Honda 2014 SXS700M2, Service Manual

Page 1: ......

Page 2: ...dures Only you can deCide whether Of not you should perform a given task AWARNING FaLlure 10 properly follov lnstructlons and precautions can cause you to be senously hurt or killed Follow the procedures and precautions In thiS manual carefully Important Safety Precautions Make sure you have a clear understand ng of a 1 baSIC shop safety practICes and that you are eanng appropriate dontlng and USi...

Page 3: ...detailed procedure Refer to the troubleshooting In each section according to the malfunction or symptom In case of an engine trouble refer to PGM Fl section troubleshooting first Your safety and the safety of others is very Important To help you make informed decisions we have provided safety messages and other information throughout this manual Of course it is not practical or possible to warn yo...

Page 4: ...bdenum disulfide grease containing more than 3 molybdenum disulfide NlGl 2 or equivalent Example Molykote BR 2 plus manufactured by Dow Corning U S A _______ M I ti purpose M 2 manufactured by Mitsubishi 0 2 il J a p a n Use molybdenum disulfide paste containing more than 40 molybdenum disulfide NlGI 2 or equivalent Example Molykote G n Paste manufactured by Dow Corning U S A Honda Moly 60 U S A o...

Page 5: ...LING SYSTEM F CY L I N D E R H E A D N A L V E C A M S H A F T W CYLINDER PISTON ALTERNATOR STARTER CLUTCH w F z SUB TRANSMISSION GEARSHIFT LINKAGE F z CRANKCASE CRANKSHAFT BALANCER w F ENGINE REMOVAL INSTALLATION DRIVETRAIN SYSTEM STEERING SYSTEM DRIVE SHAFT FINAL GEAR WHEEL SUSPENSION GF BRAKE SYSTEM 1 BATTERY CHARGING SYSTEM wU F LIGHTS METERS SWITCHES u l w u WIRING DIAGRAM INDEX ...

Page 6: ...MEMO ...

Page 7: ...EL IDENTIFICATION 1 2 SPECIFICATIONS 1 4 TORQUE VALUES 1 9 LUBRICATION SEAL POINTS 1 14 1 GENERAL INFORMATION CABLE HARNESS ROUTING 1 17 EMISSION CONTROL SySTEMS 1 32 LIFT AND SUPPORT POINTS 1 33 TECHNICAL FEATURES 1 34 1 1 ...

Page 8: ...ntal sleps unless a particular sequence is specified 6 Clean parts in cleaning solvent upon disassembly Lubricate any sliding surfaces before reassembly 7 After reassembly check all parts for proper installation and operation 8 Route all electrical wires as show in the Cable and Harness Routing page 1 17 ABBREVIATION Throughout this manual the following abbreviations are used to identify the respe...

Page 9: ...I AG IVAC II eM IVCM t REGION U S A 50 stale model Australia New Zealand Canada Be sure to refer to the procedure for the appropriate version of the SXS700 SERIAL NUMBERS LABELS I V I N Vehicle Identification Number THROTTLE BODY IDENTIFICATION NUMBER MANUFACTURERS LABEL Icaoa ooly MANUFACTURERS LABEL EMISSION CQNTROllNFQRMATIQN r BEL lcaoad t r y A EMISSION CONTROL COLOR LABEL INFORMATION LABEL 1...

Page 10: ...9 1 in 5 Rear tire size 25 x 10 00 12NHS Front rim size 12x6 0AT Rear rim size 12x7 5AT Front tire brand BLACKSTONE OTR HP 007 Rear lire brand BLACKSTONE OTR HP 007 Front brake Hydraulic disc brake Rear brake Hydraulic disc brake Casler angle 3 Trail length 14 mm 0 55 in Camber angle 0 Fuel tank capacity 30 liters 7 9 US gal 6 6 Imp gal Fuel tank reserve capacity 4 51i1ers 1 19 US gal 0 99 Imp gal...

Page 11: ...8 F _______ J t IGNITION SYSTEM SPECIFICATIONS park plug Spark plug gap gnition coil peak voltage ITEM CKP sensor pea k O a g __ r Ignition timing ELECTRIC STARTER SPECIFICATIONS r Fixed low ratio 2WD 4WQ 4WQ Differential lock Fun Transistorized Ignition Electric starter motor Tnple phase outpui a a o FET shorted triple phase full wave rectification Battery SPECIFICATIONS 1 0 1 31 0 2 2 2 7 kO SPE...

Page 12: ... I Valve IN 1 5 0006 1 EX 1 32 I 1 0 013 I I gUide Valve IN 161 X i 55 5 IN EX 18 15 25 0 Valve gUI e l i above 1 I head EX 73 58 Valve eal wldlh 00 t 39 0 043 Valve spring Free length 37 20 4 2U11 74 OeKei aim I Shaft 0 0 1 964 1 Taf INIEX 0 4718 clearance INIEX 0 016 0 054 m 1 cam fol o a am loDe nelgm IN S 34 3 1 000 30 1430 ou00 CamlOik 482 _ ORR bOle 10 526 1 1 INIEX 0 059 0 J011 1 6 Unit mm ...

Page 13: ...02 0 7 0 03 0 9 0 04 0 095 0 0037 0 075 0 0030 0 19 0 007 23 06 0 908 0 08 0 003 Unit mm in SERVICE LIMIT Unit mm in ITEM STANDARD SERVICE LIMIT _____ 00 0 7 0 2 1 0 4331 0 4339 _ 11 04 0 435 Claw thickness 4 93 5 00 0 194 0 197 4 5 0 18 Shift fork t o S h aft O D ________ 0 9B B 0 9 8 4 0 4 3 7 _ 0 4 32 4 __ _ 0 9 6 0 431 CRANKCASE CRANKSHAFT BALANCER SPECIFICATIONS Crankshaft ITEM Runout Big end...

Page 14: ...flcm 12 psi Up to maximum I Front 70 kPa 0 7 kgf cm 10 psi weight capacity Rear 120 kPa 1 2 kgf cm 18 psi BRAKE SYSTEM SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Recommended brake fluid Honda DOT 4 brake fluid Brake disc thickness Front 11 8 12 2 0 46 0 48 10 0 0 39 Rear 7 3 7 7 0 29 0 30 I 6 0 0 24 Brake disc runout 0 30 0 012 Brake pedal height from accelerator pedat 25 40 1 1 3 S Par...

Page 15: ...lt and nul N m kgf m Ib f ft __ 5 0 5 3 7 5 mm screw FASTENER TYPE N m kgf m Ibf ft 4 OA 3 0 10 1 0 7 22 2 2 f 34 3 5 25 54 5 5 40 ENGINE FRAME TORQUE VALUES 6 mm screw 6 mm flange bolt 8 mm head small flange 6 mm flange bolt 8 mm head large flange 6 mm flange bolt 10 mm head and nut __ 8 mm flange bolt and nut 10 mm flange bolt and nut 9 0 9 6 6 10 1 0 7 12 1 2 9 12 1 2 9 27 2 8 20 39 4 0 29 REMA...

Page 16: ...r VS sensor boll _____ IGNITION SYSTEM po Q lY 6 4 8 6 4 2 2 4 2 2 6 r 3 2 8 a TY 1 4 1 1 1 I I 1 I THREAD TORQUE REMARKS 1 OIA mm N m kgf m IbHt 10 10 10 10 7 16 7116 7116 7116 7 16 8 I 10 T 01 49 5 0 36 49 5 0 36 49 5 0 36 49 5 0 36 32 3 3 24 32 3 3 24 32 3 3 24 32 3 3 32 3 3 2 2 2 24 24 16 4 0 4 1 5 0 2 3 2 O 3 3 0 _ 1 1 2 4 56 5 7 41 Qnly for proper torque confirmation TORQUE N m kgf m fbI ttl...

Page 17: ...lernator stator bolt 3 Q TY C TY C TY 6 1 CKP sensor bolt Alternator stator wire holder bolt Gear selector arm pinch bolt SUB TRANSMISSION GEARSHIFT LINKAGE ITEM C TY Shift drum stopper arm pivot bolt 1 Engine oil drain bolt 1 Gear selector lever pivot nut 1 Gear selector cable lock nut 2 ENGINE REMOVAUINSTALLATION ITEM C TY Engine side mounting nut left and right 2 Front final gear case mounting ...

Page 18: ... L N m kgt f m b f 6 8 0 8 5 g ft 16 108 11 0 80 10 22 14 1 4 10 118 12 0 87 REMARKS Apply engine oil Lock nut replace with a new one Stake Apply locking agent Apply engine oil lock nut replace with a new one Stake _ _ 24 _ f 21 2 1 15 _ 20 18 1 8 13 _ 10 12 1 2 9 Q TY 4 2 2 4 3 a TV 2 2 4 10 3 1 1 3 I 1 1 4 1 2 3 2 6 _ 1 5 1 THREAD oiA mm 12 8 12 12 10 6 THREAD OIA mm 12 10 8 8 8 64 6 10 10 6 12 ...

Page 19: ... pivot nut frame side Rear lower arm pivot nut frame side Rear upper and lower arm pivot nut knuckle side Stabili zz a m momo U lilii gQbo iOf ItC _____ Stabilizer link nut BRAKE SYSTEM 4 4 12 ______Ta e w one 64 6 5 47 lock nut replace with a new one 1 10 1 44 4 5 32 r l ock nut replace with a new one 4 8 27 2 8 20 _ 1_ 4 10 46 4 7 34 Lock nul replace with I a new one ITEM a TY Drive shaft outboa...

Page 20: ...kgf m bOt 5 0 8 0 1 0 6 22 4 9 0 5 3 6 3 0 4 0 04 0 3 MATERIAL LOCATION MOlybden m O iI SO I O nC Camshaft cam lobes and decompressoream area a mixture of engine oil and Piston pin ouler surface molybdenum disulfide Starter driven grease in a ratio of 1 1 Engine il screw tip surface i 1hole Molybdenumdi sUilfidec g i grease I T81215 1 14 surface of crankshaft REMARKS REMARKS I See page 16 42 ...

Page 21: ...eering rack guide sliding surface rack side Steering rack end joint outer surlace Fmntfinal clutch pinion jOint oil seal lips Fmnt final gear case drive shaft oil seal lips Frant final gear case cover O ring Differentiallock arm shaft oil seal lips Differentiallock housing O ring Frant final clutch arm shaft oil seal Ups Fron1final clutch arm shaft O ring Fran1final clutch arm shaft outer surface ...

Page 22: ...cant Drive mode selector inner cabt Differenliallockinner cable Gear selector inner cable f S e al a nt T h e e bo nd 1 W heel hub nul rTi OiJiltIng threads of drive shaft fApply 5 mm T81215 or loctite LT5699 Rear final gear case cover mating surface or equivalenl L ___ _ iiOi i Sealant Threebond Rack guide screw threads Apply 3 Hand Grip Cement U SA only Engine 1 16 area Air I ...

Page 23: ...TOR RIGHT FRONT FENDER RIGHT HEADLIGHT BRAKE LIGHT SWITCH WIRE FAN MOTOR WIRE GENERAL INFORMATION FRONT FINAL GEAR CASE BREATHER HOSE FAN MOTOR BREATHER HOSE LEFT HEADLIGHT HEADLIGHT SUB HARNESS REAR COVER L _________________R _E _ A HEADLIGHT SUB HARNESS 1 17 ...

Page 24: ...HOSE FAN MOTOR BREATHER HOSE 1 18 LOWER RADIATOR HOSE DRIVE MODE SELECTOR CABLE THROTILE CABLE DIFFERENTIAL LOCK CABLE UPPER RADIATOR HOSE I II II DIFFERENTIAL LOCK SWITCH WIRE GEAR SELECTOR CABLE PARKING BRAKE CABLE FRONT FINAL GEAR CASE BREATHER HOSE ...

Page 25: ...L LOCK CABLE GENERAL INFORMATION DRIVE MODE SELECTOR CABLE DIFFERENTIAL LOCK SWITCH DIFFERENTIAL LOCK CABLE FRONT FINAL BRAKE PIPE CASE BREATHER HOSE DRIVE MODE SELECTOR CABLE 4WO SELECT SWITCH WIRE DRIVE MODE SELECTOR CABLE 4WD SELECT SWITCH PARKING BRAKE CABLE MAIN WIRE HARNESS 4WD SELECT SWITCH WIRE iJ I MAIN WIRE HARNESS DIFFERENTIAL LOCK SWITCH THROTIlE CABLE GEAR SELECTOR CABLE 1 19 ...

Page 26: ...RMATION Left side shown FRONT BRAKE HOSE 1 20 BRAKE PIPE to RIGHT FRONT BRAKE CALIPER 61 o I 0 BRAKE PIPE to FRONT BRAKE CALIPERS 0 0 6J 61 bO BRAKE PIPE to lEFT FRONT BRAKE CALIPER BRAKE PIPE to REAR BRAKE CALIPER ...

Page 27: ... BRAKE LIGHT SWITCH 2P Gray CONNECTOR COMBINATION METER SUB HARNESS 10P Gray CONNECTOR BRAKE LIGHT SWITCH 2P Gray CONNECTOR BRAKE INHIBITOR M REALA NY RELAY r cc r t COMBINATION METER SUB HARNESS HEADLIGHT RELAY FUEL PUMP RELAY FUSE BOX DRIVE MODE THROTTLE SELECTOR CABLE bI DIFFERENTIAL LOCK SWITCH WIRE PARKING BRAKE CABLE DIFFERENTIAL LOCK CABLE PARKING BRAKE CABLE I _ ___ HEADLIGHT SWITCH WIRE G...

Page 28: ...ORY SOCKET 2P Green CONNECTOR PARKING BRAKE CABLE ACCESSORY SOCKET DRIVE MODE SELECTOR CABLE PARKING BRAKE IGNITION SWITCH PARKING BRAKE SWITCH 2P I COMBINATION METER SUB HARNESS 10P Gray CONNECTOR IGNITION SWITCH SP BlaCk CONNECTOR ...

Page 29: ...IRE DRIVE MODE SELECTOR CABLE GENERAL INFORMATION DIFFERENTIAL LOCK SWITCH WIRE MAIN WIRE HARNESS i T ___ THROTTLE CABLE PARKING BRAKE CABLE MAIN FUSE o U GEAR SELECTOR CABLE STARTER RELAY SWITCH 2P Green CONNECTOR BATTERY STARTER RELAY SWITCH BATTERY H CABlE R1 MOTOR CABLE WIRE HARNESS 1 23 ...

Page 30: ...HOSE MAIN WIRE HARNESS FUEL TANK 8REATHER HOSE l I 1 MAIN WIRE HARNESS MAIN WIRE HARNESS c II c o J 0 AfT CLUTCH PC SOLENOID VALVE SUB HARNESS 6P Green CONNECTOR 4P CONNECTOR STARTER BATTERY eAllLE THROTTLE CABLE GEAR SELECTOR CABLE D I PARKING BRAKE CABLE 1 ...

Page 31: ...COOLER WATER PUMP BLEED HOSE GENERAL INFORMATION WATER HOSE to CYLINDER _______ AfT CLUTCH PC SOLENOID VALVE SUB HARNESS SHIFT SOLENOID VALVE B 2P Brown CONNECTOR SHIFT SOLENOID VALVE A 2P Black CONNECTOR AfT CLUTCH PC SOLENOID VALVE 2P Black CONNECTOR WATER HOSE from LOWER RADIATOR HOSE WATER HOSE from THERMOSTAT HOUSING WATER HOSE from LOWER RADIATOR HOSE 1 25 ...

Page 32: ...ATORlCKP SENSOR SP Black CONNECTOR GEAR POSITION SWITCH 3P Black CONNECTOR BATIERY CABLE THROTILE L CABLE GEAR SELECTOR CABLE MAIN WIRE HARNESS AIT CLUTCH PC SOLENOID VALVE SUB HARNESS6P Green CONNECTOR sr tl OIL COOLER FUEL FEED HOSE STARTER MOlOR CABLE J ________ C__ __ 2 t 1 PARKING J BRAKE CABLE MAIN WIRE HARNESS SATIERY CABLE THROTIlE CABLE GEAR SELECTOR CABLE 1 26 ...

Page 33: ...to UPPER RADIATOR HOSE CRANKCASE BREATHER HOSE WATER HOSE SATTERY CABLE to WATER PUMP WATER HOSE to UPPER RADIATOR HOSE GENERAL INFORMATION WATER HOSE WATER HOSE from WATER PUMP THROTTLE CABLE CRANKCASE BREATHER HOSE WATER HOSE to WATER PUMP 1 27 ...

Page 34: ...I COIL CRANKCASE BREATHER HOSE 1 28 GEAR POSITION SWITCH THROTTLE CABLE FUEL FEED HOSE IAT SENSOR 2P CONNECTOR PARKING BRAKE CABLE GEAR SELECTOR CABLE EOT SENSOR 2P CONNECTOR GEAR POSITION SWITCH WIRE ALTERNATORfCKP SENSOR WIRE GROUND CABLE ...

Page 35: ...CV 4P Black CONNECTOR FUEL INJECTOR 2P Gray CONNECTOR SENSOR UNIT 5P CONNECTOR IAT SENSOR 2P CONNECTOR GENERAL INFORMATION FUEL INJECTOR 2P Gray CONNECTOR IACV 4P Black CONNECTOR FUEL FEED HOSE Fr _ IAT SENSOR 2P CONNECTOR 1 29 ...

Page 36: ...BRAKE PIPE MAIN WIRE HARNESS 10 BRAKEITAll UGHTS VS SENSOR WIRE 1 30 REAR FINAL GEAR CASE BREATHER HOSE BRAKE PIPE PARKING BRAKE CABLE REAR BRAKE HOSE vs SENSOR WIRE REAR GEAR CASE BREATHER HOSE VS SENSOR 3P CONNECTOR I J ...

Page 37: ...0 BRAKEfTAILLIGHTS 4 PERSON TYPE MAIN WIRE HARNESS 10 BRAKEfTAILLIGHTS GENERAL INFORMATION BRAKEfTAILLIGHT WIRE BRAKEfTAILLIGHT 6P CONNECTOR BRAKEfTAILLIGHT WIRE 0 BRAKEJTAILLIGHT 6P CONNECTOR BRAKE TAILLIGHT WIRE BRAKEITAILUGHT WIRE 1 31 ...

Page 38: ...CONTROL SYSTEM The exhaust emission control system is composed of the PGM FI system and no adjustments should be made The exhaust emission control system is separate from the crankcase emission control system CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere Blow by gas is returned to the combustio...

Page 39: ...ses used on the Recreational Utility Vehicle incorporate fuel permeation control technologies Tampering with the fuel tank fuel hoses or fuel vapor charge hoses to reduce or defeat the effectiveness of the fuel permeation technologies is prohibited by federal regulations REBUILT ENGINE When you rebuild the engine including a major overhaul in which you replace the engine s pistons or power assembl...

Page 40: ...boot bands 121 help to prevent damage to the boots from debris and grass plant entanglement For drive shaft boolslboots band service page 18 8 BED TILT PREVENTION SYSTEM 4 PERSON TYPE This model employs an independent bed tilt prevention system which is separate from the bed release lever located in the fronl side of cargo bed When the cargo bed is converted to 3 or 4 person mode the rear seat fra...

Page 41: ...R COVER INSTRUMENT PANEL 2 16 4 PERSON TYPE ONLY 2 7 FRONT FLOOR COVER 2 17 MIDDLE FENDER 2 8 FRONT BUMPER 2 17 SEAT BOTTOM COVER 2 8 MAINTENANCE LID 2 18 REAR STEP 4 PERSON TYPE ONLY 2 9 CARGO BED 2 18 MUD PROTECTOR 2 PERSON TYPE ONLY 2 9 SIDE NET 2 24 REAR FOOT WELL 4 PERSON TYPE ONLY 2 10 OCCUPANT PROTECTIVE STRUCTURE OPS 2 25 REAR SIDE COVER 2 10 SEAT BELT 2 27 FRONT SIDE COVER 2 11 UNDER GUAR...

Page 42: ...haust system Always replace the gaskets after removing the exhaust system Always inspect the exhaust system for leaks after installation TOOL Push pin pliers 07AAC SJAA100 U S A only TROUBLESHOOTING Excessive exhaust noise Broken exhaust system Exhaust gas leak Poor performance Deformed exhaust system Exhaust gas leak Clogged muffler 2 2 ...

Page 43: ...e 2 11 1 1 FRONT HOOD page 2 12 12 FRONT GRILLE page 2 12 13 FRONT HEAT GUARD page 2 12 4 person type only 2 person type only FRAME BODY PANELS EXHAUST SYSTEM 22 __ 13 12 5 10 19 14 FRONT FENDER page 2 1 3 15 DOOR page 2 13 16 INSTRUMENT PANEL page 2 16 17 FRONT FLOOR COVER page 2 17 18 FRONT BUMPER page 2 17 19 MAINTENANCE LID page 2 18 20 CARGO BED page 2 18 21 SIDE NET page 2 24 22 OCCUPANT PRO...

Page 44: ...it by pushing the center pin securely FRONT SEAT SEAT CUSHION REMOVALI INSTALLATION Remove and install Release the grommets 1 by pulling the front side of the 13 1 seat cushion 2 upward then forward and remove it 2 4 lnstailihe seat cushion by aligning the prongs 3 with the frame then press it down while aligning the grommets with the frame bosses 4 BACKREST REMOVAL INSTALLATION lift up the cargo ...

Page 45: ... 8 middle fenders page 2 8 rear side covers page 2 10 upper middle OPS page 2 25 Release the following spark plug wire from the clamp 1 fuel tank breather hose from the clip 2 fuel feed hose from the clamps 3 water hose from the clamps 4 throttle cable from the guide 5 Remove the front bolls 6 side nuts 7 side bolts 8 and rear bolts 9 then remove the seat frame 10 Installation is in the reverse or...

Page 46: ...ve Ihe rear seat cushion page 2 6 Disconnect Ihe upper side of seat damper page 2 6 Unlock the rear seat latch Remove Ihe bolts 11 and release the grooves from Ihe frame bosses 2 by pulling the rear seat 3 forward then remove Ihe rear seat Installation is in the reverse order of removal SEAT DAMPER REMOVAU INSTALLATION 131 lower ball studs 21 Lower side Disconnect the seat damper 111 from Ihe uppe...

Page 47: ... m 3 3 kgf m 24 IbOt PIPE GUARD SPECIAL SCREWS WIRES SEAT BACK COVER J UPPER BACKREST SCREWS LOWER BACKREST REAR CENTER COVER 4 PERSON TYPE ONLY REMOVAL INSTALLATION SPRING COVER SEAT FRAME BUCKLES Lift up the cargo bed j i 21 1 2 tabs 3 and hooks 4 2 i Remove the rear center cover 1 releasing the bosses 3J Installation is in the reverse order of removal r 1 41 2 7 ...

Page 48: ...lowing front seat cushion page 2 4 special boll IJ special screw 2 seven clips 1 3 left middle fender 4 Installation is in the reverse order of removal SEAT BOTTOM COVER 2 8 RIGHT SEAT BOTTOM COVER REMOVAUINSTALLAnON Remove the following front seat backrest page 2 4 left seal bottom cover page 2 8 battery page 21 4 PCM page 4 28 starter relay switch page 6 8 Release the main fuse harness clamp and...

Page 49: ...l TORQUE l eft seat bottom cover mounting screw B N m 0 8 kgf m 5 9 IbH REAR STEP 4 PERSON TYPE ONLY REMOVAL INSTALLATION Remove the following two bolts 1 five clips 2 rear step 3 Installation is in the reverse order of removal MUD PROTECTOR 2 PERSON TYPE ONLY REMOVALIINSTALLATION lift up the cargo bed Remove the following clips 1J left side five clips right side seven clips mud protector 2 Instal...

Page 50: ...LATION Remove the following rear step page 2 9 three dips lJ six screws 2J right rear fool well 3 Installation is in the reverse order of removal TORQUE Rear foot well mounting screw 8 N m 0 8 kgf m 5 9 IbHt REAR SIDE COVER REMOVAUINSTALLATION Remove the following seat bottom cover page 2 8 two socket bolts 1 screw 2 five clips 3 RighI side only Temporarily remove the fuel filler cap 4 2 10 Remove...

Page 51: ...se order of removal TORQUE Front side cover socket bolt 9 N m 0 9 kgf m 6 6 Ibf ft FLOOR PANEL REMOVALIINSTALLATION Remove the following fron t side covers page 2 11 rear side covers page 2 10 fourteen screws 1 floor panel 2 Installation IS in the reverse order of removal TORQUE Floor panel mounting screw 8 N m 0 8 kgf m 5 9 IbHt FRAME BODY PANELS EXHAUST SYSTEM 111 2 11 ...

Page 52: ...ollowing front hood page 2 12 headlight assembly page 22 3 Disconnect the headlight sub harness 2P black connector 1J and release the wire band 21 Remove Ihe six clips 3 four bolts 41 and front grille 51 Installation is in the reverse order of removal FRONT HEAT GUARD REMOVAL INSTALLATION 2 12 Remove the following front hood page 2 12 three clips 1 Remove the front heat guard 2 by releaSing the bo...

Page 53: ...ide cover socket bolt 9 N m 0 9 kgf m 6 6 IbHt FRONT DOOR PANEL REMOVAU NSTALLATION Open the door Support the bottom of the front door panel 1 Remove the four socket bolts 2J and the door panel Close and latch the Installation is in the reverse order of removal door before lightening the bolts TORQUE Front door hinge socket bolt 30 N m 3 1 kgf m 22Ibf ft After installation make sure the door latch...

Page 54: ...ive force and opens smoothly If necessary loosen the socket bolls and adjust the door panel position If the door rattles when closed turn the door stopper rubber 3J so that the door latches on the second click DOOR HINGE REMOVAU INSTALLATION Front shown Remove the E clip 1 pivot pin 21 and door hinge 3 Remove the bushing 4 from the lower side Installation is in the reverse order of removal DOOR HA...

Page 55: ...e screws 4 rear seat latch cover 5 Installation is in the reverse order of removal REAR SEAT LATCH REMOVAU INSTALLATION 4 PERSON TYPE ONLY Remove the following rear seat latch cover page 2 15 two latch plate mounting bolts 111 pivot bolt 2 two mounting bolts 3 rear seat latch 4 hook 51 lever 6 spring 7 by releasing the end off of the door latch plate 8 Installation is in the reverse order of remov...

