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Mitsubishi Sigma Service Manual PWGE9004-G – PDF
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Description
Mitsubishi Sigma Service Manual PWGE9004-G – PDF DOWNLOAD
FILE DETAILS:
Mitsubishi Sigma Service Manual PWGE9004-G – PDF DOWNLOAD
Language : English
Pages : 1441
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
Mitsubishi Sigma Service Manual PWGE9004-G – PDF DOWNLOAD
GENERAL............................................................................................................................. 12 HOW TO USE THIS MANUAL.......................................................................................................... 14 SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS..................................................................... 14 DEFINITION OF TERMS......................................................................................................... 14 MODEL INDICATIONS........................................................................................................... 14 EXPLANATION OF MANUAL CONTENTS.............................................................................................. 15 EXPLANATION OF CIRCUIT DIAGRAMS............................................................................................. 17 VEHICLE IDENTIFICATION.......................................................................................................... 18 VEHICLE INFORMATION CODE PLATE.............................................................................................. 18 MODELS...................................................................................................................... 18 MODEL CODE.................................................................................................................. 19 CHASSIS NUMBER.............................................................................................................. 19 MAJOR SPECIFICATIONS............................................................................................................ 22 PRECAUTIONS BEFORE SERVICE...................................................................................................... 23 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)-AIR BAG..................................................................................... 27 SUPPORT LOCATIONS FOR LIFTING AND JACKING....................................................................................... 32 STANDARD PARTS-TIGHTENING-TORQUE TABLE.......................................................................................... 36 MAIN SEALANT AND ADHESIVE TABLE................................................................................................. 37 ENGINE.............................................................................................................................. 39 SPECIFICATIONS.................................................................................................................. 40 GENERAL SPECIFICATIONS...................................................................................................... 40 SERVICE SPECIFICATIONS...................................................................................................... 40 SEALANTS.................................................................................................................... 41 SPECIAL TOOLS................................................................................................................... 42 SERVICE ADJUSTMENT PROCEDURES <SOHC>............................................................................................ 44 DRIVE BELT TENSION INSPECTION AND ADJUSTMENT................................................................................ 44 IGNITION TIMING INSPECTION AND ADJUSTMENT................................................................................... 45 IDLE SPEED INSPECTION....................................................................................................... 46 IDLE MIXTURE INSPECTION..................................................................................................... 47 COMPRESSION PRESSURE INSPECTION............................................................................................. 49 MANIFOLD VACUUM INSPECTION.................................................................................................. 50 SERVICE ADJUSTMENT PROCEDURES <DOHC>............................................................................................ 53 DRIVE BELT TENSION INSPECTION AND ADJUSTMENT................................................................................ 53 IGNITION TIMING INSPECTION AND ADJUSTMENT <Vehicles built up to November, 1992>............................................. 54 IGNITION TIMING INSPECTION <Vehicles built from December, 1992>............................................................ 56 IDLE SPEED INSPECTION....................................................................................................... 58 IDLE MIXTURE INSPECTION..................................................................................................... 58 COMPRESSION PRESSURE INSPECTION............................................................................................. 59 MANIFOLD VACUUM INSPECTION.................................................................................................. 60 OIL PAN......................................................................................................................... 63 TIMING BELT <SOHC>.............................................................................................................. 69 TIMING BELT <DOHC>.............................................................................................................. 73 CAMSHAFT OIL SEALS <SOHC>....................................................................................................... 79 CAMSHAFT OIL SEALS <DOHC>....................................................................................................... 80 CRANKSHAFT FRONT OIL SEAL....................................................................................................... 82 CRANKSHAFT REAR OIL SEAL........................................................................................................ 83 CYLINDER HEAD GASKET <SOHC>..................................................................................................... 85 CYLINDER HEAD GASKET <DOHC>..................................................................................................... 88 ENGINE ASSEMBLY <SOHC>.......................................................................................................... 91 ENGINE ASSEMBLY <DOHC>.......................................................................................................... 94 LUBRICATION......................................................................................................................... 97 GENERAL INFORMATION............................................................................................................. 98 SPECIFICATIONS.................................................................................................................. 99 GENERAL SPECIFICATIONS...................................................................................................... 99 LUBRICANTS.................................................................................................................. 99 SERVICE ADJUSTMENT PROCEDURES................................................................................................... 99 ENGINE OIL INSPECTION....................................................................................................... 99 ENGINE OIL REPLACEMENT...................................................................................................... 100 OIL FILTER REPLACEMENT...................................................................................................... 100 ENGINE OIL COOLER <DOHC>........................................................................................................ 101 FUEL................................................................................................................................ 103 GENERAL INFORMATION............................................................................................................. 106 MULTI POINT INJECTION SYSTEM DIAGRAM........................................................................................ 106 SPECIFICATIONS.................................................................................................................. 113 GENERAL SPECIFICATIONS...................................................................................................... 113 SERVICE SPECIFICATIONS...................................................................................................... 114 SEALANTS.................................................................................................................... 115 SPECIAL TOOLS................................................................................................................... 115 TROUBLESHOOTING................................................................................................................. 117 EXPLANATION OF TROUBLESHOOTING PROCEDURES................................................................................... 117 EXPLANATION AND PRECAUTION RELATED TO HARNESS CHECING....................................................................... 118 ENGINE WARNING LAMP (CHECK ENGINE LAMP)..................................................................................... 120 ITEMS INDICATED BY THE ENGINE WARNING LAMP.................................................................................. 120 ENGINE WARNING LAMP INSPECTION.............................................................................................. 