VNX - Su Montero 1987 Service Manual PDF

mi
GROUP INDEX
Service
i Manu
,Introduction
and
,Master Troubleshooting
MONTERO
Lubrication
.*.**
and Maintenance
.+....
Front Suspension
1987 : Volume 1
Service
Parking
. . . .. .. . .. . .. ................
~ ..
,.....,..,......,.............................N
BrakesClutch
FOREWORD
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.. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. . . .. .. . ..*......
Cqoling
This Service r\;lanual has been prepared with the

latest service information
available at the time of
publication.
It is subdivided
into various group
categories
and each section contains
diagnosis,
procedures
disassembly,
repair, and installation
along with complete
specifications
and tightening
references.
Use of this manual will aid in properly
performing
any servicing necessary to maintain or
restore the high levels of performance
and reliability
designed into these outstanding
vehicles.
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Engine
Intake and Exhaust

.J . .
Body and Frame A&jnment
A .
4ib II
WE SUPPORT
VOLUNTARY
TECHNICIAN
CTF$lFMTlON
THROUGH
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for
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Erfiission
Mitsubishi
Motors
corporation
reserves
ihe right to make changes in
design or to make add&+x
to oi-improvemenfs
in its products
without
imposing
any obliga<&
upon itself to install them on its products
previously
manufact&$d.
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Printed in Japan
0 1986 Mitsubishi
Motors Corporation
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Control
Systems
NOTE
For ElectCcal,
Heater.
ins, refer to . . .
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- How To Use This Manual

,
HOW TO USE THIS MANUAL
NOOBAAA
COljlTENtS
?he preceding page contains the GROUP INDEX
which lists the group title and group number.
PAGE NUMBERS
All page numbers consist of two sets of digits
separated by a dash. The digits precding
the dash
-r: identify the number of the group. The digits follow:.ing the dash represent the consecutive page
$.rmber within the group. The page numbers can
be found on the top left or right of each page.
Indicates incidental operation

to be performed
before removal or after installation
TEXT
Unless otherwise specified, each service procedure
covers all- -models. .*.Procedures covering specific
models are identified by the model codes, or similar
designation (engin-e type, transmission type, etc.).
A descriptjon of these designations is ccvered in
this unit under VEHICLE,IDENTIFICATION.
ig..,,.
Troubleshootings are classified into master troubleshooting .and group troubleshooting and located as
follows:
,...??!$he master troubleshooting is prepared when the
t!ouble symptom relates to two or more groups and
gjven in-MASTER TROUBLESHOOTING.
The group troubleshooting guide is prepared for
causes of problems related to that individual group
only; a troubleshooting guide is prepared for each
apptopriate group.
:.
3
:..
Removal steps : The numbers before part names

correspond
to numbers in the illustration and indicate the order of
removal.
Disassembly steps : The numbers
before
part
names correspond to numbers
in the illustration, and indicate
the order of disassembly.
steps : This is provided if installation
cannot be made in the reverse
order of Removal steps; omitted if installation in the reverse
order of Removal
steps is
possible.
Reassembly steps : This is provided if reassembly
order of Disassembly
steps;
omitted if reassembly
in the
reverse order of Disassembly
steps is possible.
Installation
SERVICE PROCEDURES
Th$ service steps are arranged in numerical order

apd attentions to be paid in performing vehicle seryrce are d,escribed in detail in SERVICE POINTS.
.,G
sDEFINITION
.-;
4.
.
19,
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OF TERMS
STANDARD VALUE
Indicatesthe value used as the standard for judging
the quality of a part or assembly on inspection or the
value to which the part or assembly is corrected and
adjusted. It is given by tolerance.
LIMIT
Shows the standard for judging the quality of a part
or assembly on inspection and means the maximum
or minimum value within which the part or assembly
must be keptfunctionally or in strength. It is a value
established outside the range of standard value.
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Classification of
SERVICE ROINTS
I)+
*I)
: Installation
: Disassembly
INTRODUCTION
-T
AND MASTER TROUBLESHOOTING
Page number
Group title
Sect@
- How To Use This Mawal
title
THERMOSTAT
REMOVAL AND INSTALLATION
I*
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Supplying
of the
MAINTENANCE
Coolant
(Refer
- Maintenance
to
W-1: Nm
7-9 fths.
Ser-
Thermostat
kit
-.a
1. Connection
of water temperature
switch
connector
(Vehicles
with an air conditioner)
2. Connection
of radiator
upper
hose
3. Water
outlet
fitting
4. Water
outlet
fitting
gasket
5. Thermostat
I..:.,
NOTE
(1) Reverse the removal procedures
to reinstall
(2) **
: Refer to Service
Points of Installation
(3) p
Non-reusable
parts
SERVICE POINTS OF INSTALLATION-5.
INSTALLATION
OF THERMOSTAT
Install the thermostat to the intake manifold as illustrated.

Caution
The thermostat
flange
fits over the manifold
seat;
ensure that the thermostat
is not installed
at an angle.
An explanation
of procedures,
regarding removal, installation,
and reassembly.
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notes. etc.
disassembly
;* *
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.? 4
INTRODUCTION
-Vehicle
Identification
VEHICLE IDENTIFKATION
VEHICLE IDENTIFICATION
I
NUMBER
The vehicle identification

number (V.I.N.) is located
attached to the left top side of the instrument
panel.
VEHICLE IDENTIFICATION
1st
digit
2nd
digit
3rd
digit
4th
digit
5th
digit
LOCATIOymA
on a plate
CODE CHART PLAT$m,,;p.
All vehicle identification

numbers contain 17 .digits.
number is a code which tells country, make, vehicle
The vehicle
type, etc.
6th
digit
7th
digit
8th
digit
9th
digit
10th
digit
11th
digit
12th thru
17th digit
Make
Body
Engine
Check
digit
Feifel
Plant
Serial
number
AMitsu-,
bishi
33-door
metaltop or
van
E2.6 liter.
(155.9
C.I.D.)
H1987
year
JNagoya
-3
00000 1
0
:
3
99&99
7-Truck
9
X
*:
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-. NOTE
*Check digit means a single number or letter X used to verify the accuracy of transcription
number.
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of vehicle indentification
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UCTION AND MASTER TROUBLESHOOTING

VEHICLE
IDENTIFICATION
NUMBER
Identification
- Vehicle
LIST
FEDERAL
NOOCG-
VIN (except sequence
number)
Engine displacement
Brand
Model code
JA4FJ43EoHJ
I.
L042GVNJLF
JA4FJ43EoHJ
MITSUBISHI
2.555 liters
JA7FJ23EoHJ
MONTERO
(155.9 C.I.D.)
L042GVRJLF
L042GTNSLF
JA7FJ23EoHJ
CALIFORNIA
L042GTRSLF
(Can also be sold in Federal
number)
i. :: .
states.)
Brand
Model code
Engine displacement
JA4FJ43EoHJ
L042GVNJLH
JA4FJ43EoHJ
MITSUBISHI
2.555 liters
JA7FJ23EoHJ
MONTERO
(155.9 C.I.D.)
L042GVRJLH
JB7FJ23EoHJ
VEHICLE
INFORMATION
L042GTNSLH
;
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L042GTNSLH
NOOC+rA,
on the headlight
The plate shows model code,

model, and body color code.
model,
L042G
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2.
G54B
ENGINE
3. TRANS
AX.LE
4.
engine
$p
fry
transmis$on,,
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VNJLF
KM145
COLORTRIM
OPT
876
7
Montone exterior
color code
B21 B76H43
Two-tone color code
Exterior code
E
Two-tone
exterior
is shown
exterior code followed

color codes.
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CODE PLATE
Vehicle information
code plate is riveted
port panel in the engine compartment.
1. MODEL
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by the
by the two
INTRODUCTION
CHASSIS
-Vehicle
Identification
NUMBER.
NoacE-A
STAMPING LOCATION
The chassis number is stamped
the right rear shock absorber.
on the side of the frame
near
CHASSIS NUMBER CODE CHART
IVehicle
line
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VEHICLE SAFETY CERTIFICATION
LABEL
NOOCF-
The vehicle safety certification

label is attached to face of left
door pillar.
This label indicates the month and year of manufacture,
Gross
Vehicle Weight
Rating (G.V.W.R.), front and rear Gross Axle
Weight
Rating (G.A.W.H.),
and Vehicle Identification
Number
(V.I.N.).
ENGINE MODEL STAMPING
NOOCG-.
The engine model number is stamped at the right front side on

the top edge of the cylinder block as shown in the following:
Engine displacement
2.555 liters (155.9 C.I.D.)
The engine serial number is stamped

near the engine
number, and the serial number cycles, as shown below.
Engine serial number
Number
cycling
AA0201 to YY9999
AA0201
---3
AA9999
L ABOOOI
---+
AY9999
L BAOOOl
---3
YY9999
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model
INTRODUCTION
-Vehicle
Identification
BODY COLOR CODE
?r
7
Nmcn-
Exterior code
Body color
Monotone
676
Dark blue (Metallic)
Cl9
Brown
H43
R52
Silver (Metallic)
s70
Beige
x15
Black
(Metallic)
Red
Two-tone
821 B76H43
Silver (Metallic)/
C38C19X13
Black/
Brown (Metallic)
H15H43X13
Black/
Silver (Metallic)
R06R52X13
Black/Red
Black/Beige
S69S7OX13
X45X1 5H43
Black/
Silver (Metallic).
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PRECAUTIONS
PROTECTING
BEFORE SERVICE
THE VEHICLE
NOODAAC
If there is a likelihood
of damaging
painted or interior parts
protect them with suitable covers
during service operations,
(such as seat covers. fender covers, etc.).
001884
REMOVAL
AND DISASSEMBLY
When checking a malfunction,

find the caljse of the problem.
If it is determined
that removal and/or disassembly
is necessary, pet-form the work by following the procedures
contained
in this Workshop Manual.
If punch marks or mating marks are made to avoid error in

assembly and facilitate the assembly work, be sure to make
them in locations
which will have no detrimental
effect on
performance
and/or appearances.
If an area having many parts, similar parts, and/or parts which
aresymmetrical
right and left is disassembled,
be sure to
arrange the parts so that they do not become mixed during the
assembly process.
I. Arrange the parts removed in the proper order.
2. Determine
which parts are to be reused and which are to
be replaced.
3. If bolts, nuts, etc., are to be replaced, be sure to use only
the exact size specified.
Fcloo1
SPECIAL TOOLS
If other tools are substituted
for the special tools to do service
or repair work, there is the danger that vehicle parts might be
damaged,
or the mechanic
might be injured; therefore,
be
sure to use the special tool whenever
doing any work for
which the use of one is specified.
FOOO18
PARTS TO BE REPLACED
If any of the following
parts are removed,
replaced with new parts.
1. Oil seals
2. Gaskets (except rocker cover gasket)
3. Packings
4. O-rings
5. Lock washers
6. Cotter pins
7. Self-locking
nuts
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they
must
be
--
INTRODUCTION
AND
MASTER
TROUBLESHOOTING
- Precautions
Before Service 9
PARTS
When
replacing
VEHICLE
parts, use MITSUBISHI
genuine
parts.
WASHING
If high-pressure
car-washing equipment
or steam car-washing
.I
equipment
is used to wash the vehicle, be sure to maintain th,e,
spray nozzle at a distance of at least 300 mm (11.8 in.) fro,m
any plastic
parts and all opening
parts (doors, lugg$ge
compartment,
etc.).
5
t;
nm
(in.)
so0059
SERVICING
THE ELECTRICAL
When servicing
cable terminal
the electrical system,

from the battery.
SYSTEM
disconnect
the negative
,i
. ,.
Caution
Before connecting
or disconnectingthe
negative cable, be
*,
sure to turn off the ignition switch and the lighting switch,;~: * :
(If this is not done, there is the possibility of semicondu~$$r~
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parts being damaged.)
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WIRING
HARNESSES
1. Secure the wiring harnesses by using clamps so that there

is no slack. However, for any harness which passes to the:
engine or other vibrating
parts of the vehicle, allow some..
slack within a range that does not allow the engine
vibrations to cause the harness to come into contact with
any of the surrounding
parts. Then secure the harness by
using a clamp.
In addition,
if a mounting
indication
mark (yellow tape) is
on a harness, secure the indication
mark in the specified
location.
2.
If any section of a wiring harness contacts the edge of a

part, or a corner, wrap the section of the harness with tape
or something
similar in order to protect it from damage.
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J IO INTRODUCTION
- Precautions
3. When disconnecting
a connector,
connector, not the harness.
Before Service
be sure to pull only the
4.
Disconnect
connectors
the direction indicated
which have catches by pressing

by the arrows in the illustration.
in
,
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.
16R1284
'06347
5. Connect connectors
which have catches
connectors
until they snap.
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by inserting
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INTRODUCTION
AND MASTER TROBB LESHOOTING

ELECTRICAL
- Precautions
Before Service
11
COMPONENTS
1. When installing any of the vehicle parts, be careful

pinch or damage any of the wiring harnesses.
not to
C163Bi
2.
Sensors, relays, etc., are sensitive to strong impacts.

Handle them with care so that they are not dropped
mishandled.
or
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OOVS66
3. The electronic
parts used for relays, etc., are sensitive to
heat. If any service which causes a temperature
of 80C
(176F) or more is performed,
remove the part or parts in
question before carrying out the service.
I
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OOY632
FUSES AND FUSIBLE
LINKS
1. If a blown-out fuse is to be replaced, be sure to

fuse of the specified capacity. If a fuse of a
than that specified is used, parts may be
circuit may not be protected adequately.
10A
Caution
If a fuse is blown-out,
be sure to eliminate
the problem
before installing
a new fuse.
15A
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the cause of
1.
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If additional
optional
equipment
is to be installed
in the
vehicle, follow the procedure
listed in the appropriate
instruction
manual;
however,
be sure to pay careful
attention to the following points:
(1) In order to avoid overloading
the wiring, take the
electrical
current load of the optional
equipment
into
consideration,
and determine
the appropriate
wire size.
(2) Where possible, route the wiring through the existing
harnesses.
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WE569
T
Permissible
Nominal
size
current
2.
SAE
giTe
In engine
compartment
212A
16A
21A
31A
Other
areas
5A
13A
17A
22A
30A
40A
54A
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12 INTRODUCTION
- Precautions Before Service
(3) If an ammeter or similar instrument

is to be connected
to a live-wire circuit, use tape to protect the wire, use a
clamp to secure the wire, and make sure that there is
no contact with any other parts.
(4) Be sure to provide a fuse for the load circuit of the
optional equipment.
TUBES AND OTHER RUBBER PARTS

Be careful to avoid spilling any gasoline,
adheres to any tubes or other rubber
adversely affected.
oil, etc., because

parts, they might
if it
be
LUBRICANTS
In accordance
with the instructions
in this Workshop
Manual,
apply the specified lubricants in the specified locations during
assembly and installation.
FOO028
BRAKE FLUID
Be careful to avoid spilling
any brake fluid, because
if it
adheres to the vehicle body, the paint coat might be discolored.
DOING SERVICE WORK IN GROUPS

MORE TECHNICIANS
If the service
extra caution
work is to be done
must be taken.
_ _
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OF TWO OR
by two or more
technicians
INTRODUCTION
- Precautions
NOTE ON INSTALLATION
Before Service
13
OF RADIO EQUlPM$Fz
The computers
of the electronic
control system has been
designed
so that external radio waves will not interfere with
their operation.
However, if antenna or cable of amateur transceiver
etc. is
routed near the computers,
it may affect the operation
of the
computers,
even if the output of the transceiver
is no more
than 25W.
To protect
each of the computers
from interference
by
transmitter
(hum, transceiver,
etc.), the following
should be
observed.
1. Install the antenna on the roof.
2. Because radio waves are emitted from the coaxial cable of
the antenna,
keep it 200 mm (8 in.) away from the,;
computers
and the wiring harness. If the cable must cross I
the wiring harness, route it so that it runs at right angles to
the wiring harness.
3. The antenna and the cable should be well matched,<and
the standing-wave
ratio* should be kept low.
,.t
4. A transmitter
having a large output should not be installed
in the vehicle.
5. After installation
of transmitter,
run the.engine
at idle, emit ._I
radio waves from the transmitter
and make sure that the
.
engine is not affected.
vo,tage,
Voltage
q.;:I,I,,
Cabje
High-frequency
power supply
Antenna
00Y590
<
*STANDING-WAVE
RATIO
If an antenna and a cable having different
impedances
are
connected,
the input impedance
Zi will vary in accordance
with the length
of the cable and the frequency
of the
,.
transmitter,
and the voltage
distribution
will also vary j)~
p ,, ;
accordance with the location.
The ratio between
this maximum
voltage
and minimum.
:
voltage
is called the standing-wave
ratio. It can also be
,
represented
by the ratio between
the impedances
of .$he :
antenna and the cable.
The amount of radio waves emitted from the cable increases
as the standing-wave
ratio increases, and this increase$the
possibility
of the electronic
components
being adver$ely
, .
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affected.
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14
INTRODUCTION
AND MASTER T OUBLESHOOTING
- ~Z%YZJ%f~~ aStream
TREATMENT BEIFORE/AFTER THE FORDING OF A STREAM

INSPECTION
A STREAM
AND
SERVICE
BEFORE FORDING
NWFA-
Vehicles
which are driven through
water, or which
may
possibly be driven through water, should be subjected to the
following
inspections
and maintenance
procedures
in advance.
l
Seal the speedometer
cable with a water-resistant
grease
or tape.
0 Inspect the dust boots and breather hose for cracks or
damage, and replace them if cracks or damage are found.
r I ,Steering joint
4ower boot
r,
bar dust cover
Clutch release cylinder

l-,,,-.t?\/W//
----l
Steering
OOW521
001525
OOW529
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Speyfometer
cable
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INTRODUCTION

l
- :;:;~k%~cia
stream
I:5
Apply grease to the lubricating

points of the front suspension, steering linkage and propeller shaft.
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16
CTION AND MASTER TROUBLESHOOTING

INSPECTION
STREAM
AND
- ;~:;~;:%$a
SERVICE
AFTER
stream
FORDING
After fording a stream, check the following points. If abnormal

condition is evident, clean, replace or lubricate.
Check for water, mud, sand, etc, in the rear brake drum,
clutch housing, starter motor, brake pipe and fuel pipe.
Check for water in the fluid or oil inside the front
differential,
rear differential,
transmission
and transfer
case.
Apply grease to the lubricating
points of the front suspension, steering linkage and propeller shaft.
Check all boots and breather
hoses for cracks and
damage.
Front differenti
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INTRODUCTION.
AND
MASTER
TROUBLESHOOTING
TOWING
- Towing
AND HOISTING
and
Hoisting
17
NOOGA-
This vehicle can only be towed from the front with conventional sling-type equipment
and tow chain with grab hooks.
If a vehicle is towed from the rear, use a tow dolly.
A lumber spacer (4 x 4 x 55 wood beam) should be placed
forward of under guard and under towing hook/shipping
tie
down hook.
Then, attach J-hook to the lower arm.
A safety chain system must be used. This system must be
completely
independent
of the primary
lifting and towing
attachment.
Care must be taken in the installation
of safety
chains to insure they do not cause damage to bumper, painted
surfaces or lights.
LIFTING-GROUND
CLEARANCE
Towed vehicle should be raised until wheels are a minimum

of
10 cm (4 in.) from the ground. Be sure there is adequate
ground clearance at the opposite end of the vehicle, especiall,y
when towing over rough terrain or when crossing sharp rises,,
such as curbs. If necessary,
ground clearance
can be increased by removing
the wheels from the lifted end of the
disabled
vehicle and carrying the lifted end closer to the
ground. A 20 cm (8 in.) ground clearance must be maintained
between brake drums and ground.
FRONT TOWING
PICKUP
The vehicle may be towed on its rear wheels for extendedd:

,.*
distances, provided the parking brake is released.
Make cartain the transmission
remains in NEUTRAL.
:
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.
SAFETY PRECAUTIONS
The following
precautions
should be taken when towing the.,
:
vehicle.
.,I
1. Remove exhaust tips and any other optional
equipm&nt,.
. .
that interface with the towing sling. Padding (heavy shop ,,
towel or carpeting) should be placed between the towr@g,
sling cross bar and any painted
surfaces, and bump&
.I,
surfaces.
+$$;a
2. A safety chain system
completely
independent
of the.
i
primary lifting and towing attachment
must be used.
.
3. Any loose or protruding
parts of damaged vehicle such as
hoods, doors, fenders, trim, etc., should be secured prior
to moving the vehicle.
4. Operator should refrain from going under a vehicle unless
L,,
the vehicle is adequately
supported by safety stands.
5. Never allow passengers to ride in a towed vehicle.
6. State and local rules and regulations
must be followed
when towing a vehicle.
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18 INTRODUCTION
- Towing
and Hoisting
HOISTING
POST TYPE
Special care should be ,taken when raising the vehicle on a
frame contact type hoist. The hoist must be equipped with the
proper adapters in order to support the vehicle at the proper
locations. (See next page)
Conventional
hydraulic hoists may be used after determining
that the adapter plates will make firm contact with the side
frame.
FLOOR JACK
A regular floor jack may be used under the front crossmember
or rear axle housing.
Caution
1. A floor jack must never be used on any part of the
underbody.
2. Do not attempt
to raise one entire side of the vehicle by
placing a jack midway between front and rear wheels.
This practice
may result in permanent
damage
to the
body.
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..
: . ..
._ - , ._
EMERGENCY
JACKING
Jack receptacles
are located at the No. 2 crossmember
and
rear axle housing to accept the jack supplied with the vehicle
for emergency
road service. Always block the opposite wheels
and jack only on a level surface.
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INTRODUCTION
FRAME
CONTACT
AND
SUPPORT
MASTER
TROUBLESHOOTING
- Towing
and Hoisting
19
LOCATIONS
2,350
mm (92.5 in.)
Section
A-A
NOTE
The locations of the support point shown as Section A-A are
the same as those of the twin post hoist shown in the
illustration (OOW588) below.
001553
LIFTING
AND JACKING
c
m
SUPPORT
LOCATIONS
Twin post hoist

Floor jack
Emergency
jacking (jack supplied
with the vehicle)

OOW588
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20
INTRODUCTION
General
Date
and SpeCifiCatiOnS
GENERAL DATE AND SPECIFICATIONS
N66HA.A
OOW556
Description
L042G
Vehicle dimensions
VNJLFIH
VRJLF/H
TNSLF/H
TRSLFIH
mm (in.)
$ Overall length
3,960 (155.9)
3,960 (155.9)
3,960 (155.9)
3,960 (155.9)
0
0
3,995(157.3)
1,680 (66,l)
3,995(157.3)
3,995 (157.3)
1,680(66,1)
1,680(66,1)
3,995 (157.3)
1,680(66,1)
0
0
1,840 (72,4)
2,350(92.5)
1,840(72,4)
2.350(92.5)
1,850(72,8)
2.350(92.5)
1,850(72,8)
2.350(92.5)
Front
1,400(55.1)
1,400 (55.1)
1,400(55.1)
Rear
1,375 (54.1)
1,375(54.1)
1,375(54.1)
1,400(55.1)
1,375(54.1)
Front
Go
745(29.3)
745(29.3)
745(29.3)
745(29.3)
900(35.4)
900(35.4)
900(35.4)
900(35.4)
Front bumper to ground
480(18.9)
480(18.9)
480(18.9)
480(18.9)
Rear bumper to ground
0
63
440(17.3)
440(17.3)
440(17.3)
210(8.3)
210(8.3)
440(17.3)
210(8.3)
38
38"
38"
38"
@
@
28"
21"
28"
28
28"
21"
21"
21"
1,479(3,260)
1,493 (3,290)
1,440(3,175)
1,460(3,219)
1,910(4,210)
1,100(2,425)
1,910(4,210)
1,100(2,425)
1,450(3,197)
2
1,450(3,197)
$,$ Without
spare tire
9 With spare tire

. $verall width
.rOverall height
.i
-:.,Wheelbase
,$Tread
i,
;q
A Overhang
Rear
Height at curb weight
Minimum
clearance
(wt.)
running ground
Angle of approach
Angle of departure
Ramp breakover
Vehicle weights
Curb weight
angle
kg (Ibs.)
Gross vehicle weight
rating
1,910(4,210)
Gross axle
weight rating
Front
Rear
1,100(2,425)
1,910(4,210)
1,100(2,425)
1,450(3,197)
4
1,450(3,197)
4
Seating capacity
210(8.3)
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~_
~~L
INTRODUCTION
Descrip tiom
L042G
URJLFIH
UNJLFIH
General
Date and Specifications
21
TRSLF/H
TNSLF/H
Engine
Model No.
G54B
G54B
G54B
Type
Number of cylinders
Bore
In-line OHC
in-line OHC
In-line OHC
4
G54B
In-line OHC
4
91 .I mm (3.59 in.) 91 .I mm (3.59 in.) 91 .I mm (3.59 in.) 91 .I mm (3.59 in
Stroke
98.0 mm (3.86 in.) 98.0 mm (3.86 in.) 98.0 mm (3.86 in.) 98.0 mm (3.86 in
2,555 cm3
2,555 cm3
2,555 cm3
2,555 cm3
(155.9 CID)
(155.9 CID)
(155.9 CID)
(155.9 CID)
8.7
8.7
8.7
8.7
Piston displacement
1-3-4-2
1-3-4-2
7 BTDC f 2
1-3-4-2
7 BTDC * 2
1-3-4-2
7 BTDC * 2
7 BTDC + 2
Model No.
KM145
KM148
KM145
KM148
Tvw
5-speed
manual
4-speed
automatic
5-speed
manual
4-speed
automatic
1 st
3.967
2.826
3.967
2.826
2nd
3rd
2.136
2.136
1.360
1.493
1.360
1.493
1.000
4th
5th
1.000
0.856
0.688
-
1.000
0.856
0.688
-
Reverse
High
Low
3.578
1.000
1.944
2.703
1.000
1.944
3.578
2.703
1.000
1.944
1 .ooo
1.944
4.625
4.625
4.625
4.625
Transmission
&transfer
case
Gear ratio
Transmission
Transfer
case
Final ring gear ratio
1 .ooo
L
dt
s
R
f,!
J;
\:.I
Clutch
Dry single
disc &
Type
Dry single
disc &
diaphragm
diaphragm
spring
spring
Chassis
Tire size
Front suspension
P225175R15
We
Spring constant
(Wheel position)
Wishbone compression
22 N/mm (123 Ibs./in.)
type
Rear suspension
Type
Spring constant
Asymmetrical
At load of 1 ,OOO-2,500 N
(220-551 Ibs.)
22 N/mm (123 lbs./in.)
At load of 4.670-8.870
(1,030-l ,955 Ibs.)
50 N/mm (280 Ibsin.)
semi-elliptic
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leaf spring
22
INTRODUCTION
Description

VNJLF/H
--<
General
Date and Specifications/
TighteningTorque
VRJLFIH
TRSLF/H
TNSLFIH
Brakes
Type
Front
Disc
Rear
Drum
(Leading and trailing)
Integral type (Recirculating
ball nut)
16.4
60 liters (15.9 U.S. gaM3.2
eniTIGHTENING
TORQUE
Description
,I
:
,A
.Thread for general purposes
, -(size x pitch) mm
Head mark
8 x 1 .i5
10x 1.25
12x1.25
~:S~$,
14x 1.5
.t*: $\
%,:
5
16x 1.5
.:.
,:: ..,
.
4
;: I*
>y.; ; :.
18x 1.5
. . .I a
.i .,:.
20 x.1.5
P...:
i
:
3 22x1.5
ip
\ 24x1.5
-,
..a
Head mark
ftlbs.
Nm
ft.lbs.
3.0-3.9
7.9-l 2
2.2-2.9
5.8-8.7
4.9-7.8
3.6-5.8
13-19
9.4-l 4
16-23
12-17
27-39
20-29
Nm
6x 1.0
1.
-1
Imp. gal.)
29-43
21-32
47-72
35-53
48-70
67-l 00
35-52
51-77
77-l 10
57-85
130-I 60
90-I 20
100-I 50
150-I 90
74-l 10
180-230
130-170
1 IO-140
160-320
1go-240
200-260
150-I 90
340-430
250-320
260-320
1go-240
420-550
310-410
Nm
ft.lbs.
Description
Remarks
Taper thread for pipes (size)
PTlI8
7.9-l 2
16-19
5.8-8.7
12-14
Internal thread: Aluminum

Internal thread: Cast iron
PTlI4
19-30
34-45
14-22
25-33

PT 318
39-54
58-73
29-40
43-54

4.9-7.8
7.9-l 2
3.6-5.8
5.8-8.7

7.9-l 2
16-19
19-13
34-45
5.8-8.7
12-14
14-22
25-33

Tape thread for dry sealed pipes (size)

L
NPTF l/l 6
NPTF II8
NPTF 114
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INTRODUCTION
- Master Troubleshooting
23
MASTER TROUBLESHOOTING
ENGINE
NOOKAAC
OVERHEATS
Symptom
Reference
page
Remedy
Probable cause
,
Engine
overheats
Cooling system
Incorrect
faulty
Troubleshoot
ignition timing
cooling system
7-5
Readjust ignition timing
o-13
Remedy
Reference
paw
I
<r.-.
,
ENGINE WILL NOT CRANK OR CRANKS SLOWLY

Symptom
Probable cause
Engine will not crank

or cranks slowly
Starting system
Troubleshoot
faulty
starting system
a-94
c
;.
,
i*
;-
!_
ENGINE WILL NOT START OR START TO HARD (CRANKS
OK)
Symptom
Probable cause
Remedy
Reference
page
Engine will not start or

start to hard
(Cranks OK)
No fuel supply to carburetor
Check fuel line
1485
Carburetor
Troubleshoot
fuel system
14-20
Troubleshoot
ignition system
problems
Ignition system
problems
Vacuum leaks
l
Purge control valve hose
l
Vacuum hoses
l
Intake manifold
l
Carburetor
l
EGR valve
Repair as necessary
Compression
Check compression
(Troubleshoot engine)
too low
9-14
.)
-T
.
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24
INTROD CTION AND MASTER TROUBLESHOOTING
- Master
Troubleshooting
ROUGH BDLE OR ENGINE STAILL

Symptom
Probable cause
Remedy
Rough idle or
engine stalls
Vacuum leaks
l
l
Vacuum hoses
l
intake manifold
0 Carburetor
l
EGRvalve
Repair as necessary
Ignition system
Troubleshoot
problems
ignition system
Idle speed set too low
Readjust
idle speed
Idle mixture too lean or too rich
Readjust
idle speed and mixture
Carburetor
Troubleshoot
fuel system
Exhaust gas recirculation

(EGR) system problems
Troubleshoot
fuel system
Engine overheats
Refer to Engine Overheats
Compression
Check compression
(Troubleshoot
engine)
problems
too low
9-14
/
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lNTRODUCTlON
ENGINE
HESITATES
Troubleshooting
25
OR POOR ACCELERATION
Symptom
Engine hesitates
poor acceleration
- Master
Probable cause
or
Ignition system
Reference
paw
Remedy
problem
Troubleshoot
ignition system
8-l 09
Vacuum leaks
l
l
Vacuum hoses
0 Intake manifold
l
Carburetor
l
EGRvalve
Repair as necessary
Air cleaner filter clogged
Check air cleaner filter
11-4
Fuel line clogged
Check fuel line
14-85
Carburetor
Troubleshoot
14-20
problem
Auxiliary accelerator
engine)
pump faulty (cold
fuel system
Check auxiliary accelerator

device
14-43
Emission control system problem

EGR system always on
high-altitude compensation
(HAC) system problem
Check EGR system

Check HAC system
25-33
25-34
Engine overheats
Refer to Engine Overheats
Compression
Check compression
(Troubleshoot engine)
9-14
too low
ENGINE DIESELING
Symptom
Probable cause
Remedy
Engine dieseling (runs

after ignition switch is
turned off)
Carburetor
Troubleshoot
Incorrect
problems
ignition timing
Reference;:!
page
1,.
fuel system
Readjust ignition timing
14-20
o-13
j ,
i
! ,;7
: ?:
I(, :.
4
kJi
I
%
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1,:
i j,;;
i ,:
b-i.cl-:
.i.
..
26
INTRODUCTION
EXCESSIVE
AND MASTER
TROUBLESHOOTING
OIL CONSUMPTION
Symptom
Probable cause
Remedy
Reference
page
Excessive oil
consumption
Oil leak
Repair as necessary
Positive crankcase ventilation line clogged
Check positive crankcase

ventilation system
o-17
Valve stem seal worn or damaged
Check valve stem seal
9-45
Valve stem worn
Check valves and guides
9-45
Piston ring worn or damaged
Check piston rings
9-55
,POQR FUEL MILEAGE

-r
Symptom
Probable cause
Poor fuel mileage
Fuel leak
Air cleaner
IRemsd
Reference
we
filter clogged
ignition problems
Troubleshoot ignition system
8-l 09
Carburetor problems
Troubleshoot fuel system
14-20
Compression too low
Check compression
9-14
Tires improperly inflated
Inflate tires to proper pressure
22-2
Clutch slips
Troubleshoot clutch
6-4
Brakes drag
Troubleshoot brakes
Probable cause
Remedy
Loose bolts and nuts
Retighten as necessary
Engine noise
Troubleshoot engine
/ ST6 Revision
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Reference
paw
9-l 1
INTRODUCTION
27
HARD STEERING
. . NOOKBAC
Symptom
Probable cause
Hard steering
Loose power
steering
oil pump belt
Low fluid level

Air in power
steering
system
Low tire pressure

Excessive turning resistance
or lower ball joint
Excessively
Improper
Excessive
joint
of upper
tight linkage ball joint

front wheel alignment
turning resistance
No lubricantion
of tie-rod ball
of tie-rod
Remedy
Reference
page
Adjust
19-11
Refill
19-11
Bleed air
19-12
Adjust
22-2
Replace
2-35
2-40
Adjust
19-10
Correct
2-14
Replace
19-40
Lubricate
Siticky flow control valve
Replace
No lubrication
Lubricate
of idler arm
POOR RETURN OF STEERING
19-34
WHEEL TO CENTER
Symptom
Probable cause
Poor return of
steering wheel to
center
Improper
front wheel
Improper
tire pressure
Damaged
Remedy
alignment
Adjust
Adjust
front wheel bearing
Replace
POOR RIDING
i..
L..
Symptom
Probable cause
Remedy
Reference
we
Poor riding
Improper
tire pressure
Adjust
22-2
wheels
Repair
22-3
lmbalanced
Repair or replace
1.
;
2-14, 17-3:.
Replace
2-35, 174:
Broken or worn stabilizer
Replace
2-51
Broken or worn torsion bar spring
Replace
2-48
Loose suspension
Retighten
Improper
front or rear wheel alignment
Malfunctioning
shock absorber
securing
bolt(s)
Worn lower arm bushing
2-40
Replace
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28
INTRODUCTION
ABNORMAL
TIRE WEAR
Symptom
Abnormal
Reference
page
Remedy
Probable cause
tire wear
Troubleshooting
wheels
and tires
Loose wheel bearings

Malfunctioning
shock absorber
ROAD WANDER
Symptom
Road wander
Probable cause
Remedy
Reference
we
Improper
Adjust
2-14
17-3
Excessive
play of steering
Poor turning resistance

hessure
c
Loose or worn
Loose or worn
_^
VEHICLE
cj
19-9
wheel
of lower ball joint

jZ
lower arm bushing
1
1 Retighten
~
or replace
ZI
I
1 22:
wheel bearings
PULLS TO ONE SIDE
S+ptom
Probable cause
Vehicle pulls to
or& side
Improper
Remedy
Reference
page
Excessive
joint
turning resistance
of lower ball
2-40
Wheel bearing seizure
2-23
Broken or worn
2-48
torsion bar
Bend front axle drive shaft
2-52
Deformed
2-40
lower arm
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INTRODUCTION
STEERING
29
WHEEL SHIMMY
Symptom
Probable cause
Remedy
Reference
iwe
Steering wheel
shimmy
Improper
Adjust
2-14
17-3
Improper
tire pressure
( Adjust
1 22-2
Repair
Replace
2-37
2-40
Repair
19-9
Broken or weak stabilizer
Replace
2-51
Worn lower arm bushing
Replace
2-40
Malfunctioning
Replace
2-35
Broken or weak torsion bar spring or

leaf spring
Replace
2-48
17-4
Wear, play, or seizure of wheel bearing
Replace
2-23
Symptom
Probable cause
Remedy
Reference,
&;
page
Bottoming
Overloaded
Correct
t.:
Broken or weak torsion bar spring or

leaf spring
Replace
2-48
17-4
t:.
::
f#:
Malfunctioning
Replace
2-35, l+
lmbalanced
wheels
i Poor turning resistance

lower ball joint
of upper or
Excessive
play of steering wheel
shock absorber
BOTTOMING
vehicle
shock absorber
) STB Revision
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30
INTRODUCTION
WHEEL BEARING
TROUBLESHOOTING
Trouble
Symptom
probable cause
Pitting
Pitting occurs because of uneven rotation of race

and bearing surfaces
Excessive
Excessive
Flaking
The surface peels because of uneven rotation of

the race and bearing surfaces
End of bearing life

Improper bearing assembly
Cracking
Chipping
Impact when bearing was

installed (such as being hit
with a hammer)
Flat spotting
When large load is applied, race and roller contact

surfaces compress, forming indentations
Excessive
Excessive
Vibration
not used,
shipment
transport
bearing preload
load
when bearings are
such as during
on freight cars,
trucks, etc.
Nicks
Instead of rolling along race surface,

rollers slide, thus damaging surface
Improper
Excessive
Excessive
Faulty oil
grease
bearing preload
load
seal
Smearing
Damage or wear caused by minute particles

adhering to surfaces results in rough movement
and such high temperatures
that parts of surface
melt
Excessive variation of loads on

bearings
Use of grease other than that
specified
Improper grease
f&St, corrosion
i,q!3j
Appears
Use of grease other than

that specified
Faulty oil seal
Presence of water or moisture
or cracking
of cage or roller edges
on various areas of the bearing
I$
W)ear
Wear of surface
Improper grease
Foreign matter
Rust or corrosion due to
moisture
Use of grease other than that
specified
Faulty oil eal
areas caused by friction
,J .
.2
4
3
,I
&coloration
Grease discoloration result:s from grease

deterioration which causes particles of pigment
contained in grease to adhere to surfaces
Heat discoloration will appear as a deep brown or
purple
) STB Revision
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bearing preload
load
Use of grease other than

that specified
Faulty oil seal
Excessive bearing preload
Excessive load
O-l
LUBRICATION
AND
MAINTENANCE
CONTENTS
GENERAL INFORMATION
.................................
MAINTENANCE
SERVICE
.... .......... . ..................
Air Filter ...........................................................
Automatic
Transmission
.................................
Ball Joint, Steering Linkage
Seals and Drive Shaft Boots ............................
Ball Joints with Grease Nipple
........................
Brake Fluid ......................................................
Brake Hoses ....................................................
Canister
...........................................................
Carburetor Choke Mechanism
and Linkage
.....................................................
Carburetor or Body Mounting
.........................
Cooling System
................................................
Crankcase Emission Control
System (PCV Valve) .........................................
Distributor Cap, Rotor and
Advanced angle System
.................................
Drive Belt .........................................................
EGR Valve ........................................................
Engine Oil ........................................................
Engine Oil Filter ...............................................
Evaporative Emission Control
System (except Canisters)
..............................
Exhaust System (Connection
Portion of Muffler and Pipings
and Keeping Warmth Covers) .........................
Fuel Filter .........................................................
Fuel Hoses, Vapor Hoses, and
Fuel Filler Cap ..................................................
2
9
16
22
26
27
26
26
18
14
21
24
17
19
10
19
9
9
17
28
15
Fuel System
....................................................
Front Axle and Rear Axle .................................
:7
Front Disc Brake Pads .....................................
25
Front Wheel Bearings
.....................................
27\yYl
Ignition Cables ................................................
19!*.:.=:
+: . .I
Inspection
and Adjustment
of Engine Idling
Speed ..............................................................
93 .....:.!.
I,....
Intake Temperature
Control
System
............................................................
~21.~,,.~.~
,
8
Manual Transmission
........................
I.. .......... .$22 : A:
Oxygen Sensor ........................
........................ 2:.)1 g : .Y:i>
Propeller Shaft Joints ......................................
C;,28::.
Rear Axle Oil (Limited Slip
, p;,
Differential)
..........................
~~~~~~~~~~~~~~~.~.~~~~.~~~,~~~~,
1;
.-I
Rear Drum Brake Linings and
Rear Wheel Cylinders ......................................
. 1.25 1; ..
Secondary Air System ............. I.. .................... Fc2,1, :
Solenoid Valve Air Filter of
&
* ;:
Vacuum Control System
.................................
2& .-:
1 f3$, , .::
Spark Plugs .....................................................
Transfer Case ..................................................
23 I$??
Vacuum Hoses, Secondary Air Hoses,
: .
Crankcase Ventilation
Hoses
and Water Hoses
............................................
15
.;
Valve Clearance
...............................................
11
RECOMMENDED
LUBRICANTS
AND
LUBRICANT
CAPACITIES
TABLE
.....................
6
SCHEDULED
MAINTENANCE
TABLE ..............
3
;::
1
16
http://vnx.su/
o-2
LUBRICATION
AND MAINTIENANCE-General
GENERAL INFORMATION
NOOPA-8
Maintenance
and lubrication
service recommendations have been compiled to provide maximum protection for the vehicle owners investment against all reasonable types of driving conditions.
Since these
conditions vary with the individual vehicle owners
driving habits, the area in which the vehicle is operated
and the type of driving to which the vehicle is subjected, it is necessary to prescribe lubrication
and
maintenance
service on a time frequency as well as
mileage interval basis.
Oils, lubricants and greases are classified and graded
according to standards recommended
by the Society
of- Automotive
Engineers (SAE), the American Petroleum Institute
(API) and the National
Lubricating
Grease Institute (NLGI).
MAINTENANCE
SCHEDULES
Information
for service maintenance
is provided under
SCHEDULED
MAINTENANCE
TABLE.
Three schedules
are provided;
one for Required
Maintenance,
one for General Maintenance
and
one for Severe Usage Service.
SEVERE SERVICE
Vehicles operating under severe service conditions will

require more frequent service.
Component
service information
is included in appropri.!ate units for vehicles operaing under one or more of
.!
the following conditions:
i;? Trailer towing or police, taxi, or commercial
type
:..
$ operation.
2; Operation of Vehicle
: (1) Short-trip operation at freezing temperature
i
(engine not thoroughly warmed up)
't'; +':
.,;$._I
(2) More than 50% operation in heavy city traffic
3
,'
during hot weather above 32C (90F)
;;.:.. :I- (3) Extensive idling
,:
(4) Driving in sandy areas
.! . ;
(5) Driving in salty areas
;
83
(6) Driving in dusty conditions
:
.
(7) Driving on-off-road
ENGINE
GEAR LUBWCANTS
The SAE grade number also indicates
Multi-Purpose
Gear Lubricants.
the viscosity of
The API classification

system defines gear lubricants in terrns of usage. Typically gear lubricants
conforming
to API GL-4 or GL-5 with a viscosity of
SAE 8OW, SAE 90 are recommended
for manual
transmission,
front axle and rear axle (conventional
differential),
and MITSUBISHI
genuine gear oil Part
No. 8149630EX
or equivalent,
for rear axle (limitedslip differential).
LUBRICANTS-GREASES
Semi-solid lubricants, bear the NLGI designation
and
are further classified as grades 0, 1, 2, 3 etc..
Whenever
Chassis Lubricant
is specified, MultiPurpose Grease, NLGI grade No. 2, should be used.
FUEL USAGE STATEMENT

Use gasolines having a minimum
ant-knock index (Octane Value) of 87, (R + M)/2. This designation is comparable to a Research Octane Number of 91.
Unleaded gasolines only must be used in vehicles
equipped with catalyst emission control systems. All
vehicles, so equipped, have labels located on the instrument panel and on the back of fuel filler lid that
state, UNLEADED
GASOLINE
ONLY. These vehicles also have fuel filler tubes especially designed to
accept the smaller
diameter
unleaded
gasoline
dispensing nozzles only.
MATERIALS
ADDED TO FUEL
Indiscriminate
use of fuel system cleaning agents
should be avoided. Many of these materials intended
for gum and varnish removal may contain highly active
solvents or similar ingredients that can be harmful to
gasket and diaphragm materials used in fuel system
component
parts.
OIL
The SAE grade number indicates the viscosity of en. gine oils, for example, SAE 30, which is a single grade
oil. Engine oils are also identified by a dual number, for
;,:g
example, SAE lOW-30, which indicates a multigrade
oil.
The API classification
system difines oil performance
in terms of engine usage. Only engine oil designed
For Service SF or For Service SF/CC, when available, should be used. These oils contain sufficient:
chemical additives to provide maximum
engine protection. Both the SAE grade and the API designation
can
be found on the container.
mTB
Information
Revision
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LUBRICATION
SCHEDULED
AND MAINTENAN
MAINTENANCE
SCHEDULED MAINTENANCE
PERFORMANCE
Inspection
all vehicle
Emission
nance
E-Scheduled
System
Nooa&-
SERVICE FOR EMISSION
Mainte-
o-3
Table
TABLE
and Service should be performed

any time a malfunciton
emission
services
to protect your emission warranty.
Control
Maintenance
Kilometers
sands
Service Intervals
Mileage
sands
CONTROL
is observed
in Thouin
Thou-
AND PROPER VEHICLE
or suspected.
Retain receipts
24
48
72
80
96
15
30
45
50
60
Change Engine Oil Every 12 Months
or
Every 12,000 km (7,500 miles)
Change Engine Oil Filter Every 12 Months
or
Replace Drive Belt (for Water Pump, Alternator)
at
Check Valve Clearance (Jet Valve onlv): Adiust as Reauired
at
Check Engine Idle Speed*;
at
Clean Carburetor
Adjust as Required
Choke Mechanism
and Linkage
at
Replace Fuel Filter Every 5 Years

Check Fuel Svstem (Tank. Line and Connection)
for Leaks Everv 5 Years
Replace Vacuum Hoses, Secondary Air Hoses, Crankcase

and Water Hoses Every 5 Years
Ventilation Hoses
or
at
Air Filter
Emission Control System (PCV Valve) Every 5 Years
Check Evaporative Emission Control System (except Canister) for Leaks

and Cloqqinq Every 5 Years
Replace Canister
at
Replace EGR Valve*2
at
Replace Oxygen Sensor
at
** Every 5 Years
Check Secondary Air System *2 Every 5 Years

Replace Solenoid Valve Air Filter of Vacuum Control System ** Every 5 Years
) ST6 Revision
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or 1
or
or
or
NOTE
(1) *: Shows recommended maintenance items for California vehicles only, but are required for vehicles
except for California.
(2) l z: Except for California.
or
5 Years
or
at
Replace Spark Plugs
Cap, Rotor and Advanced Angle System *2Every
or
Replace Ignition Cables Every 5 Years
Control System
or
Replace
Check Intake Temperature
or
Check Distributor
or
Replace Fuel Hoses, Vapor Hoses and Fuel Filler Cap Every 5 Years
Clean Crankcase
for
LUBRICATION
GENERAL
MAINTENANCE
AND MAINTENAhlCE-Scheduled
Maintenance
SERVICE FOR PROPER VEHICLE

Kilometers
General Maintenance
Manual Transmission
in
Service Interval
Oil
Cooling System
Leaks Every 2 Yea
aks and Damage E
Front Axle and

Rear Axle
,+*
.t.. .,.c NOTE
:!J.;
(l)"f*l:
Except for California.

. (2):*2: LSD-Limited
slip differential
.,
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.,.
1...i,.;.:
>
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.
STB Revision
-1
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Table
PERFORMANCE
o-5
SCHEDULED
MAINTENANCE
The maintenance
Maintenance
Item
items
should
UNDER SEVERE USAGE CONDITIONS
be performed
Service to be
Performed
according
to the following
table:
Mileage Intervals Kilometers in

Thousands (Miles in Thousands)
A
Replace
Every 6 Months
or
Air Filter
Replace
Crankcase
Emission
Control System
Check and Clean

as Required
More Frequently
More Frequently
Spark Plugs
Replace at
Front Disc Brake

Pads
Inspect for Wear
More Frequently
Rear Drum Brake

Linings and Rear
Wheel Cylinders
Manual Transmission and
Transfer Case
Inspect for Wear

and Leaks
More Frequently
Engine Oil
Change
Every 3 Months
or
Engine Oil filter
Change
oil at
24 (15)
48 (30)
72 (45)
96 (60)
Severe Usage
Conditions
E
Severe usage conditions

A-Driving
in dusty conditions
B-Trailer towing, or police, taxi, or commercial type operation
C-Extensive
idling
D-Short-trip
operatibn at freezing temperatures (engine not thoroughly warmed up)
E-Driving in dandy areas
F-Driving in salty areas
G-More than 50% operation in heavy city traffic during hot weather above 32C (90F)
H-Driving
on off-road
1 STB Revision
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O-6
LUBRICATION
RECOMMENDED
RECOMMENDED
AND MAINTENANCE-R
LUBRICANTS
ecommended
Lubricants
and Lubricant
Capacities
AND LUB KANT CAPACITES
Table
TABLE
LUBRICANTS
NOORA-B
Remarks
API classification
SF or SF/CC
API classification
GL-4 or higher
For further details

vrscosrty number
refer to SAE
sAEgraden
SAE80
75Wl85W
Automatic
Transfer
transmission
case
d
$Front axle
Automatic
DEXRON
transmission
II type
fluid
API classification
GL-4 or higher
SAE grade number:

75w/a5w
SAE 80W or
API classification
GL-4 or higher
For further details, refer to SAE

viscosity number
API classification
GL-4 or higher
For further details, refer to SAE

viscosity number
-.
Mitsubishi Genuine Gear Oil Part No.

8149630EX or equivalent
(Rear axle
Conventional
Limited-slip
Power
differential
differential
steering
Automatic
DEXRON
transmission
fluid
or DEXRON II type
r,
+TLakes and clutch
Conforming
,$nt
bearings
Multipurpose
grease NLGI Grade 2
H&d lock catch, door lock

..str~k%rs, seat adjusters, back door
lockt parking brake cable
:./me+anism
Multipurpose
grease NLGI Grade 2
wheel
, ,J,
. .:
Do,$?hinges,
to DOT 3
DIA-QUEEN LONG-LIFE
COOLANT (Part No. 0103044)
or HIGH QUALITY ETHLENE
GLYCOL ANTIFREEZE COOLANT
.back door hinges
Engine oil
1 ST6 Revision
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LUBRICATION
LUBRICANT
AND MAINTENANCE
CAPACITIES
Recommended
Lubricants
and Lubricant
Capacities
Table
o-7
TABLE
Description
Metric measure
U.S. measure
Imperial measure
5.0 liters
4.4 qts.
0.5 liter
5.3 qts.
.53 qt.
8.0 liters
8.45 qts.
7.04 qts.
Manual transmission
2.2 liters
4.7 pints
3.9 pints
Automatic
Engine oil
Crankcase
(include oil filter)
Oil filter
Cooling system
tank)
(including
heater and coolant reserve
transmission
.44 qt.
7.2 liters
15.2 pints
12.7 pints
Transfer case
2.2 liters
4.7 pints
3.9 pints
Front axle
I. 1 liters
2.3 pints
1.9 pints
1 .I liters
1.8 liters
2.3 pints
3.8 pints
1.9 pints
3.2 pints
0.9 liter
60 liters
1.9 pints
15.9 gals.
1.6pints
Resr axle
Conventional differential
Limited-slip differential
Power
steering
Fuel tank
) STB
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13.2 gals.
1
T
:.
o-8
LUBRICATION
SELECTION
ENGINE
AND MAINTENANCE-
OF LUBRICANTS
i:
20
38
100
27
60
32
-12
10
-23
-10
-20
-29
SAE viscosity
No.
80
16
Lubricants
FRONT AXLE/REAR
OIL
Anticipated atmospheric
temperature range
Recommended
and
Lubricant
Capacities
AXLE (CONVENTIONAL
Table
DIFFERENTIAL)
Lubricant
API classification
GL-4 or higher
Anticipated tempeature
range
Viscosity
Above -23C (- 10F)
SAE 90
SAE 85W-90
SAE 8OW-90
-23C to -34C
SAE 80W
(- 10F to -30F)
SAE 8OW-90
Below -34C
(-30F)
REAR AXLE (LIMITED-SLIP

Refer
range
SAE 75W
DIFFERENTIAL)
I:0 P.3-11.
53E531
.i
.-,
: *SAE 5W-20 Not recommended
.-I
:-.1, .\,behicle operation.
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-. . .
Coolant
?;:
Example
.:. , .. The safe operating temperature
.; c-. (680~).
for sustained
Concentration
high speed
and Specific
Gravity
is - 15C (5F) when the measured specific gravity is 1.058 at the coolant temperature
of 20C
Cautions
1. lf the concentration
of the coolant is below 30%1, the anti-corrosion
property will be adversely affected.
In addition,
if the concentration
is above 60%, both the anti-freeze
and engine cooling properties
will
decrease, affecting the engine adversely. For these reasons, be sure to maintain
the concentration
level
within the specified range.
2. Do not use a mixture of different brands of anti-freeze.
( ST6 Revision
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LUBRICATION
AND MAlNTENANCE-Maintenance
MAINTENANCE
ENGINE
o-9
Service
SERVICE
NOOSMC
OIL (Change)
Always use lubricants which conform to the requirements

of the
API cla&ification
For Service SF/CC when available, and have
the proper SAE grade number for the expected temperature
range.
Never use nondetergent
or straight mineral oil.
(1) After warming up the engine, remove the oil filler cap.
(2) Remove the drain plug to allow the engine oil to drain.
(3) Replace the drain plug gasket with a new one and tighten
drain plug.
(4) Pour new engine oil through the oil filler.
Engine
ENGINE
oil total
quantity
: 5.0 liters
Imp.qts.)
(5.3
U.S.
qts.,
the
,; +
:
I*
4.4,
A!
1i
OIL FILTER (Replace)
The quality of replacement

filters varies considerably.
Only high < ;.-.
quality filters should be used to assure most efficient service? ,.p
Genuine oil filters require that the filter be capable of
a pressure of 1800kPa (256 psi) are, high quality filters and
recommended
as follows:
Oil Filter Part Number
Mitsubishi
Genuine Parts
:.
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ENGINE OIL FILTER SELECTION
:e f
This vehicle is equipped with a full-flow, throw-away oil filter. the: -;i ;j
same type of replacement filter is recommended
as a replacement
filter for this vehicle. It is possible, particularly in cold weather, that:. -j..
this vehicle may develop high oil pressure for a short duration. Yo&..,?. . :should be sure that any replacement
filter used on this vehicle is I,- ::$
a high-quality filter and is capable of withstanding
a pressure of , :.
1800kPa (256 psi) (manufacturers
specifications)
to avoid filter
and engine damage. The following is a high-quality
filter and is
strongly recommended
for use on this vehicle:
Mitsubishi
t ,:;
Engine Oil Filter Part No. MD084693
or MD031805.
Any replacement
oil filter should be installed in accordance with :<.i
the oil filter manufacturers
installation instructions.
REPLACEMENT
OF ENGINE OIL FILTER
1. Remove the engine oil filler cap.
2. Remove the engine oil drain plug and drain the engine oil.
3. Using the oil filter wrench, remove the engine oil filter.
/ STB Revision
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: MD031805
or equivalent
~~
LUBRICATION
AND MAINTENA
CE - Maintenance
Service
4. After putting a small amount of engine oil on the O-ring of the

new oil filter, turn it with hand and install it in the block.
CAUTION
Make sure the installation
5.
ding
mo54:
Alternator
pulley
Crankshaft
pulley
are clean.
Pour in the engine oil.
DRIVE
Water pump
pulley
surfaces
BELT (Replace)
NOOSBBA
1. Inspect the drive belts for evidence

of cuts and cracks.
Replace, if necessary.
2. Check belt for proper deflection.
If necessary, adjust the
belt deflection
as follows.
(1) Push the belt with a force of 100 N (22 Ibs.) at a point
halfway between the alternator pulley and water pump
pulley. The belt deflection
should be the standard
value.
0400020
Standard
: 9-12
value:
mm
(.35-.47
in.)
(2) If belt deflection

is not within the standard
value,
loosen alternator support nut and alternator brace bolt,
and move alternator to obtain proper belt deflection
at
IOON (22 Ibs.) force.
REPLACEMENT
OF DRIVE
BELT
Vehicles
without
an air conditioner
1. Loosen the alternator
brace bolt and alternator
nut, and then remove the alternator
drive belt.
2. Install a new alternator
drive belt.
3.
Contact a bar or similar object to the stator part of the

alternator in order to provide the appropriate
tension, and
then adjust the amount
of belt deflection.
Standard
value
: 9-12
mm
(.35-.47
in.)
4. Tighten the alternator brace bolt and alternator

at the specified
torque.
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CL
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support
nut
LUBRICATION
AND
AINTENANCE
- Maintenance
O-II
Service
Vehicles with an air conditioner

1. Loosen the tension
pulley nut.
2. Loosen the tension adjustment
nut and then
air conditioner
compressors
drive belt.
remove
the
3.
Loosen the alternator

brace bolt and alternator
support
nut.
4. Loosen the tension
adjustment
bolt, and remove
the ~, I,
,
..C
alternator
drive belt.
!
5. Install a new alternator
drive belt.
6. Adjust the amount of deflection
of the belt by using the,.
x
tension adjustment
bolt.
:,.
Standard
value
: 9-12mm
(.35-.47
in.)
.
...I
7. Tighten the alternator support nut, and the alternator brace

bolt at the specified
torque.
8. Install the air conditioner
compressors
drive belt, and
adjust the amount
of deflection
of the drive belt.
Refer to GROUP 24 HEATERS AND AIR CONDITIONING
- _
Service Adjustment
Procedures.
VALVE
quired)
CLEARANCE
(Check
and
adjust
as
r&:.. :I.!
NooSA&
Incorrect
valve clearances
will not only result in unsteady
engine operation,
but will also cause excessive
noise and
reduced engine output.
Check the valve clearances
and adjust as required while the
engine is hot.
Valve-to-rocker
Jet valves
Rocker
arm
Auto-lash
adjuster
arm clearances
:
. . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm
(.0098
in.)
VALVE CLEARANCE
ADJUSTMENT
Intake and Exhaust Valves
The auto-lash adjuster is installed to the rocker arm so that the
valve clearance
adjustment
is maintenance-free.
For additional
information
regarding
the auto-lash
adjuster,
refer to GROUP 9 ENGINE.
6EN198
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o-12
LUBRICATION
AND MAINTENANCE
Jet
- Maintenance
valves
Caution
The cyllinder
head bolts
attempting
this adjustment.
I.
2.
3.
4.
5.
Service
should
be
retightened
before
Warm up the engine until the coolant temperature

reaches
85~95C (185-205F).
Remove the air filter assembly.
In order to facilitate the work, remove all spark plugs from
the (cylinder head.
Remove the rocker cover.
Move the No. 1 cylinder to top dead center.
Align the notch in the crankshaft pulley with the T mark
on tl?e timing chain cover.
Check to be sure that the camshaft
sprocket
and the
timing chains mating mark are in the position shown in the
figure.
Caution
Be sure to turn the crankshaft
direction
(right rotation).
in the forward
Note
If the camshaft
sprockets
mating
opposite position, the No. 4 cylinder
rotation
mark is at the 180

is at top dead center.
5EN075
With the No. 1 cylinder

top dead center.
at compression
6.
Measure the jet valve clearance

arrows in the figure.
at the places shown
Standard
: 0.25
by the
Exhaust valves
rant 0
mgine
Note
The valve
value
(when
clearance
when
ct --I-Inlet valves
With the No. 4 cylinder at compression

top dead center.
- Exhaust valves
:ront
sngin
Inlet valves
5EN2
evision
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warm)
cold
mm
is 0.17
(.0098
mm
(.007
in.)
in.)
LUBRICATION
AND
MAINTENANCE
- Maintenance
o-13
Service
7. If the measured value is not the standard value, loosen the

lock nut, and, while turning the adjustment
screw,
the clearance by using the thickness
gauge.
Caution
Be careful not to press the jet valve
valve springs
force is not strong.
8.
in, because
adjust
the jet
Hold the adjustment

screw (so that it wont turn) by using a
screwdriver,
and tighten
the lock nut at the specified
torque.
9.
Coat this area with sealant
10 mm (.39 in.)
10 mm l.39 in.)
Rotate the crankshaft

360 in the forward rotation direction, and align the notch in the pulley with the T mark on
the timing chain cover.
10. Measuring
the remaining
valves; if the result is not the
standard value, adjust by following
steps 7 and 8.
11. Apply a coating of the designated
sealant to the semiri:
circular packing, at the places shown in the figure.
:,
: 3M ART Part No. 8660 or equivalent
Specified sealant
..
3EN325
12. Install
13. Install
14. Install
the rocker cover.

the air cleaner.
the spark plugs.
,b\
AND
INSPECTION
ADJUSTMENT
OF
EN
IDLING SPEED
Caution
The improper
setting (throttle
value opening)
will in
exhaust gas temperature
at deceleration,
reducing catalyst
life
greatly
and
deteriorating
exhaust
gas cleanihg
performance.
If also has effect on fuel consumption
and eni
gine braking.
Inspection
1.
-I
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;,
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P!.
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I
Conditions
Engine coolant temperature:
85-95C
(185-205F)
Lights and accessories (air-conditioner,
etc.): OFF
l
Transmission:
Neutral
l
Steering wheel: Centered (for power steering equipped vehicles)
1. Prepare a timing light and tachometer.
2. Start the engine and allow it to idle.
3. Inspect the ignition timing. Adjust the ignition timing if necessary.
l
l
Standard
*:
ignition
timing
: 7 BTDC
&2*
When inspecting the standard ignition timing at high altitudes, disconnect the white striped vacuum hose from the
distributor auxilian/ compression
chamber and temporarily
close the end of the hose with a blind plug. (Federal indicated high-altitude
specificatioin
vehicles, California).
/ STB Revision
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o-14
LUBRICATION
AND
MAINTENANCE
Maintenance
NOTE
Inspect and adjust ignition timing
ELECTRICAL-Ignition
System.
4.
5.
6.
Service
as described
in GROUP
Run rhe engine for more than 5 seconds at an engine speed of

2,000 to 3,000 rpm.
Run the engine at idle for 2 minutes.
Read the idling speed.

If outside specified limits, readjust the speed to the specified
value by adjusting the idle speed adjusting
screw No. 1
(SAS-1).
M/T alId A/T
725+15'
-100
800+100
NOTE
M/T : Manual transmlsslon
A/T : Automatic transmission
Caution
DO NOT TOUCH SAS-2. The idle speed adjusting
screw (SAS2) is the preset screw that determines
the relationship
between the throttle
valve and free lever, and has been accurately set at the factory. If this setting is disturbed,
throttle
opener adjustment
and dash pot adjustment
cannot be done
accuratlely.
CARBURETOR
(Clean)
CHOKE MECHANISM
AND LINKAGE
NOOSAEB
The choke mechanism

is used to facilitate engine starting during
cold weather. Inject a solvent into the end of the auto-choke and
the throttle valves (where they pass through the air horn) to prevent the choke from becoming
stuck by gum deposits on the
shaft. At the same time, inject a solvent to clean dirt from the fast
idle cam and link.
ST6 Revision
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LUBRICATION
AND
ramper Prevention
Concealment
plug
lFU34!
MAINTENANCE
Maintenance
Service
o-15
Caution
1. All carburetors
have a tamper-proof
choke. The chokerelated parts are factory adjusted. The choke adjustment
is
required during service, except when major carburetor
service or overhaul choke calibration
related parts adjustments are needed by state or local inspections.
2. All carburetors
also have a tamper-resistant
idle mixture
adjusting
screw. The CO setting has been done as a factory adjustment.
Neither removal of the plug nor adjustment of Uhe mixture screw is required during service unless a major
carburetor
overhaul,
throttle
body
replacement,
or high idle-CO adjustments
are needed by
state or local inspections.
1FUW
FUEL FILTER (Replace)
NOOSAFA
The fuel filter should be replaced regularly because its perfor- ) .

mance is reduced by dirt and water collected over an extendeg,
., ,
period of use. Replace as required.
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FUEL SYSTEM
(Check for leaks)
NC&+
,;
, 1.
TANK, LINES AND CONNEWTONS

1. Check for damage or leakage in the fuel lines and connections.
--.-:
2. Inspect the surface of fuel hoses for heat and mechanical .s. :
it
damage. Hard and brittle rubber, cracking, checking, tears,
cuts, abrasions and excessive swelling indicate deterioration
ii
p.
of the rubber.
3. If the fabric casing of the rubber hose is exposed by cracks and i-:;. .
abrasions in the fuel system, the hoses should be changed.
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VACUUM
HOSES,
SECONDARY
AIR HOSES,
CRANKCASE
VENTILATION
HOSES AND WATER
HOSES (Replace)
Replace them and then make sure that the hoses do not come in
contact with any heat source or moving component which might
cause heat damage or mechanical wear.
[ STB Revision
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,.
O-16
LUBRICATION
AND
MAINTENANCE
- Maintenance
FUEL MOSES, VAPOR

CAP (Replace)
Service
HOSES AND
FUEL FILLER
Service procedures to check the hoses for damage are the same
as those described in the section Vacuum hoses, secondary air
hoses, crankcase ventilation hoses and water hoses.
AIR FILTER (Replace)
NOOSAKC
The air filter will become dirty and loaded with dust during
use, and the filtering
effect will be substantially
reduced.
Replace it with a new one.
I:.,
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REPLACEMENT OF AIR FILTER

1.
2.
3.
Remove the wing nut. Use pliers only if the wing nut is difficult
to remove.
Unsnap the finger clips.
Remove the filter by hand, and replace it with a new filter.
4.
Install the air filter, and then install the cover and housing,
taking care that the arrows are aligned.
5. Tighten the wing nut by hand.
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LUBRICATION
AND
MAINTENANCE
Maintenance
CRANKCASE EMISSION
valve) (Clean)
From rocker cover
o-17
Service
CONTROL
SYSTEM
(PCV
The crankcase ventilation system must be kept clean to maintain

good engine performance.
Periodic servicing is required to remove combustion
products
from the PCV valve.
PCV valve
To intake manifold
Air filter
CV
-.
valve
\
1 i-.-i ._.. ,.../;
Ca;buretor
) M
1 /,I
Rocker
, I I;
,:
1.
Disconnect the ventilation hose from the positive crankcase

ventilation
(PCV) valve. Then, remove PCV valve from the
.li
rocker cover and reconnect it to the ventilation hose.
2. Idle the engine and put a finger to the open end of PCV valve
j-F;;_
to make sure that intake manifold vacuum is felt on the finger,.
..i;ir .e
,. 1 /
$2 :/:,it
(It
NOTE
At this time, the plunger inside the PCV valve moves back&
forth.
3.
If vacuum is not felt on finger, clean the PCV valve and v&-,
tilation hose in cleaning solvent or replace if necessary.
., :
EVAPORATIVE
EMISSION
CONTROL
SYST&l
(Check for leaks and clogging) - except canister&;.
:,
,i::
,,:,r:
:,:i
1. If the fuel-vapor vent line is clogged or damaged, a fuel-vapor
-.i:
mixture escapes into the atmosphere causing excessive emissions. Disconnect the line at both ends, and blow it clean witti:,:, ;:L:
compressed air. Remove the filler cap from the filler pipe and *::+l;i,
.!
check to see if there is evidence that the packing makes improper contact to the filler pipe.
..:T
2. The overfill limiter (2-way valve) installed on the vapor line
:.,.
should be checked for correct operation.
: ._.
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O-18
LUBRlCATlON
MAINTENANCE
AND
Purge
Air filter
control valve
To ther mo
valve
Maintenance
Service
Fuel check varlve

(,Required FMVSS 301)
Overfill limiter
@way valve)
Vapor-liquid
Bowl vent
valve
Canister
Charcoal
uel vapor
-F
---
To carburetor
--I
Purge air
Filter
I----
Fuel tank
Fuel
gauge
unit
03W527
CANISTER
(Replace)
If or when the canister filter becomes clogged, the purge air volume will decrease and consequently,
the canister capacity will be
reduced.
NoQmO
B
SPARK PLUGS (Replace)
1. Spark plugs must fire properly to assure proper engine performance and emission-control.
Therefore,
they should be replaced periodically
with new
ones.
2. The new plugs should be checked
NGK
Spark plug gap :

WZOEP-Ul 0, WZOEPR-UlO
tion
NIPPON
Other
DENS0
r-n
I
_ .
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0.9-I,0
1.0-l
type
ml_
OlR0119
for the proper gap.
mm (.035-.0.39
in.)
.l mm (.039-.043
in.)
LUBRICATION
Correct
AND
MAlNTENANCE
IG NIT1
Incorrect
- Maintenance
o-19
Service
NOOSAPB
CABLES (Replace)
The ignition cables should be replaced periodically with new ones.

After replacing, make sure that the ignition cables and terminals
are properly connected.
NOTE
When disconnecting an ignition cable, be sure to hold cable cap. If
the cable is disconnected by pulling on the cable alone, an open
circuit might result.
lEL160
NOOSARA
EGR VALVE (Replace)
-1
Replace EGR valve to a new one.
t, .
A;
REMOVAL OF EGR VALVE
1. Disconnect the vacuum hoses from the EGR valve.
2. Disconnect the EGR valve from the intake manifold.
3. Replace the EGR valve gasket with a new one.
4. Install the EGR valve onthe intake manifold and tighten to th&
specified torque.
Hexagon
Ele
nUt
Housing
OXYGEN
Spring
SENSOR
The oxygen sensor

the oxygen sensor
well as driveability
periodically with a
(Replace)
is a device which controls the fuel mixture. .$

: is damaged, the exhaust-gas cleaning effect a$
;
deteriorates.
Therefore, it should be replaced
L,.
new one.
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REMOVAL OF OXYGEN SENSOR

1. Cut off the connector of the oxygen sensor.
2. Remove the oxygen sensor from the exhaust manifold.
3. Replace the oxygen sensor on the exhaust manifold
tighten to the specified torque.
Nm
(ft.lbs.)
DISTRIBUTOR
GLE SYSTEM
CAP, ROTOR AND ADVANCED

(Check)
Check the distributor cap, rotor and spark advance

maintain driveability and good exhaust gas.
AN-
system
to
;. !.
.. (
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o-20
LUBRICATION
AND
MAINTIE.NANCE
- Maintenance
Service
INSPECTION
OF DISTRIBUTOR
CAP AND ROTOR
Inspect in accordance with the following procedure. Repair Or replace as necessary.
l
Check the cap for cracks.
l
Check the cap and rotor electrodes
for damage.
Wipe clean the cap and rotor.
INSPECTION
1.
2.
OF CENTRIFUGAL
SPARK
ADVANCE
DEVICE
Start the engine and allow it to idle.

Disconnect the vacuum hoses from the vacuum chambers*.
* : Disconnect the vacuum hoses from both the main and sub
vacuum chambers. (High-altitude areas nationwide, California)
3.
Inspect the advance angle while slowly

speled.
increasing engine
The advance angle should change smoothly

incrieases.
as engine
speed
NOTE
Centrifugal
properties
(Reference)
Symptom
Probable Cause
-Advance angle is too large
Governor
Advance angle changes

suddenly
Spring is broken
Angle too small or hysteresis

is too large
Poor governor weight or cam

operatron
spring
weak
or missing
4I. Whlan any of the above symptoms appear, disassemble and

Distributor
rpm
inspect the distributor.
5EL03t
INSPECTION
OF VACUUM
ADVANCE
DEVICE

2. Disconnect the vacuum hoses from the vacuum chamber*.
Connect a vacuum pump to the niple.
*:
Disconnect
the vacuum hoses from the main vacuum
chambers, (High-altitude
areas nationwide, California)
Slowly apply vacuum with the vacuum pump and inspect the
advance angle.
3.
The advance angle should change smoothly as the vacuum
increases.
OlRO418
Vacuum properties
(Reference)
NOTE
rSymptom
-13(-l
.9)
-27(-3.9)
Pressure
-4O(-5.8)
kPa
-67(-9.7)
-53(-7.7)
(psi)
Probable Cause
Advance angle is too large
Vacuum controller spring is weak

or missing
Advance angle changes

suddenly
Spring is broken
Angle
too small or hysteresis
Poor breaker base operation
is 60
large
Does not advance
1 Diaphragm
5EL031
pm
wision
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is damaged
LUBRICATION
AND MAINTENANCE
O-21
Service
- Maintenance
4. When any of the above symptoms appear, disassemble and

inspect the distributor.
After removing the distributor, inspect each part as described
in GROUP 8 ELECTRICAL-Ignition
System.
INTAKE
(Check)
TEMPERATURE
CONTROL
SYSTEM
?WSATA
Check the vacuum motor of the intake temperature

control sys- ,,,! :*
tern to protect driveability and fuel consumption.
Refer to GROUP 25 EMISSION
CONTROL SYSTEMS-Exhaust
Emission Control System, for the inspection procedure.
SECONDARY
AIR SYSTEM
Refer to GROUP
Emission Control
25 EMISSION
CONTRaL
System, for the inspection
SOLENOlO
Filter
assembly
I
-Filter
opener
(Check)
NWSAUA
SYSTEMS-Exhaust
procedure.
6* j
VALVE AIR FlLTER OF VACUUM CONEM (Replace)

air control
solenoid
valve, throttle::
control
solenoid
valve]
Pull out the filter assembly in the direction

place with a new filter assembly.
CARBURETOR
OR BODY MOUNTING
of the arrow and rej::. :< ::

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NOOSA{;
f.; .
Check carburetor attachment

to inlet manifold and carburetor as-.
sembly. And check body mounting.
Check the looseness of the carburetor installation
bolts and
mounting screws.
:?c: ..;
.
1 STB Revision
.:_
1;
.
: ,;
O-22
LUBRICATION
AND MAINTENANCE
MANUAL
Service
- Maintenance
TRANSMISSION
(Check oil level)
~00s~
Inspect each component for evidence of leakage, and check the oil
level by remaining the filler plug. If the oil is contaminated,
it is
necessan/ to replace it wi,th new oil.
INSPECTION
l
With the vehicle on a level surface, remove the filler plug and
chelck whether or not the oil is at the same level as the bottom
of the threads.
l
Check whether or not the transmission oil is excessively dirty,
and if the viscosity is normal.
Nm (ft.lbs.)
Drain plug
O!moo21
REPLACING
1. Rernove
2. Replace
3. Fill with
the plug
transmission
Manual
TRANSMISSION
OIL
the drain plug and drain the transmission
oil.
the gasket with a new one and tighten the drain plug.
new oil through the filler plug until the oil level reaches
hole.
transmission
oil capacity
: 2.2 liters
(4.7 U.S.
pints.,
3.9 Imperial
pints.)
03FO12
AUTOMATIC
.
HOT upper limit

HOT lower limit
COLD upper limit
COLD lower limit
COLD
HOT
372023
TRANSMISSION
(Check fluid IewlJ-
Check the fluid level by removing the fluid level gauge. If the fluid
is contaminated,
it is necessary to replace it with new fluid.
1. Place the vehicle on a levei surface.
2. Wipe the area around the oil dipstick to remove accumulated
dirt and then pull out the oil dipstick.
3. Set the selector lever to the P (Park) position and apply the
parking brake. Next, start the engine.
4. Check if the engine idle speed and fluid operating temperature
(50-80C;
122-176F)
are normal.
5. Move the selector lever to each position in turn to fill the
torque convertor and hydraulic system with fluid and then
return the selector lever to the N (Neutral) position.
6. Make sure the fluid level is in the HOT
range of the oil
dipstick . If the fluid level is low, add fluid until it reaches the
ItlOT range.
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LUBRICATION
AND MAINTENANCE
Maintenance
Service
O-23
REPLACEMENT
OF AUTOMATIC
TRANSMISSION
FLUID
Drain the fluid and check whether there is any evidence of
contamination.
Replenish with new .fluid after the cause of any contamination
has
been corrected.
1. Place a large flat container beneath the drain plug.
2. Remove the drain plug and drain the fluid.
3. Replace the gasket with a new one and tighten the drain plug.
4.
Pour 5 liters (10.6 U.S. pints., 8.8 Imp.pints.) of DEXRON II

ATF into case through dipstick hole. [Total quantity of ATF
required is approx. 7 liters (14.8 U.S. pints., 12.3 Imp. pints.).
Actually however, approx. 5.5 liters (11.6 U.S. pints., 9.7 Imp.
pints.) of fluid can be replaced because rest of fluid remains in;
.
torque converter.]
5. Check the fluid level.
TRANSFER
CASE (Change
oil)
NOOSBNB
Drain the fluid and check whether there is any evidence of

contamination.
Replenish with new fluid after the cause of any
contamination
has been corrected.
-)C--Filler
..-.
1. With the vehicle on a flat, level surface, drain out the

I
transfer case oil.
2. Replace the packing with a new one, and close the drain;
PM
Pkl
(22-25)
(ft.lbs.1
144003
3. Supply new transfer case oil through the filler plug until it
reaches the same level as the plug hole.
Transfer
case oil total
vision
capacity
I
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: 2.2
liters
(4.7
U.S.
pints, 3.9 Imp. pints)
j .
., ./-
O-24
kUBRlCATlON
AND
MAINTENANCE
COOLING
quired)
SYSTEM
Maintenance
(Check
Service
and
service
as t-eNOOSBEA
Check the cooling system parts, such as radiator, heater, and

oil cooler hoses, thermostat
and connections
for leakage and
damage.
CHECKING
THERMOSTAT
Remove the thermostat,
mostat.)
WJ6616
(Refer to GROUP
7 COOLING-Ther-
Inspection
l
Replace the thermostat
if there is even the slightest
opening
of the valve at room temperature.
l
Replace if the exterior of the thermostat
is noticeably
deformed,
or if it is damaged
or broken.
l
Clean away any corrosion
or sediment
adhered to the
valve.
l
Fill a container with water, and immerse the thermostat
in
it; increase the water temperature
and check whether or
not the thermostats
initial opening temperature
and fully
opened temperature
[valve lift amount when fully opened:
8 mm (.31 in.) or more] are the specified
values.
-.
Standard
value
: Initial
valve-opening
temperature:
88 + 1.5% (190 2 3F)
Fully opened
valve temperature:
100C (212F) or higher
NOTE
The lift amount is calculated
by first measuring
the valve
height when fully closed, and then measuring
the height at
the fully open temperature.
ANTIF:REEZE
The engine cooling system is provided with a mixture of 50%
ethylene
glycol anti-freeze
and 50% water at the time of
manufacture.
Since the cylinder head and water pump body are made of
aluminum
alloy casting, be sure to use a 30 to 60% ethylene
glycol antifreeze coolant to provide corrosion
protection
and
freezing prevention.
Caution
If the concentration
of the antifreeze
is below 30%, the
anticorrosion
property
will be adversely
affected. in addition, if the concentration
is above 60%, both the antifreezing and engine cooling
properties
will decrease,
adversely
affecting the engine. For these reasons, be sure to maintain
the concentration
level within
the specified
range.
MEASUREMENT
OF ANTIFREEZE
CONCENTRATION
Run the engine until coolant is fully mixed. Drain some coolant
(antifreeze), and measure temperature
and specific gravity of
the coolant. Determine
concentration
and safe working temperature. If the coolant is short of antifreeze, add antifreeze up
to a concentration
of 50%.
LSTB Revision
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LUBRICATION
AND MAINTENANCE
- Maintenance
O-25
Service
CHANGING
COOLANT
1. Set the temperature
control lever to the hot position.
2. Remove the radiator cap, radiator drain plug and engine
drain plug to drain the coolant.
Caution
When removing
the radiator
cap, use care to
contact with hot coolant or steam. Place a shop
over the cap and turn the cap counterclockwise
to let pressure
escape through
the vinyl tube.
relieving
the steam pressure, remove the cap by
turning
iP counterclockwise.
avoid
towel
a little
After
slowly
3. Remove the reserve tank and drain the coolant.

.
4. After draining coolant completely,
reinstall the drain plugs
and flush the engine and radiator using a radiator cleaning .I.
fluid.
5. After the flushing
is completed,
completely
drain the
cleaning fluid and install the radiator and engine drain
plugs.
6. By referring to the section on coolant (P.O-xx), select an . ,
appropriate
concentration
for safe operating
temperature
within the range of 30 to 60%. Refill the system with a high,
quality ethylene glycol antifreeze at the selected concen;
tration. A convenient
mixture is a 50% water and 50.O4
antifreeze solution [Freezing point: -36C (-32.8F)]. Rein:, .-._
7. .
stall the radiator cap.
After
running
the
engine
a
while,
check
the
coolant
lev&:
.:
7.
and add coolant
until
the specified
coolant
level is ,.-._
c;. ,Y&
maintained.
8. Add coolant to the reserve tank between the FULL and it?
LOW mark if necessary.
,if., .,7;
_I :
1: ...
Caution
Do not overfill the reserve tank.
i....
FRONT DISC BRAKE PADS (Inspect for wear)
N~fA : .,,._
Check for fluid contamination

pads if defective.
set $f
(!-
and wear. Replace
complete
:.jg
Thickness of lining (A)

Limit : 1.0 mm (44 in.)
14K512
Caution
The pads for the right and left wheels should be replaced at
the same time. Never split or intermix
brake pad sets. All
four pads must be replaced as a complete
set.
REAR DRUM BRAKE LININGS AND REAR WHEEL

CYLINDERS (Inspect for wear and leaks)
NOOSSGC
1.
Remove the brake drum and check the thickness of brake

shoe lining for wear. Check the automatic brake adjusting system by hand to see if it operates smoothly. Also see if the
gears are in proper mesh with each other. To assure smooth
functioning,
apply a very thin coat of grease to the friction
surface of adjuster and link shaft.
Specified
grease
1 STB Revision
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: Brake
:
:
grease
SAE 5310,
NLGI
No.1
1.
[
,
*.L
O-26
RICATION
BNTENANCE
AND
2.
Maintenance
Service
Inspect the wheel cylinder boots for evidence of a brake fluid

leak. Visually check the boots for cuts, tears or heat cracks. (A
slight amount of fluid on the boot may not be a leak, but may
be preservative fluid used at assembly.)
(1) Checking
the Brake Shoes for Wear.
Thickness of lining (B)

Limit : 4.0 mm (.04 in.)
14KO24
BR
i HOSES (Check for deterioration
or lea\dm
Inspection of brake hoses and tubing should be included in all

brake service operations.
The hoses should be checked for:
1. Correct length, severe surface cracking, pulling, scuffing or
worn spots. (If the fabric casing of the hoses is exposed by
cracks or abrasion in the rubber hose cover, the hoses should
be replaced. Eventual deterioration
of hose may occur with
possible bursting failure.)
2. Faulty installation, casing twisting or interference with wheel,
tire or chassis.
a..
, -4. .
..
7
BRAKE FLUID (Replace)
NOOSBIB
1. Cheek the brake system for leakage before replacing brake

fluid. Completely drain the brake fluid with the bleeder screws
loosened on each brake and refill the brake system with new
brake fluid.
Specified
brake fluid
: DOT3
2. The reservoir cap must be fully tightened to avoid contamination from foreign matter or moisture.
DO NOT ALLOW PETROLEUM
BASE FLUID TO CONTAMINATE
THE BRAKE FLUID-SEAL
DAMAGE WILL RESULTCaution
Take care in handling
brake fluid as it is harmful
and may also cause damage to painted s&aces.
to the eyes
;L
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BALL JOINT, STEERING

LINKAGE
SEALS
DRIVE SHAFT BOOTS, (Inspect for grease
and dlamage)
c--
NOOSBJA
1. These components,
which are permanently
lubricated at the
factory, do not require periodic lubrication. Damaged seals and
boots should be replaced to prevent leakage or contamination
of the grease.
2. Inspect the dust cover and boots for proper sealing, leakage
and damage. Replace them if defective.
oow949
AND
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LUBRICATION
AND
MAINTENANCE
- Maintenance
BALL JOONTS WITH

grease)
O-27
Service
IPPLE
GREASE
(Lubricate
NOOSBOB
Fill the specified grease at the grease nipple till the grease come
out of the dust seal of the pitman arm, tie rod, lower control arm
and upper control arm.
Specified
grease
: Multipurpose
No. 2
FRONT WHEEL BEARINGS

Inspect
back of
inspect
bearing
Specified
grease
SAE J310,
(Lubricate
grease)
NLGI
NOOSBKo,.I
for evidence of grease leakage around the hub cap and the
the hub. If there is leakage of grease, remove the hub and
its oil seal for damage. Clean the grease off the hub and
and repack with specified new grease.
grease
: Multipurpose
grease
SAE 5310,
NLGI
I
(
I
&
-+
:..Q/, .(I
-.%
.d
No. 2
-1
% ; , ;;z
i .,.
: y,+.5
NOTE
Refer to GROUP 2 FRONT SUSPENSION-Axle
Hub and Fre$ . .a:
(
_,_
wheeling Hub, for the removal procedures of the front hub.
I
is.
FRONT AXLE AND REAR AXLE (CONVENTIONAl+:

i t;::
*;,.
NWSBp~;:; L
DIFFERENTIAL)(lnspect
oil level)
,
Remove the filler plug and inspect the oil level at bottom of filler,,:, 8.
hole. If the oil level is slightly below the filler hole, it is in satisfac-r.,., i-i:
i,-:.y
;cI
tory condition.
:1
r
1 ST6 Revision
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O-28
LUBRICATION
AND
MAINTENANCE
- Maintenance
REAR AXLE
(Change)
OIL
(LIMITED-SLIP
Before changing the rear axle oil,

no oil leakage from the rear axle
Remove the drain plug and drain
Put the oil plug back in place, and
filler hole.
: 1.8 liter
Oil capalcity
PROPELLER
Service
SHAFT
DIFFERENTIAL)
NooSBaA
check to make sure that there is

housing.
out of the oil.
then pour new oil in through the
(3.2 U.S.pints.,
JOINTS
2.6 Imp.pints.)
(Lubricate
Lubricate grease to the propeller shaft joints.

The propeller shaft joints should be repacked
grease.
Specified
grease
EXHAlJST
MUFFLER
COVERS)
: Multipurpose
No. 2
grease
with
grease)
NOOSBRB
specified
SAE 5310, NLGI
SYSTEM (CONNECTION
PORTION OF
AND PIPINGS AND KEEPING WARMTH
(Check and service as required)
NOOSBLA
1. Check for holes and gas leaks due to damage, corrosion, etc.
2. Check the joints and connections for looseness and gas leaks.
3. Check the hanger rubber and brackets for damage.
rSTB
Revision
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9-l
N09AA--
CONTENTS
CRANKSHAFT,
FLYWHEEL AND DRIVE
PLATE
.................................................................
60
CYLINDER
BLOCK
.............................................
64
CYLINDER
HEAD
................................................
39
CYLINDER
HEAD GASKET
................................
ENGINE
AND TRANSMISSION
ENGINE
MOUNTING
FRONT
SHAFT
ASSEMBLY
17
.... 23
.........................................
CASE, OIL PUMP AND SILENT

.................................................................
50
.................................
GENERAL INFORMATION
Sectional View .................................................
JET VALVE ASSEMBLY
....................................
OIL PAN AND OIL SCREEN
...............................
PISTON
ROD
ROCKE
AND CONNECTING
ARM AND SHAFT
ASSEMBLY
....................
.............
ROCKER ARMS, ROCKER ARM SHAFT AND

........................................................
CAMSHAFT
..........
PROCEDURES
.......................
Adjustment
of Valve Clearance
Checking Engine Oil ........................................
SERVICE
ADJUSTMENT
20
2
3
48
16
54
36
33
12
13
12
. . . . . . . . . .. . . . . . . .. 14
Checking Compression
Pressure
Replacement
of Engine Oil .,.._.,......................
12
Replacement
of Engine Oil Filter .. . . . . . . . . .. . . . . . . .. 12
t .i
.,
I
Retorquing
of Cylinder Head Bold . . . . .. .. . . . . . . .. . . 13
Silent Shaft Drive Chain
.. .. . . . . . . . . .. . . . . . . . . 14
Tension Adjustment
Procedure
SPECIAL
..,..................s...............m..........
TOOLS
10
4
...............................................
SPECIFICATIONS
....................................
General Specifications
Service Specifications
.....................................
Torque Specifications
.....................................
Sealants and Adhesives
..................................
4
4
9
10
TIMING
28
CHAIN
TRAIN
TROUBLESHOOTING
Excessive Engine
. . . . .. . . . . ..*...............*..........
. . . .. . . . . . . . . . . . .. . . . . . . . . ...*..........
Rolling and Vibration
Compression
Too Low
Connecting
Rod Noise/Main
Noisy Valves
Oil Pressure Drop
Oil Pressure Too High
Timing Chain Noise
VALVE AND VA!,VE
http://vnx.su/
SPRINGS
Bearing
11
Noise
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. . . . . . . . .. . . . . . . . . .. . . . . . . ,42:,
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9-2
ENGINE-General
Information
GENERAL INFORMATION
T
:
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3
,jI
I,
NO9BACB
The 2.6L (157 cuin.) displacement

engine is a four cylinder overhead camshaft power plant with a cast iron cylinder
block, an aluminum cylinder head and a silent shaft system.
The forged steel crankshaft
is supported
by five main bearings.
The cylinder block is a Siamese type water jacket which ensures high cooling efficiency and uniform cooling of the
cylinders.
Two counterbalance
shafts (silent shafts) are incorporated in the cylinder block to reduce engine noise and vibration.
The pistons are made of aluminum alloy casting.
The piston pin is floating in the piston and pressed-in to the forged steel connecting rod. The piston pin is offset
from the piston center toward the thrust side.
The oil pump is a gear type pump and also drives the right (front) silent shaft. The oil pump and left (rear) silent shaft
are chain driven through sprockets by crankshaft.
The silent shaft system cancels the vertical vibration force of the engine and secondary vibrating forces such as the
vibrating moment in the volling direction. The silent shafts are located in the upper left (rearward side) and lower
right (forward side) of the cylinder block. The left shaft rotates in the same direction as the crankshaft while the right
shaft rotates in the opposite direction at twice crankshaft speed. Each silent shaft is supported by two aluminum
bearings.
The cylinder head is an aluminum
alloy casting with compact type combustion
chambers. The intake and exhaust
valves are made of heat resistant steel and arranged in a V with the camshaft on center. The jet valve assembly
consisting of the jet valve, jet body, stem seal, spring, retainer and retainer lock, is screwed into the cylinder head.
The cast iron camshaft is supported by five bearing journals and is driven by the crankshaft sprocket and camshaft
sprocket by the timing belt. The distributor drive gear is mounted on the front of the camshaft. The camshaft drive
belt is a cogged type belt. To provide the belt with the proper tension and ensure quiet operation at all times,
tensioner is installed on the slack side.
Two rocker arms are used with one actuating the exhaust valves and the other the intake valves and jet valves. The
rocker arm is a die cast aluminum
alloy part with carbide alloy slipper and auto-lash adjuster and does not require
adjustment
of intake and exhaust valve clearance. The oil pump is a internal/external
involute gear type pump and
is driven by crankshaft. The oil filter, a paper filter element cartridge type, is mounted on the front facing side of the
engine.
./ ST6 Revision
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9-3
IJOBBACB
5ENl44
5EN145
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t
9-4
SPECOFIC4TIONS
GENERAL
SPECIFICATIONS
NO9CA-B
Specifications
Items
In-line OHC
Type
Number of cylinders
Bore mm (in.)
4
91 .I (3.5866)
Stroke
98 (3.8583)
mm (in.)
Piston djsplacement
Compression
2555 (155.9)
cc (cu.in.)
7.0
ratio
Firing order
1-3-4-2
Valve timing
Intake valve.
Opens (BTDC)
25
Closes (ABDC)
59
Exhaust valve
Opens (BBDC)
64
Closes (ATDC)
20
Jet valve
Opens (BTDC)
Closes (ABDC)
25
59
Valve overlap
45
Intake valve duration
264
Exhaust valve duration
264
Jet valve duration
264
:SERVlCE
SPECIFICATIONS
NOSCB-
Specifications
Items
andard value
Cylinder head
Overall height
Flatness
mm (in.)
of gasket
of manifold
Oversize
rework
Intake
Exhaust
Oversize
exhaust)
mm (in.)
surface
Flatness
mounting
dimension
90.0 (3.5433)
surface
Max. 0.05 (0.020)

mm (in.)
of valve seat hole
Max. 0.15 (.0059)
mm (in.)
0.3 mm (.012 in) OS.
47.300-47.325
(1.8622-1.8632)
0.6 mm (.024 in) O.S.
47.600-47.625
(1.8740-I
,0.3 mm (.012 in) O.S.
40.300-40.325
(1.5866-1.5876)
s.O.6 mm (.024 in) O.S.
40.600-40.625
(1.5984-1.5994)
rework of valve guide,h&le

mm (in.)
,,
0.25 mm (.OlO in) 0.S:
0.50 mm (.020 in) O.S.
13.050-13.068(.5138-.5145)
I,
13.250-I
13.500-I
3.268 (.5217-.5224)
3.518 (.5315-.5422)
Timing chain
102
No. of links
mm (in.)Pitch
..
.8750)
(both intake and
0.05 mm (.002 in) O.S.

..
;I.
9.5 (.3740)
1 STB Revision
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ENGINE
9-5
- Specifications
Specifications
Items
I
Timing chain B for silentshaft
drive
90
No. of links
Pitch
mm (in.)
Clearance between
mm (in.)
chain and chain guide
4;,
8.0 (.3150)
0.2-0.8 (.0079-.0315)
Camshaft
Cam height
mm (in.)
Intake
42.4 (1.6693)
Exhaust
42.4 (1.6693)
37 (1.4567)
mm (in.)
Fuel pump drive cam 0.0.
mm (in.)
Journal diameter
34 (1.3386)
Oil clearance
0.03-0.05
mm (in.)
End play
(.0012-.0020)
.P.
_.i
,t,
0.1-0.2 (.004-,008)
mm (in.)
Rocker arm
I.D.
mm (in.)
18.9 (.7441)
Clearance (Rocker
0.01-0.04
mm (in.)
arm-to-shaft)
(.0004-.0016)
Rocker arm shaft

O.D.
18.9 (.7441)
mm (in.)
Valve
Valve length
mm (in.)
Intake
107.96 (4.2504)
Exhaust
105.86 (4.1677)
Stem 0.D
Intake
mm (in.)
8.0 (.3150)
8.0 (.3150)
Exhaust
4545.30
Face angle
Thickness
of valve head (Margin)
Intake
1.2 (.047)
Exhaust
2.0 (.079)
Valve stem to valve guide clearance
mm (in.)
mm (in.)
Intake
0.03-0.06
(.0012-.0024)
Exhaust
0.05-0.09
(.0020-.0035)
Valve guide
Length
..
mm (in.)
Intake
47 (1.8504)
Exhaust
52 (2.0474)
0.05 (.0020) 0.25 (.OlO) 0.50 (.020)
Oversize
mm (in.)
Valve seat insert

Width of seat contact
Seat angle
Oversize
rework
Intake
Exhaust
_=
c.
I).
0.7-I .2 (.0276-.0472)
mm (in.)
45
of valve seat insert height
mm (in.)
0.3 mm (.012 in)
7.9-8.1 (.31 IO-.3189)
0.6 mm (.024 in)
8.2-8.4 (.3228-.3307)
0.3 mm (.012 in)

0.6 mm (.024 in)
7.9-8.1 (.31 IO-.3189)

8.2-8.4 (.3228-.3307)
I.
,
1:
._
1 STB Revision
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9-6
ENGINE
-Specifications
Specifications
Items
Valve spring
Free length
Load
49.8 (1.961)
mm (in.)
N (Ibs.)
at installed height
322.6 (72.5)
Installed height
Out of square
mm (in.)
40.4:1.591)
2
Jet valve
Length
mm (in.)
Stem O.D.
91.58 (3.6055)
mm (in.)
4.3 (.1693)
45
Seat angle
Valve clearance-Hot
engine
Valve clearance-Cold
mm (in)
engine (reference)
0.25 (.OlO)
mm (in)
6.17 (.007)
Jet valve spring

mm (in.)
Free length
N (Ibs.)
Load
29.6(1.1654)
Installed height
21.5 (.846)
Max 1.5
34.3 (7.7)
mm (in.)
Out of squareness
at Installed height
Cylinder block
Cylinder bore
Out-of-roundness
Over height
Flatness
91 .l (3.5866)
mm (in.)
and taper of cylinder bore
mm (in.)
316 (12.4409)
mm (in.)
of gasket
Max. 0.02 (.0008)
surface
Max 0.05 (.0020)
mm (in.)
Right silent shaft

Front journal diameter
?.
mm (in.)
Rear journal diameter

Oil clearance
21 (.8268)
43 (1.6929)
mm (in.)
mm (in.)
0.1 o-o. 13 (.0039-.0053)
.,.. g @ear
Left silent shaft
Front journal diameter
mm (in.)
Rear journal diameter
mm (in.)
Oil clearance
23 (9055)
43 (1.6929)
mm (in.)
Front
0.02-0.06
(.0008-.0024)
Rear
0.10-0.13
(.0039-.0053)
Piston
O.D.
mm (in.)
Ring groove width
91 .l (3.5866)
0.02-0.04(.0008?+0016)
mm (in.)
Clearance (Piston-to-cylinder)
mm (in.)
No. 1 and No. 2
1.5 (.591)
Oil
4.0(.1575)
Compression
Pressure
pressure
difference
Oversize
kPa (psi)
between
cylinders
Max. 100 (14)

0.25(.010)0.50(.020)0.75(.030)1.00(.039)
mm (in.)
Piston ring
Side clearance
mm (in.)
0.05-0.09
0.02-0.06
No. 1
No. 2
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.,-;
_-I
.9
1200(170)960(136)
kPa (psi)
k?,
_I
(.0020-.0035)
(.0008-.0024)
9-7
ENGINE-Specifications
Specifications
Items
End gap
mm (in.)
0.30-0.45
(.0112-.0177)
No. 2
0.25-0.40
(.0098-.0158)
Oil ring side rail
0.30-0.80
(.0118,.031
No. 1
Oversize
mm (in.)
Connecting
!j)..
0.25(.010)0.50(.020)~.75(.030)1.00(.039)
rod
Bend
mm (in.)
0.05(.0020)
or less per 100 (3.937)
Twist
mm (in.)
0.10 (.0039)
or less per 100 (3.937)
Connecting
Piston
rod big end side clearance
pin press-in
Connecting
load
0.1-0.25
mm (in.)
7350-I
N(1b.s.)
(.0039-.0098)
7 150 (1650-3860)
rod oil clearance
Oil clearance
Under
size
Crankshaft
0.02-0.05
mm (in.)
mm (in.)
(.0008-.0020)
0.25 (.OlO) 0.50 (.020) 0.75 (.030)
main bearing
Oil clearance
Under
mm (in.)
0.02-0.05
mm (in.)
size
(.0008-.0020)
0.25 (.Ol 0) 0.50 (.020) 0.75 (.030)
Crankshaft
Pin O.D.
53 (2.0866)
mm (in.)
Journal
O.D.
End play
60 (2.3622)
mm (in.)
Out-of-roundness
and taper
of journal
mm (in.)
and pin
0.05-0.18
mm (in.)
Undersize
rework
Max. 0.01 (.0004)
dimension
(.0020-.0071)
mm (in.)
of pin
0.25 mm (.OlO in.) U.S.
52.735-52.750
(2.0762-2.0763)
0.50 mm (.020 in.) U.S.
52.485-52.500
(2.0663-2.0669)
0.75 mm (.030 in.) U.S.
52.235-52.250
(2.0565-2.0571)
0.25 mm (.OlO in.) U.S.
59.735-59.750
(2.3518-2.3524)
0.50 mm (.020 in.) U.S.
59.485-59.500
(2.3419-2.3425)
0.75 mm (.030 in.) U.S.
59.235-52.250
(2.3321-2.3327)
Undersize
rework
Oil pressure
temperature
dimension
of journal
at curb idle speed [Conditions:

is 75 to 90C (167 to 194F)]
mm (in.)
Min. 80 (11.4)
Oil
kPa (psi)
Oil pump
Driven
gear
-,
Tip clearance
0.1 l-0.15
mm (in.)
Side clearance
mm (in.)
0.04-O.
(.0043-.0059)
10 (.0016-.0039)
Drive gear
Tip clearance
Side clearance
Load
0.05-O.
mm (in.)
Free height
Relief spring
0.1 I-0.15(.0043-.00;9)
mm (in.)
11 (.0020-.0043)
46.4 (1.8346)
mm (in.)
60(13.4)at40.1
N (Ibs.)
mm (1.5787
in.)
Limit
Cylinder
head
Overall
* Must
height
Flatness
of gasket
Flatness
of manifold
be -0.2
* - 0.2 * ( - .0079)
mm (in.)
surface
mounting
.<
0.2 (.0079)
mm (in.)
mm (in.)
mm (- .0079 in.) or less (combined
with
0.3 (.0118)
_
the amount ot gnndlng
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IL
_
ot the cylinder
.,;- s
.
.
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.
,
.
blOCkS$asket
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9-8
ENGINE
- Specifications
Items
Camshaft .
Cam height
Specifications
mm (in.)
;
Intake
Exhaust
End play
41.9 (1.6496)
41.9 (1.6496)
,-
mm (in,)
0.4(.016)
Valve
Thickness
of valve head (Margin)
mm (in.)
Intake
0.7 (.028)
Exhaust
Valve stem to valve guide clearance
Intake
1.5 (.059)
mm (in.)
0.1 (.0039)
Exhaust
0.15 (.0059)
Valve spring
Free length
Installed
mm (in.)
height
48.8 (1.922)
mm (in.)
41.40 (1.6299)
Out of squareness
Cylinder block
Over height
Flatness
mm (in.1
of gasket surface
* - 0.2 ( - .0079)
,,,.,
is.$
-mm (in.)
0.1 (.0039)
Piston
pressure
kPa (psi)
i &&mpression
.: L.2,. F,&
~j?i&of@ing
..,;.
Side clearance
mm (in.)
-.:
., ..,.
:?
0.12 (.005)
No. 1
No. 2
0.1 (.004)
sEnd gap
..
:.*
960 (136)
mm (in.)
No. 1
0.8 (.031)
No. 2
Oil ring side rail
0.8 (.031)
1.o (.039)
Connecting
rod
,_ Connecting
.. Connecting rod oil clearance

.Qil clearance
mm (in.)
Crankshaft
main bearing
Crankshaft
End play
mm (in.)
mm (in.)
*:
0.4 (.016)
0.1 (.004)
0.1 (.004)
0.4 (.016)
Fly wheel
:Runout
.:,.Oil&~p
mm (in.)
0.13 (.0051)
Driven gear
Tip clearance
Side clearance
mm (in.)
mm (in.)
0.2 (.0079)
0.15 (.0006)
Drive gear
Tip clearance
mm (in.)
0.2 (.0079)
Side clearance ,, mm (in.)
0.15 (.0006)
>-,;..;.
,-i :._
* Must be -0.2 mn-$&0039 . in.) or less,(combined
with the amount of grinding of the cylrnder heads gasket surface.) -
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i
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TORQUE SPECIFICATIONS
Items
Cylinder head bolts-Cold
Cylinder head bolts-Hot
&f+JJ
engine
engine
100-110
<;;
&
7-3-79
Cylinder head bolts (M8 bolt)
15-22
11-15
Camshaft
bearing cap bolts
19-21
14-15
Camshaft
sprocket
50-60
bolts
Rocker cover bolts
5-7
3743
,g+>~
Jet valve assembly
18-22
g[+$3;15
Rocker arm adjusting nuts for jet valve

Main bearing cap bolts
8-10
75-85
55-61
Connecting
45-48
33-34
rod cap nuts
.9-13
Dumper pulley bolts
110-130
80-94
Oil pump driven gear bolt
60-70
44-50
60-70
44-50
4-6
4-5
130-I 40
94-l 01
130-I 40
94-l 01
50-60
37-43
8-10
6-7
Silent shaft sprocket
bolt
Silent shaft chamber
cover bolts
Flywheel
bolts
Drive plate bolts

Engine support
brackets
bolts
Chain guideB
bolt (Upper)
Chain guide B bolt (Lower)
15-22
II,15
Oil pump cover bolt
10-12
7.5-8.5
IO-12
IO-12
7.5-8.5
Thrust platebolt
IO-12
7.5-8.5
Oil pan bolt
6-8
4.5-5.5
Oil pan drain plug
35-45
26-32
Oil screen bolt
15-22
Oil relief valve plug

Oil pressure switch
30-45
Oil pump body bolt

Oil pump assembly
mounting
Air filter mounting
bolt
8-12
nut
16-19
Exhaust manifold to front exhaust

Engine mounting
pipe
front insulator to body
Engine to engine mounting

No. 2 crossmember
front insulator
to body
Plate to body
Plate to transfer mounting insulator
Transfer mounting insulator to transfer
Transfer mounting
No. 2 crossmember
mounting
bracket to transfer
to engine mounting
bracket
rear insulator
Engine mounting rear insulator to engine

Engine support rear bracket to engine
Engine mounting
rear insulator to engine support
Rear engine support

3ear engine sijpport
7.5-8.5
20-30
30-40
13-20
22-29
9-15
55-75
40-54
18-25
13-18
18-25
13-18
30-42
22-29
18-25
13-18
18-25
..
18-25
rear bracket
member to No. 2 crossmember

member to engine mounting rear insulator
qadiator ,mour;lting bolts
8-11:
shroud r$unting
3-7
bolts
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13-18
13-18
18-25
18-25
18-25
30-42
,&
i.;,
13-18
,I_;1,3-1 8 +:I
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ENGINE -Specifications
/ Special Tools
Nm
ft.lbs.
16-24
12-17
C&$ol~lWer
assembly to transfer
Cross shaft bracket to body
15-22
11-16
IO-13
7-9
Clutch release cylinder to transmission

Rear propeller shaft to rear differential
31-42
22-29
50-60
36-43
Front propeller shaft to front differential
50-60
36-43
20-25
15-18
30-35
22-25
Items
. . . ..(?i
..-.c,
f :,.
i?d$e.r steering pressure
hose to oil pump
Air-conditioner
compressor
to discharge
Air-conditioner
compressor
to suction
XSEALANTS
hose
hose
AND ADHESIVES
Items
. -,:<
S: Semi-circular packing
Cylinder block lower surface
Oil pressure
Specified
(4 places)
switch
Quantity
sealants and adhesives
3M ART Part No. 8660 or equivalent
As required
As required
As required
-A
,,
SPECIAL TOOLS
Tool (Number
and name)
;MD998377-01
:kstaller, valve stem seal
NOODA-C
Use
Tool (Number
and name)
Installing valve stem

seals
MD998250-01
Installer, silent shaft bearing
(For rear bearing)
[Used with MB990938-011
Use
Press-fitting
bearing
&silent
:
St
.[7@
-:
,.
.
4,
.J:;
7.
MD998309
Prier, jet valve ipriiii
Assembling
disassembly
assembly
and
of jet valve
.
MD998443-01
Holder, auto-lash adjuster
MD9981 84-01
Setting tool, piston pin
Removal and installation of MIT304204,

piston pin
Remover, silent shaft front
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Auto-lash adjuster holdil
Removal of silent shaft

bearing
ENGINE-Special
Tools /Troubleshooting
I
Use
Tool (Number and narne$~$.i
vlD998308-01
nstaller, jet valve stem seal
Installation of jet valve stem

seal
MD998376-01
Installer. crankshaft
seal
[Used with
vlD998310
Nrench, jet valve
Removal and installation of

jet valve assembly
M B990938-01
Installer, right silent shaft
front bearing
AD998251-01
uller, silent shaft bearing
For rear bearing)
Used with MIT3042041
Removal of silent shaft

bearing .+
roof (Number
and name)
Installation of silent shaft

bearing
TROUBLESHOOTING
L
Probable cause
Co,m@ession
33
.
too low
Reference
page
Replace gasket
9-39
Replace rings
9-56
. 5,
Qlinder head gasket blo,pn

:.
Piston ring worn or damage
Remedy
c;u ,
., __
!;
Oil pressure
.f
Piston or cylinder worn
Repair or replace piston and/or cylin-,

der block
Valve seat worn or damage
Repair or replace valve and/or seat

_t
ring
:
:i!
Check engine.oil level $<1:..
_: j; . ,
Replace oil pr+&$$&jtch
drop
Engine oil level too low
I
*,
*1,
j j
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I. .;r,
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Oil pressure
switch-faulty
Oil filter clogged
_.
Oil pump gears or body worn

) Thin or diluted engine oil
/ Change engine oil to correct viscosity
/ Oil relief valve stuck (opened)
,I
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,; .
,z
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Repair relief valve
_:
.
. i,
Install new frlteriL;?: -\

: J, .!:: ~
Replace gears and& body
Excessive
bearing clearance
.,
Replace bearings
9-54
/ 9-65
_
9-12
9-64
9-50
-.9,5p
1 g-50
.i!
9-50!i
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,._
,*,:;A
*. <*y .. :+.
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.-.
.:?$2&
_
i
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:
ENGINE-Troubleshooting/Service
.
Adjustment Procedures 1
,/:
Probable cause
Remedy
Reference
pabe
.,, I
.L
Oil pressure
too high
Noisy valves
Oil relief valve stuck (closed)
Repair relief valve
g-50
Incorrect
Replace auto-lash adjuster
,9-33.
auto-lash adjuster
..\
/I
Thin or diluted engine oil (low oil pressure)
\
Change engine oil
Valve stem or valve guide worn

damaae
Replace valve and/or guide
g& I
Check engine oil level
9-12
or
Connecting rod noise/

main bearing noise
., ?s..
ia9-1.i, :
_
,I
*
Refer to Oil pressure
drop
9-l 1
Thin or diluted engine oil
Change engine oil
g-12 ;:.
Excessive
Replace bearings
9-54.
bearing clearance
.Timing chain noise
Incorrect
Excessive engine rolling

and vibration
;:
Loose No. 2 member
Adjust chain tension .
chain tension
I
<;.,
..
Retighten
SERVICE ADJUSTMENT
.CHECKING
ENGINE
Replace
Broken mour;\t insulator
9-28
OIL
9-20,2-l
g-20,21
PROCEDURES
NOSFAAAI
.,
(1) Check to ensure that the engine oil level is$yi$in

the level
range indicated on the oil level gauge.
(2) Check to ensure that the oil is not noticeably dirty or mixed
with coolant or gasoline, an.d that it has the proper viscosity.
REPLACEMENT
OF ENGINE
Refer
to GROUP
0
Maintenance
Service.
REPLACEMENT
OF ENGINE
Refer
to GROUP
0
Miintenance
Service.
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LUBRICATION
LUBRICATION
OIL.
AND
NO9FBAAl
MAINTENANCf$
OIL FILTER
AND
MWlpAl
MAINTENANCEii
RETORQUING
OF CYLINDER
HEAD BOLTS
NOSFDAD
,.(J-). Using torque wrench, first slightly loosen cylinder

..
and then tighten to specified torque.
T/ghtening
tkque
Cylinder huad
Cold engine
Hot engine
Cylindsr head
Cold engine
Hot engine
. s.
head bolts
, *I
bolt (No. 1 to 10)
: 90-100 Nm (65-72 ftlbs.)
: 100-110
Nm (73-79 ftlbs.)
bolt (No. 11)
..
: 15-22 Nm (11-15 ft.lbs.)
: 15-22 (11-15 ftlbs.)
5ENO65
(2) Be sure to follow the specific torquing

e
Timing
chain
sequence.
:s:
;; ,
side
NOTE
Run engine u,ntil normal operating temperature
is reach&
c
allow it to cool down, and then retorque bolts to specification
i
for best results.
..I
.>, ;
t
a*,.
-i
h
5EN016
-;
ADJUSTMENT
OF VALVE CLEARANCE
,Y.( -1
CHECKING
INTAKE AND EXHAUST
VALVES
As the intake and exhaust valves are equipped wifh~fa&lash
._.adjustment mechanisms,
there is no need for valve,clearance. a$~.-~$
justment. The proper functioning of the auto-lash mecha$m
may>~z,,.,$
be determined
by checking for tappet noise. When there IS tappet,:;
4:
noise or any unusual noise, check the the auto-lash.by removing it.
,,
I
,;i
CHECKING
AND ADJUSTING
JET VALVE CLEATLANCE &FJAC.

(1) Idle the engine until radiator coolant reaches 80L90C ...l,-!i!
: ::*;
(176-194Fj:.
(2) Remove all ttie spark plugs$rom
the cylinder head.
,l(3) Remove the rocker co$r... :.
. ..,
i.>
t:
.-.
,( .
r
..:
(-J
Standard
No!1 rd.2
Intake valve side
(4) Rotate the crankshaft clockwise until the, No. 1 cvlinder is at

.
compression TDC.
(5) Measure jet valve clearance at the positions indicated by arrows in the illustration.
Timing chain side
5EN213
value
: 0.25 mm.(.OlO
/.
Caution
As jet valve springtension
the jet valve in.
http://vnx.su/
in.) when
.I
warm.
I< -
is low, be careful not to push
,. [
.
;::
9-14
ENGINE-Service
Adjustment Procedures
(6) When out of specification, loosen the lock nut and adjust clearance with a feeler gauge while turning the adjusting screw.
(7) Holding the adjusting screw with a screwdriver so that it wont
turn, tighten the lock nut to the specified torque.
(8) Turn the crankshaft 360 until the No. 4 cylinder is at compression top dead center.
(9) Measure jet valve clearance where indicated by arrows in the
illustration.
Timing chain side
Standard
value
: 0.25 mm (.OlO in.) when
(lO)When out of specification, adjust according

given in (6) and (7) above.
No.4
Nb.3
warm
to the procedures
5EN214
SILENT SHAFT DRIVE CHAIN

MENT PROCEDURE
TENSION
ADJUSTNOSFIAA
When a loose silent shaft drive chain is suspected as the probable

cause of abnormal noise, the tension must be readjusted. Tension
of silent shaft drive chain can be adjusted without removing timing
chain cover as follows:
1. Remove cover from access hole provided at center of chain
case (under water pump).
\
5EN072
2.
3.
Loosen special bolt B.

Using your finger push projection on chain guide 6 in direction of arrow. Do not push projection with a screwdriver or
other tool. Improperly chain tension will cause abnormal noise.
4. Tighten special bolt B.
5. Install cover. Do not reuse damaged gasket.
Chain guide B
/
Cover bolt tightening
torque
:, lo-11
Nm (7.5-8.5
ft. Ibs.)
Projection
5ENOO7
CHECKING
COMPRESSION
PRESSURE
NOSFFM
(1) Before checking compression,

ensure that engine oil, the
starter motor, and battery are all in normal operating condition.
(2) Start the engine and wait until engine coolant temperature
has
risen to 80-90C
(176- 194F).
(3) Stop the engine and pull the spark plug cables.
(4) Remove the spark plugs.
(5) Crank the engine to remove any foreign objects in the
cylinders.
/ ST6 Revision
-i
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----r
ENGINE-Service
Adjustment
Procedures
9-15
Caution
Cover the spark plug holes with waste cloth, etc., in order
to keep expelled foreign objects from flying out, and keep
away from the holes. When measuring
compression
with
water, oil, or fuel having entered the cylinder through
a
crack, etc., these will come flying out of the spark plug
hole hot and fast, so to sure to take the proper precautions.
(6) Set the compression gauge to the spark plug hole.
(7) Holding the throttle valve full open, crank the engine and measure compression.
1 .?:
FI ; _
..rl
Standard value : 1200 kPa (170 psi) [250400]
rl
Limit
: 960 kPa (136 psi) [250-400
rpm]
$
(8) Perform (6)and(?) above for all the cylinders, ensuring $hat compression for each of the cylinders is within the spec#ed
,
limit.
r t;,1
Limit : Max 100 kPa (14 psi)
(9) If a cylinders compression
or pressure differential exceeds.-:i
the limit, add a small amount of oil through the spark plug
..;. holeand repeat steps (6) to (8).
1 If the addition of oil brings compression
up, it is possible
that there is harmful friction between the piston ring and..
_ .
cylinder wall.
;:.;,.
i ? .
..
@ If not compression up, valve seizure, poor valve seating, or
a compression
leak from the gasket are all possible..
,i.
.
!(
,:
(
*
$1
?
[ STB Revision
http://vnx.su/
9-16
,I
ENGINE
- On-vehicle
Service
ON-VEHICLE SERVICE
OIL PAN AND SCREEN
3EMOVAL
AND INSTALLATION
NOSHA-
Post-installation
Operation
Installation of the Undercover
and
the Under Skid Plate (Refer to
GROUP 23 BODY - Under Cover.)
l
Supplying of Engine Oil (Refer to
GROUP 0 LUBRICATION
AND
MAINTENANCE
- Meintenance
Service)
Pre-removal
Operation
l
Removal of the Undercover and the
Under Skid Plate (Refer to GROUP
23 BODY - Under Cover)
l
Draining of the Engine Oil (Refer to
GROUP 0, LUBRICATION
AND
MAINTENANCE
- Meintenance
Service.)
Removal
~~
steps
I.
2.
3.
4.
5.
6.
Drain plug
Drain plug gasket
Oil pan
Oil pan gasket
Oil screen
Oil screen
gasket
35-45
25-32
NOTE
(2) l + : Refer to Service Points
parts
(3) q : Non-reusable
Nm
ft.lbs
2
5-8 hm
4.5-5.5 ftlbs
to reinstall.
of Installation.
01 BOO49
INSPECTION
Check the oil pan for cracks.

Check the oil pan fitting surface for damage and deformation.
Check the oil screen for cracked, clogged or damaged wire
net and pipe.
l
l
l
Timins chain case k$ter

I
I
I
Oil seal case

I
NOOHCAB
SERVICE
4.
POINTS
INSTALLATION
OF INSTALLATION
OF OIL PAN
NOSHDAI
GASKET
Apply a coating of the specified sealant (where shown in

the figure) to the lower surface (the surface where the oil
pan is installed)
of the cylinder block.
Specified
sealant
DEN048
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ENGINE
CYLINDER
IEMOVAL
- On-vehicle
9-17
Service
HEAD GASKET
AND
INSTALLATION
NOSJA--
Pre-removal
Operation
l
Draining of the Coolant (Refer to
GROUP 0 LUBRICATION
AND
MAINTENANCE
- Maintenance
Service.)
16-19
12-14
Post-installation
Operation
l
Supplying of Coolant (Refer to
GROUP 0 LUBRICATION
AND
MAINTENANCE
~ Maintenance
Service.)
l
Adjustment
of the Tension of the
Air Conditioner
Drive Belt (Refer to
GROUP 24 HEATERS AND AIR-CONDITIONING - Drive Belt Tension Adjustment.)
Nm
ft.lbs
Cold engine
90-100 Nm
65-72 ft.lbs. -----...
Hot engine
100-110 Nm
23-33
Removal
+I)
I)+
1. Air filter
2. Connection
3.
4.
5.
6.
7.
8.
l 4
4*
+e
+e
I)+
e+
l +
l +
I
/
I -1
18
ft.lbs.
steps
**
4*
5-7 Nm
3.6-5.0 ft.lbs.
9.
10.
11.
12.
13.
14.
15.
Fixi
16.
17.
18.
19.
of
Radiator
upper
Breather
hose
P.C.V hose
Connection
of
Air-conditioner
Connection
of
accelerator
hose
cable
oxygen
sensor
drive belt
power
steering
pipe
Spark plug cable
Connection
of high tension
Self locking
nut
Connection
of front exhaust
Gasket
Rocker cover assembly
Rocker cover gasket
ng to No. 1 cylinder
TDC
Distributor
Camshaft
sprocket
bolt
Cylinder
head assembly
Cylinder
head gasket
connector
breather
cable
pipe
OlW572
NOTE
to reinstall.
(2) +e : Refer to Service Points of Removal.
(3) l + : Refer to Service Points of Installation.
(4) 8: Non-reusable
parts
/ STB Revision
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ENGINE
- On-vehicle
SERVICE
1.
:*
Y
Service
POINTS
OF REMOVAL
REMOVAL
OF AIR FILTER
Refer to GROUP 11 INTAKE
Filter
AND EXHAUST
NOSJBAF
SYSTEM
- Air
.
$
7.
REMOVAL
OF AIR-CONDITIONER
DRIVE BELT
Loosen the tension-adjustment
nuts of the air-conditioner
drive belt and remove the air-conditioner
drive belt from
the tension pulley.
FIXING
TO NO.
1 CYLINDER
TDC
Turn the crankshaft.

Check to be sure that the camshaft
sprockets timing mark and the timing chains timing mark
(shiny white leaf plate) are aligned.
17. REMOVAL
OF CAMSHAFT
SPROCKET
BOLT
Pull the camshaft sprocket (with the timing chain attached)
out from the camshaft, and place it on top of the camshaft
sprocket
holder.
Caution
1. The crankshaft
must not be rotated
after the camshaft sprocket
is pulled out from the camshaft.
2. Be careful not to allow the timing
chain to come off
from the camshaft
sprocket.
j.8. REMOVAL
OF CYLINDER
HEAD ASSEMBLY
(1) Disconnect
the fuel hose, vacuum
hose and wiring
harness connected
to the intake manifold and carburetor.
Refer to GROUP 11 INTA E AND EXHAUST - Intake
Manifold
and GROUP
14 UEL SYSTEM-Carburetor.
(2) Loosen the bolts (in the ord r indicated in the figure) in
2 or 3 steps, and remove from the cylinder head.
Front of engine
i
SENOl6
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fit
ENGjNE
- On-vehicle
.li
* SERVICE
Timing
chain
case
Service
POINTS
OF INSTALLATION
NO9JDCE
19. INSTALLATION
OF CYLINDER
HEAD GASKET
Before cylinder head gasket is installed,
apply specified .
sealant to top surface of each butt joint between cylinder..,
block and timing
chain case. ;,;,,
<
, u:
I
i ?--.I..
b
Specified sealant : 3M ART Part No. 8660 or equivalent
Caution
Be careful not to allow
the cylinder
block.
OlWs53
sealant
to enter
the oil hole
in ,,*. .
Front of engine
5ENCM
18. INSTALLATION
OF CYLINDER
HEAD ASSEMBLY
,.:,
(1) Tighten the bolts (in the order indicated in the figure)in,::
2 or 3 steps, and finally tighten them at the-specified
)
torque.
!:
(2) Connect
the fuel hose, vacuum
hose and wiring *
harness connected
to the intake manifold and carbureiv{.
.s<.
.-.
tor.
-z:-=
Refer to GROUP 11 INTAKE AND EXHAUST - Intake
--$-!
Manifold
and GROUP 14 FUEL SYSTEM - Carburetor.,
:
-17. INSTALLATION
OF CAMSHAFT
SPROCKET
BOLT
Install the camshaft sprocket to the camshaft. Check to be
,:.
sure that the timing chains timing mark and the camshaft
sprockets
timing mark are aligned.
16. INSTALLATION
OF DISTRIBUTOR
Refer to GROUP 8 ELECTRICAL
Sealant
& J:
&z
.p.
- Ignition Sys$@$&
L
- .y.%c(>
5%
.,
c
1I 2,
&,;
v.~&,,;Ia ,b;
2
:
., Fp ,i.,?.
14. INSTALLATION
OF ROCKER COVER ASSEMBLY&:
;::b :,;
Apply a coating of the specified sealant to the semicircular
,;
packing and the cylinder head top surfaces, and then
tighten the rocker cover assembly at the specified torque.
!:
-.: ; J,f-,.
: 3M ART Part No. 8660orequ~valent
i;
Specified sealant
to be applied
f
1.
Cylinder
TL<circular
head
packing
Caution
If they are overtorqued,
leakage could result.
6ENOlZ
2. ADJUSTMENT
Refer to GROUP
a deformed
OF ACCELERATOR
14 FUEL
SYSTEM
1. INSTALLATION
OF AIR FILTER
Refer to GROUP
11 INTAKE AND
1 STB Revision
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rocker
cover
or oil
CABLE
- Accelerator.
EXHAUST
- Air Filter.
,I.
9-20
ENGINE
Service
On-vehicle
ENGINE MOUNTING
REMOVAL
Vehicles
AilID
with
INSTALLATION
a manual
NO9GA-
transmission
18-19
12-14
Nm
ftlbs.
Nm
.- -- .--.-
11-7il
Aa-IE
6-10 Nm
4-7 ftlbs.
\
i,
lation Operation
on of the Under Skid Plate,
Iver, Snow Protection
Underid Transfer Case Protector
3 GROUP 23 BODY - Under
Post-ins
0 lnstal
Unde
cover
(Refe
Covei
Ihc
Nm
ftlbs
18-25
13-18
::s.
-6
22-29
ft.lbs.
184%
13-18
Removal steps
+e e+
+e ~~
l *.
1.
2.
3.
4.
5.
6.
7.
9.
12.
Nm
ft.lbs.
12
A
! .75 Nm
d .54 ft.lbs.
Air filter
Heat protector
Front insulator stopper
Engine mounting front insulator
Plate
Transfer mounting insulator
Transfer mounting, bracket
No. 2 crossmember
Engine mounting rear insulator
NOTE
to reinstall.
(2) +e : Refer to. Service Points of Removal.
(3) l + : Refer to Service Points of Installation
http://vnx.su/
OlW575
ENGINE
Vehicles
with
an automatic
On-vehicle
Service
transmission
16-19
,I&14
Nm
ft.lbs.
6-10 Nm
4-7 ftlbs.
/
J+--Y
13-20
Nm
30-42
22-29
-fjr
3&40
22-29
Removal
+e
e+
+I)
l +
*I)
Nm
ftlbs.
-5
13-18
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Air filter
Heat protector
Front insulator
stopper
Engine
mounting
front insulator
Plate
Transfer
mounting
insulator
Transfer
mounting
bracket
Engine
support
rear bracket
No. 2 crossmember
Rear engine
support
member
Support
plate
Engine
mounting
rear insulator
Nm
ftlbs.
ftlbs.
18-25 Nm
13-18ft.lbs
OlW576
30-42
22-29
Nm
ftlbs.
. - L.
*,b,
NOTE
(I) Reverse the removal procedures
to reinstall.
(2) +*
: Refer to Service Points of Removal.
(3) *+
: Refer to Service Points of Installation.
STB Revision
http://vnx.su/
55-75
40-54
Nm
ft.lbs.
ENGINE
Service ~
On-vehicle
SERVICE
1. REMOVAL
OF AIR
Refer to GROUP
4.
OF REMC fAL
POINTS
FILTER
11 INTAKE
F D EXHAUST
- Air Filter.
NG FRONT INSULATOR
REMOVAL
OF ENGINE MOUN
(1) Attach a chain to the eng : hangers.
!, hang the engine slightly
(2) Using a chain block-and-tacl
up so that the insulator
is ree of engine weight.
g front insulator.
(3) Remove the engine mounl
NOTE
Hang the engine with a cha
mounting
front insulator.
Caution
Avoid applying
a strain
hoses and cables by rais
6.
NOSGBAD
REMOVAL
(1) Support
NOTE
Support
transfer
until installing
the engine
I the
g the
and fuel
too high.
radiator
engine
OF TRANSFER
the, transfer
f XJNTING
with
jack.
INSULATOR
the transfer with

mounting
insulate
i jack
the transfer
ing insulator.
(2) Remove
mou
until
installing
the
09wsoi
708.8
INSPECTION
(27.91)
Check the
Check the
Check the
corrosion.
Check the
Check the
sion.
l
l
l
l
l
NOSGCAE
insulators for cracks

front insulator
sto
transfer mounting
plate for deformat
No. 2 crossmembe
separation or deformation.
)ers for deformation.
racket for deformation
or
or corrosion.
for deformation
or corro-
*- ?
im (in.)
OlW504
d4r
SERVICE
4.
1.
POINTS
OF INST,
LLATION
NOSGDAG
INSTALLATION
OF ENGINE
I OUNTING
FRONT INSULATOR
.:
Make sure that the locating bo: and hole; are in alignment.,
c
\.
... .
Caution
Do not distort rubber portio;
portions
with fuel or oil.
.I)
INSTALLATION
OF AIR FILT
Refer to GROUP 11 INTAKE ,
http://vnx.su/
._
ENGINE
ENGINE
AND TRANSMISSION
REMOVAL
AND
- On-vehicle
9-23
Service
ASSEMBLY
INSTALLATION
NOSSA-B
Pre-removal
Operation
0 Removal of the hood (Refer to
GROUP 23 BODY ~ Hood.)
l
Under Cover, Under Skid Plate,
Transfer Case Protector, Cross Shaft
Protector, Snow-protector
(Refer to
GROUP 23 BODY - Under Cover.)
l
Draining of the Transmission
Fluid
or Oil and Transfer Case Oil (Refer
to GROUP 21 TRANSMISSION
Transmission
and Transfer Oil
Change and Inspection.)
l
Draining of the steering fluid (Refer
to GROUP 19 STEERING ~ Replacement of fluid.)
D Draining of the Refrigerant (Refer to
GROUP 24 HEATERS AND AIR-CONDITIONING - Refrigerant Leak Repair procedure.)
Post-installation
Operation
l
Supplying of Transmission
Fluid or
Transfer Case Oil (Refer to GROUP
21 TRANSMISSION
- Transmission
and Transfer Oil Change and Inspection.)
l
Supplying of Steering Fluid (Refer to
GROlJP 19 POWER STEERING ~
Replacement
of Fluid.)
l
Supplying of Refrigerant (Refer to
GROUP 24 HEATERS AND AIR-CONDITIONING ~ Refrigerant Leak Repair Procedure.)
l
Installation of the Undercover,
Under Skid Plate, Transfer Case Protector, Cross-shaft Protector and
Snow Protector. (Refer to GROUP
23 BODY ~ Under Cover.)
l
Installation of the Hood (Refer to
GROUP 23 BODY - Hood.)
1619
l?-14
Nm
ft.lbs.
I\
8-11 Nm
6-8 ftlbs.
1I
17
15
Removal
~~
l +
l +
e
+e
~~
14
steps
I.
2.
3.
4.
5.
6.
7.
8.
9.
10.
II.
12.
13.
Air filter
Connection
of
Radiator
upper
Radiator
lower
Upper shroud
Lower
shroud
Radiator;,.
ZConne@bn
of
hose
Connection
of
Connection
of
Connection
of
Connection
of
Connection
of
16
OlW574
;a,
accelerator
hose
hose
brake
heater
oxygen
control
battery
starter
booster
cable
vacuum
hose
sensor connector
harness
connector
positive
cable
motor connector
http://vnx.su/
14. Connection
of air conditioner
harnness
connector
(Vehicles
with an air conditioner)
15. Connection
of alternator
connector
16. Connection
gauge
unit switch
and sensor connector
17. Connection
of oil pressure
gauge
unit
connecter.
NOTE
(2) +e : Refer to Service Points
to reinstall.
of Removal.
of Installation.
._
_
16-24
,12-17
Nm
ftlbs
,-m...
25
0
15-22
11-16
QlW573
30-35
22-25
^^ ^_ Nrn
-.
m-i3
23
Nm
ft.lbs.
30-3I
22-2!
/
k.
/I
30
30-35
22-25
50-60
36-43
Nm
ft.lbs.
Nm
ft.lbs.
01 w577
*1
150-60
3M3
160 Nm
43 ft.lbs.
Nm
ft.lbs.
*2
16-22
13-16
Nm
ftlbs.
18. Connection of power steering return

hose
19. Connection of power steering pressure
hose
l + 20. Connection of throttle control cable
21. Connection of fuel main hose
22. Connection of fuel return hose
23. Connection of the air conditioner compressor and discharge hose (vehicles
with an air-conditioner)
24. Connection of the air conditioner cb
pressor and suction hose (vehicles with
nb
+* l * 29.
+* l * 30.
+e l + 31.
32.
Control lever
Rear propeller
Front propelle
Connection of
solenoid valve
33. Connection of
return tube
:: :,.
oil cooler feed tube and
, ,L
NOTE
(1) Reverse
(2) +e
(3) l *
of front exhaust pipe
;sembly
shaft
shaft
the connector for the OD
(4)
(5)
(6)
http://vnx.su/
the removal lrocedures to reinstall:.

: Refer to Sen e Points of Rem&al.
: Refer to Sen
: Non-reusable
pal
*I : Vehicles with a
2 : Vehicles with al
e Points
;.
of Installation.
ianual transmission.
automatic transmission.
ENGINE
- On-vehicle
9-25
Service
13-18
18-25
13-18
40-54
ftlbs.
Nm
ftlbs.
~~
+e
41)
+e
01W578
x.
10-13
l + 34.
35.
.
~~ 36.
l + 37.
l + 38.
39.
40.
41.
42.
l * 43.
ft.lbs.
Connection of speedometer cable

Connection of 4WD indicator light
switch
Clutchyelease cylinder
Select cross shaft
Transmission control rod Plate
Transfer mounting insulator
Transfer mounting bracket
No. 2 crossmember
Engine and transmission assembly
NOTE
(1)
Rev&se
the removal
procedures
to reinstall.
(2) 4*
: Refer
to Service
Points
of Removal.
(3)
l + : Refer to Service
Points
of Installation.
(4)
m:
Non-reusable
parts.
(5)
*1 : Vehicles
with
a manual
transmission.
(6)
2 : Vehicles
with
an automatic
transmission.
/ STB Revision
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38*2
owl544
Nm
.;i
ENGINE
On-vehicle
SERVICE
1. REMOVAL
Service
POINTS
OF AIR
Refer to GROUP
7.
OF REMOVAL
N09SBCC
FILTER
11 INTAKE
REMOVAL
OF RADIATOR
Refer to GROUP 7 COOLING
ND EXHAUST
- Air Filter.
- Radiator.
29. REMOVAL
OF CONTROL
LEVER ASSEMBLY
Refer to GROUP 21 TRANSMISSION
- Gearshift
Assembly (Manual transmissior)
or Transfer Control
matic transmission).
Lever
(Auto-
30. REMOVAL
OF REAR PROPE,LER
SHAFT/31.
FRONT
PROPELLER
SHAFT
Refer to GROUP 16 PROPELLE?
SHAFT AND UNIVERSAL
JOINTS - Propeller
shaft.
36. REMOVAL
OF CLUTCH
RELEASE CYLINDER
Refer to GROUP 6 CLUTCH - Clutch Release
37. REMOVAL
OF SELECT CROSS SHAFT/38.
SION CONTROL
ROD
Refer to GROUP
21 TRANSVllSSlON
Control.
43. REMOVAL
BLY
OF ENGINE
AND
Cylinder
TRANSMISTransmission
TRANSMISSION
ASSEM-
With the engine and transmission

assembly
tilted at an
angle, slowly remove from th I engine compartment.
Caution
Check to be sure that all cableIs, harnesses,
connectors,
etc. are disconnected
from the engine and transmission
assembly.
SERVICE
..
.
POINTS
OF INST
43. INSTALLATION
OF ENGINE
SEMBLY
(1) While checking
the corm
pipes, hoses, etc., and mak
are being caught, damaged,
transmission
assembly.
(2) Then, after the weight of t
assembly
has been put on
specified
torque.
/
,
STB Revision
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LLATION
ND TRANSMISSION
NOSSDAG
AS-
ctions of the harnesses,

ng sure that none of them
etc., install the engine and
e engine and transmission
each insulator,
tighten to
ENGINE
- On-vehicle
Service
38. INSTALLATION
OF TRANSMISSION
SELECT CROSS SHAFT
Refer to
Control.
GROUP
21
CONTROL
TRANSMISSION
36. INSTALLATION
OF CLUTCH
Refer to GROUP 6 CLUTCH
Transmission
RELEASE CYLINDER
- Clutch Release Cylinder.
34. CONNECTION
OF SPEEDOMETER
Refer to GROUP 21 TRANSMISSION
Speedometer
Cable.
31. INSTALLATION
OF FRONT
REAR PROPELLER
SHAFT
Refer to GROUP 16 PROPELLER
JOINTS - Propeller
shaft.
RODId7.
CABLE
- Replacement
PROPELLER
of the
SHAFT/30.
SHAFT AND UNIVERSAL~i,f

i
29. INSTALLATION
OF CONTROL
LEVER ASSEMBLY
Refer to GROUP
21 TRANSMISSION
- Gearshift
Assembly (Manual transmission)
or Transfer Control
matic transmission).
20. CONNECTION
OF THROlTLE
CONTROL
CABLE
Refer to GROUP
21 TRANSMISSION
- Adjustment
Throttle
Control Cable.
7.
INSTALLATION
OF RADIATOR
Refer to GROUP 7 COOLING
- Radiator.
2.
ADJUSTMENT
OF ACCELERATOR
Refer to GROUP
14 FUEL SYSTEM
1. INSTALLATION
OF AIR FILTER
Refer to GROUP 11 INTAKE AND
;.
Lever
(Auto-
of
CABLE
- Accelerator
EXHAUST
- Air Filter.
.
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TIMING CHAIN TRA!lh&&

3EMOVALAND
INSTA@$&
50-60
Nm
i\
A-IO
Nm
-0
RI
\
2-7,
II--15
ftlbs.
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,
. ;..a.
.
-1Nm
ft.lbs.
1 l&l30
80-84
Nm
ftlbs.
12-14
g-10.5
Nm
ftlbs.
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3 ENGINE-Timing
p.
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,=,iai
Removal
Chain Train
Installation
steps
steps
26. Sprocket holder

25. Tension side chain guide
24. Loose side chain guide
+4 18. Tensioner spring
l + 17. Ruhber sheet
l a 16. Tension sleeve
23. Crankshaft sprocket
P:.+
W# 22. Timing chain
21. Camshaft sprocket
80. Spring pin
19. Distributor gear
15. Spacer
l b 14. Left silent shaft sprocket
13. Oil pump sprocket
l 4 12. Crankshaft sprocket B
l 4 11. Chain B
10. Chain guide C
9. Chain guide A
8. Chain guide B
++ 7. Oil seal
6. Chain guide access hole gasket
5. Chain guide access hole cover
4. Chain case gasket
l + 3. Timing chain case
2. Crankshaft pulley
1. Special washer
1. Special washer
n side chain guide
NOTE
(1)4*
(2) **
(3) m
) STB Revision
: Refer to Service Points of Rery~l..

: Refer to Service Points of Instally@?
,_
: Non-reusable
parts
.;.
--*i--.
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..!
r-
ENGINE-Timing
Chain Train
SERVICE POINTS OF REM9 \I, AL
.
SPROCKET/22.
OF CAMSHAm
CHAIN/23.
CRANKSHAFT
SPF 33 ICKET
Remove the timing chain corn1 3r red with camshaft
and crankshaft sprocket.
21. REMOVAL
INSPECTION1
I.
1 ,$
.x1
,I
t *
Camshaft
sprocket
Sprocket
sprocket
NOSWCAA
t.iming chain for roll er play, wear, damage or dislinks.

necessary.
tensioner and chain {I1 jide rubber shoe for wear or
necessary.
and then install the oil pump.
holder
*Timing
Check the
connected
.Replace if
Check the
damage.
Replace if
TIMING
chain
side-Timing
chajn
(1) Turn crankshaft until pistor. bf No. 1 cylinder is at top dead

center.
(2) Line up plated links of tim lg chain and.timing
marks on
sprockets as chain and spr xkets are ass&bled.
(3) While sliding crankshaft sy rocket onto crankshaft, install
chain and sprocket. Place r amshaft sprocket on sprocket
holder.
auide
side
14. INSTALLATION
(1) Assemble
http://vnx.su/
OF LEFT S!LI
silent shaft&m
UT SHAFT SPROCKET
kets to chain B. Make sure
nment with plated links.
It and left sprockets, as they
ctions.
ENGINE-Timing
9-31
Chain Train
OF CRANKSHAFT
SPROCKET
ES
(for
driving silent
install crankshaft sprocket
12. INSTALLATION
:
&i-
Tiiing
side
Crankshaft
sprocket
Crankshaft
spkocket
stkooq
11. INSTALLATION
Chain
Special
bolt
bolt
guide
Cylinder
Section
Special
shafts) on
crankshaft.
chain
B
block
Y - Y
OF CHAIN
r.
(1) Holding assembled spro&ets and chain B, align timing

mark on crankshaft sprocket B with that on chain B.
and install sprockets to oil pump drive gear and left silent
..
shaft. Partially tighten bolt.
B
Timing
mark
Oil pump
body
plate1
llnk
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I
Chain
$
.
T
S,
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guide B
Section X - X
pF0
elated
R
Section
8
de
Crankshaft
sorocket
link
_.
.
5EI
{;
(2) Rotate both silent shaft sprockets slightly to position chain

slack at point P.
(3) Adjust position of chain guide B so that when-chdiri~ is , pulled in direction of arrow with finger tips, clear&e
be- $
I..I:.
?
tween chain guide B, and links of chain B.
P4 P
Specia{bolt
?
Chain and chai&gtiide
B gap
Standard
value : 0.2 4 fl.8 mm (.0079-.0315
\
5ENOOf
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c;
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.. J .
ENGINE-Timing
7.
Chain Train
INSTALLATiON
Using special
OF OIL SEAL
tools, install tt-
oil seal.
MD998376-01
3.
INSTALLATION
OF TIMING
C 4lN CASE
(1) Clean the gasket surfaces o hain case and cylinder block.
and chain case to the cylin(2) Install the chain case gaske
der block.
-.-
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ENGINE
- Rocker Arms,
Rocker Arm Shafts
and Camshaft
ROCKER ARMS, ROCKER ARM SHAFTS AND CAMSHAFT

MVIOVAL
AND
INSTALLATION
6
h
J.
fs19-20
14-15
Removal
20-26
15-19
Nm
ft.lbs.
Nm
ftlbs.
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
Breather
hose
Pipe
Oil seal
P.C.V. hose
P.C.V. valve
Oil filler cap
Packing
Rocker cover
Rocker cover gasket
:
I
I!.
+e l + 10. Rocker arm and shaft assem

+e
~~
11. Auto-lash
adjuster
l + 12. Camshaft
l + 13. Semi-circular
packing
l + 14. Circular
packing
NOTE
Reverse the removal procedures
to reinstall
(2) l * : Refer to Service Points of Removal.
(3) l * : Refer to Service Points of Installation.
(4) m: Non-reusable
parts
(I)
,._
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5EN197
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9-34
ENGINE-Rocker
Arms, Rocker Arm Shafts and Cam rhaft

SERVICE POINTS
M D998443-0
OF REM0
10. REMOVAL OF ROCKER

AUTO-LASH
ADJUSTER
ARM
JAL
\ND SHAFT
NOSLBCA
ASSEMBLY/l
1.
Before removing the rocker an- I and shaft assembly, use the
special tool to ensure that the auto-lash adjuster doesnt fall
out.
Caution
in order in
Put the rocker arms and au1 b-lash adjusters
becylinder No. separated place: , with clear distinction
tween the intake and exhaus : ones to prevent confusion.
INSPECTION
Check camshaft journals for w
essary. If journals are damage
ings for wear or damage. If ci
replace cylinder head.
Check the fuel pump drive cam
for wear or damage. Replace i
in.)
Cam height
Standard value
Intake : 42.4 mm (1.669: I In
- .I
Exhaust : 42.4 mm (1.6E 93 in.)
Limit
Intake : 41.9 mm (1.649r i in.)
Exhaust : 41.9 mm (1.6L 96 in.)
End play
Standard value : 0.1-0.2 I nm (.004-.OOS in.)
L@it : 0.4 mm (016 in.)
1ENOlS
Rear bearing cap Apply sealant
and distributor drive gear teeth

necessary.
Check for unusual cam face WI Faror damage, replace the part
if required. Measure cam heigt t (i.e., its diameter), replace the
cam if outside of the limit.
rar or damage. Replace if necI. also inspect camshaft bearnshaft bearing is badly worn,
Camshaft
Standard value
HeighU of fuel pump drh e cam : 37 mm (1.4567
Journal diameter
: 34 m n (1.3366 in.)
mm (.0012-.0020
in.)
Oil clearance : 0.03-O.O!
5EN198
NOSLCCA
SERVICE
POINTS
14. INSTALLATION
OF INST 4LLATION
OF CIRCUU
R PACKING
Coat the sealant to the O.D. c cir&&?Tp~cking

circular packing to cylinder he qji;.x
Timing chain
side
Cam
STB Revision
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NOSLDCB
and install the
ENGINE-Rocker
13. APPLY
Sealant to be applied
SEALANT
TO SEMI-CIRCULAR
Apply sealant to the top of the packing
Specified
Cylinder kead
Semi-circular
or breather
9-35
Arms, Rocker Aem Shafts and Camshaft
sealant
PACKING
and semi-circle.
packing
6EN013
12. INSTALLATION
OF CAMSHAFT
Apply engine oil to the journals of camshaft and install it to

cylinder head.
?
11. INSTALLATION
OF AUTO-LASH
ARM AND SHAFT ASSEMBLY
MD998443-1
ADJUSTEWlO.
ROCKER
(1) Insert the auto-lash adjuster from below as illustrated, being careful not to spill the diesel oil inside it. Then use the
special tool to prevent adjuster from falling while installing
it.
(2) Place the rocker arm and shaft assembly on the cylinder
head and tighten the bearing cap bolt.
(3) Remove the special tool.
6EN246
1 STB Revision
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9-36
ENGINE-Rocker
Arm and Shaft Assembly
ROCKER ARM AND SHAFT ASSEMBLY

DISASSEMBLY
Disassembly
NO9NE-B
AND REASSEMBLY
steps
1. Rear bearing cap

2. Rocker arm C
3. Rocker arm A
4. Rocker shaft spring
l + 5. Bearing cap No.4
6. -Rocker arm C
7. Rocker arm A
l + 9. Bearing cap No.3
10. Rocker arm C
11.
Rocker arm A
..^,
l 413. Bearing cap No.2
14. Rocker arm C
15. Rock& arm A
l + 16. Wave washer
l 417. Right rocker arm shaft
++18. Left rocker arm shaft
3419. Front bearing cap .:
20. Nut
21. Adjusting screw ;.
\
., <*
-I:$C.
NOTE
(1) Reverse the disassembly
prc ,edures to reassemble.
j2).*4
: Refer to Service Poin s of Reassembly.
[ ST6 Revision
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ENGINE-Rocker
9-37
INSPECTION
@ ROCKER
(1) Check
sary.
(2) Check
dil
rocker
arms
to ensure
for wear
Replace
or damage.
if neces-
that oil holes are clear.
hole
6EN364
I-
ROCKER
rocker
arm mounting
for wear or damage.

(2) Check
D
O+J- 0
ARM SHAFT
(1) Check
Oil holes
0
NO9NGADl
ARM
to ensure
Replace
portions
of rocker
arm shaft
as necessary.
that oil holes are clear.
,I
I
i
5ENO63
Front
SERVICE POINTS OF REASSEMBLY

19. INSTALLATION
OF FRONT
BEARING
ROCKER ARM SHAFTI17.
RIGHT ROCKER
(1) Insert the left and right rocker shafts into
cap. The rear end of left (intake) rocker
NOSNHCA
GAP/18.
LEFT
ARM SHAFT
the front bearing
arm shaft has a
,.!a:
notch.
Rocker arm shaft, left
Notch
(2) Align the mating mark of the rocker arm shaft front end to
the mating mark of the front bearing cap. Then insert the
bolts to hold shafts in bearing cap.
5EN077
Mating marks
13 mm (1181 in.) dia. hole]
(3) Assemble the rocker arm shaft so that the alignment mark
at the front end matches the alignment mark of the front
bearing cap.
:.
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>
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3,
c
Mating marks
[2 mm (.0787 in.) dia. embossing]
5EN012
Rocker arm
Timing chain m
side
16. INSTALLATION
OF WAVE WASHER
Install the waved washer in the direction
illustration.
Front bearing cap

5EN076
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shown
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in &6$?.~;-,.~
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.4:
9-38
ENGINE-Rocker
i CAP
13.9.5. INSTALLATION
OF BEARII
Caps 2. 3 and 4 are of similar I li 3pe and require attention
the cap number during assemb 1.
Timing chain side

b
Rocker cover installation
bolt
Identification
mark
I
/-
Rocker cover Installation bolt hole

5EN215
- .
i
:;
9
.z
:
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Ij
i
1 STB Revision
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to
ENGINE-Cylinder
9-39
Head
CYLINDER HEAD
REMOVAL
NOSOA-S
AND INSTALLATION
Cold engine
90-100
Nm
65-72 ftlbs.
...
Removal steps
NOTE
(1) Reverse the removal procedures to reinstall.
(2) +e
: Refer to Service Points of Rynoval.
(3) l + : Refer to Service Pointsof Installation.
(4) q
: Non-reusable
parts
G..
+ee+ 1. Cylinder head bolt

4e l 4 2. Bolt
3. Cylinder head
l + 4. Cylinder head gasket
1 ST6 Revision
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4.
,i ;p --
8..
ENGINE-Cylinder
Head
INTS OF REMO
1. REMOVAL OF CYLINDER HEA BOLTI.2. BOLT,

Remove cylinder head bolts in SI fuence shown in illustration.
INSPECTION
0
l
l
iimjg
12
chain
side
Apply
z.1. , ,,
, :
n
sealaGt>
SERVICE POONTS OF INSTA
Ensure tt&?he
sealant
is not allowed
to enter the oil
passages
.*.- .
::
L%
.ldentification
mark
-XT
A
INSTALLATION
1.
:..
,-:
I,
.- :,a
:e for flatness with a straight

action, either replace cylinder
jer head gasket surface.
, .;>;:,
# surface
Im :r,,,:f(992 in.)
.,?s$.;.
433 in.)
sket surface
grind)
LATloN
NWODAB
OF CYLINDER
iEAD GASKET
(1) Clean gasket surfaces of cyl lder head and cylinder block.
(2) Apply a sufficient amount o sealant or similar material .t&K
the two guides on the cylir ler block and chain case r%:.
illustrated.
-:>
. r;
Specified sealant
: 3M Al T Part&l&88.&)
or equiva$,
lent
:.
f
j.
(3; Be sure to position the gasl !t on th.ecyli&er
block with
the identification
mark up.
(
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Idyitificationmark
: 54
(4) Ali;S;; with the mark on the + ,p of the cyli&Jer head when
installing.
Caution
Do not apply
3 and carbon deposits comes, apply compressed

air to
Ire/not clogged.
IB gas passage for clogging.
lr cracks, damage and water
Caution
The cylinder
head gasket su face should be ground to
within
0.2 mm (.0079 in.) e en with the grind of the
cylinder
block gasket surfac
4.
,i
t
I
NOSOCAE
Remove scale, sealing compou

pletely. After cleaning oil passa
make certain that the passages
Check the jet air passage and E
Visually check the cylinder head
leakage.
Check cylinder head gasket surf
edge as shown in illustration.
If flatness exceeds limit in any di
head or lightly .- rnachi~,~~~,t!~~~Fiylil
,::,<.
.:
e
, I%
Flatness b$&linder
head gasI
Standard value I Max. O;,b&
Limit : 0.2 mm (0079 in:)
Overall height
Standard value : 90 mm (3.
Limit
(amount of cylinder head g
-0:2 mm (-.0079 in.)
$4
:;.
sealant
to cl inder head gasket,--
5ENO6!
. ,+,, STB pevision

: il
._.
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I_
ENGINE-Cylinder
2.
+
Timing chain side
-;::
9-41
INSTALLATION
OF BOLT/l.
CYLINDER HEAD BOLT
Install cylinder head bolts. Starting at tod:center,
tighten aI
Cylinder head bolts to l/2 of specified torque.,in sequence
shown in illustration.
i
<
5EN0!6
Head
,,
1 STB Revision
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9-42
ENGINE-Valves
and Valve Springs
VALVES AND VALVE SPRINGS

HSASSEMBLY
NOWE-B
AND REASSEMBLY
5EN212
Disassemblysteps
+e l a 1. Jet valve assembly

l *+4
2. Retainer lock
3. Valve spring retainer
l * 4. Valve spring
l * 5. Valve spring seat
~~ 6. Intake valve
+**+
7. Valve stem seal
8. Intake valve guide
9. Intake valve seat
+MW
0. Retainer lock
l *12. Valve spring
l 41 3=Valve spring seat
,d 14. Exhaust valve
*&15.
Valve stem seal
16. Exhaust valve guide
17. Exhaust valve seat
NOTE
(1) Reverse the removal procedur
(2) l * : Refer to Service Points
(3) l a : Refer to Service Points
(4) q
: Non-reusable
parts
.,,i
i
: . I;:.. ,I,.,
1 STB Revision
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i to reinstall.
f Disassembly.
f Reassembly.
ENGINE -Valves
and Valve Springs
SERVICE POINTS OF DBSASSEMBLY
MD99831 0
1.
REMOVAL
9-43
NO9PFAB
OF JET VALVE ASSEMBLY
Using special tool, remove the jet valve assembly.

Caution
When special tool is used, make certain that the wrench is
not tiUPed with respect to the center of the jet valve. If the
tool is tilted, the valve stem might be bent by the force
exerted on the valve spring retainer, resulting in defective
jet valve operation.
,.:
2.10. REMOVAL OF RETAINER
LOCK
(1) Using valve spring compressor, remove the retainer lock. .f
(2) Keep these parts in order so that they can be reinstalled in ;.,
,a*
their original positions.
3EN324
7.15. REMOVAL OF VALVE STEM SEAL

Remove the valve stem seals with pliers and discard them.
3EN121
INSPECTION
l
lEN034
NO9PGACl
VALVES
(1) Check each valve for *Lear, damage and deformation
of ,%
i
head and stem at B. Repair or replace excessively worn,
i:
demaged or deformed valves.
(2) If stem tip A has been pitted, correct with oil stone or :I
5
other means. This correction must be limited to a mini1
mum. Also reface the valve.
(3) Replace the valve if the face margin has decreased to less
than limit.
Margin
Standard
value
Intake
: 1.2 mm (.047 in.)
Exhaust
: 2.0 mm (.079 in.)
Limit
Intake
: 0.7 mm (.028 in.)
Exhaust
: 1.5 mm (.059 in.)
1 STB Revision
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9-44
ENGINE-Valves
Lean
t--*O
and Valve Springs

VALVE SPRINGS
(1) Check free length of each vt ve spring and replace if necessary.
(2). Using a square, test square ess of each valve spring. If
spring is excessively out of : quare, replace it.
Valve spring
Standard
value
Free length
: 49.8 n
Load : 322.6 N (72.!
Installed
height
: 4C
Out of squareness
:
Limit
Free length
: 48.8 IT
Installed
height
: 41
Out of squareness
:
m (1.961
in.)
Ibs.) at installed
height
4 mm (1.591 in.)
Within
2
n (1.922 in.)
$0 mm (1.6299
4
VALVE GUIDES
in.)
NO9PGCB
Check the valve stem-to-guide c ?arance. If the clearance exceeds the lirnit, replace the val e guide with new oversize
part.
diameter
lEN323
Valve stem-to-guide
clearance
Standard value
Intake : 0.03-0.06
mm (.O 12-.0024
in.)
Exhaust : 0.05-0.09
mm ( )020-.0035
in.)
Valve Guide Oversizes
4nder head hole size mm (in.)
3.050-13.068
(.5138-.5145)
3.250-13.268
(.5217-.5224)
3.500-13.518
(.5315-.5422)
Limit
Intake : 0.1 mm (.0039 in.]
Exhaust : 0.15 mm (.0059 n.1
STB Revision
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ENGINE-Valves
9-45
and Valve Springs
VALVE SEAT RECONDITIONING
PROCEDUR$!&Ac
(1) Check the valve guide for wear. Replace the worn guide.
(2) Reconditon the valve seat with a seat grinder or cutter. The
valve seat contact width should be of the specified size at the
center of the valve face.
(3) The valve and valve seat should be lapped lightly with a lapping
compound.
i
1..
j..
Intake
1 EN036
(4) Check valve seat insert sinkage. If the sinkage exceeds the
service limit, replace the insert with an oversize part as described below.
(5) Measure
the installed height of spring between
the spring
seat and the retainer with the valve spring seat, spring retainer
and retainer lock installed. The amount of sinkage can be
judged from the measured value.
Installed height of spring A (both intake and exhaust)

Standard value : 40.4 mm (1.5905 in.)
Limit : 41.4 mm (1.6299 in.)
28
0.5-l
mm
(.0197-.0394
VALVE
DURES
in.)
SEAT
INSERT
REPLACEMENT
PROCEL
NoaPlAfi 2.
;
(1) To replace : scrape the inner face of the valve seat to reduce
the wall thickness,
and remove.
0.5-I
mm
(.0197-.0394
in
lEN08;
(2) Adjust the press fit diameter of the valve seat on the cylinder
head side so that it matches the diameter of the oversize valve
seat.
Height of
valve seat
Dia
lEN066
wision
.. .
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/
L.
I
9-46
ENGINE-Valves
Seat Insert Oversizes
Valve
Description
Size mark
Size mm (in.)
Intake valve
seat insert
0.3 (.012)
0,s.
Insert height H
mm (in.)
30
7.9-8.1
(.3110-.3189)
60
8.2-8.4
(.3228-.3307)
0.3 (.012) O.S.
30
7.9-8.1
(.3110-.3189)
0.6 (.024) O.S.
60
8.2-8.4
(.3228-.3307)
0.6 (.024) O.S.
Exhaust valve
seat insert
and Valve Springs
47.60-47.63
(1.8740-1.8750)
40.30-40.33
(1.5866-1.5876)
40.60-40.63
(1.5984-l
.5994)
(3) Heat the cylinder head to about

oversie seat insert fit to the inse
normal temperature.
(4) Treat the valve seat in the way
(5) Use the lapping compound, and
-I
150C (480F) and press in an
t bore in the cylinder head at
#hewn in the diagram.
lap the valve.
1 EN036
(9) Ensure that the seat is properly centered on the valve face.
Valve
seat
II
SERVICE POINTS OF REASS EMBLY

15.7. INSTALLATION
SPRING SEAT
OF VALVE
NO9PKDB
S TEM SEAU13.5.
VALVE
Install the spring seat, then usin! special tool, install the stem
seal by lightly tapping the tool. Seal is installed in specified
position, using the special tool.
Caution
1. Incorrect installation
of the seal wituout using special
tool will result in poor St?i ling and cause oil leakage
down valve guide.
2. Do not reuse stem seal.
14. INSTALLATION
OF EXHAUST
rlALVE/G.
INTAKE
VALVE
Apply engine oil to each valve, insert valves into the valve
guides. Avoid inserting the valve nto the seal with force. After
insertion, check to see if the val le moves smoothly.
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12.4. INSTALLATION
Enamel
coated
side
OF VALVE
SPRING
Valve springs should be installed

toward the valve spring retainer.
with the enamel
coated
side
r
I $*:,.
6EN024
,g i
j,:
,:<2..... ,,;:p,
(1) Using the valve spring compressor,
compress
the valvy$& ,I)
%g
spring and install the retainer lock.
c, .,$<S
A-:
;
Caution
L
11,
When compressing
the spring with the Valve Spring
.I
Compressor,
check to see that the valve stem seal is
not pressed to the bottom
of the retainer.
Then start
installing
the retainer
lock.
10.2. INSTALLATION
(2) Make certain
6EN019
1.
INSTALLATION
(1) Apply engine
surface.
Caution
fUlake sure
Apply
engine
OF RETAINER
that retainer
LOCK
locks
OF JET VALVE
installed.
ASSEMBLY
oil to the O-ring,
that the O-ring
are positively
jet body threads
is a new
and seat
one.
oil
1 EM001
(2) Screw the jet valve assembly

into cylinder head by hand.
Tighten the jet valve to the specified torque with Special
Tool and a torque wrench while holding the special tool in
line with the jet valve center line.
.?
-. rs:..
,,i
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9-48
ENGINE- Jet Valve Assembly
NWX-0
JET VALVE ASSEMBLY

PISASSEMBLY
Disassembly
+**a
AND REASSEMBLY
steps
1. Retainer lock
3. Valve spring
4. Jet valve
5. Stem seal
6. O-ring
7. Jet body
l a
*4
l 4
l *
-6U
lEM177
NOTE
procedures to reassemble.
(2) l * : Refer to Service Points of Disassembly.
(3) l q : Refer to Service Points of Reassembly.
: Non-reusable
parts
(4) q
SERVICE POINTS
1. REMOVAL
OF DISASSEMBLY
OF RETAINER
NOSQFAAl
LOCK
Using special tool, remove the retainer lock.
lEMOO5
INSPECTION
,
t
NO9QGAAl
Make sure that the jet valve slides smoothly in the jet body
and has no play.
l
I
Caution
Combination
of the jet valve and jet body should
disturbed
and the jet valve and jet body should
placed as an assembly.
l
l
not be
be re-
Check the valve head and valve seat for damage or seizure.
Check the spring for sag, cracks or breakage.
1 STB Revision
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ENGINE-Jet
Valve Assembly
9-49
Standard value
Jet wafWe
Length : 91.58 mm (3.6055 in.)
Stem O.D. : 4.3 mm (1693 in.)
Seat angle : 45
Jet valve spring
Free length : 29.60 mm (1.1654 in.)
Load : 34.3 N (7.7 Ibs.) at installed
height
: 21.5 mm (.846 in.)
Installed
height
Out of squareness
: Max.l.5

5.
INSTALLATION
OF STEM SEAL
Using special tool, install the stem seal.
4.
INSTALLATION
OF JET VALVE
(1) Apply engine oil to the stem of the jet valve.

(2) Use care to prevent damage to the new seal lips.
(3) Check to ensure that the valve sliders smoothly.
3.
INSTALLATION
OF VALVE SPRING/Z.
VALVE SPRING RETAINER/l.
RETAINER
LOCK
(1) Mount the valve spring and valve spring retainer on jet
body.
(2) Compress the valve spring with special tool, using care not
to damage the valve stem by the bottom of valve spring
retainer.
(3) While the spring being kept compressed,
install the retainer lock.
\
1 EM005
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8.
:j.
7:
i
i;
6,:
9-50
ENGINE
- Front Case, Oil Pump and Silent Shaft
FRONT CASE, OIL PUMP AND

REMOVAL
LENT SHAFT
NOSRA-.
AND INSTALLATION
IO-12 Nm
7.5-8.5 ftlbs. --@
IO-12
Nm
dl2
Nm
7.5-8.5 ft.lbs.
I
@Y.f
10-12
7.5-8.5
bl.4
Nm
77-17
ft
15-22
I 1-15
Nm
,I;ft.lbS. ~ 1.
*/y /
A -
Ihc
Nm
ft.lbs.
,
i
t
.,
.I
6-8-Nm
4.5-5.5
I
p
1. Oil drain plug

2. Oil drain plug gasket
l *
3. Oh filter
l * ,i Oil pan
?j. Gasket
y$$f :
@.
6. Oil sc,[een
:,%*
7.+l
screen gasket
.,
(, ;
8. Plug
l +
9.
10.
11.
12.
13.
Relief spring
Relief plunger
Flange bolt
Oil pump body
Pin
,. +
,*4
e-4
+e
54.
15.
16.
-i3:7.
18.
l + 19.
.** 20.
l + 21.
~~ 22.
23.
24.
-,
b.
ftlbs.
5EN205
Removal steps- 1
Driven gear
Drive gear
Woodruff
key
Oil pump cover
Oil pump gasket
Thrust
plate (with front bearing)
.i
-O-ring
Woodruff
key
Left silent sh$t
Right silent shaft
NOTE
1.
to reinstall.
Rear bearing
(2) l * : Refer to Service Points of Removal..
(3) **
(4) 8: Non-reusable
parts.
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ENGINE-Front
Thrust
..
OBNTS OF REMOVAL
plate
L OF, THRUST
nt shaft,
8 mm
bolt
(.31/50
in.)
9-51
Case, Oil Pump and Silent Shaft
NOSRBAE
PLATE
m (.3150 in.) dia. bolts into threaded

and turn bolts in to remove the thrust plate.
left
holes of flange
\ .,\
5EN020
,4x
i
No9RcGB
OIL PUMP
*,I
..,..I
(1) Check gear contacting surfaces

of cover for step wear.
[.,
(2) Check the clearance of drive and driven gears. If clearance ;
is excessive,
replace case and cover assembly
and/or ;,,
gears.
(1.../
a
Standard value
Driven gear
Tip clearance
Side clearance
Drive gear
Tip clearance
Side clearance
Limit
Driven gear
Tip clearance
Side clearance
Drive gear
Tip clearance
Side clearance
5EN142
RELIEF PLUNGER
: 0.11-0.15
: 0.04-0.10
mm (.0043-.0059
mm (.0016-.0039
in.)
in.)
: 0.11-0.15
: 0.05-0.11
mm (.0043-.0059
mm (.0020-.0043
in.)
in.)
: 0.2 mm (.0079 in.)

: 0.15 mm (.OOSO in.)
,,I .%~.
,<c
i.,
,.;>+x>
:.).&gq 1 .
.-;%T $&:-...
I ,I.<~.
,- -.
.:.
\ /
: 0.2 mm (.0079 in.)

: 0.15 mm (.OOSO in.)
NOSACHA
,,p.;\$$;
& ,!,&
AND SPRING
(1) Insert the relief plunger in the front case and qheck to see
I
if it operates smoothly.
(2) Check the relief spring for breakage or sagging.
Standard value
Relief spring
Free length : 46.4 mm (1.8346 in.)
Load : 60 N/40.1 mm (13.4 lbsJ1.5787
SILENT
SHAFT
in.)
NOSRCIA
(1) Check journals for wear, damage and seizure4 If excessive

damage or seizure is evident, check bearing as well. If
necessary,
replace silent shaft or bearing or both.
(2) Check oil hole(passage)
for clogging. Clean or repair as
necessary.
,$A
$g
5EN07
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;
:.I
/.
;
9-52
ENGINE-Front

SILENT
Cylinder
SHAFT BEARING
(1) Using special tool, remove
block
PROCEDURE N~~REM
REPLACEMENT
silent shaft rear bearing.
5EN022
(2) Apply engine oil to O.D. of bearing, using special tool, install
silent shaft bearing to cylinder block.
tiD990938-07
Cylinder
block
5EN023
SERVICE POINTS OF INSTALLATION

22. INSTALLATION
Apply
engine
oil
OF LEFT SILENT
NOSRDCE
SHAFT
(1) Apply engine oil to journal of left silent shaft.

(2) Insert left silent shaft into cylinder block. Insert silent shaft
carefully to prevent damage to the bearing.
5EN025
20. INSTALLATION
OF O-RING
(1) Install o-ring in groove of thrust plate.
(2) Apply engine oil around O-ring.
New
O-ring
5EN026
19. INSTALLATION
Guide
[6 mm
I
OF THRUST
PLATE
(1) Install two guides in threaded holes for mounting thrust

plate. Guides should be fabricated by cutting off hexagon
heads of bolts 6 mm (.2362 in.) in diameter and 50 mm
(1.9685 in.) long.
(2) Install thrust plate into cylinder block along guides.
Without use of guide, threaded holes will be hard to align.
t.2
1
Thrust
blate
,?I4
Cylinjer
block
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ENGINE-Front
9-53

15. INSTALLATION
OF DRIVE
GEAR/14.
DRIVEN
Install oil pump gears to oil pump body and align timing
Driven
gear
Timing
marks
Drive
GEAR
marks.
Caution
If timing marks are out of alignment,
phase of silent shaft
will change and vibration
will result.
gear
5EN028
12. INSTALLATION
OF OIL PUMP
BODY
Place pump assembly in same position as it was installed on ?
engine and put approx. 10 cc (.6 cu.in.) of clean engine oil in ;
delivery port.
3.
.
Apply 10 cc
t.6 cu.in.) of
engine oil
5EN029
Chain
case
and cylinder
4.
blockElde
INSTALLATION
OF OIL PAN
Apply sealant to four places on the cylinder block side of the
hatched area.
Specified
Cylinder
block
and
rear oil seal
case
guide
sealant
1~~0%
3.
-tB*
APPLICATION
OF ENGINE OIL TO OIL FILTER
Apply engine oil to surface of packing. But must not protrude
engine oil from case.
\
Apply
oil
6LUO26
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i.r
9-54
ENGINE-Piston
PISTON AND CONNECTING

tEMOVAL
and Connecting Rod
ROD
NOSTA-
AND INSTALLATION
7
8
9
5ENo30
45-43
33-34
Nm /
ft.lbs.
Removal steps
1.
,++e l +2.
.J ,.
t :. .::,,; 3.
> 4.
I)+ 5.
6.
++ l 47.
l e *a 8.
l * 9.
4* ++ 10.
11.
12.
Nut
Connecting
rod cap
Bearing
Bearing
Piston and connecting
Bolt
No.1 piston ring
No.2 piston ring
Oil ring
Piston pin
Piston
Connecting
rod
rod assembly
NOTE
(2) +*
(3)*4
1 STB Revision
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ENGINE-Piston
9-55
and Connecting Rod
%UWICE POINTS OF REMOVAL

2.
nder
number
DEN050
7.
OF CONNECTING
REMOVAL
NOSTBDAl
ROD CAP
Mark the large end of the connecting

number for use during reassembly.
rod with
REMOVAL
NO.2 PISTON
Remove
OF NO.1
the piston
PISTON
RING/8.
rings with
a piston
the cylinder
?:.
RING
sF
8,
ring expander.
6ENl
Ident.
10. REMOVAL
mark
OF PISTON
PIN
(1) Set piston and connecting

rod assembly
in tool body in such a
way that front mark (arrow mark of piston or identification
mark of connecting
rod) will be faced upward.
(2) Press plates must be used to provide adequate support to the
base during pressing operations.
Ident.
mark
5EN206
(3) Place piston and connecting

rod with arrow mark or identification mark upward over anvil so lip of insert in between
connecting rod boss and inside surface of piston. The connecting~,$~&~~
rod boss should bear on as much of the insert surface a~+%$~.
?l :
possible.
(4) Adjust connecting
rod rear support until rod is horizonta$to
press bed surface.
Misalignment
of pin and receiving tube.::
may result if support adjutment is not correct.
a
(5) Position
ram.
Piston
pin
MD9981
Press
/
/atube
84-01
plates
piston
pin pusher
onto pin and remove
pin with
Caution
As piston pin is removed,
it must pass through
tube.
Check alignment
and adjust if necessary.
press
receiving
,..,,f
,;i:.
lEN603
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9-56
ENGINE
- Piston and Connecting
Rod
INSPECTION
.
NosTcAc1
PISTON
When there are streaks or signs of seizure on the outer suron the thrust side), or if there are
cracks in the outer surface, replace.
Q PISTON PIN
(1) The piston pin should be able to be inserted into the piston
pin hole merely by pushing it in with your finger. If any
resistance is noted or if the pin is loose, replace it.
(2) Piston pins should be replaced as a set.
,face of the piston (especially
PISTON RING
(1) Check for piston ring damage,
the rings if anything unusual
change the piston rings when
(2) Check the clearance between
groove. When it exceeds the
piston, or both.
Piston ring
Standard
No.1 :
No.2 :
Limit
No.1 :
No.2 :
NO9TCBE
wear, and bends, replaceing

is noted. Also be sure to
a new piston is installed.
the piston ring and the ring
limit, replace the rings, the
side clearance
value
0.05-0.09
mm (.0020-.0035
0.02-0.06
mm (.OOOS-.0024
in.)
in.)
0.12 mm (.005 in.)

0.1 mm (.004 in.)
(3) Insert the piston ring into the cylinder bore

against the top of the piston head and pressing
it makes a right angle, measure the piston ring
feeler gauge. When the gap is too large, replace
ring.
Piston ring
6EN031
;.
Piston ring end gap

Standard value
No.1 : 0.30-0.45
mm (.0112-.0177
in.)
No.2 : 0.25-0.40
mm (.0098-.0158
in.)
Oil ring side rail : 0.30-0.80
mm (.0118-.0315
Limit
No.1 : 0.8 mm (.031 in.)
No.2 : 0.8 mm (.031 in.)
Oil ring side rail : 1.0 mm (.039 in.)
/
.,,.
..
.,
i
I
,.
putting it
it in. When
gap with a
the piston
1STB Revision
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in.)
ENGINE
- Piston
l
and
Connecting
9-57
Rod
BEARING
WTCDBl
(1) Visually check the surface of the bearing, replaceing those

which are lopsided, streaked, damaged, or show signs of
seizure. When streaks or seizure are excessive, check the
crankshaft. If damage is discovered on the crankshaft, either replace it or reuse it after undersize machining.
(2) Measure the inner diameter of the connecting rod bearing
and the outer diameter of the crankshaft pin. If the gap (oil
clearance) exceeds limit, replace the bearing, and, if necessary, the crankshaft. Or, undersize machine the crankshaft and replace the bearings with an appropriate undersized type.
Stawdard value : 0.02-0.05
Limit : 0.1 mm (.004 in.)
mm (.OOOS-.0020
in.)
NOTE
For the method by which the oil clearance is measured
using a plastigauge, refer to the item on the crankshaft.
NOSTDAI
10. INSTALLATION
OF PISTON PIN
(1) Thread stop plug approximately
half way into the bottom of
the receiving tube.
(2) Select the largest diameter piston pin guide that will pass
through piston and rod. Install spring, spacer, and guide into
receiving tube.
I EN904
Clearance
lENSO
/ STB
(3) With connecting rod removed from piston, insert piston pin
into piston bore. Carefully measure amount of pin that protrudes equally from both sides of piston. Record this measurement for furture use.
(4) Position connecting rod and piston over the anvil. The spring
loaded piston guide will pass through piston and rod and align
it. Lubricate pin and insert it into piston.
(5) Place piston pin pusher on piston pin and push pin through
connecting rod until the pin protrudes some distance measured and recorded above in step 3.
Caution
The piston must be free to float during installation;
check
frequently.
evision
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.
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,.$
t
!.
i
,,:
1i
v.
e
i.,
9-58
ENGINE-Piston
e certain
s during
the piston
lnstallaton
and Connecting
Rod
(6) Apply hydraulic pressure to pin and adjust stop plug until stop
Plug comes in contact with spacer.
(7) Remove piston and pin assembly from anvil and check piston
pin to make sure it is centered. If it is not centered, adjust stop
plug up or down to obtain proper centering. The pin stop is
now set for any remaining pistons.
Caution
If the required installation
load is out of specification,
replace piston pin and/or connection
rod.
Piston pin press in load : 7350-l 7150 N (1650-38
Ibs.)
9.
rail
ide
QNSTALLATION
OF OIL RING
(1) Assemble the oil ring spacer into the piston ring groove.
Then, after assembling the upper side rail, assemble the
lower side rail. There is no difference between the upper
and lower side rails or spacers.
pacer
5EN062
End of side
(2) The side rail may be easily installed by pushing it in with

your finger after fitting the end over the piston groove.
rail
Caution
Do not use piston
rail.
ring expander
when
installing
side
lEN063
Distinguishing
stamped
mark
8.
1
Barrel
shaped
Distinguishing
stamped
INSTALLATION
RING
OF NO.2 PISTON
Using a piston ring expander,
RING/
7. NO.1
PISTON
install No.2 and No.1 piston ring.
Caution
1. Pay close attention
to the differences
in shape
between nos. 1 and 2 to avoid confusing them.
2. Install piston rings 1 and 2 with the maker and size
marks facing up (toward the top of the piston).
mark
Tapered
lENO64
5.
Side
rail
No.
Timing
side
Piston
spacer
alignment
holes
INSTALLATION
OF PISTON AND CONNECTING
ROD ASSEMBLY
(1) Apply plenty of engine oil to the outer piston surfaces, the
piston ring and the oil ring.
(2) Align the mating holes in the piston and oil rings (side rail,
spacer) as illustrated.
6EN641
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ENGINE-Piston
atnd Connecting
9-59
Rod
(3) Orient the piston and connecting rod assembly so that

front mark on the top of the piston and the front mark
the connecting rod (distinguishing
mark) face toward
front of the engine (the timing belt side) and insert it
the cylinder.
dentification
the
on
the
into
mark
5EN211
2.
White
paint
;
INSTALLATION
OF CONNECTING
ROD CAP
(1) When the connecting rod is installed, make sure that iden-,,;
tification mark and notch are on same side.
-2
Identification
(Front mark)
mark
Notch
(Front
I
mark
5EN201
(2) Check the connecting
rod big end side clearance.
Connecting
Standard
value : 0.1-0.25
mm (.OOSS-.0098
Limit
: 0.4 mm (.016 in.)
1 STB Revision
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in.)
9-60
ENGINE
CRANKSHAFT,
FLYWHEEL
IEMOVAL
Crankshaft,
Flywheel
and
Drive Plate
AND DRIVE PLATE
AND INSTALLATION
NOSIJA-
140 Nm
01 ft.lbs.
130-140 Nm
gF1ol
ft*bs.
18
5EN219
Removal
,
.,
steps
1. Ball bearing
2. Flywheel
3. Ring gear
4. Rear plate
5. Bell housing
cover
L 6. Adapter
plate
4, 7. Drive plate
>- &. Crankshaft
adapter
9. Crankshaft
bushing
10. Rear plate
11. Bell housing
cover
12.
13.
l 4 14.
l * 15.
l 4 16.
l 4 17.
18.
l 4 19.
for vehicles
with manual
transmission
for vehicles
with automatic
transmission
Oil seal case

Oil seal case
Oil separator
Oil seal
Bearing
cap
Lower
bearing
Crankshaft
Upper bearing
gasket
(1) Reverse the removal procddtires

to reinstall.
,I. (2) l + : Refer to Service PointsTof Installation.
.-:;,. (3) q : Non-reusable
parts
:
.:
.--
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ENGINE-Crankshaft,
9-61
Flywheel and Drive Plate
INSPECTION
l
3EN066
Nosucnc
CRANKSHAFT
(1) Check the crankshaft journals and pins for damage, uneven wear and cranks. Also check oil holes for clogging.
Correct or replace any defective part.
(2) ;n;p;;;,
out-of-roundness
and taper of crankshaft journal
Standard value
Cransshaft journal O.D. : 60 mm (2.3622 in.)
Crank pin O.D. : 53 mm (2.0866 in.)
Limit
Out-of-roundness
of journal and pin :
i
0.01 mm (0004 in.)
Taper of journal and pin : 0.01 mm (.0004 in.)
$
MAIN BEARINGS
AND CONNECTING
ROD BEARINGSNosucBA1
:A
Visually inspect each bearing for peeling, melt, seizure and
<,.,,
improper contact. Replace the defective bearings.
NO9UCCDl
OIL CLEARANCE
MEASUREMENT
To check the oil clearance, measure the outside diameter of
the crankshaft journal and the crank pin and the inside diameter of the bearing. The clearance can be obtained by calculating the difference between the measured outside and inside diameters.
Standard value
Crankshaft
main
bearing
: 0.02-0.05
mm
(.OOOS-.0020
Connecting
rod bearing
: 0.02-0.05
(.OOOS-.0020
in.)
mm
in.)
PLASTIGAUGE
METHOD
Plastigauge may be used to measure the clearance.
(1) Remove oil and grease and any other dirt from bearings and
journals.
(2) Cut plastigauge to the same length as the width of the bearing
and place it in parallel with the journal, off oil holes.
6ENO43
(3) Install the crankshaft,

bearings
and caps and tighten them
to the specified
torques.
During this operation,
do NOT
turn the crankshaft.
(4) Remove the caps. Measure
the width of the plastigauge
at
the widest
part by using a scale printed on the plastigauge
sleeve.
(5) If the clearance
exceeds the repair limit, the bearing should
be replaced
or an undersize
bearing
used.
When installing a new crankshaft,
be sure to use standard
size bearings.
(6) Should the standard
clearance
not be obtained
even after
bearing
replacement,
the journal
should
be ground
to
undersize
and a bearing
of the same
size should
be
installed.
1 EN067
*vision
http://vnx.su/
$-, :
Q; ,,,:
+.
9-62
ENGINE-Crankshaft,
.

OIL SEAL
Check front and rear oil seals for damage
any seat that is defective.
RING GEAR (vehicles
with
manual
NO9UCDA
or worn lips. Replace
transmission)
NOWCH: 1
When there is wear, cracks, or other damage to the ring gear

teeth, replace the ring gear by the following procedure. Check
the starter motor pinion.
Ring gear replacement
procedure :
(1) Tap around the ring gear to loosen and remove it from the
fly wheel.
Caution
3EN301
The ring gear cannot be removed while it is hot.

(2) Heat the ring gear to 360-380C
(500-536F)
and put it
into the flywheel
FLYWHEEL (vehicles with manual transmission)
NDSUCWI
(1) Make a visual inspection of the clutch disc. If stepped
wear, streaking, or seizure are apparent, replace it.
(2) If flywheel run out exceeds the limit, replace it.
Limit
DRIVE PLATE (vehicles with automatic

transmissip&s
Replace deformed, damaged, or cracked drive plates.
SERVICE
(for No.1, 2, 4, 5)
: 0.13 mm (.005 in.)
POINTS
OF INSTALLATION
NOSUDAE
19. INSTALLATION
OF UPPER BEARING
When reusing the main bearings, remember to install them by
referring to location marks made at the time of removal.
Be sure oil holes in bearings align with oil hole in block.
17. INSTALLATION
OF LOWER BEARING
Check to ensure that the lower bearing has no oil groove.
[ STB Revision
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ENGINE-Crsnkshaft,
9-63
16. INSTALLATION
OF BEARING
CAP
(1) The caps should be installed with the arrow mark directed
toward the crank pulley side of engine. Cap numbers must
be in correct order.
(2) Tighten cap bolts in sequence : Center, No.2, No.4, front
and rear cap bolts.
(3) Cap bolts should be tightened
evenly in 2 to 3 stages
before they are finally tightened.
(4) Make certain that crankshaft turns freely and has the
proper clearance between the center main bearing thrust
flange and the connecting rod big end bearing.
Standard value : 0.05-0.18
Limit : 0.4 mm (.016 in.)
M B990938-0
mm (.0020-.0071
in.)
15. INSTALLATION
OF OIL SEAL
Using Special Tool, press fit the oil seal all the way in without
tilting it.
Oil seal
MD998376-01
/
Timing
Oil seal
case
chain
case
011 separator
i4
t
$ltiyc;
mounting
5~~140
14. INSTALLATION
OF OIL SEPARATOR
Press the oil separator into the oil seal case. Install it so that
the separator oil hole is on the very bottom, as illustrated.
mm
(1575
in.)
dia. oil hole
6EN048
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.
,*
,
.
9-64
ENGINE-Cylinder
Block
CYLINDER BLOCK
REMOVAL
50-60
37-43
NOSVA-A
AND INSTALLATION
Nm
ft.lbs.
6
\
8-12 Nm
6-8 ftlbs.
/
4-6
4-5
Nm
ftlbs.
5EN210
50-6b
37-43
1.
2.
3.
4.
5.
l * l +6.
Right engine support bracket

Left engine support bracket
Silent shaft chamber cover
Chamber cover gasket
Cylinder block
Oil pressure switch
NOTE
(1) 4*
(2) **
Nm
ftlbs.
: Refer to Service
: Refer to Service
Points of Removal.
Points of Installation.
SERVICE POINTS OF REMOVAL

6.
REMOVAL
OF OIL PRESSURE
NOSWAD
SWITCH
As sealant has been applied to the screw, remove it without

bending it.
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9-65
INSPIECTION
l
Measuring
NO9VCAD
Visually check the cylinder block for scores, rust and corrosion.
Also check for cracks or any other defects by using a flaw
detecting agent (magnafluxing).
Correct or replace the block if
defective.
Measure the cylinder bore with a cylinder gauge at three levels
in the directions of A and B.
If the cylinder bores show more than specified out-of-round or
taper, or if the cylinder walls are badly scuffed or scored, the
cylinder block should be rebored and honed, and new oversize
pistons and rings fitted.
points are as shown.
Standard value
Cylinder bore : 91.1 mm (3.5866 in.)
Out-of-roundness
and taper of cylinder bore :
Max. 0.02 mm (0008 in.)
If cylinder top ridge is worn in stages, cut away with ridge
reamer.
Oversize pistons are available in four sizes.
6EN66:
-;
i.1.
i,:.
!;
;
a;
Piston service size and mark

6.25 mm (.OlO in.) O.S.: 0.25
0.50 mm (020 in.) O.S.: 0.50
0.75 mm (030 in.) O.S.: 0.75
1.00 mm (039 in.) O.S.: 1.00
To rebore the cylinder bore to oversize, keep the specified
clearance between the oversize piston and the bore, and make
sure that all pistons used are of the same oversize. The standard measurement
of the piston outside diameter is taken at
a level 2 mm t.0787 in.) above the bottom of the piston skirt
and across the thrust faces.
Standard value
Piston-to-cylinder
I.
r!;..
,:
wall clearance
: 0.02-0.04
mm
(.OOOS-.OOlS in.)
Check for damage and cracks.

Check too surface for flatness. If excessive flatness is evident
grind to minimum
limit or replace.
Flatness of gasket surface
Standard dimension
: Less than 0.05 mm
Limit : 0.1 mm (.0039 in.)
Overall height
Standard value : 316 mm (12.4409 in.)
Limit (amount
of cylinder block
gasket surface grind) : -0.2 mm
(.0020 in.)
( - .0079
t
.,/ L
t,
in.)
Caution
._ _
The cylinder block gasket surface should be ground to
within 0.2 mm (0079 in.) even with the grind of cylinder
head gasket surface.
1 STB Revision
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9-66
ENGINE-Winder
Block
NOSVEDA
BORING THE CYLINDER
(1) Based on the largest cylinder bore, determine
the over sized
piston to be used.
(2) Measure with the outside diameter of the piston as the datum
measurement
points.
6EN05
NOTE
There are four sizes of oversize piston: 0.25 mm (.OlO in.),
0.50 mm (.020 in.), 0.75 mm (.030 in.), 1.00 mm LO39 in.)
(3) Calculate the reground bore size based on the measured value
of the outside piston diameter.
l
Bore size = outside piston diameter
+ 0.01-0.03
mm
In. ) (gap between cylinder and piston) - 0.02
(.0004-.0012
mm (1.0008 in.) (honing)
(4) Hone each of the cylinders to the calculated measurement.
Caution
In order to avoid uneven boring due to the rise in temperature, bore the cylinders
in the following
sequence:
#2,
#4, #l, and #3.
(5) Hone the cylinders, finishing them to the proper dimension
(outside piston diameter + gap with cylinder).
(6) Check the gap between the piston and cylinder.
Standard
value
: 0.01-0.03
mm (.0004-.0012

6.
in.)
NWVDAF
INSTALLATION
OF OIL PRESSURE
SWITCH
Apply sealant to the screws and install.
Specified
sealant
/
:
Caution
Ensure that the sealant dose not extend beyond
tips.
Be sure not to tighten the screws too tight.
STB Revision
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the screw
14-1
CONTENTS
ENGINE
CONTROL
ACCELERATOR
FBC SYSTEM
. . .. .. . .. . . .. .. . .. . .. ...m...... 84
CABLE AND PEDAL
. .. . . . . . . .. . 84
. . .. .. . .. . ..*............................
CARBURETOR
. .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . .. . .
FBC SYSTEM DIAGRAM
. . . . . . . . . . .. .. .. . . . . . . . . . .. .. . .
FUEL LINE AND VAPOR LINE .. . . . . . . . . . . . . . .. .. . . . .
FUEL PUMP
. . . . . . . .. .. . . . . . . .. . . . . . . .. .. . . . . . . . . . . . .. .. .. . . . . . .
FUEL TANK . . . . . . .. . . . . . . . . .. .. . . . . . . .. .. .. . . . . . . . . . . . .. .. . . . . . .
INSPECTION
OF FBC SYSTEM
. . . . . ..a.............
Cautions on Inspection
..............................
Circuit Diagrams
.........................................
Components
Locations and Vacuum
Hoses Layout .............................................
Inspection of Throttle Opener Control
System for Air Conditioner
Load ................
INSPECTION
OF FBC SYSTEM
COMPONENTS
..............................................
Checking the Vacuum Switch ....................
Inspection of Engine Coolant
Temperature
Sensor ..................................
Inspection of Engine Speed Sensor
(Ignition Coil Terminal)
...............................
Inspection of Oxygen Sensor ....................
Inspection of Throttle Opener Control
Solenoid Valve for Air Conditioner
.............
Inspection of Throttle Position
Sensor (TPS) ...............................................
Simple Inspection of Feedback Solenoid
Valve (FBCV) ...............................................
Simple Inspection
of Slow Cut Solenoid
Valve (SCSV) .I.. ...........................................
SERVICE ADJVSTMENT
PROCEDURES
......
Carburetor External View ...........................
Checking the Auxiliary Acceleration
Pump
(AAP) ...........................................................
Checking the Therm0 Valve
(for AAP Control)
........................................
Idle Speed Adjustment
..............................
Idle Speed and Mixture Adjustment
..........
Idle Speed Check Procedure
.....................
Inspection and Adjustment
of Choke
Breaker Opening
........................................
of Dash Pot ....
of Fast Idle .....
6
61
6
82
77
80
43
43
44
46
53
57
58
57
58
58
59
57
59
59
25
25
41
42
26
26
26
Inspection of Carburetor Acceleration

Pump ..........................................................
Inspection of Carburetor Bleed Air Passage
for Clogging (Inspection of Carburetor High
Altitude Compensation
System)
................
Inspection
of Carburetor
Secondary Valve
Operation
...................................................
Inspection of Choke Breaker System
........
Inspection of Choke Valve .........................
Inspection of Distributor Advance Control
Vacuum (D Vacuum)
..................................
Inspection of EGR Valve Control
Vacuum (E Vacuum)
...................................
Inspection of Electric Choke ......................
Inspection of Electric Choke Relay ............
Inspection of Vacuum Switch Control
Vacuum (F Vacuum)
...................................
Inspection of VRV Control Vacuum
(A Vacuum)
.................................................
Replacement
of Fuel Filter .........................
Throttle Opener Adjustment
for Air Conditioner
......................................
Throttle Position Sensor (TPS)
Adjustment
................................................
SPECIAL TOOLS
............................................
TECHNICAL
DESCRIPTION
...........................
Component
of FBC System
......... .~............
Operation of the FBC System
....................
TROUBLESHOOTING
....................................
Carburetor
..................................................
Control Functions Table .............................
Fuel Tank and Fuel Line .............................
FUEL SYSTEM
...v.....m...m.........................
GENERAL INFORMATION
.............................
SPECIFICATIONS
...........................................
...............................
Lubricant
....................................................
.............................
................................
................................
39
30
40
http://vnx.su/
35
33
34
38
35
30
31
35
36
32
32
42
28
28
24
9
9
13
20
20
23
24
.
:
2
2
3
3
5
5
4
5
..
14-2
FUEL SYSTEM
GENERAL
- General
Information
INFORMATION
N14BA-
The fuel system consists of the fuel tank, the fuel lines (within the fuel return line), the vacuum
fuel pump, the fuel filter, and the carburetor.
The engine
control
is the suspended
type,
and is operated
by the accelerator
pedal
lines, the
and accelerator
cable.
The FBC (Feedback Carburetor) system is a system which functions to regulate the air/fuel mixture ratio.
Input signals from the various sensors enable the electronic
control unit (ECU) to determine
the
operating conditions
of the engine, and, depending
on the operating conditions,
the air/fuel mixture ratio
is regulated by the two solenoid valves (the feedback solenoid valve and the slow cut-off solenoid valve)
equipped
at the carburetor.
The ECU also functions
to control the electric choke, the throttle
opener, etc
3
Feedback solenoid
valve
Fuel pump
t
valve
__----_
Fuel tank
iEngine speed
Throttle position
Oxygen
Engine coolant temperature
sensor
sensor 2
sensor
sensor
ECU
012505
) ,STB Revision
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14-3
FUEL SYSTEM - Specifications
SPECIFICATIONS
GENERAL
SPECIFICATIONS
N14CA-
Specifications
Items
Qel
Fu.el tank capacity
lit. (U.S.gal., Imp.gal.)
60 (15.9, 132)
Fuel return system
Provided
Fuel filter
Cartridge type
%el pump
Mechanical
Type
Drive by
diaphragm
type
Camshaft
Discharge
pressure
19.6-29.4
kPa (psi)
(2.84.2)
- 2500 rpm
zarburetor
Down-draft,
2-barrel feedback
Type
Choke type
Automatic
Heater
PTC heater
Identification
(electric type)
model No.
for Federal
32-35 DIDEF -410 : M/-T

32-35 DIDEF -411 : A/T
for California
32-35 DIDEF 412 : M/T

32-35 DIDEF -413 : A/T
Throttle
mm (in.)
bore - primary
secondary
Feedback
mm (in.)
32 (1.26)
35 (1.38)
Duty cycle solenoid
Duty cycle solenoid
solenoid valve (FBSV)
Slow cut solenoid valve (SCSV)

Throttle operer
Diaphragm
Dash pot
Conventional
Throttle position senser (TPS)

Bowl vent valve (BW)
Variable resister
Mixture control valve (MCV)
Vacuum type : M/T only
Electronic
type
type
type
Vacuum type
control unit for FBC
Identification
model No.
for Federal
E2T55071 : M/T
E2T55075 : AIT
for California
E2T55071
E2T55075
: M/T
: A/T
Thermistor
type
Input sensors
Coolant temperature
Oxygen sensor
sensor
Zirconia sensor
Control-type
Vacuum switch
Output actuators
Secondary air control solenoid valve
Throttle opener control solenoid valve
switch
ON-OFF
Solenoid valve
ON-OFF
Solenoid valve
NOTE
M/T : Manual transmission
ATT : Automatic transmission
) STB Revision
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type
14-4
FUEL
SERVICE
SYSTEM
- Specifications
SPECIFICATIONS
NMCB-
Specifications
Items
Standard value
Engine adjustments
7+ 2 BTDC at curb idle
Besic ignition timing

Actual ignition timig at high altitude-All
altitude), California
Curb idle speed for M/T
wm
For the first 500 km (300 miles)
Approx.
U.S.A. (high
12 BTDC
725+ I50
-100
800 + 100
After 500 km (300 miles)

Curb idle speed for AA
wm
For the first 500 km (300 miles)
725+15
-100
800 -+ 100
After 500 km (300 miles)

Throttle opener adjustment
Rpm for air conditioner load
(when air conditioner ON)
Dash pot touch rpm
900-950
rpm
rpm
2000
1500
for M/T
for A/T
Throttle-position
sensor (TPS)
Adjustment voltage (throttle valve completely
closed)
0.25
Carburetor
Main jet - primary
# 107.5
secondary
Pilot jet - primary
# 190
# 55
secondary
Enrichment
# 70
# 65
Continuity-approx. 6 fl [at 20C (68PF)l
jet
Automatic choke heater

Choke breaker opening degree
mm (in.)
1st stage
2nd stage
2.5-2.7(.098-.ld6)
3.2-3.4(.126-,133)
mm (in.)
First idle rpm

MIT
vm
AIT
rpm
Approx. 2,350 .
Approx. 2,300
(no load, after warm-up, 2nd stage)
Feedback solenoid valve (FBSV) coil resistance

Slow cut-off solenoid valve (SCSV) coil resistance
Throttle-position sensor (TPS) resistance
54-66 [at 20C (68F)I
R
R
kR
4860 [at 20C (68F)I

3.5-6.5
Input sensor
Coolant temperature sensor resistance
kR
20C (68F)
2.5
80C (176F)
0.3
Oxygen sensor output voltage
Approx. 1
ON more than 40 kPa (5.8 psi)
OFF less than 26 kPa (3.9 psi)
Vacuum switch
NOTE
M/T : ,Manual transmission
A/T : Automatic transmission
1 STB Revision
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14-5
FUEL SYSTEM - Specifications

Specifications
Items
Output actuator
38 - 44 [2oC (68F)]
Secondary air solenoid valve resistance

R
Throttle opener control solenoid valve resistance
38 - 44 [2oC (68F)]
NMCC-
Nm
ft.lbs.
bolt
15-20
11-14
sensor
20-40
14-29
40-50
29-36
2,5 ~ 4,5
I,8 - 3,2
Therm0 valve (2 nipples)
20-35
Drain plug
Fuel tank to body
15-25
25-30
14-25
II-18
Fuel gauge unit

Air cleaner to rocker cover
1
16- 19
Items
Carburetor
installation
Coolant temperature
Oxygen sensor
Throttle-position
sensor
installation
screw
18-22
0.7
12-14
LUBRICANT
N14CD-
Specified
Item
Grease for accelerator
spring
SEALANTS
arm piri and return
lubricant
Multipurpose grease
SAE J310, NLGI No. 3
Quantity
As required
AND ADHESIVES
N14CE-
Specified
Items
Therm0 valve threads
Coolant temperature
sensor threads
sealant and adhesive
Quantity
3M Adhesive Nut Locking

No. 4171 or equivalent
As required

As required
/ STB Revision
,&
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14-6
FBC SYSTEM
- FBC System
Diagram
FBC SYSTEM DIAGRAM

VEHICLES
FOR THE
49 STATES
ALTITUDE
SPECIFICATIONS)
OTHER
THAN
( ST6 Revision
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CALIFORNIA
(EXCLUDlNG
HIGH-
FBC SYSTEM
FBC SYSTEM
- FBC System
14-7
Diagram
DIAGRAM
VEHICLES WITH HIGH-ALTITUDE

CALIFORNIA
SPECIFICATIONS
FOR THE 49 STATES OTHER THAN
r--
3-
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14-8
FBC SYSTEM
- FBC System
FBC SYSTEM DIAGRAM

VEHICLES
FOR CALIFORNIA
I STB Revision
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Diagram
FBC SYS
- Technical
14-9
Description
TECHNICAL DESCRIPTION
COMPONENT
Installation hole
Terminal
2 Terminal
Nl4EBAA
OF FBC SYSTEM
ENGINE COOLANT TEMPERATURE

SENSOR
The engine coolant temperature
sensor installed in the engine
coolant passage of the intake manifold is a resistor-based sensor.
The ECU judges engine warm-up state by the sensor output voltage and make a control to provide optimum fuel enrichment when
the engine is cold.
N14BBBA
THROTTLE
POSITION
SENSOR (TPS)
The TPS is a rotation type variable resistor that rotates together
with the carburetor throttle shaft to sense the throttle valve angle.
As the throttle shaft rotates, the TPS output voltage changes and
the ECU detects the throttle valve opening based on the change of
the voltage.
Using the TPS output signal, engine speed signal and other signals, the ECU judges the engine operating mode and controls the
air-fuel ratio, etc. for an optimum air-fuel mixture in that mode.
Throttle shaft
N14BBNC
ENGINE SPEED SENSOR (IGNITION
COIL MEGATIVE
TERMINAL
VOLTAGE SENSOR)
The ignition coil negative terminal voltage makes sudden increase twice per crankshaft revolution synchronously
with ignition timing.
By sensing this ignition coil negative terminal voltage change and measuring the time between peak v,oltages, the
ECU computes the engine speed, judges the engine operating mode and controls the air-fuel ratio.
Ignition switch
Ignition coil
Low rpm
High rpm
One revolution
l-=--i
I ______
------J
A7
of
w
Time
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14-10
FBC SYSTEM
Stoicbiometric
- Technical
Description
OXGENSENSOR
The oxygen sensor installed on the exhaust manifold makes use of
the principles of solid electrolyte oxygen concentration
cell. The
oxygen concentration
cell is characterized by sharp change of the
output voltage in the vicinity of the stoicbiometric
air-fuel ratio.
air-fuel ratio
5
tI/
Lean
13
l6 EC1007 ,
14Air-fuel n tid5
Stoicbiometric
air-fuel ratio
Using such characteristics, the oxygen sensor senses the oxygen

concentration in the exhaust gas and feeds it to the ECU. The ECU
then judges if the air-fuel ratio is richer or leaner as compared to
the stoicbiometric
ratio and provides feedback control to adjust
the air-fuel ratio to the stoicbiometric
ratio where the emission
purification rate of the three-catalyst converter is the optimum.
012513
element
-dil&q
Conenctor
03EW
Nl400KA
VACUUM
SWITCH
The vacuum switch is a contact type switch that is operated by
intake manifold vacuum. When the throttle valve closes, the intake
manifold vacuum acts on the vacuum switch to close its contact.
By this action, the voltage on the ECU side is grounded and the
ECU senses that the throttle valve opening is near the idle opening.
012518
Intake manifold vacuum

-
Filter
Contact
3EMO62
pm
,evision
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FBC
Control
SYSTEM
rod
IFU219
Duty
100
msec
ratio:
- Technical
14-11
Description
FEEDBACK SOLENOID
VALVE (FBSV)
N14BCAA
The FBSV is installed on the carburetor float chamber cover.
The ECU controls the air-fuel ratio by controlling the duty cycle of
the FBSV.
The higher is the duty ratio, the leaner becomes the air-fuel ratio.
NOTE
The duty cycle control means control of the solenoid valve energization rate by changing the ON time ratio T/T, (called duty ratio)
of 10 Hz pulse.
T,/T,
100 msec
16ZlOOi
N14BCBA
SLOW CUT SOLENOID
VALVE (SCSV)
The SCSV is installed on the carburetor float chamber cover.
The ECU controls the carburetor slow system fuel flow by controlling the duty cycle of the SCSV.
IG.SW.
012519
THROlTLE
OPENER CONTROL
SOLENOID
VALVE
N14BCIC
Refer to section Throttle
opener system for air Conditioning
system on page 14-14.
ELECTRIC
CHOKE RELAY
Refer to section Carburetor
14-18.
electric
choke
system.
on page
SECONDARY
AIR CONTROL
SOLENOID
VALVE
N14BCJA
CONTROL SYSTEM-Secondary
air supply system.
1 STB Revision
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:,
4,_
14-12
FBC SYSTEM
- Technical
Description
ELECTRONIC
CONTROL
UNIT (ECU)
Based on the information
from various sensors, the ECU determines
(computes)
operating conditions constantly and accordingly drives the output actuators.
The ECU consists of an 8-bit microprocessor,
random access memory (RAM),
input/output
(I/O) interface.
N14BBDAA
an optimum
control for varying
read only memory
(ROM)
IFU350
Connector
Connector
.
// > )
,
A//
c.:
cI.7\
5FUl
ECU Connector
I/O Pin Composition
1. Oxygen sensor
2. Ground for sensor
3. Power supply for sensor
4. 5. Vacuum switch
6. Ground
7. Power supply
8. Power supply
9. Power supply for back-up
10. Engine speed sensor (Ignition coil negative
11. Ground
12. Coolant temperature
sensor
13. Throttle position sensor (TPS)
Pat-t No.
Model
Nc
/
0
L
/
0
5FUl
51.
52.
53.
54.
55.
56.
57.
58.
59.
Slow cut solenoid valve

Secondary air control solenoid valve
Electric choke relay
Air conditioner relay
Feedback solenoid valve
( ST6 Revision
http://vnx.su/
terminal)
and
FBC SYSTEM
Technical
OPERATION
Jet v
Throttle
position
Oxygen
density-J
Coolant
temperatures
-J
lFU213
OF THE FBC SYSTEM
Nl4BEM
AIR-FUEL RATIO CONTROL SYSTEM

The air-fuel ratio control is achieved by the following two kinds of
control.
Closed Loop Control (Feedback Control)
In the ordinary operating region after engine warm-up, the air-fuel
ratio control is made by the feedback control based on the oxygen
sensor signal.
The oxygen sensor has such characteristics that its output voltage
changes sharply at the stoicbiometric
ratio. The control unit
senses this oxygen sensor signal and accordingly provides feedback control of the FBSV duty ratio so that the stoicbiometric
ratio
that will give the best purification rate of the 3-catalyst converter
may be accurately kept. In this state, the SCSV is kept wide open
(100% duty).
Open Loop Control (No Feedback Control)
During engine start, warm-up operation, high load operation and
deceleration,
the air-fuel ratio is open-loop controlled by the map
values* established
previously for engine speed, throttle valve
opening angle and engine coolant temperature,
to improve startability and driveability. During deceleration,
the control on SCSV
limits fuel flow for better fuel economy and for prevention of
overheating of ,the catalysts.
* Map value is a value previously
in ECU.
established
and stored in ROM
When the FBSV is energized, the main fuel jet is closed to leave
the priman/ main jet passage as the only fuel passage. This will
reduce the amount of fuel, resulting in leaner air-fuel mixture.
To ECU
FBSV
14-13
Description
,!
i:
Priman/
main
iet
lFU21
When FBSV is de-enrgized, the main fuel jet is opened to provide

two fuel passages including the primary main jet passage. Since
this will increase the amount of fuel, richer air-fuel mixture is
obtained.
With the ON-OFF
operation of SCSV, the slow fuel passage is
opened and closed.
The air-fuel ratio at deceleration
is controlled in this manner.
SECONDARY
AIR CONTROL
SYSTEM
N14BHAA
CONTROL
SYSTEM-Secondary
air supply system.
1 STB Revision
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14-14
THROlTLE
FBC SYSTEM
OPENER
SYSTEM
- Technical
Description
FOR AIR CONDITIONING
NlUUBB
Solenoid valve (Operated)

?$s+
,,,eno/d
Cnl
Electrical load switch

(lighting, defogger.
hlm.m.
c\.,;t,.h\
kt%
manifold
valve (not operated)
=~~r--!rnai;ld
/\
11
Throttle opener
setting screw
/
Engine speed sensor
switch
swlfcn
SAS3
Battery
?
Throttle opener lever
When the engine speed is below the set speed (1,450 rpm), the ECU
when the air conditioner relay is turned on (the air compressor is driven
solenoid valve is energized to introduce intake manifold vacuum to the
slightly, preventing engine speed drop that would otherwise be caused
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keeps the power transistor on. Therefore,

by the engine), the throttle opener control
throttle opener to open the throttle valve
by air conditioner load.
FBC SYSTEM
4RBURETOR
ELECTRIC
CHOKE
- Technical
SYSTEM
Nl4WBB
Choke
:hoke
14-15
Description
breaker
valve
IFU359
Intake
manifold
vacuum
IFU399
Auto
choke
relay
(ON)
Auto
Engine
speed
Engine
coolant
sensor
temperature
sensor
heater
choke
IFU399
In carburetor
electric choke system, a bimetal which is heated by
an electric heater (PTC heater*) operates the choke valve and fast
idle cam for proper engine warm-up
control.
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14-16
FBC SYSTEM
- Technical
Description
The lower the temperature

when the engine is started, the tighten
the bimetal closes the choke valve, thus improving startability at
cold weather.
As the engine is heated by the heater after start up, the bimetal
opens the choke valve gradually by thermal expansion and pushes
down the stopper lever.
NOTE
PTC stands for Positive Temperature
Coefficient
and the
heater means a heater with positive temperature
coefficient.
Namely, as the heater generates heat, its resistance
increases
hence limits the current to control heat generation.
Chole
1.
Choke
Choke
lever
Valve
and
and Fast Idle Cam Operation
Before starting the engine,

idle opening state.
valve
Bimetal
Thiottle
PTC
valve
lFU371
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the throttle
valve is in the normal
FBC SYSTEM
- Technical
2.
3.
Contraction
Description
14-17
Before starting the engine, depress the accelerator pedal to

the floor, and the fast idle cam will turn clockwise. Release the
accelerator pedal, and the lever will ride on the fast idle cam
and the throttle valve will open.
When the engine starts, the intake manifold vacuum is applied
to the choke breaker to slightly open the choke valve, preventing formation of a too rich mixture of air and fuel.
1 FU361
4.
Shortly after starting of

heater and expands to
push down the stopper
At this time, the engine
engine, the bimetal is heated by the

open the choke valve gradually and
lever.
speed increase gradually.
5.
Depress the accelerator pedal, and the fast idle cam will turn
counter-clockwise.
Release the accelerator pedal and the lever
will ride on the lower cam of fast idle cam and the throttle
valve will close slightly, decreasing the engine speed. After
warming up the engine for a while, depress the accelerator
pedal and the throttle valve will be further closed.
By repeating this procedure, the fast idle cam is released and
the throttle valve comes to have a normal idle opening.
1 FU362
Expansion
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14-18
FBC SYSTEUVI - Technical
Descrbtion
Operation of Choke Opener
(Vacuum is created
when coolant temperature
exceeds a certain value.)
If the engine has been started with the throttle valve lever on the
highest fast idle cam detent and left as it is, then the engine speed
increases with the engine coolant temperature
rises, and finally
the engine overruns. In order to prevent such overrun, the choke
opener is provided.
1. When the therm0 valve closes as the engine coolant temperature rises ]65C (149F)], the intake manifold vacuum acts on
the fast idle breaker.
2. The fast idle breaker forces the fast idle cam to turn counterclockwise so that the lever will rest on the lowest cam, closing
the throttle valve to decrease the engine speed.
Choke opener
(Faced fast
idle release)
lFU451
Electric Choke Relay

The electric choke relay is normally closed (ON) and it opens when
its coil is energized.
During engine cranking the ECU turns on the power transistor to
energize the electric choke relay coil. This prevents heating of the
electric choke heater, improving engine startability.
Auto choke heater
1 FU358
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FBC SYSTEM
-Thermovalve
- Technical
Description
14-19
N140TM
Auxiliary Accelerator
Pump (AAP)
The Auxiliary Accelerator Pump is provided to improve driveability
while the engine is still cold. AAP is controlled by a thermo-valve
and intake manifold vacuum and operates in the high load range
while the coolant temperature
is low (approx. 45C/113F).
The thermo-valve
is of the bi-metal type and is mounted on the
intake manifold. The valve opens when the engine coolant temperature is below 45C (113F) and allows the manifold vacuum to
affect AAP chamber [A]. The valve closes when the coolant temperature exceeds 45C (113F) to shut off the manifold vacuum
and stop the operation of the AAP.
The manifold vacuum operates on AAP chamber [Al. When the
diaphragm moves to the right, the fuel pushes check valve 1 open,
flows into and fills chamber [B]. When the throttle valve opens
quickly and the vacuum in chamber [A] lowers, the diaphragm is
pushed to the left by spring pressure. As a result, the fuel in
chamber [B] pushes open check valve 2 and jets into the carburetor, enriching the fuel mixture.
3FU223
A J Manifold
vacuum
With AAP
operating
3FU22d
3FU22:
NllBJAA
The dash pot delays closing of the throttle valve when it closes
from the set opening to the idle opening. This delay absorbs shock
at the time of deceleration for better driving comfort.
Throttle opkner\
)u
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14-20
FBC SYSTEM
- Troubleshooting
TROUBLESHOOTING
N14EBM
When checking and correcting engine troubles, it is important to start with inspection of the basic systems. In case
you have such troubles as (1) engine start failure, (2) unstable idling or (3) poor acceleration,
therefore,
you should
first check the following
basic systems.
(1) Power supply
l
Battery
l
Fusible link
l
Fuse
(2) Body ground

(3) Fuel supply
l
Fuel line
l
Fuel filter
l
Fuel pump
(4) Ignition
system
Spark plug
High-tension
Distributor
Ignition
cable
coil
(5) Emission control system

0 PCV system
l
EGR system
l
Vacuum leak
(6) Others
0
l
Troubles
to check
Ignition timing
Idle speed
with the FBC system are often caused
harness connector
contact.
by poor contact
of harness
connector.
It is, therefore,
important
ZARBURETOR
Symptom
Probable cause

stat-t to hard (cranks
OK)
Carburetor
Choke valve remains open-cold
Improper
Remedy
engine
choke breaker operation
Check electric choke

choke valve operation
Needle valve sticking or clogged
body
1 14-38
and
14-35
1 Repair and replace
sensor
malfunc-
Check by using checker

(Check component
and replace
faulty)
( 14-66
14-57
if
Vacuum hose disconnected or damaqed

Slow-cut solenoid valve malfunction
1 Repair or replace
1 14-49
1 Check component
1 14-59
Feedback solenoid valve malfunction
1 Check component
11 Check comoonent
I 14-59
1, 14-58
1 Replace
Repair or replace
I 14-53
-
Vacuum switch
malfunction-cold
enaine
Faulty ECU
Harness broken/short circuited or connector
not connected securely
Rough idle or evgine
stalls
Clean choke bore and link

) Check and adjust choke breaker
Electric choke malfunction
FBC system
tion
Reference
paae
14-69
Carburetor
Choke valve malfunction
Improper fast idle-cold
14-69
engine
Improper idle adjustment

1 Adjust fast idle speed

Adjust idle speed
Check choke body and choke valve
operation
Clean up or replace
Primary pilot jet clogged

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I 14-40
14-26
14-35
14-68
14-21
FBC SYSTEM-Troubleshooting
Qmptom
iough
tails
Probable
idle or engine
Remedy
cause
Adjust
Dash pot malfunciton

=BC system
Slow-cut solenoid
Engine coolant
malfunction
14-59
valve malfunction
temperature
Vacuum
hose disconnected
Throttle
position
Engine
Throttle
speed
sensor
sensor
opener
or
or damaged
or connector
pump
malfunction
14-49
and adjust
14-28

Check harnesses for continuity
Check system.
If faulty, check
components
14-58
Repair or replace
Check pump
Choke valve remains
open-cold
Choke valve remains
closed-hot
14-28
engine
engine
valve faulty
discharge
rate

Check choke valve operation
14-69
.I 4-68
Repair or replace
Main jet clogged
Clean up
14-68
Enrichment
Clean up
14-68
Check valve operation
14-36
Secondary
jet clogged
valve operation
Auxiliary acceleration
-cold engine
FBC system
Feedback solenoid
Vacuum
Engine
tion
Throttle
Engine
abnormal
pump
malfunction
coolant
temperature
speed
Check pump
discharge
rate
Check
drive
signal
checker.
Check component
by
14-41
14-59
switch
position
malfunction
valve malfunction
sensor
sensor
using

(Check
component
and replace if faulty)
sensor
malfunc-
malfunction
malfunction
Harness broken/short-circuited
not connected
properly
Engine dieseling (runs
after ignition switch is
:urned off)
malfunction
14-57
if
Repair or replace
Check component
malfunction
system
using

(Check component
and replace
faulty)
malfunction
control
by
14-35
Carburetor
Acceleration
Enrichment
Check
drive
signal
checker.
Check component
sensor
Harness broken/short-circuited
not connected
securely
Ingine
hesitates
)oor acceleration
Reference
paw
14-30
or connector

(Check componfent
and replace
faulty)
Check component
and adjust
14-58
14-57
if
14-28

Check harnesses for continuity
14-58
Repair or replace
Carburetor
Engine idle speed
too high
Adjust
14-26
FBC system
Slow cut solenoid
valve malfunction
Check component
idle speed
14-59
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14-22
FBC SYSTEM-Troubleshooting
Symptom
Probable cause
Remedy
Reference
paw
14-69
Poor fuel mileage
Carburetor
Choke valve operation abnormal
Check valve operation
Engine idle speed too high

Adjust idle speed

Check choke body and valve oper-
Enrichment valve kept open
Repair or replace
Auxiliary acceleration
-hot engine
Repair or replace
pump is in operation
FBC system
tion
sensor malfunc-
Oxygen sensor malfunction
Feedback solenoid valve malfunction
Slow-cut
solenoid valve malfunction
14-26
14-35
1 14-68
Check by using checker (Check

component and replace if faultv)
14-58
(Check component and replace if
faulty)
I
Check
drive
signal by using
14-40
checker
Check component
I
($e$er
drive
signal
by
using
Check comoonents
Check comoonent

check harnesses for continuitv
14-58
Harness broken/short circuited or connector

not connected properly
Repair or replace
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and adiust
1 14-28
Throttle position sensor malfunction

Engine speed sensor malfunction
1
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FUNCTIONS
solenoid valve (SCSV)
Slow-cut
Secondary
Throttle
control
no direct relation to the control units control functions
air control solenoid valve

(for air conditioner load)
solenoid valve (FBSV)
switch
Feedback
Air conditioner
Vacuum switch
sensor
sensor (TPS)
Oxygen sensor
Engine-speed
Throttle-position
sensor
Coolant temperature
Air/fuel mixture
ratio control (FBC)
interlock)
Function
Power supply (battery back-up)
NOTE
The * symbol indicates
output
Input
TABLE
Power supply (ignition switch
Related components
CONTROL
*X
opener
Electric choke
relay control
Secondary
control
air
GROUP 25
EMISSION
CONTROL SYSTEtv
14-36
14-59
14-59
14-59
GROUP 24
HEATERS AND
AIR-CONDITIONIN(
14-58
14-58
14-58
14-57
14-57
Individual unit
description (page)
14-24
FBC SYSTEM -Troubleshooting
/ Special
Tools
FUEL TANK AND FUEL LINE
N14EAAA
Symptom
Probable cause
Remedy
Reference
paw
Engine malfunctions
due to insufficient
fuel supply
Bent or kinked fuel pipe or hose
Repair or replace
Clogged fuel pipe or hose
Clean or replace
Clogged fuel filter or in-tank fuel filter
Replace
14-80
Water in fuel filter
Evaporative emission
control system
nalfunctions
(When
tank cap is removed,
oressure releasing
noise is heard)
Replace the fuel filter or clean

, the fuel tank and fuel line
Dirty or rusted fuel tank interior
Clean or replace
Malfunctioning
fuel pump
(Clogged filter in the pump)
Replace
14-77
Mispiping
Correct
14-82
Correct
14-82,83
Replace
14-82,83
Faulty fuel tnak cap
Replace
Malfunctioning
overfill limiter
(two-way valve)
Replace
14-81
of vapor line
Disconnect
vapor line piping joint
Folded, bent, cracked
or clogged vapor line
SPECIAL TOOLS
Tool (Number
N14DA..
and name)
Use
Tool (Number
and name)
M D998406
ECI checker
Diagnosis and inspection for ECI system

and FBC system
MD 998438
Harness connector
M D998474
Harness connector
(&pin, square)
Adiustment
for FBC
of TPS
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Use
Inspection for FBC
system
Use with MD998406
FBC SYSTEM
SERVICE
ADJUSTMENT
CARBURETOR
EXTERNAL
- Service
Adjustment
14-25
Procedures
PROCEDURES
VIEW
N14FJ-.
Mixture
control
Air nipple
2-stage choke breaker

Depression
chamber
Electrical auto-choke
Jet air nipple
pump
WP)
View B
Secondary well
bleed nipple
I
A
5FU121
5FU120
Throttle position sensor (TPS)
View C
5FUlU
Feedback solenoid valve (FBSV)
Slow cut solenoid valve (SCSV)
Throttle openerDashpot
Accelerator
pump
Vacuum nipple A (WV) / \

Vacuum nipple D (distributor)
E\nrichment
,Vacuum nipple E (EGR valve)
View A
5FU122
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14-26
FBC SYSTEM-Service
Adiustment Procedures
IDLE SPEED CHECK
PROCEDURE
Refer to GROUP 0 LUBRICATION

ing and adjustment
of the idling
N14FHAA
AND MINTENANCE-Checkrpm
IDLE SPEED ADJUSTMENT

Refer to GROUP 0 LUBRICATION
Speed Inspection and Adjustment.
Drill hole here at a 45 angle

towards concealment plug
lFU133
N14FHBA
AND
MAINTENANCE-Idle
IDLE SPEED AND MIXTURE ADJUSTMENT

scheduled Maiintenance only)
(For Un-
1. Remove carburetor
from engine. (Refer to P.14-61,)
2. Clamp carburetor in a vice with idle mixture adjusting screw
(MAS) facing up (protect gasket surface from vice jaws).
3. Drill a 2 mm (5/64 inch) pilot hole in the casting surrounding
the idle mixture adjusting screw (MAX) then redrill the hole to
3 mm (l/8 inch).
4. Insert a blunt punch into the hole and drive out plug.
5. Reinstall carburetor on engine.
6. Run the cold engine at fast idle until the cooling water temperature is raised to 80 to 95C (185 to 205F).
Inspection
Conditions
: 85-95C
(185-205F)
Light and accessory operation : off
Transmission
: neutral (N or P for automatic
transmission
equipped vehicles)
Steering wheel : center position (power steering equipped vehicles)
7. Prepare a timing light and tachometer.
8. Check the cycle of the timing light. Adjust if necessary.
Timing
light
cycle
: 7 BTDC f2
NOTE
Refer to GROUP 8 ELECTRICAL-Ignition
System,
ing cycle inspection and adjustment
procedures.
for the tim-
9. Turn off the ignition key.

10. Disconnect the cable from the negative terminal of the battery
for about 5 seconds. And then reconnect the cable to the
original terminal.
11. Disconnect the connector of the exhaust oxygen sensor.
12. Run the engine for more than 5 seconds at the engine speed
of 2000 to 3000 rpm.
13. Run the engine at idle for 2 minutes.
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FBC SYSTEM-Service
Adjustment
14-27
Procedures
14. Set the CO-HC tester.
5,
5FU12~
15. Set the idle CO and the engine speed to the specified value by
adjusting the idle speed adjusting screw No. 1 (SAS-1) and the
idle mixture adjusting screw (MAS).
Idle CO : 0.1 to 0.3% at nominal
Curb idle speed :
* 725 :;fi
rpm
/ ** 800 flO0
curb idle speed
rpm
NOTE
1. * : For the first 500 km (300 miles)
2. * : After 500 km (300 miles)
3. If the idle CO adjustment fails, suction of secondary
likely. Plug the secondary air hose and try again.
air is
Caution
DO NOT TOUCH SAS-2. The idle speed adjusting
screw
(SAS-2) is the preset screw that determines
the relationship between the throttle
valve and free lever, and has
been accurately
set at the factory. If this setting is disturbed, throttle
opener adjustment
and dash pot adjustment cannot be done accurately.
16. Turn off the ignition switch.
17. Connect the oxygen sensor connector.
18. Install the concealment
plug into the hole to seal the idle mixture adjusting screw.
,, :.
,.i L
t:
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14-28
FBC SYSTEM
- Service Adjustment
Procedures
THROTTLE OPIENER ADJUSTMENT

DITIONER
FOR AIR CONN14FKBC
The throttle opener (idle-up actuator) described

idle speed when the air conditioning
is applied.
here controls the
NOTE
Check the ignition timing and idle speed before performing this
adjustment.
Inspection
Conditions
: 85 - 95C (185 - 205F)
Lights and accessories : Set to OFF
Transmission
: Neutral
Steering wheel: Straightforward
(vehicles with a power
steering)
(1) Start the engine.
(2) Set the tachometer.
(3) Turn on the air conditioner switch.
NOTE
The solenoid valve will open and the intake manifold
will act on the throttle opener to fully actuate it.
(4) Check the engine
Standard
value
speed during this operation.

: 900-950
rpm
If the engine speed is out of specification,

throttle opener (for air conditioner) adjusting
THROTTLE
MENT
vacuum
POSITION
SENSOR
adjust using the

screw.
(TPS)
ADJUSTN14FIBC
(1) Loosen the accelerator
cable enough.
(2) Loosen the speed adjusting screw No. 1 (SASl) and No. 2
(SAS2) sufficiently
to close the throttle valve completely.
Record the number of turns loosened.
NOTE
1. Turning
[STB
the screw counterclockwise
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closes the valve.
FBC SYSTEM -Service
Adjustment
14-29
Procedures
2. At this time, the fast idle control should have been released (the lever not resting on the fast idle cam).
Fast
idle
cam
Lever
1 FU380
(3) Disconnect
the carburetor
connectors.
(4) Connect the special tool (harness connector)
disconnected
connectors.
(5) Connect
a voltmeter
output) and @ (blue:
connectors.
M D998474
Sensor output
(Red teryinal)
(Front view)
8--\
Caution
Use a good,
finely
between
the
between
terminal
0 (red: sensor
sensor ground) of the carburetors
calibrated
digital
type
voltmeter.
5FU125
NOTE
Connection
of FBC connector
as follows:
FBC connector
Terminal
0 (sensor output)
Terminal
@ (sensor ground)
Sensor
power
SUPPlY
(Black
terminal)
Sensor
ground
(Blue
terminal)
and special
tools
terminal
is
Special Tool
and Terminal
Red
and Terminal
Blue
(6) Turn the ignition

switch to ON (Dont start the engine).
(7) Measure
the voltage of the TPS output.
5FU 1YS
Standard
value
: 0.250 V
(8) If it is out of specification,

loosen the TPS attaching screw
and adjust by turning the TPS to the standard value.
NOTE
Turning the TPS clockwise
increases the output voltage.
(9) Turn the ignition switch to OFF.
(10) Tighten the SASI and SAS2 for the amount recorded in
step (2). (Return to the original position.)
(11) Remove
the voltmeter
and the special tool (harness
connector)
and connect the carburetors
connectors.
TPS
5FU127
(12) Adjust play of the accelerator

cable. (See P.14-84.)
(13) Start the engine and check that the idle speed is as
specified.
Standard value :
Curb idle speed
For the first 500 km (300 miles) : 725 +15
-100 rpm
After 500 km (300 miles) : 800 +lOO rpm
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,*
.:
,
i .
!,;.
1
14-30
Adiustment
FBC SYSTEM-Service
INSPECTION
I--
ADJUSTMENT
OF DASH
Pcl-,,
NOTE
Curb idle speed adjustment must be properly adjusted before inspecting dashpot.
Inspection
SAS-2
AND
Procedures
Conditions
Engine coolant temperature : 85 - 95C (185 - 205F)

Lights and accessories : Set to OFF
Transmission : Neutral
Steering wheel : Straightforward
(vehicles with a power
steering)
3EM07;
(1) Start the engine and run at idle.

(2) Open the throttle valve for full stroke of the rod until the free
lever contacts SAS3.
SAS3
(3) Close the throttle valve until SAS2 contacts the free lever and
check the engine speed at that moment.
Standard value
Vehicles with a manual
transmission
: 2000 rpm
Vehicles with an automat@
transmission
: 1500 rpm
(4) If engine speed is not as specified, adjust dashpot RPM by
turning SAS3.
(5) Release the free lever and verify that the engine returns to idle
speed slowly.
INSPECTION
OF DISTRIBUTOR
TROL VACUUM (D VACUUM)
Inspection
ADVANCE
Condition
: 85 - 95C (185 - 205F)
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CONNlUlJAA
FBC SYSTEM-s
ervice Adjustment
14-31
Procedures
(1) Disconnect the vacuum hose from the carburetor D vacuum

nipple and connect a hand vacuum pump to the nipple.
Vacuum pressure
A
NOTE
For the location of the nipple, refer to the Appearance
buretor (P.14-25)
of Car-
(2) Start and race the engine to make sure that D vacuum
creases with the engine speed.
f
Engine rpm
in-
NOTE
If abnormality is found in change of vacuum, blocked carburetor D port is suspected. Therefore, clean the port as necessary.
lFU445
dacuum pressure
INSPECTION
(E VACUUM)
Inspection
OF EGR VALVE
CONTROL
VACUUM
N14FVAA
Condition
Engine coolant temperature : 85-95C (185-205F)

(1) Disconnect the vacuum hose from the carburetor E vacuum
I
Engine rpm
NOTE
For the location of the nipple, refer to the Appearance of Carburetor (P.14-25).
lFU446
(2) Start and race the engine to make sure that E vacuum increases with the engine speed.
NOTE
If abnormality is found in change of vacuum, blocked carburetor E port is suspected. Therefore, clean the port as necessary.
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14-32
FBC SYSTEM-Service
INSPECTION OF VRV CONTROL

UUM)
Unspection Condition
VACUUM
(A VAC
N14FLAA

: 85-95X
(185- 205F)
(1) Disconnect the vacuum hose from the carburetor A vacuum
Vacuum pressure
A
NOTE
For the location of the nipple, refer to the Appearance of Carburetor (P.14-25)
(2) Start and race the engine to make sure that A vacuum increases gradually with the engine speed.
NOTE
If abnormality is found in change of vacuum, blocked carburetor A port is suspected. Therefore, clean the port as necessary.
>
Engine rpm
lFU447
INSPECTION OF VACUUM
UUM (F VACUUM)
Inspection
SWITCH CONTROL VACNl4FWAA
Condition

: 85-95C
(185- 205F)
(1) Disconnect the vacuum hose from the carburetor vacuum
ple and connect a hand vacuum pump to the nipple.
Vacuum pressure
A
nip- .
NOTE
For the location of the nipple, refer to the Appearance of Carburetor (P.14-25).
(2) Start and race the engine to make sure that F vacuum drops
rapidly.
>
Engine rpm
lFlJ448
.I
NOTE
If abnormality
is found in change of the vacuum, blocked carburetor F port and vacuum passage. Therefore, disassemble
and check the carburetor.
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FBC SYSTEM-Service
Additional
Adjustment
14-33
Procedures
INSPECTION
OF CARBURETOR
BLEED AIR PASSAGE FOR CLOGGING (INSPECTION
OF CARBURETOR HIGH ALTITUDE COMPENSATION
SYSTEFII
bleed air passage
INSPECTION
OF PRIMARY
WELL
CLOGGING-for
California
and high
for the 49 states
BLEED
altitude
NIPPLE
FOR
specifications
Air nipple
NOTE
For the nipple position, refer to the Appearance
(P.14-25).
9
Z!!! i
R P
(1)
(3)
and connect
Disconnect
the vacuum
ple and connect
a hand
hose from the primary

vacuum
pump.
well
bleed
nip-
(4) apply vacuum to see that it leaks and does not build up inside
the carburetor.
(5) If vacuum builds up, disassemble and check the carburetor. (Refer to P. 14-63).
PriLary
throttle
valve
the air nipple
(2) Apply vacuum to see that it leaks and does not build up inside
the carburetor.
rimary
main jet
Primary
emulsion
well
Disconnect
the vacuum
hoses from
a hand vacuum pump to the nipple.
of Carburetor
lEU376
f-71
INSPECTION
OF SECONDARY
WELL
CLOGGING-High
altitude
specifications
only (excluding
California)
BLEED NIPPLE
FOR
for the 49 states
N14FRBB
NC11rE
for the nipple position,
(P. 14-25).
Secondarv main /Iiet
ITI
Secondan/ em&ion well / J
Secondary throttle valve
refer to the Appearance
of Carburetor
Disconnect the vacuum hose from the bleed nipple and connect a hand vacuum pump to the nipple.
carburetor.
(3) If vacuum builds up, disassemble and check the carburetor. (Refer to P.14-63).
(1)
1 STB Revision
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FBC SYSTEM-Service
Adjustment
Procedures
INSPECTION
OF JET AIR NIPPLE FOR CLOGGING-High
altitude specifications
for the 49 states (excluding
California)
NlQFRCA
only
NOTE
For the nipple
(P.14-25).
position,
refer
to the Appearance
of Carburetor
(1) Disconnect
the vacuum hoses from both air nipple and jet air
nipple and connect a hand vacuum pump to the nipples.
carburetor.
(3) If vacuum
builds up, disassemble
and check the carburetor. (Refer to P.14-63).
Primary
throttle
valve
lFU378
INSPECTION
OF
VALVE OPERATION
(1) Remove
CARBURETOR
SECONDARY
N14FOM
the air filter assembly.
Diaphragm
chamber
(2) Remove the secondary

valve vacuum hose from the carburetor throttle body and connect a hand vacuum pump to
the disconnected
end of hose.
OlR0578
(3) With a vacuum of 13.3 kPa (1.9 psi) applied by the vacuum
pump, fully open the primary throttle valve and check that
the secondary
throttle valve also opens fully.
Replace depression
chamber
chamber (vacuum leaks)

Clean secondary
and related Darts
Vacuum is held but secondary

valve does not onerate
lFU38E
_ _
Revision
http://vnx.su/
throttle
valve
14-35
INSPECTION
OF CARBURETOR
ACCELERATION
N14FPM
(1) Remove the air filter assembly cover.

(2) While opening the choke valve, open the throttle valve and
check that fuel is injected from the pump nozzle.
If fuel is not injected, clean the carburetor fuel passage.
Primary
Choke
throttle
valve
INSPECTION
valve
OF CHOKE VALVE
Refer
to GROUP
NANCE-Maintenance
0 LUBRICATION
Service
Nl4FQAA
AND
MAINTE-
lFU301
INSPECTION
OF ELECTRIC CHOKE
Electric
N14FOBB
auto-choke
stage
choke
breaker
i
vacuum
pener
lFU359
1 FM95
Caution
All carburetors
have a tamper-proof
choke. The choke-related
parts are factory adjusted.
The choke adjustment
is not required during service, except when major carburetor
overhaul or choke carburetor
related
parts adjustments
are
needed by state or local inspections.
1 STB Revision
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14-36
FBC SYSTEM-Service
(1) Check that the alignment

marks on the electric choke
bimetal assembly are lined up. If not, align the marks.
and
NOTE
1. For removal of the bimetal assembly, refer to DISASSEMBLY AND REASSEMBLY
(P. 14-67).
2. Misalignment
and resultant symptom
Symptom
Misalignment
Clockwise
Better startability
but plugs
likely to be sooty
deviation
Counterclockwise
deviation
Poorer startability
to stall
more
and more likely
(2) Check that engine coolant temperature

is below 10C (50F).
(3) Start the engine and check operation of the choke valve and
fast idle cam, with hand on the electric choke body.
Electric
Choke
choke
body
valve
Gets gradually
start
Opens
rises
Fast idle cam
hotter
as bimetal
after engine
temperature
Fast idle control is released as engine coolant

temperature
rises
and fast idle breaker operates
(4) If the electric choke body remains cool even after the engine
is started, check the electric choke.
INSPECTION
OF ELECTRIC CHOKE
(1) Disconnect the carburetor connector
the heater.
Normal
N14FacA
and check continuity of
: Should
be conductive
[approx.
6 f3 at
20C (68F)]
(2) If the heater is not conductive, replace the electric choke body
(bimetal assembly).
Carburetor
float
chamber
cover
state
NOTE
For replacement procedures, refer to DISASSEMBLY
ASSEMBLY
OF CARBURETOR
(P.14-67).
5FU
AND RE-
N14FQDA
CHECKING
THE ELECTRIC CHOKE RELAY
(1) Remve the cover of the device box and remove the electric
choke
relay.
/ STB Revision
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FBC SYSTEM-Service
Adjustment
(2) Check
for continuity
flow
is not current
Item
FBC control
unit
Procedures
between
terminals
to the relay coil.
Measured
Between
Ignition
switch
No power flow
-(I%)
t
PTC
(Front
view
of relay
heatel
Auto-choke
PTC heater
Positive
Temperature
Coefficient
Heater
side)
OlR0378
Power flow
14-37
when there is and
terminals
Continuity
terminals 0 - 0
Yes (00)
Between
pp
Between
terminals
0 - 0
No (cdl)
terminals
0 - 0
Yes (approx. IOOSZ)
Between
terminals
0 -0
Yes (00)
Between
terminals
0 - @
No (dl)
NOTE
1. Andicates
the current flow direction.
2. Inspect after checking the infinity of tester.
3. Tonenergize
the relay coil, apply battery voltage directly to
terminals
0-O.
4. Use care as application of battery voltage to incorrect terminals can cause damage to the relay.
(3) If the continuity
test fails, replace the electric
choke
relay.
NOTE
If the electric choke body remains cool after engine start although the electric choke heater (PTC heater) and electric
choke relay are normal, check the vehicle body harness circuit.
1 STB Revision
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14-38
FBC SYSTEM-Service
CHECKING
THE CHOKE
BREAKER
Adjustment
Procedures
MECHANlSNs
N14FQEC
At 180C
hoke breaker rod
Stobper
L!
(65F) or higher
Primary throttle
stage)
Intake
manifold
Delay valve
,9
(2nd
Intake manifold vacuum

Therm0 valve
Closes at (18C (65F) and over)
1 FU392
Secondary throttle
Manifold /c
vacuum
To intake manifold
lFU391
(1) Remove the air cleaner.

(2) Check conditions of the choke valve according to the procedures given in the table below
Step
1
Engine coolant
temperature
Check
10C (50F) or lower
Before
10C (50F) or lower
Choke
engine
valve when
normal
Presumed
cause
when abnormal
Fully closed
Malfunction
of
bimetal assembly
Malfunction
of link
Engine idling after start (Start

after first fully depressing
accelerator
pedal one time.)
Slowly open slightly

immediately
after starting
(Clearance:
2.5-2.7 mm
(.098-.I06
in.))
Delay valve clogged

Diaphragm
damaged
(chamber
A)
10C (50F) or lower
Disconnect
the vacuum hose
(yellow stripe) from the choke
breaker during idling.
No movement
Malfunction
of
therm0 valve
25C (77F) or higher
Connect the vacuum hose

(yellow stripe) and let the
engine idle.
When the choke valve is

lightly closed by a finger,
stops at a position
open
more than step 2.
(Clearance:
approx. 3 mm
(.I2 in.))
Malfunction
of
therm0 valve
Diaphragm
damaged
(chamber
B)
NOTE
For information
concerning
the checking
Exhaust Gas Emission
Control System.
starting
conditions
of the therm0
valve,
refer
1 STB Revision
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to GROUP
25, EMISSION
CONTROL
SYSTEM
FBC SYSTEM-Swvice
INSPECTION
AND
BREAKER OPENING
Choke valve
14-39
ADJUSTMENT
OF
CHOKE
N14FQFC
(1) After inspection of the choke breaker system, disconnect the

vacuum hose (yellow stripe) from the choke breaker and make
the following check.
(2) With the engine idling, close the choke valve lightly with a
finger until the choke valve stops. Then, measure the choke
valve to choke bore clearance.
Standard
1 FU30
value
: 2.5-2.7
mm (.098-,106
in.)
(3) If the clearance is not as specified, stop the engine, remove

the bimetal assembly and adjust the rod end opening for standard clearance.
NOTE
For removal of the bimetal assembly, refer to DISASSEMBLY
AND REASSEMBLY
(P.14-67).
Choke breaker rod --(3FUl82
When removing the bimetal assembly, put a mark on the electric choke body.
NOTE
Rod end opening
Valve clearance
Expected result
Large
Large
Poorer
startability
and stall more likely
Small
Small
Plug likely to get

sooty
(4) Reconnect the removed yellow stripe vacuum hose and measure the choke valve to choke bore clearance as in step (2).
mm (.126-.133
(5) If the clearance is out of specification,

screw.
NOTE
Adjusting screw
ing direction
turn-
Clockwise
Counter
clockwise
/ STB Revision
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1
1..
in.)
adjust by the adjusting
g
yI
is,
F
p.4:
p...
1.
I!
i
Valve clearance
Expected
result
Small
Better startability
but
plug more likely to
get sooty
Large
Poor startability
stall more likely
and
14-40
FBC SYSTEM-Service
INSPECTION
AND ADJUSTMENT
Adjustment
Procedures
OF FAST IDLE
N14FGGB
Choke breaker
Electric autochoke
Two-st---
-L-,
.age c;rlu<ebreaker
Therm0valve
hifold
vacuum
-Choke
Intake manifoldvacuum
lfU386
lFU360
Inspection
l
8
l
Conditions
Engine coolant temperature: 85 - 95C (185 - 205F)

Lights and accessories:
Set to OFF.
Transmission: Neutral (N or P for vehicles with an automatic
transmission)
Steering wheel: Straightforward
ing)
(1) Remove the air filter.
(vehicles with a power steer-
(2) Install the tachometer.
(3) Disconnect
opener.
the vacuum
hose (white stripe) from the choke
(4) Set the lever on the second highest
svision
http://vnx.su/
detent
of fast idle cam.
FBC SYSTEM-Service
14-41
(5) Start the engine and check the fast idle speed.
Fast Idling adjusting screw

1 FU396
Standard value :
2350rpm
[Vehicles with a manual
transmission]
2300rpm
[Vehicles with an automatic
transmission]
(6) If the fast idle speed is out of specification, adjust with the fast
idle adjusting screw.
NOTE
Rotation direction of adjusting screw and fast idle speed
Valve opening
Fast idle speed
rection
Clockwise
Large
Counter-clockwise
Small
Increases
Decreases
Adjusting
screw
di-
(7) Connect the vacuum hose removed in step (3) to the choke
opener and check that the choke opener cancels fast idle.
CHECKING
THE
PUMP (AAP)
AUXILIARY
ACCELERATION
N14FYAA
(1) Remove the air filter cover.

(2) Check to be sure that the engine coolant temperature
is
30C (86F) or lower, and then check according
to the
steps in the table below.
NOZZLE
-Therm0
valve
(for AAP)
(Auxiliary Accelerator
With the engine

idling, disconnect
the black vacuum
hose from the
carburetor
AAP.
Negative
pressure
is felt when the
hose end is covered
by a finger.
Fuel is sprayed
from the nozzle
when the hose is
disconnected.
Negative pressure
Warm-up
the
engine until the
temperature
of
the engine coolant
reaches 50C
(122F) or higher.
3FU22:
Pump)
hose
pressure
Check conditions
7+=7h
*/UP:
Vacuum
negative
Stc ?P
Pump
nozzle
cannot be felt by
the finger.
(3) If the change of the vacuum negative pressure is incorrect,

check the therm0 valve for the APP.
If the negative pressure is normal but fuel is not sprayed
from the nozzle, clean the carburetors
fuel passage.
) STB Revision
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14-42
FBC SYSTEM-Service
CHECKING
THE THERM0
(FOR AAP CON-
VALVE
TROL)
N14FZAB
(1) Disconnect
the vecuum
hose (black) from the therm0 valve
and connect a manual vacuum
pump to the therm0 valve.
(2) Apply a negative
pressure of 66 kPa (10.0 psi) to the
therm0
valve.
When engine is cold[coolant
temperature 30C (86F) or lower1
Negative pressure
applied (leakage).
After engine warm-up[coolant

temperature 50C (122F) or higher]
Negative pressure is
applied (no leakage).
(3) If incorrect,
replace
the
therm0
adhesive
REPLACEMENT
Refer
Filter
to GROUP
(Replace)
1 ST6 Revision
http://vnx.su/
tool at the resin part

therm0
valve.
of the specified
adhetighten at a torque of
: 3M Adhesive
Nut
4171 or equivalent
OF FUEL FILTER
0 LUBRICATION
valve.
Caution
1. Do not use a wrench or similar
when removing
or installing
the
2. When installing,
apply a coating
sive to the threaded
part, and then
20-35 Nm (14-25 ftlbs.).
Specified
is not
AND
Locking
No.
N14FCAB
MAINTENANCE-Fuel
FBC SYSTEM-Inspection
of FBC System
14-43
INSPECTION OF FBC SYSTEM

CAUTIONS
ON INSPECTION
N14PAAC
1. Before removing or installing a part, disconnect

the battery
0 terminal.
2. Before disconnecting
battery terminals, turn off the ignition
switch. Removal or connection of battery terminals during engine operation or with the ignition switch ON could cause
erroneous operation of the ECU or damage to semiconductors.
3. The control harnesses between ECU and ignition coil [ 0
terminal] and between ECU and oxygen sensor are shielded wires with shield grounded to the vehicle body in order
to prevent ignition noises and radio interference.
When the
shielded wire is faulty, therefore, the control harness must
be replaced.
4. When ECI checker is handled, pay attention to the following
points.
l
Avoid rough operation of switches.
l
Do not subject ECI checker to shock and other external
forces, heat, etc.
l
Keep away water and oil.
l
Store ECI checker in a moisture- and dust-free place and
take steps to protect the checker from heat and vibration.
1 ST6 Revision
http://vnx.su/
14-44
- Inspection
FBC SYSTEM
CIRCUIT
of FBC System
DIAGRAMS
N 14EG-
FEED BACK CARBURETOR

Main
fusible
link
Battery
-1.25-B0.5-G
lEi3
A-02
CIRCUIT
Sub fusible
A-23
-15-W
link
Ignition
switch
n5-W
U
z
c:
(u
7
cu
-24 [I
To alternator
[Refer to P.8-37.1
Feed back
solenoid valve
YG
1.25-BW"
Slow cut
solenoid valve
YL
.1.25-BW"
Auto choke
heater
hrottle
#ensor
positio
G
Y
.GF
LI
A-24
Carburetor
assemblv
*;
*i
Remarks
(1) For information concerning
the ground points (example:
q ), refer to P.8-7.
(2) The symbols @I, 0 etc. indicate that the wiring is connected (using the same numerical symbol) to the facing
page. (In other words, 0 on the right page is connected to
0 on the left page.)
1 STB Revision
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FBC SYSTEM
- Inspection
14-45
of FBC System
Ignition
.,
To vacuum
Checker
A-4
A-42
solenoid
[Refer to PI-57.1
A-17
BR
rl
j;
C-24
II
,
I :
I ;
1 0.85-BW
YG,
YL,
I ,
Rb!!,
I '
I '
' 1.25-B ,-I*' 1.25-B

l
I
------
I,
2-RL.
x3 B
-----7
-----A
~-----7
B\
GY
YG
------A
r
!R
*4 2-BWl '2-BW
GB,
1
I
IB -,
GB
YG
GY
r
A-4
A-9
A-3
A-6
A-5
B-l 1
B-6
B-9
B-IO
Feed back
carburetor
control unit
B-l
B-2
B-l 2
B-3
B-13
B-8
B-7
3-5
,
I o\o--j
Vacuum
switch
A-46
Water
temperature
sensor
&T[
Oxygen
sensor
-Y
37W612
1 ST6 Revision
http://vnx.su/
14-46
FBC SYSTEM
COMPONENTS
COMPONENTS
LOCATIONS
- Inspection
AND VACUUM
FBC System
of
HOSES
LAYOUT
N14ED-
LOCATIONS
5FU131
Name
Symbol
Throttle opener control solenoid valve (for

air conditioner)
Engine-speed
Coolant temperature
Oxygen sensor
l-l
Secondary
Electronic
Feedback
Slow-cut
sensor
solenoid valve
solenoid valve
Throttle-position
Vacuum switch
sensor
Name
sensor
(ignition coil@)
control unit (ECU)

-
j STB Revision
http://vnx.su/
Symbol
G
FBC SYSTEM
A Throttle
Opener Control
Valve (for air conditioner)
- Inspection
14-47
of FBC System
Solenoid
6 Coolant
Temperature
Sensor
valve (for air conditio
C Feedback
Solenoid
Valve
D Slow-cut
Solenoid
Valve
I I
E Throttle-Positibn
Sensor
F Vacuum
Throttle-PO&ion
Coil
switch
\
sensor
5FUl23
G Ignition
Vacuum
Switch
H Oxygen
(- )
Sensor
u
Oxygen
Sensor
CD
7i
1 STB Revision
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14-48
I Secondary
Valve
FBC SYSTEM
Air Control
- Inspection
of FBC System
Solenoid
J Electric
Secondary
air control
K Electronic
Control
soGid
valve
I:,
Unit
(ECU)
1/
16W1515
1 STB Revision
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Choke
Relay
http://vnx.su/
I
I
L
I
To electrtc choke
I/
5FU115
14-50
Vacuum
Hose Layout..
. vehicles
California
with
high-altitude
of FBC System
specifications
lx
for the 4Q states
( ST6 Revision
http://vnx.su/
other
than
Vacuum
Hose Layout
. ..vehicles
for California
STB Revision
http://vnx.su/
of FBC System
14-51
14-52
FBC SYSTEIVI-Inspection
of FBC System
To secondary
Purge
/..I
Distributor
control
air control
valve
valve*
1/\
///
Therm0 valve
(for AAP control)
Therm0
valve
EGR valve
Vacuum
Device
switch
box %
Secondary
air control
solenoid
valve
.zi- ,_.
1 STB Rewision
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5FU190
14-53
of FBC System
INSPECTION
OF THROTTLE OPENER
SYSTEM FOR AIR CONDITIONER LOAD
Inspection
CONTROL
Nl4PGBB
Condition

: 85-95C (185-205F)
(1) Disconnect the vacuum hose (yellow stripe) from the throttle
opener installed on the carburetor and connect a hand vacuum
pump to the nipple.
(2) Check that the throttle opener rod is pulled up when vacuum
is applied
(3) Apply 67 kPa (10.0 psi) vacuum and check air tightness.
(4) Start the engine and close the vacuum hose (yellow stripe)
end with a finger to check vacuum when the air conditioner
switch is turned on and off.
Air conditioner
Hose end vacuum
Engine speed
switch
OFF
Absent
Idle
Present
ON
Absent
1,200 rpm or more
ELECTRONIC
CONTROL UNIT (ECU) CONNECTOR
REMOVAL
AND INSTALLATION
PROCEDURES
Nl4PMA
(1) Disconnect the battery negative (-) terminal connection.
(2) Remove the ECU cover.
(3) Unlocking the computer

connectors.
NOTE
For installation,
unit connector,
reverse the removal
pull out the harness
steps.
INSPECTION
OF ELECTRONIC
CONTROL
UNIT (ECU) INPUT
AND OUTPUT ELECTRIC SIGNALS
NllPOAB
Inspection and maintenance
of electric system in the FBC system
can be made quickly by inspecting the ECU input and output electric signals with the ECI checker and then by inspecting the component whose signal is abnormal and the harness between the
component
and the ECU.
1 STB Revision
http://vnx.su/
14-54
CHECK
of FBC System
PROCEDURE
(METHOD
USING
ECI CHECKER)
N14PDAC
Using the special tools (FBC Harness Connector

and ECI
Checker), check the FBC system by the following
procedure.
Inspection Procedure:
(1) Turn ignition switch to Lock.
(2) Remove the Large harness connector and Small harness connector from the ECU.(3) Set check switch of the ECI checker to OFF.
(4) Set select switch of the ECI checker to A.
(5) Connect the FBC HARNESS
CONNECTOR
to the connectors of the ECI checker,
and then connect
the FBC
HARNESS CONNECTOR
to the ECU and harness connectors
(6) Perform checks according to the FBC System Check Procedure chart.
(7) If checker shows any variance from specifications,
check the
corresponding
sensor and related electrical wiring then repair
or replacement.
(8) After repair or replacement,
recheck with the ECI checker to
confirm that the repair has corrected the problem.
(9) Set check switch of the ECI checker to OFF.
(lO)Set ignition switch to Lock.
(11)Disconnect
connectors of the ECI checker and the FBC HARNESS CONNECTOR
from the ECU and the body side harness connectors.
(12)Connect the body side harness connectors to the ECU.
(13)After completion
of the above test make certain that the trouble has been eliminated
on the road test.
http://vnx.su/
FBC SYSTEM
- Inspection
of FBC
14-55
System
FBC SYSTEM
CHECK PROCEDURE
CHART
(Use FBC Harness Connector
MD9984381
,b
0
,ii
-
I
:t
.!.?
I
co
http://vnx.su/
m
-
1 STB Revision
14-56
FBC SYSTEM - Inspection
of FBC System
FBC SYSTEM
CHECK PROCEDURE
CHART
(Use FBC Harness Connector
MD998438)
-
E
1
Y
8
5
a3
J-l
1 STB Revision
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z
-
v
-
14-57
of FBC Svstem ComDonents
INSPECTION OF FBC SYSTEM COMPONENTS
NlUMM
INSPECTION
SENSOR
INSPECTION
(I) Remove engine coolant temperature
sensor from the intake
manifold.
(2) With temperature
sensing portion of engine coolant temperature sensor immersed
in hot water, check electrical resistance. The sensor should be held with its housing 3 mm (.12
in.) away from the surface of the hot water.
16R1251

sensor
Temperature
;t;;r&;n\v
Resistance (kfI
C VF)
0 (32)
5.9
20 (68)
2.5
40 (104)
1.1
80 (176)
0.3
(3) If the resistance deviates greatly from the standard value. replace the engine coolant temperature
sensor.
INSTALLATION
(1) Apply specified
adhesive to threaded
portion.
:
3M
Adhesive
Nut
Locking
No.
Specified adhesive
4171 or equivalent
OlR0129
Er-:-:
OF ENGINE COOLANT TEMPERATURE
(2) Install engine coolant temperature

sensor and tighten it to
specified
torque.
Sensor tightening
torque
: 20-40 Nm (14-29 ftlbs.)
(3) Fasten harness connectors
securely.
,?
tE
sensor connector
INSPECTION
VW
OF THROTTLE
POSITION
NlUlQAQ
(1) Disconnect the carburetor connector.

(2) Measure resistance between terminal
terminal 8 (sensor ground).
Sensor
ground
output
Sensor power
OlR049
@
-0
SENSOR
1 (sensor power) and
Standard value : 3.5 - 6.5 kf2

(3) Connect an ohmmeter (pointer type) between terminal 8 (sensor ground) and terminal 2 (sensor.output).
(4) Operate the throttle valve slowly from idle position to the full
open position and check that the resistance makes a smooth
change proportionally
with the throttle valve opening.
NOTE
The resistance changes within the range from approx.0.5 kR
to the value measured at step (2).
(5) If the resistance is out of specification
or fails to change
smoothly, replace the TPS.
5FU144
TPS installation
torque
NOTE
Refer to P.14-28
procedure.
for the throttle
STB Revision
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: 2.5 - 4.5 Nm (1.8 - 3.3 ft. lbs.)

position
sensor
adjusting
14-58
INSPECTION
OF ENGINE
TION COIL 0 TERMINAL)
ess
Ignition
of FBC System Components

SPEED SENSOR
(IGNIN14QCAB
Check that there is continuity between the ignition coil @terminal

and the electronic control unit (ECU) terminal 10.
c\btrh
1
I
NOTE
Shake the harness connector
to check for lurking open circuit.
(installed at testing)
5FU145
INSPECTION
OF OXYGEN
SENSOR
N14QDAA
Caution
1.
Before checking, warm up the engine until engine coolant

temperature
reaches 85 to 95 (185 to 205F).
2. Use an accurate digital voltmeter.
(1) Separete the oxygen sensor connector and connect a voltmeter to the oxygen sensor connector.
(2) While repeating

output voltage.
Engine
engine
racing,
the oxygen
sensor
Remarks
Oxygen sensor
output voltage
Approx. 1 V
Racing
measure
Make air-fuel mixture richer

by accelerator operation
eemenyw
Conenctor
03E580
NOTE
For removal and installation
11 INTAKE AND EXHAUST
Oxygen
sensor
CHECKING
installation
of the oxygen sensor, refer to GROUP

SYSTEM -Exhaust Manifold.
torque
THE VACUUM
: 40 - 50 Nm
(36 -36 ft. Ibs.)
SWITCH
N14QIAA
(1) Disconnect
the vacuum
hose (green stripe) from the
device box, and connect a manual vacuum pump to the
device box nipple.
(2) Detach the vacuum switch connector.
(3) Apply negative pressure (vacuum) and check whether or
not there is continuity
between the switch terminals.
5FUW
1 STB Revision
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FBC SYSTEM-InsPection
14-59
of FBC Svstem Components
81
40 kPa (5.8 psi) or higher
(4) If there is a problem,

replace the vacuum
0 - @
remove the device
switch assembly.
box cover, and
5FU188
t
! L.
$43
36
OF FEEDBACK
SOLENOID
NllQOAB

(2) Apply battery voltage (approx. 12V) between the solenoid
valve terminals and check that the solenoid valve operates
with a click.
If no click is heard, replace the solenoid valve.
2 1
7 0
(Front view
at carburetor
side)
5FU147
INSPECTION
(FBSV)
NOTE
For the feedback solenoid valve removal and inspection procedures, refer to CARBURETOR
DISASSEMBLY
AND REASSEMBLY, P. 14-63.
SIMPLE INSPECTION
VALVE (SCSV)
OF SLOW
CUT SOLENOID
Nl4QPAB

(2) Apply battery voltage (approx. 12V) between the solenoid
valve terminals and check that the solenoid valve operates
with a click.
If no click is heard, replace the solenoid valve.
(Front view
at carburetor
side)
5FU148
NOTE
For the slow cut solenoid valve removal and inspection procedures, refer to CARBURETOR
DISASSEMBLY
AND REASSEMBLY, P. 14-63.
INSPECTION OF THROlTLE OPENER CONTROL SOLENOID VALVE FOR AIR CONDITIONER

N14QXEA
NOTE
When removing the vacuum hoses from the solenoid valve, put
marks on the hoses for correct installation.
(1) Remove the vacuum hoses (white stripe, yellow stripe) from
the solenoid valve.
(2) Disconnect the harness connector.
(3) Connect a hand vacuum pump to the nipple to which the white
stripe vacuum hose has been connected.
http://vnx.su/
of FBC System Components
(4) Apply vacuum and check air tightness for both when battery
voltage is directly applied to the solenoid valve terminal and
when no voltage is applied.
The other nipple of
solenoid valve
Battery voltage
Normal state
5FU150
I
n
(5) Measure
Standard
the solenoid
value
1
I
5FU151
ST6 Revision
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coil resistance.
: 38 - 44Q [at 20C (68F)I
FBC SYSTEM
14-61
- Carburetor
CARBURETOR
REMOVAL
AND INSTALLATION
N14MA--
16-19
12-14
Nm
ftlbs.
15-20
11-14
11
h$$l:ENANCE
Removal steps
4+ l + 1, Air filter
I)+ Adjusbent
of
2. Connection
3. Connection
4. Connection
5. Connection
l + Adjustment of
6. Snap pin
7. Pin
8. Connection
9. Connection
10. Connection
4*
11. Connection
4*
12. Carburetor
4*
13. Gasket
- Coolant
Replace-
I
Post-installation
accelerator cable
of accelerator cable
of water hose
of fuel vaper hose
of vacuum hoses
throttle cable
of
of
of
of
Operation
0 Supplying of Coolant (Refer to

GROUP 0 LUBRICATIONAND
MAINTENANCE - Coolant Replacement.)
l
Checking and Adjustment

of the
idling rpm (Refer to GROUP 0 LUBRICATION AND MAINTENANCE
of the
Idling rpm.)
Vehicles with an
automatic transmission
throttle cable
control harness connector
main hose
return hose
(y keverse the removal procedures

(2) 41) : Refer to Service Points
parts
to reinstall.
of Removal.
of Installation.
03W552
) STB Revision
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FBC SYSTEM
- Carburetor
SERVICE
POINTS
1. REMOVAL
OF REMOVAL
OF AIR
Refer to GROUP
Filter.
N14MBAC
FILTER
11 INTAKE
AND EXHAUST
SYSTEM
11. DISCONNECTION
OF RETURN
HOSE/lo.
MAIN
(1) Before disconnection
of the fuel hose, remove
tank cap to lower the pressure in the fuel
(2) With the receiver placed under the fuel inlet
receive fuel left in the hose, remove fuel hose
carburetor
inlet nipple.
HOSE
the fuel
tank.
fitting to
from the
12. REMOVAL
OF CARBURETOR
NOTE
When the carburetor is removed, keep it horizontally
not to spill fuel from the carburetor.
SERVICE
.
POINTS
OF INSTALLATION
ADJUSTMENT
OF THROTTLE
CABLE
Refer to GROUP
21 TRANSMISSION
Throttle
Cable.
ADJUSTMENT
OF ACCELERATOR
- Air
so as
N14MDAB
- Adjustment
CABLE
of
FREE PLAY
Refer to P.14-84.
1. INSTALLATION
Refer to GROUP
Filter.
/ STB Revision
OF AIR FILTER
11 INTAKE AND EXHAUST
I
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SYSTEM
- Air
FBC SYSTEM
DISASSEMBLY
AND
14-63
- Carburetor
REASSEMBLY
NMME-
7 .
\
-I,
f!sT
Disassembly
steps
1.
2.
3.
4.
5.
+I)
l +
Throttle-return
spring
Damper
spring
Throttle-return
spring
bracket
Throttle
opener/Dash
pot
Bracket
6. Hose
7. Vacuum-delay
valve
8. Hose
9. Screw
IO. Float chamber
cover assembly
11. Float chamber
cover gasket
12. Mixing
body and throttle
body
03W556
Carburetor
assembly
and gasket
kit
NOTE
Reverse the disassembly
procedures
to reassemble.
(2) +e : Refer to Service Points of Disassembly.
parts
(1)
assembly
5FU152
j STB Revision
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FBC SYSTEM
14-64
- Carburetor
23
V-lzl17
=-XI18
16
&
&--I5
GDisassembly
13.
+*
14.
15.
4*
4*
16.
17.
18.
19.
de l + 20.
21.
22.
23.
24.
+e ++ 25.
26.
27.
28.
+e ++ 29.
30.
31.
32.
33.
34.
35.
36.
14
k-13
steps
Pin
Float
Needle valve
Needle valve seat
O-ring
Packing
Retainer
Feedback solenoid valve (FBSV)
O-ring
O-ring
Tube
Retainer
Slow-cut
solenoid valve (SCSV)
O-ring
O-ring
Plate
Bimetal assembly
Packing
Connector
Cover
Diaphragm
Spring seat
Spring
Body
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
++ ++ 53.
++ l 4 54.
4~ +4 55.
56.
Spring
Diaphragm
Valve
Mixture control valve (MCV)
Gasket
Cover
Spring
Diaphragm
Body
Spring
Diaphragm
Bracket
Cover
Spring
Diaphragm
Body
Main air jet (primary)
Pilot jet (primary)
Pilot jet (secondary)
Float chamber cover
~~~everse
the disassembly
(2) q+ : Refer to Service
(3) I)+ : Refer to Service
(4) Q: Non-reusable
parts
1 STB Revision
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assembly
procedures
to reassemble.
Points of Disassembly.
Points of Reassembly.
5FU153
FBC SYSTEM
b I
14-65
- Carburetor
-57--0
b---58
OE
Disassembly
I)+
l +
1)4
I)+
I)+
I)+
57.
58.
59.
60.
61.
62.
63.
**
64.
qe I)* 65.
+e I)+ 66.
67.
68.
69.
70.
4*
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
steps
63
Steel ball
2.545
Nm
1 B-3.2 ftlbs
Weight
Ball
Plug
O-ring
Ball
Screw
Gasket
Main jet (primary)
Main jet (secondary)
Cover
Spring
Diaphragm
Enrichment jet valve
Enrichment jet
Spring
Ball
Pump cover assembly
Diaphragm
Spring
Pump body
Gasket
Hose
Auxiliarv acceleration pump cover
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
93.
94.
95.
96.
97.
98.
99.
Spring
Diaphragm
Check valve
Mixing body
Vacuum hose
Depression chamber
Throttle-position sensor (TPS)
Throttle lever
Cam follower
Fast-idle adjustment screw
Free lever
Apartment plate
Idle-speed adjustment screw (SAS-2)
Spring
Secondary lever
Idle-speed adjustment screw (SAS-1)
Plug
Mixture-adjustment screw (MAS)
Throttle body
NOTE
(1) Reverse the disassembly procedures to reassemble.
(2) 41) : Refer to Service Points of Disassembly.
(3) I)+ : Refer to Service Points of Reassembly.
(4) -q : Non-reusable
parts
5FU154
/ ST6 Revision
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14-66
FBC SYSTEM-Carburetor
NICE
portion
N14MFAA
Caution
1. DO not disassemble
the following
components
at the time
of disassembly.
(1) Choke valve, choke shaft and automatic
choke device
(2) Inner venturi
(3) Throttle valve and throttle
shaft
(4) Fuel inlet nipple
2. When loosening
a Philips screw which has been firmly
tightened,
use a Philips screwdriver
that is an exact fit for
the screw.
10. REMOVAL OF FLOAT CHAMBER
COVER ASSEMBLY
Connector
Stopper
POINITS OF DISASSEMBLY
Pin
Caution
Ensure that the terminal
is not bent during removal of the
connector.
(1) With a pin or the like push the stopper portion to remove
each of the three TPS terminals from the rear of the connectors.
TPS terminals
(three
pieces)
(2) Do not attempt to remove the cover at a time as it is held

