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MR2 1988
Toyota MR2 1988 Manuals
Manuals and User Guides for Toyota MR2 1988. We have
1
Toyota MR2 1988 manual available for free PDF download: Repair Manual
Toyota MR2 1988 Repair Manual (1067 pages)
Brand:
Toyota
| Category:
Automobile
| Size: 46.3 MB
Table of Contents
Table of Contents
4
Repair Procedures
5
How to Use this Manual
5
Check Piston Stroke of Overdrive Brake
6
Identification Information
7
Vehicle Identification Number
7
Engine Serial Number
7
General Repair Instructions
7
Precautions for Vehicles Equipped Witha Catalytic Converter
9
Vehicle Lift and Support Locations
10
Abbreviations Used in this Manual
11
Maintenance
12
Maintenance Schedule
13
Normal Condition Schedule
13
Severe Condition Schedule
14
Maintenance Operations
15
Cold Engine Operations
15
Replace Timing Belt
15
Inspect Drive Belts
15
Inspect Air Filter
16
Replace Air Filter
16
Replace Engine Oil and Filter
16
Replace Engine Coolant
17
Inspect Charcoal Canister
17
Hot Engine Operations
18
Inspect Fuel Lines and Connections
18
Inspect Exhaust Pipe and Mountings
18
Adjust Valve Clearance
18
Brakes
19
Inspect Brake Line Pipes and Hoses
19
Inspect Front and Rear Brake Pads and Discs
19
Inspect Steering Linkage
19
Replace Automatic Transaxle
21
Tighten Bolts and Nuts on Chassis and Body
22
Final Inspection
22
General Maintenance
23
Outside Vehicle
23
Inside Vehicle
23
Under Hood
24
Engine Mechanical
25
Troubleshooting
26
Engine Tune-Up
30
Adjustment of Valve Clearance
31
Set N0.1 Cylinder to Tdc/Compression
31
Adjusting Shim Selection Using Chart
33
Intake
33
Exhaust
34
Inspection and Adjustment of Idle Speed
35
Idle Hc/Co Concentration Check Method
36
Further Check Idle Speed
36
Initial Conditions
36
Check Oxygen Sensor Operation
36
Compression Check
38
Timing Belt Components
39
Removal of Timing Belt
39
Remove Spark Plugs
40
Set No. 1 Cylinder to Tdc/Compression
40
Remove Rh Engine Mounting Insulator
40
Remove Crankshaft Pulley
40
Cylinder Head (4A-Ge
69
Cylinder Head (4A-Gze
98
Removal of Cylinder Head
99
Remove No. 2 Air Outlet Duct
101
Disconnect No. 3 Fuel Pipe
101
Remove No. 1 Vacuum Transmitting Pipe
101
Disconnect No.2 Fuel Hose
101
Remove Delivery Pipe with Injectors
102
Lay Wire Harness to One Side
102
Remove Egr Valve with Pipe
102
Remove Intake Manifold
102
Remove Alternator Bracket
103
Remove Exhaust Manifold
103
Installation of Cylinder Head
104
Install Intake Manifold
105
Install Egr Valve with Pipe
105
Install Water Outlet with By-Pass Pipe
105
Clamp Wire Harness
105
Connect No.2 Fuel Hose
106
Install No.1 Vacuum Transmitting Pipe
106
Connect No.3 Fuel Pipe
106
Install No.2 Air Outlet Duct
106
Install Water Pump Pulley and Drive Belts
107
Connect Following Connectors and Wires
107
Cylinder Block Components
109
Removal of Engine (4A-Ge)
110
Disconnect Control Cables
112
Remove Front Mounting Insulator
113
Remove Rear Mounting Insulator
113
Remove Engine with Transaxle
113
Remove Water Inlet with Housing
114
Disconnect Following Connectors
114
Remove Flywheel Housing under Cover
114
Removal of Engine (4A-Gze)
116
Disconnect Following Connectors and Wires
117
Remove A/C Drive Belt
118
Disconnect A/C Compressor
118
Preparation for Disassembly
122
Disassembly of Cylinder Block
123
Remove Rear Oil Seal Retainer
123
Measure Connecting Rod Thrust Clearance
123
Remove Rod Caps and Measure Oil Clearance
123
Remove Main Bearing Caps and Measure Oil Clearance
126
Remove Crankshaft
128
Inspection of Cylinder Block
129
Remove Gasket Material
129
Clean Cylinder Block
129
Inspect Top of Block
129
Disassembly of Piston and Connecting Rod Assemblies
130
Check Fit between Piston and Pin
130
Remove Piston Rings
130
Disconnect Connecting Rod from Piston
130
Inspection of Piston and Connecting Rod Assemblies
131
Clean Piston
131
Inspect Piston Diameter and Oil Clearance
131
Inspect Piston Ring Groove Clearance
131
Inspect Piston Ring End Gap
132
Inspect Piston Pin Fit
132
Inspect Connecting Rods
132
Inspect Connecting Rod Bolts
133
Inspect Piston Pin Oil Clearance
133
Boring of Cylinders
135
Calculate Amount to Bore Cylinder
135
Bore and Hone Cylinders to Calculated Dimensions
135
Inspection of Crankshaft
136
Measure Crankshaft for Runout
136
Inspect Main Journals and Crank Pins
136
Replacement of Rear Oil Seal
137
Replace Crankshaft Rear Oil Seal
137
Assembly of Piston and Connecting Rod
138
Install Piston Rings
138
