GROUP INDEX

HOW TO READ THIS MANUAL

GENERAL ........................................ 00
CLUTCH ...........................................
21
MANUAL TRANSMISSION..............
22
AUTOMATIC TRANSMISSION ........
23
PROPELLER SHAFT.......................
25
FRONT AXLE................................... 26
REAR AXLE .....................................
27
WHEEL AND TIRE...........................
31
FOREWORD
FRONT SUSPENSION.....................
This Shop Manual is published for the information and guid-
33
ance of personnel responsible for maintenance of Mitsubishi REAR SUSPENSION .......................
ROSA series bus chassis, and includes procedures for ad- 34
justment and maintenance services. We earnestly look for-
BRAKE .............................................
ward to seeing that this manual is made full use of in order to
perform correct services with no wastage.
35A
ANTI-LOCK BRAKE SYSTEM (ABS)
For more details, please consult your nearest authorized
Mitsubishi dealer or distributor.
35E
PARKING BRAKE............................
Kindly note that the specifications and maintenance service
figures are subject to change without prior notice in line with 36
improvement which will be effected from time to time in the
STEERING .......................................
future. 37
FRAME .............................................
Jul. 2003 41
HEATER AND AIR-CONDITIONER
55
BODY ...............................................
Applicable models
63
BE6

©2003 Mitsubishi Fuso Truck & Bus Corporation

 HOW TO READ THIS MANUAL
HOW THIS MANUAL IS COMPLIED ................................................... 2

GENERAL EXPLANATION OF THIS MANUAL .................................. 4

TERMS AND UNITS ............................................................................. 14

1
HOW TO READ THIS MANUAL
How This Manual Is Complied
• This manual is divided into groups, with one group for each system of the vehicle.

• In addition to service procedures, each group contains specifications, troubleshooting, maintenance service stan-
dards, T tightening torque, K lubricants, fluids and sealants, and J special tools.

• The page number for each group starts at “1.”

Group No. Group denomination Contents

Model code labeling instructions, device model labeling instructions, power
00 General train list, chassis No., engine No., name plate, service operations precautions,
table of standard tightening torques
21 Clutch Clutch body and clutch control system
22 Manual transmission Transmission body and control system
23 Automatic transmission Transmission body and control system
25 Propeller shaft Rear propeller shafts, center bearing assembly
26 Front axle Front axle and wheel alignment
27 Rear axle Axle drive mechanism
31 Wheel and tire Wheel and tire
33 Front suspension Leaf suspension mechanism
34 Rear suspension Leaf suspension mechanism
Break mechanism, exhaust brake, vacuum pump, various warning and indica-
35A Break
tor circuits
35E Anti-lock brake system (ABS) Anti-lock brake system, hydraulic unit
36 Parking brake Control system, center brake body, parking brake electrical circuit
37 Steering Steering system, power steering booster, oil pump
41 Frame Frame repair
55 Heater and air-conditioner Heater, air-conditioner and ventilation
63 Body Door, exterior fittings, interior fittings, and body

2
MEMO

3
HOW TO READ THIS MANUAL
General Explanation of This Manual

4
Device service procedures

e Special tools

5
HOW TO READ THIS MANUAL
3

6
6

7
HOW TO READ THIS MANUAL

1 Exploded view

8
2

9
HOW TO READ THIS MANUAL

2 Service standards

3 Tightening torques

4 Lubricants, fluids, and/or sealants

10
5 Special tools

6 Service procedure

11
HOW TO READ THIS MANUAL
2

12
3

13
HOW TO READ THIS MANUAL
Terms and Units
The terms and units in this manual are defined as follows.

Q This service manual contains important cautionary instructions and supplementary information under the following
four headings which identify the nature of the instructions and information:

DANGER k Precautions that should be taken in handing potentially dangerous substances such as
battery fluid and coolant additives.

WARNING k Precautionary instructions, which, if not observed, could result in serious injury or death.

CAUTION k Precautionary instructions, which, if not observed, could result in damage to or destruc-
tion of equipment or parts.

Suggestions or supplementary information for more efficient use of equipment or a bet-

NOTE ter understanding.

P Front and rear

The forward running direction of this vehicle is the front and the reverse direction of the vehicle is the rear.

P Left and right

The left hand side and right hand side, when facing the forward running direction of the vehicle, are respectively right
and left.

P Service standards terminology

(1) Standard value
The standard value shows the value of the design nominal dimensions, the design dimensions of individual units,
the standard clearance between parts in an assembly, and the standard values of an assembly.
The figure shown in brackets [ ], show the basic diameter.
(2) Limit
This is the performance or strength value that when exceeded for a part requires that the part be replaced or re-
paired.

P Tightening torque
Appropriate tightening torque is particularly important in terms of performance. Accordingly, the tightening torque is
specified for locations that are tightened.
Where the tightening torque is not specified, use the standard tightening torque prescribed in the table of standard
tightening torques.
Locations that must be “wet” when tightended will be specified as “wet.” When there is no specification the location
shall be dry when tightened and shall be tightened to the specified torque.

14
P Units
Tightening torques and other parameters are given in SI (international unit) units with the metric units added in brack-
ets { }.
*
* SI: This is the abbreviation for the French Le Système International d’Unités.

Example: 390 N?m {40 kgf?m}

Conventional unit (metric unit)
SI unit (international unit)

Quantity SI unit {Metric unit} Conversion Factor to SI Unit

Force N {kgf} 9.80665 N {1 kgf}

Moment of force N?m {kgf?m} 9.80665 N?m {1 kgf?m}

Pressure Positive pressure kPa {kgf/cm2} 98.0665 kPa {1 kgf/cm2}

kPa {mmHg} 0.133322 kPa {1 mmHg}
Vacuum pressure
Pa {mmH20} 9.80665 Pa {1 mmH20}

Volume d m3 {L} 1 d m3 {1 L}
Power kW {PS} 0.7355 kW {1 PS}
Heat quantity J {kcal} 4186.05 J {1 kcal}
Heat flow W {kcal/h} 1.16279 W {1 kcal/h}
Angle ° –
Celsius temperature °C –
Current (amperes) A –
Voltage (volts) V –
Resistance (ohms) Ω –
Electric power (watts) W –

15
16
 00

GROUP 00 GENERAL

MODEL CODING SYSTEM .................................................................. 00-2

POWER TRAIN TABLE ....................................................................... 00-4

CHASSIS NO., ENGINE NO. AND NAME PLATES ............................ 00-5

PRECAUTION FOR MAINTENANCE OPERATIONS ......................... 00-6

TABLE OF STANDARD TIGHTENING TORQUES ............................. 00-18

00-1
MODEL CODING SYSTEM
Vehicle Model

1 2 3 4 5 6 7 8 9 W E
Digit

B E 6 4 9 J R M D F A C
Vehicle Max. G. V. Develop- Type of Engine Wheel- Steering Special specification
Classification

type W. & Drive ment suspen- Model or base position

system sequential sion Compo-
number nent
arrange-
ment

BE: 4: 9: J: R: M: B: Low Country C:

5.2~6.1 ton, 4×2 Indepen- 4D34T 4550 mm RHD
* With air- back seat symbol Manual
Diesel dent sus- condition- specifica- FA: Trans-
pension er tion Australia mission
Symbol

D: J:
Deluxe Auto-
matic
Trans-
mission

* RHD: Right-hand drive vehicle

00-2
 00
Equipment Model
Equipment name Model description Code description
4 D 3 4 T Equipped with turbocharger
Version No.
Engine Series No.
Stands for diesel engine
Number of cylinders (four cylinders)
C 4 W 30
Disc outer diameter
Clutch Facing material: (W: Woven)
Loading capacity of major type (tonnage)
Stands for clutch
M 035 S 6
Number of forward speeds
Transmission Meshing (S: Synchronous, A: Automatic transmission)
Loading capacity of major type (tonnage)
Stands for transmission
P 3
Propeller shaft Loading capacity of major type (tonnage)
Standard for propeller shaft
D 033 H

Reduction and Teeth profile (H: Hypoid gear)

differential Loading capacity of major type (tonnage)
Stands for reduction and differential

00-3
POWER TRAIN TABLE
Propeller
Vehicle Model Engine Clutch Transmission Final Reduction
shaft

BE649J 4D34T6 C4W30 M035S6 P3 D033H

RM FAC 105kW{143PS} 6.114/0.790 4.444
/2700rpm
BE649J 412N.m{42kgf.m} Torque M035A4 D033H
RM FAD /1600rpm converter 2.950/0.703 5.285

00-4
CHASSIS NO., ENGINE NO. AND NAME PLATES 00
The serial Nos. for chassis and engines are assigned to the respective vehicles and corresponding engine in the order in
which the vehicles are manufactured. These Nos. are required for registration and incidental inspection of the vehicles.
Please do not fail to inform the dealers of these Nos. when ordering parts.

Chassis No.
Chassis Nos. are punch-marked.

71694

Engine No.
Engine Nos. are punch-marked.

Engine No.

06469

Name plate
The name plate shows the vehicle model, chassis No., engine model
and transmission model.

74042

00-5
PRECAUTION FOR MAINTENANCE OPERATIONS
To adequately determine the condition of the vehicle before beginning servicing operations, inspect the vehicle to find
and keep record of the accumulated mileage, operation conditions, what the customer demand is, and other information
that might be necessary. Conduct servicing efficiently and in an orderly manner.

Study the causes of trouble while checking problem locations and after
determining if the problem unit needs to be removed and disassembled,
follow the work procedures specified in this manual.

71698

Conduct maintenance work on a level area and take the following prep-
arations.
• Cover the seats, upholstery, floors, and painted body surfaces with
workshop seat covers to protect them from being soiled or marred.

00008

• Lay out the general tools and special tools necessary for mainte-
nance.

WARNING k
When the use of special tools is specified in this manual, do not
attempt to substitute other tools for them as doing so could re-
sult in damage to the part and unexpected injuries.

00009

When jacking up a vehicle and working underneath it, take the following
precautions.
• Place chocks under the right and left tires.
• Jack up the vehicle using a garage jack.
• Support the vehicle with rigid racks.

WARNING k
• Securely chock to the tires so that the vehicle cannot move.
• Do not remove the chocks until all work is completed.
74044 • Only supporting the vehicle with a garage jack is very danger-
ous, so also support it with rigid jacks placed under the right
and left sides of the flame.
• Continue to support the vehicle using the garage jack and rigid
jack until all work is completed. Absolutely do not remove them
before the work is completed.

00-6
 00
• Pay special attention to safety when removing heavy and installing
heavy components such as engines, transmissions, and axles.

06474

• When removing or installing the engine, use an engine lifter and

transmission jack to support the engine and transmission assembly
and slowly move them back and down without hitting any other parts.

07286

• Do not work in shoes that have oil spilled on them, especially when
handling heavy components. When two or more people are working
together, check each other for safety (designate signals, etc.) and do
not touch unnecessary switches or levels.

00012

• Problems could be missed if oil leak inspections are conducted after

cleaning, so be sure to conduct oil leak inspections before cleaning.

00013

• Layout the replacement parts ahead of time.

00014

00-7
PRECAUTION FOR MAINTENANCE OPERATIONS
• When disassembling components, replace rubber parts, such as oil
seals, packing, and O-rings; gaskets; and split pins with new parts.
When replacing parts, use Mitsubishi genuine parts.

00015

When disassembling components, conduct a visual inspection to check

for abrasion, cracking, scratches, deformations, wear, rusting, corro-
sion, how parts turn, fatigue, clogging, and any other defects.

00016

To avoid incorrect assembly during reassembly, mark the parts with

alignment marks when necessary, and lay out the parts in the other of
disassembly.
When scratching the parts to make alignments marks or punches, do it
in a location that does not degrade the appearance of the component.
When removing parts, use covers to prevent the entry of dust.

CAUTION k
• Be careful not to get confused during assembly when there are
00017 many different individual parts, parts that look alike, or similar
parts that have right or left rotations.
• Separate the parts to be replaced from those to be reused.

During assembly, apply the specified lubricant to U-packings, oil seals,

dust seals, and bearings.
Use the specified lubricant when lubricating, and when conducting in-
spections or replacing parts, use a rag, etc., to wipe off excess lubricant
and lubricant smeared on unnecessary areas.

CAUTION k
When any of specified oil, grease and sealant is not available,
you may use the equivalent of it.
00018

00-8
 00
Always wear protective goggles when grinding or welding. In addition,
use gloves when necessary and take sufficient precautions for safety.
Be careful not to injure your hands or fingers on the edge of parts.

00019

When servicing electrical systems, disconnect the battery’s minus *

terminal to avoid blown fuses caused by short circuits.
CAUTION k
Be sure to turn the starter and lighting switches of before dis-
connecting or connecting battery terminals, or semiconductors
can be damaged.

06701

• Be careful when handling sensors and relays because they are sen-
sitive to impacts and heat. Do not carelessly remove or paint the lid
to the electronic controller unit.

00021

• When disconnecting connectors, pull the connector without pulling

on the harness. When disconnecting locking connectors, push in the
direction of the arrow sign.
When connecting locking connectors, insert the connector until you
heat the clicking sound.

00022

• When washing the car, protect the electronic system components

with water protective materials (cover with plastic, etc.). In addition,
do not directly apply water to harness connectors or sensors. If you
do get water on these components by accident, quickly wipe the wa-
ter off of them.

00023

00-9
PRECAUTION FOR MAINTENANCE OPERATIONS
When checking by applying voltage to wires, make sure which are the +
and - terminals, then be sure to apply voltage beginning at 0 V, then
gradually increasing the voltage to the specified value. Do not exceed
the specified voltage. The electronic control unit and sensors in particu-
lar are not necessarily limited to 24 V, so exercise caution.

19879

Be careful not to touch other than the terminals being tested when
touching the tester probes to the terminals to check continuity.

00027

Piercing of wire CAUTION k

insulation is prohibited. Checking wires by piercing the insulation is prohibited.
• If the insulation to the wires connected to the test bar or power
check indicator, etc. is damaged, it will cause rapid corrosion of
the wire harness, particularly in the case of the chassis harness,
so do not pierce the insulation during checking.

P50395

00-10
 00
Inspection of Harnesses
P Inspections with connectors fitted together
<Waterproof connectors>
Connect an inspection harness and connector A between the connec-
tors B of the circuit to be inspected. Perform the inspection by applying
a test probe C to the connectors of the inspection harness. Do not in-
sert the test probe C into the wire-entry sides of the waterproof connec-
tors since this would damage their waterproof seals and lead to rust.

02587

<Non-waterproof conectors>
Perform the inspection by inserting a test probe C into the wire-entry
sides of the connectors. An extra-narrow probe is required for control
unit connectors, which are smaller than other types of connector. Do
not force a regular-size probe into control unit connectors since this
would cause damage.

02588

P Inspections with connectors separated

Inspections on female terminals
Perform the inspection by carefully inserting a test probe into the termi-
nals. Do not force the test probe into the terminals since this could de-
form them and cause poor connections.

02589

Inspections on male terminals

Perform the inspection by applying test probes directly to the pins.

CAUTION k
Be careful not so short-circuit pins together with the test probes.
With control unit connectors, short-circuiting of pins can cause
damage to the control unit’s internal circuitry.

02590

00-11
PRECAUTION FOR MAINTENANCE OPERATIONS
Inspection of Connectors
P Visual inspection
Check that the connectors are fitted together securely.

02591

Check whether wires have been separated from their terminals due to
pulling of the harness.

02592

Check that male and female terminals fit together tightly.

02593

Check for defective connections caused by loose terminals, by rust on

terminals, or by contamination of terminals by foreign substances.
P Checking for loose terminals
If connector terminal retainers become damaged, male and female ter-
minals may not mate with each other when the connector bodies are fit-
ted together. To check for such terminals, gently pull each wire and see
whether any terminals slip out of their connector housings.

02594

00-12
 00
P Inspections when a fuse blows
Remove the fuse B, then measure the resistance between ground and
the fuse’s load side.
Next, close the switch of each circuit connected to the use. If the resis-
tance measurement between any switch and ground is zero, there is a
short circuit between the switch and the load. If the resistance mea-
surement is not zero, the circuit is not currently short-circuited; the fuse
probably blew due to a momentary short circuit.

The main causes of short circuits are follows:

• Harness trapped between chassis parts
• Harness insulation damage due to friction or heat
• Moisture in connectors or circuitry
• Human error (accidental short-circuiting of components)

A: Battery
B: Fuse
C: Load switch
D: Load
E: Short circuit
02596

P Service precautions for alternators

When servicing alternators, observe the following precautions:
• Never reverse the polarity of battery connections.
If the polarity of the battery connections was reversed, a large cur-
rent would flow from the battery to the alternator, damaging the di-
odes and regulator.

04746

• Never disconnect the battery terminals with the engine running.

Disconnection of the battery terminals during engine operation would
cause a surge voltage, leading to deterioration of the diodes and reg-
ulator.

04747

00-13
PRECAUTION FOR MAINTENANCE OPERATIONS
• Never perform inspections using a megger or other high-voltage mul-
timeter.
The use of a megger or other high-voltage multimeter could damage
the diodes and regulator.

02371

• Keep altnernators dry.

Water on alternators can cause internal short circuits and damage.

05165

• Never operate alternator with the B and L terminals short-circuited.

Operation with the B and L terminals connected together would dam-
age the diode trio.

04749

• Disconnect the battery terminals before quick-charging the battery

with a quick charger.
Unless the battery terminals are disconnected, quick-charging can
damagd the diodes and regulator.

05166

00-14
 00
P Remedies for transient problems
Transient problems often under specific conditions, so if these condi-
tions can be identified it is easy to presume what is the problem. To
identify the conditions under which a transient problem occurs, the trou-
ble phenomenon must be recreated by carefully interviewing the cus-
tomer with regards to the running state, weather, occurrence frequency,
and trouble phenomenon when the trouble occurs. Next, consider if the
conditions during the occurrence of trouble can be used to determine if
the trouble is caused by vibration, heat, or something else. If the cause
02597 is thought to be vibration, conduct the following inspection on individual
connections to see if the trouble phenomenon occurs.

• Carefully shake the connector up and down, right and left.

• Carefully shake the wiring harness up and down, right and left.
• By hand carefully jar the sensors and instruments.
• Carefully shake the wiring harnesses in moving areas, such as the
suspension.

The subject of the inspection conducted here the connector and individ-
02598 ual component diagnosis codes and problems that can be found by pre-
suming the cause of the problem and during the inspection.

02599
0000

00-15
PRECAUTIONS FOR MAINTENANCE OPERATIONS
P Precautions during electric welding work
• When conducting electric welding take precautions so that the welder current does not back flow from the vehicle met-
al into the ground circuit and damage electrical components, such as electronic controller unit, or the harnesses. In ad-
dition, there will be significant damage to electrical components close to where the welder’s minus cable is touching
the vehicle.

72633

• The welder’s current will back flow from the following areas.

Back flow from the battery’s minus * terminal

In this case, not only the battery but the electrical
components directly connected to the battery will be
damaged, so be sure to disconnect the battery’s mi-
nus * terminal.

72632

00-16
 00

Operation procedure
1 Turn the ignition switch off.
↓
2 Disconnect the battery’s minus * terminal. B Electrical
↓
3 Cover the surrounding area when necessary to prevent the vehicle from being damaged by the welding sparks.
↓
4 Connect the welder’s minus * cable close to the area to be welded. Do not do anything that would connect the body
with the frame.
↓
5 Set the welder’s current strength to a value appropriate to the area being welding.

00-17
TABLE OF STANDARD TIGHTENING TORQUES
• Use the specified bolts and nuts and tighten them with the applicable torques according to the following table, unless
otherwise specified.
• The threads and contact seats shall be dry.
• Where there is a difference in strength classification between the nut and the bolt (or stud bolt), the torque specified for
the bolt shall apply.

Hex-head Bolt and Stud Bolt Unit: N?m {kgf?m}

Strength
classification 4T 7T 8T
Repre-
sentation

Nominal
diameter mm 02154
2 to 3 4 to 6 5 to 7
M5 {0.2 to 0.3}
–
{0.4 to 0.6}
–
{0.5 to 0.7}
–

4 to 6 7 to 11 8 to 12
M6 {0.4 to 0.6}
–
{0.7 to 1.1}
–
{0.8 to 1.2}
–

9 to 14 17 to 26 20 to 29
M8 {0.9 to 1.4}
–
{1.7 to 2.6}
–
{2.0 to 3.0}
–

19 to 28 18 to 26 36 to 52 33 to 49 45 to 60 41 to 59
M 10 {1.9 to 2.8} {1.8 to 2.7} {3.5 to 5.5} {3.5 to 5.0} {4.5 to 6.0} {4.3 to 6.0}
35 to 50 31 to 46 70 to 95 65 to 85 85 to 110 75 to 100
M 12 {3.4 to 5.0} {3.1 to 4.7} {7.0 to 9.5} {6.5 to 8.5} {8.5 to 11} {7.5 to 10}
60 to 85 55 to 75 120 to 160 110 to 140 130 to 180 120 to 160
M 14 {6.0 to 8.5} {5.5 to 7.5} {12 to 16} {11 to 14} {13 to 18} {12 to 17}
90 to 130 90 to 120 180 to 240 160 to 220 200 to 270 190 to 260
M 16 {9.5 to 13} {9.0 to 12} {18 to 24} {16 to 22} {20 to 27} {19 to 26}
140 to 190 120 to 160 260 to 340 220 to 290 290 to 390 260 to 340
M 18 {14 to 19} {12 to 16} {25 to 35} {22 to 30} {30 to 40} {26 to 35}
190 to 260 170 to 230 350 to 470 320 to 420 410 to 550 370 to 490
M 20 {19 to 26} {17 to 23} {36 to 48} {32 to 43} {41 to 56} {37 to 50}
260 to 340 230 to 300 470 to 640 430 to 570 550 to 740 490 to 670
M 22 {26 to 35} {23 to 31} {48 to 65} {43 to 58} {56 to 75} {50 to 68}
340 to 450 290 to 390 630 to 840 540 to 730 730 to 980 630 to 840
M 24 {34 to 46} {29 to 40} {63 to 86} {55 to 74} {74 to 100} {64 to 86}

Hex-head Flange Bolt Unit: N?m {kgf?m}

Strength
classification 4T 7T 8T
Repre-
sentation

Nominal
diameter mm 02154
4 to 6 8 to 12 9 to 14
M6 {0.4 to 0.6}
–
{0.8 to 1.2}
–
{0.9 to 1.4}
–
10 to 15 19 to 28 22 to 32
M8 {1.0 to 1.5}
–
{1.9 to 2.8}
–
{2.2 to 3.3}
–
21 to 30 20 to 28 39 to 58 37 to 53 50 to 65 45 to 65
M 10 {2.1 to 3.1} {1.9 to 2.9} {3.9 to 6.0} {3.6 to 5.4} {5.0 to 6.5} {4.5 to 6.5}
38 to 54 35 to 51 80 to 110 70 to 95 90 to 120 85 to 110
M 12 {3.8 to 5.5} {3.4 to 5.2} {8.0 to 11} {7.0 to 9.5} {9.0 to 12} {8.5 to 11}

00-18
 00
Hex-head Nut Unit: N?m {kgf?m}
Strength
classification 4T 6T
Repre-
sentation

02155
Nominal
diameter Standard thread Coarse thread Standard thread Coarse thread
M5 2 to 3 {0.2 to 0.3} – 4 to 6 {0.4 to 0.6} –
M6 4 to 6 {0.4 to 0.6} – 7 to 11 {0.7 to 1.1} –
M8 9 to 14 {0.9 to 1.4} – 17 to 26 {1.7 to 2.6} –
M 10 19 to 28 {1.9 to 2.8} 18 to 26 {1.8 to 2.7} 36 to 52 {3.5 to 5.5} 33 to 49 {3.5 to 5.0}
M 12 35 to 50 {3.4 to 5.0} 31 to 46 {3.1 to 4.7} 70 to 95 {7.0 to 9.5} 65 to 85 {6.5 to 8.5}
M 14 60 to 85 {6.0 to 8.5} 55 to 75 {5.5 to 7.5} 120 to 160 {12 to 16} 110 to 140 {11 to 14}
M 16 90 to 130 {9.5 to 13} 90 to 120 {9.0 to 12} 180 to 240 {18 to 24} 160 to 220 {16 to 22}
M 18 140 to 190 {14 to 19} 120 to 160 {12 to 16} 260 to 340 {25 to 35} 220 to 290 {22 to 30}
M 20 190 to 260 {19 to 26} 170 to 230 {17 to 23} 350 to 470 {36 to 48} 320 to 420 {32 to 43}
M 22 260 to 340 {26 to 35} 230 to 300 {23 to 31} 470 to 640 {48 to 65} 430 to 570 {43 to 58}
M 24 340 to 450 {34 to 46} 290 to 390 {29 to 40} 630 to 840 {63 to 86} 540 to 730 {55 to 74}

Hex-head Flange Nut Unit: N?m {kgf?m}

Strength
classification 4T
Repre-
sentation

02155
Nominal
diameter Standard thread Coarse thread
M6 4 to 6 {0.4 to 0.6} –
M8 10 to 15 {1.0 to 1.5} –
M 10 21 to 30 {2.1 to 3.1} 20 to 28 {1.9 to 2.9}
M 12 38 to 54 {3.8 to 5.5} 35 to 51 {3.4 to 5.2}

Tightening torque for general flare nuts Unit: N?m {kgf?m}

Pipe diameter mm X4.76 X6.35 X8 X10 X12 X15
Tightening torque 17 {1.7} 25 {2.6} 39 {4.0} 59 {6.0} 88 {9.0} 98 {10.0}

Tightening torque for nylon tubes used for general air piping (DIN type) Unit: N?m {kgf?m}
Nominal diameter mm 6 ×1 10 × 1.25 12 × 1.5 15 × 1/5
+6 +0.6 +10 +1.0 +10 +1.0 +5 +0.5
Tightening torque 20 0 2.0 0 34 0 3.5 0 49 0 5.0 0 54 0 5.5 0

Tightening torque for nylon tubes used for general air piping (SAE type) Unit: N?m {kgf?m}
Nominal diameter in. 1/4 3/8 1/2 5/8
+4 +0.4 +5 +0.5 +5 +0.5 +5 +0.5
Tightening torque 13 0 1.3 0 29 0 3.0 0 49 0 5.0 0 64 0 6.5 0

00-19
00-20
 21

GROUP 21 CLUTCH

SPECIFICATIONS ................................................................................ 21-2

STRUCTURE AND OPERATION ........................................................ 21-2

TROUBLESHOOTING ......................................................................... 21-10

ON-VEHICLE INSPECTION AND ADJUSTMENT

• Clutch Fluid Replacement and Air Bleeding ...................................... 21-12
• Clutch Pedal Free Play ......................................................................... 21-13
• Inspection of Clutch Disc Wear Limit ................................................. 21-13
• Inspection of Clutch Booster Function .............................................. 21-14

CLUTCH PEDAL .................................................................................. 21-16

CLUTCH BOOSTER AND CLUTCH MASTER CYLINDER ................ 21-20

CLUTCH POWER CYLINDER ............................................................. 21-24

CLUTCH BODY .................................................................................... 21-26

CLUTCH HOUSING .............................................................................. 21-31

21-1
SPECIFICATIONS/STRUCTURE AND OPERATION
SPECIFICATIONS
Item Specifications
Clutch Model C4W30
Drive type Strap drive
Clutch disc Type Dry, single plate type
Pressure plate Type Diaphragm spring type
Control type Hydraulic pressure type
Clutch booster Manufacturer Bosch Automotive Systems
Clutch master cylinder Manufacturer NISSIN KOGYO CO.,LTD
Clutch power cylinder Manufacturer NISSIN KOGYO CO.,LTD

STRUCTURE AND OPERATION

Clutch Control

1 4

5 6
A B 7

11

10

9 8
78649

1 Clutch pedal 8 Pushrod

2 Clutch booster 9 Clutch power cylinder
3 Brake fluid tank 10 Vacuum pump L Gr 35A
4 Clutch master cylinder 11 Vacuum tank
5 Flywheel
6 Clutch disk A: Negative pressure
7 Clutch cover assembly B: Fluid pressure

21-2
 21

MEMO

21-3
STRUCTURE AND OPERATION
Clutch Booster

78650

1 Operating rod 6 Clutch master cylinder 11 Rear cylinder shell

2 Poppet spring 7 Pipe
3 Poppet assembly 8 Return spring A: Negative pressure to vacuum tank
4 Valve plunger 9 Valve body B: Fluid pressure to clutch power cylinder
5 Front cylinder shell 10 Diaphragm

Non-operating condition
• Poppet assembly 3 contacts valve plunger
4 (breather valve closed) to shut off the at-
mospheric pressure, and it is not seated on
valve body 9 (negative pressure valve
open).
• As a result, chambers C and D are con-
nected through air passage E in valve body
9. Due to negative pressure A supplied
through pipe 7 installed on front cylinder
shell 5, there is negative pressure in cham-
bers C and D.
• Since there is no internal pressure differ-
ence between chambers C and D, valve
body 9 is pressed toward the left by the
force of return spring 8.

