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1993-1996 Mitsubishi Galant & Galant Hatchback Service Manual – PDF
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1993-1996 Mitsubishi Galant & Galant Hatchback Service Manual PWDE9211 – B – PDF DOWNLOAD
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Description
1993-1996 Mitsubishi Galant & Galant Hatchback Service Manual PWDE9211 – B – PDF DOWNLOAD
FILE DETAILS:
1993-1996 Mitsubishi Galant & Galant Hatchback Service Manual PWDE9211 – B – PDF DOWNLOAD
Language : English
Pages : 1687
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
1993-1996 Mitsubishi Galant & Galant Hatchback Service Manual PWDE9211 – B – PDF DOWNLOAD
Cover ................................................................................................... 1 GENERAL.................................................................................................. 8 HOW TO USE THIS MANUAL............................................................................... 10 SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS.......................................... 10 DEFINITION OF TERMS.............................................................................. 10 INDICATION OF TIGHTENING TORQUE.................................................................. 10 MODEL INDICATIONS................................................................................ 10 EXPLANATION OF MANUAL CONTENTS................................................................... 11 EXPLANATION OF CIRCUIT DIAGRAMS.................................................................. 13 HOW TO USE TROUBLESHOOTING / INSPECTION SERVICE POINTS............................................... 14 TROUBLESHOOTING CONTENTS......................................................................... 14 HOW TO USE THE INSPECTION PROCEDURES............................................................. 15 CONNECTOR MEASUREMENT SERVICE POINTS............................................................. 16 CONNECTOR INSPECTION............................................................................. 17 INSPECTION SERVICE POINTS FOR A BLOWN FUSE....................................................... 18 POINTS TO NOTE FOR INTERMITTENT MALFUNCTIONS..................................................... 18 VEHICLE IDENTIFICATION............................................................................... 19 VEHICLE INFORMATION CODE PLATE................................................................... 19 MODELS........................................................................................... 20 MODEL CODE....................................................................................... 23 CHASSIS NUMBER................................................................................... 24 ENGINE MODEL NUMBER.............................................................................. 25 MAJOR SPECIFICATIONS................................................................................. 26 PRECAUTIONS BEFORE SERVICE........................................................................... 34 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)-AIR BAG.......................................................... 38 SUPPORT LOCATIONS FOR LIFTING AND JACKING............................................................ 44 SUPPORT POSITIONS AND SUPPORT METHOD FOR AN H-BAR LIFT............................................... 46 SPECIAL HANDLING INSTRUCTIONS FOR 4WD MODELS......................................................... 48 STANDARD PARTS-TIGHTENING-TORQUE TABLE............................................................... 52 MAIN SEALANT AND ADHESIVE TABLE...................................................................... 53 GENERAL '95 Changes..................................................................................1615 GENERAL '96 Changes..................................................................................1634 ENGINE................................................................................................... 55 4G6.................................................................................................. 57 GENERAL INFORMATION.............................................................................. 58 SERVICE SPECIFICATIONS........................................................................... 60 SEALANTS......................................................................................... 61 SPECIAL TOOLS.................................................................................... 61 SERVICE ADJUSTMENT PROCEDURES.................................................................... 63 DRIVE BELT TENSION INSPECTION AND ADJUSTMENT................................................. 63 IGNITION TIMING INSPECTION AND ADJUSTMENT.................................................... 64 IDLE SPEED INSPECTION........................................................................ 66 COMPRESSION PRESSURE INSPECTION.............................................................. 66 MANIFOLD VACUUM INSPECTION................................................................... 68 LASH ADJUSTER CHECK.......................................................................... 68 CRANKSHAFT PULLEY................................................................................ 70 CAMSHAFT AND CAMSHAFT OIL SEAL................................................................... 71 OIL PAN.......................................................................................... 74 CRANKSHAFT FRONT OIL SEAL........................................................................ 76 CRANKSHAFT REAR OIL SEAL......................................................................... 77 CYLINDER HEAD GASKET............................................................................. 79 TIMING BELT...................................................................................... 83 TIMING BELT B.................................................................................... 87 ENGINE ASSEMBLY.................................................................................. 90 4G9.................................................................................................. 94 GENERAL INFORMATION.............................................................................. 95 SERVICE SPECIFICATIONS........................................................................... 97 SEALANTS......................................................................................... 98 SPECIAL TOOLS.................................................................................... 98 SERVICE ADJUSTMENT PROCEDURES.................................................................... 99 DRIVE BELT TENSION INSPECTION AND ADJUSTMENT................................................. 99 VALVE CLEARANCE INSPECTION AND ADJUSTMENT.................................................... 101 IGNITION TIMING INSPECTION AND ADJUSTMENT.................................................... 102 IDLE SPEED INSPECTION........................................................................ 103 COMPRESSION PRESSURE INSPECTION.............................................................. 104 MANIFOLD VACUUM INSPECTION................................................................... 105 TIMING BELT TENSION ADJUSTMENT............................................................... 105 CRANKSHAFT PULLEY................................................................................ 107 CAMSHAFT, CAMSHAFT OIL SEAL...................................................................... 108 OIL PAN.......................................................................................... 110 CRANKSHAFT FRONT OIL SEAL........................................................................ 112 CRANKSHAFT REAR OIL SEAL......................................................................... 113 CYLINDER HEAD GASKET............................................................................. 115 TIMING BELT...................................................................................... 120 ENGINE ASSEMBLY.................................................................................. 124 6G7.................................................................................................. 127 GENERAL INFORMATION.............................................................................. 128 SERVICE SPECIFICATIONS........................................................................... 130 SEALANTS......................................................................................... 130 SPECIAL TOOLS.................................................................................... 131 SERVICE ADJUSTMENT PROCEDURES.................................................................... 133 DRIVE BELT INSPECTION AND ADJUSTMENT......................................................... 133 IGNITION TIMING INSPECTION AND ADJUSTMENT.................................................... 135 IDLE SPEED INSPECTION........................................................................ 136 COMPRESSION PRESSURE INSPECTION.............................................................. 136 MANIFOLD VACUUM INSPECTION................................................................... 138 LASH ADJUSTER CHECK.......................................................................... 138 CRANKSHAFT PULLEY................................................................................ 141 CAMSHAFT OIL SEAL................................................................................ 142 OIL PAN.......................................................................................... 144 CRANKSHAFT FRONT OIL SEAL........................................................................ 146 CRANKSHAFT REAR OIL SEAL......................................................................... 147 CYLINDER HEAD GASKET............................................................................. 149 TIMING BELT...................................................................................... 152 ENGINE ASSEMBLY.................................................................................. 158 6A1.................................................................................................. 161 GENERAL INFORMATION.............................................................................. 162 SERVICE SPECIFICATIONS........................................................................... 164 SEALANTS......................................................................................... 165 SPECIAL TOOLS.................................................................................... 