Service Manual
Contents
1. mark for an identification purpose Be certain to replace these parts with new ones during the assembly 3 During the assembly be sure to apply grease to those parts indicated by the mark in the figure Example Non reusable parts Tightening torque Unit N m CD Power steering pump drive belt 2 V ribbed belt 3 Water pump pulley 4 Water pump Assy 5 Water pump gasket JGI00003 00001 2 Servicing Procedure 1 In principle the servicing procedure is described in the following sequence given below Removal Inspection Installation and Disassembly Inspection Assembly 2 The explanation covers detailed servicing methods specifications and notes 3 The main point of each item explains the servicing section and servicing procedure using illustra tions Example What to do DISASSEMBLY What to do and where 1 Remove the alternator pulley lock nut by means of an impact wrench while holding the shaft by using a hexagonal box wrench NOTE sure to use an impact wrench having a hexag onal hole JGI00004 00002 GI 5 4 The inspection in this manual describes only checking operation Therefore if you find any malfunc tion replace any defective parts with new ones SST For those operations which require the use of any SST the SST numbers concerned are given in bold letters Service Specificati2. TO INDEX GENERAL INFORMATION IMPORTANT SAFETY NOTICE 01 2 HOW TO USE THIS MANUAL 01 4 ABBREVIATION CODES GI 6 GENERAL SERVICE INSTRUCTION GI 8 ENGINE NUMBER AND ENGINE TYPE STAMPED POSITIONS GI 9 JGI00001 00000 2 IMPORTANT SAFETY NOTICE The vehicle is a machine comprising a great number of parts Basically speaking the vehicle is po tentially hazard However one can handle it safely if he has the required knowledge Correct service methods and repair procedures are very vital for assuring not only the safety and re liability of a vehicle but also the safety of service personnel concerned The methods and procedures contained in this manual describe in a general way the techniques which the manufacturer has recommended Thus they will contribute to ensuring the reliability of the products The contents of the servicing operations come in a wide variety of ways Moreover techniques tools and parts necessary for each operation are different widely from each other This manual does not cover all details of techniques procedures parts tools and handling instruc tions which are necessary for these operations for such coverage is impossible Hence any one who obtains this manual is expected first to make his responsible selection as to techniques tools and parts which are necessary for servicin
3. terminal of the battery be sure to reset the watch or radio if the vehicle is equipped with such equipment 2 When it becomes necessary to disconnect the battery power supply for the purpose of carrying out checks or repairs always disconnect the negative terminal of the battery ground cable from the negative terminal of the battery first 3 To avoid damaging battery plates after the terminal nut has been loosened pull out the battery ground cable terminal straight upward rather than turning or prying the terminal NOTE e Be sure to employ a battery terminal puller commercially available to remove the battery ground cable terminal from the negative terminal of the battery if any difficulty is encountered 4 Clean the battery terminal posts or battery ground terminals using a cloth Never use a file or other adhesive agents 5 When connecting the battery ground cable terminal to the battery first the battery ground cable ter minal should be fitted onto the battery post with the attaching nut in a loose state Then tighten the nut Never tap the terminal onto the battery post using a hammer a spanner wrench or the like 6 As for the cover at the positive terminal side be sure to install it at the correct position 4 Repairing of fuel system 1 EFl equipped vehicles employ a high fuel pressure Therefore the following notes should be observed D Be sure to prevent the fuel from splashing with a cloth o
4. g the vehicle concerned properly Furthermore he must assume responsibility for his actions in connection with his own safety Therefore one should not perform any service if he is not capable of making responsible selection and or if he can not understand the contents herein described for this manual has been prepared for experienced service personnel WARNINGS CAUTIONS AND NOTES All these symbols have their specific purposes respectively WARNING e This symbol means that there is the possibility of personal injury of the operator himself or the nearby workers if the operator fails to follow the operating procedure prescribed in this manu al CAUTION e This symbol means that there is the possibility of damage to the component being repaired if the operator fails to follow the operating procedure prescribed in this manual NOTE e To accomplish the operation in an efficient manner additional instructions concerning the op eration are given in this section The list describes general WARNINGS Always wear safety glasses for eye protection Use safety stands whenever a procedure requires you to be under the vehicle Be sure that the ignition switch is always in the OFF position unless otherwise required by the procedure Set the parking brake when working on the vehicle Operate the engine only in a well ventilated area to avoid the danger of carbon monoxide Keep yourself and your clothing away from moving parts when the engine
5. is running espe cially from the fan and belts To prevent serious burns avoid contact with hot metal parts such as the radiator exhaust manifold tail pipe catalytic converter and muffler Do not smoke while working on a vehicle To avoid injury always remove rings watches loose hanging jewelry and loose clothing be fore beginning to work on a vehicle Keep hands and other objects clear of the radiator fan blades The electric cooling fan is mounted on the radiator and can start to operate at anytime by a rise in coolant temperature GI 3 or turning ON of the air conditioner switch in the case of vehicles equipped with an air condi tioner The electric cooling fan is also mounted on the condenser for air conditioner and starts to operate anytime when the air conditioner switch is turned ON For this reason care should be taken to ensure that the electric cooling fan motor is completely disconnected when work ing under the hood The UNITS used in this manual are showed as the SI UNIT International System of Unit Example 24 5 34 3 JGI00002 00000 4 HOW USE THIS MANUAL CONTENTS OF EXPLANATION 1 Schematic Diagram of Components 1 The schematic diagram of components that appears at the beginning of each section describes the nomenclature and installed conditions of each component Furthermore the tightening torque is posted in the figure 2 Those parts whose reuse is not permitted bear a
