Table Of Contents - Mazda 626 MX-6 Workshop Manual

Table of Contents

Contents2
Scheduled Maintenance3
Pre-Delivery Inspection Table4
Scheduled Maintenance Services5
Maintenance Table (Schedule 2)9
Engine11
Table Of Contents11
Engine Structural View12
Outline12
Engine Specifications13
Engine Troubleshooting13
Troubleshooting Guide13
Engine Tune-Up Procedure15
Tune-Up Procedure17
Engine On-Vehicle Inspection19
Compression19
Timing Belt Removal20
On-Vehicle Maintenance20
Timing Belt Inspection And Repair21
Timing Belt Installation22
Cylinder Head Removal26
Cylinder Head Installation29
Engine Harness Connector31
Valve Seal Removal32
Valve Seal Installation34
Valve Spring35
Rocker Arm And Shaft Assembly35
On-Vehicle Maintenance - Valve Seal36
Cylinder Head Cover And Gasket37
Distributor37
Engine Removal38
Engine Disassembly42
Auxiliary Parts42
Timing Belt View44
Cylinder Head View46
Camshaft47
Cylinder Block View48
Clutch Cover, Flywheel (Mtx) Or Drive Plate (Atx) Removal49
Oil Pan Removal49
Cylinder Block Ii View50
Main Bearing Cap51
Pilot Bearing (Mtx)51
Piston And Connecting Rod51
Engine Inspection And Repair52
Cylinder Head Check52
Valve And Valve Guide Check53
Replacement Of Valve Guide54
Valve Seat Check55
Valve Spring Check56
Camshaft Check57
Rocker Arm And Rocker Arm Shaft Check58
Hydraulic Lash Adjuster (Hla) Check59
Cylinder Block Check59
Piston Check61
Piston And Piston Ring Check61
Piston And Piston Pin Check62
Connecting Rod Check62
Crankshaft Check63
Crank Pin Journal Check63
Main Bearing And Connecting Rod Bearing Check64
Timing Belt Check64
Timing Belt Tensioner And Idler Pulley Check65
Timing Belt Tensioner Spring Check65
Timing Belt Pulley And Camshaft Pulley Check65
Timing Belt Cover Check (Lower And Upper)65
Engine Assembly66
Connecting Rod67
Piston Ring67
Crankshaft68
Oil Clearance Inspection69
Center Main Bearing Width70
Connecting Rod Cap71
End Plate73
Oil Pump73
Stiffener74
Oil Strainer74
Oil Pan75
Flywheel (Mtx), Drive Plate (Atx)75
Clutch Disc And Clutch Cover (Mtx)76
Water Pump76
Valve Seal77
Cylinder Head77
Valve And Valve Spring78
Hydraulic Lash Adjuster (Hla)79
Camshaft Cap, Rocker Arm And Shaft Assembly79
Front Housing80
Timing Belt82
Camshaft Pulley83
Timing Belt Pulley83
Timing Belt Idler Pulley84
Timing Belt Tensioner84
Timing Belt Cover85
Crankshaft Pulley Installation85
Auxiliary Parts (Engine)86
Knock Sensor (Turbo)87
Oil Pressure Switch87
Oil Cooler (Turbo)87
Intake Manifold Assembly87
Thermostat And Thermostat Cover Installation88
Spark Plug Installation88
Distributor Installation88
Alternator Installation89
Coolant Inlet Pipe And Bypass Pipe Installation89
Engine Hanger Installation89
Turbocharger Bracket (Turbo)89
Exhaust Manifold Assembly Installation90
Oil Pipe And Turbocharger Hose (Turbo) Installation90
Exhaust Manifold Insulator Installation90
P/S Oil Pump Bracket Installation90
Engine Installation91
Transaxle Assembly91
Engine Mount Installation94
Driveshaft Installation95
Lower Arm Installation95
Tie-Rod End Installation95
Stabilizer Control Rod Installation95
P/S Oil Pump Installation96
A/C Compressor Installation96
Drive Belt Installation96
Clutch Release Cylinder (Mtx) Installation97
Control Cable (Atx) Installation97
Three-Way Solenoid Assembly Installation97
Egr Solenoid Assembly (Turbo) Installation97
Turbocharger Oil Pipe And Hose (Turbo) Installation98
Radiator Installation98
Heater Hose And Fuel Hose Connection98
High-Tension Lead99
Accelerator Cable And Throttle Cable (Atx) Installation99
Battery And Battery Carrier Installation99
Air Cleaner Assembly Installation99
Lubrication System100
Lubrication Circuit View101
Lubrication System Specification102
Recommended Sae Viscosity102
Lubrication System Troubleshooting102
Specifications102
Lubrication System Inspection103
Engine Oil Check103
Oil Pressure Check103
Engine Oil Replacement103
Oil Filter Replacement104
Oil Cooler (Only Turbo) Removal And Installation104
Oil Pan Removal Note105
Oil Pan Inspection106
Oil Pan Installation106
Oil Pump Removal107
Oil Pump Disassembly108
Oil Pump Inspection108
Oil Pump Assembly109
Oil Pump Installation109
Cooling System110
Coolant Flow Chart111
Cooling System Specifications112
Cooling System Troubleshooting112
Coolant Check113
Coolant Replacement113
Inspection113
Anti-Freeze Solution Mixture Percentage114
Radiator Cap Inspection114
Radiator Cap Valve Check114
Negative Pressure Valve Check114
