Inspection And Replacement Of Reverse Restrict Pin
a Using a torx socket wrench, remove the screw plug. b Using a pin punch and hammer, drive out the slotted spring pin. c Remove the reverse restrict pin. 2. INSPECTION OF REVERSE RESTRICT PIN Turn and push the reverse restrict pin by hand while applying direction. a Install the reverse restrict pin to the extension housing or transfer adaptor. b Using pin punch and hammer, drive in the slotted spring pin. c Apply liquid sealer to the plug threads. Sealant Part No.08833-00080. THREE BOND 1344....
Outline of ECT
The conventional automatic transmission operates by mechanically converting vehicle speed into governor pressure, and throttle opening into throttle pressure, and using these hydraulic pressures to control the operation of the clutches and brakes in the planetary gear unit, thus controlling the timing of up-shift and down shift of the transmission. This is called the hydraulic control method ' In the case of the ECT, on the other hand, sensors electronically sense the speed of the vehicle and...
Inspection Of Turbocharger
Grasp the edge of the turbine wheel and turn it. Check that the impeller wheel turns smoothly. If the impeller wheel does not turn or if it turns with a drag, replace the turbocharger assembly. 2. INSPECT AXIAL PLAY OF TURBINE SHAFT Insert a dial indicator into the hole in the turbine wheel on the exhaust side and measure the axial play of the shaft. Axial play 0.13 mm 0.0051 in. or less If the axial play is not as specified, replace the turbocharger assembly. 3. INSPECT RADIAL PLAY OF TURBINE...
Inspection Of Bvsv
a Drain the coolant from the radiator into a suitable container. c Cool the BVSV to below 35 C 95 F gt with cool water, id Blow air into a pipe and check that the BVSV is closed. e Heat the BVSV to above 54 C 129 F with hot water. lt f Blow air into a pipe and check that the BVSV is open. If a problem is found, replace the BVSV. g Apply sealant to the threads of the BVSV and reinstall. Sealant Part No.08833-00070. THREE BOND 1324 or equivalent h Fill the radiator with coolant. To reduce HC and...
Assemble Inboard Joint Tulip
a Pack in grease to the inboard tulip and boot. HINT Use the grease supplied in the boot kit. Grease capacity 270 - 280 g 0.60 - 0.62 lb gt b Align the matchmarks placed before disassembly. c Install the boot to the inboard tulip. 7. ASSEMBLE BOOT CLAMPS TO BOTH BOOTS a 8e sure the boot is on the shaft groove. b Bend the band and lock it as shown in the figure. c Insure that the boot is not stretched or contracted when the drive shaft is at standard length. 551.8 - 554.8 mm 21.724 - 21.842 in.
COMPONENTS Contd
Valve Spring Retainer Valve Spring Valve Stem Oil Seal Valve Spring Seat Valve Guide Bushing Snap Ring Gasket 800 M. isT A Gasket 6 kg cm ft-lb. N-mj Specified torque Non reusable part _ imsmt
Radiator Cap
The radiator cap is a pressure type cap which seals the radiator, resulting in pressurization of the radiator as the coolant expands. The pressurization prevents the coolant from boiling even when the coolant temperature exceeds 100 C 212 F gt . A relief valve pressurization valve and a vacuum valve negative pressure valve are built into the radiator cap. The relief valve opens and lets steam escape through the overflow pipe when the pressure generated inside the cooling system exceeds the...
Installation Of Brake Booster
1. ADJUST LENGTH OF BOOSTER PUSH ROD a Set the SST on the master cylinder with the gasket, and then lower the pin until its slightly touches the piston. b Turn the SST upside down and set it on the booster. SST 09737 00010 c Measure the clearance between the booster push rod and pin head SST . d Adjust the booster push rod length until the push rod lightly touches the pin head. 2. INSTALL BRAKE BOOSTER. GASKET AND CLEVIS a Install the booster and gasket. b Install the clevis and tighten the...