78651

21-4
 21
When pedal is depressed
• When the pedal pressing force is transmit-
ted to operating rod 1, it acts on valve
plunger 4.
• When valve plunger 4 moves to the right,
poppet assembly 3 moves away from the
valve plunger (breather valve open), and
the poppet valve assembly contacts valve
body 9 (negative pressure valve closed).
• Consequently, atmospheric pressure en-
ters chamber C and acts on diaphragm 10.
This atmospheric pressure combines with
the pedal pressing force transmitted by op-
erating rod 1, and moves valve body 9 to-
ward the right.
03465 • The combined force acts on clutch master
cylinder 6, and feeds fluid pressure B to
the clutch power cylinder.

When pedal is released

• The force applied on operating rod 1 is re-
leased, thus setting valve plunger 4 free.
• As a result, valve plunger 4 seats on pop-
pet assembly 3 (breather valve closed),
and the poppet assembly moves away from
valve body 9 (negative pressure valve
open).
• This results in negative pressure in cham-
bers C and D, and valve body 9 is pressed
to the left by the force of return spring 8,
thus setting the clutch booster in non-oper-
ating condition.

03466

When there is no negative pressure

• If there is no negative pressure for some
reason, the insides of chambers C and D
are under the atmospheric pressure. Since
there is no internal pressure difference, no
power boosting effect is produced.
• Only the force transmitted by operating rod
1 which is linked to clutch master cylinder 6
acts on the clutch master cylinder to pro-
duce fluid pressure.

03467

21-5
STRUCTURE AND OPERATION
Clutch Master Cylinder

1 2
3

7 6
8 5 4
79851

1 Valve stem 5 Spring seat A: From brake fluid reservoir tank

2 Return spring 6 Valve spring B: Hydraulic pressure to/from the clutch pow-
3 Pressure cup 7 Valve case er cylinder
4 Piston 8 Valve seal

When clutch pedal is depressed

• As piston 4 is pressed in the direction as illustrated, valve spring 6 of
valve stem 1 forces down valve seal 8 to close the brake fluid tank
port.
• Then, the hydraulic pressure in the master cylinder increases to
transmit hydraulic pressure B to the power cylinder.

03461

When clutch pedal is released

• As the clutch pedal is released, hydraulic pressure B from the power
cylinder and return spring 2 push back piston 4.
• At the same time, valve stem 1 is retracted by spring seat 5 and com-
presses valve spring 6 to open the brake fluid tank port.
• Thus released, hydraulic pressure B in the master cylinder returns
piston 4 to its original position.

03462

21-6
 21
Clutch Power Cylinder
1 Bleeder screw
2 Spring
3 Piston
4 Push rod
5 Piston cup
6 Pressure cup
7 Indicator spring
8 Wear indicator
9 Cylinder body

08190 A: Hydraulic pressure from the clutch

master cylinder

During normal operation

• The hydraulic pressure A from the clutch master
cylinder acts on piston 3 which moves push rod 4
which in turn moves the clutch release rocker arm.
• The hydraulic pressure A from the clutch master
cylinder acts on piston 3 (pressure receiving area
B) unless the clutch disc is worn.

08191

When the clutch disc wears out

• As the clutch wears out, the push rod 4 retracts to-
ward the position as illustrated left.
• As the clutch disc reaches the wear limit, the wear
indicator 8 gauge makes contact with fluid port D
of the cylinder body 9, reducing the pressure re-
ceiving area C.
• Therefore, the foot pressure required will increase
until the hydraulic pressure A exceeds the force of
08192 the indicator spring 7.
• As the hydraulic pressure increases to overcome
the force of the indicator spring 7, the piston 3
moves slightly to restore the normal pressure re-
ceiving area and to reduce the foot pressure re-
quired.
• From the above, it can be deduced that if at first
unusually high foot pressure is required to depress
the clutch pedal, then as it is depressed further the
foot pressure required is sharply reduced, the
clutch disc is worn out.

21-7
STRUCTURE AND OPERATION
Clutch Body
1 Clutch housing
2 Strap plate
3 Clutch cove
4 Pivot ring
5 Diaphragm spring
6 Clutch release bearing
7 Clutch release rocker arm
8 Rocker arm pivot
9 Pressure plate
10 Clutch disc
11 Flywheel
12 Drive pinion

03473

When the clutch pedal is released

• The pressure plate 9, activated by the diaphragm spring
5, forces the clutch disc 10 against flywheel 11.
• The clutch disc 10, which is forced against flywheel 11,
turns together with the flywheel and transmits the power
from the engine to the transmission drive pinion 12.

03474

When the clutch pedal is depressed

• The hydraulic pressure from the clutch master cylinder
acts on the power cylinder. This causes the clutch release
rocker arm 7 to push out the clutch release bearing 6
which in turn pushes the diaphragm spring 5. Diaphragm
spring, using the pivot ring 4 as fulcrum, retracts the pres-
sure plate 9 which is linked with the clutch cover 3 by the
strap plate 2. This causes a gap between the clutch disc
10 and the flywheel 11, so the drive force from the engine
is no longer transmitted to the transmission.

03475
21-8
 21

MEMO

21-9
TROUBLESHOOTING
Symptoms

Clutch makes strange noise on disengagement

Clutch makes strange noise on engagement
Clutch does not engage smoothly

Judder on acceleration from zero

Clutch peddle hard to release

Clutch disengaged but drags
Remarks

Clutch slips
Possible causes
Diaphragm spring heights uneven p p p p
Pressure plate warped or faulty p p p p
Clutch cover
Diaphragm spring fatigued p p p
assembly
Rivets loose p
Strap plate bent p
Disc deformed p p p
Disc rivets loose p p
Disc torsion spring fatigued or damaged p p p p p
Spline worn p p p p
Clutch disc
Spline is rusted p p
Facing is worn p p
Facing surface hardened p p p
Facing oily or greasy p p p
Pedal play inadequate p
Pedal play excessive p
Clutch pedal Pedal stroke insufficient p
Return spring fatigued p p
Pedal sliding surfaces defective p p p
Poor sliding condition of piston and piston cup p p
Spring fatigue p p
Clutch booster Clogging at brake fluid inlet or outlet p p
Low vacuum level p p
Malfunctioning p p
Motion of piston or piston cup defective p p p p
Clutch master
Spring fatigued p p p
cylinder
Brake fluid inlet is clogged p p p
Motion of piston or piston cup defective p p p
Clutch power
Spring fatigued p p p
cylinder
Brake fluid inlet is clogged p p p
Clutch housing Release bearing defective p p p

21-10
 21
Symptoms

Clutch makes strange noise on disengagement

Clutch makes strange noise on engagement
Clutch does not engage smoothly

Judder on acceleration from zero

Clutch peddle hard to release

Clutch disengaged but drags
Remarks

Clutch slips
Possible causes
Transmission drive pinion spline worn p p L Gr22
Low engine idling rpm p B Gr13E
Engine mounting fatigued p B Gr11
Flywheel warped, deformed, or worn unevenly forming layering p p p p B Gr11
Flywheel pilot bearing faulty p p B Gr11
Air in clutch hydraulic system p
Clutch hydraulic system leaking p

21-11
ON-VEHICLE INSPECTION AND ADJUSTMENT
Clutch Fluid Replacement and Air Bleeding
T Tightening Torque Unit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks
1 Bleeder screw 6.9 to 8.8 {0.7 to 0.9} –

K Fluid
Location Points of application Specified fluid Quantity

4 Fluid tank Brake fluid As required

(SAE J1703f or FMVSS No.116 DOT3)

CAUTION k
• Use care not to splash brake fluid on painted surfaces because
it could damage the paintwork.
• Wipe off brake fluid immediately when you splash it on the
paintwork.
• Use fresh brake fluid (SAE J1703f or FMVSS No.116 DOT3) at re-
placement. Do not add fluid of different quality or mineral oil
(gas oil, engine oil, gear oil, automatic transmission fluid, etc.)
to the clutch system, because it could swell rubber parts of the
clutch system, resulting in faulty clutch operation.
• Do not allow dust and water to get into the brake fluid when
adding brake fluid, because faulty clutch operation could result.
• If you use a mug for adding brake fluid, keep one used solely for
that purpose to prevent contamination by fluids of different
quality or mineral oils.

(1) Clutch fluid replacement

• Attach the hose 2 to the bleeder screw 1 of the clutch power cylinder.
• Loosen bleeder screw 1 and depress the clutch pedal 3 several times
to drain the brake fluid completely.

03476

(2) Bleeding air from the clutch system

NOTE
• If the j warning lamp in the meter cluster lights up during this
operation, the engine should be started and sufficient vacuum
MAX pressure should be supplied.
MIN • During this service procedure, add brake fluid to maintain the
level in the brake fluid tank between “MIN” and “MAX.”

4 • Attach the hose 2 to the bleeder screw 1 of the clutch power cylinder
73969
as in the replacement procedure.
• Add brake fluid to brake fluid tank 4 and loosen bleeder screw 1 of
the clutch power cylinder then depress clutch pedal 3 continuously.

21-12
 21
• Continue depressing clutch pedal 3 and then tighten the bleeder
screw when all of the air has been bleed from the bleeder screw 1.
• Again depress clutch pedal 3 4 or 5 times and then keep the pedal
depressed at its fullest extent.
• With the clutch pedal depressed, loosen bleeder screw 1 to drain the
brake fluid that contains air. Release the pedal after tightening the
bleeder screw.
CAUTION k
Be sure to tighten bleeder screw 1 before releasing clutch pedal
3 so that air does not enter the system.
• Repeat this service procedure until air is no longer present in the flu-
id being drained.
• When the service procedure is completed, tighten bleeder screw 1 to
the specified torque.
Tightening torque: 6.9 to 8.8 N?m (0.7 to 0.9 kgf?m)
Clutch Pedal Free Play
Service standards Unit: mm
Location Maintenance item Standard value Limit Remedy
1 Free play at the end of the clutch pedal 10 to 15 – Adjust

[Inspection]
Measure the play A of the end of clutch pedal 1. If it deviates from the
standard value, check if the length of push rod of the clutch booster and
the clutch master cylinder push rod (L P21-20) is within the standard
value.

End play: 10 to 15 mm

03480

Inspection of Clutch Disc Wear Limit

• When depressing the clutch pedal, if at first unusually high foot pres-
sure is required to depress it, then as it is depressed further the foot
pressure required is sharply reduced, it means that the wear indica-
tor of the clutch power cylinder is operating. This is a sign that the
clutch disc is approaching the wear limit.
• Remove dust cover A from clutch power cylinder 1 as illustrated. If
the knurled inspection mark C to push rod B has reached the end of
the power cylinder body, replace the clutch disc.

08245

Approximately 24 mm
08246
0824

21-13
ON-VEHICLE INSPECTION AND ADJUSTMENT
Inspection of Clutch Booster Function
• With no negative pressure applied, depress the clutch pedal lightly,
and let the engine idle.
Make sure the clutch pedal advances slightly in the depressing direc-
tion after a short while.
• Start the engine, and let a string hang in front of valve body 1.
• Make sure the string is sucked forcefully into the clutch booster when
the clutch pedal is depressed
• Make sure the string is not sucked into the clutch booster when the
clutch pedal is released.
03478 If the string is sucked into the clutch booster when the clutch booster
is released, replace the clutch booster. L P21-20

21-14
 21

MEMO

21-15
CLUTCH PEDAL

5
9

8
7

4
17 2

6
1
11
10 3
14
13

13
12

16
15

79852

P Preparation before disassembly

Clutch Fluid Replacement and Air Bleeding L P21-12

P Disassembly sequence
1 Fluid hose 7 Clutch switch B Electrical 13 Bushing
2 Pipe 8 Lock nut 14 Bushing
3 Vacuum hose 9 Nut 15 Pedal pad
4 Clevis pin 10 Return spring 16 Clutch pedal arm
5 Nut 11 Clutch pedal assembly 17 Clutch pedal support
6 Clutch booster and clutch 12 Collar
master cylinder L P21-20

CAUTION k
Cover the open ends of removed fluid hose 1, pipe 2 and vacuum hose 3 with caps to prevent dust and other
particles from entering.

21-16
 21
P Assembly sequence
Follow the disassembly sequence in reverse.

P Work after assembly

Clutch Fluid Replacement and Air Bleeding L P21-12

P Inspection and adjustment after assembly

L P21-18

Service standards Unit: mm

Standard value
Location Maintenance item Limit Remedy
Basic diameter in[ ]
Clearance between clutch switch and clutch pedal
7 0.5 to 1.5 – Adjust
arm stopper
Installation of return spring
10 2.4N?m {0.24kgf?m} 2.1N?m {0.21kgf?m} Replace
(tortional angle:82°):moment
Replace
12, 13 Clearance between collar and bushing [14] 0.02 to 0.26 0.3
bushing
Installation height of clutch pedal arm (distance
between center of pedal pad and center of clutch 245 ± 3.0 – Adjust
16 pedal arm)
Full stroke of clutch pedal arm 167.4 – Replace

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
5 Nut (clutch booster and clutch master cylinder mounting) 9 to 14 {0.9 to 1.4} –
8 Nut ((clutch switch fixing) 19 to 28 {1.9 to 2.8} –
9 Nut (clutch pedal mounting) 17 to 26 {1.7 to 2.6} –

K Lubricant
Location Points of application Specified lubricant Quantity
4 Outer surface of clevis pin Chassis grease [NLGI No. 1 (Li soap)] As required
12 Inside of collar Chassis grease [NLGI No. 1 (Li soap)] As required

21-17
CLUTCH PEDAL
R Service procedure
P Inspection and adjustment after assembly
A (1) Height of clutch pedal arm
Adjust the position of clevis A on clutch booster and clutch master
cylinder 6 so that the height of clutch pedal arm 16 conforms to the
standard value. L P21-20

6 (2) Stroke of clutch pedal arm

• Make sure the fill stroke of clutch pedal arm 16 conforms to the
245±
16 3.0 mm standard value.
• If the full stroke does not conforms to the standard value, replace
clutch pedal assembly 11.

167.4 mm

78653

7 Installation of clutch switch

8 7
0.5 to 1.5 mm • Install clutch switch 7 so that the clearance between the tip of the
threaded section of clutch switch and stopper section A on clutch
pedal arm 16 conforms to the standard value.
• Tighten lock nut 8 to secure clutch switch 7 in place.
A

16
78654

21-18
 21

MEMO

21-19
CLUTCH BOOSTER AND CLUTCH MASTER CYLINDER
PDisassembly sequence
1 Nut
7 2 Clutch booster
3 Clutch master cylinder
6 4 Circlip
5 5 Clip
4 6 Packing
8 7 Union collar
8 Piston assembly
9 Cylinder body
9
X Non-reusable parts

CAUTION k
Clutch booster 2 cannot be disassem-
bled for a repair. If it is defective, re-
place the assembly.

PAssembly sequence
2 Follow the disassembly sequence in re-
verse.
1 3
Repair kit: Clutch master cylinder kit.

79853

Service standards Unit: mm

Location Maintenance item Standard value Limit Remedy

(Basic diameter in [ ])
Distance between side face of clutch booster body
2 120 ± 0.5 – Adjust
and center of clevis
Clearance between clutch master cylinder and tip of
2, 3 0 to 0.75 – Adjust
push rod of clutch booster
Clearance between piston assembly and cylinder
8, 9 [22.22] 0.02 to 0.1 0.2 Replace
body

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Nut (clutch master cylinder mounting) 8.8 to 14 {0.9 to 1.4} –
2 Lock nut of clutch booster push rod 21.6 ± 2.9 {2.2 ± 0.3} –

K Lubricant
Location Points of application Specified lubricant Quantity
8, 9 Sliding surfaces of piston assembly and cylinder body Nigulube RX2 0.2 to 0.3g

21-20
 21
R Service procedure
2 3 Installation of clutch booster and clutch master cylinder
• Measure dimensions A and B of clutch master cylinder 3 as shown in
the figure.

3 B

A
79887

• Calculate the dimension of push rod protrusion C with the following

2
formula so that the clearance between piston assembly 8 of clutch
D master cylinder 3 and push rod D of clutch booster 2 may be the di-
mension as shown in the figure.
C = A – B – clearance (0 to 0.75 mm)

• Adjust the push rod to the calculated dimension of push rod protru-
3
sion C.

0 to D
0.75 mm

3
C 79888

• Loosen lock nut E, then turn clevis F until the distance between the
F E side face of clutch booster 2 and the center of clevis conforms to the
standard value.

03488

21-21
CLUTCH BOOSTER AND CLUTCH MASTER CYLINDER

8 Piston assembly
[Removal]
Remove circlip 4,cover vent port A on cylinder body 9, then feed
B compressed air from section B shown in the diagram to remove pis-
4
ton assembly 8.
8
CAUTION k
Since compressed air causes piston assembly 8 to lunge out
9
and brake fluid to splash, be sure to cover with a cloth when
A
05950 performing the work.

[Installation]
C Apply grease to sliding surfaces C on piston assembly 8 and cylinder
body 9.
C

9
03483

21-22
 21

MEMO

21-23
CLUTCH POWER CYLINDER
P Disassembly sequence
1 Clutch hose
2 Bolt
3 Clutch power cylinder assembly
LP21-25

a: Push rod L P21-25

*b:
* Clutch release rocker arm L P21-31
P Assembly sequence
Follow the disassembly sequence in re-
verse.

08199

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
2 Bolt (clutch power cylinder assembly installation) 38 to 59 {3.9 to 6.0} –

K Lubricant
Location Points of application Specified lubricant Quantity
Wheel bearing grease
*a, *b Apply to push rod linkage
[NLGI No. 2 (Li soap)]
As required

21-24
 21
Clutch Power Cylinder Assembly
P Disassembly sequence
1 Dust cover
2 Push rod
3 Retaining ring
4 Piston assembly
5 Wear indicator
6 Spring
7 Bleeder cap
8 Bleeder screw
9 Cylinder body

P Assembly sequence
Follow the disassembly sequence in re-
verse.

Repair kit: Clutch power cylinder kit

08200

Service standards Unit:mm

Standard value
Location Maintenance item Limit Remedy
(Basic diameter in [ ] )

4, 9 Clearance between piston assembly and cylin- [22.22] 0.02 to 0.10 0.2 Replace
der body
6 Installed load of spring (installed length 31.5) 7.8 ± 0.59N {0.8 ± 0.06kgf} 6.7N {0.68 kg} Replace

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
8 Bleeder screw 6.9 to 8.8 {0.7 to 0.9} –

K Lubricant
Location Points of application Specified lubricant Quantity
Apply to the engagement part of the cylinder
1 Rubber grease As required
body
Lip area of the piston cup and the area
extending approximately 15 mm from the end Rubber grease As required
4, 9 surface of the cylinder body
Piston, piston cup (installation point), and the
Rubber grease As required
internal surface of the cylinder body

21-25
CLUTCH BODY
P Disassembly sequence
* P 1 Bolt
2 Clutch cover assembly
3 Clutch disc
3
2
*: Flywheel B Gr 11
P: Locating pins
T
1

79854

Service standards Unit:mm

Location Maintenance item Standard value Limit Remedy
Pressure plate flatness 0.05 or less 0.2 –
Friction surface of pressure plate
5.5 4.5 Replace
2 (Measured at specified positions)
Clearance between diaphragm spring and pivot ring – Play Replace
Finger heights of diaphragm spring uneven 1.0 or less 1.3 Correct
Radial runout 1.0 or less 1.5 Replace
Lateral runout 0.8 or less 1.5 Replace
3 Clutch disc
Play in rotation of spline 0.05 to 0.23 0.5 Replace
Depth from facing surface to rivet 1.9 to 2.5 0.2 Replace

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Bolt (Clutch cover assembly installation) 32 to 49 {3.3 to 5.0) –

21-26
 21
K Lubricant
Location Points of application Specified lubricant Quantity

3 Spline Molybdenum disulfide grease 3.2 to 4.2 g

[NLGI No. 2 (Li soap)]

J Special tools Unit:mm

Location Tool names and shape Part No. Application
Clutch alignment arbor

120 MH061387 Holding of clutch disc

20
28.94
01270

Sleeve

28.94
Inspection of installed
MH061425 height of diaphragm
spring
45

03509
2, 3
Plate

Adjustment of
MH061424
diaphragm spring
400

03510

Adjust wrench

Adjustment of
MH061426
diaphragm spring
260
45
03508

21-27
CLUTCH BODY
R Service procedure
3 A 2 Clutch cover assembly
[Removal]
• Insert J clutch alignment arbor into pilot bearing A on flywheel
2
hold clutch disc 3, and remove clutch cover assembly 2.
* to
* • For installation, follow the removal sequence in reverse.

NOTE
• Clean friction surfaces of the clutch disc 3 and flywheel* before
installation.
P48963 • Install the clutch disc 3 so that part No.B is visible.
• Tighten the bolts 1 gradually, in diagonal order, to the specified
torque.

05965

[Pressure plate flatness]

C
D Thickness • Place a straight edge on friction surface D of pressure plate C. Mea-
Straight edge gauge sure the clearance between the friction surface and the straight edge
at several points selected randomly across the friction surface with a
thickness gauge.
• The difference between the maximum and the minimum measure-
ments is the levelness value of pressure plate C.
2 • If the levelness value exceeds the limit, replace clutch cover assem-
bly 2.
P49023

Friction surface of pressure plate]

Measure pressure plate friction surface A at specified position B. If the
measured value is lower than the limit, replace clutch cover assembly 2.

NOTE
Measure pressure plate friction surface A at the position shown
in the table below.

08830
Maximum diameter X298mm

Minimum diameter X192mm

21-28
 21
[Inspection]
• Make sure there is no play in the diaphragm spring C.
• If there is play, replace the clutch cover assembly 2.

