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Mitsubishi L400’95 Chassis Service Manual – PDF
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Description
Mitsubishi L400’95 Chassis Service Manual – PDF DOWNLOAD
FILE DETAILS:
Mitsubishi L400’95 Chassis Service Manual – PDF DOWNLOAD
Language : English
Pages : 1159
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Mitsubishi L400’95 Chassis Service Manual – PDF DOWNLOAD
GENERAL................................................................................................... 4 HOW TO USE THIS MANUAL................................................................................ 5 SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS........................................... 5 DEFINITION OF TERMS............................................................................... 5 INDICATION OF TIGHTENING TORQUE................................................................... 5 MODEL INDICATIONS................................................................................. 6 EXPLANATION OF MANUAL CONTENTS.................................................................... 7 HOW TO USE TROUBLESHOOTING / INSPECTION SERVICE POINTS................................................ 9 TROUBLESHOOTING CONTENTS.......................................................................... 9 HOW TO USE THE INSPECTION PROCEDURES.............................................................. 10 CONNECTOR MEASUREMENT SERVICE POINTS.............................................................. 11 CONNECTOR INSPECTION.............................................................................. 12 INSPECTION SERVICE POINTS FOR A BLOWN FUSE........................................................ 13 POINTS TO NOTE FOR INTERMITTENT MALFUNCTIONS...................................................... 13 VEHICLE IDENTIFICATION................................................................................ 14 VEHICLE INFORMATION CODE PLATE.................................................................... 14 MODELS............................................................................................ 15 MODEL CODE........................................................................................ 16 CHASSIS NUMBER.................................................................................... 17 ENGINE MODEL NUMBER............................................................................... 18 MAJOR SPECIFICATIONS.................................................................................. 19 PRECAUTIONS BEFORE SERVICE............................................................................ 22 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)-AIR BAG........................................................... 25 SUPPORT LOCATIONS FOR LIFTING AND JACKING............................................................. 29 SUPPORT POSITIONS (OR A GARAGE JACK AND AXLE STANDS............................................... 29 SUPPORT POSITIONS FOR A SINGLE-POST LIFT OR DOUBLE-POST LIFT AND H-BAR LIFT....................... 30 STANDARD PARTS-TIGHTENING-TORQUE TABLE................................................................ 31 MAIN SEALANT AND ADHESIVE TABLE....................................................................... 32 ENGINE.................................................................................................... 34 4G6................................................................................................... 36 GENERAL INFORMATION............................................................................... 37 SERVICE SPECIFICATIONS............................................................................ 39 SEALANT........................................................................................... 39 SPECIAL TOOLS..................................................................................... 40 SERVICE ADJUSTMENT PROCEDURES <CARBURETTOR>....................................................... 42 DRIVE BELT TENSION INSPECTION AND ADJUSTMENT.................................................. 42 IGNITION TIMING INSPECTION AND ADJUSTMENT..................................................... 43 IDLE SPEED INSPECTION AND ADJUSTMENT.......................................................... 44 IDLE FEEDBACK CHECK........................................................................... 45 IDLE-UP MECHANISM INSPECTION AND ADJUSTMENT FOR ABS........................................... 47 COMPRESSION PRESSURE INSPECTION............................................................... 48 INTAKE MANIFOLD VACUUM INSPECTION............................................................. 49 LASH ADJUSTER CHECK........................................................................... 50 SERVICE ADJUSTMENT PROCEDURES <MPI>............................................................... 52 DRIVE BELT TENSION INSPECTION AND ADJUSTMENT.................................................. 52 IGNITION TIMING INSPECTION AND ADJUSTMENT..................................................... 52 IDLE SPEED INSPECTION......................................................................... 53 IDLE MIXTURE INSPECTION....................................................................... 54 COMPRESSION PRESSURE INSPECTION............................................................... 54 INTAKE MANIFOLD VACUUM INSPECTION............................................................. 56 LASH ADJUSTER CHECK........................................................................... 56 CAMSHAFT.......................................................................................... 57 CAMSHAFT OIL SEAL................................................................................. 59 OIL PAN, OIL SCREEN............................................................................... 62 CYLINDER HEAD GASKET.............................................................................. 64 TIMING BELT, TIMING BELT B........................................................................ 71 CRANKSHAFT FRONT OIL SEAL......................................................................... 77 CRANKSHAFT REAR OIL SEAL.......................................................................... 79 ENGINE ASSEMBLY................................................................................... 81 4D5................................................................................................... 87 GENERAL INFORMATION............................................................................... 88 SERVICE SPECIFICATIONS............................................................................ 90 SEALANTS.......................................................................................... 90 SPECIAL TOOLS..................................................................................... 91 SERVICE ADJUSTMENT PROCEDURES..................................................................... 92 DRIVE BELT TENSION INSPECTION AND ADJUSTMENT.................................................. 92 VALVE CLEARANCE INSPECTION AND ADJUSTMENT..................................................... 94 INJECTION TIMING INSPECTION AND ADJUSTMENT.................................................... 95 IDLE SPEED INSPECTION AND ADJUSTMENT.......................................................... 98 IDLE-UP MECHANISM INSPECTION AND ADJUSTMENT-FOR A/C........................................... 98 IDLE-UP MECHANISM INSPECTION AND ADJUSTMENT - FOR ABS......................................... 99 COMPRESSION PRESSURE INSPECTION............................................................... 99 TIMING BELT TENSION ADJUSTMENT................................................................ 101 TIMING BELT "B" TENSION ADJUSTMENT............................................................ 102 CRANKSHAFT PULLEY................................................................................. 103 CAMSHAFT, CAMSHAFT OIL SEAL....................................................................... 104 OIL PAN, OIL SCREEN............................................................................... 107 CYLINDER HEAD GASKET.............................................................................. 109 TIMING BELT/TIMING BELT B......................................................................... 112 CRANKSHAFT FRONT OIL SEAL......................................................................... 116 CRANKSHAFT REAR OIL SEAL.......................................................................... 117 ENGINE ASSEMBLY................................................................................... 119 LUBRICATION............................................................................................... 123 GENERAL INFORMATION................................................................................... 124 LUBRICANTS............................................................................................ 125 SERVICE ADJUSTMENT PROCEDURES......................................................................... 125 ENGINE OIL INSPECTION............................................................................. 125 ENGINE OIL REPLACEMENT............................................................................ 125 OIL FILTER REPLACEMENT............................................................................ 127 OIL LEVEL WARNING SYSTEM INSPECTION............................................................... 127 ENGINE OIL COOLER <4D56>.............................................................................. 129 FUEL...................................................................................................... 130 MULTIPOINT FUEL INJECTION (MPI)....................................................................... 132 GENERAL INFORMATION............................................................................... 133 SERVICE SPECIFICATIONS............................................................................ 136 SEALANT........................................................................................... 136 SPECIAL TOOLS..................................................................................... 136 TROUBLESHOOTING................................................................................... 138 SERVICE ADJUSTMENT PROCEDURES..................................................................... 210 THROTTLE BODY (THROTTLE VALVE AREA) CLEANING.................................................. 210 IDLE POSITION SWITCH AND THROTTLE POSITION SENSOR ADJUSTMENT.................................. 210 FIXED SAS ADJUSTMENT.......................................................................... 212 BASIC IDLE SPEED ADJUSTMENT................................................................... 