Removal Of Lower Suspension Arm
1. DISCONNECT STABILIZER 8AR LINK FROM LOWER SUSPENSION ARM 2. DISCONNECT STEERING KNUCKLE FROM LOWER BALL JOINT b Using SST, disconnect the steering knuckle from the lower ball joint. 3. DISCONNECT LOWER SUSPENSION ARM FROM SHOCK ABSORBER a Before loosen the adjusting cams, place matchmarks on the front and rear adjusting cams and body. b Remove the nuts and adjusting cams, and remove the lower suspension arm. 5. REMOVE LOWER BALL JOINT FROM LOWER SUSPENSION ARM
Principles Of Power Steering
Power steering is one type of hydraulic device for utilizing engine power to reduce steering effort. Consequently, the engine is used to drive a pump to develop fluid pressure, and this pressure acts on a piston within the power cylinder so that the piston assists the rack effort. The amount of this assistance depends on the extent of pressure acting on the piston. Therefore, if more steering force is required, the pressure must be raised. The variation in the fluid pressure is accomplished by...
Replace Rear Shock Absorber Bushing
a Using SST, press out the rear shock absorber bushing. SST 09710-22020 09710 01020. 09710 01060. 09710-01070 b Using SST, press in a new rear shock absorber bushing. SST 09710 22020 lt 09710 01020. 09710 01030, 09710 01040. 09710 01050
Replacement Of Front Axle Hub Bolt
a Remove the brake hose bracket from the steering knuckle. Ibl Remove the disc brake caliper from the steering and suspened it with wire. Place matchmarks on the rotor disc and hub. la Align the disc brake dust cover cutting portion and axle hub bolt. lb Using SST, remove the axle hub bolt. Hold the front axle hub. and install a new hub bolt. Align the matchmarks on the rotor disc. 6. MEASURE ROTOR DISC RUNOUT See page BR-28 7. INSTALL DISC BRAKE CALIPER TO STEERING KNUCKLE Torque 1.065 kg-cm...
Inspection Of Isc Valve
Using an ohmmmeter, measure the resistance between terminal 81 - SI or S3 and B2 - S2 or S4. Resistance 81 - S1 or S3 10 - 30 fl 82 - S2 or S4 10 - 30 ft If resistance is not as specified, replace the ISC valve. a Apply battery voltage to terminals B1 and B2 and while repeatedly grounding SI S2 S3 S4 S1 in sequence, check that the valve moves toward the closed position. lt b gt Apply battery voltage to terminals B1 and B2 and while repeatedly grounding S4 S3 S2 S1 S4 in sequence, check that the...
Install Ps Air Pipe
a Align the pulley set key with the key groove of the pulley. c Using SST to hold the crankshaft pulley, install and torque the pulley bolt. SST 09213-70010 and 09330 00021 Torque 2,700 kg-cm 195 ft-lb. 265 N m 8. SET N0.1 CYLINDER TO TDC COMPRESSION OF CRANKSHAFT Turn the crankshaft pulley and align its groove with the 0 mark on the No.1 timing belt cover. a Align the timing pulley matchmark with the No.2 timing belt cover matchmark. c Install the pin to the hole. HINT When replacing the...
Assembly of Valve Body
1. POSITION NEW NO. 1 GASKET ON UPPER VALVE BODY Align a new No. 1 gasket at each bolt hole. 2. POSITION VALVE BODY PLATE ON NO. 1 GASKET 3. POSITION NEW NO. 2 GASKET ON PLATE Align a new No. 2 gasket at each bolt hole. 4. PLACE UPPER VALVE BODY WITH PLATE AND GASKETS ON TOP OF LOWER VALVE BODY Align each bolt hole and gasket in the valve body. 5. INSTALL THE TWENTY-FIVE BOLTS TO UPPER VALVE BODY HINT Each bolt length mm, in. is indicated in the figure. Torque 65 kg-cm 56 in.-lb, 6.4 N-m
Power Steering ECU INSPECTION OF ECU
1. JACK UP VEHICLE AND SUPPORT IT ON STANDS HINT Do not disconnect the ECU connector. a Using a voltmeter, measure the voltage between ECU terminals SOL 0and GND while the engine is idling. b Place the transmission in gear and while running at about 50 km h 31 mph , measure the voltage between ECU terminals SOL 0and GND. Standard voltage Voltage measured in a above, minus 0.09 - 0.23 V If no voltage, try another ECU.