165 SERVICE ADJUSTMENT PROCEDURES.................................................................... 167 DRIVE BELT TENSION INSPECTION AND ADJUSTMENT................................................. 167 IGNITION TIMING INSPECTION AND ADJUSTMENT.................................................... 168 IDLE SPEED INSPECTION........................................................................ 169 COMPRESSION PRESSURE INSPECTION.............................................................. 170 MANIFOLD VACUUM INSPECTION................................................................... 171 LASH ADJUSTER CHECK.......................................................................... 172 CRANKSHAFT PULLEY................................................................................ 175 CAMSHAFT, CAMSHAFT OIL SEAL...................................................................... 176 OIL PAN.......................................................................................... 182 CRANKSHAFT FRONT OIL SEAL........................................................................ 184 CRANKSHAFT REAR OIL SEAL......................................................................... 185 CYLINDER HEAD GASKET............................................................................. 187 TIMING BELT...................................................................................... 191 ENGINE ASSEMBLY.................................................................................. 196 4D6.................................................................................................. 199 GENERAL INFORMATION.............................................................................. 200 SERVICE SPECIFICATIONS........................................................................... 202 SEALANTS......................................................................................... 203 SPECIAL TOOLS.................................................................................... 203 SERVICE ADJUSTMENT PROCEDURES.................................................................... 204 DRIVE BELT TENSION INSPECTION AND ADJUSTMENT................................................. 204 VALVE CLEARANCE INSPECTION AND ADJUSTMENT.................................................... 206 INJECTION TIMING ADJUSTMENT.................................................................. 208 ENGINE IDLE SPEED INSPECTION AND ADJUSTMENT.................................................. 210 IDLE-LIP MECHANISM INSPECTION AND ADJUSTMENT................................................. 210 COMPRESSION PRESSURE INSPECTION.............................................................. 211 TIMING BELT ADJUSTMENT....................................................................... 212 CRANKSHAFT PULLEY................................................................................ 214 CAMSHAFT, CAMSHAFT OIL SEAL...................................................................... 215 OIL PAN.......................................................................................... 217 CRANKSHAFT FRONT OIL SEAL........................................................................ 219 CRANKSHAFT REAR OIL SEAL......................................................................... 220 CYLINDER HEAD GASKET............................................................................. 222 TIMING BELT/TIMING BELT B........................................................................ 227 ENGINE ASSEMBLY.................................................................................. 232 LUBRICATION.............................................................................................. 235 GENERAL INFORMATION.................................................................................. 236 LUBRICANTS........................................................................................... 237 SPECIAL TOOL......................................................................................... 237 SERVICE ADJUSTMENT PROCEDURES........................................................................ 237 ENGINE OIL INSPECTION............................................................................ 237 ENGINE OIL REPLACEMENT........................................................................... 238 OIL FILTER REPLACEMENT........................................................................... 239 OIL LEVEL SENSOR INSPECTION...................................................................... 240 ENGINE OIL COOLER <6G73, 4D68>....................................................................... 241 ENGINE OIL COOLER <4G63-4WD, 6A12>................................................................... 243 LUBRICATION '95 Changes..............................................................................1619 FUEL..................................................................................................... 244 MULTIPOINT FUEL INJECTION (MPI)...................................................................... 246 GENERAL INFORMATION.............................................................................. 247 SERVICE SPECIFICATIONS........................................................................... 255 SEALANT.......................................................................................... 256 SPECIAL TOOLS.................................................................................... 256 TROUBLESHOOTING.................................................................................. 258 SERVICE ADJUSTMENT PROCEDURES.................................................................... 360 THROTTLE BODY (THROTTLE VALVE AREA) CLEANING................................................. 360 IDLE POSITION SWITCH AND THROTTLE POSITION SENSOR ADJUSTMENT <Vehicles without TCL>.......... 360 THROTTLE POSITION SENSOR ADIUSTMENT <Vehicles with TCL>...................................... 362 IDLE POSITION SWITCH AND ACCELERATOR PEDAL POSITION SENSOR ADJUSTMENT <Vehicles with TCL>.... 362 FIXED SAS ADJUSTMENT......................................................................... 364 BASIC IDLE SPEED ADJUSTMENT.................................................................. 364 FUEL PRESSURE TEST........................................................................... 366 FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE THE FUEL PRESSURE).......................... 368 FUEL PUMP OPERATION CHECK.................................................................... 369 ON-VEHICLE INSPECTION OF MPI COMPONENTS.......................................................... 370 COMPONENT LOCATION <4G93, 4G63>.............................................................. 370 COMPONENT LOCATION <GA12, 6G73>.............................................................. 374 CONTROL RELAY INSPECTION..................................................................... 378 INTAKE AIR TEMPERATURE SENSOR INSPECTION..................................................... 379 ENGINE COOLANT TEMPERATURE SENSOR INSPECTION................................................. 379 THROTTLE POSITION SENSOR INSPECTION.......................................................... 380 IDLE POSITION SWITCH INSPECTION.............................................................. 381 OXYGEN SENSOR INSPECTION..................................................................... 382 INJECTOR INSPECTION.......................................................................... 384 IDLE SPEED CONTROL (ISC) SERVO (DC MOTOR) INSPECTION <4G93, 4G63>............................ 386 IDLE SPEED CONTROL (ISC) SERVO (STEPPER MOTOR) INSPECTION <6A12, 6G73>....................... 386 PURGE CONTROL SOLENOID VALVE INSPECTION...................................................... 387 EGR CONTROL SOLENOID VALVE INSPECTION........................................................ 387 VENTILATION CONTROL SOLENOID VALVE INSPECTION <Vehicles with TCL>............................ 388 VACUUM CONTROL SOLENOID VALVE INSPECTION <Vehicles with TCL>................................. 388 VACUUM TANK INSPECTION....................................................................... 389 VACUUM ACTUATOR INSPECTION................................................................... 389 THROTTLE VALVE OPERATION CHECK............................................................... 389 NEGATIVE PRESSURE CHECK DURING TRACTION CONTROL OPERATION.................................... 390 INJECTOR <4G9, 4G6>.............................................................................. 391 INJECTOR <6A1, 6G7>.............................................................................. 393 MULTIPOINT INJECTION (MPI) '96 Changes...........................................................1639 MULTIPOINT INJECTION (MPI)...................................................................1640 GENERAL..................................................................................1640 GENERAL INFORMATION......................................................................1640 TROUBLESHOOTING..........................................................................1640 DIESEL FUEL.......................................................................................... 395 GENERAL INFORMATION.............................................................................. 396 SERVICE SPECIFICATIONS........................................................................... 396 SPECIAL TOOL..................................................................................... 396 SERVICE ADJUSTMENT PROCEDURES.................................................................... 396 FUEL DISCHARGE PREVENTION.................................................................... 396 EVACUATION OF WATER FROM FUEL FILTER......................................................... 397 EVACUATION OF AIR FROM FUEL LINE............................................................. 397 FUEL INJECTION PUMP INSPECTION............................................................... 397 BOOST COMPENSATOR INSPECTION................................................................. 397 INJECTION NOZZLE INSPECTION AND ADJUSTMENT................................................... 398 FUEL INJECTION PUMP AND NOZZLE................................................................... 400 FUEL FILTER...................................................................................... 403 DIESEL FUEL '96 Changes..........................................................................1648 FUEL SUPPLY AND ENGINE CONTROL....................................................................... 405 FUEL TANK........................................................................................ 406 GENERAL INFORMATION.......................................................................... 