Daihatsu 1997 Terios J100 Service Manual

Daihatsu 1997 Terios J100 is a versatile and reliable vehicle that offers a wide range of features to meet your needs. With its rugged design and powerful engine, the Terios J100 is perfect for tackling any terrain. Whether you're exploring the great outdoors or simply commuting to work, the Terios J100 is up to the task. Here are just a few of the features that make the Terios J100 the perfect choice for your next adventure:

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DAIHATSU

J100

SECTION INDEX

SECTION NAME

GENERAL INFORMATION

MAINTENANCE

ENGINE MECHANICAL

EMISSION CONTROL

EFI SYSTEM

LUBRICATION SYSTEM

COOLING SYSTEM

IGNITION SYSTEM

STARTING SYSTEM

CHARGING SYSTEM

CLUTCH

MANUAL TRANSMISSION

AUTOMATIC TRANSMISSION

TRANSMISSION & TRANSFER

PROPELLER SHAFT

FRONT & REAR DIFFERENTIAL

FRONT AXLE & SUSPENSION

REAR AXLE & SUSPENSION

BRAKE (Including A.B.S)

STEERING

BODY

BODY ELECTRICAL

(

Including Airbag system and immobilizer system

)

HARNESS & WIRING DIAGRAM

SECTION

SERVICE MANUAL

DAIHATSU

J100

FOREWORD

This service manual describes the maintenance and servicing procedures for the Model

J100.

Applicable Model: J100

In this service manual, the entire portion is divided into 23 sections. Each section has an index along with a table of contents at the beginning. For easier reference, the upper part of each page bears the section title concerned.

All information used in this service manual was in effect at the time when the manual was printed. However, the specifications and procedures may be revised due to continuing improvements in the design without advance notice and without incurring any obligation to us.

Published in June, 1997

DAIHATSU MOTOR CO., LTD.

NO. 9710-JE

DAIHATSU

J100

GENERAL INFORMATION

IMPORTANT SAFETY NOTICE .................... GI– 2

WARNINGS, CAUTIONS AND NOTES

..... GI– 2

HOW TO USE THIS MANUAL ...................... GI– 4

CONTENTS OF EXPLANATION

.............. GI– 4

ABBREVIATION CODES ............................. GI– 6

GENERAL SERVICE INSTRUCTION .......... GI– 7

HANDLING INSTRUCTIONS ON

CATALYTIC CONVERTER ......................... GI– 8

JACKING POINTS AND SUPPORTING

POINTS OF SAFETY STANDS ................. GI– 9

MODEL VARIATION ..................................... GI–13

CHASSIS SERIAL NUMBER STAMPED

POSITION ..................................................... GI–14

MANUFACTURER’S PLATE POSITION ....... GI–14

CONTENTS OF MANUFACTURER’S

PLATE

....................................................... GI–14

ENGINE NUMBER AND ENGINE TYPE

STAMPED POSITIONS...............................GI–15

BODY COLOR INFORMATION ......................GI–15

COLOR CODE IN THE WORLD

................GI–16

TRIM CODE ....................................................GI–16

JGI00001-00000

NO. 9710-JE

GI–2

IMPORTANT SAFETY NOTICE

The vehicle is a machine comprising a great number of parts. Basically speaking, the vehicle is potentially hazard. However, one can handle it safely if he has the required knowledge.

Correct service methods and repair procedures are very vital for assuring not only the safety and reliability of a vehicle, but also the safety of service personnel concerned.

The methods and procedures contained in this manual describe in a general way the techniques which the manufacturer has recommended. Thus, they will contribute to ensuring the reliability of the products. The contents of the servicing operations come in a wide variety of ways. Moreover, techniques, tools and parts necessary for each operation are different widely from each other.

This manual does not cover all details of techniques, procedures, parts, tools and handling instructions which are necessary for these operations, for such coverage is impossible. Hence, any one who obtains this manual is expected first to make his responsible selection as to techniques, tools and parts which are necessary for servicing the vehicle concerned properly. Furthermore, he must assume responsibility for his actions in connection with his own safety.

Therefore, one should not perform any service if he is not capable of making responsible selection and/or if he can not understand the contents herein described, for this manual has been prepared for experienced service personnel.

WARNINGS, CAUTIONS AND NOTES

All these symbols have their specific purposes, respectively.

WARNING:

•

This symbol means that there is the possibility of personal injury of the operator himself or the nearby workers if the operator fails to follow the operating procedure prescribed in this manual.

CAUTION:

•

This symbol means that there is the possibility of damage to the component being repaired if the operator fails to follow the operating procedure prescribed in this manual.

NOTE:

•

To accomplish the operation in an efficient manner, additional instructions concerning the operation are given in this section.

The following list describes general WARNINGS:

•

Always wear safety glasses for eye protection.

•

Use safety stands whenever a procedure requires you to be under the vehicle.

•

Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure.

•

Set the parking brake when working on the vehicle.

•

Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide.

•

Keep yourself and your clothing away from moving parts, when the engine is running, especially from the fan and belts.

•

To prevent serious burns, avoid contact with hot metal parts, such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler.

•

Do not smoke while working on a vehicle.

•

To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle.

•

Keep hands and other objects clear of the radiator fan blades! The electric cooling fan is mounted on the radiator and can start to operate at anytime by a rise in coolant temperature or turning ON of the air conditioner switch in the case of vehicles equipped with an air conditioner. The electric cooling fan is also mounted on the condenser for air conditioner and starts to operate anytime when the air conditioner switch is turned “ON”. For this reason care should be taken to ensure that the electric cooling fan motor is completely disconnected when working under the hood.

GI–3

The UNITS used in this manual are showed as the SI UNIT (International System of Unit), and alternatively showed in the metric system.

“Example”

24.5 - 34.3 N·m (2.5 - 3.5 kgf-m)

JGI00002-00000

GI–4

HOW TO USE THIS MANUAL

CONTENTS OF EXPLANATION

1. Schematic Diagram of Components

(1) The schematic diagram of components that appears at the beginning of each section describes the nomenclature and installed conditions of each component. Furthermore the tightening torque is posted in the figure.

(2) Those parts whose reuse is not permitted bear a “

★

” mark for an identification purpose. Be certain to replace these parts with new ones during the assembly.

(3) During the assembly, be sure to apply grease to those parts indicated by the mark in the figure.

(Example)

T : Tightening torque

Unit : N·m (kgf-m)

★

: Non-reusable parts

T : 11.80 - 17.7

(1.2 - 1.8) q

Brake master cylinder Ay w

Reservoir tank fill cap e

Reservoir tank cap spacer r

Reservoir tank diaphragm t

Switch operating float y

Master cylinder reservoir tank S/A u

Clamp i

Set bolt o

Gasket

Master cylinder repair kit

JGI00003-00001

2. Servicing Procedure

(1) In principle, the servicing procedure is described in the following sequence given below: Removal

→

Inspection

→

Installation, and Disassembly

→

Inspection

→

Assembly.

(2) The explanation covers detailed servicing methods, specifications and notes.

(3) The main point of each item explains the servicing section and servicing procedure, using illustrations.

(Example)

What to do

How to do it

What to do and where

3. Brake tube installation

(1) Install the brake tube to the wheel cylinder temporarily by hands.

(2) Tighten the brake tube to the wheel cylinder, using the following SST.

SST: 09751-36011-000

09751-36011-000

JGI00004-00002

GI–5

(4) The inspection in this manual describes only checking operation. Therefore, if you find any malfunction, replace any defective parts with new ones.

3. SST

For those operations which require the use of any SST, the SST numbers concerned are given in bold letters.

4. Service Specifications

Service specifications are indicated in bold letters or enclosed by heavy lines. Be certain to confirm the specifications concerned.

5. Tightening Torque

For those operations which require the control of tightening torque, the relevant tightening torque is given in bold letters. Be certain to confirm the tightening torque concerned.

6. Definitions of Terms

Specified Value …… A value which represents the allowable range during the inspection and adjustment.

Limit ………………… A maximum or a minimum limit which the value should not exceed or fall below.

JGI00005-00000

GI–6

ABBREVIATION CODES

The abbreviation codes that appear in this workshop manual stand for the following, respectively.

Abbreviation code

A/C

A/T, AT

A/Y or Ay

API

ECU

EFI

F/L

L.H.D.

Original word Meaning

Air Conditioner

Refers to air conditioner.

Automatic Transmission Refers to automatic transmission

Assembly

Refers to an assembled component comprising more than two single parts or sub-assembly parts.

American Petroleum

Institute

The standards set forth by the American Petroleum Institute (abbreviated as API

Classification) have been employed to evaluate and classify properties of various oils.

Engine oils for gasoline engines are classified as SD, SE, SF and so on, whereas engine oils for diesel engines are classified as CC, CD and so on.

Electronic Control Unit Refers to electronic control unit.

Electronic

Fuel Injection

Fusible Link

Refers to electronic fuel injection.

Refers to fusible link.

Left-Hand Drive Left-hand drive vehicle.

M/T, MT

O/S

R.H.D.

S/A

SAE

SST

STD

U/S

VSV

ETR

Left Hand Refers to left side.

Manual Transmission Refers to manual transmission.

Multipurpose

Oversize

Ply Rating

Means that the following item has multi-purposes.

In instances where fitting becomes too loose due to wear resulting from use for a long period of time or due to frequent removal/installation operations, if the fitting part (e.g. piston) is replaced with a part having larger dimensions, the other mating part may be put into use again. “Oversized” parts denote those parts having larger dimensions compared with the standard parts.

Represents strength of tires.

The larger the ply rating number, the stronger the tire strength.

Right-Hand Drive Right hand drive vehicle

Right Hand

Sub-Assembly

Refers to right side.

Refers to a component comprising more than two single parts which are welded, staked, or studded to each other to form a single component.

Society of Automotive

Engineers

For example, automotive oils are designated as SAE so and so number.

These designation numbers have been set forth by the Society of Automotive Engineers in the

United States of America (SAE). The larger the SAE number, the higher the oil viscosity.

Conversely, the smaller the SAE number, the lower the oil viscosity.

Special Service Tool Refers to a tool designed for a specific purpose.

Standard When referring to automotive parts, “standard” represents those parts which have been installed originally by the manufacturer and which have standard dimensions.

Torque

Under Size

Refers to tightening torque.

In the same manner as with the “oversized” parts, if fitting part (e.g. bush and bearing) is replaced with a part having smaller bore dimensions, the other mating part may be put into use again. “Under sized” parts denote those parts having smaller dimensions compared with standard parts.

Vacuum Switching

Valve

With

Electronic Tuning

Radio

Refers to vacuum switching valve.

Denotes that the following part is attached.

Radio which incorporates variable capacitance, etc. which varies the value according to an applied voltage or current.

JGI00006-00000

The abbreviation codes that appear in the figure stand for the following, respectively.

Bolt

Nut

Screw

Washer

JGI00007-00000

GI–7

GENERAL SERVICE INSTRUCTION

1. Use fender covers, seat covers and floor sheets so that the vehicle may not get dirty or be scratched.

2. Jacking up

(1) When only the front section or rear section of the vehicle is jacked up, be sure to place chocks at the wheels so as to insure safe operations.

(2) When the vehicle has been jacked up, be sure to support the vehicle at the specified section using safety stands. (See page GI–9)

3. Handling instructions related to battery.

(1) Before you start performing the electrical works, make certain to disconnect the battery ground cable terminal from the negative (–) terminal of the battery.

NOTE:

•

Before disconnecting the battery ground cable terminal from the negative (–) terminal of the battery, be sure to read out the diagnosis code of the EFI, Airbag and immobilizer system etc., if the vehicle is equipped with such systems, when necessary.

•

After reconnecting the battery ground cable terminal to the negative terminal of the battery, be sure to reset the watch or radio, if the vehicle is equipped with such equipment.

(2) When it becomes necessary to disconnect the battery power supply for the purpose of carrying out checks or repairs, always disconnect the battery ground cable terminal from the negative terminal of the battery first.

(3) To avoid damaging battery plates, after the terminal nut has been loosened, pull out the battery ground cable terminal straight upward, rather than turning or prying the terminal.

NOTE:

•

Be sure to employ a battery terminal puller (commercially available) to remove the battery ground cable terminal from the negative terminal of the battery, if encountered any difficulty.

(4) Clean the battery terminal posts or battery ground terminals, using a cloth. Never use a file or other adhesive agents.

(5) When connecting the battery ground cable terminal to the battery, first the battery ground cable terminal should be fitted onto the battery post with the attaching nut in a loose state.

Then, tighten the nut. Never tap the terminal onto the battery post, using a hammer or spanner wrench or the like.

(6) As for the cover at the positive (+) terminal side, be sure to install it at the correct position.

4. Repairs of fuel system

(1) The EFI equipped vehicles employ a high fuel pressure. Therefore, the following notes should be observed.

Be sure to prevent the fuel from splashing with a cloth or the like, when the union bolt or other connected section of the fuel line is loosened or slackened.

(2) When connecting/disconnecting the fuel line.

Tighten each connecting section to the specified torque.

Attach new specified clips to each connecting section.

Be certain to place a suitable container or a cloth, etc. under the connected section of the fuel line before disconnecting the fuel line.

Before the fuel line is disconnected, be sure to release the inner pressure of the fuel tank by detaching the fuel filler cap.

Be sure to follow the instruction mentioned in the main text when disconnect or connect the quick type connectors.

(3) Never work near open flames.

5. For increased work efficiency and improved accuracy, be sure to utilize SSTs (Special Service Tools) effectively.

JGI00008-00000

GI–8

HANDLING INSTRUCTIONS ON CATALYTIC CONVERTER

WARNING:

•

When a great amount of unburnt gas is admitted into the catalytic converter, overheating is prone to occur, resulting in a fire hazard.

To avoid such trouble in advance, be certain to observe the following precautions. Also, be sure to explain such precautions to your customers.

1. Use only unleaded gasoline.

2. Avoid idling the engine for a prolonged length of time.

Do not run the engine continuously at idle speed for more than 20 minutes.

WARNING:

•

Immediately check and repair the vehicle if the fast idle speed or idle speed is unstable or the system exhibits malfunction. Failure to observe this warning may result in a fire hazard.

3. Be sure to observe the following points when performing the spark jump tests.

(1) The spark jump test must be limited to cases where such test is absolutely necessary. Also, be sure to finish the test in the shortest possible time.

(2) Be sure to shut off the fuel supply when performing the spark jump test in advance.

4. Do not run the engine when the fuel tank becomes nearly empty.

Failure to observe this caution will cause misfiring. Also, it will apply excessive load to the catalytic converter, even leading to catalyst damage.

5. Do not dispose of the waste catalyst along with parts contaminated with gasoline or oil.

JGI0009-00000

GI–9

JACKING POINTS AND SUPPORTING POINTS OF SAFETY STANDS

CAUTION:

•

Be sure to support the vehicle at the flat surface of the rocker panel.

•

Do not support the vehicle at the edge part rocker panel.

•

Jacking Points

Front side ………… Differential mount bracket

Rear side ………… Rear axle housing

Front side

Rear side

Supporting points

Garage jack

•

Supporting points of safety stands

Four supporting points are located at the right and left sides. (The supporting points have been strengthened by spot-welding reinforcements. Never support the vehicle at points other than the specified points.)

•

Supporting points of tow-post lift

Align the supporting pads of a two-post lift with the supporting points of safety stands, as indicated in the figure above.

•

Supporting points of plate supporting type lift

A vehicle should be placed at the center of the supporting plates of the lift.

When lifting up the vehicle, be sure to support the front section of the vehicle.

JGI00010-00003

GI–10

TOWING INFORMATION

When towing the model J100 follow the manner mentioned below.

CAUTION:

•

Never perform towing, using sling type equipment.

Failure to observe this caution may lead to severe damage on the vehicle body.

JGI00020-00000

Flat bed type

We recommend this as the most desirable method.

CAUTION:

•

Apply the parking brake securely.

•

Be sure to tie-down the vehicle body to the carrier, using a tie-down wires. However, never apply excessive force to each hook on the vehicle body, for vehicle body may be severely damaged.

Wheel lift type

Use a towing dolly when towing the vehicle with the front wheels or rear wheels on ground.

WARNING:

•

Never allow anyone to be in the vehicle being towed.

CAUTION:

•

Be sure to secure the front or rear tires on the towing dolly.

•

Never perform the towing, using sling type equipment.

Failure to observe this caution may severely damage the vehicle body.

Emergency towing

This manner can be employed if the vehicle is equipped with a manual transmission and the road surface is hard and smooth. In this case, be certain to follow the WARNING and

CAUTION mentioned below.

WARNING :

•

The driver in the vehicle to be towed should always keep in mind that braking will require more force than usual when the engine is stopped, because the brake booster is not functioning when the engine is stopped.

JGI00021-00008

JGI00022-00009

JGI00023-00010

GI–11

•

Never tow the vehicle at speed more than 30 km/h.

•

Turn the ignition switch of the vehicle to be towed in the “ACC” position during the towing. Never pull out the key or turn the ignition switch to the “LOCK” position during the towing. Failure to observe this warning will loose controllability, causing an accident.

•

Never tow the vehicle in this manner unless the wheels, axles, drive train, steering, and brakes are in a good condition.

CAUTION:

•

Never tow an automatic transmission vehicle in this manner. Be sure to always use a towing dolly.

•

Always pull the hook in a straight-ahead direction to prevent it from being damaged. Never pull it from side or in a vertical direction. Also, never pull it sharply.

•

Never connect the towing rope, cable or such to the parts other than the hooks provided on the vehicle shell. Connection of the towing rope, cable or such to other pants than hooks may damage these components

•

Ensure that the hooks are installed on the vehicle shell securely before towing.

1. Attach a sturdy rope, towing strap or cable to the towing hook.

2. A driver must ride in the vehicle being towed and control it.

3. Release the parking brake and shift the shift lever of manual transmission to the neutral position.

4. Select the center differential lock switch in the free position.

NOTE:

•

If you cannot start the engine, ensure that the center differential lock mechanism is free by jacking up one of the wheels and making sure that the wheel turns freely.

Even if the indicator lamp in the combination meter shows that the differential lock is free, there is the possibility that it is not free actually.

5. Set the ignition switch to the “ACC” position.

6. Perform the towing.

JGI00024-00000

DIAGNOSIS CONNECTOR

The diagnosis connector is provided under the instrument panel at the driver’s seat side as shown.

Terminal table

Terminal number and name q

IG For DS-21 o

T (ITC) e

ABST r

ECUT i

REV

SIO For DS-21

EFIT

Body ground

1. Be sure to connect the following SST when utilizing this connector, in order to prevent the terminals in the diagnosis connector from being damaged.

The shape of the SST end is the same as the diagnosis connector.

SST: 09991-87401-000

JGI00025-00011

JGI00026-00012

GI–12

2. When measuring the engine tachometer, connect the following SST to the No.8 (REV) terminal of the above SST.

SST: 09991-87402-000

REV

JGI00027-00013

3. Utilize the following SST when connecting the terminals in the SST for the diagnosis connector which is specified in the main text.

SST: 09991-87403-000

CAUTION:

•

Never connect the terminals other than that specified in the main text in each section. Failure to observe this caution may lead to serlus damage or malfunction.

4. Reference

(1) Output of diagnosis code of EFI system.

Connect the 11(EFIT) and 13 (Body ground)

(2) Output of diagnosis code of ABS system.

Connect the 4(ECUT) and 13 (Body ground)

(3) Switching to the test of ABS system.

Connect the 3(ABST) and 13 (Body ground)

(4) Vf output (oxygen sensor function)

Connect the 16(VF) and 13(body ground)

(5) Output of diagnosis code of air bag system.

Connect the 4(ECUT) and 13 (Body ground)

(6) To connect the tachometer

Connect a tachometer to 8(REV) terminal.

(7) Connection of the DS-21

Connect the DS-21 utilizing the following SST. The following SST is provided with the terminal for DS-21.

SST: 09991-87401-000

CAUTION:

•

Never connect the DS-21 in another way than that manner specified.

JGI00028-00014

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

JGI00029-00015

GI–13

MODEL VARIATION

Engine

HC-EJ

Specification

Handle position

Grade

Model code

5MT

4AT

RHD

J100RG

GMDE

GPDE

General

GMXE

GPXE

J100LG

GMDE

GPDE

LHD

GMXE

GPXE

AUS

RHD

J100RG

RHD

J100RG

LHD

J100LG

GMDEQ GMXEQ GMDEW GMXEW GMDEW GMXEW

GPDEQ GPXEQ GPDEW GPXEW GPDEW GPXEW

JGI00011-00000

Explanation of vehicle model code

J1 0 0 L G G M D E W

Model code

J1 : TERIOS

Body type

G : Station

wagon

Number of doors

G : Five Door

Transmission

M : Five-speed Manual Transmission

P : Four-speed Automatic Transmission

Grade of model

D : Low grade

X : High grade

Drive system

0 : Four-Wheel Drive Vehicle (Full-time 4WD)

Engine type

0 : Type HC-EJ engine

Steering position

L : Left-Hand Drive Vehicle

R : Right-Hand Drive Vehicle

Fuel supply

E : EFI-equipped Engine

Destination

Non : General Specifications

W : European Specifications

Q : Australian Specifications

JGI00012-00000

GI–14

CHASSIS SERIAL NUMBER

STAMPED POSITION

The chassis number is stamped on the cowl panel at the right side in the engine compartment.

Serial number

JGI00013-00004

MANUFACTURER’S PLATE POSITION

The manufacturer’s plate is attached on the cowl panel.

Manufacturer’s plate

JGI00014-00005

CONTENTS OF MANUFACTURER’S PLATE

(1) General, Australian, Norwegian and Finnish specifications

q w e r t y

(2)

European Specification (except for Norway and Finland)

i o

Manufacturer’s name, Country w

Vehicle model e

Chassis No.

Engine type t

Engine displacement y

Body colors u

Trim code i

Engine number o

Manufacturer’s name in Japanese

Gross vehicle weight

Gross combination weight

Maximum permissible front axle weight

Maximum permissible rear axle weight

Production month-year (Only for AUS spec.)

Authorized number of W.V.T.A.

(Only for European specification.) w r y

JGI00015-00006

ENGINE NUMBER AND ENGINE TYPE

STAMPED POSITIONS

•

The engine number is stamped on the cylinder block.

•

The engine type is indicated by embossed letters on the cylinder block.

BODY COLOR INFORMATION

Body color name

Silver metallic

Black metallic

Red mica metallic

Turquoise mica metallic

Purplish blue mica

Violet metallic

Two-tone color

Silver metallic / Silver metallic

Two-tone color

Black metallic / Silver metallic

Two-tone color

Red mica metallic / Silver metallic

Two-tone color

Turquoise mica metallic / Silver metallic

Two-tone color

Purplish blue mica / Silver metallic

Two-tone color

Violet metallic / Silver metallic

NF0

ND9

NG1

NG2

Code

S07

6A5

R24

B36

B38

P05

NF7

NF2

GI–15

Serial number stamped position

JGI00016-00007

JGI00017-00000

GI–16

COLOR CODE IN THE WORLD

Silver metallic

Black metallic

Red mica metallic

Turquoise mica metallic

Purplish blue mica

Violet metallic

White

Two-tone color

Silver metallic / Silver metallic

Two-tone color

Color name

Black metallic / Silver metallic

Two-tone color

Red mica metallic / Silver metallic

Two-tone color

Turquoise mica metallic / Silver metallic

Two-tone color

Purplish blue mica / Silver metallic

Two-tone color

Violet metallic / Silver metallic

Two-tone color

White / Silver metallic

DAIHATSU AKZO

S07

6A5

R24

B36

B38

P05

W09

NF7

S07

DAHS07

DAH6A5

DAHR24

DAHB36

DAHB38

DAHP05

DAHW09

DAHS07

NF2

6A5

S07

DAH6A5

DAHS07

NF0

R24

S07

ND9

B36

S07

DAHR24

DAHS07

DAHB36

DAHS07

NG1

B38

S07

DAHB38

DAHS07

NG2

P05

S07

DAHP05

DAHS07

NC1

W09

S07

DAHW09

DAHS07

Color code

DUPONT

G8742

L8842

F2213

L8842

F2855

L8842

F3425

L8842

F3426

L8842

K9344

L8842

G8742

F2213

F2855

F3425

F3426

K9344

L8824

L8842

ICI

A403B

B127B

FCN6B

B127B

HMG7B

B127B

JNE4B

B127B

JNE5B

B127B

XM48

B127B

A403B

FCN6B

HMG7B

JNE4B

JNE5B

XM48

B127B

96326

97076

33273

97076

55174

97076

55603

97076

40868

97076

16461

97076

SPIES

HECKER

97076

96326

33273

55174

55603

40868

16461

97076

STANDOX

6A5

S07

R24

S07

B36

S07

B38

S07

6A5

R24

B36

B38

P05

W09

S07

P05

S07

W09

S07

JGI00018-00000

TRIM CODE

F C S5

Trim color code (Serial c

Serial code

Seat main material

F: Fabric

S: Gray

JGI00019-00000

DAIHATSU

J100

MAINTENANCE

MAINTENANCE REQUIREMENTS ... MA– 2

MAINTENANCE SCHEDULE ............ MA– 3

SCHEDULE FOR SEVERE

DRIVING

..................................... MA– 5

MAINTENANCE OPERATION ........... MA– 6

ENGINE ............................................. MA– 6

COLD ENGINE OPERATION

........ MA– 6

HOT ENGINE OPERATION

.......... MA–13

CHASSIS ........................................... MA–26

BRAKE FLUID

.............................. MA–26

BRAKE PEDAL

............................. MA–27

PARKING BRAKE HANDLE

.......... MA–27

BRAKE HOSE & TUBE

................. MA–28

FRONT BRAKE

............................. MA–29

REAR BRAKE

............................... MA–32

BRAKE BOOSTER HOSE

............. MA–34

BRAKE MASTER CYLINDER

........ MA–35

MUFFLER AND EXHAUST PIPE

... MA–37

AUTOMATIC TRANSMISSION

..... MA–37

CLUTCH

....................................... MA–38

MANUAL TRANSMISSION,

TRANSFER, FRONT AND REAR

DIFFERENTIAL

........................... MA–39

PROPELLER SHAFT

..................... MA–40

DRIVE SHAFT

............................... MA–40

WHEEL HUB NUT

........................ MA–40

WHEEL BEARING

........................ MA–40

STEERING SYSTEM

..................... MA–41

WHEEL ALIGNMENT

.................... MA–42

SHOCK ABSORBER

..................... MA–43

SUSPENSION ARM, CONTROL

ARM & DUST COVER

................. MA–43

JMA00001-00000

NO. 9710-JE

MA–2

MAINTENANCE REQUIREMENTS

The scheduled maintenance service is important to ensure trouble-free, safe and economical driving.

Failure to perform the scheduled maintenance may cause an accident or serious damage.

If you conduct the periodical maintenance, Daihatsu car owners may reduce the chance of accidents or car problems. Furthermore, it becomes possible for you to find at an earlier stage malfunctions which may lead to serious damages. Consequently, potential vehicle damage can be prevented or the degree of the damage can be minimized.

Therefore, all of the persons who are concerned with servicing the Daihatsu vehicles should offer the periodical maintenance service to Daihatsu car owners in order that they may be protected from accidents or unexpected problems.

To prevent malfunctions in advance, however, conducting the periodical maintenance service only is insufficient. It is essential that owners themselves perform maintenance, such as the pre-starting check described in the owner’s manual, so that the vehicle exhibits no abnormal change or phenomenon. Hence, please explain to owners about the necessity of maintenance performed by them. However, malfunction may occur on those vehicles which are always checked by their owners. For instance, if a part instructed to be replaced periodically should be used beyond the replacement intervals and the life of the part has expired, there are cases where malfunction occurs suddenly despite the fact that no malfunction has taken place until yesterday. To prevent such malfunction in advance, be sure to replace parts recommended to be replaced periodically at the specified replacement intervals.

This section describes those items of the scheduled maintenance service recommended by the Daihatsu and their intervals. Be sure to observe the maintenance schedule.

JMA00002-00000

MA–3

MAINTENANCE SCHEDULE

NOTE:

•

Perform the periodical maintenance at the specified mileage or the time whichever comes first, unless otherwise specified.

•

Continue to perform the periodical maintenance after 100,000 km (60,000 miles) at the same intervals as before 100,000 km.

•

If the vehicle should be operated under severe driving conditions, operated occasionally, operated in dusty areas, repeating short trip, operated under extremely cold climate and/or on salted roads, it is necessary to perform some maintenance items more frequently than the regular maintenance schedule.

•

This maintenance schedule prepared based on requirements mentioned in the owner’s manual which are to be performed by the Daihatsu owner thoroughly.

Section

Engine

Air cleaner element

Valve clearance

Engine oil & oil filter

Fuel filter

Fuel line & connections

(Including fuel hoses)

Coolant (Long-life coolant)

Drive belt

(Alternator, water pump, power steering)

Timing belt

Item What to do Inspection interval

™

···Check or inspect.

···Change or replace.

1000 km 1 10 20 30 40 50 60 70 80 90 100

1000 miles 0.6 6 12 18 24 30 36 42 48 54 60

See page

Years — 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5

Cleaning

Check

•

Damage

Check & adjustment

Change (Use API: SG or higher grade)

Change

Check

•

Crack

•

Tightness

•

Leakage

•

Damage

Change

Check

•

Tension

•

Crack

•

Damage

™

Every 12,000 km

Every 100,000 km

Every 40,000 km

Every two years

™

MA–6

MA–18

MA–13

MA–9

MA–8

MA–23

MA–6

Change Every 100,000 km

Refer to EM section.

Exhaust emission control system

Spark plug

Ignition timing

Cleaning & check

•

Condition

•

Gap

•

Damage

Check & adjustment

Blow-by gas recirculation hose (Positive crankcase ventilation hose)

Check

•

Connection

•

Damage

Charcoal canister

Check

•

Function

•

Damage

Evaporative emission hoses Change

Exhaust pipe & muffler mounting

Check

•

Tightness

•

Damage

* Replace every 10,000 km when API SF grade oil is used.

™

Every eight years

™

MA–14

MA–21

MA–7

MA–11

MA–12

MA–37

MA–4

Section

Power train system

Clutch

Item

Manual transmission

Automatic transmission

Oil cooler hose

Transfer

Differential (Front & Rear)

Propeller shaft

Drive shaft boot

Suspension system

Shock absorber

Suspension arm (Front)

Control arm (Rear)

Dust boots

Running system

Wheel bearing

Steering linkage, gear box

Steering system

Wheel alignment

Fluid hose

What to do Inspection interval

™

···Check or inspect.

···Change or replace.

1000 km 1 10 20 30 40 50 60 70 80 90 100

1000 miles 0.6 6 12 18 24 30 36 42 48 54 60

See page

Years — 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5

Check

•

Free travel

•

Reserve travel

•

Damage

Change

•

Oil

Change

•

Fluid

Check

•

Crack, scratch, cut, twist and swelling

Change

•

Oil

Change

•

Oil

Check

•

Tightness

•

Rattle

•

Damage

Check

•

Damage

Check

•

Function

•

Oil leakage (Shock absorber)

•

Damage

Check

•

Tightness

•

Damage

Check

•

Tightness

•

Damage

Check

•

Free play (Steering wheel)

•

Tightness

•

Rattle

•

Damage

Check

•

Toe-in

Check

•

Crack, scratch, cut, twist and swelling

™

Every 80,000 km

Every 40,000 km

™

Every 4 years

™

MA–38

MA–39

MA–37

MA–38

MA–39

MA–40

MA–43

MA–40

MA–41

MA–42

MA–5

Section Item What to do Inspection interval

™

···Check or inspect.

···Change or replace.

1000 km 1 10 20 30 40 50 60 70

1000 miles

80 90 100

0.6 6 12 18 24 30 36 42 48 54 60

See page

Years — 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5

Brake system

Chassis & body

Brake pedal & Parking brake

Disc pad

Brake hose, tube and P & B valve

Brake fluid

Brake lining

Brake booster vacuum hose

Master & wheel cylinder

Wheel hub nut, other bolts & nuts

Check

•

Free play (Brake pedal)

•

Reserve travel (Brake pedal)

•

Working travel (Parking brake)

Check

•

Wear

•

Damage

Check

•

Leakage (Fluid level, connection)

•

Loose clamp

•

Damage

Change

Check

•

Wear

•

Damage

Check

•

Leakage

Check

•

Tightness

™

Every 2 years

™

Every 4 years

Every 2 years

™

MA–27

MA–29

MA–28

MA–26

MA–32

MA–34

MA–35

™

MA–40

JMA00003-00000

SCHEDULE FOR SEVERE DRIVING

Section

Engine

Item

Engine oil & oil filter

Air cleaner element

What to do Inspection interval

™

···Check or inspect.

···Change or replace.

1000 km 1 10 20 30 40 50 60 70 80 90 100

1000 miles 0.6 6 12 18 24 30 36 42 48 54 60

See page

Years — 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5

Every 5,000 km MA–13

Check and cleaning: Every 5,000 km

Replacement: Every 20,000 km

MA–6

Exhaust emission control system

Exhaust pipe and mounting

Manual transmission

Power train system

Steering system

Brake system

Automatic transmission

Transfer

Differential (Front & Rear)

Steering linkage

Disc & disc pad

Brake drum & lining

Change

Check & cleaning

•

Damage

Change

Check

•

Tightness

•

Damage

Change

•

Fluid

Change

•

Fluid

Change

•

Fluid

Change

•

Fluid

Check

•

Tightness

•

Damage

Check

•

Wear

•

Damage

Check

•

Wear

•

Damage

™

™ ™ ™ ™ ™

Every 25,000 km

Every 50,000 km

Every 25,000 km

™ ™ ™ ™ ™

™ ™ ™ ™

MA–37

MA–39

MA–37

MA–39

MA–41

MA–29

MA–32

JMA00004-00000

MA–6

MAINTENANCE OPERATION

ENGINE

COLD ENGINE OPERATION

1. Inspection of drive belt

(1) Visual inspection of drive belt

Visually check the belt for separation of the adhesive rubber above and below the core, core separation from the belt side, severed core, separation of the rib from the adhesive rubber, cracks or separation of the ribs, torn or worn ribs or cracks in the inner ridges of the ribs. Replace the drive belt, if necessary.

(2) Inspection of drive belt tension

Measure the amount of the drive belt deflection when the midpoint of the drive belt between the alternator and the water pump pulley or between the crankshaft pulley and vane pump pulley is pushed with a force of

98 N (10 kgf).

Specified Belt Deflection

New Belt: Alternator and water pump 4 - 5 mm

Vane pump(Power steering) 8 - 11 mm

Used Belt: Alternator and water pump 5 - 6 mm

Vane pump(Power steering) 11 - 14 mm

If necessary, adjust the drive belt tension.

(Refer to the EM or SR section.)

Vane pump pulley

When without air conditioner

JMA00005-00001

: Measuring section for tension and deflection

Idle pulley

With air conditioner

Idle pulley

Crank shaft pulley

JMA00006-00002

2. Inspection of air filter element

(1) Removal of air filter element q

Unlock the four clips.

Gradually open the air filter case cover.

CAUTION:

Do not open the air filter case cover beyond what is necessary to remove the air filter element. Failure to observe this caution may lead to disconnection of the rubber hoses.

Take out the air filter element from the air filter case.

(2) Replacement of air filter element

Replace the air filter element with a new one when the replacement time arrives.

(3) Inspection of air filter element

Visually inspect the air filter element for being excessively dirty, damage or oily.

Replace the air filter element, if necessary.

JMA00007-00003

(4) Cleaning of air filter element

Clean the air filter element with compressed air.

First, blow compressed air from the back side of the element thoroughly. Then, blow off the upper side of the element.

WARNING:

Protect your eyes with safety goggles during the cleaning operation.

CAUTION:

The air pressure to be used for this cleaning operation should not exceed 392.3 kPa (4.0 kgf/cm

Replace the air filter element, if the element is excessively dirty.

(5) Installation of air filter element q

Install the air filter element in the air filter case cover.

NOTE:

Ensure that the air filter element faces in such a direction that the wider protrusion side comes to the air filter case cover side.

Close the air filter case cover.

Latch the four clips properly.

3. Inspection of blow-by gas recirculation device

(1) Visually inspect the hoses for improper connections, cracks, leak and damage.

NOTE:

Replace parts which exhibit damage as necessary.

(2) Remove the oil filler cap.

(3) Disconnect the blow-by gas hose from the throttle body.

(4) Ensure that no resistance exists when you blow your breath to the disconnected hose end (which was connected to the throttle body).

If resistance is felt or no air continuity exists, check blow-by gas hose and the cylinder head cover.

(5) Connect the blow-by gas hose to the throttle body.

(6) Install the oil filler cap securely.

(7) Disconnect the PCV hose which is connected to the throttle body at the throttle body side.

(8) Ensure that heavy resistance exists when you blow your breath from the disconnected hose end.

If no continuity exists or no resistance for air continuity exists, replace or repair the cylinder head cover.

(Refer to the EM section for the cylinder head cover replacement.)

NOTE:

The orifice is built in the cylinder head cover. This procedure is required for ensuring the orifice function in the cylinder head. If this orifice is plugged, correct engine idle speed will not be obtained.

(9) Connect the PCV hose to the throttle body properly.

MA–7

JMA00008-00004

JMA00009-00005

JMA00010-00006

JMA00011-00007

MA–8

4. Inspection of fuel line and connection

(1) Visually inspect the fuel line including the fuel hose for connecting condition, cracks, tightness, leakage and damage.

If cracks or any other damage exists, repair or replace the part as required.

(2) Check the connecting section of the fuel line for looseness and leakage.

If looseness or leakage exists on the connected sections of the fuel line, repair or replace the parts as required.

(3) Ensure that the ignition switch is turned OFF.

(4) Open the relay box cover in the engine compartment.

(5) Remove the fuel pump relay from the relay box.

CAUTION:

Prevent dust or water, etc. from entering the connector.

Entering of dust, water or contamination of the terminals in the fuel pump relay connector may cause fuel pump malfunction or other serious malfunctions, due to lowered insulation of each terminal.

(6) Connect the No. 1 and No. 2 terminals of the fuel pump relay in the relay box with suitable wires or the like as shown.

CAUTION:

Never deform or damage the terminals during the connection.

Never make connection on a terminal except for those specified.

Even slight contact of the other terminal causes serious trouble.

Prevent dust or water, etc. from entering the relay box.

Entering of dust, water or contamination of the terminals in the relay box causes serious malfunction, due to lowered insulation of each terminal.

(7) Turn ON the ignition switch.

(8) Ensure that no fuel leakage exists on the fuel line.

If fuel leakage exists, repair or replace the part as required.

(9) Turn OFF the ignition switch.

q w e r

JMA00012-00008

JMA00013-00009

MA–9

(10) Remove the wire from the fuel pump relay terminal in the relay box.

CAUTION:

Never deform or damage the terminals during operation.

Never make connection between terminals except for those specified.

Even slight contact of the other terminal causes serious trouble.

Prevent dust or water, etc. from entering the relay box.

Entering of dust, water or contamination of the terminals in the relay box causes serious malfunction, due to lowered insulation of each terminal.

(11) Install the fuel pump relay into the relay box.

(12) Close the relay box cover.

Fuel pump relay

5. Replacement of fuel filter

WARNING:

Never smoke or work near open flame.

Failure to observe this warning will cause fire.

Removal

(1) Ensure that the ignition switch is turned OFF.

(2) Open the fuel filler cap to release the inner pressure of the fuel tank.

(3) Remove the fuel pump relay from the relay box in the engine compartment. (See illustration above.)

CAUTION:

Never make connection on a terminal except for those specified.

Even slight contact of the other terminal causes serious trouble.

Prevent dust or water, etc. from entering the relay box.

Entering of dust, water or contamination of the terminals in the relay box causes serious malfunction, due to lowered insulation of each terminal.

JMA00014-00010

JMA00015-00011

JMA00016-00000

MA–10

(4) Start the engine and wait for a little while until the engine stops.

(5) Turn off the ignition switch.

(6) Jack-up the vehicle and support it with safety stands.

(Refer to the GI section.)

(7) Detach the fuel hose clips.

WARNING:

Never reuse the used hose clips. Failure to observe this warning may lead to fire.

(8) Disconnect the fuel hoses from the fuel filter and plug the disconnected hoses and fuel pipes of the fuel filter with a suitable plug or the like.

CAUTION:

Quite a large amount of fuel will flow out during fuel hose disconnection. Therefore, be sure to plug the disconnected hose and pipes properly.

(9) Remove the fuel filter from the fuel filter clamp.

Installation

(1) Install the fuel filter to the fuel filter clamp as shown.

CAUTION:

Be sure to install the fuel filter in such direction that the

“IN” mark of fuel filter faces to fuel pump side and

“OUT” mark faces to fuel pump side.

Failure to observe this caution may lead to fuel filter malfunction.

(2) Insert new hose clips to the fuel hoses.

(3) Connect the fuel hoses to the fuel filter until the fuel hose end comes in contact with the fuel filter body .

(4) Place the new fuel hose clips at each point between the pipe end and the spool. Then remove the clip holder to secure the fuel hoses.

CAUTION :

Never reuse the used hose clips.

(5) Install the fuel filler cap.

(6) Checking of fuel leakage

Perform the inspection described in the “Inspection of fuel line and connection”.

6. Inspection of charcoal canister

(1) Removal of charcoal canister q

Detach the hose bands from the hoses connected to the charcoal canister.

CAUTION:

Never reuse the removed hose bands.

Disconnect the rubber hoses from the upper side of the charcoal canister.

NOTE:

Prior to the disconnection of the rubber hoses, put a tag on each of the rubber hoses so that they may be reconnected correctly to the original position.

JMA00017-00012

Engine side

Fuel pump side

JMA00018-00013

Charcoal canister

JMA00019-00014

MA–11

Remove the engine undercover by removing the six attaching bolts.

JMA00020-00015 r

Disconnect the atmosphere side hose from the frame.

Remove the charcoal canister from the vehicle by pulling up the charcoal canister case to unlock it from the bracket.

Remove the atmosphere side hose from the charcoal canister.

(2) Inspection of charcoal canister q

Visually inspect the charcoal canister case for cracks or damage. If any damage is found, replace the charcoal canister with a new one.

Check the charcoal canister for air leakage. Ensure that no air leakage exceeding 0.3 ml/min is present when applying compressed air of 29.4 kPa

(0.3 kgf/cm

) into the fuel tank side pipe

B with the throttle body side

A and atmosphere side

C pipes plugged.

If air leakage exceeding the above-specified value is present, replace the charcoal canister with a new one.

Ensure that no air continuity exists when you blow into the purge side A pipe of the charcoal canister.

If air continuity exists, replace the charcoal canister with a new one.

Check of charcoal canister for restriction a. Ensure that air continuity exists to the atmosphere side

C pipe, when you blow into the fuel tank side pipe

B while the purge side

A pipe is plugged.

If no air continuity exists, replace the charcoal canister with a new one.

b. Ensure that air continuity exists when applying a negative pressure to the purge side pipe

A by a MityVac.

If no air continuity exists, replace the charcoal canister with a new one.

Throttle body

JMA00021-00016

Fuel tank

Atmosphere

JMA00022-00017

MA–12

Cleaning of charcoal canister

Clean the charcoal canister by blowing compressed air of 294.2kPa (3.0 kg/cm

) into the fuel tank side pipe

B while holding the purge side of the canister pipes

A closed.

CAUTION:

Never attempt to wash the charcoal canister.

No activated carbon should come out during the test.

If activated carbon comes out, replace the charcoal canister.

(3) Installation of charcoal canister

The installation procedure is basically reverse to the removed procedure. Therefore, no illustration is given in this installation procedure.

Install the charcoal canister to the charcoal canister holder and lock it securely.

Connect the atmosphere side hose to the charcoal canister.

Install the engine undercover with the six attaching bolts and tighten them securely.

Connect the rubber hoses and attach new hose bands.

CAUTION:

Never reuse the removed hose band.

7. Replacement of evaporative emission control hose

Replace the fuel evaporative emission control hoses with new ones when the replacement interval arrives.

WARNING :

Replace the hose bands and clips with new ones.

Never reuse the removed hose bands and clips.

JMA00023-00000

JMA00024-00018

JMA00025-00019

JMA00026-00020

JMA00027-00021

HOT ENGINE OPERATION

1. Change of engine oil and oil filter

WARNING:

Protect your eyes by wearing safety goggles.

Never burn yourself with hot engine oil or hot engine components during operation.

(1) Park the vehicle on a level surface.

(2) Check the oil level.

(3) Start the engine.

(4) Warm-up the engine to normal operating temperature.

(5) Place a suitable container under the oil drain plug.

(6) Remove the drain plug and gasket. Then, drain the engine oil into the placed container completely.

(7) Remove the oil filler cap.

(8) Place a suitable container or such to under the oil filter.

(9) Slacken the oil filter with an oil filter wrench.

CAUTION:

Care must be exercised, for quite a large amount of engine oil may flow out.

(10) Remove the oil filter by hand.

(11) Wipe off the engine oil from the oil filter attaching part of the engine oil filter bracket.

(12) Thinly apply engine oil to the O-ring of a new oil filter.

(13) Screw in the oil filter by hand, until the O-ring of the oil filter comes in contact with the oil filter installing surface of the oil filter bracket.

(14) Tighten the oil filter three fourths to one complete turn, by hand or using the following SST.

SST: 09228-87201-000

CAUTION:

Never tighten the oil filter excessively. Failure to observe this caution will cause oil leakage or damage to the oil pump, or the oil filter.

(15) Tighten the drain plug to the specified tightening torque with a new gasket interposed.

Tightening Torque: 19.6 - 29.4 N·m (2.0 - 3.0 kgf-m)

(16) Pour engine oil to the engine.

CAUTION:

Use API grade SG or higher grade oil.

Oil Capacity

With Oil Filter: 3.6 liters

Without Oil Filter: 3.4 liters

MA–13

JMA00028-00022

JMA00029-00023

JMA00030-00000

JMA00031-00024

MA–14

(17) Pull out the oil level gauge and wipe off the engine oil.

(18) Reinsert the oil level gauge as far as it will go.

(19) Pull out the oil level gauge again.

(20) Ensure that the engine oil level is between the “L” and

“F” levels on the oil level gauge.

If the engine oil level is below the “L” level, replenish the specified engine oil to the “F” level.

(21) Close the oil filler cap.

WARNING:

Securely close the oil filler cap to the cylinder head cover. Failure to observe this warning will cause engine seizure and fire.

TEMP.

Engine oil

(4 stroke)

˚C

˚F

–29

–20

–18

–7

*10W-30, 10W-40, 10W-50

100

20W-40, 20W-50

5W-30

JMA00032-00025

Low level Full level

(22) Start the engine.

(23) Warm up the engine to normal operating temperature.

(24) Stop the engine.

(25) After a few minutes, slowly pull out the oil level gauge and wipe off the engine oil.

(26) Reinsert the oil level gauge as far as it will go.

(27) Pull out the oil level gauge again and check to see if the oil level is between “F” and “L” levels.

If the engine oil level is low, replenish the specified engine oil to the “F” level of the oil level gauge.

(28) Reinsert the oil level gauge as far as it will go.

2. Inspection of spark plug

Inspection of electrode

When a megger is available:

(1) Removal of air cleaner q

Disconnect the hoses connected to the air cleaner case cover.

NOTE:

Prior to the disconnection of the rubber hose, put a tag on each of the rubber hoses so that it may be reconnected correctly to the original position.

Displace the hose band of the air duct connected to the throttle body.

Unlock the four clips of the air cleaner case cover.

Remove the air cleaner element.

Remove the air cleaner case by removing the three attaching bolts.

JMA00000-00026

JMA00034-00000

JMA00035-00027

JMA00036-00028

(2) Removal of resistive cords and ignition coils q

Disconnect the resistive cord from the ignition coil.

Remove the No. 1 and No. 3 resistive cords by disconnecting the connectors from the ignition coils and spark plugs.

CAUTION:

Never disconnect the resistive cords by holding the cord section of the resistive cords.

Disconnect the connectors from the ignition coils.

Remove the ignition coils on the spark plugs of

No. 2 and No. 4 cylinders by removing the attaching nuts.

(3) Measurement of insulation resistance

Measure the insulation resistance of each spark plug, using a megger (Insulation resistance meter) and ensure that the measured insulation resistance of each spark plug is more than the specified value.

Minimum Insulation Resistance: 20 M

If the measured insulation resistance is less than

15 M

W proceed to the step (4) onward.

If the measured insulation resistance is more than the specified value, proceed to the step (4) onward except the step (8).

When a megger is not available: q

Start the engine. Warm up the engine completely.

Race the engine at 4000 rpm for five seconds.

Stop the engine.

Remove the air cleaner.(Refer to the removal of the air cleaner.) t

Remove the resistive cords and ignition coils.

(Refer to the check and adjustment of the valve clearance section for the removal of the ignition coil and resistive cord.) y

Remove the spark plug, using a suitable spark plug wrench or the following SST.

SST: 09268-87703-000

WARNING:

Be very careful not to get scalded with hot spark plugs, since spark plugs are hot.

Visually inspect the spark plug.

If the electrode is dry: Proceed to the step (6)

(Satisfactory)

If the electrode is wet: Proceed to the step (5).

MA–15

DAIHATSU

16VALVE

JMA00037-00029

JMA00038-00030

JMA00039-00031

MA–16

(4) Removal of spark plug

(Refer to the step (3)–6 above.)

(5) Visual inspection of spark plug

Visually inspect the spark plug for electrode wear, damage in threads or insulation.

Replace the spark plug if it exhibits any damage.

Recommended Spark Plug:

DENSO

K20TNR-S

K22TNR-S

NGK

BKUR6EK

BKUR7EK

CAUTION:

All four spark plugs used for one engine should have the same heat range and be ones manufactured by the same manufacturer.

Follow the information label in the engine compartment for selecting the spark plugs. Failure to observe this caution may cause problems.

(6) Inspection of electrode gap

Measure the electrode gap, using a plug gap gauge.

Electrode Gap: 0.9 - 1.0 mm

If the electrode gap of a used spark plug is not within the specification, replace the spark plug with a new one.

If the electrode gap of a new spark plug is not within the specification, adjust the gap by bending the base of the ground electrode, being careful not to touch the tip.

(7) Cleaning of spark plug

If the electrode has traces of wet carbon, dry the electrode and clean it with a spark plug cleaner.

Air Pressure: Not to exceed 588.4 kPa (6 kgf/cm

)

Duration of Cleaning: Not more than 20 seconds.

NOTE:

If there is trace of oil, remove it with gasoline before the spark plug is cleaned by the spark plug cleaner.

(8) Inspection of spark plug insulation resistance

Ensure that the insulation resistance of the spark plug is more than the specified value.

Minimum Insulation Resistance: More than 20 M

If the insulation resistance is less than the specified value, replace the spark plug with a new one.

CAUTION:

All four spark plugs used for one engine should have the same heat range and be ones manufactured by the same manufacturer.

Spark plug gap

JMA00040-00000

JMA00041-00032

JMA00042-00033

JMA00043-00034

MA–17

(9) Installation of spark plug

Install the spark plugs. Tighten them to the specified tightening torque, using a suitable spark plug wrench or the following SST.

SST: 09268-87703-000

Tightening Torque: 14.7 - 21.6 N·m (1.5 - 2.2 kgf-m)

NOTE:

Since the insulator strength of a small spark plug is comparatively smaller than that of a regular spark plug, when tightening, be sure to use the tool exclusively used for this application. Also, when tightening, never use the wrench in a crooked way.

(10) Installation of ignition coils

Install the ignition coil on the No. 2 and No. 4 spark plugs with the attaching nuts and tighten the nuts to the specified tightening torque.

Tightening Torque: 8.5 N·m ( 0.85 kgf-m)

CAUTION:

Never damage the boot section of the ignition coils by interfering with the cylinder head cover.

(11) Connect the ignition coil connectors to the ignition coils properly.

(12) Connect the resistive cords to the spark plugs and ignition coils properly as shown in the figure.

NOTE:

Never interfere the resistive cord with the ignition coils and attaching nuts of the ignition coils.

Never bend or twist the resistive cord beyond what is necessary.

(13) Clamp the resistive cord to a clamp provided on the ignition coil as shown.

(14) Installation of air cleaner q

Install the air cleaner case to the cylinder head cover and throttle body with the three attaching bolts and tighten the attaching bolts properly.

Attach the hose band of the air cleaner duct which is connected to the throttle body.

Install the air cleaner element on the air cleaner case.

Install the air cleaner case cover and secure the four clips.

Connect the rubber hoses to the air cleaner case cover.

JMA00044-00035

DAIHATSU

16VALVE

JMA00045-00036

JMA00046-00037

MA–18

3. Inspection and adjustment of valve clearance

The measurement and adjustment of the valve clearance are carried out when each piston of the No. 1 and No. 4 cylinders is set to the top dead center at the end of compression stroke.

WARNING:

Never burn yourself with hot engine components,etc.

during operation.

CAUTION:

The valve clearance adjustment is performed normally when the engine is in a hot condition.

“HOT engine condition” denotes a condition in which the cooling water temperature is 75 - 85

C and the engine oil temperature is above 65

However, when the engine has been overhauled, it is necessary to adjust the valve clearances while the engine is cold and to readjust the valve clearance in a hot condition after warming up the engine.

(1) Warm up the engine thoroughly. (Only when necessary.)

(2) Remove the air cleaner.

(Refer to the Inspection of spark plug section for removal.)

(3) Remove the resistive cords and ignition coils.

(Refer to the removal of resistive cords and ignition coil in the inspection of the spark plug section.)

(4) Disconnect the PCV hoses(blow-by gas hose) from the cylinder head cover.

(5) Remove the bolt attaching the timing belt cover to the cylinder head cover.

(6) Loosen the eight attaching bolts (6 mm) shown in the figure over two or three stages in the sequence in the right figure.

(7) Remove the cylinder head cover by removing the attaching bolts.

CAUTION:

Never damage the spark plug grommets of the spark plug tubes and cylinder head cover gasket during the removal of the cylinder head cover.

(8) Inspection and adjustment of valve clearances

CAUTION:

Before the adjusting screw is tightened with lock nuts, apply engine oil to between the lock nut and the valve rocker arm.

Remove the engine undercover by removing the six attaching bolts.

Turn the crankshaft until the recessed mark on the crankshaft pulley is aligned with the indicator mark on the timing belt cover.

w u t e

JMA00047-00038 r y i q

JMA00048-00039

Indicator

JMA00049-00040

Timing mark

JMA00050-00041

MA–19

Check to see if the valve rocker arms of the No. 1 cylinder are free or are being pushed. According to the table below, check and adjust the valve clearance, using a thickness gauge.

Pistion position

When valve rocker arms of No. 1 cylinder are free:

(Piston of No. 1 cylinder is at top dead center under compression stroke)

When valve rocker arms of No. 4 cylinder are free:

(Piston of No. 4 cylinder is at top dead center under compression stroke)

Inkate

Exhaust

Inkate

Exhaust

NOTE:

The “O” mark denotes those valves that can be adjusted under that setting.

Valve Clearance (HOT)

Intake: 0.25

0.05 mm

Exhaust: 0.33

0.05 mm

(Reference)

Valve Clearance (COLD)

Intake: 0.18 mm

Exhaust: 0.25 mm

Tightening Torque (Lock nut): 16.7 - 22.6 N·m (1.7 - 2.3 kgf-m) r

Turn the crankshaft 360 degrees (one turn).

Proceed to check and adjust the remaining valve clearances.

(8) Installation of cylinder head cover q

Wipe off the oil from the gasket attaching surface of the cylinder head.

Check the cylinder head cover gasket for evidence of damage.

Replace the gasket, as required.

CAUTION:

Install the cylinder head gasket in such a direction that the identification mark may come at the intake side.

Check the rubber grommets of the spark plug tubes for evidence of damage.

Replace the rubber grommet, as required.

(For replacement of the rubber grommet, refer to the EM section of the service manual.) r

Install the cylinder head cover gasket on the cylinder head.

NOTE:

Install the cylinder head cover gasket in such a direction that the identification mark may come at the intake side.

JMA00051-00042

3 4

JMA00052-00000

JMA00053-00043

MA–20

Apply the Three Bond

1104 to the four points on the cylinder head, as indicated in the figure.

JMA00054-00044 y

Install the cylinder head cover on the cylinder head.

NOTE:

•

Never damage the rubber grommets for the spark plug tubes during the installation of the cylinder head cover.

•

Make sure that the rubber grommet is fitted over the spark plug tube properly.

Install the attaching bolts of the cylinder head cover and tighten them to the specified tightening torque over two or three stages in the sequence shown in the right figure.

Tightening Torque: 2.9 - 4.9 N·m (0.3 - 0.5 kgf-m) i

Install the timing belt attaching bolts with wire clamp and tighten them to the specified tightening torque.

Tightening Torque: 2.0 - 3.9 N·m (0.2 - 0.4 kgf-m) o

Connect the PCV hoses(blow-by gas hose) to the cylinder head cover.

Install the ignition coils and resistive cords to the spark plugs and ignition coils.

(Refer to installation procedure described in the inspection of spark plug section.)

Install the air cleaner assembly.

(Refer to installation procedure described in the inspection of spark plug section.)

4. Inspection and adjustment of ignition timing

(1) Start the engine.

(2) Warm up the engine.

(3) Stop the engine.

(4) Connection of tachometer q

Connect the following SST to the diagnosis connector.

SST: 09991-87401-000 w

Connect the tachometer to the REV ( i

) terminal of the SST, in combination with the following SST.

SST: 09991-87402-000 w u t e

JMA00055-00045 r y i q

JMA00056-00046

REV

JMA00057-00047

MA–21

CAUTION:

•

Never allow the tachometer terminal to touch ground. It could result in damage of the ignition system.

•

As some tachometer are not compatible with this ignition system, it is recommended to confirm the compatibility with your unit before its use.

•

Care must be exercised to ensure that no connection is made on terminals except for those specified.

Even slight contact of the other terminal causes serious malfunction.

(5) Connect a timing light to the resistive cord of the No. 1 cylinder (at the timing belt side)

(6) Connect the T (

) terminal and E (

) terminal in the

SST which was connected, using the following SST.

SST: 09991-87403-000

CAUTION:

•

Care must be exercised to ensure that no connection is made on terminals other than that specified.

Even slight contact of the other terminal causes serious malfunction.

(7) Start the engine.

(8) Ensure that the engine revolution speed is stable.

If the engine revolution speed becomes unstable, proceed to check ISC system.

(Refer to the EM section.)

(9) Check to see if the ignition timing mark of the crankshaft pulley is aligned with the indicator provided on the timing belt cover, using a timing light.

If the ignition timing mark on the crankshaft pulley is not aligned with the indicator provided on the timing belt cover, adjust the ignition timing by turning the cam angle sensor attaching position.

TDC 0

BTDC 2

JMA00058-00000

T E

JMA00059-00048

ATDC 2

JMA00060-00049

(10) Adjustment of ignition timing q

Loosen the cam angle sensor attaching bolt.

Adjust the ignition timing to the specified timing by turning the cam angle sensor.

Tighten the cam angle sensor attaching bolt to the specified tightening torque.

Tightening Torque : 14.7 - 21.6 N·m (1.5 - 2.2 kgf-m) r

Ensure that the ignition timing is not disturbed by tightening of the attaching bolts of the cam angle sensor.

Readjust the ignition timing, if the timing is not in the specified position.

(11) Stop the engine.

(12) Remove the tachometer.

(13) Remove the SST from the diagnosis connector.

CAUTION:

•

Care must be exercised to ensure that no connection is made on terminals except for those specified.

Even slight contact of the other terminal causes serious malfunction.

(14) Check the idle speed.

(See the check of the idle speed procedure in this service manual.)

JMA00061-00000

MA–22

5. Inspection of dashpot

(For automatic transmission-equipped model only)

Preparation to be made prior to idle speed adjustment

Check and adjust the ignition timing.

Check and adjust the idle speed.

Apply the parking brake fully.

Warm up the engine thoroughly.

All accessory switches are turned OFF.

(On those vehicles equipped with a day-light system, set the light control switch to the first stage, in order to turn OFF the head lights.)

The air element is installed.

All vacuum hoses are connected properly.

Ensure that the intake system exhibits no gas leakage or air admission.

Ensure that there is no gas leakage.

Place the shift lever in the “N” or “P” range.

Place the steering wheel to the straight ahead position and do not operate it during the inspection.

JMA00062-00000

(1) Connection of tachometer

(Refer to the “Inspection and adjustment of ignition timing” section for the connection of tachometer.)

CAUTION :

Never allow the tachometer terminal to touch ground. It could result in damage of the ignition system.

As some tachometers are not compatible with this ignition system, it is recommended to confirm the compatibility with your unit before its use.

(2) Start and warm up the engine.

(3) Ensure that the adjusting screw of the dashpot is not in contact with the dashpot shaft when the engine revolution is held at about 2400

100 rpm.

If the adjusting screw of the dashpot is in contact with the dashpot shaft, adjust the height of the adjusting screw.

(4) Ensure that the duration of time from dash pot adjusting screw contacts to the dash pot shaft to engine revolution returns to idle speed is within specified value when the throttle lever released slowly from the engine revolution at 3500 rpm.

Specified Duration: 0.5 - 5.0 seconds.

If the measured duration of time fails to meet with the specified value, replace the dashpot with a new one.

(Refer to the EC section.)

JMA00063-00000

MA–23

6. Change of engine coolant

WARNING:

Never open the radiator cap when the engine is still hot.

CAUTION:

As regards water to be used as cooling water, use soft water which does not contain salts of minerals, calcium, magnesium, and so forth.

If the coolant gets to the vehicle body, immediately flush away the coolant, using fresh water.

(1) Ensure that the coolant temperature is nearly the ambient temperature.

(2) Turn the radiator cap one step in an opening direction

(counterclockwise direction) until you feel the first clicking.

(3) Lightly press the radiator cap two or three times to release the inner pressure of the radiator.

(4) Close the radiator cap.

(5) Place an adequate container under the drain plug.

(6) Drain the coolant by loosening the drain plug.

(7) Remove the radiator cap.

(8) Drain the coolant in the reserve tank.

(9) Close the drain plug, after draining the coolant.

(10) Fill the water to the radiator and reserve tank.

(11) Start the engine.

NOTE:

If the water level in the radiator drops, replenish the water.

(12) Close the radiator cap.

(13) Warm up the engine.

(14) Stop the engine.

(15) Cool down the water temperature to the ambient temperature.

(16) Repeat the steps (1) through (15) two or three times.

(17) Ensure that the coolant temperature is nearly the ambient temperature.

(18) Turn the radiator cap one step in an opening direction

(counterclockwise direction) until you feel the first resistance.

(19) Lightly press the radiator cap two or three times to release the inner pressure of the radiator.

(20) Close the radiator cap.

(21) Place an adequate container under the drain plug.

(22) Drain the water by loosening the drain plug.

(23) Remove the radiator cap.

(24) Drain the water in the reserve tank.

(25) Replace the O-ring of the radiator drain plug with a new one, after draining the water.

(26) Install the radiator drain plug to the radiator securely.

Front of vehicle

Radiator cap

JMA00064-00050

Drain plug

JMA00065-00051

JMA00066-00052

MA–24

(27) Slowly pour a proper amount of antifreeze solution into the radiator in accordance with the instruction of the manufacturer of antifreeze solution.

CAUTION:

Use a good brand of ethylene-glycol base antifreeze solution.

Coolant Capacity:

Automatic Transmission: 5.3 liters

Manual Transmission: 5.4 liters

NOTE:

The amount above includes 0.6 liter for the reserve tank.

(28) Fill the water to the radiator and reserve tank.

(29) Start the engine.

NOTE:

If the water level in the radiator drops, replenish the water to the full level.

(30) Close the radiator cap.

(31) Ensure that no water leakage is present.

If water leakage is present, repair the water leakage.

(32) Warm up the engine thoroughly.

(33) Stop the engine.

(34) Cool down the coolant temperature to the ambient temperature.

(35) Ensure that the coolant level in the reserve tank will not decrease.

If the coolant level in the reserve tank decreases excessively or no coolant remains in the reserve tank, check the coolant level in the radiator to see whether the coolant in the radiator is full or not. If not, replenish the water to the radiator, and repeat the steps (30) through (35) again.

(36) Turn the radiator cap one step in an opening direction

(counterclockwise) until you feel the first resistance.

(37) Lightly press the radiator cap two or three times to release the inner pressure of the radiator.

JMA00067-00000

JMA00068-00053

JMA00069-00000

(38) Remove the radiator cap.

(39) Ensure that the concentration of antifreeze solution in the radiator meets the instruction of the manufacturer of antifreeze solution by a densitometer.

Adjust the concentration of the antifreeze solution in the radiator according to the instruction of the manufacturer of the antifreeze solution, if the concentration does not meet the instruction of the manufacturer of the antifreeze solution.

(40) Secure the radiator cap.

(41) Drain the water in the reserve tank.

(42) Pour the coolant which is mixed with antifreeze solution and water in accordance with the instruction of the manufacturer of the antifreeze solution.

(43) Secure the reserve tank cap.

MA–25

JMA00070-00054

JMA00071-00055

MA–26

CHASSIS

BRAKE FLUID

CHANGE

WARNING:

Do not mix the different kind and manufacture of brake fluid.

Recommended brake fluid:

FMVSS116 DOT3 or SAE J1703

CAUTION:

If the brake fluid is spilled inadvertently over the paint finish surface of the vehicle or the resin made part, immediately wipe off the brake fluid and flush with fresh water.

Be sure to follow the draining order of each wheel cylinder. The draining should be performed from the farthermost wheel cylinder from the brake master cylinder, one by one.

JMA00072-00000

1. Remove the brake bleeder plug cap.

2. Connect the suitable bleeder hose to the bleeder plug.

3. Prepare a suitable container and connect one end of the bleeder hose in the container.

4. Depress the brake pedal and have a person hold it in a depressed state.

5. Slacken the bleeder plug to drain the brake fluid by another person and tighten the bleeder plug temporarily.

6. Repeat the steps 4 to 5 until the brake fluid in the reservoir tank becomes zero.

However, at this state be very careful not to suck the air into the brake line, except cases where draining of the brake fluid is required.

7. Replenish the new brake fluid into the reservoir tank and maintain the brake fluid level in the reservoir tank at the

MAX level during the following operation.

8. Drain the old brake fluid or air from each brake line starting from the farthest wheel cylinder from the master cylinder one by one following the manner mentioned in the steps 4 to 5 repeatedly.

9. Tighten the air bleeder plugs to the specified tightening torque.

Tightening Torque: 6.9 - 9.8 N·m (0.7 - 1.0 kgf-m)

10. Ensure that no air exists in the brake line by depressing the brake pedal firmly.

If air is remaining in the brake line, perform the air bleeding by following the procedure described in the steps 4 to

5 repeatedly, until air will be discharged. Then, tighten the bleeder plug to the specified tightening torque.

11. Install the brake bleeder plug cap.

Front

Rear

JMA00073-00056

JMA00074-00057

JMA00075-00058

MA–27

BRAKE PEDAL

FREE PLAY

Ensure that the ignition switch is turned OFF.

Depress the brake pedal more than five times to release the vacuum saved in the brake booster.

Ensure that the specified free play exists on the brake pedal by pushing the brake pedal lightly by hand.

Free Play: 0.5 - 2.0 mm

If the free play is not within the specified value, adjust the free play by adjusting the push rod length.

(Refer to the BR section.)

RESERVE TRAVEL

1. Place chocks at the wheels.

2. Place the transmission in the neutral position.

3. Start the engine.

4. Depress the brake pedal with an applying force of 300 N

(30 kgf).

CAUTION:

At this stage the hand brake should not be applied.

5. Measure the distance between the position where the brake pedal pad upper surface is depressed and the floor panel as shown.

6. Ensure that the reserve travel meets with the specification.

Reserve Travel: 108.3 mm or more

If the reserve travel fails to meet with the specification, check/ adjust or repair the brake shoe clearance as necessary.

(Refer to the BR section.)

PARKING BRAKE HANDLE

WORKING TRAVEL

1. Chock the wheels.

2. Ensure that the number of notches is within the specified value when the parking brake handle is pulled with a force of 196 N (20 kgf) by hand.

Specified Number of Notches: 5 to 7

If the working travel fails to meet with the specification, adjust the parking brake handle working travel to the specified value.

(Refer to the BR section in this service manual.)

3. Ensure that the parking brake handle rachet operates properly and retains the handle at each notch position properly and will not be skipped or jumped.

If any trouble exists, replace the parking brake handle with a new one.

(Refer to the BR section.)

Unlock

0.5 - 2.0 mm

JMA00076-00059

108.3 mm or more

JMA00077-00060

Release

Set

JMA00078-00000

JMA00079-00061

MA–28

INSPECTION OF EFFECTIVENESS

Check to see if the vehicle can be retained in a stationary state on a dry slope with a grade of 1/5 when the parking brake is applied fully.

If not, check and repair the rear brake system.

JMA00080-00000

BRAKE HOSE & TUBE

LEAKAGE, LOOSE CLAMP AND DAMAGE

Inspect the following points. If any problem is found, repair them, as required.

1. Hoses and tubes for scratches or cracks.

2. Hoses for aging such as deformation or swelling.

3. Tubes for corrosion or rusting.

4. Tube clamps and related parts for tightness, rattle or damage.

5. Connection for fluid leakage.

6. Hoses for extreme bending, twisting or pulling.

Crack Scratch/Cut Twist Swelling

JMA00081-00062

MA–29

FRONT BRAKE

COMPONENTS

83.4

4.9

(8.5

0.5) w

★

★ o y i u r e t

49.0

4.9

(5.0

0.5)

: Tightening torque

Unit : N·m (kgf-m)

★

: Non-reusable parts

Cylinder slide main pin w

Cylinder slide sub-pin e

Disc brake No. 1 pad r

Disc brake No. 2 pad t

Anti-squeal shim y

Shim u

Disc brake pad guide No. 2 plate i

Disc brake pad guide plate o

Disc brake cylinder mounting (R, L)

Cylinder boot

Front disc brake piston

Piston seal

Pin boot

JMA00082-00063

INSPECTION OF BRAKE PAD THICKNESS

1. Jack up the vehicle and support the vehicle with safety stands.

(Refer to the GI section.)

2. Remove the front wheel.

3. Check the brake pad thickness through the inspection hole provided on the caliper as shown.

Brake Pad Thickness:

Standard Thickness: 10 mm

Minimum Thickness: 1 mm

If the brake pad thickness is less than the specified value or the wear indicator emits a warning sound, replace the brake pad with a new one.

(Refer to the BR section.)

CAUTION:

Be sure to replace the right and left side brake pads as a set. Failure to observe this caution may lead to side pull of the brake function.

4. Install the front wheel.

(Refer to FS section.)

JMA00083-00064

MA–30

INSPECTION OF FRONT BRAKE RUBBER PARTS AND

BRAKE PAD FOR DAMAGE

1. Jack up the vehicle and support the vehicle with safety stands.

2. Remove the front wheel.

3. Remove the sub-cylinder slide pins.

4. Turn up the disc brake assembly as shown.

CAUTION :

Never pull the brake hoses not more than necessary.

5. Ensure that no damage exists on the cylinder boot.

If any damage exists, replace the cylinder boots and piston seal with new ones as a set.

(Refer to the BR section.)

6. Ensure that no leakage of brake fluid exists from the disc brake cylinder, piston and around the cylinder boot.

If any leakage exists, replace the piston seal and cylinder boot with new ones.

(Refer to the BR section.)

7. Inspect the disc pads and disc brake pad-related parts for damage.

If any damage is found, replace the damaged part, as required.

(Refer to the BR section for details.)

8. Ensure that no damage exists on the disc brake pad guide plates, disc brake pad guide No. 2 plates, disc pads, shims and anti-squeal shims.

If any damage exists, replace the damaged parts with new ones.

9. Install the disc brake pad guide plates, disc brake pad guide No. 2 plates, disc pads, shims and anti-squeal shims as shown.

CAUTION :

Prior to installation, apply brake grease to the sliding surface of the component parts.

10. Ensure that no damage exists on the pin boots.

If any damage is present, replace the pin boots with new ones.

(Refer to the BR section.)

JMA00084-00065

JMA00085-00066

JMA00086-00067

11. Ensure that the brake pads, anti-squeal shims and pad guide plates are installed properly.

CAUTION:

Be very careful not to deform or lose the anti-squeal shims.

12. Thinly apply the brake rubber grease to the sub-cylinder slide pin boot.

13. Turn over the disc brake assembly onto the disc brake pads while pushing the pin boots of the sub-cylinder slide pin by finger.

CAUTION :

Never pull the brake hoses not more than necessary.

Never damage the pin boots during the operation.

Never interfere with the disc brake cylinder assembly with the brake pads and anti-squeal shims during the installation

14. Thinly apply the brake rubber grease to the sliding surface of the sub-cylinder slide pin.

15. Install the sub-cylinder slide pin of the disc brake cylinder assembly to the disc brake mounting.

CAUTION:

Be very careful not to damage the pin boot during the assembly.

16. Tighten the sub-slide pin to the specified tightening torque.

Tightening Torque: 44.1 - 53.9 N·m (4.5 - 5.5 kgf-m)

17. Depress the brake pedal more than 10 times.

18. Check to see if the brake disc can rotate smoothly.

19. Ensure that no abnormal sound is emitted or no drag exists when the wheel is rotated.

20. Install the front wheels with the attaching nuts and tighten them evenly in two or three stages to the specified tightening torque.

Tightening Torque: 88.2 - 117.6 N·m

(9.0 - 12.0 kgf-m)

21. Check effectiveness of the brake with a brake tester.

MA–31

JMA00087-00068

JMA00088-00069

JMA00089-00070

JMA00090-00000

MA–32

REAR BRAKE

COMPONENTS

9.8

2 (1.0

0.2)

!11

★

: Tightening torque

Unit : N·m (kgf-m)

★

: Non-reusable parts

o e

★

7 (6.25

0.75) r

★

★ u

★ t y o w q

INSPECTION OF BRAKE LINING THICKNESS

Jack up the vehicle and support it with safety stands.

(Refer to the GI section.)

Remove the hole plug provided on the backing plate as shown in the figure.

Inspect that the thickness of the brake shoe lining is more than the specified value through the inspection hole.

Thickness of Brake Lining

Standard Thickness: 5 mm

Minimum Thickness: 1 mm

Replace the brake shoe, if the lining thickness is less than the specified value.

If the brake lining is less than the specified value, check the brake drum inner diameter.

(Refer to the BR section.)

4. Install the hole plug securely.

CAUTION:

Be sure to install the hole plug securely. Failure to observe this caution may lead to rear brake problems owing to admission of dust, mud, water, etc.

Brake drum subassembly w

Brake shoe hold down spring e

Shoe hold down spring pin r

Tension No. 4 spring t

Tension No. 3 spring y

Tension spring u

Automatic adjust lever (R, L) i

Parking brake shoe lever subassembly (R, L) o

Brake shoe assembly

Parking brake shoe strut

Rear wheel brake cylinder assembly

Bleeder plug

Brake backing plate subassembly

Wheel cylinder boot

Wheel brake cylinder piston

Compression spring

Cylinder cup

Bleeder plug cap

JMA00091-00071

JMA00092-00072

INSPECTION OF WHEEL CYLINDER FOR LEAKAGE

Jack up the vehicle and support it with safety stands.

(Refer to the GI section.)

Remove the wheels.

Release the parking brake fully.

Remove the rear brake drum from the rear axle hub by pulling it out.

NOTE:

If any difficulty is encountered in removing the brake drum, screw in the 8 mm bolts to the brake drum evenly.

The bolt hole is of the offset type. Therefore, after tightening the bolt to a certain extent, make the brake drum float evenly by lightly tapping the brake drum with a plastic hammer or the like.

5. Ensure that no damage exists on the brake shoe lining surfaces.

If any damage is found, replace the brake shoes with new ones.

(Refer to the BR section.)

CAUTION :

Replacement should be performed for the right and left side shoes as a set.

6. Ensure that no brake fluid leakage exists around the wheel cylinder boots.

Replace the piston cups and cylinder boots if brake fluid leakage exists.

(Refer to the BR section.)

7. Clean the attaching surface of the brake drum and rear axle hub.

8. Install the brake drum on the rear axle hub.

9. Clean the attaching surface of the brake drums and wheels.

10. Install the wheels and tighten the attaching bolts to the specified tightening torque.

Tightening Torque: 103.0

14.7 N·m

(10.5

1.5 kgf-m)

11. Apply the brake pedal fully several times until the clicking sound is emitted.

12. Ensure that the brake drum turns lightly without being caught.

13. Check effectiveness of the rear brake with a brake tester.

MA–33

JMA00093-00073

JMA00094-00074

JMA00095-00000

JMA00096-00075

MA–34

BRAKE BOOSTER HOSE

COMPONENTS

LHD o t i u u

B t y t r t

25.5

2.9

(2.6

0.3) q

N e w

★

RHD

: Tightening torque

Unit : N·m (kgf-m)

★

: Non-reusable parts

e t r

9.8 - 15.7

(1.0 - 1.6) t y

9.8 - 15.7

(1.0 - 1.6) w ★

25.5

2.9

(2.6

0.3) q q

Brake booster assembly w

Master cylinder push rod clevis e

Brake booster bracket gasket r

Union to connector tube t

Clip y

Union u

Intake manifold tube clamp i

Intake manifold to connector tube o

Union to check valve hose

JMA00097-00076

CHECK OF VACUUM HOSE

1. Visually check vacuum hose for aging, cracks, scratches or cut.

If any damage exists, replace the vacuum hose with a new one.

2. Disconnect the vacuum hose from the brake booster.

3. Ensure that the negative pressure is retained when applying negative pressure to the disconnected hose.

If not, replace the vacuum hose with a new one.

JMA00098-00077

4. Ensure that the air continuity exists when air is blown into the vacuum hose from the brake booster side.

If not, replace the vacuum hose with a new one.

5. Connect the vacuum hose to the brake booster.

6. Install new hose bands.

CAUTION :

Never reuse the removed hose bands.

Insert the vacuum hose up to the spool of the brake booster.

JMA00099-00078

BRAKE MASTER CYLINDER

COMPONENTS

t w e q

7.9 - 11.7

(0.8 - 1.2) r r

★

12.7

2.5

(1.3

0.3) y

MA–35

: Tightening torque

Unit : N·m (kgf-m)

★

: Non-reusable parts

INSPECTION OF BRAKE MASTER CYLINDER FOR FLUID

LEAKAGE

1. Ensure that no brake fluid leakage exists from the grommet sections on the brake master cylinder.

If leakage exists, replace the grommet with a new one.

(Refer to the BR section.)

2. Disconnect the connecter of the brake fluid level switch.

3. Drain the brake fluid from the master cylinder.

(Refer to the “brake fluid change” section.)

4. Place a suitable piece of cloth under the master cylinder to prevent the brake fluid from being splashed on the painted surface.

5. Disconnect the brake pipes from the master cylinder.

CAUTION:

If the brake fluid is spilled inadvertently over the paintfinish surface of the vehicle or resin made parts, immediately wipe off the brake fluid and wash with fresh water.

6. Remove the master cylinder by removing the attaching nuts.

Brake master cylinder reservoir tank w

Reservoir filler cap e

Reservoir diagram r

Grommet t

Brake master cylinder assembly y

Tandem master cylinder repair kit

JMA00100-00079

JMA00101-00080

MA–36

7. Secure the master cylinder in a vise.

8. Ensure that no brake fluid leakage exists around the piston guide section of the brake master cylinder.

If any brake fluid leakage exists, replace the brake master cylinder pistons with piston cups(repair kit) with new ones.

(Refer to the BR section.)

9. Clean the master cylinder attaching surface of the brake booster.

10. Replace the O-ring of the brake master cylinder with a new one.

CAUTION:

Never make scratches on the O-ring during the installation.

11. Thinly apply brake rubber grease to the O-ring on the brake master cylinder.

12. Install the master cylinder to the brake booster with the attaching nuts. Then, tighten the attaching nuts evenly to the specified tightening torque.

Tightening Torque: 12.7

2.5 N·m (1.3

0.26 kgf-m)

WARNING:

Be sure to perform the adjustment of the brake booster push rod height if any inner part of the master cylinder has been replaced. (Refer to the BR section.)

Failure to observe this warning may lead to damage or malfunction of the brake system.

13. Connect the brake pipes to the master cylinder and tighten the flare nuts to the specified tightening torque.

Tightening Torque: 13 - 18 N·m (1.3 - 1.8 kgf-m)

14. Connect the brake fluid level switch connector.

15. Perform the air bleeding of the brake system.

(Refer to the “Brake fluid change” section.)

16. Perform the brake performance test with a brake tester.

JMA00102-00081

JMA00103-00082

MA–37

MUFFLER AND EXHAUST PIPE

DAMAGE & TIGHTNESS

1. Visually check that the exhaust pipes and mufflers for damage and exhaust gas leakage. Also ensure that there is no possibility of interference with any other parts.

WARNING

Never perform this check when the exhaust system is hot.

If any damage or gas leakage exists, repair or replace the parts as necessary.

2. Check that the muffler support of the exhaust pipe and muffler as well as their connecting section for looseness, using a suitable wrench or rock them by hand.

WARNING:

Never perform this check when the exhaust system is hot.

Be careful not to burn yourself during inspection.

If any damage or looseness is found, repair or replace parts as necessary.

Catalytic converter

JMA00104-00083

JMA00105-00000

AUTOMATIC TRANSMISSION

FLUID CHANGE

1. Place a suitable container under the drain plug.

2. Drain the transmission fluid by removing the drain plug.

3. Install the drain plug with a new gasket interposed and tighten the drain plug with the specified tightening torque.

Tightening Torque: 19.6 - 29.4 N·m (2.0 - 3.0 kgf-m)

CAUTION:

Never reuse the used gasket.

4. Fill the specified automatic transmission fluid to the automatic transmission.

Specified Automatic Transmission Fluid:

DEXRON

@ or

Capacity: 1.7 liters (Drain and refill)

JMA00106-00084

5. Check the fluid level.

CAUTION:

Inspection should be performed when the fluid temperature is between 70 - 80

Be very careful not to scald yourself with hot transmission fluid or other parts in the engine compartment.

(1) Park the vehicle on a level surface and apply the parking brake fully.

(2) With the engine idling, move the shift lever from the P range to the L range, and return it to the P range.

(3) Pull out the dipstick and wipe it clean. Then insert the dipstick and pull it out again. Ensure that the fluid level is between the upper and lower levels in the hot range of the oil level gauge.

If the fluid level is less than the lower level, add the specified automatic transmission fluid to the upper level of the dipstick. Then, recheck the fluid leakage.

JMA00107-00000

MA–38

CHECK OF OIL COOLER HOSE

Inspect the following points. If any problem is found, repair them, as required.

1. Hoses and tubes for scratches or cracks.

2. Hoses for aging such as deformation and swelling.

3. Tubes for corrosion or rusting.

4. Tube clamps and related parts for tightness, rattle or damage.

5. Connection for fluid leakage.

6. Hoses for extreme bending, twisting or pulling.

CLUTCH

FREE PLAY

1. Lightly depress the clutch pedal by hand,until you feel resistance. Then, measure the free play.

Specified Clutch Pedal Free Play: 15 - 30 mm

If the clutch pedal free play fails to meet with the specification, adjust the clutch pedal free play to the specified value.

(Refer to the CL section.)

RESERVE TRAVEL

1. Start the engine.

2. Ensure that the difference of clutch pedal upper surface height at clutch pedal depressed fully and clutch pedal positioned at point where the clutch just disengage is conforms to the specified value.

Specified Reserve Travel: 25 mm or more

If the reserve travel fails to conform to the specification, adjust the reserve travel by adjusting the free play or replace the clutch disc, clutch cover and related damaged parts, as required.

(Refer to the CL section.)

Position depressed fully

JMA00108-00000

15 - 30 mm

JMA00109-00086

Position clutch just disengage

25 mm or more

JMA00110-00087

MA–39

MANUAL TRANSMISSION, TRANSFER, FRONT

AND REAR DIFFERENTIAL

OIL CHANGE

1. Place a suitable container under the drain plug.

2. Drain the oil by removing the drain plug.

3. Remove the filler plug.

4. Reinstall the drain plug with a new gasket interposed and tighten it to the specified tightening torque.

Tightening Torque

Manual Transmission:

30 - 49 N·m (3.0 - 5.0 kgf-m)

Transfer:

30 - 49 N·m (3.0 - 5.0 kgf-m)

Front Differential:

9.8 N·m (5.0

1.0 kgf-m)

Rear Differential:

53.9 - 68 N·m (5.5 - 7.0 kgf-m)

5. Fill the specified oil, until the oil begins to overflow from the oil filler hole.

Specified Oil:

Manual Transmission

Grade: API GL-3 or GL-4

Viscosity: SAE 75W-85 or 75W-90

Capacity: 2.2 liters (With transfer)

Transfer (For automatic transmission)

Grade: API GL-3 or GL-4

Viscosity: SAE 75W-85 or 75W-90

Capacity: 1.6 liters

Front Differential

Grade: API GL-5

Viscosity: SAE 80W-90

Capacity: 0.7 liter

Rear Differential (Conventional)

Grade: API GL-5

Viscosity: SAE 80W-90

Capacity: 1.55 liters

Rear Differential (LSD)

Grade: API GL-5

Viscosity: SAE 80W-90 LSD

Capacity: 1.55 liters

6. Install the filler plug with a new gasket interposed and tighten it to the specified tightening torque.

Tightening Torque

Manual Transmission:

30 - 49 N·m (3.0 - 5.0 kgf-m)

Transfer:

30 - 49 N·m (3.0 - 5.0 kgf-m)

Front Differential:

9.8 N·m (5.0

1.0 kgf-m)

Rear Differential:

53.9 - 68 N·m (5.5 - 7.0 kgf-m)

Transmission

JMA00111-00088

Transfer

JMA00000-00089

Front differential

JMA00000-00090

Rear differential

JMA00000-00091

MA–40

PROPELLER SHAFT

CHECK OF PROPELLER SHAFT

1. Ensure that no looseness exists on the attaching bolts of the universal joint flange yokes which were connected to the front, rear differential and propeller shaft, using a torque wrench.

Tightening Torque: 51.0 - 69.6 N·m (5.2 - 7.1 kgf-m)

If any looseness exists, retighten the attaching bolts as required.

(Refer to the PR section.)

2. Ensure that no excessive play exists on the universal joints.

If any excessive play exists, repair the universal joint by replacing the spider kit or replace the propeller shaft with a new one.

(Refer to the PR section.)

3. Ensure that no excessive play exists between the propeller shaft and the transfer output shaft.

If excessive play is found, replace the front propeller shaft and/or transfer output shaft as required.

(Refer to the PR section.)

DRIVE SHAFT

CHECK OF DUST BOOT

1. Inspect that the dust boot is free from damage or cracks.

If any damage exists, replace the boot with a new one.

(Refer to the FS section.)

2. Inspect that the dust boot bands are securely installed in position properly.

If not, replace the boot bands with new ones.

(Refer to the FS section.)

WHEEL HUB NUT

Inspect the wheel hub nuts for looseness, using a wheel hub nut wrench.

Tightening Torque: 90 - 120 N·m (9.0 - 12.0 kgf-m)

WHEEL BEARING

RATTLE

1. Ensure that the wheel bearings exhibit no excessive play by rocking the tire in and out, up and down or forward and backward while holding the tire by hands.

If excessive play is found, replace the wheel bearing with a new one.

2. Ensure that no abnormal sound is emitted when the wheel is rotated by hand.

If abnormal sound is emitted, perform a repair so that no abnormal sound may be emitted.

JMA00112-00092

JMA00113-00093

JMA00114-00094

JMA00115-00095

STEERING SYSTEM

STEERING WHEEL FREE PLAY

1. Set the vehicle in a straight-ahead condition.

2. Inspect the steering wheel free play by turning it lightly with your fingers.

Specified Value: 10 mm MAX.

If the free play fails to meet with the specification, adjust the free play to the specified value.

(Refer to the SR section.)

STEERING WHEEL RATTLE

Hold the steering wheel by your hands. Ensure that the steering wheel exhibits no excessive looseness or play by moving it in an up-&-down direction, a right-&-left direction as well as in a fore-&-aft direction.

If excessive play is found, repair the steering system.

(Refer to the SR section.)

TIGHTNESS OF STEERING LINKAGE

Inspect the attaching sections for tightness or damage.

Tightening Torque:

Steering Wheel/Steering Main Shaft:

28 - 41 N·m (2.8 - 4.2 kgf-m)

Steering Main Shaft/Universal Joint:

25 - 34 N·m (2.5 - 3.5 kgf-m)

Universal Joint/Steering Pinion:

25 - 34 N·m (2.5 - 3.5 kgf-m)

DAMAGE OF STEERING LINKAGE BALL JOINT DUST

BOOT

Inspect the dust boot of the tie rod end ball joint for cracks or damage.

If any cracks or damage exists, replace the dust boot as necessary.

(Refer to the SR section.)

FLUID LEAKAGE OF STEERING GEAR BOX

1. Inspect the power steering device for fluid leakage.

2. Inspect the tightness of the power steering device.

TIGHTNESS OF STEERING GEAR BOX

Inspect the bolts of the gear box for looseness.

Tightening Torque: 53.9 - 81.4 N·m (5.5 - 8.3 kgf-m)

MA–41

Play

10 mm MAX.

JMA00116-00096

JMA00117-00097

JMA00118-00000

JMA00119-00099

JMA00120-00000

MA–42

POWER STEERING FLUID HOSE

Inspect the power steering fluid hose for aging, deformation, cracks, scratches, cut, twist and swelling.

If any problem is found, replace the fluid hose with a new one.

(Refer to the SR section.)

CAUTION:

Never reuse the removed hose bands.

WHEEL ALIGNMENT

TOE-IN CHECK

1. Ensure that the tires have been inflated with the specified pressure.

(Refer to the Owner’s manual.)

2. Place the vehicle on a flat floor and place the steering wheel to a straight ahead direction.

3. Attach a toe-in gauge to the rear side at the center point of each front tire at a height of tire center and put a mark on each tire.

4. Move the vehicle forward in a straight ahead direction gradually until the marks put on the tires come to the front side.

5. Attach the toe-in gauge to the front side, at the center point of each front tire. Determine the difference in the mark-to-mark distance between the first measurement and the second measurement. This difference constitutes the toe-in.

6. Ensure that the measured difference is within the specified value.

Specified Value: 0

1.5 mm

If the measured difference(toe-in) fails to meet with the specification, adjust the toe-in to the specified value.

(Refer to the FS section.)

JMA00121-00101

Front

JMA00122-00102

JMA00123-00103

SHOCK ABSORBER

DAMAGE AND OIL LEAKAGE

Visually inspect each shock absorber for damage and oil leakage.

If damage or oil leakage exists, replace the damaged part with a new one.

(Refer to FS or RS section.)

FUNCTION

Rock the vehicle in an up-&-down direction. Ensure that the vehicle emits no abnormal noise and the shake will finish within a few times.

If not, replace the shock absorber with a new one.

(Refer to FS or RS section.)

SUSPENSION ARM, CONTROL ARM & DUST

COVER

DAMAGE OF SUSPENSION ARMS AND DUST COVER

Visually inspect the suspension arms and dust cover for damage.

If damage exists, replace the damaged part with a new one.

(Refer to the FS section.)

TIGHTNESS OF SUSPENSION ARMS

Check the suspension arm connecting bolts and nuts for tightness.

If any looseness exists, tighten the attaching bolts and nuts to the specified tightening torque.

(Refer to the FS section.)

DAMAGE AND TIGHTNESS OF CONTROL ARMS

1. Visually inspect the control arms for damage.

If damage exists, replace them with new ones.

(Refer to the RS section.)

2. Inspect the attaching bolts and nuts for tightness.

If any looseness exists, tighten the attaching bolts and nuts to the specified tightening torque.

(Refer to the RS section.)

MA–43

JMA00124-00104

JMA00125-00105

JMA00126-00106

DAIHATSU

J100

ENGINE MECHANICAL

ENGINE TUNE-UP .............................. EM– 2

TIMING BELT ...................................... EM– 10

COMPONENTS

.............................. EM– 10

REMOVAL

...................................... EM– 11

INSPECTION

.................................. EM– 15

INSTALLATION

.............................. EM– 17

CYLINDER HEAD ............................... EM– 24

COMPONENTS

.............................. EM– 24

INSTRUCTION PRIOR TO

OPERATION

............................... EM– 25

CYLINDER HEAD REMOVAL

......... EM– 25

OVERHAUL OF CYLINDER HEAD .... EM– 31

DISASSEMBLY OF CYLINDER

HEAD

......................................... EM– 31

INSPECTION, CLEANING AND

REPAIRS OF CYLINDER HEAD

COMPONENTS

.......................... EM– 32

CYLINDER BLOCK ............................. EM– 60

COMPONENTS

.............................. EM– 60

INSTRUCTION PRIOR TO

OPERATION

............................... EM– 61

ENGINE REMOVAL

........................ EM– 61

DISASSEMBLY OF CYLINDER

BLOCK

....................................... EM– 66

INSPECTION OF EACH PART ........... EM– 79

INSPECTION OF CYLINDER

BLOCK

....................................... EM– 79

INSPECTION OF PISTONS AND

CONNECTING RODS

................ EM– 80

INSPECTION OF PISTONS

............ EM– 81

ASSEMBLY/DISASSEMBLY OF

PISTON & CONNECTING

ROD

........................................... EM– 84

CYLINDER BORING

...................... EM– 86

REPLACEMENT OF REAR OIL

SEAL

.......................................... EM– 87

REPLACEMENT OF FRONT OIL

SEAL

.......................................... EM– 87

REPLACEMENT OF CYLINDER

BLOCK

....................................... EM– 88

REPLACEMENT OF

CRANKSHAFT

........................... EM– 90

REPLACEMENT OF CONNECTING

RODS

......................................... EM– 91

DISASSEMBLY OF OIL PUMP

....... EM– 92

ASSEMBLY OF OIL PUMP

............. EM– 95

INSPECTION OF CRANKSHAFT

PULLEY

...................................... EM– 97

INSPECTION OF WATER PUMP

.... EM– 97

INSPECTION OF WATER PUMP

PULLEY

...................................... EM– 97

INSPECTION OF OIL PAN

............. EM– 98

INSPECTION OF FLYWHEEL

......... EM– 98

INSPECTION AND REPLACEMENT

OF RING GEAR

......................... EM– 98

ASSEMBLY OF CYLINDER

BLOCK

....................................... EM– 99

PREPARATION OF ENGINE

INSTALLATION

.......................... EM–112

INSTALLATION OF ENGINE

.......... EM–115

ENGINE SPECIFICATION ................... EM–121

ENGINE MECHANICALS

............... EM–124

SST (Special Service Tools) .............. EM–126

TIGHTENING TORQUE ...................... EM–128

JEM00001-00000

NO. 9710-JE

EM–2

ENGINE TUNE-UP

NOTE:

•

The adjustments or checks of this section is performed normally when the engine is in a hot condition.

•

“Hot engine condition” denotes a condition in which the cooling water temperature is 75 - 85

C and the engine oil temperature is above 65

•

Warm up the engine thoroughly. However, do not perform the adjustment while the idle-up VSV is still functioning.

•

Ensure that all accessory switches are turned OFF.

•

On the automatic transmission vehicle, the gear shift lever is placed in the [N] or [P] range.

•

On the manual transmission vehicle, the gear shift lever is placed in the neutral range.

•

Connect the engine revolution meter for measuring the engine revolution speed. If your engine revolution meter is of such a type as to be connected to the negative terminal of the ignition coil, connect the following SST to the diagnosis connector.

SST: 09991-87402-000

•

Apply the parking brake fully.

•

Set the steering wheel to the straight ahead direction.

•

Be sure that the removed parts for adjustment or checks should be reinstalled.

JEM00002-00000

1. Inspection of engine coolant

Check to see if coolant level is between the LOW and

FULL lines of the reserve tank.

If coolant level is near the LOW level or bellow the LOW level, add the coolant up to the full level.

WARNING:

•

Never open the radiator cap when the engine is still hot.

Failure to observe this caution will cause you to get scalded.

NOTE:

•

If no coolant is present in the reserve tank or the coolant level is very low, check for water leakage, using a radiator cap tester.

•

Here, the coolant refers to the coolant having an adequate freezing protection rating.