212 FUEL PRESSURE TEST............................................................................ 214 FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE THE FUEL PRESSURE)........................... 217 FUEL PUMP OPERATION CHECK..................................................................... 217 ON-VEHICLE INSPECTION OF MPI COMPONENTS........................................................... 218 COMPONENT LOCATION............................................................................ 218 CONTROL RELAY INSPECTION...................................................................... 221 INTAKE AIR TEMPERATURE SENSOR INSPECTION...................................................... 222 ENGINE COOLANT TEMPERATURE SENSOR INSPECTION.................................................. 222 THROTTLE POSITION SENSOR INSPECTION........................................................... 223 IDLE POSITION SWITCH INSPECTION............................................................... 223 OXYGEN SENSOR INSPECTION...................................................................... 224 INJECTOR INSPECTION........................................................................... 225 IDLE SPEED CONTROL (ISC) SERVO (STEPPER MOTOR) INSPECTION..................................... 226 PURGE CONTROL SOLENOID VALVE INSPECTION....................................................... 226 EGR CONTROL SOLENOID VALVE INSPECTION......................................................... 226 INJECTOR.......................................................................................... 227 THROTTLE BODY..................................................................................... 229 ELECTRONIC CONTROLLED CARBURETTOR..................................................................... 230 GENERAL INFORMATION............................................................................... 231 SERVICE SPECIFICATIONS............................................................................ 232 SEALANT........................................................................................... 233 SPECIAL TOOLS..................................................................................... 233 SERVICE ADJUSTMENT PROCEDURES..................................................................... 234 CARBURETTOR APPEARANCE........................................................................ 234 THROTTLE POSITION SENSOR (TPS) ADJUSTMENT..................................................... 235 CARBURETTOR SECONDARY VALVE OPERATION INSPECTION.............................................. 235 CARBURETTOR ACCELERATION PUMP INSPECTION...................................................... 236 CHOKE VALVE INSPECTION........................................................................ 236 ELECTRIC AUTO CHOKE INSPECTION................................................................ 237 ELECTRIC CHOKE HEATER INSPECTION.............................................................. 238 ELECTRIC CHOKE RELAY INSPECTION............................................................... 238 CHOKE BREAKER SYSTEM INSPECTION............................................................... 239 CHOKE BREAKER OPENING INSPECTION AND ADJUSTMENT............................................... 239 FAST IDLE INSPECTION AND ADJUSTMENT........................................................... 240 AUXILIARY ACCELERATOR PUMP (AAP) INSPECTION................................................... 242 VACUUM SWITCH CONTROL VACUUM INSPECTION....................................................... 242 FUEL PUMP CONTROL SYSTEM INSPECTION........................................................... 243 INSPECTION PROCEDURES USING THE ECI CHECKER................................................... 244 COMPONENT LOCATION............................................................................ 246 ENGINE COOLANT TEMPERATURE SENSOR INSPECTION.................................................. 248 THROTTLE POSITION SENSOR (TPS) INSPECTION..................................................... 248 ENGINE SPEED SENSOR (IGNITION COIL (-) TERMINAL) INSPECTION................................... 249 VACUUM SWITCH INSPECTION...................................................................... 249 OXYGEN SENSOR INSPECTION...................................................................... 250 FEEDBACK SOLENOID VALVE (FBSV) INSPECTION..................................................... 250 STOW CUT SOLENOID VALVE (SCSV) INSPECTION..................................................... 251 CARBURETTOR....................................................................................... 252 DIESEL FUEL........................................................................................... 253 GENERAL INFORMATION............................................................................... 254 SERVICE SPECIFICATIONS............................................................................ 254 SPECIAL TOOL...................................................................................... 254 SERVICE ADJUSTMENT PROCEDURES..................................................................... 254 FUEL INJECTION TIMING INSPECTION AND ADJUSTMENT............................................... 254 ENGINE IDLING SPEED INSPECTION AND ADJUSTMENT................................................. 254 FUEL DISCHARGE PREVENTION..................................................................... 254 EVACUATION OF WATER FROM FUEL FILTER.......................................................... 255 EVACUATION OF AIR FROM FUEL LINE.............................................................. 255 FUEL FILTER CARTRIDGE REPLACEMENT............................................................. 255 FUEL INJECTION PUMP INSPECTION................................................................ 256 BOOST COMPENSATOR INSPECTION.................................................................. 256 INJECTION NOZZLE INSPECTION AND ADJUSTMENT.................................................... 256 INJECTION NOZZLE.................................................................................. 258 INJECTION PUMP.................................................................................... 260 FUEL SUPPLY AND ENGINE CONTROL........................................................................ 262 GENERAL INFORMATION............................................................................... 263 SERVICE ADJUSTMENT PROCEDURES..................................................................... 263 ACCELERATOR CABLE INSPECTION AND ADJUSTMENT................................................... 263 FUEL FILTER CARTRIDGE REPLACEMENT <Diesel-powered Vehicles>................................... 264 POWER RELAY CHECK <Diesel-powered Vehicles>................................................... 264 FUEL TANK......................................................................................... 265 ACCELERATOR CABLE AND PEDAL....................................................................... 268 FUEL FILTER <PETROL-POWERED VEHICLES>............................................................. 270 FUEL FILTER <DIESEL-POWERED VEHICLES>............................................................. 271 COOLING................................................................................................... 273 GENERAL INFORMATION................................................................................... 274 SERVICE SPECIFICATIONS................................................................................ 274 LUBRICANT............................................................................................. 274 SEALANTS.............................................................................................. 275 SERVICE ADJUSTMENT PROCEDURES......................................................................... 275 RADIATOR CAP VALVE OPENING PRESSURE............................................................... 275 ENGINE COOLANT REPLACEMENT........................................................................ 275 CONCENTRATION MEASUREMENT......................................................................... 277 COOLING FAN........................................................................................... 278 THERMOSTAT............................................................................................ 280 WATER PUMP............................................................................................ 283 WATER HOSE AND WATER PIPE............................................................................. 285 RADIATOR.............................................................................................. 288 INTAKE AND EXHAUST........................................................................................ 290 SERVICE SPECIFICATIONS................................................................................ 291 SPECIAL TOOL.......................................................................................... 291 SEALANT............................................................................................... 291 SERVICE ADJUSTMENT PROCEDURES......................................................................... 292 INTAKE MANIFOLD VACUUM INSPECTION................................................................. 292 TURBOCHARGER SUPERCHARGING INSPECTION............................................................. 292 WASTE GATE ACTUATOR INSPECTION.................................................................... 292 AIR TEMPERATURE SWITCH INSPECTION................................................................. 293 POWER RELAY CHECK................................................................................. 293 AIR CLEANER........................................................................................... 294 INTERCOOLER AND INTERCOOLER FAN-ECU................................................................... 297 INTAKE MANIFOLD....................................................................................... 298 <4G63 (CARBURETTOR)>.............................................................................. 298 <4G63 (MPI), 4G64>................................................................................ 300 INTAKE AND EXHAUST MANIFOLD, TURBOCHARGER <4D56>...................................................... 302 EXHAUST MANIFOLD <4G63, 4G64>......................................................................... 304 EXHAUST PIPE AND MAIN MUFFLER......................................................................... 305 ENGINE ELECTRICAL......................................................................................... 