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1990 Talon Technical Information Manual (15 MB pdf file)

Contents

1. 13 LE n emanate wale s 9 2 ENGINE General Information GENERAL INFORMATION Rosp MAJOR SPECIFICATIONS 4 in line longitudinal Number and arrangement of cylinder 4 in line longitudinal Cylinder bore x stroke in Total displacement Compression ratio Combustion chamber Valve mechanism Number of valve Intake Exhaust Valve timing Intake Open Close Exhaust Open Close Lubrication Oil pump Fuel system Supercharger Cooling system Water pump Alternator Starter motor Ignition system Exhaust gas recirculation system Catalytic converter Crankcase ventilation system Evaporative emission control system 85 X 88 3 346 x 3 465 1997 121 9 9 0 Pentroof type Double overhead camshaft DOHC 26 BTDC 46 ABDC 55 BBDC S ATDC Pressure feed full flow filtration Gear type Electronic control multipoint fuel injection Liquid cooled forced circulation Impeller type AC generator with a built in voltage regulator Planetary gear reduction drive type Two coil type electronic control ignition Conventional type For Federal and Canada Electronical control type For California Monolithic type underfloor installation Closed type Charcoal canister type 85 x 88 3 346 x 3 465 1997 121 7 7 8 Pentroof type Double overhead camshaft DOHC
2. Canister ve dnce dati Fuel Check Valve Fuel Filler no A n d Overfill Limiter Two way Valve Purge Control Solenoid Valve Non TurbOo eee Epor Ni agii oa reitera con 11 14 14 14 Purge Control Solenoid Turbo sss Valve EXHAUST GAS RECIRCULATION EGR SYSTEM EGR Control Solenoid Val eene ve California EGR Control Valve s e RE dd EGR Temperature Sensor California Operation California Operation Federal Thermo Valve Federal GENERAL INFORMATION 25 2 GENERAL INFORMATION There are three sources of vehicle exhaust emis sions generated the exhaust gases resulting from combustion the blow by gases generated within the crankcase and the evaporative emissions generated from the fuel tank and other components of the fuel line The emissions control system which is designed to control the discharge of these exhaust gases into the atmosphere is composed of the following system components 1 Exhaust emission control system 2 Crankcase emission control system 3 Evaporative emission control system Non Turbo for Federal Air cleaner Air inlet Oxygen sensor Catalytic converter EMIS
3. 18 General Description UTERE 27 26 Selfdi E 30 Control Relay cecidi 515 Coolant Temperature Sensor 2b Crank Angle SensSot FUEL INJECTION CONTROL 33 Detonation amp ansn SETUP S ese edit 25 Fuel Injection Amount Control General Description mH mn 14 Injector Activation Duration Idle Position Switch mm 19 aac onerata et Ros 39 ignition Coil enne 26 Fuel Injection Timing Ignition Switch ir dreamed 24 Injector Activation Timing mmn 36 ignition Timing Adjustment Terminal 25 General Description 2222222 00000 33 inhibitor Switch gt 20 26 bend dett d 34 intake Air Temperature Sensor 17 Resistor turbo 2 36 Oxygen Sensor ten pn aq 21 Power Steering Oil Pressure Switch 24 FUEL SUPPLY AND FUEL PRESSURE Throttle Position Sensor 19 CONTROL 4 Vehicle Speed Sensor 22 9 Fuel pressure Control Valve Turbo 11 SUPERCHARGE PRESSURE CONTROL Fuel Pressure Regulator gt ECKE 9 Turbo Fuel PUMP nri 8 Fuel Pump Check Terminal 11 TURBO METER CONTROL Turbo seses 97 Fuel Tank nen 7 General Description
4. 32 INSPECTION TERMINAL _ 15 Operation ete Up aet eere 32 JUNCTION __ 5 Construction of Junction Block 5 ELECTRICAL Fuses FUSES MAIN FUSIBLE LINKS DIRECT TO BATTERY The main fusible links are the cartridge type and are directly mounted to the terminal of the battery No Circuit Housing Rated colour capacity A MPI circuit Bue 20 Radiator fan motor circuit Ignition switch circuit Pink SUB FUSIBLE LINKS RELAY BOX Subdivided into seven electrical circuits the sub fusible links function to protect the circuits the cartridge type fusible links are located in the relay box within the engine compartment No Circuit Housing Rated colour capacity Alternator circuit sub fusible link 2 9 9 Automatic seatbelt circuit dedicated fuse circuit Pop up circuit alternator circuit Headlight circuit dedicated fuse 1 8 circuit io wae pee n rat Ia ELECTRICAL Fuses 8 3 MULTI PURPOSE FUSES The multi purpose fuses are located within the junction block at the lower part of the instrument panel at the drivers seat side These fuses are all the blade type 1 O ampere 15 ampere and 30 ampere fuses are used apacity A Battery 10 Automatic seatbelt control unit
5. we le m 6FU1145 61 FUEL SYSTEM General 14 3 The fuel is supplied under pressure by the in tank type fuel pump and is injected from injectors into all C ders The injectors are activated by signals from the engine control unit and the amount of fuel injected is determined according to the driving conditions The intake air passes through the air flow sensor throttle body air intake plenum and intake manifold and finally enters the combustion chamber The air flow sensor detects the amount of air flow and converts this data to electric pulse signals that are EGR temperature sensor California Ignition coil Control relay Fuel pump drive signal Vehicle speed sensor Ignition switch ST terminal Ignition switch IG terminal Air conditioner switch Power steering switch Inhibitor switch lt A T gt temperature Sensor Fuel pressure E regulator 3 leturn t o uel tank dead center sensor Crank angle sensor Oxygen sensor a 9 eg 9 d idle 28 e spee Fast idle fontrol servo air valve ir 55 cleaner On sent to the engine control unit The crank angle sensor converts the crank angle that is engine turning state into an electric signal and sends it to the engine control unit The engine control unit based on these signals determines
6. 12 Exterior e teda 2 Theft alarm System Option for 4WD Vehicles ea A 8 0 2 GENERAL Technical Features TECHNICAL FEATURES ROOCAAB EXTERIOR Low and wide profile for appearance sports car impression 0040190 2 7 00A0189 No Features Flush surface and low front high rear styling for outstanding aerodynamic performance Pop up headlights of optical horn type Hood bulge indicating DOHC engine Futuristic glass upper body Removable tilt up sunroof option for all models Wide tires and wide tread to emphasize power and stability 3 4 5 6 Smooth integrated body lines giving a lean appearance 7 8 Bumpers made integral with the body 9 Wall to wall tail lamps for sporty image ee ee oe GENERAL Technical Features INTERIOR Features Cock pit type instrument panel to give sporty image Switches arranged around the driver seat for easy access and operation Hi back seats with integral head rest for comfortable and firm holding Integrally molded door trims with round and smooth transition to the instrument panel Sporty double seat with firm holding Rear quarter trims with built in dynamic speakers 00A0162 0 3 Easy to use large capacity console box 0 4 GENERAL Technical Features BASIC CONSTRUCTION driving aie bad de ee 227 independent suspension for comfortable riding T amp ave turb
7. TAD NG Ieee prone Mo o ELECTRICAL Lig htina 8 19 2 Lighting switch ON pop up switch OFF Fusible Ignition Fusipie Fusible nk 7 Switch ACC hnk hink Multi purpose 4 fuse ig Pop up motor R H switch UP stop position IHeadignis m the fully raised postion Pop up motor When the lighting switch is turned ON HEAD position current from fusible link 6 flows through the lighting switch diode and the up timer circuit of the passing control relay turning ON transistor Trl Then as in 1 the pop up motor relay is energized causing the pop up motor to start rotating which in turn results in the headlights being raised Turning ON HEAD position the lighting switch also ener gizes the headlight relay causing the headlights to be lit up 8 20 ELECTRICAL Lighting HEADLIGHT LOWERING OPERATION 1 Pop up switch from ON to OFF lighting switch OFF Ignition Fusible switch F Fusible ink ACC h link Q Multi purpose Mult fuse pu Q Q B Headignt B ji relay I QN Dimmer Lighting passing switch switch column column switch P switch Q Circun breaker telay DOWN stop position saos Headlights in the futly lowered position When the pop up switch is turned OFF from the ON position with the headlights in the raised position current from fusible link flo
8. 1052 E L25 9 re md aw Vehicle speed 15 c Sensor reed switch mies 145 Y 2 MPH NS Auto cruise control unit AUTOMATIC SEAT BELT Automatic seat belt control unit f Quarter panel Saat ber Automatic seat belt motor relay ru motor relay Ie Automatic seat b control unit ELECTRICAL Relays Control Units and Sensors HEATER AND AIR CONDITIONER Name S lt 4ir conditioner control unit n Air inlet sensor n Air thermo sensor Blower motor High relay O Condenser fan motor High Low selecting relay NOTE The Name column is arranged in alphabetical order Engine coolant temperature switch air conditioner Magnet clutch 4 22227 Condenser fan VS lr 7 motor relay 1640712 52 motor 2 Radiator fan motor relay 8 11 bol Name Symbol Condenser fan motor relay C Engine coolant temperature switch A Heater relay Magnet clutch relay 7 as Radiator fan motor relay aa m ER A 8 12 ELECTRICAL Relays Control Units and Sensors Den Air thermo X 78 sensor iw Blower motor High relay Junction block 16A0743 HEADLIGHT Pop up System Headlight relay Passing control relay NOTE The column is arranged in alphabetic
9. ON t Air Air inlet thermo Air conditioner compressor relay OFF magnetic clutch Engine control unit Engine coolant temperature switch 1340167 7 HEATERS AND AIR CONDITIONING die Speed Control E SPEED CONTROL 1 increasing idle speed to withstand air condition er load When the compressor is placed in the ON state with the engine at idle the idling speed of the engine will be increased by approx 150 rpm to prevent generation of vibration and also to prevent the engine from stalling IDLE SOPEED CONTROL CIRCUIT Ignition switch Sub fusible link Dedicated fuse control unit Dua FF pressure 9 switch Air condi tioner compres sor relay Compressor magnetic clutch Engine control unit Auto compressor s inlet Air thermo sensor sensor Po Engine coolant Qtemperature switch idie speed rpm Faster idle speed rpm to withstand air conditioner load 750 2 The stepper motor types of actuators is used for increasing the idle speed To engine control unit idie speed control 1 Actuator 13A0167 172 25 1 EMISSION CONTROL SYSTEMS CONTENTS AIR FUEL MIXTURE RATIO CONTROL SYSTEM CATALYTIC CONVERTER CRANKCASE VENTILATION SYSTEM EVAPORATIVE EMISSION CONTROL SYSTEM
10. 4 GENERAL INFORMATION 2 Construction Diagram 2 DIFFERENTIAL nnns 5 VN aperniucaigns E 3 DIFFERENTIAL SUPPORT MEMBER VISCOUS COUPLING TYPE LIMITED DRIVE SHAFT 4 DIFFERENTIAL 5 Construction 7 Functions and features 6 Operation isisisi cpr RR ee ele 8 3 2 REAR AXLE General Information GENERAL INFORMATION T The differential carrier and axle housing have been and outer in the axle housing and are coupled with separated from each other and D O J and B J the drive shaft with the companion flange in drive shafts arranged in between They are driven by between the axle shaft The front of the rear suspension and the rear side of The axle shaft is supported by ball bearings inner the differential carrier is mounted via the differential support member to the body CONSTRUCTION DIAGRAM Crossmember ifferential support member A gt 5 z C V Ww Differential carrier 12 0616 97 em 27 2 BS ieee 6 6 5 4 Trailing arm d e S Axle shaft 1140338 SPECIFICATIONS Axle shaft Type Shaft dimensions Outer bearing portion dia Inner bearing portion dia Center portion dia Overall length Bearing O D x I D Outer Inner Drive
11. PRND2L 1750233 Deactivation of the shift control solenoid valve B results in rightward movement of both the shifi control valve and the right plug by line pressure applied through the No 5b port until the valve is blocked by the stopper This rightward movement of the shift control valve opens the No 8 port anc the line pressure is directed to the rear clutct exhaust valve This pressure is called 4th pressure AUTOMATIC TRANSAXLE Transaxle Control PRESSURE CONTROL VALVE SOLENOID VALVE AND N R CONTROL VALVE Pressure Control Valve This valve regulates the pressure supplied to each clutch under the control of the pressure control solenoid valve to eliminate shock at the time of shifting Stopping Selector lever in D or 2 Reducing valve To kickdown shift valve Line Reducing pressure servo via 1 2 21 69 Pressure Control Solenoid Valve This valve has its duty controlled by the transaxle control unit command It changes an electric com mand to corresponding hydraulic pressure N R Control Valve This valve prevents shock from occurring when the select lever is shifted from N to R or from P o R by controlling the oil pressure applied to the low reverse brake Line pressure i control unit E r Pa Pressure contro valve Ex Pressure control ed valve ind Duty control Q obtain adequate creep force when stopping th
12. ignition Switch 16 OD OFF indicator light 4 A T control unit Q Rheostat 07A0015 14 66 FUEL SYSTEM Auto cruise Control System Timing Chart when RESUME switch is turned after cancellation of auto cruise control system by cancel swit 6 secs OD switch OFF ON m OD dri 3 speed A T driving OD driving e Vehicle speed vehicle speed SORO eR xU e ving cel Lag behind set vehicle speed 1 25 km h 0 8 mph ON OFF Acceleration PULL Actuator re ee EE ee ee Deceleration RELEASE L Fixed speed mpa age fg control mode CANCEL Fixed d ixed spee mode RESUME mode control mode 07L0016 Timing Chart when RESUME switch is continuously turned ACCEL 5 4 secs OD switch OFF Tr within control unit ON ON RESUME switch OFF Acceleration PULL stop Actuator DC motor Deceleration RELEASE n Fixed speed Acceleration mode Fixed speed control mode control mode 07 0017 73 FUEL SYSTEM Auto cruise Control System 14 67 Timing Chart when actual vehicle speed drops to less than set speed 1 2 sec 19 8 secs A OD switch OFF within control unit ON Set vehicle speed Vehicle speed 1 25 km h Lag behind set 0 8 mph vehicle speed 2 25 km h 1 4 mph Acceleration PULL Actuator Deceleration RELEASE
13. 4 INjECtOT NR 10 Specifications HDI 6 14 2 FUEL SYSTEM General GENERAL m The fuel system is of the Electronic Control Multi the engine control unit point Fuel Injection type which has an injector for Refer to Group 8 ELECTRICAL for No 6 IGNITION each cylinder The system comprises various sen TIMING CONTROL sors and the engine control unit together with actuators and related components and is controlled according to nine control functions as shown below Of these nine No 1 and Nos 3 to 9 are supplied by f dl mS uel pressure control valve A am m pe Fuel pump pl a Fuel pressure regulator m 1 FUELPRESSURE CONTROL I i Throttle valve Speed adjusting screw 2 INTAKE AIR CONTROL Fast idle air valve idle speed control servo 3 FUEL INJECTION L CONTROL Injectors 4 IDLE SPEED CONTROL 5 POWER SUPPLY CONTROL Control relay Se 6 IGNITION TIMING i nsors CONTROL Power transistor 7 AIR CONDITIONER Air conditioner RELAY CONTROL relay T VES mra EE NOTE 48 SUPERCHARGING p a Waste gate The 22221 is applicable to the Saa CONTROL 22224 p Solenoid __ turbo only i nenne c uc pre D WORD 7 L 9 TURBO METER e CONTROL meter 4 ew ce
14. E 2 Flexible pipe Main muffler Center exhaust pipe Catalytic convener 05A0157 Front exhaust pipe lt Turbo 4WD gt a 286 Pag e Flexible pipe Center exhaust pipe 0540171 Front exhaust pipe Catalytic converter 14 1 CONTENTS RMA ACCELERATOR COMPONENTS 58 GENERALE 2 AIR CONDITIONER RELAY CONTROL 55 IDLE SPEED CONTROL oinnes 44 General Description seals ORS URI VAR E pus i RS tS RO ed 44 AIR FLOW SENSOR AFS FILTER RESET Idle Speed Control Servo 45 CONTROL Turbo S INTAKE AIR CONTROL 12 AUTO CRUISE CONTROL SYSTEM Fast idle Air Valve 4e 13 Actuator Construction 71 General Description Boe e PEERS PESE P 56 12 Actuator Operation acte 72 13 Auto cruise Control Switch 5 45 76 Auto cruise Control Unit 220 02 61 POWER SUPPLY CONTROL 53 Cancel Switches Fund Uds 77 E 53 Self diagnosis and Input check Functions 69 General Description m Vehicle Speed Sensor SENSORS 14 ENGINE CONTROL UNIT 27 Air Conditioner Switch vesers 23 Fail f d Back F 42 Air Flow Sensor MM 15 AMES ee One hy Barometric Pressure Sensor
15. 20A0389 Temperature control knob Mode selection knob Air selection lever Blower switch Q Air conditioner switch OPERATION DIAGRAM OF COMPRESSOR MAGNET CLUTCH NOTE Temperature values shown are for information only 14 57 2 191891 ECONO mode OFF ECONO mode ON Air conditioning mode OFF Air conditioning and ECONO mode OFF Air conditioning and ECONO mode ON Evaporator outlet temperature C F 4 39 2 3 37 4 0 271569 32 89 6 Evaporator inlet temperature C F 03A0169 197 5 AND AIR CONDITIONING General information Heater Construction 24 5 VENTILATION HEATER CONSTRUCTION The air selection damper located at the upper part of the blower motor can be used to select either induction of outside air from the front deck or circulation of inside air The air taken in by the blower motor is passed through the duct or evaporator air conditioner equipped vehicles for forced supply to the heater unit At the right side of the heater unit is Mode selection To defroster damper DEF To face Mode selection damper FACE Heater unit selection damper FOOT To foot area A x To foot area Recircula tion air Blend air damper N Section A A Air intake garnish Section B B 2040388 R24CAAA the btend air damper Depending on the temper ature control knob setting the amount of blend air which has pa
16. 21 BTDC 51 ABDC 55 BBDC S ATDC Pressure feed full flow filtration Gear type Electronic control multipoint fuel injection Turbo type Liquid cooled forced circulation Impeller type AC generator with a built in voltage regulator Planetary gear reduction drive Two coil type electronic control ignition Conventional type For Federal and Canada Electronical control type For California Monolithic type under floor installation Closed type Charcoal canister type ENGINE General Information 9 3 TECHNICAL FEATURES HIGH PERFORMANCE AND FUEL ECONOMY LOW VIBRATION AND LOW NOISE SERVICEABILITY 1 The DOHC 16 valve engine ensures excellent intake and exhaust 2 3 efficiency The rocker arm is of the roller type cam follower design which minimizes friction loss The combustion chamber is of the pentroof type with a squish area that offers outstanding combustion efficiency The multipoint fuel injection system is electronically controlled The intake manifold is the inertia supercharging type which improves intake efficiency and the dual type exhaust manifold offers good exhaust efficiency The two coil type electronic control ignition system ensures good ignition performance The hydraulic lash adjuster together with the roller rocker arm contributes to reduced operating noise of the valve mechanism A cogged type belt is used to drive the cam
17. 3 if the pressure between the lands becomes higher the reducing valve moves farther to the right against the spring force and its 1 land closes the No 1 port to shut off the line pressure while the 2 lands opens the exhaust port t relieve the fluid pressure As a result the reducing presst is lowered Line To pressure control pressure solenoid valve AUTOMATIC TRANSAXLE Transaxle Control 21 63 To front clutch Manual valve Sta PRND2L ud Cae Check ball Line pressure CARBALBAS Ex Reducing pressure The hydraulic control system incorporates fail safe feature which prevents the gear shift from going into reverse should the driver inadvertently shift the selector lever from a forward drive range to the reverse range while driving This function is activated when the vehicle is running at a speed of 7 km h 4 3 mph or higher the selector lever is shifted into the R position the transaxle control unit activates the pressure control solenoid valve to release the reducing pressure Once the reducing pressure drops the lt i POP REESE T x arr EMIL S ig A Er P Pro N R control valve ic EL To low reverse brake Ex SIONS Ld Pressure control solenoid valve 1750089 N R control valve is moved toward the right by the spring force This clo
18. Eno oero Cannon s Ga or el peed coral f a ee au qp LS emm X Airtow sensor ache mersa e Coil B1 for idie speed control servo 16 seomecpesuesmo oe CorBz for ide spos convoi seno Tia Trot positon sensor _ ST terminal for ignition switch NOTE Terminals indicated by the symbol are applicable only to turbo models 14 30 FUEL SYSTEM Engine Control Unit There are 16 diagnosis items as listed below the The diagnosis memory is maintained by backup diagnosis results are stored in computer memory power from the battery not by way of the ignition The stored results can be ready by connecting a Switch so that it will not be lost even if the ignition circuit tester or voltmeter to the diagnosis connec switch is turned OFF tor Diagnosis code Output pattern Diagnosis items Faulty computer in the engine control unit N o nje Malfunction of the air fuel ratio control system Open or short circuit in the oxygen sensor circuit Open or short circuit the air flow sensor circuit Aa N Open or short circuit in the intake air temperature sensor circuit Open or short circuit in the throttle position sensor circuit e b Open or short circuit in the engine coolant temperature sensor circuit No voltage
19. Groun 0 0 2811 in the voltage level column indicate the terminal voltage 0 We t God OF less 23 42 BODY Seat Belts Input Signals The relationship between input signals as seen do so within one minute from the time that the from the control unit and the ON OFF status of the ignition switch is turned to the LOCK or various switches is as shown in the table below ACC position When making measurements of voltage be sure to Input signal Terminal Switch operation and status Voltage designation No level Ignition switch 1 Ignition switch is switched to ON Ignition switch is switched to LOCK or 1 Driver s seat Lap belt is fastened EA buckle switch Lap belt is not fastened Driver s seat outer Amount of shoulder belt wind in equals or exceeds the switch specified amount Amount of shoulder belt wind in is between 0 and the specified amount Driver s seat Driver s door is opened or belt is fastened OFF fasten switch 2 Driver s door is closed and belt is not fastened Driver s seat 5 Driver s belt is in the released condition release switch an 2 Driver s belt is the unreleased condition Driver s seat door Drivers door is closed latch switch side Driver s door is open Key reminder Key is in key cylinder ERE switch
20. REAR SUSPENSION lt 2WD gt Rear Hub REAR HUB RIVFAAA The rear hub has built in unit ball bearing to secure high bearing and hub accuracy By simply tightening the nut to specified torque optimum preloading is achieved for easier servicing Brake disc Rear hub Unit ball bearing 1140012 17 7 17 8 REAR SUSPENSION lt 4WD gt Geneal information REAR SUSPENSION lt 4WD gt GENERAL INFORMATION The rear suspension is a newly developed double bushing to external force and provides excelle wishbone independent suspension with a toe in steering stability and a good ride correction feature utilizing compliance of the The special features of this suspension include e Optimum adjustment of suspension e Improvement of straight forward geometry 2 7 motion stability 55 e Optimum adjustment of alignment e Improvement of cornering change SAA SZ stability Passive corecton union XX Improvement Of steerabiity Optimum combination of spring constant Good balance of RO i Low nbige CONSTRUCTION DIAGRAM Shock absorber 29 K Crossmember Lower arm Trailing arm 12 i eim REAR SUSPENSION lt 4WD gt Geneal nformation 17 6 THREE SIDE VIEWS Trailing arm Lower arm 12
21. gt Pec Ev x IUE n n nipi i EIE transistor B Ignition switch Battery To tachometer Terminal for engine speed detection Terminal for ignition timing and idle speed adjustment 6FU0545 consideration the operating conditions of the en gine The functions and controls of the engine control unit are described in the following page The constructions and functions of the various sensors are described in GROUP 14 m 8 28 IGNITION TIMING CONTROL ELECTRICAL Engine Electrical Detonation Top dead Crank angle T tehtel sendor K a Air flow sensor Other sensors p Reading of input signal Ignition power distribution control selection of power transistor activation Control mode decision Control mode decision data P Fnocking Basic ignition Basic energization only timing setting time setting timing data Ignition timing correction data Engine control unit Power transistor A Basic ignition T Ignition timing Correction Basic energization time data Energization time correction Energization time correction data Ignition timing control som Power transistor B 6ELOO66 The above block diagram shows the f nctions of the engine contro
22. If abnormal condition occurs during engine opera tion such as the ignition signal not being generated corresponding diagnosis code No 44 in memory and at the same time causes the engine alarm lamp Mulfunction indicator lamp to come on FUEL SYSTEM Enaine Control Unit 14 27 ENGINE CONTROL UNIT GENERAL DESCRIPTION RIAFAAA Engine control unit 7 5 Random access E j memory The engine control unit consists of 8 bit micro computer a random access memory a read only memory and an input output interface It determines the engine operating state based on various information input signals it receives from EXE 6FU078 the sensors described earlier and then controls and activates the necessary actuators as shown in the table below to achieve optimum engine operating conditions Engine control unit Control items Control contents Fuel injection control For controlling injector driving timing and duration based on multipoint gt Injectors sequential injection Sensors Power supply control Air conditioner relay control idle speed control For controlling bypass air quantity for idle speed control by activating the idle speed control servo For controlling power supply to the sensors and actuators by controlling the control relay For controlling the ON OFF position of the air conditioner relay
23. No 1 TDC No 3 TDC No 4 TDC No 2 TDC 1 I 1 7 Exhaust stroke Combustion Exhaust Intake Compres stroke stroke stroke sion stroke Compression Combuston Exhaust stroke Stroke stroke Intake Compression Combustion Exhaust stroke stroke stroke stroke intake Compression stroke stroke The cylinder to be ignited is determined based on the top dead center signal and the crank angle signal If the top dead center signal has already been input to the engine control unit when the crank angle signal is input the unit decides that the No 1 cylinder or No 4 cylinder is on the compression stroke and turns off power transistor A and causes the 1 cylinder and No 4 cylinder to fire If the top dead center signal has not been input to the engine control unit when the crank angle signal is input the unit decides that the No 3 cylinder or No 2 cylinder is on the compression stroke and turns off power transistor B and causes the No 3 cylinder and No 2 cylinder to fire In this way the power transistors A and B are turned off alternately for ignition power distribution Ignition Timing Control The period T of the crank angle signal is measured and based on this value the time t taken for the crank to make a revolution is determined t 1 180 Once tis determined the ignition timing T is calculated using the t value and the ignition advance angle advance fro
24. 3 When shifting from positions other than P position to P position When shifting is made from the positions other than P position to the P position it is not necessary to depress the brake pedal because the detent pin moves to the P position while pushing the shift lock pin If the push buttor s released the detent pin moves to the position upward and the return spring provided in the outer cable returns the shift lock pin to the state described in 1 This will fix the shift lever in the P position IRE AUTOMATIC TRANSAXLE A T Safety lock System KEY INTERLOCK DEVICE When shift lever is in P position 0940127 Projection of rotor Projection of rotor Key interlock cable assembly Detent pin The key interlock device consists of the ignition key cylinder interlock cable and the lock cam installed inside the selector handle The lock cam is inter locked with the detent pin and their movement is transmitted to the hook inside the ignition key cylinder through the key interlock cable 1 Shift lever is in P position a When the shift lever is in the P position PO the hook inside the ignition key cylinder is So B positioned that it does not interfere with the E projection of the rotor Therefore the rotor t can turn freely allowing the ignition key to be turned to the LOCK position and pulled out there yore b When the ignition key is turn
25. Detailed view of reserve cup Reserve cup 0340267 Thermistor for low fuel warning light that fuel supply is smooth even when there is only a small amount of fuel remaining A baffle plate arrangement is used at the proper place within the fuel tank in order to prevent the generation of abnormal noise caused by the undulation movement of the fuel A chipping protection coating has been applied at the lower part of the fuel tank in order to protect the tank from damage by pebbles etc thrown up from the road surface and from subsequent corrosion A fuel pump and fuel gauge unit assembly has been adopted which incorporates the fuel pump and the fuel gauge unit in one lt 4WD gt A drain plug has been provided in order to improve serviceability Fuel gauge unit B Drain plug 0340232 Fuel pump and fuel gauge unit assembly Fuel tank 03A0268 Drain plug 14 8 FUEL PUMP This fuel pump is known as the in tank type because itis located within the fuel tank itself surrounded by the fuel For this reason the pump operation noise is well insulated and it has excellent resistance to vapor locks This type of pump is also called the wet type because even its internal parts are in contact with the fuel With a construction that is the unification of a ferrite type DC motor and an impeller type pump the pump itself is composed of the impeller which is driven by the motor as well as
26. Ignition timing adjustment connector NOTE The Name column is arranged in alphabetical order 16A0734 Fuel pump adjustment check connector connector V aro 16A0790 16A0791 Engine speed Vi 3 detecting fe Self diagnosis H t C 16840741 8 16 LIGHTING HEADLIGHT The parallel link pop up headlights are employed that move up or down vertically as they are turned ON or OFF They are aerodynamic to offer less resistance to air when the vehicle is in forward motion The headlights can be moved up and down with the lighting switch or pop up switch An independent headlight moving mechanism is provided for the t 77 Lighting switch passing switch NOTE See P 8 12 for relays ELECTRICAL Lighting ROSHAAA right and left headlights should one mechanism fail the other remains operative In addition when the passing light is used the headlights are turned ON in the lowered position without popping up There is also a manual knob installed that can be used to move up and down the headlights manually when maintenance is required Hinge Headlight 1RAOR50 CONSTRUCTION Pop up The mechanism consists of the pop up motor which moves the headlights up and down The hinge and link assembly connect the pop up motor to the headlight When the pop up switch or lighting switch is turned ON the pop up
27. Note that the set speed before cancellation of the auto cruise control system will be erased from the memory circuit of the control unit if the MAIN switch or ignition switch is switched from ON to OFF or the vehicle speed is decreased to 35 km h 22 mph or less and thereafter the auto cruise control system will not operate even if the RESUME switch is turned ON Deceleration RESUME reset Fixed speed control 07L0005 14 64 FUEL SYSTEM Auto cruise Control System Eum When the RESUME ACCEL Switch is Kept Turned speed While the RESUME switch is ON the actuators DC mott caused to rotate to the PULL side the vehicle speed when the switch is switched OFF as acceleration continues is entered in the memory and is thereafter controlled as the fixed speed Fixed Accelera Speed tion High Vehicle 40 knvh speed 25 mph orhigheri CANCELLATION When during fixed speed driving the signals described below are input conductivity to the electromagnetic clutch is inter rupted thus cancelling the auto cruise control system e Stop light switch ON brake pedal depressed e Clutch switch ON clutch pedal depressed e Inhibitor switch ON selector lever at P or N position LOW SPEED LIMIT There is automatic cancellation at or below the low speed limit vehicle speed approximately 40 km h 25 mph HIGH SPEED LIMIT The vehicle cannot be driven at a fixed speed whi
28. SENC35R SPRC35R with electrogalvanized zink nickelcoating SGAC35R Phosporus added also gelvannealed he numbers in the material codes indicate the tensile strength BODY Main Body 23 7 Material lo Part name Material 3GACC SGAHC 38 Roof panel for sun roof 39 Front door inner panel 10 Hood panel inner 12 Tailgate panel outer upper 13 Tailgate panel inner ront floor side sill outer 15 Rear wheelhouse inner 16 Quarter panel outer 17 Quarter panel inner lower SGACE 50 Rear end panel inner 51 Front fender shield 52 Rear floor side sill 63 Center pillar outer 64 Spring house panel 65 Backbone rear reinforcement 66 Rear floor crossmember lower SENCE 67 Rear floor pan 68 Strut house panel 69 Rear floor sidemember reinforcement 70 Rear floor sidemember 72 Bumper bracket 73 Front sidemember inner 74 Front sidemember rear reinforcement SENC35R 75 Lateral rod bracket SENPH38 76 Trailing arm bracket ront door panel outer ood panel outer ailgate panel outer lower ront pillar inner upper B ront pillar outer upper ront pillar outer lower ront upper frame extension outer ateral rod reinforcement Sidemember seat belt reinforcement ear floor sidemember extension SGAC35R ront pillar inner upper A ront pillar inner lower SPRC35 tire bracket J SPHC SPCD or SPCE plated with an electrical zinc n
29. The space between the housing and outer and inner plates is filled with mixture of silicone oil and air OPERATION OF THE VISCOUS COUPLING Principles of operation The viscous coupling is a kind of fluid clutch that uses viscous resistance shear stress of the fluid to transmit power or limit differential action For this purpose the viscous coupling uses silicone oil whose viscosity is less variable with temperature changes The principles of operation are described below using an enlarged model consisting of two parallel plates with fluid filling the space between them Assume that fluid fills the space between plates A and B When plate A moves at velocity V the fluid that is in contact oad with plate A also moves at velocity V The velocity of the fluid Plate decreases gradually in area closer to plate B the area that is in Y contact with plate B is stationary Thus there occurs a velocity gradient in the fluid As the fluid is viscous the faster moving fluid molecules develop a force shear stress to pull or separate the more slowly moving molecules if there occurs velocity gradient Velocity This force acts as resistance to the plate that is moving at gradient velocity V plate A and as force to the stationary plate to move RRR ee ODOR RRR RARE EEO it in the same direction as plate A Stationary ae In other words shear stress works to reduce velocity differ ence of the two plates Shear stres
30. Turbocharger 11 3 TURBOCHARGER RIICBAA Exhaust manifold SX Exhaust fitting From air cleane r d To exhaust pipe EN NN Turbocharger Waste gate actuator 6 00019 1 The turbocharger is 005 water cooled type F 2 Lubricant for the turbocharger is introduced to the tur rom exhaust manifold bocharger through the oil pipe from the cylinder head oil path Waste gate 3 The coolant flows from the thermostat case to the valve turbocharger through the water hose and pipe After Exhaust cooling it is returned through the water inlet pipe fitting 22 Q 2 7 To exhaust pipe 6140018 Y iiA INTAKE AND EXHAUST Turbocharger Coolant from thermostat case inlet Water path section From exhaust manifold Oil outlet To exhaust pipe d To oil pan val Bearing Turbine wheel Compressor wheel Waste gate actuator 6 0026 2 57 INTAKE AND EXHAUST Exhaust Pipe 11 5 R11DAAA EXHAUST PIPE exhaust pipe is supported from the body by using rubber hangers and in addition a flexible pipe is used at the front exhaust pipe in order to reduce CONSTRUCTION DIAGRAM lt Non turbo gt Ge s gS Go pe the transmission of vibrations from the exhaust system to the Main muffler Center exhaust pipe Pre muffler 05A0158 Front exhaust pipe Catalytic converter lt Turbo 2WD gt
31. When code No 31 has occur 11 red 4 or more times TEE EN 1 st gear commanded Locked in 3rd D When code No 32 has occur 12 when driving at high or 2nd 2 L gear red 4 or more times speed Open circuit in pulse Locked in 3rd D When code No 33 has occur E j or 2nd 2 L gear red 4 or more times Open or short circuit in Locked in 3rd gear When code No 41 or 42 has 1 shift control solenoid occurred 4 or more times Open or short circuit in Locked in 3rd gear When code No 43 or 44 has shift control solenoid occurred 4 or more times valve Open or short circuit in Locked in 3rd D When code No 45 or 46 has pressure control sole or 2nd 2 L gear occurred 4 or more times noid valve Gear shifting out of syn Locked in 3rd D When code No 51 52 53 or 17 chronization or 2nd 2 L gear 54 has occurred 4 or more times 12A0104 21 52 AUTOMATIC TRANSAXLE Transaxle Control SELF DIAGNOSIS SYSTEM The transaxle control unit has self diagnosis function Self diagnosis codes can be read by connecting a voltmeter to the diagnosis connector on the side of the junction block 16A0741 LEERELE 6500660 Ground 69 ELC AA T Self diagnosis There are 25 diagnosis items including those items retained even after the Ignition switch is turned to indicating normal conditions a maximum of 10 the off position i
32. tank 6FUO486 Usually the negative pressure vacuum of the As a result the fuel pressure is increased and the intake manifold is applied to the fuel pressure generation of fuel vapors caused by high tem regulator and because the fuel pressure is thus perature is suppressed thereby maintaining idling held at a fixed constant level relative to the pressure stability immediately after restarting under high within the intake manifold the amount to fuel temperature conditions injected is regulated so as to be proportional to the Note that there is a return to the usual fuel pressure injectors actuation time If however the engine level after two minutes or more have passed after coolant temperature and the intake air temperature starting is completed are high when then engine is started the engine In addition the circuitry of the fuel pressure control control unit sends a flow of current to the fuel valve is interrupted thus controlling so that the fuel pressure control valve with the result that outside pressure corresponds to supercharging pressure air atmospheric pressure acts upon the fuel under high load driving conditions during super pressure regulator charged driving by the turbocharger To control FUEL PUMP CHECK TERMINAL relay This terminal is for directly driving the fuel pump By applying the battery voltage directly to this terminal you can check fuel pump operation or check fuel l
33. 1 cylinder TDC signal has been detected fuel is injected sequentially as described earlier If the engine is still cold when the first No 1 cylinder TDC signal is detected simultaneous fuel injection is performed as described in the following No 4 TDC No 2 TDC A 6FU0790 Fuel injection Fuel injection Bilan ZA mem 0 720 180 360 540 2 crankshaft revolutions 720 6FU1008 14 38 FUEL SYSTEM Fuel Injection Control When cranking the cold engine fuel is injected into all four cylinders simultaneously twice for every crankshaft revolution and fuel injection is synchro nized with the crank angle sensor s 5 BTDC signal INCREASED FUEL INJECTION DURING ACCELERATION No 1 TDC No 3 TDC No 4 TDC No 2 TDC 77777 TDC sensor signal Crank angle sensor signal 75 5 Increased fuel injection during acceleration No 1 oylinder J We We mu CES 1 Deni xe de ANS No 4 cylinder No 2 cylinder During acceleration an increased amount of fuel according to the degree of acceleration is injected simultaneously into all four cylinders every 10 msecs in addition to the sequential injection FUEL SYSTEM Fuel Injection Control 14 39 FUEL INJECTION AMOUNT CONTROL INJECTOR ACTIVATION DURATION CON TROL sntrol
34. 36 2 950 37 4 Overhang Non m Minimum running ground clearance 160 6 3 160 6 3 158 6 2 Angle of approach 16 5 13 8 14 7 Angle of departure 19 17 18 4 Vehicle weight kg lbs Curb weights M T 1 215 2 679 1 245 2 745 1 245 2 745 AIT 1 240 2 734 Gross vehicle weight rating 1 620 3 571 1 620 8 571 1 782 8 929 Gross axle weight rating Front 930 2 050 0 2 050 979 2 158 Rear 690 1 521 690 1 521 803 1 770 Engine 4G63 2 0L 4G63 2 0L 4G63 2 0L Transaxle Model No Manual transaxle F5M22 W5M33 Automatic transaxle F4A22 Type Dry single disc amp Dry single disc amp Dry single disc amp diaphragm spring diaphragm spring diaphragm spring 0 14 GENERAL General Data and Specifications D27AMNGFL4E 5E 9E D22AMNHMLAE 9E 5E D22AMNPFL4E 5E 9E D22AMRHML4E 9E 5E Chassis Tire P205 55HR16 or 205 55VR 16 Front suspension Type Rear suspension Type Independent strut 3 Link Torsion axle Brake Type Disc Disc Steering Gear type Rack and pinion Gear ratio Fuel tank Capacity liters gals ENGINE SPECIFICATIONS 4663 2 01 Non Turbo Type In line DOHC Number of cylinders 4 Bore mm in 85 0 3 35 Stroke in 88 0 3 46 Piston displacement 1 997 122 Compression ratio 9 0 Firing order 1 3 4 2 cm cu in TRANSAXLE SPECIFICATIONS P205 55VR16 or 205 55VR16 P205 55VR 16 or 205 55VR16 Independent str
35. A Key is removed from the key cylinder E NE o 2 di Key reminder switch B Key is removed from the key cylinder Key is in key cylinder Em Amount of shoulder belt wind in equals or exceeds the specified amount Front passenger s outer switch r Amount of shoulder belt wind in is between 0 and the ON specified amount Front passenger s Front passenger s door is opened or belt is fastened E eee Front passenger s Front passengers door is closed or belt is in the released release switch fasten switch Front passenger s door is closed and belt is not fastened Front passenger s door is open and the belt is in the ON L unreleased condition shoulder belt starts 3 side BODY Seat Belts 23 43 Output Signals hen the input signals change the signals output from the control unit also change This relationsihp is as shown in the table below BUZZER OPERATION TERMINAL No 20 Output signal waveforms and operation status Output signal Status at input side Buzzer Warning alarm when Ignition switch ON driver s shoulder belt Drivers door Closed is not fastened Driver s shoulder belt Fastened Fasten switch OFF Driver s outer switch OFF Approx 6 sec di Other than as above H Driver s lap belt Not fastened ON iti j OFF Ignition switch OFF ON L Approx 0 7 sec ON Other
36. Clutch brake N N Damper clutch control solenoid valve End clutch Torque converter 2 contro valve 2926 Regulator valve i NAS AT obs ayy fo i Pressure control valve t Line relief wu valve b Transaxie control unit Line Pressure Pump suction pressure Torque converter pressure fie Line Pressure DCCSV contro pressure and lubrication oil pressure control pressure Reducing pressure BEES PCSV control pressure 1750252 AUTOMATIC TRANSAXLE Transaxle Control 21 96 WIRING DIAGRAM Ae 410v10 di eli dr gt di 5 8 Y piouejos sisoubeig joual Onuoo poua youms OAJOS 208095 rum Y o ame MS sadwng emsseid 330 o 101019920 NO h prouajos 1 O t sosuas 2 paads 8 101812006 asd 290805 10 Wud 5 01 9uibu3 ANSNI 2 64 23 1 CONTENTS i BODY COLOR CODE neco nomen 18 Body Components etes 2 Body Major C Sections 10 BODY COLOR CODE INTERPRETATION 18 SIOBSORRUDHS Bodv Col 18 Dash Panel cie ded 17 HE 16 BUMPERS 220000200 24 xs e n deas 1
37. Dry weight kg Ibs 64 0 141 0 6 0 63 HG MANUAL TRANSAXLE lt 4WD gt General Information 21 7 SECTIONAL VIEW N5M33 Clutch housing 151 speed gear 1st 2nd speed synchronizer assembly Bearing retainer 2nd speed gear 3rd speed gear 3rd 4th speed synchronizer assembly 4th speed gear soda 5th speed gear 5th speed synchronizer assembly Reverse gear noise prevention device Rear cover 5th speed intermediate gear intermediate gear Viscous coupling Center differential Front output shaft f TFM0014 21 8 MANUAL TRANSAXLE lt 4WD gt General Information 4WD SYSTEM Viscous coupling 1 QR ONA Center differential Transfer T 1 inj il Viscous coupling Center differential Front differential Rear differential Viscous coupling Option 2210105 CONSTRUCTION OF THE 4WD SYSTEM The 4WD system configuration and a section of the center differential are shown above The center differential is placed on the center shaft and engine power is transmitted to the front and rear drive shafts by means of a concentric dual shaft construction The viscous coupling for the center differential is located on rear side of center differential This arrangement makes the entire transaxle simpler a more compact Differential limiting by the cente differential viscous coupling takes place b
38. If the engine coolant temperature exceeds 88 194 when the engine is started the feedback target speed after the ENQINE has started is increased a set value which is higher than normal and then is gradually decreased CONTROL DURING IDLE SPEED ADJUSTMENT Grounding the ignition timing adjusting terminal and diagnosis data transfer select terminal causes the idle speed control servo to be fixed at a position corresponding to the idle position after warm up Idle speed is therefore adjusted with the servo at the preset position after warm up 9 steps The altitude compensation control is applied to this position meaning that the motor shifts to a position so that the pintle is further retracted at high altitudes R14JAAA 7FU051 14 54 Battery pump power Relay Control Power Supply Control When the ignition switch on signal is input the engine control unit energizes the control relay coil Ls to turn on the S switch thus supplying power to the injectors air flow sensor idle speed control servo Fuel Pump Control When cranking the engine ignition switch at the ST position the engine control unit energizes the L coil to turn on the S switch thus activating the fuel pump While operating the engine ignition switch at the IG position the crank angle sensor signal is input to the engine control unit which energizes the L ump FUEL SYSTEM Power S
39. NOTE 8 18 ELECTRICAL Lighting HEADLIGHT RAISING OPERATION 1 Pop up switch ON lighting switch OFF Fusible ignition hink 7 switch ACC Dimmer passing switch column switch column switch relay md UN Cg e Fusibie Fusible link ie hankia When the pop up switch is turned ON current from fusible link 6 flows through the up timer circuit of the passing control relay turning ON transistor Trl Current from Trl passes through the U contact of the U D Up Down switch of the pop up motor This means that current flows through the pop up motor relay thus energizing the pop up motor relay The energized pop up motor relay means that current from fusible link flows through the pop up motor which results in the headlights starting going up When the crank arm of the pop up motor rotates about 180 to the UP stop position the contact of the interlocking U D switch changes from U to D which cuts off current to the pop up motor relay As a result the pop up motor relay is de energized and no current flows from fusible link 4 to the motor This results in the headlights staying in the fully raised position UP amp DOWN TIMER CIRCUIT Even if Up Down operation of the pop up headlight becomes abnormal the Up or Down timer ON for 5 2 seconds cuts the power supply to the pop up motor to protect the motor 22 ae GU MS A
40. Suspension crossmember Upper arm Lower arm Axle housing Trailing arm Middle joint 17 11 R17GAAA 12A0058 1 The suspension consists of a pair of lateral arms upper arm 2 and lower arm 3 mounted the suspension crossmember 1 and trailing arm 5 The lateral arms and axle housing 4 are connected by the ball joints The axle housing that is the rear wheel can rotate about the centerline of the upper and lower arm ball joints as a steering axis The trailing arm and axle housing are rigidly connected The suspension geometry is basically deter mined by the layout of these components 2 The trailing arm also has a middle joint provided closer to the suspension crossmember As it is connected by pin 7 that runs through it vertically parts A and B can rotate relative to the pin The insertion of rubber body 8 creates a spring constant in the direction of rotation 17 12 REAR SUSPENSION Double Wishbone Suspension This middle joint is located exterior to straight line connecting the trailing arm end mounted on the crossmei ber side with the axle housing king pin Because of this arrangement the momentary center P intersection of front member centerline 04 of the trailing arm and line 02 interconnecting the middle points of the lateral arm mounting points is positioned rearward of the wheel center 3 When the wheel is subjected to an ext
41. and the pressure is directed to the rear clutch At the same time as this happens the 4th pressure in No 19 line which has been acting on the 2 3 4 3 shift valve is released This causes the 3rd pressure established in the No 7 line to push the 2 3 4 3 shift valve to the right and creates a 3rd gear state where the line pressure from the 1 2 shift valve is directed to the front clutch and the release side chamber of kickdown servo cylinder through the No 12 line 21 78 N D CONTROL VALVE Line pressure The purpose of this valve is to prevent shock from occurring when shifting the select lever from to D The valve supplies the rear clutch with the oil pressure regulated by the pressure control valve only when the N D shifting is being performed After the shifting is completed the valve is switched over an the line pressure to be supplied to the rear clutch AUTOMATIC TRANSAXLE Transaxle Control TO rear clutch via rear clutch exhaust valve Reducing pressure Reducing pressure 1750239 Selector Lever in N When the manual valve is shifted to the range position the line pressure from the oil pump is directed to the N D control valve through the No 4 line As the 2 land has a slightly larger area to which pressure is applied than that of the 3 land of the N D control valve the movement of the valve caused by the line pressure is toward the left which closes t
42. axis of inertia support system by which the components that contact the principal axis of inertia are mounted is employed INSULATORS Absorption of Minute Vibrations The minute vibrations that are generated during idling and during driving are absorbed because the spring constant is low as a result of the fact that insulator A only causes vibration of the space within the cavity Absorption of Larger Vibrations The larger vibrations that are generated during starting from a stop and during acceleration are absorbed because insulator A and insulator B contact and the spring constant becomes high 11 1 CONTENTS RIIA EXHAUST MANIFOLD 2 INTAKE MANIFOLD nnns 2 EXHAUST PIPE 5 TURBOCHARGER 3 Construction Diagram ccs 5 11 2 INTAKE AND EXHAUST Intake Manifold Exhaust Manifold INTAKE MANIFOLD Intake manifold 6140088 R118AAA Plenum chamber 6 0016 The intake manifold is of the independent port type with a plenum chamber and long intake port which produce inertia supercharging effect for higher air intake efficiency EXHAUST MANIFOLD RTICAAA The exhaust manifold is the dual exhaust type which minimizes exhaust interference and improves exhaust efficiency The illustration shows the exhaust manifold of Non Turbo INTAKE AND EXHAUST
43. buzzer passing control relay key reminder switch theft alarm starter relay Ignition IG 2 Switch 3 10 Air conditioner control unit air conditioner switch heater relay power window relay defogger timer daytime running light relay 2 vehicles for Canada only transistor relay vehicles for Canada only EEES Cigarette lighter remote controlled mirror lanition Auto cruise control unit lt A T gt AA control unit itch inhibitor switch combination meter Wiper motor washer motor intermittent wiper relay 10 10 Horn headlight relay theft alarm control unit daytime running light relay 1 vehicles for Canada only IG 11 10 Auto cruise control unit auto cruise control actuator automatic seatbelt control unit theft alarm control unit combination meter warning light seatbelt timer Turn signal and hazard flasher unit era e 74 179 Stop light Power supply circuit Fuse No E Rated Load circuit Ignition IG 18 10 Back up light lt M T gt dome light relay Switch Battery 19 10 Dome light luggage compartment light foot light door ajarwarningligint radio MP control unit AKT axorirtro light security light 8 4 ELECTRICAL Fuses Diagnosis System DEDICATED FUSES For high load circuits fuses dedicated to each individual circuit are used The dedicated fuses are provided in the relay box
