Page 1 . yf. TOYOTA M O T O R C O R P O R A T I O N NOTE: Click on "Bookmarks" on the left side of this pdf for easy navigation.
Page 2 1985 TOYOTA TERCEL REPAIR MANUAL INTRODUCTION MAINTENANCE ENGINE MECHANICAL EMISSION CONTROL SYSTEM FUEL SYSTEM COOLING SYSTEM LUBRICATION SYSTEM IGNITION SYSTEM STARTING SYSTEM CHARGING SYSTEM CLUTCH MANUAL TRANSAXLE AUTOMATIC TRANSAXLE PROPELLER SHAFT FRONT AXLE AND SUSPENSIÓN REAR AXLE AND SUSPENSIÓN BRAKE SYSTEM...
Page 3: Table Of Contents
IN-1 INTRODUCTION Page HOW TO USE THIS MANUAL IN-2 IDENTIFICATION INFORMATION IN-4 GENERAL REPAIR INSTRUCTIONS IN-4 PRECAUTIONS FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER IN-6 VEHICLE LIFT AND SUPPORT LOCATIONS IN-7 ABBREVIATIONS USED IN THIS MANUAL IN-8...
Page 4: How To Use This Manual
IN-2 INTRODUCTION - How To Use This Manual HOW TO USE THIS MANUAL To assist in finding your way through the manual, the Section Title and major heading are given at the top of every page. An INDEX is provided on the first page of each section to guide you to the item to be repaired.
Page 5 INTRODUCTION - How To Use This Manual IN-3 The procedures are presented in a step-by-step format: • The photo or illustration shows what to do and whereto do • The task heading tells what to do. • The detailed text tells how to perform the task and gives other information such as speciÍFications and warnings.
Page 6: Identification Information
INTRODUCTION — Identification Information, General Repair Instructions IIM-4 IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the front cowl of the engine compartment This number is also stamped on top of the instrument panel and the driver's door post. ENGINE SERIAL NUMBER The engine serial number is stamped on the left side of the cylinder block.
Page 7 INTRODUCTION — General Repair Instructions lN-5 Precoated Parts Precoated parts are the bolts, nuts, etc. Which are coated with a seal lock adheasive at the factory. If a precoated part is tightened, loosened or caused to move in any way, it must be recoated with the specified adhesive.
Page 8 INTRODUCTION — General Repair Instructions IN-6 (d) When steam cieaning an engine, protect the HA, air filter, and VCV from water. Never use an impact wrench to remove or install ther- mo switches or thermo sensors. When checking continuity at the wire connector, insert the tester probé...
Page 9: Precautions For Vehicles Equipped With Catalytic Converter
INTRODUCTION — Precautions For Vehicles Equipped With Catalytic Converter IN-7 PRECAUTIONS FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER WARNING: If large amounts of unburned gasoline flow into the converter, it may overheat and créate a fire hazard. To prevent this, observe the following precautions and explain them to your customer.
Page 10: Vehicle Lift And Support Locations
IN-8 INTRODUCTION — Vehicle Lift and Support Locations VEHICLE LIFT AND SUPPORT LOCATIONS F W D 4 W D JACK POSITION Front Center of crossmember Rear Rear floor crossmember (FWD) Center of rear axie housing (4WD) PANTOGRAPH JACK POSITION SUPPORT POSITION Safety stand...
Page 11: Abbreviations Used In This Manual
INTRODUCTION — Abbreviations Used In This Manual IN-9 ABBREVIATIONS USED IN THIS MANUAL Auxiliary Acceleration Pump Air Conditioner Air Suction Air Switching Valve Automatic Transmission BTDC Before Top Dead Center CALIF. Vehicles Sold In California Choke Breaker Cold Mixture Heater EBCV Electronic Air Bleed Control Valve Electronic Control Unit...
Page 12 MA-1 MAINTENANCE Page MAINTENANCE SCHEDULE MA-2 MAINTENANCE OPERATIONS MA-4 GENERAL MAINTENANCE MA-19 GENERAL NOTES: • Every service item in the periodic maintenance list must be per- formed. • Failure to do even one item can cause the engine to run poorly and increase exhaust emissions.
Page 13 M A - 2 MAINTENANCE — Maintenance Schedule MAINTENANCE SCHEDULE Maintenance operations: A = Check and/or adjust if necessary; R = Replace, change or lubrícate; I = Inspect and correct or replace if necessary NORMAL CONDITION SCHEDULE Service interval Maintenance services beyond 6 0 , 0 0 0 miles (Odometer reading ( >r (96,000 km) should be performed at the same intervals...
Page 14 MAINTENANCE — Maintenance Schedule M A - 3 Follow the severe condition schedule if vehicle is operated mainly under one or more of the following severe conditions: • Pulling a trailer • Repeated short trips • Driving on rough and/or muddy roads •...
Page 15 M A - 4 MAlNTENANCE — Maintenance Operations MAINTENANCE OPERATIONS ENGINE Cold Engine Operations INSPECT V-RIBBED TYPE DRIVE BELT (ALTERNATOR) Visually check the belt for separation of the adhesive rubber above and below the core, core separation from the belt side, severed core, separation of the rib from the adhesive rubber, cracking or separation of the ribs, tom or w o m ribs or cracks in the inner ridges of the ribs.
Page 16 MAINTENANCE — Maintenance Operations MA-5 INSPECT AIR FILTER Visually check that the air cleaner element is not excessively dirty, damaged or oily. NOTE: Oiliness may indícate a stuck PCV valve. If necessary, replace the air cleaner element. Clean the element with compressed air. First blow from inside thoroughiy, then blow off the out- side of the element.
Page 17 M A - 6 MAINTENANCE — Maintenance Operations INSPECT IGNITION WIRING AND DISTRIBUTOR (IlA) Remove the distributor (HA) cap with wire. ^—^__^^^ V U ^ — Clean the distributor (HA) cap and wires with a clean cloth. \¿£ Visually inspect the wiring for cracks or damage. Q^SZffiA Visually inspect the cap for cracks, carbón tracks or wear.
Page 18 MAINTENANCE — Maintenance Operations M A - 7 10. REPLACE GASKET IN FUEL FILLER CAP Remove the oíd gasket (O-ring) from the fuel filler cap. Do not damage the cap. Install the new gasket by hand. Inspect the cap for damage or cracks. Install the cap and check the torque limiter.
Page 19 M A - 8 MAINTENANCE — Maintenance Operations 12. INSPECT EXHAUST PIPES AND MOUNTINGS Visually inspect the pipes, hangers and connections for severe corrosión, leaks or damage. 13. INSPECT CHOKE SYSTEM Remove the air cleaner. Clean the choke shaft and linkage. •...
Page 20 MAINTENANCE — Maintenance Operations MA-9 • Use a feeler gauge to measure between the valve stem and rocker arm. Loosen the lock nut and tum the adjusting screw to set the proper clearance. Hold the adjusting screw ¡n position and tighten the lock nut.
Page 21 MAINTENANCE — Maintenance Operations M A - 1 0 Set the idle speed by turning the IDLE SPEED ADJUSTING SCREW. Idle Speed Adjusting Screw Idle speed: 3A-C 550 rpm 4-speed M/T 5 or 6-speed M/T w / o 650 rpm Set to idle speed.
Page 22 MAINTENANCE — Maintenance Operations MA-11 Set the fast idle speed by turning the fast idle adjust- ing screw. Fast idle speed: 3,000 rpm NOTE: • Make adjustments with the engine cooling fan OFF. • Leave the tachometer connected for f urther adjustment. Idle Adjusting Screw Set to fast idle speed.
Page 23 M A - 1 2 MAINTENANCE — Maintenance Operations 18. CANADÁ 3A ENGINE ONLY: INSPECT THROTTLE POSITIONER (TP) SYSTEM Preparation • Air cleaner removed • EGR systems OFF Disconnect Disconnect the vacuum hose between the VTV and vacuum pipe at the vacuum pipe side and plug the vacuum pipe end.
Page 24 MAINTENANCE — Maintenance Operations M A - 1 3 BRAKES 19. INSPECT BRAKE LINE PIPES AND HOSES NOTE: Inspect in a well lighted área. Inspect the entire circumference and length of the brake hoses using a mir- ror as required. Turn the front wheels fully right or left before inspecting the front brake.
Page 25 M A - 1 4 MAINTENANCE — Maintenance Operations CHASSIS 22. INSPECT STEERING LINKAGE Check that the steering wheel freeplay. M á x i m u m steering w h e e l freeplay: 30 mm (1.18 in.) With the vehicle stopped and pointed straight ahead, rock the steering wheel gently back and forth with light finger pressure.
Page 26 MAINTENANCE — Maintenance Operations MA-15 26. CHECK TRANSMISSION (A/T OR M/T) AND DIFFERENTIAL OIL Visually check the transmission (A/T or M/T) and differen- tial for oil leakage. If leakage is found, check for cause and repair. 27. REPLACE MANUAL TRANSMISSION AND DIFFERENTIAL OIL A.
Page 27 MAINTENANCE — Maintenance Operations MA-16 B. For Wagón 4 W D with M/T Oil replacement procedure (See page MT-70) Oil grade: See page MA-15 Viscosity: See page MA-15 ¡ller Plug Oil capacity: 3.9 liters (4.1 US qts, 3.4 Imp. qts) Drain Plug / 7 L c Loosen about 7 or 8 turns MA0281...
Page 28 MAINTENANCE — Maintenance Operations M A - 1 7 Front Differential (With Automatic Transmission) Remove drain plug and drain the oil. rTv Filler Plug (Hypoid Gear Oil Only) Reinstall drain plug securely. Add new oil until it begins to run out of the filler hole. Front differential oil —...
Page 29 M A - 1 8 MAINTENANCE — Maintenance Operations • Front suspensión member-to-body mounting bolts and nuts. Torque: 9 0 0 kg-cm (65 ft-lb, 88 N-m) A ^ ^ s ^ Sr ^^^SS^íi MA0286 FINAL INSPECTION Check the operation of the body parts: •...
Page 30 MAINTENANCE — General Maintenance M A - 1 9 GENERAL MAINTENANCE WARNING LIGHTS AND BUZZERS These are the maintenance and inspection ¡tems which are considered to be the owner's respon- Check that all warning lights and buzzers func- sibility. They can be performed by the owner or he tion properly.
Page 31 M A - 2 0 MAINTENANCE — General Maintenance 28. BRAKE FLUID LEVELS 18. ACCELERATOR PEDAL Check that the brake fluid level is near the upper Check the pedal for smooth operation and level line on the see-through reservoir. uneven pedal effort or catching. 29.
Page 32 ENGINE MECHANICAL Page TROUBLESHOOTING EM-2 ENGINE TUNE-UP EM-4 IDLE HC/CO CONCENTRATION CHECK METHOD EM-5 COMPRESSION CHECK EM-6 I TIMING BELT EM-7 ' CYLINDER HEAD EM-14 CYLINDER BLOCK EM-36...
Page 33 EM-2 ENGINE MECHANICAL - Troubleshooting TROUBLESHOOTING Page Remedy Problem Possible cause Troubleshoot cooling system CO-2 Engine overheats Cooling system faulty IG-13 Reset timing Incorrect ignition timing ST-2 Troubleshoot starting system Starting system faulty Engine will not crank or cranks slowly Check fuel line Engine will not start/ No fuel supply to carburetor...
Page 34 ENGINE MECHANICAL - Troubleshooting EM-3 TROUBLESHOOTING (Cont'd) Problem Remedy Page Possible cause Troubleshoot cooling system CO-2 Engine overheats Compression low Check compression EM-6 EC-32 Feed back system problem Check air bleed feed back system Engine dieseling Carburetor problems Troubleshoot fuel system FU-3 (runs after ignition Incorrect ignition timing...
Page 35 EM-4 ENGINE MECHANICAL - Engine Tune-up ENGINE TUNE-UP INSPECT ENGINE COOLANT (See page CO-3) INSPECT ENGINE OIL LEVEL (See step 2 on page LU-2) INSPECT BATTERY SPECIFIC GRAVITY (See page CH-3) INSPECT AIR FILTER (See page MA-5) Clean or replace the air filter as necessary. INSPECT SPARK PLUGS (See page IG-4) Gap: 3A-C (ex.
Page 36 ENGINE MECHANICAL - Idle HC/CO Concentration Check Method EM-5 IDLE HC/CO CONCENTRATION CHECK METHOD MEASUREMENT NOTE: This check ¡s used only to determine whether or not the idle HC/CO complies with the state or city regulations. INSERT TESTING PROBÉ OF HC/CO METER INTO TAILPIPE AT LEAST 40 cm (1.3 ft) PRECHECK...
Page 37 EM-6 ENGINE MECHANICAL - Compression Check COMPRESSION CHECK NOTE: If there is lack of power, excessive oil consump- tion or poor fuel milage after engine tune up, measure the cylinder compression pressure. W A R M UP ENGINE REMOVE FOUR SPARK PLUGS MEASURE CYLINDER COMPRESSION PRESSURE Irísert a compression gauge into the spark plug hole.
Page 38 ENGINE MECHANICAL - Timing Belt EM-7 TIMING BELT COMPONENTS REMOVAL OF TIMING BELT REMOVE RADIATOR (See page CO-12) REMOVE AIR CLEANER ASSEMBLY (See page FU-7) REMOVE DRIVE BELTS REMOVE WATER PUMP PULLEY (w/ A/C) REMOVE IDLER PULLEY BRACKET TOGETHER WITH PULLEY REMOVE CYLINDER HEAD COVER Disconnect the PCV hose from the PCV valve.
Page 39 EM-8 ENGINE MECHANICAL - Timing Beit REMOVE CRANKSHAFT PULLEY Set No. 1 cylinder at TDC/compression. Turn the crankshaft pulley until the timing mark is aligned with the TDC mark. NOTE: Check that the rocker arms on the No. 1 cylinder are loóse.
Page 40 ENGINE MECHANICAL - Timing Belt EM-9 Loosen the ¡dler pulley mount bolt, push it left as far as it will go and then temporarily tighten it. Remove the belt. Remove the idler pulley mount bolt, pulley and retum spring. 1 1 . REMOVE CRANKSHAFT TIMING PULLEY 12.
Page 41 E M - 1 0 ENGINE MECHANICAL - Timing Belt If there is noticeable wear or cracks on the belt face, check to see if there are nicks on one side of the idler pulley lock. If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley.
Page 42 ENGINE MECHANICAL - Timing Beit EM-11 INSTALLATION OF TIMING BELT (See page EM-7) INSTALL CAMSHAFT TIMING PULLEY Align the knock pin of the camshaft with the pin hole of the camshaft, and install the camshaft with the píate washer and mount bolt. Secure the camshaft and tighten the mount bolt.
Page 43 EM-12 ENGINE MECHANICAL - Timing Belt CHECK VALVE TIMING AND TIMING BELT TENSIÓN Loosen the mount bolt of the timing belt idler pulley. Temporarily install the crankshaft pulley mount bolt and turn the crankshaft two revolutions from TDC to TDC. CAUTION: Always turn the crankshaft clockwise.
Page 44 ENGINE MECHANICAL - Timing Beit EM-13 If the measured valué is not within standard, readjust with the idler pulley. Remove the temporarily installed crankshaft pulley mount bolt. INSTALL CYLINDER HEAD COVER Install the half circular plug and cylinder head cover with gasket.