308 CHARGING SYSTEM....................................................................................... 309 GENERAL INFORMATION............................................................................... 309 SERVICE SPECIFICATIONS............................................................................ 310 SPECIAL TOOL...................................................................................... 311 SERVICE ADJUSTMENT PROCEDURES..................................................................... 311 ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST...................................................... 311 OUTPUT CURRENT TEST........................................................................... 312 REGULATED VOLTAGE TEST........................................................................ 314 CHECKING WITH AN ANALYZER..................................................................... 316 ALTERNATOR........................................................................................ 318 STARTING SYSTEM....................................................................................... 319 GENERAL INFORMATION............................................................................... 319 IGNITION SYSTEM....................................................................................... 320 GENERAL INFORMATION............................................................................... 320 SERVICE SPECIFICATIONS............................................................................ 322 LUBRICANT......................................................................................... 323 SPECIAL TOOLS..................................................................................... 323 SERVICE ADJUSTMENT PROCEDURES..................................................................... 323 CENTRIFUGAL ADVANCE CONTROL DEVICE INSPECTION <Carburettor>................................... 323 VACUUM ADVANCE CONTROL DEVICE INSPECTION <Carburettor>........................................ 324 IGNITION COIL INSPECTION...................................................................... 324 POWER TRANSISTOR INSPECTION <MPI>............................................................. 325 RESISTIVE CODE INSPECTION..................................................................... 326 SPARK PLUG CHECK AND CLEANING................................................................. 326 WAVE-FORM INSPECTION USING AN ANALYZER (Ignition Primary and Secondary Voltage wawe-forms).... 327 DISTRIBUTOR....................................................................................... 334 GLOW SYSTEM........................................................................................... 336 GENERAL INFORMATION............................................................................... 336 SERVICE SPECIFICATIONS............................................................................ 337 SEALANT........................................................................................... 337 SERVICE ADJUSTMENT PROCEDURES..................................................................... 338 SELF-REGULATING GLOW SYSTEM INSPECTION........................................................ 338 GLOW CONTROL UNIT INSPECTION.................................................................. 339 GLOW PLUG RELAY INSPECTION.................................................................... 341 GLOW PLUG INSPECTION.......................................................................... 341 ENGINE COOLANT TEMPERATURE SENSOR INSPECTION.................................................. 342 GLOW PLUG......................................................................................... 343 EMISSION CONTROL.......................................................................................... 344 EMISSION CONTROL <MPI>................................................................................ 346 GENERAL INFORMATION............................................................................... 346 EMISSION CONTROL DEVICE REFERENCE TABLE....................................................... 346 SERVICE SPECIFICATIONS............................................................................ 347 SEALANT........................................................................................... 347 VACUUM HOSE....................................................................................... 347 VACUUM HOSE PIPING DIAGRAM.................................................................... 347 VACUUM CIRCUIT DIAGRAM........................................................................ 348 VACUUM HOSE INSPECTION........................................................................ 348 VACUUM HOSE INSTALLATION...................................................................... 348 CRANKCASE EMISSION CONTROL SYSTEM................................................................. 349 GENERAL INFORMATION........................................................................... 349 SYSTEM DIAGRAM................................................................................ 349 COMPONENT LOCATION............................................................................ 349 POSITIVE CRANKCASE VENTILATION SYSTEM INSPECTION.............................................. 350 PCV VALVE INSPECTION.......................................................................... 350 EVAPORATIVE EMISSION CONTROL SYSTEM............................................................... 351 GENERAL INFORMATION........................................................................... 351 SYSTEM DIAGRAM................................................................................ 351 COMPONENT LOCATION............................................................................ 351 PURGE CONTROL SYSTEM INSPECTION............................................................... 352 PURGE PORT VACUUM INSPECTION.................................................................. 352 PURGE CONTROL SOLENOID VALVE INSPECTION....................................................... 353 EXHAUST GAS RECIRCULATION (EGR) SYSTEM............................................................ 354 GENERAL INFORMATION........................................................................... 354 OPERATION..................................................................................... 354 SYSTEM DIAGRAM................................................................................ 354 COMPONENT LOCATION............................................................................ 354 EXHAUST GAS RECIRCULATION (EGR) CONTROL SYSTEM INSPECTION..................................... 355 EGR VALVE INSPECTION.......................................................................... 355 EGR PORT VACUUM INSPECTION.................................................................... 356 EGR CONTROL SOLENOID VALVE INSPECTION......................................................... 356 CATALYTIC CONVERTER............................................................................... 357 GENERAL INFORMATION........................................................................... 357 CANISTER.......................................................................................... 358 TWO-WAY VALVE..................................................................................... 359 EMISSION CONTROL <ELECTRONIC CONTROLLED CARBURETTOR>.................................................. 360 GENERAL INFORMATION............................................................................... 360 EMISSION CONTROL DEVICE REFERENCE TABLE....................................................... 361 SERVICE SPECIFICATION............................................................................. 361 SEALANT........................................................................................... 361 VACUUM HOSE....................................................................................... 362 VACUUM HOSE PIPING DIAGRAM.................................................................... 362 VACUUM HOSE INSPECTION........................................................................ 362 VACUUM HOSE INSTALLATION...................................................................... 362 CRANKCASE EMISSION CONTROL SYSTEM................................................................. 363 EVAPORATIVE EMISSION CONTROL SYSTEM............................................................... 363 GENERAL INFORMATION........................................................................... 363 SYSTEM DIAGRAM................................................................................ 363 COMPONENT LOCATION............................................................................ 363 PURGE CONTROL SYSTEM INSPECTION............................................................... 364 PURGE CONTROL VALVE INSPECTION................................................................ 364 THERMO VALVE INSPECTION....................................................................... 364 PURGE PORT (D NIPPLE) VACUUM INSPECTION....................................................... 365 BOWL VENT VALVE INSPECTION.................................................................... 366 EXHAUST GAS RECIRCULATION (EGR) SYSTEM............................................................ 367 GENERAL INFORMATION........................................................................... 367 SYSTEM DIAGRAM................................................................................ 367 COMPONENT LOCATION............................................................................ 367 EXHAUST GAS RECIRCULATION (EGR) CONTROL SYSTEM INSPECTION..................................... 368 VACUUM REGULATOR VALVE INSPECTION............................................................. 368 EGR VALVE INSPECTION.......................................................................... 368 THERMO VALVE INSPECTION....................................................................... 368 EGR PORT VACUUM INSPECTION.................................................................... 369 SECONDARY AIR SUPPLY SYSTEM....................................................................... 370 GENERAL INFORMATION........................................................................... 370 SYSTEM DIAGRAM................................................................................ 370 COMPONENT LOCATION............................................................................ 371 SECONDARY AIR SUPPLY SYSTEM INSPECTION........................................................ 371 SECONDARY AIR CONTROL VALVE INSPECTION........................................................ 