Mitsubishi Montero 1987, Service Manual

Page 1: ...ITSUBISHI MOTOR SALES OF AMERICA Inc Mitsubishi Motors corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products previously manufactured I GROUP SECTION INDEX kme INTRODUCTION Electrical Electrical System Parts Location Relays Control Units Sensors Fuses Groundings In...

Page 2: ...ue used as the standard for judging the quality of a part or assembly on inspection or the value to which the part or assembly is corrected and adjusted It is given by tolerance LIMIT Shows the standard for judging the quality of a part or assembly on inspection and means the maximum or minimum value within which the part or assembly must be kept functionally or in strength It is a value establish...

Page 3: ...hermostat I This number corresponds to the number in Removal steps Disassembly steps Installation steps or Reassembly steps NOTE 1 3 q Nowreusable parts r Reverse the removal procedures to reinstall 12 l Refer to Sewce Points of Installation SERVICE POINTS OF lNSTALLATlON 45 INSTALLATION OF THERMOSTAT Install the thermostat to the Intake manifold as illustrated Caution The thermostat flange fits o...

Page 4: ...ode which tells country make vehicle type etc Country Make J A Japan Mitsu bishi Vehicle type Line 4 F J Multi 4001 Ibs MON purpose or more TERO vehicle with MPW hydraulic brakes 7 Truck 6th digit Price class 2 Low 4 High 7th 8th 9th 10th digit digit digit digit Body Engine Check Model digit year 3 E 0 H 3 door 2 6 liters 1 1987 metal 155 9 2 year top or C I D 3 van 9 X Plant 1ZZ Zer 1 NOTE Check ...

Page 5: ...SUBISHI MONTERO Engine displacement 2 555 liters 155 9 C I D Model code L042GVNJLH L042GVRJLH L042GTNSLH 1 L042GTNSLH OOK520 VEHICLE INFORMATION CODE PLATE NOOCO A Vehicle information code plate is riveted on the headlight sup port panel in the engine compartment The plate shows model code engine model transmission model and body color code 1 MODEL L042G VNJLF 2 ENGINE G54B I Engine model 3 TRANS ...

Page 6: ...cates the month and year of manufacture Gross Vehicle Weight Rating G V W R front and rear Gross Axle Weight Rating G A W R and Vehicle Identification Number V I N ENGINE MODEL STAMPING NOOCG The engine model number is stamped at the right front side on the top edge of the cylinder block as shown in the following 1 Engine model 1 Engine displacement 1 2 555 liters 155 9 C I D The engine serial num...

Page 7: ...0 x15 Two tone B21 B76H43 C38C19X13 H15H43X13 R06R52X13 S69S7OX13 X45X1 5H43 NOOCH Body color Dark blue Metallic Brown Metallic Silver Metallic Red Beige Black Silver Metallic Dark blue Metallic Black Brown Metallic Black Silver Metallic Black Red Black Beige Black Silver Metallic 1 STB Revision ...

Page 8: ...ea having many parts similar parts and or parts which are symmetrical right and left is disassembled be sure to arrange the parts so that they do not become mixed during the assembly process 1 Arrange the parts removed in the proper order 2 Determine which parts are to be reused and which are to be replaced 3 If bolts nuts etc are to be replaced be sure to use only the exact size specified SPECIAL...

Page 9: ...witch and the lighting switch If this is not done there is the possibility of semiconductor parts being damaged WIRING HARNESSES 1 Secure the wiring harnesses by using clamps so that there is no slack However for any harness which passes to the engine or other vibrating parts of the vehicle allow some slack within a range that does not allow the engine vibrations to cause the harness to come into ...

Page 10: ...ting a connector be sure to pull only the connector not the harness 4 Disconnect connectors which have catches by pressing in the direction indicated by the arrows in the illustration 5 Connect connectors which have catches by inserting the connectors until they snap STB Revision ...

Page 11: ...stion before carrying out the service FUSES AND FUSIBLE LINKS 1 If a blown out fuse is to be replaced be sure to use only a fuse of the specified capacity If a fuse of a capacity larger than that specified is used parts may be damaged and the circuit may not be protected adequately Caution If a fuse is blown out be sure to eliminate the cause of the problem before installing a new fuse 2 If additi...

Page 12: ...lling any gasoline oil etc because if it adheres to any tubes or other rubber parts they might be adversely affected LUBRICANTS In accordance with the instructions in this Workshop Manual apply the specified lubricants in the specified locations during assembly and installation BRAKE FLUID Be careful to avoid spilling any brake fluid because if it adheres to the vehicle body the paint coat might b...

Page 13: ...arness 3 The antenna and the cable should be well matched and the standing wave ratio should be kept low 4 A transmitter having a large output should not be installed in the vehicle 5 After installation of transmitter run the engine at idle emit radio waves from the transmitter and make sure that the engine is not affected High frequency power supply If an antenna and a cable having different impe...

Page 14: ...ng the wheels from the lifted end of the disabled vehicle and carrying the lifted end closer to the ground A 20 cm 8 in ground clearance must be maintained between brake drums and ground FRONT TOWING PICKUP The vehicle may be towed on its rear wheels for extended distances provided the parking brake is released Make cartain the transmission remains in NEUTRAL SAFETY PRECAUTIONS The following preca...

Page 15: ...me FLOOR JACK A regular floor jack may be used under the front crossmember or rear axle housing Caution 1 A floor jack must never be used on any part of the underbody 2 Do not attempt to raise one entire side of the vehicle by placing a jack midway between front and rear wheels This practice may result in permanent damage to the body EMERGENCY JACKING Jack receptacles are located at the No 2 cross...

Page 16: ...ection A A NOTE The locations of the support point shown as Section A A are the same as those of the twin post hoist shown in the illustration OOW588 below oow553 LIFTING AND JACKING SUPPORT LOCATIONS c Twin post hoist m Floor lack B Emergency jacking jack supplied with the vehicle OOW588 ...

Page 17: ...1 1 375 54 1 1 375 54 1 1 375 54 1 Overhang Front 745 29 3 745 29 3 745 29 3 745 29 3 Rear 900 35 4 900 35 4 900 35 4 900 35 4 Height at curb weight wt Front bumper to ground 480 18 9 480 18 9 480 18 9 480 18 9 Rear bumper to ground 440 17 3 440 17 3 440 17 3 440 17 3 Minimum running ground 210 8 3 210 8 3 210 8 3 210 8 3 clearance Angle of approach 38 38 38 38 Angle of departure 28 28 28 28 Ramp ...

Page 18: ...ase Model No KM145 KM148 KM145 KM148 Type 5 speed 4 speed 5 speed 4 speed manual automatic manual automatic Cear ratio Transmjssion 1st 3 967 2 826 3 967 2 826 2nd 2 136 1 493 2 136 1 493 3rd 1 360 1 ooo 1 360 1 000 4th 1 000 0 688 1 ooo 0 688 5th 0 856 0 856 Reverse 3 578 2 703 3 578 2 703 Transfer case High 1 000 1 000 1 000 1 040 Low 1 944 1 944 1 944 1 944 Final ring ratio gear 4 625 4 625 4 6...

Page 19: ...m ft lbs I 2 2 2 9 4 9 7 8 3 6 5 8 5 8 8 7 13 19 9 4 14 12 17 27 39 20 29 21 32 47 72 35 53 35 52 77 l 10 57 85 51 77 130 I 60 90 I 20 74 I 10 180 230 130 170 1IO 140 160 320 1go 240 150 I 90 340 430 250 320 1go 240 420 550 310 410 Description Taper thread for pipes size PT l 8 PT l 4 PT 318 Nm ft lbs Remarks Internal thread Aluminum Internal thread Cast iron Internal thread Aluminum Internal thre...

Page 20: ......

Page 21: ...Checking Ignition Timing 11 1 Spark Plug Cable Test 112 Spark Plug Test 112 INSPECTION OF HARNESS CONNECTOR 9 Check for Improper Engagement of Terminal 9 Continuity and Voltage Test for Connector 9 Engaging and Disengaging of Connector Terminal 9 LIGHTING SYSTEM 143 Column Switch I59 Dimmer Control Switch I62 Hazard Warning Switch I61 Headlight 158 Service Adjustment Procedures I57 Headlight Aimin...

Page 22: ...ner relay D Auto choke relay G Automatic free wheeling hub indicator control A unit Condenser blower motor relay H Feed back carburetor control unit C Hazard warning flasher unit F Headlight washer relay F Heater relay E Intermittent wiper relay F ___ Light control relay I ___ Over drive relay F Power window relay F Seat belt warning timer B Turn signal flasher unit F carburetor control unit Air c...

Page 23: ...ELECTRICAL SYSTEM PARTS LOCATION Relay and Control Unit 8 3 FI I h Headlight washer relay k Hazard warnina f 1 STB Revision ...

Page 24: ...YSTEM PARTS LOCATION Sensor Ileedometer 16W1506 p Items Oxygen sensor Pulse generator Throttle position sensor _____ Vehicle speed sensor Water temperature sensor Symbol A B D C E ltw722 I Throttle position sensor I Revision ...

Page 25: ...DIODE ELECTRICAL SYSTEM PARTS LOCATION Diode 8 5 Diode for automatic transmission oil Diode for EGR warning light 1 NJ22 STB Revision ...

Page 26: ...or air conditioner circuit Dedicated fuse for headlight circuit Main fusible link Multipurpose fuse Sub fusible link NOTE Symbol B I E A C D For detailed information concerning the fusible links and fuses refer to the section regarding CENTRALIZED JUNC TION P 8 69 70 16W722 Evaoorator 1 STBI levision ...

Page 27: ...ELECTRICAL SYSTEM PARTS LOCATION Grounding 8 7 GROUNDING I Headlight washer relay h Ja _ 1STB Revision ...

Page 28: ...8 8 ELECTRICAL SYSTEM PARTS LOCATION Grounding 16W1512 1 5 STB Revision 1 i ...

Page 29: ...ER ENGAGEMENT OF TERMI NAL When terminal stopper of connector is out of order engagement of male and female terminals becomes improper even when con nector itself is engaged perfectly and terminal sometimes slips out to rear side of connector Ascertain therefore that each terminal does not come off connector by pulling each harness wire ENGAGING AND DISENGAGING OF CONNECTOR TERMINAL Connector whic...

Page 30: ...ce slightly with it and pull out harness NOTE Tool No 753787 l supplied by AMP can be used instead of screwdriver 4 Insert needle through a hole provided on terminal and raise contact point of male terminal ROUND WATERPROOF CONNECTOR 1 Remove waterproof cap by using a screwdriver 2 Insert tip of screwdriver 1 4 mm 06 in or 2 0 mm 08 in width into connector in a manner as shown in the figure raise ...

Page 31: ...r and pull out harness If right size screwdriver is not available convert a conven tional driver to suit the size Housing lance 16R13 26 16R1329 L 16R1326 2 Terminal lance 16Rl330 1 STB Revision 3 Press contact point of male terminal down by holding a screw driver 1 4 mm 06 in width in a manner as shown in the figure INJECTOR CONNECTOR 1 Remove waterproof cap Insert tip of screwdriver 1 4 in a man...

Page 32: ...ness Connector 16R132i 3 Press contact point of male terminal down by holding a screw driver Il 4 mm 06 in width in a manner as shown in the figure Caution Correct lancer to be in proper condition before terminal is inserted into connector I 1 STB Revision ...

Page 33: ...irs The four steps below should be followed in troubleshooting 1 1 Observe the 1 problems symptom carefully Check if there are also other 1 Observation of Problem Symptoms b 0 2 Determination of Probable Causes In determining the probable causes it is necessary to check the wiring diagram to understand the circuit as a system Knowledge of switches relays and other parts is necessary for accurate d...

Page 34: ... the light to the body by a jumper wire to deter mine which part is responsible for the problem 3 Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly You must have sufficient knowledge and experience to handle instruments correctly INSPECTION INSTRUMENTS In inspection make use of the following instruments 1 Test lamps A test lamp consists ...

Page 35: ...he circuit voltage Normally the positive red lead probe is applied to the point of voltage measurement and the negative black lead probe to the body ground 5 Ohmmeter An ohmmeter is used to check continuity or measure resis tance of a switch or coil If the measuring range has been changed the zero point must be adjusted before measure ment CHECKING SWITCHES In a circuit diagram a switch is represe...

Page 36: ... is magnetized to attract the iron piece closing ON the contact at the tip of the iron piece When the coil current is turned off the iron piece is made to return to its original position by a spring opening the contact OFF 2 By using a relay a heavy current can be turned on and off by a switch of small capacity For example in the circuit shown here when the switch is turned on closed current flows...

Page 37: ...EVENT OF BLOWN FUSE When a fuse is blown there are two probable causes as follows One is that it is blown due to flow of current exceeding its rating The other is that it is blown due to repeated on off current flowing through it Which of the two causes is responsible can be easily determined by visual check as described below 1 Fuse blown due to current exceeding rating The illustration shows the...

Page 38: ...require power from the on vehicle battery be sure to disconnect the cable from the battery terminal This is to prevent problems that could be caused by shorting of the circuit Disconnect the terminal first and recon nect it last TROUBLESHOOTING A circuit consists of the power supply switch relay load ground etc There are various methods to check a circuit including an overall check voltage check s...

Page 39: ...he load at the connector 0 and connect the test light lead wire to the load side of the connector CD The test light should come on and the load light should also come on 5 Connect the test light lead wire to the switch side of the connecotr 0 The test light should come on 6 If the test conforms to any of the above conditions there is a shortcircuit in the wiring between the connector 0 and the con...

Page 40: ...nector symbols In case connectors of the same shape same number of wires are centralized their colors are indicated for identification Examp e p f o Connector s unique number serial number A Engine compartment B Interior and frame C Instrument panel Main fusible link A 03 A o4 4WD indicator switch A 05 Automatic transmission oil I temperature switch indicates that the connector is located in the S...

