Shift Lever And Control Cable Components
f Heater Control and Accessory Assembly Nm kgi-cm, ft-ibt j Specified torque Q Shift Lever Knob Upper Console Panel f Heater Control and Accessory Assembly Nm kgi-cm, ft-ibt j Specified torque
a i
N-m kgf cm, ft-lbf Specified torque Lithium soap base glycol grease e gt Disc brake grease Remove the wheel and temporarily fasten the disc with hub nuts. Torque 103 N m 1,050 kgfcm, 76 ftlbf a Remove the union bolt and gasket from the caliper, then disconnect the flexible hose from the caliper. Torque 30 N-m 310 kgf cm, 22 ftlbf At the time of installation, install the flexible hose lock securely in the lock hole in the caliper. b Use a container to catch the brake fluid as it drains out. a...
location Wko
Engine Room Relay Block No. 1 Heater Main Relay Engine Room Relay Block No. 1 Heater Main Relay A A I, , , -' Cooling Fan Relay No. 2 Cooling Fan Relay No. 3 A A I, , , -' Blower Speed Control Switch Blower Speed Control Switch
Inspect Supplemental Restraint System 1
a Do a diagnostic system check See page Dl-326 . b Do a visual check which includes the following items with the steering wheel pad with airbag removed from the vehicle. Check cuts, minute cracks or marked discoloration on the steering wheel pad top surface and in the grooved portion. Check cuts and cracks in wire harness, and chipping in connectors. Check the deformation of the horn button contact plate of the steering wheel.
T
Diagnostic mode operation confirmation Check the taiiiight lights up soon after the input operation of self diagnostic mode. Taiiiight - Ignition Switch OFF Taiiiight light up should be maximum despite the controller. Is the method to input the diagnostic mode is the function of operation confirmation Check taiiiight light up when pressing on each switch of 1 Received normal wave of LOCK switch. 0.2 sec. 0.5 sec 2 Received normal wave of UNLOCK switch. ON 0,2 sec. ' ' 0.5 sec. 0.2 sec. 3...
Inspect For Water Leaks
Install the engine coolant reservoir. Plug the inlet and outlet pipes of the radiator with SST. Using a radiator cap tester, apply pressure to the radiator. Test pressure 177 kPa 1.8 kgf cm2, 26 psr On radiators with resin tanks, there is a clearance between the tank and lock plate where a minute amount of air will remain, giving the appearance of an air leak when the radiator is submerged n water, therefore, before doing the water leak test, first swish the radiator around in the water until...
i Dra
Press the lock and unlock switches on the transmitter switch simultaneously for more than between 1 sec. or more and 1.5 sec. below. Press either one of 2 switches on the transmitter. Door control relay automatically performs LOCK-UNLOCK operation once or twice at a 1 sec. interval to inform the operator that the receiver has received the signal from the transmitter. Registration of recognition code is completed Registration of recognition code has not been completed. Recognition code received...
Torque Nm kgfcm ftlbf Aet
b Adjust the front door in left right and vertical directions. Adjust the door by loosening the door side hinge bolts. Torque 25 N m 260 kgf cm, 19 ft-lbf 1 Check that the door fit and door lock linkages are adjusted correctly. 2 Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a hammer. 3 Tighten the striker mounting screws again.
Rear Speed Sensor Components
m kgfcm, ft-lfc gt t gt Specified torque 2. DISCONNECT SPEED SENSOR CONNECTOR Disconnect the connector from the speed sensor. 3. REMOVE SPEED SENSOR WITH REAR AXLE HUB See Page SA-55 a Using a pin punch and hammer, drive out the 2 pins and remove the 2 attachments from SST, SST 09520-00031 b Mount the rear axle hub in a soft jaw vise. NOTICE Replace the axle hub assembly I it Is dropped or a strong shock is given to it. c Using SST and 2 bolts Diameter 12 mm, Pitch 1.5 mm , remove the speed...
installation Ayi
Install the A C control panel and 2 screws. a Install the A C control assembly temporarily. b Pass through the A C control cables as shown in the illustration. c Fit the 2 claws of heater control assembly in the instrument panel hole. a Set air inlet control lever to RECIRC position. b Set temperature control dial to MAX. COOL position. c Set mode control dial to DEF position. d Adjust air inlet damper control cable. Set air inlet damper control lever to RECIRC position and connect the inner...
