolt and crankshaft position sensor. Torque: 8.8 N-m (90 kgf . cm, 78 1n.-lbn...
Page 281 IG-14 Ohmmet e r -J A - lGN/TfON CRANKSI FT POSITlQ ENSOR INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the tempera� ture of the sensor Itself. "Cold" is from-10�C ( 1 4 •F) 50�C and "Hot" is from (122.F) 5o·c (122.F) 100•c ( 2 1 2 .
Page 282 IG-15 � IGNITION CRANKSHAFT POSITION SENSOR INSTALLATION Installation is in the reverse order of removal {See page IG-13).
Page 283 MEMO�...
Page 284 STARTING STARTI N G SYSTEM ST -1 ST-2 STARTER STARTER RELAY . ST-1 7 ....
Page 286 ST-1 ST ARTING STARTING SYSTEM S TARTING SYSTEM ON-VEHICLE INSPECTION NOTICE: • Before changing the starter, check these items again: Connector connection Accessory installation, e.g.:theft deterrent system...
Page 287 ST-2 STAH fEn STARTING STARTER Ai r F l o w Met e r Connect o r COMPONENTS Ai r Cl e aner Ai r Cl e aner Case Upper Radi a t o r Suppor t Seal LH Engi n e Under Cover RH Engi n e Under C over...
Page 289 ST-4 ST AR TIN G STARTEFI REMOVAL REMOVE UPPER RADIATOR SUPPORT SEAL REMOVE AIR CLEANER ASSEMBLY (See page EM-74) REMOVE RH AND LH ENGINE UNDER COVER REMOVE STARTER Disconnect the starter connector. Remove the nut, and disconnect the starter wire. Remove the 2 bolls and starter.
Page 290 ST-5 STARTING STARTER DISASSEMBLY REMOVE FIELD FRAME WITH ARMATURE FROM MAGNETIC SWITCH ASSEMBLY Remove the nut, and disconnect the lead wire from the magnetic switch terminal. Remove the 2 through bolts. Remove the 2 screws and end cover from the field frame. (c ) 0 R .
Page 291 ST-6 STARTING fARTErl REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEARS Remove the 2 bolts. Torque: 5.9 N·m (60 kgf.cm, lbf) 52 in Remove these parts from the magnetic switch assembly: { 1 ) Starter housing (2 ) Idler gear Bearing ( 5 ) �...
Page 292 ST-7 STARTFH STARTING INSPECTION INSPECT ARMATURE COIL COMMUTATOR FOR Continuity OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the segments of the commutator. If there is no continuity between any segment, replace the ar mature. INSPECT ARMATURE COIL COMMUTATOR FOR GROUND Using an ohmmeter, check that there is no continuity between the commutator and armature coli core.
Page 293 ST-8 STARTING STARTEn INSPECT FIELD FRAME (FIELD COIL) FOR OPEN Ohmmeter CIRCUIT Using an ohmmeter, check that there is continuity between the lead wire and field coil brush lead. II there is no continuity, replace the field frame. INSPECT FIELD FRAME (FIELD COIL) GROUND Using an ohmmeter, check that there is no continuity between Ohmmeter the field coil end and field frame.
Page 294 ST-9 STARTING STARTER INSPECT BRUSH HOLDER INSULATION 1 1 . Ohmmeter Using an ohmmeter, check that there is no continuity between the positive (+) and negative (-) brush holders. If there is continuity, repair or replace the brush holder. INSPECT GEAR TEETH Check the gear teeth on the pinion gear, idler gear and clutch assembly lor wear or damage.
Page 297 ST-12 STARTER STARTING Tighten terminal nut. Put a wooden block on the contact plate and press ( 1 ) it down with a hand press. Dimensions of wooden block: 40 mm (0.79 1.57 in.) 1 .46 Press force: 981 N (100 kgf, 221 lbf) NOTICE: Check the diameter of the hand press ram.
Page 298 ST-13 � STARTING STARTER REASSEMBLY HINT: Use high-temperature grease to lubricate the bearings and gears when assembling the starter, INSTALL ARMATURE TO MAGNETIC SWITCH AS· SEMBLY 2ZZ-GE: Ring Rotating the ring of the front bearing, set it properly so that the projection of the ring is positioned in the narrowest part Apply grease to the armature bearings.
Page 299 ST-14 -� STARTER STARTING Place these parts on the starter housing: ( 1 ) New 0--- r ing Starter clutch assembly Idler gear Bearing Install the starter housing to the magnetic switch with the 2 screws. Torque: 9.3 N·m (95 kgf.cm, 82 in.·lbf) INSTALL FIELD FRAME Install a new 0-nng to the groove of the f1led frame.
Page 300 ST-1 5 ·- STARTING STARTER TEST T erminal NOTICE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. D O PULL-IN TEST Disconnect the field coil lead wire from terminal C. Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear moves outward.
Page 301 ST-16 STARTER STARTING INSTALLATION INSTALL STARTER Install the 2 bolts and starter. HINT: Each bolt length is indicated in the illustration. Bolt length A 64 mm (2.72 in.) 8 54 mm (2.13 in.) Connect the starter wire, and install the nuL Connect the starter connector.
Page 302 ST-17 STARTER RFLIIY STARTING STARTER RELAY INSPECTION REMOVE STARTER RELAY INSPECT STARTER RELAY CONTINUITY Using an ohmmeter, check that there is continuity be tween terminals 1 and there is no continuity, replace the relay. Check that there is no continuity between terminals 3 and Ohmmet e r If there is continuity, replace the relay.
Page 303 � M EM O-...
Page 304 CHARGING CHARGING SYSTEM . CH -1 GENERATO R . CH- 5...
Page 306: Charging System
CH-1 CHARGING SYSTEM CHARGING CHARGING SYSTEM PRECAUTION • Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge. Do not pertorm tests with a high voltage insulation resistance tester. Never disconnect the battery while the engine is running.
Page 307 CH-2 CHARGING CHAflGING SYS ON-VEHICLE INSPECTION CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. Maintenance-- F ree Battery: If under the lower level, replace the battery (or add distilled wa ter if possible) and check the charging system. Except Maintenance-Free Battery: If under the lower level, add distilled water.
Page 308 CH-3 -· CHARGING SYSTEM CHARGING INSPECT DRIVE BELT Visually check the belt for excessive wear, frayed cords etc. If any defect has been found, replace the drive belt. HINT: • Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced.
Page 309 CH-4 CHAR lNG CHARGING SYS fi:M INSPECT CHARGING CIRCUIT WITHOUT LOAD HINT: If a battery/generator tester is available, connect the tester to the charging circuit as permanufacturer's instructions. lf a tester is not available, connect a voltmeter to the charging circuit as follows: •...
Page 310 CH-5 CHARGING GENERATOR GENERATOR Upper Fr o nt Fender COMPONENTS Apron Seal 2ZZ-GE: 7.0 {71, in.·lbf} Cyl i n der Head Cover {71, in.-lbf} Gener a t o r No.2 Cyl i n der Head Cover (!()712B...
Page 311 CH-6 -� CHARGING GENERATOR + Fr o nt Bear i n g Gener a t o r Washer Rot o r + Rear Bear i n g ---- ."'e � Re Ret a i n er Bear i n g over Beari n g Cover Pi a t e : T .
Page 312 CH-7 CHARGING GENEHAlOH REMOVAL REMOVE DRIVE BELT Turn the drive belt tensioner slowly clockwise and loosen it. Then, remove the drive belt and replace the drive belt tensioner little by little and fix it qu· l etly. ll·) {l,.� REMOVE GENERATOR ( a) Disconnect the wire clamp from the wire clip on the recfili�...
Page 313 CH-8 CHARGING GENERAfOH DISASSEMBLY REMOVE REAR END COVER Remove the nut and terminal insulator. (a ) Remove the bolt, 3 nuts, plate terminal and end cover. REMOVE BRUSH HOlDER AND VOlTAGE REGUlA- Remove the brush holder cover from the brush holder. Remove the 5 screws, brush holder and voltage regulator.
Page 314 CH-9 � CHARGING GENERATOR To loosen the pulley nut, turn SST {A) in the direction shown the illustration. NOTICE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn. Remove the generator from SST (C). Turn SST (8), and remove SST (A and B).
Page 315 CH-10 � GENERA TOn CHARGING �,. INSPECTION INSPECT ROTOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the slip rings . Standard resistance: Cont i n ui t y MT 2.7 - at 20"C (68"F) 3.H l AT 2.1 - 2.5 at 20"C (68"F) If there is no continuity, replace the rotor.
Page 316 � CHARGING GENERATOR INSPECT EXPOSED BRUSH LENGTH Using vernier calipers, measure the exposed brush length. Standard exposed length: 9.5 - 1 1 .5 mm (0.374 - 0.453 in.) Minimum exposed length: 1.5 mm (0.059 in.) If the exposed length is Jess than minimum, replace the brush holder assembly.
Page 317 CH-12 �· CHARGING GENERATOR Using SST and a press, press out the bearing. Wrench 09950-60010 (09951-00350) 09950-70010 (09951-Q7100) Using SST and a press, press in a new bearing. 09950-60010 (09951 -00530) 09950-7001 0 (09951-Q7100) Install the bearing retainer with the 4 screws. (d ) Torque' 3.0 N-m (31 kgf.cm, 27 ln.-lbf) 1 1 .
Page 318 CH-13 CHARGING GENERATOR ( d) Using SST and a press, press in a new bearing. SS T 0982CHJ0030 N00578 Using SST, push in the bearing cover (outside). (e ) 09285-76010...
Page 319 CH-14 '"' GENERATOfl CHARGING REASSEMBLY INSTALL ROTOR TO DRIVE END FRAME Place the drive end frame on the pulley. (a ) Pulley Install the rotor to the drive end frame. B<):j219 INSTALL RECTIFIER END FRAME Place the generator washer on the rotor. Socket Wr e nch Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.
Page 320 CH-15 CHARGING GENERATOR Mount SST (C) in a vise. Insert SST (B) into SST (C), and attach the pulley nut to SST (C). To torque the pulley nut, turn SST ( A ) in the direction shown in the illustration . Torque: 1 1 1 N·m (1,125 kgf.cm, 81 ft·lbf) Remove the generator from SST (C).
Page 321 CH-16 �· CHARGING GENERATOR INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER Place the seal plate on the rectifier end frame. (l(}9166 Place the voltage regulator and brush holder on the recti- Upward fier end frame. [illB' NOTICE: Be careful of the holder Installation direction. Install the 5 screws.
Page 322 CH-17 CHARGING GLNtRATOR INSTALLATION INSTALL GENERATOR Install the 2 bolts and generator. Torque: 14 mm head 25 N-m (250 kgf.cm, 18 ft·lbf) 1 7 mm head 1ZZ-FE: N-m {550 kgf-cm, 40 ft.Jbf) 2ZZ-GE: 58 N-m (590 kgf-cm, 43 ft.lbf) 2ZZ-GE: Install the generator bracket with the 2 bolts.
Page 323 - MEMO --...
Page 324 CLUTCH TROUBLESHOOTING ..CL-1 CLUTCH PEDAL ..CL-2 CLUTCH MASTER CYLINDER CL-4 CLUTCH RELEASE CYLINDER CL-9 CLUTCH UNIT ..CL-14...
Page 326: Troubleshooting
CL-1 CLUTCH TROUBLESHOOTING TROUBLESHOOTING PROBLEM SYMPTOMS TABLE Use the table below to help you lind the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts Suspect Area Symptom See page...
Page 327: Clutch Pedal
Cl-2 CLUTCH PFDAL Push Rod Pl a y and � CLUTCH Fr e e Pl a y Adj u st Poi n t CLUTCH PEDAL INSPECTION CHECK PEDAL HEIGHT Pedal height from asphalt sheet: Standard pedal: 135.6 - 145.6 mm (5.339 - 5.732 in.) Sport pedal: 136.9 - 146.9 mm (5.390 - 5.783 in.) IF NECESSARY, ADJUST PEDAL HEIGHT...
Page 328 CL-3 CLUTCH CLUTCH PEDAL CHECK CLUTCH START SYSTEM Check that the engine does not start when the clutch ped� al is released. Check that the engine starts when the clutch pedal is ful!y depressed. If necessary, replace the clutch start switch. Clutch Start Switch ()07 700 INSPECT CLUTCH START SWITCH CONTINUITY...
Page 330: Clutch Master Cylinder
CL-5 CLUTCH CLUTCH MASTER CYLINDER REMOVAL REMOVE BRAKE BOOSTER (See page BR-15) �� DISCONNECT RESERVOIR HOSE Using pliers, disconnect the clip. /- - (b ) Disconnect the reservoir hose from the inlet union. Use a container to catch the fluid. 001100 DISCONNECT CLUTCH LINE Using SST, disconnect the clutch line.
Page 331 CL...S CLUT H CLUTCH MASTER CYLINDER DISASSEMBLY REMOVE INLET UNION Using a pin punch (3 mm) and hammer, drive out the slotted spring pin. Remove the inlet union. Remove the grommet. REMOVE CLEVIS Loosen the lock nut to remove the clevis and remove the lock nut.
Page 332 CL-7 � CLUTCH CLUTCH MASTER CYLINDf:: r l REASSEMBLY COAT PARTS WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWN IN ILLUSTRATION INSERT PiSTON WITH SPRING INTO CYLINDER INSTALL PUSH ROD Install the washer to the push rod. Push the push rod into tho piston, using snap ring pliers, install the snap ring.
Page 333 CL-<3 CLUTCH MASTER CYLINDER CLUTCH I NSTALLATION INSTALL MASTER CYLINDER WITH 2 MOUNTING NUTS Torque: 1 2 N-m (120 kgf.cm, 9 ft·lbl) INSTALL PIN AND CLIP CONNECT CLUTCH LINE Using SST, connect the clutch line. 09023-00100 Torque: 15 N-m (155 kgf.cm, 11 ft·lbf) CONNECT RESERVOIR HOSE Connect the reservoir hose to the inlet union.
Page 334: Clutch Release Cylinder
CL-9 CLUTCH R[LEASE CYLINDER CLUTCH CLUTCH RELEASE CYLINDER COMPON ENTS ?ill�L - Bl e �- � �� (85, 74 in. · !bf} Release Cyli n der Clutch Li n e Bracket Pi s ton Push Rod Boot Clutch Li n e Cl a mp Cl u tch Une...
Page 335 CL-10 CLUTCH CLUTCH RELEASE CYLINDER REMOVAL DISCONNECT CLUTCH LINE Raise the vehicle. CAUTION: Make sure that the vehicle is securely supported. Remove the LH and RH engine under covers. Using SST, disconnect the clutch line. 09023-001 00 Use a container to catch the fluid. Lower the vehicle.
Page 336 CL-11 CLUTCH RELEASE CYLINDEH CLUTCH DISASSEMBLY REMOVE BOOT ANO PUSH ROO Pull ou t the boot with the push rod. Remove the boot from the push rod. REMOVE PISTON AND SPRING Using compressed air, remove the piston with the spring from the cy li nd e r NOTICE: •...
Page 337 CL-12 R EASSEMBLY INSTALL BLEEDER PLUG Torque: 8.4 N·m (85 kgf.cm, 74 in.·lbf) COAT PISTON WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWN INSTALL PISTON AND SPRING INTO CYLINDER INSTALL BOOT AND PUSH ROD Install the push rod to the boot. Install the boot with the push rod to the cylinder .
Page 338 CL-13 CLUTCH CLUTCH RELEASE CYLINDER INSTALLATION INSTAll RELEASE CYLINDER Install the release cylinder and clutch line bracket with the 2 bolts. Torque: 12 N·m (120 kgf . cm, 9 fl·lbf) Install the clutch line clamp to the clutch line bracket with the bolt.
Page 339: Clutch Unit
CL-14 CLUTCH CLUTCH UNIT CLUTCH UNIT COMPONENTS • 4 9 {500 , 36) Fl yw heel N· m { k gf - c m, l t : l b f • Non-r e usabl e par t Boot -<>Cl u t c h spl i n e gr e ase Rel e ase hub gr e ase...
Page 340 CL-15 CLUTCH UNIT CLUTCH REMOVA L (C56: See page MX-4) REMOVE TRANSAXLE FROM ENGINE (C60: See page MX-4) REMOVE CLUTCH COVER AND DISC Align the matchmark on the clutch cover with the one on the flywheel. Loosen each set bolt one turn at a time until spring tension is released.
Page 341 Cl-16 CLUTCH CLUTCH UNIT " - " " _ ,.. INSPECTION INSPECT CLUTCH DISC FOR WEAR OR DAMAGE Using vernier calipers, measure the rivet head depth. Minimum rivet depth: 0.3 mm {0.012 1n.) If necessary, replace the clutch disc. INSPECT CLUTCH DISC RUNOUT Using a dial indicator, check the disc runout.
Page 342 CL-17 ClUTCH CLUTCH UNIT INSTALLATION INSTALL CLUTCH DISC AND CLUTCH COVER ON FLYWHEEL Insert SST in the clutch disc, then insert them in the fly � wheeL 09301-0021 0 HINT: Take care not to insert clutch disc in the wrong direction. Align the matchmarks on the clutch cover and flywheel.
Page 343 -MEMO --...
Page 344 MANUAL TRANSAXLE (C56) TROUBLESHOOTING ..MX·-1 MANUAL TRANSAXLE UNIT . MX-2 MANUAL TRANSAXLE ASSEMBLY MX--9 INPUT SHAFT ..MX-26 OUTPUT SHAFT . . MX-34 SHIFT AND SELECT LEVER SHAFT . . . MX-44 DIFFERENTIAL CASE .
Page 346 MX-1 MANUAL TROUBLESHOOl !NG TROUBLESHOOTING PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace parts. Symptom Suspect Area See page...
Page 347 MX-2 MANUAL TAANSAXLE UNIT MANUAL TRANSAXLE(C56l MANUAL TRANSAXLE U NIT COMPONENTS Ai r Cl e aner Case Assembl y wi t h Ai r Nut C a Cl i p � � . . . � , ili - - - - � - - " 13(1 3 0 , , s�9(7Q, ECM Cover...
Page 348 MX-3 Fr o nt Dr i v e Shaf t MANUAL TR/\NSAXU:: UNIT MANUAL TRANSAXL£ Pi n Cotter - LH Engine Under Cover Engine Under Cover Speci f i e d t o r q ue [ f!� _{!(gi-:CrTI:fNbijl [}0.'1!7 Non reusable part...
Page 349 MX-4 MANUAL TRANSAXLE UNIT MANUAL TAANSAXLE REMOVAL REMOVE HOOD HINT: At the !!me of installation, please refer to the following item. Adjust the hood. (See page 80-9) REMOVE NO. 2 CYLINDER HEAD COVER Remove the 2 nut caps, clips and 2 cylinder head cover.
Page 350 MX--5 MANUAL TRANSAXLE MANUAl, TRANSAXLE UNIT DISCONNECT CLUTCH RELEASE CYLINDER Remove the 4 set bolts of the clutch line. Torque: Bolt A: 12 N-m (120 kgf.cm, 9 ft-lbf) Bolt B: 4.9 N-m (50 kgf.cm, 43 ln.-lbf) Remove the 2 set bolts of the clutch release cylinder and dutch l"lne bracket.
Page 351 MX-6 MANUAL TRANSAXLE UNIT Attach the engine chain hoist to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part. REMOVE ENGINE LEFT MOUNTING BRACKET 3 SET BOLTS AND NUT Torque: Bolt A: 60 N·m (610 kgf-cm, 44 ft-lbf) Nut B: 80 N-m (820 kgf-cm, 59 11-lbf) REMOVE ENGINE LEFT MOUNTING BRACKET...
Page 352 MX-7 MANUAL TAANSAXLE MANUAL TRANSAXLE UN!T Disconnect the front exhaust pipe from the pipe supports and remove it. REMOVE FRONT SUB-FRAME AND LOWER SUS· PENSION ARM (a ) Tie the PS gear assembly the proper position with a code or an equivalent to suspend the assembly securely. Remove the 4 set bolts of the PS gear assembly.
Page 353 MX-8 MANUAL TRANSAXLE UNIT MANUAL TRANSAXLE INSTALLATION Installation is in the reverse order of removal. (See page MX-4) HINT: After installation, check and inspect items as follows. Front wheel alignment. (See page SA-4 ) • the road test.
Page 354 MX-9 MANUAL TRANSAXLE ASSEMBLY MANUAL TAANSAXLE MANUAL TRANSAXLE ASSEMBLY COMPONENTS Vehicle Speed Sensor • ��-0 0-- R ing Control Cabl e Bracket Ve _ hicl e Speed Sensor Dnven Gear d--- - - - - - T ransaxle Case Recei v er "1i( Transaxl e Case [ii ( ki)_J...
Page 355 MX-10 MANUAl TRANSAXLE MANUAL TRANSAXLE ASSEMBLY No. 1 Gear Shi f t For k Rever s e Shi f t Ar m Br a cket Rever s e Shi f t For k Snap i g · O J - - - - - - - No.3 Gear Shi f t For k Shaf t Thr u st Washer Bal l [i!IT60,12)]...
Page 357 MX-12 MANUAL TRANSAXLE ASSEMBLY MANUAL TAANSAXLE {C56l �-""" DISASSEMBLY REMOVE FILLER PLUG AND DRAIN PLUG WITH 2 GASKETS Torque: 39 N.m (400 kgf.cm, 29 ft·lbf) REMOVE VEHICLE SPEED SENSOR Remove the bolt and vehicle speed sensor. Torque: 1 1 N·m (115 kgf.cm, 8 ft·lbl) Using a small screwdriver, remove the clip from the ve...
Page 358 MX-13 MANUAL TRANSAXLEASSEMBLY MANUAL TAANSAXLE (C56) REMOVE CONTROL SHIFT LEVER AND DUST BOOT Remove the nut and wave washer. Torque: 1 2 N·m (120 kgf. cm, 9 1!-lbf) Using a pin punch and hammer, drive out the lever lock pin. NOTICE: At the time of reassembly, please refer to the following item.
Page 359 MX-14 MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE REMOVE LOCK BALL ASSEMBLY AND CONTROL SHAFT COVER Remove the lock ball assembly. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) Remove the 4 bolts and control shaft cover with the gas ket.
Page 360 � MX-15 MANUAL TRANSAXLE ASSEMBLY MANUAl TRANSAXlE • Before driving in the No. 3 clutch hub assembly, place the suitable sized wooden block on the rear side of the input shaft, as shown in the illustration. When driving it in, fix the input shaft firmly so that it is not pushed downward.
Page 361 MX-16 MANUAL TRANSAXLE ASSEMBLY MANUAl. TRANSAXLE (C56l REMOVE NO. 3 CLUTCH HUB AND 5TH GEAR Using 2 screwdrivers and a hammer, tap out the snap ring. HINT: At the time of reassembly, please refer to the following item. Select a snap ring from the table below that will make the thrust clearance of the No.
Page 362 MX-17 MANUAL TRANSAXLE(C56) MANUAL TRANSAXLEASSEMBLY REMOVE REAR BEARING RETAINER Remove the 5 bolts and rear bearing retainer. Sealant: Part No. 0883:Hl0080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 27 N. m (280 kgf.cm, 20 ft.Jbf) REMOVE BEARING SNAP RING Using a snap ring expander, remove the 2 snap rings.
Page 363 MX-18 MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE<C56) REMOVE TRANSMISSION CASE Remove the 16 bolts. Torque: 29 N-m (300 kgf-cm, 22 11-lbf) Using a plastic hammer, carefully tap the projection of the (b ) transmission case to remove the transmission case from the transaxle case.
Page 364 MX-19 MANUAL TRI\NSAXLE ASSEMBLY MANUAL TRANSAXLE • Install the reverse Idler gear, thrust washer and shaft, as shown in the illustration. Mark 00 / 3 3 6 Align Alignment 27 . REMOVE GEAR SHIFT FORK AND GEAR SHIFT FORK SHAFT Using 2 screwdrivers and a hammer, tap out the 3 snap rings from each gear shift fork shaft.
Page 365 MX-20 MANUAL TAANSAXLE ASSEMBLY TAANSAXLE !C56l MANUAL Using a magnetic finger, remove the 2 balls from the re verse shift fork. Remove the No. 3 gear shift fork shaft and reverse shift (f ) fork. Pull out the No. gear shift fork shaft. Remove the No.
Page 366 MX-21 MANUAL TRANSAXLE (C56) MANUAL TRANSAXLEASSEMBLY INSPECTION INSPECT 5TH GEAR SYNCHRONIZER RING Check for wear or damage. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone.
Page 367 MX-22 MANUAL TRANSAXLE (C56) MANUAL TRANSAXLE ASSEMBLY Using a screwdriver. remove the oil seal. Using SST and a hammer, drive in a new oil seal. 09950-6001 0 (09951-00360), 09950-70 0 1 0 (09951-()7150) ± Drive In depth: 15.8 ± 0.2 mm (0.622 0.008 in.) Coat the lip of the oil seal with MP grease.
Page 368 MX-23 MANUAL TRANSAXLE {C56) MANUAl TRANSAXLE ASSEMBLY Using SST and a press, install a new output shaft front .�d' l - bearing. __.£-0_-r- 09950-600 1 0 (09951-00560), 09950-700 1 0 (0995Hl7150) NOTICE: • �-· Be sure to Jnstall a new bearing in the correct direc // - tion, as shown in the illustration.
Page 369 MX-24 MANUAL TRANSA.XLE ASSEMBLY MANUAL TRANSAXLE Using SST and a hammer, drive in a new bushing. 09950-6001 0 (09951-00180), 09950-70 0 1 0 (09951-Q7100) Drive In depth: 0.80 - 1 .30 mm (0.03 1 5 - 0.0512 in.) IF NECESSARY, REPLACE TRANSMISSION CASE OIL SEAL Using a screwdriver and hammer, drive out the oil seal.
Page 370 MX-25 MANUAL TAANSAXLE {C56) /1. 1 ANUAL TAANSAXLE ASSEMHL REASSEMBLY Reassembly is in the reverse order of disassembly. (See page MX-12} NOTICE: When working with FIPG material, you must observe the followings. Using a razor blade and gasket scraper, remove all old FIPG material from the gasket surfaces. Thoroughly clean all components to remove all loose material.
Page 371 INPUT MX-26 SHAFT MANUAL TAANSAXLE INPUT SHAFT COMPONENTS I n put Shaf t Needl e Rol l e r Bear i n g No.2 Synchr o ni z er Ri n g ( F or 3r d Gear ) No.2 Hub Sl e eve No.
Page 372 MX-27 MANUAl TRANSAXLE (C56) lNPUr SHAFf DISASSEMBLY INSPECT 3RD AND 4TH GEARS THRUST CLEAR ANCE Using a feeler gauge, measure the thrust clearance. Standard clearance: 3rd gear: 0.10- 0.35 mm (0.0039 - 0.0138 in.) Gear 4th gear: 0.1 0 - 0.55 mm (0.0039 - 0.0211 ln.) Maximum clearance: 3rd gear: 0.35 mm (0.0138 ln.) 4th gear: 0.55 mm (0.0217 ln.)
Page 373 MX-28 MANUAL TRANSAXLE INPUT SHAFT Remove the needle roller bearings, spacer and No. 2 syn- chronizer ring (for the 4th gear). REMOVE SNAP RING Using 2 screwdrivers and a hammer, tap out the snap ring. HINT: Take care not to damage the journal surface of the input shaft. REMOVE NO.
Page 374 MX-29 MANUAL TRANSAXLE INPUT SHAFT INSPECTION INSPECT SYNCHRONIZER RING Check for wear or damage. Check the braking effect of the synchronizer ring. Turn the synchron·lzer ring i n one direction white pushing it to the gear cone. Check that the ring locks. If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone.
Page 375 MX-30 MANUAL TRANSAXLE (C56} lNPUT SHAFT INSPECT INPUT SHAFT Check the input shaft for wear or damage. in Using a micrometer, measure the outer diameter of the put shaft journal surface. Minimum outer diameter: Part A: 24.885 mm (0.9797 in.) Part 8: 28.985 mm (1.1411 in.) Part C: 30.985 mm (1.2199 in.) Part D : 24.985 mm (0.9837 in.)
Page 376 MX-31 MANUAL TRANSAXlE {C56) INPUT SHAFT REASSEMBLY Coat all of the sliding and rotating surfaces with gear oil before reassembly. ASSEMBLE NO. 2 HUB SLEEVE ASSEMBLY Instal! the 3 No. 2 shifting key springs and No. 2 shifting Install the No. 2 hub steeve to the No. 2 clutch hub. keys to the No.
Page 377 MX-32 INPUT SHAFT MANUAl TRANSAX LE INSTALL SNAP RING Select a snap ring from the table below that will make the thrust clearance of the No. 2 clutch hub less than 0 . 1 mm (0.0039 in.). Th•ckness Mark Thk:kness (in.) Mark {in.}...
Page 378 MX-33 SHAFT INPUT MANUAL TRANSAXLE t h an INSTALL SNAP RING Select a snap ring from the table below that will make the (a ) thrust clearance of the rear radial ball bearing less 0.1 mm (0.0039 in.). (m_) Mark Thickness mm (in.) Mark...
Page 379 MX-34 OUTPUT SHAFT MANUA L TRANSAXLE (C56) - OUTPUT SHAFT Snap Ri n g Bal l COMPONENTS � Needl e Ro l l e r Bear i n g 1 s t Gear No 1 Synchr o ni z er Ri n g Out p ut Shaf t Rever s e Gear l s i Gear Thr u...
Page 380 MX-35 � MANUAL TAANSAXLE OUTPUT SHAFT DISASSEMBLY INSPECT 1ST A N D 2 N D GEARS THRUST CLEAR· ANCE Using a feeler gauge, measure the thrust clearance. Standard clearance: 1st gear: 0.1 0 - 0.40 mm {0.0039 - 0.0157 in.) 2nd gear: 0.10 - 0.55 mm (0.003 9 - 0.0217 in.) 1st gear: 0.40 mm (0.0157 in.} Maximum clearance:...
Page 381 MX-36 MANUAL TRANSAXLE OUTPUT SHAFT REMOVE 3RD DRIVEN GEAR, 2ND GEAR, NEEDLE ROLLER BEARING, SPACER AND NO. 2 SYNCHRO NIZER RING Shift the reverse gear into the 1st gear. Using SST and a press, remove the 3rd driven gear and 2nd gear.
Page 382 MX-37 � OUTPUT SHAFT MANUAL TRANSAXLE REMOVE FRONT BEARING INNER RACE Using SST and a press, remove the front bearing inner race. 09950-00020 NOTICE: When replacing the front bearing inner race, replace the output shaft front bearing along with it. HINT: Support the output shaft by hand so that it will not be dropped off.
Page 383 MX-38 � OUTPUT SHAFT MANUAL TRANSAXLE IC56) INSPECTION INSPECT 1ST GEAR SYNCHRONIZER RING Check for wear or damage. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. lf the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone.
Page 384 MX-39 MANUAL TRANSAXLE (C56) OUTPUT SHAFT INSPECT GEAR SHIFT FORK AND REVERSE GEAR CLEARANCE Using a feeler gauge, measure the clearance between the re verse gear and gear shift fork. Maximum clearance: 0.35 mm (0.014 in.) If the clearance exceeds the maximum, replace the gear shift fork or hub sleeve.
Page 385 MX-40 OUTPUf SHAFT MANUAL TRANSAXLE IC56l REASSEMBLY HINT: Coat aU of the sliding and rotating surfaces with gear oil before reassembly. INSTALL FRONT BEARING INNER RACE Using SST and a press, install the front bearing inner race. 09223-500 1 0 NOTICE: Be sure to Install the front bearing Inner race in the correct direction, as shown In the illustration.