371 SECONDARY AIR CONTROL SOLENOID VALVE INSPECTION............................................... 372 VACUUM TANK INSPECTION........................................................................ 372 INTAKE AIR TEMPERATURE CONTROL SYSTEM............................................................. 373 GENERAL INFORMATION........................................................................... 373 SYSTEM DIAGRAM................................................................................ 373 INTAKE AIR TEMPERATURE CONTROL SYSTEM INSPECTION.............................................. 373 AIR CONTROL VALVE INSPECTION.................................................................. 374 THERMO SENSOR INSPECTION...................................................................... 374 MIXTURE CONTROL VALVE (MCV)....................................................................... 375 GENERAL INFORMATION........................................................................... 375 MIXTURE CONTROL VALVE (MCV) INSPECTION........................................................ 375 CATALYTIC CONVERTER............................................................................... 376 GENERAL INFORMATION........................................................................... 376 CANISTER.......................................................................................... 377 TWO-WAY VALVE..................................................................................... 377 EMISSION CONTROL <DIESEL>............................................................................. 378 GENERAL INFORMATION............................................................................... 378 SERVICE SPECIFICATIONS............................................................................ 378 SEALANT........................................................................................... 378 SPECIAL TOOL...................................................................................... 378 EXHAUST GAS RECIRCULATION (EGR) SYSTEM............................................................ 379 GENERAL INFORMATION........................................................................... 379 SYSTEM DIAGRAM................................................................................ 379 COMPONENT LOCATION............................................................................ 379 FUNCTION INSPECTION........................................................................... 380 EGR SOLENOID VALVE OPERATION INSPECTION....................................................... 380 EGR SOLENOID VALVE RESISTANCE INSPECTION...................................................... 381 LEVER POSITION SENSOR (LPS) ADJUSTMENT........................................................ 381 ENGINE SPEED SENSOR INSPECTION................................................................ 382 ENGINE COOLANT TEMPERATURE SENSOR INSPECTION.................................................. 382 CHECK AT THE GLOW AND EGR CONTROL UNIT........................................................ 383 TWO-WAY VALVE................................................................................. 384 CLUTCH.................................................................................................... 385 <CABLE TYPE>.......................................................................................... 386 GENERAL INFORMATION............................................................................... 386 SERVICE SPECIFICATIONS............................................................................ 386 SERVICE ADJUSTMENT PROCEDURES..................................................................... 386 CLUTCH PEDAL INSPECTION AND ADJUSTMENT........................................................ 386 CLUTCH PEDAL...................................................................................... 388 CLUTCH CONTROL.................................................................................... 390 <HYDRAULIC TYPE>...................................................................................... 391 GENERAL INFORMATION............................................................................... 391 SERVICE SPECIFICATIONS............................................................................ 391 LUBRICANTS........................................................................................ 391 SERVICE ADJUSTMENT PROCEDURES..................................................................... 391 CLUTCH PEDAL INSPECTION AND ADJUSTMENT........................................................ 391 BLEEDING...................................................................................... 392 CLUTCH PEDAL...................................................................................... 393 CLUTCH CONTROL.................................................................................... 395 CLUTCH MASTER CYLINDER........................................................................ 397 MANUAL TRANSMISSION....................................................................................... 398 GENERAL INFORMATION................................................................................... 399 SERVICE SPECIFICATION................................................................................. 400 LUBRICANTS............................................................................................ 400 SEALANTS.............................................................................................. 400 SERVICE ADJUSTMENT PROCEDURES......................................................................... 400 OIL LEVEL CHECK................................................................................... 400 OIL REPLACEMENT................................................................................... 401 4WD DETECTION SWITCH CONTINUITY INSPECTION <4WD>.................................................. 402 HIGH/LOW DETECTION SWITCH CONTINUITY INSPECTION <4WD>............................................. 402 TRANSMISSION CONTROL <2WD-COLUMN SHIFT>............................................................... 403 TRANSMISSION CONTROL <2WD-FLOOR SHIFT>................................................................ 406 TRANSMISSION CONTROL <4WD-FLOOR SHIFT>................................................................ 407 TRANSMISSION ASSEMBLY <2WD>........................................................................... 410 TRANSMISSION ASSEMBLY <4WD>........................................................................... 413 4WD INDICATOR-ECU..................................................................................... 415 AUTOMATIC TRANSMISSION.................................................................................... 417 GENERAL INFORMATION................................................................................... 418 SERVICE SPECIFICATIONS................................................................................ 418 LUBRICANTS............................................................................................ 419 SPECIAL TOOLS......................................................................................... 419 TROUBLESHOOTING....................................................................................... 420 SERVICE ADJUSTMENT PROCEDURES......................................................................... 426 AUTOMATIC TRANSMISSION FLUID INSPECTION........................................................... 426 AUTOMATIC TRANSMISSION FLUID CHANGE............................................................... 427 THROTTLE CABLE CHECK AND ADJUSTMENT............................................................... 427 INHIBITOR SWITCH CONTINUITY INSPECTION............................................................ 428 INHIBITOR SWITCH AND CONTROL CABLE ADJUSTMENT..................................................... 428 A/T CONTROL COMPONENT LOCATION.................................................................... 429 A/T CONTROL COMPONENT INSPECTION.................................................................. 430 CONVERTER STALL TEST.............................................................................. 431 HYDRAULIC PRESSURE TEST........................................................................... 432 GOVERNOR PRESSURE TEST............................................................................ 432 HYDRAULIC CIRCUIT................................................................................. 434 TRANSMISSION CONTROL.................................................................................. 446 TRANSMISSION ASSEMBLY................................................................................. 450 TRANSMISSION OIL COOLER............................................................................... 454 PROPELLER SHAFT........................................................................................... 455 GENERAL INFORMATION................................................................................... 456 SERVICE SPECIFICATIONS................................................................................ 457 LUBRICANT............................................................................................. 457 SPECIAL TOOLS......................................................................................... 457 PROPELLER SHAFT....................................................................................... 458 FRONT AXLE................................................................................................ 466 GENERAL INFORMATION................................................................................... 467 SERVICE SPECIFICATIONS................................................................................ 469 LUBRICANTS............................................................................................ 469 SEALANTS.............................................................................................. 470 SPECIAL TOOLS......................................................................................... 470 SERVICE ADJUSTMENT PROCEDURES......................................................................... 474 WHEEL BEARING PLAY INSPECTION..................................................................... 474 FRONT AXLE TOTAL BACKLASH CHECK................................................................... 474 FRONT AXLE GEAR OIL LEVEL CHECK................................................................... 475 DRIVE SHAFT AXIAL PLAY CHECK...................................................................... 475 DIFFERENTIAL CARRIER OIL SEAL REPLACEMENT......................................................... 475 SOLENOID VALVE OPERATION CHECK.................................................................... 