6. ons Service specifications are indicated in bold letters or enclosed by heavy lines Be certain to confirm the specifications concerned Tightening Torque For those operations which require the control of tightening torque the relevant tightening torque is given in bold letters Be certain to confirm the tightening torque concerned Definitions of Terms Specified A value which represents the allowable range during the inspection and adjust ment t tacos A maximum or a minimum limit which the value should not exceed or fall below JGIOO0005 00000 GI 6 ABBREVIATION CODES The abbreviation codes that appear in this service manual stand for the following respectively Abbreviation code Original word Meaning ABS Anti lock Brake System Refers to anti lock brake system A C Air Conditioner Refers to air conditioner API American Petroleum The standards set forth by the American Petroleum Institute abbreviated as API Institute Classification have been employed to evaluate and classify properties of various oils Engine oils for gasoline engines are classified as SG SH SJ and so on whereas engine oils for diesel engines are classified as CC CD and so on Assy A Y or Ay Assembly Refers to an assembled component comprising more than two single parts or sub assembly parts AT Au
7. r the like when the union bolt or other connected section of the fuel line is loosened or slackened 2 When connecting disconnecting the fuel line D Tighten each connecting section to the specified torque 2 Attach new specified clips to each connecting section 3 Be certain to place a suitable container a cloth etc under the connected section of the fuel line before disconnecting the fuel line 4 Before the fuel line is disconnected be sure to release the inner pressure of the fuel tank by de taching the fuel filler cap 3 Do not work near open flames 5 For increased work efficiency and improved accuracy be sure to utilize the SSTs Special Service Tools effectively JGI00008 00000 ENGINE NUMBER AND ENGINE STAMPED POSITIONS e The engine number is stamped on the cylinder block e The engine type is indicated by embossed letters on the cylinder block B Engine number 1 JGI00009 00003 TO INDEX TO NEXT SECTION
8. time or due to frequent removal installation operations if the fitting part e g piston is replaced with a part having larger dimensions the other mating part may be put into use again Oversized parts denote those parts having larger dimensions compared with the standard parts OCV Oil Control Valve Refers to Oil Control Valve PCV Positive Crankcase Refers to positive crankcase ventilation Ventilation RH Right Hand Refers to right side 7 Abbreviation code Original word Meaning RHD R H D Right Hand Drive Right hand drive vehicle S A Sub Assembly Refers to a component comprising more than two single parts which are welded staked or studded to each other to form a single component SAE Society of Automotive For example automotive oils are designated as SAE so and so number Engineers These designation numbers have been set forth by the Society of Automotive Engineers in the United States of America SAE The larger the SAE number the higher the oil viscosity Conversely the smaller the SAE number the lower the oil viscosity Special Service Tool Refers to a tool designed for a specific purpose Standard When referring to automotive parts standard represents those parts which have been installed originally by the manufacturer and which have standard dimensions Torque Refers to tightening torque Top Dead Center Refers to top dead center Under Size In the same manner as
9. tomatic Transmission Refers to automatic transmission ATDC After Top Dead Center Refers to after top dead center BTDC Before Top Dead Refers to before top dead center Center CARB California Air Refers to California Air Resources Board Resources Board DLC Data Link Connector Has the same meaning as a check engine connector DLI Distributor Less Ignition Refers to distributor less ignition DTC Diagnostic Trouble Code Denotes a malfunction code DVVT Dynamic Variable Refers to Dynamic Variable Valve Timing Valve Timing ECU Electronic Control Unit Refers to electronic control unit EFI Electronic Fuel Injection Refers to electronic fuel injection ESA Electronic Spark Refers to electronic spark advance Advance EX Exhaust Refers to exhaust F L Fusible Link Refers to fusible link GND Ground Refers to body ground HC Hydro Carbon Refers to hydro carbon IGN Ignition Refers to ignition IN Intake Refers to intake ISC Idle Speed Control Refers to idle speed control ISO International Organization Refers to International Organization for Standardization for Standardization LH Left Hand Refers to left side LHD L H D Left Hand Drive Left hand drive vehicle MIL Malfunction Indicator Has the same meaning as a diagnosis lamp Lamp MT M T Manual Transmission Refers to manual transmission NOx Nitrogen Oxides Refers to nitrogen oxides O S Oversize In instances where fitting becomes too loose due to wear resulting from use for a long period of
10. with the oversized parts if fitting part e g bush and bearing is replaced with a part having smaller bore dimensions the other mating part may be put into use again Under sized parts denote those parts having smaller dimensions compared with standard parts Denotes that the following part is attached JGI00006 00000 The abbreviation codes that appear in the figure stand for the following respectively Bolt Screw Nut W Washer JGI00007 00000 GI 8 GENERAL SERVICE INSTRUCTION 1 Use fender covers seat covers and floor sheets so that the vehicle may not get dirty or be scratched 2 Jacking up 1 When only the front section or rear section of the vehicle is jacked up be sure to place chocks at the wheels so as to insure safe operations 2 When the vehicle has been jacked up be sure to support the vehicle at the specified section using the safety stands Refer to the relevant Chassis section in the manual for the vehicle concerned 3 Handling instructions related to battery 1 Before you start performing the electrical works make certain to disconnect the battery ground cable terminal from the negative terminal of the battery NOTE e Before disconnecting the battery ground cable terminal from the negative terminal of the battery be sure to read out the diagnosis code of the EFI system if it is equipped e After reconnecting the battery ground cable terminal to the negative
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