in position firmly by gasket. Insert a screwdriver blade
between the enrichment
cover and the float chamber
cover as illustrated and lightly pry and lift up lightly.
c
Caution
Do not apply excessive force.
14. REMOVAL
OF FLOAT / 15. NEEDLE VALVE
Remove the pin and then remove the float and needle valve.
Caution
1. Do not let the float drop or apply collapsing
load.
2. Use care not to damage the end of the needle valve.
16. REMOVAL
OF NEEDLE
VALVE
Using flat blade screwdrivers,

both edges to remove.
IIKI~ tipped)
SEAT
pry up the needle valve seat at
Caution
Use care not to damage
the float
pushing up the needle valve seat.
Needle
seat
valve
lFU288
( ST6 Revision
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chamber
cover when
20. REMOVAL
Stopper
Connector
portion
14-67
OF FEEDBACK
SOLENOID
VALVE
(FBSV)
Using a screwdriver or other tool with a thin flat end, push the
stopper portion and remove the two terminals from behind the
connector.
in
Caution
FBSV terminal
(two pieces)
,
is not bent during
removal
of the
connector.
NOTE
Unless the terminals are removed from the connector, the
feedback solenoid valve cannot be removed from the float
chamber cover.
25. REMOVAL OF SLOW CUT SOLENOID
VALVE (SCSV)
5FU156
(1) Remove
valve.
the retainer
Caution
When removing
hold the body.
and pull out the slow cut solenoid
the valve,
do not hold the leads but
(2) Using a screwdriver or other tool with a thin flat end, push
the stopper section and remove the two terminals from
behind the connector.
Caution
the connector.
SCSV terminal
(two pieces)
is not bent during
removal
of
5FU151
Plafe
Bimetal
assembly
29. REMOVAL OF BIMETAL ASSEMBLY

(1) Grind away the head of the two rivets of the bimetal assembly using an hand grinder or other tool. Remove the
screw.
(2) Remove
(3) Remove
Stopper
portion
the plate, the bimetal assembly and the packing.

the remaining rivet bodies using a pin punch etc..
(4) Using a screwdriver or other tool with a thin flat end, push
the stopper section and remove the terminal from behind
the connector.
Connector
in
Caution
the connector.
Bimetal
assembly
Terminal
5FU154
. .
STB newsron
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is not bent during
removal
of
14-68
53. REMOVAL
OF MAIN AIR JET (PRIMARY)/54.
PILOT JET
(PRIMARY)/55.
PILOT JET (SECONDARY)
(1) When removing the jets, use a screwdriver that is an exact
fit for their slot and work carefully to prevent damage.
kd
1 FM91
53. REMOVAL OF SCREW

(1) Use a Phillips screwdriver that is an exact fit and work
carefully to prevent damage.
Caution
Do not cause burrs to the recess in screw head as they
could produce gap between
throttle
body and the
manifold
surface.
65. REMOVAL
ONDARY)
OF MAIN
JET (PRIMARY)/66.
When removing the jets, use a screwdriver

and work carefully to prevent damage.
70. REMOVAL
OF ENRICHMENT
Caution
The valve has many
small
MAIN
JET (SEC-
that is an exact fit
JET VALVE
parts.
Do not lose them.
(1) When removing the enrichment jet valve from the mixing
body, use a screwdriver that is an exact fit for its screwdriver slots and work carefully to prevent damage.
(2) Using a screwdriver, loosen the enrichment
jet and take
out the spring and ball from the enrichment
jet valve.
Drill hole here at a 45 angle

towards concealment plug
Concealment
plug
f
Drill
hole
97. REMOVAL
OF PLUG
(1) Clamp carburetor in a vice with idle mixture adjusting
screw (MAS) facing up (protect gasket surface from vice
jaws).
(2) Drill a 2 mm (5/64 in.) pilot hole in the casting surrounding
the idle mixture adjusting screw (MAS) then redrill the hole
to 3 mm (l/8 in.).
(3) Insert a blunt punch into the hole and drive out plug.
lFUl33
rim
tevision
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14-69
INSPECTION
N14MGM
GENERAL INSPECTION
Check the following and repair or replace parts if necessary.
(1) Check the fuel paths (jets) and air paths (jets or orifices) for
clogging. If clogged, wash thoroughly with cleaning solvent or
detergent and blow by compressed air. Do not use metal wire
or other metal pieces.
(2) Check the diaphragms for damage and cracks.
(3) Check that the needle valve operates lightly. if the valve is
hard to slide or is binding, repair or replace. If there is overflow,
poor valve to seat contact is suspected. Check thoroughly.
(4) Check the fuel inlet filter (located above the needle valve) for
clogging and damage.
(5) Check the float operation. Check the float and lever for deformation and damage and replace if necessary.
(6) Check operation of the throttle valve, choke valve and link. If
they do not operate lightly, wash well and apply engine oil
sparelingly to their shaft.
(7) Check the float chamber and main body for damage and
cracks.
INSPECTION
OF SLOW CUT SOLENOID
VALVE (SCSV) OPERATION
NllMOBA
(1) Apply battery voltage directly to the slow cut solenoid valve
:,
terminals.
-, . : I_
(2) Check that the valve operates with a click.
1 FU25!
i
MEASUREMENT
OF SLOW CUT SOLENOID
VALVE(SCSV)
RESISTANCE
NuMtxh
(1) Using a circuit tester, check that there is no continuity between the solenoid valve body and terminals.
(2) Measure
Standard
resistance
value
I FU257
1 STB Revision
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between
the terminals.
: 48 - 60R [at 20C (68F)]
14-70
INSPECTION
OF FEEDBACK SOLENOID
VALVE (FBSV) OPERN14MGDA
ATION
(1) Apply batten/ voltage directly to the feedback solenoid valve
terminals.
(2) Check that the valve operates with a click.
1 FU258
(3) Check that the jet is free from clogging.
lFU294i
MEASUREMENT
OF FEEDBACK
SOLENOID
VALVE (FBSV)
NllMGEA
RESISTANCE
(1) Using a circuit-tester,
check that there is no continuity between the solenoid valve body and terminals.
(2) Measure
Standard
resistance
value
between
the terminals.
: 64 - 66f2 [at 20C (68F)I
MEASUREMENT
OF BIMETAL
Using a circuit tester, measure
and body.
Standard
value
STB Revision
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: Approx.
ASSEMBLY
RESISTANCE
N+lGFA
resistance between the terminal
6fI [at 20C (68F)]
14-71
INSPECTION
OF DASH POT
Nl4MGGA
Check that the dash pot operates normally. Resistance must be
felt when the dash pot rod is pulled. When the rod is released, it
must return quickly to the original position. If no resistance is felt
when it is pulled, the diaphragm or the check valve is broken. If the
rod returns slowly, the check valve is binding. In either case, replace the dash pot.
NllMGHA
INSPECTION
OF DEPRESSION
CHAMBER
Check the depression chamber diaphragm for damage. First, push
up the rod fully and closing tightly the nipple with a finger, release
the rod. The diaphragm is intact if the rod does not return to the
initial position while the nipple is held closed with a finger. If the
rod returns, the diaphragm
is broken. Replace the depression
chamber.
MIXTURE
ADJUSTING
SCREW (MAS)
Check the mixture adjusting screw (MA.54 for damage
its taper end by overtightening
etc..
N14MGIA
caused to
1 FlJ367
THROTTLE
POSITION
SENSOR
1. Measure resistance between
position sensor.
2.
(TPS)
terminals
N14MGJA
1 and 3 of the throttle
Standard value : 3.5 - 6.5 kf2

Check the body for crack and damage.
lFU29l

Size
symbol
66. 65. IDENTIFICATION

OF MAIN JETS
Make sure that correct jets are installed at correct positions.
Note the size symbol stamed on each jet for identification.
Primary : #107.5
Secondary
: #190
6FUW2
L
pm
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wision
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62.
INSTALLATION
OF BALL/Gl.
O-RING/GO.
PLUGI59.
BALL/58. WEIGHT/57.
STEEL BALL
install in correct sequence and at correct positions.
55. INSTALLATION
OF PILOT JET (SECONDARY)/54.
PILOT
JET (PRIMARYV53.
MAIN AIR JET (PRIMARY)
(1) Make sure that correct jets are installed at correct positions. Note the size symbol stamped on each jet for identification.
-
I.
Size
Main air jet (primary)

: #70
Pilot jet (primary)
: #55
Pilot jet (secondary)
: #70
29. INSTALLATION
OF BIMETAL ASSEMBLY
(1) Fit the bimetal end over the choke valve lever.
(2) Install the plate and temporarily

(3) Align the mating marks.
Bimetal assembly
body
\
\
-__---___---_--
(4) Set the rivet as illustrated.
Plate
d
lFU371
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tighten
the screw.
14-73
(5) Install the bimetal assembly using a hand rivetter or similar

tool with the mating marks aligned correctly.
(6) Tighten the screw.
Bimetal assembly
Hand rivetter
1 FU372
(7) Install terminal
to the connector
at correct position.
Front view
5FU159
FBSV (yellow)
SCSV (blue)
FEW (red) scsd (red)

Front view
25. INSTALLATION
OF SLOW
CUT
SOLENOID
VALVE
(SCSV)/SO. FEEDBACK SOLENOID
VALVE (FBSV)
Install terminals to the connector at correct positions.
For TPS
For bimetal
assembly
5FU161
TPS output (yellow green/red)

TPS 0 (orange)
\
10. INSTALLATION
OF FLOAT CHAMBER
COVER ASSEMBLY
(1) After installing the float chamber cover, install the throttle
position sensor (TPS) terminals (3) to the connector, paying close attention to their positions.
TPS 0 (b&k/red)
5FU16:
INSPECTION
BLY
AND ADJUSTMENT
FAST IDLE OPENING

(1) Set lever on the first highest
1 STBI
:vision
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AFTER ASSEMN14MIAB
cam of the fast idle cam.
(2) Measure
the primary
Standard value
Vehicles with
1.21 mm
Vehicles with
1.32 mm
valve to throttle
bore clearance.
:
a manual transmission
(6476 in.)
an automatic
transmission
(.0520 in.)

adjust using the fast idle
adjusting screw for the standard value.
NOTE
Adjusting
Choke
screw
Adjusting screw
vs. idle rpm

I
Valve opening
Fast idle rpm
Clockwise
Larger
Increases
Counter clockwise
Smaller
Decreases
UNLOADER
valve
direction
of rotation
OPENING
N14MIBA
(1) Lightly press the choke valve with a finger to fully close it.
(2) In this state, fully open the throttle valve and measure
the
choke valve to choke bore clearance.
Standard
value
: 1.9 - 2.1 mm (075
- .083 in.)

bend the throttle lever
at illustrated
portion to adjust the clearance to the standard
value.
-
Lever
NOTE
Lever bending
direction
Clearance
Remarks
UP
Down
Larger
Poor response
Smaller
Lower output
Plug likely to get sooty
1 FU375
CHOKE
BREAKER
Caution
Check and adjust
NUMICB
with
the bimetal
assembly
removed.
(1) Lightly press the choke valve with a finger to fully close it.
(2) Push the choke breaker rod toward the diaphragm
and measure the choke valve to choke bore clearance.
1 FU30
Standard
value :
1st stage : 2.5 - 2.7 mm (.098 - .106 in.)
2st stage : 3.2 - 3,4m
(726 - .133 in.)
ST6 Revision
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I
u-75

throttle lever at illustrated portion.
NOTE
di
adjust by bending
Poorer startability
the
more likely to
N14MIDA
OPERATION
OF CHOKE VALVE
(1) Operate the choke valve with a finger and check for play,
incorrect operation and binding.
(2) If the choke fails to operate smoothly and lightly, wash around
the choke valve.
(3) If the play is excessively large, replace the float chamber
cover.
Nl4MlEA
OPERATION
OF SECONDARY
THROll-LE
VALVE
(1) Fully open the throttle valve and operate the secondary throttle valve lever with a finger to check for play, incorrect operation and binding.
(2) If it fails to operate smoothly and lightly, wash and apply thin
coat of engine oil to th,e shaft.
(3) If the play is excessively large, replace the throttle body.
Nl4MlFA
PORTS
(1) Connect a hand vacuum pump to each port and check for
clogging of the passage.
(2) If there is clogging, clean the port and then blow compressed
air into the port.
STB Revision
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14-76
Additional
bleed
passage
I
air
Air nipple
bleed
Prin
main
air
Primary
well
bleed nipple
I/ /
jet
Primary
emulsion
i ]
Nl4MlGB
INSPECTION
OF HAC BLEED AIR PASSAGE
Inspection
for Clogging
of Primary Well Bleed Nipple - High
altitude specifications
for the 49 states, California
(1) Connect a hand vacuum pump to the nipple.
(2) Apply vacuum to see that vacuum leaks and does not build up.
(3) If vacuum builds up, disassemble and check the carburetor as
incorrect installation of gasket etc. is suspected.
P;imary<hroitle
valve
well
1 FU37t
Inspection
for Clogging
of Secondary
Well Bleed Nipple N14MIHB
High altitude
specifications
for the 49 states
(3) If vacuum builds up, disassemble
and check the carburetor as
Additional
Bleed air
passage
S econdaty
main- jet
5 ;econdary
emulsion
well
Secondary
._
._
r-l
/
throttle
valve
5FU377
., .
,:
Inspection
for Clogging of Jet Air Nipple - High altitude specNllMllB
ifications for the 49 states
(3) If vacuum builds up, disassemble
and check the carburetor as
._
TO
cair
Primary
throttle
valv;!
5FU371
p?Ei
levwon
http://vnx.su/
FBC SYSTEM
Fuel
Pump
FUEL PUMP
REMOVAL
AND
INSTALLATION
1619
12-14
Nm
ftlbs.
\
Removal steps
+e ~~
+*
4*
+e l +
I.
2.
3.
4.
5.
6.
Air filter
Connection of the main hose.
Connection of the return hose.
Fuel pump
Gasket
Insulator
NOTE
(2) 4~ : Refer to Service Points
(3) ~~ : Refer to Service Points
(4) m: Non-reusable
parts
03w551
to reinstall.
of Removal.
of Installation
SERVICE
POINTS
1. REMOVAL
OF REMOVAL
N14HBAC
OF AIR FILTER
Refer to GROUP 11 INTAKE AND EXHAUST SYSTEM - Air

Filter.
1 STB Revision
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14-78
FBC SYSTEM-
Fuel Pump
2. DISCONNECTION
OF MAIN HOSE/3. RETURN HOSE
Before disconnection
of the fuel hose, remove the fuel
tank cap to lower the pressure in the fuel tank.
4.
REMOVAL
OF FUEL PUMP
(1) Turn the crankshaft to place No. 1 cylinder
center on compression
stroke.
at top dead
NOTE
The above operation
places the lift of fuel pump stroke
at the minimum
position, resulting in ease of fuel pump
removal.
(2) If interference
of pump lever occurs in the cylinder
head, the washer on the cylinder head bolt may be
interfering
with the pump lever. Therefore,
proceed as
follows:
Front of engine
0
0
Remove
the rocker cover.
Loosen cylinder head bolts in the sequence
in the illustration.
Move the washer interfering with the pump lever in

the direction
shown in the illustration
and remove
the fuel pump.
>
shown
5EN016
Camshaft
Washer
*
1 1
0380606
INSPECTION
FUEL PUMP
Make the following
checks and replace as necessary.
Note that the fuel pump is a non-maintainable
assembly
must be replaced as an assembly.
l
Oil or fuel leaks from breather hole
l
Damage,
cracks on parts
l
Rocker arm for wear
1 STB Revision
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NllHChC
and
FBC SYSTEM
SERVICE
4.
cl= Front of engine
5EN016
POINTS
OF INSTALLATION
N14HDAC
INSTALLATION
OF FUEL PUMP
(1) Make sure that piston in No. 1 cylinder is in the top
dead center on compression
stroke.
(2) If the washer is moved after loosening of cylinder head
bolt proceed to the following
items.
0 Reinstall
the washer in position.
14-79
- Fuel Pump
Tighten the cylinder head bolts to specified

in the sequence
shown in the illustration.
Install the rocker cover.
torque
1. INSTALLATION
Refer to GROUP
Filter.
1 STB Revision
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OF AIR FILTER
11 INTAKE
AND EXHAUST
SYSTEM
- Air
14-80
FBC SYSTEM
- Fuel Tank
FUEL TANK
REMOVAL
AND INSTALLATION
Pre-removal
Draining
N14GA-
Operation
of the Fuel.
Post-installation
Operation
Supplying of the Fuel.
1 Nm
Z-30
18-22
Nm
ft.lbs.
15-25
11-18
Nm
ftlbs.
Removal steps
l +
l 4
~~
l +
l *
l +
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Drain plug
Fuel filler cap
Fuel filler hose protector
Vapor hose
Check valve
Overfill
limiter (Two-way
Clamp assembly
Fuel filler hose
Breather
hose
Packing
Fuel filler neck
Main hose
Return
hose
valve)
14.
15.
16.
17.
18.
19.
Fuel gauge
unit connector
connection
Fuel tank assembly
mounting
nuts
Fuel tank
Pipe assembly
Separator
tanks
Fuel tank protector
NOTE
to reinstall.
STB Revision
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FBC SYSTEM
14-81
- Fuel Tank
INSPECTION
Check
Check
Check
Check
l
l
l
l
N14GCAC
the hoses and the pipes for crack or damage.

the fuel tank cap for malfunction.
the fuel tank for deformation,
corrosion
or crack
the fuel tank for dust or foreign
material.
NOTE
If the inside of the fuel tank is to be cleaned,
of the following:
(1) Kerosene
(2) Trichloroethylene
(3) A neutral emulsion
type detergent
Check the in-tank fuel filter for damage
Check the check valve for malfunction.
l
l
CHECKING
(TWO-WAY
Outle
side
OVERFILL
VALVE)
use any one
or clogging.
LIMITER
may be adopted in
A simple way of inspection, however,
which the overfill limiter is removed and then air is lightly
blown into either the inlet or outlet by month. If the air passes
after a slight resistance, overfill limiter is in good condition.
03ROO21
SERVICE
POINTS
13. INSTALLATION
VAPOR HOSE
OF INSTALLATION
OF RETURN
HOSE/lZ.
N14GDAE
MAIN
HOSE/4.
When attaching the hoses to the pipes, be sure that the

hose is attached until its end comes in touch with the
bulge of the .pipe as shown in the illustration.
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9.
INSTALLATION
HOSE
OF BREATHER
Insert the hoses until their

5.
INSTALLATION
OF CHECK
HOSE/8.
ends contact
FUEL
FILLER
the fuel tank.
VALVE
Install the check valve to the fuel filler hose protector so

that the check valves arrow faces as shown in the figure.
I,\\
03W532
) STB Revision
http://vnx.su/
14-82
FBC SYSTEM
FUEL LINE AND VAPOR

REMOVAL
AND
- Fuel Line and Vapor
Line
LINE
INSTALLATION
N14KA-
--------
03w554
l +
e+
l +
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Fuel filter clamp

Fuel filter
Main hose
Return hose
Canister
Canister holder
Vapor hose
Fuel vapor pipe
Stay
Fuel purge hose

Purge control valve
Fuel vapor pipe
Fuel main pipe
Fuel return pipe
NOTE
l * : Refer to Service Points of Installation.
STB Revision
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FBC SYSTEM
Fuel
Line
and
Vapor
14-83
Line
INSPECTION
N14KCAB
Check the fuel hoses and pipes for cracks,

deformation,
deterioration
or clogging.
Check the fuel filter for clogging
or damage.
Check the canister for clogging
or damage.
l
l
l
bends,
CHECKING
PURGE CONTROL VALVE
(1) Make sure that the cooling water is at a temperature
between
80 and 90C (180 and 190F).
(2) Disconnect the purge control hose from the air filter and blow
into the purge hose. If the valve is not open, its operation is
normal. Then start the engine and increase the engine speed
to 1,500 to 2,000 rpm and blow into the purge hose. If the
valve is not open, check for clogged or broken vacuum hose,
or malfunctioning
therm0 valve.
t To carburetor
and therm0 valve
To air filter
From canister
03E562
SERVICE
7.
POINTS
INSTALLATION
MAIN HOSE
OF INSTALLATION
OF VAPOR
HOSE/4.
N14KDAD
RETURN
HOSE/3.
When attaching
the hose to the pipes, be sure that the
hose is attached
until its end comes in touch with the
bulge of the pipe as shown in the illustration.
/ STB Revision
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14-84
ENGINE
CONTROL
- Accelerator
Cable
ACCELERATOR
and Pedal
CABLE AND
PEDAL
ADJUSTMENT
OF ACCELERATOR
CABLE FREE PLAY
1. Run the engine until it reaches the specified
idle speed
level.
2. Loosen the locking
bolt or adjusting
nut at the cable
adjusting
portion so that the throttle
lever is free.
3. Move the holder to the position just before the throttle
lever begins to operate, and then return it far enough so
that there is an appropriate
amount of slack in the inner
cable and secure it at this position.
4. Operate the accelerator
arm and confirm that the throttle
valve changes from fully closed to fully open.
STB Revision
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ENGINE CONTROL-Accelerator
REMOVAL
AND
14-85
Cable and Pedal
N14QA-
INSTALLATION
16-19
12-14
Nm
ft.lbs.
\
8
Accelerator
+e l +
~~
~~
*+
l +
**
l +
1. Air filter
Adjustment of accelerator cable free play
2. Accelerator cable
Accelerator
l +
07W532
cable removal steps
3.
4.
5.
6.
7.
8.
pedal removal steps

Accelerator arm bracket
Cotter oin
Return spring
Accelerator arm
Spring
Pedal
NOTE
(1)
Reverse
the removal
procedures
(21 CI
: Refer
to Service
Points
64
: Refer
to Service
Points
(4) m:
Non-reusable
parts
i3j
1 STB Revision
http://vnx.su/
to
of
of
reinstall.
Removal
Installation.
14-86
ENGINE
CONTROL
- Accelerator
SERVICE
Cable
POINTS
and Pedal
OF REMOVAL
1. REMOVAL
OF AIR FILTER
Refer to GROUP 11 INTAKE
Filter.
N140BAA
AND EXHAUST
SYSTEM
INSPECTION
l
l
l
l
l
l
N140CAB
Check the
Check the
Check the
Check the
Check the
Check the
SERVICE
cable for damage.

cable outer casing for damage.
cable for unsmooth
movement.
accelerator
arm for bend.
return spring for deterioration.
connection
of accelerator
cable and end fitting.
POINTS
OF INSTALLATION
N140DAI
8. APPLICATION
OF GREASE
TO PEDAL17.
ACCELERATOR
ARM/5.
RETURN SPRING/S.
TOR ARM BRACKET
Apply the specified
of the pedal.
Specified
07FOO5
-Air
grease
grease
around
: Multipurpose
No. 3
SPRING/G.
ACCELERA-
the each moving
grease
SAE J310,
point
NLGI
25
2.
INSTALLATION
OF ACCELERATOR
Make sure that the accelerator
cable
bends.
CABLE
is laid without
ADJUSTMENT
CABLE
OF ACCELERATOR
sharp
FREE PLAY
Refer to P.14-84.
1. INSTALLATION
Refer to GROUP
Filter.
1 STB Revision
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OF AIR FILTER
11 INTAKE AND EXHAUST*SYSTEM
- Air
25-1
EMISSION CONTROL
CONTENTS
COMPONENT LAYOUT AND VACUUM
HOSE PIPING . ..m.......*.............,...,...,.....
COMPONENT
LAYOUT
VACUUM
HOSE PIPING
. . . . . . . . . . . . . . . . . . . . . . . . . ;:
. . . . . . . . . . 23
DIAGRAM
CRANKCASE EMISSION CONTROL

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSPECTION
VENTILATION
OF POSITIVE CRANKCASE
(PCV) VALVE . . . . . . . . . . . . . . . .
27
EVAPORATIVE EMISSION CONTROL

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSPECTION
OF BOWL VENT
VALVE (BW) . . . . . . . . . . . .
.. .. . . . . .
INSPECTION
OF OVERFILL
LIMITER
(TWO-WAY
VALVE) . . . . . . .
.. ... .. ... .
INSPECTION
OF PURGE CONTROL
SYSTEM
. .... .. .. ... .. .... ... .. ... ... . ...
INSPECTION
OF PURGE CONTROL
VALVE (PCV) . . . . . . . . . . . . . . . .
. ... .
INSPECTION
OF THERM0
VALVE . . . . . . . . . . .
27
30
28
28
29
EXHAUST EMISSION CONTROL SYSTEM . . 30
INSPECTION
OF AIR CONTROL
VALVE AND
THERM0
SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSPECTION
OF AIR FUEL RATIO
. . . . . . . . . . . . . . . . . . . . . 30
CONTROL
(FBC) SYSTEM
INSPECTION
OF: CARBURETOR
BLEED
AIR PASSAGE CLOGGING
. . . . . . . . . . . . . . . . . . . . . 38
INSPECTION
OF CHECK VALVE . . . . . . . . . . . . . . 37
INSPECTION
OF EGR VALVE
. . . . . . . . . . . . . . . 33
INSPECTION
OF EGR VALVE
CONTROL
VACUUM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSPECTION
OF ENGINE COOLANT
TEMPERATURE
SENSOR
. . . . . . . . . . . . . . . . . . . . . . 33
INSPECTION
OF ENGINE SPEED SENSOR
33
INSPECTION
OF EXHAUST GAS
RECIRCULATION
(EGR) SYSTEM
. . . . . . . . . . . . . 33
INSPECTION
OF HIGH ALTITUDE
COMPENSATION
SYSTEM
[High altitude specifications
for the 49 states
(excluding California)]
. . . . . . . . . . . . . . . . . . . . . 34
INSPECTION
OF HIGH ALTITUDE
COMPENSATION
SYSTEM
(Vehicles for California)
.. . .
. . . . . . . . . . . 38
N25AA-
INSPECTION
OF HIGH ALTITUDE
C04P/1PENSATOR
(HAC)
for the 49 states
. ... ... ..... .... ..... ... ....
(excluding California)]
INSPECTION
OF HIGH ALTITUDE
COMPENSATOR
(HAC)
(Vehicles for California)
... .... ,... ... ... ......
INSPECTION
OF INTAKE AIR
.. ... ...
TEMPERATURE
CONTROL
SYSTEM
INSPECTION
OF MIXTURE
CONTROL
VALVE (MCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION
OF SECONDARY
AIR
CONTROL
SOLENOID
VALVE . . . . . . . . . . . . . . . . .
INSPECTION
OF SECONDARY
AIR
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION
OF SECONDARY
AIR SUPPLY
.. ... ..... .... ... ... ... ..... ... ... .... .....
SYSTEM
INSPECTION
OF THERM0
VALVE . . . . . . . . . . .
INSPECTION
OF THREE CATALYST
CONVERTER
.. .... . .. . . .. .... . ... .... .
INSPECTION
OF VACUUM
REGULATOR
VALVE (VRV) ......................................
INSPECTION
OF VACUUM
SWITCH
........
INSPECTION
OF VACUUM
SWITCHING
VALVE (VSV) [High altitude specifications
......
for the 49 states (excluding California)]
INSPECTION
OF VRV CONTROL
.........................................
VACUUM
GENERAL INFORMATION
.......................
SPECIFICATIONS ...................................
GENERAL SPECIFICATIONS
SERVICE SPECIFICATIONS
SEALANTS AND ADHESIVES
http://vnx.su/
40
41
42
(..
32
.:<
31
1
.:,I :
ib
30
33
30
34
33
37
34
2
17
...................
....................
....................
.........................
17
17
17
18
.... . .................
CRANKCASE
EMISSION
CONTROL
SYSTEM
. .. .... .. ..... .. ... ... .... .... ... ... ..
EVAPORATIVE
EMISSION
CONTROL
SYSTEM
..... ... ... .... .... .... ... ... .... .... .... ..
EXHAUST EMISSION
CONTROL
SYSTEM
.. . .. .. ... . . .... . ... .... ... .... ..
TROUBLESHOOTING
36
t.
:.
6
7
9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
$
-?
.-
25-2
EMISSION
CONTROL
SYSTEM-General
GENERAL INFORMATION
Information
N25BEAA
The
(1)
(2)
(3)
emission control system has the following three major systems.

Crankcase emission control system
I
Evaporative emission control system
Exhaust emission control system
The crankcase emission control system is a system adopting a closed-type crankcase ventilation to prevent blow
by gas from escaping into the atmosphere.
The blow by gas generated in the crankcase is instead led to the
combustion
chamber for combustion.
The evaporative emission control system for preventing the emission of fuel vapor from the fuel tank, carburetor,
etc. into the atmosphere
consists of various components
(a canister, purge control valve, 2-way valve and so on)
which collect and lead generated fuel vapor to the combustion
chamber for combustion.
The exhaust emission control system consists of an air-fuel ratio control unit (FBC system), three catalyst converter,
exhaust gas recirculation system, secondary air supply system and so on to reduce emission ofC0, HC and NOX.
-.,
.
FBC: Feed Back Carburetor
1 STB Revision
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EMISSION
FBC SYSTEM DIAGRAM-vehicles
altitude
specification)
CONTROL
SYSTEM
- General
for the 49 states other
than
25-3
Information
California
(exclu&g
high-
!
-Ji
:
1 STB Revision
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25-4
EMISSION
CONTROL
FBC SYSWVI DIAGRAM-vehicles

other than California
with
SYSTEM
- General
high-altitude
1 STB Revision
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Information
specifications
for the 49 states
EMISSION
FBC SYSTEM
CONTROL
DIAGRAM-vehicles
for
SYSTEM
California
tI:
E
1 STB Revision
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- General
Information
25-5
25-6
EMISSION
CONTROL
SYSTEM-Technical
Description
CRANKCASE
EMISSION
CONTROL
SYSTEM
PCV valve
N25w
Carburetor
Breather hose
ker cover
Intake manifold
To intake manifold
1
5EM081
A closed-type crankcase ventilation

system is utilized to prevent the blow-by gas from escaping into the atmosphere. This system has a positive crankcase ventilation valve (PCV valve) at the rocker cover. This system supplies
fresh air to the crankcase though the air filter. Inside the crankcase, the fresh air is mixed with blow-by gases, and
this mixture passes through the PCV valve into the intake manifold. The PCV valve has a metered orifice through
which the mixture of fresh air and blow-by gases is drawn into the intake manifold in response to the intake
manifold vacuum. The valve capacity is adequate for all normal driving conditions.
1 STB Revision
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EMISSION
EVAPORATIVE
CONTROL SYSTEM-Technical
E ISSION CONTROL
Purge
Air cleaner
25-7
Description
N25HBAA
SYSTEM
Fuel check valve
yt?;;lurred by FMVSS
control valve
therm0 valve :
Overfill limiter
I (Two-way valve)
float chamber-
Bowl
Charcoal
-Fuel
Fuel filler cap (vacuum relief)
vent valve
Canister JlJ-tj
II
II
Thermal
expansion
volume
-~..
I
I
To carburetor
vapor
pi&J
--- Purge air
Filter
\
Fuel gauge
unit
Fuel tank
03W527
In order to prevent the loss of fuel vapor from the fuel system into the atmosphere, the evaporative
control system consists of charcoal canister, a bowl vent valve, a purge control valve, etc.
/ STB Revision
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emission
25-8
EMISSION
CONTROL
Vapor from carburetor

or from fuel tank
Canister
SYSTEM-Technical
Description
N25HEEA
CANISTER
While the engine is inoperative, fuel vapors generated inside the
fuel tank and the carburetor float chamber are absorbed and
stored in canister. When the engine is running, the fuel vapors
absorbed in canister are drawn into the intake manifold through
the purge control valve, and an orifice. And the carburetor bowl
vapors flow into the carburetor through the bowl vent valve.
CO3526
BOWL VENT VALVE

NZSHBCA
The bowl vent valve controls vapor in the carburetor bowl. While
the engine is running, the intake manifold vacuum acts on the
diaphragm to close the bowl vent valve so that the carburetor bowl
connects to the air vent. When the engine stops, the bowl vent
valve opens to connect the carburetor bowl to the canister, causing fuel vapor to be adsorbed by the canister.
t To carburetor
and therm0 valve
To intake
manifold
From canister
03E562
r0 fuel
(:heck valv
To fuel tank
VacuuCn
valve
PURGE CONTROL VALVE

N25HBDA
The purge control valve is kept being closed during idling to prevent vaporized fuel from entering into the intake manifold for positive control of high-idle CO emission, which is a particular problem
under high ambient temperatures
condition and once the throttle
ported vacuum working on the diaphragm
of the valve exceeds
the pre-set value, the purge control valve is opened.
N25HBEA
OVERFILL LIMITER (TWO-WAY
VALVE)
The overfill limiter consists of a pressure valve and a vacuum
valve. The pressure valve is designed to open when the fuel tank
internal pressure has increased over the normal pressure and the
vacuum valve opens when a vacuum has been producted in the
tank.
\
Pressure valve
03E506
To choke
opener
To purge
control valve
To EGR valve
To choke breaker
THERM0
VALVE
NZBHBFA
The therm0 valve, for sensing the coolant temperature
at the intake manifold, closes the purge control valve when the coolant
temperature
is lower than the pre-set value in order to reduce CO
and HC emissions under engine warm-up conditions, and opens
the purge control valve when the coolant temperature
is above the
pre-set temperature.
Therm0 sensor
for coolant temp.
detection
1 EMZO!
pm
wision
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EMISSION CONTROL SYSTEM-Technical
Description
FUEL CHECK-VALVE
To overfill
From
fuel
limiter
25-9
NZ5HBGA
The fuel check valve is used to prevent fuel leaks when the car
suddenly rolls over. This valve is connected in the fuel vapor line
(between fuel tank and overfill limiter) and is installed on the fuel
tank.
The fuel check valve contains two balls as shown in the illustration. Under normal conditions, the gasoline vapor passage in the
valve is opened, but if roll-over occurs one of the balls closes the
fuel passage, thus preventing fuel leaks.
tank
03E510
Relief
FUEL FILLER CAP

Fuel filler cap is equipped with relief valve to prevent
of fuel vapor into the atmosphere.
valve
N25HBHA
the escape
II
, ..i
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:.:;
03G0002
EXHAUST
EMISSION
CONTROL SYSTEM
N25HcAA )$
Exhaust emissions (CO, HC, NO) are controlled by a combination

of engine modifications
and the addition
of special control
components.
Modifications
to the combustion
chamber, intake manifold, camshaft, carburetor and ignition system form the basic control
system.
Additional control devices include a jet air system, an exhaust gas
recirculation (EGR) system, a catalytic converter, a secondary air
supply system, a dash pot, a heated air intake system.
These systems have been integrated into a highly effective system which controls exhaust emissions while maintaining
good
driveability and economy.
intake
stroke
1EMlOf
51
N25HcBA
JET AIR SYSTEM
In addition to the intake valve and exhaust valve, a jet ,valve has
been provided for drawing jet air (super lean mixture or air) into the
combustion chamber.
A jet air passage is provided in the carburetor, intake manifold and
cylinder head. Air flows through the intake openings provided near
the primary throttle valve of the carburetor, goes through the passage in the intake manifold and cylinder head, and flows through
the jet valve and the jet opening into the combustion
chamber.
The jet valve is actuated by the same cam as the intake valve and
by a common rocker arm so that the jet valve and intake valve
open and close simultaneously.
The jet air flowing out of the jet opening scavenges the residual
gases around the spark plug and creates a good ignition condition.
It also produces a strong swirl in the combustion
chamber which
continues throughout the compression stroke and improves flame
propagation after ignition, assuring high combustion
efficiency.
,
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i
a
&:
25-10
EMISSION
CONTROL
SYSTEM-Technical
Description
AIR FUEL RATIO CONTROL SYSTEM

[FEED BACK CARBURETOR
(FBC) SYSTEM]
The FBC system is essentially
an emissions control system which utilizes an electronic signal, generated by an
exhaust gas oxygen Sensor to precisely
control
the air-fuel mixture ratio in the carburetor. This in turn allows the
engine to produce exhaust
gases of the proper
composition
to permit the use of a three-way catalyst. The
three-way catalyst is designed to convert the three pollutants (1) hydrocarbons (HC), (2) carbon monoxide (CO), and
(3) oxides of Nitrogen (NOx) into harmless substances.
There are two operating modes in the FBC system:
(1) Open Loop-air fuel ratio is controlled by information
programmed
into the ECU at manufacture.
(2) Closed Loop-a? fuel ratio is varied by the ECU based on information supplied by the oxygen sensor.
Refer to GROUP
. .
14 FUEL SYSTEM
- General
Information
for detailed
description
of the FBC system.
,.:
CATALYTIC
CONVERTER
Stainless wire mesh

/
Exhaust
Cover
Stainless steel
lEM127
The three catalyst converter which is a monolithic

type with catalytic compositions
applied to the integrally constructed honeycomb
carrier surface is installed in the center of the exhaust pipe. The converter working in combination with the air fuel ratio feedback control oxidizes CO and HC and reduce NOx.
Function
The three catalytic converter removes CO, HC and NOx most
effectively in the vicinity of the stoichiometric
ratio. The air fuel
ratio feedback control by oxygen sensor controls the air fuel mixture to the stoichiometric
ratio and the catalytic converter promotes both oxidation and reduction of resultant exhaust gas to
make it clean before it is released to atmosphere.
Stoichiometric
ratio
wision
-7
http://vnx.su/
EMISSION
Description
25-11
Caution
The catalytic converters require the use of unleaded
gasoline
only. Leaded gasoline will destroy the effectiveness
of the
catalysts as an emission
control device.
Under normal operating
conditions,
the catalytic
converters
will not require maintenance.
However, it is important
to
keep the engine properly tuned. lf the engine is not kept properly tuned, engine misfiring
may cause overheating
of the
catalysts. This may cause heat damage to the converters
or
vehicle components.
This situation
can also occur during diagnostic testing if any spark plug cables are removed and the
engine is allowed to idle for a prolonged
period of time.
SECONDARY
AIR SUPPLY
SYSTEM
N25HCEC
Seconda
control v
From air
filter
I-
Reed valve
C.C.
C.C. : Catalytic converter
Engine speed sensor

Water temperature sensor
Vacuum switch
@JJ
1 EM206
c)
The reed valve supplies secondary air into the exhaust manifold for the purpose of promoting oxidation of exhaust
emissions. The reed valve is actuated by exhaust vacuum being generated from pulsation in the exhaust manifold,
and additional air is supplied into the exhaust manifold through the secondary air control valve.
Contents of Control
When the engine coolant is cold (18 - 52C (65 - 125F)J or when the vehicle is decelerating,
the ECU turns on
the power transistor to energize the secondan/ air control solenoid valve.
As a result, the intake manifold vacuum is introduced to the secondary air control valve and the secondary air is
supplied to the exhaust manifold.
1 STB Revision
http://vnx.su/
?
I>.
P
25-12
EXHAUST
EMISSION
GAS RECIRCULATION
CONTROL
SYSTEM-Technical
Description
(EGR) SYSTEM
N25HCFA
EGR valve
,/
EGR passage
regulator valve
Therm0 valve
Venturi
1 EM207
Exhaust Gas Recirculation

(EGR) system is designed to reduce oxides of nitrogen in the vehicle exhaust.
In this system, the exhaust gas is partially recirculated from an exhaust port at the cylinder head into a port located
at the intake manifold while the EGR flow is controlled by an EGR control valve, a vacuum regulator valve (VRV),
and a therm0 valve.
Operation
During idling or Throttle Wide Open Operation
In this case, the E port vacuum is low and the EGR valve is closed
by spring force. As a result, EGR gas does not flow.
EGR valve spring
NOTE
The EGR is not made to ensure stable idling operation.
When Engine Coolant is Cold

In this case, the therm0 valve opens to allow the E port vacuum to
escape to atmosphere.
As a result, the EGR valve does not operate.
NOTE
The EGR is shut off to secure driveability
lEMl36
j ST6 R4rvision
http://vnx.su/
when the engine is cold.
EMISSION
I
, EGR
valve
/
CONTROL
Description
25-13
During Low to Middle Load Operation

As the throttle valve is opened, the E port vacuum increases to
overcome the spring force of the EGR valve. As a result, the EGR
valve opens to cause the exhaust gas to recirculate to the intake
manifold, causing drop of the venturi pressure.
spring
Genturi
SYSTEM-Technical
1EM 13t
,VRV
spring
.(*A :
When the venturi pressure drops to near the atmospheric
pre$
sure, the VRV opens to allow the E port vacuum to escape tfi!
f.
atmosphere. Then, the EGR valve closes.
By repeating this cycle (closed loop control), EGR flow rate pro:;
!4
portional to the intake air volume can be obtained.
vk...
Y\
l&
NOTE
By controlling the EGR rate to optimum
level, exhaust emission
(NOx) is minimized without loss of driveability.
lFMlR7
@WV
E port
valve
Throttle
valve
closes
vacuum
to apply
to EGR
During High Load Operation

During high load operation, acceleration
or other conditions
in
which much NOx is produced, A port vacuum is made to act on
the VRV to shut off E vacuums escape passage to atmosphere
and to stop EGR exhaust pressure control action. As a result, the
EGR valve is controlled by E vacuum only and the EGR flow rate
increases.
1 STB Revision
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EMISSION
HIGH-ALTITUDE
fornia)]
COMPENSATION
CONTROL
SYSTEM
SYSTEM-Technical
[High
altitude
specifications
Description
for the 49 states
(excluding
Cali-
Distributor
High altitude
compensator
Intake manifold
vacuum
Additional
passage
bleed air
------.
Air inlet of
bleed air
7-d
Secondan/ emulsion
Primary throttle valve
Jet arr passage
bell
Secondary throttle valve
High-altitude compensation system

for the 49 states (excluding California)]
1 EM208
In order to meet the high-altitude

requirements
for the 49 states (ex. California), all the high-altitude
specification
carburetor vehicles are equipped with high altitude compensation
system in addition to feedback carburetor
system.
The carburetor meters fuel according to the volumetric
flow rate of air and supplies the resultant mixture to the
engine. Therefore, even if the carburetor is set for optimum
air-fuel rate at low altitude, the mixture becomes too
thick at high altitude since air is less dense at high altitude.
At high altitude, this high altitude compensation
system supplies additional bleed air to the carburetor emulsion well
and jet air passage to dilute fuel, preventing overrich air-fuel mixture that could otherwise be caused by drop of air
density at high altitude.
The system also advances the ignition timing by a fixed amount to reduce CO and HC emission and to secure
driveability at high altitude.
Operation
At low altitude, the HAC opens to allow the intake manifold vacuum to escape from the HAC to atmosphere.
Therefore, the vacuum switching valve and HACs additional bleed air passage remain closed and bleed air is not
supplied to the carburetor.
At high altitude, the HAC closes and the intake manifold vacuum is applied to the vacuum switching valve, HACs
additional bleed air passage and distributor.
As a result, the vacuum switching valve and HACs additional bleed air passage are opened to supply bleed air to
the carburetor. At the same time, the distributor advances the ignition timing.
1 STB Revision
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EMISSION
distributor
Check valve yl
compensator
Description
25-15
HIGH ALTITUDE COMPENSATION

SYSTEM FOR CALIFORNIA
VEHICLES
NZWCGD
In order to meet the California high-altitude
requirements
all the
California carburetor vehicles are equipped with high altitude compensation system in addition to feedback carburetor system.
Refor to HIGH ALTITUDE COMPENSATION
SYSTEM [High altitude specifications
California)],
P.25-14 for the contents of the system.
Primary
jet
Primary /
emission well
High-altitude compensation system

(California carburetor vehicles)
1 ENlO%
INTAKE
AIR TEMPERATURE
CONTROL
SYSTEM
Therm0 sensor
Vacuum motor
Air Ifilter
6EM071
All vehicles are equipped with a temperature

regulated air filter, as shown in illustration, so that the carburetor can
be calibrated leaner to reduce CO and HC emissions and improved engine warm-up characteristics and minimized
carburetor icing can be attained. The air filter is provided with an air control valve, inside the snorkel, to modulate
temperature
of carburetor intake air which flows through two routes. The air control valve is operated by a bi-metal
which responds to the intake air temperature,
or controlled by a vacuum motor/temperature
sensor combination
system which responds to the intake manifold vacuum and temperature
inside the air filter.
/ STB Revision
http://vnx.su/
:.
-.I-
25-16
EMISSION
CONTROL
SYSTEM-Technical
Description
Operation
l
When the bi-metal senses the temperature

ins&e air filter of below about 30C (86F) the air bleed valve of
temperature
sensor assembly
remains closed. Then, the intake manifold vacuum is applied to the diaphragm
of vacuum motor, which in turn, opens the air cdntrol valve so as to let the pre-heated
intake air flow through
the heat cowl and air duct into the air filter.
When the bi-metal senses the temperature
inside air filter of above about 45C (113F) the air bleed valve is fully
opened. As a result, the intake air to the carburetor
comes directly through the fresh air duct, since the air
control valve is positioned at B, regardless
of the intake manifold vacuum.
At intermediate
temperatures,
the air entering the carburetor
is a blend of fresh air and pre-heated
air as
regulated by the thermostatically
actuated air control valve.
MIXTURE
CONTROL
VALVE
(MCV)-VEHICLES
Filter \
WITH
A MANUAL
TRANSMISSION
1 Orifice
Purge jet
Check valve
Throttle valve
Chamber B
Chamber A
Manifold
pressure
negative
Secondary
Primary
5FUO76
When the throttle is closed suddenly during deceleration or shifting, the fuel remaining in the inlet manifold causes
an over rich mixture temporarily.
In order to prevent this, air is supplied temporarily from another passage so as to keep correct air fuel ratio and
reduce emission (HC).
Operation
When the throttle is closed suddenly, the manifold vacuum increases sharply. This increased manifold vacuum acts
on the chamber A of the MCV to open the valve so that air is supplied to the inlet manifold. The vacuum is also
supplied to chamber B but with some delay due to the orifice. When the vacuum is supplied to both chambers B
and A, they are at vacuum and hence the spring causes the valve to close, stopping supply of air. The check valve
located at the diaphragm is to prevent high vacuum from remaining in chamber B when acceleration/deceleration
is repeated successively. (If a high vacuum remains in chamber B, the valve may fail to operate when vacuum acts
on chamber A.)
m
Revision
http://vnx.su/
25-17
EMISSION CONTROL SYSTEM-Specifications
SPECIFICATIONS
GENERAL
N25cA--
SPECIFICATIONS
items
Specifications
Crankcase emission
:ontrol system
Positive
Evaporative emission
control system
Canister
2-way valve
Purge control valve (PCV)
Bowl vent valve (BW)
Equipped
Equipped
Single diaphragm
type
Vacuum type
(Purpose:
Control of HC emission)
Exhaust
control
Jet control
Jet swirl type

(Purpose:
Control
emission
crankcase
ventilation
combustion
Air fuel ratio control

Three
catalyst
(PCV) valve
Variable flow rate type

(Purpose: Control of HC emission)
type system
system
- FBC system
Oxygen sensor feedback type

1 (Purpose: Control of CO, HC, NOx emission)
I
converter
Monolithic
(Purpose:
Secondary air supply system

Reed valve
Secondary air control solenoid
Single type
With vacuum
Wax type
High altitude compensation

system - High altitude specifications
for the 49 states
and
California
High altitude compensator
(HAC)
control
Mixture
control valve (MCV)
a manual
transmission
system
- Vehicles
type
Control
With air control

On-off solenoid
valve
Exhaust gas recirculation

system
EGR valve
Vacuum regulator valve (VRV)
Therm0 valve
Intake air temperature
of CO emission)
of CO, HC, NOx emission)

valve
valve
control
COntrOl
(Purpose:
CO, HC emission)
(Purpose:
control
NOx emission)
Bellows
type
Vacuum control type

(Purpose: Control of CO, HC emission)
with
Differential
(Purpose:
pressure type valve

Control of CO, HC emission)
NZSCB-Specifications
Items
Secondary
air control
valve opening
High altitude
solenoid
valve coil resistance
temperature
compensator
operating
38 - 44 [at 20C (68F)I
!.I
18 (64)
65 (149)
C (F)
altitude
Approx.
m (ft.)
1,200 (3,900)
Nzxc--
Nm
ft.lbs.
50 - 60
37 - 44
70 - 100
52 - 74
bolt
19 - 28
14-
valve (for nipples)
20 - 40
15 - 30
Items
Secondary
air pipe control
Secondary
air pipe exhaust
EGR valve attaching

Therm0
Of
(Purpose: Control of
CO, HC emission)
Therm0
Of.
valve side joint

manifold
side joint
/ STB Revision
http://vnx.su/
20
.A,
,,:.,
25-18
EMISSION
SEALANTS
CONiROL
SYSTEM -Specifications
AND ADHESIVES
N25CE--
Items
Therm0
/ Troubleshooting
sealants
Spetified
valve
3M,
Adhesive
iNut
Locking
Quantity
and adhesives
As required
4171 or equivalent
TROUBLESHOOTING
N25EA--
Symptom
Probable
cause
Engine will not start

or is hard to start
(Cranking possible)
Vacuum
hose disconnected
Mixture
control
or damaged
idle or engine
Vacuum
Repair or replace
valve kept open
EGR valve kept open

Rough
stalls
Replace
~
hose disconnected
~-.
or damaged

High altitude specifications
and California
Faulty bowl
Mixture
control
Troubleshoot
the system and
check components
under suspicion
25-36
Repair or replace
25-33
Troubleshoot
the system and
check components
under suspicion
25-28
Replace
25-27
Replace
25-42
Replace
25-28
Troubleshoot
the system and
check each component
under
suspicion
25-33
Troubleshoot
the system and
check components
under suspicion
25-36
Replace
25-29
Troubleshoot
the system and
check components
under suspicion
25-41
line clogged
Check positive
tion system
Refer to
GROUP
0
system
Troubleshoot
the system and
check components
under suspicion
25-41
faulty
Troubleshoot
the system and
check components
under suspicion
25-33
system faulty for the 49 states,
Troubleshoot
the system and
check components
under suspicion
25-36
system
vent valve
control
valve kept open
Faulty PCV valve

Engine hesitates
poor acceleration
or
Exhaust
gas recirculation
system

and California
Therm0
Excessive
sumption
oil con-
Poor fuel mileage
Positive
crankcase
control
ventilation
Exhaust
faulty
valve faulty - cold engine
control
gas recirculation

and California
25-33
Repair or replace
Repair or replace
EGR valve kept open

Faulty purge
Reference
page
Remedy
system
system
1 ST6 Revision
faulty
faulty
-1
http://vnx.su/
crankcase
ventila-
;5
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1 STB Revision
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25-20
EfWSlON
COMPONENT
COMPONENT
CONTROL
SYSTEM-Component
Layout and Vacuum Hose Piping
LAYOUT AND VA~UUIVII HOSE PIPING
N25EA-A-
LAYOUT
A
5EM082
A PCV valve
B Canister
C Purge control valve
D Bowl vent valve
E Reed valve
F Secondary air control solenoid
G EGR valve
H Vacuum regulator valve
I
J
valve
STB Revision
Therm0 valve
High-altitude
compensator
[High-altitude
specifications
for the 49 states
(ex. California), vehicles for California]
K Vacuum
switching
valve
[High-altitude
specifications
for the 49 states]
L Air control valve
M Mixture control valve
(Vehicles with manual transmission)
rzi
http://vnx.su/
EMISSION
A
PCV valve
Purge
Reed valve
control
CONTROL
SYSTEM-Component
Layout and Vacuum Hose Wing
valve
Secondarv
ti
Vacuum
valve
air
STB Revision
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valve
regulator
High-altitude
comDensator
-.y
regulator
Vacuum
Therm0
25-21
I!+----
compensator
-I-
8 .
25-22
EMSSION
Vacuum
switching
Mixture
control
CONTROL
SYSTEM-Component
valve
Layout and Vacuum Hose Piping

.
valve (Vehicles
with
a manual transmission)
1 STB Revision
http://vnx.su/
Air control
valve
EMISSION
VACUUM
(excluding
CONTROL
SYSTEM
- c omponent
HOSE PIPING DIAGRAM-vehicles

high-altitude
specification)
II
Layout
and
Vacuum
for the 49 states
I
h
m
1 STB Revision
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Hose
piPin!
other than
25-23
California
25-24
EMlSSlON
CONTROL
SYSTEM
VACUUM
HOSE PIPING DIAGRAM-vehicles
states other than California
Component
Layout
and
with high-altitude
Vacuum
Hose
specifications
r
Ir
STB Revision
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Piping
for the 49
EMlSSlON
VACUUM
CONTROL
HOSE PIPING
SYSTEM
DIAGRAM-vehicles
- component
for
1 CTR Rnvision
http://vnx.su/
Layout
California
and
Vacuum
Hose
PiPing
25-25
u:(~
:. ,
25-26
EMISSION
CONTROL
SYSTEM
Purae control valve
Component
/3
Layout
and
Vacuum
Hose
Piping
To secondary air control valve
Therm6 valve
lfor AAP controll
EGRvalve
HAC-California
state, high altitude
specifications for the 49 states
Secondan/
5FU190
/ STB Revision
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,-.,
EMISSION
CONTROL SYSTEM
Crankcase
Evaporative
CAUTIONS
Emission
Emission
Control
Control
System
f
System
25927
ON INSPECTION
N25GALA
1. Adjust the engine before checking the system components.

(disengagement,
looseness,
etc.)
and check for break, incorrect piping and damage.
3. Check hoses, pipes and ports for clogging and check hoses
and pipes for cracks and damage.
4. When hoses are replaced, be sure to connect to original position (and in original direction).
5. After service, check piping connections
referring to service
label or service manual.
2. Check hose connections
CRANKCASE
TEM
EMISSION
N2SlAAA
INSPECTION OF POSITIVE
TION (PCV) VALVE
CRANKCASE
Refer to GROUP
0 LUBRICATION
Maintenance
Service
EVAPORATIVE
SYSTEM
INSPECTION
CONTROL SYS-
EMISSION
AND
VENTILA-
MAINTENANCE-
CONTROL
N2slBM
OF BOWL VENT VALVE (BW)
Caution
Check after the engine is allowed to cool enough. If the engine is not cold, fuel could gush out from the BW.

(2) Disconnect the bowl vapor hose from the bowl vent valve
(BW) nipple and connect a hand vacuum pump to the BW
nipple.
(3) Apply a vacuum of 20 kPa (3.0 psi) to the BW to check the
condition as follows.
Engine state
Stopped
Idling
ST6 Revision
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Normal condition
Vacuum leaks
Vacuum holds
25-28 EMISSION
CONTROL
SYSTEM
- Evaporative
Emission Control
System
INSPECTION OF PURGE CONTROL SYSTEM

From canister
t
1
l
Purge control valve

(PCV)
Therm0 valve
5EMO30
(1) Disconnect the black vacuum hose from the intake manifold
nipple and plug the nipple. Then, connect a hand vacuum
pump to the disconnected black vacuum hose.
(2) Check the following both when the engine is cold [engine
coolant temperature 50C (122F) or less] and when it is hot
[engine coolant temperature 85 to 95C (185 to 205F)J
When
engine
is cold
Normal
F%
:r59d::;zte
When
engine
condition
Vacuum is held
is hot
Vacuum
Engine state
Normal condition
53 kPa (7.7 psi)
Idling
53 kPa (7.7 psi)
2,500 rpm
Vacuum is held
Vacuum leaks
INSPECTION
OF PURGE CONTROL
VALVE
(PCVJ,
(1) Remove the purge control valve.

(2) Connect a hand vacuum pump to the vacuum nipple of the
PCV.
lEM143
/ STB Revision
-1
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-.. ,
EMISSION
CONTROL
SYSTEM
- Evaporative
Emission
Control
System
Z-29
(3) Apply a vacuum of 53 kPa (7.7 psi) to check air tightness.

(4) Blow in air lightly from the canister side nipple to check conditions as follows.
Normal condition
Hand vacuum pump vacuum

0 kPa
(No vacuum is applied)
Air does not blow through
27 kPa (3.9 psi) or more
Air blows through
INSPECTION
OF THERM0
NOTE
This therm0 valve
choke
opener.
also controls
VALVE
the choke
N25lBDb
breaker,
EGR and
Caution
1. When removing
or installing
the therm0
valve, do not
use wrenches
or other tools on the resin part.
2. When installing,
apply 3M Adhesive Nut Locking 4171 or
equivalent
to the threads and tighten to 20 to 40 Nm (15
to 30 ftlbs.).
the vacuum
hose, put a mark on
the hose so that it may be reconnected
at original
position.
(1) Disconnect
the vacuum hose (white stripe) from the therm0
valve and connect a hand vacuum pump to the therm0 valve.
(2) Apply vacuum to check therm0 valve condition as follows.
Engine coolant
Normal condition
10C (50F) or less
Vacuum leaks
25C (77F) or more
Vacuum holds
(3) Disconnect all vacuum hoses from the therm0 valve.