Page 386 MX-41 SHAFT MANUAl TRANSAXLE OUTPUT INSTALL BALL, 1 ST GEAR THRUST WASHER, NEEDLE ROLLER BEARING, 1ST GEAR, NO. 1 SYN· CHRONIZER RING AND REVERSE GEAR ASSEMBLY TO OUTPUT SHAFT Using a magnetlc finger, install the ball to the output shaft Fit the 1st gear thrust washer groove securely over the locking ball when instaiHng the thrust on the output shaft.
Page 387 MX-42 OUTPUT SHAFT MANUAL TAANSAXLE HINT: Take care not to damage the journal surface of the output shaft. INSPECT 1ST GEAR THRUST CLEARANCE (See page MX-35) INSTALL SPACER, NEEDLE ROLLER BEARING, For 2nd Gear NO. 2 SYNCHRONIZER RING, 2ND GEAR AND 3RD •••...
Page 388 MX-43 MANUAL TRANSAXLE OUTPUT SHAFT INSTALL OUTPUT GEAR SPACER, 4TH DRIVEN GEAR AND REAR RADIAL BALL BEARING Install the output gear spacer. {a ) Using SST and a press, install the 4th driven gear and rear radial ball bearing. 09608-00071 NOTICE: Be sure to install the 4th driven gear and rear radial ball bearing in the correct direction, as shown in the illustra�...
Page 389 MX--44 SELECT LEVER SHAfT SHIFT SHIFT AND SELECT LEVER SHAFT COMPONENTS Shi f t and Sel e ct Lever Shaf t Snap Ri n g Compr e ssi o n Spr i n g Sel e ct I n ner Lever Shi f t I n t e r l o ck Pl a t e No.
Page 390 MX-45 MANUAl TRANSAXlE (C56) DIFFERENTIAL CASE DIFFERENTIAL CASE COMPONENTS • Oil Seal Strai g ht Pin Di f ferenti a l Case Ri n g Gear --- - , � Pi n i o n Thrust Washer • Oi l Seal Non-- r eusable part Apply MP grease...
Page 391 MX-46 DIFFERENTIAL CASE MANUAL TRANSAXLE DISASSEMBLY REMOVE RING GEAR Place match marks on the ring gear and differential case. Remove the 8 bolts. Using a copper hammer, tap on the ring gear to remove it from the differential case. [)00855 Vehicle speed sensor drive gear side: REMOVE TAPERED ROLLER BEARING FROM DIF...
Page 392 MX-47 DIFFERENTIAL CASE MANUAL TRANSAXlE Transmission case side: IF NECESSARY, REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE Using SST, pull out the tapered roller bearing outer race (a ) and shim. 09612-65014 Using SST and a hammer, drive out the oi! seal. (b ) 09226-10010 Using SST and a hammer, drive in a new oil seal.
Page 393 MX-48 DIFFERENTIAL CASE MANUAL TRANSAXLE(C?§l Using SST, pull out the tapered roller bearing outer race and spacer. 09612-65014 Place the spacer into the differential case. 007:!72 Using SST and a press, install the tapered ro!!er bearing outer race. 09950-60020 (09951-00680), 09950-7001 0 (09951-07150) NOTICE: When replacing the tapered roller bearing outer race, re...
Page 394 MX-49 DIFFERENl CASE MANUAL TRANSAXLE � ' " " ' "' REASSEMBLY ASSEMBLE DIFFERENTIAL CASE Install the correct thrust washers and side gears. Refer to the table below, select thrust washers which will ensure that the backlash is within the specification. Try to select washers of the same size for both sides.
Page 395 MX-50 MANUAL TRANSAXLE{C56) DIFFERENTIAL CASE Vehicle speed sensor drive gear side: INSTALL TAPERED ROLLER BEARING Place the vehicle speed sensor drive gear in position to stop it turning, and install the vehicle speed sensor drive gear. NOTICE: Be sure to install the vehicle speed sensor drive gear in the correct direction, as shown In the illustration.
Page 396 MX-51 ·- OlfFERENT!AlCASE MANUAl TRANSAXLE (C56) Using SST and a torque wrench, turn the differentia! case assembly right and left 2 or 3 times to allow the bearings to settle. 09564-32011 Using SST and a torque wrench, measure the preload. 09564-32011 Preload (at starting}: New bearing...
Page 397 MX-52 MANUAL TRANSAXLE LEVER AND CONTROL CABLE SHIFT LEVER AND CONTROL CABLE COMPONENTS Fr o nt Pi l l a r Gar n i s h Passenger Ai r b ag Assembl y I n st r u ment Panel End Fi n i s h Panel Door Scuff Pl a t e Cowl Si d e Tr i m...
Page 398 SHIFT MX-53 MANUAL TRANSAXLE lEVER AND CONTROL CABLE I n st r u ment Panel Heat e r Hose Li q ui d Tube Suct i o n Tube ! No.2 Br a ce AJC Uni t Bl o wer Uni t Non-r e usabl e part...
Page 399 MX-54 LEVER AND CONTROL CABLE Ai r Cl e aner Case Assembl y wi t h Ai r Hose � ECM Out l e t Duct Shi f t Cabl e Ret a i n er Cl i p Cl i p Cl i p -·...
Page 400 MANUAL TRANSAXLE (C60) TROUBLESHOOTI N G ..MX-1 MX-2 MANUAL TRANSAXLE UNI T MANUAL TRANSAXLE ASSEMBLY ..MX-9 MX-29 I N PUT SHAFT ....OUTPUT SHAFT .. MX-37 MX-47 SHI F T AND SELECT LEVER SHAFT DI F FERENTI A L CASE ....MX-48 REVERSE SHI F T WARNI N G BUZZER SYSTEM ..
Page 402 MX-1 TROUBLESHOOTING MANUAL TRANSAXLE TROUBLESHOOTING PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Suspocl Area Sne pa.ge...
Page 403 MX-2 MANUAL TRANSAXLE (C60) UNIT MANUAL MANUAL TRANSAXLE UNIT COMPONENTS Hood Ai r Cl e aner Case Assembl y wi t h Ai r Hose rt Hol d �Down ECM Cover Cl a mp "11 � �8 No . Cyl i n der Head Cover 6.9 (70, 61 :: : <:>-...
Page 404 MX-3 RH Fr o nt Dr i v e Shaf t MANUAL TnANSAXLE UN!T MANUAL TRANSAXLE LH Fr o nt Dr i v e Shaf t L?�7650 · .- -4 _?)J- _ __ _ Oxygen Sensor -----� + Ga s ket - '] Compr e sst o n •...
Page 405 MX-4 MANUAL TRANSAXLE (C60) MANUAL TRANSAXLE UNIT ...,,,_, REMOVAL REMOVE HOOD HINT: At the time of installation, please refer to the following item. Adjust the hood. (See page 80-9) REMOVE NO. 2 CYLINDER HEAD COVER Remove the 4 bolts and No. 2 cylinder head cover. Torque: 7.0 N·m (71 kgf .
Page 406 MX-5 MANUAL TRANSAXLE UNIT MANUAL TRANSAXLE DISCONNECT CLUTCH RELEASE CYLINDER Remove the 4 set bolts of the clutch line. Torque: Bolt A: 12 N. m (120 kgf.cm, 9 ft·lbf) Bolt B: 4.9 N-m (50 kgf.cm, 43 in.-lbf) Remove the 2 set bolts of the clutch release cylinder and clutch tine bracket.
Page 407 MX--<; MAN UAL-� RANSAXLl' UN!T MANUAL TRANSAXLE Attach the engine chain hoist to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part. REMOVE ENGINE LEFT MOUNTING BRACKET 3 SET 14 . BOLTS AND NUT Torque: Bolt A: 60 N-m (610 kgl-cm, 44 ft-lbl)
Page 408 MX-7 UNJ T MANUAL TRANSAXLE (C60) TRANSAXLE MANUAL Disconnect the front exhaust pipe from the pipe supports (c ) and remove it. REMOVE FRONT SUB-FRAME AND LOWER SUS PENSION ARM Tie the PS gear assembly to the proper position with a code or an equivalent to suspend the assembly securely.
Page 409 MX-8 MANUAL TMNSAXLE UNIT MANUAL TRANSAXLE �"""'' INSTALLATION Installation Is in the reverse order of removal. (See page MX-4) HINT: After installation, check and Inspect items as follows. • Front wheel alignment. (See page SA--4 ) • Do the road test.
Page 410 MX-9 MANUAL TAANSAXLE MANUAL TRANSAXLE ASSEM8LY MANUAL TRANSAXLE ASSEMBLY COMPONENTS Q--. R i n g Cont r o l Cabl e Br a cket 1 8 ) Vehi c l e Speed Sensor Dr i v en Gear 25 (250, - �...
Page 411 MX-10 MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE {C60) � '.'U Rev erse Shif t Fork & - Stra!ght Sc!� � Plug � � - � Bai t � J Rever se Shlt t Arm . Bracke t Fork Shaft - Reverse Idl e r No.
Page 412 MX-11 MANUAL TRANSAXLE{C60) MANUAL TRANSAXLEASSEMBLY Cont r o l Shaf t Cover +Gasket Back-Up Li g ht Swi t c h diJl , &) St r a i g ht Scr e w Pl u g * /a9 _ ( 4 0 0 , �...
Page 413 MX-12 MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE (C60) DISASSEMBLY REMOVE FILLER PLUG AND DRAIN PLUG WITH 2 GASKETS Torque: 39 N-m (400 kgf . cm, 29 11-lbl) REMOVE VEHICLE SPEED SENSOR Remove the bolt and vehicle speed sensor. Torque: 1 1 N-m (115 kgf . cm, 8 ll·lbf) Using a small screwdriver, remove the clip from the ve...
Page 414 MX-13 � MANUAL TRANSAXLE (C60) MANUAL TRANSAXlC ASSEMBlY REMOVE CONTROL SHIFT LEVER AND DUST BOOT Remove the nut and wave washer. Torque: 1 2 N·m (120 kgf . cm, 9 fl·lbf) Using a pin punch and hammer, drive out the lever lock pin.
Page 415 MX-14 MANUAL R NSAXLE MANUALTRA AXLE DISASSEMBLE CONTROL SHAFT COVER AS· SEMBLY Using snap ring pliers, remove the snap ring. Remove the No. 3 select spring seat and compression spring. /- - ()07:!76 REMOVE SHIFT AND SELECT LEVER SHAFT AS- SEMBLY Remove the shift and select lever shaft assembly.
Page 416 MX-15 TRANSAXLE MANUAL TRANSAXLE MANUAL ASSEMBLY INSPECT 6TH GEAR RADIAL CLEARANCE Using a dial indicator, measure the radial clearance. Standard clearance: 0.009 - 0.050 mm (0.0003 - 0.0020 ln.) Maximum clearance: 0.050 mm (0.0020 in.) If the clearance exceeds the maximum, replace the gear. needle roller bearing or shaft.
Page 417 MX-16 MANUAL TRANSAXLE ASSEMBLY MANUAL mANSAXLE (C6Ql • Set SST to the rear radial ball bearing inner race securely, drive in the bearing with a hammer. 0951 7-1 201 0 Remove the spacer. 007699 REMOVE INPUT SHAFT REAR RADIAL BALL BEAR ING AND 6TH GEAR Using 2 screwdrivers and a hammer, tap out the snap ring.
Page 418 MX-1 7 MANUAL TRANSAXLE MANUAL TRANSAXLE ASSEMBLY REMOVE NO. 3 SYNCHRONIZER RING (FOR 6TH GEAR) NOTICE: At the time of reassembly, please refer to the following items. Align the No. 3 synchronizer ring slots with the No. 3 shifting keys. •...
Page 419 MX-18 MANUAL TAANSAXLE MANUAL TnANSA.XLE ASSEMBLY REMOVE 5TH GEAR, NO. 3 SYNCHRONIZER RING (FOR 5TH G E A R ) A N D N O . 3 CLUTCH H U B AS SEMBLY Using 2 screwdrivers and a hammer, tap out the snap ring.
Page 420 MX-19 MANUAL TAANSAXLE MANUAL TRANSAXLE ASSFMBLY Remove the No. 3 synchronizer ring (for the 5th gear) and Gear For 5th 5th gear from the input shaft. NOTICE: At the time of reassembly, please refer to the following item. Distinguish the No. 3 synchronizer ring (for the 5th gear) by the teeth on the synchronizer ring.
Page 421 MX-20 MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT AND GASKET Sealant: Part No. 0883:Hl0080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 29 N.m (300 kgf.cm, 22 ft·lbf) REMOVE SNAP RING FROM NO. 2 SHIFT FORK SHAFT Using 2 screwdrivers and a hammer, tap out the snap ring.
Page 422 MX - 2 1 MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE (COO) REMOVE OIL RECEIVER PIPE Remove the 2 bolts and off receiver pipes from the transmission case. Torque: 1 7 N.m (175 kgf.cm, 1 3 ft·lbf) NOTICE: At the time of reassembly, please refer to the following Items.
Page 423 MX-22 MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE REMOVE NO. 1 GEAR SHIFT HEAD, NO. 1 AND NO. 2 GEAR SHIFT FORKS 3 SET BOLTS Sealant: Part No. 0883:Hl0080, THREE BOND 1 344, LOCTITE 242 or equivalent Torque: 1 6 N-m (160 kgf.cm, 1 2 ft·lbf) NOTICE: At the time of reassembly, please refer to the following item.
Page 424 MX-23 MANUAl TRANSAXLE MANUAL TRANSAXLE ASSEMBLY REMOVE NO. 1 GEAR SHIFT FORK FROM REVERSE GEAR GROOVE 38 . REMOVE NO. 3 GEAR SHIFT FORK SHAFT AND RE· VERSE SHIFT FORK Remove the No. 3 gear shift fork shaft from the reverse shift fork and transaxle case.
Page 425 MX-24 MANUAL TRANSAXLE MANUAL TAANSAXLE ASSEMBLY INSPECTION INSPECT 5TH A N D 6TH GEARS SYNCHRONIZER RING Check for wear or damage. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone.
Page 426 MX-25 MANUAL TRANSAXl E ASSEMBLY MANUAL TRANSAXlE Using a screwdriver, remove the oil seal. Us ing SST and a hammer, drive in a new oil seal. 09950-6001 0 (09951-00360), 09950-7001 0 (09951-()7150) ±. Drive in depth: 15.8 ± 0.2 mm (0.622 0.008 in.) Coat the Hp of the oil seal with MP grease, Us ing SST and a press, install a new input shaft front...
Page 427 MX-26 MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE Using SST and a press, install a new output shaft front bearing. 09950-6001 0 (09951-00560), 09950-700 1 0 --- - --�--- ., - - (09951-07150) NOTICE: Be sure to install a new bearing i n the correct direction, as shown in the illustration.
Page 428 MANUAL MX-27 MANUAL TRANSAXLEASSEMBLY Using a socket wrench ( 1 7 mm) and plastic hammer, drive in a new oil seaL ± Drive i n depth: 10.0 ± 0.3 mm (0.394 0.012 in.) Coat the lip of the oil seat with MP grease.
Page 429 MX-28 MANUAL TRANSAXLE ASSEMBLY REASSEMBLY Reassembly is in the reverse order of disassembly. (See page MX-12) NOTICE: When working with FIPG material, you must observe the followings. • Using a razor blade and gasket scraper, remove all old FIPG material from the gasket surfaces. Thoroughly clean all components to remove all loose material.
Page 430 MX-29 INPUT SHAFT MANUAL TRANSAXLE INPUT SHAFT COMPONENTS Needl e Rol l e r Bear i n g Gear Snap Ri n g...
Page 431 MX-30 MANUAL TRANSAXLE (C60) INPUT SIIAFT DISASSEMBLY INSPECT 3 R D A N D 4TH GEARS THRUST CLEAR ANCE Using a feeler gauge, measure the thrust clearance. Standard clearance: 3rd gear: 0.1 0 - 0.35 mm (0.0039 - 0.0138 in.) 4th gear: 0.10 - 0.55 mm (0.0039 - 0.0217 ln.) Maximum clearance: 3rd gear: 0.35 mm (0.0136 in.)
Page 432 MX-31 SHAFT MANUAL TRANSAXLE INPUT Remove the needle roller bearings, spacer and No. 2 syn- chronizer ring (for the 4th gear). REMOVE SNAP RING Using 2 screwdrivers and a hammer, tap out the snap ring. HINT: Take care not to damage the journal surface of the input shaft. REMOVE NO.
Page 433 MX-32 MANUAL TRANSAXLE(C60l INPUT SHAFT INSPECTION INSPECT SYNCHRONIZER RING Check for wear or damage. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear NOTICE:...
Page 434 MX-33 INPUT SHAFf MANUAL TRANSAXLE INSPECT INPUT SHAFT Check the input shaft for wear or damage. Using a micrometer, measure the outer diameter of the in (b ) put shaft journal surtace. Minimum outer diameter: Part A: 21 .991 mm (0.8658 ln.) Part B: 24.885 mm (0.9797 in.) Part C: 28.985 mm (1.1411 in.) Part D: 30.985 mm (1.2199 in.)
Page 435 MX-34 MANUAL TAANSAXLE (C60} INPUT SHAFT REASSEMBLY HINT: Coat all of !he sliding and rotating surfaces with gear oil before reassembly. ASSEMBLE NO. 2 HUB SLEEVE ASSEMBLY Install the 3 No. 2 shifting key springs and No. 2 shifting keys to the No. 2 clutch hub. Install the No.
Page 436 MX-35 INPUT SHAFT MANUAL TRANSAXLE INSTALL SNAP RING Select a snap ring from the table below that will make the thrust clearance of the No. 2 clutch hub less than 0.1 mm (0.0039 in.) . Mark Thickness mm Thickness mm (in.) (in.) Mark 2.30 (0 0906)
Page 437 MX-36 SHAFT INPUT MANUAL TRANSAXLE !C60) INSTALL SNAP RING Select a snap ring from the table below that will make the thrust clearance of the center radial ball bearing less than 0.1 mm (0.00 39 in.). Mark Mark Thfckness mm {in.) Thickness mm {in .) 2.29 (0.0902) 2.47 (0.0972)
Page 438 MX-37 MANUAL TRANSAXLE OUTPUT SHAFT OUTPUT SHAFT COMPONENTS Out p ut Shaf t 1 s t Gear Thr u st Wa,sh'ec No. 1 Cl u t c h Hub Snap Ri n g No. 2 Synchr o ni z er Ri n g 2nd Gear 3 r d Dr i v en Gear Out p ut Gear Spacer 4t h Dr i v en Gear...
Page 439 � MX-38 · MANUAl TRAN$AXLE (C60) DISASSEMBLY INSPECT 1ST AND 2ND GEARS THRUST CLEAR ANCE Using a feeler gauge, measure the thrust clearance. Standard clearance: 1st gear: 0.1 0 - 0.40 mm (0.0039 - 0.0157 in.) 2nd gear: 0.1 0 - 0.55 mm (0.0039 - 0.0217 in.) Maximum clearance: 1st gear: 0.40 mm (0.0157 in.) 2nd gear: 0.55 mm (0.0217 ln.)
Page 440 MX-39 MANUAL TRANSAXLE (C60) OUTPUT SHAFT REMOVE 3RD DRIVEN GEAR, 2ND GEAR, NEEDLE ROLLER BEARING, SPACER AND NO. 2 SYNCHRO NIZER RING Shift the reverse gear into the 1st gear. Using SST and a press, remove the 3rd driven gear and 2nd gear.
Page 441 MX-40 MANUAL TRANSAXLE OUTPUT SHAFT REMOVE FRONT BEARING INNER RACE - . � Using SST and a press, remove the front bearing inner race. 0995(}-{)0020 NOTICE: - - � =; � - "' , When replacing the front bearing inner race, replace the ---- -1 output shaft front bearing along with it.
Page 442 MX-41 SHAFT MANUAL TAANSAXLE OUTPUT INSPECTION INSPECT 1ST GEAR SYNCHRONIZER RING Check for wear or damage. Check the braking effect of the synchronizer ring. Turn the (b ) synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone.
Page 443 MX-42 OUTPUT SHAFT MANUAL TRANSAXLE; INSPECT GEAR SHIFT FORK A N D REVERSE GEAR CLEARANCE Using a feeler gauge, measure the clearance between the re verse gear and gear shift fork. Maximum clearance: 0.35 mm (0.014 in.) If the clearance exceeds the maximum, replace the gear shift fork or hub sleeve.
Page 444 MX-43 SHAH MANUAL TRANSAXLE OUTPUT REASSEMBLY HINT: Coat all of the sliding and rotating surfaces wlth gear oil before reassembly. INSTALL FRONT BEARING INNER RACE Using SST and a press, install the front bearing inner race. 09223-5001 0 NOTICE: Be sure to Install the front bearing inner race in the correct direction, as shown i n the Illustration.
Page 446 MX-45 OUTPUT SHAFT MANUAL TRANSAXLE HINT: Take care not to damage the journal surlace of the output shaft. INSPECT 1ST GEAR THRUST CLEARANCE (See page MX-38) 2nd Gear INSTALL SPACER, NEEDLE ROLLER BEARING, N0.2 SYNCHRONIZER RING, 2ND GEAR AND 3RD DRIVEN GEAR install the spacer.
Page 447 MX-46 OUTPUT MANUAL TRANSAXLE SHAFT INSTALL OUTPUT GEAR SPACER, 4TH DRIVEN GEAR AND CENTER RADIAL BALL BEARING Install the output gear spacer. Using SST and a press, install the 4th driven gear and center radial ball bearing. 09608-00071 NOTICE: Be sure to install the 4th driven gear and center radial ball bearing in the correct direction, as shown in the illustra...
Page 448 MX-47 SHIFf SHAFf SELECT LEVER MANUAL TRANSAXLE (C60) SHIFT AND SELECT LEVER SHAFT COMPONENTS Shi f t and Sel e ct Lever Shaf t - - -- No. 2 Sel e ct Spr i n g Seat Compr e ss1 0 n Spnng Sl o t t e d Spr i n g Pi n Sl o t t e d Spr i n g Pi n E-Ai n g No.
Page 449 MX-48 DIFFERENTIAL CASE MANUAL TRANSAXLE DIFFERENTIAL CASE COMPONENTS (79o, s7l St r a i g ht Pi n Di f f e r e nt i a l Case Ri n g Gear -{ii) Pi n i o n 0- - - - - -Pi n i o n Thr u st Washer +Oi l Seal Speci f i e d t o r q ue...
Page 450 MX-49 DifFERENTIAL CASE MANUAl. TRANSAXI.E DISASSEMBLY REMOVE RING GEAR Place matchmarks on the ring gear and differential case. Matchmarks Remove the 8 bolts. Using a copper hammer, tap on the ring gear to remove it from the differential case. l)(yo8'>5 Vehicle speed sensor drive gear side: REMOVE TAPERED ROLLER BEARING FROM DIF- FERENTIAL CASE...
Page 451 MX-50 MANUAL TAANSAXLE DISASSEMBLE DIFFERENTIAL CASE Using a pin punch and hammer, drive out the straight pin. {a ) Remove the pinion shaft from the differential case. Remove the 2 pinions and side gears with the 4 thrust washers from each gear. Transmission case side: IF NECESSARY, REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE...
Page 452 MX-51 MANUAL TRANSAXLE DIFFERENTIAL CASE Transaxle case side: IF NECESSARY, REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE Using a screwdriver and hammer, drive out the oil seaL 0073/4 Using SST. pull out the tapered roller bearing outer race and spacer.
Page 453 MX-52 NSAXLE MANUALTRA """" REASSEMBLY ASSEMBLE DIFFERENTIAL CASE Install the correct thrust washers and side gears. Refer to the table below, select thrust washers which wil! j · -'J • ensure that the backlash is within the specification. Tr select washers of the same size for both sides. ·- ..
Page 454 MX-53 DlfH:: R ENTIALCASE MANUAL TAANSAXLE{C60) Vehicle speed sensor drive gear side: INSTALL TAPERED ROLLER BEARING Place the vehicle speed sensor drive gear in position to (a ) stop it turning, and install the vehicle speed sensor drive gear. NOTICE: Be sure to install the vehicle speed sensor drive gear in the correct direction, as shown in the Illustration.
Page 455 MX-54 DIFfERENTIAL CASE MANUAL TAANSAXLE (C60\ Using SST and a torque wrench, turn the differential case assembly right and left 2 o r 3 times to allow the bearings to settle. 09564-32011 Using SST and a torque wrench, measure the preload. 09564-320 1 1 Preload (at starting): New bearing...
Page 456 MX-55 REVERSE SHIFT WARNING BUZZER SYSTEM MANUAL TRANSAXLE REVERSE SHIFT WARNING BUZZER SYSTEM Combi n at i o n Met e r LOCATION ( R ever s e Shi f t War n i n g Buzzer ) Back-Up Li g ht Swi t c h...
Page 457 MX-56 REVERSE SHIFT WARNING BUZZER SYSTEM INSPECTION INSPECT REVERSE SHIFT WARNING BUZZER SYSTEM (See page BE-46) INSPECT BACK-UP LIGHT SWITCH CONTINUITY (See page BE-30)
Page 458 MX-57 MANUAL TAANSAXLE SHIFf LEVER AND GONlHOL CABLE SHIFT LEVER AND CONTROL CABLE COMPONENTS Pi l l a r Gar n i s h Passenger Ai r b ag Assembl y Front I n st r u ment Panel Cowl Si d e Tr i m ·...
Page 459 MX-58 SHIFT LEVER AND CONTROL CABLE MANUAL TRANSAXLE.(C60) + 0-Ri n g Rei n f o r c ement Li q ui d Tube Suction Tube ••• No. 1 Brace No. 2 Brace Uni t Blower part Non-reusable 113009...
Page 460 MX-59 LEVER AND CONTROL CABLE:: TAANSAXLE MANUAL SHIFf Ai r Cl e aner Case Assembl y Ai r Hose ECM Connect o r ECM Out l e t Duct [- ·- ··-� -- � 12 (12o,9U Shi f t Cabl e Ret a i n er Cl i p --�-- (50,...
Page 461 - M EM O -...
Page 462 AUTOMATIC TRANSAXLE (U240E) AUTOMATI C TRANSAXLE SYSTEM AX-1 AX-3 VEHI C LE SPEED SENSOR . SPEED SENSOR ....AX-4 ATF TEMPERATURE SENSOR . AX-6 PARK/NEUTRAL POSI T I O N { P NP) SWI T CH . . AX-8 VALVE BODY ASSEMBLY AX-1 0 DI F FERENTI A L OI L SEAL .
Page 464 AUTOf\MT!G TRANSAXLC SYSTEM AX-1 AUTOMATIC TAANSAXLE (U240E) AUTOMATIC TRANSAXLE SYSTEM PRECAUTION If the vehicle is equipped with a mobile communication system, refer to the precautions in the section,...
Page 465 AX-2 AUTOMATIC TllANSAXLE SYSTEM AUTOMATIC TRANSAXLE {U240E) 1 s t Rever s e Br a ke ( 8 2) OPERATION For v >' a r d Cl u t c h ( C t l & Di r e ct Cl u t c h ( C 2) No.
Page 466 AX-3 VEHICLE SPE-,ED SENSOH AUTOMATIC TRANSAXLE (U240E) VEHICLE SPEED SENSOR ON-VEHICLE REPAIR REMOVE BATIERY REMOVE ECM AND ECM CASE REMOVE ECM BRACKET DISCONNECT VEHIClE SPEED SENSOR CONNEC (a ) REMOVE VEHICLE SPEED SENSOR ASSEMBlY Remove the bolt and vehicle speed sensor assembly. Remove the dip and speedometer driven gear from the vehicle speed sensor.
Page 467: Speed Sensor
AX-4 SPEED SENSOR AUTOMATIC TRANSAXLE (U240E) SPEED SENSOR ON-VEHICLE REPAIR REMOVE BATTERY REMOVE ECM AND ECM CASE REMOVE ECM BRACKET DISCONNECT INPUT TURBINE SPEED SENSOR CONNECTOR REMOVE INPUT TURBINE SPEED SENSOR Remove the bolt and input turbine speed sensor. 0-r i n g Remove the 0-ring from the input turbine speed sensor.
Page 468 AX-5 AUTOMATIC TRANSAXLE (U240El SPEED SENSOR INSTALL ECM BRACKET Torque: Bolt: N-m (185 kgf.cm, 13 11-lbl) Nut: 12 N·m (120 kgf.cm, 9 11-lbl} INSTALL ECM AND ECM CASE Torque: 6.9 N-m (70 kgf.cm, 61 in.-ibl) INSTALL BATTERY...
Page 469 TFMPFRATUriF: AX--6 I\1 F SENSOf1 AUTOMATIC TAAN5AXLE {U240El ATF TEMPERATURE SENSOR ' - "'-<' ON-VEHICLE REPAIR DISCONNECT SOLENOID CONNECTOR REMOVE LH ENGINE UNDER COVER REMOVE DRAIN PLUG AND DRAIN ATF REMOVE OIL PAN AND GASKET NOTICE: Some fluid will remain in the oil pan. Remove the 1 8 bolts, and carefully remove the oil pan assem...
Page 470 AX-7 ATFTEMPERATURE SENSOfl AUTOMATIC TRANSAXlE (U240E) INSTALL OIL STRAINER Coat a new D-ring with ATF. Install the 0-dng to the oil strainer. Install the oil strainer with the 3 bolts. Torque: 1 1 N·m (110 kgf.cm, 8 ft·lbf) 005!! 7 9 INSTALL OIL PAN Instal! the oil pan and a new gasket with the 1 8 bolts.
Page 471 AX-ll PARK/NEUTRAL POSITION (PNP) SWITCH AUTOMATIC TRANSAXLE (U240El PARK/NEUTRAL POSITION (PNP) SWITCH ON-VEHICLE R EPAIR REMOVE AIR CLEANER ASSEMBLY DISCONNECT PARKINEUTRAL POSITION SWITCH CONNECTOR REMOVE PARKINEUTRAL POSITION SWITCH Remove the nut. Remove the nut, washer and control shift lever. Using a screwdriver. pry off the lock plate. Remove the nut and lock plate.
Page 472 rAmVNCU fHAL AX-9 � POSITION (P AUTOMATIC TRANSAXLE (U24QE) Instal! the control shift lever with the nut. Torque: 1 3 N.m (130 kgf . cm, 9 ft·lbf} Connect the control cable to the control shaft. Torque: 1 2 N-m (120 kgf.cm, 9 ft-lbf) CONNECT PARK/NEUTRAL POSITION SWITCH CON- NECTOR CHECK PARK/NEUTRAL POSITION OPERATION...
Page 473 AX-10 VALVE:; BODY ASSEMBLY AUTOMATIC TRANSAXLE (U240El VALVE BODY ASSEMBLY ON-VEHICLE REPAIR REMOVE LH ENGINE UNDER COVER REMOVE DRAIN PLUG AND DRAIN ATF REMOVE OIL PAN AND GASKET NOTICE: Some fluid will remain in the ofl pan. Remove the 1 8 bolts, and carefully remove the oil pan assem bly.
Page 474 AX-11 �- VALVE BODY ASSEMBLY AUTOMATIC TRANSAXLE (U240E) REMOVE VALVE BODY Remove the 1 7 bolts and valve body. NOTICE: Be careful not to drop the check valve body, spring and ac� cumulator piston. REMOVE CHECK BALL BODY AND SPRING 1 1 .
Page 475 AX-12 VALVE BODY ASSEMBLY INSTALL CHECK VALVE AND SPRING Align the groove of the manual valve with the pin of the INSTALL VALVE BODY manual valve lever. Temporarily install the valve body with the 1 7 bolts. Boll length: Boll A : 25 mm (0.98 ln.) Bo l t B : 41 mm (1.61 ln.)