Page 56: ...connector 1 J combination meier 10P gray connector 2 ignition switch 5P black connector 3 Remove the following drive mode selector lever knob 1 eight clips 2 four screws 1 3 Release the clips 4 from the retaining bar 5 and remove the instrument panel 6 When installing the lever knob install with the tab 7 facing the front 2 16 Installation is in the reverse order of removal TORQUE Instrument panel...

Page 57: ...erator pedal assembly page 7 17 instrument panel page 2 16 floor panel page 2 11 Disconnect the accessory socket 2P black connector 11I Remove the seven setting bolts 1 J and the front floor cover 2 Installation is in the reverse order of removal 11I FRONT BUMPER Remove the foUowing two lower side bolts 1 two side bolts 2 four nuts 3 and bolts 4 front bumper 5 Installation is in the reverse order ...

Page 58: ...2 and remove the nuts 3 and damper Remove the supports and lower the cargo bed Installation is in the reverse order of removal CARGO BED REMOVAU INSTALLATION 11 Release the two wire bands 1 and disconnect the 2 18 brakeflaillight 6P connector 2 Remove the bed damper page 2 18 Remove the two nuts 3 and pivot bolts 4 While holding on to the bed frame and being careful not to damage the brake taillig...

Page 59: ... 6 IbHt 2 PERSON TYPE Remove the following brake taillight page 22 4 three special bolts 1 mounting bolt 2 Remove the bed side covef 3J while pulling oul the brake taillight wire 4 from the hole Installation is in the reverse order of removal TORQUE Bed side cover mounting bolt 9 N m O g kgf m 6 6 Ibf ft Bed side cover special bolt 12 N m 1 2 kgf m 9lbHt REAR STEP GUARD REMOVAL INSTALLATION 4 PERS...

Page 60: ... 5 9 IbHt BED FRONT PANEL REMOVAU INSTALLATION 4 PERSON TYPE Remove the following bed center cover page 2 20 twelve screws 1 bed front panel 1 2 Installation is in the reverse order of removal TORQUE Bed front panel screw 8 N m 0 8 kgf m 5 9 IbHt 2 PERSON TYPE Remove the following bed lop cover page 2 21 len screws 1 J four clips 2 bed front panel 3 Installation is in the reverse order of removal ...

Page 61: ... in the reverse order of removal TORQUE Bed top cover screw 8 N m 0 8 kgf m 5 9 IbHt 161 121 1 31 11 rr 8 111 2 PERSON TYPE Remove the following bed side covers page 2 19 four nuts 1 bolts 2J and hooks 3J twenty screws 4 bed lop cover 5 Installation Is in the reverse order of removal TORQUE Bed top cover screw 8 N m 0 8 kgf m 5 9 Ibf ft 121 31 0 0 11 0 0 FRAME BODY PANELS EXHAUST SYSTEM 151 I A e ...

Page 62: ...ver 2 by releasing the hooks 3J from the bed frame Installation is in the reverse order of removal BED RELEASE LEVER REMOVAL INSTALLATION lift up the cargo bed Remove the following six bolts 1 and three upper holders 2J six collars 3 release lever 4J and lower holders S two return springs 6 Inslallation is in the reverse order of removal TORQUE Bed release lever holder bolt 14 N m 1 4 kgf m 10 IbH...

Page 63: ...e following three tapping screws S and pivot pipe 71 cap nul 8j socket bolt 9 washer 10 and support cable socket bolts 111 cable stay 12 and lock lever 13 Installation is in the reverse order of removal TORQUE Lock lever socket bolt 12 N m 1 2 kgf m 9 IbNt Bracket washer screw 8 N m 0 8 kgf m 5 9 IbNt Pivot pipe screw 8 N m 0 8 kgf m 5 9IbHt NOTE The tailgate must be latched on the cargo bed secur...

Page 64: ...ve Ihe following retainer bolts 4 net retainers 5 fronl side net 6 Installation is in the reverse order of removal REAR SIDE NET REMOVAU INSTALLATION 4 PERSON TYPE ONLY 31 Release the net buckle 1 straps 2J and snap hook 3 Remove the following retainer bolts 14 net retainers 5 rear side net 16 Installation is in the reverse order of removal ...

Page 65: ...removal TORQUE Front QPS mounting nut 49 N m 5 0 kgf m 361bHt Tighten the nuts twice in an alternating sequence UPPER MIDDLE OPS REMOVAU INSTALLATION Remove the following fronl seat backrest page 24 fronl OPS page 2 25 rear side OPS page 2 26 four nul caps 1 six nuts 2 and bolls 3 upper middle OPS 4 Installation is in the reverse order of removal TORQUE Upper middle OPS mounting nut 49 N m 5 0 kgf...

Page 66: ...ge 2 28 rear side net page 2 24 rear upper OPS page 2 26 four nul caps 1 four nuts 2 bolts 3 and side net wire 4 rear side OPS IS Installation is in the reverse order of removal TORQUE Rear side OPS mounting nut 49 N m 5 0 kgf m 36 IbHt Tighten the rear lower nuts twice in an alternating sequence REAR LOWER OPS REMOVAU INSTALLATION 4 PERSON TYPE ONLY Remove the following rear side OPS page 2 26 si...

Page 67: ...ssembly 5J Installation is in the reverse order of removal NOTE Before installing check that the retractor locking mechanism functions see below Assemble the wave washers and lock washers of the anchor bolt properly if it was disassembled When installing the retractor align the locating pin 6 with the hole in the frame When installing the anchor bolts make sure there no twists or kinks in the belt...

Page 68: ...24 Ibl tt After installing check the following the belt does not lock when pulled slowly and it will retract automatically when released The seat belt is designed to lock only during a sudden stop each anchor for free movement on the anchor boll If necessary remove the anchor bolt and check that the washers and other parts are not damaged or improperly installed FRONT BUCKLE Remove the left seat b...

Page 69: ... its differential oil drain hole 4 facing the left side as shown MIDDLE UNDER GUARD REMOVAU INSTALLATION Remove the following twelve boils 1J middle under guard 2 Installation is in the reverse order of removal REAR UNDER GUARD REMOVAL INSTALLATION Remove the following six bolts 1 J and special washers 2 rear under guard 3 Installation is in the reverse order of removal 131 oo 0 0 0 crl 1 2 111 CV...

Page 70: ...s 5 muffler 6 and gasket 7 two jOint nuts 8 exhaust pipe 9 and gasket 10 bushings 11 and mount rubber 12 Installation is in the reverse order of removal TORQUE Muffler band bolt 22 N m 2 2 kgf m 16 IbHt If the joint stud bolts 13 are loose tighten them Be sure to verify the distance from the lop of the stud to the cylinder head as shown Always replace the gaskets with new ones Tighten the joint nu...

Page 71: ...fied position MUFFLER DISASSEMBLY ASSEMBLY NOTE For service of the spark arrester in the muffler see Maintenance section page 3 18 loosen the band screws and remove the muffler front cover 11 and muffler rear cover 2 TORQUE Muffler front cover band screw 1 5 N m 0 2 kgf m 1 1 tbf ft Muffler rear cover band screw 3 2 N m 0 3 kgf m 2 4 IbHt Position the cover bands in specified angle Set the exhaust...

Page 72: ...MEMO j 1 1 ...

Page 73: ...TERy 3 7 VALVE CLEARANCE 3 8 ENGINE OIL 3 9 COOLING SySTEM 3 11 DRIVE SHAFT BOOTS 3 12 FINAL DRIVE OIL 3 13 3 MAINTENANCE BRAKE FLUiD 3 14 BRAKE PADS WEAR 3 15 BRAKE LIGHT SWiTCH 3 15 BRAKE SYSTEM 3 16 UNDERBODy 3 17 SUSPENSION 3 18 SPARK ARRESTER 3 18 EXHAUST SySTEM 3 19 WHEELSITIRES 3 19 TIE ROD AND JOINT BOOT 3 19 STEERING SySTEM 3 20 SIDE NET 3 23 CHASSIS LUBRICATION POINTS 3 24 3 1 ...

Page 74: ...operating hours whichever comes first 2 Regular maintenance interval 1 Appears at 600 miles 1 000 km or 100 operating hours after the initial maintenance is periormed and the maintenance minder is reset See regular maintenance interval for 100 300 and 500 operating hours or corresponding mileage interval whichever comes first in the maintenance schedule page 3 3 3 Regular maintenance interval 2 Ap...

Page 75: ...ge 4 29 Check fuel lines and connections page 3 4 Check front and rear brakes page 3 15 and 3 16 NOTE 3 Check front and rear final gear oil page 3 13 Lubricate all hinges latches and pivots page 3 24 Inspect the following Items Suspension components page 3 18 Wheels page 3 19 Drive shaft boots page 3 12 Accelerator throttle operation page 3 4 and brake pedal page 3 16 Brake light SWitch page 3 15 ...

Page 76: ...al side adjuster Remove the front hood page 2 12 Slide the boot 1 off the adjuster 121 loosen the lock nul 3 turn the adjuster as required and tighten the lock nut Install the boot over the adjuster securely The adjustment at Major adjustments are made with the throttle body side the pedal should be adjuster centered before performing major adjustment altM throttle body 4 person type only Remove t...

Page 77: ...aner housing cover 2 and remove the cover Loosen the air deaner element band screw 11 and r remove the air cleaner element assembly 2 from the I 1 0 housing t MAINTENANCE 2 Remove the element band 1J and the element core 121 from the air cleaner element 3 2 Wash the element in non flammable or high flash point solvent Squeeze out the solvent thoroughly and allow the element and filter to dry Wash ...

Page 78: ...e element band onto the air cleaner element and the element assembly over the connecting tube flange of the housing securely Tighten the band screw Install the removed parts in the reverse order of removal NOTE Failure to properly lighten the band screw will allow _____ ____________ the air cleaner element to fall off and engine damage could result AIR CLEANER HOUSING DRAIN TUBE 3 6 NOTE If the ve...

Page 79: ... DENSO SIDE elECTRODE Clean Ihe spark plug electrodes with a nylon wire type brush or special plug cleaner INSULATOR Check the gap between the center and side electrodes with a wire type feeler gauge SPARK PLUG GAP 1 00 1 10 mm 0 039 _ 0 043 in 1 00 1 10 mm 0 039 0 043 In J If necessary adjust the gap by bending the side l electrode carefully Thread the spark plug in by hand to prevent cross threa...

Page 80: ... Top Dead Center on the crankshaft only the compression stroke clockwise again This position can be obtained by confirming that there is and align This slack in both rocker arms If there is no slack it is must be done 0 because the piston is moving through the exhaust p 9venr the one stroke to TDC Rotate the crankshaft one full turn and way decompressor match up the r mark again system from functl...

Page 81: ...EL CHECK NOTE Check the oil level after starting the engine and allowing the oil to circulate through the engine thoroughly It is especially important on a dry sump engine due to the comparatively large volume of oil Do not snap Ihe throttle while idling or the oil level reading will be inaccurate Place the vehicle on level ground Start the engine and let it idle for 3 5 minutes If the air tempera...

Page 82: ... vehicle on level ground Remove the maintenance lid page 2 18 Remove the filter cap release the rubber sheet from the tabs Start the engine and let it idle for a few minutes Stop the engine Remove the drain bolt 1 to drain the engine oil Remove the D ring 11 and sealing washer 21 from the drain bolt 3J Install a new sealing washer onto the drain bolt Coat a new D ring with oil and instal it into t...

Page 83: ... with the engine running at normal operating temperature The level should be between the MAX level line 1 and MIW level line 2 with the vehicle upright on a level surface If the level is low remove the reserve tank cap 13 and fill the tank up to the MAX level line with a 1 1 mixture of distilled waler and antifreeze coolant preparation page 9 5 RECOMMENDED ANTIFREEZE Pro Honda HP coolant or an equ...

Page 84: ...re tight Remove the front grille page 2 12 Check the radiator air passage for clogs or damage Straighten bent fins with a small flat blade screwdriver and remove insects mud or other obstructions with compressed air or low pressure water Replace the radiator if the air flow is restricted over more than 20 of the radiating surface DRIVE SHAFT BOOTS Check the drive shaft boots 11J for culs or other ...

Page 85: ...Z 23 4 Imp oz at drainIng 760 cml 25 7 US OZ 26 8 Imp oz at disassembly REAR FINAL GEAR CASE LEVEL CHECK Place the vehicle on a level surface Remove the oil filter cap 1 and check Ihalthe 011 level is to the lower edge of the oil filler hole Check for leaks if the oil level is low Pour the oil through the filler hole until it reaches the lower edge of Ihe hole RECOMMENDED OIL Hypoid gear oil SAE 8...

Page 86: ...ut and this causes a low reservoir level If the brake pads are not worn and the fluid level is low check entire system for leaks page 3 16 Check the fluid level of the reservoir If the level is near the MIN levelline 1J add the brake nuid as follows Remove the front hood page 2 12 Remove the cap cover 2 and the reservoir cap 131 and fill the reservoir with DOT 4 brake fluid from a sealed container...

Page 87: ... rear brake pads for wear Replace the brake pads if the wear limit indicator mark 1 on the caliper aligns with the reference mark 2 on the caliper bracket when the brake is applied For rear brake pad replacement page 20 8 BRAKE LIGHT SWITCH Check that the brake light comes on just prior to the brake actually being engaged If the light fails to come on adjust the brake light switch 1 so thai the li...

Page 88: ...2S 40mm 1 1 315In Adjust the pedal height as follows Remove the lock plate bolt T50 3 and lock plate 4J Loosen the lock nul 51 and turn Ihe adjusting bolt T50 6 as required Temporarily tighten the lock nut while holding Ihe adjusting nul Make sure the brake pedal freeplay at the end of the pedal is within 1 5 mm If the freeplay is not within standard value loosen the lock nut and turn the adjustin...

Page 89: ... 3f8 in If the freeplay is nol as specified adjust the parking brake as follows Adjust the parking brake lever freeplay by turning the adjusting nut 1 Release the parking brake lever fully and check thai the brakes do nol drag when the rear wheels are turned Readjust if necessary UNDERBODY Check the under guards 1 for cracks or damage Replace the under guards page 2 29 as required MAINTENANCE 11 3...

Page 90: ...spension arms 2 for damage or defonnation Replace worn loose or damaged components that cannot be repaired Tighten all nuts and bolls SPARK ARRESTER 3 18 Remove the three bolts 1 J and the spark arrester 2J with the gasket 13J Use a brush to remove carbon deposits from the screen mesh 4 being careful nol to damage it The screen mesh must be free of breaks and holes Replace the spark arrester jf ne...

Page 91: ...ions using a tire depth gauge Replace the tires when the tread depth reaches the following limit MINIMUM TREAD DEPTH Front Rear 4 mm 0 2 in Raise the wheels off the ground and check the bearings in the hub for excessive play or abnormal noise Check the wheels for crack deformation or damage Check the wheel nut are tightened Torque any loose nut TORQUE Front Rear 133 N m 13 6 kgf m 981bHt TIE ROD A...

Page 92: ...ent inspect for looseness of the steering column and gear box fasteners and the steering linkage joints page 17 4 ROTATIONAL PLAY CHECK 1J 2J Set the front wheels in the straight ahead position with 1 all the wheels on the ground 3 20 Measure how far you can turn the steering wheel 1 left and right without moving the front wheels ROTATIONAL PLAY 0 10 mm 0 215 in If the play exceeds the limit adjus...

Page 93: ...page 17 9 RACK GUIDE ADJUSTMENT Remove Ihe right front wheel page 19 6 Set the left front wheel in the straight ahead position Loosen the screw lock nut 1 with the special 1001 then loosen the rack guide screw 2 TOOL Lock nut wrench 3 07MAA SL00101or 07916 SA50001 or 07AAA TL2A100 U S A only Tighten the rack guide screw until it is stops then loosen it Tighten the rack guide screw to 4 9 N m 0 5 k...

Page 94: ...i aligned with the gauge height i i Measure Ihe toe on Ihe rear part of the tires at the same i I points with no load on Ihe vehicle TOE IN 0 10 mm 0 2 5 in NOTE The front and rear measurements are the same for this vehicle Rear When Ihe toe is out of specification adjust it by changing the length of both tie rods 1 equally by loosening the lock nuts 2 and turning each tie rod while holding Ihe ba...

Page 95: ...Turn the wheels left and right with no foot brake applied and measure the turning radius angle of both wheels TURNING RADIUS ANGLE Inward 41 Outward 33 reference If the measurements are not to specification even up both sides of the tie rod 2 thread length while adjusting the toe page 3 22 Check the side net 1 webbing for tear or damage Visually inspect the snap hooks 2 buckle 3 and side net rings...

Page 96: ...ers and latch pivot D tailgate pivots page 2 23 E door latches F brake pedal pivot page 20 26 G accelerator pedal pivot page 7 17 H parking brake lever pivot page 20 27 I drive mode selector lever pivots page 18 63 J gear selector lever pivots page 13 16 Check for smooth operation after lubrication c B 0 Front E Rear F _ _ G 9 C0 I E J 3 24 1 1 1 1 ...

Page 97: ... FI SYSTEM DIAGRAM 4 5 PGM FI TROUBLESHOOTING INFORMATION 4 6 PGM FI DTC INDEX 4 9 PGM FI DTC TROUBLESHOOTING 4 10 4 PGM FI SYSTEM MIL CIRCUIT INSPECTION 4 25 TP SENSOR MAP SENSOR SENSOR UNIT 4 25 ECT SENSOR 4 27 IAT SENSOR 4 27 VS SENSOR 4 27 PCM 4 28 ENGINE IDLE SPEED 4 29 4 1 ...

Page 98: ...se of the numerical values of a situation preset in advance in the simulated program map It must be remembered however that when any abnormality is detected in fuel injector andlor the CKP sensor the fail safe function stops the engine to protect it from damage Prevent dirt and debris from entering the throttle bore IACV sensor hole clean them using compressed air A faulty PGM FI system is often r...

Page 99: ...ine stalls hard to start 1 Check the idle speed Restricted fuel feed hose rough idling page 4 29 Contaminated deteriorated fuel Backfiring or misfiring during acceleration Poor performance driveability and poor fuel economy 2 Check the IACV page 7 23 Intake air leak 3 Inspect the fuel supply system Restricted fuel tank breather hose page 7 5L __ __________ r F a u lt y ig n it io n system Check th...

Page 100: ... LOCATION IAT SENSOR IACV I VS SENSOR BATIERY MAIN FUSE 40 A PCM FUEL INJECTOR FUEL PUMP MAP SENSOR TP SENSOR SENSOR UNIT Eer SENSOR CKP SENSOR GEAR POSITION SWITCH 4 4 DLC MAIN RELAY FUEL PUMP RELAY FUSE BOX I j 1 I j I 1 1 ...

Page 101: ... 813 LG 821 POI a10 PG2 A Engme does not stan PCM C t Short temmats for reading DTC Bt Blacll Sf Brown Su Blue G Green Gr Gray Lg Ught green o Orange R Red V Violet W While Y Yellow P Pink c SMR 831 FlR 820 INJ B33 tON 811 PCM 33 21 lACV l 1ACV 1B lACV 2A 830 IACV 26 M TXOXO 1 21 p co K liNE 811 SCS 829 C 3 A_1 CO A 23 r FUEL PUMP RELAY G FUEL PUMP FUEL INJECTOR 12 1 BUR SERIAl IGNITION COIL SPARK...

Page 102: ...gine to protect it from damage OTe Diagnostic Trouble Code The OTC is composed of a main code and a sub code and it is displayed as a hyphenated number when retrieved from the PCM with the MCS The digits In front of the hyphen are the main code they indicate the component of function failure The digits behind the hyphen are the sub code they detail the specific symptom of the component or function...

Page 103: ...NFORMATION The MCS can readout the DTG stored data current dala and other peM condition How to connect the MCS Tum the ignition switch to OFF 0 Remove the front hood page 2 12 Remove the OLC 11 from the dummy connector 21 Connect the MCS to the OLC Tum the ignition switch to ON I and check the OTe and stored data NOTE Stored data indicates the engine conditions when the first malfunction was detec...

Page 104: ...tor 2J 070PZ ZY30100 CONNECTION Brown red Green 3 Turn the ignition switch to ON I 4 Remove the special tool from the OlC 5 The Mil will light for approximately 5 seconds While the MIL lights short the OLC again with the special tool The OTC is erased if Ihe MIL goes off and slarts blinking NOTE The OLC must be shorted while the MIL lights If not the MIL will not start blinking Note that the OTe c...

Page 105: ...n 4 981 V Poor engine acceleration TP sensor or its circuit malfunction Fail safe value 0 AfT shift function and anti creep function does not work 2nd gear only 9 1 IAT sensor circuit low voltage less than 0 015 V Engine operates normally 4 17 IAT sensor or its circuit malfunction Fail safe value 34 8 C 94 6 F 9 2 IAT sensor circuit high voltage more than 4 981 V Engine operates normally 4 18 Loos...

Page 106: ... Sensor Input Line Inspection Turn the ignition switch to OFF 0 Disconnect the peM 33P gray connector 1 Brownlwhite 83 page 4 28 Check the wire for continuity between the wire harness side 5P connector 2J and 33P gray connector terminals TOOL Test probe 2 pack 07ZAJ ROJA110 Connection Brown white B3 Brown white Is there continuity YES Replace the PCM with a known good one and recheck NO Open circu...

Page 107: ... poor contact on the sensor unit 5P connector 2 MAP Sensor System Inspection 2 Turn the ignition switch to OFF 0 Disconnect the sensor unit5P connector 1 page 4 25 Connect the wire harness side 5P connector terminals with a jumper wire 2J Connection Light green yellow Green red Turn the ignition switch to ON I Check the MAP sensor with the MCS Is about 0 V indicated YES Faulty sensor unit MAP sens...

Page 108: ...em Inspection Turn the ignition switch to ON I Check the EeT sensor with the MeS Is about 0 V indicated YES GO TO STEP 2 NO Intermittent failure 2 EeT Sensor Inspection Tum the ignition switch to OFF OJ Disconnect the ECT sensor 2P connector page 4 27 Turn the ignition switch to ON I Check the ECT sensor with the MCS Is about 0 V indicated YES GO TO STEP 4 NO GO TO STEP 3 3 ECT Sensor Resistance I...

Page 109: ...r for loose or poor contacts and recheck the DTG 1 Eel Sensor System Inspection Turn the ignition switch to ON I Check the Eel sensor with the MeS Is about 5 V indicated YES GO TO STEP 2 NO Intermittent failure Loose or poor contact on the EeT sensor 2P connector 2 EeT Sensor Inspection Turn the ignition switch to OFF 0 DIsconnect the ECT sensor 2P connector 111 page 4 27 Connect the wire harness ...

Page 110: ...or for loose or poor contacts and recheck the OTC 1 TP Sensor System Inspection Turn the ignition switch to ON I Check the TP sensor with the MCS with the throttle fully closed Is about 0 V indicated YES GO TO STEP 3 NO GO TO STEP 2 2 TP Sensor Inspection Check that the TP sensor voltage increases continuously when the throttle is moved from fully closed position to fully open position using the d...

Page 111: ...33P gray connector 2J terminals TOOL Test probe 2 pack 07ZAJ RDJA110 Connection Yellow blue B14 Yellow blue Is there continuity YES GO TO STEP 6 NO Open circuli in the Yellow b ue wire 6 TP Sensor Output Line Short Circuit Inspection PGM FI SYSTEM Brown white 83 c Q 111 1 1 I I Q I YelloW lue Yellow blue 814 Check the wire for continuity between the wire C harness side 5P connector 1 terminal and ...

Page 112: ...re NO Faulty sensor unit TP sensor 3 TP Sensor Resistance Inspection Turn the ignition switch to OFF 0 Disconnect the sensor unit 5P connector page 4 25 Measure the TP sensor resistance between the sensor unit side 5P connector terminals Is the res stance within 1 0 3 0 kQ YES GO TO STEP 4 NO Faulty sensor unit TP sensor 4 TP Sensor Input Voltage Inspection Turn the ignition switch to ON I Measure...

Page 113: ...rn the ignition switch to OFF 0 Measure the resistance between the side connector terminals Standard 2 2 2 1 kO 20 CI68 F IAT senso I Is the resistance within standard value 7 YES Replace the PCM with a known good one and recheck NO Faulty tAT sensor 4 tAT Sensor Output line Short Circuit Inspection Turn the ignition switch to OFF 0 Disconnect the peM 33P gray connector page 4 28 Check for continu...

Page 114: ...e 2 Connection Gray blue Green red Turn the ignition switch to ON I Check the tAT sensor with the MeS Is about 0 V indicated YES Faulty tAT sensor NO GO TO STEP 3 3 tAT Sensor Open Circuit Inspection Tum the ignition switch to OFF 0 Remove the jumper wire Disconnect the PCM 33P gray connector lJ page 4 28 Check the wires for continuity between the IAT sensor 2P connector 12 and PCM 33P gray connec...

Page 115: ...ch to ON I Measure the voltage between the wire harness side 3P connector terminal and ground Connection Black ground Is there battery voltage YES GO TO STEP 3 NO Open circuit in the Black wire 3 VS Sensor Ground Line Inspection Measure the voltage between the wire harness side 3P connector 1 terminals Connection Black Green I Is there battery voltage YES GO TO STEP 4 NO Open Clrcuil in the Green ...

Page 116: ...hedl the fuel injector with Ihe MeS Is ore 12 1 indicated NO Intermittent failure Loose or poor contact on the fuel injector 2P gray connector YES GO TO STEP 2 2 Fuel Injector Resistance Inspection Turn the ignition switch to OFF 0 Disconnect the fuel injector 2P gray connector page 7 24 Measure the resistance between the injector side connector terminals Standard 11 1 12 3 a 20 C 68D Fj Is the re...

Page 117: ...Greenlwhile wire NO Replace the PCM with a known good one and recheck DTC 29 1 IACV Before starting the troubleshooting check the IACV 4P black connector for loose or poor contacts and recheck the o TC 1 Recheck OTC Erase the DTC page 4 8 Start the engine and check the oTC with the MCS Is Dre 29 1 indicated NO Intermittent failure loose or poor contact on the IACV 4P black connector YES GO TO STEP...