Install Bearings
139
Assembly of Cylinder Block
140
Install Main Bearings
140
Install Upper Thrust Washers
140
Install Piston and Connecting Rod Assembles
141
Install Connecting Rod Caps
141
Post Assembly
143
Install Rear Oil Seal Retainer
143
Installation of Engine (4A-Ge)
144
Install Transaxle to Engine
144
Install Six Torque Converter Mounting Bolt
144
Install Flywheel Housing under Cover
144
Install Engine with Transaxle
145
Install Rear Mounting Insulator
145
Install Front Mounting Insulator
145
Install Clutch Release Cylinder and Control Bracket
146
Connect Control Cables
146
Connect A/C Compressor
147
Installation of Engine (4A-Gze)
150
Install Water Inlet with Housing
150
Supercharger System
156
Supercharger
158
On-Vehicle Inspection of Supercharger
158
Check Supercharger Oil Level
158
Inspect Magnet Clutch
158
Inspect Air By-Pass Valve (Abv)
159
Inspect Supercharger Pressure
159
Removal of Supercharger
160
Remove Intercooler
161
Remove Air Flow Meter with No.3 Air Cleaner Hose
161
Remove Drive Belt (for Supercharger)
161
Disassembly of Supercharger
164
Drain Supercharger Oil
165
Remove N0.2 Air Inlet Duct
165
Remove Clutch Hub
165
Remove Clutch Pulley
165
Remove Clutch Flange
166
Remove Front Cover
166
Remove Rear Cover
166
Remove Rear Plate
166
Inspection of Supercharger Components
167
Inspection of Air By-Pass Valve (Abv)/Air Control Valve (Acv) System
167
Installation of Supercharger
168
Install Elbows
168
Install Union
168
Install Rear Plate
168
Install Rear Cover
169
Install Housing Front Cover
169
Install Clutch Flange
170
Install Clutch Stator
170
Install Clutch Pulley
170
Install Clutch Hub
170
Inspect and Adjust Air Gap of Magnet Clutch
171
Install N0.2 Air Inlet Duct
171
Fill with Supercharger Oil
171
Install Air Inlet Duct Stay
173
Supercharger Relay
174
Inspection of Supercharger Relay
174
Inspect Relay Continuity
174
Inspect Relay Operation
174
Emission Control Systems
175
System Purpose
176
Component Layout and Schematic Drawing (4A-Ge
177
Component Layout and Schematic
178
Positive Crankcase Ventilation (Pcv) System
179
Inspection of Pcv Hoses and Connections
179
Fuel Evaporative Emission Control (Evap) System
180
Inspection of Charcoal Canister
181
Clean Filter in Canister
181
Check Bvsv by Blowing Air into Pipe
181
Dash Pot (Dp) System
182
Inspection of Dp System
183
Check Dp Setting Speed
183
Check Vtv Operation
183
Exhaust Gas Recirculation (Egr) System (4A-Ge
184
Inspection of Egr System
186
Check Seating of Egr Valve
186
Check Bvsv with Cold Engine
186
Inspection of Egr Valve
187
Inspection of Egr Vacuum Modulator
187
Check Egr Valve
187
Inspection of Bvsv
188
Inspection of Vsv
188
Inspection of Check Valve
189
Check for Open Circuit
189
Exhaust Gas Recirculation (Egr) System (4A-Gze
190
Three-Way Catalyst (Twc) System
195
EFI System
197
EFI System Description
198
Fuel System
200
Air Induction System
200
Electronic Control System
200
Maintenance Precautions
201
If Car Is Equipped with Mobile Radio System (Ham, Cb, Etc.}
201
Inspection Precautions
201
Troubleshooting Hints
205
Difficult to Start or no Start
206
Engine Often Stalls
208
Engine Sometimes Stalls
209
Rough Idling And/Or Missing
210
High Engine Idle Speed (no Drop)
212
Engine Backfires
213
Muffler Explosion (after Fire)
214
Engine Hesitates And/Or Poor Acceleration
215
Diagnosis System
217
"Check Engine" Warning Light Check
217
Output of Diagnostic Codes
217
Cancelling Diagnostic Code
219
Diagnostic Codes
220
Inspection of Diagnosis Circuit
224
Efi System Check Procedure
225
Connectors of ECU
225
Troubleshooting with Volt/ Ohmmeter (4A-Ge
225
Voltage at ECU Wiring Connectors
226
Troubleshooting with Volt/ Ohmmeter (4A-Gze
227
Location of Fuses and Fusible Links
229
Troubleshooting Efi Electronic Circuit with Volt/Ohmmeter (4A-Ge
229
Troubleshooting Efi Electronic Circuit with Volt/Ohmmeter (4A-Gze
244
Fuel Pump
260
Fuel System
260
Check Fuel Pump Operation
261
Check Fuel Pressure
261
Fuel Pump
262
Pressure Regulator (4A-GE
262
Pressure Regulator (4A-GZE
263
Removal of Fuel Pump
267
Installation of Fuel Pump
268
Remove Fuel Pump Filter from Fuel Pump
268
Install Fuel Pump to Fuel Pump Bracket
268
Install Fuel Tank
268
Cold Start Injector
269
Measure Resistance of Cold Start Injector
269
Removal of Cold Start Injector
270
Inspection of Cold Start Injector
271
Check Injection of Cold Start Injector
271
Installation of Cold Start Injector
273
Install Cold Start Injector