44. ice etc the vehicle would be inclined to swerve to the side in this case the right side of greater road surface resistance to the tires but because of the negative offset geometry construction a certain force would be generated to cause rotation in direction C employing point A as the fulcrum point At the same time there would be generated at the tires on the opposite side a corresponding force to cause rotation in direction D also employing point A as the fulcrum point but because that force is Centre point of strut upper installation part SN LH 1 Ball joint ove centre point Point Point A NN Negative offset 1240548 surface 020 greater in direction C where road surface resistance is greater the tires themselves will tend to turn in the left direction As a result because the tires automatically countersteer in the left direction even though the force applied to the vehicle by the road surface resistance is to the right the system thus functions to maintain the vehicle on a relatively straight ahead course NOTE The king pin offset is the distance from the center point of tire to ground contact when a line ex tended to the road surface is drawn to connect the ball joint center point and the center point of the strut upper installation part Direction of travel Direction of 2 vehicle move ment tendency Direction of tire movement tendenc
45. openLorr Buzzer OFF 19P0270 FITZISTATSTe T7 89 1g 111213141516 7181924 BODY Seat Belts 23 41 Warning Alarm when the Driver s Lap Belt is not Fastened sii ch ed on S lap belt unfastened the buckle switch 1 the ignition switch is tunrned from the ope n to the ON position the buzzer soun ante rmi tently for approximately 6 seconds If however the driver s lap belt is fastened during that time the ill witched OEF Note th at the warning light when the ignition switch is activated will also illuminate when the ignition switch is turned from the LOCK or ACC position to the position Warning Alarm when the ignition Key is Left in the Ignition The buzzer will sound continuously when all of these condi tions occur simultaneously the key is in the key cylinder key reminder switch A is switched ON and the ignition switch is at the LOCK or ACC position and the driver s door is open the door latch switch open is switched ON Warning Alarm when an Automatic Seat Belt Starts to Move toward the Release Side When the driver s or front seat passenger s automatic seat belt starts to move toward the release side the buzzer sounds for approximately 0 7 second AUTOMATIC SEAT BELT CONTROL UNIT INPUT OUTPUT SIGNALS Power Supply and Ground Circuit Terminal No eve Ignition switc
46. ration 31 speed RELEASE Vehicle speed High ow lapprox 40 km h 25 mph or higher Cancel signal ON OFF N Electromagnetic 9 clutch OFF RESUME switch aN switc OFF monn Acceleration motor PU oto LL Stop Fixed speed control Auto cruise control system cancellation When the SET COAST Switch is Held Down While the SET switch is ON the actuator s DC motor is caused to rotate to the RELEASE side the vehicle speed when the switch is switched OFF as deceleration continues is entered in the memory and is thereafter controlled as the fixed speed Note that the vehicle speed must be the low speed limit approximately 40 km h 25 mph or higher RESUME ACCEL SWITCH When the RESUME ACCEL Switch is Turned after the Auto cruise Control has been Canceled When after the auto cruise control system is canceled by the cancel signal the RESUME switch is switched from OFF to ON while driving at a vehicle speed which is the low speed limit approximately 40 km h 25 mph or higher the vehicle speed memorized before cancellation of the auto cruise control system will be controlled as the fixed speed Even if the vehicle speed is at or below the low speed limit there can be a return to the set speed before cancellation of the auto cruise control system by using the accelerator to increase the vehicle speed to 40 km h 25 mph or higher and then switching the RESUME switch from OFF to ON
47. the clutch pedal is depressed BATTERY BHO KX36 Ac UOR01 N lf the Clutch Pedal is Not Depressed When the Clutch Pedal is Depressed Because the inter lock switch is switched ON when The inter lock switch is switched OFF when the the ignition switch is switched to the START clutch pedal is depressed If the ignition switch is position electricity flows from the coil of the starter then switched to the START position at this time relay through the inter lock switch to ground As a the flow of electricity to the coil of the starter relay sult the contacts of the starter relay separate will be interrupted the contacts of the starter relay vitching it OFF and the starter motor is therefore will close switching it ON and the starter motor will not activated be activated 7 1 CONTENTS RO7A GENERAL INFORMATION _ 2 TRANSAXLE FLUID COOLER 5 Coolant Fow EEA ESAS T ET TWO SPEED FAN CONTROL SYSTEM Specifications Cond Chait Digan RADIATOR AND COOLING FAN _ 4 72 COOLING General Information GENERAL INFORMATION Ro7BAAA Radiator hose upper Heater hoses Heater Radiator Iniet water Radiator hose pipe ower Water pump The cooling system is the liquid cooled forced the motor only when necessary and it functions to circulation type of system Th
48. thus improving straight ahead driving at high speed ANTI LIFT GEOMETRY RTIDAAA Ordinarily when the brakes are applied the load is mc 1 toward the front of the vehicle as the result of inertial force d this causes the rear end of the vehicle to try to rise upward but this is counteracted by the use of the trailing arm type of suspension which forms a suspension link design with a high anti lift effect In other words braking force F is divided into force compo nents F and acts in the direction that contracts the rear spring so that the can be suppressed REAR SUSPENSION lt 2WD gt Three link Suspension THREE LINK SUSPENSION For this suspension an U form axle beam with built in torsional bar that combines the features of the independent suspension and the features of a rigid axle with no camber change is employed Because there is no change of the camber when the body tilts to one side during turns there is little change of the tires to road surface contact area Ordinary suspension Direction of vehicle travel Three link suspension 1280283 17 5 R17EAAA thus preventing side slip and maintaining excellent handling stability Moreover the trailing arm func tions to counteract twisting Of the axle beam and torsional bar during separate up and down move ments of the two wheels thereby suppressing body tiling to the side and maintaining excellent driving stability and co
49. to pass other vehicles at high speed The economy pattern is designed for ordinary driving H provides good fuel economy and quiet operating conditions 141 AUTOMATIC TRANSAXLE Transaxle Control 21 51 F SAFE SYSTEM 1 transaxle control unit has a fail safe function while the vehicle is moving forward at a speed that provides control to achieve maximum vehicle of 7 km h 4 3 mph or higher the hydraulic safety in the event of an electronic circuit failure or pressure to the low reverse brake is electrically malfunction or error caused by the driver The interrupted so that the shift cannot be made As control and construction are as described below a result there is unlike previously no damage 1 The circuit that supplies hydraulic pressure to to the transaxle and no engine stall the function elements that don t couple simul 3 In case the transaxle control unit detects any of taneously is composed of a switching valve the following states it considers that particular device that cannot supply hydraulic pressure state a failure and provides control Locked in simultaneouslv so that there is no internal 3rd gear or 2nd gear reverse is available locking of the gear train depending on the item considered a failure 2 Even if there is an attempted shift to R reverse Output code Remarks Item Fail safe yearn to the No Display pattern self diagnosis function Microprocessor failure Locked in 3rd gear
50. to the No 18 line during 4th gear 4th To end To 2 3 4 3 pressure clutch shift valve 2nd 3rd pressure pressure 21 84 AUTOMATIC TRANSAXLE Transaxle Control REAR CLUTCH EXHAUST VALVE to front To rear To kickdown clutch clutch servo release side t 2 3 4 3 shift valve 11 C wee From 1 2 shift valve Shift control solenoid valve A Shift control solenoid valve 1750244 The valve is actuated by the line pressure controlled the oil pressure to be supplied to the rear clutch by the shift control valve to release the oil pressure when shifting is performed from 4th to 3rd ger of the rear clutch when shifting i performed from preventing shocks from occurring 3rd to 4th gear The valve also controls the timing of 3 AUTOMATIC TRANSAXLE Transaxle Control 21 85 Upshift from 3rd to 4th Gear 1 When the 4th pressure from the shift control valve is 102 3 4 3 From rear directed to the rear clutch exhaust valve through the No 8 shift valve line it pushes the elements and B of the rear clutch t exhaust valve to the right 2 The element B of the rear clutch exhaust valve that has been moved towards the right closes the No 5 line port This prevents the line pressure coming from the N D control valve from being directed to the rear clutch ET 3 The line pressure supplied to the rear clutch is discharged from the 15 line
51. which is engaged during 1st gear 21 66 2nd Gear Transaxle control unit Shift control Shift control Solenoid valve B 16 Manual valve Ex Ex ae Line pressure The transaxle control unit deactivates the shift control solenoid valve A and activates the shift control solenoid valve B When the shift control solnoid valve A is deactivated the line pressure directed through the No 5a ports is applied to the plugs at both ends of the shift control valve pushing solenoid valve A AUTOMATIC TRANSAXLE Transaxie Control 2nd pressure to 1 2 shift valve Stopper 10 N D s control valve EOS eo NATO C MN conc To rear clutch S Sel CES PRND 2L 175023 the left plug to the right and the right plug to the lef until they are blocked by the stoppers The rightward movement of the left plug forces the shift control valve also to the right This opens tht No 6 port allowing the line pressure to the directec to the 1 2 shift valve and the end clutch valve This pressure is called 2nd pressure 7 AUTOMATIC TRANSAXLE Transaxle Control 21 67 3rd Gear Shift control solenoid valve A Shift control solenoid valve B 2nd pressure Te 3rd pressure Plug Stopper Shift control valve To N D control valve mim rear clutch Manual valve 5 NM PR
52. 011 SPECIFICATIONS Items Suspension system Coil spring Wire dia x O D x free length in Coil spring identification colour Spring constant N mm kg mm Ibs in Shock absorber Type Max length in Min length Stroke in Damping force at 0 3 m sec 0 9 ft sec Expansion kg lbs Contraction kg Ibs Wheel alignment Toe in left right wheel difference mm in Camber Specifications Double wishbone type 11 0 x 106 x 332 5 43x 4 17 x 13 1 Purple x 1 25 0 2 50 140 Hydraulic cylindrical double acting type 568 22 4 380 15 0 188 7 4 900 90 198 300 30 66 3 6 3 14 12 1 33 30 17 10 REAR SUSPENSION lt 4WD gt Wheel Alignment WHEEL ALIGNMENT 5 This rear suspension has a toe and camber adjustment mechanism TOE ADJUSTMENT Trailing arm LH N 12A0083 Section A A Adjusting cam eccentric bolt 12A0114 12A0058 Toe can be adjusted by turning the trailing arm attaching bolt at the crossmember and trailing arm connection CAMBER ADJUSTMENT Section A A Adjusting cam eccentric bolt 12A0058 12A0114 Camber can be adjusted by turning the upper arm attaching bolt at the crossmember and upper arm connection O REAR SUSPENSION Double Wishbone Suspension DOUBLE WISHBONE SUSPENSION CONSTRUCTION AND OPERATION 1
53. 1240087 Crossmember 19 1 CONTENTS RIBS GENERAL INFORMATION _ 2 PINION AND VALVE ASSEMBLY Construction Diagram eene 2 diens V n V dX Qe E ag Ne 9 PEN peration of the Pinion and Specifications DW EUR PO VI S 3 Valve Assembly MM E cR 7 T 0 ME RUMP POWER STEERING GEAR BOX Operation of the Fluid Flow control CONSTRUCTION 0042229 4 02 12 020 0202029 4 0 5 System 1 Operation of the Pump 10 TILT STEERING CONSTRUCTION 4 Operation of the Relief Valve 13 Operation of the Tilt Steering 4 Performance of the Oil Pump 11 19 2 POWER STEERING General Information GENERAL INFORMATION The steering wheel and column have the following integral rack and pinion type This power steering features for superb operational and safety character has the following features for greater reliability and istics improved steering characteristics e The steering wheel is with the best design for e The oil pump is of the vane type with flow ease of use and visibility of the meters for the control that responds to the engine speed model on which it is used Specifically the pump is controlled so that less e A tilt steering mechanism which can be used steering effort is necessary when the engine for adjustment of the height of the steering speed is low
54. 19 20 21 22 23 24 25 26 27 30 31 32 33 34 35 36 37 55 56 57 58 59 60 61 62 Rear tie down reinforcement Pan name Front door beltline reinforcement outer Front door outer rear Front door inner rear Front fender bracket Cowl top panel outer Cowl top panel inner Front upper extension inner Roof drip channel Rear wheelhouse front extension Roof drip channel extension Rear pillar outer uel filler neck bracket uel filler door panel Quarter outer lower extension Rear lamp housing extension Dash panel Front floor side sill inner front Dash panel extension Dash panel crossmember Front floor sidemember Front floor side sill inner ront floor sidemember extension Rear seat pan Rear end panel outer Rear fascia upper bracket ront end upper bar reinforcement urn lamp bracket Fender support plate Sidemember to crossmember brace eadlamp support panel Oil cooler bracket ront end upper bar Shield plate ront upper frame inner Front upper frame lower Front upper frame outer Rear floor side sill reinforcement Rear seat crossmember Rear floor crossmember reinforcement Rear floor seat belt reinforcement Jack up reinforcement Radiator bracket Front tie down bracket inner Rear floor sidemember front bulkhead Rear floor sidery amp mber rear bulkhead Rear floor sidemember center reinforcement SGACC SGACE Galvannealed steel plate SGAHC SENHC SENHE SPRC Phosphorus added
55. 3 All of these greatly reduce torque variations and the vibration and noise level No 2 center bearing No 4 universal joint No 3 universal joint L bro joint 1 0A0005 1 040001 00 aw igi PROPELLER SHAFT General Information L bro Joint 16 3 SPECIFICATIONS terns gt ropeller shaft Type Length x O D in Front Center Rear Universal joint Type No 1 front 2 center front No center rear L6bro joint No 4 rear Cross type universal joint bearing Cross type universal joint journal O D in Constant velocity joint type Constant velocity joint size NOTE Specifications 4 joint propeller shaft 707 x 50 8 27 8 x 2 00 647 5 x 50 8 25 5 x 2 00 530 5 x 50 8 20 9 x 2 00 Cross type Cross type CV type Cross type Needle roller bearing oilless type 14 689 5783 L bro joint oilless type 94 3 7 The propeller shaft length is the length between the centers of the joints LOBRO JOINT The L bro joint absorbs longitudinal displacement and angle change and prevents the transmission of vibration It has the following features Its constant velocity performance is excellent due to the inclination of the ball grooves of the inner and outer races at same degree in oppo site directions 36 No Z center bearing BET L bro joint Rear propeller shaft It has a smaller slidi
56. 3 The camshaft bearings are placed at six loca area provided in the combustion chamber tions on the intake side and six on the exhaust which promotes turbulence further mixing of side see next page illustration The thrust load the air fuel mixture and more efficient combus of each camshaft is transmitted to the No 1 tion bearing 9 8 ENGINE Base Engine Bearing cap No 6 R Exhaust side E L intake side No 5 Camshaft ce sprockets side 6ENO0077 ROCKER COVER Breather plate Rocker cover 2 7 E 3 tas Gale aaa ad iie ATIS gf Center cover 27 eL Rocker cover d TEL amp Positive crankcase ventilation valve To intake manifold Viewed from bottom of rocker cover Arrow indicating the direction that the spark Blow by gas plug cable is installed Fresh air 6 0378 6 0384 Installed inside the rocker cover is the breather plate blowby gas passes through the space between the breather plate and rocker cover and is drawn through the positive crankcase ventilation valve to the intake manifold As a result fresh air is drawn to the engine cylinders ENGINE Base Engine 9 9 CYLINDER BLOCK Engine oil to cylinder head Coolant inlet Silent shaft bearing rear Silent shaft bearing front Timing belt side Silent shaft bearing rear 248 1 There is an oil
57. 3rd line to the 25th line and hydraulic pressure is supplied between the front cover of the torque converter and the damper Damper ciutch control solenoid clutch Line Tool From As a result the damper clutch is not activated and pressure Conver Pump fena operation is the same as that of an ordinary torque control converter valve 1750228 2 When both throttle opening and vehicle speed reached the damper clutch activation area the damper clutch control solenoid valve is duty controlled by commands from the transaxle control unit thereby reducing the hydraulic pressure applied to the 1 land left side As a result the sum of the hydraulic pressure acting on the 1land plus the spring force is overcome by the hydraulic pressure applied to the 5 land and 6 land surface areas thus causing the valve to be moved toward the left When this happens the hydraulic pressure from the torque converter control valve passes through from the 3rd line to the 26th line and through the oil cooler and at the same time the line pressure of the 1 st line passes through the 27th line and enters the torque converter from the 24th line thus causing hydraulic pressure to be applied between the damper clutch and the turbine with the result that the damper clutch is pressed against the front cover thus activating the damper clutch Clutch Control Solenoid Lme From From pressure torque pump reducing conv
58. 4 If the door is unfastened while the SECURITY light illuminates ACTIVATING THE ALARM 1 if an attempt is made to open a door the liftgate or the hood without using the key while the system is armed the horn will sound intermittently and the headlights will flash on and off for approximately three minutes Furthermore the starter circuit is interrupted at this time also making starting of the engine impossible 2 if a further attempt at forcible entry is made after the first three minute alarm has finished the three minute alarm will be activated again DEACTIVATING THE ALARM 1 To deactivate the alarm insert the key into the doors key cylinder and turn the key 2 The alarm is deactivated and the system is disarmed when the liftgate is unlocked with the key CHECKING THE SYSTEM OPERATION The activation operation of the system can be checked by following the steps below 1 Turn the ignition key to the ON position and then use the power window switch to fully open the window at the drivers seat side 2 Turn the ignition key to the LOCK position and then remove the key from the ignition 3 Open only the driver s door and close all the other doors as well as the hood and the rear hatch 4 Lock the driver s door by the key or the keyless locking method 5 doors will then be locked and the SECURITY light within the combination meter will illuminate check to be sure that illumination stops in about 20 secon
59. 7 LOWER ARM The lower arm is an A type arm and is connected via a rubber bushing to the crossmember The rod bushing is optimum tuned including the spring const nt of the arm bushing to provide soft characteristics relative to the front and rear Arm bushing Front lt 2 R02GAAA and hard characteristics relative to the left and right so that road surface impacts during travel are alleviated and also so that changes of alignment caused by lateral forces are reduced thus assuring excellent driving stability Rod bushing Front lt 1240008 STABILIZER The stabilizer mounting uses pillow balls The adoption of a stabilizer link with a pillow ball on each end increases the link stiffness and ensures the effective operation of the stabilizer bar even when a Stabilizer bar Stabilizer link R02HAAB small rolling motion occurs NOTE Pillow ball Ball joint not preloaded Pillow ball Own 1 FR 8 1240009 2 8 FRONT SUSPENSION Front Axle FRONT AXLE The drive shaft is of the Bit field joint B J tripod joint T J type This type features high power transmission efficiency and low vibration and noise T J Tripod Joint B J Birfield Joint Wheel bearing RO2KAAA The knuckle has the wheel bearing assembled apd the hub press fitted The drive shaft and hub are spline coupled Hub 12405
60. A TRIANGLE SPECIAL PRODUCTS GROUP SP MILLER SPECIAL TOOLS Nem DIVISION OF THE TRIANGLE CORPORATION
61. FUNCTION lt gt When during fixed speed driving the actual vehicle speed decreases to or below a speed which is a certain fixed value below the memorized vehicle speed the overdrive is canceled temporarily for a specified period of time and then the memorized vehicle speed is restored within a short period of time Overdrive is canceled under any of the following conditions e When the RESUME switch is being operated e When during fixed speed driving the actual vehicle speed decreases from the preset speed by 1 25 km h 0 8 mph or more The arrow in the circuit diagram indicates the flow of current with the OD switch in the ON position overdrive Auto cruise control unit Overdrive signal 14 65 In the Overdrive Mode The control unit microcomputer Outputs an OD ON signal HIGH constantly keeping transistor Tr turned ON At this time transistor Tr is also causing ON signal l to be output to the transaxle control unit and maintaining the overdrive mode The Overdrive is Canceled When the actual vehicle speed becomes less than the set speed the OD ON signal HIGH is no longer output from the microcomputer and transistor turned OFF This causes transistor to be turned OFF and current h flowing by way of the OD switch of the selector lever is cut off at transistor As a result at that point the vehicle speed is controlled by the 3 speed automatic transaxle
62. Idle speed control Servo Control relay Air conditioner relay Ignition timing control For controlling the ignition timing Power transistor Supercharging control Turbo Turbo meter control Turbo For controlling the supercharging pres sure by regulating of the waste gate actuator activation pressure For controlling the turbo meter and displaying the supercharge pressure Jj Waste gate solenoid valve 0 Turbo meter Fuel pressure control For controlling fuel pressure by control Fuel pressure Turbo ling the fuel pressure control valve control valve 14 28 FUEL SYSTEM Engine Control Unit The engine control unit has an onboard diagnosis leshooting It also has a fail safe backup function tc function which is used mainly to diagnose the ensure passenger and vehicle safety sensors thus facilitating system checks and troub Onboard self Mainly for detecting failure of sensors and for Codes can be read by voltmeter diagnosis outputting diagnosis code for detecting failure of sensors etc related to ENGINE CHECK light is turned emission control and to turn ON warning light ON Malfunction indicator light The engine control unit is mounted in the passenger compart ment at the location indicated in the illustration 16A0784 Y FUEL SYSTEM Engine Control Unit 14 29 Sateqnoss cup
63. Input Output output A LOOK eS z v 5 5 Connectors Female connector Male connector 4 7 CONTROL T ge UNIT 2 2 a M Y Y Yg Dashed line indicates that the two symbols are the same connector Terminal No 3 4 7 MOTOR MOTOR SWITCH e 2 Arrow indicates direction of current flow In this particular case current flows in both directions This symbol indicates connector for equipment male connector 15 used as an intermediate connec tor viewed from in front of the terminal connector connection KX396 A0 MN E _ surface Harness splice where wire colour or wire dia meter changes Connector for equip ment with attached har ness Connector inserted directly into equipment 0 1 GENERAL CONTENTS GENERAL DATA AND SPECIFICATIONS 13 VEHICLE IDENTIFICATION 9 Engine Model Stamping 12 TECHNICAL FEATURES 2 Vehicle Identification Code Chart Plate Ade 9 PAD EOUEWIIdOI DI Ne iita i Vehicle Identification Number List 10 Safety lock System 7 Vehicle identitication Number location lt 9 pasio ConsStr ctlon oeeie 4 vehdet simati euda PaE eea na T EDO eaten 5
64. Main Bodv 23 9 ront door panel inner oof panel for sun roof anel inner ender panel 68 Rear floor sidemember front extension 69 Rear floor sidemember 70 Differential mount bulkhead 7 1 Front sidemember rear Rear floor sidemember reinforcement ront door panel outer ood panel outer ailgate panel outer lower ront pillar inner upper B ront pillar outer upper ront pillar outer lower ront upper frame extension outer AGSC35R 83 Front sidemember inner 84 Front sidemember rear reinforcement SENC35R 85 Front pillar inner upper 86 Front pillar inner lower 87 Spare tire bracket SPRC35 SENHC 7 SPHC SPCD or SPCE plated with an electrical zinc nickel alloy SENHE SPRC Phosphorus added SENC35R SPRC35R with electrogalvanized zink nickel coating SGAC35R Phosporus added also galvannealed The numbers in the material codes indicate the tensile strength 23 10 BODY Main Bodv BODY MAJOR CROSS SECTIONS 2 Cowi top panel outer Front end upper bar Hood latch bracket Cowl top panel inner Front end crossmember Dash panel Dash panel outer reinforcement Front end crossmember reinforcement Muffler hanger reinforcement Front end crossmember inn gi Dash panel crossmember Strut house bracket 4 Front upper frame outer Roof panel Strut house panel Rear roof rail outer Front upper frame lower Front sideme
65. Manual Automatic Body Transaxle Heaters and Air Conditioning Emission Control Systems MODEL INDICATIONS The following abbreviations are used in this manual for classification of model types M T Indicates the manual transaxle or models equipped with the manual transaxle A T Indicates the automatic transaxle or models equipped with the automatic transaxle MPI Indicates the multi point injection or engines equipped with the multi point injection DOHC Indicates an engine with the double overhead camshaft or a model equipped with such an engine Turbo Indicates an engine with turbocharger or a model equipped with such an engine Non Turbo Indicates an engine without turbocharger or a model equipped with such an engine 2WD Indicates the front wheel drive vehicles AWD Indicates the 4 wheel drive vehicles HOW TO READ A CIRCUIT DIAGRAM Circuit diagrams are prepared as follows using these NOTE symbols For specific details concerning the interpretation of circuit diagrams refer to the separately bound Service Manual The current flow at the ignition key positions ACC ON and ST is shown combined Be sure to trace the appropriate circuit depending on the ignition key position These symbols show the input to and output from direction of current flow to and from an electronic control unit A indicates that current flows upward Input and
66. No 18 port This allows the 3rd pressure line pressure already established in the No 7 line to be directed to the end clutch through the No 7 port The end clutch is now engaged Downshift from 3rd to 2nd Gear 1 Both front clutch pressure and kickdown servo release pressure are released and therefore the pressure the end clutch valve right end chamber is also released 2 This results in a rightward movement of the end valve by the 2nd pressure working on its left end closing the No 7 port and releasing the end clutch pressure through the No 8 port Now the end clutch is released VA N AUTOMATIC TRANSAXLE Transaxle Control 21 83 in 4th Gear 1 In 4th gear the front clutch pressure and the kickdown release pressure are both released and therefore the pressure at the No 12 port is also released 2 Once the pressure starts being released through the No 12 port the pressure acting on the right end of the plug pressure admitted through the No 18 port pushes the end clutch valve to the left and holds it in the same position as that it has in 3rd gear This holds the end clutch engaged 3 The No 8 circuit provides a fail safe feature which in the event of impossibility of line pressure transaxle to the No 18 line from the No 7 line due to improper movement of the end clutch valve by some reasons allows the line pressure to have an alternate passage through the No 8 line
67. SENSOR Senses by piezo electric element cylinder block _ Turbo vibrations that occur when there is engine knocking Senses supply of power to fuel pump Senses ignition coil primary voltage CONTROL RELAY Fuel pump drive signal IGNITION COIL Fnaine ianition siana FUEL SYSTEM Sensors AIR FLOW SENSOR L Air flow sensor Tum wave Amplifier 2 4111 Vortex generating Rectifier coiumn Modulator Karman vortex 1 Slow air flow OD S 4 6FU0423 2 Fast air flow gt oS Aae mmt Karman MMH JUUL Power supply from control relay Engine control unit gt Power supply came To throttle body Electric pulses 5 volts 6FU0493 The air flow sensor for measuring the volume of engine intake air uses the Karman vortex phenomenon to detect the air flow rate The air flow rate detected in this way is sent to the engine control unit as data on intake air volume Using this signal and the engine rpm signal the engine control unit makes computations to determine the basic injection timing A barometric pressure sensor and an intake air temperature sensor are installed on the air flow sensor The air flow sensor consists of the following parts e Rectifier Rectifies the flow of intake air admitted through the air cleaner
68. SWITCH The inhibitor switch is a switch also used in eommon as the switch for the starter If the selector lever is set to the N position during fixed speed driving current flows from the control unit to the inhibitor switch and then to the starter and to ground with the result that the cancel signal is input to the microcomputer and the fixed speed driving mode is canceled iar aae Mobi aee V AIAN 16 1 PROPELLER SHAFT AND UNIVERSAL JOINTS CONTENTS RI6A CENTER BEARING 2 2 4 LOBRO JOINT eee ees GENERAL INFORMATION _ 2 Construction Diagram Specifications 9 GENERAL INFORMATION The propeller shaft is a 3 piece 4 joint type with two center bearings The shaft made of three pieces has a high bending natural frequency which effec tively reduces vibration and noise during high speed driving Cross universal joints are used at joints No CONSTRUCTION DIAGRAM Na 1 center bearing No 1 universal joint No 2 universal joint Washer 16 2 PROPELLER SHAFT Rubber packing L bro joint assembly Companion flange General Information R16B 4 1 No 2 and No 4 of the propeller shaft and a slidable Lobro joint with low axial sliding resistance is used at joint No
69. Two mode electronic hydraulic control type Solenoid valve operation Shift control 2 control Pressure control control Damper clutch control IDuty control Diagnosis Indication method Indication with LEDs Number of diagnosis items 24 ATF IMOPAR ATF PLUS AUTOMATIC TRANSMISSION IFLUID TYPE 7176 Automatic Transmission Fluid DEXRON or DEXRON II Oil quantity liter qts 6 1 6 4 AUTOMATIC TRANSAXLE General Information 21 17 SECTIONAL VIEW F4A22 Torque Low reverse converter brake Converter housing Pulse from clutch rr add gear set Oil pump Transfer Kickdown Rear clutch idler gear Rear cover Input shaft 1 if d Y Transfer drive gear End clutch Differential Transfer driven gear l Transfer shaft Y Transaxle case Pulse generator B 1750044 21 18 AUTOMATIC TRANSAXLE Transaxle Control TRANSAXLE CONTROL i ins The transaxle control is the cable type floor shift amount of vibration transmitted to the vehicle system Rubber is used at the installation parts of interior In addition A T safety lock system has been the cable to prevent vibration thus reducing the used to prevent sudden start due to malfunction Vibration prevention rubber pieces O 09A0151 Key interlock cable A T Safety lock System Shift lock cable E Vibration preventiom NS rubber Shift lever assembly A RL N
70. a Step type motor and pintle is mounted on the throttle body As the motor operates the pintle extends or retracts to control the bypass air flow The step type motor or stepper motor is a motor that rotates a fixed angle when an electric pulse is pplied The rotor of the stepper motor used here rotates 15 degrees whenever a pulse is applied The pintle meshes with the lead screw on the magnet rotor shaft as shown in the above illustra tion When the rotor rotates in the direction of the outlined arrow the lead screw causes the pintle to retract towards the interior of the motor When the rotor rotates in the direction of the solid arrow the pintle extends i zu 14 46 FUEL SYSTEM dle Speed Control The rotor rotates in either direction by angular step increments corresponding to the number of pulses coming from the en 3 control unit causing the pintle to extend or retract As pintle retracts or extends the gap it forms between the seat changes controlling the bypass air flow The relationship between the pintle extension or retraction movement and bypass air flow rate is as shown at the left Bypass air flow rate Control relay speed control servo Engine control unit Battery power is supplied first to the control relay servo activation signal to turn the power transistor then to the idle speed control servo coil then to the on and thus forms the coil grounding circui
71. after all doors are closed and locked the rear hatch is closed and the hood is closed SYSTEM ARMED j Unauthorized A door aut hatch or hood is broken to open ALARM ACTIVATED 2 Engine is disabled to start A Driver unlocks a door or rear hatch with the key P a 4 4 i ALARM DEACTIVATED SYSTEM DISARMED 16Y3575 GENERAL Vehicle Identification 0 9 VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER LOCATION The vehicle identification number V I N is located on a plate attached to the left top side of the instrument panel VEHICLE IDENTIFICATION CODE CHART PLATE All vehicle identification numbers contain 17 digits The vehicle number is a code which tells country make vehicle type etc 4 44 11 000001 BK 12th to 17th Digits 3rd 4th Digit Digit 7th 8th 9th 10th 11th Digit Digit Digit Digit Digit Vehicle Others i Body Check Model Plant type digits year R 2 L 3 6 4 4 Manual High 3 door 2 0 liters seat belt 5 Hatch 122 cu in C T Premium back DOHC Automatic 6 MPI seat belt Special Serial number 000001 to 999999 Passenger car 2 0 liters 122 DO DOHC MPI Turbo NOTE e Check digit means a single number or letter X used to verify the accuracy of transcription of vehicle identification number 0 10 GENERAL Vehicle Identification V
72. by the ECU Current Flow in PULL Rotation solid line arrows The control unit microcomputer output causes transistors Tr and to be turned ON Then current flows from transistor Tr to DC motor transistor Tr4 and ground As a result the DC motor rotates in the PULL direction Current Flow in RELEASE Rotation dotted line arrows Microcomputer output causes transistors and Tra to be turned ON Then current flows from transistor Tra to DC motor transistor and ground resulting in the DC motor rotating in the RELEASE direction The electromagnetic clutch is controlled by the MAIN and CANCEL switches When the MAIN switch is in the ON position it keeps the clutch plate attracted under norm conditions i e where there is no cancel condition 7t FUEL SYSTEM Auto cruise Control System 14 73 IF MAIN SWITCH 15 SWITCHED OFF the driver switches OFF the MAIN switch become free relative to the sun gear DC motor 2 conductivity to the electromagnetic clutch is and the selector is returned to the original position interrupted the clutch plate is returned from the the return spring installed to the selector electromagnetic clutch side to the ring gear side by planetary pinions turn on their own axes while the spring thus freeing the spring rotating around the sun gear because of the rotation When the ring gear becomes free the planetary of the carrier As a result the ring gear id
73. chamber A and is returned to the oil reservoir Oil reservoir Oil E Oil E passageway R 13L0076 Chamber A 1310093 19 10 Cam ring Flow control valve POWER STEERING Oil Pump 13A0067 OIL PUMP maama The oil pump has a separate oil reservoir it is a vane type pump that generates hydraulic pressure by the rotor vanes and cam ring This oil pump incorporates a flow control valve in order to reduce the power assist effect during high speed driving and thereby improve steering stability and a relief valve in order to maintain the hydraulic pressure and steering linkage rela tionship NOTE The relief valve is incorporated within the flow control valve OPERATION OF THE OIL PUMP The rotation of the rotor causes the ten vanes to move radially by centrifugal force and when there is rotation along the cam curved surface of the circular cam ring there is action in the radial direction along the cam curved surface The fluid chamber is formed by the cam ring rotor and vanes when the rotor rotates the inner surface of the cam ring circular the fluid chamber pressure changes to negative pressure with the result that the fluid within the oil reservoir which is at atmospheric pressure is drawn in suction step after which the rotor rotates further discharging the fluid discharge step The action of this pump is two intake strokes and two discharge strokes for each vane during one
74. change of the crank angle sensor signal No voltage change of the TDC sensor signal No voltage change of the vehicle speed sensor signal A Open or short circuit in the barometric pressure sensor e Open circuit in the detonation sensor circuit 1 e 41 Open circuit in the injection circuit amp re Malfunction of the control relay Open or short circuit in the fuel pump drive circuit 2 43 Malfunction of the EGR system Open or short circuit in the EGR temperature sensor circuit Open circuit in either of ignition coil circuit Normal with none of above faults e te e D denotes items indicated by an illuminated engine warning light FUEL SYSTEM Engine Control Unit Diagnosis connector 16A0741 5141 151211 12111079 716 Ground 6FUO 8I ing light Malfunction aer indicator light gt Engine control unit Engine warn Control ing light relay Malfunction indicator Battery light 14 31 The diagnosis connector is located next to the junction block By connecting a voltmeter between the No 1 and No 12 terminals of the diagnosis connector the meter pointer will deflect according to the output pattern shown before so that the diagnosis code can be read To clear the diagnosis codes that are stored in the memory disconnect the battery ground cable for 10 seconds When a malfunction is detected in items related to emission
75. conditioner 1 compressor Air co Switch 6FU1155 For models equipped with the automatic transaxle when the vehicle is subjected to acceleration at which the throttle valve opening is great throttle position sensor output voltage approximately 4V or more i e throttle valve opening approximately 65 degree or more the air conditioner power relay circuit is interrupted for a certain fixed time approx imately five seconds in order to maintain the acceleration performance 14 56 FUEL SYSTEM Supercharge Pressure Control Turbo SUPERCHARGE PRESSURE CONTROL Turbo Control Engine control relay unit Waste gate E pana sblenoid valve Battery E Interccooier e ON e OFF Air n Air cleaner Power transistor Waste gate unit actuator Primary current ignition A Detonation 9 Sensor Knock control Primary current of ignition coil B deir When using premium grade gasoline the engine control unit functions to switch ON the power transistor then waste gate solenoid valve is turned ON gt e o 5 Because there is then a partial leak of the turbo pressure acting ao 9 upon the waste gate actuator as a result the waste gate valve BR amp will then not open unless there is an increase of the turbo gs pressure to a level that equals or exceeds the set pressure of Poeno the waste gate actuator spring A
76. described later becom es connected In this manner the amount of slippage of the torque convener is reduced without a damper spring to far below at even the low speed level thus making a practical improvement of fuel con sumption At the damper clutch non activation area because the torque converter actuation hydraulic pressure passes through the input shaft oil passage enters the torque converter from the B part we tween the damper clutch and the front cover the damper clutch moves away from the front cover thus releasing the damper clutch In this condition operation is as an ordinary torque converter AUTOMATIC TRANSAXLE Transaxle Mechanism 21 23 Q B1 PAG FS C TRANSAXLE MECHANISM RIEAAAs GENERAL DESCRIPTION The power train is composed of the torque converter SECTION which transfers the power from the engine to the transaxle and the shifting mechanism which functions to provide the most appropriate rotational speed The damper clutch is installed in the torque converter section and functions to reduce the amount of power loss resulting from slippage of the torque converter The shifting mechanism is composed of three sets of multiple RS SP disc type clutches as well as one set each of multiple disc type brake and band brake and a one way clutch and a Ravigneaux type planetary gear set The three sets of clutches Frontal are the elements for control of the input to the planetary
77. gear set and the two sets of brakes and the one way clutch are the lements for holding each part of the planetary gear set or for B1 Kickdown brake e Ing p p yg B2 Low reverse brake obstructing rotation OWC One way clutch As a result of the operation on these elements the shifting 1 perce cise ratio that corresponds to the driving conditions is obtained by TC Torque converter DC Den RCH Planetary gear set SP Short pinion regulating from what point of the planetary gear set there will AG Annulus LP Long ear be input and where holding will be done Under what circumstances which elements will be activated is as described in the table ELEMENT IN USE AT EACH POSITION OF SELECTOR LEVER below ELEMENT IN USE AT EACH POSITION OF SELECTOR LEVER Selector Overdrive Gear Engine 0 Clutches Brakes ever a m E fon ae start nism a B2 Neutral Possible Reverse FAC Neural pepe 359 WT 1 l9 sr Fam CD a 20 ow Cae ia eE OFF 38 te e 3 _ rm 2 let jel _ lel e Los 21 24 SELECT PATTERN Select pattern refers to the indication of transaxle positions t
78. i sf rs LASER TALON P lt gt CHRYSLER va Wa MOTORS x Z T m t PIE hil PEE Im T 3 on 34 gd GU CER L3 PE 4 dec e A ES xo 25 AU m es i 5 D m of E PR 52 d x 9 m d x tar 2 24 9 a MANUAL f wo NEZ SAFETY NOTICE CAUTION ALL SERVICE AND REBUILDING INSTRUCTIONS CONTAINED HEREIN ARE APPLICABLE TO AND FOR THE CONVENIENCE OF THE AUTOMOTIVE TRADE ONLY All test and repair procedures on components or assemblies in non automotive applications should be repaired in accordance with instructions supplied by the manufacturer of the total product Proper service and repair is important to the safe reliable operation of all motor vehicles The service procedures recommended and described in this publication were developed for professional service personnel and are effective methods for performing vehicle repair Following these procedures will help assure efficient economical vehicle performance and service reliability Some of these service procedures require the use of special tools designed for specific procedures These special tools should be used when recommended throughout this publication Special attention should be exercised when working with spring or tension loaded fasteners and devices such as E Clips Circlip
79. is composed of the impeller rear cover turbine stator damper clutch one way clutch front cover etc Furthermore the torque converter cannot be dis assembled because the outer circumference of the shell front cover and rear cover is sealed by welding Because the torque converter is coupled to the engine s crankshaft via the drive plate the shell front cover and impeller always turns in the same way when the engine is running As a result the oil pump is also caused to rotate by the hub welded to the center part of the rear of the shell at the same speed as the engine The boss at the front part of the shell is inserted in the hole at the rear part of the crankshaft thus providing support of the torque converter A facing like that attached to the transaxle s clutch disc is attached to the damper clutch and the damper clutch and the turbine are connected by the tabs of the lock ring on the outer circumference of the turbine shell that fit into the groove on the outer circumference of the damper clutch The torque converter actuation hydraulic pressure at the damper clutch activation area passes be tween the torque converter s hub and the reaction shaft and enters the torque converter When this happens the hydraulic pressure acts upon the A part between the damper clutch and the turbine with the result that the damper clutch is pressed against the front cover and the damper clutch with a slight slip as
80. jet provided for each cylinder just under the main gallery of the cylinder block When the pressure of oil from the main gallery exceeds 200 kPa 2 kg crn 28 psi the oil pushes open the check valve spurting over the inside of the piston thus cooling it Turbo engines only 2 The water jacket is the siamese type Check valve Oil jet 9 10 ENGINE Base Engine PISTON For non turbo engine Identification For turbo engine Front mark mark Steel strut 6 0125 6 0249 1 The piston is the autothermic type with steel 2 The depth of the trough in pistonhead varies for struts cast into it the non turbo and turbo engines 3 The piston pin is of the semi floating type press fitted to the connecting rod and rotates freely in the piston Connecting rod 6 0250 1 piston ring PISTON RINGS E 1 The No 1 piston ring is of the barrel type N 2 The No 2 piston ring is of the taper type The surface in 0 2 piston ring No 2 piston ring contact with the cylinder wall is coated with hard chrome plating 3 The oil ring is of the three piece type consisting of two sic Oil ring For turbo engine rails and an expander ENGINE Base Engine 9 11 CONNECTING ROD 1 The same connecting rod is used as that used in the 4G63 SOHC engine 2 The oil jet provided in the shoulder of the connecting rod is used to lubricate the cylinder wall 3 Th
81. lever Return spring Spring 14A0123 Shaft Auto adjuster spindle 5 6 BRAKES Service Brakes In addition disc removal and installation is made easy by the outer disc system in which the brake Brake disc installation cross section lt 2WD gt Hub nuts Disc wheel Brake disc 1440390 disc the disc wheel are installed to the hub the hub nuts Disc wheel 1440528 Brake amp c BRAKES Parking Brake S PARKING BRAKE The parking brake is of the mechanical rear wheel braking type The parking brake is offset toward the driver s seat from the vehicle centerline for greater ease of operation CONSTRUCTION DIAGRAM lt 2WD gt N EQ 28 lt 4WD gt P E qe d pP MM ROSDAAB The parking brake cable is of the V type and is accessible for adjustment through the service hole provided in the floor console 4 DN Qa 1440391 1440526 CLUTCH CONTENTS xm CLUTCH CONTROL eR mem GENERAL INFORMATION ater 3 Specifications Inter lock Switch 6 2 CLUTCH General Information Clutch Control GENERAL INFORMATION ROBBIIA The clutch is the dry single plate diaphragm type hydraulic pressure is used for the clutch control SPECIFICATIONS Clutch operating method Hydraulic type Hydraulic type Clutch disc Type Single d
82. limiter Two way valve Overfill limiter Leveling pipe Fuel filler cap Vacuum relief Fuel filler pipe Fuel pump Filter Fuel vapor air 6 0140 25 12 EMISSION CONTROL SYSTEMS Evaporative Emisson Control System Turbo Purge control valve 4 Air cleaner Purge control 23 solenoid valve L5 Tub R ON Overfill limiter Overfill limiter Leveling pipe Fuel filler cap Vacuum relief Fuel injector e Fuel check valve i A Fuel filler pipe Thermal expansion volume Engine Fuel gauge unit Turbo Canister ae charger Charcoal RM DM EET Fuel pump Filter 7 Fuel vapor Purge air 211 CANISTER solenoid Sm While the engine is inoperative fuel vapors generated inside valve ne the fuel tank are absorbed and stored in the canister When the engine is running the fuel vapors absorbed in the canister are drawn into the throttle body through the purge control solenoid valve Atmosphere 7 Filter 03R003 EMISSION CONTROL SYSTEMS Evaporative Emission Control System 25 13 To intake air plenum or throttle body PURGE CONTROL SOLENOID VALVE lt From canister Turbo The purge control solenoid valve is the ON OFF control type of solenoid valve it functions to control the introduction of purge air to the intake air plenum from the canis
83. m ura ervel DRIVEN BEVEL GEAR PROPELLER SHAFT REAR DIFFERENTIAL CASE REAR DIFFERENTIAL SIDE GEAR L REAR LEFT DRIVE SHAFT REAR RIGHT DRIVE SHAFT 21 10 4WD SYSTEM OPERATION Conventional 4WD systems direct coupled 4WD or center differential type 4WD have their own merits and demerits they rely on manual operation switching between 4WD and 2WD modes center differential locking to cope with their demerits With this new 4WD system the viscous coupling built in the center differential automatically performs MANUAL TRANSAXLE lt 4WD gt General Information such operations used to be made manually The driver can participate with the merits of 4WD at all times The operation of the differential and the viscous coupling under representative conditions are described in the following section Rear differential Center differential Front and rear wheel turning radius difference Right and left wheel turning radius difference Turning direction During normal driving During normal driving traveling straight on a level road at a constant speed the four wheels rotate at nearly the same speed Since there is no rotating speed difference among the four wheels the viscous coupling does not apply differential limiting torque and the three differentials distribute drive power equally to all of the wheels During a sharp turn During a sharp turn in addition to the rotatin
84. motor is started causing the link assembly to move the hinge which results in the headlight moving up A parallel link system is employed for the hinge in which the hinge is moved about the two fixed points as shown which ensures that the headlights are moved up and down vertically DOWN position motor Link assembly 16A0890 Fixed points Tees 9 Y CL f m N ANS ES i ERS Headlight moton Link assembly moton ELECTRICAL Lighting 8 17 Front turn signal light Optical horn 16A0858 OPERATION Headlight Operating Conditions Passing Light The parallel link pop up headlight mean that the headlights are facing forward even when they are in the lowered position When the passing light is used therefore the headlights are turned ON and the light is radiated through the optical horn lens installed to allow the light through of the side turn signal light Manual Knob The manual knob located behind the pop up motor is used to move up or down the headlights manually when maintenance is required To operate the manual knob remove the boot behind the pop up motor and turn the knob clockwise To ensure safety disconnect the negative battery cable or remove fusible link 4 whenever the manual knob is to be operated Headlight operation or position Headlight Pop up Lighting switch switch ON Passing switch Lighting switch Passing switch
85. motor located at the glove box It is the blend air system for excellent temperature control high cooling performance characteristics Three layer flow full blend air hea e Resistor switching type condenser fan radiator ter 7 uu fan Hi Lo control system is adopted for power The heater air conditioner and ventilation have the saving and low noise operation following features e ECONO mode is introduced to secure optimum Heater compressor operation against intake air temper e Multiple outlet shower foot duct system is ature changes adopted for better wind distribution during heat air conditioner switch is a two step rotary switch easier to operate ing Large defroster nozzle side defroster indepen dent distribution system is adopted for securing good driving field of view Press the switch in the first step then the air conditioner will perform ECONOMY operation Press the switch in the second step then the air conditioner will perform DRY operation Ventilation e Air intake garnish is reshaped for better water proofing and effective prevention of entry of fallen leaves etc e Louver type rear outlet with high ventilation performance is introduced for the side protector Model 10PA17 swash plate ty e Round shaped dial type heater control is adopted that is easy to operate and well matched with the instrument panel design e Ceramic resistors are adopted and blower switches etc are connected by