Radiator Removal And Installation115
Radiator Inspection115
Radiator Removal/Installation116
Water Pump Removal118
Thermostat Inspection119
Thermostat Installation119
Removal119
Electric Fan - System Circuit Diagram120
Electric Fan Circuit Inspection121
Fan Motor Removal And Installation121
Electric Fan Inspection122
Water Thermo Switch122
Fuel And Emission Control System (Non-Turbo)123
Fuel And Emission Control System Diagram (Non-Turbo)124
Fuel And Emission Control System Component Location125
Input Devices View125
Fuel And Output Devices View126
Exhaust System View127
Vacuum Hose Routing Diagram128
Fuel And Emission Control System Specifications129
Fuel And Emission Control System Troubleshooting130
Vacuum Hose Routing130
Fuel And Emission Control System Troubleshooting With Sst132
Inspection Procedure132
After-Repair Procedure132
Principle Of Code Cycle134
Code Number135
Code No. 01 (Ignition Pulse)136
Code No. 08 (Air Flow Meter)137
Code No. 09 (Water Thermo Sensor)138
Code No. 10 (Intake Air Thermo Sensor)139
Code No. 12 (Throttle Sensor)140
Code No. 14 (Atmospheric Pressure Sensor)141
Code No. 15 (Oxygen Sensor)142
Code No. 17 (Feedback System)143
Code No. 25 (Solenoid Valve-Pressure Regulator)144
Code No. 26 (Solenoid Valve-Purge)144
Code No. 28 (Solenoid Valve — Egr)145
Code No. 34 (Solenoid Valve — Idle Speed Control Valve (Isc))145
Switch Monitor Function146
Switch Monitor Inspection147
Neutral And Clutch Switch (Mtx)147
Inspcetion Procedure147
Idle Switch148
Brake Light Switch148
Blower Switch148
A/C Switch148
Headlight Switch149
Rear Defroster Switch149
Inhibitor Switch149
Water Thermo Switch Circuit (Not Included In Switch Inspection)149
Idle Adjustment150
Idle Speed150
Idle Mixture151
Intake Air System Overview152
Component Descriptions152
Intake Air System Components Removal153
Air Cleaner Element Check154
Accelerator Cable Check154
Throttle Body Check154
Parts Inspection154
Dynamic Chamber Check155
Intake Manifold Check155
Resonance Chamber Check155
Throttle Lever Replacement156
Intake Air System Components Installation157
Idle Speed Control (Isc) System Overview159
Idle Speed Control (Isc) System Component Description160
Idle Speed Control (Isc) System Troubleshooting161
Bac Valve162
Isc Valve162
Fuel System View163
Fuel System Component Description164
Fuel System Troubleshooting165
Fuel Pressure System Release And Servicing Fuel System166
Multi-Pressure Tester167
How To Connect Multi-Pressure Tester168
Fuel Pressure169
Fuel Pump Pressure169
Fuel Line Pressure170
Fuel Pump Operation Test170
Volume Test171
Pulsation Damper171
Injector Check172
Fuel Leakage Test And Volume Test173
Pressure Regulator Control System174
Pressure Regulator Control System Component Descriptions175
Solenoid Valve (Pressure Regulator Control) Inspection176
Solenoid Valve (Pressure Regulator Control) Replacement177
Injector178
Delivery Pipe180
Pressure Regulator181
Fuel Filter181
High Pressure Side181
Fuel Tank Removal182
Fuel Tank Inspection183
Fuel Tank Installation183
Deceleration Control System185
Deceleration Control System Component Description186
Exhaust Gas Recirculation (Egr) System188
Exhaust Gas Recirculation (Egr) System Troubleshooting189
Exhaust Gas Recirculation (Egr) System Inspection189
Solenoid Valve (Egr) Check189
Egr Modulator Valve Check190
Egr Control Valve Check190
Evaporative Emission Control (Eec) System191
Evaporative Emission Control (Eec) System Troubleshooting192
Evaporative Emission Control (Eec) System Inspection193
Purge Control Valves Check194
Vacuum Switch Valve Check194
Water Thermo Valve Check195
Three-Way Check Valve Check195
Solenoid Valve (Purge) Check195
Check And Cut Valve Check196
Separator Check196
Positive Crankcase Ventilation (Pcv) System197
Pcv Valve197
Component Description197
Exhaust System198
Exhaust System Removal And Installation199
Exhaust System Inspection199
Shift Indicator Light Control System200
Shift Indicator Control System Troubleshooting201
Shift Indicator Control System Inspection201
Shift Indicator Light Check201
Control System Overview202
Output Devices And Input Devices Relationship Chart203
Egi Main Fuse Inspection205
Main Relay Check205
Circuit Opening Relay Check205
Engine Control Unit Check206
How To Use The Engine Signal Monitor206
Control System Wiring Diagram207
Terminal Voltage208
Neutral Switch Inspection211
Clutch Switch Inspection211
Brake Light Switch Inspection211
P/S Pressure Switch212