121 SELF-DIAGNOSIS.............................................................................................................. 121 READ OUT OF MALFUNCTION CODE................................................................................................ 124 TRACTION CONTROL (TCL) SYSTEM............................................................................................... 127 AUTO-CRUISE CONTROL SYSTEM.................................................................................................. 177 SERVICE ADJUSTMENT PROCEDURES <ENGINE>.......................................................................................... 201 THROTTLE BODY (THROTTLE VALVE AREA) CLEANING................................................................................ 201 IDLE POSITION SWITCH AND THROTTLE POSITION SENSOR ADJUSTMENT <Except for Vehicles with TCL>................................. 201 THROTTLE POSITION SENSOR ADJUSTMENT <Vehicles with TCL>..................................................................... 203 IDLE POSITION SWITCH AND ACCELERATOR POSITION SENSOR (APS) ADJUSTMENT <Vehicles with TCL>................................... 203 FIXED SAS ADJUSTMENT........................................................................................................ 205 BASIC IDLE SPEED ADJUSTMENT................................................................................................. 205 ACCELERATOR CABLE INSPECTION AND ADJUSTMENT................................................................................. 207 FUEL FILTER REPLACEMENT..................................................................................................... 208 FUEL GAUGE UNIT REPLACEMENT................................................................................................. 208 TWO-WAY VALVE REPLACEMENT................................................................................................... 209 FUEL PUMP OPERATION CHECK................................................................................................... 209 FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE THE FUEL PRESSURE)......................................................... 209 INSPECTING OPERATION OF THE TCL (TRACTION CONTROL) SYSTEM................................................................... 210 AUTO-CRUISE CONTROL CABLES INSPECTION AND ADJUSTMENT........................................................................ 216 ACCELERATOR PEDAL SWITCH INSPECTION AND ADJUSTMENT.......................................................................... 220 AUTO-CRUISE CONTROL MAIN SWITCH CHECK....................................................................................... 220 AUTO-CRUISE CONTROL SETTING CHECK........................................................................................... 220 SPEED-INCREASE SETIING CHECK................................................................................................ 221 SPEED REDUCTION SETTING CHECK............................................................................................... 221 CHECK OF RETURN TO THE SET SPEED BEFORE CANCELLATION AND AUTO-CRUISE CONTROL CANCELLATION................................... 222 ON-VEHICLE INSPECTION OF MPI COMPONENTS......................................................................................... 224 COMPONENT LOCATION.......................................................................................................... 224 POWER SUPPLY AND IGNITION SWITCH-IG <Vehicles built up to November, 1992>................................................... 234 POWER SUPPLY AND IGNITION SWITCH-IG <Vehicles built from December, 1992>.................................................... 237 ENGINE CONTROL UNIT POWER EARTH............................................................................................. 241 FUEL PUMP <Vehicles built up to November, 1992>............................................................................. 242 FUEL PUMP <Vehicles built from December, 1992>.............................................................................. 245 AIR FLOW SENSOR............................................................................................................. 249 INTAKE AIR TEMPERATURE SENSOR............................................................................................... 254 BAROMETRIC PRESSURE SENSOR.................................................................................................. 257 ENGINE COOLANT TEMPERATURE SENSOR........................................................................................... 259 THROTTLE POSITION SENSOR.................................................................................................... 262 IDLE POSITION SWITCH........................................................................................................ 265 ACCELERATOR POSITION SENSOR (APS) <Vehicles with TCL>....................................................................... 268 TOP DEAD CENTRE SENSOR <SOHC, DOHC-Vehicles built up to November, 1992>..................................................... 270 CRANK ANGLE SENSOR <SOHC, DOHC-Vehicles built up to November, 1992>......................................................... 274 CAMSHAFT POSITION SENSOR <DOHC-Vehicles built from December, 1992>.......................................................... 277 CRANK ANGLE SENSOR <DOHC-Vehicles built from December, 1992>................................................................ 280 IGNITION SWITCH-ST <M/T>.................................................................................................... 283 IGNITION SWITCH-ST AND INHIBITOR SWITCH <A/T> <Vehicles built up to November, 1992>......................................... 284 IGNITION SWITCH-ST AND INHIBITOR SWITCH <A/T> <Vehicles built from December, 1992>.......................................... 286 VEHICLE SPEED SENSOR........................................................................................................ 288 POWER STEERING FLUID PRESSURE SWITCH........................................................................................ 290 AIR CINDITIONER SWITCH AND POWER RELAY...................................................................................... 292 DETONATOR SENSOR............................................................................................................ 294 ELECTRIC LOAD SWITCH ....................................................................................................... 296 FAN MOTOR RELAY (RADIATOR FAN, CONDENSOR FAN)............................................................................... 298 INDUCTION CONTROL VALVE POSITION SENSOR..................................................................................... 300 OXYGEN SENSOR............................................................................................................... 302 INJECTORS................................................................................................................... 305 IDLE SPEED CONTROL SERVO (STEPPER MOTOR).................................................................................... 312 IGNITION COIL AND POWER TRANSISTOR ......................................................................................... 318 PURGE CONTROL SOLENOID VALVE................................................................................................ 327 EGR CONTROL SOLENOID VALVE <Vehicles built from December, 1992>............................................................. 329 VACUUM SOLENOID VALVE <Vehicles with TCL>................................................................................... 331 VENTILATION SOLENOID VALVE <Vehicles with TCL>.............................................................................. 334 VARIABLE INDUCTION CONTROL SERVO............................................................................................ 337 ENGINE/TRANSMISSION OVERALL CONTROL SIGNAL <DONC-A/T>....................................................................... 339 ENGINE/TRANSMISSION OVERALL CONTROL SIGNAL <SOHC-A/T-Vehicles built from December, 1991>.................................... 341 TRACTION CONTROL SIGNAL <Vehicles with TCL>................................................................................. 343 FUEL PRESSURE TEST.......................................................................................................... 345 DETONATION SENSOR............................................................................................................... 348 FUEL TANK....................................................................................................................... 349 FUEL LINE AND VAPOR LINE........................................................................................................ 352 TCL CONTROL UNIT................................................................................................................ 354 TCL SWITCH...................................................................................................................... 355 HYRAULITIC UNIT <VEHICLES WITH TCL>............................................................................................. 355 ACCELERATOR CABLE AND PEDAL..................................................................................................... 356 AUTO-CRUISE CONTROL............................................................................................................. 358 COOLING............................................................................................................................. 369 SPECIFICATIONS.................................................................................................................. 370 GENERAL SPECIFICATIONS...................................................................................................... 370 SERVICE SPECIFICATIONS...................................................................................................... 