Glass Printed Antenna Repair Procedure
a Clean the broken wire tips with grease, wax and silicone remover. b Place the masking tape along both sides of the wire for repair. c Thoroughly mix the repair agent Dupont paste No. 4817 . d Using a fine tip brush, apply a small amount of the agent to the wire. e After a few minutes, remove the masking tape.
Front Speed Sensor Components
pN-ni kgf-cm, ft ibi Specified torque 1. DISCONNECT SPEED SENSOR CONNECTOR Torque 103 N-m 1,050 kgfcm, 76 ttlbf c Disconnect the speed sensor connector and resin clip. a Remove the 2 clamp bolts holding the sensor harness from the body and shock absorber. Torque 8.0 N-m 82 kgf cm, 71 tn. lbf b Remove the speed sensor installation bolt from the steering knuckle. Torque 8.0 N m 82 kgf cm, 71 tn. lbf NOTICE At the time of installation, please refer to the following item. There are no foreign...
onvehicle inspection Bcu
1. INSPECT COMPRESSOR FOR METALLIC SOUND Check there is abnormal metallic sound from the compressor when the A C switch is ON. If abnormal metallic sound is heard, replace the compressor assembly. 2. INSPECT REFRIGERANT PRESSURE See page AC-3 3. INSPECT VISUALLY FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. If there is any leakage, replace the compressor assembly. 4. INSPECT COMPRESSOR LOCK SENSOR RESISTANCE a Disconnect the connector, b Measure...
f
Washer Tank Washer Fluid Level Warning Switch Passenger Seat Belt Warning Light Passenger Seat Belt Warning Light Seat Belt Buckle Switch Parking Brake Switch Sport mode switch Headlight dimmer switch Headlight Turn signaf switch Left side Light control rheostat Evaporator temp, sensor Ground Ground Speed control unit Ground ECU-B Fuse ECM MPX circuit Heater main reiay SRS Fuse Airbag sensor assembly Cruise control ECU Light control rheostat Evaporator temp, sensor Ground Speed sensor Si...
Do not keep any of the opened Primer M for later use
5. COAT CONTACT SURFACE OF NEW GLASS WfTH PRIMER G a Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G as shown in the illustration. b When the primer is coated wrongly to the area other than the specified, wipe it off with a clean shop rag before the primer dries. Allow 3 minutes or more to dry the primer coated surface. Do not keep any of the opened Primer G for later use. a Cut off the tip of the cartridge nozzle. Part No. 08850-00801 or equivalent....
Brake Master Cylinder Components
Nrn kgf-cm, ft-lbf Specified torque fj Lithium soap base glycol grease 2. DISCONNECT LEVEL WARNING SWITCH CONNECTOR 3. DRAW OUT FLUID WITH SYRINGE NOTICE Do not let brake fluid remain on a painted surface. Wash it off immediately. Using SST, disconnect the 5 brake lines from the master Torque 15 N m 155 kgfcm, 11 ftlbf Using SST, disconnect the 2 brake lines from the master cylinder. Torque 15 N m 155 kgf cm, 11 ft lbf a Remove the 2 mounding nuts. Torque 13 N m 130 kgf cm, 9 ft lbf Pull out...
Install Camshafts
a Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing as shown the illustration. 1 . 1 ' ' 1 o z---------v-r ' s b Install the bearing caps in their proper locations. HINT No. 3 camshaft bearing cap has a number and front mark. 2ZZ-GE No. 2, No.3 camshaft bearing cap has a number and front mark. c Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Install and uniformly tighten the 19 bearing cap bolts. After tightening the No. 1...
Check Engine Coolant Specific Gravity Correctly
N-m kgf'Cin, ftlbfM Specified torque
back door stay replacement
a Remove the bolt and back door stay from the back door panel. While supporting the back door with your hand, remove the back door stay. b Remove the 2 bolts and back door stay from the body. 2. IF NECESSARY, REPLACE BACK DOOR STAY NOTICE Do not disassemble the back door stay because the cylinder is tilled with pressurized gas. If the back door stay is to be replaced, drill a 2.0 - 3.0 mm 0.079 - 0.118 in. hole in the bottom of the back door stay as shown in the illustration to completely...
FOG LIGHT SYSTEM location
1. INSPECT FRONT FOG LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. 2. INSPECT FRONT FOG LIGHT RELAY CONTINUITY If continuity is not as specified, replace the relay.