Page 45 E M - 1 4 E N G I N E M E C H A N I C A L - Cylinder Head CYLINDER HEAD COMPONENTS PCV Valve Seal Washer Cylinder Head Cover Intake and Exhaust Manifolds Timing Belt Upper Valve Keeper Cover and Gasket Valve Spring Retainer...
Page 46 ENGINE MECHANICAL - Cylinder Head EM-15 PREPARATION FOR REMOVAL DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY DRAIN ENGINE COOLANT (See page CO-3) DRAIN ENGINE OIL (See page LU-3) REMOVE AIR CLEANER ASSEMBLY (See page FU-7) DISCONNECT FOLLOWING HOSES: Heater inlet hose from cylinder head rear píate Brake booster hose from intake manifold Fuel hoses from fuel pump (w/ A/C)
Page 47 EM-16 ENGINE MECHANICAL - Cylinder Head REMOVAL OF CYLINDER HEAD (See page EM-14) REMOVE DRIVE BELTS REMOVE WATER PUMP PULLEY (w/ A/C) REMOVE A/C IDLER PULLEY BRACKET TOGETHER WITH IDLER PULLEY REMOVE ALTERNATOR UPPER BRACKET Remove the bolts, nut and altemator upper bracket from the cylinder head.
Page 48 ENGINE MECHANICAL - Cylinder Head EM-17 Loosen the idler puliey mount bolt and push the idler pulley toward the left as far as it will go and tem- porarily tighten it. Remove the timing belt from the camshaft timing pulley. NOTE: •...
Page 49 EM-18 ENGINE MECHANICAL - Cyünder Head DISASSEMBLY OF CYLINDER HEAD " \ (See page EM-14) REMOVE CARBURETOR (See page FU-7) REMOVE FUEL PUMP REMOVE INTAKE AND EXHAUST MANIFOLDS Remove the nuts and bolts. Remove the vacuum pipes with hoses, and remove EM0020 the manifolds.
Page 50 ENGINE MECHANICAL - Cylinder Head EM-19 Remove the each bearing cap bolt. f® ©^© ©$© ©*?© ©W ¥ ^ EM0974 Remove the camshaft, oil seal and camshaft bearing caps. NOTE: Arrange the camshaft bearing caps in correct order. Remove the HA drive gear mount bolt, píate washer and drive gear from the camshaft.
Page 51 ENGINE MECHANICAL - Cylinder Head EM-20 INSPECTION, CLEANING AND REPAIR OF CYLINDER HEAD COMPONENTS CLEAN TOP OF PISTONS AND TOP OF BLOCK Turn the crankshaft and bring each pistón to top dead center. Scrape the carbón from the pistón top. Remove all the gasket meterial from the top of the block.
Page 52 ENGINE MECHANICAL - Cylinder Head EM-21 INSPECT CYLINDER HEAD FLATNESS Using a precisión straight edge and feeler gauge, check that the head and manifold surfaces are not warped. /") \'—*-¿? \rv — EM0029 Measure warpage on all sides and diagonally as illustrated.
Page 53 EM-22 ENGINE MECHANICAL - Cylinder Head INSPECT VALVE STEMS AND VALVE GUIDE BUSHINGS Using a dial indicator or telescoping gauge, measure the inside diameter of the valve guide. Guide inside diameter: 7.01 - 7.03 mm (0.2760 - 0.2768 in.) Using a micrometer, measure the diameter of the valve stem.
Page 54 ENGINE MECHANICAL - Cylinder Head EM-23 Gradually heat the cylinder head to about 90°C (194°F). Using SST and a hammer, drive in a new valve guide until the snap ring contacts the cylinder head. SST 09201-60011 (h) Using a sharp 7 mm reamer, ream the valve guide to obtain specified oil clearance between the guide and new valve.
Page 55 EM-24 ENGINE MECHANICAL - Cylinder Head 1 1 . INSPECT AND CLEAN VALVE SEATS Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats. Check the valve seating position. Apply a thin coat of prussian blue (or white lead) to the valve face.
Page 56 ENGINE MECHANICAL - Cylinder Head EM-25 Using calipers, measure the free length of the vaive spring. h (\ Free height: 44.6 mm (1.756 in.) If the free height is not as specified, replace the valve spring. B1713 Using a spring tester, measure the tensión of the valve spring at the specified installed length.
Page 57 EM-26 ENGINE MECHANICAL - Cylinder Head Check the bearings for flaking or scoring. If bearings are damaged, replace the cylinder head and camshaft as a set. Measure the clearance of each camshaft journal. • Clean the bearing caps and camshaft journal. •...
Page 58 ENGINE MECHANICAL - Cylinder Head EM-27 Using calipers, measure the inside diameter of the rocker arm. Using a micrometer, measure the outside diameter of the shaft. Subtract the shaft diameter from the rocker arm diameter. Standard oil clearance: 0.010 - 0 . 0 4 8 mm ( 0 .
Page 59 ENGINE MECHANICAL - Cylinder Head EM-28 ASSEMBLY OF CYLINDER HEAD (See page EM-14) NOTE: Thoroughly clean all parts to be assembled. Before installing the parts, apply new engine oil to all sliding and rotating surfaces. Replace all gaskets and oil seáis with new parts. INSTALL VALVES Lubrícate and insert valves in the cylinder head valve guides.
Page 60 ENGINE MECHANICAL - Cylinder Head EM-29 Apply MP grease to a new oil seal. MP Grease Apply liquid sealer to the oil seal outside circum- Liquid Sealer ference. EM0050 EM0051 (g) Install the oil seal. NOTE: Be careful not to install the oil seal slantwise. (h) Install the No.1 bearing cap.
Page 61 EM-30 ENGINE MECHANICAL - Cylinder Head Secure the camshaft and tighten the HA dríve gear mount bolt. Torque: 300 kg-cm (22 ft-lb, 29 N-m) INSTALL CAMSHAFT TIMING PULLEY Install the camshaft timing pulley to the camshaft Secure the camshaft and tighten the camshaft timing pulley bolt Torque: 4 7 5 kg-cm (34 ft-lb, 47 N-m) NOTE:...
Page 62 ENGINE MECHANICAL - Cylinder Head EM-31 INSTALLATION OF CYLINDER HEAD INSTALL CYLINDER HEAD Instali a new cylinder head gasket. NOTE: Instali the gasket with the surface applied with sealer facing upward. (b) Gradually instali and tighten the head bolts in three passes and in the sequence shown.
Page 63 EM-32 ENGINE MECHANICAL - Cylinder Head Loosen the mount bolt of the timing belt idler pulley. CHECK VALVE TIMING AND TIMING BELT TENSIÓN Turn the crankshaft two revolutions from TDC to TDC. CAUTION: Always turn the crankshaft clockwise. Check the valve timing. Insure that each pulley aligns with the mark as shown in the figure.
Page 64 ENGINE MECHANICAL - Cylinder Head EM-33 (e) If the measured valué ¡s not within standard, readjust with the idler pulley. ADJUST VALVE CLEARANCE Set the No. 1 cylinder to TDC/compression. • Turn the crankshaft with a wrench to align the tim- ing marks at TDC.
Page 65 EM-34 ENGINE MECHANICAL - Cylinder Head INSTALL DISTRIBUTOR (See steps 1 to 3 on page IG-13) INSTALL SPARK PLUGS Install the four spark plugs and connect the high-tension cords. Torque: 180 kg-cm (13 ft-lb, 18 N-m) INSTALL TIMING BELT UPPER COVER 10.
Page 66 ENGINE MECHANICAL - Cylinder Head EM-35 19. CONNECT FOLLOWING HOSES: Heater inlet hose to cylinder head rear píate Brake booster hose Fuel hoses to fuel pump (w/ A/C) Vacuum hose of VSV for idle-up Emission control hoses (See system layout in the emission control section or the layout printed under the hood) (See pages EC-3 to 6) 20.
Page 67 EM-36 ENGINE MECHANICAL - Cylinder Block CYLINDER BLOCK COMPONENTS Pistón Ring (No. 1 Compression) .Pistón Ring (No. 2 Compression) Pistón Ring (Expander and Side Rail) -Connecting Rod and Pistón Rear Oil Seal Retainer 500 (36, 49) Rear End Píate Cylinder - Block M/T 800 (58, 78) 650 (47, 64)
Page 68 ENGINE MECHANICAL - Cylinder Block EM-37 REMOVAL OF ENGINE DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY REMOVE ENGINE HOOD DRAIN ENGINE OIL (See page LU-3) DRAIN ENGINE COOLANT (See page CO-3) REMOVE BATTERY AND BATTERY CARRIER REMOVE AIR CLEANER ASSEMBLY (See page FU-7) REMOVE RADIATOR (See page CO-12) (w/ A/C)
Page 69 EM-38 ENGINE MECHANICAL - Cylinder Block 14. DISCONNECT FOLLOWING HOSES: Heater Inlet and outlet hoses Fuel pump inlet and return hoses Brake booster hose from intake manifold. Vacuum hose of VSV for idle-up Emission control hoses NOTE: Before disconnecting the emission control hoses, use tags to indicatify how they should be reconnected.
Page 70 ENGINE MECHANICAL - Cylinder Block EM-39 26. WRAP BOTH DRIVE SHAFT BOOTS IN SHOP TOWEL |Vlll—\ "--^ ~ " ~ ~ ^ ^ - ^-~-~^___ 27. PLACE JACK UNDER TRANSAXLE 28. REMOVE TRANSAXLE LOWER MOUNT BOLTS NOTE: Hold the starter. 29.
Page 71 ENGINE MECHANICAL - Cylinder Block EM-40 PREPARATION FOR DISASSEMBLY (w/M/T) REMOVE CLUTCH COVER AND DISC (See page CL-8) (w/ M/T) REMOVE FLYWHEEL (w/ A/T) REMOVE DRIVE PLATE REMOVE REAR END PLATE INSTALL ENGINE STAND REMOVE ALTERNATOR REMOVE TIMING BELT (See steps 6 to 11 on pages EM-7 to 9) REMOVE CYLINDER HEAD (See step 12 on page EM-17) REMOVE WATER PUMP...
Page 72 ENGINE MECHANICAL - Cytinder Block EM-41 Remove the connecting rod cap nuts. Using a plastic-faced hammer, lightly tap the con- necting rod bolts and lift off the rod connecting cap. NOTE: Keep the lower bearing insert with the connecting ^ ^ I U 5SSE n S H ^ 7 "...
Page 73 EM-42 ENGINE MECHANICAL - Cylinder Block Remove the connecting rod cap. Measure the Plastigage at its widest point. Standard clearance: 0.020 - 0.051 mm (0.0008 - 0.0020 in.) Máximum clearance: 0.08 mm (0.0031 in.) If the clearance is greater than máximum, replace the bearing.
Page 74 ENGINE MECHANICAL - Cylinder Block EM-43 REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE Remove the main bearing cap bolts. Using the removed main bearing cap bolts, pry the cap fore-and-aft, and remove the main bearing caps, lower bearings and lower thrust washers (No. 3 main bearing cap only.) NOTE: •...
Page 75 EM-44 ENGINE MECHAN1CAL - Cylinder Block NOTE: If using a standard bearing, replace with one hav- ing the same number as marked on the main bearing cap. There are three sizes of standard bearings, marked 1, 2, 3 accordingly. Completely remove the Plastigage. No.1 ~ 5 EM0077 REMOVE CRANKSHAFT...
Page 76 ENGINE MECHANICAL - Cylinder Block EM-45 INSPECT CYLINDER BORE DIAMETER \ 0 Thrust Using a cylinder gauge, measure the cylinder bore diame- Front •®H Direction ter at positions A, B and C in the thrust and axial direc- tions. <D Axial Direction Máximum diameter j _ 1 0 m m...
Page 77 EM-46 ENGINE MECHANICAL - Cylinder Block DISCONNECT CONNECTING ROD FROM PISTÓN Using SST, press the pistón pin out of the pistón. SST 0 9 2 2 1 - 2 5 0 1 8 NOTE: • The pistón and pin are a matched set. •...
Page 78 ENGINE MECHANICAL - Cylinder Block EM-47 INSPECT CLEARANCE BETWEEN WALL OF PISTÓN RING GROOVE AND NEW PISTÓN RING Using a feeler gauge, measure the clearance between new pistón ring and the wall of the pistón ring groove. Ring groove clearance: No.1 0.04 - 0.08 mm (0.0016 - 0.0031 in.) No.2...
Page 79 EM-48 ENGINE MECHANICAL - Cyiinder Block • Check for twist. Máximum twist: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If the rod is bent or twisted, replace the connecting rod assembly. BORING OF CYLINDERS NOTE: • Bore all four cylinders for the oversized piston's outside diameter.
Page 80 ENGINE MECHANICAL - Cylinder Block EM-49 INSPECTION OF CRANKSHAFT INSPECT CRANKSHAFT FOR RUNOUT Place the crankshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Máximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is exceeds máximum, replace the crankshaft.
Page 81 EM-50 ENGINE MECHANICAL - Cylinder Block If rear oil seal retainer is installed in the cylinder block: Using a knife, cut off the oil seal lip. Using a screwdriver, pry out the oil seal. CAUTION: To prevent damage to the crankshaft, tape the screwdriver.
Page 82 ENGINE MECHANICAL - Cylinder Block EM-51 Position the pistón rings so that the ring ends are as f Front shown. Expander CAUTION: Do not align the end gaps. Side Rail INSTALL BEARINGS Install the bearings ¡n the connecting rods and rod caps. CAUTION: Install the bearing with the oil hole in the connecting rod.
Page 83 ENGINE MECHANICAL - Cylinder Block EM-52 INSTALL MAIN BEARING CAPS NOTE: Each main bearing cap is numbered. Install the upper thrust washers on the No. 3 main bearing cap with the oil grooves facing outward. Install the main bearing caps in numerical o.rder with J^QV r^Jd^L the arrows facing forward.
Page 84 ENGINE MECHANICAL - Cylinder Block EM-53 Check that the crankshaft turns smoothly. Check the connecting rod thrust clearance. (See page EM-40) INSTALL REAR OIL SEAL RETAINER Touque the six bolts. Torque: 95 kg-cm (82 ¡n.-lb, 9.3 N m ) POST ASSEMBLY INSTALL OIL PUMP, STRAINER AND OIL PAN (See steps 1 to 4 on pages LU-7 and 8) INSTALL WATER PUMP...
Page 85 EM-54 ENGINE MECHANICAL - Cylinder Block INSTALLATION OF ENGINE w/ A/T w / M / T APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE GREASE (NLGI NO. 2) OR MP GREASE (w/ M/T) Apply molybdenum disulphide lithium base grease to the input shaft spline. (b) Apply MP grease to the following parts: •...
Page 86 ENGINE MECHANICAL - Cylinder Block EM-55 INSTALL ENGINE MOUNT NUTS Torque: 4 5 0 kg-cm (33 ft-lb, 44 N-m) 10. CONNECT ENGINE MOUNTING ABSORBER 1 1 . INSTALL STIFFENER PLATES (See gape LU-8) Torque: 4 0 0 kg-cm (29 ft-lb, 39 N-m) 12.