86. outer panel sheet metals Access holes 32A0119 Headlamp Support The following component supply formats have been adopted in order to cope with various damage conditions e Supply as assembly Headlamp support 1 2 3 4 5 6 e Supply as individual parts 2 3 4 5 5 Front end upper bar 7 Front end upper bar reinforcement Fender support plate Headlamp support side panel Sidemember to crossmember brace Front end crossmember a 3140244 Fender Shield The following component supply formats have been adopted in order to cope with various damage conditions e Supply as assembly Fender shield 2 3 4 5 6 7 Wheelhouse inner 1424 344 e Supply as individual parts 1 2 3 6 7 8 1 Front upper frame outer 5 Front sidemember 2 Front upper frame inner 6 Front end gusset outer 3 Shield plate 7 Front end gusset inner 4 Front wheelhouse 8 Front sidemember rear 7 A BODY Main Bodv 23 17 ront Deck part coupling with the fender shield is supplied as an individual part for efficient part replacement e Supply as assembly Cowl top panel 25344 65 e Supply as individual parts 1 3 4 5 Front deck crossmember Cowl top Upper frame extension outer Upper frame extension inner Upper frame silencer co A OIN 31A0239 Dash Panel The dash panel extension is supplied as an individual part in order to cope with a side col
87. plug Ignition coil 850 tachometer Terminalfor engine 6 10045 The ignition system is two coil ignition system that supplies sufficient energy for ignition up to high speeds This engine does not have a distributor since the engine control unit directly activates the power transistor for ignition timing control The functions and controls of the engine control unit and various sensors that control the ignition timing are described in the next chapter IGNITION CON TROL SYSTEM This ignition system has two power transistors and two ignition coils Power transistor A controls the primary current of ignition coil A to activate the spark plugs of the No 1 and No 4 cylinders Similarly power transistor B controls ignition coil B which activates the spark plugs of the No 2 and No 3 cylinders In this way spark plugs of two cylinders are activated but actual ignition takes place only in the single cylinder that is on its compression stroke because the other is on its exhaust stroke at that time Power transistors and B are activated by signals from the engine control unit that controls which cylinder is fired at what time ELECTRICAL Engine Electrical IGNITION COIL Two compact ignition coils of a molded type featuring Signal unit for outstanding ignition performance are used tachometer Being a two coil type the ignition coil has a unit to supply signals for the tachomet
88. position is input to the NOT circuit and inverted L signal input to the AND circuit So when the door is closed the timer circuit does not operate and the light does not dim but goes out immediately wit t i i i 1 t 4 ELECTRICAL Enaine Electrical 8 23 ENGINE ELECTRICAL ROOGAAR ALTERNATOR Brush Stator L terminal Electronic voltage regulator Stermina B terminal A Capacitor 6 L0050 6ELO051 The alternator has a built in electronic voltage regulator The output voltage is controlled by the voltage regulator through detection of the battery voltage SPECIFICATIONS Nominal output 65A for Non turbo Engine with M T 75A for Non turbo Engine with A T and Turbo Engine Regulated voltage 14 4 0 3V at 20 68 F amp ELOO5 Rotating direction Clockwise viewed from pulley side E gt 8 24 ELECTRICAL Engine Electrical STARTER MOTOR Reduction gear Magnetic switch S terminal Shift lever Overrunning Armature clutch Permanent magnet 6 10053 6 10055 SPECIFICATIONS Reduction drive Nominal output 1 2 kW Rotating direction Clockwise viewed from pinion side T ELECTRICAL Engine Electrical IGNITION SYSTEM Engine control unit speed detection ower transistor 8 25 Ignition switch No 4 No 3 Spark
89. shaft Joint type Outer Inner Length joint to joint x diameter Differential Reduction gear type Reduction ratio mm in mm in mm in NEAM uenerai inrTormation Conventional differential Semi floating type 85 1 38 28 1 10 34 5 1 36 214 9 8 46 mm in mm in 72 x 35 2 83 x 1 38 58 28 2 28 x 1 10 mm D O J B J mm in 397 x 24 15 6 94 Hypoid gear 3 545 Differential gear type and configuration Side gear Pinion gear Number of teeth Drive gear Drive pinion Side gear Pinion gear Bearing x I D Front Rear Note Side mm in mm in mm in Straight bevel gear x 2 Straight bevel gear x 2 10 72 x 35 2 83 x 1 38 62 x 25 2 44 x 98 72 x 35 2 83 x 1 38 Viscous coupling type limited slip defferential option Semi floating type 35 1 38 28 1 10 34 5 1 36 214 9 8 46 72 x 35 2 83 x 1 38 58 x 28 2 28 x 1 10 D O J B J 397 x 24 15 6 94 Hypoid gear 3 545 Straight bevel gear x 2 Straight bevel gear x 4 39 11 16 10 72 x 35 2 83 x 1 38 62 x 25 2 44 x 98 72 x 35 2 83 x 1 38 Denotes the gear L H which is in a single body with the viscous coupling 3 4 REAR AXLE Axle Shaft Drive Shaft AXLE SHAFT The axle shaft is a semi floating type supported by ball bearings outer and inner in the housing Companion flange Trailing arm DRIVE SHAFT Bi
90. spring Snap ring Selection 1750213 Front clutch is Ot tne mi uitipie aisc type and 15 composed of a front clutch retainer discs plates and a piston The front clutch is actuated when the t is in forward third or back gear It conveys force of the input shaft to the reverse sun gear POWER FLOW Rear clutch retainer Front clutch Input shaft nout shaft Rear clutch retainer Front clutch Number of clutch discs Number of clutch plates O D mm in 116 4 57 D mm 66 260 Kickdown drum Reverse sun gear 1750214 Kickdow drum 21 26 AUTOMATIC TRANSAXLE Transaxle Mechanism REAR CLUTCH Wave spring D ring Check valve Rear clutch retainer Input shaft Return spring Clutch pressure plate Rear clutch is of the multiple disc type and is composed of a rear clutch retainer disc plates and a piston When the piston is actuated by the oil pressure the multiple disc clutch is connected conveying driving force from the input shaft to the forward sun gear in the planetary gear set The rear clutch is always actuated when the shift is in first second and third gears POWER FLOW Rear clutch Rear clutch retainer Input shaft Input shaft ear clutch retainer Rear clutch Clutch plate Clutch reaction plate Clutch disc D ring Thrust race Check valve Piston Snap ring 1750215 N
91. the basic activation timing of the injec tors The amount of intake air is determined by the degree of opening of the throttle valve and during engine idling the amount of intake aris regulated by the idle speed control Servo Waste gate solenoid valve lt Turbo gt Purge control solenoid valve EGR control solenoid valve lt California gt Fuel pump relay Control relay Air conditioner relay Diagnosis output Turbo meter lt Turbo gt Fuel pressure control valve Turbo temperature sensor Coolant temperature switch Detonation sensor Turbo eFU1003 14 4 FUEL SYSTEM Fuel Supply and Fuel Pressure Control FUEL SUPPLY AND FUEL PRESSURE CONTROL M GENERAL DESCRIPTION Seen Tune Fuel gauge unit Fuel tank Engine Fuel pump control unit Electrical Fuel pump check terminal Check valve Canister Two way valve Fuel injector In tank filter Fuel filter Delivery pipe 0340226 Fuel pressure regulator lt Turbo 2WD gt Fuel gauge Fuel tank du Engine control unit Fuel pump Electrical Fuel pump check terminal Check valve Purge control valve Two way valve In tank filter Fuel injector Fuel filter Delivery pipe Fuel pressure regulator 9349427 SR emm FUEL SYSTEM Fue Supply and Fuel Pressure Control 14 5 Turbo 4WD Fuel tank f Two way valve Engine control unit Fuel pump and fuel g
92. the most appropriate roll rigidity is provided Vibration is reduced by the use of bushings with optimum spring characteristics anti lift geometry Improved riding comfort thanks to the construc tion in which the coil spring and shock absorber are located on the same plane as the axle SUR nt eee e CONSTRUCTION DIAGRAM Coil spring Shock absorber Trailing arm Spindle 124054 oA REAR SUSPENSION lt 2WD gt General Information 17 3 SPECIFICATIONS Items Specifications 3 link torsion axle with coil spring type Suspension system Wheel alignment Toe in left right wheel difference in 0 3 0 118 Camber 45 30 Coil spring Wire dia x O D x free length in Coil spring identification color Spring constant N mm lbs in 10 2 x 105 2 x 316 5 40 x 4 14 x 12 46 Orange x1 23 128 8 Shock absorber Type Max length mm Min length in Stroke Damping force at 0 3 m sec 9 ft sec Expansion N lbs 1 Contraction Ibs Hydraulic cylindrical double acting type 485 19 1 315 12 4 170 6 7 800 176 300 66 17 4 REAR SUSPENSION lt 2WD gt Wheel Alignment Anti lift Geometry Wheel center line 12A0014 12 0004 WHEEL ALIGNMENT m The camber and toe in have been set to the optimum value in the same way as for front wheel alignment in particular the camber is negative camber
93. the re tor for the lap belt for the front passenger s seat The component is an assembly supply item and so is not to be disassembled Its construction and operation are however as described below Gear B is coupled with the shaft of the retractor it rotates in the counterclockwise direction when the belt is pulled out Gear A is meshed with gear B and revolve in the same direction as gear B The illustration 19P0373 shows the condition when the belt is completely rewound When the belt is pulled out completely gear A revolves about three times and the gear A cam contacts rod A thereby pressing rod A Rod A then presses the stopper and the stopper presses the sub pawl When the sub pawl is pressed the internal lock mechanism functions and the belt pull out motion becomes lock thus becoming ALR When the belt 15 rewound about 600 mm 23 6 in from the completely pulled out position gear A revolves in the clockwise direction with the result that the cam of gear A contacts rod B and causes rod B to be pressed Rod B then presses the stopper thus causing the sub return thereby unlocking the lock and making pull out frev thus becoming ELR M M REA Contact 18 0376 Energy absorbing belt Before absorbing shock 2 After absorbing shock 19A0332 Buckle BODY S
94. through the No 20 and No 20a lines VERA This releases the rear clutch From N D control valve From manual shift valve control valve 4th pressure 175011 Downshift from 4th to 3rd Gear 1 If the 4th pressure from the shift control valve is dis 1 charged the element of the rear clutch exhaust valve clutch is pushed to the left under the line pressure established in the No 5c line This line pressure is directed to the rear clutch via the No 20 line No 20a line and then No 15 line In one of the passages connecting the No 20 line with the No 20a line there is a check ball and in the other there is an orifice When one passage is closed by the check ball the fluid flows through the other passage with an orifice which slows down the fluid flow speed permitting gradual transaxle of pressure to the No 20a line to create condi tions ready for the rear clutch to operate Check To shift From N D control To manual contro valve valve ath valve pressure 1750118 2 When the 2 3 4 3 shift valve operates and the hydraulic 4 3 shift pressure acts on the front clutch and the release side 12 To rear clutch valve chamber of kickdown servo cylinder the pressure is directed through the No 12 line to the right end of the element B of the clutch exhaust valve Combined with the spring force this pressure pushes the element B of the
95. time contro i Engine Injector activation pulse generation control unit ER Control factor data of engine coolant temperature intake air temperature and barometric pressure etc Injector 6FU0788 INJECTOR The injection nozzle spray opening area is constant and the fuel injection pressure is also constant therefore the injection quantity is determined by the amount of time that the solenoid coil is energized Connector Solenoid coil Plunger Needle valve FUEL SYSTEM Fuel Injection Control 14 35 INJECTOR CIRCUIT Control relay Resistor Turbo No 1 No 2 No No 4 Injector Engine control unit Electricity from the battery flows to the control relay and then to the resistor turbocharger equipped models only the injector and the engine control unit Upon reception of the fuel injection signal the 6 00515 engine control unit causes the power transistor to be turned ON thus completing the injector ground circuit In this situation current flows to the injector which injects fuel while the power transistor is ON 14 36 GFUOSIC FUEL SYSTEM Fuel Iniection Control RESISTOR lt Turbo gt The resistor functions to regulate the current flowing in the co of the injector Because the injector must respond instantly to fuel injection signals the numb
96. tj 100 On command from the transaxle control unit the duty of the pressure control solenoid valve is set at 100 percent solenoid is constantly energized This reduces the No 23b line pressure to the minimum level As amp result the pressure control valve is forced to the left and the No 5 port is closed which prevents pressure from being directed to low reverse brake via the 1 2 shift valve In very low vehicle speeds however the duty is set to zero percent for the maximum pressure which is most practical for the control purpose AUTOMATIC TRANSAXLE Transaxle Control U Selector Lever in D or 2 Reducing valve Line pressure Reducing pressure N R control valve 16 21 71 To kickdown servo or front clutch via 1 2 shift valve Line pressure Pressure control valve Ex Pressure control solenoid valve Duty control 1750097 To ensure a smooth gear change when upshifting from 1st to 2nd 2nd to 3rd etc the transaxle control unit controls the duty of the pressure control solenoid valve in order to regulate the control pressure established in the 23b line which gov ems the operation of the pressure control valve The dine pressure that flows from the No 5 port to the No 10 port is regulated in this way As all upshifts are controlled in a similar manner the control for the upshift from 1st to 2nd gear will be exp
97. to flow to Tr for 0 5 second thus switching ON Tr As a result current flows to the fuse as well as to the lock side coil of the door lock relay and to ground thus switching ON the lock side contacts of the door lock relay and activating the door lock actuators thereby locking the doors Door lock Door lock actuator actuator left side right side 4 Operation when the doors are unlocked When the doors are unlocked by using the inside lock knobs or the door key the door lock switch Battery incorporated within the door lock actuator is switched ON and then because current flows to the fuse the door control unit and the lock timer the lock timer causes base current to flow to for 0 5 second thus switching ON As a result current flows to the fuse as well as to the unlock side coil of the door lock relay and to ground thus switching ON the unlock side contacts of the door lock relay and activating the door lock actuators thereby the doors Door lock relay VUL ESI TR me a Door tock actuator 7 actuator left side right side T E 23 22 BODY Power Windows POWER WINDOWS SOME MODELS gt Ry Power windows are equipped in order to facilitate A lock switch is provided at the power windows the opening and closing of the door glass The main switches when the lock switch is ON the driver s seat switch incorp
98. to the engine load calculated in this way Load Intake air volume Engine rpm If however the engine coolant temperature is low the actuation duty is attenuated the EGR control valve activation negative pressure vacuum is leaked from the throttle body A port thus reducing or interrupting the EGR flow volume and thereby Air flow sensor Coolant temperature sensor NOTE This figure shows Non Turbo EGR conte EGR temperature sensor Crank angle sensor EMISSION CONTROL SYSTEMS Exhaust Gas Recirculation EGR System maintaining driveability during cold When as a result of clogging of the contr valve or as a result of an operational malfunctio the EGR flow volume decreases the EGR gas temperature downstream from the EGR control valve decreases The engine control unit functions to detect the operation conditions of the EGR system by this characteristic The temperature of the EGR gas is detected by the EGR gas temperature sensor which is equipped at the EGR control valve when the temperature decreases to a low level the engine warning light malfunction indicator light illuminates in order to advise the driver that a malfunction has occurred in the EGR system EGR control solenoid valve Contro relay Engine warning light Engine control unit EMISSION CONTROL SYSTEMS ExhaustGas Recirculation EGR System 25 7 5222 22 25 22 Duty r
99. valve to the left This allows the high line pressure in the No 5c line to be directly transmitted to the rear clutch through the No 15 line Ba Ex A From N D H i T d control valve 175011 21 86 AUTOMATIC TRANSAXLE Transaxle Control SOLENOID VALVE There are four solenoid valves installed on the valve boo they are activated as explained previously by commands from the transaxle control unit i l 4 1 Ground Ground Pressure control Shift 1 Shift Damper solenoid valve control control clutch solenoid solenoid control valve A valve B solenoid valve Connector 1760035 5 AUTOMATIC TRANSAXLE Transaxle Control 21 87 HYORAULIC CIRCUIT S CTOR LEVER IN N Torque converter P Kickdown servo Front Rear Low reverse ci 1d clutch clutch brake clutch S9 n 7 5 7 7 7 eee N x io t 2 3 4 3 mmi im J n valve DV ms Rear clutch exhaust valve n _ c amper clutch _wenoid valve End clutch valve Torque converter control valve 000 Li Ex IE 5 13 Regulator valve N D contro valve Pressure control valve v1 Line relief valve control unit Line Pressure BEER Pu
100. 0 x 174 0 x 326 5 55 x 6 85 x 12 9 Coil spring identification color Pink x 1 Spring constant N mm lbs in 26 146 Shock absorber Type Hydraulic cylindrical double acting type Max length in 489 19 25 Min length in 340 13 39 Stroke 149 5 87 Damping force at 0 3 m sec 984 ft sec Expansion N Ibs 1 000 220 Contraction N Ibs 300 66 12 FRONT SUSPENSION Anti dive Geometry Negative offset Geometry 2 5 ANTI DIVE GEOMETRY RO2CAAA Ordinarily when the brakes are applied the load is moved toward the front of the vehicle as the result of inertial force and this causes the phenomenon known as nose dive in which the front of the vehicle is caused to tilt forward and downward For this front suspension however the suspension link design which has a high anti dive effect is such that the lower arm is tilted forward in order to counteract the nose dive phenomenon In other words braking force F is divided into force compo nents and F2 of these acts in the direction that expands the front spring with an effect that reduces the nose dive phenomenon NEGATIVE OFFSET GEOMETRY For negative offset geometry the king pin offset angle is outside the center point of tire to ground contact Thus for example if a tire on the right side is punctured during driving or if the brakes are applied while the left tires are on a slippery surface
101. 02 11 2 POWER STEERING and Valve Assembly Construction 19 7 1 OPERATION OF THE PINION AND VALVE SSEMBLY gulation of the hydraulic pressure applied to the power cylinder is performed by the input shaft and the rotary valve The concave and convex parts at the input shaft surface and the rotary valve inner surface due to the rotational difference function to either constrict or expand the fluid passageway by varying the aperture surface area of the fluid passageway and as a result thereby regulating the hydraulic pressure of the hydraulic circuit from the oil pump to the cylinder tube left chamber or right chamber and from the cylinder tube right chamber or left chamber to the oil reservoir WHEN THE STEERING WHEEL IS TURNED TO THE RIGHT When the steering wheel is turned to the right the Port b Chamber A To the right cylinder tube n Rotary valve From oil pump From the left cylinder tube 13 0263 Chamber input shaft Rotary valve Sieeve b Cylinder tube left chamber Input shaft Torsion bar Cylinder tube right chamber torsion bar is as shown in the illustration caused to torque in the direction of turning to the right with the result that the input shaft rotates by the corresponding amount to the right and a rotational difference between the input shaft and rotary valve develops The concave and convex parts of the input shaft and rotar
102. 0710018 14 68 ACCELERATOR PEDAL SWITCH OFF FUNCTION lt gt The accelerator pedal switch senses the operating condition of the accelerator pedal This function turns OFF the accelerator pedal switch in the auto cruise control mode during which the accelerator pedal is inoperative accelerator pedal switch ON Ignition switch IG Auto cruise control system in operation Not in operation ON uto cruise control unit Cruise control ON FUEL SYSTEM Auto cruise Control System In the auto cruise control mode the control ur microcomputer outputs an ON signal HIGH Stantly causing transistor Tr to be turned ON At this time transistor Tr turns OFF causing ON signal from the A T control unit to be shut off which results in the accelerator pedal switch being turned OFF control unit Accelerator pedal switch depressed OFF 07A0010 FUEL SYSTEM Auto cruise Control System 14 69 Junction Diagnosis SELF DIAGNOSIS AND INPUT CHECK FUNC connector TIONS SELF DIAGNOSIS When there is a cancellation of the auto cruise control system operation not intentionally made by the driver it is possible to determine which circuit or what operation caused the cancella tion of the auto cruise control system by following procedures 1 Stop the vehicle with the ignition switch and MAIN switch in the ON position NOTE Turning OFF either the i
103. 175011 To shift Toend From 2 3 4 3 control clutch shift vaive valve 1 land 2nd 3rd pressure pressure 1750114 Upshift from 2nd to 3rd Gear 1 When the shift control valve comes into 3rd gear position and the 3rd pressure is established the pressure is directed to the No 7 port of the end clutch valve through the No 7 line In this instance the 3rd pressure is blocked ahead by the end clutch valve and the check ball 2 If a shift to the 3rd gear is initiated the pressrue begins to be directed from the 2 3 4 3 shift valve to the front clutch and the release side chamber of kickdown servo cylinder The same pressure also is directed to the chamber at the right end of the end clutch valve through the No 12 line During the shift to the 3rd gear the pressure in the No 12 line is regulated by the pressure control valve to a level lower than the line pressure so that the No 12 line pressure is not high enough to force the end clutch valve toward the left 3 Once the front clutch has been engaged and the kickdown brake released the No 12 line pressure is raised to a level equivalent to the line pressure This means that the pressures at both ends of the end clutch valve or No 6 line pressure and No 12 line pressure are at the same level However as the area of the 3 land to which pressure is applied is larger than that of the 1 land of the end clutch valve the valve is pushed to left thus opening the
104. 21 73 1 elector Lever in R T Reducingi Y valve Pat Line Transaxle Reducing Eo Pressure control E pressure aged valve 4 23bE Pressure control N R control ig 580 Ex solenoid valve valve ij LE i X Ex Line pressure 23b 4 r Duty control 4 OFF 4 1750099 When the manual valve is shifted to the R range position the pressure control solenoid valve func ions under duty control from the transaxle control unitto reduce the reducing pressure in the No 23b and to create another control pressure in this The balance of forces established between the control pressure and the force of the N R control spring determines the degree that the No 9 lire port will be open The line pressure from the line is regulated by passing through the port K whose opening has been adjusted and then is directed to the low reverse brake Through this pressure control the shocks that would occur while shifting to reverse are minimized Once the low reverse brake is engaged the press ure control solenoid valve is deenergized and normal reducing pressure is reestablished in the No 23b line Because this reestablished reducing pressure forces the N R control valve toward the left the line pressure passing through the No 9 port is applied directly to the low reverse brake through the No 16 port and eng
105. 3 Front Deck 17 CENTRAL DOOR LOCKS 20 Front 17 Door Lock Actuator 20 Vis Centiar Desi loa Headlamp Support 5 3 pe heres 16 etes vesper enin Main Body t 12 DOORS 19 Maintenance Serviceability 15 Rear Body csitri iniii tikt 14 DOOR MIRRORS 27 eat Body Erare Emo CORR 27 Rear End Panel _ 17 Side Body coe eet 13 FLOOR CONSOLE nnns 29 Side Structure eee 15 Special Steel Panels inen 6 FRONT SEATS 020 0 0 0 30 INSTRUMENT PANEL 29 POWER WINDOWS 444 24 40 22 VS CE NE Operation of the Power Windows 23 E 2 MAIN BODY REAR SEAT 30 Access Holes enne 16 Body Center Points 15 SEAT BELT 31 Automatic Seat Belts 31 Rear Seat Belt 46 SOLID tte ns 18 SUN ROOE vene ve rv e En TRUE 25 BODY Main Body 23 2 MAIN BODY R23BAAR BODY COMPONENTS 65 0 10 Front end upper bar Headlamp support panel 3i
106. 339 Knee protector Guide rail PM L Slide anchor Fasten switch Automatic seat belt control unit Driving device Automatic seat belt motor relay 1940326 Retractor ELR A BODY Seat Belts SEAT BELTS On Federal and California vehicles automatic seat belts Manual seat belts on vehicles for Canada are installed on the front seats and the 3 point seat belts with ELR on the rear seat both contributing to the enhanced safety and ease of use 23 31 R23SBAB AUTOMATIC SEAT BELTS GENERAL INFORMATION The Automatic Seat Belts are designed to automatically fasten themselves around the driver and front passenger as they get into the vehicle and close the front door thereby by a combination of the lap belt the knee protector the corner pad and the glove box pad at the lower part of the instrument panel protecting them from second collisions during a front end crash or similar accident The lap belt for the driver s seat is provided with the ELR ELR Emergency Locking Retractor and that for the front passen gers seat with the ELR ALR to support the Child Restraint System incorporated into the seat ALR Automatic Locking Retractor The buckle tilts toward front and inside helping the belts be tight around the body The tongue plate on the driver s seat is provided with energy absorbing structure The automatic seat belts consist of a driving device assembly shoulder be
107. 42 engagement when the fluid temperature is high prevent this a special valve is provided in the low reverse brake circuit This valve has an orifice which restricts flow of fluid when the pressure is directed to the low reverse brake but has no flow restriction effect when the low reverse brake press ure is released thus preventing sluggish release of the brake SE AUTOMATIC TRANSAXLE Transaxle CLUTCH VALVE 12 19 2 3 4 3 ur ET ed shift LL valve Shift control solenoid valve A Shift control solenoid valve B Line pressure 21 81 Control To front clutch To end clutch To kickdown servo release side eip 12 8 ENSE NN Ex Plug N End clutch valve IO 9c 11 Line pressure from 1 2 shift valve 2nd pressure Ea 3rd pressure 1750243 To end Glutch From manual valve pressure pressure End clutch valve controls the timing for supplying hydraulic pressure to the end clutch 2nd Gear 1 When hydraulic pressure is not being directed to the end clutch valve it is held pushed to the left by the spring force see above figure 2 If the 2nd pressure from the shift control valve is directed to the end clutch valve via the No 6 line the end clutch valve is forced toward the right Saud 21 82 AUTOMATIC TRANSAXLE Transaxle Control To end clutch 1 2nd 3rd pressure pressure
108. 51 DRIVE SHAFT B J T J constant velocity joint combination main tains speed completely even when flexed can withstand heavy loads and shock and offer high power transmission efficiency Their special fea tures are outlined below B J e Large operating angle e Compact size and decreased space require ments B J e Axially slidable e Smaller sliding resistance Taking these characteristics into account B J is adopted on the wheel side of the shaft as it can make large deflections when the tire is steered and T J is adopted on the transmission side as it can slide axially to absorb the change in the distance between joints caused by motion of the suspension T J 1140123 Hf FRONT SUSPENSION Front Axle 2 9 HUB AND KNUCKLE The construction of the hub and knuckle consists of the wheel bearing assembled to the knuckle and the hub pressed in the drive shaft and hub are coupled by serrations 1180083 Wheel bearing Knuckle Dust shield Oil seal The wheel bearing is the double row angular contact ball bearing type to withstand the lateral thrust load The installation of the brake disc and hub are the outer disc configuration thus improving serviceability and also reducing rotation unbalance Knuckle Brake disc Hub Dust shield 11 0053 Brake disc 11 A0295 HEAR AXLE CONTENTS AXLE SHAFT
109. EAR AXLE Differential Support Member 3 9 DIFFERENTIAL SUPPORT MEMBER ROSFAAA The differential support member supports the rear side of the differential carrier That end of the member which is mounted to the body is elastically supported by use of rubber bushings Section A A Differential support 1140297 member Differential support member N Differential carrier 11A0296 BRAKES SERVICE AND PARKING CONTENTS an GENERAL INFORMATION nnn 2 SERVICE BRAKES 3 Construction Diagram 2 Front Disc Brake 4 Features conguet mo ce att 2 Rear Disc Brake 5 Specifications 2 Specifications sss 3 X Arrangement of Brake Lines 3 PARKING BRAKE Construction Diagram 5 2 BRAKES General Information GENERAL INFORMATION ROSBAAB The service brakes are a brake system featuring system as a brake system matching the vehicle excellent braking force and a high level of reliability superb driving performance Models with turbochar and durability ger are equipped with a 7 8 inch tandem brake All models are equipped with four wheel disc brake booster for lower brake pedal depression efforts SPECIFICATIONS Specifications Service brake Ventilated disc Solid disc Parking brake Mechanical rear wheel braking type FEATURES Improv
110. EHICLE IDENTIFICATION NUMBER LIST VEHICLES FOR FEDERAL V I N except sequence number Engine displacement Models Code 4E3CT44ROLE Eagle Talon 2WD 2 0 liter 122 cu in D22AMNHML4E DOHC MPI D22AMRHML4E 4E3CT54U0LE 2 0 liter 122 cu in D22AMNPFL4E MPI Turbo 4E3CT64U0LE Eagle Talon 4WD D27AMNGFL4E VEHICLES FOR CALIFORNIA Can also be sold in Federal States v I N except sequence number Engine displacement Models Code 4E3CT44ROLE Eagle Talon 2WD 2 0 liter 122 cu in D22AMNHML9E DOHC MPI D22AMRHML9E 4E3CTB5AULILE 2 0 liter 122 cu in D22AMNPFL9E DOHC MPI Turbo ee ee 4E3CT64U0LE Eagle Talon 4WD D27AMNGFL9E VEHICLES FOR CANADA V I N except sequence number Engine displacement Models Code 4E3BT44ROLE Eagle Talon 2WD 2 0 liter 122 cu in D22AMNHML5E DOHC MPI D22AMRHML5E 4E3BT54UDLE 2 0 liter 122 cu in D22AMNPFL5E DOHC MPI Turbo 4E3BT64U0LE Eagle Talon 4WD D27AMNGFL5SE 00A0163 GENERAL Vehicle Identification 0 11 VEHICLE INFORMATION CODE PLATE Vehicle information code plate is riveted onto the bulkhead in the engine compartment The plate shows model code engine model transaxle model and body color code 1 MODEL D22AMNHMLAE E sm Model series Vehicle model 2 ENGINE 4G63 Engine model 3 TRANSAXLE F5M33 L Transaxle model 4 COLOR H18 TRIM cec Monotone exterior color c
111. Fasten Switch L H Located at the rear of the guide rail BESRWM This switch is for turning the shoulder belt drive motor off VA It transmits an OFF signal to the control unit when the shoulder belt is completely fastened Once the OFF signal is received the control unit shuts off the motor Located at the combination meter This light warns the driver and or passenger to fasten his her seat belt it illuminates of flashes by the control unit and the length of the illumination or flashing time changes dependent on which seat belt is not fastened Refer to WARNING SYSTEM Located at the driver s seat belt buckle This switch transmits an OFF signal to the control unit when the lap belt is fastened and an ON signal when it is not fastened 1940311 witch L H R H Incorporated within the shoulder belt retractor ue This switch detects the amount of shoulder belt wind in and sends an OFF signal to the control unit if the amount of wind in is the specified amount or more or an ON signal if the amount of wind in is less than the specified amount 23 38 Motor L H R H i Quer Hexagonal wrench Door Latch Switch L H BODY Seat Belts nstalled to the quarter panel he motor operates to move the slide anchor t receives direction of rotation start and stop signals from the ontrol unit and operates according to these signals Not
112. IC REMOTE CONTROL MIRROR The electric remote control mirror is a two motor type mirror for independent vertical and horizontal angle adjustment The mirror system consists of a mirror assembly actuator assembly frame body etc Connecting plate fulcrum Mirror assembly Support Adjustment nut Motor B NOTE The mark denotes component parts of actuator assembly Note that the electric remote control mirror switch is the centralized control type and is installed on the door trim on the driver s seat side The one switch can be used to adjust the direction settings to the left and right and up and down of the left and right mirrors Electric remote control mirror Switch 18A0399 23 28 Mirror PM Adjustment nut A I Wm Wheel fulcrum 15P002t BODY Door Mirrors ADJUSTMENTS TO THE LEFT AND RIGHT The rotational force of motor A is transferred to the worm wheel and the pivot screw is thus turned the threaded part of the screw functions to move the adjustment nut thereby adjusting the mirror assembly in the left or right direction with the fulcrum at the center ADJUSTMENTS UP AND DOWN Motor B operates to make the up and down adjustments functioning in the same way as the adjustments to the left and right In the event of a malfunction the mirror can be adjusted by pressing the mirror part to move the meshing
113. ND2L Line pressure 1750234 i he transaxle contol unit deactivates the shift Deactivation of the shift control solenoid valve B control solenoid vaves A and allows pressure to be directed to the shift control Deactivation of the shift control solenoid valve valve through the No 5b port This forces the shift the pressure to be applied to the No 5a control valve to the right until it comes in contact ports which in turn forces both right and left plugs with the right plug When the shift control valve is in against their steppers this position the No 7 port is opened and the line 5 pressure is directed through the port to the 2 3 4 3 shift valve and the end clutch valve This pressure is called 3rd pressure 21 68 4th Gear Transaxle control unit Shift control Shift control solenoid valve 8 Line pressure The transaxle control unit activates the shift control solenoid valve A and deactivates the shift control solenoid valve B Activation of the shift control solenoid valve A releases the pressure at the No 5a ports which in turn releases the pressure acting on the plugs at the right and left of the shift control valve solenoid valve A P AUTOMATIC TRANSAXLE Transaxle Control 4th pressure 2nd pressure TTE e 3rd pressure To N D control valve m To rear clutch
114. NSAXLE Transaxle Mechanism LOW REVERSE BRAKE Center support Piston Hydraulic pressure 1750221 Low Reverse brake is of the multiple disc type and is composed of a center support disc plates and a piston The brake operates when the shift is in 1st gear in the L range or back gear It fastens the carrier in the planetary gear set That is the shafts of the long and short pinions are fastened Number of brake discs Number of brake plates pec Number of pressure plates Number of reaction plates Piston O D mm HOLDING CARRIER WITH LOW REVERSE BRAKE Low Reverse brake Carrier AUTOMATIC TRANSAXLE Transaxle Mechanism 21 31 ONE WAY CLUTCH 7 Short pinion 5 Annulus gear Long pinion Carrier NI 5 5 Reverse sun gear 2 Outer race 52 Input Planetary gear carrier d CG output QN race NS 7 Held Center support stationary sun gear 170207 170320 One way clutch is of the sprag type and is incorpo rated between the pinion carrier and the center support In 1st gear D or 2 range the long pinion rotates clockwise as viewed in the direction of arrow P This produces a force which has the tendency to cause the carrier to rotate counterclockwise but the carrier is blocked from rotating in that direction by the one way clutch As a result the long pinion transmits its force to the annulus gear The
115. NTI LIFT GEOMETRY 4 DOUBLE WISHBONE SUSPENSION 11 GENERAL INFORMATION Construction and Operation 11 Sc ea aaa a B Rear Shock Absorber 14 2 2 AEAT EE N 16 DOCINCAUONS MEME 15 REAR HUB 7 GENERAL INFORMATION 8 THREE LINK SUSPENSION 5 Construction Diagram 8 Suspension BUSHINGS 6 Specifications 9 WHEEL ALIGNMENT 4 WHEEL ALIGNMENT 10 17 2 REAR SUSPENSION lt 2WD gt General Information REAR SUSPENSION lt 2WD gt GENERAL INFORMATION The rear suspension is light weight and compact and is a trailing type three link suspension with high rolling rigidity and lateral rigidity The rear suspension has the following features Excellent serviceability thanks to its simple construction and light weight The straight ahead stability has been improved by the negative camber setting Braking stability has been improved by the 117BbAA The shock absorbers are the large capacity type with little moving resistance thus assuring a stabilized damping force as well as improved riding comfort Because the axle beam is unified with the torsional bar
116. No 9 ports This causes the regulator valve to be held at its extreme right position by the spring force and the No 3 port to be closed Therefore only fluid that passes through the orifice is directed to the torque converter 21 58 AUTOMATIC TRANSAXLE Transaxle Control Torque converter control valve Chamber B Small hole Regulator valve Line pressure 0 torque converter Pump suction Front regulator side valve 1750081 TORQUE CONVERTER CONTROL VALVE This valve maintains the torque converter pressure and lubricant pressure at a constant level 1 The excess fluid after the pressure regulation by the regulator valve is directed to the torque converter via the torque converter control valve The fluid is also directed to chamber B at the right of the torque converter control valve through the small hole in the valve The pressure applied to chamber B moves the valve to the left against the spring force in order to control the torque converter pressure 2 If the chamber B pressure is weaker than the spring force the valve is kept forced to the right by the spring force and the pressure from the regulator valve is directed straight to the torque converter 3 If the pressure from the regulator valve becomes higher the pressure inside chamber B also becomes higher If the chamber B pressure increases to a level that overcome the spring force the torque converter control valve is forced toward the
117. OFF and provides better straight ahead stability and running performance 3 When a single wheel is slipping a hump could cause the differential to approach a locked state Provision is therefore made to provide a better ability to get out even in cases of one in a million such as a stuck state REAR AXLE Viscous Coupling Type Limited Slip Differential CONSTRUCTION Silicone oil Rear drive shaft L H Serration coupled Viscous coupling case Outer plate Viscous coupling hub Inner plate Spacer ring X ring Side gear L H Side gear R H CYANO Drive gear 3 7 Rear drive shaft R H 11P0070 The viscous coupling type limited differential is a shaft shaft type consisting of the right and left rear drive shafts and viscous coupling directly coupled The viscous coupling is a unit filled with silicone oil and consists of the outer plates 2 coupled with the case 1 the inner plates 4 coupled with the viscous coupling hub 3 and the spacer rings 5 arranged alternately to hold one plate and angther with only a small spacing in between The X rings 6 are provided to prevent entry of the differential oil into the viscous coupling The rear drive shaft L H is serration coupled with the viscous coupling case 1 and coupled via the case with the side gear L H 7 which is in a single body with the viscous coupling case The rear drive shaft R H is serration cou
118. Q RA SSS Vibration preventiom DUST Sponge protector Transaxle control cable 09A0152 Transaxle control cable 09A0046 AUTOMATIC TRANSAXLE A T Safety lock System A T SAFETY LOCK SYSTEM To prevent sudden start due to malfunction of automatic transaxle vehicle the following system has been installed SHIFT LOCK DEVICE It is so designed that unless the brake pedal is depressed the shift lever cannot be shifted from the P position to any other position In addition when the ignition key is in the LOCK position or is removed from the lock the shift lever cannot be shifted from the P position to other position even if the brake pedal is depressed KEY INTERLOCK DEVICE Transaxle control cable 21 19 R21GAAA KEY INTERLOCK DEVICE It is so designed that unless the shift lever is placed in the P position the ignition key does not turn to the LOCK position Ignition key cylinder Brake pedal SHIFT LOCK DEVICE i Shift lever 8 NS Key interlock cable eem iul A ub gt Shift lock cable 09A0152 Pel vas 21 20 AUTOMATIC TRANSAXLE A T Safety lock System SHIFT LOCK DEVICE When brake pedal is not depressed Brake pedal link mechanism Brake pedal Detent pin Shift lock pin Inner Cable Shift lock cable Vi Outer cable 7 LS AN K Ey um Oe 09A0154 Shif
119. SAXLE MECHANISM 23 SENERA INFORMA p End Clutch e 27 7 Front Clutch 25 General Description e 23 TRANSAXLE CONTROL 15 B Kickdown Brake 1 sss 28 Low reverse Brake 30 VISCOUS COUPLING VEU aspetta 12 21 2 MANUAL TRANSAXLE 2WD General Information MANUAL TRANSAXLE lt 2WD gt GENERAL INFORMATION RzIBMC One of two types of manual transaxles is equipped which is based on KM21 0 manual transaxle is a new according to engine output characteristics F5M22 product with various reinforcements and with high manual transaxle is basically the same as former er capacity to match high output of turbo engine KM206 manual transaxle F5M33 manual transaxle SPECIFICATIONS Transaxle model F5M22 2 VPZS F5M33 2 SPZS 5 speed 5 speed constant mesh constant mesh cable controlled cable controlled type type Gear ratio 1st 2nd 3rd 4th 5th Reverse Primary reduction ratio 1 096 34 31 1 208 29 24 number of gear teeth Differential gear ratio 3 941 67 17 3 437 55 16 number of gear teeth Speedometer gear ratio 29 36 Oil quantity liter qts 1 8 1 9 Dry weight lbs 35 9 81 77 MANUAL TRANSAXLE lt 2 gt General Information 21 3 SECTIONAL VIEW O_O T M M Soo 5M22 4663 Engine Clut
120. SION CONTROL SYSTEMS General Information 25 exhaust emissions control system reduces the amount of carbon monoxide hydro carbon and oxides of nitrogen in the exhaust gases by adding the exhaust gas recirculation device and the cataly tic converter to fundamental improvements such as improvement of the combustion chamber and the camshaft as well as other improvements to the engine such as feedback control of the air fuel ratio by the electronically controlled fuel injection sys tem The crankcase emissions control system is a closed type so that blow by gases are not discharged out to the atmosphere The evaporative emissions control system is the canister type vapors that are gener ated within the fuel tank are introduced into the intake manifold and are combusted so that they are not emitted out to the atmosphere Canister Purge contro solenoid valve 6 0202 172 niy E ENS L E T EER M Eph det et eMe its 25 1 CONTENTS R25A AIR FUEL MIXTURE RATIO Purge Control Solenoid Valve CONTROL SYSTEM 9 STUDOS 13 CATALYTIC CONVERTER 9 Purge Control Valve Turbo _ 13 EXHAUST GAS RECIRCULATION CRANKCASE VENTILATION SYSTEM 10 EGR SYSTEM 5 EVAPORATIVE EMISSION EGR Control Solenoid Valve California 8 CONTROL SYSTEM 11 EGR Control Valv
121. SUSPENSION Double Wishbone Suspension The inputs from the shock absorber and coil spr are borne by the upper bushings and spring pad respectively for a better ride and lower vibration and noise level A polyurethane foam bump rubber has been adopted for effective shock absorption in the event of completely bottoming out Upper bushirig Upper O 69 REAR SUSPENSION Double Wishbone Suspension 17 15 TRAILING ARM The trailing arm has a welded axle housing knuckle a rod rubber and trailing arm bushing It is inserted and shock absorber bracket The axle housing is into the trailing arm and can make a rotary motion machined after welded to the trailing arm to relative to the bolt improve its presicion The arm has a connecting rod for toe in correction The connecting rod consists of Section A A B Section B B 12A0045 12A0044 5 Connecting rod Axle housing Section C C Trailing arm bushing Connecting rod 1240043 Shock absorber bracket 12A0051 17 16 REAR SUSPENSION Double Wishbone Suspension STABILIZER The stabilizer bar is a 20 mm 79 in solid bar This bar and link are joined by a pillow ball type ball joint to improve stabilizer effect Pillow ball joint Ball joint that is not preloaded lob m EL Stabilizer link A ace Dent for 12A0009 identification Stabilizer rubber Bracket e art
122. The servo drive steps during idle speed feedback Control vary aS shown at the left 14 50 FUEL SYSTEM idle Speed Control 2 When the engine coolant temperature is low the fast idle air valve together with the idle speed control serv operated to supply an adequate volume of bypass according to the engine coolant temperature control servo Speed adjusting screw Throttle valve 30 22 0132 30 86 60 140 90 194 Coolant temperature C F 6FU0541 Intake air volume Feedback Control at Idle 1 Basic target idle speed The basic target idle speed is preset as a map value optimized according to the engine coolant temperature This speed is maintained to ensure stabilized idle speed Basic targetidle spel rp 1 20 4 0 32 401104 Coolant temperature F 2 Idle speed while the air conditioner is being operated When the engine coolant temperature is high with the air conditioner switch in the ON position the idle speed is set higher than the basic idle speed Target idle speed rpm 20 4 0 32 401104 801176 Coolant temperature C F 6FUO28 Position Control When the steering wheel is turned or the air achieve the target position thus controlling the conditioner switch is operated while idling the bypass air volume and suppressing engine speed engine load changes and consequently the idle changes The engine control unit also activates the speed changes sharply Therefo
123. a psi The injectors are activated on command from the engine control unit and inject the fuel to each intake port of cylinder head sequentially according to the predetermined ignition order In addition a fuel pressure control valve has been equipped in order to maintain idling stability of turbo models immediately after restarting under high temperature conditions The fuel tank is located under the floor of the rear seat thus giving it protection in the event of a rear end collision A fuel pump drive terminal is provided in the engine compartment for greater serviceability Specifications Motor driven in tank type Minimum 90 23 8 450 600 64 85 Diaphragm type 335 47 6 255 36 3 2 2 1 1 500 233 Solenoid type 13 16 2 3 FUEL SYSTEM Fue Supply and Fuel Pressure Contro 14 7 FUEL TANK Within the fuel tank are the electric fuel pump the ank filter and the fuel gauge unit he fuel tank has the following features e The fuel tank is located below the rear seat floor thus giving it protection in the event of a rear end collision lt 2WD gt e The fuel tank is located under the engine compartment floor instead of installing it under the rear seat floor where the rear axle is located lt 4wD gt A reserve cup is provided within the fuel tank so lt 2WD gt Detaiied view of reserve cup Reserve cup Fuel tank lt 4WD gt
124. ages the brake with a strong pressure force i 1 21 74 1 2SHIFT VALVE First Speed Shift control AUTOMATIC TRANSAXLE Transaxle Control Tolow reverse brake at L range solenoid valve A Shift control solenoid valve B Shift control valve Line pressure Second Speed Line pressure The valve is actuated by the line pressure that has been regulated by the shift control valve to change the line pressure flow when shifting is performed between 1st and 2nd gears It also controls the hydraulic pressure passage to the low reverse brake when in the R reverse gear In 1st Gear The 1 2 shift valve is pushed to the left and held there by the spring force when no pressure is directed to the valve In the L range the line pressure from the pressure control valve is directed to the low reverse brake by way of the No 10 and No 17 ports Hg 1 2 shift valve 16 10 Ex 5a SEED o c Ex From pressure control valve at L range TO kickdown servo 1750235 apply side 17 11 From pressure control valve 1750236 Upshift from 1st to 2nd Gear If the 2nd pressure from the shift control valve is directed to the 1 2 shift valve through the No port the pressure acts on the left end of the valve causing it to move to the right and the No 11 port communicating with the kickdown servo is opened The line pressure coming from the pres
125. al carrier on this crossmember decreases the natural frequency of the crossmember further damping vibrations The lower natural frequency of the crossmember allows harder adjustment of the support bushing so that the tendency toward oversteering of the suspension due to side force occurring during cornering can be reduced This combined with understeering tendency by middle joint displacement described in 3 above results in totally slight understeering tendency lt Note gt Why this new rear suspension system is classified as a double wishbone suspension The new rear suspension is represented below by the diagram as an aid to understanding its construction ee ene e 7 1240037 Point A can rotate about rotary axis B C and point D can rotate about rotary axis E C The triangles ABC and DEC can rotate like wishbone suspension arms When this is compared to an ordinary double wishbone type suspension it may be regarded as one with forward points C4 and Cz of the upper and lower arms located at the same point Thus this new rear suspension system is considered as a double wishbone suspension system 17 14 REAR SHOCK ABSORBER The rear shock absorber consists of a shock absorber coil spring etc arranged concentrically The shock absorber is a hydraulic cylinder of the double action type with low sliding resistance and gives stable damping force Spring pad Bump rubber E REAR
126. al order Passing contro 22 relay Mri D PHA Petr n ch gt tq poete trum cis IP HC ILA AA AA men ELECTRICAL Relays Control Units and Sensors 8 13 OTHER RELAYS AND CONTROL UNITS gt 0 06 gt Door lock relay Theft alarm control unit EK AH Daytime running light relay 1 2 Theft alarm horn relay vehicles for Canada only Transistor relay vehicles for Canada only Fog light relay Turn signal and hazard flasher unit NOTE The Name column is arranged in alphabetical order Engine compartment and interior front 16 0802 Fog light relay Radiator fan motor relay AY 7 Alternator Intermittent wiper relay built in column switch 16A0732 8 14 ELECTRICAL Relays Control Units and Sensors Blower motor Pd Di RAS Doorloc Y Turn signal control 2 and hazard unit or flasher unit Theft alarm control unit 1 8 d 16A1051 E Starte Seatbelt time e Daytime running light relay 2 hy relay 7 Daytime running aN fight relay 1 x 18840811 6 A ELECTRICAL Inspection Terminal 8 15 INSPECTION TERMINAL Engine speed detecting terminal C Oxygen sensor check connector CEN Fuel pump check connector A Self diagnosis connector B
127. amper clutch control gem Nm 3 a edi n B Rear clutch E exhaust valve Ex Torque converter m contro valve LE n i E am E x E BE Shiftcontrol Br ee E FB E 4 IA EN N D control E Regulator E a pw E valve Pressure control valve 5 Oil Line relief h Bi filter 3 valve Line Pressure fae Pump suction pressure Torque converter pressure me Line Pressure DCCSV control pressure and lubrication oil pressure contro pressure sd Wm Reducing pressure nd PCSV control pressure IER PEU AUTOMATIC TRANSAXLE Transaxle Control 21 93 SELECTOR LEVER IN D 4th Gear Torque converter Kick Front Rear Low reverse ckdown servo clutch clutch brake Clutch RUNS H control unit 44 Damper clutch contro Damper clutch control solenoid valve Reducing valve Torque converter Pe control valve a Je Regulator valve Pressure EL control E solenoid valve Line relief NSS Fm S E valve j Ce 2 x OFF y Transaxle control unit Line Pressure EB suction pressure Damper clutch pressure Torque converter pressure Line Pressure DCCSV control pressure and lubrication oil pressure contro