406 SPECIAL TOOL................................................................................. 406 FUEL TANK.................................................................................... 407 ACCELERATOR CABLE AND PEDAL...................................................................... 416 GENERAL INFORMATION.......................................................................... 416 SERVICE SPECIFICATIONS....................................................................... 416 SERVICE ADJUSTMENT PROCEDURES................................................................ 416 ACCELERATOR CABLE AND PEDAL.................................................................. 418 AUTO-CRUISE CONTROL SYSTEM........................................................................... 420 GENERAL INFORMATION.............................................................................. 421 SERVICE SPECIFICATIONS........................................................................... 422 SPECIAL TOOLS.................................................................................... 422 TROUBLESHOOTING.................................................................................. 423 SERVICE ADJUSTMENT PROCEDURES.................................................................... 441 AUTO-CRUISE CONTROL CABLE INSPECTION AND ADJUSTMENT.......................................... 441 AUTO-CRUISE CONTROL MAIN SWITCH CHECK........................................................ 442 AUTO-CRUISE CONTROL SWITCH CHECK............................................................. 442 AUTO-CRUISE CONTROL COMPONENT INSPECTION..................................................... 444 AUTO-CRUISE CONTROL.............................................................................. 446 FUZZY TRACTION CONTROL (FUZZY TCL)................................................................... 451 GENERAL INFORMATION.............................................................................. 452 TROUBLESHOOTING.................................................................................. 453 SERVICE ADJUSTMENT PROCEDURES.................................................................... 479 SYSTEM INSPECTION USING THE TCL INDICATOR LAMPS.............................................. 479 TCL OPERATION INSPECTION..................................................................... 479 STOP LAMP SWITCH (PEDAL STROKE SENSOR) INSPECTION............................................ 480 WHEEL SPEED SENSOR INSPECTION................................................................ 480 CLUTCH SWITCH INSPECTION..................................................................... 480 TCL SWITCH....................................................................................... 481 TCL INDICATOR LAMP............................................................................... 482 TCL-ECU.......................................................................................... 483 COOLING.................................................................................................. 484 GENERAL INFORMATION.................................................................................. 485 SERVICE SPECIFICATIONS............................................................................... 485 LUBRICANTS........................................................................................... 486 SEALANT.............................................................................................. 486 SERVICE ADJUSTMENT PROCEDURES........................................................................ 486 COOLANT LEAK CHECKING............................................................................ 486 RADIATOR CAP VALVE OPENING PRESSURE.............................................................. 487 COOLANT REPLACEMENT.............................................................................. 487 CONCENTRATION MEASUREMENT........................................................................ 489 THERMOSTAT........................................................................................... 490 WATER PUMP <4G93>.................................................................................... 493 WATER PUMP <4G63>.................................................................................... 494 WATER PUMP <6A12>.................................................................................... 495 WATER PUMP <6G73>.................................................................................... 496 WATER PUMP <4D68>.................................................................................... 497 WATER HOSE AND WATER PIPE <4G93>..................................................................... 498 WATER HOSE AND WATER PIPE <4G63>..................................................................... 500 WATER HOSE AND WATER PIPE <6A12>..................................................................... 502 WATER HOSE AND WATER PIPE <6G73>..................................................................... 504 WATER HOSE AND WATER PIPE <4D68>..................................................................... 506 RADIATOR............................................................................................. 508 INTAKE AND EXHAUST....................................................................................... 512 GENERAL INFORMATION.................................................................................. 513 SERVICE SPECIFICATIONS............................................................................... 513 SPECIAL TOOL......................................................................................... 513 SERVICE ADJUSTMENT PROCEDURES........................................................................ 514 VARIABLE INDUCTION CONTROL SYSTEM INSPECTION <6A12, 6G73>........................................ 514 INTAKE MANIFOLD VACUUM INSPECTION................................................................ 515 TURBOCHARGER SUPERCHARGING INSPECTION <4D68>..................................................... 516 WASTE GATE ACTUATOR INSPECTION <4D68>............................................................ 516 INTERCOOLER <4D68>............................................................................... 517 INTAKE MANIFOLD <4G93>........................................................................... 518 INTAKE MANIFOLD <4G63>........................................................................... 521 INTAKE MANIFOLD <6A12, 6G73>..................................................................... 524 INTAKE AND EXHAUST MANIFOLD <4D68>............................................................... 527 TURBOCHARGER..................................................................................... 529 EXHAUST MANIFOLD <4G93>.......................................................................... 531 EXHAUST MANIFOLD <4G63>.......................................................................... 532 EXHAUST MANIFOLD <6A12>.......................................................................... 533 EXHAUST MANIFOLD <6G73>.......................................................................... 534 EXHAUST PIPE AND MAIN MUFFLER.................................................................... 536 EMISSION CONTROL......................................................................................... 541 EMISSION CONTROL <MPI>............................................................................... 542 GENERAL INFORMATION.............................................................................. 542 EMISSION CONTROL DEVICE REFERENCE TABLE...................................................... 542 SERVICE SPECIFICATIONS........................................................................... 542 VACUUM HOSE...................................................................................... 543 VACUUM HOSE PIPING DIAGRAM................................................................... 543 VACUUM CIRCUIT DIAGRAM....................................................................... 545 CRANKCASE EMISSION CONTROL SYSTEM................................................................ 550 GENERAL INFORMATION.......................................................................... 550 COMPONENT LOCATION........................................................................... 551 POSITIVE CRANKCASE VENTILATION SYSTEM........................................................ 551 EVAPORATIVE EMISSION CONTROL SYSTEM.............................................................. 553 GENERAL INFORMATION.......................................................................... 553 COMPONENT LOCATION........................................................................... 553 PURGE CONTROL SYSTEM......................................................................... 554 CANISTER/TWO-WAY VALVE....................................................................... 556 EXHAUST GAS RECIRCULATION (EGR) SYSTEM........................................................... 558 GENERAL INFORMATION.......................................................................... 558 OPERATION.................................................................................... 558 COMPONENT LOCATION........................................................................... 558 EXHAUST GAS RECIRCULATION (EGR) CONTROL SYSTEM................................................... 560 SYSTEM INSPECTION <4G93, 6A12, 6G73>......................................................... 560 SYSTEM INSPECTION <4G63>..................................................................... 562 CATALYTIC CONVERTER.............................................................................. 567 GENERAL INFORMATION.......................................................................... 567 EMISSION CONTROL <DIESEL>............................................................................ 569 GENERAL INFORMATION.............................................................................. 569 SERVICE SPECIFICATIONS........................................................................... 569 SPECIAL TOOL..................................................................................... 569 EXHAUST GAS RECIRCULATION (EGR) SYSTEM........................................................... 570 GENERAL INFORMATION.......................................................................... 570 COMPONENT LOCATION........................................................................... 571 FUNCTION INSPECTION.......................................................................... 