370 LUBRICANTS.................................................................................................................. 371 SEALANT..................................................................................................................... 371 SERVICE ADJUSTMENT PROCEDURES................................................................................................... 371 COOLANT LEAK CHECKING....................................................................................................... 371 RADIATOR CAP VALVE OPENING PRESSURE CHECKING................................................................................ 372 COOLANT REPLACEMENT......................................................................................................... 372 CONCENTRATION MEASUREMENT................................................................................................... 373 COOLANT INSPECTION.......................................................................................................... 374 THERMOSTAT CHECKING......................................................................................................... 374 WATER PUMP...................................................................................................................... 375 RADIATOR........................................................................................................................ 376 INTAKE AND EXHAUST.................................................................................................................. 379 SPECIFICATIONS.................................................................................................................. 380 GENERAL SPECIFICATIONS...................................................................................................... 380 SERVICE SPECIFICATIONS...................................................................................................... 380 SERVICE ADJUSTMENT PROCEDURES................................................................................................... 380 VARIABLE INDUCTION CONTROL SYSTEM INSPECTION <Vehicles built up to November, 1991>.......................................... 380 INTAKE MANIFOLD VACUUM INSPECTION........................................................................................... 382 INTAKE MANIFOLD................................................................................................................. 383 EXHAUST MANIFOLD................................................................................................................ 388 EXHAUST PIPE AND MAIN MUFFLER................................................................................................... 392 ENGINE ELECTRICAL................................................................................................................... 393 CHARGING SYSTEM................................................................................................................. 396 SPECIFICATIONS.............................................................................................................. 396 GENERAL SPECIFICATIONS.................................................................................................. 396 SERVICE SPECIFICATIONS.................................................................................................. 396 SPECIAL TOOLS............................................................................................................... 396 SERVICE ADJUSTMENT PROCEDURES............................................................................................... 397 VOLTAGE DROP TEST OF ALTERNATOR OUTPUT LINE............................................................................. 397 OUTPUT CURRENT TEST..................................................................................................... 398 REGULATED VOLTAGE TEST.................................................................................................. 400 INSPECTION USING AN ANALYZER............................................................................................ 403 ALTERNATOR <SOHC>........................................................................................................... 405 ALTERNATOR <DOHC>........................................................................................................... 406 STARTING SYSTEM................................................................................................................. 407 SPECIFICATIONS.............................................................................................................. 407 GENERAL SPECIFICATIONS.................................................................................................. 407 SERVICE ADJUSTMENT PROCEDURES............................................................................................... 407 STARTER RELAY INSPECTION <VEHICLES WITH THEFT-ALARM SYSTEM>............................................................. 407 IGNITION SYSTEM................................................................................................................. 409 SPECIFICATIONS.............................................................................................................. 409 GENERAL SPECIFICATIONS.................................................................................................. 409 SERVICE SPECIFICATIONS.................................................................................................. 410 SPECIAL TOOLS............................................................................................................... 410 SERVICE ADJUSTMENT PROCEDURES <SOHC> ....................................................................................... 410 IGNITION COIL INSPECTION................................................................................................ 410 POWER TRANSISTOR INSPECTION............................................................................................. 411 RESISTIVE CODE INSPECTION............................................................................................... 411 CHECKING THE DETONATION SENSOR.......................................................................................... 411 SPARK PLUG CHECK AND CLEANING........................................................................................... 412 INSPECTION USING AN ANALYZER (SECONDARY AND PRIMARY IGNITION VOLTAGE WAVEFORMS)......................................... 413 SERVICE ADJUSTMENT PROCEDURES <DOHC>........................................................................................ 421 IGNITION COIL INSPECTION................................................................................................ 421 POWER TRANSISTOR INSPECTION............................................................................................. 421 RESISTIVE CODE INSPECTION............................................................................................... 422 CHECKING THE DETONATION SENSOR.......................................................................................... 423 SPARK PLUG CHECK........................................................................................................ 423 INSPECTION USING AN ANALYZER (SECONDARY AND PRIMARY IGNITION VOLTAGE WAVEFORMS)......................................... 424 CRANK ANGLE SENSOR AND CAMSHAFT POSITION SENSOR ............................................................................ 429 EMISSION CONTROL.................................................................................................................... 430 SPECIFICATIONS.................................................................................................................. 431 GENERAL SPECIFICATIONS...................................................................................................... 431 SERVICE SPECIFICATIONS...................................................................................................... 431 SEALANTS AND ADHESIVE....................................................................................................... 431 SERVICE ADJUSTMENT PROCEDURES................................................................................................... 432 EMISSION CONTROL DEVICE REFERENCE TABLE..................................................................................... 432 COMPONENT LAYOUT <SOHC>..................................................................................................... 433 VACUUM HOSE PIPING DIAGRAM <SOHC - Vehicles built up to November, 1992>..................................................... 437 VACUUM HOSE LAYOUT <SOHC, DOHC - except vehicles with TCL - Vehicles built up to November, 1992> ........................... 444 CAUTIONS ON INSPECTION...................................................................................................... 447 CRANKCASE EMISSION CONTROL SYSTEM........................................................................................... 447 EVAPORATIVE EMISSION CONTROL SYSTEM......................................................................................... 449 EXHAUST EMISSION CONTROL SYSTEM <Vehicles built from December, 1992>........................................................ 453 CATALYTIC CONVERTER............................................................................................................. 456 CLUTCH.............................................................................................................................. 457 SPECIFICATIONS.................................................................................................................. 458 GENERAL SPECIFICATIONS...................................................................................................... 458 SERVICE SPECIFICATIONS...................................................................................................... 458 LUBRICANTS.................................................................................................................. 