Page 118: ... the Black red or Brown wire Open circuit in the Brown blue or Brown yellow wire 4 IACV Resistance Inspection 1 88 I 89 Black red 2 Brown yeUow I 830 __ Brown Brown blue Measure the resistance between the IACV side 4P connector terminals Connection 1A 18 2A 28 Standard 120 140 0 20 C 68 F 18 lA Is the resistance within the standard value YES GO TO STEP 5 NO Faulty IACV 28 2A 5 IACV Short Circuit I...

Page 119: ...P 2 NO Intermittent failure 2 Drive Power Input Line Inspection Turn the ignition switch to OFF 0 Disconnect the PCM 5P black connector 1 Turn the ignition switch to ON I Measure the voltage between the wire harness side 5P black connector terminal and ground Connection BlackJred Ground Is there battery voltage YES Replace the PCM with a known good one and recheck NO GO TO STEP 3 3 Main Relay Insp...

Page 120: ... the main relay normal YES GO TO STEP 3 NO Faulty main relay 3 Main Relay Coli Ground line Short Circuit Inspection Oisconnecllhe PCM 33P gray connector page 4 28 Check for continuity between the Gray wife terminal of the main relay connector 1 and ground Is there continuity YES Short circuit in the Gray wire NO GO TO STEP 4 4 Drive Power Input Voltage tnspection Turn the ignition switch to OFF 0 ...

Page 121: ...uity check for short circuit in Brown red L ______ wire between the OLC and PCM If there is no continuity replace the PCM with a known good one and recheck TP SENSOR MAP SENSOR SENSOR UNIT REMOVAL INSTALLATION NOTE After replacing the sensor unit the TP sensor reset procedure must be performed page 4 26 4 person type only Remove the left rear fool well page 2 10 Disconnect the sensor unit5P connec...

Page 122: ...r wire 2 3 Turn the ignition switch to ON I The MIL starts blinking reset receiving pattern Within 10 seconds after turning the ignition switch to ON I disconnect the jumper wire from the 2P connector 4 When the reset procedure is complete the MIL blinking changes from Reset Receiving Pattern to Confirmation Pattern Turn the ignition switch to OFF 0 If more than 10 seconds elapse or the procedures...

Page 123: ... cargo bed Disconnect the IAT sensor 2P connector 1 Remove the IAT sensor 2 from the grommet in the air cleaner housing Installation is in the reverse order of removal VS SENSOR REMOVAL INSTALLATION Slide the connector cover off the VS sensor 3P connector 1 and disconnect the connector Remove the boll 21 VS sensor 3 and O ring 4 from the rear final reduction case Coat a new O ring with engine oil ...

Page 124: ... there is no continuity check for an open circuit in the green wires POWER INPUT LINE Tum the ignition switch to ON I Measure the voltage between the wire harness side 33P gray connector 1 terminal and ground TOOL Test probe 2 pack 07ZAJ RDJA110 Connection Red white 81 ground H There should be battery voltage If there is no voltage check the following Redlwhite wire for open circuit between the PC...

Page 125: ...engine must be warm for accurate idle speed inspection This system eliminates the need for manual idle speed adjustment compared to previous designs Use a tachometer with graduations of 50 rpm or smaller that will accurately indicate a 50 rpm change Remove the front seat cushion page 2 4 Start the engine and warm it up to coolant temperature 80 C 176 O F Stop the engine and connect a tachometer ac...

Page 126: ...MEMO ...

Page 127: ...COMPONENT LOCATION 5 2 SYSTEM DIAGRAM 5 2 SERVICE INFORMATION 5 3 TROUBLESHOOTING 5 4 5 IGNITION SYSTEM IGNITION SYSTEM INSPECTION 5 5 IGNITION COIL 5 7 IGNITION TIMING 5 8 5 1 ...

Page 128: ...N RELAY lrrill BWY MAIN RELAY IGNITION SWITCH fUSE BOX 81 Black G Green Gr Gray R Red Y Yellow W While Bu Blue G GIB RfW Br t G IT L ____________ L B UR 1 3 FIFUSE 10A L ______ R1W RlBI R Q O BuNoI 5 2 Bm G 0 11 CKP SENSOR IGNITION COIL I BUR f G cRITION H IGN FUSE 15 A G Bu R Q R MAIN FUSE 40 A t SPARK PLUG BI1 BATIERY ...

Page 129: ...age 5 4 This ignition system is controlled by PCM The transistorized ignition system uses an electrically controlled ignition liming system No adjustments can be made to the ignition timing A faulty ignition system is often related to poor connections Check those connections before proceeding Make sure the battery is adequately charged Using the starter motor with a weak battery results in a slowe...

Page 130: ...an open circuit in the Greenfblue wire between the ignition coil and PCM 6 A short circuit in the ignition primary coi1 7 Faulty CKP sensor Measure the peak voltage B Faulty PCM in case when above No 1 through 7 are normal Initial voltage is normal but 1 Incorrect peak voltage adaptor connections System is normal if there is no peak voltage while measured voltage is over the specifications with re...

Page 131: ...TOOLS IgnitionMate peak voltage tester MTP07 0286 U S A only or Peak voltage adaptor 07HGJ 0020100 Not available in U S A with commercially available digital muttimeler impedance 10 MOJOCV minimum IGNITION COIL PRIMARY PEAK VOLTAGE NOTE Check all system connections before this inspection Poor connected connectors can cause incorrect readings Check the cylinder compreSSion and check that the spark ...

Page 132: ...ng chart page 5 4 CKP SENSOR PEAK VOLTAGE NOTE Check that the cylinder compression is normal and the spark plug is installed correclly in the cylinder head Remove the front seat cushion page 2 4 Disconnect the PCM 33P gray connector 1 NOTE When reconnecting the PCM 33P gray connector check that there is no dirt and oil in the connector Connect the peak voltage tester or adaptor probes to the wire ...

Page 133: ...he one measured at the alternator connector is normal the Blue yellow wire has an open or short circuit or loose connection If both peak voltages are abnormal follow the checks described in Ihe troubleshooting chart page 5 4 If Ihe CKP sensor is faulty replace the alternator CKP sensor assembly page 12 7 IGNITION COIL REMOVAL INSTALLATION 4 person type only Remove the left rear foot well page 2 10...

Page 134: ...t the engine let it idle and check the ignition timing The ignition timing is correct if the F mark 1 on the 2 flywheel is visible from the timing hole 2 in the rear 5 8 crankcase cover at idle Increase the engine speed and make sure the F mark begins to move Coat a new O ring with oil and instal it onto the timing hole cap Instalithe timing hole cap and lighten it TORQUE 10 N m 1 0 kgf m 7 lbHt I...

Page 135: ...6 ELECTRIC STARTER COMPONENT LOCATION 6 2 STARTER MOTOR 6 4 SYSTEM DIAGRAM 6 2 STARTER RELAY SWITCH 6 8 SERVICE INFORMATION 6 3 DIODE 6 9 TROUBLESHOOTING 6 3 BRAKE INHIBITOR RELAy 6 10 6 1 ...

Page 136: ... Gr Gray R Red Bf Brown I e Y Veliow Lg Light green STARTER MOTOR M BI BII IGNITION SWITCH t GiSU Lg N o 0 o GEAR POSITION SWITCH 6 2 peM IBu BI IBr G GI LgiR VIR R J O R MAIN FUSE DIODE 40 A W BI S Y R VIR 0 0 BUR BRAKE INHIBITOR RELAY WtBI G L START FUSE 10 A I R JlRiBI L II _ _ l _ B_ R GI PIGN FUSE 15 A MAIN RELAY BuM 4 B lWj BoiW SX BI BRAKE LIGHT J SWITCH BulBI 00 GfY 0 BI Bu I 1 1 1 J 4 I j...

Page 137: ...ied Starter molar Unusual condition Probable cause Che k in numerical order Starter motor does not turn 1 Loose or poor contact on related connectors and terminals 2 Blown fuse 3 Weak battery 4 Loose connection open or short Circuit in starter motor cable 5 Faulty starter relay switch 6 Faulty starter motor 7 Faulty gear position switch 8 Faulty brake inhibitor relay 9 Faulty brake light switch IO...

Page 138: ...bolts 3J hose guide 4J and starter motor 15 Remove the O ring 11 from the starter motor 2 Installation is in the reverse order of removal Apply engine oil to a new O ring DISASSEMBLY ISJ Disassemble the starter motor according to the illustration Record the location and number of shims CASE BOLTS SHIMS BRUSH HOLDER 6 4 O RING WASHER NUT INSULATOR WASHERS INSULATED BRUSH INSULATOR MOTOR CASE ARMATU...

Page 139: ...for wear or damage 12 Check the commutator bars 1 of the armature for discoloration NOTE Do nol use emery or sand paper on the commutator Check for continuity between pairs of commutator bars C O N T N U TY I 11 There should be continuity Check for continuity between each commutator bar 1 and the armature shaft 2 There should be no continuity NO CONTINUITY 6 5 ...

Page 140: ...inuity Check for continuity between the insulated brush 1J and motor case 2 There should be no continuity Measure the brush length SERVICE LIMIT 6 5 mm 0 26 in ASSEMBLY Install the following insulator 1 insulated brush 2 cable terminal 3 new O ring 4 insulator washers 5 washer 6 nut 71 CONTINUITY 121 1 121 161 111 ...

Page 141: ...net pulls the armature against the case Install the same number of shims 1 in the same location as noted during removal Install a new seal ring 2J onto Ihe molor case Apply a thin coat of grease to the armature shaft end Install the rear cover 3 aligning its groove with the brush holder tab ELECTRIC STARTER Align Install the shims Install the shims 1 and insulated washer 2 onto the properly as not...

Page 142: ...ctor 1 Pull off the terminal covers 2 Remove the terminal nuts 3J and washers 4 then disconnect the relay cables Remove the starter relay switch 5 Installation is in the reverse order of removal OPERATION INSPECTION Remove the front seat cushion page 2 4 Shift the sub transmission into neutral Tum the ignition switch to START II The coil is normal jf the starter relay switch 1 Jclicks If you don h...

Page 143: ...ly when the ignition switch is turned to START II the power input circuit is normal FUNCTION INSPECTION Disconnect the negative cable from the battery page 21 4 Disconnect the starter relay sWitch 2P green connector Remove the battery cable and starter motor cable from the starter relay Connect the fully charged 12 V battery positive terminal to the Yellow red wire termmal and negative terminal to...

Page 144: ...x cover page 6 9 Tum the ignition sWitch to OFF 0 Remove the brake inhibitor relay 11 from the connector Installation is in the reverse order of removal RELAY INSPECTION Remove the brake inhibitor relay page 6 10 Check for conllnuily between the No 1 and No 2 terminals Connect the fully charged 12 V battery terminal to the relay NO 4 terminal and the terminal 10 the NO 3 terminal There should be c...

Page 145: ...tage between the Black red wire terminal of the brake inhibitor relay connector 1 and ground Is there battery voltage YES GO TO STEP 3 NO Open circuit in the Black red wire between the junction connector and brake inhibitor relay connector 3 Relay Coil Power Ground Line Inspection Turn the ignition switch to OFF 0 Disconnect the PCM 33P black connector page 4 28 Check for continuity between the Br...

Page 146: ...e inhibitor relay connector and ground There should be battery vollage when the ignition switch is turned to START II Is there battery voltage YES The brake inhibitor relay circuits are normal NO Open circuit in the White black wire between the junction connector and brake inhibitor relay connector While black 111 1 1 1 1 l 1 1 1 ...

Page 147: ...FORMATION 7 4 FUEL LINE INSPECTION 7 5 FUEL PUMP 7 9 MAIN RELAY FUEL PUMP RELAy 7 13 FUEL TANK 7 15 7 FUEL SYSTEM AIR CLEANER HOUSING 7 16 INTAKE AIR DUCT 7 17 ACCELERATOR PEDAL 7 17 THROTTLE BODy 7 19 IACV 7 23 FUEL INJECTOR 7 24 7 1 ...

Page 148: ...FUEL SYSTEM SYSTEM COMPONENTS f 1 1 ______ A cd 7 2 ...

Page 149: ...FUEL SYSTEM rn v 7 3 ...

Page 150: ...ter the throttle body has been removed Do not damage the throttle body II may cause incorrect throtlle valve operation Prevent dirt and debris from entering the throttle bore IACV sensor hole and fuel feed hose clean them using compressed air The throttle body is factory pre set Do not disassemble in a way other than shown in this manual Do not loosen or tighten the white painted bolts nuts and sc...

Page 151: ... to OFF 0 QUICK CONNECT FITTING REMOVAL NOTE Before disconnecting fuel feed hose relieve the pressure from the system page 7 5 Do not bend or twist fuel feed hose Fuel injector side 1 Remove the left middle fender page 2 8 2 Clean the quick connect fitting if necessary and place a shop lowel over the Quick connect filling 3 Pull and release the connector damper 1 from the retainer 2 Fuel injector ...

Page 152: ...s Use Ihe specified special tool only If the connector does not move keep Ihe retainer tabs pressed down and alternately pull and push the connector until it comes off easily 1 2 3 4 5 To prevent damage and keep foreign matter oul 7 6 cover Ihe disconnected connector and pipe end with the plastic bags 1 QUICK CONNECT FITTING INSTALLATION NOTE Always replace the retainer and connector damper of the...

Page 153: ...firmly locked into place check visually and by pulling Ihe connector 2 4 Make sure the connector damper 3 is positioned correclly between the pipe 4 and retainer tabs 5 Fuel injector side 5 Instalilhe left middle fender page 2 8 6 Increase the fuel pressure page 7 7 FUEL PRESSURE INCREASING 1 Connect the fuel pump 4P connector 11 Do not staft the 2 Turn the ignition switch to ON I engine The fuel ...

Page 154: ...t idle Read the fuel pressure Standard 331 367 kPa 3 4 3 7 kgflcm 48 S3 psi If the fuel pressure is higher than specified pressure replace the fuel pump faulty fuel pump or fuel pressure regulator If the fuel pressure is lower than speCified pressure inspect the following fuel flow page 7 8 pinched or clogged fuel feed hose fuel pump page 7 9 Disconnect the fuel pump 4P connector start the engine ...

Page 155: ... install the fuel pump relay page 7 13 FUEL PUMP INSPECTION Remove the right rear side cover page 2 10 Turn the ignition switch ON I and confirm thai the fuel pump operates for a few seconds If the fuel pump does not operate inspect as follows Turn the ignition switch to OFF 0 Disconnect the fuel pump 4P connector IJ Turn the ignition switch to ON 1 and measure the voltage between the wire harness...

Page 156: ...ocking ring 1 by rotating it counterclockwise using the special tool TOOL Fuel pump lock ring wrench SPX OTe 6599 2J commercially available in the U S A Be careful not to Remove the locking ring and fuel pump assembly 3 bend the floa arm from the fuel lank 7 10 Remove the O ring 1 DISASSEMBLYIASSEMBLY Disconnect the fuel level sensor connector 11J and fuel pump connector 21 Release the wires from ...

Page 157: ...he pump retainer 2 When installing the retainer align the tabs 3 of the retainer and pump body Release the hooks 1 and pull out the fuel filter 3 assembly 2 from the fuel pump body 3 l 2 Disconnect the connector 1 and remove the fuel filter assembly 2 from the fuel pump body 3 S Remove the O ring 41 and spacer 51 Apply small amount of engine oil to a new O ring 5 2 l 7 11 ...

Page 158: ...allowed Always replace the 0 rin9 with a new one Install a new O ring 1 onto the fuel tank 8 careful not to Instailihe fuel pump assembly I into the fuel tank by damage or pinch aligning its lab with the index mark on the fuel tank the O ring 7 12 Inslall a new locking ring 11J and tighten it by rotating it clockwise using the special tool until the grooves of the locking ring 2 align with the mar...

Page 159: ...nal and the lerminallo the NO 3 terminal There should be continuity when the battery is connected and no continuity when the battery is disconnected MAIN RELAY CIRCUIT INSPECTION 1 Power Input Line Inspection Remove the main relay page 7 13 Measure the voltage between the Bluefwhite wire terminals of the main relay connector 1 and ground Is there battery voltage YES GO TO STEP 2 NO Open circuit in...

Page 160: ...ge between the Black red wire terminals of the fuel pump relay connector 1 and ground Is there battery voltage YES GO TO STEP 2 NO Open circuit in the Black red wire between the main relay and fuel pump relay connectors Faulty main relay or its circuits 2 Relay Coli Ground Line Inspection Turn Ihe ignition switch to OFF 0 Check for continuity between the Violet wire terminal of the fuel pump relay...

Page 161: ...e the following right seat bottom cover page 2 8 right reaf side cover page 2 10 Release the fuel tank breather hose 1 from the clips 121 Release the fuel feed hose 3 from the clamp 4J Remove the two washer bolts 5J bolt 6 and collar 7 Remove the fuel tank 8 with the tank band 91 Oul of the frame to the right side Installation is in the reverse order of removal Connect the quick connect filting pa...

Page 162: ... housing Release the fuel feed hose 5J from the clamp 6 Loosen the air cleaner connecting tube band screw 171 and intake air ducl band screw 8 Remove the washer screw 9 and two bolls 10 Release Ihe connecting tubes off of the throttle body and intake air duct and remove the air cleaner housing Set Ihe duel so ils Installation is in the reverse order of removal stoppers are fully TORQUE seated on h...

Page 163: ...uct cap 71_ Installation is in the reverse order of removal 111 13 141 ACCELERATOR PEDAL REMOVAL INSTALLAnON Release the cable retainer Yellow 1 by pulling it to the right side to disconnect the inner cable 2 from the accelerator pedal 3 Remove the bolt 4 10 disconnect the outer cable from the bracket Remove the two bolts 5J and accelerator pedal assembly Installation IS in the reverse order of re...

Page 164: ...ove the following cotter pin 31 and washer 4 pivot shaft 5 accelerator pedal return spring 6 collar 7 dust seals 8 ASSEMBLY Coal the lips of new dust seals 1 with grease Install the dust seals into the accelerator pedal 2J with the fiat sIde facing out untillhey are fully seated k 17J 12J I l 1 ...

Page 165: ...pring end 7 onto the pedal Install the washer 8J and a new cotter pin 9 THROTTLE BODY REMOVAL NOTE If the TP sensor MAP sensor sensor unit is removed from the throttle body the TP sensor reset procedure must be performed after installing the throttle body page 4 26 Relieve the fuel pressure page 7 5 Disconnect the quick connect fitting from the fuel injector page 7 5 Remove the air cleaner housing...

Page 166: ...ottle cable adjuster lock nut 11 remove iiO 1iiiiiiilir c iiP ji i ti 7 20 the adjuster 2 from the throttle body and disconnect the cable end 3 from the throllle drum 4 Loosen the insulator band screw 11 and remove the throttle body 21 from the insulator Loosen the insulator band screw 1 and remove the insulator 2J from the cylinder head j 1 1 j 1 1 ...

Page 167: ...hole of the insulator band 1 with the boss of r I a IJ IIT i liJ 7 iI Ji the insulator 2J Install the insulator onto the cylinder head by aligning the groove with the lug Align the hole of the insulator band 1 with the boss of the insulator 2 Install the throttle body 3 into the insulator by aligning the lug with the groove Tighten both insulator band screws so that the distance between the band t...

Page 168: ...dal freeplay page 3 4 Inslall the throttle drum cover 1 by aligning Ihe locating 7 22 tab 2 with the slot in the throttle body Install and tighten the washer screw 3 Connect the following fuel injector 2P gray connector 1J IACV 4P black connector 2 sensor unit 5P connector 3 Connect the quick connect fitting to the fuel injector page 7 6 Install the air cleaner housing page 7 16 l I I i r 2 l ...

Page 169: ...e D ring Temporarily connect the IACV 4P black connector 1 Turn the ignition switch to ON Il while holding the slide valve 2 as shown The slide valve should move back and forth Install the IACV page 7 23 REMOVAL Remove the left middle fender page 2 8 Clean the throttle body to prevent dirt and debris rrom entering the IACV passage Disconnect the IACV 4P black connector 1 Remove the two torx screws...

Page 170: ...ore removing the fuel injector and be sure that no debris is allowed to enter into the combustion chamber Disconnect the fuel injector 2P gray connector 1 and IACV 4P black connector 2 Remove the two mounting bolts 3 and the fuel injector assembly 14 from the throttle body Remove the following injector joint 1 joint rubber 2 a ring 3 fuel injector 4 seal ring 5 Apply engine oil to new seal ring an...

Page 171: ...o damage the seat ring Install the fuel injector joint mounting bolts 2J and tighten them TORQUE 5 1 N m 0 5 kgf m 3 8 IbHt Connect the fuel injector 2P gray connector 3 and IACV 4P black connector 4J Connect the quick connect fitting to the fuel injector page 7 6 FUEL SYSTEM 7 25 ...

Page 172: ...1 MEMO ...

Page 173: ...LUBRICATION SYSTEM DIAGRAM 8 2 SERVICE INFORMATION 8 3 TROUBLESHOOTING 8 3 8 LUBRICATION SYSTEM OIL PRESSURE CHECK 8 4 OIL PUMP 8 4 OIL COOLER 8 10 8 1 ...

Page 174: ...EM DIAGRAM CYLINDER HEO D OOl ER CAMSHAFT TORQUE CONVERTER SHIFTVAlVE BODY ROCKER ARMS RELIEF VALVE OIL PUMP J CRANKSHAFT FLYWHEEU I STARTER MAINSHAFT I REVERSE IDLE GEAR COUNTERSHAFT 2ndl3rd SHIFT CLUTCH OIL TANK OIL STRAINER SCREEN 8 2 ...

Page 175: ...nd filter replacement see Maintenance section page 3 9 TOOL Oil pressure gauge set 07406 0020005 If j v _ 1 J r c C y or 07ZMJ HN2A100 and 07AMJ HNBA100 U SA only TROUBLESHOOTING Oil level too low high oil consumption Oil consumption External oil leak Worn piston rings or incorrect piston ring installation Worn cylinder Worn valve guides or stem seals Low oil pressure Oil level low Oil pressure re...

Page 176: ...uge 1 and adaptor to the oil gallery hole TOOL Pressure gauge set U S A TOOLS Oil pressure gauge 0 160 psi Adaptor banjo 8 x 1 25 mm 0740S 020005 01ZMJ HN2A100 and 07AMJ HN8A100 Start the engine and check the oil pressure OIL PRESSURE 80 CI176 F 785 kPa 8 0 kgflem 114 psi at 5 000 rpm Slop the engine and remove the oil pressure gauge and adaptor Install the sealing bolt 1 with a new sealing washer...

Page 177: ...th engine oil and install it onto r the 011 relurn pipe 2J Install the pipe onto the crankcase and lighten Ihe two bolts 3J securely Coal a new a ring 1 and a new rubber seal 2 with engine 011 and Inslall them onto the strainer joint pipe 3 Install the joint pipe onto the strainer pipe 4 in the crankcase LUBRICATION SYSTEM 8 5 ...

Page 178: ...y aligning the joint pipes with the jOint holes properly Install the three mounting boits 1 and tighten them If the pump was disassembled lighten all the bolts 1 1 2 in a crisscross pattern in several steps Install the torque converter page 16 42 OISASSEMBLY Disassemble the oil pump according to the illustration RELIEF VALVE C RING INNER ROTORS PUMP BODY B ASSEMBlY BOLTS PUMP BODY C OUTER ROTORS 8...

Page 179: ...arily assemble each inner rotor outer rotor and drive pin on the pump shaft and install them into each pump body individually Measure the rotor lip clearance SERVICE LIMIT 0 20 mm 0 008 in Measure the body clearance SERVICE LIMIT 0 25 mm 0 010 in Remove the oil pump shaft and drive pin Measure the side clearance SERVICE LIMIT 0 11 mm 0 004 in 8 7 ...

Page 180: ... A aligning the drive pin with Ihe rotor grooves Apply locking agent to Ihe sprocket boll 1J threads Install the driven sprocket 2 onto the pump shaft aligning the flats Install the sprocket bolt and tighten it TORQUE 12 N m 1 2 kgf m 9lbHt 131 51 D ICS Coat a new O ring 1 with engine oil and install it into 8 8 the relief valve 2 groove Inslall the relief valve 1 into the pump body B 2J Inslall t...

Page 181: ...ll the dowel pins PI through the pump bodies C B and A Insert the drive pin 2J into the pump shaft Install Ihe inner rotor 3 onto Ihe pump shaft aligning its grooves with the drive pin Install the Quter rotor 4 into the oil pump body D 5 Install the pump body D onto the pump body C LUBRICATION SYSTEM 3 711 711 3 Iii iI Make sure thai there is no clearance at the mating surfaces of the pump bodies ...

Page 182: ...e them out of the frame Remove the O rings 3 from the oil pipes Loosen the band screws lJ and disconnect the water hoses 2 from the oil cooler 3 Remove the two mounting bolts 4 and the oil cooler INSTALLATION Install the oil cooler with the two bolts and tighten them securely Connect the water hoses to the oil cooler and tighten the band screws Coal new O rings 1 with engine oil and install them c...

Page 183: ...e wire stay 1 while aligning its edge with the oil cooler lug as shown then install and tighten the bolt 2 securely Fill the engine with the recommended oil page 3 10 Fill and bleed the cooling system page 9 5 Check the engine oil level page 3 9 DISASSEMBLY ASSEMBLY Remove the following five bolts 1j cooler cover 2 D ring 1 Replace the O ring with a new one LUBRICATION SYSTEM 8 11 ...

Page 184: ...wo joint coltars 1 two O rings 2 Assembly is in the reverse order of disassembly Clean the cooler housing cover and core fins with compressed air thoroughly Replace the joint O rings with new ones and coal them with engine oil 111 1 1 j 1 1 j j I 1 j i 1 1 j ...

Page 185: ...STEM SYSTEM FLOW PATTERN 9 2 THERMOSTAT 9 7 SERVICE INFORMATION 9 3 WATER PUMp 9 8 TROUBLESHOOTING 9 3 COOLING FAN SHROUD 9 10 SYSTEM TESTING 9 4 RADIATOR 9 12 COOLANT REPLACEMENT 9 5 RADIATOR RESERVE TANK 9 13 9 1 ...