(4) Connect a hand vacuum pump to nipples (B), (C) and (D) and
apply vacuum to check therm0 valve condition as follows.
NOTE
Plug nipples other than one to which the hand vacuum pump
is connected.
5EMO42
Normal condition
40C (104F) or less
Vacuum leaks
80C (176F) or more
1 STB Revision
http://vnx.su/
Vacuum holds
25-30
HVMSION
CONTROL
SYSTEM
Evaporative
Emission
Control
System
Exhaust Emission
Control
System
INSPECTlON
VALVE)
Refer
OF OVERFILL
LIMITER
(TWO-WAY
N25lBEA
to GROUP
14 FUEL
EXHAUST
TEM
SYSTEM-Fuel
EMISSION
Tank.
CONTROL
SYSN25lCAA
INSPECTION
SYSTEM
OF AIR FUEL RATIO CONTROL
(FBC)
Refer to GROUP
14 FUEL SYSTEM-Inspection
of FBC System.
INSPECTION
OF THREE CATALYST
CONVERTTE!
For removal and installation

procedures,
refer to GROUP
INTAKE AND EXHAUST-Exhaust
Pipes and Main Muffler.
INSPECTION
Check for damage,
cracks
or fusion
and replace
II
if faulty.
Caution
1. Operation
of any type, including
idling,
should
be
avoided if engine misfiring
occurs. Under this condition
the exhaust
system
will operate
at abnormally
high
temperature,
which may cause damage
to the catalyst
or under-body
parts of the vehicle.
2. Alteration
or deterioration
of ignition
or fuel system, or
any type of operating
condition
which results in engine
misfiring
must be corrected
to avoid overheating
the
catalytic
onveters.
3. Proper maintenance
and tuneup according
to manufacturers
specifications
should
be made to correct the
conditions
as soon as possible.
INSPECTION
TEM
OF SECONDARY
(1) Disconnect
the air suppy hose from

plate at the disconnected
small steel
suction.
Engine coolant
perature
tern-
AIIR SUPPLY
the air filter and hold a

hose end to check air
Engine state
Air suction
20-40C
(68 - 104F)
Yes
Idling
70C (158F) or more

deceleration
Rapid
from 4,000 rpm
Caution
Note that
may blow
/ STB Revision
SYS-
if secondary
back.
-7
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air control
valve
Yes (within 70 seconds after start)

No (70 seconds or
more after stat-t)
Yes
is broken,
emission
i \.
EMISSION
CONTROL
SYSTEM
- Exhaust
INSPECTION
VALVE
(1) Remove
Emission
OF
25-31
System
Control
SECONDARY
AIR
,a
:.:
CONTROL
NZSICFA
the secondary
.-
air control valve.
(2) Blow in air from the air filter side to check that air does not:,
i
blow through.
:.
Air filter
lEM150
(3) Connect a hand vacuum pump to the secondary air control

valve nipple.
(4) Apply a vacuum of 67 kPa (9.7 psi) and check air tightness.
;;;
I.,
.
Exhaust
manifold side
lEM148
(5) Apply a vacuum of 20 kPa (3.0 psi) and blow in air tocheck
condition as follows.
IAilir
direction
1 Normal
Air filter side to exhaust

Exhaust
manifold
manifold
side to air filter
condition
Air blows
through
Air does not blow
through
(6) If any fault is found in above checks, replace the secondan/

control valve.
Secondary
50-60
1 STB Revision
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air control valve tightening

Nm (37-44 ftlbs.)
torque
air
. .
I.
25-32
EMISSION
CONTROL
SYSTEM
- Exhaust
Emission
Control
INSPECTION OF SECONDARY
NOID VALVE
System
AIR CONTROL SOLE-
NOTE
When disconnecting the vacuum hose, put a mark on the hose so
that it may be reconnected at original position.
(1) Disconnect the vacuum hoses, (red stripe, green stripe) from
the device box.
(2) Separate the harness connector.
Red
e box
5EMlOZ
(3) Connect a hand vacuum pump to the nipple to which red stripe
vacuum hose has been connected.
5EM103
(4) Apply vacuum and check air tighteness both when the battery
voltage is applied directly to the solenoid valve terminal and
when not applied
1 When
not applied
(5) Measure
Standard
solenoid
value
wision
) Open
1 Vacuum
coil resistance.
: 38 - 44 [at 20C (68F)]
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holds
\
C..
a, 1.
HWSSION
CONTROL
SYSTEM
- Exhaust
Emission
Control
System
INSPECTION
SENSOR
OF ENGCNE COOLANT
INSPECTION
OF ENGINE SPEED SENSOR
INSPECTION
OF VACUUM
Refer to GROUP
dures.
14 FUEL SYSTEM
INSPECTION
OF THERM0
Refer
to PURGE
CONTROL
25-33
::
TEMPERATURE
SWITCH
Proce-
VALVE
SYSTEM,
SPECTION OF EXHAUST
(EGR) SYSTEM
P.25-28.
GAS RECIRCULATION
N25lCJA
(1) Disconnect the vacuum hose (green stripe) from the carburetor throttle body and connect a hand vacuum pump to the
vacuum hose.
(2) Check the following both when the engine is cold [engine.
coolant temperature
45F (113F) or less] and when it is hot
[engine coolant temperature
85 to 95C (185 to 205F)l
When
engine
is cold
engine
INSPECTION
Normal condition
Vacuum leaks - from
therm0 valve into atmosphere
Engine state
Vacuum
Apply vacuum
When
3,500 rpm
is hot
N25uxA
OF EGR VALVE
(1) Remove the EGR valve and check it for sticking, deposit of
carbon, etc. If such condition exists, clean with adequate solvent to ensure tight valve seat contact.
(2) Connect a hand vacuum pump to the EGR valve.
(4) Blow in air from one passage of the EGR to check condition as
follows.
3EM135
Vacuum
Normal condition
8 kPa (I .2 psi) or less

Air blows through
Caution
When installing
the EGR, use a new gasket
11 Nm (5 to 8 ftlbs.).
1 STB Revision
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>
:1.
and tighten
to 7 to
,
:
25-34
EMISSION
CONTROL
SYSTEM
Exhaust
;;;;fCTl
Emission
system
Control
REGUJLATOR VALVE
N25lclA
OF VACUUM
(1) Disconnect the -vacuum hose (white stripe) from the device
box and connect a hand vacuum pump to the device box.
(2) Apply a vacuum of 53 kPa (7.7 psi) and check VRV condition as
follow.
Normal
5EMl07
condition
Vacuum leaks
IkPECTlON
OF EGR VALVE CONTROL
INSPECTION
OF VRV CONTROL VACUUM
Refer to GROUP
dures.
14 FUEL SYSTEM
INSPECTION
OF THERM0
Refer
to PURGE
CONTROL
VACUUJ
Proce-
VALVE
SYSTEM,
P.25-28.
INSPECTION OF HIGH ALTITUDE COMPENSATION

SYSTEM - Hiah altitude mecifications
for the 49
NZSICOE
states (excludisg Californiaj
INSPECTION
AT ALTITUDE
BELOW
1,200 m (3,900 ft.)
NOTE
When disconnecting
the vacuum hose, put a mark on the t lose so
Inspection
Condition
Engine coolant temperature:85
- 95C (185 - 205F)
(1) Set the timing light.
Primary emulsion
well bleed nipple
(3) Disconnect the vacuum hoses (black, red stripe, black) from
the carburetor primary emulsion well bleed nipple, secondary
emulsion well bleed nipple and jet air nipple and plug the
nipples.
Jet air nipple

I
(4) Connect a hand vacuum pump to the vacuum hoses, one hose
at a time, and check air tightness while running the engine at
idle.
Primary emulsion well (black)

~~~
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..
..
-:___.
:
EMISSION
CONTROL SYSTEM - Exhaust Emission Control
System
25-35
(5) Connect the disconnected

vacuum hoses to original
(6) Run the engine at idle and check ignition timing.
Standard
value
: 7BTDC
I..
position.
f 2
(7) While running the engine at idle, disconnect

the vacuum hose
(yellow stripe) from the HAC and put a finger at the hose end.
to check that vacuum is felt.
i
I,
INSPECTION
AT ALTITUDE
ABOVE
1,200 m (3,900
ft.)
NOTE
When disconnecting
the vacuum hose, put a mark on the hose so
that is may be reconnected
at original position.
Inspection
Condition
: 85 - 95C (185 - 205F)
(3) Disconnect
the vacuum hoses (black, red stripe, black) from
the carburetor
primary emulsion well bleed nipple, secondary
emulsion well bleed nipple and jet air nipple.
(4) Connect a hand vacuum pump to the vacuum hoses, one hose
at a time, and check air tightness
while running the engine at
idle.
Step 1
Vacuum hose
Primary
(black)
Secondary
(red stripe)
Jet air (black)
(5) Connect
STB Revision
emulsion
emulsion
the disconnected
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Normal condition
well
well
vacuum
Vacuum leaks
hoses
to original position.
..,_
>\,:;.. 8
I,;;,, ;
.
-..
25-36
EMISSION
CONTROL
SYSTEM
Exhaust
Emission
Control
System
(6) Run the engine at ilde and check ignition

Standard
value
: Approx.
timing.
1TBTDC
INSPECTION OF HIGH ALTITUDE COMPENSATOR

for the 49
(HAC) - High altitude specifications
states (excluding
California)
INSPECTION
AT ALTITUDE
BELOW 1,200 m (3,900 ft.)
(1) Disconnect the vacuum hose (yellow stripe) from the HAC and
cennect a hand vacuum pump to the HAC nipple.
(2) Apply vacuum and check that it leaks and does not hold.
(3) Disconnect the vacuum hose (red stripe) from the HAC and
connect a hand vacuum pump to the HAC nipple.
(4) Check that vacuum holds when applied.
INSPECTION
AT ALTITUDE
ABOVE 1,200 m (3,900 ft.)
(1) Disconnect the vacuum hose (yellow stripe) from the HAC and
connect a hand vacuum pump to the HAC nipple.
(3) Disconnect the vacuum hose (red stripe) from the HAC and
connect another hand vaccum pump to the HAC nipple.
(4) With vacuum held as in step (2). check that vacuum leaks and
dose not hold.
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.~. .~
EMISSION
CONTROL
SYSTEM
Exhaust
Emission
Control
System
25-37
INSPECTION
OF VACUUM
SWITCHING
VALVE
for the 49
(VSV) - High altitude specifications
states (excluding California)
NOTE
When disconnecting
he vacuum hose, put a mark on the hose so
(1) Remove the vacuum switching valve (VSV).

(2) Connect a hand vacuum pump to the black vacuum nipple of
the VSV.
lEM169
-_
(4) Blow in air lightly from the carburetor

check condition as follows.
air bleed side nipple and
Hand vacuum pump vacuum
Normal condition
27 kPa (3.9 psi) or less

Air blows through
INSPECTION
OF CHECK VALVE - High
specifications
nia), and vehicles for California
altitude
CaliforNzslclc
NOTE
When disconnecting
(1) Remove the check valve.
(2) Connect a hand vacuum

tightness.
pump to the check valve and check air

Normal condition
Color of nipple to which hand vatuum pump is connected

Dark blue
Vacuum leaks
White
Vacuum holds
6EM969
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..
1.
,; t
25-38
EMISSION
CONTROL
SYSTEM
- Exhaust
Emission
Control
INSffECTlON
OF CARBURETOR
SAGE CLOGGING (INSPECTION
HlGk ALTITUDE COMPENSATION
Refer to GROUP
dures.
14 FUEL SYSTEM-Service
System
BLEED AUR PASOF CARBURETOR

FUNCTION)
Adjustment
PEt
INSPECTION OF HIGH ALTITUDE COMPENSATION

N25lCOF
SYSTEM - Vehicles for California
INSPECTION
AT ALTITUDE
BELOW
1,200 m, (3,900 ft.)
NOTi
When disconnecting
Inspection
Condition
: 85 - 95C (185 - 205F)

(3) Disconnect the vacuum hose (black) from the carburetor
mary emulsion well bleed nipple and plug the nipple.
pri-
(4) Connect a hand vacuum pump to the vacuum hose and check
that vacuum is held when applied while running the engine at
idle.

vacuum hose to original
Standard
value
wision
: 7BTDC
http://vnx.su/
+ 2
position.
EMISSBQN
CONTROL
SYSTEM
- Exhaust
Emission
Control
System
25-39
(7) While running the engine at idle, disconnect the vacuum hose
(white stripe, two nipples side) from the HAC and hold a finger
at the hose end to check that vacuum is felt.
INSPECTION
AT ALTITUDE
ABOVE
1,200 m (3,900 ft.)
NOTE
When disconnecting
Inspection
Condition
: 85-95C(185
-205F)
(3) Disconnect the vacuum hose (black) from the carburetor

mar-y emulsion well bleed nipple.
pri-
(4) Connect a hand vacuum pump to the vacuum hose and while
running the engine at idle, apply vacuum to check the pressure
leaks and does not build up.

vacuum hose to original
Standard
http://vnx.su/
value
: Approx.
ITBTDC
position.
I
3
!L
25-40
I ..I
EMISSION
CONTROL
SYSTEM
- Exhaust
Emission
Control
INSPECTION OF HIGH ALTITUDE

(HAC) - Vehicles for California
INSPECTION
*:.
AT ALTITUDE
BELOW
System
COMPENSATOR
1,200 m (3,900 ft.)
+
.?.Y
!.
. .._
:n
\I
I,
: /.R
I
,
(1) Disconnect
the vacuum hose (white stripe, two nipples side)

from the HAC and connect a hand vacuum pump to the HAC
nipple.
(2) Apply vacuum and check that it leaks and does not hold.
the vacuum hose (black) from the HAC and con(3) Disconnect
nect a hand vacuum pump to the HAC nipple.
: J
i-8
I
INSPECTION
AT ALTITUDE
ABOVE
1,200 m (3,900 ft.)
(1) Disconnect
the vacuum hose (white stripe, two nipples side)

from the HAC and connect a hand vacuum pump to the HAC
nipple.
the vacuum hose (black) from the HAC and con(3) Disconnect
nect another hand vacuum pump to the HAC nipple.
2, apply vacuum and
(4) Holding the vacuum applied in procedure
check that it leaks and does not hold.
STB Revision-
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EMISSION
CONTROL
SYSTEM
- Exhaust
Emission
Control
25-41
System
INSPECTION OF INTAKE AIR TEMPERATURE

TROL SYSTEM
.i:
,,
CON-
(1) Remove the air filter cover and air duct.
(2) Run the engine at idle and check air control valve condition.
Normal condition
Cold air side inlet closes
Therm0 sensor temperature

30C (86F) or less
45C (I 13F) or more
5EM122
Cold air side inlet opens
NOTE
If necessary, apply compressed
hair dryer, etc. to heat.
Compress\ed air/,
air to cool or apply hot air using a
INSPECTION
OF AIR
THERM0 SENSOR
INSPECTION
(1) Remove
CONTROL
VALVE
AND +
N25lCTA
OF AIR CONTROL
the air filter.
VALVE
(2) Disconnect the vacuum hose from the air control valve and
connect
a hand vacuum
5EM123
(4) Check air control valve operation.

Vacuum
Normal condition
9 kPa (1.4 psi) or less
Cold air side inlet opens

Cold air side inlet closes

vacuum hose to the original posi-
tion.
5EM124
INSPECTION
OF THERM0
SENSOR
(1) Connect a hand vacuum pump to the therm0
and check air tightness.
Therm0 sensor temperature
30C (86F) or less
45C (113F) or more
Rewision
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,.,,
pump to the valve nipple.
I Normal condition
Vacuum holds
Vacuum leaks
sensor nipple
- ----./.
: 1.
: ._
,,,J 25-42
~~- --
EMISSION
.-- . .
.
CONTROL
SYSTEM
- Exhaust
Emission
Control
(2) If any fault is found in above checks,
System
replace the air filter body.
INSPECTION OF MIXTURE CONTROL VALVE (MCV)

NZWUB
- Vehicles with a manual transmission
Valve
Caution
Check the valve after warming
up the engine.

(2) Start the engine and open and close the throttle
tp check MCV operation and air suction noise.
,
Normal condition
valve quickly
MCV valve operation
Air suction noise
Pops out once and

quickly closes
Heard
Remains closed
Not heard
I
..
RJST608009-828
1. STB Revision
:
.:
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II-I
INTAKE
CONTENTS
AIR FILTER
..........................................................
EXHAUST
MANIFOLD
EXHAUST
PIPES AND MUFFLERS
GENERAL
INFORMATION
INTAKE
MANIFOLD
.......................................
...................
.................................
...........................................
4
11
13
2
6
I;
Nl lAA--
SPECIFICATIONS
...............................................
....................................
..................................
.....................................
.....................................
2
2
3
........................................
TROUBLESHOOTING
Abnormal Noise
Exhaust Gas Leakage
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2
3
.
.
11-2
INTAKE AND EXHAUST
- General
/ Specifications
Information
GENERAL INFORMATION
NllBAAD
Air filter is a dry type air filter.

The intake manifold, made of cast aluminum,
functions
to circulate engine coolant to the heat-riser (located at
the carburetor
installation
part) and to facilitate the atomization
of the air/fuel mixture.
There are also passages
for jet air and EGR (exhaust gas recirculation),
and a thermostat
housing is provided
near the no. 1 port.
The exhaust
system
is a single consisting
of four divisions:
the front exhaust
pipe, the under catalytic converter, the center exhaust pipe, and the main muffler.
The exhaust
manifold,
made of cast metal,
is the dual type, and functions
to reduce exhaust
interference.
:!; SPECIFICATIONS
i GENERAL
SPECIFICATIONS
NllCA-
Specifications
items
Air filter
Type
Heated air intake
Dry type
Vacuum motor type
Exhaust system
Front exhaust
pipe
Dual type
Expansion
Muffler
Coupling
Suspension
resonance
type
Spherical coupling
Rubber hangers and suspenders
system
Specifications
Items
Standard value
Intake and exhaust
manifold
Cylinder head installation
surface
distortion
mm (in.)
0.15 (.006) or less
surface
distortion
mm (in.)
0.3 (.012) or less
Limit
Intake and exhaust
manifold
Cylinder head installation
( STB Revision
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INTAKE AND EXHAUST
11-3
- Specifications
NllCC--
Nm
ft.lbs.
Air filter to rocker cover

Carburetor to intake manifold
16-19
12-14
15-20
11-14
Intake manifold to cylinder head
15-20
11-14
Water outlet fitting assembly to intake manifold
IO-13
7-9
Therm0 valve assembly to intake manifold
20-40
14-29
E.G.R. valve assembly to intake manifold
19-28
14-20
Vacuum connector joint
8-12
6-9
Air pipe assembly to bracket

Air pipe assembly to reed valve 6 bracket
12-15
IO-13
9-l 1
7-9
Therm0 switch to intake manifold

Watertemperature gauge unit to intake manifold
6-9
4-7
8-10
6-7
Water temperature sensor to intake manifold
20-40
14-29
Joint to intake manifold

Exhaust manifold cover to exhaust manifold
20-40
14-29
12-15
9-11
Air pipe assembly to exhaust manifold
70-100
51-72
Exhaust manifold to cylinder head
Items
15-20
11-14
Exhaust manifold to front exhaust pipe
20-30
14-22
Front exhaust pipe to exhaust pipe mounting bracket
20-30
14-22
Front exhaust pipe to under catalytic converter
15-25
11-18
Under catalytic converter to center exhaust pipe
40-60
29-43
Hanger bracket to suspender
8-12
6-9
Suspender to frame
Center exhaust pipe to main muffler
8-12
6-9
20-30
14-22
Main muffler to hanger
5-10
4-7
Hanger to frame
5-10
4-7
Oxygen sensor
40-50
29-36
SEALANTS
AND ADHESIVES
Nl lCD-
Items
Specified sealant and adhesive
Quantity
Therm0 switch (threaded part)

4171 or equivalent
As required
Water temperature gauge unit

(threaded part)
Water temperature sensor
. (threaded part)

4171 or equivalent
As required

4171 or equivalent
As required
Therm0 valve assembly (threaded part)

4171 or equivalent
As required
Joint (threaded part)

4171 or equivalent
As required
Water temperature switch

(threaded part)
3M AdhesiveNut
locking
4171 or equivalent
As required
( ST6 Revision
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11-4
INTAKE AND EXHAUST
/ Air Filter
-Troubleshooting
TROUBLESHOOTING
NllEAAA
Symptom
Probable cause
Remedy
Reference
we
Exhaust gas leakage
Loose joints
Retighten
II-13
Broken pipe or muffler
Repair or replace
11-13
Broken separator
Replace
11-13
Broken rubber hangers or suspender
Replace
11-13
Interference
body
Correct
11-13
Repair or replace
II-13
Abnormal
noise
in muffler
of pipe or muffler with vehicle
Broken pipe or muffler
; AIR FILTER
REMOVAL
AND
INSTALLATION
NllFA-
Removal
1.
2.
3.
4.
5.
6.
7.
8.
Wing nut
Connection
of breather hose
Air duct
Connection
of air hose
Air filter mounting nut
Heat duct
Connection
of vacuum hose
Air filter
NOTE
(2) l + : Refer to Service Point of Installation
SERVICE
2.
POINT
INSTALLATION
NOTE
Be careful,
when
1 STB Revision
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OF INSTALLATION
OF BREATHER
installing,
NllFDAA
HOSE
not to apply
oil etc. to the hose.
INTAKE
DISASSEMBLY
AND EXHAUST
- Air
II-5
Filter
NllFEAA
AND REASSEMBLY
6
Disassembly
steps
I.
2.
3.
4.
5.
6.
Air filter
Air filter
Secondary
Secondary
Air filter
Air filter
cover
element
air case
air filter
gasket
body
NOTE
parts
procedures
to reassemble.
i.
-:
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11-6
INTAKE
AND
EXHAUST
- Ontake Manifold
INTAKE MANIFOLD
REMOVAL
AND INSTALLATION
Pre-removal
Operation
Draining of coolant (Refer to
GROUP 0 LUBRICATION
AND
MAINTENANCE
- Maintenance
vice.)
Post-installation
Operation
0 Supplying of Coolant (Refer to
GROUP 0 LUBRICATION
AND
MAINTENANCE
- Maintenance
Service.)
l
Checking and adjustment
of idling
rpm and ignition timing (Refer to
GROUP 9 ENGINE - Service Adjustment Procedures.)
Ser-
15-20 Nm
1 I-14 ft.lbs
16-19 Nm
12-14 ft.lbs.
\
15-20 Nm
1 l-14 ftlbs
,,,i
1 l-14
12
ft.lbs.
04W569
Removal steps
+e
+I)
e+
e+
1.
2.
3.
4.
5.
6.
7.
8.
Air filter
Carburetor
Gasket
Connection
Connection
Water hose
Connection
Connection
hose
9. Connection
10. Connection
connector
tioner)
11. Connection
of
connector
12. Connection
of
unit connector
13. Connection
of
(Vehicles
with
14. Intake manifold
15. Intake manifold
assembly
of radiator
upper
of water
by-pass
hose
hose
of heater
of brake
vacuum
hose
booster
of vacuum
hose
switch
(Vehicles
with an air condi-
water
temperature
sensor
water
temperature
gauge
therm0
switch
connector
an automatic
transmission)
gasket
NOTE
(3) l + : Refer to Service Points of installation
(4) q
: Non-reusable
parts
1 STB Revision
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INTAKE
AND
EXHAUST
SERVICE
- Intake
POINTS
1. REMOVAL
11-7
Manifold
OF REMOVAL
OF AIR
NllMBAD
FILTER
Refer to P.l l-4.

2. REMOVAL
OF CARBURETOR
ASSEMBLY
Refer to GROUP 14 FUEL SYSTEM - Carburetor.
INSPECT10
NllMCAD
Check
found.
the following
INTAKE
MANIFOLD
points;
replace
the part if a problem
is
;z
i
(1) Check for damage

or cracking of any part.
(2) Check for obstruction
of the negative pressure (vacuum)
outlet port, and for obstruction
of the water passage or gas
passage.
(3) Using a straight edge and a thickness
gage, check for
distortion
of the cylinder head installation
surface.
Standard value : 0.15 mm (.006 in.) or less
Limit
: 0.3 mm (.012 in.) or less
SERVICE
2.
POINTS
OF INSTALLATION
INSTALLATION
OF CARBURETOR
ASSEMBLY
Refer to GROUP 14 FUEL SYSTEM - Carburetor.
1. INSiALLATlON
Refer to P.l l-4.
1 STB Revision
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OF AIR
FILTER
NllMDAC
5I
11-8
INTAKE
DISASSEMBLY
AND
AND
EXHAUST
- Intake
Manifold
REASSEMBLY
NllME--
8-9 Nm
5-6 ft.lbs.
10-14 Nm
7-10 ftlbs.
/
IO-13 Nm
7-9 ftlbs.
20-40
14-29
,----
Nm
ftlbs.
8-12 Nm
8-9 ft.lbs.
14-29 ftlbs.
14-20 ftlbs.
8-10 Nm
6-7 ftlbs.
04W567
Disassembly steps
l +
l +
l
l
l
l
+4
+
+
+
+
1. Water temperature
switch
(Vehicles
with
an air conditioner)
2. Plug (Vehicles
without
an air conditioner)
3. Joint
4. Engine
hanger
5. Vacuum
hose assembly
6. Joint
7. Therm0
valve assembly
sensor
gauge
unit
10. P.C.V. nipple
11. Therm0
switch
(Vehicles
with an automatic transmission)
l +
12.
13.
14.
15.
16.
17.
NOTE
(1) Reverse
(2)
(3)
1 STB Revision
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EGR valve assembly

EGR valve gasket
Water outlet fitting
Gasket
Thermostat
Intake manifold
the disassembly
: Refer
to Service
: Non-reusable
parts
assembly
procedures
Points
of
to reassemble.
Reassembly.
INTAKE
AND EXHAUST
SERVICE
- Intake
POINTS
16. INSTALLATION
Refer to GROUP
Il.
APPLICATION
11-9
Manifold
OF REASSEMBLY
NllMHAB
OF THERMOSTAT
7 COOLING -Thermostat
OF ADHESIVE
TO THERM0
SWITCH
Apply a coating of the specified adhesive to the threaded

part, and then tighten at the specified torque.
Specified
adhesive
: 3M Adhesive
equivalent
Nut Locking
4171 or
04W563
9.
APPLICATION
TURE GAUGE
Apply a coating
part, and then
Specified
OF ADHESIVE
TO WATER
TEMPERAUNIT
of the specified adhesive to the threaded
tighten at the specified
torque.
adhesive
: 3M Adhesive
equivalent
Nut Locking
4171 or
04w550
8. APPLICATION
OF ADHESIVE
TO WATER
TEMPERATURE SENSOR
Specified
04w559
adhesive
: 3M Adhesive
equivalent
Nut Locking
4171 or
7. APPLICATION
OF SEALANT
TO THERM0
VALVE ASSEMBLY
Specified
04W564
j STB Revision
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adhesive
: 3M Adhesive
equivalent
Nut
Locking
4171 or
1:
:
*
I
II-10
INTAKE
AND
EXHAUST
- Intake
6. APPLICATION
Manifold
OF ADHESIVE
TO JOINT

Part, and then tighten at the specified
torque.
Specified
adhesive
: 3M Adhesive
equivalent
Nut Locking
4171 or
04W562
3. APPLICATION
OF ADHESIVE
TO JOINT
part, and then tighten
at the specified
torque.
Specified
adhesive
1. APPLICATION
TURE SWITCH
Apply a coating
part, and then
Specified
OF ADHESIVE
STB Revision
http://vnx.su/
TO
Nut
Locking
WATER
4171 or
TEMPERA-
of the specified adhesive to the threaded

tighten at the specified
torque.
adhesive
04W.560
: 3M Adhesive
equivalent
: 3M Adhesive
equivalent
Nut
Locking
4171 or
INTAKE
EXHAUST
AND EXHAUST
- Exhaust
II-II
Manifold
MANIFOLD
REMOVAL
AND
INSTALLATION
NllNA-
16-19 Nm
12-14 ft.lbs.
10-13 Nm
j-9 ftlbs.
12-15 Nm
15-20 klm
11-14 ft.lbs.
40-50
29-36
Nm
ftlbs.
/
80
04W566
Removal steps
+e
l +
I.
2.
3.
4.
5.
Air filter
Air duct
Heat duct
Air pipe assembly
Reed valve B bracket
6.
Exhaust
manifold
10.
11.
12.
13.
Gasket
Engine
Exhaust
Exhaust
hanger
manifold
manifold
cover
7. Oxygen
sensor
8. Self-locking
nut
9. Connection
of exhaust
front exhaust
pipe
gasket
,\
manifold
and
NOTE
(1)
Reverse
the removal
procedures
(2)
l * : Refer to Service
Points
(3)
Points
(4)
: Non-reusable
parts
/ STB Revision
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to reinstall.
of Removal.
of Installation.
11-12
INTAKE
AND EXHAUST
SERVICE
- Exhaust
POINTS
Manifold
OF REMOVAL
NllNBAA
1. REMOVAL
OF AIR FILTER
Refer to P.l l-4.
INSPECTION
Check
found.
NllNdAD
the following
points;
replace
the part if a problem
is
EXHAUST
MANIFOLD
(1) Check for damage
or cracking of any part.
(2) Check for obstruction
of the negative pressure (vacuum)
outlet port, and for obstruction
of the water passage or gas
passage.
(3) Using a straight edge and a thickness
gauge, check for
distortion
of the cylinder head installation
surface.
Standard value : 0.15 mm (.006 in.) or less
Limit
: 0.3 mm (.OlZ in.) or less
EXHAUST
Check
for flaking
SERVICE
1.
MANIFOLD
or damage
POINTS
INSTALLATION
Refer to P.ll-4.
1 STB Revision
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GASKET
of the gasket.
OF INSTALLATION
OF AIR
FILTER
NllNDAB
INTAKE
EXHAUST
REMOVAL
AND
EXHAUST
- Exhaust
Pipes and Mufflers
II-13
PIPES AND MUFFLERS

AND
INSTALLATION
N1lRA--
40-60
29-43
Nm
ftlbs.
5-10 Nm
4-7 ft.lbs.
8-12 Nm
-22 ftlbs.
-30 Nm
15-22 ftlbs.
15-25
11-18
l +
~~
~~
l +
1.
2.
3.
4.
5.
6.
7.
8.
9.
IO.
iO0
8-l>
Nm
6-9 ft.lbs.
io
Nm
ft.lbs.
\
20-30 Nm
15-22 ft.lbs.
05W521
:
,
*
I
Gasket
Front exhaust
pipe
Spring
Suspender
Hanger
bracket
Center exhaust
pipe
Hanger
Main muffler
Catalytic
converter
assembly
Self-locking
nut
NOTE
parts
1 STB Revision
http://vnx.su/
II-14
INTAKE
AND
EXHAUST
- Exhaust Pipes
and
Mufflers
INSPECTION
NllRCAE
@ Check the mufflers or pipes for corrosion or damage.

l
Check the rubber hangers or suspenders
for deterioration
or damage.
l
Check for gas leakage from mufflers or pipes.
SERVICE
POINTS
OF INSTALLATION
NllRDAE
2. INSTALLATION
OF FRONT EXHAUST
PIPE/G. CENTER
EXHAUST
PIW8.
MAIN MUFFLER /9. CATALYTIC
CONVERTER ASSEMBLY
(1) Temporarily
install the front exhaust pipe, the catalytic
converter assembly,
the center exhaust pipe, and the
main muffler in that order.
Caution
With temporarily
tightened,
no distortion
of the hangers.
check to be sure there
is
(2) After fully tightening

each exhaust
pipe and main
muffler, check to be sure there is no contact with the
chassis at any place.
STB Revision
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7-1
COOLING
CONTENTS
COOLING
FAN
GENERAL
INFORMATION
RADIATOR
SERVICE
.. . . . . . . . . .. . . .. . . . . . . .. . . . . . . . . . . . . .. .. . . . . . . . . . ..
. . . . . . .. . . . . . . . . . . .. .. . . . . . . . . . ..
. . . .. .. . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . . . ..
ADJUSTMENT
PROCEDURES
. . . . . . . . . . .._...._...._.....
Coolant
Concentration
Coolant
Leak Check
. . . . . .. .. . . . . . . . . . . .. ..._........._...._
Coolant
Replacement
.._.........._....._,,.._.,.,..._..,
Drive Belt Deflection
Test
. . . . . . . . ..
SPECIAL
Cap Pressure
TOOL
Test
. ... ..
....................................
Specifications
3
4
...........................................................
Sealants
3 ;,
4
.......................................................
Lubricants
Service
Specifications
.....................................
Torque
Specifications
.....................................
. . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . 10
TROUBLESHOOTING
Drive Belt Deflection

Checking
Procedure
.. . . . . . . . . . . . . ~~.~....~.,~~~_.~..~.~..~~_....~.~.~~...~~
6
Radiator
General
THERMOSTAT
.._.......
Adjustment
...............................................
SPECIFICATIONS
.. . . . . . . . . .. . . . . . . .. .. . . . . . . . . ...s......
No Rise in Temperature
Overheat
.. ... . . .
WATER
HOSE AND PIPE
. . .. . . . . . . . . . . .. .. . . . . . . . . . . .. . . . . . . . . .. .. . . . . . . . . .
WATER
PUMP
WATER
TEMPERATURE
http://vnx.su/
. . . . . . . .. .. . . . . . . . . .. .. . . . . . . . . .. . . 15
. .. . . . . . . . . . . . .. . . . . . . . . .. . . . . . ..~..........~.......
GAUGE
UNIT
12
. . . . .. .. . . . . 17
7-2
COOLING
GENERAL
- General
Information
INFORMATlON
N07BABB
The cooling system is a water cooling

type and the coolant is forcibly circulated
by the water pump. The
temperature
control of the coolant is conducted
by the thermostat installed in the intake manifold.
Immediately
after engine starting,
the coolant does not flow into the radiator until the coolant temperature
reaches the thermostat
valve opening
temperature.
The coolant circulates in the engine and it is promptly
warmed up to the proper temperature,
and at the same time, the temperature
of the coolant in the cylinder
block and cylinder head is made uniform. When the coolant temperature
rises and the thermostat
valve
opens, the coolant flows into the radiator. The coolant cooled by the radiator is pumped up and pressurized
by the water pump and delivered to the cylinders and cools the engine. Also, the cooling fan is installed at
the water pump pulley and reduces the coolant temperature
in proportion
to the engine revolution.
Furthermore,
between the fan and pulley, the fan clutch is installed, which reduces the engine output loss
and noise.
Carburetor
Thermostat
pump
Water
At cold
Radiator
ooling
fan
Carburetor
/
Thermostat
\
IHeater
At hot
-.i:-:
J
Radiaior
)
Cooling
0480047
fan
1 STB Revision
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7-3
COOLBNG -Specifications
SPECIFICATIONS
GENERAL
SPECIFICATIONS
NO7CA-
items
Specifications
Cooling method
Water-cooled,
pressurized,
forced circulation
Radiator
Pressurized
Type
Performance
corrugated
fin type
kJ/h (kcal/h, B.T.U./h)
Vehicles with a manual transmission

Vehicles with an automatic
Fan clutch
182,512 (43,600, 173,016)
transmission
187,326 (44,750, 177,579)
Type
Water pump
Thermostatic
control type with spiral type bimetal
Type
Thermostat
Impeller of centrifugal
type
Wax pellet type with jiggle valve
Type
Identification
mark
88 (Stamped on flange)
Drive belt
We
Water temperature
V-belt
gauge unit
Thermistor
Type
Thermoswitch
for automatic
Type
Water temperature
transmission
Thermo-ferrite
type
sensor
Thermistor
We
Thermoswitch
type
type
for air conditioner

Heat-sensitive
Type
thermistor
type
N07CB--
Specifications
Items
Standard value
Opening
pressure
of radiator cap high pressure
Range of concentration
Alternator
of anti-freeze
drive belt deflection
valve
%
in coolant
kPa (psi)
valve opening temperature
Thermostat
full-opening
temperature
9-12 (.35-.47)
88(190)
C (F)
100 (212) or more
C (F)
Limit
Opening
pressure
I-15)
30-60
mm (in.)
Thermostat
75-105(1
of radiator cap high pressure
valve
kPa (psi)
) ST6 Revision
http://vnx.su/
65 (9.2)
7-4
COOLING
- Specifications
N07CG
Alternator
ft.lbs.
Nm
Items
12-15
9-l 1
20-22
14-16
Radiator shroud to radiator
3-7
2-5
Radiator to headlight support
Alternator
Radiator
brace bolt
nut
support
8-l 1
6-8
Cooling fan to fan clutch
IO-12
7-9
Fan clutch to water
8-10
IO-13
6-7
pump pully
Water outlet fitting attaching
bolt
7-9
Air cleaner attaching nut

Air pipe assembly to reed valve bracket
16-19
12-14
10-13
7-9
Air pipe assembly
flare nut
70-l 00
51-72
Exhaust manifold
cover
12-15
9-l 1
Exhaust manifold attaching nut

Exhaust manifold to exhaust pipe
15-20
20-30
11-14
14-22
Water pipe attaching
IO-12
7-9
6-9
4-7
IO-14
7-10
bolt
Thermoswitch
Nater temperature
switch
JVater temperature
sensor
20-40
14-29
Water temperature
gauge unit
8-10
6-7
LUBRICANTS
NOICD--
lit.(U.S.qts.,
Items
Recommended
DIA QUEEN LONG-LIFE
-, (Part No. 0103044)or
Engine coolant
antifreeze
Imp.qts.1
*Quantity
COOLANT
8.0 (8.5,7.0)
HIGH QUALITY ETHYLENE GLYCOL

ANTIFREEZE COOLANT
..
..
;
NOTE : * Includes
SEALANTS
0.65 lit. (0.69 U.S.qts.,
0.57 Imp.qts.)
in reserve tank
AND ADHESIVES
Items
N07CE-
Specified
sealants
and adhesive
Quantity
Water temperature
gauge unit
3M ART Part No. 8660

or equivalent
As required
Water temperature
sensor
3M Adhesive Nut locking

4171 or equivalent
As required
Water temperature
switch

or equivalent
As required

4171 or equivalent
As required
Therm0 switch
1 STB Revision
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COOLING
7-5
- Special Tool / Troubleshooting
SPECIAL TOOL
Tool (Number
NQIDA-
and name)
Use
MIT2 10863
Radiator cap test adapter
Radiator cap test
:
,
TROUBLESHOOTING
NO7EBAA
Symptom
Probable cause
Remedy
Reference
we
Overheat
Improper
Replenish
7-6
Correct
7-6
Loose or broken drive belt
Replace
7-6
Inoperative
fan clutch
Replace
7-9
Damaged or blocked (insufficiently

ventilated) radiator fins
Correct
coolant
Coolant concentration
Water leaks
Damaged
too thick
radiator core joint
Replace
7-8
Corroded or cracked hoses

(radiator hose, heater hose, etc.)
Replace
7-8,15
Loose bolt or faulty gasket in

water outlet fitting (thermostat)
Correct or replace
7-l 0
Correct or replace
7-12
Faulty radiator cap valve or setting

of spring
Replace
7-6
Loose cylinder head bolt

Damaged cylinder head gasket
Correct
9-39
9-17
Cracked
cylinder block
cylinder head
Replace
Replace
9-64
Cracked
Replace
7-10
Replace
7-12
Loose water pump mounting

faulty gasket
Faulty thermostat
Faulty water
No rise in
temperature
bolt or
operation
pump operation
Replace
Water passage clogged with slime or

rust deposit or foreign substance
Clean
Faulty thermostat
Replace
1 STB Revision
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9-39
7-10
1:
f
7-6
COOLING
- Service
Adjustment
Procedures
SERVICE ADJUSTMENT
CbOLANT
PROCEDURES
LEAK CHECK
NOIFAAD
1. Loosen radiator cap.

2. Confirm that the coolant level is up to the filler neck.
3. Using a special tool, install a radiator cap tester to the
radiator filler neck and apply 160 kPa (23 psi) pressure.
Hold for two minutes in that condition,
while checking for
leakage from the radiator, hose or connections.
Caution
Be sure to completely
clean away any moisture
from the
places checked.When
the tester is removed,
be careful
not to spill any coolant
from
it. Be careful,
when
installing
and removing
the tester and when testing,
not
to deform the filler neck of the radiator.
.
!,
.-*.
.I
A
4.
.[
If there
is leakage,
repair
or replace
the appropriate
part.
.(
RADIATOR
1.
2.
CAP PRESSURE
3.
N07FBAC
Use a special tool to attach the cap to the tester.

Increase the pressure until the indicator of the gauge
moving.
Standard
value : 75-105
Limit
: 65 kPa (9.2 psi)
TEST
Replace the radiator

or above the limit.
kPa (11-15
cap if the reading
stops
psi)
does not remain
at
NOTE
Be sure that the cap is clean before testing, since rust or
other foreign
material
on the cap seal will cause an
improper indication.
COOLANT
REPLACEMENT
N07FCAA
Refer to GROUP
0 LUBRICATION
Maintenance
Service.
AND
COOLANT
TEST
CONCENTRATION
Refer to GROUP
0 LUBRICATION
Maintenance
Service.
DRIVE
DURE
BELT
DEFLECTION
AND
MAINTENANCE
N07FDAC
MAINTENANCE
CHECKING
1. Check to be sure that the belt is correctly

groove of the pulley.
PROCEN07FEAE
installed
in the
Caution
If there is belt squeal or slippage,
check the amount
deflection,
check for wear, damage
or deterioration
the surface of contact
with the pulley, and check
scars on the pulley.
1 STB Revision
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of
at
for
COOLING
Service
2.
Water pump
pulley
Adjustment
Crankshaft
pulley
04B0028
7-7
Apply a pressure of 100 N (22 Ibs.) to the rear surface of

the belt at the center between the pulleys, as shown in the
figure, and then measure the amount of deflection.
Standard
Alternator
pulley
Procedures
value
: 9-12
mm
(.35-.47
in.)
Caution
Measure the amount
of belt deflection
between the
designated
pulleys.
An overtensioned
belt could cause not only premal
ture belt wear but also noise and damage to water
pump bearing
and alternator
bearing.
A loose belt also could cause failure of the alternator
to generate
enough
power
and consequently
a
rundown
battery.
l
-1
DRIVE
BELT DEFLECTION
ADJUSTMENT
Vehicles
without
an air conditioner
1. Loosen the alternator brace bolt and the alternator
nut.
2.
3.
Vm (ft.lbs.1
(14-16)
support
04w551
Vehicles
with an air conditioner
1. Loosen the alternator support nut and the bolt holding the
alternator.
2. Adjust the amount of deflection
of the belt by using the
tension-adjustment
bolt.
3. Tighten the alternator support nut and the bolt holding the
alternator.
http://vnx.su/
N07FFAD
Place a bar or similar object in contact with the stator part

of the alternator, and manually provide the suitable tension
to adjust the amount of belt deflection.
Tighten the alternator brace bolt and the alternator support
nut to the specified torque.
rvrsron
,,.+
!,
:
.
;
,f, ,
/:
7-8
COOLING
- Radiator
RADIATOR
REMOVAL
AND INSTALLATION
NOIQA-
8-11 Nm
6-8 ftlbs.
Operation
IPre-removal
,l Draining of the Coolant (Refer to
GROUP 0 LUBRICATION AND
I
MAINTENANCE - Maintenance Ser- 1
vice.)
,l Draining of the Automatic Transmission Fluid (Refer to GROUP 0 LUBRICATION AND MAINTENANCE Maintenance Service.)
Post-installation
l
w
I
\
3-7 Nm
2-5 ftlbs.
04W572
4. Connection of overflow hose

- 5. Hadtator upper nose
6. Radiator lower hose
7. Radiator upper shroud
8. Radiator lower shroud
9. Connection of automatic oil cooler hoses
(Vehicles with an automatic transmission)
10. Radiator
Reserve tank removal steps
4. Connection of overflow hose
11. Overflow tube
12. Reserve tank
NOTE
Reversethe removal proceduresto reinstall.
Operation
Supplying of the Coolant (Refer to

MAINTENANCE - Maintenance Service.)
Supplying of the Automatic Transmission Fluid (Refer to GROUP 0
LUBRICATION AND MAINTENANCE
- Maintenance Service.)
Radiator removal steps

1. Air duct
2. Radiator cap
3. Drain plug
INSPECTION
l
l
l
l
l
l
l
Check
Check
Check
Check
tion.
Check
Check
Check
NOIQCAB
for foreign material between radiator*fins.

the radiator fins for bend or damage.
the radiator for corrosion, damage, rust or scale.
the radiator hoses for cracks, damage or deteriorathe reserve tank for damage.
the spring of radiator cap for deterioration.
the packing of radiator cap for damage or cracks.
1 STB Revision
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COOLING
COOLING
RAMOVAL
7-9
- Cooling Fan
FAN
AND
INSTALLATION
NOIHA--
8-10
Nm
6-7 ft.lbs.
Removal
2-5
steps
1. Radiator
upper
2. Cooling
fan
3. Fan clutch
ft.lbs.
NOTE
shroud
INSPECTION
COOLING
l
l
04BOO24
to reinstall.
?
N07HCAA
FAN
Check blades for damage and cracks.

Check bolt holes or their vicinity in fan hub for cracks and
damage.
FAN CLUTCH
l
Check fan clutch for fluid leaks from case joint and seals. If
fluid quantity
decreases
due to leakage, fan speed will
decrease and engine overheating
might result.
l
When a fan attached to an engine is turned by hand, it
should give a sense of some resistance. If fan turns lightly,
it is faulty.
l
Check bimetal strip for damage.
Bimetal
6COOlO
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Revision
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>:
;
I
c,
2
7-10
COOLHW
- Thermostat
THERMOSTAT
REMOVAL
Draining
AND INSTALLATION
of the Coolant
MAINTENANCE
Post-installation
(Refer to
~ Maintenance
N07GL
Ser-
Operation
Supplying of the Coolant
(Refer to
MAINTENANCE
- Maintenance
Service.)
-4
IO-13 Nm
7-9 ft.!bs.
5
0480031
Thermostat
kit
0400030
Removal steps
1. Connection of water temperature switch
connector (Vehicles with an air conditioner)
2. Connection of radiator upper hose
3. Water outlet fitting
4. Water outlet fitting gasket
l + 5. Thermostat
1 STB Revision
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NOTE
parts
COOLING
7-11
- Thermostat
INSPECTION
N07GDAC
I.
If the valve opens at all at room temperature

the part
should be replaced.
2. An obviously malformed
part or one with cracks or damage
should be replaced.
3. Clean off any rust or encrustation
on the valve.
4. Immerse
the thermostat
in a container filled with water.
Raise the temperature
of the water while stirring
it
checking to ensure that the temperatures
at which the
valve begins to open, and at which it is fully open [(the fully
opened valve should be raised at least 8 mm (.31 in.)] are
within the specified values.
Standard values :
Opening temperature
Fully open
88C ( 190F)
100C (212F) or more
NOTE
The height of the valve when fully opened
calculated
by first measuring
its height when
and determining
the difference.
5.
POINTS
OF INSTALLATION
INSTALLATION
OF THERMOSTAT
Install the thermostat
to the intake
manifold
N07GEAA
as illustrated.
Caution
The thermostat
flange
fits over the manifold
seat;
ensure that the thermostat
is not installed
at an angle.
77
Must
6e hmost
parallel
STB Revision
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c
.(
.$
0..I
y;.:
should be;,: 1.c?

fully closed
04UOO18
SERVICE
si
7-12
COOLING
- Water Pump
WATER PUiVlP
REMOVAL
AND INSTALLATION
Draining
of the Coolant
MAINTENANCE
NOIMB-
(Refer to
- Maintenance
Ser-
3-7 Nm
2-5 ft.lbs.
4*
l +
l +
a*
l +
2
1. Radiator upper shrouu
2. Radiator lower shroud
3. Cooling fan clutch assembly
Adjustment of air conditioner compressor
4. Air conditioner compressor drive belt
(Vehicles with an air conditioner)
Adjustment of alternator drive belt deflection
drive belt
of power
steering
oil pump

6. Power steering oil pump drive belt
7. Water pump pully
4*
Removal steps
5. Alternator
Adjustment
8. Connection
9. Connection
of radiator
of heater
lower
hose
hose
l * 10. Water pump

11. Water pump gasket
NOTE
to reinstall.
(3) l + : Refer to /Service Points of Installation.
parts
( STB Revision
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COOLING
7-13
- Water Pump
SERVICE
POINTS
OF REMOVAL
N07MCAC
4.
REMOVAL
OF AIR CONDITIONER
COMPRESSOR
DRIVE
BELT
(1) Loosen the nut holding the tension pulley.
(2) Loosen the nut for tension
adjustment,
and then
remove the drive belt.
5.
REMOVAL
OF ALTERNATOR
DRIVE BELT
Vehicles without
an air conditioner
Loosen the alternator brace bolt and the alternator
nut, and then remove the alternator
drive belt.
r :
support
i:
!,
04w557
Vehicles
with
an air conditioner
(1) Loosen the bolt holding the alternator and then loosen
the alternator
support nut.
(2) Loosen the bolt for deflection
adjustment,
and then
remove the alternator
drive belt.
6.
REMOVAL
OF POWER
STEERING
OIL
BELT
Loosen the bolt holding the power steering
then remove the drive belt.
INSPECTION
BELT
l
Check surface for damage, peeling or cracks.
l
Check surface for presence of oil or grease.
l
Check rubber for wear or hardening.
I STB Revision
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PUMP
DRIVE
oil pump,
and
NOIMDAC
+I
it.
;
,?.
5
7-14
COOLING
- Water
WATER
l
l
l
l
Pump
PUMP
Check each part for cracks, damage

or wear, and replace
the water pump assembly
if necessary.
Check
the bearing
for damage,
abnormal
noise
and
sluggish rotation, and replace the water pump assembly
If
necessary.
Check the seal unit for leaks, and replace the water pump
assembly
if necessary.
Check for water leakage. If water leaks from hole A seal
unit is faulty. Replace as an assembly.
1 coo05
SERVICE
POINTS
10. INSTALLATION
7J
f
7%
j-
OF WATER
N07MEAE
PUMP
The dimension
of the water pumps
installation
bolt differs
according
to the installation
location,
so care must be
taken to avoid incorrect
installation.
e
Strength classification indication
OF INSTALLATION
I /
No.
Strength classification
(Head mark)
I 1 I
4T
dxe
mm (in.)
II
8x23(.31
x.90)
8x28(.31
x1.10)
4T
4T
8x88(.31
x3.46)
4T
8x78(.31
x3.07)
ADJUSTMENT
OF POWER
BELT DEFLECTION
Refer to GROUP
Procedures.
I
I
I
I 2 I
ADJUSTMENT
TION
STEERING
19 STEERING
OF ALTERNATOR
OIL PUMP
Service
DRIVE
DRIVE
Adjustment
BELT
DEFLEC-
Refer to P.7-7.
l
ADJUSTMENT
DRIVE BELT
OF AIR CONDITIONER
DEFLECTION
COMPRESSOR
Refer to GROUP 24 HEATERS AND AIR-CONDITIONING

Service Adjustment
Procedures.
1 STB Revision
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COOLING
- Water
and Pipe
Hose
WATER HOSE AND PIPE

REMOVAL
AND
INSTALLATION
16-19
12-14
IO-13 Nm
7-9 ft.lbs.
Draining
of the Coolant
MAINTENANCE
Draining
MAINTENANCE
4-i
t
(Refer to
- Maintenance
of the Coolant
Nm
ftlbs.
Ser-
04w570
(Refer to
- Maintenance
Ser-
Water pipe removal steps

l + I)+
I)+
1.
2.
3.
4.
5.
6.
7.
8.
Air filter
Reed valve and air pipe assembly
Reed valve bracket
Exhaust manifold cover
Engine hanger
Connection of oxygen sensor connector
Self-locking nut
Connection of exhaust manifold and exhaust pipe
9. Gasket
10. Exhaust manifold
11. Exhaust manifold gasket
12.
13.
14.
Water hose
Connection of heater hose

Heater hose
Water pipe
removal stew
15. Water hose

16. Water by-pass hose
NOTE
to reinstall.
(2) +*
(4) q
: Non-reusable
parts
) STB Revision
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,i.
,:
7-16
COOLING
- Water
SERVICE
Hose and Pipe

POINTS
OF REMOVAL
N07lB-
1. REMOVAL OF AIR FILTER

Refer to GROUP
SERVICE
POINTS
11. INSTALLATION
Replace
Refer to GROUP
) STB Revision
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AND
EXHAUST
OF INSTALLATION
OF EXHAUST
the gasket
1. INSTALLATION
(?
11 INTAKE
if there
N071DAD
MANIFOLD
is peeling,
- Air Filter.
flaking
GASKET
of damage.
OF AIR FILTER
11 INTAKE
AND
EXHAUST
- Air Filter.
COOLING
WATER TEMPERATURE
REMOVAL
AND
- Water Temperature
7-17
Unit
Gauge
GAUGE UNIT
INSTALLATION
Pre-removal
Operation
l
Draining of the Coolant (Refer
GROUP 0 LUBRICATION
AND
MAINTENANCE
~ Maintenance
vice.)
N070B-
to
Ser-
Post-installation
Operation
Supplying of the Coolant (Refer to
GROUP 0 LUBRICATION
AND
MAINTENANCE
~ Maintenance
Service.)
1
k
6-9 Nm
4-7 ft.lbs.
/?-
8-10 Nm
6-7 ft.lbs.
2040
14-29
+$
Nm
ft.lbs
04w573
il.
1. Therm0 switch
(Vehicles
with
an automatic
transmission)
l + 2. Water temperature switch

(Vehicles with an air conditioner)
l + 3. Water temperature sensor
l + 4. Water temperature gauge unit
r
?
!
NOTE
SERVICE
POINTS
4. APPLICATION
GAUGE UNIT
,/
Points
OF INSTALLATION
OF SEALANT
TO WATER
N070EAF
TEMPERATURE
Apply a coating of specified sealant to the threaded

and then tighten to the specified torque.
Specified
sealant
wision
part,
http://vnx.su/
kc
of Installation.
7-18
COOLING
- Water
Temperature
3. APPLICATION
TURE SENSOR
Gauge
Unit
OF ADHESIVE
TO
WATER
TEMPERA-
a coating of specified adhesive to the threaded

and then tighten to the specified
torque.
part,
Apply
Specified
adhesive
: 3M Adhesive
equivalent
Nut Locking
4171 or
04W55!
2. APPLICATION
OF SEALANT
TO WATER TEMPERATURE
SWITCH
Apply a coating of specified sealant to the threaded part,
and then tighten to the specified
torque.
Specified
: 3M ART
sealant
No. 8660
or equivalent
04W560
1. APPLICATION
OF ADHESIVE
TO THERM0
SWITCH
Apply a coating of specified adhesive to the threaded

and then tighten
to the specified
torque.
Specified
adhesive
04W563
) STB Revision
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: 3M Adhesive
equivalent
Nut
Locking
part,
4171 or
6-1
CONTENTS
CLUTCH
DISC AND RELEASE
FORK
CLUTCH
MASTER
AND TUBE
CLUTCH
PEDAL
CLUTCH
RELEASE
GENERAL
CYLINDER
................
.......
.................................................
CYLINDER
INFORMATION
..........................
.................................
SERVICE
ADJUSTMENT
PROCEDURES
..........
..........................................................
Bleeding
of Clutch Pedal ...
14
8
7
12
2
6
6
6
SPECIFICATIONS
General
Lubricants
2
3
...............................................
....................................
Specifications
.......................................................
TROUBLESHOOTING
Clutch Chattering
. . . . . . . . .. .. . . . . . . . . . .. .. . . . . . . .. . . . .
.. .. .. . . . . . . .. . . . . . . . . . . . .. . . . . . . . . ..
. . . . . . . .. ..*...*...................*....
Clutch Dragged (Clutch Not Released)

Clutch Noisy
Clutch Operation Erratic or Rough
Clutch Slipping
Difficult Gear Shifting
(Gear Noise During Shifting)
Hard Pedal Effort
http://vnx.su/
2 ;
3 I.!
4
6-2
CLUTCH - General Information
/ Specifications
CAUTION
When
servicing
clutch assemblies
or components,
do
dust by sanding,
grinding
or by cleaning
clutch parts with a dry brush or with compressed
air. (A
water dampened
cloth should be used.) The clutch disc
contains Asbestos
Fibers which can become airborne if
dust is created during service operations.
Breathing
dust
containing
Asbestos
Fibers may cause serious bodily
harm.
NOT create
GENERAL INFORMATION
The clutch is the dry single-plate
diaphragm
type; hydraulic pressure
is used for the clutch control.
>,i The clutch control is composed
of the clutch pedal, the clutch master cylinder, the clutch tube,
1: cylinder, etc. Note that the clutch pedal is the suspended
type.
?
the release
t,,.lSPECIFICATIONS
1.I
j
.
GENERAL
SPECIFICATIONS
NOGCA-
Specifications
Items
Clutch operating
Inside diameter
Hydraulic type
method
mm (in.)
of clutch master cylinder
15.87 (.6248)
Clutch disc
Type
Facing Size (outside
Number
x inside)
mm (in.)
of torsion springs
Clutch cover assembly

Type
t
Setting load
Mounting
Single dry disc type

225 x 150 (8.9 x 5.9)
Diaphragm spring, strap drive type

3,432 (772)
N (Ibs.)
mm (in.)
bolt circle diameter
264 (10.4)
Clutch release bearing

A
I
5
1
Type
Free travel
mm (in.)
Self-centering
type
0 (O)-Constant
contact type

Cylinder bore diameter
19.05 (.75)
mm (in.)
11
NOBCB-
Specifications
Items
Standard values
186-191 (7.3-7.5)
Clutch pedal height
mm (in.)
mm (in.)
Clutch pedal clevis pin play
l-3 (.04-.12)
Clutch pedal free play
8-16 (.31-.63)
Clearance
floorboard
Limit
Master
mm (in.)
between clutch pedal and

when pedal is depressed
cylinder to piston clearance

mm (in.)
mm (in.)
mm (in.)
Clutch disc rivet sink
35 (1.38) or more
0.15 (.0059)
0.3(.012)
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6-3
CLUTCH - Specifications
Items
~
T 15522
31-42
Clutch to flywheel
Release cylinder to transmission
Fulcrum
case
ft.lbs.
Nm
1 l-16
22-30
31-42
22-30
25-35
18-25
20-25
13-17
15-18
IO-12
5-7
Clutch pedal bracket
7-9
18-25
Push rod lock nut
8-12
6-9
Clutch pedal to pedal bracket

Eye bolt
Clutch tube flare nut
Clutch master cylinder to firewall
13-18
LUBRICANTS
NOGCD-
Items
Specified
lubricants
Quantity
Fluid
DOT 3
As required
Clutch master cylinder push rod,

clevis pin and washer
Wheel brearing grease

As required
Clutch pedal shaft and bushings
Multipurpose
NLGI No.3
As required
Clutch disc spline
MITSUBISHI Genuine Grease

Part No. 0101011
As required
Clutch release fork shaft bearing

Part No. 0101011
As required
Clutch release bearing inner surface

Part No. 0101011
As required
Release cylinder inner diameter
DOT 3
As required
grease SAE J310,
1 STB Revision
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6-4
CLUTCH - Troubleshooting
TROUBLESHOOTING
NOBEAAF
Symptom
Probable cause
Remedy
Reference
we
Clutch slipping
l
Vehicle will not
respond to
engine speed
during
acceleration.
0 Improper
vehicle speed
0 Lack of power
during uphill
driving
Improper
Adjust
6-6
Clutch drags or does

not release
pedal free play
Excessive
wear of clutch disc facing
Replace
6-l 4
Hardened
surface
clutch disc facing, or oil on
Replace
6-14
Damaged
pressure
Replace
6-l 4,9-60
Replace
6-14
Adjust
6-6
Correct
6-6
Pilot bearing worn or broken
Replace
9-57
Clutch disc warped
Replace
6-14
Replace
6-14
Repair or replace
6-6
Adjust
6-6
Repair or Replace
6-6
Replace
6-14
Replace
6-14
Adjust
6-6
Replace
6-14
plate or flywheel
Weak or broken pressure
Excessive
spring
clutch pedal free play
Interference
between
pedal and floor panel
Pressure plate, disc or throwout

damaged
Hydraulic system
mixed in
Difficult gear shifting
Igear noise during
shifting)
Excessive
fluid leakage or air
pedal free play
Hydraulic system
mixed in
fluid leakage or air
Unusual wear or corrosion

spline
Excessive
disc
Clutch
ioisy
When
clutch is
not used
Improper
Excessive
bearing
vibration
of clutch disc
(distortion)
of clutch
play of clutch pedal

wear of clutch disc facing
A noise is
heard after
clutch is
disengaged
Unusual wear and/or damage of release

bearing
Replace
6-14
A noise is
heard when
clutch is
disengaged
Improper grease on the sliding surface

of bearing sleeve
Repair
6-14
Repair
6-14
A noise
is heard
when
vehicle
is suddenly rolled of with
clutch
partially
engaged
Damaged
Replace
9-60
Improperly
bearing
installed clutch assembly
or
pilot bearing
1 STB Revision
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6-5
CLUTCH -Troubleshooting
Symptom
Clutch
cause
Remedy
Refernce
we
Facing
hardened
Replace
6-l 4
Facing
stained
Repair or replace
6-l 4
Replace
6-14
Replace
6-14
Replace
6-l 4,9-62
Probable
chatters
Clutch operation
erratic or rough
oil or grease
Weak or broken
disc damper
Improper
facing
contact
Pressure
plate or flywheel
Loose
Hard pedal effort
with
engine
springs
or disc runout
warped
mounting
Repair
or replace
g-20.21
Improper
shaft
lubrication
of clutch
pedal
Repair
6-7
Improper
spline
lubrication
of clutch
disc
Repair
6-17
Improper
lubrication
lever shaft
of clutch
release
Repair
6-12
Improper
retainer
of front bearing
Repair
Refer to
GROUP 21.
lubrication
Facing
stained
Facing
worn
Torsion
Improper
spring
with grease
or oil
Repair
or rivet loose
deteriorated
lubricant
on clutch
or broken
pedal
pivot
STB Revision
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or replace
6-14
Replace
6-l 4
Replace
6-14
Lubricate
6-7
.I
6-6
(lutch
CLUTCH
pedal height
Clutch pedal
clevis pin play
- Service
Adjustment
Procedures
SERVICE ADJUSTMENT
INSPECTION
PEDAL
1.
ADJUSTMENT
OF CLUTCH
N06FAAi-l
Measure
the clutch pedal height (from the face of the
pedal pad to the floorboard)
and the clutch pedal clevis pin
play (measured at the face of the pedal pad).
value (A) : 186-191 mm (7.3-7.5

in.)
value (B) : l-3 mm (.04-.I2
Standard
Standard
2.
AND
PROCEDURES
in.)
If either the clutch pedal height or the clutch pedal clevis

pin play are not within the standard value.range,
adjust as
follows:
(1) Turn the stopper bolt to adjust the clutch pedal height
to agree with the standard value and then secure the
bolt with the lock nut.
(2) Turn the push rod to adjust the clutch pedal clevis pin
play to agree with the standard value and then secure
the push rod with the lock nut.
Caution
When adjusting
the clutch pedal clevis pin play, be
careful not to push the push rod toward the master
cylinder.
oawso3
3.
After completing
the adjustments,
confirm that the clutch
pedal free play (measured at the face of the pedal pad) and
the distance
between the clutch pedal (the face of the
pedal pad) and the floorboard
when the clutch is disengaged are within the standard value ranges.
Standard
Standard
4.
value
value
(C) : 8-16 mm (.31-.63 in.)

(D) : 35 mm (1.38 in.) or more
If the clutch pedal free play and the distance between the
clutch pedal and the floorboard
when the clutch
is
disengaged
do not agree with the standard values, it is
probably the result of either air in the hydraulic system, or
a faulty master
cylinder
or clutch.
Bleed the air, or
disassemble
and inspect the master cylinder or clutch.
BLEEDING
NO6FBAB
Whenever
the clutch tube, the clutch hose, and/or the clutch
master cylinder have been removed,
or if the clutch pedal is
spongy, bleed the system.
Caution
Use the specified
brake fluid. Avoid
specified
fluid and other fluid.
Specified
brake fluid
STB Revision
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: DOT
using
a mixture
of the
CLUTCH
- Clutch
6-7
Pedal
CLUTCH PEDAL
REMOVAL
AND
INSTALLATION
Post-installation
Operation
0 Adjustment
of Clutch Pedal
(Refer to P.6-6.)
,
25-35
18-25
Nm
ft.lbs.
Removal steps
I)+
*+
1.
2.
3.
4.
Return spring
Cotter pin
Washer
Clevis pin
5. Clutch pedal bracket

I)+
6. Pedal
shaft
7. Clutch pedal
l + 8. Bushing
l + 9. Spacer
NOTE
to reinstall.
(3) m : Non-reusable
parts
INSPECTION
l
Check the pedal shaft bushing for wear.

Check the pedal arm for bend or torsion.
Check the return spring for deterioration.
SERVICE
POINTS
OF INSTALLATION
9. APPLICATION
OF GREASE
PEDAL SHAFT
Apply specified
bushings.
Specified
II
08Y5
FTB
Grease
19
Revision
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grease
NOBPDAK
TO SPACER/8.
to the
: Multipurpose
NLGI No. 3
pedal
shaft,
grease
BUSHING/G.
spacer
SAE
and
J310,
.,
CLUTCH
- Clutch
Pedal/Clutch
Master
4. APPLlCATlON
Cylinder
OF GREASE TO CLEWS
Apply the specified

spacer
Specified
and Tube
and the inner

grease
grease to the
surface
of the
: Wheel
bearing
NLGI No. 2
outer
CLUTCH
t!,, REMOVAL
MASTER
AND
CYLINDER
grease
AND TUBE
INSTALLATION
i
,
;.
.:
.
I
.t
Clutch master cylinder

removal steps
,I..
Pre-removal
l
Draining
Cotter pin
Washer
Clevis pin
Clutch master cylinder
5. Sealer
Clutch line removal steps
l +
l *
I.
2.
3.
4.
Operation
of Clutch Fluid
Post-installation
Operation
Supplying Clutch Fluid
Bleeding
(Refer to P.6-6.)
l
Adiustment
of Clutch Pedal
(Refer to P.6-6.)
l
l
6. Eye bolt
~~ l +
I)+
,
7.
8.
9.
10.
Gasket
Clutch hose
Hose clip
Clutch tube
FFEeverse
the removal procedures
to reinstall.
(2) l + : Refer to Service Points of Removal.
(3) ~~ : Refer to Service Points of Installation.
parts
1 STB Revision
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surface
of the
bushing.
Grease
-1
PIN/3. WASHER
SAE
J310,
CLUTCH
Clutch
Master
Cylinder
SERVICE
POINTS
8. REMOVAL
and
6-9
Tube
OF REMOVAL
OF CLUTCH
NOGMBAD
HOSE
(1) Holding the nut at the clutch

nut of the clutch tube.
hose side, loosen
the flare
14w593
(2) Pull off the clutch

hose
hose from the bracket.
Clutch
clip and
remove
the
clutch
hose
14UOO87
INSPECTION
l
l
Check
Check
SERVICE
NOGMCAA
the master cylinder or clutch hose for fluid leakage.

the clutch hose or tube for cracks or clogging.
POINTS
10. INSTALLATION
OF INSTALLATION
OF CLUTCH
TUBE/8.
CLUTCH
NOGMDAE
HOSE
(1) Temporarily
tighten the clutch tube flare nut by hand;
and then tighten
it to the specified
torque,
being
careful that the clutch hose does not become twisted.
Secure
side
ot3wsa
(2) Connect
the clutch hose to the release cylinder at the
stepped
portion shown
(3) After tightening
the clutch tube flare nut and eye bolt,
check to be sure there is no leakage of the clutch fluid.
1 STB Revision
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:
I .c
,. ,,
;,
6-10
CLUTCH
Clutch
Master
Cylinder
3. APPLICATION
Apply
spacer
and
OF GREASE
Tube
TO CLEVIS
PIN/2.
WA;tMHEE
the specified
grease to the outer surface
and the inner surface of the bushing.
Specified
: Wheel
bearing
NLGI No. 2
grease
grease
SAE
of the
J310,
Grease
08W521
DISASSEMBLY
Disassembly
l *
++
~~
AND
REASSEMBLY
steps
1. Piston stop ring

2. Damper and push
3. Piston assembly
4.
Reservoir
rod
cap
5. Reservoir
l + 6. Reservoir
band
7. Master cylinder
body
\7
NOTE
(1)
(2)
(3)
Reverse
the
4~
: Refer
l + : Refer
disassembly
to Service
to Service
procedures
Points
of
Points
of
to reassemble.
Disassembly.
Reassembly.
SERVICE
\\
POINTS
08W513
OF DISASSEMBLY
1.
REMOVAL
OF PISTON
STOP
Remove the piston stop ring.
3.
REMOVAL
OF PISTON
ASSEMBLY
Pull out the piston assembly.
RING
Caution
1. Do not damage the master cylinder body
assembly.
2. Do not disassemble
piston
assembly.
08YO3
INSPECTION
l
l
l
Check the inside cylinder body for rust or scars.

Check the piston cup for wear or deformation.
Check the piston for rust or scars.
Revision
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NOSNBAA
and piston
NOGNCAB
CLUTCH
Clutch
Master
Cylinder
and
6-11
Tube
CLEARANCE
BETWEEN
MASTER CYLINDER
TER AND PISTON
OUTER DIAMETER
(1) Measure
the master cylinder
piston outside
diameter
with
micrometer.
Limit
: 0.15 mm
(.0059
DIAME-
inside diameter
and the
a cylinder
gauge and a
in.)
NOTE
Measure
the inside diameter
three-places
(bottom,
middle,
perpendicular
directions.
14E108
INNER
(2) If master cylinder-to-piston

replace the master cylinder
of the master cylinder at

and top), each in two
clearance exceeds the limit,

and/or piston assembly.
4..
3
=,
;.
i :,
.
SERVICE
POINTS
6. INSTALLATION
OF REASSEMBLY
OF RESERVOIR
After installing
the reservoir, tighten
the range shown in the figure.
NOGNDAG
BAND
the reservoir
band in
06R0005
r-l
r-l
3. APPLICATION
BLY
OF CLUTCH
FLUID
TO PISTON
ASSEM-
Apply specified
clutch fluid to the inner surface of the
cylinder and to the entire periphery of the piston assembly.
)
;
Specified
I?
clutch
/ STB Revision
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fluid
: DOT
:1
6-12
CLUTCH
- Clutch
Release
CLUTCH RELEASE CYLINDER

REMOVAL
AND INSTALLATION
Pre-removal
0 Draining
Removal
CylindQr
NOGHA-
Operation
of Clutch Fluid
31-42
22-30
steps
1.
2.
3.
++. 4.
.i+ 5.
Nm
ft.lbs.
Bleeder screw
Eye bolt
Gasket
Connection of clutch hose
NdTE
(1) Reverse the remqval procedures
(2) w+ : Refer to Service Points
(3) [iIl
: Non-reusable
parts
to reinstall.
of Installation.
20-25
14-18
08W520
INSPECTION
NO6HCAA
Check the clutch release cylinder for fluid leakage.

Check the clutch release cylinder boots for damage.
l
l
SERVICE
5.
POINTS
APPLICATION
INDER
OF INSTALLATION
OF GREASE
TO CLUTCH
NOGHDAE
RELEASE
CYL-
Apply a coating of the specified grease to the contact parts

of the release fork and release cylinder push rod.
Specified
4.
Grease
CONNECTION
: MITSUBISHI
No. 0101011
OF CLUTCH
Genuine
Grease
Part
HOSE
(1) Connect the clutch hose to the release cylinder at the

stepped portion shown in the illustration.
(2) After tightening the eye bolt, check to be sure there is
no leakage of the clutch fluid.
Revision
I
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-.
..
,:,
I,
..
,,
4
CLUTCH
DISASSEMBLY
AND
+*
1.
2.
3.
4.
l + 5.
6.
7.
8.
9.
Clutch
Release
6-13
Cylinder
REASSEMBLY
9-13 Nm
7-9 ft.lbs.
Disassembly
NOGM--
*
\
steps
00W523
Valve plate
Spring
Push rod
Boots
Piston and cup
Conical
spring
Cap
Bleeder
plug
Release
cylinder
I..
NOTE
SERVICE
5.
POINTS
REMOVAL
OF DISASSEMBLY
OF PISTON
AND
NOILBAA
CUP
Remove the piston from the release cylinder

pressed air.
i
using corn-
Caution
1. Cover with rags to prevent the piston from popping
out.
2. Apply compressed
air slowly to prevent brake fluid
from splashing.
INSPECTION
l
l
Cylinder gauge
N06LCAA
Check the release cylinder bore ofr rust and damage.

Measure the release cylinder
bore at three locations
(bottom, middle and top) with a cylinder gauge and replace
the release cylinder assembly if the clearance to the piston
outside exceeds the limit,
Limit
: 0.15
14UOO63
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mm
(.006
in.)
;
.I
;
(.
SERVICE
POINTS
5. APPLlCATlON
OF REASSEMBLY
OF FLUID
TO
NOGLDAB
PISTON
AND
CUP
After applying
a coating of the specified

brake fluid to the
inner surface of the release cylinder body and to the entire
circumference
of the piston and cup, insert the piston and
cup into the release cylinder.
Specified
brake
fluid
: DOT
DCLOOG
::
CLUTCH DISC AND RELEASE FORK
fs,, REMOVAL
Post-installation
l
AND INSTALLATION
Operation
Adjustment of Clutch Pedal

(Refer to P.6-6.)
6\
15-21Nm
11-15 ft.lbs.
31-42
22-30
\
Clutch cover and disc removal steps
+I) $+ 1. Transmission case assembly

+e e+ 2. Clutch cover assembly
I)+ 3. Clutch disc
Clutch release bearing and release fork removal
steps
Nm
ftlbs.
06W524
w+ 6. Clutch release bearing

++ +4 7. Release fork
8. Release fork boot
9. Fulcrum
NOTE
ae I)+ 1. Transmission case assembly

l + 4. Clutch release cylinder
5. Return clip
(1)
(2)
(3)
SERVICE
1.
Reverse the removal procedures to reinstall.

+e : Refer to Service Points of Removal.
l + : Refer to Service Points of Installation.
POINTS
REMOVAL
OF REMOVAL
OF TRANSMISSION
Refer to GROUP
Assembly.
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21 TRANSMISSION
NOGOBAB
CASE
ASSEMBLY
- Transmission
case
CLUTCH
Clutch
2.
Disc
and
Release
ASSEMBLY
(1) Insert clutch disc guide, or main drive gear of transmission in center spline to prevent dropping of clutch disc.
(2) Diagonally
loosen bolts retaining clutch cover to flywheel.
Back off bolts, one or two turns at a time, in succession, to avoid bending cover flange.
REMOVAL
OF CLUTCH
Caution
DO MOT clean
cleaning
7.
6-15
Fork
REMOVAL
COVER
clutch
disc
OF RELEASE
Slide release fork

fulcrum from clip.
bearing
with
FORK
in direction
AND
of arrow
to disengage
INSPECTION
fork by sliding
to clip.
it in other
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I.
T
4
1:Iv,.
N060CAB
Clean clutch dust from clutch housing with vacuum brush

or shop towel. Do not use compressed
air. Inspect for oil
leakage through
engine rear main bearing oil seal and
transmission
front oil seal. If leakage is noted, it should be
corrected at this time.
Friction face of pressure plate should be have a uniform
appearance throughout
entire disc contact area. If there is
evidence of heavy contact on one portion of wear circle
and a very light contact 180 degrees from that portion,
pressure plate may be improperly
mounted or gprung.
Friction face of flywheel should also be free from excessive discoloration,
burned
areas, small
cracks,
deep
grooves, or ridges.
Wipe friction surface of pressure plate with a cleaning
solvent.
Using a straight edge, check pressure plate for flatness.
The pressure plate friction area should be flat within 0.5
mm (.020 in.) and free from discoloration,
burned area,
cracks, grooves or ridges.
Visually
inspect
the cover outer mounting
flange for
flatness. It should be free of nicks, burrs, dents or other
damage.
The three dowels on the flywheel should be tight and
undamaged.
The cover stamping
should be a snug fit on the dowels.
If the clutch assembly does not meet these requirements,
it should be replaced.
1 STB Revision
;*
.
Caution
Attempting
to remove
release
direction
will result in damage
CLEANING
or release
solvent.
.4
h
;*
i;
;,
:,.;,
CLUTCH
Clutch
Disc and
CLUTCH
Release
Fork
DlSC
(1) The disc assembly

should be handled without
facings. Replace disc if facings show evidence
or oil soakage.
(2) Use the caliper gauge to measure the dimension
facing surface to the rivet head.
Limit
6CLOO3
: 0.3 mm
from the
in.)
(3) If the measured value is below the limit, replace the clutch
disc,
(4) The hub splines and splines on transmission
input shaft
should be a snug fit without
signs of excessive wear.
(5) Metallic portions of disc assembly should be dry and clean
and show no evidence
of having been hot. Each of the
arched springs between facings should be unbroken
and
all rivets should be tight.
SERVICE
Clutch release bearing
(.012
touching
of grease
POINTS
7. APPLICATION
6.
OF INSTALLATION
OF GREASE
TO RELEASE
Pack the release
fork fulcrum
Specified
: MITSUBISHI
No. 0101011
grease
APPLICATION
ING
Pack specified
I.D.
Specified
OF GREASE
grease
grease
NOBQDAC
FORK
hole with specified

Genuine
TO CLUTCH
in groove
: MITSUBISHI
No. 0101011
on clutch
grease.
Grease
Part
RELEASE
BEAR-
release
bearing
Genuine
Grease
or equivalent
Part
fork
kl
DCLOOE
Release
fork
4.
\%
APPLICATION
OF GREASE TO CLUTCH
RELEASE CYLINDER
Apply specified
grease to release fork to release cylinder
push rod contacting
surfaces.
Specified
grease
1 STB Revision
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: MITSUBISHI
No. 0101011
Genuine
Grease
Part
CLUTCH
- Clutch
3.
Disc
and Release
INSTALLATION
6-17
Fork
OF CLUTCH
DISC/P. CLUTCH COVER
ASSEMBLY
are oils or greases on clutch facing and
pressure plate, throughly
wipe away with a dry cloth.
(2) Lightly specified grease clutch disc spline.
(1) If there
Specified
grease
: MITSUBISHI
Genuine
Part No. 0101011
Grease
(3) Using clutch disc guide, or main drive gear of transmission, install clutch disc and clutch cover assembly on
flywheel.
(4) When installing clutch disc, be sure that surface having
manufacturers
stamped mark is on pressure plate side.
Pressure plate
6CLOO4
(5) When installing

the clutch cover assembly,
align
clutch cover assemblys
dowel pin hole and
flywheels
dowel pin, and then gradually tighten
bolts alternately.
1. INSTALLATION
Refer to GROUP
Assembly.
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OF TRANSMISSION
CASE
21 TRANSMISSION-Transmission
the
the
the
ASSEMBLY
case
21-48
AUTOMATIC
TRANSMISSION
- General
Information
GENERAL INFORMATION
Safety
goggles
should
be worn
NZlBABE
at all times
when
working
on these
transmissions,
Model KM148 automatic

transmission
combine
a torque converter
and fully automatic
4-speed
transmission.
The transmission
control
lever and transfer
control
lever are located on the floor.
The overdrive
switch
is provided
on the selector
handle part of the transmission
control
lever.
When the vehicle is driven in the D range while the overdrive
switch
is ON (the switch
is unpressed),
shifting
within
the range from 1st gear to 4th gear is automatic;
when the overdrive
switch
is OFF (the
switch
is pressed)
and the vehicle is driven in the D range, shifting within the range from 1st gear to 3rd
gear is automatic.
The transfer
control
lever can be used to select either rear-wheel
drive or four-wheel
drive, in order to
thereby
obtain the most appropriate
drive power
according
to the road surface
conditions.
In addition,
four-wheel
drive has both the HIGH range and t.he LOW range.
The torque
converter,
transmission
area and transfer
area are housed
The transmission
oil sump and the transfer oil sump of model
Accordingly,
the filling of oil is necessary to perform separately
in an integral
aluminum
die casting.
KM148-4WD
transmission
are separated.
to the transmission
and to the transfer.
The torque converter

is attached to the crankshaft
through a flexible driving plate. Cooling of the converter
is
accomplished
by circulating the transmission
fluid through an oil-to-water
type cooler, located in bottom of the
radiator. The torque converter
assembly
is a sealed unit that cannot be disassembled.
The transmission
fluid is filtered by an interval filter attached to the lower side of the valve body assembly.
Engine torque is transmitted
to the torque converter
then, through the input shaft to the multiple-disc
clutches in
the transmission.
The power flow depends on the application of the clutches and brakes. Refer to TABLE FOR
OPERATION
ELEMENTS
AT EACH POSITION OF SELECTOR
LEVER chart in this section.
The transmission
consists
of three multiple-disc
clutches, three one-way
clutches,
four multiple-disc
brakes, and
two planetary gear sets to provide four forward
ratios and a reverse ratio.
The hydraulic control circuits show the position of the various valves with color coded passages to indicate those
under hydraulic pressure
for all operation of transmission.
The transfer has a high/low selection and a 2WD/4WD
selection. By operating the transfer control lever, the running
at 2WD high (2H). 4WD high (4H) of 4WD low (4L) can be selected freely.
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1.
2.
3.
4.
5.
6.
7.
8.
9.
Torque converter
Oil pump
Over drive clutch
Over drive brake
Over drive planetary
Forward clutch
Direct clutch
Brake No.1
Brake No.2
gear
10.
11.
12.
13.
14.
15.
16.
17.
18.
Brake No.3
Front planetary gear
Rear planetary gear
Brake No.3 piston
Governor
Transfer control lever
Input gear
High-low clutch
Low speed gear
19.
20.
21.
22.
23.
24.
25.
2WD-4WD
clutch
Drive sprocket
Chain
Rear output shaft
Front output shaft
Counter gear
Valve body
21-50
AUTOMATIC
TRANSMISSION
- General
Information
TORQUE CONVERTER
Front
cover
Turbine
Impeller
Stator
The torque converter consists

of an impeller (rear cover), turbine,
stator, one-way clutch, front cover, and other parts. It is a nonmaintainable assembly with a sealed construction,
in which outer
surfaces of shell (front and rear covers) are welded together. Since
the torque converter is connected to the engine crankshaft
via the
drive plate, the shell (front cover and impeller) always rotates together with the engine. This means that the transmission
oil pump
is also driven at the same speed as the engine by the hub welded
at the center of the shells rear part. The boss provided in the front
part of the shell is fitted into the hole located at the rear end of the
crankshaft
to support the torque converter.
_ One-way
clutch
372070
TRANSMISSION
POWER TRAIN
The transmission
power train consists
of three sets of multiple
disc clutches, four sets of multiple disc brakes, three sets of oneway clutches, and a single-row
and a double-row
Simpson planetary gear set. The three sets of clutches
are an element that
controls the input to the planetary gear set, while the four sets of
brakes and three sets of one-way clutches act to hold some of the
elements
of the planetary gear set stationary
or prevent them
from turning. An appropriate
gear ratio for each driving condition
can thus be obtained through the operation
of these elements
which select the point from which the driving force is input and
points to be held stationary
in the planetary gear set.
The following
Table TABLE
FOR OPERATION
ELEMENTS
AT
EACH POSITION
OF SELECTOR
LEVER shows
particular elements in action in different selector lever positions.
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AUTOMATIC
TRANSMISSION
FO Over
drive planetary
- General
F,
gear
F,
Information
21-51
Rear planetary gear

Front planetary gear
C,:
C,:
C,:
B,:
B, :
B,:
B,:
Over drive clutch

Forward clutch
Direct clutch
Over drive brake
Brake No. 1
Brake No.2
Brake No.3
Fe: Over drive one-way

clutch
F,: One-way clutch No.1
F,: One-way clutch No.2
.,
-*
G:;
,;,, 1
(,:.I
372071
1 ST6 Revision
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>i
AUTOMATIC
TRANSMISSION
- General
Information
OVERDRIVE CLUTCH
Plate
Cylinder
The overdrive clutch, of the multiple-disc type, is actuated when

the shift is in a position other than the 4th speed or overdrive. It
couples the sun gear to carrier of the overdrive on planetary gear
set, thus imparting the input from the carrier to the forward clutch
cylinder via the ring gear.
hub
Piston
Ieturn spring
FORWARD
Plate
CLUTCH
Of the multiple-disc type, the forward clutch is actuated whenever

the vehicle is in the forward motion. It imparts the input to the ring
gear of the rear planetary gear set via the intermediate shaft.
Ieturn spring
Iclutch
hub
DIRECT
Plate
n
Disc
Return
spring
CLUTCH
The multiple-disc direct clutch, actuated in the 3rd and 4th speeds
and in reverse, transmits the input force to the sun gear, driving
the pinions of the front planetary gear set.
Cylinder
372005
OVERDRIVE
BRAKE
The overdrive (OD) brake, of the multiple-disc type, is installed in

the OD case. Actuated in the 4th speed (overdrive), the brake
holds the sun gear of the OD planetary gear set.
BRAKE
Center support
Plate
No.1
MT
In -
Plate
Disc
Brake
1 No.2
Piston
NO.1
The brake No.1, actuated in the 2nd speed of the 2 range, holds
the sun gear stationary.
BRAKE
NO.2
The brake No.2, actuated in the 2nd, 3rd, and 4th speeds of the
D range and in the 2nd speed of the 2 range, holds the outer
race of one-way clutch No.1 stationary, allowing the one-way
clutch No.1 to act as an overrunning clutch.
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AUTOMATIC
Plate
Reaction
TRANSMISSION
General
Information
21-53
BRAKE NO.3
sleeve
The brake No.3, operated in the L and R ranges, brakes the

carrier of the front planetary gear set to a standstill.
piston
372008
Free
Outer race
(9D planetary
carrier)
I
InnfG race
(OD sun gear)
355032
Outer
4.---
The one-way clutch No.1 functions as an overrunning clutch only

when the brake No.2 is actuated and prevents the sun gear from
turning counterclockwise.
This means that no engine braking is
given in the 2nd speed of the D range. In the 2nd speed of the
2 range, however, engine braking is given since the brake No.1
holds the sun gear stationary.
race
Lock
-
Free
Outer
355034
race
I
carrier)
;g+LGV
\
u
ONE-WAY CLUTCH
The three sets of one-way clutches are of the sprag type. The
overdrive (OD) one-way clutch is operated during gearshifting between 3rd and 4th (OD) speeds, ensuring smooth selection between the OD clutch and OD brake.lt is in free state when the
carrier of the OD planetary gear set rotates clockwise and locks
when the sun gear turns clockwise.
The one-way clutch No.2 prevents the front planetary carrier from
turning counterclockwise,
actuated in the 1st speed. So, no engine braking is given in the 1st speed of the D as well as 2
range. Engine braking is, however, given in the L range in which
the carrier is held stationary by the brake No. 3.
Wag
.!..u
\
Wk
Case
(skationary
side)
355032
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21-54
AUTOMATIC
TRANSMISSION
General
Information
OVERDRIVE
PLANETARY
GEAR
The planetary gear, of a single-row type, consists of the sun gear,
pinion, carrier, and ring gear. The input from the OD input shaft is
imparted to the carrier.
Ring gear
OD one-way
clutch
372009
PLANETARY
GEAR SET
This planetary gear set called the Simpson type is made up of two
planetary gear sets, each consisting of pinions, carrier, and sun
gear. The sun gear is connected to the direct clutch, front carrier
to brake No.3, and the rear ring gear to forward clutch. The front
ring gear and rear carrier are coupled to the output shaft.
Front ring gear
output
shaft
Sun gear
372010
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AUTOMATIC
TABLE
FOR OPERATION
REMARKS:
IP=lnner
TRANSMISSION
ELEMENTS
Piston.
- General
AT EACH POSITION
OP=Outer
OF SELECTOR
LEVER
Piston
Clutch
ielector
3D-OFF
3ver po- switch
sition
Gear
shift
stage
Engine Parking
mechastart
nism
Gear
ratio
21-55
Information
C2
co
One-way clutcm
Brake
IP
63
OP
B0
B,
B,
IP
OP
F0
Neutral
OK
Reverse
2.703
Neutral
OK
1st
2.826
2nd
1.493
3rd
1.ooo
4th
0.688
1st
2.826
2nd
1.493
3rd
1.000
1st
2.826
2nd
1.493
1st
1 2.826
ON
OFF
POWER
F,
F2
I
0
0
0
0
0
0
0
0
0
0
0
0
0
0
FLOW
The following is the description of the element operation and the power transmission at each gear shift stage. As
for the element operation at each gear shift stage, it is summarized on the above table.
Brake
6)
clutch
(FJ
planetary
No.1
clutch
(F,)
gear
gear
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No.2
ront
planetary
gear
planetary
gear
372071
372072
21-56
nee
AUTOMATIC
TRANSMISSION
Outer race
(Front planetary carrier)
Swg
Case. (Stationary side)
35503;
.\.
Information
First in D range
When the vehicle speed is relatively low with a greater throttle
valve opening angle, which requires a greater acceleration, the OD
clutch (C,), OD one-way clutch (F,), forward clutch (C,), and oneway clutch No.2 (F,) operate to shift gears into the 1st speed
position, the output shaft turning clockwise at a gear ratio of
2.826.
In the forward (excluding 4th speed of ID range) and reverse
ranges, Co and F, are actuated to transmit the input to the forward
clutch cylinder via the OD input shaft. As Co and F, are actuated,
the OD planetary carrier and sun gear are locked together to rotate
bodily. This causes the turning force of the OD input shaft to be
transmitted
to the planetary carrier, allowing the carrier to rotate
clockwise together with the sun gear, thus holding the pinion to a
standstill.Now,
the entire planetary gear set rotates bodily, which
couples the OD input shaft directly to the forward clutch cylinder
to allow them to rotate clockwise.
In the 1st speed, C, is also actuated allowing the turning force of
forward clutch cylinder to be transmitted
via the intermediate
gear
to the rear planetary carrier (output shaft), which turns the carrier
clockwise. The sun gear (rotating counterclockwise)
in mesh with
the pinion of the rear planetary gear set, on the other hand, tends
to turn the front planetary carrier counterclockwise;
however, F,
acts to prevent the carrier from rotating, hence the turning force in
the clockwise direction is transmitted
to the output shaft.
Though acting to prevent the front planetary carrier from rotating
counterclockwise,
F2 is driven from the axle shaft end during engine braking, thus allowing its outer race to rotate in the direction
to free the clutch. Hence, no engine braking. This also applies
when the shift is in the 1 st speed of 2 range. F, functions in the
same manner in the 2nd speed of D range.
In the L range, the brake No.3 (B,) is actuated to hold the front
planetary carrier stationary, thus providing engine braking.
6, (L range only)
D or 2 Range-1st
Input
output
2.826
D Range-1st
General
372073
1.000
F,
,
/,.:.:.::,.:./:::::/::::~:~i::I:i~i~iii:i:~:.i:,:.i:,i::~
:/.
/:::::f,
x/jf/:.g.j::::
,:,:.,,,,
>::.:.:.:.:
.A.,...
.,.....
:.,:..,::
::I./:,: .,,:.,. :, ,,,::,,I:.
/,.:.A,/..,,, .
372074
L Range-1st
372075
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AUTOMATIC
Outer
race
(combined
with
(combined
TRANSMISSION
brake
No.2)
with
\
4=---
or 2
Lock
Free
355034
- General
Information
21-57
Second in D range
As the vehicle speed is accelerated from the 1 st speed, the brake
No.2 (B2) is actuated to shift into the 2nd gear, allowing the output
shaft to rotate clockwise at a gear ratio of 1.493. The OD planetary
gear set operates in the same way as in the 1st speed. In 2nd
speed, C, is actuated, which causes the turning force of forward
clutch cylinder to be transmitted, via the intermediate
shaft and
rear planetary ring gear to the pinion. Then, the sun gear, which is
in mesh with the pinion, receives a turning force in the counterclockwise direction; however, since F,, activated by BP, prevents
the sun gear from rotating, the pinion moves around the sun
gear.This motion causes the carrier to rotate, transmitting
a rotating force in the clockwise direction to the output shaft. No rotating
force is transmitted
to the front planetary gear as the sun gear
does not turn. In the 2nd speed of 2 range, the brake No.1 (B,)
is actuated to hold the sun gear stationary, thus providing engine
braking.
(2
RANGE-2nd
range
only)
372076
D
RANGE-2nd
372077
RANGE-2nd
372078
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21-58
AUTOMATIC
TRANSMISSION
- General
Information
Third in D range
As the vehicle is further accelerated, the direct clutch (C,) comes
into play to shift into the 3rd speed. In 3rd speed, both C, and C2
operate, allowing the intermediate
shaft and sun gear to rotate in
the same direction. So, the pinion is locked causing the entire
planetary gear set to rotate bodily. This couples the input shaft to
the output shaft directly giving a l-to-l gearing.
D RANGE-3rd
c,
c2
82
Output
Input
372079
Fourth (overdrive)
in D range
When the vehicle is further accelerated with the OD-OFF switch
turned ON, the OD clutch (C,) is released and, at the same time,
the OD brake (B,) is actuated to shift into the 4th speed, allowing
the output shaft to rotate in the clockwise direction at a ratio of
0.688.
In this gear position, B, holds the OD sun gear stationary. The
rotating force of the OD input shaft is therefore transmitted via the
OD planetary gear pinion to the ring gear and the forward clutch
cylinder, which is accelerated in reference to the OD input shaft,
rotates clockwise. The rotating force of the forward clutch cylinder
is transmitted
to the output shaft in the same way as in the 3rd
speed of D ranae.
Bo
D RANGE-4th
c,
c*
B, -
lnpu
372081
372082
;;E
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AUTOMATIC
TRANSMISSION
General
21-59
Information
Reverse
When the shift is in reverse gear, the OD clutch (C,), OD one-way
clutch (F,), direct clutch (C,), and brake No.3 (B,) are actuated and
the rear output shaft rotates counterclockwise
at a ratio of 2.703.
The operation of the OD planetary gear set is the same as in the
1st speed of D range.
Since C, is activated, the rotating force of the input shaft is transmitted to the front planetary gear pinion via the sun gear. As the
front planetary carrier is held stationary by BB, the rotating force of
the sun gear is transmitted to the ring gear via pinion, turning the
output shaft in the counterclockwise
direction.
REVERSE
CO
b
I
utput
Carrier fixed
1.000
372083
372084
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21-60
AUTOMATIC
TRANSMISSION
General
Information
SELECT PAlTERN
Select pattern refers to the indication of transmission positions to
be manually selected by the driver. This transmission
is provided
with six positions; P-R-N-D-2-L.
The following text explains the function of each position selected.
P-Parking
All elements do not operate at all, and the engine output is not
transmitted
to the output shaft.
The output shaft is mechanically
locked and the vehicle does
not move either in the forward or reverse direction.
The engine can be started.
R-Reverse
The vehicle is in the reverse range.
The engine cannot be started.
N-Neutral
The engine output is not transmitted
to the output shaft as in
the case of P.
The engine can be started.
D-Drive
Corresponding
to the degree that the accelerator pedal is
pressed down (throttle valve opening angles) and vehicle
speed, D automatically
shifts between the four forward
speeds, or three forward speeds when the OD-OFF switch is
in OFF position.
The automatic shifting is performed according to the shift pattern shown on P.21-61.
The vehicle is started with the gear in first speed position.
Kickdown refers downshifting
accomplished
when the accelerator pedal is depressed while the vehicle is in motion in 2nd.
3rd. or 4th speed. In the shift pattern, it occurs when the load
exceeds the downshift point.
This function is useful when the driver is accelerating to pass
another vehicle.
No engine braking is given when the shift is in 1st speed.
2-Second
The 2 automatically
shifts between the 1 st and 2nd speeds,
and no shifting into 3rd will be performed.
The vehicle is started with the gear in 1st speed position.
When the 2 range is selected while the vehicle is in motion
in the 3rd or 4th speed of D range, gear is downshifted to
2nd or 3rd speed as the vehicle speed reaches predetermined
levels.
As in the case of D range, no engine braking is given when
the shift is in 1st speed position.
L-Lockup
While L performs downshifting
from 2nd to 1st. it does not
shift into high, from 1st to 2nd or to 3rd. This is what we call
the 1st gear holding.
The vehicle is started with the gear in 1st speed position,
when the engine braking is given.
If the L range is selected while the vehicle is in motion in
D or 2 range, downshifting
from 4th to 3rd, 3rd to 2nd. or
2nd to 1st is performed as the vehicle reaches the respective
speeds predetermined
for each gear.
1 STB Revision
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AUTOMATIC
TRANSMISSION
General
lnforrmation
21-67
When the governor pressure

is greater than the combined downward pressure of throttle pressure and spring tension, the l-2 shift
valve is pushed up, opening the circuit to B, to set the 2nd speed.
Hysteresis
(difference
in vehicle speed) of the shift timing between 1st and 2nd speed occurs when the land #2 closes the
passage to throttle pressure as the l-2 shift valve is pushed down
in 2nd speed. In other words, the closed throttle pressure circuit
provides for a downshift
to 1st speed taking place involving only
the spring tension and governor pressure.
Hence, a downshift
at
a constant vehicle speed.
Kickdown
is provided when the detent pressure
from the kickdown valve is applied to the top of 1-2 shift valve (land #l) to
push down the valve.
Low coast
modulator
pressure
(from modulator
In L
With the shift in L range, the low- coast modulator pressure

is
applied to the low-coast
shift valve, keeping the low-coast
shift
valve and l-2 shift valve down. This sets the 1 st speed and no
upshift to 2nd will not take place. The low- coast shift valve also
opens the circuit to brake No.3 (B,), thus providing for engine
braking.
range
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21-68
AUTOMATIC
TRANSMISSION
- General
Information
2-3 Shift Valve

The 2-3 shift valve automatically
selects between
the 2nd and 3rd
speed according to the governor and throttle pressure.
The throttle pressure is applied to the top of 2-3 shift valve (land #l), which
forms, together with the spring tension, a downward
pressure to
the valve.
Applied to the bottom of the valve is the upward governor pressure. When the governor pressure
is smaller than the combined
force of the throttle pressure
and spring tension, the valve is
pushed down, closing the circuit to the direct clutch (C,) to set the
2nd speed.
1rhrottle
Fxessure
T..LGovernol
I
I
In case
of low
governor
pressure
11
pressure
(2nd)
355059
ntermediate
I shift valve
coast
From
B,
Throttle
Ipressure
In case
of high
governor
pressure

is greater than the downward
pressure of throttle pressure
and spring tension, the valve is pushed
up, opening the circuit to C2 to set the 3rd speed
The difference
in vehicle speed at the point at which the gear shift
occurs when changing up from 2nd to 3rd and down from 3rd to
2nd (Hysteresis)
is due to the difference
in areas of the valve to
which governor
pressure
is applied. The area in downshift
(land
#4) is greater than that (land #3) in upshift and downshift
takes
place at a lower
speed (governor
pressure).
Kickdown
is provided
when the detent pressure
from the kickdown
valve is applied to the valve, pushing it down.
(3rd)
355060
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AUTOMATIC
TRANSMISSION
General
Information
21-69
ln 2 and IL range, the line pressure from the manUal Vak3 iS

applied to the intermediate shift valve, keeping the intermediate
shift valve as well as 2-3 shift valve down.
This sets the 2nd speed and no upshift will not take place. The
intermediate low-coast shift valve also opens the circuit to brake
No.1 (B,), allowing for engine braking.
To 6,
Throttle
Dressure
In 2 and L range
355051
3-4 Shift Valve

The 3-4 shift valve automatically selects between the 3rd and 4th
(OD) speed according to the governor and throttle pressure.
The throttle pressure is applied to the top of the 3-4 shift valve and
line pressure to the middle part of the valve. These form a downward pressure applied to the valve, together with the spring tension. Applied to the bottom of the valve is the upward governor
pressure. When the upward governor pressure is smaller than the
combined downward pressure of throttle pressure, line pressure,
and spring tension, the valve is pushed down opening the circuit
to the OD clutch and, at the same time, releasing the circuit to OD
brake to set the 3rd speed.
Throttle pressure
Sprn~
3-4-L
valve
From
Line
pressure
In case of low governor pressure
35507t
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AUTOMATIC
Throttle
TRANSMISSION
General
Information

is greater than the downward
combined pressure,
the valve is pushed up opening the circuit to OD
brake to set the 4th speed.
Hysteresis
(difference
in vehicle speed) of the shift timing between 3rd and 4th speed occurs because of the following
reason.
In 4th speed, since no line pressure
is applied, the area of land in
downshift
(#4) is greater than that in upshift (#3) and downshift
takes place at a lower speed (governor pressure).
pressure
To C,
To B,
In case
governor
of high
pressure
Line
(When
switch
And
Line
pressure
pressure
Throttle
Governor
pressure
II
t
355071
pressure
OD-OFF
is in
in 2
_ Third coast
shift valve
I <I:.IY
To C,
When the OD-OFF switch

is in the OFF position, the solenoid
valve is also OFF closing the drain circuit of the OD solenoid valve.
This causes the line pressure to be applied to the third coast shift
valve, pushing down the third coast shift valve and 3-4 shift valve,
hence no upshift to 4th speed taking place.
In 2 and L range, the line pressure
from manual valve is
applied to the third coast shift valve.
Kickdown
is provided
when the detent pressure
from the kickdown valve is applied to the third coast shift valve and 3-4 shift
valve, pushing the 3-4 shift valve down.
To B,
In case of OD-OFF
switch
OFF
pressure
355072
Cut-Back
l-1
Valve
The cut-back valve regulates the cut-back pressure which provides

the throttle valve with the effects of vehicle speed. It applies the
cut-back pressure to the throttle valve to reduce the throttle pressure. It also applies the throttle pressure to the primary regulator
valve to reduce the line pressure.
By so doing, it helps eliminate
the power loss caused by the oil pump. When the governor pressure is applied to the top of valve, it causes the valve to be pushed
down. This opens the circuit from the throttle valve causing the
throttle pressure to be applied to push up the valve because of the
difference
in valve diameters.
The cut-back pressure
is the pressure when this upward
pressure
balances with the downward
pressure
of the governor
pressure.
While the throttle pressure
remains low, there is no force involved to push up the valve and
the circuit from the throttle valve is always open. So, the throttle
pressure
is applied as the cut-back pressure.
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AUTOMATIC
Line
pressure
(from 2-3
shift valve)
In R
In D
range
Line pressure
(from manual
range
and
TRANSMISSION
Reverse
valve)
355063
3rd speed
Clutch
a-71
Valve
355064
Timing
Valve
The D-2 down timing valve ensures that engine braking is given
mildly when the select lever is shifted into the 2 range during
4th speed (OD) mode. Gear is shifted from OD to 3rd and to 2nd.
instead of directly from OD into 2nd.
While the vehicle is in motion in 4th speed, this valve is located on
the top end. When gear is shifted into 2 range, the line pressure
from the manual valve pushes down the 3-4 shift valve setting the
3rd speed. At the same time, the line pressure
is also applied to
the top of D-2 down timing valve, pushing the valve down because
of the difference
in land diameters
(#1=#2>#3).
This opens the
circuit to the intermediate
shift valve, allowing the line pressure to
be applied to push down the 2-3 shift valve, thus setting the 2nd
speed.
N+driving
To intermedlate
shift valve
In 2
Sequence
Information
The reverse clutch sequence valve, acting to dampen shocks generated when the gear is shifted into I? range, is controlled by the
line pressure applied to the inner piston of direct clutch (C,). With
the shift in R range, the line pressure
is applied both to the
circuits A and B; however,
since the circuit B does not open
before the pressure
A being applied to this valve, i.e. the line
pressure
applied to the inner piston, overcomes
the spring tension, the outer piston operates with a lag behind the inner piston.
With the shift in 3rd speed in D range, the circuit B is closed by
the manual valve, allowing only the inner piston to apply pressure.
At the time, the circuit B acts to release hydraulic pressure to be
applied to the outer piston.
D-2 Down
FEZsure
- General
range
and 2nd speed
355074
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21-72
AUTOMATIC
TRANSMISSION
General
Information
GOVERNOR
, Weights
f+-+&,
Shaft
Spring
Drain
-output
_-.I
In case
of low
shaft
vehicle
speed
aI+
,LEsure
4Governo1
pressure
In case
of high
vehicle
Installed on the output shaft, the governor

counterbalances
the
line pressure from the primary regulator valve with the centrifugal
force applied to the governor weights,
thus providing the governor
pressure
in proportion
to the output-shaft
speed, or the vehicle
speed. As the output shaft rotates, the governor weights,
shaft,
valve, and spring move bodily outward,
allowing the line pressure,
which has been blocked off by the governor valve, to enter the
governor valve. This causes the governor valve to move inward
cutting off the line pressure.
The governor pressure thus refers to
the one produced when the outward force of the governor weight
centrifugal force and spring tension balances with the inward pressure applied to the governor valve by the line pressure.
As the output-shaft
speed further increases,
the governor weights
and shaft are blocked by the governor body. After that, the governor pressure is obtained when the centrifugal
force of the governor valve balances with the spring tension.
speed
372027
Operation
ACCUMULATOR
side
C2
To inner
piston
side
I (from
Oil pump)
Accumulators
are provided for C,, C,, and B,, respectively,
to
dampen shocks when each is actuated.
The area of the pressure receiving side of the accumulator
piston
is made greater than that of the back pressure
side. The line
pressure is always applied to the back pressure
side, keeping the
piston in up position. When the circuit to the pressure
receiving
side opens causing the line pressure
to be applied to the piston,
the piston is slowly pushed downward,
thus dampening
shocks
when each device is operated.
355067
FOURTH
(OD) CONTROL
SYSTEM
A solenoid valve is used to electrically select the hydraulic circuit

to shift into the 4th speed. When the OD-OFF switch on the select
lever is turned ON, the OD solenoid is energized to select a circuit
to set the 4th speed.
When the OD-OFF switch is turned OFF, the OD-OFF indicator on
the meter panel comes on.
372028
OD-OFF Switch
3-4 shift
valve
The OD-OFF switch is located on the select lever on the drivers

seat. It turns ON or OFF the OD solenoid valve to control the shift
into 4th speed (OD).
When this switch
is turned ON, the OD solenoid is energized to
turn ON the solenoid valve, allowing for shift into 4th speed. When
the switch is OFF, the solenoid valve is OFF and no shift into 4th
speed takes place.
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AUTOMATIC
TRANSMISSION
OD Solenoid
355018
- General
Information
21-73
Valve
The OD solenoid valve, installed to the left of the transmission

case, turns ON or OFF by the operation of the OD-OFF switch to
select the hydraulic circuit. When the solenoid valve turns ON, the
plunger is pulled, releasing the line pressure to be applied to the
third coast shift valve. This positions the third coast shift valve in
the up side, allowing shift into 4th speed. When the solenoid valve
is OFF, the plunger is pushed down by spring tension, closing the
release circuit, which causes the line pressure to be applied to the
third coast shift valve. This causes the third coast shift valve and
3-4 shift valve to be pushed down, and no shift into 4th speed
takes place.
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21-74
AUTOMATIC
TRANSMISSION
- General
N (Neutral)
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Information
AUTOMATIC
TRANSMISSION
General
Information
21-75
P (Parking)
,.,3.
[
I
!,:;
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Throttle
valve
_
III i-xl
I(-lh
II %!!EJl
Cut
back
valve
~~~~~~~~
II I lregurarorll
Overdrive
brake
I
shift
II II II%%
Direct
clutch
II II II II
lUIIF=l####F
valve
II ~i----xlh7
I! II IU imllu
II IIIIII //llll II v
Nor3
Brake
modulator
modulator
valve
II medite
<,
r,
In
M%i
I/ / 1solenoid
0
0
n
valve
pressure
pressure
oressure,
Cut back
Governor
Converter
II
2ND)
II
Lubrication
Third
coast
oil pressure
pressure,
Intermediate
Low coast
modulator
D-2 (DRIVE
III1
fl h)
Line pressure
Detent
regulator
modulator
pressure,
pressure
Throttle
pressure
0
(
II
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372091
Ill/-.
II -
II
=
!
I!
coasr
valve
w
Intermediate
modulator
Reverse
seauence
valve
clutch
valve
I
0
0
0
0
I
II
IIII
oil pressure
3RD)
II II I11
Lubrication
pressure,
Inten--:-*Low
coast
mooulator
D-3 (DRIVE
Line pressure
Detent
regulator
modulator
pressure,
pressure
Throttle
pressure
Cut back oressure
Governor
pressure
Converter
pressure,
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\\I
Overdrive
brake
UK,,
I
Direct
clutch
-. -..No.1
I
II II IIIIII IIIIII II w
u,umce
No.2
I
Brake
No.3
Intermediate
modulator
modulator
valve
valve
oil pressure
3RD)
valve
OFF
11 3-4 shift11
Lubrication
pressure,
Intermediate
Low coast
modulator
D-3 (DRIVE
OD solenoid
Throttle
pressure
Cut back pressure
Governor
pressure
Converter
oressure,
a
n
n
m
so,lenoid
Line pressure
Detent
regulator
modulator
pressure,
pressure
[
0
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II u
To cooler
372093
ZIIZIZ
I,
II II
JI
Torque
converter
I
II valve
III-
11
II ffC?l
I I I ( regulatol
11 Check
valve
Overdrive
h
Overdrive
brake
Brake
No.1
II lkhl
Forward
clutch
Direct
Cl Ui tch
Brake
No.2
Brake
No.3
Ill
Intermediate
modulator
Reverse
sequence
valve
=T
D-4
I:
pressure
pressure
pressure,
(DRIVE
Third
JJ
coast
oil pressure
3-4 shift
c7?
valve
4TH)
Lubrication
pressure,
Intermediate
Low coast
modulator
L-J
snlrt
dl
valve
Cut back
Governor
Converter
0
0
0
clutch
valve
Throttle
pressure
Line pressure
Detent
regulator
modulator
pressure,
pressure
0
0
:
A
?
P
AUTOMATIC
TRANSMISSION
- General Information
D-K/D (DRIVE KICK DOWN)

4TH + 3RD
l-l
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21-81
21-82
AUTOMATIC
TRANSMISSION
- General
2 (SECOND 2ND)
I
1
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Information
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372096
-&IT
To cooler
Ivalve II
rc
IIll
ih
Overdrive
clutclyl
Overdrive
brake
Forward
clutch
Direct
clutch
Brake
Brake
Brake
No.3
modulator
Reverse
0
n
m
valve
clutch
Throttle
Cut back
Governor
Converter
L (LOCK
pressure
pressure
pressure,
pressure
Line pressure
Detent
regulator
modulator
pressure,
pressure
L
a
UP)
Lubrication
D-2 down
timing valve
oil pressure
pressure,
Intermediate
Low coast
modulator
I-
21-84
AUTOMATIC
TRANSMISSION
- General
Information
R (REVERSE)
I
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AUTOMATIC
TRANSFER
14.
15.
16.
17.
18.
19.
20.
21.
- General
21-85
Information
2?
22
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
TRANSMISSION
Control lever assembly

Input gear
Output shaft
Adapter
Counter gear shaft
Counter gear
Transfer case
Dust seal guard
Chain
Front output shaft
Cover
Rear output shaft
Dust seal guard 10
\
Rear cover
Chain cover
Drive sprocket
Clutch hub (2-4WD)
Clutch sleeve (2-4WD)
Low speed gear
Clutch hub (for H-L)
Clutch sleeve (for H-L)
21 20 19 18 17
33 34 35 32
\I
dv/
22.
23.
24.
25.
26.
Control housing
Control lever
Control sleeve
Control shaft
Shift lug (2-4WD)
27.
28.
29.
30.
31.
Shift rail (2-4WD)

Control finger
Set screw
Shift fork (2-4WD)
Oil guide
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32.
33.
34.
35.
36.
Shift rail (H-L)

Shift fork (H-L)
Control housing
Vent plug
Select plunger
cover
148001
148002
148003
148004
21-86
AUTOMATIC
TRANSMISSION
General
Information
POWER FLOW
ZWD-H
Sleeve
for H-L changeover
ZWD-H
When the H-L selector sleeve is shifted forward and engaged with
the clutch gear of input gear, the input gear is directly coupled to
the rear output shaft, thus transmitting
power to the rear wheels.
This is the power transmission
of 2WD-H, which involves no other
gears, making for quiet driving.
14ACl40
4WD-H
Sleeve for H-L

changeover
Sleeve for 2WD-4WD

changeover
1.000
--
3\
To rear
wheels
4WD-L
Sleeve for
changeover
H-L
Sleeve for 2WD4WD

changeover
4WD-H
When
mesh
mitted
chain,
If the
mode
the 2WD-4WD
selector sleeve is shifted to the rear and in
with the clutch gear of the drive sprocket,
power is transfrom the drive sprocket
to the front output shaft via the
thus driving the front wheels.
H-L selector sleeve is in the forward position at the time, the
is 4WD-H.
4WD-L
When the H-L selector
sleeve is shifted toward
rear, power is
imparted from the input gear to counter gear and to low speed
gear and the rear and front wheels are driven by the rear and front
output shaft, respectively.
This mode is 4WD-L.
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AUTOMATIC
TRANSMISSION
TRANSFER
General
CONTROL
21-87
Information
MECHANISM
The transfer control mechanism

employs the floor shift control as
in manual transmission
model. As shown below, the mechanism
uses the control lever, shift rails, shift forks, and related parts to
provide a direct-change
control. The only difference
from that of
the manual transmission
models is the control lever. With the
introduction
of four- speed automatic transmission
model, the position of the transfer has to be moved backward
as compared with
the conventional
manual transmission-4WD
model. To locate the
control lever in the same position as before, the control sleeve and
shaft are used and, as a result, the lever is now located ahead the
transfer.
H-L Shift Mechanism

A shift fork with .a shift lug is used to directly operate the H-L
selector clutch sleeve according to the movement
of the control
finger interlocking
the control lever.
The shift rail is secured to the shift fork with a spring pin. Provided
on the rear end of rail are the dents for interlock, poppet, and 4WD
indicator light switch ON-OFF.
Control
lever
Control
Shift
Shift
fork
shaft
Set
Control sleeve
(H-L)
rail (H-L)
Front
Shift
Shift
Switch
rail (24WD)
fork
(2-4WD)
Spring
A
Poppet
lug
Shift
B
Switch
Select
ball
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plunger
21-88
UTOMATIC
TRANSMISSION
2WD-4WD
- General
Information
Shift Mechanism
In the 2WD-4WD
shift mechanism,
the shift lug and shift fork are
separate. The shift lug is fastened to the shift rail with a spring pin,
while the shift fork is not secured but can slide over the shift rail,
which ensures smooth shifting from 4WD-H into 2WD-H.
Drive
When shifting into 2WD-H while

mode, the clutch hub and drive
counter
torque in the rotating
sleeves sliding motion. In such
to the 2WD-H position, the shift
4WD position.
sprocket
(24WD)
the vehicle is in motion in 4WD-H

sprocket
clutch gear tend to endirection,
impeding
the clutch
cases, the shift rail is first shifted
fork and clutch sleeve being in the
144045
As the vehicle receives road shocks and as torque fluctuates,

and
when the clutch sleeve gets loose on the clutch hub and drive
sprocket,
the shift fork is shifted by the spring force into 2WD
position, allowing the clutch sleeve to be off drive sprocket
clutch
gear, thus setting 2WD mode.
144046
Select
Plunger
The select plunger and select spring push the control finger tightly
against the H-L shift fork when the control lever is in the 4WD-H
position, thereby preventing
the lever from oscillating or coming
off position. They also provides
a resistance
when shifting into
2WD-H.
Select
In case
4WD-H
of
spring
In case
4WD-L
of
144047
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AUTOMATIC
TRANSMISSION
4WD Indicator
- General
Information
21-89
Light Switch
There are two switches installed that control the 4WD indicator
light which tells the driver that the vehicle is in 4WD mode.
When shift is mode from 2WD-H to 4WD-H or between 4WD-H
and 4WD-L, the 4WD indicator light comes on. When shifting from
4WD-H to 4WD-L, or vice versa, the switch B causes the light to
go off in the mid shift motion, allowing the driver to know that a
selection has been completed.
Switch A
Switch A
ON
OFF
144048
144049
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21-90
AUTOMATIC
TRANSMISSION
-Specifications
SPECIFICATIONS
GENERAL
SPECIFICATIONS
NZlCA-
Items
Automatic
Torque
transmission
and transfer
case model
Specifications
~~
(Ml48
converter
We
Stall torque
One-way
1 elements,
1 -step 2-phase
system
1I .96
ratio
!jprag
clutch
type
Transmission
I-orward 4 gears, reverse 1 gear, single-line
planetary gear
!Jear and Simpson
Type
Control
planetary
elements
3 pairs
Clutch
IVlultiple
Brake
4 pairs
Ivlultiple disc tyep
,Sprag type
3 pairs
One-way
clutch
disc type
Gear ratios
1st gear
2.826
2nd gear
1.493
3rd gear
1.000
4th gear
(3.688
Reverse
2.703
Shift control
Select
method
IFloor shift type

IV-N-D-2-L
pattern
and overdrive
switch
Oil pump
ISear type
Type
Drive system
Hydraulic
control
Oil-cooling
system
system
IDirectly
coupled
to engine
Throttle
opening
and vehicle
I4ir-cooled
(lsecondary
system
cooling
I4lwaysengaged
method
Single-lever
Shift ratios
LOW
1.944
HIGH
1 .ooo
Speedometer
gear ratio
2618
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speed
+ water-cooled
method)
Transfer
Type
Shift control
via torque
type
floor-shift
type
converter
detection
system
oil cooler
AUTOMATIC
TRANSMISSION
NUMBER
MARKING
TRANSMISSION
POSITION
AND DESIGNATION
1 Serial number
per month1
Fixed number
(Mitsubishi
exclusive
J-&--j
Transmission
21-91
Specifications
number
148013
-1
head number)
Classification
N: AW372
of type
1 Manufacturing
month
year
A: January
v: April
4
I
1
M : December
B
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Manutacturlng
87: 1987
21-92
AUTOMATIC
TRANSMISSION
- Specifications
NZlCB--
Specifications
Items
Standard value
Stall speed
Governor
rpm
pressure
2 100-2400
kPa (psi)
1000 rpm
138-l 66 (20-24)
2000 rpm
246-284
(36-41)
3200 rpm
402-460
(59-66)
When idling
452-529
(66-76)
During stall
991-1166(144-169)
Line pressure
D range
kPa (psi)
R range
When idling
687-804
During stall
1471-1863
Input shaft end play
mm (in.)
Overdrive
brake clearance
Overdrive
clutch return spring
Free length
Overdrive
mm (in.)
(100-l
16)
(214-270)
0.3-0.9 (.012-,035)
0.35-I .6 (.0143-,062)
14.9(.587)
mm (in.)
brake return spring
Free length
Sleeve and selector
16.1 (.634)
mm (in.)
lever clearance
15.2-15.9
(.60-.62)
Transfer
H-L clutch hub end play
mm (in.)
Input gear bearing end play

mm (in.)
mm (in.)
Input gear end play
O-0.08 (O-.003)
O-0.06 (O-.002)
O-0.06 (O-.002)
Limit
Overdrive
clutch return spring

mm (in.)
Free length
Overdrive brake return spring
Free length
mm (in.)
14.5 (.571)
15.7(.618)
http://vnx.su/
AUTOMATIC
TRANSMISSION
21-93
-Specifications
NZlCC-
Items
Nm
ft.lbs.
Transmission
Converter
housing
installation
bolt
10 mm (.39 in.) dia. bolt
27-42
20-30
48-68
35-49
18-25
13-18
6-9
24-28
4.3-6.5
27-42
20-30
screw
6-9
4.3-6.5
bolt
5-6
6-9
3.6-4.3
4.3-6.5
8-12
5.8-9
5-6
3.6-4.3
6-9
4.3-6.5
4-5
2.9-3.6
Union
Elbow connector
20-30
20-30
14-22
14-22
Plug (for hydraulic test)

Oil pan drain plug
6-9
18-23
4.3-6.5
13-17
IO-16
IO-16
7-12
14-18
IO-13
IO-13
7-9
IO-13
7-9
Oil pump assembly
installation
bolt
Oil pump body and cover-tightening

Center support
Adapter
installation
installation
bolt
Cover plate installation

All bolts of valve body
Throttle cam installation
Valve body assembly
installation
Oil screen installation
bolt
Parking cam plate installation

Oil pan installation bolt
Overdrive
bolt
bolt
bolt
bolt
solenoid valve installation
bolt
Plug
Manual lever installation
Transmission
nut
control rod (B) to pin
Cross shaft bracket (A) to body
17-20
7-12
Transmission
control arm to bracket
18-24
13-17
Transmission
oil cooler eye bolts
30-35
22-25
Oil filler tube to transmission
20-27
14-20
50-60
36-43
Front exhaust
20-30
15-22
Bell housing cover to transmission
pipe mounting
IO-12
7-9
No. 2 crossmember
55-75
40-54
IO-13
7-9
Rear engine support

No. 2 crossmember
bolt
to body
member to body
18-25
13-18
Transmission
to starter motor
to transmission
43-55
31-40
Transmission
to engine
A, B
43-55
31-40
20-27
14-20
Torque converter to drive plate

Selector handle mounting screw
35-42
2
25-30
0.4
Transmission
40-50
29-36
oil cooler tube flare nut
http://vnx.su/
21-94
AUTOMATIC
TRANSMISSION
- Specifications
NPlCC-
Items
Nm
ft.lbs.
ransfer
Transfer case installation
bolt
30-42
22-30

Chain cover bolt
nut
30-42
;!2-30
31-42
22-30
Side cover bolt
8-10
5.8-7
Rear cover bolt
15-22
1 I-16
Cover bolt
15-22
11-16
Control housing
bolt
15-22
11-16
Oil filler plug
30-35
22-25
Drain plug
30-35
22-25
Select plug
30-35
;!2-25
Locking plate bolt
15-22
11-16
Rear output shaft lock nut
100-I 30
72-94
Speedometer
1.5-2.2
1 .I-1.6
Seal plug
30-42
22-30
4WD switch
30
22
8-10
5.8-7
8-10
5.8-7
50-60
36-43
Transfer
mounting
bracket
18-25
13-18
Transfer
mounting
bracket to pipe
30-42
22-29
sleeve clamp bolt
Control shaft set screw

to control housing
to transfer
http://vnx.su/
TIC
TRANSMISSION
- SDecifications
LUBRICANTS
NZlCD--
Items
Automatic
Transfer
Specified
transmission
fluid
Automatic
II type
oil
Propeller
shaft oil seal lip
Transmission
part
control
sliding
Adaptor
Hypoid Gear Oil Part No.

or equivalent
MOPAR
2525035
Multi-Mileage
or equivalent
installation
MOPAR
3744994
(press-in
Chain cover
gasket
gasket
Cover gasket
housing
only)
Part
Hypoid Gear Oil Part No.

or equivalent
Approx.
pints)
2.2 lit. (4.7 U.S. pints, 3.9 Imp.
Small quantity
Small quantity
Small
quantity
Quantity
MOPAR
Part No. 4318025
or equivalent
as required
crrcumference)
MOPAR
Part No. 4318025
or equivalent
as required
MOPAR
Part No. 4318025
or equivalent
as required
MOPAR
Part No. 4318025
or equivalent
as required
MOPAR
Part No. 4318025
or equivalent
as required
MOPAR
Part No. 4318025
or equivalent
as required
4171 or
as required
or equivalent
as required
sides)
sides)
gasket
(cover
side
3M Adhesive
equivalent
cable
and adhesives
SH 780 (TORAY
(both
(both
sealants
sides)
(both sides)
grommet
12.7 Imp.
NZlCE--
Specified
Bolt (threads)
Speedometer
Part No.
7.2 lit. (15.2 U.S. pints,
bolt (threads)
(both
Air breather
Control
surface
lubricant
Approx.
pints)
AND ADHESIVES
gasket
Rear cover
fluid DEXRON
MOPAR
3744994
Items
Oil pump
transmission
Quantity
MOPAR Multi-Mileage
Lubricant
No. 2525035
or equivalent

assembly
O-ring
SEALANTS
lubricants
MOPAR
as required
SILICONE)
Nut Locking
Part No. 4318025
http://vnx.su/
21-96
AUTOMATIC
TRANSMISSION
- Special Tools
SPECIAL TOOLS
NZlDA-
;embly of oil pump

Stopper
nstallation
(includes MD9983311
Oil pressure gage
http://vnx.su/
of oil pump
AUTOMATIC
Tool (Number
and name)
TRANSMISSION
Use
Tool (Number
MD99821 0
Bolt
Disassembly
and
assembly of No. 3 brake
spring
Torque
MD99821 1
Retainer
Disassembly
and
spring
and name)
MD998353
http://vnx.su/
21-97
- SDecial Tools
driver set
Use
Tightening of valve body
screw
21-98
AUTOMATIC
TRANSMISSION
- Troubleshooting
SHQOTING
N21 EBAE
GENERAL
Automatic
transmission
lowing conditions:
malfunctions
may be caused
by the fol-
(1) Improper maintenance

and adjustment
(2) Mechanical malfunctions
(3) Hydraulic malfunctions
(4) Poor engine performance
Troubleshooting
in the event of any such malfunctions
should
begin by checking fluid level, ATF condition, manual linkage adjustment,
throttle control cable adjustment
and other conditions
whose deviation from standards
can be readily known.
Then, road test shall be performed
to determine
whether
or not
the problem has been corrected
or more diagnosis is necessary.
If
the problem still persists after these tests and corrections,
hydraulic tests should be performed
for further troubleshooting.
FLUID LEVEL AND ATF CONDITION

HOT upper
limit
COLD upper
COLD lowelCrnif
limit
COLD
HOT lower
limit
HOT
372029
(1) Place the vehicle on a level surface.

(2) Before removing the dipstick, wipe all dirt from area around
the dipstick.
(3) With the selector lever in the P position and the parking
brake applied, start the engine.
(4) The engine should be running at idle and the transmission
should be warmed up sufficiently.
(5) Move the selector lever through all positions to fill the torque
converter and hydraulic circuit with fluid. Then, place the lever
in the N or P position.
(6) Check to see that the fluid level is within the range between
COLD upper limit and the HOT lower limit on the dipstick.
It the fluid level is low, top up until the level rises to within the
range between the HOT lower and upper limits.
Low fluid level can allow the oil pump to take in air together with
fluid, leading to various troubles. Air trapped in hydraulic circuit
forms bubbles which make the fluid spongy. This loweres pressure and slows down pressure buildup.
If the transmission has too much fluid, gears churn up foam and
cause same conditions as when the fluid level is low, resulting in
premature deterioration of ATF. In either case, air bubbles can
cause overheating and fluid oxidation and varnishing, which can
interfere with normal valve, clutch and servo operation. Foaming
can also result in fluid escaping from the transmission vent where
it may be mistaken for a fluid leak.
Along with the fluid level, it is equally important to check condition
of fluid. When fluid smells burned, it is contaminated with metal
bushing or friction material particles and hence a complete overhaul of the transmission is needed. Be sure to examine fluid on the
dipstick closely.
After fluid has been checked, insert the dipstick until it is seated
fully to seal out water and dirt.
http://vnx.su/
AUTOMATIC
TRANSMISSION
21-93
- SDecifications
NZlCC-
Items
Nm
ft.lbs.
Transmission
Converter
housing
installation
bolt
27-42
20-30
48-68
35-49

Oil pump assembly installation bolt
Oil pump body and cover-tightening
bolt
18-25
13-18
6-9
4.3-6.5
Center support
24-28
17-20
2742
20-30
screw
6-9
bolt
5-6
6-9
4.3-6.5
3.64.3
installation
Adapter installation
bolt
bolt
Cover plate installation

All bolts of valve body
Throttle cam installation
Valve body assembly
installation
8-12
5.8-9
Oil screen installation
bolt
5-6
3.6-4.3
6-9
4.3-6.5
4-5
2.9-3.6
Union
Elbow connector
20-30
20-30
14-22
14-22
Plug (for hydraulic test)

Oil pan drain plug
6-9
4.3-6.5
18-23
13-17
IO-16
7-12
IO-16
14-18
7-12
IO-13
Parking cam plate installation

Oil pan installation bolt
Overdrive
bolt
4.3-6.5
bolt
solenoid valve installation
Plug
Manual lever installation
Transmission
bolt
nut
IO-13
7-9
Cross shaft bracket (A) to body
IO-13
Transmission
18-24
7-9
13-17
30-35
22-25
Transmission
control rod(B) to pin

control arm to bracket
oil cooler eye bolts
Oil filler tube to transmission

20-27
14-20
50-60
36-43
Front exhaust pipe mounting
20-30
15-22
Bell housing cover to transmission
IO-12
No. 2 crossmember
to body
Rear engine support member to body
55-75
7-9
40-54
IO-13
7-9
No. 2 crossmember
18-25
13-18
43-55
31-40
43-55
20-27
31-40
14-20
35-42
25-30
0.4
40-50
29-36
to transmission
Transmission
to starter
Transmission
to engine
Torque converter
bolt
motor
A, B
D
to drive plate
Selector handle mounting screw

Transmission
oil cooler tube flare nut
) STB Revision
http://vnx.su/
21-94
AUTOMATIC
TRANSMISSION
- Specifications
NZlCC--
Items
Nm
ftlbs.
Transfer
bolt
nut
3042
30-42
22-30
22-30
Chain cover bolt
3142
22-30
Side cover bolt
8-10
5.8-7
Rear cover bolt
15-22
11-16
Cover bolt
15-22
Control housing bolt
15-22
11-16
11-16
Oil filler plug
30-35
22-25
Drain plug
30-35
22-25
Select plug
Locking plate bolt
30-35
15-22
22;25
11-16

Speedometer sleeve clamp bolt
100-l 30
1.5-2.2
72-94
Seal plug
3042
22-30
4WD switch
30
22
Control shaft set screw
8-10
8-10
5.8-7
5.8-7

Transfer mounting bracket to transfer
50-60
3643
18-25
13-18
Transfer
30-42
22-29
mounting
to control housing
bracket to pipe
STB Revision
http://vnx.su/
1.1-1.6
AUTOMATIC
TRANS
21-95
ISSION - SDecifications
LUBRICANTS
NZlCD--
Items
Automatic
Transfer
transmission
Specified lubricants
Automatic
fluid
fluid DEXRON
II type
Approx. 7.2 lit. (15.2 U.S.

Hypoid gear oil API classification GL-4 or higher

SAE viscosity No. 80W or 75W-85W
Approx. 2.2 lit. (4.7 U.S.

Propeller shaft oil seal lip
Multipurpose
grease SAE J310, NLGI No. 2
Small quantity
Transmission
Multipurpose
Small quantity
Transfer
oil
transmission
Quantity
control sliding part
control lever assembly
SEALANTS
O-ring
Hypoid gear oil API classification GL-4 or higher

SAE viscosity No. 8OW. 75W-85W
Small quantity
AND ADHESIVES
Items
NPlCE-
specrrrea
sealants
ana aanewves
Uudrltlty
SH 780 (TORAY SILICONE)
As required
Adaptor gasket (both sides)

Air breather (press-in circumference)

As required
Chain cover gasket (both sides)
Oil pump installation
bolt (threads)
As required
Rear cover gasket (both sides)
As required
As required
Cover gasket (both sides)
As required
Control housing gasket (cover side

surface only)
As required
Bolt (threads)
3M Adhesive
Nut Locking 4171 or equivalent
As required
3M ART Part No. 8001 or 8011, or equivalent
As required
Speedometer
cable grommet
1 STB Revision
http://vnx.su/
21-96
AUTOMATIC
TRANSMISSION
-Special
Tools
SPECIAL TOOLS
NZlDA-
Tool (Number
Use
MD998218
Wrench
Inspection
converter
of torque
MD998212
Oil pump puller
Removal of oil pum P
MD998219
Stopper
Inspection
converter
of torque
M D998335
Oil pump band
Assembly
M D998330
Iincludes MD998331)
Oil pressure gage
:3000 kPa)
1427 psi)
Measurement
pressure
MD99841 2
Guide
Installation
of oil
and name)
Use
Tool (Number and name)
of oil punTP
of oil pl JmP
VI D999563
includes MD998331
3il pressure gage
1000 kPa)
142 psi)
Measurement
pressure
of oil
MD99821 7
Gage
Check of quality of assembly condition
9
/
M D998206
Adapter
Connection of oil
pressure gage
M D998207
Spring compressor
1 STB Revision
http://vnx.su/
Disassembly
and
assembly of clutct- I and
brake
AUTOMATIC
Tool (Number
and name)
TRANSMISSION
-Special
Use
Tool (Number
MD99821 0
Bolt
Disassembly
and
assemblv of No. 3 brake
spring
M D998353
Torque driver set
MD99821 1
Retainer
Disassembly
and
spring
1 STB Revision
http://vnx.su/
21-97
Tools
and name)
Use
Tightening
screw
of valve body
21-98
AUTOMATIC
TRANSMISSION
- Troubleshooting
TROUBLESMOOTING
NZlEBAE
GENERAL
Automatic transmission
malfunctions
may be caused by the following conditions:
(1) Improper maintenance
and adjustment
(2) Mechanical malfunctions
(3) Hydraulic malfunctions
(4) Poor engine performance
Troubleshooting
in the event of any such malfunctions
should
begin by checking fluid level, ATF condition, manual linkage adjustment, throttle control cable adjustment
and other conditions
whose deviation from standards can be readily known.
Then, road test shall be performed to determine whether or not
the problem has been corrected or more diagnosis is necessary. If
the problem still persists after these tests and corrections, hydraulic tests should be performed for further troubleshooting.
FLUID LEVEL AND ATF CONDITION

COLD
COLD
limit
upper
bve:mit
COLD
HOT
limit
HOT
upper
bvel\
Y
HOT
37202!l
(1) Place the vehicle on a level surface.

(2) Before removing the dipstick, wipe all dirt from area around
the dipstick.
(3) With the selector lever in the P position and the parking
brake applied, start the engine.
(4) The engine should be running at idle and the transmission
should be warmed up sufficiently.
(5) Move the selector lever through all positions to fill the torque
converter and hydraulic circuit with fluid. Then, place the lever
in the N or P position.
(6) Check to see that the fluid level is within the range between
COLD upper limit and the HOT lower limit on the dipstick.
If the fluid level is low, top up until the level rises to within the
range between the HOT lower and upper limits.
Low fluid level can allow the oil pump to take in air together with
fluid, leading to various troubles. Air trapped in hydraulic circuit
forms bubbles which make the fluid spongy. This loweres pressure and slows down pressure buildup.
If the transmission
has too much fluid, gears churn up foam and
cause same conditions as when the fluid level is low, resulting in
premature deterioration
of ATF. In either case, air bubbles can
cause overheating
and fluid oxidation and varnishing, which can
interfere with normal valve, clutch and servo operation. Foaming
can also result in fluid escaping from the transmission
vent where
it may be mistaken for a fluid leak.
Along with the fluid level, it is equally important to check condition
of fluid. When fluid smells burned, it is contam,inated
with metal
bushing or friction material particles and hence a complete overhaul of the transmission
is needed. Be sure to examine fluid on the
dipstick closely.
After fluid has been checked, insert the dipstick until it is seated
fully to seal out water and dirt.
1 STB Revision
http://vnx.su/
AUTOMATIC
TRANSMISSION
MANUAL
- Troubleshooting
21-99
LINKAGE
The inhibitor switch is installed on the selector lever. After checking normal.operation
of this switch, place the selector lever in the
N position. If the notch of the seletor lever on the transmission
side faces directly down, the linkage has been adjusted correctly.
THROlTLE
CONTROL
CABLE
Throttle control cable adjustment

is very important to assure normal operation of the transmission.
Shift speed control, shift feeling
and transmission
slip depend greatly on this adjustment.
If the throttle outer cable is set too long (namely, the inner cable
is too tight), the throttle valve is already in operating state and
consequently,
presense of hydraulic pressure higher than specified is suspected. The throttle pressure acts on each shift valve
and when upshifting,
the governor pressure that counteracts
against the throttle pressure is higher than normal. Namely, if the
outer cable is set too long, upshift takes place at vehicle speed
higher than normal.
On the other hand, if the outer cable is set too short (the inner
cable is slack), upshift takes at vehicle speed lower than normal.
INHIBITOR
L
.,
,
i
SWITCH
Check to see that the engine starts only when the selector lever
is in the N or P position and that it does not start when the
selector lever is in other positions.
SELECTOR LEVER
(1) Check to see that the vehicle moves forward when the selector lever is shifted from the N position to the D range and
that the vehicle reverses when the lever is shifted to the R
range.
(2) Stop the engine.
(3) Shift the selector lever from the N position to the D range
and then to the 2 position to check that the lever can be
operated smoothly and engage at each position with reasonable firmness.
(4) Check to see that shifting to each of the P, R, 2 and
L positions can take place only when the selector lever is
pushed in.
ROAD TEST
Prior to performing
road test, be sure to make basic checks including check and adjustment
of fluid level and condition and adjustment of the throttle cable. For road test, the transfer must be
placed in the 2H (2WD-high) position.
In road test, various changes such as slips in transmission
and
shifting conditions are checked and hence the transmission
operation at each shift position must have been checked.
1 STB Revision
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5
.,I(-
? _
75
,.:
21-100
D RANGE
AUTOMATIC
TRANSMISSION
- Troubleshooting
TEST
Start with throttle valve 50%/full open and check shifting from 1st to 2nd
speed, 2nd to 3rd speed and 3rd to 4th speed and compliance of shift point
with shift pattern.
Throttle control cable

adjusted improperly,
valve body faulty or
governor faulty
During operation at 2nd, 3rd or 4th speed,

1st, 3rd to 2nd speed or 4th to 1st, 4th to 2nd, 4th to 3rd speed to check that
kickdown speed limits
f
Out of downshift
timing
I
Low coast modulator valve faulty

(low coast modulator pressure
too high)
Low
coast
modulator
too low
During drive at 3rd speed, shift to 2 and L positions

brake operation at these positions.
During acceleration
pressure
to check engine
and deceleration, check for abnormal noise and check

slip and shock during shift.
1
Large shock
1
Line pressure too high.
Accumulator or check ball faulty.
/ STB Revision
http://vnx.su/
AUTOMATIC
TRANSMISSION
- Troubleshooting
21-101
NOTE
Drive at D range 3rd speed and check for abnormal noise and
vibration. Check carefully as abnormal noise and vibration are
sometimes
caused by unbalanced
propeller shaft, differential,
tires, torque converter, engine, etc.
2 RANGE TEST
(1) Shift to 2 position and start with throttle valve 50%/full open
and check if 1st to 2nd speed upshift point at these throttle
openings meets the shift pattern.
(2) Kickdown at 2nd speed in 2 range to check that 2nd to 1st
kickdown speed limits meet shift pattern.
(3) Check for abnormal noise during acceleration/deceleration
and
check for shock during up/downshift.
L RANGE TEST
(1) Drive at the L range and check that upshift to 2nd speed
does not take place.
(2) Check for abnormal noise during acceleration/deceleration.
R RANGE TEST
(1) Shift to the R range and start forward with full throttle to
check for slip.
(2) While the vehicle is running, lightly depress the accelerator
pedal to check for slip.
7 RANGE TEST
With the vehicle parked on a slope (about 5 degrees or steeper),
shift to the P range and release the parking brake to check to
see that the parking brake system functions to keep the vehicle
stationary.
CONVERTER
STALL TEST
In this test, the engine maximum

speed when the torque converter stalls with the shift lever in the D or R range is measured to check operation of the torque converter, stator and oneway clutch and check holding performance
of the transmission
clutch (including brake).
Caution
Do not stand in front or at rear of the vehicle during this test.
(1) Check the transmission
fluid level. The fluid temperature
should be at the level after normal operation [50 to 80C (120
to 18OF)I. The engine coolant temperature
should also be at
the level after normal operation [80 to 90C (180 to 195F)l.
(2) Apply checks to the rear wheels (right and left).
(3) Mount an engine tachometer.
(4) Apply fully the parking and service brakes.
(6) With the selector lever in the D range, fully depress the
accelerator pedal and read off the engine maximum
speed.
When doing so, do not keep the engine running with throttle
full open for more than necessary duration (8 seconds or
more). If two or more stall tests are needed, place the selector
lever in the N position and run the engine at about 1,000
rpm to allow the transmission
fluid to cool before another stall
test.
Standard value : 2100-2400
rpm
(7) Place the selector lever in the R range and perform the test
as above.
1 ST6 Revision
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(.
I
y.
I.
21-102
Judgement
Stall speed
AUTOMATIC
of Stall
in D
Test
and R
TRANSMISSION
- Troubleshooting
Results
range
is equal to each other but
lower than the nominal value.
(1) Engine output is low.

(2) Stator one-way clutch is faulty.
(Faulty torque convener is suspectediif it is lower than
;
nominal by more than 600 rpm.)
Stall speed in D range is higher than nominal.
(1) O.D. clutch slipping.

(2) O.D. one-way clutch faulty
(3) Forward clutch slipping
(4) One-way clutch No.2 faulty
(5) Low line pressure
Stall speed in R range is higher than nominal.
(1) O.D. clutch slipping.

(2) O.D. one-way clutch faulty
(3) Direct clutch slipping
(4) Brake No.3 slipping
(5) Low line pressure
Hydraulic pressure .testing is one of the most important steps in

troubleshooting. These tests usually reveal causes of most transmission problems.
Before performing pressure tests, perform basic checks and adjustment including fluid level and condition check and throttle cable adjustment. Prior to pressure tests, the engine and transmission must have been warmed up enough [engine coolant
temperature 80 to 90C (180 to 195F)] and the transfer must be
at 2H (2WD-High).
GOVERNOR
- I \
Line pressure
pick up
PRESSURE
TEST
(1) Place the vehicle on a chassis dynamometer.

(2) Remove the plug from the governor pressure takeoff port.
(3) Connect an oil pressure gauge using Adapter MD998206 (special tool) and bring the gauge into the inside of the vehicle.
(4) Apply the parking brake.
(6) Release the parking brake.
(7) Place the selector lever in the D range and measure the
governor pressure.
If the governor pressure is not norminal, incorrect line pressure, oil leaks from the governor pressure circuit or faulty
governor is suspected.
Governor
1000 rpm
138-l 66 kPa
(20-24 psi)
2000 rpm
246-284
kPa
(36-41 psi)
3200
402-460
kPa
(59-66 psi)
rpm
STB Revision
http://vnx.su/
pressure
ATIC TRANSMISSION
21-103
- Troubleshooting
LINE PRESSURE
TEST
(1) Place the vehicle on a

(2) Remove the plug from
(3) Connect an oil pressure
cial tool) and bring the
chassis dynamometer.
the line pressure takeoff port.
gauge using Adapter MD998206
(spegauge into the inside of the vehicle.
(4) Apply the parking brake.

(6) Place the selector
lever in the D range.
(7) Depress the brake pedal firmly by the left foot and operates
the accelerator
pedal by the right foot to measure
the line
pressure at each engine rpm. If the measured
pressure
is not
nominal, check adjustment
of the throttle cable and readjust if
necessary
before conducting
the test again.
(8) Place the selector lever in the R range and test as above.
Standard .value
Judgement
Line pressure
R range
D range
At idle
452-529 kPa
66-76 psi
At stall
991-1166
144-169
kPa
psi
687-804
100-116
1471-1863
214-270
by Line Pressure
Hydraulic pressure
Hydraulic pressure
higher than nominal in all ranges
(1) Regulator valve faulty

(2) Throttle valve faulty
(3) Throttle control cable incorrectly
lower than nominal in all ranges
Hydraulic pressure
lower than nominal in D
Hydraulic pressure
lower than nominal in R range
(1)
(2)
(3)
(4)
(5)
Oil pump faulty

Regulator valve faulty
Throttle valve faulty
Throttle control cable incorrectly
O.D. clutch faulty
(1) Large fluid leaks in D

(2) Forward clutch faulty
(3) O.D. clutch faulty
range
(1)
(2)
(3)
(4)
adjusted
adjusted
range hydraulic circuit
Large fluid leaks in R range hydraulic circuit

Brake No.3 faulty
Direct clutch faulty
O.D. clutch faulty
[ ST6 Revision
http://vnx.su/
kPa
psi
kPa
psi
21-104
CIRCUIT
AUTOMATIC
- Troubleshooting
i..rr :
DIAGRAMS
OVERDRIVE
Battery
T;Rq?JSMISSION
NZlEC--
CONTROL -SYSTEM
-1.25-B
Sub
A-02
-5
3
Main
link
CIRCUIT
5 WA-23
-5-w
fusible
link
Ignition
0.5-G
2-w
switch
/T
fusible
cf3
3
(\:I
r
L
A-22
bM STIG
_
c4
1 c-55
szz
mm
4,:
(VW)
2-BY
To combination
meter
[Refer
to P.8-52.1
To alternator
[Refer
to P.8-37.1
0.85-N
0.85-W
2
z
TO column
[Refer
to
switch
P.8-51.1
Remarks
(I)
For information
concerning.,the
ground
points
(example:
0).
refer
to P.8-7.
(2)
The
symbols
0,
0,
etc.
indicate
that
the
wiring
is
connected
(using
the same
numerical
symbol)
to the
facing
page.
(In other words,
0 on the right page is connected
to 0 on
the left page.)
Combination
RL]
1 ]
ST6 Revision
http://vnx.su/
w
YR
meter
LQ
1 1 ]
AUTOMATIC
TRANSMISSION
Inhibitor
Water
temperature
switch
switch
A-51
RL
*
21405
- Troubleshooting
OD-OFF
relay
To back-up
lrght
[Refer
to P.8-45.1
Z-BY,
To starter
[Refer
to
@4
*
R
YR
(Lg)
I
1
relay
P.8-34,
35.
A-10
cl c
JO
c
C
ii!3
ii
Automatic
transmission
oil temperature
swatch
OD-OFF
switch
Wiring
color
code
Br:
B: Black
LI: Light
blue
0:
Brown
Orange
OD-OFF
solenoid
G: Green
P: Pink
Gr: Gray
R: Red
L: Blue
Y: Yellow
Lg:
W:
1 STB Revision
http://vnx.su/
Light
White
green
37W619
21-I 06
AUTOMATIC
TRANSMISSION
- Service
Adjustment
procedures
SERVICE ADJUSTMENT
PRQCEDUREsF+
CHECKING
CHANGING
FLUID
TRANSMISSION
FLUID
LEVEL
AND
(1) Check the fluid level (automatic

transmission
and transfer
case) every year or after 20,000 km (12,500 miles) of operation.
(2) For the checking procedures of automatic
transmission
fluid
(ATF), see following.
(3) Check the transfer case oil level with the filler plug removed.
(4) The fluid level is okay if it is at the same level as the lowest
point of the filler plug hole.
I
,
:.
: i
0
>
-
--
-_
ATF CHANGING
PROCEDURES
Caution
If ATF change is required due to damage
be sure to clean the cooler system.
to the transmission,
(1) Raise.the vehicle on hoist. Place a drain container with large

opening under the drain plug (located in bottom of the oil pan).
(2) Remove the drain plug to let ATF drain
(3) Refit the drain plug and gasket.
(4) Pour ATF through the oil level gauge hole until its level reaches
the COLD lower limit of the level gauge.
~
14
COLD upper
HOT upper
limit
limit
COLD lower
HOT lower
limit
limit
Y
.
Y
COLD
HOT
(5) Start the engine and allow to idle for at least two minutes.
Then, with the parking brake and service brake applied, move
the selector lever through all positions and finally place in the
N or P position.
(6) After the transmission
is warmed up to the normal operating
temperature,
recheck the fluid level, which must be between
the HOT upper limit and HOT lower limit marks.
(7) Insert the dipstick fully to prevent dirt from entering the
transmission.
372029
rST
Revision
http://vnx.su/
AUTOMATIC
TRANSMISSION
- Service
TRANSFER
(1)
(2)
(3)
(4)
Adjustment
21-107
procedures
CASE OIL CHANGING
PROCEDURES
Remove the filler plug.

Place a drain container with large opening under the drain plug.
Remove the drain plug to let oil drain.
Refit the drain plug and gasket.
(5) Pour specified transfer case oil up to specified

(6) Refit the filler plug and gasket.
ADJUSTMENT
BLE
OF THE THROTTLE
(1) Check the engine idle adjustment.

Caution
When engine
adjustment
performed,
always adjust
52-53
mm
(2.047-2.086
level.
CONTROL
If necessary,
CA-
readjust.
:.
: ,:
(idle adjustment)
has been
the throttle
control
cable.
(2) Make sure that no bending or deformation

exists on the carburetor throttle lever and throttle cable bracket.
(3) Measure the length between the inner cable stopper and the
cover end with the carburetor throttle valve full open. If it does
not satisfy the standard value, adjust the inner cable bracket
moving upward or downward.
in.)
Standard
value:
52-53
mm (2.047-2.085
in.)
IO-14Nm
w
8- 10 ftlbs.
372098
Front
REPLACEMENT
SEALS
OF THE PROPELLER
SHAFT
OIL
NPlFGABl
(1) Using a screwdriver

(2) Install the oil seals.
or a similar
tool, remove
the oil seals.
Caution
Use a new oil seal.
(3) Apply a coating
seals.
Specified
1 ST6 Revision
http://vnx.su/
grease
of the specified
: Multipurpose
No. 2
grease to the lip of the oil

grease
SAE 5310, NLGI
:.
.
\
21-I
08
AUTOMATIC
TRANSMISSION
- Service
REPLACEMENT
Adjustment
procedures
OF THE
SPEEDOMETER
CAWIID
(1) Replace the cable assembly

if there is a malfunction.
(2) When connecting
the cable to the meter,, insert the cable
until its stopper properly fits to the meterside
groove.
(3) After installing

the speedometer,
pull the speedometer
cable through the grommet
in the toe-board until the cable
marking
is visible from the engine compartment
side.
(4) Apply the specified sealant to the outside surface of the
grommet.
Specified
sealant
: 3M ART
equivalent
Part
No.
8001
or 8011,
or
(5) Securely clamp the transmission

side marking (L.H. drive
vehicles; green, R.H. drive vehicles; yellow) of speedometer cable to the frame side clip.
Caution
Poor installation
meter pointer,
the instrument
1 STB Revision
http://vnx.su/
of the cable may cause a fluctuating

or noise and a damaged
harness inside
panel.
AUTOMATIC
TRANSMISSION
REMOVAL
AND
TRANSMISSION
- Transmission
CONTROL
INSTALLATION
N21 IA-
012,
21-109
Control
25\
/:4\Ybs.
IO-13 Nm
ft.lbs.
- ~7-9
25
012
IO-13 Nm
23
/
F9
ft.bs*
21
24
09w542
Removal
steps
I. Plate B
Floor console
3. Overdrive
switch
connection
4. Selector
handle
5. Overdrive
switch
harness
and front wiring harness
connection
6. Cover
7. Inhibitor
switch
and front wiring
harness
connection
8. Position
indicator
light and front wiring
harness
connection
9. Indicator
panel
10. Bracket
assembly
11, Heat protector
12. Cotter pin
13. Transmission
control
rod (B)
14. Dust cover
2.
+e
l +
+e
+e
++
l +
l +
l +
l +
15.
16.
17.
18.
19.
20.
21.
~~
l +
l +
w+
l +
22.
23.
24.
25.
26.
Snap ring
Spring
Cross shaft
Cross shaft
Select cross
Transmission
Cap
Bushing
Cross shaft
Cross shaft
Bushing
Pin
bushing
boot (B)
shaft
control
rod
bracket
boot
NOTE
(1)
Reverse
the removal
procedures
(2)
+e
: Refer
to Service
Points
(3)
Points
(4)
: Non-reusable
parts
1 STB Revision
http://vnx.su/
(A)
(A)
to
of
of
reinstall.
Removal.
Installation.
AUTOMATIC
TRANSMISSION
SERVICE
4.
- Transmission
POINTS
REMOVAL
Control
OF REMOVAL
OF SELECTOR
HANDLE
(1) Press the cover downward.

(2) Disconnect
the overdrive switch
selector handle.
(3) Remove
the selector
N2lIBAF
handle
from
connector
from
the shift
the
lever.
13. DISCONNECTION
OF TRANSMISSION
CONTROL
ROD
(B)
(1) Disconnect
the transmission
control rod (B) from the
transmission
control arm by lossening
the nut from
under the floor.
(2) Disconnect
the select cross shaft from the heat
protector.
(3) Disconnect
the select cross shaft from transmission
control rod B.
19. REMOVAL
OF SELECT CROSS
SION CONTROL
ROD (A)
(1) Disconnect
the select
control rod A.
I-V-)
09w521
STB Revision
http://vnx.su/
cross
SHAFT/PO.
TRANSMIS-
shaft from
transmission
AUTOMATIC
TRANSMISSION
Transmission
21-111
Control
(2) Remove the dust cover, and then remove the snap ring
that holds the spring.
(3) Remove the cross shaft bracket mounting
bolts from
the transfer assembly.
(4) Detach the cross shaft bracket from the bracket on the
No. 1 crossmember
side.
Cross
shaft
bracket
(A) v
09~011
(5) Remove
sion.
Transmission
control
rod
transmission
control
rod A from the transmis-
(A)
SERVICE
POINTS
OF INSTALLATION
NPlDAH
26. APPLICATION
OF GREASE
TO PIN/25.
BUSHING/24.
CROSS
SHAFT
BOOT/23.
CROSS
SHAFT
BRACKET
(A)/22. BUSHING/20.
TRANSMISSION
CONTROL
ROD
(A)/19. SELECT CROSS SHAFT/18.
CROSS SHAFT BOOT
(B)/17. CROSS SHAFT BUSHING/lG.
SPRING
Apply a coating of the specified
grease to the bushing
inner surface and the sliding parts shown in the figure.
Specified
grease
13. INSTALLATION
: Multipurpose
No. 2
OF TRANSMISSION
grease
SAE J310, NLGI
09w523
FRevision
http://vnx.su/
y,
c;-
:,
CONTROL
ROD (B)
(1) Move the transmission

and shift lever to the N
position, and then install the transmission
control arm
and transmission
control rod (B) as shown in the figure.
(2) Check, while driving, to be sure that the transmission
is
set to each range when the selector lever is shifted to
each position.
(3) Check, while driving, to be sure that the overdrive is
activated and cancelled
correctly when the overdrive
switch is used.
\\\
2.
21-112
AUTOMATIC
DISASSEMBLY
AND
TRANSMISSION
- Transmission
Control
REASSEMBLY
N21lE.-
3
6
18-24
13-17
/
Nm
ftlbs.
09w5.43
Removal steps
l +
l +
l +
l +
f Overdrive
\
1.
2.
3.
4.
5.
6.
7.
8.
9. Shift
Position
indicator
light
Inhibitor
switch
Overdrive
switch
Pushbutton
Spring
Selector
handle
Bushings
Transmission
control
arm
lever
l * 10. Sleeve
l + 11. Spring
l + 12. Rod assembly
13. Bracket
NOTE
(I)
(2)
Reverse
the disassembly
procedures
to reassemble.
INSPECTION
switch
l
l
l
l
l
l
N211GAA
Check for unusual wear of the brackets detent plate part.

Check for unusual wear of the rod end pin.
Check for unusual wear of the pushbutton
and sleeve
contact surface.
Check for unusual wear of each bushing.
Check for weakness
of the spring.
Check the operation
of the overdrive switch. (Check the
continuity.)
When
When
. .
the
the
overdrive
overdrive
1 STB nevmon
http://vnx.su/
switch
switch
is OFF:
is ON:
continuitv
non-continuity
TRANSMISSION
AUTOMATIC
- Transmission
Overdrive
relay
Check
21-113
Control
relay
the continuity
between
terminals
during
no current
flow
and during current flow.

Between
terminals
During no current flow
Inhibitor
Check
Continuity
Between
During current flow

(between terminals 2 and 4)
lW1575
Continuity
1 and 3
terminals
2 and 4
Between
terminals
1 and 3
Non-continuity
switch
the continuity
with
the select
lever at each position.
09w513
NOTE
o-o indicates
that there is continuity
between
the terminals.
NZllHAE
12. APPLICATION
OF GREASE TO ROD ASSEMBLY/l
ING/10.
SLEEVE/8.
TRANSMISSION
CONTROL
BUSHINGS/4.
PUSHBUlTON
Apply the specified
Specified
09w54:
Pushbutton side
: Multipurpose
No. 2
grease
part of the lever.

SAE J310, NLGI
10. INSTALLATION
OF SLEEVE
Move the selector lever to the N position, and turn the
sleeve so that the angled surface of the sleeve is at the
pushbutton
side. At this time, adjust the clearance between the sleeve and the selector lever so that it is the standard value.
B part
Selector lever
Standard
value
: 15.2-15.9
mm (.60-.62
NOTE
Move the B part of the sleeve
(drivers seat side).
09R0070
fpN
grease
grease to each sliding
1. SPRARM17.
Pin at the end of the rod

09S565
pushbutton
side
2. INSTALLATION
OF INHIBITOR
SWITCH
(1) Temporarily
install the inhibitor switch.
(2) Set the shift lever so that the pin at the end of the rod is
at the position shown in the figure.
position
im (in.)
to the
in.)
Revision
http://vnx.su/
AUTOMATIC
TRANSMISSION
Transmission
Control
(3) Using a circuit tester between 2-&Y and 2-BY of the

inhibitor switch connector,
check the continuity
when
the inhibitor switch is moved back and forth, an.d mark
the bracket.
(4) Tighten the inhibitor

switch mounting
screws at the
position
where the clearance
between
the inhibitor
switch and the selector lever is the specified distance.
1 STB Revision
http://vnx.su/
AUTOMATIC
TRANSFER
REMOVAL
Removal
+I) l +
~~
TRANSMISSION
Transfer
21-115
Control
CONTROL
AND
INSTALLATION
steps
1.
2.
3.
4.
5.
Transfer shift lever knob

Front floor console
Control housing gasket
Control housing cover
NOTE
(1)
Reverse
the
(2)
e+
: Refer
l * : Refer
(3)
removal
procedures
to Service
Points
to Service
Points
to
of
of
reinstall.
Removal.
Installation.
SERVICE
3.
POINTS
REMOVAL
OF REMOVAL
OF CONTROL
LEVER
Move the control lever to the 2H

control
lever assembly.
SERVICE
4.
POINTS
APPLICATION
GASKET
http://vnx.su/
and remove
OF INSTALLATION
surfaces
to both
OF CONTROL
LEVER
the
N21KDAA
sealant
Check to be sure
tion (transmission
illustration.
1 STB Revision
position
TO CONTROL
INSTALLATION
0980027
ASSEMBLY
OF SEALANT
Apply semi-drying
housing
gasket.
3.
NPlKBAA
HOUSING
of the control
ASSEMBLY
that the control lever assembly

installaside) part is at the position shown
in the
21416
AUTOMATIC
DISASSEMBLY
Disassembly
+*
1.
2.
3.
4.
5.
6.
TRANSMISSION
Transfer
Control
AND REASSEMBLY
NZlKE--
0980045
steps
Reassembly
Spring pin
Set screw
Control finger
O-ring
Control housing
3.
+* 5.
6.
4.
WC 1.
2.
steps

O-ring
Control housing
Control finger
Spring pin
Set screw
NOTE
(I)+*
(2)*+
(30
: Refer to Service Points of Disassembly.

: Refer to Service Points of Reassembly.
: Non-reusable
parts
SERVICE POINTS OF DISASSEMBLY

1.
REMOVAL
OF SPRING
N21KFAA
PIN
(1) Drill 12 mm (.47 in.) diameter hole in the center of the boss
16 mm (63 in.) diameter on the control housing not to
damage the control finger and control lever assembly.
(2) Draw out the spring pin using a punch.
Lf
09BOO4C

5.
APPLICATION
OF LUBRICANT
TO O-RING
Install the O-ring to the control lever assembly

small amount of the specified oil on the O-ring.
Specified
oil
N2lKHAA
and apply a
: Hypoid
Gear Oil API Classification
GL-4
or higher SAE viscosity
No. 8OW, 75W85W
1. INSTALLATION
OF SPRING PIN
(1) Drive the spring pin using a punch so that the cut out
portion of the spring pin is in the axial direction of the
control lever assembly.
(2) Apply the sealant in the inner surface of the worked hole
and drive the sealing cap up to the dimension shown in the
figure.
1.5-2.0
Control
housing
mm
(.06-.08
in.1
09l30032
evision
http://vnx.su/
AUTOMATIC
TRANSMISSION
REMOVAL
AND
TRANSMlSSlON
- Transmission
21-117
Oil Cooler
OIL COOLER
INSTALLATION
Pre-removal
Operation
Removal of Under Cover and Under
Skid Plate (Refer to GROUP 23
BODY-Under
Guard)
l
Bleeding
of the automatic transmission fluid. (Refer to GROUP 0 LUBRICATION AND MAINTENANCEMaintenance
Service)
NZlSA-
Post-installation
Operation
l
Installation of Under Cover and Under Skid Plate (Refer to GROUP 23
BODY-Under
Guard)
l
Supplying of Automatic
Transmission
Fluid. (Refer to GROUP 0 LUBRICATION AND MAINTENANCE-Maintenance Service)
18W831
46-50
26-36
Nm
ftlbs.
04w571
Removal
l *
l +
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
Radiator
grille
Eye bolts
Gaskets
Oil cooler assembly
Hose clamp
Hose
Oil cooler
tube clamp
Feed tube
Return tube
NOTE
(3) I)+ : Refer to Service Points
(4) q
: Non-reusable
parts
1 STB Revision
http://vnx.su/
to reinstall.
of Removal.
of installation.
21-118
AUTOMATIC
TRANSMlSSlON
SERVICE
- Transmission
POINTS
2. REMOVAL
Oil
Cooler
OF REMOVAL
NZlSSAS
OF EYE BOLTS
Remove the eye bolts and disconnect

from the oil cooler.
I
Caution
Loosen the eye bolts
the oil cooler.
while
the oil cooler tubes
tightening
the weld
nut of
INSPECTION
l
l
0
l
Check the oil cooler fins for bend, damage and foreign
matters caught between fins.
Check the oil cooler tubes for crack, damage, clogging and
deterioration.
Check the gaskets for damage
and deformation.
Check the eye bolts for clogging
and deformation.
SE&ICE
9.
NZlSCAD
POINTS
INSTALLATION
OF INSTALLATION
OF RETURN
TUBE/%
NZlSDAA
FEED TUBE
For installation
of the feed tube and return tube to the
transmission,
first loosely
tighten
each coupling
and
clamp, and then make the final tightening
in sequence
from the feed tube and return tube coupling.
1 STB Revision
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AUTOMATIC
TRANSMISSION
REMOVAL
AND
TRANSMISSIO
Transmission
and
Transfer
Assembly
21-I
19
AND TRANSFER ASSEMBLY

INSTALLATION
N21 LA-
Pre-removal
Operation
Removal of Cross Shaft Protector
Removal of Transfer Case Protector
Bleedina of Automatic
Transmission
Fluid atd Transfer Oil (Refer to
GROUP 0 LUBRICATION
AND
MAINTENANCE-Maintenance
Service)
Post-installation
Installation
Installation
l
l
l
l
l
Operation
of Cross Shaft Protector
of Transfer Case Protec-
1
20-27
14-20
Nm
ft.lbs.
35 Nm
22-25 ft.lbs.
50-60
35-43
16-22
13-16
,i$
Nm
ftlbs.
IO-13 Nm
7-9 ftlbs.
09w544
Removal
l +
steps
1.
2.
3.
4.
5.

Front floor console
Snap pin
Clevis pin
Throttle control cable
6. Connection
l +
l 4
of overdrive
solenoid
valve
4*
l *
4*
l *
l 4
I)*
l 4
l *
0.
1.
2.
3.
Rear propeller shaft

Front propeller shaft
Select cross shaft
Transmission control rod
NOTE
connector
7. Speedometer cable
8. Oil filler tube
9. O-ring
(1)
(2)
(3)
(4)
Reverse the
+e : Refer
l + : Refer
a
: Non
STB Revision
http://vnx.su/
removal procedures
to Service Points
to Service Points
resusable parts
to reinstall.
of Removal.
of Installation
21-120 AUTOMATIC
14
XI-30
E-2?
Nm
ftlbs.
TRANSMISSION
35-42
25-30
- Transmission
and
Transfer
Assembly
Nm
ftlbs.
22-29
ftlbs.
\
..
7-gqi$y i
18-25
13-18
55-75
40-54
Nm
ftlbs.
Nm
ftlbs.
14. Front exhaust pipe mounting bolt

15. Connection of oil cooler feed tube and
return tube
16. Bell housing cover
17. Special bolts
l *
18. Connection of 4WD indicator light
switch
19. Exhaust pipe mounting bracket
20. Rear engine support member and No. 2
crossmember.
21. Transfer mounting bracket
22. Pipe
l e l + 23. Transmission and transfer assembly
NOTE
(1)
(2)
(3)
+*
) STB Revision
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: Refer
: Refer
to
to
Service
Service
Points
Points
of
of
Removal.
Installation
AUTOMATIC
TRANSMISSION
- fransmission
SERVICE
POINTS
10. REMOVAL
PROPELLER
and
Transfer
21-121
OF REMOVAL
OF REAR
SHAFT
12. REMOVAL
OF SELECT
SION CONTROL
ROD
NZlLBAG
PROPELLER

JOINTS - Propeller
Shaft.
Refer
Assembly
SHAFT/ll.
SHAFT
CROSS
AND
SHAFT/13.
FRONT
UNIVERSAL
TRANSMIS-
to P.21-110.
17. REMOVAL
OF SPECIAL
Remove the special

er and drive plate.
23. REMOVAL
SEMBLY
bolts
BOLTS
(six) coupling
OF TRANSMISSION
the torque
AND
convert-
TRANSFER
AS-
(1) Disconnect
the transmission
and transfer
assembly
from the engine by pulling it slowly toward
the rear of
the vehicle.
(2) When lowering
the transmission
and transfer
assembly, tilt the front of the transmission
downward
and
slowly
lower forward,
while using care to make sure
that the rear of the transmission
does not hit the No. 4
crossmember.
NOTE
Detach so that the torque
the engine side.
SERVICE
POINTS
23. INSTALLATION
ASSEMBLY
converter
does
OF INSTALLATION
OF TRANSMISSION
not remain
at
NPlLDAG
AND
TRANSFER
On the engine side, there are two centering

locations.
Make sure that the transmission
mounting
bolt holes are
aligned with them before mounting
the transmission
and
transfer
assembly
to the engine.
IRevision
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21-122
AUTOMATIC
TRANSMISSION
- Transmission
and Transfer Assembly

CONTROL ROD/12.
13. INSTALLATION
OF TRANSMISSION
SELECT CROSS SHAFT
Refer to P.21-11 I.
11. INSTALLATION
OF FRONT
REAR PROPELLER
SHAFT
RLfer to GROUP 16 PROPELLER
JblNTS
- Propeller
Shaft.
9. APPLICATION
Automatic
transmission
PROPELLER
SHAFT/IO.
SHAFT AND UNIVERSAL
OF LUBRICANT
TO O-RING
Apply a small amount of the specified automatic

sion fluid to the O-ring and then install.
Specified
7.
transmission
CONNECTION
fluid
: ATF
OF SPEEDOMETER
DEXRON
transmis-
II Type
CABLE
Refer to P.21-108.
Oil filler tube O-ring
5.
CONNECTION
OF THROlTLE
Refer to P.21-107.
/ STB Revision
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CONTROL
CABLE
AUTOMATIC
TRANSMISSION
Transmission
and
Transfer
DISASSEMBLY
Assembly
23
21-I
NzlLE--
Caution
1. When removing
the transmission
assembly from the vehicle, use care so that the oil pan is not hit by the transmission jack.
2. The automatic
transmission
is built of accurately
machined parts which should be handled during disassembly
with utmost care to prevent damage.
3. When separating
light alloy metal parts such as the case,
do not pry with a screwdriver
but tap lightly with a soft
headed hammer
(plastic hammer).
4. Place rubber mat on the work bench and keep it clean.
5. During disassembly,
do not wear cloth gloves or use rags.
If necessary, use nylon cloth or paper towel.
6. Clean all parts that have been disassembled.
Ordinary detergent may be used for cleaning metallic parts but after
washing, be sure to dry with air.
7. Wash the clutch disc, brake disc, resin and rubber parts in
ATF (automatic
transmission
fluid) and keep them free
from dust.
8. If the transmission
itself is damaged,
disassemble
and
clean the cooler system.
(1) Remove sand and dirt from the outside of the transmission.
(2) Remove the transfer (P.21-174).
(3) Place the transmission
assembly on a bench with the oil pan
down.
L1.
f
P
iz;
i!,I
4::
;G;
!.
>
i
,
I:
.i-:
E
St!
-If
Caution
Do not place the assembly with the oil pan up before theit:
J
oil pan is removed.
This is necessary to prevent foreign
1
;
matter in the oil pan from entering the valve body.
1.
!,
(4) Remove the torque converter.
(5) Remove
the O.D. solenoid
valve.
(6) Remove the adapter and gasket.

(7) Remove the governor mounting bolt.
(8) Lift up the governor retaining ring lightly by a screwdriver
remove the governor assembly from the output shaft.
/ STBF lej vision
http://vnx.su/
and
21-124
AUTOMATIC
Oil screen
\
Oil pipe
/I
TRANSMISSION
- Transmissioti
and Transfer
Assemblv
(9) With the oil pan down, remove the oil pan bolts and then
remove the oil pan and gasket.
(10)Place the assembly with the valve body up.
(1 l)Remove
the oil pipe, prying with a screwdriver and using care
not to cause deformation.
(12)Remove the oil screen.
(13) Remove
17 bolts attaching
the valve body assembly.
(14)Raise the valve body assembly

inner cable from the throttle
body assembly.
(15)Push the throttle

from the case.
slowly and remove the throttle

cam. Then, remove the valve
cable adapter to disconnect
the throttle
cable
(16)Remove the plate 1 and parking pawl torsion spring 2. Then,

pull out pivot pin 3 and remove parking pawl 4.
Remove parking rod 5 from the manual valve detent lever.
le vision
-1
http://vnx.su/
AUTOMATIC
TRANSMISSION
- Transmission
and
Transfer
Assembly
21-125
(17)Drive out spring pin 1 and remove shaft 2 and manual valve
lever 3.
(18)Remove
the oil seal from the manual valve shaft using a
screwdriver.
When installing the oil seal, do so evenly.
(19)Remove the accumulator

trated position.
piston by blowing air from the illus-
Caution
Use care as the piston and fluid pops and gushes out.Pistons for B,, C,, and C, have been installed from the front
to rear in the order shown. Store the removed pistons and
springs arranged in this order.
(20)Remove
(21)Remove
(22)Remove
(23)Holding
housing.
the
the
the
the
oil pump attaching bolts.

oil pump by using the special tool.
converter housing attaching bolts.
O.D. input shaft by hand, remove the converter
..
3
I.
(24)Remove the O.D. input shaft, planetary

assembly from the O.D. case.
355212
(25)Remove
the O.D. case assembly.
1 ST6 Revision
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gear and O.D. clutch
21-I 26 AUTOMATIC
- Transmission
TRANSMISSION
and Transfer
(26)Remove
the foward
(27)Remove
the direct clutch assembly.
(28)Remove
the two center support
Assembly
clutch assembly.
(29)Remove the center support

from the case.
attaching
bolts.
and sun gear assembly
(30)Remove the snap ring from the front planetary

a screwdriver.
Snap
ring
3551oa
I
vision
http://vnx.su/
together
carrier by using
AUTOMATIC
TRANSMISSION
- Transmission
and Transfer
(31) Holding the intermediate

bly from the case.
Assembly
21-127
shaft, remove the carrier assem-
(32)Remove
case.
the output shaft thrust bearing and race from the
(33)Remove
the rear cover and gasket.
355102
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21-I 28 AUTOMATIC
- Transmission
TRANSMISSION
and
Transfer
Assembly
REASSEMBLY
NZlLF--
Caution
1. The automatic
transmission
is built of accurately
maichined parts which should be handled during reassembly
Iwith utmost
care to prevent
damage.
Damaged
parts
could cause fluid leaks or affect performance.
Check the
parts carefully before reassembly.
2. Clean all parts that are to be reassembled.
Ordinary detergent may be used for cleaning metallic
parts but after
washing, be sure to dry well with air.
3. Wash the clutch disc, resin thrust plate and rubber parts in
ATF and keep them free from dust.
4. Do not reuse gasket, oil seal and other rubber parts. At
reassembly,
replace them with new ones.
5. Never use grease other than petrolatum
or industrial
petrolatum.
6. Apply ATF to friction elements,
rotating
parts and sliding
parts before installation.
7. New clutch disc and brake disc should be immersed
in
ATF for more than two hours before installation.
8. Do not apply sealer or adhesive to gaskets.
9. When bushing must be replaced, replace assembly which
includes it.
10. Tighten parts to specified torque.

case on a cylinder as illustrated.
Use of a cylinder measuring 300 mm (12 in.) long and 180 mr-r I
(7 in.) in diameter is recommended.
Place shock absorbing
material between the case and the cylinder to prevent damage
to the case.
(2) Install output shaft thrust bearing race #21 and thrust bearing
#20 in the case.
Caution
When installing
the thrust bearing
direction,
referring to the illustration.
STB Revision
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and race, note
their
AUTOMATIC
TRANSMISSION
#4
#!i#7
#9
- Traunsmission
#lO
#12
#13
#15
#I6
and Transfer
#I7
#18
#19
Assembly
21-129
#20
372034
(3) Install the apply tube in the case. Make sure that the paw1 at
the end of the tube is inserted to inside of the piston.
(4) Install the thrust washer on the planetan/

pawl (A) securely in the (B) of the carrier.
carrier, seating
its
(5) Install the rear planetary gear and output shaft assembly in the
case. Insert slowly and taking care not to hit at the bearing.
/ STBI
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^,,i
21-I 30
AUTOMATIC
TRANSMISSION
- Transmission
and Transfer
Assembly
(6) Install the backing plate in the case. Insert firmly until it comes
into contact with the apply tube.
(7) Apply grease to the thrust washer and attach it to the front
planetan/ gear carrier. Then install the front planetary gear
assembly in the ring gear.
(8) Install the clutch discs and plates alternately in this order on
the backing plate.
355194
(9) Plate the transmission

case on a bench with the oil pan mounting surface up.
(1O)lnsert the sun gear in the one-way clutch inner race and install
the assembly in the case, aligning (A) of the one-way clutch
inner race with (B) of the case. If the inner race is hard to
engage, turn the sun gear while holding the front planetary
ring gear. Then, holding the one-way clutch inner race, remove
the sun gear. Fit the removed sun gear to the center support.
Caution
Check the snap ring end gap position
the carrier is seated completely.
(1l)lnstall the snap ring.
to make
sure that
(12)lnstall the center support assembly in the case, checking correct seating of the one-way clutch on the center support and
pushing the center support while pulling the sun gear.
The center support will not be installed completely
in the case
if the one-way clutch is floating.
(13)Pushing the center support backward, tighten the bolts alternately on side (A) in about 7 Nm (5 ft.lbs.) increments.
Finally
tighten to specified torque.
1 STB Revision
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ATIC TRANSMISSION
- Transmission
and
Transfer
21-I 31
Assembly
(14) Install the direct clutch assembly.
(15)Attach thrust race #14, bearing #15 and thrust race #16 onto
the rear of the forward clutch hub using petrolatum and noting
the direction of the thrust bearing race.
(16)lnstall the forward clutch assembly, using care not to drop the
thrust bearing attached in the step above.
(17)Check that the forward clutch has been installed completely

by using the special tool.
Measured value (A) - gauge thickness (B) = forward clutch
installation height
Standard
value
: Approx.
1.5 mm
(.059
in.)
372038
(18)Attach thrust bearing #lO and race #9 to the forward clutch

using petrolatum and noting the direction of the thrust bearing
race.
vision
http://vnx.su/
21-I
32 AUTOMATIC
TRANSMISSION
- Transunission
(19)lnstalf
MD99841
and Transfer
special tool in the transmission
Assembly
case.
(20)Along the guides, install the O.D. case assembly in the transmission case, positioning the O.D. case notch as illustrated.
(2l)lnstall
Planetary
carrier
the thrust washer on the O.D. planetary
gear.
(22)Apply petrolatum to the rear of the O.D. planetary

attach the thrust washer thereon.
side
(23)lnstall the O.D. clutch and planetan/

thrust washer in the case slowly.
NOTE
Align the O.D. case clutch disc lugs.
355247
1 STB Revision
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gear assembly
carrier and
with the
AUTOMATIC
TRANSMISSION
- Transmission
and
Transfer
Assembly
21-133
(24)Check that the O.D. clutch and planetary gear set assembly
has been installed completely
Measured value - gauge thickness = O.D. clutch assembly
installed height
Standard
value : Approx.
2 mm LO8 in.)
MD99821 7
355248 I
(25)lnstall the O-ring at illustrated

converter housing.
position
and then install
the
O-ring
355249
(26)lnstall
race #3 and bearing #2 over the O.D. input shaft.
37204C
: C.
4
(27)Apply petrolatum
I
I
U
MD99841 2
to the oil pump and install thrust race #l.
372041
(28)lnstall the oil pump slowly by using the specral tools.