571 EGR SOLENOID VALVE No. 1/No. 2 OPERATION INSPECTION.......................................... 572 EGR SOLENOID VALVE No. 1/No. 2 RESISTANCE INSPECTION......................................... 572 LEVER POSITION SENSOR (LPS) ADJUSTMENT....................................................... 573 ENGINE SPEED SENSOR INSPECTION............................................................... 573 ENGINE COOLANT TEMPERATURE SENSOR INSPECTION................................................. 573 ENGINE COOLANT TEMPERATURE SWITCH INSPECTION................................................. 574 GLOW & EGR CONTROL UNIT...................................................................... 574 CATALYTIC CONVERTER.............................................................................. 578 GENERAL INFORMATION.......................................................................... 578 TWO-WAY VALVE.................................................................................... 579 CLUTCH................................................................................................... 580 GENERAL INFORMATION.................................................................................. 581 SERVICE SPECIFICATIONS............................................................................... 581 LUBRICANTS........................................................................................... 581 SERVICE ADJUSTMENT PROCEDURES........................................................................ 581 CLUTCH PEDAL INSPECTION AND ADJUSTMENT........................................................... 581 CLUTCH SWITCH INSPECTION AND ADJUSTMENT.......................................................... 582 BLEEDING......................................................................................... 582 CLUTCH PEDAL......................................................................................... 583 CLUTCH CONTROL....................................................................................... 585 CLUTCH MASTER CYLINDER............................................................................... 587 MANUAL TRANSMISSION...................................................................................... 588 GENERAL INFORMATION.................................................................................. 589 LUBRICANTS........................................................................................... 589 SPECIAL TOOLS........................................................................................ 590 SERVICE ADJUSTMENT PROCEDURES........................................................................ 591 TRANSMISSION OIL LEVEL CHECK..................................................................... 591 TRANSMISSION OIL REPLACEMENT..................................................................... 591 TRANSFER OIL LEVEL CHECK <4WD>................................................................... 591 TRANSFER OIL REPLACEMENT <4WD>................................................................... 592 TRANSMISSION CONTROL................................................................................. 593 TRANSMISSION ASSEMBLY <VEHICLES WITHOUT INNER SHAFT>................................................. 596 TRANSMISSION ASSEMBLY <VEHICLES WITH INNER SHAFT>.................................................... 601 TRANSFER ASSEMBLY.................................................................................... 606 AUTOMATIC TRANSMISSION................................................................................... 607 GENERAL INFORMATION.................................................................................. 608 SERVICE SPECIFICATIONS............................................................................... 608 LUBRICANTS........................................................................................... 608 SPECIAL TOOLS........................................................................................ 609 TROUBLESHOOTING...................................................................................... 611 SERVICE ADJUSTMENT PROCEDURES........................................................................ 663 BASIC INSPECTION................................................................................. 663 ELC 4-SPEED AUTOMATIC TRANSMISSION CONTROL COMPONENTS LAYOUT..................................... 666 ELC-4A/T CONTROL COMPONENTS INSPECTION........................................................... 668 CONVERTER STALL TEST............................................................................. 671 OIL PRESSURE TEST................................................................................ 672 HYDRAULIC CIRCUIT................................................................................ 681 KICKDOWN SERVO ADJUSTMENT........................................................................ 690 LINE PRESSURE ADJUSTMENT......................................................................... 691 REDUCING PRESSURE ADJUSTMENT..................................................................... 693 SELECTOR LEVER OPERATION CHECK................................................................... 694 TRANSMISSION CONTROL................................................................................. 695 TRANSMISSION ASSEMBLY................................................................................ 699 TRANSMISSION OIL COOLER.............................................................................. 704 PROPELLER SHAFT.......................................................................................... 705 GENERAL INFORMATION.................................................................................. 706 SERVICE SPECIFICATIONS............................................................................... 706 LUBRICANTS........................................................................................... 706 SEALANT AND ADHESIVES................................................................................ 706 SPECIAL TOOLS........................................................................................ 707 PROPELLER SHAFT...................................................................................... 708 FRONT AXLE............................................................................................... 717 GENERAL INFORMATION.................................................................................. 718 SERVICE SPECIFICATIONS............................................................................... 718 LUBRICANTS........................................................................................... 718 SPECIAL TOOLS........................................................................................ 719 SERVICE ADJUSTMENT PROCEDURES........................................................................ 721 HUB AXIAL PLAY CHECK............................................................................. 721 FRONT HUB ASSEMBLY................................................................................... 722 KNUCKLE.............................................................................................. 724 DRIVE SHAFT <VEHICLES WITHOUT INNER SHAFT>........................................................... 726 DRIVE SHAFT <VEHICLES WITH INNER SHAFT>.............................................................. 733 REAR AXLE................................................................................................ 743 <2WD>................................................................................................ 744 GENERAL INFORMATION.............................................................................. 744 SERVICE SPECIFICATIONS........................................................................... 744 SPECIAL TOOLS.................................................................................... 744 SERVICE ADJUSTMENT PROCEDURES.................................................................... 745 WHEEL BEARING AXIAL PLAY CHECK............................................................... 745 REAR HUB ROTARY-SLIDING RESISTANCE CHECK..................................................... 745 HUB BOLT REPLACEMENT......................................................................... 745 REAR HUB ASSEMBLY................................................................................ 747 KNUCKLE.......................................................................................... 749 <4WD>................................................................................................ 751 GENERAL INFORMATION.............................................................................. 751 SERVICE SPECIFICATIONS........................................................................... 752 LUBRICANTS....................................................................................... 752 SEALANTS AND ADHESIVES........................................................................... 752 SPECIAL TOOLS.................................................................................... 753 SERVICE ADJUSTMENT PROCEDURES.................................................................... 756 REAR AXLE TOTAL BACKLASH CHECK............................................................... 756 GEAR OIL LEVEL CHECK......................................................................... 756 WHEEL BEARING AXIAL PLAY CHECK............................................................... 757 REPLACEMENT OF DIFFERENTIAL CARRIER OIL SEAL................................................. 757 HUB BOLT REPLACEMENT......................................................................... 757 REAR HUB ASSEMBLY................................................................................ 758 KNUCKLE.......................................................................................... 760 DRIVE SHAFT...................................................................................... 761 DIFFERENTIAL CARRIER............................................................................. 769 WHEEL AND TYRE........................................................................................... 786 GENERAL INFORMATION.................................................................................. 787 SERVICE SPECIFICATIONS............................................................................... 792 TROUBLESHOOTING...................................................................................... 793 SERVICE ADJUSTMENT PROCEDURES........................................................................ 794 TYRE INFLATION PRESSURE CHECK.................................................................... 