Page 186: ...COOLING SYSTEM SYSTEM FLOW PATTERN RADIATOR THERMOSTAT 9 2 RES RVETANK all CUl LO WATe PUMP 1 1 1 i ...

Page 187: ... except to refill or drain the system All cooling system service can be done with the engine installed in the frame Avoid spilling coolant on painted surfaces After servicing the system check for leaks with a cooling system tester For cooling fan motor inspection page 22 12 TROUBLESHOOTING Engine temperature too high Thermostat stuck closed Faulty radiator cap Insufficient coolant Passage blocked ...

Page 188: ...12 The engme must be Remove the radiator cap 1 cool before removing the radiator cap 9 4 Test the coolant gravity using a hydrometer 11 STANDARD COOLANT CONCENTRATION 1 1 mixture of distilled water and antifreeze look for contamination and replace the coolant if necessary 1 1 j 1 j 1 ...

Page 189: ...fied pressure for at least 6 seconds Remove the tester and install the radiator cap Install the front hood page 2 12 COOLANT REPLACEMENT PREPARATION NOTICE Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage of radiator passages Using tap waler may cause engine damage NOTE The effectiveness of coolant decreases with the accumulation of rust or ...

Page 190: ...erve tank by setting its groove onto Ihe lab v Drain the coolant from Ihe system into a pan by iiiiiiiiij iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii 9 6 removing the drain bolt 1J and sealing washer 2J Install the bolt with a new sealing washer and tighten it securely Remove the water pipe mounting bolts 1 Ihen slide the water pipe 2 and release it from Ihe frame Loosen Ihe band screws 3 and discon...

Page 191: ...m 9 lbH t 1 Shift the transmission into neutral and set the parking brake Start the engine and let it idle for 2 3 minutes 2 Snap the throttle 3 4 times to bleed air from the system 3 SlOp the engine and add coolant up 10 the filler neck 4 Inslallthe radiator cap Fill the reserve tank to the MAX hne II and install the tank cap 2 Install the following middle under guard page 2 29 front hood page 2 ...

Page 192: ...tric heating element for 5 minutes Suspend the thermostat in heated water to check its operation THERMOSTAT BEGIN TO OPEN 80 84 C 176 _ 183 F VALVE LIFT 8 mm 0 3 in minimum at 95 C 203 F Replace the thermostat if the valve opens at a temperature other than those specified WATER PUMP 9 8 MECHANICAL SEAL INSPECTION Check the bleed hose 1 aftha water pump for signs of rl coolanlleakage NOTE A small a...

Page 193: ...uide 1 onto the bleed hose 2J and r the hose onto the pump body 3J Coal a new O ring 4 with engine oil and install it on the stepped section of the pump body Install the water pump while turning the impeller to engage the pump shafts Align the mounting bolt holes in the pump body and c ___ crankcase cover and be sure the water pump is fully r seated Install a new O ring 5 into the pump body groove...

Page 194: ...e guide 4 aligning the groove with the stopper Tighten all the bolts in a crisscross pattern in several sleps Connect the water hoses 1 and lighten the band screws 2 Fill and bleed the cooling system page 9 5 COOLING FAN SHROUD REMOVAUINSTALLATION 9 10 Remove the front grille page 2 12 Pull up the reserve lank lJ and release its groove 12 from the tab Release the two wire clips 111 to free the fan...

Page 195: ...ses 3 from the grommets of the frame Release the hooks 4J of the shroud from Ihe radialor and remove the cooling fan shroud assembly being careful nol to damage the radiator fins Installation is in the reverse order of removal TORQUE Radiator mounting bolt 8 4 N m 0 9 kgf m 6 2 IbH t OISASSEMBLY ASSEMBLY Release the breather hose 1 from the four hose guides 121 Release the wire band 3 from the fan...

Page 196: ... m 0 5 kgf m 3 8 IbHtj Cooling fan mounting nut 2 7 N m 0 3 kgf m 2 0 IbHt RADIATOR REMOVAUINSTALLATION NOTE 9 12 Take care not to damage the radiator fins while servicing the radiator Drain the coolant from the system page 9 6 Remove the front grille page 2 12 Loosen the band screw 11 and disconnect the lower radiator hose 2 from the hose joint Disconnect the siphon hose 1 from the radiator Loose...

Page 197: ...2 IbHt Fill and bleed the cooling system page 9 5 RADIATOR RESERVE TANK REMOVALIINSTALLAnON Remove the front hood page 2 12 Pull up the reserve tank 1 and release its groove from the tab 12 Remove the reserve tank cap 3 and empty the reserve lank Inslall Ihe reserve lank by setting its groove onto Ihe tab Fill Ihe reserve tank with the recommended coolant to the MAX line 4J and install the tank ca...

Page 198: ...MEMO 1 J I J 1 i ...

Page 199: ...R REMOVAU DISASSEMBLY 10 5 CYLINDER HEAD REMOVAL 10 8 CYLINDER HEAD DiSASSEMBLy 10 9 CYLINDER HEAD INSPECTION 10 9 VALVE GUIDE REPLACEMENT 10 11 VALVE SEAT INSPECTIONI REFACING 10 11 CAMSHAFT 10 13 CYLINDER HEAD ASSEMBLY 10 16 CYLINDER HEAD INSTALLATION 10 17 CYLINDER HEAD COVER ASSEMBLYI INSTALLATION 10 18 CAM CHAIN TENSIONER LIFTER 10 21 10 1 ...

Page 200: ...CYLINDER HEADNALVE CAMSHAFT SYSTEM COMPONENTS 22 Nm 2 2 kgf m 16Ibf ft 12 N m 1 2 kgf m 9lbHt 10 2 65 N m 6 6 kgf m 481bHt 1 1 4 1 i J 1 I I J l 1 ...

Page 201: ...r head and head cover Be careful not to damage Ihe mating surfaces when removing the cylinder head cover and cylinder head TOOLS Valve spring compressor 07757 0010000 Valve seat culler 35 mm 450 IN EX 07780 0010400 or equivalent commercially available in U S A Interior cutler 34 mm 60 INfEX 07780 0014700 or equivalent commerCially available in U S A Valve guide driver 5 5 mm 07742 0010100 Flat cul...

Page 202: ...eaking or damaged cylinder head gasket l oose spark plug Warped or cracked cylinder head Cylinder piston problem page 11 3 Compression too high overheating or knocking Excessive carbon build up on piston head or combustion chamber Worn or damaged decompressor system Excessive smoke Worn valve stem or valve guide Damaged stem seal Cylinder piston problem page 11 3 Excessive noise Incorrect valve cl...

Page 203: ...he starter motor until the gauge reading stops rising The maximum reading is usually reached within 4 7 seconds COMPRESSION PRESSURE 549 kPa 5 6 kgf cm2 80 psi at 350 rpm Check that there is no leakage at the gauge connection Low compression can be caused by blown cylinder head gasket improper valve adjustment valve leakage worn piston ring or cylinder High compression can be caused by carbon depo...

Page 204: ...uts 3 and washers 4 cylinder head cover 5 Mark 1M push rods push rods 1 so they can be gasket 21 placed back in their dowel pins 3 original locations cam followers 11 DISASSEMBLY Remove the two bolts 1 and sealing washers 2 Push the rocker arm shaft 3 with the small screwdriver through the bolt hole until the O ring on the shaft is I Il removed out of the head cover 10 6 ...

Page 205: ...MIT 11 92 mm 0 469 in Measure each rocker arm I D SERVICE LIMIT 12 05 mm 0 474 in SUbtract each rocker ann shaft 0 0 from the corresponding rocker arm 1 0 to obtain the rocker arm to shaft clearance SERVICE LIMIT 0 08 mm 0 003 in PUSH ROD Check the push rods for wear or damage If the push rod is worn or damaged check the cam follower and camshaft CAM FOLLOWER CYLINDER HEADNALVEfCAMSHAFT 111 Check ...

Page 206: ...CYLINDER HEAD REMOVAL Remove the following spark plug page 3 7 ECT sensor page 4 27 throttle body page 7 19 exhaust system page 2 30 cylinder head cover page 10 5 thermostat page 9 7 Loosen the band screw 11 and disconnect the water hose 2 from the cylinder head Do nottap the five bolts 1 cylinder head 100 cylinder head 2 hard and do not damage the matmg surface with a screwdnver gasket 111 dowel ...

Page 207: ...ring retainer 1 so they can be placed back In thalf angina locations inner and outer valve springs 121 valve 31 slem seal 4 spnng seat 5J CYLINDER HEAD INSPECTION CYLINDER HEAD Be careful not 10 Remove the carbon deposits from the combustion damage the gasket chamber lJ being careful not to damage the gasket surface surface Check the spark plug hole and valve areas for cracks 41 Check the cylinder...

Page 208: ... the reamer clockwise TOOLS Valve guide reamer 5 5 rnm 07984 2000001 or 07984 2000000 U S A only Measure each valve guide 1 0 and record it SERVICE LIMIT 5 53 mm 0 218 in Subtract each valve stem 0 0 from the corresponding guide 1 0 to obtain the stem to guide clearance SERVICE LIMITS IN 0 12 mm 0 005 in EX 0 14 mm 0 006 In Inspect and roface If the stem to guide clearance exceeds the service limi...

Page 209: ...head from the rocker arm side until the exposed height is at the specified value al the mark TOOL Valve guide driver 5 5 mm 2 07742 0010100 VALVE GUIDE PROJECTION IN 14 8 15 2 mm 0 58 0 60 in EX 17 3 17 7 mm 0 68 0 70 in let the cylinder head cool to room temperature Take care not fa tilt Ream the new valve guides or lean the reamer Insert the reamer 1 from the combustion chamber side in the guide...

Page 210: ...at must be lowered using a 32 flat cutter If the contact area is 100 Iowan the valve the seat must be raised using a 60 interior cutter Refinish Ihe seat to specifications using a 45 finish Use a 45 cutter 10 remove any roughness or irregularities from the seat TOOLS SEAT WIDTH J 0 45 o 3 SO Reface the seat with a 45 cutter whenever a valve guide is replaced cutle I Seat cutter 35 mm IN EX 07780 0...

Page 211: ...e slots in the lifter there should be space between the bottom of tool and lifter body Then turn the tool clockwise until it stops turning and engage the tabs with the slots the lifter shaft is fully secured with the special tool TOOL Tensioner holder B 3 070MG 0010100 or 07AMG 001 A100 or U S A only 07AMG MFJA100 U S A only Remove the four camshaft holder bolts 1 Suspend the cam Raise the holder ...

Page 212: ...press on one side the decompressor cam should lock above the base of the exhaust cam lobe As you press on other side the decompressor cam lobe should extend below the base of the exhaust cam lobe INSTALLATION I1J Carefully rotate the Turn the crankshaft clockwise and align the r mark 11 crankshaft while on the flywheel with the index mark 21 in the crankcase holding the cam cover chain to avoid Re...

Page 213: ...e cylinder and instalilhe cam chain 3 over the sprocket while aligning the timing marks index lines 4J on Ihe sprocket with the cylinder lop surface and holder plale edge Locate the dowel pins into the holes in Ihe cylinder securely Be sure the timing marks lines up with Ihe cylinder top surface and holder plate edge Install the four holder bolts 1 and tighten them Apply molybdenum oil solution to...

Page 214: ...ylinder head with compressed air Install the valve spring seals 1 and new slem seals 2 Lubricate the valve stem sliding surlace with molybdenum disulfide grease Insert the valve 31 into the guide while turning it slowly to avoid damaging the stem seal Install the inner and outer valve springs 4 with the tightly wound coils facing the combustion chamber Install the spring retainer 5 4 Combustion ch...

Page 215: ... not contact anything that cause damage Place a suitable tool 1 onto the valve stem 2 Tap the 1001 gently to seat the cotters 3J firmly using a hammer CYLINDER HEAD INSTALLATION Clean the mating surface of the cylinder and head Install the dowel pins 1 and a new gasket 2 Inslallthe cylinder head 1 on the cylinder Tighten tile cylinder Inslallthe five bolts 21 and temporarily tighten them head bolr...

Page 216: ...body page 7 21 thermostat page 9 7 Eel sensor page 4 27 spark plug page 3 7 CYLINDER HEAD COVER ASSEMBLYI INSTALLATION ASSEMBLY INTAKE ROCKER ARM 10 18 EXHAUST ROCKER ARM 11 SEALING WASHERS l SETIING BOLTS Coat new O rings 1 with engine oil and install them Apply molybdenum disulfide grease to Ihe rocker arm shaft 21 sliding surface ROCKER ARM SHAFTS J O RINGS I l l j I 1 1 1 1 I 1 I 1 j ...

Page 217: ...hers 3 and lighten the bolts securely INSTALLATION Turn the crankshaft and align the r mark 1 with the index mark 2 then check the cam lobes through the cam follower holes If the cam lobes face up rolate the crankshaft one full turn and match up the r mark again so the cam lobes face down Coat the cam followers 1 with engine oil and install them into the cylinder head CYLINDER HEADNALVE CAMSHAFT 3...

Page 218: ...e rocker arm followers to the push fIfJ Ughten the head rods properly by turning the crankshaft slowly cover fasteners when the rocker ann are not aligned with the push rod end 10 20 Apply engine oil to Ihe cap nul threads and sealing surfaces and install the following fasteners four washers 1 and cap nuls 2 three new washers 3 and seven bolts 4 Tighten the nuts and bolts including the cylinder an...

Page 219: ...1A100 or U S A only 07AMG MFJA100 U S A only Remove the cam chain tensioner lifter mounting bolts 121 Remove the cam chain lensioner lifter 3J and gasket CYLINDER HEADNALVE CAMSHAFT 4 Or Install a new gasket 1 on the cam chain lensioner lifter 2 and install them to the cylinder Instan and tighten the cam chain lensioner lifter mounting bolts 1J Remove the lensioner holder Install and tighten the c...

Page 220: ... lensioner lifter body when it is pushed When it is turned clockwise with the tensioner holder or a screwdriver 21 the cam chain tensioner lifter shaft should be pulled into the cam chain tensioner lifter body The cam chain tensioner lifter shaft should spring out of the cam chain tensioner lifter body as soon as the tensioner holder is released j I 1 1 j 1 J 1 j ...

Page 221: ...SYSTEM COMPONENTS 11 2 SERVICE INFORMATION 11 3 TROUBLESHOOTING 11 3 11 CYLINDER PISTON CYLINDER PISTON REMOVAL 11 4 CYLINDER PISTON INSPECTION 11 5 CYLINDER PISTON INSTALLATION 11 8 III 11 1 ...

Page 222: ...1 CYLINDER PISTON SYSTEM COMPONENTS I j 1 j j 1 11 2 1 j ...

Page 223: ...assembled parts to ensure that they are reinstalled in their original locations TROUBLESHOOTING Compression too low hard starting or poor performance at low speed Leaking cylinder head gasket Worn stuck or broken piston ring Worn or damaged cylinder and piston Compression too high overheating or knocking Excessive carbon built up on piston head or combustion chamber Excessive smoke Worn cylinder p...

Page 224: ...owing camshaft page 10 13 cam chain tensioner lifter page 10 21 bolt 1 and water pipe 2 O ring 3 crankcase breather hose 1J Do not tap the four bolts 1 and cylinder 2 cylinder too hard and do flO damage the mating surface with a screwdriver 11 4 gasket 1 dowel pins 2 1 j j ...

Page 225: ... at a piston ring by point opposite the gap spreading the end too far Never use a wire Clean carbon deposits from the piston ring grooves with brush it will scratch a ring that will be discarded the groove CYLINDER PISTON INSPECTION CYLINDER Inspect the cylinder bore for scratch or wear Measure the cylinder 1 0 at three levels in an X and Y axis Take the maximum reading to determine the cylinder w...

Page 226: ...0 05 mm 0 002 in PISTON PISTON RING Inspect the piston rings for smooth movement by rotating the them The rings should be able to move in their grooves without catching Push the ring unlil the outer surface of the piston ring is nearly flush with the piston and measure the ring Ie ring groove clearance SERVICE LIMITS Top 0 095 mm 0 0037 In Second 0 075 mm 0 0030 in Insert the piston ring lJ into t...

Page 227: ...ston to piston pin clearance SERVICE LIMIT 0 04 mm 0 002 in CONNECTING ROD Measure the connecting rod small end 1 0 SERVICE LIMIT 23 06 mm 0 90S in Calculate the connecting rod Io plston pin clearance SERVICE LIMIT O OS mm 0 003 In CYLINDER STUD BOLT REPLACEMENT Thread two nuts onto the stud and tighten them together and use a wrench on them to turn the stud bolt out Install a new stud bolt in the...

Page 228: ...h other Stagger the side rail end gaps as shown PISTON INSTALLATION Place a dean shop towel over the crankcase to prevent the piston pin dip 1 from falling into the crankcase 20 mm ar more Apply molybdenum oil solution to the piston pin 2 outer surface Apply engine oil to the piston pin hole and connecting rod inner surface Install the piston 3 with the IN mark 4 toward the intake side and insert ...

Page 229: ...essed air Install the dowel pins 1 and a new gasket 2 Apply engine oil to the cylinder wall piston outer surface and piston rings Route the cam chain 1J through the cylinder 2 and install the cylinder over the piston while compressing the piston rings with your fingers Align the cam chain guide bosses 3 with the grooves 4 in the cylinder properly to seat the cylinder on the crankcase Make sure tha...

Page 230: ...0 Coat a new O ring 1 with coolant and install it on the water pipe 12 Ihen connect it to the cylinder Install and lighlen the bolt 13 Instalilhe following camshaft page 10 14 cam chain tensioner lifter page 10 21 j 1 1 j ...

Page 231: ...12 ALTERNATORISTARTER CLUTCH SYSTEM COMPONENTS 12 2 ALTERNATOR STATOR STARTER REDUCTION GEARS 12 5 SERVICE INFORMATION 12 3 FLYWHEELISTARTER CLUTCH 12 10 TROUBLESHOOTING 12 4 12 1 ...

Page 232: ...ALTERNATORISTARTER CLUTCH SYSTEM COMPONENTS 16 N m 1 6 kgf m 12 tbf ft 1 1 108 N m 11 0 kgf m 80 IbHt 12 2 ...

Page 233: ...o damage Ihe mating surfaces of the alternator and crankcase covers when servicing For rear crankcase cover removal installation page 13 5 For alternator stator inspection see Battery Charging System section page 21 6 For starter motor service see Electric Starter section page 6 4 TOOLS Flywheel holder 07725 004000 1 Bearing remover shaft 10 mm 07936 GE00100 or 07936 GEOAOOO U S A only Driver 0774...

Page 234: ... B 07YMJ MCF0200 nol available in U S A TROUBLESHOOTING Torque limiter attachment 0 070MJ HN80100 nol available in U S A Starter motor turns but engine does not turn Faulty starter dutch Damaged reduction gears or torque limiter 12 4 1 1 1 1 j I j I I I ...

Page 235: ... Disconnect the alternalor CKP sensor SP black connector 1J and release the wires from the clip 2 Disconnect the EDT sensor 2P connector 1 and release the wire band 2J from the cable holder Shift the sUb transmission into neutral Remove the two bolts 1J and cable holder 2 Remove the pinch bolt 1 and release the gear selector arm 2J from the gearshift spindle ALTERNATOR STARTER CLUTCH 12 5 ...

Page 236: ...ver 4 dowel pins 1 gasket 2 starter torque limiter 111 reduction gear 2 gear shaft 3 INSPECTION Check the bearings 11 in the alternator and rear crankcase covers Turn the inner race of each bearing with your finger The bearing should turn smoothly and quietly Also check that the outer race of the bearing fits lightly in the covers Torque limiter bearings replacement page 12 8 j ...

Page 237: ...ve the boll 3 and wire holder 4 then release the wire grommet ISJ off the alternator cover Remove the four bolts 6 and alternator stalorlCKP sensor assembly 7 Install the siatorfCKP sensor assembly 1 onto the alternator cover Apply sealant Threebond T81215 or equivalent to the wire grommet seating surface and install the grommet 2 into the cover groove securely Install and tighten the four alterna...

Page 238: ...6 3710200 Drive new Torque limiter bearings in with the mar1 s facing up TOOLS Driver 1 Attachment 24 x 26 mm 2J Pilot 10 mm 3 07749 0010000 07746 0010700 07746 0040100 ALTERNATOR COVER INSTALLATION NOTE Route the wires and cables properly page 1 17 Blow through the oil passage in the alternator cover with compressed air Clean the cover mating surfaces Apply molybdenum oil solution to the gear tee...

Page 239: ...scross pattern in several steps NOTE The location for the bolt With sealing washer is indicated with triangle marks on the cover Inslall the gear selector arm 1J by aligning the slit with the index hne of the spindle Install the pinch bolt 2J and tighten it to the specified torque TORQUE 16 N m 1 6 kgf m 12 IbHt Install the cable holder 11 with the two bolts 2 Installlhe wire band 111 into the cab...

Page 240: ...0 Fililhe engine with the recommended oil page 3 9 FLYWHEELISTARTER CLUTCH REMOVAL 12 10 Remove the rear crankcase cover page 13 5 Hold the flywheel 1 with the special 1001 and remove the bolt 2 and washer 3 TOOL Flywheel holder 14 07725 0040001 Remove the flywheel 1 and starter driven gear using the special 1001 TOOL Rotor puller 2 07733 020001 or 07933 3950000 U S A only Remove the needle bearin...

Page 241: ...e flywheel 1 with the special tool and remove the starter clutch bolts 2 TOOL Flywheel holder 3 07725 0040001 Remove the starter clutch assembly from the flywheel Remove the sprag clutch 1 from the clutch outer 2 Check the clutch outer and sprag clutch for abnormal 2J wear or damage Check the starter driven gear 1 teeth and needle bearing 2 for wear or damage 1 Measure driven gear boss 0 0 SERVICE...

Page 242: ...outer and the cu J clutch bolts Hold Ihe flywheel wilh the special 1 001 and lighten the bolts TOOL Flywheel holder 3 07725 0040001 TORQUE 30 N m 3 1 kgf m 22 IbHt Install the starter driven gear 1 while turning it clockwise INSTALLATION lubricate the needle bearing 111 with molybdenum oil solution Install Ihe washer 12 and bearing onto Ihe crankshaft Inslall the woodruff key 31 into the key groov...

Page 243: ...engine oil to the flywheel bolt 11 threads and seating surface then instal the washer 21 and bolt Hold the flywheel 31 using the special tool and tighten the bott TOOL Flywheel holder 4 07725 1040001 TORQUE 108 N m 11 0 kgfm 80 IbHt Instatlthe rear crankcase cover page 13 7 ALTERNATOR STARTER CLUTCH 12 13 ...

Page 244: ...MEMO j J j j I I I j I ...

Page 245: ...SSION GEARSHIFT LINKAGE SYSTEM COMPONENTS 13 2 SUB TRANSMISSION 13 9 SERVICE INFORMATION 13 3 GEAR SELECTOR LEVER LiNKAGE 13 16 TROUBLESHOOTING 13 4 GEAR SELECTOR CABLE ADJUSTMENT 13 17 REAR CRANKCASE COVER 13 5 13 1 ...

Page 246: ...SUB TRANSMISSION GEARSHIFT LINKAGE SYSTEM COMPONENTS 12 N m 1 2 kgf m 9lbHt 12 N m 1 2 kgf m 9lbHt 25 N m 2 5 kgf m 181bHt 13 2 1 1 1 1 1 1 1 1 l 1 l ...

Page 247: ...er Clean the oil passage before installing the crankcase cover Be careful nol to damage the crankcase and cover mating surfaces when servicing For automatic transmission service see Drivetrain System section page 16 3 TOOLS Remover weight 07741 0010201 or 07936 371020A or 07936 3710200 U S A only Pilot 25 mm 07746 0040600 Remover handle 07936 3710100 Attachment 37 x 40 mm 07746 0010200 Driver 0774...

Page 248: ... Wait several seconds Release the brake and check the vehicle condition Does the vehicle creep YES Perform the inspection Vehicle creeps when idling page 16 5 while applying the brake as same manner as above NO Adjust the selector cable page 13 17 Hard to shift Bent shift fork claw Bent shift fork shaft Damaged shift drum guide groove Damaged shift fork guide pin Damaged gearshift spindle and drum...

Page 249: ...ction gears page 12 5 bolt 1 and ground cable 2 two bolts 1 oil filler pipe 2J and O ring 3 Place a jack or an adjustable support under the engine Remove the engine side mounting nuts lJ and bolts 2 HOld the engine Slightly lift the engine upward until there is enough securely and lake clearance for rear crankcase cover removal care not to damage the frame and engine Remove the following two 8 mm ...

Page 250: ...ARING REPLACEMENT For rear crankcase bearings replacement page 14 9 OUTPUT SHAFT BEARING 1 Drive out the output shaft bearing 1 from the C crankcase cover Drive a new output shaft bearing 1 in with its marked iii Ii side facing up until it is fully seated TOOLS Driver 2 Attachment 42 x 47 mm 3 Pilot 25 mm 4 07749 0010000 07746 0010300 07746 0040600 1 1 l ...

Page 251: ...y seated TOOLS Driver 2 Attachment 37 x 40 mm 13 Pilot 17 mm 4J INSTALLATION 07749 010000 07746 0010200 0774S 040400 Blow through the oil passage m the rear crankcase cover with compressed air Clean the crankcase and cover malmg surfaces Apply engine oil to the lips of a new gearshift spindle oil seal 11 and grease to the lips of an output shaft oil seal 21 and install them into the crankcase cove...

Page 252: ... rear crankcase cover 4 with the following fasteners eleven 6 mm bolts 5 two 8 mm bolts 6 oil drain bolt Tighten the bolts in a crisscross pattern in severa steps TORQUE Drain bolt 25 N m 2 5 kgf m 18 IbHt l ower the engine and maneuver it into place HoIdtMengme Insert the engine side mounllng bolts 1J from the front secure yandtake side care not to damage Install the engine side mounling nuts 2 a...

Page 253: ...olor page 6 4 gear position switch page 16 54 EOT sensor page 16 55 rear propeller shaft page 18 61 front propeller shaft page 18 42 air cleaner housing page 7 16 exhaust Pipe page 2 30 SUB TRANSMISSION DISASSEMBLY Remove the following rear crankcase cover page 13 5 washer 1 idle gear 2J washer 3J gear shaft 4 two needle bearings 5J shift fork shaft 11 shift fork 121 countershaft assembly 131 outp...