(29)Apply sealer to the set bolts and tighten them uniformly and
little by little. Check input shaft end play and check that the
shaft turns lightly.
Specified
sealant
: SH700 (Toray)
(30)Tighten the oil pump assembly attaching bolts to specified

torque and check the input shaft end play.
Standard
,4
) STB Revision
http://vnx.su/
value : 0.3-0.9
mm (.012-.035
in.)
21-I
34 AUTOMATIC
TRANSMISSION
- Transmission
and Transfer
Assembly
(31)Supply low pressure air to each circuit and check operation

operating noise.
1.
2.
8.
4.
5.
6.
by
O.D. clutch
Forward clutch
Brake No.1
Brake No.2
Direct clutch
Brake No.3
(32)lnstall the parking rod assembly on manual valve lever 1 and

insert manual valve lever shaft 2 in the case. Then, drive in
slotted spring pin 3.
Caution
1. Be sure 00 use a new slotted spring pin.
2. Install the slotted spring pin in such a way that its end
protrudes
approx. 1 mm from the lever.
(33)Place parking
spring 3.
pawl 1 in the case and install pivot pin 2 and
(34)lnstall the cam plate, making sure that the parking rod assembly protrudes from the cam plate.
Cam
III
plate
372042
(35)Insert the throttle

the O-ring.
,kze
1
--- I STB Revision
355204
http://vnx.su/
cable in the case, using care not to damage
AUTOMATIC
TRANSMISSIO
- Transmission
and Transfer
Assembly
(36)lnstall accumulator
pistons and springs;
and No.3 (Cl) from front side.
Accumulator
No. 1 (82)
No. 2 (C2)
No. 3 (Cl)
Pistons
IIII
No. 2
31.8 mm
(1.252 in.)
45 mm
(1.772 in.)
No. 3
31.8 mm
(1.252 in.)
49.5 mm
(1.949 in.)
Springs
Identification
Wire
diameter
Ident.
color
Free
length
O.D.
No. 1
66.7 mm
(2.626 in.)
17.3 mm
(.681 in.)
2.8 mm
(.I 10 in.)
No. 2
55.2 mm
(2.173 in.)
16.4 mm
(.646 in.)
2.3 mm
(.091 in.)
No. 3
64.7 mm
(2.547 in.)
17.5 mm
(.689 in.)
2.0 mm
(.079 in.)
(37)lnstall throttle
assembly.
Length
48.5 mm
(1.909 in.)
Accumulator
A3
Identification
O.D.
34.8 mm
(1.370 in.)
Pin
No.1 (B2), No.2 (C2)
No. 1
372099
ml
21-135
cable to the throttle
Red
cam of the valve body
(38)Install two or three valve body attaching bolts temporarily and

place the manual valve lever pin in the manual valve groove.
Ial valve
ii,
(39)lnstall 17 valve body attaching

specified torque.
355254
1 ST6 Revision
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bolts and tighten
uniformly
to
__
21-136 AUTOMATIC
Oil screen
TRANSMISSION
,pipel
Transmission
and
Transfer
Assembly
(40)lnstall the oil screen.

(41)Shift to L and P to check that the detent scrina roller is
completely
seated in each portion of the detent lever.
(43)Attach the magnet to the oil pan (to area directly below the oil
screen).
(44)lnstall the oil pan with oil pan gasket attached. First tighten 14
bolts temporarily
and then tighten to specified torque uniformly.
(45)lnstall
the rear cover on the transmission
rear with a gasket.
(46)Insert a slot screwdriver between the governor retaining ring

and governor body and install the governor to the output shaft.
(47)lnstall the adapter and gasket.
(48)lnstall
the O.D. solenoid.
Caution
Be sure to use two O-rings.
(49)lnstall torque converter to transmission.
(50)lnstall
the transfer assembly
(P.21-178).
) STB Rewslon
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AUTOMATIC
TRAlWWSSION
- Oil Pump
21437
OIL PUMP
18-25
Nm
1. Oil seal
2. Oil pump body
6. Stator support
7. Seal ring
8. Thrust bearing race #l
9. Thrust bearing #2
10. Thrust bearing race #3
355104
DISASSEMBLY
&,;
(1) Remove six screws and remove
the stator support from the oilt/:.::;$;C

;)..I.
I ,.i :I, .
pump body.
(2) Take out the oil pump drive gear and driven gear from the$ ,.:;,;r
pump body. Put mating marks on the side of removed gears$: .
for their reassembly in correct direction. (Use a felt marker or,::
II
p
equivalent.)
1~.
(3) Remove the seal ring from the stator support.
.
: ,,
INSPECTION
Wash the parts and dry with air. Then, check the following and
replace if faulty.
(1) Oil seal damage
(2) Ridged wear on body and drive gear contact surfaces and
damage to the body crescent portion (indicated by arrow)
35510!
(3) Damage or wear of the stator support surface in contact with

the oil pump gear (indicated by arrow)
(4) Wear of the oil pump bushing
(5) Wear of the stator support bushing (both front and rear sides)
(6) Smooth insertion of the stator support into the torque converter and without abnormally large play. If faulty, replace.
(7) Wear or damage of the stator support seal ring groove and
seal ring
355104
[ STB Revision
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21-138
AUTOMATIC
TRANSMISSION
- Oil Pump
REASSEMBLY
(1) Apply ATF to the drive and driven gears and install them in the
body.
(2) Assembly the body and stator support and tighten the six bolts
finger-tight.
(3) Tighten outside of the cover and support by using the special
tool.
(4) Tighten the bolts to specified torque.
(5) After reassembly, check with a screwdriver that the drive gear
turns lightly.
STB Revision
-1
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AUTOMATIC
TRANSMISSION
Overdrive
OVERDRWE CLUTCH AND PLANETARY

1.
2.
3.
4.
5.
6.
7:
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
OD clutch cylinder
OD clutch piston
O-ring
O-ring
Return spring
Spring retainer
Snap ring
Clutch plate
Clutch disc
Snap ring No.1
OD brake hub
Snap ring No.2
Snap ring No.3
One-way clutch retainer
One-way clutch assembly
One-way clutch outer race
Thrust washer
Thrust bearing #4
Thrust bearing race #5
Pinion shaft plug
OD planetary gear
Thrust washer
15
16
Clutch
and
Planetary
GEAR SET
17
Gear
Set
21-139
NZlLHE4
22
18
19
<'
:
372045
i,,
Ir
DISASSEMBLY
(1) Remove snap ring No.2 and remove the O.D. brake hub. Then,
disassemble
the O.D. planetary gear set and O.D. clutch assembly.
(2) Remove snap ring No.3 from the O.D.planetary
gear assembly
and remove the thrust washer,
O.D. one-way
clutch, outer
race, thrust bearing and four pinion shaft plugs.
(3) Remove snap ring No.1 from the O.D.clutch

assembly
and
remove the clutch flange, clutch discs and plates.
(4) Compress
the spring and remove the snap ring by using the
special tool.
(5) Remove the spring seat and return spring.
355216
@Tici
wision
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21-140
AUTOMATIC
TRANSMISSION
Overdrive
Clutch
and
Planetary
Gear
Set
(6) Install the O.D. clutch cylinder on the oil pump

into the oil pump oil hole to remove the piston.
Caution
hold down
jDing out.
the piston
with
hand to prevent
and blow air
it from
pop-
INSPECTION
Wash the disassembled
parts and dry with air before checking the
following. Replace parts that are found faulty.
(1) Check the O.D. planetary gear for pinion wear, damage, turning condition, spline wear and damage.
(2) Check the O.D. one-way clutch for wear and damage of
spring, ribbon spring and outer race.
(3) Check the O.D. clutch cylinder for wear and damage of the
O.D. sun gear and piston slinding surface (cylinder). Also
check for wear and damage of the thrust washer and one-way
clutch contact surfaces and seal ring slinding surface.
(4) Check the clutch disc and plate for wear and damage of the
friction surfaces and of cylinder to hub engaging portions.
(5) Check the clutch piston for wear and damage of its outside
and inside surfaces.
(6) Check the spring for damage and deterioration.
Free length
Standard value : 14.9 mm (.587 in.)
Limit : 14.5 mm (.571 in.)
(7) Shake the piston to check that the check ball is not binding.
Also apply air pressure to the piston to see that it is free from
leaks. Apply air pressure to the piston inside.
355218
In case of no
clutch actuation
In case of clutch
actuation
355116
The O.D. clutch, forward clutch and direct clutch have a check
ball installed inside as illustrated. This is to prevent oil remaining in the cylinder from working to actuate the clutch by centrifugal force that develops when the clutch cylinder is rotated
at high speed. Namely, the centrifugal force developed at high
speed rotation causes the ball to separate from the, seat, thus
opening the oil path to release oil pressure that would otherwise actuate the clutch.
(8) Check the O.D. brake hub for abnormal tooth wear and damage.
(9) Check the bearings, races and thrust washers for wear and
damage.
\ ST6 Revision
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AUTOMATIC
TRANSMISSION
Overdrive
Clutch
and
Planetary
Gear
Set
21-141
REASSEMBLY
(1) Fit new O-rings in inside and outside grooves of the piston.
(2) Apply ATF to the O-rings and insert the piston into the O.D.
clutch cylinder using care not to damage the O-rings.
(3) Install the return spring and spring seat in the clutch cylinder.
Then, place the clutch assembly on a press bench and install
the snap ring by using the special tool.
(4) Install the clutch plates and clutch discs in the clutch cylinder
and fit snap ring No.1 (narrower one).
(5) Install the O.D. brake hub and then fit snap ring No.2 (wider
one).
Clutch disc
(6) Install the pinion shaft plug in the shaft portion

planetary gear set and install the thrust bearing
bearing and thrust washer in the order shown.
NOTE
Install the thrust washer
side.
(7) Assemble
assembly
noting the
(8) Install the
(9) Install the
bly.
Front -
of the O.D.
race, thrust
:,
directing
its oil groove to the front:
the one-way clutch outer race to the one-way clutch

and then install the assembly in the planetary gear,
mounting direction.
one-way clutch retainer and snap ring.
O.D. planetary gear set on the O.D. clutch assem-
355221
(1O)Check operation of the one-way clutch. With the clutch cylinder held by hand, turn the input shaft clockwise to see that the
shaft turns smoothly and turn it counter-clockwise
to see that
the shaft is locked.
!
A
1 ST6 Revision
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<:
21-142
OVERDRIVE
AUTOMATIC
TRANSMISSION
- Overdrive
Brake
N2llMA
BRAKE
16
/
1. Snap ring
2. Backing plate
3. Brake disc
4. Brake plate
5. Cushion plate
6. Spring retainer
7. Return spring
8. Brake piston
9. O-ring
10. O-ring
11.. Thrust race
12. Planetary ring
13. Thrust bearing
14. Thrust bearing
15. Thrust bearing
$ 16. OD case
:( 17. Thrust bearing
,# 18. Thrust bearing
19. Seal ring
13 15
gear
race #6
#7
race #8
race #9
#lO
355223
DISASSEMBLY
(1) Remove the snap ring and take out the backing plae, brake
discs, brake plates, cushion plate, thrust washer, planetary
ring gear, bearing and race from the O.D. case.
(2) Remove the snap ring and take out the spring retainer and
return spring.
355224
(3) Blow air into the O.D. case through the oil hole to remove
piston.
(4) Remove the O-ring from the piston.
1 STBI
tvision
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the
AUTOMATIC
TFZANSMI
N - Overdrive
21-143
Brake
INSPECTION
Wash the removed parts and dry with air. Then, check the following and replace faulty parts.
(1) Check the O.D. case for wear and damage of the piston sliding
surfaces, seal ring and ring groove.
(2) Check the piston for wear and damage of its outside (surface
in contact with the case).
(3) Check the spring for damage and deterioration.
Free length
Limit : 15.7 mm (.618 in.)
(4) Check the discs and
surfaces. Also check
and damage.
(5) Check the planetary
surfaces and splines.
(6) Check the bearings,
damage.
plates for wear and damage of the friction

the case and hub engagement
for wear
ring gear for wear and damage
races and thrust washers
of tooth
for wear and
REASSEMBLY
l
(1) Install new O-rings in the piston outside and inside grooves.
(2) Apply a light coat of ATF to the O-rings and install the piston in
the case, using care not to damage O-rings.
(3) Install the return spring and spring retainer and fit the snap
ring.
Caution
1. Make sure that the springs is installed
nation.
2. Make sure that the snap ring is seated
correctly.
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(4) Install bearing races #6 and #8, thrust bearing #7, planetary
ring gear and thrust washer in the O.D. case. Thrust bearing
races #6 and #8 should be installed in the illustrated direction.
without
(5) Install the cushion plate and then install the brake plates and
brake discs alternately. Then, install the backing plate and fit
the snap ring.
Brake plate
Braky d,/sc ,,/ $shion,plate
Caution
Note the direction
j ST6 Revision
of installation
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of the cushion
plate.
21-144
AUTOMATIC
TFIANSMISSIO
Overdrive
Brake
/ Forward
Clutch
(6) Measure the brake clearance.

Measure the backing plate to snap ring clearance. If it is larger
than nominal, replace the clutch disc or plate. If it is smaller
than nominal, incorrect installation is suspected. Disassemble
and reinstall.
Standard
value
: 0.35-1.6
mm (M-.062
in.)
=ORWARD CLUTCH
1
I
2
I
11 12111211
12
13
1. Forward clutch cylinder
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Forward clutch piston

O-ring
O-ring
Clutch return spring
Spring retainer
Snap ring
Thrust bearing race
Thrust bearing
Thrust bearing race
Clutch plate
Clutch disc
Forward clutch hub
Snap ring
Direct clutch hub
Snap ring
14 15
16
372100
DISASSEIUIBLY
(1) Remove the snap ring (for installation of the direct clutch hub)
and remove the direct clutch hub, forward clutch hub and
clutch disc from the clutch cylinder.
(2) Remove the needle bearing and thrust bearing races.
(3) Remove the snap ring and remove the clutch plates and clutch
discs.
MD998207
(4) Place the front clutch cylinder on a press bench and compress
the clutch return spring by using the special tool. Remove the
snap ring.
(5) Remove the spring retainer and return spring.
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AUTOMATIC
TRANSMISSION
- Forward
21-145
Clutch
(6) Install the clutch cylinder in the O.D. case and blow air into the
O.D. case through the oil hole to remove the piston from the
clutch cylinder.
(7) Remove the O-ring from the piston.
INSPECTION
(1) Check the input shaft and clutch cylinder for excessive wear
and binding of thrust bearing contact surface 1 and bushing
sliding surface 2, for damage of splines 3 and for wear of O.D.
case seal ring contact surface 4.
372049
(2) Check
clutch
surface
surface
the forward clutch cylinder for wear and damage of

drum teeth 1, for wear and binding of piston sliding
and for damage and binding of thrust bearing seating
2.
(3) Check the front clutch for abnormal wear and damage of teeth
1 and splines 2 and for wear, binding and damage of hub thrust
surface 3.
(4) Check the clutch

friction surfaces
with the cylinder
(5) Check the clutch
check for spring
O.D.
Standard
Free length
Standard
disc and clutch plate for wear and binding of

and for wear and damage of engagement
and hub (indicated by arrows).
return spring for damage and cracks. Also
outside wear and deterioration.
Coil
STB Revision
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value
: 8.0 mm
value
: 15.1 mm
(.315
(.594
in.)
in.)
21-146
AUTOMATIC
TRANSMISSION
- Forward
Clutch
(6) Check the clutch piston for wear and damage of the outside
(surface in contact with the cylinder). Shake the piston to
check for binding check ball. Also apply air pressure to the
piston inside to check for air leaks.
(7) Check the direct clutch hub for abnormal

the key ways (indicated by arrows).
wear and damage
of
35511'
REASSEMBLY
(1) Install new O-ring in the piston outside and inside grooves.
(2) Apply a light coat of ATF to the O-rings and install the piston in
ttie case, using care not to damage O-rings.
(3) Install the return spring and spring retainer in the clutch cylinder and compress the spring by using the special tool. Fit the
snap ring.
(4) Using Vaseline, attach thrust bearing race #l 1, bearing #12

and race #13 in the order shown onto the input shaft rear end.
#l
STB
Revision
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AUTOMATIC
TRANSMISSION
- Forward
Clutch
21-147
(5) Install the forward clutch hub in the clutch cylinder.

(6) Install the clutch plates and clutch discs alternately
in the
clutch cylinder and fit the snap ring (narrower one) in the cylinder ring groove.
Plate
37210
(7) The snap ring should be located with its ends as illustrated.
Snap hng end

372052
(8) Install one clutch disc and then install the direct clutch hub and
fit the snap ring (wider one) at illustrated location.
,.,J-!
355121
( STB Revision
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21-148
AUTOMATIC
TRANSMISSION
DIRECT CLUTCH
- Direct Clutch
Nz1LHcB
,
45676767
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Thrust bearing race

Thrust bearing
Thrust bearing race
Snap ring
Clutch backing plate
Clutch disc
Clutch plate
Snap ring
Spring retainer
Piston return spring
O-ring
O-ring
Direct clutch piston
O-ring
Direct clutch cylinder
372053
DISASSEMBLY
(1) Remove the snap ring and remove the clutch backing plate,
clutch discs and clutch plates from the direct clutch cylinder.
(2) Place the rear clutch on a press bench by using the special
tool, compress the return spring to remove the snap ring.
Then, remove the spring retainer and piston return spring.
(3) Install the clutch cylinder in the center support and blow air
through the oil hole of the center support to remove the piston
from the cylinder.
(4) Remove the O-rings from the piston.
INSPECTION
(1) Check the clutch cylinder for wear and damage of grooves 1
and piston sliding surface 2, for wear and damage of thrust
bearing surface and for wear and damage of seal ring sliding
surface.
(2) For inspection of the clutch disc, plate, piston and spring, see
FRONT CLUTCH.
355125
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AUTOMATIC
TRANSMISSION
Direct
21-149
Clutch
REASSEMBLY
(1) Fit new O-rings in inside and outside grooves of the piston.
(2) Apply a light coat of ATF to the O-rings and insert the piston
into the cylinder using care not to damage the O-rings.
(3) Place the clutch cylinder on a press bench and install the
clutch return spring and spring retainer.
(4) Compress the return spring, fit the snap ring by using the
special tool.
Plate
(5) Install the clutch plates, clutch discs and clutch backing plate
in the clutch cylinder and fit the snap ring.
Disc
Caution
Note the direction
Backing
plate
/ ST6 Revision
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of installation
of the backing
plate.
21450
AUTOMATIC
TRANSMISSION
I- Center Support
CENTER SUPPORT
1.
2.
3.
4.
5.
6.
Seal ring
Snap ring
Snap ring
Clutch backing plate
Clutch disc
Clutch plate
N21LU--
7.
8.
9.
10.
11.
12.
Spring
Brake
Brake
O-ring
O-ring
Center
retainer
return spring
piston
support
DISASSEMBLY
372055
OF BRAKE NO.1
(1) Remove the snap ring from the front of the sun gear and
remove the sun gear (with one-way clutch) from the center
support.
(2) Remove the snap ring from the center support and remove the
backing plate, clutch discs and clutch plates.
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i
13. Snap ring

14. Brake No.2 hub one-way clutch
No. 1 assembly
15. Planetary sun gear
16. Seal ring
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(3) Plate the center support on a press bench by using the special
tool. Compress the spring, remove the snap ring. Then, remove the spring retainer and 12 brake return springs.
Blow air into the oil way of the center support to remove
brake No.1 piston.
(5) Remove the O-rings from the piston.
(6) Remove the seal rings from the center support.
355130
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the
AUTOMATIC
TRANSMlSSlON
21-151
- Center Sumort
INSPECTI(IN
355131
(1) Check the center support for damage and deterioration
of the
seal rings, for abnormal wear and ridge wear of seal ring
groove, for abnormal wear and binding of bushing and for wear
of clutch plate slot (section A).
(2) Check the brake piston for damage of its outside (surface in
contact with the center support cylinder). For inspection of the
disc and plate, see FRONT CLUTCH.
(3) Check the brake return spring for damage, squareness and for
compliance with the spring specifications.
Coil
0-D.
Standard
value
Free leng!h
Standard
value
Load at height
Standard
value
REASSEMBLY
.
: 8.0 mm
(.315
: 16.1 mm
(.634
11.5 mm (.453 in.)
in.)
in.)(reference)
: 21-23N
(4.7-5.2
Ibs.)(reference)
;,
..!.
OF BRAKE NO.1
(1) Install three seal rings on the center support.

(2) Install new O-rings on outside and inside of the No.1 brake
piston.
(3) Apply a light coat of ATF to the O-rings and insert the piston in I
the cylinder, using care not to damage the O-rings.
(4) Place the center support on a press bench and fit 12 brake 1
return springs in recesses of the piston, Then place the springII
retainer thereon.
(5) Compress springs by using the special tool and fit the snip
s
ring.
1-i ,.
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(6) Install the clutch plates, clutch discs and backing
support and fit the snap ring.
Caution
Note the direction
DISASSEMBLY
For disassembly
REASSEMBLY
of installation
of the backing
AND INSPECTION
and inspection,
plate in the
plate.
OF BRAKE NO.2
see BRAKE NO.1.
OF BRAKE NO.2
(1) Install new O-rings on outside and inside of the No.2 brake
piston.
(2) Apply a light coat of ATF to the O-rings and insert the piston in
the cylinder, using care not to damage the O-rings.
(3) Place the center support on a press bench and fit 12 brake
return springs in recesses of the piston. Then place the spring
retainer thereon.
1 STB Revision
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, %
21-152
AUTOMATIC
TRANSMISSION
Center
Support
(4) Compress the springs and fit the snap rings by using the special tool.
(5) Install the clutch plates, clutch discs and backing plate in the
support and fit the snap ring.
I
Caution
Note the direction
of installation
of the backing plate.
Plate
Backing
Disc
\
plate
372102
INSPECTION
Caution
When drying the one-way
is likely to pop out.
clutch
by air, use care as the sprag
(1) Fix the brake No.2 hub (outer race) and check that the sun gear
(inner race) turns smoothly when rotated clockwise and that it
locks securely when rotated counter-clockwise.
If the one-way clutch is found faulty, replace the brake No.2
hub and one-way clutch assembly.
(2) Remove the sun gear from the one-way clutch 1 and check for
wear and damage of its surface contacting with the one-way
clutch springs. Also check for wear and damage of the seal
ring and ring groove and for damage of the sun gear teeth 3
and splines 4.
REASSEMBLY
Seal ring
groove
372056
r
) STB Revision
(1) Install two seal rings in sun gear grooves.

(2) Inset-t the sun gear in the one-way clutch
rotation.
-/
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No.1 and check
ATIC TRANSMISSIO
One-Way
Clutch
No.
2 and
Front
Planetary
Gear
Set
21-153
ONE WAY CLUTCH NO. 2 AND FRONT PLANETARY GEAR SET
NZILK-
1. One-way clutch inner race

2. Retaining ring
3. One-way clutch No.2
4. Thrust washer
5. Front planetary gear
6. Thrust washer
355136
DISASSEMBLY
(1) Disassemble the one-way clutch inner race and front planet&-y
,.r,
carrier.
(2) Remove the retaining ring from the front planetary carrier and
remove the one-way clutch No.2 assembly and thrust washers.
355137
INSPECTION
i.
Caution
When drying the one-way
is likely to pop out.
clutch
by air, use care as the sprag
(1) Check the thrust washers 1 and 2 for wear, bend and binding.
(2) Check the front planetary gear for wear of carrier thrust surface 3, for wear and damage of pinion 4 and for wear of the
one-way clutch outer race surface.
(3) Check one-way clutch No.2 for wear and damage of springs,
ribbon and sprag.
355136
1 STB Revision
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21 -I 54
AUTOMATIC
TRANSMISSION
one-way
Clutch
NO. 2 and Front
Planetary
Gear
set
(4) Check the one-way clutch inner race for wear and damage of
teeth 1 and disc sliding surface 2 and for wear and damage of
inner race surface 3.
355139
REASSEMIBLY
(1) Install the thrust washer (front) on the planetary gear.
(2) Install two end bearings on the one-way clutch and noting the
direction, install the clutch on the front planetary gear and fix
with the retaining ring.
(3) Install the one-way clutch inner race on the front planetary
carrier.
(4) Fix the inner race and check that the outer race (planetary gear
carrier) turns smoothly when rotated counter-clockwise
and
that it locks securely when rotated clockwise.
(5) Apply Vaseline to the thrust washer (rear) and attach it to the
front planetary gear carrier.
STB Revision
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AUTOMATIC
IEAR PLANETARY
TRANSMISSIO
Rear
Planetary
Gear
and
Output
Shaft
21-155
GEAR AND OUTPUT SHAFT
N21 LZ--
#18
372057
lb
1. Thrust
2.
3.
4.
5.
washer
Planetary sun gear

Front planetary ring gear
Retaining ring
Rear planetary gear
6.
7.
8.
9.
10.
Intermediate shaft
Thrust bearing #17
Rear planetary ring gear
Retaining ring
Thrust bearing race #18
11.
12.
13.
14.
15.
Thrust bearing #19

Output shaft assembly
Thrust bearing
Thrust bearing race
Seal ring
DISASSEMBLY
:I:
(1) Loosen the retaining ring and remove the intermediate
shaft
1
(front planetary ring gear and rear planetary gear) from the
i
output shaft assembly.
(2) Remove the front planetary ring gear, thrust washer
and rear +
planetary gear from the intermediate
shaft.
i
i
(3) Remove retaining ring 1 from

shaft and remove rear planetary
#17.
the rear of the intermediate

ring gear 2 and thrust bearing
INSPECTION
Wash the removed parts and dry with
ing and replace faulty parts.
air. Then, check
the follow-
(1) Check the front planetary ring gear for wear and damage
internal gear teeth 1 and parking pawl teeth 2.
1 STB Revision
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of
>iI*
21456
AUTOMATIC
TRANSMISSION
Rear
Planetary
Gear
and
Output
Shaft
(2) Check the intermediate

shaft for wear and damage of splines
1 and bushing seating surfaces 2 and for clogging of oil holes
3 in shaft.
(3) Check the rear planetary gear for wear of the carrier thrust
surface, for wear, damage and play in thrust direction of the
pinion.
(4) Check the rear planetary ring gear for wear and damage of the
internal gear teeth and internal splines.
(5) Check the output shaft for wear and damage

bearing surface 1 and shaft bushing seating
clogging of shaft oil hole 3 and governor oil
(6) Check the thrust washer and thrust race for
of the bearing surfaces.
(7) Check the seal ring for wear and damage.
groove.
of flange thrust
surface 2 and for
way 4.
wear and binding
Also check the
REASSEMBLY
(1) Install thrust bearing #17 on the intermediate
shaft and then
install the rear planetary ring gear and fix with the retaining
ring.
(2) Install thrust bearing

shaft.
/ STB Revision
#19 and bearing
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race #18 on the output
AUTOMATIC
TRANSMISSION
Rear
Planetary
Gear
and
Output
Shaft
2%157.
(3) Install the intermediate

shaft together with the rear planetan/
ring gear on the output shaft flange.
(4) Install the rear planetary gear set and thrust washer.
(5) Install the retaining ring on the front planetary ring gear and
install the ring gear on the output flange while compressing
the retaining ring.
Caution
Pay attention
1 STB Revision
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to location
of retaining
ring ends.
21458
AUTOMATIC
TFtANSMlSSOON
- Brake No. 3
BRAKE NO. 3
1.
2.
3.
4.
5.
Retaining ring
One-way clutch inner race
Clutch disc
Clutch plate
Backing plate
N21uaA
6.
7.
8.
9.
10.
Brake apply tube

Snap ring
Spring retainer
Brake return spring
Brake No.3 primary piston
11. O-ring
12. Reaction sleeve
13. Brake No.3 secondary piston
372050
DISASSEMBLY
(1) Compress the :spring and remove the snap ring by using the
special tools.
(2) Remove the spring retainer and 16 piston return springs.
For inn,er
piston

case with the front end down and
ing two air guns, blow air into inside through the inner
outer piston oil holes simultaneously
to remove the inner
outer pistons and reaction sleeve as an assembly. Place
below the case to protect the pistons.
usand
and
rag
(4) Remove primary piston 2 and secondary piston 3 from reaction sleeve 1.
(5) Remove O-rings from the pistons and reaction sleeve.
STB Revision
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AUTOMATIC
TRANS
ISSION
- Brake
No. 3
21-159
INSPECTION
Brake apply tube contact surface
(1) Check the clutch discs and clutch plates for wear and binding
of the friction surfaces and for wear of parts in engagement
with the transmission
case and hub.
(2) Check the backing plate for wear and binding of disc friction
surface and for wear and damage of brake apply tube contact
surface.
(3) Check the brake apply tube for deformation

and damage, for
wear and damage of backing plate contact surface 1 and piston contact surface 2 and for wear and deformation
of tube
detent lug 3.
(4) Check the brake piston and reaction sleeve for damage and
wear of their outside in contact with the cylinder.
(5) For inspection of the brake return springs, see the paragraph
on inspection of brake No. 1 springs.
355158
REASSEMBLY
(1) Install new O-rings on the primary and secondary
reaction sleeve.
(2) Apply ATF to the O-rings and push inner piston 2
sleeve 1 and then install outer piston 3.
(3) Slide the pistons and reaction sleeve assembled
above into the cylinder, using care not to damage
pistons and $ ..;

into reaction?
in the sted;
the O-rings:.,
355159
(4) Apply grease to 16 brake return springs and install them on the
outer piston. Then, install the spring retainer.
(5) Compress the springs and fit the snap ring by using the special
tools.
Sna? ring
M D998207
MD99821 1
355154
( ST6 Revision
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21-160
AUTOMATIC
TRANSMISSION
- Valve Body
VALVE BODY
NzllO--
7776
6
da
I
3@so
R~k-3
72
&
1 STB Revision
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71
70
Q A
372061
AUTOMATIC
ISSION
TRA
1. Throttle cam
2. Cam spacer
3. Return spring
4. Throttle valve
5. Throttle valve primary spring
6. Kickdown valve
7. Upper front valve body
8. Check valve
9. Check ball
10. Throttle valve keep plate
11. Secondary regulator valve spring
12. Secondary regulator valve
13. Front valve end cover
14. 1-2 shift valve
15. l-2 shift valve plug
16. Valve retainer
17. 3-4 shift valve
18. 3-4 shift valve plug
19. Locating pin
20. D-2 down timing valve
21. D-2 down timing valve plug
22. Valve retainer
23. Primary regulator valve
24. Primary regulator valve Spring
25. Primary regulator valve plunger
26. Primary regulator valve sleeve
27. Valve retainer
28. Check valve
29. Check valve
30. Manual valve
31. Plate
32. Oil screen gasket
33. Oil screen
34. Pressure relief valve
35. Pressure relief valve spring
36. Retainer
37. Detent spring
38. Detent spring plate
39. Lower valve body cover gasket (upper)
40. Lower valve body cover plate
41. Lower valve body cover gasket (lower)
42. Lower valve body cover
- Valve Body
21-161
43. Check valve

44. Locating pin
45. Manual plug
46. Third coast shift valve plug
47. Third coast shift valve
48. 3-4 shift control valve
49. 3-4 shift control valve spring
50. Low coast shift valve cover
51~ Low coast shift valve
52. l-2 shift valve spring
53. Lower valve body
54. Plug
55. Lower valve body gasket
56. Check valve
57. Separate plate
58. Valve body gasket
59. Check valve
60. Valve retainer
61. Cut back plug
62. Cut back valve
63. Throttle valve secondary spring
64. E-ring
65. Reverse brake sequence valve
66. Low coast modulator valve spring
67. Plug
68. Low coast modulator valve
69. Check valve
70. Valve retainer
71. Intermediate coast shift valve plug
72. Intermediate coast shift valve
73. Upper rear valve body
74. 2-3 shift valve spring
75. 2-3 shift valve
76. 2-3 shift valve plug
77. Valve retainer
78. Intermediate coast modulator valve
79. Detent regulator valve
80. Detent regulator valve spring
81. Valve retainer
82. Intermediate coast modulator valve spring
83. Reverse clutch sequence valve spring
84. Rear valve cover
.. )
1:
I
..:
j.
ST6 Revision
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21-162
AUTOMATIC
TRANSMISSION
- Valve
Bodv
DISASSEMBLY
For disassembly, observe the precautions given below.
(1) Keep the disassembled
parts orderly for efficient reassembly
operation. Attach tags to springs for identification.
(2) When disassembling
the valve, do not attempt to remove the
valve with undue force. The valve and valve hole could be
damaged or burred, leading to faulty valve operation.
(3) When removing the front upper and rear valve bodies from the
lower valve body, use care not to lose check balls and springs.
INSPECTION
Wash the removed
ing checks.
parts and dry with air. Then, make the follow-
Caution
When making ctnecks, use care not to damage
side and valve body holes.
valve land out-
(1) Check the valves for damage and wear.

(2) Insert the valves in the valve body and check smooth rotation
and sliding.
(3) Check the valve body for damage and wear of valve hole bores
and for clogging of oil holes and oil ways.
(4) Check for damage of the valve body plate wear and damage of
check balls.
(5) Check for clogging of the oil strainer.
5
PUPPER FRONT VALVE BODY
Cut back valve
Throttle valve
Kick-down
valve
I
Secondan/ regulator valve
355161
STB Revision
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AUTOMATIC
TRANS
ISSION
21-163
- Valve Body
UPPER REAR VALVE BODY

Intermediate
2-3 shift valve
Intermediate
modulator
coast shift valve
valve
*-
Detent regulator valve
Low coast modulator
valve
Reverse clutch sequence valve
(6) Check the springs and replace if broken or excessively

riorated. (See the table on page 21-164.)
dete-zf
1,
!
.5.
LOWER VALVE BODY

Plug
Low coast shift yalve
l-2 shift valve
Third coast shift valve

D-2 do&t
3-4 shift control valve
timing valve
mllml
t
Primary regulator
valve plunger
Primary regulator valve

Pressure relief valve
e-
Manual valve
372063
ST6 Revision
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:.(
<i
21-164
Valve Spring
AUTOMATIC
TRANSMISSION
Identification
~TB
Revision
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- Valve
Body
AUTOMATIC
TRA
ISSION
Body
- Valve
21-165
REASSEMBLY
Caution
Before reassembly,
wash the parts in a clean detergent
and
dry with air. Do not wipe with rags for drying. Entry of dust
could cause faulty valve operation.
(1) Install primary regulator valve 1, spring 2, plunger 3 and sleeve
4 in the lower valve body in the order shown and insert retainer 5 to prevent the valve and other parts from coming
loose.
(2) Install l-2 shift valve 1 and valve plug and insert retainer 3 to
prevent the valve from coming loose.
'3
355165
(3) Install 1-2 shift valve spring 1, low coast shift valve 2 and plug
3 and fit low coast shift valve cover 4.
372064
(4) Install pressure
relief valve 1, spring 2 and retainer 3.
(5) Install spring, check valve and check valve spring at illustrated
locations.
/;
STB Revision
1
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,.,.:
?:.
21466
AUTOMATIC
Plug
TRANSMISSION
- Valve Body
(6) Install the spring, 3-4 shift valve and plug and then inset-t the
locating pin.
355234
(7) Install the D-Z down timing
valve and plug and insert the seat.
D-2 down
hole ~~,:,
ys
Seat /355235
(8) install 2-3 shift valve spring 1, 2-3 shift valve 2, 2-3 shift valve
plug 3 and retainer 4 in the upper rear valve body.
(9) Install intermediate
coast shift valve 5, plug 6 and retainer 7.
(10)lnstall detent regulator

order shown.
valve 1, spring 2 and retainer
3 in the
(1l)lnstall
low coast modulator valve 1, plug 2, reverse brake sequence valve 3 and intermediate
coast modulator valve 4.
(12)lnstall valve springs.
(13)lnstall rear valve cover 5.
372065
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AUTOMATIC
TRA
ISSION
21-167
- Valve Body
(14)Place check balls (rubber) at illustrated

the bottom of the lower valve body.
locations
in oil ways in
(15)When installing the lower valve body cover, use the correct
gasket. One with oval holes for check balls is for the lower
valve body.
COVW
gasket 355233
.,
(16)lnsert secondary regulator valve spring 1 and secondary reg:.^.
ulator valve 2 in the front upper valve body and install front
valve end cover 3.
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35517:
1,
(17)lnsert throttle valve 1, throttle valve secondary spring 2 and E

rings 4 in the order shown and fit key plate 3 in the oil way at
illustrated location. Then, install throttle valve primary spring 5
and kickdown valve 6.
Caution
1. Install same number of E rings as before disassembly
for not disturbing
throttle
valve adjustment.
2. Insertion
of the throttle
valve key plate at incorrect
location could cause faulty valve operation.
(18)lnstall the throttle cam and spring on the upper front valve
body and tighten bolts temporarily.
When installing, note the
location of the spring end on the body side. Then, hook the
other end of the spring to the cam and bolt the cam to the
valve body. After installation, check that the throttle cam turns
through full stroke smoothly.
Caution
Hook the spring
!J
1 ST6 Revision
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to the correct
hole.
21-168
AUTOMATIC
TRANSMISSION
- Valve Body
(19)lnstall cut back valve 1, valve plug 2 and retainer 3. Install the
cut back plug with the larger land end facing out.
355176
(20)lnstall
the check ball (rubber) at the illustrated
location.
355177
(21) Place a new lower valve body gasket on the lower valve body.
NOTE
Do not use gasket for the upper valve body.
For lower valve body
For upper valve body

355236
(22)lnstall the separator

tions temporarily.
355237
plate and tighten
bolts at illustrated
loca-
(23)Piace a gasket for upper valve body, aligning with the separator plate.
(24)While using care not to disturb check valve position on the rear
upper valve body, install the lower valve body onto the rear
upper valve body and tighten the bolts (indicated by (A)) temporarily from the lower valve body side.
(25)Remove the two bolts tightened in step (22).
(26) Install the lower valve body onto the rear upper valve body and
tighten the bolts (indicated by (B)) temporarily from the lower
valve body side.
(27) Install the detent plate.
[ ST6 Revision
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AUTOMATIC
TRA
ISSION
- Valve Body
21-169
(28)lnstall the lower valve body onto the upper front valve body
and temporarily tighten the bolts shown at left from the lower
valve body side.
355240
(29)Turn the valve body upside down and temporarily

illustrated bolts from the upper valve body side.
tighten
the
(30)Then, temporarily
tighten the remaining valve body bolts as
,!
illustrated.
FI
(31)Tighten all bolts of the valve body to specified torque.
$:
(32) Install the manual valve.
;
.
Fi
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21-170
AUTOMATIC
TRANSMISSION
- Governor
GOVERNOR
&a-3
1.
2.
3.
4.
5.
6.
7.
8.
9.
E-ring
Governor weight
Governor valve
Outer governor spring
Inner governor spring
Secondary weight
Governor valve shaft
Governor body
Governor retaining ring
DISASSEMBLY
(1) Remove the E-ring 1 and remove governor weight 2.
(2) Remove governor shaft 3, spring and governor valve in the
direction of arrow. Remove the governor valve from the output
shaft hole.
INSPECTION
Wash removed parts and dry with air. Then, make the following
checks.
(1) Check the governor valve for damage and wear and check that
it slides smoothly while rotating it in the body.
(2) Check the governor body for damage and wear of the valve
sliding surface and for clogging of the oil hole and oil way.
(3) Check the governor spring.
Outer
Inner
Coil outer diameter
mm (in.)
15.34 (.604)
11.55 (.455)
Free length
mm (in.)
12.76 (.520)
11.49 (.452)
Wire diameter
mm (in.)
0.85 (.034)
0.85 (.034)
White
White
Identification
color
REASSEMBLY
Reassemble
the governor
verse order.
) STB Revision
-/
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following
the disassembly
steps in re-
AUTOMATIC
TRANSMISSION
Transmission
Case / Manual
Valve Lever /
Parking
System / Throttle
Control
Cables
TRANWHSSION
CASE
21-171
umu0--
INSPECTION
Make the
(1) Check
(2) Check
(3) Check
(4) Check
(5) Check
following checks
the bushing for
the accumulator
the brake No.3
the case inside
mating surfaces
MANUAL
and replace faulty parts.

wear and binding.
bore surface for damage.
cylinder surface for damage.
splines for excessive wear or damage.
with other parts for damage.
VALVE LEVER
INSPECTION
Make the following checks and replace faulty parts.
(1) Check the lever detent spring collar contact surface 1 for wear
and damage.
(2) Check manual valve lever pin 2 for wear.
(3) Check shaft 3 for wear.
(4) Check slotted spring pin 4 for wear.
Caution
When disassembled,
do not reuse the slotted
spring
pin.
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3.
PARKING SYSTEM
2
i
INSPECTION
1
a=D
Make the following checks and replace faulty parts.

Check parking lock pawl 1, spring 2, cam collar 3 and cam plate 4
for wear and damage.
4
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8:
+\3
QQ
372057
THROlTLE
CONTROL CABLES
INSPECTION
Make the
(1) Check
(2) Check
(3) Check
(4) Check
following checks and replace faulty parts.

the outer cable for cracks and damage.
motion of the inner cable in the outer cable.
adapter 1 and nipple 2 for wear and deformation.
the boot for damage.
355188
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levision
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.,i-.
3
21-172
AUTOMATIC
TRANSMISSION
Th rust
Bearings
and
Thrust
Washers
/ Adapter
THRUST BEARING AND THRUST WASHERS

NzlNc--
INSPECTION
(1) ~Check the thrust bearings and thrust washers
binding and replace if faulty.
for wear and
ADAPTER
INSPECTION
(1) Check the adaoter rear end for leaks and check the oil seal lip
for damage anb replace the oil seal if faulty.
When installing the oil seal, apply grease to its lip.
1. Oil seal
2. Gasket
3. Adapter
372068
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AUTOMATIC
T ANSMISSION
21473
Transfer
TRANSFER
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Snap ring
Spring retainer
Shift rail assembly
Cotter pin
H-L shift fork
Spring
Steel ball
Stopper plate
Clutch sleeve
Clutch hub
Bearing
Rear output shaft
NZIND--
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26,
Low speed gear

Needle bearing
Bearing spacer
H-L clutch hub
Snap ring
Needle bearing
Clutch sleeve
Snap ring (optional)
input gear
Bearing
Snap ring
Oil guide
Side cover
Oil seal
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
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Buffle plate
Side cover gasket
Dust seal guard
Oil seal
Transfer case
Chain cover gasket
O-ring
Thrust washer
Needle bearing
Bearing spacer
Counter gear shaft
Counter gear
Lock plate
Dust seal guard
Dust seal
Rear cover
Rear cover gasket
Steel ball
4WD lamp switch
Seal plug
Poppet spring
Steel ball
Cord fastener
50.
51.
52.
53.
Interlock plunger
Ball bearing
Steel ball
Chain
54.
55.
56.
57.
Needle bearing
Sprocket sleeve
Drive sprocket
Bearing
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
Front output shaft

Sprocket spacer
Lock nut
Chain cover
Wave spring
Spacer (if required)
Gasket
Cover
Snap ring
H-L shift rail
Wave spring
Speedometer
sleeve
assembly
Sleeve clamp
Gasket
Breather
Plug
Gasket
Select spring
Select plunger
70.
71.
72.
73.
74.
75.
76.
77.
78.
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148014
?LE
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21-174
AUTOMATIC
TRANSMISSION
- Transfer
REMOVAL
(1) Remove
take out
(2) Remove
ket.
(3) Remove
(4) Pull the
the plug from the right side of the transfer case and
the select spring and select plunger.
the control lever housing assembly, cover and gasthe transfer case to adapter attaching bolts and nuts.
transfer case back to separate from the adapter.
DISASSEMBLY
(1) Remove two 4WD light switches.Take
out two steel balls.
(2) Remove the speedometer
sleeve clamp and remove the
speedometer
sleeve assembly.
(3) Remove the rear cover attaching bolts and remove the spacer
and gasket.
(4) Remove the cover (front output shaft portion) and take out the
wave spring, spacer (if inserted) and gasket.
(5) Remove the side cover and gasket.
(6) Drive out the spring pin from the H-L shift fork by using the
special tool or a pin punch (commercially
available).
(7) Remove the two seal plugs and take out the two poppet
springs and balls.
(8) Pull out the H-L shift rail rearward.
(9) Take out the interlock plunger.
(lO)Remove
the snap ring from the rear output shaft rear bearing.
(1 l)Remove
the chain cover.
(12)Remove the oil guide.
(13)Remove
the countershaft
countershaft.
j STB Revision
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locking
plate
and pull
out the
AUTOMATIC
Thrust\ washer
Counter gear
TRANSMISSION
21475
- Transfer
(14)Take out the counter gear, two thrust washers

bearings and spacer from the side cover hole.
and needle
144011
(15) Remove the snap ring from the 2-4WD shift rail and remove
the two spring retainers and spring from the shift rail.
(16)Take out the front output shaft, rear output

together from the transfer case.
i,.
d
J-
shaft and chain

,I
I
(17)Remove
(18)Remove
(19)Remove
the 2-4WD shift rail.

the H-L shift fork and clutch sleeve.
the needle bearing from the input gear.
(20)Remove
the
assembly.
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snap ring and then
remove
the input
gear
21-176
AUTOMATIC
TRANSMilSSlON
DISASSEMBLY
- Transfer
OF REAR OUTPUT
SHAFT
(1) Remove the snap ring from the rear output shaft front end and
remove the H-L clutch hub, low speed gear, thrust washer and
needle bearing.
(2) Pry up the staked portion of the rear output shaft lock nut and
loosen and remove the lock nut.
(3) Remove the ball bearing from the rear end using a bearing
puller (commercially
available) or a press.
(4) Remove the sprocket spacer and steel ball.
(5) Remove the drive sprocket, two needle bearings, sprocket
sleeve and steel ball.
(6) Remove the 24WD clutch sleeve, hub and stop plate and pull
out the ball bearing using a puller or press.
456
123
13
14
15 16
1. Snap ring
2. H-L clutch hub
3. Low speed gear
4. Ball bearing
5. Stop plate
6. 24WD clutch sleeve
9 10
78
7.
8.
9.
10.
11.
12.
17
11
12
18
24WD clutch hub

Drive sprocket
Sprocket spacer
Ball bearing
Lock nut
Rear output shaft
Thrust washer
Needle bearing
Needle ball
Sprocket sleeve
17. Needle bearing
18. Steel ball
13.
14.
15.
16.
144616
ST6 Revision
-1
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AUTOMATIC
TRANSMISSION
21-177
- Transfer
REASSEMBLY OF REAR OUTPUT SHAFT

For reassembly, follow the disassembly
steps in reverse order,
attention to the following.
(1) Prior to reassembly, wash parts and check sliding and rotating
parts for damage. Replace parts if excessively worn or damaged.
(2) Apply transmission
oil to rotating and sliding parts before reassembly.
paying
(3) When installing the clutch hub, note the direction.

that the sleeve slides smoothly when installed.
sleeve may be installed in either direction.
Also check
The clutch
Front
1
For H-L
For 2-4WD
144023
148012
(4) Install a snap ring for H-L clutch hub on the front end of the
1,
rear output shaft. Use the thickest snap ring that fits in the
groove.
(:
H-L clutch hub end play
Standard value: O-0.08
mm (O-.003
in.)
(5) Tighten the lock nut to specified torque and then stake at the
illustrated location, aligning with the groove.
(6) Check that the low speed gear and drive sprocket ball bearing
rotate smoothly.
] STB Revision
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21-178
AUTOMATIC
TRANSMISSION
- Transfer
REASSEMBLY
(1) Press fit new oil seals in the input gear portion and front output
shaft portion of the transfer case. Fit the baffle plate on the
input shaft side. Apply specified oil to the oil seal lips.
Specified
gear oil
: Hypoid
Gear Oil API Classification
GL-4 or higher
SAE viscosity
No.
mw, 75w-a5w
14800E
(2) Press fit the ball bearing to

race. Check that the bearing
(3) Fit a snap ring on the front
thickest one that fits in the
Standard
value
the input gear, pushing the inner

rotates smoothly.
end of the input gear. Use the
groove.
: 0 - 0.06 mm (O-.002
in.)
(4) Insert the input gear assembly in the transfer case and fit a
snap ring. Use the thickest one that fits in the groove.
Standard
value : 0 - 0.06 mm (O-.002 in.)
(5) Insert the needle bearing in the input gear.
(6) Install the H-L clutch sleeve and shift fork.
1 ST6 Revision
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AUTOMATIC
TRANSMISSION
21-179
- Transfer
(7) Install the 2-4WD shift rail.
(8) Engage chain securely with the rear output shaft and front
output shaft sprockets. Then, install the rear and front output
shafts and chain together, while sliding the 2-4WD shift fork
with the clutch sleeve attached over the 2-4WD shift rail.
..
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(9) Install two spring retainers and spring over the 2-4WDshift
and fit a snap ring.
rail
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Thrust
Counter
washer
(10) Insert two needle bearings and spacer in the counter gear and
install the assembly in the transfer case. Install a thrust
washer on each of the counter gear.
gear
(1l)lnser-t
the countershaft
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and fit the locking
plate.
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,
.
21-180
AUTOMATIC
TRANSMISSION
- Transfer
(12)lnstall the oil guide.

(13)lnstall the chain cover and gasket, making sure that the oil
guide edge is in the chain cover window. Apply sealer to the
gasket.
Specified
g>
144626
sealant
(14)Tighten
the chain cover bolts to specified torque. Apply
a,dhesive to threads of bolts fitted in holes that go through
the case.
Nut Locking
4171 or
Specified adhesive
: 3M Adhesive
equivalent
(15)Fit a snap ring in the groove of the bearing at the rear end of
the rear output shaft.
(16)lnsert the interlock plunger in the hole of the chain cover.

(17)lnsert the H-L shift rail through the H-L shift fork. The H-L shift
rail cannot be inserted unless the 2-4WD shift rail is shifted to
the4WD side.
(18) Install poppet balls and springs two each and fit the seal plugs.
Face the smaller end of poppet springs toward the ball.
Spring pin
r( d
(19)Aligning the spring pin holes of the H-L shift fork and shift rail,
drive in the spring pin by using the special tool or a pin punch
(commercially
available). When installing the spring pin, face
its slit toward the shift rail center.
(20)Measure
the output shaft rear bearing protrusion A and rear
cover recess B to calculate the end play. Select the spacer that
gives specified end play.
(21)Apply sealer to a new rear cover gasket and attach it to the
chain cover side.
Specified
) STB Revision
sealant
-1
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AUTOMATIC
TRANSMISSION
21-181
- Transfer
(22)lnstall the selected spacer on the rear of the output shaft rear
bearing.
(23)lnstall
the rear cover and tighten the bolts to specified
torque. Apply adhesive to threads of bolts fitted in holes
that go through the case.
Specified
Nut Locking
4171 or
/144Q28j
(24)Measure protrusion A of the front output shaft rear bearing);.: ,

and recess B of the cover and calculate the clearance. If it is:
,,i
more than nominal, place a spacer at illustrated location.
I A
(.
2
A Gasket
Standard value : 2 mm (.078 in.)

:1
(25)Apply sealer to a new cover gasket and attach it to the chain I ,
cover.
Specified
sealant
Specified
(26)lnstall the wave spring spacer (if necessary) on the rear of the
bearing.
(27)lnstall the cover and tighten the bolts to specified torque.
Apply adhesive to threads of bolts.
: 3M Adhesive
equivalent
adhesive
adhesive
: 3M Adhesive
equivalent
Nut
Locking
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4171 0;:.
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Wave spring
Spacer
II
148011
Extension
housing
(28)lnsert the speedometer

sleeve assembly in the rear cover.J*%
Line up the mating mark on the extension housing with the
mark corresponding
to the speedometer
driven gear tooth
number range put on the sleeve.
(29)lnstall the sleeve clamp and tighten the bolt.
Mating mark
13404!i
(30)lnstall the two 4WD

balls are fitted.
1 ST6 Revision
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light switches,
making
sure that step

B
21-182
AUTOMATIC
TRANSMISSION
- Transfer
REASSEMBLY
For reassembly,
follow the removal
steps in reverse order,
paying attention
to the following.
1. Apply sealer to one side of the two control housing
gaskets and attach them to both sides of the control
liousing
cover.
Specified
2. Apply
sealant
sealer
Specified
to the adapter
sealant
( ST6 Revision
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gasket.
21-l
TRANSMISSION
MANUAL AND
UTOMATIC
CONTENTS
AUTOMATIC
TRANSMISSION
.........................
48
ADAPTER
.............................................................................
BRAKE NO. 3 .......................................................................
CENTER SUPPORT
.............................................................
DIRECT CLUTCH .................................................................
FORWARD CLUTCH
...........................................................
GENERAL INFORMATION
..................................................
GOVERNOR
.........................................................................
MANUAL VALVE LEVER ....................................................
OIL PUMP ............................................................................
ONE-WAY CLUTCH NO. 2 AND FRONT PLANETARY
GEAR SET ............................................................................
OVERDRIVE BRAKE ............................................................
OVERDRIVE CLUTCH AND PLANETARY GEAR SET .......
PARKING SYSTEM .............................................................
REAR PLANETARY GEAR AND OUTPUT SHAFT .............
SERVICE ADJUSTMENT
PROCEDURES
...........................
SPECIAL TOOLS
.................................................................
SPECIFICATIONS
................................................................
..................... ..............................
Lubricants
................ ...................... . .............................
...... .............. ........................
............. ................................ ....
.....................................................
172
158
150
148
144
48
170
171
137
THROl7LE
CONTROL CABLES .........................................
THRUST BEARINGS AND THRUST WASHERS
................
TRANSFER
...........................................................................
TRANSFER CONTROL
........................................................
TRANSMISSION
................
TRANSMISSION
CASE .......................................................
...............................................
TRANSMISSION
CONTROL
...........................................
TRANSMISSION
OIL CoO&R
TROUBLESHOOTING
.........................................................
Circuit Diagram .................... .........................................
Converter Stall Test ........................................................
Fluid Level and ATF Condition
..... .............. .................
171
172
173
115
119
171
109
117
98
104
101
98
153
142
139
171
155
106
96
90
90
95
95
92
93
NZlAA-
General ...........................................................................
..............................................
Governor Pressure Test
Inhibitor Switch ...............................................................
........................................................
Line Pressure Test
Manual Linkage ...............................................................
Road Test ........................................................................
.............................................................
Selector Lever
Throttle Control Cable .....................................................
VALVE
BODY
MANUAL
.......... .. ........... ............ ...................................
TRANSMISSION
..*...................,
........
98
102
99
103
99
99
99
99
160
CONTROL LEVER ASSEMBLY

.................... ....................... 46
30
........... ..*............................
COUNTER SHAFT ASSEMBLY
........................................
43
GEARSHIFT LEVER ASSEMBLY
2
GENERAL INFORMATION
........................... .......................
41
INPUT SHAFT ASSEMBLY
.................................................
........................................
26
MAIN DRIVE GEAR ASSEMBLY
MAIN SHAFT ASSEMBLY
... ............ ............ ..................... . . 27
OUTPUT SHAFT ASSEMBLY
.......... .......... ..a...................... 38
SERVICE ADJUSTMENT
PROCEDURES
...........................
IO
8; f?.,
SPECIAL TOOLS
................................................. . ...............
z. .- :
SPECIFICATIONS
............................. ............ ....................... ,~.a$$y
... ............................................... -~3 :
7:.
Lubricants
.......................................................................
.................................................
7
...................................................
4
...................................................
5 I
SPEEDOMETER
SLEEVE ASSEMBLY
...............................
TRANSFER ASSEMBLY
......................................................
................
TRANSMISSION
............................................
TRANSMISSION
ASSEMBLY
TROUBLESHOOTING
....................................... ..................
Gears slip out
Noise, Vibration
Oil is leaking
Shifting gears is hard or troublesome
http://vnx.su/
42
31
11
18
9
21-2
GENERAL
MANUAL
TRANSMISSION
- General
Information
INFORMATION
NPlBAAF
The KM-145 5-speed transmission

is composed
of the 4WD transmission
and the .transfer.
For the manual transmission,
the shifting
mechanism
is coupled to unit 1, and is housed
aluminum-diecast
housing.
For the gear train, forward and reverse are the constantly
engaged type.
The transfer is the par--time
system; 2WD. 4WD-HIGH
and 4WD-LOW
can be selected.
within
an
145110
( STB Revision
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MANUAL
TRANSMISSION
21-3
- Specifications
SPECIFICATIONS
GENERAL
SPECIFICATIONS
NZlCA--
Specifications
Items
Model
KM145
Transmission
5-speed 4-wheel
Type
Gear ratio
1 st
3.967
2nd
2.136
3rd
4th
1.360
1.000
5th
0.856
Reverse
3.578
4.625
4.875 (Option)
2618 ,,, Final gear ratio 4.625
2718 ._. Final gear ratio 4.875 (Option)
Final gear ratio

Speedometer
drive
gear ratio
Transfer case
Constant
Type
Gear ratio High
1.000
1.944
Low
Drive system
mesh type
Front wheel
Chain drive
Rear wheel
Direct drive
Adjustment spacer and snap ring

Snap ring for main drive gear
Thickness
mm (in.)-ldent,color-Part
2.30
2.35
2.40
2.45
2.50
No.
(.091 )-White-MD701729
(.093)-Brown-MD701730
(.094)-None-MD701731
(.096)-Blue-MD701732
(.098)-Yellow-MD701733
Spacer for main drive gear bearing to front retainer

color-Part
No.
0.84(.033)-Black-MD701845
0.93 (.037)-None-MD701839
1.02 (.040)-Red-MD701840
1 .ll (.044)-White-MD701841
1.20 (.047)-Yellow-MD701842
1.29 (.051)-Blue-MD701843
1.38 (.054)-Green-MD701844
Snap ring for mainshaft front end

mm (in.)-ldent. color-Part
Thickness
No.
2.15(.085)-Blue-MD701761
2.22 (.087)-None-MD701762
2.29 (.090)-Brown-MD701763
2.36 (.093)-White-MD701764
Thickness
mm (in.)-ldent.
1 STB Revision
http://vnx.su/
21-4
MANUAL
TRANSMISSION
- Specifications
Specifications
Items
Snap ring for input gear assembly
mm (in.)-color
Thickness
2.70 (.106)-Purple
2.75(.108)-Pink
2.80(.1 IO)--Yellow
2.85 (.I 1.&-White
2.90 (.I 14)~-Blue
Snap ring for H-L clutch hub

Thickness
mm (in.)-color
2.14
2.21
2.28
2.35
2.42
(.084)--None
(.087)--Yellow
(.090)--White
(.093j-Blue
(.095t-Red
2.30
2.35
2.40
2.45
2.50
(.091 )--None
(.093)--Red
(.094)--White
(.096)--Blue
(.098)--Green
Snap ring for input gear bearing

Thickness
mm (in.)-color
Spacer for rear output shaft bearing

mm (in.)-color
Thickness
SERVICE
0.84 (.033)-Black
0.93 (.037)--None
1.02 (.040)--Red
1.11 (.044)--White
1.20 (.047)-Yellow
1.29(.051)-Blue
1.38(.054)-Green
SPECIFICATIONS
Specifications
Items
Standard value
Front bearing retainer and bearing clearance
mm (in.)
Main drive gear end play
Counter gear end play
Input gear end play
Output shaft end play
nchronizer
mm (in.)
O-O.1 (O-.004)
O-0.06 (O-.002) _,. Adjustment
mm (in.)
mm (in.)
mm (in.)
by spacer
by snap ring
:.
-1
http://vnx.su/
by snap ring
O-0.05 (O-.002) ._. Adjustment
0.5 (.020)
STB Revision
.C
by spacer
O-0.06 (O-.002) .., Adjustment

O-O.1 (O-.004)
mm (in.)
ring and gear clearance
Adjustment
Adjustment
by spacer
MANUAL
TRANSMISSION
21-5
- Specifications
NPlCC-
Items
Nm
ft.lbs.
Manual transmission
Transmission
mounting
bolts
43-55
32-39
22-32
16-23
Mainshaft lock nut

Idler shaft lock nut
250-270
20-60
181-195
15-43
Under cover attaching bolt

gear lock nut
Countershaft
Reverse idler gear shaft nut
8-10
160-I 90
5.8-7.2
116-737
20-60
15-43
Backup light switch
30
22
Starting motor mounting
bolts
Oil drain plug
60
43
Oil filler plug
30-35
22-25
Rear bearing retainer attaching bolts

Reverse idler gear shaft attaching bolts
15-22
11-16
15-22
11-16
IO-13
IO-12
7.2-9.4
15-22
11-16
15-22
11-16
Front bearing retainer installation

Bell housing attaching
bolt
bolts
Stopper bracket assembly attaching bolt

Transfer adaptor and transmission
case coupling
bolt
7-9
Transmission
control lever mounting bolt
15-22
11-16
50-60
36-43
Front exhaust
20-30
15-22
55-75
31-42
40-54
22-29
18-25
13-18
18-25
13-18
A, B
43-55
31-40
D. E
20-27
15-20
pipe mounting
bolt
No. 2 crossmember
to body
Clutch release cylinder mounting
Engine mounting
Engine mounting
Transmission
bolt
rear insulator to No. 2 crossmember

rear insulator to transmission
to engine
/ STB Revision
http://vnx.su/
21-6
MANUAL
TRANSMISSION
Items
Transfer
-Specifications
Nm
ftlbs.
15-22
11-16
IO-13
7.2-9.4
30-42
22-30
22-30
case
Pulse rotor installation

Pulse generator
bolt
bolt
Adapter to transfer
case mounting
bolts and nuts
Chain cover bolt

Side cover bolt
30-42
8-10
5.8-7.2
Rear cover bolt
15-22
11-16
Cover bolt
15-22
11-16
Control housing bolt
15-22
11-16
Oil filler plug
30-35
22-25
Drain plug
30-35
22-25
Select plunger plug
30-35
22-25
Lock plate bolt

15-22
100-l 30
11-16
72-94
Speedometer
sleeve clamp bolt
15-22
11-16
30-42
light switch
30
IO-13
22-30
22
Seal plui
4WD indicator
Transfer
control lever assembly
7-9

Transfer mounting bracket to transmission
50-60
18-25
3643
13-18
Transfer
18-25
13-18
mounting
bracket to body
1 STB Revision
http://vnx.su/
MANUAL
TRANSMISSION
21-7
-Specifications
LUBRICANTS
NBlCD-
Items
Specified
lubricant
Quantity
Transmission
Hypoid Gear Oil API classification

GL-4 or
higher SAE viscosity 8OW, 75W-85W
2.2 lit. (4.7 U.S. pints,

pints)
3.9 Imp.
Transfer
Hypoid Gear Oil API classification

GL-4,or
higher SAE viscosity 8OW. 75W-85W

pints)
3.9 Imp.
Multipurpose
No. 2
grease
SAE J310,
NLGI
As required
Multipurpose
No. 2
grease
SAE J310,
NLGI
As required
case
Sliding
lever
parts of the transmission
Sliding
parts of the transfer
SEALANTS
control
control
lever
AND ADHESIVES
Items
NZlCE-
Specified
seatants
and adhesives
Quantity
Control
housing
or equivalent
As required
Control
lever gasket
or equivalent
As required
or equivalent
As required
Housing
cover gasket
Stopper
bracket
installation
bolt
As required
Stopper
bracket
installation
bolt (threads)
3M Scotch
As required
Extension
Adapter
gasket
gasket
Front bearing
retainer
Grip No. 2353
or equivalent
As required
As required
As required
Chain cover gasket
As required
Cover gasket
As required
3M Adhesive
As required
Cover installation
Rear cover gasket
bolt (threads)
Nut Locking
4171 or equivalent
As required
:.
.,. i
http://vnx.su/
21-8
MANUAL
TRANSIWSSION
-Special Tools
SPECIAL TOOLS
Tool (Number
and name)
NZlDA--
I
Use
Tool (Number
Driving in of lock pin ant

spring pin
MD998020
Bearing puller
Removal of main drive

gear and mainshaft
bearing
Use with MD998020

Removal of mainshaft
bearing
M D998067-0 1
Mainshaft bearing installer
Driving in of mainshaft
bearing
M D998029-0 1
Main drive gear bearing
installer
Driving in of main drive

gear bearing
M D998200-0 1
Front bearing retainer oil seal
installer
Driving in of front oil seal
VlD998348-0 1
Taper bearing puller
lqemoval
MB990938-01
Handle
Use with MD998200

Driving in of front oil seal
vl IT4336
Searing driver handle
IJse with
Pvl D998067-0 1,
rvl D998029-01
[Iriving in of main drive
Eyear and mainshaft
tIearing
M D998245-01
Lock pin installer
MD998028
Bearing puller adapter
of counter
shaft bearing
http://vnx.su/
and name)
Use
MANUAL
TRANSMISSION
- Troubleshooting
TROUBLESHOOTING
21-9
NZlEAAC
The end play of eat
..
,-*::
_
1 STB Revision
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:i
-: ..
MANUAL
TRANSMISSION
- Service
Adjustment
Procedures
SERVICE ADJUSTMENT
PROCEDURES
NZlFFM
CHANGING
AND INSPECTION
SION AND TRANSFER OIL
OF TRANSMIS-
1.
2.
Drain dua
n!mnn71
Raise vehicle on hoist

Remove the filler plug from the transmission
or transfer and
check that the transmission
oil is up to the oil level. If it is
lower, replenish specified transmission
oil to the oil level and
if it is higher, drain transmission
oil as described below.
3. Remove drain plug to let oil drain.
4. Tighten the drain plug completely.
5. Replenish the specified transmission
oil to the level.
Specified
transmission
oil :
Hypoid
Gear Oil API classification
SAE viscosity
8OW, 75W-85W
Quantity
:
Transmission
Transfer case
GL-4

or higher
3.9 Imp.
3.9 Imp.
pints)
pints)
098002;
6. Tighten
the filler plug.
098002:
REPLACEMENT
Rear
OF PROPELLER SHAFT OIL S~U&
(1) Using a screwdriver

(2) Install the oil seals.
or a similar
Caution
Use a new oil seal.
(3) Apply a coating of the specified
seals.
Specified
Grease
OBW528
( ST6 Revision
/
http://vnx.su/
tool, remove
the oil seals.
grease to the lip of the oil
: Multipurpose
NLGI No. 2
grease
SAE
J310,
MANUAL
TRANSMlSSlON
TRANSMISSION
REMOVAL
AND
20-30
- Transmission
AND TRANSFER
and
Transfer
21-11
Assembly
ASSEMBLY
NZIMA--
INSTALLATION
Nm
30-35
Nm
ft.lbs.
18-25
,13-18
50-60
36-43
Nm
ft.lbs.
Nm
ft.lbs.
/
18-25
13-18
Nm
ft.lbs.
Nni
ft.lbs:
55-75. Nm
40-54 ft.lbs.
qemoval
l *
w
+I)
l 4
l +
steps
I,
2.
3.
4.
5.
6.
7.
8.
9.
10.
+e l + 11.
12.
13.
14.
l e e+ 15.
Transmission
shift lever knob
Transfer
shift lever knob
Front floor console
Speedometer
cable
Rear propeller
shaft
Front propeller
shaft
Front exhaust
pipe mounting
bolt
Bell housing
cover
Connection
of 4WD indicator
light
stiitch
f$haust
pipe mounting
bracket
Clutch release
cylinder
Transfer
mounting
bracket
No. 2 crossmember
Engine
mounting
rear insulator
Transmission
and transfer
assembly
NOTE
to reinstail.
(3) l * : Refer to Service Points of Installat,i$n.
, e
Nm
ft.lbs.
mm (in.) Bolt identification
O.D. x Length
.*.
STB Revision
http://vnx.su/
-.,
-.-I--
21 -12
MANUAL
TRANSMISSION
- Transmission
SERVICE
POINTS
and Transfer
Assembly
OF REMOVAL
5. REMOVAL
OF REAR PROPELLER
PELLER SHAFT
JOINTS - Propeller
Shaft
11. REMOVAL
Refer
OF CLUTCH
to GROUP
SHAFT/G.
SHAFT
RELEASE
6 CLUTCH
NZlMEAG
FRONT
AND
PRO-
UNIVERSAL
CYLINDER
- Clutch
Release
Cylinder.
15. REMOVAL
OF TRANSMISSION
AND TRANSFER
Caution
When removing
the transmission
from the engine, care
must be taken not to shake or rock with force, because
to do so might
cause damage
to the end of the main
drive gear, the pilot bearing,
or the clutch disc, etc.
(1) Disconnect
the transmission
and transfer
assembly
from the engine by pulling it slowly toward
the rear of
the vehicle.
(2) When
the transmission
and transfer
assembly
are
lowered,
tilt. the front of the transmission
downward
and slowly
lower forward,
while
using care to make
sure that the rear of the transmission
does not interfere
with the No. 4 crossmember.
SERVICE
POINTS
15. INSTALLATION
ASSEMBLY
OF INSTALLATION
OF TRANSMISSION
NZlMDAH
AND
TRANSFER
:.,:, On the engine

side, there are two centering
locations.
I - Make sure that the transmission
mounting
bolt holes are
aligned with them before mounting
the transmission
and
transfer
assembly
to the engine.
http://vnx.su/
MANUAL
TRANSMISSION
- Transmission
and Transfer
11. INSTALLATION
OF CLUTCH
Refer to GROUP 6 CLUTCH
Assemblv
21-13
RELEASE CYLINDER
- Clutch Release Cylinder.
6. INSTALLATION
OF FRONT PROPELLER
SHAFT/5.
REAR
PROPELLER
SHAFT
SHAFT AND UNIVERSAL
JOINTS - Propeller
Shaft.
2.
INSTALLATION
Refer to P.21-43.
http://vnx.su/
OF TRANSFER
SHIFT
LEVER
KNOB
-r__._
j@-
21-14
MANUAL
TRANSMISSION
DISASSEMBLY
TRANSMISSION
Transmission
and
Transfer
Assembly
NZlMEC
AND REASSEMBLY
07
/
Nm
30-35
22-25
ft.lbs.
\?*
22-25
30-42
22-30
Disassembly
Nm
ft.lbs.
!
145075
steps
1. Oil filler plug
.$
4.
.-
2.
3.
4.
5.
.I 6.
l * 7.
8.
9.
ftlbs.
15. Steel ball
Oil drain plug

Select plunger plug
Gasket
Select spring
Select plunger
Spring pin
Cord fastener
Cord fastener
16.
17.
18.
19.
Seal plug
Neutral return spring
Neutral return plunger (B)
Neu&l return plunger (A)
NOTE
(1) Reverse the disassemblyproceduresto reassemble.
(2) l + : Refer to Service Points of Reassembly.
(3) q
: Non-reusableparts
http://vnx.su/
95-22
11-16
Nm
ft.lbs.
13--LL
Nrn
11-16
klbs.
30 Nm
22 ft.lbs.
6dNm
43 ftlbs.
146076
Disassembly
steps
20. Oil filler plug

21.
22.
23.
l *24.
25.
l **426.
l +27.
28.
29.
30.
31.
Oil drain plug

Backup light switch
Steel ball
Breather
Plug
Transfer adapter
Extension gasket
Lock pin
Control finger
Control shaft
Transmission
assembly
,.F
NOTE
(1) Reverse the disassembly procedure&
(2) W : Refer to Service Points of Disassembly.
(3) l + : Refer to Service Points of Reassemblp::?
S,<
(4) q
: Non-reusable parts
http://vnx.su/
21 - 16 .:,c.&IIANUAL
$pq3
TRANSMISSION
- Transmission
and
Transfer
Assembly

26. REMOVAL
OF TRANSFER
NZlMWD
ADAPTER
Turn the control shaft to the left and remove the control finger
from the groove in the shift lug, then remove the transfer
adapter from the transmission.
N21MGBG
27. INSTALLATION
OF EXTENSION
GASKETI26.
TRANSFER
ADAPTER
(1) Apply sealant to both sides of the extension gasket and
affix the gasket to the rear surface of the transmission
case.
Specified
sealant
(2) Turn the control shaft to the left and install the transfer
adapter.
(3) Turn the control shaft to the right and insert the control
finger in the groove of the shift lug.
24. INSTALLATOCDN
Identification
marl
Install
rear.
OF BREATHER
the breather
12. ASSEMBLY
OF
ASSEMBLY/lo.
(1) Apply sealant
rear surface
with the identification
mark toward
the
ADAPTER GASKETIll.
TRANSFER
CASE
CHANGE SHIFTER
to both sides of the gasket and affix it to the
of the adapter.
&?i. ._
Specified sealant
: 3M,AFJT Part No. 8001 or equiva
leni&,<
(2) Install the transfer case $stalling the change shifter to the
control shaft.
r:.;
;,Z
,$$
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MANUAL
TRANSMISSION
- Transmission
7.
DRIVING
and
IN OF SPRING
(1) Use the special
Center
control
line of
shaft
Transfer
tool
Assembly
21-17
PIN
to drive
in the spring
pin.
(2) Drive the spring pin in with the slit in the spring pin parallel
to the shaft center of the shift rail, so that the
birnensions
are as shown in the illustration.
NOTE
Do not reuse spring pin
145034
1 STB Revision
http://vnx.su/
1
t
.-
--- ..
21-18
:
MANUAL
TRANSMISSION
ISASSEMBLY
.
+a~&b~y&&f
,i . .
: : .c:p .<$,
TRANSMISSION
- Transmission
Assembly
ASSEMBLY
N2lME-D
AND REASSEMBLY
I
I)
1.
.-%-,
2.
. .;.
f:
3.
I& l . * 4.
g, l + 5.
:**4
6.
7.
Under covei
i
Under cover ask@
$
Plug
Poppet spring 1 q
Steel ball
Spr.ing.pin
l-2 speed shift rail
NO<E ].
(1)
(2)
(3j
(4)

~~ : Refer to Service Points of Disassembly.
l + : Refer to Service Points of Reassembly.
.@;, .GNon-reusable
parts
3p- ,~,i 2
,i.
.
http://vnx.su/
MANUAL
..
TRANSMISSION.
- Transmission
21-y; :
Assembly
i.
,!$/
4
Disassembly
steps
+**+13.
Main shaft lock nut
+e l +l 4. Countershaft
lock nut
4*
15. Counter rear bearing
l *
16. Counter overdrive gear
17.Spacer
18. Reverse idler gear
19. Spacer
20. Sleeve
21. Steel ball
22. Overdrive gear
250-270
Nm
181-195
ft.lbs.
-.a
&Ty
,y,.Y. -,-. j-
-0
i
I( 055*
;:;
7>
.:; .
, _(/: -c .I. ..
JU
i
._
118-137
18,
23. Needle bearing

...
s 24. Bearing sleeve
25. Bearing spacer
.:
l +26. Synchronizer ring
l +27?0D-I? synchronizer sleeve
l 428. Synchronizer spring
l +29. Synchronizer key
l *30. Synchronizer hub
31. Reverse gear
32. Needle bearing
33. Bearing sleeve
34. Spacer
35. Cotter pi@
36. Slotted nut
37,GLhrust washer
38%everse idler gear
39. Needle bearing
l **440.
Reverse idler gear shaft
41. Rear bearing retainer
4o
;s
15-22
11-18
ftlbs.
3,36
3
20-60 Nm
I w-55-43
ft.lbs.
Nm
ftlbs.
.*..q.
(2) 4,
(3) l 4
(4) q
http://vnx.su/
: Refer to Service Points of Disasgembly

: Refer to Service Poinfs cjf Reassembly,
: Non-reusable
parts
-.
MANUAL
TRANSMISSION
- Transmission
Assembly
42
lo-13
Nin
7.5-9.4 ftlbs.
Disadkhly
56
.-:.A i__ .,,.
145099
steps
+***42.
Main shaft bearing
l *43. Spacer
44. Counter rear bearing outer race
l +45. Front bearing retainer
, b ~46. Front bearing retainer gasket
+47.Spacer
,
l +%3~OilSeal
491 Spacer
50. Counter front bearing outer race
l * l *51 . Main drive gear assembly
52. l-2 speed shift f,ork
53. Countershaft assembly
NOTE
(1) Reverse the disassemblyprocedures to reassemble.
(2) 0 l : Referto Service Points of Disassembly.
(3) 04 : Refer to Service Points of Reassembly.
(4) l : Non-reusableparts
--I
http://vnx.su/
,$y.
5
-I-y-
MANUAL
TRANSMISSION
SERVICE
6.
- Transmission
POINTS
Assembly
OF DISASSEMBLY
/9. REMOVAL
OF SPRING
PIN
Drive the spring pin out using the special
NZlMFBE
,.-
-
too.!;,,,,.
13. REMOVAL-;;
MAIN SHAFT LOCK NUT/14.
COUNTER
SHAFT LOCK NUT
(1) As shown in the illustration,
use the front edge of the
blade of a chisel or a blunt punch to loosen the baffle on
the main shaft and counter shaft lock nuts.
(2) Shift the OD-R synchronizer sleevelto the reverse side,
then shift the 1-2 synchronizer sleeve to the 2nd speed
side.
(3) Remove the main shaft lock nut and the counter shaft lock
nut.
15. REMOVAL
OF COUNTER
OVERDRIVE
GEAR
Pull off counter overdrive
suitable puller.
REAR ,BEARING/lG.
,$; I* * o( : :
gear, and ba):l!bearing
COUNTER
by using8 a
i-e
.
-
40. REMOVAL OF REVERSE IDLER GEAR SHAFi
(1) Remove four reverse idler gear shaft mounting bolts.

(2) Drive reverse idler gear shaft from inside of case.
wision
http://vnx.su/
51,. REMOVAL QF MAIN)DRhik

GEAR ASSEMBLY
Pullrthe counter gear up in the case and remove the main drive
ge$ with.; bearing toward front of case. -. a.?
Q,+
7
.;7
I
*?a&
..:%;:r
3
pipi
4
II
:;,
SERVICE i0I~~s
,.
. .
0~ REASSEMBLY*
NZlMGBH
51. INSTALLATION
OF MAIN DRIVE GEAR ASSEMBLY
Hold the counter gear upward in the case&nd install the main
>
drive gearassembly.
::,
>
IN~TALLATI&&OF
$~&ER/~B:
ER~NT&@@ING
RE-TAINER GASKEX#&$RONT
BEARING RWAINER
1.1) Before ins&?&the-frpnt
bearing retainer, select a spacer
which will bringhe
&earance:(c) <:Q;y.
to the
: .:i .,standard value.
-1
-$
- -;*: >F;@:
Standard value $0-0.1
mm (Of. 004 in.)
y%-
http://vnx.su/
.*
MANUAL
TRANSMISSION
- Trah%mission
Assembly
(2) Apply sealan; & both sides of the

gasketand
affix it to the case. Then
spacer selected in (1) in place and
tainer.
$+ctfied
.t
.,a
21-i-3
-y
: 3M ART Part No. 8001 or

lent
sealant
,
..:;.
. .:
L.
43. INSTALLATION
OF SPACER
(1) Hold down counter gear and bearing outer race (in the
direction of arrovyshown in illustration).
..i
i
. ,
,
iy
(2) Put .a spacer, o$roper

thickness (slightly thinner than dimension H shown in illustration),on
outer race.. .;
,..I?
,,r
.
(3) Put straight edge on spacer and try to turn spacer byindex
finger. If spacer turns lightly, replace it with spacer one
rank (0.03 mm (0012 in.)] thicker, and similarly turn this
spacer. In this manner, choose and instG&a-spacer which
makes clearance between sstyaight $&%.and.spacer
closest to 0. Make sure that ; .the*beanngs~q@$.OT
preloaded.
p*.-& 3 . k
.&;__..~-13Standard
value
: O-045
#fk
k.
I
\
42.lNSTALLATlON.OF
MAIN
SHAFT
BEAPING
After installingthe
snap ring on,ihe ma% shaf$.bearing, drive
the main shaft bearing into theltiansmission
case using the
special tool.
1 STB Revision
http://vnx.su/
,
;
MANUAL
TRANSMISSION
Transmission
Assembly
40. INSTALLATION
OF REVERSE IDLER GEAR SHAFT
Position the reverse idler gear shaft with bolts and drive it in.
30. INSTALLATION
OF SYNCHRONIZER
HUB/ZS. SYNCHRONIZER KEY/28. SYNCHRONIZER
SPRINGI27.
OD-R SYNCHRONIZER
SLEEVE
(1) Assemble synchronizer hub and sleeve. Make sure that
hub and sleeve slide smoothly.
(2) Insert three keys into groove of hub. Assemble hub and
keys as shown in illustration
since they have a definite
direction to be assembled.
Front a
II
Hub
SleevB
3132031
(3) Install two synchronizer springs. When installing springs,

make sure that steps of front and rear springs are positioned on synchronizer key, but not on the same key.
..!
j
Step of
26. INSTALLATION
OF SYNCHRONIZER
RING
Engage synchronizer ring to OD gear as shown in illustration

before instal@g OD gear and ensure that there is certain clearI 5: ;<
ance A. :-~:
.L
If dimension
A eitcee,ds the.-fjmit, replace the ring and/or
. , ,.gear. ~
:,
j
..
,
Limit : 0.5@m
(.020 in.)
i.
14. INSTALLATION
MAIN SHAFT
OF COUNTER
LOCK NUT
SHAFT
LOCK
NUT/lB.
(I) Tighten main shaft and counter gear lock nut to specified
torque.
(2) Stake the area as shown in illustration without fajl,to prevent lock nut from loosening.
(3) Ensure that OD gear rotates smoothly.
.:
- STB Revision
: dWiMh~b,:
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MANUAL
TRANSMISSION
- Transmission
9. INSTALLATION
OF SPRING PIN/6. SPRING PIN
(1) Use the special

pin.
Shift
21-25
Assembly
tool to drive
in OD-R
shift
fork
spring
(2) Drive in spring pin so as to place slit in direction of center

line of shift rail. Drive in spring pin for 3-4 and l-2 shift
forks in the same manner.
fork
NOTE
Do not reuse
spring
pin.
Slit
14501t
-,
/ STB Revision
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,Y
.._
: MANUAL
TRANSMISSION
- Main Drive
Gear Assembly
MAIN DRIVE GEAR ASSEMBLY

DISASSEMBLY
NZlMQAB
AND REASSEMBLY
116636
Disassembly
l *l
**1)*2.
3.
steps
NOTE
(2) +*
Snap ring
Bearing
Main dri@gear
.

2.
REMOVAL
OF BEARING
(1) Remove main drive gear snap ring.

(2) Using Special Tool, pull ball bearing from main drive gear.
134616
SERVICE POINT?
2.
INSTALLATION
OF REASSEMBLY
OF BEARING
With Special Tool, applied to main drive gear press bearing in

by means of a hammer or a press.
MIT4336
MD998029-01
116616
1.
INSTALLATION
OF SNAP
RING
Select and install main drive gear snap ring of such thickness
that will minimize clearance between snap ring and bearing. In
other words, install the thickest snap ring that can fit in snap
ring groove.
Standard
value
j STB hevwon
_. -:.:.,
http://vnx.su/
: O-0.06
mm (O-.002
in.)
MANUAL
TRANSMISSION
Main
Shaft
21-27
Assembly
MAIN SHAFT ASSEMBLY

ISASSEMBLY
Disassembly
l *
l
l
l
l
+*
l
l
l
l
l
1.
2.
3.
4.
+ 5.
6.
+ 7.
+ 8.
+ 9.
10.
11.
W2.
13.
+l 4.
W 5.
+16.
417.
18.
19.
20.
N2lPE-c
AND REASSEMBLY
steps
Ball bearing inner race

First speed gear
Bearing sleeve
Needle bearing
l-2 speed synchronizer
Synchronizer
ring
Synchronizer spring
Synchronizer key
l-2 speed synchronizer
Second speed gear
Needle bearing
Snap ring
Synchronizer
ring
Synchronizer
spring
Synchronizer key
3-4 speed synchronizer
3-4 speed synchronizer
Needle bearing
Third speed gear
Main shaft
::
\
sleeve
hub
145103
hub
sleeve
NOTE
(2)+*
4
(3)**
i,
http://vnx.su/
21-28
MANUAL
TRANSMISSION
- Main Shaft
Assembly
NzlPFAAZ
1. lNSTALLATlON
OF BALL BEARING INNER RACE/lo. SECOND SPEED GEAR
Holding second speed gear on press base, push rear end of
main shaft to remove bearing inner race (double bearing only),
gear bearing sleeve, first speed gear, 1-2 speed synchronizer
and second speed gear.
145102
INSPECTION
l
Limit
Synchronizer
ring
Gear
: 0.5 mm (.020 in.)
110003

T
N2lPHAM
17. ASSEMBLY
OF 3-4 SPEED SYNCHRONIZER
SLEEVE/lG.
3-4 SPEED SYNCHRONIZER
HUB/Il5.
SYNCHRONIZER
KEY/14. SYNCHRONIZER
SPRING
(1) Mate synchronizer hub with sleeve using mark made at
disassembly.
Make sure that hub and sleeve slide
smoothly. If they slide unsmoothly,
replace hub and sleeve
assembly.
(2) 3-4 synchronizer sleeve has teeth missing at six portions.
Assemble hub to sleeve in such a way that center tooth T
between two missing teeth will touch synchronizer key.
00th missing here
Synchronizer
WlPGAA2
Check synchronizer
ring for worn and damaged
internal
threads.
With synchronizer assembled to cone of each gear check dimension A. If dimension A exceeds the limit, replace the
synchronizer ring and/or gear.
key
110012
(3) Use care when installing 3-4 synchronizer hub since only
3-4 synchronizer is directional. Smaller diameter side A
of center boss is front of 3-4 synchronizer hub.
Front
145025
(4) Insert three keys into groove of synchronizer hub.

(5) Install two synchronizer
springs to synchronizer.
When
synchronizer springs are installed, make sure that front
and rear ones are not faced in same direction.
. .
( STB Ftevrslon
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MANUAL
3-4
speed
r\
TRANSMISSION
Main
Shaft
Assembly
21-29
16. INSTALLATION
OF 3-4 SYNCHRONIZER
HUB/lZ.
SNAP
RING
(1) Assemble 3-4 synchronizer positioning hub toward correct
direction.
(2) As for main shaft front end snap ring. select and install one
of such thickness that will minimize clearance between
snap ring hub. In other words, install the thickest snap ring
that fits in snap ring groove.
(3) Make sure that 3rd speed gear turns%moothly.
Main shaft
134024
9.
ASSEMBLY OF l-2 SPEED SYNCHRONIZER

HUW8.
CHRONIZER
KEY/7.
SYNCHRONIZER
SPRING/B.
SPEED SYNCHRONIZER
SLEEVE
SYN1-2
Assembly the l-2 synchronizer by the same procedure

the 3-4 synchronizer in the previous item.
as for
.*
http://vnx.su/
.:
21-30
MANUAL
TRANSMISSION
- Counter
Shaft
Assembly
N21XE-B
COUNTER SHAFT ASSEMBLY

DISASSEMBLY
AND REASSEMBLY
Disassembly
l **+1
+**+2.
steps
. Counter
Counter
3. Counter
NOTE
(2) +*
(3) e+ : Refer to Service Points of Reassembly.
front bearing
center
bearing
shaft gear
132069
Taper bearing
Press
/
1. REMOVAL
OF COUNTER
CENTER
BEARING
MD998348-01
FRONT
BEARING/S.
N2iXFAB
COUNTER
Removal the taper roller bearing from the end of the counter
shaft gear using the special tool.
Counter gear
dylinder
PrRs
c)
,320,8
Steel pipe
(Inner diameter:
26 mm (1.02 in.)
Outer Diameter:
30 - 31 mm
(1.18 - 1.22 in.)
U2IXHAAl
1. PRESSURE INSERTION
OF COUNTER FRONT BEARING/Z.
COUNTER
CENTER
BEARING
Pressure insert the taper roller bearing using a steel pipe with
the dimensions
Set the steel pipe so that it presses on the inner race only and
doesnt contact the bearing cage.
1 STB Revision
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15-22
11-16
Nm
ft.1b.s.
16
I
15-22
11-16
C4
30-42 Nm
22-30
ft.lbs.
16-22
11-16
Disassembly
l q
l +
l +
l +
l 4
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Nm
ft.lbs.
steps
Sleeve clamp
Speedometer
gear assembly
4WD indicator
light switch
Gasket
Steel ball
Rear cover
Rear cover gasket
Spacer
Dust seal guard
Oil seal
Spring
pin
Seal plug
Poppet
spring
Steel ball
H-L shift rail
l
l
l
l
+
*
*
*+
l +
l +
l +
NOTE
http://vnx.su/
16. Interlock
plunger
17. Cover
18. Cover gasket
19. Spacer
20. Wave spring
21. Pulse generator
22. Cover
23. Cover gasket
24. Spacer
25. Wave spring
26. Pulse rotor
KM 145-9-FL
KM 145-9-FSL
Nm
ft.lbs.
MANUAL
TRANSMISSION
- Transfer
Assembly
30-42
22-30
28
Nm
ft.lbs.
27
.I
5.6-7.2
15-22
11-16
Nm
ftlbs.
\
44
145083
Disassembly
steps
r
27. Snap
<.;
*k
@:+e
%+e
ring
l + 28. Chain cover

l + 29. Chain cover
l + 30. Oil guide
~~
e+
31.
32.
33.
34:*
.,:
gasket
+e
Side cover
Side cover gasket
Lock plate
Counter
gear shaft
42.
43.
l + 44..
45.
46.
l + 47.
l + 48.
49.
Spring
Spring
retainer
Output
shaft assembly
2-4WD shift fork
2.4WD
shift rail
H-L shift fork
H-L clutch sleeve
Needle
bearing.
NOTE
(I)
(2) +e : Refer to Service
;.
y,
(3)
(4)
I)+
m
http://vnx.su/
procedures
to reassemble.
: Refer
to Service
Points
: Non-reusable
parts
of
Reassembly.
.;:-.
.
MANUAL
- Transfer
,j!
TRANSMISSION
Assembly
-;
Disassembly
steps
145084
l + $0. Snap
l + 51. Input
e+
52.
53.
54.
l + 55.
56.
ring
gear assembly
Oil seal
Baffle plate
Dust ieal guide
Oil seal
Transfer
case
i
, .,s-.4
NOTE
(I) Reverse the disassembly
procedures
to reassemble....,?
. .,.*
i^;----rLIIL
parts

33. REMOVAL
OF LOCK PLATE/34.
COUNTER
GEAR SHAFT
Remove the lock plate and pull out the counter gear shaft.
Thrust washer
36. REMOVAL OF COUNTER GEAR/37. THRUST

NEEDLE BEARING/39.
BEARING SPACER
WASHER/38.
Remove the counter gear, two thrust washers, two needle

bearings and the spacer>through the side cover opening.
Counter gear
http://vnx.su/
;I
44. REMOVAL
OF OUTPUT
Remove the front output

together.
SHAFT
ASSEMBLY
shaft, rear output
shaft and chain

55. INSTALLATION
OF OIL SEAL (FRONT OUTPUT
SHAFT)
Apply the specified oil to the lip of the oil seal and pressure
insert it.
Specified
Specified oil
oil
: Hypoid Gear Oil API classification

GL4 or higher SAE viscosity
8OW, 75W85W
144018
52. INSTALLATION
OF OIL SEAL (INPUT GEAR)
Apply the specified oil to the lip of the oil seal and pressure
insert it.
Specified
..
oil
: Hypoid Gear Oil API classification

GL4 or higher SAE viscosity
8OW, 75W85W
xi.<.
i
\t, * ,j <
1
51. INSTAl$&ON
OF INPUT GEAR/SO. SNAP RING
(1) Inset-&e
input gear assembly into the transfer case and
fasten it with the snap ring.
(2) Select the thickest snap ring that will fit into the groove
and install it.
Standard
value
: 0 - 0.06 mm (6 - .002 in.)

> -:.--.
,, Fe.
i.,..
* I,
r
:.
48. INSTALLATKjN.
OF H-L CLUTCH SLEEVE/47.
H-L SHIFT
FORK
.:.
(1) Install the H-L clutch.sleeve
and H-L shift fork
ion
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MANUAL
TRANSMISSION
21-35
Assembly
(2) Make sure the direction of the sleeve is correct. The.direction of the sleeve is the same for both 2WD and 4WD.
Front
Clutch
- Transfer
sleeve
145090
44. INSTALLATION
OF OUTPUT SHAFT ASSEMBLY
(1) Engage the chain precisely with the sprockets of the rear
output shaft and the front output shaft.
(2) Install the 2-4WD shift fork on the 2-4WD clutch sleeve.
While passing them along the 2-4WD shift rail, install the
rear and front output shaft and chain.
Thrust
washer
Counter
39. INSTALLATION
OF BEARING SPACER/38.~NEEDLE
BEARING/37. THRUST WASHER/36.
COUNTER G-EAR
(1) Assemble the needle bearings (2 PCS) in the counter gear,
then after inserting the spacer, install the counter gear
inside the transfer case.
(2) Place thrust washers on the front and rear of the counter
gear.
\.
gear
34. INSTALLATION
OF COUNTER
GEAR SHAFr/33.
LOCK
~I
.. ,..
PLATE
es.: >
1
(1) Insert the counter shaft, being careful of the direction.of
the groove in the locking plate
:J.
,>\\, , ,
(2) Install the lock plate.
,y>
$.,,.
30. INSTALLATION
KET/28. CHAIN
OF OIL GUIDe/29.
COVER
(1) Install the oil guide.

(2) Apply sealant to the gasket,
case.
Specified
_ _
sealant
http://vnx.su/
COVER
GAS-
then affix it to the transfer
1 STB Revision
CHAIN
.:
21-36
MANUAL
TRANSMISSION
- Transfer
Assembly
(3) Install the chain cover so that the end of the oil guide
enters the window in the chain cover.
25. INSTALLATION
OF THE WAVE
COVER GASKET/22.
COVER
SPRING/24.
SPACER123.
(1) Measure the amount of front output shaft rear bearing

thrust (A) and the covers indentation
(B).
If the clearance exceeds 2 mm (.08 in.), insert a spacer
at the place shown in the figure.
(2) Apply a coating of sealant to both surfaces of the cover
gasket, and attach it to the chain cover.
Specified
sealant
(3) Apply a coating of adhesive to the threaded part of the

cover installation
bolt, and then tighten
it.
HWave
spring
4
M i#
Specified
adhesive
: 3M Adhesive
or equivalent
Nut Locking
4171
Spacer
145105
20. INSTALLATION
OF WAVE
COVER GASKET/17.
COVER

(3) Apply adhesive to the threads of the cover installation
bolts and tighten
them.
I I
SPACER/18.
(1) Measure the amount of protrusion of the front output

shaft rear bearing A and the amount of inset in the cover
B. If the clearance is greater than 2 mm (08 in.), insert
a spacer in the location shown in the illustration.
(2) Apply sealant to both sides of the cover gasket and affix
the cover gasket to the chain cover.
Gasket
2E(
SPRING/lS.
Wave
Specified
sealant
Specified
adhesive
spring
Spacer
148011
/ STB Revision
http://vnx.su/
: 3M Adhesive
or equivalent
Nut Locking
4171
ANUAL
Spring
TRANSMISSION
- Transfer
11. INSTALLATION
pin
21-37
Assembly
OF SPRING
PIN
(1) Align the H-L shift fork and shift rail spring pin hole,.and
then use the special tool to drive it in.
(2) Drive in so that the slit is parallel with the axial direction
of the shift rail.
8.
Gasket
INSTALLATION
OF SPACER/7.
REAR COVER GASKET/G.
REAR COVER
(1) Measure the amount of protrusion of the rear output shaft
rear bearing A and the amount of inset in the cover B.
Select a spacer which adjusts the end play to the standard
value.
Standard
value
: 0 - 0.1 mm (0 - .004 in.)
-___
148010
(2) Apply sealant to both sides of the rear cover gasket and
affix the rear cover gasket to the chain cover.
Specified
Extension
housi
2.
Sleeve
INSTALLATION
sealant
OF SPEEDOMETER
GEAR ASSEMBLY
Match the mating marks to the number of teeth on the speedometer

driven gear and install the speedometer
gear
assembly.
Mating marks
1 STB Revision
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21-38
MANUAL
TRANSMISSION
>=
-2
OUTPUT SHAFT ASSEMBLY
.>
DISASSEMBLY
;;.
14,.
- Output Shaft Assembly

NZlMKBA
AND REASSEMBLY
8
72-94
21
ft.lbs.
Disassembly steps
,416. Clutch hub (2-4WD)
17. Stopper plate
l *
18. Bearing
19. Rear output shaft
l *
20. Bearing
21. Front output shaft
I. Chain
l + 2. Snap ring
~~ 3. Clutch hub (H-L)
4. Bearing spacer
5. Low speed gear
6. Needle bearing
~~ 7. Lock nut
l *
8. Radial ball bearing
9. Sprocket spacer
10. Steel ball
II. Drive sprocket
12. Needle bearing
13. Sprocket spacer
14. Steel ball
l *15. Clutch sleeve
NOTE
(2) 40 : Refer to Service Points of Disassembly.
(3) 60 : Refer to Service Points of Reassembly.
(4) q
: Non-reusableparts
I ST6 Revision
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MANUAL
TRANSMISSION
Output
Shaft
21-39
Assembly
n-
8.
REMOVAL
OF RADIAL
BALL BEARING/18.
BEARING
Pull the bearing out using a press.
20. REMOVAL
OF BEARING
Pull out the bearing using a press.
145107
Front
16. INSTALLATION
SLEEVE
OF CLUTCH
HUB
(2-4WD)/15.
CLUTCH
Assemble the hub and sleeve as shown in the illustration.
Hub
2l
eeve
145093
7.
INSTALLATION
OF LOCK NUT
After tightening the lock nut at the proper torque, crimp the
lock nut in the groove in the output shaft at the location shown
148008
1 STB Revision
http://vnx.su/
':
. .
ri
21-40
MANUAL
Front
TRANSMISSION
3.
- Output
INSTALLATION
Shaft
Assembly
OF CLUTCH
HUB (H-L)/2.
(1) Install the clutch hub in the direction

tion.
SNAP RING
shown
in the illustra-
144023
(2) Select the thickest snap ring that will fit into the groove
the front end of the rear output shaft and install it.
http://vnx.su/
in
MANUAL
TRANSMISSION
Input
Shaft
21-41
Assembly
INPUT SHAFT ASSEMBLY

IISASSEMBLY
NZlMlBA
AND REASSEMBLY
Disassembly
l 41.
+**+2.
3.
4.
5.
6.
7.
steps
Snap ring
Bearing
Spacer
Snap ring
Cone spring
Sub gear
Input gear
NOTE
(4) q : Non-reusable parts

2.
REMOVAL
OF BEARING
Support the bearing on a press, then press

input gear and pull out the bearing.
on the front of the
145108

2.
PRESSURE
INSERTION
OF BEARIN&
(1) Pressure inseghe

bearing into th&&put gear. Be sure to
press the..inFe&ace.
(2) After pre,ssure insertion, make sure that the bearing turns
i. *
smoothly.
1.
INSTALLATION
OF SNAP
RING
Select the thickest snap ring that will fit into the grooie
front end of the input gear and install it.
1 STB Revision
http://vnx.su/
in the
21-42
MANUAL
TRANSMISSION
- Speedometer
Sleeve Assembly
SPEEDOMETER SLEEVE ASSEMBLY

IISASSEMBLY
Disassembly
l + 1. Spring
2.
3.
4.
5.
Driven
Sleeve
O-ring
O-ring
NZlRE-C
AND REASSEMBLY
steps
pin
gear
110008
NOTE
(2) l *
: Non-reusable
parts
(3) q

1. INSTALLATION
OF SPRING
PIN
Drive spring pin in while making

gear shaft.
Spring
NOTE
Do not reuse spring pin.
110919
( STB Revision
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N21RHAAZ
sure that slit does not face
MANUAL
TRANSMISSION
- Gearshift
21-43
Lever Assembly
GEARSHIFT LEVER ASSEMBLY

REMOVAL
AND
INSTALLATION
NZlGA-
15-22
Nm
OQW541
Removal steps
1.
2.
3.
4.
+e l + 5.
6.
7.
8.
9.
+e ~~ 10.
11.
12.
13.
14.
15.
16.
~~
Transmission shift lever knob

Front floor console
Control lever cover
Transmission control lever assembly
Gasket
Stopper, plate
Gasket
Control lever bush
Transfer control lever assembly
Gasket
Control housing
Gasket
Front floor console reinforcement
Shift lever boot
NOTE
(1)
Reverse
the removal
procedures
(2)
+e
: Refer
to Service
Points
(3)
*+
: Refer
to Service
Points
(4)
liTJ
: Non-reusable
parts
http://vnx.su/
to
of
of
reinstall.
Removal.
Installation.
21-44
MANUAL
TRANSMISSION
SERVICE
5.
Gearshift
Lever
Assembly
POINTS
OF REMOVAL
NZlGBAD
REMOVAL
OF TRANSMISSION
CONTROL
SEMBLY/TO.
TRANSFER
CONTROL
LEVER
Remove the control lever attaching
control lever assembly.
LEVER ASASSEMBLY
bolts and detach
the
Caution
When the control lever assembly
is removed,
keep the
transmission
control lever and the transfer control lever
in the following
positions.
Transmission
control lever - Neutral
position
2H
(2-wheel
drive - high
range) position
After the control
lever assembly
has been removed,
cover with a cloth to prevent entry of fforeign substances
into the extension
housing.
INSPECTION
Control
lever
I lever
cover
l
NzlGcMl
Check for play between control lever and control lever B. If

play is evident, replace lever assembly.
Push control lever in and check to ensure that it moves
smoothly up and down.
Check the cover for damage and replace if necessary. To remove cover, cut away with knife. To install new cover, first
apply thin coat of oil to periphery of control lever B. Then
install by sliding it down from top of lever B.
Check the lever bushing for wear and replace if necessan/.
SERVICE
POINTS
10. INSTALLATION
SEMBLY
OF INSTALLATION
OF TRANSFER
(1) Check to be sure that the

installation
part (transmission
(2) When
Apply
assembling,
the specified
Specified
sealant
.
--
.,
Control
housing
Specified
ogBoo,
/ ST9 Revision
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grease
LEVER
AS-
transfer lever assembly

side) is at the position
replace the gaskets.

sealant to both sides
of gasket.
(3) Apply the specified

control lever sliding
Ii3
CONTROL
NZlGDAF
grease
surface.
generously
: Multipurpose
NLGI No. 2
grease
to transfer
SAE
J310,
WIANUAL
TRANSMISSION
5.
Gasket
Gearshift
INSTALLATION
ASSEMBLY
Lever
21-45
Assembly
OF TRANSMISSION
CONTROL
LEVER
(1) When assembling, replace the gaskets.

Apply specified sealant to both sides of each gasket.
Specified
sealant
(2) Apply the specified grease generously to both inside

and outside surfaces of lever bushing and control lever
sliding surface.
iousina
I
-knob
Transfer
shift lever
Specified
1
2.
/
/
Nut
Transfer
INSTALLATION
grease
: Multipurpose
NLGI No. 2
OF TRANSFER
SHIFT
grease
LEVER
SAE
5310,
KNOB
(1) After manually screwing the nut all the way to the end
of the threaded part of the shift lever, return it about a
half turn and install the spring washer.
shift lever
09wo32
Vehicle
(2) After turning the shift lever knob about one turn
beyond where the spring washer begins to yield, screw
in further and adjust until the shift pattern on the knob
faces the front of the vehicle.
front
Shift pattern
\
NOTE
If the adjustment cannot be made as described in (2)
above, first screw the shift lever all the way in, and
then return about one turn to make the adjustment.
'
09wo3:
1 STB Revision
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21-46
MANUAL
TRANSMISSION
- Control
Lever
Assembly
CONTROL LEVER ASSEMBLY

DISASSEMBLY
NZlGE-
AND REASSEMBLY
IO-13 Nm
7-9 ftlbs.
Disassembly
l
l
2\
31
steps
1. Bolt
2. Control housing cover
+ 3. Control housing cover gasket
:. 4. Transfer control lever
5. Transmission control lever
+ 6. Gasket
7. Stopper plate
8. Nut
9. Spring washer
41 0. Stopper bracket assembly
11. Return spring
a12. Special bolt
13. Control housing
9----@
8
16-22
11-16
Nm
ft.lbs.
145042
NC)TE
(3) liTJ : Non-reusablepans
INSPECTION
l
Check for play between control lever and control
If
play is evident replace lever assembly.
Push control lever in and check to ensure that it moves
smoothly up and down.
Check cover for damage and replace if necessan/. To remove
cover, cut away with knife. To install new cover, first apply thin
coat of oil to periphery of control lever B. Then install by
sliding it down from top of lever B.
Check lever bushing for wear and replace if necessary.
Control I*
Control lever cover
Spring cover
U21GGAC
Lever bushing
STB Revision
http://vnx.su/
lever B.
MANUAL
TRANSMISSION
- Control
Lever
21-47
Assembly

Stopper
bracket
assembly
NZlGHAF
STOPPER
12. INSTALLAUION
OF
SPECIAL
BOLT/lo.
BRACKET ASSEMBLY
(1) Apply sealant to peripheries (except threaded portions) of
two special bolts and install them to cover. Do not wipe
away excess sealant from cover.
Specified
sealant
(2) Mount stopper bracket assembly and apply sealant

threaded
portions
of special bolts.
Specified
sealant
: 3M Scotch
equivalent
Grip
No.
2353
to
or
(3) Check to ensure that reverse resistance plate moves

smoothly in directions A and B shown in illustration and is
brought back by return spring.
*I
6.
Adz
-_
:
._.
INSTALLATION
OF GASKET/3.
COj@&&WSING
yy=yf
I- e .~g$&r
COVER GASKET
(1) Apply specified
sealant to both su?faF& of thegas5-q; ;,.;c.
kets.
Specified
1 STB Revision
http://vnx.su/
sealant
: 3M ART Part No. 8001 or equiva

lent
16-1
PROPELLER SHAFT
AND
UNIVERSAL JOINTS
CONTENTS
GENERAL
INFORMATION
PROPELLER
SPECIAL
SHAFT
TOOL
SPECIFICATIONS
General
. . . . . . . . . . . . . .. .. . . . . . . . . . . . .. . . .
N16AA--
Lubricants
. . . . . . . . . . . . .. .. .. . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. .. .
Service
Specifications
Torque
Specification
. . . ..*............m...........s............
. . . . . . . . . . . .. .. .. . . . . . . . . . . .. .. . . . . . . . . . . .. . . . . . . . .
. . . . . . . . . .. .. . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . .
Noise
and Vibration
Noise
at Start
Specifications
.._______._._....,.,,,,...,,...,.._.
TROUBLESHOOTING
http://vnx.su/
. . . . . . . . .. . . . . . . . . . . .. .. . . . . . . . . . . .. .
,......................................
. . . . . . . .. .. . . . . . . .. .. . . . . . . . . . . .. .. . . . . .
at High Speed
2
2
2
16-2
PROPELLER SHAFT AND UNIVERSAL
JOINTS
G eneral
Information
/ Specifications
GENERAL INFORMATION
The Z-joint
lubrication.
type propeller
NlGBAAE
shaft has been adopted.
The universal
joint
includes
a grease
nipple
for easy
SPECIFICATIONS
GENERAL
SPECIFICATIONS
N16CA--
Items
Vehicles with a manual

transmission
Vehicles with an automatic

transmission
2-joint type
2-joint type
Propeller shaft
Type
Length
x O.D.
mm (in.)
Front
665 x 50.8(26.2
x 2.0)
741 x 50.8(29.2
x 2.0)
Rear
598 x 71.8 (23.5 x 3.0)
522 x 71.8(20.6
x 3.0)
Cross type
Cross type
Oiled needle roller bearing
Oiled needle roller bearing
14.7 (.58)
14.7 (.58)
Universal joint
We
Bearing
Journal O.D.
mm (in.)
N16CB--
Items
Specifications
Standard value
Journal end play
mm (in.)
0.06 (.0024)
Limits
Propeller shaft runout (Dial indicator
Front
reading)
mm (in.)
0.5 (.OZO)
Rear
0.6 (.024)
TORQUE SPECIFICATION
NlGCC--
Item
1 Flange yoke attaching
Nm
ft. Ibs.
bolts
LUBRICANTS
Items
Universal
joint
Sleeve yoke surface
Specified
Multipurpose
NLGI No. 2
lubricant
grease SAE J310,
Hypoid gear oil SAE80,75W-85W

conforming to API GL4 or higher
( STB Revision
http://vnx.su/
Quantity
As required
As required
PROPELLER SHAFT AND UNIVERSAL
JOINTS-s
pecial
Tool
16-3
/Troubleshooting
SPECIAL TOOL
Tool (Number
and name)
Mi3990840-01
Universal joint
installer set
remover
NlGDA-
Use
Removal and installation
of journal bearing
and
TROUBLESHOOTING
NlGEAAA
Symptom
Probable
Noise at start
Worn
Worn
journal
sleeve
Loose
Noise and vibration
high speed
at
cause
propeller
Unbalanced
Improper
Worn
bearing
yoke spline
shaft installation
propeller
shaft
Reference
page
Replace
16-6
Retighten
16-4
Replace
16-4
Adjust
snap ring selection
journal
Remedy
Replace
bearing
1 STB Revision
http://vnx.su/
the clearance
16-8
7 6-6
16-4
PROPELLER
SHAFT
AND
UNIVERSAL
JOINTS
Propeller
Shaft
PROPELLER SHAFT
REMOVAL
NlIGA--
AND INSTALLATION
Pre-removal
Draining
Operation
of the Transfer
0 Supplying
the Transfer
Transmission
Gear Oil
Gear Oil (Re-
and Transfer
Case.)
50-60 Nm
36-43 ftlbs.
lOG0004
Removal steps
+e
+e
l +
l +
1. Rear propeller
2. Front propeller
NOTE
(2) +I) : Refer to Service Points of Removal.
(3) ~~ : Refer to Service Points of Installation
shaft
shaft
SERVICE
POINTS
OF REMOVAL
N16GBAE
1. REMOVAL
OF REAR PROPELLER
SHAFT/P.
FRONT PROPELLER SHAFT
(1) Place the free wheel hubs in the FREE position and set
the transfer lever to 2H.
(2) Make mating
marks on the flange
yoke and the
differential
companion
flange.
evision
http://vnx.su/
\tic
PROPELLER
SHAFT
AND
UNIVERSAL
Propeller
16-5
Shaft
Caution
1. Be careful not to damage the lip of the transmission oil seal or the lip of the transfer case oil seal.
2. Do not allow foreign matter to enter the transmission or transfer.
Front
Lip
JOINTS
l@
09w529
091528
INSPECTION
l
l
l
N16GCAB
Check the sleeve yoke and flange yoke for wear, damage
or cracks.
Check the propeller
shaft yokes for wear, damage
or
cracks.
Check the propeller shaft for bends, twisting or damage.
Check the
directions.
universal
joints
CHECKING
PROPELLER
Measure propeller
shaft
Limits
Front propeller
Rear propeller
SERVICE
2.
0.5 mm
0.6 mm
1 STB Revision
http://vnx.su/
(.020
(.024
gear oil
in all
in.)
in.)
OF INSTALLATION
INSTALLATION
OF FRONT
PROPELLER
SHAFT
lOGO
operation
SHAFT RUNOUT
runout with a dial indicator.
shaft
shaft
POINTS
Specified
for smooth
PROPELLER
hypoid
NlGGDAC
SHAFT/l.
REAR
gear oil to the sleeve yoke.
: Hypoid gear oil API classification

GL-4 or higher/SAE
viscosity
8QW, 75W85W
16-6
PROPELLER
SHAFT
AND
UNIVERSAL
JOINTS
Propeller
Shaft
(2) With the mating marks in alignment,

ler shaft to the companion
flange.
install
the propel-
Caution
Degrease
the thread of the mounting
bolts and nuts
before tightening
these parts. Otherwise,
they could
become loose.
DISASSEMBLY
AND
Front
REASSEMBLY
propeller
NlGGE-
shaft
Rear propeller
Disassembly
l +
4*
+w
l +
l +
l +
shaft
steps
Adjustment
of journal
1. Snap ring
2. Grease nipple
3. Journal bearing
4. Journal
5. Flange yoke
6. Sleeve yoke
end play
lOW501
NOTE
(1)
(2)

+e : Refer to Service
(3) ~~ : Refer to Service
SERVICE
POINTS
1. REMOVAL
procedures
to reassemble
OF DISASSEMBLY
N16GFAC
OF SNAP RING
(1) Make mating marks on the yokes of the universal joint

that is to be disassembled.
(2) Remove the snap rings from the yoke with snap ring
pliers.
Caution
When disassembling,
note the positions
of snap
rings so that they may be reinstalled
in the same
positions.
3.
REMOVAL
OF JOURNAL
BEARING
(1) Remove the journal bearing from the propeller

yoke with special tool.
Revision
http://vnx.su/
shaft
PROPELLER
SHAFT
AND
UNIVERSAL
JOINTS
(2) Remove the other journal

as described above.
16-7
Shaft
Propeller
bearing
in the same
NOTE
If the journal bearing is hard to remove,
with a plastic hammer
as illustrated.
manner
strike the yoke
YlOOOS
SERVICE
4.
POINTS
INSTALLATION
OF REASSEMBLY
OF JOURNAL/3.

0
0
0
lQY6cK
JOURNAL
grease to the following
Shafts and grease sumps

Dust seal lips
Needle roller bearings
Specified
grease
N16GHAC
BEARING
parts;
of journal
: Multipurpose
NLGI No. 2
grease
SAE
J310,
Caution
Use of excessive amounts
of grease may result in
difficulty
in assembling
unit and incorrect
selection
of snap rings.
NOTE
When the journal
obtain the universal
(2) Press the journal

as illustrated.
and journal
joint kit.
bearing
propeller
shaft
2.
INSTALLATION
OF GREASE
With the grease nipple

tion, install it properly.
Rear propeller
shaft
1 STB Revision
http://vnx.su/
are replaced,
to the yoke with special
NOTE
Be sure to align the mating
Front
bearing
tool
marks on the yokes.
NIPPLE
directed
as shown
in the illustra-
PROPELLER
SHAFT AND
UNIVERSAL
.
JOINTS
ADJUSTMENT
- Propeller
OF JOURNAL
END PLAY
(1) Install snap rings of the same thickness

each yoke with snap ring pliers.
(2) Press the bearing

bar.
and journal
Shaft
onto both sides of
into one side with the brass
(3) Measure
the clearance
shown in the illustration
with a
feeler gauge. If the clearance exceeds the standard value,
the snap rings should be replaced.
Standard
value
: 0.06 mm (.0024 in.)
lOBOOl5
1 STB Revision
http://vnx.su/
3-1
CONTENTS
,
.*
NOBAA!,
,
AXLE ASSEMBLY
AXLE SHAFT
......................................................
DIFFERENTIAL
GENERAL
SERVICE
..............................................
CARRIER
INFORMATION
20
22
...................................
27
.................................
PROCEDURES
..........
Axle Shaft for End Play ....................
Gear Oil Level ..................................
Rear Axle Total Backlash
.................
17
17
Limited Slip Differential

Preload
.................................................
Measurement
Replacement
of Axle Housing Oil Seal ...........
18
18
Checking
Checking
Checking
SPECIAL
ADJUSTMENT
TOOLS
................................................
SPECIFICATIONS
General
...............................................
....................................
Specifications
.......................................................
Lubricants
......................................
Sealant and Adhesive
.....................................
.....................................
14 i.
. . . . . . .. . . . . . . . . . . ..*................m..
TROUBLESHOOTING
AXLE SHAFT, AXLE HOUSING
. . . . . . . . .. .. . . . . . . .. .. . . 14 <;,
17
17
12
9
9
11
11
10
11
http://vnx.su/
Grease Leakage
Noise While Wheels
$
are Rotating
DIFFERENTIAL
(CONVENTIONAL
DIFFERENTIAL)
. . . . .. . . . . . . . . . . .. . . . . . . . . . .. .. . . . . . . . . .. . . . . 14
Bearing Noise While Driving or Coasting
Constant Noise
Gear Noise While
Coasting
Gear Noise While Driving

Heat
Noise While Turning
Oil Leakage
DIFFERENTIAL
(LIMITED SLIP
.. . . . . . . . . . . .. .. . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . 15
DIFFERENTIAL)
)0
*.i.
Abnormal Noise during Driving or Gear
i
Changing
i: ;!..
..(
Abnormal Noise When Cornering
l
:
.:
Breakdown
in, :
Gear Noise
!$..
I.
Gear Oil Leakage
- ii
Seizure
Limited Slip Differential Does
not Function
3-2
REAR AXLE
General
Information
GENERAL INFORMATION
N03BAAB
The banjo-type,
semi-floating
type of rear axle has been adopted.
In order to improve the river-crossing
ability of this model, a vent hose has been installed from the axle
housing, and a differential
breather (air bleeder) has been used within the frame crossmember.
There are two types of differential;
conventional
differential
and limited slip differential.
The limited
slip
differential
is of great help when driving on muddy and other slippery ground.
Axle housing
llW508
1 STB Revision
http://vnx.su/
REAR AXLE
LIMITED
General
3-3
Information
SLIP DIFFERENTIAL
NOBBBAB
A limited slip differential

is an anit-slipping
device which functions as a differential during cornering to allow
the outer wheel to turn at a faster speed than the inner wheel. In the event that one wheel begins spinning
(driving on slippery road surfaces, one wheel leaves the road surface, etc.), it automatically
functions
to
prevent such spinning.
CONSTRUCTION
AND FUNCTION
With a conventional
differential,
in the event that one wheel of the vehicle is on ice, mud, or some other
slippery surface, the wheel will spin and the drive force of the vehicle will be greatly reduced. If this
happens, the speeds of the differential
case and of the side gear (axle shaft) are different because of
differential
operation.
The limited slip function acts to limit this differential
operation.
The construction
is
The multi-plate
clutches engage with the differential
case and with each of the side
gears. If spinning causes a differenece
in component
speeds, the frictional force between the clutch plates
will cause the speed of the side gear to become closer to that of the differential
case, and thus the limited
slip function will control the spinning.
In addition, the purpose of the pressure rings inside the differential
case is to transmit the driving force to the pinion gear, and the reason for the separation
is to provide an
increase in the clutch plate pressing force through the leverage of the pinion shaft.
Pinion
Pinion
shaft
Differential
Friction
lifferential
shaft
\ Pressure
case (A)
disc
case
Friction
) STB Revision
http://vnx.su/
disc
ring
3-4
REAR AXLE - Gieneral Information
OPERATION (TORQUE TRANSMISSION)
DURING STRAIGHT DRIVING
When the differential

case is turned the drive pinion via the drive gear, the pressure rings which are
interlocked
with the differential
case will also turn at the same speed. (The projections
located on the
outside of the pressure rings engage (with some platy) the grooves located on the inside of the differential
case). When the pressure rings move in the direction of rotation, they contact the tapered portion of the
pinion shaft, and thereby receive reaction force in both the lateral direction and the direction of rotation. The
reaction force in the lateral direction
presses the c:lutch plates together,
and maintains
straight driving.
During such driving, because the road surface gives equal resistance to both the left and right wheels, equal
resistance
is applied to the left and right side gears. Therefore, the pinion gear does not revolve, and the
drive gear, the differential
case, the pinion shaft, the pinion gear, and the left and right side gears all turn as
one unit.
Left pressure
ring
Right pressure
ring
-f-----T
Direction of rotation
of the pressure ring
during straight driving
$y~~;no*>
Direction of rotation
of the txessure ring
during straight drivkg
Reaction force symbol

code
P = Pressing force of the
pressure rings
on the clutch plates
F = Pressing force of the
pressure rings
on the pinion shaft
N = ys;ltant.
force of P
llF108
1 STB Revision
lS652
--A
http://vnx.su/
REAR AXLE - General
3-5
Information
OPERATION
(TORQUE
TRANSMISSION)
WHEN THE SPEEDS OF LEFT AND RIGHT WHEELS
ARE
DIFFERENT
When one wheel is in contact with a concrete road surface (which has high coefficient
of friction) and the
other wheel is in contact with a muddy or other slippery road surface (which has low coefficient
of friction),
the differential
operation will cause the speed of the wheel in contact with the slippery surface to be faster
than the speed of the drive gear, lowering the maximum
drive force. If this occurs, the limited slip function
will control the differential
operation and increase the driving force. The transmission
of torque through the
limited
slip device in this event is as follows:
case is turned by the drive gear and the drive pinion, the pressure rings which are
interlocked
with the differential
case will turn at the same speed. Also, the difference
in the road surface
resistances will cause differential
operation and the left and right side gears will revolve at speeds different
from that of the differential
case. Because of the friction produced between the clutch plates in mesh with
both the side gear and differential
case, one of the pressure rings increases its rotating speed, whereas the
other reduces its rotating speed. The pressure rings press the tapered portion of the pinion shaft with which
they are in contact, and thereby receive reaction force in both the lateral direction
and the direction
of
rotation. The reaction force in the lateral direction causes the clutch plates to mesh, increasing the frictional I:
and the drive force.
Left
ring
frictional
pressure
Right
ring
pressure
ring
Low-speed
50 + 15
force
F;flsing
side
65%
High-speed
50 - 15
symbol
P,P
F,F
= Pressing force of
N.N
Pressing
pressure
on the
force
force
rings
clutch
of
the
plates
the
pressure
rings
on the pinion
shaft
= Resultant
force
of P +
F and P + F
llF109
1 STB Revision
http://vnx.su/
llW511
side
35%
3-6
REAR AXLE - General
Information
FEATURES
OF LIMITED
SLIP DIFFERENTIAL
(1) When one wheel of the vehicle is in contact with ;3 road surface which has poor traction, the limited slip
differential,
in comparison
to a conventional
differential,
supplies additional
torque to the wheel which
has the better traction conditions
by utilizing clutch plates, thus improving
the traction
capacity.
Moreover, the effect of the limited slip differential
is to prevent the vehicle from becoming
stuck, even if
the traction of one of the wheels becomes
radically reduced.
(2) When one wheel moves from a road surface which has poor traction onto one which has good traction,
or when the wheels are constantly
leaving the road surface while driving on a rough, bumpy road, the
clutch plates of the limited slip differential
allow the torque to absorb the differences
between the
revolution speeds of the right and left wheels. In addition, the sudden changes (jolting) in the drive force
are also absorbed,
thus preventing
skidding.
(3) Because in the limited
slip differential,
the differential
operation
is slightly restricted
during normal
cornering, the understeer tendency (the tendency for the cornering of the vehicle to exceed the turning
of the steering wheel) becomes
greater; however, this does not have any detrimental
effect on the
17
driving of the vehicle. Moreover,
in the event that the inside wheel lifts up (the tire leaves the road
.
c,
.,
surface) during high speed cornering,
the clutch plates function to limit differential
operation
which
the limited
slip
would simultaneously
decrease
the drive force,= of the outside wheel; therefore,
i
differential
moderates
sudden speed reductions
during vehicle cornering, and thereby provides greater
i $ cornering
capability
than a conventional
differential.
Id
pTB
Revision
http://vnx.su/
..
I.
REAR AXLE - General

MAKING
EFFECTIVE USE OF LIMITED
Effective
Use
in Combination
with
SLIP
Brakes
Information
3-7
DIFFERENTIAL
If a wheel is in contact with a slippery road surface and has begun to spin, using the brakes in combination
with the limited slip differential
will provide even greater traction capability. The resistance caused by the
brakes will further increase the drive torque of the engine, and this increased torque will increase the clutch
plate pressing force of the pressure ring, thus increasing the traction. Also, the drive force transmitted
to the
brakes will not function
as real drive force. This is shown in the illustration
below.
In the illustration,
the application
rate is Rt = 2, and, supposing the torque from the brake operation is 1. a
drive torque of 1 + 1 = 2 will be applied to the spinning wheel (the right wheel), and a drive torque of twice
that which is applied to the spinning wheel, or (1 + 1) x 2 = 4, will be applied to the wheel which is not
spinning (the left wheel). However, because the brake force of 1 is a negative value with regard to the
propulsion
torque of each wheel, the propulsion
torque actually obtained by the right wheel is (I + 1) - 1
= 1, and that obtained
by the left wheel is [(I + 1) x 2 - I] = 3.
Therefore,
the total drive torque is 1 + 3 = 4. In the same circumstances,
the total drive torque of a
conventional
differential
is 1 + 1 = 2, and that of a limited slip differential when the brakes are not used in *.,
combination
is 1 + 2 = 3. This represents
an increase in the traction by a factor of 2 over that of a.?
conventional
differential,
and by a factor of 1.3 over that of a limited slip differential when the brakes are not,
used.
,..1.
Total drive torque
Torque
doubling
rate
..::::.,:::::.
*I.
Negative torque from

the brake operation
2. Supposing
that the
braking torque for
both wheels is 1.
llF103
1 STB Revision
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3-8
NOTES
REAR AXLE
REGARDING
SERVICE
PROCEDURES
- General
Information
FOR LlMlTED
SLIP
DIFFERENTIAL
(1) The engine must never be operated while only a single wheel is jacked up. Doing so is extremely
dangerous;
if the differential
functions while the engine is operated at high speed, the oil film between
the clutch plates will decrease, thus causing the friction coefficient
to increase, the prescribed torque
ratio will be exceeded, an excessive amount of torque will be applied to the stationary wheel, and the
vehicle will move forward. Also, resistance
must never be applied to the spinning
wheel.
(2) In the event that one of the wheels comes in contact with a slippery road surface and begins to spin, if
the engine continues
to be operated
at high speed for too long, the clutch plates might become
abnormally
worn; such action must be avoided.
(3) As gear oil, use MITSUBISHI
Genuine Gear Oil (part number 8149630 EX) or equivalent.
MITSUBISHI
Genuine Gear Oil was especially developed
for limited-slip
differential
use, and is different from ordinary
gear oil. When changing the oil, the oil which is removed will appear considerably
blacker than ordinary
oil. This, however, is not a change in color due to the deterioration
of the oil, but rather the oil has
mixed with worn particles of the special treatment
on the clutch plates.
*11\*7,?d become
1 STB Revision
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3-9
REAR AXLE - Specifications
SPECIFICATIONS
GENERAL
M13cA.-
SPECIFICATIONS
Items
Axle housing type
Vehicles with conventional

differential
Vehicles with limited slip

differential
Banjo type
Banjo type
Semi-floating type
Semi-floating type
40 (1.57)
40(1.57)
34.5 (1.358)
34.5 (1.358)
703.5 (27.700)
703.5 (27.700)
80 x 40 x 19.75
(3.15 x 1.57 x .7776)
80x40x
19.75
(3.15 x 1.57 x .7776)
Axle shaft
Supporting type
Shaft dimensions
Bearing portion dia.
Center portion dia.
Overall length
mm (in.)
mm (in.)
mm (in.)
Bearing
O.D. x I.D. x width
mm(in.)
Differential
Reduction gear type
Reduction ratio
Hypoid gear
Hypoid gear
4.625
-
4.625
Side gear
Straight bevel gear x 2
Pinion gear

Drive gear
Drive pinion
37
37
Side gear
Pinion gear
14
10
16
Differential lock type
Disc type
Differential gear type and

configuration
Number of teeth
10
1 STB Revision
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3-10
REAR AXLE -- Specifications
Vehicles with conventional
differential
Vehicles with limited slip

differential
0.05-0.20
-
0.05-0.20
Items
Standard values
Axle shaft end play
mm (in.)
(.0020--.0079)
Limited slip differential preload

(on Vehicle)
Nm (ft.lbs.)
Parking brake lever stroke
4-6 clicks
Final drive gear backlash
0.1 I-0.16(.0043--.0063)
Differential
mm (in.)
mm (in.)
gear back lash
(.0020-.0079)
35 (25) ol: more
0.1 O-O.25 (.0004--.0098)
4-6 clicks
O.ll-0.16(.0043-.0063)
-
0.4-0.5 (3.5-4.3)
0.4-0.5 (3.5-4.3)
0.65-0.75
-
0.65-0.75
, Drive pinion turning torque

;2
[
without
oil seal
with oil seal
Nm (in. Ibs.)
Nm (in. Ibs.)
Difference in total thickness

between left and right clutch
plates
mm (in.)
.
Clearance between
and the differential
the clutch plates

case
mm (in.)
(5.6-6.5)
(5.6-6.5)
0.05 (.0020) or less
0.06-.20
Difference in distances from backs

of left and right pressure rings to
end of thrust washer
mm (in.)
0.05 (.0020) or less
Clearance of the side gear

in the axial direction
mm (in.)
0.05-0.20
When equipped with new clutch

plates
Nm (ft. Ibs.)
65-l 00 (47-72)
When equipped with old clutch

plates
Nm (ft. Ibs.)
35-100 (25-72)
Rear axle total backlash

mm (in.)
5 (.20)
5 (.20)
Drive gear runout
0.05 (.0020)
0.2 (.008)
0.05 (.0020)
-
Friction plates and friction discs

warpping (flatness)
mm (in.)
0.08 (.0031)
Friction plates and friction discs

wear (difference in thicknesses
of friction surfaces and
projections)
mm (in.)
0.1 (004)
Limited slip differential
(.0024-.0079)
(.0020-.0079)
preload
Limits
Differential
mm (in.)
mm (in.)
gear backlash
1 STB Revision
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3-11
REAR AXLE - Specifications

TORQUE SPECIFICATION
NOBCG-
Items
Shackle assembly
attaching
Nm
nut
ft. Ibs.
45-60
33343
18825
85-l 10
13-18
61-80
13-17
9-12
50-60
36-43
36-43
Rear axle bearing lock nut

Filler plug
50-60
180-220
40-60
Drain plug
60-70
43-5 1
Differential carrier to rear axle housing

Companion flange
25-30
1go-250
18-22
137-181
Differential case to drive gear

Bearing cap
80-90
55-65
58-65
i
i
Lock plate
15-22
II-16
Shock absorber
attaching
U-bolt attaching
nut
nut
Brake tube flare nut

Propeller shaft attaching
nut
Bearing case to rear axle housing
130-I 59
29-43
40-47
LUBRICANTS
Items
-.
Specified
lubricants
Quantity
Rear axle gear oil

Hypoid gear oil API classification
GL-4
or higher/SAE viscosity No. 90,8OW
1.80 lit. (3.80 U.S.pints.,

3.20 Imp.pints.)
MITSUBISHI Genuine Gear Oil Part No.

8149630 EX or equivalent
1.80 lit. (3.80 U.S.pints.,

3.20 Imp.pints.)
Axle housing oil seal
Multipurpose
NLGI No. 2
grease SAE J310,
As required
Axle shaft bearing
Multipurpose
NLGI No. 2
grease SAE J310,
As required
Axle shaft oil seal
Multipurpose
NLGI No. 2
grease SAE J310,
As required
Axle shaft thread portion
Multipurpose
NLGI No. 2
grease SAE J310,
As required
Differential
carrier oil seal lip
Multipurpose
NLGI No. 2
grease SAE J310,
As required
Companion
flange washer
Multipurpose
NLGI No. 2
grease SAE J310,
As required
Conventional
differential
Limited slip differential
SEALANT
AND ADHESIVE
Item
Specified
Axle shaft shim

Differential
3M ART Part No.8663,8661
carrier gasket
Drive gear threaded
hole
or equivalent
3M ART Part No.8663,8661 or equivalent

3M Adhesive stud locking 4170 or equivalent
Quantity
As required
As required
As required
IYL
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3-12
REAR AXLE -- Special Tools
SPECIAL TOOLS
NOBDA--
Tool (Number
Removal of axle shaft
e housing
and name)
M B990799-0 1
Axle bearing remover and
installer
Pressing of axle shaft

bearing inner race
Adjustable
Removal and
adjustment of side
wrench
M B990339-0 1
Pinion carrier bearing puller
bearing outer race
Pressing of axle shaft oil
Pressing
Use
Removal of side bearing

inner race
Removal of drive pinion
rear bearing inner race
of drive pinion

inner race

bearing outer race
Pressing of axle shaft oil
front bearing outer race

Lock nut spanner

inner race
wrench
bearing and bearing
MB99081 I-01
Side bearing cup remover
remover
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inner race
REAR
AXLE - Special
3-13
Tools
Use
Use
Tool (Number
M B990767-0 1
End yoke holder
Holding of companion
flange
MIT3041 80
Handle
Pressing
oil seal
of drive pinion
MB990901-01
Pinion height gauge set
Measurement
height
MB990031-01
Drive pinion oil seal installer
Pressing
oil seal
of drive pinion
MB990802-01
Bearing installer
Pressing of drive pinion

Pressing of side bearing
inner race
M B990988
Side gear holdins tool
Measurement
of limited
slip differential preload
Tool (Number
and name)
of pinion
and name)
- r-1
Tool
A
-J
389
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3-14
REAR AXLE -Troubleshooting
TROUBLESHOOTING
NOBEAAA
Probable cause
Remedy
Reference
paw
Noise while wheels

are rotating
Brake drag
Bent axle shaft
Worn or scarred axle shaft bearing
Replace
3-22
Grease leakage
Worn or damaged oil seal

Malfunction of bearing seal
Replace
3-22
Improper final drive gear tooth contact

adjustment
Loose, worn or damaged side bearing
Loose, worn or damaged drive pinion
bearing
Correct or replace
3-29
Worn drive gear, drive pinion

Worn side gear thrust washer or pinion
shaft
Deformed drive gear or differential case
Damaged gear
Replace
3-32,35
Foreign material
Eliminate the foreign material

and check; replace the parts if
necessary
3-32,35
No oil
Fill or change
3-17
Poor gear engagement

Improper gear adjustment
Improper drive pinion preload adjustment
Correct or replace
3-29,37
Damaged gear
Replace
3-32,35
Foreign material

necessary
3-32,35
Insufficient
Fill or change
3-17
Symptom
AXLE SHAFT,
AXLE HOUSING
DIFFERENTIAL
[CONVENTIONAL
DIFFERENTIAL)
Constant
noise
?.
Gear noise while
driving
Gear noise while

coasting
oil
3-32,351
Improper
drive pinion preload adjustment
Correct or replace
3-37
Damaged
gear
Replace
3-32,35
Replace
3-32, 35
Bearing noise while

driving or coasting
Cracked
bearing
or damaged drive pinion rear
Noise while turning
Loose side bearing

Damaged side gear, pinion gear or pinion
shaft
Replace
3-32, 35
Heat
Improper gear backlash

Excessive preload
Adjust
3-29
Insufficient
Fill or change
3-l 7
oil
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REAR
Symptom
Oil leakage
3-15
-Troubleshooting
Remedy
Reference
paw
Clean or replace
3-20
Retighten, apply sealant, or

replace the gasket
3-27
Replace
3-32,35
Excessive
Adjust the oil level
3-17
Probable cause
Clogged breather
Cover tightened
Seal malfunction
DIFFERENTIAL
(LIMITED SLIP
DIFFERENTIAL)
Abnormal noise
during driving or
gear changing
AXLE
hose
not
oil
h ..A
.r
Excessive final drive gear backlash

Insufficient drive pinion preload
Adjust
3-29,47
Excessive
Adjust or replace
3-29
Replace
3-42.45
differential
gear backlash
Worn spline of a side gear

Loose spline coupling self-locking
nut
Retighten
or replace
3-42.45
NOTE
In addition to a malfunction of the differential carrier components,
abnormal noise can also be caused by the
universal joint of the propeller shaft, the axle shafts, the wheel bearings, etc. Before disassembling
any parts, take
all possibilities into consideration
and confirm the source of the noise.
. Abnormal noise
when cornering
Gear noise
Damaged differential gears

Damaged pinion shaft
Nicked and/or abnormal wear of inner and
outer clutch plates
Poor gear oil
Abnormally worn or damaged thrust
washer
Replace
3-42.45
3-51
Improper
Refill or replace
3-17
Improper final drive gear tooth contact

adjustment
Adjust or replace
3-29
Incorrect final drive gear backlash

Improper drive pinion preload adjustment
Adjust
3-29.47
Damaged, broken, and/or seized tooth

surfaces of the drive gear and drive pinion
Damaged, broken, and/or seized drive
pinion bearings
Damaged broken, and/or seized side
bearings
Damaged differential case
Poor gear oil
Replace
3-42,45
Improper
Refill or replace
3-17
gear oil quantity
gear oil quantity
NOTE
Noise from the engine, muffler vibration, transmission,
propeller shaft, wheel bearings, tires, body, etc., is easily
mistaken as being caused by malfunction in the differential carrier components.
Be extremely careful and attentive
when performing the driving test, etc.
Test methods to confirm the source of the abnormal noise include: coasting, acceleration, constant speed driving,
raising the rear wheels on a jack, etc. Use the method most appropriate to the circumstances.
1 STB Revision
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.>
i$ : .,
r -( ,..
._
,._-
I.
3-16
Symptom
Gear oil leakage
Seizure
REAR AXLE -Troubleshooting

Probable cause
Remedy
Reference
page
Worn or damaged front oil seal, or an

improperly installed oil seal
Damaged gasket
Replace
3-42,45
Loose spline coupling self-locking
Retighten
or replace
3-42,45
Loose filler or drain plug
Retighten
or apply adhesive
3-27
Clogged or damaged
Clean or replace
3-20
Improper final drive gear backlash

Excessive drive pinion preload
Excessive side bearing preload
Improper differential gear backlash
Excessive clutch plate preload
Adjust
3-29,47,
Improper
gear oil
Replace
3-17
Improper
gear oil quantity
Refill or replace
3-17
nut
breather hose
NOTE
In the event of seizure, diassemble and replace the part:s involved, and also be sure to check all components
any irregularities and repair or replace as necessary.
Breakdown
incorrect
Incorrect
Incorrect
Excessive
Incorrect
final drive gear backlash

drive pinion preload
side bearing preload
differential gear backlash
clutch plate preload
Loose drive gear clamping

Operational
clutch
malfunction
bolts
due to overloaded
Adjust
3-29,47,5
Retighten
3-42,45
Avoid excessively
operation
rough
I
NOTE
In addition to disassembling
and replacing the failed parts, be sure to check all components
repair or replace as necessary.
The limited slip device is damaged
/ STB Revision
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for
for irregularities
and
51
REAR AXLE
- Service
Adjustment
3-17
Procedures
SERVICE ADJUSTMENT
CHECKING
llY503
REAR AXLE
PROCEDUREEZ&
TOTAL
BACKLASH
If the vehicle vibrates and produces a booming

sound due to
the unbalance of the drivetrain, use the following procedure to
measure the rear axle total backlash to see if it is necessary to
remove the differential
carrier. assembly.
(1) Park the vehicle on a flat, level surface.
(2) Set both the transmission
shift lever and the transfer shift
lever to neutral.
(3) Chock the wheels.
NOTE
If the vehicle is to be raised on a lift, engage
brake to lock the wheels.
the parking
,.
>.
r;
(4) Manually turn the propeller shaft clockwise as far as it will:

go and make mating marks on the companion
flange dust:
cover and the gear carrier.
(5) Manually turn the propeller shaft couterclockwise
as far as t i
it will go and measure the movement
of the mating marks.
Limit
: 5 mm
(.20 in.)
(6) If the backlash exceeds the limit,

carrier assembly
and adjust it.
CHECKING
AXLE
SHAFT
remove
the differential
FOR END PLAY
NOBFBAB
1. Jack up the vehicle and remove the rear wheels.

2. Remove the brake drums.
I
3. Measure
the axle shaft end play with a dial indicator.
4. Pull the axle shaft all the way out and note the end play
indication
on the dial indicator.
Standard
5.
value
: 0.05-0.20
mm
(.0020-.Od79
in.)
If the axle shaft end play exceeds the standard

value,
withdraw the axle shaft, and then adjust to the standard
value by changing
the shim thickness.
(Refer to P.3-26.)
,;
\ :
CHECKING
GEAR OIL LEVEL
NOJFCAC
1. Remove the filler plug, and check the oil level.

2. The oil level is sufficient if it reaches the levei plug hole.
Specified
gear oil:
Conventional
differential
Hypoid gear oil API classification
GL-4 or higher/SAE
viscosity
No. 90, 80W
[1.80 lit. (3.80 U.S.pints.,
3.20 Imp.pints.)]
Limited
slip differential
MITSUBISHI
Genuine
Gear Oil Part No. 8149630 EX
or equivalent
[1.80 lit. (3.80 U.S.pints.,
3.20 Imp.pints.1
1 STB Revision
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(1.
3-18
REAR AXLE - Service
Adjustment
LIMITED
SLIP
SUREMENT
Procedures
DIFFERENTIAL
PRELOAD
MEANOJFDAD
1. To rneasure the preload of the limited slip differential,

set
the shift lever of the transmission
to the neutral position,
lock the front wheels, and fully release the parking brake.
One of the rear wheels should be maintained
in contact
with the ground surface, and the other should be raised
up.
2. Measure the axle shaft turning torque at the side on which
the wheel is raised position
by using the following
procedure:
(1) Remove the wheel.
(2) Mount the special tool to the hub bolts with the hub
nuts,
preload by measuring
(3) Find the limited slip differential
the axle shaft turning torque in the forward direction
with a torque wrench.
NOTE
Esefore measuring
the turning
torque,
shaft to remove any initial resistance.
Standard
value
: 35 Nm
(25 ftlbs.)
turn
the
axle
or more
(4) If the turning torque is less than the standard value,

remove the limited slip differential
from the vehicle and
repair it. (Refer to P.3-45.)
REPLACEMENT
OF AXLE
1. Disconnect
the parking
and then remove
the
cables. (Refer to GROUP
..
:.
1
NOTE
Do not disconnect
connection.
HOUSING
OIL
S$All~
brake cables from the equalizer

clamps
from the parking
brake
5 BRAKES - Parking Brake Cable.)
the parking
brake cable and rear brake
2. Before disconnecting
the brake tube, drain the brake fluid
from the bleeder screw at the left side of the rear brake.
3. Pull the rear axle shaft with rear brake assembly attached.
If the rear axle shaft is hard to remove, use the special
tools.
/B
Revision
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REAR AXLE
- Service
Adiustment
4. Use special
tool with hook attached
5. Apply the specified

rear axle housing.
Specified
3-19
Procedures
grease
to remove
grease to the oil seal fitting
the oil seal.
area of the
..t.*
: Multipurpose
No. 2
grease
SAE J310,
6. Drive the new oil seal into the rear axle housing
using the special tools.
7. Apply the specified grease to the oil seal lip.
Specified
grease
: Multipurpose
No. 2
grease
Standard
value
(Refer to GROUP
dures.) *
BSTB Revision
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end by;,,,.,
:r,.
. .
SAE J310,
8. Adjust the clearance between the bearing case

axle housing end. (Refer to P.3-26.)
9. Install the rear axle shaft assembly to the rear axle
10. Connect the brake tube and bleed out the air.
GROUP 5 BRAKES-Service
Adjustment
Procedures.)
11. Connect the parking brake cable, and adjust the
the parking brake lever.
NLGl
NLGl
and rear
housing.
(Refer to
,.
stroke
of
: 4-6 clicks
5 BRAKES-Service
Adjustment
Proce-
3-20
REAR AXLE -- Axle Assembly
AXLE ASSEMBLY
REMOVAL
N03GA-
AND INSTALLATION
33-43
ft.lbs.
l 45-60
3343
I
I
Nm
ftlbs.
Ii
85-l 10 Nm61-80 ft.lbs.
llW602
85-l 10 Nm
61-80 ft.lbs.
j18-25 Nm
13-18 ft.lbs.
Post-installation
Operation
Air Bleeding from Brake Lines (Fiefer to GROUP 5 BRAKES - Service
Adjustment
Procedures)
l
Adjustment
of Parking Brake Lever
Stroke (Refer to GROUP 5 BRAKES
Procedures)
l
Removal steps
l *
ae
I)+
1. Adjuster
(Parking
brake cable)
2. Parking
brake cable attaching
bolts
3. Parking
brake cable heat protector
(right side only)
4. Connection
of parking
brake cables
equalizer
5. Connection
of brake hose
6. Connection
of breather
hose
7. Rear propeller
shaft
4*
l +
4*
and
8. Connection
of shock absorbers
part only)
9. U-bolts and bump stopper
10. Shackle
assembly
11. Axle assembly
(lower
NOTE
(3) l + : Refer to Service Points of installation.
(4)
The
part
with
lowered
to the
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* must
ground.
be
tightened
with
the
vehicles
REAR AXLE
- Axle
3-21
Assemblv
N03GBAB
5.
DISCONNECTION
OF BRAKE HOSE
Before disconnecting
from the bleeder screw at the right side of the rear brake.
7.
REMOVAL
OF REAR
PROPELLER
SHAFT
Make the mating marks on the flange yoke of the rear

propeller shaft and the companion
flange of the differential
case.
9.
REMOVAL
OF U-BOLT AND BUMP STOPPER
IBefore removing the U-bolt and the bumper stopper, place
the jack underneath
the center of the axle assembly
to .6
x
hold it slightly upward.
h
%,I.,
,L
I*,
11. REMOVAL
OF AXLE ASSEMBLY
Draw out the axle assembly toward the reaf of the vehicle..
li3,
iv! ,,,,.
Caution
The axle assembly
is unstable on the jack; be careful not
to allow it to fall.
SERVICE
POINTS
OF INSTALLATION
10. INSTALLATION
OF SHACKLE
ASSEMBLY
Install the shackle assembly from the outside
inside of vehicle.
c3
Inside
vehicle
of
7.
NOBGDAB
toward
the
INSTALLATION
OF REAR PROPELLER
SHAFT
Align the mating
marks on the flange yoke and the
companion
flange to install the rear propeller
shaft.
12w514
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3-22
REAR AXLE - Axle Shaft
AXLE
SHAFT
REMOVAL
AND l.NSTALLATlON
180-220
130-159
NO3HA-
Nm
ftlbs.
Post-installation
ODeration
l
Air Bleeding from Brake Lines (Refer to GROUP 5 BRAKES - Service
Adjustment
Procedures)
l
Adjustment
Procedures)
Removal steps
94
1. Adjuster
(Parking
brake cable)
2. Parking
bolts
3. Parking
(right side only)
4. Connection
of parking
brake cable and
equalizer
5. Brake drum
6. Connection
of brake tubes
7. Nuts
8. Rear axle shaft assembly
(with parking
brake cable)
9. Shims
10. O-ring
Adjustment
of axle shaft end play
+e
+e
l
l
l
l
+
+
+
+
~~
*a
~~
l * l +
+e
11.
12.
13.
14.
15.
16.
17.
18.
19.
Lock nut
Lock washer
Washer
Rear axle shaft
Bearing
inner race
Bearing
case
Oil seal
Bearing
outer race
Oil seal
NOTE
(2) C& : Refer to Service Points of Removal.
(3j
(4)
64
I
1 STB Revision
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: Refer to Service
Points
: Non-reusable
parts
of Installation.
REAR AXLE
3-23
- Axle Shaft
SERVICE
POINTS
OF REMOVAL
N03HBAB
6.
DISCONNECTION
OF BRAKE TUBES
8.
REMOVAL
OF REAR AXLE SHAFT ASSEMBLY
Pull the rear axle shaft with rear brake assembly attached.
If the rear axle shaft is hard to remove, use the special
tools.
NOTE
Do not damage
the oil seal during
its removal.
11. REMOVAL
OF LOCK NUT
jr.:
Remove the lock nut by following
the steps below.
(1) Straighten
the bent tab of the lock washer with the ,
screwdriver.
,
Il.
1
e-
i
;*&, ,
yy+ +,
MB9907\85-01
(2) Remove
(3) Remove
the lock nut by using the special tool.

the lock washer and the washer.
14. REMOVAL
OF REAR AXLE SHAFT
(1) Reinsert the lock nut on the axle shaft approximately
three turns.
(2) Install the special tool as figure to remove the rear axle
shaft from the bearing case.
Be sure to install nuts and washers diagonally.
(3) Turn nuts with equal pressure
to ensure smooth
removal of the wheel bearing.
18. REMOVAL
OF BEARING
Using a hammer
bearing case.
OUTER
and drift, remove
RACE
bearing
outer race from
19. REMOVAL
OF OIL SEAL
Remove the oil seal from the end of rear axle housing
the special tool, if necessary.
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with
1(
f
i
3-24
REAR AXLE - Axle
Shaft
INSPECTION
l
l
l
l
NOBHCAA
Check the dust cover for deformation

and damage.
Check the oil seal for damage.
Check the inner and outer bearings for seizure, discoloration and rough raceway surface.
Check the axle shaft for cracks, wear and damage.
SERVIICE
POINTS
OF INSTALLATION
NOBHDAD
19. INSTALLATION
OF OIL SEAL
(1) Apply the specified grease to the oil seal fitting
the rear axle housing.
Specified
grease
: Multipurpose
NLGI No. 2
grease
SAE J310,
(2) Drive the new oil seal into the rear axle housing
Specified
MB990938-01
grease
grease
11 BOO45
: Multipurpose
NLGI No. 2
grease
/MB990937-01
17. INSTALLATION
grease
,Specified
11 BOO4f
5310,
periphery
SAE
of
J310,
case by
OF OIL SEAL
(1) .Apply the specified

,the new oil seal.
lontact
: Multipurpose
NLGI No. 2
SAE
(2) Press-fit the bearing outer race into the bearing

MB990938-01
end by
grease to the oil seal lip.
18. INSTALLATION
OF BEARING
OUTER RACE
(1) ,Apply the specified grease to the external
the bearing outer race.
Specified
area of
grease
grease
to the external
: Multipurpose
NLGI No. 2
grease
periphery
SAE
of
5310,
(2) Press-fit the new oil seal into the bearing case until it is
.flush with the face of the bearing case by using special
.too1s.
(3) ,4pply the specified
grease to the lips of the oil seal.
:Specified
1 STB Revision
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grease
: Multipurpose
NLGI No. 2
grease
SAE
J310,
3-25

15. INSTALLATION
OF BEARING
INNER
RAGE/14.
AXLE SHAFT
(1) Apply the specified grease to the roller surfaces
bearing inner race.
Specified
grease
: Multipurpose
NLGI No. 2
grease
SAE
REAR
of the
5310,
(2) Install the rear brake assembly

attached with bearing
case and the bearing inner race in that order to the axle
shaft.
(3) Press-fit the bearing inner race into the axle shaft using
the special tool.
(4) Pack the bearing case with the specified grease.
118021
Specified
grease
: Multipurpose
NLGI No. 2
grease
SAE
J310,
,ii
t
13. INSTALLATION
OF WASHER/12.
LOCK WASHER/ll.
LOCK NUT
Install these parts with cares described below.
(1) Apply the specified grease to the thread portion of the
axle shaft, to which the locking nut is installed.
Specified
grease
: Multipurpose
NLGI No. 2
grease
(2) Align the washer tab with the slot of

install the washer.
(3) Align the lock washer tab with the slot
to install the lock washer as figure.
(4) Install the lock nut with its chamfering
(5) Tighten the lock nut to the specified
the special tool.
(6) Bend the tab of the lock washer

nut.
SAE
5310,
the axle.shaft
to
of the axle shaft

in the directions
torque
by using
into the slot of the lock
NOTE
If the slot in the lock nut and the tab of the lock washer
are out of alignment,
turn the lock nut in until they are
in alignment.
1 STB Revision
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!I
:
::
3-26

l
ADJUSTMENT
OF AXLE SHAFT END PLAY
Adjust the clearance between the bearing case and rear
axle housing end by the following procedure.
(1) Insert a 1 mm (.04 in.) thick shim and O-ring into the left
side rear axle housing.
(2) Apply the specified sealant to the mating. surface of
bearing case, install the left axle shaft into rear axle
housing and tighten the nuts.
NOTE
Tighten
the nuts in diagonal
!$pecified
sealant
sequence.
: 3M ART
equivalent
Part
No 8663,
8661
or
(3) Install the right axle shaft without a shim (s) and O-ring
and temporarily
tighten to about 6 Nm (4.3 ft.lbs.).
(4) Measure the clearance between the bearing case and
rear axle housing end with a feeler gage.
(5) Select shims of the thickness
which is equal to the
sum of the measured
clearance
and 0.05-0.20
mm
(.0020-.0079
in.)
(6) Remove the right axle shaft, and install shim (s) and Oring on the right side rear axle housing end.
sealant to the mating surface of
bearing case, install the right axle shaft into rear axle
housing and tighten the nut.
NOTE
Tighten
the nuts in diagonal
Specified
sealant
sequence.
: 3M ART Part
equivalent
No. 8663,
8661
(8) Check to assure
the standard
Standard
1160671
1 ST6 Revision
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or
that the axle shaft axial play is within

value.
value
: 0.05420
mm (.0020-.0079
in.)
REAR AXLE - Differential
DIFFERENTIAL
REMOVAL
3-27
Carrier
CARRIER
NONA-
AND INSTALLATION
13-17
Nm
9-I:
ft.lbs
50-60
36-43
3u-ou
36-43
Nm
ft.lb,s.
Ivrn
ft.,bs.
18-22
40-60
29-43
n@
Nm
ft.lbs.
ft.lbs.
5
llW615
Pre-removal
l
Operation
Drain of Differential
to P.3-17.)
Post-installation
ODeration
Air Bleeding from Brake Lines (Refer to GROUP 5 BRAKES - Service

Adjustment
Procedures)
o Adjustment
Procedures)
l
Addition of Differential Gear Oil (Refer to P.3-17.)
Gear Oil (Refer
.I
,
c
2
<
Removal steps
l *
1. Adjuster
(Parking
brake cable)
2. Parking
nuts
3. Parking
(right side only)
4. Connection
of parking
brake cable
equalizer
5. Brake drums
6. Connection
of brake tubes
7.
+e
+e
+e
l +
l +
Nuts
8. Rear axle shaft assembly

9. Rear propeller
shaft
10. Differential
carrier
i\
and
NOTE
(2) +w : Refer to Service Points of Removal.
SERVICE
POINTS
OF REMOVAL
N0316AB
6.
DISCONNECTION
OF BRAKE TUBES
8.
REMOVAL
OF REAR AXLE SHAFT ASSEMBLY
Pull out the right and left axle shafts by about 70 mm (2.8
in.). If it is hard to pull out, use the special tools.
STB Revision
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I'*
3-28

9. REMOVAL
Carrier
OF REAR
PROPELLER
SHAFT
Make the mating

marks on the flange yoke of the rear
propeller shaft and the companion
flange of the differential
case.
10. REMOVAL
OF DIFFERENTIAL
CARRIER
Remlove the attaching

nuts and strike the lower
differential
carrier assembly with a square lumber
times, to remove the assembly.
, -
NOTE
Do not remove the uppermost
the way to the stud bolt end.
Caution
Use care not to strike
SERVICE
t-3 mm
.08-.12 in.)
POINTS
part of
several
nut but keep it loosened
the companion
all
flange.
OF INSTALLATION
NOBIDAB
10. APPILICATION
OF SEALANT TO DIFFERENTIAL
CARRIER
carrier is installed,
apply specified
sealant to the differential
carrier mounting
surface of the
axle housing as illustrated
in either of the illustrations.
Specified
sealant
: 3M ART
equivalent
Part
No.
8663,
8661
or
11 BOO51
9.
INSTALLATION
OF REAR PROPELLER
SHAFT
Align the mating
companion
flange to install the rear propeller
shaft.
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INSPECTION
3-29
Carrier
BEFORE DISASSEMBLY
N03lEAA
Secure the working base in a vice and then install the removed
differential carrier assembly.
FINAL DRIVE GEAR BACKLASH

With the drive pinion locked in place, measure the final drive
gear backlash with a dial indicator on the drive gear.
NOTE
Measure at four points
drive gear.
or more
on the circumference
:1:
,>
of the<
t.
Standard
value
: 0.1 l-0.16
mm (.0043-.0063
DRIVE GEAR RUNOUT

Measure the drive gear runout
side of the drive gear.
Limit
at the shoulder
in.)
on the reverse
: 0.05 mm (.0020 in.)
DIFFERENTIAL
GEAR BACKLASH
(CONVENTIONAL
DIFP-
bi,
FERENTIAL)
While locking the side gear with the wedge, measure the \I
differental
gear backlash with a dial indicator
on the pinion ;. .
gear.
;

mm (.0004-.0030
in.)
Limit
: 0.2 mm (.008 in.)
FINAL DRIVE GEAR TOOTH CONTACT

Check the final drive gear tooth contact by following the steps
below.
coat of machine
blue to both
(1) Apply a thin, uniform
surfaces of the drive gear teeth.
1 STB Revision
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Carrier
(2) Insert a brass rod between the differential

carrier and the
differential
case, and then rotate the companion
flange by
hand (once in the normal direction,
and then once in the
reverse direction) while applying a load to the drive gear,
SO that the revolution
torque [approximately
2.5-3.0 Nm
(1 .8--,2.2 ft.lbs.)] is applied to the drive pinion.
Caution
If the drive gear is rotated too much, the tooth contact
pattern will become unclear and difficult to check.
(3) Check the tooth-contact
drive pinion.
condition
of the drive gear and
NOTE
Chec:king the tooth contact pattern is the way to confirm
that the adjustments
of the pinion height and backlash
have been done properly. Continue
to adjust the pinion
height and backlash until the tooth contact pattern resembles the standard pattern.
If, after adjustments
have been made, the correct tooth
contact pattern cannot be obtained,
it means that the drive
gear and the drive pinion have become worn beyond the
allowable
limit. Replace the gear set.
Caution
If either
replaced,
the drive gear or the drive pinion

is to
be sure to replace both gears as a set.
1 STB Revision
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be
REAR
Standard
1
2
3
tooth
contact
AXLE
- Differential
3-31
Carrier
pattern
Toe
Drive-side
Heel
Coast-side
-1
Problem
Tooth contact
ion height
pattern
resulting
The drive pinion is positioned

drive gear.
from
excessivb
Solution
pin-
too far from the center of the
Increase the thickness of the pinion height adjusting shim.

and position the drive pinion closer to the center of the drive
%i/
for backlash adjustment,
farther from the drive pinion.
Tooth
height
contact
pattern
resulting

drive gear.
from
insufficient
position
the
drive
gear
pinion
too close to the center of the
Decrease the thickness of the pinion height adjusting shim,

and position the drive pinion farther from the center of the
drive gear.
Also, for backlash adjustment, position the drive gear closer
to the drive pinion.
llS641
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3-32
Carrier
(Conventional
Type)
DISASSEMBLY
Inspection
l
Before
Disassembly
Final Drive Gear Backlash
P.3-29.)
l
l
(Refer to
Drive Gear Runout (Refer to P.3-29.)