Page 476 AX-13 VALVE BODY ASSEMBLY AUTOMATIC TRANSAXLE (U240E) Install the oil strainer with the 3 bolls. Torque: 11 N·m (110 kgf.cm, 8 ft·lbf) INSTALL MAGNET IN OIL PAN Install the 3 magnets in the oil pan, as shown in the illustration. INSTALL OIL PAN Install the oil pan and a new gasket with the 1 8 bolts.
Page 477 DIFfERENTIAL OIL SEAL AX-14 AUTOMATIC TRANSAXlE (U240El DIFFERENTIAL OIL SEAL ON-VEHICLE REPAIR DRAIN ATF FROM FRONT DIFFERENTIAL CASE REMOVE LH AND RH DRIVE SHAFTS (See page SA-20) REMOVE LH AND RH SIDE OIL SEAL Using SST, drive out both the side oil seals. 09308-1 0010 INSTALL LH SIDE OIL SEAL Using SST and a hammer, drive i n a new oil seaL...
Page 478 SHIFT SYSTEM AX-15 LOCK AUTOMATIC TRANSAXLE (U240E} SHIFT LOCK SYSTEM COMPONENTS St o p Li g ht Swi t c h Shi f t lock Cont r o l Uni t Assembl y...
Page 479 AX-16 SYSTEM SHIFT AUTOMAT1C TRANSAXLE (U240E) LOCK INSPECTION INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY Using a voltmeter, measure the voltage at each terminal. HINT: Do not disconnect the shift lock control unit assembly cor ·ec tor. 00 59 10 Measuri n g Condition Terminal Voltage (V) (IG - F)
Page 480 AX -1 7 FLOOR SHIFT ASSEMBLY AUTOMATIC TRANSAXLE (U240E) FLOOR SHIFT ASSEMBLY Rei n f o r c ement COMPONENTS Fr o nt Door Openi n g Tr i m --� I n st r u ment Panel Fr o nt Door Openi n g T r'l m LH End Fi n i s h Panel Heater Cor1sole arld Cowl S' 1 d e Tr i m �...
Page 481 AX-18 AUTOMATIC TAANSAXLE (U240E) FLOOR SHIFT ASSEMBLY I n st r u ment Panel Heat e r Hoses Cl a mp Suct i o n Tube Cl a mp Bl c• w e< Uni t Rei n f o r c ement � / / No.
Page 482 AX-19 AUTOMATIC TRANSAXLE (U240E) FLOOR SHIFT ASSEMBlY HINT: ) correspond to those indicated Screw shapes and sizes are indicaled in the table below. The codes {"A" - " " � on the previous page. -- - - -f.--- : Shape Size Size ----...
Page 483 AX-20 FLOOR SHIFT ASSEMBLY AUTOMAllC Upper Posi t i o n . Shi f t Lever Knob But t o n I n di c at o r Housi n g � Shi f t Lever Knob Shi f t Lever Knob Sl i d e Cover But t o n Gui d e Sl e eve...
Page 484 AX-21 FLOOR SHIFT ASSEMBLY AUTOMATIC TRANSAXLE(U240E) REMOVAL REMOVE INSTRUMENT PANEL (See page B0-79) REMOVE AIR CONDITIONING UNIT (See page AC--26) REMOVE KEY INTERLOCK CABLE Remove the cable end from the rod of the floor shift as sembly. Pull out the cable while pressing the clip of the key inter (b ) lock cable.
Page 485 AX-22 AUTOMATIC TAANSAXLE (U240E) FLOOR SHIFT ASSEM8L Remove the cable end from the rod of the floor shift as sembly. ( e) Pull out the cable while pressing the clip of the transaxle control cable. Remove the floor shift assembly.
Page 486 FLOOR AX-23 AUTOMATIC TRANSAXlE SHIFT ASSEMBLY "-"-." DISASSEMBLY REMOVE 0/D MAIN SWITCH TERMINAL ( a) Remove the 0/D main switch connector from the shift le ver plate. Disengage the secondary locking device. Release the locking log of the terminals 5 and 6, and pull the terminals out from the rearward.
Page 487 AX-24 FLOOH SHIFT ASSEMBLY AUTOMATIC TRANSAXLE (U240EI REMOVE SHIFT LOCK UNIT Remove the 2 screws and shift !ock unit. REMOVE SCREW AND MANUAL DETENT SPRING REMOVE SHIFT LEVER SUB-ASSEMBLY Using a screwdriver and hammer, drive off the shaft contra! ' " :;r"P (j while disengaging the c!aw of the shaft control and remove the �...
Page 488 AX-25 FLOOR SHIFT ASSEMBLY AUTOMATIC TRANSAXl.E (U240E) REASSEMBLY INSTALL COLLARS INSTALL DETENT ROO Install the shift lever knob sleeve to the detent rod. Apply grease on the detent rod and spring. Install the spring and detent rod. Using a punch and hammer, install the grooved pin to the Shih detent rod pin hole.
Page 489 AX-26 FLOOR SHIFT ASSEMBLY AUTOMATIC TRANSAXLE (U240E) INSTALL LOWER POSITION INDICATOR HOUSING Apply MP grease on the spring. Install the spring and shift lock release button. Instal! the indicator lamp wire sub-- a ssembly with the screw. Install the bulb and bulb cap to the indicator lamp wire sub-assembly.
Page 490 AX-27 � FLOOH SHIFT ASSEMBLY AUTOMATIC TRANSAXLE (U240E) INSTALLATION INSTALL FLOOR SHIFT ASSEMBLY Pull in the cable white pressing the clip of the transaxle control cable to the floor shift assembly. Install the cable end from the rod of the floor shift assem bly.
Page 491 AX-28 AUTOMATIC TAANSAXLE (U24QE) FLOOR SHIFT ASSEMBLY Connect the 2 key interlock cable clamps. Pull in the cable while pressing tho clip of the key interlock cable. • ; ·- • ! ,,_, INSTALL AIR CONDITIONING UNIT (See page AC-29) INSTALL INSTRUMENT PANEL (See page B<Hl5) INSPECT KEY INTERLOCK AND SHIFT LOCK OP·...
Page 492 AX-29 FLOOR SHIFT ASSEMBLY AUTOMATIC TRANSAXLE (U240E) When the key is turned from ACC to LOCK even though the shift !ever is in other than P Position: Since the cable is too long due to improper adjustment at the automatic adjustment part of the key can not be locked.
Page 493 AX-30 AUTOMATIC TRANSAXLE UNIT AUTOMATIC TRANSAXLE UNIT COMPONENTS No. 2 Cyl i n der Head Cover Ai r Cl e aner Assembl y Radi a t o r Reser v oi r � Br a cket Engme Rear Mount m g �...
Page 494 AX-31 AUTOMATIC TRANSAXLE UNIT AUTOMATIC TRANSAXlE {U240E) REMOVAL REMOVE HOOD Torque: 1 3 N-m (130 kgf-cm, 9 ft-lbf) REMOVE BATTERY REMOVE ECM AND ECM CASE Torque: 6.9 N-m (70 kgf-cm, 61 in.-lbf) REMOVE ECM BRACKET Torque: Bolt: 18 N-m (185 kgf-cm, 1 3 fl·lbf) Nut: 1 2 N-m (120 kgf-cm, 9 ft-lbf) REMOVE AIR CLEANER ASSEMBLY REMOVE NO.
Page 495 AX-32 AUTOMATIC TRANSAXLE UNIT AUTOMATIC TRANSAXLE (U240E) REMOVE BOLT AND DISCONNECT RADIATOR RES ERVOIR Torque: 4.9 N-m (50 kgf-cm, 43 in.-lbf) REMOVE STARTER Remove the nut and wire, and disconnect the connector. Remove the 2 bolts and starter. Torque: 37 N-m (378 kgf-cm, 28 11-lbf) REMOVE LH, RH, CENTER ENGINE UNDER COVERS DRAIN ATF FROM FRONT DIFFERENTIAL CASE Torque:...
Page 496 AX-33 AUTOMATIC TRANSAXLC UNIT AUTOMATIC TRANSAXLE (U240E) REMOVE SUSPENSION MEMBER Remove the 9 bolts and 3 nuts. Torque: Bolt A : 157 N-m (1,601 kgf.cm, 1 1 6 ft.lbf) Bolt B: 52 N·m (530 kgf-cm, 38 fl·lbf) Bolt C: 39 N·m (398 kgt-cm, 29 tt-lbf) Nut: 52 N-m (530 kgf-cm, 38 ft-lbf) Remove the suspension member.
Page 497 AX-34 AUTOMATIC TRANSAXLE (U240E) AUTOMATIC TRANSAXLE UNIT REMOVE UPPER SIDE ENGINE LEFT MOUNTING, NUT AND BOLT Torque: 80 N-m (816 kgf.cm, 59 ft - l bf) REMOVE OIL COOLER HOSE Loosen the 2 clips and disconnect the 2 oil cooler hoses. SUPPORT TRANSAXLE WITH A JACK REMOVE TORQUE CONVERTER CLUTCH MOUNT...
Page 498 AX-35 AUTOMATIC TRANSAXLE UNIT AUTOMATIC TRANSAXLE (U240El INSTALLATION CHECK TORQUE CONVERTER CLUTCH INSTALLA· TION Using calipers and a straight edge, measure the distance be tween the installed surface and the front surface of the trans , - - -- axle housing. Correct distance: More than 1 3 .
Page 499 AX-36 TORQUE CONVERTER CLUTCH AND DHIVE PLATE AUTOMATIC TAANSAXLE {U240E) TORQUE CONVERTER CLUTCH AND DRIVE PLATE INSPECTION INSPECT ONE-WAY CLUTCH Install SST into the inner race of the one-way clutch. 0935Q-32014 (09351 -32010) Install SST so that it fits in the notch of the converter hub and outer race of the one-way clutch.
Page 500 TORQUE AX-37 AUTOMATIC TRANSAXLE (U240E) CONVERTER CLUTCH AND DRIVE PlATE HINT: Mark the position of the converter clutch to ensure the installa� lion is correctly performed.
Page 501 �MEM O -...
Page 502 AUTOMATIC TRANSAXLE (U341 E) AX- . . 1 AUTOMATI C TRANSAXLE SYSTEM . . AX- 3 VEHI C LE SPEED SENSOR . . I N PUT TURBI N SPEED SENSOR . AX--4 ATF TEMPERATURE SENSOR . AX-5 PARKI N EUTRAL POSI T I O N ( P NP) SWI T CH , .
Page 504 AX-1 AUTOMATIC THANSAXLE SYSTEM AUTOMATIC TRANSAXLE (U341 AUTOMATIC TRANSAXLE SYSTEM P RECAUTION If the vehicle is equipped with a mobile communication system, refer to the precautions in the section.
Page 505 AX-2 AUTOMATIC AXLE AUTOMATIC TAANSAXLE (U341 E ) TRANS SYSTEM OPERATION 1st & Brake (83) No. 2 Clutch {F2) Direct Clutch (C2}--- -- No.1 Clutch {F1) 2nd Brake {82) 0 /D & Brake (81)
Page 506 AX-3 AUTOMATIC TRANSAXLE {U341 E) VEHICLE SPEED SENSOR VEHICLE SPEED SENSOR ON-VEHICLE REPAIR REMOVE BATTERY REMOVE ECM AND ECM CASE REMOVE ECM BRACKET DISCONNECT VEHICLE SPEED SENSOR CONNEC REMOVE VEHICLE SPEED SENSOR ASSEMBLY Remove the bolt and vehicle speed sensor assembly. Remove the dip and speedometer driven gear from the vehicle speed sensor.
Page 507 AX-4 INPUT fURBIN SPEED SENSOR AUTOMATIC TRANSAXLE (U341El INPUT TURBIN SPEED SENSOR '"' '""" " ON-VEHICLE REPAIR REMOVE BATIERV REMOVE ECM AND ECM CASE REMOVE ECM BRACKET REMOVE INPUT TURBIN SPEED SENSOR Disconnect the connector. Remove the bolt and input turbin speed sensor. Remove the 0-ring from the input turbin spee d sensor.
Page 508 ATF l[MPERATURl SE:: N SOfl AUTOMATIC TRANSAXLE (U341E) ATF TEMPERATURE SENSOR ON-VEHICLE REPAIR DISCONNECT SOLENOID CONNECTOR REMOVE LH ENGINE UNDER COVER REMOVE DRAIN PLUG AND DRAIN ATF REMOVE OIL PAN AND GASKET NOTICE: Some fluid will remain in the oil pan. Remove the bolts, and carefully remove the oil pan assem...
Page 509 AX..£ ATFTEMPEAATURE SENSOR INSTAll OIL STRAINER Coat a new 0-- r ing with AT Install the 0-ring to the oil strainer. Install the oil strainer with the 3 bolts. (c ) Torque: 11 N-m (110 kgf.cm, 8 fl·lbf) INSTAll OIL PAN Install the oil pan and a new gasket with the 1 9 bolts.
Page 510 AX-7 PARKINEUfRAL POSITION (PNP) SWITCH AUTOMATIC TRANSAXlE ( U341 E) PARK/NEUTRAL POSITION (PNP) SWITCH ON-VEHICLE REPAIR REMOVE AIR CLEANER ASSEMBLY DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR REMOVE PARK/NEUTRAL POSITION SWITCH Remove the nut. Remove the nut, washer and control shift lever. Using a screwdriver, pry off the lock plate.
Page 511 AX-8 ·- AXLE (U341 EJ Install the control shift lever with the nut Torque: 1 3 N·m (130 kgf·cm, 9 1t·lbl) Connect the shift control cable to the control shaft Torque: 1 2 N·m (120 kgf·cm, 9 ft·lbl) CONNECT PARK/NEUTRAL POSITION SWITCH CON- NECTOR CHECK PARK/NEUTRAL POSITION OPERATION Check that the engine can be started with the shift lever only in...
Page 512 AX-9 VALVE BODY ASSEMBLY AUTOMATIC TRANSAXLE {U34 1 E) VALVE BODY ASSEMBLY ON-VEHICLE REPAIR REMOVE LH ENGINE UNDER COVER REMOVE DRAIN PLUG AND DRAIN ATF REMOVE OIL PAN AND GASKET NOTICE: Some fluid will remain in the oil pan. Remove the 1 9 bolts, and carefully remove the oil pan assem bly.
Page 513 AX-1 0 VALVE BODY ASSEMBLY AUTOMATIC TAANSAXLE (U341 El REMOVE VALVE BODY Remove tho 3 bolts, cover and detent spring. Remove the 1 2 bolts and valve body. NOTICE: e '· Be careful not to drop the check valve body, spring and cumulator piston.
Page 514 AX-1 1 VALVE BODY ASSEMBL Y AUTOMATIC TAANSAXLE (U341E) INSTALL CHECK VALVE AND SPRING INSTALL VALVE BODY Align the groove of the manual valve with the pin of the manual valve lever. Temporarily install the valve body with the 1 2 bolts. Bolt length: Bolt A: 55 mm (2.17 1n.) Bolt B: 45 mm (1.77 in.)
Page 515 AX-12 VALVE BODY ASSEMBLY Install the oil strainer with the 3 bolts. Torque: 11 N.m (110 kgf.cm, 8 ft·lbf) INSTALL MAGNET IN OIL PAN Install the 2 magnets in the oil pan, as shown in the illustration. DO�S05 INSTALL OIL PAN Install the oil pan and a new gasket with the 1 9 bolts.
Page 516 AX-1 3 DIFFERENTIAL OIL SEAL AUTOMATIC TRANSAXLE (U341 E) DIFFERENTIAL OIL SEAL ON-VEHICLE REPAIR DRAIN ATF FROM FRONT DIFFERENTIAL CASE REMOVE LH AND RH DRIVE SHAFTS (See page SA-20) REMOVE LH AND RH SIDE OIL SEAL Using SST, drive out both the side oil seals. 09308-1 0010 INSTALL LH AND RH SIDE OIL SEAL Using SST and a hammer, drive in a new oil seal.
Page 517 AX-14 LOCK AUTOMATIC TRANSAXLE IU341El SHIFT SYSTEM SHIFT LOCK SYSTEM COMPONENTS Oil� Ht9 Shift Lock Control Unit Assembly...
Page 518 AX-15 AUTOMATIC TAANSAXLE {U341E) - SHIFT LOCK SYSTEM INSPECTION INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY Using a voltmeter, measure the voltage at each terminaL HINT: Do not disconnect the shift lock control unit assembly con nee� tor. Terminal Measuring Condition Voltage (V) -�...
Page 519 AX-16 SHIFT ASSEMBLY AUTOMATIC TRANSAXLE {U3 FLOOR FLOOR SHIFT ASSEMBLY ' "' ' " Fr o nt Pi l l a r Gar n i s h COMPONENTS Passen ger Ai r b ag Assemb l y Br a ce Fr o nt Door Openi n g Tr i m - --- �...
Page 520 AX-17 AUTOMATIC TRANSAXLE(U341E} SHIFT ASSEMBLY FlOOR Heat e r Hoses Cl a mp � - - · · No.1 Br a ce Non- - r e usabl e par t ilooog Key I n t e r l o ck Cabl e Fl o or Shi f t Assembl y...
Page 521 AX-18 FLOOR SHIFT ASSEMBLY AUTOMATIC TAANSAXLE (U341 El HINT: Screw shapes and sizes are indicated in the table below. The codes ("A"- "N�) correspond to those indicated m i n . on the previous page. Size Shape Shape 0 oo 8 0 =- 6 C = 8 I ©...
Page 523 AX-20 FLOOR SHIFT ASSEMBLY AUTOMATIC TRANSAXLE (U341E) REMOVAL REMOVE INSTRUMENT PANEL (See page B0-79) REMOVE AIR CONDITIONING UNIT (See page AC-26) REMOVE KEY INTERLOCK CABLE Remove the cable end from the rod of the floor shift as (a ) sembly. Pull out the cable while pressing the clip of the key inter...
Page 524 AX-21 "- AUTOMATIC TRANSAXLE (U341E) FLQOH SHIFT ASSEMBLY Remove the cable end from the rod of the floor shift as (d ) sembly. Pull out the cable while pressing the clip of transaxle control cable. Remove the floor shift assembly.
Page 525 AX-22 FLOOR AUTOMATIC TRANSAXLE [U341E) SHIFT ASSEMBLY = - -c� - DISASSEMBLY REMOVE 0/D MAIN SWITCH TERMINAL Remove the 0/0 main switch connector from the shift le- ver plate. Disengage the secondary locking device. Release the locking tog of the terminals 5 and 6, and pull Secondary locki n g Devi c e the terminals out from the rearward.
Page 526 AX-23 SlllFT ASSEMBLY AUTOPJIATIC TRANSAXLE (U341 E) OOfl REMOVE SHIFT LOCK UNIT Remove the 2 screws and shift lock unit REMOVE SCREW AND MANUAL DETENT SPRING REMOVE SHIFT LEVER SUB-ASSEMBLY Using a screwdriver and hammer, drive off the shaft control while disengaging the claw of the shaft control and remove the shift lever sub-assembly.
Page 527 AX-24 FLOOR SH!FT ASSEMBLY AUTOMATIC TRANSAXLE (U341E) REASSEMBLY INSTAll 4 COLLARS INSTAll DETENT ROD Install the shill lever knob sleeve to the detent rod. Apply grease on the detent rod and spring. Install the spring and detent rod. Lever Sub-- a ssembl y Using a punch and hammer, install the grooved pin to the detent rod pin hole.
Page 528 AX-25 FLOOR SHIFT ASSEMBLY AUTOMATIC TRANSAXLE INSTALL SHIFT LOCK UNIT Install the shift lock unit with the 2 screws. 001825 INSTALL LOWER POSITION INDICATOR HOUSING Apply grease on the spring. Install the spring and shift lock release button. Install the bulb and bulb cap to the indicator lamp wire sub-assembly.
Page 529 AX-26 FLOOR SHifT ASSEMBLY NOTICE: Make sure not to catch OlD main switch wire harness. INSTALL OlD MAIN SWITCH TERMINAL Connect the 2 0/D main switch terminals to the connec� tor. Connect the connector to the shift lever plate.
Page 530 AX-27 AUTOMATIC TRANSAXLE {U341 E) FLOOR SHIFf ASSEMBLY I NSTALLATION INSTALL FLOOR SHIFT ASSEMBLY Pull in the cable while pressing the clip of the transaxle (a ) control cable to the floor shift assembly. Instal! the cable end from the rod of the floor shift assem bly.
Page 531 AX-28 AUTOMATIC TRANSAXLE (U341E) - FLOOR SHH-1 ASSEMBLY Connect the 2 key interlock cable clamps. Pull in the cable while pressing the clip of the key interlock cable. INSTALL AIR CONDITIONING UNIT (See page AC-29) INSTALL INSTRUMENT PANEL (See page AG-29) INSPECT KEY INTERLOCK AND SHIFT LOCK OP...
Page 532 AX-29 AUTOMATIC TRANSAXLE {U341E) FLOOR SHIFT ASSEMBLY When the key is turned from ACC to LOCK even though the shift lever is in other than P Position: Since the cable is too long due to improper adjustment at the automatic adjustment part of the key can not be locked.
Page 534 AX-31 AUtOMATIC TRANSAXLE UNIT AUTOMATIC TRANSAXLE (U341E) REMOVAL REMOVE HOOD Torque: 1 3 N-m (130 kgf.cm, 9 ft-lbf) REMOVE BATIERY REMOVE ECM AND ECM CASE Torque: 6.9 N·m (70 kgf.cm, 61 in .. lbf) REMOVE ECM BRACKET Torque: Bolt: 1 8 N-m (185 kgf.cm, 1 3 ft-lbf) Nut: 1 2 N-m (120 kg!-em, 9 ft-lbf) REMOVE AIR CLEANER ASSEMBLY REMOVE NO.
Page 535 AX-32 AUTOMATIC TRANSAXLE UNIT AUTOMATIC TRANSAXLE (U341E! REMOVE BOLT AND DISCONNECT RADIATOR RES ERVOIR Torque: 4.9 N-m (50 kgf.cm, 43 in..lbf) REMOVE STARTER Remove the nut and wire, and disconnect the connector. Remove the 2 bolts and starter. Torque: 37 N-m (378 kgf.cm, 28 11-lbl) REMOVE LH, RH, CENTER ENGINE UNDER COVERS _ : ' _ - - :�...
Page 536 AX-33 AUTOMATIC TRANSAXLE (U341 AUTO�MTIC TflANSAXLE UNI REMOVE SUSPENSION MEMBER Remove the 9 bolts and 3 nuts. Torque: Bolt A: 157 N-m (1,601 kgf-cm, 1 1 6 ft·lbf) Bolt B: 52 N-m (530 kgf.cm, 38 ft-lbf) Bolt C: 39 N-m (398 kgf . cm, 29 ft-lbf) Nut: 52 N-m (530 kgf-cm, 38 fHbf) Remove the suspension member.
Page 537 AX-34 AUTOMA TIC TRANSAX!,E UN!T AUTOMA TIC TAANSAXLE (U341 E) REMOVE UPPER SIDE ENGINE LEFT MOUNTING, NUT AND BOLT Torque: 80 N.m (816 kgf.cm, 59 fl·lbf) REMOVE OIL COOLER HOSE Loosen the 2 clips and disconnect the 2 oil cooler hoses. SUPPORT TRANSAXLE WITH A JACK REMOVE TORQUE CONVERTER CLUTCH MOUNT...
Page 538 � AX-35 AUTOMATIC UNIT AUTOMATIC TRANSAXLE (U341E) TRANSAXLE INSTALLATION CHECK TORQUE CONVERTER CLUTCH INSTALLA- TION Using calipers and a straight edge, measure the distance be tween the installed surface and the front surface of the trans axle housing, Correct distance: More than 13.3 mm (0.524 in.} TRANSAXLE INSTALLATION Installation is in the reverse order of removal (See page AX-31).
Page 539 AX-36 TORQUE CONVERTER CLUTCH AND DRIVE PLATE INSPECTION INSPECT ONE-WAY CLUTCH Install SST into the inner race of the one--- w ay clutch. 09350..32014 (09351-32010) Install SST so that it fits in the notch of the converter hub and outer race of the one-way clutch. 09350..320 1 4 (09351-32020) With the torque converter clutch setting up on its side, check that the clutch locks when turned counterclock...
Page 540 AX-37 AliTOMATIC CLUTG! TORQUE CONVERTER lAND OR!vt : PLAl TRAHSAXlE (U341 E ) HINT: Mark the position of the converter clutch to ensure the installa tion is correctly per1ormed.
Page 542 SUSPENSION AND AXLE TROUBLESHOOTI N G . SA-1 SA- - 2 TI R E AND WHEEL ... FRONT WHEEL ALI G NMENT SA-4 SA-8 REAR WHEEL ALI G NMENT ... FRONT AXLE HUB ..SA- - 1 1 SA - 17 FRONT WHEEL HUB BOLT ..
Page 544 SA-1 SUSPENSION AXlE TROUBLESHOOTING TROUBLESHOOTING PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary replace these parts Symptom Susper;t Area �eo page...
Page 545: Tire And Wheel
SA-2 WHEEL SUSPENSION AND AXLE TIRE AND TIRE WHEEL INSPECTION INSPECT TIRE Check the tires for wear and proper inflation pressure. Cold tire inflation pressure 1 ZZ-FE engine models: psi) Rear front T1re size kPa (kgflcm2, psi) kPa (kgf!cm2, 195160R 1 5 210(2.1, 29) 2 1 0 (2.1, 29) P 195160R1587H...
Page 546 SA-3 TIRE AND WHEEl SUSPENSION AND AXLE INSPECT WHEEL BALANCE Check and adjust the Off the-car balance. II necessary, check and adjust the On-the-car balance. Imbalance after adjustment: 8.0 g (0.018 1b) or less f\<J79?H CHECK WHEEL BEARING LOOSENESS Deviation: Backlash: Using a dial indicator, check the backlash near the center of the axle hub.
Page 547 SA-4 ALIGNMENT SUSPENSION AND FRONT WHEEL AXLE FRONT WHEEL ALIGNMENT Front: INSPECTION MEASURE VEHICLE HEIGHT Vehicle height: Frofl\"1 mm {irl_) Raar·2 l1re S<le mm(in) 224 (8.82) 195'60R15, P 1 95'60R1 5 1 9 0 (7 48) 190 {7.48} 226 (8.90) 205'55R15, P205155R15 225 {8.86) 205t50R16...
Page 548 SA-5 SUSPENSION AND AXLE fRONT WHEEL ALIGNMENT 205/55R15, P205/55R15 tire: :;!: Camber -{}'25" :;!: 45" {-{1.42. 0.75°) Right-left eaor 45" (0.75•) Or less :;!: 2'0! 45" (2.02' ± 0 75') Caster R;glll--leh eaor 45· (0.75" ) or less Steenng axis inclination 13'04"...
Page 549 SA-6 AXLE SUSPENSION AND FRONT WHEEL ALIGNMENT Adjust the camber by pushing or pulling the lower side of the shock absorber in the direction in which the camber adjustment is required. Tighten the nuts. Torque: 153 N·m (1 ,560 kgf.cm, 1 1 3 ft.tbf) Install the front wheel.
Page 550 SA-7 SUSPENSION AND AXLE FRONT WHEEL ALIGNMEN Loosen the tie rod end lock nuts. Turn the right and left rack ends by an equal amount to adjust the toe-in. HINT: Try to adjust the toe-in to the center of the specified value. Make sure that the lengths of the right and left rack ends are the same.
Page 551: Rear Wheel Alignment
SA-8 SUSPENSION AND AXLE f1EAf-l WHEELAL!GNMENT REAR WHEEL ALIGNMENT INSPECTION MEASURE VEHICLE HEIGHT (See page SA-4) INSTALL CAMBER-CASTER-KINGPIN GAUGE OR POSITION VEHICLE ON WHEEL ALIGNMENT TES· Follow the specific instructions of the equipment manufacturer. INSPECT CAMBER Camber; -1 ' 1 1 ' ± 45' {--1.18°...
Page 552 SA-9 SUSPENSION AND AXLE REAn WHEELAUGNMENr HOW TO READ ADJUSTMENT CHART (EXAMPLE) Measure the present alignment. Example: Camber (RH): -0'26' (--0.43') Camber (LH): -1 '56' (-1 .93 ·) Toe-in (total): IN 7 mm (0.28 in.) Mark tho difference between the standard value (A) and Example: the measured value (8 ) on the adjustment chart Standard value:...
Page 553 SA-10 Upper ar m cam gr a duat i o n REAR SUSPENSION AND AXLE Camber Toe- - - i n ( + )I n war d ..1 <l)l !---: - r : <'J I -+---+--�• ..- 1 £1 £1 Lower ar m cam gr a duat i o n...
Page 554 SA-11 FRONT SUSPENSION AND AXLE AXLE FRONT AXLE HUB COMPONENTS - - Fr o nt Shock Absor b er Dr i v e Shaf t Br a ke Cal i p er - - - Dr s c +Lock Nut 159) +SnapRi n g + Cot t e r Pi n...
Page 555 SA-12 SUSPENSION AND AXLE FRONT AXLE HUB REMOVAL REMOVE FRONT WHEEL Torque: 1 03 N-m (1 ,050 kgf-cm, 76 ft-lbf) CHECK BEARING BACKLASH AND AXLE HUB DEVI ATION Remove the 2 bolts, brake caliper and disc. Support the brake caliper securely. f<OSQ\7 Backlash: Using a dial indicator, check the backlash near the center...
Page 556 SA-13 SUSPENSION AND AXlE AXLE HUB FRONT LOOSEN 2 NUTS ON LOWER SIDE OF SHOCK AB SORBER Torque: 153 N.m {1,560 kgf.cm, ft·lbf) 1 1 3 HINT: Do not remove the 2 bolts and nuts. DISCONNECT TIE ROD E N D FROM STEERING KNUCKLE Remove the cotter pin and nut.
Page 557 SA-14 AXLE HUB DISASSEMBLY REMOVE LOWER BALL JOINT Remove the cotter pin and nut. Using SST, remove the lower ball joint. 09628-6201 1 REMOVE AXLE HUB Using SST, remove the axle hub. (a ) 09520-00031 (09520-00040, 09521 -000 1 0 , 0952Hl0020) Using SST and a press, remove the inner race (outside) from the axle hub.
Page 558 SA- 1 5 SUSPENSION AND AXLE FRONT AXLE REASSEMBLY INSTALL BEARING Using SST and a press, install a new bearing to the steer ing knuckle. 0995()-60020 (09951 -D0730). 09950-·70010 (09951-D71 50) Using snap ring pliers, instal! a new snap ring. INSTALL DUST COVER Place the dust cover and using a torx socket (T30), install the 3 bolts.
Page 559 SA-16 � FRONT AXLE HUB SUSPENSION AND AXLE INSTALLATION Installation is In the reverse order of removal (See page SA-12). HINT: After installation, check the ABS speed sensor signal (See page Dl-276) and front wheel alignment (See page SA-4).
Page 560 SA-17 SUSPENSION AND AXLE HUB BOLT FHONr WHEEL FRONT WHEEL HUB BOLT REPLACEMENT REMOVE FRONT WHEEL REMOVE BRAKE CALIPER AND DISC Remove the 2 bolts, brake caliper and disc. Support the brake caliper securely. REMOVE HUB BOLT Using SST, 2 nuts and a screwdriver or an equivalent, remove the hub boiL 09628 �...
Page 561: Front Drive Shaft
SA-18 FRONT DRIVE SHAFT SUSPENSION AND AXLE FRONT DRIVE SHAFT COMPONENTS 1ZZ-FE engine (MIT) and 2ZZ-GE engine: (k g f·c � , ft·l : Specified torque N + Non - -reusable part...