Inhibitor Switch Inspection212
5Th Gear Switch Inspection212
E/L Control Unit Check213
E/L Control Unit Replacement213
Air Flow Meter Inspection214
Throttle Sensor Check215
Throttle Sensor Adjustment216
Throttle Sensor Inspection218
Idle Switch Inspection219
Water Thermo Sensor Inspection219
Water Thermo Switch Inspection219
Oxygen Sensor - Inspection Of Output Voltage220
Oxygen Sensor - Inspection Of Sensitivity220
Atmospheric Pressure Sensor Inspection221
Fuel And Emission Control Systems (Turbo)222
Fuel And Emission Control System Diagram (Turbo)223
Input Devices Diagram224
Component Location224
Fuel And Output Devices Diagram225
Exhaust System Diagram226
Fuel And Emission Control System Specifications (Turbo)228
Fuel And Emission Control System Troubleshooting (Turbo)229
Troubleshooting With Sst231
Code No. 05 (Knock Sensor And Knock Control Unit)240
Code No. 16 (Egr Position Sensor)247
Code No. 28 (Solenoid Valve—Egr, Vacuum Side)250
Code No. 29 (Solenoid Valve—Egr, Vent Side)250
Code No. 42 (Solenoid Valve — Waste Gate)251
Switch Monitor Function (Turbo)252
Intake Air System258
Intake Air System Removal259
Intake Air System Inspection260
Replacement262
Intake Air System Installation263
Idle Speed Control (Isc) System265
Idle Speed Control (Isc) System (Turbo) Troubleshooting267
Idle Speed Control (Isc) System (Turbo) Inspection268
Turbocharging System270
Turbocharging System Troubleshooting271
Attachment Of Hoses271
Overboost Warning Buzzer271
Operation Note271
Service Note271
Turbocharger Boost Pressure272
Waste Gate272
Air Bypass Valve272
Intercooler272
Overboost Warning273
Turbocharger Inspection273
Inspection Of Compressor Wheel Assembly273
Inspection Of Oil Passage273
Inspection Of Solenoid Valve274
Turbocharger Removal And Installation274
Fuel System277
Troubleshooting279
Fuel Pressure Release And Servicing Fuel System280
Multi-Pressure Tester (49 9200 750A)281
Injection Pressure283
Fuel Pump284
Injector On-Vehicle Inspection286
Transfer Pump Control System (4 Wheel Steering)288
Fuel Tank299
Deceleration Control System Diagram302
Deceleration Control System Troubleshooting And Inspection304
Electronic Spark Advance (Esa) Control System306
Electronic Spark Advance (Esa) Control System Troubleshooting308
Knock Control System308
Knock Sensor Replacement309
Exhaust Gas Recirculation (Egr) System (Turbo)310
Evaporative Emission Control (Eec) System (Turbo)316
Positive Crankcase Ventilation (Pcv) System (Turbo)317
Exhaust System (Turbo)318
Control System (Turbo)319
Relationship Chart320
Egi Main Fuse322
Main Relay322
Circuit Opening Relay322
Engine Control Unit323
Control System Wiring Diagram (Turbo)324
Terminal Voltage (Turbo)325
B Ody E Lectrical326
Control System Replacement (Turbo)328
Neutral Switch328
Clutch Switch328
E/L Control Unit330
Air Flow Meter331
Throttle Sensor332
Water Thermo Sensor336
Oxygen Sensor337
Atmospheric Pressure Sensor338
Engine Electrical System339
Engine Electrical System Structural View340
Engine Electrical System Specifications341
Engine Electrical System Troubleshooting342
Battery Inspection343
Electrolyte Level343
Specific Gravity343
Battery Recharging343
Recharge343
Alternator344
Charging System344
Alternator Troubleshooting345
Alternator Warning Light Always Not Illuminate345
Alternator Warning Light Illuminates When Engine Running345
Alternator Warning Light Operates Properly, But Battery Discharged346
Battery Overcharged346
Alternator Removal350
Alternator Disassembly350
Alternator Inspection354
Rotor Check354
Stator Check354
Brush Check355
Brush Spring Check355
Bearing Check (Alternator)355
Rectifier Check356
Alternator Assembly357
Front Bracket And Rotor357
Brush Lifting357
Rear Bearing Installation (Alternator)357
V-Belt Tension Adjustment358
Installation358
Starter359
Starting System Diagram359
Starting System On-Vehicle Inspection359
Starter Removal360
Starter Disassembly360
Magnetic Switch361
Rear Bracket And Brush Holder361
Overrunning Clutch, Planetary Gears, And Internal Gear361
Yoke And Armature361
Overrunning Clutch Stopper362
Brush And Brush Holder362
Starter Inspection363
Armature Check363
Magnetic Switch Check364
Overrunning Clutch Check365
Internal Gear And Planetary Gears Check365
Yoke Check365
Bearing Check (Starter)365
Brush And Brush Holder Check366
Starter Assembly367
Installation Of Overrunning Clutch367
Installation Of Brush Holder368
Starter Operation Check368
Return Test368