FULL

LOW

JEM00003-00001

Coolant Capacity:

Manual Transmission Vehicle: 5.4 liters

Automatic Transmission Vehicle: 5.3 liters

CAUTION:

•

Use a good brand of ethylene-glycol-base antifreeze solution.

NOTE:

•

The amount above includes liter for reserve tank.

JEM00004-00000

EM–3

2. Inspection of engine oil

(1) Oil quality check

Check the engine oil for deterioration, ingress of water, discoloring and dilution.

NOTE:

•

Park the vehicle or a level surface.

•

The amount of oil between the “L” level and the “F” level equals around one liter.

JEM00005-00002

(2) Oil level check

Ensure that the engine oil level should be between the

“L” and “F” level an the dipstick.

If the engine oil level is below the “L” level, replenish the specified oil to the “F” level after oil leakage has been checked.

Oil Capacity:

Unit: liter

“F” level 3.3

“L” level

Oil capacity when oil filter replaced

Full capacity

2.3

3.5

3.6

NOTE:

•

Use API grade SF or higher multigrade viscosity, fuel efficient oil.

•

The amount of oil between the “L” level and the “F” level equals around one liter.

JEM00006-00003

TEMP.

Engine oil

(4 stroke)

°C

°F

–29

–20

–18

–7

10W-30, 10W-40, 10W-50

100

20W-40, 20W-50

5W-30

JEM00000-00004

3. Inspection of spark plugs

Recommended Spark Plug:

DENSO

K20TNR-S, K22TNR-S

NGK

BKUR6EK, BKUR7EK

NOTE:

•

All spark plugs should have the same head range and be ones manufactured by the same manufacture.

JEM00007-00000

EM–4

(1) Inspection of electrode

Measure the insulation resistance of the spark plug.

Minimum Insulation Resistance: 15 M

Ω

If the measured insulation resistance is less than the specified value, replace the spark plug with a new one after checking the electrode gap and cleaning the spark plug.

WARNING:

•

Since the spark plugs are hot, care must be exercised to avoid getting scalded.

(2) Inspection of electrode gap

Measure the electrode gap, using a plug gap gauge.

Electrode Gap: 0.9 - 1.0 mm

If the electrode gap of a used spark plug is not within the specification, replace the spark plug with a new one.

4. Inspection of drive belt

(1) Visual inspection of the drive belt

Replace the drive belt, if necessary.

JEM00008-00005

JEM00009-00006

(2) Inspection of the drive belt tension

Measure the amount of the drive belt deflection when the midpoint of the drive belt between the alternator and the water pump pulley is pushed with a force of

98 N (10 kgf).

Specified Belt Deflection

New Belt: 4 - 5 mm

[with a force of 10 kg applied at the point shown in the figure.]

Used Belt: 5 - 6 mm

[with a force of 10 kg applied at the point shown in the figure.]

If necessary, adjust the drive belt tension.

NOTE:

•

“New belt” refers to a belt which has been used on a running engine for less than five minutes.

•

“Used belt” refers to a belt which has been used on a running engine for more than five minutes or more.

•

After replacing the drive belt, check that it fits properly in the ribbed grooves, especially in the places difficult to see.

•

After installing a new belt, run the engine for about five minutes and then recheck the tension.

Alternator pulley

Crankshaft pulley

JEM00010-00007

Water pump pulley

Alternator pulley

JEM00011-00008

Vane pump pulley

Water pump pulley

Air conditioner compressor pulley

Idler pulley

JEM00012-00009

EM–5

5. Inspection and adjustment of valve clearances

The measurement and adjustment of valve clearance are carried out when each of the piston of the No. 1 and No. 4 cylinders is set to the top dead center at the end of compression stroke.

NOTE:

•

The valve clearance adjustment is performed normally when the engine is in a hot condition.

“Hot engine condition” denotes a condition in which the cooling water temperature is 75 - 85°C and the engine oil temperature is above 65°C.

JEM00013-00000

NOTE:

•

The “O” mark denotes those valves that can be adjusted under that setting.

Valve Clearances (Hot)

Intake: 0.25 ± 0.05 mm

Exhaust: 0.33 ± 0.05 mm

(Reference)

Valve Clearances (Cold)

Intake: 0.18 mm

Exhaust: 0.25 mm

Tightening Torque (Lock nut): 16.7 - 22.6 N·m

Piston positions

When valve rocker arms of No. 1 cylinder are free:

(Piston of No. 1 cylinder is at top dead center under compression strok)

When valve rocker arms of No. 4 cylinder are free:

(Piston of No. 4 cylinder is at top dead center under compression strok)

JEM00014-00010

Intake

Exhaust

Intake

Exhaust

™

3 4

™

™ ™

™

JEM00015-00000

EM–6

6. Inspection and adjustment of ignition timing

Check to see if the ignition timing mark of the crankshaft pulley is aligned with the indicator of the timing belt cover by using a timing light under the condition that the T terminal has been connected with the ground terminal in the diagnosis connector by the following SST.

SST: 09991-87403-000

NOTE:

•

The ignition timing inspection or adjustment is performed normally when the engine is in a “Hot” condition.

The “Hot engine condition” denotes a condition in which the cooling water temperature is 75 - 85

C and the engine oil temperature is above 65

•

Care must be exercised to ensure that no connection is made on terminals except for those specified.

Even a slight contact with the other terminals will cause serious malfunction.

TDC 0° BTDC 2° ATDC 2°

JEM00016-00011

If the ignition timing mark is not aligned with the indicator of the timing belt cover, adjust the ignition timing by turning the cam angle sensor.

REFERENCE:

•

If the cam angle sensor is turned clockwise, the timing will be advanced. Conversely, if the can angle sensor is turned counterclockwise, the ignition timing will be retarded.

JEM00017-00012

7. Inspection and adjustment of idle speed

Preparation to be made prior to idle speed adjustment.

•

Check and adjust the ignition timing.

•

Apply the parking brake fully.

•

Warm up the engine thoroughly.

•

All accessory switches are turned OFF.

•

The air cleaner element is installed.

•

All vacuum hoses are connected.

•

Ensure that the intake system exhibits no air leakage.

•

Ensure that the exhaust system exhibits no air leakage.

•

On the automatic transmission vehicle, the shift lever is placed in the [N] or [P] range.

•

On the manual transmission vehicle, the shift lever is placed in the neutral range.

•

Position the steering wheel to the straight-ahead direction.

NOTE:

•

Do not perform the engine idle speed adjustment, while the idle-up VSV is operating.

Prior to the adjustment of the idle speed, be sure to check that the idle-up VSV is not operating.

JEM00018-00000

Measure the engine idle speed, using a tachometer which is connector to the “REV” terminal of the diagnosis connector.

NOTE:

•

Never allow the “REV” terminal to touch the ground. It could result in damage of the ignition system.

•

As some tachometers are not compatible with this ignition system, it is recommended to confirm the compatibility with your unit before its use.

Specified Idle Speed:

MT: 800

50 rpm

AT: 850

50 rpm

If the measured engine idle speed is not within the specified value, adjust the engine idle speed by turning the idle adjusting screw placed at the throttle body.

NOTE:

•

When the idle adjusting screw is turned clockwise, the idle speed will be decreased, whereas when the idle adjusting screw is turned counterclockwise the idle speed will be increased.

8. Compression check

NOTE:

•

After completion of the engine tune-up, if the engine exhibits lock of power, excessive oil consumption or poor fuel economy, measure the cylinder compression pressure.

Diagnosis connector

EM–7

Earth terminal

Tacho-meter terminal

JEM00019-00013

JEM00020-00014

JEM00021-00000

Measure the cylinder compression pressure for each cylinder, using a compression gauge which is inserted into the spark plug hole.

NOTE:

•

Depress the accelerator pedal fully while measuring the compression pressure.

•

Always use a fully charged battery so that at least a revolution speed of 300 rpm may be attained.

Compression Pressure:

1373 kPa (14 kgf/cm 2 )/at 300 rpm

Minimum Pressure:

1030 kPa (10.5 kgf/cm 2 )/at 300 rpm

Difference in Reading Between Cylinders:

147 kPa (1.5 kgf/cm 2 )/at 300 rpm

JEM00022-00015

EM–8

If the compression of one or more cylinders is low, pour a small amount of engine oil into that cylinder through the spark plug hole and measure the cylinder compression again.

•

If adding oil helps the compression to improve, chances are that the piston rings and/or cylinder bores are worm or damaged.

•

If the pressure remains low after the operation has been performed, the valves may be sticking or seated un properly, or there may be leakage post the gasket.

JEM00023-00016

9. Checking of CO/HC concentrations

Preparation to be made prior to check of CO/HC concentrations.

•

Apply the parking brake fully.

•

Check and adjust the ignition timing.

•

Check and adjust the idle speed.

•

Warm up the engine thoroughly.

•

All accessory switches are turned OFF.

•

The air cleaner element is installed.

•

All pipes and vacuum hose are connected.

•

Ensure that the intake system exhibits no air leakage.

•

Ensure that the exhaust system exhibits no gas leakage.

•

On the automatic transmission vehicle, the shift lever is placed in the [N] or [P] range.

•

On the manual transmission vehicle, the shift lever is placed in the neutral position.

•

Position the steering wheel to the straight-ahead direction.

•

Be sure to prepare the CO/HC meter by following the instruction of its manufacturer, before it is put into use.

NOTE:

•

This check is used only to determine whether or not the idle HC/CO emission complies with the regulations.

Measure the HC/CO emission by inserting a sampling pipe of the HC/CO meter into the exhaust pipe.

Wait at least one minute before the measurement so as to allow the concentrations to stabilize.

Complete the measurement within three minutes.

If the HC/CO concentrations do not conform to the regulations, see the following table for possible causes.

EM–9

Trouble Shooting List

HC CO

High

Normal

Low

High

Problems

Rough idle

(Fluctuation in HC reading)

Rough idle

(Black smoke from exhaust)

Possible causes

1. Faulty ignition

•

Incorrect ignition timing

•

Fouled, shorted or improperly gapped spark plugs

•

Open or crossed high tension cords

2. Incorrect valve clearance

3. Leaky exhaust valves

4. Leaky cylinder

1. Lean mixture causing misfire

1. Restricted air filter

2. Faulty EFI system

•

Faulty pressure regulator

•

Clogged fuel return line

•

Defective water temp. sensor

•

Defective air temp. sensor

•

Faulty throttle position sensor

•

Faulty pressure sensor

•

Faulty ECU

•

Faulty oxygen sensor

JEM00024-00000

EM–10

TIMING BELT

COMPONENTS

y o

B i w r e u

FRONT t q q

Fan shroud w

Fan & fluid coupling e

V-ribbed belt r

Water pump pulley t

Crankshaft pulley assembly y

Timing belt upper cover u

Timing belt lower cover i

Timing belt tensioner subassembly o

Timing belt

JEM00025-00017

REMOVAL

1. Disconnect the battery ground cable from the negative (–) terminal of the battery.

2. Remove the engine undercover.

3. Removal of fan and fluid coupling

(1) Drain the coolant by loosening the drain plug and the radiator cap.

WARNING:

•

Never open the drain plug and the radiator cap when the coolant is still hot.

Failure to observe this caution will cause you to get scalded.

(2) Disconnect the water hose from the radiator upper side.

(3) Loosen the attaching nuts of the fluid coupling.

(4) Remove the fan and the fluid coupling together with the fan shroud by loosening the attaching bolts.

EM–11

IG “OFF”

JEM00026-00018

JEM00027-00019

JEM00028-00020

JEM00029-00021

JEM00030-00000

EM–12

4. Remove the power steering vane pump drive belt by loosening the power steering vane pump attaching bolts.

5. Remove the alternator drive belt.

6. Remove the crankshaft pulley.

NOTE:

•

Place the shift lever in the 4th gear position so as to prevent the rotation of the crankshaft in the case of manual transmission-equipped model.

•

On the automatic transmission vehicle, prevent the crankshaft from being rotated by inserting a screwdriver or the like into the ring gear at the rear end section of the cylinder block.

7. Disconnect the connector of the oil pressure switch and loosen the attaching bolt of the oil pressure switch wire bracket.

8. Remove the timing belt cover by removing the attaching bolts.

JEM00031-00022

JEM00032-00023

JEM00033-00024

JEM00034-00025

EM–13

9. Removal of timing belt

NOTE:

•

Prior to removal of the timing belt, put an arrow mark indicating the normal rotating direction on the belt, using a chalk or the like.

CAUTION:

•

Do not try to pry the timing belt with a screwdriver or the like during the removal or installation.

•

Do not allow the belt to come into contact with oil, water or dust.

•

Do not bend the belt at a sharp angle or turn the belt inside out, for it is very vulnerable to bending.

•

Do not utilize the tension of the timing belt pulley when loosening the set bolt of the camshaft timing belt pulley.

Mark showing normal rotating direction

JEM00035-00026

(1) Rotate the crankshaft until the “F” mark of the crankshaft timing belt pulley is aligned with the indicator of the cylinder head cover.

Indicator

“F” mark

(2) Loosen the attaching bolt of the timing belt tensioner.

Move the tensioner to the left as far as it will go and tighten the bolt temporarily.

JEM00036-00027

Anti-vibration rubber

Timing belt tensioner

JEM00037-00028

(3) Remove the timing belt.

JEM00038-00029

EM–14

10. Removal of camshaft timing belt pulley

(1) Remove the timing belt.

(2) Remove the cylinder head cover.

(3) Removal of camshaft timing belt pulley

While preventing the camshaft timing belt pulley from turning using a suitable iron rod, remove the three attaching bolts.

Then, remove the camshaft timing belt pulley.

11. Removal of crankshaft timing belt pulley

(1) Remove the timing belt.

(2) Removal of crankshaft timing belt pulley q

Remove the power train stiffener and prevent the ring gear from turning with a suitable screwdriver or the like.

While performing the operation described in the step q

, remove the set bolt of the crankshaft timing belt pulley.

Remove the crankshaft timing belt pulley.

NOTE:

•

If any difficulty is encountered in removing the crankshaft timing belt pulley, lightly screw in the set bolt of the crankshaft timing belt pulley. Then, remove the pulley, using the following SST.

SST: 09609-20011-000

SST

JEM00039-00000

JEM00040-00030

JEM00041-00031

JEM00042-00032

JEM00043-00033

EM–15

(3) Remove the timing belt pulley flange.

JEM00044-00034

INSPECTION

1. Inspection of timing belt

CAUTION:

•

Do not bend, twist or turn the belt inside out.

•

Do not allow the belt to come into contact with oil, water or steam.

If there are damages, as shown in the figures, check the following points and replace the timing belt, if necessary.

(1) Premature separation

•

Check for proper installation.

•

Check the timing belt cover gaskets for damage and check for correct installation.

(2) If the belt teeth are cracked or damaged, check to see if the camshaft is seized.

JEM00045-00035

,,,

,,,,,,

,,,,

JEM00046-00036

JEM00047-00037

(3) If there is noticeable wear or cracks on the belt surface, check to see if there are nicks on one side of the idler pulley lock.

JEM00048-00038

EM–16

(4) If there is wear or damage on only one side of the belt, check the pulley flange.

(5) If there is noticeable wear on the belt teeth, check the timing cover gasket for damage and check for correct gasket installation. Check for foreign material on the pulley teeth.

,,,,,

,,,,,,

,,,,

JEM00049-00039

JEM00050-00040

2. Inspection of camshaft timing belt pulley

(1) Measure the maximum width of the timing belt pulley, using vernier calipers.

Wear Limit of Camshaft Timing Belt Pulley: 119.8 mm

If the measured value is less than the specified value, replace the timing belt pulley with a new one.

JEM00051-00041

(2) Visually inspect the timing belt pulley for damage.

If any damage is present, replace the timing belt pulley with a new one.

JEM00052-00042

3. Inspection of timing belt tensioner

If the timing belt tensioner is damaged, check to see if the bearing exhibits an excessive play.

NOTE:

•

Check the timing belt pulleys for smooth turning.

•

Check the belt contact surface for damage.

If necessary, replace the idler pulley.

CAUTION:

•

Never wash the timing belt tensioner.

JEM00053-00043

4. Inspection of tension spring

(1) Check the free length of the spring

Free Length: 46.5 mm or less

(2) Check the tension of the spring at the specified installation length.

Specified Value:

29.4

3 N at 50.9 mm

If the tension does not conform to the specification, replace the spring.

5. Inspection of crankshaft timing belt pulley and flange

(1) Measure the maximum width of the timing belt pulley, using vernier calipers.

Wear Limit of Crankshaft Timing Belt Pulley: 59.3 mm

If the measured value is less than the specified value, replace the timing belt pulley with a new one.

(2) Visually inspect the crankshaft timing belt pulley for damage. If any damage is present, replace the crankshaft timing belt pulley.

(3) Visually inspect the crankshaft timing belt pulley flange for bend, wear and other damage.

If any damage is present, replace the crankshaft timing belt pulley flange.

INSTALLATION

1. Installation of camshaft timing belt pulley

(1) Install the camshaft timing belt pulley on the camshaft in such a way that the “F” mark can be seen and the locating pin hole is aligned.

EM–17

JEM00054-00044

JEM00055-00045

JEM00056-00046

JEM00057-00047

JEM00058-00000

EM–18

(2) Install the attaching bolts of the camshaft timing belt pulley, while preventing the pulley from turning by inserting an iron rod into the hole of the pulley.

Tightening Torque: 14.7 - 21.6 N·m

NOTE:

•

Do not turn the camshaft independently.

•

Be very careful not to damage the gasket attaching surface of the cylinder head.

•

The bolts and bolt holes should be dry during the tightening.

2. Installation of crankshaft timing belt pulley

(1) Install the crankshaft timing belt pulley flange with its recessed side facing toward the oil pump side

(Protrusion side facing toward the crankshaft timing belt pulley side).

(2) Install the crankshaft timing belt pulley on the crankshaft by aligning it with the key groove.

(3) Install the set bolt of the crankshaft timing belt pulley.

(4) Tighten the set bolt of the crankshaft timing belt pulley, while preventing the ring gear from turning with a suitable screwdriver or the like.

Tightening Torque: 88.3 - 98.0 N·m

NOTE:

•

Never allow the crankshaft to turn.

3. Attach the tension spring to the timing belt tensioner.

Hang the tension spring hook on the pin. Assemble the timing belt tensioner in place and install the bolt.

CAUTION:

•

Hang the spring hook securely on the pin groove.

•

Ensure that the pin at the oil pump is fitted into the pin hole of the timing belt tensioner.

4. Installation of timing belt

(1) Temporarily install the cylinder head cover.

JEM00059-00048

JEM00060-00049

JEM00061-00050

JEM00062-00051

JEM00063-00052

(2) Align the drilled mark of the camshaft timing belt pulley with the top surface line of the cylinder head.

(3) Align the drilled mark of the crankshaft timing belt pulley with the indicator.

(4) Assemble the timing belt in such a way that the two mating marks on the timing belt may be aligned with the corresponding drilled marks on the crankshaft timing belt pulley and camshaft timing belt pulley.

CAUTION:

•

Do not allow the belt to come into contact with oil, water or dust.

•

Do not try to pry the timing belt with a screwdriver or the like.

•

When the timing belt is reused, there should exist 35 teeth of the belt between the drilled marks of the crankshaft timing belt pulley and camshaft timing belt pulley.

•

When the timing belt is reused, the arrow mark which was put during the disassembly comes in a rotational direction of the timing belt.

Indicator

(5) Loosen the attaching bolt of the timing belt tensioner.

Apply tension to the timing belt. Temporarily tighten the attaching bolt.

NOTE:

•

Ensure that the belt exhibits no slack at the tension side of the belt (the side opposite to the tensioner).

EM–19

“F” mark

Drilled mark

Indicator

JEM00064-00053

JEM00065-00054

(6) Rotate the crankshaft 1.9 turns in the normal direction so that the “F” mark of the camshaft timing belt pulley comes at a point three teeth in the camshaft timing belt pulley before the indicator of the cylinder head cover.

NOTE:

•

At this time, never turn the crankshaft reversely.

•

Make sure that the belt is not tilted between the crankshaft timing belt pulley and the camshaft timing belt pulley.

•

If the crankshaft should be reversed or the timing belt should be tilted, turn the crankshaft two more turns.

(7) Make the tensioner free by loosening the attaching bolt of the timing belt tensioner.

about 30 degrees

JEM00066-00055

JEM00067-00056

EM–20

(8) Turn the crankshaft further in the normal direction until the “F” mark of the camshaft timing belt pulley is aligned with the indicator of the cylinder head cover.

NOTE:

•

Never turn the crankshaft reversely.

•

Never turn the crankshaft beyond the point where the

“F” mark of the camshaft timing belt pulley is aligned with the indicator.

•

If the crankshaft should be reversed or turned beyond that point, temporarily tighten the tensioner attaching bolt and repeat the operations from the step (5) onward.

(9) Tighten the attaching bolt of the timing belt tensioner to the specified torque.

Tightening Torque: 29.4 - 44.1 N·m

JEM00068-00057

(10) Ensure that the drilled marks of the crankshaft timing belt pulley and camshaft timing belt pulley are aligned with the corresponding indicators.

If the drilled mark is not aligned with the indicator, repeat the operations from the step (2) onward.

Indicator

5. Checking of timing belt tension

When the midpoint of the belt at the tension side is pushed 5 mm, ensure that the pushing force is within the specified value.

Specified Pushing Force:

7.8 - 15.7 N When belt is deflected 5 mm

If the belt does not conform to the specification, repeat the operations from the step 13 (4) onward.

6. Install the timing belt lower cover and upper cover.

Tightening Torque: 2.0 - 3.9 N·m

CAUTION:

•

Care must be exercised as to the length of each bolt.

JEM00069-00058

“F” mark

Drilled mark

Indicator

JEM00070-00059

Pushing force

7.8 - 15.7 N

5 mm

JEM00071-00060

JEM00072-00061

EM–21

7. Install the oil pressure switch wire and tighten the wire clamps.

8. Connect the oil pressure switch connector.

9. Install the crankshaft pulley with the attaching bolt. Tighten the bolt to the specified torque.

Tightening Torque: 19.6 - 29.4 N·m

NOTE:

•

Place the gear shift lever in the 4th gear position so as to prevent the rotation of the crankshaft in the case of manual transmission equipped model.

•

On the automatic transmission vehicle, prevent the crankshaft from being rotated by inserting a screwdriver or the like into the ring gear at the rear end section of the cylinder block.

10. Temporarily install the water pump pulley and the drive belt.

11. Install the power steering vane pump drive belt and adjust the belt tension.

NOTE:

•

Make sure that the V-ribbed belt is fitted properly in the groove of each pulley.

JEM00073-00063

JEM00074-00062

12. Install the fan and the fluid coupling together with the fan shroud.

13. Tighten the fluid coupling attaching nuts.

Tightening Torque: 9.8 - 17.7 N·m

Correct Wrong Wrong

JEM00075-00064

14. Tension adjustment

(1) Screw in the adjusting bolt, until the deflection of the drive belt meets the specification when you push the midpoint of the drive belt between the water pump pulley and the alternator pulley by applying a force of

98.1 N (10 kgf).

98 N

(10 kgf)

Deflection

Alternator pulley

JEM00076-00065

Water pump pulley

JEM00077-00066

EM–22

Specified Belt Deflection:

New Belt: 4.0 - 5.0 mm

With a force of 98.1 N (10 kgf) applied to point indicated in figure

Used Belt: 5.0 - 6.0 mm

With a force of 98.1 N (10 kgf) applied to point indicated in figure

NOTE:

•

The used belt denotes a belt which has been used for more than five minutes after it was put into use.

(2) Tighten the alternator attaching bolts.

(3) Install the locking plate of the adjusting bolt.

CAUTION:

•

Be sure to install the locking plate securely. Failure to observe this caution could cause falling of the adjusting bolt.

JEM00078-00067

15. Ensure that the belt deflection meets the specification when the midpoint between the water pump pulley and the alternator is pushed with a force of 98.1 N (10 kgf).

(See step 14.)

If the deflection does not conform to the specification, perform the adjustment so that the specification may be satisfied.

98 N

(10 kgf)

Deflection

Alternator pulley

16. Tighten the fan shroud attaching bolts.

17. Connect the water hoses to the radiator.

JEM00079-00068

Water pump pulley

JEM00080-00069

JEM00081-00070

18. Tighten the drain plug and fill the coolant to the radiator and reserve tank.

JEM00081-00071

19. Install the engine undercover and tighten the attaching bolts.

20. Connect the ground cable to the negative (–) terminal of the battery.

EM–23

JEM00083-00072

IG “OFF”

JEM00084-00073

EM–24

CYLINDER HEAD

COMPONENTS

★ y

e w

★

: Non-reusable parts

e u

@4 t

★ r

★

Front

@3 q

Cylinder head cover w

Camshaft e

Valve rocker shaft r

Valve guide t

Cylinder head y

Oil seal u

Spark plug i

Valve o

Spring seat

Valve stem oil seal

Valve spring

Valve spring retainer

Valve rocker arm

Camshaft timing belt pulley

Spacer

Grommet

Oil filler cap

Gasket

Timing belt upper cover

Timing belt

Timing belt tensioner

Crankshaft timing belt pulley

Crankshaft pulley

Camshaft cap

Cylinder head gasket

Ignition coil

JEM00085-00074

INSTRUCTION PRIOR TO OPERATION

•

Install the fender cover to the fenders so that so scratch may be made to the fenders.

•

Be sure to read the general information section of the service manual.

CYLINDER HEAD REMOVAL

1. Remove the battery and the battery carrier.

2. Drain the coolant.

3. Remove the cooling fan with the fluid coupling and the fan shroud.

4. Remove the radiator by loosen the attaching bolts.

5. Removal of air cleaner.

(1) Remove the attaching bolt of the air intake hose.

(2) Remove the accelerator cable and the rubber hoses from the throttle body.

(3) Release the clips of the air cleaner and remove the air cleaner lower case with air intake hose and the filter element.

(4) Remove the air cleaner lower case by loosen the attaching bolts.

EM–25

JEM00086-00000

JEM00087-00075

JEM00088-00076

JEM00089-00077

JEM00090-00078

EM–26

6. Remove the power steering vane pump from the engine.

Suspend the removed steering vane pump at body side, using an adequate rope.

7. Removal of alternator

(1) Remove the connector and the cable at the rear side of the alternator.

(2) Remove the alternator with the belt tension adjusting bar.

8. Remove the timing belt.

9. Removal of engine wire from cylinder head.

(1) Disconnect the connector of the engine wire from the following parts.

Ignition coils w

Injectors e

Pressure sensor r

Throttle position sensor t

Intake air temperature sensor y

Idle-up VSV u

Water temperature sensor i

Oxygen sensor o

Cam angle sensor

JEM00094-00081

JEM00095-00082

JEM00091-00079

JEM00092-00080

JEM00093-00000

EM–27

(2) Disconnect the harness clamps by unlocking the clamps.

(3) Remove the engine harness from the cylinder head.

10. Disconnect the water hoses

11. Remove the surge tank stay No. 1, No. 2 and No. 3.

12. Disconnect the fuel inlet hose and return hose.

CAUTION:

•

The fuel pressure at inside of the fuel line is approximately 284 kPa higher than the atmospheric pressure.

•

Therefore, be sure to gradually pull out the rubber hose so as to prevent fuel from splashing.

13. Disconnect the rubber hoses for brake booster and VSV.

JEM00096-00083

JEM00097-00084

JEM00098-00085

Inlet

Return

JEM00099-00086

JEM00100-00087

EM–28

14. Removal of intake manifold

(1) Disconnect the plugged hose at the cylinder head.

JEM00101-00088

(2) Remove the attaching bolts and nuts of the intake manifold by loosen them evenly over two or three stage, following the sequence shown in the right figure.

(3) Slowly detach the intake manifold from the cylinder head while preventing the interference with other parts.

q e r y i

o u w t

JEM00102-00089

15. Removal of exhaust manifold

(1) Remove the heat insulator by loosen the attaching bolts.

JEM00103-00090

(2) Remove the oil level gauge.

(3) Remove the oil level gauge guide by loosen the attaching bolt.

JEM00104-00091

(4) Remove the front exhaust pipe from the exhaust manifold.

JEM00105-00092

EM–29

(5) Loosen the exhaust manifold attaching bolts and nuts evenly over two or three stages in the sequence shown in the right figure.

(6) Remove the exhaust manifold from the cylinder head while preventing the interference with other parts.

16. Remove the ignition coil and resistive cords from the cylinder head cover.

JEM00106-00093

17. Loosen the cylinder head cover attaching bolts evenly over two or three stages in the sequence shown in the right figure.

18. Remove the cylinder head cover.

q t i

JEM00107-00094 e r u y w

JEM00108-00095

19. Remove the camshaft pulley and cam angle sensor.

CAUTION:

•

Do not turn the camshaft independently.

•

Do not damage the cylinder head cover gasket surface.

JEM00109-00096

20. Loosen the valve rocker shaft attaching bolts.

21. Remove the valve rocker shaft together with rocker arms from the cylinder head.

JEM00110-00097

EM–30

22. Remove the rocker arms, spacers and wave washers from the removed valve rocker shaft.

NOTE:

•

Arrange the removed parts in oder to so that their respective original installation positions may be known readily.

23. Remove the camshaft bearing caps by removing the attaching bolts.

24. Remove the camshaft from the cylinder head.

JEM00111-00098

JEM00112-00099

25. Loosen the cylinder head bolts evenly over two or three stages in the sequence shown in the right figure.

NOTE:

•

Be certain to loosen the cylinder head bolts. Failure to observe this caution will cause cracks or distortion of the cylinder head, even leading to engine seizure.

r w y i o

u t q e

JEM00113-00100

26. Remove the cylinder head bolts.

REFERENCE:

•

The bolts q and e are shorter the other bolt

Nominal Length of q and e

: 110 mm

Nominal Length of other Bolts: 155 mm

JEM00114-00000

27. Remove the cylinder head from the cylinder block.

NOTE:

•

Place the cylinder head on two suitable wooden blocks in oder that the cylinder head gasket surface may not be damaged.

JEM00115-00101

EM–31

OVERHAUL OF CYLINDER HEAD

DISASSEMBLY OF CYLINDER HEAD

1. Remove the water temperature sensor gauge from the cylinder head.

2. Remove the engine hanger.

3. Remove the valve spring retainer locks, using the following SST.

SST: 09202-87002-000

JEM00116-00102

4. Remove the valve springs.

NOTE:

•

Arrange the removed parts in order so that their installing positions may be known easily.

5. Remove the valves.

NOTE:

•

Arrange the removed parts in order so that their installing positions may be known easily.

6. Remove the valve stem oil seal by your hand or using the following SST.

SST: 09201-87704-000

SST

JEM00117-00103

JEM00118-00104

JEM00119-00105

JEM00120-00106

EM–32

7. Remove the valve spring seats.

NOTE:

•

Arrange the removed parts in order so that their installing positions may be known easily.

8. Wash the disassembled parts except for electrical parts, plastic parts and grease sealed bearings. Dry them by blowing compressed air.

INSPECTION, CLEANING AND REPAIRS OF

CYLINDER HEAD COMPONENTS

1. Cleaning of top of each piston and cylinder block

(1) Turn the crankshaft until each piston is brought to the top dead center.

Using a gasket scraper, remove all carbon deposits from the piston tops.

(2) Using a gasket scraper, remove any remaining gasket material from the top of the cylinder block.

Blow carbon deposits, water and oil from the bolt holes.

WARNING:

•

Protect your eyes during the cleaning operation using compressed air.

CAUTION:

•

Do not scratch the gasket surfaces of the piston and cylinder block.

(3) Set the piston No. 1 to the top dead center.

2. Removal of gasket material

Using a gasket scraper, remove any remaining gasket material from the cylinder head and manifold surfaces.

JEM00121-00107

JEM00122-00108

JEM00123-00109

JEM00124-00110

3. Cleaning of combustion chamber

Using a wire brush, remove all carbon deposits from the combustion chambers.

CAUTION:

•

Be careful not to scratch the cylinder head gasket contact surfaces.

4. Cleaning of valve guide bushings

Using a valve guide brush and solvent, clean all the valve guide bushings.

5. Cleaning of cylinder head

Using a soft brush and solvent, thoroughly clean the cylinder head.

6. Inspection of cylinder head for flatness

Using a precision straight edge and a feeler gauge, check the gasket surfaces contacting the cylinder block and manifolds for warpage.

Maximum Surface Warpage

Cylinder Block Side: 0.10 mm

Intake Manifold Side: 0.10 mm

Exhaust Manifold Side: 0.10 mm

If surface warpage of the cylinder block side exceeds the maximum limit, replace the cylinder head.

EM–33

JEM00125-00111

JEM00126-00112

JEM00127-00113

JEM00128-00114

JEM00129-00115

EM–34

JEM00000-00116

7. Inspection of cylinder head for cracks

Using a dye penetrant, check the combustion chamber, intake and exhaust ports, cylinder head surface and top of the cylinder head for cracks.

If a crack is found, replace the cylinder head.

8. Inspection of camshaft oil clearance

NOTE:

•

Prior to this oil clearance check, the camshaft should be checked for bend in advance.

(1) Install the camshaft to the cylinder head.

(2) Place a plastigage on each bearing.

JEM00130-00117

JEM00131-00118

Plastigauge

JEM00132-00119

(3) Install the bearing caps and rocker shafts. Tighten them to the specified torque.

Tightening Torque

M10 Bolt: 28.4 - 36.3 N·m/Dry

M8 Bolt: 12.7 - 16.7 N·m/Dry

NOTE:

•

Each bearing cap bears a cap number.

•

The intake valve rocker shaft can be identified by the recessed sections on it.

•

The valve rocker shaft should be installed in such a direction that the side having a wider chamfer comes at the timing belt side.

•

Ensure that the bolt holes and bolts are dry when tightening the bolts. (Ensure that no oil or the like gets to the bolt holes and bolts.)

(4) Remove the bearing caps and measure the oil clearance.

Clearance

Specified Value: 0.035 - 0.076 mm

Allowable Limit: 0.17 mm

If the oil clearance exceeds the allowable limit, replace the cylinder head and camshaft as a set.

NOTE:

•

After completion of the check, remove the plastigages.

Wash the camshaft and bearing caps in cleaning solvent.

9. Inspection of camshaft thrust clearance

(1) Apply engine oil to the camshaft journals.

EM–35

JEM00133-00120

JEM00134-00121

JEM00135-00122

EM–36

(2) Install the camshaft to the cylinder head. Install the bearing caps and rocker shafts and tighten them to the specified torque.

Tightening Torque

M10 Bolt: 28.4 - 36.3 N·m/Dry

M8 Bolt: 12.7 - 16.7 N·m /Dry

NOTE:

•

Each bearing cap bears a cap number.

•

The intake valve rocker shaft can be identified by the recessed sections on it.

•

The valve rocker shaft should be installed in such a direction that the side having a wider chamfer comes at the timing belt side.

•

Ensure that the bolt holes and bolts are dry when tightening the bolts. (Ensure that no oil or the like gets to the bolt holes and bolts.)

(3) With a dial gauge attached to the camshaft, measure the thrust clearance.

Thrust Clearance

Specified Value: 0.1 - 0.25 mm

Allowable Limit: 0.45 mm

If the camshaft thrust clearance exceeds the allowable limit, replace the camshaft and cylinder head as a set.

Reference:

Cylinder Head Thrust Surface Width:

4.10 - 4.20 mm

Camshaft Thrust Surface Width:

3.95 - 4.00 mm

JEM00136-00123

JEM00137-00124

10. Inspection and grinding of valves

(1) Visually inspect the valve stem for seizure or damage.

NOTE:

•

If seizure or damage is found, replace the valve and valve guide bush as a set.

•

However, this replacement should be performed only after the checks for the valve seat, valve stem and guide bush have been finished.

•

The valve guide bush hole must be used for refacing the valve seat. Hence, if the valve guide bush hole exhibits any roughness due to seizure, etc., rectify the hole with an adjustable reamer.

Seizure or damage

 

 

 

 



JEM00138-00125

(2) Visually inspect the valve head for melting or damage.

If the valve head exhibits any melting or damage, replace the valve.

If the roughness on the contact surface can be corrected, grind the valve seat contact surface with a valve refacer.

Melting or damage

EM–37

JEM00139-00126

(3) Grind the valves only enough to obtain a smooth contact surface with the valve seat.

Valve Face Angle: 45.5

NOTE:

•

Make sure the valves are ground to the correct valve face angle.

(4) Visually inspect the valve stem end for abnormal wear.

45.5°

JEM00140-00127

Wear

JEM00141-00128

If the valve stem end exhibits abnormal wear, correct the stem end with a valve refacer. However, this correction should be made within a limit of 2 mm from that of standard length.

Reference:

Valve Length (STD)

Intake Valve: 112.8 mm

Exhaust Valve: 114.5 mm

NOTE:

•

Be very careful not to allow the valve to be overheated during grinding.

(5) Inspect the valve head for its stock thickness.

Minimum Stock Thickness

Intake Valve: 0.8 mm

Exhaust Valve: 1.0 mm

If the stock thickness of the valve head is less than the minimum stock thickness, replace it with a new one.

Stock thickness

Grinding surface

JEM00142-00129

JEM00143-00130

EM–38

11. Inspection and cleaning of valve seats

(1) Using a 45-degree valve seat cutter, reface the valve seats. Remove only enough metal stock to clean the seats.

(2) Apply a thin film of red lead (or white lead) to the valve seat.

(3) Let the valve drop by its own weight onto the valve seat two or three times.

(4) Take out the valve.

(5) Inspect the valve face and seat for the following items.

Ensure that the valve seat contact surface of the valve is continuous over the whole circumference.

If not, replace the valve.

Ensure that the valve contact surface of the valve seat is continuous over the whole circumference.

If not, reface the valve seat.

Measure the width of the contact surface of valve seat.

Contact Surface of Valve Seat: 1.2 - 1.6 mm

If not, reface the valve seat.

12. Refacing of valve seat

(1) Refacing procedure for intake valve seats q

Using a 45-degree cutter, recondition the roughness on the valve-to-valve seat contact surface, only enough to obtain a smooth surface.

Using a 30-degree cutter, cut the valve seat in such way that the circumference of the surface refaced by the 45-degree cutter may become 29

0.1 mm

45°

JEM00144-00131

JEM00145-00132

Center of valve contact position

Seat contact width

JEM00146-00133

45°

JEM00147-00134

29 mm

JEM00148-00135

EM–39

Using a 70-degree cutter, cut the seat in such way that the width, of the surface refaced by the 45-degree cutter may became 1.4 mm.

Using the 45-degree cutter, remove burrs produced during the refacing by the 30-degree and

70-degree cutters.

1.4 mm (0.055 inch)

JEM00149-00136

30°

70°

45°

JEM00150-00137

(2) Refacing procedure for exhaust valve seats q

Using a 45-degree cutter, recondition the roughness on the valve-to-valve seat contact surface, only enough to obtain a smooth surface.

45° w

Using a 20-degree cutter, cut the valve seat in such a way that the circumference of the surface refaced by the 45-degree cutter may become

25 mm.

25 mm

JEM00151-00138

20°

45° e

Using a 70-degree cutter, cut the valve seat in such a way that the width of the surface refaced by the 45-degree cutter may become 1.4 mm.

1.4 mm

45°

JEM00152-00139

JEM00153-00140

EM–40

Using the 45-degree cutter, remove burrs produced during the refacing by the 20-degree and

70-degree cutters.

13. Hand lapping of valves

(1) Perform hand lapping of the valves and valve seats, using an abrasive compound.

(2) Clean the valves and valve seats after the hand lapping of the valves.

20°

45°

70°

JEM00154-00141

JEM00155-00000

14. Inspection of valve recession

After the valve seat has been refaced, install the new valve. Measure the distance between the cylinder attaching surface of the cylinder head (attaching surface of the cylinder head gasket) and the upper most section of the valve. Ensure that the distance does not exceed the following maximum limit.

Maximum Limit

Intake Valve: 2.775 mm

Exhaust Valve: 6.026 mm

If the recession exceeds the maximum limit, replace the cylinder head.

15. Inspection of valve stem-to-guide bushing oil clearance

(1) Using a caliper gauge, measure the inner diameter of the valve guide at six points.

Record the measured values.

Drive a new valve guide bush into position, until the snap ring contacts the cylinder head, using the following SST.

SST: 09201-87705-000

CAUTION:

•

Be very careful not to give an excessive impact during the installation. Failure to observe this caution will result in valve guide bush cracks.

•

Care should be exercised not to detach the snap ring due to driving the valve guide bush excessively.

09201-87705

-000

JEM00156-00142

JEM00157-00143

JEM00158-00144

Using an adjustable reamer, ream the valve guide bush to remove any burr or the like.

NOTE:

•

This reaming should be made only enough to remove the burr or the like.

Inspection of oil clearance

Ensure that the oil clearance meets the specifications.

Oil Clearance

Specified Value:

Intake 0.030 - 0.055 mm

Allowable Limit:

Intake 0.08 mm

(2) Exhaust valve guide bush

NOTE:

•

When the locating ring for the valve guide bush is located 14 mm from the upper end of the valve guide bush, replace the cylinder head.

Drive out the valve guide bush from the combustion chamber side, using the following SST.

SST: 09201-87705-000

(3) Using a micrometer, measure the diameter of the valve stem at six points.

Record the measured values.

EM–41

JEM00159-00145

JEM00160-00146

JEM00161-00147

JEM00162-00148

JEM00163-00149

EM–42

(4) Calculation of oil clearance

Calculate the oil clearance of each valve according to the following formula.

Oil clearance = Inner diameter of valve stem guide –

Outer diameter of valve stem

Specified Oil Clearance

Intake Valve Side: 0.030 - 0.055 mm

Exhaust Valve Side: 0.035 - 0.060 mm

Allowable Limit

Intake Valve Side: 0.080 mm

Exhaust Valve Side: 0.090 mm

If the calculated oil clearance exceeds the allowable limit, replace the valve guide bush and valve as a set.

JEM00164-00000

16. Replacement of valve guide bush

CAUTION:

•

Removal and installation of the valve guide bush should be carried out while the cylinder head temperature is 80

C - 100

C after heating it gradually.

(1) Intake valve guide bush

NOTE:

•

If the intake valve guide bush has been already installed with a locating ring, replace the cylinder head.

Drive out the valve guide bush from the combustion chamber side, using the following SST.

SST: 09201-87705-000

NOTE:

•

Be very careful not to tap the cylinder head.

Drive a new valve guide bush into position, until the snap ring contacts the cylinder head, using the following SST.

SST: 09201-87705-000

CAUTION:

•

Be very careful not to give an excessive impact during the installation. Failure to observe this caution will result in valve guide bush cracks.

•

Care should be exercised not to detach the snap ring due to driving the valve guide bush excessively.

Locating ring

JEM00165-00150

JEM00166-00151

JEM00167-00152

EM–43

Using an adjustable reamer, ream the valve guide bush to remove any burr or the like.

NOTE:

•

This reaming should be made only enough to remove the burr or the like.

Inspection of oil clearance

Ensure that the oil clearance meets the specifications.

Oil Clearance

Specified Value:

Exhaust 0.035 - 0.060 mm

Allowable Limit:

Exhaust 0.09 mm

17. Inspection of valve springs

(1) Check the valve spring for squareness, using a steel square.

Maximum Squareness: 1.6 mm

If the squareness exceeds the maximum limit, replace the valve spring.

(2) Measure the valve spring for free length and spring tension, using a spring tester.

Minimum Free Length

Pink Marked Spring: 43.9 mm

Orange Marked Spring: 46.1 mm

Minimum Tension/Installation Height

Pink Marked Spring: 244.9 N/38.0 mm

Orange Marked Spring: 208.9 N/38 mm

If the minimum free length and/or minimum tension is less than the minimum limit, replace the valve spring.

Reference:

Standard Free Length

Pink Marked Spring: 45.2

0.5 mm

Orange Marked Spring: About 47.4 mm

JEM00168-00153

Not to exceed

1.6 mm

JEM00169-00154

JEM00170-00155

JEM00171-00156

EM–44

(3) Check of valve spring edge surface for levelness q

Apply a load of 49 N to the valve spring on a spring tester.

Under the condition q above, insert a thickness gauge at the arrowheaded point “A” at the right figure.

Here, the thickness gauge should measure 0.07

mm in thickness and 12.5 mm in width. Ensure that the tip-end of the thickness gauge will not reach the center of the coil spring.

If the tip-end of the thickness gauge reaches the center of the coil spring, replace the coil spring with a new part.

18. Inspection of valve rocker arms and valve rocker shaft

(1) Visually inspect the valve rocker arm for cracks, seizure or wear.

Replace the valve rocker arm, if necessary.

(2) If the valve rocker arm-to-cam contact surface is worn excessively, replace the rocker arm.

(3) Visually inspect the valve rocker shaft for cracks, seizure or wear.

Replace the valve rocker shaft, if necessary.

49 N

JEM00172-00157

Roughness

JEM00173-00158

JEM00174-00159

(4) Valve rocker shaft-to-valve rocker arm

•

Using a dial gauge, measure the inner diameter of the valve rocker arm in two directions, 90 degrees apart from each other.

•

Using a micrometer, measure the outer diameter of the valve rocker arm attaching position of the valve rocker shaft in two directions, 90 degrees apart from each other.

•

Calculate the oil clearance by subtracting the rocker shaft diameter from the rocker arm diameter.

Oil Clearance

Specified Value: 0.012 - 0.053 mm

Allowable Limit: 0.08 mm

NOTE:

•

The measurement of the rocker shaft outer diameter must be performed at the assembling position of each rocker shaft.

JEM00175-00160

EM–45

Recess

Reference:

•

Identification of valve rocker shafts

•

On the intake valve rocker shaft, recesses for the spark plug tube are provided.

•

Also, the oil grooves are provided very closely to the bolt holes.

•

On the exhaust valve rocker shaft, the oil grooves are located near the midpoint of the bolt holes.

•

Installing direction of valve rocker shaft

The valve rocker shaft should be installed in such a way that the side having a wider chamfer comes at the timing belt side.

•

Identification of valve rocker arm

The valve rocker arm comes in four kinds; two kinds each for the intake side and exhaust side, as shown in the right figure.

•

Specified dimensions of valve rocker shaft and valve rocker arm

Outer Diameter of Valve Rocker Shaft:

19.468 - 19.488 mm

Bore Diameter of Valve Rocker Arm:

19.500 - 19.521 mm

19. Inspection of valve rocker arm, spacer and wave washer

(1) Measure the free width of the spacer, using vernier calipers.

Minimum Free Width: 22.0 mm

Replace the spacer whose free length is less than the minimum free width.

Timing belt side

JEM00176-00161

No. 1

No. 2 No. 3 No. 4

JEM00177-00162

JEM00178-00163

(2) Visually inspect the wave washer for flattened condition or damage.

Replace the wave washer, if necessary.

20. Inspection of camshaft

(1) Checking camshaft for runout

Support the camshaft at its both ends with V-shaped blocks. Set a dial gauge to the mid-point of the center journal section of the camshaft. Turn the camshaft one turn, making sure that the camshaft will not move in the axial direction. Take a reading on the dial gauge during the turning. Calculate the maximum runout, i.e.

the difference between the maximum and minimum readings.

Maximum Runout: 0.03 mm

If the runout exceeds the maximum limit, replace the camshaft.

JEM00179-00164

JEM00180-00165

EM–46

(2) Checking of cam lobe height

Measure the cam lobe height, using a micrometer.

Specified Cam Lobe Height:

Intake: 33.434 - 33.634 mm

Exhaust: 33.17 - 33.37 mm

Minimum Limit:

Intake: 33.2 mm

Exhaust: 33.0 mm

(3) Inspection of oil seal contact surface

Inspect the oil seal contact surface for abnormal wear.

Replace the camshaft if the contact surface exhibits any abnormal wear.

(4) Inspection of groove for driving cam angle sensor

Visually inspect to see if any damage is present at the groove for driving the cam angle sensor.

Replace the camshaft if the groove exhibits any damage.

NOTE:

•

If any damage is present, check the cam angle sensor side, too.

21. Inspection of manifold and surge tank

(1) Check the cylinder head attaching surface of the exhaust manifold for warpage, using a straightedge and a thickness gauge.

Maximum Warpage Limit: 0.1 mm

If the warpage exceeds the maximum limit, replace the exhaust manifold No. 1.

(2) Check the contact surface of the intake manifold with the cylinder head.

Maximum Warpage: 0.1 mm

JEM00181-00166

JEM00182-00167

JEM00183-00168

JEM00184-00169

JEM00185-00170

EM–47

22. Check the valve spring seats, valve spring retainers and valve retainer locks for damage and cracks.

If any damage is present, replace such faulty parts.

JEM00186-00171

23. Inspection of cylinder head cover

(1) Visually inspect the cylinder head cover gasket for damage.

If any damage is present, replace the cylinder head gasket with a new one.

Install the cylinder head gasket to the cylinder head cover in such a direction that the identification mark may face toward the intake manifold side.

(2) Visually inspect the rubber grommets of the spark plug tubes for damage.

Replace the rubber grommets, as required.

JEM00187-00000

JEM00188-00172

Replacement of spark plug grommet q

Drive out the spark plug grommets, using the slotted pin puller.

JEM00189-00173 w

Install a new spark plug grommet, using the following SST.

SST: 09268-87702-000

NOTE:

•

Make sure that the grommet is not tilted when it is driven into position.

•

Be sure to use a suitable wooden piece so as to prevent the cylinder head cover from damage.

•

Be very careful not to damage the lip section of the grommet.

09388-87702-000

JEM00190-00174

EM–48

ASSEMBLY OF CYLINDER HEAD

NOTE:

•

Thoroughly clean all parts to be assembled.

•

Before installing the parts, apply new engine oil to all sliding and rotating surfaces.

•

Replace all gaskets and oil seals with new ones.

1. Assembly of cylinder head (When a new cylinder head is installed:)

When a new cylinder head is installed, spark plug tubes and a heater outlet tube have been furnished separately.

Assemble these parts, following the procedure given below.

(1) Wash the cylinder head in cleaning solvent and dry it with compressed air.

(2) Apply a thin film of the Three Bond 1377B to the cylinder head attaching surfaces for the spark plug tubes.

(3) With a wooden piece or the like placed on the upper end of the spark plug tube, drive the spark plug tube into the cylinder head in such an extent that the distance between the spark plug tightening surface and the upper end of the spark plug tube becomes

139 mm.

NOTE:

•

Be very careful not to drive the spark plug too deeply.

•

Be very careful not to damage the upper end of the spark plug tube.

•

When driving the spark plug tube into position, make sure that the tube will not tilt in relation to the cylinder head tube hole.

(4) Put a mark at a point 45.0

1.0 mm from the forward end of the heater outlet tube.

JEM00191-00000

JEM00192-00176

JEM00193-00177

JEM00194-00178

JEM00195-00179

(5) Apply a thin film of the Three Bond 1377B to the attaching section for the heater outlet tube on the cylinder head.

(6) With a wooden piece interposed, drive the heater outlet tube to the point marked in Step (4).

(7) After completion of the operation, remove any oozed bond, wooden chips and so forth.

2. Install the valve spring seats to the cylinder head.

3. Installation of valve stem oil seal

(1) Apply engine oil to the bore of the valve stem oil seal.

(2) Drive the valve stem oil seal into the valve stem guide bush by hand.

NOTE:

•

When driving the oil seat, make sure that the oil seal is not tilted.

•

Do not reuse any oil seal which was tilted or driven diagonally.

•

Hold the frame of the oil seal. Do not touch the rubber section of the oil seal.

EM–49

JEM00196-00180

JEM00197-00181

JEM00198-00182

JEM00199-00183

JEM00200-00184

EM–50

(3) Turn the oil seal slightly by hand to see if it can be turned.

NOTE:

•

Never rotate the oil seal more than one turn, because excessive turning may cause scratches on the oil seal.

•

If the oil seal can not be turned by hand, it means that the oil seal has been tilted, driven diagonally or pressfitted improperly.

•

Do not reuse any oil seal which was tilted or driven diagonally.

4. Apply oil to the valve stem. Install the valve to the cylinder head.

NOTE:

•

Care must be exercised as to the installing position. Do not pull out the valve once it has been inserted.

•

If the inserted valve should be pulled out, replace the valve stem oil seal with a new one.

Reference:

Identification of Valves

Engine Identification No.

HC-EJ r

JEM00201-00185

JEM00202-00186

5. Assembly of valve springs, valve spring retainers and valve spring retainer locks

(1) Assemble the valve spring in such a way that the painted side (the side having a larger pitch) comes at the valve spring retainer.

(2) Install the valve spring retainer to the valve spring.

Install the valve spring retainer locks while compressing the valve spring retainer, using the following SST.

SST: 09202-87002-000

JEM00203-00187

SST

JEM00204-00188

EM–51

(3) After installing the valve spring retainer lock, lightly tap the valve spring retainer with a hammer or the like so as to ensure that the valve spring retainer locks are installed securely.

WARNING:

•

During this operation, care must be exercised to ensure that the valve spring retainer or retainer locks may not be jumped out.

•

Protect your eyes with safety goggles during this operation.

6. Clean and dry the cylinder block head bolt holes.

WARNING:

•

Protect your eyes with goggles when using compressed air.

JEM00205-00189

7. Clean the cylinder block upper gasket surface. Install the cylinder head gasket, while aligning it with the pin ring for locating use.

Intake manifold side

JEM00206-00190

JEM00207-00191

8. Turn the crankshaft so that the crankshaft key groove may come at the top position.

JEM00208-00192

9. Clean the threaded portion of the water temperature sensor. Wind seal tape around the threaded portion and install the sensor to the cylinder head.

Tightening Torque: 24.5 - 34.3 N·m

NOTE:

•

The new water temperature sensor is coated with sealer. Therefore, if the sensor is replaced with a new one, remove the sealer thoroughly before winding seal tape.

Moreover, be sure to clean the cylinder head side threaded holes.

JEM00209-00193

EM–52

10. Install the cylinder head on the cylinder block.

JEM00210-00194

11. Coat each cylinder head bolt with a thin film of engine oil.

Using these bolts, install the cylinder head to the cylinder block. Tighten the bolts evenly over two or three stages, following the sequence shown in the right figure.

Tightening Torque: 58.8 - 66.7 N·m

NOTE:

•

Failure to tighten the bolts evenly may cause cracks and distortion of the cylinder head, even leading to engine seizure.

•

Make sure that all the bolts are torqued uniformly to a constant value, also within the specified range.

12. Installation of camshaft and rocker shafts

(1) Wash and dry the holes for the camshaft cap attaching bolts.

WARNING:

•

Protect your eyes with goggles when using compressed air.

(2) Liberally apply engine oil to the journal sections and thrust bearing sections.

NOTE:

•

Be very careful not to allow any oil to flow into the bearing cap attaching holes.

JEM00211-00195

JEM00212-00196

JEM00213-00197

(3) Assemble the camshaft on the cylinder head in such a way that the locating pin for the camshaft timing belt pulley comes exactly at the top position.

JEM00214-00198

EM–53

(4) Apply the Three Bond 1104 to the camshaft cap No. 1 attaching section of the cylinder head at those points shown in the right figure.

(5) Apply engine oil to the camshaft journal section.

NOTE:

•

Be very careful not to allow any oil to flow into the bearing cap attaching holes.

(6) Install the camshaft bearing caps in the sequence of embossed figures on the caps.

NOTE:

•

Before the camshaft bearing caps are installed, wipe off any bond oozed from the camshaft cap No. 1.

(7) Assemble the valve rocker arms and wave washers onto the valve rocker shaft, while applying engine oil liberally as shown in the right figure.

NOTE:

•

The intake valve rocker shaft can be identified by the recessed sections on it.

•

The larger chamber end section of valve rocker shaft faces toward the timing belt side.

(8) Install the valve rocker shaft on the camshaft caps.

NOTE:

•

For easier installation, it is advisable to insert the camshaft cap side of rocker arm first.

No. 1

JEM00215-00199

JEM00216-00200

JEM00217-00201

JEM00218-00202

EM–54

(9) Clean the attaching bolts and dry them with compressed air. Install them to the cylinder head through the rocker shafts and camshaft caps. Tighten the bolts evenly over two or three stages to the specified torque.

Tightening Torque

M10 Bolt: 28.4 - 36.3 N·m/Dry

M8 Bolt: 12.7 - 16.7 N·m/Dry

CAUTION:

•

Never exceed the specified tightening torque.

•

The bolts and bolt holes should be dry when tightening the bolts.

WARNING:

•

Protect your eyes with safety goggles, when using compressed air.

13. Install the spacers into between the intake valve rocker arms on the rocker shaft.

JEM00219-00203

JEM00220-00204

14. Apply engine oil to the lip section of the type T oil seal of the camshaft.

15. Drive the oil seal into position, using the following SST.

SST: 09636-20010-000

CAUTION:

•

Be very careful not to tilt the oil seal against the attaching hole of the camshaft oil seal.

16. Installation of the camshaft timing belt pulley.

(Refer to the Timing Belt section of the service manual.)

17. Install the cylinder head cover and tighten the attaching bolts evenly two or three stages, following the sequence shown in the right figure.

Tightening Torque: 2.9 - 4.9 N·m u q r

JEM00221-00205 y t e w i

JEM00222-00206

EM–55

18. Connect the connector to the water temperature sensor.

19. Install the ignition coil to the cylinder head cover and tighten it.

Tightening Torque: 2.9 - 4.9 N·m

20. Connect the resistive cords between the ignition coil and the spark plug.

IG coil for No. 2 cylinder – No. 3 cylinder

IG coil for No. 4 cylinder – No. 1 cylinder

21. Installation of exhaust manifold

(1) Install the new exhaust manifold gasket in such a way that the arrow mark can be visible and it faces toward the timing belt.

Allow mark

JEM00223-00207

(2) Install the exhaust manifold to the cylinder head.

NOTE:

•

Be very careful not to interfere with other parts.

(3) Install and tighten the attaching bolts and nuts evenly over two to three stages, following the sequence in the right figure.

Tightening Torque: 29.4 - 44.1 N·m

(4) Install a new O-ring to the oil level gauge guide.

CAUTION:

•

Do not reuse the O-ring.

(5) Insert the oil level gauge guide to the cylinder block.

CAUTION:

•

Be very careful not to damage the O-ring.

u w q t

JEM00224-00208 y e r i

JEM00225-00209

JEM00226-00000

(6) Install the exhaust manifold heat insulator to the exhaust manifold with the attaching bolts and nut.

JEM00227-00210

EM–56

(7) Install and tighten the attaching bolt of the oil level gauge guide.

(8) Insert the oil level gauge to the oil level gauge guide.

JEM00228-00211

(9) Connect the exhaust front pipe to the exhaust manifold with a new gasket interposed.

CAUTION:

•

Do not reuse the used gaskets.

(10) Tighten the attaching bolts of the exhaust front pipe to the specified torque.

Tightening Torque: 41.6 - 62.4 N·m

22. Installation of intake manifold

(1) Install a new intake manifold gasket to the cylinder head.

(2) Install the intake manifold to the cylinder head.

CAUTION:

•

Do not interfere with other parts.

(3) Install the attaching bolts and nuts of the intake manifold.

NOTE:

•

Be sure to install the following parts interposed with the attaching bolts and nuts of the intake manifold.

1. By-pass pipe

2. Oil pressure switch wire clamp

3. Power steering vane pump bracket.

(4) Tighten the intake manifold attaching bolts and nuts evenly to the specified torque over two or three stages in the sequence as indicated in the right figure.

Tightening Torque: 14.7 - 21.6 N·m

(5) Install the intake manifold stays and tighten the attaching bolts.

(6) Install the engine wire ground terminal to the intake manifold.

JEM00229-00212

JEM00230-00213 i y o t

e q w r u

JEM00231-00214

JEM00232-00215

(7) Connect the rubber hoses for brake booster and VSV.

(8) Connect the fuel inlet hose and return hose.

(9) Connect the water hose.

(10) Installation of engine wire q

Connect the connector of the engine wire to the following parts.

a. Ignition coils b. Injectors c. Pressure sensor d. Throttle position sensor e. Intake air temperature sensor f. Idle-up VSV g. Oxygen sensor h. Cam angle sensor w

Install the harness clamps to each bracket.

(11) Install the timing belt.

(Refer to installation of timing belt section)

(12) Install the alternator

EM–57

JEM00233-00216

JEM00234-00217

JEM00235-00218

JEM00236-00000

JEM00237-00219

EM–58

(13) Install the power steering vane pump

(14) Install the acceleration cable to the throttle body and adjust it.

JEM00238-00220

JEM00239-00221

(15) Installation of air cleaner.

Install the air cleaner lower case to the engine and tighten the attaching bolts.

JEM00240-00222 w

Install the air filter element to the air cleaner lower case.

Install the air cleaner upper case with the air duct and fasten the clamp.

Tighten the air intake hose attaching bolt.

Connect the rubber hoses to the air cleaner.

JEM00241-00223

JEM00242-00000

(16) Install the battery carrier and the battery.

(17) Connect the battery cable to each terminals of the battery.

(18) Fill the coolant

(Refer to CO section of this manual)

EM–59

JEM00243-00224

JEM00244-00000

EM–60

CYLINDER BLOCK

COMPONENTS

Front w q

★

: Non-reusable parts

e r

★ i

★ y u

★ t o

★

Timing belt cover No. 1 w

Timing belt cover No. 2 e

Water pump assembly r

Water pump gasket t

Dust seal y

Oil pump assembly u

Oil seal i

Cylinder head gasket o

Cylinder block

Crankshaft

Crankshaft timing belt pulley flange

Crankshaft timing belt pulley

Crankshaft pulley

Crankshaft bearing

Piston with pin

Piston ring

Connecting rod

Connecting rod bearing

Oil pan

Oil pump strainer

Rear end plate

Oil seal retainer

Oil seal

Crankshaft thrust bearing

JEM00245-00225

INSTRUCTION PRIOR TO OPERATION

•

Install the fender cover to the fenders so that no scratch may be made to the fenders.

•

Be sure to read the general information section of the service manual.

ENGINE REMOVAL

1. Disconnect the battery ground cable from the negative (–) terminal of the battery.

2. Removal of engine hood

(1) Disconnect the windshield washer hose from the joint section.

(2) Remove the hose from the clamp of the engine hood.

(3) Remove the hood, being very careful not to scratch the body and hood.

3. Disconnect the wires of the positive (+) terminal from the battery positive terminal.

4. Drain the coolant.

(Refer to the CO section of the service manual.)

5. Drain the engine oil.

(Refer to the MA section of the service manual.)

6. Removal of battery

(1) Remove the battery hold down clamp by removing the two attaching nuts.

(2) Remove the battery from the battery carrier.

(3) Remove the wiring harness from the clamp section of the battery carrier.

(4) Disconnect the engine wire harness clamp from the battery carrier.

(5) Remove the battery carrier by removing the four attaching bolts.

7. Remove the power steering vane pump from the engine.

Suspend the removed vane pump at the body side, using an adequate rope.

EM–61

JEM00246-00000

JEM00247-00226

JEM00248-00227

JEM00249-00228

EM–62

8. Remove the fan and fan shroud.

9. Remove the radiator.

10. Remove the air cleaner.

JEM00250-00229

JEM00251-00230

11. Remove the alternator.

12. Remove the accelerator cable and rubber hoses.

13. Disconnect the following connectors and remove the engine wire

(1) Ignition coils

(2) Injectors

(3) Pressure sensor

(4) Throttle position sensor

(5) Intake air temperature sensor

(6) Idle-up VSV

(7) Water temperature sensor

(8) Oxygen sensor

(9) Cam angle sensor

JEM00252-00231

JEM00253-00232

JEM00254-00233

EM–63

14. Disconnect the fuel inlet hose and return hose.

CAUTION:

•

The fuel pressure at inside of the fuel line is approximately 284 kPa higher than the atmospheric pressure.

•

Therefore, be sure to gradually pull out the rubber hoses so as to prevent fuel from splashing.

15. Disconnect the heater hoses.

CAUTION:

•

Be careful not to deform the heater inlet and outlet pipes during disconnection. The heater core and pipe are made copper.

NOTE:

•

Place a suitable container under the heater hose connecting section, for the coolant may flow out.

16. Remove the charcoal canister from the engine compartment.

17. Remove the clutch cable with bracket from the transmission.

18. Removal of front exhaust pipe.

(1) Disconnect the attaching bolt and nuts of the exhaust manifold.

(2) Disconnect the clamp of the front exhaust pipe.

JEM00000-00234

Inlet

Return

JEM00255-00235

JEM00256-00236

JEM00257-00237

JEM00258-00238

EM–64

(3) Remove the bracket of the front exhaust pipe clamp from the transmission.

(4) Remove the front exhaust pipe from the engine by disconnecting the attaching nuts of the main muffler.

19. Remove the following stiffener from the engine and the transmission.

(1) Engine stiffener RH

(2) Engine stiffener LH

(3) Power train stiffener

20. Remove the starter from the engine by disconnecting the attaching bolts.

21. Disconnect the attaching bolts of the engine with the transmission.

22. Disconnect the attaching bolts of the engine mounting bracket.

23. Take out the engine from the engine compartment.

CAUTION:

•

Be very careful not to allow the engine to hit to the vehicle body and other parts.

JEM00259-00239

JEM00260-00240

JEM00261-00241

JEM00262-00242

JEM00263-00243

24. Place the engine on the suitable engine stand.

EM–65

JEM00264-00000

25. Remove the timing belt.

26. Removal of cylinder head cover.

(1) Remove the ignition coils and resistive cords.

(2) Remove the cylinder head cover attaching bolts.

(3) Remove the cylinder head cover.

q t i

JEM00265-00244 e r u y w

JEM00266-00245

27. Removal of cylinder head.

(1) Loosen the cylinder head attaching bolts evenly over two or three stages in the sequence indicated in the right figure.

NOTE:

•

Be certain to loosen the cylinder head bolts evenly.

Failure to observe this caution will cause cracks or distortion of the cylinder head, even leading to engine seizure.

(2) Remove the cylinder head bolts.

(3) Remove the cylinder head from the cylinder block.

r w y i o

u t q e

JEM00267-00246

JEM00268-00247

EM–66

(4) Remove the cylinder head gasket.

(5) Remove any remaining gasket material from the gasket surfaces of the cylinder head and cylinder block, using the gasket scraper.

DISASSEMBLY OF CYLINDER BLOCK

1. Remove the oil pressure switch and oil filter.

2. Remove the air conditioner compressor bracket.

(Air conditioner equipped vehicle only)

3. Remove the crankshaft timing belt pulley bolt.

NOTE:

•

Prevent the ring gear from turning, using the following

SST.

SST: 09210-87701-000

JEM00269-00248

JEM00270-00249

JEM00271-00250

JEM00272-00251

SST

JEM00273-00252

EM–67

4. Remove the crankshaft timing belt pulley.

NOTE:

•

If the crankshaft timing belt pulley can not be removed by hand, install the following SST with the crankshaft timing belt pulley bolt interposed.

SST: 09609-20011-000

5. Remove the crankshaft timing belt pulley flange.

JEM00274-00253

SST

JEM00275-00254

JEM00276-00255

6. Remove the tensioner and tension spring.

7. Remove the water pump.

8. Remove the water pump gasket.

JEM00277-00256

JEM00278-00000

EM–68

9. Remove the alternator bracket.

10. Remove the water inlet and thermostat.

11. Remove the water hose for the throttle body.

12. Remove the pressure plate and clutch disc. (M/T vehicle only)

NOTE:

•

Prevent the pressure plate from turning, using the following SST.

SST: 09210-87701-000

13. Check of flywheel for runout (M/T vehicle only)

NOTE:

•

If the runout does not conform to the specification, confirm the tightening torque of the flywheel. Only case where the tightening torque conforms to the specified value, replace the flywheel.

JEM00279-00257

JEM00280-00258

JEM00281-00259

SST

JEM00282-00260

JEM00283-00261

14. Loosen the attaching bolts of the flywheel or drive plate in the sequence as indicated in the right figure. Remove the flywheel or drive plate.

NOTE:

•

Prevent the flywheel from turning, using the following

SST.

SST: 09210-87701-000

15. Remove the rear end plate.

EM–69

t q r w y e

SST

JEM00284-00262

JEM00285-00263

16. Removal of oil pan

(1) Prepare two suitable wooden blocks. Place the cylinder block on those blocks.

NOTE:

•

Be very careful not to damage the piston head.

(2) Loosen the attaching bolts and nuts of the oil pan over two or three stages. Pull out the bolts and nuts.

(3) Separate the oil pan from the cylinder block by driving the following SST into between the cylinder block and the oil pan.

SST: 09032-00100-000

17. Remove the oil pan gasket.

JEM00286-00264

SST

JEM00287-00265

JEM00288-00266

EM–70

18. Remove the rear oil seal retainer.

19. Remove the oil strainer.

20. Remove the oil pump.

21. Measurement of connecting rod thrust clearance.

Measure the thrust clearance between the connecting rod and the crankshaft, using a thickness gauge.

Thrust Clearance

Standard: 0.15 - 0.4 mm

Maximum: 0.45 mm

NOTE:

•

The thrust clearance should be measured while the connecting rod is being pushed against either side of the crankshaft in the axial direction. Measure the thrust clearance at the opposite side.

If the clearance exceeds the specified value, replace the connecting rod or the crankshaft, or both of them, referring to the width of the big end of the connecting rod in the thrust direction and the side width of the crankpin journal.

JEM00289-00267

Gasket

JEM00290-00268

JEM00291-00269

JEM00292-00270

Reference:

Width of big end of connecting rod in thrust direction

21.80 - 21.85 mm

Side width of crankpin

22.0 - 22.2 mm

Crankshaft HC-EJ engine

A B

EM–71

JEM00293-00271

22. Measurement of crankpin journal oil clearance

(1) Install the flywheel temporarily.

(2) Wipe off any oil from the side of the mate surface between the connecting rod bearing cap and the connecting rod. Daub a mate mark with an oily paint on the side so that the parts can be assembled correctly in the original combination.

(Also ensure that the cylinder number may be identified)

(3) Turn the crankshaft, until the connecting rod bearing cap to be removed comes at the oil pan side.

(4) Lock the flywheel to prevent the crankshaft from turning, using the following SST.

SST: 09210-87701-000

(5) Loosen the connecting rod bearing cap nuts evenly over two or three stages. Then, remove the connecting rod bearing cap nuts.

SST

09210-87701-

000

JEM00294-00272

JEM00295-00273

JEM00296-00274

EM–72

(6) Remove the bearing cap.

NOTE:

•

Replace the crankshaft if the crankpin journals exhibit damages, such as seizure.

(7) Place a plastigage on the crankpin journal.

NOTE:

•

Wipe off any oil from the crankpin journal.

JEM00297-00275

JEM00298-00276

(8) Install the connecting rod cap, making sure that the mate marks are lined up. Tighten the connecting rod bearing cap nuts evenly over two or three stages to the specified torque.

Tightening Torque: 34.3 - 44.1 N·m

NOTE:

•

When tightening of the bearing cap nuts, apply engine oil to the bearing cap nuts.

•

Prevent the crankshaft from turning, using the SST.

SST: 09210-87701-000

(9) Loosen the connecting rod bearing cap nuts evenly over two or three stages. Then, remove the connecting rod bearing cap.

NOTE:

•

Prevent the crankshaft from turning, using the SST.

SST: 09210-87701-000

09210-87701-

000

(10) Measure the plastigage width at its widest point.

Oil Clearance: 0.020 - 0.044 mm

If the oil clearance fails to conform to the specified value, measure the crankpin journal diameter and select a suitable connecting rod bearing or replace the crankshaft.

(11) Remove the plastigage from the crankpin journal.

(12) Measure the oil clearances of the remaining crankpin journals.

JEM00299-00277

JEM00300-00278

JEM00301-00279

23. Selection of connecting rod bearings

NOTE:

•

The replacement of the connecting rod bearings should be performed after all inspections have been finished.

(1) Read the connecting rod big end bore code number.

NOTE:

•

The connecting rod big end bore code number comes in three kinds of 4, 5 and 6.

(2) Measure the diameter of the crankpin journal.

The measurement should be performed at four points,

90 degrees spaced, for each crankpin journal at the points shown in the right figure. The maximum value is regarded as the crankpin journal diameter.

However, if the variation in the measured diameters exceeds 0.044 mm, replace the crankshaft.

EM–73

Front mark

Connecting rod big end bore code number

JEM00302-00280

A B

4 14 4 14 4 14 4 14

Unit: mm

JEM00303-00281

(3) Select the connecting rod bearing or replace the crankshaft, based on the results of (1) and (2).

Connecting rod big end bore code number

Crankpin journal diameter Bearing classification number Remarks

44.993 - 45.000

44.985 - 44.992

44.976 - 44.984

44.975 or less

44.993 - 45.000

44.985 - 44.992

44.976 - 44.984

44.975 or less

44.993 - 45.000

44.985 - 44.992

44.976 - 44.984

44.975 or less

—

Crankshaft replacement

—

Crankshaft replacement

—

Crankshaft replacement

JEM00304-00000

24. Removal of pistons

(1) Remove all carbon deposits from the piston ring ridges.

(2) Turn the crankshaft, until the connecting rod bearing cap to be removed comes at the oil pan side.

JEM00305-00282

EM–74

(3) Lock the flywheel to prevent the crankshaft from turning, using the following SST.

SST: 09210-87701-000

(4) Loosen the connecting rod bearing cap nuts evenly over two or three stages. Then, remove the connecting rod bearing cap nuts.

(5) Cover each connecting rod bolt with a short piece of hose to protect the crankpin journal from damage.

09210-87701-

000

JEM00306-00283

JEM00307-00284

(6) Push out the piston and connecting rod assembly and the upper bearing through the top of the cylinder block.

NOTE:

•

Arrange the disassembled pistons and connecting rod in order so that their installation positions may be known readily.

•

Care should be exercised so as not to damage the bearings.

25. Remove the flywheel.

NOTE:

•

Prevent the ring gear from turning with the SST.

SST: 09210-87701-000

SST

JEM00308-00285

JEM00309-00286

JEM00310-00287

EM–75

26. Check of crankshaft thrust clearance

NOTE:

•

Measure the thrust clearance, using a dial gauge.

Thrust Clearance

Specified Value: 0.02 - 0.22 mm

Allowable Limit: 0.30 mm

If the thrust clearance exceeds the allowable limit, measure the width of the crankshaft thrust bearing contact surface. If the measured value is less than 23.59 mm, replace the thrust washer. If the measured value exceeds

23.59 mm, replace the crankshaft and thrust washer.

27. Check of crankshaft main journal oil clearance

(1) Gradually loosen the main bearing cap bolts over three stages in the numerical sequence shown in the figure. Remove the bearing cap bolts.

r i !0

e u o

(2) With the main bearing cap bolts inserted into the bolt holes of the main bearing cap, wiggle the bearing cap back and forth. Remove the bearing cap together with the lower bearing.

NOTE:

•

Keep the lower bearing fitted to the main bearing cap.

Arrange the removed main bearing caps in order.

JEM00311-00288 w y q

JEM00312-00289

JEM00313-00290

(3) Lift off the crankshaft.

NOTE:

•

Be very careful not to allow the main bearings to be mixed with the bearings of the other cylinders.

•

Remove the thrust washer.

•

If the main journal or crankshaft bearing exhibit damages, replace the crankshaft or crankshaft bearing as necessary.

(4) Clean the main journals and bearings, using cleaning solvent. Blow them with compressed air.

WARNING:

•

Protect your eyes with safety goggles during the cleaning operation.

JEM00314-00291

JEM00315-00000

EM–76

(5) Check the main journals and bearings for pitting or scratches.

If the main journals are damaged, replace the crankshaft.

If the main journal bearings are damaged, replace the main journal bearings.

(6) Install the main bearings to the cylinder block and crankshaft main bearing cap.

NOTE:

•

Do not touch the metal surface of the bearing.

(7) Support the both ends of the crankshaft with a V-block.

Measure the crankshaft runout with a dial gauge.

Allowable Limit of Runout: 0.06 mm

If the runout exceeds the allowable limit, replace the crankshaft.

(8) Place the crankshaft in the cylinder block.

(9) Lay a strip of plastigage across each crankshaft main journal.

JEM00316-00292

JEM00317-00293

JEM00318-00294

JEM00319-00295

JEM00320-00296

(10) Install the crankshaft bearing caps. Tighten the crankshaft bearing cap bolts evenly in the sequence indicated in the right figure.

Tightening Torque: 44.1 - 53.9 N·m u e q

EM–77

t o

(11) Remove the main bearing caps with the lower bearings fitted on them.

i r w y !0

JEM00321-00297

JEM00322-00298

(12) Measure the plastigage width at its widest point.

Oil Clearance: 0.024 - 0.042 mm

If the oil clearance fail to conform to the specified value, measure the crankshaft main journal diameter and select suitable connecting rod bearings or replace the crankshaft.

(13) Remove the plastigage from the crankshaft main journals.

28. Selection of crankshaft bearings

NOTE:

•

The replacement of the crankshaft bearings should be performed after all inspections have been finished.

•

For the selection of the crankshaft bearing as a result of the replacement of the crankshaft, refer to the section under “Replacement of Crankshaft.”

(1) Read the cylinder block main journal diameter code number.

NOTE:

•

The main journal diameter code comes in four kinds of

5, 6, 7 and 8.

JEM00323-00299

JEM00324-00000

No. 5 Journal diameter code number

No. 4 Journal diameter code number

No. 3 Journal diameter code number

No. 2 Journal diameter code number

No. 1 Journal diameter code number

JEM00325-00300

EM–78

(2) Measure the diameter of the crankshaft main journals.

The measurement should be performed at four points,

90 degrees spaced, for each crankshaft main journal at the points shown in the right figure. The maximum value is regarded as the crankshaft main journal diameter.

However, if the variation in the measured diameters exceeds 0.026 mm, replace the crankshaft.

Crankshaft

12 6 12 6 12 6 12 6 12 6

Unit: mm

JEM00326-00301

(3) Select the crankshaft bearings or replace the crankshaft, based on the results of (1) and (2).

Main journal diameter code

Crank main journal diameter mm

49.995 - 50.000

49.989 - 49.994

49.983 - 49.988

49.976 - 49.982

49.975 or less

49.995 - 50.000

49.989 - 49.994

49.983 - 49.988

49.976 - 49.982

49.975 or less

49.995 - 50.000

49.989 - 49.994

49.983 - 49.988

49.976 - 49.982

49.975 or less

49.995 - 50.000

49.989 - 49.994

49.983 - 49.988

49.976 - 49.982

49.975 or less

Bearing classification number

—

Remarks

—

Crankshaft replacement

—

Crankshaft replacement

—

Crankshaft replacement

—

Crankshaft replacement

JEM00327-00000

EM–79

INSPECTION OF EACH PART

INSPECTION OF CYLINDER BLOCK

1. Removal of gasket material

Remove all gasket materials from the cylinder block.

2. Cleaning of cylinder block

Clean the cylinder block, using a soft brush and cleaning solvent.

3. Inspection of top surface of cylinder block

Using a precision straightedge and a thickness gauge, check the surface contacting the cylinder head gasket for warpage.

Maximum Warpage: 0.10 mm

If the warpage exceeds the allowable limit, replace the cylinder block.

4. Inspection of cylinder bores

(1) Measure the bore diameter of each cylinder at the six points shown in the right figure. Ensure that the difference between the maximum and minimum bore diameters of each cylinder is within 0.1 mm.

If the difference between the maximum and minimum values exceeds 0.1 mm, perform boring and/or honing for the cylinder bore in accordance with the oversized piston.

The honing angle is 35

° ±

. The surface coarse degree is 1 - 4Z.

Reference:

The table below shows the cylinder bore diameter when oversized pistons are used.

However, after the diameter of the replacement piston has been measured, perform the finishing in accordance with the piston diameter.

Standard

76.000 - 76.030 mm

O/S 0.25

76.250 - 76.280 mm

(2) Measure the bore diameter of each cylinder at a position shown in the right figure. The measured value is regarded as the cylinder bore diameter.

JEM00328-00303

JEM00329-00304

10 mm

Center

10 mm

JEM00330-00305

45 mm

JEM00331-00306

EM–80

5. Removal of cylinder ridges

If ridges are formed at the upper parts of the cylinder bores, use a ridge reamer to remove the ridges.

INSPECTION OF PISTONS AND CONNECTING

RODS

CAUTION:

•

The piston and piston pin are available only as a set so that the oil clearance may become the specified value.

Therefore, if you replace a piston or a piston pin, be sure to replace them as a set. Moreover, the piston and piston pin should be handled at all times as a set. Care must be exercised so that the piston or piston pin may be mixed with other ones.

1. Inspection of fit between piston and piston pin

Try to move the piston back and forth on the piston pin. If any movement is felt replace the piston and piston pin as a set.

NOTE:

•

When the piston is moved back and forth on the piston pin, you may encounter hard movement. However, if the piston moves smoothly without any binding, this fitting of the piston is normal.

Reference:

1. The oil clearance between the piston and piston pin is as follows.

Specified Oil Clearance: 0.005 - 0.011 mm

NOTE:

•

In the case of a piston and piston pin assembly having this degree of oil clearance, you will hardly feel excessive play when you move the piston by your hands.

2. Measurement of oil clearance

NOTE:

•

The oil clearance can be measured, following the procedure given below.

(1) When measuring oil clearance without disassembling:

Interpose the big end of the connecting rod between

V-blocks on a surface plate. Measure the play while moving the piston, as indicated in the right figure.

JEM00332-00307

JEM00333-00000

JEM00334-00308

JEM00335-00000

JEM00336-00309

(2) When measuring oil clearance after disassembling: q

Measure the diameter of the whole circumference at the positions A and B indicated in the right figure. The minimum dimension should be the piston pin hole diameter.

Specified Value: 19.002 - 19.005 mm w

Measure the diameter of the whole circumference at the positions A and B indicated in the right figure. The maximum dimension should be the piston pin outer diameter.

Specified Value: 18.994 - 18.997 mm

EM–81

A B

8 8

Unit: mm

JEM00337-00310

A B

Unit: mm

JEM00338-00311

2. Removal of piston rings

NOTE:

•

Arrange the removed piston rings in order so that their installation positions may be known readily.

•

Do not expand the piston ring unnecessarily beyond the required extent.

(1) Remove the piston rings No. 1 and No. 2, using a piston ring expander.

(2) Remove the oil ring side rails by hand.

(3) Remove the oil ring expander by hand.

INSPECTION OF PISTONS

1. Cleaning of pistons

(1) Remove the carbon deposits from the piston top, using a gasket scraper or the like.

(2) Clean the piston grooves with a broken piston ring or a groove cleaning tool.

NOTE:

•

Be very careful not to scratch the piston.

2. Inspection of pistons

Visually inspect the piston for cracks, damage or seizure.

Replace the piston, if necessary.

JEM00339-00312

JEM00340-00313

JEM00341-00000

EM–82

3. Measurement of piston diameter

(1) Measure the piston outer diameter horizontally at a specified point shown bellow from the lower end of the piston at right angles to the piston pin.

Specified Measuring Point H: 15 mm

(2) Calculation of piston-to-cylinder bore clearance

Subtract the measured piston outer diameter from the measured cylinder bore diameter. Ensure that this piston-to-cylinder bore clearance is less than 0.045 mm.

Piston-to-Cylinder Bore Clearance

Specified Value: 0.025 - 0.045 mm

Allowable Limit: 0.11 mm

If the piston-to-cylinder bore clearance exceeds the allowable limit, perform boring and honing the cylinder bores so that the cylinder bore diameter may match with the oversized piston.

4. Inspection of piston ring groove side clearance

Measure the side clearances of the piston rings No. 1 and

No. 2 over the entire periphery of each groove, using a thickness gauge.

The maximum measured value is regarded as the piston ring side clearance.

JEM00342-00314

JEM00343-00000

JEM00344-00315

Piston ring side clearance

Compression ring No. 1

Compression ring No. 2

Specified value mm

0.03 - 0.07

0.02 - 0.06

Allowable limit mm

0.12

If the piston side clearance exceeds the allowable limit, measure the piston ring thickness. Referring to the piston ring standard thicknesses given below, replace the piston ring and/or piston so that the piston ring side clearance may become less than the allowable limit.

JEM00345-00000

Piston ring specified thickness

Unit: mm

Compression ring No. 1

Compression ring No. 2

1.17 - 1.19

1.47 - 1.49

NOTE:

•

When replacing the piston rings, a set of piston rings for the engine should be replaced.

JEM00346-00000

EM–83

5. Inspection of piston ring end gap

(1) Apply engine oil to the cylinder walls.

(2) Insert the piston rings into the cylinder bore.

(3) Using a piston, push down the piston ring to a point

110 mm from the cylinder block upper surface.

(4) Measure the piston ring end gap, using a thickness gauge or a feeler gauge.

Piston ring

JEM00347-00316

Piston ring end gap

Compression ring No. 1

Compression ring No. 2

Oil ring

With “T” mark

With “N” mark

Shape of spacer A

Shape of spacer B

Oil ring spacer shape

Specified value mm

0.27 - 0.37

0.27 - 0.40

0.4 - 0.55

0.2 - 0.6

0.15 - 0.6

JEM00348-00317

Allowable limit mm

0.7

0.8

1.0

Shape A

Shape B

If the piston ring end gap exceeds the allowable limit, a set of piston rings for that engine should be replaced.

JEM00349-00318

EM–84

ASSEMBLY/DISASSEMBLY OF PISTON & CONNECTING ROD

NOTE:

•

The piston and piston pin are handled as a set, for their oil clearance is controlled. Therefore, when disassembling the pistons, care must be exercised so that the piston and piston pin may not be mixed with other pistons or piston pins.

•

The piston disassembling should be performed only when any malfunction takes place and disassembling is required. Failure to observe this caution may loosen the interference fit between the connecting rod and the piston pin, leading to an engine damage.

1. Disassembly of piston and connecting rod

Use the following SSTs for the disassembling operation.

SST: 09221-87704-000

09221-87705-000

JEM00350-00000

(1) Install the connecting rod in the following SST as shown in the right figure.

SST: 09221-87704-000

(2) Insert the longer SST into the piston pin hole. Press off the piston, using a hydraulic press.

SST

JEM00351-00319

SST

JEM00352-00320

2. Inspection of connecting rods

(1) Visually inspect the connecting rods for damage or cracks.

(2) Check the connecting rod for bend and twist, using a connecting rod aligner.

Maximum Bend: 0.05 mm

Maximum Twist: 0.05 mm

If the bend and/or twist is greater than the maximum limit, replace the connecting rod assembly.

Bend

Twist

JEM00353-00321

EM–85

3. Inspection of piston pin-to-connecting rod interference fit

(1) Measure the outer diameter of the piston pin contacting with the connecting rod, using a micrometer.

JEM00354-00322

(2) Measure the inner diameter of the connecting rod, using a bore dial gauge.

(3) Determine the interference fit by subtracting the inner diameter of the connecting rod from the outer diameter of the piston pin.

Interference Fit: 0.015 - 0.044 mm

If the interference fit does not conform to the specification, replace the connecting rod.

4. Assembly of piston and connecting rod

Use the following SSTs for the assembling operation.

SST: 09221-87704-000

09221-87705-000

(1) Install the piston pin to the following SST in a way shown in the right figure.

SST: 09221-87705-000

(2) Install the piston and connecting rod in the SST in a way shown in the right figure. Insert the SST installed with the piston pin into the piston pin hole.

SST: 09221-87704-000

09221-87705-000

NOTE:

•

The piston and connecting rod should be assembled in such a way that the piston front mark and connecting rod front mark come in the same direction.

(3) Press the piston pin into the piston and connecting rod, using a hydraulic press.

SST

Piston pin

JEM00355-00323

JEM00356-00324

Front mark

JEM00357-00325

JEM00358-00326

EM–86

(4) Remove the piston and connecting rod assembly from the SST. Remove the SST from the piston pin.

CYLINDER BORING

NOTE:

•

When the cylinder is bored, all cylinders should be bored at the same time.

•

As for piston rings, use oversized piston rings.

1. Measurement of cylinder bore diameter

Measure the diameter at a point 45 mm from the cylinder upper surface in the direction shown in the right figure.

If the measured value exceeds 76.28 mm, replace the cylinder block.

2. Determining cylinder finishing diameter

(1) Measure the diameter of the oversized piston to be used, using a micrometer.

NOTE:

•

The measurement should be conducted at the specified skirt section from the piston lower end.

•

Perform the measurement horizontally, not in a tilted state.

(2) Calculate the finishing dimension, as follows.

A: Piston diameter

B: Piston-to-cylinder bore clearance

0.025 - 0.045 mm

C: Honing allowance

0.02 mm

D: Finishing diameter

D = A + B – C

JEM00359-00327

JEM00360-00000

45 mm

JEM00361-00328

JEM00362-00000

JEM00363-00000

EM–87

3. Hone the cylinder after the boring.

(1) Bore the cylinder, leaving a honing allowance of

0.02 mm.

(2) Hone the cylinder.

Honing Angle: 35

° ±

Surface Coarse Degree: 1 - 4Z

, ,

Honing angle

35° ± 5°

, ,

Surface coarse degree

1 - 4Z

, ,

JEM00364-00329

REPLACEMENT OF REAR OIL SEAL

(1) Removal of rear oil seal

Remove the rear oil seal from the rear oil seal retainer, using a pin punch.

NOTE:

•

Be very careful not to damage the oil seal retainer.

JEM00365-00330

(2) Installation of rear oil seal

Drive a new rear oil seal into position, using the following SST.

SST: 09223-41020-000

NOTE:

•

Care must be exercised to ensure that the oil seal is not driven in a tilted state.

REPLACEMENT OF FRONT OIL SEAL

(1) Removal of front oil seal

Remove the front oil seal from the oil pump, using a pin punch.

NOTE:

•

Be very careful not to damage the oil pump during the removal.

(2) Installation of front oil seal

Drive a new front oil seal into position, using the following SST.

SST: 09310-87102-000

JEM00366-00331

JEM00367-00332

JEM00368-00333

EM–88

REPLACEMENT OF CYLINDER BLOCK

NOTE:

•

The cylinder block is furnished along with the pistons as a set. Hence, make sure that each piston is installed in the mated cylinder bore.

1. Wash the cylinder block using cleaning solvent.

2. Drive the oil orifice until it is recessed 3.0

1.0 mm from the cylinder upper surface.

NOTE:

•

For driving this oil orifice, use an iron rod having an outer diameter of 10 mm.

3. Selection of crankshaft bearings

(1) Read the crankshaft journal diameter code number of the cylinder block.

(2) Measure the main journal diameter of the crankshaft at those points indicated in the right figure.

•

The measurement should be conducted in four directions for each main journal, 90 degrees spaced, at those points indicated in the right figure.

(3) Select the crankshaft bearings in accordance with the table next page.

JEM00369-00334

No. 5 Journal diameter code number

No. 4 Journal diameter code number

No. 3 Journal diameter code number

No. 2 Journal diameter code number

No. 1 Journal diameter code number

JEM00370-00335

Crankshaft

X X

12 6 12 6 12 6 12 6 12 6 Y

Unit: mm

JEM00371-00336

Crankshaft jurnal hole code

Crankshaft journal diameter mm

50.000 - 49.995

49.994 - 49.989

49.988 - 49.983

49.982 - 49.976

49.975 or less

50.000 - 49.995

49.994 - 49.989

49.988 - 49.983

49.982 - 49.976

49.975 or less

50.000 - 49.995

49.994 - 49.989

49.988 - 49.983

49.982 - 49.976

49.975 or less

50.000 - 49.995

49.994 - 49.989

49.988 - 49.983

49.982 - 49.976

49.975 or less

Crankshaft bearing classification No.

—

EM–89

Remarks

—

Crankshaft replacement

—

Crankshaft replacement

—

Crankshaft replacement

—

Crankshaft replacement

JEM00372-00000

4. Selection of pistons

(1) Read the cylinder block bore code number.

(2) Select a piston having the same classification number as the cylinder block bore code number.

NOTE:

•

The piston code number is stamped on the top of each piston.

Front

No. 1 Cylinder

No. 4 Cylinder bore code No.

No. 3 Cylinder bore code No.

No. 2 Cylinder bore code No.

No. 1 Cylinder bore code No.

No. 2 Cylinder

No. 3 Cylinder No. 4 Cylinder

JEM00373-00337

Outer diameter code No.

JEM00374-00338

EM–90

REPLACEMENT OF CRANKSHAFT

(Replacement of the crankshaft only)

1. Wash the crankshaft using cleaning solvent. Dry it with compressed air.

NOTE:

•

Make sure that the oil gallery exhibits no restriction due to rust-proof oil.

•

As for the crankshaft for automatic transmission, drive the rear end bush into the rear end of the crankshaft with a brass rod so as to prevent damage to the bush.

2. Selection of crankshaft bearings

(1) Read the crankshaft journal diameter code number of the cylinder block.

Front

JEM00375-00000

No. 5 Journal diameter code No.

No. 4 Journal diameter code No.

No. 3 Journal diameter code No.

No. 2 Journal diameter code No.

No. 1 Journal diameter code No.

JEM00376-00339

(2) Read the crankshaft main journal diameter code number.

No. 5 Crank main journal code No.

No. 4 Crank main journal code No.

No. 3 Crank main journal code No.

No. 2 Crank main journal code No.

No. 1 Crank main journal code No.

JEM00377-00340

(3) Establish the crankshaft bearing classification number, using the table below.

Crankshaft

Cylinder block

Crankshaft journal diameter code No.

Crankshaft journal

2 3

JEM00378-00000

3. Selection of connecting rod bearings

(1) Read the crankpin journal diameter code number.

No. 1 Crankpin journal code No.

No. 2 Crankpin journal code No.

No. 3 Crankpin journal code No.

No. 4 Crankpin journal code No.

JEM00379-00341

(2) Read the connecting rod big end bore code number.

Connecting rod

EM–91

Front mark

(3) Establish the classification number of the connecting rod bearing, using the table below.

Crankshaft

Connecting rod

Connecting rod big end bore code No.

Crankpin journal diameter code No.

REPLACEMENT OF CONNECTING RODS

1. Wash the connecting rods using cleaning solvent.

WARNING:

•

Be sure to protect your eyes, wearing goggles.

Connecting rod big end bore code No.

JEM00380-00342

JEM00381-00000

JEM00382-00000

2. Selection of connecting rod bearings

(1) Read the connecting rod big end bore code number.

A B

4 14 4 14 4 14 4 14

(2) Measure the crankshaft pin diameter of the crankshaft in four directions for each crankshaft pin, 90 degrees spaced, at those points indicated in the right figure.

NOTE:

•

The greatest value among the measured diameters is regarded as the crankpin journal diameter.

However, if the difference among the measured values exceeds 0.044 mm, replace the crankshaft.

(3) Select the connecting rod bearing in accordance with the table posted in next page.

Unit: mm

JEM00383-00343

A B

4 14 4 14 4 14 4 14

Unit: mm

JEM00384-00344

EM–92

Connecting rod big end bore code No.

Crankpin journal diameter mm

45.000 - 44.993

44.992 - 44.985

44.984 - 44.976

44.975 or less

45.000 - 44.993

44.992 - 44.985

44.984 - 44.976

44.975 or less

45.000 - 44.993

44.992 - 44.985

44.984 - 44.976

44.975 or less

Connecting rod bearing classification No.

—

Remarks

—

Crankshaft replacement

—

Crankshaft replacement

—

Crankshaft replacement

JEM00385-00000

DISASSEMBLY OF OIL PUMP

1. Detach the oil pump cover.

JEM00386-00345

2. Remove the front oil seal.

JEM00387-00346

3. Remove the oil pump rotor set.

JEM00388-00347

4. Pull out the cotter pin, while pushing the spring retainer with nose pliers or the like.

NOTE:

•

Put an appropriate cloth, etc. on the retainer spring so that it may not jump out.

5. Remove the oil pump relief valve spring retainer, compression spring and oil pump relief valve.

NOTE:

•

Wash the disassembled parts in cleaning solvent.

6. Inspection of each part

(1) Check the pump body for damage.

Replace the pump body if it exhibits damage.

(2) Check the rotor set for damage.

Replace the rotor set if it exhibits damage.

(3) Check the oil pump relief valve for damage.

Replace the relief valve if it exhibits damage. Also, check to see if any damage is present at the relief valve installation hole of the oil pump body.

EM–93

JEM00389-00348

JEM00390-00349

JEM00391-00350

JEM00392-00351

JEM00393-00352

EM–94

(4) Check the compression spring for damage. Also, measure its free length.