Remove Drive Pinion From Differential Carrier
Using SST and a press, remove the bearing from the drive pinion. HINT If the drive pinion or ring gear are damaged replace them a set. 9. REMOVE FRONT AND REAR BEARING OUTER RACE Using a hammer and brass bar, drive out the outer race from the carrier. a Remove the ring gear set bolts and lock plate. b Place matchmarks on the ring gear and differential case. c Using a plastic or copper hammer, tap on the ring gear to separate it from the differential case. Using SST, remove the side bearing from...
Removal Of Starter
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the LOCK position and the negative terminal cable is disconnected from the battery. 2. DISCONNECT TWO WIRES FROM STARTER Remove the nut and disconnect the battery cable from the magnetic switch on the starter. Disconnect the other wire from terminal 50. Remove the two mounting bolts, and remove the starter from the flywheel...
Sst
9. DISCONNECT NO.2 LOWER SUSPENSION ARM FROM AXLE CARRIER 10. DISCONNECT STRUT ROD FROM AXLE CARRIER 11. DISCONNECT SHOCK ABSORBER FROM AXLE CARRIER 12. DISCONNECT UPPER ARM FROM BODY AND REMOVE AXLE HUB ASSEMBLY 13. REMOVE UPPER ARM FROM AXLE CARRIER a Remove the upper arm mounting nut. b Separate the backing plate and axle carrier. c gt Using SST, remove the upper arm from the axle carrier.
Inspection Of Egr Vacuum Modulator
CHECK EGR VACUUM MODULATOR OPERATION a Disconnect the vacuum hoses from ports P. Q and R of the EGR vacuum modulator. b Block ports P and R with your finger. Cc gt Blow air into port Q. Check that the air passes through to the air filter freely. d Start the engine and maintain speed at 2.500 rpm. e Repeat the above test. Check that there is a strong resistance to air flow. If a problem is found, replace the EGR vacuum modulator. f Reconnect the vacuum hoses to the proper locations.
Lubrication System
DESCRIPTION TROUBLESHOOTING OIL PRESSURE CHECK AND OIL FILTER OIL PUMP VALVE 7M-GTE
Speed Sensor
INSPECT SPEED SENSOR IN COMBINATION METER a Remove the combination meter. b Check that there is continuity between terminals SPD and SPD lour times per each revolution of the shaft. Throttle Position Sensor INSPECT THROTTLE POSITION SENSOR Using an ohmmeter. check the resistance between each terminals.
Threeway Catalyst Twc System
Three-Way Catalyst fMnnnlithitf gt Three-Way Catalyst 7M-GE California Monolithic Three-Way Catalyst 7M-GE California Monolithic Three-Way Catalyst fMnnnlithitf gt To reduce HC. CO and NOx emissions. they are oxidized, reduced and converted to nitrogen N, . carbon dioxide lt CO, and water H 0 by the catalyst.
Components 1
Adjusting Shim Valve Lifter Valve Keeper Valve Spring Retainer Valve Spring Valve Stem Oil Seal Valve Spring Seat Valve Guide Bushing Snap Ring kg-cm ft-lb, N mT Specified torque Non reusable part
Circuit Opening Relay
To Ignition Switch STI _ECU STA __ ECU t8 81 Fuel Pump Switch Air Flow Meter 1l7MGE
INSPECTION AND REPAIR OF ALTERNATOR Rotor
Using an ohmmeter, check that there is continuity between the slip rings. Standard resistance cold 2.8 - 3.0 ft If there is no continuity, replace the rotor. Using an ohmmeter, check that there is no continuity between the slip ring and the rotor. If there is continuity, replace the rotor. a Check that the slip rings are not rough or scored. If rough or scored, replace the rotor. b Using vernier calipers, measure the slip ring diameters. 0.559 - 0.567 in. Minimum diameter 12.8 mm 0.504 in. If...