05966

[Installation height inspection]

• Place the a plate on a surface plate and install the clutch cover as-
sembly 2.
• Install the b sleeve and c clutch alignment arbor, measure finger
heights of the diaphragm spring C to see if they are uneven, using
the thickness gauge F. If the measured value is higher than the limit,
correct the heights.

03512

[Correction]
• Correct uneven finger heights of the diaphragm spring C using the
d adjust wrench.

03513

21-29
CLUTCH BODY
3 Clutch disc
(1) Facing height
Measure the illustrated dimension A of the clutch disc 3. If the mea-
sured value is lower than limit, replace the clutch disc.

05967

(2) Play in the direction of rotation

• Make the width so that filler gauge B can be inserted into drive pinion
spline area C, measure the width, and if the measured value exceeds
the limit, replace clutch disc 3 or the drive pinion.
• Conduct the same measurement for the new clutch disc 3, and if the
measured value exceeds the limit, replace the drive pinion.

05968

(3) Grease application

Apply grease to the entire spline D tooth surface of clutch disc 3. In
addition, be sure to apply sufficient grease in the spline grease
groove up to the spline major diameter.

NOTE
If too much grease is applied, grease will leak from spline area D
and get on the clutch disc, which will cause the clutch to slip.
Therefore, do not apply excessive grease.
74718

21-30
CLUTCH HOUSING 21

08202
P Disassembly sequence
1 Return spring 4 Rocker arm pivot
2 Clutch release bearing 5 Clutch rocker arm cover
3 Clutch release rocker arm 6 Clutch housing

NOTE
Do not remove the rocker arm pivot 4 unless it is faulty.

P Assembly sequence
Follow the disassembly sequence in reverse.

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
4 Rocker arm pivot 57 {5.8} –

K Lubricant
Location Points of application Specified lubricant Quantity
Sliding surfaces of the return spring, clutch release bearing, Wheel bearing grease
1 to 3 As required
and clutch release rocker arm [NLGI No. 2 (Li soap)]

21-31
 22

GROUP 22 MANUAL TRANSMISSION

SPECIFICATIONS ................................................................................ 22-2

STRUCTURE AND OPERATION ........................................................ 22-3

TROUBLESHOOTING ......................................................................... 22-6

REMOVAL AND INSTALLATION OF TRANSMISSION

ASSEMBLY .......................................................................................... 22-8

GEAR SHIFTER UPPER....................................................................... 22-12

EXTENSION HOUSING ........................................................................ 22-18

6TH GEAR, REVERSE IDLER GEAR .................................................. 22-22

TRANSMISSION BODY........................................................................ 22-28

DRIVE PINION ASSEMBLY ................................................................. 22-38

MAINSHAFT ASSEMBLY..................................................................... 22-40

COUNTERSHAFT ASSEMBLY ............................................................ 22-46

TRANSMISSION CONTROL ................................................................ 22-48

BEARING PULLER AND INSTALLER................................................. 22-60

22-1
SPECIFICATIONS
Item Specifications
Mode of control Floor shift remote control
Transmission model M035S6
1st 6.114
2nd 3.442
3rd 1.987
Gear ratio 4th 1.345
5th 1.000
6th 0.790
Reverse 6.114
Oil capacity dm3 {L} Approximately 4.4 {4.4}
Mass kg Approximately 97.5

22-2
STRUCTURE AND OPERATION 22
1. Transmission Assembly
2 3 4
5 6 7

8
9

11 10 42771

1 Drive pinion 7 1st and reverse constant-mesh assembly

2 4th and 5th synchronizer assembly 8 Mainshaft
3 Reverse shift lever 9 6th synchronizer assembly
4 Shift rail 10 Reverse idler gear
5 2nd and 3rd synchronizer assembly 11 Countershaft
6 Shift fork

The transmission changes revolution and torque generated by the engine into those that match the vehicle’s power re-
quirement (driving force). Revolution and torque are increased or decreased by making a selection from several sets of
engaged gears.

22-3
STRUCTURE AND OPERATION
2. Synchromesh Mechanism
Single cone type Triple cone type
< Excluding 2nd and < 2nd and 3rd > 3
3rd gears >
4
5
1
1
5 11 2
2
10 6
6
B
7

A
8
8
9
10 9
05751 37156
1 Synchronizer ring (Single cone type) 7 Mainshaft
Inner synchronizer ring (Triple cone type) 8 Synchronizer hub
2 Shifting key (Single cone type) 9 Synchronizer sleeve
Shifting plunger (Triple cone type) 10 Drive pinion (Single cone type)
3 Outer synchronizer ring (Triple cone type) 2nd gear (Triple cone type)
4 Center cone (Triple cone type) 11 Synchronizer cone (Triple cone type)
5 4th gear (Single cone type) A: Taper cone
3rd gear (Triple cone type) B: Dog clutch
6 Shifting key spring (Single cone type)
Shifting plunger spring (Triple cone type)

• The synchromesh mechanism synchronizes the rotating speed of mainshaft 7 and associated synchronizer hub 8 with
the rotating speed of the gears to be selected when shifting gear.

• Single cone type < excluding 2nd and 3rd gears >
In this cone type, gear taper cone A acts as a cone clutch for synchronization with synchronizer ring 1. So the rotating
speed of the gear to be synchronized with synchronizer hub 8 gradually changes to the matching speed. When syn-
chronizer sleeve 9 moves into the appropriate position efficiently through this process and engages with the synchro-
nizer hub and dog clutch B of the gear to be selected, gear shift is completed.

• Triple cone type < only for 2nd and 3rd gear >
In this cone type, the synchronizer ring is divided into three (inner synchronizer ring 1, outer synchronizer ring 3, and
center cone 4). The center cone is between the inner synchronizer ring and the outer synchronizer ring, the inner syn-
chronizer ring is between the center cone and the synchronizer cone 11 and, in addition, the clutch’s face is widened;
thereby reducing synchronizing time through more efficient operation of the cone clutch, as well making shift operation
easily.

22-4
 22
3. Interlock Mechanism
1 6th shift rail
< In neutral >
2 4th and 5th shift rail
1 2 3 4 3 2nd and 3rd shift rail
4 1st and reverse shift rail
5 Interlock pin

The interlock mechanism is designed to avoid dou-

ble engagement of gears. When 2nd and 3rd shift
5 rail 3 is shifted, interlock pins other than interlock pin
46791 5 in the 2nd and 3rd shift rail are pushed by the 2nd
and 3rd shift rail to lock other shift rails.

< On shifting >

46792

22-5
TROUBLESHOOTING
Symptoms

Noise when changing gears

Noise when engine is idling
Remarks

Gears hard to engage

Noise while cruising

Gears slip out
Possible causes

Mainshaft rear lock nut loose p p

Mainshaft thrust washer worn p p
Mainshaft bearing worn or damaged p p
Synchronizer ring and synchronizer sleeve spline worn p
Synchronizer ring and gears taper cone area worn p
Mainshaft pilot bearing worn or damaged p p
Transmission Drive pinion bearing worn or damaged p
body faulty Counter shaft bearing worn or damaged p
Needle bearings of gears worn or damaged p p
Mainshaft and counter shaft bearing worn or damaged p
Mainshaft and counter shaft gears backlash excessive p
Spline of gears worn p
Gears damaged p
Gear oil insufficient p
Control rod joint play p p
Control rod joint lubricated insufficiently p
Bushings worn p p
Control rod length adjusted incorrectly p
Operating Control rod bent p
mechanisms
faulty Shift rail steel ball and groove worn p
Shift rail poppet spring fatigued or cracked p
Shift rail sliding movement poor p
Shift fork claws worn p
Shift fork cracked p

22-6
 22
Symptoms

Noise when changing gears

Noise when engine is idling
Remarks

Gears hard to engage

Noise while cruising

Gears slip out
Possible causes

Clutch engagement poor p p L Gr 21

Clutch faulty
Clutch pedal play adjusted incorrectly p L Gr 21
Single cone Contacting surfaces of synchronizer ring and
p p
type gear assembly taper cone worn
Contacting surfaces of synchronizer inner and
Triple cone
outer rings, center cone and gear assembly p p
Synchronizer faulty type
taper cone worn
Shifting key worn p
Shifting key spring fatigued or damaged p
Synchronizer sleeve worn or damaged p p

22-7
REMOVAL AND INSTALLATION OF TRANSMISSION ASSEMBLY

P Disassembly sequence
1 Selector rod L P22-48
2 Shift rod L P22-48
10 11 3 Cross shaft L P22-48
9 4 Harness (ground)
5 Speed sensor harness
14 6 Chassis harness
13 7 Parking brake cable L Gr36
8 Propeller shaft L Gr25
12 9 Bolt
10 Bolt
11 Nut
18 17 17 12 U-bracket
13 Insulator
15
1 14 Transmission mounting bracket
2 15 Bolt
3
16 Transmission assembly
17 Drain plug
18 Inspection plug
P Assembly sequence
7 Follow the disassembly sequence in re-
verse.
4
16 CAUTION k
6
5 8 After removal of propeller shaft 8, tie it
to the frame temporarily at the height
of the installation assembly using a
79842 piece of rope, etc.

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
9 Bolt (rear mounting installation) 130 to 180 {13 to 18} –
10 Bolt (U-bracket installation) 39 to 58 {3.9 to 6.0} –
11 Nut (transmission mounting bracket installation) 39 to 58 {3.9 to 6.0} –
47 {4.8} M10 × 12.5
15 Bolt (transmission assembly installation)
82 {8.4} M12 × 1.75
17 Drain plug 69 w 15 {7.0 w 1.5} –
18 Inspection plug 69 w 15 {7.0 w 1.5} –

K Sealant
Location Points of application Specified sealant Quantity
17 Drain plug threads THREEBOND 1105D As required
18 Inspection plug threads THREEBOND 1105D As required

22-8
 22
R Service procedure
13 Insulator installation
Install the insulator 13 to the transmission mounting bracket 14 at the
14
50 w 1 50 w 1 angle as illustrated.

13 13

74332

16 Transmission assembly
[Draining]
When draining oil, check the quantity and quality of oil, especially for
small pieces of metal and metal dust. Clean the drain plug before in-
stalling it because it is magnetic.

[Filling]
• Check that the drain plug 17 is tightened at the specified torque and
01116
pour in the gear oil via the inspection hole until the oil overflows. (For
the oil quantity, refer to the specifications.)
• Tighten inspection plug 18 at the specified torque.
• Wipe up oil spilt during filling.
• Tightening torque and sealant for drain plug and inspection plug.

18 17 17
79872

[Supporting the transmission]

Support transmission assembly 16 using the transmission jack A.

16

07611

22-9
REMOVAL AND INSTALLATION OF TRANSMISSION ASSEMBLY
[Removal]
• Insert a screwdriver into the three removal grooves to remove trans-
mission assembly 16 from the engine.
16 CAUTION k
While conducting this service procedure, make sure that the
hoses and cables have been removed correctly.

06501

• Move transmission assembly 16 straight back until the spline of the

drive pinion is pull out of the clutch.

CAUTION k
Do not forcefully shake the transmission assembly 16.

01117

[Installation]
• Check the spline of the drive pinion for rust. If round, remove it using
a wire brush.
• By hand apply grease to the clutch sliding surfaces of the drive pin-
ion.

CAUTION k
Be careful not to apply too much grease to the sliding surfaces
because excess grease can drip and cause the clutch to slip.
07610

• Support transmission assembly 16 on transmission jack A and insert

the transmission assembly into the pilot bearing of the flywheel while
paying attention to the drive pinion spline.
16 • Tighten transmission installation bolt 15 at the specified torque to
mount the transmission assembly onto the engine.

07611

22-10
 22

MEMO

22-11
GEAR SHIFTER UPPER
P Disassembly sequence
1
1 Bolt
6 2 Gear shifter upper assembly LP22-14
2 3 Backup lamp switch
4 Screw plug
7
5 Interlock pin
3 9 6 Screw
8 8 7 Poppet spring plate
8 Poppet spring (excluding 4th and 5th gears)
10 9 Poppet spring (for 4th/5th gear)
* 10 Steel ball

: Transmission body
5 *
X: Non-reusable parts
4

P Assembly sequence
Follow the disassembly sequence in reverse.
79874

Service standards Unit: mm

Location Maintenance item Standard value Limit Remedy
8 Poppet spring free length (excluding 4th and 5th gears) 22.85 22.00 Replace
9 Poppet spring free length (for 4th/5th gear) 24.96 24.00 Replace

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Bolt (Gear shifter upper assembly mounting) 24 {2.4} –
3 Backup lamp switch 29 to 39 {3 to 4} –
4 Screw plug 37.3 {3.8} –
6 Screw (Poppet spring plate mounting) 24 {2.4} –

K Sealant
Location Points of application Specified sealant Quantity
2 Contact surface of transmission case THREEBOND 1104J As required
3 Thread area of backup lamp switch THREEBOND 1215 As required
4 Thread area of screw plug THREEBOND 1215 As required
7 Contact surface of transmission case THREEBOND 1215 As required

22-12
 22
R Service procedure
A 5 Removal of interlock pin
• 1st and reverse shift rail A is provided with hole B (X3 mm) for the re-
moval of interlock pin 5.

4
3

5 46764

• When 1st and reverse shift rail A is shifted into reverse, hole B for re-
A moval of the interlock pin aligns with the interlock pin holes of the oth-
er shift rails, backup lamp switch 3 installation hole and screw plug 4
hole.
• Remove interlock pin 5 from backup lamp switch 3 installation hole
side using a wire.
5
B

46765

22-13
GEAR SHIFTER UPPER
Gear Shifter Upper Assembly
P Disassembly sequence
1 Air breather
2 Neutral switch
5 3 Nut
6 4 Lock pin
3 5 Bushing
4
20 6 Gear selector lever B
A 1 7 Washer
7 8 Bearing
9 Gear selector lever A
B 22
16 10 Spring pin
21 23 11 6th return spring
15 12 6th return spring
24 13 Spring retainer
14 Gear shift slide lever
19 15 Steel ball
2 10
16 Poppet spring
17 17 Spring retainer
9 18 1st and reverse return spring
8 19 Spring retainer
18 20 Torsion shaft
21 Oil seal
14 22 Oil seal
11 23 Bushing
13 24 Selector lever case
12
A: Notch for spring pin
B: Recess for neutral switch
X: Non-reusable parts
79875

NOTE
Do not remove bushing 23 except for replacement.

P Assembly sequence
Follow the disassembly sequence in reverse.

CAUTIONk
Be sure when assembling gear selector lever A 9, that you turn the lever so you do not damage the lip area of
oil seal 22.

22-14
 22
Service standards Unit: mm
Location Maintenance item Standard value Limit Remedy
11 6th return spring free length 59.0 57.0 Replace
12 6th return spring free length 39.6 37.6 Replace
18 1st and reverse return spring free length 49.18 47.18 Replace

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
2 Neutral switch 49±2.9 {5±0.3} –
3 Nut (Lock pin mounting) 6.9 {0.7} –

K Lubricant and/or sealant

Location Points of application Specified lubricant and/or sealant Quantity
2 Threads area of neutral switch THREEBOND 1104J As required
7 Contact surfaces between washer and gear selector lever B Wheel bearing grease [NLGI No.2 (Li soap)] As required
21 Lip area of oil seal Wheel bearing grease [NLGI No.2 (Li soap)] As required
22 Lip area of oil seal Wheel bearing grease [NLGI No.2 (Li soap)] As required
Inner surface of gear selector lever shaft bushing and its
Wheel bearing grease [NLGI No.2 (Li soap)] As required
friction surface
23
Contact surfaces between bushing outer surface and
THREEBOND 1104J As required
selector lever case

J Special tools Unit: mm

Location Tool name and shape Part No. Application

Spring pin puller MH062445

M12 u 1.25 02399

10 Removal of spring pin

Reverse shaft puller 03726-82000

M12 u 1.25 02118

22-15
GEAR SHIFTER UPPER
R Service procedure
8 8 Installation of bearing
Install bearing 8 on gear select lever A 9 with the dimensions as illus-
trated.

0.5 w 0.2 mm
9 24020

10 Removal of spring pin

• Tap spring pin 10 using an M4 tap.
• Attach a spring pin puller with an M4 screw A of appropriate
length, and pull out spring pin 10 using b reverse shaft puller.

10

46635

14 20 Installation of gear shift slide lever and torsion shaft

45 When you install torsion shaft 20, position punch on the tip of the tor-
mark
sion shaft end gear shift slide lever 14 as illustrated.
20
24

14
07570

21 Installation of oil seal

21 Apply grease to lip area A of oil seal 21, and press-fit evenly in the di-
rection as illustrated.
A

06255

22-16
 22
22 Installation of oil seal
22 A
Apply grease to lip area A of oil seal 22 with bushing 23 press-fitted
onto selector lever case 24, and press-fit evenly in the direction as illus-
trated.

24
23

06254

23 Bushing
[Removal]
24
Bushing 23 is press-fitted onto selector lever case 24. For replacement,
remove using a screwdriver.

CAUTION k
Be careful not to damage selector lever case 24.

23
06250

[Press-fitting]
Clean the inner surface of selector lever case 24, and drive bushing 23
A evenly into the case using bar A (approximately X30 mm) taking care
not to damage the case.
After press-fitting, apply sealant to bushing outer side B.

23 NOTE
Prevent sealant from sticking to the inner surface of bushing 23.
24
B 06403

22-17
EXTENSION HOUSING
P Disassembly sequence
1 Speed sensor B Electrical
12 2 L-joint
13 3 Bolt
14
4 Speedometer gear bushing assembly
15 5 Spring pin
6 Speedometer gear
16 7 O-ring
8 Oil seal
11
9 Speedometer gear bushing
10 10 Bolt
11 Extension housing assembly
12 Drain plug
13 Gasket
14 Dust plug
2 15 Oil seal
16 Extension housing
17 Speedometer worm
17 18 Bearing
1
19 Bearing sleeve
4
18 20 Distance pipe

3
19 : Transmission body
*
X: Non-reusable parts
6
20
7 P Assembly sequence
5 Follow the disassembly sequence in re-
verse.
9

*
8

78669

Service standards Unit: mm

Standard value
Location Maintenance item Limit Remedy
(Basic diameter in [ ])
Clearance between speedometer gear and speedom-
6, 9 [12] 0.04 to 0.09 0.15 Replace
eter gear bushing

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Speed sensor 24.5 ± 4.9 {2.5 ± 0.5} –

2 L-joint 24.5 ± 4.9 {2.5 ± 0.5} –

3 Bolt (Speedometer gear bushing assembly mounting) 24 {2.4} –
10 Bolt (Extension housing assembly mounting) 44 {4.5} –
12 Drain plug 69 ± 15 {7.0 ± 1.5} –

22-18
 22
K Lubricant and/or sealant
Location Points of application Specified lubricant and/or sealant Quantity
Friction surfaces of speedometer gear and speedometer
6 Molybdenum disulfide base grease As required
gear bushing
8 Lip area of oil seal Wheel bearing grease [NLGI No.2 (Li soap)] As required
10 Thread area of bolt (only 3 upper bolts) THREEBOND 1104J As required
Contact surfaces between extension housing assembly and
11 THREEBOND 1215 As required
transmission body
15 Lip area of oil seal Wheel bearing grease [NLGI No.2 (Li soap)] As required

J Special tools Unit: mm

Location Tool name and shape Part No. Application

16.5

Installation of extension housing oil

15 Oil seal installer MH062691
seal

06252

22-19
EXTENSION HOUSING
R Service procedure
4 Installation of speedometer gear bushing assembly
A
• Position speedometer gear bushing 4 so that the stamped “15-17”
mark faces mark A, then install it.

"15 - 17"
78670

5 5 Driving-in spring pin

Drive spring pin 5 into speedometer gear bushing 9 with the opening in
the opposite direction to speedometer gear 6, as illustrated.

6
9

5 03576

6 9 Clearance between speedometer gear and speedometer

gear bushing
6 If the clearance is higher than the limit, replace faulty parts.

03577

8 Installation of oil seal

B Apply grease to lip area A of oil seal 8, and drive oil seal evenly into
speedometer gear bushing 9 in the direction as illustrated using bar B
(approximately X14 mm).

A 8
9
03578

22-20
 22
15 Installation of oil seal
Apply grease to lip area A of oil seal 15, and press-fit it.
J: Oil seal installer
15

46799

22-21
6TH GEAR, REVERSE IDLER GEAR
P Inspection before disassembly
L P22-24
1
P Disassembly sequence
2 8 1 Counter shaft rear lock nut
2 Shifting key retainer
3 Spring pin
10 4 6th shift jaw B
5 Spring pin
6 6th shift fork
9
13 7 6th shift rail B
8 Synchronizer sleeve
12 9 Shifting key
10 Shifting key spring
11 11 Sychronizer ring
17 12 Shifting key spring
14 13 Synchronizer hub
6
14 Counter shaft 6th gear assembly
21 15 6th gear sleeve
5
16 Thrust washer
17 Mainshaft 6th gear
15
18 Bolt
7
16 19 Bolt
4 20 Reverse idler gear cover
23 21 Reverse idler gear shaft
3 22 Side washer
4
23 Side washer
24
24 Reverse idler gear

* 22
: Transmission body
*
X: Non-reusable parts

19

20
18

78671

CAUTIONk
• Before performing the disassembly, put alignment mark at one point of the key built-in to synchronizer sleeve
8 and synchronizer hub 13.
• The 6th gear sleeve 15 is pressed into the counter shaft. When removing the 6th gear sleeve, remove it togeth-
er with thrust washer 16 by disconnecting the counter shaft rear bearing.

P Assembly sequence
24 23 22 21 20 19 18 17 16 15 14
*
7 4
5 3 2 1

13 8 9 12 11 10 6

22-22
 22
Service standards Unit: mm
Standard value
Location Maintenance item Limit Remedy
(Basic diameter in [ ])
6 Tilt of claw part of 6th shift fork 0.1 or less 0.2 Replace
Clearance between synchronizer sleeve and 6th shift
6, 8 0.3 to 0.6 1.0 Replace
fork
7 Bend of 6th shift rail B 0.02 or less 0.03 Replace
9, 11 Clearance between shifting key and synchronizer ring 3.5 to 3.7 4.5 Replace
9, 13 Clearance between shifting key and synchronizer hub 0.05 to 0.20 0.50 Replace
Clearance between synchronizer ring and counter shaft
11, 14 1.13 to 1.37 0.50 Replace
6th gear assembly
14 End play of counter shaft 6th gear assembly 0.25 to 0.35 0.70 Replace
Play in the diameter direction of counter shaft 6th gear
14, 15 0.08 to 0.14 0.20 Replace
assembly and 6th gear sleeve
Clearance between reverse idler gear shaft and reverse
21, 24 [24] 0.05 to 0.09 0.20 –
idler gear
Replacement of
24 End play of reverse idler gear 0.26 to 0.64 0.90
side washer

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Counter shaft rear lock nut 345 ± 49 {35 ± 5} –
18, 19 Bolt (Reverse idler gear cover installation) 44.5 {4.5} –

K Sealant
Location Points of application Specified sealant Quantity
20 Installation of reverse idler gear cover LOCTITE 5999 As required

J Special tools Unit: mm

Location Tool name and shape Part No. Application

15 Bearing puller and installer MH062696 Installation of 6th gear sleeve

46331

Removal of reverse idler gear

21 Reverse shaft puller 03726-82000
shaft

M12 u 1.25 02118

22-23
6TH GEAR, REVERSE IDLER GEAR
R Service procedure
P Inspection before disassembly
(1) The end play of counter shaft 6th gear assembly
If the measured value of the end play of counter shaft 6th gear as-
sembly exceeds the limit, replace the faulty parts.
Re-inspect the play after assembly to check that the measured value
is within the limit.

06259

(2) Play of counter shaft 6th gear assembly in the diameter direction
If the measured value of play on counter shaft 6th gear assembly in
the diameter direction exceeds the limit, replace the faulty parts. Re-
inspect the play after assembly to check that the measured value is
within the limit.

06260

3 5 Installation of spring pin

CAUTION k
• Install spring pin 3 and 5 with the notch facing to the front
5 and rear direction.
3
• Do not reuse it.
• Do not drive in spring pin 3 and 5 fully, but leave 0 to 0.5 mm
of spring pin showing. Also be careful not to overload the
shift rail 7 when driving in the spring pin.
06261

6 6th shift fork claw tilt

Measure the tilt of claw B of 6th shift fork 6 against shift rail hole A of
6th shift rail B 7.
7
A If the measured value exceeds the limit, replace the faulty parts.
6

B
06263

6 8 Clearance between 6th shift fork and synchronizer sleeve.

Measure clearance A between a groove of synchronizer sleeve 8 and a
claw of 6th shift fork 6.
6 If the measured value exceeds the limit, replace the faulty parts.
8

06262

22-24
 22
7 Deflection of 6th shift rail B

A The deflection is one half of the dial gauge A indicator mark.

If measured value exceeds the limit, replace 6th shift rail B 7.
7

01127

8 13 Assembly of synchronizer sleeve and synchronizer hub

B Align the three keyways A of synchronizer hub 13 with the three stub
13 8 teeth B of synchronizer sleeve 8 to install the synchronizer hub.