Page 41: ... alphabet after a serial number For detailed information on this specification dependent symbol refer to Item 8 under HOW TO READ CIRCUIT DIAGRAMS 3 Indication of standard mounting positions of harnesses The standard mounting positions of harnesses are shown with the mark in wiring harness configuration diagrams 4 Indication of ground point The position of ground points are shown in wiring harness...

Page 42: ...be known easily An intermediate connector has its female side only shown as a rule However both of the male and female sides are shown when they differ in wiring color Refer to Item 2 If a frame showing a connector touches the it indicates that the de a direct connec symbol of a device vice harness connectlon IS tion type Refer to Items 2 and 3 The frame shows the connector is not touch ing the sy...

Page 43: ... it possible for you to refer to a wiring harness configuration diagram and to ELECTRICAL SYSTEM PARTS LOCATION Grounding 6 Indication of wires In a circuit diagram the wire diameter and wire color are shown for each wire If there are several wires of the same color in a connector their wire color indication symbols should be such symbols as I and 2 for identification On connectors like this one g...

Page 44: ...iven a specification dependent connector identification symbol lower case alphabet following the connector symbol Example A Ola Specification dependent connector identification symbol a Vehicles with a manual transmission b Vehicles with an automatic transmission c Vehicles with a power window d Vehicles without a power window 9 Shapes of connectors The connector shapes are indicated by simplified...

Page 45: ...e male Indicates number of wires 36KO37 2 Identification of male and female connectors Connectors drawn with double outer lines are male and those with single outer lines are female 3 Connector direction The connector marks show on vehicle connectors as viewed from the direction shown here 4 Identification of connector terminals The color codes of a pair of connectors male and female if viewed at ...

Page 46: ...dentified by the following color codes Example 1 25 GB Code Wire color Code Wire color B Br Black Brown LI 0 Light blue Oranqe I P i 1 Gr 1 Grav 1 R 1 Red I I L I Blue I Y I Yellow I L 1 25 Wire size mm2 F Flexible wire T Twisted wire 1 No code indicates 0 5 mm2 0008 in 2 Cable color code in parantheses indicates 0 3 mm 0005 in Lg Light green W White NOTE If a cable has two colors the first of the...

Page 47: ...WIRING HARNESS Overall Wiring Diagram 8 27 OVERALL WIRING DIAGRAM NOBDC 3 STB Revision ...

Page 48: ... 7 Checker A 18 Diode A 19 Brake fluid level sensor A 20 Front harness and back up light A 21 land 4WD indicator wiring harness combination it Sub fusible link A 24 Carburetor assembly A 25 Control wiring harness and air conditioner wiring harness combination A 26 Front wiring harness and control wiring harness combination A 27 Device box A 53 A 52 A 54 A 28 Auto choke relay A 29 Front wiring harn...

Page 49: ...circuit A 50 Water temperature gauge unit A 51 Water temperature switch OD control circuit A 52 Oil pressure gauge or oil pressure switch 3 Low pressure switch A 55 Headlight R H A 56 Front harness and air conditioner wiring harness combination A 57 Front combination light R H A 58 Front washer motor A 59 Oxygen sensor Remarks 1 The mark shows the reference mounting position of wiring harness 2 Fo...

Page 50: ...8 30 WIRING HARNESS Interior and Frame 2 INTERIOR AND FRAIVIE Connector symbol 1 B B 32 B 33 B 01 Be03 B 05 B 08 B l 0 I2 B 06 9 B p7 B p9 1 A B 29 B 26 B 27 B 22 H 21 36W617 STB Revision 1 ...

Page 51: ...ear washer motor B 09 Defogger B l 0 Back door wiring harness and defogger cable combination B l 1 Rear side marker light R H B 12 Frame wiring harness and back door wiring harness B 13 combination B 23 Front wiring harness and frame wiring harness g combination E Rear speaker L H g Door switch L H B 30 Power window main switch B 31 Power window motor L H B 14 Rear combination light R H z License ...

Page 52: ...er C l 8 Heater relay C l 9 Air conditioner wiring harness and front wiring harness combination E Air conditioner relay C 31 Blower motor resistor C 32 Dedicated fuse Air conditioner circuit C 33 Air conditioner switch C 34 yl Jer control lonob illumination IThermostat IFeed back carburetor control unit C 26 Front speaker R H C 27 Front wiring harness and roof wiring harness combination C 28 Autom...

Page 53: ...brake switch C 50 Seat belt switch C 51 Hazard switch E3 Column switch C 54 Key reminder switch C 55 Ignition switch C 56 Stop light switch C 57 Dimmer control switch C 58 Front wiring harness and door wiring harness L H combination C 59 Turn signal flasher unit C 60 Power window relay C 61 Intermittent wiper relay C 62 Hazard flasher unit C 63 OD OFF relay C 64 Headlight washer motor relay C 65 F...

Page 54: ...tarting Circuit 1 STARTING CIRCUIT VEHICLES WITH A MANUAL TRANSMISSION Ignition switch Battery Main fusible link 25B A 23 Sub fusible link IGN SW 7 BIT B M 2 M I A 15 F TA RT L 1 z cl m w BY A Starter 37W620 1 STB Revision ...

Page 55: ...usible link IGN SW Ignition switch U Inhibitor switch c 47 a 1 2 BY 2 BY 2 BY 2 I 1 a 2 BY 2 BY 2 BY l 1 N P fTl BYBY 37W613 Remark For information concerning the ground points example 0 refer to P 8 7 Wiring color code 8 Black Br Brown G Green Gr Gray L Blue Lg Light green LI Light blue 0 Orange P Pink R Red Y Yellow W White STB Revision ...

Page 56: ...w Ignition switch IR I i r Distributor To combination meter TACHO Refer to P 8 52 1 J A 44 37W609 Remark For information concerning the ground points example q refer to P 8 7 Wiring color code B Black Br Brown G Green Gr Gray L Blue Ll Light blue Lg Light green 0 Orange P Pink R Red Y Yellow W White STB Revision 7 ...

Page 57: ...ition switch n 1 Comornatron meter Remark For information concerning the ground points example q refer to P 8 7 3 c 22 t 3 c J I To turn signal flasher unit Refer to P 8 49 1 J 3 a I 6 m I81 Multi purpose fuse 37W605 Wiring color code B Black Br Brown G Green Gr Gray L Blue Lg Light green LI Light blue 0 Orange P Pink R Red Y Yellow W White STB Revision ...

Page 58: ...fer to P 8 37 1 1 I r Feed back solenoid valve c YG 1 25 BW I I yL 0 P Slow cut solenoid valve YL 1 25 BW Auto choke heater hrottle position iensor A 24 1 Carburetor assembly Remarks 1 For information concerning the ground points example 0 refer to P 8 7 2 The symbols 0 0 etc indicate that the wiring is con nected using the same numerical symbol to the facing page In other words 0 on the right pag...

Page 59: ...7 1 7 A 42 cl BR q A 4 c 2 0 85 BW I YG I I YL I I RW I A f r A 4 A 9 A 3 A 6 A 5 B l 1 B 6 B 9 B IO Feed back carburetor control unit I II II I I 1 I I I _ __ __ L __ _ _ I L J I i B B l B 2 B l 2 B 3 B 13 B 8 B 7 B 5 A 46 Vacuum switch Device box control solenoid L L Water temperature sensor 1STB Revision ...

Page 60: ...alve D Engine speed sensor Ignition coil 0 Feed back carburetor control unit G Throttle opener control solenoid valve for the A K air conditioner Feed back solenoid valve I C Throttle position sensor I E Oxygen sensor I H Vacuum switch I F Secondary air control solenoid valve I I 1 Water temperature sensor I B Throttle opener contr solenoid valve ...

Page 61: ...WIRING HARNESS Layout of Components FBC 8 41 sensor U S 5FUl control unit 1 w1515 LTBI levision ...

Page 62: ...1 0 85 W To column switch Refer to P 8 51 1 0 85 RL Ignition switch Multi purpose fuse Remarks Combination meter I For information concerning the ground points example RLI 1 0 refer to P 8 7 IyRw 1 1 I 4 2 The symbols 0 0 etc indicate that the wiring is connected using the same numerical symbol to the facing page In other words 0 on the right page is connected to 0 on the left page 1 STB Revision ...

Page 63: ... up light Refer to P 8 45 1 2 BY t To starter relay Refer to P 8 34 35 1 IA 12 3 4 VRR 9 5 I tL 1 rA 05 10 switch RILRI Automatic transmission oil temperature switch llR 3 OD OFF solenoid Wiring color code B Black Br Brown G Green G ZJ L Blue Lg Light green LI Light blue 0 Orange P Pink Y Yellow W White 37w019 1 STB Revision ...

Page 64: ...IGHT AND BACK UP LIGHT CIRCUIT eF 7 w I 19 nwr II I 1 1 I Battery EiT Sub fusible link n1 25 Bn II Main fusible link To turn signal flasher unit O 85 RL combination combination 000 i i I 1 I I I I A 09 Inhibitor switch Back up light switch Em Wiring color code g Black Br Brown G Green L Blue Ll Light blue 0 Orange Gr Gray P Pink Lg Light green R Red Y Yellow W White 1 STB Revision ...

Page 65: ... RG RI G Tail light Rear combination fight L H Tail light Back up light I GW IBl Rear side Remarks B 22 1 The broken lines are applicable to models equipped wrtn an automatic transmission 2 For information concerning the ground points exam 37W023 I ple 0 refer to P 8 7 3 The symbols 0 0 etc indicate that the wiring is connected using the same numerical symbol to the facing page In other words 0 on...

Page 66: ...ion meter 2 B ES 71 0 J A 33 Dedicated fuse J I w C 52 32 Light control relay Lighting Dimmer Passing switch switch switch Column switch Headlight Remark For information concerning the ground POintS example 0 refer to P 8 7 9 m x2 Wiring color code B Black Br Brown G Green Gr Gray Ll Light blue 0 Orange P Pink R Red A 34 L H R H 1 A 55 37W621 L Blue Y Yellow Lg Light green W White 1 STB Revision ...

Page 67: ...P 8 46 1 m A t Combination meter C 27 Dome light B 01 Multi purpose fuse 1 25 GB 2 R I To hazard 1 25 GB flasher unit Refer to P 8 49 1 L H R H Door switch 37W620 Remark For information concerning the ground points example 0 refer to P 8 7 Wiring color code B Black Br Brown G Green Gr Gray L Blue Lg Light green LI Light blue 0 Orange P Pink R Red Y Yellow W White 1 STB Revision ...

Page 68: ... l l 2 W El3 1 81 Ignition switch r Main fusible link A 32 GW To lighting switch e Refer to P 8 46 1 2 R 2 RW I 2 B To column switch Rear to P 8 461 I l ZS tit3 a t I 0 85 GY I_ Bl 6 7 0 85 GL LO I Gw rn b d 5 c 05 lzil A 57 J CL I I IG Turn signal and hazard light Turn signal and hazard light Combination meter Front Front combination light R H el n 00 STB Revision ...

Page 69: ...light L H light OL Em B Dimmer control switch m WL 2 37W825 EJ m em s refer to P 8 7 1 For information concerning the ground points exam 2 The symbols 0 0 etc indicate that the wiring is connected using the same numerical symbol to the facing page In other words 0 on the right page is connected to 0 on the left page Wiring color code B Black Br Brown G Green Gr Gray L Blue Lg Light green LI Light ...

Page 70: ... Multi purpose fuse c 51 0 85 GR 0 85 G 0 85 G 1 85 WG 1 1 1 I I R WL Rear cdmbination light L H Rear c mbination light R H Remark For information concerning the ground points example 0 refer to P 8 7 Wiring color code B Black Br Brown G Green Gr Gray L Blue Lg Light green LI Light blue 0 Orange P Pink R Red Y Yellow W White 1 STB Revision ...

Page 71: ...e Illumination ligl c 4o1l Shift position lmer control switch C 38 4 Ashtray illumination Cigaretty Hegpane _ lighter illumination I minagn light Clock n 63 illumination light Combination meter illumination light 37w 62 1 The broken lines are applicable to models equipped with an automatic transmission 2 For information concerning the ground points exam ple 0 refer to P 8 7 Wiring color code B Bla...

Page 72: ...urpose fuse bYI To turn signal switchfd Refer to P 8 491 1 To seat belt timer Refer to P 8 661 To seat belt warning buzzer Refer to P 8 661 M G 1 I To alternator fRefer to P 8 371 0 85tW 41D 1 I 4 o dimmer passir witc h and light control Ir r n I I I clay Refer to P 8461 _ To dome light Kb Refer to P 8 471 4 To door yi h _ RG ID 1 I YBdD t m q 3 ly J _ _ I r Combination meter 1 STB Revision ...

Page 73: ...ter temperature gauge unit 37W617 les with combinatior 2 zgdeash and dot line indicates vehicles wit1 automatic free wheeling hub indicator 3 For information concerning the ground points er ample n refer to P 8 7 4 The symbols etc indicate that the wiring i connected using the same numerical symbol tl Combination gauge the facing page In other words Oon the right page is connecter to on theleftpag...

Page 74: ... Multi purpose a fuse i C Ignition switch OFF AM ACC Column switch A 3 To wiper motor Refer to P 8 59 1 A 39 37W608 Remark For information concerning the ground points example q refer to P 8 7 Wiring color code B Black Br Brown G Green GI LI Light blue 0 Orange P Pink Gray R Red L Blue Y Yellow Lg Light green W White 1STB Revision ...