Installation Of Strut Rod
al Position the strut rod to the body and temporarily install the bolt. 4b gt Temporarily connect the strut rod with the bolt and nut to the axle carrier. a Remove the stands and bounce the vehicle to stabilize the suspension. b Torque the mounting bolts and nuts. 1,670 kg-cm 121 ft-lb, 164 Nm Axle carrier x Strut rod
Output Shaft Assembly COMPONENTS
1 kg em ft lb, N-mj Specified torque DISASSEMBLY OF OUTPUT SHAFT ASSEMBLY 1. REMOVE FIFTH GEAR. CENTER BEARING AND FIRST GEAR ASSEMBLY a Using a press, remove the 5th gear, center bearing, thrust washer and 1st gear. b Remove the synchronizer ring. c Remove the straight pin and needle roller bearing.
Boring Of Cylinders
Bore all six cylinders for the oversized piston outside diameter. Replace the piston rings with ones to match the oversized pistons. 3.2835 - 3.2854 in. 7M GTE 83.41 - 83.46 mm 2. CALCULATE AMOUNT TO BORE CYLINDER a Using a micrometer, measure the piston diameter at a right angle to the piston pin hole center line. 22 mm 0.87 in. from the piston head. b Calculate the amount each cylinder is to be re bored as follows Size to be rebored P -f C - H P Piston diameter C Piston clearance 0.0020 -...
Install Front Planetary Gear
a Coat the bearing and race with petroleum jelly and install them onto the front planetary gear. b Install the front planetary gear to the sun gear. c Using SST, install the snap ring. SST 09350-30020 09350-07070 d Remove the wooden blocks under the output shaft. e Coat the bearing race with petroleum jelly and install it onto the front planetary gear. a Insert the second coast brake band to the case. b Install the pin through the brake band. 16. INSTALL FRONT PLANETARY RING GEAR TO FORWARD...
Inspection Of Front Planetary Gear
1. CHECK FRONT PLANETARY RING GEAR BUSHING Using a dial indicator, measure the inside diameter of the planetary ring gear bushing. Maximum inside diameter 24.08 mm 0.9480 in. If the inside diameter is greater than the maximum, replace the planetary ring gear. 2. MEASURE PLANETARY PINION GEAR THRUST CLEARANCE Using a feeler gauge, measure the planetary pinion gear thrust clearance. Standard clearance 0.20 0.60 mm 0.0079 - 0.0236 in. Maximum clearance 1.00 mm 0.0394 in. If the clearance is...
Mgte 1
2. DISCONNECT CAM POSITION SENSOR CONNECTOR 3. DISCONNECT SOLENOID RESISTOR CONNECTOR 4. REMOVE NO.1 AIR CLEANER HOSE See step 1 on page EM-12 8. CHECK CYLINDER COMPRESSION PRESSURE See step 7 on page EM-20 10.0 kg cm1 142 psi, 981 kPa or more 9.0 kg cm7 128 psi. 883 kPa Difference between each cylinder
Inspection Of Cam Position Sensor
Using a feeler gauge, measure the gap between the signal rotor and pickup coil projection. Air gap 0.2 - 0.4 mm 0.008 - 0.016 in. If the gap is not within specification, replace the cam position sensor. Using an ohmmeter. check resistance of the pickup coil. If the resistance is not within specification, replace the cam position sensor.
Installation Of Cam Position Sensor
1. CHECK N0.1 CYLINDER TO TDC COMPRESSION See page IG-21 a Install a new O-ring to the cam position sensor. NOTE Always use a new O-ring when installing the cam position sensor. b Align the drilled mark on the driven gear with the groove of the housing. c Insert the cam position sensor, aligning the center of the flange with that of the bolt hole on the cylinder head. d gt Lightly tighten the hold-down bolt.
Removal Of Cam Position Sensor
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY 2. DISCONNECT CAM POSITION SENSOR CONNECTOR 3. SET NO. 1 CYLINDER TO TDC COMPRESSION lt b Look through oil filler hole and turn the crankshaft clockwise until the cam nose can be seen. c Turn the crankshaft counterclockwise approximately 120 . lt dl Turn the crankshaft again approximately 10 to 40 clockwise so that the timing belt cover TDC mark and the crankshaft pulley TDC mark are aligned.