Specified Free Length: 57 mm

Replace the compression spring if it exhibits damage or the free length is less than the specified valve.

(5) Check the oil pump relief valve spring retainer for damage.

Replace the retainer if it exhibits damage.

(6) Apply engine oil to the oil pump relief valve. Insert the oil pump relief valve into the oil pump body. Check to see if the valve slides smoothly.

Replace the oil pump body if the valve fails to slide smoothly.

7. Measurement of body clearance, tip clearance and side clearance

(1) Apply a thin film of engine to the rotor mate surface of the oil pump body as well as to the rotor set. Assemble the rotor set in the oil pump body in such a way that the drilled mark may be seen from the outside.

(2) Measure the body clearance between the oil pump body and the outer rotor, using a thickness gauge.

Body Clearance: 0.20 - 0.28 mm

Replace the oil pump if the body clearance exceeds the specified value.

JEM00394-00353

JEM00395-00354

JEM00396-00355

JEM00397-00356

JEM00398-00357

(3) Measure the tip clearance of the rotor set, using a thickness gauge.

Tip Clearance: 0.16 - 0.24 mm

Replace the rotor set if the tip clearance exceeds the specified value.

(4) Measure the side clearance between the oil pump body and the rotor set, using and a straightedge and a thickness gauge.

Side Clearance: 0.035 - 0.085 mm

Replace the oil pump if the side clearance exceeds the specified value.

8. Check to see if any wear is present at the rotor set mate surface of the pump cover.

Replace the oil pump cover if it exhibits wear.

ASSEMBLY OF OIL PUMP

NOTE:

•

Wash those parts to be assembled in cleaning solvent.

Dry them using compressed air.

WARNING:

•

When you use compressed air, be sure to protect your eyes,wearing goggles.

1. Apply engine oil to the relief valve. Then, insert the relief valve into the oil pump body.

2. Insert the compression spring and retainer into the oil pump body.

NOTE:

•

Install the retainer in such a direction that its projected side may come at the compression spring side.

EM–95

JEM00399-00358

JEM00400-00359

JEM00401-00360

JEM00402-00000

JEM00403-00361

EM–96

3. Insert a new cotter pin into the retainer while the retainer is being compressed with pliers, etc. Split the end of the cotter pin to form an anchor-like shape.

4. Apply engine oil to the rotor set. Assemble the rotor set in the pump body in such a direction that the drilled mark of the rotor may be seen from the outside.

5. Install the oil pump cover. Tighten the cover to the specified torque.

Tightening Torque: 7.8 - 12.7 N·m

6. Drive a new oil seal into position, using the following SST.

SST: 09310-87102-000

NOTE:

•

Be very careful not damage the oil pump during the installation.

•

Make sure that the oil seal is not driven into position in a tilted state.

7. Turn the rotor by hand. Ensure that the rotor turns smoothly.

If the rotor will not turn smoothly, overhaul the oil pump.

NOTE:

•

The oil pump performance test procedure is described in the LU section.

JEM00404-00362

JEM00405-00363

JEM00406-00364

JEM00407-00365

JEM00408-00366

INSPECTION OF CRANKSHAFT PULLEY

1. Visual inspection of crankshaft pulley

(1) Check the crankshaft pulley attaching seat for deformation, wear or cracks.

(2) Check the V-ribbed belt attaching surface for scratches, deformation or wear.

Replace the crankshaft pulley, as required.

INSPECTION OF WATER PUMP

1. Visually inspect the water pump.

(1) Mechanical seal section for evidence of water leakage

(2) Rotary fin of water pump for scratches, deformation or cracks

(3) Water pump attaching surface for scratches

(4) Water pump pulley attaching seat for scratches or flattened condition

Replace the water pump, as required.

2. Check the water pump bearing and water pump pulley attaching section for excessive play.

Replace the water pump, if necessary.

EM–97

Check damage or cracks

JEM00409-00367

JEM00410-00368

JEM00411-00369

3. Turn the water pump by hand. Ensure that the water pump turns smoothly.

Replace the water pump, if necessary.

JEM00412-00370

INSPECTION OF WATER PUMP PULLEY

1. Visual inspection of water pump pulley

(1) Inspect the water pump pulley attaching section for deformation or wear.

(2) Inspect the V-ribbed belt attaching surface for deformation or wear.

Replace the water pump pulley, if necessary.

Deformation or wear

JEM00413-00371

EM–98

INSPECTION OF OIL PAN

Visually inspect the oil pan for damage or cracks.

Replace the oil pan, as required.

INSPECTION OF FLYWHEEL

Inspect the flywheel for cracks or damage.

Replace the flywheel if it exhibits defects.

INSPECTION AND REPLACEMENT OF RING

GEAR

Inspect the ring gear for damage.

Replace the flywheel if it exhibits defects.

CAUTION:

•

Never disassemble the flexible type flywheel by removing the flex-plate from the flywheel subassembly.

If the flywheel has undergone disassembling, it would cause breakage of the flywheel due to unbalanced flywheel mass, while the engine is running.

•

Never expose the flexible type flywheel to flame of a burner, etc. If the flywheel is exposed to flame of a burner, for example, at the time of replacement of the ring gear, the quenched state of the flex-plate will be weakened. This may lead to breakage during the engine running.

JEM00414-00372

JEM00415-00373

JEM00416-00000

EM–99

ASSEMBLY OF CYLINDER BLOCK

NOTE:

•

As for those parts to be reassembled, wash them in cleaning solvent (excluding those parts, such as grease-sealed type bearings, dust seals and electrical parts).

•

Then, dry them using compressed air.

•

Remove any remaining sealer, etc. from the threaded portions of the switches and sensors.

WARNING:

•

Protect your eyes with goggles when using compressed air.

JEM00419-00000

1. Ensure that the straight pins are installed at the positions of the front, rear and upper sides of the cylinder block, as indicated in the right figure. Also, ensure that the protrusion of each straight pin conforms to the specified amount given below.

Specified Amount of Protrusions

A: 4

0.5 mm

B: 8

1.0 mm

C: 7

1.0 mm

D: 3

1.0 mm

E: 6.5

1.0 mm

If no straight pin is installed or its protrusion fails to conform to the specified value, replace the straight pin with a new one.

Front view

Back view

Upper view

Front

C D

JEM00420-00377

2. Installation of crankshaft

(1) Install the bearings to the cylinder block and crankshaft bearing caps.

NOTE:

•

Do not touch with the front and back surfaces of each bearing. Be sure to hold the bearing at its edge surfaces.

JEM00421-00378

EM–100

(2) Lubricate the surface of each bearing with engine oil.

NOTE:

•

Do not touch with the front and back surfaces of each bearing.

•

Never apply engine oil to the crankshaft bearing caps.

(3) Install the crankshaft in the cylinder block.

JEM00422-00379

JEM00423-00380

(4) Apply engine oil to the thrust washers. With the side having the oil groove facing toward the crankshaft side, insert each thrust washer between the crankshaft main journal No. 3 and the cylinder block.

JEM00424-00381

(5) Apply engine oil to the crankshaft main journal sections.

NOTE:

•

Care must be exercised to ensure that no oil flows into the bearing cap attaching bolt holes.

(6) Install the crankshaft bearing caps with the arrow marks facing toward the oil pump side and also in the numerical sequence.

(7) Thinly apply engine oil to the crankshaft bearing cap bolts. Tighten the bolts to the specified torque over two or three stages in the sequence shown in the right figure.

Tightening Torque: 44.1 - 53.9 N·m u e q i r w t

JEM00425-00382 o y !0

JEM00426-00383

EM–101

3. Assembly of piston and connecting rod

Install the flywheel on the crankshaft temporarily.

NOTE:

•

Care must be exercised to ensure that no oil, etc. gets to the bolts or bolt holes.

JEM00427-00384

(1) Install the oil ring spacer expander in the oil ring groove. Ensure that the expander end may not line up with the thrust direction nor with the axial direction.

NOTE:

•

Do not expand the spacer expander to an extent more than necessary.

Thrust direction

(2) Fit the upper rail into position in such a manner that it is wound up while pushing the edge section of the oil ring spacer expander with your thumb.

End of spacer expander

JEM00428-00385

NOTE:

•

Ensure that the rail end is deviated 90 degrees to the left from the end of the oil ring spacer expander.

•

Do not expand the rail to an extent more than necessary.

JEM00429-00386

Lower rail end

90°

Thrust direction

Upper rail end

90°

Spacer expander

JEM00430-00387

(3) Fit the lower rail into position in such a manner that it is wound up.

NOTE:

•

Ensure that the rail end is deviated 90 degrees to the right from the end of the oil ring spacer expander.

•

Do not expand the rail to an extent more than necessary.

•

Make sure that the oil ring can be rotated smoothly.

JEM00431-00388

EM–102

(4) Install the compression ring No. 2 with the stamped mark of T, 2T, N or 2N facing upward, using a piston ring expander.

NOTE:

•

Do not expand the piston ring to an extent more than necessary.

(5) Install the compression ring No. 1 with the stamped mark of T or N facing upward, using a piston ring expander.

(6) Position the piston rings so that each ring end may come at the respective points as indicated in the right figure.

NOTE:

•

It is not necessarily required to follow strictly the right figure. However, be sure that the ring end is not lined up with the thrust direction. Also, each ring should be deviated about 120 to 180 degrees from the adjacent ring.

JEM00432-00389

End of ring No. 2

Lower rail

Thrust side Thrust side

Upper rail

End of ring No. 1

Oil ring spacer expander

JEM00433-00390

(7) Install the connecting rod bearings on the connecting rod and connecting rod cap, making sure that your fingers will not touch with the front and back surfaces of the bearings.

JEM00434-00391

(8) Cut an appropriate vinyl hose to a suitable length. Fit the vinyl hose to each connecting rod bolt sections.

JEM00435-00392

(9) Apply engine oil to the piston rings, piston pins, connecting rod bearings, cylinder walls and crankpin journals.

JEM00436-00393

EM–103

(10) Compress the piston rings by means of the piston ring compressor SST, making sure that the piston ring ends will not move during the installation.

SST: 09217-87001-000

(11) Push the piston by hand into the cylinder bore with the front mark facing toward the oil pump side.

NOTE:

•

Be very careful to avoid damaging the connecting rod bearings during the installation.

•

Care must be exercised to ensure that the crankpin journal is not scratched by the connecting rod.

(12) Push the piston by hand until the connecting rod reaches the crankpin journal.

(13) Apply engine oil to the bearing surface of each connecting rod bearing.

NOTE:

•

Do not touch with the bearing front surface.

(14) Remove the vinyl hoses which were attached to the connecting rod bolt sections.

(15) Install the connecting rod cap with the front mark facing toward the oil pump side.

JEM00437-00394

JEM00438-00395

(16) Prevent the crankshaft from turning, using the following

SST.

SST: 09210-87701-000

SST

JEM00439-00396

JEM00440-00397

EM–104

(17) Thinly apply engine oil to the connecting rod cap attaching nuts. Tighten the nuts to the specified torque evenly over two or three stages.

Tightening Torque: 34.3 - 44.1 N·m

(18) Perform the operations described in the steps (1) through (17) for each cylinder.

(19) Remove the flywheel.

(20) Remove the following SST.

SST: 09210-87701-000

JEM00441-00398

SST

4. Installation of oil pump

(1) Apply the Three Bond 1207C to the oil pump installation surface of the cylinder block, as indicated in the right figure.

(2) Replace the O-ring of the oil pump with a new part.

O-ring

JEM00442-00399

Three Bond 1207C

JEM00443-00400

(3) Apply engine oil to the inner surface of the oil seal.

Install the oil pump to the cylinder block. Perform tightening to the specified torque.

Tightening Torque: 5.9 - 8.8 N·m

JEM00444-00401

5. Installation of oil seal retainer

(1) Apply the Three Bond 1207C to the oil seal retainer installation surface of the cylinder block, as indicated in the right figure.

Three Bond 1207C

JEM00445-00402

EM–105

(2) Apply engine oil to the inner surface of the oil seal.

Install the oil seal retainer to the cylinder block.

Perform tightening to the specified torque.

Tightening Torque: 5.9 - 8.8 N·m (0.6 - 0.9 kgf-m)

6. Install the oil strainer with a new gasket interposed.

7. Installation of oil pan

(1) Apply the Three Bond 1207C to the oil pan installation surface of the cylinder block, as indicated in the right figure.

(2) Place the oil pan gaskets.

NOTE:

•

Ensure that the end section of the oil pan gasket is overlapped at least 10 mm with the Three Bond 1207C.

(3) Install the oil pan. Tighten the oil pan attaching nuts and bolts to the specified torque over two or three stages.

Tightening Torque: 6.9 - 11.8 N·m

JEM00446-00403

JEM00447-00404

Three Bond 1207C

JEM00448-00405

JEM00449-00406

JEM00450-00407

EM–106

8. Installation of rear end plate

Install the rear end plate to the cylinder block with two attaching bolts.

Tighten the attaching bolts to the specified torque.

Tightening Torque: 14.7 - 21.6 N·m

JEM00451-00408

9. Installation of flywheel

(M/T vehicle only)

(1) Install the flywheel on the crankshaft with the spacer interposed.

(2) Application of flywheel bolt sealing material q

Wash the flywheel bolts. Then, degrease and dry them.

NOTE:

•

When degreasing the bolts, remove any oil completely, using a solvent such as a degreasing spraying agent or alcohol.

CAUTION:

•

Make sure that no bond nor other foreign matter, such as dust, gets to the bolts.

•

Even when new bolts are used, be sure to perform this operation.

•

Be sure to interpose the spacer between the crankshaft and the flywheel.

Check the flywheel bolts for damage. Replace any flywheel bolt which exhibits damage with a new one.

CAUTION:

•

Even when a new bolt is used, be sure to perform the operation in the step (1).

Clean the flywheel bolt threaded holes at the rear end section of the crankshaft. Degrease and dry them.

CAUTION:

•

Make sure that no bond nor other foreign matter, such as dust, gets to the bolt threaded holes.

•

As for degreasing, wipe off any oil from the threaded portion with a cloth damped with alcohol.

•

Never allow alcohol to get to resin or rubber parts, specifically, the rear oil seal.

Clean the bolt seating surface of the flywheel and degrease it.

NOTE:

•

As for degreasing, wipe the bolt seating surface with a cloth damped with alcohol.

•

Never allow alcohol to get to resin or rubber parts.

JEM00452-00000 t

Apply two to three drops of the Three Bond 1324 to the forward end of the threaded portion of each flywheel bolt.

CAUTION:

•

If the Three Bond 1324 is applied excessively beyond the specified amount, the oil will penetrate up to the bolt seating surface. This may cause loosening of the bolts.

•

Never use bond sealers other than the designated one.

•

Never allow the bond sealer to get to resin or rubber parts.

Three bond

JEM00453-00409

EM–107

(3) Tighten the flywheel attaching bolts to the specified torque in the sequence indicated in the right figure.

Tightening Torque: 44.1 - 63.7 N·m

NOTE:

•

Prevent the crankshaft from turning at the ring gear section, using the following SST.

SST: 09210-87701-000

CAUTION:

•

When tightening the bolt, make sure that no bond is present on the bolt seating surface.

If the bond oozes out, perform the operations again, starting the step (2).

(4) Tighten the flywheel attaching bolts to the specified torque in the sequence indicated in the right figure.

Tightening Torque: 78.5 - 98.0 N·m

(5) Measure the flywheel runout, using a dial gauge.

Allowable Runout Limit: 0.1 mm

NOTE:

•

Replace the flywheel if its runout exceeds the allowable limit.

r q t w y e

JEM00454-00410

JEM00455-00411

10. Installation of drive plate

(A/T vehicle only)

(1) Application of flywheel bolt sealing material q

Wash the flywheel bolts. Then, degrease and dry them.

NOTE:

•

When degreasing the bolts, remove any oil completely, using a solvent such as a degreasing spraying agent or alcohol.

CAUTION:

•

Make sure that no bond nor other foreign matter, such as dust, gets to the bolts.

•

Even when new bolts are used, be sure to perform this operation.

Check the flywheel bolts for damage. Replace any flywheel bolt which exhibits damage with a new one.

CAUTION:

•

Even when a new bolt is used, be sure to perform the operation in the step (1).

Clean the flywheel bolt threaded holes at the rear end section of the crankshaft. Degrease and dry them.

CAUTION:

•

Make sure that no bond nor other foreign matter, such as dust, gets to the bolt threaded holes.

•

As for degreasing, wipe off any oil from the threaded portion with a cloth damped with alcohol.

EM–108

•

Never allow alcohol to get to resin or rubber parts, specifically, the rear oil seal.

Wash the centering plate. Then, degrease and dry it.

NOTE:

•

When degreasing the center plate, remove any oil completely, using a solvent such as a degreasing spraying agent or alcohol.

•

Never allow the solvent to get to resin or rubber parts.

JEM00456-00000 t

Apply two to three drops of the Three Bond 1324 to the forward end of the threaded portion of each flywheel bolt.

CAUTION:

•

If the Three Bond 1324 is applied excessively beyond the specified amount, the oil will penetrate up to the bolt seating surface. This may cause loosening of the bolts.

•

Never use bond sealers other than the designated one.

•

Never allow the bond sealer to get to resin or rubber parts.

(2) Install the drive plate and centering plate to the crankshaft end. Tighten the attaching bolts temporarily.

Tightening Torque: 44.1 - 63.7 N·m

NOTE:

•

Prevent the crankshaft from turning at the ring gear section, using the following SST.

SST: 09210-87701-000

(3) Tighten the drive plate attaching bolts to the specified torque in the sequence indicated in the right figure.

Tightening Torque: 78.5 - 98.0 N·m

NOTE:

•

Prevent the crankshaft from turning at the ring gear section, using the following SST.

SST: 09210-87701-000

CAUTION:

•

When tightening the bolt, make sure that no bond is present on the bolt seating surface.

If the bond oozes out, perform the operations again, starting the step (1).

11. Assembling of clutch disc and pressure plate

(M/T vehicle only)

(1) Insert the following SST into the crankshaft rear end.

SST: 09301-87703-000

(2) Install the clutch disc.

Three bond 1324

,, r e q y t w

JEM00457-00412

JEM00458-00000

JEM00459-00413

JEM00460-00000

(3) Install the pressure plate, lining up the locating pin of the pressure plate. Tighten the attaching bolts to the specified torque.

Tightening Torque: 14.7 - 21.6 N·m

12. Install the water hose for the throttle body use to the cylinder block. Attach the hose bands.

13. Install the thermostat in the cylinder block in such a way that the jiggle pin section may come at the upper side.

CAUTION:

•

Make sure to install the jiggle pin of the thermostat in the correct direction. Failure to observe this precaution may cause overheating.

Identification of Thermostat

Destination Identification color

European Cold spec.

Green

General spec.

Black

14. Install the water inlet.

Tightening Torque: 5.9 - 8.8 N·m

15. Install the alternator bracket.

Tightening Torque: 34.3 - 49.0 N·m

EM–109

09301-87601-000

JEM00461-00414

JEM00462-00415

Jiggle pin

JEM00463-00416

JEM00464-00417

JEM00467-00420

EM–110

16. Installation of water pump

(1) Install a new water pump gasket on the cylinder block.

(2) Install and tighten the water pump to the specified torque.

Tightening Torque: 14.7 - 21.6 N·m

NOTE:

•

When the stud bolts have been replaced, apply the

Three Bond 1377B to the threaded portion at the cylinder block side.

17. Attach the tension spring to the timing belt tensioner.

Hang the tension spring hook on the pin. Assemble the timing belt tensioner in place and install the bolt. Push the tensioner to the alternator side as far as it will go. Tighten the tensioner temporarily.

18. Install the crankshaft pulley flange in such a way that its recessed side may come at the cylinder block side.

19. Install the crankshaft timing belt pulley.

JEM00468-00421

JEM00469-00422

JEM00470-00423

JEM00471-00424

JEM00472-00425

EM–111

20. Install the crankshaft timing belt pulley attaching bolt.

Tighten the bolt to the specified torque.

Tightening Torque: 88.3 - 98.0 N·m

NOTE:

•

Prevent the crankshaft from turning, using the following

SST.

SST: 09210-87701-000

21. Install the air conditioner compressor bracket.

Tightening Torque: 29.4 - 44.1 N·m

22. Installation of oil filter

(1) Thinly apply engine oil to the oil seal of the oil filter.

(2) Screw in the oil filter until the oil seal of the oil filter comes in contact with the oil pump or the contact surface of the oil cooler.

(3) Then, rotate the oil filter further one complete turn (360 degrees), using the following SST.

SST: 09228-87201-000

JEM00473-00426

JEM00474-00427

JEM00475-00428

Oil seal

JEM00476-00429

JEM00477-00430

EM–112

23. Installation of oil pressure switch

(1) Clean the threaded portion of the oil pressure switch.

Wind seal tape around the threaded portion.

NOTE:

•

The new oil pressure switch is coated with sealer.

Hence, when the oil pressure switch is replaced with a new one, first remove the sealer thoroughly. Then wind the seal tape. Also, be sure to clean the threaded holes at the oil pump side.

(2) Tighten the oil pressure switch to the specified torque using a long box wrench having a hexagonal hole.

Tightening Torque: 11.8 - 19.6 N·m

PREPARATION OF ENGINE INSTALLATION

1. Place the cylinder block on a suitable engine stand.

2. Clean and make dry the cylinder head bolt holes.

WARNING:

•

When you use compressed air, be sure to protect your eyes, wearing goggles.

2. Align the drilled mark of the crankshaft timing belt pulley with the indicator of the oil pump.

JEM00478-00431

JEM00479-00432

JEM00480-00433

3. Place the new cylinder head gasket on the cylinder block.

Identification mark

JEM00481-00434

JEM00482-00435

EM–113

4. Turn the crankshaft, until the “F” mark of the camshaft timing belt pulley comes exactly at the top position.

JEM00483-00436

5. Install the cylinder head assembly on the cylinder block.

CAUTION:

•

Be very careful not to damage the cylinder head gasket and cylinder head gasket attaching surface.

•

Never turn the crankshaft or camshaft independently before installing the timing belt.

6. Apply engine oil to the threaded portion of the cylinder head bolts.

7. Install the bolts on the cylinder head.

CAUTION:

•

As for the two bolts at the distributor side, use the bolts whose nominal length is 112 mm, which is shorter than that of others.

8. Tighten the cylinder head bolts evenly over two or three stages to the specified torque, following the sequence shown in the right figure.

Tightening Torque: 58.8 - 66.7 N·m

9. Installation of cylinder head cover

(1) Check the cylinder head cover gasket for damage.

Replace the cylinder head gasket if it is damaged.

(2) Replacement of cylinder head gasket

(Only case where such replacement is required;) q

Remove the cylinder head cover gasket from the cylinder head cover.

Install a new cylinder head cover gasket in such a way that the identification mark comes at the intake manifold side of the cylinder head cover.

(3) Check the spark plug tube grommet for damage.

Replace any grommet which exhibits damage.

JEM00484-00000

JEM00485-00437

JEM00486-00438

JEM00487-00439

EM–114

(4) Wipe off any oil from the cylinder head cover gasket attaching surface of the cylinder head.

(5) Install the cylinder head cover to the cylinder head.

CAUTION:

•

Be very careful not to damage the spark plug tube rubber grommet during installation.

(6) Install the tighten the cylinder head cover attaching bolts to the specified torque, following the sequence in the right figure.

Tightening Torque: 2.9 - 4.9 N·m

(7) Install and tighten the ignition coils to the engine.

(8) Connect the resistive cords.

10. Install the timing belt.

(Refer to the timing belt section)

JEM00488-00440

JEM00489-00000

JEM00490-00441

JEM00491-00442

JEM00492-00000

11. Install and tighten the engine mounting bracket with the mounting to the engine.

12. Sling the engine, using a chain block.

INSTALLATION OF ENGINE

1. Insert the engine to the engine compartment.

2. Joint the engine to the transmission and temporarily install the transmission attaching bolt.

3. Place the engine to the engine mounting section of the engine support number.

4. Install and tighten the engine mounting attaching bolts.

Tightening Torque: 21.6 - 39.2 N·m

NOTE:

•

Be very careful not to allow the engine to hit the vehicle body and other parts.

5. Install and tighten the transmission attaching bolts with the power train stiffener bracket.

Tightening Torque: 49.0 - 68.6 N·m

6. Install the starter motor and starter motor attaching bolts.

Tighten the attaching bolts to the specified torque.

Tightening Torque: 31.2 - 46.8 N·m

EM–115

JEM00493-00443

JEM00494-00444

JEM00495-00445

JEM00496-00446

JEM00497-00447

EM–116

7. Install the clutch housing under cover to the transmission.

Tighten the attaching bolts to the specified torque.

Tightening Torque: 49 - 68.6 N·m

8. Install the engine stiffener to the engine and tighten it to the specified torque.

Tightening Torque: 29.0 - 44.0 N·m

9. Installation of exhaust pipe

(1) Install the front exhaust pipe to the exhaust manifold with a new gasket interposed.

NOTE:

•

Do not reuse the used gasket.

(2) Temporarily tighten the exhaust pipe attaching nut of the exhaust manifold.

(3) Connect the front exhaust pipe to the main muffler with a new gasket interposed.

(4) Tighten the attaching nuts to the specified torque.

Tightening Torque: 41.6 - 62.4 N·m

(5) Install the front exhaust pipe clamp bracket to the transmission.

Tighten the attaching bolts to the specified torque.

Tightening Torque: 15.2 - 22.8 N·m

JEM00498-00448

JEM00499-00449

JEM00500-00450

JEM00501-00451

JEM00502-00452

EM–117

(6) Clamp the front exhaust pipe to the clamp bracket.

(7) Tighten the front exhaust pipe attaching nuts of the exhaust manifold to the specified torque.

Tightening Torque: 15.2 - 22.8 N·m

10. Connect the power train stiffener between the engine .and

transfer.

Tighten the stiffener attaching bolts to the specified torque.

Tightening Torque: 29.4 - 44.1 N·m

11. Connect the heater hose.

12. Connect the fuel inlet hose and return hose.

13. Install the engine wire to the engine and connect the following connector.

(1) Ignition coils

(2) Injectors

(3) Pressure sensor

(4) Throttle sensor

(5) Intake air temperature sensor

(6) Idle-up VSV

(7) Water temperature sensor

(8) Oxygen sensor

(9) Cam angle sensor

JEM00503-00453

JEM00504-00454

Inlet

Return

JEM00505-00455

JEM00506-00456

JEM00507-00457

EM–118

14. Connect the starter wire to the starter motor.

15. Install the accelerator cable to the throttle body and adjust it.

16. Connect the rubber hoses.

17. Install the alternator to the engine and connect the connectors.

JEM00508-00458

SST

JEM00509-00459

18. Install the air cleaner to the engine.

JEM00510-00460

19. Installation of radiator

(1) Ensure that the radiator lower grommet exhibits no deformation or damage.

If any damage is existed, replace the radiator lower grommet with new one.

(2) Place the radiator into the radiator lower grommet.

(3) Ensure that the radiator upper grommet for damage.

Replace the radiator upper grommet with new one, if any damage is present.

JEM00511-00461

JEM00512-00462

(4) Secure the radiator by installing the radiator brackets with the attaching bolts.

(5) Connect the radiator lower hose and cramp the hose band.

20. Install the cooling fan with the fluid coupling together with the fan shroud.

Tighten the fluid coupling attaching nuts and the fan shroud attaching bolts.

21. Adjust the alternator driver belt tension to the specified value.

(Refer to timing belt section)

22. Install the power steering vane pump drive belt and adjust it’s belt tension.

Tightening Torque: 41.7

7.3 N·m

23. Connect the water hoses to the radiator.

24. Installation of battery

(1) Install the battery carrier and tighten it’s attaching bolts.

(2) Install the battery to the battery carrier.

(3) Secure the battery by installing the hold down clamp with the attaching nuts.

EM–119

JEM00513-00463

JEM00514-00464

JEM00515-00465

JEM00516-00000

JEM00517-00466

EM–120

25. Installation of engine hood.

(1) Install the engine hood, being very careful not to scratch the vehicle body and engine hood.

(2) Tighten the engine hood attaching bolts and adjust the engine hood dimensions.

(3) Connect the windshield washer hose to the joint section.

26. Fill the engine oil.

27. Fill the coolant to the radiator and reserve tank.

28. Connect the positive cable to the positive terminal of the battery.

29. Connect the battery ground cable to the negative terminal of the battery.

30. Perform the engine turn-up.

JEM00518-00467

JEM00519-00000

IG “OFF”

JEM00520-00468

EM–121

ENGINE SPECIFICATION

Item

Engine proper

Lubricating system

Engine type

HC-EJ

Type

Mounting location

Cylinder No. and arrangement

Combustion chamber type

Valve mechanism

Bore

× stroke

Compression ratio

Compression pressure kPa (kgf/cm 2 mm

-rpm)

Maximum output

SAE net

European kW/rpm kW/rpm

General specifications

Australian specifications

DIN kW/rpm European specifications

SAE net Nm/rpm General specifications

Maximum torque

European Nm/rpm Australian specifications

DIN Nm/rpm European specifications

Engine dimensions [Length

× width

× height] mm

Compression ring

Number of piston rings

Oil ring

Open

Intake

Valve timing

Open

Exhaust

Intake

Valve clearance mm

Exhaust

Manual transmission

Idling speed rpm

Automatic transmission

Blow-by gas recirculating system

Lubricating method

Oil pump type

Oil filter type

Lubrication oil capacity liter

Whole

When only oil is changed

When oil and oil filter are changed

850

Closed type

Fully-forced feed method

Trochoid type

Fully-flow filter type, filter paper type

3.6

3.3

3.5

Petrol, 4-cycle

Front

4-cylinder-in-line, mounted transversely

Pent roof type

Belt-driven, SOHC

76.0

71.4

9.5

0.3

1372.9

(14 - 300)

61/6100

↑

105/5100

↑

630

510

655

BTDC 1

ABDC 39

BBDC 42

ATDC 2

[HOT] 0.25

[HOT] 0.33

800

EM–122

Item

Cooling method

Radiator type

Cooling system

Coolant capacity

[Including 0.434 liter for reserve tank]

Air cleaner

Water pump type

Thermostat type

Type

Number

Fuel tank

Fuel pipe material

Fuel pump type

Fuel filter type

Fuel injection device

Injector liter

Engine type

HC-EJ

V-ribed belt driven type

Corrugation type forced circulation

Manual transmission 5.4

Automatic transmission 5.3

Capacity

Location

Type of nozzle retainer

Nozzle type

Injection pressure kPa (kgf/cm 2 ) liter

Centrifugal type belt-driven type

Wax pellet type bottom-by-pass type

Filter unwoven fabric type

Underneath rear seat floor

Rubber and steel tube

Electromotor type

Filter paper type

(Voltex type)

Electronic type

With cushion rubber type

Electronic controlled throttle type

284 (2.9)

Item

Engine electrical system

Voltage

Type

Ignition timing

Ignition system

Firing order

Spark plug

Battery

Alternator

Type

Capacity

Type

Output

V-A

Regulator type

Starter

Type

Output

Radio noise suppressing device

Manufacturer

& Type

Sparkplug gap

Thread mm

DENSO

NGK

DENSO

NGK

EM–123

Engine type

HC-EJ

V-kW

12 [Negative ground]

Full transistorized type (ESA) battery ignition type

TDC 0

° ±

° with the check connector connected with ground terminal

1-3-4-2

K20TNR-S, K22TNR-S

BKRU6EK, BKRU7EK

0.9 - 1.0

1.25

36B20L

28 Ah

Three-phase alternating current commuting type

12 - 50

12 - 55

Contact pointless type

(IC regulator type)

Magnet engaging type

12 - 0.8

Resistive cord

JEM00521-00000

EM–124

ENGINE MECHANICALS

Timing belt pulley

Timing belt tension spring

Camshaft

Wear limit Camshaft

Crankshaft

Free length

Installation load

Oil clearance

(Cylinder head to camshaft)

Maximum limit

Thrust clearance

Maximum limit

Fuel pump cam diameter

Minimum

Fuel pump cam stroke

Standard

Valve cam lobe height

Minimum

Intake

Exhaust

Minimum limit

Intake

Exhaust

Maximum circle run out

Cylinder head Warpage

Valve seat angle

Cylinder block side

Intake manifold side

Exhaust manifold side

Intake

Exhaust

Valve contacting angle

Valve seat contacting width

Standard

Allowance

Maximum valve seat recession

Valves

(Depth measured from cylinder head gasket attaching surface to uppermost part of a new valve inserted into position)

Intake

Exhaust

Valve stem diameter

Valve length

Intake valve

Exhaust valve

Intake valve

Exhaust valve

Valve face angle

Valve stock thickness (Minimum)

Intake

Exhaust

Valve stem oil clearance

Intake Standard

Maximum

Exhaust

Standard

Maximum

119.8 mm

59.3 mm

46.5 mm

29.4

3 N at 50.9 mm (3.0

0.3 kg at 50.9 mm)

0.035 - 0.076 mm

0.17 mm

0.1 - 0.25 mm

0.45 mm

42.65 mm

5.0 mm

4.8 mm

33.434 - 33.634 mm

33.17 - 33.37 mm

33.2 mm

33.0 mm

0.03 mm

0.10 mm

- 45

- 70

- 45

- 70

1.4 mm

1.2 - 1.6 mm

0.5 mm

2.775 mm

6.026 mm

6.560 - 6.580 mm

6.555 - 6.575 mm

112.8 mm

114.5 mm

45.5

0.8 mm

1.0 mm

0.030 - 0.055 mm

0.080 mm

0.035 - 0.060 mm

0.090 mm

Valve springs

Valve rocker arm and valve rocker shaft

Valve rocker arm spacer

Exhaust manifold

Intake manifold

Cylinder block

Piston, piston pin and piston rings

Flywheel

Connecting rod

Crankshaft

Free length:

Standard Pink marked spring

Orange marked spring

Minimum Pink marked spring

Orange marked spring

Installed tension at 38.0 mm

Pink marked spring

Orange marked spring

Maximum out-of squareness

Oil clearance Standard

Maximum

Valve rocker arm bore diameter

Valve rocker shaft outer diameter

Free width

Warpage

Warpage Cylinder head side

Maximum cylinder head surface warpage

Cylinder bore diameter

Standard

O/S 0.25

Bore honing angle

Coarse degree

Piston-to-cylinder bore clearance

Standard

Maximum limit

Piston ring groove-to-piston ring side clearance

Standard No. 1 Other than below

No. 2

Maximum

Piston ring thickness

Standard No. 1 Other than below

No. 2

Piston ring end gap

Standard No. 1 With “T” mark

With “N” mark

No. 2 With “2T” mark

Oil

With “2N” mark

Shape of spacer A

Shape of spacer B

Maximum No. 1

No. 2

Oil

Piston pin-to-connecting rod inference fit

Piston-to-piston pin clearance

Runout Maximum

Big end thrust clearance Standard

Maximum

Maximum bend

Maximum twist

Crankpin journal oil clearance

Main journal oil clearance

Crankpin journal diameter

Main journal diameter

Thrust clearance Standard

Runout

Maximum limit

Maximum

45.2

0.1 mm

0.5 mm

About 47.4 mm

43.9 mm

46.1 mm

244.9 N (24.97 kgf)

208.9 N (21.3 kgf)

1.6 mm

0.012 - 0.053 mm

0.08 mm

19.500 - 19.521

19.468 - 19.488 mm

22.00 mm

76.000 - 76.030 mm

76.250 - 76.280 mm

° ±

1 - 4 Z

0.025 - 0.045 mm

0.11 mm

0.03 - 0.07 mm

0.02 - 0.06 mm

0.12 mm

1.17 - 1.19 mm

1.47 - 1.49 mm

0.27 - 0.37 mm

0.27 - 0.40 mm

0.40 - 0.55 mm

0.2 - 0.6 mm

0.15 - 0.60 mm

0.7 mm

0.8 mm

1.0 mm

0.015 - 0.044 mm

0.005 - 0.011 mm

0.15 - 0.4 mm

0.45 mm

0.05 mm

0.020 - 0.044 mm

0.024 - 0.042 mm

44.976 - 45.000 mm

49.976 - 50.000 mm

0.02 - 0.22 mm

0.30 mm

0.06 mm

EM–125

JEM00522-00000

EM–126

SST (Special Service Tools)

Shape Part No. and Name

09090-04010-000

Engine sling device

09219-87202-000

Engine overhaul stand

09219-87101-000

Engine overhaul attachment

Purpose

Removal and installation of engine

Remarks

Stand for engine overhaul

Attaching engine to overhaul stand

This stand is to be used in combination with engine overhaul attachment.

This attachment is to be used in combination with engine overhaul stand.

Preventing crankshaft from turning

09210-87701-000

Flywheel holder

09609-20011-000

Steering wheel puller

Removal of crankshaft timing belt pulley

09636-20010-000

Upper ball joint dust cover replacer

09202-87002-000

Valve cotter remover & replacer

Installation of camshaft oil seal

Installation and removal of valves

09217-87001-000

Piston replacing guide

Guiding piston during insertion

09223-41020-000

Crankshaft rear oil seal replacer

Installation of crankshaft rear oil seal

09201-87704-000

Valve stem oil seal cover

Removal of valve stem oil seals

09310-87102-000

Counter shaft front bearing replacer

09221-87704-000

Piston pin remover & replacer body

09221-87705-000

Piston pin remover & replacer guide

Installation of crankshaft front oil seal

Removal and installation of piston pins

This remover & replacer body is to be used in combination with piston pin remover & replacer guide

This remover & replacer guide is to be used in combination with piston pin remover & replacer body.

* 1

* 3

REFERENCE:

Shape

EM–127

Part No. and Name

09201-87705-000

Valve guide bush remover & replacer

09301-87703-000

Clutch guide tool

09258-00030-000

Plug set

09648-87201-000

Drive shaft replacer

Purpose

Removal and installation of valve guide bushes

Assembling clutch

Plugging rubber hoses

Disconnecting drive shafts

Remarks

09388-87702-000

Transfer replacer

Press-fitting of rubber grommets

09268-87704-000

Oil cooler set bolt box wrench

Removal and installation of oil cooler (only for oil coolerequipped vehicle)

Only for oil cooler-equipped vehicle

Removal of oil pan 09032-00100-000

Oil pan seal cutter

09228-87201-000

Oil filter wrench

09268-87703-000

Plug wrench

Removal and installation of oil filter

Removal and installation of spark plugs

09991-87401-000

Wire engine control system inspection

09611-87701-000

Tie rod end puller

EFI system inspection

ABS system inspection

Measure engine speed

Disconnection of tie rod end

JEM00523-00469

ESB-1

Engine support bridge

Handled by BANZAI Limited

JEM00524-00470

EM–128

TIGHTENING TORQUE

Tightening component

Cylinder head

Spark plug

Cylinder head

Cylinder head cover

Cylinder head

Rocker shaft (camshaft cap)

Cylinder head

Cylinder block

Cylinder head

Exhaust manifold

Cylinder head

Intake manifold

Cylinder head

Water outlet

Cylinder block

Water inlet

Cylinder block

Crankshaft main bearing cap

Cylinder block

Oil pump

Cylinder block

Rear oil seal retainer

Cylinder block

Water pump

Cylinder block

Transmission

Cylinder block

Alternator bracket

Cylinder block

Rear end plate

Crankshaft

Flywheel

Crankshaft

Drive plate

Crankshaft

Crankshaft timing belt pulley

Camshaft

Camshaft timing belt pulley

Connecting rod

Connecting rod cap

Intake manifold

Gas filter

Intake manifold

Union bolt for brake booster

Intake manifold

Plug screw

Intake manifold

Delivery pipe

Intake manifold

Rear stiffener

Exhaust manifold

Front exhaust pipe

Engine mounting stiffener RH

Transmission (MT)

Engine mounting stiffener LH

Transmission

M10

44.1 - 53.9

5.9 - 8.8

14.7 - 21.6

49.0 - 68.6

34.3 - 49.0

9.8 - 14.7

78.5 - 98.0

88.3 - 98.0

14.7 - 21.6

34.3 - 44.1

11.8 - 19.6

N·m

Tightening torque kgf-m

14.7 - 21.6

2.9 - 4.9

28.4 - 36.3

1.5 - 2.2

0.3 - 0.5

2.9 - 3.7

12.7 - 16.7

58.8 - 66.7

29.4 - 44.1

14.7 - 21.6

5.9 - 8.8

1.3 - 1.7

6.0 - 6.8

3.0 - 4.5

1.5 - 2.2

0.6 - 0.9

11.8 - 19.6

14.7 - 21.6

49.0 - 68.6

41.6 - 62.4

29.4 - 44.1

1.2 - 2.0

1.5 - 2.2

5.0 - 7.0

4.2 - 6.4

3.0 - 4.5

4.5 - 5.5

0.6 - 0.9

1.5 - 2.2

5.0 - 7.0

3.5 - 5.0

1.0 - 1.5

8.0 - 10.0

9.0 - 10.0

1.5 - 2.2

3.5 - 4.5

1.2 - 2.0

Oil pump

Oil pressure switch

Oil pump body

Oil pump cover

Oil pan

Water inlet

Thermo control switch

Pressure plate

Lower member subassembly

Drive plate

Torque converter

Power train stiffener

Clutch housing under cover

Power train stiffener

Tightening component

Ball joint

Steering knuckle

Lower arm bracket connecting rod

Water outlet

Water temperature sensor

Front exhaust pipe

Rear exhaust pipe

EM–129

N·m

Tightening torque

11.8 - 19.6

kgf-m

1.2 - 2.0

7.8 - 12.7

6.9 - 11.8

24.5 - 34.3

14.7 - 21.6

48.1 - 89.2

22.6 - 32.4

0.8 - 1.3

0.7 - 1.2

2.5 - 3.5

1.5 - 2.2

4.9 - 9.1

2.3 - 3.3

6.9 - 9.8

29.4 - 44.1

14.7 - 21.6

29.4 - 44.1

39.2 - 92.2

24.5 - 34.3

15.2 - 22.8

0.7 - 1.0

3.0 - 4.5

1.5 - 2.2

3.0 - 4.5

4.0 - 9.4

2.5 - 3.5

1.6 - 2.3

JEM00525-00000

DAIHATSU

J100

EMISSION CONTROL SYSTEMS

COMPONENT LAYOUT .............................. EC– 2

POSITIVE CRANKCASE VENTILATION

SYSTEM .................................................. EC– 3

INSPECTION OF PCV HOSE &

CONNECTION

................................... EC– 4

FUEL EVAPORATIVE EMISSION

CONTROL SYSTEM ............................... EC– 5

DASHPOT (DP) SYSTEM (only for automatic transmission models) .......... EC– 8

THREE-WAY CATALYST (TWC)

SYSTEM .................................................. EC–10

INSPECTION OF EXHAUST PIPE

ASSEMBLY

......................................... EC–10

INSPECTION OF HEAT INSULATOR

...... EC–10

THREE-WAY CATALYST

......................... EC–11

SST (Special Service Tools) ...................... EC–13

TIGHTENING TORQUE ............................... EC–13

SERVICE SPECIFICATIONS ...................... EC–13

JEC00001-00000

NO. 9710-JE

EC–2

COMPONENT LAYOUT

[Manual transmission Vehicle]

Throttle body

Air cleaner

Intake air pressure sensor

Idle-up VSV

Intake air temperature sensor

Throttle position sensor

To canister

[Automatic transmission Vehicle]

Air cleaner

Throttle body

Intake air pressure sensor

Fuel return hose

JEC00002-00001

Idle-up VSV

Intake air temperature sensor

Fuel return hose

Throttle position sensor

To canister

JEC00000-00002

EC–3

POSITIVE CRANKCASE VENTILATION SYSTEM

The engine equipped with a sealed type blow-by gas recirculating system in order to prevent blow-by gases generated inside the crankcase from being released into atmosphere.

When the no blow-by gases is generated in the cylinder, air in the cylinder head cover are ventilated by the fresh air introduced from up stream of the throttle valve to down stream of the throttle valve through inside of the cylinder head cover.

At this time, the flow rate of air is regulated by a jet provided at the cylinder head cover, thus stabilizing the engine idle speed, if engine at the idling.

When the generating amount of the blow-by gases is small, the blow-by gases generated inside the crankcase flow into the cylinder head cover side through the gas path of the cylinder block, oil in the blowby gases is separated by oil separator provided at the cylinder head cover.

Then, the blow-by gases in the cylinder head cover introducing to the cylinders through down stream of the throttle body to be burnt there again in the cylinders.

At this time, the air flow rate of the blow-by gases is regulated by a jet provided at the cylinder head cover, thus stabilizing the engine idle speed, if engine at the idling.

When the large amount of the blow-by gases are generated, the blow-by gases are flow into the cylinders both through the upstream path and downstream path of the throttle valve.

Jet Jet

Crankcase gases

Fresh air

Blow-by gases amount is small

Crankcase gases

Fresh air

Blow-by gases amount is large

JEC00003-00003

EC–4

INSPECTION OF PCV HOSE & CONNECTION

Visual inspection of hoses and connections

Check the hoses and connections for cracks, leakage or damage.

If any parts exhibit fault, replace or repair them, as required.

Inspection of blow-by gas recirculation device

1. Disconnect the blow-by gas hose from the throttle body side.

2. Ensure that a heavy resistance exists when you blow your breath from the disconnected hose end.

If no resistance is felt, replace the cylinder head cover.

NOTE:

•

Slight air continuity normally exists.

3. Connect a MityVac to the disconnected hose.

4. Ensure that air continuity exists without resistance when air is sucked in the MityVac.

If no air continuity exists, replace the cylinder head cover.

5. Disconnect the MityVac from the disconnected hose.

6. Connect the blow-by hose to the throttle body.

JEC00004-00004

JEC00005-00000

JEC00006-00005

EC–5

FUEL EVAPORATIVE EMISSION CONTROL SYSTEM

The fuel evaporative emission control system employs a charcoal canister type. The charcoal canister type leads the fuel vapor into the charcoal canister which uses activated carbon to absorb HC emission. The absorbed HC emission is drawn into the throttle body to be burnt together with mixture in the combustion chamber.

Purging line

Check valve 1

Check valve 3

Purge port

Combustion chamber

Throttle body

Fuel tank vapor line

Check valve

Pressure condition in tank

High pressure in tank

Low vacuum pressure in tank

High vacuum pressure in tank

Check valve 2

Fuel tank

JEC00007-00006

Engine condition

Canister check valve

1 2 3

Check valve in safety filler cap

Engine is running at idle condition

Closed Open Closed Closed

Vehicle is running Open Open Closed Closed

Engine is running at idle condition

Closed Closed Open Closed

Engine is running at idle condition

Closed Closed Open Open

Fuel Evaporative emission (HC)

HC emission is absorbed by the charcoal canister.

HC emission is sucked into the engine through the charcoal canister.

HC emission absorbed by the charcoal canister is returned to the tank.

If the vacuum pressure rises, even after the check valve of charcoal canister has opened, the safety valve in the fuel filler cap will open to prevent damage to fuel tank

JEC00008-00000

Inspection of fuel vapor lines, fuel tank & filler cap

1. Visual inspection of fuel vapor lines and connections for loose connections, kinks or damage

If any damage is present, repair or replace the parts, as required.

2. Visual inspection of fuel tank

Check the fuel tank for deformation, cracks or fuel leakage.

If any damage is present, repair or replace the part, as required.

Replace the fuel tank cap, if any deformation is caused by the negative pressure in the fuel tank.

JEC00009-00000

EC–6

3. Inspection of the fuel filler cap

Check the fuel filler cap and gasket for damage or deformation.

Also check the air continuity with some resistance is existing on the fuel filler cap.

Replace the cap, if necessary.

NOTE:

•

If fuel tank deformed by negative pressure, be sure to replace the fuel filler cap with new one after replacing the fuel tank.

4. Inspection of the charcoal canister

(1) Detach the hose band from charcoal canister.

(2) Disconnect the rubber hoses from charcoal canister.

NOTE:

•

Prior to disconnection of the rubber hose, put a tag on each of the rubber hoses so that they may be reconnected correctly to the original position.

(3) Remove the charcoal canister from vehicle by pull up the charcoal canister case.

(4) Visually inspect the charcoal canister case for cracks or damage.

If any damage is found, replace the charcoal canister with new one.

(5) Check of charcoal canister for air leakage Ensure that no air leakage is present when applying compressed air of 29.4 kPa (0.3 kgf-cm 2 ) into the fuel tank side pipe

B with carburetor side

A and atmosphere side

C pipes plugged.

If air leakage is present, replace the charcoal canister with new one.

(6) Ensure that the no air continuity is exist when blowing your breath into purge side

A pipe of the charcoal canister.

If air continuity is exist, replace the charcoal canister with new one.

(7) Check of charcoal canister for restriction.

Ensure that the air continuity is existing to the atmosphere side

C pipe, when blow your breath into the fuel tank side pipe

B while the purge side

A pipe is plugged.

If no air continuity is exist, replace the charcoal canister with new one.

Ensure that the air continuity is existing when applying a negative pressure to the purge side pipe

A by the Mity Vac.

If no air continuity is exist, replace the charcoal canister with new one.

JEC00010-00007

JEC00011-00008

JEC00012-00009

EC–7

(8) Cleaning of charcoal canister Clean the charcoal canister by blowing compressed air of 294.2 kPa

(3.0 kg/cm 2 ) into the fuel tank side pipe

B while holding the purge side of canister pipes

A closed.

NOTE:

•

Do not attempt to wash the charcoal canister.

•

No activated carbon should come out during the test.

If activated carbon comes out replace the charcoal canister.

(9) Install the charcoal canister to vehicle.

(10) Reconnect the rubber hoses and attach the new hose band.

JEC00013-00000

EC–8

DASHPOT (DP) SYSTEM (only for automatic transmission models)

This system prevents the throttle valve from suddenly closing, thus reducing the CO and HC emissions.

Conditions

Idling

Throttle valve

Idle speed position

Normal driving Opened position

Deceleration

Slightly opens and then slowly closes to the idle position

Dashpot

Pushed in by return force of throttle lever.

Pushed out by the diaphragm spring.

Pushed in by return force of the throttle lever.

JEC00014-00010

JEC00015-00000

Inspection and adjustment of dashpot (DP) system

1. Connection of tachometer

Connect the tachometer to the engine (REV terminal, vehicle side of connector), by connecting the following SST between them.

SST: 09991-87402-000

REV

Diagnosis check connector

for RHD vehicle

(LHD vehicle’s connecter is located symmetrically opposite position.)

JEC00016-00011

2. Start and warm-up the engine.

3. Ensure that the adjusting screw of the dashpot is not contact with dashpot shaft when the engine revolution speed at 3500 rpm.

If adjusting screw of the dashpot is contact with the dashpot shaft, adjust the adjusting bolt height.

JEC00017-00012

4. Slowly release the throttle lever.

5. Ensure that the engine revolution within the specified range.

Specified Engine Revolution

AT: 2400

100 rpm

If not adjust the engine revolution speed by adjusting screw and repeat the step (3) to (5) again.

6. On condition that engine revolution speed is 3500 rpm, release the throttle lever quickly.

Make sure that the engine revolution speed changes from

3500 rpm to idle speed within 0.5 - 5.0 seconds after dashpot works.

7. Stop the engine.

8. Remove the tachometer.

9. Remove the SST from the REV terminal, vehicle side of connector.

EC–9

JEC00018-00000

JEC00019-00000

EC–10

THREE-WAY CATALYST (TWC) SYSTEM

In this three-way catalyst, the oxidation of carbon monoxide (CO) and the reduction of nitrogen oxides

(NOx) contained in exhaust gas can take place simultaneously. Thus, the three-way catalyst purifies the exhaust gas by converting its harmful component gas into harmless carbon dioxide (CO

), water vapor (H

O) and nitrogen (N

Exhausta gas component

HC, CO and NOx

TWC

Oxidation and reducation

JEC00020-00013

Exhaust gas

O and N

JEC00021-00000

INSPECTION OF EXHAUST PIPE ASSEMBLY

1. Check the connections for looseness or damage.

2. Check the clamps for weakness, bend or damage.

Catalytic converter

JEC00022-00014

INSPECTION OF HEAT INSULATOR

1. Check heat insulator for damage.

2. Check for adequate clearance between the three-way catalyst and heat insulator.

JEC00023-00015

THREE-WAY CATALYST

INSPECTION

1. Check the connection for looseness or damage.

2. Check the three-way catalyst for dents or damage.

REMOVAL

WARNING:

•

Do not perform any operation while the exhaust pipe is still hot.

1. Jack up the vehicle and support it with safety stands.

2. Remove the engine undercover, by removing the six attaching bolts.

3. Separate the tail pipe assembly from the front exhaust pipe assembly by removing the two bolts and nuts.

4. Separate the front exhaust pipe assembly from the exhaust manifold by removing the three bolts and nuts.

NOTE:

•

When replace the catalytic converter, replace it as the front exhaust pipe assembly.

EC–11

JEC00024-00016

JEC00025-00000

JEC00026-00017

JEC00027-00018

JEC00028-00019

EC–12

INSTALLATION

1. Install a new gasket to the front exhaust pipe and tail pipe.

2. Install the front exhaust pipe assembly to the exhaust manifold.

Tightening Torque: 36.3 - 51.0 N·m (3.7 - 5.2 kgf-m)

NOTE:

•

Mark sure that the front mark is located at front side.

3. Tighten the attaching bolts and nuts for the three-way catalyst at the tail pipe side.

Tightening Torque: 36.3 - 51.0 N·m (3.7 - 5.2 kgf-m)

4. Install the engine undercover, by attaching the six bolts.

JEC00029-00000

JEC00030-00021

JEC00031-00022

JEC00032-00023

SST (Special Service Tools)

Shape Part No. and name

09991-87402-000

Tacho pulse pick-up wire

Plug set

09258-00030-000

EC–13

Purpose

Connecting engine tachometer

Plugging rubber hoses.

JEC00033-00024

TIGHTENING TORQUE

Tightening component

Cylinder head

Exhaust manifold

Exhaust pipe

Exhaust manifold clamp

Exhaust pipe front

Exhaust pipe rear

Exhaust pipe support

SERVICE SPECIFICATIONS

Ignition timing

Idle speed

Transmission type

Idle speed

Throttle positioner touch revolution

Throttle positioner operating time

Compression pressure at 300 rpm

M/T

800

50 rpm

Standard

Minimum

Difference between cylinders

N·m

29.4 - 44.1

34.3 - 49.0

29.4 - 44.1

36.3 - 51.0

9.8 - 15.7

Tightening Torque kgf-m

3.0 - 4.5

3.5 - 5.0

3.0 - 4.5

3.7 - 5.2

1.0 - 1.6

Remark

Dry

JEC00034-00000

B.T.D.C. 0

/800

50 rpm (M/T)

B.T.D.C. 0

/850

50 rpm (A/T)

A/T

850

50 rpm

2400

100 rpm (A/T)

0.5 - 5.0 seconds (A/T)

1373 kPa (14.0 kgf/cm

)

1030 kPa (10.5 kgf/cm

)

147 kPa (1.5 kgf/cm

)

JEC00035-00000

DAIHATSU

J100

EFI SYSTEM

SYSTEM DESCRIPTION .................... EF– 2

LOCATION OF ELECTRONIC

CONTROL PARTS

..................... EF– 2

SYSTEMATIC DIAGRAM

............... EF– 2

DIAGNOSIS SYSTEM

.................... EF– 3

SUMMARY OF TROUBLE

SHOOTINGS

............................. EF– 5

CAUTION FOR IMMOBILIZER-

EQUIPPED VEHICLE

................. EF– 6

PRECAUTIONS .................................. EF– 7

BASIC INSPECTION .......................... EF– 9

WIRING DIAGRAM OF EFI

SYSTEM

..................................... EF– 9

ARRANGEMENT OF EFI ECU

TERMINAL

................................. EF–10

TROUBLE SHOOTING ACCORDING

TO DIAGNOSIS CODE ................... EF–18

PREPARATION OF TROUBLE

SHOOTING WITH SST

.............. EF–18

DIAGNOSIS CODE TABLE

............ EF–19

DIAGNOSIS CODE NO. 13

........... EF–20

DIAGNOSIS CODE NO. 21

........... EF–22

DIAGNOSIS CODE NO. 31

........... EF–25

DIAGNOSIS CODE NO. 42

........... EF–27

DIAGNOSIS CODE NO. 43

........... EF–29

DIAGNOSIS CODE NO. 44

........... EF–31

DIAGNOSIS CODE NO. 45

........... EF–33

DIAGNOSIS CODE NO. 51

........... EF–35

DIAGNOSIS CODE NO. 52

........... EF–37

DIAGNOSIS CODE NO. 81

........... EF–39

REPLACEMENT OF ECU .................. EF–41

INSPECTION

................................. EF–41

CHARACTERISTICS OF ECU

OUTPUT (1)

............................... EF–42

CHARACTERISTICS ECU

OUTPUT (2)

............................... EF–43

ECU REPLACEMENT

.................... EF–44

INSPECTION OF IDLE-UP

CONTROL SYSTEM ....................... EF–45

WIRING DIAGRAM

........................ EF–45

UNIT INSPECTION

........................ EF–45

SYSTEM INSPECTION

.................. EF–46

INSPECTION OF FUEL SYSTEM ...... EF–47

FUEL TANK

................................... EF–47

FUEL PUMP

................................... EF–48

FUEL LINE

..................................... EF–48

SST (Special Service Tools) ............. EF–49

TIGHTENING TORQUE ...................... EF–49

JEF00001-00001

NO. 9710-JE

EF–2

SYSTEM DESCRIPTION

LOCATION OF ELECTRONIC CONTROL PARTS

Relay Block

EFI ECU

Pressure sensor

Throttle sensor

Injector

Cam angle sensor

Oxygen sensor

JEF00002-00011

SYSTEMATIC DIAGRAM

Speed sensor

Intake air temp.

sensor

Pressure sensor

Throttle position sensor

VSV

IG key

Electrical load signal

Shift position switch (A/T)

Back up

Cam angle sensor

Ignition coil

Fuel pump

Oxygen sensor

Injector

Coolant temp.

sensor

Aux. valve

Fuel pressure regulator

JEF00003-00021

EF–3

DIAGNOSIS SYSTEM

DESCRIPTION

A self-diagnosis system is built in the ECU. If any abnormality should occur in the signal systems of various sensors, the self-diagnosis system memorizes the malfunction code number in the ECU. In respect to important abnormalities, the check engine lamp at the instrument panel goes on, thus warning the driver of the abnormality.

When the abnormality is cleared, the check engine lamp goes out.

When the Test terminal of the diagnosis connector is connected with the earth terminal, the malfunction code number that has been memorized in the ECU will be indicated in a form of blinking of the check engine lamp in the instrument panel.

CHECK ENGINE LAMP

1. When the ignition switch is turned on, the check engine lamp goes on.

(The engine is under a stopped state.)

2. When the engine starts, the check engine lamp goes off.

If the check engine lamp remains illuminated, it indicates that the diagnosis system has detected system malfunction.

READING OUT OF DIAGNOSIS CODE

1. Initial conditions

(1) Battery voltage of 11 volts or more

(2) Throttle valve fully closed

(3) All accessory switches turned OFF

2. Reading out of diagnosis code

(1) Connect the terminal between the test terminal and the earth terminal with a jump wire as indicated in the illustration.

(2) Turn the ignition switch to the “ON” position. At this time, be careful not to start the engine.

(3) Read out the diagnosis code by observing the flashing number of the check engine lamp.

NOTE:

•

When system malfunction was detected, go to page

EF–18, “TROUBLE SHOOTING ACCORDING TO DI-

AGNOSIS SYSTEM”.

•

If the check engine lamp fails to blink, it is likely that the

ECU is malfunctioning. Hence, proceed to the inspection of the diagnosis system circuit.

JEF00004-00031

Diagnosis connector

JEF00005-00032

Test terminal

Earth terminal

JEF00006-00033

JEF00007-00034

EF–4

EXPLANATION OF DIAGNOSIS CODES

1. Indication of normal code

The engine check lamp glows for 0.25 second, 0.25 second after the ignition switch has been turned ON. After a lapse of 0.25 second, the check engine lamp again glows for 0.25 second.

Then, this pattern will be repeated.

Glowing

0.25 Sec.

2. Indication of malfunction code

(1) When a single malfunction code is indicated:

The diagnosis code is composed of two digits. These two numbers are indicated by blinking of the check engine lamp. Four seconds after the ignition switch has been turned ON, the check lamp indicates first the number of the tens digit of the diagnosis code by glowing the same times as the number. The lamp glows for 0.5 second each time and then it is extinguished for 0.5 second. After a pause of 1.5 seconds, the check lamp indicates the number of the units digit of the diagnosis code by glowing the same times as the number. The lamp glows for 0.5 second each time and then it is extinguished for 0.5 second. Then, this pattern will be repeated after a pause of 4 seconds.

(2) When plural malfunction codes are indicated:

In cases where plural malfunction codes have been detected, the two-digit diagnosis codes are indicated in the sequence of the code number, starting from a smaller number. Each diagnosis code is indicated in the above described pattern. A pause of 2.5 seconds occurs between the outputs of respective diagnosis codes, thus separating one from another. After all of the plural diagnosis codes that have been detected are indicated, the check engine lamp is extinguished for four seconds. Then, the detected plural diagnosis codes will be indicated again.

Extinguished

0.25 Sec.

JEF00008-00036

In case of malfunction code number 21

0.5 Sec.

Glowing

Extinguished

4 Sec.

1.5 Sec.

JEF00009-00037

In case of malfunction code number 21 and 31

Glowing

Extinguished

2.5 Sec.

4 Sec.

JEF00010-00038

3. Canceling of diagnosis code

To erase the diagnosis codes memorized in the ECU after malfunctions have been repaired, disconnect the battery ground cable from the negative (–) terminal of the battery for at least 10 seconds with the ignition switch turned OFF.

[When ambient temperature is about 20

C.]

NOTE:

•

After the diagnosis codes have been read, remove the

SST at the diagnosis connector.

IG “OFF”

JEF00011-00039

EF–5

SUMMARY OF TROUBLE SHOOTINGS

NOTE:

•

Prior to the troubleshooting according to malfunction phenomena, conduct the basic inspections so as to narrow down the possible causes for malfunctions. For instance, if the spark inspection of the basic inspection proves to be normal, it can be assumed that the ignition system is functioning normally. Moreover, the information obtained during diagnosis through questions can help further narrow down the possible causes.

Malfunction phenomena

Poor starting Unstable idling Engine stalling Poor running

Possible malfunctioning parts

Pressure sensor

Water temperature sensor

Intake air temperature sensor

Throttle position sensor

Air conditioner switch

Oxygen sensor

Neutral start switch

Cam angle sensor

Fuel pump system

Pressure regulator

Fuel filter

Injector

IG coil

Spark plug

Resistive cord

Ignition timing

Idle-up VSV

Throttle valve

Throttle body

Hose, etc., disconnected

ECU power supply circuit

IG switch

Fuel pump relay

Main relay

JEF00012-00101

EF–6

CAUTION FOR IMMOBILIZER-EQUIPPED

VEHICLE

1. The immobilizer system is formed by communication between the Immobilizer ECU and the EFI ECU by means of the rolling code. The rolling code will be automatically retained both in the immobilizer ECU and in the EFI ECU when the engine is started once with the key of the immobilizer system. The engine will not start if the rolling code in the immobilizer ECU and EFI ECU are not identical.

Therefore, the engine will not start when using the EFI

ECU which was mounted before on another vehicle with the immobilizer system without resetting the rolling code.

2. Even when the EFI ECU has been replaced according to the check results of the trouble shooting and the relevant malfunction has been remedied, be sure to reinstall the old EFI ECU so as to confirm that the malfunction was obviously caused by the faulty EFI ECU.

NOTE:

•

Be sure to reset the rolling code in the EFI ECU and

Immobilizer ECU using a diagnosis tester (DS-21).

Furthermore, registration of the ignition key should be performed when installing the EFI ECU which was mounted on the vehicle equipped with the immobilizer system to another vehicles.

•

Refer to the BE section of the service manual.

3. However, the engine can start when using the EFI ECU which was mounted on a vehicle without the immobilizer system. However, after completion of the test where this

EFI ECU was used for the vehicle with the immobilizer system, if this EFI ECU is returned to the original vehicle, the engine of the original vehicle will not start any more.

JEF00013-00102

JEF00014-00103

JEF00015-00104

EF–7

PRECAUTIONS

1. When resistance or voltage measurement is conducted at the connector section, insert a measuring probe from the back of the connector, being very careful not to damage the harness to terminal connections.

In the case of water-proof type connectors, a measurement is conducted at the connector section, while the measuring probe is in contact with the terminal at the connection side of the connector. Be very careful not to apply any excessive force to the terminal at the connector side.

As an alternative method, insert a male or femele terminal into the connector terminal or connect an adequate attachment.

2. The fuel line at the high-pressure side is pressurized to a fuel pressure of about 284 kPa. Therefore, a large amount of gasoline flows out when parts of the fuel line are disconnected. Hence, take the following countermeasures.

WARNING

•

Release the inner pressure of the fuel tank by removing the fuel filler cap in advance.

3. Tachometer connection

Connect a tachometer probe to the measuring terminal of the diagnosis connecter.

CAUTION:

•

This does not apply if your tachometer is a pick-up type.

•

Never allow the tachometer probe to touch the ground, for it could result in damage to the igniter and/or ignition coil.

•

Some kinds of tachometers may not be suited for the ignition system of the vehicle. Therefore, ensure that your tachometer is compatible with the ignition system of the vehicle.

4. Precautions during oxygen sensor handling

(1) Do not drop the oxygen sensor or hit it to other objects.

(2) Do not immerse the sensor in water or do not cool it by water.

5. Do not open the cover of the ECU proper.

(Failure to observe this caution could cause ECU malfunction.)

6. Before disconnecting or reconnecting the connector of the

ECU proper of the EFI system, be sure to turn off the ignition switch and all accessory switches. Also, disconnect the battery ground cable from the battery negative terminal.

Failure to observe this caution could cause ECU malfunction.

7. Never apply strong impacts to the EFI parts. Pay utmost attention during the installation/removal.

Especially, special caution must be exercised as to the handling of the ECU.

JEF00016-00201

Diagnosis connector

JEF00017-00202

Earth terminal

Tacho-meter terminal

JEF00018-00203

JEF00019-00204

JEF00020-00205

EF–8

8. When installing the battery, care must be exercised not to mistake the battery polarity.

CAUTION:

•

A battery of 12 volts for automotive use must be used.

9. When the voltage or resistance of the ECU is measured during the check, never touch terminals other than the specified terminals. Failure to observe this caution could cause ECU malfunction.

10. When the system is checked on a rainy day, be very careful not to allow water to get to connectors and/or terminals.

Also, when the engine compartment is washed, prevent water from splashing the EFI-related parts and connectors.

11. Every EFI part should be replaced as an assembly.

12. When disconnecting or reconnecting the connector, care must be exercised as to the following points.

(1) Carefully observe the shape of the lock prior to the disconnection/connection.

(2) Release the lock. Then, disconnect the connector.

NOTE:

•

When disconnecting the connector, be sure to hold the connector holder, not to pull the wire.

(3) Insert the connector, until the lock is engaged completely.

(4) Be sure to keep the number of disconnection/reconnection of the connector at a minimum level.

13. When the vehicle is equipped with wireless installations

(HAM, CB, etc.)

The ECU has been so designed that it is resistant to external influence.

However, if a vehicle is equipped with a CB wireless installation and so forth (even if its output is only 10 W), it may affect the ECU adversely. Therefore, observe the following precautions.

(1) Install an antenna at a place as far away as possible from the ECU.

The ECU is installed under the instrument panel.

Therefore, the antenna should be installed at the rear of the vehicle.

(2) The antenna cord should be kept at least 20 cm away from the engine wire. Never wind the antenna cord together with the engine wire with tapes.

(3) Adjust the antenna output correctly.

(4) Never install a wireless installation with a high output on the vehicle.

Pull up.

JEF00021-00207

JEF00022-00208

JEF00023-00209

JEF00024-00211

JEF00025-00212

BASIC INSPECTION

WIRING DIAGRAM OF EFI SYSTEM

To A/C dual pressure SW

To off board connector

(SIO)

Check engine lamp

(Combination meter)

Idle up VSV

Idle up VSV(for A/C)

Idle up VSV(for A/T)

Injector

ECU IG

10A

A/C relay

A/C

10A

Fuel pump relay

Magnet clutch

Fuel pumo

EFI main relay

EFI

15A

Back-up 10A

Ignition coil

Engine

10A

Ignition coil

F/L

To spark plug

EF–9

To heater resister

To heater relay

To heater blower SW

To head lamp fuse

To head lamp

To defogger SW

To defogger

A/C evap.

temp sensor

(T)

(VF)

Off board connector

Throttle

Position sensor

Intake manifold pressure sensor

Intake air temp.

sensor

Cooling

water

temp.

sensor

Oxygen sensor

Off board connector

(REV)

Tacho meter

Vehicle speed sensor

Crank angle sensor

To A/T neutral starter SW

A/T starter relay

Starter motor

JEF00026-00301

EF–10

ARRANGEMENT OF EFI ECU TERMINAL

ECU Terminal

33 34 35 36 37 38 39 40 41 42 43

52 53 54 55 56 57 58 59 60 61 62 63

1 2 3 4 5 6 7 8 9 10 11 20 21 22 23 24 25 26 27 28 29 30 31 32

Connector B

CONNECTOR A

No.

KNK

—

ALT

IG2

—

#20

#10

N+

—

PIM

THW

Contents of connection

Sensor system ground

Cam angle sensor (+)

Throttle position sensor (Idle)

Pressure sensor power supply

Pressure sensor signal

Coolant temperature sensor

A/C lock sensor

Alternator cut

Ignition signal (#2,#3 cylinder)

Injector (#2, #4 cylinder)

Injector (#1, #3 cylinder)

CONNECTOR B

No.

MGC

BAT

Contents of connection

A/C Magnet clutch

Battery (Back-up power supply)

ACEV

—

A/C Evaporator temp, sensor

ACSW A/C Switch

BLW

SPD

Heater blower

Vehicle speed sensor

—

+B1

Check engine lamp

Power supply

Connector A

No.

N–

PSW

—

Contents of connection

Sensor ground

Cam angle sensor

Throttle position sensor

THA

VSV3

Oxygen sensor

Intake air temperature sensor

Idle up VSV (for A/C)

VSV2 Idle up VSV (for A/T)

VSV1 Idle up VSV (for electrical load)

—

E01

E02

IG1

Power supply system ground

Ignition system ground

Ignition signal (#1, #4 cylinder)

SIO

REV

+B2

FC2

FC1

—

DEF

H/L

A/T

No.

Contents of connection

Fuel pump relay (Without IMB.)

Fuel pump relay (With IMB.)

Defogger switch

Headlamp switch

Neutral start switch

Test terminal

Diagnosis tester

Engine speed signal

VF monitor terminal

Power supply

JEF00027-00302

Trouble shooting hints

1. In most cases, engine troubles are attributable to systems other than the EFI system.

(1) Battery voltage, fuse blown or fusible link blown

(2) Body earth

(3) Fuel leakage, fuel filter clogged or fuel pump malfunctioning

(4) Spark plugs faulty, spark plug wires faulty, distributor faulty, igniter faulty, or ignition timing adjusted improperly

(5) Admission of air

2. Most of troubles related to the EFI system are merely caused by poor wire connections.

Ensure that connectors are connected securely.

Check connectors, being careful as to the following points.

(1) Visually inspect that terminals are not bent.

(2) Ensure that connectors are securely connected and locked.

(3) Check to see if the malfunction phenomenon takes place when applying light vibration to the connector or the wire connected to the connector.

3. If engine misfire takes place, the following measures should be taken.

(1) Ensure that the battery terminals and so forth are connected properly.

(2) Handle the spark plug wires carefully.

(3) After completion of repairs, ensure that the ignition coil terminals and other ignition system wire are reconnected securely.

Check to see if diagnosis detects malfunction code.

1. Check of diagnosis code

When the engine starts, the check engine lamp in the combination meter remains illuminated. It indicates that the diagnosis has detected system malfunctions.

2. Read out the diagnosis code.

NOTE:

•

See page EF–4.

•

When system malfunction has been detected, proceed to page EF–18, “TROUBLE SHOOTING ACCORDING

TO DIAGNOSIS SYSTEM”.

Check of power supply circuit

1. Check the fuses and fusible link.

If the fuses are blown out, be sure to perform the trouble shooting.

EF–11

JEF00028-00303

JEF00029-00305

JEF00030-00306

JEF00031-00309

JEF00032-00311

EF–12

2. Check the EFI main relay.

(a) Turn the ignition switch to the “ON” position. Check to see if the relay emits an operating sound.

(b) Remove the EFI main relay from the relay box.

Check that there is continuity between the terminals 1 and 2.

Specified Resistance: 40 - 100

Ω

(c) Check that there is continuity between the terminals 3 and 4 when a voltage of 12 V is applied to across the terminals 1 and 2.

NOTE:

•

Even when the trouble has not been solved by repairing the relay, check the wire harness.

3. Check the fuel pump relay.

(a) When the ignition switch is set to the “ON” position, check to see if the relay emits an operating sound.

(b) Remove the fuel pump relay from the relay box.

Check that there is continuity between the terminals 1 and 2.

Specified Resistance: 40 - 100

Ω

(c) Check that there is continuity between the terminals 3 and 4 when a voltage of 12 V is applied to across the terminals 1 and 2.

r w e q

JEF00033-00312 q e w r

JEF00034-00313

JEF00035-00314

Check of ignition system

1. Connect a timing light to the ignition wire of the No. 1 cylinder.

2. Check to see if the ignition timing mark on the crankshaft pully is aligned with the indicator.

Specified Value: 0

BTDC/ at Idle

NOTE:

•

Remove the air cleaner case.

•

Connect the test terminal and the earth terminal with a jump wire at the diagnosis connector.

Diagnosis connector

Test terminal

Earth terminal

JEF00036-00319

EF–13

3. Remove the spark plug(s).

4. Visually inspect the spark plug for electrode wear, thread or insulator damage.

5. Measure the electrode gap, using a plug gap gauge.

Specified Value: 0.9 - 1.0 mm (NGK, DENSO)

NOTE:

•

If the gap will not conform to the specification, replace the plug.

6. Check if the resistance of the the spark plug distance piece and the ignition wire is within the specification.

Spark Plug Distance Piece 1: 0.3

Ω or less

Ignition Wire 2: 3.8 k

Ω

Ignition Wire 3: 5.6 k

Ω

NOTE:

•

Remove the ignition coils from the cylinder head cover.

Then, remove the wire and distance piece.

7. Check if the ignition coil resistance is within the specification.

Secondary Coil: 13.6 - 2.0 k

Ω

Check of compression pressure

1. Temporarily remove the main relay and fuel pump relay.

2. Insert a compression gauge into the spark plug hole.

3. Depress the accelerator pedal fully.

4. While cranking the engine, measure the compression pressure.

Minimum Value: 1030 kPa at 300 rpm

NOTE:

•

Always use a fully charged battery so that at least a revolution speed of 300 rpm is attained.

Check of fuel system

1. Using a sound scope, check to see if each injector emits an operating sound when the engine is being started or cranked.

NOTE:

•

If a sound scope is not available, apply a screwdriver or the like to the injector. So you can feel an operating vibration.

•

If the injector emits no operating sound, check the wiring or connectors. Then, perform the following procedure.

q w

JEF00037-00320 e

JEF00038-00321

JEF00039-00322

JEF00040-00323

JEF00041-00331

EF–14

2. Disconnect the injector connector of the engine wire.

3. Measure the resistance between the terminals of each injector.

Specified Resistance: 11 - 17

Ω

(at 20

NOTE:

•

If the resistance is not within the specification, replace the injector.

•

If the resistance will conform to the specification, perform the following procedure.

4. Using a test lamp (12 V 6 W), check to see if the lamp will be illuminated as shown in the illustration when the engine is being started or cranked.

If not, check the wiring harness and ECU output.

Derivery pipe

Injector

JEF00042-00332

Terminal of engine wire

(Injector)

JEF00043-00333

5. Remove the fuel delivery pipe.

Remove the injectors.

6. Remove the injector grommet and O-ring.

NOTE:

•

Check to see if the injector grommet exhibits damage.

7. Using the following SSTs, connect the injector, as indicated in the figure. Insert the injector into the measuring cylinder.

SST:

(1) 09268-87701-000

(2) 09268-87702-000

(3) 09842-30070-000

NOTE:

•

Install a new grommet to the injector.

Install a new O-ring to the O-ring seal section.

Attach the hose bands to the rubber hose connections.

JEF00044-00334

To fuel filter

(On the vehicle)

SST

(09268-87701)

Hose band

(09268-87702) SST

O-Ring Grommet

SST(09283-87703)

Pressure regulator

SST(09842-30070)

Battery

To fuel return pipe

(On the vehicle)

JEF00045-00335

Insulator

Pressure regulator

Intake manifold

JEF00046-00336

8. Remove the fuel pump relay. Then, connect the terminal with a jump wire as shown in the illustration.

9. Turn the ignition switch to the “ON” position.

EF–15

r e

Relay terminal

10. Connect the SST wire to the battery terminal for 15 seconds.

11. Measure the amount of fuel collected in the measuring cylinder.

Specified Amount of Fuel: Approx. 42 - 48 ml

Variation Between Injectors: 5 ml or less

SST

(09268-87702)

Vinyl pipe

JEF00047-00337

SST (09842-30070)

Battery

JEF00048-00338

NOTE:

•

Attach a suitable vinyl hose to the tip-end of the injector so as to prevent fuel from splashing.

•

Conduct the measurement two or three times for each injector.

•

Before the injector is pulled out, make certain to turn off the ignition switch.

•

When removing the injector, use a suitable cloth or the like so as to prevent fuel from splashing.

•

Prior to the test, perform air bleeding for the fuel hose.

12. Ensure that no fuel is leaking from the injector nozzle when the SST wire is removed from the battery terminal.

Specification: Less than one drop of fuel per minute

NOTE:

•

If the leakage exceeds the specification, replace the injector.

13. Turn off the ignition switch.

SST

(09268-87702)

14. Loosen the hose band at the fuel filter.

15. Connect a suitable fuel hose (about 2 meter long) to the fuel filter.

16. Insert one end of the fuel hose in a measuring cylinder.

CAUTION:

•

The fuel pressure of the fuel line is approximately

284 kPa. Hence, be sure to gradually remove the pipe so as to prevent fuel from splashing.

•

Since the fuel will flow out, be certain to place a suitable container or cloth under the fuel filter so that no fuel may get to the resin or rubber parts of the vehicle.

JEF00049-00338

SST (09842-30070)

Battery

JEF00050-00339

JEF00051-00341

EF–16

17. Remove the fuel pump relay. Then, connect the terminal with a jump wire as indicated in the illustration.

18. Turn the ignition switch to the “ON” position for 10 seconds. Then, turn off the ignition switch.

r e

Relay terminal

JEF00052-00342

19. Measure the amount of fuel collected in the measuring cylinder.

Specified Amount of Fuel: 230 ml or more

NOTE:

•

Check to see if the fuel lines and filter exhibit leakage, deformation or choking.

20. Remove the fuel pressure regulator from the fuel delivery pipe. Then, install a fuel pressure gauge between the pressure regulator and the fuel pipe from the fuel filter as shown in the illustration.

SST: 09268-87701-000

09283-87703-000

JEF00053-00343

SST (09268-87701)

Hose bands

Hose band

SST (09283-87703)

To fuel filter

Pressure regulator

To fuel return pipe

JEF00054-00344

21. Turn the ignition switch to the “ON” position.

22. Check to see if the fuel pressure conforms to the specified pressure.

Specified Value: 284

5 kPa

NOTE:

•

If the fuel pressure is less than the specification, check the fuel pump and fuel pressure regulator.

JEF00055-00345

EF–17

Diagnosis connector

23. Check the idle revolution speed.

(1) Connect a tachometer to the terminal of the diagnosis connector.

(2) Check to see if the fast idle revolution speed is within the reference value.

Reference Value: Around 1400 rpm/25

NOTE:

•

The fast idle revolution speed can not be adjusted to the specification. If the revolution speed will not conform to the reference value, perform the inspection of the auxiliary air system, following the procedure given below.

(3) Remove the air cleaner case from the throttle body.

(4) Start the engine. Check that there is air continuity at the auxiliary air port under the following conditions.

Apply your finger to the auxiliary air valve port.

Ensure that the engine speed drops.

When the cooling water temperature is above

C, apply your finger to the auxiliary air port.

Ensure that the engine speed does not change.

NOTE:

•

If the auxiliary air system exhibits malfunction, replace the throttle body.

(5) Check to see if the idle revolution speed conforms to the specification when the engine water temperature is higher than 80

Specified Value

M/T Vehicle: 800

50 rpm

A/T Vehicle: 850

50 rpm

NOTE:

•

If the revolution speed will not conform to the specification, check the EFI ECU unit. See page EF–41.

Earth terminal

Tacho-meter terminal

From air cleaner

Auxiliary air valve port

JEF00056-00346

Idle adjusting screw

To manifold

Engine coolant

Throttle valve

Auxiliary air valve

JEF00057-00347

JEF00058-00348

EF–18

TROUBLE SHOOTING ACCORDING TO

DIAGNOSIS CODE

PREPARATION OF TROUBLE SHOOTING WITH

SST

The EFI unit can be checked by measuring the resistance or voltage at the SST terminals.

1. Disconnect the battery ground cable from the negative (–) terminal of the battery.

CAUTION:

•

Be sure to memorize the malfunction code before disconnecting the battery cable. Otherwise the maifunction code(s) will be erased by disconnecting the battery code.

IG “OFF”

JEF00059-00401

2. Disconnect the wire harness connectors from the EFI ECU connectors at the cowl side of the passenger seat.

3. Connect the following SST between the wire harness connectors and the EFI ECU connectors.

SST: 09842-87706-000

4. Reconnect the battery ground cable to the negative (–) terminal of the battery.

CAUTION:

•

When disconnecting or reconnecting the EFI ECU connectors, be sure to disconnect the battery ground cable from the negative (–) terminal of the battery with the ignition switch and all accessory switches in the off state.

•

When installing a new battery, care must be exercised not to mistake the battery polarity. Failure to observe this caution could cause ECU malfunction.

•

Before using the SST, be sure to check to see if short or open wire exists between the terminals of the SST.

EFI ECU

SST

1 2

33 34 35

4 5

6 7

36 37

38 39 40

10 11

41 42 43

12 13 14

15 16 17

47 48 49

44 45 46

18 19

20 21

50 51

52 53 54

23 24 25

55 56 57

26 27 28

29 30

61 62

58 59 60

31 32

63 64

JEF00060-00402

JEF00061-00403

EF–19

DIAGNOSIS CODE TABLE

When the diagnosis system detects malfunctions, the check engine lamp will go on even if the diagnosis connector test terminal is not connected to the earth terminal.

See page

Code

No.

Number of flashing

Diagnosis item

Diagnosis contents Trouble area

Engine revolution signal

Oxygen sensor signal

Pressure sensor signal

Cooling water temperature signal

•

When the engine revolution signal is not inputted while the starter switch is on.

•

When the input signal from the oxygen sensor shows too lean air-to-fuel ratio under certain conditions:

When the input signal from the pressure sensor becomes more than 4.9 V or less than 0.7 V.

•

When the engine cooling water temperature sensor circuit becomes open or shorted.

1. Cam angle sensor & circuit

1. Oxygen sensor circuit

2. Oxygen sensor

1. Pressure sensor circuit

2. Pressure sensor

1. Water temp. sensor circuit

2. Water temperature sensor

Intake air temp.

signal

A/C evapo.

temperature sensor

A/C compressor

Switch signal

•

When the intake air temperature sensor circuit becomes open or shorted.

1. Air temperature sensor circuit

2. Air temperature sensor

•

When the A/C evaporator temperature sensor circuit exhibits open or short.

•

When the A/C switch is turned on, the rotation signal from the A/C compressor becomes too low because of slipping of the magnet clutch or overload.

1. A/C evaporator temperature sensor circuit

2. A/C evaporator temperature sensor

1. A/C magnet clutch

2. A/C lock sensor circuit

•

When the A/C switch is turned on, the idle switch is turned off with the test terminal of the diagnosis connector shorted. However no memorizing will take place.

1. A/C switch circuit

2. A/C switch

3. Idle switch circuit

4. Throttle position sensor

•

When the vehicle speed sensor signal circuit exhibits open wire or or short circuit.

1. Vehicle speed sensor circuit

2. Vehicle speed sensor

Vehicle speed sensor signal

Immobilizer signal

•

When the rolling codes can not be exchanged between the EFI

ECU and the immobilizer ECU or the rolling codes are not matched.

•

When the rolling codes can not be exchanged in the EFI ECU.

1. Wire harness between the

Immobilizer ECU and EFI ECU

2. Immobilizer ECU

3. EFI ECU

1. EFI ECU

EF–202

EF–22

EF–257

EF–27

EF–29

EF–31

EF–33

EF–35

EF–37

EF–39

JEF00062-00405

EF–20

DIAGNOSIS CODE NO. 13

CAM ANGLE SENSOR & CIRCUIT

EFI ECU

21 53

Z49

Cam angle sensor

When no cam angle sensor signal is inputted within 2 seconds while the engine is being cranked by the starter motor.

1. Check of cam angle sensor

(1) Disconnect the connector of the cam angle sensor.

(2) Check that there is the specified resistance between the respective terminals of the cam angle sensor.

Specified Value: 205 - 255

Ω

NOTE:

•

If the resistance will not conform to the specification, replace the signal generator. Refer to the IG section.

(3) Temporarily remove the EFI main relay at the relay box.

(4) Check that there is a voltage between the terminals of the cam angle sensor when the engine is being cranked.

Specified Value: About AC 150 mV/300 R.P.M.

NOTE:

•

The generating voltage should be measured, using the

AC range of a volt meter.

•

If the measured value does not conform to the specification, adjust the gap. See the IG section.

JEF00063-00501

JEF00064-00502

JEF00065-00503

EF–21

REFERENCE

(1) Prepare an oscilloscope.

(2) Connect a probe to the respective terminals.

(3) Check to see if a signal shown in the graph appears at the terminals when the engine is being cranked.

NOTE:

•

If not, check the air gap of the signal generator.

Refer to the IG section of the service manual.

3. Check the wire harness and ground earth.

(1) Check to see if the earth bolt exhibits looseness or corrosion.

JEF00066-00504

JEF00067-00506

(2) Connect the connector of the cam angle sensor and the wire harness connector.

(3) Connect the SST.

NOTE:

•

Refer to page EF–18, “Preparation of trouble shooting with SST”.

•

At this time, disengage the connector between the SST and the EFI ECU.

(4) Measure the resistance between the SST terminals 21 and 53.

Specified Value: 205 - 255

Ω

NOTE:

•

If the trouble has not been solved by repairing the wire harness or parts, then, proceed to page EF–41,

Replacement of ECU.

SST

12 13 14

15 16 17 18 19

44 45 46

47 48 49 50 51

20 21 22

52 53 54

JEF00068-00507

JEF00069-00508

EF–22

DIAGNOSIS CODE NO. 21

OXYGEN SENSOR & CIRCUIT

EFI ECU

J/C

X28

Z49

Oxygen sensor

The ECU detects malfunction when the input signal from the oxygen sensor shows too lean air-to-fuel mixture continuously for 2 seconds or more when the engine revolution speed is 1500 rpm or more and the engine is in a hot condition.

1. Inspection of oxygen sensor circuit

(1) Warm up the engine completely.

(2) Connect the test terminal and the earth terminal with a jump wire at the diagnosis connector.

(3) Measure the voltage between the VF terminal and the earth terminal as indicated in the illustration.

Specified Voltage: 0 - 5 V

(4) While keeping the engine revolution speed at

3000 rpm for about 2 minutes, count how many times the pointer of the voltmeter swings within 10 seconds.

8 Times or more: Normal

0 - 7 Times: Proceed to the following steps.

NOTE:

•

The throttle valve must be opened.

VF monitor terminal

JEF00070-00511

Diagnosis connector

Test terminal

Earth terminal

VF terminal

5 V

0 V

JEF00071-00512

JEF00072-00513

REFERENCE

(1) Prepare an oscilloscope.

(2) Connect a jump wire to the test terminal and the earth terminal.

(3) Connect a probe to the VF terminal and the earth terminal.

(4) Check to see if a signal shown in the graph appears at the terminals while the engine is rotating at 3000 rpm.

NOTE:

•

There are cases where the measurement can not be conducted with a tester having a low reaction speed.

Therefore, use a tester having a high reaction speed or oscilloscope.

•

If no voltage appears, check the oxygen sensor unit.

EF–23

Diagnosis connector

Test terminal

Earth terminal

VF terminal

JEF00073-00514

JEF00074-00515

2. Check of oxygen sensor

(1) Warm up the engine completely.

(2) Disconnect the connector of the oxygen sensor.

(3) Connect a voltmeter to the connector terminal of the oxygen sensor.

(4) Hold the engine revolution speed for 2 minutes at about 3000 rpm. At this time, ensure that the reading of the voltmeter registers 0.45 V or more.

NOTE:

•

When the oxygen sensor connector has been disconnected, an air-to-fuel mixture ratio of the engine will become rich. The oxygen sensor therefore generates an electromotive force of about 0.45 volts or more.

•

Replace the oxygen sensor with a new part, if the reading will not register 0.45 V or more.

•

If the reading conforms to the specification, proceed to the following procedure.

3. Check of wire harness

(1) Connect the SST between the ECU connectors and the wire harness connectors. (See page EF–18.)

(2) Ensure that the voltage between the SST terminals 56 and 62 is the specified value while keeping the engine revolution speed at 3000 rpm.

Specified Voltage: 0.2 - 1.0 V

NOTE:

•

At this stage, remove the jump wire from the test terminal and the earth terminal of the diagnosis connector.

Oxygen sensor

SST

23 24 25 26 27 28 29 30

31 32

55 56 57 58 59 60 61 62 63 64

Judgment line

0 V

JEF00075-00516

JEF00076-00517

1.0 V

0.45 V

Oxygen sensor output

JEF00077-00518

EF–24

(3) Perform the procedure given in the table, according to the measurement results.

0 V

The measured voltage varies mainly within a range under

0.45 V.

Measured voltage Remedy

1) Check the oxygen sensor circuit for open wire or short circuit.

Remedy causes for too-lean fuel mixture.

•

Pressure sensor

•

Pressure regulator

•

Fuel line

•

Fuel filter

•

Fuel pump

•

Injector

The measured voltage varies within a range of 0 - 1.0 V, centering around 0.45 V.

However, the reaction speed the is low.

(The pointer of the voltmeter swings less than 8 times within

10 seconds.)

Check the ECU. (Go to page EF–41, REPLACEMENT OF ECU.)

The measured voltage varies mainly within a range above

0.45 V.

1.0 V

Remedy causes for too-rich fuel mixture.

•

Pressure sensor

•

Fuel line

•

Pressure regulator

•

Injector

Remedy causes for too-rich fuel mixture.

•

Pressure sensor

•

Fuel line

•

Pressure regulator

•

Injector

Check the oxygen sensor circuit for short circuit with other positive line.

More than 1.0 V

Repair or replace the wiring harness.

JEF00078-00519

NOTE:

•

If the trouble has not been solved by repairing the wire harness or parts, then, proceed to page

EF–41, Replacement of ECU.

JEF00079-00520

EF–25

DIAGNOSIS CODE NO. 31

PRESSURE SENSOR & CIRCUIT

J/C

52 57

EFI ECU

24 23

X44 X45 X46

Intake air temp.

sensor

Cooling

water

temp.

sensor

Intake manifold pressure sensor

JEF00080-00521

When the pressure sensor becomes open or shorted:

1. Check the pressure sensor.

(1) Connect the SST between the ECU connectors and the wire harness connectors.

(2) Ensure that the voltage between the SST terminals 23 and 52 is within the specified value when the ignition switch is turned to the ON position.

Specified Value: 4.5 - 5.5 V

NOTE:

•

If no voltage appears, check the ECU power supply circuit, ECU ground circuit and the wire harness.

(3) Ensure that the voltage between the SST terminals 24 and 52 is within the following specified voltage when the ignition switch is turned to the ON position.

Altitude

(From sea level) m

500

1000

Atmospheric pressure kPa (mmHg)

101.3 (760)

95.5 (716)

89.9 (674)

Voltage

3.30 - 4.0 V

3.10 - 3.8 V

2.95 - 3.65 V

SST

12 13 14

15 16 17 18 19

44 45 46

47 48 49 50 51

20 21 22

52 53 54

23 24 25 26 27 28 29 30

31 32

55 56 57 58 59 60 61 62 63 64

SST

12 13 14

15 16 17 18 19

44 45 46

47 48 49 50 51

20 21 22

52 53 54

23 24 25 26 27 28 29 30

31 32

55 56 57 58 59 60 61 62 63 64

JEF00081-00522

JEF00082-00523

EF–26

(4) Temporarily connect a vacuum gauge (The MityVac may be used) to the negative pressure port of the VSV so that the inner pressure of the intake manifold may be measured. Next, start the engine and keep it idling.

At this time, ensure that the gauge reading and the voltage across the SST terminals 24 and 52 satisfy the following formula given below.

V = 0.004

+ 0.6

Where:

V = P sensor output during idling (V)

= Intake manifold negative pressure during idling (–mmHg)

JEF00083-00524

CAUTION:

•

Once the pressure sensor is removed from the intake manifold, even for the purpose of inspection, never reuse the pressure sensor. This is because the grommet of the sensor will be damaged by the removal.

NOTE:

•

If the measured voltage fails to drop by the specified value, replace the pressure sensor.

•

If the measured voltage does not conform to the specifications, check the wire harness.

•

If the trouble has not been solved by repairing of the wire harness or parts, proceed to page EF–41,

Replacement of ECU.

Grommet

JEF00084-00525

EF–27

DIAGNOSIS CODE NO. 42

WATER TEMPERATURE SENSOR & CIRCUIT

J/C

52 57

EFI ECU

24 23

X31

X30

Intake air temp.

sensor

Cooling

water

temp.

sensor

Intake manifold pressure sensor

JEF00085-00531

When the pressure sensor becomes open or shorted:

1. Check to see if the connector is connected properly.

2. Check of wire harness

(1) Connect the SST between the ECU connectors and the wire harness connectors.

(2) Ensure that the voltage between the SST terminals 25 and 52 is within the specified value when the ignition switch is turned to the ON position.

NOTE:

•

If the measured voltage does not conform to the specifications, check the wire harness.

Measuring points

Temperature

80 - 90

Voltage

2.450

0.15

0.318

0.01

SST

12 13 14

15 16 17 18 19

44 45 46

47 48 49 50 51

20 21 22

52 53 54

23 24 25 26 27 28 29 30

31 32

55 56 57 58 59 60 61 62 63 64

JEF00086-00532

JEF00087-00533

EF–28

3. Check the water temperature sensor unit.

(1) Turn off the ignition switch.

(2) Disconnect the connector of the water temperature sensor.

(3) Drain the engine cooling water.

(4) Remove the water temperature sensor unit.

NOTE:

•

Be certain to perform the replacement and repairs of the sensor only after the intake manifold has been removed from the cylinder head.

(5) Check that the resistance between the terminals X30 and X31 of the water temperature sensor is within the specified value in the table. See page EF–27.

NOTE:

•

If the trouble has not been solved by repairing the wire harness or parts, proceed to page EF–41, Replacement of ECU.

JEF00088-00534

O ring

X31

X30

Spring

For water temp. gauge

Electric

conductor ring

Thermistor

(For water temp. gage)

Case

Insulator

Thermistor

(For engine control)

JEF00089-00535

EF–29

DIAGNOSIS CODE NO. 43

INTAKE AIR TEMPERATURE SENSOR & CIRCUIT

J/C

52 57

EFI ECU

24 23

X34 X33

Intake air temp.

sensor

Cooling

water

temp.

sensor

When the pressure sensor becomes open or shorted:

1. Check to see if the wire harness connectors are connected properly.

2. Disconnect the connector of the intake air temperature sensor.

NOTE:

•

Before the wire harness connector is disconnected, be sure to turn off the ignition switch.

3. Check that the resistance between the terminals X33 and

X34 of the intake air temperature sensor is within the specified value.

Temperature

Resistance k

Ω

1.140

0.3

2.450

0.5

5.880

1.5

Intake manifold pressure sensor

JEF00090-00541

X33

X34

JEF00091-00542

JEF00092-00543

EF–30

4. Check of wire harness

(1) Connect the SST between the ECU connectors and the wire harness connectors.