Checking Operation368
No-Load Test369
Starter Installation369
Spark Plugs Inspection370
Removal And Installation370
High-Tension Lead Inspection371
Ignition Coil Inspection371
Insulation Of Case371
Ignition Timing372
Spark Test372
Spark Control (Non-Turbo)373
Centrifugal Advance373
Vacuum Advance373
Distributor Removal374
Distributor Disassembly375
Distributor Inspection376
Pick-Up Coil With Igniter (Non-Turbo) Check376
Cap And Rotor Check376
Distributor Shaft, O-Ring, And Oil Seal Check376
Distributor Assembly And Installation377
Distributor - Hei Troubleshooting (Non-Turbo)378
Igniter (Turbo) Inspection379
Starter Interlock System (Only M/T)380
Interlock Switch Inspection380
Clutch381
Clutch Structural View382
Clutch Specifications383
Clutch Troubleshooting383
Clutch On-Vehicle Maintenance384
Pedal Height Inspection384
Pedal Freeplay Inspection And Adjustment384
Fluid Level384
Clutch Pedal View385
Clutch Pedal Inspection385
Clutch Master Cylinder Removal386
Clutch Master Cylinder Disassembly387
Clutch Master Cylinder Inspection388
Clutch Master Cylinder Assembly388
Clutch Master Cylinder Installation389
Clutch Release Cylinder View389
Clutch Release Cylinder Removal390
Clutch Release Cylinder Disassembly390
Clutch Release Cylinder Inspection391
Assembly391
Air Bleeding (Clutch)392
Clutch Release Cylinder Installation392
Clutch And Flywheel Removal393
Clutch And Flywheel Inspection394
Clutch Disc Check395
Clutch Release Bearing Check395
Clutch Release Fork Check396
Flywheel Check396
Clutch And Flywheel Installation397
Manual Transaxle399
Manual Transaxle Structural View400
Structural V Ie W400
Manual Transaxle Cross-Sectional View402
Manual Transaxle Specifications404
Manual Transaxle Troubleshooting405
Manual Transaxle On-Vehicle Maintenance406
Transaxle Oil Inspection406
Transaxle Oil Replacement406
Driveshaft Oil Seals Replacement407
Manual Transaxle Removal410
Manual Transaxle Disassembly415
Lock Nut416
Shift Fork And Shift Rod Assembly416
Secondary 3Rd Gear And 2Nd Gear420
1 St Gear420
Bearing Inner Race (Secondary Shaft End)420
Bearing Inner Race (4Th Gear End)421
Clutch Hub Assembly (3Rd/4Th)421
Bearing Inner Race (Primary Shaft End)421
Differential422
Step 4422
Manual Transaxle Inspection423
1St, 2Nd, 3Rd, 4Th, And 5Th Gears Check423
Primary Shaft Gear And Primary Gear Check423
Secondary Shaft Gear Check423
Synchronizer Ring Check424
Clutch Hub Check424
Clutch Hub Sleeve Check424
Synchronizer Key And Spring Check424
Reverse Idle Gear Check425
Clutch Housing, Transaxle Case, And Differential Gear Case Check425
Bearing Check (Manual Transaxle)425
Speedometer Driven Gear Assembly Check425
Manual Transaxle Assembly426
Step 1426
Bearing Preload (Manual Transaxle)434
Secondary Shaft Adjust Shim436
Manual Transaxle Torque Specifications441
Manual Transaxle Disassembly - H-Type Mtx (Turbo)446
Manual Transaxle Inspection - H-Type Mtx (Turbo)454
Manual Transaxle Assembly - H-Type Mtx (Turbo)458
Synchronizer Ring And Clutch Hub Assembly461
Manual Transaxle Torque Specifications - H-Type Mtx (Turbo)464
Manual Transaxle Installation - H-Type Mtx (Turbo)475
Torque Specifications475
Transaxle Control Removal And Installation481
Automatic Transaxle (Electronically Controlled)484
Automatic Transaxle Specifications485
Automatic Transaxle Component Location486
Mode Switch486
Hold Switch486
16. Inhibitor Switch486
Water Temperature Switch 7B486
12. Fluid Temperature Switch486
Vehicle Speed Sensor486
Cruise Control Switch486
Sensor486
15. Solenoid Valves486
Light486
Ec-At Control Unit486
Automatic Transaxle Structural View487
12. Throttle Cable487
Band487
14. Oil Pump487
Low And Reverse Brake487
6. 2-4 Brake Band487
10. Differential487
Output Gear487
Idle Gear487
Automatic Transaxle - Operation Of Components488
Fluid Passage Location (Automatic Transaxle)489
Automatic Transaxle Troubleshooting492
Ec-At Tester495
No. 12 Code Display (Throttle Sensor)501
No. 55 Code Display (Pulse Generator)501
No. 60, 61, 62, Or 64 Code Display501
No. 63 Code Display (Lock-Up Solenoid Valve)502
Automatic Transmission Preliminary Inspection503
Automatic Transmission Signal Inspection505
Solenoid Valve Operation Table507
Automatic Transmission Stall Test508
Automatic Transmission Time Lag Test511
Automatic Transmission Oil Pressure Test512
Throttle Pressure Test514
Automatic Transmission Road Test515
D Range Test515
S Range Test519
L Range Test520