Page 254: ...move the oil seal 1 from the front crankcase cover Remove the shift drum 1 while lifting the stopper arm 2 with a screwdriver Remove the following washer 1 gearshift spindle 2J pivot bolt 3 stopper arm 4 washer 5 return spring 6 1 t j I I j 1 1 ...

Page 255: ...e gear dogs and splines in the shaft guides 1 for abnormal wear or damage Check the teeth and splines of the drive gear 2 and reverse gear 13 for abnormal wear or damage Check the gear shifter 4 for smooth operation Check the gear shifter groove dogs and splines for abnormal wear or damage Check the countershaft 5 and needle bearings 6 for abnormal wear or damage OUTPUT SHAFT Check the teeth and s...

Page 256: ... 131 Check shift fork guide pin for abnormal wear or damage Measure each shift fork claw thickness SERVICE LIMIT 4 5 mm 0 18 in Measure the shift fort 1 0 SERVICE LIMIT 11 04 mm 0 435 in Measure the shift fork shaft 0 0 SERVICE LIMIT 10 96 mm 0 431 in SHIFT DRUM Check the guide groove I for abnormal wear or damage Check the drum center plale 2 and shifter gear 3 for abnormal wear or damage GEARSHI...

Page 257: ...il to the teeth of the reverse gear 1 Instalilhe shaft guide 2 reverse gear and lock washer 3 onto the counlershaft 4 Apply engine oil to the needle bearings Install the gear shifter 1 washer 2 needle bearing 20 x 24 x 13 3 and needle bearing 20 x 24 x 17 4 711 onto the countershaft 5 iii Apply engine oil 10 Ihe teeth of the drive gear 1 Install the shaft guide 2 drive gear and washer 3 onto the c...

Page 258: ... facing the snap ring aligning the wide groove with the wide tooth Install the gearshift spindle 4J and rest It onto the stopper 5J on the crankcase Install the washer 6 onto the spindle Apply engine oil to the shift drum 1 guide groove lift the stopper arm 2J and install the shift drum so the index line 3J on the spindle shifter gear is aligned between the punch marks 4 Turn the shift drum clockw...

Page 259: ...T1 InslaUthe shift fork 2 into the gear shifter groove and be sure thai he drum guide groove with the mark SIde facing out switch pin groove Insert the fork shaft through the fork and Install it into 3J in the shift drum the crankcase s vertICal as shown D I I Apply molybdenum oil solution to the reverse idle gear 1ii iRiii shaft lJ whole surface Apply engine oil to the gear teeth and needle beann...

Page 260: ... Remove the following pivot nut and boll 8 selector lever spring 9J ASSEMBLY Apply grease to the groove of the pivot boll lJ Sel the spring 2 onto the selector lever 3 and insert the pivot bolt into the arm 4 and lever Inslallthe pivot nul lS Apply grease to the sliding surface of the arm pivot bolt washer bott 6 Install the selector lever assembly and the bolt while holding the lever Tighten the ...

Page 261: ...e gear selector lever 1 to the neutral N position Completely loosen the upper and lower cable nuts 1 on the selector cable 2 Tum the ignition Operate the selector arm I on the rear side of the switch 10 ON lJ and engine by hand and shift the sub transmission into check thaI the neutral the selector arm will be vertical neutral indicator comes on at this lime 21 l lllnC bF 13 17 ...

Page 262: ...l they the nell ral positIOn touch the cable holder 2 Tighten the cable nut while holding the other nut TORQUE 26 N m 2 7 kgf m 191bHt 1 1 2 Make sure the gear selector lever 11 freeplay is as indicated when in the neutral N position 13 18 After adjustment check Ihat the selector lever operates properly Install the front hood page 2 12 1 N More than 2 mm 0 1 in j j 1 1 ...

Page 263: ...RANKCASE CRANKSHAFT BALANCER SYSTEM COMPONENTS 14 2 CRANKSHAFT 14 6 SERVICE INFORMATION _ 14 3 CRANKCASE BEARING REPLACEMENT 14 9 TROUBLESHOOTING 14 4 CRANKCASE ASSEMBLY 14 11 CRANKCASE SEPARATION 14 5 14 1 ...

Page 264: ...CRANKCASE CRANKSHAFT BALANCER SYSTEM COMPONENTS 14 2 J J IS l _ x 1 J ...

Page 265: ...e 16 3 Be careful not to damage the crankcase mating surfaces when servicing TOOLS Remover weight 07741 0010201 or 07936 371020A or 07936 3710200 U S A only Bearing remover 20 mm 07936 3710600 Attachment 52 x 55 mm 07746 0010400 Pilot 17 mm 07746 0040400 Remover handle 07936 3710100 Attachment 37 x 40 mm 07746 0010200 Attachment 62 x 68 mm 07746 0010500 Pilot 20 mm 07746 0040500 Bearing remover 17...

Page 266: ...orn connecting rod smaU end Worn balancer bearing Pilot 40 mm 07746 0040900 Ball joint remover installer 07WMF HN00100 Threaded adaptor 07965 VM00300 or 07931 KF00200 U S A only Worn seized or chipped transmission gear Worn transmission bearings Abnonnal vibration Improper balancer timing 14 4 Attachment 20 mm 1 0 07746 0020400 Assembly coltar 07965 VM00100 U S A only Assembly shaft 07965 VM00200 ...

Page 267: ...pump drive chain 3 pivot boll 41 cam chain tensioner 5 and coliar 61 The crankcase nine rear crankcase bolts 1 bolts are loosened in a crisscross pattem in several sleps five front crankcase bolts 1J Place the crankcase assembly with the rear crankcase down Do nor pry he Remove the front crankcase while tapping it at several crankcase apaft locations with a soft hammer With a screwdriver Remove th...

Page 268: ...aft 2 Refer 0 Drivetrain System section for mainshaft and countershaft page 16 44 Becarefu nolto Remove the crankshaft 1 and balancer 2 from the damage the rear crankcase using a hydraulic press Be sure to hold crankcase matIng the crankshaft and balancer while pressing them out of surface and the crankcase crankshaft assembly 14 6 Remove crankshaft bearing 1 using a commercially available bearing...

Page 269: ...tor I SERVICE LIMIT 0 15 mm 0 006 in Measure the side clearance between the connecting rod big end and crank weight with a feeler gauge SERVICE LIMIT 0 8 mm 0 03 in Measure the radial clearance al the connecting rod big end in an X and Y directions SERVICE LIMIT 0 05 rnm O 002 In Check the balancer gear for wear or damage 14 7 ...

Page 270: ...e sides of the balancer drive gear Ii and driven gear 2 as shown and install them together into the rear crankcase Assemble the special tools onto the crankshaft Draw the crankshaft into the bearing inner race by turning the assembly shaft while holding the shaft nut TOOLS Ball joint remover installer 1 07WMF HN00100 AHachment 20 mm 1 0 2 07746 0020400 Assembly shaft 3 07965 VM00200 Threaded adapt...

Page 271: ...nd shift drum r __ 3J bearings with the specialloois TOOLS Balancer and Shift Drum Bearings Bearing remover 17 mm 4J 07936 3710300 Remover handle 07936 3710100 Remover weight 5 07741 0010201 or 07936 371020A or 07936 3710200 U S A only Mainshaft Bearing Bearing remover 20 mm Remover handle Remover weight 07936 3710600 07936 3710100 07741 0010201 or 07936 371020A or 07936 3710200 U S A only Drive t...

Page 272: ... 0010000 Attachment 62 x 68 mm 07746 0010500 Pilot 28 mm 07746 0041100 FRONT CRANKCASE Remove the balancer 1 and countefShaft 21 bearings with the spedallools TOOLS Balancer Bearing Bearing remover 17 mm 3 Remover handle Remover weight 4 Countel haft Bearing Bearing remover 20 mm Remover handle Remover weight 07936 3710300 07936 3710100 07741 0010201 or 07936 371020A or 07936 3710200 U S A only 07...

Page 273: ...d side Attachment 42 x 47 mm 07746 010300 facing down Pilot 20 mm 07746 0040500 Crankshaft Bearing Driver 07749 0010000 Attachment 78 x 90 mm 07GAD SD40101 CRANKCASE ASSEMBLY Before installing the front crankcase cover make sure the gear side surfaces Cl and Ml gears 1 of the countershaft 21 and mainshaft 3 are flush Clean the front and rear crankcase mating surfaces thoroughly being careful not t...

Page 274: ...ing in Apply liquid sealant Threebond T61215 or equivalent to the mating surface of the front crankcase InsleUthe front crankcase 1 ovef the rear crankcase aligning the oil strainer pipe 2 with the pipe hole Install the five front crankcase bolls 3 Check thai the mainshaft 4 and crankshaft 151 turn smoothly and quietly Install the nine rear crankcase bolts 1 Tighten all the crankcase bolls in a cr...

Page 275: ...and tighten the bott Install the oil pump drive chain 1 and cam chain 2 1111 onto the crankshaft Instal the cam chain guide 3J by aligning its end wllh the groove in the crankcase Install the following oil pump page 8 5 1st shift clutch page 16 53 torque converter page 16 42 flywheelfstarter clutch page 12 12 sub transmissionfgearshift Imkage page 13 13 cylinder and piston page 11 8 engine page 15...

Page 276: ...MEMO l 1 1 1 I I J 1 1 ...

Page 277: ...15 ENGINE REMOVAUINSTALLATION SYSTEM COMPONENTS 15 2 ENGINE REMOVAL 15 4 SERVICE INFORMATION 15 3 ENGINE INSTALLATION 15 8 15 1 ...

Page 278: ...ENGINE REMOVAUINSTALLATION SYSTEM COMPONENTS 27 N m 2 8 kgf m 20 IbHI 15 2 16 6 kgf m 121bUt 54 N m 5 5 kgf m 40 IbHt J j j I 1 1 j i ...

Page 279: ...ne tape the frame around the engine and final gear case and cover the body panels beforehand for frame and plastic components protection The following components require engine removal for service mainshaft and 2nd 3rd shift clutch counlershaft page 16 44 crankshaft balancer page 14 6 15 3 ...

Page 280: ...e 20 20 seat frame page 2 5 fuel lank page 7 15 Remove the bolts 1 and oil filler 2 from the frame Disconnect the spark plug cap 1 Eel sensor 2P connector 2 and ignition coil primary wire connectors 3j Remove the clips 4 and ignition coillray 5J Disconnect the EDT sensor 2P connector 1 and release the wire band 2 from the cable holder 3 Remove Ihe two bolts 4 and cable holder Remove the pinch bolt...

Page 281: ...arking brake cable clamp 4 Release the three harness clips 11 from the frame Secure the main wire harness 2 to the right side of the vehicle with a string to prevent interference when removing the engine Loosen the front final gear case front mounting nut 1J Remove the following front final gear case upper mounting nut 2J and bolt 131 two front final gear case mounting bracket bolts 4J 15 5 ...

Page 282: ... shaft boot 4 and pull it off from the pinion joint 15 Pull the fronl propeller shaft rearward to force the stopper ring 6 past the groove in the pinion joint to disconnect it from the front final gear case Remove the propeller shaft out of the frame Remove the stopper ring from the propeller shaft Remove the O ring 7 from the output shaft Remove the following four side engine hanger nuts 1 and bo...

Page 283: ... rings 4 from the output shaft and rear propeller shaft I NOTICE I 00 not hold or strike the solenoid valves on the shift valve body during engine romoval Holding the solenoid valve or 8Kcessive shock may damage the solenoid valve Remove the engine out of the frame from the upper side Remove the six nuls 1 and three engine mounting rubbers 2 from the frame Remove the engine side mounting nuts 1 an...

Page 284: ...ase to new O rings 1 and install them into the grooves of the output shaft 2 and rear propeller shaft 3 Apply molybdenum disulfide grease to the splines in the universal joint 4 then install it to the rear propeller shaft lift up the engine and maneuver it into place With the engine slightly lifted above the mounting position move the engine forward and connect the output shaft into the universal ...

Page 285: ... tighten the engine side mounting nuts TORQUE 54 N m 5 5 kgf m 40 IbHt Tighten the engine hanger nuts and mounting rubber nuts Install a new stopper ring 1 into the groove in the propeller shaft 2 Apply molybdenum disulfide grease to the seal lip of the front side boot 3J Make sure the seal lip is not turned outside in Apply molybdenum disulfide grease to the fronl end of the propeller shaft ENGIN...

Page 286: ...shaft groove Apply molybdenum disulfide grease to the propeller shaft joint 71 splines Move the front final gear case forward for maximum clearance between the shaft joint and output shaft Engage the shaft jOint over the output shaft and move the front final gear case rearward The mountmg bolt Align the upper mounting boll holes in the front final r is Installad from the gear case and frame then i...

Page 287: ...e ground cable 1J and lighten the bolt 2 by aligning the terminal edge with the case rib as shown ENGINE REMOVAUINSTALLATION Inslalithe gear selector arm 1J by aligning the slit with iiiiiiiiiiii ir the index line of the spindle Install the pinch bolt 121 and tighten it to the specified torque TORQUE 16 N m 1 6 kgf m 121bHt Instalilhe cable holder 1 with the two bolts 2 Install the wire band 31 in...

Page 288: ...he following fuel tank page 7 1S seat frame page 2 S rear brake caliper mounting bolts page 20 2S throttle body page 7 21 cargo bed page 2 18 exhaust system page 2 30 all cooler page 8 10 front bumper page 2 17 Check the gear selector lever for smooth operation and adjust the selector cable if necessary page 13 17 Fill the engine with the recommended oil page 3 10 Fill and bleed the cooling system...

Page 289: ...TEM OIAGRAM 16 11 DRIVETRAIN TROUBLESHOOTING INFORMATION 16 12 DRIVETRAIN DTC INDEX 16 13 16 DRIVETRAIN SYSTEM DRIVETRAIN DTC TROUBLESHOOTING 16 14 SHIFT VALVE BODY 16 25 FRONT CRANKCASE COVER 16 34 TORQUE CONVERTER 16 40 SHIFT CLUTCH MAINSHAFT COUNTERSHAFT 16 44 GEAR POSITION SWITCH 16 54 EOT SENSOR 16 55 l1li 16 1 ...

Page 290: ...DRIVETRAIN SYSTEM SYSTEM COMPONENTS 118 N m 12 0 kgf m 871bHt 108 N m 11 0 kgf m 80 Ibf ft 8 N m 0 8 kgf m 5 9Ibf ft 16 2 14N m 1 4 101bHt 21 N m 2 1 kgf m 15 Ibf ft I 1 j ...

Page 291: ...ion system service oil pump and oil cooler page B 2 AIT and lubricating all is fed through the oil passage in the front crankcase cover Clean the oil passages before installing the crankcase cover Be careful not to damage the crankcase and cover mating surfaces when servicing Replace the torque converter as an assembly if it is faulty Front final clutch and differential lock clutch service page 1B...

Page 292: ...ssor bolt assembly 07GAE PG40200 or 07GAE PG4020A U S A only Test probe 2 pack 07ZAJ ROJA11 0 16 4 Remover handle 07936 3710100 l Clutch compressor attachment 07LAE PX4Q100 2 required or 07LAE PX4A100 U S A only Bearing remover 17 mm 07936 3710300 SCS service connector 070PZ ZY301QO J ...

Page 293: ...age 16 7 Check the 1st shift clutch system page 16 44 D vC o g p o wC e f al O c iC h e c k th e AfT dOiC tiOich PC solenoid valve operation when starting page 16 5 insufficient engine Check the 1st clutch oil pressure page 16 7 f Cb a ke cc _ 1__ Check the 1st shift clutch system page 16 44 Engine stalls when Check the engine idle speed page 4 29 starting Check the 1st clutch oil pressure page 16...

Page 294: ... solenoid valve should operate sound when the battery is connected SHIFT SOLENOID VALVE OPERATION INSPECTION Remove the valve body cover page 16 25 Disconnect the shift solenoid valve A 2P black connector 1 and shift solenoid valve B 2P brown connector 2J 121 11 Connect a 12 V battery 1 to the terminals of each 1III o o I11I11I11I11I11I11I11I11I11I11I111 o solenoid valve connector 2 as shown The s...

Page 295: ... Remove Ihe sealing bolt and washer 2 from the right Is aI owed 10 enter side of the shift valve body the 0 1 gallery DRIVETRAIN SYSTEM Connecllhe oil pressure gauge II and adaptor to the sealing bolt hole hole threads M8 x 1 25 Except U S A TOOL Pressure gauge set U S A TOOLS Oil pressure gauge 0 160 psi Adaptor banjo 8 x 1 25 mm 07406 0020005 07ZMJ HN2A100 and 07AMJ HN8A100 U S A only Shift the ...

Page 296: ...uges 11 and adaptors to I each sealing bolt hole hole threads MB x 1 25 lJ Except U S A TOOL Pressure gauge set U S A TOOLS Oil pressure gauge 0 160 psi Adaptor banjo 8 x 1 25 mm 07406 0020005 07ZMJ HN2A100 and 07AMJ HN8A100 U S A only Start the engine and shift the sub transmission into Drive set the gear selector lever in the rear position Raise the engine speed and measure each shift dutch oil ...

Page 297: ... A f o 0 Shift solenoid valve 8 0 0 2nd orifice control valve 3rd orifice control valve Shift valve body D o Orifice control valve body 0 151 shift clutch 0 2nd shift clutch 0 0 3rd shift clutch D Feed pipe A 0 Feed pipe B 0 0 0 Feed pipe C 0 0 0 ITorque converter Oil pump Oil pipe selling collar 0 0 0 Oitfilter Oil strainer Oil level DRIVETRAIN SYSTEM Abnormal I Blank Normal Referto page 0 0 16 2...

Page 298: ...STEM COMPONENT LOCATION SHIFT SOLENOID VALVE B TP SENSOR SENSOR UNIT VS SENSOR peM EOT SENSOR SHIFT SOLENOID VALVE A GEAR POSITION SWITCH AfT CLUTCH PC SOLENOID VALVE 16 10 I I SWITCH J SRI KE LIGHT SWITCH FUSE BOX ...

Page 299: ...tE1 IGN RIW GND G 1 C LO M B I N A T IO N M E T ER ________ J SFT SOL A LO A26 SHIFT SOLENOID VALVE A 15 1 15 2 19 GlBu 0 11 GPN G 1 25 GP R G 813 LG G 811 PGl G 810 PG2 PCM C l C 3 IOTC BI Black Br Brown Bu Blue G Green Gr Gray Lb Light blue 19 Light green 0 Orange P Pink R Red V Violet W White Y Yellow 6 d cr9 I C C 5 SFT OL B A29 LIN P AS LIN M 0 9 RR VSP SENVBl A 1 G r1JSHIFT SOLENOID VALVE B ...

Page 300: ... affecllhe system operation of both systems The drivetrain system is equipped with the self diagnoslic system When any abnormality occurs in the NT system the PCM turns on the MIL and stores a DTG in its erasable memory FAIL SAFE FUNCTION The drivetrain system is provided with a fail safe function to secure a minimum running capability even when there is trouble in the system When the PCM detects ...

Page 301: ...p fu ct O 1 4 19 does not work 2nd gear only f t VS sensor or its circuit malfunction 15 1 Shift solenoid valve A short L h Shift solenoid valve A or its circuit malfunction 15 2 Shift solenoid valve A open _ 1 Shift solenoid valve A Of its circuit malfunction 16 1 Shift solenoid valve B short __ c Shift solenoid valve B Of its circuit malfunction 16 2 Shift solenoid valve B open NT shift function...

Page 302: ...gine Recheck the current DI G with the MeS Is Dre 4 1 or 4 3 indicated YES GO TO STEP 2 NO Intermittent failure 2 AIT Clutch PC Solenoid Valve Inspection Turn the ignition switch to OFF 0 Disconnect the NT clutch PC solenoid valve 2P black connector page 16 25 Measure the resistance between the solenoid valve side 2P connector 1 lerminals Standard 5 1 5 7 a 20 C 6S F Is the resistance within stand...

Page 303: ...e engine Recheck the OTG with the MeS Is DTC 4 1 or 4 3 indicated YES Replace the peM with a known gOOd one and recheck NO Intermittent failure DTC 4 2 AfT CLUTCH PC SOLENOID VALVE HIGH INPUT 1 Recheck OTC Test drive the vehicle and stop the engine Recheck the current DTG With the MeS Is DTC 4 2 indicated YES GO TO STEP 2 NO Intermittent failure 2 AfT Clutch PC Solenoid Valve Inspection Turn the i...

Page 304: ...e 4 8 Test drive the vehicle and slop the engine Recheck the oTC with the MeS Is DTe 4 2 indicated YES Replace the peM with a known good one and recheck NO Intermittent failure DTC 15 1 SHIFT SOLENOID VALVE A SHORT 1 Recheck oTC Test drive the vehicle and stop the engine Recheck the current DTe with the MeS Is DTe 15 1 indicated YES GO TO STEP 2 NO Intermittent failure 2 Shift Solenoid Valve A Ins...

Page 305: ...th the MeS Is DTC 15 1 indicated YES Replace the peM with a known good one and recheck NO Intermittent failure DTC 15 2 SHIFT SOLENOID VALVE A OPEN Before starting the troubleshooting check the shift solenoid valve A 2P black connector for loose or poor contacts and recheck Ihe OTG 1 Recheck DTC Test drive the vehicle and slop the engine Recheck the current DTG with the MeS Is DTC 15 2 indicated Y...

Page 306: ...black peM 33P black and 33P gray connectors Erase the OTC page 4 8 Test drive the vehicle and stop the engine Recheck the o TC with the MCS Is DTC 15 2 Indicated YES Replace the PCM with a known good one and recheck NO Intermittent failure DTC 16 1 SH FT SOLENO D VALVE B SHORT 1 Recheck OTe Test orive the vehicle and stop the engine Recheck the current DTC with the MeS Is OTC 16 1 indicated YES GO...

Page 307: ...ith a known good one and recheck NO Intermittent failure DTe 16 2 SHIFT SOLENOID VALVE B OPEN Before starting the troubleshooting check the shift solenoid valve B 2P brown connector for loose or poor contacts and recheck the DTC 1 Recheck OTC Test drive the vehicle and stop the engine Recheck the current DTC with the MCS Is DTC 16 2 indicated YES GO TO STEP 2 NO Intermittent failure 2 Shift Soleno...

Page 308: ...terminal and ground Is there continuity YES GO TO STEP 5 NO Open circuit in the Green wire 5 Failure Reproduction Connect the shift solenoid valve B 2P brown connector and peM 33P black connector Erase Ihe oTC page 4 8 Test drive the vehicle and stop the engine Recheck the OTC with the MCS Is OTC 16 2 indicated YES Replace the PCM with a known good one and rechecl NO Intermittent failure DTC 31 1 ...

Page 309: ...d slop the engine Recheck the DTC with the MeS Is DTC 31 1 indicated YES Replace the PCM with a known good one and recheck NO Intermittent failure DTC 32 1 FAIL SAFE RELAY CIRCUIT 1 Recheck DTe Erase the OTG page 4 8 Recheck the OTG with the MGS Is DrC 32 1 indicated YES Replace the PCM with a known good one and recheck NO Intermittent failure DTC 41 1 GEAR POSITION SWITCH CIRCUIT Before starting ...

Page 310: ...position switch 3P black 16 22 connector 11 page 16 54 Check for continuity between Ihe switch side 3P connector terminals and ground There should be continuity in each gear position and no continuity in the other position ear POSI Ion onnector ermma rive eutra everse Igt ue Ie Ig t green cay Are the test results normal YES Open or short circuit in the light bluel white wire Open or short circuit ...

Page 311: ...T Sensor Resistance Inspection Turn the ignition switch to OFF 0 Measure the resistance between the sensor side 2P connector 1 terminals Standard 2 5 2 8 kO 20 CI68 F Is the resistance within standard value YES Replace the peM with a known good one and recheck NO Faulty EDT sensor 4 EOT Sensor Line Short Circuit Inspection Disconnect the PCM 33P gray connector page 4 28 Check for continuity betwee...

Page 312: ... wire 1 2 Connection Orange Green red Tum the ignition switch to ON I Check the EaT sensor with the MCS Is about 0 V indicated YES Faulty EOT sensor NO GO TO STEP 3 3 EOT Sensor Une Open Circuit Inspection Tum the ignition SWitch to OFF 0 Remove the jumper wire Disconnect the PCM 33P gray connector 1 page 4 28 Check for conlinuity between the wire harness side EOT sensor 2P connector 2 and PCM 33P...

Page 313: ...case the transmission will be fixed in the 2nd range and the vehicle creeps during idling The stopper bolt 1 that operates the emergency valve Is secured with the lock plate 2 When trouble occurs remove the plate screw 31 and lock plate and then turn the stopper boll all the way in to activate the emergency valve REMOVAL Remove the following left seat bottom cover page 2 9 left rear side cover pag...

Page 314: ...irt away from all the parts Take care nol to damage the mating surfaces of the valve bodies SOLENOID AND EMERGENCY VALVES Remove the following two bolts 1 and valve body cover stay 2J shift solenoid valves A 31 and B 1 4 four bolts and AfT clutch PC solenoid valve assembly 5 rubber seal 61 5 6 Use a hand Connect a pressure pump to the input port filter side of operated air pump the shift solenoid ...

Page 315: ...es for operation DRIVETRAIN SYSTEM OUTLET PORTS INLET PORT EB 8 121 111 The valve should move away from the solenoid side when the battery is connected and should be returned by spring force when the battery is disconnected SPOOL VALVE Remove the following from the AfT clutch PC solenoid valve assembly screw 1 and lock plate 2 valve stopper bolt PI emergency valve 4J valve spring 5J Wash atl the r...

Page 316: ... CONTROL AND SHIFT VALVES Remove the following four bolts 1 orifice control valve body 2 separator plate 1 shift valve body 2 two dowel pins 1 separator plate 2 four sealing bolts 111 and washers 12 111 1 VI 1 1 1 l 1 j i i j j 1 I I ...

Page 317: ...pring seals 1 valve springs 2J shift valves 1 2 3J and 2 3 4 Blow through all the Wash all the parts with a high flash pOint or non oil passages flammable solvent and blow dry them with compressed thoroughly air to clean completely Check the orifice control valves shift valves and valve bores for scoring scratch or abnormal wear DRIVETRAIN SYSTEM 131 121 111 141 111 141 16 29 ...