273
Install Cold Start Injector Pipe
273
Pressure Regulator (4A-GE)
274
Removal of Pressure Regulator
274
Installation of Pressure Regulator
274
Pressure Regulator (4A-GZE)
275
Injector
276
Check Injector Operation
276
Measure Resistance of Injector
276
Removal of Injector
277
Remove Fuel Inlet Pipe
279
Remove Delivery Pipe
279
Remove Injectors
279
Inspection of Injector
280
Test Injection of Injectors
280
Check Leakage
281
Installation of Injectors
284
Install Injectors into Delivery Pipe
284
Install Delivery Pipe with Injectors
284
Connect Injector Connectors
285
Connect Fuel Inlet Pipe
285
Fuel Tank and Line
289
Air Flow Meter
290
Measure Resistance of Air Flow Meter
290
Air Induction System
290
Removal of Air Flow Meter
291
Inspection of Air Flow Meter
291
Installation of Air Flow Meter
291
Throttle Body
293
Check Throttle Body
293
Check Throttle Position Sensor
294
Removal of Throttle Body
295
Disconnect Following Hoses
295
Inspection of Throttle Body
296
Clean Throttle Body before Inspection
296
Check Throttle Valve
296
Disassembl V of Throttle Body
298
Assembly of Throttle Body
299
Install Isc Valve
299
Install Throttle Position Sensor
299
Installation of Throttle Body
300
On-Vehicle Inspection
302
Inspect Resistance of Isc Valve
302
Idle Speed Control (ISC) Valve (4A-GZE
302
Inspect Operation of Isc Valve
303
Installation of Isc Valve
303
Auxiliary Air Valve (4A-GE)
304
Check Operation of Auxiliary Air Valve
304
Removal of Auxiliary Air Valve
304
Installation of Auxiliary Air Valve
304
Location of Electronic Control Parts
305
Electronic Control System
305
EFI Main Relay
305
Circuit Opening Relay
305
EFI Main Relay
306
Inspection of Efi Main Relays
306
Check Operation of Main Relays
306
Circuit Opening Relay
307
Inspection of Circuit Opening Relay
307
Check Circuit Opening Relay Operation
307
Solenoid Resistor (4A-GZE) and Injector Relay
309
Inspection of Solenoid Resistor
309
Measure Resistance of Solenoid Resistor
309
Inspect Injector Relay
310
Start Injector Time Switch
311
Inspection of Start Injector Time Switch
311
Measure Resistance of Start Injector Time Switch
311
Water Temperature Sensor
312
Inspection of Egr Gas Temperature Sensor
313
EGR Gas Temperature Sensor (for California
313
High Temperature Line Pressure up System
314
Inspection of High Temperature Line Pressure up System
314
Inspect Fuel Pressure Vsv
314
Idle-Up System
315
Oxygen Sensor
316
Inspection of Feedback Voltage (Vf)
316
Electronic Controlled Unit (ECU)
319
Inspection of Ecu
319
Measure Voltage of Ecu
319
Connectors of ECU (4A-GE)
319
Voltage at ECU Wiring Connectors {4A-GE)
320
Connectors of ECU (4A-GZE)
321
Voltage at ECU Wiring Connectors (4A-GZE)
322
Resistances at ECU Wiring Connectors (4A-GE)
323
Resistances at ECU Wiring Connectors (4A-GZE)
323
Fuel Cut RPM
324
Inspection of Fuel Cut Rpm
324
Cooling System
325
Check of Engine Coolant
326
Check Coolant Level
326
Check Coolant Quality
326
Troubleshooting
326
Replacement of Engine Coolant
327
Cooling Circuit
327
Drainage of Engine Coolant
327
Close Drain Cocks
328
Connect Service Hoses
328
Refill with Coolant
328
Water Pump Components
330
Removal of Water Pump
330
Remove Water Inlet Pipe
331
Remove Oil Dipstick Guide and Dipstick
331
Remove Water Pump
331
Installation of Water Pump
332
Install Oil Dipstick Guide and Dipstick
332
Install Inlet Pipe
332
Adjust Drive Belt Tension
333
Removal of Thermostat
334
Inspection of Thermostat
334
Installation of Thermostat
334
Cleaning of Radiator
335
Inspection of Radiator
335
Removal of Radiator
335
Check Radiator Cap (Water Filler Cap)
335
Installation of Radiator
336
Install Radiator and Support
336
Turn Ignition Switch on
337
Disconnect Temperature Switch Connector
337
Electric Cooling Fan (Radiator)
337
Inspection of Electric Cooling
338
Inspect Temperature Switch
338
Inspect Fan Main Relay
338
Inspect No. 1 Fan Relay
339
Inspect Fan Motor
339
Removal of Electric Cooling Fan
340
Disassembly of Electric Cooling Fan
340
Assembly of Electric Cooling Fan
340
Installation of Electric Cooling Fan
340
Electric Cooling Fan (Engine Compartment)
341
Inspection of Cooling Fan Circuit
342
Inspection of Electric Cooling Fan
343
Inspect Temperature Sensor
343
Inspect Engine Main Relay
343
Lubrication System
346
Oil Pressure Check
348
Check Engine Oil Quality
348
Check Engine Oil Level
348
Start Engine
348
Replacement of Engine Oil and Oil Filter
349
Drain Engine Oil