476 FRONT HUB ASSEMBLY <2WD>.............................................................................. 478 FRONT HUB ASSEMBLY <4WD>.............................................................................. 481 KNUCKLE <2WD>......................................................................................... 485 KNUCKLE <4WD>......................................................................................... 487 DRIVE SHAFT........................................................................................... 492 INNER SHAFT........................................................................................... 500 DIFFERENTIAL CARRIER.................................................................................. 504 FREE-WHEELING CLUTCH.................................................................................. 524 REAR AXLE................................................................................................. 530 GENERAL INFORMATION................................................................................... 531 SERVICE SPECIFICATIONS................................................................................ 533 LUBRICANTS............................................................................................ 535 SEALANTS.............................................................................................. 535 SPECIAL TOOLS......................................................................................... 536 SERVICE ADJUSTMENT PROCEDURES......................................................................... 539 REAR AXLE TOTAL BACKLASH CHECK.................................................................... 539 AXLE SHAFT AXIAL PLAY CHECK....................................................................... 539 AXLE SHAFT AXIAL PLAY ADJUSTMENT <2WD (without ABS)>.............................................. 539 GEAR OIL LEVEL CHECK.............................................................................. 540 LIMITED SLIP DIFFERENTIAL PRELOAD MEASUREMENT..................................................... 541 AXLE HOUSING OIL SEAL REPLACEMENT................................................................. 541 AXLE ASSEMBLY......................................................................................... 542 AXLE SHAFT <VEHICLES WITH DRUM BRAKE>................................................................. 546 AXLE SHAFT <VEHICLES WITH DISC BRAKE>................................................................. 554 DIFFERENTIAL CARRIER.................................................................................. 560 LIMITED SLIP DIFFERENTIAL CASE ASSEMBLY <2WD 4G63>.................................................... 579 LIMITED SLIP DIFFERENTIAL CASE ASSEMBLY <EXCEPT 2WD VEHICLES WITH 4G63 ENGINE>........................ 584 WHEEL AND TYRE............................................................................................ 590 GENERAL INFORMATION................................................................................... 591 SERVICE SPECIFICATIONS................................................................................ 591 TROUBLESHOOTING....................................................................................... 592 SERVICE ADJUSTMENT PROCEDURES......................................................................... 593 TYRE INFLATION PRESSURE CHECK..................................................................... 593 TYRE WEAR CHECK................................................................................... 593 WHEEL RUNOUT CHECK................................................................................ 593 WHEEL AND TYRE........................................................................................ 593 POWER PLANT MOUNT......................................................................................... 594 GENERAL INFORMATION................................................................................... 595 SPECIAL TOOLS......................................................................................... 596 FRONT ENGINE MOUNT <2WD>.............................................................................. 597 FRONT ENGINE MOUNT <4WD>.............................................................................. 598 REAR ENGINE MOUNT..................................................................................... 599 FRONT DIFFERENTIAL MOUNT.............................................................................. 600 FRONT DIFFERENTIAL MOUNT INSULATOR REPLACEMENT.................................................... 601 SUSPENSION CROSSMEMBER ASSEMBLY <2WD>................................................................. 602 SUSPENSION CROSSMEMBER ASSEMBLY <4WD>................................................................. 604 FRONT SUSPENSION.......................................................................................... 606 GENERAL INFORMATION................................................................................... 607 SERVICE SPECIFICATIONS................................................................................ 609 SEALANTS.............................................................................................. 609 SPECIAL TOOLS......................................................................................... 610 SERVICE ADJUSTMENT PROCEDURES......................................................................... 612 FRONT WHEEL ALIGNMENT INSPECTION AND ADJUSTMENT................................................... 612 SHOCK ABSORBER AND LOWER ARM.......................................................................... 615 UPPER ARM............................................................................................. 620 TORSION BAR........................................................................................... 624 STRUT BAR <2WD>....................................................................................... 627 STABILIZER BAR........................................................................................ 628 REAR SUSPENSION........................................................................................... 631 GENERAL INFORMATION................................................................................... 632 SERVICE SPECIFICATIONS................................................................................ 634 SPECIAL TOOLS......................................................................................... 634 SERVICE ADJUSTMENT PROCEDURES......................................................................... 635 REAR WHEEL ALIGNMENT.............................................................................. 635 REAR SUSPENSION ASSEMBLY <LEAF SPRING TYPE>........................................................... 636 REAR SUSPENSION ASSEMBLY <COIL SPRING TYPE>........................................................... 639 STABILIZER BAR <COIL SPRING TYPE>..................................................................... 641 SERVICE BRAKES............................................................................................ 643 BASIC BRAKE SYSTEM.................................................................................... 645 GENERAL INFORMATION............................................................................... 646 SERVICE SPECIFICATIONS............................................................................ 648 LUBRICANTS........................................................................................ 649 SEALANTS.......................................................................................... 649 SPECIAL TOOLS..................................................................................... 649 TROUBLESHOOTING................................................................................... 650 SERVICE ADJUSTMENT PROCEDURES..................................................................... 653 BRAKE PEDAL INSPECTION AND ADJUSTMENT......................................................... 653 STOP LAMP SWITCH INSPECTION................................................................... 654 BRAKE BOOSTER OPERATING TEST.................................................................. 654 CHECK VALVE OPERATION CHECK................................................................... 655 BRAKE BOOSTER VACUUM SWITCH CHECK <DIESEL-POWERED VEHICLES>................................... 655 BLEEDING...................................................................................... 655 LOAD SENSING SPRING LENGTH CHECK AND ADJUSTMENT............................................... 656 LOAD SENSING PROPORTIONING VALVE FUNCTION TEST................................................ 657 DISC BRAKE PAD CHECK AND REPLACEMENT.......................................................... 658 FRONT DISC BRAKE ROTOR INSPECTION............................................................. 660 REAR BRAKE DISC RUN-OUT CHECK................................................................. 661 REAR BRAKE DISC RUN-OUT CORRECTION............................................................ 661 REAR BRAKE DISC THICKNESS CHECK............................................................... 662 BRAKE LINING THICKNESS CHECK <VEHICLES WITH REAR DRUM BRAKE>.................................. 662 BRAKE DRUM INSIDE DIAMETER CHECK <VEHICLES WITH REAR DRUM BRAKE>.............................. 663 BRAKE LINING AND BRAKE DRUM CONNECTION CHECK <VEHICLES WITH REAR DRUM BRAKE>.................. 663 BRAKE LINING THICKNESS CHECK <VEHICLES WITH REAR DISC BRAKE>.................................. 663 BRAKE DRUM INSIDE DIAMETER CHECK <VEHICLES WITH REAR DISC BRAKE>.............................. 664 BRAKE LINING AND BRAKE DRUM CONNECTION CHECK <VEHICLES WITH REAR DISC BRAKE>.................. 664 BRAKE PEDAL....................................................................................... 665 MASTER CYLINDER AND BRAKE BOOSTER................................................................. 668 LOAD SENSING PROPORTIONING VALVE.................................................................. 674 FRONT DISC BRAKE <SINGLE PISTON TYPE>............................................................. 676 FRONT DISC BRAKE <DUAL PISTON TYPE>............................................................... 680 REAR DISC BRAKE................................................................................... 685 REAR DRUM BRAKE <2WD>............................................................................. 689 REAR DRUM BRAKE <4WD>............................................................................. 693 ANTI-SKID BRAKING SYSTEM (ABS) <2WD>.................................................................. 