Page 75: ...L Refer to P 8 49 1 n H M2 Ml bFF P I Blower switch Remark 37W614 For information concerning the ground points example 0 refer to P 8 7 Wiring color code B Black Br Brown G Green Gr Gray L Blue Lg Light green LI Light blue 0 Orange P Pink R Red Y Yellow W White Blower motor resistor LBLI El3 LRLW Blower motor M T i C 18 I Heater relay 8 L El LR LR 1 2 STB Revision ...

Page 76: ...I T 3 LRwQ To turn signal flasher unit 0 85 RL Refer to P 849 1 J L I I 0 85 LW FA2 Ml bFF To cigarette lighter Refer to P 8 62 1 I f Y Blower motor 8 I M 4JY motor T Ii 1 Blower switch lower 1C 18 l a Heater relay 0 85 WB Wiring color code B Black Br Brown G Green Gr Gray L Blue Lg Light green LI Light blue 0 Orange P Pink I Red Y Yellow W White STB Revision II ...

Page 77: ... solenoid valve A 45 0 85 BWnBW Is la Magnetic clutch compressor U Water temperature switch Condenser Condenser blower I BY blower motor motor relay rl 37W611 Remarks 1 For information converning the ground points exam ple l n refer to P 8 7 2 The svmbols 0 0 etc indicate that the wiring is connedted using the same numerical symbol to the facing page In other words 0 on the right page is connected...

Page 78: ...y r r C 64 Remarks 1 For information concerning the ground points example q refer to P 8 7 2 The symbols 0 0 etc indicate that the wiring is connected using the same numerical symbol to the facing page In other words 0 on the right page is connected to 0 on the left page Headlight washer motor I 1 Headlight washer motor relay Wiring color code B Black LI Light blue Br Brown 0 Orange G Green P Pink...

Page 79: ...umn switch FronthiDer switch 1 BP f EEl 118 B Headlight washer switch Rear wiper and washer switch I 1 I _I c 53 z 09 4 z o YL JY BR Lw 1 j I 1A 58 A 14 Frontwasher motor I Front wiper motor Rearwasher Rear wiper motor 37W024 motor WB QI 1 STB Revision ...

Page 80: ...lm 1 Battery _ A 02 Sub fusible link 1 25 B A 23 0 5 G 2 w 5 5 w m rlin fusible To light control relay Refer to P 8 461 To combination BY meter 4 Refer to P 8 521 DIN Cable Tape player L1 EQ3 1 Ignition switch To air conditioner Refer to P 8 561 c JC 3 A C 1 Radio 1 STB Revision 7 ...

Page 81: ... exam ple 0 refer to P 8 7 2 The symbols 0 0 etc indicate that the wiring is connected using the same numerical symbol to the facing page In other words 0 on the right page is connected to 0 on the left page Wiring color code B Black Br Brown G Green Gr Gray L Blue Lg Light green LI Light blue 0 Orange P Pink I Red Y Yellow W White 1STB Revision ...

Page 82: ...unit4 I LJ G Refer to P 8 491 II I Multi purpose fuse illumination light To heater control illumination light Refer to P 8 511 Clock CT 0 1 h J 6 Jc 36 To combination mete BY Refer to P 8 521 1 Wiring color code B Black LI Light blue To dimmer control switch BY Br Brown 0 Orange Refer to P 8 511 M G Green P Pink Gr Gray H Red L Blue Y Yellow Lg Light green W White Remark For information concerning...

Page 83: ... pFJ 0 Defogger 1 25 B m 1 25 BR Bg 2 FB m 3 B B 05 L l U m B 13 I Ki B Q BR Q 4 37W62 Wiring color code B Black LI Light blue Br Brown G Green Gr Gray L Blue Lg Light green 0 Orange P Pink R Red Y Yellow W White 1STB Revision LY ii T Rheostat Detogger switch x7 I z A i Multi purpose D fuse m of A To column switch Refer to P 8 461 Remarks For information concerning the ground points example a refe...

Page 84: ...wer window main switch I I I Multipurpose fuse 1 1 25 R 2 1 25 G 1 25 R 1 25 G Remarks I For information concerning the ground points exam ple m refer to P 8 7 2 The symbols 0 0 etc indicate that the wiring is connected using the same numerical symbol to the facing page In other words 0 on the right page is connected to 0 on the left page 1 STB Revision ...

Page 85: ... B g 2 RL 1 25 R 1 25 G 8 b M r I I 2 B To colunm switch Refer to P 8 511 washer relay Refer to P 8 581 Power window relay Wiring color code B Black Br Brown G Green Gr Gray L Blue LI Light blue 0 Orange P Pink R Red Y Yellow Power window sub switch R H 37w003 Lg Light green W White 1STB Revision ...

Page 86: ...o P 8 491 0 1 C P P a 3 CCl P mm l z z CY m aa cd c 03 r c 50 J A I 5 bb IC ski t switch Key reminder Combination meter and seat belt warning buzzer Remark For information concerning the ground points example q refer to P 8 7 Seat belt warning timer 37W607 Wiring color code B Black Br Brown G Green Gr Gray L Blue Lg Light green LI Light blue 0 Orange P Pink R Red Y Yellow W White 1ST9 Revision ...

Page 87: ...Refer to P 8 461 z 1 m 0 C 1 LR I 1 I 0 2 I I I m m m cAcJl T r m z I c 07 C 06 c 04 I q OE L 1 Combination meter EleAtrir d V circuit power 1 Pulse Vehicle detective speed circuit detective circuit r Automatic free wheeling hub indicator control unit 37W610 For information concerning the ground points example 0 refer to P 8 7 Wiring color code B Black Br Brown G Green L Blue LI Light blue 0 Orang...

Page 88: ...r to P 8 551 1 25F R 1 25 R 2 B To column switch B l 2 Refer to P 8 511 cza I I xx 0 I 77 m B 24 cLL3 ALA CVN 77 Back door lock actuator Remark 37W602 For information concerning the ground points example q Wiring color code refer to P 8 7 B Black Br Brown G Green Gr Gray L Blue Lg Light green LI Light blue 0 Orange P Pink R Red Y Yellow W White STB Revision ...

Page 89: ...sible Link Item Circuit Cable color Fusible link size mm7 in 2 Permissible continuous current A Fusing current A Dedicated Fuse Lighting circuit Green 0 5 0008 27 100 Alternator circuit Feed back carburetor control circuit Stop light door lock and heater circuit Red 0 85 0013 34 150 Ignition circuit Power window circuit Green Green 0 5 0008 0 5 0008 27 27 100 100 Upper beam indicator circuit Air c...

Page 90: ...t belt switches Power window relay Fuel and water temperature gauges Oil pressure gauge Voltage meter Indicator and warning lights Inhibitor switch Automatic free wheeling hub indicator control unit 4 IO Back up lights Auto choke relay OD OFF relay __ 5 15 Rear window defogger Battery 6 20 Heater Back door lock 7 15 Key reminder switch Stop lights Buzzer Ignition switch ACC 8 15 Windshield wipers ...

Page 91: ...current to direct current Accordingly the alternator terminal B is D C Furthermore the alternator regulates the charge voltage through the use of battery voltage detection system The main parts of the alternator are rotor stator rectifier condenser brush bearing drive belt pulley and a brush holder with built in electronic voltage regulator I I C regulator I A I C alternator y Brush heat sink asse...

Page 92: ... the maintenace free battery The battery is completely sealed except for small vent holes in the cover These vent holes allow what small amount of gasses are produced in the battery to escape The special chemical composition inside the battery reduces the produc tion of gas to an extremely small amount at normal charging voltages The battery contains a visual test indicator which indicates the con...

Page 93: ... is the current a battery can deliver for 30 seconds and maintain a terminal voltage of 7 2 or greater at a specified temperature 2 RESERVE CAPACITY RATING is the amount of time a battery can deliver 25 A and maintain a minimum terminal voltage of 10 5 at 26 7 C 80 F SERVICE SPECIFICATIONS NOBEC Items Standard values Regulated voltage V Ambient temp at voltage regulator 20 C 4 F 20 C 68 F 60 C 140...

Page 94: ...STEM Specifications TORQUE SPECIFICATIONS items Nm ft lbs __ Alternator brace bolt 12 15 9 l 1 Alternator support bolt nut 20 22 14 16 High pressure hose nut 20 25 14 18 Low hose nut pressure 30 35 22 25 1 STB Revision ...

Page 95: ...usible link blown Electronic voltage regulator or alternator faulty Wiring faulty Drive belt loose or worn Wiring connection loose or open circuit Fusible link blown Replace voltage regulator Adjust tension or replace drive belt Repair or replace cables Check fuses Replace fusible link Test alternator Repair wiring Adjust tension or replace drive belt Tighten loose connection or repair wiring Repl...

Page 96: ...usible link IGN SW IAM IG c 55 3 3 A m A To turn signal flasher unit Refer to P 8 49 1 Multi n Irnn4P ComSeter Remark For information concerning the ground points example q refer to P 8 7 37W605 Wiring color code B Black Br Brown G Green Gr Gray L Blue Lg Light green LI Light blue 0 Orange P Pink R Red Y Yellow W White 1 STB Revision ...

Page 97: ...sult causes for the trouble may not be determined 5 Connect a digital voltmeter between the alternator B termi nal and battery terminal Connect the lead wire of the voltmeter to the B terminal and the lead wire to the battery terminal 6 Connect the battery ground cable 7 Leave the hood open Test 1 Start the engine 2 Turn on or off the headlights and small lights and adjust the engine speed so that...

Page 98: ...ries between the B terminal and the disconnected output wire Connect the lead of the ammeter to the B terminal and connect the lead wire to the disconnected output wire NOTE Tighten each connection by bolt and nut securely as a heavy current will flow Do not relay on clips 6 Connect a voltmeter 0 to 20 V between the B terminal and ground Connect the lead wire to the alternator B ter minal and lead...

Page 99: ...ompletion of the output current test lower the engine speed to the idle speed and turn off the ignition switch 3 Disconnect the battery ground cable 4 Remove the test ammeter and voltmeter and the engine ta chometer 5 connect the alternator output wire to the alternator B ter minal 6 Connect the battery ground cable REGULATED VOLTAGE TEST The purpose of this test is to check that the electronic vo...

Page 100: ...value Voltage Battery voltage If it reads 0 V there is an open circuit in the wire between the alternator S terminal and the battery or the fusible link is blown 2 Start the engine Keep all lights and accessories off 3 Run the engine at a speed of about 2500 rpm and read the voltmeter when the alternator output current drops to 10 A or less Result 1 If the voltmeter reading agrees with the value l...

Page 101: ...ea with a stiff bristle brush and wipe off with a cloth moistened with ammonia or baking soda in water 4 Clean top of battery with same solutions as described in Step 3 INSPECTION OF BATTERY NOBEIBA VISUAL INSPECTION OF BATTERY 1 The batten contains a visual test indicator which gives blue signal when an adequate charge level exists and white signal when charging is required VISUAL INSPECTION OF B...

Page 102: ...perature may temporarily be allowed to rise to 55 C 131 F Increase of electrolyte temperature above 55 C 131 F is harmful to the battery causing deformation of battery cell decrease in life of battery etc CHARGE RATE If the test indicator is white the battery should be charged as outlined below When the dot appears or when maximum charge shown below is reached charging should be stopped NOTE If th...

Page 103: ...2 l Refer to Service Points of installation 16W1565 SERVICE POINTS OF INSTALLATION 2 INSTALLATION OF ALTERNATOR 1 Position the alternator and insert the support bolt Do not attach the nut 2 Push the alternator forward and determine how many spacers thickness 0 198 mm 0078 in should be inserted between the front leg of the alternator and the front case space A in the illustration There should be en...

Page 104: ...CONDITIONING Service Adjust ment Procedures D Adjustment of Drive Belt Tension Refer to GROUP 7 COOLING and GROUP 24 HEATERS AND AIR CONDITIONING Service Adjust ment Procedures emoval steps 1 Connection of high pressure hose 2 Connection of low pressure hose 3 Connection of compressor connector 4 Compressor 5 Connection of alternator connector 6 Alternator OTE Reverse the removal procedures to rei...

Page 105: ...he alternator forward and determine how many spacers thickness 0 198 mm 0078 in should be inserted between the front leg of the alternator and the front case space A in the illustration There should be enough spacers so that they do not fall out when you let go of them 3 Insert the spacers space A in the illustration attach the nut and complete the installation i STB Revision ...

Page 106: ... 6 Front bearing 4 7 Front bracket 8 Stator 9 Terminal 10 Plate 4 11 Regulator and brush holder 12 Brush 13 Brush spring 14 Slinger 15 Rectifier assembly 4 16 Rear bracket NOTE 1 Reverse the disassembly procedures to reassemble 2 e Refer to Service Points of Disassembly 3 l Refer to Service Points of Reassembly 1 EL666 1STB Revision ...

Page 107: ...Clamp the rotor in a vise with soft jaws 11 REMOVAL OF REGULATOR AND BRUSH HOLDER 1 Unsolder three stator leads soldered to main diodes on rectifier 2 Unsolder two plates soldered to rectifier Caution 1 When soldering or unsoldering use care to make sure that heat of soldering iron is not transmitted to diodes for a long period Finish soldering or un soldeing in as short a time as possible 2 Use c...

Page 108: ...l for grounding Check to ensure that there is no continuity between coil and core If there is continuity replace stator assembly RECTIFIERS l Positive rectifier test Check for continuity between positive rectifier and stator coil lead connection terminal with a circuit tester If there is con tinuity in both directions diode is shorted Replace rectifier assembly l Negative rectifier test Check for ...

Page 109: ... replaced REPLACEMENT OF BRUSH A brush worn away to the limit is replaced using the procedure below 1 Remove the pigtail solder and take out the old brush and spring 2 Install brush spring and new brush in brush holder 3 Insert the brush to where there is a space 2 3 mm 079 118 in between the limit line and the end of the brush holder 4 While maintaining the position of the step solder the pigtail...