(2) Check that the voltage between the SST terminals 52 and 57 is within the specified value when the ignition switch is turned to the ON position.

Reference: 20

C 1.8 - 2.9 V

SST

12 13 14

15 16 17 18 19

44 45 46

47 48 49 50 51

20 21 22

52 53 54

23 24 25 26 27 28 29 30

31 32

55 56 57 58 59 60 61 62 63 64

NOTE:

•

If the measured voltage does not conform to the specifications, check the wire harness.

•

If the diagnosis code No. 43 is flashing, most likely it denotes that open wire occurs intermittently or the shielding is poor.

•

If the trouble has not been solved by repairing the wire harness or parts, then, proceed to page EF–41,

Replacemeny of ECU.

JEF00093-00544

JEF00094-00545

EF–31

DIAGNOSIS CODE NO. 44

AIR CONDITIONER EVAPORATOR TEMPERATURE SENSOR & CIRCUIT

IG SW

ACC

IG No. 1

IG No. 2

Main

R/B

EFI ECU

KP5

KK4

ACC

MAIN

K02

K44

K30

Resister

K04

K05 K07

K06 K08

Z21

JEF00095-00551

When the air conditioner evaporator temperature sensor and circuit becomes open or shorted:

1. Check to see if the wire harness connectors are connected properly.

2. Disconnect the connector of the evaporator temperature sensor.

NOTE:

•

Before the wire harness connector is disconnected, be sure to turn off the ignition switch.

3. Check the resistance between the terminals.

Temperature

Resistance k

Ω

1.500

0.15

2.340

0.23

4.850

0.24

KP5

KK4

JEF00096-00552

JEF00097-00553

EF–32

4. Check of wire harness

(1) Connect the SST between the ECU connectors and the wire harness connectors.

(2) Check that the voltage between the SST terminals 3 and 52 is within the specified value when the ignition switch is turned to the ON position.

Reference: 20

C 1.8 - 2.9 V

SST

1 2

34 35 36 37

6 7

9 10 11

38 39 40 41

42 43

12 13 14

44 45 46

15 16 17 18

20 21 22

52 53 54

47 48 49 50

NOTE:

•

If the measured voltage does not conform to the specification, check the wire harness.

•

If the trouble has not been solved by repairing the wire harness or parts, then, proceed to page EF–41,

Replacement of ECU.

JEF00098-00554

JEF00099-00555

EF–33

DIAGNOSIS CODE NO. 45

AIR CONDITIONER LOCK SENSOR & CIRCUIT

IG SW

ACC

IG No. 1

IG No. 2

Main

R/B

EFI ECU

KP5

KK4

ACC

MAIN

K02

K44

K30

Resister

K04

K05

K07

K06 K08

Z21

When the ECU detects malfunction of the A/C lock sensor circuit.

1. Check the drive belt tension of the A/C compresser. Check the A/C compresser for sticking before checking the A/C lock sensor circuit.

2. Check the connection of the A/C lock sensor connector.

NOTE:

•

This code will not be memorized.

•

The diagnosis code will be indicated only when the test terminal is connected with the ground terminal.

3. Check the A/C lock sensor and circuit.

(1) Connect the SST between the ECU and the cowl wire.

(2) Check the output voltage across the SST terminals 26 and 20 when the A/C compresser is operating.

Specified Value: 0.1 - 3 V (Pulse signal)

JEF00100-00556

Vane pump pulley

Water pump pulley

Air conditioner compressor pulley

Alternator pulley

Crankshaft pulley

SST

12 13 14

15 16 17 18 19

44 45 46

47 48 49 50 51

20 21 22

52 53 54

23 24 25 26 27 28 29 30

31 32

55 56 57 58 59 60 61 62 63

Idler pulley

JEF00101-00557

JEF00102-00558

EF–34

4. Check of wire harness

(1) If the measured voltage is o volt, check the wiring between the ECU and the A/C lock sensor connector for open wire or short circuit.

(2) Check the A/C lock sensor by measuring the output voltage at the sensor connector.

NOTE:

•

If the trouble has not been solved by repairing the wire harness or parts, then, proceed to page EF–41,

Replacement of ECU.

JEF00103-00559

JEF00104-00560

EF–35

DIAGNOSIS CODE NO. 51

SWITCHING SIGNAL CIRCUIT

IG SW

ACC

IG No. 1

IG No. 2

Main

To starter relay coil

Neutral start switch (A/T)

Throttle position sensor

EFI ECU

When the ECU detects malfunction of the switching circuit.

1. Check that the following wire harness connector or switching circuits are connected properly.

(1) Throttle position sensor circuit

(2) A/C switch circuit

(3) Neutral start switch circuit of the A/T.

NOTE:

•

This code will not be memorized.

•

The diagnosis code will be indicated only when the test terminal is connected with the earth terminal as shown in the illustration.

2. Check of wire harness and switches

(1) Connect the SST between the ECU connectors and the wire harness connectors.

(2) Check that there is continuity between the SST terminals 62 and 38 when the A/T shift lever is shifted to the

P or N position.

ACC

MAIN

K02

K44

K30

Resister

K04

K05 K07

K06 K08

Z21

JEF00105-00561

Diagnosis connector

Test terminal

Earth terminal

JEF00106-00562

34 35 36 37

9 10 11

38 39 40 41

42 43

23 24 25

55 56 57

26 27 28 29

58 59 60

31 32

61 62 63

JEF00107-00563

EF–36

(3) Check the voltage between the SST terminals 20 and

23 when the throttle valve is opened and the ignition switch is turned on.

Specified Value: 4.5 - 5.5 V

SST

12 13 14

15 16 17 18 19

44 45 46

47 48 49 50 51

20 21 22

52 53 54

SST

23 24 25 26 27 28 29 30

31 32

55 56 57 58 59 60 61 62 63 64

(4) Check the voltage between the SST terminals 20 and

54 when the throttle valve is fully closed and the ignition switch is turned on.

Specified Value: 0.4 - 0.8 V

SST

12 13 14

15 16 17 18 19

44 45 46

47 48 49 50 51

20 21 22

52 53 54

JEF00108-00564

JEF00109-00565

(5) Check the voltage between the SST terminals 5 and 62 when the A/C switch is turned on.

Specified Value: Battery voltage

34 35 36 37

9 10 11

38 39 40 41

42 43

23 24 25

55 56 57

26 27 28 29

58 59 60

31 32

61 62 63

JEF00110-00566

(6) Turn off the ignition switch. Then, disconnect the connector of the throttle position sensor.

(7) Check the resistance between the terminals PSW and

VC of the throttle position sensor.

Specified Value: 2.5 - 6.0 k

Ω

PSW

–

JEF00111-00567

NOTE:

•

If the trouble has not been solved by repairing the wire harness or parts, then, proceed to page EF–41,

Replacement of ECU.

JEF00112-00568

EF–37

DIAGNOSIS CODE NO. 52

VEHICLE SPEED SENSOR & CIRCUIT

Vehicle speed sensor

EFI ECU

B11

Combination meter

Speedometer cable

B10

JEF00113-00571

When the pressure sensor becomes open or shorted:

1. Check of the reed switch

(1) Remove the combination meter.

(2) Ensure that continuity occurs four times at the terminals B10 and B11 of the combination meter while the speedometer drive shaft completes a turn.

NOTE:

•

The sensor has been so constructed that its rotary shaped-magnet rotates at the same revolution speed as the speedometer cable turns ON/OFF reed switch, thereby making it possible to input the vehicle speed to the computer. Four pulses are generated as the speedometer cable completes its one turn.

2. Check of wire harness

(1) Connect the SST between the ECU connectors and the wire harness connectors.

(2) Check that the voltage between the SST terminals 7 and 62 is within the following specified value when the vehicle moves and the ignition switch is turned to the

ON position.

Specified Value: 0 - 5 V for pulse signal

JEF00114-00572

34 35 36 37

9 10 11

38 39 40 41

42 43

23 24 25

55 56 57

26 27 28 29

58 59 60

31 32

61 62 63

JEF00115-00573

EF–38

NOTE:

•

If the measured voltage is 0 volt, check that the wire harness or connector is shorted.

•

If the measured voltage is still 5 volts, check that the wire harness or connector exhibits open wire.

•

If the diagnosis code No. 43 is flashing, most likely it denotes that open wire occurs intermittently or the shielding is poor.

•

Check to see if the earth bolt exhibits looseness or corrosion.

•

If the trouble has not been solved by repairing the wire harness or parts, then, proceed to page EF–41,

Replacement of ECU.

JEF00116-00574

EF–39

DIAGNOSIS CODE NO. 81

IMMOBILIZER SIGNAL CIRCUIT

EFI ECU

62 40

IMMOBILIZER ECU

Diagnosis connector

(DS-21)

Antenna

(IG key)

When the rolling codes cannot be exchanged between the engine EFI ECU and the immobilizer ECU or the rolling codes are not matched.

1. Check of wire harness

(1) Connect the SST between the ECU connectors and the wire harness connectors.

(2) Remove the screws of the glove compartment subassembly.

(3) Disconnect the connector of the Immobilizer ECU.

Immobilizer ECU

JEF00117-00581

EFI ECU

JEF00118-00582

(4) Check that continuity exists between the terminal 7

(Cowl wire side terminal of the Immobilizer ECU) and terminal 40 (SST terminal).

If not, check the wire harness.

NOTE:

•

If the diagnosis code No. 43 is flashing, most likely it denotes that open wire occurs intermittently or the shielding is poor.

•

If the trouble has not been solved by repairing the wire harness or connectors, then, proceed to the following steps.

SST

1 2

6 7

8 9 10 11

34 35 36 37

38 39 40 41

42 43

Immobilizer connector

(Wire harness side)

JEF00119-00583

EF–40

2. Check the Immobilizer system.

NOTE:

•

In cases where the ECU is replaced with a new EFI

ECU, be sure to use the master key to start the engine for the first time. The engine will not start with a key other than the master key. In cases where the ECU is replaced with an EFI ECU other than a new one, the engine will not start even if the master key is used.

For details, refer to the immobilizer manual.

•

When the diagnosis code No. 81 occurs because of reasons other than abnormality of the wire harness, most likely the immobilizer ECU is malfunctioning.

Refer to the immobilizer manual.

Master key

(black)

JEF00120-00585

EF–41

REPLACEMENT OF ECU

INSPECTION

NOTE:

•

Even when the replacement of the ECU is required in previous checks, make sure that the ECU malfunction has not been caused by factors other than the ECU by carrying out the following checks. Then, proceed to replace the ECU.

•

The measurement of voltage should be conducted while all of the connectors are connected.

CAUTION:

•

In cases where the ECU is replaced with a new EFI

ECU, be sure to use the master key and connect the test terminal with the earth terminal to start the engine for the first time. The engine will not start with a key other than the master key.

•

In cases where the ECU is replaced with an EFI ECU other than a new one, the engine will not start even if the master key is used.

For details, refer to the immobilizer manual.

1. Install the SST.

See page EF–18, “Preparation of trouble shooting with

SST”.

2. Measurement of voltage or resistance

(1) Measure the voltage or resistance between respective terminals.

(2) Check to see if the measured voltage or resistance conforms to the specifications in accordance with the following “CHARACTERISTICS OF ECU OUTPUT” table.

JEF00121-00701

JEF00122-00702

EFI ECU

SST

34 35

4 5

36 37 38

39 40

10 11

41 42 43

12 13 14

44 45 46

20 21

15 16 17

18 19

47 48 49

50 51

52 53 54

23 24 25

55 56 57

26 27 28

29 30

61 62

58 59 60

31 32

63 64

JEF00123-00703

EF–42

CHARACTERISTICS OF ECU OUTPUT (1)

Followings are standard voltage or resistance at ECU.

Item

Power supply

Terminal

2 – 62

Condition

All times

Ignition switch is turned on.

Earth group

Pressure sensor

11 – 62

43 – 62

23 – 52

24 – 52

All times

Water temp.

sensor

Intake air temp.

sensor

Oxygen sensor

Cam angle sensor

Throttle position sensor

Vehicle speed sensor

25 – 52

57 – 52

56 – 62

21 – 53

23 – 20

54 – 20

7 – 62

Ignition switch is turned on.

Atmospheric pressure is

101 kPa.

Ignition switch is turned on.

After engine has warmed up fully. (Cooling water temperature is 80 - 90

C.)

Ignition switch is turned on. Air

temperature sensor inside the surge tank is 20 (68).

Engine is rotating at about

3000 r.p.m., after engine has warmed up fully.

While the engine is being cranked by the starter motor.

Ignition switch is turned on.

Throttle valve is fully closed.

Ignition switch is turned on.

Throttle valve is fully opened.

Ignition switch is turned on.

When vehicle is moved.

(Measured voltage changes 4 times for movement of 1.6 m)

Ignition switch is turned on.

Ignition coil drive

Injector drive

Fuel pump drive

63 – 29

63 – 64

31 – 62

32 – 62

33 – 62 or

34 – 62

42 – 62

Ignition switch is turned on.

VF monitor

Alternator

28 – 62

Engine is rotating at about

3000 r.p.m. after engine has warmed up fully.

Engine is running.

Standard voltage or resistance

Battery voltage

Ω

or less

Remedies

Check back-up fuse in the relay box.

Check main relay in the relay box.

Check ground earth of wiring harness.

4.5 - 5.5 V

3.3 - 4.0 V

0.4 - 0.65 V

1.8 - 2.9 V

Check ECU power supply.

Check pressure sensor.

Check cooling water temperature sensor.

Check air temp. sensor.

Voltage varies within

0.2 - 1.0 V

Check oxygen sensor.

0.1 - 0.3 V (AC range)

Check crank angle sensor.

4.5 - 5.5 V

1.0 V or less

Check throttle position sensor.

3.5 - 4.1 V

Change in voltage between 0.1 V and approx. 5 V

Check speed sensor.

3 V or less

Check ignition coil.

Approx. battery voltage

Check injector(s).

Approx. battery voltage Check fuel pump relay.

The terminal 34 is for immobilizer system.

1.8 - 3.2 V

Check oxygen sensor.

Approx. battery voltage Check alternator.

JEF00124-00704

EF–43

CHARACTERISTICS ECU OUTPUT (2)

Followings are standard voltage or resistance at ECU.

Item

Terminal Condition

Headlamp switch is turned on.

37 – 62

36 – 62

Electrical load

Tachometer signal

Automatic transmission signal

6 – 62

41 – 62

38 – 62

Ignition switch is turned on and defogger switch is turned on.

Ignition switch is turned on and heater blower switch is turned on.

Heater blower switch is turned off.

Ignition switch is turned on.

Engine is rotating at idling speed.

When A/T shift lever is in P or

N range.

Air conditioner signal

Idle-up

VSV control

Test terminal

Check engine lamp

5 – 62

1 – 62

26 – 62

3 – 62

60 – 62

59 – 62

58 – 62

39 – 62

10 – 62

Standard voltage or resistance

Approx. battery voltage

0.1 V or less

Remedies

Check headlamp fuse or switch.

Check defogger fuse or switch.

Check heater blower switch.

Approx. battery voltage

Check gauge fuse or heater blower relay.

0.1 V or less Check tachometer.

Approx. 6 V (AC range) Replace ECU.

Ω

or less

Check wire harness.

When ignition SW is turned on and A/C switch is turned on.

Engine is running at idling speed and A/C SW is turned on.

Engine is running at idling speed and A/C switch is turned on.

Ignition SW is turned ON.

Engine is running at idling speed and headlamp switch, defogger switch or heater switch is turned on.

Engine is running at idling speed and A/C switch is turned on.

Ignition switch is turned on.

Approx. battery voltage

3.0 V or less

0.1 V - 0.4 V

(AC range)

0.15 - 4.8 V

0.5 V or less

4.5 - 5.5 V

Approx. battery voltage

Check wire harness.

Check ECU.

Check wire harness.

JEF00125-00705

After completion of inspection

(1) Disconnect the ground cable terminal from the negative (–) terminal of the battery.

(2) Remove the SST by disconnecting its connectors from the ECU and engine wire connectors.

(3) Connect the wire harness connectors to the ECU.

(4) Reconnect the ground cable terminal to the negative (–) terminal of the battery.

JEF00126-00706

EF–44

ECU REPLACEMENT

1. Disconnect the ground cable terminal from the negative

(–) terminal of the battery.

2. Remove the glove compartment subassembly.

3. Disconnect the wire harness connector from the ECU.

4. Remove the ECU by removing the attaching bolts and nuts.

5. Install a new ECU.

CAUTION:

•

Never touch the bracket screws mounted on the ECU proper. This tampering will cause an ECU malfunction.

6. Connect the wire harness connector to the ECU.

7. Install the glove compartment subassembly.

8. Connect the ground cable terminal to the negative (–) terminal of the battery.

IG “OFF”

JEF00127-00707

JEF00128-00708

EF–45

INSPECTION OF IDLE-UP CONTROL SYSTEM

WIRING DIAGRAM

IG SW

ACC

IG No. 1

IG No. 2

Main

R/B

Main relay

Fuel pump relay

Fuel

pump

M

To starter relay

EFI ECU

VSV No. 3

VSV No. 2

VSV No. 1

Neutral start switch

ACC

MAIN

JEF00129-00901

UNIT INSPECTION

1. Remove the air cleaner case subassembly and its relevant parts.

2. Disconnect the connector of the idle-up VSV.

3. Measure the resistance between the respective terminals of the VSV.

4. Ensure that the specified resistance exists between the terminals described below.

Specified Value: 32

Ω

NOTE:

•

If the resistance will not conform to the specified value, replace the idle-up VSV.

5. Apply a negative pressure of 13.3 kPa (100 mmHg) to the

VSV, using a MityVac or a vacuum pump.

6. Check to see if the negative pressure applied in the step 5 becomes zero when the battery voltage is applied to the terminals of the VSV.

NOTE:

•

If not, replace the idle-up VSV.

X08

X09

JEF00130-00911

JEF00131-00912

EF–46

SYSTEM INSPECTION

VSV No. 1

1. Connect the SST between the EFI ECU connector and the wire harness connectors. See page EF–18.

2. With the engine running, measure the voltage between the terminals 60 and 62 of the SST.

Condition

Until engine is warmed up fully after engine starting from engine cold state.

Defogger switch is turned on.

Heater blower switch is turned on.

Headlamp switch is turned on.

Specified value

0.5 V or less

NOTE:

•

The measurement should not be performed when plural conditions of those discribed above one met concurrently .

•

If the check results will not conform to the requirements given in the table, check and repair those related systems.

VSV No. 2

1. Connect the SST between the EFI ECU connector and the wire harness connectors. See page EF–18.

2. With the engine running, measure the voltage between the terminals 59 and 62 of the SST.

Condition

Until engine is warmed up fully after engine starting from engine cold state.

The shift lever has been moved from D, 2, L or R to P or N.

Defogger switch, heater blower switch and headlamp switch have been turned on.

Specified value

0.5 V or less

NOTE:

•

This VSV is equipped on A/T vehicles only.

•

If the check results will not conform to the requirements given in the table, check and repair those related systems.

VSV No. 3

1. Connect the SST between the EFI ECU connector and the wire harness connectors. See page EF–18.

2. With the engine running and air conditioner switch turned on, measure the voltage between the terminals 58 and 62 of the SST.

Specified Value: 0.5 V or less

NOTE:

•

This VSV is used for the air conditioner system.

•

If the check results will not conform to the requirements given in the table, check and repair those related systems.

23 24 25

55 56 57

26 27 28 29

58 59 60

31 32

61 62 63

No. 1

No. 2

JEF00132-00941

JEF00133-00942

23 24 25

55 56 57

26 27 28 29

58 59 60

31 32

61 62 63

JEF00134-00943

JEF00135-00944

23 24 25

55 56 57

26 27 28 29

58 59 60

31 32

61 62 63

JEF00136-00945

INSPECTION OF FUEL SYSTEM

EF–47

FUEL TANK

UNIT INSPECTION

1. Check the fuel tank for deformation, cracks or fuel leakage.

2. Check the filler neck for damage or fuel leakage.

3. Check to see if the hose and tube connections are installed as shown in the right figure.

4. Check to see if the fuel tank cap and gasket exhibit damage.

NOTE:

•

If the fuel tank and its related parts exhibit any defect, repair or replace the fuel tank.

•

Replace the gasket if it is damaged. Also, replace the fuel tank cap if it exhibits damage.

JEF00137-01001

JEF00138-01002

JEF00139-01003

EF–48

FUEL PUMP

INSPECTION

See page EF–14, Check of fuel system.

REMOVAL

1. Disconnect the battery ground cable from the negative (–) terminal of the battery.

2. Remove the fuel tank.

Refer to the BO section of the sevice manual.

WARNING:

•

Never allow any fire to be brought near the working site.

3. Remove the fuel pump assembly.

INSTALLATION

1. Install a new fuel pump assembly to the fuel tank with a new gasket interposed.

2. Tighten the attaching screws.

Tightening Torque: 1.5 - 2.5 N·m

3. Install the fuel tank and its related parts to the body.

Refer to the BO section of the service manual.

FUEL LINE

REMOVAL & INSTALLATION OF QUICK CONNECTOR

Refer to the BO section of the service manual.

WARNING:

•

Always keep fire away from the working site.

NOTE:

•

Always use a new gasket and a hose band (clip) when replacing the fuel tank or components.

•

Each part should be tightened securely to the specified torque.

JEF00142-01013

IG “OFF”

JEF00140-01011

JEF00141-01012

EF–49

SST (Special Service Tools)

Shape

Part No. and name

09283-87703-000

Pressure regulator adapter

09268-87702-000

Injection measuring tool set

09268-87701-000

EFI fuel pressure gauge

Purpose

* Inspection of injectors

* Inspection of pressure regulator

* Inspection of fuel pressure

* Inspection of injectors

* Inspection of pressure regulator

* Inspection of fuel pressure

Inspection of fuel pressure

Remarks

Used in combination with 09268-87702-000

Used in combination with 09283-87703-000

09842-30070-000

EFI inspection wire

Inspection of fuel injectors

09991-87401-000

Engine control system inspection wire

09991-87402-000

Tacho-pluse pick-up wire

Measurement of engine revolution speed

Shorting terminal T

Measurement of engine revolution speed

09991-87403-000

Diagnosis check wire

Shorting terminal T

09842-87706-000

EFI-

computer check subharness

TIGHTENING TORQUE

Tightening components

Ignition coil

Cylinder head over

Spark plug

Cylinder head

Cam angle sensor

Cylinder head

Oxygen sensor

Exhaust manifold

Cooling water temperature sensor

Cylinder head

Intake air temperature sensor

Intake head

Idle-up VSV

Intake manifold

Delivery pipe

Intake manifold

Fuel pump

Intake manifold

Inspection of computer input/output voltage

N·m

Tightening torque kgf-m

5.9 - 8.8

14.7 - 21.6

0.6 - 0.9

1.5 - 2.2

14.7 - 21.6

29.4 - 39.2

24.5 - 34.3

29.5 - 39.2

1.5 - 2.2

3.0 - 4.0

2.5 - 3.5

3.0 - 4.0

14.7 - 21.6

1.5 - 2.5

1.5 - 2.2

0.15 - 0.25

JEF00143-01101

Remarks

JEF00144-01201

DAIHATSU

J100

LUBRICATION SYSTEM

OIL PRESSURE WARNING ........................ LU– 2

OIL PRESSURE CHECK ............................. LU– 2

OIL PUMP .................................................... LU– 3

COMPONENTS

...................................... LU– 3

REMOVAL

............................................... LU– 3

DISASSEMBLY

....................................... LU– 4

ASSEMBLY

............................................. LU– 7

INSTALLATION

....................................... LU– 8

TIGHTENING TORQUE ............................... LU–10

JLU00001-00001

NO. 9710-JE

LU–2

OIL PRESSURE WARNING

1. Check to see if the oil pressure warning will be illuminated when the ignition switch is turned on.

NOTE:

•

If the warning lamp will not go on, check to see if the bulb in the combination meter is burnt out.

(Refer to the BE section of the service manual.)

•

If the warning lamp is illuminated when the engine has started, perform the following checks.

(In advance, be sure to check that the engine oil is at a sufficient level.)

OIL PRESSURE CHECK

1. Remove the engine undercover.

2. Disconnect the oil pressure switch connector.

3. Remove the oil pressure switch.

NOTE:

•

Use a hexagonal long box wrench for removal.

4. Install a suitable oil pressure gauge.

5. Measuring of oil pressure

Start the engine and warm it up to the normal operating temperature.

Ensure that the oil pressure is within the specification.

Specified Oil Pressure

At Idle Speed: 20 kPa or more

At 3000 rpm: 245 - 490 kPa

NOTE:

•

If the measured value fails to conform to the specified value, check and repair the oil pump.

6. Stop the engine.

7. Remove the oil pressure gauge.

8. Clean the threaded portion of the oil pressure switch.

9. Wind seal tape around the threaded portion of the oil pressure switch.

10. Install the oil pressure switch to the oil pump.

Tightening Torque: 11.8 - 19.6 Nm

NOTE:

•

Use a hexagon long box wrench for the installation of the oil pressure switch.

•

The new oil pressure switch is coated with sealer.

•

Therefore, when replacing the oil pressure switch with the new one, remove the sealer thoroughly before winding seal tape.

•

Be sure to clean the hole threads at the oil pump side before installation of the oil pressure switch.

11. Connect the connector of the engine wire to the oil pressure switch.

12. Start the engine and check it for oil leakage.

JLU00002-00011

JLU00003-00101

JLU00004-00102

JLU00005-00103

JLU00006-00104

LU–3

OIL PUMP

COMPONENTS

Oil pump assembly

Oil pressure switch

Gasket

REMOVAL

NOTE:

•

In order to remove/install the oil pump, it is necessary to remove the oil pan. For a reliable service, it is not recommended to perform this operation with the engine mounted on the vehicle. Therefore, this manual describes only for the operation that is to be performed after the engine has been removed from the vehicle.

•

For the operations that precede the removal of the oil pump, refer to the EM section of this manual.

Oil strainer

Oil filter

JLU00007-00201

JLU00008-00202

LU–4

1. Install the engine unit to the suitable engine stand.

Refer to EM section of the service manual.

2. Remove the oil filter element.

3. Remove the attaching bolts and nuts of the oil pan.

4. Separate the oil pan from the cylinder block.

5. Remove the oil strainer by removing the attaching bolts.

JLU00009-00203

JLU00010-00204

6. Remove the attaching bolts of the oil pump assembly evenly.

7. Remove the oil pump from the cylinder block.

DISASSEMBLY

1. Detach the oil pump cover by removing the attaching screws.

2. Remove the front oil seal.

JLU00011-00205

JLU00012-00301

Front oil seal

JLU00013-00302

3. Remove the oil pump rotor set.

4. Pull out the cotter pin, while pushing the spring retainer with nose pliers or the like.

NOTE:

•

Put an appropriate cloth, etc. on the retainer spring so that it may not jump out.

5. Remove the oil pump relief valve spring retainer, compression spring and oil pump relief valve.

6. Inspection of each part

(1) Wash the disassembled parts in cleaning solvent.

(2) Check the pump body for damage.

(3) Check the rotor set for damage.

(4) Check the oil pump relief valve for damage.

(5) Check the oil pump relief valve spring retainer for damage.

NOTE:

•

Replace the each parts if it exhibits damage.

(6) Check the compression spring for damage. Also, measure its free length.

Specified Free Length: 57 mm

NOTE:

•

Replace the compression spring if it exhibits damage or the free length is less than the specified value.

(7) Apply engine oil to the oil pump relief valve. Insert the oil pump relief valve into the oil pump body. Check to see if the valve slides smoothly.

NOTE:

•

Replace the oil pump body if the valve fails to slide smoothly.

LU–5

JLU00014-00303

JLU00015-00304

JLU00016-00305

JLU00017-00306

JLU00018-00307

LU–6

7. Measurement of body clearance, tip clearance and side clearance

(1) Apply a thin film of engine oil to the rotor mate surface of the oil pump body as well as to the rotor set.

Assemble the rotor set in the oil pump body in such a way that the drilled mark may be seen from the outside.

(2) Measure the body clearance between the oil pump body and the outer rotor, using a thickness gauge.

Body Clearance: 0.20 - 0.28 mm

NOTE:

•

Replace the oil pump if the body clearance exceeds the specified value.

(3) Measure the tip clearance of the rotor set, using a thickness gauge.

Tip Clearance: 0.16 - 0.24 mm

NOTE:

•

Replace the rotor set if the tip clearance exceeds the specified value.

(4) Measure the side clearance between the oil pump body and the rotor set, using and a straightedge and a thickness gauge.

Side Clearance: 0.04 - 0.08 mm

NOTE:

•

Replace the oil pump if the side clearance exceeds the specified value.

8. Check to see if any wear is present at the rotor set mate surface of the pump cover.

NOTE:

•

Replace the oil pump cover if it exhibits wear.

JLU00019-00308

JLU00020-00309

JLU00021-00310

JLU00022-00311

JLU00023-00312

ASSEMBLY

NOTE:

•

Wash those parts to be assembled in cleaning solvent.

Dry them using compressed air.

WARNING:

•

When you use compressed air, be sure to protect your eyes, wearing goggles.

1. Apply engine oil to the relief valve. Then, insert the relief valve into the oil pump body.

2. Insert the compression spring and retainer into the oil pump body.

CAUTION:

•

Install the retainer in such a direction that its projected side may come at the compression spring side.

3. Insert a new cotter pin into the retainer while the retainer is being compressed with pliers, etc. Split the end of the cotter pin to form an anchor-like shape.

4. Drive a new oil seal into position if the oil seal exists damaged, using a hydraulic press.

NOTE:

•

Be very careful not damage the oil pump during the removal and the installation of the oil seal.

•

Make sure that the oil seal is not driven into position in a tilted state.

5. Apply engine oil to the rotor set. Assemble the rotor set in the pump body in such a direction that the drilled mark of the rotor may be seen from the outside.

LU–7

JLU00024-00411

JLU00025-00412

JLU00026-00413

JLU00027-00414

Mark

JLU00028-00415

LU–8

6. Install the oil pump cover. Tighten the cover to the specified torque.

Tightening Torque: 7.8 - 12.7 N·m

JLU00029-00416

7. Turn the rotor by hand. Ensure that the rotor turns smoothly.

If the rotor will not turn smoothly, overhaul the oil pump.

JLU00030-00417

INSTALLATION

1. Remove the gasket material of the sealer from the oil pump and cylinder block.

2. Apply the Three Bond 1207-F (or 1207-C) to the oil pump installation surface of the cylinder block, as indicated in the illustration.

3. Apply engine oil to the inner surface of the oil seal.

4. Replace the O-ring of the oil pump with a new part.

O ring

JLU00031-00511

JLU00032-00512

5. Install the oil pump to the cylinder block with the attaching bolts.

Tightening Torque: 5.9 - 8.8 N·m

CAUTION:

•

Be very careful not to damage the crankshaft oil seal during the oil pump installation.

•

Be very careful not to drop the O-ring during the oil pump installation.

JLU00033-00513

6. Install the oil strainer to the cylinder block with a new gasket interposed.

Tightening Torque: 14.7 - 21.6 N·m

LU–9

7. Attach the oil pan gaskets to the cylinder block.

NOTE:

•

The oil pan gaskets are provided at two points; one at the oil pump side and the other at the flywheel side. Fit the protruding section of the gasket into the cut-out section of the cylinder block.

8. Apply the Three Bond 1207-F (or 1207-C) to the cylinder block attaching section of the oil pan as shown in the right figure.

NOTE:

•

Be sure to apply the Three Bond to both ends of the oil pan gasket in such a way that the applied portions may be overlapped.

9. Install the oil pan to the cylinder block with the attaching bolts and nuts.

10. Tighten the oil pan attaching bolts and nuts to the specified torque evenly over two or three stages.

Tightening Torque: 6.9 - 11.8 N·m

Gasket

JLU00034-00514

JLU00035-00515

Three Bond 1207C

JLU00036-00516

JLU00037-00517

LU–10

TIGHTENING TORQUE

Tightening components

N·m

Tightening torque kgf-m

Oil pressure switch

Oil pump

Oil pump cover

Oil pump

Cylinder block

Oil strainer

Cylinder block

Oil pan

Cylinder block

11.8 - 19.6

7.8 - 12.7

5.9 - 8.8

14.7 - 21.6

6.9 - 11.8

1.2 - 2.0

0.8 - 1.3

0.6 - 0.9

1.5 - 2.2

0.7 - 1.2

Remarks

JLU00038-00801

DAIHATSU

J100

COOLING SYSTEM

DESCRIPTION ................................... CO– 2

RADIATOR ......................................... CO– 3

RADIATOR CAP

............................ CO– 3

RADIATOR RESERVE TANK

......... CO– 3

RADIATOR HOSES & PIPES

......... CO– 4

FAN-EQUIPPED

FLUID COUPLING ......................... CO– 5

COOLING FAN

............................. CO– 5

FLUID COUPLING WITH FAN

...... CO– 5

WATER PUMP PULLEY

................. CO– 6

THERMOSTAT

............................... CO– 7

PRECAUTIONS ................................. CO– 8

CHECK & CHANGE OF

ENGINE COOLANT ....................... CO– 8

WATER PUMP ................................... CO–10

COMPONENTS

............................. CO–10

REMOVAL OF WATER PUMP

....... CO–10

INSPECTION OF WATER

PUMP-RELATED PARTS

........... CO–11

INSTALLATION OF

WATER PUMP

........................... CO–11

THERMOSTAT ................................... CO–13

REMOVAL OF THERMOSTAT

....... CO–13

INSPECTION OF

THERMOSTAT

........................... CO–13

INSTALLATION OF

THERMOSTAT

........................... CO–14

RADIATOR ......................................... CO–15

CLEANING OF RADIATOR

........... CO–15

INSPECTION OF RADIATOR

........ CO–15

REMOVAL OF RADIATOR

............ CO–16

INSTALLATION OF RADIATOR

..... CO–17

TIGHTENING TORQUE ..................... CO–19

SERVICE SPECIFICATION ............... CO–19

JCO00001-00000

NO. 9710-JE

CO–2

DESCRIPTION

The cooling system is a water-cooled, forced-circulation type. Furthermore, it employs a fluid coupling fan.

The cooling system employs a bottom by-pass type in which the thermostat equipped with a by-pass valve is provided at the inlet side.

The cooling system is composed of the radiator, water pump, thermostat, cylinder head, water jackets of cylinder block, water hoses and their connecting parts.

The total capacity of the cooling water is approximately 5.4 L (for manual transmission models) and 5.3 L

(for automatic transmission models)

[HC-E Engine]

[View from left side]

[View from right side]

JCO00002-00001

CO–3

RADIATOR

JCO00003-00002

Radiator specification

Item

Fin pitch

Radiator water capacity

Heat radiating rate

Core dimensions (width

height

thickness) mm

W/h mm

RADIATOR CAP

A pressure type radiator cap is installed at the upper part of the radiator.

The radiator cap has two valves: a pressure regulating valve and a negative pressure valve.

When the pressure of the cooling system exceeds a specified limit, the rising pressure opens the pressure regulating valve of the radiator cap. As a result, the coolant in the radiator flows to the reserve tank.

On the other hand, the negative pressure valve opens when the inner pressure drops below the atmospheric pressure due to a dropped water temperature after the engine has stopped.

Thus, the coolant returns from the reserve tank to the radiator.

Radiator cap specifications

Item

Radiator cap opening pressure kPa (kgf/cm )

Specifications

88.3 (0.9)

RADIATOR RESERVE TANK

A reserve tank with an overflow hose is employed.

Specifications

Total capacity

Cooling water capacity L

F level

L level

1.1 or more

0.6

0.15

Specification

1.6

1.66 (M/T) · 1.54 (A/T)

48.3

572

425

FULL

LOW

JCO00004-00000

JCO00005-00003

JCO00006-00004

JCO00007-00005

CO–4

RADIATOR HOSES & PIPES

These components come in four radiator hoses and two radiator pipe subassemblies.

Radiator hose

Radiator pipe

No. 1

No. 2

No. 4

No. 1

Radiator pipe No. 1 to radiator upper tank

Radiator lower tank to inlet of cylinder block section

Outlet at rear of cylinder head to radiator pipe No. 1

Radiator hose No. 4 to radiator hose No. 1

JCO00008-00000

[View from left side]

Radiator hose No. 1 Radiator pipe No. 1

Radiator hose No. 4

(to water outlet)

Water inlet

Radiator hose

No. 2

[View from right side]

JCO00000-00006

FAN-EQUIPPED FLUID COUPLING

The fan-equipped fluid coupling with a temperature control device is employed in order that the noise level may be reduced.

Furthermore, the drop in engine output due to the installation of cooling fan has been kept to a minimum level.

1. COOLING FAN

The fan made of propylene is a seven-blade fan.

CO–5

JCO00009-00000

JCO00010-00007

Specifications

Item

Fan outer diameter

Number of blades

Type

Air flow rate mm

Specification

380

Axial flow

0.40 at 1000 rpm

0.85 at 2000 rpm

2. FLUID COUPLING WITH FAN

The fluid coupling employs a two-stage temperature control type.

The fluid coupling is available in two kinds. The optimum fluid coupling can be selected and installed in accordance with the vehicle specifications.

JCO00011-00000

JCO00012-00000

Specifications

Item

Fluid coupling outer diameter

Fan revolution speed

(when the water pump revolution speed is 4000 rpm) mm rpm

Specifications

M/T

2500 at 80

136

1300 at 70

A/T

2900 at 80

JCO00013-00000

CO–6

Operation of coupling fan

During cold operation (Below about 55

When the cooling water temperature is low, the port is closed by the coupling divider. Consequently, the silicon oil will not move into the operating chamber. Hence, the coupling body remains at its low speed operation.

During hot operation

(Above about 70

When the spiral bimetal detects the temperature of the air passing through the radiator, this rotates the coupling divider integral with the bimetal shaft. As a result, the silicon oil flowing out from the port enters into the operating chamber, thus pushing the coupling rotor. Consequently, the coupling body is rotated.

As is explained above, the revolution speed of the coupling fan is switched over two stages. In this way, the output loss due to the cooling fan has been kept at a minimum level and the fan noise level has been reduced.

Port

Spiral

Bimetal

Coupling

Divider

Coupling rotor

3. WATER PUMP PULLEY

The water pump pulley is made of sheet metal. This pulley is attached to the water pump pulley seat along with the fluid coupling by means of four nuts.

All water pump pulleys use a V rib belt.

Operating

Chamber

Coupling

Body

JCO00014-00008

JCO00015-00000

Water pump

The water pump used for circulating the cooling water is installed at the front section of the cylinder block.

Specifications

Item

Type

Delivery output

(When shaft revolution speed is 2000 rpm)

Rotor outer diameter

L/min mm

Specifications

Centrifugal type

JCO00016-00010

CO–7

THERMOSTAT

The thermostat is a wax type with a bypass valve. The thermostat helps the engine to warm up quickly by allowing the cooling water to be recirculated through the cylinder block and cylinder head without passing through the radiator.

Furthermore, the thermostat is equipped with a jiggle pin which performs the air bleeding while the engine is stopped. Also, the jiggle pin allows the temperature of the cooling water to rise quickly during the warming-up period.

Moreover, a baffle plate attached to the thermostat makes it possible to get better temperature sensing characteristics.

Jiggle pin

Position of jiggle pin

(just top position) jiggle pin

Baffle plate

Thermostat specifications

Item

Type

Valve opening temperature

Valve full opening temperature

JCO00017-00011

Standard specifications

Wax type

Cold region specifications

JCO00018-00000

CO–8

PRECAUTIONS

•

As regards water to be used as cooling water, use soft water which does not contain salts of minerals, calcium, magnesium and so forth.

•

If the coolant gets to the vehicle body, immediately flush away the coolant using water.

•

Never open the radiator cap when the cooling water is hot.

WARNING:

•

The inside of the radiator is under a pressurized condition when the cooling water is hot. Therefore, if the radiator cap should be removed, the cooling water will blow off, possibly causing injuries such as scald.

JCO00019-00000

CHECK & CHANGE OF ENGINE

COOLANT

1. Check of coolant level

Check to see if the coolant level is between the LOW and

FULL lines of the reserve tank.

If the coolant level is near the low level or below the low level, add the coolant up to the full level.

Reserve tank cap

“Full” line

“Low” line

FULL

LOW

JCO00020-00012

2. Check of coolant quality

There should not be any excessive deposits of rust or water scales around the radiator cap or the radiator filler hole. Also, the coolant should be free of oil.

Change the coolant if it is excessively dirty or the time due to change the coolant has already arrived.

WARNING:

•

Never open the radiator cap when the engine is hot.

JCO00021-00013

3. Change of engine coolant

(1) Remove the radiator cap.

WARNING:

•

Never open the radiator cap and/or the drain plug when the engine is still hot. Care must be exercised to avoid getting scalded.

JCO00022-00000

(2) Remove the engine under cover.

(3) Place an adequate container below the radiator drain plug. Drain the coolant by removing the drain plug.

(4) Close the drain plug.

(5) Fill the system with water.

(6) Start the engine, and stop it.

(7) Repeat the steps (1) through (5) two to three times.

NOTE:

•

Replace the drain plug gasket with a new one.

JCO00023-00014

(8) Fill the radiator and reserve tank with antifreeze solution in accordance with the instructions of the manufacturer of the antifreeze solution.

CAUTION:

•

Use a Good brand of ethylene-glycol base antifreeze solution.

Coolant Capacity (Vehicle with front heater):

5.3 liter (for automatic transmission)

5.4 liter (for manual transmission)

(9) Fill the system with water.

(10) Start the engine. Check the coolant level. Add water, as required.

(11) Tighten the radiator cap.

(12) Warm the engine. Afterwards, allow the coolant to cool down to the atmospheric temperature. Recheck the coolant level at the reserve tank. Add coolant to the full level, as required.

If no coolant remains at all in the reserve tank, recheck the coolant level in the radiator. Replenish the radiator with water, as required. Replenish the reserve tank with coolant up to the full level.

NOTE:

•

Here, the coolant refers to the mixture of water and antifreeze that has been mixed in accordance with the instructions of the antifreeze manufacturer.

(13) Install the engine under cover with attaching bolts.

CO–9

JCO00024-00015

JCO00025-00016

CO–10

WATER PUMP

COMPONENTS

Nut

Fluid coupling

Water pump pulley

Dust seal

Nut

Water pump

★

Gasket

REMOVAL OF WATER PUMP

1. Disconnect the battery ground cable from the negative (–) terminal of the battery.

2. Remove the engine under cover.

3. Drain the coolant. (See page CO–8.)

Open the radiator cap and drain plug, and allow the coolant to drain into a container.

WARNING:

•

Never open the radiator cap and/or drain plug. When the engine is hot.

4. Remove the timing belt.

(Refer to the EM section.)

★

: Non-reusable parts

JCO00026-00017

JCO00027-00018

JCO00028-00019

5. Remove the water pump by removing the attaching bolts and nuts of the water pump.

JCO00029-00020

INSPECTION OF WATER PUMP-RELATED PARTS

1. Check the water pump pulley for damage or deformation.

Replace the water pump if it exhibits damage or deformation.

2. Visually inspect the water pump rotor for damage or deformation.

Replace the water pump if the water pump rotor exhibits damage or deformation.

3. Ensure that the water pump rotates smoothly by hand.

Replace the water pump if it will not rotate smoothly.

4. Check the water pump cover section of the cylinder block for damage or wear.

Replace the cylinder block if the water pump cover section exhibits damage or wear.

INSTALLATION OF WATER PUMP

1. Remove the gasket material from the water pump installing surface of the cylinder block, using a gasket scraper.

CO–11

JCO00030-00021

JCO00031-00022

JCO00032-00023

JCO00033-00024

JCO00034-00000

CO–12

2. Remove the gasket material from the water pump, using a gasket scraper.

3. Install a new gasket to the cylinder block.

4. Install the water pump to the cylinder block. Tighten the attaching bolts and nuts evenly over two or three stages to the specified torque.

Tightening Torque:

14.7 - 21.6 N·m (1.5 - 2.2 kgf-m)

NOTE:

•

After tightening bolts, ensure that the water pump rotates smoothly by hand.

5. Install the timing belt.

(Refer to the EM section.)

6. Fill coolant.

(See page CO–9.)

7. Install the engine under cover.

8. Connect the battery ground cable to the negative (–) terminal of the battery.

JCO00035-00025

JCO00036-00026

JCO00037-00027

JCO00038-00028

JCO00039-00029

THERMOSTAT

REMOVAL OF THERMOSTAT

1. Disconnect the ground cable terminal from the negative

(–) terminal of battery.

2. Drain the coolant

(See page CO–8.)

WARNING:

•

Never open the radiator cap and/or drain plug when the coolant is hot.

3. Remove the power steering vane pump assembly.

(Refer to the EM section.)

4. Remove the radiator hose No. 2 from the water inlet.

CAUTION:

•

Cover the alternator to prevent entering the cooling water to the alternator.

5. Remove the water inlet and the thermostat.

INSPECTION OF THERMOSTAT

1. Ensure that the thermostat valve is closed completely at room temperature 20

C and the spring has no play.

Replace the thermostat if the valve is open or the spring has a play.

2. Check the rubber grommet of the thermostat for damage or crack.

Replace the thermostat if the rubber grommet exhibits damage or crack.

CO–13

JCO00040-00030

JCO00041-00031

JCO00042-00032

JCO00043-00033

JCO00044-00034

CO–14

3. Immerse the thermostat in water, and check the valve opening temperature by heating the water gradually.

Specifications

Valve opening temperature

Valve lift

Cold region specifications

Standard specifications

82 - 86

76 - 80

8.5 mm or more at

Replace the thermostat if the valve operation fails to conform to the specifications.

INSTALLATION OF THERMOSTAT

1. Assemble the thermostat in such a way that the jiggle pin comes exactly at the top of the engine.

NOTE:

•

The thermostat should be installed in such a way the jiggle pin may face upward. Failure to observe this caution may cause engine malfunction.

2. Install the water inlet.

Tightening Torque: 5.9 - 8.8 N·m (0.6 - 0.9 kgf-m)

3. Install the power steering vane pump assembly into position.

(Refer to the EM section.)

4. Fill coolant.

(See page CO–9.)

5. Connect the battery ground cable to the negative (–) terminal of battery.

6. Start the engine and check it for leakage.

Repair the leaky point if the leakage exists.

JCO00045-00035

JCO00046-00036

JCO00047-00037

JCO00048-00038

RADIATOR

CLEANING OF RADIATOR

Using water or steam cleaner, remove mud and dirt from the radiator core.

CAUTION:

•

When using a high pressure type cleaner, be careful not to deform radiator core fins.

•

Keep a distance of more than 40 - 50 cm between the radiator core and cleaner nozzle when the cleaner nozzle pressure is 2.9 - 3.4 MPa (30 - 35 kgf/cm 2 ). Also, the injection angle of pressurized water should be right angles to the radiator.

INSPECTION OF RADIATOR

1. Check of radiator cap

(1) Check the radiator cap by means of a radiator cap tester to see if the relief valve opens at a pressure of

74 - 103 kPa (0.75 - 1.05 kgf/cm 2 ).

If the radiator cap does not conform to the specification, replace the radiator cap.

WARNING:

•

Never open the radiator cap when the engine is hot.

(2) Check the seal packing of the radiator cap for damage.

Replace the radiator cap with a new one, if any damage exists.

(3) Lift the valve at the vacuum side with your fingers.

Ensure that the valve is functioning properly.

Replace the radiator cap with a new one, if the valve fails to function.

CO–15

JCO00049-00039

JCO00050-00040

JCO00051-00041

JCO00052-00042

CO–16

2. Check of cooling system for leakage

(1) Fill the radiator with coolant. Attach a radiator cap tester.

(2) Warm up the engine.

(3) Apply a pressure of 118 kPa (1.2 kgf/cm 2 ) to the cooling system by means of a radiator tester.

If the pressure drops, check the hoses, radiator, water pump and heater for evidence of leakage.

If no external leakage is found, check the heater core, cylinder block, cylinder head, oil cooler and throttle body for evidence of leakage.

Check the hoses for deterioration, cracks, bulge or damage.

Replace the defective part(s) if necessary.

(4) Remove the radiator cap tester from the radiator.

WARNING:

•

Never remove the radiator cap tester when the coolant temperature is high.

REMOVAL OF RADIATOR

1. Disconnect the battery ground cable terminal from the negative (–) terminal of the battery.

2. Drain the coolant as follows:

(1) Remove the radiator cap.

WARNING:

•

Never open the radiator cap and/or drain plug when the coolant is hot.

(2) Remove the engine under cover.

(3) Place a suitable container below the radiator drain plug. Drain the coolant by removing the drain plug.

(4) Tighten the drain plug.

3. Disconnect the two oil cooler hoses for the automatic transmission. (A/T vehicle for European market only)

NOTE:

•

Receive the oil with a suitable container because the torque converter oil flows out.

•

Prevent oil flowing by installing suitable plugs to the disconnected hoses.

CAUTION:

•

Never reuse the oil cooler hoses and hose bands for automatic transmission use. Failure to observe this caution will cause the hoses to be disconnected.

JCO00053-00043

JCO00054-00044

JCO00055-000045

JCO00056-00046

4. Removal of radiator

(1) Temporarily detach the power steering vane pump.

(2) Remove the radiator hose No. 1 and the breather hoses at radiator side.

CAUTION:

•

When the radiator hose is loosened, be sure to protect the alternator because the coolant flows out.

(3) Disconnect the radiator hose No. 2 from the radiator lower tank.

(4) Remove the two attaching bolts of the radiator upper tank.

(5) Remove the two attaching bolts of the fan shroud.

Then, disconnect the lock section of the fan shroud from radiator.

(6) Remove the four attaching nuts of the cooling fan.

(7) Remove the fan shroud and the cooling fan at the same time.

(8) Remove the radiator.

INSTALLATION OF RADIATOR

1. Radiator installation

(1) Place the radiator fan shroud to the cooling fan side.

(2) Install the radiator in the engine room.

NOTE:

•

Before attaching the fan shroud to the radiator, insert the lock section of the fan shroud to the lower section of the radiator.

(3) Tighten the two attaching bolts of the radiator upper tank.

(4) Tighten the two attaching bolts of the fan shroud.

CO–17

JCO00057-00047

JCO00058-00048

JCO00000-00049

JCO00060-00050

JCO00061-00051

CO–18

(5) Connect the radiator hose No. 1 and the breather hoses to the radiator upper tank.

(6) Connect the radiator hose No. 2 to the radiator lower tank.

(7) Connection of oil cooler hoses (A/T vehicle for

European market only) q

Remove the oil cooler hoses.

Wipe off any oil from the connecting section of the oil cooler hoses.

Connect new oil cooler hoses. Install new hose clips.

CAUTION:

•

Never reuse the oil cooler hoses and hose clips.

•

Make sure that no oil or dirt gets to the connected sections.

•

Failure to observe this caution will cause the hoses to be disconnected.

(8) Add automatic transmission oil

(See the Chassis Workshop Manual)

(9) Install the power steering vane pump.

2. Fill the coolant.

(See page CO–9.)

3. Connect the battery ground cable to the negative (–) terminal of the battery.

4. Start the engine and check it for leakage.

Repair the leaky point if leakage exists.

JCO00062-00052

JCO00063-00053

JCO00064-00054

JCO00065-00055

TIGHTENING TORQUE

Tightening component

Cylinder head

Water temperature sensor

Cylinder block

Water inlet

Cylinder block

Water pump

Fluid coupling

Water pump pulley

Water pump

Cooling fan

Fluid coupling

Tightening torque

N·m

24.5 - 34.3

5.9 - 8.8

kgf-m

2.5 - 3.5

0.6 - 0.9

14.7 - 21.6

10 - 18

4.3 - 6.5

1.5 - 2.2

1.0 - 1.8

0.44 - 0.66

CO–19

Remark

Dry

JCO00066-00000

SERVICE SPECIFICATION

Coolant capacity w/heater [Excluding 1.1 L for reserve tank]

Radiator cap

Thermostat

Relief valve opening pressure

Valve opening temperature

Valve lift

Standard

Minimum

Cold region specifications

Standard specifications

Cold region specifications

Standard specifications

5.4 L (M/T) · 5.3 L (A/T)

82 - 86

76 - 80

8.5 mm or more at 97

8.5 mm or more at 91

JCO00067-00000

DAIHATSU

J100

IGNITION SYSTEM

WIRING DIAGRAM ....................................... IG– 2

SPARK TEST ................................................ IG– 3

SPARK PLUG

.......................................... IG– 3

POWER SUPPLY

..................................... IG– 4

IGNITION WIRE

....................................... IG– 5

IGNITION COIL

....................................... IG– 5

CAM ANGLE SENSOR

............................ IG– 5

EFI ECU

................................................... IG– 7

IGNITION TIMING ......................................... IG– 9

TIGHTENING TORQUE ................................ IG–10

SSTs ............................................................. IG–10

JIG00001-00001

NO. 9710-JE

IG–2

WIRING DIAGRAM

F/L 1.25

IG SW

ACC

IG No. 1

IG No. 2

Main

F/L

10A

FUSE

(Engine)

10A

FUSE

(Back-up)

Ignition coil

(#1,#4 Cylinder)

Ignition coil

(#2,#3 Cylinder)

EFI ECU

Vehicle speed sensor

Tachometer

Cam angle

sensor

JIG00002-00011

SPARK TEST

SPARK PLUG

1. Remove the air cleaner case and relative parts.

2. Connect a timing light to the ignition wire of the No. 1 cylinder.

3. Ensure that the timing light flashes while the engine is being cranked by the starter motor.

NOTE:

•

If the timing light will not flash, perform the following inspection.

4. Remove the ignition wire from the spark plug at the cylinder No. 1.

5. Connect a spark plug to the ignition wire.

6. Check ignition sparks while the engine is being cranked by the starter motor.

WARNING:

•

Before performing this operation, check that no fuel is spilled inside the engine compartment. Remove any spilled fuel. Also, be sure to perform this operation at a well-ventilated place where no volatile liquid, gas, etc.

exist nearby.

NOTE:

•

If no ignition sparks occur, check power supply.

7. Remove the spark plug.

CAUTION:

•

When the operation of the step 7 is performed, care must be exercised to avoid getting scalded, for the spark plugs may be still very hot.

8. Cleaning of spark plug

NOTE:

•

If there are traces of oil, remove it with gasoline before the spark plug is cleaned by the spark plug cleaner.

•

If the electrode has traces of wet carbon, dry the electrode and clean it with a spark plug cleaner.

Air Pressure: Not to exceed 588 kPa

Duration: Less than 20 seconds

9. Visually inspect the spark plug for electrode wear, thread or insulator damage.

NOTE:

•

Replace the spark plug if it exhibits damage.

IG–3

JIG00003-00101

JIG00004-00102

JIG00005-00103

JIG00006-00104

IG–4

10. Inspection of electrode gap

Measure the electrode gap, using the plug gap gauge.

Electrode Gap: See page IG–9

NOTE:

•

If the electrode gap of a used spark plug is not within the specification, replace the spark plug with a new one.

•

If the electrode gap of a new spark plug is not within the specification, adjust the gap by bending the base of the ground electrode, being careful not to touch the tip.

•

All four plugs should be the same heat range and be ones manufactured by the same manufacturer.

11. Inspection of spark plug insulation resistance

More Than 20 M

Ω

NOTE:

•

If the insulation resistance is less than the specified value, replace the spark plug.

12. Install the spark plugs. Tighten them to the specified torque.

Tightening Torque: 14.7 - 21.6 N·m

13. Install the ignition coil with ignition wire to the cylinder head cover.

14. Connect the ignition wire to the spark plug.

15. Install the air cleaner case and relative parts.

POWER SUPPLY

1. Remove the air cleaner case and relative parts.

2. Disconnect the connector of the ignition coil.

3. Measure the voltage between the terminals 1 and 3 of the wire harness connector side when the ignition switch is turned on.

Specified Value: Battery voltage

NOTE:

•

If the voltage is not the specified value, check the fuse and wiring harness.

4. Connect a test lamp (12 V, 6 W) between the terminals 2 and 3 of the wire harness connector side. Check to see if the lamp will illuminate while the engine is being cranked.

NOTE:

•

Under this condition, the test lamp flashes. If the test lamp will not flash, check the outputs of the cam angle sensor and EFI ECU. (Refer to the EF section of the service manual.)

1 2 3

2 3

JIG00007-00105

JIG00008-00106

JIG00009-00107

JIG00010-00201

JIG00011-00202

IG–5

IGNITION WIRE

1. Remove the air cleaner case and relative parts.

2. Disconnect the connector of the ignition coil.

3. Remove the ignition coil by removing the attaching nuts.

4. Disconnect the spark plug distance piece and the ignition wire from the ignition coil.

NOTE:

•

Carefully remove the ignition wire from the spark plugs and ignition coil by holding their rubber boots.

5. Check that the ignition wire resistance is about same as the specification.

Ignition Wire 3: 5.6 k

Ω

NOTE:

•

Spark plug distance piece 1: 0.3

Ω

(Cylinder No. 2 and No. 4)

Ignition wire 2: 3.8 k

Ω

(Cylinder No. 3)

•

If the above inspection will conform to the specification, perform the following procedure.

IGNITION COIL

1. Remove the air cleaner case and relative parts.

2. Disconnect the connector of the ignition coil.

3. Remove the ignition coil by removing the attaching nuts.

4. Disconnect the spark plug distance piece and the ignition wire from the ignition coil.

5. Check that the ignition coil resistance is within the specification.

Secondary Coil: 13.6

2.0 k

Ω

NOTE:

•

For the primary coil, it is impossible to check the resistance because it incorporates electronic parts.

CAM ANGLE SENSOR

1. Remove the air cleaner case and relative parts.

2. Disconnect the connector of the cam angle sensor.

3. Measure the resistance between each terminal of the connectors.

Specified Value: 230

Ω

(at 20

4. Check to see if a signal shown in the graph appears at the terminals when the engine is being cranked by the starter motor.

NOTE:

•

When the voltage across the connector terminals is measured during the engine cranking period, using an oscilloscope, you will get wave forms as indicated in the illustration, if the signal generator is functioning normally.

q w

JIG00012-00301 e

JIG00013-00302

JIG00014-00401

JIG00015-00501

JIG00016-00502

IG–6

5. Remove the cam angle sensor from the cylinder head by removing the attaching bolt.

6. Remove the cam angle sensor cover.

7. Turn the shaft of the rotor, until the signal rotor faces toward the signal generator.

8. At all four points, check to see if the air gap between the signal generator and the signal rotor conforms to the specified value.

Specified Air Gap: 0.2 - 0.4 mm

NOTE:

•

If the air gap fails to conform to the specified value, adjust the air gap.

9. Adjustment of air gap.

(1) Loosen the attaching screws of the signal generator.

(2) Adjust the air gap between the signal generator and the signal rotor to specified value.

(3) Tighten the attaching screws of the signal generator.

10. Install the cam angle sensor cover.

11. Install the cam angle sensor to the cylinder head. tighten the attaching bolt.

Tightening Torque: 14.7 - 21.6 N·m

12. Check the ignition timing and adjust it, as required.

(See page IG–9)

JIG00017-00503

JIG00018-00504

JIG00019-00505

JIG00020-00506

IG–7

EFI ECU

1. Check to see if diagnosis detect malfunction code.

(Refer to EF section of the service manual)

2. Connection of SST

(Refer to EF section of the service manual)

NOTE:

•

The EFI unit can be checked by measuring the resistance or voltage at the SST terminals.

(1) Disconnect the battery ground cable from the negative

(–) terminal of the battery.

CAUTION:

•

Be sure to memorize the malfunction code before disconnecting the battery cable. Otherwise the malfunction code(s) is erased by disconnecting of the battery code.

(2) Disconnect the wire harness connectors from the EFI

ECU connectors at the upper side of the glove compartment.

(3) Connect the following SST between the wire harness connectors and the EFI ECU connectors.

SST: 09842-87706-000

(4) Reconnect the battery ground cable to the negative (–) terminal of the battery.

CAUTION:

•

When disconnecting or reconnecting the EFI ECU connectors, be sure to disconnect the battery ground cable from the negative (–) terminal of the battery when the ignition switch and all accessory switches are in the off state.

•

When installing new battery, care must be exercised not to mistake the battery polarity. Failure to observe this caution could cause ECU malfunction.

•

Before using the SST, be sure to check to see if short or open wire exists between the terminals of the SST.

NOTE:

•

Even when the replacement of the ECU is required in previous check, make sure that the ECU malfunction has not been caused by factors other than the ECU by carrying out the following checks. Then, proceed to replace the ECU.

•

The measurement of voltage should be conducted while all of the connectors are connected.

JIG00021-00701

IG “OFF”

JIG00022-00702

EFI ECU

SST

23 24 25

55 56 57

26 27 28

29 30

58 59 60

61 62

31 32

63 64

2 3

34 35

5 6

36 37 38

7 8

39 40

9 10 11

41 42 43

12 13 14

44 45 46

15 16 17

18 19

47 48 49

50 51

20 21

52 53 54

JIG00023-00703

JIG00024-00704

JIG00025-00705

IG–8

CAUTION:

•

In cases where the ECU is replaced with a new EFI

ECU, be sure to use the master key and connect the test terminal with the earth terminal, to start the engine for the first time. The engine will not start with a key other than the master key.

Refer to BE section of service manual. (Immobilizer system)

•

In cases where the ECU is replaced with an EFI ECU other than a new one, the engine will not start even if the master key is used.

For details, refer to the immobilizer manual.

3. Measurement of the voltage or resistance

(1) Measure the voltage or resistance between each terminal.

(2) Check that if the measured voltage or resistance conform to the specifications in accordance with the following table.

SST

12 13 14 15 16 17 18 19 20 21 22

44 45 46 47 48 49 50 51 52 53 54

JIG00026-00706

JIG00027-00707

CHARACTERISTICS OF ECU OUT PUT

Followings are standard voltage or resistance at ECU.

Family Terminal Condition

Power supply

Earth group

Cam angle sensor

Ignition coil drive

2 - 62

11 - 62

43 - 62

21 - 53

63 - 29

63 - 64

All time

Ignition switch is turned on

All time

While the engine is being cranked by the starter motor.

Ignition switch is turned on.

Standard voltage or resistance

Battery voltage

Remedies

Check back up fuse in the relay box

Check main relay in the relay box



or less

Check ground earth of wiring harness

0.1 - 0.3 V (AC range) Check crank angle sensor

3 V or less Check ignition coil

JIG00028-00708

NOTE:

•

If the measured voltage or resistance is not conform to the specified value, check the wiring harness.

•

Even when the trouble has not been solved by the repair the wire harness or parts, replace the EFI ECU.

After completion of the inspection

1. Disconnect the ground cable terminal from negative (–) terminal of the battery.

2. Remove the SST by disconnecting its connectors from the

ECU and engine wire connectors.

3. Connect the wire harness connectors to the ECU.

4. Reconnect the ground cable terminal to the negative (–) terminal of the battery.

JIG00029-00709

JIG00030-00710

IGNITION TIMING

1. Connect the test terminal and the earth terminal with a jumper wire of the diagnosis connector.

2. Connect a timing light to the ignition wire of the No. 1 cylinder.

3. Start the engine.

4. Check to see if the ignition timing mark of the crankshaft pulley is aligned with the indicator of the timing belt cover, using the timing light.

5. Adjust the ignition timing by turning the cam angle sensor, if the ignition timing mark is not aligned with timing belt cover.

Ignition Timing: B.T.D.C. 0

° ±

/Idle speed

6. Adjustment of ignition timing

(1) Loosen the cam angle sensor attaching bolts.

(2) Adjust the cam angle sensor installation angle by turning the cam angle sensor, until the ignition timing mark of the crankshaft pulley is aligned with the indicator of the timing belt cover.

NOTE:

•

If the cam angle sensor is turned clockwise, the timing will be advanced. Conversely, if the cam angle sensor is turned counterclockwise, the ignition timing will be retarded.

(3) Tighten the cam angle sensor attaching bolts to the specified torque, making sure that the ignition timing is not disturbed.

Tightening Torque: 14.7 - 21.6 N·m

Recommended spark plug

Manufacturer

NGK

DENSO

Type

BKUR6EK

K20TNR-S

Electrode air gap

0.9 - 1.0 mm

IG–9

Diagnosis connector

Test terminal

Earth terminal

JIG00031-00801

JIG00032-00802

JIG00033-00802

JIG00034-00803

IG–10

TIGHTENING TORQUE

Tightening components

Cam angle censor

Cylinder head

Spark plug

Cylinder head

N·m

14.7 - 21.6

Tightening torque kgf-m

1.5 - 2.2

SSTs

Shape

2 3

34 35

5 6

36 37 38

39 40

9 10 11

41 42 43

12 13 14

44 45 46

15 16 17

18 19

47 48 49

50 51

20 21 22

52 53 54

23 24 25

26 27 28

55 56 57

58 59 60

29 30

61 62

31 32

63 64

Part number

09842-87706-000

EFI computer check sub harness

Remarks

JIG00035-00901

Part name

Inspection of computer input/output voltage & resistance

Remarks

JIG00036-00902

DAIHATSU

J100

STARTING SYSTEM

STARTING SYSTEM CIRCUIT .................... ST– 2

STARTER MOTOR ....................................... ST– 3

COMPONENTS

...................................... ST– 3

SERVICING INSTRUCTIONS OF

STARTER

............................................ ST– 4

IN-VEHICLE INSPECTION

...................... ST– 4

REMOVAL

............................................... ST– 5

PLANETARY TYPE STARTER

MOTOR

.............................................. ST– 5

INSTALLATION OF STARTER

MOTOR

.............................................. ST–19

SERVICE SPECIFICATIONS ....................... ST–21

TROUBLE SHOOTING ................................ ST–21

JST00001-00000

NO. 9710-JE

ST–2

STARTING SYSTEM CIRCUIT

Ignition switch

ST Starter relay

*

Neutral start switch

*

Engine

ECU

Battery

Planetary type starter

(AT vehicle only)

: AT vehicle only

JST00002-00001

ST–3

STARTER MOTOR

COMPONENTS

0.8 kW, Planetary Type Starter Motor

For automatic transmission vehicles

@5 q

Bearing w

Drive housing e

Snap ring r

Stop collar t

Clutch y

Snap ring u

Washer i

Drive lever o

Bearing

w r t e ★

For manual transmission vehicles

y u i o

▲

@2 ★

@0 ★

★

: Non-reusable parts

▲

: Asbestos parts

Center bearing

Magnet switch

Internal gear

Washer

Planet carrier shaft

Bearing

End frame

Bearing

Armature

Brush holder

O-ring

Yoke

O-ring

Plate

Planet gear

Washer

JST00003-00002

ST–4

SERVICING INSTRUCTIONS OF STARTER

1. When connecting the starter terminal or battery terminal, perform positive tightening so as to avoid poor connection.

If poor connection should exist, it presents the hazard of serious danger that a large amount of current flowing during starter operation can overheat the poor connection.

2. When removing the starter, first disconnect the negative

; terminal of the battery. Then, disconnect the positive terminals (+B, ST) at the starter side. Since the battery voltage is always applied to the starter

+B terminal, failure to observe this removing sequence may lead to battery short, which is extremely dangerous.

3. When installing the starter, install the starter in the clutch housing positively and be sure to tighten the attaching bolts to the specified torque. Improper installation can cause premature wear of the teeth of the pinion gear or ring gear and also can cause breakage of the clutch housing.

JST00004-00000

IN-VEHICLE INSPECTION

1. Place the shift lever to the neutral position. Apply the parking brake lever.

2. Disconnect the ignition coil coupler so that the engine will not start.

3. Set the ignition switch to the ST position. Check to see if the engine cranks.

4. If the engine will not crank, perform the following checks.

•

Inspect the battery for damage. Charge the battery.

•

Perform harness continuity test.

5. If the starter motor still will not rotate even after the checks above have been performed, remove the starter motor and perform the unit check.

JST00005-00003

JST00006-00000

REMOVAL

1. Disconnect the ground cable terminal from the negative

(–) terminal of the battery.

2. Remove the battery and battery carrier.

3. Jack up the vehicle and support it with safety stands.

(Refer to the GI Section of the service manual.)

4. Removal of starter motor attaching bolt

(1) Remove the upper side and lower side attaching bolt from the under side of the vehicle.

5. Disconnection of two wires from starter

(1) Disconnect the starter terminal ST of the alternator wire from the starter.

(2) Disconnect the starter terminal B of the alternator wire from the starter.

6. Remove the starter motor.

PLANETARY TYPE STARTER MOTOR

UNIT CHECK OF PLANETARY TYPE STARTER MOTOR

CAUTION:

•

Each of the following tests must be performed within three to five seconds. If you fail to observe this caution and the starter should be energized for more than this duration, the coil may be burnt out.

1. Pull-in test

(1) Disconnect the lead wire form the magnetic switch terminal.

ST–5

JST00007-00000

JST00008-00004

JST00009-00005

JST00010-00006

JST00011-00007

ST–6

(2) Connect the negative (–) terminal of the battery to the starter body and magnetic switch terminal.

(3) Connect the positive (+) terminal to the terminal ST.

Ensure that the pinion is pushed outward.

If the drive pinion fails to move out, replace the magnetic switch.

2. Hold-in test

After the check has been performed following the same procedure as with the pull-in test, disconnect the negative terminal of the magnetic switch terminal.

Ensure that the drive pinion is held in a pushed-out state.

If the drive pinion fails to be held, replace the magnetic switch.

3. Inspection of plunger return

After the check has been performed following the same procedure as with the hold-in test, disconnect the ground terminal of the starter body. Ensure that the drive pinion is drawn into the drive housing.

If the drive pinion fails to be drawn, replace the magnetic switch.

4. No-load performance test

Connect the battery and an ammeter to the starter as shown in the right figure. Ensure that the starter rotates smoothly with the pinion moving out.

Measure the current the starter is drawing.

Specified Current: Less than 90A at 11.5V

NOTE:

•

Prior to the test, be sure to connect the lead wire to the magnetic switch.

JST00012-00008

JST00013-00009

JST00014-00010

JST00015-00011

JST00016-00012

DISASSEMBLY OF PLANETARY TYPE STARTER MOTOR

1. Disconnect the lead wire from the magnetic switch.

2. Remove the attaching nut of the magnetic switch from the drive housing.

3. Remove the magnetic switch from the drive housing.

4. Remove the two through bolts from the commutator end frame.

5. Remove the yoke with armature and the drive lever from the drive housing.

ST–7

JST00017-00013

JST00018-00014

JST00019-00015

JST00020-00016

JST00021-00017

ST–8

6. Separate the yoke with armature from the clutch with center bearing.

7. Remove the O-ring.

8. Remove the end frame cover by removing the two screws.

9. Remove the brushes from the brush holder by lifting the brush springs by means of nose pliers or the like.

NOTE:

•

Care must be exercised not to damage the brushes during the removal.

10. Then, remove the armature from the yoke.

11. Removal of planetary gear

(1) Remove the plate for starter armature.

(2) Remove the three planetary gears.

(3) Remove the plate washer.

12. Remove the stop collar from the snap ring by tapping the collar with a screwdriver or the like placed on it.

JST00022-00018

JST00023-00019

JST00024-00020

JST00025-00021

JST00026-00022

13. Detach the snap ring by prying it off with snap ring pliers.

Then, remove the collar.

14. Remove the clutch.

15. Detach the snap ring. Separate the center bearing from the planetary carrier shaft.

16. Remove the internal gear by aligning the recessed section provided at the outer periphery of the internal gear with the protruded section provided at the inner periphery of the center bearing.

INSPECTION OF PLANETARY TYPE STARTER MOTOR

Check of armature

1. Check of armature insulation

Ensure that no continuity exists between the commutator and the armature coil, using an ohmmeter.

If continuity exists, replace the armature.

ST–9

JST00027-00023

JST00028-00024

JST00029-00025

JST00030-00026

JST00031-00027

ST–10

2. Check of commutator continuity

Check continuity between each adjacent segment of the commutator, using an ohmmeter.

If no continuity exists between any adjacent segments, replace the armature.

Check of commutator

1. Check each contact surface of the commutator segments with the brushes for burning.

If the surfaces are dirty or burnt, correct the commutator surfaces, using abrasive paper (No. 400) or a lathe.

2. Check of commutator for circle runout

Support the armature at its both ends on a Vee block.

Check the commutator for circle runout, using a dial gauge.

Circle Runout Limit: 0.05 mm

If the circle runout exceeds the allowable limit, turn down the commutator on a lathe.

At this point, care must be exercised to ensure that the commutator diameter is not less than the minimum requirement diameter of 27 mm.

3. Measurement of commutator diameter

Measure the commutator diameter by means of a micrometer or vernier calipers.

Standard Diameter: 28 mm

Minimum Diameter: 27 mm

If the commutator diameter is less than the minimum diameter, replace the armature.

4. Check of commutator undercut

Measure the insulator groove depth between commutator segments.

Minimum Depth: 0.2 mm

If the insulator groove depth becomes less than the limit value, replace the commutator.

JST00032-00028

JST00033-00029

JST00034-00030

JST00035-00031

JST00036-00032

ST–11

Check of field coil

1. Field coil continuity test

Perform field coil continuity test at a point between the lead wire and the brush, using an ohmmeter.

If no continuity exists, replace the yoke.

2. Field coil short test

Perform field coil short test at a point between the brush and the yoke proper, using an ohmmeter.

If no continuity exists, replace the yoke.

JST00037-00033

Check of brushes

1. Measurement of brush length

Measure the brush length, using vernier calipers.

Standard Length: 14 mm

Minimum Length: 11 mm

2. Replacement of brush.

If the length is less than the minimum requirement, replace the brush holder or the yoke, as required.

3. Procedure for brush replacement

(1) Cut the brush lead wire at the terminal side.

NOTE:

•

Replacement can be made only for the two brushes at the yoke side (positive (+) side). The brush at the negative (–) side should be replaced together with the brush holder.

14 mm

(2) Remove welding traces with a file or the like to correct the brush terminal to the specified dimensions.

Specified Dimensions:

Thickness: 1.5 mm - 1.7 mm

Width: 5 mm

NOTE:

•

Be sure to remove the section of the brush terminal as indicated in the right figure. Since the section to be removed is narrow, be very careful not to damage the field coil.

JST00038-00034

11 mm

JST00039-00035

JST00040-00036

JST00041-00037

ST–12

(3) Stack the plate section of a replacement brush onto the welding side of the lead wire. Make pressure connection over the overlaid section by pinching it with pliers.

NOTE:

•

Be sure to take out the brush lead wire in the correct direction.

(4) Solder the pressure connection section. Correct the section, using a file or the like, so that the section conforms to the dimensions, as indicated in the right figure.

NOTE:

1. When performing the soldering, heat the section to be soldered thoroughly. Be very careful not to allow any solder to flow into the positive side lead wire.

2. Be sure to allow solder in a sufficient amount to flow into the inside of the plate.

3. Ensure that no solder oozes to the field side.

Check of brush holder

1. Check of brush holder for insulation

Measure the insulation between the positive and negative terminals of the brush holder, using an ohmmeter.

Insulation Resistance: 0.1 M

Ω or more

2. Replacement of brush holder.

If the insulation resistance is less than the specification, replace the brush holder.

Check of brush spring

Measure the brush spring tension, using a spring scale.

Standard Tension: 15.7 N (1.6 kgf)

Check of clutch

1. Inspection of pinion gear and spline teeth

Check the teeth of the pinion gear and spline for wear or damage.

If the teeth exhibit any damage, replace the clutch. Also, inspect the flywheel ring gear for wear or damage.

JST00042-00038

JST00043-00039

JST00044-00040

JST00045-00041

JST00046-00042

2. Check of starter clutch

While holding the clutch, turn the pinion clockwise. Ensure that the pinion turns smoothly.

Turn the pinion counterclockwise. Ensure that the pinion is locked.

If the check results are unsatisfactory, replace the starter clutch.

Check of magnetic switch

1. Plunger check

Push in the plunger with your fingers and release your fingers. Ensure that the plunger returns quickly to the original position. If the plunger exhibits poor returning or fails to return, replace the magnetic switch.

2. Pull-in coil open circuit test

Using an ohmmeter, ensure that continuity exists between the terminal ST and terminal C.

If no continuity exists, replace the magnetic switch.

3. Hold-in coil open circuit test

Ensure that continuity exists between the terminal ST and the switch body.

If no continuity exists, replace the magnetic switch.

Check of bearing

Center bearing

1. Measure the outer diameter of the center bearing sliding section of the planetary carrier shaft.

Specified Value: 15 mm

ST–13

JST00047-00043

JST00048-00044

JST00049-00045

JST00050-00046

JST00051-00047

ST–14

2. Measure the inner diameter of the center bearing so as to determine the clearance.

Specified Value: 0.04 mm

Allowable Limit: 0.15 mm

If the clearance exceeds the allowable limit, replace the oilless bearing or the planetary carrier shaft.

3. Bearing replacement

(1) Remove the bearing, using a suitable tool in combination with a press or the like.

NOTE:

•

When pulling out the bearing, be sure to remove it from the inside.

(2) Install the bearing, using a suitable tool in combination with a press or the like.

NOTE:

•

When installing the bearing, be sure to install it from the outside.

NOTE:

•

The bearing should be driven into position in such a way that the bearing is recessed within 0.5 mm from the edge of the center bearing.

End frame bearing

1. Measure the outer diameter of the end frame sliding section of the armature shaft.

Specified Value: 7 mm

JST00052-00048

JST00053-00049

JST00054-00050

JST00055-00051

JST00056-00052

2. Measure the inner diameter of the end frame bearing so as to determine the clearance.

Specified Value: 0.035 mm

Allowable Limit: 0.1 mm

If the clearance exceeds the allowable limit, replace the oilless bearing or the armature.

3. Bearing replacement

(1) Remove the bearing, using a tap having an outer diameter of 8 mm.

NOTE:

•

Be certain to clamp the end frame in a vise with a cloth interposed so that no scratch may be made on the end frame.

(2) Install a new bearing, using a suitable tool in combination with a press or the like.

Planetary carrier shaft bearing

1. Measure the outer diameter of the front sliding section of the armature shaft.

Specified Value: 7 mm

2. Measure the inner diameter of the planetary carrier shaft bearing so as to determine the clearance.

Specified Value: 0.06 mm

Allowable Limit: 0.10 mm

If the clearance exceeds the allowable limit, replace the oilless bearing or the armature.

ST–15

JST00057-00053

JST00058-00054

JST00059-00055

JST00060-00056

JST00061-00057

ST–16

3. Bearing replacement

(1) Remove the bearing, using a tap having an outer diameter of 8 mm.

NOTE:

•

Be certain to clamp the planetary carrier shaft in a vice with a cloth interposed so that no scratch be made on the planetary carrier shaft.

(2) Install a new bearing, using a suitable tool in combination with a press or the like.

NOTE:

•

The bearing should be driven into the position, as indicated in the right figure.

ASSEMBLY OF PLANETARY TYPE STARTER MOTOR

NOTE:

•

Use high-temperature grease to lubricate the bearings and sliding parts when assembling the starter motor.

1. Install the internal gear by aligning the recessed section provided at the outer periphery of the internal gear with the protruded section provided at the inner periphery of the center bearing.

2. Put the plate washer onto the planetary carrier shaft. Then, install the center bearing to the planetary carrier shaft.

JST00062-00058

JST00063-00059

JST00064-00060

JST00065-00061

JST00066-00062

3. Install the plate washer in place.

Install the snap ring.

4. Install the clutch.

5. Install the stop collar and a new snap ring. Compress the snap ring, using a vise or the like.

6. Tap the collar so that it may come onto the snap ring, using a screwdriver.

7. Installation of planetary gear

(1) Install the plate washer.

(2) Install the three planetary gears.

(3) Install the plate for starter armature.

NOTE:

•

Be certain to install the plate, aligning with the mate mark on the center bearing.

ST–17

JST00067-00063

JST00068-00064

JST00069-00065

JST00070-00066

JST00071-00067

ST–18

8. Install the yoke to the armature. Install the brushes to the brush holder while lifting the brushes by means of nose pliers or the like.

9. Install the commutator end frame, together with a new Oring, to the yoke by means of the two screws.

10. Install the drive lever and the clutch with center bearing to the drive housing.

NOTE:

•

Apply high-temperature grease to the sliding section of the drive lever.

•

Make sure to align the mate mark of the drive housing with that of the yoke during the assembly.

11. Install the armature with yoke and a new O-ring to the drive housing.

NOTE:

•

Make sure to align the mate mark of the center bearing with that of the yoke during the assembly.

12. Install the two through-bolts.

JST00072-00068

JST00073-00069

JST00074-00070

JST00075-00071

JST00076-00072

13. While hooking the magnetic switch over the drive lever, install the magnetic switch onto the drive housing. Secure the magnetic switch with the two nuts.

NOTE:

•

Be sure to install the rubber boot in the spring section securely.

14. Connect the lead wire to the magnetic switch.

INSTALLATION OF STARTER MOTOR

1. Install the starter motor to the bell housing.

2. Tighten the lower side and upper side attaching bolt from the under side of the vehicle.

Tightening Torque: 31.2 - 46.8 N·m (3.2 - 4.8 kgf-m)

3. Connect the starter terminal B of the alternator wire to the starter.

4. Connect the starter terminal ST of the alternator wire to the starter.

ST–19

JST00077-00073

JST00078-00074

JST00079-00000

JST00080-00075

JST00081-00076

ST–20

5. Jack up the vehicle. Remove the safety stands from the vehicle. Then, remove the jack.

6. Install the battery and battery carrier.

7. Connect the ground cable terminal to the negative (–) terminal of the battery.

8. Ensure that the starter motor rotates smoothly.

NOTE:

•

The battery should be in the full charged condition.

JST00082-00000

JST00083-00000

ST–21

SERVICE SPECIFICATIONS

Reduction type starter motor

Rating voltage and output power

No-load characteristic at 11.5V

Amperage

Brush length

Standard

Minimum

Commutator

Outer diameter Standard

Minimum

Undercut depth

Standard

Minimum

Maximum circle runout

Spring installed load

12V 0.8 kW

Less than 90A

14.0 mm

11.1 mm

28 mm

27 mm

0.45 - 0.75 mm

0.2 mm

0.05 mm

15.7 N (1.6 kgf)

JST00084-00000

TROUBLE SHOOTING

Problem Possible cause Remedies Page

Engine will not crank Battery not fully charged

Check specific gravity of battery electrolyte.

CH–6

Charge or replace battery.

Battery cables loose, corroded or worn CH–6

Neutral start switch faulty

Repair or replace cables.

Adjust or replace Neutral start switch.

Engine cranks slowly

Starter keeps running

Starter spins – engine will not crank

Fusible link blown

Starter faulty

Ignition switch faulty

Battery not fully charged

Battery cables loose, corroded or worn

Starter faulty

Ignition switch faulty

Short in wiring

Pinion gear teeth broken or faulty starter

Flywheel teeth broken

Replace fusible link.

Repair starter.

Replace ignition switch.

Check specific gravity of battery electrolyte.

Charge or replace battery.

Repair or replace cables.

Repair starter.

Replace ignition switch.

Repair wiring.

Repair starter.

Replace flywheel.

ST–4

CH–6

ST–4

JST00085-00000

DAIHATSU

J100

CHARGING SYSTEM

OUTLINE OF CHARGING SYSTEM ........... CH– 2

CHARGING SYSTEM CIRCUIT .................. CH– 2

PRECAUTIONS ........................................... CH– 3

IN-VEHICLE INSPECTION ......................... CH– 3

ALTERNATOR ............................................. CH– 9

SERVICE SPECIFICATIONS ...................... CH–22

TROUBLE SHOOTING ............................... CH–22

JCH00001-00000

NO. 9710-JE

CH–2

OUTLINE OF CHARGING SYSTEM

An IC regulator type alternator is employed on this model.

Moreover, an alternator cut-off system is adopted on automatic transmission vehicles to shut off the alternator operation so that the startability of the engine may be enhanced when the ambient temperature is extremely low at the starting period.

This system is controlled by the EFI ECU.

JCH00002-00000

CHARGING SYSTEM CIRCUIT

Battery

Ignition switch

Engine fuse

Gauge fuse

For manual transmission vehicles

0.5

∝

MIC

L L

Charge lamp

For automatic transmission vehicles

EFI

ECU

JCH00003-00001

CH–3

PRECAUTIONS

1. Prior to the inspection, make sure that the battery cables are connected securely.

2. When a quick charging operation is carried out, first be sure to disconnect the battery cables.

3. Never use a high-voltage insulation resistance tester for the purpose of conducting this inspection.

4. Under no circumstances should the battery cables be disconnected while the engine is rotating.

JCH00004-00000

IN-VEHICLE INSPECTION

1. Inspection of battery

•

First-aid treatment for dilute sulfuric acid

Nature of accident First-aid treatment

Acid gets to vehicle body.

Immediately flush the affected area using a large amount of clean running water, until no acid content remains any more.

* Acid gets into your eyes.

* Acid gets to your skin or clothes.

Immediately flush your eyes using a large amount of clean running water for at least 15 minutes with your eyes in open state.

Immediately flush the affected area using a large amount of clean running water, until no acid content remains any more. Afterwards, neutralize them with a soap.

Finally flush them with water.

Acid is spilled.

* Acid is swallowed.

Immediately flush the affected area using a large amount of water, until no acid content remains any more. Afterwards, neutralize the area with slacked lime, sodium or the like.

Immediately flush the mouth with clean water. Let him drink raw eggs. Milk or a large amount of water. Let him lie quietly.

* After the aforesaid first-aid treatment has been done, call a physician immediately.

JCH00005-00000

2. Inspection of drive belt

(Refer to the MA section of the service manual.)

3. Check of fuses for continuity

Fusible link

Fusible link block

EFI No. 1 fuse

Engine fuse

Gauge fuse

4. Checking alternator wiring and listening for abnormal noises

(1) Check to see if the alternator wire is connected properly to the alternator.

(2) Ensure that the alternator emits no abnormal noise while the engine is running.

5. Check of charge warning lamp circuit

(1) Turn OFF all accessory switches.

(2) Start the engine and warm up the engine thoroughly.

Turn OFF the ignition switch.

(3) When the ignition switch is turned ON, ensure that the charge warning lamp goes on.

(4) After the engine has started, ensure that the charge warning lamp goes out.

JCH00006-00000

If the warning lamp does not function as specified, troubleshoot the warning lamp circuit.

JCH00007-00002

CH–4

6. Check of charging circuit under unloaded state

NOTE:

•

If a battery/alternator tester is available, connect such tester to the charging circuit according to the manufacturer’s instructions of the alternator tester.

(1) If a battery/alternator tester is not available, connect a voltmeter and an ammeter to the alternator wiring and alternator as follows:

•

Disconnect the battery ground cable from the negative (–) terminal of the battery.

•

Connect an ammeter in series between the alternator wire terminal B and the alternator as indicated in the right figure.

•

Connect the positive (+) terminal of a voltmeter to the terminal B of the alternator as indicated in the right figure.

•

Connect the negative (–) terminal of the voltmeter to the engine ground.

•

Wind vinyl tape around each connection section so as to prevent short.

•

Reconnect the battery ground cable to the negative terminal of the battery.

(2) Connection of SST

Install the following SST between EFI ECU and EFI

ECU connectors of the engine wire.

(Refer to the EF section of the service manual for installation of the SST.)

SST: 09842-87706-000

(3) Checking the charging circuit as follows: q

Start the engine and warm it up.

Raise the engine speed from the idle speed to

2000 rpm.

Ensure that the ammeter and voltmeter reading are within the specified value.

Standard Amperage: Not to exceed 10 A.

Standard Voltage: 13.6 - 14.4 Volts

If the voltage reading is greater than the standard voltage, replace the IC regulator.

JCH00008-00000

Terminal B

JCH00009-00003

This terminal is not used for this model

JCH00010-00004

JCH00011-00005

For automatic transmission models, ensure that a voltage of 4.0 volts or higher is applied to between the terminal

@8 of the SST and the body ground.

If the specified voltage is not applied, check the wiring between the EFI ECU and the alternator as follows: a. Turn OFF the ignition switch.

b. Disconnect the battery ground cable terminal from the negative terminal of the battery.

c. Disconnect the EFI ECU terminal of the SST from the

EFI ECU. (Do not disconnect the engine wire side connector of the SST.) d. Connect the battery ground cable terminal to the negative terminal of the battery.

e. Turn ON the ignition switch.

Ensure that a voltage of 4.0 volts or higher is applied to between the terminal

@8 of the SST and the body ground.

If the voltage between the terminal

@8 of the SST and the body ground is 2.5 volts or less, check the EFI computer and its related circuits for short or open circuit.

The standard voltage between the terminal

@8 of the SST and the body ground is approximately equal to the battery voltage.

7. Check of charging circuit under loaded state

(1) Start the engine. Maintain the engine speed at

2000 rpm. Turn ON the high beams of the headlamps and set the blower fan motor switch to the Hi position.

Take a reading of the ammeter.

Standard Amperage: 30 A or more

If the ammeter reading is less than 30 A, repair the alternator.

(Refer to the overhaul of the alternator.)

NOTE:

•

When the battery is in a fully-charged state, the ammeter reading may be less than 30 A during the aforesaid test.

CH–5

Terminal F

JCH00012-00006

JGCH00013-00007

JCH00014-00008

CH–6

Removal of battery

WARNING:

•

Never touch the battery terminals immediately after the engine stopped.

•

Be certain to turn OFF the ignition switch.

•

Never allow any fire to be brought near the battery.

CAUTION:

•

Be very careful not to drop the battery or apply strong vibration to the battery.

1. Ensure that the ignition switch is turned OFF.

2. Disconnect the battery ground cable from the negative terminal of the battery.

3. Disconnect the positive cable terminal from the positive terminal of the battery.

4. Remove the battery hold-down clamp.

Terminals

5. Remove the battery.

JCH00015-00000

Hold down clamp

JCH00016-00009

JCH00017-00000

CLEANING AND INSPECTION OF BATTERY

1. Remove any rust from the battery terminals by means of a wire brush, a fine abrasive paper, or sodium water and a soft brush.

NOTE:

•

After the battery terminals have been cleaned, make sure that no rust particle remains on the terminals.

2. Using adhesive tape or the like, seal the vent hole of each cell plug.

3. Flush the battery with clean water, using a soft brush.

4. Wipe off the battery surface using a cloth dampened with clean water.

5. Dry the battery case surface.

JCH00018-00010

JCH00019-00011

Battery capacity check

1. Reserve capacity check, using hydrometer

2. Reserve capacity check, using battery tester

CAUTION:

•

The battery tester should be operated in accordance with the operating instructions of the service manual.

•

The battery to be check should be fully charged.

(1) Connect a battery tester to the battery.

(2) Check the battery capacity.

NOTE:

•

If the check results are not satisfactory, recheck the reserve capacity, after having checked the electrolyte level and/or replenished distilled water. Then, charge the battery until the battery capacity reaches the specified level.

•

Replace the battery with a new one, if the check results are still unsatisfactory after the rechecking of the battery reserve capacity.

Battery recharging (Except Delco freedom battery)

CAUTION:

•

If the Delco Freedom Battery requires the recharging, be sure to consult with the distributor or agent of Delco

Freedom Battery.

CH–7

JCH00020-00012

CH–8

INSTALLATION OF BATTERY

1. Clean any dust from the battery carrier.

2. Place the battery on the battery carrier in such a direction that the negative terminal of the battery may come at the front side of the vehicle.

3. Install the battery hold-down clamp.

CAUTION:

•

Be very careful not to tighten the hold-down clamp excessively.

NOTE:

•

Install the battery hold-down clamp in such a direction that the hold-down clamp on the battery may come to the straight position against the battery not in a tilted state.

4. Connect the positive cable terminal to the battery positive terminal of the battery.

NOTE:

•

Ensure that the terminal at the wiring exhibits no rust or the like.

•

If any rust is present, remove the rust, using a wire brush or a fine abrasive paper.

Terminals

JCH00021-00013

Hold down clamp

JCH00022-00014

CH–9

ALTERNATOR

COMPONENTS

Alternator assembly

Generator cap

Nut

Bolt

Wave washer

Alternator rotor assembly

Spacer

Drive end flame assembly

Stud bolt

Bearing cover

Bearing

Alternator pulley

Bolt

Pulley lock nut

Bearing

Retainer plato

Bolt

Insulator terminal

Nut

Brush holder

Brush spring

Rear end cover

Brush

Generator regulator assembly

Rectifier holder

Bolt

Rectifier end frame

Alternator 50A for manual transmission vehicles and 55A for automatic transmission vehicles

JCH00023-00015

CH–10

REMOVAL OF ALTERNATOR

1. Disconnect the ground cable terminal from the negative terminal of the battery.

2. Remove the generator cap.

3. Disconnect the terminal B of the alternator wire from the alternator.

4. Disconnect the alternator connector of the alternator wire from the alternator.

NOTE:

•

Be sure to disengage the lock of the connector before disconnection.

5. Removal of alternator drive belt

(1) Remove the air conditioner drive belt.

(Refer to the air conditioner installation manual issued by DENSO CO., LTD.)

(2) Remove the upper attaching bolt of alternator.

Generator cap

Attaching bolt

JCH00024-00016

(3) Remove the engine undercover.

JCH00025-00017

(4) Remove the lower attaching bolt of the alternator.

(5) Take out the alternator from the vehicle.

DISASSEMBLY OF ALTERNATOR

1. Remove the alternator pulley lock nut by means of an impact wrench.

NOTE:

•

Be sure to use an impact wrench having a hexagonal hole.

JCH00026-00000

JCH00027-00018

CH–11

2. Remove the alternator pulley.

3. Remove the attaching nut of the terminal insulator.

4. Pull out the terminal insulator.

5. Remove the three rear end cover attaching nuts.

6. Remove the terminal plate attaching bolt.

7. Remove the rear end cover.

8. Remove the brush holder by removing the two attaching bolts.

Rear end cover

JCH00028-00019

Nut

Terminal insulator

JCH00029-00020

JCH00030-00021

9. Remove the rectifier holder and regulator assembly attaching bolts.

10. Remove the regulator assembly.

11. Remove the rectifier holder.

12. Remove the rectifier end frame assembly by removing the four attaching nuts or two bolts and two nuts.

JCH00031-00022

JCH00032-00023

CH–12

13. Remove the wave washer from the alternator rotor assembly.

14. Remove the alternator rotor assembly from the drive end frame assembly.

INSPECTION OF ALTERNATOR

Rotor

1. Inspection of rotor for open circuit

Using an ohmmeter, check to see if the specified resistance exists between the rotor slip rings.

Standard Resistance: 2.9

0.2 ohm

If the resistance does not conform to the specification, replace the rotor.

2. Inspection of rotor for ground

Ensure that no continuity exists between the rotor slip rings and the rotor core.

If continuity exists, replace the rotor.

3. Inspection of slip rings

(1) Check to see if the slip ring surface exhibits roughness, abnormal wear and/or burning.

Replace the rotor, if necessary.

JCH00033-00024

JCH00034-00025

JCH00035-00026

JCH00036-00027

JCH00037-00028

(2) Measure the outer diameter of the slip ring, using vernier calipers.

Standard Diameter: 14.4 mm

Minimum Diameter: 14.0 mm

If the slip ring diameter is less than the minimum diameter, replace the rotor assembly.

Stator

1. Inspection of stator for open circuit

Using an ohmmeter, check to see if any open circuit of the stator coil is present between the leads.

If no continuity exists, replace the end frame assembly.

2. Inspection of stator for short circuit

Using an ohmmeter, check to see if any short circuit of the stator coil is present between the coil lead and the drive end frame.

If continuity exists, replace the drive end frame assembly.

Brush and brush holder

1. Measurement of exposed brush length

Measure the exposed brush length, using a scale.

Standard Exposed Length: 10.5 mm

Minimum Exposed Length: 8.4 mm

If the exposed length is less than the minimum requirement, replace the brushes.

2. Replacement of brushes (If necessary)

(1) Remove the brush and spring from the brush holder by melting the solder by means of a soldering iron.

CH–13

JCH00038-00029

JCH00039-00030

JCH00040-00031

JCH00041-00032

JCH00042-00033

CH–14

(2) Install the brush cord in the brush holder with the spring fitted in place.

(3) Solder the brush cord in the brush holder in such a way that the exposed length of the brush meets the specification.

Standard Exposed Length: 10.5 mm

(4) Ensure that the brush moves freely in the brush holder.