458 SERVICE ADJUSTMENT PROCEDURES................................................................................................... 459 CLUTCH PEDAL INSPECTION AND ADJUSTMENT...................................................................................... 459 BLEEDING.................................................................................................................... 460 CLUTCH PEDAL.................................................................................................................... 461 CLUTCH MASTER CYLINDER.......................................................................................................... 466 MANUAL TRANSMISSION................................................................................................................. 467 SPECIFICATIONS.................................................................................................................. 468 GENERAL SPECIFICATIONS...................................................................................................... 468 SERVICE SPECIFICATIONS...................................................................................................... 468 LUBRICANTS.................................................................................................................. 468 SPECIAL TOOLS................................................................................................................... 468 SERVICE ADJUSTMENT PROCEDURES................................................................................................... 469 OIL LEVEL CHECK............................................................................................................. 469 CHANGING OIL................................................................................................................ 469 SPEEDOMETER CABLE REPLACEMENT............................................................................................... 469 TRANSMISSION CONTROL............................................................................................................ 471 SHIFT LEVEL ASSEMBLY............................................................................................................ 473 TRANSMISSION ASSEMBLY........................................................................................................... 474 AUTOMATIC TRANSMISSION.............................................................................................................. 479 GENERAL INFORMATION............................................................................................................. 481 SPECIFICATIONS.................................................................................................................. 491 GENERAL SPECIFICATIONS...................................................................................................... 491 SERVICE SPECIFICATIONS...................................................................................................... 491 LUBRICANTS.................................................................................................................. 491 SPECIAL TOOLS................................................................................................................... 492 TROUBLESHOOTING................................................................................................................. 493 SERVICE ADJUSTMENT PROCEDURES................................................................................................... 509 TRANSMISSION FLUID LEVEL INSPECTION......................................................................................... 509 TRANSMISSION FLUID REPLACEMENT.............................................................................................. 510 READ OUT OF MALFUNCTION CODE................................................................................................ 511 SHIFT PATTERNS.............................................................................................................. 521 CONVERTER STALL TEST........................................................................................................ 527 OIL PRESSURE TEST........................................................................................................... 528 ACTUATOR TEST............................................................................................................... 532 KICKDOWN SERVO ADJUSTMENT................................................................................................... 532 LINE PRESSURE ADJUSTMENT.................................................................................................... 533 REDUCING PRESSURE ADJUSTMENT................................................................................................ 535 THROTTLE-POSITION SENSOR ADJUSTMENT......................................................................................... 538 ACCELERATOR PEDAL SWITCH INSPECTION AND ADJUSTMENT.......................................................................... 538 SELECTOR LEVEL OPERATION CHECK.............................................................................................. 538 INHIBITOR SWITCH AND CONTROL CABLE ADJUSTMENT............................................................................... 539 SPEEDOMETER CABLE REPLACEMENT............................................................................................... 540 TRANSMISSION CONTROL............................................................................................................ 541 SELECTOR LEVER ASSEMBLY......................................................................................................... 543 TRANSMISSION OIL COOLER HOSES................................................................................................... 545 TRANSMISSION ASSEMBLY........................................................................................................... 547 FRONT AXLE.......................................................................................................................... 551 SPECIFICATIONS.................................................................................................................. 552 GENERAL SPECIFICATIONS...................................................................................................... 552 SERVICE SPECIFICATIONS...................................................................................................... 552 LUBRICANTS.................................................................................................................. 552 SPECIAL TOOLS................................................................................................................... 553 SERVICE ADJUSTMENT PROCEDURES................................................................................................... 555 HUB END PLAY INSPECTION..................................................................................................... 555 AXLE HUB........................................................................................................................ 556 DRIVE SHAFT..................................................................................................................... 562 REAR AXLE........................................................................................................................... 573 SPECIFICATIONS.................................................................................................................. 574 GENERAL SPECIFICATIONS...................................................................................................... 574 SERVICE SPECIFICATIONS...................................................................................................... 574 SERVICE ADJUSTMENT PROCEDURES................................................................................................... 574 WHEEL BEARING END PLAY INSPECTION........................................................................................... 574 REAR HUB ROTARY-SLIDING RESISTANCE (TORQUE) ADJUSTMENT...................................................................... 575 REAR AXLE HUB................................................................................................................... 575 WHEEL AND TYRE...................................................................................................................... 577 SPECIFICATIONS.................................................................................................................. 578 GENERAL SPECIFICATIONS...................................................................................................... 578 SERVICE SPECIFICATIONS...................................................................................................... 578 TROUBLESHOOTING................................................................................................................. 579 SERVICE ADJUSTMENT PROCEDURES................................................................................................... 580 TYRE INFLATION PRESSURE CHECK............................................................................................... 580 TYRE WEAR CHECK............................................................................................................. 580 WHEEL RUNOUT CHECK.......................................................................................................... 580 POWER PLANT MOUNT................................................................................................................... 581 SPECIFICATIONS.................................................................................................................. 582 SERVICE SPECIFICATIONS...................................................................................................... 582 SPECIAL TOOLS................................................................................................................... 