128. an overload of the motor The illustration at left shows the condition of the limit switch when the throttle valve is fully closed indicating that limit switch 1 is in the OFF and the RELEASE circuit is being deenergized da mensum aco expe poo Ni MUT Wes CUNCTI VEO ad we Mm LTE TOME emm TUTUP YAT Cee SP cri b FUEL SYSTEM Auto cruise Control System TTE as INTERMEDIATE LINKS elector Accelerator cable B throttle valve side Actuator Intermediate link B Accelerator cable A throttle valve side accelerator pedal side 03A0224 Intermediate link A accelerator pedal side During Auto cruise Control Driving The rotation of the selector causes intermediate link B to turn which opens and closes the throttle valve However intermedi ate link A is not operated and accelerator cable A does not move so the accelerator pedal remains stationary in its original position During Normal Driving When the accelerator pedal is operated the rotation of intermediate link A which is connected to accelerator cable A accelerator pedal side causes intermediate link B to turn and accelerator cable B which is connected to intermediate link B then opens and closes the throttle valve VEHICLE SPEED SENSOR The vehicle speed sensor functions to send pulse signals which are proportional to the rotation speed vehicle speed of ces the transaxle s output gear t
129. an be con firmed vehicle speed sensor circuit is normal Driving at less than approx 40 km h 25 mph or stopped 12A0107 NOTE 1 If two or more input operations are performed at the same time and the microcomputer receives the corresponding signals their output codes are indicated repeatedly in code number order as long as the corresponding signals are input 2 If the input operation is canceled while the output code is being indicated the code continued to be indicated until it completes a display cycle If the code does not disappear the switch or harness is probably defective FUEL SYSTEM Control System 14 71 ACTUATOR CONSTRUCTION The actuator unit consists of a DC motor a worm gear a worm wheel a planetary pinion gear a magnetic clutch and two limit switches The magnetic clutch consists of a magnetic coil mounted to the actuator case and a clutch plate connected to the ring gear of the planetary wheel gear by a spring The magnetic clutch is energized and deenergized by the control signal supplied by the control unit The clutch transmits the rotation of the DC motor to the selector drive shaft and allows the selector drive shaft to rotate freely with the ring gear regardless of whether the DC motor is being energized or not Internal construction Magnetic clutch coil Circuit diagram MAIN switch DC motor am Actuator Magnetic clutch coil Stop light swit
130. and increases when the engine wheel is equipped so that the driver can select speed is high the combination best suited to his position and e cooler tube is installed between the steering posture gear and the oil reservoir for effective cooling of The steering gear box is of a compact light weight the power steering fluid CONSTRUCTION DIAGRAM Steering wheel and column Three spoke type steering wheel lt Tilt steering column gt Steering wheel Steering shaft Steering column Tilt bracket Steering gear box and oil pump 1340302 Oil reservoir Pressure hose Oil pump Return tube Gear box 13A0303 SPECIFICATIONS Items Steering wheel O D in Steering wheel maximum turns Shaft and joint type Steering angle Inner wheel Outer wheel Tilt stroke in Steering gear type Rack stroke in Oil pump type Oil pump displacement cm rev cu in rev POWER STEERING General Information 19 3 Specifications 372 14 6 2 7 Collapsible cross joints two joints used 35 00 2 29 20 30 1 2 Rack and pinion 138 5 4 Vane type 9 6 59 19 4 TILT STEERING CONSTRUCTION The tilt steering mechanism is composed of the tilt lever tilt bracket a plate tilt bolts etc A tilt screw is welded to the end of the tilt lever at the two ends the left side of the tilt screw is right threaded POWER STEERING Tilt Steerin
131. ating to pass another vehicle Engine brake does not function when the shift is in 1st gear When the vehicle is stopped shifting is made to the 2nd gear to minimize creep and vibration Upon starting shifting is made to 1st gear 2 Second 1 2 automatically shifts between 1st and 2nd gears This means no upshift to 3rd gear occurs 2 Driving off is always performed in 1st gear 3 Downshift to 2nd or 3rd gear is performed by selecting the 2 range while the vehicle is running in 3rd or 4th gear when a speed lower than the set value is reached 4 As in the case of the D range engine brake does not work when the shift is in 1st gear L Lock up 1 While L Lock up performs downshift from 2nd to 1st gear it does not shift up the gear from 1st to 2nd or 3rd The enables what is called 1st gear holding Driving off is always performed in 1st gear Engine brake functions in the case of this 1st gear By selecting the L range while the vehicle is running in the D or 2 range downshift from 4th to 3rd 3rd to 2nd or 2nd to 1st is performed when the vehicle reaches the respective speed prescribed for each gear 4 5 2 IRE AUTOMATIC TRANSAXLE Transaxle Mechanism FRONT CLUTCH Clutch plate Check valve Piston Front clutch retainer D ring 21 25 Hydraulic pressure Snap ring Spring retainer Return
132. atio The duty ratio is the ON duration ratio of 16 7 Hz pulse or 2 1621002 Diapliragm The higher the duty ratio the more mean current flows to the boost meter and as a result the boost meter reads the higher value The smaller is the duty ratio the boost meter reads the smaller value To intake manifold eme Exhaust gas emei NOTE 7 0012 This illustration indicates Non Turbo models The EGR control valve is a diaphragm that functions When the negative pressure becomes stronger than to control the flow of EGR gases by opening and the spring force the valve opens as shown in the closing the valve according to the negative pressure illustration and the exhaust gases can flow vacuum acting upon the partitioned chamber t E ye te ee xs Ia Valve Bimetal THERMO VALVE lt Federal gt The thermo valve functions in response to the temperature of the engine coolant thus controlling the negative pressure acting upon the EGR control valve The valve opens at a temperature of 65 C 149 F or lower and closes at 65 149 or higher 25 8 EMISSION CONTROL SYSTEMS 7 Exhaust Gas Recirculation EGR System EGR TEMPERATURE SENSOR California Sensor part 1 0033 Enaine control unit EGR emperature sensor 5V 208 EGR temperature sensor is thermistor type It to electric signal and sends the signal to the engine
133. ator fan is em ployed in order to improve the cooling performance Upper insulator Condenser tank Radiator Cooling radiator fan Lower insulator Condenser fan for air conditioner Transaxle fluid cooler hose A T 0440106 i o AS oot te ace RID RAE TOTS COOLING Radiator and Cooling Fan Transaxle Fluid Cooler 7 Cross section A flexible support system is used at the installation points of Radiator installatio n the radiator in order to reduce the transmission of vibration and noise to the Lower insulator 04A0101 TRANSAXLE FLUID COOLER ua On vehicles provided with automatic transaxle the The transaxle fluid cooling path is as described in radiator has a transaxle fluid cooler that improves the figure below soling efficiency of the transaxle fluid Transaxle 9 Fluid cooler hose 7 Transaxle fluid cooler Radiator Transaxle fluid cooler hose Transaxle fluid cooler 7 6 COOLING Two speed Fan Control System TWO SPEED FAN CONTROL SYSTEM CONTROL SYSTEM CIRCUITRY DIAGRAM ELI BUB FUSIBLE LINK 2 3 MAIN FUSIBLE LINK e Thermo sensor operation modes ON at 85 185 F or higher ES 5 B papiator RADIATOR FAN MOTOR 1336 a6 99801 H1 This system functions to detect the operation mode and to regulate the sp
134. auge unit assembly Fuel pump check terminal Canister Check valve Purge control valve N e In tank filter Fuel injector 1 1 0340266 Delivery pipe Fuel pressure regulator 14 6 FUEL SYSTEM Fuel Supply and Fuel Pressure Control intake manifold Delivery pipe 5 regulator Engine Fuel filter Fuet pressure control valve Turbo Fuel pressure 03A0010 The fuel supply system comprises electromagnetic type injectors a delivery pipe a fuel pressure regulator a motor driven fuel pump and the engine control unit which activates and controls the injec tors and fuel pump based on data supplied by the various sensors After being filtered by an in tank filter the fuel is pumped from the tank and is filtered again by an external filter before it is distributed to the injectors through the delivery pipe The pressure of fuel delivered to the injectors is regulated by the fuel pressure regulator excess fuel after pressure reg ulation has been performed is returned to the fuel tank SPECIFICATIONS Fuel pump Type Delivery rate Delivery pressure Fuel pressure regulator Type Regulated fuel pressure lt Non Turbo gt lt Turbo gt Fuel filter Rated flow rate liters qts min Filter area in Injectors Type Coil resistance Q lt Non Turbo gt lt Turbo gt liters gals Hr kPa psi kP
135. bination meter is illuminated and operation 15 as a 3 speed automatic transaxle 21 50 AUTOMATIC TRANSAXLE Transaxle Control VEHICLE SPEED SENSOR Vehicle speed sensor The vehicle speed sensor is the transistor open collector type it generates pulse signals four pulse signals for each rotation of the gear that are proportional to the rotational speed of the transaxle s output gear and therefore proportional to the vehicle speed and sends these signals to the transaxle control unit This sensor is installed in the speedometer AIR CONDITIONER RELAY In order to adjust the improper correspondence between the engine output and throttle valve opening that is caused by an air conditioner load the transaxle control unit corrects the solenoid drive duty when an on signal from the air conditioner relay is detected OIL TEMPERATURE SENSOR The oil temperature sensor is of the thermister type anc senses the automatic transaxle fluid temperature Using the signal from this sensor the transaxle control unit corrects the solenoid drive duty when the transaxle is cold The sensor output characteristics areindicated on the graph at the left Terminal voltage V 1 5 Fluid temperature C 1750409 POWER ECONOMY SELECT SWITCH This switch permits the driver to intentionally select either shift pattern The power pattern is designed for use when high power needed when driving on mountain roads or when acceleratir
136. bout 12V when the switch is OFF These voltage changes digital sign s are input to the microcomputer as and OFF signals 2 switches 03A0269 WE FUEL SYSTEM Auto cruise Control System 14 77 e Bt Stop light J ON d OFF For auto cruise control 1680994 4 3 4903 sia 07A0002 CANCEL SWITCHES The cancel switches consist of the stop light switch the clutch switch and the inhibitor switch N position The auto cruise control operation is canceled if any one of these switches functions STOP LIGHT SWITCH The stop light switch is a four pin type of stop light switch that combines the switch for the stop light NO and the switch for the auto cruise control NC When the brake pedal is depressed the contacts for the AUtO CIUISE control open the supply of current to the actuator netic clutch is cut off and the fixed speed driving Rhe cance same LIME the closure of the contacts for the stop light causes a cancel signal to be sent to the control unit and within the control unit the current supply to the actuator magnetic clutch is stopped thus causing the cancellation of the fixed speed driving mode CLUTCH SWITCH The contacts of the clutch switch close when the clutch pedal is depressed with the result that the cancel signal is sent to the control unit thus canceling the fixed speed driving mode INHIBITOR
137. c T Where T Crank angle sensor signal frequency Engine speed FEEDBACK CONTROL CLOSED LOOP CONTROL Lean Stoichio Air fuel ratio fnetric ratio Rich x o High Oxygen sensor Comparison 5 output voltage voltage 3 Low amp 0 Rich Lean Stoichiometric ratio Fuel injection amount 012513 Decrease 6FU0795 FUEL SYSTEM Fuel Injection Control During normal operation including idling the en gine control unit controls the injector activation time shieve the stoichiometric air fuel ratio which e res maximum efficiency of the catalytic conver ter on the basis of the oxygen sensor signal When the air fuel mixture is richer than the stoichiometric ratio there is less oxygen in the exhaust gas and thus the oxygen sensor output voltage is higher hence a mixture rich signal is input to the engine control unit Then the engine control unit decreases the amount of fuel injected If the air fuel ratio decreases to the point that and the mixture becomes leaner than the stoichiometric ratio the oxygen concentration in the exhaust gas increases and the oxygen sensor output voltage becomes lower Then a mixture lean signal is Map value 14 41 input to the engine control unit Upon input of this signal the engine control unit increases the feedback correction factor thus caus ing more fuel to be injected By means of the above mentioned controls collec tively cal
138. carrier which is coupled with the one way HOLDING CARRIER WITH ONE WAY CLUTCH Oneway clutch f Camer clutch outer race is free to turn in clockwise direction In an engine braking condition under which the annulus gear is turned first the carrier turns clockwise freely and therefore the engine braking effect is not obtained Number of sprags 26 Width of clutch mm 18 3 720 21 32 AUTOMATIC TRANSAXLE Transaxle Mechanism PLANETARY GEAR Long pinion Reverse sun gear Carner X Outer race One way clutch Forward sun gear Low reverse brake s hub Short pinion 22222 EMEND Parking sprag v T SS End clutch shaft Output flange Annulus gear 175024 The planetary gear set incorporated this transaxle is of the Ravigneaux type and consists of a forward sun gear a reverse sun gear a short pinion a long pinion a carrier to support both pinions and an annulus gear The reverse sun gear is connected to the front clutch retainer via the kickdown drum while the forward sun gear is connected to the rear clutch hub The carrier is built in one unit with the low reverse brake s hub and the outer race of the one way clutch The carrier is connected to the end clutch via the end clutch shaft The annulus gear to which the output flange is connected conveys driving force to the transfer drive gear installe
139. cation where the vehicle is and corrects the fuel injection quantity for the optimum air fuel ratio at that altitude and also corrects the COOLANT TEMPERATURE SENSOR Terminal 1 Terminal 2 6ELOO69 Resistance kf 20 4 16A0860 The engine coolant temperature sensor installed in the coolant passage of the thermostat case is a thermistor whose resistance changes with the engine coolant temperature The enaine control unit iudaes the enoine warm FUEL SYSTEM Sensors Engine Barometric control unit pressure sensor 5 volts D 6FUO575 z4 8 3 2 2 8 1 760 30 Barometric pressure mmHg in Hg ECI551 ignition timing This ensures improved driveability at high altitudes The barometric pressure sensor converts the pres sure to a voltage making use of the fact that the resistance of a strain gauge changes in direct proportion to the pressure as shown in this diagram which illustrates the relationship between barometric pressure and output voltage Engine control unit Coolant temperature 5 volts 6FU0494 Output voltage 0 32 20 68 Coolant temperature C F 162458 Coolant temperature 1621006 state based on the output voltage of this sensor and provides optimum mixture enrichment when the engine is cold The sensor characteristics are as shown above 1 FUEL SYSTEM Sensors THROTTLE POSITION SENSOR Throttle position
140. ch Auto cruise control unit Clutch plate Planetary pinion Ring gear i Worm wheel DC motor 03R0077 Cross section of actuator installation Bushing Actuator bracket 03A0162 14 72 ACTUATOR OPERATION IF SET TO A FIXED SPEED When the SET switch is set to the ON position the control unit causes current to flow to the actuator s electromagnetic clutch coil the clutch plate is then attracted the ring gear of the planetary gear is secured and at the same time the path from the ECU to the DC motor becomes conductive and the DC motor begins to rotate at high speed DC motor Selector Selector diive shaft Ring gear Worm wheel FUEL SYSTEM Auto cruise Control System As shown in the illustration the rotation of the DC motor is transmitted to the worm gear worm wheel sun gear unified planetary pinion Because the ring gear is fixed at this time the planetary pinion revolves while rotating around the sun gear and because the planetary pinions are installed to the carrier the carrier and the unified selectcr drive shaft and selector rotate Limit switch Magnetic clutch coil Carrier Sun gear Planetary pinion 07R0103 MAIN switch Auto cruise control unit 07A0016 The selection of the direction PULL or RELEASE of the selector rotation is performed by the reversal of the direction of conductivity to the motor and this is controlled
141. ch housing Bearing retainer 2nd speed gear 1st speed 3rd speed gear gear 3rd 4th speed synchronizer assembly Input shaft 1st 2nd 4th speed gear speed synchro 5th speed gear nizer 5th speed synchronizer assembly Rear cover Reverse gear noise orevention device Sth speed inter mediate gear Intermediate gear Spacer output shaft Spacer Transaxle case Differential drive gear Spacer Drain plug 011 21 4 MANUAL TRANSAXLE lt 2WD gt General Information F5M33 Clutch housing Bearing retainer 2nd speed gear ist speed 3rd speed gear gear 3rd 4th speed synchronizer assembly Input shaft 4th speed gear 5th speed gear 1st 2nd speed 5th speed synchro synchronizer nizor assembly assembly device ps mm T Rear Cover d YES IRE am Reverse gear 4 i zi now prevention 5th speed inter mediate gear Intermediate gear Spacer Output shaft Spacer Transaxle case Differential drive gear Spacer Drain plug MANUAL TRANSAXLE lt 2WD gt Transaxle Control 21 5 XANSAXLE CONTROL RICAAA For transaxle control a floor shift system employing e A vibration absorbing steel plate has been pro cables for control has been adopted vided at the shift lever bracket s cable connec e Rubber vibration absorbers have been provided tion point in order to reduce the shifting noise at the points of connection of the shi
142. ch is at or higher than the high speed limit approximately 145 km h 90 mph Note that the vehicle speed memorized when the SET switch 5 pressed while the vehicle is traveling at the high speed limit or higher will be the high speed limit vehicle speed FAIL SAFE FUNCTION When the following situations are encountered during fixed speed driving the signals to interrupt conductivity to the electromagnetic clutch are input thus canceling the auto cruise control system When vehicle speed decreases to the low speed limit approx 40 km h 25 mph e f the vehicle speed decreases to a speed which is approximately 20 km h 12 mph or more below the memorized vehicle speed e When the vehicle speed drops by 20 km h 12 mph or more after having reached the set speed 10 km h 6 mph in the RESUME mode e f there is damaged or disconnected wiring of the input line stop light switch load side of the stop light switch e ifthere is no input of the vehicle speed signal for a certain fixed time 1 second or longer e lf the SET and RESUME control switches are switched at the same time e f the cancel switches stop light switch clutch switch or inhibitor switch and command switches SET switch oc RESUME switch are switched ON at the same time e f the actuator clutch driver transistor of the control unn remains ON short circuit 92 FUEL SYSTEM Auto cruise Control System OVERDRIVE CANCEL
143. ch pedal is depressed the clutch switch is turned ON and the battery voltage is applied to the cancel circuit of the control unit then MAIN switch Actuator Limit Switch 1 Auto cruise control unit FUEL SYSTEM Auto cruise Control System a cancel signal is input to the microcomputer causing the transistor that energizes the actuator electromagnetic clutch coil to turn OFF This results in the electromagnetic clutch coil grounding circuit being cut off which cancels the auto cruise control mode When Canceled by the Selector Lever position N dotted line arrows When the transaxle control selector lever is placed in the N neutral position the inhibitor switch is turned ON and as a result current flows from the control unit to the inhibitor switch starter and ground Then a cancel signal is input from the cancel circuit to the control unit causing the transistor which energizes the actuator electro magnetic clutch coil to be turned OFF As a result the electromagnetic clutch coil grounding circuit is cut off and the auto cruise control mode is canceled Although a small current voltage 5 V flows through the starter it is not activated LIMIT SWITCH The function of the limit switch is to shut off the flow of current to the motor and apply an electric brake to quickly stop the motor if the throttle valve becomes either fully open or fully closed thus preventing problems which might be caused by
144. chamber A 13A0257 Section A A Section B B Torsion bar Input shaft Bearing To oil From oil pump i reservoir To oil reservoir From oil pump Rotary valve Pinion gear To cylinder tube left chamber peering To cylinder tube 180077 right chamber Yoke spring 1380298 19 6 POWER STEERING Pinion and Valve Assembly Construction PINION AND VALVE ASSEMBLY CONSTRUCTION The pinion and valve assembly is composed of the input shaft torsion bar pinion gear and rotary valve e The input shaft is hollow and incorporates the torsion bar within it the upper end is secured by a pin to the torsion bar and the lower end is held by the bushing within the pinion gear e The torsion bar is coupled to the pinion gear by the serrated part at the lower end e n order to prevent excessive torsion of the Torsion bar Pm Input shaft Rotary valve Dowe pin Pinion gear Bushing 13A0076 Dowel pin RISKAAA torsion bar the pinion gear is provided with a stopper Note that this stopper also functions to facilitate the transmission of the turning effort of the steering wheel directly to the pinion gear by the input shaft in the event of a malfunction of the hydraulic system such as breakage of the oil pump s V belt fluid leakage etc The rotary valve is attached to the pinion gear by a dowel pin Section A A Input shaft Torsion bar Stopper Pinion gear Rotary valve 12902
145. control items marked in the table the engine warning light Malfunction indicator light is illuminated to warn the driver of the necessity for an engine check When the malfunction is corrected the light goes off The light also goes off when the ignition switch is turned OFF At that time it will not come on when the ignition switch is turned ON unless a malfunction is detected again However the light remains on for 2 5 seconds after the ignition switch is turned on This is to allow the driver to check that the engine warning light circuit is operating normally 14 32 FAIL SAFE AND BACKUP FUNCTION 1 The fail safe function controls the system so that passenger and vehicle safety can be maxi mized in the event of failure of sensors or other parts If a sensor related to ISC fails for example the engine control unit is programmed to prevent sharp increases in the engine speed FUEL SYSTEM Enaine Control Unit 2 The backup function of the engine control unit ignores the output signal of a failed sensor and instead uses a built in program or set of values so that the vehicle may continue to function The operating state when the backup function is being used is termed the emergency mode and the engine control unit keeps the engine warn ing light ON during this mode Fail safe Backup Function Faulty system Control contents Fuel injection control Idle speed control Ignition timing control Air flow
146. control system the vehicle speed de creases to less than approximately 20 km h 12 mph and _ 1i are erased by switching OFF the ignition switch or the MAIN switch After the diagnosis codes in the memory are erased if when the power supply of the electronic control unit is switched ON once again the power supply of the electronic control unit is normal continuous ON OFF signals will be displayed at 0 5 second intervals regardless of whether the system condition is normal or not Refer to the illustration at the left INPUT CHECK FUNCTION The input check function allows you to check if the input signal is normal when a cruise control failure occurs including the situation where the cruise control cannot be set 1 Connect a voltmeter to the diagnosis connector of the junction block 2 Operate the SET and RESUME switches simultaneously 3 Turn ON the ignition switch the input check can now be carried out Perform the corresponding input operations to read the output codes Output codes Input operation Check results Display patterns SET switch ON SET switch circuit is normal RESUME switch ON RESUME switch circuit is normal Each cancel switch ON Each cancel switch 1 Stop light switch circuit is normal brake pedal depressed 2 Clutch switch clutch pedal depressed 3 Inhibitor switch ON shift lever to N position Driving at approx 40 km h 25 When both No 24 and mph or higher No 25 c
147. control unit incorporates a micro the Vehicle speed sensor computer which provides the set coast resume COE mol i 10 ich acceleration cancel low speed limitation high teneas DATES LAO d limitati d OFF trol d memicrocompeter accordance with programming software ol the microcomputer CONTROL LOGIC BLOCK DIAGRAM tion Auto cruise control wi ia IG Interface 2 F hicl 3 Constant Vehicle voltage circuit circuit Control switches SET COAST Vehicle speed ser conem JL vere sor ce RESUME ACCEL input circuit Auto cruise indicator light switch pepe Stop light Cancel signal sr inhibitor input switch lt A T gt i circuit i ea ond Clutch T gt LI OVS ERS 1 Accelerator pedal switch lt A T gt NC Accelerator pedal switch OFF output circuit Diagnosis Tm output circuit Diagnosis mm connector l 5 MM 4 control unit 0790006 NC Normally closed 14 62 FUEL SYSTEM Auto cruise Control System SET COAST SWITCH throttle valve to a degree of opening wt When the SET COAST Switch is Depressed approximately corresponds to the vehicie The vehicle speed at the moment the SET switch was switched from ON to Of F i
148. d feedback control is provided under stabilized idling conditions and not when any of the following conditions occur e When the vehicle is moving at 2 5 km h 1 6 mph or more Air conditioner switch N range b Coolant temperature 8 14 49 the target value In position control the idle speed control is adjusted to the target position to cope with air conditioner and other load changes Position controlis also performed when cranking the engine and decelerating e When the idle switch is turned from OFF to pee and while the idle switch is in the OFF position e When the air conditioner switch is turned from ON to OFF or vice versa e When power steering oil pressure switch is turned from ON to OFF or vice versa e When the ignition switch is turned from ST to IG or vice versa e While the dash pot control is in operation e When the inhibitor switch is switched from range to D range or vice versa Idle speed Stepper motor Engine speed Servo drive steps Difference between the target and actual idle speed rpm 6FUOB99 Servo drive steps Time sec Servo Drive Steps 1 If there is a difference between the target and actual idle speeds the servo is activated the number of angular steps corresponding to the difference thereby extending or retracting the pintie to control the amount of bypass air and adjusts the actual idle speed to the target value
149. d gear 4th gear i i AUTOMATIC TRANSAXLE Transaxle Control 14 Once the operation is step 2 is completed the hydraulic control device functions by hydraulic pressure force to change the state of the clutches and brakes to accomplish the gear shifting 1 O minimize the shock that would otherwise be produced during gear shifting hydraulic pressure is controlled during the gear shifting period by the duty control of the pressure control solenoid valve The duty control is explained later HYDRAULIC PRESSURE CONTROL DURING SHIFTING 1 The hydraulic pressure that functions during gear shifting to engage the clutches and apply the brakes is regulated by the pressure control valve The hydraulic pressure that works on the pressure control valve is further regulated by the pressure control solenoid valve which functions under the control of the transaxle control unit The transaxle control unit controls the solenoid valve through the duty control thus providing appropriate regulation of the hydraulic pressure Figure A gt Voltage 1750066 Duty Control The transaxle control unit outputs the pressure control solenoid valve drive pulses as shown in Figure A These pulses drive the pressure control solenoid valve at a frequency of 35Hz one cycle period T 28 6 ms Change in hydraulic pressure tS achieved by changing the pulse duration t Such a method of control is called duty c
150. d made from tempered glass to provide a well ventilated and well lighted cabin with ample openness It also consists of the glass assembly tilt handle and removable sunshade This sunroof has the following features The tilt up mechanism for lifting the rear of glass by the tilt handle lever has been adopted The roof lid glass can be removed to have as much openness as offered by an open convertible In amp addition a storage bag and fastening belt have been provided to stow the removed glass in the trunk te The removable sunshade has been installed to keep off the strong sun e The removable deflector has been adopted to prevent air turbulence R23TAAA Roof lid glass Deflector Weatherstrip ges evan cd nmi tl rcr ik Sunshade Base plate assembly Splash shield Splash shield 48 Hinge female assembly 1840771 Drain hose l Headlining 3 26 BODY Sunroof 18A0747 Section A A Roof lid glass Roof lid glass Hinge female 18A0744 Section B B Section C C Roof lid glass Roof lid glass 18A0746 Tilt handie lever Base plate EBERT M MM BODY Door Mirrors DOOR MIRRORS large size Talbot mirrors are attached on the front doors that smoothly blend into the body styling They also contribute to the reduced aerody namic drag ELECTR
151. d on the output flange And the parking sprag is provided on the outer circumfer ence of the annulus gear Number of forward sun gear teeth 26 Number of reverse sun gear teeth 3 4 Number of short pinion teeth 22 Number of long pinion teeth 20 Number of annulus gear teeth 74 32 AUTOMATIC TRANSAXLE Transaxle Mechanism 21 33 POWER FLOW GEAR D and 2 ranges Short pinion Carrier Forward sun gear iransfer drive gear One way clutch Annulus gear Idler gear Rear clutch Long pinion Operating elements ehear clutch Transfer eOne way clutch driven gear 1750057 Since the rear clutch is actuated when the shift is in 1st gear in the D 2 or L range driving force is transmitted to the forward sun gear which rotates in the clockwise direction Therefore torque is conveyed from the forward sun gear through the short pinion counterclockwise and the long pinion clockwise to the annulus gear clockwise to achieve the reduction ratio of 1 st gear Since the long pinion s shaft that is the carrier tries to turn counterclockwise at this time the one way clutch prevents this to provide for a sufficient amount of driving force to be transmitted to the annulus gear This means that because the carrier can turn clockwise engine brake does not function when the shift is in 151 gear in the D or the 2 range 21 34 AUTOMATIC TRANSAXLE Transaxle Mechani
152. d to the N pole of the stator and the rotor moves or rotates one step to the right Stator Coil A2 Stator Il 95 4 COOU 505550520 2 6FU0525 When coil B2 is energized instead of coil B1 the lower half of stator becomes and pole This means that the N pole is moved one step to the right compared to the condition in Step 1 Thus as in step 1 the rotor rotates one step to the right Each time a different pair of coils energized as shown above the rotor rotates one step When the coil energizing sequence is as Al B1 B1 2 gt A2 B2 B2 Al B1 the I rotates clockwise When coil pairs are energized in the reverse sequence namely in the order B1 Al gt Al B2 B2 2 gt A2 B1 B1 Al the rotor rotates counterclockwise T FUEL SYSTEM idle Speed Control Servo Control Servo control includes feedback control and position ontrol In feedback control the engine control unit constantly calculates the actual idle speed and if the value differs from the target idle speed the unit drives the stepper motor to adjust actual speed to Feedback Control While the engine runs at idle speed the stepper motor is activated to keep the engine speed at the preset target idle speed by controlling the bypass air volume The target idle speed that is optimum for each operating condition including air conditioner switch ON OFF has been preset This engine spee
153. de rail outer Roof drip channel Front floor side sill outer BODY Main Body 23 5 Side sill silencer Shelf corner bracket Seat striker reinforcement Rear wheelhouse inner Rear wheelhouse front extension Quarter panel inner upper Quarter panel inner lower Beltline reinforcement Center pillar outer Rear pillar outer Rear lamp housing Rear lamp housing extension Quarter outer lower extension Quarter panel outer Center pillar reinforcement upper Roof drip channel extension Roof panel Front roof rail Rear roof rail Front floor side sill inner Front floor crossmember front Front floor crossmember rear Front floor pan Front floor sidemember Rear seat crossmember Rear seat pan Rear floor crossmember upper Rear floor crossmember lower Rear end crossmember Rear floor pan Spare tire bracket Rear floor sidemember front extension Rear floor side sill Rear floor sidemember Rear fascia bracket upper Rear end panel 23 6 BODY Main Body SPECIAL STEEL PANELS Special steel panels high tensile steel panel and galvanized steel panel are used in the illustrated positions lt 2WD gt Y gt gt g 129 LETT 2 5 IFAS OS m A 2 2 A YY iy Laity Me H vl 277 Indicates galvanized steel panel 4 Indicates high tensile steel panel 140254 67 10 11 12 13 14 15 16 17 18
154. demember to crossmember brace Front end crossmember Fender support panel Front end upper bar reinforcement Front upper frame outer Front upper frame lower Front upper frame inner Front fender shield Shield plate Strut house panel Front tie down bracket outer Front tie down bracket inner Front sidemember Front sidemember rear Dash panel crossmember Dash panel extension Front floor side sill inner front Dash panel Cowl top panel inner Cowl top panel outer Steering column support bracket Front deck crossmember Front upper frame extension inner Front upper frame extension outer Upper frame extension silencer Roof side rail inner Front pillar inner upper Front pillar inner upper B Front pillar inner lower Front pillar outer lower Front pillar outer upper Roof side rail outer Roof drip channel Front floor side sill outer Side sill silencer BODY Main Body 23 3 Shelf corner bracket Seat striker reinforcement Rear wheelhouse inner Rear wheelhouse front extension Quarter panel inner upper Quarter panel inner lower Beltline reinforcement Center pillar outer Rear pillar outer Rear lamp housing Rear lamp housing extension Quarter outer lower extension Quarter panel outer Center pillar reinforcement upper Roof drip channel extension Roof panel Front roof rail Rear roof rail Front floor side sill inner Front floor crossmember front Front floor cr
155. detects the temperature of gas passage in EGR control unit control valve converts the detected temperature To EGR control EGR CONTROL SOLENOID VALVE lt California gt val ad The EGR control solenoid valve is the duty control type of solenoid valve it functions to regulate the EGR control valve activation negative pressure vacuum EGR control solenoid valve Engine control unit EMISSION CONTROL SYSTEMS Catalytic Converter Air fuel Mixture Ratio Contro System 25 9 LATALYTIC CONVERTER The catalytic converter is installed on the middle of the exhaust pipe under the floor This catalytic converter uses monolithic type catalyst with a honeycomb structure that has its surface coated with catalytic components The catalyst is supported by a stainless steel wire mesh S DLE S ab Wa Exhaust air gt Stainless steei shell Cover 25 0 and surrounded by a stainless steel shell The catalytic converter oxidizes carbon monoxide and hydrocarbon and reduces oxides of nitrogen which are present in the exhaust gas in order to minimize their emission levels Stainless steel wire mesh 1 0031 AIR FUEL MIXTURE RATIO CONTROL SYSTEM MPI system is a system which employs the signals from the oxygen sensor to activate and control the injector installed at the each cylinder head thus precisely regulating the air fuel mixture ratio and reducing
156. ds 6 After about two seconds have passed after the SECURITY light illumination stopped reach through the window of the driver s door pull up the lock lever to unlock the door and then open the door 7 Check to be sure that when the door is opened the horn starts sounding and the headlights flash on and Off 8 To stop the alarm insert the key into the door s key cylinder and turn the key NOTE To check the alarm for the opening of the liftgate or hoad anen the liftgate or the hood by using the remote liftgate release lever or the hood release lever located at the driver s seat side either before the alarm is activated by the opening of a door or after the finish of the first three minute alarm 46 9 1 Rosa BASE ENGINE eren 7 GENERAL INFORMATION 2 Connecting Rod een 11 Engine Cut away View 2 24 4 0 4 Grankshaft 11 Major Specifications 2 Crankshaft Pulley e 12 Technical Features aita det 3 LUBRICATION SYSTEM 2 20 NGG qua Specifications 20 Main Bearing Caps unies 11 10 MOUNTS Pisf n Rings 10 Construction Diagram 21 Rocker desde etate 8 Silent Shaft System 12 Timing Belt Train ecacceteiet nte 17 Valve Mechanism
157. during Normal Operating Conditions Basic driving time deter mination Air flow sensor Crank angle Sensor Oxygen sensor Engine coolant temperature sensor Intake air temperature Sensor Barometric pressure sensor Battery voltage The injector activation duration is determined basi cally by the intake air flow signal from the air flow sensor and the crank angle signal engine rpm signal The duration determined in this way is called basic activation duration A correction factor is applied to the basic duration according to the signals Open loop control Feedback control closed loop control Injected fuel amount control depending on engine coolant temperature injected fuel amount control depending on intake air temperature High altitude compensation Injected fuel amount control during accel eration and deceleration Injector Batten voltage compensation se on 6200794 from various sensors to obtain the optimum injec tor activation duration fuel injection volume for current driving conditions 14 40 FUEL SYSTEM Fuel injection Control BASIC INJECTOR ACTIVATION DURATION In sequential injection under normal operating conditions fuel is injected into each cylinder once every cycle i e two crankshaft revolutions The injector activation duration required to inject the amou
158. e is kept in 2nd gear by directing the pressure to the rear clutch and the kickdown brake this purpose the pressure acting on the 4 ickdown i adjusted by the following method 0 alevel lower than that it would be when driving in mend gear isle pressure control solenoid valve is duty control Sled by transaxle control unit so that the 230 ine pressure will be lower than the No 23 line Pressure reducing pressure As a result the pressure control valve moves to the left under the line pressure which acts on the difference in area between the pressure control valve 1 and 2 lands and the reducing pressure which acts on the difference in area between the 2 and 3 lands thus closing the No 5 port by its 2 land This reduces the No 10 port pressure and the pressure control valve is moved to the right by the spring force Through the No 5 port thus opened the line pressure is directed to the kickdown servo The pressure applied to the kickdown servo is adjusted by the above mentioned sequence 21 70 AUTOMATIC TRANSAXLE Transaxle Control 1st Gear Selector Lever in D or 2 Reducing To low reverse brake via 1 2 Line pressure shift valve PE Line 10 5 Transaxle pressure Reducing control unit pressure E Pressing control N R control e FOUND i Pressure Pw solenoid valve iwi valve 1
159. e 7 12 EGR Temperature Sensor California 8 Fuel Check Valve retta eb asinis 14 Operation California 6 Fuel Fileto Gap atit 14 Operation Federals 3 5 Overfill Limiter Two way Valve 14 Thermo Valve Federal 2202022 2 7 P Control Solenoid Val den a P de DA 13 GENERAL INFORMATION 2 1 2 e 25 2 EMISSION CONTROL SYSTEMS General Information GENERAL INFORMATION There are three sources of vehicle exhaust emis sions generated the exhaust gases resulting from combustion the blow by gases generated within the crankcase and the evaporative emissions generated from the fuel tank and other components of the fuel line The emissions control system which is designed to control the discharge of these exhaust gases into the atmosphere is composed of the following system components 1 Exhaust emission control system 2 Crankcase emission control system 3 Evaporative emission control system Non Turbo for Federal Air cleaner Air inlet Oxygen sensor Catalytic converter Fuel injector R25BA The exhaust emissions control system reduces the amount of carbon monoxide hydro carbon and oxides of nitrogen in the exhaust gases by adding the exhaust gas recirculat
160. e Ba obo 5c M n From N D 1750107 control valve From 3rd 1 2 shift i Rear clutch pressure walve 4th Gear release side aum em 1 From N D 4th pressure control valve 3rd pressurevalve 1 2 shift 1750108 Upshift from 3rd to 4th Gear When the 4th pressure line pressure from the shift control valve is directed to the rear clutch exhaust valve through the No 8 line the valve is pushed to the right closing the No 5c port This cuts off the pressure to the rear clutch and also releases the pressure acting on the rear clutch through No 15 port No 20a port and No 20 port On the other hand the rear clutch exhaust valve which is pushed to the right opens the NO 19 port and directs the 4th pressure line pressure to the right end of the 2 3 4 3 shift valve The 3rd pressure or the No 7 line pressure is acting on the left end of the 2 3 4 3 shift valve As this Pressure is equal to the No 19 line pressure and acts on the same area the spring at the right end of the valve shes the valve toward the left closing the No 11 me pressure port This blocks the pressure to the front clutch and the release side chamber of kickdown servo cylinder and the pressure is re leased through the No 12 and then the No 9c port Downshift from 4th to 3rd Gear When the 4th pressure is released by the move ment of the shift control valve the rear clutch exhaust valve moves to the left creating a 3rd gear state
161. e Vortex generating column Serves to generate Karman vortices e Transmitter Transmits ultrasonic waves e Receiver Receives ultrasonic waves e Amplifier Generates ultrasonic waves e Modulator Converts ultrasonic waves that have been received into electric pulses e Acoustic material Karman Vortex When a triangular column is placed in an air stream regularly spaced vortices are generated downstream alternately on either side of the column These vortices are called Karman vortices The number of vortices generated is proportional to a close dearee to the volume of air flow in a given time the higher the flow speed the more vortices are generated 14 16 FUEL SYSTEM Sensors MEASUREMENT OF INTAKE AIR FLOW 1 When there is no air flow No vortices are generated in the absence of air flow Therefore the ultrasonic waves transmitted from the transmitter take a fixed time to reach the receiver This time is called the reference time This time shall be referred to as T 2 When a clockwise vortex passes under transmitter When a vortex passing between the transmitter and receiver revolves clockwise the direction of ultrasonic wave transmission is the same as that of the air movement of the leading half of the vortex so that the time elapsed for the ultrasonic waves to reach the receiver is shorter than the reference time This time shall be referred to as T4 In the trailing half of the vorte
162. e big end bearing is the kelmet metal with metal backing Front mark CRAN KS HAFT 1 The crankshaft is supported by the five main bearings 2 The oil passages drilled to the crankpins permit the flow of lubricating oil from the main bearing to the connecting rod bearing 3 The crankshaft has been subjected to special surface treatment Therefore do not grind it for reuse 4 The main bearing is an aluminum alloy with a backing of another metal The center bearing is provided with flanges to receive the thrust load of the crankshaft Oil jet Oil passage Balance weight Oil passage 6ENOO89 MAIN BEARING CAPS The No 1 and No 2 main bearing caps are joined as are the No 4 and No 5 main bearing caps by means of a beam to minimize vibration of the bearing saddles and to enhance rigidity of the crankshaft support e 5 9 12 ENGINE Base Engine CRANKSHAFT PULLEY Drives the water Drives the air pump and MESS conditioner Timing belt cover compressor 6 0145 1 The crankshaft pulley not only drives the water 2 There are fins provided at the back of the pulley pump and alternator but also functions as a that ventilate the inside of the timing belt cover torsional damper to reduce torsional vibration of when the pulley rotates they draw air out of the _ the crankshaft timing belt cover SILENT SHAFT SYSTEM Silent shaft 6ENO128 Forward l
163. e cooling radiator fan efficiently regulate the temperature of the engine is the electric motordriven type the fan is driven by coolant thereby reducing losses of engine output power COOLANT FLOW The cooling system is liquid cooled forced circula tion type The engine coolant circulates as follows When engine is cold Thermostat closed Cylinder head Throttle body mau Heater Turbocharger Water inlet pipe When engine is warm Thermostat open Cylinder block Water pump Cylinder head Throttle body Turbocharger Thermostat Water inlet pipe Water outlet fitting CLUTCH General Information _ 7 3 lt Non turbo gt p 2 Throttle body lt lt i f water outlet fitting AY Water pump S A gt VSS Thermostat From heater ay d e AES To heater Water inlet pipe Water temperature gauge unit Fromradiator Aw NY 6CO0018 lt Turbo gt 6CO0019 7 4 CLUTCH General Information Radiator and Cooling Fan SPECIFICATIONS Items Specifications Water pump Type Centrifugal impeller type Delivery rate i t qt min Max 140 148 at 6 000 rpm Thermostat Type Wax type with jiggle valve Valve opening temperature F 88 190 Drive belt V ribbed type RADIATOR AND COOLING FAN ROICMA The radiator is of the corrugated fin type The full shroud type cooling radi
164. e does not increase to the regulated level or above CHECK VALVE When the pump stops the check valve is closed by spring force so that there is high pressure remaining within the fuel line By in this way maintaining a high pressure within the fuel line the restarting of the engine becomes easier and vapor locks at high temperature are prevented 2 edet totis crt tmt m a am Diaphragm Non Turbo T PE Absolute pressure Kra psi FUEL SYSTEM Fuel Supply Fuel Pressure Control 14 9 Manifold vacuum from intake air plenum Return to fuel tank Fuel from delivery pipe 335 kPa 47 6 psi 335 kPa 47 6 psi Pressure gauge reading Gauge pressure a psi 98 14 2 Positive pressure FUEL FILTER A high pressure type filter is installed at the delivery end of the fuel pump FUEL PRESSURE REGULATOR The fuel pressure regulator maintains the pressure of fuel delivered to the injectors at a constant level of 335 kPa 47 6 psi Non Turbo models or 255 kPa 36 3 psi Turbo models higher than the manifold internal pressure thus keeping the volume of fuel injected constant regardless of changes in the manifold pressure The spring chamber is connected by a vacuum hose with the intake air plenum thus its interior pressure is always controlled by the manifold vacuum The manifold vacuum created in the chamber functions to decrease the spring pressure which forces down t
165. e drive spring and the tape which occurs depending on the amount of wind in at drum A and drum B is absorbed by the tension applied to the tape by the drum spring 23 36 BODY Seat Belts IRCUIT DIAGRAM Ignition switch IG Fusible link 6 Fusible link 3 Automatic Automatic seat belt seat belt Key reminder Driver s side 11 Automatic seat belt contro unit V U V 3H B B Bs POWER SUPPLY e OFF OFF Buckle Outer Release Fasten Release switch Switch switch Switch Switch Passen Driver s ger s side side OPEN 5 Door latch Door latch 1 2 3 4 5 6 7 819 10 switch switch 11101314 516517181420 Driver s Passen side ger s side Automatic seatbelt control unit connector terminals 1940343 34 BODY Seat Belts 23 37 COMPONENT PARTS AND FUNCTION Automatic Seat Belt Control Unit Located at the quarter panel on the driver s seat side The system is controlled based upon various input signals thereby Quarter panel regulating motor operation warning light illumination or continuous flashing and buzzer sounding Located at the front of the guide rail This switch is for turning the shoulder belt drive motor off It transmits an OFF signal to the control unit when the shoulder belt is completely unfastened Once the OFF signal is received the control unit shuts off the motor Guide rail
166. e fluid discharged from the oil pump passes through the pilot port and hydraulic pressure is applied to the rear surface of the plunger but because this hydraulic pressure is weak the plunger is pushed toward the left as a result of the force applied by the plunger s spring thus opening the Plunger To steering gear box Variable orifice Pilot port WHEN OIL PUMP OPERATES AT MEDIUM SPEED 1 000 3 000 RPM When the engine speed increases and the pump s speed also increases the hydraulic pressure of the fluid discharged from the pump becomes higher overcoming the plunger spring s force and causing the plunger to move toward the right As a result of this action one of the variable orifices closes At the Variable orifice Plunger To steering gear box Variable orifice Variable orifice From oil pump Fixed orifice From oil pump Bypass port variable orifices As a result of this action the fluid passes through the variable and fixed orifices and is sent by way of the plunger to the gear box The amount of discharge to the gear box at this time is almost maximum with the result that an extremely low steering effort is required Fixed orifice Flow control valve To oil pump 13P0038 Fixed orifice same time the flow control valve also is pressed toward the right the bypass port opens more and the surplus fluid is returned back to the oil pump In this way the amount of discharge flow t
167. e map value is corrected gradually in the delay direction In the absence of knocking the map value is corrected gradually in the advance direction In this way optimum ignition timing is constantly control led this control is effective even when fuels of different octane ratings are used This means that the engine is protected from knocking damage even when the fuel is switched from premium to regular or vice versa Power transistor gt Ignition coil K primary current 6FU0548 In order to obtain stable ignition energy the ener gization time of the ignition coil primary current is controlled as to keep current at a constant value when the primary current is shut off 1 DURING NORMAL OPERATION Basic energization time The increase of the ignition coil primary current changes with the battery voltage Therefore the energization time is so controlled that the primary current at time of ignition becomes 6A The basic energization time is so set that it is longer when the battery voltage is low and is shorter when the Energization time clip The new two coil ignition system has its ignition interval doubled when compared to the convention al single coi type allowing a longer clip time As a result a long energization time is secured for sufficient ignition energy even during high speed operation 2 WHILE CRANKING When cranking the ignition coil is energized in synchronization with the crank angle