Automatic Transmission Troubleshooting521
P Range Test521
Vehicle Speed At Gearshift Table522
Slippage Test523
Electrical System Components524
Mode Switch Inspection524
Hold Switch Inspection524
Water Temperature Switch Inspection526
Fluid Temperature Switch Inspection526
Pulse Generator Inspection527
Speed Sensor Inspection527
Solenoid Valves Inspection528
Automatic Transmission On-Vehicle Maintenance531
Automatic Transaxle Fluid (Atf) - Inspection For Leaks531
Selector Level Inspection532
Automatic Transaxle Fluid (Atf) - Inspection For Condition532
Throttle Cable Inspection533
Throttle Cable Adjustment535
Control Valve Body Removal536
Control Valve Body Installation537
Oil Strainer Removal, Inspection And Installation538
Adjustment Of 2-4 Brake Band539
Oil Cooler Removal, Inspection And Installation540
Automatic Transmission Removal541
Automatic Transmission Disassembly546
Automatic Transmission Inspection And Repair564
Torque Converter Inspection564
Oil Pump Disassembly And Inspection565
Clutch Assembly Disassembly570
Clutch Assembly Inspection572
Clutch Assembly Assembly573
Small Sun Gear And One-Way Clutch Disassembly And Inspection579
Replacement Of One-Way Clutch580
One-Way Clutch Assembly581
One-Way Clutch And Carrier Hub Assembly Disassembly And Inspection583
One-Way Clutch And Carrier Hub Assembly Assembly584
3-4 Clutch Disassembly585
3-4 Clutch Inspection586
3-4 Clutch Assembly586
2-3 Accumulator Disassembly, Inspection And Assembly589
Low And Inverse Brake Inspection590
2-4 Brake Band Inspection591
Band Servo Inspection591
Control Valve Body592
Control Valve Body Disassembly593
Premain Control Body Disassembly597
Premain Control Body Inspection598
Premain Control Body Assembly598
Main Control Body Disassembly600
Main Control Body Inspection601
Main Control Body Assembly601
Rear Control Body Disassembly603
Rear Control Body Inspection604
Rear Control Body Assembly604
Assembly Of Control Valve Body605
Differential Disassembly611
Differential Inspection612
Differential Assembly613
Output Gear Disassembly614
Idle Gear Disassembly615
Idle Gear Inspection616
Idle Gear Assembly616
Bearing Cover Assembly Disassembly618
Bearing Housing Disassembly619
Bearing Housing Inspection619
Automatic Transmission Assembly620
Thrust Washer, Bearing, And Race Locations629
Automatic Transmission Torque Specifications639
Automatic Transmission Installation646
Hydraulic Circuit - P Range652
Hydraulic Circuit - R Range653
Hydraulic Circuit - N Range654
Hydraulic Circuit - D Range656
Hydraulic Circuit - S Range661
Hydraulic Circuit - L Range666
Front And Rear Axles670
Driveshaft (Mtx) Structural View671
Driveshaft (Atx) Structural View672
Front Axle Structural View673
Rear Axle Structural View674
Front And Rear Axles Troubleshooting676
Front Axle On-Vehicle Maintenance677
Wheel Bearing Play677
Front Axle Removal678
Front Axle Disassembly680
Front Axle Inspection681
Front Axle Assembly682
Front Axle Installation683
Front Axle Torque Specifications683
Rear Axle On-Vehicle Maintenance685
Rear Axle Removal686
Rear Axle Disassembly687
Rear Axle Inspection688
Rear Axle Installation689
Rear Axle Torque Specifications689
Disc Brake Removal (2Ws)690
Disc Brake Removal (4Ws)691
Disc Brake Disassembly692
Disc Brake Inspection693
Disc Brake Assembly694
Disc Brake Installation695
Driveshaft On-Vehicle Maintenance697
Driveshaft Removal698
Driveshaft (Mtx) Disassembly700
Driveshaft (Mtx) Inspection701
Driveshaft (Mtx) Assembly702
Driveshaft (Atx) Disassembly704
Driveshaft (Atx) Inspection705
Driveshaft (Atx) Assembly705
Driveshaft Installation/Torque Specifications706
Joint Shaft Disassembly And Assembly708
Steering System709
Manual Steering Structural View710
Power Steering (Esps) Structural View711
Power Steering (Ecps) Structural View712
Power Steering (4Ws) Structural View713
Steering System Specifications714
Steering System Troubleshooting715
Steering System On-Vehicle Maintenance718
Steering Wheel Play718
Steering Wheel Effort718
Power Steering Fluid Level719
Loose Or Damaged Oil Pump Belt720
Leakage Of Power Steering Fluid721
Steering System Inspection And Adjustment723
Bleeding Of Power Steering System723
Power Steering Pressure724
Tie-Rod End Boot Removal And Installation726
Steering Wheel And Column Structural View729
Steering Wheel And Column Removal730
Steering Wheel And Column Disassembly And Assembly732
Steering Wheel And Column Inspection733
Steering Wheel And Column Installation735