Page 110: ... POINTS OF REASSEMBLY 3 REASSEMBLY OF ROTOR ASSEMBLY Perform reassembly in reverse procedure of disassembly Before rotor is attached to rear bracket insert wire through small hole made in rear bracket to lift brush After rotor has 6een installed remove the wire STB Revision ...

Page 111: ...rt position In so doing the solenoid plunger and clutch shift lever move the clutch pinion engages with the ring gear and then the solenoid contacts shut and the starter motor cranks As soon as the engine begins to run and in order to prevent damage due to over revolution by the armature starter the running clutch pinion gear over rides Thus in order not to cause damage to the starter motor once t...

Page 112: ...8 92 STARTING SYSTEM General Information S terminal Sole oid coil 6 terminal clutch Brush gear type reduction 1 ST6 Revision ...

Page 113: ...Starter motor Free running characteristics Terminal voltage V Current A Speed r p m Under cut depth mm in Commutator diameter mm in Pinion gap mm in Commutator runout mm in Limit Commutator diameter mm in Commutator runout mm in Specifications 11 Max 90 Min 3000 0 5 0 8 020 031 29 4 1 157 0 5 2 0 020 079 0 05 0020 28 8 1 134 0 1 004 _ TORQUE SPECIFICATIONS Items Nm ftlbs Starter motor mounting bol...

Page 114: ...ROUP 21 Fusible link blown Replace fusible link 8 69 Starter motor faulty Repair starter motor 8 97 Ignition switch faulty Replace ignition switch 8 l 22 Battery charge low Check battery specific gravity 8 8 1 Charge or replace battery 8 82 Battery cables loose corroded or worn Repair or replace cables 8 8 1 Starter motor faulty Repair starter motor 8 97 Starter motor faulty Repair starter motor 8...

Page 115: ...ING SYSTEM Circuit Diagram 8 95 1 STARTING CIRCUIT VEHICLES WITH A MANUAL TRANSMISSION 11171 w in fusible START I k 9 OFF ON ACC ST c 55 I m I BY Sub fusible link Ignition switch Starter 37W626 STB Revision ...

Page 116: ...754 1 0 5 G 1 1 L l m 1L W Battery Ignition switch c 47 2 BY Z BY 2 N P BY Z BY1 Z BY L l R BYBY I 2 Remark For information concerning the ground points example q refer to P 8 7 Wiring color code B Black Br Brown G Green Gr Gray L Blue LI Light blue 0 Orange P Pink Lg Light green R Red Y Yellow W White STB Revision ...

Page 117: ...motor NOTE 1 Reverse the removal procedures to reinstall 2 Refer to Service Points of Installation 6EL05 This test must be performed quickly in less than 10 sec onds to prevent coil from burning D Revision INSPECTION PINION GAP ADJUSTMENT I Disconnect field coil wire from M terminal of magnetic switch 2 Connect a 12V battery between S terminal and M terminal 3 Set switch to ON and pinion will move...

Page 118: ...nnect a 12V battery between S terminal and M terminal Caution This test must be performed quickly in less than 10 sec onds to prevent coil from burning 3 If pinion moves out then pull in coil is good If it doesn t replace magnetic switch HOLD IN TEST OF MAGNETIC SWITCH 1 2 Disconnect field coil wire from M terminal of in ignetic switch Connect a 12V battery between S terminal and body Caution This...

Page 119: ...ry voltage shown on the voltme ter reads 1IV 7 Confirm that the maximum amperage is within the stand ard value and that the starter motor turns smoothly and freely Standard value Current Speed Max 90A Min 3 000 rpm RETURN TEST OF MAGNETIC SWITCH 1 Disconnect field coil wire from M terminal of magnetic switch 2 Connect a 12V battery between M terminal and body Caution This test must be performed qu...

Page 120: ...rmature 10 Yoke assembly 4 11 Ball 12 Packing A 13 Packing B 14 Plate 15 Planetary gear 16 Lever l d 17 Snap ring l a 18 Stop ring 19 Over running clutch 20 Internal gear 21 Planetary gear holder 22 Front bracket 6ELlSS NOTE 1 Reverse the disassembly procedures to reassemble 2 a Refer to Service Points of Disassembly 3 l O Refer to Service Points of Reassembly STB Revision ...

Page 121: ...nning clutch CLEANING STARTER MOTOR PARTS 1 Do not immerse parts in cleaning solvent Immersing the yoke and field coil assembly and or armature will damage insulation Wipe these parts with a cloth only 2 Do not immerse drive unit in cleaning solvent Overrunning clutch is pre lubricated at the factory and solvent will wash lubrication from clutch 3 The drive unit may be cleaned with a brush moisten...

Page 122: ...RUNNING CLUTCH 1 While holding clutch housing rotate the pinion Drive pinion should rotate smoothly in one direction but should not rotate in opposite direction If clutch does not function properly re place overrunning clutch assembly 2 Inspect pinion for wear or burrs If pinion is worn or burred replace overrunning clutch assembly If pinion is damaged also inspect ring gear for wear or burrs FRON...

Page 123: ...xcess solder do not come out onto brush surface 5 When replacing ground brush slide the brush from brush holder by prying retaining spring back TESTING ARMATURE TESTING ARMATURE FOR SHORT CIRCUIT 1 Place armature in a growler 2 Hold a thin steel blade parallel and just above while rotating armature slowly in growler A shorted armature will cause blade to vibrate and be attracted to the core Replac...

Page 124: ...8 104 STARTING SYSTEM Starter Motor SERVICE POINTS OF REASSEMBLY 18 REASSEMBLY OF STOP RINGi17 SNAP RING Using a suitable pulling tool pull overrunning clutch stop ring over snap ring 1 STB Revision I ...

Page 125: ... spark plug high tension cable ignition switch and connecting wire Ignition switch 0 m I 1 AMR 1Gl I Ignition coil r Ignite Distributor lEL117 The distributor is composed of signal generator signal rotor and igniter internalized pickup linear current control unit igniter advance control unit governor and vacuum controller and distribution unit rotor plus distributor cap ...

Page 126: ...creases oscillation ceases 3 This oscillation introduces power to the oscillation detector circuit and after output is amplified it drives the power transistor During oscillation when the projection and core are apart electricity flowing through the ignition coil and when oscillation stops when the projection and core are facing the electric current is inter rupted 4 The electrical detection circu...

Page 127: ...TION COIL Type Model No Part No Items Oil filled E 089 M DO73079 Specifications SPARK PLUG Items Factory installed plug Model No Manifacturer W20EP U 10 NIPPON DENS0 W20EPR Sll BURGEA 1 1 Alternate plug BPGES 1 1 BPRGES 1 1 BUGEA 11 NGK W20EPR U IO W20EPSll NIPPON DENS0 IGNITION SWITCH Items ignition switch Load capacity AM ACC AM IG AM ST AM R Voltage drop under actual load Key reminder switch Ra...

Page 128: ...nal 231280 California Governor crank deghpm initial O l 600 Middle 912800 Final 1g 6000 Vacuum crank deg mmHg Initial O 80 Middle 8 l 50 Final 201360 Idle advance crank deg mmHg Initial O 60 Final 5180 Ignition coil Primary resistance at 20 C 68 F R 1 1 1 3 Secondary resistance at 20 C 68 F k0 14 5 19 5 External resistor resistance at 20 C 68 F 1R 1 22 1 48 Spark plug gap mm in 1 0 I I 039 043 TOR...

Page 129: ...en Inspect wiring Rough idle or stalls Spark plugs faulty Replace plugs 8 115 Ignition wiring faulty Inspect wiring Incorrect ignition timing Adjust ignition timing 8 111 Ignition coil faulty Inspect ignition coil 8 116 Ignition faulty Inspect igniter 8 120 High tension cord faulty Inspect high tension 8 116 cord Engine hesitates poor acceleration Spark plugs faulty Replace plugs 8 115 Ignition wi...

Page 130: ...link m ze 3 cj _ A p m N CL I 64 b I I I m I EiI L Disi To combination meter d A an b TACHO Refer to P 8 52 1 I I Ignition coil 37 w009 Remaik For information concerning the ground points example q refer to P 8 7 Wiring color code c B Black Br Brown G Green Gr Gray L Blue Lg Light green LI Light blue 0 Orange P Pink R Red Y Yellow V White 1 STB Revision 1 ...

Page 131: ...ng 6 After adjustment securely tighten mounting nut 7 Reconnect pressure sensor connector disconnected in Step 3 Then run engine at curb idle speed to make sure that actual ignition timing is obtained CHECKING IGNITION SYSTEM NOBDIDB CHECKING CENTRIFUGAL ADVANCE EQUIPMENT 1 Set the tachometer and timing light 2 Start the engine and allow it to idle 3 Pull out vacuum hose from vacuum controller 4 C...

Page 132: ...aired movement of breaker base Broken diaphragm 5 If the malfunction indicators above are confirmed dismantle and check the distributor 6 Allow the engine to idle and then turn the ignition switch to OFF 7 Remove the vacuum pump and attach the vacuum hose to the vacuum controller nipple 8 Remove the timing light SPARK PLUG CABLE TEST NWGIGB Hold the spark plug cable about 6 8 mm 24 31 in away from...

Page 133: ...n the illustration turn the crankshaft man ually so that the projection of the signal rotor is moved away from the center part of the pick up In order words the signal rotor should be positioned so that current can flow to the ignition coil 3 Disconnect the high tension cable from the center tower of the distributor cap and hold the end of the cable about 5 10 mm 2 4 in away from the cylinder bloc...

Page 134: ...park plug Distributor removal steps 16W1563 l 1 4 Spark plug cables 6 Connection of distributor connector 7 High tension cable 8 Connection of vacuum hose de l q 9 Distributor Ignition coil removal steps 7 High tension cable NOTE 10 Connection of ignition coil connector 1 Reverse the removal procedures to reinstall 2 e Refer to Service Points of Removal 11 Ignition coil 3 l Refer to Service Points...

Page 135: ...S 1 Pull the spark plug cables out of the spark plugs 2 Using a spark plug wrench take all the spark plugs out of the cylinder head Caution Ensure that no foreign bodies fall from the spark plug holes 3 Using the following criteria check that there is no electrode spark loss that there is no damage to the outer insulation and that sparking is good l Existence of insulation damage l Spark dissipati...

Page 136: ...insulating coating 2 Ctieck the resistance value High tension cable Spark plug cable No 1 1 No 2 1 No 3 1 No 4 I 9 I 11 I 13 I 14 CHECKING THE IGNITION COIL 1 Measurement of the resistance of the external resistor Measure the resistance of the external resistor Standard value 1 2 1 4 IR 2 Measurement of the resistance of the primary coil Measure the resistance between the positive terminal and the...

Page 137: ...r installing stud and tighten nut l 4 INSTALLATION OF SPARK PLUG CABLE Improper arrangement of spark plug cables will induce voltage between the cables causing miss firing and developing a surge at acceleration in high speed operation Therefore be careful to arrange the spark plug cables properly by the fol lowing procedure 1 Install the spark plug cable clamps as shown in the illus tration 2 The ...

Page 138: ...8 118 IGNITION SYSTEM Ignition System SPARK PLUG CABLE INSTALLATION I 1 4 3 3 1 2 3 I 3 2 4 View P STB Revision 5EL04 1 ...

Page 139: ...1 Signal rotor l 12 Breaker plate 4 13 Spring retainer 4 14 Governor spring 15 Governor weight 16 Lock pin Vehicles for California Vehicles except for California 8 4 17 Driven gear 18 Washer 19 0 ring 20 Distributor shaft 21 Washer 22 Oil seal 23 Distributor housing NOTE 1 Reverse the disassembly procedures to reassemble 2 e Refer to Service Points of Disassembly 3 Hw Refer to Service Points of Re...

Page 140: ...r springs 17 DISASSEMBLY OF DRIVEN GEAR 1 Mark location of driven gear on distributor shaft 2 Place driven gear on soft base wood block so that spring pin can be removed 3 Using a pin punch remove spring pin INSPECTION Check according to the following provisions and repair or replace anything faulty CAP ROTOR 1 Ensure there are no cracks in the cap 2 Ensure that the electrodes of the cap and of th...

Page 141: ... OF BREAKER PLATE Install igniter base to housing Position the igniter base so that the projection A fits into the groove 9 11 REASSEMBLY OF SIGNAL ROTOR Install signal rotor to rotor shaft Position the signal rotor so that the dowel pin fits into the groove ADJUSTMENT OF AIR GAP Adjust air gap between signal rotor and pick up of igniter Standard value 0 8 mm 0315 in 1 STB Revision ...

Page 142: ...nd switch NOTE Reverse the removal procedures to reinstall NOEGLAE 16W1557 16UO36C I INSPECTION 1 Disconnect the wiring connector from the ignition switch and connect an ohmmeter to the switch side connector 2 Operate the switch and check the continuity between the terminals START Ignition switch NOTE O C indicates that there is continuity between the terminals 1STB Revision 7 ...

Page 143: ...or 7V Variable resistance type Bimetal type 7V operation Thermistor type Bimetal type Bimetal type Gravity type Oil filled system Bimetal type INDICATOR AND WARNING LIGHTS NOEHC B Items Specifications Turn signal indicator lights W 1 4 74 High beam indicator light W 1 4 74 Door ajar warning light W 1 4 74 Fasten seat belt indicator light W 1 4 74 Brake warning light W 1 4 74 Charging warning light...

Page 144: ...r min f 250 Fuel gauge resistance value R Between terminals 1 power supply and 2 fuel gauge unit 23 27 Between terminals 2 fuel gauge unit and 3 ground 122 l 48 Between terminals 1 power supply and 3 ground 100 l 20 Fule gauge unit resistance value R Float point F 14 9 19 1 Float point E 113 5 l 26 5 Fuel gauge unit float position mm in Float point F 29 7 34 7 1 169 l 366 Float point E 183 8 185 8...