582 ENGINE MOUNTING................................................................................................................. 583 TRANSMISSION MOUNTING........................................................................................................... 584 ENGINE ROLL STOPPER AND ENGINE DAMPER........................................................................................... 585 RIGHTMEMBER, LEFTMEMBER AND CROSSMEMBER......................................................................................... 586 FRONT SUSPENSION.................................................................................................................... 589 SPECIFICATIONS.................................................................................................................. 590 GENERAL SPECIFICATIONS...................................................................................................... 590 SERVICE SPECIFICATIONS...................................................................................................... 590 SPECIAL TOOLS................................................................................................................... 591 SERVICE ADJUSTMENT PROCEDURES................................................................................................... 592 FRONT WHEEL ALIGNMENT INSPECTION AND ADJUSTMENT............................................................................. 592 STRUT ASSEMBLY.................................................................................................................. 593 LOWER ARM....................................................................................................................... 596 STABILIZER BAR.................................................................................................................. 598 ACTIVE-ELECTRONIC CONTROL SUSPENSION................................................................................................ 600 SPECIFICATIONS.................................................................................................................. 603 GENERAL SPECIFICATIONS...................................................................................................... 603 SERVICE SPECIFICATIONS...................................................................................................... 604 SPECIAL TOOLS................................................................................................................... 605 TROUBLESHOOTING................................................................................................................. 607 SERVICE ADJUSTMENT PROCEDURES................................................................................................... 694 ALARM LAMP CHECK............................................................................................................ 694 SYSTEM CHECKING BY USING ALARM LAMP......................................................................................... 694 CHECKING BY SELF-DIAGNOSIS.................................................................................................. 694 ROLLING DIAPHRAGM CHECKING.................................................................................................. 696 SYSTEM OPERATION CHECK...................................................................................................... 696 LOW-PRESSURE SWITCH (LOW-PRESSURE TANK SIDE) ACTUATION PRESSURE CHECK....................................................... 698 HIGH-PRESSURE SWITCH (HIGH-PRESSURE TANK SIDE) ACTUATION PRESSURE CHECK..................................................... 701 G-SENSOR OUTPUT VOLTAGE CHECK............................................................................................... 702 STRUT ASSEMBLY.................................................................................................................. 703 LOWER ARM....................................................................................................................... 708 SHOCK ABSORBER ASSEMBLY......................................................................................................... 710 RESERVE TANK ASSEMBLY (FRONT)................................................................................................... 714 RESERVE TANK ASSEMBLY (REAR).................................................................................................... 716 AIR COMPRESSOR ASSEMBLY......................................................................................................... 717 SOLENOID VALVE AND DRYER........................................................................................................ 719 AIR TUBE........................................................................................................................ 725 HEIGHT SENSOR................................................................................................................... 727 ACTIVE-ECS SENSOR AND SWITCH.................................................................................................... 730 CONTROL UNIT.................................................................................................................... 731 ACTIVE-ECS RELAY................................................................................................................ 732 REAR SUSPENSION..................................................................................................................... 734 SPECIFICATIONS.................................................................................................................. 735 GENERAL SPECIFICATIONS...................................................................................................... 735 SERVICE SPECIFICATIONS...................................................................................................... 735 SPECIAL TOOLS................................................................................................................... 736 SERVICE ADJUSTMENT PROCEDURES................................................................................................... 737 WHEEL ALIGNMENT INSPECTION AND ADJUSTMENT................................................................................... 737 REAR SUSPENSION ASSEMBLY <Vehicles not equipped with 4WS>....................................................................... 738 REAR SUSPENSION ASSEMBLY <Vehicles equipped with 4WS>.......................................................................... 740 UPPER ARM, LOWER ARM AND ASSIST LINK............................................................................................ 741 TRAILING ARM.................................................................................................................... 743 SHOCK ABSORBER ASSEMBLY......................................................................................................... 745 STABILIZER BAR.................................................................................................................. 747 SERVICE BRAKES...................................................................................................................... 749 SPECIFICATIONS.................................................................................................................. 750 GENERAL SPECIFICATIONS...................................................................................................... 750 SERVICE SPECIFICATIONS...................................................................................................... 751 LUBRICANTS.................................................................................................................. 752 SEALANTS AND ADHESIVES...................................................................................................... 752 SPECIAL TOOLS................................................................................................................... 752 ANTI-LOCK BRAKE SYSTEM TROUBLESHOOTING.......................................................................................... 753 SERVICE ADJUSTMENT PROCEDURES................................................................................................... 833 BRAKE PEDAL INSPECTION AND ADJUSTMENT....................................................................................... 833 BRAKE BOOSTER OPERATING TEST................................................................................................ 833 CHECK VALVE OPERATION CHECK................................................................................................. 834 PROPORTIONING VALVE FUNCTION TEST........................................................................................... 834 BRAKE FLUID LEVEL SENSOR CHECK.............................................................................................. 835 BLEEDING.................................................................................................................... 835 FRONT DISC BRAKE PAD CHECK AND REPLACEMENT.................................................................................. 836 FRONT DISC BRAKE ROTOR INSPECTION........................................................................................... 838 THICKNESS CHECK............................................................................................................. 840 REAR DISC BRAKE PAD CHECK AND REPLACEMENT................................................................................... 840 REAR BRAKE DISC THICKNESS CHECK............................................................................................. 842 REAR BRAKE DISC RUN-OUT CHECK............................................................................................... 842 REAR BRAKE DISC RUN-OUT CORRECTION.......................................................................................... 842 BRAKE LINING THICKNESS CHECK................................................................................................ 