CAUTION k
B When reusing synchronizer hub 13 and synchronizer sleeve 8,
B before assembly align the alignment marks being marked dur-
A B
ing disassembly.
01129

9 11 Clearance between shifting key and synchronizer ring

11 If the measured value exceeds the limit, replace the faulty parts.

9
01132

9 13 Clearance between shifting key and synchronizer hub

9
If the measured value is higher than the limit, replace the faulty parts.

13
01179

22-25
6TH GEAR, REVERSE IDLER GEAR
10 12 Shifting key spring installation
10, 12 9
Place shifting key 9 and install shifting key spring 10 and 12, taking care
not to locate the opening away from the shifting key position. The two
openings of shifting key spring should not be aligned with each other.

01130
0112

13 11 Synchronizer ring installation

To install synchronizer ring 11, align the keyway to synchronizer hub 13
11
with A side of oil keyways.

A 01131

11 14 Clearance between synchronizer ring and counter shaft 6th

gear assembly
Uniformly press in synchronizer ring 11 and take measurements around
the entire circumference. If the measured value for clearance is below
the limit, replace the faulty parts.
A: Counter shaft 6th gear cone part
14
11
A
01133

15 Installation of 6th gear sleeve

J: Bearing puller and installer

15

46332

16 Thrust washer installation

16
A CAUTION k
Install the thrust washer with the oil groove A, facing to the gear
side.

46333

22-26
 22
20 Reverse idler gear cover
20 * [Removal]
• After removing bolt 18, 19 insert scraper A between transmission
body * from the lower right or lower left of reverse idler gear cover 20.
Use a plastic hammer B, if necessary.
18
• With the scraper A inserted, push forward the scraper clockwise and
counterclockwise to the upper part of the reverse idler gear cover 20
A
along the flange of reverse idler gear cover, then removing the re-
19 B verse idler gear cover.
78661
0112 • Be sure to get rid of all the sealant adhered to reverse idler gear cov-
er 20 and the flange surface of the transmission body , by using the
scraper A.
*

CAUTION k
• Never scoop out the scraper A on the way because it would
deform the reverse idler gear cover 20 or damage the trans-
mission body .
*
• When getting rid of the sealant, it is recommendable to use a
remover available in the market.

[Installation]
20 • Using the dedicated nozzle (nozzle diameter: 2 mm), form a continu-
ous line of sealant C on the transmission body mounting face of re-
verse idler gear cover 20.
*
2 mm
• Within five minutes from the time of sealant C application, install re-
verse idler gear cover 20 to transmission body .
*
C CAUTION k
78662 • Clean all of the parts before applying sealant C.
• When using the sealant C, do not apply it uniformly and flatly
since it can be hard to disassemble due to its strong bonding
power.
• Never pour in the oil, etc. within thirty (30) minutes after the
assembling.

21 Removal of reverse idler gear shaft

J: Reverse shaft puller

48868
4886

22-27
TRANSMISSION BODY
P Disassembly sequence
1 Bolt
T5
2 Front bearing retainer
6 3 Oil seal
7 4 Lever set bolt
8 5 Bolt
9 6 Rear bearing retainer
7 Snap ring
8 Snap ring
T10 11 9 Shift rail bushing
10 Bolt
11 Transmission case
4TK 12 Bolt
13 Bearing retainer
14 Shift rail and shift fork L P22-34
17 15 Countershaft assembly L P22-46
15 16 Drive pinion assembly L P22-38
17 Mainshaft assembly L P22-40
14 18 Clutch housing
12 T
13
X: Non-reusable parts
16
NOTE
• After removing parts bolt 1 to oil seal 3, disas-
semble the transmission assembly with
clutch housing 18 placed stably on a flat sur-
face.
18 K • Remove parts shift rail and shift fork 14 to
mainshaft assembly 17 as a group.
• Note that shift rail and shift fork 14 can be dis-
assembled on their own when parts 14 to
drive pinion assembly 16 are not disassem-
K 3 bled.
2 K L P22-34
T1 • Do not remove shift rail bushing 9 unless it
must be replaced due to abnormalities.
46814

P Assembly sequence
Follow the disassembly sequence in reverse.

22-28
 22
T Tightening torque Unit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks
1 Bolt (Front bearing retainer mounting) 44.5 {4.5} –
4 Lever set bolt 165 ± 25 {16.9 ± 2.5} –
5 Bolt (Installation of rear bearing retainer) 44.5 {4.5} –
10 Bolt (Transmission case mounting) 54 {5.5} –
12 Bolt (Bearing retainer mounting) 44.5 {4.5} –

K Lubricant and/or sealant

Location Points of application Specified lubricant and/or sealant Quantity
Contact surfaces between front bearing retainer and clutch
2 THREEBOND 1215 As required
housing assembly
3 Front bearing retainer oil seal lip area Wheel bearing grease [NLGI No.2 (Li soap)] As required
4 Screw of lever set bolt LOCTITE 271 As required
Contact surfaces between clutch housing assembly and
18 THREEBOND 1215 As required
transmission case

J Special tools Unit: mm

Location Tool names and shape Part No. Application

Protection of front bearing retainer oil

2, 3 Oil seal guide MH063322
seal

36.5
09918

Installation of front bearing retainer oil

3 Oil seal installer MH062714
seal

89
09917

7, 8 Snap ring expander MH061268 Removal and installation of snap ring

01137

11 Eye bolt MH062340 Lifting up transmission case

M10 u 1.5
01140

22-29
TRANSMISSION BODY
Unit: mm
Location Tool names and shape Part No. Application

Steel lifting band MH063410

251
22884 Removal and installation of
15, 16, 17 countershaft assembly, drive pinion
assembly and mainshaft assembly

Eye nut MH063308

M24 u 1.5
01142

94
Prevention of synchronizer sticking
16, 17 Synchro guard 29 MH063318
when driving-in mainshaft

06708

R Service procedure
16 2 Installation of front bearing retainer
Install J oil seal guide onto drive pinion 16 to protect oil seal 3 installed
on front bearing retainer 2. Then install the front bearing retainer.
2, 3

72603

3 Installation of oil seal

Apply grease to lip area A of oil seal 3, and press-fit into front bearing
retainer 2.

A
3 J: Oil seal installer

2 03694

22-30
 22
7 8 Removal and installation of snap ring

J: Snap ring expander

8
7

08382

11 Removal of transmission case

• Wen lifting up with a crane, install J eye bolts on transmission case
17 11 and pass the steel sling through them.
• After removing bolt 10, lift transmission case 11 up with a crane and
15 keep hitting the rear ends of clutch housing 18, mainshaft assembly
17 and countershaft assembly 15 to remove the transmission case.
11
10 A
NOTE
Never hit any parts other than rib A of clutch housing 18 as illus-
trated, because it can damage the clutch housing. Be sure to hit
the rib part as shown.
18

06274

22-31
TRANSMISSION BODY
• After removing transmission case 11, fit the 2nd gear using J steel
17 lifting band to ensure safety.

CAUTION k
Be sure to tighten J steel lifting band adequately, but not ex-
cessively, when fitting the case.

15

14

73964

14 to 17 Shift rail and shift fork, countershaft assembly, drive pin-

ion assembly and mainshaft assembly
[Removal]
• When removing or installing shift rail and shift fork 14, countershaft
17 assembly 15, drive pinion assembly 16 and mainshaft assembly 17,
handle them as a group.
• After removing the case, install a eye nut on mainshaft assembly
14
15 17 with b steel lifting band fitted so that the whole assembly can be
lifted up.
• Fix shift rail and shift fork 14 to mainshaft assembly 16 using rubber
bands.
• Attach pieces of wood to clutch housing 18. Then lift the whole as-
sembly (with drive pinion assembly 16) up with a crane to remove
them. During hoisting, hit the assembly using a mallet.
16
18
42758 WARNING k
You must hold drive pinion 16 to prevent it from falling to the
ground when you lift up the case.

CAUTION k
Be sure to tighten b steel lifting band adequately, but not ex-
cessively, when fitting the case.

22-32
 22
[Installation]
16 • Follow the removal sequence in reverse.
• Before installing parts, install c oil seal guide onto drive pinion 16
to prevent damage to oil seal 2 of front bearing retainer 3.

18

72604

• To drive-in drive pinion 16, mainshaft assembly 17 and countershaft

assembly 15, attach J synchro guard which prevents the drive pin-
ion and the mainshaft synchronizer sticking during installation.
17
15 NOTE
Remember to remove all special tools after use.

16 07591

22-33
TRANSMISSION BODY
Shift Rail and Shift Fork

C
D
*a
B
A

20 15

17 8
3
*b
16
11 6
12 9
7 10
1
18

13
19
14 5 2
4
A
1st and
reverse
B
C D
2nd and 3rd
4th and 5th 6th
42777

Arrow mark: Direction of press-fitting and removal of spring pin

P Disassembly sequence
(When the mainshaft assembly is not removed or installed, but only shift rail and shift fork are disassembled)

1 Spring pin 9 4th and 5th reverse shift lever 17 1st and reverse shift fork
2 6th shift rail jaw 10 Gear shift fork piece 18 Spring pin
3 6th shift rail A 11 Spring pin 19 1st and reverse shift rail jaw
4 Spring pin 12 2nd and 3rd shift fork 20 1st and reverse shift rail
5 4th and 5th shift rail jaw B 13 Spring pin
6 Spring pin 14 2nd and 3rd shift rail jaw *a: Mainshaft assembly
7 4th and 5th shift rail jaw A 15 2nd and 3rd shift rail b: Counter shaft assembly
8 4th and 5th shift rail 16 Spring pin
*X: Non-reusable parts

P Assembly sequence
Follow the disassembly sequence in reverse.

22-34
 22
Service standards Unit: mm
Location Maintenance item Standard value Limit Remedy
3 Deflection of 6th shift rail A 0.04 or less 0.05 Correct or replace
8, 15, 20 Deflection of shift rail 0.04 or less 0.05 Correct or replace
Clearance between gear shift fork piece and syn-
10, *a 0.3 to 0.6 1.0 Replace
chronizer sleeve
12, 17 Shift fork claw tilt 0.1 or less 0.2 Replace
Clearance between shift fork and synchronizer
12, 17, *a 0.3 to 0.6 1.0 Replace
sleeve

R Service procedure
1 4 6 11 13 16 18 Driving-in spring pin

CAUTION k
Be careful not to overload shift rail 3, 8, 15, 20 when driving-in
the spring pin.

NOTE
• For installation, position the opening in the direction of the shift
05756 rail axis as illustrated.
0112 • Do not drive in the spring pin fully, but leave 0 to 0.5 mm of the
spring pin.

3 8 15 20 Deflection of shift rail

The deflection is one half of the dial gauge A indicator mark.
A
If the measured value exceeds the limit, correct or replace shift rail 3, 8,
3, 8, 15, 20
15 and 20.

01127

10 Gear shift fork piece installation

9
Install gear shift fork piece 10 on the 4th and 5th reverse shift lever 9 in
the direction as illustrated, and assemble it in synchronizer sleeve.
10

06281

22-35
TRANSMISSION BODY

*a 10 *a Clearance between the gear shift fork piece and the main-
shaft synchronizer sleeve
10 If the measured value is higher than the limit, replace the faulty parts.

*a: Synchronizer sleeve of mainshaft assembly

A 06412

12 17 Shift fork claw tilt

15, 20 B B'
A Measure the tilt (difference between B and B’) of claw B-B’ against hole
A of shift rail 15 and 20 of shift fork 12 and 17 with the shift rail standing
upright.
12, 17
C: V-block
D D: Dial gauge
C

14946

12 17
*a Clearance between the gear shift fork and the synchro-
nizer sleeve of mainshaft
If the measured value for clearance A exceeds the limit, replace the
faulty parts.
12, 17
*a: Synchronizer sleeve of mainshaft assembly
*a

A
71556

22-36
 22

MEMO

22-37
DRIVE PINION ASSEMBLY
P Disassembly sequence
3
1 Snap ring
2 Drive pinion bearing
4 3 Pilot bearing
4 Drive pinion
2
P Assembly sequence
1 Follow the disassembly sequence in reverse.

07641

J Special tools Unit: mm

Location Tool name and shape Part No. Application

1 Snap ring expander MH061268 Removal and installation of snap ring

01137

Removal and installation of drive pin-

2 Bearing puller and installer *MH062697
ion bearing

92.5
08978

* Use an appropriate combination of bearing puller and installer for specific application. L P22-60

22-38
 22
R Service procedure
1 1 Removal and installation of snap ring

J: Snap ring expander

09968

2 Drive pinion bearing

[Removal]
J: Bearing puller and installer

09920

[Installation]
J: Bearing puller and installer

NOTE
Press-fit drive pinion bearings 2 with their snap ring grooves
facing the gear side.

2
06283

22-39
MAINSHAFT ASSEMBLY
21
20
19
14
* 15 17
16

18
17 25
14 26

29

30
8
26
13 27
25
28 10
31

27
24 12
9
23
6
22 11

32 33
34

1
9
2

3
4
5
6
7
37157

P Inspection before disassembly L P22-42

P Disassembly sequence
1 Bearing 14 Synchronizer ring 26 Synchronizer center cone
2 1st gear thrust washer 15 Synchronizer sleeve 27 Synchronizer outer ring
3 1st gear assembly 16 Shifting key 28 Synchronizer sleeve
4 Needle bearing 17 Shifting key spring 29 Shifting plunger
5 Snap ring 18 Synchronizer hub 30 Synchronizer spring
6 Synchronizer ring 19 4th gear assembly 31 Synchronizer hub
7 Synchronizer sleeve 20 Snap ring 32 3rd gear assembly
8 Shifting key 21 2nd gear thrust washer 33 Needle bearing
9 Shifting key spring 22 2nd gear assembly 34 Mainshaft
10 Synchronizer hub 23 Needle bearing
11 Reverse gear assembly 24 Snap ring
12 Needle bearing 25 Synchronizer inner ring
*: Drive pinion
13 Snap ring

22-40
 22
NOTE
• For single cone synchromesh:
Before disassembling synchronizer hub 15 and synchronizer sleeve 12, put alignment marks on shifting key
13. When reusing them, align the alignment marks before assembly.
• Triple cone type synchromesh
Before disassembling, put alignment marks on each center cone 26, gear assembly 22 and 32, outer ring 27,
and inner ring 25. When reusing them, align the alignment marks being made during disassembly, before dis-
assembly.
P Assembly sequence
34 33 32
24 23 22 21 20 19
31 28 29 30 28 27 26 25 13 12 11
18 15 16 17 14 5 4 3 2 1

10 7 8 9 6

Service standards Unit: mm

Location Maintenance item Standard value Limit Remedy

3 End play of 1st gear assembly 0.15 to 0.46 0.70 Replace

Play in the diameter direction after assembling 1st
3, 4, 34 0.02 to 0.06 0.12 Replace
gear assembly
Clearance between 1st gear assembly and
3, 6 1.13 to 1.37 0.50 Replace
synchronizer ring
Clearance between synchronizer ring and reverse
6, 11 1.13 to 1.37 0.50 Replace
gear assembly
6, 8, 14, Clearance between synchronizer ring keyway and
4.75 to 4.95 5.7 Replace
16 shifting key
8, 10, 16, Clearance between shifting key and synchronizer
0.05 to 0.20 0.50 Replace
18 hub keyway
11 End play of reverse gear assembly 0.15 to 0.46 0.70 Replace
11, 12, Play in the diameter direction after assembling re-
0.04 to 0.07 0.12 Replace
34 verse gear assembly
Clearance between synchronizer ring and 4th
14, 19 1.13 to 1.37 0.50 Replace
gear assembly
Clearance between synchronizer ring and drive
14,
* pinion
1.13 to 1.37 0.50 Replace

19 End play of 4th gear assembly 0.20 to 0.56 0.80 Replace

Play in the diameter direction after assembling
19, 34 0.05 to 0.09 0.20 Replace
4th gear assembly
22 End play of 2nd gear assembly 0.15 to 0.61 0.80 Replace
22, 23, Play in the diameter direction after assembling
0.02 to 0.05 0.12 Replace
34 2nd gear assembly
Clearance between 2nd gear assembly and
22, 27 0.96 to 1.54 0.50 Replace
synchronizer outer ring
Clearance between synchronizer outer ring and
27, 32 0.96 to 1.54 0.50 Replace
3rd gear assembly
32 End play of 3rd gear assembly 0.15 to 0.46 0.70 Replace
32, 33, Play in the diameter direction after assembling
0.02 to 0.06 0.12 Replace
34 3rd gear assembly

22-41
MAINSHAFT ASSEMBLY
J Special tools Unit: mm
Location Tool name and shape Part No. Application

Removal and installation of mainshaft

1 Bearing puller and installer *MH062697
rear bearing

96.8
08978

5, 13,
Snap ring expander MH061268 Removal and installation of snap ring
20, 24

01137

* Use an appropriate combination of bearing puller and installer for specific application. L P22-60

R Service procedure
P Inspection before disassembly
(1) End play of gears
E CD B A
A: 1st gear
B: Reverse gear
C: 2nd gear
D: 3rd gear
E: 4th gear
If the measured value is higher than the limit, replace faulty parts.
06286

(2) Play of gears in the diameter direction

If the measured value is higher than the limit, replace faulty parts.

01149

22-42
 22
1 Bearing
[Removal]
J: Bearing puller and installer

09921

[Installation]
J: Bearing puller and installer

NOTE
Press-fit bearing 1 with its snap ring groove facing the rear.

09922

22-43
MAINSHAFT ASSEMBLY
2 21 Installation of thrust washer
Install thrust washer with oil groove A facing gear side.

2, 21 06287

3 6 11 14 19 Clearance between synchronizer ring and

A *
gear assemblies
6, 14 3, 11, 19,
* If the measured value for clearance A is lower than the limit, replace
faulty parts.
NOTE
Press in synchronizer rings 6, 14 evenly, and measure all cir-
cumferences.

06288

5 13 20 24 Removal and installation of snap ring

J: Snap ring expander

09969

8, 16 6 8 14 16 Clearance between synchronizer ring or synchroniz-

6, 14 er outer ring and shifting key
If the measured value for clearance A is higher than the limit, replace
faulty parts.

06290

22-44
 22
7 10 15 18 28 31 Installation of synchronizer sleeve and syn-
B chronizer hub
10, 18, 31 7, 15, 28
To install synchronizer sleeves 7, 15, 28 align three keyways A of syn-
chronizer hubs 10, 18, 31 with the three stub teeth B of synchronizer
sleeves.
B NOTE
Before assembling synchronizer hubs 10, 18, 31 and synchro-
A B B
nizer sleeves 7, 15, 28 align the alignment marks (made before
01129 disassembly).

8, 16 8 10 16 18 Clearance between shifting key and synchronizer

hub
If the measured value for clearance A is higher than the limit, replace
A
10, 18 faulty parts.

06291

9 17 Installation of shifting key spring

9, 17 8, 16
• Place shifting keys 8, 16 into the keyway of synchronizer hubs 10, 18
and install shifting key springs 9, 17 taking care to locate the open-
ings away from the shifting key positions.
• Two openings of shifting key springs 9, 17 should not align with each
other.

01130

A 22 27 32 Clearance between gear assemblies and synchronizer

27 22, 32 outer rings
If the measured value for clearance A is lower than the limit, replace
faulty parts.
26 NOTE
Press in synchronizer inner ring 25, synchronizer center cone
25 26 and synchronizer outer ring 27 evenly, and measure all cir-
cumferences.
37794

22-45
COUNTERSHAFT ASSEMBLY
P Disassembly sequence
2 1 Countershaft front bearing
2 Countershaft rear bearing
3 Countershaft assembly

3 P Assembly sequence
Follow the disassembly sequence in re-
verse.
1

46334

J Special tools Unit: mm

Location Tool name and shape Part No. Application

Removal and installation of counter-

1 Bearing puller and installer *MH062696
shaft front bearing

72
08978

Bearing puller and installer

*MH062697 Removal of countershaft rear bearing

68
46335
2

Bearing puller and installer

*MH062696 Installation of countershaft rear bearing

46830

* Use an appropriate combination of bearing puller and installer for specific application. L P22-60

22-46
 22
R Service procedure
1 Countershaft front bearing
[Removal]
J: Bearing puller and installer

09924

[Installation]
J: Bearing puller and installer

NOTE
Press-fit countershaft front bearing 1 with their snap ring
grooves facing the gear side.

09925

2 Countershaft rear bearing

[Removal]
A
J: Bearing puller and installer
B

46336

[Installation]
J: Bearing puller and installer

NOTE
Press-fit countershaft rear bearing 2 with its snap ring groove
facing the rear.

09927

22-47
TRANSMISSION CONTROL

21
16 *
8 1

5 2
7
12
9 3
6
19
4
18 10 11

20

15

13 17

14

79843

P Disassembly sequence
1 Change lever cover 12 Shift rod No.2
2 Shift lever knob 13 Selector rod No.2
3 Change lever boot 14 Selector rod No.3
4 Bracket 15 Selector rod No.4
5 Ball joint 16 Shift rod No.3
6 Ball joint 17 Lever assembly L P22-54
7 Grommet 18 Shift lever assembly L P22-56
8 Change lever assembly L P22-52 19 No.2 select lever assembly L P22-57
9 Hose 20 No.3 select lever assembly L P22-58
10 Shift rod No.1 21 Cross shaft assembly L P22-59
11 Selector rod No.1
*: Transmission body
T Tightening torque Unit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks
– Nut (ball joint installation) 33 to 43 {3.4 to 4.4} –
– Nut (securing ball joint) 16 to 24 {1.6 to 2.4} –
15, 16 Knuckle (securing turn buckle) 19 to 27 {1.9 to 2.8} –

K Lubricant
Location Points of application Specified lubricant Quantity
14 to 16 Rod installation points Chassis grease [NLGI No.1 (Li soap)] As required

22-48
 22
R Service procedure
<Ball joint type> 5 6 10 to 16 Rod installation
A: 17 mm or more (except select rod No.4)
13 mm or more (select rod No.4)
Adjust dimension A to the same value on the both sides
except for selector rod No. 4.

A
79618

B: 16 to 24 N?m {1.6 to 2.4 kgf?m}

C: 33 to 43 N?m {3.4 to 4.4 kgf?m}
D: Spring washer

06304

• Apply grease to area G.

<Split pin type> <Snap pin type> • Firmly install split pin H or snap pin J.

E: Washer
F: Bushing

14 to 16

14 to 16

06305

22-49
TRANSMISSION CONTROL
• Turn the turn buckles of shift rod No.3, 16 and selector rod No.4, 15
to adjust the change lever assembly position.

210
5 mm

282 5 mm 74710

NOTE
Adjust the thread area dimension K of rods 15 and 16 that ex-
tend from both ends of the turn buckles. Exposed threads
should be almost identical at the right and left ends.

• After adjustment, tighten the lock nuts for the turn buckles at the
K
specified torque.
15, 16 • Make sure that the shift or select into each position can be performed
smoothly.
06307

22-50
 22

MEMO

22-51
TRANSMISSION CONTROL
Change Lever Assembly
PDisassembly sequence
1 Bolt
2 Nut
3 Change lever assembly
4 Wave washer
2 5 Spacer (for adjustment)
3 6 Collar
7 Nut
8 Spacer (for adjustment)
9 Collar
6
10 Return spring
5 11 Bushing
4 12 Cross sleeve
13 Change lever bracket
11
11
12 10 PAssembly sequence

11 11 13

12 11 10 9 6
8 1
9
8 7 3 5 4 2 1
13
7

79844

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Bolt (change lever bracket installation) 9 to 14 {0.9 to 1.4} –
2 Nut (change lever assembly installation) 17 to 26 {1.7 to 2.6} –
7 Nut (cross sleeve installation) 17 to 26 {1.7 to 2.6} –

K Lubricant
Location Points of application Specified lubricant Quantity
6 Collar periphery Chassis grease [NLGI No.1 (Li soap)] As required
9 Collar periphery Chassis grease [NLGI No.1 (Li soap)] As required

22-52
 22
R Service procedure
4, 5 4 5 Spacer selection and wave washer installation
• Select spacer 5 to obtain the specified clearance A when nut 2 is
2
tightened at the specified torque. Two thicknesses are available for
spacers: 0.3 and 0.5 mm.

A: 0.8 to 1.3 mm
• After obtaining the above clearance, insert wave washer 4.
A
73974

10 8 Spacer selection
• Select spacer 8 to obtain the specified clearance A when nut 7 is
7
tightened at the specified torque. Two thicknesses are available for
spacers: 0.3 and 0.5 mm.

A: 0 to 0.3 mm

8 • After installation the lever should operate smoothly without any

A catching.
79890

11 Bushing installation
Ream out bushing 11 (all four bushings) to the specified dimensions A
after press-fitting into the cross sleeve 12.
12
+0.22 mm
A: X14
+0.02 mm
A
11

06313

22-53
TRANSMISSION CONTROL
Lever Assembly
P Disassembly sequence
1 Return spring
2 Nut
3 Nut
7 4 Cover
6 5 Dust boot
5
4 6 Bushing
8
7 Lever bracket A
8 Nut
9 Lock pin
3
10 Lever
9 11 Spacer (for adjustment)
10 11 12 12 Bushing
12 13 No.1 lever B
13 14 No.1 lever A
15 Cover
16 Dust boot
1 17 Bushing
18 Lever bracket B

14

15 18
16
17

79880

P Assembly sequence
18 17 16 15

14 11 10
13 12 3 2 1 9 8

7 6 5 4

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
2, 3 Nut (lever bracket installation) 27 to 34 {2.8 to 3.5} –
8 Nut (lock pin installation) 10 to 15 {1.0 to 1.5} –

22-54
 22
K Lubricant
Location Points of application Specified lubricant Quantity
5, 16 Pack interior of dust boot Chassis grease [NLGI No.1 (Li soap)] –
14 No.1 lever A periphery Chassis grease [NLGI No.1 (Li soap)] –

R Service procedure
4 5 15 16 Cover and dust boot installation
• Fully press in covers 4 and 15.
• Pack grease into the interior space A to dust boots 5 and 16.