Page 87 EM-56 ENGINE MECHANICAL - Cylinder Block 18. CONNECT FOLLOWING WIRES: Heater inlet and outlet hoses Fuel pump inlet and return hoses Brake booster hose Vacuum hose of VSV for ilde-up Emission control hose (See system layout in the emission control section or the layout printed under the hood.) ( w / A / T ) CONNECT THROTTLE LINKAGE FOR AUTOMATIC...
Page 88 ENGINE MECHANICAL - Cylinder Block EM-57 31. ADJUST DRIVE BELT (See page EM-13) 32. PERFORM ENGINE ADJUSTMENT (See page EM-35) 33. INSTALL AND ADJUST ENGINE HOOD (See page BO-2) 34. ROADTEST Perform a road test. 35. RECHECK COOLANT AND ENGINE OIL LEVEL...
Page 89 EC-1 EMISSION CONTROL SYSTEMS Page SYSTEM PURPOSE EC-2 COMPONENT LAYOUT AND SCHEMATIC DRAWING EC-3 POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM EC-7 FUEL EVAPORATIVE EMISSION CONTROL (EVAP) SYSTEM EC-9 THROTTLE POSITIONER (TP) SYSTEM EC-15 MIXTURE CONTROL (MC) SYSTEM EC-18 EXHAUST GAS RECIRCULATION (EGR) SYSTEM EC-20 AIR SUCTION (AS) SYSTEM...
Page 90: System Purpose
SYSTEM PURPOSE System Abbreviation Purpose * 3 A - C Calif 4-Spee Wagon A Positive crankcase ventilation Reduces blow-by gas (HC) • • • Fuel evaporative emission control EVAP Reduces evaporative HC • • • Throttie positioner Reduces HC and CO •...
Page 91: Component Layout And Schematic Drawing
E M I S S I O N C O N T R O L S Y S T E M S — C o m p o n e n t Layout and Schematic Drawing EC-3 COMPONENT LAYOUT AND SCHEMATIC DRAWING (Federal Vehicles) S (Reed Valve) (For A/T &...
Page 92 E C - 4 E M I S S I O N C O N T R O L S Y S T E M S — C o m p o n e n t Layout and Schematic Drawing COMPONENT LAYOUT AND SCHEMATIC DRAWING (California Vehicles and Canadá...
Page 93 E M I S S I O N C O N T R O L S Y S T E M S — Component Layout and Schematic Drawing EC-5 COMPONENT LAYOUT AND SCHEMATIC DRAWING (Canadá Vehicles Wagón M/T) HIC Valve Distributor TVSV Charcoal-...
Page 94 EC-6 EMISSION CONTROL SYSTEMS — Component Layout and Schematic Drawing COMPONENT LAYOUT AND SCHEMATIC DRAWING (Canadá Vehicles 3A Engine) Distributor Charcoal Canister HAI Diaphragom MC Valve HAI Diaphragm AS Valve TVSV J=ÜZ Check Valve Heat Control Valve...
Page 95: Positive Crankcase Ventilation (Pcv) System
EMISSION CONTROL SYSTEMS - Positive Crankcase Ventilation (PCV) System EC-7 POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM Air Cleaner PCV Valve •Blow-by Gas •Fresh Air EC1030 To reduce HC emission, crankcase blow-by gas (HC) is routed through the PCV valve to the intake manifold for combustión in the cylinders.
Page 96 EC-8 EMISSION CONTROL SYSTEMS - Positive Crankcase Ventilation (PCV) System INSPECTION OF PCV VALVE Cylinder Head Side Clean Hose REMOVE PCVVALVE ATTACH CLEAN HOSE TO PCV VALVE BLOW FROM CYLINDER HEAD SIDE Check that air passes through easily. CAUTION: Do not suck air through the valve. Petroleum substances inside the valve are harmful.
Page 97: Fuel Evaporative Emission Control (Evap) System
EMISSION CONTROL SYSTEMS - Fuel Evaporative Emission Control (EVAP) System EC-9 FUEL EVAPORATIVE EMISSION CONTROL (EVAP) SYSTEM (USA Vehicles and Canadá Vehicle 3A-C Engine 4-Speed & Wagón A/T) Computer (ON) Thermo Vacuum Switch (A) Switch Outer Vent Control Valve, Fuel Filler Cap / r u é...
Page 98 EC-10 EMISSION CONTROL SYSTEMS - Fuel Evaporative Emission Control (EVAP) System INSPECTION OF FUEL VAPOR LINES, FUEL TANK AND FUEL FILLER CAP Tí VISUALLY INSPECT LINES AND CONNECTIONS Look for loóse connections, sharp bends or damage. VISUALLY INSPECT FUEL TANK (For Wagón 4WD) Look for deformation, cracks or fuel leakage.
Page 99 EMISSION CONTROL SYSTEMS — Fuel Evaporative Emission Control (EVAP) System EC-11 INSPECTION OF OUTER VENT CONTROL IG S/W "OFF' VALVE OPEN CHECK OUTER VENT CONTROL VALVE OPERATION Disconnect the hoses from the valve. Check that the valve is open when the ignition switch is OFF.
Page 100 EC-12 EMISSION CONTROL SYSTEMS - Fuel Evaporative Emission Control (EVAP) System Disconnect the battery positive (+) terminal. Blow into the pipe and check that the VSV is closed. If a problem is found, repiace the VSV. nClosed oooooo EC0431 CHECK FOR SHORT CIRCUIT Ohmmeter Using an ohmmeter, check that there is no continuity be- tween the positive (+) terminal and the VSV body.
Page 101 EMISSION CONTROL SYSTEMS — Fuel Evaporative Emission Control (EVAP) System EC-13 FUEL EVAPORATIVE EMISSION CONTROL (EVAP) SYSTEM (Canadá Wagón M/T & 3A Engine) Fuel Filler Cap Charcoal Fuel Tank Canister Check Valve To reduce HC emission, evaporated fuel from the fuel tank is routed through the charcoal canister to the carburetor for combustión in the cylinders.
Page 102 EC-14 EMISSION CONTROL SYSTEMS - Fuel Evaporative Emission Control (EVAP) System INSPECTION OF CHARCOAL CANISTER REMOVE CHARCOAL CANISTER VISUALLY INSPECT CHARCOAL CANISTER Look for cracks or damage. CHECK FOR CLOGGED FILTER AND STUCK CHECK VALVE Purge Pipe—jj ft- Using low pressure compressed air, blow into the Tank Pipe tank pipe and check that air flows without resistance from the other pipes.
Page 103: Throttle Positioner (Tp) System
EMISSION CONTROL SYSTEMS - Throttie Positioner (TP) System EC-15 THROTTLE POSITIONER (TP) SYSTEM USA and Canadá 3A-C Engine, 4-Speed & Canadá Wagón M/T & 3A Engine Wagón A/T TP Diaphragm TP Diaphragm EC0438 Deceleration .VTV TP Diaphragm TPPort ECOA40 To reduce HC and CO emissions, the throttie positioner opens the throttie valve slightly more than at idle when decelerating.
Page 104 EC-16 EMISSION CONTROL SYSTEMS - Throttie Positioner (TP) System INSPECTION OF TP SYSTEM W A R M UP ENGINE CHECK IDLING SPEED AND ADJUST, IF NECESSARY DISCONNECT HOSE FROM TVSV M PORT AND PLUG M PORT This will shut off the choke opener and EGR systems. CHECK TP SETTING SPEED AND OPERATION OF VTV (For 3A-C Engine) Disconnect...
Page 105 EMISSION CONTROL SYSTEMS - Throttie Positioner (TP) System EC-17 Check that the engine rpm has increased to specification. TP setting speed: 1,700 rpm M/T 1,400 rpm A/T NOTE: Make adjustments with the engine cooling fan OFF. If not, turn the TP adjusting screw until the specified rpm is reached.
Page 106: Mixture Control (Mc) System
EC-18 EMISSION CONTROL SYSTEMS - Mixture Control (MC) System MIXTURE CONTROL (MC) SYSTEM (Canadá Wagón M/T & 3A Engine) 3A Engine Wagón M/T -Gas Filter MC Valve MC Valve EC0445 CONSTANT RPM SUDDEN DECELERATION, STEP (1) Chamber A Orífice Chamber B 'ntake Manifold To reduce HC and CO emissions, this system allows air to enter the intake manifold on sudden deceleration.
Page 107 EMISSION CONTROL SYSTEMS - Mixture Control (MC) System EC-19 INSPECTION OF MC SYSTEM MC Valve 1. START ENGINE Disconnect 2. CHECK MC VALVE Disconnect the vacuum hose from the MC valve. Place your fingers over the air inlet of the MC valve. No Vacuum Check that vacuum is not felt.
Page 108 EC-20 EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) System EXHAUST GAS RECIRCULATION (EGR) SYSTEM (USA Vehicles and Canadá 3A-C Engine 4-Speed & Wagón A/T) 5rü if/í EGR Valve ^ G a s Filter EGR Vacuum ^ C h e c k Valve Modulator ECO450 TVSV...
Page 109 EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) System EC-21 INSPECTION OF EGR SYSTEM CHECK AND CLEAN FILTERS IN EGR VACUUM MODULATOR Check the filter for contamination or damage. Using compressed air, clean the filters. PREPARATION EGR Vacuum Vacuum Gauge Modulator Disconnect the vacuum hose from the EGR valve and, using a 3-way unión, connect a vacuum gauge to it.
Page 110 EC-22 EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) System INSPECTION OF TVSV Below 7°C CHECK TVSV BY BLOWING AIR INTO PIPES F»> Drain the coolant from the radiator into a suitable container. Remove the TVSV. Cool the TVSV to below 7°C (45°F). Check that air flows from pipe J to pipe M and L, and flows from pipe K to pipe N.
Page 111 EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) System EC-23 INSPECTION OF EGR VALVE REMOVE EGR VALVE Check the valve for sticking and heavy carbón deposits. If a problem is found, replace it. REINSTALL EGR VALVE WITH NEW GASKET INSPECTION OF CHECK VALVE Orange Pipe CHECK VALVE BY BLOWING AIR INTO EACH PIPE Check that air flows from the orange pipe to the...
Page 112: Exhaust Gas Recirculation (Egr) System
EC-24 E M I S S I O N C O N T R O L S Y S T E M S - Exhaust Gas Recirculation (EGR) S y s t e m EXHAUST GAS RECIRCULATION (EGR) SYSTEM (Canadá Vehicles Wagón M/T & 3A Engine) TVSV .Check Valve EGR Port EGR R Port I...
Page 113 EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) System EC-25 INSPECTION OF EGR SYSTEM CHECK AND OLEAN FILTER IN EGR VACUUM MODULATOR Check the filters for contamination or damage. Using compressed air, clean the filters. PREPARATION Using a 3-way connector, connect a vacuum gauge to the hose between the EGR valve and vacuum pipe.
Page 114 EC-26 EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) System CHECK EGR VALVE i <Dl¡ AMrv Apply vacuum directly to the EGR valve with the engine idling. n K j — G a s Filter Check that the engine dies. Reconnect the vacuum hoses to the proper location.
Page 115: Air Suction (As) System
EMISSION CONTROL SYSTEMS - Air Suction (AS) System EC-27 AIR SUCTION (AS) SYSTEM (Federal Vehicles) AS Filter AS Reed Valve OC (Sweeper) EC0461 EC0459 Air is drawn through the air filter and air suction valve into the catalytic converter to burn the HC and CO. Pulsation in the AS Valve Fresh Air from AS Filter...
Page 116 EC-28 EMISSION CONTROL SYSTEMS - Air Suction (AS) System AIR SUCTION (AS) SYSTEM (California Vehicíes and Canadá 3A-C Engine 4 Speed & Wagón A/T) TP Port Shut Off Valve AS Valve EC0462 Shut Off Valve VCC^iXVXVNXWVXVXV^WY^ W W W W W V SWK^NC^i^^VCCC^NiMK««:^»NWAkKKmMAnN EC0463 Air is drawn though the air filter and air suction valve into exhaust manifold No.
Page 117 EMISSION CONTROL SYSTEMS - Air Suction (AS) System EC-29 AIR SUCTION (AS) SYSTEM (Canadá Wagón M/T & 3A Engine) Air is drawn through the air filter and air suction valve into the exhaust manifold to bum the remaining HC and CO. Pulsation in the Fresh Air from Air Filter AS Valve...
Page 118 EMISSION CONTROL SYSTEMS - Air Suction (AS) System EC-30 INSPECTION OF AS SYSTEM VISUALLY CHECK HOSES AND TUBES FOR CRACKS, KINKS, DAMAGE OR LOÓSE CONNECTIONS ¡3 CHECK AS VALVE (Fed. and Canadá 3A-C Engine, 4-Speed) Start the engine. V ^ J (b) With the engine idling, check that air is drawn into the inlet pipe.
Page 119 EMISSION CONTROL SYSTEMS - Air Suction (AS) System EC-31 INSPECTION OF AS VALVE (Calif. and Canadá 3A-C Engine 4-Speed & Wagón A/T) CHECK AS VALVE BY BLOWING AIR INTO PIPES Apply vacuum to the diaphragm. Check that air flows from the filter side to the outlet pipe.
Page 120: Carburetor Feedback System
E C - 3 2 E M I S S I O N C O N T R O L S Y S T E M S - Carburetor Feedback S y s t e m CARBURETOR FEEDBACK SYSTEM (USA Vehicles and Canadá 3A-C Engine 4-Speed & Wagón A/T) TP Port TVSV Gas Filter...
Page 121: (Twc-Oc) System
EMISSION CONTROL SYSTEMS - Carburetor Feedback System EC-33 INSPECTION OF CARBURETOR FEEDBACK Below 7°C SYSTEM EBCV 1. CHECK TVSV WITH COLD ENGINE The coolant temperature should be below 7°C (45°F). Vacuum S/W (B) Disconnect the vacuum hose from the vacuum switch (B).
Page 122 EMISSION CONTROL SYSTEMS - Carburetor Feedback System EC-34 INSPECTION OF EBCV CHECK FOR SHORT CIRCUIT Using an ohmmeter, check that there is no continuity be- tween the positive (+) terminal and the EBCV body. If there is continuity, replace the EBCV. CHECK FOR OPEN CIRCUIT Using an ohmmeter, measure the resistance between the positive (+) terminal and the other terminal as shown.
Page 123 EMISSION CONTROL SYSTEMS - Carburetor Feedback System EC-35 Start the engine and warm up the engine normal operating temperature. Using an ohmmeter, check for continuity between the switch terminal and the body. Vacuum Switch INSPECTION OF TVSV (See page EC-22) INSPECTION OF Ox SENSOR CHECK Ox SENSOR WITH VOLTMETER Warm up the engine to normal operating tem-...
Page 124 EC-36 EMISSION CONTROL SYSTEMS - Three-way and Oxidation Catalyst (TWC-OC) System THREE-WAY AND OXIDATION CATALYST (TWC-OC) SYSTEM (Federal Vehicles) AS Valve 0 0 * N* HJO Three-way Catalyst (TWC) Oxidation Catalyst (OC) (Monolithic) (Monolithic) To reduce HC, CO and NOx emissions, they are oxidized, reduced and converted to nitrogen (N ), carbón dioxide ) and water (H 0) by the catalyst.