Page 145: ...ants and adhesives 3M nut locking No 4171 or equivalent Quantity As required TROUBLESHOOTING TACHOMETER NOBHH Inspection items Symptom The tachometer fails to operate IThe tachometer pointer is faulty NOTE Number in circle indicates inspection sequence FUEL GAUGE Inspection items Symptom The fuel gauge fails to operate The fuel gauge pointer is faulty NOTE Number in circle indicates inspection seq...

Page 146: ...0 c 2 5 a 0 0 0 a IThe water temperature gauge pointer is faulty a NOTE Number in circle indicates inspection sequence OIL PRESSURE GAUGE jnspection items Symptom 0 0 a The oil pressure gauge fails to operate The oil pressure gauge pointer is faulty NOTE Number in circle indicates inspection sequence STB Revision IIII ...

Page 147: ...luminate when the parking brake is on when the brake fluid falls below the regulation volume a a Co NOTE Number in circle indicates inspection sequence EGR WARNING LIGHT U 5 P W 0 Co When the ignition key is at ON without starting the engine the indicator fails to illuminate 0 The EGR warning indicator fails to illuminate after the car has travelled every 50 000 miles Light bulb is OK Even when th...

Page 148: ... I To seat belt timer Refer to P 8 661 P 8 511 To seat belt warning buzzer Refer to P 8 661 1 25 GBA To alternator 48 5 W III 1 1 1 f d ii j IRefer to P 8 371 D I I_ 0 dimmkr passinq I I I I II I I r I I I II YI witch and light control y K clay Refer to P 8 461 To dome liaht 5 hIIII I m w Refer to P 47 w Combination meter STB Revision ...

Page 149: ...k Br Brown G Green Gr Gray LI Light blue 0 Orange P Pink R Red Y Water temperature gauge unit Remarks I The broken line indicates vehicles with com bination gauge 2 The dash and dot line indicates vehicles with automatic free wheeling hub indicator 3 For information concerning the ground points example 0 refer to P 8 7 4 The symbols I etc indicate that the wiring is connected using the same numeri...

Page 150: ...er be sure to chock the non drive wheels to prevent the vehicle from moving Also be sure to set the transfer shift lever to 2H 2 If there is a special regulation for speedometer indication error in the area where the vehicle is operated be sure to meet the requirement of the regulation TACHOMETER INSPECTION NOBHIBA Connect a tach dwell meter and then compare the meter readings at various engine sp...

Page 151: ...he fuel gauge unit refer to GROUP 4 FUEL SYSTEM Fuel Tank FUEL GAUGE UNIT FLOAT POSITION CHECK Check to be sure that the height of the fuel gauge float relative to the center part of the fuel gauge unit is within the standard value range when the float is at the F position upper limit and E position lower limit Standard value A 29 7 34 7 mm 1 170 I 366 in B 183 8 185 8 mm 7 236 7 315 in FUEL GA E ...

Page 152: ...d WATER TEMPERATURE GAUGE UNIT RESISTANCE CHECK Immerse the gauge unit in hot water at 70 C 158 F and measure the resistance value with an ohmmeter Standard value 90 5 117 5 LR OIL PRESSURE GAUGE SIMPLE TEST NOEHIFA 1 Disconnect the wiring connector from the oil pressure gauge unit inside the engine compartment 2 Ground the connector at the harness through a test light 3 Turn the ignition key to t...

Page 153: ...rtment 2 Apply battery voltage through the test light to the gauge unit side terminal 3 Check to be sure that the test light switches OFF when the engine is stopped and that it flashes while the engine is running VOLTAGE METER SIMPLE TEST NOEHIGC 1 Connect a voltmeter for testing 2 Turn the ignition key to the ON position 3 Compare the readings of the voltmeter for testing and of the vehicle s vol...

Page 154: ...r to Service Points of Installation 16W1553 I 1 I I f 16W1645 INSPECTION REED SWITCH Using an ohmmeter check that continuity and discontinuity alternate between terminals 1 and 2 four times at every rotation of the shaft of the speedometer cable connection BUZZER Check to be sure that buzzer sounds when the battery s positive terminal is connected to terminal 2 and the battery s negative terminal ...

Page 155: ...d the fuel gauge will cause permanent distortion of the bimetal resulting in the indications being consistently lower than the actual value For this reason therefore be sure to make the earth contact securely WATER TEMPERATURE GAUGE Measure the resistance value between the terminals by using an ohmmeter Standard value Bimetal type l 2 terminals 50 80 n SERVICE POINTS OF INSTALLATION 2 INSTALLATION...

Page 156: ...I 10 16W1664 I Disassembly steps 1 Meter cover 2 Buzzer 8 Window plate 3 Fuel and water temperature gauge 9 Meter case 4 Tachometer 10 Printed circuit boad 5 Speedometer 6 Indicator panel NOTE 7 Meter glass Reverse the disassembly procedures to reassemble 1STB Revision 1 ...

Page 157: ...y NOTE Reverse the removal procedures to reinstall 16W1560 lBW077 INSPECTION OIL PRESSURE GAUGE Measure the resistance value between the terminals with an ohmmeter Standard value Approx 50 CR VOLTAGE METER Measure the resistance value between the terminals with an ohmmeter Standard value 380 4601 1 1STB Revision ...

Page 158: ...ight 2 The i nclinometer can be considered to be in good condi tion If the pointer indicates the spherical dial horizontal centre line when the meter case is placed on a level surface 6 Disassembly steps 1 Oil pressure gauge 2 Inclinometer 3 Voltage meter 4 Meter glass 5 Window plate 6 Meter case 7 Meter harness NOTE Reverse the disassembly procedures to reassemble 16W1561 1 ST6 Revision ...

Page 159: ...meter consists of an outer case which inclines with the vehicle a pointer which is provided in an oil case and always maintains a level position and a spherical dial The spherical dial is coupled through the dial support plate to the rolling damper plate The rolling damper plate is swivel bearing coupled to a stationary frame by the center axis so it can incline side to side but is always held in ...

Page 160: ...ght 16W969 10 d15 15 downhill Inclined IO to left I 16W968 I Forward or Backward Inclination The spherical dial inclines forward or backward with the vehicle but the pointer maintains a level position so the pointer indicates the forward or backward inclination angle Combined Forward or Backward and Side to Side Inclina tion The forward or backward inclination angle and the side to side inclinatio...

Page 161: ... ON position and goes off after the engine has started This warning light comes on when the drive belt breaks or the trouble occurs in the charging system Oil pressure warning light This warning light comes on when the ignition key is in ON P position and goes off after the engine has started This warning light comes on when the oil fails or the trouble occurs in the oil circulating system 00 Over...

Page 162: ... is driven in order to inform the driver that it is time to check the EGR system The warning light bulb will light up when the ignition switch is set to ON while the engine is not running thus allowing the driver to confirm that the bulb is not burned out RESET SWITCH Use the switch on the back of the odometer to reset the EGR warning system NOTE If the speedometer is to be replaced set the new od...

Page 163: ...n light Cigarette lighter illumination light W Ashtray illumination light W Shift illumination light automatic transmission W W NOTE The values in parentheses denote SAE grade numbers RELAY AND FLASHER UNIT Items Light control relay Rated load W Range of voltage used V Voltage drop between terminals V Turn signal flasher unit Type Rated load W Blinking frequency I 2 8 V 20 C 68 F l Hazard flasher ...

Page 164: ...he rated load V 0 2 or less Turn signal switch Rated load A TB FL TB FR 2 2 2 8 TB RL TB R R 4 2 4 8 ST RL ST RR 4 2 4 8 Voltage drop at 12V and the rated load V 0 2 or less HAZARD WARNING SWITCH Items Specifications IVoltage drop at 12V the rated load V 0 1 or less I DIMMER CONTROL SWITCH Items Specifications Type Variable resistance type Rated load n 15 Min 26 6 Max Voltage drop at 14V the rated...

Page 165: ...rd warning switch TROUBLESHOOTING HEADLIGHT Inspection items 1Symptom Headlights do not illuminate or illuminate intermittently It is not possible to change the headlight s beam Headlights arm dim Headlights on only one side illuminate NOTE Number in circle indicates inspection sequence 0 0 0 NOIIG B 0 K 2 t 0 0 0 STB Revision ...

Page 166: ... Symptom Lights fail to illuminate Lights on only one side illuminate NOTE Number in circle indicates inspection sequence BACK UP LIGHT 0 c c a I Il 5 m 0 0 0 Back up light does not illuminate 0 0 Only back up light on one side illuminates NOTE Number in circle indicates inspection sequence STB Revision I ...

Page 167: ...light does not illuminate 0 I NOTE Number in circle indicates inspection sequence TURN SIGNAL LIGHT AND HAZARD LIGHT Inspection items Symptom All turn signal lights fail to flash The turn signal light will not flash illumination remained The hazard light fails to operate The turn signal indicator fails to flash NOTE Number in circle indicates inspection sequence 1 STB Revision ...

Page 168: ... circle indicates inspection sequence INSTRUMENT PANEL ILLUMINATION CIRCUIT Inspection iterns Symptom Illumination light fails to illuminate the tail light also fails to illuminate Illumination light fails to illuminate the tail light illuminates Illumination light cannot be dimmed 0 a A 0 0 Other inspection items 0 Installation parts of the stop light switch 1 STB Revision 1 ...

Page 169: ...se YR 11 25 Y 1 1 I Combination meter I I Wlir L n 7 32 A I A 55 I Lighting Dimmer Passing switch switch switch Column switch Lrght control relay FP R R RL x2 XI J LTH R H Headlight 37W621 Remark For information concerning the ground points example q refer to P 8 7 Wiring color code B Black Br Brown G Green Gr Gray LI Light blue 0 Orange P Pink R Red L Blue Y Yellow Lg Light green W White STB Revi...

Page 170: ... l 5 w 1 Main A 02 A 23 1m fusible link m w 3 cl 22 To turn signal flasher unit 0 85 RL Refer to P 8 49 T I lB Position light Front A 57 Position light v A 08 A 09 Inhibitor Front switch combination light L H _ _ combination Ii h IQ LA Backy light switch i Wiring color code 6 Black Br Brown G Green Gr Gray L Blue Lg Light green LI Light blue 0 Orange P Pink R Red Y Yellow W White STB Revision 7 ...

Page 171: ... Rear combination light L H Rear side marker light L H Remarks 1 2 3 The broken lines are applicable to models equipped with an automatic transmission For information concerning the ground points exam ple 0 refer to P 8 7 B 22 37W823 The symbols 0 0 etc indicate that the wiring is connected using the same numerical symbol to the facing page In other words 0 on the right page is connected to 0 on t...

Page 172: ...Ignition switch Main fusible link I 1 I z II I I Multi purpose fuse 0 85 RL 2 B To column switch Rear to P 8 461 I 1 25 GB a I I 0 85 GY o I_ BJ 0 0 85 GL o I Gw 3 cs I z dm A 31 1 Turn signal and hazard light Turn signal and hazard light Front combination Combination meter w I I I GYa q Front combination light R H 000 light L H 1 STB Revision 1 ...

Page 173: ...mer control switch Rear combination light L H OL EZB B WL 37W029 B 20 m Rern s refer to P 8 7 1 For information concerning the ground points exam 2 The symbols 0 0 etc indicate that the wiring is connected using the same numerical symbol to the In other words 0 on the right page is connected to 0 on the left page Wiring color code B Black Br Brown G Green Gr Gray L Blue Lg Light green LI Light blu...

Page 174: ... A 23 I I fusible IInk 63 L To column switch Combination meter To hazard EL B 01 RB El B RF RB H 28 B RG L H R H Door switch Remark For information concerning the ground points example 0 refer to P 8 7 37W020 Wiring color code B Black Br Brown G Green Gr Gray L Blue Lg Light green LI Light blue 0 Orange P Pink R Red Y Yellow W White 1 STB Revision ...

Page 175: ...e c 51 0 85 G 0 85 WG 2 B To column switcf Refer to P 8 461 Remark For information concerning the ground points example q refer to P 8 7 d B 20 1 B 14 Stop light 1 Stop light Rear cdmbination light L H Rear c mbination light R H Wiring color code B Black Br Brown G Green Gr Gray L Blue Lg Light green Ll Light blue 0 Orange P Pink R Red Y Yellow W White 1 STB Revision ...

Page 176: ...l knob ght control lay Combination gauge B 01 0 Illumination light n c C c 57 0 ti QBY Lighting switch Dimmer control switch rel Combination meter illumination light illumination lighter Remarks 1 The broken lines are applicable to models eouipped with 37W822 an automatic transmission 2 For information concerning the ground points exam ple 0 1 refer to P 8 7 Wiring color code 6 Black Br Brown G Gr...

Page 177: ...ume its normal position 8 If fuel tank is not full place a weight in trunk of vehicle to simulate weight of a full tank 3 kg 6 5 Ibs per gallon 9 There should be no other load in the vehicle other than driver or substituted weight of approximately 70 kg 150 Ibs placed in driver s position 10 Throughly clean headlight lenses 11 Adjust headlights by following the instructions for the headlight teste...

Page 178: ...TION HEADLIGHT CONTROL RELAY Remove the headlight control relay from the inner side of the left fender shield For models equipped with headlight washers remove the headlight washer tank and then remove the headlight control relay Check for continuity between the terminals while power is being supplied and while it is not Terminal 1 2 3 4 5 6 Battery voltage not applied Battery voltage applied NOTE...

Page 179: ...olumn cover hlnTC 16W1569 5 Column switch 6 Cable band I I IC I Reverse the removal procedures to reinstall 2 l Refer to Service Points of Removal SERVICE POINTS OF REMOVAL 2 REMOVAL OF STEERING WHEEL Remove the steering wheel by using the steering wheel puller Caution Do not hammer on the steering wheel to remove it doing so may damage the collapsible mechanism STB Revision ...