06315

8 Nut tightening
Tighten nut 8 at the specified torque pressing in direction A with approx-
A
imately 98N {10 kgf} of force.
C
B 11 Spacer selection
• Select spacer 11 to obtain the specified clearance B when nut 8 is
tightened at the specified torque. Two thicknesses are available for
spacers: 0.3 and 0.5 mm.

11 B: 0 to 0.3 mm

C
• After installation lever 10, No.1 lever B 13, and No.1 lever A 14
8 should operate smoothly without catching.

C C
79881

22-55
TRANSMISSION CONTROL
Shift Lever Assembly
PDisassembly sequence
1 Bolt
2 Nut
1 3 Bushing
4 No.2 shift lever
5 Spacer (for adjustment)
6 No.2 shift lever bracket
5
PAssembly sequence
4 6 5
3 2 1

2 4 3
6

73977

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Bolt (shift lever bracket installation) 27 to 34 {2.8 to 3.5} –
2 Nut (shift lever installation) 27 to 34 {2.8 to 3.5} –

K Lubricant
Location Points of application Specified lubricant Quantity
6 Selector lever bracket shaft periphery Chassis grease [NLGI No.1 (Li soap)] As required

R Service procedure
5 Spacer selection
• Select spacer 5 to obtain the specified clearance A when nut 2 is
tightened at the specified torque. Two thicknesses are available for
spacers: 0.3 and 0.5 mm.
• After installation lever 4 should operate smoothly without catching.

A: 0 to 0.3 mm

73978

22-56
 22
No.2 Selector Lever Assembly
PDisassembly sequence
1 Bolt
2 Nut
1 3 Bushing
4 Selector lever
5 Spacer (for adjustment)
5
6 Selector lever bracket
4
3 PAssembly sequence
2 6 5
2 1
6
4 3

79845

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Bolt (selector lever bracket installation) 27 to 34 {2.8 to 3.5} –
2 Nut (selector lever installation) 27 to 34 {2.8 to 3.5} –

K Lubricant
Location Points of application Specified lubricant Quantity
6 Selector lever bracket shaft periphery Chassis grease [NLGI No.1 (Li soap)] As required

R Service procedure
5 Spacer selection
• Select spacer 5 to obtain the specified clearance A when nut 2 is
tightened at the specified torque. Two thicknesses are available for
spacers: 0.3 and 0.5 mm.
• After installion lever 4 should operate smoothly without catching.

A: 0 to 0.3 mm

73980

22-57
TRANSMISSION CONTROL
No.3 Selector Lever Assembly
PDisassembly sequence
1 1 Bolt
2 Nut
6 3 Bushing
4 Selector lever
5 5 Spacer (for adjustment)
6 Selector lever bracket

PAssembly sequence
3 6 5
2 1
2
4 3

79882

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Bolt (selector lever bracket installation) 27 to 34 {2.8 to 3.5} –
2 Nut (selector lever installation) 27 to 34 {2.8 to 3.5} –

K Lubricant
Location Points of application Specified lubricant Quantity
6 Selector lever bracket shaft periphery Chassis grease [NLGI No.1 (Li soap)] As required

R Service procedure
5 Spacer selection
• Select spacer 5 to obtain the specified clearance A when nut 2 is
tightened at the specified torque. Two thicknesses are available for
spacers: 0.3 and 0.5 mm.
• After installion lever 4 should operate smoothly without catching.

A: 0 to 0.3 mm

73982

22-58
 22
Cross Shaft Assembly
PDisassembly sequence
1 Bolt
2 Cross shaft bracket
1 3 Bolt
4 Cross shaft bushing
2 5 Cross shaft boot
6 Cross shaft

PAssembly sequence
6 5 4 2 1 3
6 3

4
5

79883

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Bolt (installation to frame) 27 to 34 {2.8 to 3.5} –
3 Bolt (installation to transmission) 15 to 20 {1.5 to 2.0} –

K Lubricant
Location Points of application Specified lubricant Quantity
2 Inside of cross shaft bracket pipe Chassis grease [NLGI No.1 (Li soap)] As required
Exterior and interior sliding surfaces of cross shaft
4 Chassis grease [NLGI No.1 (Li soap)] As required
bushing
5 Packing the interior of the cross shaft boot Chassis grease [NLGI No.1 (Li soap)] As required

22-59
BEARING PULLER AND INSTALLER
Application

Installation of countershaft front bearing

Installation of countershaft rear bearing

Removal of countershaft front bearing

Removal of countershaft rear bearing

Installation of mainshaft rear bearing
Removal of mainshaft rear bearing
Installation of drive pinion bearing
Removal of drive pinion bearing

Installation of 6th gear sleeve

and 6th gear sleeve
Bearing puller
and installer Part name Part No.
Adapter MH062590 p
Plug 03726-81017 p p p
Bolt MH062700 p
Body MH062701 p p p p
MH062696 Protector MH061306 p
Countershaft bearing claw 03726-81012
Bearing claw MH062707 p
Mainshaft bearing claw MH061305
Bearing claw MH062706
Bearing claw MH062589 p
Plug 03726-81017 p p
Bolt MH062700 p p p
MH062697 Body MH062702 p p p p p
Protector ME624229 p p p
Mainshaft bearing claw ME624226 p
Bearing claw MH062636 p

Use an appropriate combination of bearing puller and installer for specific application.

22-60
 23

GROUP 23 AUTOMATIC TRANSMISSION

SPECIFICATIONS ................................................................................ 23-2

STRUCTURE AND OPERATION ........................................................ 23-3

TROUBLESHOOTING PROCEDURES ............................................... 23-40

TROUBLESHOOTING .......................................................................... 23-42

ON-VEHICLE INSPECTION AND ADJUSTMENT

• Stall test.................................................................................................. 23-50
• Time lag test .......................................................................................... 23-51
• Line pressure test ................................................................................. 23-52
• Road test ............................................................................................... 23-54
• Inspection of automatic transmission fluid ........................................ 23-55
• Replacement of automatic transmission fluid .................................... 23-56

REMOVAL AND INSTALLATION OF AUTOMATIC

TRANSMISSION ASSEMBLY .............................................................. 23-58

OIL COOLER ........................................................................................ 23-64

AUTOMATIC TRANSMISSION CONTROL.......................................... 23-66

REPLACEMENT OF AUTOMATIC TRANSMISSION PARTS ............. 23-74

INSPECTION OF ELECTRIC PARTS................................................... 23-80

PART MOUNTING POSITION .............................................................. 23-84

ELECTRICAL WIRING DIAGRAM ....................................................... 23-87

23-1
SPECIFICATIONS
Item Specifications
Manufacturer Aisin Seiki Co., Ltd.
Transmission type M035A4
Type 3-element, 1-stage, 2-phase (with lock-up clutch)
Torque converter
Stall torque ratio 1.82
Type Planetary gear type, 4 forward speeds, 1 reverse speed
1st 2.950
2nd 1.530
Automatic transmission
Gear ratio 3rd 1.000
4th 0.703
Rev 2.678
Range selector pattern P - R - N - D - 2 - L (Engine starts in P and N positions only)
Oil type DEXRON III type
Total oil capacity dm3 {L} 13 {13}
Automatic transmission
fluid Quantity of oil required in
automatic transmission Approximately 4.5 {4.5}
fluid change dm3 {L}

23-2
STRUCTURE AND OPERATION 23
Automatic Transmission Assembly
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

17 18 19 20 21 22 23 24
79559

1 Converter housing 10 Rear clutch 19 Oil pan

2 Torque converter 11 Front planetary gear 20 Valve body
3 Transmission case 12 No. 2 one-way clutch 21 Input shaft
4 Overdrive direct clutch 13 1st and reverse brake 22 Intermediate shaft
5 Overdrive brake 14 Rear planetary gear 23 Extension housing
6 Overdrive one-way clutch 15 Parking lock gear 24 Speedometer drive gear
7 Overdrive planetary gear 16 Output shaft
8 Front clutch 17 Overdrive input shaft
9 2nd brake 18 Oil pump

The automatic transmission is comprised of a torque converter with a lock-up mechanism and a fully automatic 4-speed
gear system.
P Torque converter
The torque converter is driven by the engine crankshaft, and functions as the input device for the transmission. The
torque converter is a fluid coupling device that magnifies torque produced by the engine and absorbs shock that gen-
erates when the vehicle accelerates from a standstill or when the transmission shifts. At a cruising speed, the lock-up
mechanism prevents slippage for improved power transmitting efficiency.
P Transmission gear section
The gear system provides four forward speeds and one reverse speed. The gear section contains two one-way clutch-
es, three sets of planetary gears, each comprised of a sun gear, pinion gears and a ring gear, three sets of hydraulic
wet-type multi-plate clutches; and three sets of wet-type multi-plate brakes.
P Hydraulic control section
The electronic control system uses a microcomputer to regulate the mechanism operations for precise shifting.

23-3
STRUCTURE AND OPERATION
Control Mechanism
Control system

Multi-plate clutch
Torque Multi-plate brake
Overdrive input One-way clutch Output shaft
converter
shaft Planetary gear
(Lock-up piston)

Oil pump Vehicle speed

sensor

Control valves Valve body

Throttle Automatic
Shift Shift Lock-up Timing
pressure transmission fluid
solenoid 1 solenoid 2 solenoid solenoid
solenoid temperature sensor

Automatic
transmission
electronic control unit

A B
Accelerator Engine electronic Engine speed
position sensor control unit sensor

: Power transmission
A: Accelerator opening signal (PWM signal)
: Hydraulic control circuit
B: Engine speed signal
: Electrical signal
79857

23-4
 23
System Block Diagram

Throttle
pressure
Automatic control
transmission fluid Throttle
temperature pressure
sensor solenoid
Accelerator opening
Shift
signal (PWM signal
from engine electronic control
control unit)
Shift
Brake Shift solenoid 1
switch pattern
selector
control

Shift
Inhibitor solenoid 2
switch Lock-up
control
Engine speed
sensor (from
engine electronic
control unit) Lock-up
Overdrive solenoid
cancellation
control
Overdrive
OFF switch

Automatic 2nd-to-3rd
shift Timing
transmission fluid
temperature switch timing solenoid
control
Power
mode
switch Exhaust Exhaust
brake brake cut
control relay
Exhaust brake
operation
signal
Fail-safe
control
Vehicle speed
sensor 2 (mounted
on automatic
transmission)

Vehicle speed Diagnosis

sensor 1 (from memory
pulse divider) Multi-use
tester-II

Self-
Diagnosis
diagnosis Warning
switch
function lamp
79858

23-5
STRUCTURE AND OPERATION
The control function is broadly classified into the shift control, lock-up control and the overrun clutch control. The elec-
tronic control unit provides detailed control for each driving condition.
Control Item and Input/Output List
Control item

Overdrive cancellation control

2nd-to-3rd shift timing control

Shift pattern selector control

Throttle pressure control

Self-diagnosis function
Exhaust brake control

Fail-safe control
Lock-up control
Item Shift control
Mounted on transmission p
Vehicle speed sensor 2 (output shaft rotation p p p p p
Note 1
p p
sensor)
Vehicle speed sensor 1 p p p p p
Mounted on transmission Note 3 Note 3 Note 3 Note 3 Note 3
(from pulse divider)
Engine speed sensor (from engine electronic con- p p
p
p
trol unit) Note 1
Accelerator position sensor (PWM signal from en- p p
p
p p
p Note 1
gine electronic control unit)
Overdrive OFF switch p p p
Input

p
Inhibitor switch p p p p Note 1 p p
Automatic transmission fluid temperature switch p p
p
Automatic transmission fluid temperature sensor p p Note 1 p p

Power mode switch p

Brake switch p
p
Exhaust brake operation signal Note 1 p
p
Diagnosis switch Note 2 p
p
Shift solenoid 1 p p p Note 1 p
p
Shift solenoid 2 p p p Note 1 p
p
Timing solenoid p p Note 1 p
Output

p
Lock-up solenoid p Note 1 p
p
Exhaust brake cut-off relay p Note 1 p
Warning lamp p
p
Throttle pressure solenoid Note 1 p p

Note 1: If input/output signal is abnormal, the automatic transmission electronic control unit activates the fail safe func-
tion.
Note 2: This switch activates the self-diagnosis function.
Note 3: Backup for of vehicle speed sensor 2 (mounted on transmission)
P Shift control
With the accelerator opening signal and the signal from the vehicle speed sensor equivalent to the vehicle speed, a
signal is sent from the automatic transmission electronic control unit to shift solenoids 1 and 2 and the timing solenoid
on the valve body according to the designated shift wiring diagram in order to shift the gear automatically to the opti-
mum position.

23-6
 23
P Lock-up control
The lock-up control prevents slippage of the torque converter to improve the transmission efficiency. With the acceler-
ator opening signal and the signal from the vehicle speed sensor equivalent to the vehicle speed, a signal is sent from
the automatic transmission electronic control unit to the lock-up solenoid on the valve body according to the designat-
ed shift wiring diagram in order to turn ON/OFF the lock-up control.
P 2nd-to-3rd shift timing control
With the accelerator opening signal and the signal from the vehicle speed sensor, a signal is sent from the automatic
transmission electronic control unit to the timing solenoid on the valve body in order to control the exhaust timing of the
brake oil to reduce the shifting shock.
P Throttle pressure control
By detecting the PWM signal from the engine electronic control unit and by controlling the throttle pressure solenoid,
the hydraulic pressure from the reducing valve is controlled to the optimum level (throttle pressure) for driving.

P Shift pattern selection control

1v2 2v3 Two types of driving modes can be selected; the economy mode
Accelerator opening

1'v2' 2'v3' which provides excellent economical performance and the power
mode which provides excellent acceleration performance.
The power mode uses a faster vehicle speed during shifting than the
3v4 3'v4' economy mode does. The figure on the left shows a model of shifting
Power mode point characteristics when downshifted.
Economy mode

Vehicle speed
29802

P Fail-safe control
The fail safe control minimizes loss of driving performance if a failure occurs on the vehicle speed sensor, engine
speed sensor, accelerator position sensor, inhibitor switch or any solenoid.
P Accelerator position sensor (from engine electronic control unit)
The throttle is completely closed during shifting, and the 2nd-to-3rd shift timing control is prohibited to enable driving.
P Inhibitor switch
If a failure occurs in the inhibitor switch while the vehicle is not in motion or is in motion, and if no signal is input to the
automatic transmission electronic control unit, the range selector position is judged as the D range. Shifting from the
3rd to 4th range is prohibited. If multiple signals are input to the automatic transmission electronic control unit, the
range selector position is set in the priority order of L, R, 2nd, D, N and P in order to enable driving. Since the oil circuit
in the valve body is switched with the manual valve for each range selector lever position, the actual driving statuses
are as shown below.
Actual position of range
Input signal of inhibitor switch Vehicle driving status
selector lever
P P and other selector signals P
R R and other selector signals R
N N and other selector signals N
D and other selector signal (except for R, L and 2 range signals) D1 vn D2 vn D3 vn D4
D and L range signals D1 vn D2 vb D3
D
D and R range signals D4
D and 2 range signals D1 vn D2 vn D3
2 and other selector signals (except for R and L range signals) 21 vn 22 vb 23
2 2 and L range signals 21 vn 22 vb 23
2 and R range signals 23
L L and other selector signals L1 vn L2 vn L3

23-7
STRUCTURE AND OPERATION
P Engine speed sensor
The 2nd to 3rd shift timing control becomes inactive to ensure proper vehicle operation.
P Shift solenoid 1 and shift solenoid 2
If a solenoid malfunction occurs when the transmission is in the D, 2 or L range, the operating conditions of the sole-
noids change as shown in the following table. The automatic transmission electronic control unit also deactivates the
lock-up solenoid and timing solenoid to allow vehicle operation.
Malfunctioning of S1
Range selector Normal Malfunctioning of S1 Malfunctioning of S2
and S2
position
S1 S2 ST Gear S1 S2 Gear S1 S2 Gear S1 S2 Gear
p u u 1st – u→p 3rd p – 1st – – 4th
p p u 2nd – p 3rd p→u – 4th – – 4th
D rang
u p u 3rd – p 3rd u – 4th – – 4th
u u u 4th – u 4th u – 4th – – 4th
p u u 1st – u→p 3rd p – 1st – – 3rd
2 range p p u 2nd – p 3rd p→u – 3rd – – 3rd
u p u 3rd – p 3rd u – 3rd – – 3rd
p u u 1st – u 1st p – 1st – – 1st
L range p p u 2nd – p 2nd p – 1st – – 1st
u p p 3rd – p 2nd u – 1st – – 1st
p: Electric current supplied
u: Electric current not supplied – : Malfunctioning n : Fail-safe function
S1: Shift solenoid 1 S2: Shift solenoid 2 ST: Timing solenoid
• Throttle pressure solenoid
The malfunctioning solenoid is deactivated to bring the line pressure to a maximum level, thus allowing vehicle op-
eration.
• Timing solenoid and lock-up solenoid
The malfunctioning solenoid is deactivated to allow vehicle operation.
P Self-diagnosis function
The warning lamp lights when an abnormality occurs during vehicle operation.
• The warning lamp does not light if the abnormality causes minimum effect to vehicle operation.
• The warning lamp lights when the following parts are malfunctioning to indicate the abnormal condition since these
malfunctions significantly reduce vehicle performance.
• Vehicle speed sensor 2 • Accelerator position sensor
• Vehicle speed sensor 1 and 2 • Timing solenoid
• Shift solenoid 1 • Inhibitor switch
• Shift solenoid 2 • Throttle pressure solenoid

CAUTIONk
The warning lamp lights only when the malfunction prevents proper vehicle operation.

The indicator lamp provides self-diagnosis information.

• To facilitate the discovery of malfunctions that may not reproduce themselves frequently, the automatic transmission
electronic control unit stores in the memory information of malfunctions that occur during vehicle operation.
• An input of a self-diagnosis start signal produces the output of the data from the memory, and causes the automatic
transmission warning lamp to flash according to the data.

CAUTIONk
The automatic transmission electronic control unit stores information of all malfunctions that occur after
the previous self-diagnosis operation.

23-8
 23
Electronic Control Devices
1 Automatic transmission electronic
control unit
2 Accelerator position sensor
2
3 Vehicle speed sensor 2

79859

P Automatic transmission electronic control unit

The automatic transmission electronic control unit is installed near the left footing of the driver's seat. It judges the driv-
ing condition of the vehicle by the signals from each sensor and outputs solenoid signals to allow shift control, lock-up
control and other automatic transmission control that are required for driving of the vehicle. It also performs the failure
self-diagnosis of main sensors and solenoids.

P Accelerator position sensor (PWM signal)

Accelerator position sensor voltage 1.1 V
The accelerator position sensor voltage detected by the electronic
B
B = 10% governor control unit is converted to a PWM signal and output to the
A automatic transmission electronic control unit. The PWM signal is a
chopping wave with a duty ratio shown in the diagram at the left.
Accelerator position sensor voltage 3.6 V

B B = 90%
A A
32400

P Vehicle speed sensor 2

The sensor is mounted on the extension housing of the transmission, and converts the vehicle speed to a pulse signal
by means of the parking lock gear and sends it to the automatic transmission electronic control unit.

P Shift solenoids 1 and 2

These solenoids are mounted on the valve body, and control shifting by turning ON and OFF in accordance with the
signals sent from the automatic transmission electronic control unit.
The ON and OFF conditions of the two solenoids result in the following gear positions.
Shift solenoid 1 ON ON OFF OFF
Shift solenoid 2 OFF ON ON OFF
Gear position 1st gear 2nd gear 3rd gear 4th gear

23-9
STRUCTURE AND OPERATION
P Throuttle pressure solenoid
Hydraulic pressure

The throttle pressure solenoid is mounted on the valve body. It ad-

justs the throttle pressure based on the throttle opening signal sent
from the automatic transmission electronic control unit. The throttle
pressure adjustment characteristics are shown in the diagram.

Electric current 31512

P Timing solenoid
This solenoid is mounted on the valve body, and regulates the 2nd to 3rd shift timing control by turning ON and OFF in
accordance with the signal sent from the automatic transmission electronic control unit.
P Lock-up solenoid
The lock-up solenoid is mounted on the valve body. According to the signal sent from the automatic transmission elec-
tronic control unit, the solenoid repeats ON and OFF operations, thereby opening and closing the drain circuit to con-
trol the hydraulic pressure at a predetermined level. The lock-up solenoid is a duty-cycle type that can control the ON
and OFF time ratio in each cycle between 0 and 100%.
P Automatic transmission fluid temperature switch
This switch is mounted on the oil cooler outlet section of the transmission case. It detects abnormal temperatures of
the automatic transmission fluid and turns on the warning lamp located on the meter cluster to indicate the abnormal
condition.

P Automatic transmission fluid temperature sensor

Resistance (Ω)
This sensor is mounted on the control valve in the transmission. It co-
verts temperature changes into continuous electric signals and
sends to the automatic transmission electronic control unit. The char-
acteristics of the sensor’s electric output signal are shown at the left.
Based on this output signal, the automatic transmission electronic
control unit prohibits overdrive shifting and lock-up operation and
also performs partial correction of line pressure control.
Temperature (!C) 07451

P Engine speed sensor

Engine speed sensor The engine revolution is converted to the pulse signal and is output to
the engine electronic control unit. This pulse signal is sent to the au-
tomatic transmission electronic control unit through the engine elec-
tronic control unit.

79860

23-10
 23
P Overdrive OFF switch
The overdrive OFF switch is installed to the selector lever. The driver
operates this switch to select the 3rd and 4th shifting modes.
OFF: Since the gear is shifted up to the 4th, fuel cost improves.
ON: Since the gear is not shifted up to the 4th, the engine brake
works effectively and the hill-climbing force is improved.
P P
R R
N N
D D
2 2
L L

Overdrive OFF SW
29806

P Power mode switch

The power mode switch is installed on the instrument panel. The
driver operates this switch to select the setting of vehicle speed dur-
ing shifting.
PWR (Power): The setting is fixed to the power mode, a faster
vehicle speed, during shifting.
ECO (Economy): The setting is fixed to the economy mode, a slow-
er vehicle speed, during shifting.

29807

23-11
STRUCTURE AND OPERATION
Hydraulic Control Devices
P Valve Layout Diagram
• Upper valve body

12 11 9 2 3 6 5

10 8 7
4

31513

• Lower valve body

8 2 3 7 9
4

1 6 5
31514

23-12
 23
P Valve Functions
• Upper valve body

No. Valve name Description of function

1 2-3 Shift valve Switches between 2nd and 3rd gears

When range selector is shifted to R range while vehicle is moving forward at moderate or high
2 Reverse inhibitor valve
speed, this valve, operated by solenoid output, prevents shifting to reverse.
Adjusts line pressure and supplies hydraulic pressure to lock-up signal valve and orifice con-
3 Modulator valve
trol valve
Adjusts signal pressure (throttle pressure) that is used to provide optimum line pressure in ac-
4 Throttle valve
cordance with operating conditions
Controls pressure of automatic transmission fluid supplied from primary regulator valve to
5 Secondary regulator valve
torque converter as well as lubricating oil pressure
6 Reducing valve Reduces line pressure and feeds to throttle valve
7 Lock-up signal valve Engages and disengages lock-up mechanism
Lowers accumulator back pressure when throttle opening becomes smaller, and obtains ac-
8 Accumulator control valve
cumulator control pressure from line pressure that is used to reduce shift shock
9 Low coast modulator valve Lowers line pressure to reduce shift shock when range selector is shifted to L range
10 Orifice control valve Switches orifices to reduce shock
When range selector is shifted to L range at high vehicle speed, this valve, operated by timing
11 Low inhibitor valve
solenoid output, shifts to 3rd gear
12 Check valve Switches fluid passage to rear clutch (C2) in D range and R ranges

• Lower valve body

No. Valve name Description of function

1 Manual valve Switches fluid passage according to the position (P, R, N, D, 2, L) of range selector lever

2 1-2 Shift valve Switches between 1st and 2nd gears

3 3-4 Shift valve Switches between 3rd and overdrive gears
4 Pressure relief valve Maintains pressure supplied to cooler at low level
5 Primary regulator valve Regulates hydraulic pressure (line pressure) to devices
6 Lock-up control valve Adjust flow rate of automatic transmission fluid to torque converter
7 C0 exhaust valve Reduces shock in 3rd-to-2nd shifting
8 2-3 Timing valve Adjusts hydraulic pressure switching timing in 3rd-to-2nd shifting to reduce shock
9 Cutback valve Applies cutback pressure to throttle valve to reduce line pressure

23-13
STRUCTURE AND OPERATION
Shift Function
1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 18 19 20 21 22 23 24
16 17
29810

1 Overdrive direct clutch (C0) 13 Overdrive input shaft

2 Overdrive brake (B0) 14 Overdrive one-way clutch (F0)
3 Overdrive planetary carrier 15 Overdrive planetary sun gear
4 Oerdrive planetary ring gear 16 Input shaft
5 Overdrive planetary pinion gears 17 Rear clutch (C2)
6 Front clutch (C1) 18 Intermediate shaft
7 2nd brake (B1) 19 Front planetary carrier
8 1st and reverse brake (B2) 20 Front planetary sun gear
9 No. 2 one-way clutch (F1) 21 Front planetary pinion gears
10 Front planetary ring gear 22 Rear planetary carrier
11 Rear planetary ring gear 23 Rear planetary sun gear
12 Rear planetary pinion gears 24 Output shaft

P Clutch and brake functions

No. Name Function

1 Overdrive direct clutch (C0) Interlocks overdrive sun gear and overdrive planetary carrier

2 Overdrive brake (B0) Prevents rotation of overdrive sun gear

6 Front clutch (C1) Interlocks input shaft and intermediate shaft
7 2nd brake (B1) Prevents rotation of front and rear planetary sun gears
8 1st and reverse brake (B2) Prevents rotation of front planetary carrier
Prevents counterclockwise rotation of front planetary carrier and allows only clockwise
9 No. 2 one-way clutch (F1)
rotation
Prevents overdrive planetary carrier from rotating in counterclockwise direction relative
14 Overdrive one-way clutch (F0)
to overdrive sun gear during driving
17 Rear clutch (C2) Interlocks input shaft with front and rear planetary sun gears

23-14
 23
P Clutch, Brake and Solenoid Operations
Shift position C0 C1 C2 B0 B1 B2 F0 F1 S1 S2 Remarks

P Parking p p Parking
R Reverse p p p P Reverse
N Neutral p p Neutral
1st p p P P p
Automatic shifting
2nd p p P p p 1 vn 2 vn 3 vn 4
D
3rd p p p P p Overdrive OFF mode
1 vn 2 vn 3 vn 4
Overdrive p p p
1st p p P P p
Automatic shifting
2 2nd p p p P p p
1 vn 2 vn 3
3rd p p p P p
1st p p p P P p Locked in 1st gear
1 v 2v 3 (3rd gear
L 2nd p p p P p p shifting occurs only
when timing solenoid
3rd p p p P p activates.)