168. e offset geometry for outstanding stabil GENERAL Technical Features 0 5 ENGINE The engines are the transverse mounted engine operation low vibration low noise low fuel especially for front engine front wheeldrive or consumption features an engine that fully displays front engine 4 wheel drive models the 2 0L DOHC the most up to date engine technology 16 valve engine with high performance silent SPECIFICATIONS Engine model Displacement Max output SAE net Max torque SAE net HP rpm ft Ibs rpm 4G63 Non Turbo 1997 122 135 6000 125 5000 4G63 Turbo 1997 122 195 6000 203 3000 FEATURES High performance and low fuel consumption e The rocker arm reduces the valve actuation torque as well as fuel consumption e Airintake efficiency improved through the adoption of the optimum air intake system layout e Improved response and fuel consumption has been achieved by electronic control multipoint fuel injection e Water cooled turbocharger Turbo Quiet operation e Noise and vibration have been decreased by the adoption of roller rocker arms e Noise generated by the valve mechanism has been decreased by the hydraulic auto lash adjusters e Vibrations have been decreased by the adoption of bearing caps with beams which increase the rigidity of the crankshaft support points Serviceability e Complete self diagnosis functions e Enhanced reliability through the ado
169. e that an automatic seat belt motor relay is installed at the motor f due to a malfunction the slide anchor stops before it reaches the nd of its travel note that the slide anchor can also be moved nanually by using the hexagonal wrench included with the vehicle ocated at the door latch hese switches detect the open close condition of the doors The following components also constitute the automatic seat belts system Ignition Switch ON position Kev reminder Switch E mill amp Key cylinder Buzzer This switch sends a High signal to the control unit when the ignition is at the ON position incorporated within the key cylinder ON signals are sent to the control unit by switch A while the key is inserted in the key cylinder ON signals are sent by switch B when the key is not in the key cylinder Located at the rear side of the instrument panel The power for this buzzer is supplied from the battery through fuse 1 o 1 Note that the buzzer sounds an alarm to warn that the key has been left in the ignition Vus BODY Seat Belts 23 39 OPERATION Beit Fastening Motion 1 If the belt is not in the fastening position the When the belt is completely fastened the L H or R H door latch switch at Door Closed position the L H or R H fasten switch at ON position when the door is closed with the ignition switch in the ON position the belt automatically move
170. e valve capacity is adequate for all normal driving conditions Positive crankcase ventilation valve From air cleaner 6 0115 intake manifold From rocker Cover Blow by gas lt Freshair EX 222224555666 CZ AA 7 0021 EMISSION CONTROL SYSTEMS Evaporative Emission Control Sysyem MAPORATIVE EMISSION CON TROL SYSTEM In order to prevent the escape of fuel vapor from the fuel system into the atmosphere the evaporative emission control system consists of a charcoal canister a purge control solenoid valve etc When the fuel vapors generated inside the fuel tank fill the tank they press and open the overfill limiter s valve and pass to the canister where they are absorbed into and accumulated by the charcoal Because the purge control solenoid valve is ON open when the engine is running as a conse Non Turbo Air cleaner Fuel injector 4 Purge control solenoid valve Engine Canister Fuel check valve 25 11 R25GAAB quence of the purge air being taken in from the canister in accordance with the intake negative pressure vacuum the fuel vapors accumulated in the canister are taken from the charcoal and are also taken into the intake manifold Note that the purge control solenoid valve is OFF closed when the engine is cold and during idling and so fuel vapors are not taken into the intake manifold at that time Overfill
171. eaks from the fuel line Fuelpump checkterminal Fuel pump 7FUO30C Pa 14 12 FUEL SYSTEM Intake Air Control INTAKE AIR CONTROL GENERAL DESCRIPTION Speed adjusting screw Idle positions w Throttle position sensor Throttle valve Fast idle air valve Bypass air flow nd before metering c Bypass air flow after metering Coolant from thermostat case Idle soeed control servo i ee return pipe 6FU0777 Control of the volume of intake air is performed by the throttle valve the speed adjusting screw the fast idle air valve and the idle speed control servo all of which are mounted on the throttle body Control idle DURING ENGINE WARM UP speed control servo The intake air flow during fast idle is controlled by both the wax Cont actuated air valve which functions in response to the engine idle air coolant temperature and the idle speed control servo that is controlled by the engine control unit AFTER ENGINE HAS BEEN WARMED UP Speed adjusting screw Control of the intake air flow during curb idle or the control of Throttle valve curb idle speed is performed by the idle speed control servo 230429 0132 30186 60140 901194 which in turn is controlled by the engine control unit Coolant temperalUre cm eruosa Refer to page 1445 for control of the idle speed control servo The idle speed can be adjusted by increasing or decreasing the intake air
172. ear side the connectors for connections E intermediate connection connectors of wiring har from the body harness are provided and are con ness fuse box and relay On the front side of the nected in the junction block as shown below junction block the connectors for connections from the heater relay fuse box engine compartment ELECTRICAL Junction Block INTERNAL CIRCUIT DIAGRAM e e ad The aiphabetical symbols on the connectors are associated with the connector symbols P 8 5 27 ELECTRICAL Relays RELAYS CONTROL UNITS AND SENSORS ontrol Units and Sensors 8 7 ROBEAAC The relays control units and sensor for the various systems are located as described below ALTI POINT FUEL INJECTION SYSTEM Symbol Crank angle sensor and top dead center sensor Detonation sensor Turbo Idle switch The column is arranged in alphabetical order Name Air flow sensor incorporated within barometric pressure sensor and intake air temperature sensor EGR temperature sensor vehicles for California Engine coolant temperature sensor Air flow sensor X S incorporated within barometric pressure sensor and intake temperature sensor temperature is MENS ut Magnet clutch relay MPI control rela
173. eat Belts 23 33 CONSTRUCTION AND OPERATION OF THE OUTER SWITCH The outer switch is installed at the retractor for the shoulder belt The component is an assembly supply item and so is not to be disassembled Its construction and operation are however as described below Gear A rotates in unison with the shaft of the retractor gear C s speed is reduced by way of gear B thus resulting in rotation A cam is installed to gear C In the illustration the belt is at the fully rewound position contacts A and B are separated and the switch is switched OFF When the belt is pulled out about 750 mm 29 5 in the cam presses contact A with the result that contacts A and B contact and the switch is switched ON The switch is ON until the completely pulled out position is reached At the time of rewind the cam is caused to rotate in the direction opposite to the direction during pull out and the switch is switched from ON to OFF when the belt reaches the approximately 750 mm 29 5 in pulled out position If the sequence switch is turned OFF the warning light comes on CONSTRUCTION AND OPERATION OF THE ENERGY ABSORBING BELT AND THE BUCKLE The driver s seat belt has on it a sleeve inside which the seat belt webbing is folded back over itself in a loop so as to absorb the energy of a shock by pulling loose and releasing slack There is a spring installed in the portion connecting the buckle to the arm allowing the buckle to ti
174. ed About 20 seconds after all doors are closed and locked the rear hatch is closed and the hood is closed SYSTEM ARMED door rear hatch or hood is broken to open ALARM ACTIVATED D Engine is disabled to start Driver unlocks a door or rear hatch with the ey ALARM DEACTIVATED SYSTEM DISARMED 16407 ELECTRICAL Theft alarm System 8 33 ARMING THE SYSTEM After the following procedures have been completed the SECURITY light illuminates for about 20 seconds and when illumination stops the system is armed 1 Pull out the ignition key from the key cylinder 2 Open a door The other door is closed 3 Lock the door with the key or the keyless locking method The central door locking system will then function to lock all doors NOTE 1 The system is set regardless of whether the hood and liftgate are open or closed and is armed as soon as the light goes out 2 Even after the system has been armed if the key is used to open the liftgate the system will not be activated when the liftgate is then closed moreover the system will be armed DISARMING THE SYSTEM 1 The system will be disarmed if the key is used to unlock a door 2 If the system is armed while the driver is still in the vehicle the system can be disarmed by inserting the ignition key and turning it to the ACC or ON position 3 If the door lock is unlocked while closing the door or the door is ajar
175. ed braking performance Improved serviceability 1 Adoption of 4 wheel disc brake on all models 1 Adoption of an outer disc system on the rear brake discs of all models 2 Adoption of a white reserve tank cap for the master cylinder CONSTRUCTION DIAGRAM Brake booster Master cylinder Proportioning valve Rear disc brake 14A0389 Front disc brake 71 BRAKES Service Brakes 5 3 SERVICE BRAKES SPECIFICATIONS Master cylinder Tandem with level sensor Tandem with level sensor in 22 2 23 8 15 16 Brake booster Multiple vacuum boost type Multiple 70081 type Piece dia of 230 9 0 power cylinder mm in Proportioning valve Type Dual type Split point 4 200 597 kPa psi Decompression 0 3 ratio Front brakes Type M R44V Cylinder D 53 9 2 8 mm in Clearance Automatic adjustment Rear disc brakes Type ADS3OP Cylinder 1 0 30 1 1346 mm lin Clearance Automatic adjustment NOTE 4WD X ARRANGEMENT OF BRAKE LINES The X arrangement of brake lines is the arrange ment by which the right front and left rear and the left front and right rear are connected so that the Master cylinder Front side 18 Rear side 8 0 Dual type 4 200 597 0 3 or 0 4 M R44V 53 9 278 Automatic 30 1 1346 Automatic braking force will be applied at the front and rear wheels even in the unlikely event of a malfunction of failure
176. ed to the LOCK E position or it is pulled out the projection of S the rotor moves to the position where it prevents the hook inside the key cylinder from moving Therefore even if an effort is made to depress the push button of the shift lever the lock cam prevents the detent pin from moving and the shift lever cannot be shifted to the positions other than the P LOCK position Ignition key Cylinder 09 0091 21 21 When shift lever is in positions other than P position ACC position 0940128 O9AOO90 2 When shift lever is in position other than position When the shift lever is in the positions other than the P position for example N posi tion the lock cam turns clockwise and held in that state as shown in 2 of the illustration Therefore the key interlock cable is in a stroked state with the hook inside the ignition key cylinder inserted in the notch made in the projection of the rotor Thus even if it is attempted to return the ignition key to the LOCK position the hook prevents the rotor from turning and the ignition key can be turned only up to the ACC position making it impossi ble to pull out the key 21 22 AUTOMATIC TRANSAXLE Torque Converter TORQUE CONVERTER Lock ring _ Impeller Startor When damper clutch is activated When damper clutch is not activated Input shaft 175202 The torque converter
177. eed of the cooling radiator of the air conditioner the coolant temperature etc fan and of the condenser fan to either the low speed by way of the air conditioner switch the thermo or the high speed sensor for the radiator fan and air thermo sensor Switch Sensor conditions Fan rotating condition Air conditioner switch Thermo sensor Air thetmo sensor ene radiator fan the Soniai of the thermo sensor is closed at the ON setting and open at the OFF setting 8 1 ELECTRICAL CONTENTS ane DIAGNOSIS SYSTEM CHECK LIGHTING 16 CONNEC TORS 4 Delayed Switch off Dome Light 22 ENGINE ELECTRICAL 23 Headlight sss 16 Alternator 23 RELAYS CONTROL UNITS AND Ignition System oe 25 SENSORS gt o ates onmi e 7 Ignition Timing Control System 27 Auto cruise Control System 10 Starter Motor 2 2 24 Automatic Seat Belt _ 10 2 2 Dedicated Fuses 4 9 ys E A Heater and Air Conditioner 11 Main Fusible Links sese 2 Multi point Fuel Injection System 7 Multi purpose FUSES 3 arer nane Gra 13 Sub fusible Links s 2 THEFT ALARM SYSTEM
178. eering wheel from protruding into the driver during collision thereby ensuring safety of the driver Crash bead 2 The safety hook prevents the hood from entering the passenger compartment during collision thereby ensuring safety of the driver as well as passengers DASH PANEL Sine M The dash panel consists of the deadening sheet sandwiched between two sheets of panel Coupled with the silencer attached to the panel on the passenger compartment side the dash panel is effective in deadening noise and resisting to Dash panel vibration SIDE BODY 1 The front pillar is of the concealed construction to offer the flush surface body Front pillar inner upper A Front door outer upper Front pillar inner upper Front door sash 31A0207 BODY Main Body 23 15 MAINTENANCE SERVICEABILITY Structure Notches are provided in the door openings for use in aligning panel positions thus facilitating the assembly of new parts 31X0073 pA FADA 32A0089 Body Center Points Body center points are provided at the following locations which serve as reference points for measurements at replacement of panels Refer to Body Dimensions 32A0108 Front body center point reference location 23 16 BODY Main Bodv Access Holes Access holes are provided in inner panels including doors and quarter panels to facilitate correction of
179. elief valve closes once again This action takes place in a moment and in this way by maintaining the correct balance the maximum pressure is controlled Steel ball Relief valve To oil pump PA Bypass port 13P0041 ist 21 1 CONTENTS RI AUTOMATIC TRANSAXLE 16 One way Clutch 0 31 A T SAFETY LOCK SYSTEM 19 Parking Mechanism 39 GENERAL INFORMATION _ 16 Planetary 32 Sectional VIEW eer cr 17 Power EIOW as dnd nERE 33 Specifications duse senti qe Den Ret 16 Rear Cl tehi 26 ORQUE CONVERTER 25 Select Pattern 24 Start Safety Mechanism 40 TRANSAXLE CONTROL 1 MANUAL TRANSAXLE lt 2WD gt 2 TRANSAXLE CONTROL 41 GENERAL INFORMATION 2 Electronic Control Device 42 Sectional View 3 General Description 41 Specifications rre 2 Hydraulic Circuit 87 TRANSAXLE CONTROL 5 Hydraulic Control System 55 Wiring Diagram ideis crannies 96 MANUAL TRANSAXLE 4WD 6 TRAN
180. ely the power pattern and the economy pattern in its internal memory The driver selects either of the two shift patterns by using the power economy select switch which determines the shift pattern that is to be used While the transaxle is cold oil temperature is Shift Pattern POWER pattern 100 80 60 Throttle opening 96 Vehicle speed km h 3000 Output shaft speed rpm S 22 E _ 2 L 21 43 20 C 68 F or lower the economy pattern is used exclusively The transaxle control unit monitors the throttle position sensor output which detects the de gree that the throttle valve is open and the pulse generator B output which detects output shaft speed and when it determines that the shift line of the shift pattern has been crossed it issues a shift command 4000 1750473 21 44 AUTOMATIC TRANSAXLE Transaxle Control ECONOMY pattern Throttle opening 3000 4000 Output shaft speed rpm 0 50 100 150 Vehicle speed km h 175047 of the A and shift contro solenoid valves corresponding to the gear shifting sequence The combination of on off states of the and B shift control solenoid valves in each gear is shown in the table below 3 The transaxle control unit provides on off control Shift control solenoid val 1st gear 2nd gear 3r
181. emissions This in turn allows the engine to produce exhaust gases of the proper composition to permit the use of a three way catalytic converter The three way catalytic converter is designed to convert the three pollutants 1 hydrocarbons 2 carbon monoxide CO and 3 oxides of Nitrogen NOx into harmless substances There are two operating modes in the MPI system 1 Open Loop Air fuel ratio is controlled by information programmed into the engine control unit at manufacture 2 Closed Loop Air fuel ratio is varied by the engine control unit based on information supplied by the oxygen sensor NOTE For detailed information concerning the system refer to Fuel System zd N one se mFS ta 25 10 CRANKCASE VENTILATION SYS TEM closed type crankcase ventilation system is uti lized to prevent the blow by gas from escaping into the atmosphere This system has a positive crankcase ventilation valve PCV valve at the rocker cover This system supplies fresh air to the crankcase through the air cleaner Inside the crankcase the fresh air is mixed EMISSION CONTROL SYSTEMS Crankcase Ventilation Svstem R25FAAA4 with blow by gases and this mixture passes through the PCV valve into the intake manifold The valve has a metered orifice through which the mixture of fresh air and blow by gases is drawn into the intake manifold in response to the intake manifold vacuum Th
182. engine is running since the drive gear is driven by 2 pawis of the pump drive hub welded at the center of the torque converter shell Reaction shaft Jil pump housing support ea EH m n ELE 21 56 AUTOMATIC TRANSAXLE Transaxle Control REGULATOR VALVE To torque convertor control valve To shift control valve pressure control valve and N D control valve in D 2 or L range To N D contro valve in N D 2 or L range Oil filter To N R control valve in R range Line relief valve Oil pan 1750076 This valve regulates the hydraulic pressure generated by the oil pump to a hydraulic pressure corresponding to the regulator valve spring force The pressure so regulated is called the line pressure Selector Lever in D 2 or L The hydraulic pressure from the oil pump is directed to the regulator valve through the No 1 line After passing through the regulator valve hydraulic pressure is directed to the torque converter via the torque converter control valve Also at the same time the pressure from the No 1 line is directed to the manual valve and then to the chamber A at the right end of the regulator valve through the No 4 port The pressure directed to t et N S the chamber A acts on the regulator valve against the E regualtor valve spring force and shifts the valve to regulate the line pressure When t
183. ently 14 20 FUEL SYSTEM Sensors CRANK ANGLE SENSOR Disc amsha a Sensor unit GFUO780 The crank angle sensor is mounted on the cylinder The crank angle sensor consists of a disc and a head and is directly coupled to the intake camshaft sensor unit The disc made of metal has four slits located 90 degrees apart on its periphery and two slits located 180 degrees apart inward of the four slits 5 The inner slits are used by the top dead center sensor th detects the top dead center of the No 1 and No 4 cylinders and the outer four slits are used by the crank angle sensor that detects the crank angle The disc is positioned on the sensor shaft and rotates as a unit with it being turned by the intake camshaft The sensor unit has two LEDs and two photo diodes used to detect the crank angle sensor slits and the top dead center sensor slits The disc rotates between the LEDs and the photo diodes Each time a slit comes between a LED and photo diode pair the light emitted by the LED reaches the photo diode by passing through the slit Sht for detecuon of No 1 cylinder TDC Slit for crank angle sensor Slit for No 4 TDC sensor Sit for TOC sensor LED Slit for crank angle sensor Photo diode Sensor unit Power supply Engine control unit 5 volts 5 volts D Photo diode 5 volts gt Crank angle Es s
184. er Specifications Primary coil resistance 0 86 at 20 C 68 F Secondary coil resistance kQ 12 1 at 20 C 68 F Connector Capacitor Noo mark 6ELOO57 To 1 spark plug To No 4 spark plug To No 3 spark plug To No 2 spark plug POWER TRANSISTOR The power transistor is driven by a signal from the engine control unit and turns the primary current of the ignition coil on and off Terminal symbol External connection Ground Engine control unit Engine control unit Ignition coil terminal 2 Ignition coil terminal 1 SPARK PLUG BPR6ES 11 W20EPR 11 RN9YCA BPR6ES Turbo W20EPR w __ 1 0 1 1 mm 039 043 in 0 7 0 8 mm 028 031 in Non turbo ELECTRICAL Engine Electrical 8 27 IGNITION TIMING CONTROL SYSTEM Engine control unit Air flow sensor Intake air temp sensor Barometric pressure sensor Engine coolant temp sensor idle position switch Spe dieit Top dead center sensor i Crank angle sensor T Vehicle speed sensor Ignition switch ST terminal 5 Detonation sensor for d turbo engine only 12 E E a 5 The ignition control system uses the engine control unit that judges which cylinder is to be fired at what time based the signals coming from various sensors The engine control unit activates the power transistors so that ignition occurs taking into
185. er valve ter control S 1750229 21 60 AUTOMATIC TRANSAXLE Transaxle Control REDUCING VALVE Reducing valve Adjusting screw 5 deer EI Pressure ps control valve Line pressure amp 11 E a Transaxle 3 16 contro unit NH control valve CoCr E lt ARASARA F3 i u A A Ex Ex E i bopooe 230 gt T d amp Pressure control EF BEE LAS SN 7 solenoid valve 1750082 The reducing valve is installed at the lower valve body it functions to produce a constant pressure which is alwavs lower than the line pressure With this pressure as hydraulic pressure source the control pressure is produced the pressure control solenoid valve thus activating t he pressure control valve 1 Line pressure is directed through the No 1 port to the space created between the 1 and 2 lands of the reducing valve and is then directed to the above mentioned pressure control solenoid valve from the No 23 port as the reducing pressure The pressure directed to the space between the 1 and 2 lands of the reducing valve is applied to the area equivalent to the difference in area between the lands and constantly forces the valve toward the right against the Line To pressure control spring force The reducing pressure is regulated in this pressure Solenold yalve manner by the operation of the reducing valve 2 gt
186. er of windings of the coil is reduced in order to facilitate current rise when the current is flowing in the coil By doing so the resistance of the injector coil becomes smaller and a greater amount of current can flow with the result that the calorific value of the injector coil becomes greater and overheating occurs For this reason for turbocharger equipped models which have low resistance of the injector coil a resistor is provided between the power supply and the injector in order to regulate the amount of current flowing in the coil FUEL INJECTION TIMING INJECTOR AC TIVATION TIMING The fuel injection timing in multipoint fuel injection has two modes sequential and simultaneous In sequential injection fuel is injected into each cyl inder sequentially throughout the entire normal Sequential Injection No 1 cylinder TOC signal No 1 TDC TDC sensor signal Crank angle sensor signal No 1 cylinder No 3 cylinder No 4 cylinder No 2 cylinder No 3 TDC 7 En eaa Com Com Saron f __ Compression operating range including idling simultaneous injection fuel is injected simultaneously into all cylinders during starting and acceleration No 4 TDC No 2 TDC intak Com ntake pression 6FU1006 In sequential injection the injectors are activated for each cylinder on the combustion stroke of the piston T
187. erence ignition timing When the engine speed is approx imately 1 200 rpm or higher however the timing advance is according to normal operation and therefore this ignition timing adjustment is not available 4 Knocking Control for Turbo Engine Only Engine coolant tem fature Correction value arometric pressure Advance map correction Knocking correction Detonation sensor Failure detection ELECTRICAL Engine Electrical oe Knock wibration Knocking ievel Delay angle ignition uming detection determination caiculation letermination Cone nae ignition coi primaty Current 6FU0565 Engine knocking is detected and the ignition timing is controlled accordingly to prevent continued knocking and to protect the engine When knocking is detected the engine control unit delays the ignition timing according to the signal from the detonation sensor until the knocking is eliminated up to a maximum 12 in crank angle In the case of an open or short circuit of the detonation sensor harness the timing is delayed by a fixed angle approximately 8 in crank angle to prevent knocking Energization Time Control While cranking Synchronized with crank angle sensor signal During normal operation responding to battery voltage Map value Cor H Energization time is clipped at 7596 of ignition interval H If knocking continues the advance angl
188. ernal force acting towards the rear or to a braking reaction the force FR acts as a moment about momentary center P causing the tire to steer in the toe in direction thereby securing directional stability of the vehicle While the vehicle is cornering side force Fc acts on the outer wheel from the inside and side force Fc acts on the inner wheel from the outside These forces work moments about momentary centers P and P respective to cause the outer wheel to be steered toward toe in and the inner wheel toward toe out As a result both wheels are steered in the same direction as the cornering direction of the vehicle This results in under steering to improve cornering performance and stability 4 The change in toe angle and camber to ground is kept small for bumps or rebounds as shown at the left and this contributes to steering stability while cornering REAR SUSPENSION Double Wishbone Suspension Differential carrier Upper arm Lower arm Trailing arm system viu mue eue 772 17 13 5 The suspension crossmember is mounted with the mem ber support bushing on the body The input from the wheel is first damped by the trailing arm and the bushings of the lateral arms It is then further damped by the member support bushing This dual anti vibration construction pro vides low vibration and low noise addition mounting of the differenti
189. etween the center differential case and the center shaft rear wheel drive shaft A0 MANUAL TRANSAXLE lt 4WD gt General information wer flow is as shown in the chart below The power from the engine is first transmitted through the input shaft and intermediate gear to the center differential The center differential which distributes power to the front and rear wheels normally operates at a 50 to 50 ratio As the differential always transmits more power to the lighter load side there may be the case for example when one axle is spinning the total drive force of the vehicle reduces In order to prevent this the viscous coupling limits ENGINE INPUT SHAFT FRONT FRONT DIFFERENTIAL e DIFFERENTIAL SIDE GEAR L PINION GEAR FRONT LEFT DRIVE SHAFT FRONT RIGHT DRIVE SHAFT 21 9 differential action of the center differential according to the rotating speed difference between the center differential case and the center shaft thereby securing drive force Half of the drive power distributed by the center differential is transmitted through the front differen tial to the front drive shaft The other half of the drive power distributed by the center differential is transmitted through the trans fer the propeller shaft and the rear differential to the rear drive shaft i CENTER CENTER DIFFERENTIAL DIFFERENTIAL DIFFERENTIAL comen SHA SIDE GEAR PINION GEAR SIDE GEAR
190. fastened 1 When the motor shaft rotates in the clockwise direction gear A and the lock plate also rotate in the same direction When gear A rotates gear B rotates in the counterclockwise direction In the counterclockwise direction there is no transfer of force from gear B to drum B 2 After the lock plate rotates and the drum spring within drum A is compressed drum A rotates the tape is wound in and the slide anchor moves toward the fasten side When the Tape is Wound Out when the auto matic seat belt is released 1 When the motor shaft rotates in the counter clockwise direction gear A and the lock plate also rotate in the same direction When gear A rotates gear B rotates in the clockwise direc tion In the clockwise direction the projection of gear B contacts the projection of drum B thus causing drum B to rotate 2 As a result of the rotation of drum the drive At the same time that the tape is wound into drum A the drive spring is also wound in and drum B rotates The slight difference in the amount of move ment of the drive spring and the tape which occurs depending on the amount of wind in at drum A and drum B is absorbed by delaying the rotation of drum B relative to the rotation of gear B spring wound to drum A is pulled out and at the same time the tape is pulled out and the slide anchor moves toward the release side The slight difference in the amount of move ment of th
191. ferential at low load 3 8 5 5 5 2 LZ E 1 Difference in rotating speed between right and left wheels rpm Remarks e hump occurs when there is a large difference in rotating speed between the right and left wheels Since the large difference causes violent shearing of the silicone oil in the viscous coupling by the plates the oil tempera ture rises the silicone oil expands and the torque abruptly rises If the hump occurs the inner and outer plates enter a directly coupled differential locked state 114005 Drive pinion rear bearing Side gear L H Side gear R H Pinion shaft Differential case 8 ra LEONE ur 7 Differential cover Viscous coupling with side gear L H Differential case A Pinion shaft Side bearing RN 2 Drive gear 1140337 FUNCTIONS AND FEATURES 1 The viscous coupling type limited slip differential is functionally the same as the conventional mechanical type which reduces slipping of the rear wheels for better performance when travel ing on a rough road or when getting out of a snowy or muddy surface 2 The viscous coupling type limited slip differential responds to a difference in rotating speed and has outstanding characteristics for use in an on road 4WD vehicle as it has no difference in characteristics in the normal operating range between when power is ON and when it is
192. flow rate with the speed adjusting screw The off idle intake air flow is controlled by the throttle valve operation of the accelerator pedal determines the degree that the throttle valve is open at any particular moment o E 2 x amp FUEL SYSTEM Intake Air Control 14 13 SPECIFICATIONS tems Specifications Throttle body Throttle bore diameter mm Fast idle air valve Type Valve closing temperature F speed control servo Type 60 2 362 Wax type Approximately 50 122 Stepper motor type FAST IDLE AIR VALVE Engine coolant Bypass air outlet Bypass air inlet Throttle body 6FU0542 The fast idle air valve is a wax actuated valve The engine coolant circulates around the wax pellet gt causing the air valve to be forced out as the coolant 122 higher air flow rate The valve is closed completely when the coolant temperature is approximately 50 C temperature increases thus decreasing the bypass 14 14 FUEL SYSTEM Sensors SENSORS mat GENERAL DESCRIPTION The types and functions of the sensors are as listed send corresponding signals to the engine control below These sensors detect engine conditions and unit SENSORS FUNCTION AIR FLOW SENSOR Senses the intake air volume with a Karman vortex flow meter INTAKE AIR TEMPERATURE Senses the intake temperature temperature of air at SENSOR the point of entry int
193. ft and e Shaking movement of the shift lever during select cables to the transaxle and the body in acceleration and deceleration has been attenu order to prevent the transmission of minor ated by the flexibility of the shift and select vibrations to the body cables Vibration prevention rubber pieces b Shift cable Selector cable Vibration prevention rubber pieces Shift lever assembly 2 fe Vibration prevention a rubber pieces 09A0099 21 6 MANUAL TRANSAXLE lt 4WD gt General Information MANUAL TRANSAXLE lt 4WD gt GENERAL INFORMATION W5M33 transaxle is a transaxle for 4WD having center differential mounted on the output shaft of the conventional front wheel drive type transaxle so as to distribute drive power to the front and rear SPECIFICATIONS R21BAAD wheels Using the viscous coupling as a device for limiting differential of the center differential this transaxle is a full time 4WD type and provides improved traction and easy drive Transaxle model W5M33 2 NPZS 5 speed constant mesh cable controlled type Gear ratio 1st 3 083 2nd 1 684 3rd 1 115 4th 0 833 5th 0 666 Reverse 3 166 Primary reduction ratio 1 275 37 29 number of gear teeth Front differential gear ratio 3 866 58 15 number of teeth Transfer gear ratio 1 090 24 22 number of teeth Speedometer gear ratio 29 36 Oil quantity liter qts Transaxle 2 3 2 43 Transfer
194. g seal Cylinder Piston Check ball Spring 6ENO344 8 The auto tensioner applies tension to the timing belt of the piston are filled with silicone oil P by causing the tensioner arm to move back and Both the tensioner pulley and idler pulley are of the forth in the directions shown by arrow 2 ball bearing type into which grease has been J The bottom figure shows the construction of the packed auto tensioner The chambers on the right and left ha e Pressure chamber BENQ34 6ENO34 9 19 Operation of the Auto Tensioner WHEN THE BELT TENSION HAS INCREASED 1 The tensioner ALM pushes the piston in the direction shown by AIFOW 6 causing the raulic pressure in the pressure chamber to build up 2 The check ball closes 3 The oil in the pressure chamber is compressed by the piston which causes a small amount of oil to gradually leak through the clearance between the piston and cylinder into the reservoir chamber This causes the piston to move slow in the direction shown by arrow 4 The piston stops moving when the load in the direction balances the spring tension which determines the load i e tension applied to the belt WHEN THE BELT TENSION HAS DECREASED 1 The piston moves in the direction shown by arrow B by the spring tension 2 As the piston moves the hydraulic pressure in the pressure chamber becomes lower than that in
195. g Construction Rist and the other is left threaded with the result that the tilt bracket is sandwiched by the tilt bolts and the plate part of the column when the tilt lever is raised thus securing the steering column Tilt bracket Tilt bolt Right threaded OPERATION OF THE TILT STEERING 1 When the tilt lever is lowered to the free position the tilt screw turns in the direction of ioosing the tilt bolts that sandwiched the tilt bracket move toward the outer side and the steering column sliding is then possible 13A0254 Section A A eS EY m 7 d Tilt bolt Left threaded Tilt lever 1340255 When the tilt lever is raised to the lock position the tilt screw turns in the direction of tightening the tilt bolts move to the inner side the bracket is pressed against the column s pk and the steering column is secured ili POWER STEERING Power Steering Gear Box Construction 19 5 POWER STEERING GEAR BOX CONSTRUCTION msuaas ne steering gear box is of the rack and pinion type The steering gear box in the same way as the with a built in hydraulic control unit which uses a manual steering gear box is installed to the body by compact and highly reliable rotary valve way of the mounting rubber in order to reduce the transmission of vibrations Hydraulic control unit Cylinder tube Cylinder tube right chamber left
196. g speed difference between the left and right wheels a small difference in rotati speeds between the front and rear wheels also occurs Such rotational speed difference is absorbed by the differential action of the three differentials thereby allowing smooth driving The rotational speed difference is also transmitted to the viscous coupling but the difference is so small that the coupling makes almost no differential limiting torque application conse quently it does not affect the differential action of the center differential When starting out and accelerating When starting out and accelerating the center of gravity of the vehicle shifts towards the rear increasing the rear wheel load and decreasing the front wheel load The center differenti causes less drive power to be transmitted to the rear whee resulting in a lower driving torque At the same time however the rotational speed difference between the front and rear wheels increases and the viscous coupling operates to limit the differential action of the center differential securing a supply of drive power to the rear wheels In this way performance when starting out and accelerating is secured MANUAL TRANSAXLE lt 4WD gt General Information 21 11 When driving on rough roads In case either a front or rear wheel starts spinning on a slippery or muddy road or when the vehicle is stuck in mud and one tire spins the drive power will be decreased by diffe
197. ght Auto cruise control 03A0164 COMPONENT PARTS AND FUNCTION OUTLINE omponent part unction Vehicle speed sensor onverts vehicle speed to pulse Auto cruise control UNIT HeCelves SIgha s TOIT 5 5 and control switches microcomputer controls all auto cruise control functions auto cruise control unit Control switch MAIN switch SET COAST switch RESUME ACCEL switch Cancel switch Clutch switch M T Inhibitor switch A T Accelerator switch A T 4 speed automatic transaxle control unit AT Auto cruise indicator light Diagnosis connector Switch for auto cruise control power supply Controls auto cruise control functions by SET COAST and RESUME ACCEL Outputs the auto cruise control cancel signals During constant speed driving the accelerator pedal is inactive and the accelerator switch is turned ON Therefore OFF signal is output from the auto cruise control unit to the ELC 4A T control unit during constant speed driving only Controls overdrive ON and OFF based on overdrive ON and OFF signals from the auto cruise control unit for the auto cruise contro This indicator light illuminates to indicate that the vehicle is traveling in the auto cruise mode By connecting a voltmeter control unit diagnosis and input check codes can be read out for details refer to P 14 69 70 FUEL SYSTEM Auto cruise Control System 14 61 AUTO CRUISE CONTROL UNIT auto cruise
198. gnition switch or MAIN switch erases the diagnosis data Be sure to keep the ignition switch and MAIN switch in the ON position until you finish the inspection 2 Connect a voltmeter to the diagnosis connector of the junction block and read the output code 3 Check the output code against the following table to isolate the cause for cancellation of the auto cruise control mode Diagnosis Display Patterns and Codes Output codes Probable cause Display patterns 2 Sec 18485 05 S86 Abnormal condition of actuator clutch coil drive system 3 SEC Abnormal condition of vehicle speed signal system tow speed limiter activation The system is normal if it can be reset Automatic cancellation activated by vehicle speed reduction The system is normal if it can be reset Control switch malfunction when SET and RESUME switches switched ON simultaneously Cancel switch ON signal input stop light switch clutch switch or inhibitor switch input wiring damage disconnection or occurrence of abnormality in circuit within control unt 14 70 FUEL SYSTEM Auto cruise Control System NOTE 1 Codes indicated by the symbol are displayed if t DU ROT conditions are satisfied even if the system is normal i auto cruise control system is set either case the system is normal if it can be reset 2 Diagnosis codes are displayed when after cancellation of the auto cruise
199. he No 1 cylinder TDC signal is the refer ence signal for sequential injection The signal represents the compression stroke in the No 1 cylinder and with that timing as a reference fuel is injected into the cylinders in the order of No 2 No 1 No 3 and No 4 The injection for each cylinder is synchronized with the crank angle sen sors 5 BTDC signal Fuel is injected in each cylinder once for every two revolutions of the crankshaft FUEL SYSTEM Simultaneous Injection INJECTION UPON START CRANKING Start of cranking No 4 TDC TDC sensor signal Crank angle sensor signal No 1 cylinder exhaust No 3 cylinder Combustion No 4 cylinder Compression Com No 2 cylinder During the period immediately following the start of cranking fuel is first injected once in synchrony with the 5 BTDC signal from the crank angle sensor Thereafter fuel injection is synchronized with the ink angle sensor s 5 BTDC signal until the first 1 cylinder TDC signal is detected FUEL INJECTION DURING COLD START No 1 TDC TDC sensor signal Crank angle sensor signal Fuel injection EZ No 1 cylinder Fuel Injection Control f E eem VA ln intake Compression No 3 TDC Fuel injection 14 37 No 2 TDC 1 TDC No 3 TDC 5 TM ry cwm T Intake Lom 17 Exhaust 6FU1007 After the first No
200. he No 5 port 57 AUTOMATIC TRANSAXLE Transaxle Control Torear clutch via rear clutch exhaust valve From manual valve To 1 2 shift valve Line pressure From pressure from manual control valve valve From manual valve 1 2 shift alve i n From manual From pressure valve control valve 175024 21 79 Shift from N to D When the manual valve is shifted from the N to the D range position the following sequence of events occur 1 The line pressure from the manual valve is distributed through the No 5 line to the No 5 NO 5d and No 5e lines of the N D control valve 2 The No 5 port is closed at this stage by the N D control valve 3 There is a chamber with a check ball on the No 5d line As the check ball is held pressed against the downstream opening of the chamber by the line pressure the line pressure passes through the No 5e line which has an orifice provided 4 The line pressure after being attenuated by the orifice is directed to the No 5c line 5 Meanwhile the pressure from the pressure control valve which has been regulated by the pressure control solenoid valve is supplied through the No 10 line 6 There is an orifice in the No 10 line and the pressure which is attenuated by passing through this orifice flows into the No 5c line 7 The 5c line pressure is directed to the rear clutch via the rear clutch exhaust val
201. he engine speed and in turn the oil pump Spe becomes higher the hydraulic pressure increases This al increases the hydraulic pressure directed to the chamber A The increased chamber A pressure forces the regulator valve Ex toward the left overcoming the spring force At this point the Line No 3 port leading to the torque converter is opened wide Line pressure Pump pressure which allows more fluid to flow to the torque converter from oil pump suction 175007 AUTOMATIC TRANSAXLE Transaxle Control To torque converter 1 contro valve Regulator valve Spring Adjusting screw Line pressure To N D control valve shift control valve PRND2L f To N R Line pressure i control valve oil pump 1750072 To torque converter control valve L Orifice Regulator valve Adjusting screw Line pressure f from oil pump Pump suction To N D control valve To shift control valve PRND2L Line pressure from oil pump 1750056 21 57 If the hydraulic pressure increases even the regulator valve is forced further leftward and the No 2 port opens In this state the fluid flows through the port toward the suction side of the pump and the line pressure is released When the line pressure drops the chamber pressure also drops and the regulator valve is forced back toward the right by the spring force closing the N
202. he valve actuated by a diaphragm If this pressure forcing down the valve becomes less than the fuel pressure the diaphragm is forced up allowing excess fuel to flow back through the return pipe to the fuel tank Level A in the diagram to the left denotes the pressure gauge reading when the vacuum hose is disconnected in other words when the manifold vacuum is not applied to the spring chamber Level B denotes the pressure gauge reading when the vacuum hose is connected 14 1 0 FU EL SYSTEM Fuel Suppiy and Fuel Pressure Control INJECTOR Delivery pipe Injector Cylinder head 6FU0775 An injector is mounted on each of the four intake ports of the cylinder head The injector is activated by electric current controlled by the engine control unit When current flows through the solenoid coil the plunger and needle valve which form a single unit are magnetically attracted causing the injector nozzle to open and fuel to be injected When the current is interrupted the plunger and needle valve are pushed back by the spring closing the injector nozzle Solenoid coil SYSTEM aa eei pressure co 14711 FUEL PRESSURE CONTROL VALVE Turbo Control relay ES a c 5 zi Fuel pressure Fuel pressure 22 control valve c regulator Coolant temperature sensor i Intake air control temperature sensor unit To fuel
203. her degree of precision of position control 14 52 FUEL SYSTEM Idle Speed Control CONTROL WHEN THE ENGINE SPEED IS UNUSUALLY LOW The followipg controls are provided when the engine spee falls below rpm after the engine has been fully warmed up with engine coolant temperature more than 55 131 1 During feedback control The idle speed control servo is activated immediately by a particular number of angular steps which represent the feedback correction 2 During servo position control The idle speed control servo is activated to conform to a position corresponding to an increased number of steps 40 steps DASH POT CONTROL Control is provided to dampen the extending motion of the pintle from a certain opening degree thereby absorbing deceleration shocks 1 Control while cruising While cruising or racing the idle speed control servo is activated to further open the bypass air path corresponding to the dash pot position which is more open than the idle position The idle speed control servo is activated in this way when the following conditions are met e Engine speed 500 rpm or higher e ldle position switch in the OFF position The dash pot position is dependent on the throttle valve opening map value 2 Control during deceleration When the vehicle is decelerated from a cruising or racing speed the idle speed control servo is activated to close the bypass air path gradually from the dash pot position
204. hereby maintaining the optimum idle speed This basic position of the idle control servo directly corresponds to the basic idle speed described earlier Servo position during shift to range For models equipped with the automatic transaxle when the position of the shift lever is anywhere other than the P or N range the servo position is increased in proportion to the load of the torque converter Idle control servo position during operation of the power steering system When the power steering oil pressure switch is turned on because the steering wheel is being turned while the vehicle is stationary the servo position is changed to correspond to the increased power steering pump load Servo position while the air conditioner is being operated When the air conditioner switch is turned on the servo position is changed to correspond to the increased air conditioner load High altitude compensation A correction is performed by increasing the opening of the idle speed control servo to allow increasing bypass air flow in order to compensate for the loss of intake air volume as measured by weight caused by a reduction in intake air density due to a drop in barometric pressure at increased altitude 6 Training function A training function that enters a value based upon the engine rpm and the target rpm into the memory and corrects the servo position according to this value is provided in order to obtain an even hig
205. his time lag is called the dead needie time valve The dead time varies with different battery conditions the j lower the battery voltage the longer the dead time Valve opening time Since the injector activation duration depends on the intake air 162402 volume and other factors longer dead time means shorter activation duration or a smaller amount of fuel injected This results in an improper air fuel ratio At such times the solenoid coil is energized for a longer period of time depending on the current battery voltage to correct the valve opening time thus ensuring that the optimum amount of fuel is injected iValve openng time Battery voltage V Fuel Injection Control at Starting When the engine is cranked the map value preset according to the engine coolant temperature is used as the basic injector activation duration to which the high altitude compensation is applied Basic injector acti vation duration msec 80 176 Coolant temperature C F 162401 2 z o amp valve opening Throttle Injector activation duration Engine has started FUEL SYSTEM Fuel Injection Control 14 43 Fuel Injection Control during Acceleration During acceleration acceleration correction described in the section Simultaneous Injection is performed in relation to the change in throttle valve opening Fuel Limiting Control during Decelera
206. ich all doors can unlocking each door when passengers get out or be locked or unlocked from the inside by using the get in but also maintains passenger safety inside door lock knob at either front door or from the central door lock system the operation of the outside by using the door key not only serves the lock actuator is regulated by the door control to reduce the trouble of individually locking or unit Door lock actuator right side Door control unit Door lock actuator left side Door lock 18A0454 control relay PTC heater DOORLOCK ACTUATOR The actuator is light in weight and is the highly reliable motor type NOTE Y The door lock actuator incorporates an internal thermist so as to Prevent damage as the result of overheating of motor PTC is an acronym for Positive Temperature Coefficient The thermistor with a positive temperature coefficient resistance provides more resistance as it generates heat thus limiting current and controlling the amount of heat generated Switch BODY Central Door Locks 23 21 OPERATION OF THE CENTRAL DOOR LOCKS Operation when the doors are locked When the doors are locked by using the inside lock knobs or the door key the door lock switch incorporated within the door lock actuator is switched OFF and then because current flows to the fuse as well as to the door control unit and the lock timer the lock timer causes base current
207. ickel alloy 23 8 BODY Main Body lt 4WD gt 9 e 2 2 PORT 4 P7777 R 00 yy 5 us QA 22 5 90 7 267024 2 7 e 522 EA e 22 7 P QT 2 ZA Nd UY 2 gt p 255 ES 2 lt lt A LESS 74 2 7 D WY 6504 7 j Sy te 22 lt gt Lo 22 Mis MY M Q ROY Ly GEE o 2 Esse Indicates high tensile steel panel Indicates galvanized steel panel 1 csse de itia DIEN ESAE yey pee Pea idee Ratti oes Part name Front door beltline reinforcement outer ront floor side sill inner front Front floor sidemember ront floor side sill inner ear seat crossmember ear seat pan ear end crossmember hild restraint reinforcement Oil cooler bracket eadlamp support panel Sidemember to crossmember brace ender support plate urn lamp bracket Front end upper bar Front end upper bar reinforcement ront upper frame outer ront upper frame lower ront upper frame inner Shield plate ear floor side sill reinforcement Radiator bracket ront tie down bracket inner ear tie down reinforcement Rear floor seat belt reinforcement Rear floor sidemember front bulkhead Rear floor sidemember rear bulkhead m SGACC SGACE Galvannealed steel plate SGAHC BODY
208. id Fail safe item valve B 12A0105 21 54 AUTOMATIC TRANSAXLE Transaxle Control Diagnosis item Remarks 0 Open circuit in pressure control solenoid Fail safe item 45 valve Short circuit in pressure control solenoid Fail safe item nmw 12A0105 Damaged or disconnected wiring of the Duty control is stopped after damper clutch control solenoid valve generation Short circuit of the damper clutch control Duty control is stopped after generation Malfunction of the damper clutch control Duty control is stopped after generation 1 st gear out of synchronization Fail safe item 2nd gear out of synchronization Fail safe item 3rd gear out of synchronization Fail safe item 4th gear out of synchronization Fail safe item 43 AUTOMATIC TRANSAXLE Transaxle Control 21 55 HYDRAULIC CONTROL SYSTEM The hydraulic control system consists of an oil pump which generates hydraulic pressure for the system and valves and solenoid valves to control the pressure or switch the oil passages The valves and solenoid valves are all built in the valve body OIL PUMP Oil pump generates the pressure for supplying oil to the torque converter for lubricating frictional parts of the planetary gear set and the overrunning clutch etc and for activating the hydraulic control system The pump is of the inner teeth engaging involute gear type It always generates the oil pressure when the