349
Replace Oil Filter
349
Fill with Engine Oil
349
Oil Pump Components
350
Removal of Oil Pump
350
Remove Front Exhaust Pipe
350
Remove Oil Strainer
351
Remove Oil Pan Baffle Plate
351
Remove Oil Dipstick and Guide
351
Remove Oil Pump
352
Disassembly of Oil Pump
352
Remove Drive and Driven Gears
352
Remove Relief Valve
352
Inspection of Oil Pump
353
Inspect Relief Valve
353
Inspect Drive and Driven Gears
353
Replacement of Oil Seal
354
Assembly of Oil Pump
354
Remove Oil Seal
354
Install Oil Seal
354
Installation of Oil Pump
355
Install Oil Pump
355
Install Oil Pan Baffle Plate
355
Install Oil Strainer
356
Install Oil Pan
356
Install Front Exhaust Pipe
357
Oil Cooler and Pressure Regulator
358
Removal and Disassembly of Pressure Regulator (Relief Valve)
358
Remove Oil Filter
359
Remove N0.2 Oil Filter Bracket
359
Remove N0.1 Oil Filter Bracket
359
Remove Oil Cooler
360
Inspection of Oil Cooler and Pressure Regulator (Relief Valve)
360
Assembly of and Installation of Pressure Regulator (Relief Valve)
361
Install Relief Valve
361
Install N0.1 Oil Filter Bracket
361
Connect Oil Cooler Pipes
362
Ignition System
363
Precautions
364
Electronic Spark Advance
365
Esa System Circuit
365
Spark Test
366
Check that Spark Occurs
366
Inspection of High-Tension Cord
367
Inspection of Spark Plug
367
Inspect Electrode
367
Inspection of Ignition Coil
369
Inspection of Distributor
369
Inspect Air Gaps
369
Check Signal Generator
370
Distributor
371
Removal of Distributor
371
Replacement of Distributor Driven Gear
372
Grind Driven Gear and Pin
372
Remove Pin and Drive Gear
372
Installation of Distributor
372
Starting System
375
Starter
377
Removal of Starter
377
Disassembly of Starter
378
Inspection of Starter
379
Armature Coil
379
Measure Diameter of Commutator
380
Inspect Undercut Depth
380
Field Frame (Field Coil}
380
Inspect Field Coil for Open Circuit
380
Brush Spring
381
Brush Holder
381
Clutch and Gears
381
Bearings
381
Magnetic Switch
382
Perform Pull-In Coil Open Circuit Test
382
Assembly of Starter
383
Performance Test of Starter
385
Perform Pull-In Test
385
Perform Hold-In Test
385
Inspect Plunger Return
385
Installation of Starter
386
Clutch Starter Relay
386
Inspection of Clutch Starter Relay
386
Inspect Clutch Starter Relay
386
Charging System
387
Precautions
388
Troubleshooting
388
On-Vehicle Inspection
389
Alternator
392
Removal of Alternator
393
Disassembly of Alternator
393
Remove Rectifier Holder
394
Remove Pulley
394
Remove Rear End Frame
394
Inspection and Repair of Alternator
395
Rotor
395
Inspect Rotor for Open Circuit
395
Inspect Rotor for Ground
395
Brush and Brush Holder
396
Measure Exposed Brush Length
396
Inspect Positive Side Rectifier
396
Inspect Negative Side Rectifier
397
Inspect Front Bearing
397
Inspect Rear Bearing
398
Assembly of Alternator
399
Install Rectifier Holder
399
Install Brush Holder and IC Regulator
400
Install Brush Holder
400
Install Rear End Cover
400
Installation of Alternator
401
Install Alternator Drive Belt
401
Engine Main Relay
402
Inspection of Engine Main Relay
402
Clutch
403
Check and Adjustment of Clutch Pedal
405
Bleeding of Clutch System
405
Inspection of Clutch Start System
406
Check Clutch Pedal
406
Check Clutch Start System
406
Inspection and Adjustment of Clutch Start Switch
406
Clutch Master Cylinder Components
407
Removal of Master Cylinder
407
Disassembly of Master Cylinder
408
Disconnect Clutch Line Tube
408
Remove Clevis Pin and Clip
408
Remove Master Cylinder
408
Inspection of Master Cylinder
409
Assembly of Master Cylinder
409
Installation of Master Cylinder
410
Clutch Release Cylinder
411
Removal of Release Cylinder
411
Disconnect Clutch Line and Bleeder Tubes
411
Remove Bleeder Tube with Bleeder Plug
411
Disassembly of Release Cylinder
412
Inspection of Release Cylinder
412
Assembly of Release Cylinder
413
Installation of Release Cylinder
413
Clutch Unit Components
414
Removal of Clutch Unit
414
Remove Clutch Cover and Disc
415
Inspection and Repair of Clutch Parts
415
Inspect Clutch Disc for Wear or Damage
415
Inspect Clutch Disc Runout
415
Inspect Diaphragm Spring for Wear
416
Inspect Release Bearing
416
Installation of Clutch Unit
416
Install Clutch Disc and Cover on Flywheel
416
Manual Transaxle
418
Precautions
419
Troubleshooting
419
Removal of Transaxle
420
Remove Exhaust Pipe Assembly
421
Remove Starter
422
Remove No. 2 Engine Rear Plate
422
Remove Front Engine Mounting