843 BRAKE DRUM INSIDE DIAMETER CHECK............................................................................................ 843 BRAKE LINING AND BRAKE DRUM CONNECTION CHECK................................................................................ 843 CHECKING OPERATION OF THE ABS (ANTI-LOCK BRAKING SYSTEM).................................................................... 844 BRAKE PEDAL..................................................................................................................... 856 MASTER CYLINDER AND BRAKE BOOSTER............................................................................................... 858 BRAKE LINE...................................................................................................................... 861 FRONT DISC BRAKE................................................................................................................ 868 REAR DISC BRAKE................................................................................................................. 874 HYDRAULITIC UNIT <VEHICLES WITH A.B.S.>......................................................................................... 878 WHEEL SPEED SENSOR <VEHICLES WITH A.B.S.>....................................................................................... 883 ELECTRONIC CONTROL UNIT <VEHICLES WITH A.B.S.>.................................................................................. 886 PARKING BRAKES...................................................................................................................... 888 SPECIFICATIONS.................................................................................................................. 889 GENERAL SPECIFICATIONS...................................................................................................... 889 SERVICE SPECIFICATIONS...................................................................................................... 889 LUBRICANTS.................................................................................................................. 889 SEALANTS.................................................................................................................... 889 SERVICE ADJUSTMENT PROCEDURES................................................................................................... 889 PARKING BRAKE LEVER STROKE CHECK............................................................................................ 889 PARKING BRAKE SWITCH CHECK.................................................................................................. 890 LINING RUNNING-IN........................................................................................................... 891 PARKING BRAKE LEVER AND PARKING BRAKE CABLE..................................................................................... 893 PARKING BRAKE DRUM.............................................................................................................. 896 STEERING............................................................................................................................ 899 SPECIFICATIONS.................................................................................................................. 902 GENERAL SPECIFICATIONS...................................................................................................... 902 SERVICE SPECIFICATIONS...................................................................................................... 902 LUBRICANTS.................................................................................................................. 905 SEALANT AND ADHESIVES....................................................................................................... 905 SPECIAL TOOLS............................................................................................................... 907 TROUBLESHOOTING <E.P.S.>........................................................................................................ 911 SERVICE ADJUSTMENT PROCEDURES................................................................................................... 926 STEERING ADJUSTMENT PROCEDURES.............................................................................................. 926 STEERING ANGLE CHECK........................................................................................................ 926 TIE ROD END BALL JOINT VARIATION CHECK (SHAFT DIRECTION).................................................................... 926 TIE ROD BALL JOINT STARTING TORQUE CHECK.................................................................................... 927 STATIONARY STEERING EFFORT CHECK............................................................................................ 927 CHECKING STEERING WHEEL RETURN TO CENTRE.................................................................................... 931 E.P.S. SOLENOID CHECK....................................................................................................... 931 V-BELT TENSION CHECK........................................................................................................ 935 FLUID LEVEL CHECK........................................................................................................... 936 FLUID REPLACEMENT........................................................................................................... 937 BLEEDING.................................................................................................................... 937 OIL PUMP PRESSURE TEST...................................................................................................... 938 POWER STEERING OIL PRESSURE SWITCH CHECK.................................................................................... 939 STEERING WHEEL AND SHAFT........................................................................................................ 940 POWER STEERING GEAR BOX......................................................................................................... 946 POWER STEERING OIL PUMP......................................................................................................... 960 POWER STEERING HOSES............................................................................................................ 965 E.P.S. CONTROL UNIT............................................................................................................. 968 4-WHEEL STEERING SYSTEM (4WS)....................................................................................................... 969 SPECIFICATIONS.................................................................................................................. 970 GENERAL SPECIFICATIONS...................................................................................................... 970 SERVICE SPECIFICATIONS...................................................................................................... 970 SPECIAL TOOLS................................................................................................................... 971 TROUBLESHOOTING................................................................................................................. 972 SERVICE ADJUSTMENT PROCEDURES................................................................................................... 973 BLEEDING.................................................................................................................... 973 FUNCTION CHECK.............................................................................................................. 974 REAR OIL PUMP DISCHARGE FLOW VOLUME CHECK................................................................................... 974 BALL JOINT ROTATION STARTING TORQUE CHECK................................................................................... 974 POWER CYLINDER.................................................................................................................. 975 CONTROL VALVE................................................................................................................... 978 REAR OIL LINE................................................................................................................... 979 REAR OIL PUMP................................................................................................................... 980 BODY................................................................................................................................ 981 SPECIFICATIONS.................................................................................................................. 983 GENERAL SPECIFICATIONS...................................................................................................... 983 SERVICE SPECIFICATIONS...................................................................................................... 984 SEALANT AND ADHESIVE........................................................................................................ 984 SPECIAL TOOLS................................................................................................................... 985 TROUBLESHOOTING <SUNROOF>....................................................................................................... 986 SERVICE ADJUSTMENT PROCEDURES................................................................................................... 991 HOOD ALIGNMENT ADJUSTMENT................................................................................................... 991 TRUNK LID ADJUSTMENT........................................................................................................ 991 FUEL FILLER DOOR ADJUSTMENT................................................................................................. 992 DOOR GLASS ADJUSTMENT....................................................................................................... 