Page 562 SA-- -- 1 9 SUSPENSION AND AXlE FRONT DRIVE SHAFT engine {AfT): ZZ-FE +Snap Ri n g +Cl a mp + Bo ot + Cent e r Bear i n g " " " >·--- -- -- -- Joi n t Shaf t I n boar d Joi n t Shaf t St r a i g ht Pi n Outboard...
Page 563 SA-20 SUSPENSION AND AXlE FnONT DnlVF. SHAFT REMOVAL NOTICE: The hub bearing could be damaged if it is subjected to the vehicle weight, such as when moving the ve� hicle with the drive shaft removed. Therefore, if It Is absolutely necessary to place the ve� hicle weight on the hub bearing, first support it with the SST.
Page 564 HlONT SA-21 SUSPENSION AND AXlE DRIVE SHAFT DISCONNECT LOWER BALL JOINT FROM LOWER SUSPENSION ARM Remove the 2 nuts and bolt. Torque: 142 N.m (1,450 kgf.cm, 105 ft.lbl) DISCONNECT DRIVE SHAFT FROM AXLE HUB Using a plastic hammer, disconnect the drive shaft from the axle hub.
Page 565 SA-22 SUSPENSION AND AXLE FRONT DRIVE SHAFT DISASSEMB LY 1ZZ-FE engine (Mff) and 2ZZ-GE engine: DISASSEMBLE DRIVE SHAFT Check the drive shaft. Check to see that there is no remarkable play in the ( 1 ) outboard joint. Check to see that the inboard joint slides smoothly ( 2 ) in the thrust direction.
Page 566 SA-23 SUSPENSION AND AXLE FRONT DRIVE SHAFT Disassemble the outboard joint shaft. Place matchmarks o n the outboard joint shaft, inner ( 1 ) race and cage. NOTICE: Do not punch the marks. Remove the 6 balls. Slide the cage toward outboard joint. Using a snap ring expander, remove the snap ring.
Page 567 SA-24 DRIVE SHAF' f SUSPENSION AND AXLE FflON f Place match marks on the inboard joint shaft, tripod and outboard joint shaft. NOTICE: Do not punch the marks. Remove the inboard joint shaft from the outboard joint shaft. Remove the tripod. { 1 ) Using a snap ring expander, remove the snap ring.
Page 568 SA-25 SUSPENSION AND AXLE FRONT DRIVE SHAFT Remove the center bearing. i� , . , c·� · · · Using a screwdriver, remove the outside snap ring. · · · ..1- · · · · - � t -. \ · Using a press, remove the center bearing case.
Page 569 SA-26 SUSPENSION AND AXLE FRONT DRIVE SHAFT REASSEMBLY REASSEMBLE INBOARD JOINT SHAFT 1 ZZ � FE 2ZZ�GE Install dust cover. Using a press, install a new dust cover. LH shaft of engine (Mff) and engine: { b) Using a snap ring expander, install a new outer snap ring. Install center bearing.
Page 570 SA-27 SUSPENSION AND AXLE FHONT DFliVl:: SHAFf Install the transax!e side dust cover. Using a steel plate and press, install a new trans axle side dust cover until the distance from the tip of the inboard joint shaft to the dust cover reaches the specified value, 6 87 mm as shown in the illustration.
Page 572 SA-29 SUSPENSION AND AXLE - Ff10N f DRIVE SHAH Assemble the outboard joint shaft. Install the cage to the outboard joint shalt. ( 1 ) NOTICE: The side with smaller diameter must face outboard joint. Align the matchmarks on the inner race and out (2 ) board joint shaft f103•...
Page 573 SA-30 SUSPENSION AND AXLE DRIVE FHONT SHAFT ---/ �" - - - - Align the matchmarks on the inboard joint shaft and Matchmarks outboard joint shaft. Install the inboard joint shaft to the outboard joint shaft. Instal! a new snap ring. Temporarily install the boot to the inboard joint shaft.
Page 574 MIT: SA-31 ·- SUSPENSION AND AXLE FRONT DRIVE SHAFT Assemble the dynamic damper clamp. Set the dynamic damper distance, as described be ( 1 ) lo w . Distance; 155.0 ± 2.0 (6.102 ± 0.079 1n.) Bend the band and lock the dynamic damper clamp with a screwdriver.
Page 575 SA-32 SUSPENSION AND AXLE FRONT DRIVE SHAFT I NSTALLATION Installation is i n the reverse order removal (See page SA-20). H IN T: After installation, check the ABS speed sensor signal (See page 01-276} and front wheel alignment (See page SA-4).
Page 576: Front Shock Absorber
SA-33 SUSPENSION AND AXLE FRONT SHOCK ABSORBER FRONT SHOCK ABSORBER COMPONENTS �cap �-- � -- · - Suspensi o n Suppor t Oust Seal ®----- - - - - - Spr i n g Seat ,�--"--- St a bi l i z er Bar Li n k Shock Absor b er wi t h Coi l Spr i n g li\;�'it-- -- -...
Page 577 SA-34 SUSPENSION AND AXLE FRONT SHOCK ABSORBEH REMOVAL REMOVE FRONT WHEEL Torque: 103 N·m (1,050 kgf.cm, 76 ft·lbf) DISCONNECT ABS SPEED SENSOR WIRE HARNESS CLAMPS FROM SHOCK ABSORBER Remove the bolt and disconnect the ABS speed sensor ,...,, e Torque: 8.0 N-m (82 kgf.cm, 71 in . harness clamp.
Page 578 SA--35 SUSPENSION AND AXLE FRONT SHOCK ABSORB!:'f'{ DISASSEMBLY REMOVE COIL SPRING lnstat1 2 nuts and a bolt to the bracket at the lower side of the shock absorber and secure it in a vise. Using SST. compress the coH spring. 09727-30021 (09727-00010, 09727-0002 1 , 09727-00031) NOTICE:...
Page 579 SA- 36 FnONT SHOCK ABSORBER SUSPENSION AND AXLE...
Page 580 SA-37 FRONT SHOCK ABSORBER SUSPENSION AND AXLE DISPOSAL FULLY EXTEND SHOCK ABSORBER ROD DRILL HOLE TO DISCHARGE GAS FROM CYLINDER Using a drill, make a hole in the cylinder as shown in the illustra tion to discharge the gas inside. CAUTION: •...
Page 581 SA--38 FRONT SHOCK ABSORBER SUSPENSION AND AXLE REASSEMBLY INSTALL LOWER INSULATOR ONTO SHOCK AB· SORBER INSTALL SPRING BUMPER TO PISTON RoD INSTALL COIL SPRING (a ) Using SST, compress the coil spring. 09727-30021 (09727-D0010, 09727-D0021 , 09727...()0031 ) NOTICE: Do not use an impact wrench. It will damage the SST. Install the coil spring to the shock absorber.
Page 582 SA-39 SUSPENSION AND AXLE fHON f SHOCK A8SORBER grease 'mto the suspension support Apply Install the c --==-:.:_ )
Page 583 SA-40 � FRONT SHOCK ABSORBER I NSTALLATION Installation is in the reverse order of removal (See page SA-34). HINT: After installation, check the front wheel alignment (See page SA-4 ) .
Page 584 SA-41 SUSPENSION AND AXLE FRONT LOWER SUSPENSION ARM FRONT LOWER SUSPENSION ARM COMPONENTS Engine Mount Rear �- . . � - -- - -- Gear Assembly Non-reusable part...
Page 585 SA-42 FRONT LOWER SUSPE'NSION ARM SUSPENSION AND AXLE REMOVAL REMOVE FRONT WHEEL Torque: 103 N-m (1,050 kgf.cm, 76 ft-lbf) Mrr or RH side: REMOVE LOWER SUSPENSION ARM Remove the f!ngine under cover . Remove the bolt and 2 nuts, and disconnect the lower suspension arm from the lower ball joint.
Page 586 SA-43 SUSPENSION AND AXLE FRONT LOWER SUSPENSION Disconnect the RH and LH stabilizer bar Jinks. Remove t h e nut and disconnect the stabilizer bar { 1 ) link from the shock absorber. Torque: 44 N·m (449 kgf.cm, 32 ft·lbf) HINT: If the ball joint turns together with the nut, use a hexagon (5 mrn) wrench to hold the stud.
Page 587 SA-44 SUSPENSION AND AXLE FRONT LOWER SUSPENSION Ar-lM Disconnect the PS gear assembly from the suspension member. Remove the 4 set bolts. ( 1 ) Torque: 58 N-m (591 kgf.cm, 43 11-lbl) Tie the PS gear assembly to suspend it securely. Remove the bolt A and 3 nuts, and disconnect the engine rear mount Torque: 52 N-m (530 kgf.cm, 38 11-lbl)
Page 588 SA-45 SUSPENSION AND AXLE FRON f LOWER SUSPENSION ARM INSTALLATION Installation is In the reverse order of removal (See page SA-42}. HINT: After installation, check the front wheel alignment (See page SA-4).
Page 589 SA-46 SUSPENSION AND AXLE FRONT LOWER BALL JOINT FRONT LOWER BALL JOINT "'"' 01 COMPONENTS Cott e r Pi n • Lock Nut Brake Caliper �- Di s c...
Page 590 I " SA-47 FRONT l_OWtR BALL JOIN SUSPENSION AND AXLE REMOVAL REMOVE STEERING KNUCKLE WITH AXLE HUB (5ee page SA-12) REMOVE LOWER BALL JOINT Remove the cotter pin and nut. SS T Using SST, remove the lower ball joint. 09628-62011...
Page 591 SA-48 SUSPENSION AND AXLE - FRONT LOWER JOINr BALL INSPECTION INSPECT LOWER BALL JOINT FOR ROTATION CONDI· TION As shown in the illustration, flip the ball joint stud back and forth 5 times, before installing the nut. Using a torque wrench, turn the nut continuously at a rate of 2 - 4 seconds per 1 turn and take the torque reading on the 5th turn.
Page 592 SA-49 AXLE SUSPENSION FRONT LOWeR BALL JOINT I NSTALLATION INSTALL LOWER BALL JOINT Install the lower ball joint and tighten the nut. Torque: 103 N-m (1,050 kgf.cm, 76 ft·lbl) Install a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut fur ther up to 60 Q.
Page 593: Front Stabilizer Bar
SA-50 SUSPENSION AND AXLE FRONT STABIUZEA BAR FRONT STABILIZER BAR COMPONENTS - - - - - - -- - Engi n e Hood � PS Gear Assembl y St a bi l i z er Bar Li n k Engi n e Rear Mount &-- &Ji - - - - - - - B r a cket...
Page 594 SA-51 SUSPENSION AXLE FRONT STABILIZER BAR REMOVAL REMOVE STABILIZER BAR LINKS Remove the 2 nuts and stabilizer bar link. Torque: 44 N-m (449 kg!-em, 32 11-lbf) HINT: If the ball joint turns together with the nut, use a hexagon (5 mm) wrench to hold the stud.
Page 595 SA-52 SUSPENSION AND AXLE INSPECTION INSPECT STABILIZER BAR LINK BALL JOINT FOR ROTA· TION CONDITION · - As shown in the illustration, flip the ba!l joint stud back and forth 5 times, before installing the nut. Using a torque wrench, turn the nul continuously at a rate of 2 - 4 seconds per 1 turn and take the torque reading -�...
Page 596 SA -53 SUSPENSION AND AXLE FRONT STABILIZER BAR I NSTALLATION Installation is in the reverse order of removal (See page SA-51 ). H IN T: After installation, check the front wheel alignment (See page SA-4 ).
Page 597 SA-54 SUSPENSION AND AXLE HEAR AXLE CARA!ER REAR AXLE CARRIER COMPONENTS Axl e Hub Assembl y Upper Suspensi o n Ar m ABS Speed _ Sensor wl ABS: -�� Dr u m Connect o r -------- � Di sc + ABS Speed Sensor w/ ABS: Car n Bol t ! �...
Page 598 SA-55 SUSPENSION AND AXLE REAR AXLE CARRJI::: H REMOVAL REMOVE REAR WHEEL Torque: 103 N-m (1,050 kgf-cm, 76 ft.fbf) Disc brake: REMOVE BRAKE CALIPER AND DISC (a ) Remove the 2 bolts, brake caliper and disc. Torque: 47 N-m (475 kgf.cm, ft-lbf) Support the brake caliper securely.
Page 599 SA-56 SUSPENSION REAR AXLE CARRIER AXLE DISCONNECT UPPER SUPPORT SUSPENSION ARM Remove the bolt and nut, and disconnect the upper suspension arm. Torque: 74 N·m (755 kgf.cm, 55 ft·lbf) NOTICE: Do not turn the nut. HINT: At the time of installation, after stabilizing the suspension, torque ttle bolt.
Page 600 SA-57 SUSPENSION AND AXLE REAR AXLE CARA!EA DISASSEMBLY dr i v e wl ABS: out the 2 pins and REMOVE ABS SPEED SENSOR Using a pin punch and hammer, remove the 2 attachments from SST. 09520-00031 (09520-00040, 0952H l0020) Mount the axle hub assembly in a soft jaw vise. NOTICE: Replace the axle hub assembly if it is dropped or a strong shock is given to it.
Page 601 SA-58 SUSPENSION AND AXLE REAR AXLE CARRIER REASSEMBLY w/ ABS: INSTALL NEW ABS SPEED SENSOR Clean the contacting surface of the axle hub and a new ASS speed sensor. NOTICE: Do not allow any foreign matter sticking to the sensor rotor. Place the ABS speed sensor on the axle hub so that the connector is set at the bottom under the on-vehicle condi...
Page 602 SA-59 SUSPENSION AND AXLE REAR AXLE CARnlER I NSTALLATION Installation is In the reverse order of removal (See page SA-55). HINT: After installation, check the ASS speed sensor signal (See page Dl-276) and rear wheel alignment (See pa ge SA -8 ).
Page 603 SA-60 SUSPENSION AND AXLE REAR WHEEL HUB OOL T REAR WHEEL H U B BOLT REPLACEMENT REMOVE REAR WHEEL wl Disc brake: REMOVE BRAKE CALIPER AND DISC Remove the 2 bolts, brake caliper and disc. Support the brake caliper securely. w/ Drum brake: REMOVE BRAKE DRUM REMOVE HUB BOLT...
Page 604 SA-61 SHOCK ABSORBEH SUSPENSION AND AXLE REAR REAR SHOCK ABSORBER COMPONENTS Rear Deck Tr i m Cover Luggage Compar t m ent Mat Deck Tr i m Si d e Panel 0-Ri n g �- - ®------ Cushi o n Spt i n g Bmcket Spr m g ..
Page 605 SA-62 SUSPENSION AND AXLE REAR SHOCK ABSORBER REMOVAL REMOVE REAR WHEEL Torque: 103 N·m (1,050 kgf.cm, 76 11·1bl) REMOVE PACKAGE TRAY TRIM REMOVE LUGGAGE COMPARTMENT MAT REMOVE REAR DECK TRIM COVER REMOVE DECK TRIM SIDE PANEL REMOVE REAR LOWER SUSPENSION ARM (See page SA-72) REMOVE REAR SHOCK ABSORBER Remove the 3 nuts and rear shock absorber.
Page 606 SA-63 SUSPENSION AND AXLE REAR SHOCK ABSORBER DISASSEMBLY REMOVE COIL SPRING Using SST, compress the coil spring. SS T 09727-30021 (09727-0001 0, 09727-00021 , 09727-{)0031 ) NOTICE: Do not use an impact wrench. It will damage the SST. (b ) Using a 6 mm hexagon wrench to hold the piston rod, re...
Page 607 SA-64 � SUSPENSION AND AXLE REAR SHOCK ABSORBER INSPECTION INSPECT SHOCK ABSORBER --- - Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual sound during opera- tio n. If there is any abnormality, replace the shock absorber witt a new one.
Page 608 SA-65 SUSPENSION AND AXLE nEAR SHOCK ABSORBER DISPOSAL FU�LY EXTEND SHOCK ABSORBER ROD DRILL HOLE TO DISCHARGE GAS FROM CYLINDER Using a drill, make a hole in the cylinder as shown in the illustra tion to discharge the gas inside. CAUTION: When drilling, chips may fly out, work carefully.
Page 609 SA-66 REAR SHOCK ABSORBER AXLE ""'C '-< REASSEMBLY INSTALL COIL SPRING Using SST, compress the coil spring_ 09727-30021 (09727-0001 0 , 09727-00021 , 09727-0003 1 ) NOTICE: Do not use an Impact wrench. It will damage the SST . Insert the coil spring to the shock absorber. F��:?21 HINT: Fit the lower end of the coil spring into the gap of the spring low...
Page 610 SA-67 · SUSPENSION AND AXLE SHOCK REAR ABSORBER I NSTALLATION Installation is in the reverse order of removal {See page SA-62). H INT: After installation, check the rear wheel alignment (See page SA-8).
Page 611 SA-68 SUSPENSION AND AXLE REAR UPPER SUSPENSION ARM REAR U PPER SUSPENSION ARM COMPON ENTS Heat I n sul a t o r Cam Pl a t e l Uppe< Suspensi o n A< m · · I Cam Bol t &1<1 Suspensi o n Member : Speci f i e d t o r q ue...
Page 612 SA--69 SUSPENSION AND AXLE REAil UPPER SUSPENSION ARM R EMOVAL REMOVE REAR WHEEL Torque: 103 N-m (1,050 kgf-cm, 76 11-lbf) REMOVE TAILPIPE AND HEAT INSULATOR Remove the 2 bolts, springs, gasket, 3 0-rings and tail� pipe. Torque: 43 N-m (440 kgf.cm, 32 ft-lbf) Remove the 4 bolts and heat insulator.
Page 613 SA-70 SUSPENSION AND AXLE REAli UPPER SUSPFNSION ARM INSTALLATION Installation is in the reverse order of removal (See page SA-69). HINT: After installation, check the rear wheel alignment (See page SA-8).
Page 614 SA-71 SUSPENSION AND AXLE REAR LOWER SUSPENSION REAR LOWER SUSPENSION ARM COMPONENTS © + Gasket / "�> � Tailpipe 5.4{55,48in,·lbf) .. , L--o<- -- Lower Suspension Arm Parking Brake Ca�� ;426, · 1-03) ASS Speed Se H�ness 19 {194, 14) Stoppec Acm :cac ke��...
Page 615 SA-72 SUSPENSION AND AXLE REAR LOWER SUSPENSION ARM REMOVAL REMOVE REAR WHEEL Torque: 1 0 3 N-m {1 ,050 kgf.cm, 76 ft·lbf) REMOVE ABS SPEED SENSOR WIRE HARNESS CLAMP Remove the bolt and disconnect the ASS speed sensor wire harness clamp. Torque: 1 9 N·m (194 kgf.cm, 1 4 ft·lbf) REMOVE TAILPIPE Remove the 2 bolts, springs, gasket, 3 0-rings and tailpipe.
Page 616 SA-73 SUSPENSION AND AXlE REAR LOWER SUSPENSION ARM Remove the nut, cam plate and cam bolt. Torque: 74 N·m (755 kgf.cm, 55 ft.lbf) HINT: At the time of installation, after stabilizing the suspension, torque the nut. Disconnect the rear axle carrier from the lower suspen sion arm.
Page 617 SA-74 SUSPENSION AND AXLE REAR LOWER SUSPENSION ARM INSTALLATION Installation is in the reverse order of removal (See page SA-72). HINT: After installation, check the rear wheel alignment (See page SA-8).
Page 618 SA-75 REAR S fABlUZER BAR SUSPENSION AND AXLE REAR STABILIZER BAR COMPONENTS If} , __ �Br a cket 44(449,32) Spnng .IL- - "' f t · l b f ) _];Speci f i e d t o r q ue Nor t - r e usabl e par t...
Page 619 SA-76 SUSPENSION AND AXLE REAR STABILIZER BAR REMOVAL REMOVE REAR WHEEL Torque: 103 N-m (1,050 kgf.cm, 76 ft-lbf) REMOVE TAILPIPE AND HEAT INSULATOR Remove the 2 bolts, springs, gasket, 3 0-- r ings and tail {a ) pipe. Torque: 43 N.m (440 kgf.cm, 32 ft.lbf) Remove the bolts and heat insulator.
Page 620 SA-77 SUSPENSION AND AXLE REAR STAB!LIZER BAR INSPECTION INSPECT STABILIZER BAR LINK BALL JOINT FOR ROTA TION CONDITION As shown in the illustration, flip the ball joint stud back and forth 5 times, before installing the nut. Using a torque wrench, turn the nut continuously at a rate of 2 4 seconds per 1 turn and take the torque reading on the 5th turn.
Page 621 SA-78 SUSPENSION AND AXLE REAR STABlUZEA BAR INSTALLATION Installation Is in the reverse order of removal (See page SA-76).
Page 622 BRAKE BRAKE SYSTEM TROUBLESHOOTI N G . BR-2 BRAKE FLUI D BR-4 81+--1 BRAKE PE: D AL . BR-6 BR- 8 PARKI N G BRAKE LEVER . BRAKE MASTER CYLI N DER . BR-9 BRAKE BOOSTER ASSEMBLY . BH-1 3 FRONT BRAKE PAD BR-1 7 FRONT BRAKE CALI P ER...
Page 624 BR-1 BRAKE BHAKf: SYSTEM B RAKE SYSTEM PRECAUTION Care must be taken to replace each part properly as it could affect the performance of the brake system and result in a driving hazard. Replace the parts with parts of the same part number or equivalent.
Page 625 BR-2 TROUBLESHOOl lNG BRAKE TROUBLESHOOTING PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Suspect Area See page...
Page 626 BR-3 BRAKE ROUBLESt lOOTING leaks for brake system Fluid 01-323 2. Air rn brake system BR-4 3. Pad or llnirlg {Wom) BR-17 Bfl-33 BR-28 BR-42 4. Pad or lining (Cracked or distorte<l) BR-17 BR-33 BR-28 !:JH--42 BR-32 BR--46 Hard pedal but brake inefficient BH-17 BR-33 BR--28...
Page 628 BR-5 BRAKE BRAKE FLUID CHECK FLUID LEVEL IN RESERVOIR Check the fluid level and add fluid if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT3...
Page 629: Brake Pedal
BR-6 BRAKE HRAKE-: PEDAL St o p Li g ht BRAKE PEDAL Swi t c h ON-VEHICLE INSPECTION CHECK PEDAL HEIGHT Pedal height from asphalt sheet: 1 39.8 - 149.8 mm (5.504 - 5.898 in.) If the pedal height is incorrect, adjust it. IF NECESSARY, ADJUST PEDAL HEIGHT Remove the lower No.
Page 630 BA - 7 BRAKE BRAKE P[DAL COMPONENTS AfT: p--· - -- � St o p Li g ht Swi t c h Pedal Br a cket Cushi o n Pl a t e -- _ _ , Br a ke Pedal Cl e v1 s Pedal Pad - - - Br a ke Pedal...
Page 631: Parking Brake Lever
BR-8 BRAKE PAHKING SHAKE LEVFR PARKING BRAKE LEVER ON-VEHICLE INSPECTION CHECK PARKING BRAKE LEVER TRAVEL Pull the parking brake lever all the way up, and count the num ber of clicks. Parking brake lever travel at 196 N (20 kgf, 44.1 lbf): 7 - 8 clicks ---- If incorrect, adjust the parking brake.
Page 632: Brake Master Cylinder
BR-9 BRAKE BRAKE MASTf-R CYUNDf:R BRAKE MASTER CYLINDER COMPONENTS - - ----1 , '%/r/ . 3-way Hold-down Clamp * � Brake Rooster -- -- --- -- - - � Battery - - --· '- � � Level W?.rning Switch Connector [_1�5_, _ 1 �0 cJ·...
Page 633 BR-10 BRAKE BRAKf: MA .STEH CYLINDER REMOVAL REMOVE BATTERY DISCONNECT LEVEL WARNING SWITCH CONNEC- DRAW OUT FLUID WITH SYRINGE NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. MIT: DISCONNECT RESERVOIR HOSE 5 - - � - - - - o , --- - '\::��:-- DISCONNECT BRAKE LINE...
Page 634 BR-11 BRAKE 8RAKE MASTER CYLINDER REMOVE RESERVOIR Pull out the reservoir stopper. HINT: At the time of installation, make sure to insert the reservoir stop per through holes of the reservoir and the master cylinder groove. Remove the rese!Voir and 2 grommets. Remove the cap and strainer from the reservoir.
Page 635 BR-12 BRAKE OflAKE MASTER CYLINDER --<Y-' I NSTALLATION Installation is i n the reverse order of removal (See page BR-10). HINT: Before installation, adjust length of brake booster push rod (See page BR-16). • After installation, fill the brake reservoir with brake fluid, bleed the brake system (See page BR--4), and check for leaks.
Page 636: Brake Booster Assembly
BR-13 BRAKE BRAKE BOOSTER ASSEMBLY BRAKE BOOSTER ASSEMBLY ON-VEHICLE INSPECTION OPERATING CHECK Depress the brake pedal several times with the engine off and check that there is no change in the pedal reserve distance. Depress the brake pedal and start the engine. If the pedal """"...
Page 637 BR-14 STERASSFM - BLY BRAKE BRAKE BOO COMPONENTS Hol d -down Cl amp Bat t e r y Tr a y A ABS Act u at o r , ssemb! y � - · Cl a mp � Lower No 1 p ane! ·...
Page 638 BR-15 BRAKE 8RAKF BOOSTER ASSEMBLY REMOVAL REMOVE FRONT L H WHEEL Torque: 103 N·m (1 ,050 kgf.cm, 76 ft·lbf) REMOVE MASTER CYLINDER (See page BR-10) DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER ABS: REMOVE ABS ACTUATOR ASSEMBLY (See page BR-53) REMOVE FRONT LH BRAKE LINE Using SST and spanner, disconnect the brake line from the flexible hose of front LH brake_ 09751-36011...
Page 639 ---- -- -- -- -- -- -- -"BcoR,A K,E�· BA-16 BRAKE BOOS' EHASSEMDl INSTALLATION INSTALL BRAKE BOOSTER Install a new gasket and brake booster with 4 nuts. Torque: 13 N-m (130 kgf-cm, 9 ft-lbf) Install the clevis, and torque the lock nut Torque: 25 N·m (260 kgf.cm, 1 9 ft.Jbf) Install the clevis pin into the clevis and brake pedal, and install the clip to the clevis pin.
Page 640 BR-17 H!ONT BRAKE PAD BRAKE FRONT BRAKE PAD COMPONENTS engine: 2ZZ-GE Anti-squeal Shim Anti-squeal Shim engine: 1 ZZ-FE � Anti-squeal Shim ---- -- Pad Support Plate Inner Anti�squeal Shim Outer Pad Inner Anti-squeal Shim Anti-squeal Shim � Pad Support Plate Specified torque �...
Page 641 BR-18 BRAKE FRONT BRAKE PAD REPLACEMENT REMOVE FRONT WHEEL INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspection hole and replace the pads if they are not within the specification. Minimum thickness: 1.0 mm (0.039 in.) F09535 LIFT UP CALIPER Hold the sliding pin and remove the bottom side instaHa·...
Page 642 BR-19 BRAKE FRONT BRAKE PAD Install the pads with the pad wear indicator plate facing upward. NOTICE: There should be no oil or grease adhering to the friction surfaces of the pads or the disc. INSTALL CALIPER Draw out a small amount of brake fluid from the reservoir. Press in the piston with a hammer handle or similar imple- ment.
Page 643: Front Brake Caliper
BR-20 BRAKE FRON I BFIAKE CALIPER FRONT BRAKE CALIPER COMPONENTS 1ZZ-FE engine: � J Sl i d i n g Pi n � � +Dust Boot� Pad Suppor t Pl a t e � - Sl i d i n g Pi n - - - �...
Page 645 BR-22 BRAKE FRONT BAAKf' CALIPE!1 REMOVAL REMOVE FRONT WHEEL Remove the wheel and temporarily fasten the disc with hub nuts. Torque: 103 N·m (1,050 kgf.cm, 76 ft.lbf) DISCONNECT FLEXIBLE HOSE Remove the union bolt and gasket from the caliper, then disconnect the flexible hose from the caliper.
Page 646 BA-23 rRONf BRAKE CAl iPER BRAKE DISASSEMBLY REMOVE SET RING AND CYLINDER BOOT Using a screwdriver, remove the set ring and cylinder boot from the caliper. REMOVE PISTON Place a piece of cloth or similar, between the piston and the caliper. Use compressed air to remove the piston from the cylin- der.
Page 647 BR-24 BRAKE FRONT l3RAK[ CALIPER INSPECTION MEASURE PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 1ZZ-FE engine: 11.0 mm (0.433 in.) 2ZZ-GE engine: 11.5 mm (0.453 in.) Minimum thickness: 1.0 mm (0.039 in.) '09!B1 Replace the pad if the pad's thickness is at the minimum thick ness or less, or if the pad has severe, uneven wear.
Page 648 BR-25 BRAKE FRONT BRAKE CALIPER Repeat (b) until the disc has been installed on the 3 re maining hub positions. lf the minimum runout recorded in {b) and (c) is less than 0.05 mm (0.0020 in.), instal! the disc in that position. If the minimum runout recorded in (b) and (c) is greater than 0.05 mm (0.0020 in.), replace the disc and repeat step 3.
Page 649 BA-26 -� BRAKE FRONT BRAKI:' CALIPER REASSEMBLY Reassembly Is in the reverse order of disassembly (See page BR-23). NOTICE: Apply lithium soap base glycol grease to the parts Indicated by arrows (See page BA-20).
Page 650 BA-27 BRAKE FHON'I £3f1AKE CAliPlH INSTALLATION Installation is i n the reverse order of removal (See page BR-22). H INT: After installation, fill the brake reservoir with brake fluid and bleed brake system (See page BR-4). Check for leaks.
Page 651 BR-28 � BRAKE R[Af1 DRUM BflAKE REAR DRUM B RAKE COMPONENTS ,----- - --- - Return Spnng Parking Brake Lever Automatic f 'l'h C-Washer i � -- � {.;;;, - - - Adjuster - - - - - - - - � Ancho r Spring Shoe Hold-Down Spring Adjusting Lever Sprrng...
Page 652 BR-29 BRAKE REAR DRUM fJRAKC REMOVAL INSPECT SHOE LINING THICKNESS Remove the inspection hole plug, and check the shoe lining ·:r thickness through the hole. If less than minimum, replace the shoes. Minimum thickness: 1.0 mm (0.039 ln. ) --- _ REMOVE REAR WHEEL 1-097'7 REMOVE BRAKE DRUM...
Page 653 BA-30 BHAKE BRAKE llEAA DRUM Using needle nose pliers, disconnect the parking brake cable from the parking brake lever, and remove the rear shoe. REMOVE PARKING BRAKE LEVER Remove the C-washer. Remove the parking lever from the rear shoe. REMOVE WHEEL CYLINDER Using SST, disconnect the brake line.
Page 654 BR-31 REAH DRUM BRAKE BRAKE INSPECTION INSPECT DISASSEMBLED PARTS Inspect the disassembled parts for wear, rust or damage_ MEASURE BRAKE SHOE LINING THICKNESS Using a ruler, measure the shoe lining thickness Standard thickness: 4.0 mm (0.157 in. ) Minimum thickness: 1.0 mm (0.039 in.) lf the thickness is less than the rninirnurn or shoe lining shows signs of uneven wear, replace the brake shoes.
Page 655 BA-32 REAR DRUM BRAKE BRAKE INSTALLATION Installation is in the reverse order of removal (See page BR-29). NOTICE: Apply lithium soap base glycol grease and high tempera· ture grease to the parts indicated by the arrows (See page BR-28). CHECK OPERATION OF AUTOMATIC ADJUSTING MECHANISM Move the parking brake !ever of the rear shoe back and forth.