422
Remove Rear Engine Mounting
422
Remove Transaxle
423
Remove Side Gear Shaft from Transaxle
423
C52 Transaxle
424
Transmission
424
Components
424
Disassembly of Transmission
427
Remove Control Shaft Retainer
428
Remove Lock Bolt
428
Remove Lock Nut
428
Remove Transmission Case
430
Remove Reverse Shift Arm Bracket
430
Remove Reverse Idler Gear and Shaft
430
Remove Shift Forks and Shift Fork Shafts
430
Remove Snap Ring
432
Inspection of Transmission Components
435
Inspect Input Shaft
435
Inspect Output Shaft
435
Check Oil Clearance of each Gear
435
Inspect Synchronizer Rings
436
Assembly of Transmission
441
Install Snap Ring
441
Measure Third Gear Thrust Clearance
441
Measure First Gear Thrust Clearance
443
Measure Second Gear Thrust Clearance
444
Install Magnet
444
Adjust Differential Side Bearing Preload
444
Install Input and Output Shaft
445
Install Shift Forks and Shift Fork Shafts
445
Install Reverse Shift Arm
447
Install Reverse Idler Gear and Shaft
447
Install Transmission Case
447
Install and Torque Reverse Idler Gear Shaft Lock Bolt
448
Install Rear Bearing Retainer
448
Install Fifth Driven Gear
448
Insert No.3 Clutch Hub into Hub Sleeve
449
Install Lock Nut
450
Install Bolt
450
Install Lock Bolt
451
Install Control Shaft Cover
451
Install Shift Lever
452
Install Transmission Case Cover
452
Install Front Bearing Retainer
453
Install Release Fork and Bearing
453
Install Back-Up Light Switch
453
Removal of Differential
454
Installation of Differential
454
E51 Transaxle
455
Components
455
Removal of Component Parts
458
Remove Speedometer Driven Gear
458
Remove Shift Lever
458
Remove Rear Bearing Retainer
461
Remove Plug, Seat, Spring and Locking Ball
461
Remove No. 2 Oil Pipe
462
Remove Reverse Idler Gear and Shift
463
Remove No.1 Shift Fork Shaft
463
Remove Interlock Roller
463
Remove Snap Rings
464
Remove Input and Output Shaft Assembly
464
Remove Differential Assembly
465
Remove Oil Pump Assembly
465
Inspection of Component Parts
466
Inspect Synchronizer Ring for Fifth Gear
466
Input Shaft Assembly
470
Disassembly of Input Shaft Assembly
470
Check Oil Clearance of Third and Fourth Gear
471
Inspection of Input Shaft Component Parts
473
Assembly of Input Shaft Assembly
474
Measure Fourth Gear Thrust Clearance
475
Output Shaft Assembly
476
Disassembly of Output Shaft Assembly
476
Inspection of Output Shaft Component Parts
478
Assembly of Output Shaft Assembly
480
Insert No. 1 Clutch Hub into Hub Sleeve
480
Install Spacer and Fourth Driven Gear
481
Install Output Shaft Rear Bearing
481
Oil Pump Assembly
482
Check Operation of Oil Pump
482
Remove Oil Pump Cover
483
Check Rotor Body Clearance
483
Check Rotor Tip Clearance
483
Check Side Clearance
484
Install Oil Pump Cover
485
Torque Oil Pump Cover Bolts
486
Install Gasket
486
Shift and Select Lever Assembly
487
Disassembly of Shift and Select Lever Assembly
487
Remove No.2 Shift Inner Lever
487
Remove Select Inner Lever
488
Assembly of Shift and Select Lever Assembly
489
Install Select Inner Lever
489
Install No. 2 Shift Inner Lever
490
Differential
491
Disassembly of Differential Case
492
Remove Side Bearing
492
Remove Ring Gear
492
Disassemble of Differential Case
492
Assemble of Differential Case
496
Install Ring Gear
498
Install Side Bearing
498
Install Differential Case Assembly
498
Install Output Shaft Assembly
499
Install Shim
499
Adjust Differential Case Preload
500
Installation of Component Parts
501
Install Oil Pump Assembly and Oil Pipe
501
Install Snap Rings
504
Install Interlock Roller
505
Install No. 1 Shift Fork Shaft
505
Install Set Bolts
506
Installation of Transaxle
513
Shift Lever and Control Cable
517
Automatic Transaxle
519
System Description
520
Basic Troubleshooting
520
General Troubleshooting
521
Preliminary Check
523
Check Fluid Level
523
Check Fluid Condition
523
Replace Atf
523
Inspect and Adjust Throttle Cable
524
Adjust Control Cable
524
Adjust Neutral Start Switch
524
Inspect Idle Speed (N Range)
524
Manual Shifting Test
525
Disconnect Ect Computer Connector
525
Inspect Manual Driving Operation
525
Connect Ect Computer Connector
525
Stall Test
526
Measure Stall Speed
526
Evaluation
526
Time Lag Test
527
Measure Time Lag
527
Hydraulic Test
528
Measure Line Pressure
528
Road Test
529
Inspect Lock-Up Mechanism
530
2 Range Test
531
L Range Test
531
R Range Test
532
P Range Test
532
Electronic Control Circuit
533
Troubleshooting of Electronic Control System
535