695 GENERAL INFORMATION............................................................................... 697 SERVICE SPECIFICATIONS............................................................................ 698 LUBRICANTS........................................................................................ 698 SEALANTS.......................................................................................... 698 SPECIAL TOOLS..................................................................................... 698 TROUBLESHOOTING................................................................................... 699 SERVICE ADJUSTMENT PROCEDURES..................................................................... 723 ABS OPERATION CHECK........................................................................... 724 MASTER CYLINDER AND BRAKE BOOSTER................................................................. 729 HYDRAULIC UNIT.................................................................................... 735 WHEEL SPEED SENSOR................................................................................ 737 STEEPING WHEEL SENSOR............................................................................. 739 ELECTRONIC CONTROL UNIT........................................................................... 740 ANTI-SKID BRAKING SYSTEM (ABS) <4WD>.................................................................. 741 GENERAL INFORMATION............................................................................... 742 SERVICE SPECIFICATION............................................................................. 743 SPECIAL TOOLS..................................................................................... 743 TROUBLESHOOTING................................................................................... 744 G-SENSOR.......................................................................................... 753 PARKING BRAKES............................................................................................ 754 GENERAL INFORMATION................................................................................... 755 SERVICE SPECIFICATIONS................................................................................ 756 LUBRICANTS............................................................................................ 756 SEALANT............................................................................................... 756 SERVICE ADJUSTMENT PROCEDURES......................................................................... 757 PARKING BRAKE LEVER STROKE CHECK.................................................................. 757 PARKING BRAKE SWITCH CHECK........................................................................ 758 LINING RUNNING-IN................................................................................. 758 PARKING BRAKE LEVER................................................................................... 759 PARKING BRAKE CABLE................................................................................... 760 PARKING BRAKE DRUM.................................................................................... 762 STEERING.................................................................................................. 764 GENERAL INFORMATION................................................................................... 765 SERVICE SPECIFICATIONS................................................................................ 767 LUBRICANTS............................................................................................ 768 SEALANT............................................................................................... 768 SPECIAL TOOLS......................................................................................... 768 SERVICE ADJUSTMENT PROCEDURE.......................................................................... 770 STEERING WHEEL FREE PLAY CHECK.................................................................... 770 STEERING ANGLE CHECK.............................................................................. 770 TIE ROD END BALL JOINT VARIATION CHECK (SHAFT DIRECTION).......................................... 771 TIE ROD END BALL JOINT STARTING TORQUE CHECK...................................................... 771 STATIONARY STEERING EFFORT CHECK.................................................................. 772 CHECKING STEERING WHEEL RETURN TO CENTRE.......................................................... 772 DRIVE BELT TENSION CHECK.......................................................................... 772 FLUID LEVEL CHECK................................................................................. 773 FLUID REPLACEMENT................................................................................. 773 BLEEDING.......................................................................................... 774 OIL PUMP PRESSURE TEST............................................................................ 775 POWER STEERING OIL PRESSURE SWITCH CHECK <PETROL>................................................. 777 STEERING WHEEL AND SHAFT.............................................................................. 778 POWER STEERING GEAR BOX............................................................................... 784 POWER STEERING OIL PUMP............................................................................... 790 POWER STEERING HOSES.................................................................................. 795 BODY...................................................................................................... 801 HOOD.................................................................................................. 803 FENDER................................................................................................ 804 SEALANT........................................................................................... 804 SPECIAL TOOL...................................................................................... 804 FENDER............................................................................................ 805 FUEL FILLER DOOR...................................................................................... 806 WINDOW GLASS.......................................................................................... 807 ADHESIVES......................................................................................... 807 SPECIAL TOOLS..................................................................................... 807 WINDOW REPAIR..................................................................................... 808 WINDSHIELD........................................................................................ 810 DELTA WINDOW GLASS................................................................................ 814 REAR WINDOW GLASS................................................................................. 816 QUARTER WINDOW GLASS.............................................................................. 818 TAILGATE WINDOW GLASS............................................................................. 820 ROOF WINDOW GLASS................................................................................. 822 FRONT DOOR............................................................................................ 824 SERVICE SPECIFICATIONS............................................................................ 824 SEALANT........................................................................................... 824 SPECIAL TOOLS..................................................................................... 824 TROUBLESHOOTING................................................................................... 825 SERVICE ADJUSTMENT PROCEDURES..................................................................... 834 DOOR FIT ADJUSTMENT........................................................................... 834 DOOR WINDOW GLASS ADJUSTMENT.................................................................. 834 SASH SPAN INSPECTION.......................................................................... 834 POWER WINDOW SAFETY MECHANISM INSPECTION...................................................... 835 DOOR OUTSIDE HANDLE PLAY INSPECTION........................................................... 835 POWER WINDOW OPERATION CURRENT INSPECTION..................................................... 835 CIRCUIT BREAKER (INCORPORATED IN THE POWER WINDOW MOTOR) INSPECTION........................... 835 DOOR INSIDE HANDLE PLAY INSPECTION AND ADJUSTMENT............................................. 835 FRONT DOOR ASSEMBLY............................................................................... 836 FRONT DOOR TRIM AND WATERPROOF FILM............................................................... 838 DOOR GLASS AND REGULATOR.......................................................................... 840 FRONT DOOR HANDLE AND LATCH....................................................................... 843 FRONT DOOR RUNCHANNEL............................................................................. 846 FRONT DOOR WEATHERSTRIP........................................................................... 847 SLIDE DOOR............................................................................................ 848 SERVICE SPECIFICATIONS............................................................................ 848 SEALANT........................................................................................... 848 SPECIAL TOOLS..................................................................................... 848 TROUBLESHOOTING................................................................................... 848 SERVICE ADJUSTMENT PROCEDURES..................................................................... 849 DOOR FIT ADJUSTMENT........................................................................... 849 DOOR OUTSIDE HANDLE PLAY INSPECTION AND ADJUSTMENT............................................ 850 DOOR INSIDE HANDLE PLAY INSPECTION AND ADJUSTMENT............................................. 850 SLIDE DOOR ASSEMBLY............................................................................... 851 SLIDE DOOR TRIM AND WATERPROOF FILM............................................................... 853 SLIDE DOOR HANDLE AND LATCH....................................................................... 854 SLIDE DOOR WEATHERSTRIP........................................................................... 856 TAILGATE.............................................................................................. 