Page 656: Rear Brake Pad
BR-33 REAR BRAKE PAD BRAKE REAR BRAKE PAD COMPONENTS Anti-squeal Shim Outer Pad Anti-rattle Spring ¢ Disc brake grease...
Page 657 BR-34 BRAKE RE'AR BRAKE PAD """'"' REPLACEMENT REMOVE REAR WHEEL INSPECT PAD LINING THICKNESS Check the pad thickness. Minimum thickness: 1 .0 mm (0.039 in.) REMOVE CLIP, 2 ANTI-RATTLE SPRINGS AND 2 PAD GUIDE PINS Using a screwdriver, remove the clip and 2 anti-rattle springs.
Page 658 BR-35 REAR BRAKE: PAO BRAKE NOTICE: There should be no oil or grease adhering to the friction sur1aces of the pads and the disc. INSTALL 2 PAD GUIDE PINS, 2 ANTI-RATTLE SPRINGS AND CLIP Install the 2 anti-rattle springs on the each pad. While pressing the anti-rattle spring, and install guide pin.
Page 659 BR-36 BRAKE Ht:: A n 8HAKC CAUPEH REAR B RAKE CALIPER COMPONENTS Di s c Gasket • Ant i - squeal Shi m I n ner Pad Bl e eder Pl u g Out e r Pad Ant i - squeal Shi m {85 ' 7 Ant i - r a t t l e Spr i n g...
Page 660 BR-37 BRAKE REAR BRAK!::: CALIPER REMOVAL REMOVE REAR WHEEL Torque: 103 N-m (1,050 kgf . cm, 76 ft-lbl) DISCONNECT FLEXIBLE HOSE Remove the union bolt and gasket from the caliper, then disconnect the flexible hose from the caliper. Torque: 30 N.m (310 kgf.cm, 22 ft·lbf} HINT: At the time of installation, insert the flexible hose lock securely in the lock hole in the caliper.
Page 661 BR-38 BRAKE HEAR !3f1AKE CALIPER DISASSEMBLY REMOVE SET RING AND CYLINDER BOOT Using a screwdriver, remove the set ring and cylinder boot. REMOVE PISTON Put a piece of cloth or an equivalent between the piston and caliper, Use compressed air to remove the piston from the cylin- der.
Page 662 BR-39 BRAKE REAR BRAKE CALIPER , .. ,_ " INSPECTION MEASURE PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 10.0 mm {0.394 in.) Minimum thickness: 1.0 mm (0.039 in.) Replace the pad if the pad's thickness is at the minimum thick ness or less, or if the pad has severe, uneven wear.
Page 663 BR--40 BRAKE REMl BRAKf: CALIP[R REASSEMBLY Reassembly is in the reverse order of disassembly (See page BR-38). NOTICE: Apply lithium soap base glycol grease to the parts indicated by the arrows (See page BR-36).
Page 664 BR-41 � BRAKE HtAR BRAKE CAUfJER INSTALLATION Installation Is in the reverse order of removal {See page BR-37). HINT: • Arter installation, fi!! the brake reservoir with brake fluid and bleed the brake system (See page BR-4). Check for leaks_...
Page 665 BA-42 BRAKE PARKING Bf1AKf= PARKING BRAKE COMPONENTS - - - - Parking Brake Shoe Lever -- -- - Rear Shoe Shoe Strut � Front Shoe - - - - Adjuster Dis c , ___ e �r � ' Tension Spring •...
Page 666 BR-43 BRAKE PARKiNG BRAKE DISASSEMBLY REMOVE REAR WHEEL Torque: 103 N-m (1 ,050 kgf-cm, 76 tt-lbf) REMOVE REAR DISC BRAKE ASSEMBLY Remove the installation bolts and rear brake caliper. Torque: 47 N-m (475 kgf-cm, 34 ft-lbf) HINT. Do not disconnect the flexible hose from the brake caliper. (b ) Suspend the disc brake securely.
Page 667 BR-44 BRAKE PARKING BRAKE REMOVE REAR SHOE Using SST, remove the shoe hold-down spring and pin from the rear shoe. 09718-00010 Disconnect the rear shoe from the parking brake shoe le ver, and remove rear shoe. REMOVE PARKING BRAKE SHOE LEVER Using needle-nose pliers, disconnect the parking brake cable from the parking brake shoe lever.
Page 668 BR-45 PAHKING BRAKE BRAKE INSPECTION Inspect the disassembled parts for wear, rust or dumagc. INSPECT DISASSEMBLED PARTS MEASURE BRAKE SHOE LINING THICKNESS Using a ruler, measure the thickness of the shoe lining. Standard thickness: 2.0 mm (0.079 in.) If the lining thickness is at the minimum thickness or less, or if Minimum thickness: 1.0 mm (0.039 in.) there is severe, uneven wear, replace the brake shoe.
Page 669 BR-46 BRAKE PARKING BRAKE REASSEMBLY Reassembly is in the reverse order of disassembly (See pa ge BR -4 3) . NOTICE: Apply high temperature grease to the parts indicated by the arrows (See page BR-42). ADJUST PARKING BRAKE SHOE CLEARANCE T emporarily install the hub nuts.
Page 670 BR-47 BRAKE PflOPORTIONING VALVE VALV£:> PROPORTIONING VALVE (P VALVE) ON-VEHICLE INSPECTION INSTALL LSPV GAUGE (SST) AND BLEED AIR 09709--29018 BLEED AIR FROM FLUID PRESSURE GAUGE RAISE MASTER CYLINDER PRESSURE AND CHECK REAR WHEEL CYLINDER OR REAR BRAKE CALIPER PRESSURE 1 ZZ-FE engine: Master cylir�der fluid pressure Rear wheol cyllf!der flutd pressure 2.94 Wa (30 kgf/cm2, 427 1--'�•:•...
Page 671 ON-VEHICLE INSPECTION IN CASE OF USING TOYOTA HAND-HELD TESTER: Connect the TOYOTA lland�held tester to the DLC3 Start the engine and run it at idle. Select the ACTIVE TEST mode on the TOYOTA hand- held tester. HINT: OLC3 Please refer to the TOYOTA hand-held tester operator's manu...
Page 672 BR--49 BRAKE ABS ACTUATOR CLEAR DTC (See page Dl-276) IN CASE OF NOT USING TOYOTA HAND-HELD TES TER: HINT: Using the ABS actuator checker (SST), check the operation of the actuator. If the actuator does not operate, check the opera...
Page 673 BA-50 ABS CTUATOR INSPECT ABS ACTUATOR OPERATION OF REAR LH WHEEL ESC ACTUATOR CHECKEil HINT: --�·· The functions of the ABS actuator checker switches are shown " ' in the table below. 0 · Motor ON/OFF rront LH solenoid ONIOFF ·- - - - !-OJ46'1...
Page 674 BR-51 BRAKE ABS ACTUATOH Similarly, inspect �front LH" and "rear RH" wheel. HINT: When inspecting the "front LW wheel, push the "8" switch instead of the POWER SWITCH. This makes it possible to in spect wherever the selector switch position indicates. 1 2 .
Page 675 BR-52 -� BRAKE ABS ACTUATOfl COMPONENTS Clamp Hol d - d own Br a ke Boost e r Mast e r Cyl i n der Bat t e r y - - - Check Val v e Br a cket \ \\\ Gasket Level War n mg...
Page 676 BR-53 BRAKE ABSACTUA+OR REMOVAL REMOVE BATTERY Remove the hold-down clamp, battery and battery tray. REMOVE MASTER CYLINDER (See page BR-10) REMOVE ECM AND ECM BRACKET Remove the 3 bolts, and move the ECM aside. Disconnect the harness clamp, and remove the bolt, 2 nuts and ECM bracket.
Page 677 BR-54 BRAKE ABS ACTUATOR I NSTALLATION Installation is in the reverse order of removal (See page BR-53). H IN T: • After installation, fiJI the brake reservoir with brake fluid and bleed brake system (See page BR-4). • Check for leaks.
Page 678: Front Speed Sensor
BA -5 5 FRONT SPE-ED SENSOR BRAKE FRONT SPEED SENSOR COMPONENTS Resin / � � Clip Front Speed Sensor...
Page 679 BR-56 BRAKE t-HQNT SPF.I-:0 SENSOR REMOVAL DISCONNECT SPEED SENSOR CONNECTOR Remove the front wheel. Torque: 103 N·m ( 1,050 kgf.cm, 76 fl·lbf) Remove the fender liner. Disconnect the speed sensor connector and resin clip. (c ) REMOVE SPEED SENSOR Remove the 2 clamp bolts holding the sensor harness from the body and shock absorber.
Page 680 BR-57 BRAKE FRONT SPECD SENSOR '""'' " I NSTALLATION Installation is in the reverse order of removal (See page BR-56). AFTER INSTALLATION, CHECK SPEED SENSOR SIGNAL (See page 01-276)
Page 681: Rear Speed Sensor
BA-56 REAR SPEED SENSOR BRAKE REAR SPEED SENSOR COMPON ENTS - - - � � - ---- --- - --- - -- - Rear Speed Sensor -- � --- -- �--- - - ---...
Page 682 ., . . ,.., , BR-59 SPEED SENSOH BRAKE HEAR REMOVAL REMOVE REAR WHEEL DISCONNECT SPEED SENSOR CONNECTOR Disconnect the connector from the speed sensor. REMOVE SPEED SENSOR WITH REAR AXLE HUB (See Page SA-55) REMOVE SPEED SENSOR Using a pin punch and hammer, drive out the 2 pins and remove the 2 attachments from SST.
Page 683 BA-60 BRAKE REAR SPEED SE'NSOR Remove the clamp bolts holding the sensor harness from the lower arm and body. Torque: Lower arm side: 1 9 N.m (195 kgf.cm, 14 ft·lbt) Body side: 8.0 N·m (82 kgf.cm, 71 in.·lbt) Replace the sensor wire harness with the grommet.
Page 684 BR-.61 BRAKE REAR SPEED SENSOR INSTALLATION INSTALL NEW SPEED SENSOR Clean the contacting surface of the axle hub and a new speed sensor. NOTICE: Do not stick any foreign objects to the sensor rotor. Place the speed sensor on the axle hub so that the con nector makes the most downward position under the on...
Page 685 - M EM O -...
Page 686 STEERING STEERING SYSTEM . SR-1 TROUBLESHOOTING . SR-2 SR- - 3 DRIVE BELT POWER STEERING FLUID SR--4 STEERING WHEEL . SR--B SR - 9 TILT STEERING COLUMN POWER STEERING VANE PUMP SR-22 SR� 33 POWER STEERING GEAR...
Page 688: Steering System
SR-1 STEERING STEERING SYSTEM STEERING SYSTEM P RECAUTION • Care must be taken to replace parts properly because they could affect the performance of the steering system and result in a driving hazard. The CELICA is equipped with an SRS (Supplemental Restraint System) such as the driver air� bag and front passenger airbag.
Page 689 SR-2 STEERING TRQUfll ESHOOT!NG TROUBLESHOOTING PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause ot the problem Check each part in the order shown. If necessary, repair or replace these parts Symptom Suspect Area T<res...
Page 690 SR- 3 STEERING DftiVE BCLl DRIVE BELT INSPECTION INSPECT DRIVE BELT Visually check the drive belt for excessive wear, frayed cords, etc. If any defect has been found, replace the drive belt. HINT: • Cracks on the rib side of a belt are considered acceptable . If the missing chunks from the ribs are found on the drive belt, it should be replaced.
Page 691: Power Steering Fluid
SR-4 -� STEERING POWER STEERING FLUID POWER STEERING FLUID BLEEDING CHECK FLUID LEVEL (See page SR-5) JACK UP FRONT OF VEHICLE AND SUPPORT IT WITH STANDS TURN STEERING WHEEL With the engine stopped, turn the steering wheel slowly from lock to lock several times. LOWER VEHICLE START ENGINE Run the engine at idle for a few minutes_...
Page 692 SR-5 STEERING FLUID POWER STEERING "" ' "" ' , INSPECTION CHECK FLUID LEVEL Keep the vehicle level. With the engine stopped, check the fluid level in the oil reservoir. If necessary, add fluid. Fluid: ATF DEXRQN® II or Ill HINT: H1H�O Check that the fluid level is within the HOT LEVEL range on the...
Page 693 SR-<l STEERING fLUID CHECK STEERING FLUID PRESSURE Disconnect the pressure feed tube from the PS vene pump (See page SR-24). Connect SST, as shown in the illustration below. 09640- 1 0 0 1 0 (0964 1 -0 1 01 0, 09641-01030, 09641-01 060 ) NOTICE: Check that the valve of the SST is In the open position.
Page 694 SA-7 STEERING EERING POWER S l FLUID r e ser v oi r With the engine idling, open the valve fully. Measure the fluid pressure at eng'rne speeds of 1 ,000 rpm (h ) PSGea and 3,000 rpm. Difference fluid pressure: 490 kPa (5 kgf/cm 2 , 71 psi) or less PS vane Pump NOTICE:...
Page 695: Steering Wheel Inspection
SR-S � STEERING SfEERINGWHLEL STEERING WHEEL INSPECTION CHECK STEERING WHEEL FREEPLAY Stop the vehicle and face the tires straight ahead. Rock the steering wheel gently up and down with a finger lightly, check the steering wheel freeplay. Maximum freeplay: 30 mm (1.18 1n.) f(l{l655 CHECK STEERING EFFORT Center the steering wheel.
Page 696: Tilt Steering Column
SR-9 STEERING TILT $ l EERING COLUMN TILT STEERING COLUMN COMPONENTS Speed Control Main Switch Assembly control main switch: pteNi"g Wheel Pad Speed � 2 5) � Transmission Cluster Transmission Shill shift switch; �- Instrument Switch Assembly - - - - ----- j;>...
Page 697 SR-10 � STEERING TILT STEERING COLUMN Key Cylinder + Tapered-head Bolt Column Uppec Bcacket Key UolockWamlng Swltch . . /� V{ Tilt Sp<lng Column Upper Clamp Break Away Bracke � !gmt1on Sw1tch " · · � � No. 2 Support Collar �- + Snap Tilt Lever Lock Bo Ring...
Page 698 SR-11 T!LT STEEf\ING COLUMN STEERING REMOVAL REMOVE STEERING WHEEL PAD NOTICE: If the airbag connector is disconnected with the ignition switch at ON, DTCs will be recorded. Place the front wheels facing straight ahead. Using a torx socket wrench. loosen the 2 torx screws until the groove along the screw circumference catches on the screw case.
Page 699 Tllf STEERING COLUMN SR-12 ·- STEERING REMOVE COLUMN UPPER AND LOWER COVERS Remove the 3 screws, column upper and lower covers. REMOVE SPIRAL CABLE, LIGHT CONTROL SWITCH AND HEADLIGHT DIMMER SWITCH AND WIPER AND WASHER SWITCH Disconnect the 3 connectors from the spiral cable, light control switch and headlight dimmer switch and wiper and washer switch.
Page 700 SA-13 TILT STEEHJNG COLUMN STEEAJNG w/ Transmission shift switch: REMOVE TRANSMISSION SHIFT SWITCH AS Horn Switch Terminal SEMBLY FROM STEERING WHEEL Remove the 2 screws. Disengage the secondary locking device of the connec tor. Release the locking lug of the terminal 1 (horn switch ter minal), and pull the terminal out of the rear.
Page 701 SR-14 STEERING TILT STEERING COLUMN ""'"'"'' - -: DISASSEMBLY 5'" REMOVE COLUMN UPPER BRACKET AND COLUMN UPPER CLAMP · .l["3 Using a centering punch, mark the center of the 2 ta- E't c act m pered-head bolts. � l . ' Using a 3 - 4 mm (0.
Page 702 SR-15 STEERING TILT STEERING COLUMN Remove the adjusting nut, tilt lever, stopper, tilt lever lock bolt and break away bracket. HINT: This nut is left-handed one. Remove the No. 2 support collar from the break away bracket. REMOVE MAIN SHAFT BUSHING Using a screwdriver and hammer, tap out the main shaft bush...
Page 703 SR-16 STEERING TILT STEERING INSPECTION INSPECT STEERING LOCK OPERATION Check that the steering lock mechanism operates properly. IF NECESSARY, REPLACE KEY CYLINDER Place the ignition key at the ACC position. Push down the stop pin with a screwdriver, and pull out the cylinder.
Page 705 SR-18 STEERING TILT STEERING COLUMN Install the No. 1 support reinforce with the No. 2 tilt lever lock bolt by turning it counterclockwise. Torque: 5.4 N-m (55 kgf.cm, in.-lbf) HINT: Align the No. 1 support reinforce with the nut to eliminate loose ness by turning the No.
Page 706 STEERING COLUMN SA-19 � STEERING INSTALLATION Horn Switch Terminal w/ Transmission shift switch: INSTALL TRANSMISSION SHIFT SWITCH ASSEMBLY Q) � �- - - · - - - - · � TO STEERING WHEEL ·-1 ( a) Install the transmission shift switch assembly. '"...
Page 707 SR-20 STEERING TILT STEERING COLUMN CONNECT NO. 2 INTERMEDIATE SHAFT ASSEMBLY Align the match marks on the No. 2 intermediate shaft as sembly and intermediate extension. Install the bolt B. Torque: 35 N-m (360 kQI·cm, 26 H-lbf) Torque the bolt A. Torque: 35 N-m (360 kgf .
Page 708 SA-21 � STEERING TILT STEERING COLUMN CENTER SPIRAL CABLE Check that the front wheels are facing straight ahead. Turn the cable counterclockwise by hand until it becomes (b ) harder to turn. Then rotate the cable clockwise about 2.5 turns to align the marks.
Page 709 SR-22 STEERING POWER STEERING VANE PUMP POWER STEERING VANE PUMP COMPONENTS Pr e ssur e Feed Tube Oi l Pr e ssur e Swi t c h Connect o r [ � ; � ;;�;,'�¥ ] ' Pump Assembl y Suct i o n Hose - Dr i v e Bel t �---- -�-- -...
Page 711 POWER STEERING VANE STEERING PUMP REMOVAL REMOVE RH AND CENTER ENGINE UNDER COVERS REMOVE DRIVE BELT Loosen the drive belt tension by turning the drive belt tensioner arm clockwise, and remove the drive belt. DISCONNECT SUCTION HOSE Remove the clip and disconnect the suction hose. NOTICE: Take care not to spill fluid on the drive belt.
Page 712 SR-25 STEERING POWER STEERING VANE PUMP DISASSEMBLY NOTICE: When using a vise, do not overtighten it. MEASURE PS VANE PUMP ROTATING TORQUE Check that the pump rotates smoothly without abnormal noise. Using a torque wrench, check the pump rotating torque. Rotating torque: 0.27 N-m (2.8 kgf .
Page 713 SR-26 STEERING STEERING POWER VANE PUMP INSPECTION MEASURE OIL CLEARANCE BETWEEN VANE PUMP SHAFT AND BUSHING Using a micrometer and a caliper gauge, measure the oil clear- ance. Standard clearance: 0.021 - 0.043 mm (0.0008 - 0.0017 1n.) Maximum clearance: 0.07 mm (0.0028 in.) If it is more than the maximum, replace the front housing and vane pump shaft.
Page 714 SR-27 STEERING - POWER STEERING VANE PUMP it is more than the maximum, replace the vane plate and/or vane pump rotor with the one having the same mark stamped on the cam ring. Inscribed mark: 0, 1 , 2, 3, or 4 HINT: There are 5 vane plate lengths corresponding to the following Mar k...
Page 715 SR -2 8 STEERING POWER STEERING VANE PUMP INSPECT SPRING Using vernier calipers, measure the free length of the spring. Minimum free length: 35.8 mm (1.409 in.) " • _ _ __ __ ____i. \ !�>ll-':;1_• _ - _ 'l"' !f it is not within the specification, replace the spring.
Page 716 SR-29 STEERING POWER STEERING VANE PUMP REPLACEMENT NOTICE: When using a vise, do not overtighten it. IF NECESSARY, REPLACE OIL SEAL Us'mg a screwdriver with vinyl tape wound around its tip, remove the oil sea!. NOTICE: Be careful not to damage the bushing of the front housing. Coat a new oil seal lip with power steering fluid.
Page 717 SR-30 POWER STEERING VANE PUMP STEERING REASSEMBLY NOTICE: When using a vise, do not overtighten it. COAT PARTS INOICATED B Y ARROWS WITH POWER STEERING FLUID (See page SR-22) INSTALL VANE P U M P SHAFT WITH VANE PUMP PULLEY INSTALL SIDE PLATE Coat 2 new 0-rings with power steering fluid, and install them to the side plate.
Page 718 SR-31 STEE R ING POWER STEERING VANE PUMP INSTALL SPRING, FLOW CONTROL VALVE AND PRESSURE PORT UNION Install the spring. valve facing in the correct direction Install the ffow control (See page SR-22). 0-ring with power steering fluid, and install Coat a new union.
Page 719 SR-32 POWEn STEERING VANE PUMP STEERING INSTALLATION INSTALL PS VANE PUMP ASSEMBLY Install the PS vane pump assembly with the 2 pump assembly set bolts and nuts. Torque: 37 N·m (370 kgf.cm, 27 ft.lbl) CONNECT OIL PRESSURE SWITCH CONNECTOR NOTICE: Be careful to prevent oil from being attached to the connecM tor.
Page 720: Power Steering Gear
SR-33 STEERING POWER STEER!NG GEAn POWER STEERING GEAR COMPONENTS Cent e r Engi n e Under Cover Engi n e Under Cover f t · l b t ) Speci f i e d t o r q ue Non-r e usabl e par t For use wi t h SST (�...
Page 721 SR-34 STEERING POWER STEERING GEAR Tie Rod End lock Nut {750, •ii --I Ra ck En d {630 , 46) i +Claw Was h er ""9/ \ � " +Teflon Rin g " , -._ "", +0-Ring Steeri n g Rack -- �...
Page 723 SR-36 STEERING POWER Sl EERING GEAR REMOVAL NOTICE: Remove the steering wheel assembly before the steering gear removal, because there is possibility of breaking of the spiral cable. PLACE FRONT WHEELS FACING STRAIGHT AHEAD REMOVE STEERING WHEEL PAD (See page SR-11 ) REMOVE STEERING WHEEL (See page SR-11 ) REMOVE RH, CENTER AND LH ENGINE UNDER COV...
Page 724 SR-37 � STEERING POWER SIEEF�JNG GEAR ATTACH ENGINE SLING DEVICE TO ENGINE HANG- No. 2 Engine Hanger (a } Remove the 4 bolts and No. 2 cylinder head cover_ Disconnect the PCV hoses from the cylinder head cover. Install the No. 1 and No. 2 engine hangers in the correct direction.
Page 725 SR-38 POWER STEERING GEAR STEERING Place matchmarks on the intermediate extension and control valve shaft. Remove the bolt and intermediate extension. REMOVE ENGINE REAR MOUNT INSULATOR AND 19 . ENGINE REAR MOUNT BRACKET Remove the through bolt and engine rear mount insulator. (a ) Remove the 3 bolts and engine rear mount bracket.
Page 726 SR-'39 STEERING POWER STEERING GEAR OISASSEMBL Y NOTICE: When using a vise, do not overtighten it. SECURE PS GEAR ASSEMBLY IN VISE Using SST, secure the PS gear assembly in a vise. 09612�00012 REMOVE 2 TURN PRESSURE TUBES Using SST, remove the 2 turn pressure tubes. 09633-{)0020 REMOVE RH AND LH TIE ROD ENDS AND LOCK NUTS...
Page 727 SR-40 STEERING POWER STEERING GEAR Using a spanner, hold the steering rack steadily and using remove the rack end. SST, 09922-10010 NOTICE: Use SST 09922-10010 In the direction shown in the lllustra� tion. HINT Mark the RH and LH rack ends. Remove the claw washer.
Page 728 SR-41 POWER STEERING GEAR STEERING INSPECTION Dial Indicator NOTICE: When using a vise, do not overtighten it. INSPECT STEERING RACK Using a dial indicator, check the rack for runout, teeth wear and damage. Maximum runout: 0.1 mm (0.004 in.) Check the back surface for wear and damage.
Page 729 SR-42 S'tEERlNG POWER STEEniNG GEAR REPLACEMENT NOTICE: When using a vise, do not overtighten it. IF NECESSARY, REPLACE BEARING Using SST, remove the bearing guide nut and bearing. 0961 7-35020 Coat a new bearing with molybdenum disulfide lithium base grease. Install the bearing and using SST, install the bearing guide nut.
Page 730 SR-43 STEERING - POWER STEERING GEAR Using SST and a hammer, tap in the oil seaL 09950-6001 0 (09951 -00240, 09951 -00350, 09952-06010), 0995Q-70010 (09951-071 50) NOTICE: Make sure that the oil seal is installed facing in the correct direction. IF NECESSARY, REPLACE BEARING Using a punch and a hammer, tap out the bearing.
Page 731 SR-44 POWER STEERING GEAR STEERING IF NECESSARY, REPLACE TEFLON RING AND RING Using a screwdriver, remove the teflon ring and 0-- r ing from the steering rack. NOTICE: Be careful not to damage the groove for the teflon ring. (b ) Coat a new 0-ring with power steering fluid and install it to the steering rack.
Page 732 SA-45 STEERING POWER STEERING GEAR Carefully slide the tapered end of SST over the teflon rings until they fit to the control valve assembly. 09631-20081 NOTICE: Be careful not to damage the teflon rings.
Page 733 SR-46 STEERING POWER STEERING GEAR REASSEMBLY NOTICE: When using a vise, do not overtighten it. COAT PARTS INDICATED BY ARROWS WITH POWER STEERING FLUID OR MOLYBDENUM DISULFIDE LITHIUM BASE GREASE (See page SR-33) SST · · INSTALL OIL SEAL Coat a new oil seal lip with power steering fluid. Install the oil seal to SST, and press them into the rack housing.
Page 734 SR-47 � G!::- A H STEERING POWER STEERING INSTALL OIL SEAL Coat a new oil seat lip with power steering fluid. To prevent all seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid. Install the oil seat by pushing it into the rack housing with...
Page 735 SR-48 STEERING POWER STEERING GEAR Apply sealant to 2 or 3 threads of the rack guide spring cap. Sealant: Part No. 08833-00080, THREE BOND 1 344, LOCTITE 242 or equivalent Temporarily install the rack guide spring cap. ADJUST TOTAL PRELOAD To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH rack ends.
Page 736 SR-49 STEERING POWER STEEiliNG GEAR INSTALL RH A N D L H CLAW WASHERS AND RACK 1 1 . ENDS Install a new claw washer, and temporarily install the rack end. HINT: Align the claws of the claw washer wlth the steering rack grooves.
Page 737 SR-50 POWER STEERING GEAR STEERING As shown in the illustration, bend the wire to the circular direction to prevent damage to the boot. Employ the same manner described above to the other (e ) side. F09925 INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS Screw the lock nut and tie rod end onto the rack end until the match marks are aligned.
Page 738 SR-51 POWER STEERING GEAI'1 STEERING INSTALLATION INSTALL ENGINE REAR MOUNT INSULATOR AND ENGINE REAR MOUNT BRACKET Install the engine rear mount bracket with the 3 bolts. Torque: 64 N-m (655 kgl-cm, 47 1t-lbl) Instal! the engine rear mount insulator with the through boll.
Page 739 SR-52 STEERING POWER STEERING GEAI1 DISENGAGE ENGINE SLING DEVICE FROM ENGINE No. 2 Engine HANGERS Hanger Disengage the engine sling device from the engine hang� ers. Remove 1t1e No. 1 and No. 2 engine hangers. Connect the PCV hoses to the cylinder head cover. Install the No.
Page 740 SR-53 STEERING POWER STEERING GEAR CHECK STEERING WHEEL CENTER POINT TORQUE STEERING WHEEL SET NUT Torque: N-m (350 kgf.cm, 25 lt-lbf) INSTALL STEERING WHEEL PAD (See page SR-19) CHECK FRONT WHEEL ALIGNMENT (See page SA-4)
Page 741 � M EM O ·-...
Page 742: Supplemental Restraint System
SUPPLEMENTAL RESTRAINT SYSTEM SRS AI R BAG ....RS-1 STEERI N G WHEEL PAD AND SPI R AL CABLE RS-1 2 FRONT PASSENGER AI R BAG ASSEMBLY RS-26 SI D E AI R BAG ASSEMBLY . . RS- 3 9 AI R BAG SENSOR ASSEMBLY RS-52 FRONT AI R BAG SENSOR .
Page 744 RS-1 SUPPLEMENTAL RESTRAINT SYSTEM SRS AIRBAG SRS AIRBAG P R ECAUTION CAUTION: • The CELICA is equipped with SRS, which comprises a driver alrbag, front passenger airbag and side airbag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident.
Page 745 RS-2 SUPPLEMENTAL RESTRAINT SYSTEM SRS AIRBAG OPERATION STEERING WHEEL PAD (with AIRBAG) The inflater and bag of the are stored in the steering wheel pad and cannot be disassembled. The inflater contains a squib, igniter charge, gas generator, etc., and inflates the bag when instructed by the airbag sensor assembly.
Page 746 RS-3 SRS AIRBAG SUPPLEMENTAL RESTRAINT SYSTEM SRS WARNING LIGHT The SRS warning light is located on the combination meter. It goes on to alert the driver of trouble in the system when a mal function is detected in the airbag sensor assembly self--diagno sis.
Page 747: Srs Connectors
R&-4 SUPPLEMENTAL RESTRAINT SYSTEM SRS AlnBAG SRS CONNECTORS HINT: SRS connectors are located as shown in the following illustra· tion. Si d e Ai r b ag Sensor Assembl y ( R H) Si d e Ai r b ag Assembl y ( R H) { S qui b ) Seat Bel t Pr e t e nsi o ner ( RH) Door Si d e Ai r b ag...
Page 748 RS-5 SRSAiflBAG SUPPLEMENTAL RESTRAINT SYSTEM All connectors in the SRS are colored in yellow to distin guish them from other connectors. Connectors having special functions and specifically designed for the SRS e used in the locations shown on the previous page to ensure high reliability.
Page 749 AS-S SRSAIRBAG SUPPLEMENTAL RESTRAltff SYSTEM HINT: The type of connector is shown in the diagram on the previous page. Electrical Connection Check Mechanism This mechanism electrically checks that connectors Di s connect i o n are connected correctly and completely. The electri ·Det e ct i o n Pi n cal connection check mechanism is designed so that the disconnection detection pin connects with...
Page 750 RS-7 � SUPPLEMENTAL RESTRAINT SYSTEM Sib AIABAG When the vehicle is involved in a frontal collision in the hatched area (Fig. 1 ) and the shock is larger than the pre determined level, the SRS is activated automatically. A safing sensor is designed to go on at a smaller decelera tion rate than the airbag sensor.
Page 751 RS-8 SUPPLEMENTAL RESTRAINT SYSTEM SRSAIRBAG CONNECTION OF CONNECTORS FOR FRONT AIR 1 3 . BAG SENSOR, SIDE AIRBAG SENSOR AND DOOR SIDE AIRBAG SENSOR Out e r Align the male connector {of the side of sensor) and fe male connector in the same direction as shown in the il lustration and fit in them without rubbing.
Page 752 As-9 SUPPLEMENTAl RESTRAINT SYSTEM SRSA!HBAG DISCONNECTION OF SIDE AIRBAG CONNECTOR Place a finger on the slider. Slide the slider to release lock. Disconnect the connector. compl e t e d Disconnection is 15 . CONNECTION OF SIDE AIR BAG CONNECTOR Sl i d er...