Page 318: ...j y 9 L 1 G I It SHIFT VALVE 12 3 1 SHIFT SOLENOID VALVE B _ SHIFT SOLENOID VALVE A ill SHIFT VALVE 1 2 SPRING SEAT fh SEPARATOR PLATE J VALVE BODY COVER STAY VALVE SPRING SPRING SEAT 4 ORIFICE CONTROL VALVE 2nd SHIFT AND ORIFICE CONTROL VALVES Apply engine oil to the shift valves Install the spring Insert the shift valves 1 2 1J and 2 3 2 and springs seats with the slit 3J into the shift valve bo...

Page 319: ...ift valve body and secure them faclfIg away from with the spring seats 4 the shiff valve body page 16 30 Install the four sealing bolts PI into the solenoid valve body 2 with new seating washers 3 Install the foUowing two dowel pins 1 separator plate 2 shift valve body 131 separator plate 1 orifice control valve body 2 DRIVETRAIN SYSTEM L 1111131 e 111 111 16 31 ...

Page 320: ... ring 1J with engine oil and install it into the stopper bolt 2 groove Install the valve stopper bolt and lurn it in until the groove edge is aligned with the valve body surface Secure the stopper bolt with the lock plate 31 as shown and lighten the screw 4 Coat a new rubber seal 11 with engine oil and install il into the groove In the AfT clutch PC solenoid valve body 121 Install the AfT clutch P...

Page 321: ...ay 1J and two bolls 21 and tighten the bolts INSTALLATION Clean the mating surtaces of the valve body assembly and front crankcase cover being careful not to damage them Coat new O rings 11 with engine oil and install them into the grooves in the oil joint collars 21 Install the four joint collars and a new gasket 3 Install the shift valve body assembly 1 with the six bolts 2 and tighten bolts sec...

Page 322: ...4J Into the body cover Check the transmission oit pressure if necessary page 16 7 Inslalithe following left rear side cover page 2 10 left seal bottom cover page 2 9 FRONT CRANKCASE COVER REMOVAL 16 34 Remove the following exhaust system page 2 30 oil cooler page 8 10 water pump page 9 8 front propeller shaft page 18 14 shift valve body coverfconnectors page 16 25 Loosen the pipe setting cap 1 Rem...

Page 323: ...d O ring 4 output shaft oil seal 5 oil filter page 3 11 shift valve body page 16 25 dipstick 1 sealing bolts 2 and washers 3 oil passage sealing cap 4 and O ring 5 three bolts 61 oil pipe joint 71 and O ring 18 Wash the crankcase cover with solvent and blow through all the passages with compressed air to clean them thoroughly DRIVETRAIN SYSTEM 111 I VI3 16 35 ...

Page 324: ...k the crankshaft seal collar 1 behind the bearing for abnormal wear or damage NOTE The crankshaft seal collar is for the engine oil supplied to the torque converter and crankpin Replacement page 16 36 BEARING REPLACEMENT Remove the crankshaft bearing 1 using the special lools TOOLS Bearing remover 17 mm 2 07936 3710300 Remover handle 07936 3710100 Remover weight 3J 07741 0010201 or 07936 371020A o...

Page 325: ...shaft bearing 5 Driver Attachment 42 x 47 mm Pilot 25 mm INSTALLATION 07749 0010000 07746 0010300 07746 0040400 07749 0010000 07746 0010300 07746 0040600 Clean the crankcase and cover mating surfaces Coat a new O ring 1 with engine oil and install il into the oil pipe jOint 2 groove Install the oil pipe joint and three bolts 31 and tighten the bolts Coat a new O ring 4 with engine oil and install ...

Page 326: ... them onto the joint pipes 2 Install the joint pipes into the oil pump Apply liquid sealant Threebond T81 215 or equivalent to the mating surface of the fronl crankcase cover as shown Blow the oil orifice with compressed air to clean the passage Coal new O rings 1 with engine oil and inslall them into the orifice 2 grooves Install the oil orifice with the small end facing oui j j ...

Page 327: ...case Coat a new O ring 1 with engine oil and install it onto the flange of the feed pipe B 2 Apply engine oil to the outer surface of pipe 8 Align the nange tabs Carefully insert the feed pipe B while turning it slowly to with the grooves in avoid damaging the oil seal in the crankcase the cover Coat new O rings 1 with engine oil and install them into the setting collar 21 grooves Install the sett...

Page 328: ...body page 16 33 front propeller shaft page 18 42 water pump page 9 9 oil cooler page 8 10 exhaust system page 2 30 TORQUE CONVERTER REMOVAL Remove the front crankcase cover page 16 34 Be careful not to Unstake the lock nul 1 damage the Loosen the lock nul while holding the converter boss crankshaft threads with an open end wrench width across flats 32 mm 16 40 Remove the lock nut and washer 2J Rem...

Page 329: ...e gear to check the one way clutch in the torque converter The gear should turn counterclockwise smoothly and should not turn clockwise Check the needle bearings for abnormal wear or damage Check the sprag clutch 1 in the stator shaft 2 for abnormal wear damage or irregular movement Check the sprag clutch contacting surface of the inner collar 3 for abnormal wear or damage Check the seal ring 1J o...

Page 330: ...the bearings gear teeth and sprag clutch TORQUE CONVERTER Apply molybdenum disulfide grease to the inner collar needle bearing 1 and thrust needle bearing 2 Install the needle bearing into Ihe inner collar 3 Instan Ihe inner collar onto Ihe crankShaft by aligning the cutout with the stopper pin Install the thrust needle bearing onto the inner coliar with the needle roller side facing in Install th...

Page 331: ...torque converter 1 by aligning the splines carefully and engaging the primary drive and driven gear teeth 2 Inslallthe washer 3 Apply engine oil to the threads of a new lock nut 1 Install the lock nut and tighten it while holding the converter boss with an open end wrench width across flats 32 mm TORQUE 118 N m 12 0 kgf m 87IbHt Be careful not to Slake the lock nut into the crankshaft groove damag...

Page 332: ...iven gear boss with an open end wrench width across flats 29 mm 16 44 Remove the following lock nut washer 2 181 shift dutch assembly 3 washer l M1 gear guide 12J O rings 3 Remove the primary driven gear 1 by prying it Remove the O rings from the primary driven gear MAINSHAFT DISASSEMBLY Remove the mainshaft page 14 6 Remove the following M1 gear 11 needle bearing 2 washer 3 M3 gear 14 snap rings ...

Page 333: ...ear 2 bearing thrust washer 3 2nd 3rd shift clutch assembly 4 O rings SHIFT CLUTCH DISASSEMBLY NOTE DRIVETRAIN SYSTEM 131 11 3 4 12 The following procedures are for the 1s1 clutch The c _ ____ procedures for the 2nd and 3rd clutches are the same as for the 1st clutch Remove the following stopper nng 1 end plate 2 three clutch discs 1 and plates 2 wave spring 3 16 45 ...

Page 334: ...ng 11 by lightening the nut Remove the snap ring 21 from the boss Loosen the nut and remove the special toots snap ring spring retainer 13 and return spring Wrap a shop towel around the clutch drum Apply air pressure to the oil hole while closing the other holes with your finger to remove the clutch piston I _ Remove the O rings from the piston Clean aU the parts of the shift clutch in solvent tho...

Page 335: ...al wear made by the clutch plates Check the oil holes in the drum boss and check valve 121 in the piston 3 for clogs CLUTCH DISC AND PLATE Check the linings of the clutch discs 1 for wear disc groove disappearance Check the clutch plates 121 for discoloration CLUTCH RETURN SPRING Measure the spring free length SERVICE LIMIT 31 8 mm 1 25 in 16 47 ...

Page 336: ... PLATES 3 pes STOPPER RING q I WAVE SPRING SPRING RETAINER SNAP RING RETURN SPRING 2ndJ3rd SHIFT CLUTCH O RINGS et CLUTCH PISTON et CLUTCH PISTON PRIMARY DRIVEN GEAR CLUTCH DRUM CLUTCH PLATES 3 pes O RINGS 6 CLUTCH DISCS 3 pes SPRING RETAINER END PLATE WAVE SPRING RETURN SPRING SNAP RING STOPPER RING 1 ...

Page 337: ... DRIVETRAIN SYSTEM 13J g l Becarefufnotto Install the piston 111 while turning it to ensure proper pinch the rings seating with too much force Place the return spring 11 spring retainer 2 and snap ring 3 mto the clutch drum Instalilhe special tools 4J while adJustmg their position carefully page 16 46 To prevent loss of Compress the return spring by tightening the nut spnng tension do not compress...

Page 338: ...nd plate 111 with the plale lowered Lift the end plate up against the stopper ring and read the clearance and record it Perform this inspection althe three points in 120 apart STANDARD 0 7 0 9 mm 0 03 0 04 in If the clearance is nol within the standard value select the replacement end plate as follows Remove the stopper ring and end plale Measure the flange thickness of the end plate at several po...

Page 339: ...S mm Inslall the end plate into the drum Inslall the stopper ring 12J into the drum grooves property COUNTERSHAFT ASSEMBLY I I i I ___ ___111 C2 GEAR LOCK WASHER J THRUST WASHER j 9 I C GEAR J g END WASHER ENDWA c O RINGS j NEEDLE BEARIN 2 r ii j V I 1 1 C GEAR NEEDLE BEARING THRUST WASHER 2nd 3rd SHIFT CLUTCH Blow through the oil passages in the counlershaft with compressed air Coat new O rings 1...

Page 340: ...4J D Ill Inslall the lock washer 1 by aligninglhe four grooves with the tabs on the clutch drum boss Apply engine 011 to the teeth of C2 gear 1J and needle bearing 2J and inslalithe following needle bearing C2 gear thrust washer 3 Apply engine oil 10 the teeth of Cl gear 1J and install the following C1 gear end washer 21 Install the countershaft assembly page 14 9 I ...

Page 341: ...es Apply engine oil to the gear teeth and needle bearing and install the following thrust washer 1 needle bearing 2 M1 gear 3 Install the mainshafl assembly page 14 9 1sl SHIFT CLUTCH INSTALLATION Blow through the oil holes in the primary driven gear 1 boss with compressed air Coal new O rings 2 with engine oil and install them into the grooves in the driven gear boss Install the driven gear into ...

Page 342: ...nstall the washer 2 and lock nut Tighten the lock nut while holding the driven gear boss with an open end wrench width across flats 29 mm TORQUE 108 N m 11 0 kgf m 80 IbHt Stake the lock nut into the mainshaft groove Instatl the torque converter page 16 42 GEAR POSITION SWITCH REMOVALIINSTALLATION 16 54 Remove the heat guard plale page 2 30 Disconnect the gear position switch 3P black connector 1 ...

Page 343: ...o bolts and tighten them Route the gear position switch wire properly page 1 17 Connect the gear position switch 3P black connector Install the heat guard plate page 2 30 EOT SENSOR REMOVALIINSTALLATION Drain the engine oil page 3 10 Disconnect the 2P connector 1 from the EaT sensor 21 Remove the EOT sensor and sealing washer 3 Install the EDT sensor with a new sealing washer and tighten it TORQUE...

Page 344: ...MEMO ...

Page 345: ...SYSTEM COMPONENTS 17 2 SERVICE INFORMATION 17 3 TROUBLESHOOTING 17 3 STEERING WHEEL 17 4 17 STEERING SYSTEM STEERING COLUMN AND SHAFT 17 4 TIE ROD BALL JOINT 17 7 STEERING GEAR BOX 17 9 17 1 ...

Page 346: ...STEERING SYSTEM SYSTEM COMPONENTS 49 N m 5 0 kgf m 361bHt 27 N m 2 8 kgf m 20 IbHt 27 N m 2 8 kgf m 20 IbHt 39 N m 4 0 kgf m 29 o 65 N m 6 6 kgf m 481bHt 17 2 ...

Page 347: ...ide adjustment Worn or damaged steering column bearing Damaged steering shaft Lock nut wrench 07MAA SL00101 or 07916 SAS0001 U S A only or 07AAA Tl2A100 U S A only Worn or damaged steering gear box components Damaged suspension components page 19 4 Steers to one side or does not track straight Unequal tire pressure Damaged tie rod steering gear box or column components Incorrect wheel alignment pa...

Page 348: ...l TORQUE Steering wheel nut 49 N m 5 0 kgf m 361bHt Apply grease to the dust sealfcollar lips Check Ihe condition of dust seal collar and replace if necessary STEERING COLUMN AND SHAFT REMOVAL 17 4 Remove the following steering wheel page 17 4 left front fender page 2 13 Raise Ihe front wheels off the ground Remove the upper pinch bolt 11 and lock washer 2 Remove Ihe lower pinch bolt 3 and lock wa...

Page 349: ...washer 2 INSPECTION Check the steering column bushings 1 for wear or r i damage If the they are damaged also check the column shaft Check the column shaft 1 for deformation or other damage Check the shaft splines for wear or damage If the they are damaged check the steering shaft splines 1J 17 5 ...

Page 350: ...he shaft splines for wear or damage If the they are damaged check the column shaft and pinion splines INSTALLATION Apply grease to the top and inner surfaces of steering column bushings I Instalilhe washer 2 and column shaft 3 Install the washer I and snap ring 2 into the column shaft groove Apply grease to the lips of a new dust seal 1 3 and install it 111 j j ...

Page 351: ...new lock washer 4 10 be sure the shafts are aligned properly Tighten the upper and lower pinch bolts to the specified torque while supporting the shaft to ensure thai the bolts are centered vertically in the slols TORQUE 27 N m 2 8 kgf m 20 Ibf ft Install the following left front fender page 2 13 steering wheel page 17 4 Check that the steering wheel rotates smoothly from lock to lock without bind...

Page 352: ... penetrallng type lubncanl lO loosen lhe baN joint 17 8 To prevent the tool from dropping lie the strap 1J on a neighboring solid part such as the upper arm frame pipe etc before operation NOTE Do not tie the strap on the brake hose brake pipe rubber boot and other parts that can be damaged easily Once the tool is in place turn the adjusting bolt 1 as necessary to make the jaws parallel Then hand ...

Page 353: ...adjusting the Temporarily tighten the lock nut while holding the ball wheel alignment joint 121 111 STEERING SYSTEM 5 7mm 0 2 0 3 in l 131 121 Connect the ball jOint 11 to the knuckle with the joint nut 121 Tighten the joint nut to the specified torque TORQUE 65 N m 6 6 kgf m 48 IbHt Install the front wheel page 19 6 Adjust the wheel alignment page 3 22 STEERING GEAR BOX REMOVAL Remove he lie rod ...

Page 354: ...n disconnect the boots and shaft steering shaft splines Remove the gear box assembly 3 oul of the frame to the right while moving the clutch arm cover base 41 rearward OISASSEMBLY Cut off the boot band 1 in the position as shown and remove it Remove Ihe boot clip 21 and the tie rod boot 3 Loosen the rack end joint 1 of the tie rod while holding Ihe steering rack 2J to remove the tie rod Remove Ihe...

Page 355: ...l TOOL lock nut wrench 2 Remove the following lock nut rack guide screw 3 cone washer 4 pressure spring 5 rack guide 61 dust cover 11 dust seal 2 snap ring 11 07MAA Sl00101or 07916 SA50001or 07AAA Tl2A100 U S A only STEERING SYSTEM 2 o 3 1 17 11 ...

Page 356: ...remove the steering pinion bearing assembly Do not reuse the pinion andlor bearing Remove Ihe steering rack 2 from the gear box housing Remove the snap ring 1Jand end bushing 2J Clean the disassembled parts with a high flash point or non flammable solvent and dry them with compressed air INSPECTION Check the rack 1J teeth for wear chipping or damage Check the gear box housing 2 for damage Check th...

Page 357: ...nimum TIE ROD STEERING SYSTEM DUST COVER DUSTSEAL I 0 2 9 minimum SNAPRING 0 2 9 minimum STEERING PINION BEARING GEAR BOX HOUSING 1 9 minimum RACK END BUSHING SNAP RING 5 9 minimum STEERING RACK BOOT BOOT CLIP fI BOOT BAND Apply 1 9 minimum of grease to the inner surface of the r end bushing 1 and install it into the gear box housing Install the snap ring 2l into the housing groove 17 13 ...

Page 358: ...earing 1 in the gear box housing and Ihe bal bearing 2 on the steering pinion Make sure Ihe rack teeth 3J can be seen through the pinion hole and insert a new pinionfbearing assembly 4 into the housing Press the bearing in until it is fully seated using Ihe special tool TOOL Driver 22 mrn 1 0 5 07746 0020100 Make sure the snap Install the snap ring 1 into the groove in the housing ring is finnly s...

Page 359: ...nd dust cover 1 shadowed area Be sure the dust Install the dust cover and fit it into the pinion groove 2 cover does not contact fhe gear box housing 3 Apply 0 2 0 5 g of grease to the sliding surface rack side of the rack guide 1 Apply sealant Threebond TB1102 or equivalent to the 3 threads of the rack guide screw 2J Instali lhe following rack guide cone washer 3 with the concave side facing out ...

Page 360: ...of the lock washer it will cause the tool to pop Qut Set the components in a hydraulic press properly and hold the special tool and gear box securely TOOL Lock washer clinch pilot 2 07NAZ SR30100 or a commercially available punch U S A only Inslall the other side tie rod in the same procedure as above Clean off any grease or contamination from the boot groove in the housing end Apply 1 2 g of grea...

Page 361: ... S A Install the other side boot in the same procedure as above Slide the rack right and left to be certain that the boots are not deformed or twisted INSTALLATION Place the gear box assembly 111 into the frame from the right side Hold the gear box securely and connect the steering pinion to the steering shaft carefully Align the bolt holes and install the four bolts 2 from the front side Install ...

Page 362: ...ertically in the slot TORQUE 27 N m 2 8 kgf m 20 IbHt Inslall the holder bracket PI and cover base 2 with the two bolls 3 and tighten them to the specified torque TORQUE 10 N m 1 0 kgf m 1 Ibf ft Instalilhe clutch arm cover 4 by aligning the slits with the tabs 5 and tighten the boll 6 to the specified torque TORQUE 10 N m 1 0 kgf m 7lbHt Connect the tie rods page 17 9 I j i 1 ...

Page 363: ...L GEAR DISASSEMBLYI INSPECTION 18 30 FRONT FINAL GEAR CASE BEARING REPLACEMENT 18 36 FRONT FINAL GEAR ASSEMBLY 18 39 FRONT FINAL DRIVE INSTALLATION 18 42 REAR FINAL DRIVE REMOVAL 18 45 REAR FINAL DRIVE DlSASSEMBLYI INSPECTION 18 49 REAR FINAL DRIVE GEAR CASE BEARING REPLACEMENT 18 55 REAR FINAL DRIVE ASSEMBLY 18 57 REAR FINAL DRIVE INSTALLATION 18 61 DRIVE MODE SELECTOR LEVER LINKAGE 18 63 DRIVE M...

Page 364: ...DRIVE SHAFT FINAL GEAR SYSTEM COMPONENTS FRONT 54 N m 5 5 kgf m 40 IbHt 10 N m 1 0 kgf m 7lbHt 54 N m 5 5 kgf m 40 Ibf ft 18 2 1 I 1 10 N m 1 0 kgf m 7lbHt ...

Page 365: ...REAR 4 5 kgf m 32 Ibf ft 44 N m DRIVE SHAFT FINAL GEAR I I 18 3 ...

Page 366: ...tion given is the actual torque applied to the lock nut not Ihe reading on the torque wrench Do not overtighten the lock nut The specification later in the text gives both actual and indicated Replace the ring and pinion gears as a set Do not confuse the left and right drive shaft shafts Protect the gear case with a shop towel or soft jaws while holding it in vise Do not clamp it too tight as it c...

Page 367: ......

Page 368: ...ft 07931 ME40000 or 07931 ME4010B and 07931 HB3020A U S A only Remover shaft 15mm 07936 KC101 00 or 07936 KC10S00 U S A only Oil seal driver 07965 KE80200 no available in U SA Oil seal driver attachment 07JAO PH80101 Remover head 12 mm 07936 166011 0 Remover head 15mm 07936 KC10200 or 0793 KC10S00 U S A only Puller shaft and nut Q7965 VMOO200 or 07931 ME4010B and 07931 HB3020A U S A only Driver at...

Page 369: ...pped or damaged gears Improper tooth contact between ring gear and pinion gear Gear noise while coasting Chipped or damaged gears Abnormal noises when turning Worn or damaged ring gear bearing Damaged differential components side gear pinion or shaft Worn or damaged gear case housing Abnormal noises at start or during acceleration Excessive backlash between ring gear and pinion gear Worn different...

Page 370: ...joint honzonlal until he drive shaff IS dear o the gear case Remove the stopper ring 1 from the inboard joint REAR DRIVE SHAFT REMOVAL Remove the knuckle page 19 21 To prevent damage Hold the inboard joint 1 of the drive shaft and tug firmly 0 the gearc8se oil to force the stopper ring on the inboard joint end past seal hold the the groove while prying with a screwdriver Inboard JOint horizontal u...

Page 371: ...ard joint seems to be worn or damaged the drive shaft must be replaced NOTE To replace the outboard boot first remove the inboard boot as described In the following steps Then remove the bands and outboard boot from the inboard end of the shaft The outboard joint cannot be disassembled DRIVE SHAFT FINAL GEAR 2J Outboard 2 Inboard Rep ace the band Cut off and remove the boot bands 11 from the inboa...

Page 372: ...ng them Cut off and remove the boot bands 1 from the outboard boot 2 Remove the outboard boot ASSEMBLY NOTE III The following procedure is common to front and rear drive shaft iNBOARD JOINT Front80 100g Rear 60 80 g ld INBOARD __jiIII BOOT BANO BEARING STOPPER RING INB DAFID BOOT INBOARD SHAFT BOOT BAND OUlrBO O JOINT 45 65 91 OUTBOARD SHAFT DRIVE SHAFT BOOT BAND llJ y OUTBOARD BOOT BAND II OUTBOA...

Page 373: ...D 25 INBOARD BOOT BAND 68 OUTBOARD SHAFT BOOT BAND 24 OUTBOARD BOOT BAND 69 REAR DRIVE SHAFT BAND INBOARD SHAFT BOOT BAND 25 INBOARD BOOT BAND 72 5 OUTBOARD SHAFT BOOT BAND 24 OUTBOARD BOOT BAND 69 Pack Ihe outboard joint with the specified grease SPECIFIED GREASE Front rear NKG708 AMOUNT Front rear 45 65 g Install the following outboard boot 11 new shaft boot bands 2 inboard boot 3 Do not tighten...

Page 374: ...oint properly Install the boot over the inboard joint securely 11 Adjust the length of the drive shaft to the figure given below FRONT DRIVE SHAFT LENGTH Left 730 mm 28 7 in Right 632 mm 24 9 in REAR DRIVE SHAFT LENGTH Left Right 706 mm 27 8 in Install a new outboard boot band lJ onto the outboard 000 2 lock the shaft boot band 3 and outboard boot band with commercially available pliers TOOL Plier...

Page 375: ...rential Make sure that the stopper ring is seated properly by pulling on the inboard joint lightly Install the knuckle page 19 13 REAR DRIVE SHAFT INSTALLATION Install a new stopper ring 1 into the groove in the inboard jOint splines Be careful not 0 Install the drive shaft by holding the inboard joint 1 damage the oil seal until the stopper ring seats in the groove of the ring in the gear case ge...

Page 376: ...s page 19 6 left drive shaft page 18 8 Remove the following from the gear case 4wD select switch connector 1 differential lock switch connector p breather hose 2 cotter pin 1 and washer 2 differential lock cable loosen the cable nul 3J and remove from the cable holder 4 and lock arm 5 coverboll 1J clutch arm cover 21 releasing from the two tabs 3 j 1 1 ...

Page 377: ...n base bolts 1 arm cover base 2 holder bracket 13 DRIVE SHAFT FINAL GEAR 31 61 Loosen the two bracket bolts 10 mm 1 and remove lii II I the lower mounting nut 2 and bolt 12 mm 3 I Remove the bracket bolls and mounting bracket 4 Support the gear case 5J with wooden blocks and remove the upper mounting nut 6 and bolt 12 mm 7 18 15 ...

Page 378: ...r case assembly 2 out of the frame OPERATION CHECK Turn the pinion jOint 1 while the clutch arm 2 is set to the upper side 4WD position and check that the gear turns smoothly and quietly without binding If the gear does not turn smoothly or quietly the pinion gear ring gear bearing and or clutch components may be damaged or faulty They must be checked after disassembly replace them if necessary Op...

Page 379: ...ust seal 3 shaft boots 4 Check the propeller shaft for deformation Of damage Check the splines 5 of the propeller shaft and jOint for wear or damage If they are damaged check the splines of the output shaft and pinion joint Check the boots and dust seal for cuts deterioration or damage Check the seal lip in each boot for damage ASSEMBLY SEAL LIP I il PROPELLER SHAFT 14J 12J 5 SEAL LIP SPLINES 5 8 ...

Page 380: ...ooves being careful not to damage the seal lip Install the inner boot bands into the each boot groove Install the joint spring 3 Into the propeller shaft securely 131 121 111 Apply 5 8 9 of molybdenum disulfide grease to the 18 18 propeller shaft joint splines Sel the shaft joint 1 onto the propeller shaft while compressing the spring then install the boot 2 over the shaft joint groove and the out...

Page 381: ... 5 from the sleeve clutch sleeve 6 O ring 7J dowel pins BJ 4 Check the splines of the pinion joint clutch sleeve and pinion gear shaft for wear or damage Check the needle bearing in the pinion gear shaft for wear or damage Release the clutch spring end 1 from the stopper plate 2J by pulling the arm shaft Remove the fork bott 11 Pry the clutch arm tab to release it from the collar 2 and slide the s...

Page 382: ...laws 11 for wear or damage Check the arm shaft 2 and stopper plate 3 for deformation or damage Check the clutch spring 4 and lock spring 5 for fatigue or damage PINION JOINT BALL BEARING REPLACEMENT Remove the snap ring 1 and drive the pinion joint 2 out of the bearing Remove the oil seal 1J and the snap ring 2J Drive the bearing 3J oul of the housing 151 A t t 14 13 11 12 j 1 I ...