Blinking Overdrive Indicator Light (While Driving)
535
No Shifting
536
Shift Point too High or too Low
538
No Up-Shift to Overdrive (after Warm-Up)
539
No Lock-Up (after Warm-Up)
540
Read of Diagnostic Code
541
Turn Ignition Switch and Od Switch to on
541
Short Dg Terminal Circuit
541
Read Diagnostic Code
541
Cancel out Diagnostic Code
542
Inspect Terminal Ect Voltage
543
Inspect Throttle Position Sensor Signal
543
Inspect Brake Signal
543
Inspect each up Shift Position
543
Inspection Electronic Control Components
544
Inspect Voltage of Ect Computer Connector
544
Inspect Solenoid
545
Inspect Neutral Start Switch
545
Inspect Throttle Position Sensor
545
Inspect Speed Sensor in Atm
546
Inspect Speed Sensor in Combination Meter
546
Inspect Pattern Selection Switch
546
Inspect Od Switch
546
Operating Mechanism for each Gear
548
Transmission System
548
Solenoid System
548
Automatic Shift Diagram
549
D Range NORM Pattern
550
D Range PWR Pattern
550
2 Range NORM, PWR Pattern
551
L Range NORM, PWR Pattern
551
Automatic Shift Diagram (A241 E/4A-Gze
552
On-Vehicle Repair
555
Removal of Speed Sensor
555
Inspection of Speed Sensor
555
Inspect Speed Sensor
555
Removal of Throttle Cable
556
Disconnect Throttle Cable
556
Remove Neutral Start Switch
556
Installation of Throttle Cable
557
Install Cable in Transmission Case
557
Connect Throttle Cable
557
Install Neutral Start Switch
557
Removal of Valve Body
558
Clean Transmission Exterior
558
Drain Transmission Fluid
558
Remove Oil Pan, and Gasket
558
Remove Oil Tubes
559
Remove Valve Body
559
Installation of Valve Body
559
Place Valve Body on Transmission
559
Install Bolts in Valve Body
560
Install Detent Spring
560
Install Oil Tubes
560
Install Apply Tube Bracket
561
Removal of Transaxle
562
Clean Torque Converter
566
Inspection of Torque Converter
566
Insert Sst in End of Torque Converter
566
Test One-Way Clutch
566
Oil Pump
566
Replacement of O-Ring
567
Install Oil Pump Mounting Bolt
567
Disassembly of Transmission Components
568
Separate Basic Subassembly
571
Remove Pan and Gasket
572
Examine Particles in Pan
572
Remove Accumulator Pistons and Springs
574
Remove Second Coast Brake Piston
575
Remove Transaxle Housing
581
Remove Governor Driven Gear
581
Remove Counter Shaft Lock Nuts
582
Component Group Disassembly, Inspection and Assembly
588
General Cleaning Notes
588
Parts Arrangement
588
General Assembly
588
Oil Pump
589
Check Body Clearance of Driven Gear
590
Check Tip Clearance of both Gears
590
Check Side Clearance of both Gears
590
Remove Stator Shaft
590
Install Thrust Washer
591
Check Pump Drive Gear Rotation
591
Direct Clutch
592
Disassembly of Direct Clutch
592
Inspection of Direct Clutch
593
Inspect Clutch Piston
593
Assembly of Direct Clutch
593
Install Clutch Piston in Direct Clutch Drum
593
Install Plates, Discs and Flange
594
Install Outer Snap Ring
594
Check Piston Stroke of Direct Clutch
594
Forward Clutch
595
Disassembly of Forward Clutch
595
Inspection of Forward Clutch
596
Blow out Piston
596
Inspect Disc, Plate and Flange
596
Assembly of Forward Clutch
597
No.1 One-Way Clutch and Sun Gear
598
Disassembly of No.1 One-Way Clutch and Sun Gear
598
Check Operation of One-Way Clutch
598
Assembly of No. 1 One-Way Clutch and Sun Gear
599
Remove Sun Gear from Drum
599
Remove Shaft Snap Ring
599
Install Sun Gear to Drum
599
No. 2 One-Way Clutch and Rear Planetary Gear
600
Disassembly of One-Way Clutch
600
Assembly of One·way Clutch
600
First and Reverse Brake Piston
602
Disassembly of First and Reverse Brake Piston
602
Assembly of First and Reverse Brake Piston
603
Intermediate Shaft
604
Replacement of Intermediate Shaft
604
Replacement of Intermediate Shaft Rear Bearing
604
Counter Shaft
606
Disassembly of Counter Shaft
606
Inspection of Underdrive Unit
609
Inspect Underdrive Clutch Piston
609
Assembly of Counter Shaft
610
Valve Body
614
Remove Solenoid Valves
614
Remove Lower Valve Body Cover
614
Upper Valve Body
616
Disassembly of Upper Valve Body
616
Remove Primary Regulator Valve
616
Remove Lock-Up Relay Valve
617
Remove Low-Coast Modulator Valve
617
Remove Throttle Cam
617
Remove Throttle Valve
617
Remove Throttle Modulator Valve
618
Remove Accumulator Control Valve
618
Remove Cut Back Valve
618
Specifications of Upper Valve Body Springs
619
Assembly of Upper Valve Body
619
Install Cut Back Valve
619
Install Accumulator Control Valve
619
Install Kick-Down Valve
620
Install Throttle Valve