992 WATER TEST.................................................................................................................. 993 SUNROOF FIT ADJUSTMENT...................................................................................................... 993 HOOD............................................................................................................................ 995 TRUNK LID....................................................................................................................... 998 FUEL TANK FILLER DOOR...........................................................................................................1001 FENDER..........................................................................................................................1002 WINDSHIELD GLASS................................................................................................................1004 QUARTER WINDOW GLASS............................................................................................................1015 REAR WINDOW GLASS...............................................................................................................1016 DOOR ASSEMBLY...................................................................................................................1022 DOOR TRIM AND WATERPROOF FILM...................................................................................................1025 DOOR GLASS AND REGULATOR........................................................................................................1026 DOOR HANDLE AND LATCH...........................................................................................................1031 DOOR RUNCHANNEL.................................................................................................................1044 DOOR MOULDING AND DRIP LINE WEATHERSTRIP........................................................................................1045 SUNROOF.........................................................................................................................1046 EXTERIOR............................................................................................................................1053 SPECIFICATIONS..................................................................................................................1054 GENERAL SPECIFICATIONS......................................................................................................1054 SERVICE SPECIFICATIONS......................................................................................................1055 SPECIAL TOOLS...................................................................................................................1055 FRONT BUMPER....................................................................................................................1056 REAR BUMPER.....................................................................................................................1060 GRILLES.........................................................................................................................1062 GARNISHES AND MOULDINGS.........................................................................................................1065 AERO PARTS......................................................................................................................1069 MUD GUARD.......................................................................................................................1072 WINDSHIELD WIPER AND WASHER.....................................................................................................1073 REAR WIPER AND WASHER...........................................................................................................1089 HEADLAMP WASHER.................................................................................................................1092 DOOR MIRROR.....................................................................................................................1095 INTERIOR............................................................................................................................1096 SPECIFICATIONS..................................................................................................................1097 GENERAL SPECIFICATIONS......................................................................................................1097 SERVICE SPECIFICATIONS......................................................................................................1097 ADHESIVE....................................................................................................................1097 SPECIAL TOOLS...................................................................................................................1098 INSTRUMENT PANEL................................................................................................................1098 FLOOR CONSOLE...................................................................................................................1105 TRIMS...........................................................................................................................1105 HEADLINING......................................................................................................................1107 INSIDE REAR VIEW MIRROR.........................................................................................................1108 FRONT SEAT......................................................................................................................1109 REAR SEAT.......................................................................................................................1119 FRONT SEAT BELT.................................................................................................................1121 REAR SEAT BELT..................................................................................................................1122 SUPPLEMENTAL RESTRAINT SYSTEM (SRS).................................................................................................1124 GENERAL INFORMATION <Vehicles without front passenger's air bag>................................................................1125 CONSTRUCTION DIAGRAM........................................................................................................1125 GENERAL INFORMATION <Vehicles with front passenger's air bag>...................................................................1126 CONSTRUCTION DIAGRAM........................................................................................................1126 SRS SERVICE PRECAUTIONS.........................................................................................................1127 SPECIFICATIONS..................................................................................................................1132 SERVICE SPECIFICATIONS......................................................................................................1132 SPECIAL TOOLS AND TEST EQUIPMENT................................................................................................1132 TROUBLESHOOTING.................................................................................................................1135 SRS DOAGNOSTIC PROCEDURES - INITIAL STOPS...................................................................................1135 DIAGNOSTIC SEQUENCE.........................................................................................................1136 SRS MAINTENANCE.................................................................................................................1194 POST-COLLISION DIAGNOSIS........................................................................................................1199 INDIVIDUAL COMPONENT SERVICE....................................................................................................1203 WARNING/CAUTION LABELS......................................................................................................1203 FRONT IMPACT SENSOR.............................................................................................................1205 SRS DIAGNOSIS UNIT (SDU)........................................................................................................1207 AIR BAG MODULE AND CLOCK SPRING.................................................................................................1215 AIR BAG MODULE DISPOSAL PROCEDURES..............................................................................................1231 UNDEPLOYED AIR BAG MODULE DISPOSAL..........................................................................................1231 DEPLOYED AIR BAG MODULE DISPOSAL PROCEDURES.................................................................................1238 CHASSIS ELECTRICAL..................................................................................................................1239 BATTERY.........................................................................................................................1241 SPECIFICATION...............................................................................................................1241 SERVICE ADJUSTMENT PROCEDURES...............................................................................................1241 IGNITION SWITCH.................................................................................................................1243 SPECIAL TOOLS...............................................................................................................1243 TROUBLESHOOTING ............................................................................................................1244 IGNITION SWITCH.............................................................................................................1251 METERS AND GAUGES...............................................................................................................1255 