Page 753 RS-10 SRSAIRBAG SUPPLEMENTAL RESTRAI NT SYSTEM Align a lock part of male connector and a slider of female (a ) connector in the same direction as shown in the illustra tion, fit in them without rubbing. Be sure to insert until they are locked. After fitting in pull them slightly to check that they are locked.
Page 754 RS-11 SUPPLEMENTAL RESTRAINT SYSTEM AIRBAG CONNECTION OF CONNECTORS FOR STEERING WHEEL PAD (with AIRBAG) A N D FRONT PAS· SENGER AIRBAG ASSEMBLY Align a lock part of male connector and a slider of female connector in the same direction as shown in the illustra tion, fit in them without rubbing.
Page 755 R5-12 SUPPLEMENTAL RESTRAINT SYSTEM STEEnJNG WHEEl PAD AND SPIRAl CABLE STEERING WHEEL PAD AND SPIRAL CABLE COMPONENTS Column Upper Cover Spiral Cable Steering Wheel Pad � Column L wer Cover L s.a (90, Torx screw...
Page 756 RS-13 SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL PAD AND SPIRAL CABLE REMOVAL HINT: For step 1 to 4, refer to page SR-11 . REMOVE STEERING WHEEL PAD REMOVE STEERING WHEEL REMOVE UPPER AND LOWER COLUMN COVERS REMOVE SPIRAL CABLE...
Page 757 RS-14 SUPPLEMENTAL AESTRAif'lT SYSTEM STEERING WHEEL PAD AND SPIRAL CABLE INSPECTION Vehicle not Involved I n collision: INSPECT SUPPLEMENTAL RESTRAINT SYSTEM Do a diagnostic system check (See page Dl-326). Do a visual check which includes the following item with the steering wheel pad (with airbag) installed in the ve hicle.
Page 758 RS-15 SUPPlEMENTAL RESTRAINT SYSTEM STEERING WHEEL PAD AND SPIRAL CABLE Vehicle involved in collision and airbag is deployed: INSPECT SUPPLEMENTAL RESTRAINT SYSTEM Do a diagnostic system check {See page 01-326). Do a visual check which includes the following items with the steering wheel pad (with airbag) removed from the ve·...
Page 759 {with airbag), always first deploy the air bag in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: • Never dispose of a steering wheel pad which has an undeployed airbag.
Page 760 RS-17 SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEl PAD AND SPIRAl CAB I t; Check functioning of the SST. CAUTION: When deploying the airbag, always use the specified SST: SRS Airbag Deployment Tool. 09082-00700 Arl0\52 Connect the red clip of the SST to the battery posi ( 1 } tive (+ ) terminal and the black clip to the battery neg...
Page 761 RS-18 UPPLEMENTAL RE SYSTEM STEERING WHEEL PAD AND SPIRAL CABLE Batt e r y _ _ _ _ _ Move the SST at least 1 0 m {33 ft) away from the front of the vehicle. Close all the doors and windows of the vehicle. or mor e NOTICE: Take care not to damage the SST wire harness.
Page 762 RS-19 SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL PAO ANO SPIRAL CABLE Remove the steering wheel pad (See page SR-1 1 ) . CAUTION: • When removing the steering wheel pad, work must be started 90 seconds after the ignition switch is turned to the "LOCK"...
Page 763 RS-20 RESTRAINT SYSTEM STEFR!NG WHEEL PAD AND SPIRAL CABLE Using 3 wire harness, wind the wire harness at least 2 times each around the bolts installed on the left and right sides of the steering wheel pad. CAUTION: • Tightly wind the wire harness around the bolts so that there is no slack.
Page 764 RS-21 SUPPLEMENTAL RESTRAINT SYSTEM SlEERING WHEEL PAD AND SPIRAL CABLf Install the SST. CAUTION: Place the disc wheel on the level ground. Connect the connectors of the 2 SST t o the steering ( 1 ) wheel pad connector. 09082�00700, 09082-{)0760 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock.
Page 765 R$-22 SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL PAD AND SPIRAL CABLE • Covering method using tires: Place at least 3 tires without disc wheel on top of the disc wheel with tire to which the steering wheel pad is tied. Tire size: Must exceed the following dimensions Width: 185 mm (7.87 in.) Inner diameter: 360 mm (14.17 in.) CAUTION:...
Page 768 RS-23 SPIRAL SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL PAD AND CABLE DEPLOYMENT WHEN DISPOSING OF STEERING WHEEL PAD WITH AIRBAG DEPLOYED IN COLLI SION Dispose of the steering wheel pad (with airbag). CAUTION: • The steering wheel pad is very hot when the alrbag is deployed, so leave It alone for at least 30 minutes af...
Page 769 R$-24 CABLE STEERING WHEEL PAD AND SPIRAL REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the steering wheel pad, steering wheel or splral cable. deployed. Case Replacing part Steering wheel been been abbag wheel found to faulty in troubleshootlng. Steering wheel the steering pad has...
Page 770 R5-25 SUPPLEMENTAL RESTRAINT SYSTEM STEEHING WHEEL PAD AND SPIRAL CABLE INSTALLATION HINT: For step 1 to refer to page SR-19. INSTALL SPIRAL CABLE INSTALL UPPER AND LOWER COLUMN COVERS INSTALL STEERING WHEEL INSTALL STEERING WHEEL PAD...
Page 772 RS-27 SUPPLEMENTAL RESTRAINT SYSTEM FRONT PASSENGER AIRBAG ASSEMBLY REMOVAL NOTICE: • If the wiring connector of the SRS is disconnected and the ignition switch is in ON position, DTCs will be recorded. Never use the alrbag parts from another vehicle. When replacing parts, replace them with new parts.
Page 773 RS-28 SUPPLEMENTAL RESTRAINT SYSTEM FRONT PASSENGER AlRSAG ASSEMBLY INSPECTION Vehicles not involved in collision: INSPECT SUPPLEMENTAL RESTRAINT SYSTEM Do a diagnostic system check {See page DJ-326). Do a visual check which includes the following item with the front passenger airbag assembly installed in the ·e hic!e.
Page 774 RS-29 SUPPLEMENTAL RESTRAINT SYSTEM FRONT PASSENGER AIRBAG ASSEMBLY Vehicle involved in a collision and airbag is deployed: INSPECT SUPPLEMENTAL RESTRAINT SYSTEM Do a diagnostic system check (See page 01-326). Do a visual check which includes the following items with the front passenger airbag assembly removed from the vehicle.
Page 775 • abnormality occurs with the airbag deployment, contact SERVICE DEPT of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: Never dispose of a front passenger airbag assembly which has an undeployed alrbag.
Page 776 RS-31 SUPPLEMENTAL RESTRAINT SYSTEM FFlONT PASSENGER AIR BAG ASSEMBLY Disconnect the airbag connector. Using a screwdriver, pry out the glove compartment door finish plate inside the lower paneL HINT: Tape the screwdriver tip before use. Remove the connector from the glove compartment door finish plate.
Page 777 R8-32 SUPPLEMENTAL RESTRAINT S YSTEM H10NT PASSENGJ:R AIRBAG ASSEMBLY CAUTION' • The front passenger airbag assembly is very hot when the airbag is deployed, so leave It alone for at least 30 minutes after deployment. Use gloves and safety glasses when handling the front passenger airbag assembly with the deployed airbag.
Page 778 RS-33 PASSENGER AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM FRQN Di a met e r Using a service-purpose wire harness, tie down the front passenger airbag assembly to the tire. Wire Harness Wire harness: Stripped wire harness section 1.25 mm 2 or more (0.0019 in. 2 or more) CAUTION: If the front passenger airbag assembly is tied down with St r i p ped...
Page 779 RS-34 SUPPlEMENTAL RESTRAINT SYSTEM FRONT PASSENGER A! BAG ASSEMBLY CAUTION: • Make sure that the wire harness is tight. It is very dan gerous if looseness in the wire harness results in the front passenger alrbag assembly coming tree due to the shock from the airbag deploying.
Page 780 RS-35 FRONT PASSENGER AIR BAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM Install the SST Connect the connectors of the 2 SST to the front passen· ger airbag assembly connector. 09082-00700, 09082-00760 NOTICE: To avoid damaging the SST connector and wire harness, o m (33ft) do not lock the secondary lock of the twin lock, Also, se...
Page 781 SUPP L EMENTAL RE$TRAJNT SYSTEM FRONT CAUTION: • The front passenger airbag assembly is very hot when the alrbag Is deployed, so leave it alone for at least minutes after deployment. • Use gloves and safety glasses when handling a front passenger airbag assembly with the deployed alrbag.
Page 782 RS-37 SUPPLEMENTAL RESTRAINT SYSTEM FRONT PASSENGER AIR BAG ASSEMBLY REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the front passenger airbag assembly, instrument pane! or instrument panel reinforcement . !leplacir�g pmt Case passtmger airtJag assembly airbag has been deployOO. Front faulty in lroubie- foufld to the front passenger airbag assembly has been...
Page 783 RS-38 SUPPLEMENTAL RESTRAINT SY$TEM FRONT PASSENGER AIRBAG ASSEMBLY I NSTALLATION NOTICE: Never use airbag parts from another vehicle. When replac ing parts, replace them with new parts. INSTALL FRONT PASSENGER AIRBAG ASSEMBLY Install the front passenger airbag assembly with the 2 nuts.
Page 784 AS-3 9 SUPPLEMENTAL RESTRAINT SYSTEM SIDE AIRBAG ASSEMBLY SIDE AIRBAG ASSEMBLY COMPONENTS \1'��/\,J Si d e Ai r b ag Assembl y " -----�--- + Hog Ri n g ----.: l n ner Fr o nt Seat Cushi o n Shi e l d Seat Tr a ck Cover Fr o nt Seat Cushi o n Shi e ! d...
Page 785 RS-40 SUPPLEMENTAL AIRBAG ASSE:MBLY SIDE RESTRAINT SYSTEM REMOVAL NOTICE: If the wiring connector of the SRS Is disconnected and the ignition switch is at ON position, DTCs will be • recorded. Never use the airbag parts from another vehicle. When replacing parts, replace them with new parts. REMOVE FRONT SEAT Remove the 2 seat track covers and 4 bolts.
Page 786 AS-41 SIDE AIRBAG ASSEMBI SUPPLEMENTAL RESTRAINT SYSTEM REMOVE SEAT BACK ASSEMBLY Remove the hog rings of the seatback frame, as shown in the illustration. Remove the 4 bolts and seatback assembly. CAUTION: Do not store the seatback assembly with the airbag deploy ment side facing downward.
Page 787 RS-42 SUPPLEMENTAL RESTRAINT SYSTEM SIOEAIRBAG ASSEMBLY INSPECTION Cross Section Vehicles not involved in collision: INSPECT SUPPLEMENTAL RESTRAINT SYSTEM Do a diagnostic system check (See page Dl-326). (a ) Do a visual check which includes the following item with the seatback assembly installed in the vehicle. Check that there are no cuts and cracks of the outside of side airbag assembly.
Page 788 If any abnormal" ity occurs with the airbag deployment, contact the SERVICE DEPT of TOYOTA MOTOR SALES, U.S.A .. INC. CAUTION: •...
Page 789 Rs-44 S!DE A!ABAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM Disconnect the side airbag connector. NOTICE: When handling the airbag connector, take care not to dam age the airbag wire harness. Install the SST. ( 1 ) Connect the connectors of the 2 SST to the airbag connector.
Page 790 AS-45 SUPPLEMENTAL RESTRAINT SYSTEM SlOt: AIRBAG ASSEMBLY HINT: The airbag deploys simultaneously as the LED of SST activa tion switch lights up. DEPLOYMENT WHEN DISPOSING OF SIDE AIRBAG ASSEMBLY NOTICE: When disposing of the side airbag assembly only, never use the customer's vehicle to deploy the air� bag.
Page 791 RS-46 SIDE AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM ( 1 ) Install the 2 nuts to the side airbag assembly. Hl19<!1 Wind the wire harness around the stud bolts of the side airbag assembly as shown in the illustration. H11962 Position the side airbag assembly inside the tire with the airbag deployment direction facing inside.
Page 792 RS-47 SUPPLEMENTAL RESTRAINT SYSTEM S I DE AIR BAG ASSEMBLY Place the tires. Place at least 2 tires under the tire to which the side (i ) airbag assembly is tied. or Mor e } Place at least 2 tires over the tire to which the side Tires airbag assembly is tied.
Page 793 Rs-48 SUPPLEMENTAl RESTRAINT SYSTEM SlOE A!RBAG ASSEMBLY • Always wash your hands with water after completing the operation. Remove the side alrbag assembly from the tire, ( 1 ) Place the side airbag assembly in a vinyl bag, tie the end tightly and dispose of it in the same way as oth�...
Page 794 As-49 SUPPLEMENTAL RESTRAINT SYSTEM SlOE AIRBAGASSEMBLY REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the seatback assembly. Case Replacing pan Seatbar }; assembly lf the side airbag has been cleploytJ<i. If the side airhag assembly has been found to be faulty i" troubleshooting. Seiltbilck assembly If the side airbag assamb1y has cuts during checking items Sealback assembly...
Page 795 R5-50 SlOE AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM INSTALLATION NOTICE: Never use alrbag parts from another vehicle. When replac ing parts, replace them with new parts. INSTALL SEATBACK ASSEMBLY Install the seatback assembly to the seat adjuster with the 4 bolts. T orque: 43 N·m (440 kgf.cm, 32 fl·lbf) Install 5 new hog rings.
Page 796 RS-51 SUPPLEMENTAL RESTRAINT SYSTEM SIDE AIRBAG ASSEMBLY INSTALL INNER FRONT SEAT CUSHION SHIELD Install the inner front seat cushion shield with the screw. INSTALL FRONT SEAT CUSHION SHIELD INSTALL RECLINING ADJUSTER KNOB INSTALL RECLINING ADJUSTER RELEASE HANDLE INSTALL FRONT SEAT NOTICE: When mounting the seat to the vehicle, take care not to damage the airbag wire harness.
Page 797 RS-52 SUPPLEMENTAL RESTRAINT SYSTEM AIRBAG AIRBAG SENSOR ASSEMBLY COMPONENTS Ai r b ag Sensor Assembl y End Fi n i s h Panel RH 20 <2os, 15) Lower Fi n i s h Panel - · - - - ' End Fi n i s h Panel LH F i n i s h Panel Consol e Box Hol e Cover...
Page 798 RS-53 AlR8AG SENSOR ASSFMBt Y SUPPLEMENTAL RESTRAINT SYSTEM REMOVAL NOTICE: Do not open the cover or the case of the ECU and various electrical devices unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) HINT: 80-79.
Page 799 Rs-54 SUPPLEMENTAL RESTRAINT SYSTEI'JJ AIA8AG SENSOR ASSEMBLY INSPECTION VEHICLE NOT INVOLVED IN COLLISION Do a diagnostic system check (See page Dl-326). VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED Do a diagnostic system check (See page Dl-326). VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED Replace the alrbag sensor assembly (See page Dl-326).
Page 800 RS- 55 SUPPLEMENTAL RESTRAINT SYSTEM AIRBAG SENSOR ASSEMBLY R EPLACEMENT REPLACEMENT REQUIREMENTS In the followi n g cases, replace the airbag sensor assembly . • If the SRS has been deployed in a collision . • If the airbag sensor assembly has been found to be faulty in troubleshooting. •...
Page 801 R!hS6 SUPPLEMENTAL SYSTEM AIRBAG SENSOR ASSEMBLY I NSTALLATION NOTICE: • Never use SRS parts from another vehicle. When re placing parts, replace them with new parts. • Never reuse the airbag sensor assembly involved in a collision when the airbag has deployed. •...
Page 802 RS-57 SUPPLEMENTAL RESTRAINT SYSTEM FRONT AJRBAG SENSOR FRONT AIRBAG SENSOR COMPONENTS Air Cleaner Hose Air Cleaner Cap---------- Air Filter -- Air Cleaner Case -- - Upper Front Fender Apron Seal - -- H11S07...
Page 803 RS-08 FRONT AIRBAG SENSOR RESTRAINT SYSTEM REMOVAL NOTICE: • If the wiring connector of the SRS is disconnected with the Ignition switch at ON position, DTCs will be recorded. Never use SRS parts from another vehicle. When rr placing parts, replace them with new parts. •...
Page 804 RS-5 9 SUPPLEMENTAL RESTRAINT SYSTEM FRONT A!ABAG SENSOR INSPECTION VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check (See page Dl-326}. VEHICLES INVOLVED IN COLLISION Do a diagnostic system check (See page 01-326). If the front fender of the car or its periphery is damaged, do a visual check for damage to the front airbag sensor, which includes the following items even if the airbag was not deployed:...
Page 805 RS-60 FRONT AIRBAG SENSOR SUPPLEMENTAL RESTRAINT SYSTEM REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the front alrbag sensor. • 1f the SRS has been deployed in a collision. (Replace both the left and right airbag sensors. ) • 1f the front airbag sensor has been found to be faulty in troubleshooting. If the front airbag sensor has been found to be faulty during checking items (See page RS--59: •...
Page 806 RS-61 � SUPPLEMENTAL RESTRAINT SYSTEM FHONT AIRBAQ SE:NSOR INSTALLATION INSTALL FRONT AIRBAG SENSOR LH AND RH Install the front airbag sensors with the 4 bolts. Torque: 20 N-m (205 kgf-cm, 1 5 ft-lbf) (b ) Connect the front airbag sensor connector. NOTICE: •...
Page 807 R!Ml2 SIDE AIRBAG SIDE AIRBAG SENSOR ASSEMBLY COMPON ENTS Si d e Ai r b ag Sensor Assembl y Ser v i c e Hol e Cover Quar t e r Tnm Panel Rear Seat Cushi o n Assembl y Deck Tr i m Si d e Cover Package Tr a y Tr i m Panel Deck Tr i m Rear Cover...
Page 808 RS--<; 3 �- SUPPLEMENTAL RESTRAINT SYSTEM SIDE AIRBAG SENSOR ASSEMBLY REMOVAL NOTICE: • If the wiring connector of the SRS is disconnected with the ignition switch at ON position, DTCs will be recorded. • Do not open the cover or the case of the ECU and vari ous electrical devices unless absolutely necessary.
Page 809 Rs-<;4 SlOE AIABAG SENSOR ASSEMBLY INSPECTION VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check (See page 01-326). VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED Do a diagnostic system check {See page 01-326). VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED Replace the side airbag sensor assembly (See page Dl-326).
Page 810 Rs-<iS S!DEA,IRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the side airbag sensor assembly. If the side airbag assembly has been deployed in a collision. If the side airbag sensor assembly has been found to be faulty in troubleshooting. •...
Page 811 Rs-<>6 SUPPLEMENTAL RI?.STRAfNT SYSTEM SIDE AIRBAG SENSOR ASSEM8L INSTALLATION NOTICE: • Never use SRS parts from another vehicle. When reM placing parts, replace them with new ones. " Never reuse the side airbag sensor assembly in- volved in a collision when the airbag has deployed. •...
Page 812 R�7 DOOH SIDE SENSOR A!RBAG SUPPLEMENTAL RESTRAINT SYSTEM DOOR SIDE AIRBAG SENSOR COMPONENTS Fr o nt Door Lower F r a me Br a cket Gar n i s h No.2 Door I n si d e Handl e Bezel Out e r Mi r r o r Swi t c h Assembl y : Speci f i e d t o r q ue...
Page 813 DOOR SJDE AtRBAG SENSOR SUPPLEMENTAL ESTRAl SYSTEM REMOVAL NOTICE: • If the wiring connector of the SRS is disconnected with the ignition switch at ON position, OTCs will be recorded. Never use SRS parts from another vehicle. When re� placing parts, replace them with new parts. •...
Page 814 RS-69 SUPPLEMENTAl RESTRAINT SYSTEM DOOR S!DE AIA8AG SENSOR INSPECTION VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check (See page Dl-326). VEHICLES INVOLVED IN COLLISION Do a diagnostic system check (See page 01-326). If the front door or its periphery is damaged, do a visual check for damage to the door side airbag sensor, which includes the following items even if the airbag was not deploye d:...
Page 815 RS-70 DOOR SIDE AIRBAG SENSOR REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the front airbag sensor. • If the side airbag assembly has been deployed in a collision. • If the door side airbag sensor has been found to be faulty in troubleshooting. •...
Page 816 As-71 SUPPLEMENTAL RESTRAINT SYSTEM DOOR SIDE AIRBAG SENSOR INSTALLATION HINT: For step 2 to 5, refer to page B0-21 . INSTALL DOOR SIDE AIRBAG SENSOR Install the door side airbag sensor with the 2 bolts. Torque: 8.0 N.m {82 kgf . cm, 71 in..lbf} NOTICE: •...
Page 817 RS-72 WIRE HARNESS AND CONNECTOR SUPPLEMENTAL RESTRAINT SYSTEM WIRE HARNESS AND CONNECTOR LOCATION St e er i n g Wheel Pad ( w i t h Ai r b ag) Spi r a l Cabl e Si d e Ai r b ag Assembl y ( R H) Si d e Ai r b ag Sensor Assembl y ( R H) Door Si d e Ai r b ag...
Page 818 AS-73 SUPPLEMENTAL RESTRAINT SYSTEM WIRE HARNESS AND CONNECTOR INSPECTION H I NT : The SRS wire harness is integrated with the instrument panel wire harness assembly. AU the connectors in the system are a standard yellow color. VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check {See page Dl-326).
Page 819 R5- 74 SUPPLEMENTAL RESTRAINT SYSTEM WIRE I-1ARNESS REPLACEMENT In the following cases,replace the wire harness or connector. • If any part of the SRS wire harness or any connector has been found to be faulty in troubleshoot ing. If any part of the SRS wire harness or any connector has been found to be faulty during checking items (See page R$-73).
Page 820 BODY ELECTRICAL BODY ELECTRI C AL SYSTEM . BE-1 BE-2 TROUBLESHOOTI N G . POWER SOURCE ..BE-10 I G NI T I O N SWI T CH AND KEY UNLOCK WARNI N G SWI T CH . . BE-1 3 HEADLI G HT AND TAI L LI G HT SYSTEM BE-15 FOG LI G HT SYSTEM BE-22...
Page 822: Body Electrical System
BE-1 ELECTRICAL BODY RODY ELECTRICAL SYSTEM BODY ELECTRICAL SYSTEM PRECAUTION HINT: Take care to obseiVe the following precautions when performing inspections or removal and replacement of body electrical related parts. HEADLIGHT SYSTEM Halogen bulbs have pressurized gas inside and require special handling. They can burst if scratched or dropped.
Page 823 BE-2 BODY TROUBLESHOOTING TROUBLESHOOTING PROBLEM SYMPTOMS TABLE IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH: Symptom Suspect Area " See page ignition switch is not set to each position. " Ignition Switch BE-14 GAUGE Fuse BE� t o 2. Key Unk:Jck Warning Switch BE-14 3 Door Courtesy Switch BE-28...
Page 824 BE-3 BODY ElECTRICAL TROUBLESHOOTING 1 . ECU-- I G Fuse BE-10 2. DOME Fuse BE-10 3 Automatic Light Control Sensor BE--17 "Automattc light wntrot system· does not operate- Light Control Switch BE-17 Door Courtesy Switch BE-28 6 Body Control System DJ-.-535 �...
Page 825 BE-4 TROUBLESilOOTING TURN Fuse BE:-10 Turn sign does not light Turn S<gral Switcll 8£:-26 (Combination meter, wiper aM washer are normal.) 3. Wire Hamess 1 Turn Signal Switch BE-26 Tum signal does not light vp in one direction. Wire Harness Bulb Only one bulb does not tight up.
Page 826 BE-5 BODY ElECTRICAl TROUBLESHOOTING WIPER AND WASHER SYSTEM Symptom Suspect Area Seepage WIPER Fuse BE-10 2. Ignition Switch BE--14 Wipers and washers do not op<Jra\e, 3. Wiper and Washer Switch BE - 35 4. Wire Harness Front Wiper and Washer Sw•lch BE--35 Front wiper doss not operate.
Page 827: Warning Lights
BE--6 ELECTRICAL BODY TROUBLESHOOTING Warning Lights: COMBINATION METER Symptom Suspect Area See page Bulb or LEO 2 IGN Fuse BE:-10 BE - 14 3 Ignition Switch Warning lights do not light up. 4. Meter Circurt (Except discharge and door open.) BE--42 CH--10 6 Wire Harness...
Page 828 BE-7 BODY ElECTRICAL TRO 8 ES OOTtNG Bulb Tum Signal and Hazard Waming Syslem BE-2 Turn indicaiOf hghl does not l;ght up. Meter C1rcuit BE-42 ' · Wire Harness Bulb Headlight and Taillrghl System BE-2 High beam indicator light does not light up. Meter Circuit BE--42 WiU'J Harness...
Page 829 BE-8 BODY ELECTRICAL TROUBLESHOOTING POWER DOOR lOCK CONTROl SYSTEM Symptom Suspect Area page ' Body Control System 01�535 2 DOOR Fuse BE-10 3. GAUGE Fuse ·'Door lock conlrol system' dons not operale.(All) RE-10 BE . --£3 Door Lock CorJtrol Switch 2 Body Conlrol System Dl-535 Malfunction in Dom Lock...
Page 830 BE-9 ELECTRICAL BODY TROU6LESHOOTING Key Unlock Warning SWi BE-14 Only confinement prevention function is not possible. Wireless Door Lock Receiver BE-73 Wire rness Wireless lock function operates even when each door is doo r Door Courtesy Switch opened. BE-28 • Automatic lock function Of)6rates even if opened 30 seconds after...
Page 831: Power Source
BE-10 BODY ELECTRICAl POWER SOURCE "'""-<' LOCATION Engine Room Junction Block Relay Block Cent e r Junct i o n Block...
Page 832 BE-11 BODY ElECTRICAL POWER SOURCE ENGINE ROOM JUNCTION BLOCK ��I Rel a y Rel a y RELAYS FUSES C. Ci r c ui t Openi n g Rel a y A. FAN N 1 . Fl ALT 120A D. Hor n Rel a y B.
Page 833 BE-12 POWER SOURCE BODY ELECTRICAL CENTER JUNCTION BLOCK A. - B. I G l Rel a y RELAYS 15 A 15A FUSES 1. GI G 2. S/ R OOF C. Def o gger Rel a y 25A 20A 3. A M1 D.
Page 834 BE -13 BODY ELECTRICAL IGNITION SWITCH AND UNLOCK WARNING SWITCH IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH LOCATION I g ni t i o n Swi t c h Key Unl o ck War n i n g Swi t c h •...
Page 835 BE-14 BODY ELECTRICAL IGNITlON SW!l CHAND KEY UNLOCK WARNING SWITCH INSPECTION LOCK INSPECT IGNITION SWITCH CONTINUITY Switch position Tester connecNon Speclfled condit!on LOCK No COI'ltinuity Continuity 1 - 2 - 3 Co111inuity 5 - 6 , � 2 100<1(l7 START Continuity 4 - 5 - 6 If continuity is not as specified, replace the switch.
Page 836 BE-15 BODY ElECTRICAl HEADLIGHT AND TAILLIGHT SYSTEM HEADLIGHT AND TAILLIGHT SYSTEM LOCATIO N Engi n e Room Junct i o n Bl o ck HEAD LH-LWR Fuse HEAD RH-LWR Fuse • HEAD LH-UPR Fuse • HEAD RH-UPA Fuse • Headl i g ht Cont r o l Rel a y •...
Page 837 BE-16 � BODY ELECTAICAL HEADLIGHT AND TAILLIGHT SYSTEM COMPONENTS Combi n at i o n Swi t c h Li g ht Cont r o l Swi t c h Headl i g ht Di m mer Swi t c h •...
Page 838 BE-17 ODY ELECTRICAL HEADLIGHT AND TAil l iGHT SYSTFM '"-"''-'< INSPECTION INSPECT LIGHT CONTROL SWITCH CONTINUITY Switch position lester connBCtion Specified COildlliOil '" No continuity lAlL 14-- 16 Cmllinuity ""- HEAD 1 3 � 1 4 - 16 Continuity If continuity is not as specified, replace the switch, INSPECT HEADLIGHT DIMMER SWITCH CONTINU- Switch posotion Tester connection...
Page 839 BE-18 BODY ElECTRICAL HEADLIGHT AND TAILLIGHT SYSTEM w/ Automatic light control system: INSPECT AUTOMATIC LIGHT CONTROL Gradually expose the sensor. Verify that the headlights and the accessory lights turn OFF. Automatic light control system: INSPECT LIGHT-OFF CONDITION Turn the ignition switch Gradually cover the top of the sensor.
Page 840 BE-19 BODY ELECTRICAL SYSTEM HEADLIGHT AND TAILLIGHT Connect the wire harness side connector to the sensor and inspect wire harness side connector from the back side. H IN T: Ignition switch ON. Light control switch OFF. • Vehicle's surroundings are bright. 1012$5 Specilied Tester connecl!0/1...
Page 841 BE-20 BODY ELECTRICAL HEADLIGHT AND TAILLIGHT SYS fEM ADJUSTMENT Adjustment in Vertical Direction 11)67e ADJUST HEADLIGHT AIM ONLY · 1 · � 1 0 : . · � · � - � Put the vehicle below conditions. Make sure the body around the headlight is not de formed.
Page 842 BE-21 BODY ELECTRICAL HEADLIGHT AND TAILLIG! IT SYSTEM Draw the vertical lines on the paper where the headlights (low beam center marks) of the vehicle are to be,(V RH and LH lines) Take an appropriate measure to avoid affecting the other light.
Page 843 BE-22 BODVELECTRICAL LIGHT SYSTEM FOG LIG HT SYSTEM LOCATION Engi n e Room Junct i o n Bl o ck Fog Li g ht s 113;88...
Page 844 BE-23 BODY ELECTRICAL FOG LIGHT SYSTEM INSPECTION INSPECT FRONT FOG LIGHT SWITCH CONTINUITY Switch position les!arconnection Sp«:ifiEXI condition No continuity 1 0 � 1 1 Continuity If continuity is not as specified, replace the switch. INSPECT FRONT FOG LIGHT RELAY CONTINUITY "r:1s Condition Tester connecbon...
Page 845 BE-24 BODY ELECTRICAL FOG UGHT SYSTEM ADJUSTMENT - - - _ _ . _ _ ADJUST FOG LIGHT AIM A-bolt Vertical Direction...
Page 846 BE-25 " aODY ELECTRICAL TURN SIGNAL AND HAZARD WARNING TURN SIGNAL AND HAZARD WARNING SYSTEM LOCATION Engi n e Room Junct i o n Bl o ck HAZ Fuse • Hazar d War n i n g Swi t c h Tur n Si g nal Li g ht s Tur n Si g nal Fl a sher - ----- -a Cent e r Junct i o n...
Page 847 BE-26 BODY ELECTRICAL TURN SIGNAL AND HAZARD WARNING SYSTEM INSPECTION INSPECT TURN SIGNAL SWITCH CONTINUITY T ester connection Switch position Specified condition 1 - 2 lei! turn Contini.II\y Neutral No continuity Ri ht tum 2 - 3 Conlinui If continuity is not as specified, replace the switch. 11��...
Page 848 BE-27 BODY ELECTRICAL INTERIOR LIGHT SYSTEM INTERIOR LIGHT SYSTEM LOCATION I13WJ...
Page 849 BE-28 INTERIOR l G T SYS fE ... «-<• BODY ELE CTRtCAL INSPECTION w/ Sliding roof: INSPECT FRONT PERSONAL LIGHT SWITCH CONTI- NUlTY T ester connection Switch position Specified condition No continuity 2 - 7 DOOR Continuity 101676 2 - 8 Continuity II conttnutty rs not as spectfred, replace the lrght assembly or bulb.