620
Assemble Throttle Cam
620
Install Low-Coast Modulator Valve
621
Assemble Lock-Up Relay Valve
621
Assemble Primary Regulator Valve
622
Install Primary Regulator Valve
622
Lower Valve Body
624
Disassembly of Lower Valve Body
624
Remove 3-4 Shift Valve
625
Remove 1-2 Shift Valve
625
Remove Secondary Regulator Valve
625
Remove 2-3 Shift Valve
625
Specifications of Lower Valve Body Springs
626
Remove Lock-Up Signal Valve
626
Assembly of Lower Valve Body
627
Install Lock-Up Signal Valve
627
Install Second Coast Modulator Valve
627
Install 2-3 Shift Valve
627
Assembly of Valve Body
628
Install 3·4 Shift Valve
628
Position New Gaskets and Plate on Upper Valve Body
628
Install Lower Valve Body Cover
629
Install Solenoids
629
General Assembly Notes
630
Assembly of Transmission
630
Install Bearing to Transaxle Housing
631
Install Bearing to Transmission Case
631
Install Oil Gallery Cover and Gasket
632
Install Oil Seal Rings to Transmission Case
632
Install Manual Shaft and Lever
632
Install Underdrive Brake Piston
634
Install Anti-Rattle Clip
635
Install Underorive Clutch Assembly
635
Check Height Clutch Assembly
635
Install Counter Shaft Assembly
636
Check Height of Counter Shaft
636
Install Counter Driven Gear
637
Tighten New Lock Nut
637
Check End Play of Counter Shaft
637
Install Transaxle Rear Cover
638
Check Intermediate Shaft
639
Install First and Reverse Brake in Case
639
Install Rear Planetary Gear
641
Check Operation of No.2 One-Way Clutch
641
Install Second Brake into Case
642
Check Operation of Second Brake
643
Install Second Brake Drum Gasket
643
Install Sun Gear and Sun Gear Input Drum
643
Install Race and Bearing
644
Install Races and Bearing
644
Install Front Planetary Ring Gear
644
Install Second Coast Brake Band
645
Install Forward Clutch and Direct Clutch
645
Install Transaxle Housing
646
Install Oil Pump into Case
646
Measure Thrust Play of Input Shaft
647
Install Second Coast Brake Piston
647
Check Second Coast Brake Piston Stroke
647
Install Accumulator Pistons and Springs
647
Install Throttle Cable in Case
648
Install the Twelve Bolts in Valve Body
649
Install Oil Tube Bracket
650
Install Magnets in Place as Shown
650
Install Oil Pan with New Gasket
650
Install Speed Sensor
650
Differential Components
652
Replacement of Differential
654
Replace Side Bearing from Differential Case
654
Replace Ring Gear
654
Replacement of Oil Seal and Outer Race
655
Replace Lh Side Bearing Outer Race
655
Replace Rh Oil Seal
656
Replace Rh Side Bearing Outer Race
656
Adjustment of Differential Case
657
Check Side Gear Backlash
657
Disassemble Differential Case
657
Assemble Differential Case
657
Adjustment of Differential Side Bearing Preload
659
Replace Lh Adjusting Shim
659
Install Differential Case
659
Installation of Transaxle
662
Check Torque Converter Installation
662
Align Transmission at Installation Position
662
Install Torque Converter Mounting Bolts
662
Front Axle and Suspension
666
Troubleshooting
667
Front Wheel Alignment
668
Measure Chassis Ground Clearance
668
Install Wheel Alignment Equipment
668
Adjust Wheel Angle
669
Adjust Camber
669
Inspect Steering Axis Inclination
669
Adjust Caster
670
Adjust Toe-In
670
Inspect Side Slip with Side Slip Tester
671
Front Axle Hub Components
672
Removal of Front Axle Hub
673
Remove Disc Brake Caliper
673
Remove Rotor Disc
673
Disconnect Stabilizer Link
673
Disassembly of Front Axle Hub
674
Remove Hub Grease Cap
674
Remove Front Axle Hub Lock Nut
674
Remove Axle Hub
674
Remove Outer Oil Seal
675
Remove Bearing Inner Race (Outside)
675
Remove Hole Snap Ring
675
Remove Hub Bearing
675
Assembly of Front Axle Hub
676
Install Hub Bearing
676
Install Hole Snap Ring
676
Install Outer Oil Seal
676
Installation of Front Axle Hub
677
Install Hub Grease Cap
677
Install Steering Knuckle to Shock Absorber
677
Connect Tie Rod End to Steering Knuckle
678
Torque Steering Knuckle to Ball Joint
678
Connect Stabilizer Link
678
Install Roter Disc to Axle Hub
678
Replacement of Front Axle Hub Bolt
679
Remove Brake Caliper
679
Remove Front Axle Hub Bolt
679
Install Rotor Disc
679
Front Shock Absorber Components
680
Removal of Front Shock Absorber Assembly
680
Disconnect Brake Hose
680
Remove Shock Absorber from Body
681
Clamp Shock Absorber in Vise
681
Remove Coil Spring
681
Inspection of Front Shock Absorber Assembly
682
Inspect Operation of Shock Absorber
682
Installation of Front Shock Absorber Assembly
683