Differential Gear Backlash (Refer to
P.3-29.)
0 Final Drive Gear Tooth Contact (Refer to P.3-29.)
56
15-22 Nm
/ / ?514,
80-90
190-250
137-181
Disassembly
Nm
58-65 ftlbs.
Nm
ft.lbs.
steps
lW546
1. Lock plates
2. Side bearing nuts
3. Bearing caps
4. Differential case assembly
5. Side bearing outer races
6. Side bearing inner races
7. Bolts (10)
8. Drive gear
9. Lock pin
IO. Pinion shaft
11. Thrust block
12. Pinion gears
13. Pinion washers
14. Side gears
15. Side gear thrust spacers
16. Differential case
17. Self-locking nut
18. Washer
19. Drive pinion assembly

20. Drive pinion rear bearing inner race
21. Drive pinion rear shim (for pinion height
adjustment)
22. Drive pinion
23. Companion flange
24. Drive pinion spacer
25. Drive pinion front shim (for preload adjustment)
26. Oil seal
27. Drive pinion front bearing inner race
28. Drive pinion front bearing outer race
29. Drive pinion rear bearing outer race
30. Differential carrier
l *
4*
NOTE
(1) +e
(2)
: Non-reusable
SERVICE
2.
POINTS
parts
OF DISASSEMBLY
REMOVAL
OF SIDE BEARING
Using the special tool, remove
1 STB Revision
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NUT
the side bearing
NOOIGAA
nut.
REAR AXLE
Differential
4.
Carrier
REMOVAL
Take out
handles.
(Conventional
3-33
Type)
OF DIFFERENTIAL
CASE ASSEMBLY
the differential
case assembly
with
hammer
NOTE
Keep the right and left side bearings and side bearing nuts
separate, so that they do not become mixed at the time of
reassembly.
6.
MB990339-0
REMOVAL
OF SIDE BEARING INNER RACE
Pull out the side bearing inner races by using the special
tools.
#l.
8.
REMOVAL
OF DRIVE GEAR
(1) Make the mating marks to the differential
case and the
drive gear.
(2) Loosen the drive gear attaching
bolts in diagonal
sequence to remove the drive gear.
9.
DRIVE-OUT
OF LOCK PIN
Drive out the lock pin with a punch.
NOTE
The removed side gears and side gear thrust
and right, should be retained for reassembly.
17. REMOVAL
OF SELF-LOCKING
NUT
Use the special tools to hold the companion
remove the companion
flange self-locking
nut.
1 STB Revision
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:.
>
2:
,
spacers,
left
flange
and
1;.
Carrier
(Conventional
Type)
19. REMOVAL OF DRIVE PINION ASSEMBLY

(1) Make the mating
marks to the drive
companion
flange.
pinion
and
Caution
The mating
mark made on the companion
flange
Imust not be on the coupling surface of the flange
yoke and the rear propeller shaft.
(2) Drive out the drive pinion together with the drive pinion
spacer and drive pinion front shims.
20. REMOVAL
RACE
OF DRIVE
Pull out the drive

the special tools.
28. REMOVAL
RACE
Brass rod
PINION
pinion
OF DRIVE
REAR
rear bearing
PINION
Drive out the drive pinion

gear carrier.
FRONT
front bearing
BEARING
inner
INNER
race by using
BEARING
OUTER
outer race from the
29. REMOVAL
OF DRIVE PINION
REAR BEARING
OUTER
RACE
Drive out the drive pinion rear bearing outer race from the
gear carrier.
INSPElCTlON
l
l
l
l
l
l
l
N03lHAA
Check the companion

flange for wear or damage.
Check the oil seal for wear or deterioration.
Check the bearings for wear or discoloration.
Check the gear carrier for cracks.
Check the drive pinion and ring gear for wear or cracks.
Check the side gears, pinion gears and pinion shaft for
wear or damage.
Check the side gear spline for wear or damage.
STB Revision
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REAR AXLE
- Differential
Carrier
(Conventional
3-35
Type)
REASSEMBLY
N0311.-
11
80-90 Nm
58-65 ftlbs.
190-250 Nm
137-181 ftlbs.
11-16
lW546
Differential gear Set
Final drive gear Set
Reassembly steps
I, Differential carrier
1)4 2. Drive pinion rear bearing outer race
I)*
l + Adjustment of pinion height
l +
4. Drive pinion
adjustment)
l *
l +
l + Adjustment of drive pinion preload
l +
8. Oil seal
~~
l +
13. Washer
14. Self-locking nut
NOTE
(I) l +
(2) q
1 STB Revision
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17. Side gears

18. Pinion washers
19. Pinion gears
Adjustment of differential gear backlash
20. Thrust block
21. Pinion shaft
22. Lock pin
23. Drive gear
24. Bolts (10)
28. Bearing caps
Adjustment of final drive gear backlash
30. Lock plates
: Non-reusableparts
3-36
REAR AXLE
- Differential
Carrier
SERVICE
2.
MB990936-01
(Conventional
POINTS
INSTALLATION
ER RACE
Type)
OF REASSEMBLY
OF DRIVE
PINION
REAR BEARING
Press-fit the drive pinion rear bearing

gear carrier by using the special tools.
NOTE
Perform
race.
press-fitting
carefully
NOBIJAB
outer
OUT-
race into the
so as not to tilt the outer
llYO53
3.
INSTALLATION
OF DRIVE PINION
OUTER RACE
Press-fit the drive pinion front bearing
carrier by using the special tools.
NOTE
Perform
race.
press-fitting
carefully
FRONT
outer
BEARING
race into gear
llW595
MB990905-1-01
HW518
OF PINION
HEIGHT
Adjustment
the drive pinion
height
by the following
procedures:
(1) Install special tools and drive pinion front and rear
bearing inner races to the gear carrier in the sequence
MB990901-0
lit-
AD.JUSTMENT
NOTE
Apply a thin coat of the specified grease
face of the washer of the special tool.
Specified
grease
: Multipurpose
NLGI No. 2
to the mating
grease
SAE J310,
(2) Tighten the handle of the special tool until the standard
value of drive pinion turning torque is obtained.
(3) Measure
seal).
the drive pinion
torque
value
NOTE
Gradually
checking
tighten the handle of the special

the drive pinion turning torque.
http://vnx.su/
Nm (3.5-4.3
(without
Standard
1 STB Revision
: 0.4-0.5
turning
the oil
in.lbs.)
tool while
REAR AXLE
Differential
Carrier
(Conventional
3-37
Type)
(4) Position the special tool in the side bearing seat of the
gear carrier, and then select a drive pinion rear shim of
a thickness which corresponds
to the gap between the
special tools.
NOTE
Be sure to clean the side bearing seat thoroughly.
When positioning
the special tool, be sure that the cutout sections
of the special tool are in the position
shown in the illustration,
and also confirm
that the
special tool is in close contact with the side bearing
seat.
When selecting the drive pinion rear shims, keep the
number of shims to a minimum.
,P
(5) Fit the selected drive pinion rear shim(s) to the drive !
pinion, and press-fit the drive pinion rear bearing inner J
4
race by using the special tool.
i
!.a..
ADJUSTMENT
OF DRIVE
Adjust the drive pinion
following procedure:
Without
PINION
turning
PRELOAD
torque
by using
the
Oil Seal
(1) Fit the drive pinion front shim(s) between the drive
pinion spacer and the drive pinion front bearing inner
race.
(2) Tighten the companion
flange to the specified torque
by using the special tools.
NOTE
Do not install the oil seal.
(3) Measure
seal)
Standard
the drive pinion
value
: 0.4-0.5
turning
torque
Nm (3.5-4.3
(without
the oil
i
i
i.
;i
in.lbs.)
(4) If the drive pinion turning torque is not within the range
of the standard value, adjust the turning torque by
replacing
the drive pinion front shim(s) or the drive
pinion spacer.
.
NOTE
When selecting
the drive pinion front shims, if the
number of shims is large, reduce the number of shims
to a minimum
by selecting
the drive pinion spacers.
(5) Remove
again.
/ STB Revision
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the companion
flange
and drive pinion
,:/
/.
once
:t
3-38
Carrier
(Conventional
Type)
With Oil Seal

(1) After setting the drive pinion front bearing inner race,
drive the oil seal the gear carrier front lip by using the
special tool.
(2) Apply specified grease to the Oil seal lip.
Specified
d
J
grease
: Multipurpose
NLGI No. 2
grease
SAE
5310,
(3) Apply a thin coat of specified grease to the companion

flange contacting
surface of the washer before installing drive pinion assembly.
Specified
grease
: Multipurpose
NLGI No. 2
grease
-
SAE
J310,
llD554
(4) Install the drive pinion assembly and companion

flange
with mating marks properly aligned,
and tighten
the
companion
flange self-locking
nut to the specified
torque by using the special tools.
(5) Measure the drive pinion turning torque (with oil seal)
to verify that the drive pinion turning torque complies
with the standard value.
Standard
value
: 0.65-0.75
Nm (5.6-6.5
in.lbs.)
111223
ADJUSTMENT
OF DIFFERENTIAL
GEAR BACKLASH
(1) ,4ssemble
the side gears, side gear thrust spacers,
ipinion gears, and pinion washers into the differential
(case.
(2) Temporarily
install the pinion shaft.
NOTE
00 not drive in the lock pin yet.
1 STB Revision
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Carrier
3-39
Type)
(Conventional
(3) Insert a wedge between the side gear and the pinion
shaft to lock the side gear.
(4) While locking the side gear with the wedge, measure
the differential
gear backlash with a dial indicator
on
the pinion gear.
Standard
value : 0.01-0.076
Limit
: 0.2 mm (.008 in.)
mm
(.0004-.0030
in.)
(5) If the differential

gear backlash
exceeds
the limit,
adjust the backlash by installing thicker side gear thrust
spacers.
(6) Measure the differential
gear backlash once again, and
confirm that it is within the limit.
If adjustment
is not possible,
replace the side gears
and pinion gears as a set.
llS606
*<
22. INSTALLATION
OF LOCK PIN
(1) Align the pinion shaft lock pin hole with the differential
case lock pin hole, and drive in the lock pin.
(2) Stake the lock pin with a punch at two points.
23. INSTALLATION
OF DRIVE GEAR
(1) Clean the drive gear attaching bolts.
(2) Remove the adhesive adhered to the threaded holes of
the drive gear by turning the tap tool (Ml0 x 1.25),eand
then clean the threaded holes by applying compressed
air.

the drive gear.
Specified
adhesive
adhesive
to the threaded
: 3M adhesive
or equivalent
holes of
stud locking
4170
(4) Install the drive gear onto the differential

case with the
mating marks properly aligned. Be sure to tighten the
bolts to the specified torque in a diagonal
sequence.
1 STB Revision
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.
4;.
:
,
REAR AXLE - Differerltial
Carrier
(Conventional
Type)
25. PRESS-FIT OF SIDE BEARING

INNER RACE
Press-fit the side bearing inner races to the differential
case by using the special tool.
28. INSTALLATION
OF BEARING
CAP
Align the mating marks on the gear carrier and the bearing
cap, and then tighten the bearing cap.
ADJUSTMENT
OF FINAL
DRIVE
GEAR
BACKLASH
(1) Using the special tool, temporarily

tighten
the side
bearing nut until it is in the state just before preloading
of the side bearing.
-8,
ri,
:,
3-t
(2) Measure
<Standard
,
?
the final drive gear backlash.

value
: 0.11-0.16
mm (.0043-.0063
in.)
,?+5
When
backlash
(3) IJsing the special

backlash to standard
nut as shown.
is in-
tool (MB990201-Ol),
adjust the
value by moving the side bearing
NOTE
First turn the side bearing nut for loosening,
and then
turn (by the same amount)
the side bearing nut for
tightening.
LWhen
badladh
cessive
is ex110267
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REAR
AXLE
- Differential
Carrier
(Conventional
Type)
3-41
(4) Using the special tool, to apply the preload, turnn down
both right and left side bearing
nuts on half the
distance between centres of two neighbouring
holes.
MB092153
(5) Choose and install the lock plates (two kinds).
MB092154
(6) Check the final tooth contact. If poor contact

make adjustment.
(Refer to P.3-29.)
(7) Measure the drive gear runout.
Limit
: 0.05
mm
is evident,
(.OOZO in.)
If the drive gear runout exceeds the limit, reinstall by

changing the phase of the drive gear and differential
case, and remeasure
1 STB Revision
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3-42
REAR AXLE
- Differential1
Carrier
(Limited
Slip Type)
DISASSEMBLY
NOBISA-
Inspection
Before Disassembly
Final Drive Gear Backlash (Refer to
0 Final Drive Gear Tooth
Contact
(Re-
15-22 Nm
11-16 ft.lbs.
55-65 Nm
40-47 ftlbs.
80-90 Nm
58-65 ft.lbs.
Disassembly
steps
1,
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Lock plates
Side bearing
nuts
Bearing
caps
Differential
case assembly
Side bearing
outer races
Side bearing
inner races
Bolts
Drive gear
Limited
slip differential
case assembly
Self-locking
nut
Washer
Drive pinion assembly
Drive pinion
rear bearing
inner race
Drive pinion
rear shim (for pinion
height
adjustment)
/ STB Revision
15.
16.
17.
18.
l *
4*
NOTE
(1) qe
(2) m
http://vnx.su/
19.
20.
21.
22.
23.
Drive pinion
Companion
flange
Drive pinion
spacer
Drive pinion front shim (for preload
adjustment)
Oil seal
Drive pinion front bearing
inner race
Drive pinion front bearing
outer race
Drive pinion
rear bearing
outer race
Differential
carrier
: Refer to Service Points of Disassembly

Carrier
(Limited
SERVICE POINTS
Slip
REMOVAL
Take out
handles.
3-43
OF DISASSEMBLY
2. REMOVAL
OF SIDE BEARING
Using the special tool, remove
4.
Type)
NOllLAA
NUT
the side bearing.
OF DIFFERENTIAL
CASE ASSEMBLY
the differential
case assembly
with
hammer
,.1.
NOTE
Keep the right and left side bearings and side bearing nuts;
separate, so that they do not become mixed at the time of :.
reassembly.
e,
6.
REMOVAL
OF SIDE BEARING
INNER RACE
tools.
8.
REMOVAL
OF DRIVE GEAR
case and the r,
Y
drive gear.
bolts in diagonal
.;
..
10. REMOVAL
OF SELF-LOCKING
NUT
Use the special tools to hold the companion
flange self-locking
nut.
1 STB Revision
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flange
and
REAR
AXLE
Differential
Carrier
(Limited
Slip
Type)
12. REMOVAL
OF DRIVE PINION ASSEMBLY
(1) Make the mating
marks to the drive
companion
flange.
pinion
and
Caution
The mating
flange
must not be on the coupling
surface of the flange
yoke and the rear propeller
shaft.
(2) Drive out the drive pinion together with the drive pinion
spacer and drive pinion front shims.
13. REMOVAL
OF DRIVE PINION
REAR BEARING
RACIE
Pull out the drive pinion rear bearing innerrace
the special tools.
INNER
by using
21. REMOVAL
OF DRIVE PINION
FRONT BEARING
OUTER
FUKIE
Drive out the drive pinion front bearing outer race from the
gear carrier.
llWS94
22. REMOVAL
OF DRIVE PINION
REAR BEARING
OUTER
RACIE
Drive out the drive pinion rear bearing outer race from the
gear carrier.
INSPECJTON
NOBIMAA
Wash the disassembled

parts in cleaning
solvent, dry them
using compressed
air, and then check the following
areas:
l
Check the companion
l
l
Check the bearings for wear or discoloration
l
l
1 STB Revision
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Carrier
(Limited
Slip
3=45
Type)
REASSEMBLY
NOBIT-
15-22 Nm
11-16 ft.lbs.
55-65 Nm
40-47 ftlbs.
190-250
137-181
Nm
ft.lbs.
/
80-90 Nm
58-65 ftlbs.
HBOO97
Final drive gear set

,
Reassembly steps
1. Differential carrier
1)4 2. Drive pinion rear bearing outer race
l + 3. Drive pinion front bearing outer race
l a Adjustment of pinion height
4. Drive pinion
adjustment)
w+ Adjustment of drive pinion preload
8. Oil seal
IO. Drive pinion spacer
3. Washer
4. Self-locking nut
5. Limited slip defferential case assembly
6. Drive gear
7. Bolts
l + 21. Bearing caps
l + Adjustment of final drive gear backlash
23. Lock plate
NOTE
(1) l + : Refer to Service Pointsof Reassembly
(2) q : Non-reusableparts
/ STB Revision
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,,
::
>
3-46
REAR AXLE
- Differential
-
Carrier
SERVICE
(Limited
POINTS
Slip Type)
OF REASSEMBLY
NOBINAB
2. INSTALLATION
OF DRIVE PINION
REAR BEARING
OUTER RACE
Pressfit the drive pinion rear bearing outer race into the
MB990938-01
NOTE
Perform
race.
press-fitting
carefully
llYO53
3.
MB990938-01
MB990934-01
INSTALLATION
OF DRIVE PINION
OUTER RACE
carrier by using the special tools.
NOTE
Perform
race.
press-fitting
carefully
FRONT
outer
BEARING
race into gear
llW595
ADJUSTMENT
OF PINION
HEIGHT
Adjust the drive pinion height by the following procedures:

(1) Install special tools and drive pinion front and rear
NOTE
Apply a thin coat of the specified grease to the mating
face of the washer of the special tool.
Specified
grease
: Multipurpose
NLGI No. 2
grease
SAE
5310,
value of drive pinion turning torque is obtained.
MB990905-1-01
(3) Measure
seal).
the drive pinion
: 0.4-0.5
turning
torque
Standard
value
NOTE
Gradually
checking
tighten the handle of the special

the drive pinion turning torque.
1 STB Revision
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Nm (3.543
(without
the oil
in.lbs.)
tool while
REAR AXLE
- Differential
Carrier
(Limited
3-47
Slip Type)
gear carrier, and then select a drive pinion rear shim of
special tools.
NOTE
Be sure to clean the side bearing seat thoroughly.
When positioning
the special tool, be sure that the cutout sections
of the special tool are in the position
and also confirm that the
special tool is in close contact with the side bearing
seat.
When selecting
the drive pinion rear shims, keep the
number of shims to a minimum.
(5) Fit the selected drive pinion rear shim(s) to the drive
pinion, and press-fit the drive pinion rear bearing inner
i
i.
.
MB990767-01
ADJUSTMENT
OF DRIVE PINION
PRELOAD
Adjust the drive pinion turning
torque
by using the
following
procedure:
Without
Oil Seal
(1) Fit the drive pinion front shim(s) between the drive
pinion spacer and the drive pinion front bearing inner
race.
flange to the specified torque
by using the special tools.
NOTE
Do not install
(3) Measure
seal).
the oil seal.
the drive pinion
Standardvalue
llY223
, I!
: 0.4-0.5
turning
torque
(without
Nm
(3.5-4.3
in.lbs.)
the oil ?,
t
..>
(4) If the drive pinion turning torque is not within the range
of the standard
value, adjust the turning torque by
replacing
the drive pinion front shim(s) or the drive
pinion spacer.
NOTE
When selecting
the drive pinion front shims, if the
to a minimum
by selecting
(5) Remove
again.
/ STB Revision
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the companion
flange
and drive
pinion
once
Carrier
Slip Type)
(Limited
With Oil Seal

(I) After setting the drive pinion front bearing inner race,
drive the oil seal the gear carrier front lip by using the
special tool.
(2) Apply specified grease to the Oil seal lip.
MIT304180
Specified
: Multipurpose
NLGI No. 2
grease
MB990031-01
grease
SAE J310,
llV224
(3) Apply a thin coat of specified

multipurpose
grease to
tine companion
flange contacting
surface of the washer
before installing drive pinion assembly.
Specified
grease
: Multipurpose
NLGI No. 2
grease
SAE
J310,
llD554

flange
and tighten the
companion
flange self-locking
(5) Measure the drive pinion turning torque (with oil seal)
to verify that the drive-pinion
turning torque complies
with the standard value.
Standard
value
: 0.65475
Nm (5.6-6.5
in.lbs.)
16. INSTALLATION
OF DRIVE GEAR
the drive gear by turning the tap tool (Ml 0 x 1.25), and
air,
llVl96
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- Differential
REAR AXLE
Carrier
(Limited
3-49
Slip Type)
adhesive
to the threaded
holes of
the drive gear.

Specified
adhesive
: 3M Adhesive
or equivalent
stud locking
4170

case with the
mating marks properly aligned. Be sure to tighten the
bolts to the specified torque in a diagonal sequence.
18. PRESS-FIT
OF SIDE BEARING
INNER RACE
Press-fit the side beating inner races to the
21. INSTALLATION
OF BEARING
differential
,!,.,
T.i;
CAP
Align the mating marks on the gear carrier and the beating
cap: an.d&then tighten the bearing cap.
ADJUSTMENT
OF FINAL DRIVE GEAR BACKLASH
(1) Using the special tool temporarily
tighten
the side
bearing nut until it is in the state just before preloading
of the side bearingL
lW522
(2) Measure
Standard
STB Revision
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the final drive gear backlash.

value
: 0.11-0.16
mm (.0043-.0063
in.)
I,
3-50
R@R
When
backlash
AXLE
- Differential
Carrier
(Limited
Slip
Type)
(3) Using the spec:ial tool (MB990201-Ol),

adjust the
Ibacklash to standard value by moving the side bearing
nut as shown.
is in-
NOTE
First turn the side bearing nut for loosening,
and then
turn (by the same amount)
the side bearing nut for
.tightening.
cessive
(4) Using the special tool, to apply the preload, turn down
both right and left side bearing
nuts on half the
distance between centres of two neighbouring
holes.
(5) IChoose and instal I the lock plates (two kinds).
MB092153
(6) Check the final tooth contact. If poor contact

rnake adjustment.
(Refer to P.3-29.)
(7) Measure
the drive gear runout.
Limit
: 0.05
mm
(.0020
is evident,
in.)
If the drive gear runout exceeds the limit, reinstall by

changing
the phase of the drive gear and differential
case, and remeasure.
1 STB Revision
I
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REAR AXLE
- Differential
Carrier
(Limited
Slip
3-51
Type)
OVERHAUL
I
I
Differential
gear set
Disassembly steps
l * *+
I. Screw
2. Differential case (A)
3. Thrust washer
4. Spring plate
5. Spring disc
6. Friction plate
7. Friction disc
8. Friction plate
9. Friction disc
10. Pressure ring
11. Side gear
12. Thrust block
13. Differential pinion gear
14. Differential pinion shaft
15. Thrust block
16.
17.
18.
19.
20.
21,
22.
23.
24.
l + 25.
Side gear
Pressure ring
Friction disc
Friction plate
Friction disc
Friction plate
Spring disc
Spring plate
Thrust washer
Differential case (6)
NOTE
(I) Reverse the disassembly procedures to reassembly
(2) *e
1 STB Revision
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3-52
Carrier
SERVICE
(Limited
POINTS
Slip Type)
OF DISASSEMBLY
NOBIPAA
1. REMOVAL
OF SCREW
(1) Loosen screws of the differential
cases (A) and (B)
uniformly a little at a time.
(2) Separate differential
case (A) from differential
case (B).
NOTE
Before disassembling
the differential
cases, confirm
that the mating rnarks (numbers) on case A and case B
are the same.
1lSBBC
(3) Remove
the components
from differential
case (B).
NOTE
Keep the right and left thrust washers, spring plates,
spring discs, friction plates, and friction discs separate
in order to be able to distinguish
them for reassembly.
INSPECTION
l
l
NO3lClAA
wear or damage.
INSPECTION
PARTS
OF CONTACT
AND
SLIDING
SURFACES
OF
(1) Inspect the friction plate, friction disc, spring plate, spring
disc: and pressure ring.
A The friction surfaces of the friction plate, friction disc,
spring plate, and spring disc. If there are any signs of
seizure, severe friction, or color change from the heat, it
will adversely affect the locking performance;
replace
the part with a new one.
NOTE
The strong contact on the inner circumference
of the
friction surfaces is because of the spring plate and the
spring disc; this wear is not abnormal.
6
D
G
The six projections

on the inner circumference
of the
friction disc.
If there are nicks and dents, it will cause abnormalities
in the clutch pressure.
Repair the parts by using an oil stone; if the parts
cannot be repaired,
replace them.
on the outer circumference
of the
C The four projections
friction disc.
If there are nicks and dents, it will cause abnormalities
in the clutch pressure.
Repair the parts by using an oil stone; if the parts
cannot be repaired,
replace them.
D The friction surface of the friction disc of the pressure
ring.
If there are nicks or scratches,
repair the part by first
grinding
with an oil stone and then polishing
with
rubbing compound
on a surface plate.
\
D
llS659
NOTE
.The strong contact on the inner circumference
of the
.friction surface is because of the spring plate and the
spring disc; this wear is not abnormal.
1 STB Revision
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REAR AXLE - DffI erential
I N
(Limited
Slip
3-53
Type)
(2) Inspect the contact and sliding surfaces listed below, and
repair any nicks and burrs by using an oil stone.
E The sliding surfaces of the thrust washer and the case.
F The spring contacting
surface of the differential
case.
G The contact surfaces of the outer circumference
of the
pressure
ring and the inner circumference
of the
differential
case.
H The sliding surface of the thrust washer.
I The sliding surfaces of the hole in the pressure ring
and the outer circumference
of the side gear.
J The projection
on the outer circumference
of the
pressure ring.
K The spherical
surface of the differential
pinion. gear
)
and the inner diameter
of the pressure ring.
L The V-shaped groove in the pressure ring, and the V- ,,.,,:
ir
shaped part in the pinion shaft.
M The outer diameter of the pinion shaft and the hole of ii
!
the differential
pinion gear.
;,
N The outer circumference
groove of the side gear.
0 The inner circumference
groove of the differential
!,- ,
case.
P The sliding surface of the thrust block.
llS658
Carrier
L
lS662
INSPECTION
FOR WARPING
OF FRICTION
PLATE AND
FRICTION
DISC
Using a dial indicator,
measure the amount of warping (the
flatness) of the friction plate and the friction disc on a surface
plate by turning the friction plate or disc.
Limit
: 0.08
mm
(.0031
in.)
INSPECTION
FOR WEAR OF FRICTION
PLATE AND FRICTION DISC
(1) In order to measure the wear, measure the thickness
of
the friction surfaces and projections
of the friction disc and
plate, and then find the difference.
(The same procedure is used for the spring discs and the
spring plates.)
Limit
: 0.1 mm
(.004
NOTE
Make the measurement
11swo
in.)
at several
(2) If the parts are worn beyond

them with new parts.
STB Revision
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different
the allowable
points.
limit,
replace
.:
i.
!
Carrier
SERVICE
Slip Type)
(Limited
POINTS
OF REASSEMBLY
NOBIRAC
25. INSTALLATION
OF DIFFERENTIAL
CASE (6)
Before assembly,
use the following
method to adjust the
clearance between the spring plates and differential cases
(for adjustment
of the clutch plate friction force), and to
adjust the axial clearance of the side gear when installing
the internal components
into the differential
case.
(1 )Arrange the two (each) friction discs and friction plates

for each side, one on top of another, as shown in the
figure, combining
them
so that the difference
in
thickness between the left and the right is the standard
value.
Standard
value
: 0.05 mm (.0020 in.) or less
IVOTE
IFor new ones, there is one type of friction plate: 1.75
mm (.0689 in.); there are two types of friction disc:
1.75 mm (.0689 in.) and 1.85 mm (.0728in.).
(2).Arrange one spring disc and one spring plate for each
side, one on top of the other, so that the difference
,between the left and the right thickness
is minimized.
IPJOTE
IFor new ones, there is one type
spring plate: 1.75 mm (.0689 in.).
of spring
disc and
(3),Assemble
the pressure
rings internal
components
(differential
pinion shaft and pressure
ring) and the
friction discs and friction plates, and then, as shown in
the figure, measure the overall width.
of the
(4 .)Calculate the total value (C) of the thickness
spring discs and spring plates plus the value measured
in (3) above.
(5)Obtain
the dimension
(D) between
the spring plate
contact surfaces when differential
cases (A) and (B) are
combined.
(D=E+F-G)
(6)Change the thickness
of the friction disc so that the
clearance (D - C) between the differential
case and
the spring plate becomes the standard value.
!Standard
evision
value
: 0.06-0.20
-http://vnx.su/
mm (.0024-.0079
in.)
REAR AXLE
Differential
Carrier
(Limited
Slip
3-55
Type)
(7)Remove
the spring plates, spring discs, friction plates
and friction disc.
(8)lnstalI the thrust washer as shown in the figure, and
then select a thrust washer so that the difference
between
the left and right dimensions
from the
pressure ring rear face to the thrust washer end face is
the standard value.
Standard
Thrust
washer
value
: 0.05 mm (.0020 in.) or less
NOTE
Measure the distance
groove manually.
115654
while
(9)Measure the dimension

surafce to end surafce.
squeezing
the V-shaped
(H) from the thrust washer
end
:,.
l.&
Thrust
washer
1,cIIs4
(10)Obtain
the dimension
(I) between the thrust washer
combined.
(I=J+K+L)
NOTE
Dimension
J is the distance between the spring plate
combined.
(Refer to P.3-54.)
(1 l)Change
the thickness of the thrust washer so that the
clearance ( I - H ) between the thrust washer and the
differential
case is the standard value.
Standard
value
: 0.05-0.20
mm
(.0020-.0079
in.)
NOTE
I. Select the thrust washer so that the difference
between the left and right dimensions
from the
pressure ring rear face and the thrust washer end
surface are the standard
value even when the
thrust washer is changed.
2. There are three sizes of new thrust washers: 1.50
mm (.0591 in.), 1.60 mm (.0630 in.), and 1.70 mm
(.0670 in.)
ng
Spri
plate
Friction
(12)Place
the each part in the differential
directions shown in the figure.
plate
case
(B) as
NOTE
1. . Before assembly,
apply the specified
gear oil to
each component
especially careful to coat contact
surfaces and sliding surfaces.
1
spring
disc
Fribtion
disc
llsst
1STBsion
http://vnx.su/
3-56
EAR AXLE - Differential
Carrier
(Limited
!jpecified
gear oil:
MITSUBISHI
Genuine
or equivalent
2.
Slip Type)
Gear Oil Part No. 8149630
EX
Be careful not to insert the friction

plates and
friction discs in the incorrect order and to install the
spring plates and spring disc in incorrect direction.
1. INSTALLATION
OF SCREW
(1) Align the mating
marks (the same numeral
on each
case) of differential
case (A) and differential
case (B).
(2) Turning the screwdriver
slowly several times, tighten
the screw so that the cases are in close contact.
i s66a
Tool
MB990!
NOTE
If, even though
the screw is tightened,
the end
surfaces of case (A) and case (B) do not come into
close contact, probably the thrust washer and spring
plate are not fit correctly into the groove, so make the
assembly
again.
(3) After assembly, in order to check the frictional force of
the clutch plate, use the special tools to measure the
starting torque.
38 G
Standard
value:
When a new clutch plate is used
65-100 Nun (47-72 ft.lbs.)
When an old clutch plate is used
35-100 Nun (25-72 ftlbs.)
NOTE
Measure
the starting
torque
after rotating
slightly.
When measuring
the torque, do so at the beginning
of
movement.
1 STB Revision
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22-1
wti&LS
AND
CONTENTS
GENERAL
INFORMATION
. . . . .. .. .. . . . . . . . . .. .. . . . . . . .. . . .
SERVICE ADJUSTMENT
PROCEDURES
. . . . . .. . . .
Checking Tire Inflation Pressure
,......,.............
Checking Tire Wear . . .. . . . . . . . . . . . . . .._..................
. . . . . . . . . . . . . . . . .. . . . .
4
4
4
. . . . . . . . . . . .. .. .. . . . . . . .. .. . . . . . . . . .. .. .
.*.....................................a.......
SPECIFICATIONS
. . . . . . . . . . . . . .. .. .. . . . . . . . . .. .. . . . . .
. . . .. .. . . . . . . . . . . .. . . . . . . . . .. .
. .. .. .. . . . . . . . . . . . . . .. . . . . . . . . . . .. . . .
2
2
2
2
Checking
Wheel
Runout
SPARE TIRE CARRIER
Torque
Specifications
. . . . . .. . . . . . . . . . .. . . . . . .. .
N22AA--
TROUBLESHOOTING
Bald Spots
Cracked Treads
. . . . . . . . . . . .. . . . . . . . . . . . .. .. . . . . . . .. .. . .
Feathered Edge
Rapid Wear at Center
Rapid Wear at Shoulders
Scalloped Wear
Wear on One Side
WHEELS
http://vnx.su/
AND TIRES
. . . . .. . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .
4, .
1..
i IT
>\ :
c,
I&.
22-2
WHEELS
AND TIRES - General Information
/ Specifications
GENERAL INFORMATION
All models
are equipped
with tubeless
N22BAAD
radial tires and styled wheels.
SPECIFICATIONS
GENERAL
SPECIFICATIONS
N22CA-
Specifications
Items
Wheel
Tire size
P225ff 5R-15
Wheel type
Steel type
Wheel size
6JJx 15
Amount
of wheel
mm (in.)
offset
Tire inflation pressure
22 (.87)
kPa (psi)
Front wheels
180 (26)
Rear wheels
240 (341, * 180 (26)
NOTE
*Minimum
tire inflation pressure
for improving
ride comfort
when driving with no cargo.
+: <i SERVICE SPECIFICATIONS
N22CB.-
Specifications
Items
I
* Limit
Wheel runout
Radial
3(.12)
mm (in.)
3 (.12)
1.6 (.06)
Lateral
mm (in.)
Tread depth of tire
mm (in.)
Items
Hub nuts for steel wheel
Spare tire bracket
SEALANT
to body
AND ADHESIVE
N22CD.-
Item
Spare tire bracket
mounting
Specified
3M ART Part No. 8634 or

equivalent
bolts
pTB
Revision
http://vnx.su/
Quantity
As required
22-3
WHEELS AND TIRES-Troubleshooting
TROUBLESHOOTING
N22EA-
Symptom
Probable cause
Remedy
Reference
Rapid wear
at shoulders
Underinflation
or lack of
rotation
Adjust the tire

pressure
22-2
Rapid wear
at center
Overinflation
or lack of
rotation
Cracked
treads
Under-inflation
Wear on
one side
Excessive
camber
Inspect the camber
2-l 5
Feathered
edge
Incorrect
toe
Adjust the toe-in
2-l 5
Bald spots
Unbalanced
wheel
Adjust the
imbalanced
wheels
Scalloped
wear
Lack of rotation of tires

or worn or out-ofalignment suspension
Rotate the tires

Inspect the front
suspension alignment
22-6,
2-l 5
1 ST6 Revision
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22-4
WHEELS
AND TIRES - service
Adjustment
procedures
/ Wheels
SERVICE ADJUSTMENT
CHECKING
TIRE
Measure
Tires
PROCEDURES
INFLATION
PiRESSURE
Check the inflation pressure of the tires.

If it is not within the standard value,
adjustment.
CHECKING
and
make
the
N22FDAA
necessary
TIWE WEAR
N22FBAB
the tread depth of tires
53Y510
Limit
: 1.6 mm (.06 in.)
If the remaining
tire.
tread depth
is less than the limit,
NOTE
When the tread depth of tires is reduced
less, wear indicators will appear.
CHECKING
WMEEL
replace
the
to 1.6 mm (.06 in.) or
RUNOUT
N22FCAB
Jack up the vehicle so that the wheels are clear of the floor.
While slowly turning the wheel, measure wheel runout with a
dial indicator.
i
34,
5
Limit
: Radial 3.0 mm (.12 in.)

Lateral 3.0 mm (.12 in.)
If wheel
runout
exceeds
the
limit,
replace
the wheel.
hAlHEELS AND TIRES

.;REMOVAL
,.-!
AND
INSTALLATION
NZZGA-
Removal steps
1.
2.
l + 3.
4.
Center cap
Hub nut
Center cap holder
Balance
weight
5. Steel wheel
6. Tire
11w599
100-120
72-87
NOTE
1 STB Revision
---I
http://vnx.su/
Nm
ft.lbs.
WHEELS
AND TIRES
SERVICE
Wheels
POINTS
and
22-5
Tires
OF REMOVAL
1. REMOVAL
OF CENTER CAP
(1) Using the vehicle equipped
wheel nut wrench), remove
NZZGBAB
tool (wheel cap wrench

the center cap.
Caution
Use a piece of cloth or other, similar
material
prevent scratching
the wheel when the wheel
wrench or wheel nut wrench is used.
or
to
cap
(2) For vehicles with manual free-wheel hubs, remove the

wheel caps as described below.
0 Move the wheel cap wrench or wheel nut wrench
as shown in the figure so as to slightly lift the
wheel cap so that there is a space. Insert a
screwdriver in this space.
0
0
For front
wheel
For rear wheel
SERVICE
3.
Remove
the wheel cap wrench
or wheel nut
1
J
wrench and use it at the opposite side.
Move each tool as shown in the figure so as to $ ;$
remove the wheel cap.
.
4t
POINTS
INSTALLATION
OF INSTALLATION
OF CENTER
N22GDM
CAP HOLDER
NOTE
Note that the center cap attaching
metal fittings
front and rear wheels are different in shape.
for the
C;t ends
Front
wheel
(1) Align any of the guides (three projections)

inside the
fitting with a bolt position, and install the fitting on the
hub, while using care to make sure that the cut ends
are not opened. (Front wheel)
Flea! wheel
(2) Align any of the guides (three projections)

inside the
fitting with the position of a wheel attaching
hole (6)
and install the fitting properly to the disc wheel from
inside the disc wheel. (Rear wheel)
( STB Revision
i
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22-6
WHEELS
AND TIRES - Wheels and Tires

WHEEL
/ Spare
Tire Carrier
ROTATION
N22GE.-
Rotate the wheels in order to equalize

illustrated.
TIRE CHAINS
03-W
AND SNOW
tire wear in the patterns
TIRES
N22GGAB
1. Use tire chains only on rear wheels. Do not use tire chain
on front wheels.
2. When using snow tires, use them on all four wheels for
maneuverability
and safety.
60E501
SPARE TIRE CARRIER

REMOVAL
AND
INSTALLATION
N22HA-
8-10 Nm
6-7 ftlbs.
llW600
Removal
steps
1. Hub nut
NOTE
(2) **
: Refer to Service Points of Installation
2. Spare tire
l + 3. Spare tire bracket
SERVICE
POINTS
OF INSTALLATION
3. APPLICATION
OF SEALANT
Apply a coat of the specified
bracket mounting
bolts.
Specified
sealant
STB Revision
http://vnx.su/
N22HDAC
TO SPARE TIRE BRACKET

sealant around the spare tire
2-1
SUSPE
CONTENTS
AXLE HUB AND FREE-WHEELING
DIFFERENTIAL
CARRIER
DRIVE SHAFT
FRONT
INNER
KNUCKLE
LOWER
...................................
MOUNTING
INFORMATION
SHAFT
...........
52
.................................
2
62
44
ARM
......................................................
Replacement
of Lower Arm Bushing
.............
Replacement
of Lower Ball
Joint Dust Cover ..............................................
SERVICE ADJUSTMENT
PROCEDURES
..........
Checking Drive Shaft End Play ........................
Checking Front Axle Total Backlash
...............
..................................
and Adjustment
of Wheel
........................................................
Replacement
of Differential Carrier Oil Seal
ABSORBER
Replacement
SPECIAL
TOOLS
AND UPPER
of Upper Ball Joint
ARM
SPECIFICATIONS
...............................................
....................................
Lubricants
.......................................................
42
42
14
16
15
14
... 17
............
....................
................................................
40
16
Inspection
Alignment
SHOCK
STABlLlZER
TORSION
.....................................................
Gear Oil Level

BAR
.. . . . . . . . . . . .. .. . . . . . . . . .. . . . . . . .. . .
. . . . . . . . . .. .. . . . . . . . . .. .. . . . . . .. . . . . .
. . . . . . . .. . . . . . . .. .. . . . . . . . .. . . . . .
7
!?I
6 ,-.
. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. .. . . . . . . . .. . . . . 51
66
................
...........................................................
Checking
16
68
.....................................................
DIFFERENTIAL
GENERAL
HUB
35
37
8
4
4
7
BAR
TROUBLESHOOTING
. . .. . . . . . . . . .. .. . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . .. . . . . 48
.. ..a...................................
AUTOMATIC
FREE WHEELING
Does not lock
Locks but does not become
HUB
11
. . .. .. . . . . . . . 11
free
:
,-,,.t
Ratcheting
readily occurs
-$ I ;j;;.
.. . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. .. . . . . . . . . . I$ -:Y+:
DIFFERENTIAL
II. ,;.
Bearing noise while driving or. coasting
: , ,.;,
;
Constant noise
i t
.:I
. ,;J.;
Gear noise while coasting
.a
*;,*.,..,.f. .
Gear noise while driving
:.
k
Heat
j L.t
Noise while turning
Oil leakage
DRIVE SHAFT, INNER SHAFT . . .. . .. . . . . . . .. .. . . . . . . . 12
Noise due to excessive play of wheel in
turing direction
Noise due to excessive wheel end play
Noise during wheel rotation
MANUAL FREE WHEELING
HUB,
FRONT AXLE HUB, KNUCKLE
. . . . . .. .. . . . . . . . . .. .. . . . 11
Noise due to excessive play of wheel in
turning direction
http://vnx.su/
?i
,;
2-2
FRONT
GENERAL
SUSPENSION
Information
- General
I FORMATION
The-front suspension
torsion bar spring.
NOZBBAA
is an independent
suspension
which
is a combination
of the double-wishbone
and
The front axle assembly consists of a front differential,

a Ihousing tube, an inner shaft, drive shafts, etc.
For better serviceability
of the differential,
the spacer for backlash iadjustment
of the final drive gear is
placed between the side bearing outer race and the gear carrier.
The double-offset-joint
which can slide in the axial direction,
is used at the differential
carrier side; the
Bit-field joint, with large operation angle, is used at the axle hub side.
To reduce vibration, noise, and fuel consumption
when 2WD is applied, manual or automatic
free-wheeling
hubs are equipped;
in particular, tha automatic
one is an outstanding
feature in that the driver can switch
between
lock and free without having to leave his seat.
R
Drive
sh
Torsion
Shock
absorber
Free-wheeling
Drive
if.
I i
Follower
Clutch
shaftL.H.
Lower
MANUAL
bar
hub
arm
FREE-WHEELING
HUB
OPERA-K)ly
Free State + Locked State

When the control handle is set to the LOCK position,
the
follower moves along the oblique groove in the control handle
and causes the clutch (which is always in mesh with the freewheeling
hub body) to engage the splines of the inner hub,
thus coupling the free-wheeling
hub body with the drive shaft.
f
I_...
lS063
;,;a F
PJ
>
Locked State + Free State

When the control handle is set to the FREE position,
the
follower moves along the oblique groove in the control handle
and uses the tension spring to disengage
the clutch from the
splines of the inner hub, thus separating the free-wheeling
hub
body from the drive shaft.
Tension/spring
11 SO63
wision
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FRONT
SUSPENSION
General
AUTOMATIC
Information
FREE-WHEELING
2-3
HUB OPERATlq$m
he@ State + Locked State

When the transfer is shifted from 2WD to 4WD and driving is
begun, rotation of the drive shaft is transmitted
from the drive
gear to the slide gear to the cam to retainer (A) to brake (A).
When this happens, brake (A) is pressed against brake (6) by
the function of the cam of retainer (A), and friction force is
generated.
Because brake (B) is secured to the knuckle.
retainer (A)
ceases to rotate, and therefore, the cam, while compressing
the return spring, rises out of the cam groove of the retainer
(A) and compresses
the shift spring. The slide gear is pushed
by the shift spring, and then engages with the gear of the
_.
housing when the two are in phase and enters the locked *,state.
The cam turns until the lug of the drive gear contacts the lug of
brake (A). Because of this contact, brake (A) is turned by the
drive gear, and therefore, there is also no longer any force of
retainer (A) with a tendency to turn brake (A). As a result, there
is also no longer any force which presses brake (A) against
brake (B) and the drive gear causes brake (A) to turn lightly. (there is no friction force).
Because the cam remains meshed, it turns until it contacts the
lug of retainer (A), and is locked.
Free
state
Locked
state
~04:
Locked State +Free State

When the transfer is shifted from 4WD to 2WD and the vehicle
1,s:
!.
is driven in reverse, rotation
of the gear of the body is
transmitted
from the slide gear to cam to retainer (A) to brake J%.C
(A), but retainer .(A) ceases to turn, just as when the shift is?<,.,!;
made from the free state to the locked state. The can$
!:i;.i
therefore, turns as far as the cam groove of retainer (A)-and is ,t!?
pushed into the cam groove by the return spring.
if
:!
The slide gear moves with the cam, disengages
from the gear ....,.C
[ ,I:; +,;:
of the doby, and enters a free state.
\:
llWO23
Lug
Locked
state
of the
retainer
(A)
Meshed
state
llWO44
wision
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2-4
FRONT SUSPENSION
- Specifications
SPECIFICATIONS
GENERAL
SPECIFICATIONS
NOZCA-
Specifications
Items
Suspension
system
Independent double wishbone

shock absorber
8
Kingpin inclination angle
with torsion bar and telescopic
Torsion bar
Length x O.D.
mm (in.)
Spring constant
1277.5 x 24.5 (50.29!5 x ,965)
N/mm (Ibs./in.)
22 (123)
Shock absorber
Hydraulic cylindrical
Type
Maximum
length
Compressed
Stroke
mm (in.)
length
mm (in.)
215 (8.46)
120 (4.72)
mm (in.)
Damping force [at 0.3m/sec.

Expansion
N (Ibs.)
double-acting
335(13.19)
(.984 ft./set.)]
1,940-2,560
N (Ibs.)
C,o$Wion
Front axie hub bearing
(428-564)
900-I ,300 (198-287)

Tapered roller bearing
Type
Dimensions
(O.D. x I.D.)
mm (in.)
Outer
7:3.431 x 45.242 (2.8910 x 1.7811)
,. Inner
7r3.431 x 45.242 (2.8910 x 1.7811)
Drive shaft
. Joint type
Length
$ (Joint to joint)
Outer
B.J. (Birfield Joint)
Inner
Right
D.O.J. (Double Offset Joint)

267 (10.5)
Left
mm (in.)
mm (in.)
294(11.6)
Q&-rer shaft
x
;:(Shaft
overall length
mm (in.)
,.&earing
$3s O.D. x I.D.
mm (in.)
Differential
432 (17.0)
62 x 35 (2.44 x 1.38)
Final drive gear type

Reduction
Differential
Number
Hypoid gear
4.625
ratio
gear type
Straight bevel gear
of teeth
Drive gear
Drive pinion
37
8
Side gear
Pinion gear
I 4
I 0
rSTB
Revision
http://vnx.su/
type
FRONT SUSPENSION
2-5
- Specifications
NOZCE-
Items
Specifications
Standard values
Toe-in
mm (in.)
2-9 (.08-.35)
Camber
lt30
Caster
257 i 30
0.2-0.5 (.008-.020)
Drive shaft end play

mm (in.)
Front hub turning resistance
Ncm (in.lbs.)
[Spring scale reading]
N (Ibs.)
30-I 30 (2.6-l 1.3)

5-18(1.1-4.0)
Front hub play in the axial direction
0.05 (.0020) or less
Automatic
free-wheeling
Brake contact surface

Brake assembly
mm (in.)
hub
height
thickness
Upper ball joint starting torque

Clearance between
Shock absorber
Stabilizer attaching
dimension
mm (in.)
dimension
bolt end attaching
Anchor arm attaching
dimension
(.465-,480)
10.5 (.41)
Ncm (in.lbs)
and bump stopper
bump stopper
attaching
11.8-12.2
mm (in.)
mm (in.)
80-350 (7-30)
bracket
mm (in.)
71 (2.80)
7-8 (.27-.31)
mm (in.)
6-8 (.24-.31)
..:
mm (in.)
L.H.
135.2-143.2
R.H.
124.3-l 32.3 (4.894-5.210)
Setting of D.O.J. boot length
mm (in.)
(5.323-5.638)
77-83 (3.03-3.27)
Differential
Final drive gear backlash
Differential
mm (in.)
gear backlash
0.1 l-0.16
mm (in.)
O-0.076 (O-.0030)
Drive pinion rotation torque

Nm (inlbs.)
with oil seal
without
oil seal
(.0043-.0063)
0.6-0.7 (5.2-6.1)
Nm (inlbs.)
0.4-0.5 (3.5-4.3)
Limits
Front axle total backlash
Automatic
mm (in.)
free-wheeling
Free-wheeling
hub
hub turning resistance
9.6 (.378)
35 (1.38)
mm (in.)
Shift spring deterioration
mm (in.)
30(1.18)
Nm (ft.lbs.)
15(11)
N (Ibs.)
mm (in.)
ball joint end play
100 (8.7)
14(3.1)
mm (in.)
Upper arm shaft starting torque

Ncm (in.lbs.)
N(lbs.)
Brake assembly thickness

Return spring deterioration
Lower
14(.55)
6.8 (1.5)
0.5 (.020)
Differential
Drive gear runout
Differential
mm (in.)
gear backlash
0.05 (.0020)
mm (in.)
0.2 (.008)
) STB Revision
http://vnx.su/
2-6
FRONT SUSPENSION
- Specifications
TORQUE SPECIFIC
NOZCC-
Nm
Items
Automatic
free-wheeling
hub cover
ft.lbs
18-35
13-25
Manual free-wheeling
hub cover
Free wheeling jub body or drive flange
Front hub to brake disc
Knuckle to front brake assembly
IO-14
7-10
50-60
50-60
80-100
36-43
Upper arm shaft to crossmember
100-120
72-87
Rebound
8-12
6-9
43-65
stopper to upper arm
36-43
58-72
Upper ball joint to knuckle

Front shock absorber to crossmember
60-90
12-18
Front shock absorber to lower arm

Lower ball joint to knuckle
15-22
120-180
87-130
Lower arm shaft
140-160
101-116
Lower arm ball joint to lower arm

Bump stopper to lower arm
54-75
20-30
39-54
Anchor arm B
95-l 20
69-87
Anchor arm lock nut
40-50
29-36
Stabilizer bar clamp A
8-12
6-9
Knuckle to tie rod assembly
45
Right drive shaft to inner shaft
50-60
33
36-43
Left diffefential
mounting
bracket to differential
carrier
Right differential mounting bracket to housing tube

Differential mounting brackets to frame
Housing tube to differential
Bracket to differential
carrier
carrier
kront propeller shaft to differential carrier

Faont suspension
crossmember
mounting
Irain plug
.. .
zjller plug
$mpanion
jover
bolts
flange
3earing cap
9-13
11-16
14-22
80-100
80-100
58-72
80-110
80-100
58-80
58-72
80-110
58-80
50-60
100-120
36-43
58-72
60-70
72-87
43-51
40-60
2943
160-220
15-22
116-159
11-16
55-65
40-47
case to drive gear
80-90
58-65
Jnder skid plate to side frame
18-25
Jnder cover to frame

3rake tube flare nut
IO-13
13-18
7-9
13-17
9-12
Differential
LSTB Revision
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FRONT SUSPENSION
LUBRICANTS
2-7
- Specifications
\
Items
NOZCD-
Quantity
Specified lubricants
Front axle gear oil

Front differential
1.10 lit.
(1.16 U.S. qts., 0.97 Imp. qts.)
Hypoid gear oil

API classification GL-4 or higher
SAE viscosity NO. 80 W, SO
Multipurpose grease
Front axle hub bearing

Oil seal lip
As required
Multipurpose
grease
As required
Multipurpose
grease
As required
hub
Multipurpose
grease
As required
Upper and lower ball joints
Multipurpose
grease
As required
Torsion bar serrations, anchor arm

assembly serrations, anchor arm 6
serrations, dust cover inside and
anchor bolt thread
Multipurpose
grease
As required
Needle bearing
Multipurpose
grease
As required
Multipurpose
grease
As required
Repair kit grease

Repair kit grease
110g(1.902.)
110g(1.90z.)
Housing tube dust seal lip
Multipurpose
grease
As required
Housing tube dust cover
Multipurpose
grease
As required
Companion flange contacting

surface of the washer
Multipurpose
grease
As required
Automatic
free wheeling
Manual free wheeling
hub
Contact surface of knuckle

spacer
D.O.J. boot grease
B.J. boot grease
SEALANTS
and
, .,. : #I
..,
.I
Items
Specified
Slot of the upper or lower ball joint

Contact surface of free-wheeling
I
f
AND ADHESIVES
Drive gear threaded
3M ART Part No. 8663, No. 8661 or equivalent

hub and front axle hub
hole

3M Adhesive
Gasket
STUD LOCKING 4170 or equivalent
f STB Revision
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2-8
FRONT SUSPENSION
- Special Took
SPECIAL TOOLS
NOZDA-
Tool (Number
and name)
MB990955-01
Oil seal installer
attachment
Use
Pressing of front a
hub oil seal
Sliding hammer
Disassembly
and
reassembly of
automatic
free-wheeling
hut
Removal of side
bearing inner race
set
Pressing
of differential
Pressing of drive pinion

bearing outer race
MB990778-01
Ball joint remover
Removal of knuck
Disconnection
of
upper ball joint
MB990799-01
Ball joint remover
and installer A
Removal and
installation of upr
MB990800-01
MB990840-01
Universal joint remover
and installer
Lock nut wrench
ustment
of lock
ME3990809-01
Pitman arm puller
1 STB Revision
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Removal of knuck
Disconnection
of
FRONT SUSPENSION
Tool (Number
and name)
MB990958-01
Torsion bar bushing
and installer
remover
M B990883-0 1
Arbor
Use
2-9
- Special Tools
Tool (Number
and name)
Use
MD998348-01
Bearing separator
Removal and pressing

inner shaft bearing

of the bushing B
M B990339-0 1
Pinion carrier bearing
puller

inner race
front bearing inner race
Removal of knuckle
Disconnection
of tie rod
MIT3031 73
Insert

inner race

bushing A
of
of
/I
M B990635-0 1
Steering linkage puller
Q
BJ
M B990956-0 1
Needle bearing instal1e.r
Pressing of knuckle
needle bearing

inner race
MIT44801
Collet set
CJ
e!J
cc
M B990985-0 1
Oil seal installer
Pressing
oil seal
of knuckle
(?
\
$
,.,J
,,
.
.I
Holding of end yoke 7, i
M B990767-0 1
End yoke holder
4. ..
$..
- .,
k,
6
63
G2J
MB991 150
Dust cover installer
Pressing of drive
shaft dust cover
Qs!@%l
Qaz
MB990901-01
Pinion height gauge set
/ STB Revision
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Adjustment of
pinion height
2-10
FRONT SUSPENSION
- Special Tools
Use
Use
MB990802-01
Bearing installer
Pressing of drive
pinion front bearing inner
race
Pressing of side
bearing inner race
M IT3041 80
Handle
Pressing of the drive

pinion oil seal
klB990031-01
Irive pinion oil seal installer
Pressing of drive
pinion oil seal
1 ST6 Revision
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2-11
FRONT SUSPENSION-Troubleshooting
TROUBLESHOOTING
Symptom
NOZEA-
Remedy
Reference
page
Replace
2-33
Front axle hub bearing play, seizure, wear
Check and adjust or replace if

necessary
2-l 5
2-23
Knuckle needle bearing play, seizure, wear
Replace
2-46
Free wheeling
hub serration
Replace
2-33
Free wheeling
hub looseness
Tighten or replace
2-29
Brake sliding portion worn
Replace parts and adjust hub

attaching surface shims
2-2 1
2-25
Brake (B) lug portion broken

Housing damaged
Drive gear damaged
Slide gear damaged
Retainer (A) damaged
Cam damaged
Shift spring deteriorated
Slide gear C ring out of position
Replace parts
2-25
Probable cause
MANUAL FREE
WHEELING HUB,
FRONT AXLE HUB,
KNUCKLE
Noise due to excesFree wheeling
sive play of wheel in
turning direction
hub serration
play
play
AUTOMATIC FREE
WHEELING HUB
Does not lock
Automatic
loose
Locks but does not
become free
free wheeling
hub attaching
Return spring deteriorated

Foreign substances
on tooth surfaces
drive gear and slide gear
Foreign substances
on tooth surfaces
slide gear and housing gear
Excessive
Ratcheting
occurs
readily
bolt
front power
Retighten
attaching
bolts
Replace parts
of
2-l 8
2-25
Clean tooth surfaces

parts
or replace
of
train resistance
Adjust differential
preload
Water in brake portion
Clean and then apply grease
Retainer (B) worn

Slide gear damaged
Housing gear damaged
Shift spring deteriorated
Replace parts
Automatic free wheeling

bolts loose
Retighten the attaching
hub attaching
1 STB Revision
http://vnx.su/
bolts
2-2 1
2-25
2-l 8
., ;
-.. 2-12
FRONT SUSPENSION
ymptom
-Troubleshooting
-lizRemedy
Probable cause
Reference
we
RIVE SHAFT, INNER

-iAFT
Noise during wheel
rotation
Replace
2-62
Replace
2-64
Check or replace
2-52
Replace
2-62
2-74
Replace
2-52
2-74
Replace
2-52
2-62
Adjust or replace
2-J 6
Tighten or replace
2-62
Improper adjustment of drive gear and drive

pinion (poor meshing)
Correct or replace
2-68
Loose, worn or damaged
side bearing
Correct
or replace
2-73,76
Loose, worn or damaged

bearing
drive pinion
Correct
or replace
2-73,
2-76
Housing tube bent

Inner shaft bent
Inner shaft bearing worn,
pounding
r Drrve shaft assembly worn damaged, bent

--Noise due to excesInner shaft and side gear serration play
sive play of wheel in
turning direction
Drive shaft and side gear serration play
Drive shaft and drive flange serration
play
Noise due to excesDrive shaft and drive flange end play

sive wheel end play Drive flange looseness
FFERENTIAL
Constant
noise
Correct or replace
2-73,76
Replace
2-73,76
Replace
2-73, 76
Replace
2-73, 76
Foreign material

necessary
2-73,
2-76
No oil
Fill or change
2-l 6
Poor gear engagement
Correct
or replace
2-69
Improper
gear adjustment
Correct
or replace
2-69
Improper
drive pinion preload adjustment
Correct
or replace
2-77
Worn drive gear, drive pinion

Worn side gear thrust washer
shaft
Gear noise while

driving
or pinion
Deformed
drive gear or differential
Damaged
gear
Damaged
case
gear
Replace
2-73,76
Foreign material

necessary
2-73,
2-76
Insufficient
Fill or change
2-16
oil
bTB
Revision
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T.
.
FRONT SUSPENSION
symptom
Gear noise while
coasting
2-13
-Troubleshooting
Probable cause
Remedy
Reference
page
Improper drive pinion rotation torque

adjustment
Correct or replace
2-77
Damaged
gear
Replace
2-73,76
drive pinion rear
Replace
2-73,
2-76
differential
Bearing noise while

driving or coasting
Cracked
bearing
Noise while turning
Loose side bearing
Replace
2-73, 76
Damaged
shaft
Replace
2-73,
2-76
Adjust
2-69
Fill or change
2-16
Clogged vent plug
Clean or replace the parts
Cover tightened not

Seal malfunction
Retighten, apply sealant, or replace the gasket
2-73,
2-76
Replace
2-73,76
Excessive
Adjust the oil level
2-l 6
Heat
side gear, pinion gear or pinion
Improper differential
Excessive preload
Insufficient
Oil leakage
or damaged
gear backlash
oil
oil
/ STB Revision
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2-14
FRONT
SlJSPiENSlON
- Service
Adjustment
Procedures
SERVICE ADJUSTMENT
INSPECTION
ALIGNMENT
AND
PROCEDURES
NOZFBAC
ADJUSTMENT
OF WHEEL
1. Mea:sure the wheel alignment

with the vehicle parked on
level ground and with the front wheels placed in the
straight ahead positions.
2. Front suspension,
steering
system,
wheels
and tires
should be serviced to normal condition
prior to measurement of wheel alignment.
TOE-IN
1. Measure
Standard
the toe-in.
value
: 2-9 mm (.08-.35
in.)
2.
If the toe-in does not agree with the standard value, use
the left and right tie rod turnbuckles
to adjust it.
3. Make the adjustment
by turning the left and right turnbuckles the same amount
in opposite
directions.
The toe-in
value will decrease if the left turnbuckle
is turned toward
the front of vehicle and the right one is turned toward the
rear, and vice a half-turn of the turnbuckles
will result in an
approximately
15 mm (.59 in.) adjustment
in the toe-in.
CAMBER
I. Remove the free-wheeling
hub.
2. Measure the camber with a camber/caster/kingpin
Standard
3.
value
gauge.
: 130
Make adjustment
of the camber by incerasing
or decreasing the thickness
of the adjusting
shims between
the
upper arm shaft and the crossmember.
A total of 4 mm (.I6 in.) shim thickness is normally required
for standard camber. A 1.0 mm (.039 in.) adjustment
in
thickness
of shims will provide about 13 minutes
adjustment of camber.
Camber
adjustment
1 STB Revision
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shim
(yellow
plating)
FRONT
SUSPENSIO
- Service
Adjustment
2-15
Procedures
CASTER
I.
2.
Remove the free-wheeling

hub.
Measure caster with a camber/caster/kingpin
turning radius gauge.
Standard
Leir
To increase
To increase
To reduce
caster
caster
value
: 257
gauge
and a
t 30
If caster does not meet specifications,

remove the upper
arm from the crossmember
and then adjust by turning the
2
upper arm shaft.
A half turn of upper arm shaft will cause 1.25 mm (.049 in.),
fore or aft movement
of the upper arm shaft, resulting in
about 17 minutes adjustment
of caster.
*The adjustment
must be made so that the difference
between the casters left side and right side is within 30;
!.
minutes.
1
12w529
CHECKING
FRONT
AXLE
TOTAL
BACKL/iSi
1. If the vehicle vibrates and produces a booming

sound due
to the unbalance
of the drivetrain,
measure the front axle
total backlash as follows to see if the differential
carrier
assembly
requires removal.
(1) Set the hubs for 4WD.
0
NOTE
On vehicles with manual free-wheeling
hubs, place the ,:1
< f:. (.I.
control handles in the LOCK position.
>*
On vehicles with automatic
free-wheeling
tubs, place; *..the transfer shift lever in 4H position
and drive the .
vehicle 1 to 2 m (3.3 to 6.5 ft.) to engage the hubs with<:,.,.
ii :
the drive shafts.
:* ,+
(2) Secure the wheels and set the transfer control lever to - Z;
.;$
2H.
ii.,..;
NOTE
.:
If the vehicle is raised on a jack, the wheels will turn
and it will not be possible to measure the backlash.
(3) Turn the companion

flange clockwise
until all play is
removed. Make mating marks on the dust cover of the
companion
flange and on the differential
carrier.
1
http://vnx.su/
2-16
FRONT
SUSPENSION
Service
Procedures
Adjustment
(4) Turn the companion

flange counterclockwise
until all
play is removed and measure the amount of distance
through which the mating marks moved.
(5) If the backlash exceeds the limit, remove the differential carrier assembly and adjust the backlash and drive
shaft or inner shaft spline play.
L.imit
2.
: 14 mm ($5 in.)
If the backlash exceeds the limit, remove the differential

carrier assembly
and final drive gear, and check for
differential
gear meshing condition
and drive shaft or inner
shaft spline looseness.
CHECKING
GEAR OIL LEVEL
NOZFEAB
Remove the filler plug and check the oil level. The oil level
should be somewhere
within 8 mm (.31 in.) from the bottom
of the filler plug hole.
Specified
gear oil
CHECKING
: Hypoid gear oil API classification

GL-4
or higher SAE viscosity
No. 8OW, 90
[I.10 lit. (1.16 U.S.qts.,
0.97 Imp.qts.)]
DRIVE
SHAFT
END PLAY
NOZFFAA
VEHICLES
WITH AUTOMATIC
FREE-WHEELING
HUBS
I. Place the free-wheeling
hubs in the free condition.
NOTE
The free condition
can be obtained by shifting the transfer
shift lever to the 2H position and then moving in reverse
for 1 to 2 m (3.3 to 6.5 ft.).
2.
3.
4.
5.
Jack: the vehicle up and remove the front wheels.

Remove the free-wheeling
hub covers.
Rotate the drive shaft forward, and backward and then set
the drive shaft to the position (the position where end play
is maximum)
mid-way between where the rotation feels
heavy for each (where there is a stopping
feeling).
Set the dial gauge as shown in the figure; then move the
drive shaft in the axial direction
and measure the play.
Standard
6.
value
: 0.2-0.5
mm (.008-.020
If the play is out of standard

removing shims.
value,
in.)
adjust
by adding
or
llWO2!
VEHICLES WITH MANUAL

FREE-WHEELING
HUBS
I. Jack the vehicle up and remove the front wheels.
2. Move the control handles for the free-wheeling
hub to the
FREE position.
3. Remove the free-wheeling
hub covers.
4. Set the dial gauge as shown in the figure; then move the
drive shaft in the axial direction and measure the play.
Standard
5.
wision
value
: 0.2-O-5 mm (.008-.020

removing shims.
I
I
http://vnx.su/
value,
in.)
adjust
by adding
or
FRONT
SUSPENSION
Service
Adjustment
REPLACEMENT
SEAL
1. Remove
2. Remove
3. Remove
2-17
Procedures
OF DIFFERENTIAL
CARRIER
OIL
NOZFGAB
the under cover. (Refer to 2-40.)

the front hub and knunkle assembly.
the left drive shaft. (Refer to 2-52.)
Caution
When pulling
the left drive shaft from the differential
carrier assembly,
be careful that the drive shaft spline
does not damage the oil seal.
4. Remove
bly.
5. Remove
tools.
the right drive shaft from the inner shaft assemthe inner
shaft
assembly
by using
Caution
When pulling the inner shaft assembly
tial carrier, be careful that the spline
the special
i
from the differen;

of the inner shaft-!<;,
l. -I
6. Remove
the differential
mounting
bracket
(R.H.)
housing tube. (Refer to 2-66, 68.)
7. Use the special tool to remove the oil seal.
8. Press-fit the oil seal positively

apply a thin coat of specified
seal.
Specified
grease
: Multipurpose
No. 2
and
with the special tool and

grease to the lip of the oil : .
.. *,::
grease
SAE 5310, NLGI

the oil seal
NOTE
On R.H. side, after installation
of the oil seal, install the
housing tube and differential
mounting
bracket (R.H.).
Install the inner shaft with care not to damage the oil seal
lip, and install the drive shaft.
Caution
Be careful not to damage the lip of the oil seal. Replace
the circlip which is attached
to the B.J. side spline with
a new one.
1 STB Revision
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ii
?
9. Install the drive shaft using care not to damage

lip.
10. Install the front hub and knuckle

11. Install the under cover.
,,,+$-
assembly.
2-18
FRONT SUSPENSION
AXLE
- Axle
HUB AND FREE-WHEELING
REMOVAL
AND
B&j00
58-72
INSTALLATION
(Vehicles,
Hub
and
Free-Wheeling
Hub
HUB
with
Automatic
Free-Wheeling
Hubs) NOZGA--
Nm
ft.lbs.
,13-25
80-100 Nm
58-72 klbs.
-T
/
130-200 Nm+ONm+25
Nm
94-145 ft.lbs.+Ofit.lbs+lB
ft.lbr
_c
Removal
.5040
3643
steps
1. Cover
l + Adjustment of drive shaft end play
2. Snap ring
l *
3. Shim
4. Front brake assembly
++
l + Adjustment
of automatic
free-wheeling
hub
turning resistance
5. Bolts
+*
l + 6. Automatic
free-wheeling
hub assembly
I)* Height adjustment of brake contact surface
+*
7. Shim
4*
4*
8. Lock washer
l 4 Adjustment of wheel bearing preload
9. Lock nut
10. Front hub assembly
NOTE
(2) ++ : Refer to Service Points of Removal.
(3) l * : Refer to Service points of installation
1 ST6 Revision
http://vnx.su/
Nm /
ft.lbs.
,k.
FRONT
SUSPENSION
Axle
SERVICE
Hub
and
POINTS
2-19
Hub
Free-Wheeling
OF REMOVAL
1. REMOVAL OF COVER
(1) Place the free-wheeling
NOZGBAB
hub in the free condition.
NOTE
The free condition
can be obtained
by shifting the
transfer shift lever to the 2H position and then moving
in reverse for 1 to 2 meters (3.3 to 6.5 ft.).
(2) Remove
the automatic
free-wheeling
hub cover.
NOTE
When the cover cannot be loosened by hand, use an oil
filter wrench with a protective
cloth in between not to
damage the cover.
..
:::
__
,,#..f
.-..c
2.
4.
5.
Hexagonal
wrench
REMOVAL
OF SNAP RING
Using a snap ring pliers, remove
drive shaft.
,+. .
the sna$ ring from
r S&f;
the
:
REMOVAL
OF FRONT BRAKE ASSEMBLY
(1) Remove the front brake assembly with the brake hose
I .3;;: :
connected.
(2) Use wire to suspend the front brake assembly from thei,,,*
.i
upper arm so that the front brake assembly wont fall.
Ai
.,-iII-1:
Caution
I ._1
Do not twist the brake hose.
2.
REMOVAL
OF BOLTS
Remove tha automatic
hexagonal wrench.
1 STB nevlslon
http://vnx.su/
free-wheeling
hub
by using
the
FRONT SUSPENSION
- Axle
9.
Hub
and
Hub
Free-Wheeling
REMOVAL
OF LOCK NUT/IO.
FRONT HUB ASSEMBLY
(1) After the lock washer has been removed, remove the
lock nut with the Ispecial tool.
(2) Remove
the front hub assembly
from the knuckle
together with the inner and outer bearings.
4
r
5!
INSPECTION
l
l
l
Check the wheel bearing for seizure, discoloration

rough raceway surface.
Check the front hub -for cracks.
Check the oil seals for cracks and damage.
SERVICE
.
N02GCAA
POINTS
OF INSTALLATION
AD.JUSTMENT
OF WHEEL BEARING
(1) Using the special tool, tighten
following procedures.
PRELOAD
the lock nut
and
N02GDAB
by the
Tighten to 130-200 Nm (94-145 ft.lbs.)

+
Loosen to 0 Nm (0 ftlbs.)
11568
Retighten
to 25 Nm (18 ft.1b.s.) and then loosen 3P-40
(2) Loosen the lock nut approximately

30 to 40 degrees to
adjust the front hubs turning resistance and play in the
axial direction
so that they agree with the standard
*
values.
Standard
value
Standard
value
http://vnx.su/
: 30-130 Ncm
.
(2.6-l 1.3 in.lbs.)
.:. ,
5-18 N (I.140
Ibs.)
: 0.05 mm (.0020 in.) or less
FRONT
SUSPENSION
- Axle
Hub
and
Free-Wheeling
2-21
Hub
NOTE
If adjustment
is not possible,
the bearing
may
incorrectly installed; check and, if necessary, repair.
The lubrication
condition should also be checked.
be
(3) Mount the lock washer. If the lock washer holes do not
align with the lock nut holes, loosen the lock nut (no
more than 30 to 40 degrees) to align them.
HEIGHT ADJUSTMENT
OF BRAKE CONTACT
SURFACE
Measure the height of brake contact surface.
,p +
0 Using a depth gauge, measure the dimension
A shown f
1.
in illustration
at two points.
8:.*
T.
Standard
value : 11.8-12.2 mm (.465-.480
in.)
1,
0
6.
If the average
of the measured
values
standard value, adjust by inserting shims.
INSTALLATION
ASSEMBLY
OF AUTOMATIC
is out
FREE-WHEELING
..
ok
$
vjj 1
.%;::
HUB
(1) Apply a coating of specified sealant, equally all around

and without any missed spots, to the free-wheeling
hub body assembly
and front jub contact surfaces.
Specified
sealant
: 3M ART Part No.

8663, or equivalent
Caution
Make sure that there is no excess
on the hub outside
surface,
8661
specified
or No.
sealant
,.
I 2.
(2) Align the key of the brake (B) and the keyway of,
knuckle spindle and loosely install the automatic
free-l: t !,,..:$
5 ;*i;:wheeling hub assembly.
(3) Check that the hub proper and automatic
free-wheeling
-:I~,,$$+
hub assembly are brought into intimate
contact when
,,.:
the assembly is fored lightly against the hub proper. If
:,;.,
not; turn the hub until intimate. contact is achieved.
ADJUSTMENT
OF AUTOMATIC
FREE-WHEELING
HUB
TURNING
RESISTANCE
Check the automatic
free-wheeling
hub turning resistance
by the following procedure.
0 Use a spring scale to measure the front hub turning
resistance again. Subtract the value measured
in step
(1) from
that measured
here to find the turning
resistance of the free-wheeling
hub.
j STB Revision
).i.,
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2-22
RONT SUSPENSION
- Axle Hub and Free-Wheeling

L,imit
Hub
: 100 Ncm (8.7 in. Ibs.)

14 N (3.1 Ibs.)
If the free-wheeling
limit, disassemble
hub again.
hub turning resistance exceeds the

and reassemble
the free-wheeling
ADJUSTMENT
OF DRIVE SHAFT END PLAY
After the installation
of shim and snap ring, check the drive
shaft end play by the following
procedure.
0 Rotate the drive shaft forward, and backward and then
set the drive shaft to the position (the position where
end play is maximum)
mid-way between
where the
for each (where there is a
rotation
feels heavy
stopping
feeling).
Set the dial gauge as shown in the figure; then move
the drive shaft in the axial direction
and measure the
play.
!Standard
0
value
: 0.2-0.5
If the play isout of standard

removing
shims.
1 STB Revision
http://vnx.su/
mm
(.OO&.020
value, adjust
in.)
by adding
or
DISASSEMBLY
AND
REASSEMBLY
50-60
3643
Disassembly
1. Outer
bearing
NOTE
procedures
to reassemble.
(3) ++ : Refer to Service Points of Reassembly.
(4) @I : Non-reusable parts
3. Inner bearing
4. Brake disc
5. Front hub
4.
Iuter bearing
NOPHA-
Nm
ft.lb
SERVICE
)uter bearing
Hub)
steps
l 4 2. Oil seal
*I)
(Front Axle
Inner bearing
Inner bearing
f=i
POINTS
OF DISASSEMBLY
1
4
NOZHBAA
REMOVAL
OF BRAKE DISC
Make the mating marks on the brake disc and front hub,
and then separate
the front hub and brake disc, if
necessary.
REPLACEMENT
OF BEARING
NOZHDAB
di,
(1) Remove the oil seal.
4.;
(2) Wipe off grease from the front hub interior.
(3) Using the drift against,
drive out the inner and outer CT,,,:i
ri ,
bearing outer races by tapping them uniformly.
(4) Apply the specified grease to the outside surface of the
. .,
new inner and outer bearing outer races.
T
Specified grease : Multipurpose
grease SAE 5310, NLGI
No. 2
(5) Press-fit the inner and outer bearing
the special tools.
NOTE
The bearing inner race and bearing
replaced as an assembly.
evision
http://vnx.su/
outer
races by using
outer
race should
be
2-24
FRONT SUSPENSION
SERVICE
POINTS
Hub
OF REASSEMBLY
NOMEAB
2. INSTALLATION
OF OIL SEAL
(1) Apply the specified grease to the oil seal lip and inside
surface of the front hub.
Specified
grease
: Multipurpose
NLGI No. 2
grease
SAE 5310,
(2) Apply the specified grease to the inner bearing

race and install the inner race into the front hub.
Specified
grease
: Multipurpose
NLGI No. 2
grease
SAE
inner
5310,
(3) Press-fit the new oil seal into the front hub by using the
special tools, until it is flush with the front hub end
face.
STB Revision
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FRONT SUSPENSION
DISASSEMBLY
Disassembly
AND
REASSEMBLY

(Automatic
Free-Wheeling
Hub
Hub)
steps
1. Cover
2. O-ring
3. Housing
4.Housing
C ring
4*
l 4 5.Brake (B)
6. Brake (A)
7. Brake spring
8.Housing
snap ring
41)
9.Retainer
(B) C ring
41)
IO.
Drive
gear
assembly
4*
II.
Slide
gear
assembly
41)
4* +4 12. Return spring
l 4 13.Retainer
(B)
14. Retainer bearing
4*
4+
15. Drive gear snap ring

16. Retainer (A)
17. Drive gear
18. Slide gear C ring
19.Cam
20. Spring holder
21 Shift spring
22. Slide gear
NOTE
procedures
to reassemble.
(2) C) : Refer to Service Points of Disassemblv.
i3j 64 : Refer to Service points of Reassembly
(4) m
: Non-reusable
parts
1 STB Revision
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2-25
NOWA-
2-26
FRONT SUSPENSION
- Axle
Hub
SERVICE
4.
and
Hub
Free-Wheeling
POINTS
OF DISASSEMBLY
OF HOUSING
c RING
REMOVAL
Remove the housing
C ring.
NOTE
The ring is easily removable by pushing
using asmall-end
screwdriver, etc.
8.
REMOVAL
Remove
9.
OF HOUSING
the housing
NOlJBAA
SNAP
the brake (B) in and
RING
snap ring.
REMOVAL
OF RETAINER
(B) C RING
Using a special tool, lightly push the drive
remove the retainer(B)
C ring.
gear
in and
NOTE
Since the return spring relaxes approx. 40 mm (1.57 in.),
the stroke of the press should be set to more than 40 mm
(1.57 in.)
Caution
1. Place a protective
cover not to damage
the cover
attaching
surface of the housing
before setting
on
the press table.
2. Make sure that the pressing force does not exceed
200 N (44.1 Ibs.).
10. REIMOVAL
OF DRIVE GEAR ASSEMBLY/l
ASSEMBLY/lZ.
RETURN SPRING
Slowly reduce the pressure
spring fully relaxes.
1. SLIDE
of the press until
the return
Caution
When the pressure of the press is removed,
make
that the retainer
(A) is not caught by the retainer
/
llWO2C
r-STB
I tvision
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GEAR
sure
(B).
FRONT
SUSPENSION
- Axle
Hub
2-27
Hub
Free-Wheeling
OF DRIVE GEAR SNAP RING
15. REMOVAL
Remove
and
the drive gear snap ring.
Caution
When the drive gear snap ring is removed,
replace it with a new one.
18. REMOVAL
be sure to
OF SLIDE GEAR GRING
Push the cam in and remove

spring compressed.
the slide gear C ring with the
,.3
, .
!-
llWOl8
INSPECTION
l
l
o
l
l
, Brake (B)
E
-
NOZJCAA
Check the
Check the
damage.
Check the
Check the
damage.
Check the
wear and
drive gear and slide gear splines for damage.

cam portion
of retainer (A) for wear and
cam for wear and damage.
slide gear and housing
tooth
retainer
damage.
B and
housing
contact
surfaces
for
surfaces
for
,.?pZ
c, :;
4:. . .t:
./,:
Check the brake assembly
thickness
by following
the steps (j,:.:,zji ,j
! . .:,
below.
(1) Assemble
brake (A) and brake (B) and then use slide
k;y$
calipers to measure the thickness
of the assembly
at the
,-,,f
two lugs on brake (A).
.$
BRAKE ASSEMBLY
THICKNESS

Limit : 9.6 mm (.378 in.)
NOTE
Measure
each side separately.
(2) If the measured value is below

and brake (B) as a set.
STB Revision
http://vnx.su/
the limit,
replace
brake (A)
2-28
FRONT
SUSPENSION
AxIf:
Hub
and
Free-Wheeling
Hub
DETERIORATION
OF RETURN SPRING
Check the return spring for deterioration
by following
the
steps below.
(1) Measure
the dimension
A shown in illustration
at the
opposite side of spring end.
Limit
: 35 mm (1.38 in.)
Caut:ion
To measure
the dimension
A shown
in illustration,
measure the dimension
from the outermost
extremity
of
one wire diameter
to that of the other wire diameter.
llW567
(2) If the measured

DETERIORATION
value is below the limit,

OF SHIFT
replace
the spring.
SPRING
Check the shift spring for deterioration

by following
the steps
below.
(1) Measure
the dimension
6 shown in illustration
at the
opposite side of spring end.
Limi,t
: 30 mm (1.18 in.)
llW566
Cau,tion
To measure
the dimension
B shown
in illustration,
mealsure the dimension
from the outermost
extremity
of
one wire diameter
to that of the other wire diameter.
(2) If the measured
SERVICE
value is below the limit,
POINTS
Apply the specified

components.
Specified
grease
replace
the spring.
OF REASSEMBLY
grease
NOPJDAB
to the attaching
: Multipurpose
No. 2
grease
surfaces
SAE
of all
J310,
NLGI
13. AWLICATION
OF GREASE TO RETAINER
(B)
Pack the grooves of retainer (B) with the specified
Specified
grease
: Multipurpose
No. 2
grease
12. INSTALLATION
OF RETURN SPRING
Install the return spring with the smaller
toward the cam.
5.
APIPLICATION
OF GREASE
TO BRAKE
Pack the grooves
of brake
Specified
: Multipurpose
No. 2
grease
1 STB Revision
1
http://vnx.su/
grease.
SAE 5310, NLGI
coil diameter
side
(B)
(B) with the specified

grease
grease.
SAE 5310, NLGI
FRONT
REMOVAL
AND
SUSPENSION
INSTALLATION
with
(Vehicles
Manual
2-29
IHubS
Free-Wheeling
Hubs)
80-100 Nrb
58-72 ftlbs.
130-200 Nm+O Nm+2 5 Nm

94-145 ft.lbs.+Oft.lbss18
ft.lbs.
50-60
36-43
Removal steps
1. Free-wheeling hub cover
2. Gasket
+a Adjustment of drive shaft end play
3. Snap ring
*I)
4. Shim
+I)
+4 6. Manual free-wheeling hub assembly
7. Lock washer
+*
I)+ Adjustment of wheel bearing preload
a. Lock nut
l *
9. Front hub assembly
l *
*+
NOTE
(2) +* : Refer to Service Points of Removal.
(3) ++ : Refer to Service Points of Installation.
(4) m:
Non-reusable
parts
1 STB Revision
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Nm
ft.lbs.
lo-14 Nm
7.10 ftlbs.
N02GA-
Z-30
FRONT SUSPENSION
- Axle
Hub and Free-Wheeling
SERVICE
POINTS
Hub
OF REMOVAL
NOZGBBA
1. REMOVAL
OF FREE-WHEELING
HUB COVER
(1) Set the control handle to the FREE position.
(2) Remove the free-wheeling
hub cover.
3.
5.
REMOVAL OF SNAP RING

drive shaft.
REMOVAL
OF FRONT
the snap
ring from
the
BRAKE ASSEMBLY
connected.
(2) Use wire to suspend the front brake assembly from the
upper arm so that the front brake assembly wontt fall.
Caution
Do not twist
8.
the brake
hose.
REMOVAL
OF LOCK NUT/S. FRONT HUB ASSEMBLY
(1) After the lock washer has been removed,
remove the
lock nut with the special tool.
(2) Remove
the front hub assembly
from the knuckle
together with the inner and outer bearings.
118695
INSPECTION
l
l
l
Check the wheel bearing for seizure, discoloration

rough raceway surface.
Check the front hub for cracks.
Check the oil seal for cracks and damage.
1 STB Revision
http://vnx.su/
NOZGCAA
and
FRONT SUSPENSION
- Axle
SERVICE
Q
Hub
and
Free-Wheeling
POINTS
ADJUSTMENT
2-31
Hub
OF INSTALLATION
OF WHEEL
(1) Using the special

following
procedure.
BEARING
tool,
tighten
NOZGDBB
PRELOAD
the
Tighten to 130-200 Nm (94-145
lock
nut by the
ft.lbs.)
w
Loosen to 0 Nm (0 ft.lbs.)
Retighten to 25 Nm (18ft.lbs.)
and then loosen 3040
(2) Loosen the lock nut approximately

30 to 40 degrees
to
adjust the front hubs turning resistance
and play in the
axial direction
so that they agree with the standard
values.
Standard
value
Standard
value
: 30-130 Ncm (2.6-l 1.3 in.lbs.)

5-18 N (1.140
Ibs.)
: 0.05 mm (.0020 in.) or less
f"
,:I
: Ii .L
be{
1:
Cc.F
T :~~~~
. _*
(3) Mount the lock washer.
If the lock washer
holes do not
L .y
align with the lock nut holes, loosen the lock nut (no
more than 30 to 40 degrees)
to align them.
NOTE
If adjustment
is not possible,
the bearing
may
incorrectly
installed;
check and, if necessary,
repair.
The lubrication
condition
should also be checked.
6.
INSTALLATION
ASSEMBLY
OF
MANUAL
FREE-WHEELING
HUB
Apply a coating of specified

sealant, equally all around and
without
any missed
spots, to the free wheeling
hub body
assembly
and front hub contact surfaces.
Specified
---
sealant
: 3M ART Part No. 8661, No. 8663, or

equivalent
Caution
Make sure that there is no excess
the hub outside surface.
/ STB Revision
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specified
sealant
on
2-32
FRONT SUSPENSION
- axle
l
Hub
and
ADJUSTMENT
Free-Wheeling
OF DRIVE
Hub
SHAFT
END
After assembly in the order of the shim

ring, check the drive shaft end play.
PLAY
and then the snap
Set the dial gauge as shown in the figure; then move the
drive shaft in the axial direction
and measure the play.
Standard
wo70
value
: 0.2-0.5
mm

removing
shims.
~STB Revision
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(.008-.020
value,
adjust
in.)
by adding
or
FRONT
SUSPENSION
- Axle
Hub
and
DISASSEMBLY
Hub)
Refer
DISASSEMBLY
8
Disassembly
l d
l +
1.
2.
3.
4.
5.
6.
~~
7.
8.
*I)
l + 9.
10.
l +
+4 11.
12.
AND
REASSEMBLY
Free-Wheeling
AND
2-33
Hub
REASSEMBLY
(Front
NOZHA-
to P.2-23.
(Manual
free-Wheeling
Hub)
N02JA-
90
steps
Free wheeling
hub
Gasket
Free wheeling
hub
Compression
spririg
Follower
Tension spring
Free wheeling
hub
Wheel snap ring
Inner hub
Shaft snap ring
Free wheeling
hub
Spacer
Axle
cover
llW574

L
\
i, . j;
< ,..$,Z.f~
I
;. :?.:i,r.
clutch
:iq;
body
r: .p,
1,:
NOTE
(2) +e : Refer to Service Points of ,Disassembly.
(4) m:
Non-reusable parts
ring
SERVICE
8.
POINTS
REMOVAL
RING
OF DISASSEMBLY
OF WHEEL
SNAP
RING/lo.
NOPJBBA
SHAFT
SNAP
(1) Using a screwdriver,

remove the snap ring and remove
the inner hub from the free wheeling
hub body.
(2) Remove the snap ring from the inner hub with a snap
ring pliers.
1 STB Revision
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2-34
NT SUSPENSION
- Axle
Hub
and
Free-Wheeling
Hub
INSPECTION
0
0
0
NOZJCBA
Check the free wheeling

hub ring, inner hub, free wheeling
hub body, and clutch for wear or seizure.
Check the gasket for damage.
Check the compression
spring
and tension
spring
for
deterioration.
SERVICE
POINTS
OF REASSEMBLY
NOZJDBB
11. APPLICATION
OF GREASE TO FREE WHEELING
HUB
RING/g.
INNER HUB17. FREE WHEELING
HUB BODY/3.
FREIE WHEELING
HUB CLUTCH/l.
FREE WHEELING
HUB COVER
(1) Apply the specified grease to the entire periphery of
the free wheeling hub ring, inner hub and free wheeling hub clutch, free wheeling hub cover and the inside
of the free wheeling hub body.
hub clutch
Specified
Hub cover assembly

Hub body assembly
\
Grease
,Drive shaft
llWO7E
grease
: Multipurpose
NLGI No. 2
grease
SAE
J310,
(2) Check to be sure that the hub body assembly and hub
cover assembly ;are coated (at the positions shown in
the figure) with a sufficient coating of the specified
grease.
(3) ,4dd more grease if necessary.
IVOTE
,4 liberal amount of grease should be applied, especially when grease is wiped away or a new free-wheeling
hub is installed.
/ STB Revision
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RONT
SUSPENSION
Shock
Absorber
and
Upper Arm
2-35
SHOCK ABSORBER AND UPPER ARM

REMOVAL
AND
IO&120
INSTALLATION
N02MA--
Nm
72-87 ft.bls.
8-
6-12 Nm
6-9 ft.lbs.
60-90
43-65
Shock
absorber
l +
Upper
removal
1. Shock
arm
removal
Nm
ftlbs
15-22
11-16
401
-- 50 Nm
29-36 ft.lbs.
Nm
ft.lbs.
steps
absorber
steps
l + Adjustment of clearance between bump

stopper and bump stopper bracket
2. Anchor arm assembly adjusting nut
l *
3. Hose clip
4. Connection of brake hose
5. Cotter pin
6. Connection of upper ball joint and
knuckle
7. Brake hose support

8. Rebound stopper
9. Shim
l * l + 10. Upper arm
NOTE
to reinstall.
(4) q
: Non-reusable
parts
STB Revision
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2-36
FRONT SUSPENSION
- Shock Absorber
SERVICE
POINTS
and Upper Arm
OF REMOVAL
NOZMBAA
2. LOOSENING
OF ANCHOR
ARM ASSEMBLY
ADJUSTING NUT
Loosen the anchor bolt of the torsion bar all the way.
NOTE
When the anchor arm assembly adjusting nut is loosened,
use a jack to support the lower arm of the side to be
loosened, thus the work easier.
6.
DISCONNECTION
1OF UPPER
BALL
KNUCKLE
(1) Loosen the nut tightening
the upper
knuckle.
NOTE
The nut should
removed.
be partially
(2) lJsing a special tool,

from the knuckle.
loosened
disconnect
JOINT
FROM
ball joint
to the
and should
not be
the upper
Caution
Tie the special tool to the upper
with a string to prevent bouncing.
arm,
ball joint
for example,
10. REMOVAL
OF UPPER ARM
Remove the upper arm from the crossmember.
NOTE
The camber
adjustment
shims
should
be stored
reference at assembly.
Do not turn the upper arm shaft, as it changes caster.
12W5lC
INSPECTION
l
l
for
NOZMCU
Check the upper arm for cracks or deformation.

Check the upper arm shaft for cracks or bends.
SHOCK: ABSORBER
Expand and contract
the shock absorber
damage, oil leakage or abnormal
noise.
wision
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to check
it for
FRONT SUSPENSION
Shock
UPPER
Absorber
ARM SHAFT
and
Upper
STARTING
2-37
Arm
TORQUE
Check the upper arm shaft starting torque by following

the
steps below.
1. With the upper arm shaft held in a vice, measure the upper
arm shaft starting torque with a spring balance.
Limit
2.
: 15 Nm (1 lftlbs.)
6.8 N (1.5 Ibs.)
If the upper arm shaft starting

replace the upper arm assembly
UPPER
BALL JOINT
STARTING
torque
exceeds
the limit,
TORQUE
f .
Check the upper ball joint starting torque by following

the !
steps below.
I. Measure the upper ball joint starting torque with a torque,
wrench.
i, 4. .
, :
P
Standard
value : 80-350 Ncm (7-30 in.lbs.)
12se21
72.5(2.854)
2.
72.5(2.854)
If the upper ball joint starting

replace the upper ball joint.
UPPER
ARM SHAFT
TIGHTENING
Give appropriate
amount
the specified dimension.
Caution
The dimensions
shown
dimensions
that determine
REPLACEMENT
torque
is out of specification,
AMOUNT
of turn to the shaft so as to obtain
in the illustration
the caster.
are
OF UPPER BALL JOINT
important
NOZMDAB
t:
.,: 2;
,:. <.i,%
1. Remove the dust cover together

with the ring.
2. Remove the snap ring from the upper ball joint by using ax: ,ji
8;
snap ring pliers.
q :.~
;i :;;.
I;.i jr;.
*;
.i
120079
MB990840-01
Upper
arm
128055
3.
I
Press the upper ball joint out of the upper arm by using the
special tools.
ball joint
STB Revision
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2-38
FRONT
SUSPENSION
- Shlock Absorber
4.
and Upper
Arm
Press-fit the new upper ball joint with special

mark with the upper arm center.
tools aligning
the mating
,---
&tltf$f
.-
-01 C-+-+
upper arm=
MB990800
-3-01
5.
Using a snap ring pliers,

groove of the joint case.
Caution
Limilt the opening
fit the snap ring securely
of the snap ring to a minimum.
6. Apply the specified

grease to both
cover and the upper ball joint.
Specified
Specified
sealant
i ;/:,,,,
7.
Apply the specified

joint.
Specified
8.
grease
sealant
: Multipurpose
No. 2
sealant
POINTS
the interior
grease
to the grooves
of dust
SAE 5310, NLGI
in the upper ball
: 3M ART Pat-t No. 8663,

equivalent
Secure the dust cover to the upper
SERVICE
in the
ball joint
No. 8661 or
with a ring.
OF INSTALLATION
NOZMEAA
10. INSTALLATION
OF UPPER ARM
When the upper arm assembly
is installed
to the crossmember,
insert the upper arm shaft attaching
bolts from
outside the crossmember
and put adjusting
shims between the crossmember
and upper arm shaft.
ADJUSTMENT
OF CLEARANCE
BETWEEN
PER TO BUMP STOPPER
BRACKET
Refer
to P.2-49.
1 STB Revision
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BUMP
STOP-
FRONT
SUSPENSION
- Shock Absorber
1.
and Upper
Arm
2-39
INSTALLATION
OF SHOCK ABSORBER
(1) Tighten the shock absorber installation
nut so that the
dimension
shown in the figure is the standard value.
Standard
value
: 7-8 mm (.27-.31
in.)
12W533
(2) Install the shock absorber so that the white paint mark
at the lower side of the shock absorber faces the outer
side of the vehicle.
p :I
,!
r
-1
,.b
t
i.1
12W54:
/ STB Revision
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2-40
FRONT
SUSPENSllON
- Lower
Arm
LOWER ARM
REMOVAL
AND
INSTALLATION
NOPNA-
18-25
13-18
Nm
ftlbs.
18W654
1
15-22
Nm
11-16
ft.lbs.
IO-13 Nm
7-9 ft.lbs.
12W541
Nm
ft.lbs.
b%?
63
e3
40-50
29-36
120-180 Nm
87-130 ftlbs.
12W556
14-22
ftlbs.
!S4-75
139-54
Removal
steps
1. Under skid plate

2. Under cover
I)+ Adjustment
of clearance between
bump
stopper and bump stopper bracket
+I) l + 3. Torsion bar
4. Cotter pin
5. Connection
of lower ball joint and knuckle
l *
6. Self-locking
nut
I)+
4*
Nm
ftlbs.
7. Stabilizer
bar
8. Shock absorber
mounting
bolts
9.Lower arm shaft

lO.Anchor arm B
11. Lower arm
12. Bump stopper
13.Lower
ball
joint
mounting
nuts
NOTE
(2) +*
parts
(5)
[ STB Revision
: Must
II
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be
tightened
while
vehicle
is unladen.
FRONT
SUSPENSION
SERVICE
3.
POINTS
REMOVAL
Refer
5.
- Lower
OF REMOVAL
OF TORSION
NOZNBAA
BAR
to P.2-48.
DISCONNECTION
OF LOWER
BALL
KNUCKLE
(1) Loosen the nut tightening
the lower
knuckle.
NOTE
The nut should
removed.
be partially
loosened
JOINT
FROM
ball joint
and should
to the
A.:*
I.
+::
*I.
not be
!\4.
51 Iii:
(2) Using a special tool,

from the knuckle.
8.
2-41
Arm
disconnect
the lower
ball joint
REMOVAL
OF SHOCK ABSORBER
MOUNTING
BOLTS
Remove the shock absorber lower part and compress the
shock absorber.
INSPECTION
l
l
l
Check the lower arm for cracks or deformation.

Check the anchor arm assembly
for wear or damage.
i ,.,;,;,Y;;
Check the lower ball joint dust cover for cracks or ;, $
,. t
deterioration.
4, ..@
\B i;
LOWER BALL JOINT

END PLAY
Check the lower ball joint end play by following
the steps
below.
1. Measure the lower ball joint end play with a dial indicator.
Limit
2.
: 0.5 mm
(.020
If the lower ball joint

the lower ball joint.
http://vnx.su/
in.)
end play exceeds
the limit,
replace
2-42
FRONT SUSPENSION
- Lower Arm
OF LOWER ARM BUSHING
REPLACEMENT
1.
Using a special
bracket.
tool,
remove
the
bushing
NOTE
When removing
the left hand bushing
differential
carrier. (Refer to P.2-69.)
2.
Using a special
bracket.
tool,
3.
Remove
the
special tools.
4.
Coat the bushing B and the

and press-fit the bushing B
special tools and taking care
B.
NOl-E
Press-fit the bushing
again
equalize bushing projections
bushing
NOZND~
A from
the
A, detach
the
press-fit
the
bushing
B from
the
lower
A into
arm
the
by using
MB990883-01
12SO71
REPLACEMENT
COVER
lower arm with soap solution

into the lower arm by using
not to twist or tilt the bushing
from the opposite

at both ends.
OF LOWER
BALL
2.
Apply the specified

joint.
Specified
3.
wision
grease
Secure
sealant
: Multipurpose
No. 2
sealant
grease
to the grooves
DUST
of the dust cover
SAE 5310, NLGI
in the lower ball
: 3M ART Part No. 8663,

equivalent
the dust cover to the lower

I
http://vnx.su/
to
NOZNEAB
1. Apply the specified grease to the interior

and the lower ball joint.
Specified
JOINT
side
ball joint
No. 8661 or
with
a ring.
FRONT
SUSPENSION
SERVICE
- Lower
POINTS
2-43
Arm
OF INSTALLATION
NOZNFAA
7. INSTALLATION
OF STABILIZER
BAR
Install the stabilizer bar to the lower arm in such a way that
the amount of protrusion
of the stabilizer bar installation
bolt is the standard value.
Standard
value
: 6-8
NOTE
The dimension
show
bushing is used.
3.
.
mm
(.&l-.31
in figure
in.)
is the value
INSTALLATION
OF TORSION
BAR
Refer to P.2-48.
ADJUSTMENT
OF CLEARANCE
BETWEEN
PER AND BUMP STOPPER
BRACKET
Refer to P.2-49
1 STB Revision
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when
..
a n&V
+. .
BUMP
STbP-
T.
,:
vi
2-44
-.
FRONT
SUSPENSION
- Knuckle
KNUCKLE
REMOVAL
AND INSTALLATION
60-90
43-65
NOZPA-
Nm
ft.lbs.
80-100 Nm
58-72 ftlbs.
33 ftlbs.
18-35
120-180
Nm
87-130
ft.lbs.
36-43
ftlbs.
Nm
80-100 Nm
58-72 ft.lbs.
130-200 Nm + 0 Nm i, 25 Nm
94-145 ft.lbs. + 0 ft.lbs. $ 18 ftlbs.
lW14Nm
7-10 ft.lbs.
Manual
hub
i
11W611
Removal steps
+e 1)4 1.
2.
3.
4.
4*
4*
4*
5.
6.
7.
8.
9.
Front axle
Dust cover
Cotter pin
Connection
knuckle
Cotter pin
Connection
Cotter pin
Connection
Knuckle
free-wheeling
hub and free-wheeling
hub
of tie rod assembly and
of lower ball joint and knuckle

of upper ball joint and knuckle
NOTE
(2) +*
(3) I)4 : Refer to Service Points of Installation.
(4) m
/ STB Revision
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FRONT SUSPENSION
SERVICE
2-45
- Knuckle
POINTS
1. REMOVAL
HUB
OF REMOVAL
OF FRONT
AXLE
NOZPBAA
HUB AND FREE WHEELING
For models equipped

with the automatic
.free-wheeling
hub, refer to page 2-18; for models e,quipped with the
manual free-wheeling
hub, refer to page 2-29.
.4.
6.
DISCONNECTION
KNUCKLE
Disconnect
the
special tool.
I/
TIE
tie rod from
ROD
the
ASSEMBLY
knuckle
FROM
by using
the +, :
pf
Q
$i
Caution
1. Use cord to bind the special tool closely so it wo&
become separated.
2. The nut should be loosened only, not removed.
DISCONNECTION
OF LOWER
BALL
JOINT
FROM
KNUCKLE/8.
UPPER BALL JOINT
FROM KNUCKLE
Using
upper
j663
OF
the special
ball joint.
tool,
remove
the
lower
ball joint
and
Caution
1. Support
the lower arm with a jackwhen
removing
the knuckle from the lower ball joint or the upper
ball joint.
2. After the knuckle has been removed,
lower the jack
slowly.
12W524
INSPECTION
l
l
l
Check
Check
Check
SERVICE
the needle
the knuckle
the knuckle
POINT
NOZPCAA
bearing for wear or damage.

for cracks or bends.
spindle for wear or pounding.
OF INSTALLATION
1. INSTALLATION
OF
WHEELING
HUB
FRONT
AXLE
NOZPDAA
HUB
AND
FREE-
For mddels
equipped
with the automatic
free-wheeling
hub, refer to page 2-18; for models equipped
with the
manual free-wheeling
hub, refer to page 2-29.
/ STB Revision
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I\.
!
./I,
2-46
FRONT SUSPENSION
DISASSEMBLY
Disassembly
+ee+
AN
- Knuckle
REASSEMBLY
NOZPE-
steps
I)+
1. Oil seal
**
2. Spacer
3. Needle
4. Knuckle
bearing
llW605
NOTE
procedures
to reassemble
(2) 41) : Refer to Service Points of Disassembly.
(3) l rC : Refer to Service Points of Reassembly.
(4) q
: Non-reusable
parts
SERVICE
3.
POINTS
REMOVAL
OF DISASSEMBLY
OF NEEDLE
NOZPFAA
BEARING
(1) Remove the oil seal and take out the spacer.
(2) Drive out the needle
bearing
by tapping
uniformly.
Caution
Once removed,
reused.
SERVICE
3.
POIINTS
the
needle
bearing
needles
must
not
OF REASSEMBLY
NOZPGAB
INSTALLATION
OF NEEDLE BEARING
(1) /4pply the specified grease to the roller surface
new needle bearing.
Specified
grease
: Multipurpose
NLGI No. 2
grease
1 STB Revision
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driving
the needle
of the
SAE J310,
(2) Press-fit the needle bearing by using the special

until it is flush with the knuckle end face.
Caution
llse care to prevent
f,ar in.
be
bearing
tools,
too
FRONT SUSPENSION
2.
INSTALLATION
2-47
Knuckle
OF SPACER

surface of the spacer.
Specified
grease
grease
to the knuckle
: Multipurpose
NLGI No. 2
grease
(2) Install the spacer to the knuckle

side toward
the center or vehicle.
1. INSTALLATION
with
the
attaching
SAE
J310,
chamfered
OF OIL SEAL
(1) Press-fit
the new oil seal by using the special tools,
until it is flush with the knuckle end face.
(2) Pack the specified
grease in the oil seal inside and lip,.!,
Specified
grease
: Multipurpose
grease
:.
SAE 5310, NLGII:,
No. 2
,
/ STB Revision
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2-48
FRONT SUSPENSION
- Torsion
Bar
TORSION BAR
REMOVAL
AND
lNSTALLATlON
NOZSA--
iNl-50 Nm
12W558
Removal
I)+
l *
I)+
steps
1. Heat
Adjustment
stopper
2. Anchor
3. Dust
4. Heat
5. Torsion
protector
(right side only)
of clearance
between
bump
and bump stopper
bracket
arm assembly
covers
cover (left side only)
bar
NOTE
(2) 4*
SERVICE
2.
POINTS
OF REMOVAL
N02SBAA
REMOVAL
OF ANCHOR ARM ASSEMBLY
Support the lower arm from which the torsion
removed, with a jack.
bar is to be
INSPECTION
NOZSCAA
Check the torsion bar for bends or damage.

Check the dust cover for cracks or damage.
l
l
SERVICE
POINTS
OF INSTALLATION
NOZSDAB
Apply the specified grease to the torsion bar serrations,

the
anchor arm assembly serrations, the anchor arm B serrations,
the dust cover inside and the anchor bolt thread.
Specified
grease
1 STB Revision
: Multipurpose
No. 2
http://vnx.su/
grease
SAE
5310,
NLGI
FRONT
SUSPEIWION
5.
Mating
mark
Whie
Identification
mark
mark
M\ating rn,:,J
- Torsion
2-49
Bar
INSTALLATION
OF TORSION
BAR
(1) Identify the right and left torsion bars referring to the
identification
mark put on the torsion bars.
Face the end having identification
mark forward, and
align the mark on anchor arm B with the mating mark
on torsion bar when the torsion bar is inserted in the
anchor arm B.
NOTE
When installing
a new torsion bar, align the serration
painted white with the mark on anchor arm 9.
(2) Select the relative position of the torsion bar serrations
and the anchor arm serrations so that the length shown
:I-
in the illustration
may have specified dimension
when
the torsion bar and the anchor arm are assembled,
with ,
the upper arm rebound
stopper in contact with the:;.
crossmember.
Standard
12s6oo
value
: L.H. 135.2-143.2
in.)
R.H. 124.3-132.3
in.)
mm
(5.323-5.638
mm
(4.894-5.210
ADJUSTMENT
OF CLEARANCE
BETWEEN
PER AND BUMP STOPPER BRACKET
BUMP
(1) Use the curb weight to obtain the amount

bolt projection from the following table.
:;:
STOP-
of anchor
NOTE
The anchor bolt projection
amount
is a reference
dimension
used when the torsion bar spring is installed.
Finally, adjust so that the distance to the bump stopper
bracket is the standard value.
,
This method can also be used to make the adjustment
,!,
on previously sold vehicles.
;. !, ai::.
I.
..
Example
.;?
For a vehicle with a curb weight of 1,440 kg (3,175 lbs.),
the table shows the following
left and right anchor bolt5 p, .:!
projections.
i; ; $5.
h*t!;
Left
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 mm (2.36 in.)
k,
Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 mm (2.80 in.)
NOTE
For curb weights of the various models, refer to INTRODUCTION
- General
Date and Specifications.
80 (3.15)
I r nlgnr s
70 (2 76)
60 (2.36)
50 (1.97)
14wo31
40 (1.57)
1618 1712
1312 1316 141.0 14.4 14:8 1512 15:6 Id.0 Id4
(29.1 )(30.0)(30.8)(31.7)(32.6)(33.5)(34.4)(35.3~(36.2)(37.0)(37.9)(38.8~~39.7~l40.6
STB Revision
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1716
18!.0
1d.4
Curb weigh ItxlOOkg

(x 100 Ibs.)
.:
2-50
FRONT SUSPENSION
Torsion
Bar
(2) With the vehicle unladen, measure the dimension

from
the bump stopper to the bump stopper
bracket to
check for conformance
with standard value.
Standard
value
:: 71 mm (2.80 in.)
(3) If it is out of specification.

on the anchor bolt.
ii-J
12woo
/ STB Revision
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adjust with the adjusting
nut
FRONT SUSPENSION
Stabilizer
2-51
Bar
STABILIZER BAR
REMOVAL
AND
INSTALLATION
NOZTA-
7-9 ft.lbs.
Removal
I)+
steps
1.
2.
3.
4.
5.
6.
7.
8-12 r&l
6-9 ftlbs.
Under skid plate

Self-locking
nut
Clamp A
Stabilizer
bushing
Self-locking
nut
Hanger
Stabilizer
bar
12W555
NOTE
(I 1 Reverse the removal procedures to reinstall.
parts.
p
$jfJ / ;..
N02T& -.I;j
INSPECTION
l
l
l
Check the stabilizer bar for deformation

or damage.
6, .:::T. $
IJ;t. .; 2.
Check the hanger for bends or damage.
Check the rubber parts for cracks, deterioration
or wear!. ,:, .if
-bk ,.::
e,..
-:
&- ,.,
t &
SERVICE
POINTS
7. INSTALLATION
OF INSTALLATION
OF STABILIZER
BAR
When installing the hanger to the stabilizer bracket,

the nut so as to obtain the specified dimension.
Standard
value
When installing
arms, tighten
dimension.
Standard
value
: 6-8 mm (.24-.31
http://vnx.su/
tighten
in.)
both ends of the stabilizer bar to the lower

the nut so as to obtain
the specified
: 6-8 mm (.24-.31
NOTE
The dimension
shown
new bushing is used.
;
N02TOAA
in the figure
in.)
is the value when
2-52
FRONT SUSPENSION
- Drive
shaft
DRIVE SHAFT
REMOVAL
NOPClA-
AND INSTALLATION
Left drive
shaft
lo-13 Nm
7-9 ft.lbs.
Nm
ft.lbs.
50-60
35-43
Removal steps
4*
4*
4*
4*
4*
4*
4*
+e
1. Under cover
2. Cover
(automatic
free-wheeling
hub)
3. Free-wheeling
hub cover
(manual
free-wheeling
hub)
4. Gasket (manual
free-wheeling
hub)
1)4 Adjustment
of driveshaft
end play
5: Snap ring
6. Shim
8. Cotter pin
9. Connection
of tie rod assembly
and
knuckle
10. Cotter pin
11. Connection
of lower
ball joint and
knuckle
12. Cotter pin
13. Connection
of upper ball joint and
knuckle
14. Front hub and knuckle assembly
l + 15. Left drive shaft
16. Circlip
17. Right drive shaft
llW581
NOTE
(1) Reverse
(2)
(3)
(4)
l
l
e
+
m:
/ STB Revision
the removal
: Refer to Service
: Refer to Service
Non-reusable
parts
http://vnx.su/
procedures
Points
Points
to reinstall.
of Removal.
of Installation.
SUSPENSION
SERVICE
2.
2-53
- II wive shaft
POINTS
OF REMOVAL
NOZOBAC
REMOVAL OF COVER (Automatic

free wheeling
hub)
(1) Place the free-wheeling
hub in the free condition.
NOTE
The free condition
can be obtained
by shifting the
transfer shift lever to the .2H position and then moving
in reverse for 1 to 2 meters. (3.3 to 6.5 ft.)
(2) Remove
the automatic
free wheeling
hub cover.
NOTE
When the cover cannot be loosened by hand, use an oil
filter wrench with a protective
cloth in between not to ,jJ.,JJ,
damage the cover.
J3:
3.
REMOVAL
OF FREE WHEELING
HUB COVER
free wheeling
hub)
(1) Set the control handle to the FREE position.
(2) Remove the free wheeling hub cover.
(Manual
>
,,..
; y
9,
i9,
5.
REMOVAL
OF SNAP RING
drive shaft.
the snap
llWO50
7.
REMOVAL
OF FRONT
BRAKE ASSEMBLY
connected.
(2) Use wire to suspend the front brake assembly from the
upper arm so that the front brake assembly wont fall.
Caution
Do not twist
1 STB Revision
http://vnx.su/
the brake
hose.
; j
5
,.:
ring from the;
~::
1.
:( ,I I
.,, 1
hr%.
>-.
c
2-54
FRONT SUSPENSION
9.
Drive
shaft
DISCONNECTION
OF TIE ROD
ASSEMBLY
FROM
KNUCKLE
Disconnect
the tie rod from the knuckle
by using the
special tool.
Cuation
1. Use cord to bind the special tool closely so it wont
become separated.
2. The nut should Ibe loosened only, not removed.
11. DISCONNECTION
OF LOWER
BALL
JOINT
FROM
KNIUCKLE/13.
UPPER BALL JOINT FROM KNUCKLE
Using the special tool, remove the lower ball joint and
upper ball joint.
Caution
1. Support
the lower arm with a jack when removing
the knuckle from the lower ball joint or the upper
ball joint.
2. After the knuckle has been removed,
lower the jack
slowly.
15. REMOVAL
OF LEFT DRIVE SHAFT
Pull the drive shaft out from the differential
carrier.
Caution
When pulling
the drive shaft out from the differential
carrier, be careful Uhat the spline part of the drive shaft
INSPECTION
l
l
l
NOZCXAB
Check the boot for damage or deterioration.

Check the ball joint for operating
condition
looseness.
Check the splines for wear or damage.
SERVICE
POINTS
OF INSTALLATION
15. INSTALLATION
OF LEFT DRIVE SHAFIDrive the drive shaft into the front differential
plastic hammer.
and excessive
NOZQDAC
carrier with a
Caution
Be careful not to damage the lip of the oil seal. Replace
the circlip which is attached
to the D.O.J. side spline
part with a new one.
( STB Revision
http://vnx.su/
FRONT SUSPENSION
.
- Drive
ADJUSTMENT
Vehicles with
OF DRIVE SHAFT END PLAY

automatic
free-wheeling
hubs
(1) Rotate the drive shaft

set the drive shaft to
end play is maximum)
rotation
feels heavy
stopping feeling).
(2) Set the dial gauge as
the drive shaft in the
play.
Standard
2-55
shaft
value
forward, and backward and then

the position (the position where
mid-way between where the
for each (where there is a
shown in the figure; then move
axial direction and measure the
: 0.2-0.5
mm (.008-,020
(3) If the play is out of standard

removing shims.
value, adjust
in.)
by adding
or
r
Vehicles with manual free-wheeling

hubs
(1) Set the dial gauge as shown in the figure; then move
the drive shaft in the axial direction and measure the
play.
Standard
value
: 0.2-0.5
(2) If the play is out of standard

removing shims.
1 STB Revision
http://vnx.su/
mm (.008-.020
value, adjust
in.)
by adding
or
,L
2-56
FRONT SUSPENSION
DISASSEMBLY
AND
Drive
Shaft
REASSEMBLY
NOZCIE-
Left drive shaft
I In--_
l?
16
11 BOO25
17ilj
llW60E
Drive shaft kit LH
*5
llW609
11 W602
I
Disassembly
Reassembly
steps
Boot band A
Boot band B
Circlip
D.O.J. outer race
5. Balls
6. D.O.J. cage
7. Snap ring
9.
10.
11.
12.
13.
14.
15.
16.
17.
NOTE
(1) +e
(2) e+
inner
steps
16. Drive shaft and B.J.

I)+ 15. B.J. boot
~~ 13. Boot band A
l + 14. Boot band B
l + 2. Boot band B
l + 9. D.O.J. boot
l + 1. Boot band A
l + 6. D.O.J. cage
l + 8. D.O.J. inner race
7. Snap ring
l a 5. Balls
e+
4. D.O.J. outer race
3. Circlip
17. Circlip
+a 12. Boot protector
e+ 11. Boot protector band
l + 10. Dust cover
1.
2.
3.
4.
8. D.O.J.
Boot repair kit (D.O.J.)
Boot repair kit (B.J.)
D.O.J. kit
race
D.O.J. boot
Dust cover
Boot protector band
Boot protector
Boot band A
Boot band B
B.J. boot
Drive shaft and B.J.
Circlip
: Birfield Joint
B.J.
D.O.J. : Double Offset Joini
(3) ml
(4)
(5)
1 STB Revision
http://vnx.su/
FRONT SUSPENSION
Right
Drive
2-57
Shaft
drive shaft
llBOO25
Drive shaft kit RH
UJ
llW60
llW609
,.
D.O.J. kit
Boot repair kit (B.J.)
Boot repair kit (D.O.J.)
.*.
Reassembly steps
Disassembly steps
l *
l *
l *
l *
l *
*I)
c*
NOTE
(1) 4I)
(2) ++
1.
2.
3.
4.
5.
6.
7.
8.
9.
IO.
11.
12.
13.
14.
15.
16.
Boot band A
Boot band B
Circlip
D.O.J. outer race
Balls
D.O.J. cage
Snap ring
D.O.J. inner race
D.O.J. boot
Dust cover
Boot protector
band
Boot protector
Boot band A
Boot band B
B.J. boot
: Refer to Service
: Refer to Service
l
l
l
l
l
+
+
+
+
+
~~
l +
e+
l +
l +
l +
~~
l +
(3)
(4)
(5)
16.
15.
13.
14.
2.
9.
1.
6.
8.
7.
5.
4.
3.
12.
11.
10.

B.J. boot
Boot band A
Boot band B
Boot band B
D.O.J. boot
Boot band A
D.O.J. cage
D.O.J. inner race
Snap ring
Balls
D.O.J. outer race
Circlip
Boot protector
Boot protector
band
Dust cover
B.J.
: Birfield Joint
D.O.J. : Double Offset Joint
1 STB Revision
http://vnx.su/
:i
I-
2-58
FRONT
SUSPENSION
SERVICE
5.
6.
Shaft
- Drive
POINTS
OF DISASSEMBLY
REMOVAL
OF BALLS
Rernove the balls from
REMOVAL
Remove
direction
OF D.O.J.
the D.O.J.
NOZQFAB
cage.
CAGE
the D.O.J. cage from the D.O.J.

of the B.J.
inner race in the
7.
REMOVAL OF SNAP RING

Remove the snap ring from the drive shaft with a snap ring
pliers, and then withdraw the D.O.J. Inner race and D.O.J.
cage from the drive shaft.
9.
RElMOVAL
1 lY09E
OF D.O.J.
BOOT
(1) Wrap vinyl tape around the spline part on the D.O.J.
side of the drive shaft so that the D.O.J. boots are not
damaged
when they are removed.
(2) Withdraw
the D.O.J. boots from the drive shaft.
..
i
llYO97
10. REiMOVAL
Remove
OF DUST
COVER
the dust cover from the drive shaft and B.J.
wision
http://vnx.su/
FRONT
SUSPENSION
Drive
Shaft
2-59
12. REMOVAL OF BOOT PROTECTOR

After extending the folded over part of the boot protector
and removing
the boot protector
band, push the boot
protector to the B.J. side and then remove it.
15. REMOVAL
OF B.J. BOOT
(1) Wrap vinyl tape around the spline part on the D.O.J.
side of the drive shaft so that the B.J. boot are not
damaged when they are removed.
,
:,
(2) Withdraw the B.J. boot from the drive shaft.
_I
;
Caution
Do not disassemble
the B.J.
e.
llW604
INSPECTION
l
l
0
o
l
l
NOPOGAB
Check the drive shaft for bending

or wear.
Check the B.J. for entry of water, foreign matter and rust.
Check the B.J. ball for damage.
Check the D.O.J. cage, D.O.J. inner race and ball for rust,
wear and damage.
Check the circlip for damage
or deformation.
Check the D.O.J. outer race for wear or damage.
h,,.Gi.
()I;i.*(
_
/ &,:
,.
SERVICE
POINTS
15. INSTALLATION
BOOT BAND
BOOT BAND
(1) Apply the
vinyl tape
the drive
Specified
OF REASSEMBLY
NOZQHAB
OF B.J. BOOT / 13. BOOT BAND A / 14. i. ::;

B / 2. BOOT BAND B / 9. D.O.J. BOOT / 1. 9%;:.:!i
y:;:: ;*;;
A
specified grease to the drive shaft, and wrap
;;>,i<
around the spline part on the D.O.J. side of
:,<t
shaft.
::
?
grease : Repair kit grease
(2) Install the B.J. boot, boot bands (new ones), and D.O.J.
boot on the drive shaft, in that order.
Caution
The B.J. and D.O.J. boots are different
shape, so make sure they are correct.
~STB Revision
http://vnx.su/
i.
in size and
2-60
FRONT SUSPENISION
Shaft
Drive
(3) Apply all the specified grease, half of it to the inner side
of the B.J., and the other half to the inner side of the
B.J. boot.
Specified
?p
4I,
;
:,.:
: Repair
kit grease
(4) Secure the B.J. boot to the driveshaft

and B.
Driveshaft rotation direction

during vehicle forward movement
iI&
grease
Caution
Be sure that the
bands is correct.
Boot b
installation
[llO
gr (3.9 oz.)]
by boot bands A
direction
of the
boot
/ ;
,*A
; I (I
1180076
6.
Cage
\
INSTALLATION
OF D.O.J. CAGE / 8. D.0.J INNER RACE
(1) Install the D.O.J. cage onto the drive shaft so that the
smaller diameter
side of the cage is installed
first.
(2) Apply the specified grease to the D.O.J. inner race and
the D.O.J. cage, and then fit them together.
Specified
grease
: Repair
kit
grease
D.O.J. inner race

lB075
5.
I
APPLICATION
OF GREASE TO BALLS
Apply the specified grease to the ball insertion parts of the
D.O.J. inner race and D.O.J. cage, and insert the balls.
Specified
4.
grease
: Repair
kit grease
INSTALLATION
OF D.O.J. OUTER RACE
grease to the D.O.J.
Specified
grease
wision
grease
: Repair kit grease

[55 gr (1.9 oz.)]
I
http://vnx.su/
race.
: Repair kit grease

[55 gr (1.9 oz.)]
(2) Fit the drive shaft into the D.0.J outer

(3) Add the specified
grease to the D.O.J.
Specified
outer
race.
outer
race.
FRONT
SUSPENSION
- Drive
(4) Install the circlip onto the D.O.J. outer race.

(5) Place the D.O.J. boot over the D.O.J. outer
then use boot band B to secure the boot.
Driveshaft rotation direction

during vehicle forward movement
Caution
Be sure that the
bands is correct.
(6) Replace
installation
direction
race, and
of the
boot
the boot band A on D.O.J. boot.
Caution
Do not secure the boot
2-61
Shaft
band A
(7) Secure the driveshaft, and then move the D.O.J. outer
q:
race until it is at the position where the D.O.J. bootgV3
assembly
dimension
is the standard value.
\5
. I.
t,f
Standard value : 77-83 mm (3.03-3.27
in.)
..
.
fr,
(8) Remove a part of the D.O.J. boot from the D.O.J. outer b:,
race and release the air within the boot.
(9) Secure the boot band A on D.O.J. boot.
Boot band B
Bo
band A
llYO99
Caution
Be sure that the
bands is correct.
installation
direction
of the
boot
g,
:,
12. INSTALLATION
OF BOOT
PROTECTOR
/ 11. BOOT f: ,:.$:j
.i>;
PROTECTOR
BAND
CA
(1) After installating
the boot protector to the B.J., secure\., : ~~
by the boot protector
band.
c,
is,.,, ;
Caution
Be sure that the installation
direction
of the boot
.
bands is correct.
(2) Securely
fold over the end of the boot
protector.
llB0017
10. INSTALLATION
Using
cover
Steel pipe
OF DUST
COVER
the steel pipe as specified

to the drive shaft.
wision
http://vnx.su/
below,
force
the dust
2-62
FRONT SUSPENSION
- Inner
Shaft
INNER SHAFT
REMOVAL
AND
INSTALLATION
80-100 Nm
58-72 ftlbs.
80-110 Nm
58-80 ft.lbs.-
58-72
50-50
3543
ftlbs.
Nm
ftlbs,
10-13 Nm
7-9 ftlbs.
Removal
+e
l *
+e
steps
1.
l + 2.
3.
l * 4.
~~ 5.
6.
7.
8.
9.
llW582
Under cover
Front hub and knuckle
assembly
Shock absorder
lower
mounting
bolts
Drive shaft assembly
(R.H.)
Inner shaft
Circlip
Self locking
nut
Differential
mounting
bracket
(R.H.)
Housing
tube
NOTE
(2) l I) : Refer to Service Points of Removal.
(3) *+
(4) m
: Non-reusable
pans
1 STB Revision
http://vnx.su/
FRONT
SUSPENSION
SERVICE
2.
POINTS
2-63
Shaft
OF REMOVAL
NOZRBAB
REMOVAL
OF FRONT HUB AND KNUCKLE
BLY/4. DRIVE SHAFT ASSEMBLY
(R.H.)
Refer
5.
Inner
to 2-44,
REMOVAL
ASSEM-
52.
OF INNER
SHAFT
Attach the special tools to the flange of the shaft, and drive
the inner shaft out from the front differential
carrier.
, _.\
,C
Caution
1. Being careful
not to scratch
or scar the shocki
absorber
with the special tool, remove
the lower a
mounting
bolts of the shock absorber, and compress
the shock absorber as much as possible.
2. When pulling
the inner shaft out from the front
differential
carrier, be careful that the spline part of
the inner shaft does not damage the oil seal.
INSPECTION
l
l
l
l
Check
Check
Check
Check
SERVICE
5.
NOZRCAA
the inner shaft for bend.

the bearing for wear or discoloration.
the housing
tube for cracks.
the dust seal for cracks
or damage.
POINTS
INSTALLATION
OF INSTALLATION
OF INNER
Drive the inner shaft into

NO2DAf
I.
,
SHAFT
the front
differential
carrier
by d
7
1
Caution
1. Replace the circlip which is attached
to the inner
shaft spline part with a new one.
2. Be careful not to damage the lip of the dust seal and
oil seal.
4.
INSTALLATION
FRONT HUB
Refer
to 2-44,
STB Revision
http://vnx.su/
OF DRIVE SHAFT ASSEMBLY

AND KNUCKLE
ASSEMBLY
52.
<
(R.H.)/2.
:.
2-64
FRONT SUSPENSION
DISASSEMBLY
AND
- Inner
Shaft
REASSEMBLY
NOZRE-
.,
$,
:rrr
?
Disassembly
1.
+e I)+ 2.
+e l + 3.
4.
ae ~b+ 5.
1
_.
: I
4
steps
llW597
Inner shaft
Bearing
Dust cover
Housing tube
Dust seal
NOTE
procedures
to reassemble.
(4) q
SERVICE
2.
POINTS
OF DISASSEMBLY
REMOVAL
OF BEARING
(1) 13end the outside periphery
hammer.
NOZRFAB
of dust cover inward with a
(2) After the special tool has been installed

as shown,
ttghten the nut of the special tool until the portion A
of the special tool touches the bearing outer race.
(3) Press out the inner shaft from the bearing.

CZaution
Do not allow
the inner shaft to drop.
Q
118727
) STB Revision
II
http://vnx.su/
FRONT SUSPENSION
3.
REMOVAL
Inner
2-65
Shaft
OF DUST
COVER
Remove the dust cover from the inner shaft.
5.
REMOVAL
OF DUST
SEAL
Remove the dust seal from the housing tube.
l-
llW56
SERVICE
5.
POINTS
INSTALLATION
OF REASSEMBLY
OF DUST
NOZRHAD
SEAL
(1) Press-fit the new dust seal into the housing tube by
using the special tools, until it is flush with the housing
tube end face.
(2) Apply the specified grease to the dust seal lip.
MB990938-01
MB990955-01
Specified
grease
: Multipurpose
NLGI No. 2
grease
SAE
J310,
lW561
l-l
Steel pipe
3.
INSTALLATION
OF DUST
COVER
,.
Using a steel pipe, force a new dust cover onto the inner:
i\
shaft.
mm (in.)
Steel pipe
Overall length
50 (1.97)
Outside diameter
/ 75 (2.95)
Wall thickness
1 4i.16)
NOTE
After the dust cover has been installed,
grease to the inside of the dust cover.
Specified
2.
grease
INSTALLATION
: Multipurpose
No. 2
http://vnx.su/
SAE 5310, NLGI
OF BEARING
Using the special tool, force

shaft.
STB Revision
grease
apply specified
the bearing onto the inner
2-66
FRONT
SUSPENSION
FRONT DIFFERENTIAL
REMOVAL
AND
Front
Differential
Mounting
MOUNTING
INSTALLATION
NOZUA-
q 10 ~E;ft%i.
80-110
Nm
13
CY
8
ICE%,&
80-100 Nm
58-72 ft.lbs.
^^ _--
3042
22-30
_.
UU-100
Nm
58-72
ftlbs.
Nm
ft.lbs.
12W554
lo-13 Nm
7-9 ft.lbs.
Removal steps
+e
l +
+e
l +
l *
1.
2.
3.
4.
5.
6.
7.
8.
9.
IO.
11.
12.
Under cover
Drive shaft
Circlip
Inner shaft
Circlip
Self-locking
Differential
Differential
Differential
Self-locking
Differential
Differential
13.
14.
15.
16.
nut
mounting
mounting
mounting
nut
mounting
mounting
rubber
rubber
bracket
rubber
rubber
A
B
(L.H.)
A
Differential
Self-locking
Differential
Differential
mounting
nut
mounting
mounting
bracket
rubber
rubber
(R.H.)
C
D
NOTE
(I)
(2)

to reinstall.
l * : Refer to Service Points of Removal.
(3)
(4)
: Refer to Service
Points
: Non-reusable
parts
STB Revision
http://vnx.su/
of Installation.
FRONT
SUSPENSION
Front
SERVICE
Differential
POINTS
OF REMOVAL
2. REMOVAL
OF DRIVE
Refer to P.2-52.
4.
2-67
Mounting
NOZUBAB
SHAFT
REMOVAL
OF INNER SHAFT
Attach the special tools to the flange of the shaft, and drive
carrier.
Caution
1. Being
careful
not to scratch
or scar the shock
absorber
the lower
mounting
the shock absorber
as much as possible.
2. When pulling
,, I
differential
carrier, be careful that the spline part of $
the inner shaft does not damage
the oil seal.
d
;
9.
REMOVAL
OF DIFFERENTIAL
MOUNTING
BRACKET::
(L.H.) / 13. DIFFERENTIAL
MOUNTING
BRACKET
(R.H.)
:.
While supporting
the differential
carrier with a jack, remove
the differential
mounting
bracket.
NOTE
Support the differential
carrier with
the differential
mounting
bracket.
a jack until
INSPECTION
installing
NOZUCAA
Check the differential

mounting
bracket for deformation
and damage.
Check the bracket for deformation
and damage.
mounting
rubber for cracks and
damage.
l
l
l
SERVICE
4.
POINTS
INSTALLATION
OF INSTALLATION
INNER
2.
not to damage
INSTALLATION
Refer to P.2-52.
1 STB Revision
http://vnx.su/
OF DRIVE
, :
l-r
SHAFT
Drive the inner shaft into the front

Caution
Be careful
seal.
NOPUDAA
differential
carrier
b\l;.
j I .+
1, .:
;;, ,yf
the lip of the dust seal and oil ;-i;i.
SHAFT
2-68
FRONT SUSPENSION
- Differential
Carrier
DIFFERENTIAL CARRIER
REMOVAL
AND
INSTALLATION
NOZVA-
mg,
PILlIll
Qz&&y
11 El/
-iJ..,
Nm
80-I 10 Nm
/ 58-80 ft.lbs.
50-60 NIY
/36-43
fds.
100-120 Nm ---------i
72-87 ft.lbs.
i2
80-100 Nm
58-72 ft.lbs.
80-106 Nm
58-72 ft.lbs.
IO-13 Nm
7-9 ft.lbs.
Removal steps
I+*
~~
4*
4*
1.
2.
l +
3.
I)+
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Under cover
Drive shaft
Circlip
Inner shaft
Circlip
Front propeller
shaft
Self-locking
nut
Differential
mounting
bracket
(L.H.)
Self-locking
nut
Front suspension
crossmember
and
differential
carrier assembly
Self-locking
nut
Front suspension
crossmember
Differential
mounting
bracket (R.H.)
Housing
tube
Front differential
carrier assembly
Pre-removal
Draining
Operation
of Gear Oil (Refer to P.2-
16.)
Post-installation
Operation
l
Supplying Gear Oil (Refer to P.2-16.)
front
NOTE
(3)
l * : Refer to Service Points of Installation.
(4) q
: Non-reusable
parts
/ STB Revision
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FRONT SUSPENSION
Differential
Carrier

AND DRIVE SHAFT
2-69
NOZVBAB
2.
REMOVAL
OF KNUCKLE
Refer to P.2-44, 52.
ASSEMBLY
4.
REMOVAL
OF INNER SHAFT
Attach the special tools to the flange of the shaft, and pull
carrier.
Caution
1. Being careful
not to scratch
or scar the shock
absorber
the lower
mounting
the shock absorber as much as possible.
2. When pulling
differential
carrier, be careful that the spline part of
the inner shaft does not damage the oil seal.
6.
REMOVAL
Make the
differential
Detach the
assembly.
,I.<I
...
+,.
p
q
\
*ll.
L,
OF FRONT PROPELLER
SHAFT
mating
companion
flange.
propeller shaft from the front differential
carrier
,,r:' bb
1'
8.
REMOVAL
OF DIFFERENTIAL
MOUNTING
BRACKET ;:. _:
(L.H.)
g,. .i,,:.,
While supporting
the differential
carrier with a jack, removei< *I..:{
,5. .)I
the differential
mounting
bracket.
?->
::
<5
i ,
INSPECTION
BEFORE DISASSEMBLY
NOZVCAA
Remove the cover and gasket. Hold the working base in a vice,
and install the differential
carrier assembly
to the working
base.
evision
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z-70
FRONT
SUSPENSION
FINAL
- Differential
DRIVE
GEAR
Carrier
BACKLASH
Check the final drive gear backlash by following

the steps
below.
(1) With the drive pinion locked in place, measure the final
drive gear backlash with a dial indicator on the drive gear.
NOTE
Measure at four points
the drive gear.
Standard
llV16i
value
or more
: 0.11-0.16
mm
(.0043-.0063
in.)
(2) If the backlash is not within the standard value, adjust

using the side bearing adjustment
spacers.
DRIVE GEAR RUNOUT

Check the drive gear runout by following
the steps
(1) Measure
the drive gear runout at the shoulder
reverse side of the drive gear.
Limiit
: 0.05
mm
(.0020
GEAR
it by
below.
on the
in.)
(2) If the runout

exceeds
the limit,
check
tightening
of the drive gear and differential
DIFFERIENTIAL
of
for improper
case.
BACKLASH

gear backlash
by following
the steps
below.
(1) While locking the side gear with the wedge, measure the
differential
gear backlash with a dial indicator on the pinion
gear.
NOTE
The measurement
individually.
should
be made
Standard
value : O-0.076 mm
Limit : 0.2 mm (.0079 in.)
(2) If the backlash exceeds
gear thrust spacers.
I STB Revision
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the limit,
for both
(O-.0030
adjust
pinion
gears
in.)
by using the side
FRONT SUSPENSION
FINAL
Differential
DRIVE
GEAR
2-71
Carrier
TOOTH
CONTACT
Check the tooth contact of the final drive gear by following the
steps below.
(1) Apply a thin, uniform
coat of machine
blue to both
surfaces of the drive gear teeth.
(2) Insert the brass between the differential

carrier and the
differential
case, and then rotate the companion
flange by
=:
hand (once in the normal direction,
and then once in the
reverse direction) while applying a load to the drive gear so +..
that the revolution torque [approximately
2.5 to 3.0 Nm (1.8 $:
to 2.2 ft.lbs.)] is applied to the drive pinion.
II
!!,
F
Caution
*i-.
If the drive gear is rotated too much, the tooth contact
8 4
pattern will become unclear and difficult to check.
(3) Check the tooth
drive pinion.
contact
condition
of th drive
gear and
NOTE
1. Checking
the tooth contack
pattern is the way to
confirm that the adjustments
of the pinion height and
backlash have been done properly.
2. Continue to adjust the pinion height and backlash nutil
the tooth contact
pattern
resembles
the standard
pattern.
3. If, even after adjustments
have been made, the correct
tooth contact pattern cannot be obtained, it means that
.the drive gear and the drive pinion have become worn
beyond the allowable limit; replace the gear set.
Caution
If either
replaced,
,:
:.
i: :
the drive gear or the drive pinion

is to be 1. : :
d
be sure to replace both gears as a set.
.1..
.
.I , ,a
1, ;,
k+ _-
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2-72
FRONT
Standard
tooth
1 Toe
2 Drive-side
3 Heel
4 Coast-side
contact
SUSPENSIOPIJ
Differential
Carrier
pattern
Solution
Problem
Tooth
pinion
contact
height
pattern
resulting

of the drive gear.
Tooth
pinion
contact
height
pattern
excessive
too far from the center
resulting

of the drive gear.
from
from
Increase the thickness of the pinion height adjusting

shim, and position the drive pinion closer to the
center of the drive gear.
Also, for backlash adjustment, position the drive gear
farther from the drive pinion.
improper
Decrease the thickness of the pinion height adjusting

shim, and position the drive pinion farther from the
center of the drive gear.
Also, for backlash adjustment, position the drive gear
closer to the drive pinion.
too close to the center
118642
SERVICE
4.
OF
INSTALLATION
INSTALLATION
OF INNER SHAFT
Drive the inner shaft into the front
Caution
Be careful
seal.
2.
POINTS
not to damage
INSTALLATION
Refer to P.2-52.
Revision
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OF DRIVE
N02VDAB
differential
carrier
by
the lip of the dust seal and oil

SHAFT
FRONT SUSPE
SOON - Differential
2-73
Carrier
160-220
116159
Nm
ft.lbs.
170
31
25
\I*:
8
\
40-60
2643
Nm
ft.lbs.
do-70
43-51
15-22
11-16
Nm
ft.lbs.
Nm
ft.lbs.
aI
Disassembly steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Cover
Gasket
Bearing caps
Differential case assembly
Side bearing adjusting spacers
Side bearing outer races
Side bearing inner races
Bolts (IO)
Drive gear
Lock pin
Pinion shaft
Pinion gears
Pinion washers
Side gears
Side gear thrust spacers
Differential case
Companion flange self-locking nut
Washer
Drive pinion assembly
Drive pinion front bearing inner race
pinion front shim (for pinion height

adjustment)
Drive pinion
Companion flange
Drive pinion spacer
Drive pinion rear shim (for preload adjustment)
21. Drive
22.
23.
24.
25.
26. Oil seal

29. Drive
pinion
front
bearing
outer
30. Oil seals

31. Gear carrier
32. Vent plug
NOTE
(1) ++
(2) q
STB Revision
: Refer to Service Points

: Non-reusable
parts
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of Disassembly.
race
,/- L
.i
.
!b<. .:
2-74
FRONT SUSPENSION
SERVICE
4.
- Differential
POINTS
Carrier
OF DISASSEMBLY
NOZVFAA
REMOVAL OF DIFFERENTIAL
CASE ASSEMBLY
Take out the differential
case assembly
with a hammer
handle.
Caution
When taking
out the differential
case assembly,
be
careful not to drop and damage the side bearing outer
races.
NOTE
Keep the right and left side bearings
and side bearing
adjusting
spacers separate, so that they do not become
mixed at the time of reassembly.
MB990339-01
7.
REMOVAL
OF SIDE BEARING
INNER RACES
tools.
9.
REMIOVAL OF DRIVE GEAR

case and the
drive gear.
bolts in diagonal
801
10. REMOVAL
OF LOCK PIN
Drive out the lock pin with a punch.
NOl-E
The removed side gears and side gear thrust
and right, should be retained for reassembly.
17. REIWIOVAL
NUT
OF COMPANION
Use the special tool

ST6 Revision
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FLANGE
spacers,
left
SELF-LOCKING
to hold the companion

flange self-locking
nut.
flange
and
FRONT
SUSPENSION
Differential
19. REMOVAL
OF DRIVE
(1) Make mating

flange.
2-75
Carrier
PINION
ASSEMBLY
marks on the drive pinion
and companion
Caution
The mating
flange
must not be on the coupling
surface of the flange
yoke and the front propeller
shaft.
(2) Drive out the drive pinion together
spacer and drive pinion shims.
with the drive pinion
20. REMOVAL
OF DRIVE PINION
FRONT BEARING
INNER
RACE
Pull out the drive pinion front bearing inner race by using
the special tools.
MIT303173
llS732
28. REMOVAL
RACE
ss rod
OF DRIVE
PINION
REAR
Drive out the drive pinion rear bearing

gear carrier by using the brass rod
BEARING
outer
OUTER
race from the
118596
29. REMOVAL
OF DRIVE PINION
FRONT BEARING
OUTER
RACE
Drive out the drive pinion front bearing outer race from the
gear carrier by using the brass rod.
INSPECTION
l
l
l
l
l
l
l
NOZVGAA
Check the companion

Check the bearings for wear or discoloration.
wear or damage.
1 STB Revision
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$
:,
1.
.z
2-76
FRONT
SUSPENSION
- Differential
Carrier
N02VH.-
EASSEMBLY
160-220
1%159\
40-60
26-43
11
Nm
ft.lbs.
TV \
16El
\
Nm
ft.lbs.
Pi-22
11-16
Nm
ftlbs.
511134
Differential gear set
Reassembly
l *
l +
~~
l +
l +
steps
Final drive gear set

1. Vent plug
19. Side gears
2. Gear carrier
20. Pinion washers
3. Oil seals
21. Pinion gears
l * Adjustment of differential gear backlash
22. Pinion shaft
Adjustment of pinion height
I)+ 23. Lock pin
6. Drive pinion
l * 24. Drive gear
7. Drive pinion front shim (for pinion height
25. Bolts (IO)
adjustment)
++ 26. Side bearing inner races
Adjustment of drive pinion preload
l + Adjustment of fina. drive gear backlash
28. Side bearing adjusting spacers
10. Oil seal
11. Drive pinion rear shim (for preload ad30. Bearing caps
justment)
l * 31. Gasket
32. Cover
15. Washer
NOTE
16. Companion flange self-locking nut
(2) q : Non-reusable parts
1 STB Revision
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FRONT
w/
SUSPENSION
MB990938-01
- Differential
2-77
carrier

3.
MB990934-01
INSTALLATION
OF OIL SEALS
Install the oil seal with the special tool and apply a thin coat
of specified grease to the lip of the oil seal.
Specified
4.
0938-01
N02VlAB
grease
: Multipurpose
No. 2
grease
INSTALLATION
OF DRIVE
PINION
OUTER RACE
SAE 5310, NLGI
FRONT
BEARING
outer races into the
0936-01
NOTE
Perform
race.
5.
4
MB990938-01
MB990934-01
press-fitting
carefully
J
,i
.

1..
INSTALLATION
OF DRIVE PINION
REAR BEARING OUTER RACE
Press-fit the drive pinion rear bearing outer races into the
NOTE
Perform
race.
press-fitting
carefully
11 w593
, jj$(%lB990905-4-01
MB990905-3-01
MB990905-2-01
MB990901-01
ADJUSTMENT
Adjustment
procedures:
OF PINION HEIGHT
the drive pinion
height
.I
by the
following
,
\
!,
(1) Install special tools and drive pinion front and rear ,
!
value of drive pinion rotation torque is obtained.
MB990905-l-01
llW518
(3) Measure the drive pinion rotation

oil seal) by using the special tools.
Standard
MB990905-l-01
1 STB Revision
http://vnx.su/
value
: 0.4-0.5
Nm (3.54.3
torque
(without
in. Ibs.)
the
.
.$
:g.
2-78
FRONT SUSPENSION
Differential
Carrier
NOTE
I, Gradually
tighten
the hardle of the special tool
while checking the drive pinion preload.
2. Because one rotation
cant be made when the
special tool is in contact with the gear carrier, move
it a few times
and, after seating
the bearing,
measure the rotation torque.
gear carrier, and then select a drive pinion front shim of
special tools.
NOTE
1. Be sure to clean the side bearing seat thoroughly.
When positioning
the special tool, be sure that the
cut-out
sections
of the special tool are in the
position shown in the illustration,
and also confirm
that the special tool is in close contact with the side
bearing seat.
2. When selecting the drive pinion front shims, keep
the number of shims to a minimum.
(5) IFit the selected drive pinion front shim(s) to the drive
pinion, and press-fit the drive pinion front bearing inner
ADJUSTMENT
OF DRIVE
Adjust the drive pinion
following
procedure:
PINION
turning
PRELOAD
torque
by
using
the
Without
Oil Seal
(1) Insert the drive pinion into the gear carrier, and then
install, from the front side of the carrier, the drive
Ipinion spacer, the drive pinion rear shim; the drive
pinion rear bearing
inner race, and the companion
flange in that order.
NOTE
Do not install the oil seal.
flange
1 STB Revision
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to the specified
torque
FRONT SUSPENSION
Differential
(3) Measure
oil seal).
Standard
2-79
Carrier
the drive pinion
rotation
value
Nm (3.5-4.3
: 0.4-0.5
torque
(without
the
in.lbs.)
(4) If the drive pinion rotation torque is not within the

range of the standard
value, adjust the preload by
replacing
the drive pinion rear shim(s) or the drive
pinion spacer.
NOTE
When selecting
the drive pinion rear shims, if the
to a minimum
by selecting
(5) Remove
again.
With
the companion
flange
and drive pinion
once
T
?
?
Oil Seal
(1) After setting the drive pinion rear bearing inner race, drive
the oil seal into the gear carrier front lip by using the
special tool.
(2) Apply the specified grease to the oil seal lip.
Specified
MB990031-01
grease
: Multipurpose
No. 2
grease
SAE 5310, NLGI
(3) Apply a thin coat of specified

grease to the companion
flange contacting
surface of the washer before installing
drive pinion assembly.
Specified
grease
: Multipurpose
No. 2
grease
,
$
1 s
.SAE 5310, NLGI :.
li.,. :
i;?.

flange
and tighten the
companion
flange self-locking
wision
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2-80
FRONT
SUSPENSION
- Differential
Carrier
(5) Measure the drive pinion rotation torque (with oil seal)
to verify that the drive pinion preload complies with the
standard value.
!standard
value
: 0.647
Nm
(5.2-6.1
in.lbs.)
(6) If the measured value is not within the standard value

range, check for faulty installation
of the oil seal or
faulty tightening
of the self-locking
nut.
ADJUSTMENT
OF DIFFERENTIAL
GEAR BACKLASH
(1) Assemble
the side gears, side gear thrust spacers,
pinion gears, and pinion washers into the differential
case.
(2) Temporarily
install the pinion shaft.
NOTE
Do not drive in the lock pin yet.
(3) Insert a wedge between the side gear and the pinion
shaft to lock the side gear.
(4) Measure
the differential
gear backlash
with a dial
indicator on the pinion gear.
Standard
value : O-0.076 mm
Limit : 0.2 mm (.008 in.)
(O-.0030
in.)
(5) If the differential

gear backlash
exceeds
the limit,
adjust the backlash by installing thicker side gear thrust
spacers.
(6) Measure the differential
gear backlash once again, and
confirm that it is within the limit.
If adjustment
is not possible,
replace the side gears
and pinion gears as a set,
,I
23. INSTALLATION
OF LOCK PIN
(1) Align the pinion shaft lock pin hole with the differential
case lock pin hole, and drive in the lock pin.
(2) Stake the lock pin with a punch at two points.
wision
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FRONT
SUSPENSI
h! - Differential
2-81
Carrier
24. INSTALLATION
OF DRIVE GEAR
the drive gear by turning the tap tool (Ml0 x 1.25), and
air.

the drive gear.
Specified
adhesive
adhesive
to the threaded
: 3M Adhesive
or equivalent
holes of
stud locking
4170
{*
/.

case with the
mating marks properly aligned. Be sure to tighten the 1;
bolts to the specified torque in a diagonal sequence.
,(
26. INSTALLATION
OF SIDE BEARING
INNER RACES
Press-fit the side bearing inner races to the differential
.I fE!-.:
.i:
ADJUSTMENT
OF FINAL DRIVE GEAR BACKLASH
f :.,:
(1) Install the side bearing adjusting
spacers, which areFd, ::;;
tinner than those removed, to the side bearing outer\,
;
races, and then mount the differential
case assembly \,,
-3
into the gear carrier.
:;: 2
I ,
NOTE
Select side bearing adjusting
spacers with the same
I.
thickness
for both the drive pinion side and the drive
gear side.
(2) Push the differential

case assembly to one side, and
measure the clearance between the gear carrier and
the side bearing adjusting
spacer with a feeler gauge.
1 STB Revision
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2-82
FRONT
+ Clearance + 0.05
2
SUSPENSIO
Differential
Carrier
(3)Measure
the thickness
of the side bearing adjusting
spacers on one side, select two pairs of spacers which
correspond
to that thickness
plus one half of the
clearance plus 0.05 mm (.002 in.), and then install one
pair each to the drive pinion side and the drive gear
side.
mm
(.002 in.)
= Thickness
of the
spacer on one side
llY241
(4)lnstall the side bearing adjusting

spacers and differential case assembly,
as shown in the illustration,
to the
gear carrier.
(5)Tap the side bearing adjusting

spacers with the brass
bar to fit them to the side bearing outer race.
(6)Align the mating

marks on the gear carrier and the
bearing cap, and then tighten the bearing cap.
(7)With the drive pinion locked in place, measure the final

drive gear backlash with a dial indicator
on the drive
gear.
NOTE
Mleasure at four points
of the drive gear.
Standard
value
evision
or more
: 0.11-0.16
http://vnx.su/
mm
(.0043-.0063
in.)
FRONT
SUSPENSION
Differential
2-83
Carrier
(8)Change the side bearing adjusting

spacers as illustrated, and then adjust the final drive gear backlash
between the drive gear and the drive pinion.
NOTE
When increasing the number of side bearing adjusting
spacers, use the same number for each, and as few as
possible.
(9)Check the drive gear and d-rive pinion for tooth contact.
If poor contact is evident, make adjustment.
(Refer to P.2-71)
(lO)Measure
reverse
Limit
the drive gear runout at the shoulder

side of the drive gear.
: 0.05
mm
(.0020
on the
0.
..11
..:
in.)
(1 l)lf the drive gear runout exceeds the limit, reinstall by

changing
the phase of the drive gear and differential
case, and remeasure.
llY168
31. APPLICATION
OF SEALANT
TO GASKET
Apply the specified sealant to both sides of the gasket

install the differential
cover to the differential
carrier.
Specified
llSO58
1 STB Revision
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sealant
: 3M ART Part
or equivalent
No. 8661
and
or No. 8663,
t
I,
i, G
17-1
REAR
SUSPE
CONTENTS
GENERAL
INFORMATION
REAR SUSPENSION
SERVICE
ADJUSTMENT
Inspection
. . . . . . . .. .. . . . . . . . .. . . . . . .. .. . . . .
ASSEMBLY
. . . . . .. . . . . . . . . . . .. . .
PROCEDURES
of Rear Wheel Alignment
2
4
. . . . .. .. . .
. . .. . . . . . . . . ..
N17AA-
SPECIFICATIONS
. . ..a..........................................
. . . . . . . . . . . . . . . .. .. . . . . . . . .. .
http://vnx.su/
. . . . . . . .. .. . . . . . . . . . . . .. . . . . . . . . . .
. . . . . . . .. .. . . . . . . . . . .. .. . . . . . . . . . . .
2
2
3
3
17-2
REAR SUSPENSION
- General
Information
/ Specifications
GENERAL INFORMATION
N17BAAB
The leaf spring type of rear suspension

has been adopted. The leaf spring is secured to the rear axle housing
by U-bolts, so that the vibration and noise transmitted
to the body during off-road driving are reduced by the
bump stopper.
The shock absorbers have a bias arrangement.
Shock absorber
hock absorber
lW614
SPECIFICATIONS
GENERAL SPECIFICATIONS
Nl7CL
Specifications
Items
Suspension
Asymmetrical semielliptic leaf springs
system
Leaf springs
Number of leaf springs
4
1,196.5-l ,203.5 (47.106-47.382)
mm (in.)
Straight span
Camber (unladen)
mm (in.)
73.5-82.5 (2.894-3.248)
N/mm (Ibs./in.)
Spring constant
-as installed
at load of 1,OOO-2,500N (220-551 Ibs.)
22 (123)
at load of 4,670-8,870 N (1,030-l ,955 Ibs.)
50 (280)
Shock absorbers
Type
Max. length
Min. length
Stroke
Hydraulic cylinder, double-acting type

545-548 (21.5-21.6)
mm (in.)
mm (in.)
325-328 (12.8-l 2.9)

220 (8.7)
mm (in.)
Damping force
[at 0.3 m/set. (0.984 ft./set.)]
Expansion
N (Ibs.)
Compression
1.580-2.100 (348-463)
590-850 (130-I 87)
N (Ibs.)
/ ST6 Revision
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SUSPENSION
SERVICE
- Specifications
/ Service
Procedures
Adjustment
SPECIFICATIONS
Items
Specifications
Standard value
Toe-in
mm (in.)
0 (Non adjustable)
Camber
0 (Non adjustable)
Items
Nm
ft.lbs.
45-60
33-43
Front pin assembly attaching nut

Shock absorber attaching nut
45-60
18-25
33-43
13-18
Front pin assembly
14-20
85-l 10
IO-14
Shackle assembly
U-bolt attaching
attaching
attaching
nut
bolt
nut
61-80
SERVICE ADJUSTMENT
INSPECTION
OF REAR WHEEL ALIGNMENT
The rear suspension

assembly must
damaged parts prior to measurement
Standard
PROCEDURE$,.
value
be free of worn, loose or

of rear wheel alignment.
: Toe-in 0 mm (0 in.)
Camber 0
NOTE
Toe-in
and
camber
are
set
at the
factory
and
cannot
be
adjusted.
If toe-in
or camber
replace
bent
is not within
or damaged
/ STB Revision
http://vnx.su/
the standard
parts.
value,
check and
17-4
- Rear Suspension
REAR SUSPENSldN
REAR SUSPENSION
REMOVAL
Assembly
ASSEMBLY
N17GA-
AND INSTALLATION
18-25
13-18
45-60
33-43
Nm
ft.lbs.
14-20
IO-14
llW613
Nm
ftlbs.
61-80
Post-installation
l
Operation
Inspection of Rear Wheel

(Refer to P.17-3.)
Removal
~~
l +
l +
l +
l +
ft.lbs.
Alignment
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Il.
Parking
brake cable
Shock absorber
U-bolt seat
U-bolts
Bump stopper
Front pin assembly
Rubber
bushings
Shackle
plate
Shackle
assembly
Rubber
bushings
Rear spring
attaching
bolt
NOTE
(1) Reverse the removal procedures to reinstall.. ,,
(2)
** : Refer to Servrce Pornts of lnstallatron
: Tighten when the vehicle is unloaded.
(3)
1 STB Revision
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REAR SUSPENSION
Rear
&pension
17-5
Assembly
INSPECTIQN
Check the shock absorbers
for oil leakage,
malfunction.
Check the leaf springs for damage or deterioration.
Check the U-bolt for cracks or bends.
Check the rubber parts for cracks or deterioration.
l
l
l
l
SERVICE
VehE
POINTS
noise
OF INSTALLATION
or
Nl7GDAE
11. INSTALLATION
OF REAR SPRING
Install the spring assembly to vehicle. Make sure the front
end (front pin side) to center bolt distance is shorter than
the rear end to center bolt distance.
front
NllGCh0
Center
bolt
125566
Front
Shackle
pin side
Inside of ~3
vehicle
9.
side
Inside of e
vehicle
12w515
INSTALLATION
ASSEMBLY
(1) Install the
the inside
(2) Install the
the inside
OF SHACKLE
front pin assembly
of vehicle.
shackle assembly
of vehicle.
ASSEMBLY/G.
FRONT
PIN
from the outside
toward
from
toward
the outside
12W51.
4.
INSTALLATION
OF U-BOLT/S.
U-BOLT SEAT
Before the U-bolts
are tightened
to specified
torque,
confirm the relative position
of the center bolt and axle
housing and that of the center bolt and the hole in the Ubolt seat.
1 STB Revision
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li
.1
;:
19-1
POWER
TEERING
CONTENTS
GENERAL
INFORMATION
OIL PUMP
POWER
.................................
...........................................................
STEERING
SERVICE
GEAR BOX
ADJUSTMENT
Air Bleeding
PROCEDURES
Fluid Level
Checking
Stationary
Checking
Steering
Angle
Checking
Steering
Gear Backlash
Checking
Steering
Wheel
Free Play
Checking
Steering
Wheel
Return
Checking
Drive-Belt
Pressure
..........
.....................................................
.......................................
Steering
Ball Joint
Effort
End Play
Test of Oil Pump
...............
................................
Tension
23
.........................
Checking
Measuring
33
...................
...............
to Center
9
12
11
10
10
9
9
... 11
...........................
11
........................
10
..............................
13
NlSAA--
Replacement
Steering
SPECIAL
Wheel
Centering
TOOLS
SPECIFICATIONS
General
Lubricants
Sealants
Service
Torque
..............................
...... .........................................
....................................
and Adhesives
Specifications
Specifications
STEERING
HOSES
STEERING
LINKAGE
TROUBLESHOOTING
14
.......................................................
COLUMN
11
........... . ....................................
Specifications
STEERING
http://vnx.su/
......................................
of Fluid
..................................
2
5
5
.....................................
.....................................
AND SHAFT
....................
16.
.............................................
3%
..........................................
39
. . . . . . . . . .. . . . . ..*......................
, 912
;::;< I,:!.
POWER STEERING - General Information
/ Specifications
GENERAL INFORMATION
NlSBABB
A tilt steering system in which the steering column can be adjusted in four steps of 3 each for the most
suitable driving position has been adopted.
A ball-and-nut type (variable-ratio
gear) manual steering gear box has been adopted;
it features excellent wear
resistance and withstand
resistance
to impact shocks from the road surface, and assures
excellent operation
of the steering system.
In addition, an integral type of power steering
gear box has been adopted
ing force during full-angle turns and during low-speed
driving.
which
reduces
the required
steer-
SPECIFICATIONS
GENERAL
SPECIFICATIONS
NlOCA--
Specifications
Items
Steering wheel
diameter
Power
gear box
steering
mm (in.)
380 (14.9)
Steering gear type
Ball and nut, torsion

16.4
Steering gear ratio

Oil pump
Oil pump type
Displacement
SERVICE
bar type (integral type)
Vane type
cc/:ev. (cu.in./rev.)
9.6 (.59)
SPECIFICATIONS
NlOCB--
items
Specifications
Standard value
mm (in.)
Steering wheel free play

Steering angle
Inner wheel
3230..0,,
Outer wheel
29OO
Steering gear oil level

Stationary
steering
Drive belt tension
25 (.98) or less
mm (in.)
effort
25 l.98)
N (Ibs.)
mm (in.)
Oil pump pressure
37 (8.2)
9-l 2 (.35-.47)
kPa (psi)
Gauge hose valve closed
7,500-8,200
Gauge hose valve opened
980 (142) or less
Ncm (in.lbs.)
Mainshaft starting torque
Cross-shaft
end play
mm (in.)
25-65 (2-6)
Mainshaft
50-90 (4-8)
total starting torque
Backlash between
balls
mm (in.)
Ncm (in.lbs.)
ball groove of rack piston and
Ball joint starting torque

Idler arm turning torque
Spring balance reading
Ncm (in.lbs.)
Ncm (in.lbs.)
N (Ibs.)
(1,067-l
0.05 (.0020)
0.05-o. 1 (.0020-,004)
100-300
(8.9-26)
300-900
(26-78)
25-75 (5.5-16.5)
1 ST6 Revision
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,I 66)
POWER
STEERING
-Specifications
Items
Specifications
Limit
Steering wheel free play
Steering gear backlash
Bail joint end play
mm (in.)
50 (2.0)
mm (in.)
0.5 (.02)
mm (in.)
1.5 (.06)
Oil pump pressure
kPa (psi)
Gauge hose valve closed
Backlash between ball groove of rack piston and balls
Clearance
TORQUE
between
oil pump drive shaft and bushing
1,500 (218)
mm (in.)
0.2 (.008)
mm (in.)
0.1 (.004)
SPECIFICATIONS
NlOCC--
Items
Nm
ft.lbs.
Steering column and shaft

Steering wheel lock nut
Steering column A to steering
35-45
25-33
20-25
14-18
Column tube clamp
8-10
6-7
Dash panel cover

Steering shaft A to steering shaft B
Steering shaft B to joint assembly
3-5
2-4
11-15
Joint assembly
30-35
22-25
22-25
18-25
13-18
Gear box installation

Gear box to joint assembly
55-65
30-35
40-47
22-25
Pitman arm to relay rod

Gear box to pressure hose
45
40-50
33
29-36
Gear box to return hose
30-40
22-29
Side cover
45-55
33-40
30-45
22-33
Breather plug
3-4
2-3
Pitman arm installation
130-I 50
94-l 08
Circulators
Plate
Power steering
Adjusting
to steering
column
gear box
15-20
30-35
gear box
bolt lock nut
3.5-4.5
2.5-3.2
Valve housing
installation
45-55
33-40
Lock nut*
180-230
130-I 66
NOTE
* If the special tool is used to measure the tightening
torque, the measurement
/ STB Revision
http://vnx.su/
is 135-175
Nm (98-l 27 ftlbs.).
1.4
1~ :p
POWER STEERING
,9-4
-Specifications
ftlbs.
Nm
Items
il pump
Oil pump bracket to engine
Front
14-21
IO-15
Front
14-21
IO-15
Rear
Right side
27-41
20-30
Oil pump to pressure hose
16-24
12-17
Oil reservoir assembly

Reservoir to reservoir bracket
6-10
4-7
18-22
13-16
25-33
40-60
2943
6-10
4-7
18-22
13-16
18-25
13-18
IO-13
7-9
Reservoir to oil pump body

Oil pump body to oil pump bracket
Connector
Suction plate
Pump cover
18-24
eering hoses
Under skid plate
Front
Rear
Pressure hose
Oil pump side
Gear box side
16-24
12-17
30-40
21-29
Return tube
40-50
29-36
Clip
8-10
6-7
Pressure hose clip
8-12
6-9
Return hose clip

Tube stay
8-12
6-9
16-24
12-17
Tube clip
8-12
6-9
Breather pipe
8-12
6-9
18-25
13-18
IO-13
7-9
Tie rod end to knuckle
45
33
Tie rod end to relay rod

Tie rod end to pipe
45
33
65-80
47-58
Relay rod to pitman arm
45
33
Relay rod to idler arm
45
33
Idler arm to idler arm support

Idler arm support to frame
40-60
29-43
55-65
40-47
eering linkage
Underskid plate
Front
Rear
( STB Revision
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POWER STEERING - Specifications

LUBRICANTS
Specified
Items
Quantity
lubricant
Between the cap and stop bolt for

steering angle adjustment, and the
head of the stop bolt
Multipurpose
NLGI No. 2
grease SAE J310,
As required
Steering shaft C and D
Multipurpose
NLGI No. 2
grease SAE J310,
As required
Surface of lever cam which

contacts steering column B
Multipurpose
NLGI No. 2
grease SAE J310,
As required
Surface of plate clevis pin which

contacts steering column B
Multipurpose
NLGI No. 2
grease SAE J310,
As required
Between
spring
Multipurpose
NLGI No. 2
grease SAE J310,
As required
Dash panel cover grommet
Multipurpose
NLGI No. 2
grease SAE J310,
As required
Installation location of steering

shaft A bushing
Multipurpose
NLGI No. 2
grease SAE J310,
As required
Installation locations
column A bushings
Multipurpose
grease SAE J310,
NLGI No. 2
Automatic transmission
fluid
DEXRON type
As required
Oil seal lip of mainshaft
Multipurpose
NLGI No. 2
grease SAE J310,
As required
U-packing
Multipurpose
NLGI No. 2
grease SAE J310,
As required
Needle bearing of side cover
Multipurpose
NLGI No. 2
grease SAE J310,
As required
Oil seal lip of cross-shaft
Multipurpose
NLGI No. 2
grease SAE J310,
As required
Lip portion of dust cover
Multipurpose
NLGI No. 2
grease SAE J310,
As required
Inside of dust cover
Multipurpose
NLGI No. 2
grease SAE J310,
As required
Inside surface of idler arm bushing

and shaft of idler arm support
Multipurpose
NLGI No. 2
grease SAE J310,
As required
plate clevis pin and return
Power steering
of steering
fluid
of side cover
SEALANTS
AND ADHESIVES
NlSCE--
Specified
Items
Dash panel cover bolt installation
Inside steering
Installation
900 cc (54.9 cu.in.1
column
hole
sealant
3M ART Part No. 8663, or equivalent

3M Stud locking 4170, or equivalent
B nut
3M ART Part No. 8663, or equivalent
surface of dust cover
/ STB Revision
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; .j :
19-6
"
POWER STEERING -Troubleshooting
TROUBLESHOOTING
NlSEABB
Symptom
Probable cause
Excessive play of
steering wheel
Excessive
play in steering
Loose steering
Loose or worn
Steering wheel
operation is hard
(insufficient power
assist)
gear box
gear mounting
bolts
stud of tie rod end
Shrill noise
Hissing
Whistling
noise
noise
19-25, 28
Retighten
19-23
Retighten
necessary
or replace as
19-39
Replace the belt
Low fluid level
Refill with fluid
19-11
Air in fluid line
Bleed the system
19-12
Twisted
Correct the hose routing or

replace the hoses
19-38
Check the fluid leakage
Damaged
belt
or damage hoses
Malfunction
of gear box
Check and replace the gear box

if necessary
19-23
Malfunction
of oil pump
Check the oil pump pressure

repair oil pump
19-l 3
Loose installation
of oil pump or gear box
Retighten
box
and
the oil pump or gear
1g-23., 33
interference around column or between

pressure hose and other parts
Correct or replace the pressure

hose and the parts around the
column
19-38
Abnormal
pump
Replace the gear box or oil pump
19-23.33
Check the oil level and hose

clips, bleed the system or
replace the oil pump
19-11,38,
19-33
19-33
Loose belt
Replace the oil pump

sI
Adjust the belt tension
19-11
Oil pump seizure
19-33
Air sucked
Check the oil level and hose

clips; bleed the system
19-II,38
Damage to the olive of the gear box port

section
Replace the gear box
19-23
Malfunction
of return hose
Replace the hose
19-38
Malfunction
of gear box port section
19-23
Air sucked
noise
Repair
19-I 1
noise inside of gear box and oil

into oil pump
Oil pump seizure

Squealing
Reference
page
Adjust the belt tension
Loose belt
Fluid leakage
Rattling noise
Remedy
into oil pump
1 STB Revision
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ii
POWER STEERING -Troubleshooting
Droning noise
Loose mounting
Interference
bolt on oil pump or oil
of wheel with vehicle bod
connectron
Oil leakage from oil

reservoir
Oil leakage from oil

pump
Oil leakage from gear
box
Improperly
welded
pipe
Overflow
Weld the pipes or replace
19-33
Bleed the system

oil level
19-II,12
or adjust the
Malfunction
oil pump housing
19-33
Malfunction
of O-ring and/or oil seal
Replace the O-ring and oil seal
19-34
Malfunction of gear box housing (including

leakage from air hole)
19-23
Malfunction
Replace the O-ring and oil seal
19-25, 28
of O-ring and/or oil seal
NOTE
* A slight beat noise is produced by the oil pump; this is not a malfunction.
(This noise occurs particularly when a
stationary steering effort is made.)
** A slight vibration may be felt when the stationary steering effort is made due to the condition of the road surface. To
check whether the vibration actually exists or not, test-drive the vehicle on a dry concrete or asphalt surface.
Moreover, a very slight amount of vibration is not a malfunction.
1 STB Revision
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POWER STEERING - Special Tools
SPECIAL TOOLS
NlSDA--
Steering
linkage puller
Bearing and oil seal installer
seal and the ball bearir

(Refer to GROUP 3)
Housing lock nut special
of the housing lock nu
MB990778-01
Ball joint remover
M B990228-01
Preload socket
Measurement of the
mainshaft starting
M B990853-01
Top cover remover
Removal and installati
M B990662-0 1
Oil pressure gage
Measurement of the oil

pump pressure
M B9908540 1
Snap ring installer
Installation of the snaj
pressure gage
pressure gage
1 STB Revision
http://vnx.su/
..
<.
_
POWER
STEERING
Service
Adjustment
Procedures
19-9
SERVICE ADJUSTMENT
PROCEDURES
CHECKING
FREE PLAY
STEERING
WHEEL
NlSFABD
1. With the engine stationary

and the steering wheel in the
straight-ahead
position, apply a force of 5N (1 .I Ibs.) to the
steering wheel in the peripheral
direction.
Measure
the
play on the circumference
of the steering wheel.
Standard
Limit
value
: 50 mm
: 25 mm
(2.0
(.98 in.) or less
in.)
13K706
2.
If the measured
value exceeds the repair limit, check the
steering gear backlash and linkage ball joint end play.
CHECKING
STEERING
GEAR BACKLASH
NlSFOAB
1. Jack up to the vehicle front and hold the steering

the straight ahead position.
2. Apart the pitman arm and the relay rod.
Caution
1. Use cord
2.
to bind
become
separated.
The
should
nut
the special
be loosened
tool
only,
closely
not
wheel in
so it wont
removed.
135742
3.
Measure the steering gear backlash

end with a dial indicator.
Limit
4.
: 0.5 mm
(.02
at the pitman
arm top
in.)
If the measured
value exceeds the limit, screw in the
steering gear box adjusting
bolt until steering wheel free
play is within the range of standard value.
Caution
1. Be sure to make the adjustment
with the steering
wheel
in the straight-ahead
position.
2. If the adjusting
bolt is over-tightened,
more steering
effort will be required,
and return
of the wheel
will
be adversely
affected.
I STB Revision
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1940
._
POWER
STEERING
MEASURING
Procedures
BALL JOINT
END PLAY
NlSFPAA
1. Hold the ball joint with pliers.