Page 125 EMISSION CONTROL SYSTEMS - Three-way and Oxidation Catalyst (TWC-OC) System EC-37 INSPECTION OF HEAT INSULATOR Heat Insulator 1. CHECK HEAT INSULATOR FOR DAMAGE 2. CHECK FOR ADEOUATE CLEARANCE BETWEEN ///////////////////(^//////ty/m CATALYTIC CONVERTER AND HEAT INSULATOR EC0491 REPLACEMENT OF CATALYTIC CONVERTER Catalytic Converter REMOVE CATALYTIC CON VERTER Jack up the vehicle.
Page 126: Three-Way Catalyst (Twc) System
Three-Way Catalyst (TWC) System, EC-38 EMISSION CONTROL SYSTEMS - Oxidation Catalyst (OC) System THREE-WAY CATALYST (TWC) SYSTEM (California and Canadá 3A-C Engine 4-Speed & Wagón A/T) ^ v P HCCONOx tSmm^ CO, N, H,0 2 »*2 " 2 "\H¿! ¡/ Three-Way Catalyst (TWC) (Monolithic) EC2901...
Page 127 EMISSION CONTROL SYSTEMS - Oxidation Catalyst (OC) System EC-39 INSPECTION OF EXHAUST PIPE ASSEMBLY CHECK CONNECTIONS FOR LOOSENESS OR DAMAGE CHECK CLAMPS FOR WEAKNESS, CRACKS OR DAMAGE INSPECTION OF CATALYTIC CONVERTER CHECK FOR DENTS OR DAMAGE If any part of protector is damaged or dented to the extent "Y^"^ "...
Page 128: High Altitude Compensation (Hac) System
EC-40 EMISSION CONTROL SYSTEMS - High Altitude Compensation (HAC) System HIGH ALTITUDE COMPENSATION (HAC) SYSTEM (Federal Vehicles) Check Valve Gas Filter Air Bleed Port Slow Air Bleed Port At High Altitude Main Air Bleed Port Slow Air Bleed Port EBCV PortB HAC Valve (Open)
Page 129 EMISSION CONTROL SYSTEMS - High Altitude Compensation (HAC) System EC-41 INSPECTION OF HAC SYSTEM CHECK HAC VALVE Visualiy check and clean the air filter in the HAC valve. Air Filter Cover EC1060 (b) At high altitude [Above 1,198 m (3,929 ft)] With the engine idling, apply vacuum to the HAC valve lower port and blow into any one of the two ports on top of the HAC valve, and check that the...
Page 130 EMISSION CONTROL SYSTEMS - High Altitude Compensation (HAC) System EC-42 CHECK THE CHECK VALVE Disconnect the vacuum hose from the check valve at Check Valve the black side and plug the hose end. Check that the ignition timing remains stationary for more than one minute.
Page 131: Auxiliary Systems
E M I S S I O N CONTROL S Y S T E M S - Auxiliary Systems E C - 4 3 AUXILIARY SYSTEMS 1. Automatic Hot Air Intake (HAI) System HIC Valve HAI Diaphragm COLD Atmospheric Port (Closed) Atmospheric Port HIC Valve...
Page 132 EC-44 EMISSION CONTROL SYSTEMS - Auxiliary Systems INSPECTION OF HAI SYSTEM Diaphragm CHECK AIR CONTROL VALVE OPERATION Remove the air cleaner cover. Cool the HIC valve by blowing compressed air on it. Check that the air control valve closes the cool air Air Control Valve passage at idle.
Page 133: Hot Idle Compensation (Hic) System On Air Cleaner
E M I S S I O N C O N T R O L S Y S T E M S - Auxiliary Systems E C - 4 5 2. Hot Idle Compensation (HIC) System on Air Cleaner HIC Valve HAI Diaphragm EC0505 HOT (1)
Page 134 EC-46 EMISSION CONTROL SYSTEMS - Auxiliary Systems INSPECTION OF HIC SYSTEM Carburetor Side CHECK HIC VALVE BY BLOWING AIR Check that air flows from the HAI diaphragm side to the carburetor side while closing the atmospheric port. HAI Diaphragm Side Check that air does not flow from the carburetor side to the HAI diaphragm side.
Page 135: Automatic Choke System
E M I S S I O N C O N T R O L S Y S T E M S - Auxiliary Systems E C - 4 7 3. Automatic Choke System Bimetal Heater (Ceramics) Choke Valve COOL Heater (Ceramics) Bimetal .Generator...
Page 136 EMISSION CONTROL SYSTEMS - Auxilíary Systems EC-48 INSPECTION OF AUTOMATIC CHOKE SYSTEM START ENGINE SHORTLY AFTER, CHECK THAT CHOKE VALVE BEGINS TO OPEN AND CHOKE HOUSING IS HEATED INSPECTION OF HEATING COIL )hmmeter UNPLUG WIRING CONNECTOR MEASURE RESISTANCE WITH OHMMETER Resistance: 3A-C (ex.
Page 137: Choke Breaker (Cb) System
EMISSION CONTROL SYSTEMS - Auxiliary Systems EC-49 4. Choke Breaker (CB) System USA and Canadá 3A-C Engine 4-Speed & Canadá Wagón M/T & 3A Engine Wagón A/T CB Diaphragm CB Diaphragm TVSV TVSV Gas Filter EC0507 EC0508 COLD Diaphragm A Diaphragm A Diaphragm B Diaphragm B...
Page 138 EC-50 EMISSION CONTROL SYSTEMS - Auxiliary Systems INSPECTION OF CB SYSTEM Choke Breaker Diaphragm B CHECK TVSV WITH COLD ENGINE Start the engine. With the coolant temperature below 7°C (45°F), dis- connect the vacuum hose from choke breaker diaphragm B and check that the choke linkage does not move.
Page 139: Choke Opener System
EMISSION CONTROL SYSTEMS - Auxiliary Systems EC-51 5. Choke Opener System USA Vehicles and Canadá 3A-C Engine 4-Speed & Canadá Wagón M/T Wagón A/T Choke Opener Diaphragm Choke Opener Diaphragm TVSV -TVSV Gas Filter Gas Filter EC0509 EC0510 COLD TVSV TVSV Choke Opener Diaphragm...
Page 140 EMISSION CONTROL SYSTEMS - Auxiliary Systems EC-52 INSPECTION OF CHOKE OPENER SYSTEM Choke Opener Diaphragm ^ Disconnect 1. CHECK TVSV WITH COLD ENGINE Disconnect the vacuum hose from the choke opener diaphragm. (b) With the coolant temperature below 50°C (122°F), step down on the accelerator pedal and reléase it.
Page 141 EMISSION CONTROL SYSTEMS - Auxiliary Systems EC-53 INSPECTION OF TVSV (See page EC-22) INSPECTION OF DIAPHRAGM CHECK THAT CHOKE LINKAGE MOVES IN ACCORDANCE WITH APPLIED VACUUM If a probiem is found, replace the diaphragm.
Page 142: Auxiliary Acceleration Pump (Aap) System
E C - 5 4 E M I S S I O N C O N T R O L S Y S T E M S - Auxiiiary Systems 6. Auxiiiary Acceleration Pump (AAP) System Canadá Wagón M/T & 3A Engine USA and Canadá...
Page 143 EMISSION CONTROL SYSTEMS - Auxiliary Systems EC-55 INSPECTION OF AAP SYSTEM 1. CHECK SYSTEM WITH COLD ENGINE Check that the coolant temperature is below 50°C (122°F). Remove the air cleaner cover. Start the engine. Pinch the AAP hose, and stop the engine. Reléase the hose.
Page 144: Deceleration Fuel Cut System
E C - 5 6 E M I S S I O N C O N T R O L S Y S T E M S - Auxiliary S y s t e m s 7. Deceleration Fuel Cut System (USA and Canadá...
Page 145 EMISSION CONTROL SYSTEMS - Auxiliary Systems EC-57 INSPECTION OF DECELERATION FUEL CUT SYSTEM CHECK SYSTEM OPERATION Connect a tachometer to the engine. Start the engine. Disconnect Check that the engine runs normally. Disconnect the vacuum switch (A) connector. Vacuum S/W (A) Gradually increase engine speed to 2,300 rpm, and check that the engine rpm is fluctuating.
Page 146 E C - 5 8 E M I S S I O N CONTROL S Y S T E M S - Auxiliary Systems 7. Deceleration Fuel Cut System (Canadá Wagón M/T) 2nd Fuel Cut Solenoid Valve Vacuum Switch EC1078 2nd Fuel Cut Solenoid Valve (OFF) Vacuum Switch (OFF) •«Eli...
Page 147 EMISSION CONTROL SYSTEMS - Auxiliary Systems EC-59 INSPECTION OF SYSTEM CHECK SYSTEM OPERATION Start the engine. Disconnect the vacuum hose from the vacuum switch and plug the hose end. Check that you can feel a "click" from the 2nd fuel cut solenoid valve when the vacuum hose is con- nected and disconnected at idle.
Page 148: Heat Control Valve
E C - 6 0 E M I S S I O N C O N T R O L S Y S T E M S - Auxiliary Systems 8. Heat Control Valve COLD ENGINE HOT ENGINE From Bimetal Exhaust Ports Heat Control...
Page 149: Cold Mixture Heater (Cmh) System
EMISSION CONTROL SYSTEMS - Auxiliary Systems EC-61 9. Cold Mixture Heater (CMH) System (USA and Canadá 3A-C Engine 4-Speed & Wagón A/T) CMH Relay o*>o -cnu> ^\\v\v\^ ñ IG Switch Fuse ^v^\^^^^^ Computer Altemator L Terminal Thermo Switch EC1081 To reduce cold engine emission and improve driveability, the intake manifold is heated during cold engine operation to accelerate vaporization of the liquid fuel.
Page 150 EMISSION CONTROL SYSTEMS - Auxiliary Systems EC-62 CHECK CMH WITH W A R M ENGINE Warm up the engine to above 55°C (131°F). Check that there is no voltage. IF NO PROBLEM IS FOUND WITH THIS INSPECTION, THE SYSTEM IS OKAY; OTHERWISE INSPECT EACH PART ÉC4202 INSPECTION OF CMH MEASURE RESISTANCE...
Page 151 FU-1 FUEL SYSTEM Page PRECAUTIONS FU-2 TROUBLESHOOTING FU-2 ON-VEHICLE INSPECTION FU-3 CARBURETOR FU-4 FUEL PUMP FU-31 FUEL TANK AND LINES FU-33...
Page 152: Precautions
FU-2 FUEL SYSTEM — Precautions, Troubleshooting PRECAUTIONS Before working on the fuei system, disconnect the cable from the negative battery terminal. When working on the fuel system, keep away from possible fire hazards and do not smoke. Keep gasoline off rubber or leather parts. Work on only one component group at a time to avoid confusión between similar looking parts.
Page 153: On-Vehicle Inspection
FUEL SYSTEM - On-Vehicle Inspection FU-3 ON-VEHICLE INSPECTION REMOVE AIR CLEANER (See page FU-7) CHECK CARBURETOR AND LINKAGE Check that the various set screws, plugs and unión bolts are tight and correctly installed. Check the linkage for excessive wear and missing snap rings.
Page 154: Carburetor
F U - 4 FUEL S Y S T E M - Carburetor CARBURETOR CARBURETOR CIRCUIT Power Pistón Primary 2nd Fuel Cut Main Nozzle 1 st Fuel Cut Solenoid Valve (3A-C) Solenoid Valve Pump Jet Needle Valve Power Valve Power Jet Primary Main Jet MAS Plug Idle Mixture Adjusting Screw...
Page 155 FUEL S Y S T E M - Carburetor F U - 5 COMPONENTS 3A-C Fuel Pipe Air Horn Choke Opener Link Choke Breaker Diaphragm Pump Plunger Coil Housing • Air Horn Gasket Needle Val ve Seat Needle Valve Power Pistón Choke Breaker Diaphragm Choke Valve Choke Valve Shaft...
Page 156 FU-6 FUEL SYSTEM - Carburetor COMPONENTS (Cont'd) Secondary Slow Jet Small Ventury Power Valve with Jet Primary Pump Discharge Weight Small Ventury -Pump Plunger • Fast Idle Cam .Choke Opener (3A-C) and TP Solenoid Valve (3A-C) + Gasket • Gasket Q ^ Primary Main Jet Throttie Back Spring Secondary Throttie Diaphragm...
Page 157 FUEL SYSTEM - Carburetor FU-7 REMOVAL OF CARBURETOR PCV Hose REMOVE AIR CLEAÑER ASSEMBLY Disconnect the air intake hoses. Disconnect the emission control following hoses from the air cleaner: HAI hose (Calf. and Canadá 3A-C) ASV hose TT FU0387 (ex. Fed.) AS hose PCV hose Remove the two mount bolts and batterfly nut.
Page 158 FU-8 FUEL SYSTEM - Carburetor DISASSEMBLY OF CARBURETOR (See pages FU-5 and 6) NOTE: To conform with regulations, the idle mixture adjusting screw is adjusted and plugged with a steei plug by the manufacturer. Normally, this plug should not be removed.
Page 159 FUEL SYSTEM - Carburetor FU-9 REMOVE POWER PISTÓN AND PUMP PLUNGER Remove the power pistón retainer, power pistón and spring. Pulí out the pump plunger and remove the boot. (3A) DISASSEMBLE CHOKE VALVE Remove the three screws, coil housing and gasket. NOTE: Remove the following parts only if it is necessary to replace the choke shaft or choke breaker.
Page 160 FU-10 FUEL SYSTEM - Carburetor Disassembly of Carburetor Body (See page FU-6) REMOVE CHOKE OPENER (3A-C) AND THROTTLE POSITIONER (TP) Disconnect the opener and TP links. Remove the two bolts. REMOVE CHECK BALL FOR ACCELERATION Remove the stopper gasket, pump discharge weight, long spring and discharge large ball.
Page 161 FUEL SYSTEM - Carburetor FU-11 REMOVE SMALL VENTURIES IF NECESSARY, REMOVE SIGHT GLASS REMOVE THROTTLE LEVER AND FAST IDLE CAM ASSEMBLY Remove the throttle return spring. Remove the throttle back spring. Remove the nut and throttle lever. Remove the bolt and fast idle cam. REMOVE SECONDARY THROTTLE VALVE DIAPHRAGM Disconnect the link.
Page 162 FU-12 FUEL SYSTEM - Carburetor GENERAL CLEANING PROCEDURE CLEAN DISASSEMBLED PARTS BEFORE INSPECTION Wash and clean the cast parts with a soft brush ¡n carburetor cleaner. Clean off any carbón around the throttle valve. Wash the other parts thoroughly in carburetor cleaner.
Page 163 FUEL SYSTEM - Carburetor FU-13 (3A-C) INSPECT SECOND FUEL CUT SOLENOID VALVE Connect the solenoid valve body and terminal to the battery termináis. You should feel a click from the solenoid valve when the battery power is connected and disconnected. If the solenoid valve is not operating properly, replace it.
Page 164 FUEL SYSTEM - Carburetor FU-14 INSTALL SIGHT GLASS Install a new O-ring, the sight glass and retainer with the two screws. INSTALL SMALL VENTURIES Install a new gasket and the primary small ventury with the two screws. Install a new gasket and the secondary small ventury with the two screws.