Installation Of Propeller Shaft
SST 09325-40010 for A T and R154 M T gt 09325-20010 for W58 M T b Insert the yoke into the transmission. 2. CONNECT PROPELLER SHAFT TO DIFFERENTIAL a Align the matchmarks on the flanges and connect the propeller shaft with the four bolts, washers and nuts. b Torque the bolts and nuts. Torque 750 kg-cm 54 ft-lb, 74 N-m 3. INSTALL CENTER SUPPORT BEARING TO BODY a Install the center support bearing to the body with the two mount bolts finger tight. b Check that the bearing bracket is at right...
Vehicle Lift And Support Locations
Front Center of front suspension crossmember Rear Jack up support of differential carrier Safety stand
Installation Of Distributor
1. CHECK NO.1 CYLINDER TO TDC COMPRESSION See page IG-17 a Install a new O-ring to the distributor. HINT Always use a new O-ring when installing the distributor. b Align the groove of the distributor housing with the protrusion on the driven gear. c Insert the distributor, aligning the center of the flange with that of the bolt hole on the cylinder head. d Lightly tighten the hold-down bolt. 4. CONNECT DISTRIBUTOR CONNECTOR 5. CONNECT HIGH-TENSION CORDS TO DISTRIBUTOR CAP Allow the engine to...
Output Of Diagnostic Codes
To obtain an output of diagnostic codes, proceed as follows a Battery voltage above 11 volts b Throttle valve fully closed throttle position sensor IDL points closed c Transmission in neutral position 2. Turn the ignition switch to ON. Do not start the engine. 3. Using SST, connect terminals Tn and Et of the check connector. HINT The check connector is located near the ignition coil. CHECK ENGINE Warning Light 4. Read the diagnostic code as indicated by the number of flashes of the CHECK ENGINE...
Inspect Synchronizer Rings
a Turn the ring and push it in to check the braking action. bl Measure the clearance between the synchronizer ring back and the gear spline end. 0.028 - 0.067 in. Minimum clearance 0.5 mm 0.020 in. If the clearance is less than the limit, replace the synchronizer ring. 4. MEASURE CLEARANCE OF SHIFT FORKS AND HUB SLEEVES Using a feeler gauge, measure the clearance between the Maximum clearance 1.0 mm 0.039 in. If the clearance exceeds the limit, replace the shift fork or hub sleeve.
Thermostat
The thermostat is a wax type one and is mounted in the water outlet housing. The thermostat includes a type of automatic valve operated by fluctuations in the coolant temperature. This valve closes when the coolant temperature drops, preventing the circulation of coolant through the engine and thus permitting the engine to warm up rapidly. The valve opens when the coolant temperature has risen, allowing the circulation of coolant. Wax inside the thermostat expands when heated and contracts when...
Diagnostic Codes 1
Defective No. 1 speed sensor in combination meter -severed wire harness or short circuit Defective No. 2 speed sensor in ATM -severed wire harness or short circuit Severed No. 1 solenoid or short circuit -severed wire harness or short circuit Severed No. 2 solenoid or short circuit -severed wire harness or short circuit Severed lock-up solenoid or short circuit -severed wire harness or short circuit HINT If codes 62, 63 or 64 appear, there is an electrical malfunction in the solenoid. Causes...
Components Sut
Upper Suspension Arm with Upper Ball Joint Upper Suspension Arm with Upper Ball Joint kg-cm ft lb, N-m Specified torque Non-reusable part
c Apply the battery voltage between terminals At this time confirm that a
a Disconnect the solenoid connector. b Using an ohmmeter, measure the resistance between terminals. c Apply the battery voltage between terminals. At this time, confirm that a solenoid operation. 4. INSPECT SHIFT LOCK CONTROL SWITCH Inspect that there is continuity between each terminals. 4. INSPECT SHIFT LOCK CONTROL SWITCH Inspect that there is continuity between each terminals.
Assembly Of Direct Clutch
1. INSTALL DIRECT CLUTCH PISTON TO DIRECT CLUTCH a Coat new O-rings with ATF and install them on the direct clutch piston. b Being careful not to damage the O-rings, press in the direct clutch piston into the clutch drum with both hands. a Install the piston return spring. b Place SST on the spring retainer, and compress the return spring with a shop press. c Install the snap ring with snap ring pliers. Be sure the end gap of the snap ring is not aligned with the spring retainer claw.