794 TYRE WEAR CHECK.................................................................................. 794 WHEEL RUNOUT CHECK............................................................................... 794 WHEEL AND TYRE....................................................................................... 794 POWER PLANT MOUNT........................................................................................ 795 GENERAL INFORMATION.................................................................................. 796 SERVICE SPECIFICATIONS............................................................................... 797 SPECIAL TOOLS........................................................................................ 797 ENGINE MOUNTING...................................................................................... 798 TRANSMISSION MOUNTING................................................................................ 800 ENGINE ROLL STOPPER, CENTERMEMBER.................................................................... 801 CROSSMEMBER.......................................................................................... 803 FRONT SUSPENSION......................................................................................... 805 FRONT SUSPENSION..................................................................................... 807 GENERAL INFORMATION.............................................................................. 808 SERVICE SPECIFICATIONS........................................................................... 811 SPECIAL TOOLS.................................................................................... 811 SERVICE ADJUSTMENT PROCEDURES.................................................................... 812 FRONT WHEEL ALIGNMENT INSPECTION AND ADJUSTMENT.............................................. 812 UPPER ARM ASSEMBLY............................................................................... 814 SHOCK ABSORBER ASSEMBLY.......................................................................... 816 COMPRESSION LOWER ARM AND LATERAL LOWER ARM ASSEMBLIES........................................... 819 STABILIZER BAR................................................................................... 822 ELECTRONIC CONTROL SUSPENSION (ECS).................................................................. 824 GENERAL INFORMATION.............................................................................. 825 SERVICE SPECIFICATIONS........................................................................... 826 SPECIAL TOOLS.................................................................................... 827 TROUBLESHOOTING.................................................................................. 828 SERVICE ADJUSTMENT PROCEDURES.................................................................... 840 WARNING DISPLAY BY MEANS OF THE ECS INDICATOR LAMP........................................... 840 DAMPING FORCE CHECK.......................................................................... 840 FRONT SHOCK ABSORBER ASSEMBLY.................................................................... 841 REAR SHOCK ABSORBER ASSEMBLY..................................................................... 845 ECS-ECU.......................................................................................... 848 SWITCH AND SENSOR................................................................................ 849 ELECTRONIC CONTROL SUSPENSION (ACTIVE-ECS)........................................................... 851 GENERAL INFORMATION.............................................................................. 853 SERVICE SPECIFICATIONS........................................................................... 855 SPECIAL TOOLS.................................................................................... 856 TROUBLESHOOTING.................................................................................. 857 SERVICE ADJUSTMENT PROCEDURES.................................................................... 893 ALARM LAMP CHECK............................................................................. 893 SYSTEM CHECKING BY USING ALARM LAMP.......................................................... 893 NORMAL VEHICLE HEIGHT CHECK AND ADJUSTMENT................................................... 894 POLLING DIAGRAM CHECK........................................................................ 895 SYSTEM OPERATION CHECK....................................................................... 896 LOW-PRESSURE SWITCH (LOW-PRESSURE TANK SIDE) ACTUATION PRESSURE CHECK........................ 898 HIGH-PRESSURE SWITCH (HIGH-PRESSURE TANK SIDE) ACTUATION PRESSURE CHECK...................... 899 G-SENSOR OUTPUT VOLTAGE CHECK................................................................ 900 FRONT SHOCK ABSORBER ASSEMBLY.................................................................... 901 REAR SHOCK ABSORBER ASSEMBLY..................................................................... 907 RESERVE TANK ASSEMBLY............................................................................ 911 AIR COMPRESSOR ASSEMBLY.......................................................................... 913 SOLENOID VALVE ASSEMBLY AND DRYER ASSEMBLY....................................................... 915 AIR TUBE......................................................................................... 921 FRONT AND REAR STOKE SENSOR...................................................................... 923 ACTIVE-ECS SENSOR AND SWITCH..................................................................... 926 ECS-ECU.......................................................................................... 928 ACTIVE-ECS RELAY................................................................................. 929 REAR SUSPENSION.......................................................................................... 931 GENERAL INFORMATION.................................................................................. 932 SERVICE SPECIFICATIONS............................................................................... 935 SPECIAL TOOLS........................................................................................ 935 SERVICE ADJUSTMENT PROCEDURES........................................................................ 936 REAR WHEEL ALIGNMENT INSPECTION AND ADJUSTMENT................................................... 936 REAR SUSPENSION ASSEMBLY............................................................................. 938 UPPER ARM ASSEMBLY................................................................................... 941 TRAILING ARM ASSEMBLY................................................................................ 944 LOWER ARM AND TOE CONTROL ARM ASSEMBLIES............................................................. 945 SHOCK ABSORBER ASSEMBLY.............................................................................. 947 STABILIZER BAR....................................................................................... 950 SERVICE BRAKES........................................................................................... 952 BASIC BRAKE SYSTEM................................................................................... 954 GENERAL INFORMATION.............................................................................. 955 SERVICE SPECIFICATIONS........................................................................... 957 LUBRICANTS....................................................................................... 958 SEALANT AND ADHESIVES............................................................................ 958 SPECIAL TOOLS.................................................................................... 958 TROUBLESHOOTING.................................................................................. 959 SERVICE ADJUSTMENT PROCEDURES.................................................................... 962 BRAKE PEDAL INSPECTION AND ADJUSTMENT........................................................ 962 STOP LAMP SWITCH INSPECTION.................................................................. 963 BRAKE BOOSTER OPERATING TEST................................................................. 963 CHECK VALVE OPERATION CHECK.................................................................. 964 PROPORTIONING VALVE FUNCTION TEST............................................................ 964 BRAKE FLUID LEVEL SENSOR CHECK............................................................... 965 BRAKE BOOSTER VACUUM SWITCH CHECK <4D68>..................................................... 966 BLEEDING..................................................................................... 966 FRONT DISC BRAKE PAD CHECK AND REPLACEMENT................................................... 966 FRONT DISC BRAKE ROTOR INSPECTION............................................................ 969 RUN-OUT CHECK................................................................................ 970 RUN-OUT CORRECTION........................................................................... 970 THICKNESS CHECK.............................................................................. 971 BRAKE LINING THICKNESS CHECK <VEHICLES WITH REAR DRUM BRAKE>................................. 971 BRAKE DRUM INSIDE DIAMETER CHECK <VEHICLES WITH REAR DRUM BRAKE>............................. 971 BRAKE LINING AND BRAKE DRUM CONNECTION CHECK <VEHICLES WITH REAR DRUM BRAKE>................. 972 REAR DISC BRAKE PAD CHECK AND REPLACEMENT.................................................... 972 REAR BRAKE DISC THICKNESS CHECK.............................................................. 974 REAR BRAKE DISC RUN-OUT CHECK................................................................ 974 REAR BRAKE DISC RUN-OUT CORRECTION........................................................... 974 BRAKE LINING THICKNESS CHECK................................................................. 975 BRAKE LINING AND BRAKE DRUM CONNECTION CHECK................................................. 975 BRAKE PEDAL <M/T>................................................................................ 976 BRAKE PEDAL <A/T>................................................................................ 978 MASTER CYLINDER AND BRAKE BOOSTER <L.H. drive vehicles>.......................................... 979 MASTER CYLINDER AND BRAKE BOOSTER <R.H. drive vehicles>.......................................... 984 FRONT DISC BRAKE................................................................................. 