Page 165 FUEL SYSTEM - Carburetor FU-15 INSTALL CHECK BALLS FOR ACCELERATION Instad the discharge large ball, long spring, pump dis- charge weight and stopper gasket. Using tweezers, insert the plunger small ball and retainer. INSTALL CHOKE OPENER (3A-C) AND THROTTLE POSITIONER Assembly of Air Horn (See page FU-5) (3A)
Page 166 FU-16 FUEL SYSTEM - Carburetor (3A) INSTALL COIL HOUSING Install a new gasket. Align the bi-metal spring and the choke lever, and install the coil housing. Align the scale center of the thermostat case with the coil housing line, and install the three screws. Check the choke valve action.
Page 167 FUEL SYSTEM - Carburetor FU-17 Adjust by bending the portion of the float lip marked (A). Lift up the float and, using SST, check the clearance between the needle valve plunger and float lip. SST 0 9 2 4 0 - 0 0 0 1 4 \Ío Float level (lowered position): 1.67 —...
Page 168 FU-18 FUEL SYSTEM - Carburetor INSTALL NEEDLE VALVE AND FLOAT Install the needle valve into the seat. Insert the float lip between the plunger and clip, and install the float with the pivot pin. ASSEMBLE AIR HORN AND BODY Install the solenoid valves with new gaskets into the car- buretor body.
Page 169 FUEL SYSTEM - Carburetor FU-19 14. CONNECT FOLLOWING LINKS: Choke link Pump connecting link 15. (3A) INSTALL VACUUM HOSE Insta 11 the vacuum hoses and the jet. 16. INSTALL FUEL PIPE Instad the fuel pipe with new gaskets and the unión bolt. Torque the unión bolt.
Page 170 FUEL SYSTEM - Carburetor FU-20 Adjust by bending the secondary throttie stop lever. Secondary Throttie Stop Lver /^^r^^fcÍ^^«/ /"" W_>\ ~ FU0065 CHECK AND ADJUST KICK-UP SETTING With the primary throttie valve fully opened, check the clearance between the secondary throttie valve and body.
Page 171 FUEL SYSTEM - Carburetor FU-21 (3A) SET AUTOMATIC CHOKE Set the coil housing line so that ¡t is aligned with the scale center line of the thermostat case. NOTE: The choke valve becomes fully closed when the atmospherlc temperature reaches 30°C (86°F). (b) Depending on vehicle operating conditions, turn the coil housing and adjust the engine starting mixture.
Page 172 FU-22 FUEL SYSTEM - Carburetor Adjust by bending the unloader lever. (3A-C) CHECK AND ADJUST CHOKE OPENER Set the fast idle cam. While holding the throttie slightiy open, push the choke valve closed, and hold it closed as you reléase the throttie valve.
Page 173 FUEL SYSTEM - Carburetor FU-23 Apply vacuum to choke breaker diaphragm A. SST- Check the choke valve angle. Standard angle: s^l^ ls§ ( ji 3A-C (ex. Canadá Wagón M/T) 38° from horizontal Others 39° from horizontal 7Ü\ Jfjp? Vacuum FU0079 Adjust by bending the relief lever.
Page 174 FU-24 FUEL SYSTEM - Carburetor INSTALLATION OF CARBURETOR (See page FU-5) INSTALL CARBURETOR Place the insulator in the intake manifold. Valve Place the carburetor in position. Install the EGR vacuum modulator bracket. Connect the EGR vacuum modulator hose (1). Clamp the cold mixture heater wire. Install the carburetor mount nuts.
Page 175 FUEL SYSTEM - Carburetor FU-25 ADJUSTMENT OF CARBURETOR (ON-VEHICLE) INITIAL CONDITIONS Air cleaner installed Normal operating coolant temperature Choke fully open All accessories switched off All vacuum lines connected Ignition timing set correctly Transmission in N range Front wheels straight ahead position for PS Fuel level should be about even with the correct level in the sight glass.
Page 176 FU EL SYSTEM - Carburetor FU-26 ADJUST FAST IDLE SPEED Plug s T ^ - A S V H o s e Stop the engine and remove the air cleaner. HIC Hose # / cañada 3A Plug the AS hose (for California and Canadá) to pre- and ex.
Page 177 FUEL SYSTEM - Carburetor FU-27 Start the engine and adjust the TP setting speed by turning the TP ADJUSTING SCREW. TP Adjusting Screw TP setting speed: 3A-C 1,400 rpm 1,400 rpm A/T 1,700 rpm M/T FU0091 Reconnect the vacuum hose to the TP diaphragm. Check that the engine speed returns to idle.
Page 178 FU-28 FUEL SYSTEM - Carburetor IDLE MIXTURE ADJUSTMENT OF IDLE MIXTURE NOTE: • To conform with regulations, the idle mixture adjusting screw is adjusted and plugged with a steel plug by manufacturer. Normally, this plug should not be removed. • When troubleshooting rough idle, check all other possi- ble causes before attempting to adjust the idle mixture (see TROUBLESHOOTING on page FU-2).
Page 179 FUEL SYSTEM - Carburetor FU-29 (e) Use a 7.5 mm <f> (0.295 in. <f>) drill to forcé the plug off. MAS Plug FU0097 INSPECT MIXTURE ADJUSTING SCREW Blow off any steel partióles with compressed air. Remove the screw and inspect it. If the drill has gnawed into the screw top or if the tapered portion is damaged, replace the screw.
Page 180 FU-30 FUEL SYSTEM - Carburetor Set to 650 rpm by screwing in the IDLE MIXTURE ADJUSTING SCREW. NOTE: Make adjustment with the cooling fan OFF. This is the Lean Drop Method for setting idle speed and mixture. Idle Mixture Adjusting Screw FU0102 Set to the idle speed by screwing in the IDLE SPEED ADJUSTING SCREW.
Page 181: Fuel Pump
FUEL SYSTEM - Fuel Pump FU-31 FUEL PUMP REMOVAL OF FUEL PUMP DISCONNECT FUEL HOSES FROM FUEL PUMP REMOVE FUEL PUMP Remove two bolts, fuel pump and gasket. INSPECTION OF FUEL PUMP (Airtight Test) Cutaway View Return Pipe Inlet Pipe Check Valve- Outlet Valve- Prechecks...
Page 182 FUEL SYSTEM - Fuel Pump FU-32 CHECK OUTLET VALVE Block off the inlet pipe with your finger and check that the Inlet Pipe arm locks (does not opérate with same amount of forcé used in the precheck above). NOTE: Never use more forcé than that used in the precheck.
Page 183: Fuel Tank And Lines
FUEL SYSTEM - Fuel Tank and Lines FU-33 FUEL TANK AND LINES COMPONENTS Sedan and Wagón FWD Separator Fuel Sender Gauge Fuel Tank Cap Carburetor Fuel Hose OVCV Fuel Filter 35 (30 in.-lb, 3.4) Tube Protector ** 1 5 Section Tube Filter ***& Rubber Protecotr >, Charcoal Canister Gasket...
Page 184 FU-34 FUEL SYSTEM - Fuel Tank and Lines PRECAUTIONS Always use new gaskets when replacing the fuel tank or component parts. When re-installing, be sure to include the rubber pro- tectors on the upper surfaces of the fuel tank and tank band.
Page 185 CO-1 COOLING SYSTEM Page TROUBLESHOOTING CO-2 CHECK AND REPLACEMENT OF ENGINE COOLANT CO-3 WATER PUMP CO-4 THERMOSTAT CO-11 RADIATOR CO-12 ELECTRIC COOLING FAN CO-18...
Page 186: Troubleshooting
CO-2 COOLING SYSTEM - Troubleshooting TROUBLESHOOTING Problem Possible cause Remedy Page EM-13 Engine overheats Water pump drive belt loóse or missing Adjust or replace belt Dirt, leaves or insects on radiator Clean radiator Hoses, water pump, thermostat housing, Repair as necessary radiator, heater, core plugs or head gasket leakage Thermostat faulty...
Page 187: Check And Replacement Of Engine Coolant
COOLING SYSTEM — Check and Replacement of Engine Coolant CO-3 CHECK AND REPLACEMENT OF ENGINE COOLANT CHECK ENGINE COOLANT LEVEL AT RESERVE TANK FULL The coolant level should be between the "LOW" and "FULL" lines. If low, check for leaks and add coolant up to the "FULL" line.
Page 188: Water Pump
CO-4 COOLING SYSTEM - Water Pump WATER PUMP COMPONENTS Bearing Water Pump Body Water Pump Pulley Pulley Seat • Gasket • O-Ring Rotor • Seal Set Water Pump Suction Cover • Gasket +: Non-reusable part REMOVAL OF WATER PUMP DRAIN ENGINE COOLANT (See page CO-3) REMOVE RADIATOR (See page CO-12) 1 —...
Page 189 COOLING SYSTEM - Water Pump CO-5 REMOVE WATER INLET HOUSING AND THERMOSTAT REMOVE TIMING BELT UPPER COVER DISCONNECT HEATER OUTLET HOSE FROM OUTLET PIPE REMOVE HEATER OUTLET PIPE MOUNT BOLT Heater Outlet Pipe Mount Bolt REMOVE OIL LEVEL GAUGE AND GUIDE Remove the oil level gauge.
Page 190 CO-6 COOLING SYSTEM - Water Pump DISASSEMBLY OF WATER PUMP (See page CO-4) REMOVE WATER PUMP SUCTION COVER Using a screwdriver, pry off the water pump suction cover. REMOVE PULLEY SEAT Usíng a press and SST, remove the pulley seat from the water pump bearing shaft.
Page 191 COOLING SYSTEM - Water Pump CO-7 ASSEMBLY OF WATER PUMP (See page CO-4) NOTE: Always assemble the water pump with a new seal set. INSTALL WATER PUMP BEARING Gradually heat the water pump body to about 85°C (185°F). (b) Using a press and SST, install the water pump bear- ing into the water pump body.
Page 192 CO-8 COOLING SYSTEM - Water Pump INSTALL ROTOR (a) Install a new packing and seat into the rotor. (b) Apply a líttle engine oil to the seal and rotor contact surface. Using a press, install the rotor on the water pump bearing shaft.
Page 193 COOLING SYSTEM - Water Pump CO-9 INSTALLATION OF WATER PUMP INSTALL WATER PUMP Instali the heater outlet pipe together with a new gasket to the water pump with the two nuts. Instali a new O-ring to the block and instali the pump with the three bolts.
Page 194 CO-10 COOLING SYSTEM - Water Pump Install the water outlet together with the water by- pass pipe. Install the two mount bolts. INSTALL WATER PUMP PULLEY Place drive belts on the water pump pulley and install the water pump pulley with the bolts. INSTALL RADIATOR (See page CO-17) 10.
Page 195: Thermostat
COOLING SYSTEM - Thermostat CO-11 THERMOSTAT T^=S" REMOVAL OF THERMOSTAT DRAIN ENGINE COOLANT (See page CO-3) DISCONNECT RADIATOR OUTLET HOSE REMOVE WATER INLET HOUSING AND ^ ( @ THERMOSTAT Remove the two nuts, water inlet housing, thermostat and C00006 gasket. INSPECTION OF THERMOSTAT NOTE: The thermostat ¡s numbered according to the...
Page 196: Radiator
COOLING SYSTEM - Radiator CO-12 RADIATOR CLEANING OF RADIATOR Using water or steam cleaner, remove mud and dust from radiator core. CAUTION: If using high pressure type cleaner, be careful not deform fin of the radiator core. For exam- ple, keep distance more than 40 - 50 cm (15.75 — 19.59 in.) between the radiator core and cleaner nozzle when cleaner nozzle pressure is 30 - 35 kg/cm (427 - 498 psi, 2,942 - 3,432 kPa).
Page 197 COOLING SYSTEM - Radiator CO-13 COMPONENTS Upper Tank- • Tank Plate- • O-Ring ^Core Píate Core Assembly- -Core- Core Píate- • 0-R¡ng • Tank Píate - (w/ A/T) Oil Cooler Lower Tank" • : Non-reusable parts CO0099 DISASSEMBLY OF RADIATOR IF NECESSARY, REMOVE TEMPERATURE SWITCH FROM LOWER TANK REMOVE TANK PLATE...
Page 198 CO-14 COOLING SYSTEM - Radiator (b) Pulí the tank plates outward. REMOVE TANK AND O-RING ¡nrj^^rrrrytT] Pulí the tank upward. Tank- (b) Remove the O-ring. O-Ring Core Píate £ Core ASSEMBLY OF RADIATOR (See page CO-13) INSPECT CORE PLATE Core Píate Core Píate Inspect the core píate for damage.
Page 199 COOLING SYSTEM - Radiator CO-15 INSTALL TANK PLATES Inserí new tank plates from both ends in the direction of the arrows. Inserí to where the portions shown with an asterisk make conract with the tank. STAKE CLAWS OF TANK PLATES Set the punch of SST to "LOW".
Page 200 CO-16 COOLING SYSTEM - Radiator Do not stake the áreas protruding around the pipes. The points shown in the illustration cahnot be staked with the SST. Use a pliers or such and be careful not to damage the core píate. t f o n a CO0O45 B3640...
Page 201 COOLING SYSTEM - Radiator CO-17 INSTALLATION OF RADIATOR INSTALL RADIATOR Place the radiator in installed position and install the two supports with two bolts. NOTE: After installation, confirm that the rubber cushion (A) of the support is not depressed. CONNECT TWO RADIATOR HOSES CONNECT COOLANT RESERVOIR TUBE INSTALL BOND CABLE Temperature Switch...
Page 202: Electric Cooling Fan
CO-18 COOLING SYSTEM - Electric Cooling Fan ELECTRIC COOLING FAN COMPONENTS USA (Sedan w/ A/T and Wagón) CANADÁ (Sedan w/ A/C and Wagón w/ A/T or A/C) © Bushing Fan Motor á Fan Shroud C00092 ON-VEHICLE INSPECTION Low Temperature [ below 83°C (181°F)] TURN IGNITION SWITCH "...
Page 203 COOLING SYSTEM - Electric Cooling Fan CO-19 INSPECTION OF ELECTRIC COOLING FAN INSPECT TEMPERATURE SWITCH LOCATION: In the radiator lower tank Using an ohmmeter, check that there is no continuity when the coolant is above 90°C (194°F). Check that there is continuity when the coolant tem- perature ¡s below 83°C (181°F).
Page 204 CO-20 COOLING SYSTEM - Electric Cooling Fan INSPECT IGNITION M A I N RELAY LOCATION: In the engine compartment relay box. Inspect Relay Continuity and Operation (See Taillight Control Relay on page BE-12) ü* BEOO08 INSPECT FAN MOTOR Connect the battery and ammeter to the fan motor connector.
Page 205 COOLING SYSTEM - Electric Cooling Fan CO-21 ASSEMBLY OF ELECTRIC COOLING FAN (See page CO-18) INSTALL FAN MOTOR Install the fan motor with the bushings and screws. INSTALL FAN Install the fan with the nut. INSTALLATION OF ELECTRIC COOLING FAN INSTALL ELECTRIC COOLING FAN ASSEMBLY INSTALL FRONT GRILL CONNECT CONNECTOR OF FAN MOTOR...
Page 206 LU-1 LUBRICATION SYSTEM Page TROUBLESHOOTING LU-2 OIL PRESSURE CHECK LU-2 REPLACEMENT OF ENGINE OIL AND OIL FILTER LU-3 OIL PUMP LU-4 •ü...