S1 and S2 refer to shift solenoid 1 and shift solenoid 2, respectively

p: Activates
P: Activates only during driving
vn: Overrun preventive control

23-15
STRUCTURE AND OPERATION
P Overdrive Direct Clutch

1 2 3 4 5 6 7 9 10

3 1 12

13 11 14
29811

1 Overdrive direct clutch drum 7 Clutch plates 13 Overdrive input shaft

2 O-ring 8 Clutch discs 14 Input shaft
3 Overdrive direct clutch piston 9 Clutch flange
4 O-ring 10 Snap ring A: Operating pressure
5 Overdrive clutch return springs 11 Overdrive planetary sun gear
6 Snap ring 12 Overdrive planetary carrier

< Active condition >

The control valve supplies operating pressure A to overdrive direct clutch piston 3, coupling clutch discs 8 and clutch
plates 7. This interlocks overdrive planetary sun gear 11 with overdrive planetary carrier 12.
As a result, the entire overdrive planetary gear acts as a single unit to transmit the engine’s driving power from over-
drive input shaft 13 to input shaft 14.

< Inactivate condition >

Since operating pressure A is not supplied, the force of overdrive clutch return springs 5 presses against overdrive di-
rect clutch piston 3.
As a result, clutch plates 7 are separated from clutch discs 8, and the engine power is not transmitted.

23-16
 23
P Front Clutch (C1)

1 2 3 4 5 6 7 8

1 4 13

10 11 12 13 14

15 12 16
29812

1 Front clutch drum 7 Clutch cushion plate 13 Rear clutch hub

2 O-ring 8 Clutch plates 14 Snap ring
3 O-ring 9 Clutch discs 15 Input shaft
4 Front clutch piston 10 Thrust bearing lace 16 Intermediate shaft
5 Front clutch return springs 11 Thrust bearing
6 Snap ring 12 Front clutch hub A: Operating pressure

< Active condition >

The control valve supplies operating pressure A to front clutch piston 4, which causes the coupling of clutch discs 9
and clutch plates 8, thus transmitting the engine’s driving power from input shaft 15 to front clutch hub 12 and interme-
diate shaft 16.

< Inactivate condition >

Since operating pressure A is not supplied, the force of front clutch return springs 5 presses against front clutch piston
4.
As a result, clutch plates 8 are separated from clutch discs 9, and the engine power is not transmitted.

23-17
STRUCTURE AND OPERATION
P Rear Clutch (C2)

1 2 3

5 6 7 8 9 10

11 13 10 7 12 29813

1 Snap ring 7 Rear clutch piston 13 Rear clutch hub

2 Clutch flange 8 O-ring
3 Clutch discs 9 O-ring A: Operating pressure
4 Clutch plates 10 Rear clutch drum
5 Snap ring 11 Input shaft
6 Rear clutch piston return springs 12 Front and rear planetary sun gears

< Active condition >

The control valve supplies operating pressure A to rear clutch piston 7, which causes the coupling of clutch discs 3
and clutch plates 4, thus transmitting the engine’s driving power from input shaft 11 and rear clutch hub 13 to rear
clutch drum 10 and front and rear planetary sun gears 12.

< Inactivate condition >

Since operating pressure A is not supplied, the force of rear clutch piston return springs 6 presses against rear clutch
piston 7.
As a result, clutch plates 4 are separated from clutch discs 3, and the engine power is not transmitted.

23-18
 23
P Overdrive Brake (B0)
1 2 3 5

4
8
7
6

11

10
9 12 11 8 A

13 29814

1 Snap ring 6 Snap ring 11 Overdrive case

2 Brake flange 7 Overdrive brake return springs 12 Overdrive direct clutch
3 Clutch discs 8 Overdrive brake piston 13 Overdrive planetary sun gear
4 Brake plates 9 O-ring
5 Brake plates 10 O-ring A: Operating pressure

< Active condition >

The control valve supplies operating pressure A to overdrive brake piston 8, which causes the coupling of clutch discs
3 and brake plates 4, 5, thus interlocking overdrive direct clutch 12 with overdrive case 11. This sets overdrive plane-
tary sun gear 13 in locked condition.

< Inactivate condition >

Since operating pressure A is not supplied, the force of overdrive brake return springs 7 presses against overdrive
brake piston 8.
As a result, brake plates 4, 5 are separated from clutch discs 3, and the engine power is not transmitted.

23-19
STRUCTURE AND OPERATION
P 2nd Brake (B1)

1 2 4

5 6
3

7 8 9 10

11 10 7

12

29815

1 Snap ring 6 2nd brake return springs 11 Rear clutch

2 Brake flange 7 Brake piston No. 1 12 Front and rear planetary sun gears
3 Clutch discs 8 O-ring
4 Brake plates 9 O-ring A: Operating pressure
5 Snap ring 10 Center support

< Active condition >

The control valve supplies operating pressure A to brake piston No.1 7, which causes the coupling of clutch discs 3
and brake plates 4, thus interlocking rear clutch 11 with center support 10. This sets front and rear planetary sun gears
12 in locked condition.

< Inactivate condition >

Since operating pressure A is not supplied, the force of 2nd brake return springs 6 presses against brake piston No.1
7.
As a result, brake plates 4 are separated from clutch discs 3, and the engine power is not transmitted.

23-20
 23
P 1st and Reverse Brake (B2)

1 2 3 4

8 9 10
5

13 11 12 8 A

6 7

29816

1 Snap ring 7 1st and reverse brake return springs 12 Transmission case
2 Brake flange 8 1st and reverse brake piston 13 Front planetary carrier
3 Clutch discs 9 O-ring
4 Brake cushion plates 10 O-ring A: Operating pressure
5 Brake plates 11 1st and reverse brake hub
6 Snap ring

< Active condition >

The control valve supplies operating pressure A to 1st and reverse brake piston 8, which causes the coupling of clutch
discs 3 and brake plates 5, thus interlocking 1st and reverse brake hub 11 with transmission case 12. This sets front
planetary carrier 13 in locked condition.

< Inactivate condition >

Since operating pressure A is not supplied, the force of 1st and reverse brake return springs 7 presses against 1st and
reverse brake piston 8.
As a result, brake plates 5 are separated from clutch discs 3, and the engine power is not transmitted.

23-21
STRUCTURE AND OPERATION
P Planetary Gears
Overdrive planetary gear
3
2 4

8
7
6 29866

5
Front and rear planetary gears
9
12
10
11
1
07468
16
13
15
14 29817

1 Pinion gear 7 Overdrive pinion gears 13 Rear sun gear

2 Ring gear 8 Overdrive ring gear 14 Rear planetary carrier
3 Sun gear 9 Front sun gear 15 Rear pinion gears
4 Planetary carrier 10 Front planetary carrier 16 Rear ring gear
5 Overdrive sun gear 11 Front pinion gears
6 Overdrive planetary carrier 12 Front ring gear

• Three sets of Simpson-type planetary gears provide a total of five gear ratios: four forward speeds and one reverse
speed.
• Each planetary gear set consists of a sun gear 3 at the center and pinion gears 1 that revolve around the sun gear and
on their axes. This set of gears are contained in a ring gear 2. The pinion gears are attached to a planetary carrier 4,
so that all pinion gears rotate in the same direction and at the same rate. Gear shifting occurs when these four ele-
ments — sun gear, pinion gears, ring gear and planetary carrier — are provided with certain conditions. Clutches and
brakes provide operating conditions to the planetary gears in accordance with shifting.

P Overdrive One-Way Clutch

1 Overdrive direct clutch drum and overdrive one-way clutch inner

race
2 Overdrive one-way clutch
3 Overdrive one-way clutch outer race

2
3
1 29818

• During acceleration in the 1st, 2nd and 3rd gears, the overdrive one-way clutch 2 engages and becomes interlocked
with the overdrive sun gear and overdrive planetary carrier.
• In the 4th gear, the overdrive one-way clutch 2 rotates freely.

23-22
 23
P No. 2 One-Way Clutch

1 1 Front planetary carrier and No. 2 one-way clutch inner race

2 No. 2 one-way clutch
3 3 No. 2 one-way clutch outer race

29819

• During acceleration in the 1st gear, the No. 2 one-way clutch 2 engages and becomes interlocked with the front plane-
tary carrier.
• In the 1st, 2nd and 3rd gears, the No. 2 one-way clutch 2 rotates freely.

23-23
STRUCTURE AND OPERATION
Torque Transmission Process
1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 18 19 20 21 22 23 24
16 17
29810

1 Overdrive direct clutch 13 Overdrive input shaft

2 Overdrive brake 14 Overdrive one-way clutch
3 Overdrive planetary carrier 15 Overdrive planetary sun gear
4 Oerdrive planetary ring gear 16 Input shaft
5 Overdrive planetary pinion gears 17 Rear clutch
6 Front clutch 18 Intermediate shaft
7 2nd brake 19 Front planetary carrier
8 1st and reverse brake 20 Front planetary sun gear
9 No. 2 one-way clutch 21 Front planetary pinion gears
10 Front planetary ring gear 22 Rear planetary carrier
11 Rear planetary ring gear 23 Rear planetary sun gear
12 Rear planetary pinion gears 24 Output shaft

23-24
 23
P D, and 2 Ranges (1st Gear)

1 3 A 4 6 9 19 B 10 C 22 11

21 12 24
13 14 15 5 16 20 18 23

Planetary gear rotates as assembly Fixed in position by one-way clutch

Output Input

Output
Input

A B C

29820

Overdrive direct clutch 1, front clutch 6, overdrive one-way clutch 14 and No. 2 one-way clutch 9 activate to provide the
1st gear. At overdrive planetary gear A, overdrive direct clutch 1 operates to interlock overdrive planetary carrier 3 (over-
drive input shaft 13) with overdrive planetary sun gear 15. This disables overdrive planetary pinion gears 5 from rotating
on their axes, and overdrive planetary carrier 3 becomes locked (direct coupling) in position with overdrive planetary ring
gear 4, thus transmitting driving force to input shaft 16. Clockwise rotation of overdrive planetary carrier 3 results in a
force that attempts to turn overdrive pinion gears 5 in a counterclockwise direction, producing clockwise rotating force for
overdrive planetary sun gear 15. However, since overdrive planetary sun gear 15 rotates faster than overdrive planetary
carrier 3, overdrive one-way clutch 14 activates, interlocking overdrive planetary carrier 3 with overdrive planetary sun
gear 15. This disallows overdrive planetary pinion gears 5 from rotating on their axes, in the same way as when overdrive
direct clutch 1 activates. Therefore, overdrive planetary carrier 3 becomes locked (direct coupling) in position with over-
drive planetary ring gear 4, thus transmitting the driving force to input shaft 16.
These two power transmitting systems reduce the load on overdrive direct clutch 1.
The clockwise rotating force of input shaft 16 is transmitted to intermediate shaft 18 by the action of front clutch 6, then
turns rear planetary pinion gears 12 clockwise by means of rear planetary ring gear 11. In this process, rear planetary
carrier 22 is stationary due to vehicle weight. Therefore, rear planetary sun gear 23 receives counterclockwise rotating
force and transmits this force to front planetary pinion gears 21, exerting force to rotate front planetary carrier 19 in a
counterclockwise direction. However, since No. 2 one-way clutch 9 prevents front planetary carrier 19 from rotating in a
counterclockwise direction, pinion gears 12, 21 cause front planetary ring gear 10 and rear planetary carrier 22 to rotate
in a clockwise direction, thereby transmitting the rotating force to output shaft 24. (Rotational directions are described as
viewed from the torque converter side.)

23-25
STRUCTURE AND OPERATION
Power transmitting process
Overdrive input shaft 13 → Overdrive planetary carrier 3 → Overdrive planetary pinion gears 5 → Overdrive planetary
ring gear 4 → Input shaft 16 → Front clutch 6 → Intermediate shaft 18 → Rear planetary ring gear 11 → Rear planetary
pinion gears 12 → Rear planetary carrier 22 → Output shaft 24

→ Front and rear planetary sun gears 20, 23 → Front planetary pinion gears 21

→ Front planetary ring gear 10

23-26
 23
P D Range (2nd Gear)

3 4 A 6 7 B C 22 11

18 23 12 24
13 14 5 16
Front planetary sun gear Rear planetary sun gear
Planetary gear rotates as assembly locked in position locked in position

Input

Output

A B C

29821

Front clutch 6, 2nd brake 7 and overdrive one-way clutch 14 activate to provide the 2nd gear. In this gear, overdrive one-
way clutch 14 transmits the rotating force of input shaft 16 to rear planetary pinion gears 12 by means of intermediate
shaft 18 and rear planetary ring gear 11. Although rear planetary sun gear 23, which is meshed with pinion gears 12, re-
ceives a counterclockwise rotating force, 2nd brake 7 prevents its rotation, disabling the transfer of the rotating force to
front planetary gear B. As a result, the rotating force transmits to rear planetary carrier 22 via rear planetary pinion gears
12, then to output shaft 24.

Power transmitting process

Overdrive input shaft 13 → Overdrive planetary carrier 3 → Overdrive planetary pinion gears 5 → Overdrive planetary
ring gear 4 → Input shaft 16 → Front clutch 6 → Intermediate shaft 18 → Rear planetary ring gear 11 → Rear planetary
pinion gears 12 → Rear planetary carrier 22 → Output shaft 24

23-27
STRUCTURE AND OPERATION
P D Ranges (3rd Gear)
1 3 A 4 6 17 10 B C 22 11

18 21 20 23 12 24
13 14 5 16
Planetary gear Planetary gear Planetary gear
rotates as assembly rotates as assembly rotates as assembly

A B C

29822

Overdrive direct clutch 1, front clutch 6, rear clutch 17 and Overdrive one-way clutch 14 activate to provide the 3rd gear.
In this gear, front clutch 6 and rear clutch 17 cause intermediate shaft 18 and front and rear sun gears 20, 23 to rotate in
the same direction. Therefore, front and rear planetary pinion gears 12, 21 become locked in position, thus the entire as-
semblies of planetary gears A, B, C rotate together to transmit the rotating force of input shaft 16 to output shaft 24 with-
out reducing the rate of rotating speed.

Power transmitting process

Overdrive input shaft 13 → Overdrive planetary carrier 3 → Overdrive planetary pinion gears 5 → Overdrive planetary
ring gear 4 → Input shaft 16 → Front clutch 6 → Intermediate shaft 18

→ Rear planetary ring gear 11 → Rear planetary pinion gears 12

→ Rear clutch 17 → Rear planetary carrier 22 → Output shaft 24

→ Rear planetary sun gear 23 → Rear planetary pinion gears 12

→ Front planetary sun gear 20 → Front planetary pinion gears 21 → Front planetary ring gear 10

23-28
 23
P D Range (4th Gear)
1 2 3 4 6 17 10 C 22 11
A B

13 5 15 16 18 21 20 23 12 24
Overdrive planetary sun gear 15
Planetary gear rotates as assembly Planetary gear rotates as assembly
Output

Input

A B C

29823

If the overdrive conditions (see the table below) are fulfilled when the transmission is in 3rd gear, overdrive direct clutch 1
disengages, and overdrive brake 2 activates at the same time to provide the overdrive gear ratio. In the overdrive gear,
overdrive brake 2 is in operation, thus locking overdrive planetary sun gear 15 in position. Therefore, the rotating force
transmitted from overdrive input shaft 13 to overdrive planetary carrier 3 causes overdrive planetary pinion gears 5 to re-
volve around the sun gear and on their own axes, which results in an increased rotating speed of overdrive planetary ring
gear 4 (input shaft 16). The rotating force of input shaft 16 is transmitted to output shaft 24, in the same way as in the 3rd
gear.
Overdrive conditions
Shift position D
Overdrive OFF SW OFF
Temperature of oil in oil pan Approximately 0°C or higher

Power transmitting process

Overdrive input shaft 13 → Overdrive planetary carrier 3 → Overdrive planetary pinion gears 5 → Overdrive planetary
ring gear 4 → Input shaft 16 → Front clutch 6 → Intermediate shaft 18

→ Rear planetary ring gear 11 → Rear planetary pinion gears 12

→ Rear clutch 17 → Rear planetary carrier 22 → Output shaft 24

→ Rear planetary sun gear 23 → Rear planetary pinion gears 12

→ Front planetary sun gear 20 → Front planetary pinion gears 21 → Front planetary ring gear 10

23-29
STRUCTURE AND OPERATION
P 2 Range (2nd Gear)

1 3 A 4 6 B C 22 11

13 16 18 12 24
14 5 15
Planetary gear Front planetary sun Rear planetary sun gear
rotates as assembly gear locked in position locked in position
Input

Output

A B C

29824

The rotating power is transmitted in the same way as in the previously described 2nd gear in the D range. However, when
engine brake is applied, overdrive direct clutch 1 activates and prevents overdrive planetary sun gear 15 from rotating
clockwise. In other words, when the transmission is in 2nd gear with the range selector in the D range, overdrive one-way
clutch 14 transmits the rotating power to input shaft 16. When the engine brake is applied, however, the counterclockwise
rotating force of overdrive planetary sun gear 15 inactivates overdrive one-way clutch 14 and causes overdrive planetary
sun gear 15 to spin freely. This disallows the transmission of the engine brake force. To properly transmit the engine
brake force in the 2 range, overdrive direct clutch 1 is activated to interlock overdrive planetary sun gear 15 with overdrive
planetary carrier 3.

Power transmitting process

Overdrive input shaft 13 → Overdrive planetary carrier 3 → Overdrive planetary pinion gears 5 → Overdrive planetary
ring gear 4 → Input shaft 16 → Front clutch 6 → Intermediate shaft 18 → Rear planetary ring gear 11 → Rear planetary
pinion gears 12 → Rear planetary carrier 22 → Output shaft 24

23-30
 23
P L Range (1st Gear)
3 A 4 6 8 9 19 B 10 C 22 11

13 5 16 18 21 20 23 12 24
Planetary gear Front planetary carrier
rotates as assembly fixed in position
Output Input

Output
Input

A B C

29825

The rotating power is transmitted in the same way as in the previously described 1st gear in the D and L ranges. Howev-
er, when the engine brake is applied, 1st and reverse brake 8 activates and prevents front planetary carrier 19 from rotat-
ing clockwise. In other words, when the transmission is in 1st gear with the range selector in the D or 2 range, No. 2 one-
way clutch 9 prevents a counterclockwise rotation of front planetary carrier 19 and transmits the rotating power to output
shaft 24. When the engine brake is applied, however, a rotating force in the reverse direction is generated, inactivating
No. 2 one-way clutch 9 and allowing front planetary carrier 19 to spin freely. This disallows the transmission of the engine
brake force. To properly transmit the engine brake force in the L range, 1st and reverse brake 8 is activated to lock front
planetary carrier 19 in position.

Power transmitting process

Overdrive input shaft 13 → Overdrive planetary carrier 3 → Overdrive planetary pinion gears 5 → Overdrive planetary
ring gear 4 → Input shaft 16 → Front clutch 6 → Intermediate shaft 18 → Rear planetary ring gear 11 → Rear planetary
pinion gears 12 → Rear planetary carrier 22 → Output shaft 24

→ Front and rear planetary sun gears 20, 23 → Front planetary pinion gears 21

→ Front planetary ring gear 10

23-31
STRUCTURE AND OPERATION
P R Range

1 3 A 4 17 8 19 B 10 C

13 14 5 16 21 20 23 24
Planetary gear
Front planetary carrier in fixed position
rotates as assembly
Output

Input

A B C

29826

In the R range, overdrive direct clutch 1, overdrive one-way clutch 14, rear clutch 17 and 1st and reverse brake 8 activate
to provide reverse gear. The rotating force of overdrive input shaft 13 is transmitted to input shaft 16 via direct coupling, in
the same way as in the 1st gear in the D and 2 ranges. Since rear clutch 17 in operation, the rotating force of input shaft
16 is transmitted to pinion gears 21 of front planetary gear B by means of the sun gear. However, because front planetary
carrier 19 is locked in position by 1st and reverse brake 8, the rotating force of front planetary sun gear 20 is transmitted
to the ring gear by means of front planetary pinion gears 21, thus providing a counterclockwise rotating force to output
shaft 24.

Power transmitting process

Overdrive input shaft 13 → Overdrive planetary carrier 3 → Overdrive planetary pinion gears 5 → Overdrive planetary
ring gear 4 → Input shaft 16 → Rear clutch 17 → Front planetary sun gear 20 → Front planetary pinion gears 12 → Front
planetary ring gear 10 → Output shaft 24

23-32
 23
P N Range
6 17

24
16 29827
• N range
Since front clutch 6 and rear clutch 17 are disengaged, the driving force of input shaft 16 is not transmitted to output
shaft 24.

P P Range
1 Parking lock gear
1 2 Output shaft
3 Transmission case
2 4 Parking lock pawl

29828

• P range
In the same way as in the N range, the driving force of the input shaft is not transmitted to output shaft 2. Parking lock
pawl 4, which is linked with the range selector lever, meshes with parking lock gear 1 which is directly connected to the
output shaft, thus disallowing vehicle movement.

23-33
STRUCTURE AND OPERATION
P Torque Converter
1 Pump impeller
2 Turbine liner
3 Stator
4 Lock-up damper
5 One-way clutch
6 Front converter cover
1
7 Lock-up piston

2 • The torque converter transfers engine torque to the

transmission. It transmits engine torque by means of oil
3 when it is not in a lock-up condition, and it transfers
power via the lock-up piston when it is in a lock-up con-
dition.
4 • The torque converter is a 3-element, 1-stage, 2-phase
type.
5 • “1-stage” indicates that the torque converter has one
turbine liner, which is an output element. “2-phase”
means that it provides a torque converter function when
6 the turbine liner speed is relatively slow as compared to
the pump impeller speed, and acts as a fluid coupler
7 when the turbine liner speed is high.

29829

< Lock-up mechanism in inactive condition >

B The lock-up control valve supplies the torque converter operating
pressure through oil passage A to the space between the front con-
verter cover and lock-up piston. This oil pressure separates the
clutch facing of the lock-up piston from the front converter cover. As a
result, the torque converter operating pressure supplied through oil
A
passage A is released from oil passage B, and enters the oil cooler.

07480

< Lock-up mechanism in active condition >

B
The lock-up control valve switches the operating oil passage. The
torque converter operating pressure is supplied through oil passage
B to the pump impeller, turbine liner and stator.
As a result, the oil pressure applied to the lock-up piston causes the
clutch facing of the lock-up piston to engage with the front converter
C cover for improved power transmitting efficiency.
C : Drain

07481

23-34
 23
P Oil Pump
1 Driven gear
2 Crescent
1 3 Drive gear
4 Oil pump body
2 5 Outlet port
6 Inlet port
3

6
29830

• Feature ........The oil pump gears have a small number of gear teeth and features a special high-performance tooth
profile.
• Operation .....The drive gear is fitted to the extension sleeve of the torque converter, and rotates in the same direction
(in the direction of the arrow) as the engine to compress and discharge the intake oil.