988 REAR DRUM BRAKE SHOE............................................................................. 997 REAR DRUM BRAKE WHEEL CYLINDER................................................................... 999 REAR DISC BRAKE..................................................................................1001 PROPORTIONING VALVE..............................................................................1006 ANTI-LOCK BRAKING SYSTEM (ABS) <2WD>.................................................................1007 GENERAL INFORMATION..............................................................................1009 SERVICE SPECIFICATIONS...........................................................................1010 SEALANT AND ADHESIVES............................................................................1010 SPECIAL TOOLS....................................................................................1010 TROUBLESHOOTING..................................................................................1011 SERVICE ADJUSTMENT PROCEDURES....................................................................1037 BRAKE PEDAL INSPECTION AND ADJUSTMENT........................................................1037 STOP LAMP SWITCH INSPECTION..................................................................1038 PEDAL STROKE SENSOR INSPECTION...............................................................1038 BLEEDING.....................................................................................1039 ABS OPERATION CHECK..........................................................................1040 BRAKE PEDAL <M/T>................................................................................1045 BRAKE PEDAL <A/T>................................................................................1047 MASTER CYLINDER AND BRAKE BOOSTER <L.H. drive vehicles>..........................................1048 MASTER CYLINDER AND BRAKE BOOSTER <R.H. drive vehicles>..........................................1050 PROPORTIONING VALVE..............................................................................1054 HYDRAULIC UNIT...................................................................................1055 WHEEL SPEED SENSOR...............................................................................1057 ELECTRONIC CONTROL UNIT..........................................................................1060 ANTI-BRAKE SYSTEM (ABS) <2WD> '95 Changes...........................................................1621 ANTI-LOCK BRAKING SYSTEM (ABS) <4WD>.................................................................1061 GENERAL INFORMATION..............................................................................1063 SERVICE SPECIFICATIONS...........................................................................1064 SPECIAL TOOLS....................................................................................1064 TROUBLESHOOTING..................................................................................1065 SERVICE ADJUSTMENT PROCEDURES....................................................................1083 ABS OPERATION CHECK..........................................................................1083 MASTER CYLINDER AND BRAKE BOOSTER <R.H. drive vehicles>..........................................1089 HYDRAULIC UNIT...................................................................................1091 WHEEL SPEED SENSOR...............................................................................1093 ELECTRONIC CONTROL UNIT..........................................................................1095 G-SENSOR.........................................................................................1096 PARKING BRAKES...........................................................................................1097 GENERAL INFORMATION..................................................................................1098 SERVICE SPECIFICATIONS...............................................................................1099 LUBRICANTS...........................................................................................1099 SPECIAL TOOLS........................................................................................1099 SERVICE ADJUSTMENT PROCEDURES........................................................................1100 PARKING BRAKE LEVER STROKE CHECK.................................................................1100 PARKING BRAKE SWITCH CHECK.......................................................................1101 LINING RUNNING-IN................................................................................1101 PARKING BRAKE LEVER..................................................................................1103 PARKING BRAKE CABLE <DRUM BRAKE>.....................................................................1104 PARKING BRAKE CABLE <DRUM IN DISC BRAKE>.............................................................1105 PARKING BRAKE DRUM...................................................................................1107 STEERING.................................................................................................1112 STEERING.............................................................................................1114 GENERAL INFORMATION..............................................................................1115 SERVICE SPECIFICATIONS...........................................................................1116 LUBRICANTS.......................................................................................1117 SEALANT AND ADHESIVES............................................................................1117 SPECIAL TOOLS....................................................................................1118 TROUBLESHOOTING..................................................................................1121 SERVICE ADJUSTMENT PROCEDURE.....................................................................1132 STEERING WHEEL FREE PLAY CHECK...............................................................1132 STEERING ANGLE CHECK.........................................................................1132 TIE ROD END BALL JOINT STARTING TORQUE CHECK.................................................1132 STATIONARY STEERING EFFORT CHECK.............................................................1133 CHECKING STEERING WHEEL RETURN TO CENTRE.....................................................1134 EPS SOLENOID CHECK...........................................................................1134 FLUID LEVEL CHECK............................................................................1134 FLUID REPLACEMENT............................................................................1134 BLEEDING.....................................................................................1135 OIL PUMP PRESSURE TEST.......................................................................1136 POWER STEERING OIL PRESSURE SWITCH CHECK.....................................................1137 STEERING WHEEL AND SHAFT.........................................................................1138 POWER STEERING GEAR BOX..........................................................................1143 POWER STEERING OIL PUMP..........................................................................1158 POWER STEERING HOSES.............................................................................1168 EPS-ECU..........................................................................................1173 ACTIVE 4-WHEEL STEERING SYSTEM (ACTIVE 4WS)..........................................................1174 GENERAL INFORMATION..............................................................................1175 SERVICE SPECIFICATIONS...........................................................................1176 SPECIAL TOOLS....................................................................................1176 TROUBLESHOOTING..................................................................................1177 SERVICE ADJUSTMENT PROCEDURES....................................................................1195 BLEEDING.....................................................................................1195 FUNCTION CHECK...............................................................................1196 FLOW DIVIDER VALVE ASSEMBLY FUNCTION CHECK...................................................1197 OIL PUMP PRESSURE TEST.......................................................................1197 BALL JOINT ROTATION STARTING TORQUE CHECK....................................................1197 POWER CYLINDER...................................................................................1198 REAR WHEEL CONTROL VALVE.........................................................................1200 REAR OIL LINE....................................................................................1202 ACTIVE 4WS CONTROL UNIT..........................................................................1203 BODY.....................................................................................................1204 SERVICE SPECIFICATIONS...............................................................................1205 SEALANT AND ADHESIVE.................................................................................1205 SPECIAL TOOLS........................................................................................1206 TROUBLESHOOTING......................................................................................1207 SUNROOF..........................................................................................1207 POWER WINDOW.....................................................................................1209 CENTRAL DOOR LOCKING SYSTEM......................................................................1212 KEY REMINDER SYSTEM..............................................................................1216 SERVICE ADJUSTMENT PROCEDURES........................................................................1219 DOOR FIT ADJUSTMENT..............................................................................1219 DOOR GLASS ADJUSTMENT............................................................................1219 INSIDE HANDLE PLAY ADJUSTMENT....................................................................1219 OUTSIDE HANDLE PLAY CHECK........................................................................1220 CIRCUIT BREAKER (INCORPORATED IN THE POWER WINDOW MOTOR) INSPECTION..............................1220 WATER TEST.......................................................................................1220 SUNROOF FIT ADJUSTMENT...........................................................................1220 