(5) Cut off any excess remaining wire and apply an insulation paint.

JCH00043-00034

JCH00044-00035

JCH00045-00036

JCH00046-00037

Rectifier

NOTE:

•

Be sure to confirm the specification of the ohmmeter to be used for inspection before putting it into use.

•

The current flow direction differs according to the design of an ohmmeter.

•

This manual is described, based on a digital tester manufactured by DENSO Japan.

•

The measured resistance should be about the same as those of other rectifiers, for the measurement results differ according to the input voltage of each tester.

•

If the measured resistance of the rectifier differs more than 20 percent, replace the rectifier holder.

1. Inspection of rectifier at positive side

(1) Ensure that continuity exists between the positive stud bolt of the rectifier holder and the rectifier terminal by connecting an ohmmeter as indicated in the right figure.

If no continuity exists, replace the rectifier holder.

(2) Ensure that no continuity exists between the positive stud bolt of the rectifier holder and the rectifier terminal by connecting an ohmmeter as indicated in the right figure.

If continuity exists, replace the rectifier holder.

2. Inspection of rectifier at negative side

(1) Ensure that continuity exists between each of the negative terminals of the rectifier holder and each rectifier terminal by connecting an ohmmeter as indicated in the right figure.

If no continuity exists, replace the rectifier holder.

(2) Ensure that no continuity exists between each of the negative terminals of the rectifier holder and each rectifier terminal by connecting an ohmmeter as indicated in the right figure.

If continuity exists, replace the rectifier holder.

CH–15

JCH00047-00038

JCH00048-00039

JCH00049-00040

JCH00050-00041

CH–16

Bearings

1. Inspection of front bearing

Ensure that the bearing turns smoothly.

Replace the bearing, if necessary.

2. Replacement of bearing

(1) Remove the four screws and retainer plate.

(2) Remove the front bearing from the drive end frame, using a suitable socket wrench in conjunction with a press.

CAUTION:

•

Be very careful not to damage the coil and stud bolts during bearing removal.

(3) Press a new front bearing into the drive end frame, using a suitable socket wrench in conjunction with a press.

CAUTION:

•

Be sure to hold the outer race of the new bearing during installation. Holding of the inner race or side cover will cause bearing damage.

(4) Attach the retainer plate to the drive end frame with the four screws.

JCH00051-00042

JCH00052-00043

JCH00053-00044

JCH00054-00045

JCH00055-00046

3. Inspection of rear bearing

Ensure that the bearing turns smoothly.

Replace the bearing, if necessary.

4. Replacement of rear bearing

(1) Remove the rear bearing cover from the rotor, using the armature bearing puller.

CAUTION:

•

Be very careful not to damage the fan during the removal.

(2) Place the parts on the rotor in the following order.

Spacer

New rear bearing

New bearing cover

(3) Press the assembled parts into the rotor, using a hydraulic press in combination with a suitable attachment or following SST.

SST: 09236-00100-000

NOTE:

•

Care must be exercised so that the point where the bearing is assembled to the rotor shaft may not deform the bearing cover.

Therefore, be sure to select a suitable attachment to assemble the bearing cover.

5. Inspection/replacement of stud bolt

Visually inspect the thread portion of the stud bolt.

If any damage exists, replace the stud bolt.

CH–17

JCH00056-00047

JCH00057-00048

JCH00058-00049

JCH00000-00050

JCH00059-00051

CH–18

ASSEMBLY OF ALTERNATOR

1. Install the rotor in the drive end frame assembly.

2. Installation of rectifier end frame on drive end frame

(1) Place the wave washer on the rear bearing.

(2) Install the rectifier end frame on the drive end frame with the two bolts and two nuts or four attaching nuts.

CAUTION:

•

Be very careful not to damage the coil cord during the installation.

3. Installation of rectifier holder, regulator assembly and brush holder

(1) Attach the rectifier holder to the end frame with the coil wires passed through the aperture of the rectifier holder.

(2) Wind the coil wires around the installing section of the rectifier attaching bolt hole.

JCH00060-00052

JCH00061-00053

JCH00000-00054

JCH00062-00055

JCH00063-00056

CH–19

(3) Connect the coil wires to the rectifier holder with the attaching screws.

(4) Install the rectifier holder and regulator assembly with the attaching screws.

NOTE:

•

Make sure that the regulator assembly is installed properly with the attaching screws as it works.

(5) Install the brush holder in such a way that a gap of at least 1 mm is provided between the brush holder and the regulator assembly.

Secure the brush holder with the two screws.

4. Installation of rear end cover

JCH00064-00057

JCH00065-00058

JCH00066-00000

(1) Install the rear end cover on the alternator.

(2) Secure the rear end cover with the three attaching nuts or screws.

(3) Install the terminal insulator.

(4) Secure the terminal insulator attaching nut.

Rear end cover

5. Attach the pulley to the rotor shaft.

Nut

Terminal insulator

JCH00067-00059

JCH00068-00060

CH–20

6. Install the pulley lock nut by means of an impact wrench.

CAUTION:

•

Be sure to use an impact wrench having a hexagonal hole.

•

Be sure to set the tightening torque of the impact wrench as follows.

Tightening Torque: 110.5 N·m

7. Ensure that the rotor turns smoothly.

INSTALLATION OF ALTERNATOR

1. Insert the alternator from under side of the vehicle.

2. Install the alternator to the alternator bracket temporarily with the attaching bolt.

3. Install the upper attaching bolt of the alternator temporarily.

4. Installation of alternator drive belt

Install the alternator drive belt to the engine properly.

CAUTION:

•

Make sure that the alternator drive belt is properly engaged in the groove of each pulley.

JCH00069-00061

JCH00070-00062

JCH00071-00000

JCH00072-00063

5. Tension adjustment of drive belt

(1) Install the following SST to the alternator and adjusting bar as shown in the right figure.

SST: 09286-87701-000

(2) Adjust the drive belt tension to the specified value by adjusting the nut of the SST.

Specified Belt Deflection

New Belt: 4 - 5 mm

[with a force of 10 kgf applied to the point shown in the figure]

Used Belt: 5 - 6 mm

[with a force of 10 kgf applied to the point shown in the figure]

NOTE:

•

As for definition of new belts and used belts, refer to the MA section of the service manual.

(3) Tighten the alternator attaching bolts to the specified torque.

Tightening Torque: 34.3 - 54.9 N·m

(3.5 - 5.5 kgf-m)

(4) Remove the SST from the alternator and adjusting bar.

SST

CH–21

JCH00073-00064

JCH00000-00066

6. Connect the alternator connector of the alternator wire to the alternator.

NOTE:

•

Make sure that the lock of the connector is locked properly after connection.

7. Connect the terminal B of the alternator wire to the alternator with the attaching nut.

8. Install the generator cap.

9. Reconnect the ground cable terminal to the negative terminal of the battery.

10. Perform the in-vehicle inspection.

11. Install the right engine undercover.

12. Install the air conditioner drive belt.

(Refer to the air conditioner installation manual issued by

DENSO CO., LTD.)

Attaching bolt

Generator cap

JCH00074-00065

CH–22

SERVICE SPECIFICATIONS

Battery specific gravity (Except Delco Freedom battery) 1.25 - 1.27

Alternator:

50A (For manual transmission vehicles)

Rated output

Rotor coil resistance

Slip ring diameter

Brush exposed length

IC regulating voltage

Amperage

Resistance

Standard

Minimum

Standard

Minimum

Hi level

50A

2.9

Ω

at 20

C (68

14.4 mm

14.0 mm

10.5 mm

8.4 mm

14.1 - 15.2 volts

Rated output

Rotor coil resistance

Slip ring diameter

Alternator:

55A (For automatic transmission vehicles)

Brush exposed length

IC regulating voltage

Amperage

Resistance

Standard

Minimum

Standard

Minimum

Hi level

55A

2.9

Ω

at 20

C (68

14.4 mm

14.0 mm

10.5 mm

8.4 mm

14.1 - 15.2 volts

JCH00075-00000

TROUBLE SHOOTING

Charge warning lamp will not glow even if ignition switch is turned ON.

Charge warning lamp will not go out even if engine has started.

Problem Possible causes Remedies Page

Fuse blown

Lamp bulb burnt

Poor connection of wiring

Drive belt loose or worn

Battery cables loose, corroded or worn

Fuse blown

Fusible link blown

IC regulator or alternator faulty

Wiring faulty

Check gauge fuse.

Replace bulb.

Repair poor connection of wiring.

Repair or replace.

Replace regulator assembly.

Adjust or replace.

Repair or replace cables.

Check gauge fuse.

Replace fusible link.

Check charging system.

Repair or Replace.

BE–6

BE Section

CH–3

MA–6

CH–3

JCH00076-00000

DAIHATSU

J100

CLUTCH

OUTLINE ..................................................... CL– 2

CLUTCH SECTIONAL VIEW

.................. CL– 2

CLUTCH PEDAL ADJUSTMENT ................ CL– 3

PEDAL INSTALLATION HEIGHT

............ CL– 3

ADJUSTMENT OF CLUTCH PEDAL

FREE TRAVEL

..................................... CL– 3

CLUTCH PEDAL & CLUTCH CABLE ......... CL– 4

1. Main points of clutch pedal installation

.......................................... CL– 6

2. Main points of clutch cable installation

.......................................... CL– 6

CLUTCH RELEASE MECHANISM ............. CL– 7

COMPONENTS

...................................... CL– 7

1. Operation prior to removal

................. CL– 7

2. Main points of removal

....................... CL– 7

3. Check

................................................. CL– 8

4. Main points of installation

................... CL– 9

5. Operation after installation

................. CL–11

APPENDIX ................................................... CL–12

SSTs (Special Service Tools)

.................. CL–12

SERVICE SPECIFICATIONS

................... CL–12

TIGHTENING TORQUE

.......................... CL–12

JCL00001-00000

NO. 9710-JE

CL–2

OUTLINE

1. The clutch mechanism has employed a cable-operated mechanical clutch. This clutch has adopted a dry, single disc type diaphragm type which features easy operation and excellent serviceability.

2. The release mechanism employs a lever type featuring superb stroke efficiency and load efficiency, as is the case with S100 series.

3. For improved cooling performance of the clutch friction surface, the clutch housing is provided with cooling holes at its front and rear sides.

JCL00002-00000

CLUTCH SECTIONAL VIEW

Clutch cover

Diaphragm spring

Clutch release bearing

Clutch disc

Clutch release fork

JCL00003-00001

CL–3

CLUTCH PEDAL ADJUSTMENT

PEDAL INSTALLATION HEIGHT

Loosen the lock nut. Adjust the pedal height by turning the adjusting bolt.

Pedal Installation Height: 175 - 180 mm

(Distance from center of pedal pad upper surface to dash panel)

Lock Nut Tightening Torque: 11.8 - 27.4 N·m

(1.2 - 2.8 kgf-m)

Adjusting bolt

Lock nut

ADJUSTMENT OF CLUTCH PEDAL FREE

TRAVEL

1. Pull the clutch outer cable toward the vehicle front, until the clutch release bearing hub is brought into contact with the diaphragm spring of the clutch cover.

2. Under the condition in the step 1, turn the adjusting nut in such a way that the gap relative to the grommet (dimension (A) in the right figure) may be adjusted to 4 - 7 mm.

3. Align the nearest groove of the adjusting nut with the protrusion of the grommet, and secure it.

4. Ensure that the free travel of the clutch pedal conforms to the specification.

Clutch pedal free travel: 15 - 30 mm

(A)

Pedal height

175 - 180 mm

JCL00004-00002

JCL00005-00003

CL–4

CLUTCH PEDAL & CLUTCH CABLE

COMPONENTS

RHD

3.9 - 6.9

(0.4 - 0.7)

FRONT u

3.9 - 6.9

(0.4 - 0.7)

3.9 - 6.9

(0.4 - 0.7)

B r

B e

3.9 - 6.9

(0.4 - 0.7) w t y

6.9 - 15.7

(0.7 - 1.6)

B o

: Tightening torque

Unit : N·m (kgf-m)

10.3 - 24.0

(1.05 - 2.45) i

q q

Clutch housing cover w

Clutch cable bracket e

Clutch cable bracket r

Clutch cable bracket t

Clutch cable bracket y

Clutch cable bracket (ABS vehicle only) u

Clutch release cable assembly i

Pedal shaft o

Spring

Bush

Clutch pedal subassembly

Cushion

Clutch pedal pad.

JCL00006-00004

CL–5

LHD

10.3 - 24.0

(1.05 - 2.45)

N y i t

FRONT

3.9 - 6.9

(0.4 - 0.7)

B u r

3.9 - 6.9

(0.4 - 0.7)

B w e

B i

6.9 - 15.7

(0.7 - 1.6) q q

Clutch housing cover w

Clutch cable bracket e

Clutch cable bracket r

Clutch cable bracket t

Clutch release cable assembly y

Pedal shaft u

Spring i

Bush o

Clutch pedal subassembly

Cushion

Clutch pedal pad

: Tightening torque

Unit : N·m (kgf-m)

JCL00000-00005

CL–6

1. Main points of clutch pedal installation

(1) Apply MP grease to the points where the inner surface of the clutch pedal subassembly is connected to the clutch release cable assembly; the inner surface and hook section of the torsion spring; and the inner/outer surfaces of the bush.

NOTE:

•

Be very careful not to allow grease to get to the threaded portion of the pedal shaft.

2. Main points of clutch cable installation

(1) Pull the clutch release cable assembly into the vehicle interior. Apply MP grease to the cable end section.

Install the assembly to the clutch pedal.

(2) Install the clutch release cable assembly to the clutch re Clutch cable bracket (ABS vehicle only) lease fork assembly in such a way that the end section of the clutch release cable assembly is aligned with the ellipse section of the clutch release fork assembly.

NOTE:

•

Be sure to install all clamps.

(3) Adjust the clutch pedal free travel.

MP grease

JCL00007-00006

JCL00008-00007

(4) Install the clutch housing cover.

NOTE:

•

Be sure to install the clutch housing cover in the direction shown in the right figure.

JCL00009-00008

CL–7

CLUTCH RELEASE MECHANISM

COMPONENTS

: Tightening torque

Unit : N·m (kgf-m)

14.7 - 21.6

(1.5 - 2.2) y u

B t r e w

14.7 - 21.6

(1.5 - 2.2) w q

MP grease

FRONT

MP grease

1. Operation prior to removal

(1) Remove the transmission assembly from the vehicle.

(Refer to the MT section.)

MP grease q

Clutch release fork support w

Anti-rattle spring e

Clutch release fork r

Clutch release bearing hub t

Release bearing hub clip y

Clutch cover assembly u

Clutch disc assembly

JCL00010-00009

JCL00011-00000

2. Main points of removal

(1) Remove the clutch cover assembly and clutch disc assembly, while preventing the ring gear from turning by means of the following SST.

SST: 09210-87701-000

JCL00012-00010

CL–8

3. Check

Clutch cover and diaphragm spring

Inspect the following parts. Replace any parts which exhibit defects.

(1) Check the clutch pressure plate and the clutch disc contracting surface of the flywheel for evidence of wear or burns.

(2) Check the diaphragm spring lever for wear, corrosion or damage.

Clutch disc

(1) Check the clutch disc for wear.

Rivet Depth

Limit: 0.4 mm

(2) Check the clutch disc for runout.

Runout

Limit:

(Longitudinal Runout): 1.0 mm

(Lateral Runout): 0.7 mm

Release bearing

(1) Checking of release bearing for smooth turning. Turn the release bearing while applying a force to the bearing by your hand in the thrust direction. Ensure that you feel no abnormal stiffness or binding.

(2) Check the release bearing hub for damage or wear.

Also, check to see if any damage or wear is present at the clip contact surface and the housing sliding section.

Release bearing hub clip

(1) Check for wear or damage.

JCL00013-00011

JCL00014-00012

JCL00015-00013

JCL00016-00014

JCL00017-00015

CL–9

Clutch release fork

(1) Check for wear or damage.

JCL00018-00016

Anti-rattle spring

(1) Check for wear or damage.

JCL00019-00017

Clutch release fork support

(1)

Check for wear or damage.

JCL00020-00018

4. Main points of installation

(1) Thinly apply EP grease to the clutch release fork or the entire periphery of the sliding surface of the clutch release bearing hub assembly.

(2) Install the release bearing hub clip to the clutch release fork.

NOTE:

•

Be sure to assemble the release bearing hub clip in the direction shown in the right figure.

Apply grease

Fork side

Apply grease

JCL00021-00019

Clip assembling direction

JCL00022-00020

CL–10

(3) Apply EP grease to the entire periphery of the sliding surface of the release fork support.

Apply grease

JCL00023-00021

(4) Apply EP grease to the entire inner periphery of the clutch release bearing hub assembly. Install the clutch release fork to the transmission.

Apply grease

JCL00024-00022

(5) Thinly apply EP grease to the spline section of the clutch disc assembly.

NOTE:

•

The grease should be applied from the clutch cover side. Be sure to apply the grease as sparsely as possible so that no excess grease may ooze out to the flywheel side.

Specified Amount: 0.1 - 0.2 g

Apply grease

JCL00025-00023

(6) With the clutch disc assembly placed at the center position by means of the following SST, install the clutch disc assembly to the flywheel.

SST: 09301-87703-000

NOTE:

•

Be very careful not to mistake the installation direction of the clutch disc assembly.

(7) Install the clutch cover assembly, aligning with the locating pins of the flywheel at three points. Tighten the six bolts to the specified torque, while preventing the flywheel from turning by means of the following SST.

SST: 09210-87701-000

NOTE:

•

As for the tightening sequence of the bolts, first temporarily tighten the bolt (1). Then, fully tighten the bolts in order of (2) - (3) - (1) - (4) - (5) - (6). (Here, any bolt can be the bolt (1).)

Tightening Torque: 14.7 - 21.6 N·m (1.5 - 2.2 kgf-m)

SST

JCL00026-00024

JCL00027-00025

5. Operation after installation

(1) Check the diaphragm spring section for unevenness in height, using the following SST.

SST: 09210-87701-000

Limit: 0.5 mm

(2) If the check above reveals that the unevenness in height exceeds its limit, correct the unevenness, using the following SST.

SST: 09333-00016-000

(3) Install the transmission assembly to the vehicle.

SST

CL–11

SST

JCL00028-00026

JCL00029-00027

CL–12

APPENDIX

SSTs (Special Service Tools)

Illustration Tool No.

09210-87701-000 Flywheel holder

Tool name

09301-87703-000

Clutch guide tool

09302-87702-000

Clutch diaphragm spring height gauge No.4

09333-00013-000

Clutch diaphragm spring aligner

JCL00030-00028

SERVICE SPECIFICATIONS

Item

Clutch pedal

Clutch disc

Height

Free travel

Run-out

Lining wear

TIGHTENING TORQUE

Tightening component

Clutch cover

Flywheel

Clutch release fork support

Clutch housing

Clutch release cable

Right stiffener plate

Clutch cable bracket attaching bolt

Clutch release cable

Dash panel

Pedal shaft attaching nut

Specified value

175 - 180

15 - 30

–

Allowable limit

–

Longitudinal: 1.0

Lateral: 0.7

0.4

Unit : mm

Remark

Distance from upper surface of pedal to floor

Rivet depth

JCL00031-00000

N·m

14.8 - 21.5

14.7 - 21.6

6.9 - 15.7

3.9 - 6.9

10.3 - 24.0

Tightening torque kg-m

1.5 - 2.2

0.7 - 1.6

0.4 - 0.7

1.05 - 2.45

JCL00032-00000

DAIHATSU

J100

MANUAL TRANSMISSION

OUTLINE ............................................ MT– 2

SECTIONAL VIEW OF MANUAL

TRANSMISSION

....................... MT– 2

SPECIFICATIONS

......................... MT– 3

POWER FLOW ROUTE ..................... MT– 4

SHIFT CONTROL MECHANISM ....... MT– 5

INSTALLATION/REMOVAL OF

MANUAL TRANSMISSION ............ MT– 6

COMPONENTS

............................. MT– 6

DISASSEMBLY/ASSEMBLY OF

MANUAL TRANSMISSION ............ MT–10

COMPONENTS (PART 1)

.............. MT–10

NOTICE PRIOR TO

OPERATION

.............................. MT–11

COMPONENTS (PART 1)

.............. MT–11

COMPONENTS (PART 2)

.............. MT–12

COMPONENTS (PART 2)

.............. MT–13

REMOVAL OF TRANSFER

ASSEMBLY

................................ MT–14

DISASSEMBLY

.............................. MT–14

INSPECTION

................................. MT–17

SHIFT FORKS AND HEADS

.......... MT–17

REPLACEMENT OF TYPE S OIL

SEAL

......................................... MT–18

SHIFT LEVER & SHIFT RELATED

PARTS REPLACEMENT

............ MT–18

INPUT SHAFT .................................... MT–20

COMPONENTS

............................. MT–20

COMPONENTS

............................. MT–21

COUNTER GEAR .............................. MT–28

COMPONENTS

............................. MT–28

COMPONENTS

............................. MT–29

INSPECTION PRIOR TO

OPERATION

.............................. MT–30

DISASSEMBLY

.............................. MT–30

INSPECTION

................................. MT–31

REPLACEMENT OF CONICAL

SPRING WASHER

..................... MT–33

INSPECTION

................................. MT–33

ASSEMBLY

.................................... MT–33

OUTPUT SHAFT ................................ MT–37

DISASSEMBLY

.............................. MT–37

INSPECTION

................................. MT–37

ASSEMBLY

.................................... MT–37

INSTALLATION

............................. MT–37

INSTALLATION/REMOVAL OF SHIFT

CABLE & SELECT CABLE ........... MT–46

COMPONENTS

............................. MT–46

INSTALLATION/REMOVAL OF

TRANSMISSION FLOOR SHIFT

ASSEMBLY .................................... MT–48

COMPONENTS

............................. MT–48

DISASSEMBLY/ASSEMBLY OF

TRANSMISSION FLOOR SHIFT

ASSEMBLY .................................... MT–50

COMPONENTS

............................. MT–50

APPENDIX ......................................... MT–51

SSTs (Special Service Tools)

........ MT–51

SERVICE SPECIFICATIONS ............. MT–52

TIGHTENING TORQUE ..................... MT–55

JMT00001–00000

NO. 9710-JE

MT–2

OUTLINE

1. The manual transmission employs five gears on all vehicles.

2. The gear train arrangement uses the output reduction type. This design has made possible the following features given below.

(1) The number of pair of gears which are idling during the engine idling has been reduced to only two pairs (first gear and second gear). Consequently, the number of components emitting rattling noise has been decreased and the mechanism loss has been reduced.

(2) For reduced mechanism loss, the counter gear is not rotating while the transmission is in neutral.

(3) The shift feeling has been further improved by reducing the inertial weight at the time of synchronizing gears.

JMT00002-00000

SECTIONAL VIEW OF MANUAL TRANSMISSION

Input gear

Reverse idler gear

Output reduction gear

Output shaft

Sub gears

Counter gear

Transfer input hub

JMT00003-00001

SPECIFICATIONS

Type

Gear ratio

Oil used

Item

Engine type

Forward gears

Reverse gear

1st gear

2nd gear

3rd gear

4th gear

5th gear

Reverse gear

Type

Capacity liter

MT–3

Specifications

HC-EJ

Constant-mesh type

Selective sliding type

4.059

2.045

1.376

1.000

0.838

4.128

SAE 75W-85 API GL-3 or GL-4

2.21 (including transfer)

JMT00004-00000

MT–4

POWER FLOW ROUTE

The gear train has been so designed that the fourth gear makes direct connection, while the fifth gear makes overdrive. Furthermore, as for the gear arrangement, the first gear, reverse gear, second gear, fifth gear and output reduction are located in this sequence, counting from the front.

1st gear

2nd gear

3rd gear

4th gear

5th gear

Input shaft

Counter gear

Reverse idler gear

A-A cross-section

Reverse

JMT00005-00002

MT–5

SHIFT CONTROL MECHANISM

1. The shift control mechanism employs the remote control method in which two push-pull cables are used, in the same way as with S100. Also, for improved shift feeling, an aluminum housing has been adopted.

Select cable

Housing

Shift cable

Dust cover

JMT00006-00003

MT–6

INSTALLATION/REMOVAL OF MANUAL TRANSMISSION

COMPONENTS

: Tightening torque

Unit : N·m (kgf-m)

29.4 - 44.1

(3.0 - 4.5)

31.4 - 47.0

(3.2 - 4.8)

29.4 - 44.1

(3.0 - 4.5)

49.0 - 68.6

(5.0 - 7.0)

29.4 - 44.1

(3.0 - 4.5)

14.7 - 21.6

(1.5 - 2.2)

29.4 - 44.1

(3.0 - 4.5)

14.7 - 21.6

(1.5 - 2.2)

29.4 - 44.1

(3.0 - 4.5)

26.0 - 48.5

(2.65 - 4.95)

49.0 - 68.6

(5.0 - 7.0) w

B o

29.4 - 44.1

(3.0 - 4.5) i

29.4 - 44.1

(3.0 - 4.5)

B q e

34.3 - 61.7

(3.5 - 6.3) q

Frame front lower crossmember subassembly w

Engine mounting rear insulator e

Engine rear support member subassembly r

Speedometer driver cable assembly t

Starter assembly y

Backup lamp switch harness u

Control cable bracket i

Power train stiffener o

Stiffener plate bracket

Stiffener right plate

Stiffener left plate

Clutch cover undercover

Transmission assembly with transfer

Engine mounting rear bracket

Transmission control cable bracket

JMT00007-00004

Tool

MT–7

1. OPERATION PRIOR TO REMOVAL

(1) Disconnect the negative (–) terminal of the battery.

(2) Suspend the engine by means of an engine support bridge.

NOTE:

Attach the hook to the engine hanger.

(3) Raise the vehicle with a lift.

(4) Drain the transmission oil.

(5) Remove the propeller shaft assembly and propeller front shaft assembly.

(6) Remove the front exhaust pipe assembly.

(7) Remove the clutch cable.

(8) Remove the shift cable assembly and select cable assembly.

JMT00008-00005

2. MAIN POINTS OF REMOVAL

(1) Remove the front lower frame crossmember subassembly. With the transmission assembly supported by a transmission jack, etc., remove the attaching bolts of the engine mounting rear insulator and engine rear support member subassembly. Proceed to remove the engine rear support member subassembly.

(2) Remove the stiffener right plate by removing the three attaching bolts.

JMT00009-00006

(3) Separate the stiffener left plate from the transmission by removing the two attaching bolts.

(4) Remove the transmission assembly with transfer from the vehicle by removing the five attaching bolts.

Stiffener left plate

Stiffener right plate

JMT00010-00007

JMT00011-00008

MT–8

3. OPERATION AFTER REMOVAL

(1) Ensure that the locating pin is positioned securely at both the transmission and engine sides.

NOTE:

Make sure to replace the locating pin that has exhibited severely scored.

Locating pin (at engine side)

Engine side

Transmission side

Locating pin

(at transmission side)

Engine side

Transmission side

4. MAIN POINTS OF INSTALLATION

(1) With the transmission assembly with transfer supported by a transmission jack, etc., bring the surface of the transmission in close contact with the surface of the engine. Tighten the attaching bolts to the specified torque.

Tightening Torque: 49.0 - 68.6 N·m (5.0 - 7.0 kgf-m)

(2) Tighten the attaching bolts of the stiffener left plate.

Tightening Torque: 29.4 - 44.1 N·m (3.0 - 4.5 kgf-m)

(3) Tighten the attaching bolts of the stiffener right plate.

NOTE:

Temporarily tighten the

✻

-marked bolts until the stiffener plate is brought in close contact with the transmission. Securely tighten the

✩

-marked bolts.

Then, proceed to tighten the

✻

-marked bolts to the specified torque.

Tightening Torque: 29.4 - 44.1 N·m (3.0 - 4.5 kgf-m)

(4) Install the power train stiffener in the direction as indicated in the right figure.

NOTE:

Temporarily tighten the

✻

-marked bolts. Securely tighten the

✩

-marked bolts. Then, proceed to tighten the remaining two bolts securely.

Tightening Torque: 29.4 - 44.1 N·m (3.0 - 4.5 kgf-m)

✻

Stiffener left plate

✻

JMT00012-00009

✩

JMT00013-00010

Stiffener right plate

JMT00014-00011

✩

Identification mark

JMT00015-00012

(5) Tighten the attaching bolts of the engine mounting rear insulator and engine rear support member subassembly. Proceed to install the attaching bolts of the engine rear support member subassembly to the body.

(6) Remove the transmission jack, etc. Install the front

lower frame crossmember subassembly.

NOTE:

For the tightening torque, refer to MT–6.

5. OPERATION AFTER INSTALLATION

(1) Install the shift cable assembly and select cable assembly.

(2) Assemble the clutch release cable assembly to the clutch release fork. Adjust the clutch free travel.

(3) Install the front exhaust pipe assembly.

(4) Install the propeller shaft assembly and propeller front shaft assembly.

(5) Pour the transmission oil.

(6) Lower the vehicle.

(7) Remove the engine support bridge.

(8) Connect the negative (–) terminal of the battery.

MT–9

JMT00016-00013

JMT00017-00000

MT–10

DISASSEMBLY/ASSEMBLY OF MANUAL TRANSMISSION

COMPONENTS (PART 1)

: Tightening torque

Unit : N·m (kgf-m)

★

: Non-reusable parts

18.6 - 30.4

(1.9 - 3.1)

★

24.5 - 39.2

(2.5 - 4.0)

14.7 - 21.6

(1.5 - 2.2)

★

14.7 - 21.6

(1.5 - 2.2)

18.6 - 30.4

(1.9 - 3.1)

★

14.7 - 21.6

(1.5 - 2.2)

★

18.6 - 30.4

(1.9 - 3.1)

★

18.6 - 30.4

(1.9 - 3.1)

★

2 ★

14.7 - 21.6

(1.5 - 2.2)

★

@8 q

Clutch housing

★ w

Type S oil seal e

Shift interlock plate r

Tension spring t

Reverse shift arm y

Input shaft bearing lock plate u

Reverse idler gear i

Reverse idler gear thrust washer o

Reverse idler gear shaft

★

Slotted spring pin

Hexagon bolt

★

Gasket

★

Gasket

Compression spring

Ball

5th & reverse shift fork shaft

5th & reverse shift head

★

Slotted spring pin

5th shift fork

3rd & 4th shift fork shaft

3rd & 4th shift head

3rd & 4th shift fork

1st & 2nd shift fork shaft

1st & 2nd shift fork

1st & 2nd shift head

★

Tight plug

Transmission case

Transmission magnet

Backup lamp switch assembly

Breather plug

JMT00018-00014

MT–11

NOTICE PRIOR TO OPERATION

This section summarizes the main points of each section of the configuration drawings posted on those pages previous to MT–10, MT–12, MT–20 and MT–28. The description is so arranged that the removal and assembly may readily be understandable when the configuration drawings are referred to the contents posted at the lower section of the page.

For more details, refer to the relevant pages.

JMT00019-00000

COMPONENTS (PART 1)

Clutch housing

★ w

Type S oil seal e

Shift interlock plate r

Tension spring t

Reverse shift arm y

Input shaft bearing lock plate u

Reverse idler gear i

Reverse idler gear thrust washer o

Reverse idler gear shaft

★

Slotted spring pin

Hexagon bolt

The clutch housing is connected to the transmission case by means of eight bolts of M8

(

= 40 mm) and two bolts of M8 (

= 60 mm).

Tightening torque: 14.7 - 21.6 N·m (1.5 - 2.2 kgf-m)

Be sure to apply gear oil to the lip section when assembling. Press this oil seal by means of a 35 mm dia. rod.

Overall length = 23.25 - 23.55 mm

Length at inside = 17.7 - 17.9 mm

The same plate is used in common at two points.

The tension spring is provided between Items t and y

Ensure that the operating pin moves lightly and freely between the neutral position and the 5th gear position.

The reverse shift arm is installed with three bolts of M8 (

= 20 mm).

Tightening torque: 14.7 - 21.6 N·m (1.5 - 2.2 kgf-m)

The input shaft bearing lock plate is installed with three bolts of M8 (

= 20 mm).

Bush bore diameter d = 20.03 - 20.06 mm

Care must be exercised as to the correct assembling direction.

Nylon-made washer

D = 20 mm

This shaft is secured by means of the hexagon bolt

Ensure that the section protruding from the shaft is 2.5 mm or less.

Black bolt, hexagon socket

Be sure to pull out this bolt when disassembling the transmission.

Tightening torque: 18.6 - 30.4 N·m (1.9 - 3.1 kgf-m)

★

Gasket

★

Gasket

Compression spring

Ball

5th & reverse shift fork shaft

5th & reverse shift head

★

Slotted spring pin

5th shift fork

3rd & 4th shift fork shaft

3rd & 4th shift head

3rd & 4th shift fork

1st & 2nd shift fork shaft

1st & 2nd shift fork

1st & 2nd shift head

★

Tight plug

Transmission case

Transmission magnet

Backup lamp switch assembly

Breather plug

The same spring is used in common at three points.

L = 40 mm

This compression spring is secured by means of a bolt of M10 (

= 19 mm).

Tightening torque: 18.6 - 30.4 N·m (1.9 - 3.1 kgf-m)

The same ball is used in common at four points, including the reverse restrict ball.

D = 7.9375 mm

This fork shaft is the longest one among the three shafts.

L = 265 mm, D = 13.0 mm

Width contacting with inner lever: 12.1 - 12.2 mm

Width contacting with reverse shift arm pin: 15.0 - 15.043 mm

The same pin is used in common at six points.

D = 5 mm, L = 23 mm

Thickness of rib section contacting with hub sleeve: 6.7 - 6.9 mm

This shaft has the middle length among three shafts.

L = 259 mm, D = 13.0 mm

Groove width at section contacting with shift inner lever: 12.1 - 12.2 mm

Thickness of rib section contacting with hub sleeve: 6.7 - 6.9 mm

This fork shaft is the shortest one among the three shafts.

L = 224 mm, D = 13.0 mm

Thickness of section contacting with hub sleeve: 9.7 - 9.9 mm

(Only the 1st & 2nd shift fork is wider than other shift forks.)

Groove width at section contacting with shift inner lever: 12.1 - 12.2 mm

This plug is not required to remove, unless exceptional situation, such as oil leakage, occurs.

The clutch housing is connected to the transmission case with 10 bolts.

Tightening torque: 14.7 - 21.6 N·m (1.5 - 2.2 kgf-m)

The transfer assembly is connected to the transmission case with 6 bolts.

Tightening torque: 29.4 - 44.1 N·m (3.0 - 4.5 kgf-m)

This magnet is not secured with a bolt.

Tightening torque: 24.5 - 39.2 N·m (2.5 - 4.0 kgf-m)

Tightening torque: 14.7 - 21.6 N·m (1.5 - 2.2 kgf-m)

JMT00020-00000

MT–12

COMPONENTS (PART 2)

: Tightening torque

Unit : N·m (kgf-m)

★

: Non-reusable parts

29.4 - 49.0

(3.0 - 5.0)

14.7 - 21.6

(1.5 - 2.2)

★

18.6 - 30.4

(1.9 - 3.1)

B w

^0 ★

14.7 - 21.6

(1.5 - 2.2)

#7 ★

14.7 - 21.6

(1.5 - 2.2)

★

★ %5

176.4 - 215.8

(18.0 - 22.0)

%9 ★

$8 ★

★ ^1

24.5 - 39.2

(2.5 - 4.0)

Torsion spring

Reverse restrict cam

Reverse restrict shaft

Select lever subassembly

★ #5

Grooved pin

Control shaft cover

Transmission case cover gasket

Torsion spring

Select inner lever

Output shaft

Reverse restrict pin holder

★ $2

Gasket

Compression spring

Ball

Transmission case

Shift inner lever

Control shaft boot

★ $8

Grooved pin

Shift lever shaft subassembly

Radial ball bearing

Hole snap ring

Rear bearing retainer

Transfer input hub

Conical spring washer

Lock nut

Needle roller bearing

Extension housing gasket

Transfer assembly

Type T oil seal

Type K oil seal

Gasket

W/head straight screw plug

Clamp

JMT00021-00015

MT–13

COMPONENTS (PART 2)

Torsion spring

Reverse restrict cam

Reverse restrict shaft

Select lever subassembly

★

Grooved pin

Control shaft cover

★

Transmission case cover gasket

Torsion spring

Select inner lever

Output shaft

Reverse restrict pin holder

★

Gasket

Compression spring

Ball

Transmission case

Shift inner lever

Control shaft boot

★

Grooved pin

Shift lever shaft subassembly

Radial ball bearing

Hole snap ring

Rear bearing retainer

Transfer input hub

Conical spring washer

★

Lock nut

Pay special attention to the assembling direction in the same way as with Item

Pay special attention to the assembling direction during disassembly and assembly, for the reverse restrict cam has the correct assembling direction to be observed.

D = 8 mm, L = 7.15 mm

Pay special attention to the assembling direction of the lever when Items

#8 and

#9 are assembled.

D = 6 mm, L = 22 mm

Drive this pin into position from the side where no groove is provided.

The transmission case cover is installed with a total of four bolts; two bolts of M8 and two reamer bolts (olive green) of M8 with Item

#7 interposed.

(Non-asbestos)

Pay special attention to the up-and-down direction of the spring during assembly.

Width of section contacting with shift head: 14.88 - 14.98 mm

This shaft corresponds to the 4th gear.

Tightening torque: 29.4 - 49.0 N·m (3.0 - 5.0 kgf-m)

Free length: 24.00 mm

Length as installed: 17.00 mm

The same ball is used in common at four points, including the shift fork ball.

Description is made in the “Components (part 1).”

Apply Three Bond ® 1216 or 1217 to the mating sections with the clutch housing and extension housing.

Width of section contacting with shift head: 11.88 - 11.98 mm

Width of section contacting with select inner lever: 15.1 - 15.2 mm

Install this boot in such a way that the air bleeding section faces downward.

D = 6 mm, L = 24 mm

Pay special attention to the assembling direction of the lever during assembly.

This ring can be reused.

This retainer is installed with five bolts of M8 (

= 20 mm).

Tightening torque: 14.7 - 21.6 N·m (1.5 - 2.2 kgf-m)

Pay special attention to the correct installing direction during the assembly.

Width across flats of lock nut: 32 mm

Tightening torque: 176.4 - 215.8 N·m (18.0 - 22.0 kgf-m)

Be sure to stake the lock nut after tightening.

Needle roller bearing

★

Extension housing gasket

Transfer assembly

★

Type T oil seal

★

Type K oil seal

★

Gasket

W/head straight screw plug

Clamp

The transmission case is connected to the transfer assembly by means of five bolts of

M10 (

= 40 mm) and two bolts of M10 (

= 210 mm).

The protruding dimension should be observed strictly at the time of installation to be 5

0.3 mm.

The seal inclination at the time of prese-fitting should be 1

° or less.

Apply MP grease to the lip section.

Tightening torque: 24.5 - 39.2 N·m (2.5 - 4.0 kgf-m)

JMT00022-00000

MT–14

REMOVAL OF TRANSFER ASSEMBLY

NOTE:

For disassembly of the transfer assembly, refer to

Section TR.

1. Remove the seven bolts indicated in the right figure.

NOTE:

The numeral in the right figure denotes the nominal length of each bolt. (Unit: mm)

2. Top the rib section of the transfer case. Then, pull out it toward you.

3. Remove the extension housing gasket.

NOTE:

Never reuse the removed gasket.

4. Remove the needle roller bearing at the forward end of the transmission output shaft.

DISASSEMBLY

DISASSEMBLY OF SHIFT AND SELECT LEVER RELATED

PARTS

NOTE:

After the sifting feeling and continuity for the reverse backup lamp switch have been checked.

1. Remove the clutch-related parts.

(Detach the engagement of the spring (A).)

2. Remove the control shaft cover with gasket {(A) bolts are used for the reamer bolt}.

3. Remove the compression spring and ball of the reverse restrict pin holder (B) with the gasket.

NOTE:

Disassemble the control shaft cover, as required.

Prior to the disassembly, drive out the grooved pin of the shift lever shaft.

4. Remove the hexagon bolt (C) of the reverse idler gear shaft with the gasket.

NOTE:

This hexagon bolt is for securing the reverse idle shaft.

Hence, be sure to remove this bolt before the transmission is disassembled.

(A)

JMT00023-00016

210

(A)

JMT00024-00017

(B)

(A)

JMT00025-00018

(C)

JMT00026-00019

5. Pull out the shift lever subassembly and shift inner lever by driving out the grooved pin.

6. Remove the reverse restrict cam (A), torsion spring (B) and reverse restrict shaft (C) by removing the hexagon bolt with the gasket.

NOTE:

The reverse restrict cam (A) has the correct assembling direction to be observed during assembly.

Therefore, when disassembling the reverse restrict cam, make sure to remember the assembling direction in order that the part may be assembled correctly.

7. Remove the backup lamp switch assembly with the gasket.

NOTE:

Do not reuse the gasket removed above.

DISASSEMBLY OF TRANSMISSION CASE

NOTE:

Disassemble the transmission case after checking to see if any variation in rotation exists between the input and output shafts.

1. Remove the 10 bolts of the transmission case, (including the two bolts to be removed from the side of the clutch housing).

NOTE:

Of those bolts that are installed from the clutch housing side, one bolt is a hexagon socket head bolt due to a reason in the production line. However, here it is permissible to install the same hexagonal bolt as other bolts.

2. Tap the rib section of the transmission case. Then, pull it out toward you.

3. Remove the lock nut by means of a deep socket.

NOTE:

Do not reuse the removed lock nut.

[Reference]

Deep socket dimensions (Tool commercially available)

Width across flats: 32 mm

Overall length: 100 mm

4. Remove the conical spring washer.

MT–15

JMT00027-00020

JMT00028-00000

JMT00029-00021

Deep socket

JMT00030-00022

MT–16

5. Remove the transfer input hub.

6. Remove the rear bearing retainer and transmission magnet by removing the five bolts.

7. Remove the hole snap ring with a snap ring expander.

8. Remove the output shaft from the transmission case.

REMOVAL OF SHIFT FORK

NOTE:

Check the movement of reverse shift arm and contact width between the shift fork and the rib sleeve.

Make sure that the shift fork is removed only after the gear concerned is placed in neutral.

1. Detach the tension spring (A).

2. Remove the compression spring and ball by removing the hexagon bolt with the gasket (B).

3. Remove the 5th & reverse shift fork shaft by removing the slotted spring pin of the shift fork and shift head.

NOTE:

When the slotted spring pin is driven out, a measure to sustain the reaction force for pulling out should be taken at the opposite side.

4. Remove the 1st & 2nd shift fork shaft and the 3rd & 4th shift fork shaft progressively, following the procedure described in the steps 2 through 3 above.

JMT00031-00023

JMT00032-00024

JMT00033-00000

(A)

(B)

JMT00034-00025

JMT00035-00026

REMOVAL OF INPUT SHAFT AND COUNTER GEAR

NOTE:

Confirm that each gear can be engaged properly.

1. Pull out the output shaft assembly with the needle roller bearing, synchronizer ring and wave spring.

2. Remove the reverse shift arm by removing the three bolts.

3. Pull out reverse idler gear shaft, thrust washer and reverse gear.

4. Remove the input shaft bearing lock plate by removing the three bolts.

5. While holding both the input shaft and counter gear assembly by your hands, pull out them in such a way that they face toward the upper side.

INSPECTION

1. Measure the free length of the compression spring for shift fork shafts and reverse restrict pin.

Free length

Load as installed: N (kgf)

Height as installed

For shift fork shafts

40 mm

47.33 N (4.83 kgf)

30 mm

For reverse restrict pin

24 mm

23.83 N (2.43 kgf)

17 mm

2. Visually inspect the balls for deformation or scratches.

3. Measure the contact width section between the select inner lever shaft and shift heads.

Unit: mm

Specified Value

Select inner lever

–0.02

–0.12

Shift inner lever heads

+0.2

+0.1

SHIFT FORKS AND HEADS

INSPECTION

1. Measure the outer diameter of the shift fork shafts and inner diameter of the case sides.

Unit: mm

Specified Value

Case sides

13.0

+0.043

Shaft sides

13.0

–0.050

–0.077

MT–17

JMT00036-00027

JMT00037-00028

JMT00038-00029

JMT00039-00030

MT–18

2. Measure the contact width section between the shift heads and the shift inner lever.

Unit: mm

Specified Value

Shift heads

12.1

+0.1

Shift inner lever

–0.02

–0.12

REVERSE IDLER GEAR

1. Visually inspect the chamfered section of the reverse idle gear for damage.

2. Measure the bore diameter of the reverse idle gear bush.

3. Measure the outer diameter of the reverse idle gear shaft.

Also, check its surface for scores, etc.

Specified Value

(d)

+0.061

+0.032

(D)

20.0

–0.013

Unit: mm

REPLACEMENT OF TYPE S OIL SEAL

1. Remove the Type S oil seal with a common screwdriver.

NOTE:

Do not reuse the removed Type S oil seal.

2. Install a new Type S oil seal in the clutch housing, using the SST given below.

SST: 09606-87201-000

NOTE:

Prior to assembly, apply gear oil to the whole periphery of the lip section.

SHIFT LEVER & SHIFT RELATED PARTS

REPLACEMENT

REMOVAL

1. Remove the select lever boot.

2. Remove the tight plug (if necessary).

3. Remove the Type T oil seal.

NOTE:

Do not reuse the removed tight plug and oil seal.

JMT00040-00031

JMT00041-00032

SST

JMT00042-00033

JMT00043-00034

JMT00044-00035

INSTALLATION

1. Install the new tight plug as shown in the right figure.

2. Install the new Type T oil seal as shown in the right figure.

3. Ensure that the protrusion section (A) of the Type T oil seal conforms to the specified value.

Specified Value: 5

0.3 mm

CAUTION:

If the protrusion section (A) exceeds the specification above (i.e. above 5.3 mm), it would cause oil leakage.

4. Check that continuity exists at the backup lamp switch assembly.

MT–19

JMT00045-00000

MT–20

INPUT SHAFT

COMPONENTS

★

: Non-reusable parts

: Selection parts

★

★ q

Shaft snap ring w

Radial ball bearing (front) e

Input shaft r

Split type needle roller bearing t

5th gear y

Synchronizer ring No. 1 u

Synchromesh shifting key spring i

Synchronizer No. 3 hub assembly o

Synchromesh shifting key

Transmission hub sleeve stopper

★ !1

Shaft snap ring

Needle roller bearing

3rd gear

Synchronizer ring No. 1

Wave spring

Synchromesh shifting key spring

Synchronizer No. 2 hub assembly

Synchromesh shifting key

★ !9

Shaft snap ring

Synchronizer ring No. 1

Needle roller bearing

JMT00046-00036

MT–21

COMPONENTS

★ q

Shaft snap ring This is shared in common with the snap ring of Item

. Thickness selection type snap ring w

Radial ball bearing e r

Input shaft

Split type needle roller bearing

Needle roller bearing rotating section: D = 31.971 - 31.991 mm, two points

Needle roller bearing rear end section: D = 19.966 - 19.984 mm

The opening width of mating ends of the bearing should not exceed the shaft diameter +

5 mm during installation and removal.

The opening end should not exceed 37 mm.

✻

-1 t

5th gear Bore diameter: 37.00 - 37.025 mm

Width: 27.82 - 27.88 mm y

Synchronizer ring No. 1

Thrust end play: 0.1 - 0.4 mm

Items y

and

@0 are used in common.

Clearance between the gear and the synchronizer ring: 0.95 - 1.35 mm

Items u and

are used in common.

Synchromesh shifting key spring

Make sure that no mating end of the spring comes in the same direction in assembly.

Synchronizer No. 3 hub assembly Thickness at boss section: 12.37 - 12.43 mm

The sleeve is shared in common with Item

However, be very careful not to mix the

★ o

Synchromesh shifting key

Shaft snap ring

Synchronizer ring No. 1

Needle roller bearing sleeve with others, for the hub and sleeve are assembled as a set.

Assemble the hub in such a way that the oil-groove side of the hub comes at the front, namely the 5th gear side.

The sleeve has no correct assembling direction to be observed. However, be sure to align the missing teeth provided at three points when the hub and sleeve are assembled.

Items o and

are used in common.

Transmission hub sleeve stopper

Therefore, a total of six pieces are used in common.

Thickness: 4.6 - 4.8 mm

Thickness: 7.19 - 7.25 mm

Assemble this retainer in such a way that the flat surface comes at the front; the oil-

★

Shaft snap ring groove side comes at the rear.

This is shared in common with Item q of the counter gear.

Thickness selection type

This is shared in common with Item u of the counter gear.

Needle roller bearing

3rd gear Bore diameter: 37.00 - 37.025 mm

Width: 37.95 - 37.98 mm

Number of gear teeth: 33

Outer diameter: 63.7

Thrust end play: 0.1 - 0.52 mm

Items y

and

@0 are used in common.

Synchronizer ring No. 1

Wave spring

Synchromesh shifting key spring

Clearance between the gear and the synchronizer ring: 0.95 - 1.35 mm

✻

-2

This wave spring is provided between items

Items u and

are used in common.

and

Make sure that no mating end of the spring comes in the same direction in assembly.

Synchronizer No. 2 hub assembly Thickness at boss section: 18.52 - 18.58 mm

Assemble the hub in such a way that the oil-groove side of the hub comes at the front, namely the 3rd gear side.

Be sure to align the missing teeth provided at three points when the hub and sleeve are assembled. The sleeve has no correct assembling direction to be observed.

Width of shift fork groove: 7.05 - 7.12 mm

Items o and

are used in common.

Therefore, a total of six pieces are used in common.

Thickness: 4.6 - 4.8 mm

This is shared in common with the snap ring of Item q

Thickness selection type

Items y

and

@0 are used in common.

Refer to Items y and

This needle roller bearing is located between the input shaft and the output shaft.

✻

-1 When the snap ring

is removed, those parts r to

can be removed collectively.

✻

-2 When the snap ring

is removed, those parts

can be removed collectively.

JMT00047-00000

MT–22

INSPECTION PRIOR TO OPERATION

1. Measure the contact section of the shift forks for 3rd gear

(A), 5th gear (B) and with the hub sleeves.

Specified Value

Allowable Limit

3rd gear (A) and 5th gear (B)

Unit: mm

Fork

–0.1

–0.3

6.6

Hub sleeve

+0.12

+0.05

7.2

2. Measure and record the thrust clearance for 3rd gear (C) and 5th gear (D), using a feeler gauge.

Specified Value

(C)

0.10 - 0.52

Unit: mm

(D)

0.10 - 0.40

NOTE:

Ensure that the thrust clearance is measured at several points.

If the measured thrust clearance fails to conform to the specification above, proceed to disassemble the input shaft assembly.

DISASSEMBLY

1. Using soft jaws, clamp the input shaft assembly in a vice so as to avoid the damage in the spline section.

2. Remove the selection type shaft snap ring at the rear side.

3. For reference at the time of installation, measure and record the removed shaft snap ring.

4. Remove the following parts, using the following SST.

SST: 09950-20017-000

NOTE:

The following parts can be removed by driving out the input shaft by means of a press, with the 3rd gear section sustained by the SST (09334-87301-000)

(1) Synchronizer No. 2 hub assembly

(2) Synchronizer ring No. 1

(3) 3rd gear

5. Remove the needle roller bearing.

6. Remove the selection type shaft snap ring.

7. For reference at the time of installation, measure and record the removed shaft snap ring.

8. Remove the transmission hub sleeve stopper.

JMT00048-00037

JMT00049-00038

JMT00050-00039

JMT00051-00040

JMT00052-00041

9. Remove the following parts, using the following SST.

SST: 09950-20017-000

NOTE:

The following parts can be removed by driving out the input shaft by means of a press, with the 5th gear section sustained by the SST (09334-87301-000).

(1) Synchronizer No. 3 hub assembly

(2) Synchronizer ring No. 1

(3) 5th gear

10. Remove the split type needle roller bearing.

CAUTION:

When the split type needle roller bearing is removed, make sure that the gap (B) at the opening of the needle roller bearing will not exceed the outer diameter of the input shaft by more than 5 mm.

11. Remove the selection type shaft snap ring.

12. Measure and record the thickness of the removed snap ring for the reference of installation.

13. Remove the radial ball bearing at the front side, using the following SST.

SST: 09950-20017-000

INSPECTION

1. Check the clearance between the gear tapered section and the synchronizer rings.

Specified Value: 0.95 - 1.35 mm

2. Measure the outer diameter of the input shaft at the sections (A), (B) and (C) as shown in the right figure.

3. Visually inspect the sections (A), (B) and (C) for scratch or discoloration.

Unit: mm

(A) and (B)

(C)

Specified Value

–0.009

–0.029

–0.016

–0.034

MT–23

JMT00053-00042

JMT00054-00043

JMT00055-00044

JMT00056-00045

JMT00057-00046

MT–24

4. Measure the dimensions between the outer diameter of the synchronizer No. 2 for 3rd (A) and synchronizer No. 3 for 5th (B) and bore diameter of both hub sleeves.

Classification

(A) and (B) Hub sleeve

Unit: mm

Identification

No. 2

No. 1

No. 3

57.78 - 57.84

57.68 - 57.74

57.58 - 57.64

57.871 - 57.97

57.771 - 57.87

57.67 - 57.77

Yellow

None

White

CAUTION:

If any part which has exceeded the value specified in the table above should be used, it would cause abnormal noise. Therefore, be certain to replace those parts as a set.

5. Measure the thickness of the synchronizer hub No. 2 (C) and No. 3 (D).

Specified Value

(C)

18.55

0.03

Unit: mm

(D)

12.4

0.03

6. Measure the height of the transmission hub sleeve stopper.

(A) section:

Specified Value: 7.2

+0.05 mm

–0.01 mm

JMT00058-00047

JMT00059-00048

7. Measure the thickness and inner diameter of the 3rd and

5th gears.

3rd gear (A)

Unit: mm

5th gear (B)

Specified Value

37.0

+0.025

Specified Value

3rd gear (C)

37.95

0.03

5th gear (D)

27.85

0.03

8. Measure the height of the synchromesh shifting key.

Specified Value: 5

–0.2 mm

–0.4 mm

NOTE:

All of the six shifting keys assembled in the input shaft are common parts.

9. Visually inspect the synchromesh shifting key spring for wear or damage.

3rd gear

JMT00060-00049

5th gear

JMT00061-00050

JMT00062-00051

ASSEMBLY

NOTE:

Be sure to apply gear oil to the relevant parts at every process.

Never reuse those parts bearing an asterisked mark posted at the pages MT–20 and 21.

1. Install the split type needle roller bearing and apply gear oil to it.

CAUTION:

When the split type needle roller bearing is installed, make sure that the gap (B) at the opening of the needle roller bearing does not exceed the outer diameter of the input shaft by more than 5 mm.

2. Install the 5th gear and synchronizer ring to the input shaft.

3. Assemble the synchromesh shifting key and key spring to the hub as shown in the illustration.

NOTE:

Make sure that no opening end of the shifting key spring comes in the same direction in assembly.

Be sure to align the missing teeth provided at three points when the hub and sleeve are assembled.

The same hub sleeve is used for both the 3rd gear and

4th gear. However, the hub differs in shape between the 3rd gear and the 4th gear.

4. Ensure that the grooved section in the protrusion position of the synchronizer No. 3 hub faces toward the front (i.e.

the 5th gear) side and press them, using the following

SST.

SST: 09310-87302-000

NOTE:

Make sure that the synchronizer ring is aligned with the shifting key grooves (three points), while the synchronizer No. 3 hub is being pressed.

5. Install the transmission hub sleeve stopper.

NOTE:

Ensure that the oil groove section of the 5th shifting key retainer faces toward the 3rd gear side.

MT–25

JMT00063-00000

JMT00064-00052

JMT00065-00053

JMT00066-00054

JMT00067-00055

MT–26

6. Selection procedure for new shaft snap ring

(1) Using the table below, select a new shaft snap ring having the same thickness as that measured at the time of the removal, or the thinnest shaft snap ring.

Then, install the thus-selected snap ring on the shaft snap ring installation groove of the input shaft.

(2) Measure the end play, using a feeler gauge as shown in the right figure.

(3) Select a snap ring shaft whose end play is zero or almost zero and that can be set readily, using the table below.

JMT00068-00056

(4) Again, ensure that the end play between the 5th shifting key retainer and the shaft snap ring conforms to the specified value.

End Play:

Specified Value: 0

Allowable Limit: Less than 0.16 mm

Part No.

Thickness Identification Part No.

Thickness

Unit: mm

Identification

90045-20263 2.06

None 90045-20267 1.90

Brown

90045-20264

90045-20265

90045-20266

2.02

1.98

1.94

Brown

Blue

None

90045-20268

90045-20269

90045-20270

1.86

1.82

2.10

Blue

None

Brown

NOTE:

The shaft snap rings in the table above are the common parts as those used when the hub of the counter gear is set.

JMT00069-00000

7. Install the needle roller bearing and apply gear oil.

8. Install the 3rd gear and synchronizer ring.

9. Assemble the synchromesh shifting key spring and shifting key to the synchronizer No. 2 hub assembly.

NOTE:

For the handling of the hub sleeve, refer to the step 3 at page MT–25.

10. Ensure that the oil grooved section (A) of the synchronizer

No. 2 hub assembly faces toward the 3rd gear side.

NOTE:

Make sure that the wave spring is interposed between the synchronizer hub No. 2 and the synchronizer ring in advance of the synchronizer hub No. 2 pressing, using the following SST.

SST: 09310-87302-000

JMT00070-00057

JMT00071-00058

MT–27

11. Selection procedure for new shaft snap ring

(1) For the selection procedure of the shaft snap ring, refer to the step 6 at page MT–26.

JMT00072-00059

(2) Again, ensure that the end play between the hub and the shaft snap ring conforms to the specified value.

End Play:

Specified Value: 0

Allowable Limit: Less than 0.16 mm

Unit: mm

Part No.

Thickness Identification Part No.

Thickness Identification

90045-20271

90045-20272

2.06

2.02

None

Brown

90045-20275

90045-20276

1.90

1.86

Brown

Blue

90045-20273

90045-20274

1.98

1.94

Blue

None

90045-20277

90045-20278

1.82

1.78

None

Brown

NOTE:

The shaft snap rings in the table above are the common parts as those used at the front bearing section of the input shaft.

JMT00073-00000

12. Press the radial ball bearing.

NOTE:

Be very careful not to drop and disassemble the synchronizer ring and hub sleeve, while the radial ball bearing is being pressed.

The assembling operation of the radial ball bearing may be conducted first.

13. In the same manner of the step 11 above, install the selection type shaft snap ring.

JMT00074-00060

MT–28

COUNTER GEAR

COMPONENTS

★

: Non-reusable parts

: Selection parts

★ q

Shaft snap ring w

Radial ball bearing e

1st gear thrust washer

★ r

Shaft snap ring t

1st sub-gear y

Conical spring washer u

Needle roller bearing i

1st gear o

Synchronizer ring No. 2

Synchromesh shifting key spring

Synchronizer No. 1 hub assembly

Synchromesh shifting key

Synchronizer ring No. 3

Split type needle roller bearing

2nd gear

Conical spring washer

2nd sub-gear

★

Shaft snap ring

Counter gear

Radial ball bearing

★

Shaft snap ring

JMT00075-00061

MT–29

COMPONENTS

★ q

Shaft snap ring w

Radial ball bearing e

1st gear thrust washer

Thickness selection type

Assemble the bearing so that the side having a seal comes at the front.

Thickness = 3.97 - 4.03 mm

Assemble the washer in such a way that the protruding side comes at the front; the oilgroove side comes at the 1st gear side.

Thrust end play of 1st gear = 0.1 - 0.52 mm

★ r

Shaft snap ring t y u i

1st sub-gear

Conical spring washer

Needle roller bearing

1st gear

✻

-1

Items r and

are used in common.

Items r to i are normally handled as assembled parts.

Items y and

are used in common.

This bearing is shared in common with Item

of the input shaft.

Inner diameter: 37.00 - 37.025 mm

Effective thickness: 27.31 - 27.37 mm

Clearance with synchronizer ring: 0.95 - 1.35 mm o

Synchronizer ring No. 2

Limit: 0.9 mm

Not interchangeable with Item

To distinguish this from Item

, missing teeth are provided at three points.

Synchromesh shifting key spring Make sure that no mating end comes in the same direction in assembly.

Synchronizer No. 1 hub assembly The hub and sleeve (reverse gear) are assembled as a set.

Synchromesh shifting key

Synchronizer ring No. 3

Split type needle roller bearing

2nd gear

Conical spring washer

2nd sub-gear

★

Shaft snap ring

Counter gear

Radial ball bearing

★

Shaft snap ring

Effective hub width: 26.97 - 27.03 mm

Assemble the hub assembly so that the side having a larger boss protruding dimension comes at the front.

As for the sleeve (reverse gear), make sure that the shift fork groove comes at the front side.

Shift fork groove width: 10.05 - 10.12 mm

✻

-2

Thickness = 5.0 - 5.2 mm, composed of 3 pieces.

Not interchangeable with Item o

This is shared in common with Item r of the input shaft.

The opening width of mating ends should not exceed 37 mm during installation and removal.

Inner diameter: 37.00 - 37.025 mm

Effective thickness: 36.27 - 36.33 mm

Clearance with synchronizer ring: 0.95 - 1.35 mm

Limit: 0.9 mm

Thrust clearance: 0.1 - 0.4 mm

Items y and

are used in common. Assemble each part to the 2nd gear in such a way that the portion having a wider spring diameter comes at the sub-gear side.

Items

are serviced as assembled parts together with the ring

Items r and

are used in common.

Outer diameter of roller bearing rotating section: 31.971 - 31.991 mm

This is used in common with Item

of the input shaft. Thickness selection type.

✻

-1 When the snap ring q is removed, those parts up to i can be removed collectively.

✻

-2 When the snap ring

@2 is removed, those parts

can be removed collectively.

JMT00076-00000

MT–30

INSPECTION PRIOR TO OPERATION

1. Measure the contact width section of the synchronizer No.

1 hub assembly (B) with the 1st & 2nd shift fork (A).

Specified Value

(A)

–0.1

–0.3

(B)

+0.12

+0.05

Unit: mm

Allowable Limit 9.6

10.2

2. Measure and record the thrust clearance for 1st gear (C) and 2nd gear (D) as shown in the right figure.

NOTE:

Prior to disassembling, make sure to measure the thrust clearance at several points.

If the measured thrust clearance exceeds the specified value in the table below, proceed to disassemble the counter gear.

Unit: mm

1st gear (C) 2nd gear (D)

Specified Value 0.10 - 0.52

0.10 - 0.40

DISASSEMBLY

1. Using soft jaws, clamp the spline section of the counter gear assembly in a vice so as to avoid damage.

2. Remove the selection type shaft snap ring.

3. For reference at the time of installation, measure and record the removed selection type shaft snap ring.

4. Remove the following parts by pressing the counter gear by means of a suitable rod.

(1) Radial ball bearing

(2) 1st gear thrust washer

(3) 1st gear

(4) Synchronizer ring No. 2

(5) Needle roller bearing

NOTE:

The parts described above can be removed by pressing the counter gear, while the 1st gear is supported by means of the following SST.

SST: 09334-87301-000

5. Remove the selection type shaft snap ring.

6. For reference at the time of installation, measure and record the removed selection type shaft snap ring.

JMT00077-00062

JMT00078-00063

JMT00079-00064

JMT00080-00065

7. Remove the following parts.

(1) Synchronizer No. 1 hub assembly

(2) Synchronizer ring No. 3

(3) 2nd gear with sub-gear

NOTE:

The parts described above can be removed by pressing the counter gear, while the 2nd gear (sub-gear surface) is supported by means of the following SST.

SST: 09334-87301-000

8. Remove the split type needle roller bearing.

CAUTION:

When the split type needle roller bearing is removed, make sure that the gap (A) at the opening of the needle roller bearing does not exceed the outer diameter of the counter gear by more than 5 mm. Failure to observe this caution would cause abnormal noise from the transmission.

9. Remove the radial ball bearing at the rear side of the counter gear, using the SST given below.

SST: 09306-87602-000

INSPECTION

1. Measure the height of the synchromesh shifting spring keys.

Specified Value: 5.1

0.1 mm

2. Visually inspect the spring for synchromesh shifting key spring for damage or distortion.

3. Measure the outer diameter of the counter gear at the sections (A) and (B).

Unit: mm

(A) (B)

Specified Value

–0.009

–0.029

4. Visually inspect the sections (A) and (B) for discoloration and scratches.

MT–31

JMT00081-00066

JMT00082-00067

JMT00083-00068

JMT00084-00069

JMT00085-00070

MT–32

5. Measure the thickness of the 1st gear thrust washer.

Specified Value: 4

0.03 mm

JMT00086-00071

6. Measure the dimensions between the outer diameter of the synchronizer No. 1 hub (A) and the bore diameter of synchronizer hub sleeve (B).

[Reference information]

The parts (A) and (B) are available only as a set. An identification mark is applied to the end surface of the synchronizer hub.

Classification

No. 2

(A)

69.78 - 69.84

(B)

69.871 - 69.97

Unit: mm

Identification

Yellow

No. 1

No. 3

69.68 - 69.74

69.58 - 69.64

69.771 - 69.87

69.67 - 69.77

None

White

CAUTION:

When replacing those parts (A) and (B), be sure to replace them as a set.

7. Measure the thickness (A) of the synchronizer No. 1 hub.

Specified Value: 27

0.03 mm

JMT00087-00072

8. Measure the inner diameter of 1st and 2nd gear.

1st gear (A)

Unit: mm

2nd gear (B)

Specified Value

37.0

+0.025

9. Measure the thickness of 1st and 2nd gear.

Specified Value

1st gear (C)

27.34

0.03

Unit: mm

2nd gear (D)

36.30

0.03

1st gear 2nd gear

JMT00088-00073

JMT00089-00074

REPLACEMENT OF CONICAL SPRING WASHER

1. Clamp the 1st gear together with the following SST in a vice as shown in the right figure.

SST: 09350-32014-000

2. Remove the conical spring washer and sub-gear by removing the shaft snap ring.

INSPECTION

1. Measure the height of the conical spring washer.

Specified Value: 2.01 mm

Allowable Limit: 1.04 mm

2. Place a new conical spring washer (1) and sub-gear on the 1st gear.

3. Ensure that the expanded side of the conical spring washer faces toward the sub-gear side as shown in the right figure.

4. Install a new shaft snap ring by pressing the conical spring washer, using the following SST.

SST: 09350-32014-000

5. In the same manner of the operation stated above, replace the conical spring washer for the 2nd sub-gear.

6. Ensure that the expanded side of the conical spring washer (1) for 2nd sub-gear faces toward the sub-gear side as shown in the right figure.

ASSEMBLY

When assembling the counter gear, apply gear oil at each step and assemble each part.

As for those parts which bear the “

★

” marks at pages

MT–28 and MT–29, never reuse them.

1. Install the radial ball bearing at the rear side of the counter gear, using a press in combination with the following SST given below.

SST: 09310-87301-000

MT–33

JMT00090-00075

JMT00091-00076

JMT00092-00077

JMT00093-00078

JMT00094-00079

MT–34

2. Install the split type needle roller bearing.

CAUTION:

When the split type needle roller bearing is installed, make sure that the gap (A) at the opening of the needle roller bearing will not exceed the outer diameter of the counter gear by more than 5 mm.

3. Apply gear oil to the outer periphery of the split type needle roller bearing and install the 2nd gear to the counter gear.

4. Place the synchronizer ring No. 3 into the synchronizer

No. 1 hub.

NOTE:

The external appearance of the synchronizer ring No. 3

{for 2nd gear (B)} differs from that of the synchronizer ring No. 2 {for 1st gear (A)}, as evident from the right illustration.

5. Install the synchronizer ring No. 3 to the synchronizer

No. 1.

6. Assemble the synchromesh shifting key and synchromesh shifting key spring to the synchronizer No. 1 hub assembly.

NOTE:

During assembling, make sure that the mating ends of the shifting key springs come at different positions.

When installing the hub and hub sleeve, be sure to align three teeth-missing sections.

7. Prior to pressing the synchronizer No. 1 hub assembly, make sure that the protrusion section (A) of the hub faces toward the front side. (The hub sleeve has a shift fork groove.)

8. Apply gear oil to the tapered section of the 2nd gear.

9. Apply gear oil to the spline section.

10. Align the spline section. Press the synchronizer No. 2 hub assembly by using the following SST.

SST: 09310-87302-000

NOTE:

While the synchronizer No. 2 hub assembly is being pressed into the counter gear, make sure that the shifting key assembled to the hub is aligned with the shift key groove of the synchronizer ring.

JMT00098-00083

JMT00095-00080

JMT00096-00081

JMT00097-00082

MT–35

11. Selection sequence of new shaft snap ring.

(1) Using the table below, select a new shaft snap ring having the same thickness as that measured at the time of removal, or the thinnest shaft snap ring.

Then, install the thus-selected shaft snap ring on the shaft snap ring installation groove of the counter gear.

(2) Measure the end play, using a feeler gauge as shown in the right figure.

(3) Select a shaft snap ring whose end play is zero or almost zero and that can be set readily, using the table below. Then, proceed to install it.

(4) Again, ensure that the end play conforms to the specified value.

End Play:

Specified Value: 0

Allowable Limit: Less than 0.16 mm

Part No.

90045-20263

90045-20264

90045-20265

90045-20266

Thickness

2.06

2.02

1.98

1.94

Identification

None

Brown

Blue

None

Part No.

90045-20267

90045-20268

90045-20269

90045-20270

Thickness

1.90

1.86

1.82

2.10

JMT00099-00084

Unit: mm

Identification

Brown

Blue

None

Brown

NOTE:

The shaft snap rings in the table above are the same as those used when the hub of the input shaft is set.

JMT00100-00000

12. Install the needle roller bearing. Apply gear oil to the outer periphery of the needle roller bearing.

13. Place the synchronizer ring No. 2 (the ring having missing teeth).

14. Install the 1st gear with the sub-gear assembled.

15. Install the 1st gear thrust washer.

NOTE:

Ensure that the protrusion section (A) of the 1st gear thrust washer faces toward the front side.

16. Press the radial ball bearing, using the following SST.

SST: 09310-87301-000

NOTE:

Make sure that the radial ball bearing having a seal faces toward the front.

JMT00101-00085

JMT00102-00086

MT–36

17. Selection sequence of new shaft snap ring

(1) For the selection procedure of the shaft snap ring, refer to the step 11 at page MT–35.

JMT00103-00087

(2) Ensure that the end play conforms to the specified value.

End Play:

Specified Value: 0

Allowable Limit: Less than 0.16 mm

Part No.

90045-20279

90045-20280

90045-20281

90045-20282

Thickness

2.06

2.02

1.98

1.94

Identification

None

Brown

Blue

None

Part No.

90045-20283

90045-20284

90045-20285

90045-20286

Thickness

1.90

1.86

1.82

1.78

Unit: mm

Identification

Brown

Blue

None

Brown

JMT00104-00000

OUTPUT SHAFT

DISASSEMBLY

1. Remove the radial ball bearing (for rear), using the following SST.

SST: 09306-87602-000

INSPECTION

1. Check the clearance between the synchronizer ring and gear tapered section.

Specified Value 0.95 - 1.35 mm

2. Visually inspect the gear and spline section of the output shaft for wear and damage.

3. When you rotate the rear and center of the radial ball bearing inner race with your fingers, as shown in the right figure, they should be rotated smoothly without any bindings.

ASSEMBLY

1. Press the inner race of the radial ball bearing.

•

Ensure that the retaining section of the radial ball bearing faces toward the rear side.

NOTE:

•

The radial ball bearing can be pressed by using either the SST (09310-87302-000) or a pipe with which the inner race can be pressed.

INSTALLATION

1. While holding both the input shaft and counter gear assemblies by your hands, install them to the clutch housing.

NOTE:

•

Be careful not to damage the Type S oil seal during the installation of the shafts.

MT–37

JMT00105-00088

JMT00106-00089

JMT00107-00090

JMT00108-00091

JMT00109-00092

MT–38

2. Attach the tension spring to the input shaft bearing lock plate.

3. Tighten the input shaft bearing lock plate with the three bolts.

Tightening Torque: 14.7 - 21.6 N·m (1.5 - 2.2 kgf-m)

4. Place the two pieces of the shift lock plates on the clutch housing side.

5. Assemble the reverse idler gear, shaft and thrust washer to the clutch housing.

NOTE:

When installing, install the knock pin for use in preventing rotation of the idler gear shaft to the groove section at the clutch housing side.

Make sure that the gear chamfer and thrust washer

(nylon) face upward (i.e. rear side).

6. Tighten the reverse shift arm with the three bolts.

Tightening Torque: 14.7 - 21.6 N·m (1.5 - 2.2 kgf-m)

JMT00110-00093

JMT00111-00094

7. Check of reverse shift arm for movement

With the idler gear pushed against the lower edge surface, check that the pin moves freely (drops by its own weight) between the position

(neutral position) to the position

(5th gear position).

JMT00112-00095

8. Assemble the tension spring.

NOTE:

Attach the spring to the recessed section of the arm subassembly.

Idler gear Reverse shift arm subassembly

JMT00113-00096

JMT00114-00097

CONFIRMATION OF LENGTH/SHAPE OF SHIFT FORK

AND SHIFT FORK SHAFT

9. The following three shift fork shafts differ in the overall length, as shown in the right figure.

NOTE:

Be very careful not to make any wrong installation of these shift fork shafts.

Unit: mm

Shift fork shafts Overall Length

(1)

(2)

(3)

1st & 2nd

3rd & 4th

5th & Reverse

224.00

259.00

265.00

10. The shift forks and shift heads differ in the external view, as shown in the right figure. Hence, be very careful not to make any wrong installation of these shift forks and shift heads.

(1) 1st & 2nd

(2) 3rd & 4th

(3) 5th & Reverse

NOTE:

It is advisable to install the shift fork shaft and fork temporarily and confirm that the combination and direction are right. Then, proceed to the operation.

INSTALLATION TO SHIFT FORK AND SHIFT FORK SHAFT

Apply gear oil to the required points. Perform the operations, following the procedure given below.

11. Temporarily drive a new slotted spring pin into all of the shift forks and heads so that the slotted spring pin may be driven easily during installation.

MT–39

JMT00115-00098

JMT00116-00099

JMT00117-00100

MT–40

12. Install the 3rd & 4th shift fork into the hub sleeve and insert the 3rd & 4th shift fork shaft.

NOTE:

Make sure that the gear is in the neutral position.

In order to drive a new slotted spring pin smoothly, it is advisable to prepare a guide pin whose outer diameter is 4.0 mm and whose length is 50.00 mm.

Perform the operations, while confirming the assembling direction of the shift fork and shift head and the positional relationship with the gears.

As for the shapes and lengths of the shift fork shaft, shift fork and shift head, refer to the steps 9 and 10 at page MT–39.

When driving a new slotted spring pin into position, a measure to sustain the reaction force against the driving force should be taken at the opposite side of the shift fork shaft.

13. Insert a guide pin or the like into the back side groove of the shift fork, as the guide of installation for the slotted spring pin.

14. Install a new slotted spring pin.

15. In the same manner as described in the steps 12 and 13, insert the 3rd & 4th shift head.

16. Install the 1st & 2nd shift fork into the hub sleeve and insert the 1st & 2nd shift fork shaft.

17. As for the installation of 1st & 2nd shift fork and shift head, refer to the steps 12 and 13 described above.

18. Insert the 5th & reverse shift head into the shift fork shaft.

19. As for the installation of the 5th & reverse shift fork and shift head, refer to the steps 12 and 13 described above.

20. Install the three balls and compression springs and tighten the three bolts with a new gasket interposed.

Tightening Torque: 18.6 - 30.4 N·m (1.9 - 3.1 kgf-m)

JMT00118-00101

JMT00119-00102

JMT00120-00103

JMT00121-00104

21. Place the output shaft with the needle roller bearing, synchronizer ring and wave spring.

NOTE:

Make sure to assemble the wave spring according to the convex shape of the synchronizer ring. (See the right figure.)

22. Assemble the output shaft in the transmission case. Install the hole snap ring by means of a snap ring expander.

23. Assemble the transmission magnet.

24. Install the rear bearing retainer. Tighten the retainer with the five bolts.

Tightening Torque: 14.7 - 21.6 N·m (1.5 - 2.2 kgf-m)

25. Assemble the transfer input hub.

MT–41

JMT00122-00105

JMT00123-00106

JMT00124-00107

JMT00125-00108

JMT00126-00109

MT–42

26. With the smaller diameter end placed at the nut side, assemble the conical spring.

NOTE:

Make sure that the conical spring is assembled in the correct direction.

Conical spring Lock nut

JMT00127-00110

27. Insert a deep socket into the output shaft.

[Reference]

Deep socket dimensions (Tool commercially available)

Width across flats: 32 mm

Overall length: 100 mm

28. Using soft jaws, clamp the periphery of the transfer input hub in a vice so as to avoid damaging the hub.

Tighten a new lock nut with a torque wrench.

Tightening Torque: 176.4 - 215.8 N·m

(18.0 - 22.0 kgf-m)

29. Stake the new lock nut.

NOTE:

When staking the new lock nut, point a suitable staking tool toward the output shaft axis center to lock securely, as shown in the right upper figure.

Poor staking, such as shown in the right middle and lower figures, may cause loosening of the lock nut.

Deep socket

30. Clean the contact surface between the clutch housing and the transmission case side, using solvent or the like.

31. Apply the following bond to the transmission case surface as shown in the right figure.

Specified Bond: Three bond

1216 or 1217

[Reference information]

Nozzle Inner Diameter: 0.9 mm

32. Quickly install the transmission case.

33. Tighten the ten bolts between the transmission case side and the clutch housing side.

Tightening Torque: 14.7 - 21.6 N·m (1.5 - 2.2 kgf-m)

34. With a new gasket interposed, tighten the hexagon bolt

(A) for reverse idler gear shaft.

Tightening Torque: 18.6 - 30.4 N·m (1.9 - 3.1 kgf-m)

JMT00128-00111

JMT00129-00112

Apply liquid

gasket

JMT00130-00113

(A)

JMT00131-00114

35. Install the clutch related parts.

MT–43

JMT00132-00000

36. Install the shift lever boot and shift lever shaft correctly as shown in the right illustration.

CAUTION:

Ensure that the air bleeding section (A) of the boot faces toward the lower side.

NOTE:

Apply MP grease to those points specified in the right figure.

37. Assemble the shift inner lever in the shift lever shaft subassembly. Drive a new grooved pin into position with a knock pin punch so that the shift inner lever may be secured.

Apply grease

(A)

,, ,

JMT00133-00115

JMT00134-00116

NOTE:

When driving a new grooved pin into position, the pin should be inserted from the smaller end of the taper.

NOTE:

When driving the pin into position, be sure that the assembling is made in such a way that the installation angle is displaced from the trace of the former pin.

Former pin

JMT00135-00117

Inner lever

New pin

JMT00136-00118

MT–44

38. Install the ball and compression spring and tighten the reverse restrict pin holder (B) with a new gasket interposed.

Tightening Torque: 29.4 - 49.0 N·m (3.0 - 5.0 kgf-m)

JMT00137-00119

39. Assemble the torsion spring, reverse restrict cam and reverse restrict shaft in the transmission case in this sequence.

NOTE:

Make sure to attach the torsion spring securely at the two points of the cam (the section

A and the shift lever shaft (the section

40. Install and tighten the washer based head hexagon bolt with a new gasket used.

Tightening Torque: 18.6 - 30.4 N·m (1.9 - 3.1 kgf-m)

41. With a new gasket interposed, tighten the select lever shaft subassembly with the four bolts.

Tightening Torque: 14.7 - 21.6 N·m (1.5 - 2.2 kgf-m)

NOTE:

Ensure that the reamer bolts (A) are placed as shown in the right figure.

Reamer bolt (A)

42. Install and tighten the backup lamp switch assembly with a new gasket used.

Tightening Torque: 24.5 - 39.2 N·m (2.5 - 4.0 kgf-m)

NOTE:

Install the connector, using the drilled hole of the clamp.

Clamp

Connector

JMT00138-00120

Standard bolts

JMT00139-00121

Backup lamp

JMT00140-00122

INSTALLATION OF TRANSFER ASSEMBLY

1. Install a new extension housing gasket to the rear edge surface of the transmission case.

2. Install the needle roller bearing to the forward end of the transmission output shaft.

JMT00141-00123

3. Install and tighten the transfer assembly with the seven bolts.

Tightening Torque: 29.4 - 44.1 N·m (3.0 - 4.5 kgf-m)

NOTE:

The numeral in the right figure denotes the nominal length of each bolt. (Unit: mm)

MT–45

JMT00142-00124

210

JMT00000-00125

MT–46

INSTALLATION/REMOVAL OF SHIFT CABLE & SELECT CABLE

COMPONENTS

14.7 - 21.6

(1.5 - 2.2)

: Tightening torque

Unit : N·m (kgf-m)

★

: Non-reusable parts

★

14.7 - 21.6

(1.5 - 2.2)

★ 7

★

6 3 ★

14.7 - 21.6

(1.5 - 2.2)

★

4 4

6.9 - 9.8

(0.7 - 1.0)

★ 5

★

5 q

Cover, shift lever housing dust w

Clamp e

Clip r

Washer, plate t

Clip y

Washer, plate u

Clip i

Cable assembly, select o

Cable assembly, shift

1. MAIN POINTS OF REMOVAL

(1) Detach each clip with pliers or the like.

NOTE:

•

Care must be exercised to ensure that the pliers, etc.

will not touch with the cable section during the removal.

JMT00143-00126

JMT00144-00127

(2) Remove the select cable assembly and shift cable assembly.

NOTE:

•

Do not allow the ends of the shift and select cables to be bent beyond 8 degrees.

JMT00145-00128

2. CHECK

(1) Check that the inner cables of the shift cable and select cable slide smoothly.

(2) Check for boot breakage, other damage or distortion.

3. MAIN POINTS OF INSTALLATION

(1) Insert the clips t and u until their upper edges become flush with the upper edges of the bracket or the retaining surface of the floor shift assembly.

NOTE:

Install the clips after the eye end has been installed first.

Make sure that the clips are inserted in the correction direction as indicated in the figure. Never insert them reversely.

Never allow a hammer, etc. to tap the cable during the clip installation. (If the cable should be tapped inadvertently, be certain to replace the cable with a new one.)

(2) When the shift cable is retained to the clamp w

, retain it to the H-shaped protector section of the shift cable.

NOTE:

Care should be taken as to the correct direction of the clamp w

. (For the correct direction, see the right figure.)

MT–47

Boot breakage

JMT00146-00129

JMT00147-00130

JMT00159-00136

JMT00160-00137

MT–48

INSTALLATION/REMOVAL OF TRANSMISSION FLOOR SHIFT

ASSEMBLY

COMPONENTS

: Tightening torque

Unit : N·m (kgf-m)

★

: Non-reusable parts

14.7 - 21.6

(1.5 - 2.2)

3 ★

★

5 ★

6.9 - 9.8

(0.7 - 1.0) q

Knob, shift lever w

Cover, shift lever housing dust e

Clip r

Washer, plate t

Clip y

Cable assembly shift u

Cable assembly select i

Floor shift assembly, transmission o

Boot, shift & select lever

1. MAIN POINTS OF REMOVAL

(1) Detach the clips e and t

, two each, with pliers or the like.

NOTE:

Care must be exercised to ensure that the pliers, etc.

will not touch with the cable section during the removal.

JMT00148-00131

JMT00149-00132

2. MAIN POINTS OF INSTALLATION

(1) Tighten the floor shift assembly with the attaching bolts.

Tightening Torque: 14.7 - 21.6 N·m (1.5 - 2.2 kgf-m)

NOTE:

Be certain to tighten the attaching bolts in the sequence specified in the right figure.

Front r w

(2) Install the shift cable assembly and select cable assembly in the floor shift assembly. Secure them by means of the clips.

NOTE:

Make sure that the clips are inserted in the correction direction as indicated in the figure. Never insert them reversely.

Never allow a hammer, etc. to tap the cable during the clip installation.

Insert the clips until they become flush with the lower edges of the cable retaining surface.

Install the clips after the eye end has been installed first. e q

MT–49

JMT00150-00133

JMT00151-00134

MT–50

DISASSEMBLY/ASSEMBLY OF TRANSMISSION FLOOR SHIFT

ASSEMBLY

COMPONENTS

: Tightening torque

Unit : N·m (kgf-m)

9.8 - 15.6

(1.0 - 1.6)

W o

MP grease o

MP grease

39.2 - 49.0

(4.0 - 5.0)

MP grease

(Outer diameter, spherical sections)

39.2 - 49.0

(4.0 - 5.0) q

Support, control link w

Bolt, washer based head hexagon e

Bolt, washer based head hexagon r

Nut t

Washer, spring y

Washer, plate u

Lever subassembly, shift i

Lever subassembly, control select o

Bush

Guide, control select lever

Holder subassembly, shift lever

Ring, O

Bush

Boot, shift lever

JMT00152-00135

1. OPERATION PRIOR TO DISASSEMBLY

(1) Remove the transmission floor shift assembly.

2. MAIN POINTS OF ASSEMBLY

(1) Uniformly apply MP grease to the outer diameter and spherical section of the control select lever guide

, the sliding sections of the bushes o and

, and the O-ring

3. OPERATION AFTER ASSEMBLY

(1) Install the transmission floor shift assembly.

JMT00153-00000

MT–51

APPENDIX

SSTs (Special Service Tools)

Shape Part No.

09306-87602-000

09310-87301-000

09310-87302-000

09334-87301-000

09350-32014-000

09606-87201-000

09950-20017-000

Part name

Counter gear front bearing puller

Counter shaft front bearing replaer

Counter shaft rear bearing replacer

Transmission rear bearing anvil

TOYOTA Automatic transmission tool set

Front hub bearing remover & replacer

Universal puller

JMT00154-00000

MT–52

SERVICE SPECIFICATIONS

Free length of compression spring for reverse restrict pin

Free length of compression spring for shift fork shaft

Diameter

Free length

Load as installed: N (kgf)

Height as installed:

Free length

Load as installed: N (kgf)

Height as installed:

Outer Reverse idler gear shaft

Inner

Outer

Reverse idler shaft

Select inner lever

Dimensions

Inner

Outer

Inner

Outer

Inner

Shift inner lever

Shift fork shafts

Case sides

Shift inner lever

Shift heads

Outer

Inner

Reverse restrict shaft

Reverse restrict cam

Clearance between scynchronizer ring and gear

Specified Value

24.00

28.83 (2.43)

17.00

40.00

47.33 (4.83)

30.00

20.0

–0.013

20.0

+0.061

+0.032

–0.02

–0.12

15.0

+0.2

+0.1

13.0

–0.050

–0.077

13.0

+0.043

–0.02

–0.12

12.1

+0.1

–0.065

–0.090

+0.16

+0.07

0.9 - 1.4

Unit: mm

Allowable Limit

—

0.5

JMT00155-00000

MT–53

AT THE INPUT SHAFT SIDE

Contact width section between shift forks and synchronizer No. 2 & No. 3 hub sleeves

Shift forks

Hub sleeves

3rd & 5th

Thrust clearance

3rd

5th

Clearance between synchronizer rings and gears

Outer diameter of input shaft

Classification

(A) and (B)

(C)

Identification

Dimensions

Outer diameter of hubs

Inner diameter of hub sleeves

No. 2

No. 1

No. 3

Yellow

None

White

Yellow

None

Thickness of synchronizer hubs

Thickness of transmission hub sleeve stopper

Inner diameter 3rd and 5th gears

Dimensions

Thickness

3rd gear

5th gear

Height of synchromesh shifting key

End play between the snap ring shaft and input shaft

White

No. 2

No. 3

Specified Value

–0.1

–0.3

+0.12

+0.05

0.10 - 0.52

0.10 - 0.40

0.95 - 1.35

–0.009

–0.029

–0.016

–0.034

—

57.78 - 57.84

57.68 - 57.74

57.58 - 57.64

57.871 - 57.97

57.771 - 57.87

57.67 - 57.77

18.55

0.03

12.40

0.03

7.2

+0.05

–0.01

37.0

+0.025

37.95

0.03

27.85

0.03

–0.2

–0.4

Unit: mm

Allowable Limit

6.6

7.2

—

0.90

—

Less than 0.16

JMT00156-00000

MT–54

AT THE COUNTER SHAFT SIDE

Contact width section between the synchronizer No. 1 hub sleeve and 1st/2nd shift fork

Hub sleeve

Shift fork

Thrust clearance between gear and counter shaft

1st

2nd

Height of shifting key

Outer diameter of countershaft (A) and (B)

Thickness of 1st gear thrust washer

Classification

Outer diameter of synchronizer No. 1 hub

Identification

Yellow

None

Dimensions

Inner diameter of synchronizer No. 1 hub sleeve

Dimensions

No. 2

No. 1

No. 3

Inner

Thickness

White

Yellow

None

White

1st and 2nd gear

1st

2nd

Height of conical spring washer

End play between the snap ring shaft and countershaft

Specified Value

+0.12

+0.05

–0.1

–0.3

0.10 - 0.52

0.10 - 0.40

5.1

0.1

–0.009

–0.029

0.03

—

69.78 - 69.84

69.68 - 69.74

69.58 - 69.64

69.871 - 69.97

69.771 - 69.87

69.67 - 69.77

37.0

+0.025

27.34

0.03

36.30

0.03

2.01

Unit: mm

Allowable Limit

10.2

9.6

—

1.04

Less than 0.16

JMT00157-00000

TIGHTENING TORQUE

Tightening components

Engine

Clutch housing

Stiffener right

Engine, Clutch housing

Stiffener left

Engine, Clutch housing

Clutch housing undercover

Clutch housing

Stiffener plate bracket

Powertrain stiffener

Transfer case

Lock nut

Output shaft

Reverse restrict pin holder

Transmission case

Transmission case cover

Transmission case

Bolt for reverse restrict shaft

Transmission case

Clutch housing

Transmission case

Input shaft bearing lock plate

Clutch housing

Reverse shift arm

Clutch housing

Bolt for shift fork shaft

Clutch housing

Rear bearing retainer

Transmission case

Washer based head hexagon

Transmission case

Backup lamp switch assembly

Transmission case

Breather plug

Clutch housing

W/head straight screw plug

Transmission case

Transfer assembly

Transmission case

Transmission control cable bracket

Transfer case

Control cable bracket

Transfer case

Control cable bracket

Clamp

Shift lever housing dust cover

Control link support

Floor

Floor shift washer based head hexagon bolt

Floor shift nut

MT–55

18.6 - 30.4

14.7 - 21.6

18.6 - 30.4

24.5 - 39.2

14.7 - 21.6

24.5 - 39.2

29.4 - 44.1

14.7 - 21.6

6.9 - 9.8

14.7 - 21.6

39.2 - 49.0

9.8 - 15.6

N·m

49.0 - 68.6

29.4 - 44.1

14.7 - 21.6

29.4 - 44.1

176.4 - 215.8

29.4 - 49.0

14.7 - 21.6

18.6 - 30.4

14.7 - 21.6

kgf-m

5.0 - 7.0

3.0 - 4.5

1.5 - 2.2

3.0 - 4.5

18.0 - 22.0

3.0 - 5.0

1.5 - 2.2

1.9 - 3.1

1.5 - 2.2

1.9 - 3.1

1.5 - 2.2

1.9 - 3.1

2.5 - 4.0

1.5 - 2.2

2.5 - 4.0

3.0 - 4.5

1.5 - 2.2

0.7 - 1.0

1.5 - 2.2

4.0 - 5.0

1.0 - 1.6

JMT00158-00000

DAIHATSU

J100

AUTOMATIC TRANSMISSION

OUTLINE ............................................. AT– 2

SECTIONAL VIEW OF AUTOMATIC

TRANSMISSION

........................ AT– 2

SPECIFICATIONS

.......................... AT– 3

TORQUE CONVERTER ...................... AT– 4

CONSTRUCTION

.......................... AT– 4

OPERATION

.................................. AT– 4

POWER TRAIN MECHANISM ............ AT– 5

DESCRIPTION

............................... AT– 5

CONSTRUCTION

.......................... AT– 5

OPERATION

.................................. AT– 6

HYDRAULIC PRESSURE CONTROL

SYSTEM .......................................... AT–11

DESCRIPTION

............................... AT–11

HYDRAULIC PRESSURE CIRCUIT

DIAGRAM

.................................. AT–12

COMPONENTS

............................. AT–13

CASE & COVER ................................. AT–25

DESCRIPTION

............................... AT–25

ELECTRIC CONTROL SYSTEM ........ AT–26

OVERDRIVE SWITCH

.................... AT–26

SHIFT CONTROL MECHANISM ........ AT–27

DESCRIPTION

............................... AT–27

COMPONENTS

............................. AT–27

PRELIMINARY CHECK ...................... AT–28

TESTING ............................................. AT–32

STALL TEST

................................... AT–32

TIME LAG TEST

............................. AT–33

HYDRAULIC PRESSURE TEST

..... AT–33

RUNNING TEST

............................ AT–37

ELECTRIC–RELATED TESTS

......... AT–38

REMOVAL AND INSTALLATION OF

AUTOMATIC TRANSMISSION ....... AT–40

COMPONENTS

............................. AT–40

CONNECTION AND DISCONNECTION

OF OIL COOLER HOSES .............. AT–44

COMPONENTS

............................. AT–44

DISASSEMBLY AND ASSEMBLY OF

AUTOMATIC TRANSMISSION ....... AT–46

COMPONENTS

............................. AT–46

COMPONENTS (INNER PARTS)

... AT–47

REMOVAL

...................................... AT–48

DISASSEMBLY AND ASSEMBLY OF

COMPONENTS

......................... AT–61

INSPECTION

................................. AT–63

ASSEMBLY

.................................... AT–67

INSTALLATION AND REMOVAL

OF CONTROL CABLE AND

FLOOR SHIFT ................................ AT–90

COMPONENTS

............................. AT–90

APPENDIX .......................................... AT–92

SSTs (Special Service Tools)

......... AT–92

SERVICE SPECIFICATIONS

.......... AT–94

TIGHTENING TORQUE

................. AT–95

JAT00001-00000

NO.9710-JE

AT–2

OUTLINE

1. A hydraulic pressure control planetary gear type, four-speed automatic transmission with overdrive is employed, which has been newly developed for FR vehicles with an engine mounted longitudinally.

2. The automatic transmission fluid has employed a DEXRON

III which features excellent heat and oxidation stability.

SECTIONAL VIEW OF AUTOMATIC TRANSMISSION

q w e r t y u i o !0

Torque converter w

Oil pump e

Direct clutch r

Forward clutch t

Rear clutch y

One-way clutch u

1st & reverse brake i

Planetary long pinion o

Rear planetary sun gear

!6 !7

Output shaft

Input shaft

Valve body

2nd brake band

Front planetary sun gear

Planetary short pinion

Planetary output shaft

Intermediate shaft

Parking lock gear

Governor drive gear

JAT00002-00001

AT–3

SPECIFICATIONS

Torque converter

Transmission type

Control system

Item

Type

Stall torque ratio/Stall revolution speed

One-way clutch type

Type

Control element

Gear ratio

Speedometer gear ratio

Oil pump

Fluid to be used

Fluid capacity

Cooling method

Gear shift control method

Automatic gear shift

Manual control pattern liter

Specifications

Three-element, one-stage, two-phase type

2.0/1990 - 2540 rpm

Sprag type

Four forward speeds, one reverse gear, planetary gear type

Wet type multiple clutch

3 set

Band type brake

1 set

Wet type multiple brake

1 set

One-way clutch

1st gear: 2.800 2nd gear: 1.540 3rd gear: 1.000

4th gear: 0.700 Reverse gear: 2.333

1 piece

24/5

Internal gear type

ATF DEXRON

Except for EU: 4.2 liters , For EU: 4.29 liters

Except for EU: Water-cooled (radiator built-in type),

For EU: Water-cooled (radiator built-in type) plus air-cooled oil cooler separately mounted

Governor and throttle pressure shift control method

Four forward speeds, full automatic shift

P—R—N—D—2—L (with overdrive switch)

JAT00003-00000

AT–4

TORQUE CONVERTER

The torque converter employs a three-element, one-stage, two- phase type converter, as has been hitherto employed.