Wiper And Washer System
Combination Switch Wiper and Washer Switch Combination Switch Wiper and Washer Switch 1. INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY If continuity is not as specified, replace the switch. If continuity is not as specified, replace the switch. INSPECT FRONT WIPER INTERMITTENT OPERATION Turn the wiper switch to INT position. Turn the intermittent time control switch to FAST position. Connect the positive lead from the battery to terminal 16 and the negative - lead to terminal 2. Connect the...
Parking Brake Components
Tension Spring Shoe Hold-down Spring m kgfcm, ft lbf Specified torque Torque 103 Nm 1,050 kgf cm, 76 ft Ibt 2. REMOVE REAR DISC BRAKE ASSEMBLY a Remove the 2 installation bolts and rear brake caliper. Torque 47 N m 475 kgf cm, 34 tt-lbf Do not disconnect the flexible hose from the brake caliper. b Suspend the disc brake securely. Ensure that the hose is not stretched. Release the parking brake lever, and remove the disc. HINT If the disc cannot be removed easily, turn the shoe adjuster until...
Removal Spj
If the wiring connector of the SRS is disconnected with the ignition switch at ON position, DTCs will be recorded. Do not open the cover or the case of the ECU and various electrical devices unless absolutely necessary. If the IC terminals are touched, the IC may be destroyed by static electricity. For step 1 to 9, refer to page BO-88. 1. REMOVE PACKAGE TRAY TRIM PANEL 2. REMOVE REAR SEATBACK ASSEMBLY LH AND RH 3. REMOVE REAR SEAT CUSHION ASSEMBLY 7. REMOVE LUGGAGE COMPARTMENT TRAY S. REMOVE...
Components Pkt
N m kgi cm. ft Ibf Specified torque N m kgi cm. ft Ibf Specified torque O-Ring Dust Protector Terminal C Kit Part Dust Protector Terminal C Kit Part Dust Protector Wave Washer - lt gt Terminal Nut f 17 170,12 psi m kgf-cm, ft-lbf Specified torque Non-reusable part
Inspect No Cooling Fan Relay 1
a Remove the relay box cover. b Remove the No. 2 cooling fan relay. Marking FAN No. 2 c Inspect the No. 2 cooling fan relay continuity. t Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2 Check that there is continuity between terminals 3 and 4. If there is no continuity, replace the relay. 3 Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. . . Continuity No...
Assemble Piston And Connecting Rod
a Using a small screwdriver, install a new snap ring at one end of the piston pin hole. Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. Gradually heat the piston to 80-90 C 176 - 194 F . c Coat the piston pin with engine oil. d Align the front marks on the piston and connecting rod, and push in the piston with your thumb. e Using a small screwdriver, install a new snap ring on the other end of the piston pin hole. Be sure that end gap of the...
Disconnect Connecting Rod From Piston
a Using a smail screwdriver, pry out the 2 snap rings. Gradually heat the piston to 80 - 90 C 176 - 194 F . Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. lt d 2ZZ-GE Remove the pin and connecting rod from the piston.
Automatic Transaxle Unit
__ _ V 0il Cooler, I 37 378,28 T Hose Engine Left Mounting Bracket Engine Rear Mounting Insulator I N'm kgf-cm, ti-lbf j Specified torque N Non-reusable part Torque 13 N-m 130 kgf-cm, 9 ft-ibf 3. REMOVE ECM AND ECM CASE Torque 6.9 N-m 70 kgf-cm, 61 in.-lbf Bolt 18 N-m 185 kgf cm, 13 ft-ibf Nut 12 N-m 120 kgf-cm, 9 ft-lbf 6. REMOVE NO. 2 CYLINDER HEAD COVER Torque 7.0 N m 71 kgf-cm, 62 in.-lbf 7. REMOVE 2 GROUND CABLES Torque 18 N m 185 kgf-cm, 13 ft-lbf 8. DISCONNECT CONTROL CABLE FROM CLAMP 9....