HOOD.................................................................................................1223 TRUNK LID <Sedan>....................................................................................1225 TAILGATE <Hatchback>.................................................................................1230 FENDER...............................................................................................1233 FUEL FILLER DOOR.....................................................................................1235 WINDOW GLASS.........................................................................................1236 WINDSHIELD...........................................................................................1238 QUARTER WINDOW GLASS <Hatchback>.....................................................................1243 REAR WINDOW GLASS <Sedan>............................................................................1245 TAILGATE WINDOW GLASS <Hatchback>....................................................................1249 DOOR ASSEMBLY........................................................................................1252 DOOR TRIM AND WATERPROOF FILM........................................................................1255 DOOR GLASS AND REGULATOR.............................................................................1258 DOOR HANDLE AND LATCH................................................................................1261 WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP................................................1265 SUNROOF..............................................................................................1267 HEADER PANEL.........................................................................................1273 UNDER COVER..........................................................................................1274 EXTERIOR.................................................................................................1275 SERVICE SPECIFICATIONS...............................................................................1276 SEALANT AND ADHESIVE.................................................................................1276 SPECIAL TOOLS........................................................................................1276 FRONT BUMPER.........................................................................................1277 REAR BUMPER..........................................................................................1278 GRILLES AND GARNISHES................................................................................1279 MOULDINGS............................................................................................1280 MUD GUARD AND STONE GUARD............................................................................1285 AERO PARTS...........................................................................................1286 WINDSHIELD WIPER AND WASHER..........................................................................1288 REAR WIPER AND WASHER................................................................................1293 HEADLAMP WASHER......................................................................................1297 DOOR MIRROR..........................................................................................1300 EXTERIOR '95 Changes.................................................................................1624 INTERIOR.................................................................................................1302 INTERIOR.............................................................................................1304 SERVICE SPECIFICATIONS...........................................................................1305 ADHESIVES........................................................................................1305 SPECIAL TOOLS....................................................................................1305 INSTRUMENT PANEL.................................................................................1306 FLOOR CONSOLE....................................................................................1315 TRIMS <Sedan>....................................................................................1316 TRIMS <Hatchback>................................................................................1318 HEADLINING AND INSIDE REAR VIEW MIRROR...........................................................1321 FRONT SEAT.......................................................................................1323 REAR SEAT........................................................................................1329 FRONT SEAT BELT..................................................................................1332 REAR SEAT BELT...................................................................................1333 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)..................................................................1334 GENERAL INFORMATION..............................................................................1335 SRS SERVICE PRECAUTIONS..........................................................................1337 SERVICE SPECIFICATIONS...........................................................................1340 SPECIAL TOOLS AND TEST EQUIPMENT.................................................................1340 TROUBLESHOOTING..................................................................................1342 SRS MAINTENANCE..................................................................................1366 POST-COLLISION DIAGNOSIS.........................................................................1370 INDIVIDUAL COMPONENT SERVICE.....................................................................1373 WARNING/CAUTION LABELS...........................................................................1373 FRONT IMPACT SENSORS.............................................................................1374 SRS DIAGNOSIS UNIT (SDU).........................................................................1376 AIR BAG MODULES AND CLOCK SPRING.................................................................1379 AIR BAG MODULE DISPOSAL PROCEDURES...............................................................1386 UNDEPLOYED AIR BAG MODULE DISPOSAL...........................................................1386 DEPLOYED AIR BAG MODULE DISPOSAL PROCEDURES..................................................1391 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) '95 Changes..................................................1625 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) '96 Changes..................................................1649 CHASSIS ELECTRICAL.......................................................................................1392 BATTERY..............................................................................................1395 SERVICE SPECIFICATION............................................................................1395 SERVICE ADJASTMENT PROCEDURES....................................................................1395 FLUID LEVEL AND SPECIFIC GRAVITY INSPECTION..................................................1395 VISUAL INSPECTION............................................................................1395 CHARGING.....................................................................................1396 BATTERY TEST.................................................................................1396 IGNITION SWITCH......................................................................................1398 SPECIAL TOOLS....................................................................................1398 TROUBLESHOOTING..................................................................................1398 IGNITION SWITCH..................................................................................1402 COMBINATION METERS...................................................................................1405 SERVICE SPECIFICATIONS...........................................................................1405 SEALANT AND ADHESIVES............................................................................1406 SPECIAL TOOLS....................................................................................1406 TROUBLESHOOTING..................................................................................1407 SERVICE SPECIFICATION............................................................................1408 SPEEDOMETER INSPECTION.......................................................................1408 TACHOMETER INSPECTION........................................................................1409 FUEL GAUGE SIMPLE INSPECTION.................................................................1410 FUEL GAUGE UNIT INSPECTION...................................................................1411 ENGINE COOLANT TEMPERATURE GAUGE SIMPLE INSPECTION...........................................1413 ENGINE COOLANT TEMPERATURE GAUGE UNIT INSPECTION.............................................1413 COMBINATION METERS...............................................................................1414 HEADLAMP.............................................................................................1418 SERVICE SPECIFICATIONS...........................................................................1418 SPECIAL TOOLS....................................................................................1418 TROUBLESHOOTING..................................................................................1419 SERVICE ADJUSTMENT PROCEDURES....................................................................1421 HEADLAMP AIMING..............................................................................1421 INTENSITY MEASUREMENT........................................................................1423 BULB REPLACEMENT.............................................................................1424 HEADLAMP.........................................................................................1425 FRONT TURN-SIGNAL LAMP...............................................................................1430 SIDE TURN-SIGNAL LAMP................................................................................1431 FRONT FOG LAMP.......................................................................................1433 SERVICE SPECIFICATIONS...........................................................................1433 SPECIAL TOOL.....................................................................................1433 SERVICE ADJUSTMENT PROCEDURES....................................................................1433 