Steering Wheel And Column Torque Specifications735
Steering Gear And Linkage Structural View736
Steering Gear And Linkage Removal737
Steering Gear And Linkage Installation738
4-Wheel Steering Gear And Linkage Structural View739
4Ws Performance Inspection740
Adjustment Of Steering Angle Transfer Shaft743
4Ws Removal And Installation745
Steering Angle Transfer Shaft746
Rear Steering Gear746
4Ws Torque Specifications747
Front Steering Gear And Linkage Inspection752
Steering Angle Transfer Shaft Inspection753
Rear Steering Gear And Linkage Inspection754
Manual Steering Disassembly756
Manual Steering Inspection759
Manual Steering Assembly760
Engine Speed Sensing Power Steering Disassembly766
Engine Speed Sensing Power Steering Inspection770
Engine Speed Sensing Power Steering Assembly772
Spacer And Pinion Housing Side Oil Seal775
Pinion Shaft Assembly778
Oil Seal778
Electronically Controlled Power Steering Disassembly783
Electronically Controlled Power Steering Inspection784
Electronically Controlled Power Steering Assembly785
Oil Pump Removal And Installation791
Electrical Components Of Electronically-Controlled Power Steering793
Electronically-Controlled Power Steering Troubleshoting793
Power Steering Solenoid Valve Inspection799
Electrical Components Of 4-Wheel Steering (4Ws) Circuit Diagram800
Electrical Components Of 4-Wheel Steering (4Ws) Troubleshooting801
4Ws Warning Light808
Speed Sensors809
Rear To Front Steer Ratio Sensor809
Oil Level Switch (In P/S Reservoir)809
Relay And Timer810
Braking System811
Braking System Structural View812
Anti-Lock Brake System (Abs) View813
Braking System Specifications814
Braking System Troubleshooting815
Braking System On-Vehicle Maintenance816
Brake Hydraulic Line Structural View816
Brake Fluid Level In Master Cylinder Reservoir816
Brake Lines On-Vehicle Inspection817
Brake Lines Removal And Installation818
Brake Fluid Replacement818
Air Bleeding Locations (Braking System)818
Brake Pedal On-Vehicle Inspection And Adjustment820
Brake Pedal Removal821
Brake Pedal Inspection And Installation822
Master Cylinder Removal823
Master Cylinder Disassembly And Assembly824
Master Cylinder Inspection826
Master Cylinder Installation827
Power Brake Unit Function Check829
Inspection Of Check Valve831
Power Brake Unit Removal831
Power Brake Unit Disassembly And Assembly832
Power Brake Unit Inspection834
Power Brake Unit Installation835
Dual Proportioning Valve Function Check837
Dual Proportioning Valve Removal And Installation838
Front Disc Brake Inspection And Replacement839
Front Disc Brake Removal841
Front Disc Brake Disassembly And Assembly842
Front Disc Brake Inspection844
Front Disc Brake Installation845
Rear Disc Brake Inspection846
Disc Pad Replacement846
Rear Disc Brake Removal848
Rear Disc Brake Disassembly And Assembly849
Rear Disc Brake Installation854
Rear Drum Brake Removal855
Wheel Cylinder Disassembly And Assembly858
Wheel Cylinder Inspection859
Wheel Cylinder Installation860
Parking Brake On-Vehicle Maintenance864
Parking Brake Adjustment864
Parking Brake Lever Removal And Installation865
Parking Brake Cable Removal867
Parking Brake Cable Installation868
Anti-Lock Brake System (Abs) Structural View870
Anti-Lock Brake System (Abs) Wiring Diagram871
Anti-Lock Brake System (Abs) Troubleshooting872
Anti-Lock Brake System (Abs) Diagnosis Indication Mode885
Anti-Lock Brake System (Abs) Memory Cancel885
Abs Warning Light Inspection For No Illumination886
Relay Box Inspections886
Wheel Speed Sensor Inspection886
Front Wheel Speed Sensor Removal And Installation887
Rear Wheel Speed Sensor Removal And Installation888
Front Sensor Rotor Removal889
Front Sensor Rotor Installation890
Rear Sensor Rotor Removal891
Rear Sensor Rotor Installation892
Hydraulic Unit Fluid Replacement893
Hydraulic Unit Inspection893
Inspection Of Proportioning Valve894
Anti-Lock Brake System (Abs) Removal895
Anti-Lock Brake System (Abs)897
Inspection Of Control Unit Circuit898
Wheels And Tires899
Wheels And Tires Specifications900
Wheels And Tires Troubleshooting900
Wheels And Tires Inspection And Adjustments901
Tire Rotation902
Wheel Balance903
Wheel Mounting903
Note Regarding Tire Replacement904
Suspension905
Front Suspension Structural View906
Rear Suspension Structural View907
Suspension Specifications908
Suspension Troubleshooting911
Front Shock Absorber And Spring Removal And Installation913
Front Shock Absorber And Spring Disassembly And Assembly914