Page 383: ...chamfered edge facing the bearing Pack the seal lips of a new oil seal 2 with grease Instali lhe oil seal so it is flush with the housing end Hold the bearing inner race and press the pinion joint cf i 1 into the bearing until it is fully seated TOOLS Fork seal driver body 2 Driver attachment 33 mm 1 0 3 Oriver attachment 07747 0010100 07747 010501 07HMD MR70100 Install the snap ring 1 into the pi...

Page 384: ...ove Apply grease 10 the arm shaft outer surface collar fork and housing contacting area Install the collar 2 and the loel spring 3 in shown direction and set the spring end into the hole 4 in the collar 121 L Apply grease to the lips of a new oil seal 1 and install it into the clutch housing until it is fully seated Take care not 0 let Install the arm shaft assembly 2 being careful not to the ocJ ...

Page 385: ...l the clutch spring 3 with the bent end 4 toward the shift fork the shaft end into the pivot hole in the housing DRIVE SHAFT FINAL GEAR Tum the arm shaft 1 clockwise by holding the collar 21 IIIIIIII with a open end wrench and align the arm tab with the collar groove then tap the shaft to fit them securely Align the bolt hole in the fork with the groove in the shaft and install a new fork bolt 3 T...

Page 386: ...inside Coat a new D ring 2 with grease and install it into the case groove Install the two dowel pins 3 Aligning the fork claws 1 with the sleeve groove 2 install the final clutch housing 3 white turning the clutch arm 41 then secure it with the bolts 5 Tighten the three bolts TORQUE 25 N m 2 5 kgf m 18 IbUt Install the 4WD select switch 6 with a new sealing washer 7 and tighten it TORQUE 12 N m 1...

Page 387: ...er spring 5 steel ball 6 four bolts 7 and cable holder 8 DRIVE SHAFT FINAL GEAR 18 differenliallock clutch housing 1 by releasing the shift fork 2 from the sleeve differential half shaft 3 lock sleeve 41 O ring 5 two dowel pins 6 Check the splines of the lock sleeve and half shaft for wear or damage Check the sleel ball and stopper spring for wear or damage 3 18 25 ...

Page 388: ...fork spring 4 from the spring pin 5 on the stopper arm 6 Remove the following arm boll11J and washer 2J stopper arm 3J fork spring 4 shift fork 5J lock arm shaft 6 oil seal 7 Check the shift fork claws 11 for wear or damage Check the arm shaft 21 and stopper arm 3 for deformation or damage Check the spring 4 for fatigue or damage 1V 21 71 161 21 141 I 1 l i I ...

Page 389: ...0 kgf m 7 WASHER 20 N m 2 0 kgf m 15Ibf ft Apply grease to the lips of a new oil seal 1 and install it into the clutch housing until it is fully sealed 3J Install the lock arm shaft 21 being careful not to damage the oil seal then installhe shift fork 3 with the bolt hole facing up 21 Install the fork spring 1J and stopper arm 2J and set the shaft end into the pivot hole in the housing so the spri...

Page 390: ... spring ends 31 Align the bolt hole in the fork with the groove in the shaft jllII III III and install a new fork bolt 1 Tighten the fork bolt TORQUE 10 N m 1 0 kgf m 7lbHt Install a new oil seal 1 so that it is flush with the housing end being careful not to damage the lip TOOLS Driver 2 Oil seal driver attachment 3 07749 OQ10000 07JAD PH80101 Pack the seal lips of the oil seal with grease 1 _ _ ...

Page 391: ...new O ring 3 with grease and install it into the case groove Inslall the two dowel pins 4 Install the differenliallock dutch housing 1 by aligning the lork claws 2 with the sleeve groove 3 Install the four bolts 4 with the cable holder 5 and tighten them TORQUE 25 N m 2 5 kgf m 181bHt 13J J2J 11J ISJ 18 29 ...

Page 392: ...ing final clutch housing page 18 19 differential lock clutch housing page 18 25 BACKLASH INSPECTION Set the final gear case into a jig or vise with soft jaws Remove the oil filler cap Cover fhe clutch Hold the pinion gear with the special tools housing mating surface WIth TOOLS protective tape or Pinion puller base 1J en equiYalent to Puller shaft and nut 2 prevent damaging Threaded adaptor 3J 18 ...

Page 393: ...r one If the backlash is too small replace the ring gear left side shim with a thicker one The backlash is changed by about 0 06 mm 0 002 in when the thickness of the shim is changed by 0 10 mrn 0 004 in NOTE Fifteen different left shims from A to 0 and seventeen different right shims from A to 0 are available in thickness increments of 0 06 mm 0 002 in RING GEAR SHIMS Right s ide A thinnest 0 64 ...

Page 394: ...your finger The bearings should turn smoothly and quietly Also check thai the bearing outer race fils tightly in the case or cover For differential bearing replacement page 18 36 GEAR TOOTH CONTACT PATTERN CHECK 2 Apply thin coat of Prussian Blue to Ihe pinion gear teeth for a tooth contact pattern check Inslall the ring gear shims 1J onto the differential assembly 12 Inslalilhe differential assem...

Page 395: ...e approximate center of each tooth but slightly to the heel side and to the flank side If the patterns are not correct remove and change the pinion shim with one of an alternate thickness 31 NORMAl I j DRIVE SHAFT FINAL GEAR 21 HEEl TOE FACE __ __ FACE 1 9 1 FLANK FLANK Coast side Replace the pinion shim 1 with a thicker one if the T O O H G H contact pattern is too high toward Ihe face J 11 FACE ...

Page 396: ...without binding Check each gear for wear or damage RING GEAR REMOVAL Remove the ten bolts 111 and the ring gear 2 PINION GEAR REMOVAL Be careful that Unstake the bearing lock nul 1 Jwith a drill or grinder metal particles do not enter the bearing and the threads of the case are not damaged 18 34 Remove the lock nut and discard it TOOL Lock nut wrench 30 x 64 mm 1J 07916 MB00002 21 ...

Page 397: ...rom the gear case PINION BALL BEARING AND SHIM REPLACEMENT Take care notlo Press the pinion gear 1J oul of the bearing contact the support blocks agamst he gear eeth Remove the pinion shim 2 Replace the pinion joint needle bearing in the shaft end if necessary page 18 36 DRIVE SHAFT FINAL GEAR __ 21 131 Install the shim 111 and a new bearing 2J onto the pinion gear 3 NOTE When the gear set differe...

Page 398: ... mm Remover weight 07936 1660110 07936 1660120 or 07936 166010A U S A only 07741 0010201 or 07936 371020A U S A only or 07936 3710200 U S A only Press a new bearing Ii into the pinion gear with the marking facing up so that it is flush with the shaft end TOOLS Driver 2 Attachment 22 x 24 mm 3 Pilot 12 mm 41 07749 1010000 07746 0010800 07746 0040200 Install the pinion ball bearing page 18 35 FRONT ...

Page 399: ...01 Pack the seal lips of the dust seal with grease PINION NEEDLE BEARING Rotate the stopper ring 1 untit its end appears in the access hole 2 Strike gently near the end of the ring with a punch to bend the end upward Grasp the end of the ring with needle nosed pliers and pull the stopper ring out through the access hole Heat the gear case to about ao c 176 F and remove the needle bearing 3 using t...

Page 400: ...e driver to the compressor 15 TOOLS Drtver Attachment 22 x 24 mm Pilot 15 mm 07949 3710001 07746 0010800 07746 0040300 Place the bearing and tool assembly into a freezer for at least 30 minutes Using a heat gun heatlhe gear case to ao c 176 F Remove the bearing and tool assembly from the freezer and drive the bearing into the gear case using the special tools Only strike the driver once If you str...

Page 401: ...TIAL PINION JOINT NEEDLE LOCK NUT f BEARING 6009 BEARING 12 x 18 x 12 PINION NEEDLE 49 N m 5 0 kgrm 36 BEARING 15 x25 x 16 DIFFERENTIAL slip Q rings sealing washers and bearings a rings and oil seals DIFFERENTIAL BEARING 6008 GEAR CASE PINION GEAR INSTALLATION Drive the pinion gear assembly IJ into the gear case TOOLS Driver 2 Attachment 42 x 47 mm 3 011 seal driver attachment Fork seal driver bod...

Page 402: ...ndicated 89 N m 9 1 kgf m 66 tbHt careful not to Slake the lock nut into the case groove damage the threads orrha case RING GEAR INSTALLATION 11 121 Clean the mating surfaces of the ring gear 1 and 18 40 differential housing 2 thoroughly and install the ring gear aligning the bolt holes in the gear and housing Install new ring gear bolts 31 and lighten them in a crisscross pattern in several steps...

Page 403: ... Clean the mating surface of the gear case and cover being careful not to damage them Blow compressed air through the breather hole in the case cover Install the proper ring gear shims 1 onto the differential 111111111111111 111111111111 assembly 1J Inslall the differential assembly 1 into Ihe gear case ___ 2 ll iW Coat a new O ring 3 with grease and install it into the 3 case cover groove Install...

Page 404: ...47 N m 4 8 kgf m 351bHt 8 mm bolt 2 25 N m 2 5 kgf m 18 lbHtl Make sure that the gear assembly rotates smoothly without binding Install the following final clutch housing page 18 24 differentiallockclulch housing page 18 29 FRONT FINAL DRIVE INSTALLATION Place the gear case assembly 1 into the frame Install the right drive shaft 2 into the gear case page 18 13 12 Install a new stopper ring 1 into ...

Page 405: ...rease to the propeller shaft joint splines Move the gear case assembly forward for maximum clearance between the shaft joint 5 and output shaft 6 Engage the shaft joint over the output shaft and move the gear case assembly rearward The mounfing bolts Install the mounting bracket 1 onto the gear case 2 are installed from with the lower mounting bolt 12 mm 3J and a new the left Side mounting nut 41 ...

Page 406: ...le holder to secure the cable Operate the differenliallQck arm to the upper side to set it to the lock free position Connect the differential lock cable to the lock arm 11 and install it into the cable holder 2 by aligning the flat surfaces Install the washer 3 and a new cotter pin 4 Make sura that the Screw the cable nuts 5 together gradually to move dnWJ mode selector both nuts to the cable hold...

Page 407: ... the selector cable page 18 65 REAR FINAL DRIVE REMOVAL Drain the rear final drive oil page 3 13 Remove the following right rear drive shaft page 18 8 right lower arm page 19 23 rear brake caliper mounting bolts page 20 20 breather hose 1 VS sensor 3P connector 2 Remove the boot bands 1 and release the propeller iii shaft boot 2 off the pinion joint 3 of the gear case DRIVE SHAFT FINAL GEAR 18 45 ...

Page 408: ...m Ihe mounting points by pulling it rearward and disconnect Ihe t propeller shaft 3 Hold Ihe inboard joint 1 of Ihe left rear drive shaft and tug firmly to force the stopper ring 2J on the inboard joint end past the groove while prying with a screwdriver Move the drive shaft aside and remove the rear final gear case 3 Disconnect the universal joint 1 from the output shaft 2J and remove the O ring ...

Page 409: ...oot 4 boot bands 5 INSPECTION PROPELLER SHAFT Check the splines 1J of the propeller shaft for wear or damage If they are damaged check the pinion and universal joint splines also UNIVERSAL JOINT Check the boot for cuts or other damage Check that the joint moves smoothly without binding or noise 111 DRIVE SHAFT FINAL GEAR 121 5 41 3 1 I 18 47 ...

Page 410: ...ry UNIVERSAL JOINT DISASSEMBLYI ASSEMBLY Bend up the lock tabs 1 and raise the band ends 211o loosen the boot bands Remove the joint boot 3 Apply grease to the joint bearing and boollips Inslall the boot and set it onto the universal joint properly Install new boot bands 111 so the band ends are facing opposite the forward direction Viewed from the rear side Bend down each band end 2 and secure it...

Page 411: ... measurements exceeds the service limit it indicates that the bearing is not installed squarely or the case is deformed Inspect the bearings and case If the backlash is excessive replace the ring gear right shim 1 with a thinner one If the backlash is too small replace the ring gear right shim with a thicker one Backlash is changed by about 0 06 mm 0 002 in when thickness of the shim is changed by...

Page 412: ...ve the bolts 1 and rear brake disc 2 Loosen the cover bolts 11 in a crisscross pattern in several sleps and remove them Pry the case cover 1 altha prying points 12J using a I I screwdriver and remove the case cover Remove the ring gear 1 and shims 121 18 50 ...

Page 413: ... contact pattern check I is Important 10 tum the pin Ofl while lighlenmg the bolts If the ring gear shims is 00 IhlCk the gears will lock after only light tightening Install the ring gear shims 1J onto the ring gear 21 Inslallthe ring gear with the shims into the gear case Align the boll holes and install the case cover 1 Install the cover bolls and tighten them in several steps until the cover ev...

Page 414: ...contact pattern is too high toward the face 1 FACE I FACE I Drive side Coast side Replace the pinion shim 1J with a thinner one if the T O O L O W contact pattern is too low toward the flank The pattern will shift about 0 5 1 0 mm 0 02 0 04 in when the thickness of the shim is changed by 0 12 mm 0 005 in Pinion gear shims A 1 32 mm 0 052 in B 1 38 mm 0 054 in C 1 44 mm 0 057 In 0 1 50 mm 0 059 in ...

Page 415: ...ds of the case are not damaged Remove the lock nut using the special tool TOOL Holding tool 111 Snap on YA6010A or equivalent Install the special tools onto the pinion gear shaft and gear case TOOLS Pinion puller base 111 Puller shaft 2 07HMC MM80110 or 07HMC MM8011A U S A only 07931 ME40000 or 07931 ME4010B and 07931 HB3020A U S A only Puilihe pinion gear assembly out from the gear case 18 53 ...

Page 416: ...ion shim 13 13J Inslalithe shim 1 and a new bearing 2 onlo the pinion gear 3 NOTE When the gear set ring gear bearing andlor gear case has been replaced use a 1 50 mm 0 059 in thick shim for initial reference Press the pinion gear 1 in the bearing until it is seated by supporting the bearing inner race with the special tool TOOL Attachment 25 mm 1 0 2 07746 0030200 11 j ...

Page 417: ...cover Driver 2J 07749 010000 Attachment 62 x 68 mm 3 07745 010500 Pilot 30 mm 4 07746 1040700 Gear case Driver Attachment 62 x 68 mm Pilot 30 mm 07749 0010000 07746 Q010500 07746 0040700 DRIVE SHAFT FINAL GEAR 13VI4j Apply grease to new oil seal 1J lips iiiiliil Install each oil seal with the metal side facing oul until it is fully seated TOOLS Driver 40 mm 1 0 2 07746 0030100 Attachment 35 mm 1 0...

Page 418: ...bearing cage and bearings from the inside of the pinion bearing to allow the special 1001 to grip the bearing Install a new stopper ring 11 into the groove in a new bearing 1 2 Inslall the bearing into the special tool until the stopper ring is flush with the end of the tool TOOL Bearing clip compressor 25 mm 3 070ME HN80100 or 070ME HN8A100 U S A only Freeze the pinion bearing with the tool on ic...

Page 419: ...IM PINION GEAR SHIM 0 f PINION BEARING PINION JOINT e STOP PIN c fl SHIM LOCK NUT GEAR CASE COVER INNER OIL SEAL 47 N m 4 8 kgf m 35 Ib ft 1m 25 N m 2 5 kgf m 181bHt OIL SEAL 111 20 N m 2 0 kgf m 1Slbf ft BRAKE OISC OUTER OIL SEAL iii Actual 98 N m IO O kgf m 72lbHt Indicated 89 N m g t kgf m 66lbHt PINION JOINT LOCK NUT 108N m 11 0kgf m 80IbHt 18 57 ...

Page 420: ...to ao c 176 F avoid bums when Drop the cold pinion assembly into Ihe warm gear case handting the healed gear case Using a torch 0 heal he gear case may cause warpage 11 Install a new lock nul IJ and lighten it using Ihe special 1001 I Refer to torque wrench reading informallOTl OIl Service InfonnallOfl page 18 4 TOOL Holding tool 12 nap on YA6010A or equivalent TORQUE Actual 98 N m 10 0 kgf m 721b...

Page 421: ...50500 Clean the threads of the pinion gear shaft thoroughly Install the pinion joint 1 onto the pinion gear shaft being careful nol to damage the oil seal lips Apply locking agent to Ihe threads of the pinion joint nut 12 and screw it in by hand as far as it goes Hold the pinion joint with the special tool and tIghten the joint nut TOOL Pinion holder 31 07SMB HM70200 TORQUE 108 N m 11 0 kgf m 80 I...

Page 422: ...ll a stop pin shim 2 to obtain the correct clearance STOP PIN SHIMS A 0 10 mm 0 004 In 8 0 15 mm 0 006 In Drive the stop pin into the case cover FINAL GEAR CASE ASSEMBLY NOTE When the gear set bearing and or gear case has been replaced check the tooth contact pattern check page 18 51 Check the gear backlash page 18 49 Clean the mating surface of the gear case and cover being careful not to damage ...

Page 423: ... N m 2 5 kgf m 18 IbHt Check thai the gear assembly turns smoothly without binding Install the rear brake disc 1 Install and tighten new brake disc bolts 2 TORQUE 20 N m 2 0 kgf m 151bHt DRIVE SHAFT FINAL GEAR 3tJ 121 REAR FINAL DRIVE INSTALLATION Inslall a new dust seal 1 onto the seal groove in the propeller shaft 2 in the direction as shown Apply molybdenum disulfide grease to the lips Install ...

Page 424: ...mbly 11 into the frame Be careful not to Install the left rear drive shaft by holding the inboard damage the 011S6a joint 21 until the stopper ring seals in the groove of the m the gear case differential 18 62 Make sure thai the stopper ring is seated properly by pulling on the inboard joint lightly Apply 5 8 9 of molybdenum disulfide grease to the pinion toint splines Apply molybdenum disulfide g...

Page 425: ...ooves of the boot Install the following breather hose 1 VS sensor 3P connector 2 rear brake caliper mounting bolts page 20 25 right lower arm page 19 25 right rear drive shaft page 18 13 Fill the gear case with the recommended oil page 3 13 DRIVE MODE SELECTOR LEVER LINKAGE REMOVAL Remove the front hood page 2 12 Sellhe drive mode selector lever to the 2WD position Remove the following selector le...

Page 426: ... bolt Tighten the pivot boll 1 2 2 1 3 1 Apply grease to the groove in the selector lever pivot bolt 1 _ jjjVp Install the lever spring 2 onto Ihe selector lever 3 in the direction as shown Instal the selector lever through the lever gale and onto the lever arm by setting the lower spring end into the arm groove as shown Hold the lever pivot securely to align the bolt holes then install the pivot ...

Page 427: ...move the following right front wheel page 19 6 front hood page 2 12 Set the drive mode selector lever 11 to the 2WD position Remove the bolt 11 and the clutch arm cover 12 by releasing it from the two labs 13 loosen the adjusting nul 11 on the drive mode selector cable 2J thoroughly until the cable is not forced to get the clearance between the jOint pin 3 and upper side of the arm slot 4 DRIVE SH...

Page 428: ... to the lock free position upper side check thai the differentia lock indica or does not rome on Do not move the Screw the cable nuls 111 on the differential lock cable r selector lever from together gradually to move both nuts to the cable the 2WD position holder 2 side by your hands so that the cable is not forced until they are touched to the cable holder 18 66 Tighten the cable nul while holdi...

Page 429: ...usting nut 2J on the drive mode selector cable clockwise until the joint pin 31 just touches the clutch arm slot 4J with the nut ends 5 contacting the joint pin cutout is not seated Then further turn it clockwise 1 4 of a turn to seat the cutout in Ihe nut onto the joint pin Make sure that the clearance between the joint pin and arm slot is 0 25 2 mm 0 01 0 39 in After adjustment check the selecto...

Page 430: ...MEMO ...

Page 431: ...ION 19 4 TROUBLESHOOTING 19 5 WHEELS 19 6 TIRES 19 6 FRONT WHEEL HUB KNUCKLE 19 10 19 WHEEUSUSPENSION FRONT SUSPENSION ARM 19 15 FRONT SHOCK ABSORBER 19 20 REAR WHEEL HUB KNUCKLE 19 21 REAR SUSPENSION ARM 19 23 REAR SHOCK ABSORBER 19 27 19 1 ...

Page 432: ...I 11 N m 1 1 kgf m 8Ibf t 29 N m 3 0 kgf m 21 Ibf ft 32IbHt 34 N m 3 5 kgf m 251bHt 12 N m 1 2 kg m 9lbHt _ _ ___ JU 12N m 1 2 kgf m 9Ibf ft 65 N m 6 6 kgf m 48 IbUt 108 N m 11 0 kgf m 80 Ibfo tt 19 2 137 N m 14 0 kgf m 101 Ibf ft 133 N m 13 6 kg m 981bHt j j j ...

Page 433: ... 44 N m 4 5kgf m 321bHt 64 N m 6 5 kgf m 47 1 bf tt l 46 N m 4 7 kgf m 34 Ibf H 44 N m 4 S kgf m 32 Ibf ft WHEEUSUSPENSION 34 N m 3 S kgl m 251bHt 64 N m 6 5 kgf m 471bHt 46 N m 4 7 kgfm 34lbf ft 27 N m 2 8 kgf m 20 IbHt 137 N m 14 0 kgf m 101 Ibf ft 133 N m 13 6 kgf m 981bHt 19 3 ...

Page 434: ...st toe whenever the knuckle or steering gear box components are replaced or removed page 3 22 For brake system service see Brake System section page 20 4 For steering system service see Steering System section page 17 3 TOOLS Attachment 62 x 68 mm 07746 0010500 Attachment 72 75 mm 07746 0010600 Driver 07749 0010000 Attachment 28 x 30 C m m F o seal driver Oil seal driver attachment 07946 1870100 0...

Page 435: ...ly installed suspension arms Faulty suspension arm bushings Suspension noise Faulty shock absorber Loose suspension fasteners Worn suspension pivot bushings Damaged suspension components Inner bearing driver attachment 07HMD MR70100 Ball jOint base 07965 5800300 or 07JAF SH20200 Steers to one side or does not track straight Unequal tire pressure Damaged suspension arm or frame Worn or damaged knuc...

Page 436: ...rotectors and tire irons may be used Adjust the bottom rim supports PI to the proper rim size Align the flat side of the support with the corresponding rim size indicator US90nlywarerasa Lube the bead area of the tire with water pressing lubncanr when down on the tire sidewalVbead area in several places to remoVing 01 allow the water to run into and around the bead mounting tires Soap or soma moun...

Page 437: ...ts the rim back the crank out two turns to Ihe bead lock allow Ihe shoe to clear the rim s bead lock which may cause the fire to eak 131 11 121 Push down on the leverage bar 1 to push the tire bead I over the bead lock Use only short strokes on the wheel as far as it will go between strokes as you break handle While the shoe 21 is still engaged turn the 1 _ 1 1 1 the bead around the rim Remove the...

Page 438: ...is three times Do not let the cement dry Insert and center a rubber plug through the eye of the inserting needle Apply cement to rubber plug Push the inserting needle with plug into the injury until the plug is slightly above the tire Be careful not to Twist the needle and remove it from the tire the plug push the plug all the will slay in the tire way into the tire fo prevent from fa ling inside ...

Page 439: ...rim shoulder width is the narrowest to simplify installation Clean the rim bead seat and flanges Use only waler as a Apply clean water to the rim flanges bead seat and lubricant when base removing or mounting tires Soap or some mounting lubricants may leave a slippery residue which can cause the tire to shift on the rim and lose air pressure dunng dn ving Install the valve core in the valve stem I...

Page 440: ...age 19 6 outboard guard page 20 8 boll 11 and brake hose clamp 2 bolt 131 and splash guard 4 Support the caliper two mounting bolts 11 and brake caliper 2 so thaI il does nol hang from the brake hoS6 Do 001 twist orbend the brake hosa cotter pin 11 hub nut 21 wheel hub 3 19 10 j 131 ...

Page 441: ...g instructions TOOL Ball joint remover 28 mm 2J 07MAC SL00201 or 07MAC 5L00202 U S A only Apply grease to the ball jOint remover at the point shown This will ease installation of the tool and prevent damage to the pressure bolt 1 threads Insert the jaws carefully making sure that you do not damage the ball joint boot If necessary apply Adjust the Jaw spacing by turning the pressure bolt penetratin...

Page 442: ...eck the jaws to make sure they are stili parallel Tighten the pressure bolt with a wrench until the ball joint stud pops loose Remove the ball joint nuts and the knuckle INSPECTION Remove the dust seals 11 from the knuckle 21 Turn the inner race of the bearing PI in the knuckle with your finger The bearings should turn smoothly and quietly Also check that the bearing outer race fils tightly knuckl...

Page 443: ...lall the snap ring into the knuckle groove with the chamfered side facing in INSTALLATION WHEEL SUSPENSION Install the inner seal Coat the lips of new inner dust seal 1 and Quter dust r first then install he seal 2 with grease and install each dust seal until it is outer seal flush with the knuckle being careful nollo damage the lip TOOLS Driver 3 07749 0010000 Oil seal driver aHachment 4 07947 63...

Page 444: ...with the ball joint 19 14 nut 12 Tighten the joint nut to the specified torque TORQUE 65 N m 6 6 kgf m 48 IbHt Apply molybdenum disulfide grease to the drive shaft 1 splines Apply 5 mm 0 2 in bead of sealant Threebond TB 1215 or l octile l T5699 or equivalent to the innermost threads of the drive shaft hub nut mounting area Install the wheel hub 1 to the knuckle and drive shaft Install the hub nul...

Page 445: ... 9 lbHt Install the hose clamp 3 with a new clamp bolt 4 and tighten it to the specified torque TORQUE 12 N m 1 2 kgf m 9lbHt Install the following outboard guard page 20 8 front wheel page 19 6 FRONT SUSPENSION ARM REMOVAL Remove the following front wneel page 19 6 outboard guard page 20 8 Remove the two bolls 1 and brake hose clamps 2 Remove the cotter pins PI from the ball joint studs Loosen th...