FRONT FOG LAMP AIMING........................................................................1433 FRONT FOG LAMP...................................................................................1434 REAR COMBINATION LAMP, REAR LID LAMP.................................................................1436 SPECIAL TOOLS....................................................................................1436 TROUBLESHOOTING..................................................................................1436 REAR COMBINATION LAMP, REAR LID LAMP.............................................................1437 HIGH MOUNTED STOP LAMP...............................................................................1440 INTERIOR LAMP........................................................................................1442 SPECIAL TOOLS....................................................................................1442 TROUBLESHOOTING..................................................................................1442 INTERIOR LAMP....................................................................................1446 RHEOSTAT.............................................................................................1448 SPECIAL TOOL.....................................................................................1448 RHEOSTAT.........................................................................................1448 HAZARD LAMP SWITCH...................................................................................1449 SPECIAL TOOL.....................................................................................1449 HAZARD LAMP SWITCH...............................................................................1449 HORN.................................................................................................1451 CIGARETTE LIGHTER....................................................................................1454 SPECIAL TOOL.....................................................................................1454 CIGARETTE LIGHTER................................................................................1454 CLOCK................................................................................................1455 SPECIAL TOOL.....................................................................................1455 CLOCK............................................................................................1455 RADIO AND TAPE PLAYER................................................................................1457 SPECIAL TOOL.....................................................................................1457 TROUBLESHOOTING..................................................................................1457 CHART............................................................................................1458 NOISE SUPPRESSOR MOUNTING LOCATION...........................................................1464 RADIO AND TAPE PLAYER............................................................................1475 SPEAKER..............................................................................................1476 FRONT SPEAKER....................................................................................1476 REAR SPEAKER.....................................................................................1477 ANTENNA..............................................................................................1478 SPECIAL TOOL.....................................................................................1478 POLE ANTENNA.....................................................................................1478 MOTOR ANTENNA....................................................................................1479 REAR WINDOW DEFOGGER.................................................................................1482 SPECIAL TOOLS....................................................................................1482 TROUBLESHOOTING..................................................................................1482 SERVICE ADJUSTMENT PROCEDURES....................................................................1485 PRINTED-HEATER LINE INSPECTION...............................................................1485 REAR WINDOW DEFOGGER.............................................................................1485 THEFT-ALARM SYSTEM...................................................................................1488 SPECIAL TOOL.....................................................................................1488 TROUBLESHOOTING..................................................................................1488 CHASSIS ELECTRICAL '95 Changes.......................................................................1626 CHASSIS ELECTRICAL '96 Changes.......................................................................1667 HEATER, AIR CONDITIONER AND VENTILATION..................................................................1502 MANUAL AIR CONDITIONER...............................................................................1504 GENERAL INFORMATION..............................................................................1504 SAFETY PRECAUTIONS...........................................................................1504 SERVICE SPECIFICATIONS...........................................................................1505 LUBRICANTS.......................................................................................1506 SPECIAL TOOLS....................................................................................1506 TROUBLESHOOTING..................................................................................1507 SERVICE ADJUSTMENT PROCEDURES....................................................................1510 SIGHT GLASS REFRIGERANT LEVEL TEST...........................................................1510 MAGNETIC CLUTCH TEST.........................................................................1510 RECEIVER DRIER TEST..........................................................................1510 TRIPLE PRESSURE SWITCH CHECK.................................................................1511 DUAL PRESSURE SWITCH CHECK...................................................................1511 COMPRESSOR DRIVE BELT ADJUSTMENT.............................................................1511 CHARGING.....................................................................................1512 PERFORMANCE TEST.............................................................................1516 REFRIGERANT LEAK REPAIR......................................................................1517 COMPRESSOR NOISE.............................................................................1517 POWER RELAY CHECK............................................................................1518 IDLE-UP OPERATION CHECK......................................................................1519 VACUUM ACTUATOR CHECK........................................................................1520 IDLE-UP SOLENOID VALVE CHECK.................................................................1521 HEATER CONTROL ASSEMBLY..........................................................................1522 INSIDE/OUTSIDE AIR CHANGEOVER SWITCH AND AIR CONDITIONER SWITCH..................................1525 HEATER UNIT AND HEATER CORE......................................................................1527 BLOWER ASSEMBLY AND RESISTOR.....................................................................1529 INSIDE/OUTSIDE AIR CHANGEOVER DAMPER MOTOR ASSEMBLY..............................................1531 EVAPORATOR.......................................................................................1532 AIR PURIFIER ASSEMBLY............................................................................1536 COMPRESSOR AND TENSION PULLEY....................................................................1539 REFRIGERANT LINE.................................................................................1548 ENGINE COOLANT TEMPERATURE SWITCH................................................................1552 CONDENSER AND CONDENSER FAN MOTOR................................................................1553 IDLE-UP SYSTEM...................................................................................1557 VENTILATORS......................................................................................1558 FULL AUTOMATIC AIR CONDITIONER.......................................................................1560 GENERAL INFORMATION..............................................................................1560 SERVICE SPECIFICATIONS...........................................................................1560 LUBRICANTS.......................................................................................1561 SPECIAL TOOLS....................................................................................1561 TROUBLESHOOTING..................................................................................1562 SERVICE ADJUSTMENT PROCEDURES....................................................................1589 POWER RELAY CHECK............................................................................1589 IDLE-UP OPERATION CHECK......................................................................1589 AIR CONDITIONER CONTROL PANEL AND ECU ASSEMBLY...................................................1590 DAMPER MOTOR ASSEMBLY............................................................................1591 COMPRESSOR AND TENSION PULLEY....................................................................1594 REVOLUTION PICK-UP SENSOR AND REFRIGERANT TEMPERATURE SWITCH.....................................1597 REFRIGERANT LINE.................................................................................1598 CONDENSER FAN MOTOR..............................................................................1602 PHOTO SENSOR.....................................................................................1604 OUTSIDE AIR TEMPERATURE SENSOR...................................................................1605 BELT LOCK CONTROLLER <6G73> AND POWER TRANSISTOR.................................................1606 ENGINE COOLANT TEMPERATURE SENSOR................................................................1607 OTHER MAINTENANCE SERVICE POINTS.................................................................1610 HEATER, AIR CONDITIONER AND VENTILATION '95 Changes..................................................1627 HEATER, AIR CONDITIONER AND VENTILATION '96 Changes..................................................1686
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