Rear Wheel Hub Bolt Replacement
a Remove the 2 bolts, brake caliper and disc. b Support the brake caliper securely. 3. w Drum brake REMOVE BRAKE DRUM Using SST and a brass bar, remove the hub bolt. SST 09628-10011 a Install a washer and nut to a new hub bolt as shown in the illustration, b Using a brass bar to hold, install the hub bolt by torquing the nut. 6. w Drum brake INSTALL BRAKE DRUM INSTALL DISC AND BRAKE CALIPER Install the disc and brake caliper and 2 bolts. Torque 47 N-m 475 kgfcm, 34 ttibf Torque 103 N m 1,050...
removal Cnj
1. REMOVE STEERING WHEEL PAD AND STEERING WHEEL See page SR-11 4. REMOVE LOWER NO. 1 FINISH PANEL a Remove the 2 screws and hood lock release lever. c Using a screwdriver, remove the lower No. 1 finish panel. HINT Tape the screwdriver tip before use. 6. REMOVE COLUMN COVERS See page SR-11 7. REMOVE SPIRAL CABLE See page SR-11 8. REMOVE WIPER AND WASHER SWITCH AND LIGHT CONTROL SWITCH AND HEADLIGHT DIMMER SWITCH See page SR-11 b Using a screwdriver, remove the cluster finish panel. HINT Tape the...
Front Brake Caliper Components
g Toque Plate - Inner Anti-squeal Shim g Toque Plate - Inner Anti-squeal Shim j N-m jkgf-cm, ftibf J Specified torque Mon reusable part Lithium soap base glycol grease gt Disc brake grease
Door Side Airbag Sensor 1
Front Door lower Frame Bracket Garnish Front Door lower Frame Bracket Garnish N-m kgt'cm, ft-lbf Specified torque If the wiring connector of the SRS is disconnected with the ignition switch at ON position, OTCs will be recorded. Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. Never reuse the sensor involved in a collision when the SRS has deployed. Never repair a sensor in order to reuse it. For step 1 to 4, refer to page SO-11. 1. REMOVE NO. 2 DOOR...
Atf Temperature Sensor Onvehicle Repair
1. DISCONNECT SOLENOID CONNECTOR 2. REMOVE LH ENGINE UNDER COVER 3. REMOVE DRAIN PLUG AND DRAIN ATF 4. REMOVE OIL PAN AND GASKET NOTICE Some fluid will remain in the oil pan. Remove the 18 bolts, and carefully remove the oil pan assembly. Discard the gasket. Remove the 3 boits and oii strainer. Remove the O-ring. 6. DISCONNECT 5 SHIFT SOLENOID VALVE CONNECTORS 7. REMOVE ATF TEMPERATURE SENSOR Remove the bolt and lock plate, and remove the ATF temperature sensor. 8. SEPARATE WIRE HARNESS FROM 2...
Rear Axle Carrier Components
l y, 'i Rear Axle Carrier l y, 'i Rear Axle Carrier N Brake Caliper Hub Bolt lt v I Nm kgi'cm, ft ftaf ___j Specified torque
Valve Body Assembly Onvehicle Repair 1
U y t i 2. REMOVE DRAIN PLUG AND DRAIN ATF 3. REMOVE OIL PAN AND GASKET NOTICE Some fluid will remain in the oil pan. Remove the 19 bolts, and carefully remove the oil pan assembly. Discard the gasket. Remove the magnets and use them to collect any steel chips. Look carefully at the chips and particles in the pan and on the magnet to anticipate what type of wear you will find in the trans-axle. Steel magnetic bearing, gear and plate wear Brass non-magnetic bushing wear a Remove the 3 bolts and...
Replace Valve Guide Bushings
a Gradually heat the cylinder head to 110 266 F . b Using SST and a hammer, tap out the guide bushing, SST 09201-01055, 09950-70010 09951-07100 c Using a caliper gauge, measure the bushing bore diameter of the cylinder head. Select the new guide bushing STD or O S 0.05 . if the bushing bore diameter of the cylinder head is greater than 10.306 mm 0.4057 in. , machine the bushing bore to the following dimension 10.335 - 10.356 mm 0.4068 - 0.4077 in. If the bushing bore diameter of the cylinder...
If Necessary Replace Input Shaft Front Bearing And Oil Seal
a Using SST, remove the input shaft front bearing. SST 09612-65014 b Using a screwdriver, remove the oil sea . c Using SST and a hammer, drive in a new oil seal. SST 09950-60010 09951-00360 , 09950-70010 09951-07150 Drive In depth 15.8 0.2 mm 0.622 0.008 in. d Coat the lip of the oil seal with MP grease. e Using SST and a press, install a new input shaft front bearing. SST 09950-60010 09951-00400 , 09950-70010 09951-07150 Drive in depth 0 - 0.3 mm 0 - 0.012 in. NOTICE Be sure to install a new...