Front Lower Arm Removal And Installation918
Lower Arm Bushing Removal And Installation920
Ball Joint Dust Boot Removal And Installation921
Lower Arm922
Front Stabilizer (4Ws) Removal And Installation923
Front Stabilizer Removal And Installation927
Rear Shock Absorber And Spring Removal And Installation929
Rear Shock Absorber And Spring Disassembly And Assembly932
Lateral Link And Trailing Link Removal And Installation934
Rear Lower Arm And Trailing Link (4Ws) Removal And Installation936
Rear Stabilizer Removal And Installation939
Rear Stabilizer And Control Link (4Ws) Removal And Installation941
Rear Crossmember (4Ws) Removal And Installation944
Front Wheel Alignment950
Camber And Caster Inspection And Adjustment951
Rear Wheel Alignment952
Rear Turning Angle (4Ws)954
Body955
Hood Structural View956
Hood Removal957
Hood Installation958
Hood Adjustment958
Trunk Lid Sructural View959
Trunk Lid Removal960
Trunk Lid Installation961
Trunk Lid Adjustment962
Rear Hatch Structural View963
Rear Hatch Removal964
Rear Hatch Installation966
Rear Hatch Adjustment966
Front Doors Structural View967
Front Doors Removal969
Front Doors Installation971
Front Doors Adjustment972
Rear Doors Structural View973
Rear Doors Removal974
Rear Doors Installation975
Rear Doors Adjustment976
Front Bumper Structural View977
Front Bumper Removal And Installation978
Rear Bumper Structural View979
Rear Bumper Removal And Installation980
Radiator Grille Removal And Installation981
Headlight And Combination Light Removal And Installation982
Headlight Aiming985
Rear Combination Light Removal And Installation986
Rear Combination Light Lens Replacement987
License Plate Light And Cargo Room Light Removal And Installation989
Interior Light And Map Light Removal And Installation990
High Mounted Stop Light Removal And Installation991
Molding And Garnish Structural View992
Windshield Molding Removal And Installation993
Windshield Lower Molding Removal And Installation993
Drip Molding Removal And Installation993
Beltline Molding Removal And Installation993
Rear Window Side Molding Removal And Installation994
Rear Window Lower Molding Removal And Installation994
Rear Window Upper Molding Removal And Installation994
Hood Molding Removal And Installation994
Quarter Window Molding Removal And Installation995
Trunk Lid Molding Removal And Installation996
Center Pillar Garnish Removal And Installation996
Rear Finisher Removal And Installation996
Sail Garnish Removal And Installation997
Side Protector Molding Structural View997
Side Protector Molding Removal And Installation998
Door Mirror Disassembly And Assembly999
Trunk-Lid Lock Remote Release Removal And Installation1000
Fuel Filler Lid Remote Release Removal And Installation1001
Windshield Glass Structural View1002
Windshield Glass Removal1003
Windshield Glass Installation1004
Hardening Time Of Repair Seal1005
Rear Window Glass Structural View1007
Rear Window Glass Removal1009
Rear Window Glass Installation1010
Rear Hatch Glass Structural View1013
Rear Hatch Glass Removal And Installation1014
Quarter Window Glass Structural View1017
Quarter Window Glass Removal And Installation1019
Headliner Structural View1022
Headlinger Removal1024
Headlinger Installation1027
Instrument Panel Structural View1028
Instrument Panel Installation View1029
Instrument Panel Removal1030
Instrument Panel Installation1035
Sliding Roof Structural View1036
Sliding Roof Removal1037
Sliding Roof Installation1040
Windshield Wiper Structural View1046
Windshield Wiper Removal1047
Windshield Wiper Installation And Adjustment1048
Rear Window Wiper Structural View1049
Rear Window Wiper Removal And Installation1050
Rear Window Wiper Adjustment1051
Washer Spray Adjustment1051
Seat Structural View1052
Front Seat Inspection1053
Rear Seat Removal And Installation1053
Seat Belts (Standard Shoulder Belt) Structural View1054
Seat Belts Inspection1054
Seat Belts (Automatic Shoulder Belts) Structural View1055
Seat Belts Tightening Torques1056
Seat Belts Removal And Installation1057
Underbody Projected Dimensions1058
Underbody Straight-Line Dimensions1061
Body Electrical System1062
Electrical Troubleshooting Tools1063
Wiring Color Code1064
Replacement Of Terminal1065
Replacement Of Fuse1066
Thin Insulation Wire1066
Shielded Braid Wire1066
Electrical Symbols1067
Location Of Unit, Relay And Switch Structural View1068
Main Fuse Block Structural View1070