23-35
STRUCTURE AND OPERATION
P Anti-wrong operation prevention unit
1 Key interlock solenoid
2 Starter switch
3 Overdrive OFF switch
4
4 Automatic transmission knob
2 5 5 Range selector cover
1 6 Range selector lever
3 6 7 Pin
8 Converter
14 9 Shift lock actuator
13 10 Reverse buzzer
7
11 Lever bracket
8 12 Shift lock link
16
13 Shift unlock knob
12 14 P range switch
15 11 15 Brake pedal
9 16 Stop lamp switch
10

29831

Key interlock unit

• The key interlock unit allows the ignition key to be removed from the keyhole only when range selector lever 6 is in the
P (parking) range.

P shift lock unit

• The P shift lock unit is a safety unit which prevents the vehicle from moving by not allowing range selector lever 6 to be
shifted from the P range position unless the brake pedal is depressed.

Key interlock unit

4 <Lock condition>
• Condition: When range selector lever 6 is in positions other than the
P range, or when automatic transmission knob 4 is pressed while the
range selector lever is in the P range position, pin 7 is disengaged
from P range switch 14 (the switch is free) and the switch is turned
ON.
6 • Current runs from the key interlock control unit to key interlock sole-
noid 1. The key interlock solenoid is turned ON.
14 • When key interlock solenoid 1 is activated, starter switch 2 cannot be
turned to the LOCK position and the key cannot be removed.

<Unlock condition>
7
• Condition: When range selector lever 6 is in the P range position and
automatic transmission knob 4 is not pressed, pin 7 pushes P range
switch 14 (switch is activated) and the switch is turned OFF.
• Current does not run from the key interlock control unit to key inter-
lock solenoid 1. The key interlock solenoid is turned OFF.
29833 • When key interlock solenoid 1 is not activated, starter switch 2 is un-
locked and can be turned to the LOCK position. The key can be re-
moved.

23-36
 23
P shift lock unit
4
• When shift lock actuator 9 is activated with range selector lever 6 in
the P range position (refer to the table below), the shift lock actuator
6 is locked and pin 7 is locked to shift lock link 12.
• Therefore, automatic transmission knob 4 cannot be pushed, and
range selector lever 6 is fixed to the P range position.
Operating condition
Operating status
Power source Switch
IG +B Brake P range Unlock Lock
p p p p p
7
p p p p
p p p p
p p p
p p p p
9 p p p
12 29834 p p p
p p
IG: Starter switch ON power source
+B: Direct battery power source

• When shift lock actuator 9 is activated with range selector lever 6 in

4
the P range position (refer to the table above), the shift lock actuator
is unlocked and shift lock link 12 collapses forward and is released
from pin 7.
6
• Therefore, automatic transmission knob 4 can be pushed, and range
selector lever 6 can be shifted from the P range.
• If there is any electrical failure, pull shift unlock knob 13. The P shift
lock unit can be unlocked.

13

9
12 29835

23-37
STRUCTURE AND OPERATION
Range selector lever reverse position alarm unit
• When range selector lever 6 is set to the R (reverse) range while the
starter switch is ON, the reverse position detection switch (Inhibitor
switch: Built into the automatic transmission) is activated. Reverse
buzzer 10 sounds and alerts a driver that the range selector lever is
6 in the reverse position.

10
29836

23-38
 23

MEMO

23-39
TROUBLESHOOTING PROCEDURES
Automatic transmission problems can be caused by the following malfunctions.
• Engine malfunction
• Improperly adjusted parts
• Faulty hydraulic system
• Faulty mechanical functions
• Faulty electrical system
When diagnosing the above abnormalities, be sure to inspect the following basic items.
• Engine condition
• Automatic transmission fluid level and condition: L P23-55
• Control cable adjustment
In addition to the inspection of the above items, use the self-diagnosis function to locate the cause of the problem and
take necessary measures.
After repair is complete, test-drive the vehicle to determine whether the problem is corrected or further inspection is
necessary.
If the cause of the problem cannot be located, or if repair work does not correct the problem, conduct a line pressure
test and a stall test. L P23-50, 52
It should be noted that special knowledge and tools are required to repair the automatic transmission unit or replace
parts. Therefore, conduct an inspection for the purpose of evaluating the operating condition of the transmission. For
maintenance or repair of the automatic transmission, contact your nearest authorized Mitsubishi dealer or distributor.
Use of the Multi-use tester-II allows efficient inspection of the automatic transmission system.

Self-diagnosis process
Abnormality generation (Note 1)
Note 1: The following abnormalities sig-
nificantly lower driving perfor-
mance. In the case that these
Delivery of vehicle abnormalities generate during
operation, the automatic trans-
mission warning lamp lights.
Self-diagnosis procedure (Note 2) • Faulty operation of vehicle
speed sensors
• Faulty operation of solenoid
Correct problem or replace parts Test drive (Note 3)
other than lock-up solenoid
• Faulty operation of accelera-
Test drive Self-diagnosis procedure (Note 4) tor position sensor
• Faulty operation of inhibitor
switch
Self-diagnosis Abnormality found in self-diagnosis? • Faulty throttle position PWM
Yes
signal
No
Note 2: Inspect for malfunctions that
Is there abnormality? occurred during user operation.
Yes Check for other abnormalities
• Inspection of individual symptoms Record inspection results.
No • Inspection of transitory problems Note 3: • Check abnormal conditions.
End
• In a test drive, operate the ac-
celerator pedal in full range
(from the released position to
full throttle) with a vehicle
speed of up to approximately
50 km/h.
Note 4: Inspect problems that generate
during a test drive. Record in-
spection results.

23-40
 23
Types of Self-Diagnosis
The following two types of self-diagnosis function can be selected.

Self-diagnosis

Using diagnosis switch Using Multi-use tester-II

Disconnect the diagnosis switch

(plug connector) to indicate mal- Data list function
Flight recorder function
function codes.
Data of malfunctions stored in the Connect the Multi-use tester-II to the au-
memory can be deleted with the tomatic transmission electronic control
memory clear switch. unit with a test harness to download and
display malfunction codes.
In addition to the self-diagnosis function,
the Multi-use tester-II is equipped with a
data list function that indicates sensor
and switch values and a flight recorder
function that records those data for a
certain length of time before and after
the triggering. These functions are use-
ful in analyzing malfunctions.
(Refer to the Multi-use tester-II operation
manual.)

Features of the two self-diagnosis methods

Self-diagnosis method
Use of diagnosis switch Use of Multi-use tester-II
Item
Convenience p
Number of self-diagnosis items
Data reading ease p
Data application range u

: Good
: Good
p: :Fair
p Fair
u: Bad
u : Bad

23-41
TROUBLESHOOTING
Reading and erasing diagnosis code
P Reading diagnosis code
Current diagnosis code
• Turn ON the starter switch.
• Disconnect diagnosis switch 1.
• The diagnosis code is displayed by flashing of warning lamp 3.
1
Current and past diagnosis code
• Turn ON the starter switch.
2 • Disconnect diagnosis switch 1.
79861
• Disconnect memory clear switch 2.
• The diagnosis code is displayed by flashing of warning lamp 3.
• In this case, both the past diagnosis code and current diagnosis
codes, if any, are displayed.

P P
R R
N N
D D
2 2
L L

3
29838

• Read the diagnosis code with the flashing count and time of warn-
10 place digit 1 place digit ing lamp 3.
• The flashing time of the 10 place digit is different from that of the 1
ON
place digit.
• 10 place digit: Interval of 1.2 seconds
OFF • 1 place digit: Interval of 0.4 second
• The diagnosis code is displayed in the sequence of the 10 place
1.2 0.6 digit and the 1 place digit. The code that begins with 0 for the 10
0.4
place digit indicates only 1 place digit.
0.6 • One diagnosis code is displayed three times repeatedly in the as-
0.4 cending order.
Diagnosis switch • If there is no new code, the display returns to the first code and the
disconnected same display is repeated three times.
Displayed for the 1st time • When diagnosis switch 1 is connected, the electronic control unit
(Diagnosis code 12) stops (ends) display of the code immediately.
ON Displayed
OFF for the
2nd time
2.4 2.4 2.4 2.4
13705

23-42
 23
P Erasing diagnosis code
By disconnecting and reconnecting memory clear switch 2 while the
starter switch is ON and diagnosis switch 1 is connected, all diagno-
sis codes stored in the electronic control unit are erased.

1
CAUTION k
• Note that diagnosis codes are erased only with operation of
memory clear switch 2 only.
2
• If you do not want to erase the stored memory after displaying
79861 diagnosis codes, turn OFF the starter switch while memory
clear switch 2 is disconnected and connect the memory clear
1 sec or
more switch.
3 sec

Connection

Open Memory is
erased here.
02739

23-43
TROUBLESHOOTING
P Diagnosis code list
Diagno-
Location of failure Judgment criteria Fail safe action
sis code
Power source volt- Power source voltage is 15V or less continu-
11
age ously for 1 sec or more.
• Vehicle sensor 2 backs up. If a failure also occurs
in vehicle speed sensor 2, take the following ac-
If the pulse of vehicle speed sensor 1 against
tions:
the input pulse from vehicle speed sensor 2
Vehicle speed sen- • The gear is fixed at the position immediately be-
12 is less than the specified value, or if vehicle
sor 1 fore the failure judgment.
speed sensor 1 rapidly decelerates with the
• If the engine speed sensor is less than 1000 rpm,
failure of vehicle speed sensor 2
shift solenoids 1 and 2 are turned OFF, and then
the throttle pressure is set to the maximum value.
• If the judgment criteria are satisfied immediately
after the starter switch is turned ON, the lowest oil
temperature range setting and the 300-second
highest oil temperature range are maintained.
• If the judgment criteria are satisfied by 300 sec-
Automatic transmis- The output voltage of the automatic transmis-
onds after the starter switch is turned ON, the oil
13 sion fluid tempera- sion fluid temperature sensor is out of the
temperature range at that time is maintained and
ture sensor specified range.
the value is specified as the 300-second highest
oil temperature range.
• The judgment criteria are satisfied 300 seconds
after the starter switch is turned ON, and the high-
est oil temperature is maintained.
When the shift position is out of N and P • 2nd-to-3rd shift timing control is prohibited.
Engine speed sen- ranges and the speed of output shaft is 1000 (Timing solenoid OFF)
15
sor rpm or higher, the output signal from the en- • Lock-up is prohibited.
gine speed sensor is 100 rpm or less. (Lock-up is permitted only at a high speed.)
• Accelerator opening 0%
• 2nd-to-3rd shift timing control is prohibited.
Accelerator posi- The duty ratio of the engine electronic control
24 • Maximum throttle pressure
tion sensor unit is out of the specified range.
• Lock-up is prohibited.
(Lock-up is permitted only at a high speed.)
• Vehicle sensor 1 backs up. If a failure also occurs
in vehicle speed sensor 1, take the following ac-
If the pulse of vehicle speed sensor 2 against
tions:
the input pulse from vehicle speed sensor 1
Vehicle speed sen- • The gear is fixed at the position immediately be-
25 is less than the specified value, or if vehicle
sor 2 fore the failure judgment.
speed sensor 2 rapidly decelerates with the
• If the engine speed sensor is less than 1000 rpm,
failure of vehicle speed sensor 1
shift solenoids 1 and 2 are turned OFF, and then
the throttle pressure is set to the maximum value.
Solenoid voltage is low while the solenoid
output is ON.
31 Shift solenoid 1 Turn OFF output of shift solenoid 1.
Solenoid voltage is high while the solenoid
output is OFF
Solenoid voltage is low while the solenoid
output is ON.
32 Shift solenoid 2 Turn OFF output of shift solenoid 2.
Solenoid voltage is high while the solenoid
output is OFF.
The plus terminal voltage of the throttle pres-
sure solenoid is detected to be low or high
continuously for 10 ms.
Throttle pressure
34 The minus terminal current of the throttle Turn OFF output of throttle pressure solenoid.
solenoid
pressure solenoid is detected to be 1.2 A or
more or 0.05 A or less continuously for 500
ms.

23-44
 23
Solenoid voltage is low while the solenoid
output is ON.
35 Lock-up solenoid Turn OFF output of lock-up solenoid.
Solenoid voltage is high while the solenoid
output is OFF.
• Shift positions to D range and 4th position are pro-
No signal is sent from inhibitor switch. hibited.
43 Inhibitor switch
Excessive signal is sent from the inhibitor • Shift is controlled in the priority order of L>R>2>D
switch. >N and (P).

Solenoid voltage is low while the solenoid

output is ON.
51 Timing solenoid Turn OFF output of timing solenoid.
Solenoid voltage is high while the solenoid
output is OFF.
• Exhaust brake cut control is prohibited.
Exhaust brake cut The exhaust brake signal is input for 500 ms
54 • Lock-up is prohibited.
signal while the exhaust brake cut is output.
(Lock-up is permitted only at a high speed.)

Procedure for servicing with Multi-use tester-II

J Special tools
Location Tool names and shape Part No. Application

– Multi-use tester-II MB991496

19492

– Multi-use tester-II harness MK327601 System inspection

19141

– ROM pack (MRT-E10) MH062867

19493

P Connecting the Multi-use tester-II

• Turn the starter switch to the LOCK position.
• Connect the b Multi-use tester-II Harness to the a Multi-use
tester-II, and insert the c ROM Pack.
• Connect Multi-use tester-II connector A (16 terminals) and con-
A
nector B (16 terminals).

B
       
      
NOTE
Instructions for operation of the Multi-use tester-II are given in
A 29385 the separate Multi-use tester-II Reference Manual.

23-45
TROUBLESHOOTING
P Inspection with Multi-use tester II
a Diagnosis code is displayed to allow checking of abnormal items. (Parts for inspection are displayed.)
b Information signals from each sensor are displayed in values (service data). Status can be judged by comparing the
service data with the judgment criteria. The service data code is displayed separately from the diagnosis code.
a b

Displayed on Multi-use tester-II Displayed on Multi-use tester-II Inspection procedure

Diagno- Abnormal item (Parts Service Information signal Service
Inspection condition Judgment criteria
sis code for inspection) data code name data
11 POWER VOLTAGE
When vehicle is not in motion 0 km/h
www.w
12 VEH SPD SNSR1 12 VEH SPEED 1 Synchronous with
km/h When vehicle is in motion
speedometer
Equivalent to ambient
When engine is cold
temperature
Gradual temperature
13 OIL TEMP SNSR 13 A/T OIL TEMP w w w . °C When engine is warmed-up
rise
When engine is stopped after Gradual temperature
warm-up drop
Idling after warm-up 650 rpm
wwww
15 ENG SPD SNSR 15 ENGINE SPEED Synchronous with ta-
rpm Racing
chometer
Selector P ON
19 P POS. SW
Selector other than P OFF
Selector R ON
20 R POS. SW
Selector other than R OFF
Selector N ON
21 N POS. SW
Selector other than N OFF
Selector D ON
22 D POS. SW
Selector other than D OFF
Accelerator pedal is fully closed. 0%
ACCEL PER- Accelerator pedal is gradually The percentage in-
24 ACCEL SNSR 24 www.w %
CENT pressed. creases continuously.
Accelerator pedal is fully opened. 100 %
When vehicle is not in motion 0 km/h
www.w
25 VEH SPD SNSR 2 25 VEH SPEED 2 Synchronous with
km/h When vehicle is in motion
speedometer
Selector 2nd ON
26 2 POS. SW
Selector other than 2nd OFF
Selector L ON
27 L POS. SW
Selector other than L OFF
Overdrive OFF switch is ON. ON
28 OD-OFF SW
Overdrive OFF switch is OFF. OFF
Power mode is selected. ON
29 POWER S/W
Economy mode is selected. OFF
Driving with 1st and 2nd gears ON
31 SHIFT VALVE 1 31 SHIFT VALVE 1
Driving with 3rd and 4th gears OFF

23-46
 23
Driving with 2nd and 3rd gears ON
32 SHIFT VALVE 2 32 SHIFT VALVE 2
Driving with 1st and 4th gears OFF

w w w . w The accelerator pedal is de- The value increases

34 LINE PRESS. V 34 LINE PRESS pressed slowly from the full-close
kgf/cm2 position. continuously.

Turn ON according to
The vehicle is driven at a constant the lock-up vehicle
35 LOCK-UP VALVE 35 LOCK-UP VALVE accelerator pedal opening. speed list of the road
test. L P23-54
Stop the vehicle with the D-range. OFF
Oil temperature is abnormal. (Oil
ON
temperature lamp is ON.)
36 OIL TEMP SW
Oil temperature is normal. (Oil
OFF
temperature lamp is OFF.)
Depress the brake pedal. ON
37 BRAKE SW
Release the brake pedal. OFF
Exhaust brake operates during
ON
38 EXH. BRAKE SIG driving.
Exhaust brake does not operate. OFF
43 INHIBIT SIG.
Anti-lock braking system oper-
ON
ates.
47 ABS SW
Anti-lock braking system does not
OFF
operate.
Disconnect the connector. OPEN
48 M CLEAR SW
Connect the connector. CLOSE
Disconnect the connector. OPEN
49 DIAGNOSIS SW
Connect the connector. CLOSE
When gear position is shifted
from 2nd to 3rd while accelerator ON
51 TIMING VALVE 51 TIMING VALVE pedal is released.
When the vehicle is not in motion OFF
The system has a failure. (Warn-
ON
ing lamp is ON.)
53 DIAG LAMP
The system is normal. (Warning
OFF
lamp is OFF.)
Exhaust brake operates during
OFF
driving.
54 EXB CUT SIG. 54 EXB CUT SIG.
The vehicle stops when the ex-
OFF → ON
haust brake operates.
The selector position
Shift the selector from P to L in changes in the order
55 SELECTOR POS. w .RANGE
sequence. of P → R→N→D→2nd
and L.
Operated according to
1ST the lock-up vehicle
Accelerated gradually from 0 km
2ND speed list of the road
at a constant accelerator pedal
3RD test. L P23-54
opening.
56 GEAR POS. 4TH (1st → 2nd → 3rd →
4th)
N Selector N N
REV Selector R REV

23-47
TROUBLESHOOTING
Symptoms and problems
Malfunction Abnormal movement Abnormal shift operation

Vehicle does not move in D, 2 or L range

Parking position is still engaged when

Does not shift down from 3rd to 2nd

Vehicle does not move in any range

Does not shift down from 2nd to 1st

Lock-up point extremely high or low

Does not shift down from 4th to 3rd

Vehicle does not move in R range

Does not shift up from 2nd to 3rd

Does not shift up from 1st to 2nd
Does not shift up from 3rd to 4th
Shift point extremely high or low
selector is moved from P range

Kick-down does not operate

No engine brake in 2 range
No engine brake in L range

Engine revs up in 2-3 shift

Vehicle moves in P range
Vehicle runs in N range

Does not lock-up

Suspected problem factor

Automatic transmission fluid level and condition p

Control linkage p p p p p p
Inhibitor switch p p p
Accelerator position sensor p p p p p
Vehicle speed sensor p p p p p p p p p
Engine speed sensor p p
Engine idle speed
Line pressure p p
Shift solenoid 1 p p p p p p
Shift solenoid 2 p p p p p p p p p
Timing solenoid p
Lock-up solenoid p p
Starter circuit
Overdrive OFF switch p
Exhaust brake switch p
Automatic transmission fluid temperature sensor p p
Automatic transmission electronic control unit p p p p p p p p p p p p p p
Torque converter p p
Automatic transmission unit malfunction p p p p p p p p p p p p p p p p p p

23-48
 Starter circuit
Line pressure
Inhibitor switch
Control linkage

Shift solenoid 2
Shift solenoid 1

Timing solenoid

Torque converter
Lock-up solenoid
Engine idle speed

Exhaust brake switch

Engine speed sensor
Vehicle speed sensor

Overdrive OFF switch

Suspected problem factor

Accelerator position sensor

Automatic transmission unit malfunction

Automatic transmission electronic control unit
Automatic transmission fluid level and condition

Automatic transmission fluid temperature sensor

Malfunction

During lock-up operation

p
p

p
p
When shifting from 3rd to 2nd
Wehn shifting from 4th o 3rd

p
When shifing from 1st to 2nd, to 3rd, to 4th
When shifting from 3rd to 4th
shifting

p
When shifting from 2nd to 3rd

p p
p p
When shifting from 1st to 2nd
Excess shock during

p
p
p p p p p p p p
When shifting from N to D and from N to R
When shifting from N to D
When shifting from N to R
In 4th gear
In 3rd gear
In 2nd gear
Sippage

In 1st gear
In reverse gear
In forward and backward

p p p p p p p p p p p p p p p p p
p p
p
p
p p
p p p p p p p
p p

Transmission overheat and oil blow-off from breather.

Engine stalls when range selector is moved to R, D, 2

p
p
p
p

or L, or when vehicle is stationary

Engine starts with range selector in position other than
p
p
Others

N or P range
Engine cannot be started with range selector in N or P
23

p
p
p

range

23-49
ON-VEHICLE INSPECTION AND ADJUSTMENT
Stall test
P Purpose
The stall test is used for checking the frictional part in the transmis-
sion, slippage of the one-way clutch in the torque converter, opera-
tion of the torque converter and overall engine performance.

P Measurement procedure
• Before starting the test, check the levels of engine coolant, oil and
automatic transmission fluid.
• Apply the parking brake securely, and then put scotches on the
wheels.
• Warm up the engine sufficiently.
• Depress the brake pedal firmly with the left foot and shift the range
selector lever to the D range.
• Press the accelerator pedal slowly to the full travel. When the engine
revolution becomes stable, read the engine revolution (stall revolu-
tion) quickly. Then release the accelerator pedal immediately.

CAUTION k
• Make sure to depress the accelerator pedal to the full travel
for less than 5 seconds. Finish measurement of the engine
revolutions within this period.
• If the engine revolution is unstable and continues to increase
gradually or increases like racing, stop the test immediately.

• Shift the range selector to the N range and cool the engine at 1200
rpm for 2 minutes.
• Perform a similar test when the shift selector is in the 2nd, L and R
ranges.
• Stall revolution
Standard value 1840 ± 150 rpm

P Result diagnosis

Measurement result Main cause

Insufficient engine output
Lower than standard value in all ranges
Malfunction of one-way clutch in torque converter
Slippage of front clutch
Higher than standard value in D range Malfunction of one-way clutch No. 2
Low line pressure
Slippage of rear clutch
Higher than standard value in R range Slippage of 1st and reverse brake
Low line pressure
Low line pressure
Level of automatic transmission fluid is out of standard range.
Higher than standard value in all ranges
Slippage of overdrive direct clutch
Malfunction of overdrive one-way clutch

23-50
 23
Time lag test
P Purpose
The time lag test is used for checking the condition of overdrive direct
clutch, front clutch, rear clutch and 1st and reverse brake.

P Measurement procedure
• Warm up the engine sufficiently.
• Check the revolution in idling.
• Shift the range selector lever from the N range to the D range, and
measure the time with a stopwatch until a shock is felt.
• Similarly, measure the time until a shock is felt after shifting the se-
lector lever from the N range to the R range.
Standard value
When shifted from N to D 0.7 sec or less
When shifted from N to R 1.2 sec or less

P Result diagnosis
Measurement Estimated abnormality
Low line pressure
Time lag in shifting from N to D Slippage of front clutch
range is large.
Malfunction of overdrive one-way
clutch
Low line pressure
Slippage of rear clutch
Time lag in shifting from N to R
range is large. Slippage of 1st and Reverse brake
Malfunction of overdrive one-way
clutch

23-51
ON-VEHICLE INSPECTION AND ADJUSTMENT
Line pressure test
Service standards
Location Maintenance item Standard value Limit Remedy
529 to 794 kPa
D range –
{5.4 to 8.1 kgf/cm}
Idling oil pressure
745 to 1127 kPa
R range –
{7.6 to 11.5 kgf/cm}
– Line pressure Inspection
980 to 1470 kPa
D range –
{10.0 to 15.0 kgf/cm}
Stall oil pressure
1392 to 2097 kPa
R range –
{14.2 to 21.4 kgf/cm}

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Pressure detection plug 27 {2.75} 1/2-20 UNF

P Purpose
This test checks the performance of the oil pump and the function of
1
the control valve, and checks for oil leakage from any part.

P Measurement procedure

CAUTION k
The line pressure test must be performed by two people; one
checks the conditions of tires or scotches in a distant place
29841
and the other performs the test.
• Apply the parking brake securely and put scotches on the wheels.
• Remove pressure detection plug 1, and install the oil pressure
gauge.

CAUTION k
• Prevent dirt from entering the pressure detection outlet.
• Remove dirt from the pressure detection outlet before install-
ing plug 1.
• Warm the engine sufficiently and check the idling revolution.
• Depress the brake pedal strongly with the left foot, shift the range se-
lector lever to the D range and measure the oil pressure in idling.
• Depress the accelerator pedal to the full travel and quickly measure
the oil pressure at stall.

CAUTION k
If the rear wheels start to rotate before the engine revolution
reaches the stall revolution, stop the test immediately.
• Measure the R range in the same manner.
• After measurement, tighten pressure detection plug 1 to the specified
torque.