2. Set a caliper gauge as shown in left figure and measure
the displacement
with the ball stud compressed.
Limit
3.
\
L-.
: 1.5 mm
If the measured
ball joint.
CHECKING
(.06 in.)
displacement
STEERING
is over the limit,
ANGLE
value
: Inner wheel
Outer wheel
radius
gauge
NOTE
After adjusting
the
jam bolt so that the
head of the stop
direction, and then
specified
grease.
Specified
grease
Caution
Be sure
adjusting
that
the
CHECKING
steering
edge of
bolt are
pack the
and
3230 -%
29OO
2. Adjust the steering angle of each wheel by turning

bolt of the knuckle arm.
13FOOf
the
NlSFDAC
1. Place the front wheel on a turning

measure the steering angle.
Standard
replace
the stop
angle, mount the cap onto the

the slit side of the cap and the
flush and face in the same
head of the stop bolt with the
: Multipurpose
No. 2
grease
the toe-in
is properly
steering
angle.
STATIONARY
SAE 5310, NLGI
adjusted
STEERING
before
EFFORT,,,,,,,
1. Place the vehicle on a level surface and place the steering

wheel in the straight-ahead
position.
2. Set the engine speed to 1,000 r/min.
3. Measure
the tangential
force with a spring balance by
turning the steering
wheel clockwise
and counterclockwise one and a half turns.
Standard
13K705
4.
value
: 37 N (8.21
Ibs.) or less
If the stationary steering effort exceeds the standard value,

check for belt slackness, damage, insufficient
oil, air mixed
into oil, collapsed
or twisted
hoses, etc., and repair if
found.
/ STB Revision
-1
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POWER
STEERING
- Service
-.
*
Adjustment
CHECKING
CENTER
.:
;*,r
19-11
Procedures
STEERING
WHEEL
RETURN
TO
N19FGAD
To check for the return of steering wheel to center, carry out

drive test and check the following
points.
1. Make gentle and sharp turns and check to get a feel for
that there is no appreciable
difference
in steering effort
and return to center between right and left turns.
2. Drive at a speed of about 35 km/h (22 mph), turn the
steering wheel 90 clockwise
or counterclockwise,
and
release the wheel a second or two later. If the wheel
returns more than 70, the return may be considered
good.
NOTE
When the steering wheel is turned abruptly, momentary
hard steering might result, but this does not mean any
problem.
It is caused by low oil pump delivery during
idling.
CHECKING
131613
DRIVE-BELT
TENSION
NlSFHAD
1. Check the belt for slackness by applying

(22lbs.) to the center of the belt.
Standard
2.
value
: 9-12mm
(.35-.47
FLUID
of IOON
in.)
If the measured
tension
is different
value, adjust the drive belt tension.
CHECKING
pressure
from
the standard
LEVEL
NlBFlAF
1. Start the engine on a level surface, and turn the steering

wheel several times fully to the right and left while the
engine is idling.
2. Replace the fluid if it has bubbles or has become white.
3. Fill the reservoir with specified
automatic
transmission
fluid to the MAX level.
Specified
fluid
: Automatic
Type
REPLACEMENT
transmission
fluid
OF FLUID
DEXRON
NlOFJAF
Check for contamination

in the fluid reservoir. Foamy or cloudy
fluid should be replaced.
1. Remove the reservoir cap.
2. Disconnect
the return hose from the reservoir tank and
remove the fluid.
3. Disconnect
the high tension cable.
4. Run the engine
intermittently
several times
with the
starting motor, and remove the fluid from the gear box.
5. Attach the return hose and supply the specified
fluid.
Specified
6.
Bleed
fluid
: Automatic
Type
the system
1 STB Revision
http://vnx.su/
and check
transmission
the fluid
fluid
pressure.
DEXRON
19-12
POWER STEERING
- Service
Adjustment
Procedures
AIR BLEEDING
NlSFKAD
Check stationary
s#teering effort. If it is different
standard value, air in the system is suspected.
system.
1. Make certain the reservoir is filled up.
2. Jack up the front wheels.
3. Remove the high tension cable.
from
Bleed
the
the
4 While turning the steering wheel completely

to the right
and to the left, turn the engine over by using the starting.
motor. Repeat this several times.
Caution
Do not carry out bleeding
with the engine running,
high
speed rotation
of the oil pump mixes the power steering
fluid with air, making
it impossible
to throughly
bleed
the system.
5. Lower the front wheels.

6. Connect one end of a vinyl tube of suitable length to the
breather plug of the gear box, and place its other end in a
container.
7. Start the engine and idle it.
8. Loosen the breather plug, and then turn the steering wheel
completely
to the right and left continuously
until air
bubbles no longer appear in the fluid coming out of the
tube.
Caution
Do not hold the steering
completely
for 10 seconds
or more.
to the left or right
9. After completion
of the bleeding, tighten the breather plug.
Check the fluid level, and refill if necessary.
10. When turning the steering wheel right and left fully, check
that the fluid level variation is less than 4 mm (.I6 in.)
/ ST6 Revision
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POWER
STEERING
Service
Adjustment
PRESSURE
MB990662
TEST OF OIL PUMP
NOTE
Use the adapter
M B990662
19-13
Procedures
1. Disconnect
the pressure
connect the special tool
s
Lf/
Thermometer
to connect
NlSFlAD
hose from the

as illustrated.
the special
oil
pump
and
tool to the pump.
Bleed the power steering system.

Start the engine and operate it until the fluid temperature
reaches about 55C (131F).
4. Run the engine at 1,000 r/min.
5. Completely
close the shut-off valve of the special tool and
read the gauge pressure.
2.
3.
3s(w
MB990994-01
Caution
Do not close the shut-off
more than 3 seconds.
Standard
Valve
Valve
Limit
:
Valve
valve
of the special
value :
closed 4,900-7,800
kPa (711-1,138
opened 980 kPa (142 psi)
opened
6.
1,500
tool
for
psi.)
kPa (218 psi)
If the hydraulic pressure is not within the range of the

standard value, replace the oil pump.
7. Completely
open the shut-off valve of the special tool and
read the gauge pressure. If the hydraulic pressure is not
within the range of the standard value, check for a clogged
or collapsed oil line, or for a clogged oil passage inside the
gear box.
8. With the shut-off valve of the special tool completely
open,
and turn the steering wheel completely
to the right or left,
then measure the maximum
oil pressure in this condition.
If the maximum
oil pressure is not within the range of the
standard value, (valve closed) the valve of the gear box is
faulty, and the gear box must be replaced.
1 STB Revision
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POWER
STEERING
Tape or mark
on steering
column cover
Tape or mark
on steering
wheel hub
13W584
Distance
Service
STEERING
Adjustment
Procedures
WHEEL
CENTERING
SMilPLlFlED
STEERING
WHEEL CENTERING
,:
DETERMINING
STEERING
WHEELS
OFF CENTER
1. For the road test, take along chalk or tape and a ruler.
2. Drive straight ahead on an uncambered
level surface.
3. When the vehicles
wheels are pointing
straight ahead,
mark the steering wheel hub and column
cover with a
chalk or tape line.
4. Stop the vehicle and line up the marks on the hub and
column cover.
5. Place a tape strip or mark on the steering wheel rim.
6. Hold a ruler next to the rim as shown in the illustration,
and
then steer the steering wheel until it is in the desired
centered
position.
7. Record the distance
the strip or mark on the rim has
moved. This is how far the steering wheel is off center. If it
is more than16 mm (5/8 in.) off center, it can be centered
by indexing
it ten degrees towards the center.
off-center
INDEXING
STEERING
WHEEL TO CENTER IT
The steering wheel shaft has 36 splines, allowing
wheel to be indexed in ten-degree
increments.
the steering
I. Remove the steering wheel.

2. Without disturbing
the position of the steering wheel shaft,
re-install the wheel as near on-center
as possible.
36 splines
13W589
16 mm (5/8 in.
NlBFNAB
16 mm (5/8 in.)
13W582
STB Revision
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POWER
STEERING
Service
Adjustment
19-15
Procedures
PRECISION
STEERING
WHEEL CENTERING
In general, the tie rods are adjusted to steer the front wheels
in
the same direction that the steering wheel is off center. If the
steering wheel is off center to the left, center it by adjusting
the tie rods to make the front wheels

vice versa.
steer toward
the left, and
Steering whedl off center left

13W583
Adjust tie rods to steer left
13W586
I.
2.
Hold the tie rods with a wrench while loosening the

locking nuts at least 114 turn.
Hold the tie rod end with a wrench and turn the tie rod the
desired number
same direction
of turns. Adjust
to center
both tie rods equally
the steering
in the
wheel.
NOTE
By turning the tie rods l/6 of a turn, an adjustment

of 2 (at
the steering wheel center) or 6 mm (.25 in.) (at the steering
wheel rim) can be made.
13W587
Off center to right
I
13W587
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. ,.I
19-16
POWER
STEERING COLUMN
REMOVAL
STEERING
- Steering
Column
and Shaft
AND SHAFT
AND INSTALLATION
NlSGA-
3545
25-33
22-25
Nm
ft.lbs.
ftlbs.
13W644
Removal steps
++
I.
2.
3.
l + 4.
5.
6.
7.
8.
9.
10.
Bolt
Horn pad
Jam nut
Steering
wheel
assembly
Lower
column
cover
Upper column
cover
Lap heater duct
Cable band
Column
switch
Ignition
switch
l 4
l +
l 4
1.
2.
3.
4.
5.
6.
Key remained
switch
Brake pedal return spring
Clutch pedal return spring
Washer
bolts
Bolts
Steering
column
and shaft
assembly
NOTE
(1)
(2)
(3)
Reverse
l
l
*
+
1 STB Revision
the removal
: Refer
: Refer
to
to
procedures
Service
Service
http://vnx.su/
Points
Points
to reinstall.
of
of
Removal.
Installation
POWER
STEERING
Steering
SERVICE
4.
Column
and
POINTS OF REMOVAL
REMOVAL
OF STEERING
WHEEL
Remove the steering wheel.
SERVICE
19-17
Shaft
POINTS
NlSGBAH
ASSEMBLY
OF INSTALLATION
NlBGDAE
13. APPLICATION
OF SEALANT
TO WASHER
BOLTS
Attach the dash panel cover and apply a coating of the
specified
sealant in the bolt installation
hole from inside
the vehicle.
Specified
sealant
Caution
Do not loosen the column tube clamp bolts. If the clamp
bolts should be loosened,
retighten
them securely while
pulling the steering
shaft out fully toward the interior
side.
13. INSTALLATION
OF CLUTCH
/12.BRAKE
PEDAL RETURN
Install the return
figure.
4.
spring
PEDAL
SPRING
to the position
RETURN
SPRING
as shown
in the
INSTALLATION
OF STEERING
WHEEL ASSEMBLY
Position the front wheels in the straight-ahead
position and
install the steering wheel.
If the center of the steering wheel is not in alignment,
make the steering wheel centering
adjustment.
(Refer to
19-14.)
1 STB Revision
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19-18
POWER
DISASSEMBLY
AND
STEERING
- Steering Column and Shaft
REASSEMBLY
NlSGE-
2510
/
--
15
\4
20-25
14-18
Nm
ft.lbs.
8-10 Nm
5-7 ftlbs.
i6
Disassembly
l 4
l * l +
l +
l +
~~
4*
l +
I)+
l +
I.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
1 3.
1 4.
1 5.
1 6.
1 7.
1 8.
19.
20.
21.
22.
steps
Bolt
Return springs
Clevis pin
Bolts
Bolt
Bushings
Snap ring
Stopper
Spacer
Steering shaft A
Dust seal
Bushing
Steering column A
Special bolts
Steering lock assembly
Dash panel cover
Column tube clamp
Steering column B
Column bushing
Column tube
Steering shaft B
Snap ring
+e l +
+e l +
l +
l +
l +
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
Clip
Bearing
Special bolts
Plate
Nut plate
Snap pin
Lever assembly
Snap ring
Plate assembly
Lower boot
Upper boot
Dust cover
Spring
Steering shaft C
Steering shaft D
Joint assembly
NOTE
(1)
(2)
(3)
(4)
Reverse
the disassembly
procedures
+e
: Refer
to Service
Points
of
Points
of
: Non-reusable
parts
1 STB Revision
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to reassemble
Disassembly.
Reassembly.
POWER STEERING
- Steering
Column
and
19-19
Shaft

3.
7.
REMOVAL
OF CLEWS PIN
Knock the clevis pin out from
column.
REMOVAL
OF SNAP
the inside
NISGFAF
of the steering
RING
Using the snap ring pliers, remove the snap ring from
steering shaft A and extract steering shaft A from the
bottom
of steering
column A.
NOTE
Release
the steering
14. REMOVAL
SEMBLY
OF SPECIAL
lock to extract
steering
BOLTSI15.STEERING
shaft A.
LOCK AS-
If it is necessary to remove the steering lock, cut a groove

on the head of each special bolt with a metal saw, and
remove the steering lock with a screwdriver.
25. REMOVAL
OF SPECIAL
BOLTW26.PLATE
If it is necessary to remove the plate of steering column B,
cut a groove on the head of each special bolt with a metal
saw, and remove the plate with a screwdriver.
INSPECTION
l
l
l
l
l
l
l
l
NlSGGAF
Check the plate for cracks or damage.

Check the column
bushing for damage.
Check the dash panel cover for damage.
Check the steering shaft bearing for wear.
Check the steering shaft for damage and deformation.
Check the teeth of the plate assembly
for wear.
Check the steering shaft joint for play or faulty operation.
Check the dust seal and bushing for damage or unusual
wear.
1 STB Revision
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19-20
POWER
STEERING
Steering
SERVICE
Column
POINTS
and
Shaft
OF REASSEMBLY
NlSGHAK
38. INSTALLATION
OF JOINT
ASSEMBLY
(1) Plate the upper boot over steering shaft C assembly
the lower boot and dust cover over steering
shaft
NOTE
Leave the upper and lower boots
assembling
them to the universal

Specified
Steering
Steering
shaft D
Steering
shaft C
\
Steering
/
grease
to the steering
: Multipurpose
NLGI No. 2
without
shaft C and D.
grease
SAE
5310,
shaft C
Caution
After inserting
steering shaft D make sure that the tilt of
the yoke of steering
shaft D in relation
to the yoke of
steering shaft C is within the angle measurement
shown
shaft D
(3) Assemble
upper
Q
(0i
III
Q
Lower
grease
on the shafts
joint.
and
D.
the upper
and lower
boots
and the dust cover.
NOTE
Align the arrows on the upper and lower boots to the slits
on the yokes in order to assemble.
Slit
S/it
13S699
31. APPLICATION
OF GREASE
LEVER ASSEMBLY
TO PLATE
ASSEMBLY/28
When installing
the lever assembly
and the plate assembly, apply the specified grease to the following
locations:
Specified
grease
: Multipurpose
No. 2
grease
SAE 5310, NLGI
(1) The surfac$of

the cam part of the lever which contact
steering,,.column
6.
(2) The surface of the plates clevis pin which contact
steering, co!umn
B.
(3) The sp@e,ibetween
the
pin and return
+-;-13W558
spring,..-,:...=-;7;;:
-. ..-
STB Revision
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POWER
STEERING
- Steering
Column
and
19-21
Shaft
26. INSTALLATION
OF PLATE/25.SPECIAL
BOLTS
When mounting
the plate onto the steering
column
tighten the special bolts until the heads twist off.
16. APPLICATION
OF GREASE
Apply the
grommet.
Specified
specified
grease
15. INSTALLATION
SPECIAL
BOLTS
TO DASH
grease
to
the
PANEL
dash
B.
COVER
panel
cover
: Multipurpose
No. 2
OF STEERING
LOCK
ASSEMBLY/14.
(1) When installing the steering lock onto steering column

A, install it loosely in alignment
with the column boss
and check that it works properly.
(2) Then tighten the special bolts until the heads twist off.
13W605
12. APPLICATION
Dust, seal
l.DUST
SEAL
Apply a coating of specified grease to the bushing

dust seal and steering shaft A contact surfaces.
of the
Specified
OF GREASE
grease
TO BUSHING/l
: Multipurpose
No. 2
10. INSTALLATION
STEERING
SHAFT A
Align the projection
of the dust seal and the notch of
steering
column A, and then install steering
shaft A to
steering column A.
Iion
http://vnx.su/
POWER
STEERING
Steering
Column
6. APPLICATION
5.
Yellow
line
Shaft
OF GREASE
Apply the specified

steering column A.
Specified
and
grease
TO BUSHINGS
grease
to th,e bushings
: Multipurpose
No. 2
grease
and install
SAE J310,
NLGI
INSTALLATION
OF BOLT
Assemble
steering column A and steering column B by
aligning the yellow line on the serrated part of steering
shaft B with the yoke groove in steering shaft A.
13W604
4. APPLICATION
OF ADHESIVE
Apply specified adhesive

and tighten the bolt.
Specified
adhesive
TO BOLTS
to the nut of steering
: 3M Adhesive
equivalent
Caution
If there is any adhesive
hardened
tap to remove
it before applying
3.
stud
locking
column
4170
or
inside the nut,

the adhesive.
use a
INSTALLATION
OF CLEVIS PIN
Insert a new clevis pin until the tip of the pin is flush with
steering column
B.
1. INSTALLATION
OF BOLT
Align the whit:e line on steering

shaft B and the yoke
groove in steering
shaft C, and then tighten
at the
specified
torque.
White
line
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::
POWER STEERING
POWER STEERING
REMOVAL
Bleeding
AND
Power
Steering
Gear
19-23
.
Box
GEAR BOX
INSTALLATION
of the Power
NlONA-
Steering
30-40
22-29
Nmy
ft.lbs.
30-35
22-25
Nm
ft.lbs.
:\\I--
55-65
4047
Nm
ft.lbs.
Removal
+*
l *
l *
~~
45 Nm/
33 ft.lbs.
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
Bolt
Connection
of pressure
hose
Connection
of return hose
Cotter pin
Slotted
nut
Connection
of relay rod
Self-locking
nuts
Connection
of joint assembly
Power
steering
gear box
13W64i
40
,,:: . .
*, _;I., /, <i!
; &. <:, . y!.*
.:-&
., c%$&$;<,;:
.:. -..;,
:,?
\
\..~
, I,:-J
y .;,.4- , .y., ,:
NOTE
:,
.I tfli. ,+r$
to reinstall.
Iii ,s:: I ,.
YR
(4) q
: Non-reusable
parts
:*q.
:i.
?
( ST6 Revision
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.,
aib4
;:o, I
: f
P'2
f
POWER STEERING
Power
SERVICE
2.
Steering
POINTS
Gear
Box
OF REMOVAL
DISCONNECTION
OF
HOSE
Disconnect
the pressure
gear box.
NlONBAC
PRESSURE
HOSE/3.
hose and return
RETURN
hose from
the
Caution
Use waste cloth to close the end of each hose in order to
prevent escape of fluid and entrance
of dirt and other
foreign material.
6.
DISCONNECTION
OF RELAY
Disconnect the pitman

special tool.
ROD
arm from the relay rod by using the
Caution
1. Use cord to bind the special
ifl~.4@ijme
separated.
2. /The nut should be loosened
tool
closely
only,
not
so it wont
removed.
MB990635-01
SERVICE. POINTS
9.
INSTALLATION
OF INSTALLATION
OF POWER
STEERING
N19NDAB
GEAR
BOX
Install the power steering

gear box to the frame after
inserting the power steering gear box mainshaft
into the
joint assembly.
( STB Revision
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POWER
STEERING
- Power
Steering
Gear
Box
DISASSEMBLY
33-40
Disassembly
ft.lbs.
steps
1. Jam nut
2. Pitman arm
3. Dust cover
4. Breather
plug cap
5. Breather
plug
6. Washer
bolts
.7,. ,,Side cover
8,:Adjusting
bolt lock
9. Cross-shaft
,lO. Adjusting
bolt
11. Adjusting
plate
12. O-ring
13. U-packing
14. Valve housing
lock
15. Bolts
16. Valve housing
17. Rack piston
18. Seal ring
l *
nut
l *
l *
nut
c.1.
x-t
.gi.
.-*
NOTE
, 1, (1) l *
(2) q
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
O-rings
Screws
Circulator
holder
Circulators
Balls
Top cover
Main shaft
Thrust
needle
bearings
Ball bearing
Oil seal
O-rings
.
Seal, rings
Oil seal
Upacking
Gear box housing
: Refer t; Service Points

: Non-reusable
parts
-
Y 7.
T>,
.%i
1 STB Revision
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;,
. .
._
..
~~.~,.:~;~,
, r;
>
of 6isasse;i7bQ~~.
- .
-2.
:z-$-$
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j
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: .
i --;.:*&g
-.
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b
- -.
19-26
-
POWER STEERING
\p,
MB990809-01
Power
SERVICE
2.
REMOVAL
Steering
POINTS
Gear
BOX
OF DISASSEMBLY
OF PITMAN
NlSNFAC
ARM
Remove the pitman arm from the gear box assembly

using the special tool.
5.
8.
REMOVAL
OF BREATHER
PLUG
Remove the breather plug, and drain the steering
REMOVAL
OF ADJUSTING
BOLT
LOCK
by
gear oil.
NUT
Loosen the lock nut of the adjusting

bolt and screw in the
adjusting
bolt so that the side cover raises slightly.
9.
REMOVAL
OF CROSS-SHAFT
With the mainshaft
and cross-shaft placed in the straight
ahead position,
tap the bottom
of the cross-shaft with a
plastic hammer to take out the cross-shaft together
with
the side cover.
10. REMOj/AL
OF ADJUSTING
BOLT
.+gg~Remove the side cover by turnrng3be
_ IXT
13. REMOVAL
;.$-a
;y..
bolt.
OF U-tiAC$%JG
Do not remove the

bearing unless there
the adjusting
bolt.
packing with a new
adjusting
U-packing
at the rear of the needle
is fluid leakage from the threads of
If there is leakage,
replace the Uone.
. :
2<..:,
I,,i;<.
1 .-r+-;
<:,.
MB990852-01
\
14. REMOVAL
OF VALVE HOUSING
LOCK NUT
Remove the valve housing lock nut by using the special
tool.
REMOVAL
OF VALVE HOUSING
Remove the valve housing together
Caution
Use care not
http://vnx.su/
to drop
the
rack
with the rack piston.
piston.
POWER
STEERING
- Power
17. REMOVAL
Steering
Gear Box
OF RACK
PISTON
Remove the rack

counterclockwise.
Caution
Be careful
piston
from
the mainshaft
not to lose the 26 balls
24. REMOVAL
OF TOP
19-27
inside
by turning
it
the rack piston.
COVER
Remove the top cover by using the special tool, and take
out the mainshaft,
together
with the top cover, from the
valve housing.
27. REMOVAL
OF BALL
BEARING/28.0lL
SEAL
(1) Temporarily
attach the top cover to the valve
(2) Drive out the ball bearing
and the oil seal.
housing.
13YO24
INSPECTION
l
l
l
l
l
NIONGAA
Check the mainshaft

Check the tooth surface of cross shaft and the rack piston
Check the contact
part of adjusting
bolt for uneven wear.
Check the dust seal and the oil seal for wear and damage.
Check the O-rings
for damage.
CHECKING
BACKLASH
PISTON
AND BALLS
BETWEEN
BALL GROOVE
OF RACK
Set the rack piston to the position

shown
in the figure,
then measure
the backlash
by using a dial gauge.
mm
Standard valud : 0.05-0.1
Limit
: 0.2 mm (.008 in.)
http://vnx.su/
,;
(.0020-.004
I&-
in.)
and
19-28
POWER
STEERING
- Power
Steering
Gear Box
REASSEMBLY
NlSNE--
26
30
/2g
3.04.0
Nm
, Nm
ftlbs.
L
-25
'--45-55
\ -
3340
17nl
hm
ftlbs.
13W609
Reassembly steps
Gear box housing
:_
U-packing
Oil seal
Seal rings
O-rings
l + 6. Oil seal
l + 7. Ball bearing
l + 8. Thrust needle bearings
9. Main shaft
l + Adjustment
of main shaft starting
10. Top cover
1. Valve housing
lock nut
2. O-rings
3: Seal ring
4. Rack piston
5. Balls
6. Circulators
7. Circulator
holder
l +
l Q
1.
2.
3.
4.
5.
l + 19. Valve
l + 21. U-packing
l * 22. O-ring
l + Adjustment
of cross-shaft
play
l
l
l
l
starting
+
+
+
+
torque
housing
l +
NOTE
(1) l *
(2) q
(3)
*
20. Bolt
STB Revision
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end
23. Adjusting
plate
24. Adjusting
bolt
25. Cross-stiaft
26. Adjusting
bolt lock nut
27. Side cover
Adjustment
of main shaft total
torque
28. Washer
bolts
29. Breather
plug
30. Breather
plug cap
31. Dust cover
32. Pitman
arm
33. Jam nut
: Refer to Service Points of Reassembly.yR,

: Non-reusable
parts
!lq,y;:
: If the special tool is used to measure the tightening
torque, the measurement
is 135-175
Nm. (98-127
ft.lbs.)
POWER
STEERING
- Power
Steerina
Gear
19-29
Box

2.
INSTALLATION
OF UPACKING/3.
Install the U-packing

seal.
6.
INSTALLATION
N19NHAB
OIL
SEAL
on the gear box, and press-fit
OF OIL
SEAL17.
BALL
the oil
BEARING
(1) Press-fit
the ball bearing and oil seal into the top cover.
(2) Apply specified
grease to the oil seal of the top cover.
Specified
8.
INSTALLATION
grease
: Multipurpose
NLGI No. 2
OF THRUST
NEEDLE
grease
SAE J310,
BEARING
,,
(1) Install the thinner thrust

plate, thrust
needle bearing
and thicker thrust plate to the top cover in that order as
shown
(2) Attach the top cover to the valve housing.
Caution
Be careful that the thrust
plates and the thrust
needle bearing
do not come off the top cover.
L,
C1318
Thrust
needle
(3) Install the thinner

and thicker thrust
as shown
in the
bearing
o
240
mm
(9.4
in.)
ADJUSTMENT
thrust
plate, thrust
needle bearing
plate to the mainshaft
in that order
illustration.
OF MAINSHAFT
STARTING
TORQUE
(1) In order to fit in the assembly

parts, use the special tool
and a spring balance, and tighten the top cover until.the tangest
force becomes
62-83 N (14-19 Ibs:). Then
return -the top cover until the tightening
tor&ie is 0 ,:,t$(&.~
:*-;I
- .+
% ft.)
.;f
3
Caution
After tightening
the top cover, rotate
to confirm
that there is no torque
abnormal
noise.
1 STB Revision
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the mainshaft:
fluctugtion
or
!
:
;!.
i
.I.,.
: ,i
-.+
19-30
POWER
STEHBING
Power
Steering
Gear
BOX
starting torque by using the

(2) Measure the mainshaft
special tools.
CL -(3) Tighten
the top cover until the mainshaft
starting
torque is 20-30 Ncm (1.8-2.7 in.lbs.) greater than the
previously
mentioned
measurement
value.
NOTE
Tighten
starting
(4) Tighten
torque
the top cover gradually

torque.
while
the
the valve housing

lock nut to the specified
Caution
Be sure that the top cover does
with the lock nut at this time.
MB990852-01
measuring
(5) Measure the mainshaft

special tools.
Standard
value
: 25-65
starting
Ncm
not turn
torque
(2-6
together
by using
the
in.lbs.)
MB990228-01
(6) If the measured

mainshaft
starting torque does not
comply
with the standard
value, remove
the valve
housing lock nut and adjust the tightening
of the top
cover.
14. INSTALLATION
OF RACK PISTON
Install the rack piston until it comes in contact with the
edge of the mainshaft.
Rotate the mainshaft to align the ball raceway with the ball
insertion
hole.
Yw
I13 mm I.51 in.)
15. INSTALLATION
OF BALLS
(1) Insert 19 balls into the ball-insertion
gently with a brass bar.
Caution
Do not
balls.
rotate
(2) Measure,
by
surface of the
holes.
(3) If the distance
figure, remove
(4) Insert 7 balls
STB Revision
.iA
the
rack
while
inserting
them
the
using calipers,
the distance
from the
rack-piston
to the ball top point at both
differs from the value shown in the
the rack piston and reinsert the 19 balls.
into the circulators.
J
http://vnx.su/
piston
hole, pushing
POWER
STEERING
- Power
Steering
16. INSTALLATION
lnstal
Gear
OF CIRCULATORS
the circulators
19. INSTALLATION
of the
rack
OF VALVE
fluid
piston.
HOUSING
(1) Apply specified

automatic
ring of the rack piston.
Specified
19-31
Box
transmission
fluid to the seal
: Automatic
transmission
RON Type
(2) Insert the valve housing.

(3) Rotate the mainshaft
until the rack piston
neutral position
(center).
21. APPLICATION
OF GREASE
Apply specified
and the needle
Specified
: Multipurpose
No.
22. APPLICATION
TO O-RING
seal
surface
fluid
OF AUTOMATIC
grease
: Automatic
& Tyr;~
;;
,.. >,\?ij&p
:I*_
$;+J.y:,*: d;,.:
;;,y;
.A..;
NOTE
Install the adjusting
plate
faces the contact
surface
Standard
wision
http://vnx.su/
SAE 5310, NLGI
FLUID
fluid to the O-ring,
trarh$@n
(2) Measure
gauge.
of U-packing
TRANSMISSION
.I!
:
.i
fluid
DEXRON
.I
so that the bevelled

of the cross-shaft.
the end play of the a.djusting

..
bolt with
: 0.05
mm (.0020,,iy.)
,
.,i;,,
.(2.. ;:,.
<
side
a feeler
1
:
value
to the
Apply specified
automatic
transmission
and attach it to the side cover.
i ,:
Specified
moves
DEX-
TO U-PACKING
grease
to the
bearing.
grease
fluid
or I&
; i:
.
s
19-32
POWER
- Power
STEERING
Steering
Gear Box
(3) If the end play exceeds the standard value, select a

suitable adjusting
plate from the table, install it, and
then measure the end play once again.
25. INSTALLATION
OF CROSS
SHAFT/26.
ADJUSTING
BOLT LOCK NUT
Install the cross-shaft to the side cover, and then temporarily tighten the adjusting
bolt lock nut.
27. INSTALLATION
OF SIDE
COVER
Install the side cover assembly

gear box.
(with the cross-shaft)
to the
NOTE
Apply specified automatic
transmission
fluid to the teeth
and shaft areas of the rack piston, and apply specified
grease to the oil seal lip.
Specified
fluid
: Automatic
Type
Specified
grease
transmission
: Multipurpose
No. 2
grease
fluid
DEXRON
SAE 5310, NLGI
Caution
Do not rotate the side cover during
installation.Take
care not to damage
the cross-shaft
oil seal.
-.
ADJUSTMENT
TORQUE
OF
MAINSHAFT
TOTAL
STARTING
(1) While turning the adjusting

bolt, measure
the mainshaft total starting torque by using the special tools.
Standard
NOTE
^. Position
the
measurement.
MB990228-01
Mating
value
(2) Tighten
torque.
marks
the
: 50-90
mainshaft
adjusting
Ncm
in the -center
bolt
lock
32. INSTALLATION
OF PITMAN
ARM
Install the pitman arm to the gear
marks aligned.
.-
/ STB Revision
http://vnx.su/
(4-8
in.lbs.)
position
nut to the
box with
during
specified
the mating
POWER STEERING
Oil
Pump
OIL PUMP
REMOVAL
AND
INSTALLATION
NlSRA-
Post-installation
Operation
Supplying of Power Steering Fluid
(Refer to P.19-11.)
l
Bleeding of the Power Steering
Fluid Line (Refer to P.19-12.)
6-10 Nm
4-7 ft.lbs.
16-24
12-17
Nm
ftlbs.
13W634
3\
/l
8
13-16
14-21
/ IO-15
25-33
18-24
Nm
ft.lbs.
Nmft.lbs.
25-33
18-24
14-21
IO-15
Nk
ftlbs.
-2&l
Nm
ftlbs.
Nm
ftlbs.
Nm
13W648
SERVICEPOINTS
8.
:?rar,
REMOVAL
OF DRIVE VELT
When removing the.,drive belts, remove
compressor
drive belt (models equipped
er) and the alternator
drive belt.
SERVICEPOINTS
8.
.I*NlSRBAD
OF REMOVAL
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the air conditionkr

with air condition*i
OF INSTALtAtION
ADJUSTMENT
OF DRIVE
Refer to P.19-11.
STB Revision
( $$
.&LT
TENSION
- NlSRDAD
:>,.
..I-.-.~
:e.
POWER STEERING
DISASSEMBLY
AND
- Oil Pump
REASSEMBLY
NlSRE--
13w945
Oil pump
cartridge
kit
Oil pump
9
Pulley assembly
seal kit
13W646
kit
40-60
Nm
6-10 Nm
4-7 ftlbs.
16-2;
13-16
130
.I8
40
Nm
ftlbs.
7
13W636
Disassembly steps
5;
.i,
. :i.
l *
l +
l +
1. Reservoir bracket
2. Pump cover
3. Cam case
l *
4. O-ring
5.
6.
l * l *
7.
l + 8.
9.
4* .
-10.
_
;,-a%,__ _I
I. .:: 11.
: ; 12.
13. Oil seal

14. Connector
15. O-ring
Cam ring
Vanes
Snap ring
Rotor
Pulley assembly
Plate
Suction plate
Suction tube
+e ~~ 16. Flow control valve

17. Flow control spring
l *
l + 18. Oil pump body
NOTE
procedures
to reassemble.
(4) q
: Non-reusable
parts.
1 STB Revision
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POWER STEERING
SERVICE
7.
19-35
- Oil Pump
POINTS
REMOVAL
OF DISASSEMBLY
OF SNAP
NlSAFdE
RING
Remove the snap ring from the shaft (pulley assembly)

with snap ring pliers and separate the rotor from the shaft.
9.
REMOVAL
OF PULLEY ASSEMBLY
Tap the rotor side of the shaft lightly with
hammer,
and take out the pulley assembly.
16. REMOVAL
OF FLOW CONTROL
VALVE/17.FLOW
TROL SPRING
Remove the flow-control
valve and the flow-control
from the oil pump body.
Caution
Do not
disassemble
the
flow
control
INSPECTION
l
l
l
l
l
l
l
Check the
Check the
Check the
Check the
Check the
stepped
Check the
Check the
with rotor
a plastic
CONspring
valve.
NlSRGAD
flow control valve for clogging.

pulley assembly
for wear or damage.
drive velt for cracks and deterioration.
groove of rotor and vane for Stepped
wear.
contact surface of cam ring and vanes for
wear.
vanes for damage.
contact surface of pump body, and pump cover
for streak-like
abrasion.
CHECKING
CLEARANCE
BETWEEN
SHAFT
AND PUMP
BODY
Check the clearance between pulley assemblys
shaft and the
pump body.
(1) Place the dial gauge against
the end of the pulley
assemblys
shaft.
(2) Move the pulley assembly up and down;anb
measure the
.i
play.
Limit
: 0.1 mm
http://vnx.su/
(.004
in.)
I:
_
-=G
;,f.,
19-36
POWER STEERING
SERVICE
- Oil Pump
18. INSTALLATION
TROL VALVE
Mark A, B or C
l-t
OF OIL
PUMP
NlBRHAH
BODY/lG.FLOW
CON-
(1) If the flow control valve is to be replaced, install the

flow control valve to the oil pump body corresponding
with the body identification
mark (A, B, C).
(2) Apply specified
automatic
transmission
fluid to the
outside of the flow control valve.
13v902
Mark A, 6 or C
OF REASSEMBLY
POINTS
Specified
13W623
: Automatic
transmission
RON Type
fluid
(3) Install the flow control spring, flow

connector
into the pump body.
MB990938-01
13. INSTALLATION
OF OIL
8.
INSTALLATION
control
DEX-
valve and
SEAL
Drive the oil seal into the pump

Caution
Do not disassemble
fluid
the flow
body with the special
control
tools.
valve.
OF ROTOR
Install the rotor to the pulley assembly.

When the rotor is
to be installed, face the countersunk
portion to the pump
cover
7.
side.
INSTALLATION
OF SNAP RING
(1) Install the snap ring with the special
tool
(2) Lift the rotor and check to be sure that the snap ring
has entered the countersunk
part.
STB Revision
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POWER STEERING
5. INSTALLATION
When
pump
install
body
19-37
- Oil Pump
OF CAM
RING
installing the cam ring, align the dowel pins of the

body with the dowel holes of the cam ring, and then
so that the cam rings punch mark is at the pump
side.
4. APPLICATION
OF FLUID
TO O-RING
Apply the specified automatic transmission fluid to the Oring, and then install it to the cam case.
Specified
Direct round edge
the cam ring
fluid
to
3.
: Automatic
Type
INSTALLATION
OF CAM
(1) Mount the cam

(2) Apply specified
vanes and install
attention to the
transmission
fluid
DEXRON
CASE
case onto the pump body.

automatic transmission fluid to the
the vanes on the rotor, paying close
installation direction.
ring
Specified
Cl3217
1 STB Revision
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fluid
: Automatic
transmission
RON Type
fluid
DEX-
19-38
POWER
STEERING
REMOVAL
STEERING
- Steering
Hoses
HOSES
AND
INSTALLATION
NlSTA-
S&&ing
of Power
Steering
Fluid
Bleeding of the Power Steering

Fluid Line (Refer to P.19-12.)
8-12 Nm
&IO Nm
6-7 ftlbs.
8-12 Nm
6-9 ftlbs.
40-50 Nm
/29-36 ft.lbs.
13W617
Removal steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
II.
Under skid plate

Return
hose
Return
hose clip
Tube clip
Return tube
Clip
Pressure
hose clip
Pressure
hose
Breather
hose
Breather
pipe
Tube stay
10-13 Nm
7-9 ft.lbs.
16W654
NOTE
Reverse
) STB Revision
http://vnx.su/
the removal
procedures
to reinstall
POWER
STEERING
REMOVAL
55-65
40-47
Steering
19-39
Linkage
LINKAGE
AND
Nm
ftlbs.
\
STEERING
INSTALLATION
NlSVA--
8lIl
/
18
17
18
45 Nm
33 tklbs.
45 Nm
33 ftlbs.
45
Nrh
33 ftlbs.
\
45 Nm
33 ftlbs.
5ml
4
65-80
47-58
Nm
ftlbs.
13W637
18-25
13-18
/
Nm
ftlbs.
10-13 Nm
7-9 ftlbs.
16W654
Removal steps
+e
**
64
I.
2.
3.
4.
5.
6.
7.
8.
9.
10.
II.
12.
Under skid plate

Cotter pins
Slotted
nuts
Tie rod ends
Cotter pins
Slotted
nuts
Relay rod
Self-locking
nuts
Idler arm support
Dust covers
Nuts
Pipes
13.
14.
15.
16.
17.
18.
a:
.zq
Dust cover
O-ring
Self-locking
Washer
Idler arm
Bushings
nut
NOTE
(I)
(4) q
: Non-reusable
parts
( STB Revision
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to reinstall.
of Removal.
of Installation
19-40
POWER
STEERING
SERVICE
4.
- Steering
Linkage
POINTS
DISCONNECTION
OF REMOVAL
OF THE
ROD
NlSVBAC
ENDS
Using the special tool, disconnect

then remove the tie rod assembly.
Caution
Use cord to bing the special
become separated.
The nut should be loosened
the tie rod ends,
tool
closely
only,
not
so it wont
removed.
7. DISCONNECTION
OF RELAY ROD
Using the special tool, disconnect
the connecting
of the idler arm and the steering
gear box,
remove the relay rod.
INSPECTION
l
l
l
l
l
l
Standard
CHECKING
Standard
portions
and then
NlSVCAB
Check the
Check the
Check the
Check the
Check the
Check the
CHECKING
and
idler arm support for damage and deformation.

idler arm for damage
and deformation.
dust covers for damage
and cracks.
tie rods for damage
and deformation.
relay rod for bends and damage.
grease nipples for clogging
and looseness.
BALL
value
JOINT
: 100-300
IDLER
value
Revision
http://vnx.su/
ARM
: 300-900
(5.5-16.5
STARTING
Ncm
STARTING
Ncm
Ibs.)]
TORQUE
(8.9-26
inIbs.)
TORQUE
(26-78
in.lbs.)
[25-75
POWER STEERING
Steering
REPLACEMENT
(1) Remove
arm
grease
/
OF DUST COVER
arm,

cover.
Specified
grease
also remove
grease
(3) Use the specified

grease
the O-ring.
to the lip portion
: Multipurpose
No.
Specified
NlBVEAB
the dust cover from the tie rod end or the idler
NOTE
For the idler
Pack
19-41
Linkage
grease
SEA J310.jl$LGl.
._
.-; :
grease
of the dust
inside
the dust
: Multipurpose
grease
cover.
SAE 5310, NLGI
No. 2
13W556]
(4) Apply the specified sealant to the dust cover installation

surface, and then press in.
Specified
sealant
REPLACEMENT
: 3M ART Part
OF IDLER ARM
BUSHING
NlSVFAE

grease to the inside surface
bushing and the idler arm support shaft.
Specified
grease
: Multipurpose
No.
grease
of the
SAE J310,
NLGI
(2) Insert the bushing into the idler arm.

(3) Insert the idler arm support into the idler arm.
(4) Install so that the knurled surface of the washer is facing
the bushing side.
(5) Tighten the self-locking
nut at the specified
torque.
SERVICE
4.
R,elay
rod
side
Knuckle
side
POINTS
INSTALLATION
OF INSTALLATION
OF TIE
ROD
NlSVDAA
ENDS
(1) Apply the specified anti-corrosion

agent to the threaded portion of the tie rod end.
(2) Temporarily
tighten the tie rod so that the distance
between stud bolts of the tie rod is the value shown in
the figure.
Caution
Tie rod
uniform.
end
tightness,
left
and
right,
should
be
(3) Install the tie rod assembly after first confirming

which
side is the relay rod side and which side is the knuckle
side.
1 STB Revision
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BRAKE
SERVICE AND PARKING
CONTENTS
BRAKE
BOOSTER
BRAKE LINE
BRAKE PEDAL
FRONT
GENERAL
..............................................
...................
.m...................................
....................................................
DISC BRAKE CALIPER

INFORMATION
........... . ..............
.................................
..........................................
25
Inspection
and Adjustment
of
Brake Pedal . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . .. . . . . .
27
Inspection and Replacement

of
Brake Pad ..,,...,,...............................................
18
29
2
MASTER
CYLINDER
PARKING
BRAKE CABLE
...................................
40
PARKING
BRAKE LEVER
...................................
39
21
REAR BRAKE SHOE
...........................................
33
REAR BRAKE WHEEL
CYLINDER
36
......................
SERVICE
ADJUSTMENT
PROCEDURES
..........
..........................................................
Bleeding
Blend Proportioning
Valve
Function Test ..................................................
Brake Booster Operating Test ........................
of Parking
Brake Lever Stroke ..........................................
Checking Brake Fluid Level Sensor
................
Checking Parking Brake Switch ......................
NowA.-
10
14
14
12
11
12
12
SPECIAL
TOOLS
. . . . .. . . . . . . .. . . . . . . . ..a........................
15
7
SPECIFICATIONS
. . . . . . . . . . . .. . . . . . . . . . . .. .. . . . . . . . . . .. . . . . . ...*
. . . . . . .. .. . . . . . . . . .. .. . . . . . . . . . . . .. .
. .. .. . . . . . . . . .. . . . . . . . . . . .. . . . . . . .. . .. . . . . . . . . . . .. .. .._
Lubricants

. . . . .. . . . . . . .. .. .. . . . . . . . . . . . .. . . .
. . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . .. . . .
. . . . . .. .. . . . . . . .. .. . . . . . . . . . .. . . .. . . .
TROUBLESHOOTING
Brake drag
Groaning, clicking
Improper
Improper
braking
parking
.. . . . . . . . . .. . . . . . . . . . . . .. . . .. . . . . . . ... . .
or rattling
noise
power
brake function
Increased pedal stroke

Poor parking brake function
Scraping or grinding noise
Squealing, groaning or chatterein.g
Squealing noise
Vehicle pulls to one side
http://vnx.su/
,noise
81
li .j
5-2
BRAKES - General
Information
CAUTION
do not create dust by sanding,
servicing
brake bssemblies
or compqnents,
cleaning brake parts dith a dry brush or with compressed
air.
A WATER DAMPENED
bLOTH
SHOULD
BE USED. Many brake components
contain
which can become airdorne
if dust is created during service operations.
Breathing
dust which hontains
asbestos
fibers c,an cause serious bodily
harm.
When
GENERAL
SERVICE
grinding,
or by
asbestos
fibers
BNFOfSMATlON
BRAKE
For high reliability

and itopping
force, the brake system comprises
ventilated
disc brakes for the front
wheels and leading-trailiig
drum brakes with automatic
adjuster for the rear wheels. A brake booster is also
added to reduce the foirce required for braking.
Braking stability is imprpved
by the adoption
of the blend-proportioning
valve.
Brake
booster
Blend
Fro&
disc bl
proportioning
14W614
From ma_ster,
To
BLEND PROPORTIONING
far brake
VALVE
The blend proportioning

valve serves to improve
efficiency
within normal braking range by distributing
braking force most
effectively to the front and rear wheels and also to increase
braking force to the rear wheels by releasing decompressing
effect if a farge braking force is required
also for the rear
wheels as when the vehicle is loaded or when the front brake
should burst.
, w501
( STB Revision
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BRAKES
PARKING
- General
Information
5-3
BRAKE
The parking brake is the mechanical

type (internal-expansion
type). The parking brake lever is located to the
drivers side of the center of the floors back bone for easier operational
access. The brake cable is the Vtype, and the parking brake lever stroke adjustment
is made by the equalizer at the lower part of the floor.
Floor
\
I.
?i.
..
1 STB Revision
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5-4
BRAKES - Specifications
SPECIFICATIONS
GENERAL
Master
SPECIFICATIONS
NOICA-
I
hems
Specifications
cylinder
Type
I.D.
Tandem type
mm (in.)
Brake booster
Type
Effective
Boosting
dia. of power
ratio [Brake pc
inder
vacuum type
203.2 (8.0)
mm (in.)
II depressing
4.0
force]
Front brakes
F-type disc
Type
Disc O.D.
Disc thickness
Pad thickness
Cylinder I.D.
Clearance
mmi
255 (10.0)
20 (.79)
mm (8
10.5 (.413)
mm (in.)
53.97 (2.1248)
mm (in
Automatic
adjustment
Rear brakes
Leading and trailing shoe type drum
Type
Drum I.D.
Lining thickness
Cylinder I.D.
Clearance
254(10.0)
mm (in.)
mr
4.6(.18)
n.)
20.64(13/16)
mm (in
Automatic
adjustment
Parking brakes
Type
Brake engagement
Mechanical
Lever type
Cable routing
V-type
/ STB Revision
http://vnx.su/
brake acting on rear wheels
,---
5-5
BRAKES -Specifications
N05CB--
Items
andard Value
Brake pedal height
mm (in.)
191-196 (7.5-7.7)
Stop light switch outer case to pedal arm clearance

Brake pedal free play
mm (in.)
Brake pedal to firewall clearance
mm (in.)
Parking brake lever stroke
Brake booster
operating
test with no load
Air-tightness
test under load
function
mm (in.)
0.5-I .o (.020-,039)
1O-l 5 (.39-.59)
95 (3.74) or more
4-6 clicks
test
Air-tightness
Boosting
Specifications
kPa (mmHg)
kPa (mmHg)
3.3 (25) or less

3.3 (25) or less
test
MPa (psi)
At 100 N (22 Ibs.) foot force
3.0-4.0 (427-570)
6.5-8.0 (925-l
Non-boosting
function
test
MPa (psi)
0.2 (28)
0.4 (57)

Blend proportioning
valve function
138)
test
MPa (psi)
At 6.0 MPa (853 psi) input pressure
3.325-3.725
(472.9-529.8)
At 9.0 MPa (1,280 psi) input pressure
4.725-5.325
(672.0-757.4)
Brake dragging force
N (Ibs.)
57(13.l)orless
[Brake dragging torque]

Booster
Nm (ft.lbs.)
push rod to master cylinder piston clearance
[4 (3) or less)]
mm (in.)
0.1-0.5 (.004-,020)
nit
Pad thickness
Disc thickness
mm (in.)
1 .o (.039)
18.4 (.724)
mm (in.)
Brake disc runout
mm (in.)
Master cylinder body to piston clearance
Lining thickness
Drum I.D.
0.15 (.0059)
mm (in.)
mm (in.)
0.15 (.0059)
1 .o (.039)
mm (in.)
256.0 (10.079)
Wheel cylinder body to piston clearance
mm (in.)
1 STB Revision
http://vnx.su/
0.15 (.0059)
5-6
BRAKES - Specifications
NOBCC-
Items
8-12
25-35
6-9
Pedal support member installation bolt

Steering column assembly installation bolt
8-12
6-9
18-25
13-18
Reservoir
1.5-3.0
l-2
Piston stopper
Master cylinder to brake booster
Fitting
1.5-3.0
8-12
15-18
l-2
Master
25-35
11-13
18-25
Brake line flare nut
13-17
9-12
Bleeder screw
7-9
5-7
Mounting support to knuckle

Wheel cylinder to backing plate
80-I 00
58-72
18-21
13-15
Brake booster to pedal support

Brake pedal shaft
,_.,i
ftlbs.
Nm
stopper
cylinderto
member
bolt
brake line connector
18-25
6-9
LUBRICANTS
Items
Specified
Quantity
lubricant
Brake fluid
DOT 3
Brake pedal bushing and spacer
Chassis
Clevis pin and washer
Wheel bearing grease SAE J310, NLGI No. 2
Dust boot mounting

body
groove in the caliper
Plug plate and stopper

Contacting surfaces
and backing plate
plug
at the shoe assemblies
Rear brake piston and wheel
cylinder
Rotating portion of the shoe adjuster

assembly
Clevis pin, bushing and ratchet plate
As required
Small quantity
Repair kit grease (orange)
Small quantity
As required
Brake grease SAE J310, NLGI No. 1
Small quantity
Small quantity
Repair kit grease (orange)

As required
Chassis
As required
Small quantity
;i SEALANTS
AND ADHESIVES
NOBCE-
Specified
Items
sealants
and adhesives
Thread part of fitting
3M ART Part No. 8663,866l
Shoe hold-down pin

Rear wheel cylinder
3M Sealant Part No. 8634 or equivalent
As required
3M Sealant Part No. 8634 or equivalent
As required
As required
I Both sides
of the sealer
or equivalent
Quantity
/ ST6 Revision
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As required
BRAKES -Special
Tools
5-7
/ Troubleshooting
SPECIAL TO
1 Tool (Number
NOCDA-
and name)
1 Use
Installation of rear wheel
cylinder piston cap
TROUBLESHOOTING
Symptom
Probable cause
Remedy
Reference
paw
Vehicle pulls to one

side when brakes are
applied
Grease or oil on pad or lining surface
Replace
5-15
Inadequate
Correct
5-15,34
Adjust
Repair or replace as necessary
5-33
Replenish
contact of pad or lining
Auto adjuster
malfunction
Drum eccentricity
Improper
power
braking
NOBEAAB
or uneven wear
Low or deteriorated
brake fluid
or change
Air in brake system
Bleed air
5-14
Overheated brake rotor due to dragging of

pad or lining
Correct
Grease or oil on pad surface
Replace
5-15
Inadequate
Correct
5-l 5,34
Replace
5125
Adjust
Replace
5-27
Air in brake system
Bleed air
5-14
Worn lining or pad
Replace
5-l 5,34
Broken vacuum hose
Replace
5-25
Brake fluid leaks
Correct
Auto adjuster malfunction
Adjust
Excessive
clearance
Adjust
5-23
Replace
5-21
contact
Brake booster
Auto adjuster
of pad or lining
malfunction
malfunction
2
F
<
Lb,.
i
Clogged brake line

Proportioning
Increased pedal
stroke
(Reduced pedal to
firewall clearance)
valve malfunction
push rod to master cylinder
Faulty master cylinder
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1 5-27
5-8
BRAKES -Troubleshooting
Symptom
Probable cause
Remedy
Reference
page
Brake drag
Incomplete
Correct
Adjust
Worn brake pedal return spring
Replace
5-18
Broken rear drum brake shoe return spring
Replace
5-33
Lack of lubrication
Lubricate
5-35
Improper push rod to master cylinder

clearance
Adjust
5-23
Faulty master cylinder piston return spring
Replace
5-21
Clogged master cylinder return port
Correct
5-21
Worn brake lining
Replace
5-33
Excessive
Adjust the parking brake lever

stroke or check the parking brake
cable routing
Grease or oil on lining surface
Replace
5-l 5,34
Auto adjuster
Adjust
Parking brake cable sticking
Replace
5-40
Sticked wheel cylinder or caliper piston
Replace
5-29,36
Worn brake linings
Replace
5-l 5,34
Caliper to wheel interference
Correct
or replace
5-29
Dust cover to drum interference
Correct
or replace
5-33
Bent brake backing plate
Correct
or replace
5-33
Cracked
Correct
or replace
5-29,33
Incorrect
Improper parking
brake function
Scraping or grinding
noise when brakes
3re applied
Squealing, groaning
lr chattering noise
when brakes are
applied
release of parking brake

parking brake adjustment
parking brake lever stroke
malfunction
drums or brake disc
Disc brakes-missing
outer shim
Replace
5-15
Brake drums and lining, discs and pads

worn or scored
Correct or replace
5-l 5,34
Improper
or damaged
brake pad
Correct or replace
5-29,33
Clean or deburr
5-29
Clean or replace
5-29,33
Drum brakes-weak
damaged or incorrect
shoe hold-down springs, loose or
damaged shoe hold-down pins and springs
Correct or replace
5-33
incorrect adjustment
booster push rod
Adjust
lining parts
Disc brakes-burred
Dirty, greased,
linings
.:
in sliding parts
or rusted calipers
contaminated
or glazed
of brake pedal or
1 STB Revision
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.
5-10
5-9
BRAKES - Troubleshooting
Remedy
Reference
we
plate causing
Replace
5-33
Improper
machining
of drum causing
interference
with backing plate or shoe
Replace
Disc brakes-rusted,
Lubricate
or replace
5-29
Worn, damaged
or insufficiently
lubricated
wheel bearings
Drum brakes-weak,
damaged
or incorrect
shoe return spring
Lubricate
or replace
5-33
Loose
Retighten
of pads in caliper
Correct
5-29
of support
Correct
5-29
Replace
5-21,25
Adjust
5-IO,23
Symptom
Probable
cause
Squealing
noise
when brakes are not
applied
Bent or warped
backing
interference
with drum
stuck
or extra parts in brakes
Improper
positioning
Improper
installation
and caliper body
Poor return of brake booster

cylinder or wheel cylinder
Incorrect adjustment
booster push rod
Groaning,
clicking or
rattling noise when
brakes are not
applied
Stones or foreign
wheel covers
Loose
wheel
material
brake
trapped
of shim
Disc brakes-loose
installation
damaged
or dry wheel
of brake
Worn brake lining

Poor condition
of brake lining
Parking brake cable sticking
Auto-adjuster
Excessive
inside
brake
stones,
etc.
Replace
5-15
bolt
Retighten
5-29
bearings
Lubricate
pedal or
or replace
Adjust
5-IO,23
Replace
5-33,40
Adjust the parking brake lever

stroke or check the parking brake
cable arrangement
5-39
surface
malfunction
parking
Remove
Retighten
nuts
Incorrect adjustment
booster push rod
Poor parking
function
or master
of brake pedal or
Disc brakes-failure
Worn,
mounting
5-33
drum
lever stroke
1 STB Revision
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BRAKES
Service
Adjustment
Procedures
PROCEDURES
SERVICE ADJUSTMENT
INSPECTION
DAL
NOSFAAA
AND ADJUSTMENT
OF BRAKE PE-
1. Measure the brake pedal height as illustrated.

If the brake
pedal height is not within the standard value, adjust as
follows.
Standard
value (A) : 191-196
(1) Disconnect
loosen the
Move the
not contact
(2) Adjust the
rod with
loosened),
obtained.
mm (7.5-7.7
in.)
the stop light switch connector,

and then
stop light switch locking nut.
stop light switch to a position where it does
the brake pedal arm.
brake pedal height by turning the operating
pliers (with the operating
rod locking
nut
until the correct
brake pedal height
is
(3) Adjust the stop light switch

until the dimension
between the outer case of the stop light switch and the
brake pedal arm reaches the standard value, and then
lock the switch in place with locking nut.
Standard
(4) Connect
value
(B) : 0.5-l
.O mm (.020-.039
in.)
the stop light switch connector.
2. While the engine is stopped, depress the brake pedal two

or three times. After thus eliminating
the vacuum in the
brake booster, press the pedal down by hand, and confirm
that the amount of movement
before resistance is met (the
free play) is within the standard value range.
Standard
value
(C) : 10-15 mm (.39-.59
in.)
If the free play is less than the standard value, confirm that
the clearance
between the outer case of the stop light
switch and brake pedal is within the standard value.
If the free play exceeds the standard value, the clearance
between the clevis pin and the brake pedal arm might be
excessive. Check and replace the faulty parts if necessary.
1 STB Revision
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BRAKES
- Service
Adjustment
5-11
Procedures
3. Start the engine,
depress the brake pedal

mately 500N (110 Ibs.) of force, and measure
between the brake pedal and the firewall.
Standard
value
(D) : 95 mm
(3.74
with approxithe clearance
in.) or more
If the clearance is less than. the standard value, check for

air in the brake line or brakefluid
leakage, and check the
brakes themselves
(for excessive shoe clearance caused
by a malfunction
of the automatic
adjuster mechanism),
and repair where necessary.
CHECKING AND ADJUSTMENT

BRAKE LEVER STROKE
OF PARKING
NO5FUB
1. Pull the parking brake lever with a force ofapprox.

(45 Ibs.), and count the number
of clicks.
Standard
2.
value
ZOON $4
&
i.4,
;L
: 4-6 clicks
If the parking brake lever stroke is not within the standard

value range, make adjustment
by the following
procedures:
(1) Loosen the adjuster to slacken the parking brake cable.
(2) Tighten
the adjuster
slightly,
repeating
pulling
and
releasing the parking brake lever, to adjust the brake
shoe clearance.
(3) lighten
the adjuster until the parking barke lever stroke
is the standard value.
NOTE
After adjustment,
be sure that the adjuster
with the nut holder.
is secured
Caution
If the number
of brake lever clicks engaged
is less
than the standard
value, the cable has been pulled
excessively,
and failure of the automatic
adjuster
mechanism
will result. Be sure to adjust it to within
the standard value.
3.
Return the parking brake lever, remove

and check to ensure that the brake
touching the shoe.
the brake drum,

lever adjuster
is
Caution
If the parking brake cable is pulled too far, the adjuster
lever does not fit the adjuster,
resulting
in faulty
operation
of the brake shoe adjuster.
4.
.d
Jr It 1
With the parking brake lever in the released position, turn

the rear wheel to confirm that the rear brakes are not
dragging.
I-SiWTevision
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!
. ..
542
BRAKES
- Service
Adjustment
CHECKING
Procedures
BRAKE
FLUID
LEVEL
SENSOR
N~J~FBAA
1. Connect an ohmmeter
to the connector
of the brake fluid
level sensor.
2. Move the float from top to bottom and check for continuity. The brake fluid level sensor is in good condition
if there
k no continuity
when the float surface is above A, and if
there is continuity
when the float surface is below A.
,
CHECKING
PARKING
BRAKE
SWITCH
NOSFDAA
1, Remove the floor console.

2. Disconnect
the parking brake switch connector,
and then
connect
an ohmmeter
between
parking
brake switch
terminal and the mounting
bolt.
3. If there is continuity
when the parking brake is pulled, and
there is no continuity
when it is released, the parking brake
switch is good condition.
Good
_.
When engine
stopped
14uoo59
Good
is
0I
k
No good
BOOSTER
TEST WITHOUT
OPERATING
TEST
NOSFCAD
A TESTER
For simple checking of the brake booster operation,

carry out
the following tests:
1. Run the engine for one or two minutes,
and then stop it.
Step on the brake pedal several times
with normal
pressure.
If the pedal depress
fully the first time but gradually
becomes
higher when depressed
succeeding
times, the
booster is operating properly.
If the pedal height remains
unchanged,
the booster
is
faulty.
14UOO62
When engine
started
BRAKE
is
2. With the engine stopped, step on the brake pedal several

times with the same foot pressure to make sure that the
pedal height will not change.
Then step on the brake pedal and start the engine.
If the pedal moves downward
slightly, the booster is in
good condition.
If there is no change, the booster is faulty,
14UOO6C
3.
No good
I
With the engine

stop the engine.
Hold the pedal
height does not
the pedal rises,
running,
step on the brake pedal and then
depressed
for 30 seconds.
If the pedal
change, the booster is in good condition,
if
the booster is faulty.
If the above three tests are okay, the booster performance

can
be determined
as good.
If one of the above three tests is not okay at last, the check
valve, vacuum hose, or booster will be faulty.
14w605
1
1 STB Revision
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BRAKES
Service
Adjustment
TEST
WITH
5-13
Procedures
A SIMPLE
TESTER
Prior to the test, remove the check valve from the brake
booster and check the check valve for operation.
(Refer to P.526.)
With the check valve removed, make connections
as shown,
using another check valve (MB238892,
etc.), vacuum gauge,
pressure gauges and foot pressure gauge, bleed the pressure
gauges, and proceed as follows:
Test with No Load
Test 1 - Air-tightness
(2) Stop the engine when the vacuum gauge reaches approximately 68 kPa (500 mmHg).
After stopping the engine, wait approximately
15 seconds,
and then measure the decrease in vacuum.
Standard
value
: 3.3 kPa (25 mmHg)
4:
<
or less
(3) If the vacuum decrease exceeds the standard value, check

the vacuum hoses, and the brake booster, and make any
necessary corrections.
ME109
,--b
..
.:
* t.,.:
Test 2 - Air-tightness
Test Under Load
(2) Depress the brake pedal at a force of approximately
200 N
(44 Ibs.).
Stop the engine when the vacuum gauge reaches approximately 68 kPa (500 mmHg).
(3) After stopping the engine, wait approximately
15 seconds,
and then measure the decrease in vacuum.
Standard
value
: 3.3 kPa (25 mmHg)
or less
(4) If the vacuum decrease exceeds the standard value, check

the check valve, the vacuum hoses, and the brake booster,
and make any necessary corrections.
Test
3 - Boosting
Function
/
I
Test

(2) Depress the brake pedal when the vacuum gauge reaches
approximately
68 kPa (500 mmHg).
(3) Check to be sure that the brake fluid pressure is the
standard value when the brake pedal is depressed at a foot
force of 100 N (22 Ibs.) and 300 N (66 tbs.)
Standard
value : .
3.0-4.0 MPa (427-570
psi)
At 300 N (66 Ibs,) foot force
6.5-8.0 MPa (925-1,138
psi)
(4) If the output fluid pressure agrees with the standard
the brake booster is functioning
properly.
/ STB Revision
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value,
:I
.
5-14
BRAKES
Procedures
Function
Test
4 - Non-boosting
(1) Stop the engine.
(2) Confirm that the vacuum gauge indicates 0 kPa (0 mmHg).
(3) Check to be sure that the brake fluid pressure is the
standard value when the brake pedal is depressed at a foot
force of IOON (22 Ibs.) and 300N (66 Ibs.)
Test
Standard
value :
At 100 N (22 Ibs.) foot- force
0.2 MPa (28 psi)
0.4 MPa (57 psi)
(4) If the output.fluid
pressure agrees with the standard
the brake booster is functioning
properly.
BLEND PROPORTIONING
TEST
value
VALVE FUNCTION
N05FKAB
1. Connect two pressure gauges, one each, to the input side

and output side of blend proportioning
valve. Bleed the
system.
2. Gradually depress the brake pedal and check to be sure
that the fluid pressure at.the output side is the standard
value when the fluid pressure at the input side is 6.0 MPa
(853 psi) and 9.0 MPa (1,280 psi).
.
Standard value :
At 6.0 MPa (853 psi)
3.325-3.725
MPa
(472.9-529.8
psi)
At 9.0 MPa (1,280 psi)
4.725-5.325
MPa
(672.0-757.4
psi)
1:
k:
.
.+
3.
_-
If the measured
pressures are not within the permissible
ranges, replace the blend proportioning
valve.
Caution
Do not
depends
disassemble
the B.P.V. since
on preset load of the spring.
BLEEDING
its performance
N05FYE.a
The brake hydraulic

system should be bled whenever
the
brake tube, brake hose, master cylinder or wheel cylinder has
been removed
or whenever
the brake pedal feels spongy
when depressed.
Bleed the brake system in the sequence
Specified
brake fluid
evision
: DOT 3
1
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BRAKES
- Service
Adjustment
$915
Procedures
c ;, ..+qj 4
Caution
1. Use the specified
brake fluid. Avoid using a rni&$
of
the specified brake fluid and other fluid.
2. Of brake fluid is exposed
to the, air, it will absorb
moisture;
as water is absorbed
from the atmosphere,
the boiling point of the brake fluid will decrease and the
braking performance
will be seriously impaired.
For this
reason, use a hermetically
sealed 1 lit. (1.06 U.S.qt., 0.88
Imp.qt.) or 0.5 lit. (0.52 U.S.qt., 0.44.Imp.qt.)
brake fluid
container.
3. Firmly close the cap of the brake fluid container
after
use.
h,
INSPECTION
1.
Check the wear

inspection
hole
Limit
2.
: 1.0 mm
condition
of the brake
in the caliper body.
(.039
the caliper assembly

at an angle.
NOTE
Hold the front brake assembly
wires
or other suitable
means
the brake hose is not twisted.
Outer
rsad clb
(4)Remove
anti-rattle
Anti-
&+.p.~
~-7
rattle
wring
the pad assemblies,

springs
from the
ad
zip
B
14W608
----
) ST6 Revision
http://vnx.su/
through
the
f.
;.
,..
a
,
II 1
.,7
beyond
out the spigot

pins.
pliers to pull the stopper
(3)Remove
downward
pads
in.)
If the pad assemblies

are worn
them as following
procedure.
(1)Pull
(2)Use
OF BRAKE f%i%& ,.:.s
AND REPLACEMENT
plug
the limit,
replace
out to the side.
by moving
it upward
or
6
by suspending
it with.
in such a manner that
.
!k.
outer
mounting
shim, pad
support.
clips,
-..
.
--J,&.
BRAKES
Servic6
%djustm,ent
(5)Check
(6)Check
Procedures
the brake
the brake
disc thickness.
(Refer to P.5-31.)
disc runout. (Refer to P.5-32.)
(7)Measure
the rotational force of the hub, with the pad
removed so as to measure the pad dragging force after
installation.
4:
(8)Clean the exposed

part of the piston.
push the piston into the original position,
push it straight.
Then, gently
taking care to
Caution
If it is hard to push the piston with the hammer
handle, loosen the bleeder screw, and the piston will
go in easily. After the piston has been set in this
manner,
be sure to bleed the system. (Refer to P.514.)
(9)lnstall
(1O)lnstall
Anti-rattle
spring
new anti-rattle springs to the mounting

support.
new pad clips to the mounting
support.
u
w
14W552
(11)Attach
the tabs of the new outer shim to -the outer
brake pad at three places, and install the outer shim to
the brake pad.
.*
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lvision
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BRAKES
Service
Adjustment
Procedures
(12)Install
the
support.
new
pad
assemblies
to
the
mounting
Caution
The pad assemblies
should be replaced as sets (inner
and outer) for both the left and right wheels at the
same time.
.-
(13)Apply a thin coat of specified grease to the plug plate

and stopper .plug contact surface.
Specified
(14) Install
grease
the caliper
: Brake grease
No. 1
SAE J310,
NLGI
I:.,
.,*..
1:
,!. ;.
assembly.
(15)Use the following

procedure
to measure the brake
dragging
force:
0 Start the engine and depress the brake pedal for 5
... .
seconds.
,.p
0 Turn engine off.
0 Rotate the brake disc a few revolutions.
@ Use a spring scale as illustrated
to measure
the
brake drag.
i;
0 The difference
between brake drag and rotational
i
force (measured
at the time of inspection)
should,
not exceed the standard value.
Standard
) STB Revision
value
: 57 N (13.1 Ibs.) or less [Dragging torque

: 4 Nm (3 ftlbs.)
or less]
If the difference
exceeds the standard value, remove the caliper body and disassemble
it. Check
the piston and seal for deterioration,
corrosion, dirt
or scoring. (Refer to P.5-29.)
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,;
/
* a
5-18
BRAKES
- Brake Pedal
BRAKE PEDAL
REMOVAL
AND INSTALLATION
NO5GA--
14W604
13. Brake
I)+ 15. Bushing

l * 16. Spacer
Removal steps
1. Meter cover
2. Combination
screw
+*
3.
4.
5.
6.
7.
l + 8.
l * 9.
10.
l + 11.
** 12.
.,.
pedal installation bolt
meter
installation
bolt
17. Pedal
(under
18. Pedal
and
Combination meter assembly

Lower column cover
Upper column cover
Stop light switch connector connection
Stop light switch
Return spring
Return spring of clutch pedal
Cotter pin
Washer
Clevis pin
support
member
the combination
support
member
installation
meter)
installation
bolt
bolt
(fastened together with the steering column assembly)

19. Pedal support member installation bolt
and nut
l + 20. Pedal support member
NOTE
(4) q
: Non-reusable
parts
/ STB Revisio4$&
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ES
- Brake
5-19
Pedal

3.
REMOVAL
OF COMBINATION
METER
Refer to GROUP 8 ELECTRICAL-Meter
NOBGBAB
ASSEMBLY
and Gauges.
INSPECTION
l
l
l
NOIGCAD
Check the bushing for wear.

Check the brake pedal for bend or twisting.
Check the brake pedal return spring for damage.
4. .f
{.
k
CHECKING
STOP LIGHT SWITCH
Connect an ohmmeter
to the connector
of the stop light
switch, and then check for continuity
when the plunger of the
stop light switch is pressed
in and when it is released
outward.
The stop light switch is in good condition
if there is no
continuity
when the plunger is pressed in, and if there is
continuity when the plunger is released outward.
Plunger
3t
----
No
A,
continuity
Continuity
SERVICE
Steering
column
assembly
$edal
support
POINTS
OF INSTALLATION
NOIGDAG
20. INSTALLATION
OF PEDAL SUPPORT
MEMBER
After temporarily
fastening
the installation
bolts and~r;ldts~..~~
of the pedal support member,
tighten
them in the&quence shown by the numbers in the figure.
member
I/
STB Revision
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5-20
BRAKES - Brake Pedal

16. APPLICATION
Grease
OF GREASE
TO SPACER/15.
Apply the specified

grease to the outer
spacer and the inner surface of the bushing.
Specified
grease
: Chassis
grease
BUSHING
surface
of the
SAE 5310, NLGI No. 0
14W596
12. APPLICATION
OF GREASE TO CLEVIS PIN/l 1. WASHER
After applying the specified
grease to the clevis pin and
washer, insert a clevis pin and bend the cotter pin tightly.
Specified
grease
: Wheel
bearing
NLGI No. 2
grease
SAE
J310,
Grease
9.
INSTALLATION
DAL/8. RETURN
Install the return
figure.
14w59
1 STB Revision
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OF RETURN
SPRING
spring
SPRING
to the position
OF CLUTCH
as shown
PEin the
5-21
BRAaeQES- Master Cylinder
MASTER
REMOVAL
Pre-removal
l
Draining
CYLINDER
AND
12
INSTALLATION
-@?9
Operation
Brake Fluid
1.5-3.0 Nm/
l-2 ftlbs.
12
13-17 Nm
9-12ft.lbs.
14W567
Removal steps
l *
1. Connection
of brake
connector
2. Connection
of brake
3. Connector
4. Master
cylinder
5. Reservoir
cap
6. Diaphragm
7. Oil reservoir
float
8. Reservoir
installation
9. Reservoir
10. Reservoir
seal
fluid
level
18-25 ftlbs.
9-12 ftlbs.
sensor
+e
11. Piston stopper

bolt
12. Gasket
l + Adjustment
of clearance
between
brake
booster
push rod and primary
piston
13. Piston stopper
ring
l *
+e l + 14. Primary piston assembly
++ l + 15. Secondary
piston assembly
tube
NOTE
to reinstall.
(2) 4*
screw
(I)
SERVICE
9.
POINTS
REMOVAL
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NOBIBAD
OF RESERVOIR
When removing
1 STB Revision
OF REMOVAL
the reservoir,
pull it out straight
upward.
5-22
BRAKES
Master
Cylinder
11. REMOVAL OF PISTON STOPPER BOLT

Remove the piston stopper bolt while
piston.
depressing
13. REMOVAL OF PISTON STOPPER RING

Remove the piston stopper
ring while
piston.
depressing
14. REMOVAL
OF PRIMARY
Caution
Do not disassemble
15. REMOVAL
PISTON
the primary
OF SECONDARY
the
the
ASSEMBLY
piston
PISTON
assembly.
ASSEMBLY
NOTE
If the secondary
piston
is difficult
to remove,
apply
compressed
air gradually from the secondary
side outlet
port of the master cylinder, and then remove the secondary piston from the cylinder.
Caution
Do not disassemble
the secondary
piston
assembly.
INSPECTION
Check the
scars.
Check the
ing, wear,
Check the
l
l
l
NO5ICAA
inner surface
of master
cylinder
primary and secondary pistons for rust, scourdamage or deterioration.

diaphragm
for cracks or deterioration.
CLEARANCE
BETWEEN
MASTER
CYLINDER
TER AND PISTON
OUTER DIAMETER
Primary
INNER
DIAMENOBICBC
(1) Measure
approximately
three positions
of the master
cylinder inner diameter
[bot=to&(A),
middle (B) and top (C)]
by using a cylinder gauge.
(2) Measure
O.D. of pistons at illustrated
location
using a
micrometer.
piston
NOTE
Measure the inner diameter
of master cylinder at the two
places described
above and at D and E shown in the
illustration.
B
Secondary
body for rust or
piston
(3) If the difference

between these inner diameters
and the
piston outer diameter
exceeds
the limit,
replace
the
master cylinder and the piston assembly
as set.
Limit
j ST6
: 0.15 mm
wision
(.0059
in.)
I
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BRAKES
- Master
SERVICE
5-23
Cylinder
POINTS
OF INSTALLATION
N05lDAH
15. APPLICATION
OF BRAKE FLUID TO SECONDARY
PISTON ASSEMBLY/14.
PRIMARY PISTON ASSEMBLY
Apply the specified
brake fluid sufficiently
to the inner
surface of the master cylinder body and to the entire
periphery of the secondary and primary pistons.
Specified
brake fluid
: DOT 3
14KO28
ADJUSTMENT
OF
BOOSTER PUSH ROD
Check and adjust the
booster push rod and
steps below.
(1) Measure
master
CLEARANCE
BETWEEN
BRAKE.
AND PRIMARY
PISTON
clearance
(A) between the brake r.P
the primary piston by following the?
<I
ii.
Lk
the dimension
(B) from
cylinder to the piston.
the
edge
of the
NOTE
Obtain the dimension
(B) by first placing a straight
scale against the edge of the master cylinder, and then
measuring
and subtracting
the thickness of the straight
scale.
(2) Obtain the dimension

(C) from the master cylinders
brake booster installation
surface to the edge.
i;
.
(3) Measure the dimension

(D) from the brake boosters
master cylinder installation
surface to the end of the
push rod.
NOTE
Obtain the dimension
(D) by first placing a straight
scale against the edge of the brake booster, and then
measuring
and subtracting
the thickness of the straight
scale.
) STB Revision
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2,
5-24
BRAKES
Master
Cylinder
(4) Obtain the clearance (A) between the brake booster

push rod and the primary
piston from the values
obtained in (I), (2) and (3) previously.
Standard
value
: 0.1-0.5
mm
(.00&.020
in.)
(5) If the clearance is not within the standard value range,

adjust by changing the push rod length by turning the
screw of the push rod.
Caution
Improper
ST6 Revision
http://vnx.su/
clearance
may cause excessive
brake
drag.
BRAKES
5-25
- Brake Booster
BRAKE BOOSTER
REMOVAL
AND
INSTALLATION
N05JA..
5-9 ftlbs.
14W616
5-9 ftlbs.
9-12 ft.lbs.
18-25 ft.lbs.
Removal steps
l +
~~ l +
l +
l *
l +
1. Connection of brake fluid level sensor

connector
2. Connection of brake tube
3. Connector
4. Master cylinder assembly
Adjustment of clearance between brake
booster push rod and primary piston
5. Vacuum hose
6. Check valve
7. Cotter pin
8. Washer
9. Clevis pin
10. Brake booster installation nuts
11. Brake booster
12. Sealer
13. Spacer
14. Sealer
15. Fitting
Pre-removal
l
Draining
Operation
of Brake Fluid
/ozz;i;:gy4,,
l
Adjustment
of Brake Pedal (Refer to
NOTE
(2) 4)
: Refer to Service Points of Removal
(3j 64 : Refer to Service Points of Installation.
(4) q
SERVICE
POINTS
5 . REMOVAL
OF REMOVAL
OF VACUUM
N06JBAD
HOSE
Caution
1. When removing
the vacuum hose from the brake
booster, pull it out straight.
2. The check valve installed on the brake booster will
be damaged if the vacuum hose is forced up and
down or to the left and right.
1 STB Revision
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5-26
BRAKES
Brake
Booster
INSPECTION
NO5JCAB
CHECKING
CHECK VALVE
Blow into the check valve. If the air passes through when you
blow from the booster side, but not when you blow from the
engine side, the check valve is functioning
properly.
14W523
SERVICE
POINTS
OF INSTALLATION
NO5JDAG
15. INSTALLATION
OF FITTING
When installing the fitting, apply the specified
threaded portion.
Fitting
Specified
sealant
: 3M ART
equivalent
Part
No.
sealant
8663,
to its
8661
or
Sealant
14V626
9. APPLICATION
OF GREASE TO CLEVIS PIN/8. WASHER
After applying the specified
grease to the clevis pin and
washer, insert a clevis pin and bend the split pin tightly.
Specified
grease
: Wheel
bearing
NLGI No. 2
grease
SAE
5310,
Grease
5.
Clio
Vacuum
hose
Check valve
INSTALLATION
OF VACUUM
HOSE
Fasten the vacuum hose securely to prevent
the connections.
air leaks from
NOTE
When the hose clip on the brake booster side is installed,
fix it on the brake booster pipe and do not bring it into
contact with the check valve.
Brake
booster
side
14KOQS
ADJUSTMENT
OF CLEARANCE
BETWEEN
BOOSTER
PUSH ROD AND PRIMARY
PISTON
Refer to P.5-23.
/ STB Revision
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BRAKE
5-27
KES - Brake Line
BRAKE LINE
IEMOVAL
AND INSTALLATION
Flare
nut
13-17 Nm
9-12 ft.lbs.
14FO38
.
I
,I
Pre-removal
l
Draining
Operation
of Brake Fluid
,
<I
>
:
Bi
14W578
Removal steps
++
4*
l +
1.
2.
3.
4.
5.
6.
7.
8.
9.
IO.
11.
Brake tube (R.H.)

Brake hoses
Brake tube (front, L.H.)
Brake tube (front, R.H.)
Connector
Brake tube (A)
Blend proportioning
valve
Brake tube (main)
Brake tube (L.H.)
Brake tube (rear, R.H.)
Brake tube (rear, L.H.)
NOTE
(1) *I)
STB Revision
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BRAKES - Brake Line

SERVICE
POINTS
OF REMOVAL
NO5KBAD
2. REMOVAL OF BRAKE HOSE

(1) Holding the nut at the brake hose side, loosen the flare
I nut of the brake tube.
14wss3
(2) Pull off the brake hose clip and remove

from the bracket.
the brake hose
tube
Brake hose
7.
REMOVAL
Caution
Do not
depends
OF BLEND
disassemble
on preset
PROPORTIONING
the B.P.V.
load of the
VALVE
since its performance

spring.
INSPECTION
l
0
l
Check the brake tubes for cracks, crimps and corrosion.

Check the brake hoses for cracks, damage and leakage.
Check the brake tube flare puts for damage and leakage.
SERVICE
2.
POINTS
INSTALLATION
Install
r
i
NO5KCAB
the brake
NOTE
When installing,
contact edges,
/ STB Revision
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OF INSTALLATION
OF BRAKE
hoses
NO5KDAB
HOSE
without
twisting
them.
check to be sure the brake hose does not

weld beads or moving parts.
BRAKES
Front
Disc
Brake
5-29
Caliper
FRONT DISC BRAKE CALIPER

REMOVAL
AND INSTALLATION
W-100
N05LA-
Nm
ft.lbs.
58-72
80-100
ft.lbs.
58-72
14W610
Pre-removal
l
Draining
Operation
of Brake Fluid
18
11
Disc brake caliper removal steps

l e l +
4*
*+
l +
l *
l *
l e I)+
l * l +
+* l 4
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Il.
12.
Connection
of brake hose
Clip
Spigot
pin
Stopper
plug
Plug plate
Caliper assembly
Brake tube
Boot ring
Piston boot
Piston
Piston seal
Mounting
support
and brake
bly
pad
l 4
l 4
++
I)+
3.
4.
5.
13.
14.
15.
16.
17.
18.
19.
Spigot
pin
Stopper
plug
Plug plate
Pad assembly
Outer shim
Outer pad clip
Inner pad clip
Pad clip B
Anti-rattle
spring
Mounting
support
i5
l-8
l-3
17
1518 13
Brake
pad kit
NOTE
Reverse the rE:moval procedures to reinstall.
(2) l * : Refert 0 Service Points of Removal.
(3) *+
(4)
q : Non-re usable part
(1)
ST6 Revision
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14
14W607
assem-
Brake pad removal steps

4*
17
sea ana Do
.:
...>
-ft
;
5-30
BRAKES
Front
Disc
SERVICE
Brake
Caliper
POINTS
1. DISCONNECTION
OF REMOVAL
OF BRAKE
NOBLBCA
HOSE
Refer to P.5-28.
4.
REMOVAL
OF STOPPER
Pull the stopper
PLUG
plug out to the side by using pliers.
6. REMOVAL
OF CALIPER ASSEMBLY
Remove the caliper assembly
by moving
downward at an angle.
it upward
or
NOTE
Hold the front brake assembly by suspending
it with wires
or other suitable means in such a manner that the brake
hose is not twisted.
8.
REMOVAL
OF BOOT RING
Remove the boot ring by using a screwdriver.
9.
REMOVAL
OF PISTON BOOT/IO.
PISTON
Remove
the piston and piston boot by applying
pressed air through the brake hose fitting hole.
com-
Caution
Place a piece of cloth in front of the piston, and slowly
increase the force of the compressed
air to prevent the
piston from springing
out abruptly.
14E619
Il.
REMOVAL
OF PISTON
(1) Remove the piston
SEAL
seal from the cylinder
by hand.
Caution
Never use a screwdriver
or similar
tools,
doing so could damage the cylinder surface.
(2) Clean the caliper
brake fluid.
zvision
bore with trichloroethylene,
because
alcohol
,..
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or
BRAKES
- Front Disc Brake

43. REMOVAL
(I)
5-31
Caliper
OF PAD ASSEMBLY
Remove
downward
the caliper assembly

at an angle.
NOTE
Hold the front
wires or other
the brake hose
(2) Remove
brake assembly
suitable means
is not twisted.
the brake
by moving
it upward
by suspending
it with
in such a manner that
pad assembly.
INSPECTION
N05LCAB
Check the piston for rust.

Check the cylinder
portion
of caliper body for cracks
or !
rust.
+
Check the piston seal for wear and deterioration.
i.
Check the piston boot for cracks and deterioration.
,;
Check the mounting
support for cracks.
Check pads for deformation,

metal backing
for damage,
and oil on the linings.
l
l
0
e
l
CHECKING
BRAKE
PAD THICKNESS
Measure
the thickness
wear is the greatest.
/,6
A
or
Limit
: 1.0 mm
of the pad assembly
(.039
If the pad assemblies
at the place where
in.)
are worn
beyond
the limit, replace
them.
14110072
CHECKING
BRAKE
(1) Clean
the brake
DISC
disc
THICKNESS
surface
to remove
dirt
and rust.
(2) Measure
the thickness
of the brake disc at least four
places on the sliding surface of the brake disc and the pad.
Limit
I.2
14F611
: 18.4 .mm
(.724
in.)
If the thickness
of the brake disc is less than the limit (even
at only one location)
or there is wear, replace the brake
disc. (for removal
of the brake disc, refer to GROUP 2
FRONT SUSPENSION-Axle
Hub and Free-Wheeling
Hub.)
STB Revision
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-t, :.:! -
5-32
BRAKES
- Front
Disc Brake Caliper
CHECKING
BRAKE DISC RUNOUT
Measure the runout of the brake disc at the edge of the brake
disc circumference.
Limit
: 0.15 mm
(.0059
in.)
If the brake disc runout exceeds the limit, change its position
on the hub and/or retorque evenly.
Check the runout again, and if it cannot be corrected,
replace
the brake disc. Do not resurface it. (for removal of the brake
disc, refer to GROUP 2 FRONT SUSPENSION-Axle
Hub and
Free-Wheeling
Hub.)
NOTE
Before measuring the runout of the brake disc, check the play
of the wheel bearing and, if necessary,
correct it.
SERVICE
POINTS
13. INSTALLATION
Refer
\\
Grease
OF PAD
ASSEMBLY
OF PISTON
SEAL
NOBLDCB
to P.5-15.
11. INSTALLATION
Piston
OF INSTALLATION
The piston seal is already packed and coated

specified grease; do not wipe it away.
,
brake
fluid
with
the
10. APPLICATION
OF BRAKE FLUID TO PISTON
Apply brake fluid to the outside surface of the piston and
slowly insert the piston by hand, while using care not to
twist it.
14Y184
Specified
9.
: DOT 3
APPLICATION
OF GREASE TO PISTON BOOT
Apply the specified
grease to the piston boot
groove in the caliper body.
Specified
5.
brake fluid
grease
: Repair
kit grease
mounting
(orange)
APPLICATION
OF GREASE TO PLUG PLATE/4.
STOPPER
PLUG
Apply a thin coat of the specified grease to the plug plate
and stopper plug contact surface.
Specified
grease
: Brake
grease
1. CONNECTION
OF BRAKE
Refer to P.5-28.
evision
I
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HOSE
SAE J310,
NLGI
No. 1
5-33
ES - Rear Brake Shoe
REAR BRAKE SHOE

REMOVAL
AND
Post-installation
l
INSTALLATION
NO!iUA-
Operation
Adjustment
Stroke (Refer to P.5-11,)
14Wf99
Removal
steps
*I)
1. Brake drum
++
2. Shoe
return
spring
with
brake
shoe
ad-
juster
NOTE
(1) Reverse the removal procedures to reinstail.
(2) 4* : Refer to Service.Points
of Remc~val.
3. Adjusting
spring 4. Shoe retainer
spring
5. Shoe hold-down
spring
SERVICE
Brake shoe adjuster

14W601
6. Shoe and lining assembly

7. Shoe and lever assembly
8. Shoe hold-down pin
e+
e+
(I)+
POINTS
OF REMOVAL
MQSJ0Af)
1. REMOVAL
OF BRAKE DRUM
If the brake drum is difficult to remove, follow either of the
steps described below.
(1) When using the brake shoe adjuster.
0 Remove the adjusting hole cover at the muside of
the backing plate.
0 Insert a screwdriver
into the adjustment
hole and
use it to separate the adjustment
lever from the
brake shoe adjuster.
0
Brake shoe
Insert another screwdriver into the adjustment

hole
and use it to turn the brake shoe adjuster in the
direction of the arrow so as to compress the brake
shoe.
14W602
wision
1
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, 1
,.
..
,a
BRAKES
- Rear Brake Shoe

(2) When using the bolts.
Screw the bolts (M8 x 1.25) in the threaded
provided in the drum flange surface.
INSPECTION
NOIUCAD
CHECKING
BRAKE LINING THICKNESS
(1) Measure the wear of the brake lining
most.
Limit
14110075
holes
at the place worn the
: 1 .O mm (.039 in.)
(2) If the thickness

of the brake lining is the limit value or
below, or if there is noticeable
abnormal wear, replace the
shoe assembly.
NOTE
In order to prevent one-sided braking,
and right shoe assemblies
as a set.
replace
both the left
CHECKING
BRAKE DRUM INSIDE DIAMETER
(1) Measure the inside diameter
of the drum at more than two
positions by using a caliper gage.
Limit
: 256.0 mm (10.079
in.)
(2) If the internal diameter of the brake drum is the limit value
or more, or if there is noticeable
abnormal
wear, replace
the brake drum.
CHECKING
BRAKE
LINING
AND
BRAE
DRUM
CONTACT
(1) Apply chalk powder to the inner surface of the brake drum
and turn the brake drum so that it rubs against the shoe
assembly.
(2) If places of noticeably
poor contact are discovered,
replace
the shoe assembly and/or brake drum.
SERVICE
8.
OF INSTALLATION
APPLICATION
OF GREASE TO SHOE HOLD-DOWN
Apply the specified
sealant to the shoe hold-down
inserting portion of the backing plate.
Specified
POINTS
sealant
: 3M Sealant
lent
140612
1 STBi% evision
I
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NOSUDAH
PIN
pin
Part No. 8634 or equiva-
5-35
- Rear Brake Shoe
7. APPLICATION
OF SEALANT
TO SHOE AND LEVER
ASSEMBLY/G.
SHOE AND LINING ASSIEMBLY
Apply the specified grease to the contacting
surfaces of
the shoes and backing
plate, anchor plate and wheel
cylinder piston ends.
Specified
grease
: Brake
lent
grease
SAE 5310,
NLGI
. ;I
.:
No. 1
Cl4074
2.
Grease
INSTALLATION
OF SHOE
RETURN
SPRING
BRAKE SHOE ADJUSTER
(1) Apply the specified grease to the thread portion
adjuster.
Specified
Identification
groove
14W581
grease
: Brake grease
No. 1
(2) Install the R.H. thread

brake, and L.H. thread
brake.
SAE
brake adjuster
brake adjuster
5310,
WITH
-,!
of the
;ri:
1;
I:
NLGI i;i,.
I.,<..
to the L.H. side

to the R.H. side
(3) Install the brake shoe adjuster, so that the identification

grooves face outward.
(4) Attach the longer end of the shoe return spring to the
shoe and lever assembly.
qroove
to be directed
ou<warA
14w504
(5) Turn the brake shoe adjuster to adjust

diameter of brake shoe as illustrated.
NOTE
Adjusting
illustrated
ante.
253.1 -mm976
in.) ,4w503
1 STB Revision
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the outside
will facilitate
diameter
adjustment
the
outside
of brake shoe as
of the shoe clear-
t (:
1
L.
i:
1..
1
5-36
BRAKES
- Rear Brake VWhd
Cylinder
REAR BRAKE WHEEL CYLINDER

REMOVAL
AND INSTALLATION
18-21 Nm
13-15 ft.lbs.
Pre-removal
l
Draining
l
l
Operation
of Brake Fluid
Supplying Brake Fluid

Bleedina (Refer to P.5-14.)
Removal
steps
l *
1.
2.
3.
4.
~~
14W600
Brake drum
Bleeder screw
Brake tube
Wheel cylinder assembly
NOTE
(2) l * : Refer to Service Points of Remova,l.
SERVICE
1.
POINTS
OF REMOVAL
REMOVAL
OF BRAKE
Refer to P.5-33.
SERVICE
POINTS
NO6VBAB
DRUM
OF INSTALLATION
NOBVDAE
4. APPLICATION
OF SEALANT
TO WHEEL CYLINDER
ASSEMBLY
Apply the specified sealant to the wheel cylinder assembly
fitting surface before installation
to the backing plate.
Specified
sealant
http://vnx.su/
: 3M Sealant
lent
Part No. 8634 or equiva-
BRAKES
DISASSEMBLY
AND
5-37
- Rear Brake Wheel Cylinder
REASSEMBLY
NOBVE-
I
Disassembly
l +
l +
l * l *
1.
2.
3.
4.
5.
Wheel
cylinder
kit
steps
Wheel
Piston
Piston
Piston
Wheel
cylinder
assembly
boot
NOTE
procedures
to reassemble
(2) ~~ : Refer to Service Points of Disassembly.
(3) l + : Refer to Serwce Points of Reassembly.
(4)
q : Non-reusable parts
(I)
cup
cylinder
body
SERVICE
4.
POINT
REMOVAL
OF PISTON
Remove the
screwdriver.
OF DISASSEMBLY
piston
NOlVFAB
f:
>
CUP
cup from
the
piston
by using
4:
A.
,.
i
it
..
INSPECTION
Check the piston
damage.
CHECKING
CYLINDER
NOBVGAB
and wheel
AND PISTON
cylinder
walls for rust or
CLEARANCE
Measure in two perpendicular directions to figure the clearance between the wheel cylinder inner diarneter (max. value)
and the piston outer diameter (min. value).
Limit
: 0.15 mm (.0059 in.)
NOTE
If the difference is more than the limit, replace the piston and
wheel cylinder as an assembly.
wision
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.
-.: :1
.:,
5-38
BRAKES
Rear
Brake
SERVICE
Wheel
Cylinder
POINTS
OF REASSEMBLY
N05VHAD
4. INSTALLATlON
OF PISTON CUP
(1) Wash the inner surface of the wheel cylinder and outer
surface of the piston with trichloroethylene,
alcohol or
brake fluid.
brake fluid to the entire surface of
the piston cups and to the external periphery of the
special tool.
Specified
brake fluid
: DOT 3
Caution
Use a repair kit to replace
cylinder boot.
the piston
cup and wheel
(3) Attach the special tool to the piston, fit the piston cup
onto the special tool with the lips of the piston cup
directed upward, and push down (with finger tips) to
let it slide along the outer surface of the special tool
until it fits into position.
Face iip upward
Caution
When pushing down the piston cup, push uniformly
and slowly with both hands, without
stopping,
so
that deformation
or turning over will not result.
14uoo93
2. APPLICATION
OF BRAKE
Apply the specified brake
wheel cylinder and to the
cups, and install the piston
Specified
brake fluid
1. APPLICATION
FLUID TO PISTON ASSEMBLY

fluid to the inner surface of the
entire periphery of the piston
assemblies.
: DOT 3
OF GREASE
TO WHEEL
CYLINDER
Apply the specified

grease to the piston
cylinder, and install the boot.
Grease
(orange)
Specified
grease
/ STB Revision
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: Repair
kit grease
BOOT
and the wheel
(orange)
BRAKES
PARKING
- Parking
5-39
Brake Lever
:j
BRAKE LEVER
REMOVAL
AND
INSTALLATION
NOBWA-
14W613
17
Removal
12. Parking
lever bushing
13. Connection
of parking
brake
nectar
brake lever assembly
l 4 14. Parking
15. Parking
brake switch
++ 16. Cover
17. Sealer
18. Cotter pin
19. Clevis pin
20. Parking
brake cable
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Rear console
panel
Inner box
Floor console
assembly
Floor console
bracket
Cable adjuster
Connection
of parking
brake
Lever pin
Nut holder
Cable equalizer
Parking
brake shaft cover
Parking
lever stay
cables
NOTE
(2) ~~ : Refer to Service Points of Installation
(3) q
: Non-reusable
parts
(I)
/ STB Revision
http://vnx.su/
switch
con-
BRAKES
- Parking
Brake
Lever / Parking Brake Cable
INSPECTION
l
Check
SERVICE
NOBWCAA
the brake
POINTS
16. APPLICATION
lever
ratchet
OF INSTALLATION
OF SEALANT
Apply a coat of the specified

sealer.
Specified
Specified
,PARKING
REMOVAL
TO COVER
sealant
to the both side of the
grease : Chassis grease SAE J310, NLGI No. 0
pin
BRAKE CABLE
AND INSTALLATION
NOSXA-
14W561
Removal
steps
+w
1. Brake drum
2. Cable adjuster
3. Parking
cable
4. Parking
brake
l *
NOIWDAB
14. APPLICATION
OF GREASE TO PARKING
BRAKE LEVER
ASSEMBLY/lZ.
PARKING
LEVER BUSHING
Apply the specified grease to the clevis pin, bushing and
ratchet plate.
Bushing
Clevis
sealant
for wear.
heat protector
cables
NOTE
(1)
Reverse
the
(2)
+e
: Refer
(3)
l + : Refer
/ STB Revision
http://vnx.su/
removal
procedures
to Service
Points
to Service
Points
to reinstall.
of Removal.
of Installation.
BRAKES
,Shoe
retainer
Parking
Brake
SERVICE
4.
POINTS
REMOVAL
5-41
Cable
OF REMOVAL
OF PARKING
N05XBAA
BRAKE CABLE
(1) Remove the shoe return spring, shoe retainer spring

and shoe hold-down
pin and remove the brake shoe
assembly.
(2) Disconnect
the cable end of the parking brake cable
from brake shoe assembly.
spring
(3) Pass the parking brake cable through an offset box-end

wrench (12 mm) and push the wrench further on the
parking brake cable until it reaches the stopper part. In ,,.A
that condition,
pull the parking brake cable out from the 1pi,
rear side of the backing plate.
Parking
brake
cable
1Nr
NOTE
Push the offset box-end
stopper is pushed in.
14W60
wrench
until
the parking
SERVICE
POINTS
4.
mm (9.965 -9.976
in.)
14~503
NOlXCAA
Check
253.1 -253.4
i-V 1.
INSPECTION
the tab of the
INSTALLATION
(1) Install the
(2) Install the
(3) Turn the
diameter
brake
cable
for operation
OF INSTALLATION
or damage.
N05XOAA
OF PARKING
BRAKE CABLE
cable end to the brake shoe assembly.
brake shoe assembly.
brake shoe adjuster to adjust the outside
of brake shoe as shown in the illustration.
NOTE
Adjusting the outside diameter
in the illustration
will facilitate
clearance.
/ STB Revision
http://vnx.su/
of brake shoe as shown

adjustment
of the shoe
1
f
I
23-1
BODY
CONTENTS
BACK DOOR ASSEMBLY
..................................
BACK DOOR HANDLE AND LATCH
.................
BACK DOOR LOCK SWITCH
.............................
BACK DOOR TRIM
.............................................
BACK DOOR WINDOW
GLASS
........................
.............................................
BODY MOUNTING
...........................................................
BUMPERS
............................................
CENTER CONSOLE
DOOR ASSEMBLY
.............................................
DOOR HANDLE AND LATCH
............................
DOOR TRIM AND WATERPROOF
FILM ...........
FENDERS
............................................................
..............................................
FLOOR CONSOLE
FRONT DOOR GLASS AND REGULATOR
.......
FRONT SEATS ....................................................
...........................................
FUEL FILLER DOOR
.................................
GENERAL INFORMATION
.............................................
GRILLE, GARNISH
..................
HEADLINING
AND ASSIST STRAP
HOOD ..................................................................
INSTRUMENT
PANEL ........................................
LOOSE PANEL ....................................................
......................................................
MUD GUARD
.............................................
OUTSIDE
MIRROR
............................
QUARTER WINDOW
GLASS
REAR SEAT .........................................................
SEAT BELTS .......................................................
..........
SERVICE ADJUSTMENT
PROCEDURES
.............
Adjustment
of Back Door Installation
Adjustment
of Door Glass ...............................
......................
Adjustment
of Door Installation
Adjustment
of Fuel Filler Door Hook Fit ..........
Adjustment
of Hood Fit ...................................
47
50
52
49
31
18
57
66
32
44
33
24
67
35
75
22
2
59
68
20
61
55
54
60
29
77
78
15
17
16
15
15
15
..........................
Adjustment
of Inside Handle
Adjustment
of Outside Handle
.......................
..................
Adjustment
of Ventilator Window
................................................
SPECIAL TOOLS
...............................................
SPECIFICATIONS
....................................
Lubricants
.......................................................
..................................
.....................................
.....................................
.................................................................
TRIMS
........................................
TROUBLESHOOTING
Back Door ........................................................
Hard back door operation, abnormal noise
from hinges
.............................
Back Door Locking System
Back door fails to unlock or lock
Back door is locked but cannot be unlocked
Back door is unlocked but cannot be locked
Front Door .......................................................
Hard door glass operation
No door glass operation
Power Windows
..............................................
Door windows cannot be operated
Door windows do not operate smoothly
Front door windows cannot be operated
None of the windows can be operated
Wind Noises ....................................................
Wind noise from around the door
Wind noise from back door
..................................................
UNDER GUARD
WINDOW
GLASS RUNCHANNEL
AND DOOR
...............................
OPENING
WEATHERSTRIP
.....................................................
WINDSHIELD
http://vnx.su/
N23AA--
16
16
16
8
6
6
:.
(
.:*
7
8
6
7<
71 vt
g (
9::
$
,
I{?
.:;
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q.
%,.&.$
9
14
9
53
45
26
BODY
23-2
GENERAL
- General
Information
INFORMATION
BODY
The body and frame construction is the independent division type.
N23BAAB
The body form is the tumble type, and the frame is the ladder type.
For body mounts, the compression
type, with t&o body mount rubber
frame, is employed.
pieces
fit between
the body and
Rear
shock
absorber
bracket,
right
I
Engine
Stabilizer
mounting
bracket
bradket
Lower
arm
Body
bracket
No.
mounting
bracket
Rear
1 crossmember
shock
absorber
bracket,
left
15w519
BODY
Body
rubber
MOUNTING
mounting
STB Revision
http://vnx.su/
BODY - General
SHEET
23-3
Information
METAL
The instrument
panel is made of sheet metal to which urethane padding is attached.
The adhesive-type
of headlining is used.
The injection-type
of trim is used.
Separate,
low-back
front seats are equipped;
suspension
seats are available as an option.
For the metal-top
van, the rear seat is a front-facing
seat for two passengers.
The front seat belts are 3-point seat belts with E.L.R.
The rear seat belts for the metal-top
van are 2-point retractable
seat belts.
Front
Front
pillar
seat
trim
Instrument
panel
I
trim
wheelhouse
Rear
seat
belt
Rearseat
Rear\
(metal
pillar trim
top-van)
19W665
1 STB Revision
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23-4
BODY - General
SUSPENSION
Information
SEAT
The suspension seat has a special suspension

mechanism
in the base frame and is installed on the drivers
seat side.
When the vehicle travels on an uneven ground surface
or rough road, the seat absorbs the body vibration
the vehicle takes from the road surface, reducing driver fatigue and assuring a more comfortable
ride.
The
(I 1
(2)
(3)
(4)
I
seat offers the following
features:
Pantograph
type link mechanism
Optimum
combination
of coil spring and shock absorber
More comfortable
ride by adjust body weight meter to drivers weight
Fixed position of seat can be adjusted in three height levels
The components
of the suspension
seat are as follows:
1'
1. Lock lever
2. Guide 6
3. Coil spring
4. Link
5. Upper
6.
7.
8.
9.
10.
19W696
bracket
Shock absorber
Link
Handle
Lower
bracket
Guide A
jpper bracket
Pantograph
OPERATION
type link
Front
_ower
bracket
Royler
Whenthere
is no
load
Suspension
Mechanism
The suspension
mechanism
is constructed
as shown.
The lower and upper brackets of the link are coupled by hinges
at one end and by rollers at the other, allowing forward and
backward sliding. If a force in the direction
of the arrow is
exerted to the link (pantograph),
the upper bracket is moved
downward, so the shock absorbers hinge-coupled
to the lower
and upper brackets absorb vibration.
19W606
pm
wision
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BODY - General
23-5
Information
Body Weight Adjusting

Mechanism
The configuration
of the body weight adjusting mechanism
of
the suspension seat is as shown in the illustration.
When the handle (1) is turned in the clockwise direction, guide
A (2) moves along the slope of guide B (3), pushing guide B (3)
as it moves. The coil spring (4) is thus compressed,
increasing
the spring force and resulting in a harder suspension.
When
the handle is turned in the conterclockwise
direction,
the
spring force is weakened,
resulting
in a softer suspension.
NOTE
The illustration above shows the top view
of the body weight adjusting mechanism.
Thecshows
the working
of each part
when the spring force is increased.
Suspension
Lock Mechanism
The suspension
lock mechanism
is constructed
as shown
the illustration
at left. The seat lock position can be selected
three levels by a lock lever.
Upper bracket
Lock lever
, 1,
Lower lock bosi6on

w:
Medium
lock position
Upper
I
When lock
is OFF
bracket
b,.
.:.
lock poiition
,
Lower
in ..?
in >,
Wh\en lock is ON
l9W667
1 STB Revision
http://vnx.su/
23-6
BODY
- Specifications
SPECIFICATIONS
GENERAL
SPECIFICATIONS
N23CA--
Specifications
Items
Hood
Rear hinged, front opening type
Type
Front door
Construction
Front hinged, sash construction
Regulator system
Locking system
X-arm type
Pin-fork type
3ack door
Construction
Right hinged, sash construction
Locking system
Pin-fork type
Slass installation
method
Windshield
Weatherstrip
type
Quarter window
Front door window
Weatherstrip
type
Weatherstrip
type
Back door window
Weatherstrip
type
;lass thickness
mm (in.)
5.7 (.22)
Windshield
Quarter window
4.0(.16)
glass
.Front door glass
4.0(.16)
Back door window
glass
4.0 (.16)
Ventilator
glass
4.0(.16)
window
Irame Type
Ladder type
Sectional form
j&pension
seat
Box type
Suspension
Up-and-down
Body weight
Coil spring type with shock absorber
mechanism
movement
adjustment
70 (2.76)
mm (in.)
stroke
kg (Ibs.)
50-I 00 (110.2-220.5)
3 levels
Seat height adjustment
Specifications
Items
Standard values
mm (in.)
Front door glass holder mounting position
Distance between the glass holder (A) and (B)
Distance
between
the glass holder(B)
Door outside handle play

Door inside handle plav
and the glass edge
466.5-467.5
76.5-77.5
(18.367-l
(3.012-3.051)
5-l 0 (.20-.40)
4-l 0 (. 16-.40)
mm (in.)
mm (in.)
1 ST6 Revision
http://vnx.su/
8.406)
BODY
23-7
- Specifications
23CG-
ft.lbs.
Nm
Item
Body to frame
Hood hook to hood
28-32
20-23
4.0-6.0
2.94.3
Hood latch to body
4.0-6.0
2.9-4.3
Hood latch release cable
3.5-4.0
2.5-2.9
Under skid plate to frame
18-25
Under cover installation bolts

Snow-protection
under cover installation bolts
Transfer case protector to No. 2 crossmember
IO-13
IO-13
18-25
13-18
7-9
Transfer case protector
IO-13
7-9
IO-13
7-9
17-26
35-55
12-19
Cross shaft protector
to frame
installation
bolts
Front door hinge to door panel

Front door hinge to body
Ventilator
window
assembly
to door panel
Window regulator to door panel

Door lower sash to door panel
Air duct to body

Seat anchor bolts
Head marked 8
Head marked 10
Front seat cushion to seat adjuster
Front seatback
to Seat cushion (Reclining
Front seatback
to seat cushion
Rear seat leg bracket

Rear seatback
adjuster side)
to body
to seat cushion
All seat belt tightening
bolts
13-18
25-40
6
6
4.3
4.3
25-40
4.3
35-55
Back door hinge to body

Spare tire bracket to back door
7-9
8-10
6-7
4-6
3-4
9-14
6.5-I 0
35-55
9-14
25-40
6.5-10
45-60
33343
IO-15
9-14
7-11
6.5-10
45-60
35-55
33-43
25-40
LUBRICANTS
23CD.
Specified
Items
Back door hinges
Sliding parts of front seat adjuster
Sliding parts of rear seat leg bracket,
stopper striker
rear seat
lubricants
Quantity
Multipurpose
As required
Multipurpose
As required
Multipurpose
As required
( STB Revision
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23-8
BODY - Specifications
SEALANTS
/ Special Tools
AND ADHESIVES
23CE.-
Items
Specified
Hood rear weatherstrip
Quantity
As required
3M ART Part No, 8513 or equivalent

3M ART Part No. 8531 or No. 8646. or
equivalent
3M ART Part No. 8626 or 3M Adhesive
EC-5310, or equivalent
Front fender and front shield

Front fender and splash shield
Windshield
weatherstrip
and windshield
glass
Windshield
weatherstrip
and body flange
As required
As required
3M ART Part No. 8001 or No. 8011, or

equivalent
As required

EC-531 0, or equivalent
As required
Quarter window weatherstrip

window
rear glass
and quarter

equivalent
As required
Quarter window
and body flange

equivalent
As required

equivalent
As required

EC-531 0, or equivalent
As required
3M Adhesive
As required
weatherstrip
Back door window weatherstrip

door window glass
Waterproof
and back
film
Door window
runchannel
Door window
assembly
runchannel
and ventilator
Ventilator window glass, ventilator

and ventilator window pad
sash
sash
EC-870 or equivalent
3M ART Part No. 8080 or 3M

Adhesive EC-1368, or equivalent
As required
3M AMT Part No. 8001 or No. 8011, or

equivalent
As required
Ventilator sash assembly

vlvindow weatherstrip
and ventilator

Adhesive EC-l 368, or equivalent
As required
Ventilator sash assembly

window weatherstrip
and ventilator
3M AMT Part No. 8001 or No. 8011, or

equivalent
As required

equivalent
As required

equivalent
As required

Adhesive EC-l 368, or equivalent
As required
\
I
Back door opening weatherstrip

door
JVaterproof
ieadlining
and back
pad and fender

and roof panel
SPECIAL TOOLS
Tool (Number
IB990900-01
oor adjusting
and name)
23DA--
Use
Tool (Number
Adjustment
and name)
of door fit
wrench
Windshield
STB Revision
http://vnx.su/
moulding
remover
Use
23-9
BODY-Troubleshooting
TROUBLESHOOTING
FRONT DOOR
N23EAAC
Remedy
Reference
page
Adjust
Attach
Broken sash
Replace
Collapsed
sash
Repair or replace
Collapsed
window
Repair or replace
Replace
Adjust
23-16
Symptom
Probable cause
Door glass fails to

operate up and down
Dismount
window
Detached
sash
Broken window
Door glass operates
up and down hardly
glass regulator arm

glass regulator
Improper
window
Collapsed
sash
i Collapsed
glass regulator
glass position
Repair or replace
window
Broken window
regulator arm
regulator
handle
Repair or replace
Replace
BACK DOOR
; y.
Symptom
Probable cause
Remedy
Back door is hard

when opened/closed;
abnormal noise is
heard from hinges
Insufficient
Apply chassis
grease on hinges
grease
23-48
. ..;,,,
;
WIND NOISES
Remedy
Reference
page
holding force
Adjust the door installation
23-l 5
installed, or de-
Repair or replace
23-45
Door fails closing
Adjust
Improper
Adjust
23-l 5
Adjust
Repair or replace
holding force
Adjust the back door installation
23-l 7
installed, or de-
Repair or replace
23-47
Uneven
clearance between the body and

back door
Adjust
23-l 7
Deformation of the back door
Repair or replace
Symptom
Probable cause
Wind noise from

around the door
Insufficient
weatherstrip
Weatherstrip
teriorated
improperly
door position
Uneven clearance
runchannel
Deformation
Wind noise from back
door
li .
4
Insufficient
Weatherstrip
teriorated
between
door glass and
of the door
weatherstrip
improperly
( STB Revision
http://vnx.su/
.*
23-10
BODY
- Troubleshooting
HOW TO LOCATE WIND
NOISES
(1) Attach cloth tape to every place which might conceivably

be the source of wind noise, such as panel seams,
projections,
moulding
seams, glass and body seams, etc.
(2) Then make a road test in order to determine
that the
places not covered by tape are not sources of wind noise.
18W809
(3) Then remove the strips of tape one by one, making a road
test after each is removed,
until a wind noise source is
discovered.
nemove
18W809
(4) When such a place

with the procedure
other noise sources.
If no others
source.
is found, cover it again and continue

so as to determine
if there are any
are found,
the last remaining
tape is the only
ex. Noise produced

here
(6) Cut the remaining

piece of tape into smaller pieces, attach
it again as it was before, and then remove the pieces one
by one in the same way so as to narrow down the source.
Cut tape into pieces
(7) Check to confirm that wind noise occurs when the last
remaining
tape is removed, and that noise does not occur
when it is re-attached.
(8) When the source(s) of the wind noise is finally located,
attach butyl tape, body sealer or similar
material
to
obstruct this source as much as possible.
wision
http://vnx.su/
23-11
BODY - Troubleshooting
BACK DOOR LOCKING
T\
SYSTEM
Inspection
items
Symptom
j;
When the switch is operated, the

back door fails to unlock or lock.
The back door is locked but cannot
be unlocked.
The back door is unlocked
not be locked.
NOTE
Number in circle indicates
CIRCUIT
but can-
inspection
sequence.
DIAGRAM
1.25F-G
cz
J
N
-1.25-G
1.25F-R
2-I-R
-To
heater relay
[Refer to P 8.551
2-B
-To
column
switch
[Refer to PM11
1.25-R
B-12
CC
I
Rkc
--
0
R
EE%3
M
Back door
lock aCtato,
Whng
color code
B Black
Br Brown
LI Light blue
0 Orange
Hemark
For InformatIon
refer lo P 8-7
G Green
P Pink
Gr Gray
R Red
concerning
L Blue
Y Yellow
1 STB Revision
http://vnx.su/
Lg
W
the ground
Light green
Whlre
pants
37W302
(example
23-12
POWER WINDOW
CIRCUIT
DIAGRAM
Ignition
WA
Battery
A-02
-
Sub fusible
switch
link
5-W
U
1.25-B
Main
lrnk
fusible
3
m
c:
Multipurpose
fuse
z
d
[Refor to P.8-491
Power window
main switch
Remarks
(1) For information
concernina
the around pornts (example:O), refer to P.8-7.
(2) The symbols 0, 0, etc. indicate
that the wiring
is
connected
(usina the same numerical
symbol) to the
facing page.
(In other words, 0 on the right page is connected to 0 on
the left page.)
ST6 Revision
http://vnx.su/
(RL)
2-I-R :g
BODY
2-B
R
B0
Power
motor
23-13
- Troubleshooting
To colunm switch
[Refer to P.8-511
window
(L.H.)
2-B
MU,
B-31 1
c!
Ll
C-Y
0.:2-LR
(RL)
To headlight
washer relay
[Refer to P.8-581
Power
7-
motor
'
c+l~
(R.H.)
window
relay
tr,
1 '
2-RL,ZF-G
Z-LB
ZF-L
Z-GL
ZF-R
I
I
(y
c-30
\
0
Power window
sub switch (R.H.)
37W603
Wiring color code

B: Black
LI: Light blue
Br: Brown
0: Orange
G: Green
P: Pink
Gr: Gray
R: Red
/ ST6 Revision
http://vnx.su/
L: Blue
Y: Yellow
Lg: Light green

W: White
23-14
POWER
WINDOWS
23EAAD
Inspection items
a
.-8
.L
Symptom
done of the door windows can be
operated.
Co
-he front door windows cannot be

operated by using the main switches
-he door windows can be operated

myusing the main switches, but
.annot be operated by using the sub
witches.
.he door windows can be operated

3y using the sub switches) even
hough the lock switch is at ON.
he door windows do not operate

moothly.
Number in circle indicates inspection sequence.
STB Revision
http://vnx.su/
BODY
Service
Adjustment
23-15
Procedures
SERVICE ADJUSTMENT
ADJUSTMENT
OF HOOD
PROCEDURES
FIT
N23FAAC
l.
18W50!
Adjust the fit of hood with the hood adjusting

bolts, hood
latch adjusting
bolts and hood bumper
while they are
installed. Loosen the hood adjusting
bolts and adjust the
hood laterally with reference to the hood latch.
2. After lateral adjustment
of hood, adjust the hood vertically
with the hood adjusting
bolts and hood latch adjusting
bolts.
Make sure that the hood hook is properly engaged with the
hood latch.
NOTE
Apply chassis grease to the sliding portion,
portion and the spring of the hood latch.
3.
the rotating
Turn the hood bumper and adjust the vertical position of

the hood by adjusting the hood bumper either up or down.
P
II,
.. ,
ADJUSTMENT
FIT
OF FUEL
FILLER
DOOR
HOOK.
N23FDAB
Loosen the fuel filler door hook mounting

screws and move
the fuel filler door hook to the left and right so that the door is
flush with the body.
ADJUSTMENT
1.
OF DOOR INSTALLATION
Use the special tool to loosen the hinge mounting

bolts on
the body side, and then adjust so that the clearance
around the door is uniform on all sides.
Caution
Attach
protection
place where
the
rSTB
N23FEAC
Revision
http://vnx.su/
tape
hinge
to the fender
is installed.
edges
near
the
23-16
BODY - Service
Adjustment
Procedures
2.
At the facing surface of the front fender and door panel,

loosen the installation
bolts at the door side, and then
adjust by increasing or decreasing
the number of shims.
3. At the facing surfaces of the door and rear pillar outer
panel, adjust by loosening
the striker installation
screws.
4. Adjust the engagement
of the striker and door latch by
increasing
or decreasing
the number
of striker shims,
and/or by moving the striker.
ADJUSTMENT
OF DOOR GLASS
NZOFFAB
I,
Remove the door trim and waterproof film. (Refer to P.2333.)

2. Raise the door glass fully, and then adjust the following
items so that the door glass fits evenly into the window
glass runchannel
all the way around.
Loosen the screws and/or bolts securing the window and
rear lower sash.
Move the window, rear lower sash and the sub roller guide
(vehicles without ventilator window) of the window regulator to adjust the door glass position.
ADJUSTMENT
OF VENTILATOR
WINDOW
N23FJAA
1. Remove the door trim and waterproof film. (Refer to P.2333.)

2. Remove the ventilator
window.
(Refer to P.23-35.)
3. Adjust the ventilator
window by turning the adjusting
nut
so that the ventilator
window can be operated smoothly.
Lock
[mm
NOTE
Fix the adjusting
adjustment.
washer
(in.)
18W561 I
ADJUSTMENT
I.
2.
nut by bending
OF INSIDE
the lock washer
HANDLE
after the
N23FGAB
Remove the door trim and waterproof

film. (Refer to P.2333.)
Move the mounting
position of the inside handle longitudinally in order to adjust the play of the inside handle.
Standard
value
: 4-10
mm
(.16-.40
in.)
@J+
1880033
ADJUSTMENT
FRONT
OF OUTSIDE
HANDLE
NZBFHAB
DOOR
1. Remove the door trim and waterproof

film. (Refer to P.2333.)
2. Disconnect
the outside
handle from the outside
handle
rod, and turn it right to left to adjust the outside handle
play.
v
16Y 066
1857481
Caution
The rod
snap
Standard
value
STB Revision
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must
: 5-10
be replaced.
mm
(.20-.40
in.)
BODY
Service
Adjustment
BACK
23-17
Procedures
DOOR
1. Remove the back door trim and waterproof

P.23-49.)
2.
film.
(Refer to
Disconnect
the outside handle from
rod, and turn it right to left to adjust
play.
the outside
the outside
Standard
(.20-.40
in.)
DOOR
INSTALLA;l02
value
ADJUSTMENT
: 5-10
OF
mm
BACK
handle
handle
(1) To loosen the hinge mounting

bolts on the body side, and
then adjust so that the clearance around the back door is
uniform on all sides.
(2) At the facing surface of the right side quarter panel and the
back door, adjust by loosening
the installation
bolts.
(3) At the
door,
(4) Adjust
latch
shims,
facing surface of the left side quarter panel and back

adjust by loosening
the striker installation
screws.
the engagement
of the striker and the back door
by increasing
or decreasing
the number
of striker
and/or by moving the striker.
( STB Revision
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j:.
i
4
i
1
:.
I
23-18
BODY - Body
Mounting
BODY MOUNTING
REMOVAL
AND
INSTALLATION
N23GW
1.
2.
3.
4.
5.
6.
7.
8.
9.
Special bolt
Plain washer
Body mounting rubber
Spacer
Body mounting rubber
Washer
Self locking nut
Body shim
Mounting bolt
NOTE
m :Non-reusable parts
28-32Nm
20-23ftJbs.
28-32Nm
20-23ft.lbs.
28-32Nm
20-23ft.lbs.
1 STB Revision
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28-32Nm
20-23ftlbs.
(A)
(6)
BODY - Body Mounting
23-19
REMOVAL
(1) Remove or disconnect
the following - parts:
0
Air filter
0
Accelerator cable
0
Vapor hose
0
Heater hoses
0
Brake booster vacuum hose
0
Starter motor wiring harness
0
Alternator wiring harness
0
Engine ground (on body side)
0
Steering shaft joint
0
Fuel cut solenoid valve connector
0
E.S.S. solenoid valve connector
0
High-tension
cable
0
Water temperature
gage connector
0
Power steering pump
0
Oil pressure switch harness
0
Transmission
oil cooler
0
Radiator assembly
0
Oxygen sensor connector
0
Hydraulic clutch hoses
0
Brake pipes
l
Speedometer
cable (transmission
side)
0
Carburetor
control wiring harness
0
Air temperature
sensor connector
0
Water temperature
sensor connector
0
Backup light switch connector
0
4WD indicator light switch connector
0
Pulse generator connector
0
Fuel pipe
0
Filler hose protector
0
2-way va Ive
0
Rear combination
light connector
0
Filler neck
0
Transmission
gearshift lever
0
Transfer gearshift lever
0
Parking brake cable
0
Front and rear seats
0
Door opening trim
(2) After removing

the body mounting
bolts and the body
shims, insert wood blocks into the body and gently lift with
a crane.
Caution
Hoist the body carefully
after assuring
that all the
connections
between
body and frame and engine are
separated.
Sling wires with a suitable
bar or frame used and with
good protection
made by fitting coverings
at necessary
points.
1 STB Revision
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23-20
BODY - Hood
HOOD
REMOVAL
AND INSTALLATION
4.0-6.0
2.943
Kim
ftlbs.
3.5-4!0
2.5-2.9
Nm
ftlbs.
18W731
Hood removal steps

l +
l 4
1. Hood
2. Hood
3. Hood
hook
hinge
Hood latch release cable removal steps

l + 4. Hood latch
5. Hood
6. Hood
latch
latch
release
release
handle
cable
Hood rear weatherstrip removal

l + 7. Hood rear weatherstrip
NOTE
(2) *+
SERVICE
POINTS
7. APPLICATION
STRIP
OF INSTALLATION
OF SEALANT
TO HOOD
REAR WEATHER-
Apply the specified

sealant to and around the two hood
rear weatherstrip
attaching holes at the right and left ends
of the front deck.
Specified
sealant
http://vnx.su/
: 3M ART Part
23-21
BODY - Hood
4.
ADJUSTMENT
OF HOOD
LATCH
/2. HOOD
HOOK
(1) Loosen the hood latch and hood catch stay attaching
bolts.
(2) Adjust the position of the hood latch and hood hook to
align the lock with the hook.
NOTE
Apply chassis grease to the sliding portion,
portion of the hood hook and hood lath.
I~_
--
the rotating
1. ADJUSTMENT
OF HOOD
(1) Adjust the longitudinal
and lateral positions of the hood
by utilizing the oblong holes in the hinge.
(2) Adjust the vertical position of the hood by adjusting the
hood bumper either up or down.
--
STB Revision
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j .
1..
,
23-22
BODY - Fuel Filler Door
FUEL FILLER DOOR

REMOVAL
AND
INSTALLATION
N23JAAD
Fuel filler door panel

l + 1. Fuel filler door panel
Lock cylinder assembly
removal steps
2. Cylinder lock retainer
3. Lock cylinder assembly
Fuel filler door lock release cable removal steps
4. Front scuff plate (L.H.)
5. Ashtray (L.H.) [metal top-van]
6. Quarter trim (L.H.)
7. Center pillar trim
8. Rear combination. light
9. Lock release handle
++ IO. Fuel filler door lock release cable
Fuel filler
door hook removal steps

8. Rear combination
light
l + 10. Fuel filler door lock release
nection
l + 11. Fuel filler door hook
cable con-
NOTE
(2) I)+ : Refer to Service Points of Installation.
[ STB Revision
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BODY - Fuel Filler
23-23
Door

11. ADJUSTMENT
OF FUEL FILLER DOOR HOOK
Loosen the fuel filler door hook mounting
screws and
move the fuel filler door hook to the left and right so that
the door is flush with the body.
10. INSTALLATION
OF FUEL FILLER DOOR LOCK RELEASE
CABLE
Install so that the installation
position mating mark (yellow
paint) on the release cable is aligned with the position
shown in the figure.
.i
.
-I
IT
1. ADJUSTMENT
OF FUEL FILLER
DOOR PANEL
Loosen the fuel filler door mounting

that the upper and lower clearances
is flush with the body.
( STB Revision
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screws and adjust so

are equal and the door
v, . ) _
23-24
BODY - Fenders
FENDERS
REMOVAL
Removal
l +
AND
INSTALLATION
N23KAAE
steps
1.
2.
3.
4.
5.
6.
7.
8.
Radiator
grille
Front combination
Headlight
bezel
Grille filler panel
Front mud guard
Partial wheel
lip
Splash
shield
Front fender
light
NOTE
(1)
(2)
Reverse the removal procedures to reinstall,

: Refer to Service
Points of Installation.
*4
STB Revision
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181111824
23-25
BODY - Fenders
Cross-section
(Iross-section B-B
A-A

8.
Specified
sealant
ONSTALLATION
OF FRONT FENDER

sealant
fender up to the ends.
Butyl rubber
tape
Specified sealant
fully to the
top
part of
: 3M ART No. 8531 or No. 8646, or
equivalent
i
-J-J
(2) Apply butyl rubber tape to the flange

when installing the splash shield.
Specified adhesive
part of the fender
: 3M ART Part No. 8626 or 3M
Adhesive
lent
EC-5310,
or equiva-
(3) Fasten the fender temporarily

in position,
make sure
that clearance is uniform at all points, and then fasten
completely.
STB Revision
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23-26
BODY - Windshield
WINDSHIELD
3EMOVAL
AND INSTALLATION
Removal
steps
+*
4*
1.
2.
3.
4.
5.
6.
7.
8.
4*
4*
4*
4*
4*
4*
h*
+e
++
I)+
N23LBAD
Upper moulding joint

Lower moulding joint
Upper moulding, R.H.
Upper moulding, L.H.
Lower moulding, R.H.
Lower moulding, L.H.
Side moulding, R.H.
Side moulding, L.H.
9. Windshield
IO. Windshield
18W723
NOTE
to reinstall.
(2) a*
(3) +*
(4) m: Non-reusable
parts
weatherstrip
SERVICE
POINTS
1. REMOVAL
MOULDING
OF REMOVAL
OF UPPER
MOULDING
JOINT/2.
JOINT/3.
TO 8. MOULDINGS
On vehicles equipped with mouldings,

ing with the weatherstrip
straightened
after sliding
the
moulding
WINDSHIELD
WEATH-
out from the inside of the cabin with
the lip of the weatherstrip

straightened
periphery with a screwdriver.
http://vnx.su/
the mould-
with a special tool
joint.
OF WINDSHIELD/lO.
Push the windshield
remove
LOWER
along
the entire
BODY -
23-27
Windshield
INSPECTION
l
Check
SERWCE
the body
POINTS
flange
for deformation.
OF INSTALLATION
10. INSTALLATION
OF WINDSHIELD
WEATHERSTRIP/S.
WINDSHIELD
(1) Fill the weatherstrip
with the specified adhesive and fit
it to the windshield.
Specified
adhesive
: 3M ART Part No. 8001 or No.

8011, or equivalent
18W776
jt.: :
(2) Set round
strings
in the weatherstrip
groove.
(
NOTE
Make certain that the strings
ends.
mm (in.)
105711
.1
f
hi?!&
overlap each other at both
(3) Apply soap solution to the entire surface of the body

flange.
(4) Place the windshield
in position from outside with the
strings placed inside the cabin.
Soap solution
18W774
(5) With the aid o f an assistant to push the windshield

from outside, slowly pull one end of the string at right
angles to the windshield
and fit the lips of the
weatherstrip
correctly on the windshield
flange.
NOTE
Pull the strings,
working
from both sides of
windshield
toward the center and pushing from
outside of the glass.
Caution
Press lightly
to
flange surface.
STB Revision
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hold
the
glass
against
the
the
the
body
df :4
1
,v
!I:
:
,
<
!
23-28
BODY
- Windshield
(6) Apply specified
adhesive
between
and the body flange at the locations
illustration.
Specified
,/
I
: 3M ART Part No. 8626 or 3M

Adhesive
EC-5310,
or equivalent
(7) Apply an ample amount

around the weatherstrip
flange.
Specified
. .
.L
adhesive
18W55E
1 ST6 Revision
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adhesive
the weatherstrip
indicated
in the
of the specified
adhesive all
between
it and the body
: 3M ART Part No. 8001

8011, or equivalent
or No.
BODY - Quarter
QUARTER
REMOVAL
WINDOW
AND
Window
23-29
Glass
GLASS
INSTALLATION
N23LEBFJ
181773
Removal
+e
4*
4*
I)+
steps
Slide glass
1. Glass and weatherstrip

assembly
of step No. 2-10)
2. Quarter window
weatherstrip
3. Stopper
4. Stopper
5. Quarter window
sash
6. Quarter window runchannel
7. Holder
8. Rubber seal
9. Quarter window front glass
10. Quarter window rear glass
(parts
lock removal
11. Connector
12. Packing
13. Slide glass
steps
lock
NOTE
to reinstall.
(2) 4*
parts
SERVICE
POINTS
1. REMOVAL
OF REMOVAL
AND WEATHERSTRIP
ASSEMBLY
With the glass in position, push the quarter
window
assembly outward while raising the lip of the weatherstrip
http://vnx.su/
OF GLASS
23-30
BODY - Quarter
9.
Window
Glass
REMOVAL
OF QUARTER
WINDOW
FRONT GLASS/IO.
QUARTER
WINDOW
REAR GLASS
Move the quarter window glass to the middle position and
remove it by opening the weatherstrip
up and down.
SERVICE
POINTS
OF INSTALLATION
1. APPLICATION
OF ADHESIVE
TO GLASS AND WEATHERSTRIP
ASSEMBLY
(1) Apply the specified adhesive to the weatherstrip
at the
location indicated
Specified
adhesive

8011, or equivalent
or No.
16W717
Quarter
(2) After the quarter window rear glass has been installed,
install the stopper by applying the specified adhesive.
window
Specified
adhesive
: 3M Adhesive
lent
EC-870 or equiva-
1 ED586
(3) Apply the specified adhesive between

and the body flange at the location
illustration.
Specified
16W662
mm
(in.)
18W716
(TB
Revision
-1
http://vnx.su/
adhesive
the weatherstrip
indicated
in the

8011, or equivalent
or No.
BODY - Back
BACK DOOR WINDOW

REMOVAL
AND
Door Window
23-3 1
Glass
GLASS
INSTALLATION
N23LDAD
7-10 Nm
5-7 ft.lbs.
18W610
Removal
1
2
3
*+
steps
4
5
Spare
Wiper
with
Rear
rear
Back
Back
tire
arm and blade assembly
a rear wiper)
defogger
terminal
(Vehicles
defogger)
door window
weatherstrip
door window
glass
1
.
f< .;,.;:;$
(Vehicles
with
NOTE
(1)
to reinstall.
(2) l 4 : Refer to Service Points of Installation.
I;,,
..
*\
i. ,;
t I

4. APPLICATION
WEATHERSTRIP
(1) Apply
..
OF ADHESIVE
the specified
Specified
adhesive
adhesive
TO BACK DOOR WINDOW

to the weatherstrip.

8011, or equivalent
or No.
(2) As shown in the figure, attach butyl tape between

weatherstrip
and the body flange.
18W752
levision
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the
23-32
BODY - Door Assembly
DOOR ASSEMBLY
REMOVAL
AND
INSTALLATION
N23MAAF
Nm
ft.lbs.
35-55
25-40
17-26 Nm
12-19 ft.lbs.
Removal
steps
1. Door opening trim

(Vehicles with a Power Window)
2. Cowl side trim
3. Connection
of door
wiring harness connector
4. Spring pin
5. Door
l + 6. Door upper hinge
7. Door upper hinge shim
l + 8. Door lower hinge
9. Door lower hinge shim
Striker removal
steps
IO. Striker
11. Striker shim
Door switch
removal
steps
Door switch
13. Door switch
12.
Nm
ft.lbs.
3&55
25-40
18W792
NOTE
(2)
cap
I)4
: Refer
to
Service
Points
to reinstall.
of
Installation.
INSPECTION
l
Check
noise.
the
door
hinges
for
cracks,
damage
or abnormal
DOOR SWITCH
Operate
minals.
the switch,
and check
the continuity
between
the ter-
Y16885
Release
Push
NOTE
O-O indicates that there is continuity
SERVICE
OF GREASE
HINGE
Apply the chassis

hinges.
I
-m
\ ST6 hevmon
the terminals.
POINTS OF INSTALLATION
8. APPLICATION
DOOR UPPER
10w722
between
-I
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grease
TO DOOR
LOWER
HINGE/G.
to the sliding
part
of the door
BODY
- Door
Trim
DOOR JRJM AND WATERPROOF

REMOVAL
AND
Removal
steps
4*
1.
2.
3.
4.
5.
6.
7.
*+
INSTALLATION
trim
film
23-33
Film
FILM
(Vehicles
Clip
Regulator
handle
Escutcheon
Armrest
Inside handle
cover
Door trim
Trim clip
8. Door upper
9. Waterproof
and Waterproof
without
/-
a Power
Window)
N23MBAE
NOTE
to reinstall.
(3) l * : Refer to Service Points of Installation
(4) CI : Clipping position

1. REMOVAL
OF CLIP
Remove the clip by using
regulator handle.
1auo392
a rag, and then
remove
the
18UO43C
7.
REMOVAL
OF TRIM CLIP
If trim clips remain at the door side when the door trim is
removed, improvise a tool (such as shown in the figure) to
remove them.
wision
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23-34
BODY - Door
Trim
and
Waterproof
Film

9. APPLICATION
Apply
shown
film.
Specified
REMOVAL
I
Removal
l *
l +
AND INSTALLATION
(Vehicles
OF ADHESIVE
TO WATERPROOF
FILM
a coating
of specified
adhesive
to the position
in the illustration,
and then attach the waterproof
adhesive
: 3M ART
Adhesive
Part No. 8626 or 3M

with a Power Window)
. !;
steps
1.
2.
3.
4.
5.
6.
7.
Armrest
Inside handle cover
Power window
switch
Door trim
Trim clip
Door upper trim
Waterproof
film
cover
I\IIC

(2)
(3)
a*
+*
: Refer
: Refer
to Service
to Service
Points
Points
of Removal.
of Installation
(4) a : Clipping position
SERVICE
5.
REMOVAL
POINTS OF REMOVAL
OF TRIM
If trim clips remain

removed,
improvise
remove
them.
1 STB Revision
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CLIP
at the door side when
a tool (such as shown
the door trim is

in the figure) to
BODY -
Door
Trim
and
Waterproof
Film
SERVICE
7.
/ Front
Door
POINTS
Grass
and
OF INSTALLATION
APPLICATION
Apply
OF ADHESIVE
a coating
of specified
shown
in the
23-35
Regulator
illustration,
TO WATERPROOF
FILM
adhesive
to the position
then attach
the waterproof
and
film,
Specified
adhesive
: 3M ART
Adhesive
Part No. 8626 or 3M

FRONT DOOR GLASS AND REGULAT

REMOVAL
AND
INSTALLATION
N23MCAE
2L6
Removal
steps
+e
l + 1. Door trim and waterproof

l + Adjustment
of door window
l *
2. Outer weatherstrip
3. Inner weatherstrip
4. Center sash protector
l + Adjustment
of ventilator
window
5. Ventilator
window
assembly
6. Glass holder
7. Door glass pad
w+ 8. Door window
glass
l + 9. Window
regulator
**
+e
+I)
Nm
4 .3 ft.lbs.
film
glass
18W781
*g
assembly
NOTE
(1) Reverse the
(2) l * : Refer
(3) +*
: Refer
(4) * : Vehicles
) STB Revision
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removal procedures
to reinstall.
to Service Points of Removal.
to Service Points of Installation.
with a power window
23-36
BODY - Front
Door Glass and Regulator
SERVICE
POINTS
OF REMOVAL
1. REMOVAL
OF DOOR
Refer to P.23-33.
TRIM
AND
WATERPROOF
FILM
..
1
2. REMOVAL
OF OUTER
WEATHERSTRIP
(1) Remove the outer weatherstrip

fromthe
fixing clips by
prying upward with a screwdriver.
(2) Remove the outer weatherstrip
rearward.
5.
REMOVAL
(1) Remove
window
(2) Pull
8.
OF VENTILATOR
WINDOW
ASSEMBLY
the screws and bolts mounting
the ventilator
assembly.
out the ventilator
window
assembly
upward.
REMOVAL
OF DOOR WINDOW
GLASS
(1) Lower the door glass to the access hole position.
(2) Peel the waterproof film off with care not to damage it.
(3) Remove
the glass mounting
bolts from the glass
holder.
NOTE
When removing
glass to avoid
18WSl7~
1 STB Revision
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the glass mounting

dropping
it.
bolts,
support
the
23-37
BODY - Front Door Glass and Regulator
(4) Gently pull out the door glass upward while tilting it so
that the rear end of the glass comes up to the top.
9. REMOVAL OF WINDOW
REGULATOR
Vehicles without
a Power Window
(1) Remove the window regulator
mounting
NOTE
Hold the regulator assembly
when bolts are removed.
(2) Take
hole.
out the window
bolts.
, ito
so that it does not drop off
regulator
through
the
access
Vehicles with a Power Window

(1) Remove
the regulator
mounting
bolts and nut, and
then remove regulator from the access hole.
_
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i-,
(2) Disconnect
tor.
the power
window
motor
from the regula-
Caution
Because the force of the regulator
spring may cause the
regulator
arm to jump up when the screws attaching
the
motor to the window
regulator
are removed,
remove
the regulator
spring before removing
the screws.
18K324
1 STB Revision
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23-38

INSPECTION
POWER WINDOW
MOTOR
(1) Connect the motor terminals
directly to the battery and
check that the motor operates smoothly.
Next, reverse the
polarity and check that the motor operates smoothly in the
reverse direction.
(2) Check the circuit breaker incorporated

in the motor, as
described below, after installing the motor and regulator to
the body.
0 Press the UP switch to fully close the window glass,
and continue to press the switch for 10 to 20 seconds.
0 At the moment
that the UP switch is released, press
the DOWN switch. The circuit breaker can be considered good if at this time the door window glass begins
to open within 60 seconds.
MAIN SWITCH
Operate the switch,
terminals.
and check
the continuity
between
the
lBW023
I\
Terminal
L.H. side
NOTE
O--O indicates
that there
is continuity
between
the terminals.
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R.H. side
LOCK
23-39

SUB SWITCH
Operate the switch,
terminals.
and check
the continuity
between
the
UP
16W972
NOTE
POWER WINDOW
(1) After removing
window relay.
between
RELAY
the
(2) Check for continuity
cowl
side
between
trim,
ED
2
the
power
2
,
3
I
4
I
NOTE
(1) M
indicates that there is continuity between the terminals.
(2) O----O indicates the connection with the power supply.
10W906
T
3
1
1
remove
the terminal.
Terminal
the terminals.
6 1
lBW909
wision
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II
23-40
BODY - Front
Door
Glass
and
SERVICE
9.
POINTS
lNSTALLATlON
Regulator
OF INSTALLATION
OF WINDOW
REGULATOR
Vehicles without
a Power Window
Apply a coating chassis grease to the sliding
rotating parts of the window regulator.
parts and
Vehicles with a Power Window

;, . r
When .assembling
the windo.w,regu?atb?and
power window motor, first install the, reguYaf@+ spring, and then
proceed with assembly.
;
~
INSTALLATION
OF DOOR WINDOW
GLASS
When the door glass has been removed
from the glass
holder, install to the position
shown in illustration.
Standard
value
Distance
Distance
:
X 466.5-467.5
mm (18.366-18.406
Y 76.5-77.5
mm (3.012-3.051
in.)
ADJUSTMENT
OF VENTILATOR
Refer to P.23-16.
ADJUSTMENT
OF DOOR
Refer to P.23-16.
1. INSTALLATION
OF DOOR
FILM
Refer to P.23-33. 34.
http://vnx.su/
WINDOW
TRIM
WINDOW
GLASS
AND
WATERPROOF
in.)
BODY
Door
Front
Glass
and
23-41
Regulator
DISASSEMBLY
AND REASSEMBLY
(Ventilator
Window Assembly)
Disassembly
l +
steps
1. Door window
2. Screw
3. Screw
glass runchannel
h?
4. Washer
l +
l +
~~
I)+
l +
l a
Q
6
0
14
5. Packing
6. Hinge
7. Pin
8. Ventilator window lock handle
9. Push button
10. Push button spring
11. Wave washer
12. Screw
13. Ventilator open handle
Adjustment of ventilator window
14. Ventilator sash spring kit
15. Ventilator sash
16. Ventilator window glass pad
17. Door ventilator window glass
18. Ventilator window weatherstrip
19. Ventilator sash assembly
8
z
0
jaw797
NOTE
(2) l + : Refer to Service
1 STB Revision
http://vnx.su/
procedures
to reassemble.
23-42
BODY
- Front
Door Glass and Regulator
SERVICE
POINTS
19.APPLlCATlON
ASSEMBLY/18.
OF REASSEMBLY
OF ADHESIVE
VENTILATOR
TO VENTILATOR
SASH
WINDOW
WEATHERSTRIP

adhesive to the pItice marked A in
the figure, between the ventilator
sash assembly and the
ventilator
window weatherstrip.
Specified
18W814
adhesive

the figure.
Specified
adhesive
: 3M Super Weatherstrip
Adhesive
8001 or 8011 or equivalent
adhesive
to the place
: 3M ART
Adhesive
marked
B in
Part No. 8080 or 3M

EC-1368,
or equivalent
17. APPLICATION
OF ADHESIVE
TO DOOR VENTILATOR
WINDOW
GLASS/lG.
VENTILATOR
WINDOW
GLASS
PAD/15.
VENTILATOR
SASH
(1 ) The SECT. A-A and VIEW B parts in the illustration are to be
coated with the specified
adhesive.
Specified
adhesive
: 3M Super Weatherstrip
Adhesive
8001 or 8011 or equivalent
(21) The SECT. C-C and SECT. D-D parts in the illustration
be coated
Specified
SECT. A-A
Apply the
adhesive so that
with
adhesive
VIEW 0
the specified
: 3M ART
Adhesive
without ripples,
-high
parts, etc.
18W799
SECT. C-C
SECT. D-D
Specified
adhesive
18W804
16W805
4
_i
wision
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are to
adhesive.
Part No. 8080 or 3M
EC-1368,
or equivalent
BODY - Front
Door
Glass
and
ADJUSTMENT
sash assembl
23-43
Regulator
OF VENTILATOR
WINDOW
Refer to P.23-16.
Door
window
glass
runchannel
1. APPLICATION
OF ADHESIVE
GLASS RUNCHANNEL
mm (in.)
18W800
DOOR
WINDOW
Apply the specified adhesive between the door window

glass runchannel
and the ventilator
sash assembly at the
location indicated
Specified
adhesive
: 3M ART
Adhesive
Door window
glass runchannel
Ventilator
window
1. y eatherstrp
TO
SpeGfied
adhesive
SECT. A-A
[ STB Revision
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Part No. 8080 or 3M

23-44
BODY - Door handle
and latch
DOOR HANDLE AND LATCH

REMOVAL
AND INSTALLATION
N23MDAD
18W741
Removal
ae
l +
l *
l +
steps
1. Door trim and waterproof
film
Adjustment
of outside
handle
Adjustment
of inside handle
2. Inside lock knob
3. Outside
handle
4. Door latch
5. Inside handle
NOTE
(I 1 Reverse the
(2)
O*
: Refer
(3)
l + : Refer
SERVICE
1.
removal procedures
to Service
to Service
POINTS
TRIM
ADJUSTMENT
OF INSIDE
Refer to P.23-16.
ADJUSTMENT
OF OUTSIDE
Refer to P.23-16.
1. INSTALLATION
OF DOOR
FILM
Refer
to P.23-33,
III1
http://vnx.su/
AND
WATERPROOF
FILM
OF INSTALLATION
1 STB Revision
to reinstall.
of Removal.
of Installation.
POINTS OF REMOVAL
REMOVAL
OF DOOR
Refer to P.23-33.
SERVICE
Points
Points
34.
HANDLE
HANDLE
TRIM
AND
WATERPROOF
BODY -
WINDOW
STRIP
REMOVAL
Window
GLASS
AND
Glass
and
Runchannel
RUNCHANNEL
Door
Opening
23-45
Weatherstrip
AND DOOR OPENING
WEATHER-
INSTALLATION
N23MEAD
6Nm
4.3 ft.lbs.
Removal steps
+e l +
41) l +
41) l +
+e l +
4*
1.
2.
3.
4.
5.
Door trim and waterproof film

Ventilator window assembly
Door window glass runchannel
Door window glass
Window glass runchannel
6. Door lower sash
7. Door opening weatherstrip
10w705
NOTE
(2) 4*

1. REMOVAL
OF DOOR TRIM
Refer to P.23-33.
2.
REMOVAL
AND WATERPROOF
OF VENTILATOR
WINDOW
FILM
ASSEMBLY
Refer to P.23-36.
4.
REMOVAL
Refer
5.
OF DOOR WINDOW
tto P.23-36.
REMOVAL
Remove
GLASS
OF WINDOW
the window
sides with your fingers.
http://vnx.su/
GLASS
glass
RUNCHANNEL
runchannel
by pressing
both
23-46
BODY - w. In d ow
Glass Runchannel
7.
and Door
Opening
Weatherstrip
REMOVAL OF DOOR OPENING

Remove
the door opening
WEATHERSTRIP
weatherstrip
with
the tool

50 (1.97)
5. APPLICATION
OF ADHESIVE
TO WINDOW
GLASS RUNCHANNEL
Apply the specified
adhesive to the positions
shown in
illustration
and install the window glass runchannel.
Specified
; ..,.2
ii
;
I
\
?
,
. .
;,L
I
I
adhesive
: 3M Adhesive
4.
INSTALLATION
OF DOOR WINDOW
Refer to P.23-40.
2.
INSTALLATION
OF VENTILATOR
Refer to P.23-35.
1. INSTALLATION
OF DOOR
FILM
Refer to P.23-33, 34.
STB Revision
IIIII
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TRIM
EC-870
or equivalent
GLASS
WINDOW
AND
ASSEMBLY
WATERPROOF
23-47
BODY - Back Door Assembly
BACK DOOR ASSEMBLY

REMOVAL
AND
INSTALLATION
N230AAE
35-55 Nm
25-40 ft.lbs.
Back
door
removal
steps
1. Spare tire
2. Spare tire carrier
3. Rear opening
trim
4.
Quarter
trim
l *
5. Rear pillar lower trim
l *
l + Adjustment
of back door installation
6. Cotter pin
7. Clevis pin
8. Connection
of rear washer
tube
cles with a rear wiper)
9. Connection
of back door wiring
harness
connectors
l + 10. Door upper hinge
~~ 11. Door lower
hinge
12. Back door
l *
Striker
(Vehi-
removal steps
13. Striker
14. Striker
shim
l + 15. Door
opening
:
NOTE
(1) Reverse the removal procedures to rein&II.
(4) a : Non-reusable parts
Door opening weatherstrip

+e
weatherstrip
SERVICE POINTS
4.
REMOVAL
OF REMOVAL
OF QUARTER TRIM
Refer to P.23-73.
5.
REMOVAL
Refer
OF REAR PILLAR LOWER TRIM
to P.23-74.
1 STB Revision
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23-48
BODY - Back Door Assembly

15. REMOVAL
OF DOOR OPENING
Remove
the door opening
WEATHERSTRIP
weatherstrip
with
the tool

15. APPLICATION
OF ADHESlVE
TO DOOR
OPENING
WEATHERSTRIP
Apply a coating
of specified
adhesive
at the position
and then attach the door opening
weatherstrip.
Specified
mm
(in.)
WWK?
adhesive
: 3M ART Part No. 8001 or No. 8011,

or equivalent
11. APPLICATION
QF GREASE TO DOOR LOWER HINGE /
10. DOOR UPPER HINGE
Supply specified grease from the grease holes of the door
hinges.
Specified
grease
: Multipurpose
No. 3
grease
NOTE
The nozzle of the grease gun should
tip.
SAE J310,
have a small-diameter
ADJUSTMENT
OF BACK DOOR INSTALLATION
Refer to P.23-17.
2.
INSTALLATION
Refer to GROUP
Carrier.
STB Revision
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OF SPARE
NLGI
TIRE CARRIER
22 WHEELS
AND
TIRES
- Spare
Tire
BODY - Back Door Trim
BACK DOOR TRIM

REMOVAL
AND
Removal
steps
4*
1.
2.
3.
4.
5.
6.
l *
N230BAB
INSTALLATION
Inside handle cover

Back door trim
Trim clip
Armrest
Tailgate trim (metal top-van)
Waterproof
film
,
:
NOTE
(2) ~~
4* : Refer to Service Points of Removal.
(3) ~)a
*a : Refer to Service Points of Installation
(4) l
: Clipping position
i.,
10w794

3.
REMOVAL
OF TRIM
CLIP
If trim clips remain at the door side when the back door
in the
trim is removed,
improvise
a tool (such as shown
figure) to remove them.

6.
APPLICATION
OF ADHESIVE
TO WATERPROOF
Apply specified
adhesive
at the positions
shown
illustration,
and then attach the waterproof
film.
Specified
adhesive
1 STB Revision
http://vnx.su/
FILM
in the
: 3M ART Part
No. 8626 or
Adhesive
3M
23-50
BODY - Back
Door
Handle
and
Latch
BACK DOOR HANDLE AND LATCH

REMOVAL
AND
INSTALLATION
N230CAA
18W795
Removal
+e
l +
~~
**
*I)
a*
a*
4*
steps
1. Back
Adjustment
2. Back
3. Back
4. Outside
5. Inside
6. Back
7. Back
door
trim and waterproof

of outside
handle
door garnish
bracket
door garnish
handle
handle
door latch
door lock actuator
film
NOTE
(2) q*
L
//
II I I
SERVICE POINTS
OF REMOVAL
REMOVAL
OF BACK
FILM
Refer to P.23-49.
DOOR
TRIM
AND
REMOVAL
OF BACK
DOOR
GARNISH
BACK DOOR GARNISH
Remove the back door garnish installation
and then remove the back door garnish.
http://vnx.su/
WATERPROOF
BRACKET/3.
nuts and bolts,
BODY - Back
4.
6.
Door
Handle
and
23-51
Latch
REMOVAL OF OUTSIDE
HANDLE
Disconnect
the outside
handle rod from
handle, and then remove the outside handle.
REMOVAL
OF BACK
LOCK ACTUATOR
DOOR
LATCHI7.
the
outside
BACK
DOOR
(1) Disconnect the outside lock rod and the inside lock rod
from the lock cylinder.
(2) Disconnect the actuator rod from the outside lock rod.
(3) Remove
(4) Remove
the back door latch together

the back door lock actuator.
with
the rods.
18W757
INSPECTION
BACK DOOR LOCK ACTUATOR

Connect the battery source to the actuator terminal, and check
the shaft for operation.
If the shaft moves in opposite direction
when the connection
polarity is changed, the actuator should
be considered to be in normal condition.
16WO46

ADJUSTMENT
Refer
OF OUTSIDE
HANDLE
to P.23-16.
1. INSTALLATION
PROOF FILM
Refer to P.23-49.
1 STB Revision
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OF BACK
DOOR
TRIM
AND
WATER-
:.
.
1
3,.
43
23-52
BODY - Back Door Lock Switch

REMOVAL
AND
INSTALLATION
II
1. Back door lock switch

NOTE
4*
: Refer to Service PointL3 I-4 ,D--nl,nv
ltil
I lUcl
,
\
SERVICE
IPOINTS
18iV802
OF REMOVAL
1. REMOVAL OF BACK DOOR LOCK SWITCH

(1) Pry off the switch by using the special tool and pull out the
switch from the meter hood.
(2) Disconnect
the connector from the back of the switch and
take out the switch.
INSPECTION
Operate the switch, and check
the continuity
between
the
terminals
16W974
J
OFF
LOCK
NOTE
0-C indicates that there is continuity between the terminals.
STB Revision
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BODY
Under
23-53
Guard
UNDER GUARD
REMOVAL
AND
Vehicles
with
transmission
INSTALLATION
N23WW
a manual
18-25
13-18
Nm
ft.lbs.
y13Nm
7-9 ft.lbs.
lo-13 Nm
7-9 ft.lbs.
Vehicles
with
transmission
l&l3
Nm
7-9 ftlbs.
18-25 Nm
13-18 ftlbs.
16W787
an automatic
IO-13 Nm
7-9 ft.lbs.
I.
2.
3.
4.
5.
Snow-protection
under
Under cover
Under skid plate
Transfer
case protector
Cross shaft protector
cover
l&l3
Nm
7-9 ft.lbs.
1 STB Revision
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~~
,r
23-54
BODY l- Mud Guard
MUD GUARD
REMOVAL
AND
INSTALLATION
NZBWBAA
1. Front mud guard

2. Rear mud guard
3. Mud guard bracket
18W779
( STB Revision
-1
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23-55
BODY - Loose Panel
LOOSE PANEL
REMOVAL
AND INSTALLATION
2.943
Waterproof
+e
l +
e+
NPJSAAC
ft.lbs.
pad and air duct
removal
steps
l + 12. Hood
latch
13. Hood catch bracket
14. Bridge
panel cover
1. Front fender
2. Waterproof
pad
3. Air duct
Front floor cover removal steps

(Vehicles with a manual transmission)
4*
4. Floor
5. Front
console
floor cover
Splash shield removal steps

15. Partial
l + 16. Splash
grille
grille
6.
8.
9.
10.
11.
Radiator
grille
Front combination
light
Head light bezel
Grille filler panel assembly
Hood catch stay
lip
17. Shield rubber

(Vehicles
tic transmission)
18. Shield
rubber
bracket
Bridge panel cover assembly removal steps
wheel
shield
Shield rubbers
Radiator grille bracket removal steps

6. Radiator
7. Radiator
assembly
assembly
Rear ventilator
with
an automa-
(Vehicles
without
cover
19. Rear ventilator

rear seat)
cover
NOTE
(2) +*
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23-56
BODY - Loose Panel

SERVICE POINTS
OF REMOVAL
1. RFMOVAL
OF FRONT
Rbfer to P.23-24.
FENDER
4.
CONSOLE
REMOVAL OF FLOOR
Refer to P.23-67.