Page 446: ...trap 111 Release the ball joints using the special tool according to the instructions page 19 11 TOOL Ball joint remover 28 mm 2 07MAC 5L00201 or 07MAC 5L00202 U S A only Remove the ball joint nuts 3 washers 4 and the wheel hub knuckle assembly from the arms and drive shaft and support it securely Remove the following pivot nuts 1J bolts 2 and lower arm 3 pivot nuts 4J bolts 5J and upper arm 6J j ...

Page 447: ...her damage replacement by moving the ball jOint stud page 19 17 II should move freely and smoothly BALL JOINT REPLACEMENT UPPER ARM Remove the snap ring 1 Jfrom the ball joint 2J WHEEUSUSPENSION 31 11 SUpport the upper arm with the special tool and press the ban Joint 1 oul of the upper arm TOOLS Attachment 28 x 30 mm 2J 07946 1870100 Fork seal driver attachment 07947 KA40200 31 19 17 ...

Page 448: ...in LOWER ARM Remove the bool from the ball joint 1 Support the lower arm with the special tool and press the ball joint out of the lower arm TOOLS Attachment 52 x 55 mm 2 Inner driver attachment 3 Ball joint base 4 07146 0010400 07HMD MR70100 07965 5800300 or 07JAF sH20200 Support the lower arm with the special tool as shown Press the ball joint 1 into the lower arm until it is fully seated using ...

Page 449: ...t to the specified torque and further tighten until its grooves align with the cotter pin hole TORQUE 29 N m 3 0 kgf m 21 IbHt Install new cotter pins Pl Adjust the suspension arm angle with a jack supporting the lower arm so that the distance between the centers of the shock absorber mounting bolt holes is 440 448 mm 17 3 17 6 in After adjusting the angle lighten all the upper and lower arm pivot...

Page 450: ...ard page 20 8 Install the front wheel page 19 6 FRONT SHOCK ABSORBER REMOVAUINSTALLATION Raise the front wheels off the ground Support the lower arm Remove the mounting nuts Pl bolts 2 and shock absorber 3 Insert the bolfs from Inslalilhe shock absorber with the mounting bolts and the front side new nuls and lighten them TORQUE 44 N m 4 5 kgf m 32Ibf ft INSPECTION Check the bushings 1 for wear or ...

Page 451: ...l 2 upper arm pivot nut 3 and bolt 4J knuckle 5 from the drive shaft INSPECTION Check the pivot bushings 1 for wear or damage Inspect the knuckle 2 for damage or cracks Turn the inner race of the bearing 3 in the knuckle with your finger The bearing should tum smoothly and quietly Also check that the bearing outer race fits tightly in the knuckle WHEEUSUSPENSION 131 19 21 ...

Page 452: ...and lower arms with its UP mark 2 facing up as shown nserrtheOOlls from Install the pivot bolts 13 and new nuls 4 then tighten the rearside them to the specified torque 19 22 TORQUE 44 N m 4 5 kgf m 32 IbHt Apply 5 mm 0 2 in bead of sealant Threebond TB 1215 or loclile LT5699 or equivalent to the innermost threads of the drive shaft hub nut mounting area Install the wheel hub 11to the knuckle and ...

Page 453: ...owing lower arm pivot nut 1 and bolt 2 knuckle side lower arm pivot nuts 3 and bolls 4 frame side lower arm 5 UPPER ARM Remove the following upper arm pivot nut 1 and bolt 2 knuckle side upper arm pivot nuts PI and bolts 4 frame side upper arm 5 STABILIZER ARM AND LINK Remove the following link nuts 1 while holding the stud bolt end stabilizer links 2 WHEEUSUSPENSION 19 23 ...

Page 454: ...other damage Check the pivot bushings 31 for wear or damage For pivot bushing inspection of the knuckle side see Rear Wheel Hub Knuckle page 19 21 Check the stabilizer bushings 11 for wear or damage Check the stabilizer arm 21 for distortion or damage Inspect the ball joint boots 131 of the stabilizer link 4 for lears or other damage by moving the ball joint stud 131 ...

Page 455: ...shings 1 and holders 2 onto the stabilizer arm 3 Install the stabilizer arm onto the frame with bolts 4J and nuts 5 Tighten the four bolts while holding the nuts alternately TORQUE 27 N m 2 8 kgf m 20 IbHt The stabilizer links 1 have the identification mark Left link L mark 2 Righi link R mark 3 Install the stabilizer links with new link nuts 4 and lighten them while holding the stud bolt end TORQ...

Page 456: ...Connect lower arm to the knuckle with the pivot bolt 4 and a new nut 5 Tighten the fasteners with both the upper and lower arms installed page 19 26 SUSPENSION ARM FASTENER TIGHTENING 11 Adjust the suspension arm angle with a jack supporting the lower arm so that the distance between the centers of the shock absorber mounting bolt holes is 409 417 mm 16 1 16 4 in 409 417 mm 19 26 After adjusting t...

Page 457: ...rber in pOSition while pushing down the lower arm Insert the bolts from Install Ihe mounting bolts and new nuts and tighten the front side them TORQUE 64 N m 6 5 kgf m 47 Ibl tt Instailihe stabilizer link 1 with a new link nut 2J and tighten it while holding the stud bolt 3 end TORQUE 46 N m 4 7 kgf m 341bHt Instalilhe rear wheel page 19 6 INSPECTION Check the pivot bushings 11 for wear or damage ...

Page 458: ...MEMO I l I ...

Page 459: ...20 2 MASTER CYLINDER 20 1 2 SERVICE INFORMATION 20 4 FRONT BRAKE CALIPER 20 16 TROUBLESHOOTING 20 5 REAR BRAKE CALIPER 20 20 BRAKE FLUID REPLACEMENT AIR BRAKE PEDAL 20 26 BLEEDING 20 6 PARKING BRAKE LEVER 20 27 BRAKE PAD DISC 20 8 20 1 ...

Page 460: ...BRAKE SYSTEM SYSTEM COMPONENTS 14 N m 1 4 kgf m 10 Ibf ft 27 N m 2 8 kgf m 20 Ibf ft 108 N m 11 0 kgf m 80 IbHt 11 N m 1 1 kgf m 81bHtJ 20 2 I I I I I Y 34 N m 3 5 kgf m 25Ibf ft ...

Page 461: ...30 N m 3 1 kgf m 22Ibf ft 32 Nm 3 3 kgf m 24 Ibf ft 27 N m 2 8 kgf m 20 IbHt BRAKE SYSTEM 34 N m 3 5 kgf m 25Ibf ft 20 3 ...

Page 462: ...move the reservoir cap A contaminated brake disc or pad reduces stopping power Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent Never allow contaminates dirt water etc to get into an open reservoir Once the hydraulic system has been opened or if the brake feels spongy the system must be bled Always use fresh DOT 4 brake fluid from a sealed containe...

Page 463: ...deformed brake disc Stickinglworn caliper piston Sticking wom master cylinder piston Incorrect pedal height adjustment page 3 16 Brake pedal hard Clogged restricted brake system Stickinglwom caliper piston SlickinglWorn master cylinder piston Caliper not sliding properly Bent brake pedal Brake drags Contaminated brake pad disc Badly worn brake pad disc Warpedfdeformed brake disc Caliper not slidin...

Page 464: ...ul of the reservoir tank Remove the reservoir cap 2 by turning it counterclockwise Remove the bolts 1 and outboard guard 21 Remove the bleed valve cap 1 i Connect the bleed hose 2 to the caliper bleed valve 3 Loosen the bleed valve and pump the brake pedal unlil no more fluid flows out of the bleed valve Perform above procedure for each caliper bleed valve 1 I I I ...

Page 465: ...bHt Rear 5 4 N m 0 6 kgf m 4 0 IbHt Inslallihe valve cap Perform the above procedure al each remaining bleed valve After bleeding air operate the brake pedal If it still feels spongy bleed the system again If the brake bleeder is nol available perform the following procedure Pump up the system pressure with the brake pedal until the pedal resistance is felt Connect a bleed hose 1 to the caliper bl...

Page 466: ...from a sealed container Install the reservoir cap 2 so the arrow 31 is facing forward Tum the cap cover 11 inside out and install it over the IIIIIIIIIIII reservoir cap securely Install the front hood page 2 12 BRAKE PAD DISC 20 8 FRONT BRAKE PAD REPLACEMENT Remove the front wheel page 19 6 Remove the bolts 11 and outboard guard 2 Remove the lower slide pin bolt 3 PI 1 ...

Page 467: ...nstall the outboard guard 21 and new bolts 31 then tighten them TORQUE 11 N m 1 1 kgf m 8lbHt Operate the brake pedal to seat the caliper piston against the pad Install the front wheel page 19 6 REAR BRAKE PAD REPLACEMENT Remove the right rear wheel page 19 6 Remove the slide pin bolts 11J Remove the caliper body 1 2 from the caliper bracket Remove the brake pads 1 Jfrom the caliper bracket Always...

Page 468: ...iston with the pin on the pad Instal the slide pin bolts 21 and tighten them TORQUE 32 N m 3 3 kgf m 24 1bHt Install the right rear wheel page 19 6 Operate the brake pedal to seal the caliper piston against the pad BRAKE DISC INSPECTION Remove the brake pad page 20 8 Visually inspect the brake disc for damage or crack Measure the brake disc thickness at several points SERVICE LIMIT Front 10 0 mm 0...

Page 469: ...RVICE LIMIT 0 30 mm 0 012 in Check the knuckle bearing for excessive play if the runout exceeds the service limit Replace the brake disc if the bearing Is normal Brake disc replacement front page 19 10 rear page 18 50 BRAKE SYSTEM 20 11 ...

Page 470: ...unting nuts 6J bolts 7J and master cylinder 61 from the frame Install the master cylinder with the mounting bolls and the nut aligning the push rod slit with the brake pedal Connect the brake pipes to the master cylinder with the joint nuts joint nuts Tighten the mounting nuts then tighten the jOint nuts 20 12 TORQUE Mounting nut 27 N m 2 8 kgf m 20 IbHt Brake pipe joint nut 14 N m 1 4 kgf m 10 Ib...

Page 471: ...condary piston assembly 21 primary piston assembly 3 Clean the reservoir master cylinder and pistons in clean brake fluid INSPECTION Check the piston cups 4 and boot for wear deterioration or damage Check the piston springs 51 for damage Check the master cylinder and piston for scoring scratches or damage BRAKE SYSTEM 121 121 131 I 151 20 13 ...

Page 472: ...ean DOT 4 brake fluid Do not allow the Install the primary and secondary piston assemblies pIston cup lips to into the master cylinder tum inside oul SECONDARY PISTON A ASSEMBLY I t PUSH ROD I Be certa n the Sfl8p Install the snap ring 1J into the groove in the master nng IS firmly sealed cylinder with the chamfered edge facing in in the groove 1 20 14 ...

Page 473: ...rod 1 Install the boot 2 into the boot groov8 Apply 0 1 9 of silicone grease to the boot groove in the master cylinder body and to the push rod end Install Ihe push rod boot assembly into the piston and boot groove in the master cylinder Install new oil seals 1 onto the reservoir 2J InSlali the reservoir into the master cylinder and secure it with the bolt 131 TORQUE 2 5 N m 0 3 kgf m 1 8Ibf ft 20...

Page 474: ...iper will be disassembled loosen the two slide pin bolts 1 Remove the two mounting bolts 121 and brake caliper 31 DISASSEMBLY Remove the two slide pin bolts 1 and separate the 20 16 caliper bracket 2 from the caliper body Remove the brake pads 3 121 Release the boot 1 rib from the pin groove and remove the pin A 21 and pin B 3 Remove the boots from the caliper bracket Remove the pad retainers 14 1...

Page 475: ...e caliper body with the piston down and apply small squirts of air pressure to the fluid inlet to remove the piston Remove the piston boot 1 Push the piston seal 11 in and lift it out Clean the boot and seal grooves caliper cylinder and piston with clean brake fluid INSPECTION Check the caliper cylinder and piston for scoring scratches or damage BRAKE SYSTEM 20 17 ...

Page 476: ...ove in the caliper cylinder Pack the inner and outer edge of a new piston boot 2J with 0 6 1 5 g of silicone grease Install the inside boot rib of piston boot into the boot groove in the caliper cylinder properly Coat the caliper piston 3J with clean brake fluid and place it into the caliper body with the groove side toward the brake pad Cover the piston with the boot carefully then push the pisto...

Page 477: ...ll the brake pads 1 onto the caliper bracket 2 so the wear indicator 3 on the inner pad is facing the IJ lower side Inslall the bracket on to the caliper body with the slide 131 pin bolts 4J 121 INSTALLATION Install the brake caliper I onto the knuckle With new mounting bolls 2 and lighten them TORQUE 108 N m 11 0 kgf m 80 IbHt If the caliper was disassembled tighten the slide pin bolts 3 while ho...

Page 478: ... 3 Remove the cable from the caliper body 4 Remove the joint pin 5 Disconnect the brake hose 1 from the caliper body by removing the oil bolt 2J and sealing washers 3 If the brake caliper 1 will be disassembled loosen the slide pin bolt 2 Remove the two mounting bolts 3 and the brake caliper from the final gear case DISASSEMBLY Remove the slide pin bolt 1 and pivot the caliper body 121 I1J 20 20 ...

Page 479: ... body 1 J from the caliper bracket 21 Remove the boots 3 and coilar 4J from the caliper bracket Remove the caliper piston 11 by turning it counterclockwise Remove the piston boot 2 Be careful not 10 Push the piston seal 1Jin and 11ft II out damage the pIs on sliding surface 20 21 ...

Page 480: ...B 2 spacer 3 bearing A 4J adjusting bolt 5J cup 6 sleeve piston 7 rod 8 D ring 9 tetum spring 1 parking brake arm nut 2 spring washer 3 brake arm 4 brake cam 5 dust cover 6 07914 5A50001 or 07914 3230001 Clean the disassembled parts in clean brake fluid INSPECTION Check the caliper cylinder and piston for scoring or other damage 71 lSI 31 PI ...

Page 481: ... facing the caliper cylinder Instalilhe brake arm 13 spring washer 4 and parking brake arm nut 5 Tighten the parking brake arm nul TORQUE 27 N m 2 8 kgf m 20 IbHtj Install the return spring 6J as shown Coat a new O ring 1J with silicone grease and install it into the sleeve piston 2 groove 1 iiSiII Coat a new cup 3 with 0 1 g of silicone grease and j install it onto the adjusting bolt 4 Install th...

Page 482: ... the piston boot into the groove in the caliper Install the caliper piston into the caliper cylinder and onto the adjusting bolt by turning it clockwise Install the piston boot into Ihe groove in the caliper piston 13J 121 1 Apply 0 4 g minimum of silicone grease to the sliding area of new boots 1 and install them into the caliper bracket Inslalilhe collar 2 into the caliper bracket Coal Ihe slide...

Page 483: ...QUE 32 N m 3 3 kgf m 24 IbHt Connect the brake hose 1 to the brake caliper with the oil bolt 2 and new sealing washers 3J and tighten the oil bolt TORQUE 34 N m 3 S kgf m 25 IbHt Install the pa ing brake cable 111 into the caliper body 2 and connect It to the brake arm 3 with the joint pin 141 Install the adjuSling nut 51 Fill and bleed the hydraulic system page 20 6 Adjust the par1 ing brake leve...

Page 484: ...per bolts 8J two lower bolts 9 and the brake pedal assembly INSTALLATION Install the brake pedal assembly with the four bolls and two nuts aligning the pedal arm with the push rod slit Tighten the fasteners alternately TORQUE 27 N m 2 8 kgf m 20 IbHt Connecllhe push rod to the pedal with the jOint pin and secure it with the clip Hook the relum spring and switch spring Install the front hood page 2...

Page 485: ...stall the washer 5 and a new cotter pin 6 PARKING BRAKE LEVER REMOVAUINSTALLATION Remove the left front fender page 2 13 BRAKE SYSTEM 1 4 Release the parking brake 4J Disconnect the parking brake switch 2P black connector 1J Remove the nuts 2 bolts 3 and parking brake lever 4 from the frame Remove the lever boot 5 Remove the cotter pin 6 washers 7 and joint pin 8 then disconnect the parking brake ...

Page 486: ...MEMO ...

Page 487: ... CHARGING SYSTEM COMPONENT LOCATION 21 2 BATIERY 21 4 SYSTEM DIAGRAM 21 2 CHARGING SYSTEM INSPECTION 21 5 SERVICE INFORMATION 21 3 ALTERNATOR CHARGING COIL 21 6 TROUBLESHOOTING 21 4 REGULATORJRECTIFIER 21 6 21 1 ...

Page 488: ...STEM COMPONENT LOCATION BATTERY MAIN ALTERNATOR SYSTEM DIAGRAM MAIN FUSE 40 A REGULATOR RECTIFIER G Green R Red Y Yellow 81 Black R o ro R y y y y Y Y R G R I I I I I r L L o e ALTERNATOR REGULATOR RECTIFIER BATTERY 21 2 ...

Page 489: ... overcharge often results from problems in the battery itself which may appear to be an overcharging symptom If one of the battery cells is shorted and battery voltage does not increase the regulator rectifier supplies excess voltage to the battery Under these conditions the electrolyte leve goes down quickly Before troubleshooting the charging system check for proper use and maintenance of the ba...

Page 490: ... removal positive cable first and then the negative cab e 21 4 VOLTAGE INSPECTION Remove the front seat cushion page 2 4 Measure the battery voltage using a commercially available digital mullimeter VOLTAGE 20 C 68 F FuUy charged 13 0 13 2 V Under charged Below 12 3 V BATTERY TESTING Remove the battery page 21 4 Refer to the instructions that are appropriate to the battery testing equipment availa...

Page 491: ...nt leakage exceeds the specified value a shorted circuit is likely Locate the short by disconnecting connections one by one and measuring the curren CHARGING VOLTAGE INSPECTION Remove the front seat cushion page 2 4 Be sure the battery is in good condition before performing this test Warm up the engine to normal operating temperature Connect the multimeter between the battery positive and negative...

Page 492: ...SS INSPECTION Disconnect the regulator rectifier 3P black connector 1 and 3P gray connector 21 Check the connectors for loose contacts or corroded terminals Check the following at the wire harness side connectors Battery Une Measure the voltage between the Red wire terminal and ground There should be battery voltage at all times Ground Une Check the continuity between the Green wire terminal and g...

Page 493: ...N 22 2 HEADLIGHT 22 3 BRAKEITAILLlGHT 22 4 COMBINATION METER 22 4 ACCESSORY SOCKET 22 8 IGNITION SWITCH 22 9 HEADLIGHT SWiTCH 22 10 HEADLIGHT RELAY 22 10 COOLING FAN MOTOR 22 12 FUEL METERIFUEL LEVEL SENSOR 22 14 BRAKE LIGHT SWITCH 22 15 PARKING BRAKE SWITCH 22 16 22 1 ...

Page 494: ...ands clean it with a cloth moistened with alcohol to prevent its early failure A halogen headlight bulb becomes very hot while the headlight is on and remains hot for a while after it is turned off Be sure 1 0 let it cool down before servicing All plastic connectors have locking tabs that must be released before disconnecting and must be aligned when reconnecting To isolate an electrical failure c...

Page 495: ...eadlight bulb Fingerprints can create hot spots that cause 8 bulb to fai Align the bulb tabs Installation is in the reverse order of removal with the headlll hl grooves properly REMOVAL INSTALLAnON Remove the following headlight bulb page 22 3 four tapping screws 1 boll 121 wire band 3 headlight assembly 4J adjusting screw 1 washer 2 nut 3J spring 4 headlight unit 5 from the cover 6 by releasing t...

Page 496: ...NSTALLATION Remove the screws 1 and brake taillight unit 2 Disconnect the 3P connector 3 from the brake taillight Remove Ihe well nuts 41 Installation is in the reverse order of removal COMBINATION METER REMOVAUINSTALLATION 22 4 Remove Ihe left front fender page 2 13 Release the harness clamp 1 Remove the four screws 21 and combination melerfrear cover assembly 3 Remove the three screws 11 and com...

Page 497: ...ppears To end the adjustment push the mode switch or turn the ignition switch to OFF POWER GROUND LINE INSPECTION Remove the front hood page 2 12 Disconnect the combination meter sub harness 1QP gray connector 1J Check the power and ground lines at the wire harness side connector POWER INPUT LINE Measure the voltage between the Black red wire terminal and ground There should be battery voltage wit...

Page 498: ... line page 4 28 2 Connector Check Check the combination meter sub harness 10P gray connector and PCM 33P connectors for loose contacts or corroded terminals Are the connectors in good condition YES GO TO STEP 3 NO loose or poor contacts at the combination meter sub harness 10P gray connector or PCM 33P connector 3 Combination Meter Serial Line Short Circuit InspectIon Turn the ignition switch to O...

Page 499: ...ub harness lOP gray connector terminal Connection Blue red Green Is the resistance 0 1 100 kO YES Replace the combination meIer with a known good one and recheck NO Replace the PCM with a known good one and recheck SPEEDOMETER Speedometer does not operate 1 Combination Meter Power Ground Line Inspection Check the odometerllrip meter and meter indicators functions Do they unction properly YES GO TO...

Page 500: ...ront hood page 2 12 Disconnecllhe accessory socket 2P green connector 11J Measure the voltage between the Whitelblack and Green wire terminals of the wire harness side 2P green connector There should be battery voltage with the ignition switch turned to ON I If there is no voltage check for blown ACC fuse 10 A and an open drcuit in the wire harness Remove the accessory socket cap 1 Check for conti...

Page 501: ...Disconnect the ignition switch 5P black connector 1 Check for continuity between the connector terminals in each switch position according to the continuity chart page 23 2 REMOVAL INSTALLAnON Disconnect the ignilion switch 5P black connector page 22 9 Remove the ignition switch nut 1 and ignilion switch 2 from the instrument panel Install the ignition switch into the instrument panel by aligning ...

Page 502: ... the switch is turned to ON I REMOVAL INSTALLATION Disconnect the headlight switch 2P black connector page 22 10 Release the hooks 111 and remove the headlight switch 2 from the instrument panel Installation is in the reverse order of removal HEADLIGHT RELAY REMOVAL INSTALLATION 22 10 Remove the relaylf1lse box cover page 6 9 Tum the ignilion switch to OFF 0 Remove the headlight relay 11 from the ...

Page 503: ... STEP 2 NO Open circuil in the Brown wire between the relay connector and fuse box Blown LIGHT fuse 15 A Open circuit in the Redlblack wire between the fuse box and ignition switch 2 Relay Coli Circuit Inspection Turn the ignition switch and headlight switch to ON Measure the voltage between the Whitelblack and Green terminals of the headlight relay connector 1 Is there battery voltage YES The hea...

Page 504: ... the PGM FI system DTC page 4 7 Is DTe 7 1 and or 7 2 Indicated YES Perform the DTC 7 1 troubleshooting page 4 12 Perform the DTC 7 2 troubleshooting page 4 13 NO GO TO STEP 3 3 Ground Line Inspection Remove the front seat cushion page 2 4 Disconnect the PCM 5P black connector 1 Check for continuity between the Green wire terminal of the wire harness side 5P black 22 12 connector and ground Is the...

Page 505: ...he jumper wire connected to the PCM 5P black connector check for continuity between the Green black wife terminal of the wire harness side 2P connector and ground Is there continuity YES GO TO STEP 6 NO Open circuit in the Greenlblack wire 6 Cooling Fan Motor Power Input Line Inspection Turn the ignition switch to ON I Measure the voltage between the Blue wire terminal of the wire harness side 2P ...

Page 506: ... in Whilel blue or Light blue wire and loose contact of the wire harness connectors Check for continuity between the combination meier sub harness lOP gray connector and ground CONNECTION White blue Ground If there is continuity check for short drcui in Whilelblue wire If the wires are OK check the fuel level sensor page 22 14 If the fuel level sensor is OK replace the combination meter FUEL LEVEL...

Page 507: ... fully locked BRAKE LIGHT SWITCH REMOVAL INSTALLATION Route the brake light sWitch wire properly page 1 17 Remove the front hood page 2 12 Disconnect the brake light switch 2P gray connector and 11 release the wire from the two wire clips 2 Unhook the brake light switch spring 3 and brake pedal return spring 4 from the brake pedal and brake light switch 5 Remove the brake light switch from the sta...

Page 508: ...onnect the parking brake switch 2P black connector 1 Check for continuity between the switch side connector terminals There should be continuity when Ihe parking brake is applied and no continuity when the parking brake is released REMOVAUINSTALLATION Disconnect the parking brake switch 2P black connector page 22 16 Puilihe parking brake lever fully and remove the screw 1 and parking brake switch ...

Page 509: ...23 WIRING DIAGRAM WIRING DIAGRAM 23 2 23 1 ...

Page 510: ......

Page 511: ...MEMO 1 1 I j ...

Page 512: ...BLE ADJUSTMENT 18 65 DRIVE MODE SELECTOR LEVER LINKAGE 18 63 DRIVE SHAFT 18 8 DRIVE SHAFT BOOTS 3 12 DRIVETRAIN DTC INDEX 6 13 INDEX DRIVETRAIN DTC TROUBLESHOOTING 16 14 DRIVETRAIN SYSTEM DIAGRAM 16 11 DRIVETRAIN TROUBLESHOOTING INFORMATION 16 12 ECT SENSOR 4 27 EMISSION CONTROL SYSTEMS 1 32 ENGINE IDLE SPEED 4 29 ENGINE INSTALLATION 15 8 ENGINE OIL 3 9 ENGINE REMOVAL 15 4 EOT SENSOR 16 55 EXHAUST...

Page 513: ...ICE RULES 1 2 SHIFT CLUTCH MAINSHAFT COUNTERSHAFT 16 44 SHIFT VALVE BODY 16 25 SIDE NET FRAME BODY PANELS EXHAUST SYSTEM 2 24 3 23 MAINTENANCE SPARK ARRESTER SPARK PLUG 3 18 3 7 SPECIFICATIONS STARTER MOTOR STARTER RELAY SWITCH STEERING COLUMN AND SHAFT STEERING GEAR BOX STEERING SySTEM STEERING WHEEL SUB TRANSMISSION 1 4 6 4 6 8 17 4 17 9 3 20 17 4 13 9 SUSPENSION 3 18 SYMPTOM TROUBLESHOOTING DRI...