Page 180: ...uity between the terminals LIGHTING SWITCH IO NOTE GO indicates that there is continuity between the terminals DIM ER PASSING SWITCH i Switch position Terminal 14 4 O 7 D2 1 1 I Pl IP2 NOTE GC indicates that there is continuity between the terminals TURN SIGNAL SWITCH Termina Switch positi 2 3 9 22 21 16 Left 0 n 0 o o NOTE 0 C indicates that there is continuity between the terminals STB Revision ...

Page 181: ...SERVOCE POINTS OF REMOVAL 1 HAZARD WARNING SWITCH Insert the special tool into the switch and pry the switch to remove it from the instrument panel INSPECTION Operate the switch and check the continuity between the ter minals NOTE CC indicates that there is continuity between the terminals STB Revision ...

Page 182: ...mmer control switch NOTE Reverse the removal procedures to reinstall 16W936 INSPECTION 1 Measure the continuity between the dimmer control switch terminals with an ohmmeter 2 If the resistance value varies smoothly between 0 and 10 IR throughout the entire operation range the dimmer control switch is functioning properly 1 STB Revision ...

Page 183: ...ifications sec Tank capacity lit US qts Imp qts Intermittent wiper relay Intermittent time sec Delay time in washer moving sec Working load W HEADLIGHT WASHER Items Washer motor and pump Motor type Pump type Power consumption A Nozzle injection pressure kPa psi Tank capacity lit U S qts Imp qts Headlight washer control unit Time setting sec Check valve Valve opening and closing pressure kPa psi er...

Page 184: ...ade Wiping angle Blade length mm in Window washer motor and pump Motor type Pump type Power consumption A Allowable period of continuous use With washer fluid Empty operation sec Nozzle jet spray pressure kPa psi 78 11 4 or more Tank capacity lit U S qts Imp qts 1 I 1 2 1 O or more 3 5 0 17 0 27 4 5 18 0 2 or less 3 0 5 or less 0 5 0 2 or less Specifications Ferrite magnet type Dynamic braking syt...

Page 185: ... Items Nm Windshield wiper pivot shaft installing nut IO 16 Windshield wiper arm locking nut IO 16 Windshield wiper motor 7 10 Steering wheel lock nut 35 45 Rear wiper pivot shaft installing nut 8 12 Rearwiper arm locking nut 7 10 Rearwioer motor 7 10 SPECIAL TOOLS NOEKG B 1 STB Revision ...

Page 186: ... is at OFF the wiper continues to operate a 0 0 Wiper s auto stop fails to operate stops vyith the switch at OFF position 0 0 0 The wiper does not operate at intervals 0 0 0 When the washer is operated the wiper fails to function 0 0 The wiper intervals cannot be regulated 0 0 0 The washer fails to operate 0 0 0 0 NOTE 1 Number in circle indicates inspection sequence 2 The symbol indicates vehicle...

Page 187: ... AND WASHER SYSTEM Troubleshooting 8 167 HEADLIGHT WASHER Inspection items Symptom Headlight washer fails to operate NOTE Number in circle indicates inspection sequence Other inspection items 1 STB Revision ...

Page 188: ...wiper control relay r m JJ 1C 64 Headlight washer motor relay Remarks I For information concernina the ground points example a refer to P 8 7 2 The svmbols 0 0 etc indicate that the wiring is connected using the same numerical symbol to the facing page In other words 0 on the right page is connected to 0 on the left page a c m LB EEEI L B L1 Wiring color code B Black Br Brown LI Light blue 0 Orang...

Page 189: ...9 m Column switch Front koer switch 1 Rear wiper and washer switch r I Headlight washer switch o YL JYJ BR Lw L B l 2 w2 B 1 L 7 A 14 1 B 07 81 M A 58 1 GE washer I Rear wiper Front washer motor Front wiper motor motor motor 37W124 STB Revision ...

Page 190: ...bber 3 To attach a new rubber assemble the rubber and backing blade insert from the direction opposite the stopper and secure by the stopper Note that because the backing blade is curved installation should be as shown in the figure REAR WIPER 1 Pull out one side of the wiper blade rubber from the stopper 2 Pull out the wiper blade rubber and then remove the blade rubber 3 Installation of the new ...

Page 191: ... 2 4 Refer to Service Points of Removal 3 I Refer to Service Points of Installation SERVICE POINTS OF REMOVAL 5 WIPER MOTOR Uncouple the linkage and motor with the wiper motor pulled slightly outward Caution Because the installation position of the crank arm and the motor determine the wiper auto stop angle do not disas semble them unless it is necessary to do so If the crank arm must be removed f...

Page 192: ...ring connector from the wiper motor and connect battery to the wiper motor connector to check that the viper motor runs LOW SPEED OPERATION CHECK Connect battery to terminal 1 and battery to terminal 3 and check that the motor runs at low speed HIGH SPEEID OPERATION CHECK Connect battery to terminal 1 and battery to terminal 4 and check that the motor runs at high speed AUTOMATIC STOP OPERATION CH...

Page 193: ...onnect battery to terminal 1 and battery to the wiper motor bracket to check that the motor starts to run at low speed and then stops INTERMITTENT WIPER RELAY Remove the intermittent wiper relay located at the upper part of the left side cowl side trim CONTINUITY CHECK Check to see that there is continuity between terminals 2 and 5 STB Revision ...

Page 194: ...r and over again WASHER INTERLOCK OPERATION CHECK 1 Connect the battery and the test light to the relay as shown in the figure 2 When terminal 3 is connected to the battery s negative terminal the test light will illuminate approximately 1 s econd thereafter and then there will be a release for a bout seconds after connecting to the battery s negative terminal The condition is normal if about 3 se...

Page 195: ...N 3 INSTALLATION OF WIPER BLADE Install the wiper arm so that the wiper blade is parallel to the lower edge of the window glass 2 INSTALLATION OF BACK DOOR TRIM AND WATER PROOF FILM Refer to GROUP 23 BODY Back Door Trim and Water proof Film INSPECTION WIPER MOTOR Disconnect the wiring connector from the wiper motor and connect battery to the wiper motor connector to check that the wiper motor runs...

Page 196: ... ch eck that the motor runs AUTOMATIC OPERATION CHECK 1 Connect battery to terminal 1 and battery to terminal 3 to run the motor 2 While the motor is running disconnect terminal 1 to stop the motor 3 Connect terminal 2 to terminal 3 and connect battery to terminal 1 and battery to wiper motor bracket to check that the motor starts to run again and then stops 1 STB Revision 7 ...

Page 197: ...NSPECTION WASHER MOTOR AND PUMP Make the check while the motor is installed to the washer tank 1 2 18K1514 1 Check to be sure that there is washer fluid in the washer tank 2 Check to be sure that the washer motor operates and the fluid is forced out under pressure when the battery s positive terminal is connected to terminal 2 and the negative terminal is connected to terminal I STB Revision ...

Page 198: ...er trim 2 Rear washer tank 3 Washer motor and pump NOTE 4 Washer tube 1 Reverse the removal procedures to reinstall 2 l Refer to Service Points of Removal 5 Washer nozzle and tube 3 l Refer to Service Points of Installation SERVICE POINTS OF REMOVAL 1 REMOVAL OF REAR WHEELHOUSE TRIM AND QUAR TER TRIM Refer to GROUP 23 BODY Trims 1 STR Ravisinn 7 ...

Page 199: ...nected to terminal 1 INSPECTION WASHER MOTOR AND PUMP Make the check while the motor is installed to the washer tank SERVICE POINTS OF INSTALLATION 1 INSTALLATION OF REAR WHEELHOUSE TRIM AND QUARTER TRIM Refer to GROUP 23 BODY Trims HEADLIGHT WASHER REMOVAL AND INSTALLATION NOEKPAA Removal steps 1 Radiator grille 2 Front combination light 3 Headlight bezel 4 Headlight washer nozzle 5 Washer tube 6...

Page 200: ...battery s positive terminal is connected to terminal 2 and the negative terminal is connected to terminal 3 18W943 Test light 16W945 HEADLIGHT WASHER RELAY Remove the headlight washer relay located a of the left side cowl side trim It the upper part WASHER OPERATION CHECK 1 Connect the battery and the test light to the relay as shown in the figure 2 If when terminal 1 is connected to the negative ...

Page 201: ...er 4 Upper column cover 5 Column switch 6 Cable band NOTE 1 Reverse the removal procedures to reinstall 2 I Refer to Service Points of Removal 16W1569 SERVICE POINTS OF REMOVAL 2 REMOVAL OF STEERING WHEEL Remove the steering wheel by usiing the steering wheel puller Caution Do not hammer on the steering wheel to remove it doing so many damage the collapsible mechanism STB Revision ...

Page 202: ...eck the continuity between the terminals 16W1530 WIPER WASHER SWITCH 16W153C 20 18 15 14 19 13 1 OFF I I o t t o I Ip I HI v 1 v o 0 NOTE 1 GC indicates that there is continuity between the terminals 2 The dotted lines indicate that the washer switch ON HEADLIGHT WASHER Switch Poisition Terminal 2 5 OFF ON NOTE C C indicates that there is continuity between the terminals STB Revision ...

Page 203: ...ATION 4 I NOTE l Refer Rear wiper to Service 16W944 SERVICE POINTS OF REMOVAL 1 REMOVAL OF REAR WIPER AND WASHER SWITCH Insert the special tool into the switch and pry the switch to remove it from the instrument panel INSPECTION Operate the switch and check the continuity between the ter minals STB Revision ...

Page 204: ...evel dB Fundamental frequency Hz High sound Low sound 11 14 5 Max 3 5 100 7 10 400 440 340 380 Specifications TORQUE SPECIFICATIONS Steering wheel lock nut Items i Nm ft lbs 35 45 26 33 TROUBLESHOOTING HORN NOBLH Horn does not sound Horn will not stop sounding NOTE Number in circle indicates inspection sequence 0 Q 0 I 0 l Horn contact plate 0 0 1 STB Revision 1 ...

Page 205: ...er to Horn switch Column switch mm mm I I I I 2 2 dd I J dd A 37 A 36 A 39 A 38 motor P 8 59 1 H U 37W608 Remark For information concerning the ground points example refer to P 8 7 Wiring color code B Black Br Brown G Green Gr Gray L Blue Lg Light green LI Light blue 0 Orange P Pink R Red Y Yellow W White 1STB Revision ...

Page 206: ...rn the adjusting screw in the UP direction within a range of about 180 and then set it in position when a satisfactory sound volume has been obtained 0 The sound volume is too loud Turn the adjusting screw 20 to 30 in the DOWN direction and then set it in position when a satisfactory sound volume has been obtained 0 Horn will not sound Turn the adjusting screw slightly in the UP direction until th...

Page 207: ...edure to reinstall 2 e Refer to Service Points of Removal SERVICE POINTS OF REMOVAL 2 REMOVAL OF STEERING WHEEL Remove the steering wheel by using the steering wheel puller Caution Do not hammer on the steering wheel to remove it doing so may damage the collapsible mechanism INSPECTION l A burned out or short circuited horn switch contact l A broken or damaged horn switch spring l A damaged horn s...

Page 208: ...ions Maximum current A 10 Return time sec I I 18 or less I CLOCK Type Display type Items Specifications Crystal oscillating type Fluorescent digital display TROUBLESHOOTING ZIGARETTE LIGHTER AND CLOCK Inspection items Symptom Cigarette lighter fails to operate Clock stopped NOTE Number in circle indicates inspection sequence MB Revision ...

Page 209: ... 601 1 25 GB To hazard flasher unit4 Refer to P 8 491 Multi purpose fuse illumination light To heater control illumination light Refer to P 8 511 r i I To combination meter BY Wiring color code B Black LI Light blue Br Brown 0 Orange G Green P Pink Gr Gray R Red L Blue Y Yellow Lg Light green W White I I m I N Q Refer to P 8 521 To dimmer control switch BY Refer to P 8 511 I Remark 37W615 For info...

Page 210: ...ment l Using an ohmmeter check the continuity of the element l Confirm that there is no dirt on the surface of the socket CAUTIONS FOR USE OF THE CIGARETTE LIGHTER SOCKET AS AUXILIARY POWER SOURCE 1 When using a plug in type of accessory do not use anything with a load of more than 120W 2 It is recommended that only the lighter be inserted in the receptacle Use of plug in type accessories may dama...

Page 211: ...ACCESSORY Clock 8 191 CLOCK REMOVAL AND INSTALLATION NOBMKAD Removal steps 1 Knob 2 Plug 3 Center panel 4 Clock 16W1558 NOTE Reverse the removal procedures to reinstall 1STB Revision ...

Page 212: ...Rated input power Center pillar trim Model Reted input power Antenna Type Spe cifications AR 7 127PY AR 7 177PY AM FM AMI FM CX 25Y _ SR 28A4 Y K 2 5W Max 7W SG 13SL4 G2 GRAY or SG 13SL4 G2 GRAY or SG 13SL4 BE87 BEIGE SG 13SL4 BE87 BEIGE 15W Max 30W 15W Max 3OW Pole antenna Pole antenna TROUBLESHOOTING Symptom NOTE Number in circle indicates inspection sequence STB Revision ...

Page 213: ...nd of noise Whistling sound Equipment Alternator Symptom of noise generation Noise increases when accelerator pedal is depressed and it subsides soon after engine is stopped Scratching sound Water temperature gauge unit Noise is produced while engine is running and it persists for a while after engine shutdown Fuel gauge unit Noise is produced at sudden acceleration driving on rough road or when i...