209. ignal 70 FUEL SYSTEM Sensors When exposed to light the photo diode conducts urrent in a direction opposite to an ordinary diode 5 a result current flows in the direction indicated by the arrow and dotted line and a voltage 5 volts is applied to the comparator of the sensor unit so that the terminal voltage of the engine control unit becomes 5 volts When the disc rotates further and OXYGEN SENSOR 14 21 the slit moves beyond the space between the LED photo diode pair the light can no longer reach the photo diode thus the current indicated by the dotted line ceases to flow and the terminal voltage of the engine control unit becomes 0 volt this way pulse signals are sent to the engine control unit from the sensor unit u M a i n C 4 Sensor he x DoooQ element Heater Lead wires Connector Housing Cover eFU1004 Heater Engine control unit Battery Owen m sensor The oxygen sensor is mounted at the outlet of the exhaust manifold or the turbocharger The sensor which uses an oxygen concentration cell having a solid electrolyte has such characteristics that its output voltage changes sharply in the vicinity of the stoichiometric air fuel ratio The sensor makes use of this characteristic to detect oxygen concentration in the exhaust gas and feeds back the signal to the engine control uni
210. il tempera ture drops and normal function is restored Rotating speed difference Transmitted torque Temperature Silicone volume 100 Silicone full level mode Hump mode QE oM Eie 2 REA Pt rata ILE ndi s 5 2210115 23 i MANUAL TRANSAXLE lt 4WD gt Transaxle Control 21 15 1 TRANSAXLE CONTROL RZICAAB construction and operation refer to TRANSAX LE CONTROL of 2WD system Ee 21 16 AUTOMATIC TRANSAXLE General Information AUTOMATIC TRANSAXLE GENERAL INFORMATION 4 22 automatic transaxles with different shift pattern introduced to match engine output characteristics These F4A22 automatic transaxles are transaxles of KM1 70 Type ll series and each is a two mode electronically controlled automatic transaxle with shift patterns of two modes SPECIFICATIONS Transaxle model F4A22 2 MPA1 Torque convertor Type 3 element 1 stage 2 phase with damper clutch Stall torque ratio 2 17 Transaxle Type 4 speed forward 1 reverse Gear ratio 1st 2 846 2nd 1 581 3rd 1 000 4th 3 685 Reverse 2 176 Primary reduction ratio 1 125 Differential gear ratio 3 611 Friction elements Number of front clutch discs 3 Number of rear clutch discs 3 Number of end clutch discs 3 Number of low reverse brake discs 6 Number of kickdown brake band 1 Control system Manual control system P R N D 2 L lever type with overdrive switch Shift pattern type
211. in bearings and eight balance weights GENERAL Technical Features 0 7 4WD Four wheel drive center differential of 4WD vehicle to achieve auto matic and ideal distribution of engine torque to the The full time 4WD system adopts viscous coupling front and rear wheels unit VCU as the differential limiting device for the Viscous coupling Transfer m i T O Center Viscous coupling VCU type differential limited slip differential Option 3 piece 4 joint ront propeler shart differential a Rear differential Viscous coupling Ut 11A0296 00 0031 SAFETY LOCK SYSTEM interlock device has been adopted to improve safety Key interlock device T safety lock system shift lock device and key Selector handle Key interlock bl A T control cable Shift lock cable 09A0152 0 8 GENERAL Technical Features THEFT ALARM SYSTEM OPTION for 4WD VEHICLES To make the vehicle theftproof this system is so designed that the headlights go on and off and the horn is sounded intermittently for about three Authorized Horn to sounds 2 Headlights flicker 1 5529 SYSTEM DISARMED Normal starting i 2 minutes when the locked door hood or liftgate has been forced open without using a key Furthermore the starter circuit is interrupted so that the engine may not be operated making the vehicle theftproof About 20 seconds
212. ings e Excellent driving stability thanks to the antidive geometry CONSTRUCTION DIAGRAM lt 2WD gt Rubber insulator Stabilizer bar Coil spring Rubber bushing Centermember lower si lt 4WD gt Stabilizer bar Stabilizer link Strut assembly Rubber bushing No 1 Crossmember Rubber bushing L ower arm FRONT SUSPENSION General Information 2 3 SPECIFICATIONS lt 2WD gt With a manual With an automatic With a manual transaxle transaxle transaxle Suspension system McPherson strut with coil spring and compression rod type Camber 5 30 Caster 2 24 30 Toe in in 0 3 0 12 Coil spring Wire dia x O D x free length in 13 7 x 173 7 x 314 13 9x 173 9 x 321 5 54 x 6 84 x12 4 55 6 85 x12 7 Coil spring identification color Light blue x 1 Light blue x 2 Spring constant N mm 105 24 134 24 134 Shock absorber Type Hydraulic cylindrical double acting type Max length in 483 19 02 Min length in 330 12 99 Stroke in 153 6 02 Damping force at 0 3 m sec 984 ft sec Expansion N lbs 1 000 220 Contraction N lbs 300 66 2 4 FRONT SUSPENSION General Information lt 4WD gt Suspension system McPherson strut with coil spring and compression rod type Camber 10 30 Caster 2 18 30 Toe in in 0 3 0 12 Coil spring Wire dia x O D x free length 14
213. ion device and the cataly tic converter to fundamental improvements such as improvement of the combustion chamber and the camshaft as well as other improvements to the engine such as feedback control of the air fuel ratio by the electronically controlled fuel injection sys tem The crankcase emissions control system is a closed type so that blow by gases are not discharged out to the atmosphere The evaporative emissions control system is the canister type vapors that are gener ated within the fuel tank are introduced into the intake manifold and are combusted so that they are not emitted out to the atmosphere Canister Purge contro solenoid valve 6 0202 EMISSION CONTROL SYSTEMS General Information 25 3 Non Turbo for California Canister Air cleaner Air inlet j ON Purge control solenoid 1 valve on rial uel tank Fuel EGR control solenoid valve s injector EGR temperature sensor Oxygen 5 Catalytic converter Turbo for Federal 3 Canister Purge control vaive ig ida Air Cleaner Air inlet iM Han Purge control E solenoid valve Catalytic converter 6EM 25 4 EMISSION CONTROL SYSTEMS General Information Turbo for California 3 Canister Purge control Air valve cleaner Purge control solenoid Nir OWE valve EGR control m so
214. ir Note that the power assist is not activated because no pressure difference develops in the left and right cylinder tube chambers A Oil reservoir Cil passageway L 13L0074 Chamber A lt gt V Nem 1310079 i5 POWER STEERING Pinion and Valve Assembly Construction WHEN THE STEERING WHEEL IS TURNED TO THE LEFT When the steering wheel is turned to the left the torsion bar is as shown in the illustration caused to torque in the direction of turning to the left with the result that the input shaft rotates by the correspond ing amount to the left and a rotational difference between the input shaft and rotary valve develops The concave and convex parts of the input shaft and rotary valve cause oil passageways L and R to become constricted with the result that for the fluid sent from the oil pump the flow of fluid is stopped from port a to port d and port b Port d To the right cylinder tube From oil pump To the left cylinder tube 1310073 Cylinder tube left chamber 19 9 When this happens the fluid flows from the oil pump to sleeve a port a port and sleeve c and is sent to the cylinder tube left chamber thus causing the generation of a force to move the rack in the rightward direction thereby assisting the steering effort of the steering wheel At the same time the cylinder tube right cha
215. it is set to preset fixed timing 1 WHILE CRANKING When cranking the ignition advance angle is fixed at in synchronization with the crank angle signal 2 DURING NORMAL OPERATION Basic ignition advance angle Map values that have been preset for all cylinder stroke intake air volumes engine load and engine Speeds Engine coolant temperature correction The engine coolant temperature sensor detects the engine coolant temperature and when it is low the ignition timing is advanced to improve driveability Barometric pressure correction The barometric pressure sensor detects the barometric pressure and determines the altitude When the pressure is low i e when the vehicle is at a high altitude the ignition timing is advanced to secure maximum driveability intake air temperature correction The intake air temperature sensor detects the intake air temperature and when it is low the ignition timing is delayed to prevent knocking in cold weather When it is high the timing is also delayed to prevent of knocking 3 DURING ADJUSTMENT OF IGNITION TIMING When the terminal for ignition timing and idle speed adjustment is shorted to ground the ignition timing is set at 5 BTDC in synchronization with the crank angle signal If the ignition timing does not agree with the reference ignition timing of 5 BTDC turn the crank angle sensor to adjust the timing so that the crank angle signal agrees with the ref
216. its pressure regulated by the valve body the oil passages drilled in the cylinder head And pressure regulator and is supplied to each la adjuster ENGINE Base Engine 9 17 CAMSHAR Stamped identification mark Exhaust camshaft No 2 cams No 3 cam No 4 cams Intake camshaft E Sprocket side Hexagon Crank angle sensor NOTE driving slit J Journal 6ENO112 1 Each camshaft is supported by the six bearings 2 A hexagon between the No 1 and No 2 cams is provided for holding the camshaft with a wrench when loosening or tightening the camshaft sprocket bolt TIMING BELT TRAIN Exhaust side Intake tide o of te sprocket o of teeth 48 Camshaft sprocket No of teeth 48 6ENO139 Timing belt 6ENO140 idler pulley Auto tensioner Oil pump sprocket No of teeth 18 Crankshatt sprocket No of teeth 241 9 18 ENGINE Base Engine 1 The intake camshaft exhaust camshaft and the tensioner absorbs these changes in belt tens n oil pump are driven by a single timing belt not only to prevent the noise problem 2 Timing belt tension varies at different engine getting worse but to improve durability well temperatures and ages of the belt The auto AUTO TENSIONER Engine support bracket Tensioner pulley Tensioner arm Auto tensioner 6ENOTI i LZ Diaphragm y Hi U
217. l pressure um R Reducing pressure PCSV control pressure 1750250 i y B TPR P ES ANN E 3 TORIA Eu G E 2 E E H 4 B b 4 amp gt 3 B mS SSS N 3 a See ASS SES AS www HAT 21 94 AUTOMATIC TRANSAXLE Transaxle Control SELECTOR LEVER IN L Torque converter Kickdown servo Front Rear Low reverse End clutch clutch brake clutch 066 n 12 n Ex Transaxie control unit 7 1 20 20 22222 5 rp 3 OFF fp B Rear clutch B E exhaust valve Bee gt lt V B E Damper clutch H C control J solenoid valve e M e il End clutch 4 Reducing valve S valve Torque converter P control valve E 5 l ia arn Ex c N D control TAA IED DD a valve Regulator valve P Pressure 4 control valve H Line relief valve Line Pressure Pump suction pressure ER Torque converter pressure Line Pressure DCCSV control pressure and lubrication oil pressure control pressure mus Reducing pressure EE PCSV control pressure 00 Pena 1750251 63 AUTOMATIC TRANSAXLE Transaxle Control 21 95 SELECTOR LEVER IN R Torque converter Kickdown servo Front Rear Low reverse S
218. l unit for ignition timing control One feature is that the engine control unit provides ignition power distribution control which is neces sary because this engine is without a distributor as has been described earlier By activating two power transistors alternately the primary current of two ignition coils one for the No 1 and No 4 cylinders and one for the No 2 and No 3 oylinders is turned on and off thus causing the cylinders to fire in the order of 1 3 4 2 is determined by making preset corrections which has been for engine coolant temperature intake air temperature and other conditions of the ignition advance angle that has been preset according to the engine operating conditions For vehicles with tur bocharger have a knocking control that corrects tl ignition advance angle according to the presence or absence of knocking The engine control unit also controls the primary current energization time in order to secure stable ignition energy _These controls are explained in detail below T eon airs CHR TA iit qo HANS Pre La oer ipd ree eig Vict Les Ir spaa EAE er tees cr n fe ES 2 p WO uem yere tre TON ts ELECTRICAL Engine Electrical 8 29 Ignition Power Distribution Contro op dead center signal Crank le signal No 1 cylinder No 3 cylinder No 4 cylinder No 2 cylinde 75 BTDC T pulse Spark Intake stroke
219. lained as an example The state of the hydraulic line in the 1St gear condition is as mentioned on the previous page f the transaxle control unit gives order that an upshift from the 1st to the 2nd gear be initiated and the duty of the pressure control solenoid valve iS usted accordingly the No 23b line Pressure 1S Jught higher than it is 1st gear Then the pressure control valve moves to the right opening the No 5 port Through the No 5 port thus opened the line pressure from the No 10 port is directed to the kickdown servo via the 1 2 shift valve When the line pressure is applied between the 2 lands of the pressure control valve the pressure effectively acts on an area equivalent to the differ ence in area between these two lands and pushes the valve to the left the No 5 port is closed by the 2 land When the No 5 port is closed the No 10 port pressure decreases and as a result the valve moves to the right opening the No 5 port Through the No 5 port thus opened line pressure is intro duced By this sequence the pressure directed to the kickdown servo through the No 10 port is controlled The No 10 pressure is controlled by the duty of the pressure control solenoid valve That is if the duty is increased the No 23b line pressure which pushes the pressure control valve to the right decreases and this causes a reduced No 10 port pressure When the 1st to 2nd upshift is completed the press
220. led feedback control the air fuel mixture is maintained at the stoichiometric ratio Under the following specific conditions this feed back control is not performed in order to improve driveability 1 While cranking the engine 2 During engine warm up when engine coolant temperature is less than 45 113 F 3 During acceleration deceleration 4 During high load operation When oxygen sensor is not functioning OPEN LOOP CONTROL The amount of fuel injected is controlled according to the map value preset for each engine speed and A N refer to P 14 39 FOR YOUR INFORMATION Map value Value preset and stored in the ROM of the engine control unit 27 ENRICHMENT Engine speed rpm Amount of fuel injected 80 176 Coolant temperature C F 2 Amount of fuel injected 25 77 Intake air temperature C F 462404 When the throttle valve is wide open control is performed to increase the amount of fuel injected in order to secure good driveability under high load conditions FUEL INJECTION CONTROL DURING ENGINE WARM UP To secure good driveability when the engine is still cold control is performed to increase the amount of fuel injected when the engine coolant temperature is low FUEL INJECTION CONTROL ACCORDING TO INTAKE AIR TEMPERATURE Given a constant intake air volume the change in intake air temperature alters the intake air density resulting in an improper air fuel
221. left The leftward movement of the valve opens the No 2 port and through this port the fluid returns to the suction side of the pump As a result the line pressure drops If the line pressure drops the chamber B pressure also drops and the valve is shifted back toward the right by the spring force thus closing the No 2 port Repetition of the above mentioned cycle regulates the torque converter pressure and maintains it at a constant level AUTOMATIC TRANSAXLE Transaxle Control 21 59 DAMPER CLUTCH CONTROL VALVE AND DAMPER CLUTCH CONTROL SOLENOID VALVE Damper Clutch Control Valve The damper clutch control valve is installed within the lower valve body it functions to regulate the hydraulic pressure acting upon the damper clutch incorporated within the torque converter Damper Clutch Control Solenoid Valve The damper clutch control solenoid valve is duty controlled by the signals from the transaxle control unit this valve functions to convert electric signals to hydraulic pressure Operation 1 Because reducing pressure is applied to the 23rd line and line 23a when the damper clutch is released the sum of the hydraulic pressure acting on the 1 land plus the spring force overcomes the hydraulic pressure applied to the 5 land and 6 land surface areas thus causing the valve to be moved toward the right When this happens the hydraulic pressure from the torque converter control valve enters from the
222. lenoid valve Ali temperature rd sensor RT GEMOZ61 TE Catalytic converter GY EMISSION CONTROL SYSTEMS Exhaust Gas Recirculation EGR System FXHAUST GAS RECIRCULATION GR SYSTEM EGR system is designed to reduce oxides of nitrogen in exhaust emissions In this system the exhaust gas is partially recirculated from the ex haust manifold into the intake manifold while EGR flow is controlled by the EGR control valve OPERATION Federal The amount of EGR flow is reaulated bv the throttle E port vacuum Because the E port 25 5 R25CAAB vacuum is low during engine idling or during wide open throttle operation the EGR control valve is closed by the force of the spring with the result that there is no flow of EGR gas If the temperature of the engine coolant is below 65 149 F the thermo valve opens and the port vacuum is leaked to the throttle body A port with the result that the EGR valve does not function EGR control valve Thermo valve NOTE This figure shows Non Turbo 6EMO138 2b 6 OPERATION California The engine control unit functions to calculate the engine load based upon the intake air volume signals from the air flow sensor and the rpm signals from the crank angle sensor and the EGR control solenoid valve is activated according to the engine load The EGR amount is then regulated according
223. les All this pinion carrier selector drive shaft and selector results in the cruise control being canceled Worm gear Clutch plate APA Limit switch Wormiwheel Planetary pinion Selector drive shaft 07R0104 IF CANCEL SWITCH IS SWITCHED ON Battery Ignition switch Inhibitor switch NC Normaliy closed position ON NO Normally opened magnetic clutch coil Stop light V switch NO Auto cruise Cancel interface circuit 3 3 control unit T magnetic clutch drive 2 00 Microcomputer transistor light 07A0012 14 74 When Canceled by the Stop Light Switch broad solid line arrows The stop light switch is a four pole type that integrates the switch for the stop light NO with that for the auto cruise control NC When the brake pedal is depressed the contacts for the auto cruise control NC open cutting off the circuit to energize the electromagnetic clutch coil At the same time the contacts for the stop light NO close to allow a cancel signal to be input from the 12 V power supply of the control unit to the cancel circuit and to the microcomputer As a result the transistor which energizes the actuator electro magnetic clutch coil turns OFF and the electro magnetic clutch coil grounding circuit is cut off thus canceling the auto cruise control mode When Canceled by the Clutch Switch thin solid line arrows When the clut
224. ling fin ae W 4 Val 9 VA 7 y Companion flange Gear carrier RO3EAAA For better serviceability spacers for adjustment of final drive gear backlash have been inserted be tween the side bearing outer race and gear carrier A speed difference responsive type viscous cou pling type limited slip differential which provides outstanding performance during operation on a Drive pinion Differential case Drive ge r 1140017 VISCOUS COUPLING TYPE LIMITED SLIP DIFFERENTIAL While the conventional mechanical type limited slip differential uses a cam differential pinion shaft and disc equipment composed of a friction plate disc and spring seat in limiting the differential the Front wheel Center differential viscous coupling Front differential ROSEBAA viscous coupling type limited slip differential limits the differential by use of a viscous coupling equip ment consisting of outer and inner plates and silicone oil Rear wheel Limited slip differential assembly Differential Differential limiting section viscous coupling 11 P0066 3 6 REAR AXLE Viscous Coupling Type Limited Slip Differential Differential case B Gear carrier Pinion mate gear Drive pinion front bearing Bearing cap Companion flange Normal operating range Hump region t I I 1 1 Mechanical type limited slip differential at high load 1 Mechanical type limited slip dif
225. lision to the front pillar e Supply as assembly Dash panel 15243 44 e Supply as individual parts 2 3 4 1 Dash panel 2 Front floor side sill inner front 3 Dash panel extension 4 Dash panel crossmember 31A0240 Rear End Panel The rear fascia upper bracket is supplied as an individual part in order to cope with a minor collision e Supply as assembly Rear end panel 142 e Supply as individual parts 2 1 Rear end panel 2 Rear fascia bracket upper 31A0241 Front Door For the door the outer panel is Supplied as an individual part for efficient part replacement _ e Supply as assembly Front door panel 142 e Supply as individual parts 1 Front door panel outer 2 Front door panel inner 23 18 BODY Body Color Code Body Color Code Interpretation Solid BODY COLOR CODE The body color code is imprinted on the vehicle information code plate which is mounted on the front deck BODY COLOR CODE INTERPRETATION The information contained in the body color code is explained in the body color parts 0040163 Body color code BODY COLOR Check the vehicle s body color code and then use this body color chart to determine the refinishing paint supplier from which the color can be purchased M Metallic paint P Pearl tone paint Engine compartment and lug Body color gage compartment color code Body color Color number Body color name Co
226. lor number Color name em po ke SOLID Solid on this vehicle has one more layer of a clear coat on the top coating to increase depth and luster is As for coating operation this solid is applied by the same procedure as metallic coat Paint used by manufacturer Common solid Solid on this vehicle Exe Pre treatment Electrodeposition coating eet ae meine j73 BODY Doors S RZXCAAA The doors are front hinged sash doors opening rigidity of the outer panels and the rigidity of the towards the rear with the following features beltline openings have been improved The sash is flush with the body and has had its e A two step door check has been adopted to hold height difference with the glass surface mini the door securely at the midway position mized to reduce wind noise e The window regulator is of a compact By effectively employing reinforcements the light weight wire winding type Door Door beltline inner reinforcement Door beltline outer reinforcement 18A0464 Door lower hinge neinforcement Door latch reinforcert ent Door side impact bar 1840463 Door inside handie Door upper hinge Door outside handie Door check Door latch 1840462 Door lower hinge 23 20 BODY Central Door Locks CENTRAL DOOR LOCKS SOME MODELS m The central door lock system by wh
227. lt manual lap belt knee protector and other components The driving device assembly is composed of the slide anchor the release switch the guide rail the fasten switch the automatic seat belt motor relay and the driving device There is an emergency release button on the slide anchor this button can be used to release the shoulder belt in the event of an emergency resulting from an accident etc A Release switch QE gt Emergency release button Shoulder belt Lap belt Tongue plate Buckle Retractor Retractor ELR ELR 1940331 23 32 Lever spring Stopper Rod Sub Rod B 19P037 19P0375 BODY Seat Belts OPERATION OF AUTOMATIC SEAT BELTS The operation of the Automatic Seat Belts is as follows 1 The belts fasten itself around the occupant when the front door is closed with the ignition switch in the ON position 2 The belts release itself from the occupant when the front door is opened with the ignition switch in the ON or LOCK or position 3 The belts cease to fasten itself around the occupant if the ignition switch is turned to LOCK or or when the front door is opened during the belt motion 4 The belts for the drivers and front passengers seats operate independently of each other CONSTRUCTION AND OPERATION OF THE ELR ALR SWITCHOVER MECHANISM The ELR ALR switchover mechanism is installed at
228. lt forward and inward so that the belts can be tight enough around the body 23 34 CONSTRUCTION OF DRIVING DEVICE Drum B Torque shaft BODY Seat Belts Gear B gm eo 0 H A V j e Drum spring Tape housing Drum A Lock plate Gear A Housing cover 1900288 Gear housing The component is an assembly supply item and so is not to be disassembled Its construction is however as described below Drum A the lock plate and gear A are installed to the motor shaft The lock plate and gear A rotate the same as the motor shaft The drum spring is attached to drum A In addition the end of the slide anchor s tape and the end of the drive spring are also attached to drum A and these are wound to drum A Drum B is installed to the tape housing by the torque shaft Gear B is installed to the torque shaft The gear B and gear A teeth mesh There are projections on gear B and drum B the gear B projection contacts the drum B projection only when gear B rotates in the clockwise direction and in that way the rotational force of gear Bis transmitted to drum B BODY Seat Belts OPERATION OF DRIVING DEVICE Tape Drive spring Motor shaft When the tape is wound in 23 35 When the tape is wound out Projection of drum B Projection of gear Drum B Gear 8 19P0289 Drum spring When the Tape is Wound In when the automa lic seat belt is
229. m TDC determined by the engine control unit with the 75 BTDC Signal as a reference then the primary current shut off signal 15 Sent to the power transistor when T time has elapsed from the count start position 75 BTOC tx 75 8 where e is the ignition advance angle calculated by the engine contro unit mai 8 30 Ignition Advance Angle Control While cranking ELECTRICAL Engine Electrical Fixed angle 5 Engine coolant temperature 1722 2 gt During normal operation Advance angle map value according to engine speed and intake air volume temperature correction During ignition timing adjustment Fixed angle 5 BTDC Barometric pressure sensor Barometric pressure correction ntake air temperature sensor Power transistor To ignition Intake air dol temperature 4 correction 6ELOO068 The engine control unit has the ignition advance angle value for all cylinder stroke intake air volumes engine load and engine speeds stored in its memory this is called the basic ignition advance angle The control unit makes corrections in this value according to the engine operating conditions such as the engine coolant temperature barometric pressure altitude and intake air temperature to obtain optimum advance angle for current engine conditions At the engine start and during ignition timing adjustment however
230. mber Front upper frame uu Inner inner Front sidemember Rear roof rail inner outer E 32A0108 32A0089 Roof panel Front roof rail Rear pillar outer Quarter panel inner upper 67 ES SSSR a BODY Main Bodv Rear end panel outer Rear fascia bracket upper E Tailgate lock bracket Rear floor pan Rear end panel inner s m Roof panel Roof drip channel Side roof rail inner Side roof rail outer Center pillar outer 23 11 Front pillar Front floor side sill inner upper A inner Front floor pan 3340171 Front pillar outer upper 3340172 Front floor side sill Front pillar outer inner upper B 12 Quarter panel inner upper Quarter panel inner upper Shelf corner bracket Quarter panel outer Seat striker reinforcement Spring house reinforcement Rear wheelhouse Quarter panel inner inner lower 3140196 Beltline reinforcement 23 12 BODY Main Bodv d MAIN BODY Major changes due to adaption of 4WD as follows Rear floor sidemember front end changed Rear floor pan changed in shape lt 2WD gt lt 2WD gt Propeller shaft bracket added Rear end crossmember added 2300306 70 a BODY Main Body 23 13 FRONT BODY FRONT DECK 1 A crash bead is provided in the inner cowl top panel that absorbs energy during collision It prevents the st
231. mber fluid flows through sleeve b port b port d and chamber A and is returned to the oil reservoir pump Oil reservoir Oil 13L0076 Chamber A Oylinder tube right chamber 13L0093 19 10 Cam 3 Vane Flow control valve O ring 13A0067 Intake side Discharge side 13719 POWER STEERING Oil Pump OIL PUMP The oil pump has a separate oil reservoir it is a vane type pump that generates hydraulic pressure by the rotor vanes and cam ring This oil pump incorporates a flow control valve in order to reduce the power assist effect during high speed driving and thereby improve steering stability and a relief valve in order to maintain the hydraulic pressure and steering linkage rela tionship NOTE The relief valve is incorporated within the flow control valve RIBLAAA OPERATION OF THE OIL PUMP The rotation of the rotor causes the ten vanes to move radially by centrifugal force and when there is rotation along the cam curved surface of the circular cam ring there is action in the radial direction along the cam curved surface The fluid chamber is formed by the cam ring rotor and vanes when the rotor rotates the inner surface of the cam ring circular the fluid chamber pressure changes to negative pressure with the result that the fluid within the oil reservoir which is at atmospheric pressure is drawn in suction step after which the rotor rota
232. mfort Torsional motion during left cornering SS 2 3 12 0020 lt Torsional force application Torsion counteractive force 17 6 SUSPENSION BUSHINGS In order to improve both the driving stability and riding comfort even further and to reduce vibration and noise the optimum spring characteristic has been employed for each suspension bushing The front end of the trailing arm is elastically coupled to the body via a rubber bushing of high spring capacity This rubber bushing has an asym metrical non linear characteristic in the front rear direction and therefore functions to reduce the Lateral rod bushing Axle b Rubber bushing Cam Torsional bar 128001 REAR SUSPENSION lt 2WD gt Three link Suspension transmission of tire vibration input to the body itserf Individual independent bushings with non linear characteristics are also employed at the couplings to the body of the shock absorbers and the coil springs these together with the use of spring pads with large channels serve to reduce the transmis sion of vibrations to the body thereby improving even further the driving stability and riding comfort Bushina A Channel Spring pad 1240069 1240045 WE CL Bushing al aaa is SS k 5 1240115 Hollow Section A A 14A0402 c ete it Pn Dl ere enia ict PMI mpi at FEET ffoi sii
233. mount of intake air when there is a signals are sent to the air flow sensor change from high speed high load driving to deceleration TURBO METER CONTROL lt Turbo gt RIAQAAA Engine control unit Turbo meter Control relay Air flow sensor AFS Crank angle sensor 6 00566 The turbo meter is a current type meter The engine Then the unit determines the duty ratio according control unit receives the intake air volume signal to the load and drives the turbo meter from the air flow sensor and the rpm signal from the Intake air volume crank angle sensor and calculates the engine load Duty ratio Load DUI TaUO The duty ratio is defined as ON time ratio T T of 33 3 Hz pulse When the duty ratio increases average current that flows to the turbo meter also increases so that the turbo meter indicates higher value When the duty ratio is decreased the turbo meter indicates smaller value 30 msec 30 msec 14 58 FUEL SYSTEM Accelerator Components ACCELERATOR COMPONENTS The accelerator is the cable type and the pedal is generated the suspended type A nylon bushing is installed on the end of the accelerator cable preventing contact noise be tween the cable and accelerator arm from being In addition the accelerator pedal switch which is used as a control sensor on models with the 4 speed A T is equipped at the pedal support member CONSTRUCTION DIAGRAM N
234. mp suction pressure Damper clutch pressure Torque converter pressure BN Line Pressure DCCSV control pressure and lubrication oil pressure control pressure Reducing pressure Bs PCSV contro pressure 1750224 21 88 AUTOMATIC TRANSAXLE Transaxle Control SELECTOR LEVER IN 4 20 2 3 4 3_ 1 shit fea qpe as n u valve i Rear clutch 4 a exhaust valve H eee Damper clutch control solenoid valve Torque converter a i control valve em Y i i b E is Regulator valve valve Bz Line Pressure Pump suction pressure Torque converter Kickdown servo Front Rear Low reverse End clutch clutch brake clutch N ooo Transaxie control unit e End clutch valve on Reducing valve Pressure control valve eo Line relief valve Torque converter pressure ng Line Pressure DCCSV contro pressure and lubrication oil pressure controi pressure Reducing pressure PCSV control pressure 60 AUTOMATIC TRANSAXLE Transaxle Control 21 89 LECTOR LEVER IN D Stopping Torque converter i Kick Rear Kowraverse End ickdown servo clutch clutch brake clutch mn CAD Ni 22 1 xA ox er m UTE n OFF B Rear clutch SN exhaust valve gt Ex Damper clutch control sole
235. ned status Warning Alarm when the Drivers Shoulder Belt is not Fastened When with the driver s door closed the ignition switch ON anc the slide anchor at the fasten position the fasten switch is OFF the shoulder belt is not fastened the outer switch is switched OFF the buzzer will sound continuously for approx imately 6 seconds and at the same time the warning light will flash for approximately 68 seconds If however the shoulder belt is fastened the outer switch is switched ON during that period the warning light and buzzer will be switched OFF Warning Alarm when the Front Seat Passenger s Shoulder Belt is not Fastened When with the front seat passenger s shoulder belt unfas tened the outer switch is switched OFF the ignition switch 18 turned from the LOCK or ACC position to the ON position the warning light will illuminate steadily for approx imately 68 seconds If however the shoulder belt is fastened the outer switch is switched ON during that period the warning light will be switched OFF et 2 u tede ntn a H E 2 x f x amp x Approx 0 7 apes 7 nd SD HRS LOCK or ACC ver ON AU l m or sec Ignition ON Switch LOCK or ACC Key teminder 04 ei teh A OFF Driver s side ON door latch switch
236. ng resistance in the axial direction than a spline type slip joint It has smaller rotational variations and hence is more suitable for high speed operation than other constant velocity joints due to smaller ball play achieved by crossing the ball grooves of the inner and outer races 10A0002 4 i i 16 4 Outer race Inner race inclined ball Ball groove 10 001 Outer race inner race Ball Inner race ball groove Outer race ball groove CENTER BEARING The No 1 and No 2 center bearings are of the dual anti vibration support type that minimizes vibration and noise The first mount in the center bearing S E X Center bearing Sana Longitudinal motion PROPELLER SHAFT Lobro Joint Center Bearing L BRO JOINT This joint consists of the inner and outer races each axially inclined grooves balls and a cage to hold the balls When longitudinal or angular change takes place the balls move the inner and outer race grooves to absorb the change ASSEMBLY Angular change 10 0043 R16DAAA reduces propeller shaft vibration transmission to floor The second mount at the bearing to connection reduces the noise level Section A A NS A Ni F 10 0001 2nd mount 10U0003 0 17 1 CONTENTS REAR SUSPENSION 2WD 2 REAR SUSPENSION lt 4WD gt 8 A
237. nion has walked 9 The reduction ratio of 2nd gear is achieved in this way 21 35 1750059 21 36 AUTOMATIC TRANSAXLE Transaxle Mechanism 3RD GEAR Forward sun gear Carrier End clutch 22 IIIA a tt A ARS ER A Front clutch Rear clutch Annulus gear Reverse sun gear Operating elements eFront clutch eRear ciutch eEnd clutch When the shift is in 3rd gear in the D range the rear clutch and the front clutch are actuated and other elements are all released Therefore driving force is transmitted from the forward sun gear and the reverse sun gear Since the short and long pinions rotate in the same direction they are placed under a locked condition causing the planetary gear set to rotate as one unit 1750060 This means that the engine rotation is directly connected setting the ratio between the input to and output from the planetary gear set to 1 1 The reduction ratio of 3rd gear is achieved in this way Note that the end clutch is aotuated to provide for smooth shift change to 4th gear AUTOMATIC TRANSAXLE Transaxle Mechanism 21 37 EAR Overdrive Kickdown brake Long pinion Carrier End clutch Annulus gear Reverse sun gear Operating elements eEnd clutch eKickdown brake 1750061 When the shift is in 4th gear the end clutch and the kickdown brake are actuated and driving force is
238. noid valve orque converter ontro valve Shift control solenoid valve B PER N D control Regulator valve valve p 4 Shift control valve B Pressure control valve E Pressure control B solenoid E valve E Oil t Line relief as Ri filter valve 1 7 x D Trensaxie control unit emmy Line Pressure Pump suction pressure fac Damper clutch pressure EES Torque converter pressure 54 4 Line Pressure DCCSV ecol ntrol and lubrication oil pressure control pressure control pressure EE Reducing pressure PCSV contro pressure 1750246 21 90 AUTOMATIC TRANSAXLE Transaxle Control SELECTOR LEVER IN D 1st Gear Torque converter Kickdown serv Front Rear Low reverse End clutch clutch brake clutch X Damper clutch contro valve i Damper clutch control solenoid valve End clutch valve orque converter ontrol valve PAD Shift control solenoid valve B Regulator valve B Pressure w valve d Pressure 811 control 3 Ex solenoid 9 E valve Line relief gt HIE valve NT TTA Ex Ex U Oil pan contro Transaxle control unt Line Pressure Pump suction pressure RENS Damper clutch pressure EE Torque conver
239. nt of fuel that achieves the stoichiometric air fuel ratio 15 times as much air by weight as gasoline by weight with regard to the amount of air admitted during one cycle in each cylinder is called the basic injector activation duration The amount of air admitted to each cylinder during one cycle is calculated by the engine control unit based on the signals provided by the air flow sensor and crank angle sensor FOR YOUR INFORMATION Calculation of the Amount of Intake Air into Each Oylinder during One Cycle The amount of intake air used by the four cylinders in one cycle in a four cylinder engine can be calculated by counting the number of pulses output from the air flow sensor during the period of time in which the crankshaft rotates two complete revolutions i e during which four complete pulses are output from the crank angle sensor The amount of intake air used by each cylinder in one cycle can therefore be calculated by counting the number of air flow sensor output pulses during the time in which the crank angle sensor outputs one pulse The amount of intake air into each cylinder per cycle is denoted Engine one revolution by the symbol A N which varies in proportion to the intake EM manifold vacuum absolute pressure Calculation of the Engine Speed The engine speed can be calculated by measuring the one pulse frequency of the crank angle sensor signal 60 sec 30 Nrpm c P 2xT se
240. ntegral soft fascia is installed both for the front and rear bumpers which prevents perma nent deformation in light collision The bumpers feature the highly rigid bumper rein 1840420 Front bumper Section A A Front turn signal light Body frame Front bumper fascia Front bumper absorber Front bumper reinforcement 18A0418 Section B B Rear combination light BODY Power Windows Bumpers After the glass is fully open 1 After the delay time 0 7 second has elapsvu the voltage comparison voltage at the negative side of IC becomes higher than the refer ence voltage at the positive side with the result that the output voltage of becomes low and the transistor Tr is switched OFF 2 As a result of the transistor Tr being switched OFF current stops flowing to the coil L and thus there is no longer the force to hold the plunger 3 As a result the switch is returned to the neutral status by the return spring and the motor operation stops R23JAAB forcement shock absorber and highly rigid b frame all of which contributes to the reduc protrusion yet ensuring 5 mph bumper perform ance for the enhanced safety 1840406 Rear bumper bumper ascia Rear end inner panel j Rear bumper Rear bumper 2 reinforcement absorber 1840419 7 BODY Sunroof 23 25 SUNROOF lt OPTION gt ihe sunroof is fitted with a roof li
241. o 2port Through this cyclical operation of the regulator valve the line pressure is maintained at a constant level The line relief valve provided in the No 1 tine opens if the line pressure becomes so high that the regulator valve cannot deal with it In this way the hydraulic circuit is protected Selector Lever in R When the manual valve is shifted to the range position the No 4 port that was open is closed The No 9 port is opened instead This allows the line pressure to be directed to the 4 land of the regualtor valve As this pressure works on the area equivalent to the difference between the diameter D4 of the 4 land and the diameter D5 of the 5 land the force pushing the regulator valve toward the left is relatively weak as compared with the force the same level of pressure would generate when applied to the other portion of the valve Therefore a pressure higher than that of previously described forward drive ranges is required to open the No 2 port The higher pressure thus created serves to move the elements in the reverse range The operation of the regulator valve driven by the higher pressure is the same as that of the aforementioned forward drive ranges Selector Lever in P When the manual valve is shifted to the P range position the manual valve exhaust port communicates with the line press ure port and the line pressure is relieved In this situation no pressure is directed to the No 4 and
242. o be manually selected by the driver This transaxle is provided with 6 positions P R N D 2 L The following contains the explanations of the function of each position selected P Parking 1 Each element does not operate at all Therefore the engine output is not transmitted to the output shaft 2 The output shaft is completely locked by mecha nical means Therefore the vehicle does not move in forward or reverse direction 3 The engine can be started R Reverse 1 The vehicle moves in reverse direction 2 The engine cannot be started N Neutral 1 The engine output is not transmitted to the output shaft as in the case of P 2 The engine can be started D Drive 1 Corresponding with the degree that the accelerator pedal is pressed down i e throttle opening and vehicle speed D automatically shifts between forward 4 speeds Note howev er that the forward 3 speeds are selected when the overdrive control switch is OFF The automa tic shifting up or down is performed according to the shift pattern shown in the illustration on page 2 1 30 2 Driving off is always performed in 1st gear 3 Kickdown refers to the downshift that is per formed if the accelerator pedal is pressed down AUTOMATIC TRANSAXLE Transaxle Mechanism when the vehicle is running in 2nd 3rdor 44 gear It is performed when the load exceeds the downshift point This functionis useful when the driver is acceler
243. o support the upper part of the engine and the upper part of the transaxle thereby effectively suppressing engine vibrations Note that there are the following features at the various installation parts CONSTRUCTION DIAGRAM 01 629 Transaxle mount Front roll stopper Front side Front roll stopper Centermember Cross member ROSEAAA The transmission of engine vibration to the body is reduced by the installation via bushings of the centermember to the The insulators each have a cavity that serves to effectively absorb vibrations Cy itll Enaine mount 0140022 Al ag 722 2 2 0180766 1 9 22 Principal axis of inertia The 7 indicates mount positions 01R0770 Absorption action during minute vibrations PPP 2 77 JILL IRENI 8 22 Cavity Insulator A Cavity insulator B 0180267 Absorption during large vibrations or rolling Insulator insulator B 01R0267 ENGINE Mounts PRINCIPAL AXIS INERTIA SUPPORT SYSTEM The vibrations generated from the engine and drive train consist of such elements as vertical vibrations caused by the engine s combustion processes as well as rollings caused by the torque reaction force of the tyres and the crankshaft rotation etc In order to effectively suppress these vibrations the principal
244. o the air cleaner Senses the barometric pressure altitude with a semiconductor diffusion type pressure sensor BAROMETRIC PRESSURE SENSOR SENSOR TEMPERATURE Senses the engine coolant temperature with a thermistor THROTTLE POSITION SENSOR Senses the throttle vaive opening with potentiometer Senses whether or not the accelerator pedal is being operated with a contact switch IDLE POSITION SWITCH TOP DEAD CENTER SENSOR Senses the top dead center on compression stroke of 1 and No 4 cylinders with an LED and photo diode pair 2 CRANK ANGLE SENSOR Senses the crank angle of each cylinder with an LED and photo diode pair OXYGEN SENSOR Senses the oxygen concentration in the exhaust gas with girconia and platinum electrodes VEHICLE SPEED SENSOR Senses the vehicle speed with a reed switch AIR CONDITIONER SWITCH Senses activation of the air conditioner compressor pP POWER STEERING OIL Senses the power steering load with a contact switch PRESSURE SWITCH ENGINE CONTROL UNIT Senses ON OFF position of the ignition switch IGNITION SWITCH Senses engine cranking IGNITION TIMING When this terminal is shorted the ignition timing and idle ADJUSTMENT TERMINAL speed coniro servo is set in the adjusting mode by the engine control unit INHIBITOR SWITCH s the P and N positions of the select lever for the automatic transaxle DETONATION
245. o the control unit The vehicle speed sensor is installed within the speedometer The vehicle speed sensor is the reed switch type it generates Aufoscruisa four pulse signals for each rotation of the output gear This control unit sensor is also used in common for other electronic control systems Vehicle speed detection circuit Vehicle speed sensor 14 76 FUEL SYSTEM Auto cruise Control System Ignition switch IG Auto cruise control switch M oldi Actuator electro magnetic clutch Stop light ON switch NC oes 1 t M A IN OM I 1 Constant voltage circuit Control unit d power supply 12V m terminal voltage 0 0340264 NC Normally closed 0740040 AUTO CRUISE CONTROL SWITCH MAIN switch The auto cruise control switch is built into the steering column switch MAIN SWITCH The MAIN switch is an automatic reset type switch to turn ON and OFF the power supply of the control unit COMMAND INPUT SWITCHES SET and RESUME RESUME switch indicator The SET and RESUME switches function to input the control signals of the auto cruise control system both are the automatic reset type These switches are ON while pressed and OFF when released For the ECU s input interface each of the input terminals is pulled up by the battery voltage the terminal voltage is LOW level 0V when the switch is ON and is HIGH level a
246. o the gear box is reduced thus resulting in a somewhat heavier steering effort Flow control valve To oil pump 13P 0039 POWER STEERING Oil Pump WHEN OIL PUMP OPERATES AT HIGH SPEED 0 RPM OR MORE Waien the pump operation becomes high speed the plunger is pushed further toward the right than for medium speed and both variable orifices close Furthermore the flow control valve also moves and the bypass port opens wider The fluid flowing to Piunger To steering gear box Variable orifice OPERATION OF THE RELIEF VALVE When the A chamber pressure increases when the steering wheel is turned while the vehicle is stopped the B chamber pressure also increases and when the pressure exceeds the relief spring set load of 8 000 kPa 1 138 psi the relief valve port which is closed by a steel ball opens and the fluid passes through the bypass port and is returned to the pump s intake port To steering gear box From oii pump Variable orifice From oil pump Relief spring 19 13 the gear box then is supplied only from the fixed orifice with the result that the amount of discharge flow is reduced to minimum and as a result the steering effort becomes moderately heavy thus providing excellent handling stability at high speed Fixed orifice Flow control valve To oil pump Bypass port 13P0040 As a result of this action the pressure of the B chamber decreases and the r
247. ocharged engine and incorporate new Adopted 2WD vehicles are 2 0L DOHC 16 valve ine trut type front suspension technologies such as full time 4WD of center e de ph differential type with viscous coupling differential and 19islon iater type Sano limiting for excellent running stability and excellent Steering Rear suspension e Light weight and compact rack and pinion type for high steering response e Tilt steering mechanism to give optimum driving position e Self aligning double wishbone type suspen sion for comfortable ride 4WD e Torsion axle type 3 link suspension for outstanding driving stability 2WD e Negative chamber for outstanding steer ability during high speed driving Anti lift geometry for high stability during braking e Integral torsional bar type axle beam for optimum roll stiffness 2WD 0040191 00A0188 Front propeller shaft 3 piece 4 joint type e R bro joint to absorb lengthwise and angular change and prevent transmission of vibrations 4WD Front suspension The front suspension of McPherson strut type independent suspension system Brakes e Under steer geometry for outstanding steering el e Cross piping dual type proportioning valve stability that keeps balanced braking power even at failure of the hydraulic system e Four wheel disc brake system for high braking power ity at braking Offset coil springs for comfortable ride e Negativ
248. ode BODY COLOR CODE Exterior code Body color Light Gray M Red Dark Red Turquoise Blue M Dark Blue M White Black 0 12 GENERAL Vehicle Identification VEHICLE SAFETY CERTIFICATION LABEL 1 The vehicle safety certification label is attached to the face of left door pillar 2 This label indicates the month and year of manufacture Gross Vehicle Weight Rating G V W R Gross Axle Weight Rating G A W R front rear and Vehicle identification Number ENGINE MODEL STAMPING 1 The engine model number is stamped at the front side on the top edge of the cylinder block as shown in the following Engine model Engine displacement 4G63 2 0 liter 122 cu in DOHC MPI or DOHC MPI Turbo 2 The engine serial number is stamped near the engine model number and the serial number cycles as shown below Engine serial number Number cycling 0201 to 9999 0201 gt 9999 GENERAL General Data and Specifications 0 13 GENERAL DATA AND SPECIFICATIONS 00A0159 Items Vehicle dimensions Overal length Overall width Overall height Wheel base Tread 4 330 170 5 4 350 171 3 4 380 172 4 1 690 66 5 1 700 66 9 1 700 66 9 1 306 51 4 1 306 51 4 1 321 52 0 2 470 97 2 2 470 97 2 2 470 97 2 1 465 57 7 1 465 57 7 1 465 57 7 1 450 57 1 1 450 57 1 1 455 57 3 950 37 4 960 37 8 960 37 8 910 35 8 920
249. of one system 14 0454 5 4 BRAKES Service Brakes FRONT DISC BRAKE The front brake is the M R44V type featuring highly efficient heat dissipation quick recovery of braking force when wet and highly stabilized braking force Section Ff m 222 x SS 2 1440530 Wear indicator Pad Brake disc 1440531 Brake disc installation In addition disc removal and installation is made easy by the sross section gt outer disc system in which the brake disc is installed to the disc wheel by the hub nuts Disc wheel Brake disc BRAKES Service Brakes REAR DISC BRAKE he rear brake is the AD30P type featuring highly afficient heat dissipation quick recovery of braking force when wet and highly stabilized braking force lt 2WD gt Brake disc lever Brake hose 1440003 Parking brake Brake disc sable Parking brake lever 14A0122 Parking brake 5 5 The brake system incorporates an auto adjuster that automatically adjusts the clearance between the pad and brake disc when the brake pedal is depressed Section A A Piston seal Piston Piston boot ERAN Connecting link SY Ea ES cmd mE SM MET 17 Auto adjuster Return spring spindle 14A0002 Section B B Piston seal Connecting link Piston boot Piston Parking brake