CONSTRUCTION

The torque converter consists of a front cover to which a drive plate is attached, a pump impeller integral with the torque converter cover, a turbine runner which is spline-fitted with the input shaft at the transmission side, a stator, a one-way clutch which supports the stator and so forth.

Front cover

Stator

One-way clutch

OPERATION

When the ratio of the turbine runner speed to the pump impeller speed is small, the fluid returning from the turbine runner to the pump impeller flows in such a direction that prevents the rotation of the pump impeller. Therefore, the installation of the stator helps converting the fluid flow in such a direction that the pump impeller rotation is assisted.

The torque ratio becomes a maximum of about 2.0 when the speed ratio is zero (at the time when the turbine runner is stopped). The torque ratio at this time is called the stall torque, whereas this stage is called the stall point.

Until the speed ratio reaches about 0.8, fluid transmission takes place, while increasing the torque. As the speed ratio becomes greater, the torque ratio decreases. This stage is called the torque converter range.

When the speed ratio becomes above about 0.8, the torque ratio is maintained at about one, transmitting the same torque without altering it. This stage is called the fluid coupling range.

The efficiency rises in proportion to the speed ratio. After passing a certain point, however, the increase rate of the efficiency starts to decline. This is because the fluid from the turbine runner begins to strike the back side of the stator, thus preventing the fluid flow.

Then, the one-way clutch of the stator operates, making the stator rotate. As a result, the increase rate of the efficiency starts to increase again.

Turbine runner

Pump impeller

JAT00004-00002

1 a

η t b

100

0.2

0.4

0.6

Speed ratio (e)

0.8

1.0

: b

Torque converter range

Fluid coupling range e: Speed ratio =

Turbine shaft revolution speed

Pump shaft revolution speed t: Torque ratio =

Turbine shaft torque

Pump shaft torque

: Efficiency =

Output horse power

Input horse power

100 (%)

JAT00005-00003

AT–5

POWER TRAIN MECHANISM

DESCRIPTION

In the power train mechanism, the power that has been transmitted from the engine to the input shaft of the transmission through the torque converter is transmitted from various clutches to the planetary gear, using reduction ratios optimum for the running condition.

JAT00006-00000

CONSTRUCTION

(1) Planetary gear

A Ravingeau type planetary gear is employed.

The following are the main components: Intermediate shaft, front planetary sun gear, planetary short pinion, planetary long pinion, rear planetary sun gear and planetary output shaft.

The input section of the driving force at the planetary gear unit section is composed of three systems: One is the intermediate shaft; another is the front planetary sun gear; and the third is the rear planetary sun gear.

This input section is switched by making gear shifts.

Furthermore, the output section is the planetary output shaft.

Planetary short pinion

Intermediate shaft

Front planetary sun gear

Planetary output shaft

Rear planetary sun gear

Planetary long pinion

JAT00007-00004

(2) Shift control element

The shift control element consists of three kinds of wet type multiple-disc clutches, namely, the direct clutch

(C1), forward clutch (C2) and rear clutch (C3), as well as the 1st & reverse brake (B2) of the wet type multiple-disc brake, the 2nd brake (B1) of the band type brake, and the one-way clutch (F). Moreover, the following table shows functions of each control element.

Functions of Each Shift Control Element

Shift control element

Direct clutch (C1)

Forward clutch (C2)

Rear clutch (C3)

2nd brake band (B1)

1st & reverse brake (B2)

One-way clutch (F)

Operations

Connects input shaft with front planetary sun gear.

Connects input shaft with rear planetary sun gear.

Connects input shaft with intermediate shaft.

Locks front planetary sun gear.

Prevents planetary carrier from rotating.

Prevents planetary carrier from rotating counterclockwise.

JAT00008-00000

AT–6

OPERATION

(1) Power Train Route

The input route of the power train has three routes: One is a route in which the power is transmitted from the input shaft to the front planetary sun gear via the C1 clutch. Another is a route in which the power is transmitted to the rear planetary sun gear via the C2 clutch. The other is a route in which the power is transmitted to the intermediate shaft via the C3 clutch. Conversely, there is only one output route of the planetary output shaft.

Moreover, the following table shows functions of each shift control element according to the transmission gear.

Planetary short pinion

Planetary long pinion

Front planetary sun gear

Input shaft

Output shaft

Intermediate shaft

Planetary carrier

Rear planetary sun gear

Planetary output shaft

Table Showing Functions of Shift Control Elements

C1 C2

Shift position

Parking

Reverse

Neutral

1st

2nd

3rd

4th (O/D)

1st

2nd

3rd

1st

™

JAT00009-00005

™

JAT00010-00000

AT–7

(2)

and

ranges <1st gear> (without engine brake)

When the transmission is in the 1st gear with the shift lever set to the

Î or x range, the forward clutch (C2) is activated. Therefore, the rotating force of the input shaft is directly transmitted to the rear planetary sun gear, thus transmitting a counterclockwise rotating force to the planetary short pinion.

Conversely, the planetary long pinion which is in mesh with the planetary short pinion receives a clockwise rotating force and tries to rotate the planetary carrier counterclockwise. However, the rotation is prevented by the function of the one-way clutch (F). Consequently, the planetary output shaft receives a clockwise rotating force.

Planetary short pinion

Planetary long pinion

Output shaft

Input shaft

Planetary carrier

Rear planetary sun gear

Planetary output shaft

JAT00011-00006

(3)

and

ranges <2nd gear>

When the transmission is in the 2nd gear, the forward clutch (C2) is activated. Therefore, the rotating force of the input shaft is directly transmitted to the rear planetary sun gear, thus transmitting a counterclockwise rotating force to the planetary short pinion.

Conversely, the front planetary sun gear is locked by the 2nd brake band (B1). As a result, the planetary long pinion which is in mesh with the planetary short pinion receives a clockwise rotating force and revolves around the front planetary sun gear while rotating on its axis. Consequently, a clockwise rotating force is transmitted to the planetary output shaft.

Planetary short pinion

Planetary long pinion

Front planetary sun gear

Output shaft

Input shaft

Rear planetary sun gear

Planetary output shaft

JAT00012-00007

AT–8

(4)

range <3rd gear>

When the transmission is in the 3rd gear, the direct clutch (C1) and forward clutch (C2) are activated.

Therefore, the input shaft, front planetary sun gear and rear planetary sun gear rotate in the same direction.

As a result, the planetary short pinion and planetary long pinion come in a locked state. Consequently, the planetary output shaft receives a clockwise rotating force.

Planetary short pinion

Planetary long pinion

Front planetary sun gear

Output shaft

Input shaft

Planetary carrier

Rear planetary sun gear

Planetary output shaft

JAT00013-00008

(5)

range <4th gear>

When the transmission is in the 4th gear, the rear clutch (C3) is activated. The rotating force of the input shaft is directly transmitted to the intermediate shaft, thus transmitting a clockwise rotating force to the planetary carrier.

Conversely, the front planetary sun gear is locked by the 2nd brake band (B1). Therefore, the planetary long pinion supported by the planetary carrier receives a clockwise rotating force and revolves around the front planetary sun gear while rotating on its axis. Consequently, a clockwise rotating force is transmitted to the planetary output shaft.

Planetary long pinion

Front planetary sun gear

Input shaft

Output shaft

Planetary carrier

Planetary output shaft

Intermediate shaft

JAT00014-00009

AT–9

(6)

range <1st gear>

The rotating force is transmitted in the same way as the 1st gear of the

Î range, as previously explained.

However, the 1st & reverse brake (B2) operates to prevent the planetary carrier from rotating clockwise at the time of engine braking.

In other words, at the time of driving with the

Î range, the counterclockwise rotation of the planetary carrier is locked by the function of the one-way clutch (F). Thus, the rotating force is transmitted to the planetary output shaft.

However, at the time of engine braking, a reverse force is applied. As a result, the one-way clutch (F) will not operate and the planetary carrier rotates idly. Therefore, in order to make the function of engine brake possible, the planetary carrier is secured by operating the 1st & reverse brake (B2).

Planetary short pinion

Planetary long pinion

Output shaft

Input shaft

Planetary carrier

Planetary output shaft

JAT00015-00010

(7)

range <Reverse gear>

When the transmission is in the reverse gear, the direct clutch (C1) is activated, as shown in the figure below. Therefore, the rotating force of the input shaft is directly transmitted to the front planetary sun gear.

Conversely, the planetary carrier is locked by the function of the 1st & reverse brake (B2). Therefore, the rotating force transmitted to the front planetary sun gear makes the planetary long pinion rotate counterclockwise on its axis. Consequently, the counterclockwise rotating force is transmitted to the planetary output shaft.

Planetary long pinion

Front planetary sun gear

Output shaft

Input shaft

Planetary carrier

Planetary output shaft

JAT00016-00011

AT–10

(8)

∏

range

When shifted to the

∏ range, the parking cam is pushed out through the parking rod. Thus, the parking cam pushes up the parking pawl. As a result, the parking lock pawl becomes engaged with the parking lock gear. Consequently, locking is made.

Parking lock gear

Output shaft

Cam spring

Parking rod

Parking lock pawl

Parking cam

JAT00017-00012

AT–11

HYDRAULIC PRESSURE CONTROL SYSTEM

DESCRIPTION

Utilizing the hydraulic pressure generated at the oil pump, the hydraulic pressure control system switches fluid passages leading to each shift control element of the power train mechanism according to running conditions, regulates the line pressure as well as lubricates each section of the transmission.

The following table shows operating conditions of the hydraulic pressure applied to each shift control element in each shift position.

Table Showing Operating Conditions of Hydraulic Pressure

Shift position C1 C2 C3

B1 (Applied side) B1’ (Released side)

Parking

Reverse

Neutral

1st

2nd

3rd

4th (O/D)

1st

2nd

1st

™

*: In cases where hydraulic pressure is applied both to the applied side and to the released side, B1 is released by the difference in the pressure-receiving area.

JAT00018-00000

AT–12

HYDRAULIC PRESSURE CIRCUIT DIAGRAM

JAT00019-00013

COMPONENTS

(1) OIL PUMP

A trochoid type gear oil pump has been adopted.

The oil pump consists of an oil pump body, an oil pump drive gear, and an oil pump driven gear. The oil pump drive gear, which is driven by the torque converter, drives the oil pump driven gear to send the automatic transmission fluid to the hydraulic pressure control system under a pressurized state.

AT–13

Oil pump driven gear

Oil pump drive gear

Oil pump body

JAT00020-00014

(2) VALVE BODY

The valve body is mounted at the lower surface of the transmission. It incorporates hydraulic pressure-regulating valves, such as a throttle valve, a regulator valve, a modifier valve, a secondary regulator valve, and a throttle modulator valve. It also incorporates a manual valve, and valves that will switch fluid passages of each shift valve, thus reducing gear shift impacts of each timing valve, etc.

JAT00021-00015

1) Manual valve

The manual valve is interlocked with the shift lever by the control cable. According to the shift lever movement, the manual valve switches the line pressure of each range.

q w e

L 2 D N R P

r t

Range

Line pressure

(From regulator valve)

Circuit q w e r t

JAT00022-00016

AT–14

2) Regulator valve

The regulator valve regulates the pressurized fluid sent from the oil pump to a hydraulic pressure (line pressure) suited for the running condition.

The forces applied to the valve are the spring force (force F

S pushing to the right side), line pressure r

(the discharging pressure from the oil pump y flowing via e

) (force F

L pushing to the left side), modifier pressure t

(force F

MF pushing to the right side), and line pressure w

(force F

RL pushing to the right side) which will be applied only when the shift lever is moved to the

Â range.

Therefore, the line pressure y is regulated under the following conditions, thus becoming an optimum hydraulic pressure suited for the running condition.

1. Except

Â range: F

= F

+ F

= F

+ F

MF q w e t y u i q Line pressure (

range) w

Lubrication pressure (To secondary regulator valve and torque converter) e ry

Line pressure (From oil pump to manual valve and throttle valve) t

Modifier pressure u

Drain (To oil strainer) i

Drain r

3) Modifier valve

The modifier valve regulates the modifier pressure which will regulate the line pressure to an optimum pressure according to the running condition (throttle opening angle).

The forces applied to the valve are the spring force (force F

S pushing to the left side), force applied to the valve by the modifier pressure w when it enters the chamber A through the fluid passages inside the valve (force F

MF pushing to the right side), and throttle pressure q

(force F

TH pushing to the left side).

In cases where the throttle opening angle is less than approximately 25% with the shift lever set to a place other than the x and

Ò ranges, the throttle pressure q flows into w without being regulated. Therefore, the modifier pressure becomes equal to the throttle pressure. Conversely, in cases where the throttle opening angle is more than approximately 25%, the modifier pressure will be regulated under a condition of F

+ F

When the shift lever is moved to the x or

Ò range, the line pressure will be applied to q

. As a result, the modifier pressure becomes a constant value, regardless of the throttle opening angle.

Chamber B

Chamber A e

JAT00023-00017 q w q

Throttle pressure

(Except for x

and

ranges)

Line pressure

( x

and

ranges) w

Modifier pressure e

Drain

JAT00024-00018

AT–15

4) Secondary regulator valve

The secondary regulator valve regulates the lubrication pressure to an optimum hydraulic pressure.

The forces applied to the valve are the spring force (force F

S pushing to the right side), and force pushing the valve by the lubrication pressure q when it enters the chamber A through the fluid passages inside the valve (force F

LUB pushing to the left side). Hence, the lubrication pressure will be regulated under a condition of F

LUB

= F

Chamber A w q

Lubrication pressure

(From regulator valve to torque converter) w

Drain (To oil strainer)

JAT00025-00019

5) Throttle valve & downshift plug

The throttle pressure is generated in proportion to the throttle opening angle.

The forces applied to the throttle valve are the adjuster spring force (force F

SA pushing to the right side), main spring force

(force F

SM pushing to the left), and force generated by the difference in the pressure-receiving area after the throttle pressure q enters the chamber A through the fluid passages inside the valve (force F

TH pushing to the right side). As a result, the throttle pressure is regulated under a condition of F

+ F

= F

. Since the F

SM becomes greater in proportion to the throttle opening angle, the throttle pressure is in proportion to the throttle opening angle.

The downshift plug outputs the throttle pressure from w to the shift valve when the throttle opening angle becomes 85%.

Then, this outputted pressure acts as a force counteracting the governor pressure, thus raising the shifting point.

The throttle pressure e acts as a force pushing the downshift plug to the left side, thus reducing the accelerator pedal application force.

Adjuster Spring q

Downshift plug w e

Chamber A r Main spring

Throttle valve q w e r

Throttle pressure

Throttle pressure (Throttle opening

angle is 85% or more.)

Throttle pressure

Line pressure

Throttle opening angle

JAT00026-00020

AT–16

6) 1-2 shift valve

The 1-2 shift valve allows or does not allow the hydraulic pressure be applied to the B1 (the applied side), depending on conditions of the vehicle speed and throttle opening angle.

1. When shifted from 1st gear to 2nd gear:

When the shift lever is set to the

Î or x range, the forces applied to the valve are the spring force

(force F

S pushing to the right side), throttle pressure y

(force F

TH pushing to the right side), and governor pressure u

(force F

G pushing to the left side). When a condition of F

> F

+ F

TH is obtained, the valve is moved to the left side. Thus, the line pressure w is applied to the B1 e

(the applied side).

When the shift lever is moved to the

Ò range, the line pressure (force F

L pushing to the right side) is applied to r and y from the manual valve. In this case, since a condition of F

< F

+ F

L is always obtained, the valve will not move to the left side (The transmission will not be shifted to the 2nd gear).

Furthermore, at this time the line pressure r is applied through the fluid passages inside the valve and q

, thereby causing B2 to operate.

2. When shifted from 2nd gear to 1st gear:

In cases where the throttle opening angle is less than 85% with the shift lever set to the range other than the

Ò range, the throttle pressure y will not be applied to the valve. Therefore, when a condition of F

< F

S is obtained, the valve moves to the right side. As a result, the hydraulic pressure will not be applied to the B1 e

(the applied side). (The shifting point comes to a speed lower than the shifting point for 1st-to-2nd gear shifting.)

In cases where the throttle opening angle is more than 85% with the shift lever set to the range other than the

Ò range (at the time of kick down), the throttle pressure (force pushing to the right side) is applied to t

. Therefore, the valve moves to the right side under a condition of F

< F

+ F

(when the vehicle speed is lower than a certain value).

When the shift lever is shifted to the

Ò range while running with the 2nd gear, the line pressure (F

) will be applied to t

. Therefore, the valve will not move to the right side, until a condition of F

< F

+ F

L is satisfied. (The 2nd gear is held, until the vehicle speed decreases below a certain vehicle speed, so as to prevent the engine from overrunning.) e

<Except 2nd, 3rd and 4th gears> r t y u

<2nd, 3rd and 4th gears> r t y e u q w q

To B2 w

Line pressure

(

, x

and

ranges) e

To B1 r

Line pressure (

range) q w t

Line pressure (

range),

Throttle pressure (

and x

ranges, throttle opening

angle of 85% or more) y

Line pressure (

range), throttle pressure

(Except for

and x

ranges) u

Governor pressure

JAT00027-00021

AT–17

7) 2-3 shift valve

The 2-3 shift valve allows or does not allow the hydraulic pressure be applied to the C1, C3, and B1’ (at the released side), depending on conditions of the vehicle speed and throttle opening angle.

1. When shifted from 2nd gear to 3rd gear:

When the shift lever is set to the

Î range, the forces applied to the valve are the spring force (force F

S pushing to the right side), throttle pressure y

(force F

TH pushing to the right side), throttle modulator pressure u

(force F

TM pushing to the right side), and governor pressure i

(force pushing to the left side). When a condition of F

> F

+ F

TM is satisfied, the valve moves to the left side. Thus, the line pressure from the 1-2 shift valve q is applied to the C1 and B1’ via the servo control valve from w

; and to the C3 via the 2-3 timing valve.

When the shift lever is moved to the x or

Ò range, the line pressure (force F

L pushing to the right side) is applied to e

, t and y from the manual valve. In this case, since a condition of F

< F

+ F

L is always satisfied, the valve will not move to the left side (The transmission will not be shifted to the 3rd gear).

2. When shifted from 3rd gear to 2nd gear:

In cases where the throttle opening angle is less than 85% with the shift lever set to the

Î range, the throttle modulator pressure u will not be applied to the valve. Therefore, when a condition of F

< F

TH is satisfied, the valve moves to the right side. As a result, the hydraulic pressure will not be applied to the C1 w

, B1’ and C3. (The shift point comes to a speed lower than the 2nd-to-3rd gear shift point.)

In cases where the throttle opening angle is 85% or more with the shift lever set to the

Î range, the throttle pressure (force F

KD pushing to the right side) is applied to t

. Therefore, the valve is moved to the right side when a condition of F

< F

+ F

KD is satisfied (when the vehicle speed is lower than a certain value).

When the shift lever is shifted to the x or

Ò range while running with the 3rd gear, the line pressure (F

) of the manual valve will be applied to e and t

. Therefore, the valve will not move to the right side, until a condition of F

< F

+ F

L is satisfied. (The 3rd gear is held, until the vehicle speed decreases below a certain vehicle speed, so as to prevent the engine from overrunning.)

<Except for 3rd and 4th gears> q w r y u i

<3rd and 4th gears> q w r y u i e t q

Line pressure , From 1-2 shift valve

(2nd, 3rd and 4th gears) w

Servo control valve / To C1 and B1’

2-3 timing valve / To C3 e

Line pressure , From manual valve

( x

and

ranges) r

To 2-4 timing valve e t t

Line pressure , From manual valve ( x

and

ranges),

Throttle pressure , From throttle valve

(throttle opening angle of 85% or more) y

Throttle pressure , From throttle valve

(Except for x

and

ranges)

Line pressure / From manual valve ( x

and

ranges) u

Throttle modulator pressure , From throttle modulator valve i

Governor pressure , From servo control

JAT00028-00022

AT–18

8) 3-4 shift valve & 3-4 relay valve

•

3-4 relay valve

The relay valve changes the force applied to the shift valve, depending on the throttle opening angle.

The forces applied to the valve are the large spring force (force F

S pushing to the left side), small spring force (force F

S’ pushing to the right side) and throttle pressure q

(force F

TH pushing to the right side).

In cases where the throttle opening angle is less than approximately 20%, a condition of F

≥

S’

+ F

TH is satisfied. Consequently, the force applied to the shift valve becomes F

In cases where the throttle opening angle is between approximately 20% and 85%, a condition of F

≤

S’

TH is satisfied. Then, the relay valve moves to the right side, coming into contact with the shift valve.

Consequently, the force applied to the shift valve becomes F

S’

+ F

In cases where the throttle opening angle is more than 85%, the throttle pressure w

(force F

KD pushing to the left side) is applied, thus satisfying a condition of F

+ F

> F

S’

+ F

). As a result, the relay valve returns to the left again. Consequently, the force applied to the shift valve becomes F

+ F

JAT00029-00000

•

3-4 shift valve

The 3-4 shift valve allows or does not allow the line pressure be applied to the servo control valve and C2, depending on conditions of the vehicle speed, throttle opening angle and overdrive switch, so as to perform gear shifting between the 3rd gear and the 4th gear.

1. When shifting from 3rd gear to 4th gear:

The forces applied to the 3-4 shift valve are the force generated by the relay valve (force F

R pushing to the right side (= F

, or F

S’

+ F

, or F

+ F

)), and governor pressure i

(force F

G pushing to the left side).

When running at a low speed (F

< F

), the valve is located at the right side. Therefore, the line pressure t will be applied to the servo control valve and C2 via r

. However, when running at a high speed (F

> F

), the valve moves to the left side. Consequently, the line pressure which was applied via r will be drained. Thus, gear shifting to the 4th gear takes place.

Furthermore, when the overdrive is turned OFF, the line pressure (force F

L pushing to the right side) is applied to e

. Therefore, a condition of F

< F

+ F

L is always satisfied. Consequently, the valve will not move to the left side. (No gear shifting to the 4th gear will take place.)

2. When shifting from 4th gear to 3rd gear:

When the valve is located at the left side, the pressure-receiving diameter of the governor pressure i becomes greater. As a result, the force (F

G’

) pushing the valve to the left side also becomes greater.

Consequently, the 4th-to-3rd gear shift point comes at a speed lower than the 3rd-to-4th gear shift point.

Furthermore, when the overdrive is turned OFF, the line pressure (force F

L’ pushing to the right side) is applied to e and u

. However, since a condition of F

G’

< F

+ F

L’ is always satisfied, the valve moves to the right side (gear shifting to the 3rd gear takes place), regardless of the vehicle speed and throttle opening angle.

<4th gear>

3-4 relay valve w e

Small spring

3-4 shift valve t u i i

3-4 relay valve w e

Small spring

3-4 shift valve t u i i q

Large spring r y q

Throttle pressure , Throttle valve w

Line pressure , From 2-4 timing valve (1st and 2nd gears)

Throttle pressure , From 2-4 timing valve

(Throttle opening angle of 85% or more) e

Line pressure , From overdrive solenoid

(When overdrive is turned OFF with shift lever

set to

, x

range) r

3-4 & select timing valve / To C2

Servo control valve / To C1, B1’ q

Large spring r y t

Line pressure , From manual valve

(

, x

and

ranges) y

To B1 u

Line pressure , From overdrive solenoid

(When overdrive is turned OFF

with shift lever set to

, x

range) i

Governor pressure , From governor valve

JAT00030-00023

AT–19

9) Throttle modulator valve

The throttle modulator valve regulates the throttle modulator pressure which is applied to the 2-3 shift valve as a force counteracting the governor pressure. This throttle modulator valve causes shifting to take place at a low vehicle speed when the throttle is opened slightly; and at a high vehicle speed when the throttle is opened widely. Furthermore, when the throttle opening angle is less than approximately 10% and no throttle pressure is being generated, this valve assures the difference in speed between the 2nd-to-3rd gear shift point and the 3rd-to-2nd gear shift point (hysteresis).

In the

, x and

Ò ranges, the line pressure is applied to e from the manual valve. This pressure flows into w

, thus generating the throttle modulator pressure.

The forces applied to the valve are the spring force (force F

S pushing to the right side), throttle pressure q

(force F

TH pushing to the right side), and throttle modulator pressure w

(force

TM pushing to the left side). Thus, the throttle modulator pressure is regulated under a condition of F

= F

+ F

q w e q

Throttle pressure , From throttle valve

(Except for x

and

ranges)

Line pressure , From manual valve

( x

and

ranges) w

Throttle modulator pressure /

To 2-3 shift valve e

Line pressure / From manual valve

(

, x

and

ranges)

JAT00031-00024

AT–20

10) Servo control valve

When gear shift takes place between the 3rd gear and the 4th gear, the servo control valve turns ON and

OFF the C1 pressure and B1’ pressure (at released side) simultaneously.

Moreover, in order to prevent downshift from the 4th gear to the 2nd gear from taking place all at once (because it will apply a great torque to the forward clutch suddenly), the servo control valve causes downshift to the 3rd gear to take place first. Then, the transmission is shifted to the 2nd gear.

When the transmission is in the 3rd gear, the forces applied to the valve are the spring force (force pushing to the left side), line pressure o

(force pushing to the left side) from the 3-4 shift valve, and the line pressure q

(force pushing to the right side) from the 2-3 shift valve.

When conditions for upshifting to the 4th gear are satisfied and the 3-4 shift valve is switched, the line pressure o will be drained. Therefore, the valve moves to the right side. At this time, u and i are connected to each other. Consequently, the pressure B1’ u will be drained from the 3-4 shift valve via i

. At the same time, the pressure C1 w will be drained, too.

Moreover, although the vehicle speed decreases and conditions for switching the 2-3 shift valve (downshift to the 2nd gear) are satisfied, the servo control valve allows the 2-3 shift valve be switched only after the 3-

4 shift valve has been switched (downshift to the 3rd gear has taken place). The servo control valve does this by making the line pressure, instead of governor pressure, applied to the 2-3 shift valve from r

<4th gear>

<Except for 4th gear> r t u i o r t u i o q q w e y q q w e y q

Line pressure , From 2-3 shift valve (3rd and 4th gears) w

To C1 e

Governor pressure (From governor valve) r

To 2-3 shift valve t

Line pressure , From manual valve (

, x

and

ranges) y

Line pressure , From 2-3 shift valve (3rd and 4th gears) u

To B1’

To 3-4 & select timing valve i o

}

Line pressure , From 3-4 shift valve

(1st, 2nd and 3rd gears)

JAT00032-00025

AT–21

11) 3-4 & select timing valve

When upshift from the 3rd gear to the 4th gear takes place, the 3-4 & select timing valve makes the turning OFF of the pressure C2 synchronized with the turning OFF of the pressure B1’, thus preventing the engine from racing and making smooth shifting possible.

When the transmission is in the 3rd gear, the forces applied to the valve are the spring force (force F

S pushing to the left side), and line pressure q

(pressure B1’) (force pushing to the right side). Since a condition of F

< F

L is satisfied, the valve is located at the right side. If the line pressure q

(pressure B1’) is turned OFF when upshifting to the 4th gear, the valve moves to the left side. Also, r and t are connected to each other simultaneously. In this way, the pressure C2 w will be quickly drained.

Orifice r t e w y

Check valve q

Line pressure (pressure B1’) w

From C2 e

3-4 shift valve / Drain

JAT00033-00026

12) 2-3 timing valve

When gear shift takes place between the 2nd gear and the 3rd gear, the 2-3 timing valve raises the pressure C3 after the pressure C1 reaches a certain pressure.

When the transmission is in the 2nd gear with the shift lever set to the

Î range, the forces applied to the valve are the spring force (force F

S pushing to the left side), and line pressure q

(force F

L pushing to the right side) from the manual valve. Furthermore, since a condition of F

< F

L is satisfied, the valve is located at the right side. When upshifting from the 2nd gear to the 3rd gear takes place, the line pressure t

(force

L’ pushing to the left side) from the 2-3 shift valve is applied gradually via the orifice. As a result, at the point when a condition of F

+ F

L’

> F

L is satisfied, the valve moves to the left. At the same time, w and e are connected to each other. Consequently, the line pressure w is applied to the C3 via e

<D range, 1st and 2nd gears> <D range, except for 1st and 2nd gears> q w e r t q

Line pressure , From manual valve

(

, x

and

ranges) w

Line pressure , From 2-3 shift valve

(3rd and 4th gears) e

To C3 q w e r t r

Line pressure , From 3-4 shift valve (4th gear) t

Line pressure , From 2-3 shift valve (3rd and 4th gears)

JAT00034-00027

AT–22

13) 2-4 timing valve

If upshift from the 2nd gear to the 4th gear takes place all at once (when making the C2 inoperative and the

C3 operative), the engine starts racing, for no load is applied temporarily. In order to avoid this, the 2-4 timing valve prevents the pressure C2 from being turned OFF (through shifting to the 3rd gear temporarily), until the pressure C3 reaches a certain pressure.

When the transmission is in the 2nd gear with the shift lever set to the

Î range, only the spring force (force

S pushing to the left side) is applied to the valve. Therefore, the valve is located at the left side. In this case, the line pressure from the manual valve is applied to the 3-4 shift valve via e as a force counteracting the governor pressure.

If conditions for upshift to the 4th gear are satisfied and the 2-3 shift valve is switched (moved to the left side), the line pressure q

(pressure C3) (force F

C3 pushing to the right side) starts to be applied. However, the valve remains located at the left side, until a condition of F

< F

C3 is satisfied. Therefore, since the line pressure is applied to the 3-4 shift valve, the 3-4 shift valve cannot move to the left side. In other words, the pressure C2 cannot be turned OFF and the transmission remains in the 3rd gear. When a condition of C

C3 is satisfied and the valve moves to the right side, e and r are connected to each other and the line pressure which was applied to the 3-4 shift valve will be drained. Consequently, the 3-4 shift valve moves and upshifting to the 4th gear takes place.

When the overdrive is turned OFF (the overdrive solenoid is energized), the line pressure (force F

L pushing to the left side) is applied to t

. Since a condition of F

< F

+ F

L is always satisfied, the valve will not move to the right side (upshifting to the 4th gear will not take place).

<Except for 3rd and 4th gears> q

<3rd and 4th gears> q w e r t q

Line pressure (Pressure C3) w

Line pressure , From manual valve

(

, x

and

ranges) e

To 3-4 shift valve w e r t r

Line pressure ( x

and

ranges)

Throttle pressure

(opening angle of 85% or more)

From 2-3 shift valve t

Line pressure , From overdrive solenoid

(When overdrive is turned OFF with

, x

range)

JAT00035-00028

14) 3-2 timing valve

When a downshift is made from the 3rd gear to the 2nd gear, the change in the engine speed is relatively small during lowspeed operation. However, the change in the engine speed is great during high-speed operation, resulting in a strong shift shock. The 3-2 timing valve is provided to reduce this shift shock.

q w

Spring

Orifice control valve q

From Bl’ w

To 2-3 shift valve e

Governor pressure e

JAT00286-00257

AT–23

15) 4-3 timing valve

When downshift from the 4th gear to the 3rd gear takes place at a high speed, the 4-3 timing valve retards the rising speed of the line pressure (pressure C2), thus reducing shift impacts.

The forces applied to the valve are the spring force (force F

S pushing to the left side) and governor pressure w

(force F

G pushing to the right side).

When running at a low speed (F

< F

), the valve moves to the left side, and y and u are connected to each other.

Therefore, the line pressure q from the 3-4 shift valve is quickly raised through the route of r

/ u

/ y

/ e

When running at a high speed (F

> F

), the valve moves to the right side, and y and u are cut off. Therefore, the line pressure q will be raised slowly through the route of t

/ orifice / e

r e

Orifice q t

Check valve y u w q

Line pressure , From 3-4 shift valve

(Except for 4th gear) w

Governor pressure e

3-4 & select timing valve / To C2

16) Overdrive solenoid

The overdrive solenoid makes the line pressure applied to the

3-4 shift valve and 2-4 timing valve, thus preventing upshift to the 4th gear from taking place.

When the overdrive switch is turned ON (overdrive possible), the solenoid is not energized, thus draining the line pressure q

When the overdrive switch is turned OFF (overdrive impossible), the solenoid is energized. As a result, the plunger is pulled to close the fluid passage. Consequently, the line pressure q is retained.

JAT00036-00029

<When electric current is not energized (Overdrive “ON”)> q w w

<When electric current is energized

(Overdrive “OFF”)> q w w q

Line pressure

(

, x

and

ranges) w

Drain

JAT00037-00030

17) Accumulators

The accumulator has functions to relax the connecting of the shift control elements and to reduce gear shift impacts. There are two kinds of accumulators: One is for the forward clutch

(C2); and the other is for the 2nd brake band (B1). These are provided in the transmission case.

Accumulator B1

Accumulator C2

JAT00038-00031

AT–24

(3) GOVERNOR VALVE

The governor valve is driven by the governor drive gear mounted on the output shaft. The governor valve generates a governor pressure which is corresponding to the vehicle speed (output shaft revolution speed).

The forces applied to the valve are the governor weight, centrifugal force of the governor inner weight

(force F

1 pushing to the right side), centrifugal force of the governor valve (force F

2 pushing to the right side), and governor pressure w

(force pushing to the left side).

When running at a low speed (spring force F

> F

), the governor pressure is regulated under a condition of

= F

+ F

. As the vehicle speed becomes high (F

< F

), the governor inner weight comes in contact with the stopper. Consequently, the governor pressure is regulated under a condition of F

= F

+ F

Governor valve

Governor inner weight

Governor weight w

Governor pressure q

Line pressure

Governor shaft revolution speed

(vehicle speed) w

Governor pressure q

Line pressure

JAT00039-00032

(4) COOLING DEVICE

The automatic transmission fluid is cooled down by the oil cooler incorporated in the radiator.

On vehicles with the EU specifications, the fluid is once cooled down by the air-cooled oil cooler separately mounted. Then, the fluid is sent to the oil cooler inside the radiator to be cooled down further.

This illustration shows specifications except for the EU specifications

Oil cooler front hose

Front tube

A/T tubes

Oil cooler inlet hose

Oil cooler outlet hose

Engine side tubes

Oil cooler hoses

JAT00040-00033

AT–25

CASE & COVER

DESCRIPTION

The case and cover consist of the transmission case, transmission case side cover, and transmission oil pan.

For improved rigidity of the case, the transmission case is integrated with the converter housing.

Furthermore, liquid gasket featuring excellent sealing ability has been applied at the mating surfaces of each case.

Transmission case

Transmission case side cover

Transmission oil pan

JAT00041-00034

AT–26

ELECTRIC CONTROL SYSTEM

OVERDRIVE SWITCH

DESCRIPTION

The overdrive solenoid provided in the transmission valve body is energized (overdrive possible) by turning

ON (pushing) the overdrive switch incorporated in the shift lever. Also, the overdrive solenoid is non-energized (overdrive impossible) by turning OFF (releasing) the overdrive switch.

Gauge, back

10A

IG1

F/L AM

60A

Battery

O/D OFF indicator

Overdrive relay

Overdrive switch

O/D ON: Switch “OFF”

(Button pushed)

O/D OFF: Switch “ON”

(Button released)

Overdrive solenoid

JAT00042-00035

COMPONENTS

Overdrive switch

Overdrive relay

The overdrive relay is mounted on the floor shift assembly with a bracket interposed.

Overdrive solenoid

Overdrive relay

JAT00043-00036

SHIFT CONTROL MECHANISM

DESCRIPTION

1. The shift control mechanism has employed a remote control type, using a push-pull cable.

AT–27

JAT00044-00037

COMPONENTS

(1) Shift lever assembly

The floor shift assembly has employed a six-position type having the

∏

, x and

Ò positions.

Also, the overdrive switch is incorporated.

Overdrive switch

JAT00045-00038

AT–28

PRELIMINARY CHECK

1. Check of transmission fluid level

NOTE:

•

Prior to the fluid level check, be sure to run the vehicle until the engine and transmission have reached their normal operating temperature.

(Fluid temperature: 70 - 90°C)

2. Check of engine idling speed.

Specified Value: 850 ± 50 rpm

(Refer to the EM section.)

(a) Park the vehicle on a level surface. Apply the parking brake.

(b) With the engine idling, smoothly move the shift lever all through the ranges from P to L. Finally, return the shift lever to the P range.

(d) Push it back fully into the tube.

(e) Pull it out and check that the fluid level is in the HOT range.

If the fluid level is too low, add the fluid.

Fluid To Be Used: DEXRON

III

Full Capacity: Approx. 4.2 R (For EU: 4.29 R )

Drain and Refill: Approx. 1.7

(For EU: 1.74

)

CAUTION:

•

Do not overfill the fluid.

•

Transmission warming-up method

1. Warm up the engine.

2. If the vehicle runs for about 15 minutes at a speed of 60 km/h or for about 30 minutes at a speed of 40 km/h, the temperature of the fluid inside the transmission becomes about 80

Reference

When the engine is cold, if the engine is operated for about 35 minutes at the idling speed after the engine has started, the temperature of the fluid inside the transmission will rise to about 60

JAT00046-00039

NOTE:

•

If it is necessary to check the fluid level at a low temperature (20 - 30°C), e.g. at the time of fluid change, first adjust the fluid level so that it may become within the COLD level. Then, recheck the fluid level under the hot conditions.

•

If the fluid level fails to reach the cold level on the fluid level gauge, be sure to check the transmission for fluid leakage. Also, pull out the fluid level gauge and check the fluid for contamination or smell of fluid burning.

3. Check of fluid condition

If the fluid smells burning or it presents a black appearance, change the fluid.

4. Change of transmission fluid

(1) Remove the drain plug with the gasket. Drain the fluid.

NOTE:

•

Never reuse the removed gasket.

H C

H range C range

JAT00047-00040

JAT00048-00041

AT–29

(2) With a new gasket interposed, tighten the drain plug securely.

Tightening Torque: 19.6 - 29.4 N·m (2.0 - 3.0 kgf-m)

(3) Add new fluid through the filler tube.

Fluid To Be Used: DEXRON



III

Full Capacity: Approx. 4.2

(For EU: 4.29

)

Drain and Refill: Approx. 1.7

(For EU: 1.74

)

(4) Start the engine. Move the shift lever to all positions from P through L. Then, move it to the P position.

(5) With the engine idling, check the fluid level. Add fluid up to the COLD level on the fluid level gauge.

(6) Check the fluid level at the normal fluid operating temperature (70 - 90

C). Add the fluid, as required.

5. Adjustment of throttle cable

The purpose of this adjustment is to make the full open state of the throttle link of the throttle body at the engine side equal to the full-open position of the throttle valve inside the transmission.

NOTE:

•

Do not perform the adjustment, using the attaching nut of the throttle link at the engine side. The nut

A in the right figure is secured with bond.

(1) Remove the neutral start switch.

(2) Reset the automatic adjusting mechanism, following the procedure given below.

NOTE:

•

When turning the casing cap with pliers or the like, be sure not to apply a lateral force. If a lateral force should be applied, it may damage (break) the casing cap section.

1) Turn the casing cap about 60 to 90 degrees. (The circlip will be expanded.)

NOTE:

•

When turning the casing cap with pliers or the like, be sure to clamp the hexagonal staked section of the casing cap.

2) Pull the casing cap, until it is brought into contact with the stopper.

JAT00049-00000

JAT00050-00043 w

Hexagonal staked section q

Casing cap

Circlip

JAT00051-00044

AT–30

3) Turn the casing cap in the reverse direction of the step 1). (The circlip will be closed so that the casing cap may be secured.) e

JAT00052-00045

(3) Fully depress the accelerator pedal or turn the throttle link at the engine side, until it comes in contact with the full-open stopper.

At this time, ensure that the free play of the throttle cable has been automatically adjusted by listening to a clicking sound.

(4) Install the neutral start switch assembly.

(See the step 7.)

6. Inspection of neutral start switch

Using an ohmmeter, check the continuity of the terminals for each switch position shown in the table below.

Terminal

E R RB P N D 2 L

Range

™

™ ™

™

If the continuity does not conform to the specifications, replace the switch.

7. Adjustment of neutral start switch

(1) Move the shift lever to the

ˆ range.

(2) Remove the attaching bolts of the control cable and control shaft lever subassembly.

(3) Remove the control shaft lever subassembly.

P D 2

JAT00053-00000

JAT00054-00046

JAT00055-00000

(4) Install the SST. Check that the gauge section of the

SST is aligned with the scribed line of the neutral start switch.

SST: 09302-87201-000

(5) If they are not aligned with each other, loosen the bolt.

Then, perform the adjustment by turning the switch section so that they may be aligned. Tighten the bolt to the specified torque.

Tightening Torque: 14.7 - 21.6 N·m (1.5 - 2.2 kgf-m)

NOTE:

•

Do not use an impact wrench to tighten the securing bolt of the neutral start switch.

(6) Remove the SST. Install the control shaft lever subassembly.

Tightening Torque: 9.8 - 15.7 N·m (1.0 - 1.6 kgf-m)

(7) In cases where the operation in (5) has been performed, confirm the operation of the control shaft lever, following the procedure given below:

1) With the control shaft lever set to the

∏ range, move it approximately 2 to 3 mm toward the

Â range by your hand. At this time, ensure that the control shaft lever fully returns to the

∏ range.

2) If the lever will not return to the

∏ range, once loosen the securing bolt of the neutral start switch.

After performing the adjustment, retighten the bolt.

(8) Install the control cable, making sure that the backlash will not be deviated to one side.

Tightening Torque: 6.9 - 9.8 N·m (0.7 - 1.0 kgf-m)

8. Check of shift lever position

(1) Move the shift lever from the

ˆ range to each range.

Ensure that the shift lever button and shift lever can be operated smoothly with a positive detent feeling at each range. Check that the position indicator functions properly.

(2) Start the engine. Ensure that the vehicle moves forward when you move the shift lever from the

ˆ range to the

, x and

Ò ranges, respectively. Make sure that the vehicle moves backward when you move the shift lever to the

Â range.

(3) With the ignition switch set to the ON position, move the shift lever from the

∏ to

Â range and from the

ˆ to

Â range while depressing the brake pedal.

e mark: Shift can be made only while shift lever button is being pushed a mark: Shift can be made without pushing shift lever button

(4) With the ignition switch turned ON and the shift lever placed in the

Â range, check that the back-up lamp goes on and the reverse warning buzzer is set off.

AT–31

SST

Scribed line

JAT00056-00047

Excessive play

JAT00057-00048

JAT00058-00049

AT–32

TESTING

CAUTION:

•

Perform the stall test at the normal fluid operating temperature (70 - 90

C).

•

Do not conduct this test continuously for more than five seconds.

•

Wait at least one minute before the switching is made from the

Î range to the

Â range.

•

Be sure to turn OFF the air conditioner (if equipped so on).

JAT00059-00000

STALL TEST

1. Place chocks at the wheels of the vehicle.

2. Connect an engine tachometer. Apply the parking brake.

3. Start the engine.

4. While strongly depressing the brake pedal by your left foot, move the shift lever to the

Î and

Â ranges, respectively. Then, depress the accelerator pedal fully by your right foot. At this time, quickly read the engine revolution speed.

NOTE:

•

Do not conduct this test continuously for more than five seconds.

•

There must be an interval of at least one minute between the

Î range and the

Â range.

Specified Value: 1990 - 2540 rpm

REFERENCE:

•

If the stall revolution speed fails to conform to the specified value, most likely the following malfunctions are taking place.

Although the stall revolution speed in the

range is the same as that in the

range, they are lower than the specified value.

Although the stall revolution speed in the

range is the same as that in the

range, they are higher than the specified value.

The stall revolution speed in the

range is higher than the specified value.

The stall revolution speed in the

range is higher than the specified value.

•

Insufficient engine output

•

Faulty torque converter stator one-way clutch

•

Insufficient transmission fluid amount

•

Low line pressure

•

Slipping of forward clutch, direct clutch and 1st &

reverse brake, and malfunction of one-way clutch

•

Low line pressure

•

Slipping of forward clutch, and malfunction of one-way

clutch

•

Low line pressure

•

Slipping of direct clutch and 1st & reverse brake

JAT00060-00000

AT–33

TIME LAG TEST

1. Apply the parking brake and place chocks at the wheels of the vehicle.

2. Start the engine.

3. While depressing the brake pedal, move the shift lever from the

ˆ range to the

Î range; and from the

ˆ range to the

Â range at the idle speed. At this time, measure the time elapsed from shifting until a shock is felt.

NOTE:

•

If the time lag is to be measured consecutively, be sure to put a one-minute interval between the tests.

•

Conduct the test several times. Obtain the mean value.

Specified Value:

→

: 1 second or less

→

: 1 second or less

REFERENCE:

•

If the time lag fails to conform to the specified value, most likely the following malfunctions are taking place.

The time lag when shifted from the

range to the

Î range is longer than the specified value.

The time lag when shifted from the

range to the

Â range is longer than the specified value.

•

Forward clutch slipping

•

Low line pressure

•

Direct clutch slipping

•

1st & reverse brake slipping

•

Low line pressure

JAT00061-00000

HYDRAULIC PRESSURE TEST

1. Articles to be prepared

Shape Part number, nomenclature

SST

09325-87201-000

A/T pressure gauge No. 1 adapter

Pressure gauge for automatic transmission fluid

Instrument

Oil pressure gauge adapter

Grease DEXRON

III

JAT00062-00050

AT–34

2. Plug position for hydraulic pressure test

Pressure B2

Throttle pressure

Governor

Pressure C3

Pressure C1

Pressure B1 Pressure C2

Pressure B1’

range pressure

Test plug tightening torque

6.9 - 9.8 (0.7 - 1.0)

Unit: N·m (kgf-m)

JAT00063-00051

3. Installation procedure for pressure gauges

NOTE:

•

Be sure to use new gaskets for the SST and instrument.

•

Never reuse the test plugs.

(1) Remove the test plug and install the pressure gauge.

NOTE:

•

Be very careful not to allow the pressure gauge to interfere with the front propeller shaft.

(2) Start the engine and warm up the transmission (fluid temperature 70 - 90

C). Check the fluid level.

Also, check each section for fluid leakage.

4. Measurement procedure for each hydraulic pressure

Throttle pressure,

range pressure, pressure C1, pressure C2 and pressure B2

(1) Apply the parking brake and place chocks at the wheels of the vehicle.

(2) Start the engine.

(3) Strongly depress the brake pedal by your left foot. With the shift lever moved to the

Î range,

Â range, and

Ò range, respectively, operate the accelerator pedal by your right foot. At this time, measure each hydraulic pressure.

Pressure B1

(1) Jack up the four wheels. Then, support the vehicle by rigid racks.

(2) Start the engine.

(3) With the shift lever moved to the

Î range and x range, gradually depress the accelerator pedal.

Measure the hydraulic pressure after upshift to the 2nd gear takes place. However, in cases where the shift lever is set to the

Î range, measure the hydraulic pressure at the time when the accelerator pedal is released.

Pressure C3 and pressure B1’

(1) Jack up the four wheels. Then, support the vehicle by rigid racks.

(2) Start the engine.

(3) With the shift lever moved to the

Î range, gradually depress the accelerator pedal so that upshift to the

3rd gear may take place. Then, measure the hydraulic pressure at the time when the accelerator pedal is released.

JAT00064-00000

AT–35

Governor pressure

(1) Drive the vehicle onto a speedometer tester.

(2) Start the engine.

(3) With the shift lever moved to the

Î range, gradually depress the accelerator pedal. Measure the hydraulic pressure at each vehicle speed.

Specified Value

Item

Throttle pressure

range pressure

C1, B2

Line pressure

B1’, C3

Governor pressure

Measurement condition

Idling revolution condition

Stall revolution condition

Idling revolution condition

Stall revolution condition

Idling revolution condition

Stall revolution condition

Idling revolution condition

Stall revolution condition

—

Idling revolution condition

Stall revolution condition

3rd gear with accelerator pedal “OFF”

2nd gear with accelerator pedal “OFF” x 2nd gear

30 km/h

60 km/h

Specified value (kPa {kg/cm

})

29 {0.3} or less

598 - 637 {6.1 - 6.5}

530 - 628 {5.4 - 6.4}

843 - 941 {8.6 - 9.6}

530 - 628 {5.4 - 6.4}

843 - 941 {8.6 - 9.6}

1265 - 1363 {12.9 - 13.9}

1971 - 2069 {20.1 - 21.1}

431 - 530 {4.4 - 5.4}

1265 - 1363 {12.9 - 13.9}

1971 - 2069 {20.1 - 21.1}

530 - 628 {5.4 - 6.4}

902 - 1000 {9.2 - 10.2}

49 - 147 {0.5 - 1.5}

167 - 265 {1.7 - 2.7}

JAT00065-00000

AT–36

REFERENCE:

•

If each hydraulic pressure fails to conform to the specified value, most likely the following malfunctions are taking place.

All line pressures fail to conform to the specified value.

Only a certain clutch or brake pressure fails to conform to the specified value.

range pressure fails to conform to the specified value.

Throttle pressure fails to conform to the specified value.

Governor pressure fails to conform to the specified value.

1. Oil pump faulty

2. Oil strainer clogged

3. Faulty O-ring of oil strainer

4. Improper adjustment of throttle cable

5. Faulty valve body assembly

•

Loose connecting bolt of valve body

•

Faulty modulator valve

6. Improper throttle pressure

1. Faulty valve body assembly

•

Leakage or clogging at circuit of the clutch or brake

pressure concerned

•

Faulty piston accumulator of the clutch or brake

pressure concerned

•

Shift valve faulty

2. Manual valve faulty, or improper adjustment of position

1. Faulty valve body assembly

•

Faulty manual valve, or improper adjustment of position

•

Leakage or clogging of

range pressure circuit

2. Improper line pressure

1. Improper adjustment of throttle cable

2. Throttle cable detached or broken

3. Faulty valve body assembly

•

Faulty throttle valve

•

Leakage or clogging of throttle pressure circuit

4. Improper line pressure

1. Faulty governor valve assembly

2. Faulty valve body assembly

•

Leakage or clogging of governor pressure circuit

3. Improper line pressure

JAT00066-00000

AT–37

RUNNING TEST

NOTE:

•

Be sure to confirm safety on the road when conducting the running test.

•

Make sure that the fluid temperature is in a normal running condition (70 - 80

C).

range test

(1) Move off the vehicle with the shift lever set to the

Î range. Check to see if upshift and downshift take place between the 1st gear and the 2nd gear; between the 2nd gear and the 3rd gear; and between the 3rd gear and the 4th gear (overdrive). Also, check to see if each shift point conforms to the specified value. Furthermore, check that there is no abnormal shock and slipping, etc.

(2) While driving the vehicle with the shift lever set to the

Î range and the transmission in the 4th gear

(overdrive), 3rd gear, and 2nd gear, respectively, perform the kick-down operation. At this time, check to see if kick-down takes place from the 4th gear (overdrive) to the 3rd gear, from the 3rd gear to the 2nd gear; and from the 2nd gear to the 1st gear. Also, check to see if the vehicle speed range during which kick-down is possible conforms to the specified value. Furthermore, check that there is no abnormal shock or slipping, etc.

(3) When the overdrive switch is turned OFF while driving the vehicle in the 4th gear (overdrive), ensure that the downshift from the 4th gear (overdrive) to the 3rd gear takes place.

range test

(1) Move off the vehicle with the shift lever set to the x range. Check to see if upshift and downshift take place between the 1st gear and the 2nd gear. Also, check to see if each shift point conforms to the specified value. Furthermore, check that there is no abnormal shock and slipping, etc.

(2) Move off the vehicle with the shift lever set to the x range. At this time, ensure that upshift from the

1st gear to the 2nd gear takes place and that no upshift to the 3rd gear will take place.

(3) While driving the vehicle with the shift lever set to the x range and the transmission in the 2nd gear, perform the kick-down operation. Check to see if kick-down takes place from the 2nd gear to the 1st gear. Also, check to see if the vehicle speed range during which kick-down is possible conforms to the specified value. Furthermore, check that there is no abnormal shock and slipping, etc.

(4) When the shift lever is shifted to the x range while driving the vehicle with the shift lever set to the

Î range and the transmission in the 3rd gear, check that downshift from the 3rd gear to the 2nd gear takes place and engine brake is applied. Also, check to see if the shift point conforms to the specified value.

range test

(1) Move off the vehicle with the shift lever set to the

Ò range. At this time, ensure that no upshift to the

2nd gear will take place.

(2) When the shift lever is shifted to the

Ò range while driving the vehicle with the shift lever set to the

Î range and the transmission in the 3rd gear, check that downshifts from the 3rd gear

/ the 2nd gear / the 1st gear take place and engine brake is applied. Also, check to see if the shift point conforms to the specified value.

JAT00067-00000

AT–38

∏

range test

(1) Park the vehicle on a grade (approximately 5 degrees or more) in a climbing state and move the shift lever to the

∏ range. Then, release the parking brake. At this time, check that the parking lock mechanism functions and the vehicle will not move.

(2) Park the vehicle in a descending state, and perform the same check as stated above.

(3) Under conditions above, move the shift lever from the

∏ range to other ranges. At this time, check to see if the vehicle moves.

Specified Value

Throttle opening angle Range

100 %

0 %

0 - 100%

Î x

Gear shifting

1st / 2nd

2nd

3rd

3rd / 4th

4th / 3rd

3rd / 2nd

2nd / 1st

4th / 3rd

3rd / 1st

3rd / 2nd

2nd

1st

Vehicle speed (km/h)

31.6 - 47.6

67.6 - 83.6

107.8 - 123.8

89.4 - 105.4

60.7 - 76.7

24.5 - 40.5

12.0 - 28.0

6.3 - 22.3

85.6 - 101.6

33.7 - 49.7

JAT00068-00000

ELECTRIC-RELATED TESTS

OVERDRIVE SYSTEM

Wiring diagram

Gauge, back

10A

IG1

F/L AM

60A

Battery

O/D OFF indicator

Overdrive relay

Overdrive switch

O/D ON: Switch “OFF”

(Button pushed)

O/D OFF: Switch “ON”

(Button released)

Overdrive solenoid

JAT00069-00052

Unit inspection

•

Overdrive switch

1. When the overdrive switch is turned ON (overdrive possible), check that no continuity exists between the terminals q and w of the connector in the right figure. Also, when the overdrive switch is turned OFF (overdrive impossible), check that continuity exists between the same terminals.

•

Overdrive relay

1. Measure the resistance between the terminals q and w

Specified Value: Approx. 70

Ω

2. Ensure that no continuity exists between the terminals q and e

3. When the battery voltage is applied across the terminals q and e

, ensure that continuity exists between the terminals q and w

•

Overdrive solenoid

1. Measure the resistance between the terminal of the overdrive solenoid connector and the ground (transmission case).

Specified Value: 24 - 27.2

Ω

AT–39

2 e q

JAT00070-00053 w

Overdrive relay

JAT00071-00054

Terminal

JAT00072-00055

AT–40

REMOVAL AND INSTALLATION OF AUTOMATIC TRANSMISSION

COMPONENTS

: Tightening torque

Unit : N·m (kgf-m)

★

: Non-reusable parts

e t

6.9 - 9.8

(0.7 - 1.0)

29.4 - 39.2

(3.0 - 4.0)

★

6.9 - 9.8

(0.7 - 1.0)

★

49.04 - 68.64

(5.0 - 7.0)

★ y

29.4 - 44.1

(3.0 - 4.5)

29.4 - 39.2

(3.0 - 4.0) r

78.45 - 98.07

(8.0 - 10.0)

MP grease

29.4 - 44.1

(3.0 - 4.5)

B o

14.7 - 21.6

(1.5 - 2.2)

14.7 - 21.6

(1.5 - 2.2)

29.4 - 44.1

(3.0 - 4.5)

B i

B q

26.0 - 48.5

(2.65 - 4.95)

34.3 - 61.7

(3.5 - 6.3) q

Ground wire w

Vacuum hose e

Neutral start switch connector r

Overdrive solenoid connector t

Speedometer drive cable assembly y

Oil cooler hose u

Bolt (tube bracket

× transmission) i

Front lower frame crossmember subassembly o

Power train stiffener

Bolt (torque converter

× drive plate)

Engine rear support member subassembly with engine mounting rear insulator

Transmission assembly with transfer assembly

Torque converter assembly

Drive plate & ring gear subassembly

JAT00073-00056

AT–41

1. Operations prior to removal

(1) Disconnect the negative (–) terminal of the battery.

(2) Disconnect the throttle cable at the engine side.

(3) Drain the automatic transmission fluid.

(4) Remove the propeller front shaft.

(5) Remove the propeller shaft.

(6) Remove the front exhaust pipe.

(7) Remove the starter assembly.

(8) Disconnect the control cable at the transmission side.

2. Main points of removal

(1) Disconnect the neutral start switch connector and overdrive solenoid connector.

JAT00074-00000

Neutral start switch connector

Overdrive solenoid connector

JAT00075-00057

(2) Support the engine, using an engine supporting bridge. Remove the engine rear support member subassembly with the rear engine mounting rear insulator.

(3) Support the transmission assembly with the transfer, using a transmission jack, etc. Remove the transmission assembly with the transfer.

NOTE:

•

Be very careful not to deform the oil pan during the removal.

3. Check

(1) Check the drive plate for runout.

Limit: 0.25 mm

JAT00076-00058

(2) Install the torque converter to the drive plate. Check the shaft for runout, using the following SST.

SST: 09351-87203-000

Limit: 0.30 mm

NOTE:

•

Be very careful not to drop the torque converter during the operation.

SST

JAT00077-00059

JAT00078-00060

AT–42

4. Main points of installation

(1) Insert the torque converter assembly into the transmission assembly. Ensure that the torque converter has been inserted securely.

Specified Value: Dimension A is 28 mm or more.

(Dimension A: Dimension between edge surface of housing and drive plate installation seat of torque converter)

(2) Install the transmission assembly with the transfer.

1) Face the reference hole (elongated hole) of the drive plate downward.

2) Support the transmission assembly with a transmission jack, etc. Then, connect the transmission assembly to the engine.

NOTE:

•

Be very careful not to dent the oil pan during the operation.

NOTE:

•

Before securely tightening the bolts and nuts (engine

× transmission), make sure that the torque converter turns lightly. If the torque converter will not turn lightly, it means that the torque converter is deviated from the specified position. Therefore, remove the transmission and securely insert the torque converter into the specified position. (If the bolts and nuts are tightened securely with the torque converter deviated from the specified position, there will be the possibility that the oil pump be damaged.)

Tightening Torque: 49.04 - 68.64 N·m

(5.0 - 7.0 kgf-m)

(3) Install the bolts (drive plate

× torque converter).

1) First, tighten the bolt in the reference hole (elongated hole) of the drive plate.

NOTE:

•

Never use bolts other than the bolt indicated in the right figure. (If those bolts longer than the specified bolt should be used, it would lead to improper tightening or deformation of the inner shape of the converter, thus resulting in hampering the functions.)

Tightening Torque: 29.4 - 44.1 N·m (3.0 - 4.5 kgf-m)

(2)

0.3

JAT00082-00064

JAT00079-00061

Reference hole

JAT00080-00062

Ensure that the torque converter assembly rotates lightly.

JAT00081-00063

AT–43

(4) Install the power train stiffener. Tighten the bolts in the following sequence.

1) Temporarily tighten the bolt (A).

2) Securely tighten the bolts in the sequence of the bolt (B), bolt (A), bolt (E), bolt (F), bolt (C), and bolt

(D).

REFERENCE:

•

If any difficulty is encountered in inserting the bolts (E) and (F), loosen the bolt (a) before the operation.

Tightening Torque:

M10 29.4 - 44.1 N·m (3.0 - 4.5 kgf-m)

M8 14.7 - 21.6 N·m (1.5 - 2.2 Kgf-m)

5. Operations after installation

(1) Install the starter assembly.

(2) Install the control cable assembly at the transmission side.

(3) Install the front exhaust pipe.

(4) Install the propeller shaft.

(5) Install the propeller front shaft.

(6) Connect the throttle cable at the engine side.

(7) Fill automatic transmission fluid.

(8) Perform the basic check and adjustment.

(D)

(C)

(A)

(B)

JAT00083-00065

(E)

(a)

(F)

JAT00084-00066

JAT00085-00000

AT–44

CONNECTION AND DISCONNECTION OF OIL COOLER HOSES

COMPONENTS

1. Operations prior to removal

(1)

•

Remove the center engine undercover. (Except EU specifications)

•

Remove the center engine undercover, radiator grill and front bumper cover. (EU only)

: Tightening torque

Unit : N·m (kgf-m)

★

: Non-reusable parts

29.4 - 39.2

(3.0 - 4.0)

★

6.9 - 9.8

(0.7 - 1.0)

B w ★

29.4 - 44.1

(3.0 - 4.5) B

6.9 - 9.8

(0.7 - 1.0)

To radiator

Specifications other than

EU specifications











★ e

FRONT

To radiator

6.9 - 9.8

(0.7 - 1.0) r ★ y q ★

★

29.4 - 39.2

(3.0 - 4.0)

EU specifications u

6.9 - 9.8

(0.7 - 1.0)

★ r q

Oil cooler hose w

Oil cooler inlet hose e

Oil cooler outlet hose r

Oil cooler front hose t

Oil cooler front inlet hose y

Oil cooler assembly u

Transmission oil cooler bracket i

Clamp

6.9 - 9.8

(0.7 - 1.0)

★ t

To radiator i

JAT00086-00067

AT–45

2. Main points of removal

Table showing identification of oil cooler hose q

Oil cooler hose w

Oil cooler inlet hose e

Oil cooler outlet hose r

Oil cooler front hose t

Oil cooler front inlet hose

Length (mm)

125

246

189

—

Remarks

—

Moulded hose

(1) Completely degrease the hose connecting section. Insert new oil cooler hoses q

, w

, e

, r and t up to the second stage spools of the oil cooler tube and the union at the oil cooler side, while making sure that those hoses may not be twisted. Then, attach the clip, while aligning it with the edge of the marking. However, the oil cooler front hoses

(moulded hoses) r and t should be connected in such a way that the marking faces just downward of the vehicle.

JAT00087-00000 q

, w

, e

Second stage spool r

, t

Second stage spool

Marking Marking

JAT00088-00068

3. Operations after installation

(1) Check the automatic transmission fluid level. Replenish the fluid, as required.

(2)

•

Install the center engine undercover. (Except EU specifications)

•

Install the center engine undercover, front bumper cover and radiator grill. (EU only)

JAT00089-00000

AT–46

DISASSEMBLY AND ASSEMBLY OF AUTOMATIC TRANSMISSION

COMPONENTS

: Tightening torque

Unit : N·m (kgf-m)

★

: Non-reusable parts

6.9 - 9.8

(0.7 - 1.0)

6.9 - 9.8

(0.7 - 1.0)

6.9 - 9.8

(0.7 - 1.0)

★ q

★ w

#0 e

★ r

9.8 - 15.7

(1.0 - 1.6)

14.7 - 21.6

(1.5 - 2.2)

@9 t

6.9 - 9.8

(0.7 - 1.0)

14.7 - 21.6

(1.5 - 2.2)

29.4 - 44.1

(3.0 - 4.5) i

★ @2

6.9 - 9.8

(0.7 - 1.0)

6.9 - 9.8

(0.7 - 1.0)

22.5 - 30.4

(2.3 - 3.1)

@4 ★

★

19.6 - 29.4

(2.0 - 3.0)

6.9 - 9.8

(0.7 - 1.0)

★

29.4 - 44.1

(3.0 - 4.5)

B u

o q

T-type oil seal w

O-ring e

Stator shaft & oil pump assembly r

Clutch drum oil seal ring t

Transmission case subassembly y

Transmission case side cover subassembly u

Transfer assembly i

Needle roller bearing o

Hole snap ring

Governor cover

O-ring

Governor body assembly

Ball

O-ring

Transmission oil filler tube subassembly

Transmission oil level gauge subassembly

Transmission oil pan assembly

Transmission magnet

gasket

W/head straight screw plug

Oil strainer subassembly

O-ring

Transmission brake band assembly

Transmission brake band adjusting anchor bolt

Throttle cable assembly

Neutral start switch assembly

Transmission control shaft lever subassembly

Power train stiffener

Control cable bracket

Throttle cable clamp

Breather plug No. 1

Breather plug No. 2

JAT00090-00069

AT–47

COMPONENTS (INNER PARTS)

q w e r t y u i o

Clutch drum thrust washer w

Direct clutch assembly e

Thrust needle roller bearing r

Thrust bearing race t

Forward clutch assembly y

Thrust needle roller bearing u

Intermediate shaft subassembly i

Thrust needle roller bearing o

Thrust bearing race

Forward clutch hub

Thrust needle roller bearing

2nd brake drum

Planetary sun gear subassembly

Thrust needle roller bearing

Rear planetary sun gear subassembly

Hole snap ring

One-way clutch

Brake plate

Brake disc

Brake cushion plate

Planetary gear assembly

Thrust needle roller bearing

Planetary output shaft subassembly

Radial ball bearing

Output shaft assembly

JAT00091-00070

AT–48

REMOVAL

1. Remove the bolt of the transmission oil filler tube subassembly.

2. Pull out the transmission oil filler tube subassembly toward upside.

3. Remove the O-ring from the transmission oil filler tube subassembly.

NOTE:

•

Never reuse the removed O-ring.

4. Remove the breather plug (A) and union bolts (B) (for oil cooler).

NOTE:

•

Never reuse the removed gaskets.

5. Remove the clamp (C) for the throttle cable.

6. Removal of governor valve

(1) Remove the hole snap ring, using standard snap ring pliers.

(2) Remove the governor cover with the O-ring installed, using standard pliers.

(3) Remove the O-ring from the governor cover.

NOTE:

•

Never reuse the removed O-ring.

(4) Remove the governor body assembly from the transmission case.

(5) Remove the ball (A), using a standard magnet hand.

(B)

(A)

JAT00092-00071

(C)

JAT00093-00072

(A)

JAT00094-00073

JAT00095-00074

7. Detach the connector (A) of the solenoid wire assembly from the clamp of the control cable bracket.

8. Removal of neutral start switch assembly

(1) Remove the control cable bracket by removing the two bolts.

(2) Detach the connector (B) (of the neutral start switch) from the clamp of the control cable bracket.

(B)

(A)

JAT00096-00075

(3) Remove the transmission control shaft lever subassembly by removing the nut.

(4) Remove the neutral start switch assembly by removing the bolt.

9. Remove the nine inspection plugs from the transmission.

NOTE:

•

Never reuse the removed plugs.

10. Remove the power train stiffener.

AT–49

JAT00097-00000

JAT00098-00076

11. Removal of transfer assembly

NOTE:

•

For the disassembling procedure of the transfer, refer to the TR section.

(1) Remove the seven bolts indicated in the right figure.

NOTE:

•

The numerals in the right figure denote the nominal length of each bolt. (Unit: mm)

(2) Tap the rib section of the transfer case. Then, pull it out toward you.

12. Remove the needle roller bearing at the forward end of the output shaft assembly.

170

JAT00099-00077

170

JAT00100-00078

JAT00101-00079

AT–50

13. Remove the transmission oil pan assembly by removing the fourteen bolts.

CAUTION:

•

Do not turn over the transmission, for this will contaminate the valve body with foreign materials deposited at the bottom of the oil pan.

NOTE:

•

Never reuse the removed oil pan assembly.

14. Check of pan for particles

Remove the transmission magnet and use them to collect any steel chips. Inspect the oil pan for any chips and particles collected on the magnet. Inspect them carefully to find out the type of wear of the transmission.

Steel (magnetic) ... Wear of bearing, gear and plate

Brass (nonmagnetic) ... Wear of bush

15. Disconnect the throttle cable from the throttle valve cam.

16. Remove the throttle cable attaching bolt.

17. Pull out the throttle cable from the transmission case.

18. Remove the O-ring of the throttle cable.

NOTE:

•

Never reuse the removed O-ring.

19. Disconnect the connector of the solenoid wire assembly indicated by the arrow mark in the right figure.

JAT00102-00080

JAT00103-00081

JAT00104-00082

20. Remove the oil strainer subassembly by removing the three bolts.

NOTE:

•

Be sure to remove the bolts evenly and uniformity.

•

The numerals in the right illustration indicate the nominal length of the bolt.

21. Disconnect the valve body tube (A).

48.5

48.5 (A)

JAT00105-00083

48.5

JAT00106-00084

22. Remove the O-ring by sticking a needle into the O-ring for the oil strainer which has been installed at the valve body side.

NOTE:

•

Be very careful not to scratch the valve body when sticking the needle into the O-ring.

•

Never reuse the removed O-ring.

23. Remove the manual detent spring by removing the two bolts.

NOTE:

•

Be sure to remove the bolts evenly and uniformity.

•

The numerals in the right illustration indicate the nominal length of the bolt.

24. Remove the valve body assembly.

NOTE:

•

Be sure to remove the bolts evenly and diagonally.

•

The numerals in the right illustration indicate the nominal length of the bolt.

25. Remove the compression spring of the B

1 piston.

accumulator

26. Lightly hold the arrow-headed section of the accumulator

No. 1 piston.

27. Remove the piston with the accumulator seal No. 1 and

No. 2 rings installed by applying compressed air into the oil hole (A).

NOTE:

•

Be sure to put on protection goggles since oil may splash when using compressed air.

28. Remove the accumulator No. 2 piston with the seal No. 1 ring installed and compression spring.

AT–51

O-ring

Needle

JAT00107-00085

JAT00108-00086

JAT00109-00087

(A)

JAT00110-00088

JAT00111-00089

AT–52

29. Remove the roller for manual valve lever shaft subassembly, using a standard magnet hand.

JAT00112-00090

30. Remove the solenoid wire assembly attaching bolt.

31. Pull out the the solenoid wire assembly from the transmission case.

JAT00113-00091

32. Removal of 2nd brake piston assembly

(1) Remove the lock nut of the transmission brake band adjusting anchor bolt.

(2) Remove the transmission brake band adjusting anchor bolt, using a standard screwdriver or the like.

NOTE:

•

Never reuse the removed anchor bolt.

(3) Remove the hole snap ring, using snap ring pliers in combination with the following SSTs.

SST: 09202-87002-000 ..... (A)

09202-87002-0A0 ..... (B)

(4) Gradually loosen the SSTs (A) and (B) above, until the compression spring for the 2nd coast brake piston is released fully. Then, remove the SSTs.

NOTE:

•

In cases where the 2nd coast brake piston will not come out, slightly loosen the SSTs above. Then, apply a light impact by means of a plastic hammer to remove the 2nd coast brake piston.

(5) Remove the 2nd brake piston assembly and compression spring.

SST(A)

JAT00114-00092

SST(B)

JAT00115-00093

33. Remove the slotted spring pin, using a pin punch and a hammer.

NOTE:

•

When removing the slotted spring pin, be very careful not to drop it into the transmission case.

•

Never reuse the removed slotted spring pin.

34. Pull out the manual valve lever shaft subassembly.

35. Remove the manual valve lever by aligning the cut-out groove of the manual valve lever (B) with the protruding section of the parking lock rod (A).

(B)

AT–53

JAT00116-00094

(A)

JAT00117-00095

36. Remove the parking lock cam support and parking lock rod subassembly by removing the three bolts.

JAT00118-00096

37. Remove the roller for the one-way clutch outer race, and compression spring by removing the bolt.

JAT00119-00097

38. Measure the input shaft end play, using a dial gauge in conjunction with the following SST.

SST: 09351-87210-000

Specified Value: 0.28 - 0.92 mm

NOTE:

•

Be sure to record the measured value for a guide during the assembly.

JAT00120-00098

AT–54

39. Remove the T type oil seal, using the following SST.

SST: 09308-10010-000

NOTE:

•

Never reuse the removed oil seal.

40. Remove the seven bolts of the stator shaft & oil pump assembly.

NOTE:

•

Be sure to remove the bolts evenly and diagonally.

•

Never loosen any bolt other than the specified ones in the right figure.

41. Remove the stator shaft & oil pump assembly with the Oring installed, using the following SST.

SST: 09820-00021-000

42. Remove the O-ring from the stator shaft & oil pump assembly.

NOTE:

•

Never reuse the removed O-ring.

43. Remove the two clutch drum oil seal rings.

NOTE:

•

Never reuse the removed oil seal rings.

SST

JAT00121-00099

JAT00122-00100

JAT00123-00101

JAT00124-00102

44. Remove the clutch drum thrust washer (resin made) from the direct clutch.

NOTE:

•

If no thrust washer (resin made) is provided on the direct clutch, make sure that the thrust washer is installed at the stator shaft & oil pump assembly side.

JAT00125-00103

45. Remove the direct clutch together with the forward clutch at the same time.

46. Remove the direct clutch from the forward clutch.

47. Remove the thrust needle roller bearing from the forward clutch.

48. Remove the thrust bearing race from the forward clutch.

49. Removal of intermediate shaft subassembly

(1) Remove the thrust needle bearing from the intermediate shaft subassembly.

(2) Remove the intermediate shaft subassembly.

(3) Remove the thrust needle bearing from the intermediate shaft subassembly.

50. Removal of forward clutch hub and 2nd brake drum

(1) Remove the thrust bearing race from the forward clutch hub.

AT–55

JAT00126-00104

JAT00127-00105

JAT00128-00106

JAT00129-00107

JAT00130-00108

AT–56

(2) Remove the 2nd brake drum (together with the forward clutch hub).

(3) Remove the rear planetary sun gear subassembly from the 2nd brake drum.

(4) Remove the thrust needle bearing from the rear planetary sun gear subassembly.

(5) Remove the forward clutch hub from the 2nd brake drum.

(6) Remove the thrust needle bearing from the 2nd brake drum.

(7) Remove the planetary sun gear assembly from the 2nd brake drum.

51. Remove the transmission brake band assembly.

JAT00131-00109

JAT00132-00110

JAT00133-00111

JAT00134-00112

JAT00135-00113

52. Measurement of 1st & reverse brake end play

(1) Turn over the transmission case.

(2) Measure the 1st & reverse brake end play, using a standard feeler gauge.

Specified Value: 1.04 - 1.41 mm

NOTE:

•

Be sure to record the measured value for a guide during the assembly.

•

The tightness which you encounter during this insertion/withdrawal of the feeler gauge should be virtually the same as the tightness which you would encounter during the thickness adjustment of the valve rocker arm.

53. Removal of planetary gear and one-way clutch

(1) Remove the hole snap ring, using snap ring pliers.

(2) Remove the planetary gear assembly with the one-way clutch installed.

(3) Remove the one-way clutch from the planetary gear assembly.

54. Removal of 1st & reverse brake

(1) Move the brake discs, brake plates and brake cushion plate as a set in such a way that they face toward the front side.

(2) Remove the discs, plates and cushion plate in the following order.

D = Brake disc, P = Brake plate

B = Brake cushion plate

D / P / D / P / D / P / D / P / B

AT–57

JAT00136-00114

JAT00137-00115

JAT00138-00116

JAT00139-00117

JAT00140-00118

AT–58

(3) Remove the thrust needle roller bearing (A) from the planetary output shaft subassembly.

(A)

55. Removal of transmission case side cover

(1) Remove the nine bolts and oil guide plate (A).

NOTE:

•

The numerals in the right figure denote the nominal length of each bolt.

•

Never reuse the removed three bolts (B).

(2) Remove the transmission case side cover, using a plastic hammer.

NOTE:

•

Lightly apply an impact to the right and left sides of the transmission case side cover, using a plastic hammer, when removing the cover.

•

Be very careful not to scratch the oil seal lip by the spline of the output shaft when removing the transmission case side cover.

(A)

JAT00141-00119

(B)35

(B)85

(B)35

JAT00142-00120

56. Remove the output shaft assembly.

JAT00143-00121

57. Remove the torsion spring.

58. Remove the parking lock pawl.

59. Remove the parking lock pawl shaft.

JAT00144-00122

60. Removal of planetary output shaft subassembly

(1) Tap the planetary output shaft subassembly lightly, using a plastic hammer, until the planetary output shaft subassembly becomes free.

(2) Remove the planetary output shaft subassembly from the transmission case side.

(3) Remove the hole snap ring, using snap ring pliers.

(4) Remove the radial ball bearing.

NOTE:

•

If any difficulty is encountered in removing the radial ball bearing, remove it by applying a light impact from the inside of the transmission case, using a suitable brass bar in combination with a plastic hammer.

61. Disassembling of first & reverse brake piston

(1) Temporarily install the removed B2 inspection plug to the transmission case.

(2) Assemble the following SSTs and set them to the transmission case to remove the first & reverse brake return spring.

SSTs: 09351-87201-000

09351-87707-000

09351-87709-000

09351-87710-000

NOTE:

•

To prevent the first & reverse brake return spring seat from being deformed, be sure to stop pressing when the first & reverse brake return spring seat has been lowered 1 to 2 mm from the shaft snap ring installation position.

(3) Remove the shaft snap ring, using snap ring pliers.

NOTE:

•

Be very careful not to deform the shaft snap ring by spreading it excessively.

(4) Remove the first & reverse brake return spring.

AT–59

JAT00145-00123

JAT00146-00124

JAT00147-00125

JAT00148-00126

JAT00149-00127

AT–60

(5) Hold the first & reverse brake piston, using the following SSTs (to prevent the piston from being tilted when removing the piston).

SSTs: 09351-87201-000

09351-87707-000

09351-87709-000

09351-87710-000

(6) While applying compressed air of 392 - 784 kPa (4 -

8 kgf/cm

) from the oil hole indicated in the right figure, gradually loosen the bolt of the SST and remove the first & reverse brake piston.

(7) Remove the outer O-ring of the first & reverse brake piston.

NOTE:

•

Never reuse the removed O-ring.

(8) Remove the inner O-ring of the first & reverse brake piston.

NOTE:

•

Never reuse the removed O-ring.

SST

JAT00150-00128

JAT00151-00129

JAT00152-00130

AT–61

DISASSEMBLY AND ASSEMBLY OF COMPONENTS

COMPONENTS

: Tightening torque

Unit : N·m (kgf-m)

★

: Non-reusable parts

★ w

★ r q t

6.9 - 9.8

(0.7 - 1.0) e q

Transmission case w

T type oil seal e

Transmission case side cover subassembly r

D type oil seal t

Breather plug

1. Disassembly and assembly of transmission case

(1) Remove the type T oil seal, using a standard screwdriver.

NOTE:

•

Never reuse the removed oil seal.

JAT00153-00131

JAT00154-00132

AT–62

(2) Assemble a new type T oil seal, using the following

SST.

SST: 09301-87702-000

2. Disassembly and assembly of transmission case side cover subassembly

(1) Remove the type D oil seal, using the following SST.

SST: 09309-87502-000

NOTE:

•

Never reuse the removed oil seal.

(2) Assemble a new type D oil seal, using the following

SST.

SST: 09309-87203-000

(3) Tighten the breather plug to the specified torque.

Tightening Torque: 6.9 - 9.8 N·m (0.7 - 1.0 kgf-m)

JAT00155-00133

JAT00156-00134

JAT00157-00135

INSPECTION

COMPONENTS

(A) w e

(B) r

(D)

(F)

y u i

(E)

AT–63

Direct clutch assembly w

Forward clutch assembly e

Brake band assembly r

Intermediate shaft subassembly t

Forward clutch hub y

2nd brake drum u

Planetary sun gear subassembly i

Rear planetary sun gear subassembly o

One-way clutch

Brake plate

Brake disc

Brake cushion plate

Planetary gear assembly

Planetary output shaft subassembly

(A) - (F) Thrust needle roller bearing

Visually inspect each part for wear and damage.

JAT00158-00136

AT–64

1. Brake band assembly

If the lining of the brake band is exfoliated or discolored, or even a part of the printed number is defaced, replace the brake band.

NOTE:

•

When the brake band assembly is replaced, be sure to check the band contacting surface at the 2nd brake drum side.

•

If the contacting surface is damaged or discolored, be sure to replace the 2nd brake drum together with the band.

•

Before assembling a new brake band, soak it in the

ATF for at least two hours.

2. Direct clutch assembly

Check of piston stroke of direct clutch

(1) Install the clutch drum thrust washer (resin made) to the oil pump.

(2) Install the direct clutch on the oil pump.

NOTE:

•

Be very careful not to scratch the clutch drum oil seal ring of the oil pump.

(3) Secure the direct clutch, using the following SST in combination with a press, to such an extent that the direct clutch will not move in an up-&-down direction.

(4) Install the following SSTs to the dial gauge.

SST: 09351-87203-000 ... (B)

09527-87301-000 ... (A)

NOTE:

•

Make sure that the SST (09351-87203-000) installed to the dial gauge is in contact at right angles with the direct clutch outer piston. Make sure that the SST is not in contact with any part other than the piston.)

(5) Measure the direct clutch piston stroke while applying and releasing compressed air 392 - 784 kPa (4 - 8 kgf/cm 2 ) through the section (A) as shown in the right figure.

SST: 09527-87301-000, 09351-87203-000

Piston Stroke: 1.22 - 1.53 mm

•

If the piston stroke is greater than the maximum, replace the direct clutch with a new one.

•

Perform the measurement at several points.

•

Before assembling a new direct clutch, soak it in the

ATF for at least two hours.

Piston

SST (B)

JAT00159-00137

JAT00160-00138

JAT00161-00139

JAT00162-00140

(6) While pressing the direct clutch flange with a force of 9.8 -

29.4 N (1.0 - 3.0 kgf), using the following SST (A) in combination with a suitable pushable gauge, measure the end play between the direct clutch flange and the snap ring, using a flat thickness gauge (B).

Specified Value: 0.93

+0.15mm

–0.16mm

SST: 09306-87302-000 ... (A)

(7) Confirmation of turning effort of clutch disc

Insert the input shaft (forward clutch) and rotate it. At this time, ensure that the clutch disc rotates lightly.

(8) Measure the bush inner diameter of the direct clutch piston subassembly, using an inner caliper gauge.

Specified Value: 44.000 - 44.025 mm

Allowable Limit: 44.075 mm

NOTE:

•

Ensure that the measurement should be performed at several points.

•

If the measured value exceeds the allowable limit, replace the direct clutch drum subassembly with a new one.

•

If the measured value exceeds the allowable limit of the bush inner diameter, check the bush contacting surface of the stator shaft of the oil pump assembly. If the contacting surface is scratched or discolored, replace the stator shaft & oil pump assembly with a new one, too.

3. Forward clutch assembly

•

Operation check of forward clutch piston

(1) Secure the input shaft on a vice with aluminum sheets interposed.

NOTE:

•

Be very careful not to score the bush contacting surface of the input shaft.

(2) Blow compressed air of 392 - 784 kPa (4 - 8 kgf/cm

) into the fluid hole of the input shaft indicated in the right figure. At this time, check that the piston slides smoothly.

Air blowing hole

AT–65

JAT00163-00141

JAT00164-00142

JAT00165-00143

JAT00166-00144

AT–66

•

Operation check of rear clutch piston

(1) Blow compressed air of 392 - 784 kPa (4 - 8 kgf/cm

) into the fluid hole of the input shaft indicated in the right figure. At this time, check that the piston slides smoothly.

Air blowing hole

•

Confirmation of rotating weight of clutch disc

(1) Install the thrust needle bearing to the forward clutch.

REFERENCE:

Dimensions of thrust needle roller bearing:

Outer diameter: 32 mm

Inner diameter: 16.5 mm

Thickness: 4.1 mm

(2) Assemble the intermediate shaft subassembly and rotate it. Ensure that the clutch No. 3 disc rotates lightly.

Needle roller bearing

JAT00167-00145

JAT00168-00146

JAT00169-00147

(3) Assemble the thrust needle bearing and thrust bearing race to the intermediate shaft subassembly.

REFERENCE:

Dimensions of thrust needle bearing:

Outer diameter: 32 mm

Inner diameter: 16.5 mm

Thickness: 4.1 mm

Thrust needle bearing

Thrust bearing race

JAT00170-00148

(4) Assemble the forward clutch hub and rotate it. Ensure that the clutch No. 2 disc rotates lightly.

JAT00171-00149

4. One-way clutch

Hold the one-way clutch and turn the planetary gear assembly.

NOTE:

•

Ensure that the one-way clutch turns freely when turned counterclockwise. Also, ensure that it is locked when turned clockwise.

5. Thrust bearing specifications

Be sure to install the thrust bearings in the correct direction and position.

NOTE:

•

Since the following six bearings have been staked at the race side, these bearings can not be removed from the race.

Approx

Outer diameter

Inner diameter

Thickness

35.7

22.7

2.8

16.5

4.1

16.5

4.1

46.5

25.0

5.0

35.7

22.7

2.8

Unit: mm

46.5

25.0

5.0

ASSEMBLY

1. Assembly of 1st & reverse brake piston

(1) Coat new O-rings with ATF.

(2) Install the new O-rings (B) to the first & reverse brake piston

NOTE:

•

Be sure to install the (A) section of the new O-rings faces toward the first & reverse brake piston side, for the O-ring has a D-type shape.

(3) Apply ATF to the outer periphery of the first & reverse brake piston.

(4) Apply ATF to the inserted section of the first & reverse brake piston of the transmission case.

(5) Insert the first & reverse brake piston into the transmission case.

AT–67

JAT00172-00150

JAT00173-00000

JAT00174-00151

JAT00175-00152

AT–68

(6) Install the first & reverse brake piston, using the following SSTs.

SSTs: 09351-87201-000

09351-87707-000

09351-87709-000

09351-87710-000

NOTE:

•

When installing the first & reverse brake piston, care must be exercised to ensure that the O-ring may not be deviated from the specified position and may not be scratched.

(7) Remove the aforesaid SST from the transmission case.

(8) Place the first & reverse brake return spring.

(9) Compress the first & reverse brake return spring (seat section), using the following SSTs.

SSTs: 09351-87201-000

09351-87707-000

09351-87709-000

09351-87710-000

NOTE:

•

To prevent deformation, be sure to stop tightening the

SST when the first & reverse brake return spring has been lowered 1 to 2 mm from the snap ring installation groove.

(10) Install the shaft snap ring, using snap ring pliers.

NOTE:

•

Do not expand the ring excessively.

•

Make sure that the end gap of the shaft snap ring is not aligned with the stopper section of the spring retainer claw.

(11) Remove the B2 inspection plug.

SST

JAT00176 -00153

JAT00177-00000

JAT00178-00154

JAT00179-00155

JAT00180-00156

2. Measure the inner diameter of the planetary output shaft subassembly, using an inner caliper gauge.

Specified Value: 12.000 - 12.018 mm

Allowable Limit: 12.068 mm

NOTE:

•

Perform the measurement at several points. Calculate the mean value.

•

If the measured value exceeds the allowable limit, replace the planetary output shaft subassembly with a new one. Moreover, when replacing the planetary output shaft subassembly, be sure to check the bush contacting surface of the intermediate shaft for scratch or discoloration. If the contacting surface is scratched or discolored, replace the intermediate shaft with a new part.

3. Assembly of planetary output shaft subassembly

(1) Install the radial ball bearing to the transmission case, using the following SST.

SST: 09310-87301-0000

(2) Assemble the hole snap ring into the groove of the transmission case, using snap ring pliers.

NOTE:

•

Replace any scored or deformed hole snap ring with a new one.

(3) Insert the planetary output shaft subassembly into the transmission case as far as it will go.

(4) Install the planetary output shaft subassembly, using the following SST in combination with a hammer.

SST: 09506-87303-000

4. Install the parking lock pawl shaft to the transmission case.

5. Install the parking lock pawl.

6. Install the torsion spring, as indicated in the right figure.

NOTE:

•

Push the parking lock pawl toward the direction (B) and release it. At this time, make sure that the parking lock pawl returns to the original position by the reaction force of the torsion spring.

AT–69

JAT00181-00157

JAT00182-00158

(B)

JAT00183-00159

JAT00184-00160

AT–70

7. Install the output shaft assembly.

NOTE:

•

Securely insert the output shaft assembly into the spline of the planetary output shaft assembly.

8. Installation of transmission case side cover

(1) Apply the Three Bond 1281B to the entire periphery of the transmission case without any discontinuation, as indicated in the right figure.

(2) Assemble the transmission case side cover to the transmission case. Tighten the nine bolts.

Among the nine bolts, one bolt should be tightened together with the oil guide plate (A).

Tightening Torque: 14.7 - 21.6 N·m (1.5 - 2.2 kgf-m)

NOTE:

•

The numerals in the right figure denote the nominal length of each bolt.

•

Make sure that new bolts are used at the three sections (B).

•

Be very careful not to scratch the oil seal lip by the spline of the output shaft when installing the transmission case side cover.

JAT00185-00161

✩

2.5 (Entire

R5 periphery)

✩

Details of bolt hole section at asterisked marks

(A)

JAT00186-00162

(B)35

(B)85

(B)35

JAT00187-00163

9. Install the thrust needle roller bearing to the planetary output shaft subassembly.

Reference Value:

Thrust needle roller bearing dimensions

Outer Diameter: 46.5 mm

Inner Diameter: 25 mm

Thickness: 5 mm

NOTE:

•

Be sure to install the (B) section of the thrust needle roller bearing in such a way that it faces toward the output shaft assembly side.

JAT00188-00164

AT–71

10. Install the planetary gear assembly.

NOTE:

•

Ensure that the planetary gear assembly rotates smoothly.

JAT00189-00165

11. Installation of first & reverse brake

(1) Install the brake cushion plate.

NOTE:

•

Ensure that the stamped mark “O” of the brake cushion plate faces toward the upper side.

JAT00190-00166

(2) Install the plates and discs in the following order.

P = Brake plate, D = Brake disc

P / D / P / D / P / D / P / D

NOTE:

•

Before assembling new discs, soak them in the ATF for at least two hours.

•

Be sure to align the cut-out section of the brake plate with the protruding section of the transmission when installing the brake plate.

(3) Coat the sliding section of the one-way clutch and planetary gear assembly with the ATF.

(4) Install the one-way clutch.

NOTE:

•

Ensure that the one-way clutch with the snap ring faces toward the upside.

•

Align the cut-out section at the inside of the transmission case with the protruding section provided with the groove (O mark) of the one-way clutch.

Disc

Plate

Brake cushion plate

One-way clutch assembly

JAT00191-00167

Transmission case

JAT00192-00168

(5) Measure and record the thickness of the hole snap ring.

NOTE:

•

Replace any scratched or deformed hole snap ring with a new part.

JAT00193-00169

AT–72

(6) Install the hole snap ring to the grooved section of the transmission case.

JAT00194-00170

12. Measurement of first & reverse brake end play

(1) Turn over the transmission case.

JAT00195-00171

(2) Measure the first & reverse brake end play, using a flat thickness gauge.

Specified Value: 1.04 - 1.41 mm

NOTE:

•

The tightness which you encounter during this insertion/withdrawal of the flat thickness gauge should be virtually the same as the tightness which you would encounter during the thickness adjustment of the valve rocker arm.

•

If the measured end play fails to conform to the specified value above, select a snap ring from the right lower table, using the following calculation formula. Then, install it.

JAT00196-00172

Calculation formula

A = B - C + D

A = Thickness of snap ring to be selected

(Refer to the right table.) Measured value of end play

B = Measured value of end play

C = Specified value of end play

D = Thickness of snap ring that has been already installed

JAT00197-00173

Snap ring thickness

Unit: mm

1.97 - 2.03

2.22 - 2.28

2.48 - 2.53

2.72 - 2.78

Part No.

90045-21119-000

90045-21120-000

90045-21121-000

90045-21123-000

JAT00198-00000

13. Installation of transmission brake band assembly-related parts

(1) Install the compression spring to the second brake piston assembly.

(2) Install the 2nd brake piston assembly to the transmission case together with the compression spring.

(3) While compressing the 2nd brake piston with the following SSTs, install the hole snap ring, using snap ring pliers.

SSTs: 09202-87002-000 ... (A)

09202-87202-0A0 ... (B)

(4) Install a new brake band adjusting anchor bolt to the transmission.

NOTE:

•

Be sure to tighten the anchor bolt, until the head section of the anchor bolt appears at the inside of the transmission case, as indicated in the right figure.

(5) With the brake band assembly contracted, assemble the band while aligning its recessed section with the head of the brake band anchor bolt and with the head of the 2nd coast brake piston rod.

NOTE:

•

Before assembling the brake band assembly, soak it in the ATF for at least two hours.

14. Assembly of forward clutch hub and 2nd brake drum

(1) Measure the bush bore diameter of the rear planetary sun gear subassembly.

Specified Value: 15.500 - 15.518 mm

Allowable limit: 15.568 mm

NOTE:

•

The measurement should be performed at several points. Determine the mean value.

•

If the bore diameter exceeds the allowable limit, replace the rear planetary sun gear subassembly.

•

When replacing the rear planetary sun gear subassembly, be sure to check the bush contacting surface of the intermediate shaft subassembly. If the contacting surface is scored or discolored, replace the intermediate shaft subassembly, too, with a new one at the same time.

SST(A)

AT–73

SST(B)

JAT00199-00174

JAT00200-00175

JAT00201-00176

JAT00202-00177

AT–74

(2) Assemble the thrust needle roller bearing to the rear planetary sun gear subassembly.

NOTE:

•

Make sure that the thrust needle roller bearing is assembled in the correct direction.

REFERENCE:

Dimensions of thrust needle roller bearing

Outer diameter: 35.7 mm

Inner diameter: 22.7 mm

Thickness: 2.8 mm

(3) Assemble the rear planetary sun gear subassembly to the planetary gear assembly.

NOTE:

•

Apply ATF to the bush section.

(4) Measure the bush bore diameter of the planetary sun gear subassembly.

Specified Value: 22.020 - 22.038 mm

Allowable Limit: 22.088 mm

NOTE:

•

The measurement should be performed at several points. Determine the mean value.

•

If the bore diameter exceeds the allowable limit, replace the planetary sun gear subassembly.

•

When replacing the planetary sun gear subassembly, be sure to check the bush contacting surface of the rear planetary sun gear subassembly. If the contacting surface is scored or discolored, replace the rear planetary sun gear subassembly with a new one, too, at the same time.

(5) Assemble the planetary sun gear subassembly to the planetary gear assembly.

NOTE:

•

Apply ATF to the bush section.

JAT00203-00178

JAT00204-00179

JAT00205-00180

JAT00206-00181

(6) Assemble the thrust needle roller bearing to the 2nd brake drum.

NOTE:

•

Make sure that the thrust needle roller bearing is assembled in the correct direction.

REFERENCE:

Dimensions of thrust needle roller bearing

Outer diameter: 46.5 mm

Inner diameter: 25 mm

Thickness: 5 mm

(7) Assemble the forward clutch hub to the 2nd brake drum.

(8) Assemble the 2nd brake drum to the transmission case.

15. Assembly of intermediate shaft subassembly

(1) Assemble the thrust needle roller bearing and thrust bearing race to the intermediate shaft subassembly.

NOTE:

•

Make sure that the thrust needle roller bearing is assembled in the correct direction.

REFERENCE:

Dimensions of thrust needle roller bearing

Outer diameter: 32 mm

Inner diameter: 16.5 mm

Thickness: 4.1 mm

(2) Assemble the intermediate shaft subassembly.

NOTE:

•

Be sure to apply ATF to the intermediate shaft subassembly before assembling.

16. Assemble the thrust needle roller bearing to the intermediate shaft subassembly.

NOTE:

•

Make sure that the thrust needle roller bearing is assembled in the correct direction.

REFERENCE:

Dimensions of thrust needle roller bearing:

Outer diameter: 32 mm

Inner diameter: 16.5 mm

Thickness: 4.1 mm

AT–75

JAT00207-00182

JAT00208-00183

JAT00209-00184

JAT00210-00185

Intermediate

JAT00211-00186

AT–76

17. Align the pawls of the clutch disc of the forward clutch with each other.

18. While aligning the pawls of the clutch disc of the forward clutch with the groove of the forward clutch hub and with the groove of the intermediate shaft subassembly, assemble these parts.

19. Measure the height of the forward clutch between the installation section of the oil pump and the thrust bearing race of the forward clutch, using the following SST.

SST: 09351-87208-000

Specified Value: Approx. 54 mm

NOTE:

•

If the actually measured value is less than the specified value, there is the possibility that the pawl section of the forward clutch disc is not fitted in the groove of the forward clutch hub. Be sure to perform the operation of the step 15-(2) again and recheck the specified dimension.

20. Turn the forward clutch clockwise and counterclockwise.

At this time, ensure that the forward clutch turns lightly and the 2nd brake drum makes a relative movement with the forward clutch.

21. Installation of direct clutch

(1) Measure and record the thickness of the thrust bearing race.

(2) Install the thrust bearing race (A).

(3) Install the direct clutch.

(4) Install the direct clutch to the 2nd brake drum while turning the direct clutch clockwise and counterclockwise.