Page 207 LU-2 LUBRICATION SYSTEM - Troubleshooting, Oil Pressure Check TROUBLESHOOTING Page Problem Possible cause Remedy Oil Ieakage Cylinder head, cylinder block or oil pump Repair as necessary body damaged or cracked L U - 4 , Replace oil seal Oil seal faulty EM-52 Replace gasket Gasket faulty...
Page 208 LUBRICATION SYSTEM - Replacement of Engine Oil and Oil Filter LU-3 REPLACEMENT OF ENGINE OIL AND OIL FILTER DRAIN ENGINE OIL Remove the oil filler cap. Remove the oil drain plug and drain the oil into a con- tainer. REPLACE OIL FILTER Using SST, remove the oil filter.
Page 209 LU-4 LUBRICATION SYSTEM - Oil Pump OIL PUMP COMPONENTS Drive Gear Oil Pump Cover Oil Pump Body Driven Gear Oil Level Gauge Guide- 4 O-Ring 220 (16, 22) • Oil Seal Relief Valve Pistón Spring Retainer- 95 (82 in.-lb, 9.3) s&>...
Page 210 LUBRICATION SYSTEM - Oil Pump LU-5 (d) Remove the four nuts and seventeen bolts. Inserí the blade of SST between the cylinder block and oil pan, cut off applied sealer and then remove the oil pan. SST 09032-00100 NOTE: • Do not use SST for the oil pump body side. If necessary, use a screwdriver.
Page 211 LU-6 LUBRICATION SYSTEM - Oil Pump INSPECTION OF OIL PUMP INSPECT BODY CLEARANCE Using a feeler gauge, measure the clearance between the driven gear and body. Standard clearance: 0.100 - 0.191 mm (0.0039 - 0.0075 in.) Máximum clearance: 0.20 mm (0.0079 in.) If the clearance is exceeds máximum, replace the gear and/or body.
Page 212 LUBRICATION SYSTEM - Oil Pump LU-7 ASSEMBLY OF OIL PUMP (See page LU-4) ~--\ INSTALL RELIEF VALVE f V R e l i e f Valve Pistón Insert the relief valve pistón, spring and retainer into the pump body. S—Spring Using snap ring pliers, install the snap ring.
Page 213 LU-8 LUBRICATION SYSTEM - Oil Pump INSTALL OIL PAN /<5 v£> O — — ^ v¡¿<—va; £^-y\ Remove any oíd packing material and be careful not to drop any oil on the contacting surfaces of the oil pan and cylinder block. •...
Page 214 IG-1 IGNITION SYSTEM Page PRECAUTIONS IG-2 TROUBLESHOOTING IG-2 ON-VEHICLE INSPECTION IG-3 INTEGRATED IGNITION ASSEMBLY (HA) IG-7...
Page 215 IG-2 IGNITION SYSTEM — Precautions, Troubleshooting PRECAUTIONS Do not keep the ignition switch "ON" for more than 10 minutes if the engine will not start. When using a tachometer, connect the tachometer test probé to the service connector of the HA. It is recommended that you consult with the manufac- turer before using a tachometer as some are not com- patible with this system.
Page 216 IGNITION SYSTEM — On-Vehicle Inspection IG-3 ON-VEHICLE INSPECTION SPARK TEST NOTE: Perform this test to check that there is voltage from the HA to each spark plug. CRANK ENGINE AND CHECK THAT LIGHT FLASHES Connect a timing light to the spark plug. If the timing light does not flash, check the wiring connections, ignition coil, igniter and distributor.
Page 217 IG-4 IGNITION SYSTEM - On-Vehicle Inspection ADJUST ELECTRODE CAP Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: 3A-C (ex. Canadá Wagón M/T) 1.1 mm (0.043 in.) Others 0.8 mm (0.031 in.) INSTALL SPARK PLUGS Torque: 180 kg-cm (13 ft-lb, 18 N m ) INSPECTION OF IGNITION COIL...
Page 218 IGNITION SYSTEM - On-Vehicle Inspection IG-5 Using a dry cell battery (1.5 V), connect the positive (+) pole of the battery to the pink wire terminal and the negative (-) pole to the white wire terminal. CAUTION: Do not apply voltage more than 5 seconds to avoid destroying the power transistor in the igniter.
Page 219 IGNITION SYSTEM - On-Vehicle Inspection IG-6 INSPECT GOVERNOR ADVANCE ^ © ^ Turn the rotor shaft counterclockwise, reléase it and check that the rotor returns slightly clockwise. Check that the rotor shaft is not excessively loóse. IG0013...
Page 220 IGNITION SYSTEM — Integrated Ignition Assembly (HA) IG-7 INTEGRATED IGNITION ASSEMBLY (HA) COMPONENTS HA Cap Breake Píate (with Pick-up Coil) -Rotor Grease Stopper- -Signal Rotor Signal Rotor Shaft Governor Spring— Governor Weight— -Igniter Dust Gasket Cover Vacuum Advancer •Igniter Housing with Ignition Coil Governor Shaft"...
Page 221 IGNITION SYSTEM — Integrated Ignition Assembly (HA) IG-8 DISASSEMBLY OF HA (See page IG-7) REMOVE HA CAP AND ROTOR REMOVE IGNITER DUST COVER REMOVE IGNITION COIL DUST COVER REMOVE IGNITION COIL Remove the nuts and disconnect the wires from the termináis of the ignition coil.
Page 222 IGNITION SYSTEM - Integrated Ignition Assembly (HA) IG-9 REMOVE BREAKER PLATE Remove the two screws and píate washers. Remove the breaker píate. 10. REMOVE GOVERNOR SPRINGS 1 1 . REMOVE SIGNAL ROTOR SHAFT — Remove the grease stopper. /fáS Remove the screw at the end of the governor shaft. fíe ^ u ( y ^ ' Pulí...
Page 223 IG-10 IGNITION SYSTEM - Integrated Ignition Assembly (HA) INSPECT SIGNAL ROTOR SHAFT Temporarily install the signal rotor shaft to the governor shaft and check that they fit correctly. If they don't fit, replace the signal rotor shaft or HA. REPLACEMENT OF DRIVEN GEAR REPLACE DRIVEN GEAR Using a grinder, grind the driven gear and pin.
Page 224 IGNITION SYSTEM — Integrated Ignítion Assembly (HA) IG-11 INSTALL SIGNAL ROTOR SHAFT Install the signal rotor shaft on the governor shaft as shown. Instad the screw. Pack high-temparature grease into the shaft. Push on the grease stopper with your finger. INSTALL GOVERNOR SPRINGS Many Spring Windings Stopper Pin...
Page 225 IG-12 IGNITION SYSTEM - Integrated Ignition Assembly (HA) INSTALL SIGNAL ROTOR Install on the rotor with a new spring. INSPECT AIR GAP Using a feeler gauge, measure the gap between the signal rotor and pick-up coil. Air gap: 0.2 - 0.4 mm (0.008 - 0.016 in.) "f INSTALL IGNITER Install the igniter with the two screws.
Page 226 IGNITION SYSTEM - Integrated Ignition Assembly (HA) IG-13 14. INSTALL ROTOR AND CAP Install the rotor. Place a new gasket and the cap in position. Install the condenser and three screws. 15. INSTALL NEW O-RING TO HA HOUSING NOTE: Lightly coat the O-ring with engine oil. INSTALLATION OF HA SET NO.
Page 227 IG-14 IGNITION SYSTEM - Integrated Ignition Assembly (HA) ADJUST IGNITION TIMING (3A-C) Disconnect the hose from the vacuum advancer sub- diaphragm and plug the hose ends. Using a timing light, slowly turn the HA until the t i m - ing mark on the crankshaft pulley is aligned with the mark.
Page 228 ST-1 STARTING SYSTEM Page TROUBLESHOOTING ST-2 CONVENTIONAL STARTER ST-3 REDUCTION TYPE STARTER ST-11...
Page 229 STARTING SYSTEM - Troubleshooting ST-2 TROUBLESHOOTING Problem Possible cause Remedy Page CH-4 Engine will not crank Battery charge low Check battery specific gravity Charge or replace battery Repair or replace cables Battery cables loóse, corroded or worn Neutral start switch faulty (auto, trans.) Replace switch Fusible link blown Replace fusible link...
Page 230 STARTING SYSTEM - Conventional Starter ST-3 CONVENTIONAL STARTER COMPONENTS 12V 0.8kw Drive Houslng Magnetic Switch Drive Lever Terminal Cover • S n a p Ring • S t o p Collar Starter Clutch Rubber Lock Píate Spring Field Frame Bearing Cover Brush Holder Commutator End Frame Through Bolt...
Page 231 STARTING SYSTEM — Conventional Starter ST-4 DISASSEMBLY OF CONVENTIONAL STARTER (See page ST-3) REMOVE MAGNETIC SWITCH Remove the nut, and disconnect the lead wire from the magnetic switch terminal. Loosen the two nuts holding the magnetic switch to the switch housing. Lift the magnetic switch up and out to unhook the plunger from the drive lever.
Page 232 START1NG SYSTEM - Conventional Starter ST-5 REMOVE STARTER CLUTCH Using a screwdriver, tap in the stop collar. Using a screwdriver, pry off the snap ring. Remove the collar from the shaft. (d) If the pinion was difficult to pulí out smooth out the shaft with an oil stone.
Page 233 ST-6 STARTING SYSTEM — Conventional Starter INSPECT DIAMETER OF COMMUTATOR Standard diameter: 28 mm (1.10 in.) Minimum diameter: 27 mm (1.06 in.) If the diameter of the commutator is less than minimum, replace the armature. INSPECT SEGMENT Check that the segment is clean and free of foreign material.
Page 234 STARTING SYSTEM — Conventional Starter ST-7 PERFORM PULL-IN COIL OPEN CIRCUIT TEST Terminal C Using an ohmmeter, check that there is continuity be- tween termináis 50 and C. If there is no continuity, replace the magnetic switch. PERFORM HOLD-IN COIL OPEN CIRCUIT TEST Switch Body Using an ohmmeter, check that there is continuity be- Terminal 50...
Page 235 ST-8 START1NG SYSTEM — Conventional Starter Brush Holder INSPECT INSULATION OF BRUSH HOLDER Using an ohmmeter, check that there is no continuity be- tween the positive (+) and negative (-) brush holders. If there is continuity, repair or replace the brush holder. ASSEMBLY OF CONVENTIONAL STARTER (See page ST-3) NOTE:...
Page 236 STARTING SYSTEM — Conventional Starter ST-9 INSTALL BRUSH HOLDER Place the brush holder over the armaute shaft. Using a piece of steel wire, hold the brush spring back and install the brush in the brush holder. Insta 11 the four brushes. INSTALL END FRAME Apply grease to the end frame bushing.
Page 237 STARTING SYSTEM — Conventional Starter ST-10 CHECK PINION GEAR RETURN Disconnect the negative (-) lead from the switch body. Check that the pinion retums inward. If the pinion does not return, replace the magnetic switch. CHECK PINION GEAR CLEARANCE Terminal 50 Connect the battery to the magnetic switch as Terminal C shown.
Page 238 STARTING SYSTEM — Reduction Type Starter ST-11 REDUCTION TYPE STARTER COMPONENTS REMOVAL OF REDUCTION TYPE STARTER (See procedure on page ST-3) DISASSEMBLY OF REDUCTION TYPE STARTER REMOVE FIELD FRAME AND ARMATURE ASSEMBLY FROM MAGNETIC SWITCH Disconnect the lead wire from the magnetic switch terminal.
Page 239 ST-12 STARTING SYSTEM — Reduction Type Starter REMOVE CLUTCH ASSEMBLY AND IDLER GEAR FROM STARTER HOUSING REMOVE STEEL BALL AND SPRING Using a magnetic finger, remove the spring and steel ball from the clutch shaft hole. REMOVE BRUSH HOLDER Remove the end cover from the field frame. (b) Using a screwdriver or steel wire, hold the brush spring back, and remove the brush from the brush holder.
Page 240 STARTING SYSTEM — Reduction Type Starter ST-13 INSPECT DIAMETER OF COMMUTATOR Standard diameter: 30 mm (1.18 in.) Minimum diameter: 29 mm (1.14 in.) If the diameter is less than minimum, replace the armature. INSPECT SEGMENT Check that the segment is clean and free of foreign material and smooth out the edge.
Page 241 ST-14 STARTING SYSTEM — Reduction Type Starter Brush Springs INSPECT BRUSH SPRING LOAD WITH PULL SCALE Spring installed load: 1.79 - 2.41 kg (3.9 - 5.3 Ib, 1 8 - 24 N) NOTE: Take the pulí scale reading at the very instant the brush spring separates from the brush.
Page 242 START1NG SYSTEM - Reduction Type Starter ST-15 Using SST and a hammer, tap a new front bearing onto the shaft. SST 09285-76010 Using a press, instad a new rear bearing onto the shaft. Magnetic Switch PERFORM PULL-IN COIL OPEN CIRCUIT TEST Terminal 50 Using an ohmmeter, check that there is continuity be- tween termináis 50 and O...
Page 243 ST-16 STARTING SYSTEM — Reduction Type Starter INSERT STEEL BALL INTO CLUTCH SHAFT HOLE Apply grease to the ball and spring and insert them into the clutch shaft hole. INSTALL GEAR AND CLUTCH ASSEMBLY Bearing Apply grease to gear and the clutch assembly. Place the clutch assembly, idler gear and bearing in the starter housing.
Page 244 STARTING SYSTEM - Reduction Type Starter ST-17 PERFORMANCE TEST OF REDECTION TYPE r5^\ STARTER CAUTION: These tests must be performed w i t h i n 3 to 5 seconds to avoid burning out the coil. PERFORM PULL-IN TEST Terminal C í Disconnect the field coil lead from terminal C.
Page 245 CHARGING SYSTEM Page PRECAUTIONS CH-2 TROUBLESHOOTING CH-2 ON-VEHICLE INSPECTION CH-3 ALTERNATOR CH-7 ALTERNATOR REGULATOR CH-22 IGNITION MAIN RELAY CH-24...
Page 246: Precautions
CH-2 CHARGING SYSTEM — Precautions, Troubleshooting PRECAUTIONS Check that the battery cables are connected to the correct termináis. Dísonnect the battery cables when the battery is given a quick charge. Do not perform tests with a high voltage insulation resistance tester. Never disconnect the battery when the engine is run- ning.
Page 247: On-Vehicle Inspection
CHARGING SYSTEM - On-Vehicle Inspection CH-3 ON-VEHICLE INSPECTION INSPECT BATTERY SPECIFIC GRAVITY Check the specific gravity of each cell. Standard specific gravity: When fully charged at 20°C (68°F) 1.25 - 1.27 Check the electrolyte quantity of each cell. If insufficient, refill with distilled (or purified) water. CHECK BATTERY TERMINALS, FUSIBLE LINKS AND FUSES Check that the battery termináis are not loóse or cor-...
Page 248 CH-4 CHARGING SYSTEM - On-Vehicle Inspection NOTE: • "New beit" refers to a brand new beit which has never been used. • "Used beit" refers to a beit which has been used on a running engine for 5 minutes or more. ÚMf^ \<Nkfok LÉÉÉJ •...
Page 249 CHARGING SYSTEM - On-Vehicle Inspection CH-5 CHECK CHARGING CIRCUIT WITHOUT LOAD Disconnect Wire from Terminal B NOTE: If a battery/alternator tester is available, connect the tester to the charging circuit as per manufacturéis instructions. If a tester is not available, connect a voltmeter and ammeter to the charging circuit as follows: •...