857 SERVICE SPECIFICATION............................................................................. 857 SEALANT........................................................................................... 857 SPECIAL TOOLS..................................................................................... 857 TROUBLESHOOTING................................................................................... 857 SERVICE ADJUSTMENT PROCEDURES..................................................................... 858 TAILGATE FIT ADJUSTMENT....................................................................... 858 TAILGATE HANDLE PLAY INSPECTION............................................................... 858 TAILGATE ASSEMBLY................................................................................. 859 TAILGATE TRIM AND WATERPROOF FILM................................................................. 861 TAILGATE HANDLE AND LATCH......................................................................... 862 FRONT SUNROOF......................................................................................... 864 SERVICE SPECIFICATIONS............................................................................ 864 TROUBLESHOOTING................................................................................... 864 SERVICE ADJUSTMENT PROCEDURES..................................................................... 866 SUNROOF LEAKAGE INSPECTION.................................................................... 866 SUNROOF FIT ADJUSTMENT........................................................................ 866 FRONT SUNROOF..................................................................................... 867 REAR SUNROOF.......................................................................................... 874 SERVICE SPECIFICATION............................................................................. 874 TROUBLESHOOTING................................................................................... 874 SERVICE ADJUSTMENT PROCEDURES..................................................................... 877 SUNROOF LEAKAGE INSPECTION.................................................................... 877 SUNROOF FIT ADJUSTMENT........................................................................ 877 REAR SUNROOF...................................................................................... 878 CRYSTAL LITE ROOF SUNSHADE............................................................................ 887 UNDER COVER........................................................................................... 889 EXTERIOR.................................................................................................. 890 FRONT BUMPER.......................................................................................... 892 REAR BUMPER........................................................................................... 893 GRILLES, GARNISHES AND MOULDINGS...................................................................... 894 SPECIAL TOOL...................................................................................... 894 GRILLES, GARNISHES AND MOULDINGS.................................................................. 894 WINDSHIELD WIPER AND WASHER........................................................................... 895 SERVICE SPECIFICATION............................................................................. 895 WINDSHIELD WIPER AND WASHER....................................................................... 895 INSPECTION.................................................................................... 897 COLUMN SWITCH INSPECTION...................................................................... 897 REAR WIPER AND WASHER................................................................................. 898 SERVICE SPECIFICATION............................................................................. 898 REAR WIPER AND WASHER............................................................................. 898 INSPECTION.................................................................................... 900 COLUMN SWITCH INSPECTION...................................................................... 900 INTERMITTENT WIPER RELAY INSPECTION........................................................... 900 WASHER MOTOR INSPECTION....................................................................... 901 HEADLAMP WASHER....................................................................................... 902 INSPECTION........................................................................................ 903 DOOR MIRROR........................................................................................... 904 SPECIAL TOOL...................................................................................... 904 DOOR MIRROR....................................................................................... 904 INSPECTION.................................................................................... 905 REAR UNDER GUARD <4WD>................................................................................ 906 ADHESIVE.......................................................................................... 906 REAR UNDER GUARD.................................................................................. 906 STEP <4WD>............................................................................................ 907 ADHESIVE.......................................................................................... 907 STEP.............................................................................................. 907 INTERIOR.................................................................................................. 908 INTERIOR.............................................................................................. 910 ADHESIVE.......................................................................................... 911 SPECIAL TOOL...................................................................................... 911 INSTRUMENT PANEL.................................................................................. 911 TRIMS............................................................................................. 916 HEADLINING (PASTE TYPE)........................................................................... 924 HEADLINING (MOULDED TYPE)......................................................................... 926 SEAT.............................................................................................. 929 FRONT SEAT.................................................................................... 929 SECOND SEAT (BENCH TYPE)...................................................................... 931 SECOND SEAT (SEPARATE TYPE)................................................................... 933 THIRD SEAT.................................................................................... 935 HEATED SEAT SWITCH............................................................................ 937 SEAT BELT......................................................................................... 938 FRONT SEAT BELT............................................................................... 938 SECOND SEAT BELT.............................................................................. 939 THIRD SEAT BELT............................................................................... 940 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)................................................................... 941 SERVICE PRECAUTIONS............................................................................... 942 SERVICE SPECIFICATIONS............................................................................ 944 SPECIAL TOOLS..................................................................................... 944 TEST EQUIPMENT.................................................................................... 945 TROUBLESHOOTING................................................................................... 945 POST-COLLISION DIAGNOSIS.......................................................................... 968 INDIVIDUAL COMPONENT SERVICE...................................................................... 971 WARNING/CAUTION LABELS............................................................................ 971 FRONT IMPACT SENSORS.............................................................................. 972 SRS DIAGNOSIS UNIT (SOU).......................................................................... 974 AIR BAG MODULE AND CLOCK SPRING................................................................... 977 AIR BAG MODULE DISPOSAL PROCEDURES................................................................ 983 UNDEPLOYED AIR BAG MODULE DISPOSAL............................................................ 983 DEPLOYED AIR BAG MODULE DISPOSAL PROCEDURES................................................... 988 SENSOR CABLE INSTALLATION PROCEDURES.............................................................. 990 CHASSIS ELECTRICAL........................................................................................ 992 BATTERY............................................................................................... 995 SERVICE SPECIFICATION............................................................................. 995 SERVICE ADJUSTMENT PROCEDURES..................................................................... 995 FLUID LEVEL AND SPECIFIC GRAVITY INSPECTION................................................... 995 VISUAL INSPECTION............................................................................. 995 CHARGING...................................................................................... 996 BATTERY TESTING PROCEDURE..................................................................... 997 IGNITION SWITCH....................................................................................... 998 TROUBLESHOOTING................................................................................... 