JAT00212-00187

JAT00213-00188

JAT00214-00189

(A)

JAT00215-00190

JAT00216-00191

(5) Confirm the height of the oil pump attaching surface from the upper surface of the direct clutch, using the following SST.

SST: 09351-87208-000

Specified Height: Approx. 22 mm

NOTE:

•

If the actually measured value is less than the specified height, there is the possibility that the two pawls of the clutch disc are not fitted into the groove of the forward clutch. Be sure to perform the operation of the step (4) above again.

22. Inspection of stator shaft & oil pump assembly

(1) Inspection of oil pump operation

Ensure that the oil pump drive gear rotates smoothly, using the following SST.

SST: 09351-87206-000

NOTE:

•

Be sure to insert the flat sections (2 points) of the SST into the flat sections of the oil pump drive gear.

(2) Measure the inner diameter of the oil pump bush section, using an inner caliper gauge.

Unit: mm

Specified value Allowable limit

Front side 15.50 - 15.522

15.572

Rear side 21.100 - 21.121

21.171

NOTE:

•

Perform the measurement at several points. Calculate the mean value.

•

If the actually measured value exceeds the allowable limit, replace the stator shaft & oil pump assembly with a new one.

•

When replacing the stator shaft & oil pump assembly, be sure to check the bush contacting surface of the input shaft subassembly. If the contacting surface is scratched or discolored, replace the input shaft subassembly with a new one, too, at the same time.

23. Check of input shaft end play

(1) Apply a small amount of vaseline to the protruding sections (2 points) of the clutch drum thrust washer.

AT–77

JAT00217-00192

JAT00218-00193

JAT00219-00194

JAT00220-00195

JAT00221-00196

AT–78

(2) Install the clutch drum thrust washer by aligning its protruding section with the recessed section of the oil pump assembly.

NOTE:

•

Be sure to apply vaseline in a small amount enough to prevent the clutch drum thrust washer from dropping.

(3) Apply a small amount of vaseline to the race side of the thrust needle roller bearing.

NOTE:

•

Be sure to apply vaseline in a small amount enough to prevent the thrust needle roller bearing from dropping.

(4) Install the thrust needle roller bearing to the oil pump assembly.

NOTE:

•

Ensure that the section (A) of the thrust needle roller bearing race faces toward the oil pump assembly side.

Reference Value:

Thrust needle roller bearing dimensions

Outer Diameter: 35.7 mm

Inner Diameter: 22. 7 mm

Thickness: 2.8 mm

(5) Install the following SST to the transmission case.

SST: 09351-87207-000

SST

(6) Align the attaching holes (sections (A)) of the stator shaft & oil pump assembly with the SST that has been installed at the step (5).

JAT00222-00197

JAT00223-00198

JAT00224-00199

JAT00225-00200

JAT00226-00201

AT–79

(7) Apply the ATF to the outer periphery of the stator shaft

& oil pump assembly.

(8) Install the stator shaft & oil pump assembly to the transmission case.

NOTE:

•

Be very careful not to damage or twist the O-ring during the installation of the stator shaft & oil pump assembly.

(9) Tighten the seven bolts of the stator shaft & oil pump assembly.

Tightening Torque: 6.9 - 9.8 N·m (0.7 - 1.0 kgf-m)

NOTE:

•

Be sure to tighten the bolts alternately and diagonally.

JAT00227-00202

JAT00228-00203

(10) Measure the input shaft end play with a dial gauge and the following SST.

SST: 09351-87210-000

Specified Value: 0.28 - 0.92 mm

NOTE:

•

If the measured end play exceeds the specified value, remove the stator shaft & oil pump assembly and the direct clutch from the transmission case. Then, select the thickness of the thrust bearing race from the right lower table. Proceed to perform the operations of the steps from 21-(2) to 23-(10).

JAT00229-00204

Thrust Bearing Race Availability

Thrust bearing race thickness Unit: mm

Part No.

1.55 - 1.65

35789-87208-000

1.95 - 2.05

2.35 - 2.45

35789-87209-000

35789-87210-000

JAT00230-00000

AT–80

24. Assembly of stator shaft & oil pump assembly

(1) Coat a new O-ring of the stator shaft & oil pump assembly with the ATF.

(2) Install the two new clutch drum oil seal rings to the stator shaft & oil pump assembly.

NOTE:

•

Do not spread the new oil seal rings excessively.

(3) Coat a new O-ring of the stator shaft & oil pump assembly with the ATF.

(4) Install the new O-ring to the stator shaft & oil pump assembly.

(5) Assemble the stator shaft & oil pump assembly, following the procedure given in the steps 23-(1) through 23-

(9).

(6) Install a new T-type oil seal, using the following SST.

SST: 09310-87301-000

NOTE:

•

Make sure that the T-type oil seal is in contact at right angles with the stator shaft & oil pump assembly when installing the oil seal.

25. Install the roller, compression spring and bolt to the transmission case in this order.

Tightening Torque: 6.9 - 9.8 N·m (0.7 - 1.0 kgf-m)

26. Assemble the manual valve lever subassembly to the parking lock rod subassembly in advance.

NOTE:

•

Apply ATF to the arrow-headed section indicated in the right figure.

JAT00231-00205

SST

JAT00232-00206

JAT00233-00207

JAT00234-00208

27. Install the parking lock rod subassembly and parking lock pawl cam support, as indicated in the right figure. Tighten the three bolts.

Tightening Torque: 14.7 - 17.7 N·m (1.5 - 1.8 kgf-m)

NOTE:

•

Tightening should be made in the following sequence:

(A) (Tighten temporarily.)

(B) (Tighten securely.)

28. Installation of manual valve lever shaft assembly

(1) Install the manual lever shaft subassembly.

NOTE:

•

Care must be exercised so that the lip of the oil seal may not be scratched when installing the shaft.

(2) Install a new slotted spring pin, using a pin punch and a hammer.

NOTE:

•

Be sure to positively install the new slotted spring pin, until it becomes flush with the edge surface of the manual valve lever.

29. Install the solenoid wire assembly to the transmission case.

Tightening Torque: 6.9 - 9.8 N·m (0.7 - 1.0 kgf-m)

NOTE:

•

Apply ATF to the outer periphery of the O-ring of the solenoid wire assembly. Care must be exercised so that the O-ring may not be caught in when inserting it.

30. Adjustment of brake band

(1) Set the brake band parallel to the 2nd brake drum.

(C)

(B)

(A)

AT–81

JAT00235-00209

JAT00236-00210

JAT00237-00211

JAT00238-00212

(2) Tighten the brake band adjusting anchor bolt, until the

E-ring (A) of the 2nd coast brake piston slightly floats.

(3) At the time when the E-ring of the 2nd coast brake piston floats, stop tightening the brake band adjusting anchor bolt.

JAT00239-00213

AT–82

(4) Under the condition of the step (3) above, loosen the brake band anchor bolt 3.2 turns counterclockwise (direction (A)).

JAT00240-00214

(5) Install the nut to the brake band anchor bolt.

(6) While holding the brake band anchor bolt by means of a screwdriver or the like, tighten the nut.

Tightening Torque: 22.5 - 30.4 N·m (2.3 - 3.1 kgf-m)

JAT00241-00215

31. Install the roller for the manual valve lever shaft subassembly as illustrated in the right figure.

NOTE:

•

Make sure that the roller edge surface is lower than the transmission case edge surface.

32. Assembly of C2 accumulator piston

(1) Measure the free length and outer diameter of the C2 accumulator compression spring.

Reference Value:

Free Length: 85.8 mm

Outer Diameter: 18.3 mm

(2) Apply ATF to a new C2 accumulator seal No. 1 ring.

Then, assemble the ring to the accumulator No. 2 piston.

NOTE:

•

Do not expand the oil seal ring beyond the minimum extent needed for assembly.

•

Be sure to align the opening ends with each other after assembling.

Seal ring

JAT00242-00216

JAT00243-00217

JAT00244-00218

(3) Assemble the compression spring and accumulator

No. 2 piston to the transmission case.

33. Assembly of B1 accumulator piston

(1) Measure the free length and outer diameter of the B1 accumulator compression spring.

Reference Value:

Free Length: 50.5 mm

Outer Diameter: 20 mm

(2) Coat the A section of the new accumulator seal No. 1 and No. 2 ring with ATF.

(3) Install the accumulator seal No. 1 and No. 2 ring to the accumulator No. 1 piston.

NOTE:

•

Do not spread the seal ring end excessively.

(4) Install the accumulator No. 1 piston to the transmission case.

(5) Install the compression spring.

34. Assembly of valve body

(1) Ensure that the manual valve operates smoothly without any binding.

(2) Set the manual valve to the neutral position, using the following SST.

SST: 09351-87211-000

AT–83

JAT00245-00219

JAT00246-00220

JAT00247-00221

JAT00248-00222

JAT00249-00223

AT–84

(3) Install the valve body assembly with the aforesaid SST to the transmission case.

NOTE:

•

Ensure that the protrusion of the manual valve lever (A) and grooved section of the manual valve (B) are matched securely.

(4) Tighten the bolts of the valve body assembly.

Tightening Torque: 6.9 - 9.8 N·m (0.7 - 1.0 kgf-m)

NOTE:

•

The numeral in the right illustration indicates the nominal length of the bolt.

•

If the bolt is tightened with any oil getting to the bolt’s threaded portion, it may cause the bolt looseness.

Therefore, be sure to clean the bolt threaded portion by applying compressed air.

•

Care must be exercised so that the wire may not be caught in between the transmission case and the valve body assembly.

(5) Connect the connector of the solenoid wire assembly.

(A)

(B)

JAT00250-00224

JAT00251-00225

JAT00252-00226

35. Tighten the (A) bolt firstly with the aforesaid SST. Then, proceed to tighten the (B) bolt of the manual detent spring.

Tightening Torque: 6.9 - 9.8 N·m (0.7 - 1.0 kgf-m)

NOTE:

•

The numeral in the right figure indicates the nominal length of the bolt.

(A) = 12 mm (B) = 40 mm

•

Be sure to tighten the bolts alternately.

36. Assembly of oil strainer

(1) Coat a new O-ring (A) with ATF.

(2) Install the new O-ring to the groove section of the valve body.

(B)

(A)

JAT00253-00227

O-ring

JAT00254-00228

48.5

AT–85

48.5 (A)

(3) Apply ATF to the O-ring contact section of the oil strainer.

(4) Install the valve body tube (A).

(5) Install the oil strainer with the 3 bolts.

Tightening Torque: 6.9 - 9.8 N·m (0.7 - 1.0 kgf-m)

NOTE:

•

The numeral in the right illustration indicates the nominal length of the bolt.

•

Be sure to tighten the bolts alternately and diagonally.

37. Assembly of throttle cable

(1) Coat a new O-ring with the ATF.

(2) Install the new O-ring to the throttle cable.

(3) Insert the throttle cable to the transmission case.

(4) Tighten the throttle cable with a bolt.

Tightening Torque: 6.9 - 9.8 N·m (0.7 - 1.0 kgf-m)

(5) Connect the throttle cable to the throttle valve cam.

38. Assembly of oil pan

(1) Place the transmission magnet in the protrusion (A) of the transmission oil pan assembly.

(2) Apply the Three Bond 1281B to the entire periphery of the oil pan without any discontinuation, as indicated in the right figure.

NOTE:

•

Be very careful not to get oil to the application surface.

(3) Install the new transmission oil pan assembly with the

14 bolts.

Tightening Torque: 6.9 - 9.8 N·m (0.7 - 1.0 kgf-m)

NOTE:

•

Be sure to tighten the bolts alternately and diagonally.

•

When installing the transmission oil pan, be very careful not to allow the oil pan to come in contact with any inside part.

48.5

JAT00255-00229

JAT00256-00230

(A)

Transmission magnet

JAT00257-00231

3.8 mm

JAT00258-00232

JAT00259-00233

AT–86

39. Clean the contact surface between the transmission case side cover subassembly and the transfer assembly, using solvent or the like.

40 Apply the following bond to the transmission case side cover subassembly surface as shown in the right figure.

Specified Bond: Three bond 1216 or 1217

NOTE:

•

Be sure to apply the bond to the entire periphery without any discontinuation.

41. Install the needle roller bearing to the forward end of the output shaft assembly.

1 mm

JAT00260-00234

42. Install the transfer assembly. Tighten the seven bolts.

Tightening Torque: 29.4 - 44.1 N·m (3.0 - 4.5 kgf-m)

NOTE:

•

The numerals in the right figure denote the nominal length of each bolt. (Unit: mm)

170

JAT00261-00235

170

JAT00262-00236

43. Tighten nine new inspection plugs to the transmission case.

Tightening Torque: 6.9 - 9.8 N·m (0.7 - 1.0 kgf-m)

JAT00263-00237

44. Adjustment of neutral start switch

(1) Temporarily tighten the bolt of the neutral start switch assembly.

JAT00264-00238

AT–87

(2) Place the transmission control shaft lever subassembly.

(3) Push the transmission control shaft lever subassembly toward the front side (ie:

∏ range)

(4) Back off the lever two notches to the NEUTRAL position

(5) Remove the transmission control shaft lever subassembly.

(6) Install the following SST

SST: 09302-87201-000

(7) Adjust the neutral start switch assembly until the neutral basic line should be aligned with the SST above.

(8) Tighten the bolt.

Tightening Torque: 14.7 - 21.6 N·m (1.5 - 2.2 kgf-m)

45. Tighten the transmission control shaft lever subassembly with a nut.

Tightening Torque: 9.8 - 15.7 N·m (1.0 - 1.6 kgf-m)

D N R

JAT00265-00239

SST

Scribed line

JAT00266-00240

JAT00267-00241

46. Install the control cable bracket. Tighten the two bolts.

Tightening Torque: 14.7 - 21.6 N·m (1.5 - 2.2 kgf-m)

47. Secure the connectors of the neutral start switch assembly

(B) and solenoid wire assembly (A), respectively, to the control cable bracket.

(B)

(A)

48. Installation of governor valve.

(1) Place the ball into the transmission case side cover.

JAT00268-00242

JAT00269-00243

AT–88

(2) Coat the whole of governor body assembly with ATF.

(3) Install the governor body assembly into the transmission case side cover.

JAT00270-00244

(4) Coat a new O-ring with ATF.

(5) Install the new O-ring to the governor cover.

(6) Install the governor cover to the transmission case side cover.

NOTE:

•

Be very careful not to damage the new O-ring during installation.

(7) Install the hole snap ring, using standard pliers.

NOTE:

•

Make sure that the hole of the snap ring comes in the slant line section indicated in the right figure when assembling.

49. Assemble the union bolts (B) with a new gasket interposed. (B)

Tightening Torque: 29.4 - 39.2 N·m (3.0 - 4.0 kgf-m)

50. Tighten the breather plug (A).

Tightening Torque: 6.9 - 9.8 N·m (0.7 - 1.0 kgf-m)

51. Assemble the clamp (C) for the throttle cable. Tighten the bolt to the specified torque.

Tightening Torque: 6.9 - 9.8 N·m (0.7 - 1.0 kgf m)

JAT00271-00245

(B)

2 mm-dia. hole

JAT00272-00246

(B)

(A)

(C)

JAT00273-00247

AT–89

52. Coat a new O-ring with the ATF.

53. Install the new O-ring to the transmission oil filler tube subassembly.

NOTE:

•

Be very careful not to twist or damage the O-ring during the installation of the transmission oil filler tube subassembly.

54. Insert the transmission oil filler tube subassembly to the transmission case.

55. Tighten the transmission oil filler tube subassembly with the bolt.

Tightening Torque: 6.9 - 9.8 N·m (0.7 - 1.0 kgf-m)

JAT00274-00248

56. Install the power train stiffener. Tighten the bolts in the following sequence.

(1) Temporarily tighten the bolt (A) and bolt (D).

(2) Securely tighten the bolt (B).

(3) Tighten the bolts in the sequence of the bolt (A), bolt

(D) and bolt (C).

Tightening Torque: 29.4 - 44.1 N·m (3.0 - 4.5 kgf-m)

(A)

(B)

(C)

(D)

JAT00275-00249

AT–90

INSTALLATION AND REMOVAL OF CONTROL CABLE AND FLOOR

SHIFT

COMPONENTS

: Tightening torque

Unit : N·m (kgf-m)

w q

B e

14.7 - 21.6

(1.5 - 2.2)

B r

6.9 - 9.8

(0.7 - 1.0) q

Console rear box assembly w

Console panel with shifting hole vessel e

Control cable assembly

1. Main points of removal

NOTE:

•

Be very careful not to rock the control cable end (both shift lever side and transmission side) beyond 8 degrees. Also, never apply any load to it.

14.7 - 21.6

(1.5 - 2.2)

9.8 - 15.7

(1.0 - 1.6)

JAT00276-00250

(1) Remove the control cable assembly.

1) First, confirm that a white mark for identifying the upper side and lower side is put on the upper side of the cable end. Then, remove the control cable assembly at the transmission side. If the mark is erased, put a mark.

JAT00277-00251

Vehicle upper side mark

JAT00278-00252

AT–91

2. Check

(1) Check that the inner cable of the control cable assembly slides smoothly. Also, check that the control cable assembly exhibits no damage and deformation, such as rapture of the boot.

Rapture of boot

JAT00279-00253

3. Main points of installation

(1) Install the control cable assembly.

1) Move the shift lever and transmission control shaft lever to the

ˆ range.

2) Connect the control cable (at the shift lever side) to the floor shift assembly so that the flange section of the collar may come at the lever side. Then, secure the control cable with the clip.

3) Install the control cable end at the transmission side to the transmission control shaft lever assembly, while making sure that the white mark for identifying the upper side and lower side comes at the upper side.

Tightening Torque: 6.9 - 9.8 N·m (0.7 - 1.0 kgf-m)

D N R

JAT00280-00254

Flange section

JAT00281-00255

Vehicle upper side mark

JAT00282-00256

AT–92

APPENDIX

SSTs (Special Service Tools)

Shape

Part No.

09302-87201-000

09325-87201-000

09202-87002-000

09301-87702-000

09308-10010-000

09309-87203-000

09309-87502-000

09310-87301-000

09527-87301-000

09820-00021-000

09306-87302-000

Part name

Neutral start switch adjusting gauge

Automatic transmission pressure gauge

No. 1 adapter

Valve cutter remover & replacer

Clutch guide tool

Oil seal puller

4M/T friction dumper No. 2 replacer

Countershaft front bearing replacer

Rear axle shaft bearing remover

Alternator rear bearing puller

Counter gear front bearing puller

Shape Part No.

09350-87202-000

09351-87201-000

09351-87203-000

09351-87206-000

09351-87207-000

09351-87208-000

09351-87210-000

09351-87211-000

Part name

AT–93

Automatic transmission tool set

Piston spring No. 1 compressor

Dial gauge attachment

Oil pump driver

Oil pump guide

Direct & forward clutch measure

Dial gauge stand base

Manual valve setting tool

09350-87704-000 Automatic tool set

09351-87707-000

09351-87709-000

09351-87710-000

Piston spring No. 1 compressor

Brake piston rod

Brake piston plate

JAT00283-00257

AT–94

SERVICE SPECIFICATIONS

Items

Free play of input shaft

Bush bore diameter of direct clutch drum subassembly

Stroke of direct clutch piston

End play of direct clutch

End play of 1st & reverse brake

Bush bore diameter of planetary sun gear subassembly

Bush bore diameter of rear planetary sun gear subassembly

Bush bore diameter of planetary output shaft subassembly

Bush bore diameter of stator shaft

& oil pump assembly

Front side

Rear side

Dimensions of compression spring for accumulator C2 piston

Dimensions of compression spring for accumulator B1 piston

Free length

Outer diameter

Free length

Outer diameter

The number in brackets < > denotes the reference value.

Specified value

0.28 - 0.92

44.000 - 44.025

1.22 - 1.53

0.77 - 1.08

1.04 - 1.41

22.020 - 22.038

15.500 - 15.518

12.000 - 12.018

15.500 - 15.522

21.100 - 21.121

⟨

85.8

⟩

⟨

18.3

⟩

⟨

50.5

⟩

⟨

20.0

⟩

Allowable limit

Unit: mm

—

44.075

—

22.088

15.568

12.068

15.572

21.171

—

JAT00284-00000

TIGHTENING TORQUE

Tightening components

Drive plate

Crankshaft

Transmission

Engine direct-connecting bolt

Torque convertor

Drive plate

Power train stiffener

Engine, Transmission

Starter shaft & oil pump

Transmission case

Nut (for brake band anchor bolt)

Transmission case

Roller, bolt for securing spring

Transmission case

Parking lock pawl cam support

Transmission case

Valve body

Transmission case

Manual detent spring

Transmission case

Transmission oil pan

Transmission case

Inspection plugs

Transmission case

Breather plug

Transmission case

Throttle cable

Transmission case

Clamp for throttle cable

Transmission case

Oil strainer

Transmission case

Unions (for oil cooler)

Transmission case

Neutral start switch

Transmission case

Transmission control shaft lever

Manual shaft lever

Control cable bracket

Transmission case side cover

Transmission oil filter tube

Transmission case

Transmission case side cover

Breather plug

Transmission case side cover

Solenoid wire assembly

Transmission case

Transmission

Transfer

Control cable

Transmission control shaft lever

Drain plug

Oil pan

Oil cooler

Oil cooler bracket

Power train stiffener

Transmission, Transfer

M10

AT–95

N·m

78.45 - 98.07

49.04 - 68.64

Tightening torque kgf-m

8.0 - 10.0

5.0 - 7.0

29.4 - 44.1

14.7 - 21.6

29.4 - 44.1

3.0 - 4.5

1.5 - 2.2

3.0 - 4.5

6.9 - 9.8

22.5 - 30.4

6.9 - 9.8

14.7 - 17.7

6.9 - 9.8

29.4 - 39.2

14.7 - 21.6

9.8 - 15.7

14.7 - 21.6

6.9 - 9.8

14.7 - 21.6

0.7 - 1.0

2.3 - 3.1

0.7 - 1.0

1.5 - 1.8

0.7 - 1.0

3.0 - 4.0

1.5 - 2.2

1.0 - 1.6

1.5 - 2.2

0.7 - 1.0

1.5 - 2.2

0.7 - 1.0

6.9 - 9.8

29.4 - 44.1

6.9 - 9.8

19.6 - 29.4

6.9 - 9.8

29.4 - 44.1

3.0 - 4.5

0.7 - 1.0

2.0 - 3.0

0.7 - 1.0

3.0 - 4.5

JAT00285-00000

DAIHATSU

J100

TRANSFER

DESCRIPTION ............................................. TR– 2

CENTER DIFFERENTIAL SYSTEM

......... TR– 2

OPERATION OF CENTER

DIFFERENTIAL LOCK SYSTEM

......... TR– 2

IN-VEHICLE INSPECTION .......................... TR– 4

COMPONENTS ........................................... TR– 5

REMOVAL .................................................... TR– 5

DISASSEMBLY ............................................ TR– 8

INSPECTION ............................................... TR–10

ASSEMBLY .................................................. TR–15

INSTALLATION ........................................... TR–17

SSTs ............................................................ TR–20

TIGHTENING TORQUE ............................... TR–20

JTR00001-00000

NO. 9710-JE

TR–2

DESCRIPTION

A driving system equipped with a center differential is employed.

Transmission

Transfer

Engine

Center differential

Rear differential

Front differential

JTR00002-00101

CENTER DIFFERENTIAL SYSTEM

The input power from the transmission of the driving system is always distributed to the front and rear wheels. The transfer system employs a negative pressure-driving actuator type, with a center differential lock mechanism.

The negative pressure which has been taken from the intake manifold is transmitted to a diaphragm type actuator provided inside the transfer case.

The negative pressure is controlled by two VSV’s. For improved response of the actuator, these VSV’s have been installed in the engine compartment.

JTR00003-00102

JTR00004-00103

OPERATION OF CENTER DIFFERENTIAL LOCK SYSTEM

Differential lock switch

VSV2 (green)

VSV1 (blue)

Check valve

To intake manifold

Indicator lamp

Lock

Chamber A

IG S/W

Chamber B

Free

Actuator for transfer

Differential case

Differential clutch hub

JTR00005-00110

1. When center differential lock switch is turned off.

(1) The VSV1 and VSV2 become unenergized. Thus, the

VSV1 is connected to the air filter side. As a result, the transfer actuator chamber B becomes equal to the atmospheric pressure.

(2) On the other hand, the intake manifold negative pressure is transmitted to the check valve, VSV2, and then, transfer actuator chamber A. Consequently, the differential clutch hub assembly of the transfer moves backward. In this way, the center differential is switched to a free state.

2. When center differential lock switch is turned on.

(1) A electric current flows into the VSV1 and VSV2. Thus, the intake manifold negative pressure is transmitted to the check valve, VSV1, and then, transfer actuator chamber B.

(2) On the other hand, the VSV2 is connected to the air filter. As a result, the transfer actuator chamber A becomes equal to the atmospheric pressure.

Consequently, the differential clutch hub assembly of the transfer moves forward, thus engaging with the differential case subassembly. In this way, the center differential becomes in a locked state.

TR–3

VSV2

(green)

To intake manifold

Check valve

Differential lock switch

Chamber B

Free

Chamber A

VSV1

(blue)

JTR00006-00111

VSV2

(green)

To intake manifold

Check valve

Differential lock switch

Chamber B

Free

Chamber A

VSV1

(blue)

JTR00007-00112

VSV2

(green)

To intake manifold

Check valve

Differential lock switch

Lock

Chamber B

VSV1

(blue)

Chamber A

JTR00008-00113

VSV2

(green)

To intake manifold

Check valve

Differential lock switch

Lock

Chamber B

Chamber A

VSV1

(blue)

JTR00009-00114

TR–4

IN-VEHICLE INSPECTION

1. Turn the ignition switch to the “ON” position.

2. Check to see if the indicator will illuminate when the differential lock switch is turned on.

NOTE:

•

If not, check the indicator valve.

3. Turns off the differential lock switch.

4. Disconnect the pipe A. Then, Connect a MityVac to the pipe A.

5. Start the engine.

6. Check to see if the MityVac indicates a negative pressure while keeping the engine revolution speed at idling.

JTR00010-00201

7. Connect the MityVac to the diaphragm with a suitable pipe.

8. Set the MityVac to –200 mmHg manually.

9. Hold the negative pressure of the MityVac at –200 mmHg for about 10 seconds.

NOTE:

•

If the diaphragm exhibits damage, deterioration and so forth, the negative pressure will rapidly return to positive pressure.

10. Disconnect the pipe B.

11. Connect the MityVac to the pipe B.

12. Start the engine. Turns on the differential lock switch.

13. Check to see if the MityVac indicates a negative pressure while keeping the engine revolution speed at idling.

Pipe A

JTR00011-00202

JTR00012-00203

Pipe B

JTR00013-00204

14. Connect the MityVac to the diaphragm with a suitable pipe.

15. Set the MityVac to –200 mmHg manually.

16. Hold the negative pressure of the MityVac at –200 mmHg for about 10 seconds.

NOTE:

•

If the diaphragm exhibits damage, deterioration and so forth, the negative pressure will rapidly return to positive pressure.

JTR00014-00205

TR–5

COMPONENTS

Transfer No. 2

Transfer oil oil plate supply left pipe

T type oil seal

★

K type oil seal

★

Transfer oil supply right pipe

Hanger

Oil seal

★

T type oil seal

★

Diaphragm cylinder cover

Tube

Filler plug

Drain plug

Gasket

Front drive shift link lever sub-assembly

Transfer shift shaft sub-assembly

E ring

Slotted pin

★

O ring

★

Slotted pin

★

Ball

E ring

★

Compression spring

Transfer fork shaft

Hale snap ring

Transfer oil plate

Transfer rear case

Shaft snap ring

★

T type oil seal

Transfer case

★

Differential pinion thrust washer

Differential pinion sub-assembly

Transfer control

Differential case shaft washer

Transfer clutch hub

Transfer output rear shaft

Shaft snap ring

★

Transfer front drive gear bearing inner race

Needle roller bearing

Differential side gear

Differential pinion shaft

Differential No. 2 case sub-assembly

: Non-reusable parts

Differential side gear

Differential side gear thrust washer

Transfer front drive gear

Transfer front drive chain

Transfer gear shift head

Transfer diff. rock shift fork

Compression spring

Needle roller bearing

Radial ball bearing

Speedometer drive gear

Lock nut

★

Bearing

Radial ball bearing

Transfer output front shaft

Radial ball bearing

JTR00015-00301

REMOVAL

1. Remove the transmission & transfer assembly from the vehicle. Refer to MT and AT section of the service manual.

2. Remove the transfer from the transmission by removing the attaching bolts.

NOTE:

•

Never reuse the removed gasket.

JTR00016-00401

3. Drive off the slotted pin of the transfer fork shaft.

JTR00017-00402

TR–6

4. Remove the speedometer shaft sleeve by removing the bolt.

5. Remove the drain plug.

6. Remove the filler plug.

7. Remove the transfer case by removing the attaching bolts.

NOTE:

•

While lightly tapping the transfer case at the rib sections, using a plastic hammer or the like, remove the transfer case.

Filler plug

8. Remove the transfer output front shaft with the radial ball bearings.

Rib section

Drain plug

JTR00018-00403

Rib section

JTR00019-00404

JTR00020-00405

9. Detach the snap ring of the speedometer drive gear.

10. Remove the speedometer drive gear.

JTR00021-00406

11. Remove the lock nut of the radial ball bearing in the transfer output rear shaft.

NOTE:

•

Release the staking of the lock nut, using a suitable chisel and a hammer.

•

Prior to loosen the nut, grab the shaft by the vise with the soft metal for not rotating.

(Be careful not to damage the shaft.)

•

Never reuse the removed nut.

JTR00022-00407

TR–7

12. Remove the radial ball bearing in combination with the gear, using the following SST.

SST: 09306-87602-000

13. Remove the transfer output rear shaft with differential gear.

JTR00023-00408

JTR00024-00409

14. Remove the ring retainer of the bearing.

15. Remove the radial ball bearing with the transfer clutch inner hub from the transfer case.

16. Drive off the slotted pin of the transfer gear shift head.

17. Remove the E ring.

18. Remove the following parts.

(1) Transfer fork shaft

(2) Compression spring

(3) Transfer control shaft washer

(4) Shaft snap ring

(5) O ring

(6) Transfer differential lock shift fork

(7) Transfer clutch outer hub

(8) Transfer gear shift head

E ring

JTR00025-00410

JTR00026-00411

JTR00027-00412

TR–8

19. Remove front drive shift link lever sub-assembly and E ring.

20. Remove the diaphragm cylinder cover.

JTR00028-00413

JTR00029-00414

21. Remove the transfer shift shaft sub-assembly from the diaphragm cylinder.

DISASSEMBLY

1. Disassemble the transfer clutch inner hub and the radial ball bearing, using the following SST in conjunction with a press.

SST: 09310-87102-000

09253-87202-000

SST

SST SST

Ring retainer

Bearing

2. Disassemble the following parts.

(1) Transfer front drive gear

(2) Needle roller bearing

(3) Transfer front drive gear bearing inner race

JTR00030-00415

SST

JTR00031-00501

JTR00032-00502

3. Disassemble the rear bearing from the transfer output front drive shaft, using the following SST in conjunction with a press.

SST: 09253-87101-000

09301-87601-000

4. Disassemble the front bearing from the transfer output front drive shaft, using the following SST in conjunction with a press.

SST: 09253-87101-000

5. Remove the transfer output rear shaft and needle roller bearing from the differential case sub-assembly, using the following SST, in conjunction with a press.

SST: 09238-87202-000

6. Push the differential pinion shafts by pushing it with your fingers.

7. Remove the differential case No. 2 case sub-assembly.

TR–9

JTR00033-00503

JTR00034-00504

JTR00035-00505

JTR00036-00506

JTR00037-00507

TR–10

8. Remove the following parts from the differential case.

(1) Differential side gear No. 2

(2) Differential side gear

JTR00038-00508

(3) Differential pinion shafts

(4) Differential pinions

(5) Differential pinion thrust washers

JTR00039-00509

INSPECTION

1. Bearings

Visually inspect the roller and roller guide surface for seizure due to poor oil lubrication and so forth.

JTR00040-00601

2. Needle roller bearings

Check the roller outer periphery of the needle roller bearing for damage by scratching it by your fingernails. Also, visually inspect the roller outer periphery for seizure due to poor oil lubrication or use of deteriorated oil.

3. Check the fitting section (A) and spline section (B) of the transfer output rear shaft and the spline section (C) of the transfer output front shaft for damage or abnormal wear.

JTR00041-00602

JTR00042-00603

TR–11

4. Visually inspect the transfer front drive gear and the transfer output front shaft gear for damage or wear.

JTR00043-00604

5. Visually inspect the transfer front drive chain for damage or wear.

6. Check the contact surface between the differential lock shift fork (A) and the transfer clutch outer hub (B).

Unit: mm

Allowable limit

(A)

(B)

Specified value

–0.1

–0.2

7.2

+0.06

6.7

7.3

7. Measure the outer diameter of the shaft and socket section.

If the measured valve does not conform to the specification, replace the parts.

Also inspect the snap ring for damage or wear.

Unit: mm

Allowable limit

(A)

(B)

Outer diameter of the shaft

Specified value

–0

–0.1

–0

–0.1

–0.13

–0.063

11.8

←

8. Visually inspect the transfer shift shaft for damage or wear.

NOTE:

•

Also inspect the diaphragm for damage.

JTR00044-00605

(A)

(B)

JTR00045-00606

JTR00046-00607

JTR00047-00608

TR–12

9. Visually inspect the transfer gear shift head for damage or wear

NOTE:

•

Also inspect the ball and compression spring for damage or wear.

10. Measure the outer diameter of the transfer fork shaft.

If the measured value does not conform to the specification, replace the shaft.

Also inspect the compression spring and the transfer control shaft washer for damage or wear.

Unit: mm

Specified value

–0.043

11. Measure the outer and inner diameter of the transfer front drive gear bearing inner race.

Unit: mm

Specified value Allowable limit

Inner diameter

+0.02

+0.002

26.020

Outer diameter

–0

–0.014

38.986

12. Visually inspect the differential pinion for damage or wear.

13. Visually inspect the differential side gear for damage or wear.

14. Measure the thickness of the differential pinion thrust washer.

Unit: mm

Specified value 0.8

0.06

Allowable limit 0.74

JTR00048-00609

JTR00049-00610

JTR00050-00611

JTR00051-00613

JTR00052-00614

15. Visually inspect the differential case sub-assembly for damage or wear.

16. Measure the outer diameter of the differential pinion shaft.

17. Measure the inner diameter of the differential pinion.

Specified value

Unit: mm

Allowable limit

Pinion

Inner diameter

+0.06

+0.03

15.06

Pinion

Shaft

Outer diameter

–0.016

–0.043

14.943

18. Measure the inner diameter of the transfer front and rear output shaft bearing.

NOTE:

•

If the measured value does not conform to the specification, replace the transfer case.

Output front shaft bearing

Output rear shaft bearing

Front

Rear

Front

Rear

Unit: mm

Inner diameter specified value

–.0

–0.010

–.0

–0.008

–.0

–0.012

–.0

–0.010

19. Visually inspect the type T oil seal in the diaphragm cylinder for damage or wear.

NOTE:

•

Replace the oil seal if it exhibits damage or wear.

20. Visually inspect the type K oil seal of the front drive shift link lever for damage or wear.

NOTE:

•

Replace the oil seal if it exhibits damage or wear.

TR–13

JTR00053-00615

JTR00054-00617

JTR00055-00618

JTR00056-00619

JTR00057-00620

TR–14

21. Visually inspect the type T oil seal of the transfer output rear shaft for damage or wear.

NOTE:

•

Replace the oil seal if it exhibits damage or wear.

SST: 09308-10010-000

09309-87201-000

22. Visually inspect the transfer rear drive output shaft inner oil seal for damage or wear.

NOTE:

•

Replace the oil seal if it exhibits damage or wear.

23. Visually inspect the type T oil seal of the transfer output front shaft for damage or wear.

NOTE:

•

Replace the oil seal if it exhibits damage or wear.

SST: 09308-10010-000

09309-87201-000

JTR00058-00621

JTR00059-00622

JTR00060-00623

TR–15

ASSEMBLY

NOTE:

•

Prior to the assembly, clean the transfer case and the parts by removing any dirt or the like. And then, apply gear oil to the all parts.

1. Press the radial ball bearing (Front) to the transfer output front shaft.

2. Press the radial ball bearing (Rear) to the transfer output front shaft, using the following SST.

SST: 09238-87202-000

SST

JTR00061-00701

3. Press the radial ball bearing to the transfer inner hub, using the following SST.

SST: 09388-20010-000

NOTE:

•

Make sure that the groove section of the redial ball bearing comes upper side.

4. Install the differential side gear to the differential case.

5. Install the differential pinion shafts, the differential pinions and the differential pinion thrust washers to the differential case No. 2.

NOTE:

•

Make sure that the machine-ground side of the differential pinion shaft section faces toward differential side gear.

6. Align the pinion shafts and shaft holes. Then, Insert the differential case sub-assembly to the differential case

No. 2.

SST

JTR00062-00702

Machine ground side

Groove section

JTR00063-00703

Differential case No. 2

Differential case

JTR00064-00705

JTR00065-00706

TR–16

7. Push the pinion shaft in the shaft hole with finger to the differential case outside so as to the transfer output rear shaft can go through.

8. Install the new snap ring to the transfer output rear shaft.

Shaft hole

JTR00066-00707

Snap ring

JTR00067-00708

9. Install the needle roller bearing to the transfer output rear shaft with applying the gear oil for not to fall off.

Oil: API GL-3, SAE75W-85

JTR00068-00709

10. Insert the transfer output front shaft with the needle roller bearing to the differential case assembly, using a press.

NOTE:

•

Make sure that the transfer output rear shaft rotates smoothly when inserting has been done.

JTR00069-00710

INSTALLATION

1. Install the transfer shift shaft sub-assembly to the diaphragm cylinder.

2. Install the front drive shift link lever to the transfer case.

NOTE:

•

Make sure that the drive shift link lever is fitted securely in the groove.

Shaft

3. Install the diaphragm cylinder cover to the diaphragm cylinder and tighten the bolts.

Tightening Torque: 14.7 - 21.6 N·m (1.5 - 2.2 kgf-m)

TR–17

Groove section

JTR00070-00802

JTR00071-00803

4. Install the radial ball bearing with the transfer clutch inner hub to the transfer case.

5 Install the snap ring to the radial ball bearing.

NOTE:

•

Make sure that the snap ring is fitted securely in the groove.

6. Insert the transfer output rear shaft and center differential assembly to the transfer clutch inner hub.

7. Install the transfer clutch outer hub to the transfer clutch inner hub.

8. Install the differential lock shift fork to the transfer clutch outer hub.

9. Insert the transfer fork shaft with the compression spring and transfer control shaft washer to the differential lock shift fork.

10. Insert the transfer fork shaft with the transfer differential lock shift fork. to the transfer case.

11. Install the compression spring and ball to the transfer gear shift head.

12. With the ball pushed down by means of a suitable rod from the hole section of the head, insert the transfer gear shift head to the transfer fork shaft.

13. Drive new slotted pin to the transfer gear shift head.

Install the new E ring.

E ring

JTR00072-00805

JTR00073-00810

Slotted pin

JTR00074-00813

TR–18

14. Insert the transfer front drive gear to the transfer output rear shaft.

15. Install the transfer output front shaft with the chain to the transfer case.

NOTE:

•

Prior to the installation, make sure that the chain is set to the both gears.

(After the installation, the chain will not be able to set.)

16. Install the radial ball bearing to the transfer output rear shaft.

17. Install new lock nut to the transfer output rear shaft and tighten the lock nut.

Tightening Torque:

225.6 - 264.8 N·m (23.0 - 27.0 kgf-m)

NOTE:

•

When staking the lock nut, point a suitable staking tool toward the transfer output rear shaft axis center and stake to lock nut securely.

•

Prior to install new lock nut, grab the shaft by the vise with the soft metal for not rotating.

18. Insert the speedometer drive gear to the transfer output rear shaft.

19. Install new snap ring of the speedometer drive gear.

NOTE:

•

Make sure that the snap ring is fitted securely in the groove.

20. Install new “O” ring to the transfer fork shaft.

NOTE:

•

Prior to the installation of a new “O” ring, wind a suitable vinyl sheet around the transfer fork shaft and apply gear oil to the “O” ring installing section.

JTR00075-00815

JTR00076-00817

JTR00077-00819

21. Apply the liquid gasket interposed, assemble the transfer case and transfer case No. 2 by tapping it evenly and lightly at the rib sections (A), (B) and (C) by means of a plastic hammer or the like.

22. Tighten the transfer case with the bolts.

Tightening Torque: 14.7 - 21.6 N·m (1.5 - 2.2 kgf-m)

NOTE:

•

Be sure to tighten the bolts evenly and diagonally.

•

Prior to the tightening of the bolts, apply Three Bond

1216 to the threaded portions of the bolts.

(B)

(A)

JTR00078-00820

(C)

JTR00079-00822

23. Apply gear oil to the “O” ring prior to the insertion of the speedometer shaft sleeve.

24. Insert the speedometer shaft sleeve into the output shaft bearing rear retainer.

25. Tighten the speedometer sleeve lock plate with a bolt.

Tightening Torque: 5.9 - 8.8 N·m (0.6 - 0.9 kgf-m)

26. Tighten the transfer drain plug with new gasket.

Tightening Torque: 29.4 - 49.0 N·m (3.0 - 5.0 kgf-m)

27. Install the transfer assembly to the transmission. (Refer to the MT or AT section of the service manual.)

28. Fill the transfer with oil.

29. Tighten the transfer filler plugs with new gasket.

Tightening Torque: 29.4 - 49.0 N·m (3.0 - 5.0 kgf-m)

TR–19

JTR00080-00825

JTR00081-00828

TR–20

SSTs

Shape

TIGHTENING TORQUE

Tightening components

Diaphragm cylinder cover

Diaphragm cover

Radial ball bearing

Transfer output rear shaft

Transfer case

Transfer case No. 2

Speedometer sleeve

Transfer case

Transfer filler plug

Transfer case

Transfer drain plug

Transfer case

Part No. and name

09253-87101-000

Transfer output front shaft bearing anvil

09238-87202-000

Transfer output front shaft rear bearing replacer

09253-87202-000

Transfer clutch inner hub bearing anvil

09301-87601-000

Tool, clutch guide

09306-87602-000

Transfer output rear shaft bearing replacer

09308-10010-000

Oil seal puller

09309-87201-000

Transfer output shaft oil seal replacer

09310-87102-000

Transfer clutch inner hub bearing puller

09388-20010-000

Transfer clutch inner hub bearing replacer

Purpose

Removal of bearing

Removal of output rear shaft

Assembling bearing

Removal of bearing

Removal of oil seal

Assembling oil seal

Removal of bearing

N·m

Tightening torque kgf-m

14.7 - 21.6

225.6 - 264.8

14.7 - 21.6

5.9 - 8.8

29.4 - 49.0

1.5 - 2.2

23.0 - 27.0

1.5 - 2.2

0.6 - 0.9

3.0 - 5.0

See page

TR–9

TR–15

TR–8

TR–9

TR–7

TR–14

TR–8

TR–15

JTR00082-00901

Reference

JTR00083-00902

DAIHATSU

J100

PROPELLER SHAFT

COMPONENTS ........................................... PR– 2

IN-VEHICLE INSPECTION .......................... PR– 3

REMOVAL ................................................... PR– 3

INSPECTION ............................................... PR– 4

INSTALLATION ........................................... PR– 5

TIGHTENING TORQUE ............................... PR– 7

JPR00001-00000

NO. 9710-JE

PR–2

COMPONENTS

Front

60.3

9.5 (6.15

0.95)

Rear

60.3

9.5 (6.15

0.95)

36.8

7.3 (3.75

0.75) q

Propeller shaft assembly

: Tightening torque

Unit : N·m (kgf-m)

JPR00002-00001

PR–3

IN-VEHICLE INSPECTION

Ensure that the universal joint section of the propeller shaft exhibits no excessive play by turning it by your hand in up-anddown and right-and-left directions.

If any excessive play exists, replace the propeller shaft with a new one.

REMOVAL

1. Jack up the vehicle and support it with safety stands. (As for the jacking-up points and supporting points for safety stands, refer to the GI section in this service manual.)

2. Put mate marks on the flange yoke and companion flange, respectively.

Front

Rear

JPR00003-00002

Mating marks

JPR00004-00003

3. Remove the two attaching bolts of the center support bearing and support the center bearing with a suitable hanger or jack, etc., so that no bending force may be applied to the center support. (For rear propeller shaft)

CAUTION:

•

Never apply the bending force to the center bearing and No. 2 joint of the rear propeller shaft.

4. Loosen the attaching bolts of the flange yoke evenly.

5. Remove the propeller shaft assembly by removing the attaching bolts and disconnect it from the transfer case.

NOTE:

•

Prior to disconnection of the propeller shaft from the transfer case, drain the transfer oil from the transfer case or prepare a suitable oil stopper and install it immediately after disconnection of the propeller shaft, for quite large amount of the transfer oil will flow out.

Mating marks

JPR00000-00004

JPR00005-00005

JPR00006-00006

PR–4

INSPECTION

Front & rear

1. Check the propeller shaft for evidence of damage or bend.

Limit of bend: 0.5 mm

2. Check the spider bearing cup-fitting section for damage.

3. Check the flange yoke and sleeve yoke.

(1) Inspect to see whether any damage is present at the differential drive pinion companion flange-contact section

(2) Check the oil seal sliding section

B for damage or wear.

(3) Check the spline

C for damage or wear.

(4) Fit the sleeve yoke onto the sliding spline of the transmission output shaft.

Ensure that the spline exhibits no looseness in the rotating direction and the sleeve can slide freely in the axial direction on the spline.

4. Check the universal joint for looseness as follows:

(1) Check the spider for looseness in an axial direction.

(2) Check the spider for looseness in a right-angled-direction.

(3) Check the spider for smooth rotation.

If any damage is found, replace the propeller shaft with a new one.

JPR00007-00007

JPR00008-00008

JPR00009-00009

JPR00010-00010

PR–5

5. Check of universal joint preload

(1) Hook a spring scale at the bolt hole of the flange yoke as well as at the sleeve yoke end.

(2) Gently pull the spring scale to measure the starting torque.

Starting Torque: 0.029 - 1.47 N·m (0.003 - 0.15 kgf-m)

Replace the propeller shaft, if the preload fails to meet the specified value.

Front

Rear

JPR00011-00011

INSTALLATION

1. Apply the specified transmission fluid to both the inner and outer sides of the sleeve.

Specified Gear Oil

Grade: API GL-3 or GL-4

Viscosity: SAE 75W-85 or 75W-90

2. Insert the propeller shaft assembly into the output shaft of the transfer case.

CAUTION:

•

Never insert the propeller shaft to the transfer case by force. Failure to observe this caution may damage the bush or oil seal in the transfer case.

•

Never apply the bending force to the center bearing and No. 2 joint of the rear propeller shaft.

3. Assemble the propeller shaft while aligning it with the mating mark put on the companion flange of the differential.

(As for the illustration, refer to the disassembling procedure.)

CAUTION:

•

Never insert the propeller shaft into the transfer case by force. Failure to observe this caution may damage the bush or oil seal in the transfer case.

•

Never apply the bending force to the center bearing and No. 2 joint of the rear propeller shaft.

JPR00000-00012

Propeller shaft assenbly

JPR00012-00013

JPR00013-00000

PR–6

4. Install the propeller shaft yoke flange to the flange of the differential with new four attaching bolts with washers.

CAUTION :

•

Be sure to clean the attaching surface of the yoke and flange properly. Failure to observe this caution may lead to propeller shaft vibration or damage, etc.

5. Tighten the attaching bolts evenly over two or three stages to the specified tightening torque.

Tightening Torque: 60.3

9.5 N·m (6.15

0.95 kgf-m)

6. Temporarily install the center support with two attaching bolts.

JPR00014-00000

7. Ensure that the clearance between the center bearing support rubber and the dust cover is within the specified value.

Specified clearance: 6 mm or more at installation.

If the clearance fails to meet the specified value, adjust the clearance by adjusting the center support attaching position.

8. Tighten the attaching bolts to the specified tightening torque evenly in two or three stages.

Tightening Torque: 36.8

7.3 N·m (3.75

0.75 kgf-m)

9. Check and fill the specified transfer oil to the transfer case.

(Refer to the TR section.)

10. While turning the propeller shaft, ensure that the propeller shaft turns smoothly without exhibiting abnormal noise and/or binding.

11. Jack down the vehicle and check the clearance between the center support rubber and the dust cover.

12. Ensure that the clearance between the center bearing support rubber and the dust cover is within the specified value.

Specified clearance: 10 mm or more

If the clearance fails to meet the specified value, adjust the clearance by adjusting the center support attaching position. Then, tighten the attaching bolts to the specified tightening torque.

Dust cover

JPR00015-00014

Center bearing support rubber

JPR00016-00015

TIGHTENING TORQUE

Tightening component

Propeller shaft flange

Differential flange

Center bearing support

Body

PR–7

N·m

60.3

9.5

36.8

7.3

Tightening torque kgf-m

6.15

0.95

3.75

0.75

JPR00017-00000

DAIHATSU

J100

FRONT & REAR DIFFERENTIAL

FRONT DIFFERENTIAL .............................. DF– 2

COMPONENTS

...................................... DF– 2

REAR DIFFERENTIAL ................................ DF– 3

COMPONENTS

...................................... DF– 3

IN-VEHICLE SERVICE ................................ DF– 4

REPLACEMENT OF FRONT AND

REAR DIFFERENTIAL COMPANION

FLANGE OIL SEALS

.......................... DF– 4

REPLACEMENT OF FRONT

DIFFERENTIAL SIDE OIL SEAL

......... DF– 7

REMOVAL

............................................... DF– 9

DISASSEMBLY ............................................ DF–11

INSPECTION ............................................... DF–16

ASSEMBLY .................................................. DF–18

INSTALLATION ........................................... DF–25

SSTs ............................................................. DF–28

TIGHTENING TORQUE ............................... DF–30

JDF00001-00000

NO. 9710-JE

DF–2

FRONT DIFFERENTIAL

COMPONENTS

@2 t

83.4 + 4.8

(8.5 + 0.5)

t q w

★ e i

★

@1 t r

u t

49.1 + 9.7

(5.0 + 1.0) y o

11.3 + 1.4

(1.15 + 0.15)

117.7 + 19.5

(12.0 + 2.0)

20.6 + 2.9

(2.1 + 0.3)

36.8 + 7.3

(3.75 + 0.75)

: Tightening torque

★

: Non-reusable parts

Unit : N·m (kgf-m)

Drive pinion companion flange subassembly w

Plate washer e

T type oil seal r

Tapered roller bearing (rear inner) t

Shim y

Differential drive pinion bearing spacer u

Tapered roller bearing (front inner) i

Differential drive pinion o

Breather plug

Differential carrier

Differential bearing cap

W/head straight screw plug

T type oil seal

Lock nut

Bearing

Tapered roller bearing (rear outer)

Differential case

Differential ring gear

Differential front carrier assembly

Front axle housing cover subassembly

Tapered roller bearing (rear inner)

Differential pinion

Differential side gear thrust washer

Differential side gear

Differential pinion shaft

Differential case assembly

Front differential carrier support bracket

JDF00002-00001

DF–3

REAR DIFFERENTIAL

COMPONENTS

@3 q

★

: Non-reusable parts

: Tightening torque

Unit : N·m (kgf-m)

46.6

7.3 (4.75

0.75)

★

117.7

19.6 (12.0

2.0)

★

r w

o u i i o y

83.4

4.9 (8.5

0.5) r e q

Differential cap bearing w

Differential case assembly e

Shim r

Radial ball bearing t

Differential ring gear y

Differential case u

Differential pinion shaft i

Differential pinion o

Differential side gear

Side gear thrust washer

Lock nut

Plate washer

Drive pinion companion flange subassembly

T type oil seal

Tapered roller bearing

Shim

Drive pinion bearing spacer

Tapered roller bearing

Differential drive pinion

Shim

Front tapered roller bearing outer race

Rear tapered roller bearing outer race

Differential carrier

JDF00003-00002

DF–4

IN-VEHICLE SERVICE

REPLACEMENT OF FRONT AND REAR DIFFERENTIAL COMPANION FLANGE OIL

SEALS

NOTE:

•

This section describes the replacement procedure both for the front and rear companion flange oil seals. Therefore, some descriptions and figures may not be applicable or differ from each other.

1. Jack up the vehicle and support it with safety stands. (As for the jacking-up points and support points for safety stands, refer to the GI section.)

JDF00004-00000

Front

2. Drain the differential oil by removing the drain plug and gasket.

CAUTION:

•

Do not reuse the used gasket.

Rear

Filler plug

JDF00005-00003

Drain plug

JDF00000-00004

3. Disconnect the propeller shaft from the companion flange of the front or rear differential.

(Refer to the PR section.)

CAUTION:

• Sling the companion flange of the propeller shaft at the body side with a suitable string or the like to prevent the unnecessary force from applying to the spider section of each universal joint or the center bearing section of the front propeller shaft.

4. Release the staking of the lock nut, using a suitable chisel and a hammer.

JDF00006-00000

JDF00007-00005

DF–5

5. Loosen the lock nut of the companion flange while preventing the companion flange from turning, using the following SST in combination with a long box wrench or the like.

SST: 09330-87301-000

6. Remove the lock nut and plate washer.

CAUTION:

•

Never reuse the removed lock nut and plate washer.

Front

Rear

SST

JDF00008-00006

SST

JDF00000-00007

7. Remove the drive pinion companion flange subassembly.

NOTE:

•

If any difficulty is encountered in removing the companion flange, use the following SST.

SST: 09950-20017-000

8. Remove the T type oil seal, using the following SST.

SST: 09308-10010-000

CAUTION:

•

Do not reuse the used oil seal.

JDF00009-00008

JDF00010-00009

DF–6

9. Clean the T type oil seal attaching surface with a piece of cloth or the like.

10. Thinly apply the lithium soap base multi-propose grease to the lip section of the T type oil seal.

11. Install a new T type oil seal, using the following SST.

SST: 09635-20010-000

CAUTION:

•

Drive the T type oil seal until the outer surface of the T type oil seal becomes flush with the flange surface of the front differential.

12. Install the drive pinion companion flange subassembly, a new washer plate and a new lock nut.

13. Tighten the new lock nut to the specified tightening torque while preventing the companion flange from turning, using the following SST.

SST: 09330-87301-000

Tightening Torque: 98.1 - 137.2 N·m (10.0 - 14.0 kgf-m)

14. Stake the lock nut to the recessed part of the drive pinion shaft, using a suitable chisel or the like properly.

CAUTION:

•

Make sure that the lock section of the nut is positively staked down to the bottom of the drive pinion groove.

Failure to observe this caution may lead to looseness.

15. Connect the propeller shaft.

(Refer to the PR section)

16. Install and tighten the drain plug with a new gasket interposed.

Tightening Torque:

Front 39.3 - 58.8 N·m (4.0 - 6.0 kgf-m)

Rear 53.9 - 68.6 N·m (5.5 - 7.0 kgf-m)

17. Remove the oil filler plug.

18. Fill the specified differential oil from the oil filler plug hole.

Specified differential oil

Grade : API GL-5 (Front & rear)

Viscosity: SAE 80W-90 (Standard)

: SAE 80W-90 LSD (For LSD)

Capacity: 0.7 liters (Front)

1.55 liters (Rear)

NOTE:

•

The specified oil level is 0 to 5 mm from the lower end of the oil filler hole.

19. Install the oil filler plug with a new gasket interposed and tighten it to the specified tightening torque.

Tightening Torque:

Front 39.3 - 58.8 N·m (4.0 - 6.0 kgf-m)

Rear 53.9 - 68.6 N·m (5.5 - 7.0 kgf-m)

20. Jack down the vehicle.

21. Ensure that no oil leakage exists.

Front

Rear

JDF00011-00010

JDF00012-00011

JDF00013-00012

Filler plug

5 mm or less

Drain plug

JDF00014-00013

REPLACEMENT OF FRONT DIFFERENTIAL SIDE

OIL SEAL

1. Jack up the vehicle and support it with stands. (As for the jacking-up points and support points for safety stands, refer to the GI section.)

2. Remove the front wheels.

3. Drain the differential oil by removing the drain plug and gasket.

CAUTION:

•

Do not reuse the removed gasket.

4. Remove the tie rod end attaching castle nut lock clip.

5. Remove the tie rod end attaching castle nut.

6. Disconnect the tie rod end from the steering nuckle, using the following SST.

SST: 09611-87701-000

7. Remove the lock clip of the castle nut for the lower arm.

8. Remove the castle nut for the lower arm.

9. Disconnect the lower arm from the steering nuckle, using the following SST.

SST: 09611-87701-000

CAUTION:

•

Be sure to protect the speed sensor rotor and sensor from damage, using a piece of cloth or the like.

10. Loosen both sides of the suspension support attaching nuts.

CAUTION:

•

Never reuse the used nut.

11. Disconnect the front drive shaft assembly from the front differential, using the following SST.

SST: 09648-87201-000

DF–7

JDF00015-00014

JDF00016-00015

JDF00017-00016

JDF00018-00017

JDF00019-00018

DF–8

12. Remove the T type oil seal, using the following SST.

SST: 09308-00010-000

13. Clean the oil seal attaching surface of the front differential.

14. Apply the lithium soap base multi-purpose grease to the lip section of the new oil seals.

15. Install a new T type oil seal, using the following SST.

SST: 09636-20010-000

16. Apply the lithium soap base multi-purpose grease to the oil seal attaching surface of the drive shafts.

17. Connect the drive shafts to the front differential carrier.

CAUTION:

•

Never made scratch on the oil seal during the connection of driver shaft.

18. Replace the suspension attaching nuts with new ones.

19. Tighten the new suspension attaching nuts evenly until the tightening torque reaches the specified tightening torque.

Tightening Torque: 28.4 - 42.2 N·m (2.9 - 4.3 kgf-m)

CAUTION:

•

Never reuse the used nut.

20. Connect the lower arms to the steering knuckles with a new attaching castle nut and tighten it to the specified tightening torque.

Tightening Torque: 44.1 - 58.8 N·m (4.5 - 6.0 kgf-m)

21. Install new clips securely.

NOTE:

•

Never reuse the used clips.

22. Connect the tie rod end to the steering knuckle with a new attaching castle nut and tighten it to the specified tightening torque.

Tightening Torque: 39.2 - 53.9 N·m (4.0 - 5.5 kgf-m)

23. Install a new clip.

CAUTION:

•

Never reuse the removed clip.

24. Install and tighten the drain plug with a new gasket interposed.

Tightening Torque: 39.3 - 58.8 N·m (4.0 - 6.0 kgf-m)

JDF00020-00019

JDF00021-00020

JDF00022-00021

JDF00023-00022

DF–9

25. Remove the filler plug and gasket.

26. Fill the differential oil from the filler plug.

Specified differential oil

Grade: API GL-5

Viscosity: SAE 80W-90

Capacity: 0.7 liters

NOTE:

•

The specified oil level is 0 to 5 mm from the lower end of the oil filler hole.

27. Install and tighten the filler plug with a new gasket interposed.

Tightening Torque: 39.3 - 58.8 N·m (4.0 - 6.0 kgf-m)

28. Install the front wheels.

29. Jack down the vehicle.

30. Inspect the front wheel alignment.

31. Ensure that no oil leakage exists.

Front

5 mm or less

JDF00024-00023

JDF00025-00024

REMOVAL

NOTE:

•

This section describes the removal procedure both for the front and rear differentials. Therefore, some descriptions and figures may not be applicable or differ from each other.

1. Jack up the vehicle and support it with safety stands. (As for the jacking-up points and support points for safety stands, refer to the GI section.)

2. Remove the front and/or rear wheels.

3. Drain the differential oil by removing the drain plug and gasket.

CAUTION:

•

Never reuse the removed gasket.

4. Disconnect the tie rod end from the steering knuckle. (For front differential)

(Refer to the procedure described in “REPLACEMENT OF FRONT DIFFERENTIAL SIDE OIL SEAL.”)

5. Disconnect the lower arm from the steering knuckle. (For front differential)

(Refer to the procedure described in “REPLACEMENT OF FRONT DIFFERENTIAL SIDE OIL SEAL.”)

6. Loosen the suspension support attaching nuts. (For front differential)

(Refer to the procedure described in “REPLACEMENT OF FRONT DIFFERENTIAL SIDE OIL SEAL.”)

CAUTION:

•

Never reuse the suspension support attaching nuts.

7. Pull out the front drive shaft assembly from the differential carrier assembly, using the following SST.

SST: 09611-87701-000

(Refer to the procedure described in “ REPLACEMENT OF FRONT DIFFERENTIAL SIDE OIL SEAL.”)

8. Remove the propeller shaft assembly. (Refer to the PR section.)

CAUTION:

•

Prior to the disconnection of the propeller shaft from the transfer case, drain the transfer oil or prepare the oil stopper to prevent the transfer oil from flowing out and install it immediately after disconnecting the propeller shaft from the transfer case.

JDF00026-00000

DF–10

9. Support the differential carrier, using a suitable engine hanger, transmission jacks or the like.

10. Remove the three attaching bolts of the differential carrier support bracket and differential carrier assembly.

(Only for front differential.)

11. Remove the differential carrier assembly by removing three attaching bolts of the differential carrier support bracket mount.

(Only for front differential.)

12. Remove the front axle housing cover by removing the attaching bolts.

(Only for front differential.)

NOTE:

•

Be sure to place a suitable container under the front axle housing connected sections, for a large amount of the differential oil may flow out.

13. Remove the rear axle shaft assembly. (Refer to the RS section.)

(Only for rear differential.)

14. Remove the propeller shaft assembly. (Refer to the PR section.)

(Only for rear differential.)

15. Loosen the attaching bolts of the differential carrier assembly evenly.

(Only for rear differential.)

16. Remove the rear differential carrier assembly by removing the attaching bolts.

(Only for rear differential.)

NOTE:

•

It should be noted that a large amount of oil may flow out. Hence, prior to the disconnecting of the differential carrier, place a suitable container under the connected section between the differential and the rear axle housing.

JDF00027-00025

JDF00028-00026

JDF00029-00027

DISASSEMBLY

1. Place the differential carrier removed from the vehicle on a disassembly stand.

SST: 09219-87202-000

09548-87201-000

2. Inspection before disassembly

(1) Checking of ring gear runout

Ensure that the ring gear runout is within the specified value, using a dial gauge.

Maximum limit: 0.1 mm or less

If the ring gear runout fails to meet the specified value, retighten the ring gear attaching bolt evenly after loosening the bolts evenly or replace the ring gear and drive pinion as a set.

(2) Checking of ring gear backlash

Ensure that the backlash of the ring gear is within the specified value.

Ring gear backlash: 0.08 - 0.15 mm

NOTE:

•

If the measured backlash fails to meet the specified value, replace the ring gear and drive pinion as a set.

(3) Ensure that the backlash of the side gear is within the specified value.

Side pinion backlash: 0.025 - 0.10 mm

CAUTION:

•

Be sure to employ the shims which have the same thickness at the right and left side.

NOTE:

•

If the measured backlash fails to meet the specified value, adjust the backlash with the thrust washer thickness.

(4) Measure the preload of the drive pinion.

Preload: 0.59 - 0.98 N·m (0.06 - 0.1 kgf-m)

NOTE:

•

If the measured preload fails to meet the specified value, adjust the preload by selecting the thickness of shims.

(5) Check of tooth contact between ring gear and pinion

(Refer to page DF–21)

SST

DF–11

SST

JDF00030-00028

JDF00031-00029

JDF00032-00030

JDF00033-00031

JDF00034-00032

DF–12

3. Remove the T type oil seals, using the following SST.

SST: 09308-00010-000

(For front differential)

SST

4. Put mating marks (paint or the like) on the bearing caps and differential carrier.

NOTE:

•

Machining process should be carried out with carrier and cap as a set. Arrange the removed bearing caps in order.

5. Remove the bearing caps by removing the four attaching bolts.

Mating marks

JDF00035-00033

Mating marks

JDF00036-00034

6. Remove the shims and differential case assembly from the carrier.

CAUTION:

•

Be sure to keep the shims installed at the right and left sides separately as a reference value for assembly.

Shims

JDF00000-00035

JDF00037-00036

7. Remove the side bearings, using the following SST.

SST: 09950-20017-000

JDF00038-00037

8. Put mating marks on the differential case and ring gear.

9. Loosen the differential ring gear attaching bolts evenly.

CAUTION:

•

Be sure to loosen the attaching bolts evenly. Failure to observe this caution may damage the ring gear or the differential case.

10. Remove the differential ring gear by removing the eight attaching bolts.

NOTE:

•

If any difficulty is encounter in separating the ring gear from the differential case, lightly tap the ring gear evenly, using a plastic hammer or the like.

11. Remove the differential pinion, differential side gear and differential thrust washer from the differential case.

(Except LSD)

CAUTION:

•

Arrange the removed differential side gears and thrust washeres as a set.

•

Never disassemble the LSD. The inner parts are not available as spare parts.

12. Release the staking of the lock nut, using a chisel and a hammer. (Refer to the procedure described in “REPLACE-

MENT OF FRONT DIFFERENTIAL COMPANION FLANGE

OIL SEAL.”).

13. Loosen the companion flange attaching nut while preventing the companion flange from turning, using the following

SST. (Refer to the procedure described in “(REPLACE-

MENT OF FRONT DIFFERENTIAL COMPANION FLANGE

OIL SEAL.”).

14. Remove the lock nut and plate washer.

CAUTION:

•

Do not reuse the used lock nut and plate washer.

15. Remove the drive pinion companion flange subassembly, using the following SST. (Refer to the procedure described in “REPLACEMENT OF FRONT DIFFERENTIAL COMPAN-

ION FLANGE OIL SEAL.”).

SST: 09950-20017-000

DF–13

Mating marks

JDF00039-00038

JDF00040-00039

JDF00041-00000

JDF00042-00000

DF–14

16. Remove the T type oil seal, using the following SST.

SST: 09308-10010-000

Front

SST

Rear

SST

JDF00043-00040

JDF00000-00041

17. Remove the differential drive pinion spacer and shims from the differential carrier, using a hydraulic press or tapping the drive pinion, using a hydraulic press.

CAUTION:

•

Never drop the drive pinion on the floor.

•

Be very careful not to damage the threaded section of the drive pinion.

NOTE:

•

Measure the thickness of the removed shims for the reference value at assembly.

Front

Rear

JDF00044-00042

18. Remove the tapered roller bearing from the drive pinion, using the following SST or the like.

SST: 09950-87701-000

SST

JDF00000-00043

JDF00045-00044

19. Remove the front and rear tapered roller bearing outer races and shims, using a press in combination with the following SST.

SST: 09608-87501-000

(Use No. 2 and No. 5 in the above component, in case front differential.)

(Use No. 3 and No. 5 in the above component, in case rear differential.)

CAUTION:

•

Care must be exercised so that the outer race may not be tilted during removal.

NOTE:

•

Measure the thickness of the removed shim for the reference value at assembly.

•

Be sure to remove the smaller sized bearing outer race first, otherwise some SST can not utilized.

Front

Rear

SST

DF–15

SST

JDF00046-00045

SST

JDF00000-00046

DF–16

INSPECTION

Inspect each section of the following parts for any sign of damage, wear or excessive looseness. Replace any parts which exhibit defects.

1. Differential drive pinion & ring gear

(1) Gear teeth q

(2) Spline portion w of drive pinion

(3) Bearing fitting section e

CAUTION:

•

Replace the drive pinion and ring gear as a set, if any damage is found on either drive pinion or ring gear.

2. Differential side gear, differential pinion and differential pinion shaft q w e

JDF00047-00047

3. Differential case

(1) Side gear boss contact sections

(2) Pinion contact section w

(3) Ring gear attaching section

(4) Side bearing press-fitting section

(5) The differential case proper e t q r

4. Bearings

Turn the bearings lightly. Ensure that the tapered roller bearing (front and rear) and bearing (differential side) rotate smoothly without any binding or abnormal noise.

CAUTION:

•

Replace the front and rear bearings as a set, if any damage is found on any bearing.

5. Drive pinion companion flange

(1) Oil seal contact section q

(2) Spline section w r

JDF00048-00048 e t w r q

JDF00049-00049 q

JDF00050-00050 w

JDF00051-00051

6. Differential carrier

(1) Side bearing fitting sections q

(2) Tapered roller bearing outer race fitting sections w

(3) Oil seal inserting section e

(4) Carrier cover attaching section r

(5) The differential case proper t

Front q w

DF–17

e w

Rear q r w t

JDF00052-00052 e

7. Inspection of the LSD (Limited Slip Differential)

(For LSD only)

(1) Install the rear axle shaft to a vise.

(2) Connect the differential case to the rear axle.

(3) Connect the rear axle shaft to the differential case.

(4) Install the wheel hub nut to one of the hub bolt with a suitable spacer interposed.

(5) Install the torque wrench to the hub nut.

(6) Ensure that the starting torque (a reading of the torque wrench at time when it is turned) is within the specified value.

Starting torque: 49.0

9.8 N·m (5.0

1.0 kgf-m)

If the specified measured starting torque fails to meet the specified value, replace the differential case with a new one.

NOTE:

•

The distance from the shaft center to the hub bolt center is 57.15 mm. When measuring the starting torque with a torque wrench, the reading of the torque wrench should be compensated using this value.

w r t

JDF00000-00053

JDF00053-00054

DF–18

ASSEMBLY

1. Installation of differential drive pinion

(1) Install the shim which was assembled or a shim having the same thickness with the one which was assembled as well as the front and rear tapered roller bearing outer races to the differential carrier, using the following SST in combination with a hydraulic press.

SST: 09608-87501-000

(Use No. 7 of the above SST in case front differential.)

(Use No. 7 and 8 of the above SST in case rear differential.)

CAUTION:

•

If any problem is found on the shims, replace the shims with new ones which have the same thickness with the former one.

•

Never apply a force beyond 19.6 kN (2000 kgf) during the installation.

•

Care must be exercised so that the race may not be tilted during the press-fitting operation.

(2) Install the tapered roller bearing to the differential drive pinion, using the following SST in combination with a hydraulic press.

SST: 09515-10010-000

Front

SST

Rear

SST

(3) Install the drive pinion shaft assembly, drive pinion and companion flange to the differential carrier temporarily.

CAUTION:

•

Liberally apply the specified differential oil to the tapered roller bearings.

•

Do not assemble the drive pinion shaft bearing spacer and shims at this moment.

(4) Press the drive pinion shaft tapered roller bearing into position, using a hydraulic press.

CAUTION:

•

Never apply excessive force to the bearings during pressing.

•

Ensure that no excessive force is applied to the bearings by turning the differential carrier.

SST

JDF00054-00055

SST

JDF00000-00056

JDF00055-00057

JDF00056-00058

JDF00057-00059

(5) Install the washer plate and lock nut for drive pinion companion flange subassembly.

CAUTION:

•

Apply the specified differential oil to the threaded portion of the lock nut and drive pinion before the installation.

•

Do not install the spacer, shim and T type oil seal at this moment.

(6) Tighten the lock nut until the preload of the tapered bearings becomes the following specified value while preventing the companion flange from turning, using the following SST.

SST: 09330-87301-000

Preload: 0.59 - 0.98 N·m (0.06 - 0.1 kgf-m)

NOTE:

•

Be sure to turn the companion flange several turns to stabilize the bearing contacting condition before measuring the preload.

2. Assembly of differential case

(1) Liberally apply the specified differential oil to the sliding surfaces of all component parts.

(2) Install the side gear thrust washer, side gear, pinion and pinion shaft to the differential case.

SST

DF–19

JDF00058-00060

JDF00059-00061

(3) Ensure that the backlash of the differential side gear is within the specified value with a dial gauge.

Backlash: 0.025 - 0.1 mm

If the backlash is not within the specified value, select a suitable washer from the spare parts mentioned below.

Thrust washer availability: 0.8 mm

0.9 mm

1.0 mm

JDF00060-00062

JDF00061-00063

DF–20

CAUTION:

•

Be sure to adjust the backlash in such a manner that the thickness of the thrust washers at both sides should be the same or differ not more than 0.1 mm.

(4) Install the differential gear to the differential case while aligning the mating marks put at the disassembly procedure.

(5) Install and tighten the attaching bolts evenly to the specified tightening torque.

Tightening Torque: 78.5 - 88.2 N·m (8.0 - 9.0 kgf-m)

(6) Install the radial ball bearings into position, using a hydraulic press in combination with the following SST.

SST: 09309-87201-000

3. Inspection and adjustment of ring gear backlash

(1) Install the differential case assembly to the differential carrier. Also, install shims having the same thickness as the one that was assembled to the back side of the differential gear tooth.

CAUTION:

•

Apply the specified differential oil to the sliding surface of the component parts.

•

Be sure to assemble the differential case assembly to the differential case while pushing the differential case assembly against the inserted shim side.

(2) Install the differential bearing caps with bolts to the differential carrier according to the mating marks which were put during the disassembling.

CAUTION:

•

Be sure to push the differential case assembly against the inserted shim side when assembling the bearing cap.

(3) Tighten the attaching bolts evenly to the specified tightening torque.

Tightening Torque: 29.5 - 44.1 N·m (3.0 - 4.5 kgf-m)

(4) While applying a dial gauge perpendicular to the tooth surface of the differential ring gear, secure the flange of the driving pinion. Under this condition, measure the backlash by moving the ring gear.

Specified value: 0.08 - 0.15 mm

CAUTION:

•

The measurement should be performed at three or more points on the circumference of the ring gear.

•

In cases where a backlash is too large, increase shims.

Conversely, in cases where a backlash is too small, decrease shims.

SST

Mating marks

JDF00062-00064

JDF00063-00065

JDF00064-00066

JDF00065-00067

JDF00066-00068

(5) Adjust the backlash to the specified value by selecting suitable shims from spare part, if the backlash fails to meet the specified value.

Shim availability: 0.15 mm

0.20 mm

0.25 mm

0.50 mm

(6) Note the selected shim thickness.

4. Adjustment of play of differential case assembly in axial direction

(1) Remove the bearing cap.

(2) Measure the clearance between the bearing at the ring gear tooth surface side and the differential carrier, using a thickness gauge. Select and insert shims so that the clearance may become the specified value.

Specified Value: 0 - 0.05 mm

NOTE:

•

If any difficulty is encountered in assembling shims, first insert shims at the back gear tooth surface side.

•

Then, insert shims at the back side by lightly tapping the back side, using a plastic hammer.

Shim availability: 0.15 mm

0.20 mm

0.25 mm

0.50 mm

(3) Note the selected shim thickness.

(4) While aligning the mating marks that were put during the disassembling, assemble the differential bearing cap. Gradually tighten the four bolts evenly to the specified tightening torque.

Tightening Torque: 29.5 - 44.1 N·m (3.0 - 4.5 kgf-m)

(5) Ensure that the ring gear runout is within the specified value. (Refer to page DF–11.)

If the ring gear runout fails to meet the specified value, retighten the attaching bolts of the ring gear evenly after loosening them once or replace the ring gear and drive pinion gear as a set.

5. Check and adjustment of tooth contact condition with ring gear and drive pinion.

Apply blue lead to the gear teeth. Turn the flange to check the tooth contact between the ring gear and the drive pinion.

CAUTION:

•

Be sure to turn the flange in both the forward and backward directions and check the tooth contact pattern at several points.

DF–21

JDF00067-00069

JDF00068-00070

JDF00069-00071

JDF00070-00072

JDF00071-00073

DF–22

JDF00000-00074

6. Adjustment of drive pinion bearing preload

(1) Remove the differential bearing caps by removing the attaching bolts and differential case with the shims. (Refer to the disassembly procedure.)

NOTE:

•

Be sure to keep the removed shims at the right and left sides separately for reassembly.

(2) Loosen the lock nut of the drive pinion while preventing the companion flange from turning, using the following SST. (Refer to the disassembly procedure.)

SST: 09330-87301-000

(3) Remove the lock nut.

(Refer to the disassembly procedure.)

(4) Remove the companion flange from the pinion shaft, using the following SST in combination with an adjustable wrench or the like.

(Refer to the disassembly procedure.)

SST: 09950-20017-000

(5) Remove the drive pinion from the differential carrier, using a hydraulic press or lightly tapping the drive pinion, using the plastic hammer.

(Refer to the disassembly procedure.)

(6) Remove the outer race of the tapered roller bearing. (Pinion gear side.)

JDF00072-00000

(7) Assemble the drive pinion spacer and shims having the same thickness as those measured during the disassembling to the drive pinion.

NOTE:

•

Replace the shims to new ones which have the same thickness with former shims, if they are damaged.

JDF00073-00000

(8) Install the drive pinion shaft assembly, drive pinion and companion flange to the differential carrier temporarily.

(9) Press the drive pinion shaft bearing into position, using a hydraulic press.

CAUTION:

•

Never apply excessive force to the bearings during pressing.

Ensure that the no excessive force is applied to the bearings by turning the differential carrier.

(10) Apply the specified differential oil to the threaded section of the drive pinion and lock nut.

(11) Install the plate washer and lock nut. Then, tighten the lock nut to the specified tightening torque while preventing the companion flange from turning, using the following SST.

(Refer to the assembly procedure.)

SST: 09330-87301-000

Tightening torque: 98.1 - 137.2 N·m

(10.0 - 14.0 kgf-m)

(12) Ensure that the preload is within the specified value, using a torque wrench.

Preload: 0.59 - 0.98 N·m (0.6 - 1.0 kgf-m)

If the measured preload fails to meet the specified value, select suitable preload adjusting shims from the spare parts. Then, repeat the preload adjustment, until the specified preload is obtained.

Shim availability: 0.25 mm

0.30 mm

0.40 mm

0.50 mm

7. Installation of drive pinion oil seal

(1) Remove the drive pinion shaft lock nut while preventing the companion flange from turning, using the following SST. (Refer to the assembly procedure.)

SST: 09330-87301-000

(2) Remove the companion flange, using the following

SST in combination with a suitable adjusting wrench.

(Refer to the disassembling procedure.)

SST: 09950-20017-000

8. Assembly of companion flange

(1) Install a new T type oil seal to the differential case, using the following SST.

SST: 09635-20010-000

CAUTION:

•

Apply lithium soap base multi purpose grease to the lip section of the oil seal.

•

Make certain to drive the oil seal into position so that it becomes flush with the edge surface of the housing.

SST

Front

Rear

DF–23

JDF00074-00075

JDF00075-00076

JDF00076-00077

SST

JDF00077-00078

SST

JDF00078-00079

DF–24

(2) Install the companion flange subassembly, washer plate and lock nut.

(3) Tighten the lock nut to the specified tightening torque while preventing the companion flange from turning, using the following SST.

SST: 09330-87301-000

Tightening Torque: 98.1 - 137.2 N·m

(10.0 - 14.0 kgf-m)

(4) Turn the drive pinion shaft several times.

(5) Ensure that the preload is within the specified value.

If not, adjust the preload to the specified value by replacing the adjusting shims, as required.

(6) Stake the lock nut to the recessed section of the drive pinion shaft by a chisel of the like.

CAUTION:

•

Make sure that the lock section of the lock nut is positively staked down to the bottom of the driving pinion groove.

•

Never damage the threaded section of the drive pinion shaft.

9. Installation of front axle housing cover

(For front differential)

(1) Degrease the surface of the front axle housing cover attaching surface and front axle housing cover.

(2) Apply the specified seal adhesive to the front axle housing cover attaching surface.

Seal adhesive: Three bond 1216 or equivalents

(3) Install the front axle housing cover with attaching bolts and tighten them evenly to the specified tightening torque.

Tightening torque: 17.7 - 23.5 N·m (1.8 - 2.4 kgf-m)

10. Installation of drive shaft oil seal

(For front differential)

(1) Install new T type oil seals to the differential case, using the following SST.

SST: 09635-20010-000

(2) Apply the lithium soap base multi-purpose grease to the lip section of the T type oil seals.

SST

JDF00079-00080

JDF00080-00081

SST

JDF00081-00082

JDF00082-00083

INSTALLATION

(Front differential)

1. Install the differential carrier assembly and differential support bracket with the attaching bolts.

2. Tighten the bolts to the specified tightening torque.

Tightening Torque: Differential carrier

68.6 - 83.4 N·m

(7.0 - 8.5 kgf-m)

Differential support

34.3 - 61.8 N·m

(3.5 - 6.3 kgf-m)

3. Install the propeller shaft to the front differential with the attaching bolts and tighten them to the specified tightening torque.

(Refer to PR section)

4. Insert the drive shaft assembly into the differential carrier assembly. (Refer to the procedure described in “Replacement of Front differential side Oil Seal” and FS section.)

CAUTION:

•

Apply lithium soap base multi-purpose grease to the lip section of the differential side oil seal.

5. Tighten the new attaching nut of the suspension support to the specified tightening torque.

Tightening Torque: 28.4 - 42.2 N·m (2.9 - 4.3 kgf-m)

6. Install the lower arm to the steering nuckle and tighten the castle nut to the specified tightening torque.

(Refer to the procedure described in “Replacement of

Front differential side oil seal.”)

Tightening Torque: 44.1 - 58.8 N·m (4.5 - 6.0 kgf-m)

7. Install a new clip.

(Refer to the procedure described in “Replacement of

Front differential side oil seal.”)

8. Install the tie rod end to the steering knuckle and tighten the castle nut to the specified tightening torque.

(Refer to the procedure described in “Replacement of

Front differential side oil seal.”)

Tightening Torque: 39.2 - 53.9 N·m (4.0 - 5.5 kgf-m)

9. Install a new clip.

(Refer to the procedure described in “Replacement of

Front differential side oil seal.”)

10. Install the drain plug with a new gasket interposed and tighten the drain plug to the specified tightening torque.

Tightening Torque:

Front 39.3 - 58.8 N·m (4.0 - 6.0 kgf-m)

DF–25

JDF00083-00084

JDF00084-00085

JDF00085-00086

JDF00086-00000

DF–26

11. Fill the specified differential oil from the filler plug.

(Refer to the “REPLACEMENT OF FRONT DIFFERENTIAL

COMPANION FLANGE OIL SEAL” section.)

12. Install the filler plug with a new gasket interposed and tighten it to the specified tightening torque.

Tightening Torque:

Front 39.3 - 58.8 N·m (4.0 - 6.0 kgf-m)

13. Install the front wheels.

14. Jack down the vehicle.

15. Ensure that no trouble persists.

(Rear differential)

1. Apply liquid gasket to the mating surface of the rear axle housing cover.

(1) Degrease the surface of the rear differential attaching surface or the rear axle housing.

(2) Apply the specified seal adhesive to the rear axle.

Seal adhesive: Three bond 1217 or equivalents

2. Install the rear differential carrier assembly with the attaching bolts.

3. Tighten the attaching bolts to the specified tightening torque evenly.

Tightening Torque: 24.5 - 39.2 N·m (2.5 - 4.0 kgf-m)

JDF00087-00087

Application of bond sealer

JDF00088-00088

4. Install the propeller shaft assembly. (Refer to the PR section.)

5. Install the rear axle shaft. (Refer to the RS section.)

6. Install the drain plug with a new gasket interposed and tighten the drain plug to the specified tightening torque.

Tightening Torque: 53.9 - 68.6 N·m (5.5 - 7.0 kgf-m)

7. Fill the specified differential oil from the filler plug.

Specified differential oil

Grade : API GL-5

Viscosity : SAE 80W-90 (Standard)

SAE 80W-90 LSD (For LSD)

Capacity : 1.55 liters

JDF00089-00000

Filler plug

Drain plug

JDF00090-00089

8. Install the filler plug with a new gasket interposed and tighten it to the specified tightening torque.

Tightening Torque: 53.9 - 68.6 N·m (5.5 - 7.0 kgf-m)

9. Install the rear wheel.

10. Jack down the vehicle.

11. Ensure that no trouble is persists.

DF–27

JDF00091-00000

DF–28

SSTs

09515-10010-000 Rear axle bearing replacer

09309-87201-000 Transmission bearing replacer

09608-87501-000

Axle hub & drive pinion bearing tool set

09635-20010-000 Lower ball joint dust cover replacer

09548-87201-000 Differential overhaul attachment

09330-87301-000 Drive pinion flange holding tool

09611-87701-000 Tie rod end puller

09648-87201-000 Drive shaft replacer

09636-20010-000 Upper ball joint dust cover replacer

09219-87202-000 Engine overhaul stand

09308-10010-000 Oil seal puller

09308-00010-000

Oil seal puller

09950-20017-000 Universal puller

09950-87701-000

Bearing pulling attachment

DF–29

JDF00092-00090

DF–30

TIGHTENING TORQUE

Tightening compartment

Drive pinion companion flange subassembly

lock nut

Drain plug (Front)

(Rear)

Oil filler plug (Front)

(Rear)

Suspension support attaching nut

Lower arm

steering knuckle

Tie rod end

steering knuckle

Differential gear

differential case

Differential bearing cap

differential carrier

Front axle housing cover

front axle

Differential carrier

× differential support bracket

Differential support bracket

× frame

Differential carrier

× frame

N·m

98.1 - 137.2

39.3 - 58.8

53.9 - 68.6

39.3 - 58.8

53.9 - 68.6

28.4 - 42.2

44.1 - 58.8

39.2 - 53.9

78.5 - 88.2

29.5 - 44.1

17.7 - 23.5

68.6 - 83.4

34.3 - 61.8

Tightening torque kgf-m

10.0 - 14.0

4.0 - 6.0

5.5 - 7.0

4.0 - 6.0

5.5 - 7.0

2.9 - 4.3

4.5 - 6.0

4.0 - 5.5

8.0 - 9.0

3.0 - 4.5

1.8 - 2.4

7.0 - 8.5

3.5 - 6.3

JDF00093-00000

DAIHATSU

J100

FRONT AXLE & SUSPENSION

WHEEL ALIGNMENT ......................... FS– 2

PREPARATION

.............................. FS– 2

FRONT AXLE AND SUSPENSION .... FS– 4

COMPONENTS

............................. FS– 4

FRONT AXLE ..................................... FS– 5

REMOVAL

...................................... FS– 5

DISASSEMBLY

.............................. FS– 7

INSPECTION

................................. FS– 8

ASSEMBLY

.................................... FS– 9

INSTALLATION

.............................. FS–10

FRONT STABILIZER BAR ................. FS–12

REMOVAL

...................................... FS–12

DISASSEMBLY

.............................. FS–12

INSPECTION

................................. FS–12

ASSEMBLY

.................................... FS–13

INSTALLATION

.............................. FS–13

SHOCK ABSORBER AND

SPRING .......................................... FS–14

REMOVAL

...................................... FS–14

DISASSEMBLY

.............................. FS–14

INSPECTION

................................. FS–15

ASSEMBLY

.................................... FS–15

INSTALLATION

.............................. FS–16

SUSPENSION LOWER ARM ............. FS–17

REMOVAL

...................................... FS–17

INSPECTION

................................. FS–17

REPLACEMENT OF SUSPENSION

LOWER ARM BUSH

.................. FS–18

REPLACEMENT OF SUSPENSION

LOWER ARM BALL JOINT

DUST COVER

............................ FS–18

INSTALLATION

.............................. FS–19

DRIVE SHAFT .................................... FS–20

COMPONENTS

............................. FS–20

REMOVAL

...................................... FS–20

DISASSEMBLY

.............................. FS–21

INSPECTION

................................. FS–22

ASSEMBLY

.................................... FS–23

REPLACEMENT OF TRANSFER

OIL SEAL

................................... FS–25

INSTALLATION

.............................. FS–25

TIGHTENING TORQUE ...................... FS–26

JFS00001-00000

NO. 9710-JE

FS–2

WHEEL ALIGNMENT

PREPARATION

Prior checks

1. Inspect the wear of tires.

2. Inspect the air pressure of the tires.

NOTE:

Perform the check on a level floor.

Make sure that the same maker’s tires having the same size are mounted.

Keep the vehicle in an unloaded state. “Unloaded state” denotes a condition where the fuel tank is full, a spare tire is mounted, standard tools and a jack are mounted at correct storage locations.

Tire Size: 205/70R15 95S

Pressure: 180 kPa (1.8 kgf/cm

)

3. Inspect the runout of tires.

Maximum Limit: 2 mm in a right-and-left direction

1.4 mm in an up-and-down direction

NOTE:

The measurement should be conducted within five minutes after the vehicle has been run for at least 30 minutes at a speed of 60 to 80 km/h.

4. Ensure that the no looseness are exists on the bolts and nuts on the related parts of the front axle and steering linkage.

5. Check of related sections of the front axle and steering linkage for excessive play

(1) Jack up the vehicle and support it with safety stands.

(Refer to GI section.)

(2) Ensure that no excessive play are exists on the connecting sections of the each front axle and steering linkage by rocking the tire alternately in-and-out or push and pull while holding the upper and lower parts of the tire.

JFS00002-00001

JFS00003-00002

JFS00004-00003

FS–3

Camber, Caster and Kingpin angle

Specified Value

Camber

Caster

¢ ±

Kingpin angle 13

¢ ±

NOTE:

No adjustment can be made for the camber, caster and kingpin angle. Therefore, if the camber, caster or kingpin angle fails to meet the specified value, check that no damage or deformation exists on the frame or correct the frame, as required.

Toe-in, Turning radius

Specified Value:

Toe-in

Turning Radius In

1.5 mm

Out 33

–2

NOTE:

If the toe-in or turning radius fails to meet the specified value, perform the adjustment, following the procedure given below, so that both the toe-in and turning radius may conform to the specified values.

Front

JFS00005-00004

JFS00006-00005

Front

JFS00000-00006

Adjustment of Toe-in and Turning radius

1. Loosen the lock nuts of the tie-rod ends.

2. Perform the toe-in and turning radius adjustment by turning the tie-rod ends.

CAUTION:

When adjusting the toe-in, the tie-rods at the right and left sides should be turned by the same amount.

Make the length (a) indicated in the illustration equal between the right and left sides. If the length differs between the right and left sides, a difference occurs in the wheel turning angle between the right and left sides.

3. Tighten the lock nut.

Tightening Torque: 59.8 - 89.2 N·m (6.1 - 9.1 kgf-m)

(a)

JFS00007-00007

FS–4

FRONT AXLE AND SUSPENSION

COMPONENTS

: Tightening torque

Unit : N·m (kgf-m)

37.8 - 56.4

(3.85 - 5.75)

N q

N w e r

28.4 - 42.2

(2.9 - 4.3) o

12.7 - 23.5

(1.3 - 2.4)

12.7 - 23.5

(1.3 - 2.4)

12.7 - 23.5

(1.3 - 2.4)

117.6 - 176.4

(12.0 - 18.0)

117.6 - 176.4

(12.0 - 18.0)

12.7 - 23.5

(1.3 - 2.4) t y u

101.9 - 152.9

(10.4 - 15.6)

39.2 - 53.9

(4.0 - 5.5)

196.6 - 29.4

(20.0 - 3.0)

@2 @3 q

Bearing dust cover w

Front suspension support e

Bearing r

Front spring upper seat t

Front spring bumper y

Front spring u

Front shock absorber i

Front stabilizer bracket sub-assembly o

Front stabilizer bar

Stabilizer bush

Stabilizer bracket

Washer

Bush

Stabilizer link rod

Suspension lower arm

Steering knuckle

Bearing

Snap ring

Disc brake dust cover

Front axle hub

Washer

Front wheel adjusting lock cap

Cotter pin

JFS00008-00008

FRONT AXLE

REMOVAL

1. Jack up the vehicle and support it with safety stands.

(Refer to the GI section.)

2. Remove the front wheels.

3. Remove the attaching bolts of the disc brake assembly.

4. Suspend the disc brake assembly with suitable string.

5. Remove the brake disc.

NOTE:

Remove the brake disc by screw-in the two bolts (M8

1.25) evenly to the bolt holes provided on the brake disc, if any difficulty is encountered.

6. Inspection of wheel bearing

(1) Ensure that no excessive looseness exists between the drive shaft and axle hub.

(2) Ensure that the free play with in the specified value, using the dial gauge as shown.

Axial Free Play: Not more than 0.05 mm

If the free play is exceeds the allowable limit, replace the wheel bearing.

7. Inspection of axle hub

Ensure that the axle hub runout is with in specified value, using dial gauge.

Runout Limit: Not more than 0.05 mm

If the runout exceeds the allowable limit, replace the axle hub.

NOTE:

Measure the runout at a point of the axle hub outer edge.

8. Removal of front axle hub

(1) Remove the cotter pin, then remove the front wheel adjusting lock cap.

(2) Remove the nut while preventing the front hub from turning, using the following SST.

SST: 09511-87202-000

CAUTION:

Prevent the hub bolt from damage by installing the suitable hub nut or the like, when using the SST.

FS–5

JFS00009-00009

JFS00010-00010

JFS00011-00011

JFS00012-00012

JFS00013-00013

FS–6

(3) Pull out the front axle hub sub-assembly with inner bearing race, using the following SST.

SST: 09520-00031-000

CAUTION:

Never reuse the removed bearing.

9. Remove the sensor mounting bracket with the skid control sensor from the steering knuckle by removing the attaching bolts.

(Only for vehicles equipped with ABS.)

10. Removal of steering knuckle

(1) Disconnection of tie-rod end from steering knuckle q

Remove the clip.

Loosen the castle nut until the upper end of the castle nut becomes flash with the end of the threaded section of the lower ball joint.

Disconnect the tie-rod end from the steering knuckle, using the following SST.

SST: 09611-87701-000 r

Disconnect the tie-rod end from the steering knuckle by removing the castle nut.

CAUTION:

Never make damage on the threaded section of ball joint during the disconnection using the SST.

(2) Disconnection of suspension lower arm from steering knuckle q

Remove the clip.

Loosen the castle nut until the upper end of the castle nut becomes flash with the end of the threaded section of the lower ball joint.

Disconnect the suspension lower arm from the steering knuckle, using the following SST.

SST: 09611-87701-000 r

Disconnect the suspension lower arm from the steering knuckle by removing the castle nut.

CAUTION:

Never make damage on the threaded section of ball joint during the disconnection using the SST.

SST

JFS00014-00014

JFS00015-00015

JFS00016-00016

JFS00017-00017

(3) Disconnection of shock absorber from steering knuckle q

Remove the attaching nuts of the steering knuckle to shock absorber.

NOTE:

Never reuse the removed bolt and nut.

Disconnect the front shock absorber from the steering knuckle.

DISASSEMBLY

Front axle hub

1. Wrench out the bearing dust cover from the front axle hub, using screwdriver or the like.

2. Remove the inner bearing race (outer side) from the front axle hub, using the following SST.

SST: 09950-20017-000

CAUTION:

Never reuse the removed bearing.

3. Drive out the hub bolts from the front axle hub, using a plastic hammer or the like.

Steering knuckle

1. Remove the disc brake dust cover, using a suitable brass bar or the like in combination with suitable hammer.

NOTE:

Never remove the disc brake dust cover unless its replacement is required.

FS–7

JFS00018-00018

JFS00019-00019

JFS00020-00020

JFS00021-00021

JFS00022-00022

FS–8

2. Removal of front axle bearing.

(1) Detach the hole snap ring, using snap ring pliers.

Hole snap ring

(2) Remove the bearing from the steering knuckle, using a following SST in combination with the hydraulic press.

SSTs: 09544-10010-000

09252-10010-000 (Use the 09550-10012-000 that is a part of the set.) 09506-87302-000

CAUTION:

Never reuse the removed bearing.

INSPECTION

Front axle hub

Visually check front axle hub for crack, deformation or excessive wear.

Ensure that no damage is exits on the serration section of the front axle hub.

If any damage is exists replace the front axle hub with new one.

Steering knuckle

Visually check steering knuckle for crack, deformation or any other damages.

Ensure that no damage exists on the bearing attaching section.

If any damage is exists replace the steering knuckle with new one.

SST

JFS00023-00023

JFS00024-00024

JFS00025-00025

JFS00026-00026

FS–9

ASSEMBLY

Front axle hub

Install the hub bolt to the front axle hub by tapping it with suitable hammer.

Steering knuckle

1. Installation of disc brake dust cover

Press the disc brake dust cover until it comes in contact with the steering knuckle, using the following SSTs in combination with the hydraulic press.

SSTs: 09506-87302-000

09718-87702-000

CAUTION:

Ensure that the disc brake dust cover is press-fitted to the steering knuckle positively by ensuring the dust cover properly contacts with the steering knuckle.