Page 250 CHARGING SYSTEM - On-Vehicle Inspection CH-6 If the voltage reading is less than standard voltage, check the IC regulator and alternator as follows: Terminal F • With terminal F grounded, start the engine and check the voltage reading of terminal B. CH0206 •...
Page 251: Alternator
CHARGING SYSTEM - Alternator (w/o IC Regulator) CH-7 ALTERNATOR w/o IC Regulator COMPONENTS • Rear Bearing Drive End Frame Rotor Front Bearing Spacer Collar Stator Assembly Spacer Ring Rectifier End Frame Insulator Washer Terminal Insulator <¿ ® Noise Suppression Condenser Rectifier Holder •: Non-reusable part CH0184...
Page 252 CH-8 CHARGING SYSTEM — Alternator (w/o IC Regulator) DISASSEMBLY OF ALTERNATOR (See page CH-7) REMOVE DRIVE END FRAME AND ROTOR ASSEMBLY FROM STATOR Remove the three through bolts. Using a screwdriver, pry the end frame and remove it together with the rotor. CAUTION: Do not pry on the oil wires.
Page 253 CHARGING SYSTEM - Altemator (w/o IC Regulator) CH-9 INSPECTION OF ALTERNATOR Rotor INSPECT ROTOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity be- tween the slip rings. Standard resistance: 4.0 — 4.2 O, If there is no continuity, replace the rotor. INSPECT ROTOR FOR GROUND Using an ohmmeter, check that there is no continuity be- tween the slip ring and the rotor.
Page 254 CH-10 CHARGING SYSTEM - Altemator (w/o IC Regulator) Brushes INSPECT EXPOSED BRUSH LENGTH Minimum exposed length: 5.5 mm (0.217 in.) If the exposed length is less than minimum, replace the brushes. IF NECESSARY REPLACE BRUSHES Unsolder and remove the brush and spring. Put the brush wire through the spring, and ¡nsert the brush into the brush holder.
Page 255 CHARGING SYSTEM - Alternator (w/o IC Regulator) CH-11 INSPECT REAR BEARING Check that the bearing is not rough or worn. IF NECESSARY, REPLACE REAR BEARING Using SST, remove the bearing from the rotor shaft. SST 09286-46011 (b) Using a press, install a new rear bearing onto the rotor shaft.
Page 256 CHARGING SYSTEM - Altemator (w/o IC Regulator) CH-12 Place the two terminal insulators on the positive side studs. Install the noise suppression condenser and four nuts on the studs. INSTALL DRIVE END FRAME, FAN AND PULLEY Mount the rotor in a soft jaw vise. Slide the following parts on the rotor shaft.
Page 257 CHARGING SYSTEM - Alternator (w/o IC Regulator) CH-13 Make sure the rotor rotates smoothly. Seal the access hole. INSTALLATION OF ALTERNATOR (See page CH-7) Adjusting Bolt INSTALL ALTERNATOR Place the alternator in position. Install the pivot bolt and nut. Do not tighten the nut yet.
Page 258 CH-14 CHARGING SYSTEM - Altemator (w/ IC Regulator) w/ IC Regulator COMPONENTS Rear Bearing Rotor Bearing Retainer Drive End Frame Bearing Cover Rectifier End Cover Terminal Insulator -Brush Holder Cover -Spring -Brush Rectifier End Cover IC Regulator Rectifier Holder Terminal Insulator CH0209 REMOVAL OF ALTERNATOR DISCONNECT CABLE FROM NEGATIVE TERMINAL...
Page 259 CHARGING SYSTEM - Alternator (w/ IC Regulator) CH-15 DISASSEMBLY OF ALTERNATOR (See page CH-14) REMOVE REAR END COVER Remove the nut and terminal insulator. Remove the three nuts and end cover. REMOVE BRUSH HOLDER Remove the two screws, brush holder and cover. REMOVE IC REGULATOR Remove the three screws and IC regulator.
Page 260 CH-16 CHARGING SYSTEM - Alternator (w/ IC Regulator) As shown in the figure, mount SST " C " in a vise, and install the alternator to SST " C " . To loosen the pulley nut turn SST " A " in the direc- tion shown in the figure.
Page 261 CHARGING SYSTEM - Alternator (w/ IC Regulator) CH-17 Stator INSPECT STATOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity be- tween the coil leads. If there is no continuity, replace the drive end frame assembly. INSPECT STATOR FOR GROUND Using an ohmmeter, check that there is no continuity be- tween the coil leads and drive end frame.
Page 262 CH-18 CHARGING SYSTEM - Alternator (w/ IC Regulator) Bearings INSPECT FRONT BEARING Check that the bearing is not rough or worn. IF NECESSARY, REPLACE FRONT BEARING Remove the four screws, bearing retainer and bear- ing. Instad the bearing. Align the claws of the bearing retainer with the slots of the drive end frame.
Page 263 CHARGING SYSTEM - Altemator (w/ IC Regulator) CH-19 Using SST and a press, press in the bearing and bear- ing cover. SST 0 9 2 8 5 - 7 6 0 1 0 ASSEMBLY OF ALTERNATOR (See page CH-14) INSTALL ROTOR TO DRIVE END FRAME INSTALL RECTIFIER END FRAME Using a plastic-faced hammer, lightly tap in the end frame.
Page 264 CHARGING SYSTEM - Alternator (w/ IC Regulator) CH-20 Install the rectifier with the four screws. INSTALL IC REGULATOR Install the IC regulator with the three screws. INSTALL BRUSH HOLDER Install the brush holder cover to the brush holder. Install the brush holder with the two screws. Install the brush holder cover to the rear end frame.
Page 265 CHARGING SYSTEM - Alternator (w/ IC Regulator) CH-21 MAKE SURE ROTOR ROTATES SMOOTHLY INSTALLATION OF ALTERNATOR INSTALL ALTERNATOR Mount the alternator on the engine bracket with the pivot and adjusting bolts. Do not tighten the bolts yet. Adjusti INSTALL AND ADJUST DRIVE BELT Instad the drive belt, and tighten the adjusting and pivot bolts.
Page 266: Alternator Regulator
CH-22 CHARGING SYSTEM - Altemator Regulator ALTERNATOR REGULATOR (w/o IC Regulator) INSPECTION OF ALTERNATOR REGULATOR LOCATION: On the left tender apron in the engine compartment. REMOVE ALTERNATOR REGULATOR COVER INSPECT POINT SURFACES FOR BURN OR DAMAGE If detective, replace the regulator. INSPECT RESISTANCE BETWEEN TERMINALS Using an ohmmeter, measure the resistance between termináis IG and F.
Page 267 CHARGING SYSTEM - Altemator Regulator CH-23 Using an ohmmeter, measure the resistance between termináis B and L Resistance (voltage relay): At rest Infinity Pulled in Using an ohmmeter, measure the resistance between termináis N and E. Resistance: Approx. 24 O If any of the above checks are not positive, replace the alternator regulator.
Page 268: Ignition Main Relay
CH-24 CHARGING SYSTEM - Ignition Main Relay IGNITION MAIN RELAY LOCATION: In the engine compartment relay box. INSPECTION OF IGNITION MAIN RELAY INSPECT RELAY OPERATION AND CONTINUITY (See Sun Roof Relay on page BE-34)
Page 269 CL-1 CLUTCH Page TROUBLESHOOTING CL-2 CHECK AND ADJUSTMENT OF CLUTCH PEDAL CL-3 CLUTCH PEDAL CL-4 CLUTCH RELÉASE CABLE CL-6 CLUTCH UNIT CL-8 • n...
Page 270: Troubleshooting
CL-2 CLUTCH — Troubleshooting TROUBLESHOOTING Problem Page Possible cause Remedy CL-3 Hard to shift or Clutch pedal freeplay excessive Inspect clutch pedal will not shift Inspect clutch disc CL-9 Clutch disc out of true, lining greasy or broken Repair as necessary Spiines on input shaft or clutch disc dirty or burred Clutch pressure píate faulty...
Page 271: Check And Adjustment Of Clutch Pedal
CLUTCH — Check and Adjustment of Clutch Pedal CL-3 CHECK AND ADJUSTMENT OF CLUTCH PEDAL CHECK THAT PEDAL HEIGHT IS CORRECT AS SHOWN Pedal Height Pedal height from asphalt sheet: 177 — 187 mm Adjust Point (6.97 - 7.36 in.) IF NECESSARY, ADJUST PEDAL HEIGHT Loosen the lock nut and turn the adjusting bolt until the height is correct.
Page 272 CL-4 CLUTCH - Clutch Pedal CLUTCH PEDAL COMPONENTS Clutch Reléase Cable Bushing Clutch Pedal Pedal Shaft Collar Reléase Lever Bushing Reléase Sector Snap Ring Bushing -Pedal Return Spring — Pedal Adjusting Bolt © Lock Nut •Sector Tensión Spring E-Ring P a w | Lever Return Spring REMOVAL OF CLUTCH PEDAL REMOVE PEDAL RETURN SPRING...
Page 273 CLUTCH - Clutch Pedal CL-5 REMOVE PAWL Using a screwdriver, remove the E-ring and washer. Remove the pawl together with the spring. REMOVE RELÉASE SECTOR AND LEVER Using snap ring pliers, remove the snap ring, spacer, reléase sector, lever and bushings. ASSEMBLY OF CLUTCH PEDAL (See page CL-4) NOTE:...
Page 274: Clutch Reléase Cable
CL-6 CLUTCH — Clutch Reléase Cable CLUTCH RELÉASE CABLE COMPONENTS Pedal Return Spring Clutch Reléase Cable •Sector Tensión Spring Reléase Fork Le ver- CL0109 REMOVAL OF CLUTCH RELÉASE CABLE DISCONNECT SECTOR TENSIÓN SPRING FROM CLUTCH PEDAL DISCONNECT CLUTCH RELÉASE CABLE FROM FORK LEVER REMOVE CLUTCH RELÉASE CABLE Turn the reléase sector toward the front side and dis-...
Page 275 CLUTCH — Clutch Reléase Cable CL-7 INSTALLATION OF CLUTCH RELÉASE CABLE (See page CL-6) CONNECT CLUTCH RELÉASE CABLE IN PEDAL Run the reléase cable through the hole in the floor- board. Turn the reléase sector, and connect the reléase cable in the groove of it. CONNECT CLUTCH RELÉASE CABLE IN FORK LEVER CONNECT PEDAL TENSIÓN SPRING CHECK PEDAL FREEPLAY (See page CL-3)
Page 276: Clutch Unit
CL-8 CLUTCH - Clutch Unit CLUTCH UNIT COMPONENTS REMOVAL OF CLUTCH UNIT REMOVE TRANSAXLE (See page TA-4) NOTE: Do not drain the gear oil. REMOVE CLUTCH COVER AND DISC Loosen each mount bolt one tum at a time until spring tensión is released. Remove the mount bolts, and pulí...
Page 277 CLUTCH - Clutch Unit CL-9 REMOVE RELÉASE FORK, RETURN SPRING AND FORK LEVER Remove the mount bolt. Pulí out the reléase f ork lever, and remove the reléase fork and retum spring. Remove the lever boot. INSPECTION AND REPAIR OF CLUTCH PARTS INSPECT CLUTCH DISC FOR WEAR OR DAMAGE Using calípers, measure the rivet head depth.
Page 278 CL-10 CLUTCH - Clutch Unit INSPECT PILOT BEARING Turn the bearing by hand while appiying forcé in the axial direction. IF NECESSARY, REPLACE PILOT BEARING Using SST, remove the pilot bearing. SST 09303-35011 (b) Using SST, install a new pilot bearing. SST 09304-30012 INSPECT DIAPHRAGM SPRING FOR WEAR Using calipers, measure the diaphragm spring for depth...
Page 279 CLUTCH - Clutch Unit CL-11 IF NECESSARY, REPLACE RELÉASE BEARING Using a press and SST, press the reléase bearing from the hub. SST 0 9 3 1 5 - 0 0 0 1 0 Using a press and SST, press a new reléase bearing into the hub.
Page 280 CL-12 CLUTCH - Clutch Unit Using a socket wrench, drive in a new oil seal. Oil seal depth: 2.2 mm (0.087 in.) INSTALLATION OF CLUTCH UNIT { JjjO (See page CL-8) INSTALL DISC ON FLYWHEEL Front Using SST, install the clutch on the flywhee!. r v i ^ ^ \ SST 0 9 3 0 1 - 3 6 0 1 0 ^ f l...
Page 281 CLUTCH - Clutch Unit CL-13 APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE GREASE (NLGI NO.2) OR MP GREASE Apply molybdenum disulphide lithium base grease to the following parts: • Reléase fork and hub contact points • Reléase fork and fork lever contact points •...
Page 282 MT-1 MANUAL TRANSAXLE Page TROUBLESHOOTING MT-2 MANUAL TRANSAXLE MT-3 Removal of Transaxle (FWD) MT-3 Installation of Transaxle (FWD) MT-5 Removal of Transaxle (4WD) MT-7 Installation of Transaxle (4WD) MT-9 MANUAL TRANSMISSION MT-11 Removal of Transmission (FWD) MT-11 Removal of Transmission (4WD) MT-13 Components MT-15...
Page 283: Troubleshooting
MT-2 MANUAL TRANSAXLE - Troubleshooting TROUBLESHOOTING Transaxle Problem Possible cause Remedy Page Noise Transmission of differential faulty Disassembly and inspect MT-3 transmission or differential Wrong oil grade Replace oil Oil level low Add oil MT-66, 70 Oil leakage Oil level too high Drain oil MT-66, 70 Oil seal or gasket worn or damaged...
Page 284: Manual Transaxle
MANUAL TRANSAXLE - Manual Transaxle (FWD) M T - 3 MANUAL TRANSAXLE REMOVAL OF TRANSAXLE (FWD) DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY REMOVE TRANSAXLE UPPER MOUNT BOLTS REMOVE BOTH DRIVE SHAFTS (See page FA-13) RAISE VEHICLE CAUTION: Be sure the vehicle is securely supported. DISCONNECT CLUTCH CABLE (See page CL-4) (Fed.) REMOVE CONVERTER AIR INLET PIPE...
Page 285 MANUAL TRANSAXLE - Manual Transaxle (FWD) MT-4 10. DISCONNECT BACKUP LIGHT SWITCH CONNECTOR 1 1 . DISCONNECT SPEEDOMETER CABLE 12. REMOVE RIGHT STIFFENER PLATE 13. REMOVE TRANSAXLE LOWER MOUNT BOLTS 14. REMOVE REAR SUPPORT MEMBER Put a wooden block between the engine and dash panel because the HA will make contact with the brake booster when the rear support member is removed.
Page 286: Installation Of Transaxle (Fwd
MANUAL TRANSAXLE - Manual Transaxle (FWD) MT-5 INSTALLATION OF TRANSAXLE (FWD) APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE GREASE (NLGI NO. 2) OR MP GREASE TO INPUT SHAFT Apply molybdenum disulphide lithium base grease to the input shaft spiine. Apply MP grease to the input shaft end. Apply MP grease to the front of the reléase bearing.