Page 214: ...tch Battery A 02 IL Sub fusible link 0 1 25 B A 23 0 5 G 2 w 1 5 w 5 w ll5 w m u Main fusible link N To light control relav Z RW 3 4 Refer to P 8 461 Z RW To air conditioner LW Refer to P 8 561 To combination By meter 4 Refer to P 8 521 DIN Cable I J I Y z I c 45 It II 1 L Radio Tape player STB Revision ...

Page 215: ...exam ple 0 refer to P 8 7 2 The symbols 0 0 etc indicate that the wiring is connected using the same numerical symbol to the facing page in other words 0 on the right page is connected to 0 on the left page Wiring color code B Black Br Brown G Green Gr Gray L Blue LI Light blue 0 Orange P Pink R Red Y Yellow Rear speaker Lg Light green W White STB Revision ...

Page 216: ...ions for adjustment 1 Turn the ignition key to the ACC position 2 Extend the antenna all the way 3 Tune accurately to a station near 1 400 kHz in order to receive a broadcast in as weak an electric field as can be barely received If there is no station near 1 400 kHz tune to any high frequency station above 1 000 kHz available If there are two or more stations near 1 400 kHz choose the louder one ...

Page 217: ...ation l Adjustment of Antenna Trimmer Refer to P 8 196 Removal steps 1 Knob 2 Plug 3 Center console 4 Connection of center panel wiring har ness to front wiring harness connector 7 Radio 8 Tape player 9 Box Vehicles without tape player 5 Radio panel 6 Radio bracket NOTE Reverse the removal procedures to reinstall 1STB Revision ...

Page 218: ...ALLATION NOONMAE Removal steps 1 Mounting screws 2 Front speaker NOTE Reverse the removal procedures to reinstall 16W1520 REAR SPEAKER REMOVAL AND INSTALLATION 16Wl570 Removal steps 1 Mounting screws 2 Rear speaker NOTE Reverse the removal procedures to reinstal 1 STB Revision ...

Page 219: ...enna mast e w 3 Front fender panel 4 Ground base 5 Antenna base NOTE 1 Reverse the removal procedures to reinstall 2 Refer to Service Points of Removal 3 l Refer to Service Points of Installation 16W1579 SERVICE POINTS OF REMOVAL 1 REMOVAL OF MOUNTING NUT Hold the antenna mast and then remove the mounting ...

Page 220: ...stem Before performing any checking or adjustments first confirm the following points Adjust the antenna trimmer completely Set the push buttons tuning properly Extend the antenna all the way PREVENTION OF IGNITION CIRCUIT NOISE A resistance equipped cable is used for the high tension cable in order to prevent noise however if any noise from the ignition circuit does occur check the tightness and ...

Page 221: ...ect a 0 5 FF noise suppression capacitor to the B terminal of the horn 2 For an FM radio connect an LC filter to the horn terminals Noise when the wind shield washer oprates Washer motor Horn LC filter 16E71 1 Connect a 0 5 PF noise suppression capacitor between the terminal of the washer motor and the power source wire 2 For an FM radio connect an LC filter between the terminal of the washer moto...

Page 222: ...8 202 AUDIO SYSTEM Noise Suppression NOISE SUPPRESOR LOCATION I 1 Grou d cable 16W722 Noise condenser 16W1580 1 1STB Revision ...

Page 223: ...r window defogger switch Type Seesaw type Specifications Rated current Back door window defogger timer Timer Back door window glass with defogger No of printed heater lines Power consumption 2O C 68 F 20A 11 112 148W SPECIAL TOOLS Tool Number and name MB990784 Ornament remover Use Removal of back door window defogger switch NOBPG B 1 STB Revision ...

Page 224: ...hooting TROUBLESHOOTING NOBPH B Neither the back door window defogger nor the indicator function 0 0 0 The indicator functions but the back door window defogger does not function 0 0 0 Number in circle indicates inspection sequence STB Rqvision ...

Page 225: ...k To light control relay w zmR Refer to P 8 461 q l 2 fuse i Multi purpose m E c t To column switch Refer to P 8 461 1 25 B a c Rheostat Defogger switch a cl 31 W02 Remarks For information concerning the ground points example D refer to P 8 7 Wiring color code B Black Br Brown G Green Gr Gray L Blue Lg Light green LI Light blue 0 Orange P Pink R Red Y Yellow W White STB Revision ...

Page 226: ...GGER SWITCH lr rt the special tool into the switch and pry the switch to remove it from the instrument panel INSPECTION DEFOGGER SWITCH 1 Remove the defogger switch from the instrument panel and connect an ohmmeter to the switch side connector 2 Operate the switch and check the continuity between the terminals Indicator light Illumination light NOTE 0 C indicates that there is continuity between t...

Page 227: ...ace where there is a sudden change in the voltage to 0 V 5 This place where the voltage suddenly changes indicates the location of the broken heater line 6 If OV is indicated at point A the heater line is broken between point A and the positive terminal Find the point where there is a sudden change in the voltage to 12V as described in step 4 above REPAIR I Prepare the following items e Conductive...

Page 228: ...meter Based upon the output signals from the pulse generator and from the vehicle speed sensor reed type switch the automatic free wheeling hub indicator control unit judges whether the automatic free wheeling hub is in the locked condition or the free condition When it is in the locked condition the indicatok light illuminates when it is in the free condition the indicator light does not illumina...

Page 229: ...or and when in addition the vehicle speed sensor detects a vehicle speed of approximately 2 5 mph 4 km h or higher The locked condition is entered in the memory even if the vehicle is stopped with ignition key still at ON while the automatic free wheeling hub is in the locked condition and the indicator light illumination continues After the automatic free wheeling hub is changed from the locked c...

Page 230: ...uminate Pulse generator Speed sensor Reed switch Pulse detection circuit I I Memory circuit rp I Automatic free wheeling hub Lock discrimin ion circuit indicator control unit 16W1535 Ignition switch use No 3 n J 2 I_ Power supply circuit Vehicle speed detection circuit 1 Sub fusible link 1 Main fusible link 1 1Battery When vehicle is stopped with ignition key still at ON with automatic free wheeli...

Page 231: ...47 rator Front out put shaft 16W1546 The pulse generator is located at the rear part of the front output shaft of the transfer and is composed of the magnet the coil and the pole iron core When a magnetic material iron nickel etc is brought close to and moved away from the pole iron core the magnetic flux within the pole changes thus generating AC voltage in the coil Because the front output shaft...

Page 232: ...ives the input signals from the pulse generator the vehicle speed detection circuit which receives the input signals from the vehicle speed sensor the lock discrimination circuit which based on both of these input signals judges the condition of the automatic free wheeling hub and then trans mits indicator output signals to the memory circuit and the memory circuit which memorizes the indicator ou...

Page 233: ...ped with the ignition key at ON after traveling even though the automatic free wheeling hub is in the locked condition The indicator light remains illuminated when the ignition key is turned from OFF to ON 0 0 0 0 a 0 The indicator light remains illuminated when after traveling with the automatic free wheeling hub in the locked condition the vehicle is stopped the automatic free wheeling hub is ch...

Page 234: ...02 Sub fusible link 15 w r 5 w 0 5 G 2 w I I I I Main fusible link 7 N 22 3 Pulse c generator h Ignition switch I Locking check circuit 1 q IIEI Combination meter Automatic free wheeling hub indicator control unit 1 B R Em El1 Y L Remark For information concerning the ground points example q refer to P 8 7 37W610 Wiring color code B Black Br Brown G Green L Blue LI Light blue Lg Light green 0 Oran...

Page 235: ...pole iron core of the pulse generator l Check whether or not the installation bolts of the pulse rotor or the pulse generator are loose For detailed information concerning the pulse rotor refer to GROUP 21 TRANSMISSION Transfer CHECKING PULSE GENERATOR RESISTANCE Check whether or not the resistance between the terminals shown in the figure is within the standard value range Standard value 215 275 ...

Page 236: ...TPUT VOLTAGE OF THE VEHICLE SPE D SENSOR REED TYPE SWITCH I Turn the ignition key to ON 2 Insert a test probe from the rear side of the conncetor of the automatic free wheeling hub indicator control unit 3 Measure the output voltage of the vehicle speed sensor when the vehicle is moved a distance of about 0 5 m 1 6 ft Standard values Vehicle speed sensor OFF 4V or higher Vehicle speed sensor ON OV...

Page 237: ...dures 29 Testing System for Leaks 33 SPECIAL TOOLS 22 SPECIFICATIONS 21 General Specifications 21 Service Specifications 21 Torque Specifications 21 TROUBLESHOOTING 22 Air is Emitted but Is Not Cool Cool Air Flow Is Intermittent Insufficient Air Flow Insufficient Cooling HEATERS BLOWER ASSEMBLY a 14 CIRCUIT DIAGRAM 4 GENERAL INFORMATION 2 HEATER CONTROL 9 HEATER UNIT 12 SERVICE ADJUSTMENT PROCEDUR...

Page 238: ...ble and the temperature can be set to the optimum level The lap heater ducts which provide warm air to th knee area for the front seats and the rear heater ducts which provide warm air to the foot area for the rebr seats from the heater unit plus the warm water type rear heater assure heating comfort throughout Blower motor 2OW640 Rear heater duct eselection I Mode selection lever I I 58W540 Tempe...

Page 239: ...or replace 24 l 3 No ventilation even Incorrect adjustment of changeover dam Adjust 24 5 when mode selection pers lever is operated Incorrect installation mode selection control Adjust 24 5 wire Blower motor oper ates on high speed only Blower motor inop erative Ducts are incorrectly incompletely con netted crushed bent or clogged Broken blower motor resister Broken blower switch Burnt out fuse Po...

Page 240: ...M 5 LA a3 To turn sional flasher Init 0 85RI I I f Y I Refer to P 8 49 7 d r i I Blower Blower switch CJ 18 Heater r v Blower motor resistor Remark For information concerning the ground points example q refer to P 8 7 Wiring color code B Black Br Brown G Green Gr Gray LI Light blue 0 Orange P Pink R Red L Blue Y Yellow Lg Light green W White 1 STB Revision ...

Page 241: ... damper lever all the way in the direction of the arrow 5 Connect the mode selection control wire to the mode selection damper lever and to the clip part of the heater unit Caution Be careful that the lever does not move when clipping 6 Check to be sure that the mode selection lever moves smoothly to each position and that the air flow is correct for each position 7 If the air flow is not correct ...

Page 242: ...he mode selection damper lever all the way in the direction of the arrow 3 Pull the FOOT DEF damper lever completely upward and move the FOOT DEF damper to the position shown in the figure The packing should contact the case NOTE Confirmation can be made that the FOOT DEF damp er is raised upward through the defroster blower outlet of the heater unit with defroster duct disconnected 4 Attach the e...

Page 243: ... Unfasten the clip of the blend air damper lever and disconnect the link for water valve lever from the blend air damper lever 5 Push the water valve lever all the way inward so that the water valve is at the closed position 6 Turn the blend air damper lever all the way in the direction of the arrow so that the blend air damper is completely closed at the lower most position 7 Attach the end of th...

Page 244: ... the blend air damper lever and the heater unit s clip 6 Remove the water valve cover 7 Remove the piping clamp 8 Unfasten the clip of blend air damper lever and disconnect the link for the water valve lever from the blend air damper lever 9 Remove the joint hose clamp 10 Cut the joint hose 11 Remove the water valve from the heater core 12 Apply a coating of soapy water to the inside surface of th...

Page 245: ...ness connector 7 Lap heater duct B 8 Defroster duct l 9 Mode selection control wire l 10 Water valve control wire l a II Heater control assembly 12 Blower switch EyTEeverse the removal procedures to reinstall 2 4 Refer to Service Points of Removal 3 eq Refer to Service Points of Installation SERVICE POINTS OF REMOVAL N24GBAE 1 REMOVAL OF GLOVE BOX STOPPERS 1 Open the glove box lid 2 Remove the glo...

Page 246: ...trol wire pull the outer cable to remove it from the clip 2 Disconnect the inner cable of the mode selection control wire from the end of the mode selection damper lever 10 REMOVAL OF WATER VALVE CONTROL WIRE 1 Use a screwdriver to pry and remove the clip that holds the outer cable of the water valve control wire 2 Disconnect the inner cable of the water valve control wire from the end of the wate...

Page 247: ... 9 INSTALLATION OF MODE SELECTION CONTROL WIRE Connect the mode selection control wire to the mode selection damper lever by following the steps below 1 Move the mode selection lever to the E position 2 With the mode selection damper lever pressed inward in the direction indicatecl by the arrow connect the inner cable of the mode selection control wire to the end of the mode selection lever and th...

Page 248: ...er hose connection l 4 2 Instrument panel 3 Duct 4 Center ventilator duct 5 Heater unit NOTE 1 Reverse the removal procedures to reinstall 2 e Refer to Service Points of Removal 3 l Refer to Service Points of Installation 2OW823 SERVICE POINTS OF REMOVAL 1 DISCONNECTION OF HEATER HOSES 1 Remove the air filter 2 Set the temperature lever to the far 3 Remove the radiator drain plug and engine coolan...

Page 249: ...ction damper lever 4 Move the damper lever to the position at which the mode selection damper lever does not protrude very much to the heater core side 5 Remove the heater core If at this time the damper lever and heater core are in contact making removal difficult remove the damper lever Caution To prevent interference between the heater core and case use care not to peel the heater core felt awa...

Page 250: ... 2 l Refer to Service Points of Removal 3 l Refer to Service Points of Installation SERVICE POINTS OF REMOVAL N24KBAE 2 REMOVAL OF GLOVE BOX 1 Open the glove box lid 2 Remove the glove box stopper 3 Remove the glove box from the hinge 3 REMOVAL OF AIR SELECTION CONTROL WIRE 1 Use a screwdriver to pry and remove the clip that holds the outer cable of the air selection control wire 2 Disconnect the ...