998 IGNITION SWITCH...................................................................................1000 COMBINATION METERS....................................................................................1004 SERVICE SPECIFICATIONS............................................................................1004 SEALANT...........................................................................................1005 SPECIAL TOOLS.....................................................................................1005 TROUBLESHOOTING...................................................................................1006 SERVICE ADJUSTMENT PROCEDURES.....................................................................1009 SPEEDOMETER INSPECTION........................................................................1009 TACHOMETER INSPECTION.........................................................................1009 FUEL GAUGE SIMPLE INSPECTION..................................................................1010 FUEL GAUGE UNIT INSPECTION....................................................................1011 ENGINE COOLANT TEMPERATURE GAUGE SIMPLE INSPECTION............................................1012 ENGINE COOLANT TEMPERATURE GAUGE UNIT INSPECTION..............................................1013 COMBINATION METERS................................................................................1013 MULTI-METER...........................................................................................1017 TROUBLESHOOTING...................................................................................1017 SERVICE ADJUSTMENT PROCEDURE......................................................................1019 VOLTMETER SIMPLE INSPECTION...................................................................1019 MULTI-METER.......................................................................................1020 OUTSIDE TEMPERATURE SENSOR, INSIDE TEMPERATURE SENSOR.................................................1021 SERVICE SPECIFICATIONS............................................................................1021 OUTSIDE TEMPERATURE SENSOR, INSIDE TEMPERATURE SENSOR.............................................1021 HEADLAMP..............................................................................................1022 SERVICE SPECIFICATIONS............................................................................1022 SPECIAL TOOL......................................................................................1022 TROUBLESHOOTING...................................................................................1022 SERVICE ADJUSTMENT PROCEDURES.....................................................................1024 HEADLAMP AIMING...............................................................................1024 INTENSITY MEASUREMENT.........................................................................1025 BULB REPLACEMENT..............................................................................1025 HEADLAMP..........................................................................................1026 FRONT TURN-SIGNAL LAMP................................................................................1030 SIDE TURN-SIGNAL LAMP.................................................................................1031 REAR COMBINATION LAMP, TAILGATE LAMP..................................................................1033 REAR FOG LAMP.........................................................................................1035 SPECIAL TOOL......................................................................................1035 REAR FOG LAMP.....................................................................................1035 INTERIOR LAMP.........................................................................................1037 RHEOSTAT..............................................................................................1039 SPECIAL TOOL......................................................................................1039 RHEOSTAT..........................................................................................1039 HAZARD LAMP SWITCH....................................................................................1040 SPECIAL TOOL......................................................................................1040 HAZARD LAMP SWITCH................................................................................1040 HORN..................................................................................................1041 CIGARETTE LIGHTER.....................................................................................1042 SPECIAL TOOL......................................................................................1042 CIGARETTE LIGHTER.................................................................................1042 ACCESSORY SOCKET......................................................................................1044 CLOCK.................................................................................................1045 SPECIAL TOOL......................................................................................1045 CLOCK.............................................................................................1045 RADIO AND TAPE PLAYER.................................................................................1046 SPECIAL TOOL......................................................................................1046 TROUBLESHOOTING...................................................................................1046 QUICK-REFERENCE TROUBLESHOOTING CHART.........................................................1046 RADIO AND TAPE PLAYER WITH ANTI-THEFT SYSTEM..................................................1062 RADIO AND TAPE PLAYER.............................................................................1065 SPEAKER...............................................................................................1066 ANTENNA...............................................................................................1068 SPECIAL TOOL......................................................................................1068 ANTENNA...........................................................................................1068 REAR WINDOW DEFOGGER..................................................................................1070 SPECIAL TOOL......................................................................................1070 SERVICE ADJUSTMENT PROCEDURE......................................................................1070 PRINTED-HEATER LINE INSPECTION................................................................1070 REAR WINDOW DEFOGGER SWITCH.......................................................................1071 HEATER, AIR CONDITIONER AND VENTILATION...................................................................1073 GENERAL INFORMATION...................................................................................1075 SAFETY PRECAUTIONS....................................................................................1076 SERVICE SPECIFICATIONS................................................................................1077 LUBRICANTS............................................................................................1077 SEALANT...............................................................................................1078 SPECIAL TOOLS.........................................................................................1078 TROUBLESHOOTING.......................................................................................1078 SERVICE ADJUSTMENT PROCEDURES.........................................................................1088 COMPRESSOR DRIVE BELT ADJUSTMENT..................................................................1088 SIGHT GLASS REFRIGERANT LEVEL TEST................................................................1088 MAGNETIC CLUTCH TEST..............................................................................1088 RECEIVER DRIER TEST...............................................................................1088 CHARGING..........................................................................................1089 PERFORMANCE TEST..................................................................................1093 REFRIGERANT LEAK REPAIR...........................................................................1095 COMPRESSOR NOISE..................................................................................1095 DUAL PRESSURE SWITCH CHECK........................................................................1096 POWER RELAY CHECK.................................................................................1096 IDLE-UP OPERATION CHECK...........................................................................1098 VACUUM ACTUATOR CHECK <4G63>......................................................................1099 IDLE-UP SOLENOID VALVE CHECK <4G63, 4D56>.........................................................1100 FRONT PANEL ASSEMBLY, REAR HEATER SWITCH AND FRONT A/C SWITCH.........................................1102 FRONT HEATER UNIT AND FRONT HEATER CORE...............................................................1106 FRONT BLOWER MOTOR ASSEMBLY AND RESISTOR..............................................................1107 FRONT EVAPORATOR AND A/C-ECU..........................................................................1109 REAR PANEL ASSEMBLY AND REAR A/C SWITCH <BUILT-IN TYPE>...............................................1112 REAR EVAPORATOR ASSEMBLY <BUILT-IN TYPE>..............................................................1115 REAR EVAPORATOR ASSEMBLY <OVERHEAD TYPE>..............................................................1119 REAR HEATER UNIT <UNDER SEAT TYPE>....................................................................1123 REAR HEATER CORE, REAR BLOWER MOTOR ASSEMBLY AND RESISTOR <BUILT-IN TYPE>.............................1124 REAR HEATER CORE, REAR BLOWER MOTOR ASSEMBLY, BLOWER MOTOR LO RELAY AND RESISTOR <UNDER SEAT TYPE>....1127 HEATER HOSE...........................................................................................1129 COMPRESSOR AND TENSION PULLEY.........................................................................1133 FRONT CONDENSER AND CONDENSER FAN MOTOR...............................................................1141 SIDE CONDENSER AND CONDENSER FAN MOTOR <DUAL A/C>.....................................................1143 REFRIGERANT LINE......................................................................................1145 ENGINE COOLANT TEMPERATURE SWITCH.....................................................................1152 IDLE-UP SYSTEM <4G63-Carburettor, 4D56>...............................................................1154 VENTILATORS...........................................................................................1155 VENTILATORS (INSTRUMENT PANEL)........................................................................1156 REAR VENTILATORS <BUILT-IN TYPE>......................................................................1158 ROOF DUCT <BUILT-IN TYPE>.............................................................................1159
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S.S 08/24