SPECIFICATIONS..............................................................................................................1255 SERVICE ADJUSTMENT PROCEDURES...............................................................................................1256 COMBINATION METER...........................................................................................................1260 INDICATORS AND WARNING LAMPS................................................................................................1262 LIGHTING SYSTEM.................................................................................................................1263 SPECIFICATIONS..............................................................................................................1263 SPECIAL TOOLS...............................................................................................................1263 TROUBLESHOOTING ............................................................................................................1264 SERVICE ADJUSTMENT PROCEDURES...............................................................................................1271 HEADLAMP AND FRONT TURN SIGNAL LAMP.........................................................................................1278 FRONT FOG LAMP..............................................................................................................1281 REAR COMBINATION LAMP.......................................................................................................1282 REAR LID LAMP...............................................................................................................1284 ROOM LAMP...................................................................................................................1284 HIGH MOUNTED STOP LAMP......................................................................................................1285 RELAY.......................................................................................................................1286 RESISTOR <R.H. Drive Vehicle>...............................................................................................1287 SWITCH......................................................................................................................1288 RHEOSTAT....................................................................................................................1289 LIGHTING MONITOR BUZZER.....................................................................................................1290 COLUMN SWITCH...................................................................................................................1291 SPECIAL TOOLS...............................................................................................................1291 COLUMN SWITCH ..............................................................................................................1291 HORN............................................................................................................................1295 HORN SWITCH.................................................................................................................1295 HORN RELAY..................................................................................................................1295 AUDIO SYSTEM....................................................................................................................1297 TROUBLESHOOTING.............................................................................................................1297 RADIO AND TAPE PLAYER.......................................................................................................1319 DOOR SPEAKER................................................................................................................1319 MOTOR ANTENNA AND ANTENNA FEEDER CABLE......................................................................................1320 REAR WINDOW DEFOGGER............................................................................................................1323 SPECIAL TOOLS...............................................................................................................1323 TROUBLESHOOTING.............................................................................................................1324 SERVICE ADJUSTMENT PROCEDURES...............................................................................................1330 REAR WINDOW DEFOGGER SWITCH.................................................................................................1330 REAR WINDOW DEFOGGER RELAY..................................................................................................1330 SWS (Simplified Wiring System)..................................................................................................1332 TROUBLESHOOTING.............................................................................................................1332 THEFT-ALARM SYSTEM..............................................................................................................1339 SPECIAL TOOLS...............................................................................................................1339 TROUBLESHOOTING.............................................................................................................1340 HEATER, AIR CONDITIONER AND VENTILATION.............................................................................................1353 SPECIFICATIONS..................................................................................................................1356 GENERAL SPECIFICATIONS......................................................................................................1356 SERVICE SPECIFICATIONS......................................................................................................1356 LUBRICANTS..................................................................................................................1357 SEALANT.....................................................................................................................1357 SPECIAL TOOLS...................................................................................................................1357 TROUBLESHOOTING.................................................................................................................1358 SAFETY PRECAUTIONS..............................................................................................................1381 SERVICE ADJUSTMENT PROCEDURES...................................................................................................1384 TEST PROCEDURES.............................................................................................................1384 COMPRESSOR DRIVE BELT ADJUSTMENT............................................................................................1386 CHARGING PROCEDURES <Vehicles using R-12 refrigerant>.......................................................................1387 CHARGING THE REFRIGERANT <Vehicles using R-12 refrigerant>..................................................................1389 CHARGING <Vehicle using R-134a refrigerant>.................................................................................1394 PERFORMANCE TEST............................................................................................................1398 REFRIGERANT LEAK REPAIR PROCEDURE...........................................................................................1400 HANDLING TUBING AND FITTINGS................................................................................................1401 COMPRESSOR NOISE............................................................................................................1401 INSPECTION OF ENGINE COOLANT TEMPERATURE SWITCHES FOR CONDENSER FAN <VEHICLES WITH AIR CONDITIONER> AND FOR RADIATOR FAN....1402 POWER RELAY CHECK...........................................................................................................1403 IDLE-UP OPERATION CHECK.....................................................................................................1404 AIR CONDITIONER CONTROL PANEL ASSEMBLY..........................................................................................1405 A/C CONTROL UNIT................................................................................................................1409 POWER TRANSISTOR, BELT LOCK CONTROLLER..........................................................................................1409 HEATER UNIT.....................................................................................................................1410 DAMPER CONTROL MOTOR ASSEMBLY...................................................................................................1411 SENSOR..........................................................................................................................1414 BLOWER ASSEMBLY.................................................................................................................1418 EVAPORATOR......................................................................................................................1419 COMPRESSOR......................................................................................................................1422 CONDENSER AND CONDENSER FAN MOTOR...............................................................................................1432 REFRIGERANT LINE................................................................................................................1434 VENTILATORS (INSTRUMENT PANEL FLOOR)............................................................................................1438 VENTILATORS (AIR INLET AND AIR OUTLET)..........................................................................................1441
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S.S 08/24