Page 287 MANUAL TRANSAXLE - Manual Transaxle (FWD) MT-6 11. INSTALL EXHAUST FRONT PIPE Torque the two nuts holding the front pipe to the exhaust manifold. Torque: 630 kg-cm (46 ft-lb, 62 N-m) 12. (Fed.) INSTALL CONVERTER AIR INLET PIPE 13. CONNECT CLUTCH CABLE (See page CL-7) 14.
Page 288: Removal Of Transaxle (4Wd
MANUAL TRANSAXLE - Manual Transaxle (4WD) MT-7 REMOVAL OF TRANSAXLE (4WD) DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY REMOVE CONSOLÉ BOX REMOVE SHIFT LEVER FROM INSIDE OF VEHICLE Using snap ring pliers, remove the snap ring. REMOVE TRANSAXLE UPPER MOUNT BOLTS REMOVE BOTH SHAFTS RAISE VEHICLE CAUTION:...
Page 289 MANUAL TRANSAXLE - Manual Transaxle (4WD) MT-8 11. DISCONNECT SELECTING ROD FROM REAR DRIVE SHIFT LINK LEVER 12. DISCONNECT FOLLOWING CONNECTORS: Back-up light switch connector (b) 4WD indiacator switch connector Extra low (EL) gear indicator siwtch connector 13. DISCONNECT SPEEDOMETER CABLE 14.
Page 290: Installation Of Transaxle (4Wd
MANUAL TRANSAXLE - Manual Transaxle (4WD) M T - 9 INSTALLATION OF TRANSAXLE (4WD) APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE GREASE (NLGI NO. 2) OR MP GREASE TO INPUT SHAFT Apply moiybdenum disuiphide Iithium base grease to the input shaft spiine. Apply MP grease to the input shaft end.
Page 291 M T - 1 0 M A N U A L TRANSAXLE - Manual Transaxle (4WD) 10. INSTALL EXHAUST FRONT PIPE Torque the two nuts holding the front pipe to the exhaust manifold. Torque: 6 3 0 kg-cm (46 f t - l b , 62 N-m) 1 1 .
Page 292: Manual Transmission
MANUAL TRANSAXLE — Manual Transmission MT-11 MANUAL TRANSMISSION REMOVAL OF TRANSMISSION (FWD) DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY DISCONNECT AIR CLEANER INLET DUCT RAISE VEHICLE CAUTION: Be sure the vehicle is secureiy supported. DRAIN GEAR OIL ríh^vM. §** Remove the three drain plugs and drain the gear oil. y^&...
Page 293 MT-12 MANUAL TRANSAXLE — Manual Transmission 11. REMOVE REAR SUPPORT MEMBER Put a wooden block between the engine and dash panel because the HA will make contact with the brake booster when the rear support member is removed. Remove the four bolts and rear support member. 12.
Page 294: Removal Of Transmission (4Wd
MANUAL TRANSAXLE — Manual Transmission MT-13 REMOVAL OF TRANSMISSION (4WD) DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTE DISCONNECT AIR CLEANER INLET DUST REMOVE CONSOLÉ BOX REMOVE SHIFT LEVER FROM INSIDE OF VEHICLE RAISE VEHICLE CAUTION: Be sure the vehicle is securely supported. DRAIN GEAR OIL Remove the three drain plugs and drain the gear oil.
Page 295 MANUAL TRANSAXLE — Manual Transmission MT-14 DISCONNECT SELECTING ROD FROM REAR DRIVE SHIFT LINK LEVER 10. DISCONNECT FOLLOWING CONNECTOR Back-up light connector (b) 4WD indicator switch connector Extra low gear (EL) indicator switch connector 11. DISCONNECT SPEEDOMETER CABLE 12. REMOVE REAR SUPPORT MEMBER Put a wooden block between the engine and dash panel because the HA will make contact with the brake booster when the rear support member is...
Page 296: Components
MANUAL TRANSAXLE — Manual Transmission MT-15 COMPONENTS Z45, 46, 53, 54F Transmission Case Cover Back-up Switch • Gasket • Gasket Transmission Case • Oil Seal Oil Reciver 250 (18, 25) • Gasket | • Gasket -<S> Filler Plug Drain Plug 410 (30, 40) •...
Page 297 M T - 1 6 MANUAL TRANSAXLE — Manual Transmission COMPONENTS (Cont'd) Z45, 46, 53 Detent Ball Spring Detent Bali 185 (13, 18) Detent Ball Spring Detent Ball No. 1 Shift Head Reverse Shift Fork No. 1 Shift Fork Shaft No.
Page 298 M A N U A L T R A N S A X L E — Manual Transmission M T - 1 7 COMPONENTS (Cont'd) Z54F Interlock Pin Detent Ball S p r i n g — § No. 1 Shift Head Detent Ball No.
Page 299 M T - 1 8 MANUAL TRANSAXLE - Manual Transmission COMPONENTS (Cont'd) Z45, 46, 53, 54F Rear Bearing Input Shaft No. 2 Synchronizer Front Bearing 4th Gear Thrust Washer -NoT2 Cuten Hub Assembly Sleeve Yoke Output Shaft Locking Ball i - — Speedometer Drive Gear Rear Bearing (Z45, 46, 53)
Page 300 MANUAL TRANSAXLE - Manual Transmission MT-19 COMPONENTS (Cont'd) Z45, 46, 53, 54F Reverse Idler Gear Shaft & Reverse Idle Gear Front Bearing Rear Bearing No. 2 Front Bearing Idler Gear (Z45, 46) 130 (9, 13) No. 1 Rear Bearing Counter Gear Píate Counter Gear (Z53) Thrust Washer...
Page 301: Disassembly Of Transmission
MANUAL TRANSAXLE — Manual Transmission MT-20 DISASSEMBLY OF TRANSMISSION (See page MT-15) REMOVE MOUNTING INSULATOR REMOVE SPEEDOMETER DRIVEN GEAR REMOVE FOLLOWING SWITCH: Back-up light switch (Z54F) ¿^-—(c) 4WD indicator switch (Z54F) Jfes (b) ¿ ¿ ^ Extra low gear (EL) indicator switch ZM0035 REMOVE EXTENSIÓN HOUSING (Z45, 4 6 , 53)
Page 302 MANUAL TRANSAXLE — Manual Transmission MT-21 (Z54F) Remove the reverse restrict pin. Remove the six bolts, shift lever retainer and gasket. Unstake the lock washer of the select lever housing mount bolt. Remove the select lever housing mount bolt. Remove the nine bolts, extensión housing, select lever housing and gasket.
Page 303 M T - 2 2 MANUAL TRANSAXLE — Manual Transmission (Z54F) REMOVE TRANSFER SHIFT FORK Using SST, remove the screw plug. SST 0 9 3 1 3 - 3 0 0 2 1 Using a magnetic finger, remove the spring seat, spring and detent ball.
Page 304 MANUAL TRANSAXLE — Manual Transmission MT-23 (Z54F) REMOVE NO. 4 SHIFT FORK SHAFT AND NO. 4 SHIFT HEAD Remove the four bolts, transfer case cover and gasket. Remove the spring seat and spring. Using a magnetic finger remove the detent ball. Unstake the lock píate of the No.
Page 305 MANUAL TRANSAXLE — Manual Transmission M T - 2 4 Pulí out the No. 4 shift fork shaft and remove the No. 4 shift head. Using a magnetic finger, remove the interlock pin. y ^ ^ \ ^ r ^ ^S^\^^W^ \ )jpYX H3®...
Page 306 MANUAL TRANSAXLE — Manual Transmission MT-25 1 1 . (Z54F) CHECK EXTRA LOW GEAR THRUST CLEARANCE Install the needle roller bearing, extra low gear, transfer clutch hub with the snap ring. Using a feeler gauge, measure the extra low gear thrust clearance, and record the result for later reference.
Page 307 MANUAL TRANSAXLE — Manual Transmission M T - 2 6 (Z54F) Using two screwdriver and a hammer, tap out the snap ring. Remove the drive gear. Using a magnetic finger, remove the locking ball. & » > 2M0048 ZM0026 14. (Z54F) REMOVE SHIFT HEADS (NO.
Page 308 MANUAL TRANSAXLE — Manual Transmission MT-27 17. REMOVE REVERSE SHIFT ARM PIVOT 18. REMOVE TRANSMISSION CASE Using SST, remove the three screw plugs. SST 09313-30021 Using a magnetic finger, remove the three springs and detent balls. Using snap ring pliers, remove the snap ring. (d) Using a plastic-faced hammer, tap the case protru- sion to remove the case from the intermidíate píate.
Page 309 MT-28 MANUAL TRANSAXLE — Manual Transmission 19. MOUNT INTERMEDÍATE PLATE IN VISE Secure the protrusion on the lower part of the intermedí- ate píate. 20. REMOVE SHIFT FORKS, SHIFT ARM AND SHIFT FORK SHAFTS Using SST, remove the screw plug. SST 09313-30021 Using a magnetic finger, remove the spring and detent ball.
Page 310 MANUAL TRANSAXLE — Manual Transmission MT-29 Remove the No. 2 shift fork and No. 2 shift fork shaft. (g) Remove the reverse shift fork. No. 1 shift fork and No. 1 shift fork shaft. Remove the three interlock pin from the No. 2 shift fork shaft and intermedíate píate.
Page 311 M T - 3 0 MANUAL TRANSAXLE — Manual Transmission Using snap ring pliers, remove the snap ring. Using SST, remove the No. 3 clutch hub assembly, No. 3 cynchronizer ring and counter 5th gear to- gether. Remove the needle roller bearing. SST 0 9 9 5 0 - 2 0 0 1 5 CAUTION: Be careful not to drop the needle roller...
Page 312 MANUAL TRANSAXLE — Manual Transmission MT-31 Using a plastic-faced hammer, tap the idler gear and output shaft halfway out from the intermedíate. NOTE: Support the gear shaft by hand. Using a plastic-faced hammer, tap the idler gear to remove the idler gear, reverse idler gear and reverse idler gear shaft together.
Page 313 MT-32 MANUAL TRANSAXLE — Manual Transmission 26. REMOVE SLEEVE YOKE Using SST and a press, press out the sleeve yoke. SST 0 9 9 5 0 - 0 0 0 2 0 27. (Z53, 54F) REMOVE FIFTH GEAR Using snap ring pliers, remove the snap ring. Using SST and a press, press out the 5th gear.
Page 314 MANUAL TRANSAXLE — Manual Transmission MT-33 31. REMOVE FOURTH GEAR THRUST WASHER AND THRUST BEARING Using two screwdriver and a hammer, tap out the snap ring. Remove the thrust washer and thrust bearing. ^^^kÍí/Mi >& ZM0141 REMOVE NO. 2 CLUTCH HUB ASSEMBLY AND THIRD GEAR Using SST and a press, press the 3rd gear and remove the No.
Page 315: Inspection Of Transmission Components
MT-34 MANUAL TRANSAXLE — Manual Transmission INSPECTION OF TRANSMISSION COMPONENTS INSPECT OUTPUT SHAFT AND FIRST GEAR INNER RACE Using a dial indicator, measure the circle runout. Máximum runout: 0.06 mm (0.0024 in.) Using calipers, measure the output shaft flange thickness. Standard thickness: 4.24 - 4.54 mm ( 0 .
Page 316 MANUAL TRANSAXLE — Manual Transmission MT-35 INSPECT OIL CLEARANCE OF COUNTER FIFTH GEAR Using a dial indicator, measure the oil clearance between the gear and counter gear shaft with the needle roller bearing installed. Standard clearance: 0.009 — 0.055 mm (0.0004 - 0.0022 in.) Máximum clearance: 0.06 mm (0.0024 in.)
Page 317: Replacement Of Transmission Components
MT-36 MANUAL TRANSAXLE — Manual Transmission Install the pump rotors with the pump cover and three bolts. Torque the bolts. Torque: 195 kg-cm (14 ft-lb, 19 N-m) Check that the rotors rotates smoothly. REPLACEMENT OF TRANSMISSION COMPONENTS REPLACE INPUT SHAFT FRONT BEARING AND OIL SEAL Using a screwdriver and hammer, tap out the oil seal.
Page 318 MANUAL TRANSAXLE — Manual Transmission MT-37 REPLACE INPUT SHAFT REAR BEARING Using snap ring pliers, remove the snap ring. Using SST and a press, press out the bearing. SST 0 9 9 5 0 - 0 0 0 2 0 Using SST and a press, press in a new bearing.
Page 319 MT-38 MANUAL TRANSAXLE — Manual Transmission (Z53, 54F) REPLACE COUNTER GEAR NO. 1 FRONT BEARING Using SST, remove the bearing. SST 09310-36021 and 09612-10092 (b) Using SST and a hammer, tap in a new bearing until its surface is flush with the transaxle case edge. SST 09304-47010 REPLACE COUNTER GEAR NO.
Page 320 MANUAL TRANSAXLE — Manual Transmission MT-39 Using SST and a press, press in a new bearing. SST 0 9 5 1 5 - 2 0 0 1 0 Front Snap Ring Groove ZM0088 ZM0240 Select a snap ring that will allow minimum axial play and install it on the shaft.
Page 321 MANUAL TRANSAXLE — Manual Transmission M T - 4 0 Select a rear snap ring that will allow mínimum axial play and install it on the shaft. Snap ring thickness mm un., 1.925 - 1.975 (0.0758 - 0.0778) 1.975 - 2.025 (0.0778 - 0.0797) 2.025 - 2.075 (0.0797 - 0.0817) 2.075 - 2.125 (0.0817 - 0.0837) 2.125 - 2.175 (0.0837 - 0.0856)
Page 322 MANUAL TRANSAXLE — Manual Transmission MT-41 Select a snap ring that will allow minimum axial play and install it on the shaft. Snap ring thickness mm (in.) 2.40 - 2.45 (0.0945 - 0.0965) 2.45 - 2.50 (0.0965 - 0.0984) REPLACE REAR BEAR OF IDLER GEAR Remove the two bolts and oil receiver.
Page 323 MANUAL TRANSAXLE — Manual Transmission MT-42 Using SST and a press, press in a new bearing. SST 09608-20011 Using snap ring pliers, install the snap ring. 12. (Z54F) REPLACE EXTENSIÓN HOUSING BUSHING AND OIL SEAL Using SST, remove the oil seal. SST 0 9 3 0 8 - 0 0 0 1 0 or 0 9 3 0 8 - 1 0 0 1 0 with output shaft installed Gradually heat the extensión housing end 80 -...
Page 324 MANUAL TRANSAXLE — Manual Transmission MT-43 Using SST and a hammer, tap in a new oil until 4.7 - 5.7 mm (0.185 - 0.224 in.) of it is left protruding from the extensión housing. SST 0 9 3 0 4 - 3 0 0 1 2 14.
Page 325 MANUAL TRANSAXLE — Manual Transmission MT-44 16. REPLACE SPEEDOMETER DRIVEN GEAR OIL SEAL Using SST, pulí out the oil seal. SST 09921-00010 (b) Using SST and a hammer, tap in a new oil seal to a depth of 20 mm (0.79 in.) from the sieeve edge. SST 09201-60011 20 mm WM0109...

Toyota TERCEL 1985 Repair Manual

Introduction

Emission Control Systems

Fuel System

Cooling System

Charging System

Clutch

Manual Transaxle

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Troubleshooting

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