250. of the adjust ment nut and the pivot screw the tab at the adjustment nut side toward the outer side Even for full stroke operation the adjustment nut condition will be as described above thus protecting the motors and improving reliability 7 _ _ BODY Instrument Panel Floor Console 23 29 NSTRUMENT PANEL ine instrument panel is of the round trim type like a cockpit with shelf styling to give a wide view in front without the sense of being boxed in The panel itself is an integral unit made of a plastics based material the surface is covered with soft padding Instrument panel Knee protector FLOOR CONSOLE The floor console has its front console and rear nsole molded integrally The rear console on the higher grade model is provided with a large size lid for the greater ease of use The floor console has the following features e The parking brake lever is offset from the vehicle centerline to increase the capacity of the rear console Side cover Coin box Large size lid assembly R23PAAB It has the following features e The surface is covered with soft padding for safety in the event of a collision e The large capacity glove box also functions as the knee protector Glove box 1940277 R23QAAB e The coin box is installed on all models e On vehicles with manual transmission a coin holder is provided in the
251. of the engine compartment Circuit Housing Rated colour capacity 1 Tail light circuit Red Fog light circuit Red 10 3 Hazard waming light circuit Red 0 4 Upper beam circuit Red 10 l 5 Air conditioner magnet Red 10 clutch circuit 6 Condenser fan motor Yellow 20 circuit NOTE Air conditioner equipped models DIAGNOSIS SYSTEM CHECK CON NECTORS ROSDAAB The connectors for diagnosis of the following systems are provided beside the junction block 1 Multi point Fuel injection System 2 Automatic Transaxle 3 Diagnosis control 4 Simulated vehicle speed 5 Ground 6 Auto cruise control 768133 5 ELECTRICAL Junction Block JUNCTION BLOCK The junction block is a feature in which wiring harness connections are centralized for simpler and more reliable wiring harness connections The junction block is provided under the instrument panel at the drivers seat side CONSTRUCTION OF JUNCTION BLOCK Front side Rear side To engine compartment wiring harness hd hha No connection To instrument panel wiring harness To body wiring harness Theft alarm Heater relay horn relay Fuse box multi purpose fuses 16A0805 16A0002 NOTE The alphabetical symbols on the connectors are associated with the internal circuit diagrams P 8 6 i4 The junction block is an integrated assembly of On the r
252. ontrol in the sense that the more the duty or the pulse duration t is the lower the hydraulic pressure becomes Figure B Duty The ratio of the power supply duration n t to Osa tede nd TET ET UG 2 The transaxle control unit decides the timing of the gear shifting period during which it per forms hydraulic pressure control for gear shift ing according to the change in the kickdown drum rotating speed that it detects The unit identifies the time just before the kickdown brake is applied and uses that as the timing for initiating control of the hydraulic pressure which is to be applied to the kickdown brake 8 When the transaxle is cold the fluid viscosity is high causing slower oil pressure response in such conditions the transaxle control unit pro vides a correction for the oil pressure by changing the control duty of the pressure control solenoid valve This control is performed when the fluid temper atures as indicated by the oil temperature sensor is lower than 60 C 140 F After the engine has been started and the vehicle is in motion the transaxle control unit continues to refine its performance for smooth est possible gear shifting Figure Hydraulic pressure Duty 95 1750067 one cycle period T 28 6 ms expressed in a percentage as obtained by the following formula Duty UT x 100 Figure A Vp and tp represent the
253. orates a one touch open window cannot be opened or closed by using the mechanism that causes the driver s door window to main switch for the front passenger seat window open completely once the switch is pressed all the Furthermore at this time none of the sub switches way even if it is released immediately can be used for opening or closing the windows Power window relay Sub switch Main switch 1540453 CIRCUIT DIAGRAM Ignition Battery switc Lock switch Main switch 1840427 One touch down open circuit Sub switch 175 BODY Power Windows 23 23 OPERATION OF THE POWER WINDOWS lt During one touch operation gt 1 When the switch is operated contacts b and c at the DOWN side are caused to connect and current flows from the battery to contact b contact c the motor contact contact resistor and to ground and as a result the motor rotates to the DOWN side 2 Current from contact b and contact flows through diode D and R then Rs and R and Re cause reference voltage to be applied to the negative side of IC and the positive side of IC The reference voltage is maintained at a certain fixed level by the ZD 3 During the time that the motor is in operation the amount of current flowing to the motor is not very much and because
254. ossmember rear Front floor pan Front floor sidemember Front floor sidemember extension Rear seat crossmember Rear seat pan Rear floor crossmember upper Lateral rod bracket Spare tire bracket Rear floor crossmember lower Jack up reinforcement Rear floor pan Trailing arm bracket Rear floor side sill Rear floor sidemember Rear end panel Rear fascia bracket upper 23 4 BODY Main Body lt 4WD gt 44 nes Eget uH EEO VEND FT bos COOnNOOBWN Front end upper bar Headlamp support panel Sidemember to crossmember brace Front end crossmember Fender support panel Front end upper bar reinforcement Front upper frame outer Front upper frame lower Front upper frame inner Front fender shield Shield plate Strut house panel Front tie down bracket outer Front tie down bracket inner Front sidemember Front sidemember rear Dash panel crossmember Dash panel extension Front floor side sill inner front Dash panel Cowl top panel inner Cowl top panel outer Steering column support bracket Front deck crossmember Front upper frame extension inner Front upper frame extension outer Upper frame extension silencer Roof side rail inner Front pillar inner upper A Front pillar inner upper B Front pillar inner lower Front pillar outer lower Front pillar outer upper Roof si
255. oward the left tightening the composed of a kickdown band drum kickdown brake band to hold the kickdown drum As a result servo switch and anchor the reverse sun gear interlocked with the kickdown When the 2nd pressure is admitted to the apply side drum is held This brake functions during 2nd gear chamber of kickdown servo cylinder the kickdown and during overdrive jo AUTOMATIC TRANSAXLE Transaxle Mechanism 21 29 To transmission control unit Kickdown servo switch 1750394 The kickdown servo switch detects the position of the kickdown piston just before the brake is applied and sends the signal to the transaxle control unit Using this signal the transaxle control unit controls the 2nd pressure both before and during application of the brake In the initial control stage or until just beiore the kickdown brake is applied a higher 2nd pressure is supplied to the kickdown servo so that the kickdown piston can move quickly for faster response to the kickdown condition that has been initiated In the second control stage or while the brake is being applied the 2nd pressure is regulated at an optimum level so that the band is tightened on the drum the proper amount for good kickdown feeling AOLDING DRUM WITH KICKDOWN BRAKE ee nm Ree ee Kickdown drum Kickdown brake Kickdown brake Kickdown drum Reverse sun gear 1750220 21 30 AUTOMATIC TRA
256. own in the illustration Under normal conditions the fuel vapor passage in the valve is opened but if roll over occurs one of the balls closes the fuel passage thus preventing fuel leaks FUEL FILLER CAP The fuel filler cap is equipped with a relief valve to prevent the escape of fuel vapor into the atmosphere NOTES NOTES 6 2 UNITED STATES gt CHRYSLER Va CORPORATION The special service tools referred to herein are required for certain service operations These special service tools or their equivalent if not obtainable through a local source are available through the following outlet 32615 Park Lane Garden City Michigan 48135 U S A TRIANGLE SPECIAL PRODUCTS GROUP SP MILLER SPECIAL TOOLS DIVISION OF THE TRIANGLE CORPORATION CANADA lt d gt CHRYSLER Wa CANADA The special service tools referred to herein are required for certain service operations These special service tools or their equivalent if not obtainable through a local source are available through the following outlet C amp D Riley Enterprises Ltd Box 243 Amherstburg Ontario N9V 224 INTERNATIONAL CHRYSLER Va INTERNATIONAL The special service tools referred to herein are required for certain service operations These special service tools or their equivalent if not obtainable through a local source are available through the following outlet 32615 Park Lane Garden City Michigan 48135 U S
257. passenger s shoulder belt is not fastened Passenger s outer switch OFF ON Ignition swtich OFF ON Other than as above DRIVER S SHOULDER BELT FASTENING OPERATION TERMINAL 8 Output signal waveforms and operation Status Status at input side Output signal Driver s shoulder belt Ignition switch ON Operates is fastened Driver s shoulder belt Not fastened Fasten switch ON ON Door latch switch close Other than as above Max 60 sec Se BODY Seat Belts 23 45 DRIVER S SHOULDER BELT RELEASING OPERATION TERMINAL No 9 Status at input side Driver s door Driver s shoulder belt Driver s shoulder belt is released A Other than as above Ignition switch Drivers shoulder belt Release switch Key Key reminder switch Driver s shoulder belt is released B Output signal waveforms and operation status Output signal L ce stops ON 00 5 60 sec Not released OFF Not released Operates Not in cylinder OFF ON Other than as above FRONT PASSENGER S SHOULDER BELT FASTENING OPERATION TERMINAL No 18 Status at input side Ignition switch Front passenger s shoulder belt Fasten switch Door latch switch close dnt passenger s oulder belt is fastened Other than as above Output signal waveforms and opera
258. passes this through a frequncy filter detecting only the knocking thus resulting in a spark retardation of the ignition timing that corresponds to the strength of the knocking Engine control unit ignition AC 415 AcE inhibitor switch Starter 6FU0507 Control relay Battery Engine control unit 6 01149 FUEL SYSTEM Sensors INHIBITOR SWITCH lt gt The inhibitor switch s ON when or P or OFF when other than N or P signals are input to the engine contro unit The engine control unit based on these signals then determines whether the transaxle is in neutral or is in a drive range and then activates the idle speed control servo so as tc regulate the idling rpm CONTROL RELAY Fuel pump drive signal This relay senses that power is supplied to the pump If power failed to be supplied to the fuel pump during e cranking or during driving the engine control unit judges that a fault has occurred and stores corresponding diagnosis code No 42 in memory and at the same time causes the engine alarm lamp Mulfunction indicator lamp to come on IGNITION COIL Engine ignition signal 1st cylinder 4th cylinder 3rd cylinder 2nd cylinder Engine control unit From ignition switch Power transistor unit 6FU0573 at ignition timing The engine control unit stores This coil senses generating state of the ignition signal
259. pled with the side gear R H and its end serration coupled with the viscous coupling hub 3 The viscous coupling must not be disassembled 3 8 REAR AXLE Viscous Coupling Type Limited Slip Differential OPERATION Drive force smaller Slipping side Rear drive shaft Road surface L H Left wheel resistance smaller 1 Drive force larger Grippina side V Rear drive shaft H R H Right wheel Road surface resistance larger gt lt Viscous coupling Viscous coupling hub se 1 11 P0071 If a difference in rotating speed occurs between the right and left wheels the viscous coupling case 1 and viscous coupling hub 3 relatively rotate with the same difference in rotating speed as the rear drive shafts As a result a differential limiting torque is generated by the shear resistance of silicone oil and helps suppress the differential slipping For example assume that the right wheel rotates at 20 rpm due to the road surface resistance whereas the left wheel rotates at 30 rpm The difference in rotating speed between the right and left wheels is 10 rpm Since the viscous coupling is provided between the right and left wheels a differential limiting torque compensating for the difference of 10 rpm in rotating speed is transmitted from the left wheel to the right one Therefore a larger drive force is transmitted to the right wheel rotating at the lower speed R
260. position the dome light stays lit for a given period of time and then dims ON before going out If the ignition switch is in the ON position the dome light does OFF not dim but goes out as soon as the door is closed Foot light ignition key Ignition ON switch OFF Door ON switch OFF Dome light The foot light and ignition key illumination light operate in exactly the same way illumination light 1 2103 seconds 2 1 12 About 6 seconds 16U0094 OPERATION Ignition switch IG Fusible link 6 Ignition key illu mination Timer circuit About 6 seconds 16A0804 When a door is opened the door switch placed in the ON state with the dome light switch in the DOOR position current flows from the battery to the dome light to the dome light switch and the foot light and ignition key illumination light to diode D to the door switch to the ground and the dome light lights When the ignition switch is in the OFF position L signal is input to the NOT circuit and inverted H signal input to the AND circuit When the door is closed at this time door switch OFF the circuit A le ml so the AND circuit outputs H signal to operate the timer circuit The timer circuit outputs to the base of Tr the signal which gradually varies in about six seconds So the voltage applied to the light 7 gradually reduced to cause the light to dim When the ignition switch is in the ON
261. ption of gold plated connector terminals e Use of an auto tensioner achieves maintenance free automatic adjustment of timing belt tension e Use of the auto lash adjusters achieves maintenance free automatic adjustment of valve clearance The 2 coil ignition system without a distributor supplies sufficient ignition energy even during high speed operation 0 6 Fuel injection The electronic control multipoint fuel injection maintains optimum injection timing Valve mechanism e The roller rocker arms de crease losses due to friction in the valve system e The auto lash adjusters elimin ate the need to adjust the valve clearance Combustion chamber The combustion chamber is pro vided with a squish area for high combustion efficiency GENERAL Technical Features Intake manifold The large diameter intake port provides high intake efficiency Ignition system The 2 coil ignition system without a distributor supplies sufficient ignition energy even in the high Speed operation Activation of valve system The timing belt has excellent dura bility achieving a low noise level while driving Crankshaft pulley The pulley provided with a torsion al damper reduces the transmis sion of vibrations 6ENO376 Auto tensioner The auto tensioner eliminates the need to adjust the timing belt tension Crankshaft The low noise low vibration crankshaft has five ma
262. r T generates more pulses and when less air is drawn it generates less pulses The air flow sensor measures the intake air flow based on this principle Pulses generated by modulator 6FU042 When less air is drawn T T Pulses generated by modulator INTAKE AIR TEMPERATURE SENSOR Non Turbo Intake air Engine control unit temperature sensor Air bypass pipes Intake air temperature sensor 6FU0494 lt Turbo gt Intake air Air bypass pipes 5 temperature sensor S 14 gt gt E 5 e 3 E 3 20 4 0 32 20 68 intake air temperature Intake air temperature C 162458 1621008 554 intake air temperature sensor mounted at the Based on the sensor output voltage the engine AStrated location on the air flow sensor is a control unit determines the intake air temperature thermistor which is a kind of resistor whose and corrects the amount of fuel to be injected resistance changes as a function of the intake air accordingly temperature Curves indicating the sensor characteristics are shown above 14 18 BAROMETRIC PRESSURE SENSOR Barometric pressure sensor 537 A barometric pressure sensor is alos mounted on the aif flow sensor It senses the barometric pressure and converts it to electrical voltage which is sent as a signal to the engine control unit Using this signal the engine control unit calculates the altitude of the lo
263. r clutch controt vatve Manual vatve Danvper clutch control solenoid valve Pressure control solenoid vaive Shift contro solenoid valve i Transaxle Control Unit L TCU Diagnosis ERR Electronic control connector t HS E P gt E 6 8 5 t E 2 1521 i ae 1750346 E The transaxle control system is composed of detected and based upon the preset damper clutch amp various type of sensors the transaxle control unit engaging range shift pattern and hydraulic pattern and the hydraulic control device and it functions for the damper clutch control solenoid valve the shift 1 damper clutch control 2 shift pattern control control solenoid valve and the pressure control and 3 hydraulic control during shifting solenoid valve are driven which assures that a good In other words data signals received from the feeling during shifting is maintained various sensors enable the driving conditions to be EMI D i 21 42 ELECTRONIC CONTROL DEVICE DAMPER CLUTCH CONTROL The damper clutch is engaged or disengaged according to the map stored in the transaxle control unit This map is composed as the parameters of the vehicle speed and the degree of throttle opening and somewhat approximates in the main the diagram below When the control unit detect
264. r to maintain the hydraulic pressure at a maximum AUTOMATIC TRANSAXLE Transaxle Control 21 47 SSeS TRANSAXLE CONTROL UNIT Part No and Ident No t visio eei reaa 24 0 00 h Accelerator Switch The transaxle control unit functions based upon the data signals from the various sensors to drive the shift control solenoid valves A and and the pressure control solenoid valve and to make shifting pattern control and hydraulic pressure control during shifting The transaxle control unit is installed within the passenger compartment at the lower part of the heater unit Connections of the transaxle control units terminals and sensors with the drive devices are as described below 6505086 mca pol pefepeps pe oben 17504106 Diagnosis control Pulse generator A Overdrive control switch Pulse generator Inhibitor switch R Sensor ground Inhibitor switch D Power supply for sensor Inhibitor switch L Damper clutch control solenoid valve Power supply for backup Shift control solenoid valve B Pulse generator A Accelerator switch Pulse generator B Power Economy select switch Kickdown servo switch Ground Throttle position sensor output Power supply Vehicle speed sensor Inhibitor switch P Oil temperature sensor Inhibitor switch N Ground inhibitor s
265. ransaxle control unit identifies the period from the time the kickdown rotating speed begins to decrease to the time when it becomes zero as the gear shifting period Next let s talk about the hydraulic pressure control performed by the pressure control solenoid valve by referring to Figure B The point is the time when a signal is sent from the transaxle control unit to the shift control solenoid ve instructing the valve to start the pressure control operation tor gear shifting In response to the signal the shift control valve operates to create the 4th speed pressure and causes the kickdown brake to begin its operation The kickdown servo switch contacts which have been closed open just before the brake begins to be applied This point of time is represented by b in the figure Using this kickdown servo switch contact open signal the transaxle control unit begins the duty control of the pressure control solenoid valve The duty at the point b is determined with reference to the throttle valve opening so that the gear shifting can be completed smoothly without shock At the same time when application of the kickdown brake starts at point c the hydraulic pressure acting on the brake begins increasing by degrees i e duty is decreased to tighten the kickdown drum Once the brake is totally applied the drum stops rotating at point d On detection of the stopping of the drum the transaxle control unit gives orde
266. ratio To correct this deviation the amount of fuel injected is controlled i e the amount of fuel injected is increased to compensate for the higher intake air density caused by the decreased intake air temperature 14 42 FUEL SYSTEM Fuel Injection Control HIGH ALTITUDE COMPENSATION A change in barometric pressure which may be caused by change in altitude alters the intake air density resulting in an improper air fuel ratio To compensate this deviation the amount of fuel injected is controlled i e the amount of fuel injected is decreased to compensate for the lower intake air density caused by the decreased barometric pressure or the higher altitude injected Amount of fl 760 30 i Barometric pressure mmHg in Hg sFu0929 CONTROL FOR FUEL ENRICHMENT DURING ACCELERA TION During acceleration at low and middle loads fuel supply rate is increased to improve acceleration performance FUEL DECREASE CONTROL DURING DECELERATION During deceleration fuel supply rate is decreased to improve fuel economy Fuel enrichment during acceleration BATTERY VOLTAGE COMPENSATION As described earlier in INJECTOR the needle valve of the Drive injector is pulled to the fully open position when current flow current OFF Inead time through the solenoid coil This means that there is a time I between the time when the current starts flowing and when Injector Open the needle valve starts opening T
267. re immediately idle speed control servo to achieve the optimum after detection of such a load signal the engine target position while cranking driving and decelerat control unit activates the idle speed control servo to ing according to the operating conditions Power steering oil Dash pot pressure SWitC condition Air conditioner Switch Inhibitor switch Idle speed control servo E t LI J temperature Dash 8 pot Se contro si NO Stepper 5 8 motor Stepper Coolant control motor 1 i i e me m oe m m el FUEL SYSTEM Idle Speed Control 58 v De Do S6 ot 5 BE o 32 80 176 Coolant temperature C F 6FU0289 Target position during operation of the power steering system at ervo poss number of steps 80 176 6FU0291 0 32 Coolant temperature C F Servo position during operation of the air conditioner ervo position number of steps 0 32 80 176 Coolant temperature C F 6FU0757 Amount of correction 760 30 Barometric pressure mmHg in Hg 6FU101C 14 51 IDLE CONTROL SERVO POSITION CONTROL WHEN THE ENGINE 15 IDLING 1 Basic position 3 5 The basic position is preset as a map value Optimized according to the engine coolant temperature The idle speed control servo is activated to conform to this position t
268. rential action However as this also causes a sharp increase of speed difference of the viscous coupling a large differential limiting torque is now applied with more power transmitted to the tires that are not spinning so that the vehicle can drive through or get out of mud 21 12 VISCOUS COUPLING VCU Seal X ring Housing Output Hub flange LED N E 3 MANUAL TRANSAXLE lt 4WD gt Viscous Coupling VCU Silicone oil Center shaft 2210098 CONSTRUCTION OF VISCOUS COUPLING The construction of the viscous coupling for the center differential is as shown above The housing is spline coupled to the center shaft and the hub is also spline coupled to the output flange of the center differential case Therefore the housing turns with the rear wheel drive shaft and the hub turns with the center differential Within the housing outer plates with their outer edge fixed to the housing inside splines and inner _ plates with their inner edge fixed to the hub Splines are arranged alternately The outer plates have spacer rings set between them on the outer edge in order to space them and are fixed to the housing MANUAL TRANSAXLE lt 4WD gt Viscous Coupling VCU 21 13 In contrast the inner plates have no such spacer rings and each can slide to some extent over the hub spline shaft between the outer plates
269. rfield type constant velocity ball joints have been provided for the drive shaft On the axle shaft side the D O J type has been adopted to absorb the change in distance between the joints that may be caused by the movement of the suspension On the differential carrier side the B J type has been adopted which allows considerable flection in keeping with the movement of the suspension Drive shaft R H two stageserration ECLIPSE Viscous coupling type limited slip differential equipped vehicles D O J Outer race D O J Inner race RO3CAAA To prevent mud that may be deposited around the bearing outer a dust cover has been provided Dust cover Axle shaft 1140013 R03DAAA On the axle shaft side they are coupled with the axle shaft with the companion flange in between On the differential side they are spline coupled with the side gears On vehicles with a viscous coupling type limited slip differential the right and left drive shafts are different in length In addition the B J side of the drive shaft R H is two stage serration coupled 11A0338 REAR AXLE viscous Coupling Type Limited Slip Differential o 9 DIFFERENTIAL The differential uses lower torque bearings and lower torque oil seals to improve power perform ance and fuel consumption For faster differential cooling and higher reliability during high speed operation a differential carrier with cooling fins has been adopted Coo
270. rge volume air Outside air Recircu Recircu gt Circu lation aest Tas lation air 9 4 ss aoe FACE m FOOT FOOT arge volume air 200244 Reci Outside air IAT ecircu fo lation air sto tee lation air gt VA C 2040245 HEATERS AND AIR CONDITIONING Heater Construction 24 7 Jamper position and air tlow direction Ait outflow locations Outside air Recircu DEF SQ gt 2 aa gt FOOT 20A0246 Outside air ircu Dra DE Ze c Z4 7 2040247 Temperature Control Knob From lt 5 blower motor Blend air damper c Blend GUT damper A C RE de openings lt Chamber RS Heater core 2040391 Blend aif amo 8 24 8 HEATERS AND AIR CONDITIONING Compressor COMPRESSOR COMPRESSOR CONTROL When both the blower switch and air conditioner switch are ON ON OFF control of the magnetic clutch is accomplished by the auto compressor R24GA control unit dual pressure switch engine coolant temperature switch and control unit Fusible link ML HI OFF MH Hi Blower switch oFFe ML 10 Sub fusible AC 5 link OFF Air conditioner 5 ECONO ECONO switch Dedicated fuse Auto compressor control unit b GND v 5 v v Dual pressure switch
271. riable resistor type senses the throttle valve opening As the throttle shaft turns the resistance i e output voltage of throttle position sensor changes This throttle position sensor output voltage is input to the transaxle control unit to compute the throttle opening The throttle position sensor output voltage can be adjusted by turning the throttle position sensor body Throttle position sensor output characteristics voltage V Output 10 20 30 40 50 60 70 80 82 Totally Throttle valve opening degrees Totally closed opened 70075 KICKDOWN SERVO SWITCH The adjust sleeve and the retainer constitute the contacts of the kickdown servo switch The switch detects the position of the kickdown piston just before the kickdown brake is applied and sends the signal to the transaxle control unit When the kickdown servo is not in operation the switch contacts are kept closed When the hydraulic pressure is applied to the kickdown servo and the piston is operated the adjust sleeve separates from the retainer turning off the switch Using the kickdown servo switch OFF signal as its standard the transaxle control unit controls the 2nd pressure before and during application of the brake by actuating the pressure control solenoid valve OVERDRIVE CONTROL SWITCH When the overdrive control switch is ON operation is as a O speed automatic transaxle When the overdrive control switch is OFF the indicator light within the com
272. rotation of the rotor f POWER STEERING Oil Pump 19 11 1 L 6 366 1 Td SL 0 1000 2 000 3 000 4 000 5 000 6 000 Pump speed N rpm PERFORMANCE OF THE OIL PUMP 1 P Qf characteristic pump pressure vs discharge quantity At pump rotation of 600 rpm and fluid temperature of 50 60 C 122 1 40 F 4 4 lit min 268 5 cu in min or more at pump pressure of 4 000 kPa 569 psi 2 N Qf Characteristic pump rpm vs discharge quantity At pump pressure of 2 000 kPa 285 psi and fluid temperature of 50 60 122 140 p 2000 569 853 1138 6 58 lit min 396 7 488 2 cu in min at pump rotation of Pump pressure kPa psi _ __ 1380576 M Pump discharge 0 Imin cu in mir A S 1 500 3 8 6 lit min 231 9 366 1cu in min at pump rotation of 3 000 rpm 2 5 3 5 lit min 152 6 213 6 cu in min at pump rotation of 4 500 rpm OPERATION OF THE FLUID FLOW NNTROL SYSTEM plunger and flow control valve are activated by the oil pump thus regulating the amount of fluid the hydraulic pressure of the fluid discharged from flow to the gear box Connector Plunger Plunger spring Flow control Flow control spring Ef Reliefspring Relief valve 13P0037 19 12 POWER STEERING Oil Pump WHEN OIL PUMP OPERATES AT LOW SPEED 700 1 000 RPM A part of th
273. rvo is activated according to the preset speed control logic to control the air flow that bypasses the Inhibitor switch lt A T gt Ignition switch Idle speed Fast idle air valve control servo Coolant temperature sensor Throttle position sensor Crank angle sensor Vehicle speed sensor Air conditioner switch Barometric pressure sensor Power steering oil pressure switch Intake air temperature sensor Engine control unit position switch ignition timing adjustment terminal Self diagnosis data trans mission switching terminal From air cleaner To intake manifold 6FU0796 Other sensors Input signal reading Control mode decision Idle speed control position Target position data control Idle speed feedback control Target speed data Idle speed control servo drive pulse setting data speed control servo drive pulse setting data Drive pulse setting Drive pulse setting Drive pulse generation idle speed control Servo FUEL SYSTEM idie Speed Control IDLE SPEED CONTROL SERVO Throttle valve Idle speed control servo n Pintle Lead screw 9 a 6 0 6 6 o o ea ato uL D NC Y 14 45 Pintle Throttle bodv 6F U0 796 Magnet rotor Coil Stepper motor 6FU0799 The idle speed control servo consisting of
274. ry disc type Single dry disc type Facing diameter O D x I D in 215 x 140 8 5 x 5 5 225 x 150 8 9 x5 9 Clutch cover assembly Type Diaphragm spring Diaphragm spring strap drive type strap drive type Clutch release cylinder I D mm 20 64 13 1 6 19 05 3 4 Clutch master cylinder LD in 15 87 10 16 15 87 1 0 16 CLUTCH CONTROL ROSCAAA In order to prevent sudden movement of the vehicle The clutch switch for the auto cruise control system when the engine is started an inter lock switch has has been equipped at the pedal support bracket been equipped within the pedal support bracket Clutch master cyli lt Non turbo gt Clutch switch Inter lock switch Pedal support bracket Clutch pedal Clutch tube lt Turbo gt Clutch switch Ciutch release cylinder Clutch master cylinder Inter lock switch Oil clutch bracket Pedal support bracket A Vara mae ers FAR CLUTCH Clutch Control 6 3 INTER LOCK SWITCH The inter lock switch is a switch provided in order to prevent sudden movement of the vehicle when the engine is star ted Inter lock switch 1 orr ION A Thus the starter motor will not be switched ON unless the O8POO28 clutch pedal is depressed thereby switching OFF the inter lock switch NOTE The inter lock switch is normally ON it is switched OFF when
275. s Torque characteristics When differential action occurs in the center differential a rotating speed difference occurs between the inner and outer plates of the viscous coupling and the oil between plates is sheared developing viscous resistance differential limiting torque This viscous resistance changes with the rotational speed difference as shown at the left Namely the differential limiting torque increases with rotating speed difference o E 2 2 3 2 Rotating speed difference 221011 21 14 MANUAL TRANSAXLE lt 4WD gt Viscous Coupling Hump phenomenon specific to viscous couplings Hump is a phenomenon specific to viscous couplings althouy it does not occur under normal operating conditions This phenomenon occurs when the silicone oil temperature has risen due to sustained differential action Normally silicone oil fills the space between the inner and outer plates preventing their direct coupling When silicone oil expands at a high temperature to such a degree as to develop abnormally high pressure between the plates normal thermal expansion is absorbed by compression of air mixed in silicone oil silicone oil escapes from between the plates As a result the plates couple directly causing abrupt torque transmission When the Plate surface l viscous coupling is directly coupled in this way a rotating pressure speed difference does not exist and then silicone o
276. s Snap rings etc as careless removal may cause personal injury Always wear safety goggles whenever working on vehicles or vehicle components It is important to note that this publication contains various Cautions and Warnings These should be carefully read in order to minimize the risk of personal injury or the possibility that improper service methods may damage the vehicle or render it unsafe It isimportant to notethat these Cautions and Warnings cover only the situations and procedures Chrysler Motors has encountered and recommended Chrysler Motors could not possibly know evaluate and advise the service trade of all conceivable ways that service may be performed or of the possible hazards of each Consequently Chrysler Motors has not undertaken any such broad service review Accordingly anyone who uses a service procedure or tool that is not recommended in this publication must assure oneself thoroughly that neither personal safety nor vehicle safety be jeopardized by the service methods they select WE SUPPORT VOLUNTARY TECHNICIAN THE pr m CERTIFICATION SERVICE mam THROUGH PROFESSIONALS SERVIGE TALON BACKUP TECHNICAL INFORMATION MANUAL FOREWORD This manual has been prepared as an introduction to the specifications features construction and func tions of the newly developed TALON Please read this manual carefully as it will be of assistance for service and sales activi
277. s as a result of the signals from the sensor that both throttle opening and vehicle speed have reached the damper clutch activation area duty control of the damper clutch control solenoid valve is activated thereby activat ing the damper clutch The damper clutch is regulated so that it slips slightly although it is possible to increase the Damper clutch activation conditions 1 Shift range 2nd to 4th gear 2 Oil temperature 60 C 140 F or higher 3 Not a sudden downshift 10 AUTOMATIC TRANSAXLE Transaxle Control amount of slippage by duty signals from the control unit The control unit functions to calculate the amount of slippage and performs duty control so that the amount becomes close to the target amount of slippage as set beforehand The relationship between the hydraulic pressure circuit and the damper clutch control solenoid valve is described in the later section concerning the hydraulic control system please refer to page 21 59 For detailed information concerning duty control this is described in the later section concerning the hydraulic pressure control during shifting please refer to page 21 45 Damper clutch activation area Throttle opening 96 Vehicle speed 1750141 127 AUTOMATIC TRANSAXLE Transaxle Control PATTERN CONTROL gear shifting sequence is performed as follows 1 The transaxle control unit stores two types of shift patterns nam
278. s a consequence there is sufficient supercharging when pring set pressure ium i i i Turbo pressure acting 6FUO570 premium grade gasoline is used and a high level of output can on waste gate actuator be obtained If regular grade gasoline is used the power transistor is switched OFF by the engine control unit thus interrupting the circuit of the waste gate solenoid valve and stopping the leakage of turbo pressure When the turbo pressure then increases as a result to reach the waste gate actuator spring set pressure the waste gatc valve opens When regular grade gasoline is used therefore the turbo pressure becomes smaller and coupled with knock control the engine is thus protected from the effects of knocking 3 Air Flow Sensor AFS Filter Reset Control Turbo FUEL SYSTEM Turbo Meter Control lt Turbo gt 14 57 AIR FLOW SENSOR AFS FILTER RESET CONTROL Turbo Engine control unit Air flow sensor Air flow sensor X Reset terminal Crank angle sensor Idle position switch Jens position sensor When the idle switch is ON or when the throttle When these Signals are input the air flow sensor position sensor output voltage is low the engine resets the modulator There is a switch to the circuit control unit functions to switch ON the power that lessens turbo noise This eliminates any error in transistor and as a result air flow sensor reset measuring the a
279. s as the cam rotates friction loss is drastically reduced as compared with the conventional slipper type 4 Due to the construction of the roller rocker arm the valve train driving torque is reduced to about half that of the p S 4 DOHC slipper type conventional slipper type which is equivalent to or IE amp S 2 valve SOHC slipper type compares favorably with the 2 valve SOHC slipper type All NE 8 these factors contribute to enhanced engine performa 2 and fuel economy z LASH ADJUSTER i The hydraulic lash adjuster is of the end pivot type It eliminates 5 4 DOHC roller type the need for adjustment of the valve clearance There are four E DIT SOOO lash adjusters provided for each cylinder 16 in all Engine speed rpm 6EN010 Camshaft Plunger cap Oil assage I p 0 Lash adjuster Oil hole Reservoir chamber Cylinder head Plunger Check ball Valve High pressure chamber Plunger spring 6 0255 6 0256 ENGINE Base Engine 9 15 Operation of the Lash Adjuster When the valve starts opening During the valve opening stroke 6ENO254 6 0257 When the valve corgpletes the opening stroke 6 0258 1 Before the valve starts opening 3 During the valve opening stroke No external load is applied to the plunger thus A very small amount of oil leaks through the causing the plunger to be pushed ur by
280. s gear Parking sprag rod Detent plate Manua control shaft Detent ball 170007 When the shift is in the range the parking paw engages with the parking sprag provided on outer circumference of the annulus gear to fasten the output shaft preventing wheels from rotating In other words when the selector lever is set to the P range the detent plate and the parking sprag rod move in the direction of arrow causing the cam on the parking sprag rod to push up the parking pawl to engage with the sprag case the parking paw collides against a crest of the sprag only the rod moves because the parking pawl cannot be moved upward and the cam while pressing the spring collides with the parking paw and the support and is withheld in this condition If the vehicle is moved even slightly in this condition the turning of wheels causes the annulus gear to turn as well Since the cam is pressed in the direction of arrow the parking pawl is pushed up as a bottom of the sprag aligns with the parking sprag to engage with the sprag In this way the parking mechanism eliminates any chances of the vehicle from being idly moved 21 40 AUTOMATIC TRANSAXLE Transaxle Mechanism START SAFETY MECHANISM Inhibitor switch Manual control lever 1750253 1750149 The start safety mechanism ensures the safety Internal Connection in the inhibitor Switch during the engine starting operation When the
281. s memorized as the set vehicle speed and thereafter the actuator is controlled so that fixed speed driving at that speed is possible The illustration below shows the timing speed this pulse is output when the auto cruise control system is set e Trim pulse The trim pulse is a control pulse for correcting the vehicle speed this pulse is output at certain fixed cycle intervals The output pulse width is eias determined based upon the amount of deviation e Initial pulse between the current vehicle speed and the set The initial pulse is the pulse for opening the vehicle speed and upon vehicle speed accelera tion MAIN switch ON OFF Control unit 12V power supply terminal voltage ov ON SET switch OFF Acceleration PULL Actuator DC motor stop Deceleration RELEASE M Actuator ON electromagnetic clutch OFF Manual driving witch Actuator DC motor Y hh a ru Auto cruise control unit 07 0011 PULL i RELEASE Fixed speed driving e DC motor drive operation Operation is as described in the table below based upon control signals from the microcomputer Acceleration PULL OFF ON Stop OFF OFF OFF Deceleration RELEASE OFF OFF FUEL SYSTEM Auto cruise Control System 14 63 Fixed Speed High Vehicle Speed Low SET ON switch OFF DC Stop motor Decele ration
282. s to the fastening position For the period between the initiation and com pletion of the belts motion in the fastening direction the seat belt warning light either stays lit or blinks Belt Releasing Motion 1 When the belt is not in the release position the L H or R H release switch is in the ON position and the left or right door is opened the belt will automatically move to the release position if the ignition switch is at either the ON LOCK or position For the belt at the driver s seat side moveover the belt will automatically move to the release position if the key is taken out while the belt is fastened The buzzer sounds for approximately 0 7 second since the start of the belt s motion Ignition Switch ON i LOCK or ACC OFF I 4 Warnin light fasten switch is switched OFF and the motor stops 2 With a lapse of approximately 60 seconds after 2 the belt has stopped its fastening motion due to foreign object wedged in the mechanism the protective timer of the control unit is activated causing the motor output to the shut off When the belt completes its releasing motion the L H R H release switch is turned OFF and the motor stops If the belt is still in the process of releasing with a lapse of approximately 60 seconds after the start of motion the protective timer in control unit is activated causing the motor output to be shut off At the
283. same time the buzzer sounds for approximately 0 7 second WARNING SYSTEM Warning Alarm when Ignition Switch is Activated When the ignition switch is moved from the LOCK or ACC position to the ON position the warning light illuminates continuously for approximately 6 seconds If within the time the ignition switch is moved from the ON position to the LOCK or ACC position the warning light illumination will stop Door latch switch OFF oe ON switch LOCK or ACC ON Fasten switch OFF I Warning ON NL d light OFF Approx e sec 1 Warning alarm when ignition Switch is activated 2 Approx 0 7 sec cycle Drivers side latch switch Ignition ON Switch LOCK or ACC ON Fasten switch Drivers side outer switch Buzzer Warning light Waming alarm when ignition switch is activated 2 Approx 0 7 sec cycle Approx 66 SEC en Lock Front seat ON x d a a Warning ON light OFF A x BODY Seat Belts Warning Alarm when the Automatic Seat Belt is Completely Fastened when the slide anchor during movement stops before completion of travel or when it moves toward the fasten side amning light flashes if the door is closed the ignition witch is at ON position and the driver s or front passenger s fasten switch is switched ON unfaste
284. selector tever is in the position other than P or N the electrical circuit for starting the engine is No kept in the OFF state by the inhibitor switch Therefore the engine does not start even if the Transaxle control unit ignition switch is turned to the START position Transaxle control unt Inhibitor switch is installed on the transaxle case eO TI GUN located at the upper end of the manual control shaft and is interlocked with the manual control lever By umm shifting the selector to the P or range the ron switch ON electrical circuit inside the inhibitor switch is con termina nected to form the ignition circuit with which the engine can be started When the shift is in the R range the backup light lights up as the backup light circuit is energized The inhibitor switch in addition to the start safety device also includes a circuit for detection of the ignition switch ST selector lever position for sending signals to the terminal transaxle control unit Connected circuits Starter motor S terminal Ignition switch ON terminal 11 Hr Backup light 136 AUTOMATIC TRANSAXLE Mechanism 21 41 RANSAXLE CONTROL RIAM GENERAL DESCRIPTION Pulse oenerator A Power train To damper To each clutch 55 clutch and brake Pulse generator B From oil pump Hydraulic pressure control mechanism Dampe
285. sensor idle position Switch Connector 6FU0779 14 19 Throttle position sensor Engine control unit p 41 5 volts 6F U0782 Output voltage V 7 0 8082 Full 50 60 close open Throttle opening deg Ful 10 20 30 40 012510 The throttle position sensor is a variable resistor whose movable contact rotates coaxially with the valve shaft thus sensing the throttle valve ening As the throttle valve shaft rotates the sensor output voltage changes Based on the signal the sensor IDLE POSITION SWITCH Idle position switch Throttle lever Lock nut Throttle body ine idle position switch is a contact type switch that detects operation of the accelerator pedal This switch also serves as the throttle stop screw which has been set at the minimum opening of the throttle vaive so as to prevent the throttle valve from biting Terminal Rubber cap generates the engine control unit detects the throttle valve opening and determines the engine operation mode acceleration or deceleration The relationship between the throttle opening and the output voltage is as shown above 7020 Engine control unit Idle position Switch attery voltage 6FU0497 into the throttle bore when the valve is fully closed This setting has been performed accurately at the factory the lock nut should not be loosened or the idle position switch be moved inadvert
286. sensor Uses throttle position sensor Fixes stepper motor at Uses throttle position sensor signal for control position wider than idle signal for control Provides control with intake air temperature assumed to be 25 C 77 F Intake air temper ature sensor Throttle position sensor Provides control with intake air temperature assumed to be 25 C 77 F Provides control with intake air temperature assumed to be 25 C 77 F Does not perform driving and acceleration deceleration control Engine coolant temperature sensor Provides control with engine coolant temperature assumed to be 80 C 176 F Provides control with baro metric pressure assumed to be 760 mmHg 30 in Hg Barometric pressure sensor Provides control with engine coolant temperature assumed to be 80 C 176 F Provides control with baro metric pressure assumed to be 760 mmHg 30 in Hg Provides control with engine coolant temperature assumed to be 80 C 176 F Prevides control with baro metric pressure assumed to be 760 mmHg 30 in Hg Fuel not injection to a cylinder whose ignition signal is abnormal Ignition coil Feedback control of air fuel ratio by oxygen sensor signal is not made Oxygen sensor FUEL SYSTEM Fuel Injection Control 14 33 FUEL INJECTION CONTROL R14GAAB GENERAL DESCRIPTION Air flow sensor Barometric pressure sensor Intake air temperature sensor Em Coolant tempera
287. ses the No 9 port and causes the pressure in passage 16 to be released When the pressure in passage 16 is released the check ball is forced against the right hand port opening thus shutting off the line pressure As a result the low reverse brake is released Although the front clutch is engaged in this situation the transaxle cannot transmit the reverse driving power unless the low reverse brake is applied Therefore when the transaxle is placed under the abovementioned condition it is the same as when it is in neutral 21 64 SHIFT CONTROL VALVE AND SOLENOID VALVES Shift control EF solenoid valve Transaxle Shift control solenoid valve B valve The line pressure acting upon the shift control valve is controlled by the two shift control solenoid valves which are switched ON and OFF according to the shifting gear by the transaxle control unit com mand and the shift control valve is activated according to the shifting gear thus switching the oil passage The relationship of the shifting gear and the switch ON and switch OFF shift control solenoid valve A and B is shown in the table below Shift control solenoid valve A B Shift control AUTOMATIC TRANSAXLE Transaxle Control 2nd pressure 3rd pressure Line pressure 1750230 The shift control solenoid valve A controls the line pressure that acts on the plugs while the solenoid valve B con
288. shaft The auto tensioner maintains the optimum timing belt tension The torsional damper reduces twisting vibration in the crankshaft to a minimum The silent shaft system reduces engine vibration and rolling moment to a minimum The self diagnosis system makes troubleshooting easier The lash adjuster eliminates the need for valve clearance adjustment The auto tensioner eliminates the need for timing belt tension adjustment FNGINF General Information ENGINE CUT AWAY VIEW PAL WV Ro i ES 2 gt D lt p ay RR 2 SA Q FEL 9 5 ENGINE General information 6ENO382 9 6 ENGINE General Information Fr i FB Li 171 I rams LIC 6ENO383 11 PU ENGINE Base Engine 9 7 BASE ENGINE Kis YLINDER HEAD mome o ee UT Hen TRIS C EE n VPN 2 Cre LAS Oil passages for lash adjuster Valve guide Valve seat 6ENO246 Squish area intake port Spark plug hole Exhaust port Piston O D 0076 Camshaft lubricating Camshaft lubricating il oil passage oil passage Spark plug hole 6 0247 1 The combustion chamber is of the pentroof 2 The spark plugs are located at the center of the type The two intake and two exhaust ports are combustion chambers in a crossflow arrangement There is a squish
289. signal ih voltage is high 8 32 THEFT ALARM SYSTEM When the theft alarm system has been armed by a fixed sequence for locking the doors with the key or without the key if thereafter a door the rear hatch or the hood is opened in an unauthorized way the horn will sound intermittently for period of approx imately three minutes and at the same time the headlights will flash on and off thus providing audible and visual warning signals NOBIAAA Headlight relay Hom Headlights Key reminder switch 4 Security light Theft alarm starter relay ELECTRICAL Theft alarm System Furthermore the starter circuit is interrupted in si a way that the engine cannot be started if X ignition key is not used Note that this system is controlled by the electronic control unit ECU This ECU includes an independent microcomputer for the exclusive use of the theft alarm system This microcomputer arms disarms activates and deacti vate the alarm system The system is composed of the components de scribed below Liftgate unlock switch Door key cylinder unlock switch LH and Door lock actuator switch L H and R H Door switch L H and R H 1641072 Horn relay Starter relay idaytime running light relay OPERATION Authorized Hom sounds Headlights flicker SYSTEM DISARMED of gt Normal starting l k Unauthoriz
290. sm 1ST GEAR L range Low Reverse brake Carrier Short pinion Forward sun gear Annulus gear Rear clutch Long pinion perating elements eRaar clutch Low Reverse brake When the shift is in ist gear in the 4 range the low reverse brake is actuated to fasten the planetary gear carrier so that the gear does not turn in either direction This means that engine brake works when the shift is in 1 st gear in the L range i NOTE The power flow in 161 gear in the L range is the same as it is in 1st gear in the D and 2 ranges 1750058 2ND GEAR Long pinion t n ane Revers sun gear e ear eKickdown brake AUTOMATIC TRANSAXLE Transaxle Mechanism Kickdown Drake sto Pinion Forward sun gear Amulus QE ar Since the rear clutch and the kickdown brake are actuated when the shift is in 2nd gear in the D or the 2 range driving force is transmitted to the forward sun gear which rotates in the clockwise direction Therefore torque is conveyed from the forward sun gear through the short and long pinions to the annulus gear as in the case of 1 st gear However since the reverse sun gear is fastened by in the case of 2nd gear the long pinion walks on the reverse sun gear in the direction of arrow A causing the annulus gear to rotate faster or more than in the case of 1 st gear in proportion to the length that the long pi