16. INSTALLATION
OF SPLASH
Refer to P.23-24.
12. INSTALLATION
OF HOOD
Refer to P.23-20.
2. APPLICATION
OF SEALANT
Apply the specified
sealant
figure.
Specified
sealant
1. INSTALLATION
Refer
to P.23-25.
STB Revision
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SHIELD
LATCH
TO WATERPROOF
PAD
to the places marked in the
: 3M ART Part No. 8001 or No. 8011,

or equivalent
OF FRONT
FENDER
23-57
BODY - Bumpers
BUMPERS
REMOVAL
AND
INSTALLATION
(Front
N23ZBAB
Bumper)
18W820
1. Front
DISASSEMBLY
bumper
assembly
AND REASSEMBLY
Disassembly steps
1.
2.
3.
4.
NOTE
Reverse
Bumper
stay assembly
Front bumper
side
Bumper
guard (metal
Front bumper
center
the disassembly
procedures
/3
top-van)
to reassemble.
1 STB Revision
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23-58
BODY - Bumpers
REMOVAL
AND INSTALLATION
(Rear Bumper)
18W821
1. Rear bumper
DISASSEMBLY
Disassembly
AND REASSEMBLY
steps
1.
2.
3.
4.
5.
6.
7.
NOTE
Reverse
assembly
the
Rear
Rear
Rear
Rear
Side
Rear
Rear
bumper
bumper
bumper
bumper
bumper
bumper
bumper
disassembly
stay
reinforcement
plate
side
stay
stay
face
procedures
to
181772
reassemble
1 STB Revision
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23-59
BODY - Grille, Garnish
GRILLE, GARNISH
REMOVAL
AND
INSTALLATION
NZJRAAF
q
18W826
18W828
/,
18W827
rille removal
steps
1. Radiator
grille
2. Front combination
3. Headlight
bezel
light
Air outlet garnish removal

l 4
+*
4. Upper quarter
trim (metal top-van)
5. Rear ventilator
cover (except
for metal
top-van)
6. Air outlet garnish
NOTE
+*
: Refer to Service Points of Removal..
(1)
(2)

4.
REMOVAL
OF UPPER QUARTER TRIM
Refer to P.23-73.

4.
INSTALLATION
OF UPPER QUARTER
Refer to P.23-74.
1 STB Revision
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TRIM
?3-60
BODY
- Outside
Mirror
OUTSIDE MIRROR
REMOVAL
AND INSTALLATION
N23QBAB
18W789
1. Rearview
mirror
1 STB Revision
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BODY - Instrument
INSTRUMENT
Panel
PANEL
For installation
of the instrument
panel, the bolts, screws and nut described below are used.
They are indicated by symbols in the illustration in the section SERVICE POINTS OF REMOVAL.
/ STB Revision
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23-61
23-62
REMOVAL
BODY
AND
- Instrument
Panel
INSTALLATION
16
\-
19W690
Removal
12. Connection
of recirculation/fresh
air
changeover
control wire
13. Connection of mode selection control
wire
14. Connection
of water valve control wire
15. Center reinforcement
16. Horn pad
17. Steering wheel
18. Fuse box cover
19. Fuse box assembly
20. Instrument
panel
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Lap heater duct (B)

Lap heater duct (C)
Hood release cable bracket
Demister
grille (L.H.)
Demister grille (R.H.)
Glove box
Meter cover
Meter case
Combination
meter pad
Combination
meter case
Center panel
4*
4*
+*
NOTE
(1)
(2)
(3)
/ STB Revision
*4

40 : Refer to Service Points
I)*
: Refer to Service Points
-1
http://vnx.su/
to reinstall.
of Removal.
of Installation
BODY - Instrument
SERVICE
23-63
Panel
POINTS
OF REMOVAL
1. REMOVAL
OF LAP HEATER DUCT (B)/3.HOOD
RELEASE
CABLE BRACKET
Remove the lap heater duct B and hood release cable
bracket.
4.
REMOVAL
OF DEMISTER
GRILLE (L.H.) /5. DEMISTEb.
i,,:
GRILLE (R.H.)
.
Remove the right and left demister
grilles by raising the<
5;
attaching
projections
with a screwdriver.
t..
Caution
Use care not to break
6.
REMOVAL
(1) Remove
(2) Remove
the
projections.
OF GLOVE BOX
the glove box stopper.
side lap heater duct(C) on the assistants
,,..:
seat.
(3) Remove the glove box frame attaching

screws from
the instrument
panel and remove the glove box.
19W52(
7.
REMOVAL
OF METER COVER
Remove the meter cover with a screwdriver.
19W66:
1 STB Revision
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23-64
BODY - Instrument
Panel
8. REMOVAL
OF METER
(1) Remove
(2) Remove
CASE
the screws from the bottom

of the case.
the bolt from the upper part of the case.
(3) Disconnect
the speedometer
cable from the meter
case by pushing
the stopper
of the plug on the
speedometer
cable side of the connection.
(4) Disconnect
the connectors
of the meter harness and
also of the body harness.
(5) Disconnect
the connectors
(all located
behind the
meter case at the bottom)
of the hazard switch, the
rear window defogger,
rear fog lamp switch, electric
tailgate
locking
switch,
and the rear wiper/washer
switch, and then remove the meter case.
9.
F~EMOVAL 0F COMBINATION
METER
Remove the combination
meter pad.
10. REMOVAL
OF COMBINATION
METER
PAD
CASE
(1) Remove the meter case attaching

screws.
(2) Disconnect
the connectors
of the meter
located behind the meter case.
harness
Caution
To prevent internal
trouble,
the meter must not be
dropped
or subjected
to shock or must
not be
abruptly
inclined
to the extent that the maximum
indication
angle is exceeded.
19WE14
15. REMOVAL
OF CENTER
REINFORCEMENT
(1) Remove
the center console.
(Refer to P.23-66.)
(2) Remove
the center reinforcement
attaching
screws.
(3) Remove the center reinforcement,
radio and car stereo
player as a unit.
(4) Disconnect
the radio and car stereo player from the
front harness and feader wire.
wision
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BODY - Instrument
23-65
Panel
N23UAAE
17. REMOVAL
OF STEERING
WHEEL
Remove the steering wheel.
NOTE
Before removal, make the mating
shaft and steering wheel.
marks
on both steering
20. REMOVAL
OF INSTRUMENT
PANEL
Remove the instrument
panel attaching
bolts and nuts,
and withdraw
and remove the instrument
panel toward
you.
SERVICE
POINTS
20. INSTALLATION
OF INSTRUMENT
all of the connectors
(1) Connect
(2) Make sure
19w701
DISASSEMBLY
OF INSTALLATION
that
PANEL
securely.
any of the wiring
harnesses
pinched.
:,;
b.
! ;rI:*
I..
AND REASSEMBLY
lQW692
1.
2.
3.
4.
5.
are not
Assist grip
Instrument
pad B
Switch holder
Instrument
pad A
Instrument
panel
1 STB Revision
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23-66
BODY - Center Console
CENTER CONSOLE
REMOVAL
AND
INSTALLATION
N23UBAD
Removal steps
1. Knob
2. Plug
3. Center panel
4. Connection
of center
panel wiring
harness to front wiring
harness. connector
NOTE
DISASSEMBLY
to reinstall.
AND REASSEMBLY
N23UBAE
7
Disassembly steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
IO.
11.
12.
Plug
Center panel pad
Cigarette
lighter
Clock (Vehicles
with a clock)
Ashtray
Ashtray
bracket
Cigarette
lighter
bracket
Lamp holder
Heater control
panel
Center panel wiring
harness
Box panel
Center panel
19W695
NOTE
Reverse
( STB Revision
the disassembly
http://vnx.su/
procedures
to reassemble.
BODY - Floor
23-67
Console
FLOOR CONSOLE
REMOVAL
AND INSTALLATION
Vehicles
manual
Removal
Vehicles
automatic
with a
transmission
with an
transmission
,1
I?
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
Front floor console

Plate B
Rear console
panel
Inner box
Lid assembly
Floor console
Rear floor console
Console
inner bracket
Floor console
bracket
NOTE
19W696
to reinstall.
1 STB Revision
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23-68
BODY
- Headlining
HEADLINING
AND ASSIST STRAP
REMOVAL
INSTALLATION
AND
and Assist Strap
NZBUDAF
19W669
Assist
strap
1. Assist
2. Assist
3. Hook
strap
grip
a*
40
+O
~~
l +
10. Rear roof rail trim

11. Rear headlining
12. Front headlining
(metal
top-van)
Headlinings removal steps
l *
1.
4.
5.
6.
Assist strap
Door opening
trim
Front side roof rail trim (metal top-van)
Inside rear view mirror
7. Sun visor
8. Front roof rail trim (metal top-van)
9. Rear opening
trim
INOTE
(2) 4*
1 STB Revision
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BODY
Headlining
and
Assist
23-69
Strap

5.
REMOVAL
OF FRONT
SIDE ROOF RAIL TRIM
Refer to P.23-72.
8.
REMOVAL
OF FRONT
ROOF RAIL TRIM
Refer to P.23-72.
10. REMOVAL OF REAR ROOF RAIL TRIM

Refer to P.23-73.
11. REMOVAL
OF REAR HEADLINING/12.
ING
(1) Remove the dome light.
(2) Slowly peel the headlining
away,
corner of the roof panel.
FRONT
HEADLIN-
beginning
with
the
Caution
Make sure that the headlining
is removed slowly;
the sponge portion of the headlining
is left behind
the roof panel.
as
on
(3) Thoroughly
remove the drying sealant and sponge left
behind on the roof panel by using a toluol solution, etc.
Caution
Make sure that all remaining
sealant and sponge are
thoroughly
removed,
as they produce
uneven surfaces when the headlining
is bonded
to the roof
panel.
1 STB Revision
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23-70
BODY - Headlining
and
Assist
Strap

lZ./dPPLICATION
OF SEALANT
1~1.REAR HEADLINING
(1) Evenly apply the specified
When the headlining
(rear)
dome light connector,
put
lining, and bond the lining
matches the dome light
Specified
sealant
TO FRONT
HEADLINING/
sealant to the roof panel.

is installed, couple the room
it through the cut hole in the
so that the lining cut hole
attaching
hole.
: 3M ART
Adhesive
Part No. 8080 or 3M

(2) Using care to prevent wrinkles and slackness, bond the

1 headlining
and insert the edges securely into the roof
~ panel flange by using a spatula, etc.
(3) Bond the headlining

Headlining
\
Roof
panel
flange
10w547
(front)
Dome
Headlining
light
(rear)
1ew540
1 STB Revision
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edges as shown.
23-7 1
BODY - Trims
TRIMS
REMOVAL
AND
INSTALLATION
N23UCAF
6
I
18
10
Front
4*
4,. . ,4
4*
Cowl
. Center
4*
t Quarter
4*
pillar
1.
2.
3.
4.
5.
6.
7.
8.
trim
and roof rail trim
removal
removal
steps
1. Front scuff plate

2. Door opening trim
9. Cowl side trim
pillar
I,
2.
10.
11.
trim
trim
removal
10. Ashtray
12. Quarter
steps
(metal
trim
Rear wheelhouse
~~
only)
top-van)
trim
l + 13. Rear wheelhouse
Upper
quarter
trim
removal
trim (metal top-van)

steps
2.
12.
14.
15.
16.
41) l + 17.
Door opening trim

Quarter trim
Assist grip
Front seat belt anchor plate
Rear opening trim
Upper quarter trim (metal top-van)
Rear
rail
4*
steps
Front scuff plate

Door opening trim
Ashtray (metal top-van)
Center Pillar trim
removal
side
steps
Front scuff plate

Door opening trim
Assist grip
Front side roof rail trim
Front pillar trim (metal top-van)
Inside rear view mirror
Sun visor
Front roof rail trim
side trim
(Left
roof
Rear pillar
4,
lower
http://vnx.su/
trim
removal
steps
12. Quarter trim

16. Rear opening trim
19. Rear pillar lower trim (metal top-van)
NOTE
(1)
Reverse
the
(2)
++
: Refer
(3)
l + : Refer
1 ST6 Revision
trim
18. Rear roof rail trim
removal
procedures
to Service
Points
to Service
Points
to reinstall.
of Removal.
of Installation
23-72
BODY - Trims
dlining
Cross section
marked
4.
REMOVAL
OF FRONT SIDE ROOF RAIL TRIM
Remove the front side roof rail trim
5.
REMOVAL
OF FRONT PILLAR
Remove the front pillar trim.
8.
REMOVAL
OF FRONT ROOF RAIL TRIM
Remove the front roof rail trim
9.
REMOVAL
C
lQW64C
portion I-
Cross section of
portion marked C
Headlining
Front roof rail trim
Front roof rail
TRIM
1QW641
OF COWL
SIDE TRIM
(1) Insert
a special tool under

remove the clips.
(2) Remove the cowl side trim.
portion
marked-
t:he cowl
side
trim
and
11. REMOVAL
OF CENTER PILLAR TRIM
(1) On vehicles with cassette stereo player, remove the
rear speaker. (Refer to GROUP 8 ELECTRICAL-Radio
and Stereo.)
(2) Remove the clips at two places (upper and lower) at
the foremost
part of the quarter trim.
(3) Insert the tip of a flat-tip (-) screwdriver or similar tool
beneath the center pillar trim and cut the top part of
the clips.
NOTE
When cutting
body panel.
/evision
http://vnx.su/
the clips,
be careful
not to scratch
the
23-73
BODY - Trims
3oss section
narked C
of portion
12. REMOVAL
OF QUARTER
TRIM
Insert the tip of a flat-tip (-) screwdriver

or similar tool
beneath the quarter trim and cut the top part of the clips.
NOTE
When cutting
panel.
the clips, be careful not to scratch
the body
19W552
13. REMOVAL
OF REAR WHEELHOUSE
TRIM
(3) Remove the rear seat. (Rear to P.23-77.)
(2) Remove the hooks and the rear wheelhouse
Cross section of
portion marked e
Uppe;
trim
Cross section of
portion marked e
trim.
17. REMOVAL
OF UPPER QUARTER TRIM
(1) Insert the special tool under the upper quarter
remove the clips.
(2) Remove the upper quarter trim.
quarter
lBW544
18. REMOVAL
OF REAR ROOF RAIL TRIM
Remove the rear roof rail trim.
774
1 STB Revision
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trim and
,
.:
23-74
BODY - Trims
19. REMOVAL
OF REAR PILLAR
LOWER
TRIM
(I)
Remove the clips at 2 places at the rear part of the

quarter trim and the 2 clips at the rear pillar part of the
upper quarter trim.
(2) Remove the clip to remove the rear pillar lower trim.
,-w
I
a
L
SERVICE
Clip
-
POINTS
17. INSTALLATION
Long
hole
OF INSTALLATION
OF UPPER
QUARTER
TRIM
When attaching
clips to the upper quarter trim, attach so
that the clip is at a right angle relative to the long hole of
the body panel.
19W630
19W627
13. INSTALLATION
OF REAR WHEELHOUSE
Install the rear wheelhouse

on top of it.
5.
trim
TRIM
with the cargo floor mat
INSTALLATION
OF FRONT PILLAR TRIM
When attaching
clips to the front pillar trim, attach so that
the
clap
IS
at
a
right
angle relative to the long hole 0 f the
front IlIar,
STB Revision
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BODY - Front
23-75
Seats
FRONT SEATS
DISASSEMBLY
N23UEAD
AND REASSEMBLY
Suspension
seat
Normal
seat (L.H.)
45-60
33-43
Nm
ft.lbs.
35-55
Nm
.I,. -,
35-55
25-40
Nm
ft.lbs.
Normal
seat (R.H.)
33-43
Disassembly
e+
l +
ftlbs.
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
Parallel
link assembly
Seat support
bracket
Suspension
seat assembly
Seat adjuster
Adjuster
cover
Reclining
lever knob
Front seatback
Head restraint
Front seat cushion
35-55
25-40
Nm
ft.lbs.
NOTE
(1)
1 STB Revision
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procedures
to reassemble.
23-76
BODY - Front

4.
APPLICATION
OF GREASE TO SEAT ADJUSTER/l.
PARALLEL LONK ASSEMBLY
(1) Apply the specified grease to the following points.
I
I
links
Specified
0
0
0
Sliding
Sliding
Sliding
grease
: Multipurpose
NLGI No. 2
grease
WE
5310,
parts of seat adjusters

parts of parallel links
parts of reclining adjusters
(2) After the seat has been installed, check to ensure that
the seat adjusters lock at all lock positions when the
seatback is moved slowly.
(3) Check to ensure that the forward folding and return
mechanisms
of the parallel links operate smoothly
and
lock securely.
Seat adjusters
Parallel
Seats
lQW693
INS+ECTION
l
l
l
l
l
l
l
l
Check
Check
Check
Check
Check
Check
damage
Check
Check
the springs for damage and deterioration.

the shock absorber for noise and fluid leaks.
the all tightened
points for looseness.
the rollers for noise and damage.
the links for cracks, bending or dents.
the body weight
adjusting
handle
for
or looseness.
the lock lever for bends and damage.
the damper rubber for cracks and damage.
1 STB Revision
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bends,
23-77
BODY - Rear Seat
REAR SEAT
DISASSEMBLY
AND REASSEMBLY
N23UFAF
33-43 ft.lbs.
Disassembly steps
19W684
l +
1.
2.
3.
4.
Rear seat leg bracket

Reclining
cover
Rear seatback
Rear seat cushion
NOTE
(I) Reverse the disassembly
procedures
to reassemble

1. APPLICATION
OF GREASE TO REAR LEG BRACKET

Specified
Rear seat stopper

striker
19w510
grease
grease to the following

: Multipurpose
No. 2
place.
0 Sliding part of rear seat leg bracket

0 Contacting
part of rear seat stopper striker
(2) After the seat has been installed, check to ensure that the
lock release, forward-down,
folding
and return mechanisms all operate smoothly.
(3) Check to ensure that when the seat cushion is folded, the
leg bracket locks securely.
1 STB Revision
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23-78
BODY - Seat Belts
SEAT BELTS
REMOVAL
AND
(Front ~seat belts)
INSTALLATION
35-55
Nm
N23UGAD
35-55 Nm
25-40 ft.lbs.
-------
19W699
Removal
steps
l *
1.
2.
3.
4.
+e
l +
I)+
pillar trim
Center
Sash guide cover
Front seat belt assembly
Connection
of seat belt
tor
5. Buckle stalk
35-55 Nm
25-40 ft.lbs.
switch
connec-
NoTE
(2) 4*
SERVICE
POINTS OF REMOVAL
1. REMOVAL
OF CENTER
Refer to P.23-72.
3.
REMOVAL
OF FRONT
Caution
Special
bolts (l-in.
mounting
bolts.
Do not disassemble
SERVICE POINTS
5.
PILLAR
TRIM
SEAT BELT ASSEMBLY
bolts)
are used
for
http://vnx.su/
seat
belt
the retractor.
OF INSTALLATION
INSTALLATION
OF BUCKLE STALK
Install the seat belt buckle stalk in parallel
line of the vehicle.
evision
the
with the center
23-79
BODY - Seat Belts

3. INSTALLATION
Anchor
plate
REMOVAL
l +
AND INSTALLATION
1. Rear
seat
OF FRONT SEAT BELT ASSEMBLY
(1) Fit the anti-rotation

stopper pin of the webbing into the
hole of the side sill.
(2) Fit the anchor plate anti-turning
boss positively
in the
retractor side hole and jointly tighten the retractor and
anchor plate.
(Rear seat belts)
19W602
belt
35-55 Nm
25-40 ft.lbs.
NOTE
Paral

1. INSTALLATION
OF REAR SEAT BELT
Position the anchor plates at the center of the vehicle so
that the belts are parallel to the vehicle center line, and
then secure the plates with the bolts.
NOTE
After tightening
the bolts, securely
mount
covers for the inner end of the seat belts.
Caution
Special
bolts (l-in.
mounting
bolts.
/ STB Revision
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bolts)
are used
for the
the
anchor
seat
belt
._ -..
23-80
BODY - Seat Belts

SEAT BELT WARNING
light
Buzzer
OFF
ON-
SYSTEM
When the seat belt switch in ON (seat belts not buckled) with
the i$nition key in the ON position, the seat belt warning timer
caus& the seat bel-t warning light to illuminate
and the buzzer
to sobnd for 4 to 8 seconds. If the seat belts switch is set to
OFF (the seat belts buckled) during the seat belt warning timer
interval, only the buzzer is cancelled.
4,to
8 set
I
16Y1805
SYSTEM
INSPECTION
1. Disconnect the seat belt warning timer connector.
2. When the YG wire (terminal 2) and B wire (terminal
3) are
connected
with a jumper wire, the seat belt warning light
should illuminate.
If it fails to illuminate,
check the bulb,
key-reminder
switch and fuse.
3. Also the buzzer should sound when the RB wire (terminal
4)l and B wire (terminal
3) are connected
with a jumper
wire. In this condition,
fasten the buckle;
if the buzzer
stops sounding, the seat belt switch is good.
.,
16C953
3
L
18UO385
4.
If the buzzer does not sound when terminal 3 and terminal

4 are connected
with a jumper wire, check continuity
of
the seat belt switch. If there is continuity
in the seat belt
switch, replace the buzzer.
I Terminal
Buckle unlock
1 Buckle lock
16UO368
+o
I
I
NOTE
0-C
indicates
that there
is continuity
between the terminal.
5. After performing
the above inspections,
reconnect the seat
belt warning timer.
6. With the ignition switch turned to IG, verify the function of
the seat belt warning system.
/ STB Revision
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..-.
BODY - Seat
23-81
Belts
SEAT BELT EXTENDER

The seat belt extender
as described below will provide
additional seat belt length that the vehicle seat belt is not long
enough for a person.
Seat belt extender
B
Type
Part number
M B544777
lQW666
:
Caution
1. The seat belt extender is intended for use only when the
seat belt is not long enough to fit around an occupant.
It
must be renioved and stowed when not required by that
occupant.
2. Incorrect
use of seat belt extender
or other extender
which is not specified
may result in serious injury.
SEAT
hide
seat belt
BELT
EXTENDER
INSTRUCTIONS
1. To use the extender, insert and latch the tip of the vehicle
seat belt in the buckle of the extender.
19W668
Vehicle
2. The tip of the extender is then inserted and latched in the

buckle end of the vehicle seat belt.
seat belt
Seat belt extender
FTB
Revision
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6;
13-1
NMENT
FRAME ALI
!(
CONTENTS
BODY DIMENSIONS
AND MEASUREMENT
METHODS
. . . .. . . . . . . . . . . . .. .. . . . . . . .. . . . . . . . . . . .. . . . . . . . . .. .. . . . . . .
. . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . . . .. . .
Body Center Points
TYPE A (PROJECTED
2
3
How Body Dimensions
Are Indicated
Indication of Reference
Measurement
Methods
Dimensions
. . . . . . .. . . . . . . . . .. .. . . . . . .. . . .
. . .. .. . . . . . . . . .. . . . . . . . . .. . . . . . . .. .. . .
3
2
FRAME CENTERING
GAGE INSTALLATION
POSITIONS
. . . . . . .. . . . . . . . . . .. .. . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. . . . .
Measurement
Points
. . . . . . .. . . .
. . . . . . . . .. . . .
NlBAA-
2
2
DIMENSIONS)
.. . . . . . . .. . . . . .
<
1,
c
I
TYPE B (ACTUAL-MEASUREMENT
....................................................
DIMENSIONS)
......................................
Engine Compartment
.............................................................
Interior
http://vnx.su/
Side Body
........................................................
Upper Body .....................................................
10
12
16
16
12
13-2
BODY AND
FRAME
mm (in.)
ALIGNMENT
Bodv
Dimensions
and
Measurement
Methods
MEASURE-
BODY DIMENSIONS
MENT METHODS
AND
HOW BODY DIMENSIONS
ARE INDICATED
(1) Type A (projected dimensions)

These dimensions
are the dimensions
measured
measurement
points are projected
into the
plane.
These dimensions
are the reference dimensions
body alterations.
(2) Type B (actual-measurement
dimensions)
These dimensions
indicate
the actual linear
between
measurement
points,
and are the
dimensions
for use if a tracking gage is used for
ments
NOTE
The units given for the dimensions
are mm (in.).
INDICATION
OF REFERENCE
NlOGAAC
when the
reference
used for
distance
reference
measure-
of both types (A and B)
DIMENSIONS
If the reference dimension

number (in a circle) shown on the
top line of the dimension
table at left is marked
with *,
measurements
are taken of this dimension
and another which
are symmetrical
with respect to the car centerline.
32WO65
MEASUREMENT
Hecenu.
POINTS
Measurement
points are used to indicate the following:
(1) Hole centers
If a measurement
is to be made at a hole center, the point
of the surface from which the measuring
instrument
is
applied is the measurement
point.
-+
Q
I
yiIr....
Hole civmference
(2) Hole circumferences

If a measurement
is to be made at the circumference
of a
hole, the point of the hole circumference
of the surface
from which the measuring
instrument
is applied
is the
measurement
point.
..
32UO13:
/
svision
I
http://vnx.su/
BODY AND
FRAME
ALIGNMENT
Body
Dimensions
MEASUREMENT
ww)
and
gage
13-3
Methods
METHODS
NOTE
Make sure that the tracking
between its body and probes.
robe
Measurement
(using
used
a tracking
is free from
play
(1) Type A (projected

dimensions)
If the length of the tracking gage probes are adjustable,
make the measurement
by lengthening
one probe by the
amount equivalent
to the difference
in height of the two
surfaces.
32UO141
(2) Type B (actual-measurement

Measure by first adjusting
(A = A)
dimensions)
both probes to the same length
,:(*
j
!
2UO142
(3) If hole diameters

are same and the probes are conical
For both Type A and Type B, insert the probes into the
holes, and then make the measurement.
This method of
measurement
should be used if the diameters
of the holes
in the location to be measured are the same.
(4) If hole diameters
are different, or the probes are pointed
Because measurement
at the hole centers is impossible,
the circumferences
must be used instead.
How $0 Determine
I
Dimensions
1Hole circumference
Desired
L=
dimensions:
Example:
Reference
Measured
e+y
1 = 600 (23.6)
D = 20 (.79)
d = 10(.39)
Desired measu
+ 20(.79);10(.39)
= 605 (23.8)
32110144
BODY CENTER POINTS

When measuring
locations that should be symmetrical
left and
right and there are no specific instructions
with regard to
measurements
in Body Dimensions,
the body center points
should be used to confirm that the left and right measurements from these points are the same. One body center point
is specified for the front of the body and another is specified
for the rear.
3lUo130
svision
http://vnx.su/
Z~
%
dimensions:
L = 600(23,6)
Body center point
.,
mm (in.)
dimensions:
hole diameters:
Desired
;:
;.:
13-4
BODY AND
FRAME
FRAME CENTERING
ALIGNMENT
Frame
Centering
GAGE INSTALLATIIQN
Mount the frame centering

gages
bend and torsion of the body.
indicated
at locations
Frame centering
gage
in illustration
Gage
Installation
Positions
POSITIONS
N13HA-
to check for horizontal
and vertical
y
mm (in.)
32WO53
32WO52
NOTE
Dimensions shown
the panel thickness.
in the side view are the distances
from the bottom
end of the panel at each measurement
1 STB Revision
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point, not including
BODY AND
FRAME
ALIGNMENT
Frame
Centering
Gage
Installation
Positions
13-5
31
15w512
Center of body mounting

: 30 mm (1.18 in.)]
hole [diameter

: 32 mm (1.26 in.)]
hole [diameter

: 32 mm (1.26 in.)]
hole [diameter
1 STB Revision
http://vnx.su/

: 32 mm (1.26 in.)]
hole [diameter
http://vnx.su/
;.
.._
TYPE A (PROJECTED DIMENSIONS)
(l/2)
NlUA-
mm (in.)
32WO52
32WO53
BODY AND
FRAME
ALIG
ENT - Type A (Projected
1 STB Revision
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Dimensions)
13-7
http://vnx.su/
TYPE A (PROJECTED DIMENSIONS)
:-
(2/2)
mm (in.)
Y AND
FRAME
ALIGNMENT
Type
A (Projected
Dimensions)
13-9
%k
&g
Fs
se
1 STB Revision
/
http://vnx.su/
http://vnx.su/
710
(27.95)
(41.36)
1,051
No.
Length
No.
Length
(45.28)
1,150
817
(32.16)
@)*
(65.23)
1,657
o*
762
(30.00)
@*
(60.75)
1,543
a*
840
(33.07)
(44.42)
1,128
1,031
(40.58)
a*
(50.39)
1,280
707
(27.84)
a*
(41.44)
1,053
CT
522
(20.55)
TYPE B (ACTUAL-MEASUREMENT
@*
(9.53)
242
a*
959
(37.77)
(3??8)
758
(29.83)
a*
870
(34.25)
@
695
(27.38)
o*
DIMENSIONS)
0
439
(17.28)
@I*
1,344
(52.90)
a*
1,031
(40.59)
43
266
(10.47)
1,251
(49.23)
Nl3KA.m
0
(I+:&
$3
(3y;l)
8
1262
(4b.68)
1598
(6i.93)
CD*
mm (in.)
BODY
AND
FRAME
if?
5.
VD
ALIGNMENT
1 STB Revision
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Type
B (Act&measurement
Dimensions)
13-11
13-12
BODY AND FRAME ALIGNMENT
- Type
1 STB Revision
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B (Actual-measurement
Dimensions)
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5 (Body center
Front
pillar
lower
part
of accelerator
C enter
hi ale [diameter
: 9 mm
I L
I
I -
Hole in top of headlamp

ter : 6.6 mm (.26 in.)]
[diame-
cable
mounting
(.35 in.)]
point)
support
of roof
10I
Joint
and
Center
of fender
ter : 6.6 mm (.26
I6
front
pillar
mounting
in.)]
Center
of fender
mounting
ter : 9 mm (.35 in.)]
hole
hole
[ diame-
[diame-
Joint
-I11
Headlight
of side
roof
mounting
Center
of fender
ter : 6.6 mm (.26
rail
and
hole
mounting
in.)]
quarter
hole
panel
[diame-
of
of
Body center
eter : 5 mm
mounting
in.)]
point)
point reference
(.20 in.)]
center
hole
front
fender
mounting
: 10 mm (.39 in.)]
weatherstrip
: 5.5 mm (.22
12 (Body
Center
[diameter
Center
[diameter
[ diam-
hole
hole
13-14
- Type
6 (Actual-measurement
Dimensions)
--z
\
\
\
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m
0
~a------
BODY AND
FRAME
ALIGNMENT
Type
Dimensions)
13-15
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13-16
TvDe B (Actual-measurement
n?I
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Dimensions)
BODY AND
FRAME
ALIGNMENT
Type
0al
6
3
#
1 STB Revision
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Dimensions)
13-17
GROUP/SECTION
INDEX kme-.
Service Manual
..............................
INTRODUCTION
MONTERO
...........................................
Electrical
1987 : Volume
Electrical System Parts

Location .........................................
Relays, Control Units, Sensors,
Fuses, Groundings
Inspection of Harness
......................................
Connector
.............................
Wiring Harness
Charging
FOREWORD
This Service Manual has been prepared with the
latest service information
available at the time of
publication.
It is subdivided
into various group
categories
and each section contains
diagnosis,
procedures
disassembly,
repair, and installation
along with complete
specifications
and tightening
references.
Use of this manual will aid in properly
performing
any servicing necessary to maintain
or
restore the high levels of performance
and reliability
designed into these outstanding
vehicles.
..........................
System
Starting
System
............................
Ignition
System
.............................
Meters and Gauges

Lighting
......................
.............................
System
Wiper and Washer System

Horn
..........
...............................................
Accessory
......................................
Audio System
................................
Back Door Window Defogger ......

Automatic
Free-wheeling
Hub
..........................
Indicator System
WE SUPPORT
VOLUNTARY
TECHNICIAN
CERTIFICATION
THROUGH
Heaters and Air-conditioning

Heaters
.........
..........................................
Air-conditioning
............................
MITSUBISHI
MOTOR SALES
OF AMERICA.
Inc.
Mitsubishi
Motors
corporation
reserves
the right to make changes
in
design or to make additions
to or improvements
in its products without
imposing
any obligations
upon itself to install them on its products
previously
manufactured.
0 1986 Mitsubishi
Motors
Corporation
Printed
For Engine
**,
in Japan
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Chassis
& Body
refer
to
INTRODUCTION
HOW TO USE THIS MANUAL
NOOBAAK
CONTENTS
The preceding
page contains
the GROUP
which lists the group title and group number.
INDEX
PAGE NUMBERS
All page numbers
consist of two sets of digits
separated by a dash. The digits preceding the dash
identify the number of the group. The digits following the dash represent
the consecutive
page
number within the group.
The page numbers can
be found on the top left or right of each page.
piiiKL=lIndicates
TEXT
Unless otherwise specified, each service procedure
covers all models.
Procedures
covering specific
models are identified by the model codes, or similar
designation
(engine type, transmission
type, etc.).
A description
of these designations
is covered in
this unit under VEHICLE IDENTIFICATION.
SERVICE
PROCEDURES
Installation steps This is provided
OF TERMS
Reassembly
STANDARD
VALUE
Indicates the value used as the standard for judging
the quality of a part or assembly on inspection
or the
value to which the part or assembly is corrected and
adjusted.
It is given by tolerance.
operation
Removal steps : The numbers before part names

correspond
to numbers in the illustration and indicate the order of
removal.
Disassembly steps : The numbers
before
part
names correspond to numbers
in the illustration, and indicate
the order of disassembly.
The service steps are arranged in numerical

order
and attentions
to be paid in performing
vehicle service are described in detail in SERVICE POINTS.
DEFINITION
incidental
if installation
order of Removal steps; omitted if installation in the reverse
order of Removal
steps is
possible.
.
steps : I his IS provided It reassembly
order of Disassembly
steps;
omitted if reassembly
in the
reverse order of Disassembly
steps is possible.
LIMIT
Shows the standard for judging the quality of a part
or assembly on inspection and means the maximum
or minimum
value within which the part or assembly
must be kept functionally
or in strength.
It is a value
established
outside the range of standard value.
http://vnx.su/
Classification of
SERVICE ROINTS
Oe : Removal
**
: Installation
Oe : Disassembly
I)+ : Reassembly
Page number
INTRODUCTION
Group title
Section title
THERMOSTAT
REMOVAL
AND
INSTALLATION
1 torque
-L
0480031
Thermostat
kit
Repair
kit or set
parts
are
Removal
+
I s
B~C
1. Connectw
of water
temperature
switch
connector
(Vehicles
with an air condltloneri
2 Connection
of radiator
upper
hose
3 Water
outlet
fitting
4 Water
outlet
fitting
gasket
5. Thermostat
This number corresponds

to
the number
in Removal
steps, Disassembly
steps, Installation
steps
or Reassembly steps.
NOTE
to reinstall
12) l * : Refer to Sewce
Points of Installation
Nowreusable
parts
(3) q
-r
SERVICE
45.
POINTS
OF lNSTALLATlON--
INSTALLATION
Install
the
OF
thermostat
Caution
The
thermostat
ensure
that
the
THERMOSTAT
to the
flange
thermostat
fits
Intake
over
is not
manifold
as illustrated.
the
manifold
installed
at an
seat;
angle.
An explanation
of procedures,
notes, etc.
regarding removal installation
disassembly
(and reassembly.
-1
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INTRODUCTION
Vehicle
Identification
VEHlCLE IDENTIFICATION
&LE
IDENTIFICATION
NUMBER
LOCATIOyo(lcAmm
The vehicle identification

number (V.I.N.) is located
attached to the left top side of the instrument
panel.
VEHICLE
lDENTlFlCATlON
All vehicle identification

number is a code which
\
6th
digit
Country
Make
JJapan
AMitsubishi
Vehicle
type
4-
Multipurpose
vehicle
(MPW
CODE CHART PLATEo,,.,
numbers
contain 17 digits.
tells country, make, vehicle
7th
digit
8th
digit
9th
digit
10th
digit
Price
class
Body
Engine
Check
digit
Model
year
JF4001 Ibs. MON-
2-
3-
Low
or more TERO
with
hydraulic
brakes
4-
3-door
metaltop or
van
E2.6 liters
(155.9
C.I.D.)
Line
High
0
1
2
3
on a plate
Plant
The vehicle
type, etc.
1 ZZ-Zer
H1987
year
7-Truck
9
X
NOTE
*Check digit means a single number or letter X used to verify the accuracy of transcription of vehicle indentification
number.
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INTRODUCTION
VEHICLE
IDENTIFICATION
NUMBER
- Vehicle Identification
LIST
FEDERAL
NOOCC-
number)
Model code
Engine displacement
Brand
L042GVNJLF
L042GVRJLF
JA4FJ43EoHJ
JA4FJ43EoHJ
MITSUBISHI
JA7FJ23EoHJ
MONTERO
2.555 liters
(155.9 C.I.D.)
L042GTNSLF
L042GTRSLF
JA7FJ23EoHJ
CALIFORNIA
(Can also be sold in Federal
number)
states.)
Model code
Engine displacement
Brand
L042GVNJLH
JA4FJ43EoHJ
JA4FJ43EoHJ
JA7FJ23EoHJ
L042GVRJLH
2.555 liters
MITSUBISHI
MONTERO
L042GTNSLH
(155.9 C.I.D.)
1 L042GTNSLH
JB7FJ23EoHJ
VEHICLE
INFORMATION
CODE PLATE
Vehicle information
code plate is riveted
port panel in the engine compartment.
The plate shows
model code, engine
model, and body color code.
1.
MODEL
L042G
2.
ENGINE
G54B
on the headlight
model,
Engine
COLOR,
transmission
model
KM145
TRANS
AXLE
Transaxle
4.
sup-
VNJLF
I
3.
NOOCO-A
TRIM
OPT
model
876
Montone
exterior
color code
OOK520
B2 1 B76H43
Two-tone
color code
Exterior code
Two-tone
exterior is shown
by the
exterior code followed
by the two
color codes.
._:
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INTRODUCTION
- Vehicle
Identification
CHASSIS
NUMBER
STAMPING
LOCATION
NOOCE-A
The chassis
number is stamped
the right rear shock absorber.
CHASSIS
NUMBER
on the side of the frame
near
CODE CHART
LO4
HJOOOOOl
VEHICLE
SAFETY CERTIFICATION
LABEL
NOOCF-
The vehicle safety certification

label is attached
to face of left
door pillar.
This label indicates
the month and year of manufacture,
Gross
Vehicle Weight
Rating (G.V.W.R.),
front and rear Gross Axle
Weight
Rating (G.A.W.R.),
and Vehicle Identification
Number
(V.I.N.).
ENGINE
MODEL STAMPING
NOOCG-
The engine model number is stamped

at the right front side on
the top edge of the cylinder block as shown
in the following:
1 Engine model
1 Engine displacement
1 2.555 liters (155.9 C.I.D.)
The engine serial number

is stamped
number, and the serial number cycles,
Engine serial number
Number
near the engine

as shown
below
model
cycling
AA020toYY=
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j . f
.,,.
..-.
INTRODUCTION
- Vehicle
Identification
BODY COLOR CODE
NOOCH-
Body color
Exterior code
Monotone
B76
Cl9
Brown
H43
Silver (Metallic)
R52
Red
s70
x15
Beige
(Metallic)
Black
Two-tone
B21 B76H43
Silver (Metallic)/
C38C19X13
Black/
Brown (Metallic)
H15H43X13
Black/
Silver (Metallic)
R06R52X13
Black/Red
S69S7OX13
Black/Beige
X45X1 5H43
Black/
Silver (Metallic)
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INTRODUCTION
- Precautions Before Service
PRECAUTIONS
PROTECTIN
BEFORE SERVICE
THE VEHICLE
NOODAAC
If theIre is a likelihood
of damaging
painted or interior parts
during service operations,
protect them with suitable covers
(such as seat covers. fender covers, etc.).
REMOVAL
AND DISASSEMBLY
When checking a malfunction,

find the cause of the problem.
If it is determined
that removal and/or disassembly
is necessary, perform the work by following the procedures
contained
in this, Workshop
Manual.
oorn,
FOOOl;
If punch marks or mating marks are made to avoid error in

assembly
and facilitate the assembly
work, be sure to make
them in locations
which will have no detrimental
effect on
performance
and/or appearances.
If an area having many parts, similar parts, and/or parts which
are symmetrical
right and left is disassembled,
be sure to
arrange the parts so that they do not become mixed during the
assembly process.
1. Arrange the parts removed in the proper order.
2. Determine
which parts are to be reused and which are to
be replaced.
3. If bolts, nuts, etc., are to be replaced, be sure to use only
the exact size specified.,
SPECIAL TOOLS
If other tools are substituted
for the special tools to do service
or repair work, there is the danger that vehicle parts might be
damaged,
or the mechanic
might be injured;
therefore,
be
sure to use the special tool whenever
doing any work for
which the use of one is specified.
FOOOl8
r
PARTS TO IBE REPLACED
DO05111
If any of the following

parts are removed,
replaced with new parts.
1. Oil seals
2. Gaskets (except rocker cover gasket)
3. Packings
4. O-rings
5. Lock washers
6. Cotter pins
7. Self-locking
nuts
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they
,j
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must
be
INTRODUCTION
- Precautions
Before Service
PARTS
When
replacing
VEHICLE
parts,
use MITSUBISHI
genuine
parts.
WVASHING
If high-pressure
car-washing
equipment
or steam car-washing
equipment
is used to wash the vehicle, be sure to maintain the
spray nozzle at a distance
of at least 300 mm (1 1.8 in.) from
any plastic
parts
and all opening
parts
(doors,
luggage
compartment,
etc.).
nm
(in.)
so0059
SERVICING
THE ELECTRICAL
When
cable
the electrical
system,
from the battery.
servicing
terminal
SYSTEM
disconnect
the negative
Caution
Before connecting
or disconnecting
the negative
cable, be
sure to turn off the ignition
switch
and the lighting
switch.
(If this is not done, there is the possibility
of semiconductor
parts
being damaged.)
WIRING
HARNESSES
1.
Secure the wiring

harnesses
by using clamps so that there
is no slack. However,
for any harness which passes to the
engine or other vibrating
parts of the vehicle, allow some
slack within
a range that does
not allow
the engine
vibrations
to cause the harness
to come into contact with
any of the surrounding
parts. Then secure the harness
by
using a clamp.
In addition,
if a mounting
indication
mark (yellow
tape) is
on a harness,
secure the indication
mark in the specified
location.
2.
If any section
of a wiring
harness
contacts
the edge of a
part, or a corner, wrap the section of the harness with tape
or something
similar in order to protect
it from damage.
F161711
:,
:,
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INTRODUCTION
- Precautions
Before
Service
a connector,
connector, not the harness.
be sure to pull only the
4.
Disconnect
connectors
the direction indicated
which have catches by pressing

by the arrows in the illustration.
5.
Connect connectors
which have catches
connectors
until they snap.
in
16Rl263
16R1264
Y16347
by inserting
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.
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the
INTRODUCTION
- Precautions
Before
ELECTRICAL COMPONENTS
1. When installing any of the vehicle
pinch or damage
2.
any of the wiring
Sensors,
relays, etc., are sensitive
Handle them with care so that
mishandled.
3.
11
Service
parts, be careful
harnesses.
not to
to strong impacts.
they are not dropped
or
The electronic
parts used for relays, etc., are sensitive
to
heat, If any service
which causes
a temperature
of 80C
(176F) or more is performed,
remove the part or parts in
question
before carrying out the service.
OOY63:
FUSES AND FUSIBLE

1.
LINKS
If a blown-out
fuse is to be replaced,
be sure to use only a
fuse of the specified
capacity.
If a fuse of a capacity
larger
than that specified
is used, parts may be damaged
and the
circuit may not be protected
adequately.
Caution
If a fuse is blown-out,
be sure to eliminate
the problem
before installing
a new fuse.
15A
IOA
the cause
of
oOY58S
Permissible
current
Nominal
size
0.3 mm2
05mm
0.85 mm2
1.25 mm2
2.0 mm2
AWG22
AWG 20
AWG18
AWG 16
AWG14
~
I
5A
13A
17A
22A
30A
zi
12A
16A
If additional
optional
equipment
is to be installed
in the
vehicle,
follow
the procedure
listed in the appropriate
instruction
manual;
however,
be sure to pay careful
attention to the following
points:
(1) In order
to avoid overloading
the wiring,
take the
electrical
current
load of the optional equipment
into
consideration,
and determine
the appropriate
wire size.
(2) Where
possible,
route the wiring through
the existing
harnesses.
Revision
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12
INTRODUCTION
- Precautions
Before
Service
(3) If an ammeter
or similar instrument
is to be connected
to a live-wire
circuit, use tape to protect the wire, use a
clamp to secure the wire, and make sure that there is
,i no contact with any other parts.
(4) Be sure to provide a fuse for the load circuit of the
optional equipment.
TUBES AND OTHER RUBBER PARTS

Be careful to avoid spilling any gasoline,
adheres
to any tubes or other rubber
adversely
affected.
oil, etc.. because

parts, they might
if it
be
LUBRICANTS
In accordance
with the instructions
in this Workshop
Manual,
apply the specified
lubricants
in the specified
locations
during
assembly
and installation.
FooO281
BRAKE FLUID
Be careful
to avoid spilling
adheres
to the vehicle body,
ored.
DOING SERVICE WORK

MORE TECHNICIANS
If the service
extra caution
any brake fluid, because

if it
the paint coat might be discol-
IN GROUPS
work is to be done
must be taken.
by two
OF TWO OR
or more
-FOOO3OI
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technicians
INTRODUCTION
- Precautions
IKITE
13
Before Service
ON INSTALLATION
OF RADIO
EQUIPMW&
The computers
of the electronic
control
system
has been
designed
so that external
radio waves
will not interfere
with
their operation.
However,
if antenna
or cable of amateur
transceiver
etc. is
routed near the computers,
it may affect the operation
of the
computers,
even if the output of the transceiver
is no more
than 25W.
To protect
each of the computers
from
interference
by
transmitter
(hum, transceiver,
etc.), the following
should be
observed.
1. Install the antenna
on the roof.
2. Because radio waves are emitted from the coaxial cable of
the antenna,
keep
it 200 mm (8 in.) away
from
the
computers
and the wiring harness.
If the cable must cross
the wiring harness,
route it so that it runs at right angles to
the wiring
harness.
3. The antenna
and the cable should be well matched,
and
the standing-wave
ratio* should
be kept low.
4. A transmitter
having a large output should not be installed
in the vehicle.
5. After installation
of transmitter,
run the engine at idle, emit
radio waves
from the transmitter
and make sure that the
engine is not affected.
High-frequency
power supply
_.
If an antenna
and a cable having different
impedances
are
connected,
the input impedance
Zi will vary in accordance
with
the length
of the cable and the frequency
of the
transmitter,
and the voltage
distribution
will also vary in
accordance
with the location.
The ratio between
this maximum
voltage
and minimum
voltage
is called the standing-wave
ratio. It can also be
represented
by the ratio between
the impedances
of the
antenna and the cable.
The amount of radio waves
emitted from the cable increases
as the standing-wave
ratio increases,
and this increases
the
possibility
of the electronic
components
being
adversely
affected.
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;
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INTRODUCTION
- Towing
TOWING
and Hoisting
AND HOISTING
NOOGA-
This vehicle can only be towed from the front with conventional sling-type
equipment
and tow chain with grab hooks.
If a vehicle is towed from the rear, use a tow dolly.
A lumber spacer (4 x 4 x 55 wood beam) should be placed
forward
of under guard and under towing
hook/shipping
tie
down hook.
Then, attach J-hook to the lower arm.
A safety chain system
must be used. This system
must be
completely
independent
of the primary
lifting and towing
attachment.
Care must be taken in the installation
of safety
chains to insure they do not cause damage to bumper,
painted
surfaces
or lights.
LIFT!NG-GROUND
CLEARANCE
Towed vehicle should be raised until wheels

are a minimum
of
10 cm (4 in.) from the ground.
Be sure there is adequate
ground clearance
at the opposite
end of the vehicle, especially
when towing
over rough terrain or when crossing
sharp rises
such as curbs.
If necessary,
ground
clearance
can be increased
by removing
the wheels
from the lifted end of the
disabled
vehicle
and carrying
the lifted end closer
to the
ground. A 20 cm (8 in.) ground clearance
must be maintained
between
brake drums and ground.
FRONT TOWING
PICKUP
The vehicle may be towed

on its rear wheels
for extended
distances,
provided the parking brake is released.
Make cartain the transmission
remains in NEUTRAL.
SAFETY PRECAUTIONS
The following
precautions
should be taken when towing
the
vehicle.
1. Remove
exhaust
tips and any other optional
equipment,
that interface
with the towing
sling. Padding (heavy shop
towel or carpeting)
should be placed between
the towing
sling cross
bar and any painted
surfaces,
and bumper
surfaces.
2. A safety
chain system
completely
independent
of the
primary lifting and towing
attachment
must be used.
3. Any loose or protruding
parts of damaged
vehicle such as
hoods, doors, fenders,
trim, etc., should be secured
prior
to moving the vehicle.
4. Operator
should refrain from going under a vehicle unless
the vehicle is adequately
supported
by safety stands.
5. Never allow passengers
to ride in a towed vehicle.
6. State and local rules and regulations
must be followed
when towing
a vehicle.
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INTRODUCTION
- Towing
and
15
Hoisting
HOISTING
POST TYPE
Special care should
be taken when raising the vehicle on a
frame contact type hoist. The hoist must be equipped
with the
proper adapters
in order to support
the vehicle at the proper
locations.
(See next page)
Conventional
hydraulic
hoists may be used after determining
that the adapter
plates will make firm contact
with the side
frame.
FLOOR
JACK
A regular floor jack may be used

or rear axle housing.
under the front
crossmember
Caution
1. A floor jack must
never
be used on any part of the
underbody.
2. Do not attempt
to raise one entire side of the vehicle by
placing a jack midway
between
front and rear wheels.
This practice
may result
in permanent
damage
to the
body.
EMERGENCY
JACKING
Jack receptacles
are located at the No. 2 crossmember
and
rear axle housing
to accept the jack supplied
with the vehicle
for emergency
road service. Always
block the opposite
wheels
and jack only on a level surface.
.::
. Y!.I,,.
.
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16
FRAME
INTRODUCTION
CONTACT
SUPPORT
support
of the
below.
and
Hoisting
LOCATIONS
2,350
NOTE
The locations
of the
the
same
as those
illustration
(OOW588)
Towitng
point
twin
shown
as Section
post
hoist
shown
mm
A-A
in
(92.5
in.)
Section
A-A
are
the
oow553
LIFTING
AND JACKING
c
m
@B
SUPPORT
Twin
post
Floor
lack
Emergency
LOCATIONS
hoist
jacking
(jack
supplied
with
the
vehicle)
OOW588
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INTRODUCTION
GENERAL
- Geraeral
17
Data and Specifications
DATA AND SPECIFICATIONS
NOOHA-A
OOW556
L042G
Description
Vehicle dimensions
VNJ LFIH
VRJLFIH
TRSLF/H
TNSLFIH
mm (in.)
Overall length
Without spare tire
3,960 (155.9)
3,960 (155.9)
3,960 (155.9)
3,960 (155.9)
With spare tire

Overall width
0
0
3,995 (157.3)
1,680 (66.1)
3,995 (157.3)
1,680 (66.1)
3,995 (157.3)
1,680 (66.1)
3,995 (157.3)
1,680 (66.1)
Overall height
1,840 (72.4)
1,840 (72.4)
1,850 (72.8)
1,850 (72.8)
Wheelbase
2,350 (92.5)
2,350 (92.5)
2,350 (92.5)
2,350 (92.5)
Front
1,400 (55.1)
1,400 (55.1)
1,400 (55.1)
1,400 (55.1)
Rear
1,375 (54.1)
1,375 (54.1)
1,375 (54.1)
1,375 (54.1)
Front
745 (29.3)
745 (29.3)
745 (29.3)
745 (29.3)
Rear
900 (35.4)
900 (35.4)
900 (35.4)
900 (35.4)
480 (18.9)
480 (18.9)
480 (18.9)
440(17.3)
210 (8.3)
440(17.3)
440(17.3)
210 (8.3)
480(18.9)
440(17.3)
210 (8.3)
210 (8.3)
@
@
38
28
38
28
38
28
38
28
21
21
21
21
1,479 (3,260)
1,493 (3,290)
1,440 (3,175)
1,460 (3,219)
I,91 0 (4.210)
Tread
Overhang
Height at curb weight
(wt.)
Front bumper to ground

Rear bumper to ground
Minimum running ground
clearance
Angle of approach
Angle of departure
Ramp breakover
Vehicle weights
Curb weight
angle
kg (Ibs.)
Gross vehicle weight

Gross axle
rating
Front
1,910 (4,210)
1 ,I 00 (2,425)
I,91 0 (4,210)
1 ,I 00 (2,425)
1,910(4,210)
1 ,I 00 (2,425)
weight ratin!g~:+y~
Seating,c&ac&~
.
:I ;.,* . ..,,
VU.,
,: ,_.: .,
,_;. ,; ,: 3,. r
Rear
1,450 (3,197)
4
1,450 (3,197)
4
1,450 (3,197)
2
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1,100 (2,425)
1,450 (3,197)
2
18
INTRODUCTION
L042G
Description
- General
Data and Specifications
VNJLFIH
TNSLFIH
VRJ L.F/H
TRSLFIH
Engine
Model
G54B
No.
Type
Number
i In-line
4
of cylinders
G54B
G54B
OHC
In-line
4
G54B
In-line
OHC
OHC
In-line
OHC
Bore
91 .I mm (3.59 in.) 91 .I mm (3.59 in.) 91 ,I mm (3.59 in.) 91 .I mm (3.59 in.)
Stroke
98.0 mm (3.86 in.) 98.0 mm (3.86 in.) 98.0 mm (3.86 in.) 98.0 mm (3.86 in.)
Piston
displacement
Compression
ratio
Firing
order
Basic
ignitron
Transmission
Model
trming
&transfer
2,555 cm
(155.9 CID)
8.7
2,555 cm
(155.9 CID)
2,555 cm3
(155.9 CID)
2,555 cm3
(155.9 CID)
8.7
8.7
8.7
I-3-4-2
I-3-4-2
1-3-4-2
7 BTDC
? 2
7 BTDC
? 2
1-3-4-2
7 BTDC
2 2
7 BTDC
case
No.
KM145
KM148
KM145
KM148
5-speed
manual
4-speed
automatic
5-speed
manual
4-speed
automatic
1 st
3.967
2.826
3.967
2.826
1.493
Type
Cear ratio
Transmjssion
Transfer
case
2nd
2.136
1.493
2.136
3rd
1.360
1 .ooo
1.360
1.000
4th
5th
1.000
0.856
0.688
-
1 .ooo
0.856
0.688
-
Reverse
3.578
2.703
3.578
2.703
High
1.000
1.000
1.000
1 ,040
Low
1.944
1.944
1.944
1.944
4.625
4.625
4.625
4.625
Dry single
Dry single
Final ring gear ratio

Zlutch
Type
disc &
disc &
diaphragm
diaphragm
spring
spring
Chassis
Tire size
Front suspension
P225/75R15
Type
Spring
constant
Wishbone
compression
(Wheel
position)
22 N/mm
(123 Ibs./in.)
type
Rear suspension
Type
Spring
Asymmetrical
semi-elliptic
leaf spring
constant
At load of 1 ,OOO-2,500
(220-551
Ibs.)
22 N/mm
(123 Ibs./in.)
At load of 4,670-8,870
(1,030-I
,955 tbs.)
50 N/mm
(280 Ibs./in.)
..,j ;
* :
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? 2
INTRODUCTION
Description
m--__
L042G
Data and
General
Specifications
VRJLFIH
VNJLFIH
/ Tightening
Torque
TNSLFIH
19
TRSLFIH
Brakes
We
Power
Front
Disc
Rear
Drum
(Leading
steering
Gear type
Integral
Gear ratio
16.4
Fuel tank capacity
NOOJA-
Head mark
Head mark
Nm
07
ft.lbs.
ft.lbs.
Nm
2.2-2.9
4.9-7.8
3.6-5.8
5.8-8.7
13-19
9.4-14
purposes
I
6x 1.0
3.0-3.9
8x 1.25
7.9-I
10x 1.25
16-23
12-17
27-39
20-29
12 x 1.25
29-43
21-32
47-72
35-53
14x 1.5
48-70
35-52
77-l
16x 1.5
677100
51-77
130-I
18x1.5
100-l
50
74-I
150-I
90
20x
1.5
10
10
57-85
60
90-I
20
180-230
130-170
1 IO-140
160-320
1 go-240
22 x 1.5
200-260
150-I
340-430
250-320
24x
260-320
1 go-240
420-550
310-410
Nm
ft.lbs.
1.5
Description
Tape
ball nut)
TORQUE
Description
Thread for general

(size x pitch) mm
type (Recirculating
60 liters (15.9 U.S. gal./1 3.2 Imp. gal.)
TIGHTENING
Taper
and trailing)
thread
for pipes
90
Remarks
(size)
PT l/8
Internal
Internal
thread:
thread:
Aluminum
Cast iron
PT l/4
Internal
Internal
thread:
thread:
Aluminum
Cast iron
PT 318
Internal
Internal
thread:
thread:
Aluminum
Cast iron
thread
for dry sealed
pipes (size)
NPTF l/16
4.9-7.8
7.9-I 2
3.6-5.8
5.8-8.7
Internal
Internal
thread:
thread:
Aluminum
Cast iron
NPTF l/8
7.9-I 2
16-19
5.8-8.7
12-14
Internal
Internal
thread:
thread:
Aluminum
Cast iron
NPTF l/4
19-13
34-45
14-22
25-33
Internal
Internal
thread:
thread:
Aluminum
Cast iron
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8-1
ELECTRICAL
CONTENTS
ACCESSORY
......................................................
188
Cigarette Lighter
............................................
,190
Clock ...............................................................
,191
AUDIO SYSTEM
................................................
.192
AUTOMATIC
FREE-WHEELING
HUB
INDICATOR
SYSTEM
........................................
208
Automatic
Free-wheeling
Hub
Indicator Control Unit .....................................
,216
Pulse Generator
..............................................
215
BACK DOOR WINDOW
DEFOGGER
................ .203
Defogger switch
............................................
,206
Printed Heater Lines ......................................
,207
CHARGING
SYSTEM
.........................................
71
Alternator
........................................................
83
Service Adjustment
Procedures
.....................
77
Battery Charging
........................................
82
Inspection
of Battery ..................................
81
Output Current Test ...................................
78
Regulated Voltage Test ..............................
79
Voltage Drop Test of Alternator Output
Wire ............................................................
77
ELECTRICAL
SYSTEM PARTS LOCATION
...... 2
Diode ...............................................................
5
Fusible Link and Fuse .....................................
6
.......................................................
Grounding
7
Relay and Control Unit ....................................
2
Sensor .............................................................
4
HORN ..................................................................
184
Horn Switch
....................................................
187
IGNITION
SYSTEM
............................................
105
Ignition Switch ................................................
122
Ignition System
...............................................
1 14
Service Adjustment
Procedures
.................... .l 1 1
Checking Ignition System
..........................
11 1
Checking Ignition Timing
...........................
11 1
Spark Plug Cable Test ................................
1 12
Spark Plug Test ..........................................
1 12
NOBAA-
......
9
INSPECTION
OF HARNESS CONNECTOR
Check for Improper Engagement
of
..........................................................
9
Terminal
Continuity and Voltage Test for Connector
.... 9
Engaging and Disengaging
of Connector
Terminal
..........................................................
9
143
LIGHTING
SYSTEM
...........................................
Column Switch ................................
. .............. .I59
Dimmer Control Switch .................................
.I62
Hazard Warning Switch .................................
.I61
Headlight
........................................................
,158
Service Adjustment
Procedures
.................... .I57
Headlight Aiming
.......................................
157
METERS AND GAUGES
....................................
123
Service Adjustment
Procedures
.................... .I30
Fuel Gauge Simple Test .................................
.I31
Fuel Gauge Unit Inspection
...........................
.I31
Oil Pressure Gauge Simple Test .................... .I32
Oil Pressure Gauge Unit Simple Test ............ ,132
Speedometer
Inspection
.I30
...............................
Tachometer
Inspection
..................................
,130
Voltage Meter Simple Test ............................
.I33
Water Temperature
Gauge Simple Test ....... ..I3 1
Water Temperature
Gauge Unit Inspection
. ..I3 2
..........................................
91
STARTING
SYSTEM
97
Starter Motor ............ .......................................
WIPER AND WASHER SYSTEM
.163
.......................
WIRING
HARNESS
............................................
13
Centralized Junction
.......................................
69
Circuit Diagram
...............................................
34
27
Configuration
Diagram
....................................
How to Read Wiring Diagrams
.......................
20
Troubleshooting
..............................................
13
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8-2
ELECTRICAL
ELECTRICAL
SYSTEM
- Relay
and Control
Unit
IPARTS LOCATION
NOIBAB-A
RELAY AND CONTROL UNIT

Items
--
Symbol
D
Air conditioner
relay
-Auto choke relay
-Automatic
free-wheeling
hub indicator control
unit
16W722
n 17
Condenser blower motor relay
Feed back carburetor control unit
Hazard warning flasher unit
Headlight washer relay
Heater relay
Intermittent wiper relay

~___
Light control relay
~___
Over drive relay
F
I
F
Power window relay
Seat belt warning timer
Turn-signal flasher unit
Automatic free-wheeling
2
\ hub indicator control unit
carburetor
control unit
Air conditioner
d---
Blower
assembiy&
v/i
16W152B
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Jr
relay
I-
EvaporatorE
ELECTRICAL
FI)I
-Headlight h
k\\\
washer
SYSTEM
PARTS LOCATION
relay
Hazard warnina
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- Relay and Control Unit
8-3
8-4
ELECTRICAL
- Sensor
SENSOR
Symbol
Items
Oxygen
sensor
Pulse generator
--
Throttle position sensor

_____
Vehicle-speed
sensor
~~
Water
temperature
sensor
ltw722
Throttle
Ileedometer
16W1506
p
Revision
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position
sensor.
ELECTRICAL
SYSTEM
PARTS LOCATION
8-5
- Diode
DIODE
Diode (for automatic
transmission
Diode (for EGR warning
1 @NJ22
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light)
oil
ELECTRICAL
SYSTEM
PARTS LOCATION
- Fusible Link and Fuse
FUSIBLE LINK AND FUSE

-Items
Symbol
Dedicated
fuse (for air conditioner
Dedicated
fuse (for headlight
circuit)
I E
A
Multipurpose
fuse
NOTE
For detailed information
concerning
fuses, refer to the section regarding
TION (P.8-69, 70.)
16W722
/ STBI
Main fusible link
Sub fusible link
-Evaoorator
circuit)
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D
the fusible links and
CENTRALIZED
JUNC-
ELECTRICAL
8-7
-Grounding
GROUNDING
Headlight
washer relay,
h
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_ .-----
-/
8-8
ELECTRICAL
\\/
16W1512
SYSTEM
PARTS LOCATION
-Grounding
5.
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:.,
INSPECTION
OF HARNESS
CONNECTOR
Inspection
of Harness
8-9
Connector
INSPECTION OF HARNESS
CONNECTOR
CONTINUITY
TOR
AND VOLTAGE
NOECAM
TEST FOR CONNEC-
Following procedures shall be followed for testing continuity and

voltage at connector in order to prevent improper contact and
deterioration of waterproof in connector.
CONVENTIONAL
(NON-WATERPROOF)
CONNECTOR
Check shall be done by inserting a probing needle from harness
side.
WATER PROOF CONNECTOR
Caution.
Do not insert probing needle from harness side as it will deteriorates
waterproof
and cause for rusting. To inspect the
energized circuit, use the ECI checker.
Connect
harness
to
16UO500
CHECK FOR IMPROPER

NAL
ENGAGEMENT
OF TERMI-
When terminal stopper of connector is out of order, engagement

of male and female terminals becomes improper even when connector itself is engaged perfectly and terminal sometimes
slips out
to rear side of connector. Ascertain, therefore, that each terminal
does not come off connector by pulling each harness wire.
16R1317
ENGAGING
TERMINAL
AND DISENGAGING
OF CONNECTOR
Connector which gives loose engagement

shall be rectified by
removing female terminal from connector housing and raise its
lance to establish securer engagement.
Removal of connector
housing and raise its lance to establish securer engagement.
Removal of connector terminal used for ECI and ELC 4 ,4/l control
circuit shall be done in the following manner.
COMPUTER
CONNECTOR
(1) Insert screwdriver [1.4 mm (06 in.) width] as shown
figure, disengage front holder and remove it.
8;
:
4
.j _.
16R1319
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in the
8-10
INSPECTION
OF HARNESS
CONNECTOR
Inspection
of Harness
Connector
(2) Insert harness of terminal to be rectified deep into connector

from harness side and hold it there.
(3) Insert tip of screwdriver [1.4 mm (.06 in.) width] into connector
in a manner as shown in the figure, raise housing lance slightly
with it and pull out harness.
Housing lance
NOTE
Tool No. 753787-l
of screwdriver.
-5
supplied
by AMP can be used instead
16R1321
(4) Insert needle through a hole provided on terminal and raise

contact point of male terminal.
Needle
16Ffi322
ROUND
WATERPROOF
CONNECTOR
(1) Remove waterproof cap by using a screwdriver.

(2) Insert tip of screwdriver [1.4 mm (.06 in.) or 2.0 mm (.08 in.)
width] into connector in a manner as shown in the figure, raise
housing lance slightly with it and pull out harness.
Housing lance
16R1323
(3) Insert screwdriver through a hole provided on terminal and

raise contact point of male terminal.
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INSPECTION
OF HARNESS
CONNECTOR
RECTANGULAR
Inspection
WATERPROOF
(1) Disengage
front
of Harness
Connector
8-71
CONNECTOR
holder by using a screwdriver
and remove
it.
(2) Insert tip of screwdriver

[*0.8 mm (03 in.) width] into connector in a manner as shown in the figure, push it lightly to raise
housing lancer and pull out harness.
*If right size screwdriver
is not available, convert a conventional driver to suit the size.
Housing
lance
16R13
26
(3) Press contact point of male terminal down by holding a screwdriver [1.4 mm (.06 in.) width] in a manner as shown
in the
figure.
16R1329
INJECTOR
(1) Remove
CONNECTOR
waterproof
cap.
16R1326)
Terminal
lance
(2) Insert tip of screwdriver

in a manner as shown
pull out harness.
16Rl330
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[1.4 mm (06 in.) width] into connector

in the figure, press in terminal lance and
8-12
INSPECTION
OF HARNESS
CONNECTOR
Inspection
of Harness
Connector
(3) Press contact point of male terminal down by holding a screwdriver Il.4 mm (.06 in.) width] in a manner as shown in the
figure.
Caution
Correct lancer to be in proper
inserted into connector.
I
16R132i
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condition
before terminal
is
WIRING
HARNESS
8-13
- Troubleshooting
WIRING HARNESS
TROUBLESHOOTING
NO8DAAA
The most important

point in troubleshooting
is to determine
Probable
Causes.
Once the probable causes are
determined,
parts to be checked can be limited to those associated
with such probable causes. Therefore,
unnecessary checks can be eliminated.
The determination
of the probable causes must be based on a theory and be
supported
by facts and must not be based on intuition only.
TROUBLESHOOTING
STEPS
If an attempt is made to solve a problem without

going through correct steps
symptoms
could become more complicated,
resulting in failure to determine
incorrect repairs. The four steps below should be followed in troubleshooting.
1 1 1 Observation
of Problem
Symptoms
Observe
the symptom
problems.
carefully.
for troubleshooting,
the causes correctly
Check
if there
the problem
and making
are also other
b
0,
Determination
of Probable
In determining
the probable causes, it is necessary
to check the
wiring diagram to understand
the circuit as a system.
Knowledge
of switches,
relays and other parts is necessary
for accurate determination.
The causes of similar problems
in the past must be
taken into account.
Causes
Checking
14
1 Repair
of Parts
and
Confirmation
Associated
Troubleshooting
is carried out by making step by step checks until
the true cause is found. Always go through the procedures
considering what check is to be made where for the best results.
with
After the problems

are corrected,
be sure to check that the system
operates
that new problems
have not
been
caused
bycorrectly
the
repair, Also check
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8-14
WIRING
HARNESS
- Troubleshooting
INSPECTION
1. Visual and aural checks
Check relay operation, blower motor rotation, light illumination, etc. visually or aurally. The flow of current is invisible but
can be checked by the operation of the parts.
I
2. Simple checks
For example, if a headlight does not come on and a faulty fuse
or poor grounding is suspected, replace the fuse with a new
one or ground the light to the body by a jumper wire to determine which part is responsible for the problem.
1680222
3.
Changeover
knob
Checking with instruments

Use an appropriate instrument
in an adequate range and read
the indication correctly. You must have sufficient knowledge
and experience to handle instruments
correctly.
1680224
INSPECTION
INSTRUMENTS
In inspection, make use of the following

1. Test lamps
instruments.
A test lamp consists of a 12 V bulb and lead wires. It is used

to check voltages or shortcircuits.
1680225
2.
Self-power
test lamp
A self-power test lamp consists of a bulb, battery and lead
wires connected in series. It is used to check continuity or
grounding.
,.!?i,
,,
1680226
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WIRING
HARNESS
3.
8-15
- Troubleshooting
Jumper wire
A jumper wire is used to close an open circuit. Never use one
to connect a power supply directly to a load.
1660227
4.
Voltmeter
A voltmeter is used to measure the circuit voltage. Normally,
the positive (red lead) probe is applied to the point of voltage
measurement and the negative (black lead) probe to the body
ground.
Black lead wire
Ground
1680228
5.
Ohmmeter
An ohmmeter is used to.check continuity or measure resistance of a switch or coil. If the measuring range has been
changed, the zero point must be adjusted before measurement.
CHECKING
Normal open (NO) type

OFF
SWITCHES
In a circuit diagram, a switch is represented by a symbol and in the

idle state.
ON
1. Normal open or normal close switch

Switches are classified into those which make the circuit open
and those which make the circuit closed when off.
ax
Current does not flow
Current flows
Normal close (NC) type

OFF
ON
-op--
l-2
Current flows
IX
Current does not flow
1680229
pm
#vision
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8-16
WIRING
HARNESS
- Troubleshooting
2.
CONNECTION
SWITCH
figure
illustrates
a complex switch. The switch plates
indicated by solid lines move in the direction of the arrow
when operated.
The continuity between terminals at each position is as indicated in the table below.
This
OFF
1st
stage
2nd stage
3rd stage
1
--_
4th stage
1660230
NOTE
M
denotes
continuity
between
terminals.
16W896
CHECKING
Cover
Coil
1. When current flows through the coil of a relay, its core is

magnetized to attract the iron piece, closing (ON) the contact
at the tip of the iron piece. When the coil current is turned off,
the iron piece is made to return to its original position by a
spring, opening the contact (OFF).
Spring
Iron
core
Iron
piece
RELAYS
Contact
1660231
2.
Relav
l-
Battery:
-I
d
T
1660232
3. The relays may be classified into the normal open type and the
normal close type by their contact construction.
Normal ooen (NO) tvoe

Deenergized
state
Energized
I
ED
1
2
3
4
CurreZ!
not flow
By using a relay, a heavy current can be turned on and off

by a switch of small capacity. For example,
in the circuit
shown here, when the switch is turned on (closed), current
flows to the coil of the relay. Then, its contact is turned on
(closed) and the light comes on. The current flowing at this
time to the switch is the relay coil current only and is very
small.
state
1
BP
NOTE
The deenergized
state means that no kurrent is flowing
through the coil and the energized state means that current is
flowing through the coil.
2
3
4
1 YZZZw;6B0233
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WIRING
Normal
Deenergized
close
state
INC) type
Energized
state
Current
-flows
Current
does
HARNESS
8-17
- Troubleshooting
When a normal close type relay as illustrated here is checked,

there should be continuity
between
terminals
(1) and (2) and
between
terminals 3 and 4 when the relay is deenergized,
and the continuity should be lost between
terminals
3 and 4
when the battery voltage is applied to the terminals 1 and 2. A
relay can be checked in this manner and it cannot be determine if a relay is okay or faulty by checking its state only when
it is deenergized
(or energized).
not flow
1680234
CHECKING
FUSES
A blade type fuse has test taps provided to allow

the fuse itself without
removing
it from the fuse
fuse is okay if the test light comes
on when its
connected
to the test taps (one at a time) and the
grounded.
(Change
the ignition switch
position
adequately
fuse circuit beomes
live.)
checking
of
block. The
one lead is
other lead is
so that the
=
1680235
State
of fuse
blown
CAUTIONS
due to overcurrent
IN EVENT
OF BLOWN
FUSE
When a fuse is blown, there are two probable causes as follows

: One is that it is blown due to flow of current exceeding its rating.
The other is that it is blown due to repeated on/off current flowing
through it. Which of the two causes is responsible
can be easily
determined
by visual check as described
below.
1660237
State
of fuse
blown
due to thermal
fatigue
(1) Fuse blown due to current exceeding rating

The illustration
shows
the state of a fuse blown due to this
cause. In this case, do not replace the fuse with a new one
hastily since a current heavy enough to blow the fuse has
flowed
through
it. First, check the circuit for shorting
and
check for abnormal electric parts. Only after the correction
of
such shorting or parts, fuse of the same capacity should be
used as a replacement.
Never use a fuse of lager capacity than
the one that has blown. If such a fuse is used, electric parts or
wirings could be damaged before the fuse blows in the event
an overcurrent
occurs again.
(2) Fuse blown due to repeated current on/off

The illustration
shows
the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs
after fairly long period of use and hence is less frequent than
the above type. In this case, you may simply replace with a
new fuse of the same capacity.
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WIRING
HARNESS
- Troubleshooting
CHECKING
1660236
CABLES AND WIRES
1. Check connections for looseness, rust and stains.

2. Check terminals and wires for corrosion by battery electrolyte,
$tc.
3. Check terminals and wires for open circuit or impending open
circuit.
4. Check wire insulation and coating for damage, cracks and degrading.
5. Check conductive parts of terminals for contact with other
metallic parts (vehicle body and other parts).
6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body.
7. Check for incorrect wiring.
8. Check that wirings are so clamped as to prevent contact with
sharp corners of the vehicle body, etc. or hot parts (exhaust
manifold, pipe, etc.).
9. Check that wirings are clamped firmly to secure enough clearance from the fan pulley, fan belt and other rotating or moving
parts.
10. Check that the wirings between the fixed parts such as the
vehicle body and the vibrating parts such as the engine are
made with adequate allowance for vibrations.
HANDLING
ON-VEHICLE
BAlTERY
When checking or servicing does not require power from the onvehicle battery, be sure to disconnect the cable from the battery
(-)terminal.
This is to prevent problems that could be caused by
shorting of the circuit. Disconnect the (-) terminal first and reconnect it last.
TROUBLESHOOTING
supply
Power
/----
Fuse
ON
Motor
1660239
A circuit consists of the power supply, switch, relay, load, ground,

etc. There are various methods to check a circuit including an
overall check, voltage check, shortcircuit
check and continuity
check. Each of these methods is briefly described in the following.
1. Voltage check
(1) Ground one lead wire of the test light. If a voltmeter
is
used instead of the test light, ground the grounding
side lead wire.
(2) Connect the other lead wire of the test light to the
power side terminal
of the connector 0. The test light
should come on or the voltmeter
should indicate
a
voltage.
(3) Then, connect
the test light or voltmeter
to the
connector (3,. The test light should not come on, or the
voltmeter
should indicate no voltage. When the switch
is turned on in this state, the test light should come on,
or the voltmeter
should indicate
a voltage,
with the
motor starting to run.
(4) The circuit illustrated
here is normal but if there is any
problem
such as the motor
failing to run, check
voltages
beginning
at the connector
nearest to the
motor unit the faulty part is identified.
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WIRING
Power
HARNESS
supply
Fuse block
(remove
fuse)
Test
light
rTJ Switch
Illumination
light
- Troubleshooting
8-19
2. CHECKING
SHORTCIRCUITS
(1) Remove the blown fuse connect the test light to the
disconnected
terminal. The test light should not come
on.
(2) Connect a lead wire of the test light to the power side
of the connector 0. The test light should not come on.
(3) Connect a lead wire of the test light to the load side of
the connector 0. The test light should come on and the
load light should also come on.
(4) Disconnect
the load at the connector
0 and connect
the test light lead wire to the load side of the connector
CD.
The test light should come on and the load light should
also come on.
(5) Connect the test light lead wire to the switch side of
the connecotr
0. The test light should come on.
(6) If the test conforms
to any of the above conditions,
there is a shortcircuit
in the wiring between
the
connector
0 and the connector
0.
4,
1680241
3.
Self
power
test
light
Switch
ON
OFF
CHECKING
CONTINUITY
(I) When the switch is in the OFF position, the self power
test light should come on or the ohmmeter
should read
0 R only when the terminals
2 and 3 are interconnected.
(2) When the switch is in the ON position, the self power
test light should come on or the ohmmeter
should read
0 LR only when the terminals
1 and 4 are interconnected.
1680242
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8-20
WIRING
HARNESS
- How to Read Wiring Diagrams
HOW TO READ WIRING DIAGRAM

HOW TO READ CONFIGURATION
NOEDBAE
DIAGRAMS
(1) Connector symbols

A wiring diagram shows the installed condition of each connector in a schematic style. The connectors are
shown and classified as follows, depending on their locations and are marked by connector symbols.
In case connectors of the same shape (same number of wires) are centralized, their colors are indicated for
identification.
Exampe
: p.!-
f.~~~~
~;~~o,
Connectors unique number
(serial number)
A : Engine compartment
B : Interior and frame
C : Instrument
panel
Main
fusible
link
A-03
A-o4 > 4WD indicator switch
A-05
Automatic
transmission
temperature
switch
oil
indicates
I
Same
diagram
connector
and
No. is used in the wiring
the circuit
diagram.
Indicates color of the

A-58 connector.
I
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that the connector
is located
in the
WIRING
HARNESS
- HOW to Read Wiring
Diagrams
8-21
(2) Identification
of connectors
differing according
to different vehicle specifications
Without wiring harness connectors, the inter-device or -wiring harness connectors which vary in shape or
position on different vehicle specifications are given the specification-dependent
connector identification svmbol (lower case alphabet) after a serial number.
For detailed information on this specification-dependent
symbol, refer to Item (8) under HOW TO READ
CIRCUIT DIAGRAMS.
(3) Indication of standard mounting positions of harnesses
The standard mounting positions of harnesses are shown with the mark * in wiring harness configuration
diagrams.
(4) Indication of ground point
The position of ground points are shown in wiring harness configuration diagrams. For detailed information on
the ground portion, refer to ELECTRICAL SYSTEM PARTS LOCATION (Grounding).
Referto item (3)
Ground symbol
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8-22
WIRING
HOW TO READ CIRCUIT

The circuit diagrams
HARNESS
How
to
Read
Wiring
Diagrams
DIAGRAMS
are functionally
separated.
(1) Indication of circuit connected

to another circuit
When the circuit in a circuit diagram connected to another circuit in a different diagram, the page number of that
different diagram is indicated so that it can be referred to.
(2) Indication of device connections
The circuit diagram shows whether
a device harness connection
is one with an attached cable or is a direct
connection
type.
(3) Indication of connectors
in circuit diagrams
A connector
in a circuit diagram is shown
in a frame and is assigned
a connector
symbol. This symbol
corresponds
to the symbol in a wiring harness configuration
diagram so that the connector
location can be
known easily. An intermediate
connector
has its female side only shown as a rule. However
both of the male
and female sides are shown when they differ in wiring color.
Refer to Items (2) and (3).

The frame shows the connector is not touching the symbol
of a device,
and indicates
that
the device harness
connection
is one with an
attached
cable.
Refer to Item (2)

If a frame showing
a connector
touches
the
symbol
of a device ?. it indicates
that the device harness connectlon IS a direct connec-
Indicates
direct grounding
the device to the bodv.
tion type.
Ignition
*I RL **2-RL
1
BI
L
r------B-39
43
Refer to item
Indicates
that
nectar.
(3)
this
connector
switch
RL
Z-RL
B
BRL*I
RL*2
is a B-39
con-
Dome
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/
/B-6&
RB-
(RG) - (RB)
(REV 1 I (GR)
B-68b
L-2
B-35
I
I
--------_
---__---___----
--------
31103LI
Refer to Item (1)

On a circuit connected
to another
circuit the
names of devices
to which the circuit is connected and pages on which diagrams
of such
another
circuit appear
are indicated.
1 STB Revision
light
17
from
WIRING
HARNESS
BO Read
HOW
Wiring
8-23
Diagrams
(4) Indication of fuses, fusible links and centralized relays

The fuses and fusible links in a circuit diagram are indicated by a wave symbol (-) and a double wave symbol
(~1, respectively. At a centralized junction, the fuses are given fuse numbers and centralized relays are given
connector symbols.
Example
of centralized
junction
symbol:
A - 01 x
Centralized junction
Connectors unique
Connector symbol
indication symbol
number (serial number)
(5) Indication of ground point

The ground point in a circuit diagram is marked by a ground symbol, making it possible for you to refer to a
wiring harness configuration
diagram and to ELECTRICAL SYSTEM PARTS LOCATION (Grounding).
(6) Indication of wires
In a circuit diagram, the wire diameter and wire color are shown for each wire. If there are several wires
of the same color in a connector, their wire color indication
symbols should be such symbols as I and
2 for identification.
On connectors like this one given a central-
to CENTRALIZED
1shaoe. etc.
JUNCTION
for connector
-I
Headlight
ignition switch
relay
Dome light
B-68b
II
B-35
P:8-47)
I
BI
0
III-
L
B-39
RL
2-RL
B
IEU
2I
-----____________
- - - - - _ _ _ _ _ __
_ _ _ _ _
Refer to Item (5).

Refer to Item (6)
The connector
B-39 has two wires identical
in color (RL), so they are given identification
symbols *I and *2 in order to distinguish
them.
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8-24
WIRING
HARNESS
- How
to
Read Wiring
Diagrams
(7) Indication of shielded cables

A shielded cable used , for example, in an electronic control circuit for prevention of malfunctions
that may
otherwise be caused by radio interference is indicated by a solid line sandwiched between dashed lines ( E).
(8) Indication of specification-dependent
connectors
With regard to harness connectors, the inter-device and -harness connectors which vary in shape or position on
different vehicle specifications,
such as those with rear wipers and turbocharger and those without turbocharger, are given a specification-dependent
connector identification symbol (lower case alphabet) following the
connector symbol.
Example:
A - Ola
Specification
a : Vehicles
b : Vehicles
c : Vehicles
d : Vehicles
- dependent
connector
identification
with a manual transmission
with an automatic
transmission
with a power window
without a power window
(9) Shapes of connectors

The connector shapes are indicated by simplified symbolic
connectors, refer to HOW TO IDENTIFY CONNECTORS.
marks.
For distinction
symbol
between
male and female
Refer to Item (8)

The b at the end of the connector symbol
is a specification-dependent connector
identification symbol and indicates that
Ignition switch
Headlight
relay
the connector
is used for vehicles
automatic transmission.
Dome light
B-68a
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B-68b
with
WIRING
HARNESS
How
to
Read
IDENTIFYING
Position
improper
of guide to prevent
connection
8-25
Diagrams
CONNECTORS
In circuit diagrams,
the connectors
are indicated
by symbolic
marks which show the number of their wires and whether
they
are male,or female connectors.
(1) Number of connector
wires
The number of divisions
in the connector
diagram indicates
the number of wires. A cross in a division, however,
indicates
the position of a guide to prevent improper connection.
The
connector
shown here, therefore,
is a g-wire connector.
fl!liB
9-wire
Wiring
connector
1680219
(2) Identification
of male and female connectors
Connectors
drawn with double outer lines are male, and those
with single outer lines are female.
jpg$&
R
-y
Male
On-vehicle
terminal
connector
Female
terminal
Connector
in
wiring diagram
(3) Connector
direction
The connector
marks show on-vehicle
from the direction shown here.
connectors
as viewed
1680220
(4) Identification
of
The color codes
viewed
at their
illustrated
here.
joining surfaces
so the terminals
NOTE
The color codes
identical.
connector
terminals
of a pair of connectors
(male and female), if
joining surfaces,
will appear symmetrical
as
When the connectors
are connected,
their
are put together in the way a book is closed,
of identical codes are connected
together.
of male and female
connectors
are not always
16R0459
Guide to prevent
connection
Double
male.
@
lines
indicate
(5) Identification
of sealed connectors
Identification
of round, sealed connectors
(water-proof
pin terminal connectors)
used in radiator fan motor circuits, turbo
circuits,
etc. is accomplished
by the same
method
as
described
above.
improper
Numb&ions
Indicates
number
of wires
36KO37
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8-26
WIRING
SYMBOLIC
Various
HARNESS
- HOW to Read Wiring
Diagrams
MARKS
equipment
is indicated
Battery
Body ground
Fuse
Equipment
Fusible link
Motor
symbolically
in circuit idiagrams
as shown
Single bulb
Resistor
Speaker
Coil
below.
Capacitor
Diode
ground
Transistor
4
Crossing of lines
with conron
-1~
WIRE COLOR CODES

Wire colors are identified by the following color codes.
Example:
1.25 - GB
Code
Wire color
Code
Wire color
Black
Brown
LI
Light blue
Oranqe
Br
1 Gr
Grav
Blue
Light green
Lg
1.25: Wire size (mm2)
F: Flexible wire
T: Twisted wire
(1) No code indicates 0.5 mm2(.0008 in.*).

(2) Cable color-code in parantheses indicates
0.3 mm* (.0005 in.).
I
1
P
R
i
1
I Y I
W
Red
Yellow
White
NOTE
If a cable has two colors, the first of the two color code characters
indicates the basic color (color of the cable coating) and the second indicates the marking color.
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WIRING
OVERALL
WIRING
HARNESS
- Overall
DIAGRAM
Wiring
Diagram
8-27
NOBDC-3
) STB Revision
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8-28
WIRING
HARNESS
- Engine
Compartment
1 ENGINE COMPARTMENT
Connector
symbol
AA156
;:::I Main
fusible link
;:::I 4WD indicator switch

A-05 Automatic transmission
oil
temperature
switch
A-06 Back-u light and 4WD indicator
A-07)wiring
f!arness and cord
assembly combination
;:g> Back-up light switch
A-l 0 OD-OFF solenoid
A-l 1 Pulse generator
A-l 2 Front wiring harness and
transmission wiring harness
combination
A-13 Air conditioner solenoid valve
A-l 4 Front wiper motor
A-53
A-54
A-52
A-28
A-29
A-34
A-35
Auto choke relay

Front wiring harness and air
conditioner wiring harness
combination
Headlight washer motor
Front combination
light (L.H.)
Light control relay
Dedicated fuse (Upper beam
indicator circuit)
Headlight (L.H.)
Condenser fan motor
A-40
Condenser
A-55
A-l 7 Checker
A-18 Diode
A-19 Brake fluid level sensor
A-20 Front harness and back-up light
A-21 land 4WD indicator wiring
harness combination
Sub
fusible link
it;;>
A-24 Carburetor assembly
A-25 Control wiring harness and air
conditioner wiring harness
combination
A-26 Front wiring harness and control
wiring harness combination
A-27 Device box
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A-30
A-31
A-32
A-33
fan motor relay
WIRINGA-06
;
,.
A-08 A-1 0 A-12
,I
A-48
HARNESS
A-14
1 A-15
I,
- Engine
8-29
Compartment
WI
&-ii&
A-39
A-37
A-35
A41
i-$
Ignition coil
A-44
A-45 Magnetic clutch
A-46 Water temperature
sensor (FBC circuit)
;rii}Alternator
A-49 Water temperature switch (Air conditioner circuit)
A-50 Water temperature gauge unit
A-51 Water temperature switch (OD control circuit)
A-52 Oil pressure gauge or oil pressure switch
Low pressure switch
$3
Ai34
A!33
J-3:
36W618
A-55
A-56
A-57
A-58
A-59
Headlight (R.H.)
Front harness and air conditioner
combination
Front combination
light (R.H.)
Front washer motor
Oxygen sensor
wiring harness
Remarks
(1) The mark * shows the reference mounting
position of
wiring harness.
(2) For information
concerning
the ground points (example: q ), refer to P.8-7.
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8-30
WIRING
HARNESS
- Interior
B-01
Be03
and Frame
2 INTERIOR AND FRAIVIE

Connector
symbol
B
B-32
B-33
\
B-29
-I2
B-05
\
B-06
B-08
\ B-p7 \
B-p9
B-l 0
1
AB-26
B-27
B-22
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H-21
-1
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36W617
WIRING
HARNESS
B-01 Dome light

B-02 Door switch (R.H.)
:::3 Rear speaker (R.H.)
B-05 Defogger (-)
B-06 Back door wiring harness and license plate light wiring
harness combination
B-07 Rear wiper motor
B-08 Rear washer motor
B-09 Defogger (+)
B-l 0 Back door wiring harness and defogger cable (+)
combination
B-l 1 Rear side marker light (R.H.)
B-12 Frame wiring harness and back door wiring harness
B-13)combination
B-14 Rear combination
light (R.H.)
&z}License
plate light (R.H.)
Remark
The mark + shows
harness.
the reference
mounting
position
- Interior
/&}License
plate light (L.H.)
B-19 Back door lock actuator
B-20 Rear combination
light (L.H.)
B-21 Fuel gauge unit
B-22 Rear side marker light (L.H.)
B-23 Front wiring harness and frame wiring
combination
;:g
E$
Rear speaker (L.H.)
:::g>
B-30
B-31
B-32
B-33
Door switch (L.H.)

Power window main switch
Power window motor (L.H.)
Power window motor (R.H.)
Power window sub switch
of wiring
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8-31
and Frame
harness
8-32
WIRING
3 INSTRUMENT
Connector
HARNESS
- Instrument
Panel
PANEL
c-04
symbol
C-06
C
C-65
C-64
C-63
C-61
CL57 C-b6 C!55
Remarks
For information
refer to P.8-7.
concerning
the ground
points
(example:
d54
c!5
),
C-01 Back door lock switch

C-02 Defogger switch
C-03 Kev reminder and seat belt
warning buzzer
c-04
Combination
meter
pi;
C-l 8 Heater relay

C-l 9 Air conditioner wiring harness
and front wiring harness
combination
E:$)}Air conditioner relay
C-31 Blower motor resistor

C-32 Dedicated fuse (Air conditioner
circuit)
C-33 Air conditioner switch
C-34 yl;Jer control lonob illumination
C-08 Diode
C-09 Rear wiper and washer switch
r&~}Oil
pressure gauge
C-12 f;hybination
gauge illumination
$:;;IThermostat
$:;;IFeed back
carburetor control unit

C-26 Front speaker (R.H.)
C-27 Front wiring harness and roof
wiring harness combination
C-28 Automatic free-wheeling
hub
indicator control unit
C-29 Seat belt warning timer
C-30 Front wiring harness and door
wiring harness (R.H.)
combination
c-35 Blower switch

C-36 Clock
c-37 Heater control panel illumination
light
C-38 Ashtray illumination
light
c-39 Air conditioner switch
illumination light
c40 Front wiring harness and center
panel wiring harness
combination
C-l 3 Blower switch

C-14 Combination
gauge wiring
harness and front wiring harness
combination
C-15 F;hybination
gauge illumination
C,::F}Voltage
meter
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WIRING
cy50
C149
Cl48
HARNESS
- Instrument
Panel
c-47
El$,}Cigarette
lightet
C-43 Cigarette lighter illumination light
E::$ Radio
C-46 Shift position illumination light
C-47 Inhibitor switch
C-48 OD-OFF switch
C-49 Parking brake switch
C-50 Seat belt switch
C-51 Hazard switch
Column switch
C-54 Key reminder switch
C-55 Ignition switch
C-56 Stop light switch
C-57 Dimmer control switch

C-58 Front wiring harness and door
wiring harness (L.H.) combination
C-59 Turn-signal flasher unit
C-60 Power window relay
C-61 Intermittent wiper relay
C-62 Hazard flasher unit
C-63 OD-OFF relay
C-64 Headlight washer motor relay
C-65 Front speaker (L.H.)
E3
Ision
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8-33
8-34
WIRING
MARNESS
1 STARTING CIRCUIT
(VEHICLES WITH A MANUAL
- Starting
Circuit
TRANSMISSION)
Ignition
switch
TA RT
Battery
Main
link
@.25B+
L1!
zcl
fusible
A-23
mw BY
Sub fusible link

(IGN - SW)
M
2
M
I
7 A-15
BIT/B
F=
Starter
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37W620
WIRING
HARNESS
(VEHICLES WITH AN AUTOMATIC
Battery
-p
8-35
Circuit
TRANSMISSION)
Sub fusible link

(IGN . SW)
A-23
Main
fusible
link
- Starting
Ignition
switch
lrrilI
1.25-B
-5-w
A-02
U
c-47
a 1 2-BY
Ia- 1
2-BY
1
Inhibitor
switch
N
2-BY,2-BY*2
2-BY
2-BY*l
P
BYBY
fTl
37W613
Remark
For information concerning
the ground
refer to P.8-7.
Wiring color code
Br: Brown
8: Black
LI: Light blue
0: Orange
points (example:
G: Green
P: Pink
0 ).
Gr: Gray
R: Red
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L: Blue
Y: Yellow
Lg: Light green

W: White
8-36
WIRING
2 IGNITION
HARNESS
- Ignition
Circuit
CIRCUIT
A-23
Main
fusible
link
Batterv
Sub fusible
(IGN * SW)
link
Ignition
switch
IR
I
i
r
mw
Distributor
To combination
meter
(TACHO)
[Refer to P.8-52.1
J A-44
37W609
Remark
For information
refer to P.8-7.
concerning
Wiring color code

B: Black
Ll: Light blue
the ground
Br: Brown
0: Orange
points
(example:
G: Green
P: Pink
),
Gr: Gray
R: Red
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L: Blue
Y: Yellow
7
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Lg: Light green

W: White
WIRING
3 CHARGING
HARNESS
- Charging
8-37
Circuit
CIRCUIT
Ignition
switch
.n
Main
fusible
link
Battery
I
3
cl
m L
A-02
Sub fusible link

(IGN - SW)
A-23
,
I81
m
3
c:
-22
3
c!J
t
El
A-48
Alternator
To turn signal flasher

unit [Refer to P.8-49.1
Comornatron
Remark
For information
refer to P.8-7.
concerning
Wiring color code

B: Black
LI: Light blue
the ground
Br: Brown
0: Orange
points (example:
3
a
I
6
Multipurpose
fuse
meter
37W605
),
Gr: Gray
R: Red
G: Green
P: Pink
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L: Blue
Y: Yellow
Lg: Light green

W: White
8-38
WIRING
HARNESS
4 FEED BACK CARBURETOR
Battery
Main
fusible
link
Feed
Back
Carburetor
Circuit
CIRCUIT
m
A-02
efl
EEI
j
i
-1.25-B-
Sub fusible
link
Ignition
BW
switch
uA-2i
I
I:
h
A-28
zix--I
c:
qi
To alternator
[Refer to P.8.37.1 1
-26c-1
ziE2
BW ".
r
Feed back
solenoid valve
YG
1.25-BW"'
Slow cut
solenoid valve
2-BW wQ
I
I
YL
1.25-BW*'
yL ,0
P
Auto choke
heater
-hrottle
iensor
position
1 A-24
Carburetor
assembly
Remarks
(1) For information
concerning
the ground points (example:
0). refer to P.8-7.
(2) The symbols 0, 0 etc. indicate that the wiring is connected (using the same numerical symbol) to the facing
page. (In other words, 0 on the right page is connected to
0 on the left page.)
STB Revision
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WIRING
HARNESS
- Feed Back Carburetor
8-39
Circuit
Ignition
coil
) _ ,E3
$-To
A-42
A-4
vacuum
solenoid
valve [Refer to P.8-57.1
BR
cl
c-2 Af r
I
I
I
I
I
;
:
;
:
0.85-BW
YG
YL.
I
RW,
II
II
(I
A-4
A-9
A-3
A-6
A-5
B-l 1
B-6
B-9
B-IO
I
I I- - - - -. -_ __ __
L---__._._
1I ! !
I i-----,
+L----J
Feed back
carburetor
control unit
B
B-l
B-2
B-l 2
B-3
B-13
B-8
B-7
B-5
Vacuum
switch
Device
box
control
A-46
Water
temperature
sensor
1 STB Revision
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solenoid
8-40
WIRING
HARNESS
- Layout
of Components
WC)
LAYOUT OFCOMPONENJS [FBC)
CD
II
\\
5FU131
Items
Items
Symbol
Auto choke relay
Slow-cut
solenoid valve
Engine speed sensor
(Ignition coil 0)
Feed back carburetor
control unit
Throttle opener control solenoid valve (for the

air-conditioner)
Feed back solenoid valve
Throttle
Oxygen sensor
Vacuum switch
Secondary
Throttle
solenoid
opener
valve
position sensor
1 Water temperature
contr
http://vnx.su/
Symbol
sensor
D
A
WIRING
sensor
US) /
control
HARNESS
- Layout
of Components
5FUl
unit
w1515
1/
LTBI levision
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(FBC)
8-41
8-42
WIRING
5 OVERDRIVE
HARNESS
CONTROL
- Overdrive
Control
System
Circuit
SYSTEM CIRCUIT
/ Sub
fusible
link
Ignition
$in
switch
fusible
To combination
meter
[Refer
to P.8-52.1
To alternator
[Refer
to P.8-37.1
0.85-W
To column
[Refer
to
0.85-RL
switch
P.8-51.1
0.85-W
i
Remarks
(I)
For information
concerning
the ground
points
(example:
0).
refer
to P.8-7.
(2)
The
symbols
0,
0,
etc.
indicate
that
the
wiring
is
connected
(using
the same
numerical
symbol)
to the
facing
page.
(In other words,
to 0 on
the left page.)
1 STB Revision
Multi-purpose
fuse
Combination
RLI
1 IyRw
-7
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meter
4
1 1 I
WIRING
HARNESS
- Overdrive
Control
System
8-43
Circuit
*I
Inhibitor
Water
temperature
switch
OD-OFF
relav
C--63
RL
)
To back-up light
[Refer to P.8-45.1
2-BY
9
3
4
5
To starter relay
[Refer to P.8-34, 35.1
IA-12 @@
VRR
r
A-05
Automatic
transmission
oil temperature
switch
switch
OD-OFF
solenoid
llR)3
[RILRI
Wiring color code

B: Black
Br: Brown
LI: Light blue 0: Orange
-10
G: Green
P: Pink
G;; ;ZJ
L: Blue
Y: Yellow
Lg: Light green

W: White
1 STB Revision
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37w019
8-44
WIRING
HARNESS
Tail Light. Position

Light, Rear Side Marker
Light,
License Plate Light and Back-Up
Light Circuit
6 TAIL LIGHT, POSITION LIGHT, REAR SIDE MARKER LIGHT,

LICENSE PLATE LIGHT AND BACK-UP LIGHT CIRCUIT
?I w19
eF=7
I 1 1 I
nwr
II
Battery
Sub
EiT
n1.25-Bn
fusible
link
II
Main
fusible
link
To turn-signal
flasher
unit
O-85-RL
i
I
I
I
Inhibitor
switch
A-09
combination
i
1
I
I
combination
000
Back-up
switch
light
Em
Wiring
color
code
g: Black
Ll: Light
blue
Br:
0:
Brown
Orange
G: Green
P: Pink
Gr: Gray
R: Red
1 STB Revision
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L: Blue
Y: Yellow
Lg:
W:
Light
White
green
WIRING
HARNESS
Tail Light,
Position
License
Plate
Light
Light,
Rear
and Back-Up
Side Marker
Light.
Light Circuit
8-45
fl!FEEl
Column
switch
Lighting
switch
Light control
relay
F-GW -GW
B-l 2
B-l 1
Tail light
Tail light
Back-up
light
Rear
$ combination
light
(R.H.)
RG
RI.G
El3
Tail light
Tail light
Back-up
light
I
Remarks
(1) The broken lines are applicable to models equipped wrtn
an automatic transmission.
(2) For information
concerning
the ground
points (example: 0 ). refer to P.8-7.
(3) The symbols
0, 0, etc. indicate that the wiring is
connected
(using the same numerical
symbol) to the
facing page.
the left page.)
,
) STB Revision
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GW
IBl
Rear side
B-22
37W023
Rear
combination
fight
(L.H.)
8-46
WIRING
HARNESS
Headlight
Circuit
1
7 HEADLIGHT
CIRCUIT
M-!l
Battery
-1.25-B1
Main
link
R
YR
il II viI!Ii
Sub fusible
link
A-02
5-w
5-w m5-w
M 0.5-G
2-R
U
A-23
fusible
2-B
71' 0
[ES
$$J
A-33
Dedicated
1 c-05
fuse
BEAM
1 ('R;
J
Combination
meter
I w
C-52
-32
A-34
Light
relay
control
Lighting
switch
Dimmer
switch
Column
Remark
For information
concerning
the ground
POintS
(example: 0 ), refer to P.8-7.
Wiring color code
B: Black
Ll: Light blue
A-55
Br: Brown
0: Orange
Passing
switch
(L.H.)
switch
(R.H.)
Headlight
37W621
9
G: Green
P: Pink
x2
m
Gr: Gray
R: Red
1 STB Revision
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L: Blue
Y: Yellow
Lg: Light green

W: White
WIRING
HARNESS
- Dome
8-47
Circuit
Light
8 DOME LIGHT CIRCUIT
A-02
Battery
1.25-B
\
3
Main
fusible
Sub
5-w rl5-w
u
2-w
fusible
link
0.5-G
2-R
A-23
link
To column
[Refer
to
Multi-purpose
fuse
switch
P.8-46.1
1.25-GB
2-R
&
m
At
Combination
meter
1.25-GB
To hazard
flasher
unit
[Refer
to P.8.49.1
I--
C-27
B-01
Dome
light
(L.H.)
(R.H.)
Door
switch
37W620
Remark
For information
refer
to P.8-7.
Wiring
B: Black
LI: Light
color
blue
concerning
the
ground
points
(example:
),
code
Br: Brown
0: Orange
G:
P:
Green
Pink
Gr: Gray
R: Red
1 STB Revision
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L: Blue
Y: Yellow
Lg:
W:
Light
White
green
8-48
WIRING
HARNESS
9 TURN-SIGNAL
AND
A-02
a3
1.25-B-
Main
fusible
Hazard
Light
Circuit
LIGHT CIRCUIT
Sub fusible
link
0.5-G
A-23 5-W
l-l
(5-W
Turn-Signaland
HAZARD
1
m
Battery
1 81
El3
Ignition
2-R
switch
2-W
link
A-32
GW To lighting
switch
e [Refer to P.8-46.1
2-R
2-RW
I-
2-B
To column switch
[Rear to P.8-461
'I
7
l.ZS-tit3
0.85-GY
+a
I_ \
(Bl -6
0.85-GL
LO
Gw -@
rn&
lzil
A-57
Turn-signal
and
hazard light
Front
Turn-signal
and
hazard light
Front
combination
light (R.H.)
el
n00
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b-d
5
c-05
J CL
--.
I- \I--
IG
Combination
meter
WIRING
HARNESS
- Turn-Signal
and
OR
0 RI.
Turn-signal
Turn-signal
flasher
unit
I
I
switch
Hazard
GO
0 0.3
iazard
Hazard
flasher
unit
r
E
L:
ci
Light
8-49
Circuit
switch
*2
C-62
Turn-signal
and hazard
->
&
light
Rear Combination
light (R.H.)
light
Rear combination
light (L.H.)
mm
c-57
Dimmer
switch
control
OL
Em B
WL
EJ
(1) For information

concerning
the ground points (examem~:~s~
) refer to P.8-7.
(2) The symbols 0, 0, etc. indicate that the wiring
is
connected
symbol) to the
facing page.
the left page.)
Wiring color code

B: Black
LI: Light blue
Br: Brown
0: Orange
37W825
-2
G: Green
P: Pink
Gr: Gray
R: Red
L: Blue
Y: Yellow
Lg: Light green

W: White
I
STB Revision
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8-50
WIRING
HARNESS
- Stop Light
Circuit
IO STOP LIGHT CIRCUIT
1
In3
Sub
fusible
link
A-07
Main
link
fusible
Multi-purpose
fuse
0.85-GR
0.85-G
c-51
0.85-G
Hazard
switch
1.85-WG
$R
WL
1 1 1
,I
,I
Turnsignal
switch
Rear
light
Remark
For information
refer
to P.8-7.
concerning
Wiring
color
code
B: Black
LI: Light
blue
the
Br: Brown
0: Orange
ground
points
(example:
G: Green
P: Pink
cdmbination
(L.H.)
Rear
light
c:mbination
(R.H.)
),
Gr: Gray
R: Red
1 STB Revision
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L: Blue
Y: Yellow
Lg:
W:
Light
White
green
WIRING
HARNESS
11 INSTRUMENT
Instrument
Panel
Wumination
PANEL ILLUMINATION
Battery
CIRCUIT
Sub fusible
5-w
Main
fusible
5-w l-75-W
LA-23
8-51
Circuit
link
0.5-G
2-R
link
@L
CA
M
A
A-22
rx
c-l
Y$lO
I
Optical
fiber
Multi-purpose
fuse
control
illumination
0
3
a
.ight contr
clay
c-4o1l
knob
light
Combination
gauge
Illumination
ligl
control
switch
&01BY
7t
Shift-position
lmer
C-38
4
Ashtray
illumination
Cigaretty
lighter
minagn
n+
Hegpane
illumination
light
63
_
Clock I
illumination
(1) The broken lines are applicable to models equipped with

(2) For information
concerning
the ground
points (example: 0 ), refer to P.8-7.
Wiring color code
B: Black
Br: Brown
G: Green
Gr: Gray
P: Pink
R: Red
LI: Light blue
0: Orange
1 STB Revision
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Combination
illumination
light
meter
light
37w '62;
L: Blue
Y: Yellow
Lg: Light green

W: White
WIRING
HARNESS
- Meter
Circuit
12 METER CIRCUIT
1
m
A-02
Sub fusible
link
Ignition
switch
15-w
Main
link
fusible
--
A-22
1
m
-ffiFirmer
control
[Refer to P.8-511
I 0 column :
[Refer to P.E
BY
4
@/
Multi-purpose
fuse
To turn,signal
switchfd,,, (bYI ,
[Refer to P.8-491
1
To seat belt timer
[Refer to P.8-661
G 1
To seat belt warning
buzzer [Refer to P.8-661 M
I
To alternator
0.85tW
fRefer to P.8-371 41D\ 1
o dimmer, passir, ,, ,
witc :h and light control Ir r n ! , I
~ -_
clay [Refer to P.8461
Kb
To dome light
[Refer to P.8-471 4
To door yi~,h,,_(RG)
I
I
ID,.&-* +,.
YBdD
q
3_---_-ly-J
Ir
t
Combination
1 STB Revision
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meter
WIRING
HAFNESS
Meter
8-53
Circuit
O&y-ssure
[Eal
> El
Oil pressure
gauge unit
YRB BRYR
ElxQ
A-20
I.+
A-03
A-06
4WD
indicator
--
.-
I
I
I
E
I
I
*
- -,,-
--
YB
L,
I
4
Brake fluid
level sensor
0.85-B
Jo
cigarette lighter
[Refer to P.8-621
-I m-w
I
I
k-1
A-04
A-07
rA
fs
Ei
switch
Parking
switch
? I
brake
I
I
I
I
I
I
1
' 1
I
I I
I 1
B-23
, I I I
I !
Fuel gauge
unit
Water
temperature
gauge unit
37W617
les with combinatior
Combination
(2) %?zgdeash and dot line (- -) indicates vehicles wit1

automatic free-wheeling
hub indicator.
(3) For information
concerning
the ground points (er
ample:n),
refer to P.8-7.
(4) The symbols@,@,
etc. indicate that the wiring i
connected
symbol) tl
the facing page.
(In other words,Oon
the right page is connecter
gauge
to@ontheleft page.)
Wiring color code
B: Black
LI: Light blue
Br: Brown
0: Orange
G: Green
P: Pink
Gr: Gray
R: Red
1 STB Revision
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L: Blue
Y: Yellow
Lg: Light green

W: White
8-54
HARNESS
WIRING
- Horn Circuit
13 HORN CIRCUIT
/I
1
m
Battery
Sub fusible
A-23
5-w/-75-w
m 0.5-G
Main
fusible
link
Ignition
switch
Z-W
link
OFF
]AM
ACC]
Multi-purpose
fuse
a
-i
::
C
To wiper motor
[Refer to P.8-59.1
A-3
Column
A-39
switch
37W608
Remark
For information concerning
the ground
refer to P.8-7.
Wiring color code
Br: Brown
B: Black
LI: Light blue
0: Orange
points (example:
G: Green
P: Pink
),
GI.: Gray
R: Red
1 STB Revision
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L: Blue
Y: Yellow
Lg: Light green

W: White
WIRING
HARNESS
Heater
8-55
Circuit
14 HEATER CIRCUIT
*I BI
l!zEl
lonition
switch
Battery
0
(Ignition
switch)
Multi-purpose
fuse
To turn
signal
flasher
[Refer
to P.8-49.1
unit4
-P---
H
M2
Ml
bFF
0.85-RL
Blower
motor
C-18
Blower
!!
i
\
Blower
resistor
switch
motor
LBLI
LRLW
El3
I
Heater
relay
8L
LRLR
El *2
*1
37W614
Remark
For information
concerning
refer
to P.8-7.
Wiring
color
code
B: Black
LI: Light
blue
the
Br: Brown
0: Orange
ground
points
G:
P:
(example:
Green
Pink
),
Gr: Gray
R: Red
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L: Blue,
Y: Yellow
Lg:
W:
Light
White
green
8-56
WIRING
HARNESS
15 AIR CONDITIONER
- Air Conditioner
Circuit
CIRCUIT
Ignition
Main
fusible
I;..,,
Sub fusible
(Fuse B)
m
1
switch
link
+2
0.85-R
(lonition
switch)
,!..I
unit ~ 0.85-RL

[Refer to P.849.1
L
I
3-LRwQ
,0.85-LW
To cigarette
lighter
[Refer to P.8-62.1
0.85-WB@
FA2
Ml
Ii
Blower
Br: Brown
0: Orange
1C-18
bFF
Wiring color code

B: Black
LI: Light blue
Blower
motor
8
I
IY4JYl!!!a
f
1
switch
G: Green
P: Pink
lower
motor
Gr: Gray
I?: Red
T-
L: Blue
Y: Yellow
Heater
relay
Lg: Light green

W: White
STB Revision
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WIRING
HARNESS
- Air
Conditioner
8-57
Circuit
B 0.3
LvfL
ElFI
Air conditioner
relay
*2
Air :on!$!er
to feed back carburetor

unit
[Refer to P.8-39.1
85-Bw:o.85-Bw
0
0:
) control
u
A-25
(Bl
rela
Lw
20.85-BWr
ll 10.85-BWL&
A-13
Vacuum
valve
solenoid
@,0.85-WB
A-45
0.85-BWnBW
Is*la
Magnetic
clutch
(compressor)
Condenser
blower motor
Condenser
blower
motor relay
Water temperature
switch
BY
rl
-I37W611
Remarks
(1) For information
converning
the ground
points (example:(l)n),
refer to P.8-7.
(2) The svmbols
0, 0, etc. indicate that the wiring
is
connedted
symbol) to-the
facing page. (In other words, 0 on the right page is
connected
to 0 on the left page.)
) STB Revision
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8-58
WIRING
HARNESS
16 WIPER AND WASHER
- Wiper
Circuit
Washer
LW
1
m
CIRCUIT
IL&
Battery
and
Sub fusible
Ignition
link
-1.25-BAs2
Main
fusible
switch
2-R
5-w r--(5-w
Z-W
link
To lighting
switch
Light
control
relay
Multi-purpose
fuse
I-2-B
Intermittent
wiper
control
relay
Remarks
(1) For information concerning the
ground points (example: q ).
refer to P.8-7.
(2) The symbols 0.0, etc. indicate
that the wiring is connected (using
the same numerical symbol) to the
facing page.
(In other words, 0 on the right
page is connected to 0 on the left
page.)
C-64
Headlight
washer motor
Wiring
I
1
Headlight washer
motor relay
color code
B: Black
LI: Light blue
Br: Brown
0: Orange
G: Green
P: Pink
Gr: Gray
R: Red
L: Blue
Y: Yellow
/ STB Revision
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Lg: Light green

W: White
WIRING
HARNESS
m --
- Wiper
and
Column switch
FronthiDer
switch
Washer
8-59
Circuit
-1
BP
118 B
f!EEl
Headlight
washer
switch
I
-_I
Rear wiper and

washer switch
I
1
z-09
c-53
@4-zo-(YL)
@JY'
@- BR
@- Lw
-1 j
A-14
I
1A-58
Frontwasher
motor
Front wiper
motor
Rearwasher
motor
WB
Q I.
Rear wiper
motor
37W024
1 STB Revision
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S-60
WIRING
HARNESS
17 RADIO/CASSETTE
Battery
A-02
/ Cassette
Deck
Circuit
DECK CIRCUIT
L1
1
EQ3
1
lm
Ignition
Sub fusible
1.25-B
A-23
\
rlin
- Radio
5-*5-w
link
0.5-G
2-w
fusible
To light control
relay
[Refer to P.8-461
To air conditioner
[Refer to P.8-561
To combination
4
meter
[Refer to P.8-521
BY
DIN Cable
JC
3:
A-C-1
Tape
Radio
player
1 STB Revision
-7
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switch
WIRING
HARNESS
- Radio / Cassette
8-61
Deck Circuit
(R.H.)
Front speaker
1
(L.H.)
Rear speaker
37W618
Remarks
(1) For information
concerning
the ground points (example: 0 ), refer to P.8-7.
(2) The symbols 0, 0, etc. indicate that the wiring
is
connected
symbol) to the
facing page.
the left page.)
Wiring color code
Br: Brown
G: Green
Gr: Gray
B: Black
I?: Red
P: Pink
LI: Light blue
0: Orange
1 STB Revision
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L: Blue
Y: Yellow
Lg: Light green

W: White
8-62
WIRING
18 CIGARETTE
HARNESS
Cigarette
Lighter
/ Clock
Circuit
LIGHTER / CLOCK CIRCUIT

Sub
fusible
r-l E-f?
Ignition
link
)
switch
-u
yn;in
fusible
7-R
To light control
[Refer
to P.8-461
To radio
[Refer
to
To hazard
[Refer
to
flasher
P.8-491
\*I
relay
GW
P&601-,
unit4
3FI .LJ-
Pm
G
Multi-purpose
II
illumination
fuse
light
To heater
illumination
[Refer
to
control
light
P.8-511
Clock
1
J
h
6
CT
0:
Jc-36
To combination
[Refer
to P.8-521
Wiring
B:
Br:
G:
Gr:
L:
Lg:
Black
Brown
Green
Gray
Blue
Light
color
mete&
BY
code
green
LI:
0:
P:
H:
Y:
W:
Light
Orange
Pink
Red
Yellow
White
blue
To dimmer
[Refer
to
control
P.8-511
switch
Remark
For information
refer
to P.8-7.
http://vnx.su/
BY
concerning
the
ground
points
(example:
1,
WIRING
19 DEFOGGER
HARNESS
- Defogger
CIRCUIT
Sub fusible
A-23
5-wn5-w
ynlin
8-63
Circuit
0.5-G
I ml
EEH
link
Ignition
fusible
switch
z-w ,
A
I
l%
7
N
(#IO
-22
To light control
~-RN
w
relay
[Refer to P.8-461
+!I00
Defogger
1.25-B
m
I
Ki .
4
1.25-BR
B-05 /
B
Q
z
A
pFJ
Bg
L-l
2-FB m
Multi-purpose
@fuse
3-B
B-13
BR
Q
m
of
A
To column switch
[Refer to P.8-461
LY!ii!T
Rheostat
x7.
Remarks
For information
refer to P.8-7.
concerning
the ground
points
Detogger
*I
switch
(example:a),
37W62
Wiring color code

B: Black
LI: Light blue
Br: Brown
0: Orange
G: Green
P: Pink
Gr: Gray
R: Red
1 STB Revision
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L: Blue
Y: Yellow
Lg: Light green

W: White
8-64
WIRING
20 POWER WINDOW
HARNESS,
Power
Window
Circuit
CIRCUIT
w
EEH
Ignition
- ..
I
81
switch
II
1.25-B
Main
link
fusible
Multipurpose
fuse
[Refor to P.8-491
, I-
(RL)
2-LR bg
Power window
main switch
-I
*1 1.25-R
*2 1.25-G
Remarks
(I) For information
concerning
the ground
points (example:m). refer to P.8-7.
(2) The symbols 0, 0, etc. indicate
that the wiring
is
connected
symbol) to-the
facing page.
the left page.)
1 STB Revision
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1.25-R
1.25-G
,@
,@
WIRING
R
B0
Power
motor
window
(L.H.)
bM
B-31
c
::
r
HARNESS
- Power
2-B
,
r
>
.I.
-I
Window
8-65
Circuit
To colunm switch
[Refer to P.8-511
washer relay
[Refer to P.8-581
Power
window
relay
IRL)
:=2-L,
04 2-L
g:
2-B
2-RL
Power window
sub switch (R.H.)
1.25-R
@*1.25-G
8*
37w003
Wiring color code

B: Black
LI: Light blue
Br: Brown
0: Orange
G: Green
P: Pink
Gr: Gray
R: Red
1 STB Revision
http://vnx.su/
L: Blue
Y: Yellow
Lg: Light green

W: White
8-66
WIRING
HARNESS
Buzzer
Circuit
21 BUZZER CIRCUIT
nil1
Battery
-1.25-B
A-02
Sub fusible
I 01
IT8
link
Ignition
switch
0
Main
link
fusible
dhm
b-
Multi-purpose
OR Key reminder
A0 switch
[Refer to P.8-491
c-03 r
C
-CCl
z-CY
z-
m
c-50
P-P
mm-l
aa-cd
-.A
IC
-J
ski&t
switch
I.5
bb
Key reminder
and seat belt
warning
buzzer
Combination
meter
Seat belt
warning timer
Remark
For information
refer to P.8-7.
37W607
concerning
Wiring color code

B: Black
LI: Light blue
the ground
Br: Brown
0.: Orange
points
(example:
G: Green
P: Pink
),
Gr: Gray
R: Red
1 ST9 Revision
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L: Blue
Y: Yellow
Lg: Light green

W: White
WIRING
HARNESS
Automatic
Free-Wheeling
FREE-WHEELING
Battery
-5-w
Main
link
Indicator
System
HUB INDICATOR
Sub
171.
Hub
fusible
Circuit
B-67
SYSTFM
link
1 m2-G
fusible
rgntrron
Iz-w
- _I
swrtcn
ON
Pulse
generator
Multi-purpose
fuse
To column
[Refer
to
switch
P.8-461
::
0:
2I
I++m
c-07
Vehicle
speed
detective
circuit
Pulse
detective
circuit
EleAtrir
circuit
power
d&V+
LR
m
m
,:cAcJl
!!I
T-r-
q OE!
z-
C-06
-.I;
c-04
Combination
meter
Automatic
indicator
For information
refer
to P.8-7.
Wiring
B: Black
LI: Light
color
blue
free-wheeling
control
unit
concerning
the
ground
hub
37W610
points
(example:
).
code
Br: Brown
0: Orange
G: Green
P: Pink
,;:
;;;Y
STB Revision
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L: Blue
Y: Yellow
Lg:
W:
Light
White
green
WIRING
HARNESS
- Back Door Lock Circuit
23 BACK DOOR LOCK CIRCUIT
Battery
Sub fusible
link
Multi-purpose
fuse
1.25F-G
-1.25-G
1.25F-R
2-LR -To
1.25-R
2-B
B-l 2
cza
I I
xx. .
77
B-24 [
cLL3
ALA
CVN
. .
77
-To
heater relay
[Refer to P.8-551
column switch
[Refer to P.8-511
Back door
lock actuator
Wiring color code

B: Black
Br: Brown
LI: Light blue
0: Orange
Remark
For information
refer to P.8-7.
G: Green
P: Pink
Gr: Gray
R: Red
L: Blue
Y: Yellow
/ STB Revision
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37W602
concerning
the ground
Lg: Light green

W: White
points (example:
),
WIRING
HARNESS
- Centralized
896!
Junction
CENTRALIZED JUNCTION
Main
Fusible
Link
Circuit
Cable color
mm (ir?.)
continuous
Fusing current
Sub Fusible
current
40
190
Link
Circuit
Cable color
Fusible link size
mm7 (in.2)
continuous
Fusing current
Dedicated
Feed back carburetor

control circuit
1.25 (.0019)
A
Item
Permissible
circuit
Black
Fusible link size

Permissible
Alternator
Main circuit
current
Lighting circuit
Stop light, door lock

and heater circuit
Ignition circuit
Green
0.5(.0008)
Red
Green
0.85(.0013)
27
34
0.5(.0008)
27
100
150
100
Power window
circuit
Green0.5(.0008)
27
100
Fuse
Upper beam indicator circuit
http://vnx.su/
Air conditioner
cixit
WIRING
Multi-purpose
Power
- Centralized
Junction
Fuse
supply circuit
Battery
Headlight
HARNESS
relay
Ignition switch
(IG)
Battery
Ignition switch
(ACC)
Fuse No.
Rated
capacity A
Applicable
20
Clock, Dome light, Hazard warning
10
10
Tail lights, License plate lights, Illumination lights, Headlight

washer relay, Position lights
__Heater relay, Seat belt warning timer, Turn-signal lights,
Alternator, Seat belt switches,
Power window relay, Fuel and
water temperature gauges, Oil pressure gauge, Voltage meter,
Indicator and warning lights, Inhibitor switch, Automatic
free-wheeling
hub indicator control unit
IO
15
Back-up lights, Auto choke relay, OD-OFF relay

__Rear window defogger
20
Heater, Back door lock
15
Key-reminder
15
Windshield
Intermittent
10
Rear window
10
15
Cigarette lighter, Radio, Tape player, Clock (ACC), Spare terminal,

Air conditioner relay
http://vnx.su/
circuits
switch,
Stop lights, Buzzer
wipers and washer,

wiper relay, Horn
wiper
flashers
Headlight
washer
relay,
and washer
CHARGING
CHARGING
SYSTEM
General
8-71
Information
SYSTEM
GENERAL INFORMATION
NOBEMD
The charging system comprises

battery, alternator with regulator, charging indicator light and wire.
The alternator has 6 built in rectifiers
(3 positive and 3 negative), which rectify alternating current to direct current.
Accordingly,
the alternator terminal B is D/C. Furthermore
the alternator regulates the charge voltage through the
use of battery voltage detection
system.
The main parts of the alternator
are: rotor, stator, rectifier, condenser,
brush, bearing, drive belt pulley and a
brush holder with built in electronic
voltage
regulator.
light
:--\;-----------I
I.C.
-A
I.C.
regulator
alternator
-y
I
6EL239
Drive
-belt
Brush
heat
-sink
pulley
Rotor
assembly
Stator
6EN246
1 STB Revision
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6EN211
8-72
CHARGING
SYSTEM
- General Information
MAINTENANCE
Test indicator
FREE TYPE BATTERY
The maintenace-free
battery is, as the name implies, totally
maintenance
free and has no removable
battery cell caps.
Water
never needs to be added to the maintenace-free
battery.
The battery is completely
sealed, except for small vent holes in
the cover, These vent holes allow what small amount
of
gasses are produced
in the battery to escape. The special
chemical composition
inside the battery reduces the production of gas to an extremely
small amount at normal charging
voltages. The battery contains a visual test indicator
which
indicates
the condition
of the battery.
( ST6 Revision
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CHARGING
SPECIFICATIONS
GENERAL
SPECIFICATIONS
ALTERNATOR
NOOEB-B
Specifications
~-Battery voltage sensing
Items
Type
Model No.
A2T03477
Part No.
MD1 10318
Rated output
12150
VIA
Voltage regulator
Electronic built-in type
BAlTERY
Specifications
Items
Type
Ampere hours (5 HR) Ah
55824R (S)-MF
36
Cranking
rating [at - 178C (OF)]

min.
Reserve capacity
420
75
NOTES
1. CRANKING RATING is the current a battery can deliver for 30 seconds and maintain a terminal voltage of 7.2 or
greater at a specified temperature.
2. RESERVE CAPACITY RATING is the amount of time a battery can deliver 25 A and maintain a minimum terminal
voltage of 10.5 at 26.7C (80F).
NOBEC-
Specifications
Items
Standard values
Regulated voltage
Ambient
temp. at voltage regulator
- 20C ( - 4F)
14.2-15.4
20C (68F)
13.9-14.9
60C (140F)
13.4-14.6
80C (176F)
13.1-14.5
Slip ring O.D.
23 (.906)
mm (in.)
Field coil resistance
3.1
Limit
Output current
Slip ring O.D.
Min. 35
22.2 (.874)
mm (in.)
[ STB Revision
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8-74
CHARGING
items
__-
Nm
ft.lbs.
Alternator
brace bolt
12-15
9-l 1
Alternator
support
20-22
14-16
bolt nut
High pressure
hose nut
20-25
14-18
Low pressure
hose nut
30-35
22-25
1 STB Revision
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CHARGING
8-75
SYSTEM -Troubleshooting
TROUBLESHOOTING
NOBEH-
Symptom
Probable cause
Remedy
Reference
we
Charging warning indicator does not light

with ignition switch
ON and engine off.
Fuse blown
Check fuses
8-70
Replace light
loose
Tighten loose connections
voltage regulator faulty
Replace voltage regulator
8-79
Adjust tension or replace drive

belt
Refer to
GROUPS.
Repair or replace cables
8-8 1
Fuse blown
Check fuses
8-70
Fusible link blown
Replace fusible link
8-69
Electronic
faulty
Test alternator
8-77
8-79
Wiring faulty
Repair wiring
Drive belt loose or worn
Adjust tension or replace drive

belt
Refer to
GROUP 9.
Wiring connection
Tighten loose connection

repair wiring
Light burned out

1
1 Wiring connection
Electronic
Charging warning indicator does not go

out with engine
running
(Battery requires frequent recharging)
Drive belt loose or worn

Battery cables loose, corroded
t
Run-down
or worn
battery
voltage regulator or alternator
loose or open circuit
or
Fusible link blown
Poor grounding
1 Repair
I
Overcharge
8-69
I-I
Electronic
faulty
voltage regulator or alternator
Test alternator
8-77
8-79
Decrease
in life of battery
Replace battery
8-81
Replace voltage regulator
8-79
Electronic voltage regulator faulty
STB Revision
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8-76
CHARGING
3 CHARGING
SYSTEM
- Circuit
Diagram
CIRCUIT
Ignition
switch
OFF
IAM
Main
fusible
link
fl.3-Br
Battery
3
A
m L
A-02
1~5~~
Sub fusible
(IGN . SW)
A-23
IG
] c-55
m
A
link

unit [Refer to P.8-49.1
Multin, Irnn4P
ComSeter
Remark
For information
refer to P.8-7.
concerning
Wiring color code

B: Black
LI: Light blue
the ground
Br: Brown
0: Orange
points (example:
G: Green
P: Pink
37W605
),
Gr: Gray
R: Red
1 STB Revision
http://vnx.su/
L: Blue
Y: Yellow
Lg: Light green

W: White
CHARGING
SYSTEM
Service
Adjustment
SERVICE ADJUSTMENT
INSPECTION
8-77
Procedures
OF THE CHARGING
PROCEDUREswmAB
SYSTEM
VOLTAGE DROP TEST OF ALTERNATOR

OUTPUT WIRE
This test judges whether or not the wiring (including the fusible
link) between the alternator B terminal and the battery (+) terminal
is sound by the voltage drop method.
Preparation
(2) Disconnect the battery ground cable.
(3) Disconnect the alternator output lead from the alternator B
terminal.
(4) Connect a DC ammeter
(0 to 100 A) in series to the B
terminal and the disconnected
output lead. Connect the (+)
lead of the ammeter to the B terminal and the (-) lead to
the disconnected
output wire.
lEL15I
NOTE
Use of a clamp type ammeter that can measure current without disconnecting
the harness is preferred. The reason is that
when checking a vehicles that has a low output current due to
poor connection of the alternator B terminal, such poor connection is corrected as the B terminal is loosened and a test
ammeter is connected in its place and as a result, causes for
the trouble may not be determined.
(5) Connect a digital voltmeter between the alternator B terminal and battery (+) terminal. Connect the (+) lead wire of the
voltmeter
to the B terminal and the (-) lead wire to the
battery (+) terminal.
(6) Connect the battery ground cable.
(7) Leave the hood open.
Test
(2) Turn on or off the headlights and small lights and adjust the
engine speed so that the ammeter reads 20 A and read off the
voltmeter indication under this condition.
Result
(1) It is okay if the voltmeter indicates the standard value.
Standard value : 0.2 V max.

(2) If the voltmeter indicates a value that is larger than the standard value, poor wiring is suspected, in which case check the
wiring from the alternator B terminal to fusible link to battery (+) terminal. Check for loose connection,
color change
due to overheated harness, etc. and correct them before testing again.
(3) Upon completion of the test, set the engine speed at idle. Turn
off the lights and turn off the ignition switch.
(5) Disconnect the ammeter and voltmeter that have been connected for the test purpose.
(6) Connect the alternator output wire to the alternator B terminal.
( STB Revision
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8-78
CHARGING
SYSTEM
- Service Adiustment
Procedures
OUTPUT CURRENT
TEST
This test judges whether or not the alternator
current that is equivalent to the nominal output.
gives an output
Preparation
(1) Prior to the test, check the following items and correct as
necessary.
(a) Check the battery installed in the vehicle to ensure that it
is in sound state*. The battery checking method is described in BATTERY.
NOTE
*The battery that is used to test the output current should
be one that has been rather discharged.
With a fully
charged battery, the test may not be conducted correctly
due to an insufficient load.
(b) Check tension of the alternator drive belt. The belt tension
check method is described in GROUP
7 COOLING
Service Adjustment
Procedures.
(2) Turn off the ignition switch.
(4) Disconnect the alternator output wire from the alternator B
terminal.
80A
Iad
(5) Connect a DC ammeter (0 to 100 A) in series between the B

output wire. Connect the (+)
lead of the ammeter to the B terminal and connect the (-)
lead wire to the disconnected
output wire.
NOTE
Tighten each connection by bolt and nut securely
current will flow. Do not relay on clips.
Relay with diode
Voltmeter
Ammeter
176
as a heavy
(6) Connect a voltmeter (0 to 20 V) between the B terminal and

ground. Connect the (+) lead wire to the alternator B terminal and (-) lead wire to a sound ground.
(7) Set the engine tachometer
and connect the battery ground
cable.
(8) Leave the engine hood open.
Test
(1) Check to see that the voltmeter
reads the same value as the
battery voltage.
If the voltmeter reads 0 V, an open circuit in the wire between
the alternator B terminal and battery (-) terminal, a blown
fusible link or poor grounding is suspected.
(2) Turn on the headlight switch and start the engine.
(3) Set the headlight at high beam and the heater blower switch
at HIGH, quickly increase the engine speed to 2500 rpm and
read the maximum
output current value indicated by the ammeter.
NOTE
After the engine start up, the charging current quickly drops.
therefore, above operation must be done quickly to read maximum current value correctly.
[ STB Revision
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CHARGING
SYSTEM
8-79
Procedures
Result
(1) The ammeter reading must be higher than the limit value. If it
is lower but the alternator output wire is normal, remove the
alternator from the vehicle and check it.
Limit
value
: 31 A min.
Caution
1. The nominal
output
current value is shown on the
nameplate
affixed to the alternator
body.
2. The output current value changes with the electrical
load and the temperature
of the alternator
itself.
Therefore, the nominal
output current may not be obtained if the vehicle electrical load at the time of test is
small. In such a case, keep the headlights
on to cause
discharge of the battery or use lights of another vehicle as a load to increase the electrical load. The nominal output current may not be obtained if the temperature of the alternator
itself or abmient temperature
is
too high. In such a case, reduce the temperature
before testing again.
(2) Upon completion of the output current test, lower the engine
speed to the idle speed and turn off the ignition switch.
(3) Disconnect
the battery ground cable.
(4) Remove the test ammeter
and voltmeter
and the engine tachometer.
(5) connect the alternator output wire to the alternator
B terminal.
REGULATED
VOLTAGE
TEST
The purpose of this test is to check that the electronic

regulator controls the voltage correctly.
voltage
Preparation
(1) Prior to the test, check
essary.
the following
items
and correct
if nec-
(a) Check the battery installed on the vehicle to see that it is

fully charged. For battery checking
method, see BATTERY.
(b) Check the alternator
drive belt tension. For belt tension
check, see GROUP
7 COOLING
Procedures.
(3) Disconnect
the battery ground cable.
(4) Connect a digital voltmeter
between
the S terminal of the
alternator and ground. Connect the (+) lead of the voltmeter to
the S terminal of the alternator, inserting from the wire side
of the 2-way connector
and connect the (-1 lead to sound
ground or battery (-) terminal.
1 ST6 Revision
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8-80
CHARGING
SYSTEM
- Service
Adjustment
Procedures
e
Ignition
switch
Load
Alternator
Ammeter
Voltmeter
I
@
lid-hi!
6EK52
(5) Disconnect the alternator output wire from the alternator B

terminal.
(6) Connect a DC ammeter (0 to 100 A) in series between the B
output wire. Connect the (+I
lead of the ammeter to the B terminal and connect the (-1
lead wire to the disconnected
output wire.
(7) Set the engine tachometer
and connect the battery ground
cable.
Test
(1) Turn on the ignition switch and-check that the voltmeter indicates the following value.
Voltage : Battery voltage
If it reads 0 V, there is an open circuit in the wire between the
alternator S terminal and the battery (+) or the fusible link
is blown.
(2) Start the engine. Keep all lights and accessories off.
(3) Run the engine at a speed of about 2500 rpm and read the
voltmeter when the alternator output current drops to 10 A or
less.
Result
(1) If the voltmeter
reading agrees with the value listed in the
regulating voltage table below, the voltage regulator is functioning correctly. If the reading is other than the standard
value, the voltage regulator or the alternator is faulty.
Regulating
Voltage regulator ambient
temperature C (F)
-20
1 STB
voltage
table
Regulating voltage V
(-4)
14.2-15.4
20 (68)
13.9-14.9
60 (140)
13.4-14.6
80 (176)
13.1-14.5
Revision
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CHARGING
SYSTEM
Procedures
8-81
(2) Upon completion

of the test, set the engine speed at idle and
turn off the ignition switch.
(4) Remove the test voltmeter and ammeter and the engine tachometer.
(5) Connect the alternator output wire to the alternator B terminal.
INSPECTION
VISUAL
OF BATTERY
INSPECTION
OF BATTERY
NOBEIBA
(1)
The batten/ contains a visual test indicator which gives blue signal
when an adequate charge level exists, and white signal when
charging is required.
VISUAL
ll3Y1848
INSPECTION
OF BAlTERY
(2)
Make sure ignition switch is in Off position and all battery feed
accessories are Off.
1. Disconnect ground cable from battery before disconnecting
(+) cable.
2. Remove battery from vehicle.
Caution
White
I
Care should be taken in the event battery case is cracked

or leaking to protect
hands from the electrolyte.
A suitable pair of rubber gloves (not the household
type) should
be worn when removing
battery
by hand.
Blue
I
3.
4.
5.
6.
7.
8.
9.
10.
Inspect battery carrier for damage caused by loss of acid from

battery. If acid damage is present, it will be necessary to clean
area with a solution of clean warm water and baking soda.
Scrub area with a stiff bristle brush and wipe off with a cloth
moistened with ammonia or baking soda in water.
Clean top of battery with same solutions as described in Step
(3).
Inspect battery case and cover for cracks. If cracks are
present, battery must be replaced.
Clean the battery post with a suitable battery post cleaning
tool.
Clean the inside surfaces of the terminal clamps with a suitable battery terminal cleaning tool. Replace damaged or frayed
cables and broken terminals clamps.
Install the battery in vehicle.
Connect (+) and (-) cables to battery in the order of mention.
Tighten the clamp nut securely.
1 STB Revision
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8-82
CHARGING
SYSTEM
- Service
BATTERY
Adjustment
Procedures
CHARGING
NOEEICDZ
Caution
When batteries
are being charged, an explosive
gas forms
beneath the cover of each cell. Do not smoke near batteries
on charge or which have recently
been charged.
Do not
break live circuits
at the terminals
of the batteries
on
charge. A spark will occur where the live circuit is broken.
Keep all open flames away from the battery.
Battery electrolyte
temperature
may temporarily
be allowed to
rise to 55C (131F). Increase of electrolyte
temperature
above
55C (131F) is harmful to the battery, causing deformation
of
battery cell, decrease in life of battery, etc.
CHARGE
RATE
If the test indicator is white, the battery should be charged as
outlined
below.
When the dot appears or when maximum
charge shown
below is reached, charging
should be stopped.
NOTE
If the indicator does not turn to blue even after the battery is
charged, the battery should be replaced;
do not overcharge.
Charge
Rate Chart
Battery
55B24R (S)-MF
(420 amps)
Slow Charging
Fast Charging
20 amps 2.5 hrs.

30 amps 1.5 hrs.
/ STB Revision
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CHARGING
SYSWVI
- Alternator
8-83
ALTERNATOR
REMOVAL
AND
INSTALLATION
(Vehicles
without
Air Conditioner)
NOEEJAE
0 Adjustment
of the Drive Belt Tenslon (Refer to GROUP 7 COOLINGService Adjustment
Procedures)
Removal
I)+
steps
1. Connection
of alternator
connector
2. Alternator
3. Shim
4. Support bolt
5. Brace
NOTE
(I) Reverse
(2)
the removal
: Refer
to
Service
9-11
<I
16W1565
procedures
Points
ft.lbs.
to
of
reinstall.
installation.
SERVICE
POINTS
OF INSTALLATION
2. INSTALLATION
OF ALTERNATOR
(1) Position the alternator and insert the support bolt. (Do not
attach the nut.)
(2) Push the alternator
forward and determine
how many
spacers
[thickness:
0.198 mm (.0078 in.)] should
be
inserted between the front leg of the alternator
and the
front case (space A in the illustration).
(There should be
enough spacers so that they do not fall out when you let
go of them.)
(3) Insert the spacers (space A in the illustration),
attach the
nut, and complete
the installation.
ST6 Revision
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8-84
CHARGING
REMOVAL
AND
INSTALLATION
SYSTEM
(Vehicles
with
- Alternator
Air Conditioner)
30-35
D Draining
of Refrigerant
CONDITIONING
(Refer to
- Service Adjust-
ost-installation
Operation
1 Charging of Refrigerant (Refer to
GROUP 24 HEATERS AND AIR
CONDITIONING
- Service Adjustment Procedures)
D Adjustment
of Drive Belt Tension
(Refer to GROUP 7 COOLING and
GROUP 24 HEATERS AND AIR
CONDITIONING
~ Service Adjustment Procedures)
:emoval
~~
Nm
20-22
14-16
Nm
ft.lbs.
16W1566
steps
1.
2.
3.
4.
5.
6.
Connection
Connection
Connection
Compressor
Connection
Alternator
of high pressure
hose
of low pressure
hose
of compressor
connector
of alternator
OTE
) Reverse the removal procedures
I) e+ : Refer to Service Points
connector
to reinstall.
of installation
/ STB Revision
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CHARGING
SYSTEM
SERVICE
6.
- Alternator
POINTS
INSTALLATION
8-85
OF INSTALLATION
OF ALTERNATOR
(1) Position the alternator and insert the support bolt. (Do not
attach the nut.)
(2) Push the alternator
forward and determine
how many
spacers [thickness:
0.198 mm (.0078 in.)] should
be
inserted between the front leg of the alternator
and the
front case (space A in the illustration).
(There should be
enough spacers so that they do not fall out when you let
go of them.)
(3) Insert the spacers (space A in the illustration),
attach the
nut, and complete
the installation.
; .-:,
i
) STB Revision
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CHARGING SYSTEM-Alternator
10
\I
11
14
I
1 EL666
Disassembly
4*
1.
2.
l a 3.
4.
5.
6.
4*
7.
8.
9.
10.
4*
11.
12.
13.
14.
4,
steps
Pulley
Seal
Rotor assembly
Rear bearing
Bearing retainer
Front bearing
Front bracket
Stator
Terminal
Plate
Regulator and brush holder
Brush
Brush spring
Slinger
15. Rectifier assembly

16. Rear bracket
NOTE
1 STB Revision
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CHARGING
8-87
SYSTEM-Alternator
SERVICE
POINTS
OF DISASSEMBLY
7. REMOVAL OF FRONT BRACKET/lG.
(1) Insert plain screwdriver
core and pry downward.
between
Caution
Do not insert screwdriver
of damage to stator coil.
REAR BRACKET
front bracket
and stator
too deep, as there is danger
(2) Rear cover may be hard to remove because a ring is used

to lock outer race of rear bearing. To facilitate removal of
rear cover, heat just bearing box section with a 200-W
soledering iron.
Do not use a heat gun, as it can damage diode assembly.
1.
REMOVAL
OF PULLEY
Clamp the rotor in a vise with
11. REMOVAL
OF REGULATOR
(1) Unsolder
rectifier.
(2) Unsolder
three
two
stator
soft jaws.
AND BRUSH
leads
plates soldered
soldered
HOLDER
to main diodes
on
to rectifier.
Caution
1. When soldering
or unsoldering,
use care to make
sure that heat of soldering
iron is not transmitted
to diodes for a long period. Finish soldering
or unsoldeing in as short a time as possible.
2. Use care that no undue force is exerted to leads of
diodes.
INSPECTION
ROTOR
l
Check rotor coil for continuity.

Check to ensure that there is
continuity between
slip rings.
If resistance
is extremely
small, it means that there is a short.
If there is no continuity or if there is short circuit, replace rotor
assembly.
Standard
value
: 3.1 f2
6ELllt
.
1 STB hewsion
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8-88
CHARGING
l
SYSTEM-Alternator
Check rotor coil for grounding. Check to ensure that there is no
continuity between slip ring and core. If there is continuity,
replace rotor assembly.
6EL115
STATOR
l
Make continuity test on stator coil. Check to ensure that there
is continuity between coil leads.
If there is no continuity, replace stator assembly.
3ELOlO
l
Check coil for grounding.

Check to ensure that there is no
continuity between coil and core. If there is continuity, replace
stator assembly.
RECTIFIERS
l
Positive rectifier test
Check for continuity between positive rectifier and stator coil
lead connection terminal with a circuit tester. If there is continuity in both directions, diode is shorted.
Replace rectifier assembly.
lELll0
l
lELll1
Negative
rectifier test
Check for continuity between negative rectifier and stator coil
lead connection terminal. If ther is continuity in both direction,
diode is shorted, and rectifier assembly must be replaced.
) STBRc evision
-7
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8-89
CHARGING SYSPE
l
Diode trio test

Check three diodes for continuity by connecting a circuit tester
to both ends of each diode. If there is no continuity or no
continuity in both directions, diode is defective and heatsink
assembly must be replaced.
lELll2
REPLACEMENT
OF BRUSH
A brush worn away to the limit
below.
is replaced
using the procedure
(1) Remove
spring.
the pigtail
solder
and take out the old brush and
(2) Install brush spring and new brush in brush holder.

(3) Insert the brush to where there is a space 2-3
mm
(.079-,118
in.) between the limit line and the end of the brush
holder.
(4) While maintaining

the position of the step, solder the pigtails
to the end of the brush holder.
1 STB Revision
1
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8-90
CHARGING SYSTEM-Alternator
3. REASSEMBLY
OF ROTOR
ASSEMBLY
Perform reassembly in reverse procedure of disassembly,

Before rotor is attached to rear bracket, insert wire through
small hole made in rear bracket to lift brush. After rotor has
6een installed, remove the wire.
Wire
6EL122
Rear bracket
6EL123 I
STB Revision
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STARTING
SYSTEM-General
STARTING SYSTEM
GENERAL INFORMATION
Information
8-91
NOBFAAJ
The electrical circuit of the starter system consists of battery, starter motor, solenoid switch, ignition switch,
inhibitor switch, connecting wire and battery cable.
In the starter system and electrical circuit, electricity flows to activate the coils of the starter motor solenoid when
the ignition switch is turned to the start position. In so doing, the solenoid plunger and clutch shift lever move, the
clutch pinion engages with the ring gear and then the solenoid contacts shut and the starter motor cranks.
As soon as the engine begins to run and, in order to prevent damage due to over-revolution
by the armature starter,
the running clutch pinion gear over-rides, Thus in order not to cause damage to the starter motor once the engine
is running, the ignition switch must be immediately
turned back to the ON position.
The starter motor is the reduction-drive
type, and is compact and lightweight.
Inhibiter
-
switch
lEL151
1 STB Revision
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8-92
STARTING
terminal
SYSTEM
General
terminal
\
Sole;oid
Information
coil
clutch
Brush
gear
type
reduction
1 ST6 Revision
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STARTING
8-93
SYSTEM - Specifications
SPECIFICATIONS
GENERAL
SPECIFICATIONS
NOIFB-
Items
Specifications
Starter motor
Type
Model No.
Reduction
Part No.
M DO99667
Rated output
drive
MIT70481
kW1 v
I.2112
No. of pinion teeth
Items
Standard
Specifications
values
Starter motor
Free running characteristics
Terminal voltage
11
Current
Max. 90
Speed
r.p.m
Min. 3000
0.5-0.8(.020-,031)
mm (in.)
Under-cut depth
Commutator diameter
mm (in.)
Pinion gap
Commutator
mm (in.)
runout
29.4(1.157)
0.5-2.0(.020-,079)
mm (in.)
0.05(.0020)
mm (in.)
28.8(1.134)
Limit
Commutator
diameter
Commutator
runout
mm (in.)
0.1 (.004)
'_'
Items
Starter motor mounting
Air filter mounting
bolts
nuts
1 STB Revision
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Nm
ftlbs.
27-34
16-19
20-24
12-14
8-94
STARTING
SYSTEM
-Troubleshooting
TROUBLESHOOTING
NOFH-
Remedy
Reference
paw
Check battery specific gravity

Charge or replace battery
8-81
8-82
8-81
Adjust or replace switch
Refer to
GROUP 21.
Fusible link blown
8-69
Starter motor faulty
Repair starter
8-97
Ignition switch
Replace ignition switch
8-l 22
Check battery specific gravity

Charge or replace battery
8-8 1
8-82
8-8 1
Repair starter
motor
8-97
Repair starter
motor
8-97
Ignition switch
Replace ignition switch
Symptom
Probable cause
Engine will not crank
Battery charge low
,
I

Inhibitor Switch faulty
(Vehicle with automatic
Engine cranks
slowly
transmission
__~
only)
faulty
Battery charge low

Starter keeps running
or worn
or worn
faulty
Short in wiring
Starter spins but enJine will not crank
motor
Ring gear teeth broken
-7
http://vnx.su/
8-l 22
I
Repair wiring
Pinion gear teeth broken or starter

faulty
1 STB Revision
motor
Repair starter motor
8-97
Replace flywheel
torque converter
Refer to
GROUP 9.
ring gear or
STARTING
1 STARTING
(VEHICLES
SYSTEM
CIRCUIT
WITH A MANUAL
- Circuit
8-95
Diagram
TRANSMISSION)
Ignition
switch
Ik
\
OFF
START
ON
9
w
11171
$in
ACC
c-55
ST
fusible
.I
Sub fusible
BY
link
37W626
Starter
/ STB Revision
http://vnx.su/
8-96
STARTING
SYSTEM
Circuit
Diagram
(VEHICLES WITH AN AUTOMATIC TRANSMISSION)
Sub
(IGN
A-23
_ 5-WI-754
L-l m
fusible
. SW)
link
0.5-G
Ignition
switch
1, 1,
1L-W
Battery
c-47
2-BY-Z-BY*2
!-BY
N
Z-BY1
L-l
(Z-BY*]
BYBY
R
I
Remark
For information
refer
to P.8-7.
concerning
Wiring
color
code
B: Black
LI: Light
blue
the
Br: Brown
0: Orange
ground
points
(example:
G: Green
P: Pink
),
Gr: Gray
R: Red
STB Revision
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L: Blue
Y: Yellow
Lg:
W:
Light
White
green
STARTING
WSTEM
- Starter
Motor
8-97
STARTER MOTOR
REMOVAL
AND
INSTALLATION
16-19
12-l?
12-14
NOBFJAE
Nm
ft.lbs.
15W1564
Removal
steps
1. Air filter
2. Connection
of starter
l * 3. Starter motor
NOTE
(2) ++ : Refer to Service Points
motor
connector
to reinstall.
of Installation
INSPECTION
PINION GAP ADJUSTMENT
I,
Disconnect field coil wire from M -terminal of magnetic

switch.
2. Connect a 12V battery between S -terminal and M terminal.
3. Set switch to ON, and pinion will move out.
6EL05(
Caution
This test must be performed quickly
onds) to prevent coil from burning.
Revision
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(in less than 10 sec-
8-98
STARTING SYSTEM -Starter
Motor
4. Check pinion to stopper

gauge.
Standard
Pinion
value : 0.5-2.0
clearance
(pinion gap) with a feeler
mm (.020-.079
in.)
6EL003
5.
If pinion gap is out of specification, adjust by adding or removing gaskets between magnetic switch and front bracket.
lEL113
PULL-IN TEST OF MAGNETIC

SWITCH
1. Disconnect field coil wire from M-terminal
of magnetic switch.
2. Connect a 12V battery between S-terminal and M-terminal.
/
Field
3.
coil wire
Caution
This test must be performed
quickly (in less than 10 seconds) to prevent coil from burning.
If pinion moves out, then pull-in coil is good. If it doesnt,
replace magnetic switch.
HOLD-IN TEST OF MAGNETIC

SWITCH
1. Disconnect field coil wire from M-terminal of in;ignetic switch.
2. Connect a 12V battery between S-terminal and body.
3.
Field
coil wire
Caution
If pinion remains out, everything is in order. If pinion moves in,
hold-in circuit is open. Replace magnetic switch.
1 ST6 Revision
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WEEM -Starter
I-
Carbon-pile
rheostat
6EL07
8-99
Motor
FREE RUNNING
TEST
1. Place starter motor in a vise equipped with soft jaws and
connect a fully-charged 12-volt battery to starter motor as follows :
2. Connect a test ammeter (loo-ampere
scale) and carbon pile
rheostat in series with battery positive post and starter motor
terminal.
3. Connect a voltmeter (16volt scale) across starter motor.
4. Rotate carbon pile to full-resistance position.
5. Connect battery cable from battery negative post to starter
motor body.
6. Adjust rheostat until battery voltage shown on the voltmeter reads 1 IV.
7. Confirm that the maximum
amperage
is within the standard value and that the starter motor turns smoothly
and
freely.
Standard
value
Max. 90A
Min. 3,000 rpm
: Current
Speed
RETURN TEST OF MAGNETIC

SWITCH
1. Disconnect field coil wire from M terminal of magnetic
switch.
2. Connect a 12V battery between M-terminal
and body.
Caution
3. Pull pinion out and release. If pinion quickly returns to its original position, everything is in order. If it doesnt, replace magnetic switch.

3.
INSTALLATlON
OF STARTER MOTOR
Clean both surfaces of starter motor flange and rear plate.
[ ST6 Revision
1
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DISASSEMBLY
Disassembly
+*
4*
+*
+*
Motor
AND REASSEMBLY
steps
1. Screw
2. Magnetic switch
3. Screw
4. Screw
5. Rear bracket
6. Brush holder
7. Brush
8. Rear bearing
9. Armature
10. Yoke assembly
11. Ball
12. Packing A
13. Packing B
14. Plate
15. Planetary gear
16. Lever
l d 17. Snap ring
l a 18. Stop ring
19. Over running clutch
20. -Internal gear
21. Planetary gear holder
22. Front bracket
6ELlSS
NOTE
(2) a+: Refer to Service Points of Disassembly.
(3) l O: Refer to Service Points of Reassembly.
] STB Revision
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STARTING SYSTEM-Starter
8-101
Motor

9. CAUTION
OF ARMATURE/ll.
BALL
When removing the armature, do not lose the ball which acts
as a bearing for the armature and tip.
17. DISASSEMBLY
OF SNAP RING/18.
STOP RING
(1) Push the stop ring towards the snap ring using the proper
socket.
(2) After removal of the snap ring with the snap ring pliers,
remove the stop ring and the over-running clutch.
Snap
Armature
CLEANING
STARTER MOTOR PARTS
1, Do not immerse parts in cleaning solvent. Immersing the yoke
and field coil assembly and/or armature will damage insulation.
Wipe these parts with a cloth only.
2. Do not immerse drive unit in cleaning solvent. Overrunning
clutch is pre-lubricated
at the factory and solvent will wash
lubrication from clutch.
3. The drive unit may be cleaned with a brush moistened with
cleaning solvent and wiped dry with a cloth.
INSPECTION
CHECKING
COMMUTATOR
(1) Place the armature on a pair of V blocks and check run-out with
a dial gauge.
Standard value : 0.05 mm (-0020 in.)
Limit : 0.1 mm (.0039 in.)
1ELlO
pi-
wision
I
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8-102
Motor
(2) Check the outer diameter.

Standard value : 29.4 mm (1.157 in.)
Limit : 28.8 mm (1.134 in.)
lEL116
(3) Check the depth of the undercut

Standard
value
: 0.5-0.8
between
mm (.020-.031
segments.
in.)
lEL66
BRUSH HOLDER
Check conductivity
between the brush holder
holder. If there is no conductivity this is normal.
Brush
plate and brush
holder
OVERRUNNING
CLUTCH
1. While holding clutch housing, rotate the pinion. Drive pinion
should rotate smoothly in one direction, but should not rotate
in opposite direction. If clutch does not function properly, replace overrunning clutch assembly.
2. Inspect pinion for wear or burrs. If pinion is worn or burred,
replace overrunning
clutch assembly. If pinion is damaged,
also inspect ring gear for wear or burrs.
FRONT AND REAR IBRACKET BUSHING

Inspect bushing for wear or burrs. If bushing is worn or burred,
replace front bracket assembly or rear bracket assembly.
1 STB Revision
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8-103
REPLACEMENT
OF BRUSHES AND SPRINGS
1. Brushes that are worn beyond limit line, or are oil-soaked,
should be replaced.
2. When replacing field coil brushes, crush worn brush with pliers, taking care not to damage pigtail.
i&l
E
-Limit
Motor
line
1ELOlI
New brush
Soidered
(Make sure that
there is no excess
solder on brush
surface)
3. Sand
4. Insert
Make
brush
5. When
holder
pigtail end with sandpaper

pigtail into hole provided
sure that pigtail and excess
surface.
replacing ground brush,
by prying retaining spring
to ensure good soldering.

in new brush and solder it.
solder do not come out onto
slide the brush from
back.
brush
Surface marked If
1ELM
TESTING
ARMATURE
TESTING ARMATURE
FOR SHORT-CIRCUIT
1. Place armature in a growler.
2. Hold a thin steel blade parallel and just above while rotating
armature slowly in growler. A shorted armature will cause
blade to vibrate and be attracted to the core. Replace shorted
armature.
6EL082
TESTING ARMATURE
FOR GROUNDING
Check the insulation in the space between the segments of the
commutator
and the armature and coil core. If there is no conductivity this is normal.
CHECKING CIRCUIT BREAK BETWEEN ARMATURE

AND COIL
Check conductivity between each segment. If there is conductivity this is normal.
1FL
108
1 STB Revision
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8-104
Motor

18. REASSEMBLY
OF STOP RINGi17.
SNAP RING
Using a suitable pulling tool, pull overrunning clutch stop ring
over snap ring.
1 STB Revision
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IGNITION
SYSTEM -General
Information
8-105
IGNITION SYSTEM
GENERAL INFORMATION
NOUGAAB
The ignition system consists of battery, distributor,

ignition switch and connecting wire.
(igniter-integrated)
ignition coil, spark plug, high tension
cable,
Ignition
switch
1 AMR
1Gl
Ignition
coil
Ignite;
Distributor
lEL117
The distributor is composed of signal generator (signal rotor and igniter internalized pickup), linear current control
unit (igniter) advance control unit (governor and vacuum controller) and distribution unit (rotor plus distributor cap).
http://vnx.su/
IGNITION
SYSTEM-General
Information
IISTRIBUTOR
Vacuum
controller
lEL153
IGNITER
OPERATION
(1) When the signal rotor revolves a projection inside the signal rotor alternately moves away from and faces
towards the core detector inside the igniter.
(2) When the projection is separated from the core, an oscillating electrical circuit begins to oscillate, and when it
faces, magnetic flux issuing from the core moves across the inside of the signal rotor, so when loss increases,
oscillation ceases.
(3) This oscillation introduces power to the oscillation detector circuit, and after output is amplified it drives the
power transistor. During oscillation (when the projection and core are apart) electricity flowing through the
ignition coil and when oscillation stops (when the projection and core are facing) the electric current is interrupted.
(4) The electrical detection circuit, in preventing excessive electrical flow to the power transistor, protects the
transistor.
Ignition
switch
Sig,nal
rotor
Detection
coil
-I-
and core
-.IT1 Battery
----
Power
Oscillation
detector
Amplifier
Oscillation
Current
ditector
Igniter
1 STB Revision
J152
-7
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- I
IGNITION
8-107
SPECIFICATIONS
GENERAL
SPECIFICATIONS
DISTRIBUTOR
N08GB.B
Items
California
Federal
pointless
Contact pointless
T3T61980A
Part No.
Igniter
MD109013
Built-in type
Built-in type
Firing order
1-3-4-2
1-3-4-2
IGNITION
type
Contact
Type
Model No.
T3T65571
MD1 10264
COIL
Specifications
Items
Type
Model No.
Oil filled
Part No.
M DO73079
SPARK
type
E-089
PLUG
Model No.
Items
W20EP-U 10
W20EPR-Sll
Factory installed plug
Manifacturer
NIPPON DENS0
BURGEA-1 1
Alternate
plug
IGNITION
BPGES-1 1
BPRGES-1 1
BUGEA-11
NGK
W20EPR-U
W20EPSll
NIPPON DENS0
IO
SWITCH
Specifications
Items
ignition switch
Load capacity
AM-ACC
15A
AM-IG
30A
AM-ST
15A
AM-R
15A
0.1 V or less
Voltage drop (under actual load)

Key reminder
switch
Rated load
IW
Voltage drop
0.2 V or less
) STB Revision
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8408
IGNITION
N08GC-B
Specifications
Items
Basic ignition timing at curb idle speed
7BTDC
Distributor
Federal
Governor
Initial
(crank deghpm)
O/l 600
1 9/2800
Middle
Final
1g/6000
Vacuum (crank deg/mmHg)

Initial
O/80
Middle
12/I 50
231280
Final
California
Governor
(crank deghpm)
initial
O/l 600
Middle
912800
Final
1g/6000
Vacuum (crank deg/mmHg)

Initial
O/80
Middle
8/l 50
Final
201360
Idle advance (crank deg/mmHg)

Initial
O/60
Final
5180
Ignition coil
Primary resistance
at 20C (68F)
Secondary resistance at 20C (68F)

k0
External resistor resistance at 20C (68F)
Spark plug gap
TORQUE
1.1-1.3
14.5-19.5
1R
mm (in.)
1.22-1.48
1.0-I .I (.039-,043)
SPECIFICATIONS
NOBGD-
Items
Spark plug
1 STB Revision
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Nm
ft.lbs.
20-30
15-21
IGNITLON
8-109
TROUBLESHOOTING
NOBGH--
Symptom
Probable
cause

hard to start (cranks
OKI
Incorrect
ignition
Ignition
coil faulty
Inspect
ignition
Ignition
faulty
Inspect
igniter
8-120
Inspect
distributor
8-120
Inspect
cord
high tension
8-116
Replace
plugs
Distributor
Remedy
timing
Adjust
faulty
High tension
cord faulty
Spark plugs faulty

Ignition
Rough
idle or stalls
wiring
wiring
Spark plugs faulty
Replace
plugs
Ignition
Inspect
wiring
Adjust
ignition
wiring
Engine
mileage
overheats
faulty
timing
timing
8-111
coil
8-116
8-115
8-115
-
Incorrect
ignition
Ignition
coil faulty
Inspect
ignition
Ignition
faulty
Inspect
igniter
8-120
Inspect
cord
high tension
8-116
cord faulty
Spark plugs faulty
Replace
plugs
Ignition
Inspect
wiring
Incorrect
Poor gasoline
or broken
ignition
Inspect
High tension
Engine hesitates/poor
acceleration
disconnected
Reference
paw
wiring
faulty
ignition
Spark plugs
timing
Adjust
faulty
Replace
timing
8-111
coil
8-116
8-115
-
timing
8-111
8-115
plugs
Incorrect
ignition
timing
Adjust
ignition
timing
8-111
Incorrect
ignition
timing
Adjust
ignition
timing
8-111
1 STB Revision
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8-110
IGNITION
2 IGNITDN
SYSTEM
- Circuit
Diagram
CIRCUIT
Sub fusible
(IGN - SW)
A-23
5-wn5-wu
0.5-G
link
Ignition
switch
1
Z-W
63-I
IAT
Main
fusible
link
Rnttprv
64-b
ze
cj _-
3m
A:p
N
CL
m
I
Ei I
Disi
To combination
meter
(TACHO)
[Refer to P.8-52.1
A-an
Ignition
coil
37 w009
Remaik
-For information
refer to P.8-7.
concerning
Wiring color code

B: Black
LI: Light blue
the ground
Br: Brown
0: Orange
points (example:
c
G: Green
P: Pink
),
Gr: Gray
R: Red
L: Blue
Y: Yellow
1 STB Revision
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Lg: Light green

V/: White
IGNITION
SYSTEM
Service Adjustment
SERVICE ADJUSTMENT
CHECKING
IGNITION
IGNITION
TIMING
8-111
Procedures
PROCEDURES
TIMING
NOEGIBA
ADJUSTMENT
Adjustment
conditions:
Coolant temperature:
80-90C
(170-I
Lights and all accessories:
Off
Transmission:
N (Neutral)
90F)
1. Connect
tachometer
and timing light.
2. Start eng.ine and run at curb idle speed.
Curb idle speed rpm

First 500 km
(300 mile)
725';;;
After 500 km
(300 mile)
800 ?I00
3.
4.
To make adjustment at high altitude, disconnect pressure

sensor connector
before stopping engine. Then restart
engine and run it at curb idle speed.
Check basic ignition timing and adjust if necessary.
Basic
ignition
timing:
7 + 2BTDC
5. To adjust ignition timing, loosen distributor mounting nut

and turn distributor housing.
6. After adjustment,
securely tighten mounting nut.
7. Reconnect
pressure sensor connector
disconnected
in
Step 3. Then run engine at curb idle speed to make sure
that actual ignition timing is obtained.
..
CHECKING
CHECKING
1.
2.
3.
4.
IGNITION
SYSTEM
CENTRIFUGAL
ADVANCE
NOBDIDB
EQUIPMENT
Set the tachometer
and timing light.

Start the engine and allow it to idle.
Pull out vacuum hose from vacuum controller.
Check the advance while slowly raising RPM. If the advance is
smooth when accompanying the increasing RPM, this is
normal.
Symptom
Assumed causes
Excessive advance
Weakness of the governor spring
Sudden advance rise
Broken spring
Insufficient advance or large

hysteresis
Impaired movement of the governor weight or cam.
5.
6.
7.
If the malfunction indicators above are confirmed, dismantle

and check the distributor.
After checking, let the engine idle and then turn the ignition
switch to OFF.
Remove the tachometer and timing light..
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8-112
IGNITION
SYSTEM
- Service
Adjustment
CHECKING
NEGATIVE
Procedures
PRESSURE
ADVANCE
EQUIPMENT
1. Set the timing light.

3. Pull out the vacuum hose from vacuum controller and attach
vacuum pump to nipple.
4. Check the advance while slowly applying negative pressure to
the vacuum pump. If the advance is smooth when accompanying the increase in negative pressure,
this is normal.
Assumed
Symptom
Excessive
advances
Weakness
spring
Broken spring
Insufficient
hysteresis
Impaired movement
base
5.
6.
7.
cable
~~
8.
advance or large
\
5ELO45
If the malfunction
indicators
above are confirmed,
dismantle
and check the distributor.
Allow the engine to idle and then turn the ignition switch to
OFF.
Remove the vacuum pump and attach the vacuum hose to the
vacuum controller
nipple.
Remove the timing light.
NOUGIHB
Connect the spark plug to the high tension cable, ground outer
electrode (main body), and crank engine. In the atmosphere,
only
short sparks are produced because of small discharge
gap. If the
spark plug is good, however,
sparks will occur in discharge
gap
(between
electrodes).
In a defective
spark plug, no sparks will
occur because of leak of insulation puncture.
plug
5ELO46
Iefective
NWGIGB
SPARK PLUG TIEST

Spark
of breaker
Hold the spark plug cable about 6-8 mm (.24-.31

in.) away from
engine proper (grounding portion such as cylinder block) and crank
engine to verify that sparks are produced.
Cylinder
block
6-8
mm
(.24-.31
in.)
controller
Broken diaphragm
SPARK PLUG CABLE TEST
Primaw
cable
of vacuum
Sudden advance rise
No advance
Secondary
causes
insula
5ELO47
/
fvision
I
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IGNITION
SYSTEM-Service
Adjustment
SPARK TEST - ENGINE
Procedures
CANNOT
8-113
BE CRANKED
If spark test is performed

by cranking while the catalyst is hot,
unburned gas will be supplied to the catalyst, and this is not desirable to the catalyst.
For this reason, use the following
methods which allow spark test
to be performed
without
cranking.
1.
2.
Remove the distributor

cap.
Check signal rotor position in relation to the pick-up. If it is not
the position shown in the illustration, turn the crankshaft
manually so that the projection of the signal rotor is moved away
from the center part of the pick-up. In order words, the signal
rotor should be positioned
so that current can flow to the
ignition coil.
3.
Disconnect
the high tension cable from the center tower of
the distributor
cap, and hold the end of the cable about 5 - 10
mm (.2 - .4 in.) away from the cylinder block of the engine.
Turn the ignition switch to ON. Then, when a piece of metal
(the tip of a screwdriver
for instance) is inserted into the detection coil of the pick-up and then moved away, a spak can be
generated.
4.
Secondary
+
!:
cable
5-10
(.2-.4
km
in.)
5EL0
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8-114
IGNITION
IGNITION
SYSTEM
- Ignition
System
SYSTEM
REMOVAL
AND
INSTALLATION
NOEGJAE
20-30
Spark
+e
~~
+e
*e
plug
l +
~~
e+
e+
removal
1.
2.
3.
4.
5.
Distributor
~~
l +
+*
de l q
Ignition
Spark
Spark
Spark
Spark
Spark
steps
plug
plug
plug
plug
plug
removal
cable
cable
cable
cable
No.
No.
No.
No.
removal
1
2
3
4
16W1563
steps
1-4. Spark plug cables

6. Connection
of distributor
7. High tension
cable
8. Connection
of vacuum
9. Distributor
coil
Nm
connector
hose
steps
7. High tension
cable
10. Connection
of ignition
11. Ignition
coil
coil
connector
NOTE
(1) Reverse
(2)
(3)
+e
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the removal
: Refer
: Refer
to
to
Service
Service
procedures
Points
Points
to reinstall.
of
of
Removal.
Installation
IGNITION
Ignition
8-115
Svstem
No good
Good
SYSTEM
l-4. CAUTION
CABLE
OF SPARK
PLUG
CABLES17.
The cable is to be pulled out by grasping
721017
HIGH
TENSION
the cap part.
72T06t
9.
16W947
REMOVAL
OF DISTRIBUTOR
Before removing the distributor,
position the piston in No.
1 cylinder at the top dead center on compression
stroke by
the following
procedure.
(1) Remove the cap from the distributor.
(2) Turn the crankshaft
until the distributor
rotor lines up
with the No. 1 spark plug cable electrode
on the
distributor
cap.
(3) Align the notch on the crankshaft pulley with the timing
mark T on the timing indicator to set the engine SO
that the piston in No. 1 cylinder is at the compression
top dead center.
INSPECTION
CLEANING
1. Pull the
2. Using a
cylinder
AND INSPECTION
OF SPARK PLUGS
spark plug cables out of the spark plugs.
spark plug wrench, take all the spark plugs out of the
head.
Caution
Ensure that no foreign bodies fall from the spark plug
holes.
3. Using the following criteria check that there is no electrode
spark loss, that there is no damage to the outer insulation, and
that sparking is good.
l
Existence of insulation damage
l
Spark dissipation
l
Carbon accumulation
Using either plug cleaner or wire brush, clean both the upper part and the glass part.
l
Damage to or breakage of gaskets
l
Spark action in spark glass area
In cases where there are black deposits due to carbon, this
indicates excessive passage of mixed gases so that air intake becomes extremely deficient.
Owing to the excessively large spark gap, spark loss and so
on can be expected.
In case of white scorching, this indicates an excessively
thin gas mixture and prolongment
of sparking time, which
suggests poorly fitted plugs.
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8-116
IGNITION
SYSTEM-Ignition
System
4.
Clean with plug cleaner. Sand which has accumulated

in
the screw thread of the plugs is blown out by compressed
air.
5.
Using the plug gap gauge, check whether

is normal, and if not, adjust it.
Plug
cleaner
OlUOO89
NIPPON
Plug gap
gauge
termine
direction
Standard
rl
CHECKING
value
SPARK
: 1.0-1.1
PLUG
the plug gap reading
mm (.039-.043
in.)
CABLE
(1) Check that there are no cracks in the cap or in the insulating
coating.
(2) Ctieck the resistance value.
Spark plug cable
High tension
cable
I
CHECKING
1 No.2
No.1
9
THE IGNITION
11
1 No.3
I
13
Standard
value
14
COIL
(1) Measurement
of the resistance
of the external
Measure
the resistance
of the external resistor.
High voltage
terminal
1 No.4
: 1.2-1.4
resistor
IR
(2) Measurement
of the resistance
of the primary coil
Measure the resistance between the positive (+) terminal
and the negative
(-) terminal
of the ignition
coil.
Standard
value
: 1.1-1.3
IR
(3) Measurement
of the resistance
of the secondary
coil
Measure the resistance between the high voltage terminal
and the positive (+) terminal
of the ignition
coil.
Standard
value
: 14.5-19.5
01R0234
wision
http://vnx.su/
kfl
IGNITION
SYSTEM-Ignition
SERVICE
9.
POINTS
INSTALLATION
8417
System
OF INSTALLATION
OF DISTRIBUTOR
(1) Align the notch on the crankshaft

pulley with the timing
mark T on the timing indicator
to set the engine so
that the No. 1 cylinder is at the compression
top dead
center.
Notch on
crankshaft
pulley
(2) Align mating mark on distributor

on distributor
driven gear.
Stud
housing
with
mating
mark
(3) Install distributor

to cylinder head while aligning mating
mark on distributor
attaching flange with center of distributor installing stud and tighten nut.
l-4.
INSTALLATION
OF SPARK
Improper arrangement
between
the cables,
surge at acceleration
careful to arrange the
lowing procedure.
1.
2.
3.
PLUG
CABLE
of spark plug cables will induce voltage

causing miss firing and developing
a
in high-speed
operation. Therefore,
be
spark plug cables properly by the fol-
Install the spark plug cable clamps as shown in the illustration.

The numerals on the support and clamp indicate the spark
plug cable No.
Pay attention to the following
items when the spark plug
cables are installed.
(1) Install the cables securely
to avoid possible contact
with metal parts.
(2) Install the cables neatly, ensuring
they are not too
tight, loose, twisted
or kinked.
( STB Revision
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8-118
SPARK
IGNITION
PLUG CABLE
SYSTEM
- Ignition
System
INSTALLATION
I(1
3
-4
-3
-1
-2
3
I
View
5EL04
/ STB Revision
1
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IGNITION
SYSTEM
8-119
- Distributor
DISTRIBUTOR
DISASSEMBLY
Disassembly
AND REASSEMBLY
steps
1. Breather
2. Distributor cap
3. Packing
4. Contact carbon
5. Rotor
6. Vacuum control
7. Ground wire
8. Lead wire
l + Adjustment
of air gap
9. Igniter
10. Rotor shaft
4*
+***
11. Signal rotor
l * 12. Breaker plate
13. Spring retainer
4*
4*
14. Governor spring
15. Governor weight
16. Lock pin
4**+
17. Driven gear
18. Washer
19. 0 ring
20. Distributor shaft
21. Washer
22. Oil seal
23. Distributor housing
Vehicles for
California
Vehicles except
for California
NOTE
(3) Hw: Refer to Service Points of Reassembly.
parts
1 STB Revision
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lEL104
8-120
IGNITION
SYSTEM
Distributor

10. DISASSEMBLY
OF ROTOR SHAFT/l 1. SIGNAL ROTOR
Place igniter base on soft base (wooden block) and lightly tap
rotor shaft to remove it from signal rotor.
13. DISASSEMBLY
SPRING
OF SPRING
RETAINERI14.
GOVERNOR
Remove two spring retainers with pliers and then remove two
governor springs.
6ELO6i
ti
II
17. DISASSEMBLY
Pin punch
OF DRIVEN
GEAR
(1) Mark location of driven gear on distributor shaft.