Page 251: ... 2 25112 Approx OlR 1 Connect the blower motor terminals directly to the battery and check that the blower motor operates smoothly 2 Next reverse the polarity and check that the blower motor operates smoothly in the reverse direction SERVICE POINTS OF INSTALLATION N24KDAC 3 INSTALLATION OF AIR SELECTION CONTROL WIRE Connect the air selection control wire to the air selection damper lever by follow...

Page 252: ...conditioner 9 Lap heater duct A 10 Air duct L H Only vehicles with air conditioner 11 Instrument panel 12 Defroster duct 13 Center ventilator duct 14 Center air outlet 15 Knob 16 Air duct 17 Side air outlet NOTE 1 Reverse the removal procedures to reinstall 2 e Refer to Service Points of Removal SERVICE POINTS OF REMOVAL N24MBAG 1 REMOVAL OF DEMISTER GRILL While using a screwdriver to pry the lock...

Page 253: ...e glove box stopper 3 Pull the glove box outward 4 Remove the defroster duct R H 5 Remove the air duct R H 9 REMOVAL OF LAP HEATER DUCT A 1 Remove the center panel Refer to GROUP 23 BODY Floor console 2 Remove the heater control assembly Refer to P 24 9 3 Insert a hand through the heater control assembly installation hole in the instrument panel and remove the installation screw of the lap heater ...

Page 254: ...AND INSTALLATION Rear ventilator duct N24MA 1 L042GT 18W825 Removal steps I 1 Upper quarter trim L042GV Rear ventilator cover L042GT 2 Nut 3 Screw 4 Air outlet garnish 5 Screw 6 Rear ventilator duct 3 2OW796 NOTE 1 Reverse the removal procedures to reinstall 2 e Refer to Service Points of Removal SERVICE POINTS OF REMOVAL N24MBAI 1 REMOVAL OF UPPER QUARTER TRIM L042GV OR REAR VENTILATOR COVER L042...

Page 255: ...ir damper and adjusts the mixing ratio of the cooled air and warm air The blowout made is z and the cooled air is blown out from four directions and the blowout can be adjusted by the blower switch changes the blowout in four stages by the cabin condition The air selector is set on P J during cooling and can be changed to according to the offensive smell and pollution e election I Mode selection l...

Page 256: ...event damage to the air conditioning system in the event that excessive pressure develops due to condenser air flow being restricted by for example leaves newspaper an overcharge of refrigerant or air in the system LOW PRESSURE SWITCH prevents damage to the compressor in case of system loss of refrigerant charge EXPANSION VALVE The expansion valve is used for all applications Its function is to me...

Page 257: ... 41 Burn out temperature 106 222 Fusible plug C F R l 2 600 900 1 3 2 0 Refrigerant and quantity g Ibs 1 SERVICE SPECIFICATIONS N24CE Items Specifications Standard value Drive belt deflection mm in 17 20 7 8 Pressure plate to rotor clearance mm in 0 4 0 7 02 03 TORQUE SPECIFICATIONS N24CG Items Nm ftlbs Suction hose to cooling unit 30 35 22 25 Liquid pipe to cooling unit 12 15 9 l 1 Liquid pipe to...

Page 258: ...ribe the problem refer to appropriate section for detailed explanation N24DA After correcting the malfunction check out the complete system to assure satisfactory performance MALFUNCTION CAUSES AND REMEDIES Numbers indicate checking inspection order 1not cool 1 Air is emitted but is 1 Magnetic clutch is not switched ON SEE NEXT PAGE 1 Replace 1 I I I 4 2 Check the fuse IOA t l Replace I I I I I 3 ...

Page 259: ... the refrigerant amount _1 Supply P 24 29 refrigerant Check the receiver drier Replace P 24 29 4 Abnormal rotation of Drive belt loose compresspor P 24 40 __ Adjust the belt 1 5 Expansion valve clogged Check the expansion valve Replace P 24 44 t 6 Poor compression of compressor c Check the compressor P 24 32 Replace 1 STB Revision ...

Page 260: ... before charging the system and for connecting the supply of refrigerant when charging the system glass 2OW724 N24FEAE The receiver drier assembly consists of Drier reservoir Refriger ant level sight glass and Fusible plug To Test the Receiver Drier 1 Operate the unit and check the piping temperature by touching the receiver drier outlet and inlet 2 If there is a difference in the temperatures the...

Page 261: ...frost D Check the thermistor or therm0 relay P 24 31 A Replace 3 Blower motor mal function Check the blower motor Replace Cool air flow is 1 Air in refrigerant Measure the pressure P 24 34 Apply inter vacuum mittent supply refrigerant i 2 Expansion valve malfunction Check the expansion valve P 24 44 _ Replace STB Revision ...

Page 262: ...sher unit 0 85 RL Refer to P 8 49 1 i I 1 0 85 LW F 0 85 WB yl lLG1 Refer to P 8 62 1 C C Blower motor M E Blower motor T IA2 Ml kFF 18 Heater relav N BI ower switch B L EEJ LRLR resistor LBLY El3 LRLI x 2 Wiring color code B Black Br Brown G Green Gr Gray L Blue Lg Light green LI Light blue 0 Orange P Pink R Red Y Yellow W White ST6 Revision ...

Page 263: ...um solenoid A 13 valve A 45 Condenser Condenser blower blower motor motor relay A rl z BY 37W611 Magnetic clutch compressor Remarks 1 For information converning the ground points exam ple l m refer to P 8 7 2 The symbols 0 0 etc indicate that the wiring is connected using the same numerical symbol to the facing page In other words 0 on the right page is connected to 0 on the left page STB Revision...

Page 264: ...most instances moderate heat is required to bring the pressure of the refrigerant in its container above the pressure of the system when charging or adding refrigerant A bucket or large pan of hot water not over 52 C 125 F is all the heat required for this purpose Do not heat the refrigerant container with a blow torch or any other means that would raise temperature and pressure above this tempera...

Page 265: ... before charging the system and for connecting the supply of refrigerant when charging the system glass 2OW724 N24FEAE The receiver drier assembly consists of Drier reservoir Refriger ant level sight glass and Fusible plug To Test the Receiver Drier 1 Operate the unit and check the piping temperature by touching the receiver drier outlet and inlet 2 If there is a difference in the temperatures the...

Page 266: ...ic clutch It cuts off the electrical power supply to the clutch when refrigerant pressure drops below the cont ol point of the switch Whenever the system is inactivated by the low pressure switch due to refrigerant loss the refrigerant oil may have been lost Therefore to prevent damage to the com pressor due to operation without sufficient lubrication the leak must be repaired and the compressor o...

Page 267: ...e clutch operates replace the thermostat WATER TEMPERATURE SWITCH The water temperature switch is located on the thermostat hous ing The water temperature switch is connected to the clutch in series When the coolant temperature in the radiator reaches above 113 C 235 F it turns the compressor OFF This is to prevent engine overheating When the water temperature switch is activated and the clutch is...

Page 268: ...d gauge set and run the air conditioner 2 If a pressure of approx 490 kPa 71 psi is indicated on the suction gauge side and a pressure of approx 883 kPa 128 psi is indicated on the discharge gauge side the compressor has abnormal compression Replace the compressor 3 If a pressure of 294 to 392 kPa 43 to 59 psi is indicated on the suction gauge side and a pressure of approx 1961 kPa 284 psi is indi...

Page 269: ...g drawn in through the sampling tube or the copper reaction wire is dirty 1 Assemble leak detector as shown be sure detector is seated tightly over torch gasket 2 Holding torch upright screw in butane charger clockwise until punctured Do not use force 3 Screw out butane charge counterclockwise about l 4 turn 4 Point torch away from body then light escaping gas with match Always keep torch in uprig...

Page 270: ...a 1 406 2 109 kPa 132 188 psi 152 220 psi 172 252 psi 190 280 psi 200 300 psi 127 148 kPa 131 162 kPa 134 176 kPa 135 188 kPa 136 194 kPa 18 21 psi 18 6 23 psi 19 25 psi 19 2 26 8 psi 19 4 27 6 psi REFRIGERANT LEAK REPAIR PROCEDURE N24FnAB LOST CHARGE If the system has lost all charge due to a leak 1 Evacuate the system See the procedure 2 Charge the system with approximately one pound of refriger...

Page 271: ...of water containing the refrigerant can on an accurate scale so the amount of refrigerant added can be weighed Open the refrigerant manifold valve 8 Purge all air from test hoses Air in the system will be trapped in the condenser causing abnormally high discharge pressures and interfering with condensing of the refrigerant 9 Slightly loosen both test hoses at the gauge set manifold Tighten the hos...

Page 272: ... compressor is installed at the factory it contains 110 c c 3 7 U S fl oz 3 9 Imp fl oz of refrigerant oil While the air conditioning system is in operation the oil is carried through the entire system by the refrigerant Some of this oil will be trapped and retained in various parts of the system When the following system components are changed it is nec essary to add oil to the system to replace ...

Page 273: ...lable in bulk tanks or small cans Follow the safety precautions for handling R 12 as listed in the beginning of this group Charging with Small Cans When using disposable cans of this type follow carefully the can manufactures instructions Caution Never use these cans to charge into the high pressure side of the system compressor discharge port or into a system that is at high temperature because t...

Page 274: ...utch will remain engaged 7 Start the engine and move the controls to air conditioner switch on and low blower position The low pressure switch will prevent the clutch from engaging until refrigerant is added to the system If the clutch does engage replace the switch before proceeding any further 8 Charge through the suction side of the system by slowly open ing the suction manifold valve Adjust th...

Page 275: ...ischarge before opening any fitting or connection in the refrigeration system Open fittings with caution even after the system has been discharged If any pressure is noticed as a fitting is loosened allow trapped pressure to bleed off very slowly Never attempt to rebend formed lines to fit Use the correct line for the installation you are servicing A good rule for the flexible hose lines is keep t...

Page 276: ...nger than necessary Cap or plug all lines and fittings as soon as they are opened to prevent the en trance of dirt and moisture All lines and components in parts stock should be capped or sealed until they are ready to be used All tools including the refrigerant dispensing manifold the gauge set manifold and test hoses should be kept clean and dry COMPRESSOR DRIVE BELT ADJUSTMENT N24FJAE Satisfact...

Page 277: ...different engine speeds and depending upon belt tension belts can develop unusual noises that are often mistaken for mechanical problems within the compressor Adjustment Procedures 1 Select a quiet area for testing Duplicate conditions as much as possible Switch compressor on and off several times to clearly identify compressor noise To duplicate high ambient conditions high head pressure restrict...

Page 278: ... Plugs 5 Center panel 6 Connection of center panel wiring har ness to front wiring harness connector 7 Air conditioner switch NOTE 1 Reverse the removal procedures to reinstall 2 e Refer to Service Points of Removal SERVICE POINTS OF REMOVAL 1 REMOVAL OF GLOVE BOX STOPPERS 1 Open the glove box lid 2 Remove the glove box stopper 3 Pull the glove box outward 1 STB Revision ...

Page 279: ...OTE I Reverse the removal procedures to reinstall 2 l Refer to Service Points of Installation Nut I Union 2OUO267 SERVICE POINTS OF REMOVAL Caution N24MAC If the hoses or pipes are disconnected cap the hoses or pipes with a blank plug to prevent entry of dust dirt and water SERVICE POINTS OF INSTALLATION N24AOAE 2 APPLICATION OF COMPRESSOR OIL TO SUCTION HOSE l LIQUID PIPE Apply specified compress...

Page 280: ...6 2OW828 2OW718 2ow722 a 0 rina Expansion valve O rim SERVICE POINTS OF DISASSEMBLY 4 REMOVAL OF CLIP N24RFAB Remove the clips with a flat blade screwdriver covered with a shop towel to prevent damage to case surfaces 8 REMOVAL OF EXPANSION VALVE Use two wrenches to loosen the flare nut on the pipe con nection for both the inlet and outlet SERVICE POINTS OF REASSEMBLY N24RHAE 8 APPLICATION OF COMP...

Page 281: ...rant Refer to P 24 37 l Adjustment of the Tension of the Air Conditioner Drive Belt Refer to P 24 40 2OW832 Receiver drier removal steps Compressor clutch assembly removal steps 1 Reveiver drier mounting bolt 8 Drive belt 2 Receiver drier 9 Compressor clutch assembly mounting Condenser removal steps 3 Blower motor connector 4 Blower motor mounting bolt 5 Blower motor 6 Condenser mounting bolt 7 Co...

Page 282: ...ly 6 Snap ring 7 Ground terminal l 8 Clutch coil l5Dl 2QY947 Compressor front housing and service valve disas sembly steps 9 Oil drain guide 10 Woodruff key Il Through bolt Refilling of compressor oil 12 Front housing o 13 Shaft seal 04 14 Shaft plate 15 Gasket 16 O ring NOTE 1 Reverse the disassembly procedures to reassemble 2 e Refer to Service Points of Disassembly 3 e Refer to Service Points o...

Page 283: ...s and deforma tion l Check the front housing for cracks or scoring on the sealing surfaces l Check the compressor shaft for scoring SERVICE POINTS OF REASSEMBLY N24THAH 14 INSTALLATION OF SHAFT PLATE 1 Lubricate the shaft plate and a new O ring with compressor oil Push the shaft plate and O ring into the front housing 2 Install the seal plate into the front housing with a special tool 13 INSTALLAT...

Page 284: ...he compression housing ADJUSTMENT OF CLUTCH CLEARANCE 1 Check the pressure plate to rotor clearance as illus trated Pressure plate to rotor clearance 0 4 0 7 mm 016 028 in NOTE Remove clearance adjusting shims to decrease clutch clearance Add shims selected from the following table to increase clutch clearance Clearance Adjustment Shims Part No Thickness RSI 3023A 0 1 mm 004 in RSI 3023B 0 2 mm 00...