Main Fuse Block Replacement1070
Joint Box And Fuse Structural View1071
Ignition Switch Inspection1072
Combination Switch Structural View1073
Combination Switch Inspection1073
Cluster Switch Structural View1076
Hazard Switch Inspection1077
Defroster Switch Inspection1077
Rear Wiper And Washer Switch Inspection1078
Meter Structural View1079
Meter Assembly And Disassembly1080
Meter Troubleshooting1081
Analog Meter Inspection1083
Speedometer Check1083
Tachometer Check1083
Fuel Gauge Check1083
Water Temperature Gauge Check1084
Digital Meter Inspection1084
Meter Sender Inspection1086
Warning Light And Sender Circuit Diagram1088
Warning Light And Sender Troubleshooting1089
Warning And Sender Inspection1095
Central Processing Unit (Cpu) Structural View1097
Central Processing Unit (Cpu) Functions1097
Central Processing Unit (Cpu) Circuit Diagram1098
Central Processing Unit (Cpu) Removal And Installation1099
Central Processing Unit (Cpu) On-Vehicle Inspection1099
Turn And Hazard Light Structural View1100
Turn And Hazard Light Circuit Diagram1101
Turn And Hazard Light Troubleshooting1102
Stop Light Structural View1104
Stop Light Circuit Diagram1105
Stop Light Troubleshooting1105
Stop Light Inspection1107
Horn Structural View1108
Horn Circuit Diagram1108
Horn Troubleshooting1109
Horn Inspection1109
Headlight Structural View1110
Headlight Circuit Diagram1110
Headlight Troubleshooting1111
Panel Light Control Circuit Diagram1112
Panel Light Control Troubleshooting1112
Panel Light Control Inspection1113
Rear Window Defroster Structural View1114
Rear Window Defroster Circuit Diagram1114
Rear Window Defroster Troubleshooting1115
Rear Window Defroster Inspection1116
Defroster Relay Check1116
Defroster Filament Check1116
Repairing Defroster Filament1116
Power Window Structural View1117
Power Window Circuit Diagram1118
Power Window Troubleshooting1119
Power Window Inspection1122
Power Window Motor1124
Remote Control Mirror Structural View1125
Remote Control Mirror Circuit Diagram1125
Remote Control Mirror Troubleshooting1126
Remote Control Mirror Inspection1126
Rear Window Wiper Circuit Diagram1128
Rear Window Wiper Troubleshooting1129
Rear Window Wiper Inspection1131
Windshield Wiper Circuit Diagram1133
Windshield Wiper Troubleshooting1134
Windshield Wiper Inspection1137
Cruise Control System Structural View1138
Cruise Control System Circuit Diagram1139
Cruise Control System On-Vehicle Inspection1140
Cruise Control System Check Table1142
Cruise Control System Inspection1143
Sliding Sunroof Structural Diagram1145
Sliding Sunroof Circuit Diagram1146
Sliding Sunroof Troubleshooting1147
Sliding Sunroof Inspection1148
Limit Switch Check1149
Auto Adjusting Suspension (Aas) Circuit Diagram1150
Auto Adjusting Suspension (Aas) Troubleshooting1150
Auto Adjusting Suspension (Aas) Inspection1160
Actuator Inspection1160
Power Door Lock Structural View1161
Power Door Lock Circuit Diagram1161
Power Door Lock Troubleshooting1162
Power Door Lock Inspection1163
Automatic Shoulder Belt Structural View1164
Automatic Shoulder Belt Circuit Diagram1165
Automatic Shoulder Belt Troubleshooting1166
Automatic Shoulder Belt Inspection1167
Automatic Seat Belt Motor Check1167
Door Catch Switch Check1167
Buckle Switch (Lap Belt) Check1168
Seat Belt Warning Switch Check1168
Audio System Outline1169
Rear Connector View (Audio System)1171
Audio System Troubleshooting1176
Power Antenna Structural View1184
Power Antenna Circuit1185
Inspection Of Power Antenna Relay1185
Heater Structural View1186
Heater - Air Flow At Each Mode1187
Heater - Lever Control Type1190
Heater - Logical Control Type1191
Heater Circuit Diagram1192
Logicon Switch Inspection1193
Checking Rec-Fresh Air Selector Circuit1193
Checking Mode Control Circuit1194
Checking Air Mix Control Circuit1195
Checking A/C Switch And Eco Switch Circuit1196
Checking Fan Speed Control Lever1197
Checking Dim Indicator Circuits1198
Checking Illumination Circuit1198
Theft-Deterrent System Structural View1199
Theft-Deterrent System Circuit Diagram1200
Theft-Deterrent System Troubleshooting1201
Theft-Deterrent System1205
Technical Data1206
Special Tools1225
For Turbo Ignition System - Engine And Fuel Control System Diagram1235
For Turbo - Engine And Fuel Control System Wiring Diagram1236
Turn And Hazard Flasher Lights/Horn/Stop Lights Wiring Diagram1239
General Information1241
Fundamental Procedures1242
Vehicle Lift (2-Support Type) Positions1245
Towing1246