Page 850 BE-29 SYSTEM BODY ELECTRICAL INTERIOR LIGHT INSPECT LICENCE PLATE LIGHT CONTINUITY Using an ohmmeter, check that continuity exists between termi nals. If continuity is not as specified, replace the light assembly or bu lb .
Page 851 BE-30 BODY ELECTRICAL BACK UP LIGHT SYSTEM BACK-UP LIGHT SYSTEM LOCATION -----· Back-Up Li g ht s lllS90...
Page 852 BE-31 BODY ELECTRICAL BACK UP UGH T SYSTEM "@ ><1 INSPECTION INSPECT BACK-UP LIGHT SWITCH CONTINUITY r-�- - - Switch position Tester connection Specilied condition Fre e No continuity Push 1 - 2 Continuity If continuity is not as specified, replace the switch. Fr ee 1142<!6 INSPECT PARK/NEUTRAL POSITION SWITCH CON...
Page 853 BE-32 BODY ELECTRICAL STOP SYSTfM LIGHT STOP LIGHT SYSTEM LOCATION St o p Li g ht Swi t c h - -� � - - - --- -- - -- - - - - - - - - � -- Sl o p Li g ht s 113501...
Page 854 BE-33 BODY ELECTRICAL LIGHT STOP SYSTCM .." " " " INSPECTION Free Pushed INSPECT STOP LIGHT SWITCH CONTINUITY w/o cruise control system: Switch JX>Sition Tester connocl10n Specified condition Switch pin pushed ;n No conliiiUII Y (Pedal released) Switch pin tree Continuity 1 - 2 (Pedal depressed)
Page 855 BE-34 BODY ELECTRICAL WIPER AND WASHER SYSTEM WIPER AND WASH E R SYSTEM LOCATION Combi n at i o n Swi t c h Wi p er and Washer Swi t c h • Washer Tank Washer Mot o r •...
Page 856 BE-35 ELECTRICAL � BODY WIPER WASHER SYSTEM INSPECTION INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY Switch position lCster conne<;tion Specified cond•tion 7 � 1 6 Continuity MIST {w/ Mist wiper) 7 � t 7 Continuity !NT (w/ lntarmil\ent wiper) 7 - 16 Continuity Continuity 8 - 1 7...
Page 857 BE-36 WIPER AND WASHER SYSTEM INSPECT FRONT WASHER liNKED OPERATION Connect the positive (+) lead from the battery to terminal 16 and the negative (-) lead to terminal 2. Connect the positive (+} lead from the voltmeter to tcrmi- nal 7 and the negative (-} lead to terminal 2. Push in the washer switch, and check that the voltage Washer Swi t c h changes, as shown in the table.
Page 858 BE-37 BODY ElECTRICAl AND WASHER SYSTEM WIPER High Speed: INSPECT FRONT WIPER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 3 and the negative {-) lead to terminal 4, check that the motor oper ates at high speed. If operation is not as specified, replace the motor.
Page 859 BE-38 BODY ELECTRICAL WIPEH AND WASHER SYSTEM Intermittent: INSPECT REAR WIPER MOTOR AND RELAY OPERA TION Connect the positive ( +) lead from the battery to terminal 1 , and the negative ( ) lead to terminal 2 and the motor body, check that the motor operates intermittently for 9 - 1 5 seconds.
Page 860 BE-39 BODY ELECTRICAL COMBINATION METER COMBINATION METER LOCATION Washer Tank Washer Fl u i d Level War n i n g Swi t c h • Cl o ck Assembl y Passenger Seat Bel t War n i n g Li g ht Occupant Det e ct i o n Sensor •...
Page 861 BE-40 BODY ELECTRICAL COMBINATION METER Door Cour t e sy Swi t c hes Fuel Sender Gauge IIJW�...
Page 862 BE-41 BODY ELECTRICAL - COMBINATION METER " A " " 8 " Connector Connector >- '-: ::. . ' \Sx�) � I l l 735...
Page 863 BE-42 BODY COMBINATION METER ELECTRICAL CIRCUIT EC U BLJUer A l 3 FLJs llav el __ ___ --��-- __...
Page 864 BE-43 BODY COMBINATION METER ELECTRICAL No. Wi r i n g connect o r si d e Spor t mode swi t c h Headl i g ht di m mer swi t c h Headl i g ht Tur n si g na! swi t c h ( L ef t s' 1 d e) Li g ht cont r o l r h eost a t Evapor a t o r t e mp.
Page 866 BE·-45 BODY ELECTRICAL COMBINATION METER DISASSEMBLY COMBINATION METER COVER: Remove the 8 screws. Remove the combination meter cover. Remove the meter circuit plate. Ill):!{; Remove the 6 clips and the meter glass. Remove the 4 clips and the meter plate.
Page 867 BE-46 BODY EbECTAICAL - COMBINATION METER INSPECTION INSPECT SPEEDOMETER O�VEHICLE Using a speedometer tester, inspect the speedometer for allow able indication error and check the operation of the odometer. HINT: Tire wear and tire over or under inflation will increase the indica tion error.
Page 868 BE-47 �- BODY ELECTRICAL COMBINATION METER RPM (DC 1 3.5 V, 25 ·c (n •F)) Standard indication Allowable range 700 - 770 1,000 900 - 1 ,100 2.000 1.850-2,150 2.800 - 3,200 3,000 4,000 3,800- 4,200 4,800--5,200 5,000 6,000 5,800- 6,200 7,000 6,800 - 7.200 If error...
Page 869 BE-48 BODY METER ELECTRICAL - COMBINATION INSPECT FUEL SENDER GAUGE RESISTANCE Measure the resistance between terminals 2 and 3 for each float position. Float position: (in.) Resis1anc<J Approx. 1/2: Approx. 17.2 {0.68) Approx. 31.6 pr o x. Approx. 110.0 50.8 (2.00) 111639 If resistance value is not as specified, replace the sender gauge.
Page 870 BE-49 BODY ELECTRICAL COMBINATION Mt:TCR INSPECT ENGINE COOLANT TEMPERATURE SEND- ER GAUGE RESISTANCE 35.63 I Connect the wire harness as shown in the illustration, and ad �o" 0.1 .n just the ammeter pointer to indicate using the slide rheostat, then read the rheostat indication. Temperature ('F) Rcsistaneo (.Q)
Page 871 BE-50 COMBINATION METER BODY ELECTRICAL INSPECT BRAKE FLUID LEVEL WARNING SWITCH CONTINUITY Remove the reservoir tank cap and strainer. Disconnect the connector. Check that no continuity exists between terminals wllh the switch OFF (float up). Use syphon, etc. to take fluid out of the reservoir tank. Check that continuity exists between terminals with the 111650 switch ON (float down).
Page 872 BE-51 BODY ElECTRICAl COMBINATION METER INSPECT LIGHT CONTROL RHEOSTAT OPERATION Gradually, turn the rheostat knob from the bright side to dark side and check that the resistance decreases from 1 0 k.Q to 0 between terminal 2 and 1 . (Rheostat knob turned to clock wi se ) If operation is not as specified, replace the rheostat light control.
Page 873 BE-52 BODY ELECTRICAL ELECTRIC TENSION REDUCER SYSTEM ELECTRIC TENSION REDUCER SYSTEM LOCATION Buckl e Swi t c h Tensi o n Reducer Sol e noi d ( i n Ret r a ct o r Assembl y ) 1\3594...
Page 874 BE-53 BODY ELECTRICAL ELECTrliC TENSION REDUCER SYSTEM INSPECTION INSPECT TENSION REDUCER SOLENOID OPERA TION Connect the positive (+) lead from the battery to terminal and the negative (-) lead to terminal 2. Pull the belt upward and check that the belt is slowly re tracted when released.
Page 875 BE-54 BODY ELECTRICAL DEFOGGER SYSTEM DEFOGGE SYSTEM LOCATION I g ni t i o n Swi t c h ---- Cent e r Junct i o n Bl o ck : Def o gger Re! a y Y) use MULTI ( D EFRL F •...
Page 876 BE-55 DV ELECTRICAL OEFOGGER SYSTEM ""'"'""" ' I NSPECTION Gl§:> INSPECT DEFOGGER TIMER OPERATION Connect the positive ( +) lead from the battery to terminal • 1 and negative (-) lead to terminal 3 . Connect the positive (+) lead from the battery to terminal 5 through a 3.4 W test bulb.
Page 877 BE-56 BODY DEFOGGER SYSTEM ELECTRICAL INSPECT DEFOGGER SWITCH CIRCUIT Connector connected: Connect the connector from the switch and inspect the wire har· ness side connector from the back side as shown in the chart Condition Tester connection Sp�;Jcihe<l condition Ground Ignition switch ON and de!ogger switch OFF Battery positive voltage nit ion switch ON and defogger switch ON...
Page 878 BE-57 BODY ELECTRICAL OEFOGGEfl SYSTEM HINT: !f there is approximately 1 0 V, the wire is broken between the center of the wire and the positive ( +) end. If there is no voltage, the wire is broken between the center of the wire and ground. Place the voltmeter positive {+) lead against the defogger positive (+) terminal.
Page 879 BE-58 BODY ELECTRICAL POWER WINDOW CONTflOL SYSTEM POWER WINDOW CONTROL SYSTEM LOCATION Power Wi n dow Mast e r Swi t c h Wi n dow Lock Swi t c h I g ni t i o n Swi t c h Cent e r Junct i o n Bl o ck Body ECU PWR No.
Page 880 BE-59 BODY ELECTRICAL POWER WINDOW CONTROL SYSTEM INSPECTION INSPECT POWER WINDOW MASTER SWITCH CON TINUITY Driver's switch: Tester connection Switch position Specilied cond•lion 2 - 9, 1 7 - 1 8 Continurty 9 - 17. 1 7 - 1 8 Continuity DOWN 2 - 18, 9 - 1 7...
Page 881 BE-60 POWER WINDOW CONTROL SYSTEM ELE CTR ICAL - BOD Y Reverse the polarity, check that the motor turns counter clockwise. II operation is not as specified, replace the motor. Passenger's door: INSPECT POWER WINDOW MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, check that the motor turns clockwise.
Page 882 BE-61 BODY ELECTRICAL SYSTEM POWER WINDOW CONTROL Passenger's door: INSPECT PTC OPERATION Disconnect the connector from the power window switch. Connect the positive {+) lead from the ammeter to termi of the wire harness side connector and the negative (-) lead to negative terminal of the battery. Connect the positive (+) lead from the battery to terminal 2 of the wire harness side connector, and raise the win- dow to the fully closed position.
Page 883 BE-62 POWER DOOR LOCK CONTROL SYSTEM BODY ELECTRICAL POWER DOOR LOCK CONTROL SYSTEM Power Wi n dow Mast e r Swi t c h LOCATION Door Lock Manual Swi t c h -- - ----- - Cent e r Junct i o n Bl o ck l g mt ! O n Swi t C h Body ECU DOOR Fuse...
Page 884 BE-63 BODY ElECTRICAL POW En DOOR LOCK CONTROL SYS [EM INSPECTION Master switch: INSPECT DRIVER'S DOOR LOCK CONTROL SWITCH CONTINUITY Switch position Tester connection LOCK Conhnuity No continuity 6 - 1 7 UNLOC K Contmuily If continuity is not as specified, replace the switch. Driver's door: INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY...
Page 885 BE-64 E ECTRICAL POWER DOOR LOCK CONTROL SYSTEM Passenger's door: INSPECT DOOR UNLOCK DETECTION SWITCH CON- TINUITY LOCK Switch position Tester connection Specified condition OFF (Door Lock set to No continuity LOCK) lock ON (Door set to 3 - 4 Continuity UNLOCK) If continuity is not as specified, replace the switch.
Page 886 BE-65 BODY ElECTRICAL POWER DOOR LOCK CONTROL SYS1 H1 INSPECT DRIVER·s DOOR PTC THERMISTOR OP- ERATION (a ) Connect the negative (-} lead from the battery to terminal Connect the positive (+) lead from the ammeter to termi- nat 1 and the negative {-} lead to battery negative (-) ter- minat, and check that the current changes from approxi- matety 3.2 A to Jess than 0.5 A within 20 to 70 seconds.
Page 887 BE-66 POWER OOOR LOCK CONTROL BODY ELECTRICAL SYSTEM Disconnect the leads from terminals. Approximately 60 seconds later, reverse the polarity, and check that the door lock moves to the LOCK position. If operation is not as specified, replace the door Jock assembly. 1 1 .
Page 888 BE-<>7 BODY ElECTRICAl WIRELESS DOOR LOCK CONTROL SYSTEM WIRELESS DOOR LOCK CONTROL SYSTEM LOCATION -- -- - � - � - -- - � - Door Lock Assembly • Switch Door Lock Motor • Door Unlock Detection PANIC --- - Back Door t�...
Page 889 BE-68 BODY ELECTRICAL WIRELESS DOOR LOCK CONTROL SYSTEM PRE-CHECK Only wireless function (Remote control} will not o p erate. (If a new transmitter or transmitter of the same ty p e that with the properly vehicle available.) Make the vehicle in the initialized condition: The initialized condition is the condition when the following conditions are satisfied.
Page 890 BE-69 BODY ELECTRICAL WiRELESS DOOR LOCK CONTHOl SYSTEM ans � t t e r bat t e r y chec � Bat t e r y f a ul ! y . Repl a ce t h e t r a nsmi t t e r bat t e r y wi t h a new or nor m al one and check UNLOCK-LOCK f u nct i o n wor k s under t h e st a ndar d oper a t i o n.
Page 891 BE-70 �- BODY ELECTRICAL WIRELESS DOOR LOCK CONTROL SYSTEM Di a gnost i c mode oper a t i o n conf i r m at i o n: Check t h e t a i l l i g ht l i g ht s up soon af t e r t h e i n put oper a - No I s t h e met h od t o i n put t h e di a gnost i c mode t i o n of sel f di a gnost i c mode.
Page 892 BE-71 BODY ELECTRICAL - WIRELESS DOOR CONTROL SYSTEM LOCK ..Yee Ot h er body cont r o l syst e m f a ul t y . · · ·� ( T r a nsmi t t e r and r e cei v er ar e nor m aL} I s t h e wave r e achi n g r a nge nor m al ? ar e a ar o und vehi c l e ) ( W hi l e t h e t r a nsmi t t i n g swi t c h i s pr e ssed,...
Page 893 BE-72 WIRELESS DOOR LOCK CONTROL SYSTEM BODY ELECTRICAL DOME fuse or wire harness faulty. Check that there is constantly 1 0 to Vvoltage at the connector terminal S (+B) of wireless door control receiver. Wire harness faulty. Body ground open and contact error. Check that continuity exists between the connector terminal 1 (GND) of the wireless door control receiver and body ground.
Page 894 BE-73 BODY ELECTRICAL WIRELESS DOOR LOCK CONTROLS YSTEM INSPECTION INSPECT WIRELESS DOOR LOCK TRANSMITTER OPERATION HINT: Refer to "Wireless door lock control receiver and transmitter re placement" on page BE-77. Using a screwdriver, remove the screw and cover. Remove the battery (lithium battery). Install a new or normal battery (lithium battery).
Page 895 WIRELESS DOOR LQCK CONTROL SYSTEM CHECK BATTERY CAPACITY HINT: • Make sure to use the TOYOTA electrical tester. With the battery unloaded, judge can not be made wheth er the battery is available or not on the test • When the transmitter is faulty, the energy amount left in the battery might not be checked correctly.
Page 896 BE-75 BODY ELECTRICAL OOOR LOCK CONTROL SYSTEM WIRELESS HINT: • When the temperature of the battery is low, the judge can not be made correctly. When the outcome of the test is less than 2.1 V, conduct the test again after leaving the battery in the place at 1 8 4C for more than 3 0 minutes.
Page 897 BE-76 BODY ELECTRICAL WIRELESS DOOR LOCK CONTROL SYSTEM Connect the wire harness side connector to the receiver From back side: and inspect the wire harness side connector from the back side, as shown below. 11207:l Condition T ester connection Specified condition 1 0 - 14 v Grou(l(l Normal mode...
Page 898 BE-77 BODY ELECTRICAL WIRELESS DOOR LOCK CONTROL SYSTEM REPLACEMENT REPLACE TRANSMITTER (LITHIUM) BATTERY NOTICE: Special caution should be taken for handling each compo nent as they are precision electronic components. Using a screwdriver, remove the cover. NOTICE: Do not pry out the cover forcibly. HINT;...
Page 899 BE-78 BODY ElECTRICAL SYSTEM REPLACE DOOR CONTROL RECEIVER AND TRANS· MITIER NOTICE: When replacing the door control receiver and transmitter, registration of recognition code is necessary because they are provided as single components. Select which operation mode should be performed from the following modes.
Page 900 BE-79 BODY ELECTRICAL WIRELESS DOOR LOCK CONTROL SYSTEM Start registration of recognition code The vehicle should be in the following conditions. • The key is not inserted in the ignition key cylinder. • Driver's door is OPEN. (Other doors are CLOSED) •...
Page 901 BE-80 ELECTRICAl WIRELESS DOOR LOCK CONTROL SYSTEM BODY Turn the ignition switch from ON to LOCK at approx. 1 sec. interval 1 to times to select the mode. Confirmation mode Add mode � ON - LOCK change occurs 3 times LOCK change occurs 1 time �: Approx.
Page 902 BE--81 BODY ElECTRICAL WIRELESS DOOR LOCK CONTHOL SYSTEM When prohibition mode is selected. Within Door control relay performs LOCK-UNLOCK operation times at a sec. sees. interval to inform the operator that prohibition mode has been selected. Approx. Approx. 1 soc. 1 soc.
Page 903 BE-82 BODY ROOF SLIDING SLIDING ROOF SYSTEM TROUBLESHOOTING Sliding roof cannot be closed and neverses in error for some reason. Thi s shi f t s i t t o t h e manual oper a t i i o n i n whi c h t h e j a m pr o t e ct i o n syst e m i s pr o hi b i t e d. ( w i t h t h e i g ni t i o n ON} I n t h e manual oper a t i o n, cl o se t h e sl i d i n g r o of compl e t e l y and st o p t h e mot i o n.
Page 904 BE-<33 BODY ELECTRICAL SliDING ROOF SYSTEM LOCATION Sliding Roof Assembly • • Sliding Roof ECU Sliding Roof Switch • Sliding Roof Motor Center Junction Block • S/Roof Fuse 1!1593...
Page 905 BE-M ROOF SLIDING SYSTEM BODY ELECTRICAL "'""'"'' INSPECTION INSPECT SLIDING ROOF SWITCH CONTINUITY Swrtch position rester connection Spocified condition OPEN Continuity 4 ·-8 No continuity CLOSE Continuity If continuity Is not as specified, replace the switch. IOI&7e INSPECT SLIDING ROOF CONTROL ASSEMBLY CIR· Wire Harness Side CUlT Disconnect the connector from the ECU and inspect the con...
Page 907 BE-86 BODY ELECTRICAL POWER MIRROR CONTROL SYSTEM .,,""<' INSPECTION INSPECT LEFT SIDE MIRROR SWITCH CONTINUITY Switch poSl\IOn Tester conMction Specified cond<tion continuity 4 - 8 Continuity 6 - 7 4 - 7 Continuity DOWN 6 - 8 S - 8 Continuity LEFT 6 - 7...
Page 908 BE-87 BODY POWER MIRROR CONTROL SYSTEM ELECTRICAL Connect the positive(+) lead from the battery to terminal 3 and the negative (-) lead to terminal 5, and check that the mirror turns to the downward. 101813 3 " ' Reverse the polarity, and check that the mirror turns to the upward.
Page 909: Audio System
BE-88 BODY ELECTRICAl - AUDIO SYSTEM AUDIO SYSTEM DESCRIPTION RADIO WAVE BAND radio wave bands used in radio broadcasting are as follows: ---- � --- - Radio wave --�fll plitude mo ? �� tion _ _ _ _ Frequency modulation ·-·--·...
Page 910 BE-89 p at BODY ElECTRICAl AUDIO SYSTEM Multipalh One type of interference caused b y bouncing of ra dio waves off obstructions is called "mu!tipath". Mul ti path occurs when a signal from the broadcast transmitter antenna bounces off buildings and mountains and interferes with the signal that is re...
Page 911 BE-90 BODY ELECTRICAL AUDIO SYSTEM Matlers that require attention when checking: Noise coming into the radio usually has no harm for practical use as the noise protection is taken and it is hardly thinkable for an extremely loud noise to come in.
Page 913 What is AVC-LAN? AVC-LAN is the abbreviation, which stands for Audio Visual Communication-Local Area Network. This is a unified standard co-developed by 6 audio manufactures associated with Toyota Motor Corpo · ration. The Unified standard covers signals, such as audio signal, visual signal, signal for switch indication and communication signal.
Page 914 BE-93 AUDIO SYSTEM BODY ElECTRICAL DIAGNOSIS FUNCTION Error codes over tuner and connected equipment are displayed on the screen of tuner_ Diagnosis start--- u p For shifting to diagnosis mode, push "CD" switch 3 times with pressing "1" and ''6" of PRESET switch at the same time while the audio power is OFF and ACC Is ON.
Page 915 BE-94 AUDIO BODY ELECTRICAL SYSTEM HINT: It sometimes takes approx. 40 sees. til! the system inspection is completed. The chart below is an example of when diagnosis code "21� appears on the physical address (190) equipment. (ROM error occurs on the radio receiver.) The smaller code numbers (physical address) are displayed in order (code No., diagnosis code, sup...
Page 916 BE-95 BODY ElECTRICAl AUOIO SYSTEM Periodic commlmication number of when occurring in the diagnosis memory code. • PnessingTUHN UP" 1 9 0: rros$ing TUHN "DOWN' This shows the equipment has a diagnosis code. Physical address • This is the number allotted to the diagnosis code 2 1 : that occurred.
Page 917 BE-96 BODY ELECTRICAL AUDIO SYSTEM DIAGNOSIS CODE LIST • there is " O n in the column of system check, an error can be detected when the mode is switched to the system check mode. • there is "0" i n the column of diagnosis mode, each unit is monitoring whether or not it has failure. - �...
Page 918 BE-97 BODY ELECTRICAL AUDIO SYSTEM TROUBLESHOOTING NOTICE: When replacing the internal mechanism (computer part) of the audio system, be careful that no part of your body or clothing comes in contact with the terminals of the leads from the IC, etc. of the re� placement part (spare part).
Page 919 BE-98 AUDIO SYSTEM BODY ELECTRICAL _ _ _ _ _ - -- - - - - - - RADIO NOT OPERATING WHEN POWER SWITCH TURNED TO "ON" Is power supplied to ACC termmal of power ampliher? ACC wire harness faulty. .
Page 920 BE-99 BODY ELECTRICAL AUDIO SYSTEM l a yer () _ pe r a t l n g _ _ _ _ _ _ _ · - � � --- �-- --- --�- -��---- · · Check i f ECU-ACC f u se i s _ O _ K? _ _ _ _ _ _ ·...
Page 921 BE-100 BODY AUDIO SYSTEM ELECTRICAL NOISE PRESENT, BUT AM-FM NOT OPERATING I f r a di o si d e f a ul t y . _ _ _ _ _ _ _ _ _ [ Radi o ANY SPEAKER DOSE NOT WORK Radi o assembl y f a ul t y .
Page 922 BE-101 BODY ELECTRICAL AUDIO SYSTEM I s t a pe pl a yer ope r a t i n g no r m a � l � l y � ? ' _ __ _ _ · · · Hi s s noi s e f r o m speaker ? No Recheck syst e m af t e r r e pai r .
Page 923 BE-102 BODY AUDIO SYSTEM _ __ _ _ ] Does the condi t i o Yes removi n g them? · - � .�� No� - � - �� Check 1l lhero is any scratch and breaking of a the glass antenna and the defogger pa!tem. (visual check.
Page 924 BE-103 BODY ELECTRICAL AUDIO SYSTEM -- - -- - - - -- -] Tempor a r i l y i n st a l l anot h er speaker . Fu r l c t i o ns di o assembl y or power ampl i f i 8 � -i a �- - - - - - check syst e m af t e r r e pai r .
Page 925 BE-104 SYSTEM BODY ELECTRICAL AUDIO Tape Player P ower ampl i f i e r f a ul t y . assembl y faul t y . ampl i f i e r f a ul t y . I s power suppl i e d t o t e rmi n al of radi o assembl y ?
Page 926 BE-105 BODY AUDIO SYSTEM ELECTRICAL POWER COMING IN, BUT TAPE PLAYER NOT OPERATING �- Rechec k syst e m aft e r re � ai r �- Radi o assembl y f a u l t y . Recheck syst e m af t e r repai r . ANY SPEAKER DOES NOT WORK...
Page 927 BE-106 BODY ELECTRICAL AUDIO SYSTEM · - Tape Playe Casset t e t a pe faul t y . I s there a lorei g n obj e ct i n si d e tape pl a yer?. � �-- · -- Operates normal l y af t e r cl e ani n g the heads? Head di r ty.
Page 928 BE-107 BOOYELECTAICAL AUOIOSYSfEM Radi o assembl y f a ul t y . - - - - - - - No Is au1o search _ _ _ si d e) of CD pl a yer gr o unded NG- . nor m al l y ? OK �...
Page 929 BE-108 BODY ELECTRICAL AUDIO Pl a yer CD INSERTED, BUT NO POWER termi n al of pl a yer? Radio assembly faulty. Ye s Check i f fuse i s OK? ECU-ACC wi r e harness faul t y. I s power suppl i e d t o termi n al of power ampl i f i e r? POWER COMING IN, BUT CO PLAYER NOT OPERATING Ye s...
Page 930 BE-109 � AUDIO SYSTEM BODY ElECTRICAL Y es � � CD - ;;i�yer properly installed? - · - - � · CD player faulty. SOUND QUALITY POOR (VOLUME FAINT) Function OK if different CD inserted? CD fau�y. player tautly. -- - ---- � - _ ___ ·...
Page 931 BE-110 � · BODY ELECTRICAL AUDIO SYSTEM ANY SPEAKER DOES NOT WORK CD Player I s r a di o oper a t i n g nor m al l y ? Radi o assembl y f a ul t y . Yes Recheck syst e m af t e r r e pai r .
Page 932 � BE-111 SYSTEM BODY ELECTRICAL AUDIO - - -- _ I s tape pl a yer operati n g norma l l y � ? =: == ==== == =J ly ;;g - • � J � R � a � d � l o � a � s � s e � m "§ b � l y � f � a � u � l l y � - = ==== ==J --- - - ==-:J -- -- - - - - - - - NG...
Page 933 -112 · · - - - �� - -- BODY l:LECTRICAL AUDIO SYSTEM Check i f termi n al of power ampl i f i e �? wi r e harness f a ul t y. t e rmi n al of power ampl i f i e r? wi r e harness faul t y .
Page 934 BE-113 "- AUDIO SYSTEM BODY ELECTRICAL Is radio opera �-p;� Recheck system a f ter repair. �e harness? Temporarily instal! another speaker. Function OK? Power amplifier faulty. Recheck system a f ter repair.
Page 935 BE-114 AUDIO BODY ELECTRICAL SYSTEM NOISE OCCURS Noise (Jt occurs i n the cassette and CD.) Refer to No. 2 7. Does the noi s e occur onl y in the radi o ? Does the noi s e occur in � aj p � a � r t � ; c � u � l a � ' � P � I � a � c e � ' � · ==J -;;-:: --�.[� A� n � e � l e � c � t � ,; � c � e � n � v � i r o � n � m � e � n � t . = ======= Does the noise stop by removi n g it? Is there any addi t i o nal i n stal l a ti o n part around the gl a ss i m pri n ted antenna?
Page 937 BE-116 � SYSTEM BODY ELECTRICAL AUDIO LOCATION Tweeter Power Amplifier Center J u nction Block • CIG Fuse • Radio Assembly RAO Fuse Front Speakers Rear Speakers 113595...
Page 938 BE-117 � BODY ELECTRICAl AUDIO SYSTEM INSPECTION 8 speaker type: INSPECT RADIO RECEIVER ASSEMBLY CIRCUIT Connect the connector from radio receiver assembly and in· spec! the connector on the wire harness side. Condition SpecHied condition Taster c:onnectiO n �Ground Constant Battery positive vol1age {+8 ) 2 - Groulld...
Page 939 BE-118 BODY ELECTRICAL AUDIO SYSTEM 4 speaker and speaker type: INSPECT RADIO RECEIVER ASSEMBLY CIRCUIT Connect the connectors from the radio receiver assembly, and inspect the connector on the wire harness side. Radio Receiver Side Connector Connector HA" "B" Cond1t•on Tester connection Specified condition At - Groulld...
Page 940 BE-119 BODY ELECTRICAL ANTENNA ANTENNA LOCATION Antenna Assembl y ---- �-- - --- --- - --- � --- - "' --- L-- - - --- - ----- �--- --- - Audi o Assembl y...
Page 941 BE-120 BODY ElECTRICAL ANTENNA INSPECTION GLASS PRINTED ANTENNA INSPECTION PROCE DURE NOTICE: • When cleaning the glass, use soft dry cloth, and wipe the glass in the direction of the wire. Take care not to damage the wires. • Do not use detergents or glass cleaners with abrasive ingredients.
Page 942 BE-121 BODY ELECTRICAL ANTENNA Using a nne tip brush, apply a small amount of the agent to the wire. After a few minutes, remove the masking tape. 8E0151...
Page 943 BE-122 BODY ELECTRICAL CLOCK CLOCK TROUBLESHOOTING HINT: Troubleshoot the clock according to the table below. Troublllshooting Passenger seal bel! wam·tng does not t up. light Clock will not operate Clock los-as or ga1ns lime ± 1.5 seconds INSPECT CLOCK CIRCUIT TROUBLESHOOTING N0.1 PASSENGER SEAT BELT WARNING LIGHT DOES NOT OPERATE CLOCK WILL NOT OPERATE...
Page 944 BE-123 BODY ELECTRICAL CLOCK Is there battery pos11ive voltage between larwinai +B and +B wire harness faulty. body ground? Is there battery positive voltage between lenninal ilnd +B wire harness faulty. bodygr(}I.Jnd? Is there battery positive voltage between JerminaJ GND and OOdy Ground wire ha.r n ss faulty.
Page 945 BE-124 BODY E LECTRICAL Bellow ! O V Is there battery pos1tive voltage between terminal +B and locate cause and repair, or recharge battery, Bellow 1 0 V ts there battery positive voHage between termmal ACC and locate cause and repair, or rechargo battery. body ground? Adjust or replace clock.
Page 946 BE -1 25 SYSTEM BODY ELECTRICAL HORN HORN SYSTEM LOCATION Engi n e Room Juncti o n Bl o c k HORN Fuse • HORN Rel a y • __ , Ho rn ----- -- --�-=-=-=-- - --� IS;�-i '· C) \ �...
Page 947 BE-126 � SYSTEM BODY ELECTRICAL '""-.o> INSPECTION INSPECT HORN SWITCH Disconnect the negative (-) terminal from the battery. Remove the left and right covers from the steering wheel. Using a torx socket wrench, loosen the 2 bolts. Pull up the horn pad and place it on the steering column, as shown.
Page 948 BE-127 SYSTEM BODY ELECTRICAL HORN -�· ·· INSPECT HORN RELAY CONTINUITY Condition Tesler connection Specified condition ,, ·-�Y0 Constant Contmvrty Apply 8+ between uO L -. Cont•nu1ty 3 - 5 terminals If continuity !s not as specified, replace the relay. !0'200...
Page 949 -M EM O -...
Page 950 BODY CLIP ......B0-1 SRS A!RBAG ..80-3 FRONT BUMPER ... . . B0-4 REAR BUMPER .
