Content

Introduction

• How to use this manual
• Identification information
• General repair instructions
• Precautions for vehicles equipped with a catalytic converter
• Vehicle lift and support locations
• Abbreviations used in this manual

Maintenance

• Maintenance schedule
• Maintenance operations
• General maintenance

Engine mechanical

• Troubleshooting
• Idle HC/CO concentration
• Compression check
• Timing belt
• Components
• Cautions
• Inspection and adjustment of valve timing
• Removal of timing belt
• Inspection of components
• Installation of timing belt
• Cylinder head
• Components
• Preparation for removal
• Removal of cylinder head
• Disassembly of cylinder head
• Inspection and cleaning of components
• Assembly of cylinder head
• Inspection of camshaft
• Replacement of camshaft housing oil seal
• Installation of cylinder head
• Cyunder block
• Components
• Removal of engine
• Disassembly of cylinder block
• Inspection of cylinder block
• Disassembly of piston and connecting rod assembly
• Inspection of piston and connecting rod assembly
• Replacement of rod bushing
• Boring of cylinders
• Assembly of piston and connecting rod assembly
• Inspection and repair of crankshaft
• Inspection and repair of oil pump drive shaft components
• Replacement of oil seals
• Assembly of cylinder block
• Installation of engine

Emission control system

• System purpose
• Component layout and schematic drawing
• Positive crankcase ventilation (PCV) system
• Fuel evaporative emission control (EVAP) system
• Dash pot (dp) system
• Exhaust gas recirculation (EGR) system
• Three-way catalyst (TWC) system

EFI system

• System description
• Precautions
• Inspection precautions
• Troubleshooting
• Diagnosis system
• Troubleshooting with volt / ohmmeter
• Troubleshooting for efi electronic
• Circuit with volt / ohmmeter
• Fuel system
• Fuel pump
• Cold start injector
• Pressure regulator
• Injector
• Fuel tank and line
• Air induction system
• Air flow meter
• Idle speed control (ISC) valve
• Throttle body
• Electronic control system
• Location of electronic control parts
• Main relay
• Circuit opening relay
• Solenoid resistor
• Start injector time switch
• Water temp. Sensor
• Oxygen sensor
• Electronic controlled unit (ECU)
• Fuel cut RPM

Cooling system

• Troubleshooting
• Check and replace engine coolant
• Water pump
• Thermostat
• Radiator

Lubrication system

• Troubleshooting
• Oil pressure check
• Replacement of engine oil and oil filter
• Oil pump
• Oil pressure regulator (for lash adjuster valve)

Ignitiom system

• Precautions
• Troubleshooting
• Electronic spark advance (ESA)
• On-vehicle inspection
• Distributor

Starting system

• Troubleshooting
• Starting system circuit
• Starter

Chargimg system

• Precautions
• Troubleshooting
• On-vehicle inspection
• Alternator

Clutch

• Troubleshooting
• Check and adjustment of clutch pedal
• Bleeding of clutch system
• Clutch master cylinder
• Clutch release cylinder
• Clutch unit

Manual transmission

• Troubleshooting
• W58 transmission
• Removal of transmission
• Components
• Disassembly of transmission
• Inspection of transmission components
• Assembly of transmission
• Installation of transmission

Automatic transmission

• Troubleshooting
• Atf inspection
• Adjustments
• Electric control
• Stall test
• Time lag test
• Hydraulic test
• Road test
• Operating mechanism for each gear
• Automatic shift diagram
• On-vehicle repair
• Removal of transmission
• Disassembly of transmission
• Component group disassembly, inspection and assembly
• Oil pump
• Overdrive input shaft and clutch
• Overdrive case and brake
• Front clutch
• Rear clutch
• Center support assembly
• Planetary gear output shaft
• Transmission case and rear brake pistons
• Valve body
• Extension housing
• Torque converter
• Electrical parts
• Assembly of transmission
• Installation of transmission

Proprller shaft

• Precautions
• Troubleshooting
• Propeller shaft

Front axle and suspension

• Troubleshooting
• Front wheel alignment
• Front axle hub
• Front axle shock absorber
• Front suspension
• Ball joints
• Lower arm
• Strut bar
• Stabilizer bar

Rear axle and suspension

• Troubleshooting
• Rear wheel alignment
• IRS type rear axle shaft
• Rear drive shaft
• IRS type differential
• Limited slip differential
• IRS type rear suspension
• Differential support member

Brake system

• Precautions
• Troubleshooting
• Checks and adjustments
• Master cylinder
• Brake booster
• Front brake
• Rear brake
• Brake hoses and tubes

Steering

• Precautions
• Troubleshooting
• On-vehicle inspection
• Steering column assembly with tilt steering
• Power steering
• On-vehicle inspection
• Bleeding of power steering system
• Oil pressure check
• Power steering pump
• Gear housing

Body electrical system

• General information
• Location of switches and relays
• Ignition switch
• Lighting
• Headlight cleaner
• Wipers and washers
• Instruments and sender gauges
• Rear window defogger
• Heater
• Power window
• Door lock control system
• Sun roof
• Cruise control system
• Remote control mirror
• Mirror heater
• Theft deterrent system
• Radio. Stereo tape player and antenna
• Clock
• Trip computer

Body

• Hood
• Front door
• Back door
• Moulding
• Windshield
• Quarter window glass
• Back door glass
• Sun roof
• Safety pad
• Front seat
• Rear seat
• Seat belt
• Body dimensions

Air conditioning system

• Precautions
• Troubleshooting
• Checking of refrigeration system with manifold gauge
• Special tools and test equipment
• Air conditioning system circuit
• On-vehicle inspection
• Refrigeration system
• Checking of refrigerant charge
• Installation of manifold gauge set
• Discharging of refrigeration system
• Evacuating and charging of refrigeration system
• Functional test and adjustment
• Vacuum circuit
• Power servo unit operation
• Automatic temperature control
• Air mix damper linkage
• Sensor circuit
• Double vacuum valve (DVV)
• Water temperature switch
• Condenser motor
• System components
• Compressor
• Condenser
• Receiver
• Cooling unit
• Evaporator
• Refrigerant lines
• Expansion valve
• Vacuum switching valve (VSV)

Service specifications

• Maintenance
• Engine mechanical
• EFI system
• Cooling system
• Lubrication system
• Ignition system
• Starting system
• Charging system
• Clutch
• Manual transmission
• Automatic transmission
• Propeller shaft
• Front axle and suspension
• Rear axle and suspension
• Brake system
• Steering
• Body
• Lubricant

Standard bolt torque specifications

SST and SSM

• SST (special service tools)
• SSM (special service materials)

Automatic transmission hydraulic circuit

Electrical wiring diagrams