291. so that the intake air volume is not abruptly reduced thereby dampening deceleration shocks The idle speed control servo is activated when either one of the following conditions are met e When the throttle position sensor output voltage drops e When the idle switch is turned on position number of steps idle speed control servo Time sec CONTROL WHEN STARTING While the engine is being cranked the idle speed control servo is controlled to provide optimum bypass air volume for starting Immediately after the ignition switch is turned on idle speed servo position control is provided to achieve the optimum position 5S7 ca 3 c go E PE o t 5 On famperature es 9 FUEL SYSTEM Speed Control Power Supply Control 14 53 Engine has started Increased number of steps Target posi ion Time sec Increased speed rpm ws Time sec 6FU0758 POWER SUPPLY CONTROL GENERAL DESCRIPTION 16A0783 1 ldling stabilization control immediately after starting Immediately after starting the idle speed control servo steps are increased above the idle position in other words bypass air volume is increased The number of steps AYE decreased gradually afterwards The increased number of steps are preset as a map value according to the engine coolant temperature IDLE STABILIZING CONTROL AT HIGH TEMPERATURE
292. space otherwise taken up by the power economy changeover switch e Onhigher grade model cup holder is available as an option The two cup holders are linked with a slit making it possible to store sun glasses Stopper 1940271 1940270 23 30 FRONT SEATS The front seats are sporty highback seats with an integral headrestraint that hold your body in place on curves The driver s seat on the higher grade model is provided with the lumbar support that is adjust able in four positions Seatback Seat cushion BODY Front Seats Rear Seat R23 The driver s seat slides 260 mm 10 2 in 230 mm 9 1 in on the front passenger s seat The front passenger s seat can be folded down to ensure easy egress ingress for the rear seat pas sengers Adjustment mechanisms 1 Sliding adjustment 2 Reclining adjustment 3 Lumbar support adjustment driver s seat only 4 Fold down mechanism on front passenger s seat only REAR SEAT The rear seat is for two passengers having low seatback and contoured seat cushions The seat back can be folded down to give an additional luggage compartment space Seatback Seat cushion R23RBAB There are cushion pockets at the center into which the rear seat belt buckles are stored when the seatback is folded down Cushion pocket 1940325 179 Shoulder belt Corner pad Glove box pad 1940
293. ssed through the heater core and of cool air which has not passed through the heater core is varied thus regulating the temper ature The area to which the air will flow can be selected by the mode selection damper Air selection damper N Fresh air Recirculation air 7 0340168 Blower motor Evaporator EPA Sire oes Gusta S i m 24 6 HEATERS AND AIR CONDITIONING Heater Construction RELATIONSHIP BETWEEN THE DAMPER POSITION AND THE AIR SELECTION LEVER MOD SELECTION KNOB AND TEMPERATURE CONTROL KNOB SETTINGS Air selection Lever Lever Damper Operation position position When the air selection lever is placed in the illustrated mark position the air selection damper closes the inside air inlet air from the vehicle interior and opens the outside air inlet air from the front deck When the air selection lever is placed in the illustrated mark position the air selection damper closes the outside air inlet and opens the inside air inlet air from the vehicle interior 20A0235 Mode selection Knob wb Large volume air Small volume air Rampat positon ang Air outflow locations Outside air gt Mecircu lation air gt D 20A0242 Outside air Recircu Recircu VA lation air zo NN SS FACE r E mm ZA E gt FOOT Mies 2040243 La
294. sure contro valve through the No 10 line is then directed to the kickdown servo via the No 11 line In 2nd 3rd and 4th gears the 1 2 shift valve is always held pushed to the right AUTOMATIC TRANSAXLE Transaxle Control 21 75 Shift control valve To low reverse brake Val 1 2 shift vaive Mc 1 Line pressure gd from manual valve N R control valve a me E Line pressure rom manual valve eem From kickdown servo apply side 1 2 shift valve 1750237 Downshift from 2nd to 1st Gear Af the shift control valve is moved to the 151 gear position the 2nd pressure is released and the 1 2 shift valve is pushed to the left by the spring force This opens the exhaust port and the pressrue that was acting on the kickdown servo is now released through the No 11 line In Reverse When the manual valve is shifted to the reverse position line pressure is directed to the No 16 port of the 1 2 shift valve by way of the N R control valve The combination of a larger area to which pressure is applied on the 2 land and a smaller area on the 1 land of the 1 2 shift valve causes the valve to move to the right thus opening the No 17 line port Pressure is directed to the low reverse brake through this opened port M vx 21 76 AUTOMATIC TRANSAXLE Transaxle Control 2 3 4 3 SHIFT VALVE Rear clutch exhaust valve Kickdown servo Kickdo
295. t Center of crankshaft Silent shaft 6EN132 The silent shaft system counteracts the secondary reducing the vibration and noise generated by the exciting moment in the engine s vertical direction as engine The system is exactly the same as that used kn well as the rolling moment thereby drastically in the conventional 4G63 SOHC engine z 20 ENGINE Base Engine 9 13 VALVE MECHANISM Rocker arm Exhaust Lash adjuster camshaft 3 arched Valve spring Vaive stem seal Intake port 6ENO253 Exhaust valve Intake valve 6 1 The valve mechanism is the DOHC 16 valve generated by the valve train They also eliminate system the need for valve clearance adjustment 2 The rocker arm with a roller follower i e the 4 The valve springs whose cross section is oval roller rocker arm is used that reduces drastically contribute to the enhanced spring load This in the friction loss of the valve train turn ensures that the valves operate properly 3 The hydraulic type lash adjusters automatically especially at high speed adjust the valve clearance minimizing noise 9 14 ENGINE Base Engine ROCKER ARM 1 The cam follower of the rocker arm is a roller with nee bearings Roller 6ENO10 2 A jet of oil spurts onto the contact area between the cam and roller from an oil jet located on the fulcrum side of the rocker arm 3 Since the roller rotate
296. t As the engine control unit coils are sequentially energized the magnet rotor of The engine control unit uses the idle speed control the idle speed control servo is caused to rotate FUEL SYSTEM idle Speed Control 14 47 Operating Principles of Stepper Motor Fig A Fig B 7FU043 6FUO519 The stepper motor construction is as shown in Fig A Its operating principles are explained below with reference to the schematic Fig B STEP 0 Power supply Engine control unit Stepper motor Voltage Vom Coil A1 Coil A1 Stator Coil B1 Stator Il 6FU0520 6 00521 When coils Al and B1 are energized the upper attract the S poles and N poles of rotor magnets halves of stators and il are N poles and their lower respectively and the rotor is held stationary halves are S poles Thus their N poles and S poles 14 48 STEP 1 Power Supply Engine control unit Voltage Coil A1 Coil B1 When coil A2 is energized instead of coil Al the lower half of stator becomes an N pole This means that the N pole is moved one step to the right compared to the condition in Step As a STEP 2 Power supply Engine control unit Voltage Coil A1 Coil A2 Coil B1 FUEL SYSTEM Idle Stepper motor Coil A2 Coil B2 6FU0522 Stepper motor 6FU05 24 Speed Control Stator Il 6FU0523 result the S pole of the rotor is attracte
297. t which then decides if the air fuel ratio is rich or iean relative to the stoichiometric ratio Based on this decision the air fuel ratio is feedback controlled to achieve the stoichiometric ratio at which the catalytic converter operates most effectively In addition because this oxygen sensor incorporates a heater the response of the sensor is good even if the temperature of the exhaust gas is low and as a result feedback control of the air fuel ratio is possible for a short time after the engine is started Stoichiometric Airfuel rato 16 EC1007 14 22 VEHICLE SPEED SENSOR Output voltage 5 volts gt 5 8 5 amp 5 1 revolution Vehicle speed km h mph FUEL SYSTEM Sensors Engine control unit Vehicle Speed sensor o6 5 volts 5 00504 16A0051 The vehicle speed sensor is a reed switch type sensor and is installed in the speedometer It converts the transmission speedometer driven gear revolutions vehicle speed to pi signals and sends them to the engine control unit The sensor generates four pulse signals for each rotation of the speedometer driven gear Therefore the sensor output frequency increases in proportion to the vehicle speed as shown at the left 7i FUEL SYSTEM Sensors 14 23 AIR CONDITIONER SWITCH Batten Ignition switch R STe 1G Air conditioner orr 0 Air conditioner Q control unit l
298. t a voltage Dual pressure switch OF OFF Coolant OFF Air conditioner relay temp ature 2 switc HON ON OFF Engine control unit Air conditioner compressor GFUIISS This switch sends the air conditioner ON OFF signal to the engine control unit When the air conditioner is turned on and the engine control unit receives the ON signal from the switch it commands the idle speed control servo to increase the idle speed to the preset rom Thus engine rpm loss due to air conditioner operation while the engine is idling is prevented and smooth idling operation is ensured 14 24 FUEL SYSTEM Sensors POWER STEERING OIL PRESSURE SWITCH SFutI47 When the steering wheel is turned and the oil pressure of the power steering oil pump increases the power steering oil pressure switch sends an ON signal to the engine control unit The engine control unit detects the oil pump load with this signal and IGNITION SWITCH Battery Starter motor S terminal Engine control unit Battery voltage Power steering oil pressure switch 6FUO50 activates the idle speed control servo to control th idle speed Specifically it prevents the idle speec from dropping due to oil pump load thus ensurinc stable engine idling Ignition switch Engine control unit 6FU0783 The signal indicating that the ignition switch is ON OFF or cranking ST is input
299. t lock pin Return spring The shift lock device consists of the brake pedal link mechanism and the shift lock cable When the brake pedal is depressed the shift lock pin combined in one unit with the inner cable moves into the outer cable 1 When brake pedal is not depressed When the shift lever is in the P position and the brake pedal is not depressed the shift lever cannot be operated into the position other than the P position despite an effort to operate the lever because the shift lock pin combined with the inner cable in one unit prevents the detent pin movement making it impossible to depress the push button of the shift lever 2 When brake pedal is depressed When the shift lever is in the P position and the brake pedal is depressed from the released state the inner cable of the shift lock cable is pulled by action of the brake pedal linkage In this case the shift lock pin at the end of the inner cable is also pulled and the detent pin is released 22 TERELTE OA mens When brake pedal is depressed Outer cable 09A0153 09A0155 Therefore the shift lever can be shifted to the positions other than the P position NOTE Even if the brake pedal is depressed with the ignition key in the LOCK position or the key removed from the ignition lock the selector handle cannot be shifted to the positions other than the P position Refer to 2 Key interlock
300. tems can be stored in memory in the order that To clear the memory once an inspection has been they occur The memory is supported by a power completed keep negative terminal of the supply directly connected to the battery so that it is battery disconnected for 10 seconds or longer Output code Diagnosis item Remarks No Display pattern Normal Abnormal increases of throttle position Once this occ sensor output garded as 2 5 US Output IS re Abnormal decrease of throttle position Once this occurs output is re sensor output garded as 2 5 V Poor adjustment of throttle position sen sor Open circuit in oil temperature sensor Once this occurs oil temperature iS regarded as 80 C 176 F AUTOMATIC TRANSAXLE Control 21 53 Output code Diagnosis item Remarks Display pattern Open circuit or poor contact in kickdown TT Short circuit in kickdown servo switch Open circuit in ignition pulse pickup cable Short circuit in accelerator switch or poor adjustment 12A0107 Computer fault Fail safe item 1 st gear commanded when driving at Fail safe item high speed Open circuit in pulse generator B Fail safe item Open circuit in shift control solenoid Fail safe item valve A Short circuit in shift control solenoid Fail safe item valve A Open circuit in shift control solenoid Fail safe item valve B Short circuit in shift control soleno
301. ter TEMOIZ Control relay Purge control solenoid valve Engine control unit From throttle body PURGE CONTROL SOLENOID VALVE lt Turbo gt The purge control solenoid valve is the ON OFF control type of solenoid valve it functions to control the activation of the purge control valve To purge control valve 212 Control relay Purge control solenoid valve Engine control To body PURGE CONTROL VALVE Turbo The purge control valve functions to control the introduction of purge air to the air intake hose from the canister To purge control solenoid valve gt To air intake hose From canister 119 EMISSION CONTROL SYSTEMS Evaporative Emisson Control System 2050 0404 To fuel Check valve Pressure valve Vacuum valve To overfill limiter Ball From fuel tank O3E510 Relief valve OVERFILL LIMITER TWO WAY VALVE The overfill limiter consists of a pressure valve and a vacuum valve The pressure valve is designed to open when the fuel tank internal pressure has increased over the normal pressure and the vacuum valve opens when a vacuum has been producted in the tank FUEL CHECK VALVE The fuel check valve is used to prevent fuel leaks if the vehicle rolls over This valve is connected in the fuel vapor line between canister and overfill limiter and is installed on the firewall The fuel check valve contains two balls as sh
302. ter pressure EM Line Pressure EE DCCSV contro pressure and lubrication pressure control pressure Reducing pressure EX PCSV control pressure 1750247 AUTOMATIC TRANSAXLE Transaxle Control 21 91 LECTOR LEVER IN D 2nd Gear Torque converter Kickdown servo Front Rear Low reverse End clutch clutch brake 4 Transaxie 9 4 L Damper clutch 2 control unit A fF control o valve CD e 2 3 4 3 shift 3 Rear clutch B exhaust valve H Shift control solenoid valve E L pisa E gt ac Transaxie control unit Damper clutch control Solenoid valve End cluth valve x Reducing vave ON rer Q pee rque converter vaive 1 Ex valve B N D control valve Regulator valve ressure control valve Line relief filter valve Ex Line Pressure Pump suction pressure Torque converter pressure NN Line Pressure DCCSV control pressure and lubrication oil pressure control pressure BER Reducing pressure PCSV control pressure 1750248 21 92 AUTOMATIC TRANSAXLE Transaxle Control SELECTOR LEVER IN D 3rd Gear Torque converter Kickdown servo Front Rear Low reverse End clutch Clutch brake clutch N rper 4 4 D
303. tes further discharging the fluid discharge step The action of this pump is two intake strokes and two discharge strokes for each vane during one rotation of the rotor 5 POWER STEERING Pinion and Valve Assembly Construction 19 9 WHEN THE STEERING WHEEL IS TURNED TO THE LEFT When the steering wheel is turned to the left the torsion bar is as shown in the illustration caused to torque in the direction of turning to the left with the result that the input shaft rotates by the correspond ing amount to the left and a rotational difference between the input shaft and rotary valve develops The concave and convex parts of the input shaft and rotary valve cause oil passageways L and R to become constricted with the result that for the fluid sent from the oil pump the flow of fluid is stopped from port a to port and port b To the right cylinder tube From oil pump To the left cylinder tube 13 0073 Portb Sleeve b Cylinder tube left chamber iL Cylinder tube right chamber When this happens the fluid flows from the oil pump to sleeve a port a port and sleeve c and is sent to the cylinder tube left chamber thus causing the generation of a force to move the rack in the rightward direction thereby assisting the steering effort of the steering wheel At the same time the cylinder tube right chamber fluid flows through sleeve b port b port d and
304. th The pulses are picked up by the coil and fed to the transaxle control unit Using these pulses the transaxle control unit determines the kickdown drum and transfer driven gear rotating speeds on the basis of which the control unit makes the shift pattern control and the hydraulic pressure control during gear shifting A Kickdown ub drum View Transfer driven gear 1 2 Pulse generator A 3 4 Pulse generator B 1750002 Output pulse waveform Change in waveform 1st Pulse The frequency and the peak to peak voltage increase as the rotating speed increases No pulse No pulse is generated as the kickdown drum is held stationary The frequency and the peak to peak voltage increase as the rotating speed increases No pulse No pulse is generated as the kickdown drum is held stationary Pulse 151 The frequency and the peak to peak volte generator through ANY NI NF SI V increase as the vehicle speed increases B 4th PP 1750070 AUTOMATIC TRANSAXLE Transaxle Control 21 49 Throttle P4 position sensor Transaxle Power supply control unit From engine control unit 1250072 7 Dee h ON e VO T UB 4 E lt E Aa 1750132 175039 Overdrive control switch 175040 THROTTLE POSITION SENSOR The throttle position sensor is installed on the throttle body The throttle position sensor Of va
305. than as above OFF Approx 6 sec Warning alarm when driver s lap belt is not fastened 2 Warning alarm when ignition switch OFF key is left in key Key In cylinder cylinder Key reminder switch A ON Driver s door latch switch Open ON Other than as above When seat belt is released Approx 60 seconds after automatic seat belt motor relay Approx is electrically 0 7 sec activated Time expiration Other than as above Warning alarm when Shoulder belt release When begins OFF 0 7 L ION e SS moving to release Other than as above 23 44 BODY Seat Belts WARNING LIGHT OPERATION TERMINAL No 10 Output signal waveforms S and operation status tatus at input side Output signal Warning alarm when Ignition switch OFF ON ignition switch is activated Other than as above Warning alarm when Ignition switch ON automatic seat belt Driver s or passenger s seat Not fastened fastening is belt ON ON incomplete Fasten switch Door latch Switch close Other than as above OFF Warning alarm when Ignition switch ON ON H driver s shoulder b e I It Drivers door Closed is not fastened Driver s shoulder belt Fastened L Approx Fasten switch OFF ON 0 7 sec Driver s outer switch OFF y Approx Other than as above 68 sec Warning alarm when front
306. the casing and the cover There are in addition a relief valve a safety valve for protection of the fuel pressure circuit and a check valve to maintain residual pressure The electric fuel pump has the following features e It has greater discharge pressure than mechanical type fuel pump as well as less FUEL SYSTEM Fue Supply and Fuel Pressure Control discharge pulsation e It has a lower level of operation sound that the electromagnetic type Bendix type of fuel pump PRESSURE SUPPLY OF FUEL When the impeller is caused to rotate by the motor a pressure differential develops at the upper and lower parts of the impeller caused by the grooves in the circumference of the impeller When this happens a whirlpool effect is generated within the fuel pump causing the fuel pressure to become higher thereby causing the fuel to be expelled from the pump chamber and to pass through the motor opening the check valve and to be discharged from the discharge port Discharge port Relief valve Check valve Circum ferential flow pumr Intake 4 impeller 9380071 REWEF VALVE If for some reason such as an abnormal condition at the discharge side the fuel were not to be discharged the fuel pressure within the fuel pump would become abnormally high Thus when the pressure within the fuel pump reaches 450 600 kPa 64 85 psi the relief valve opens and the pressure escapes so that the fuel line pressur
307. the clearance between the lash adjuster body and plunger spring maintaining zero clearance plunger When the valve starts opening 4 When the valve completes its opening stroke e When the cam pushes the rocker arm the ball in the high pressure chamber immediately is held pressed against the seat by the hydraulic press ure fully closing the high pressure chamber As the check ball closes the pressure in the high pressure chamber surges causing the plun ger to support the load from rocker arm which allows the valve to start opening There is no external load being applied to the plunger as the valve closes causing the plunger to be pushed up by the plunger spring This causes the pressure in the high pressure cham ber to be lowered which pushes the check ball open The oil which has leaked is replaced in the high pressure chamber from the reservoir cham ber 9 16 ENGINE Base Engine Hydraulic Flow to Lash Adjusters 7 Exhaust side EN De 0 27485 adjuster si M Cylind head bolt hol j SD Cylinder hea olt hole 2 Valve body E Intake side NS Lash adjuster J NN 0 0 6ENO107 To lash adjuster on To lash adjuster on the exhaust side the intake side Relief spring Relief plunger Valve body 6ENO108 The oil moves through the cylinder head bolt hoie to then has
308. the direct insertion method to improve serviceability and reliability To defroster To side defroster To side defroster Ede c __ AN Ar Ue xm u Ds HRS Air selection damper Fresh air Mode selection damper air damper SS i S Recircula Driver s seat knee area under the steering wheel Side ventilator driver s seat side lt z Stion air ton air venta ventilators Side ventilator front passenger s a seat side SNP Eveporator cooling unit 9 55 0 4 Front passenger s seat foot and knee areas Blower motor Heater core fS 5 Driver s seat foot and knee areas Blend air damper 20A0384 3 E HEATERS AND AIR CONDITIONING General information COMPONENTS Water temperature s Q switch SW Oz Condenser Receiver e fa 2 ED Y Uf gt 5 gt Compressor Condenser Discharge tube 2040438 High capacity evaporator Three layer flow full blend air heater 24 3 20A0383 24 4 HEATERS AND AIR CONDITIONING General Information To windshield glass To side door window side defroster To face area 2 side ventilator i i A knee areas eral 559 2 4 To knee area Tofacearea To foot and knee areas side ventilator To side door win side defroster
309. the reservoir cham ber 3 The check ball opens 4 Oil enters the pressure chamber 5 The piston stops moving when the belt tension balances the spring tension which determines the tension applied to the belt 9 20 ENGINE Lubrication System LUBRICATION SYSTEM BENEERENIESSTTN To turbocharger 90 m Valve body amp A BA A A B amp cil pressure regulator 2000000000000 BANOO Tat on GE BUD RN ERTIES ST E E GUT 9 S8 UU YUU UH i nm PEN D E Ep cooler 550550 an z 3 tice BERS Ti cooler by pass valve Oil jet Relief valve pressure Switch 6LUO043 The lubrication system is the pressure feed full through the cartridge type oil filter before being flow filter system The engine oil sent under delivered to the various engine parts pressure by the gear type oil pump is filtered SPECIFICATIONS Items Specifications Oil pump Type Gear type Delivery rate 10 em 61cu in engine revolution Relief valve opening pressure 550 kPa 78 psi or more Oil pressure switch Type Contact point type ON pressure 30 kPa 4 3 psi or less Oil filter Cartridge type ENGINE Mounts 9 21 MOUNTS the mounts the principal axis of inertia support system is employed This principal axis of inertia support system of mounting functions t
310. the voltage IC comparison voltage at point A is lower than the reference voltage at the negative side of IC the output voltage of IC becomes low For because the voltage IC comparison voltage at the negative side becomes lower than the reference voltage at the positive side the output voltage of IC becomes high and the transistor Tr is switched ON 4 Because the transistor Tr is switched ON current also flows from diode D the coil L thus causing excitation of the coil L with the result that the switch is held by the plunger When the glass reaches the lowermost gt 1 When the glass reaches the lowermost point the amount of current flowing to the motor increases and the voltage applied at point A also increases 2 When the voltage IC comparison voltage at the positive side of IC becomes higher than the reference voltage at the negative side the output voltage becomes higher but voltage is prevented from being applied momentarily to the negative side of IC by resistor R and the capacitor C This is a delay circuit that delays the time that the transistor Tr will be switched OFF when the output voltage of becomes low so that the glass is correctly opened to its full extent The motor operates for 0 7 second after the glass reaches its lowermost position Battery 23 24 P9325 BUMPERS A large size i
311. ties Please note that the service manuals are also available and should be used in conjunction with this manual All information illustrations and product descrip tions contained in this manual are current as at the time of publication We however reserve the right to make changes at any time without prior notice or obligation This BACKUP DSM manual IS to be used ONLY as a BACKUP Please DO NOT REDISTRIBUTE WHOLE SECTIONS This BACKUP was sold to you under the fact that you do indeed OWN a GENUINE DSM MANUAL It CANNOT BE considered a REPLACEMENT Unless your original manual was lost or destroyed Please See README TXT or for additional information Thank you Gimmiemymanual hotmail com A CHRYSLER Chrysler Motors reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products previously manufactured m sanm nans atarna amanen 644 Printad in U S A GROUP INDEX General qredetsqpystsesesketgueseevees ere ere reece Eee Front Suspension Rear Axle uud ueste to vi toe Service Parking Clutch 2 2 Brakes Cooling Electrical dT Fuel System Propeller Shaft and Universal Joint Rear Suspension mE Power steering ese
312. tion The amount of fuel injected is limited during deceleration in order to prevent the catalyst temperature from going up excessively and to enhance fuel economy Fuel Cut Control during Overrun Fuel is cut off when the engine speed exceeds 7 500 rpm to protect the engine from overrunning Fuel Cut Control during Overboost Turbo When A N becomes the prescribed value or higher the fuel supply is cut in order to prevent an excessive increase of the supercharging pressure As a result an excessive increases of the supercharging pressure even in the unlikely event of a malfunction of the waste gate valve of the turbocharger is prevented Hot Engine Stabilizing Control When the intake air temperature exceeds 60 C 140 F and the coolant temperature 90 194 F when the engine is started the fuel temperature is high with a greater possibility of vapor being generated This means that the amount of fuel injected becomes smaller if the injector activation duration remains the same The activation duration is therefore prolonged im mediately after a hot engine has been started The activation duration is then gradually decreased to the normal activation duration This contributes to a stable idling speed 14 44 FUEL SYSTEM Idle Speed Control IDLE SPEED CONTROL manana GENERAL DESCRIPTION If the load changes while idling the idle speed throttle valve thus maintaining the optimum idle control se
313. tion status Output signal ON Operates Not fastened ON ON FRONT PASSENGER S SHOULDER BELT RELEASING OPERATION TERMINAL No 19 Status at input side Passenger s door Front passenger s shoulder belt Front passenger s shoulder belt is released A Other than as above Output signal waveforms and operation status Output signal Open Operates Not released H OFF L ON poof Max 60 sec 23 46 BODY Seat Belts REAR SEAT BELT The rear seat belts are the 3 point seat belts with The buckle can be tilted forward and inward whicn ELR which ensures safety of the rear seat passen helps make the belts tight around the body gers Retractor Retractor Inward Forward 1940333 1940295 37 24 1 HEATERS AND AIR CONDITIONING CONTENTS Rx amp COMPRESSOR naana aet ete biet 8 HEATER CONSTRUCTION 5 Compressor Control E TOF pec IDLE SPEED CONTROL MRNA NN SERRE 9 GENERAL INFORMATION s 2 COMPONSHES _ 3 5 24 2 GENERAL INFORMATION Ri Air conditioner e High capacity evaporator cooling unit com pressor and condenser are adopted to secure HEATERS AND AIR CONDITIONING General Information The heater is a separated configuration with the heater unit located at the center of the chassis and the blower
314. to the engine control unit When the ignition switch ON signal is input to the engine control unit the unit energizes the control relay coil to supply power to the sensors and actuators When the ignition switch ST signal is input to the engine control unit it determines that the engine iS cranking and controls the fuel injection rate speed control servo ignition timing etc for mum cranking conditions 93 FUEL SYSTEM Sensors 14 25 Engine control unit 5 volts Terminal for ignition timing adjustment 6FUO51 Piezoelectric elements 6FUOS10 Engine control Detonation unit sensor IGNITION TIMING ADJUSTMENT TERMINAL This terminal is used when adjusting the basic ignition timing or basic idle speed When this terminal is shorted to ground the engine control unit cancels the ignition timing control and idle speed control and sets the ignition timing and idle speed control servos in their adjusting mode For the basic idle speed adjustment the diagnosis terminal is also shorted to ground DETONATION SENSOR lt Turbo gt The detonation sensor is installed at a position where it can detect with a high degree of precision knocking generated at each cylinder it detects cylinder block vibrations caused by knocking and outputs voltage proportional to the magnitude of those vibrations Because cylinder block vibrations caused by knocking vary from engine to engine the engine control unit
315. transmitted from the input shaft through to the planetary gear set to drive the annulus gear the output flange via the long pinion Since the reverse sun gear is fastened at this time the long pinion rotates whie revolving on the reverse sun gear in the same direction asthe carrier The annulus gear rotates more Or faster than in the case of 3rd gear in proportion to the rotation of the long pinion The gear ratio of overdrive is achieved in this way 21 38 AUTOMATIC TRANSAXLE Transaxle Mechanism REVERSE Low Reverse brake Long pinion Front clutch Reverse sun gear Annulus gear Operating elements ront clutch zx eLow Reverse brake When the shift is in reverse gear driving force is transmitted to the reverse sun gear because the front clutch is actuated And the low reverse brake is also actuated fastening the planetary gear set carrier This means that the driving force is conveyed from the reverse sun gear clockwise through the long pinion counter clockwise to the annulus gear counterclockwise Since the carrier is fastened at this time the long pinion s shaft is also fixed causing the long pinion to function as an idler gear The counterclockwise rotation and reduction ratio of back gear are obtained in this way p3 AUTOMATIC TRANSAXLE Transaxle Mechanism PARKING MECHANISM Parking Parking sprag Annulu
316. trols the pressure that acts on th t end of he shift control valve 1 land As the 1 tand diameter is larger than that of the 2 land the direction of movement of the shift control valve caused by application of pressure between these lands is to the left If the pressure is also directed to the left end of the 1 land through the No 5b port the pressure acting on its right end is cancelled by this pressure and the shift control valve is forced to the right by the pressure applied to the 2 land AUTOMATIC TRANSAXLE Transaxle Control 45 Gear Transaxle control unit Shift control solenoid valve A E Shift control r solenoid valve Manual valve qm B np Line pressure When the manual valve is shifted to the D 2 or L range position the transaxle control unit acti vates both shift control solenoid valves A and In this situation where both valves are acti yated the line pressure from the manual valve is released and as a Tesult no pressure is directed to the 5a and 5b ports cdi cat 21 65 N D control valve To rear clutch E PRND2L 1750231 Meanwhile the line pressure from the manual valve remains applied between the lands of the shift control valve as mentioned previously pushing the valve to the left against the plug The line pressure is directly applied through the No 5 port of the manual valve to the rear clutch
317. ture sensor Throttie position sensor Engine idie position switch control Fuel pressure From fuel Crank angle sensor unit Tofuel Typ J egulator pump tank Top dead center sensor ignition switch C2 O SZ Nas gt it j 6FU0SES The engine control unit activates the injectors and controls the fuel injection rate in response to the sensor information so that the optimum air fuel ratio can be maintained at all times under ever changing engine operating conditions The fuel injection rate is determined by the injection frequency corres ponding to the engine speed and by the injection duration corresponding to the intake air volume Fuel is injected into each cylinder sequentially and takes place once for each cylinder every two revolutions of the crankshaft The injection duration namely the injector activation time is the basic activation time determined according to the intake air volume of each cylinder with corrections applied according to the intake air temperature engine coolant temperature and other factors 14 34 FUEL SYSTEM Fuel Injection Control Crank angle sensor Oxygen sensor Other sensors Reading of input signal Operation mode decision Operation mode decision data 12 Injector activation time setting Massa activation ig Basic valve opening time data D Injector activation
318. umber of clutch discs 73 Number of clutch plates 2 l Number of reaction plates 1 Number of pressure plates 1 Piston O D mm in 1 D mm in 121 4 76 36 1 42 Rear clutch hub Forward sun gear 1750216 Rear clutch hub Forward sun gear AUTOMATIC TRANSAXLE Transaxle Mechanism 21 27 END CLUTCH tch disc End clutch is of the multiple disc type and is installed at the rear xi end of the input shaft The clutch is actuated in the fourth gear overdrive to transmit the power from the input shaft to the planetary gear carrier Reaction plate E i Actually the end clutch also operates during third gear and this J End clutch is to maintain smooth up shifting to fourth gear a retainer leturn spring Hydraulic SEN pressure Number of clutch discs Number of clutch plates Number of reaction plates Piston O D mm 124 4 88 1 D mm POWER FLOW End clutch End clutch retainer End clutch hub Input shaft End clutch shaft 1750218 Input shaft 21 28 AUTOMATIC TRANSAXLE Transaxle Mechanism KICKDOWN BRAKE Kickdown drum Kickdown band Adjust rod Kickdown piston Kickdown sleeve Kickdown servo switch Lock nut Apply pressure 2nd pressure Release pressure 3rd pressure Anchor 1750219 The kickdown brake is a band type brake it is piston and rod moves t
319. upply Control The engine control unit controls the power sup t the sensors engine control unit and actuato the control relay ignition switch R LOCK sional eFuo1 etc Approximately seven seconds after input of the ignition switch off signal the unit turns off the S switch control relay coil to keep the 5 switch on thus continuing to activate the fuel pump When the crank angle sensor signal fails to be input for 0 6 second or longer due to engine stalling the engine control unit immediately turns the 3 switch off to stop the fuel pump as a safety precaution FUEL SYSTEM Air Conditioner Relay Control AIR CONDITIONER RELAY CONTROL Air conditioner 1640712 control unit gil 14 55 R14KAAA Q Q Ignition switch R ste 1G Air RE Switch ae Dual pressure Switch e OF 4 OFF Coolant OFF 4 Air conditioner temperature a relay switch ON Engine control unit Crank angle sensor When the air conditioner switch ON signal is input the engine control unit turns the air conditioner relay ON to activate the air conditioner compressor In order to prevent vibrations or engine stalling due to activation of the compressor the engine control unit controls the air conditioner relay so that the compressor is activated after a predetermined interval according to the current operating condi tions ignition switch ST Air
320. ure control solenoid valve is deactivated In this state the No 23b line pressure level is equiva lent to that of the No 23 line and therefore the pressure control valve is held pushed all the way to the right allowing the No 5 port line pressure to be applied directly to the kickdown servo through the No 10 port and thus the kickdown brake is applied M PETITE TEE TE ew 21 72 ist Gear Selector Lever in L Reducing 3 via 1 2 shift E 2 valve Fy Line pressure 11 Reducing pressure N R control 23b vaive 16 23b FAL Low reverse brake AUTOMATIC TRANSAXLE Transaxle Control Line pressure 11 3 Transaxle control unit L1 Pressure contro gS valve 23 Ex Pressure control solenoid valve Duty contro 1750090 The low reverse brake has the capacity that the vehicle can be reversed at any point Therefore the low reverse brake operating pressure for the L range is set to a level lower than that for R range This lower pressure is produced by reducing the line pressure from the No 5 port of the pressure control valve by a certain level before being delivered fron the No 10 port to the low reverse brake via the 1 shift valve The method of regulation of pressure from the No port to the No 10 port is the same as that for th Upshift explained on the previous page m AUTOMATIC TRANSAXLE Transaxle Control
321. ut Independent strut 3 Link Torsion axle Double wishbone Disc Disc Disc Disc Rack and pinion Rack and pinion oo co 60 16 4G63 2 0L Turbo In line DOHC 4 85 0 3 35 88 0 3 46 1 997 122 7 8 1 3 4 2 5 speed M T 3 363 1 947 1 285 0 939 5th 0 756 Reverse 3 083 Transfejearatio Final driwearatio 3 941 Type Gear ratio 1st 2nd 3rd 4th 5 speed M T 3 038 1 833 1 217 0 888 0 741 3 166 3 437 4 speed A T 2 846 1 581 1 000 0 686 5 speed A T 3 083 1 684 1 115 0 833 0 666 3 166 1 090 3 866 2 176 3 562 SUSPENSION CONTENTS ANTI DIVE GEOMETRY FRONT AXLE Drive Shaft Hub and Knuckle e GENERAL INFORMATION Construction Diagram Specifications 5 LOWER ARM atas eS 8 NEGATIVE OFFSET GEOMETRY OFFSET SPRING menn 2 STABILIZER qur 2 3 R0O2A 2 2 FRONT SUSPENSION General Information GENERAL INFORMATION ROZBAAB The front suspension has a simple construction the e Excellent braking stability thanks to the McPherson strut type independent suspension negative offset geometry d featuring light unsprung weight e Greatly improved riding comfort thanks to the The front Suspension has the following features offset arrangement of the coil spr
322. ve 8 If the rear clutch completes engagement the duty setting of the pressure control solenoid valve becomes zero percent increasing the pressure to the line pressure level 9 The line pressure thus established in the No 5c line works on the N D control valve to move it towards the right This rightward movement is caused by the difference in area to which pressure is applied between the two lands IO The above movement of the N D control valve opens the No 5 port and through the port the line pressure estab lished in the No 5 line flows into the No 5c line and then is directed to the rear clutch via the rear clutch exhaust valve 21 80 VALVE WITH ORIFICE ear Prid opt capa K When pressure is released is applied Line pressure If the accelerator pedal is depressed immediately after shifting the select lever from N to D the rear clutch engages directly and the vehicle moves in 1st gear Due to the arrangement of the hydraulic circuit in this case the hydraulic pressure is actually directed to both the rear clutch and the low reverse brake thus dividing the quantity of the distributed fluid This in turn can cause a delay in clutch When pressure AUTOMATIC TRANSAXLE Transaxle Control To low reverse brake Valve with Valve with orifice orifice To rear clutch via rear clutch exhaust valve a 1 2 shift valve 17502
323. voltage and time at which the solenoid valve is over excited for ore rapid valve operation while and t repre ent the voltage and the time at which the solenoid valve is maintained in an excited state 21 46 a 5 0 Duty ratio AUTOMATIC TRANSAXLE Transaxle Control Figure Time sec Figure B Time sec Gear Shift Operation 3rd to 4th While the vehicle is being drive in 3rd gear the gear ratio is 1 1 that is the torque converter turbine rotating speed i e the input shaft rotating speed the kickdown drum rotating speed Np and the transfer drive gear rotating speed are all the same Let us explain the 3rd to 4th gear shift at this point as it is easy to understand In Figure A the single horizontal line extending to the point in time c indicates the rotating speeds No Ny and No when driving in 3rd gear It shows that they are all the same in this situation If the vehicle accelerates at point C both Np and begin to decrease The shift from 3rd to 4th as expressed in other terms means that the front clutch and rear clutch are both released and the kickdown brake is applied Here let s discuss the behavior of the kickdown brake whose operation is detectable electrically When the kickdown brake begins to be applied the kickdown drum rotating speed gradually decrease and becomes zero when it is completely tightened The t
324. witch 2 Pressure control solenoid valve Shift control solenoid valve A Ignition pulse signal Diagnosis output Air conditioner relay signal ACCELERATOR SWITCH The accelerator switch is installed on the upper portion of the accelerator pedal The accelerator switch closes its contacts when the accelera tor is totally closed or the accelerator pedal is completely released and sends on ON signal to the transaxle control unit When the accelerator is depressed it send an OFF signal to the transaxle control unit While the switch is kept ON for example when the vehicle is stationary with the accelerator pedal completely released the vehicle remains in 2nd gear but if the accelerator pedal is depressed sending the accelerator switch OFF signal to the transaxle control unit the unit sends a signal to the shift control solenoid valve instructing it to cause a downshift to 1 st thereby producing maximum acceleration When the vehicle is stationary the gear is kept in the 2nd which produces an adequate creeping force and also de creases vibrations 666 PE EEEN at al 21 48 AUTOMATIC TRANSAXLE Transaxle Control PULSE GENERATORS The pulse generators are installed on the top of the transaxle The pulse generator A generates pulses by holes provided on the outer circumference of the kickdown drum The pulse generator B generates pulses by the transfer driven gear according to the number of gear tee
325. wn servo Front clutch Rear clutch release side apply side To end ciutch valve 12 19 2343 f mes E shift valve 9 9c E c tx From N D control valve En SENE renee ee Ba 3 n EET ELLA 1 2 shift TH E EI ee H 16 10 C From pressure control valva Line pressure 1750238 The 2 3 4 3 shift valve operates in response to tine pressure 3rd or 4th pressure from the shift control valve and controls the pressure acting on the front and rear clutches and also the kickdown servo release pressure Upshift from 2nd to 3rd Gear When the 2 3 4 3 shift valve is free from hydraulic pressure the valve is held pushed to the left by the spring force In this situation the No 11 port is closed cutting off the line pressure from the 1 2 shift valve If the 3rd pressure is directed to the 2 3 4 3 shift valve through the 7 line the pressure forces the valve to the right clearing the No 11 port This allows line pressure from the 1 2 shift valve to be directed via the To front clutch and j Rick down SeT VO i 2 3 4 3 shift valve to the front clutch kickdown serv 12 release side 19 release side end clutch valve and rear clutch exhaust 9c 11a 11 3rd pressure 4 Line pressure 1750106 ment AUTOMATIC TRANSAXLE Transaxle Control 21 77 Rear clutch Kickdown 3rd Gear sero release side Front clutch m
326. ws through the down timer circuit of the passing control relay turning ON transistor Tr2 The current from transis tor Tr2 passes through the D contact of the U D switch of the pop up motor to the pop up motor energizing the pop up motor relay When the pop up motor relay is energized the current from fusible link 4 flows through the pop up motor which in turn results in the motor starting rotating As a 1640807 result the headlights start lowering When the crank arm of the pop up motor rotates about 180 to the DOWN stop position the contact of the inter locking U D switch changes from D to U thus cutting off circuit to the pop up relay The de energized pop up motor relay means the current from fusible link amp being cut off Then the pop up motor stops and the headlights remain in the fully lowered position ELECTRICAL Lighting 8 21 2 Lighting switch from ON to OFF pop up switch OFF ignition Fusible switch Fusible ACC link 6 link 4 Multi purpose fuse Tartign relay Dimmer passing switch column switch switch Pop up Crank Greuil ER a DOWN stop position Headlights in the tully4owered position 16A0807 ELECTRICAL Lighting DELAYED SWITCH OFF DOME LIGHT When the door is closed with the dome light switch in the DOOR position and ignition switch in the OFF
327. x the directions of the wave transmission and the vortex air movement are opposite to each other thus the elapsed time required by the ultrasonic waves to reach the receiver becomes longer 3 When a counterclockwise vortex passes under the trans mitter When the vortex passing between the transmitter and_ receiver revolves counterclockwise the direction of ultr sonic wave transmission and that of the air movement the vortex are opposite to each other for its leading half thus the time taken for the ultrasonic waves to reach the receiver is longer than the reference time This time shall be referred to as T5 In the trailing half of the vortex the directions of the two are the same so that the time taken for the ultrasonic waves to reach the receiver becomes shorter than the reference time 4 When clockwise and counterclockwise vortices are passing in an alternate fashion When clockwise and counterclockwise vortices are passing alternately between the transmitter and the receiver the Reference time taken for ultrasonic waves to reach the receiver time T changes as illustrated in the upper diagram at the left 5 Modulator generated signal Each time the point is passed and transmission time converges on the reference time T the modular gener ates one pulse Pulses generated by modulator 6 FUEL SYSTEM Sensors 14 17 When more air is drawn As a result when more air is drawn the modulato
328. y 1 control unit K Oxygen sensor H Throttle position sensor D Vehicle speed sensor reed switch 16A0734 Air ED Air flow sensor 7 incorporated within barometric pressure sensor and intake air temperature sensor angle sensor and top dead center E es Y 8 8 ELECTRICAL Relays Control Units and Sensors Detonation sensor Cylinder block GFUO8S qmi 85 75 85 P E Vehicle speed sensor reed switch MPI control unit MPI controll relay 16A0783 Pro Pr a re SE n MIN c a We Pit altra ELECTRICAL Relays Control Units and Sensors AUTOMATIC TRANSAXLE xontrol unit D PisegeertorB B Automatic transaxle fluid temperature e eser Throttle position sensor MPI control unit MPI control unit iT D J Vehicle speed sensor reed switch E PuseaenertorA B Jo NOTE The Name column is arranged in alphabetical order S ania body Ne A A Throttle pc un 5 Automatic transaxle fluid temperature sensor MPI control 8 10 ELECTRICAL Relays Control Units and Sensors AUT O CRUISE CONTROL SYSTEM Name Symbol Auto cruise control unit B Vehicle speed sensor reed switch 16407354 2 ppm US 65 75 gs SS 65 95 S 2 2 445
329. y 12A0030 2 6 OFFSET SPRING Because struts are installed at an angle the road surface reaction force R applied to the tyres tends to act vertically upon the tyre centre and that force tries to bend the strut toward the inside of the vehicle When this happens the force trying to bend the strut toward the inside of the vetiicle acts upon the strut bearing component as bending moment reaction force Rs because the upper part of the strut is fixed in place thus increasing the friction of the bearing and as a result of the bending of the strut amplifying the moving resistance of the shock absorber Strut bend R1 Road surface reaction force 2 Strut axial reaction force R3 Strut bend direction reaction force Ra Strut bending force by spring offset FRONT SUSPENSION Offset Spring RO2EAAA Then because the coil spring is installed so that itg centre is greatly offset toward the outside of the vehicle from the centre of the strut the counterac tive force for the spring tends to become great toward the outside of the vehicle thus resulting in the generation of bending force opposite to the bending of the strut and thereby decreasing the friction applied to the strut bearing As a result the shock absorber s internal movement friction is reduced thereby improving riding comfort as well as the durability of components 1240547 13 FRONT SUSPENSION Lower Arm Stabilizer 2
330. y valve cause oil passageways R and L to become constricted with the result that for the fluid sent from the oil pump the flow of fluid is stopped from port to port and port When this happens the fluid flows from the oil pump to sleeve a port port b and sleeve b and is sent io the cylinder tube right chamber thus causing the generation of a force to move the rack in the leftward direction thereby assisting the steering effort of the steering wheel At the same time the cylinder tube left chamber fluid flows through sleeve c port c port and chamber A and is returned to the oil reservoir Oil reservoir P4 Oil pump Oil passageway R Oil passageway L Bi Cylinder tube Cylinder tube left chamber right chamber 13 0075 Torsion bar Port b 19 8 WHEN THE STEERING IS AT THE CENTER POSI TION Because the input shaft does not rotate the position is the center neutral position relative to the rotary valve and the fluid supplied from the oil pump flows through sleeve a port a port d Port d To the right cylinder tube To the left cylinder tube Cylinder tube left chamber 13L0072 m 4 Ea uA 4 y A SWAN ley 4 x ff D 44 right chamber POWER STEERING Pinion and Valve Assembly Construction and chamber A returning to the oil reservo
331. ylon bushing Accelerator cable Accelerator cable Accelerator pedal Switch lt gt Accelerator arm 07 P0001 Pedal support member Accelerator arm 4 Accelerator pedai 0340183 FUEL SYSTEM Auto cruise Control System 14 59 AUTO CRUISE CONTROL SYSTEM RMPAAA using the auto cruise control system the vehicle The actuator is the DC motor driven type for a high can be maintained at a constant driving speed degree of adherence to the set speed A flexible between 40 km h 25 mph or higher and 145 km support system is used for installation of the 90 mph or lower as selected by the driver actuator in order to prevent the transaxle of body without using the accelerator pedal vibrations to the actuator CONSTRUCTION DIAGRAM Vehicle speed sensor reed switch Auto cruise control switch 0340269 Accelerator cable B Actuator Inhibitor switch lt A T gt Electronic control unit O3A0160 Accelerator cable A Clutch switch M T Accelerator pedal switch A T Stop light switch 14 60 FUEL SYSTEM SYSTEM BLOCK DIAGRAM Auto cruise Control System ELC 4A T EA Diagnosis connector Accelerator pedal rol switch switch ACCEL switc Cancel switches Stop light switch e Clutch switch lt M T gt e Inhibitor switch lt A T gt Auto cruise t Vehicle speed sensor indicator li

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