Install Shock Absorber Assembly to Body
683
Install Shock Absorber to Steering Knuckle
683
Connect Flexible Hose
684
Front Suspension Components
685
Ball Joint
685
Inspection of Ball Joint
685
Inspect Ball Joint for Excessive Looseness
685
Removal of Lower Arm
686
Disconnect Lower Arm from Ball Joint
686
Remove Lower Arm
686
Installation of Lower Arm
687
Install Lower Arm
687
Connect Lower Arm to Ball Joint
687
Torque Lower Arm to Body
687
Removal of Stabilizer Bar and Link
688
Inspection of Stabilizer Link
688
Installation of Stabilizer Bar and Link
689
Removal of Strut Bar
690
Installation of Strut Bar
690
Torque Lower Arm to Strut Bar
691
Adjust Strut Bar Length
691
Torque Strut Bar to Body
691
Rear Axle and Suspension
692
Rear Wheel Alignment
694
Inspect Camber
694
Inspect Toe-In
695
Rear Axle Hub and Carrier
697
Removal of Rear Axle Hub and Carrier
698
Disassembly of Rear Axle Hub and Carrier
699
Remove Dust Deflector
699
Remove Inner Oil Seal
699
Assembly of Rear Axle Hub and Carrier
701
Install New Outer Oil Seal
701
Installation of Rear Axle Hub and Carrier
702
Install Dust Deflector
702
Install Rear Axle Carrier with Axle Hub
702
Connect Suspension Arm
702
Replacement of Rear Axle Hub Bolt
704
Remove Rear Axle Hub Bolt
704
Install Rear Axle Hub Bolt
704
Rear Drive Shaft Components
705
Removal of Rear Drive Shaft
706
Disconnect Suspension Arm
706
Disassembly of Rear Drive Shaft
710
Check Drive Shaft
710
Disassemble Inboard Joint Tulip
710
Disassemble Tripod Joint
710
Remove Boots
711
Disassemble Inboard Joint
711
Assembly of Rear Drive Shaft
713
Assemble Tripod Joint
713
Install New Snap Ring
714
Assemble Boot to Outboard Joint
714
Assemble Inboard Joint Tulip to Drive Shaft
714
Assemble New Boot Clamps to both Boots
715
Assemble New Inboard Joint Cover
715
Assemble Inboard Joint
716
Installation of Rear Drive Shaft
718
Install Side Gear Shaft
718
Pack in Grease to Side Gear Shaft
718
Install Rear Drive Shaft
718
Rear Suspension Components
721
Removal of Rear Shock Absorber
722
Disconnect Rear Axle Carrier
722
Assembly of Rear Shock Absorber
723
Install Coil Spring
723
Installation of Rear Shock Absorber
724
Inspection and Removal of Ball Joint
726
Installation of Ball Joint
727
Lower Arm
727
Removal of Strut Rod
729
Installation of Strut Rod
729
Removal of Suspension Arm
730
Disassembly of Suspension Arm
730
Inspect Ball Joint for Rotation Condition
730
Assembly of Suspension Arm
731
Installation of Suspension Arm
731
Brake System
732
Precautions
733
Troubleshooting
733
Check and Adjustment of Brake Pedal
736
Checks and Adjustments
736
Operational Test of Brake Booster
737
Bleeding of Brake System
737
Bleed Master Cylinder
737
Check and Adjustment of Parking Brake
738
Removal of Master Cylinder Components
739
Brake Booster
739
Remove Reservoir and Hose
741
Remove Reservoir Union
741
Install Two Springs and Pistons
743
Install Piston Stopper Bolt and New Gasket
743
Install Reservoir Union
743
Removal of Brake Booster
746
Installation of Brake Booster
747
Adjust Length of Booster Push Rod
747
Front Brake
749
Replacement of Brake Pads
749
Remove Front Wheel
749
Inspect Pad Lining Thickness
750
Remove Cylinder from Torque Plate
750
Remove Following Parts
750
Install New Pads
751
Install Cylinder
751
Removal of Cylinder
752
Disconnect Brake Line
752
Disassembly of Cylinder
753
Inspection and Repair of Front Brake Components
754
Measure Pad Lining Thickness
754
Measure Rotor Disc Thickness
754
Measure Rotor Disc Runout
754
Assembly of Cylinder
755
Installation of Cylinder
756
Rear Brake Components
757
Remove Rear Wheel
757
Brake Hoses and Tubes
771
Steering
772
Precautions
773
Troubleshooting
773
Steering Column Assembly
774
Removal of Steering Column Assembly
774
On-Vehicle Inspection
774
Remove Universal Joint
775
Remove Steering Wheel
775
Disassembly of Steering Column Assembly
778
Remove Combination Switch
778
Remove Tension Springs and Grommets
778
Remove Tilt Steering Support
778
Inspection and Repair of Steering Column Assembly
780
Inspect Upper Bracket
780
Inspect Lower Bearing
780
Assembly of Steering Column Assembly
781
Install Tilt Steering Support
781
Install Breakaway Bracket
782
Install Tension Springs and Grommets
782
Install Combination Switch
782
Installation of Steering Column Assembly
783
Install Steering Wheel
784
Steering Gear Housing
785
Removal of Gear Housing
785
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