(2) Place driven gear on soft base (wood block) so that spring
pin can be removed.
(3) Using a pin punch, remove spring pin.
INSPECTION
Check according to the following provisions and repair or replace
anything faulty.
CAP ROTOR
(1) Ensure there are no cracks in the cap.
(2) Ensure that the electrodes of the cap and of the rotor are
undamaged.
(3) Wipe off any dirt from the cap or the rotor.
1ELlOi

Before servicing
1 STB Revision
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be sure to clean and inspect all parts.
IGNITION
8-121
SYSTEM-Distributor
17. REASSEMBLY
Install driven
location.
Distributor
OF DRIVEN
GEAR
gear into distributor shaft at previously
marked
6EL093
12. REASSEMBLY
/ A
OF BREAKER
PLATE
Install igniter base to housing. Position the igniter base so that

the projection (A) fits into the groove (9).
I -1--
11. REASSEMBLY
OF SIGNAL
ROTOR
Install signal rotor to rotor shaft. Position the signal rotor so

that the dowel pin fits into the groove.
Socket
ADJUSTMENT
OF AIR GAP
Adjust air gap between signal rotor and pick-up of igniter.
Standard
value
1 STB Revision
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: 0.8 mm (.0315 in.)
8-122
IGNITION
IGNITION
REMOVAL
Removal
SYSTEM
- Ugnition
Switch
SWITCH
AND INSTALLATION
NOEGLAE
steps
16W1557
1. Lower
column
cover
2. Upper column
cover
3. Cable band
4. Ignition
switch
5. Key remaind
switch
NOTE
Reverse
the
removal
procedures
to reinstall
INSPECTION
(1) Disconnect
the wiring connector from the ignition

switch,
an ohmmeter
to the switch
side connector.
(2) Operate the switch, and check the continuity between the
terminals.
and
connect
Ignition
16UO36C
switch
!I
START
NOTE
O-C indicates
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that there
-7
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is continuity
between
the terminals.
8-123
METERS AND GAUGES-Specifications
METERS AND GAUGES

SPECIFICATIONS
GENERAL
METERS
SPECIFICATIONS
AND GAUGES
NOEHB-
Specifications
Items
Speedometer
Electromagnetic
Type
Tachometer
Type
Detection
type
Pulse type
Ignition coil
source
Fuel gauge
Bimetal type (constant-voltage
Type
Fuel gauge unit
Variable resistance
Type
Water temperature
Type
Oil pressure
type
Bimetal type (7V operation)

gauge unit
Thermistor
type
gauge
Bimetal type
gauge unit
Bimetal type
Type
Inclinometer
Type
Damping
for 7V)
gauge
Type
Water temperature
Type
Oil pressure
relay incorporated
Gravity type
Oil-filled system
system
Voltage meter
Bimetal type
Type
INDICATOR
AND WARNING
LIGHTS
NOEHC-B
Specifications
Items
Turn signal indicator
lights
High beam indicator
light
Door-ajar warning
light
1.4 (74)
1.4 (74)
1.4 (74)
W
W
Fasten seat belt indicator light

Brake warning light
W
1.4 (74)
1.4 (74)
light
1.4 (74)
1.4 (74)
EGR warning light

Oil pressure warning
W
light
1.4 (74)
1.4 (74)
Charging warning
4WD indicator
light
A/T oil temperature

Overdrive indicator
1.4 (74)
1.4 (74)
Free-wheeling
1.4 (74)
warning light
light
W
hub indicator light
NOTE
The values in parentheses
denote SAE grade numbers.
1 STB Revision
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8-124
METERS
AND
GAUGES - Specifications
BUZZER
Specifications
Items
Range of voltage used
IO-16
While buzzing (Terminal voltage at 13 V)

Sound pressure
Fundamental
dB
frequency
53-7
goo* 150
Hz
Specifications
Items
Standard values
Speedometer
indication error
Meter with km/h
indication
km/h
f4
-1
+4
0
+5
0
+5.5
+0.5
20 km/h
40 km/h
80 km/h
120 km/h
Meter with mph
indication
mph
10 mph
+- 1.5
25 mph
+ 1.5
50 mph
75 mph
+I.5
Tachometer
k 1.5
indication
error
r/min
1,000 r/min
3,000 r/min
*IO0
+150
5,000 r/min
f 250
Fuel gauge resistance

Between terminals
Between
Between
terminals
terminals
value
1 (power
R
supply) and 2 (fuel gauge unit)
122-l 48
2 (fuel gauge unit) and 3 (ground)

1 (power supply) and 3 (ground)
Fule gauge unit resistance

Float point F
value
Float point E
Fuel gauge unit float position
23-27
100-l 20
R
14.9-19.1
113.5-l 26.5
mm (in.)
Float point F
29.7-34.7
Float point E
183.8-185.8(7.236-7.315)
Water temperature
Between terminals
temperature
gauge
Water temperature
resistance value R
gauge resistance
value
R
50-60
1 (power supply) and 2 (water

unit)
gauge unit
[at 70C (158F)l
Oil pressure gauge resistance value

Voltage meter indication error
V
90.5-I 17.5
45-55
1R
IOV
to.5
k 0.5
16V
( ST6 Revision
(1.169-l
-7
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.366)
METERS AND GAUGES-Specifications
8425
/Troubleshooting
Items
Water temperature
SEALANTS
gauge unit
Nm
ft.lbs.
8-10
6-7
AND ADHESIVES
Items
Water temperature
Specified sealants and adhesives
gauge unit threaded
portion
3M nut locking No. 4171 or equivalent
Quantity
As required
TROUBLESHOOTING
TACHOMETER
NOBHH-
Inspection
Symptom
The tachometer
I The tachometer
NOTE
Number
fails to operate
pointer is faulty
in circle indicates
inspection
sequence.
FUEL GAUGE
Inspection
Symptom
The fuel gauge fails to operate
The fuel gauge pointer is faulty
NOTE
Number
in circle indicates
inspection
sequence.
1 STB Revision
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items
items
8-126
METERS AND GAUGES -Troubleshooting
WATER TEMPERATURE
GAUGE
-0
c
2
(5
Symptom
The water temperature
I The water temperature
gauge fails to operate

gauge pointer is faulty
0
a
NOTE
Number in circle indicates inspection sequence.
OIL PRESSURE
GAUGE
jnspection items
Symptom
The oil pressure gauge fails to operate
The oil pressure gauge pointer is faulty
NOTE
Number in circle indicates inspection sequence
( STB Revision
-IIII
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8-127
METERS AND GAUGES -Troubleshooting

BRAKE WARNING
LIGHT
Inspection
Symptom
When the ignition key is at ON (without

engine) the indicator fails to illuminate
items
\
starting the
Starting the engine does not make the indicator

off (when the parking brake is not engaged)
go
The indicator does not illuminate when the parking

brake is on, when the brake fluid falls below the
regulation volume
NOTE
Number
in circle indicates
EGR WARNING
inspection
Other inspection
items
t
c
Co
sequence.
LIGHT
U
5
P
When the ignition key is at ON (without

fails to illuminate
starting the engine) the indicator
Co
The EGR warning indicator fails to illuminate after the car has travelled
every 50,000 miles (Light bulb is OK.)
Even when the reset switch
NOTE
Number
in circle indicates
is turned over the light does not go off
inspection
sequence.
[ STB Revision
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8-128
METERS
AND
GAUGES
- Circuit
Diagram
CIRCUIT DIAGRAM
METER CIRCUIT
Ignition
[Refer to P.8-511
To turn-signal
switch
[Refer to P.8-491
I
To seat belt timer
[Refer to P.8-661
To seat belt warning
buzzer [Refer to P.8-661
To alternator
48,5!W
IRefer to P.8.371
D
-0 dimmkr, passinq
I+,:
!
;witch and light control \ y K
clay [Refer to P.8-461
To dome liaht
5--hIIII
[Refer to P&47] -w
switch
1.25-GBA
, ^.
III
I
-1
I
r I
I
I
I
I
/
II
II
1
-I
YI
1 '----f--d+ii$$j
I
I
----m-w-
Combination
( STB Revision
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meter
.I_
METERS
AND GAUGES
011 pressure
switch
A-52
\
(
UY
>
I
H
> Oil A-52
pressure
gauge
unit
A-20
r..,
8-129
Diagram
YB
YR mYR
B
-0.85-B
Circuit
A-06
A-03
YR,RL
RL
El
switch
--
I I 1
L7
I I I I I
I
1 !
1 1
8-23
Fuel gauge
unit
YB
g--
4WD
indicator
L
WL/B
YL
y
1I I1
I'4 . I. 'I8. ;
LY)T~
OD OFF switch
[Refer to P.8-431
1 I
Combination
Wiring color code

6: Black
LI: Light blue
Br: Brown
0: Orange
Remarks
(I) The broken line indicates vehicles with combination gauge.
(2) The dash and dot line (-.-) indicates vehicles
with automatic free-wheeling
hub indicator.
(3) For information concerning the ground points
(example: 0 ). refer to P.8-7.
(4) The symbols @I,@, etc. indicate that the wiring
is connected (using the same numerical
symbol) to the facing page.
(In other words, 0 on the right page is
connected to 0 on the left page.)
gauge
G: Green
P: Pink
Water
temperature
gauge unit
Gr: Gray
R: Red
/ STB Revision
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L: Blue
Y: Yellow
Lg: Light green

W: White
8430
METERS
AND
GAUGES
- Service
Adjustment
Procedures.
BJUSTMENT. PROCEDURES
SERVICE
SPEEDOMETER
INSPECTION
NOSHIAA
I.
Adjust tire inflation pressure to the standard value. (Refer

toGROUP
22 WHEELS AND TIRES-General
Specifications)
2. Use speedometer
tester to make sure that the speedometer indication
error is within the standard value.
Standard
Meter
value :
with km/h
40 km/h
80 km/h
120 km/h
10
25
50
75
with
mph
mph
mph
mph
km/h
+4
-1
+4
0
+5
0
+ 5.5
+0.5
20 km/h
Meter
indication
mph
indication
mph
+I.5
21.5
+I.5
&I.5
Caution
1 When
using a speedometer
tester to inspect
the
speedometer,
be sure to chock the non-drive
wheels
to prevent the vehicle from moving.
Also be sure to
set the transfer
shift lever to 2H.
2 If there
is a special
regulation
for speedometer
indication
error in the area where the vehicle
is
operated,
be sure to meet the requirement
of the
regulation.
TACHOMETER
INSPECTION
NOBHIBA
Connect a tach-dwell
meter, and then compare
the meter
readings at various engine speeds with the values indicated on
the tachometer.
Standard
value:
1,000 r/min
3,000 r/min
5,000 r/min
Tgch-dwell
meter
f 100 r/min
2150 r/min
&250 r/min
Caution
The tachometer
is the negative-ground
type, and therefore
should not be connected
in reverse polarity
to the battery.
If the tachometer
is connected
in reverse
polarity,
the
transistors
and diodes will be damaged.
evision
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METERS
AND GAUGES
- Service
Adiustment
FUEL GAUGE
(harness
side)
16W834
SIMPLE
(upper)
TEST
UNIT
INSPECTION
NOEHIIF
To check the fuel gauge unit, first remove it from the fuel tank.
For detailed
information
concerning
installation
of the fuel
gauge unit, refer to GROUP 4, FUEL SYSTEM - Fuel Tank.
FUEL GAUGE
UNIT FLOAT
Check to be sure that the
(relative to the center part of
standard value range when
(upper limit) and E position
NOEHICE
(1) Disconnect,
from below the vehicle, the wiring connector
from the fuel gauge unit.
(2) Ground the connector
at the harness through a test light.
key to the ON position.
(4) Check to be sure that the test light flashes and the fuel
gauge indicator
moves.
(5) If both the test light and gauge operate, the circuit to the
gauge unit is normal and the gauge unit itself is faulty.
If the test light flashes but the gauge does not operate, the
gauge is faulty.
If neither the test light nor the gauge operates, the fuel
gauge circuit is faulty.
FUEL GAUGE
Stopper
8-131
Procedures
POSITION
CHECK
height of the fuel gauge float
the fuel gauge unit) is within the
the float is at the F position
(lower limit).
Standard
value:
A 29.7-34.7
mm (1.170-I .366 in.)
B 183.8-185.8
mm (7.236-7.315
in.)
FUEL
GA&E
UNIT
RESISTANCE
CHECK
Confirm that the resistances when the float of the fuel gauge
unit is at the F position (top) and the E position (bottom)
are within the standard value ranges.
Standard
Float
Float
WATER
value:
position
position
F point
E point
TEMPERATURE
14.9-19.1
IR
113.5-126.5
IR
GAUGE
SIMPLE
T,5$2
(1) Disconnect
the wiring connector
from the water temperature gauge unit inside the engine compartment.
(4) Check to be sure that the test light flashes and the water
temperature
gauge indicator
moves.
,
1 STB Revision
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8-132
METERS
AND
GAUGES
- Service
Adjustment
Procedures
gauge is faulty.
If 1neither the test light nor the gauge operates, the water
temperature
gauge circuit is faulty.
VVATER TEMPERATURE
TION
Se
GAUGE
UNIT
ONSPECNOBHIKD
To check the water temperature

gauge unit, first remove it
from the intake manifold.
For detailed information
concerning
installation
of the water
temperature
gauge unit, refer to GROUP
11, INTAKE AND
EXHAUST SYSTEM - Intake Manifold.
WATER
TEMPERATURE
GAUGE
UNIT
RESISTANCE
CHECK
Immerse
measure
the gauge unit in hot water at 70C (158F)

the resistance
value with an ohmmeter.
Standard
value:
OIL PRESSURE
90.5
GAUGE
SIMPLE
- 117.5
TEST
and
LR
NOEHIFA
(1) Disconnect
from the oil pressure
gauge unit inside the engine compartment.
(4) Check to be sure that the test light illuminates
steadily and
the indicator
of the oil pressure gauge moves.
gauge is faulty.
If neither the test light nor the gauge operates,
the oil
pressure gauge circuit is faulty.
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METERS
IOil
Oil pressure
p ressure
gauge unit
\
AND
\ 1 I Test light
@(12V
- 3.4 W)
GAUGES
I
Service
Adjustment
OIL PRESSURE
GA
Procedures
GE UNIT
CURRENT
8-133
CHEC,l<,
(1) Disconnect
from the oil pressure
gauge unit inside the engine compartment.
(2) Apply battery voltage (through the test light) to the gauge
unit side terminal.
(3) Check to be sure that the test light switches OFF when the
engine is stopped, and that it flashes while the engine is
running.
16W1576
VOLTAGE
METER
SIMPLE
TEST
(1) Connect a voltmeter

for testing.
(3) Compare the readings of the voltmeter
for testing
the vehicles
voltage meter.
Standard
value
1 STB Revision
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: 1OV
16V
+ 0.5v
+ 0.5v
NOEHIGC
and of
8-134
METERS
COMBINATION
METER
REMOVAL
Removal
AND
GAUGES
- Combination
AND INSTALLATION
Meter
NOBHJAF
steps
1. Meter cover
of speedometer
l 4 2. Connection
3. Meter asset nbly
NOTE
(I)
Reverse
the
l + : Refer
(2)
removal
procedures
to Service
Points
to
of
reinstall.
Installation.
cable
16W1553
INSPECTION
REED SWITCH
Using an ohmmeter,
check that continuity and discontinuity
alternate between terminals 1 and 2 four times at every
rotation of the shaft of the speedometer
cable connection.
I
BUZZER
Check to be sure that buzzer sounds when the batterys
positive (+) terminal is connected
to terminal 2 and the
batterys negative (-) terminal is connected
to terminal 1.
16W1645
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METERS
AND GAUGES
Combination
FUEL GAUGE
Measure the resistance
an ohmmeter.
.3
Standard
value
l-2 terminals:
2-3 terminals:
l-3 terminals:
8-135
Meter
value between
t.he terminals
by using
:
23-27 R
122-148 Sz
100-120 IR
16WQ25
Caution
If there is a malfunction
of the ground
contact of the
voltage
regulator
even once during vehicle operation,
the excessive current flowing
through
the heat coil of
the water temperature
gauge and the fuel gauge will
cause permanent
distortion
of the bimetal,
resulting
in
the indications
being consistently
lower than the actual
value.
For this reason, therefore,
be sure to make the earth
contact
securely.
16W925
WATER TEMPERATURE
an ohmmeter.
GAUGE
value between
the terminals
by using
Standard
value:
Bimetal
type
l-2 terminals:
50-80 n
10W926
SERVICE
2.
POINTS
INSTALLATION
OF INSTALLATION
OF SPEEDOMETER
Insert the cable until

speedometer
groove.
Caution
Poor installation
meter pointer,
the instrument
16F554
) STB Revision
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its stopper
CABLE
properly
fits
to the
of the cable may cause a fluctuating

or noise and a damaged
harness inside
panel.
8-136
METERS
DISASSEMBLY
AND
AND
GAUGES
- Combination
Meter
REASSEMBLY
I
10
16W1664
Disassembly
steps
1.
2.
3.
4.
5.
6.
7.
Meter cover
Buzzer
Fuel and water
Tachometer
Speedometer
Indicator panel
Meter glass
temperature
8. Window
plate
9. Meter case
10. Printed circuit boad
gauge
NOTE
Reverse
1 STB Revision
the disassembly
-1
http://vnx.su/
procedures
to reassemble.
METERS
3-METER
REMOVAL
Removal
AND
GAUGES
3-meter
Unit
lJN(IT
AND
INSTALLATION
steps
1. Meter
pad
2. Gauge assembly
NOTE
Reverse
the removal
procedures
16W1560
to reinstall
INSPECTION
OIL PRESSURE
Measure
ohmmeter.
Standard
GAUGE
the resistance value
value
: Approx.
between
the terminals
with an
the terminals
with an
50 CR
lBW077
VOLTAGE
METER

ohmmeter.
Standard
value
1 STB Revision
http://vnx.su/
value between
: 380-4601(1
8-138
METERS
AND GAUGES
- s-meter
Unit
INCLINOMETER
(1) Check
to be sure
that
operation
is smooth
when
the
inclinometer
is tilted up/down
and to the left and right.
(2) The i,nclinometer
can be considered
to be in good condition If the pointer
indicates
the spherical
dial horizontal
centre
line when
the meter case is placed
on a level
surface.
16W678
DISASSEMBLY
AND
REASSEMBLY
Disassembly
1.
2.
3.
4.
5.
6.
7.
NOTE
Reverse
the
steps
Oil pressure gauge
Inclinometer
Voltage meter
Meter glass
Window
plate
Meter case
Meter harness
disassembly
procedures
to
reassemble.
16W1561
1 ST6 Revision
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METERS
Center shaft of
pitching damper
AND
GAUGES
s-meter
Unit
8-139
INCLINOMETER
plate
OUTLINE
inclinometer
is an instrument
which indicates the forward
or backward inclination
(pitching)
or side to side inclination
(ding)
of vehicle.
Motion
of a pendulum
in the system
is displayed
on the
system. The pitching
and rolling pointer is supported
by a
double support mechanism
in which the rolling fulcrum
is
supported in such a way as to be rotative around the case and
the pitching fulcrum supported
on the rolling system
The
16W 600
Pointer
Spherical
dial
Spherical
horizontal
16W966
Spherical
\
Gxizontal
dial
Dial support
/
plate
Oil case
centerlinewtationaryframe
Blind plate
;ide to side inclination
Forward
CONSTRUCTION
The inclinometer
consists of an outer case which inclines with
the vehicle, a pointer which is provided
in an oil case and
always maintains
a level position,
and a spherical
dial. The
spherical dial is coupled through the dial support plate to the
rolling damper plate. The rolling damper plate is swivel bearing
coupled to a stationary
frame by the center axis, so it can
incline side-to-side,
but is always held in a level position by a
pendulum.
The pointer is coupled with the pitching damper
plate.
Since the pitching damper plate is swivel bearing coupled to
the rolling damper
plate by the center axis, it can incline
forward and backward,
but is always maintained
in a level
position
by the pendulum.
16W627
or backwarc
OPERATION
The side-to-side
inclination
angle should be read on a scale of
the front panel as indicated
by the horizontal centerline
of the
spherical dial, whereas the forward or backward inclination
angle should be read on a scale of the spherical
dial as
indicated
by the pointer.
Hokizontal
line
Horizbntal
line
[ STB Revision
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8-140
AND GAUGES
METERS
Side-to-Side
- 3-meter
Unit
Inclination
The front panel inclines with the vehicle, but the spherical dial
maintains
a horizontal condition,
so the horizontal centerline of
the s&lerical
dial shows the side-to-side
inclination
angle.
Inclined
15"
to right
16W969
Forward
or Backward
Inclination
The spherical
dial inclines
forward
or backward
with the
vehicle,
but the pointer
maintains
a level position,
so the
pointer indicates
the forward or backward inclination
angle.
Combined
Forward
or Backward
and Side-to-Side
Inclination
The forward or backward inclination
angle and the side-to-side
inclination
angle are indicated by the pointer and spherical dial.
@
10 d15
15 downhill
Inclined
IO
to
left
16W968
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METERS
INDICATORS
AND
GAUGES
AND WARNING
Symbol
and Warning
8-141
Lights
LIGHTS
Operation
Turn signal indicator
This indicator flashes, as do the same side of turn-signal light

flashes. If the turn-signal light is burnt out, the blinking of
indicator slows down.
This indicator is common with hazard light.
High beam indicator
This indicator
beam.
Door-ajar warning
This warning light comes

not completely
closed.
+e3
=
=
- Indicators
light
illuminates
when the headlights
on when
are on high
the door is either open or
*
Fasten seat belt indicator
This indicator goes on for four to eight seconds when the

ignition key is in ON position, even if the driver has fastened
his seat belt.
Brake warning
This warning light comes on when the ignition key is in ON

position, and goes off after the engine has started. This
warning light comes on when the parking brake is applied
or brake fluid level falls less than the specific level.
4
light
BRAKE
Charging warning
III
light
This warning
light comes on
ON position, and goes off
This warning
light comes on
or the trouble occurs in the
Oil pressure
warning
light
This warning light comes on when the ignition key is in ON

position, and goes off after the engine has started. This
warning
light comes on when the oil fails or the trouble
occurs in the oil circulating system.
P
Overdrive
00
when the ignition key is in

after the engine has started.
when the drive belt breaks
charging system.
indicator
This indicator will illuminates when the overdrive

switch is switched to the OFF position.
control
OFF
68R0133
A/T oil temperature
warning
light
A/T
TEMP
This A/T oil temperature

automatic transmission
mally high.
warning
light comes on when
fluid temperature
becomes abnor-
68WO68
Free-wheeling
hub indicator
YEL
This indicator comes on when the automatic

hubs are locked.
free-wheeling
68WO80
4WD indicator
This indicator will light up when the transfer case shift lever is
shifted to the four wheel driving position (either the 4H or the
4L position) and the ignition key is in the ON position.
z4
EGR warning
light
CHECK
EGR
The EGR warning light will illuminate every 50,000 miles of

driving. When this occurs, bring the vehicle to an authorized
dealter to have the EGR system checked.
) STB Revision
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8-142
METERS
AND
GAUGES
- EGR Warning
EGR WARNING
System
SYSTEM
The EGR warning system consists of a microswitch

connected
to the odometer,
a reset switch, and a warning light bulb.
This system will cause the EGR warning light to light up every
50,000 miles that the vehicle is driven in order to inform the
driver that it is time to check the EGR system.
The warning light bulb will light up when the ignition switch is
set to ON while the engine is not running, thus allowing the
driver to confirm that the bulb is not burned out.
RESET SWITCH
Use the switch on the back of the odometer
warning system.
NOTE
If the speedometer
the same reading
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is to be replaced,
as the odometer
to reset the EGR
set the new odometer

being, removed.
to
LIGHTING
8-143
LIGHTING SYSTEM
SPECIFICATIONS
GENERAL
EXTERIOR
SPECIFICATIONS
AND INTERIOR
LIGHTS
NOEIB-
Specifications
Items
Exterior lights
Head lights
60/50
Front combination
Turn-signal
lights
cp
lights
32
Front side marker and position lights

Rear combination
Turn-signal
lights
cp
light
32
32/3
Stop and tail lights
32
Back-up lights
Rear side marker lights
Licence plate lights
3.8(194)
6
Interior lights
Dome light
W
Heater panel illumination
10
light
1.4 (74)
Combination meter and gauge illumination

Cigarette lighter illumination light
W
Ashtray
illumination
Shift illumination
light
1.4 (74)
1.4 (74)
light
W
light (automatic
3.4 (158)
transmission)
NOTE
The values in parentheses
denote SAE grade numbers.
RELAY AND FLASHER
UNIT
1.4 (74)
Specifications
Items
Light control relay
Rated load
Max. 200
Range of voltage used

Voltage drop between
Turn-signal
IO-16
V
terminals
0.2 or less
flasher unit
Type
Rated load
W
Blinking frequency
Condenser type
84.4
[I 2.8 V, 20C (68F)l
cycle/min
85210
Hazard flasher unit

Type
Rated load
W
Blinking frequency
Heat band type

49.4-168.8
[ 12.8 V, 20C (68F)l
cycle/min
1 STB Revision
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902 10
8-144
LIGHTING
COLUMN
SWITCH
Specifications
Items
Lighting switch
Rated load
A
Voltage drop (at 12V and the rated load)
Dimmer-passing
0.17-0.27
V
0.2 or less
switch
Dimmer switch
Rated load
Upper bearm
16.1-18.7
Lower
9.4-10.8
beam
0.2 or less
Passing switch
Rated load
Upper beam
Lower
beam
16.1-18.7
0.17-0.27
0.2 or less
Turn signal switch

Rated load
TB-FL, TB-FR
2.2-2.8
TB-RL, TB-R R
4.2-4.8
ST-RL, ST-RR
4.2-4.8
HAZARD
WARNING
0.2 or less
SWITCH
Specifications
Items
I Voltage
DIMMER
drop (at 12V the rated load)
CONTROL
0.1 or less
SWITCH
Items
Specifications
Variable-resistance
Type
Rated load
15 (Min.)-26.6
Voltage drop (at 14V the rated load)
type
(Max.)
0.15 or less
Items
Specifications
Limit
Headlight
intensity
cd
20,000 or more
N08lb
Items
I
Steering wheel
Nm
35-45
lock unt
1 STB Revision
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ft.lbs.
I.
26-33
LIGHTING
SYSTEM
- Special tools / Troubleshooting
SPECIAL TOOLS
Tool
(Number
MB990784
Ornament
NOIIG-B
and name)
Use
Removal
warning
remover
of hazard
switch
TROUBLESHOOTING
HEADLIGHT
Inspection
1Symptom
Headlights
-0
K
2
t
do not illuminate,
It is not possible
items
to change
or illuminate
the headlights
intermittently
beam
Headlights
arm dim
Headlights
on only one side illuminate
NOTE
Number
in circle indicates
inspection
sequence.
( STB Revision
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8-146
LIGHTING
TAIL LIGHT, POSITION
LIGHT, SIDE MARKER LIGHT AND LICENSE
PLATE LIGHT
Symptom
Lights fail to illuminate
Lights on only one side illuminate
NOTE
Number
in circle indicates
BACK-UP
inspection
sequence.
LIGHT
-0
c
c-a
Il
5
m
Back-up
light does not illuminate
Only back-up light on one side illuminates

NOTE
Number
in circle indicates
inspection
sequence.
/ STB Revision
:I
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I
0
LIGHTING
SYSTEM
8-147
- Troubleshooting
DOME LIGHT
Inspection
The dome light does not illuminate when the door is opened (illuminates
the borne light switch is ON)
in circle indicates
TURN SIGNAL
inspection
sequence.
LIGHT AND HAZARD
LIGHT
Inspection
items
Symptom
All turn signal lights fail to flash
The turn signal light will not flash
(illumination
remained)
The hazard light fails to operate

The turn signal indicator fails to flash
NOTE
Number
in circle indicates
inspection
when
I
0
Dome light does not illuminate

NOTE
Number
items
sequence
1 STB Revision
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8-148
LIGHTING
SYSTEM
-Troubleshooting
STOP LIGHT
Other inspection
items
The stop light fails to illuminate
The stop light does not go off
The stop light on one side does not illuminate
0
A
NOTE
Number
in circle indicates
INSTRUMENT
inspection
sequence
PANEL ILLUMINATION
CIRCUIT
Inspection
iterns
Symptom
Illumination
light fails to illuminate (the tail light also fails to illuminate)
Illumination
light fails to illuminate (the tail light illuminates)
Illumination
light cannot be dimmed
1 STB Revision
-1
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0 Installation parts
of the stop light
switch
LIGHTING
SYSTEM
CIRCUIT DIAGRAM
HEADLIGHT CIRCUIT
Circuit
Battery
Sub
link
A-02
5-v m5-w
L-l
Main
lrnk
8-149
Diagram
fusible
0.5-G
2-R
A-23
fusible
z
A
2-B
r
2-B
ItfYH
A-33
Dedicated
c-05
dl
dl
fuse
YR[
11.25-Y
1-1
I
Combination
meter
I
n
*
Wlir,L
A .-32
Lrght
relay
control
A-55
Lighting
switch
Dimmer
switch
Passing
switch
(LTH.)
(R.H.)
R R RL
FP
x2
Remark
For information
points
(example:
Wiring
B: Black
LI: Light
color
blue
Column
concerning
), refer
Headlight
switch
XI
37W621
the ground
to P.8-7.
code
Br:
Brown
0:
Orange
G:
P:
Green
Pink
Gr: Gray
R: Red
/ STB Revision
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L: Blue
Y: Yellow
Lg:
W:
Light
White
green
8-150
LIGHTING
SYSTEM
- Circuit
Diagram
CIRCUIT DIAGRAM
TAIL LIGHT, POSITION LIGHT, REAR Sl!DE MARKER LIGHT,
LICENSE PLATE LIGHT AND BACK-UP LIGHT CIRCUIT
Battery
Sub fusible
A-02
link
-1.25-B3
1
Main
fusible
link
5-w r-l 5-w 1

A-23
A-02
mw
3
cl
1m
-22
To turn-signal
flasher unit
[Refer to P.8-49.]-
0.85-RL
T
I
lB-@
A-57
Position
light
Front
- .
combination
light (L.H)
Position
v
light
A-08
Front
_ _
combination
Ii-h+ IQ LA\
Backy
switch
Wiring color code

6: Black
LI: Light blue
Br: Brown
0: Orange
G: Green
P: Pink
Gr: Gray
R: Red
L: Blue
Y: Yellow
A-09
Inhibitor
switch
light
i
Lg: Light green

W: White
-
/ STB Revision
--7
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LIGHTING
Column
SYSTEM
- Circuit
8-154
Diagram
switch
Light control
relay
1
-32
C-52
J
F-GW -GW
F-B
B
L
B-06
B-12
B-14
Tail light
Tail lrght
Rear
combination
light
(R.H.)
Back-up
light
Tail light
Tail light
Rear
combination
light
(L.H.)
Back-up
light
L-l5
B-20
Rear side
marker light
(L.H.)
Remarks
with
(1) The broken lines are applicable to models~equipped
concerning
the ground points (exam(2) For information
ple: 0 ). refer to P.8-7.
0, 0, etc. indicate that the wiring
is
(3) The symbols
connected
symbol) to the
facing page.
the left page.)
) STB Revision
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B-22
37W823
8-152
LIGHTING
SYSTEM
CIRCUIT DIAGRAM
TURN-SIGNAL
AND HAZARD
A-02
63
-1.25-BMain
fusible
Circuit
Diagram
LIGHT CIIRCUIT
I
lml
Battery
Sub fusible
1BI
m
link
Ignition
switch
link
II I z I
Multi-purpose
fuse
2-B
To column switch
[Rear to P.8-461
'I
0.85-RL
1.25-GB
0.85-GY
I_\
0.85-GL
-o
ao
(BJ -0
Gw -@
I
3
cs
I
z
dm
A-31 1
1.I
I-
000
Turn-signal
and
hazard light
Turn-signal
and
hazard light
Front
combination
Front
combination
light (R.H.)
light
(L.H.)
Combination
w
q
1 STB Revision
http://vnx.su/
meter
I IGYIa.
LIGHTING
SYSTEM
- Circuit
Diagram
8-153
I
Turn-srgnal
Turn-signal
flasher
unit
I
r
switch
iazard
Hazard
flasher
unit
l!d
switch
C-62
-W\*1W++
\&VB/
aI
::
I v-l--c
n
c
I
::
nC
*
o- 0.85-RL
1 ')r rTurn -signal
and hazard
a-
Y-
light
Rear Combination
light (R.H.)
Rear combination
light (L.H.)
Dimmer
switch
control
OL
EZB B
WL
-
(1) For information

concerning
the ground
points (examRern~:~s~
) refer to P 8-7.
(2) The symbols
0. 0, etc. indicate that the wiring
is
connected
symbol) to the
(In other words,

the left page.)
Wiring color code
B: Black
LI: Light blue
Br: Brown
0: Orange
37W029
B-20
G: Green
P: Pink
Gr: Gray
R: Red
) STB Revision
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L: Blue
Y: Yellow
to 0 on
Lg: Light green

W: White
8-154
LIGHTING
SYSTEM
Circuit
Diagram
CIRCUIT DIAGRAM
DOME LIGHT CIRCUIT
v
I=32
A-02
Battery
Sub
5-w
Main
fusible
Combination
To
5-w r-l5-w
u
fusible
0.5-G
*
63
column
2-R
A-23
IInk
link
switch
To
meter
hazard
RB
B
ElRF
EL
B-01
RB
B
RG
H-28
(L.H.)
Door
(R.H.)
switch
37W020
Remark
For information
refer
to P.8-7.
Wiring
B: Black
LI: Light
color
blue
concerning
the
ground
points
(example:
),
code
Br: Brown
0: Orange
G: Green
P: Pink
Gr: Gray
R: Red
1 STB Revision
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L: Blue
Y: Yellow
Lg:
W:
Light
White
green
LIGHTING
SYSTEM
- Circuit
8-155
Diagram
CIRCUIT DIAGRAM
STOP LIGHT CIRCUIT
Sub
fusible
link
-1
Main
link
3-w
fusible
07
Multr-purpose
fuse
c-51
-0.85-G
2-B
Hazard
switch
To column
*[Refer
to
switcf
P.8-461
0.85-WG
d
B-20
]B-14
Turnsignal
switch
Stop
Rear
light
Remark
For information
refer
to P.8-7.
concerning
Wiring
color
code
B: Black
Ll: Light
blue
the
Br: Brown
0: Orange
ground
points
(example:
G: Green
P: Pink
light
cdmbination
(L.H.)
Stop
Rear
light
light
c;mbination
(R.H.)
).
Gr: Gray
R: Red
1 STB Revision
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L: Blue
Y. Yellow
Lg:
W:
Light
White
green
8-156
LIGHTING
SYSTEM
- Circuit
CIRCUIT DIAGRAM
INSTRUMENT PANEL ILLUMINATION
CORCUIT
-1.25-B0
Battery
.5-w
5-w 15-w
0.5-G
2-R
A-23
A-02
Main-Err
fusible link
Diagram
Sub fusible
z
A
cy]llo
link
a
I
N
A-22 [
CY
c-i
Optical
fiber
Heater
control
Heater
control knob
illumination
light
Multi-purpose
fuse
Combination
gauge
Illumination
ght control
lay
knob
B01 0
light
c
Cn
/
-
Lighting
switch
ti
Dimmer
illumination
0
QBY
switch
rel
lighter
Remarks
(1) The broken lines are applicable to models eouipped
an automatic
transmission.
(2) For information
concerning
the ground
points
ple: 0 1, refer to P.8-7.
Wiring color code
6: Black
Br: Brown
G: Green
Ll: Light blue
0: Orange
P: Pink
control
c-57
Combination
illumination
with
meter
light
37W822
(exam-
Gr: Gray
R: Red
1 ST6 Revision
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L: Blue
Y: Yellow
Lg: Light green

W: White
LIGHTING
SYSTEM
- Service
Adjustment
Procedures
E ADJUSTMENT
8-157
PROCEDURES
T AIMING
PRE-AIMING
J;it A:I w
Targets
Must be used
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Calibration fixture
Thumb adjusting screws
Level vial
Floor level offset dial
Horizontal dial knob
Vertical dial knob
Aimer level vial
Level vial bubble
Top port hole
Viewing port
Split image
not aligned
Bubble not centered
1660245
INSTRUCTIONS
1. Test dimmer switch operation.

2. Observe operation of high beam indicator light mounted
in
instrument cluster.
3. Inspect for badly rusted or faulty headlight assemblies.
These conditions must be corrected before a satisfactory adjustment can be made.
4. Place vehicle on a level floor.
5. Jounce front suspension through three (3) oscillations by
applying body weight to hood or bumper.
6. Inspect tire inflation.
7. Rock vehicle sideways to allow vehicle to assume its normal
position.
8. If fuel tank is not full, place a weight in trunk of vehicle to
simulate weight of a full tank [3 kg (6.5 Ibs.) per gallon].
9. There should be no other load in the vehicle other than driver
or substituted weight of approximately 70 kg (150 Ibs.) placed
in drivers position.
10. Throughly clean headlight lenses.
11. Adjust headlights by following
the instructions
for the
headlight tester manufacturer.
LUMINOUS
Split image
aligned
INTENSITY
MEASUREMENT
Measure the luminous intensity of headlights with a photometer in

accordance with the instruction manual prepared by the manufacturer of the photometer and make sure that the luminous intensity
is within the following limit.
Luminous intensity at the center of high intensity zone for high
beam.
Bubble centered
1660246
Limit
: 20,000 cd or more
NOTE
1. When measuring the luminous
engine at 2,000 rpm and have
2. If there are specific regulations
lights in the region where the
that the intensity conforms to
ulations.
pTB
Revision
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intensity of headlight, keep the

the battery charged.
for luminous intensity of headvehicle is operated, make sure
the requirements of such reg-
8-158
LIGHTING
SYSTEM
- Headlight
HEADLIGHT
REMOVAL
AND INSTALLATION
Post-installation
Operation
Adjustment
of Headliaht
( fer to P.8-157.)
l
Aimina
NOBIJAE
Removal steps
1.
2.
3.
4.
5.
NOTE
Reverse
Radiator grille
Front combinatior I light
Headlight bezel
Retaining ring
Headlight
the removal
procedure
to reinstall.
16W963
INSPECTION
HEADLIGHT
CONTROL
RELAY
Remove the headlight
control relay from the inner side of the
left fender shield.
For models
equipped
with headlight
washers,
remove the
headlight washer tank, and then remove the headlight
control
relay.
Check for continuity

between the terminals
being supplied
and while it is not.
while
Terminal
power
is
Battery voltage
not applied
Battery voltage
applied
iswasa
NOTE
(I 1 C-C
(2) O--O

indicates the connection with the power supply.
ewision
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LIGHTING
COLUMN
SYSTEM
Column
8-159
Switch
SWITCH
REMOVAL
AND
INSTALLATION
NOBIPAG
3
Removal
*I)
16W1569
steps
I.
2.
3.
4.
5.
6.
Steering
wheel
Steering
wheel
Lower
column
Upper column
Column
switch
Cable band
center
pad
cover
cover
I\IIC
hlnTC
(I)
(2)
SERVICE
2.
POINTS
REMOVAL
Remove
puller.

to reinstall.
l * : Refer to Service Points of Removal
OF REMOVAL
OF STEERING
the
steering
wheel
WHEEL
by
using
the
steering
wheel
Caution
Do not hammer on the steering wheel to remove
doing so may damage the collapsible mechanism.
) STB Revision
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it;
LIGHTING
SYSTEM
- Column
Switch
INSPECTION
Rem&e
the steering lower column cover, and then detach the
conn&tor
of the column
switch from the wiring harness.
Operate the switch and check the continuity
between the
terminals.
LIGHTING
SWITCH
16W1530
IO
NOTE
GO
indicates that there is continuity
DIM$ER*PASSING
between
SWITCH
Terminal
Switch
the terminals.
14
.,O
position
D2
1-1
Pl
P2
NOTE
GC
TURN
SIGNAL
SWITCH
Termina 2
Switch positi&?Left
3
n
22
0
21
o-----o
NOTE
/ STB Revision
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16
LIGHTING
SYSTEM
- Hazard Warning
8-161
Switch
HAZARD WARNING
REMOVAL
AND
INSTALLATION
NOBICLAC
SERVOCE POINTS
1.
OF REMOVAL
HAZARD WARNING
SWITCH
Insert the special tool into the switch and pry the switch
remove it from the instrument
panel.
to
INSPECTION
Operate
minals.
the switch
and check the continuity
between
16W1531
NOTE
CC
indicates
that there
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is continuity
between
the terminals.
the ter-
8-162
LIGHTING
DIMMER
CONTROL
REMOVAL
AND INSTALLATION
Removal
SYSTEM
- Dimmer
Control
Switch
SWITCH
NOBIRAB
steps
1. Knob
2. Ring
nut
3. Dimmer
control
NOTE
Reverse
switch
the removal
procedures
to reinstall.
16W936
INSPECTION
(1) Measure
the continuity
between
the dimmer
control
switch terminals
with an ohmmeter.
(2) If the resistance value varies smoothly between 0 and 10 IR
throughout
the entire operation
range, the dimmer
control
switch is functioning
properly.
1 STB Revision
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WIPER AND WASHER
WIPER AND WASHER
8-163
SYSETM
SPECIFICATIONS
GENERAL
SPECIFICATIONS
WINDSHIELD
WIPERS
AND WASHER
NOBKB-
Sbecifications
Items
Windshield
wiper
motor
Type
Speed control system
ermanent-magnet
Braking system
Dynamic brake system
Revolution under load

wm
Low speed [I .9 Nm (1.4 ft.lbs.)]
3524
Third brush system
45?8
High speed [I .3 Nm (.9 ftlbs.)]

Nm (ftlbs.)
Nominal torque
Windshield
wiper
type
13(g)
blade
Wiping angle
35.5 & 1.5
11451.5
Drivers side
Passengers
side
mm (in.)
Wiper blade length

Window
washer
401 (16)
motor and pump
Motor type
Iirect
Pump type
Zentrifugal
3.5 or less
Power consumption
A
Allowable period of continuous
With washer
Max. 20
kPa (psi)
relay
time
load
HEADLIGHT
1.5~0.7-10.5~3
sec.
Delay time in washer

Working
,-
70 (12.8) or more
1.5 (1.6, 1.3) or more
lit. (US. qts., Imp.qts.)
Tank capacity
Intermittent wiper
type
sec.
fluid
Nozzle jet pressure
Intermittent
use
current ferrite magnet type
moving
0.4-I .2
sec.
60
WASHER
Specifications
Items
Washer
motor and pump
Motor type
Ferrite magnet type
Pump type
Centrifugal
21 or less
Power consumption
177 (25.6) or more
kPa (psi)
Nozzle injection pressure
lit.
(U.S.
qts.,
Imp.qts.)
Tank capacity
Headlight
washer
Time setting
Check valve
Valve opening
3.0 (3.2, 2.6)
control unit
sec.
and closing pressure
type
0.52 -+ 0.1
kPa (psi)
49-108(7.1-15.6)
1 STB Revision
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8-164
WIPER AND WASHER
COLUMN
SYSTEM
-Specifications
SWITCH
Specifications
Wiper-washer
switch
Wiper switch
Rated load
Low
3.5
intermittent
0.17-0.27
High
4.5
18
Lock
Washer
switch
Rated load
Voltage drop (at

Headlight
washer
Rated load
0.2 or less
2V and the rated load)
switch
/
I
0.5 or less
0.5
A
V
REAR WIPER
0.2 or less
AND WASHER
Specifications
Items
Wiper motor
Ferrite magnet type

Dynamic braking sytem
Motor type
Braking system
Revolution under no-load
4025
Nm (ftlbs.)
Nominal torque
Wiper blade
8 (6)
108
Wiping angle
Blade length
Window
380(15)
mm (in.)
washer
motor and pump

Direct current ferrite magnet type
Motor type
Pump type
Centrifugal
Power consumption
3.5 or less
Allowable
period of continuous
With washer
use
sec.
Max. 60
Max. 20
fluid
Empty operation
Nozzle jet-spray
Tank capacity
REAR WIPER
pressure
78 (11.4) or more
1 .I (1.2, 1 .O) or more
kPa (psi)
lit. (U.S.qts.,
AND WASHER
Imp.qts.)
SWITCH
Specifications
Items
Rated load
type
Wiper switch
Washer
5
0.1 or less
switch
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WIPER
AND
WASHER
SYSETM
- Specifications
/ Special
TOOIS
8-165
N08KLb-
Nm
Items
Windshield wiper pivot shaft installing
Windshield wiper arm locking nut
IO-16
nut
IO-16
Windshield wiper motor
7-10
Steering wheel lock nut
35-45
Rear wiper pivot shaft installing nut

Rear wiper arm locking nut
8-12
Rear wioer motor
7-10
7-10
SPECIAL TOOLS
NOEKG-B
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8-166
WIPER AND WASHER SYSTEM -Troubleshooting
TROUBLESHOOTING
WINDSHIELD/REAR
WIPERS AND WASHER
N08KW
/
Inspection
items
Other inspectior
items
co ~
2s
a, al
2 2
Ll-LL
1
T
+c
E
&
.;
1
0
E
-0 i;
6%
Symptom
Wiper fails to operate
Even when the wiper switch
wiper continues to operate
is at OFF, the
Wipers auto stopfails to operate (stops

vyith the switch at OFF position)
*The wiper does not operate at intervals
*When the washer

fails to function
is operated
the wiper
*The wiper
intervals cannot be regulated
The washer
fails to operate
0
0
NOTE
(1) Number in circle indicates inspection sequence.
(2) The *symbol indicates vehicle with intermittent wipers
1 STB Revision
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8-167
WIPER AND WASHER SYSTEM -Troubleshooting

HEADLIGHT
WASHER
Inspection
Other inspection
items
Symptom
Headlight washer
fails to operate
NOTE
Number in circle indicates
inspection
sequence.
1 STB Revision
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items
8468
WIPER
AND
CIRCUIT DIAGRAM
WIPER AND WASHER
lattery
WASHERS SYSTEM
Diagram
- Circuit
CIRCU
Sub
-1.SBAz2
A-23
fusible
Ignition
link
0.5-G
2-R
5-w m5-w
Z-W
U
Main
fusible
Light
control
relay
link
switch
IL
P1 I?
J.
-RW
,
Multi-purpose
fuse
JA
:
II,
.
C>
L
0.85-L
'
I-2-B
Intermittent
wiper
control
relay
-r
,m:
JJ-.
Remarks
(I)
For information
concernina
the
ground
points
(example:
a ),
refer to P.8-7.
(2)
The svmbols
0.0.
etc. indicate
that the wiring
is connected
(using
the same numerical
symbol)
to the
facing
page.
(In other words,
0 on the right
page is connected
to 0 on the left
page.)
1 C-64
a
c:
Headlight
washer
motor
relay
EEEI
m
Wiring
B: Black
LI: Light
color
blue
code
Br: Brown
0: Orange
G: Green
P: Pink
Gr:
R:
Gray
Red
/ STB Revision
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L:
Y:
Blue
Yellow
Lg:
W:
LB
L1
Light
White
green
WIPER AND WASHER
Column
--
SYSTEM
Circuit
8469
Diagram
switch
Front-koer
-1
switch
Headlight
washer
switch
Rear wiper
and
washer
switch
r
I
o-(YL)
@JYJ
(+
BR
@- Lw
w2-B
B-l 2
)1L
!(
7
A-58
1
washer
81
B-07
>
Front
motor
A-14
Front
motor
wiper
GE&washer
motor
I
Rear
motor
wiper
37W124
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8-170
WIPER
AND WASHER
SYSTEM
- Service
Adjustment
SERVICE ADJUSTMENT
WIPE#l BLADE
WINdSHIELD
RUBBER
Procedures
PROCEDURES
REPLACEMENT
NOBKIAA
WIPER
1. Pull out the rubber

side.
and backing
blade
from
the stopper
2. Remove the backing blade from the rubber.

3. To attach a new rubber, assemble the rubber and backing
blade, insert from the direction
opposite the stopper, and
secure by the stopper.
Note that, because the backing
blade is curved, installation
should be as shown in the
figure.
Back&g
blade
REAR WIPER
1. Pull out one
stopper.
2.
3.
side
of the wiper
blade
rubber
from
the
Pull out the wiper blade rubber, and then remove the blade
rubber.
Installation
of the new blade rubber
is the reverse
procedure
of removal.
( ST6 Revision
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WIPER AND
WINDSHIELD
WIPE
REMOVAL
INSTALLATION
AND
WASHER
SYSTEM
- Windshield
8-171
Wipers
NOBKJAD
16W961
Removal
steps
1. Wiper
l + 2. Wiper
4*
3.
4.
5.
6.
Wiper
Wiber
Wiper
Wiper
blades
arms
pivot shield
pivot collars
motor
link
caps
NOTE
to reinstall.
(2) 4* : Refer to Service Points of Removal.
(3) I)* : Refer to Service Points of Installation
SERVICE
5. WIPER
POINTS
OF REMOVAL
MOTOR
Uncouple
the
pulled
slightly
linkage
outward).
and
motor
(with
the
Caution
Because the installation
position
of the crank
motor determine
the wiper auto stop angle,
semble them unless it is necessary to do so. If
must be removed
from the motor,
remove
marking
their mounting
positions.
svision
I
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wiper
motor
arm and the

do not disasthe crank arm
it only after
8-172
WIPER
AND WAsHER
SYSTEM
SERVICE
2.
POINTS
INSTALLATION
Wipers
Windshield
OF INSTALLATION
OF WIPER
ARMS
Install the wiper arm to the pivot shaft so that the wiper
blades stop position is the position shown in the illustration.
nm (in.1
16Y1568
INSPECTION
WIPER
MOTOR
Disconnect
from the wiper motor
connect battery to the wiper motor connector
to check
the @viper motor runs.
LOW
SPEED
OPERATION
CHECK
Connect battery ( + ) to terminal 1 and battery ( - ) to terminal

and check that the motor runs at low speed.
(v
and
that
L
I
Battery
HIGH SPEEID OPERATION

CHECK
Connect battery (+) to terminal 1 and battery (-)
and check that the motor runs at high speed.
to terminal
+
Battery
II
16W1538
AUTOMATIC
STOP OPERATION
CHECK
(1) Connect
battery ( +) to terminal
1 and battery ( -) to
terminal
3 to run the motor at low speed.
(2) Disconnect
terminal
1 during operation
to stop the motor.
bv
J
.jr
2.
Battery
16W1539
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WIPER
AND WASHER
SYSTEM
- Windshield
8-173
Wipers
(3) Connect terminal 2 to terminal

3 and connect battery (+)
to terminal 1 and battery (-) to the wiper motor bracket to
check that the motor starts to run at low speed and then
stops.
Battery
I
To wiper
motor
bracket
16W1540
INTERMITTENT
WIPER RELAY
Remove the intermittent
wiper relay (located
of the left side cowl side trim).
at the upper part
16W1524
CONTINUITY
CHECK
Check to see that there
5.
16UO373
) STB Revision
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is continuity
between
terminals
2 and
a-174
WIPER AND
WASHER
$YSTEM
Wipers / Rear Wiper
INTERMITTENT
OPERATION
CHECK
(1) Cpnnect the battery and the test light to the relay, as
shown in the figure.
(2) l&ert a variable resistance between terminal 8 and battery
(1) (VR = O-50 kfl)
(3) The condition is normal if, when the batterys negative (-)
terminal is connected
to terminal
7, the test light illuminates at the same time, and thereafter,
in accordance with
the value of the variable resistance,
stops illumination
(approx. 1.5 sec. - approx. 10.5 sec.) and then illuminates
(approx. 1 sec.) over and over again.
7-est
- Windshield
WASHER
INTERLOCK
OPERATION
CHECK
(1) Connect the battery and the test light to the
shown in the .figure.
light
relay,
as
(2) When terminal 3 is connected

to the batterys
negative (-)
terminal,
the test light will illuminate
approximately
1
second thereafter,
and then there will be a release
for
about seconds
after connecting
to the batterys
negative
( - ) terminal.
is normal if about 3 seconds thereafter the
(3 The condition
test light stops illumination.
16K1920
REAR WIPtER
REMOVAL
AND
INSTALLATION
NOOKKAC
16W962
Removal
+e
steps
1. inside handle cover

l + 2. Back door trim and waterproof
++ 3. Wiper blade
4. Wiper arm
5. Wiper pivot cap
6. Wiper pivot washer
7. Wiper pivot packing
8. Wiper motor
film
1 STB Revision
NOTE
(2) 4* : Refer to Service Points of Removal.
(1)
-7
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WIPER
AND WASHER
SYSTEM
SERVICE
2.
POINTS
REMOVAL
FILM
3.
2.
16K394
Rear
POINTS
8-175
Wiper
OF REMOVAL
OF BACK
Refer to GROUP
proof Film.
SERVICE
DOOR
TRIM
AND
WATERPROOF
23 BODY - Back Door Trim
and Water-
OF INSTALLATION
INSTALLATION
Install the wiper
the lower edge
OF WIPER BLADE
arm so that the wiper blade
of the window glass.
INSTALLATION
PROOF FILM
Refer to GROUP
proof Film.
OF BACK
DOOR
TRIM
is parallel
AND
23 BODY - Back Door Trim
to
WATERand Water-
INSPECTION
WIPER MOTOR
Disconnect
from the wiper motor
connect battery to the wiper motor connector
to check
the wiper motor runs.
I STB Revision
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and
that
8476
WIPER
AND WASHER
SYSTEM
- Rear Wiper
OPERATION
CHECK
Connect battery (+ :I to terminal 1 and battery
to check that the motor runs.
( -) to terminal
16W1541
AUTOMATIC
OPERATION
CHECK
(1) Connect
battery (+) to terminal
1 and. battery ( - ) to
terminal
3 to run the motor.
(2) While the motor is running, disconnect
terminal
1 to stop
the motor.
Battery
2.3
(3) Connect terminal

2 to terminal
3 and connect battery (+)
to terminal
1 and battery (-) to wiper motor bracket to
check that the motor starts to run again and then stops.
t
Battery
-
To wiper
motor
bracket
+
10w1543
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WIPER
AND WASHER
WINDSHIELD
WASHER
REMOVAL
INSTALLATION
AND
SYSTEM
- Windshield
8-177
Washer
N08KlAD
16W1556
1.
2.
3.
4.
Windshild washer tank

Washer motor and pump
Washer tube
Washer nozzle
INSPECTION
::I:;rl
_
+
WASHER
MOTOR
AND
PUMP
Make the check while the motor is installed to the washer

tank.
(1) Check to be sure that there is washer fluid in the washer
tank.
(2) Check to be sure that the washer motor operates and the
fluid is forced out under pressure when the batterys
positive (+) terminal
is connected
to terminal
2 and the
1
2
18K1514
negative
( -)
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terminal
is connected
to terminal
I.
8-178
WIPER AND WASHER
SYSTEM
- Rear Washer
REAR WASHER
REMOVAL
AND INSTALLATION
N08KLCA
16W1669
Removal
steps
+e
1.
2.
3.
4.
5.
~~
Rear wheelhouse
trim and quarter
Rear washer tank
Washer motor and pump
Washer tube
Washer nozzle and tube
trim
NOTE
(1)
(2)
(3)
SERVICE
1.
Reverse
POINTS
REMOVAL
TER TRIM
Ravisinn
procedures
Points
Points
-7
http://vnx.su/
to reinstall.
of Removal.
of Installation.
OF REMOVAL
OF REAR WHEELHOUSE
Refer to GROUP
1 STR
the removal
23 BODY
- Trims.
TRIM
AND
QUAR-
WIPER
AND WASHER
+1
li.if
I
SYSTEM
- Rear Washer
/ Headlight
Washer
8-179
INSPECTION
WASHER MOTOR AND PUMP

tank.
tank.
positive (+) terminal is connected to terminal 2 and the
negative (-) terminal is connected
to terminal 1.
SERVICE
POINTS
1. INSTALLATION
OF INSTALLATION
OF
REAR
WHEELHOUSE
TRIM
AND
QUARTER TRIM
Refer to GROUP
HEADLIGHT
REMOVAL
Removal
AND
23 BODY - Trims.
WASHER
INSTALLATION
NOEKPAA
steps
1.
2.
3.
4.
5.
Radiator grille
Front combination light
Headlight bezel
Headlight washer nozzle
Washer tube
6. Check valve
7. Headlight washer tank
8. Washer motor and pump
16W1562
NOTE
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WIPER AND
WASHER
SYSTEM
Headlight
Washer
INSPECTION
WASHER
16Wl544
MOTOR
AND
PUMP

tank.
tank.
positive (+) terminal
is connected
to terminal
2 and the
negative (-) terminal
is connected
to terminal
3.
HEADLIGHT
WASHER
RELAY
Remove the headlight washer relay (located

of the left side cowl side trim).
WASHER
OPERATION
aIt the upper
part
CHECK
(1) Connect the battery and the test light to the relay as
,shown in the figure.
(2) If, when terminal
1 is connected
to the negative
(-)
terminal of the battery, the light illuminates
(for about 0.5
second), the unit is operating
normally.
18W943
Test light
16W945
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WIPER
COLUMN
AND
WASHER
SYSTEM
8-181
Switch
Column
SWITCH
REMOVAL
AND
INSTALLATION
NOBKMAE
35-45 Nm
3
Removal
l *
16W1569
steps
1.
2.
3.
4.
5.
6.
Steering wheel center

Steering wheel
Lower column cover
Upper column cover
Column switch
Cable band
pad
NOTE
(1)
Reverse
the
(2)
*I)
: Refer
SERVICE
2.
removal
procedures
to Service
Points
POINTS
REMOVAL
Remove
to
of
reinstall.
Removal
OF REMOVAL
OF STEERING
the steering
WHEEL
wheel
by usiing
the steering
wheel
puller.
Caution
Do not hammer
doing so many
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on the
damage
steering
wheel
the collapsible
to remove
mechanism.
it;
8482
WIPER AND WASHER SYSTEM - Column Switch

INSPECTION
Remove
the steering lqwer cover, and the!
detach the
conn#ctor of the c:olumn switch from the wlnng harness.
Operate the switch
terminals.
between
the
16W1530
WIPER-WASHER
SWITCH
20
1 OFF
Ip-I
18
15
HI
14
19
o-t--t-o
v
o-
13
- -
-0
NOTE
(1) GC
indicates that there is continuity
between
the terminals.
(2) The dotted lines indicate that the washer switch ON.
HEADLIGHT
WASHER
Terminal
.,2
Switch Poisition
OFF
ON
NOTE
C-C indicates
that there
16W153C
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is continuity
between
the terminals.
WIPER
AND
WASHER
SYSTEM
REAR WIPER AND WASHER

REMOVAL
4*
AND
- Rear Wiper
and
Washer
8-183
Switch
SWITCH
INSTALLATION
I. Rear wiper
NOTE
SERVICE
POINTS
1. REMOVAL
OF REMOVAL
OF REAR
WIPER
AND
WASHER
SWITCH
Insert the special tool into the switch and pry the switch to
panel.
INSPECTION
Operate
minals.
the switch,
16W944
) STB Revision
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between
the ter-
8-184
HORN
Specifications
/ Troubleshooting
HORN
SPECIFICATIONS
GENERAL
SPECIFICATIONS
NOBLE--
Specifications
Items
Effective
Power
sounding
voltage
consumption
Sound level
Fundamental
(at 12V)
11-14.5
A
Max. 3.5
dB
100-7 10
frequency
Hz
High
sound
400--440
Low
sound
340--380
Items
Steering wheel
lock nut
Nm
ft.lbs.
35-45
26-33
TROUBLESHOOTING
HORN
NOBLH-
Horn does not sound
Horn will not stop sounding

NOTE
Number
in circle indicates
inspection
0
sequence.
1 STB Revision
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@I
0
Horn contact
plate
HORN - Circuit
8485
Diagram
CIRCUIT DIAGRAM
HORN CIRCUIT
fusible
link
OFF
Multi-purpose
fuse
I r
m
I
2
d
t
1
mm
I
I
mm
2%
$2
dd
dd
A-37
Horn switch
Column switch
To wiper motor
[Refer to P.8-59.1
A-36
A-38
A-39
I--J!
(H)
(U
37W608
Remark
For information
concerning the ground
refer to P.8-7.
Wiring color code
Br: Brown
B: Black
LI: Light blue
0: Orange
points (example:
G: Green
P: Pink
Gr: Gray
R: Red
1 STB Revision
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L: Blue
Y: Yellow
Lg: Light green

W: White
8486
HORN - Horn
HORN
REMOVAL
Removal
AND INSTALLATION
NOBWAE
steps
1. Radiator grille
2. Horn (High)
3. Horn (Low)
NOTE
Reverse tne removal procedures to reinstall.

16W964
INSPECTION
o
o
l
A loose horn adjustment

screw.
Water, dirt, or other foreign matter lodged inside the horn.
A loose horn bracket mounting bolt.
HORN ADJUSTMENT
169744
(1) Secure the horn bracket in a vice, and then connect a

battery of the 12 volts.
(2) Sound the horn, and adjust it by turning the adjusting
screw.
0 The sound volume is too low.
Turn the adjusting screw in the UP direction within a
range of about 180, and then set it in position when a
satisfactory
sound volume has been obtained.
0 The sound volume is too loud:
Turn the adjusting screw 20 to 30 in the DOWN
direction, and then set it in position when a satisfactory
sound volume has been obtained.
0 Horn will not sound:
Turn the adjusting screw slightly in the UP direction
until the horn sounds, find a satisfactory sound volume
by continuing to turn the screw within a range of 180,
and then set the screw in place. If a satisfactory
volume cannot be obtained, replace the horn.
Caution
After the adjustment
apply lacquer to prevent
adjusting screw from becoming
loose.
1 ST6 Revision
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the
HORN - Horn
8-187
Switch
HORN SWITCH
REMOVAL
AND
INSTALLATION
NOILKAE
T--J2
Removal
+I)
steps
1.
2.
3.
4.
5.
Steering wheel pa
Steering wheel
Steering bossplate
Steering wheel cover
Horn switch
16W1570
I IL
(1)
(2)
SERVICE
2.
Reverse the removal procedure

+e : Refer to Service Points
POINTS
REMOVAL
Remove
puller.
OF REMOVAL
OF STEERING
the steering
to reinstall.
of Removal.
wheel
WHEEL
by using
the steering
wheel
Caution
Do not hammer
on the steering
wheel to remove
doing so may damage
the collapsible
mechanism.
INSPECTION
l
l
l
A burned out or short-circuited

horn switch
A broken or damaged
horn switch spring.
A damaged
horn switch harness.
1 STB Revision
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contact.
it;
8-188
ACCESSORY
- Specifications
/ Troubleshooting
ACCESSORY
SPECIFICATIONS
GENERAL
SPECIFICATIONS
CIGARETTE
LIGHTER
NOBMB-
Specifications
Items
Maximum
current
Return time
A
I
I
sec.
10
18 or less
CLOCK
Items
Specifications
Crystal oscillating type
Fluorescent digital display
Type
Display type
TROUBLESHOOTING
ZIGARETTE LIGHTER AND CLOCK
Inspection
Symptom
Cigarette
lighter fails to operate
Clock stopped
NOTE
Number
in circle indicates
inspection
sequence.
MB
Revision
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items
ACCESSORY
- Circuit
8-189
Diagram
CIRCUIT DIAGRAM
CIGARETTE LIGHTER / CLOCK CIRCUIT
Sub
,-fs
M
Main
link
15-W
fusible
5-W 25-W
I I
fusible
LW
w
EB
Ignition
link
switch
;I;
3e
I
NN
I
,
To- .J
linht . cnntrnl
__._ [Refer
to P.8-461
To radio
[Refer
to
To hazard
[Refer
to
illumination
flasher
P.8-491
P.8-601
r&v
-.,
GW
1 .25-
Z-RW
I 4
I 4
L-K
GB
unit4
Multi-purpose
fuse
light
r
To heater
illumination
[Refer
to
control
light
P 8-511
iI
I
-I To combination
[Refer
to P.8-521
Wiring
B: Black
Br: Brown
G: Green
Gr: Gray
L: Blue
Lg: Light
color
green
meter
BY
m
I
N
Q-
code
LI: Light
0: Orange
P: Pink
R: Red
Y: Yellow
W: White
To dimmer
[Refer
to
blue
control
P 8-511
switch
.I
BY
37W615
Remark
For information
refer
to P.8-7.
1 STB Revision
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concerning
the
ground
points
(example:
).
8-190
ACCESSORY;
CIGARETTE
REMOVAL
Lighter
LIGHTER
AND
Removal
- Cigarette
INSTALLATION
NOEMJAE
steps
1. Knob
Plug
3. Center
4. Plug
5. Nut
6. Socket
2.
7.
Outer
panel
case
8. Cigarette
lighter
NOTE
Reverse
bracket
the
removal
procedure
to
reinstall.
16W1555
INSPECTION
l
l
l
Take out the plug, and check

element
spot connection,
and
other material
on the element.
Using an ohmmeter,
check the
Confirm that there is no dirt on
for a worn edge on the

for shreds of tobacco
or
continuity
of the element.
the surface of the socket.
CAUTIONS
FOR USE OF THE CIGARETTE
AS AUXILIARY
POWER SOURCE
LIGHTER
SOCKET
1. When using a plug-in

type of accessory,
do not use
anything
with a load of more than 120W.
2. It is recommended
that only the lighter
be inserted
in
the receptacle.
Use of plug-in
type accessories
may damage
the
receptacle
and result in poor retention
of the lighter.
NOTE
The specified
overloaded
1 STB Revision
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load should be strictly observed,

because
cord burns the ignition
switch and herness.
ACCESSORY
Clock
8-191
CLOCK
REMOVAL
Removal
AND
INSTALLATION
NOBMKAD
steps
1. Knob
2. Plug
3. Center
4. Clock
panel
16W1558
NOTE
Reverse
the removal
procedures
to reinstall
1 STB Revision
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8-192
AUDIO SYSTEM - Specifications
AUDIO
I/
SYSTEM
SPECIFICATIONS
GENERAL
SPECIFICATIONS
NOENB-
Items
Spe,cifications
Radio
Model
AR-7 127PY
AR-7 177PY
Receiving band
AM/ FM
AMI FM
Tape player
Model
-_-
CX-25Y
Speaker
Instrument
panel
-
Model
SR-28A4-Y K-2
5W (Max. 7W)
Rated input power

Center pillar trim
Model.
SG-13SL4-G2 (GRAY) or
SG-13SL4-BE87 (BEIGE)
SG-13SL4-G2 (GRAY) or
SG-13SL4-BE87 (BEIGE)
Reted input power
15W (Max. 30W)
15W (Max. 3OW)
Pole antenna
Pole antenna
Antenna
Type
TROUBLESHOOTING
Symptom
NOTE
Number
in circle indicates
inspection
sequence
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8-193
AUDIO SYSTEM - Specifications

NOISE SOURCES
Source
of Electrical
System
Noise
Ignition system
Power generation
(1) Spark plug
(1) Ripple at contact between alternator

armature and carbon brush
(2) Spark from voltage regulator contact
(2) High tension cable
system
Other electrical device
(3) Distributor
(1) Armature
motors.
of wiper,
(2) Starter and switch
blower
and other
when starting engine
(3) Spark from changeover
switch
(4) Horn
(5) Contact of turn signal
(6) Loose contact of wiring
!
Noise
Sourse
of Vehicle
harness
(7) Static electricity generated by tire or

generator drive-belt
(8) Voltage stability unit for instrument
Equipment
Kind of noise
Equipment
Symptom
Whistling
Alternator
Noise increases when accelerator pedal is

depressed and it subsides soon after engine
is stopped.
Scratching
sound
sound
Water temperature
gauge unit
of noise generation
Noise is produced while engine is running

and it persists for a while after engine
shutdown.
Fuel gauge unit
Noise is produced at sudden acceleration,

driving on rough road or when ignition key is
placed to ON.
Jarring
Oil pressure
Noise is produced with engine operation

and no noise is made when engine is idling.
Wish-wash,
wish-wash
Flasher relay
Noise is produced
signal light
Buzz, click
Horn
Noise is made when

or released.
Whinning
Wiper motor
Noise is generated
Washer
Noise is made when washer
switch
motor
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with operation
of turn
horn button is pressed

with the wiper speed.
is operated.
8-194
AUDIO
SYSTEM
Diagram
- Circuit
CIRCUIT DIAGRAM
I
RADIO/CASSETTE
DECK CIRC,UIT
LW
w
033
Ignition
A-02 IL-
Battery
Sub fusible
1.25-B
5-w
Main
link
A-23
5-w ll5-w
u
switch
link
0.5-G
2 w
-
fusible
To light control 4 Z-RW

relav
[Refer to P.8-461
Z-RW,,: 3
To air conditioner,LW
[Refer to P.8-561
To combination
4
meter
[Refer to P.8-521
By
DIN Cable
Tape
I
I
/
J
It, /II
=z
c- 45
player
Radio
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AUDIO
SYSTEM
- Circuit
8-195
Diagram
Front
speaker
(L.H.)
C-65
B-03
YL
Gr,=:
(L.H.)
B-04
Rear
speaker
B-29
YR c
GrRC+
(R.H.)
B-2?
Remarks
(1)
For information
concerning
the
ground
points
(example: 0 ), refer
to P.8-7.
(2) The
symbols
0,
0,
etc.
indicate
that
the
wiring
is
connected
(using
the same
numerical
symbol)
to the
facing
page.
(in other words,
to 0 on
the left page.)
Wiring
color
B: Black
LI:
Light
blue
code
Br:
0:
Brown
Orange
G: Green
P: Pink
Gr: Gray
R: Red
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L: Blue
Y: Yellow
Lg:
Light
W:
White
green
8-196
AUDIO
SYSTEM
- Service
Adjustment
Procedures
SERVICE ADJUSTMENT
ANTkNNA
PROCEDURES
TRUMMER
NOBNIAA
1. The antenna
trimmer is essential for matching the antenna

with the radio in order to obtain the maximum
sensitivity of
the radio.
2. It must be adjusted with the antenna actually mounted
on
the vehicle. If the trimmer
is not adjusted
properly, the
radio suffers from not only low sensitivity
but also noises,
such as external noise and noise from passing vehicles.
3. In the following
cases, therefore,
adjust it as described
below.
(1) When radio is installed.
(2) If antenna is replaced.
(3) If radio has low sensitivity.
(4) If radio is noisy.
AkTENNA
1.
TRIMMER
ADJUSTMENT
Mgke the following

preparations
for adjustment:
key to the ACC position.
(2) Extend the antenna all the way.
(3) Tune accurately to a station near 1,400 kHz in order to
receive a broadcast in as weak an electric field as can
be barely received. If there is no station near 1,400 kHz,
tune to any high-frequency
station (above 1,000 kHz)
available. If there are two or more stations near 1,400
kHz, choose the louder one.
(4) Set the volume
control to the proper volume.
(5) Set the tone ccontrol to treble position.
2.
70R0351
Be sure that preparations

1 through 5 have been correctly
made.
3. Insert a screwdriver
into the trimmer
adjusting
hole.
4. Tumrn the screwdriver
clockwise
or counterclockwise
for
maximum
sensitivity
(maximum
broadcast
wave sound).
5. If the optimum
sensitivity
point cannot be found, check for
an antenna malfunction
or a broken wire.
NOTE
The antenna trimmer
require adjustment.
/ STB Revision
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of an electronic
tuning
radio does not
AUDIO
RADIO
REMOVAL
SYSTEM
- Radio and Tape
e-197
Player
AND TAPE PLAYER

AND
INSTALLATION
NOINJAF
16W1519
Post-installation
Operation
l
Adjustment
of Antenna
(Refer to P.8-196.)
Trimmer
Removal steps
1. Knob
2. Plug
3. Center console
7. Radio
8. Tape player
9. Box (Vehicles without tape player)
4. Connection
of center panel wiring
harness to front wiring
harness
connector
5. Radio panel
6. Radio bracket
NOTE
Reverse
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the removal
procedures
to reinstall.
8-198
AUDIO
SYSTEM
- Front
Speaker
/ Rear Speaker
FRONT SPEAKER
REMOVAL
AND INSTALLATION
Removal
NOONMAE
steps
1. Mounting screws
2. Front speaker
NOTE
Reverse
16W1520
the
removal
procedures
to
reinstall.
REAR SPEAKER
REMOVAL
AND
INSTALLATION
16Wl570
Removal
steps
1. Mounting screws
2. Rear speaker
NOTE
Reverse
the
removal
procedures
to
reinstal
1 STB Revision
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AUDIO
SYSTEM
8-199
- Antenna
ANTENNA
REMOVAL
AND
NOSNPAC
INSTALLATION
16W1579
Removal
4*
+e
w+
steps
1.
2.
3.
4.
5.
Mounting nut
Antenna mast
Front fender panel
Ground base
Antenna base
NOTE
(1)
(2)
(3)

to reinstall.
+*
l * : Refer to Service Points of Installation
SERVICE
POINTS
OF REMOVAL
1. REMOVAL
OF MOUNTING
NUT
Hold the antenna mast, and then
http://vnx.su/
remove
the mounting
8-200
AUDIO
SYSTEM
3.
Antenna/Noise
REMOVAL
OF FRONT
Refer to GROUP
SEFiVlCE
3.
Suppression
ff OINTS
FENDER
23 Body-Front
PANEL
Fender
OF INSTALLATION
IbSTALLATION
OF FRONT FENDER PANEL
Refer to GROUP 23 Body-Front
Fender.
NOISE SWPRESSION
N08NOAA
I.
Noise interfering
with radio reception
may be roughly
classified
as follows:
(1) Noise produced
by the vehicle itself
Noise from the ignition circuit, alternator
circuit, etc
(2) Noise generated
in the radio itself
Thermal
noise from transistors,
IC, resistor, etc.
(3) Atmospheric
noise
Noise from other cars, neon signs, etc.
2. The radio has devices to suppress noise of the radio itsel f
and atmospheric
noise, but it is difficult to eliminate
them
completely.
Noise produced by the vehicle includes whining from the alternator
system, and a strong, impulsive,
fast popping
noise from the ignition
system.
3. Before performing
any checking
or adjustments,
first
confirm the following
points.
Adjust the antenna trimmer
completely.
Set the push buttons (tuning) properly.
Extend the antenna all the way.
PREVENTION
OF IGNITION
CIRCUIT
NOISE
A resistance-equipped
cable is used for the high-tension
cable
in order to prevent noise; however, if any noise from the
ignition
circuit does occur, check the tightness
and ground
connection
of the positive (+) terminal of the noise filter, and,
if necessary,
check the noise filter.
Caution
Be careful not to connect the noise filter to the hightension
cable; doing so could damage
the noise filter.
PREVENTION
OF OTHER CIRCUIT
NOISE
1. For other noises, take necessary
corrective
actions
in
accordance
with the following
items and the NOISE
SUPPRESSION
CHART.
2. Polish the grounding
cable terminal, and connect it properly.
3. Polish the pillar antenna ground terminal,
and connect it
properly.
4. Ground electric parts completely.
5. Keep the antenna cable and speaker lead wire away from
other electric wiring.
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AUDIO SYSTEM - Noise

NOISE
SUPPRESSION
8-201
Suppression
CHART
Symptom
Remedy
Unusual noise
engine speed.
related
to
Securely
hood.
ground
the engine,
frame
and/or
body and engine
Ground wire
16E71C
Clatter
flashing
noise related to the

of turn signal lights
Turn signals
Connect a 0.5 FF noise-suppression

of the flasher unit.
?L
capacitor
to the 6 terminal
0.5pF noise suppression

capacitor
16E71:
Abnormal
noise when
the horn is operated.
Horn
1.
2.
Connect a 0.5 FF noise-suppression

capacitor
to the + B
terminal of the horn.
For an FM radio, connect an LC filter to the horn terminals.
Horn
LC filter
16E71:
Noise when the windshield washer oprates.
Washer
motor
1.
2.
Unusual noise when

engine is started.
the
Water temperature gauge unit
Connect a 0.5 PF noise-suppression

capacitor
between
the terminal
of the washer motor and the power source
wire.
For an FM radio, connect an LC filter between
the terminal
of the washer motor and the power source wire.
Connect a 0.1 p,F noise-suppression

the water temperature
gauge unit.
capacitor
to the terminal
0.1 PF noise suppression

capacrtor
1 STB Revision
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8-202
AUDIO
NOISE SUPPRESOR
SYSTEM
- Noise Suppression
LOCATION
16W722
--I
1
Grou:d
cable
- Noise condenser
1 STB Revision
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16W1580
BACK DOOR WINDOW
BACK DOOR WINDOW
DEFOGGER - Specifications
/ Special Tools
8-203
DEFOGGER
SPECIFICATIONS
( ;ENERAL
SPECIFICATIONS
NOOPB-B
Specifications
Items
Back door window
defogger
switch
Type
Seesaw
Rated current
20A
Back door window
defogger
timer
-
Timer
Back door window glass with defogger
No. of printed heater lines
Power consumption
11
112-148W
[2OC (68F)]
SPECIAL TOOLS
Tool (Number
MB990784
Ornament
type
and name)
remover
NOBPG-B
Use
Removal of back door
window defogger
switch
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8-204
BACK DOOR WINDOW
I
DEFOGGER-Troubleshooting
TROUBLESHOOTING
Neither the back door window

The indicator
function.
functions,
NOBPH-B
defogger
nor the indicator
but the back door window
function.
defogger
does not
.--Number
in circle indicates
inspection
sequence.
/ STB Rqvision
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0
0
BACK
DOOR WINDOW
CIRCUIT DUAGRAM
DEFOGGER CIRCUIT
-
8-205
- Circuit Diagram
-t IDI L
H-ULm
Ll&J
5-w
Main
link
DEFOGGER
Sub fusible
A-23
5-w"5'w
fusible
link
0.5-G
ignition
switch
z-w ,
To light control
zmR~
w
relay
[Refer to P.8-461
q--l-
Multi-purpose
@fuse
1.25-B
m
E
c:
To column switch
[Refer to P.8-461
a
c!
\
Rheostat
Defogger
Remarks
For information
refer to P.8-7.
concerning
the ground
points
switch
a
cl
(example:D).
31 W02:
Wiring color code

B: Black
LI: Light blue
Br: Brown
0: Orange
G: Green
P: Pink
Gr: Gray
R: Red
STB Revision
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L: Blue
Y: Yellow
Lg: Light green

W: White
8-206
BACK DOOR WINDOW
DEFOGGER SWITCH
REMOVAL
AND
OEFOGGER
I
- Defogger Switch
INSTALLATION
NOEPJAB
\
A
w
I_
1. Defogger
NOTE
+* : Refer.to
switch
Service Points ot. ^Kernoval
SERVICE
1.
POINTS
REMOVAL
16W932
OF REMOVAL
OF DEFOGGER
SWITCH
lr@rt the special tool into the switch and pry the switch
panel.
to
INSPECTION
DEFOGGER
SWITCH
(1) Remove the defogger
switch from the instrument
panel
and connect an ohmmeter
to the switch side connector.
(2) Operate the switch and check the continuity
between the
terminals.
* : Indicator light
** : Illumination light
16W976
NOTE
1 STB Revision
~-E
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BACK
Normal
characteristic
DOOR WINDOW
DEFOGGER
INSPECTION
I;\\
Abnormal
Printed
heater
line
characteristic
Negative
terminal
curve
Voltage
Tf
IZV
I Open-circuit
I point
I
6V
ov :Positive
terminal
Printed
heater
line
Printed
Heater
Lines
B-207
PRINTED HEATER LINES
curve
Voltage
Positive
terminal
Negative
terminal
N08PKAA
1. The printed heater lines should be tested while the engine

is running at 2,000 rpm and the battery is being charged.
2. Turn the defogger
switch
to the ON position,
and use
voltmeter
to measure
the voltage of each printed heater
line at the back door window
glass center point A.
3. If all of the heater lines indicate approximately
6V, the back
door window
printed heater lines are functioning
properly.
4. If a voltage of 12V is indicated
at point A, the heater line
is broken between
point A and the negative (-) terminal.
Move the test probe gradually
toward
the negative
(-)
terminal, and search for the place where there is a sudden
change
in the voltage
(to 0 V).
5. This place where the voltage suddenly
changes
indicates
the location of the broken
heater line.
6. If OV is indicated
at point A, the heater line is broken
between
point A and the positive (+) terminal.
Find the
point where
there is a sudden
change in the voltage (to
12V). as described
in step 4. above.
161332
Alignme.nt
REPAIR
holes
I.
Masking
tape
16FfiSCl
2.
3.
4.
Prepare the following

items:
e Conductive
paint
@ Paint thinner
e Masking
tape, decal, etc.
a, Unleaded
gasoline
@ Thin brush
Wipe the glass adjacent to the broken
heater line, clean
with unleaded gasoline, and bond a decal or masking
tape
as shown.
Shake
the electroconductive
paint container
well,
and
remove the amount of paint needed. Dilute it with a small
quantity
of paint thinner,
and apply three coats with the
brush at intervals
of about 15 minutes.
Remove the tape or decal and leave the repaired defogger
unused
for a while
before supplying
power.
For a better finish, scrape
away excess
deposits
with a
knife after drying is complete
(one day later).
Caution
After repair, clean the glass with a soft dry shop towel
or wipe along the printed
heater line with a slightly
moistened
shop towel.
1 STB Revision
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8-208 AUTO
ATIC FREE-WHEELING
GENERAL INFORMATION
HUB INDICAUOR
SYSTEM
General
Information
N08RAAA
This system is composed

of the automatic
free-wheeling
hub indicator
light, the vehicle-speed
sensor (reed
type switch), the automaic
free-wheeling
hub itidicator
control unit, and the pulse generator.
The pulse generator
is located
at the rear part of the front output
shaft of the transfer;
the vehicle-speed
sensor is incorporated
within the combination
meter.
Based upon the output signals from the pulse generator and from the vehicle-speed
sensor (reed type
switch), the automatic
free-wheeling
hub indicator control unit judges whether the automatic
free-wheeling
hub is in the locked condition
or the free condition.
When it is in the locked condition,
the indicatok light illuminates;
when it is in the free condition,
the
indicator
light does not illuminate.
This is, therefore, a system which makes it easy to see, from the drivers seat, whether the automatic
freewheeling
hub is in the locked condition
or the free condition.
j
I
21
1
Automatic
free-wheeling
hub
16W1567
hub indicator
16W1506
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AUTOMATIC
OPERATIONAL
FREE-WHEELING
CHARACTERISTICS
HUB INDICATOR
SYSTEM
General
Information
8-209
OF THE SYSTEM
Time-----w
16W1548
Symbols used in
above diagram
Indication by automatic free-wheeling hub indicator light
No illumination of the indicator light when the ignition key is turned from OFF to ON,
regardless of the condition of the automatic free-wheeling hub.
The indicator light illuminates when the automatic free-wheeling hub is locked and pulse
signals are output from the pulse generator, and when, in addition, the vehicle-speed sensor
detects a vehicle speed of approximately 2.5 mph (4 km/h) or higher.
The locked condition is entered in the memory even if the vehicle is stopped (with ignition
key still at ON) while the automatic free-wheeling hub is in the locked condition, and the
indicator light illumination continues.
After the automatic free-wheeling hub is changed from the locked condition to the free
condition (the pulse signals from the pulse generator cease), the indicator light remains
illuminated until the vehicle-speed sensor detects a vehicle speed of approximately 2.5 mph
(4 km/h) or higher.
1 STB Revision
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8-210
AUTOMATIC
EXPLANATION
FREE-WHEELING
OF INDICATOR
HUB INDICATOR
SYSTEM
General
Information
OPERATION
1. Automatic
free-wheeling
hub in locked condition
The output of the pulse generator
is input to $ertninal
4 of the control
unit, and the output signals from
the vehicle-speed
sensor are input to termi#al
3 of the control unit.
Only when there are pulse signals from the pulse generator,
and when, moreover, the vehicle-speed
signals indicate a vehicle speed of approximatkly
2.5 mph (4 km/h) or highter does the control unit judge
that the automatic
free-wheeling
hub is the locked condition
at the lock-discrimination
circuit of the
control unit, and therefore the set signal (locked condition)
is output.
This signal is entered into the memory
circuit, thus causing the indicator
light to illuminate.
Speed sensor
(Reed switch)
Pulse generator
use No. 3
Ignition
n
J 2
switch
I_
Power-supply
Pulse-detection
circuit
link
Main
link
1
1
Vehicle-speed
detection
circuit
circuit
Sub fusible
fusible
)1
Battery
Memory
circuit
rp*
I
Automatic
free-wheeling
2.
hub
Lock-discrimin&ion
circuit
16W1535
When vehicle is stopped

(with ignition
key still at ON) with automatic
free-wheeling
hub locked
Signals are not output from the pulse generator
and the vehicle-speed
sensor when the vehicle is
stopped.
However, because the set signal (locked condition)
is entered into the memory circuit, the indicator light
shows the condition
in effect when the vehicle was traveling.
Speed
Pulse generator
sense
use
No. 3
Ignition
switch
10~ Automatic
free3; wheeling
hub
I/\ indicator light
Sub fusible
Power-supply
Pulse-detecti:
Lock-discrimination
Memory
ci~uit~~I~
circuit
detection
circuit
Automatic
free-wheeling
hub
[ STB Revision
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circuit
circuit
Main
fusible
link
link
AUTOMATIC
3.
FREE-WHEELING
HUB INDICATOR
SYSTEM
8-211
Generallnformation
Automatic
free-wheeling
hub in free condition
For the free condition,
although there are (when the vehicle is traveling)
output signals from the vehiclespeed sensor,
there are no signals from the pulse generator,
with the result that the memory
circuit is
erased (because
reset signals are output from the lock-discrimination
circuit), and so the indicaotr
light
does not illuminate.
ipeed
Ignition
sensor
Automatic
switch
free-
Sub fusible
link
i
link
detection
IUse-detection
Lock -discrimination
circuit
circuit
Memory
circuit
Automatic
free-wheeling
Pulse
generator
cross-sectional
Coil
PULSE
view
hgnet
16W1547
rator
hub
GENERATOR
The pulse generator is located at the rear part of the front

output shaft of the transfer, and is composed of the magnet,
the coil and the pole (iron core).
When a magnetic material (iron, nickel, etc.) is brought close
to and moved away from the pole (iron core), the magnetic flux
within the pole changes, thus generating AC voltage in the
coil.
Because the front output shaft does not rotate when the
hub is in the free condition, there is
no generation of AC voltage in the pulse generator.
In the locked condition, however, the front output shaft and
the pulse rotor rotate, with the result that the magnetic flux
(within the p o Ie (Iron core) of the pulse generator) changes in
accordance with the rotations of the pulse rotor, thereby
generating AC voltage in the coil.
This AC voltage is transmitted to the automatic free-wheeling
hub indicator control unit.
Front output shaft
16W1546
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8-212 AUTOMATIC
FREE-WHEELING
HUB lNCDlCATOR SYSTEM - $%%60n~aton

VEHICLE-SPEED
Speedometer
I
iensor
SENSOR
(REED-TYPE
SWITCH)
The vehicle-speed
sensor functions to substitute
pulse signals
for the rotations (vehicle speed) of the transmissions
output
gear;/ it is located within the speedometer.
Pulse signals are generated
when the speedometer
cable
rotates.
Vehicle-speed
sensor
12R0058
16W1506
AUTbMATlC
FREE-WHEELING
CONTROL UNIT
Circuit
HUB
INDICATOR
The control unit is located at the upper part of the right cowl
side.
The control unit is composed
of the pulse-detection
circuit
(which receives the input signals from the pulse generator),
the vehicle-speed-detection
circuit (which receives the input
signals from the vehicle-speed
sensor), the lock-discrimination
circuit (which, based on both of these input signals, judges the
condition
of the automatic
free-wheeling
hub and then transmits indicator output signals to the memory
circuit), and the
memory
circuit (which
memorizes
the indicator
output
signals from the lock-discrimination
circuti).
Diagram
16W153
SPECIFICATIONS
GENERAL
SPECIFICATIONS
Specifications
Items
Automatic free-wheeling
Pulse generator
hub indicator light
W (SAE
trade number)
Magnet coil type
Type
Vehicle-speed
1.4(74)
sensor
Reed switch
Type
Pulse generation
4 pulses/
type
rotation
NOORG-
Specifications
Items
Standard values
Pulse generator
Vehicle-speed
resistance
215-275
sensor output voltage
1 STB Revision
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When
OFF
4 or more
When
ON
AUTOMATIC
FREE-WHEELING
HUB
INDICATOR
SYSTEM
-Troubleshooting
8-213
TROUBLESHOOTING
Inspection
NOIRH-
items
Symptom
Reference
page
3-21E
The indicator light does not illuminate

although the automatic free-wheeling
hub is in the locked condition and the
vehicle speed is approximately
2.5 mph
(4 km/h) or higher.
The indicator light does not illuminate

when the vehicle is stopped (with the
ignition key at ON) after traveling, even
though the automatic free-wheeling
hub
is in the locked condition.
The indicator light remains illuminated
when the ignition key is turned from OFF
to ON.
The indicator light remains illuminated

when (after traveling with the automatic
free-wheeling
hub in the locked
condition) the vehicle is stopped, the
hub is changed
to the free condition, and the vehicle is
then driven at a speed of approximately
2.5 mph (4 km/h) or higher.
NOTE
Number
in circle indicates
inspection
sequence.
/ STB Revision
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Cc
8-214 AUTOM
TIC FREE-WHEELING
VU6
INDICATOR
SYSTEM
Circuit
Diagram
CIRCUIT DIAGRAM
AUTOMATIC FREE-WHEELING
CIRCUIT
F==e=%
HUB INDICATOR
lu-!
A-02
Battery
Main
link
Sub fusible
15-w
r-)5-w
I I
SYSTEM
link
0.5-G
I
Ignition
2-w
switch
fusible
7
N
-22
Pulse
generator
3
c:
h
IA-21 m
v?~
r:
BI I
= 9i
To column switch
[Refer to P.8-461
A
m
c:
2
CT
I
z
d
LR
I
!J
/Locking check circuit 1
q IIEI
Automatic
free-wheeling
Combination
meter
hub
37W610
1 B R
El1 Y L
Em
Remark
For information
refer to P.8-7.
concerning
Wiring color code

B: Black
LI: Light blue
the ground
Br: Brown
0: Orange
points (example:
G: Green
P: Pink
),
,r: RG,dY
1 STB Revision
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L: Blue
Y: Yellow
Lg: Light green

W: White
AUTOMATIC
FREE-WHEELING
HUB INDICATOR
SYSTEM
Pulse
Generator
8-215
PULSE GENERATOR
REMOVAL
Removal
AND
INSTALLATION
NOBRJM
steps
I. Pulse
2. O-ring
generator
NOTE
parts
to reinstall
l
l
Check whether or not metal particles are adhered to the

pole (iron core) of the pulse generator.
Check whether or not the installation bolts of the pulse
rotor or the pulse generator are loose.
(For detailed information concerning the pulse rotor, refer
to GROUP 21 TRANSMISSION
- Transfer.)
CHECKING
PULSE GENERATOR
RESISTANCE
Check whether or not the resistance between the terminals

shown in the figure is within the standard value range.
Standard
value
: 215 - 275 LR
If the resistance is not within the standard value range, replace

the pulse generator.
16WO92
i
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8-216 AUTOMATIC
AUTOMATIC
REMOVAL
Removal
FREE-WHEELING
FREE-WHEELING
HUB INDICATOR
SYSTEM
HUB INDICATOR
AND INSTALLATION
Control
CONTROL
Unit
UNIT
NOBRKAA
steps
1. Glove compartment stopper

2. Automatic free-wheeling hub indicator
control unit
/
16W1568
1
NOTE
CHECKING OUTPUT VOLTAGE OF THE VEHICLESPE$D SENSOR (REED TYPE SWITCH)

I. Turn the ignition key to ON.
2. Insert a test probe from the rear side of the conncetor of
the automatic free-wheeling
hub indicator control unit.
3. Measure the output voltage of the vehicle-speed
sensor
when the vehicle is moved a distance of about 0.5 m (1.6
ft.).
Standard
values
Vehicle-speed
Vehicle-speed
:
sensor
sensor
OFF : 4V or higher
ON : OV
If there is a malfunction
of the vehicle-speed
sensor,
replace it by replacing the speedometer
assembly.
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24-1
AIR-CO
IONING
CONTENTS
AIR-CONDITIONING
AIR CONDITIONER
CIRCUIT DIAGRAM
SWITCH
.........................
......................................
42
.. 26
COMPRESSOR
...............................................
EVAPORATOR
............................................
....
GENERAL INFORMATION
.............. . ....... . . . ....
RECEIVER DRIER, CONDENSER,
COMPRESSOR
CLUTCH ASSEMBLY
..........
SAFETY PRECAUTIONS
................................
SERVICE ADJUSTMENT
PROCEDURES
......
Compressor
Drive Belt Adjustment
Compressor
Noise
.....................................
Handling
Tubing
and Fittings
Manifold
Gauge
Set Installation
Performance
Refrigerant
Test
Testing
.....................
System
SPECIAL TOOLS
SPECIFICATIONS
................
......................................
Leak Repair Procedure
Test Procedures
...........
...........
.........................................
for Leaks
46
43
19
45
28
29
40
but Is Not Cool
Cool Air Flow
Is Intermittent
Insufficient
Air Flow
Insufficient
Cooling
HEATERS
14
BLOWER ASSEMBLY
. . .. . . . . . . . . .. .. . . ..a...............
CIRCUIT DIAGRAM
. . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. .. . . . . . . 4
GENERAL INFORMATION
. . . . . . . . . .. . . . . . . . . . . . .. . . . . . 2
. . . . . . . . . . . . .. . . . . . . . . .. .. . . . . . . . . .. .. . . 9
HEATER CONTROL
.
.
.
.
.
.
.
.
.
.. . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . .. . . 12
HEATER UNIT
SERVICE ADJUSTMENT
PROCEDURES
. . . . .. 5
41
39
Temperature
Adjustment
29
Water
34
Control System
. . .. .. .. . . . . . . . . . . .. .. . . . . . . . . . . . .. .. . . . . . . . . .. .
Valve Replacement
Blower
Motor
29
Blower
Speed
Motor
Only
..........................
33
............................................
...... . . .. .................................
22
21
Specifications
...............................
21
Service
Specifications
................................
21
Torque
Specifications
................................
21
....................................
22
Improper
. . . . . . . . . . . . .. . . . . . . . ..
. .. .. . . . . . . . . . . . .. .. . . . . . . . . .. . . . . . .
TROUBLESHOOTING
34
General
TROUBLESHOOTING
Air is Emitted
5
8
Inoperative
Operates
on High
Heat
No Ventilation
Even When Mode
Selection Lever Is Operated
VENTILATORS
http://vnx.su/
. . . . . . .. .. . . . . . . . . . . .. . . . . . ..a..... .. .. . . . . . . .. 16
24-2
HEATERS
GENERAL
- General
Information
INFORMATION
24BAAD
The heater unit and the blower motor are the separate type.
For temperature
control of the heater, the blend air system is used for excellent
response and easy
temperature
adjustment.
Because the damper in the blend air system controls the warm air, which passes through the heater core,
of the temperature
are
and fresh (cool) air, which does not pass througlh the core, minor adjustments
therefore
possible,
and the temperaturecan
be ,set to the optimum
level.
The lap heater ducts (which provide warm air to th$ knee area for the front seats)
(which provide warm air to the foot area for the rebr seats) from the heater unit,
rear heater, assure
heating comfort
throughout.
:
and the-rear heater ducts

plus the warm-water-type
Blower motor
/
;;eselection
Mode selection lever
I
2OW640
Rear heater duct
Blower
To defroster and
Blend
air
damper
demister
Air selection
damper
Fresh air
Mode selection
damper (VENT)
To lap heater &@

duct
To foot area
ro
rear heater
duct
Mode
To rear heater
duct
selection
damper (FOOT/DEF)
1 ST6 Revision
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2OW706
switch
58W540
Temperature
contra
lever
24-3
HEATERS -Troubleshooting
TROUBLESHOOTING
Symptom
Improper
N24EAAC
Probable
heat
cause
Obstructed
Correct
24-5
malfunction
Replace
heater
Replace
24-l 2
Adjust
24-5
Clean or replace
24-l 3
Adjust
24-5
Adjust
24-5
hoses
adjusted
control
cables
Plugged
or partially
plugged
heater
Incorrect
pers
adjustment
of changeover
Incorrect
wire
installation
mode
Blower motor operates on high speed

only
Broken
blower
motor
Broken
blower
switch
Blower
erative
Burnt-out
inop-
, Thermostat
selection
Ducts are incorrectly/incompletely

netted, crushed,
bent or clogged.
motor
adjusted
Correct
dampers
Improperly
improperly
Reference
paw
Changeover
or binding
Obstructed
No ventilation
even
when mode selection
lever is operated
floor outlets
Remedy
core
damcontrol
con-
resister
fuse
Poor grounding
Repair
or replace
Replace
24-l 5
Replace
24-l 0
Replace
Correct
Malfunction
blower
switch
Replace
24-l 0
Malfunction
blower
motor
Replace
24-l 4
1 STB Revision
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24-4
HEATERS
CIRCUIT
DIAGRAM
c Circuit
Diagram
I
1 El1
El3
lanition
Battery
link
Sub fusible
(Fuse
B)
m-
switch
link
(Ignition
switch)
Multi-purpose
fuse
$5
LA,:
a3 M
To turn
sional
flasher
[Refer
to P.8-49.7-
(Init
- d
0.85RI
f-Y
I I
-r
Blower
-18
Blower
Remark
For information
concerning
refer
to P.8-7.
Wiring
color
code
B: Black
LI: Light
blue
the
Br. Brown
0: Orange
ground
Blower
resistor
switch
CJ
points
(example:
G: Green
P: Pink
motor
Heater
r&v
Lg:
W:
Light
White
),
Gr: Gray
R: Red
1 STB Revision
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L: Blue
Y: Yellow
green
HEATERS
Service
Adjustment
SERVICE
24-5
Procedures
DJUSTMENT
TEMPERATURE
ENT
CONTROL
PROCEDURES
SYSTEM
ADJUSTN24FAAD
MODE SELECTION
LEVER
1. Move the mode selection lever to each position and check
the air flow with the blower operating.
2. If the air flow is not correct for any position of the mode
selection lever, adjust the mode selection control wire. If
this adjustment
does not help, adjust the damper.
Adjustment
of the Mode Selection
1. Disconnect
the defroster duct and
at the drivers seat side from the
2. Disconnect
the mode selection
mode selection
damper
lever and
Control
Wire
the lap heater duct (B)
heater unit.
control wire from the
the heater unit,s clip.
3.
Set the mode selection lever of temperature

control
ws position.
4. Turn the mode selection
damper lever all the way
direction
of the arrow.
5. Connect the mode selection
control wire to the
selection damper lever, and to the clip part of the
unit.
Caution
Be careful
that
the lever does not move
when
to the
in the
mode
heater
clipping.
6.
Check to be sure that the mode selection

lever moves
smoothly
to each position and that the air flow is correct
for each position.
7. If the air flow is not correct for any position of the mode
selection lever even after the mode selection control wire
has been adjusted,
adjust the VENT damper
and the
FOOT/DEF
damper.
8. Connect the drivers side defroster
duct and lap heater
duct (B) to the heater unit.
Adjustment
of the Damper
1. Disconnect
the. mode selection
control wire from the
mode selection
damper lever and the heater units clip.
2. Adjust the VENT damper as described
below:
(1) Unfasten the clip of the mode selection damper lever,
and disconnect
the link for the VENT damper from
the mode selection
damper
lever.
1 STB Revision
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24-6
HEATERS
Service
Adjustment
Procedures
(2) Turn the mode selection damper lever all the way in the
direction
of the arrow.
(3) Pull the VENT damper lever completely
downward
and move the VENT damper
to the position
(not
visible) shown in the figure.
(4) Attach the end of the link for the VENT damper to the
: mode selection
damper
lever.
3.
Adjust the FOOT/DEF

damper
as described
below.
(1) Unfasten the clip of the mode selection damper lever,
and disconnect
the link for the FOOT/DEF
damper
from the mode selection
damper
lever.
(2) Turn the mode selection damper lever all the way in the
direction
of the arrow.
(3) Pull the FOOT/DEF

damper lever completely
upward
and move the FOOT/DEF
damper
to the position
shown in the figure. (The packing should contact the
case.)
NOTE
Confirmation
can be made that the FOOT/DEF
damper is raised upward through the defroster blower outlet
of the heater unit (with defroster duct disconnected).
(4) Attach the end of the link for the FOOT/DEF

to the mode selection
damper
lever.
damper
NOTE
When attaching it, pull the lever end (A in the figure)
the direction
of the arrow.
4.
in
Referring to the section which explains the adjustment

of
the mode selection
control wire, connect the control wire
to the mode selection
damper
lever.
1 STB Revision
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HEATERS
- Service
Adjustment
Procedures
TEMPERATURE CONTROL
24-7
LEVER
1. Move the temperature

control lever from its extreme
left
position to its extreme right position and check to be sure
that it moves correctly and smoothly
to each position.
2. Then move the temperature
control lever to the extreme
left position, and check to be sure that warm air does not
come out when the blower is operated.
3. If the air flow is not correct in the above step, adjust the
temperature
control wire.
Adjustment
of the Blend Air
Damper
I.
Move the warm water flow control lever to the extreme left
position.
2. Disconnect the water valve control wire from the blend air
damper
lever and the heater units clip.
3. Remove the water valve cover.
h?*
IWater
4.
valve lever
Unfasten
the clip of the blend air damper
lever, and
disconnect
the link for water valve lever from the blend air
damper
lever.
5.
Push the water valve lever all the way inward so that the
water valve is at the closed position.
6. Turn the blend air damper lever all the way in the direction
of the arrow so that the blend air damper is completely
closed at the lower most position.
Blend
air d
7. Attach the end of the link for the water valve lever to the
blend air damper lever.
8. Install the water valve cover.
9. After connecting
the water valve control wire to the blend
air damper lever, connect to the clip part of the heater unit.
Caution
Be careful that the lever does not move when clipping.
10. Check to be sure that

operates smoothly
at each
that the blend air damper
temperature
control lever
position
and the extreme
1 STB Revision
http://vnx.su/
the temperature
control
lever
position. Also check to be sure
is completely
closed when the
is moved to the extreme
left
right position.
24-8
HEATERS
- Service
WAiER
Adjustment
VALVE
Procedures
REPLACEMENT
N24FBAC
I.
Set the temperature

control lever to the extreme
right
position.
2. Remove the radiator drain plug, and then drain the engine
coolant.
3. Remove the air filter
4. Remove the heater hose clamp to disconnect
the heater
hose.
5.
Disconnect
the water valve control wire from the blend air
damper lever and the heater units clip.
6. Remove the water valve cover.
ater valve cover
7.
8.
9.
10.
11.
12.
2OW751
13.
Remove the piping clamp.

Unfasten the clip of blend air damper lever, and disconnect
the link for the water valve lever from the blend air damper
lever.
Remove the joint hose clamp.
Cut the joint hose.
Remove the water valve from the heater core.
Apply a coating of soapy water to the inside surface of the
new joint hoses, and then connect them to the pipe part of
the water valve and the heater core.
Connect the link, and then install the heater cover.
1 STB Revision
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HEATERS
24-9
Heater Control
HEATER CONTROL
REMOVAL
AND
N24GA-
INSTALLATION
2QW824
Removal
steps
1. Glove box stoppers

2. Air selection control wire
3. Knobs
4. Plugs
5. Center panel
6. Connection of center panel wiring harness to front wiring harness connector
7. Lap heater duct (B)
8. Defroster duct
++ l + 9. Mode selection control wire
++ l + 10. Water valve control wire
l a II. Heater control assembly
12. Blower switch
4+
++
~~
EyTEeverse
the removal procedures
to reinstall.
(2) 4+ : Refer to Service Points of Removal.
(3) eq : Refer to Service Points of Installation.
SERVICE
POINTS
1. REMOVAL
OF GLOVE
(1) Open the glove
(2) Remove
BOX
STOPPERS
box lid.
the glove
(3) Pull the glove
http://vnx.su/
OF REMOVAL
box stopper.
box outward.
N24GBAE
24-10
HEATERS
I- Heater
Control
VIOVAL
OF AIR
SELECTION
CONTROL
WIRE
Use a screwdriver
to pry and remove the clip that holds
the outer cable of the air selection
control wire.
Disconnect
the inner cable of the air selection
control
wire from the end of the recirculation/fresh-air
changeover damper
lever.
9.
REMOVAL
OF MODE
SELECTION
CONTROL
(1) While using a screwdriver

to pry
outer cable of the mode selection
/ outer cable to remove
it from
(2) Disconnect
the inner cable of
control
wire
from the end of
damper
lever.
10. REMOVAL
OF WATER
VALVE
WIRE
the clip that holds the

control wire, pull the
the clip.
the mode
selection
the mode
selection
CONTROL
WIRE
(1) Use a screwdriver

the outer cable of the water
valve control
wire.
(2) Disconnect
the inner cable of the water valve control
wire from the end of the water
valve control
lever.
INSPECTION
BLOWER
SWITCH
Operate
minals.
the switch,
N24GCAC
and check
the continuity
Terminal
Switch
position
between
the ter-
214567
OFF
2ow7a7
o--O
.
NOTE
/ STB Revision
-7
http://vnx.su/
between
0
0
the terminals.
HEATERS
Top view
Bottom
Heater
SERVICE
view
I
POINTS
11. APPLICATION
SEMBLY
24-11
Control
OF INSTALLATION
OF GREASE
N24GDAD
TO HEATER
CONTROL
Apply the chassis grease to all the moving

heater control assembly.
2OW553
AS-
parts of the
2OW534
10. lNSTALLATlON
OF WATER
VALVE
CONTROL
WIRE
Connect the water valve control wire to the water valve

control lever by following the steps below.
(1) Move the temperature control lever to the extreme left
position
(2) With the water-valve
control lever pressed inward in
the direction indicated by the arrow, connect the inner
cable of the water-valve control wire to the end of the
water-valve
control lever, and then secure the outer
cable by using a clip.
\
2OW750
9.
INSTALLATION
OF MODE
SELECTION
CONTROL
WIRE
Connect the mode selection control wire to the mode

selection damper lever by following the steps below.
(1) Move the mode selection lever to the %E position.
(2) With the mode selection damper lever pressed inward
in the direction indicatecl by the arrow, connect the
inner cable of the mode selection control wire to the
end of the mode selection lever, and then secure the
outer cable by using a clip.
2.
INSTALLATION
OF AIR SELECTION
CONTROL
WIRE
Connect the air selection control wire to the air selection

damper lever by following the steps below.
(1) Move the air selection control lever to the&
position.
(2) With the air selection damper lever pressed inward in

cable of the air selection control wire to the end of the
air selection lever, and then secure the outer cable by
using a clip.
1 STB Revision
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24-12
HEATERS
I
- Heater Unit
HEATER UNBT
REMOVAL
AND
INSTALLATION
Pre-removal
Operation
0 Draining of Coolant
(Refer to GROUP 0 LUBRICATION
AND MAINTENANCE-Maintenance
Service)
Post-installation
Operation
0 Supplying of Coolant
(Refer to GROUP 0 LUBRICATION
AND MAINTENANCE-Maintenance
Service)
2OW823
Removal steps
l *
+* l 4
I, Heater
hose
connection
2. Instrument panel
3. Duct
4. Center
5. Heater
ventilator
unit
duct
NOTE
to reinstall.
(2) +e : Refer to Service Points of Removal
SERVICE
POINTS
1. DISCONNECTION
OF REMOVAL
OF HEATER
N24lBAE
HOSES

(2) Set the temperature
lever to the far right position.
(3) Remove the radiator drain plug and then drain the
engine coolant.
(4) Remove the heater hose clamp, and disconnect the
heater hose.
ETB
Revision
http://vnx.su/
HEATERS
2.
24-13
- Heater Unit
REMOVAL
OF INSTRUMENT
PANEL
Refer to GROUP 23 BODY-Instrument
Panel.
INSPEGTION
l
l
l
N24cAa
Check the damper and link mechanism

for operation.
Check the heater core for clogging or water leakage.
Check the water valve for operation and clogging.
EATER CORE REPLACEMENT

I.
Remove
2.
Remove the following

(1) Piping clamp
(2) Water valve link
(3) Joint hose clamp
(4) Joint hose
(5) Screw
3.
Remove
the FOOT/DEF
damper
link from the mode
selection
damper
lever.
Move the damper lever to the position at which the mode
selection damper lever does not protrude very much to the
heater core side.
Remove the heater core. If at this time the damper lever
and heater core are in contact, making removal difficult,
remove the damper
lever.
4.
5.
the water
valve
cover.
parts
to remove
the water
Caution
To prevent
interference
between
the heater
case, use care not to peel the heater core
when the heater core is removed.
valve.
core and
felt away
6. After installing the heater core and water valve, install the
link for each damper
after referring
to the Service
adjustment
procedures
section.
SERWOCE POINTS
2.
INSTALLATION
Refer
to GROUP
1 STB Revision
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OF INSTALLATION
OF INSTRUMENT
23 BODY-Instrument
N241EAD
PANEL
Panel.
24-14
HEATERS
+ Blower
Assembly
BLOWER ASSEMBLY
REMOVAL
Removal
+*
+e
4*
NXKA-
AND INSTALLATION
steps
1.
2.
l + 3.
4.
5.
6.
7.
8.
9.
10.
Lap heater duct (C)

Glove box
Air selection control wire
Duct
Blower assembly
Resistor
Hose
Blower motor
Packing
Fan
2oWBO6
NOTE
(1)
Reverse
the
removal
procedures
to
relnstall.

SERVICE
2.
REMOVAL
POINTS
OF REMOVAL
OF GLOVE
BOX
(1) Open the glove box lid.

(2) Remove
(3) Remove
the glove box from the
3.
REMOVAL
OF AIR
N24KBAE
SELECTION
hinge.
CONTROL
WIRE
(1) Use a screwdriver

the outer cable of the air selection
control
wire.
(2) Disconnect
the inner cable of the air selection
control
wire from the end of the air selection
damper
lever.
http://vnx.su/
HEATERS
Blower
24-15
Assembly
5. REMOVAL
OF BLOWER
ASSEMBLY
(1) Disconnect the connector of the front wiring harness

(connected to the resistor).
(2) Remove the ground installation bolt. (Tightened together with the blower assembly.)
(3) Remove the blower assembly installation bolt.
Front wirina
--I
harness
2OW537
INSPECT00
N24KCAD
RESISTOR
Connect an ohmmeter to each terminal
measure the resistance.
Terminal
2OW768
BLOWER
connections
of the resistor and
Resistance
1 -2(M1)
Approx. 1.22R
1 -3(M2)
Approx. 0.41 R
I-4(Low)
Approx. 2.25112
1 - 5 (High)
Approx. OlR
MOTOR
(1) Connect the blower motor terminals

and check that the blower motor
(2) Next, reverse the polarity and check
operates smoothly in the reverse
directly to the battery

operates smoothly.
that the blower motor
direction.
2OW779
SERVICE
3.
POINTS
INSTALLATION
OF INSTALLATION
OF AIR
SELECTION
N24KDAC
CONTROL
WIRE
Connect the air selection control wire to the air selection

damper lever by following the steps below.
(1) Move the air selection control lever to the&
position.
(2) With the air selection damper lever pressed inward in
cable of the air selection control wire to the end of the
air selection damper lever, and then secure the outer
cable by using a clip.
1 STB Revision
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24-16
HEATER?
- Ventilators
VENTILATORS
REMOVAL
AND
INSTALLATON
(Ventilators
of instrument
panel)
N24MA-
16
zowaa
Removal
I4
steps
1.
2.
3.
4.
5.
6.
7.
8.
Demister
grill
Lap heater garnish
Lap heater duct (B)
Lap heater duct (C)
Defroster
duct (L.H.)
Lap heater duct (A)
Defroster
duct (R.H.)
Air duct (R.H.) (Only vehicles
conditioner)
9. Lap heater duct (A)
10. Air duct (L.H.) (Only vehicles
conditioner)
11.
12.
13.
14.
15.
16.
17.
with
with
Instrument
panel
Defroster
duct
Center ventilator duct
Center air outlet
Knob
Air duct
Side air outlet
air
air
SERVICE
NOTE
(1)
Reverse
the
(2)
+e
: Refer
POINTS
removal
procedures
to Service
Points
OF REMOVAL
to
of
reinstall.
Removal
N24MBAG
1. REMOVAL OF DEMISTER GRILL

While using a screwdriver
to pry the lock of the demister
grill, use another
screwdriver
to pry the end of the
demister
grill to remove it.
levision
http://vnx.su/
HEATERS
24-17
- Ventilators
2.
REMOVAL
OF LAP HEATER GARNISH
While using a screwdriver to pry the lock of the lap heater
garnish, use another screwdriver to pry the end of the lap
heater garnish to remove it.
6.
REMOVAL
OF LAP HEATER
DUCT (A)
Remove the screw at the side of the instrument
then remove the lap heater duct (A).
2OW75l
panel, and
2OW759
7.
REMOVAL
(R.H.)
OF DEFROSTER
DUCT
(R.H.)/8.
AIR
DUCT

(2) Remove the glove box stopper.
(3) Pull the glove box outward.
(4) Remove
the defroster
duct (R.H.)
(5) Remove the air duct (R.H.)
9.
REMOVAL
OF LAP HEATER DUCT (A)
(1) Remove the center panel. (Refer to GROUP 23 BODY Floor console)
(2) Remove the heater control assembly. (Refer to P.24-9)
(3) Insert a hand through
the heater control assembly
installation
hole in the instrument
panel, and remove
the installation
screw of the lap heater duct (A).
10. REMOVAL
OF AIR DUCT (L.H.)
(1) Remove the combination
meter. (Refer to GROUP
ELECTRICAL-Meters
and Gauges)
(2) Remove the air duct (L.H.).
11. REMOVAL
OF INSTRUMENT
PANEL
Refer to GROUP 23 BODY-Instrument
1 STB Revision
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Panel.
8 HI
24-18
HEATERS
REMOVAL
AND INSTALLATION
[Rear heater
1
REMOVAL
ducts)
'f------A
7F-T
Removal
- Ventilators
steps
1.
2.
3.
4.
5.
6.
Floor console
Front seat
Rail cover
Carpet
Rear heater duct (B)
Rear heater duct (A)
AND
2ow.307
NOTE
Reverse
INSTALLATION
the removal
(Rear ventilator
procedures
to reinstall.
duct)
N24MA-
1 (L042GT)
18W825
Removal
*I)
steps
1. Upper quarter trim (L042GV)
Rear ventilator cover (L042GT)
2. Nut
3. Screw
4. Air outlet garnish
5. Screw
6. Rear ventilator duct
2OW796
NOTE
SERVICE
POINTS
1. REMOVAL
OR REAR
OF REMOVAL
OF UPPER
VENTILATOR
Refer to GROUP
( STB Revision
http://vnx.su/
to reinstall.
of Removal.
QUARTER
COVER
23 BODY-Trims,
N24MBAI
TRIM (L042GV)
(L042GT)
Loose Panel.
AIR-CONDITIONING-General
24-19
Information
GENERAL INFORMATION
N2400AC
The air conditioner

blows out cooled air by driving the compressor
when the air conditioner
switch installed
on the heater control papnel is pressed ON and the position of the blower switch is out of OFF position.
The temperature
in the cabin is adjusted by the position of the temperature
control lever which determines
the
opening of the blend air damper and adjusts the mixing ratio of the cooled air and warm air.
The blowout made is z
, and the cooled air is blown out from four directions, and the blowout can be adjusted
by the blower switch changes the blowout in four stages by the cabin condition.
The air selector is set on P&J during cooling, and can be changed to &
according to the offensive smell and
pollution.
$;e;election
Mode
lever
Blower
sditch
selection
I
Air-cdnditioner
switch
Temberature
control lever
58W539
Mode selection
damper (VENT)
Heater
core
Fresh air
selection
Mode selkction
damper
(FOOT/DEF)
Evapdrator
Blower!
motor
2OW830
STB Revision
http://vnx.su/
damper
24-20
AIR-CONDITIONING
AIR-CONDITION!NG-General
I
SYSTEM COMPO
MDuct,
Information
N24BBBB
joint (Blower
side)
oint (Heater
unit side)
Condenser
Condenser
2OWB31
Suction
Pipe
Receiver
bracket
COMPRESSOR
- The prime purpose of the compressor
is to compress the low pressure refrigerant vapor
from the evaporator
into a high pressure, high temperature
vapor. The 6 cylinder 6P148 compressor
is used.
MAGNETIC
CLUTCH is mounted
on the compressor
providing
a convenient
way to drive and disengage
compressor
in accordance
to the cooling needs. CONDENSER
is located in front of the radiator. Its function
is to cool the hot, high pressure refrigerant gas causing it to condense into high pressure liquid refrigerant.
RECEIVER DRIER is used to remove any traces of moisture from the refrigerant
system. This component
incorporates
the sight glass and fusible plug. SIGHT GLASS at the top of the receiver drier is provided as a
diagnostic
tool to observe refrigerant
flow and observe refrigerant
level. THE FUSIBLE PLUG is located on
the receiver drier. Its function
is to prevent damage
to the air conditioning
system in the event that
excessive pressure develops due to condenser air flow being restricted by, for example, leaves, newspaper,
an overcharge
of refrigerant,
or air in the system.
LOW PRESSURE
SWITCH
prevents damage
to the
compressor
in case of system loss of refrigerant charge. EXPANSION
VALVE - The expansion valve is used
for all applications.
Its function
is to meter refrigerant
into the evaporator
in accordance
with cooling
requirements.
EVAPORATOR
COIL is located in the unit and its function is to cool and dehumidify
the air
before it enters the vehicle. FREEZE UP CONTROL
FIN THERMOSTAT
SENSOR is installed at the heater
side of evaporator.
The main function of a freeze control is to keep condensate
water on the face of the
evaporator
coil from freezing
and restricting
air flow. WATER TEMPERATURE
SWITCH
- When the
temperature
of the radiator coolant became high, this switch functions to stop the compressor
and prevent
engine overheating.
SERVICE VALVE at the compressor
and the discharge line. The valves are used to test
and service the refrigerant
system. REFRIGERANT
R-12 is used maximum
amount 907 g (32 oz.) R-12.
COMPRESSOR
OIL is used DENS0 oil 6 maximum
amount
110 cc (3.7 U.S.fl.oz.,
3.9 Imp.fl.oz.).
/ STB Revision
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AIR-CONDITIONING
24-2 1
-Specifications
SPECIFICATIONS
GENERAL
SPECIFICATIONS
N24CA-
Items
Specifications
Compressor
Model
6P148lnclined-plate
No. of cylinders and displacement

cc. (U.S.fl. oz., Imp.fl.02.)
Refrigeration unit lubricant
Protective equipment
6 cylinders
cc. (U.S.fl. oz., Imp.fl.oz.)
110 (3.7,3.9)
OFF: 1.O (22)
ON:4.5 (39)
ON:230 (33)
Cycling clutch switch
C(F)
OFF:210 (30)
kPa (psi)
OFF: 113 (235)
Water temperature
switch
Freezor prevention
Fusible plug
Refrigerant
C (F)
Air temperature
OFF:3 (37.4)
C (F)
6,148 (208,216)
DENS0 oil 6
Low pressure
switch
type
ON:106(222)
thermostat
ON:5 (41)
106 (222)
Burn out temperature
R-l 2
600-900 (1.3-2.0)
C (F)
and quantity
g (Ibs.1
N24CE-
Items
Specifications
Standard value
Drive belt deflection
Pressure
mm (in.)
17.20 (.7-.8)
plate to rotor clearance
mm (in.)
0.4-0.7
(.02-.03)
N24CG
Items
Nm
ftlbs.
Suction hose to cooling unit
30-35
22-25
Liquid pipe to cooling unit

Liquid pipe to receiver drier
12-15
12-15
9-l 1
9-l 1
Suction hose to suction hose

Liquid pipe to liquid pipe
30-35
12-15
22-25
9-l 1
Liquid pipe to condenser
20-25
15-18
Suction hose to compressor
30-35
22-25
Discharge hose to compressor
20-25
15-18
Discharge hose to liquid pipe
20-25
15-18
Compressor shaft nut
15-17
11-13
Through bolt
25-26
18-20
/ STB Revision
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24-22
AIR-CONDITIONING
Special
TOOIS
/ Troubleshooting
SPECIAL TOOLS
N24DA.-
Use
MB990783-01
Steering/pinion
remover/installer
Installation
of seal plate
gear
TROUBLESHOOTING
Before replacing or repairing air
charge, air flow, or compressor
The following diagnostic charts
malfunction.
If these charts do
explanation.
After correcting the malfunction,
MALFUNCTION
CAUSES
Air is
emitted
but is
1 not cool
N24EBAE
conditioning
compofents,
first determine
if the malfunction
is; due to refrigerant
related.
have been developed as a quick reference aid in determining
the cause of
not satisfactorily
describe the problem, refer to appropriate
section for detailed
check out the complete
AND REMEDIES
system
(Numbers
indicate
to assure satisfactory
performance.
checking/inspection
order.)
Replace
1. Magnetic clutch is
not switched ON
-4 2.Check
I
the fuse (IOA)
t-l
I
I
Replace
the air-conditioner
(P.24-32)
__)
Replace
4.Check
switch
the low pressure

(P.24-30)
Replace
---L 5.Check the thermistor

and therm0 relay (P.24-31)
Replace
Replace
-i
6.Check
switch
the blower
(P.24-10)
7.Check the blower

(P.24-15)
8.Check the magnetic
(P.24-32)
1 STB Revision
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I,
3,Check
switch
SEE NEXT PAGE
relay
Replace
M
clutch
Replace
I
24-23
AIR-CONDITIONING-Troubleshooting
1 CONTINUED
FROM
--)
PREVIOUS
2lnsufficient
PAGE]
refrigerant
Check the
(P.24-29)
refrigerant
Check the receiver

(P.24-29)
amount
_1
Supply
refrigerant
.--+
Replace
__)
Adjust
belt
?
--)
3.Receiver
--.
4.Abnormal
rotation
compresspor
i-
5.Expansion
drier clogged
of
*
valve clogged
6.Poor compression
compressor
of
drier
Drive belt loose

(P.24-40)
Check the expansion

(P.24-44) t
Check the compressor

(P.24-32))
1 STB Revision
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valve
Replace
Replace
the
1
AIR-CONDITIONING-Service
SERVICE ADJUSTMENT
MANIFOLD
GAUGE
PROCQDURES
SET INSTALLATUON
24-29
N24FDAD
Discharge
gauge
Suction
gauge
Suction
gauge
valve
Manifold Gauge Valves should be closed when

connecting
the manifold gauge set to the service port of the
compressor and the discharge hose. The suction gauge valve at the left is opened to provide a passage between
the suction gauge and the center manifold outlet. The discharge gauge valve at the right is opened to provide a
passage between the discharge pressure gauge and the center manifold outlet.
Detailed instructions for proper use of the gauge set manifold are contained in the text covering each test and
service operation employing these gauges.
Suction Gauge; the left side of the manifold set is calibrated to register 0 to-100 kPa (0 to 30 in. of vacuum) and
0 to 1000 kPa (0 to 150 psi). This gauge is connected to the suction port of the compressor.
Discharge Gauge; the right of the manifold set is calibrated to register 0 to 2100 kPa (0 to 300 psi). For all
tests this gauge is connected to the discharge port of the system.
Center Manifold Outlet provides the necessary connection for a long service hose used when discharging the
system, using a vacuum pump to pull a vacuum before charging the system, and for connecting the supply of
refrigerant when charging the system
N24FEAE
The receiver drier assembly consists of; Drier reservoir, Refrigerant level sight glass and Fusible plug.
To Test the Receiver
glass
Drier
(1) Operate the unit and check the piping temperature by

touching the receiver drier outlet and inlet.
(2) If there is a difference
in the temperatures,
the
received drier is restricted.
Replace the receiver drier.
2OW724
SIGHT
GLASS
REFRlGERANT
LEVEL TEST
The sight glass is a refrigerant level indicator. To check the refrigerant level, clean the sight glass and start the
vehicle engine. Push the air conditioner button to operate the compressor, place the blower switch to high and
move the temperature lever to extreme left.
After operating for a few minutes in this manner, check the sight glass.
(1) If the sight glass is clear, the magnetic clutch is engaged, the compressor discharge line is warm and the
compressor inlet line is cool; the system has a full charge.
(2) If the sight glass is clear, the magnetic clutch is engaged and there is no significant temperature difference
between compressor inlet and discharge lines; the system has lost some refrigerant.
(3) If the sight glass is clear and the magnetic clutch is disengaged; the clutch is faulty or, the system is out of
refrigerant. Perform low pressure switch test to determine condition. Check low pressure switch and clutch coil
for electrical continuity.
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AIR-CONDITIONING
lnsuffi
cient air
flow
1 .Leakage
joint
at a duct
2.Evaporator
frost
3.Blower
motor
function
mal-
24-25
- Troubleshooting
.
Check the duct joint
D Check the thermistor

or
therm0 relay (P.24-31)
Replace
Check the blower
Replace
Measure
(P.24-34)
Apply
vacuum;
supply
refrigerant
Replace
motor
+
Cool air
flow is
intermittent
i--)
1 .Air in refrigerant
2.Expansion
valve
malfunction
the pressure
Check the expansion

(P.24-44)
STB Revision
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valve
24-26
AIR-CONDITIONING
CIRCUIT DIAGRAM
Diagram
Circuit
N24ZB-I
Ignition
Main
Sub fusible
(Fuse
B)
link
Battery
switch
link
To turn
signal
flasher
[Refer
to P.8-49.1
0.85-RL
unit ~
,0.85-LW
1
yl
lLG1
[Refer
to
P.8-62.1
0.85-WB*
C-C
Blower
motor
IA2
Ml
kFF
switch
Blower
resistor
motor
LBLY
LRLI
El3
B: Black
LI: Light
color
blue
-18
BI ower
Wiring
E!!
i
\
Heater
relav
B L
LRLR
EEJ
x,
$2
code
Br:
0:
Brown
Orange
G: Green
P: Pink
Gr: Gray
R: Red
/ ST6 Revision
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L: Blue
Y: Yellow
Lg:
W:
Light
White
green
AIR-CONDITIONING
- Circuit
24-27
Diagram
Air
conditioner
relay
El
Low
pressure
switch
El
A-54
85-BW:0.85-BW
u
A-25
*20.85-BWr
*10.85-BWi&
A-13
@,0.85-WB
To feed
back
carburetc
control
unit
[Refer
to P.8-39.1
Vacuum
valve
solenoid
++
A-45
Magnetic
clutch
(compressor)
A
Condenser
blower
motor
Condenser
motor
relay
blower
z-
BY
rl
37W611
Remarks
(1)
For
information
ple.(l)m),
refer
(2) The
symbols
0,
connected
(using
facing
page
(In
connected
to 0
( STB Revision
http://vnx.su/
converning
the
ground
points
(examto P.8-7.
0,
etc
indicate
that
the
wiring
is
the same
numerical
symbol)
to the
other
words,
0 on the right
page
is
on the left page.)
24-28
AIR-CONDITIONING-Safety
Precautions
SAFETY PRECAUTIONS
SAFETY
N24PAAB
PRECAUTIONS
The refrigerant used in all air-conditioning

vapor state. Since it has a boiling point of
temperatures
and pressures. The vapor
except when it is in direct contact with
following precautions must be observed
installations is R-12. It is transparent and colorless in both the liquid and

-29.8T
(-21.7F). at atmospheric pressure, it will be a vapor at all normal
is heavier than air, non- flammable,
and nonexplosive.
It is nonpoisonous
open flame. It is noncorrosive except when combined with water. The
when handling R-12.
Caution
Wear safety goggles when servicing the refrigeration
system.
R-12 evaporates so rapidly at normal atmospheric
pressures and temperatures
that it tends to freeze anything it
contacts. For this reason, extreme care must be taken to prevent any liquid refrigerant from contacting the skin and
especially the eyes.
Always wear safety goggles when servicing the refrigeration part of the air- conditioning
system. Keep a bottle of
sterile mineral oil handy when working on the refrigeration system. Should any liquid refrigerant get into the eyes,
use a few drops of mineral oil to wash them out. RI12 is rapidly absorbed by the oil. Next, splash the eyes with
plenty of cold water. Call your doctor immediately
even though irritation has ceased after treatment.
Caution
Do not heat R-12 above 52C (125F).
In most instances, moderate heat is required to bring the pressure of the refrigerant in its container above the
pressure of the system when charging or adding refrigerant. A bucket or large pan of hot water not over 52C
(125F) is all the heat required for this purpose. Do not heat the refrigerant container with a blow torch or any other
means that would raise temperature
and pressure above this temperature.
Do not weld or steam clean on or near
the system components
or refrigerant lines.
Caution
Keep R-12 containers
upright when charging the system.
When metering
R-12 into the refrigeration
system, keep the supply tank or cans in an upright position. If the
refrigerant container is on its side or upside down, liquid refrigerant will enter the system and damage the
compressor.
Caution
Always work in a well-ventilated
room.
Good ventilation is vital in the working area. Always discharge the refrigerant into the service bay exhaust system
or outside the building. Large quantities of refrigerant vapor in a small, poorly ventilated room can displace the air
and cause suffocation.
Although R-12 vapor is normally nonpoisonous,
contact with an open flame can cause the vapor to become very
poisonous. Do not discharge large quantities of refrigerant in an area having an open flame. A poisonous gas is
producted when using the flame-type leak detector. Avoid inhaling the fumes from the leak detector.
Caution
Do not allow liquid refrigerant
to touch bright metal.
Refrigerant will tarnish bright metal and chrome surfaces, and in combination
all metal surfaces.
/ STB Revision
-I
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with moisturecan
severely
corrode
SERVICE ADJUSTMENT
MANIFOLD
GAUGE
PROCQDURES
SET INSTALLATUON
24-29
N24FDAD
Discharge
gauge
Suction
gauge
Suction
gauge
valve
Manifold Gauge Valves should be closed when

connecting
the manifold gauge set to the service port of the
compressor and the discharge hose. The suction gauge valve at the left is opened to provide a passage between
the suction gauge and the center manifold outlet. The discharge gauge valve at the right is opened to provide a
passage between the discharge pressure gauge and the center manifold outlet.
Detailed instructions for proper use of the gauge set manifold are contained in the text covering each test and
service operation employing these gauges.
Suction Gauge; the left side of the manifold set is calibrated to register 0 to-100 kPa (0 to 30 in. of vacuum) and
0 to 1000 kPa (0 to 150 psi). This gauge is connected to the suction port of the compressor.
Discharge Gauge; the right of the manifold set is calibrated to register 0 to 2100 kPa (0 to 300 psi). For all
tests this gauge is connected to the discharge port of the system.
Center Manifold Outlet provides the necessary connection for a long service hose used when discharging the
system, using a vacuum pump to pull a vacuum before charging the system, and for connecting the supply of
refrigerant when charging the system
N24FEAE
The receiver drier assembly consists of; Drier reservoir, Refrigerant level sight glass and Fusible plug.
To Test the Receiver
glass
Drier
(1) Operate the unit and check the piping temperature by

touching the receiver drier outlet and inlet.
(2) If there is a difference
in the temperatures,
the
received drier is restricted.
Replace the receiver drier.
2OW724
SIGHT
GLASS
REFRlGERANT
LEVEL TEST
The sight glass is a refrigerant level indicator. To check the refrigerant level, clean the sight glass and start the
vehicle engine. Push the air conditioner button to operate the compressor, place the blower switch to high and
move the temperature lever to extreme left.
After operating for a few minutes in this manner, check the sight glass.
(1) If the sight glass is clear, the magnetic clutch is engaged, the compressor discharge line is warm and the
compressor inlet line is cool; the system has a full charge.
(2) If the sight glass is clear, the magnetic clutch is engaged and there is no significant temperature difference
between compressor inlet and discharge lines; the system has lost some refrigerant.
(3) If the sight glass is clear and the magnetic clutch is disengaged; the clutch is faulty or, the system is out of
refrigerant. Perform low pressure switch test to determine condition. Check low pressure switch and clutch coil
for electrical continuity.
1 STB Revision
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24-30
AIR-CONDITIONING
-Service
Adjustunent
Procedures
(4) If the sight glass shows foam or bubbles, the systpm could be low on charge. Occasional foam or bubbles are
normal when the ambient temperature
is above 43C(110F) or below 21C(7OF).
Adjust the engine speed to 1,500 rpm. Block the airflow through the condenser to increase the compressor
discharge pressure to 1,422 to 1,520 kPa (20$ to 220 dsi). If sight glass still shows bubbles or foam, system charge
level is low.
The refrigerant system will not be low on charge unless there is a leak. Find and repair the leak. If the leak can be
repaired without discharging the system an oil level check is not necessary. Use the procedure for correcting low
refrigerant level found in the Refrigerant Sy$em Service Procedure Section.
FUSIBLE PLUG
When ambient temperature
of the fusible plug reach& 105~221~F),
the fusible plug melts and the refrigerant
the system is released.
Once the fusible plug is operated, it cannot be used again.
SO, it is necessary to install new one and charge the refrigerant in the system.
in
LOW PRESSURE
SWITCH
The Low Pressure Switch, located on the liquid line, is wired in
series with the magnetic clutch. It cuts off the electrical power
supply to the clutch when refrigerant pressure drops below the
cont$ol point of the switch. Whenever the system is inactivated by
the low pressure switch due to refrigerant loss, the refrigerant oil
may have been lost. Therefore, to prevent damage to the compressor due to operation without sufficient lubrication, the leak
must be repaired and the compressor oil level checked before final
charge of the system. The switch is a sealed, factory calibrated
unit. No attempt should be made to adjust or otherwise repair it.
If it is found to be faulty it must be replaced.
Low pressure
switch
,
To
(1)
(2)
(3)
Test the Low Pressure Switch (Engine Off)

Jump the wire leads.
Press the air conditioner switch and blower switch on.
Momentarily
turn the ignition switch on (do not crank the engine), listen for the compressor clutch engaging.
(4) If the clutch does not engage, the fin thermostat,
water temperature switch or fuse may be faulty.
(5) If clutch engages,
connect the manifold
gauge set and
read pressure. At pressure of 210 kPa (30 psi) or above,
switch must actuate the clutch.
If the pressure is below 210 kPa (30 psi), the refrigerant
system is low in charge. For corrective
action refer to
refrigerant
leak repair procedure.
(6) Reconnect boot on switch and perform step number 3.
If the clutch does not engage, discharge the system, replace
the switch, and recharge the system.
[ STB Revision
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Adiustment
Procedures
24-31
FREEZE UP CONTROL
Evaporator freeze up is controlled by a thermistor attached to the
evaporator fins. The control is an electronic type and consists of
two parts_(thermo
relay and thermistor.)
It is connected to the
magnetic clutch of the compressor in series. When the temperature of the evaporator drops below 3C (37.4F), the compressor is
turned OFF.
To Test the Thermistor

(1) Jump the wire lead (LB to GB) of the connector
portion.
(2) Press the air conditioner switch and blower switch on.
(3) Momentarily
turn the ignition switch on (do not crank the engine), listen for the clutch engaging.
(4) If the clutch does not engage, the low pressure switch,
water temperature
switch wiring or fuse may be faulty.
(5) If the clutch operates,
replace the thermostat.
WATER TEMPERATURE
SWITCH
The water temperature
switch is located on the thermostat
housing. The water temperature
switch is connected
to the clutch
in series. When the coolant
temperature
in the radiator
reaches above 113C (235F), it turns the compressor
OFF.
This is to prevent engine overheating.
When the water temperature
switch is activated and the clutch is
OFF, check the surface of the condenser and radiator, the belt
tension, and the coolant volume in the radiator, and return to the
normal condition.
To Test the Water Temperature
Switch
(1) Remove wire from water temperature
switch and jump lead
wires.
(2) Press the air conditioner switch and blower switch on.
(3) Momentarily
(4) If the clutch does not-engage, the fin thermistor, low pressure
switch, wiring or fuse may be faulty.
(5) If clutch engages, replace the switch.
1 STB Revision
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24-32
i->
9
Procedures
AIR CONDITIONER
SWITCH
To jest the Air Conditioner
Switch
(1) Disconnect the harness connector
for the air conditioner
switch.
(2) Jump the lead wires as shown.
(3) Turn the blower switch ON.
(4) Momentarily
(5) If the clutch does not engage,
fin thermostat,
water
temperature
switch, wiring or fuse may be faulty.
(6) If clutch engages,
replace the air conditioner
switch.
2ouo319
Adjustment
MAGNETIC
CLUTCH
(1) Disconnect the wiring to the magnetic clutch.
(2) Connect battery (+) voltage directly to the wiring for the magnetic clutch.
(3) If the magnetic clutch is normal, there will be a click. If the
pulley and armature do not make contact (click), there is a
malfunction.
Suction gauge
2OW627
Discharge
/
Suction
ww
w-w
Discharge
w-w
2OUO306
Suction
w-w
COMPRESSOR
(1) Install the manifold gauge set, and run the air conditioner.
(2) If a pressure of approx.490 kPa (71 psi) is indicated on the
suction gauge side and a pressure of approx.883 kPa (128 psi)
is indicated on the discharge gauge side, the compressor has
abnormal compression.
Replace the compressor.
(3) If a pressure of 294 to 392 kPa (43 to 59 psi) is indicated on the
suction gauge side and a pressure of approx.1961
kPa (284
psi) is indicated on the discharge gauge side, it is suspected
that air is present in the air conditioning
system.
Discharge the system, evacuate and recharge with specified
amount of refrigerant.
(4) During operation of the air conditioner, cold air may stop flowing after the elapse of time and this state is maintained before
cold air flows out again. If cold air stops flowing out with
negative pressure indicated on the suction gauge side and a
pressure of 588 to 980 kPa (85 to 142 psi) indicated on the
discharge gauge side, it is suspected that water is present in
the air conditioning
system.
Discharge the system. Replace receiver drier. Evacuate and
check for leaks, and recharge with specified amount of refrigerant.
Discharge
gauge
2OUO307
/ STB Revision
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TESTING
Adjustment
SYSTEM
24-33
Procedures
FOR LEAKS
N24FFA8
A leak is likely to occur where two components

are connected
together. See illustration for possible locations.
The Leak Detector Torch is a butane gas-burning torch used to
locate a leak in any part of the refrigeration system. Refrigerant
gas drawn into the sampling or sniffer hose will cause the flame
to change color in proportion to the size of the leak. A very small
leak will produce a flame varying from yellowish-green
to bright
green. A large leak will produce a brilliant blue flame.
Caution
Do not use the lighted detector in any place where explosive
gases, dust or vapors are present. Do not breathe the fumes
that are produced
by the burning
of refrigerant
gas. Large
concentrations
of refrigerant
in the presence of a live flame
become dangerously
toxic.
2080113
Compressor
6
T-7
Cl
Refrigerant
tester
Leak
, tester
pick up
tube
b/
If the flame remains bright yellow when the tester is removed

from a possible leak point, insufficient air is being drawn in through
the sampling tube, or the copper reaction wire is dirty.
(1) Assemble leak detector as shown be sure detector is seated
tightly over torch gasket.
(2) Holding torch upright screw-in butane charger (clockwise) until
punctured. (Do not use force).
(3) Screw-out butane charge (counterclockwise)
about l/4 turn.
(4) Point torch away from body-then
light escaping gas with
match. Always keep torch in upright position.
(5) Adjust flame by turning cartridge in or out as required.
(6) Allow 30 seconds to heat copper reaction wire.
Caution
Never remove butane charger
presence of any open flame.
while
torch is lighted
or in the
2OUO316
(7) Examine all tube connectors and other possible lead points by
moving the end of the sampling hose from point to point.
Always keep torch in upright position. Since R-12 is heavier
than air, it is good practice to place the open end of sampling
hose directly below point being tested. Be careful not to pinch
sampling tube since this will shut off air supply to flame and
cause a color change.
(8) Watch for a change in the color of the flame. Small leaks will
produce a green color and large leaks a bright blue color. If
leaks are observed at tube fittings, tighten the connection,
using the proper flare wrenches, and retest.
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24-34
PEAFORMANCE
TESI
r---:ES :
Dry
bulb therr&neter
TEST
N24FWAB
NOTE
Air temperature in test room must be 21C (70F) minimum for this
test.
(1) Connect a tachometer and manifold gauge set.
(2) Set air conditioner controls to Max air conditioner, temperature lever on full cool, and blower on high.
(3) Turn engine on 1000 rpm with air conditioner clutch engaged.
(4) Engine should be warmed up with doors, windows, and hood
open.
(5) Insert a thermometer in the left center air conditioner outlet
and operate the engine for 5 minutes.
(6) Note the discharge air temperature.
2OW825
NOTE
If the clutch cycles, take the reading before the clutch disengages.
Performance
Garage ambient
temperature
Discharge air
temperature
21 C
(70 F)
1.7-4.4
(35-40
Temperature
26.5 C
(80 F)
C
F)
1.7-5.0
(35-41
Chart
32 C
(90 F)
C
F)
1.7-5.6
(35-42
C
F)
37.5 C
(100 F)
1.7-6.1
(35-43
C
F)
40.6 C
(I 05 F)
1.7-6.7
(35-44
C
F)
Compressor
discharge pressure
928- 1,322 kPa

(132-188
psi)
1.069-1.547 kPa
(152-220
psi)
1,209-1,772 kPa
(172-252
psi)
1,336-1,969 kPa
(190-280 psi)
1,406-2,109 kPa
(200-300
psi)
Evaporator suction
pressure
127-148 kPa
(18-21
psi)
131-162 kPa
(18.6-23
psi)
134-176 kPa
(19-25 psi)
135- 188 kPa

(19.2-26.8 psi)
136-194 kPa
(19.4-27.6 psi)
REFRIGERANT
LEAK REPAIR PROCEDURE
N24FnAB
LOST CHARGE
If the system has lost all charge due to a leak:
(1) Evacuate the system. (See the procedure).
(2) Charge the system with approximately one pound of refrigerant.
(3) Check for leaks.
(4) Discharge the system.
(5) Repair leaks.
(6) Replace receiver drier.
Caution
Replacement
filter-drier
units must be sealed while in storage. The drier used in these units will saturate water quickly
upon exposure to the atmosphere.
When installing
a drier,
have all tools and supplies
ready for quick reassembly
to
avoid keeping the system open any longer than necessary.
Refrigerant
leak tester
(7) Evacuate and charge the system.
LOW CHARGE
tester
up
2OUO316
If the system has not lost all of its refrigerant charge; locate and
repair all leaks. If it is necessary to increase the system pressure
to find the leak (because of an especially low charge) add refrigerant. If it is possible to repair the leak without discharging the
refrigerant system, use the procedure for correcting low refrigerant level.
1 STB Revision
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CORRECTING
LOW
REFRIGERANT
Adiustment
Suction
gauge
\-
LEVEL
Discharge
gauge
a/
Discharge
gauge
24-35
Procedures
gauge
valve
II
II
Ho\t water
52C i 125F)
2OUO325
Since the refrigeration system is completely

sealed, refrigerant level will not be low unless there is a leak in the
system.
Before adding refrigerant when the cause of low level is not known, the system should be tested for leaks.
Assuming that leaks have been corrected without discharging the system, proceed with partial charge.
Install and connect manifold gauge set.
(I) Close both gauge set manifold valves.
(2) Connect the suction gauge test hose to the suction port of the compressor. Connect the discharge gauge test
hose to the discharge port.
(3) Connect one end of long test hose to center manifold outlet, other end to refrigerant dispensing manifold.
(4) Close two dispensing manifold valves and open remaining dispensing manifold valve. Remove protective cap
from opened valve.
(5) Screw a can of R-12 to the opened manifold valve. Be sure gasket is in place and in good condition. Tighten
refrigerant can and manifold locking nut to insure a good seal. Do not overtighten. 8 to 11 Nm (6 to 8 ft.lbs.) is
sufficient if gasket is in good condition.
(6) Turn manifold valve (above the refrigerant can) completely clockwise to puncture the can. This closes the valve
and seals the refrigerant in the can.
Caution
Never heat small cans of refrigerant
over 52C (125F) as they may explode.
(7) Place the refrigerant in a large pan of water heated to 52C (125F). Place pan of water containing the refrigerant
can on an accurate scale so the amount of refrigerant added can be weighed. Open the refrigerant manifold
valve.
(8) Purge all air from test hoses. Air in the system will be trapped in the condenser causing abnormally
high
discharge pressures and interfering with condensing of the refrigerant.
(9) Slightly loosen both test hoses at the gauge set manifold. Tighten the hoses as soon as the air is purged.
(10)Slightly loosen charging hose connection at gauge set manifold. This will purge air from the charging hose.
Tighten connection as soon as air is purged.
(1l)With vehicle windows open and hood up, operate engine at 1,500 rpm and jump the switch terminals located
on so the clutch will remain engaged.
(12)Place air conditioner control on air conditioner and place the blower switch on high.
(13)lf necessary, block the condenser to maintain a discharge pressure of 1,422 to 1,520 kPa (206 to 220 psi.).
System must be charged through the evaporator suction service ports as follows:
(a) Slowly open the suction service gauge valve. Meter flow of refrigerant by adjusting the suction service
gauge valve so that pressure registered at the suction service gauge does not exceed 345 kPa (50 psi).
Keep refrigerant
container
upright.
(b) Add refrigerant gas until there is no foam visible at the sight glass.
(c) Close the suction gauge valve.
Caution
Too much refrigerant in the system can cause abnormally high discharge pressures. Care must be
used so that the exact recommended
amount of refrigerant is added after foam clears in the sight
glass.
(d) Close dispensing

install protective
manifold valve. Remove test hoses and adapters

caps at service ports and reconnect wiring.
/ STB Revision
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from the service ports of compressor,
24-36
COllector
can
2OUO315
2OUO31
/vision
Adjustment
Procedures
D&ARG,NG
THE SYSTEM
Since the air conditioning
refrigerant system is pressurized, it will
be necessary to completely discharge the system (in a well ventilated area) before replacing any refrigerant component.
The procedure is as follows:
(1) Install manifold gauge set. Make sure the gauge set valves are
closed before attaching the hoses to the refrigerant system.
(2) Install a long hose to the manifold gauge set connector. Run
this hose to the oil collector can near a shop exhaust system.
A good oil collector can may be made from a large empty
coffee can with a plastic top. Slit the plastic top in the form of
a Y to make an entrance for the refrigerant hose and an exit for
the gas.
(3) Open the compressor
discharge and suction line pressure
valves and blow the refrigerant into the oil collect can. Watch
to make sure the hose does not blow out of the collector can.
(4) When the system has been completely
discharged, measure
the amount of oil collected in the can. The amount of oil measured should be added to the refrigerant system before it is
re-charged. Add new oil-discard
the used oil.
Caution
It is important
to have the correct amount of oil in the refrigerant system.
Too little oil will provide inadequate compressor
lubrication and
cause a compressor failure. Too much oil will increase discharge
air temperature.
When a 6P148 compressor
is installed
at the factory, it
contains 110 c.c. (3.7 U.S.fl.oz., 3.9 Imp.fl.oz.) of refrigerant oil.
While the air conditioning
system is in operation,
the oil is
carried through the entire system by the refrigerant.
Some of
this oil will be trapped and retained in various parts of the
system.
When the following system components
are changed, it is necessary to add oil to the system to replace the oil being removed
with the component.
Compressor
- 4Occ (1.4 U.S.fl.oz.,
1.4 Imp.fl.oz.)
Condenser
- 30 cc (1.0 U.S.fl.oz.,
1.1 Imp.fl.oz.)
Evaporator
- 60 cc (2.0 U.S.fl.oz.,
2.1 Imp.fl.oz.)
Piping - 10 cc (.3 U.S.fl.oz.,
.4 Imp.fl.oz.)
Receiver drier - 0 cc (0 U.S.fl.oz.,
0 Imp.fl.oz.)
EVACUATING
THE SYSTEM
Whenever the system has been opened to the atmosphere,
it is
absolutely essential that the system be evacuated or vacuumed
to remove all the air and moisture. Air in the refrigerant system
causes high compressor
discharge pressures, a loss in system
performance,
and oxidation of the compressor oil into gum and
varnish. Moisture in the refrigerant system can cause the expansion valve to malfunction.
Under certain conditions,
water can
react with the refrigerant to form destructive acids. It is necessary
to adhere to the following procedure to keep air and moisture out
of the system.
(1) Install manifold gauge set. Make sure the gauge set valves are
closed before attaching the hoses to the refrigerant system.
(2) Discharge the system if the manifold gauge set indicates pressure in the system.
(3) Connect a long test hoses from gauge set manifold center
connection to vacuum pump.
(4) Open both manifold gauge set valves.
/
I
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AIR-CONDITION1
G-Service
Adjustment
24-37
Procedures
(5) Start the vacuum pump and operate until the evaporator
suction gauge registers
at least-101
kPa (29.9 in.of vacuum).
If at least-101
kPa (29.9 in. of vacuum) cannot be obtained,
either the system has a leak or the vacuum pump is defective.
Check the vacuum pump. If the pump proves to be functioning
properly, the system has a leak. Charge the system with one
pound of refrigerant.
Locate and repair all leaks. Discharge the
refrigerant and evacuate the system.
(6) Continue to operate the pump for at least five minutes.
(7) Close manifold valves. Turn off the vacuum pump and observe
evaporator
suction gauge for two minutes. The vacuum level
should remain constant.
If the vacuum level falls off, the system has a leak. Charge the
system with one pound of refrigerant.
Locate and repair all
leaks. Discharge the system and repeat evacuation procedure.
CHARGING
THE SYSTEM
The refrigerant
system must have been evacuated using the previous procedure
before charging. Charge using only R-l 2 refrigerant R-l 2 is available in bulk tanks or small cans. Follow the safety
precautions
for handling R-12 as listed in the beginning of this
group.
Charging
with
Small
Cans
When using disposable

cans of this type, follow
manufactures
instructions.
water
carefully
the can
2OUO326
Caution
Never use these cans to charge into the high pressure side of
the system (compressor
discharge port) or into a system that
is at high temperature,
because the high system pressures
could be transferred
into the charging can causing it to explode.
Keep the refrigerant
manifold valves capped when not in use.
Keep a supply of extra refrigerant-can-to-refrigerant-manifold
gaskets on hand so that gaskets can be replaced periodically. This will
insure a good seal without
excessive
tightening of the can or the
manifold nuts.
(1) Attach center hose from manifold gauge set to refrigerant
dispensing
manifold. Turn refrigerant
manifold valves completely counterclockwise
so they are fully open. Remove protective caps from refrigerant
manifold.
(2) Screw refrigerant
cans into manifold. Be sure manifold-to-can
gasket is in place and in good condition. Tighten can and manifold nuts to 8 to 11 Nm (6 to 8 ft.lbs.)
(3) Turn refrigerant
manifold
valves completely
clockwise
to
puncture the cans and close the manifold valves.
/ ST6 Revision
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24-38
Adjustment
Procedures
(4) Purge the air from the charging line by loosening the charging
hose at the gauge set manifold and turning one of the refrigerant valves counterclockwise
to release refrigerant. When
the refrigerant gas starts escaping from the loose connection,
re-tighten the hoses.
Caution
Never heat small
mad explode.
refrigerant
cans over 52C (125F) as they
(5) qully open all refrigerant manifold valves being used and place
the cans of refrigerant into a pan containing 52C (125F) water
will warm the charging can and aid in the transfer of the charge
into the system. Place the water pan and refrigerant cans on
a scale and note the weight.
(6) Jump the low pressure switch terminals
located on the receiver drier so the clutch will remain engaged.
(7) Start the engine and move the controls to air conditioner
switch on and low blower position.
The low pressure switch will prevent the clutch from engaging
until refrigerant is added to the system. If the clutch does
engage, replace the switch before proceeding any further.
(8) Charge through the suction side of the system by slowly opening the suction manifold valve. Adjust the valve as necessary
so charging
pressure does not exceed 345 kPa (50 psi).
Maintain the temperature
of the water in the pan by adding
warm water as necessary.
Note the weight
of water
added, to ensure accuracy when determining
amount
of
refrigerant
added to system.
(9) Adjust the engine speed to a fast idle of approximately
1500
rpm.
(IO) When specified refried refrigerant charge 730 (1.6 Ibs.) has
entered the system, close the gauge set manifold valves,
refrigerant
manifold
valves, and reconnect
wiring. Each
can contains 397 g (14 oz.) of R-12. Use 2 l/2 cans.
1 STB Revision
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HANDLING
TUBING
Adjustment
24-39
Procedures
AND FllTlNGS
N24FlAA
12-15 Nm
9-l 1 ft.lbs.\
20-25
15-18
Nm
ftlbs.
\
22-25
15-18
ftlbs.
ft.lbs.
20-25
Nm 15-18
ft
2080122
Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the
entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised
to make sure that all connections are pressure tight.Dirt and moisture can enter the system when it is opened for
repair or replacement of lines or components. The following precautions must be observed.
The system must be completely discharge before opening any fitting or connection in the refrigeration system.
Open fittings with caution even after the system has been discharged. If any pressure is noticed as a fitting is
loosened, allow trapped pressure to bleed off very slowly. Never attempt
to rebend formed lines to fit. Use the
correct
line for the installation
you are servicing.
A good rule for the flexible hose lines is keep the radius of all bends at least 10 times the diameter of the hose.
Sharper bends will reduce the flow of refrigerant. The flexible hose lines should be routed so that they are at least
80 mm (3 in.) from the exhaust manifold. It is good practice to inspect all flexible hose lines at least once a year
to make sure they are in good condition and properly routed.
Unified plumbing connections with O-rings. These O-rings are not reusable.
1 STB Revision
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24-40
Nut
I
O-RING INSTALLATION
(1) Clean sealing surface.
(2) Make sure O-ring does not have any scratches.
(3) Connect fitting, install fastener, and torque to amount shown
in illustration.
The internal part of the refrigeration system will remain in a state
of chemical stability as long as pure-moisture-free
R-l 2 and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can
upset the chemical stability and cause operational troubles or even
serious damage if present in more than minute quantities.
When it is necessary to open the refrigeration system, have everything you will need to service the system ready so the system
will not be left open any longer than necessary. Cap or plug all
lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture. All lines and components
in parts stock
should be capped or sealed until they are ready to be used.
All tools, including the refrigerant dispensing manifold, the gauge
set manifold and test hoses should be kept clean and dry.
Union
20110267
COMPRESSOR
Tension pulley
IOON (22 Ibs.1 Compressor
Crankshaft
pulley
2OY907
N24FJAE
Satisfactory performance of the air-conditioning

system is dependent upon drive belt condition and tension. If the proper tensions
are not maintained,
belt slippage will greatly reduce air- conditioning performance and drive belt life. To avoid such adverse effects,
the following service procedure should be followed:
(1) Any belt that has operated for a minimum
of one half-hour is
considered to be a used belt. Adjust air- conditioning
drive
belt at the time of new-car preparation.
(2) Check drive belt tension at regular service intervals and adjust
as needed.
Standard
1 STB Revision
DRIVE BELT ADJUSTMENT
value
-7
http://vnx.su/
: 17-20
mm (.67-.78
in.)
AIR-CONDITIONING
COMPRESSOR
-Service
Adjustment
NOISE
Procedures
24-41
NWLM
When investigating
an air conditioning
related noise, you must first know the conditions when the noise occurs.
These conditions
are: weather, vehicle speed, in gear or neutral, engine temperature
or any other special
conditions.
Noises that develop during air- conditioning
operation can often be misleading.
For example: what sounds like a
failed front bearing or connecting rod, may be caused by loose bolts, nuts, mounting brackets, or a loose clutch
assembly. Verify accessory drive belt tension (power steering,
alternator or air pump). Improper accessory drive belt
tension can cause a misleading noise when the compressor is engaged and little or no noise when the compressor
is disengaged.
Drive belts are speed sensitive. That is, at different engine speeds, and depending upon belt tension, belts can
develop unusual noises that are often mistaken for mechanical problems within the compressor.
Adjustment
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Procedures
Select a quiet area for testing. Duplicate conditions as much as possible. Switch compressor on and off several
times to clearly identify compressor noise.
To duplicate
high ambient
conditions
(high head pressure), restrict air-flow through condenser. Install
manifold
gauge set to make sure discharge
pressure does not exceed 2,070 kPa (300 psi).
Tighten all compressor mounting bolts, clutch mounting bolt, and compressor drive belt. Check to assure clutch
coil is tight (no rotation or wobble).
Check refrigerant hoses for rubbing or interference that can cause unusual noises.
Check refrigerant charge (See Charging the System).
Recheck compressor noise as in Step 1.
If noise still exists, loosen compressor mounting bolts and retorque. Repeat Step 1.
If noise continues, replace compressor and repeat Step 1.
1 STB Revision
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24-42
AIR-CONDITIONING
AIR CONDITIONER
REMOVAL
AND
- Air Conditioner
Switch
SWITCH
INSTALLATION
N24CLA-
2ow929
Removal
steps
1. Lap heater duct (C)
2. Glove box stoppers
3. Knobs
4. Plugs
5. Center panel
6. Connection
of center panel wiring harness to front wiring harness connector
7. Air conditioner
switch
NOTE
(1)
Reverse
the
(2)
+e
: Refer
SERVICE
POINTS
1. REMOVAL
removal procedures
to
Service
Points
OF REMOVAL
OF GLOVE
BOX
STOPPERS

(2) Remove
(3) Pull the glove box outward.
1 STB Revision
http://vnx.su/
to reinstall.
of
Removal
AIR-CONDBTIONI
G - Evaporator
EVAPORATOR
REMOVAL
Operation
Discharge
P.24-36)
Removal
~~
l +
N24RA--
AND INSTALLATION
Pre-removal
l
24-43
the refrigerant.
(Refer
to
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
Liquid pipe connection

Suction hose connection
Nut
Glove box
Main harness connector connection
Duct joint
Drain hose connection
Bolt
Evaporator
NOTE
to reinstall.

Nut
I
N24MAC
Caution
If the hoses or pipes are disconnected, cap the hoses or pipes:
with a blank plug to prevent entry of dust, dirt, and water.
Union
/
SERVICE
2OUO267
POINTS
OF INSTALLATION
N24AOAE
2. APPLICATION
OF COMPRESSOR
OIL TO SUCTION
HOSE/l.
LIQUID PIPE
Apply specified
compressor
oil to portions indicated
before installing the liquid pipe (C) and suction flexible
hose.
Specified oil : DENS0 oil 6
!vision
http://vnx.su/
24-44
AIR-CONDOTIONING-Evaporator
DISASSEMBLY
N24RE--
AND REASSEMBLY
1
\
Disassembly
4*
+e
l +
1.
2.
3.
4.
5.
6.
7.
8.
steps
Air conditioner
relay
Thermostat
Screw
Clip
Evaporator
case (upper)
Evaporator case (lower)
Evaporator assembly
Expansion valve
NOTE
-6
2OW828
SERVICE POINTS
4.
REMOVAL
OF DISASSEMBLY
N24RFAB
OF CLIP
Remove the clips with a flat-blade screwdriver covered with a

shop towel to prevent damage to case surfaces.
2OW718
8.
REMOVAL
OF EXPANSION
VALVE
Use two wrenches to loosen the flare nut on the pipe connection (for both the inlet and outlet).
2ow722
SERVICE
0-rina
8.
Expansion
valve
O-rim
POINTS
APPLICATION
VALVE
OF REASSEMBLY
OF COMPRESSOR
OIL
N24RHAE
TO EXPANSION
Apply specified compressor oil to the O-rings and install

the expansion valve to the evaporator assembly.
Specified
oil
1 STB Revision
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: DENS0
oil 6
AIR-CONDITIONING
RECEIVER
REMOVAL
Receiver
DRIER, CONDESER,
AND
drier,
Condenser,
Compressor
COMPRESSOR
Clutch
24-45
Assembly
CLUTCH ASSEMBLY
INSTALLATION
N24TA--
Pre-removal
Operation
Discharge the Refrigerant.
(Refer to
P.24-36)
l
Remove the Radiator Grille. (Refer
to GROUP 23 BODY-Grille, Garnish,
Moulding)
l
Disconnect the Liquid Pipes and
Hoses.
Post-installation
Operation
l
Install the Radiator Grille. (Refer to
GROUP 23 BODY-Grille, Garnish,
Moulding)
l
Charge the Refrigerant. (Refer to
P.24.37)
l
Adjustment
of the Tension of the
Air Conditioner
Drive Belt. (Refer to
P.24-40)
2OW832
Receiver drier removal steps
Compressor clutch assembly removal steps
1. Reveiver drier mounting bolt

2. Receiver drier
Condenser removal steps
3.
4.
5.
6.
7.
8. Drive belt
9. Compressor clutch assembly mounting
bolt
10. Compressor clutch assembly
Blower motor connector

Blower motor mounting bolt
Blower motor
Condenser mounting bolt
Condenser
NOTE
Reverse
the removal
procedures
to reinstall.
N24TBAB
Caution
If the hoses or pipes are disconnected,cap
the hoses or pipes
with a blank plug to prevent entry of dust, dirt, and water.
1 STB Revision
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24-46
AIR-CONDITIONING
- Compressor
COMPRESSOR
DISASSEMBLY
AND
REASSEMBLY
N24TE-
16
15-h
11-13
Nm
ftlbs
26-26
16-20
Nm
ftlbs.
\
l5Dl
2QY947
Magnetic
4*
clutch disassembly steps
1. Nut
~~ Adjustment of clutch clearance
2. Clutch hub
3. Shims
4. Snap ring
5. Rotor assembly
6. Snap ring
7. Ground terminal
l + 8. Clutch coil
Compressor front
sembly steps
**
o+
04
housing and service valve disas-
9. Oil drain guide

10. Woodruff key
Il. Through bolt
Refilling of compressor oil
12. Front housing
13. Shaft seal
14. Shaft plate
15. Gasket
16. O-ring
NOTE
(3) e+ : Refer to Service
parts
1 STB Revision
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procedures
to reassemble.
AIR-CONDITIONING
SERVICE
5.
24-47
- Compressor
POINTS
OF DISASSEMBLY
N24TFAE
REMOVAL
OF ROTOR ASSEMBLY
It may be necessary to lightly tap the rotor with
hammer.
a plastic
2OY713
INSPECTION
l
l
l
Shaft pl&e
Check the
Check the
Check the
tion.
Check the
surfaces.
Check the
SERVICE
Front housing
N24TGAC
surface of the clutch hub for scoring or bluing.

surface of the rotor for scoring or bluing.
sealing surfaces for cracks, scratches and deformafront housing
compressor
POINTS
MB990?83-01
shaft for scoring.
OF REASSEMBLY
N24THAH
14. INSTALLATION
OF SHAFT PLATE
(1) Lubricate
the shaft plate and a new O-ring with
compressor
oil. Push the shaft plate and O-ring into the
front housing.
2OY789
(2) Install the seal

special tool.
for cracks or scoring on the sealing
plate
into
the
front
housing
with
2OY790
13. INSTALLATION
OF SHAFT
Lubricate
the shaft seal with
shaft seal on the shaft.
SEAL
compressor
oil. Install
NOTE
Rotate the shaft seal lightly by hand to check that
fitted into the notch on the compressor
shaft.
the
it is
2OY788
evision
http://vnx.su/
,: 24-48
AIR-CQNDITIONING
- Compressor
REFILL
OF COMPRESSOR
OIL
Fill 110 cc. (3.7 U.S. fl.oz., 3.9 Imp.fl;oz.)

specified
compressor
oil from the suction
hole side and install the flange fitting
assembly.
Specified
8.
: DENS0
oil
INSTALLATION
The clutch
compression
oil 6
OF CLUTCH
coil
must
be
COIL
aligned
with
the
pin
in the
housing.
2OY717
ADJUSTMENT
(1) Check
trated.
OF CLUTCH
the
Pressure
pressure
plate
plate
CLEARANCE
to rotor
clearance
as illus-
to rotor clearance
:
mm (.016-.028
in.)
0.4-0.7
NOTE
Remove
clearance
adjusting
shims to decrease
clearance.
Add shims selected
from the following
iOY718
to increase
Clearance
clutch
Adjustment
Part No.
clutch
table
clearance.
Shims
Thickness
RSI 3023A
0.1 mm (.004 in.).
RSI 3023B
0.2 mm (.008 in.)
RSI 3024
0.5 mm (.020 in.)
(2) Turn the rotor
by hand to confirm
that it rotates
freely.
RJST608009-284
1 STB Revision
-1
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mi

This Service r\;lanual has been prepared with the

Intake and Exhaust

- How To Use This Manual

HOW TO USE THIS MANUAL

Indicates incidental operation

Removal steps : The numbers before part names

Th$ service steps are arranged in numerical order

AND MASTER TROUBLESHOOTING

- How To Use This Mawal

SERVICE POINTS OF INSTALLATION-5.

Install the thermostat to the intake manifold as illustrated.

AND MASTER TROUBLESHOOTING

The vehicle identification

CODE CHART PLAT$m,,;p.

All vehicle identification

UCTION AND MASTER TROUBLESHOOTING

VIN (except sequence

(Can also be sold in Federal

VIN (except sequence

The plate shows model code,

exterior code followed

AND MASTER TROUBLESHOOTING

on the side of the frame

CHASSIS NUMBER CODE CHART

VEHICLE SAFETY CERTIFICATION

The vehicle safety certification

ENGINE MODEL STAMPING

The engine model number is stamped at the right front side on

The engine serial number is stamped

AND MASTER TROUBLESHOOTING

BODY COLOR CODE

Dark blue (Metallic)

When checking a malfunction,

If punch marks or mating marks are made to avoid error in

parts, use MITSUBISHI

the electrical system,

1. Secure the wiring harnesses by using clamps so that there

If any section of a wiring harness contacts the edge of a

AND MASTER TROUBLESHOOTING

which have catches by pressing

AND MASTER TROBB LESHOOTING

1. When installing any of the vehicle parts, be careful

Sensors, relays, etc., are sensitive to strong impacts.

FUSES AND FUSIBLE

1. If a blown-out fuse is to be replaced, be sure to

AND MASTER TROUBLESHOOTING

- Precautions Before Service

(3) If an ammeter or similar instrument

TUBES AND OTHER RUBBER PARTS

oil, etc., because

DOING SERVICE WORK IN GROUPS

AND MASTER TROUBLESHOOTING

AND MASTER T OUBLESHOOTING

TREATMENT BEIFORE/AFTER THE FORDING OF A STREAM

bar dust cover

Clutch release cylinder

AND MASTER TROUBLESHOOTING

Apply grease to the lubricating

CTION AND MASTER TROUBLESHOOTING

After fording a stream, check the following points. If abnormal

Towed vehicle should be raised until wheels are a minimum

The vehicle may be towed on its rear wheels for extendedd:

AND MASTER TROUBLESHOOTING

Twin post hoist