Differential Case Components 1
Tapered Roller Bearing and Outer Race Tapered Roller Bearing and Outer Race - Shim N-m kgf'cm, ft'lbf Specified torque Non-reusable part p Apply MP grease Place matchmarks on the ring gear and differential case. Remove the 8 bolts. Using a copper hammer, tap on the ring gear to remove it from the differential case. 2. Vehicle speed sensor drive gear side REMOVE TAPERED ROLLER BEARING FROM DIFFERENTIAL CASE a Using SST, remove the tapered roller bearing. SST 09950-00020, 09950-00030,...
Inspect Armature Coil Commutator For Open Circuit
Using an ohmmeter, check that there is continuity between the segments of the commutator. If there is no continuity between any segment, repiace the armature.
Install Rear Wiper Arm
a Operate the wiper motor once and turn the wiper switch OFF. b Install the rear wiper arm and tighten the nut by hand. Adjust the installation position of the wiper arm at a point in defogger pattern. Tighten the nut. Torque 5.4 N m 55 kgfcm, 48 in.lbf w Rear spoiler REMOVE REAR SPOILER
Inspect Water Pump
a Visually check the drain hole for coolant leakage. If leakage is found, replace the water pump. b Turn the pulley, and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump. a Place a new O-ring on the timing chain cover. b Install the water pump with the 6 bolts. Torque Bolt A 9.0 N-m 92 kgf-cm, 80 in.-lbf Bolt B 11 N m 113 kgf-cm, 8 ft-lbf Each bolt length is indicated in the illustration. A 30 mm 1.18 in. B 35 mm 1.38 in, a Place a new O-ring...
Install Clutch Disc And Clutch Cover On Flywheel
a Insert SST in the clutch disc, then insert them in the flywheel. Take care not to insert clutch disc in the wrong direction. b Align the matchmarks on the clutch cover and flywheel. c Following the procedures shown in the illustration, tighten the 6 bolts in the order starling the bolt locating near the knock pin on the top.
Inspect Camshaft Oil Control Valve Operation
Connect the positive lead from the battery to terminal 1 and negative - lead to terminal 2, and check the movement of the valve. If operation is not as specified, replace the valve. If operation is not as specified, replace the valve.
Rear Brake Caliper Components
I N'm kgt'cm, ft'ibl j Specified torque Non-reusable part Lithium soap base glycol grease N O Disc brake grease Torque 103 N m 1,050 kgf cm, 76 ft-ibt a Remove the union bolt and gasket from the caliper, then disconnect the flexible hose from the caliper. Torque 30 N m 310 kgf cm, 22 ft Ibf At the time of installation, insert the flexible hose lock securely in the lock hole in the caliper. b Use a container to catch the brake fluid as it drains out. a Remove the 2 installation bolts and...
Power Steering Fluid Bleeding
1. CHECK FLUID LEVEL See page SR-5 2. JACK UP FRONT OF VEHICLE AND SUPPORT IT WITH STANDS With the engine stopped, turn the steering wheel siowiy from Run the engine at idle for a few minutes. a With the engine idling, turn the steering wheel to left or right full lock position and keep it there for 2-3 seconds, then turn the steering wheel to the opposite full lock position and keep it there for 2-3 seconds. 8. CHECK FOR FOAMING OR EMULSIFICATION II the system has to be bled twice specifically...
windshield components
w Sliding roof Sliding Roof Opening Sun Visor Holder - --------------------- w Sliding roof Sliding Roof Opening rN-m kgi-cm, ft- bf Specified lorque I p Non-reusable part rN-m kgi-cm, ft- bf Specified lorque I p Non-reusable part
INSTALL KNOCK SENSOR Torque N m kgfcm ft lbf
a Install a new gasket and ventilation case with the 3 bolts. Torque 8.5 Nm 87 kgfcm, 75 in.-lbf b Install the No. 3 ventilation hose and connect the clip. 25. INSTALL THERMOSTAT See page CO-11 26. INSTALL WATER BYPASS PIPE Torque 1ZZ-FE 9.0 N m 92 kgf cm, 80 in.lbf 2Z2--GE Bolt 8.5 N m 87 kgf cm, 75 In. lbf Nut 10 N m 100 kgf cm, 7 ftlbf a Install a new O-ring on the dipstick guide. b Apply soapy water on the O-ring. c Connect the dipstick guide end to the main bearing cap. d Install the...