Page 952 80-1 � BODY CLIP REPLACEMENT The removal and installation methods of typical clips used in body parts are shown in the table below. H IN T: n g the operation, always replace it with a new clip. If the clip is damaged dur Removal!lnstallation Sha p e (Exam p le) Remover...
Page 953 B0-2 BODY Shape (Exam p le} Removal/Installation I n stal l a ti o n Removal Remova l � VOCHJ12...
Page 954 0-;l � B ODY SAS AIRBAG SRS AIRBAG PRECAUTION The CEUCA is equipped with an SRS (Supplemental Restraint System) such as the driver airbag, front pas senger airbag, side airbag and seat belt pretensioner. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious acci·...
Page 955 80-4 FRONT BUMPf:R BODY FRONT B UMPER COMPONENTS Upper Front Fender Apron Seal Upper Radi a t o r Suppor t Seal Front Bumper Extensi o n Retai n er Front Bumper Energy Absorber Front Bumper Cover Si d e Mar k er Radi a t o r Gri l l e �-.
Page 956: Rear Bumper
80-5 HEAR BODY BUMPf:fl REAR BUMPER COMPONENTS � Luggage Compartment Tray RH Deck Trim Side Panel Luggage LH Deck Trim Compartment Side Pane! � Hook Deck Trim No. 1 Luggage Compartment Side Panel 0>- Trim Hook Rear Bumper Cover/ · Specified torque Non�reusable part...
Page 957 B0-6 BODY HEAOUGI HEADLIGHT COMPONENTS Upper Front Fender Apron Seal Upper Radi a tor Support S eal/ Headl i g ht Headl i g ht Front Bumper Cover...
Page 958 B0-7 BODY HFADLIGHT REMOVAL REMOVE UPPER FRONT FENDER APRON SEAL REMOVE UPPER RADIATOR SUPPORT SEAL REMOVE FRONT BUMPER COVER (See page B0-4) REMOVE HEADLIGHT Remove the 3 bolts. Disconnect the connectors, then remove the headlight as shown in the illustration. Employ the same manner described above to the other side.
Page 959 BODY HEADLIGHT INSTALLATION Installation Is in the reverse order of removal (5ee page 80-6).
Page 960 !lOOD 80-9 BODY HOOD ADJUSTMENT HINT: hinge Since the centering bolt is used as the hood and Jock set bolt, the hood cannot be adjusted with it on. Substitute the stan dard bolt for the centering bolt. Centering Bolt Standard Bolt ADJUST HOOD I N FORWARD/REARWARD A N D LEFT/LIGHT DIRECTIONS Adjust the hood by loosening the hood side hinge bolts.
Page 961: Front Door
B0-10 FRONl OOOf-1 BODY FRONT DOOR """"'" COMPONENTS oOOf Front - - Moulding Belt...
Page 962 B0-11 BODY moNT DOOR DISASSEMBLY w/o Power window: REMOVE REGULATOR HANDLE Pull off the snap ring with a shop rag and remove the regulator handle and plate. ,�� HINT: 1 5 " ; 1 5 " ' ' ;, : j ' At the tlme ot reassembly, please refer to the following item.
Page 963 B0-12 BODY FRONT DOOR REMOVE DOOR TRIM Using a screwdriver, remove the 2 plug hole covers. HINT: Tape the screwdriver tip before use. Remove the 6 screws. Insert a screwdriver between the door panel and door trim to pry the trim out. HINT: Tape the screwdriver tip before use.
Page 964 B0-13 BODY FRONT DOOR • The sensor is equipped with an electrical connection check mechanism. Be sure to lock this mechanism securely when connecting the connector. If not, a malfunction code may be detected by the diagnostic system. Torque: 8.3 N·m (85 kgf.cm, 74 in . REMOVE OUTSIDE REAR VIEW MIRROR fbf) wl Tweeter speaker:...
Page 965 B0-14 � FRONT DOOR REMOVE UPPER WINDOW STOPS Remove the 2 bolts and 2 upper window stops. Torque: 1 1 N·m (115 kgf . cm, 8 ft.lbf) REMOVE DOOR GLASS Close the door glass until the nuts appear in the service hole.
Page 966 B0-15 BODY FRONI DOOR w/ Power window: If replacing the window regulator: REMOVE WINDOW REGULATOR FROM MOTOR Remove the 2 screws and cover plate, Using needle nose pliers, remove the drum and wire guide from the motor. NOTICE: Do not use a screwdriver etc. to remove them. REMOVE SPEAKER Using a rivet cutter and drill, drill out the rivets and remove speaker.
Page 967 80-16 BODY rRONT DOOR REMOVE DOOR GLASS FEMALE STABILIZER Remove the screw and door glass female stabilizer. Torque: 4.9 N-m (50 kgf-cm, 43 in..lbf) N21387 REMOVE FRONT LOWER FRAME Remove the 2 screws. Disengage the clamp of door wire harness from the front lower frame.
Page 968 80-17 FRONT OOOR BODY Remove the door lock through the service hole. Remove the door lock link clamp. (e ) HINT: • the time of reassembly, please refer to the following item. • Apply M P grease to the sliding and rotating parts of the door lock.
Page 969 moNT B0-18 ooon BODY INSPECTION INSPECT FRONT DOOR GLASS Check the following. If the conditions are not met, readjust the glass. (1 ) When you close the door with the glass fully closed, b-b, the a�a, c-c sections are in the same condition as shown in the illustration.
Page 970 80-19 FRONT DOOR BODY ADJUSTMENT FRONT DOOR ADJUSTMENT HINT: Since the centering bolt is used as the door side hinge bolt, the door hinge cannot be adjusted with it on. Substitute the bolt with washer for the centering bolt. Centering Bolt Standard Bolt Adjust the front door in forward/rearward and vertical directions.
Page 971 80-20 BODY FRONT DOOR Adjust the tower part of the glass inward/outward. Loosen the 2 nuts on the top of the window regula ( 1 ) tor. Insert the shim to adjust the glass position (inside/ outside). Shim thickness: 1.0 mm ( 0.039 in.) 2.0 mm (0.079 in.) Tighten the nuts.
Page 972 B0-21 FRONT DOO R BODY REASSEMBLY Reassembly is in the reverse order of disassembly (See page 80-1 1).
Page 973: Back Door
B0-22 � BODY BACK DOOR BACK DOOR COMPONENTS , Rear Wi p er Arm Bac k Door Stay w; Rear spoi l e r: Rear Spoi l e r Lower Stopper Door Pul l Handl e ��., StopPer Cushi o n Bac k Door Weat h erst n p Rear Deck Tri m Cover...
Page 974 80-23 BODY BACK DOOR DISASSEMBLY w/ Rear spoiler: REMOVE REAR SPOILER REMOVE DOOR PULL HANDLE REMOVE BACK DOOR TRIM BOARD Using a screwdriver, remove the back door trim board. HINT: Tape the screwdriver tip before use. REMOVE REAR WIPER ARM HINT: •...
Page 975 BQ-24 BODY BACK DOOR REMOVE CONTROL CABLE Disconnect the cable from the back door lock. Disconnect the cable from the outside back door handle. Remove the clamp and control cable. REMOVE BACK DOOR lOCK Remove the wire harness clamp from the door lock. Remove the 3 bolts and back door lock.
Page 976 BACK OOOH B0-25 BODY """-' " ' -- -- ADJUSTMENT ----- -- - - � -� � � - ADJUST DOOR IN LEFT/RIGHT AND VERTICAL DIRECTIONS ;:::}7 - -_ .. / - - - · Loosen the door side hinge bolts to adjust. Torque: 11 N·m (115 kgf .
Page 977 B0-26 BODY BACK DOOH REASSEMBLY Reassembly Is In the reverse order of disassembly (See page B0-23).
Page 978 B0-27 BODY DOOR BACK STAY BACK DOOR STAY REPLACEMENT REMOVE BACK DOOR STAY Remove the bolt and back door stay from the back door panel. HINT: While supporting the back door with your hand, remove the back door stay. Remove the 2 bolts and back door stay from the body. IF NECESSARY, REPLACE BACK DOOR STAY NOTICE: When handling the back door stay...
Page 979: Front Wiper And Washer
80-28 BODY FRONT WIPER AND WASI·IER FRONT WIPER AND WASHER COMPONENTS Wi p er Arm Wi p er Arm Head Cap � Washer Nozz l e Cowl Venti l a tor Lower Cowl Top Hood to Seal Wi p er Motor Wi p er Assembl y Link...
Page 980 B0-29 FRONT WIPER AND WASHI:-'11 BODY REMOVAL REMOVE WIPER ARMS Remove the 2 wiper arm head caps, 2 nuts and 2 wiper arms. REMOVE HOOD TO COWL TOP SEAL REMOVE COWL TOP VENTILATOR LOUVER Remove the 4 screws and 6 clips. Using a screwdriver, remove the cowl top ventilator lou- ver, then disconnect the washer hoses.
Page 981 B0-30 BODY FRONT WIPER AND WASHER INSPECTION 2 Jet nozzle: INSPECT WASHER NOZZLE While operating the washer check whether the point where the washer f!uid hits the windshield and the surge area are within the range indicated by the hatched line. A: 241.9 mm (9.524 in.) 219.6 mm (8.646 in.) C : 381.2 mm (15.008 in.)
Page 982 B0-<31 FRONT WIPER AND WASHER BODY ADJUSTMENT 2 - 2.5 mm ADJUST FRONT WASHER NOZZLE (0.079 - 0.098 in.) Using a tool like the one shown in the illustration, change the direction of the nozzle hole to adjust the point where washer fluid hits the windshield.
Page 983 B0-32 FRONT WIPER AND WASHER BODY INSTALLATION INSTALL WIPER MOTOR Install tile wiper motor with the 3 screws to the wiper link. Torque: 5.4 N.m (55 kgf . cm, 48 ln .. lbf) Align the matchmarks on the wiper link and wiper motor, then install the nut.
Page 984: Rear Wiper And Washer
B0-33 BODY REAR WIPER AND WASHER REAR WIPER AND WASHER COMPONENTS Rear spoi l e r: Rear Spoi l e r -- '" -'- --- - :: li;> ->: �- - � - Rear Wi p er Arm K1/5h...
Page 985 REAR WIPER AND WASHE;R B0--3 4 BODY REMOVAL Rear spoiler: REMOVE REAR SPOILER REMOVE DOOR PULL HANDLE �:-.: REMOVE BACK DOOR TRIM BOARD 1 0 CliR Using a screwdriver, remove the back door trim board. HINT: Tape the screwdriver tip before use. REMOVE REAR WIPER ARM REMOVE REAR WIPER MOTOR ( a )
Page 986 80-35 REAR WIPER AND WAS!lER BODY "'"" < > INSPECTION INSPECT WASHER NOZZLE While operating the washer, check if the upper point where the washer fluid hits the back door glass and surge area are within range indicated by the hatched line. A : 205 mm (8.07 in.) B: 105 mm (4.13 in.)
Page 987 B0-36 REAR WIPEH AND WASHER I NSTALLATION INSTALL REAR WASHER NOZZLE Install the rear wiper nozzle to the center step light with the screw. Ht2&94 Connect hte connector and wsher hose, then install the center stop light with the 2 nuts in order A, B as shown in the illustration.
Page 988 80-37 BODY REAR WIPER AND WASHER Adjust the installation position of the wiper arm at a point (c ) in defogger pattern. Tighten the nut. Torque: 5.4 N·m (55 kgf.cm, in.·lbl) wl Rear spoiler: REMOVE REAR SPOILER H12€<39...
Page 989 B0-38 BODY ROOF DRIP SIDE MOULDING ROOF DRIP SIDE MOULDING COMPONENTS Roof Dri p Si d e Moul d i n g Roof Si d e Rai l Weat h erstri p !112516...
Page 990 B0-39 BODY ROOF DRIP SIDE MOULDING REMOVAL REMOVE ROOF SIDE RAIL WEATHERSTRIP Using a clip remover, remove the clips. Remove the roof side rail weatherstrip. REMOVE ROOF DRIP SIDE MOULDING Remove the 8 screws and roof drip side moulding.
Page 991 B0-40 � BODY INSTALLATION CLEAN BODY MOUNTING SURFACE Using a heat Hght, heat the body mounting surface to 40 - 60 "C ( 1 04 - 1 40 "F). NOTICE: Do not heat the body excessively. Remove the adhesive tape from the body. Wipe off stains with cleaner.
Page 992 80-41 ROOF DRIP SIDf MOULDING BODY INSTALL ROOF SIDE RAIL WEATHERSTRIP Install the roof side rail weatherstrip with the clips as shown in the illustration. Butyl T ape H125l/ Clips ::�· 4...
Page 993 ROOF 80--4 2 IDE MOULDING BODY ROOF SIDE MOULDING COMPONENTS Roof Si d e Moul d i n g HI �500...
Page 994 B0--4 3 ROOF SIDE BODV MOULDING Adhesi v e Tape REMOVAL REMOVE ENDS OF MOUlDING Apply protective tape to the outer surface as shown in the illustration to keep the surface from being scratched. � C (68 - Using a heat light, heat the moulding to 20 - 30 86 "F).
Page 995 B0-44 B DV ROOF SIDE MOULDING INSTALLATION CLEAN CONTRACT SURFACE OF BODY Using a heat light, heat the moulding surface to 40 - 60 ·c (104 - 140 " F). NOTICE: Do not heat the body excessively. Using a knife, cut away any rough areas on the body. NOTICE: Be careful not to damage the body.
Page 996 80-45 MOULDING BODY ROOF SlOE APPLY ADHESIVE Cut off the tip of the cartridge nozzle. Part No. 08850-00801 or equivalent Adhesi v e HINT: After cutting off the tip, use all adhesive within the lime de- scribed in the table below. Temperature Tackhee time 35 ·c (95 ·F1...
Page 997 B0-46 BODY SIDE MUD GUARD SIDE M U D GUARD COMPONENTS �·\ : :9Ct i p s Side Mud Guard...
Page 998 B0-47 ·- BODY WINDSHIELD WINDSHIELD COMPONENTS w/ Sl i ding roof: Roof Sl i ding Openi n g Tri m � Sliding roof; Roof Headl i ning Map U ght Assembl y � Map Li g ht Lens SLJn Vi s or I n ner Rear View Mirror Wi n dshi e l d Gl a ss Stopper...
Page 999 80-48 BODY WINDSHIELD R EMOVAL :::: 2 Clips REMOVE FRONT PILLAR GARNISH Using a screwdriver, remove the front pillar garnish. HINT: Tape the screwdriver tip before use. Employ the same manner described above to the other side. Sliding roof: REMOVE MAP LIGHT ASSEMBLY Using a screwdriver, remove the lens.
Page 1000 B0-49 VVINOSHIELD BODY REMOVE WINOSHIELD OUTSIDE MOULDING Using a knife, cut off the moulding as shown in the Hlustra· tion. NOTICE: Do not damage the body with the knife. Remove the remaining moulding. REMOVE WINDSHIELD GLASS Insert a piano wire between body and glass and let it pass through.
Page 1001 B0-- 5 0 WINDSHIELD BODY INSTALLATION CLEAN A N D SHAPE CONTACT SURFACE O F BODY Using a knife, cut away any rough areas on the body. HINT: Leave the adhesive on the body as much as possible. Clean the cut surface of the adhesive with a shop rag sat urated Jn cleaner.
Page 1002 B0-51 WINDSHIELD BODY INSTALL NEW DAMS Install new dams with double--stick tape as shown in the illustra tion. A: 7.0 mm (0.276 in.) r- . --__ b - b POSITION GLASS Place the glass in the correct position. Check that all contacting parts of the glass rim are set per fectly even.
Page 1003 B0-52 WINDSHIELD BODY COAT CONTACT SURFACE OF GLASS WITH PRIMER " G " Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G as shown in the illustra tion. When the primer is coated wrongly to the area other than the specified, wipe it off with a clean shop rag before the primer dries.
Page 1004 B0-53 BODY WlNOSHIELD Correct insufficient or protruded adhesive agent using a spatula. HINT: Apply the adhesive agent up to the windshield glass edge. Install a new windshield moulding to the windshield glass before the adhesive agent hardens. HINT: Install the moulding, aligning the center of moulding with the center of body.
Page 1005 ()-M INSTALL INNER REAR VIEW MIRROR INSTALL SUN VISOR HOLDERS INSTALL SUN VISOR INSTALL MAP LIG HT ASSEMBLY INSTALL FRONT PILLAR GARNISH...
Page 1007 80-56 � BODY QUART !::' A WINDOW GLASS REMOVAL REMOVE DOOR SCUFF PLATE Using a screwdriver, remove the door scuff plate. HINT: Tape the screwdriver tip before use. REMOVE PACKAGE TRAY TRIM REMOVE REAR SEAT (See page 80 . .102) REMOVE LUGGAGE COMPARTMENT TRAY Using a clip remover, remove the 2 clips.
Page 1008 80-57 QUARTER WINDOW BODY GLASS REMOVE QUARTER TRIM PANEL Using a screwdriver, remove the quarter trim panel. HINT: Tape the screwdriver tip before use. REMOVE FRONT SEAT OUTER BELT SHOULDER AN CHOR Torque: 42 N-m (430 kgf-cm, 31ft-lbf) REMOVE ROOF SIDE INNER GARNISH Using a screwdriver, open the cap of coat hook.
Page 1009 80-58 BODY WINDOW GLASS REMOVE ROOF DRIP SIDE MOULDING Remove the 8 screws and root drip side moulding, REMOVE QUARTER WINDOW GLASS Using a knife, cut off the moulding as shown in the below (a ) illustration. NOTICE: Do not damage the body with the knife. Remove the remaining moulding.
Page 1010 B0-59 BODY QUARTER WINDOW GLASS Insert a piano wire between body and glass and let it pass - - - ----- through. Tie both wire ends to wooden blocks or similar objects. HINT: Apply protective tape to the outer surface to keep the surface from being scratched.
Page 1011 B0--6 0 � QUAATEfl. WINDOW GLASS BODY I NSTALLATION Adhesive CLEAN AND SHAPE CONTACT SURFACE OF BODY PANEL Uslng a knife, cut away any rough areas on the body. HINT: Leave the adhesive on the body as much as possible. Clean the cut surface of the adhesive with a shop rag sat- urated in cleaner.
Page 1012 B0--61 QUARTER WINDOW BODY GlASS COAT CONTACT SURFACE OF NEW GLASS WITH PRIMER "G" Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G as shown in the i!lustra� tion. When the primer is coated wrongly to the area other than the specified, wipe it off with a clean shop rag before the primer dries.
Page 1013 B0-62 GLASS BODY WINDOW QUARTER APPLY ADHESIVE Cut off the tip of the cartridge nozzle. Part No. 08850-00801 or equivalent. HINT: After cutting off the tip, use all adhesive within the time de scribed in the table below Temperature Tackflee time 35°C (95'f) minutes...
Page 1014 B0-6 3 QUARTER GLASS BODY WINDOW INSTALL NEW GLASS Install new glass to the body. Hold the glass in place securely with a protective tape or equivalent until the adhesive hardens. NOTICE: Take care not to drive the vehicle during the time described in the table below .
Page 1015 80-64 BACK OOOfl GLASS BODY BACK DOOR GLASS COMPONENTS No. 1 Dam • Back Door Grass -- -- Outside Lower Moul d i n g :;- _ _,. --- - " " Door Pull Handl e Rear spoil e r: Rear Spoi l e r - - - -- �...
Page 1016 80-j;S BODY BACK DOO R GLASS REMOVAL w/ Rear spoiler: REMOVE REAR SPOILER REMOVE REAR WIPER ARM REMOVE DOOR PULL HANDLE REMOVE BACK DOOR TRIM BOARD /·.: 10 Using a screwdriver, remove the back door trim board. HINT: Tape the screwdriver tip before use. Hl? % 0 REMOVE CENTER STOP LIGHT Remove the 2 nuts.
Page 1018 B0-6 7 BOO'.' BACK C -QOR GLASS COAT CONTACT SURFACE OF BODY WITH PRIMER Pr im er M " " Using a brush, coat Primer M to the exposed part of body on the vehicle side. ,<._ NOTICE: Allow 3 minutes or more to dry the primer coated sur 1>\ face.
Page 1019 80-08 BODY K OOORGlA Coat the glass with adhesive as shown In the illustration. Adhesive A: 12.0 mm (0.472 in.) B: 8.0 mm (0.315 in.) " INSTALL BACK DOOR GLASS Install the back door glass to the back door. HINT: Confirm that the dams is attached to the back door panel.
Page 1020: Sliding Roof
B0-69 BODY SUOING ROOF SLIDING ROOF ON-VEHICLE INSPECTION INSPECT SLIDING ROOF GLASS ALIGNMENT Start the engine and check the operation time of the slid- ing roof. Operation time: Approx. 6 sees. Check for abnormal noise or binding during operation. With the sliding roof fully closed, check for water leakage. Check for a difference in level between the sliding roof weatherstrip and roof panel.
Page 1021 B0-70 BODY SLIDING HOOF COMPONENTS Sunshade Trim _..- -- - No. 2 Sunshade Trim Drain Hose LH Roof Drip Channel Drive Cable Cable Guide Casing H12<Ht...
Page 1022 B0-71 BODY SUDINO ROOF REMOVAL REMOVE ROOF HEADLINING (See page B0-1l8) REMOVE SLIDING ROOF GLASS Remove the screws. Pull the glass upward to remove it. REMOVE DRIVE GEAR NOTICE: Remove the drive gear with the sliding roof fully closed. Remove the 2 screws and room light bracket. Disconnect the connector.
Page 1023 80-72 SLIO!NG ROOf BODY DISASSEMBLY REMOVE SUNSHADE STOPPERS Torque: 2.0 N.m (20 kgf.cm, 1 7 1n .. lbf) REMOVE NO. AND NO. 2 SUNSHADE TRIMS REMOVE FRONT HOUSING FRAME Remove the 6 screws and front housing frame as shown in the illustration.
Page 1024 B0- 73 BODY SliDING ROOF ADJUSTMENT ADJUST SLIDING ROOF GLASS FORWARD OR REARWARD Loosen the sHding roof glass installation bolts_ Adjust the slide roof glass forward or rearward. ADJUST SLIDING ROOF GLASS IN CLEARANCE (Difference In left and right clearance) When the front or rear alignment is not correct, remove the drive gear and sliding roof glass, then adjust the drive cables.
Page 1025 80-74 BODY SllDlNG ROOr REASSEMBLY Reassembly is i n the reverse order of disassembly {See page B0-72).
Page 1026 B0-75 SLIDING BODY ROOF INSTALLATION Installation is in the reverse order of removal (See page B0-88). HINT: After installing the sliding roof, sliding roof need to be re--ini!ialized. Refer to BE--84.
Page 1027: Instrument Panel
BQ-76 BODY INSTR MENT PANEL INSTRUMENT PANEL Pi l l a r Gar n i s h COMPONENTS Front Reinforcement Passenger Airbag Assembly Openi n g Brace Front Door Trim Cowl Side Trim Pl a t e Do or Sc uff Instrument Panel Panel Finish...
Page 1028 60-- 7 7 �- BODY INSTRUMENT PANEL Heater to Register Duct No. 1 Healer to Register Duct �-- - - <El m ® No. 1 Register Automatic light Console Sensor ®or® 1 Pin ®or({) No. 1 Pin � or ® ®or®...
Page 1029 80-78 BODY INSTRUMENT PANEL HINT: Screw shapes and sizes are indicated in the table below. The codes ("A" - �N") correspond to those indicated on the previous page. Size Shape Shape Size Size .� .. - � · 0 "' 8 0 ""...
Page 1030 8 0- 79 BODY INSTRUMENT PANEL REMOVAL REMOVE STEERING WHEEL PAD AND STEERING WHEEL (See page SR-11) REMOVE DOOR SCUFF PLATE REMOVE COWL SIDE TRIM REMOVE LOWER NO. 1 FINISH PANEL Remove the screws and hood lock release lever_ Remove the 2 bolts. Using a screwdriver.
Page 1031 80-aO BODY INSTRUMENT PANEL Using a clip remover, disengage the airbag connector clamp. Disconnect the connector, then remove the lower finish ( d) paneL DISCONNECT PASSENGER AIRBAG CONNECTOR Disconnect the passenger airbag connector. NOTICE: When disconnecting the airbag connector, take care not to damage the airbag wire harness.
Page 1032 BO-<l1 BODY INSTRUMENT PANEL REMOVE END FINISH PANELS Driver's side: Remove the 2 screws. Passenger's side: Remove the screws. Using a screwdriver, remove the end finish panels. HINT: Tape the screwdriver tip before use. REMOVE CENTER ClUSTER FINISH PANEL WITH HEATER CONTROl NAME PLATE Remove the heater control knobs.
Page 1033 BO-a2 INSTRUMENT PANEL BODY REMOVE INSTRUMENT PANEL Disconnect the connectors. Disengage the wire harness clamps. Remove the J/B set bolts and nuts. Using a screwdriver, remove the caps. HINT: Tape the screwdriver tip before usc. Remove the 2 bolts, nut, screws and instrument paneL REMOVE NO.
Page 1034 B0-83 BODY INSTHUMENT PANEL DISASSEMBLY REMOVE NO. 1 PINS REMOVE INSTRUMENT PANEL WIRE REMOVE DEFROSTER NOZZLE REMOVE NO. 1 HEATER TO REGISTER DUCT REMOVE NO. 2 HEATER TO REGISTER DUCT REMOVE NO. 3 HEATER TO REGISTER DUCT REMOVE AUTOMATIC LIGHT CONTROL SENSOR REMOVE LIGHT CONTROL RHEOSTAT REMOVE HAZARD SWITCH REMOVE WINDOW LOCK SWITCH...
Page 1035 B0-84 BODY INSTRUMENT PANEL 1 ,, !10>0 REASSEMBLY Reassembly is in the reverse order of disassembly (See page B0-83).
Page 1036 0-85 BODY INSTRUMENT PANEL INSTALLATION Installation is In the reverse order of removal (See page B0-79).
Page 1037 60-<16 ROOF !EADUNlNG BODY ROOF H EADLINING COMPONENTS Front Pillar Garnish Cowl Side Trim Rear Seat Cushion Front Pillar Garnish Hook Hl?633 Luggage Compartment Mat...
Page 1038 B0-8 7 ROOF HEADLINING aoov Sliding roof: Roof Headlining Front Roof Side Rail Pad Front Roof SideRaH Pad Sun Visor Sliding Roof Opening Trim �/ Ma p UghtCover Vi s or Hol d er Sun Visor '�...
Page 1039 B0-88 HEADLINING ROOF BODY REMOVAL REMOVE DOOR SCUFF PLATE Using a screwdriver, remove the door scuff plate. HINT: Tape the screwdriver tip before use. Employ the same manner described above to the other side. REMOVE PACKAGE TRAY TRIM REMOVE REAR SEAT (See page BQ-102) REMOVE LUGGAGE COMPARTMENT TRAY Using a clip remover, remove the 2 clips.
Page 1040 BO-S9 SOOY fiOOF HEAOLINING \, \ \, \ \ ___ REMOVE REAR SEAT OUTER BELT FLOOR AN CHORS HINT: At the time of installation, please refer to the following item. Out side _ __ ___ Install the rear seat outer belt floor anchor as shown in the il· .-Fron! - lustration.
Page 1041 80-90 BODY ROOF HEADLINING - - - - - - v :- - - - - - - - - w/o Sliding roof: - - - -- --- --- � REMOVE MAP LIGHT ASSEMBLY / , -- -' 5 ed' f' l! / Using a screwdriver, remove the lens.
Page 1042 80-91 BODY INSTALLATION Installation is in the reverse order of removal (See page 80-88).
Page 1043: Front Seat
BQ-9 2 BODY FRONf SEAT FRONT SEAT COMPONENTS Seatback Pad Seatback Frame Vertical adjuster: Seatback Cover w/ Side airbag assembly: Side Airbag Assembly + Hog Ring < Front Seat Cushion Inner Shield ---- Front Seat Inner Belt '<> X + Hog Ring Seat Cushion Cover Seat Cushion Pad �...
Page 1044 B0-93 � BODY FRONT SEAT REMOVAL REMOVE SEAT TRACK COVERS Using a screwdriver, remove the seat track covers. HINT: Tape the screwdriver tip before use. REMOVE FRONT SEAT Remove the 4 bolts. ( b) Disconnect the connectors. Remove the front seat. ( c) NOTICE: Be careful not to damage the body.
Page 1045 80- 94 BODY FRONT SEAT DISASSEMBLY w/ Vertical adjuster: REMOVE VERTICAL ADJUSTER KNOB Using a screwdriver, remove the dip and vertical adjuster knob. HINT: Tape the screwdriver tip before use. REMOVE RECLINING ADJUSTER RELEASE HANDLE REMOVE FRONT SEAT CUSHION SHIELD Remove the front seat cushion shield as shown in the illustra...
Page 1046 B0-95 FRONT SEAT BODY w/ Side airbag assembly: Remove the side airbag assembly as shown in the il lustration. CAUTION: Do not store the side airbag assembly with the airbag deployment side facing down. Never disassemble the side airbag assembly. Using a clip remover.
Page 1047 B0-96 FRONT SEAT BODY INSPECTION INSPECT RECLINING LOCK POSITION AND SLIDING LOCK POSITION SLIPPING OFF When reclining the seat, inspect that the outer and Inner recliners are released at the same time. H IN T: When the reclining lock position slips off, disassemble the seat to adjust the position. When sliding the seat, inspect that the outer and inner tracks are locked at the same time.
Page 1048 80-97 FRONT SEAT BODY REASSEMBLY ASSEMBLE OUTER TRACK AND INNER TRACK Assemble the outer track and inner track with a new E�ring. INSTALL SEAT TRACK HANDLE INSTALL RECLINING CONNECTING PIPE Adjust the reclining lock positions of the seat adjusters. Slide the seat adjusters to the most front position. Place the adjusters on a spacer to adjust the seat rail in parallel and install the connecting pipe.
Page 1049 B0-98 FHONT BODY SEAT INSTALL SEATBACK COVER Install the seatback cover to tho seat cushion pad wlth new hog rings. HIN T When installing the hog rings, take care to prevent wrinkles as much as possible. Install the seatback frame to the seatback cover with pad. w/ Side airbag assembly: Install the clips.
Page 1050 B0- 99 BODY FRONT SEAT INSTALL FRONT SEAT INNER SHIELD INSTALL FRONT SEAT CUSHION SHIELD INSTALL RECLINING ADJUSTER RELEASE HANDLE 1 1 . Vertical adjuster: INSTALL VERTICAL ADJUSTER KNOB...
Page 1051 B0-100 FRONT SEAT B DY I NSTALLATION INSTALL FRONT SEAT Mount the front seat to the vehicle. NOTICE: Be careful not to damage the body. Connect the connectors. Slide the front seat to the most front position. Tighten the bolts on the rear side temporarily, starting from the bolt on the inner side tighten them com pletely.
Page 1053 80- 102 BODY REAR SEAT REMOVAL REMOVE SEATBACK ASSEMBLY LH AND RH Release the seatback assembly LH and RH. ( a) Remove the 4 bolts. Torque: 18 N·m (185 kgf.cm, 1 3 ft.lbl) Remove the seatback assembly LH and RH. REMOVE SEAT CUSHION ASSEMBLY REMOVE SIDE HINGE LH AND RH Torque: 7.8 N·m (80 kgf .
Page 1054 B0-103 BODY REAR SEAr DISASSEMBLY REMOVE SEATBACK LOCK KNOBS REMOVE SEATBACK LOCK KNOB HOLDERS REMOVE SEATBACK FRAME Using a clip remover, remove the 5 clips. Turn over the seatback cover, then remove the hog rings. Remove the seatback frame from the seatback cover with pad. Employ the same manner described above to the other side.

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