Be sure to assemble the brake dust cover to steering knuckle in such position, as indicated in the figure.

2. Installation of front axle bearing

(1) Press a new bearing into the steering knuckle, using the following SSTs in combination with hydraulic press.

SSTs: 09310-87302-000

09506-87302-000

(2) Install a new hole snap ring, using snap ring pliers.

CAUTION:

Never reuse the used snap ring.

¡ ±

0.5

JFS00027-00027

SST

JFS00028-00028

JFS00029-00029

JFS00030-00030

FS–10

INSTALLATION

1. Press the front axle hub into the steering knuckle sub-assembly using the following SST in combination with hydraulic press.

SST: 09559-10010-000, 09252-10010-000 (Use the

09550-10012-000 that is a part of the set.)

NOTE:

Press in the steering knuckle into the axle hub after the axle hub placed on the SST 09506-87302-000.

2. Install the steering knuckle after insert the drive shaft to the steering knuckle as follows.

(1) Connection of shock absorber to steering knuckle q

Connect the steering knuckle on the shock absorber lower bracket.

Install the new bolts and nuts, then tighten the bolts and nuts to specified tightening torque.

Tightening Torque: 101.9 - 152.9 N·m

(10.4 - 15.6 kgf-m)

CAUTION:

Be sure to tighten the attaching nuts when tightening.

(2) Connection of tie-rod end to steering knuckle q

Connect the tie-rod end to the steering knuckle with the castle nut. Then, tighten the castle nut to specified tightening torque.

Tightening Torque: 39.2 - 53.9 N·m (4.0 - 5.5 kgf-m) w

Install the clip to the castle nut.

CAUTION:

Never adhere a grease or oil, etc. to the taper section of the lower ball joint.

Never make any damage on the dust cover of the ball joint.

(3) Connection of suspension lower arm to steering knuckle q

Connect the suspension lower arm to the steering knuckle with the castle nut. Then, tighten the castle nut to specified tightening torque.

Tightening Torque: 44.1 - 58.8 N·m (4.5 - 6.0 kgf-m) w

Install the clip to the castle nut.

CAUTION:

Never adhere a grease or oil, etc. to the taper section of the lower ball joint.

Never made any damage on the dust cover of the ball joint.

3. Install the sensor mounting bracket with the skid control sensor to the steering knuckle.

Tightening Torque: 6.9 - 9.8 N·m (0.7 - 1.0 kgf-m)

JFS00031-00031

JFS00032-00032

JFS00033-00033

JFS00034-00034

JFS00035-00035

4. Tightening of drive shaft end nut

(1) Install the conical washer to the drive shaft.

(2) Install the nut and tighten the nut to specified tightening torque while prevent the front axle hub from turning, using the following SST.

SST: 09511-87202-200

Tightening Torque: 196.6

29.4 N·m

(20.0

3.0 kgf-m)

CAUTION:

Be sure to install the conical washer in the correct direction.

(3) Install the front wheel adjusting lock cap to the nut.

(4) Install a new cotter pin.

CAUTION:

Bend the legs of the cotter pin, as indicated in the figure.

When bending the cotter pin, make sure that the cotter pin is not protruding from the head of the bolt.

5. Install the brake disc to the front axle hub.

6. Install the disc brake assembly to the steering knuckle.

Tightening Torque: 90.2 - 135.3 N·m

(9.2 - 13.8 kgf-m)

7. Install the wheel with hub nuts and tighten the hub nut fully by hand.

8. Jack down the vehicle.

9. Tighten the hub nut to specified tightening torque.

Tightening Torque: 88.2 - 117.6 N·m

(9.0 - 12.0 kgf-m)

FS–11

Inside Outside

Serrated section

JFS00036-00036

JFS00037-00037

JFS00038-00038

FS–12

FRONT STABILIZER BAR

REMOVAL

1. Jack up the vehicle and support it with safety stands.

(Refer to the GI section.)

2. Remove the stabilizer bar end lower nut.

CAUTION:

Never reuse the removed nut.

3. Remove the bush and washer.

4. Remove the stabilizer bracket from the stabilizer bracket sub-assembly.

5. Remove the stabilizer bar.

JFS00039-00039

DISASSEMBLY

1. Remove the stabilizer bar end upper nut.

CAUTION:

Never reuse the removed nut.

2. Remove the bush, washer and stabilizer link rod from the stabilizer bar.

INSPECTION

Bush

Ensure that no damage such as crack, wear, deterioration, aging and/or so forth.

Stabilizer bar

Visually inspect that no damage or wear is exists on the stabilizer bracket.

Stabilizer bracket

Visually inspect that no damage or wear is exists on the stabilizer bracket.

Stabilizer bush

Ensure that no damage such as crack, wear, deterioration, aging and/or so forth.

Stabilizer link rod

Ensure that the no wear, bent, damage on threaded section.

If any damage is exists replace the damaged part as required.

Nut

Washer

Bush

Washer

JFS00040-00040

JFS00041-00041

ASSEMBLY

1. Install the washer and bush to the stabilizer link rod.

2. Install the stabilizer link rod to the stabilizer bar.

3. Install the bush and washer to the stabilizer link rod. Then, tighten the stabilizer bar end upper nut.

CAUTION:

Be sure to assemble the bush and washer as shown in the right figure.

INSTALLATION

1. Install the stabilizer link rod, washer and bush to the suspension lower arm with the attaching nuts as shown in the right figure. Then, tighten the stabilizer bar end lower nut temporary.

CAUTION:

Be sure to insert the protrusion section on the washer

B to the hole provided on the stabilizer bracket on the suspension lower arm.

2. Attach the bushes to the stabilizer bar.

CAUTION:

Be sure to attach the bushes to the stabilizer bar in such manner that the bushes should be attached on the mark provided on the stabilizer bar during installation.

3. Install the stabilizer bar to the stabilizer bracket sub-assembly by installing the stabilizer bracket with the attaching bolts. Then, tighten the attaching bolts to specified tightening torque.

Tightening Torque: 12.7 - 23.5 N·m (1.3 - 2.4 kgf-m)

4. Tighten the stabilizer bar end lower nut.

Tightening Torque: 12.7 - 23.5 N·m (1.3 - 2.4 kgf-m)

5. Jack down the vehicle.

Marker

Nut

FS–13

Washer

Bush

Washer

JFS00042-00042

Washer A

Bush

Washer A

Bush

Washer B

Bush

Washer A

JFS00043-00043

JFS00044-00044

JFS00045-00045

FS–14

SHOCK ABSORBER AND SPRING

REMOVAL

1. Jack up the vehicle and support it with safety stands.

(Refer to the GI section.)

2. Remove the front wheels.

3. Remove the brake hose bracket from the shock absorber lower bracket by removing its attaching nut.

4. Remove the skid control sensor harness bracket from the shock absorber lower bracket by removing its attaching bolt.

(Only for vehicles equipped with ABS.)

5. Remove the attaching nuts of the shock absorber lower bracket which is connected to the steering knuckle.

CAUTION:

Never reuse the removed nut.

6. Remove the attaching nuts of the suspension support at the front fender apron.

CAUTION:

Never reuse the removed nut.

7. Remove the attaching nuts and bolts of the shock absorber lower bracket which is connected to the steering knuckle.

NOTE:

Never reuse the removed nuts.

Be sure to prevent the drive shaft boot from the damage, using the suitable piece of cloth or the like.

DISASSEMBLY

1. Compress the coil spring, using the following SST.

SST: 09727-87701-000 or

09727-30020-000

2. Secure the front shock absorber in a vice.

3. Remove the bearing dust cover.

4. Remove the nut.

CAUTION:

Never remove the nut by applying impacts to it, using an impact wrench or the like.

Never reuse the removed nut.

5. Remove the front suspension support.

6. Remove the bush and front spring upper seat.

7. Remove the coil spring and spring bumper.

JFS00046-00046

JFS00047-00047

JFS00048-00048

JFS00049-00049

FS–15

INSPECTION

CAUTION:

Replace the parts with new one, if any damage or malfunction is found in following inspections.

Suspension support

Visually check that deformation, rust, crack nor other damage are not exists and also check that no damage is exists on the threaded portion of the stud bolts.

Spring upper seat

Ensure that the spring upper seat is free from crack, rupture, deformation aging, wear and other damage.

Bumper

Ensure that the bumper is free from crack, rupture, deformation aging, wear and other damage.

Bearing

Ensure that the bearing is turns freely without any pulling.

Coil spring

Ensure that the coil spring is free from deformation, deterioration, crack or other damage.

Shock absorber

Ensure that the shock absorber piston operates smoothly without any rattling, shock or abnormal resistance or noise by pulling and pushing the piston rod.

WARNING:

Release the gas completely before discarding the shock absorber.

ASSEMBLY

1. Insert the spring bumper to the piston rod.

2. Compress the coil spring, using the following SST.

SST: 09727-87701-000 or

09727-30020-000

3. Install the coil spring which is compressed with SSTs to the shock absorber.

4. Install the front spring upper seat to the shock absorber piston rod.

5. Install the bearing to the shock absorber piston rod.

6. Install the front suspension support.

CAUTION:

Be sure to align the cut-out section of the front suspension support with the protrusion section of piston rod during the assembly.

JFS00050-00050

JFS00051-00051

Cut-out

JFS00052-00052

FS–16

7. Temporarily attach the new piston end nut.

8. Hold the front suspension support in a vice.

CAUTION:

Never apply the excessive force to the suspension support.

9. Tightening the piston end nut to specified tightening torque.

Tightening Torque: 37.8 - 56.4 N·m

(3.85 - 5.75 kgf-cm)

10. Install the bearing dust cover.

11. Remove the SSTs which is compress the coil spring while aligning coil spring end with the recessed section provided on the each of the upper and lower seats.

INSTALLATION

1. Install the suspension support to the fender apron with the new attaching nuts.

2. Tighten the suspension support attaching nuts to specified tightening torque.

Tightening Torque: 28.4 - 42.2 N·m (2.9 - 4.3 kgf-cm)

3. Connect the shock absorber to the steering knuckle.

(Refer to the FS–10.)

4. Install the skid control sensor harness bracket to the shock absorber lower bracket.

(Only for vehicles equipped with ABS.)

5. Install the brake hose bracket to the shock absorber with the attaching bolt.

6. Install the wheel with hub nuts and tighten them fully by hand.

7. Jack down the vehicle.

8. Tighten the hub nut to specified tightening torque. (Refer to the FS–11.)

9. Perform the inspection of the front wheel alignment. (Refer to the “WHEEL ALIGNMENT” section.)

JFS00053-00053

JFS00054-00054

JFS00055-00055

JFS00056-00056

JFS00057-00057

SUSPENSION LOWER ARM

REMOVAL

1. Jack up the vehicle and support it with safety stands.

(Refer to the GI section.)

2. Remove the front wheels.

3. Remove the front stabilizer bar. (Refer to the “STABILIZER” section.)

4. Remove the stabilizer bracket sub-assembly from the suspension member.

5. Remove the skid control sensor from the sensor mounting bracket. (Only for vehicles equipped with ABS.)

6. Disconnection of suspension lower arm

(1) Disconnect the suspension lower arm from the steering knuckle. (Refer to the FS–6.)

(2) Loosen the attaching nuts of the shock absorber to the suspension lower arm.

(3) Remove the lower side attaching bolt and nut of shock absorber.

CAUTION:

Never reuse the removed bolts and nuts.

(4) Remove the attaching bolts and nuts of the suspension lower arm to suspension member.

CAUTION:

Never reuse the removed bolts.

(5) Remove the suspension lower arm from the suspension member.

INSPECTION

Suspension lower arm

1. Ensure that the ball joint dust cover is free from rupture, crack, aging, deformation and other damages.

2. Ensure that the ball joint is operates smoothly without any rattle.

3. Visually inspect that no damage or wear exists on the suspension lower arm.

If any damage is exists replace the damaged part with new one.

FS–17

JFS00058-00058

JFS00059-00059

JFS00060-00060

FS–18

REPLACEMENT OF SUSPENSION LOWER ARM

BUSH

1. Remove the bush, using a suitable tool in combination with a hydraulic press.

NOTE:

Use a suitable tool, such as a tool indicated in the figure.

2. Apply the Samper ® 115 to a new bush (Only for the front side bush.). Then, press-fit the bush in the suspension lower arm, using a suitable tool in combination with a hydraulic press.

CAUTION:

Never apply the pressure to the inner sleeve of the bush.

Be sure to install the front side bush in such positions that the both flange section of the bush properly positioned as shown.

Be sure to install the rear bush to suspension lower arm in such positions that the holes provided on the bush align with the position as shown.

Be sure to install the rear side bush outer sleeve to suspension lower arm in such positions that the edge of the rear side bush outer sleeve be comes flash with the attaching hole edge of the suspension lower arm.

REPLACEMENT OF SUSPENSION LOWER ARM

BALL JOINT DUST COVER

1. Remove the dust cover, using a screwdriver or the like.

NOTE:

Never remove the dust cover, unless its replacement is required due to the damage or deterioration.

2. Pack the specified amount of multi purpose grease to inside of the dust cover.

Amount of Multi Purpose Grease: 4

0.5 cc

3. Install the new dust cover to suspension lower arm by using following SST in combination with a hydraulic press.

SST: 09618-87301-000

Rear side

Front

Front side

25 mm

35 mm

60 mm

JFS00061-00061

JFS00062-00062

JFS00063-00063

JFS00064-00064

INSTALLATION

1. Install the suspension lower arm to the suspension member with the attaching bolts and nut.

2. Tighten the attaching bolts and nut to specified tightening torque.

Tightening Torque: 117.6 - 176.4 N·m

(12.0 - 18.0 kgf-m)

CAUTION:

Be sure to tighten the bolts and nut while locating the suspension lower arm in position as show.

3. Connect the shock absorber to the steering knuckle.

(Refer to the FS–10.)

4. Connect the suspension lower arm and steering knuckle.

(Refer to the FS–10.)

5. Install the skid control sensor to the sensor mounting bracket. (Only for vehicles equipped with ABS.)

6. Install the stabilizer bracket sub-assembly to the suspension member. (Refer to the “STABILIZER” section.)

7. Install the stabilizer. (Refer to the “STABILIZER” section.)

8. Install the wheel with hub nuts and tighten the hub nut fully by hand.

9. Jack down the vehicle.

10. Tighten the hub nut to specified tightening torque. (Refer to the FS–11.)

11. Perform the inspection of the front wheel alignment.

(Refer to the “WHEEL ALIGNMENT” section.)

FS–19

Suspension member

JFS00065-00065

JFS00066-00066

FS–20

DRIVE SHAFT

COMPONENTS

★ w e ★ r t y

★ u i ★ o i

★ i

★ o i

★ q

Snap ring w

Inboard joint e

Snap ring r t y u

Snap ring i

Boot band o

Boot

Outboard joint

REMOVAL

1. Jack up the vehicle and support it with safety stands.

(Refer of the GI section.)

2. Remove the front wheels.

3. Drain the transmission oil. (Refer to the MA section.)

4. Remove the disc brake assembly. (Refer to the FS–5.)

5. Remove the brake disc. (Refer to the FS–5.)

6. Remove the skid control sensor from the sensor mounting bracket. (Only for the vehicles equipped with ABS.)

7. Remove the cotter pin.

8. Remove the adjusting lock cap.

9. Remove the drive shaft end nut and washer. (Refer to the

FS–5.)

10. Disconnect the tie-rod end from the steering knuckle.

(Refer to the FS–6.)

11. Disconnect the suspension lower arm from the steering knuckle. (Refer to the FS–6.)

12. Disconnect the shock absorber from the steering knuckle.

(Refer to the FS–7.)

13. Remove the steering knuckle with the front axle hub from the drive shaft.

14. Disconnect the drive shaft from the transfer, using the following SST.

SST: 09648-87201-000

JFS00067-00067

JFS00068-00068

JFS00069-00069

DISASSEMBLY

Inboard joint side

1. Pry up the boot band clip with a screwdriver.

NOTE:

Be very careful not to damage the boot.

2. Remove the snap ring, using a screwdriver or the like.

3. Remove the front axle inboard joint sub-assembly from shaft.

4. Remove the balls.

5. Remove the snap ring, using snap ring pliers.

6. Remove the inner race, using the following SST.

SST: 09950-20017-000

7. Remove the cage from the shaft.

FS–21

JFS00070-00070

JFS00071-00071

JFS00072-00072

JFS00073-00073

JFS00074-00074

FS–22

8. Wind vinyl tape to the splined section of the shaft so that the boot may not be damaged during the removal.

9. Remove the boot.

vinyl tape

Outboard joint side

1. Pry up the boot band clip with a screwdriver.

2. Remove the boot.

NOTE:

Outboard joint is non-disassembling parts.

Be very careful not to damage the boot.

INSPECTION

Ball sub-assembly

Visually check that no damage such as crack excessive wear or any other damage.

Shaft and outboard joint

Ensure that the outboard joint operates smoothly with out any rattle or pulling.

Inboard joint

Visually check that no damage such as crack excessive wear or any other damage.

Boot

Ensure that the boot is free from damage such as crack, deterioration, aging or any other damage.

If any damage is exists replace the damaged part with new one.

JFS00075-00075

JFS00076-00076

JFS00077-00077

FS–23

ASSEMBLY

Outboard joint side

1. Wind vinyl tape to the spline section of the inboard joint shaft, so that the boot may not be damaged during the installation.

2. Install the boot to outboard joint in position as shown.

3. Install the new boot band (smaller diameter side) on the outboard joint.

4. Pack the specified amount of specified grease into outboard joint.

Specified Amount of Grease: 65

10 g

CAUTION:

The grease for outboard joint should be use specified grease only which is supplied with the spare parts.

5. Install and tie-up the new boot band (Larger diameter side) in place.

Inboard joint side

1. Temporarily install the boot and boot band (smaller diameter side).

2. Remove the vinyl tape that was wound around the splined portion.

3. Install the cage to the shaft.

NOTE:

The cage should be inserted in the direction indicated in the figure.

4. Install the inner race, using the following SST.

SST: 09309-87201-000

JFS00078-00078

JFS00079-00079

JFS00080-00080

SST

JFS00081-00081

5. Install the new snap ring to the shaft, using a snap ring pliers.

CAUTION:

Ensure that the snap ring installed in the groove properly after installation.

JFS00082-00082

FS–24

6. Assemble the inner race and cage, and install the ball.

While holding the ball to prevent it from dropping, assemble the inboard shaft subassembly.

7. Install the snap ring to the inboard joint.

CAUTION:

Ensure that the snap ring installed in the groove properly after installation.

8. Tie-up the smaller side boot band.

CAUTION:

Place the boot in position as shown. (Refer to the

FS–23.)

9. Pack the specified amount of grease into inboard joint.

Specified Amount of Grease: 75

10 g

CAUTION:

The grease for inboard joint should be use specified grease only which is supplied with the spare parts.

10. Install and tie-up the new band (Larger diameter side) in place.

JFS00083-00083

JFS00084-00084

JFS00085-00085

REPLACEMENT OF TRANSFER OIL SEAL

Replace the oil seal, as required. (For the replacement procedure, refer to the TR section.)

INSTALLATION

1. Apply chassis grease to the whole serrated section of the front drive shaft at the outboard joint side.

2. Connect the inboard joint section of the front drive shaft into the transfer.

NOTE:

Apply lithium soap base multi purpose grease to the lip section of the oil seal.

Never made scratch on the oil seal during the installation of the drive shaft.

3. Install the steering knuckle with front axle hub to the drive shaft.

4. Connect the steering knuckle to the shock absorber with attaching bolts and nuts. (Refer to the FS–10.)

5. Connect the suspension lower arm to the steering knuckle. (Refer to the FS–10.)

6. Connect the tie-rod end to the steering knuckle. (Refer to the FS–10.)

7. Install the drive shaft end washer and nut. (Refer to the

FS–11.)

8. Install the adjusting lock cap.

9. Install the new cotter pin. (Refer to the FS–11.)

10. Install the skid control sensor to the sensor mounting bracket. (Only for vehicles equipped with ABS.)

11. Install the brake disc to the steering knuckle.

12. Install the disc brake assembly to the steering knuckle.

(Refer to the FS–11.)

13. Fill the specified transmission oil to the transfer. (Refer to the TR section.)

14. Install the wheel with hub nuts and tighten the hub nut fully by hand.

15. Jack down the vehicle.

16. Tighten the hub nut to specified tightening torque. (Refer to the FS–11.)

17. Perform the inspection of the front wheel alignment.

(Refer to the “WHEEL ALIGNMENT” section.)

FS–25

JFS00086-00000

JFS00087-00086

JFS00088-00087

FS–26

TIGHTENING TORQUE

Components

Wheel hub nut

Steering knuckle

Suspension lower arm

Member

Stabilizer link

Suspension lower arm

Shock absorber

Steering knuckle

Stabilizer bracket

Stabilizer bracket sub-assembly

Shock absorber piston end nut

Suspension support

Front fender apron

Stabilizer bracket sub-assembly

Frame

Drive shaft

Front axle hub

Tie-rod end lock nut

Tie-rod end

Steering knuckle

Speed sensor bracket

Speed sensor

Steering knuckle

Disc brake assembly

N·m

88.2 - 117.6

44.1 - 58.8

117.6 - 176.4

12.7 - 23.5

101.9 - 152.9

12.7 - 23.5

37.8 - 56.4

28.4 - 42.2

12.7 - 23.5

196.6

29.4

59.8 - 89.2

39.2 - 53.9

6.9 - 9.8

90.2 - 135.3

kgf-m

9.0 - 12.0

4.5 - 6.0

12.0 - 18.0

1.3 - 2.4

10.4 - 15.6

1.3 - 2.4

3.85 - 5.75

2.9 - 4.3

1.3 - 2.4

20.0

3.0

6.1 - 9.1

4.0 - 5.5

0.7 - 1.0

9.2 - 13.8

JFS00089-00000

Shape Part number

09309-87201-000 Replacer

Part name

09310-87302-000 Replacer

09506-87302-000 Replacer

09511-87202-00 Stopper, brake drum

09520-00031-000 Puller, axle shaft

09611-87701-000 Puller, tie-rod end

09648-87201-000 Replacer, drive shaft

09718-87702-000 Replacer, front disc

09722-87702-000 Attachment, camber

09727-87701-000 Compressor, spring

09950-10012-000 Tool set, replacer

09950-20017-000 Puller, universal

Remarks

FS–27

JFS00000-00088

DAIHATSU

J100

REAR AXLE & SUSPENSION

REAR AXLE & SUSPENSION ........... RS– 2

COMPONENTS

............................. RS– 2

PRIMARY INSPECTION

................ RS– 3

SHOCK ABSORBER ......................... RS– 4

REMOVAL

..................................... RS– 4

INSPECTION

................................. RS– 4

INSTALLATION

.............................. RS– 4

LATERAL CONTROL ROD ................ RS– 6

REMOVAL

..................................... RS– 6

INSPECTION

................................. RS– 6

INSTALLATION

.............................. RS– 7

UPPER CONTROL ARM ................... RS– 9

REMOVAL

..................................... RS– 9

INSPECTION

................................. RS– 9

INSTALLATION

.............................. RS– 9

LOWER CONTROL ARM ................... RS–11

REMOVAL

..................................... RS–11

INSPECTION

................................. RS–11

INSTALLATION

.............................. RS–12

REAR AXLE SHAFT .......................... RS–13

REMOVAL

..................................... RS–13

DISASSEMBLY

.............................. RS–14

INSPECTION

................................. RS–15

ASSEMBLY

.................................... RS–15

INSTALLATION

.............................. RS–17

REAR AXLE SHAFT HOUSING ........ RS–18

REMOVAL

..................................... RS–18

DISASSEMBLY

.............................. RS–19

INSPECTION

................................. RS–20

ASSEMBLY

.................................... RS–20

INSTALLATION

.............................. RS–21

TIGHTENING TORQUE ...................... RS–23

SST...................................................... RS–23

JRS00001-00000

NO. 9710-JE

RS–2

REAR AXLE & SUSPENSION

COMPONENTS

q r

49.0 - 88.3

(5.0 - 9.0) e t y u i y t

N o

6.9 - 15.7

(0.7 - 1.6)

73.5 - 93.1

(7.3 - 9.5)

53.9 - 78.5

(5.5 - 8.0)

73.5 - 107.9

(7.3 - 11.0)

: Tightening torque

Unit : N·m (kgf-m)

@6 q

Upper rear spring seat w

Rear spring bumper e

Coil spring r

Under rear spring seat t

Plate y

Bush u

Collar i

Lateral control rod o

Dynamic dumper

Bush

Stay

Rear axle shaft housing

Plate

Bush

Shock absorber

Bush

Upper control arm

Bush

Lower control arm

Backing plate

Rear axle shaft bearing inner retainer

Rear axle shaft bearing

Shim

Rear axle shaft bearing outer retainer

Rear axle shaft

Hub bolt

JRS00002-00001

PRIMARY INSPECTION

Inspection of tire & wheel

1. Check that the wheel exhibits no breakage, cracks, dent, and so forth.

2. Check the tire for wear, breakage and cracks. Also, check that no foreign substance is embedded into the tire.

3. Inspect the air inflation pressure of the tires.

4. Inspect the runout of the tires. (Refer to the FS section.)

Inspection of wheel bearing free play

1. Jack up the vehicle and support it with safety stands.

(Refer to the GI section.)

2. Remove the rear wheels.

3. Perform the free play measurement at a point of the hub edge with a dial gauge.

4. If the free play exceeds the allowable limit, replace the rear axle bearing.

Allowable Limit

Axial Direction: 0.8 mm or less

Vertically Against Axial Direction: 0.1 mm or less

Inspection of rear axle shaft runout

1. Jack up the vehicle and support it with safety stands.

(Refer to the GI section.)

2. Remove the rear wheels.

3. Remove the brake drum. (Refer to the BR section.)

4. Perform the runout measurement at a point of the axle hub outer edge.

5. If the runout exceeds the allowable limit, change the rear axle shaft.

Runout Limit : 0.2 mm

RS–3

JRS00003-00000

JRS00004-00002

JRS00005-00003

RS–4

SHOCK ABSORBER

REMOVAL

1. Jack up the vehicle and support it with safety stands.

(Refer to the GI section.)

2. Remove the rear wheels.

3. Remove the shock absorber attaching nuts.

NOTE:

•

At this stage, do not take out the bolt.

4. Lift the rear axle carrier, using a garage jack, so that no tension may be applied to the shock absorber attaching bolt. Under this condition, remove the shock absorber attaching bolt.

5. Remove the plates, bushes and shock absorber from the shock absorber attaching stud bolt.

JRS00006-00004

INSPECTION

Shock absorber

Check that the shock absorber exhibits no oil leakage nor major scores by observing its external appearance.

Extend and contract the shock absorber by your hands.

During this operation, ensure that the shock absorber moves smoothly and that there is no abnormal resistance or rattle.

Ensure that the maximum and minimum lengths conform to the specified values.

Specified Length: Min: 305 mm

Max: 496 mm

If any damage or malfunction is exists, replace the part with new one.

Upper bush and Plate

Bush

Check that the bush exhibits no breakage cracks, deformation, and so forth.

Plate

Check that the plate exhibits no deformation, warpage, and so forth.

If any damage is exists, replace the part with new one.

INSTALLATION

1. Install the plate and bush to the shock absorber attaching stud bolt.

CAUTION:

•

Assemble the plate and bush as indicated in the figure.

305 mm

496 mm

JRS00007-00005

Plate

Bush Bush

JRS00008-00006

Plate

Vehicle side

Nut

Sock absorber

JRS00009-00007

2. Install the shock absorber to the shock absorber attaching stud bolt.

3. Install the bush and plate to the shock absorber attaching stud bolt.

CAUTION:

•

Assemble the plate and bush, as indicated in the figure in Step 1.

4. Temporarily tighten the shock absorber attaching nut.

5. Lift the rear axle carrier, using a garage jack, so that the installation section of the shock absorber may be aligned with that of the lower control arm. Under this condition, install and temporarily tighten the shock absorber attaching bolt.

CAUTION:

•

Make sure that the threaded portions of the bolts face toward the vehicle outside.

6. Install the rear wheels.

Tightening Torque: 88.2 - 117.6 N·m

(9.0 - 12.0 kgf-m)

7. Jack down the vehicle.

8. Rock the vehicle in an up-and-down direction several times so that the suspension may be settled.

9. Tighten the sock absorber attaching bolt and nuts.

Tightening Torque: 53.9 - 78.5 N·m (5.5 - 8.0 kgf-m)

RS–5

JRS00010-00008

JRS00011-00009

JRS00012-00010

RS–6

LATERAL CONTROL ROD

REMOVAL

1. Jack up the vehicle and support it with safety stands.

(Refer to the GI section.)

2. Remove the lateral control rod.

CAUTION:

•

Never reuse the removed nuts.

3. Remove the dynamic dumper from the lateral control rod.

INSPECTION

Lateral control rod

Check that the lateral control rod exhibits no warpage, deformation and major scores.

If any damage is exists, replace the damaged part with new one.

Check that the bush exhibits no cracks, breakage, deformation, and so forth.

Replace any abnormal bush.

Dynamic dumper

Check that the rubber section exhibits no cracks, deformation, and so forth.

If any damage is exists, replace the damaged part with new one.

Bush, Plate and collar

Bush

Check that the bush exhibits no cracks, deformation, and so forth.

Plate and collar

Check that the bush and collar exhibit no deformation, warpage, and so forth.

If any damage is exists, replace the damaged part with new one.

JRS00013-00011

JRS00014-00012

JRS000015-00013

JRS00016-00014

JRS00017-00015

RS–7

Replacement of lateral control rod bush

1. Remove the bush, using a suitable tool in combination with a hydraulic press.

NOTE:

•

Use a suitable tool, such as a tool indicated in the figure.

2. Apply the Samper R 107 to a new bush. Then, press-fit the bush in the lateral control rod, using a suitable tool in combination with a hydraulic press.

CAUTION:

•

Be very careful not to apply pressure to the inner sleeve of the bush. Make sure that the difference in dimensions at the sections A and B is within 1 mm during the press-fitting, as indicated in the figure.

INSTALLATION

1. Install the dynamic dumper to the lateral control rod.

Tightening Torque: 6.9 - 15.7 N·m (0.7 - 1.6 kgf-m)

JRS00018-00016

JRS00019-00017

JRS00020-00018

2. Install the plate and bush to the lateral control rod attaching stud bolt.

CAUTION:

•

Assemble the plate and bush, as indicated in the figure.

Plate

Bush

Cdor

Bush

Plate

3. Install the lateral control rod to the lateral control rod attaching stud bolt. (Lower control arm attaching side)

4. Install the collar, bush and washer to the lateral control rod attaching stud bolt. (Lower control arm attaching side.)

CAUTION:

•

Assemble the collar, bush and plate, as indicated in the figure in Step 2.

5. Temporarily tighten the lateral control rod attaching nut.

(Lower control arm attaching side)

Nut

JRS00021-00019

JRS00022-00020

RS–8

5. Temporarily install the lateral control rod to the reinforcement.

CAUTION:

•

Make sure that the threaded portions of the bolts face toward the vehicle outside.

6. Jack down the vehicle.

7. Rock the vehicle in an up-and-down direction several times so that the suspension may be settled.

8. Tighten the lateral control rod attaching nuts.

Tightening Torque:

Rear axle shaft housing side:

49.0 - 88.3 N·m (5.0 - 9.0 kgf-m)

Reinforcement side:

73.5 - 93.1 N·m (7.5 - 9.5 kgf-m)

JRS00023-00021

JRS00024-00022

UPPER CONTROL ARM

REMOVAL

1. Jack up the vehicle and support it with safety stands.

(Refer to the GI section.)

2. Remove the rear wheels.

3. Retain the rear axle shaft housing, using a garage jack, etc.

4. Remove the speed sensor wire from the bracket at the upper control arm. (Only for vehicles equipped with ABS)

5. Remove the upper control arm.

INSPECTION

Upper control arm

Check that the upper control arm exhibits no warpage, deformation and major scores.

If any damage is exists, replace the damaged part with new one.

Check that the bush exhibits no cracks, breakage, deformation, and so forth.

Replace any abnormal bush.

Replacement of upper control arm bush

For the replacement procedure for the bush, refer to the procedure for the lateral control rod bush, for the replacement procedure is the same. However, care must be exercised so that the difference in dimensions at the sections A and B of the bush may become within 1 mm. Also, make sure that the slit assumes the position indicated in the figure during the press-fitting.

INSTALLATION

1. Temporarily install the upper control arm.

CAUTION:

•

With regard to the bolts connecting the upper control and rear axle shaft housing, make sure that the threaded portions of the bolts face toward the vehicle outside.

RS–9

JRS00025-00023

JRS00026-00024

JRS00027-00025

JRS00028-00026

JRS00029-00027

RS–10

2. Install the rear wheels. (Refer to the RS–5.)

3. Jack down the vehicle.

4. Rock the vehicle in an up-and-down direction several times so that the suspension may be settled.

5. Tighten the upper control arm attaching bolt and nut.

Tightening Torque:

73.5 - 107.9 N·m (7.5 - 11.0 kgf-m)

JRS00030-00028

LOWER CONTROL ARM

REMOVAL

1. Jack up the vehicle and support it with safety stands.

(Refer to the GI section.)

2. Remove the rear wheels.

3. Remove the brake cable from the bracket at the lower control arm.

4. Loosen the bolts and nuts at the following sections: Lower control arm

× shock absorber, lower control arm

× rear axle shaft housing, and lower control arm

× body.

5. Lift the rear axle carrier, using a garage jack, so that no tension may be applied to each bolt that has been loosened in Step 4. Then, remove the lower control arm by removing the bolts and nuts.

INSPECTION

Lower control arm

Check that the lower control arm exhibits no warpage, deformation and major scores.

If any damage is exists, replace the damaged part with new one.

Check that the bush exhibits no cracks, breakage, deformation, and so forth.

Replace any abnormal bush.

Replacement of lower control arm bush

For the replacement procedure for the bush, refer to the procedure for the lateral control rod bush, for the replacement procedure is the same.

RS–11

JRS00031-00029

JRS00032-00030

JRS00033-00031

RS–12

INSTALLATION

1. Temporarily install the lower control arm attaching bolts and nuts.

CAUTION:

•

As regards the bolts connecting the lower control arm to the shock absorber, and the lower control arm to the rear axle shaft housing, make sure that the threaded portions of the bolts face toward the vehicle outside.

2. Install the rear wheels. (Refer to the RS–5.)

3. Jack down the vehicle.

4. Rock the vehicle in an up-and-down direction several times so that the suspension may be settled.

5. Tighten the lower control arm attaching bolts and nuts.

Tightening Torque: lower control arm

× shock absorber :

53.9 - 78.5 N·m (5.5 - 8.0 kgf-m) lower control arm

× rear axle shaft housing :

73.5 - 107.9 N·m (7.5 - 11.0 kgf-m) lower control arm

× body :

73.5 - 107.9 N·m (7.5 - 11.0 kgf-m)

6. Connect the brake cable to the bracket at the lower control arm.

JRS00034-00032

JRS00035-00000

REAR AXLE SHAFT

REMOVAL

1. Jack up the vehicle and support it with safety stands.

(Refer to the GI section.)

2. Remove the rear wheels.

3. Drain the rear differential oil. (Refer to the DF section.)

4. Remove the rear brake drum. (Refer to the BR section.)

5. Remove the rear axle shaft bearing outer retainer attaching nuts, using the box wrench through the hole on the rear axle hub.

6. Remove the rear axle shaft assembly, using the following

SST.

SST : 09520-00031-000

CAUTION:

•

Be very careful not to damage the oil seal of the rear axle shaft housing when removing the rear axle shaft.

7. Remove the shim.

CAUTION:

•

Never make damage on the shim during removal.

RS–13

JRS00036-00033

JRS00037-00034

JRS00038-00035

JRS00039-00036

RS–14

DISASSEMBLY

1. Clamp the rear axle shaft in a vice.

2. Grind off the rear axle shaft bearing inner retainer, using a hand grinder or the like.

WARNING:

•

Be sure to observe the operation instructions by the hand grinder manufacturer.

•

Be sure to wear goggles during the grinding operation.

CAUTION:

•

When grinding the retainer with a grinder, if the bearing should be ground inadvertently, most likely the bearing may break off during the vehicle running, (because this bearing is a critical part that sustains fully the vehicle weight.) Also a defective bearing could result in poor sealing. Therefore, be certain to replace the bearing with a new one.

•

Likewise, when the bearing inner race should be ground inadvertently, also be sure to replace it with a new one.

3. Split the retainer with a chisel and a hammer.

WARNING:

•

Before splitting the retainer with a chisel, be sure to wear protective goggles and gloves.

4. Pull out the rear axle shaft bearing with the rear axle shaft bearing inner retainer.

5. Remove the rear axle shaft outer retainer from the rear axle shaft.

6. Drive out the hub bolts from the rear axle shaft, using a plastic hammer or the like.

CAUTION:

•

Never reuse the removed hub bolts.

Hand grinder

JRS00040-00037

JRS00041-00000

JRS00043-00040

INSPECTION

Rear axle shaft

1. Place the rear axle shaft on a V-block.

2. Ensure that the runout at the flange end surface is within the allowable limit.

Maximum Allowable Limit: 0.2 mm

NOTE:

•

This maximum allowable runout does not include the runout caused by roughness on the flange surface.

•

If the flange surface exhibits roughness, finish the surface with an abrasive paper or the like.

3. Ensure that the runout at the center unmachined section is within the allowable limit.

Maximum Allowable Limit: 1.5 mm

4. Ensure that the rear axle shaft spline section exhibits no damage, such as cracks and/or wear.

5. Ensure that the oil seal contact surface or rear axle shaft exhibits no damage, such as cracks, scores and/or rust.

If any damage is exists, replace the damaged part with new one.

ASSEMBLY

1. Install the hub bolt to the rear axle shaft.

2. Install the rear axle shaft bearing outer retainer to the rear axle shaft.

3. Install the rear axle shaft bearing to the rear axle shaft, using a hydraulic press.

RS–15

JRS00044-00041

JRS00045-00042

JRS00046-00043

JRS00047-00044

SST

JRS00048-00045

RS–16

4. Installation of rear axle shaft bearing inner retainer.

(1) Heat the retainer to 150

C in an oil bath.

NOTE:

•

Perform this operation promptly before the retainer temperature drops.

•

When the temperature exceeds 150

C, the surface of the retainer will be turned to yellow. In this case, be careful not to heat the retainer any further.

WARNING:

•

Special attention must be paid not to burn yourself.

(2) Install a new retainer to the rear axle shaft, using a hydraulic press.

150

Inner retainer

Oil bath

JRS00049-00046

JRS00050-00000

Replacement of rear axle shaft housing oil seal

1. Remove the rear axle shaft housing oil seal, using the following SST.

SST : 09308-00010-000

2. Install a new oil seal to the rear axle shaft housing, using the following SST.

SST : 09517-12010-000

CAUTION:

•

Make sure that the oil seal assumes the position indicated in the figure.

3. Apply lithium-based multi purpose grease to the lip section of the installed oil seal.

JRS00051-00048

4.8

0.5

JRS00052-00049

INSTALLATION

1. Apply Three Bond R 11040 or relevant to both sides of the shim, as indicated in the figure.

CAUTION:

•

Do not apply sealer to the drain hole.

•

As regards the rear axle shaft bearing shim, the thickness of the shim has been determined according to the thickness of the backing plate. Therefore, be sure to select a shim having the same thickness as that of the removed shim. (For selection of the rear axle bearing shim, refer to the BR section.)

2. Install the rear axle shaft bearing shim to the backing plate.

3. Install the rear axle shaft to the rear axle shaft housing.

CAUTION:

•

Be very careful not to damage the rear axle shaft housing oil seal by the spline section of the rear axle shaft.

•

Care must be exercised so that the rear differential may not be damaged when inserting the rear axle shaft. Never insert it forcibly.

4. Tighten the attaching nuts of the rear axle shaft.

Tightening Torque : 53.9 - 68.6 N·m (5.5 - 7.0 kgf-m)

5. Install the brake drum to the backing plate.

6. Fill the differential oil. (Refer to the DF section.)

7. Install the rear wheels. (Refer to the RS–5.)

8. Jack down the vehicle.

RS–17

JRS00053-00050

JRS00054-00051

JRS00055-00052

RS–18

REAR AXLE SHAFT HOUSING

REMOVAL

1. Drain the brake fluid. (Refer to the BR section.)

2. Jack up the vehicle and support it with safety stands.

(Refer to the GI section.)

3. Remove the rear wheels.

4. Drain the differential oil. (Refer to the DF section.)

5. Remove the brake drum. (Refer to the BR section.)

6. Remove the rear axle shaft. (Refer to the “REAR AXLE

SHAFT” section.)

7. Disconnect the brake tube from the backing plate.

CAUTION:

•

Since the brake fluid flows out, be very careful not to get the fluid to your hands. Also, care must be exercised so that the fluid may not get to other parts.

8. Remove the ABS sensor from the backing plate. (Only for vehicles equipped with ABS)

9. Remove the backing plate from the rear axle housing.

NOTE:

•

If any difficulty is encountered in removing the backing plate, prior to the removal, lightly tap the backing plate, using a plastic hammer or the like.

•

Leave the backing plate suspended, as indicated in the figure.

10. Remove the rear propeller shaft. (Refer to the PR section.)

11. Disconnect the brake tube from the brake hose at the rear axle shaft housing.

CAUTION:

•

Since the brake fluid flows out, be very careful not to get the fluid to your hands. Also, care must be exercised so that the fluid may not get to other parts.

12. Disconnect the brake hose from the bracket by removing the E-ring.

JRS00056-00053

JRS00057-00054

JRS00058-00055

JRS00059-00056

13. Remove the lateral control rod and upper control arm so that the rear axle shaft housing may be retained by the lower control arm and shock absorber. (Refer to the “LAT-

ERAL CONTROL ROD, UPPER CONTROL ARM” section.)

14. Retain the rear axle shaft housing with a garage jack, etc.

Under this condition, remove the shock absorber and lower control arm.

15. Remove the coil spring.

16. Take out the rear axle shaft housing.

17. Remove the rear spring bumper from the body.

18. Remove the upper rear spring seat from the body.

DISASSEMBLY

1. Remove the under rear spring seat from the rear axle shaft housing.

2. Remove the brake tube from the rear axle shaft housing.

3. Remove the breather plug oil deflector from the rear axle shaft housing.

4. Remove the rear differential carrier assembly from the rear axle shaft housing. (Refer to the DF section.)

RS–19

JRS00060-00057

JRS00061-00058

JRS00062-00059

JRS00063-00060

JRS00064-00061

RS–20

INSPECTION

Rear axle shaft housing

Check that the external appearance of the rear axle shaft housing exhibits no major dent and scores. Also, check that the lateral control rod attaching stud bolt exhibits no scores.

If any damage is exists, replace the damaged part with new one.

Replace the oil seal, if necessary. (For the changing procedure, refer to the RS–16.)

Coil spring

Ensure that the coil spring is free from deformation, deterioration, crack or other damage.

If any damage is exists, replace the damaged part with new one.

Upper and under rear spring seats and rear spring bumper

Ensure that the upper and under rear spring seats and rear spring bumper free from cracks, deterioration, aging and other damage.

If any damage is exists, replace the damaged part with new one.

ASSEMBLY

1. Install the rear differential carrier assembly to the rear axle shaft housing. (Refer to the DF section.)

2. Install the breather plug oil deflector to the rear axle shaft housing.

3. Install the brake tube to the rear axle shaft housing.

4. Install the under rear spring seat to the rear axle shaft housing.

JRS00065-00062

JRS00066-00063

JRS00067-00064

JRS00068-00065

JRS00069-00066

INSTALLATION

1. Install the rear spring bumper to the body.

2. Install the upper rear spring seat to the body.

3. Put the coil spring on the spring seat. Then, lift the rear axle shaft housing to an appropriate height, using a garage jack or the like.

NOTE:

•

Set the coil spring in such a way that the marking comes at the lower side, as viewed from the rear side of the vehicle.

•

Be sure to insert the coil spring into the specified position when lifting the rear axle shaft housing, using a garage jack.

4. Temporarily install the lateral control rod, upper control arm, lower control arm and shock absorber.

5. Install the rear propeller shaft. (Refer to the PR section.)

6. Connect the brake hose to the bracket with the E-ring.

7. Connect the brake tube to the brake hose

Tightening Torque : 12.8 - 17.6 N·m (1.3 - 1.8 kgf-m)

8. Installation of backing plate

(1) Apply silicon bond No. 1212 or relevant to the housing end, as indicated in the figure.

(2) Install the backing plate to the rear axle shaft.

RS–21

JRS00070-00067

JRS00071-00068

JRS00072-00069

JRS00073-00070

JRS00074-00071

RS–22

9. Install the rear axle shaft. (Refer to the “REAR AXLE

SHAFT” section.)

10. Connect the brake tube to the backing plate.

Tightening Toque : 12.8 - 17.6 N·m (1.3 - 1.8 kgf-m)

11. Connect the brake hose to the bracket of the upper control arm.

12. Install the ABS sensor to the backing plate.

13. Install the brake drum.

14. Fill the differential oil. (Refer to the DF section.)

15. Install the rear Wheel. (Refer to the RS–5.)

16. Jack down the vehicle.

17. Rock the vehicle in an up-and-down direction several times so that the suspension may be settled.

18. Securely tighten the attaching bolts and nuts of the lateral control rod, upper control rod, lower control rod and shock absorber. (For the tightening torque and tightening procedure, refer to the relevant sections.)

19. Fill the brake oil. (Refer to the MA section.)

JRS00075-00072

JRS00076-00073

JRS00077-00000

TIGHTENING TORQUE

Components

Shock absorber

Body

Shock absorber

Lower control arm

Lateral control rod

Dynamic dumper

Lateral control rod

Rear axle shaft housing

Lateral control rod

Stay

Upper control arm

Body

Upper control arm

Rear axle shaft housing

Lower control arm

Rear axle shaft housing

Lower control arm

Body

Rear axle shaft

Backing plate

Brake tube

Brake hose

Brake tube

Backing plate

SST

Shape

RS–23

N·m

53.9 - 78.5

6.9 - 15.7

49.0 - 88.3

73.5 - 93.1

73.5 - 107.9

53.9 - 68.6

12.8 - 17.6

kgf-m

5.5 - 8.0

0.7 - 1.6

5.0 - 9.0

7.5 - 9.5

7.5 - 11.0

5.5 - 7.0

1.3 - 1.8

At the rear axle shaft housing

JRS00078-00000

Part number

09520-00031-000

Part name

Puller, rear axle shaft

Remarks

09308-00010-000

09517-12010-000

Puller, oil seal

Replacer, oil seal

JRS00079-00000

DAIHATSU

J100

BRAKES

BASIC CHECK ............................................ BR– 2

BRAKE PEDAL ........................................... BR– 5

BRAKE MASTER CYLINDER .................... BR– 7

BRAKE BOOSTER ..................................... BR–13

FRONT BRAKE ........................................... BR–16

REAR BRAKE ............................................. BR–22

PARKING BRAKE ....................................... BR–30

PROPORTIONING VALVE .......................... BR–33

BRAKE HOSE ............................................. BR–34

ANTI-LOCK BRAKE SYSTEM ................... BR–36

JABS CIRCUIT DIAGNOSIS ..................... BR–37

ABS RELATED CONNECTORS ............... BR–38

ABS CIRCUIT CONNECTION TABLE ...... BR–40

PRECAUTIONS ......................................... BR–42

TROUBLE SHOOTING HINTS .................. BR–44

HOW TO PROCEED TROUBLE

SHOOTING ............................................ BR–45

DIAGNOSIS CODE CHECK ...................... BR–46

UNIT INSPECTION & REPLACEMENT .... BR–70

TIGHTENING TORQUE ............................ BR–91

SSTs .......................................................... BR–92

JBR00001-00000

NO. 9710-JE

BR–2

BASIC CHECK

BRAKE PEDAL

1. Ensure that the brake pedal height is with in specified valve by measuring the brake pedal height.

Specified Value: 162.8 mm (*155.8 mm)

CAUTION:

“*” Mark denote brake pedal height between upper surface of brake pedal pad and upper surface of protrude section of floor panel.

2. Pedal height adjustment

(1) Disconnect the connector from the stop lamp switch.

(2) Slacken the nut of the stop lamp switch and screw out the stop lamp switch, until the brake pedal has a free travel.

(3) Slacken the lock nut of the brake pedal clevis. Turn the push rod so as to adjust the pedal height to the specified value.

(4) Tighten the lock nut of the brake pedal clevis to the specified tightening torque.

Tightening Torque: 25.5

2.9 N·m (2.6

0.3 kgf-m)

(5) Screw in the stop lamp switch, until the clearance between the brake pedal cushion and the edge of the threaded portion of the stop lamp switch becomes 1.5 mm.

(6) Tighten the lock nut of the stop lamp switch to the specified tightening torque.

Tightening Torque: 19.6

7.8 N·m (2.0

0.8 kgf-m)

(7) Connect the connector of the stop lamp switch.Then, proceed to the brake pedal free play check.

3. Pedal free play check

(1) After turning off the engine, depress the brake pedal several times so that no vacuum may remain in the brake booster.

(2) Measure the brake pedal free play by pushing the brake pedal lightly by hand. Here, the brake pedal free play means the distance from a point where the brake pedal is free to a point where you begin to feel a resistance.

Specified Value: 0.5 - 2 mm

(3) Ensure that the free play is within the specified value.

If the brake pedal free play fails to meet the specified value, adjust the brake pedal free play to the specified value.

4. Pedal free play adjustment

(1) Slacken the nut of the brake pedal clevis.

(2) Turn the push rod so as to adjust the pedal free play to the specified value.

Specified Value: 0.5 - 2 mm

(3) Tighten the lock nut of the brake pedal clevis.

Tightening Torque: 25.5

2.9 N·m (2.6

0.3 kgf-m)

(4) Ensure that the brake pedal height is within the specified value and the stop lamp functions properly.

Lock nut

Cushion

Pad

JBR00002-00001

Pedal free play

JBR00003-00002

JBR00004-00003

BR–3

5. Pedal reserve travel check

(1) Start the engine and run the engine at idling.

(2) Depress the brake pedal with a pedal applying force of 300 N (30kgf) with the parking brake lever returned.

(3) Measure the distance between the upper surface of brake pedal pad center and the upper surface of protrude section of floor panel.

Specified Value: 85 mm or more

BOOSTER

IN-VEHICLE CHECK

1. Booster air-tight performance check

(1) Start the engine.

(2) Turn off the engine after a few minutes.

(3) Ensure that the position of the brake pedal height progressively rises every time the brake pedal is depressed.

If the position of the brake pedal rises progressively at the second and third applications, it indicates the brake booster is functioning properly.

CAUTION:

Be sure to keep intervals of each application of the brake pedal at least five seconds or more between the first and second applications as well as the second and third applications.

JBR00005-00004

3rd application

2nd application

1st application

JBR00006-00005

2. Booster air-tight performance check under loaded condition

(1) Start the engine.

(2) Depress the brake pedal fully.

(3) Turn off the engine while depressing the brake pedal.

(4) Ensure that the brake pedal height remains unchanged for more than 30 seconds. It indicates that the booster is functioning properly.

3. Booster operation check

(1) Depress the brake pedal several times under the engine stopped state, until the brake pedal height will no longer change (to release the vacuum pressure retained in the brake booster).

(2) Ensure that the height of the brake pedal will go down when the engine is started while keeping the depressing force of the brake pedal unchanged.

It indicates that the booster is functioning properly.

While the engine is running.

The pedal is held for 30 seconds after the engine is stopped.

Bad

JBR00007-00006

JBR00008-00007

BR–4

4. Booster air-tight performance check under loaded condition

(1) Connect a negative pressure gauge to the booster, using a “T or Y” pipe joint.

(2) Start the engine with the brake pedal depressed with a force of 200 N.

(3) Stop the engine when the negative pressure exceeds

500 mmHg.

(4) Ensure that the negative pressure retained in the brake booster will not drop 25 mmHg or more for 15 seconds since the engine is stopped.

It means that the air tightness is proper. If not, check air leakage of the check valve in the brake booster hose.

AIR BLEEDING

1. Fill and maintain the brake fluid level in the reservoir tank at the upper level during the operation.

NOTE:

If the brake fluid is spilled inadvertently over the paintfinish surface of the vehicle or resin-made parts, immediately wipe off the brake fluid and flush with fresh water.

When drain the brake fluid, do not fill brake fluid into the reservoir tank.

2. Connection of vinyl hose to bleeder plug of wheel cylinder

Connect a suitable vinyl or rubber hose to the bleeder plug of the wheel cylinder and submerge one end of the vinyl or rubber hose in a container filled with the brake fluid. Connect the other end of the vinyl hose to the wheel cylinder bleeder plug of the vehicle.

NOTE:

Start the air bleeding operation at the wheel cylinder which is located at the furthermost point from the master cylinder.

3. Air bleeding

(1) Perform the operation by two persons. One person should depress the brake pedal slowly and hold it in a depressed state.

(2) While depressing the brake pedal, the other person slackens the bleeder plug 1/3 through 1/2 turn to drain the brake fluid. Then, tighten the bleeder plug temporarily.

(3) Repeat the steps (1) and (2) above, until bubbles are no longer observed in the fluid.

NOTE:

It may require more time than the ordinary brake system if the vehicle is equipped with ABS.

(4) Tighten the bleeder plug securely to the specified tightening torque.

Tightening Torque: 6.9 - 9.8 N·m (0.7 - 1.0 kgf-m)

4. Checking of brake fluid leakage

Ensure that no brake fluid leakage exists on the brake line when the brake pedal is depressed fully.

T pipe joint

1 x100mmHg

Front

Rear

JBR00009-00008

JBR00010-00009

JBR00011-000010

JBR00012-00011

BR–5

BRAKE PEDAL

COMPONENTS

★

: Non-reusable parts

★

B q

Brake pedal subassembly w

Brake pedal pad e

Cushion r

Brake pedal bracket t

Brake pedal shaft y

Pedal bracket stay u

Bush i

Spring

NOTE:

★

: The brake pedal shaft installed from right side when model with left hand drive.

Contrary, the brake pedal shaft installed from left side when model with right hand drive.

REMOVAL

1. Remove the instrument panel. (Only when the brake pedal bracket removal is required)

(Refer to the BO section.)

2. Disconnect the connector from the stop lamp switch while unlocking its lock.

3. Remove the stop lamp switch by screwing it out.

4. Disengage the clutch cable from the clutch pedal. (Only for models with manual transmission.)

(Refer to the CL section.)

5. Remove the clip and pin from the brake pedal clevis.

6. Disconnect the wire harness clamp from the brake pedal bracket.

7. Remove the brake pedal bracket by removing the attaching bolts and nuts.

8. Remove the brake pedal by removing its attaching bolts and nuts.

7. Remove the spring from the brake pedal.

8. Remove the bushes from the brake pedal.

9. Remove the brake pedal pad and cushion from the brake pedal.

JBR00013-00012

JBR00014-00000

BR–6

10. Inspect the following parts.

Damage or deformation

Wear or damage

Bend or twist

Damage or deformation

JBR00015-00013

INSTALLATION

1. Apply the specified grease to those points indicated in the right figure.

Specified Grease:

Lithium soap base multi-purpose grease

Both inside and outside

2. Install the cushion, brake pedal pad, bushes and spring to the brake pedal.

Inside

Both inside and outside

JBR00016-00014

3. Install the brake pedal on the brake pedal bracket.

4. Install the brake pedal to the brake pedal bracket while connecting the spring end to the brake pedal bracket with the brake pedal shaft and nut. Then, tighten the nut to the specified tightening torque.

Tightening Torque: 15.2 - 23.0 N·m (1.55 - 2.35 kgf-m)

5. Apply the lithium soap base multi-purpose grease to the clevis pin contacting surface of the brake pedal.

6. Connect the clevis to the brake pedal with the pin and install the clip to the pin securely.

7. Install the brake pedal bracket to the body with the pedal bracket stay, attaching bolts and nuts.

8. Screw in the stop lamp switch to the brake pedal bracket. (Refer to the “Brake pedal” section.)

9. Perform the check and adjustment of the brake pedal. (Refer to the “Brake pedal” section.)

10. Install the instrument panel. (Refer to BO section.)

11. Check that no abnormal noise is emitted when the brake papal is depressed.

JBR00017-00000

BRAKE MASTER CYLINDER

COMPONENTS

q r r w e t

For conventional model only.

BR–7

Brake master cylinder reservoir tank w

Reservoir filler cap e

Reservoir diaphragm r

Grommet t

Brake master cylinder assembly y

Tandem master cylinder repair kit

REMOVAL

1. Disconnect the connector of the brake fluid level switch.

2. Drain the brake fluid from the master cylinder.

(Refer to the “Air bleeding” section for procedure.)

3. Disconnect the brake pipes from the master cylinder.

CAUTION:

If the brake fluid is spilled inadvertently over the paintfinish surface of the vehicle or resin-made parts, immediately wipe off the brake fluid and wash with fresh water.

NOTE: For ABS model

JBR00018-00015

JBR00019-00016

BR–8

4. Remove the master cylinder from the brake booster.

NOTE:

The O-ring is installed on the master cylinder.

It may be hard to remove the master cylinder from the brake booster.

5. Secure the master cylinder to a vise.

6. Remove the slotted pin of the master cylinder reservoir tank, using a suitable knock pin punch.

7. Pull out the brake master cylinder reservoir tank from the master cylinder.

8. Remove the grommets from the master cylinder or reservoir tank.

9. Remove the set bolt and gasket while the pistons are being pushed fully by means of a suitable bar.

(Only when equipped)

NOTE:

Do not push the piston rapidly in order to prevent the brake fluid from splashing.

10. Using snap ring pliers, detach the snap ring while the pistons are being pushed by means of a suitable bar.

JBR00020-00017

JBR00021-00018

JBR00022-00019

JBR00023-00020

JBR00024-00021

BR–9

11. Remove the piston No. 1 from the master cylinder.

CAUTION:

Remove the piston straight, being very careful not to scratch the cylinder bore.

12. Remove the piston No. 2 by lightly applying compressed air at the brake pipe hole.

WARNING:

Be sure to protect your eyes by wearing safety goggles, when using compressed air.

CAUTION:

Never score the cylinder bore during the removal of the piston No. 2.

Remove the piston in a straight direction.

NOTE:

Be sure to prevent the brake fluid from splashing, using a piece of cloth or the like.

13. Inspect the following parts. If any problem is found, repair them, as required.

Damage, deformation or deterioration

JBR00025-00022

Cylinder bore for uneven wear

Damage, deformation or deterioration

Damage or deterioration

ASSEMBLY

1. Wash the master cylinder and components with washing solvent and dry them with compressed air.

WARNING:

Be sure to protect your eyes by wearing safety goggles, when using compressed air.

Damage or corrosion

JBR00026-00023

JBR00027-00024

BR–10

2. Thinly apply brake rubber grease to the lip section of the cups of the piston No. 2 assembly.

3. Install the piston No. 2 into the master cylinder.

4. Thinly apply brake rubber grease to the lip section of the cups and O-ring on the piston No. 1 assembly.

5. Install the piston No. 1 assembly into the master cylinder.

6. Install a new snap ring while pushing the piston No. 1 into the master cylinder, using snap ring pliers.

WARNING:

Never reuse the removed snap ring.

7. Install the set bolt of the piston No. 2 assembly to the master cylinder with a new gasket interposed while pushing the piston No. 2.

Tightening Torque: 7.9 - 11.7 N·m (0.8 - 1.2 kgf-m)

8. Thinly apply brake rubber grease to the grommets.

9. Install the grommets to the master cylinder.

10. Install the brake master cylinder reservoir tank to the master cylinder.

11. Secure the master cylinder reservoir tank to the master cylinder by installing a new slotted pin.

CAUTION:

Never reuse the used slotted pin.

JBR00028-00025

JBR00029-00026

JBR00030-00027

JBR00031-00028

JBR00032-00029

BR–11

INSTALLATION

1. Check the clearance between the master cylinder and the brake booster push rod.

(1) Prepare the following SSTs.

SST: 09730-87401-000

09737-87003-000 q

09733-87401-000 w

09731-87401-000 e

09732-87401-000 r

09734-87401-000 t

09735-87401-000 y

(2) Assemble the components of the above SSTs as follows.

Install the O-ring ( w

) to the O-ring groove of the adjusting rod( q

Install the attachment ( e

) on the adjusting rod

( q

Thinly apply the brake rubber grease to the outer surface of the attachment ( e

(3) Install the O-ring ( t

) and O-ring ( y

) to the adapter

( r

) and apply the brake rubber grease to the O-rings.

(4) Install the adapter ( r

) to the brake booster.

Adapter

O-ring

JBR00033-00000

Attachment

JBR00034-00030

JBR00035-00031

(5) Attach the SST assembled in step (2) on the master cylinder.

(6) Turn the adjusting rod to adjust the clearance between the SST and the piston rod end to zero.

JBR00036-00032

(7) Set the SST on the brake booster as shown.

NOTE:

Apply brake rubber grease to the attaching section of the SST.

(8) Connect a Mity Vac to the brake booster.

(9) Apply a vacuum of 500 mmHg to the booster housing, using the Mity Vac.

(10) Ensure that the clearance between the SST and the piston rod is zero by turning the adjusting rod lightly.

Attachment

Push rod

Adapter

JBR00037-00033

BR–12

WARNING:

Be sure to adjust the clearance properly. Failure to observe this warning may lead to brake system problem.

NOTE:

If the clearance fails to meet the specified value, adjust the clearance between the SST and the push rod of the brake booster to zero, by turning the adjusting tip provided at the top of the push rod of the brake booster.

(11) Adjustment of brake booster push rod height

Adjust the brake booster push rod height while depressing the brake pedal fully.

(12) Ensure that the clearance between the push rod and the SST is zero.

WARNING:

Be sure to adjust the clearance properly. Failure to observe this warning may lead to brake system problem.

(13) Remove the SST from the brake booster.

(14) Remove the Mity Vac from the brake booster.

(15) Connect the vacuum hose to the brake booster.

2. Thinly apply brake rubber grease to the oil seal on the master cylinder piston shaft.

3. Install the master cylinder to the brake booster with attaching nuts. Tighten the attaching nuts evenly to the specified tightening torque.

Tightening Torque: 12.7

2.5 N·m (1.3

0.3 kgf-m)

WARNING:

Be sure to perform the adjustment of the brake booster push rod height, if any inner part of the master cylinder has been replaced.

Failure to observe this warning may lead to damage or malfunction of the brake system.

4. Temporarily connect the brake pipes to the master cylinder and tighten the flare nuts to the specified tightening torque.

Tightening Torque: 12.7 - 17.7 N·m (1.3 - 1.8 kgf-m)

5. Connect the brake fluid level switch connector.

6. Perform air bleeding for the brake system.

7. Ensure that no fluid leakage exists on the brake system.

8. Perform the checks and adjustments of the brake pedal height. (Refer to the brake papal section.)

9. Check the brake fluid leakage on the brake system.

JBR00038-00000

JBR00039-00034

JBR00040-00000

JBR00041-00035

JBR00042-00036

BR–13

BRAKE BOOSTER

COMPONENTS

RHD t

★ r e

★

N w

★ t y

LHD r t

★ q

B i u u

★ t y

★ t o

★ t q

Brake booster assembly w

Master cylinder push rod clevis e

Brake booster bracket gasket r

Union to connector tube t

Clip y

Union u

Intake manifold tube clamp i

Intake manifold to connector tube o

Union to check valve hose

REMOVAL

1. Remove the brake master cylinder.

(Refer to the “Brake master cylinder” section for removal.)

CAUTION:

If the brake fluid is spilled inadvertently over the paint finish surface of the vehicle or resin part, immediately wipe off the brake fluid and wash with fresh water.

2. Remove the vacuum hose from the vehicle.

★

: Non-reusable parts

N q w e

★

JBR00043-00037

JBR00044-00038

BR–14

3. Remove the instrument finish lower panel by removing the two attaching bolts.

4. Remove the clip of the push rod clevis pin.

5. Remove the push rod clevis pin.

6. Loosen the brake booster attaching nuts evenly.

7. Remove the brake booster attaching nuts.

8. Remove the brake booster from the dash panel.

CAUTION:

Be very careful not to deform the brake tubes during the removal of the brake booster.

INSPECTION

1. Inspection of check valve (vacuum hose)

Check that continuity exists from the booster side to the engine side. Also, check that no continuity exists from the engine side to the booster side.

If the inspection results are not satisfactory, replace the vacuum hose.

2. Inspection of booster push rod-to-master cylinder clearance

Check the clearance of the brake booster push rod.

(Refer to the “Brake master cylinder” section.)

INSTALLATION

1. Install the brake booster to the dash panel with a new brake booster bracket gasket interposed.

2. Install the attaching nuts and tighten them to the specified tightening torque.

Tightening Torque: 9.8 - 15.7 N·m (1.0 - 1.6 kgf-m)

CAUTION:

Care must be exercised so that the brake tubes may not be interfered with the brake pedal during the installation.

3. Connect the clevis and brake pedal with the clevis pin.

If any difficulty is encountered in installing the clevis pin, loosen the lock nut of the clevis and adjust the length of the push rod of the brake booster by turning the brake booster push rod or clevis.

4. Apply chassis grease to the sliding surface of the components.

5. Install a new clip to the clevis pin.

6. Perform the check and adjustment of the brake pedal.

(Refer to the “Brake pedal” section.)

JBR00045-00039

JBR00046-00040

Engine side

JBR00047-00041

JBR00048-00000

JBR00049-00042

6. Install the instrument finish lower panel and install two attaching screws.

7. Install the brake master cylinder.

(Refer to the brake master cylinder section for installation.)

CAUTION:

Be sure to follow the installation procedure for the brake master cylinder described in the above mentioned section. Failure to observe this caution may lead to serious accidents or problems.

8. Perform the air bleeding.

(Refer to BR–4.)

9. Check the brake performance with a four-wheel brake tester.

BR–15

JBR00050-00000

BR–16

FRONT BRAKE

COMPONENTS

★

: Non-reusable parts

★

o q

Main cylinder slide pin w

Sub-cylinder slide pin e

Disc brake No. 1 pad r

Disc brake No. 2 pad t

Anti-squeal shim y

Shim u

Disc brake pad guide No. 2 plate i

Disc brake pad guide plate o

Disc brake cylinder mounting (R, L)

Cylinder boot

Front disc brake piston

Piston seal

Pin boot

INSPECTION

1. Jack up the vehicle and support the vehicle with safety stands. (Refer to the GI section.)

2. Remove the front wheels.

3. Check the pad thickness through the inspection hole provided at the disc brake caliper as shown.

Specified Thickness: 10 mm

Minimum Thickness: 1 mm

If the brake pad thickness is less than the specified value or the wear indicator emits a warning sound, replace the brake pad with a new one.

CAUTION:

Be sure to replace the right and left side brake pads as a set. Failure to observe this caution may lead to side pull of the brake function.

4. Install the front wheels.

y i u r e t

JBR00051-00043

JBR00052-00044

REMOVAL

NOTE:

The replacement procedure of the brake pads is not mentioned in this service manual. Refer to the procedure which is necessary to replace the brake pads.

1. Jack up the vehicle and support the vehicle with safety stands. (Refer to the GI section.)

2. Remove the front wheels.

3. Drain the brake fluid from the front brake line.

(When only necessary. Refer to the “Air bleeding” section.)

4. Disconnect the brake hose from the disc brake cylinder by removing the union bolt and gasket. (When necessary)

5. Loosen the cylinder slide pins.

6. Remove the cylinder slide sub pin.

7. Turn up the disc brake assembly as shown.

CAUTION:

Be very careful not to pull the brake hoses more than necessary.

8. Remove the disc brake cylinder assembly from the disc brake cylinder mounting.

9. Detach the following parts from the disc brake cylinder mounting.

(1) Disc brake pad

(2) Anti-squeal shims No. 1 and No. 2

(3) Brake pad guide plates No. 1 and No. 2

10. Inspection of brake pad-related parts

Ensure that the disc brake pad-related parts are free from damage, deformation, deterioration or corrosion.

If any damage is found, replace the damaged part with a new one.

CAUTION:

Replace the brake pad when damage or uneven wear exists.

Replace the right and left side brake pads as a set when replacing the brake pads. Failure to observe this caution may lead to side pull of the brake function.

Be sure to perform the brake pad replacement one side by one side. Failure to observe this caution may cause the piston to jump out.

BR–17

JBR00053-00000

JBR00054-00045

JBR00055-00046

JBR00056-00047

BR–18

11. Ensure that the disc rotor thickness is more than that specified value by means of vernier calipers.

Inspect the disc rotor thickness.

Specified Thickness: 16 mm

Minimum Thickness: 15 mm

12. Inspection of disc rotor runout

(1) Secure the disc rotor with hub nuts properly.

CAUTION:

Be sure to use suitable hub nuts if the hub is of a decorated type.

(2) Ensure that the wheel bearings exhibit no looseness.

If an excessive play is found, replace the wheel bearings.

(3) Ensure that the disc rotor runout is within the specified value, using a dial gauge.

Maximum disc runout: 0.10 mm

CAUTION:

Be sure to check the runout at a point 10 mm inward from the outer edge of the disc rotor.

If the measured runout exceeds the allowable limit, replace the disc with a new one.

13. Remove the pin boots from the disc brake cylinder mounting.

14. Remove the disc brake cylinder mounting by removing the attaching bolts.

15. Remove the disc rotor.

Disassembly of front disc brake cylinder assembly

1. Removal of brake piston

Apply compressed air gradually to the brake hose connecting hole of the disc brake cylinder assembly while a piece of cloth is placed at the piston end side, in order to prevent the piston from getting damaged and to prevent the brake fluid from splashing.

WARNING:

Utmost care must be exercised so that your fingers or hands may not be pinched by the piston end.

Be sure to protect your eyes by wearing safety goggles when using compressed air.

JBR00057-00048

JBR00058-00049

JBR00059-00050

JBR00060-00051

2. Remove the cylinder boot from the cylinder.

3 Detach the piston seal from the cylinder, using a suitable minor screwdriver or the like.

CAUTION:

Be very careful not to score the cylinder bore wall, etc.

during the removal.

Assembly of front disc brake cylinder assembly

NOTE:

The assembly procedure is basically reverse to the disassembly procedure. Therefore, some illustrations are not mentioned in this installation procedure.

Please refer to the illustration mentioned in the disassembly procedure if any difficulty is encountered.

1. Assembly of front brake cylinder assembly

(1) Wash the disc brake cylinder and related parts, except rubber parts, with washing solvent and dry them with compressed air.

WARNING:

Be sure to protect your eyes by wearing safety goggles, when using compressed air.

If any damage, deformation, deterioration or wear exists on the components, replace the parts with new ones.

CAUTION:

Replace the rubber parts with new ones.

(2) Thinly apply brake rubber grease to the cylinder wall and the piston seal.

(3) Insert the piston seal to the groove in the disc brake cylinder.

(4) Thinly apply brake rubber grease to the piston and boot.

(5) Install the outer end of the boot to the groove in the cylinder.

(6) Insert the piston into cylinder through the boot, making sure that the piston is not tilted during the installation.

WARNING:

Never score or damage the piston seal, boots, piston and cylinder during the installation.

BR–19

JBR00061-00052

JBR00062-00053

JBR00063-00000

JBR00064-00054

JBR00065-00055

BR–20

(7) Insert the outer end of the boot to the groove provided on the piston properly.

CAUTION:

Never score or damage the boots.

(8) Install the cylinder main pin to the disc brake cylinder assembly by hand.

JBR00066-00056

INSTALLATION

NOTE:

The installation procedure is basically reverse to the removal procedure. Therefore, some illustrations are not mentioned in this installation procedure.

Please refer to the illustration mentioned in the disassembly procedure if any difficulty is encountered.

JBR00067-00000

1. Install the disc rotor on the front hub.

CAUTION:

Be sure to clean the disc rotor attaching surface of the front hub and disc rotor before assembly.

2. Install the disc brake cylinder mounting with the attaching bolts and tighten the attaching bolts to the specified tightening torque.

Tightening Torque: 90.2 -135.3 N·m (9.2 - 13.8 kgf-m)

3. Thinly apply the brake rubber grease to the pin boots.

4. Install the pin boots to the disc brake cylinder mounting.

NOTE:

Install the sub-cylinder slide pin boot, using the sub-cylinder slide pin.

5. Install the disc brake pad guide plates on the disc brake cylinder mounting.

6. Install the brake pads, anti-squeal shims and shims to the disc brake cylinder mounting.

7. Thinly apply the brake rubber grease to the sliding surface of the cylinder slide main pin.

8. Install the disc brake cylinder assembly to the disc brake cylinder mounting.

9. Turn over the disc brake assembly onto the disc brake pads, anti-squeal shims and shim while the pin boots of the sub-cylinder slide pin are being pushed by fingers.

CAUTION:

Be very careful not to pull the brake hoses more than necessary. (When the brake hose is not disconnected)

Be very careful not to damage the pin boots during the assembly.

Care must be exercised so that the brake cylinder may not be interfered with the disc brake pads, anti-squeal shims and shim during the installation.

JBR00068-00000

10. Thinly apply the brake rubber grease to the sliding surface of the sub-cylinder slide pin.

11. Install the sub-cylinder slide pin of the disc brake cylinder assembly to the disc brake mounting.

CAUTION:

Be very careful not to damage the pin boot during the assembly.

12. Tighten the main and sub cylinder slide pins to the specified tightening torque.

Tightening Torque:

Main: 78.5 - 88.3 N·m (8.0 - 9.0 kgf-m)

Sub: 44.1 - 53.9 N·m (4.5 - 5.5 kgf-m)

13. Connect the brake hose to the disc brake cylinder assembly by the union bolt with new gaskets interposed.

14. Tighten the union bolt to the specified tightening torque.

Tightening Torque: 26.5 - 34.3 N·m (2.7 - 3.5 kgf-m)

NOTE:

Make sure that the brake hose is not twisted or stretched.

After completion of the installation, turn the steering wheel from lock to lock position. Make sure that the brake hose is not interfered with other parts.

15. Perform the air bleeding for the brake line.

(Refer to the “Air bleeding” section.)

16. Ensure that no fluid leakage is present on the brake hose connected section and parts between the disc brake cylinder and the disc brake piston.

17. Install the front wheels.

18. Depress the brake pedal more than 10 times.

19. Check to see if the brake disc can rotate smoothly.

20. Ensure that no abnormal sound is emitted or no drag exists when the wheel is rotated.

21. Check the brake performance with a brake tester.

BR–21

JBR00069-00057

JBR00070-00000

BR–22

REAR BRAKE

COMPONENTS

: Tightening torque

Unit : N·m (kgf-m)

★

: Non-reusable parts

9.8

2 (1.0

0.2)

★

7 (6.25

0.75) r

★ t

★

o i

★

★ u y o q

Brake drum subassembly w

Shoe hold-down spring & retainer e

Shoe hold-down spring pin r

Tension No. 4 spring t

Tension No. 3 spring y

Tension spring u

Automatic adjust lever (R, L) i

Parking brake shoe lever (R, L) o

Brake shoe assembly

Parking brake shoe strut

Cylinder assembly

Cylinder cap

Brake backing plate subassembly

Wheel cylinder boot

Wheel brake cylinder piston

Compression spring

Cylinder cup w q

REMOVAL

1. Remove the hole plug at the inspection hole provided on the backing plate.

2. Inspect that the thickness of the brake shoe lining is more than the specified value, through the inspection hole.

Standard thickness: 5.0 mm

Minimum thickness: 1.0 mm

JBR00071-00058

JBR00072-00059

DISASSEMBLY

1. Jack up the vehicle and support it with safety stands.

(Refer to the GI section.)

2. Drain the brake fluid from the rear brake line.

(Refer to the Air breeding section.)

3. Remove the rear wheels.

4. Release the parking brake fully.

5. Remove the rear brake drum from the rear axle hub by pulling it out.

NOTE:

If any difficulty is encountered in removing the brake drum, screw in the 8mm bolts to the brake drum evenly.

The bolt hole is offset. Therefore, after tightening the bolt to a certain extent, lightly tap the brake drum, using a plastic hammer or the like, so that the brake drum may be lifted up evenly.

6. Check the brake drum inner diameter, using suitable vernier calipers.

Specified Diameter: 228.6 mm

Allowable Limit: 229.6 mm

If the diameter exceeds the specified value, replace the brake drum with a new one.

7. Check the brake shoe thickness, using suitable vernier calipers or ruler.

Specified Thickness: 5.0 mm

Allowable Limit: 1.0 mm

If the diameter exceeds the specified value, replace the brake drum with a new one.

8. Check the brake shoe for seizure or abnormal wear, etc.

If any damage exists, replace the brake shoe with a new one.

9. Remove the tension No. 4 spring, using the following SST.

SST: 09703-30010-000

BR–23

JBR00073-00060

JBR00074-00061

JBR00075-00062

JBR00076-00063

BR–24

10. Remove the shoe hold-down spring pin retainers and springs from the shoe hold-down spring pins.

11. Remove the shoe hold-down spring pins.

12. Detach the brake shoes from the backing plate.

13. Remove the leading side brake shoe from the tension

No. 3 spring.

14 Remove the tension No. 3 spring.

15. Remove the parking brake shoe strut from the brake shoe.

16. Disconnect the parking brake cable from the parking brake shoe lever.

NOTE:

If any difficulty is encountered in disconnecting the parking brake cable from the parking brake shoe lever, loosen the parking brake lever adjusting nut fully.

17 Remove the tension spring.

18. Remove the automatic adjuster lever from the brake shoe by removing the E-ring.

CAUTION:

Never reuse the removed E-ring.

19. Remove the parking brake shoe lever and parking brake lever pin from the brake shoe by extracting the C-ring, using outside nose pliers or the like.

CAUTION:

Never reuse the removed C-ring.

20. Remove the wheel cylinder boots, wheel cylinder pistons with the cup and compression spring from the wheel cylinder.

21. Remove the piston cup and boots from the wheel cylinder pistons.

JBR00077-00064

JBR00078-00065

E-ring

JBR00079-00066

JBR00080-00067

JBR00081-00068

BR–25

22. Disconnect the brake pipe from the wheel cylinder by disconnecting the flare nut, using a flare nut wrench.

23. Remove the wheel cylinder by removing the attaching bolts.

JBR00082-00069

24. Disconnect the parking brake cable from the backing plate by removing the two attaching bolts.

25. Remove the wheel speed sensor by removing the attaching bolt. (Only when equipped)

26. Remove the backing plate.

(Refer to the RS section.)

JBR00083-00070

INSPECTION

1. Inspect the components with point mentioned in figure.

If any damage is found, replace the damaged parts with new ones.

Backing plate

Wear / rust / warpage / damage

Wheel cylinder

Rusting / wear / cracks

Parking brake lever pin

Rusting / wear / damage

Brake shoe

Wear :

Brake lining thickness

Specified thickness: 5.0 mm

Allowable limit: 1.0 mm

Rusting / crack / burning adhesion of oil

Shoe hold-down spring pin

Wear / rust

Spring wear / rust / stretching

Parking brake shoe strut

Wear / damage

Spring

Wear / rusting / stretching

Brake drum

Wear / rusting / cracks / damage

JBR00084-00071

BR–26

2. Checking of brake lining contacting condition with brake drum

(1) Apply powder of chalk to the brake drum. Then, check the brake lining surface contacting condition with the brake drum by rubbing the brake lining in the brake drum.

If the contacting condition of the brake lining with brake drum is poor, grind the brake lining surface with abrasive paper or the like.

CAUTION:

Replace the brake lining with a new one if an excessive uneven contact exists.

Ensure that the brake lining thickness is within the specified value after grinding.

(2) Make sure that the contacting condition of the brake lining is sufficient after grinding the brake lining.

(3) Clean the brake lining and brake drum after performing the checking of the brake lining contacting condition.

JBR00085-00072

INSTALLATION

CAUTION:

Be sure to apply brake grease to the metal and metal sliding surfaces, unless otherwise specified.

NOTE:

The installation procedure is basically reverse to the removal procedure. Therefore, some illustrations are not mentioned in this installation procedure.

Please refer to the illustration mentioned in the removal procedure if any difficulty is encountered.

JBR00086-00000

1. Installation of backing plate

Refer to the RS section for installation of the backing plate.

Be sure to select the correct shim when the backing plate is replaced with a new one in the manner described as follows.

Selection of shim

(1) Measure the thickness of the new backing plate.

(2) Select the shim from the following table which corresponds to the thickness of the new backing plate.

Rear axle bearing retainer gasket (shim)

Thickness of backing plate

2.650 - 2.790

2.505 - 2.650

2.410 - 2.505

Thickness of shim

0.15

0.30

0.40

JBR00087-00073

2. Install the backing plate with the selected shim.

(Refer to the RS section for installation.)

3. Connect the parking brake cable to the brake backing plate with two attaching bolts and tighten them to the specified tightening torque.

Tightening torque: 6.0 - 9.0 N·m (0.64 - 0.96 kgf-m)

BR–27

4. Thinly apply brake grease to the sliding portions of the parking brake shoe lever.

5. Install the parking brake shoe lever to the trailing side brake shoe with the parking brake lever pin together with a new C-ring. Then, retract the C-ring with pliers or the like.

WARNING:

Never reuse the removed C-ring.

6. Connect the automatic adjuster lever to the parking brake lever pin. Then, install the new E-ring.

7. Install the tension spring to the brake shoe and automatic adjuster lever.

8. Clean the backing plate thoroughly.

9. Connect the parking brake cable to the backing prate with two attaching bolts and tighten them to the specified tightening torque.

10. Install the wheel cylinder to the backing plate with attaching bolts and tighten the attaching bolts to the specified tightening torque.

Tightening Torque: 7.5 - 11.5 N·m (0.8 - 1.2 kgf-m)

11. Connect the flare nut of the brake tube to the wheel cylinder fully by hand and tighten the flare nut to the specified tightening torque.

Tightening Torque: 12.7 - 17.6 N·m (1.3 - 1.8 kgf-m)

12. Assemble new piston cups and rubber boots to the pistons.

13. Thinly apply brake rubber grease to the lip section of the piston cup.

WARNING:

Never install the piston cups in a wrong direction.

Failure to observe this warning may lead to brake fluid leakage or serious brake malfunction.

JBR00088-00074

E-ring

JBR00089-00075

JBR00090-00076

JBR00091-00077

BR–28

14. Install the compression spring and wheel cylinder pistons with the wheel cylinder boots to the wheel cylinder.

NOTE:

Loosen the bleeder plug fully before installing the wheel pistons.

JBR00092-00078

15. Apply brake grease to the six brake shoe contacting points on the backing plate, one point each on the wheel cylinder pistons and two points on the brake lining anchor.

WARNING:

Be careful not to allow lubricants, such as grease or oil etc., to get to the wheel cylinder boot or brake shoe lining.

JBR00093-00079

16. Connect the parking brake cable to the parking brake shoe lever.

17. Install the rear side brake shoes on the backing plate with the shoe hold-down pin, spring and retainer.

18. Connect the tension spring to the back side of the brake shoe.

19. Connect the other side of the brake shoe to the tension spring.

20. Thinly apply brake grease to the sliding section of the parking brake shoe strut.

JBR00094-00000

21. Install the other side of the brake shoe to the backing plate with the shoe hold-down pin, spring and retainer while placing the parking brake shoe strut in position.

22. Install the tension No. 4 spring to the brake shoes, using the following SST.

SST: 09921-00010-000

23. Clean the brake drum contacting surface of the rear axle hub and axle hub contacting surface of the brake drum properly.

24. Install the brake drum to the rear axle hub.

CAUTION:

Never allow the brake drum to interfere with the brake shoe during the installation.

Make sure that the parking brake lever strut is retracted fully before the installation.

25. Install the rear wheels.

Tighten the attaching hub nuts to the specified tightening torque.

Tightening Torque: 103.0

14.7 N·m (10.5

1.5 kgf-m.)

26. Perform air bleeding. (Refer to the “Air bleeding” section.)

27. Apply the parking lever several times, until the clicking sounds emitted from the rear brake will stops.

JBR00095-00000

BR–29

Reference:

Manual adjusting method of brake shoe-to-drum clearance

NOTE:

The illustration shows the brake at the right hand side.

The brake at the left hand side is symmetric to the brake at the right hand side.

(1) Remove the adjusting hole plug provided on the backing plate.

(2) Turn the adjusting wheel by a flat screwdriver (A) inserted from the adjusting hole in the direction (C) as shown in the figure, until the brake shoe comes in contact with the brake drum.

(3) Turn back the adjusting wheel in the direction (D) by the screwdriver (A) while pushing up the adjusting lever with the L-shaped head bar (E), until the brake drum turns without dragging.

(4) Install the adjusting hole plug to the backing plate.

28. Adjust the working travel of the parking brake lever.

(Refer to the “Parking brake” section for adjustment.)

29. Check the brake performance with a four-wheel brake tester.

B A

Adjusting hole

(Backing plate side)

JBR00096-00080

BR–30

PARKING BRAKE

COMPONENTS

: Tightening torque

Unit : N·m (kgf-m)

S w

✩

✩ ✩

18.1

3.4 (1.85

0.35) r

7.3

1.5 (0.75

0.15)

✩

B e

B q

Rear console box assembly w

Parking brake lever assembly e

Parking brake left cable assembly r

Parking brake right cable assembly

JBR00097-00081

INSPECTION

1. Pull up the parking brake control handle several times and place it to fully-returned position.

2. Ensure that the parking brake control handle travel is 5 to

7 notches when the parking brake control handle in pulled up with a force of 196 N (20 kgf).

If the number of the notches fails to meet the specified numbers, adjust the parking brake control handle travel to the specified value.

ADJUSTMENT

1. Depress the brake pedal fully several times and ensure that the parking control lever travel fails to meet the specified notches.

2. Remove the rear console box by removing the two attaching screws.

JBR00098-00082

JBR00099-00083

3. Adjust the parking brake control handle travel to the specified number of notches by turning the adjusting nut of the parking brake pull rod.

Specified Value: 5 - 7 notches

CAUTION:

Be sure to use a hexagon socket (box) wrench for adjustment to prevent the adjusting nut from being damaged.

4. Install the rear console box with the two attaching screws.

REMOVAL

1. Remove the rear console box by removing the two attaching screws. (Refer to the BO section.)

2. Remove the adjusting nut from the parking brake pull rod.

3. Disconnect the connector from the parking brake switch.

4. Remove the parking brake control handle by removing the two attaching bolts.

5. Remove the parking brake pull rod by disconnecting the parking brake cables from the parking brake pull rod.

6. Lift up the vehicle and support the vehicle with safety stands.

(Refer to the GI section for supporting section of the safety stands.)

7. Disconnect the parking brake cable assembly from the brake backing plate.

(Refer to the rear brake section.)

8. Remove the parking brake cable by removing the attaching bolts of the parking brake cable and its clamps.

9. Remove the clamps from the parking brake cable assembly.

BR–31

JBR00100-00084

JBR00101-00085

JBR00102-00086

JBR00103-00000

BR–32

INSPECTION

Inspect the components with the following point. Replace any damaged parts.

JBR00104-00087

INSTALLATION

NOTE:

The installation procedure is basically reverse to the removal procedure. Therefore, some illustrations are not mentioned in this installation procedure.

Please refer to the illustration mentioned in the removal procedure, if any difficulty is encountered.

1. Install the parking brake cable to the vehicle with the attaching bolts of the parking brake cable and its clamps.

Tightening Torque: 5.8 - 8.8 N·m (0.6 - 0.9 kgf-m)

2. Connect the parking brake cable assembly to the brake backing plate. (Refer to the rear brake section.)

3. Lift down the vehicle.

4. Connect the parking brake cables to the parking brake pull rod.

5. Install the parking brake handle assembly to the floor panel while connecting the parking brake pull rod to the parking brake handle assembly and tighten the attaching bolts to the specified tightening torque.

Tightening Torque: 14.7 - 21.6 N·m (1.5 - 2.0 kgf-m)

6. Install the adjusting nut.

7. Connect the connector of the parking brake switch.

8. Perform the adjustment of the parking brake lever. (Refer to the adjustment section.)

9. Install the rear console box with the two attaching screws.

JBR00105-00000

BR–33

PROPORTIONING VALVE

COMPONENTS

Front

Left

JBR00106-00088

INSPECTION

Inspect the proportioning valve function with a four-wheel brake tester.

1. Place the vehicle on the four-wheel brake tester.

2. Ensure that the rear wheels will not be locked before the front wheels are locked.

If the rear wheel will be locked simultaneously or before the front wheels are locked, replace the proportioning valve with a new one.

JBR00107-00000

REPLACEMENT

1. Open the engine hood.

2. Drain the brake fluid from the brake line.

(Refer to the “Air bleeding” section.)

3. Remove the battery and battery carrier. (For RHD vehicle)

4. Disconnect the brake tubes from the proportioning valve.

5. Remove the proportioning valve by removing the attaching bolts.

JBR00108-00000

INSTALLATION

1. Install a new proportioning valve with the bolts and tighten them to the specified tightening torque.

Tightening Torque: 13 - 15 N·m (1.3 - 1.5 kgf-m)

2. Connect the brake tubes to the proportioning valve fully by hand.

3. Tighten the flare nut to the specified tightening torque.

Tightening Torque: 12.7 - 17.6 N·m (1.3 - 1.8 kgf-m)

4. Perform the air bleeding for the brake system.

(Refer to the “Air bleeding” section.)

5. Perform the brake performance test with a four-wheel brake tester.

JBR00109-00000

BR–34

BRAKE HOSE

COMPONENTS

q r

u t o

y i w e q

Front brake No. 8 tube w

Front flexible hose e

Rear brake No. 1 tube r

Front brake No. 6 tube t

Front brake No. 7 tube y

Front brake No. 9 tube u

Front brake No. 1 tube i

Rear brake No. 6 tube o

Rear flexible hose

Rear brake No. 5 tube

Hose

INSPECTION

Inspect the brake hose for following points and replace it with a new one if any damage exists.

Crack Scratch/Cut Twist Swelling

JBR00110-00089

JBR00111-00090

REPLACEMENT

Front brake hose

1. Drain the brake fluid from the brake system.

(Refer to the “Air bleeding” section.)

2. Disconnect the flare nut of the brake pipe from the brake hose, using a flare nut wrench.

3. Disconnect the brake hose from the clamp by removing the E-ring.

NOTE:

Never reuse the used E-ring.

JBR00112-00091

BR–35

4. Disconnect the brake hose from the disc brake cylinder assembly by removing the union bolts and washers.

CAUTION:

Do not reuse the used washers.

5. Remove the brake hose by removing the attaching bolt of the clamp bolts.

6. Install the brake hose with the clamp bolt and tighten the clamp bolt to the specified tightening torque.

Tightening Torque: 6.9 - 15.7 N·m (0.7 - 1.6 kgf-m)

7. Connect the brake hose to the disc brake cylinder assembly with the union bolt with a new gasket interposed.

JBR00113-00000

8. Tighten the union bolt to the specified tightening torque.

Tightening Torque: 26.5 - 34.3 N·m (2.7 - 3.5 kgf-m)

9. Connect the brake hose to the bracket and secure it by installing a new E-ring.

CAUTION:

Be sure to connect the E-ring in such a manner that the

E-ring is securely inserted in the groove provided on the brake hose end properly.

10. Connect the flare nut of the brake pipe to the brake hose fully by hand.

11. Tighten the flare nut to the specified tightening torque.

Tightening Torque: 12.7 - 17.6 N·m (1.3 - 1.8 kgf-m)

12. Perform the air bleeding.

(Refer to the “Air bleeding” section.)

13. Ensure that no brake fluid leakage exists.

JBR00114-00092

Rear brake hose

1. Drain the brake fluid from the brake system.

(Refer to the “Air bleeding” section.)

2. Disconnect the flare nut of the brake pipes from the brake hose, using a flare nut wrench.

3. Remove the brake hose from the clamps by removing the

E-rings.

WARNING:

Never reuse the used E-rings.

4. Connect the brake hose to the brackets and secure it by installing new E-rings.

WARNING:

JBR00115-00093

Never reuse the used E-ring.

Be sure to connect the E-ring in such a manner that the E-ring is securely inserted in the groove provided on the brake hose end properly.

5. Connect the flare nuts of the brake pipes to the brake hose fully by hand.

6. Tighten the flare nuts to the specified tightening torque.

Tightening Torque: 12.7 - 17.6 N·m (1.3 - 1.8 kgf-m)

7. Perform the air bleeding.

(Refer to the “Air bleeding” section.)

8. Ensure that no brake fluid leakage exists.

BR–36

ANTI-LOCK BRAKE SYSTEM

SYSTEM OUTLINE

The ABS is a brake system to prevent the wheels from locking which may cause the vehicle to slip. For this purpose, the ABS assures proper braking forces at all times by maintaining the coefficient of friction between the tires and the road surface to an optimum level through controlling the hydraulic pressure of each of the front right, front left and rear wheels. In this way, the controllability or steerability of the steering wheel is assured even under sudden braking/hard braking, except for the case of over-speeding or sharp turning in a corner.

ABS ECU

•

Controlling the actuator based on signals

from each speed sensor and gravity sensor.

Actuator

•

Controlling the hydraulic pressure

in each wheel cylinder under

control of ABS ECU.

Front vehicle speed sensors

•

Detecting wheel speed.

ABS warning lamp

•

Warning the driver of malfunction of

the system by illumination of this lamp.

•

Indicating the diagnosis code at

inspection.

Rear vehicle speed sensors

•

Detecting wheel speed.

Gravity sensor

•

Detecting the gravity being

applied to the vehicle.

NOTE: LHD model

JABS00002-00001

BR–37

JABS CIRCUIT DIAGNOSIS

ABS fuse

Back-up fuse

IG SW(IG2)

ECU IG fuse

Tail fuse STOP fuse stop lamp switch stop lamp

Diagnosis connector

Front vehicle speed sensor (right)

Front vehicle speed sensor (left)

Battery

Rear vehicle speed sensor (right)

Rear vehicle speed sensor (left)

GS1 3

Gravity sensor

GS2

GST

GGND

BAT

ABS ECU

ECUT

ABST

11 SIO

STP

6 FR+

+BS

SR t r q

+BM

1 r q

GND

Body ground

R+ 3 solenoid relay

R+ e w e

BS BM

2 w

Motor relay

7 FR–

FL+

FL–

AST 24

SFRH 8

31 RR+

32 RR–

9 RL+

10 RL–

GS1

SFRR 29

SFLH 1

SFLR 2

SRH 22

SRR 23

AST

SFRH

SFRR

SFLH

SFLR

SRH

12 10

SRR

GND MT

9 13

Actuator

Inspection diode

Body ground

15 GS2

MT 25

13 GST

34 GGND

19 GND

GND

WA 41

ABS Warning lamp

Gauge fuse

Body ground

JABS00003-00002

BR–38

ABS RELATED CONNECTORS

EFI ECU

21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22

Ignition switch

IG2

1 2 3 4 5 6 7 8

22 23 24 25 26 27 28 29

9 10 11 12 13 14 15 16 17 18 19 20 21

30 31 32 33 34 35 36 37 38 39 40 41 42

SFRH SFLH

SRH

SRH SFLH SFRH

SRR

SFLR SFRR

SFRR SFLR

SRR

GND

10 9

13 12 11

Actuator

AST

+BS

3 4

R+ GND SR w q

GND BM

AST BS MT

Actuator connector

Stop lamp switch

+BM

3 w

R+

MR q

GGND

3 4 5

GS1 GS2 GST

Vehicle speed sensors

1 2

2 1

Inspection diode

ABST ECUT

2 (WA)

1 (BS) t r

Solenoid relay e r

Motor relay e

5 4

Gravity sensor

SIO Ground

Diagnosis connector

ABS00004-00003

BR–39

SST (Sub - harness)

1 2 3 4 5 6 7 8

22 23 24 25 26 27 28 29

9 10 11 12 13 14 15 16 17 18 19 20 21

30 31 32 33 34 35 36 37 38 39 40 41 42

1 2 3 4 5 6 7 8 9 10 11

22 23 24 25 26 27 28 29 30 31 32

12 13 14 15 16 17 18 19 20 21

33 34 35 36 37 38 39 40 41 42

21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22

(To diagnosis connector)

SST (Diagnosis connector)

14 36

For DS - 21

Body ground.

(For inspection side)

ABS00000-00004