23-52
 23
P Diagnosis of results
Measurement result Estimated abnormality
Poor adjustment of accelerator position
sensor
Measurement is higher than the
standard value in all ranges. Sticking of regulator valve
Sticking of throttle valve
Poor adjustment of accelerator position
sensor
Sticking of regulator valve
Measurement is lower than the
standard value in all ranges. Sticking of throttle valve
Worn oil pump
Abnormality of overdrive direct clutch
Measurement is lower than the Oil leakage in the D range system
standard value in the D range
only. Abnormality of front clutch

Oil leakage in the R range system

Measurement is lower than the
standard value in the R range Abnormality of rear clutch
only.
Abnormality of 1st and reverse brake

23-53
ON-VEHICLE INSPECTION AND ADJUSTMENT
Road test
P Measurement procedure
• Before the road test, check the level and the condition of the automatic transmission fluid. Adjust the automatic trans-
mission control cable and the accelerator control cable. Make sure that each cable is inspected and adjusted.
• Shift the automatic transmission to each position during the road test and check slipping feel in shifting and other
changes.
• Check if shifting is felt too hard or too soft.
• Check the shift point where upshifting and downshifting occur.
• Measure the vehicle speed in shifting with different driving conditions.

P Vehicle speed in shifting Unit: km/h

Throttle opening Shifting Economy mode Power mode
D1 → D2 7.8 to 10.4 7.8 to 10.4
Half throttle D2 → D3 14.9 to 17.5 16.2 to 18.8
D3 → D4 24.3 to 26.9 25.6 to 28.2
D1 → D2 18.0 to 20.6 18.0 to 20.6
Full throttle D2 → D3 37.1 to 39.7 37.1 to 39.7
D3 → D4 64.0 to 66.6 64.0 to 66.6
D1 → D2 5.2 to 7.8 5.2 to 7.8
Throttle is completely closed D2 → D3 5.2 to 7.8 5.2 to 7.8
D3 → D4 15.1 to 17.8 20.4 to 23.0

P Lock-up vehicle speed Unit: km/h

Throttle opening Shifting Economy mode Power mode
20N 34.2 to 36.8 34.2 to 36.8
Half throttle 30N 48.6 to 51.2 48.6 to 51.2
40N 48.6 to 51.2 48.6 to 51.2
20N 39.9 to 42.6 39.9 to 42.6
Full throttle 30N 48.6 to 51.2 48.6 to 51.2
40N 64.0 to 66.6 64.0 to 66.6
20FF 35.2 to 37.9 35.2 to 37.9
Throttle is completely closed 30FF 37.9 to 40.5 37.9 to 40.5
40FF 45.7 to 48.3 45.7 to 48.3

• Values in the table are for the differential gear ratio of 5.285 and the tire radius of 0.366 (205/85R16).
• If the differential gear ratio or the radius of tire is different, the vehicle speed at shifting becomes slower or faster for the
ratio of the difference. Adjust the values in the table above.

23-54
 23
Inspection of automatic transmission fluid
• If the level of the automatic transmission fluid is low, the automatic transmission absorbs air with the automatic trans-
mission fluid from the pump. The automatic transmission fluid becomes spongy due to air bubbles, which may cause
slip of internal clutch due to a pressure drop.
• If the level of the automatic transmission fluid is too high due to excessive supply of the automatic transmission fluid,
rotating parts may generate air bubbles due to stirring. The same problem as the case of low automatic transmission
fluid level may occur.
• In both cases, air bubbles cause over-heating, oxidation of oil and generation of varnish that disturb normal operation
of valves and clutches.
• Furthermore, the automatic transmission fluid blows out of the vent hole or filler tube of the automatic transmission due
to foaming and it may be misunderstood as leakage of the automatic transmission fluid.
• In order to prevent these problems, check the level of automatic transmission fluid correctly with the following proce-
dures:
P Inspection of characteristics
1
If the automatic transmission fluid has a burnt odor and worn parti-
cles of metal or abrasive material, the automatic transmission needs
a complete overhaul. Be sure to check the automatic transmission
fluid on level gauge 1 carefully. If there is any concern about the sta-
HOT

tus of the automatic transmission fluid, take a sample and check it

again.
A P Inspection of automatic transmission fluid quantity
79598 • Drive the vehicle until the automatic transmission fluid is warmed suf-
ficiently (70 to 80°C).
• Park the vehicle on a level place.
• Apply the parking brake securely and put scotches on the wheels.
• In order to fill the oil circuit with the automatic transmission fluid while
the engine is idling, slowly shift the range selector lever on each
range from the P range to the L range in sequence, and then return
the lever to the P range.
• While the engine is idling, pull out level gauge 1. Wipe off the auto-
matic transmission fluid on the level gauge and insert the gauge. Pull
out the level gauge again and check the level of automatic transmis-
sion fluid.
• If the reading is within HOT area A of level gauge 1, the level is ap-
propriate.
CAUTION k
• Make sure to perform the quantity check of the automatic
transmission fluid at a level area.
• Make sure to perform the quantity check of the automatic
transmission fluid while the engine is idling and while the
range selector lever is at the N range. If the engine is stopped,
the apparent quantity of the automatic transmission fluid in-
creases than the actual level.
• Remove dirt completely on the upper area of the filler tube be-
fore removing level gauge 1.
• Since the fluid level is checked while the engine is running,
beware of injuries like being caught in or burned.
• Maintain the engine in idling until the level of the automatic
transmission fluid is adjusted completely. Do not increase the
engine revolution.
• If the level is different between the front and back of level
gauge 1, use the lower reading.
• If the quantity of the automatic transmission fluid is insufficient, refill
fluid from the filler tube to the specified position of the level gauge.

23-55
ON-VEHICLE INSPECTION AND ADJUSTMENT
Replacement of automatic transmission fluid
T Tightening torque Unit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks
1 Drain plug 27 {2.75} –

K Lubricant
Location Points of application Specified lubricant Quantity
Quantity of automatic Replacement by removal of oil pan DEXRON III type Approx. 4.5 dm3 {4.5L}
– transmission fluid to
be filled Replacement by removal of drain plug DEXRON III type Approx. 3.5 dm3 {3.5L}

P Drain
• Place the automatic transmission fluid tray under the transmission oil
pan. Remove drain plug 1 of the oil pan to drain automatic transmis-
sion fluid.

CAUTION k
• The automatic transmission fluid is hot immediately after the
engine is stopped. Since you may be burnt, wait until the au-
1 tomatic transmission fluid is cooled down to a safe tempera-
29843 ture.
• Warm-up of the engine and the automatic transmission fluid
allows faster drain.
• The automatic transmission fluid in the oil circuit, around the
converter and around the oil cooler cannot be drained.
• Check the drained fluid for contamination, metal powder or
metal particles.

• After drained, approximately 1 dm3 (1 L) of automatic transmission

fluid remains in the oil pan. To replace the remaining fluid, remove
the oil pan. L P23-74

P Filling
• Install oil pan drain plug 1.
• Pour the automatic transmission fluid for the amount drained through
filler tube A.

CAUTION k
Be sure to prevent entry of dirt or foreign matter.
• Shift the range selector lever to the P range. Start the engine and idle
A for at least 2 minutes.
29844
• After shifting to all ranges in sequence, return the range selector le-
ver to the P range.

CAUTION k
Keep the engine idling only. Never race the engine.

• Check the quantity of the automatic transmission fluid. L P23-55

23-56
 23
P Oil leakage
• Converter housing of automatic transmission
• Area to be checked for leakage
• Since leakage at or around the converter may be leakage of en-
gine oil, check this area carefully.
• Since the automatic transmission fluid is red, the difference is dis-
tinctive from the engine oil.
• Perform the following inspection before removing the automatic
transmission:
Check whether the leakage is from the converter or from the auto-
matic transmission (oil sealing of the oil pump housing or matching
area between the oil pump housing and the case).

23-57
REMOVAL AND INSTALLATION OF AUTOMATIC TRANSMISSION ASSEMBLY

79863

P Preparation
1 Put scotches on the wheels.
2 Remove the minus terminal of battery.
3 Put a garage jack at the center of the suspension cross member, and jack up the vehicle.
4 Support the suspension cross member and the lower arm mounting area with rigid racks.

WARNING k
• Since the parking brake is removed, it does not function. Put scotches on the wheels securely so that the
vehicle does not move.
• Do not remove the scotches until the work is completed.
• Since supporting the vehicle with only the garage jack is extremely dangerous, support the left/right sus-
pension cross member and the lower arm mounting area with rigid racks.
• Leave the rigid racks under the vehicle until the work is completed. Never remove them while the work is in
progress.
• Perform the work while the automatic transmission is in the N range.

P Work after removal/installation

Follow the preparation sequence in reverse.

23-58
 23
Preparation
P Disassembly sequence
1 Exhaust pipe B Gr15
2 Control cable L P23-70
2 3 Electrical harness
4 Propeller shaft L Gr25
1 5 Parking brake LGr36
3
6 Oil cooler hose L P23-64
7 Speed sensor harness

79864
CAUTION k
After removing propeller shaft 4, bind it to the frame tempo-
rarily with a rope at the same height as when installed.

P Assembly sequence

5 Follow the disassembly sequence in reverse.

CAUTION k
4 If considerable impurity is found in the automatic transmis-
sion fluid while replacing the automatic transmission assem-
30821 bly due to failure of the automatic transmission main unit,
flush the oil cooler circuit. L P23-64

29847

79865

23-59
REMOVAL AND INSTALLATION OF AUTOMATIC TRANSMISSION ASSEMBLY
Removal
P Removal sequence
1 Bolt
2 Bolt
3 Dust cover
*a 9
4 Bolt (8)
7 5 Bolt
5
8 6 Bolt
8 7 Bolt (4)
*c 7
8 Drive plate
*b 9 Automatic transmission assembly
1
4 3 *a: Torque converter
6 2 *b: Flywheel
c: Pilot section
*
79884

P Installation sequence
Follow the removal sequence in reverse.

CAUTIONk
Remove the automatic transmission assembly with drive plate 8 attached to torque converter a. *

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
Bolt (Automatic transmission assembly mounting and
1 47 {4.8} –
dust cover mounting)
2 Bolt (Dust cover mounting) 13 {1.3} –
4 Bolt (Flywheel and drive plate coupling) 32 {3.3} –
5 Bolt (Rear mounting) 83 to 105 {8.5 to 11} –
82 {8.4} M12
Bolt (Automatic transmission assembly mounting)
6 47 {4.8} M10
Bolt (Bracket mounting) 40 {4.1} –
7 Bolt (Drive plate mounting) 79 ± 12 {8.1 ± 1.2} –

K Lubricant
Location Points of application Specified lubricant Quantity

*c *
mission assembly
*
Pilot section c on torque converter a in automatic trans- Molybdenum disultide grease
[NLGI No.2 (Li soap)]
As required

23-60
 23
R Service procedure
9 Automatic transmission assembly
[Removal]
• Remove dust cover 3.

3
07934

• Turn the engine so that bolt 4 is positioned at service window A.

4 4 • Remove eight bolts 4. Remove two bolts at each of the four locations
*a by turning the engine and stopping at the proper position.

A 07936

• Support automatic transmission assembly 9 with a jack, then remove

6
9 5 automatic transmission assembly mounting bolts 5, 6.
• Remove automatic transmission assembly 9 by pulling towards the
back of the vehicle.

CAUTION k
• Do not support the automatic transmission by the oil pan,
since it causes shape deformation of the oil pan and oil pan
gasket.
• Since torque converter a can easily separate from the auto-
79885 *
matic transmission assembly, be careful not to drop the
torque converter.
• Mounting bolts 6 are different in length. Record the length of
each bolt when removing, so that bolts can be re-installed in
the original locations.

[Installation]
• Install drive plate 8 to torque converter a before installing the torque
*
converter into automatic transmission assembly 9.
Tighten bolts 7 to the specified torque.
8

9
07938

23-61
REMOVAL AND INSTALLATION OF AUTOMATIC TRANSMISSION ASSEMBLY
• Check to make sure that torque converter a is properly mounted in
40 mm or more
automatic transmission assembly 9.
*
8
*
b 9
When the torque converter is properly installed, the distance be-
tween the surface of drive plate 8 and the case mounting surface is
as indicated in the diagram.
*a • Apply grease on pilot sections c of flywheel b and torque convert-
* *
* c er a.
*

07939

• Turn flywheel b so that one of bolt holes B on the flywheel is located

*
at the lowest position. Bolt holes are used to connect drive plate 8 to
the flywheel.

*b
B 07940

• Turn drive plate 8 so that one of bolt holes B is located at the lowest
position.

8
B 07941

• Install automatic transmission assembly 9 into position slowly and

6 9 5 carefully while aligning pilot section c and the dowel pin of the rear
*
* a plate.
• Tighten several mounting bolts 6 on automatic transmission assem-
bly 9 for temporary holding. Tighten bolts 5 to the specified torque to
mount the automatic transmission assembly to the rear support.
*c
CAUTION k
• Torque converter a can easily separate from the automatic
*
79886 transmission assembly 9. To keep the torque converter in
place, set the back side of automatic transmission assembly
slightly lower than the front part.
• Before mounting the automatic transmission assembly 9,
wipe oil adhered on the internal wall of the torque converter
housing.

23-62
 23
• Align the bolt holes of drive plate 8 and flywheel b by looking
4 *
*
a 4 through service hole A, and mount bolts 4.
• Temporarily tighten all eight bolts, two bolts at each of the four loca-
tions, by turning the engine and stopping at the proper position.
Then, repeat the same process, and tighten the bolts to the specified
torque.

*b 8

A 07943

• Tighten all automatic transmission assembly mounting bolts 6 to the

3
specified torque.
• Tighten bolts 2 to the specified torque to secure dust cover 3 in
2
place.

07944

23-63
OIL COOLER

9
3
1

4
1
1

9
9

4
1
1
* 12
8
4
2 9

2
2
1
4
8
2
14

11
10

13

7
6

79862

23-64
 23
P Disassembly sequence
1 Hose clip 9 Bracket
2 Clip 10 Automatic transmission fluid thermostat switch L P23-80: Inspection of electric parts
3 Oil cooler hose assembly 11 Connector
4 Oil cooler hose 12 Automatic transmission fluid cooler fan motor L P23-80: Inspection of electric parts
5 Clamp 13 Oil cooler
6 Eye bolt 14 Bracket
7 Oil cooler tube
8 Oil cooler tube
*: Automatic transmission unit
P Work before assembly
LP23-65

P Assembly sequence
Follow the disassembly sequence in reverse.

CAUTIONk
Be sure to check the quantity of automatic transmission fluid after removing the fluid line. L P23-55

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
6 Eye bolt 71 to 106 {7.2 to 10.9} –
Automatic transmission fluid thermostat switch (for operation
10 29 to 39 {3.0 to 4.0} –
of automatic transmission fluid cooler fan motor)

K Sealant
Location Points of application Specified sealant Quantity
10 Thread of automatic transmission fluid thermostat switch THREEBOND TB1110B As required

R Service procedure
P Work before assembly
Flushing of oil cooler circuit
• If considerable impurity is found in the oil cooler circuit, flush the oil
cooler circuit.
• Remove oil cooler 13, oil cooler tubes 7 and 8, oil cooler hose as-
sembly 3 and oil cooler hose 4. Blow compressed air into the cir-
cuit for cleaning.

23-65
AUTOMATIC TRANSMISSION CONTROL
Range selector lever

12
11
8 13
10
9

6
20
5 7

17
15
4

16
1
14

19

18
77414

P Disassembly sequence
1 Shift lock release knob 13 Range selector cover
2 Screw 14 Screw
3 Range selector lever cover 15 Indicator panel
4 Connector 16 Bolt
5 Screw 17 Converter L P23-80: Inspection of electric parts
6 Cover 18 Shift lock actuator L P23-80: Inspection of electric parts
7 Screw 19 Reverse buzzer L P23-80: Inspection of electric parts
8 Switch button 20 Lever bracket assembly L P23-68
9 Overdrive OFF switch L P23-80: Inspection of electric parts
10 Pin
11 Spring
12 Automatic transmission knob

P Assembly sequence
Assemble in the reverse Disassembly sequence.

23-66
 23
T Tightening torque Unit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks
2 Screw (range selector lever cover mounting) 4 to 6 {0.4 to 0.6} –
5 Screw (cover mounting) 2 {0.2} –
7 Screw (range selector cover mounting) 2 {0.2} –
14 Screw (indicator panel mounting) 1 to 2 {0.1 to 0.2} –
16 Bolt (lever bracket mounting) 10 to 15 {1.0 to 1.5} –

K Lubricant
Location Points of application Specified lubricant Quantity
Multipurpose grease
11 Entire spring As required
[NLGI No.2 (Li soap)]
Multipurpose grease
12 Sliding area of shift button As required
[NLGI No.2 (Li soap)]

R Service procedure
4 Removal of connector
B Remove terminal B of overdrive OFF switch 9 in connector 4 with flat
9 head screwdriver A. Then remove the connector.

A
4
07625

8 9 Removal of switch button and overdrive OFF switch

• Remove switch button 8 from overdrive OFF switch 9 with flat head
8 screwdriver A.
9
• While pressing overdrive OFF switch 9, remove the switch from
9 range selector cover 13.

A
13

07626

12 10 Removal of pin
While automatic transmission knob 12 and spring 11 are depressed,
13
remove pin 10 inside range selector cover 13.

11 10

07627

23-67
AUTOMATIC TRANSMISSION CONTROL
Lever bracket assembly
4 P Removal sequence
1 Clamp
2 Cable bracket
3 Pin
5
4 Sleeve
5 Rod
6 Spring
7 Control cable L P23-70
8 Nut
6 9 Pipe
10 Bushing
11 Pin
12 Ball spring
15 13 Ball support
14 Steel ball
8 15 Range selector lever
10 14
13 16 Screw
12 17 P range switch L P23-80:
11
Inspection of electric parts
18 Plate
19 Clevis pin
10 20 Shift lock link
9 21 Shift lock link
22 Clevis pin
3
23 Shift lock link
19
24 Lever bracket
20 25 Bolt
7
19 26 Base plate
P Assembly sequence
Follow the disassembly sequence in re-
21 verse.
22
16
23

17

24
18
25

26

1
2 79879

23-68
 23
T Tightening torque Unit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks
8 Nut (range selector lever mounting) 10 to 14 {1.0 to 1.4} –
16 Screw (P range switch mounting) 0.2 to 0.3 {0.02 to 0.03} –
25 Bolt (base plate mounting) 10 to 15 {1.0 to 1.5} –

K Lubricant
Location Points of application Specified lubricant Quantity
Wheel bearing grease
4 Sliding area of sleeve As required
[NLGI No.2 (Li soap)]
Chassis grease
10 Inner surface of bushing As required
[NLGI No.1 (Li soap)]
Chassis grease
13 Sliding area of ball support As required
[NLGI No.1 (Li soap)]
Wheel bearing grease
15 Sliding area of range selector lever As required
[NLGI No.2 (Li soap)]
Chassis grease
19, 22 Sliding area of clevis pin As required
[NLGI No.1 (Li soap)]
Chassis grease
24 Sliding area between lever bracket and other parts As required
[NLGI No.1 (Li soap)]

R Service procedure
4 Installation of sleeve
Shift range selector lever 15 to the position of P range switch 17. Ro-
4 tate and install sleeve 4 so that the distance between the sleeve and
the edge of selector lever may be as shown in the figure.

15.2 to
15.9 mm
15

07629

17 Installation of P range switch

Install P range switch 17 so that it is turned OFF at the P range posi-
tion.

17

29877

23-69
AUTOMATIC TRANSMISSION CONTROL
Control cable

1
4
2 5
3
9

8
6

7 6 11
12
5

10

78493
P Disassembly sequence
1 Nut 8 Bushing
2 Nut 9 Lever
3 Control cable 10 Transmission control shift lever
4 Adjuster 11 Bracket
5 Bushing 12 Bracket
6 Spacer
7 Lever
*: Automatic transmission unit
P Assembly sequence
Follow the assembly sequence in reverse.

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1, 2 Nut (control cable mounting) 3.9 to 5.9 {0.4 to 0.6} –

K Lubricant
Location Points of application Specified lubricant Quantity
Chassis grease
8 Inside of bushing As required
[NLGI No.1 (Li soap)]

23-70
 23
R Service procedure
2 1 3 4 Control cable and adjuster
[Installation]
• Loosen nuts 1 and 2 to both edges of the thread as shown in the
figure.

3
4 07770

• Set interior range selector lever A and timing control shift lever 10
to the N range position.
A

10
78494

• Move interior range selector lever A forward and backward to

straighten control cable 3.

07772

• Make sure that interior range selector lever A is at the N position.

2 1 Tighten nuts 1 and 2 to the specified torque while the lever is
pressed slightly to the R range side.
A
CAUTION k
Do not move the position of adjuster 4 while tightening nuts
1 and 2.

3
4
07773

• Make sure that starter key B can be pulled out when interior range
A selector lever A is at the P range position.
B

30766

23-71
AUTOMATIC TRANSMISSION CONTROL
[Adjustment]
A Adjust the position of adjuster 4 with nuts 1 and 2 so that transmis-
sion control shift lever 10 may move smoothly from the L to the P
10 ranges when interior range selector lever A is shifted from the L to
the P range to the full travel.
2 1
CAUTION k
If adjuster 4 is misaligned, interior range selector lever A may
not be smoothly operated around the L or the P range, or the
3 4 starter key may not be pulled out at the P range.
07776

23-72
 23

MEMO

23-73
REPLACEMENT OF AUTOMATIC TRANSMISSION PARTS

21 18 19 20

23
26
*b
22

25
27
17 24 28
15 16

7 31
30

8
9
32 34
33

12 11
6
29 * a 5
14
4
10
13

3 2
1

77417

P Removal sequence
1 Drain plug 14 Inhibitor switch 27 Breather plug
2 Bolt 15 Nut 28 Rear oil seal
3 Oil pan 16 Nut 29 Torque converter
4 Oil cleaner magnet 17 Transmission control shift lever 30 Bolt
5 Bolt 18 O-ring 31 Speedometer sleeve lock plate
6 Oil strainer 19 Oil temperature switch 32 Speedometer driven gear
7 Bolt 20 O-ring 33 O-ring
8 O-ring 21 Elbow 34 Speedometer sleeve
9 Speed sensor 22 O-ring
10 Nut 23 Elbow a: Automatic transmission unit
11 Lock washer 24 O-ring
*b:
* Parking brake assembly
12 Gasket 25 Hose clip L: Gr36
13 Bolt 26 Hose X: Non-reusable parts

P Installation sequence
Follow the removal sequence in reverse.

23-74
 23
Service standards
Location Maintenance item Standard value Limit Remedy
9 Speed sensor resistance (at normal temperature) 560 to 680 Ω – Replace

Oil temperature switch activating OFF → ON 144 ± 4°C

19 – Replace
temperature ON → OFF Approximately 120°C

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Drain plug 27 {2.8} With magnets
2 Bolt (Oil pan mounting) 7 {0.7} –
5 Bolt (Strainer mounting) 10 {1.0} –
7 Bolt (Speed sensor mounting) 8 {0.8} –
10 Nut (Inhibitor switch mounting) 7 {0.7} –
13 Bolt (Inhibitor switch mounting) 12.5 {1.3} –
15, 16 Nut (Transmission control shift lever mounting) 12.5{1.3} –
19 Automatic transmission fluid temperature switch 24.5 {2.5} –
21, 23 Elbow 32 {3.3} –
30 Bolt (Speedometer sleeve lock plate mounting) 12.5 {1.3} –

K Lubricant and/or sealant

Location Parts of application Specified lubricant and/or sealant Quantity
– O-rings Automatic transmission fluid As required
Mounting surfaces of oil pan and automatic transmission
3 THREEBOND 1281B As required
unit
28 Lip section of oil seal Wheel bearing grease [NLGI No.2 (Li soap)] As required

J Special tools
Location Tool names and shapes Part No. Application

3 Oil pan remover MD998727 Removal of oil pan

29856

28 Oil seal installer MH063608 Installation of oil seal

29857

23-75
REPLACEMENT OF AUTOMATIC TRANSMISSION PARTS
R Service procedure
3 Oil pan
[Removal]
• Remove bolts 2.

CAUTION k
To prevent oil pan 3 from dropping when separating the
sealant from the oil pan, keep several bolts (not tightened)
mounted at intervals of three bolt holes.
3
2
29871 • Insert J oil pan remover at a corner of oil pan 3, and separate the
oil pan from the automatic transmission unit.
CAUTION k
• Be careful not to deform the shape of oil pan 3 when insert-
ing J oil pan remover.
• Do not tilt the oil pan during removal since the oil pan 3
contains oil.

[Installation]
3
• Remove the sealant from the mounting surfaces of the automatic
transmission unit and oil pan 3.
• Clean oil cleaner magnets 4, and mount them in the oil pan.
• Apply sealant on oil pan 3, and mount the oil pan on the automatic
transmission unit.
4 • Tighten bolts 2 to the specified torque.

CAUTION k
• Do not allow automatic transmission fluid on the contact
surfaces of oil pan 3 and the automatic transmission unit.
• Apply sealant continuously with a diameter of 2 or 3 mm,
as shown in the diagram.
• Install the oil pan within 10 minutes after the application of
the sealant.
• Tighten bolts 2 evenly by conducting the tightening opera-
tion for each bolt several times.

29872

14 Inhibitor switch
[Installation]
• Set control shaft A to the N position.
14
• Mount inhibitor switch 14 on control shaft A.
• Tighten two bolts 13.
• Tighten nut 10.

13 10 A 29860

23-76
 23
• Loosen two bolts 13, and position inhibitor switch 14 so that refer-
ence line B on the inhibitor switch aligns with groove C.
B • While holding inhibitor switch 14 with one hand, tighten two bolts
13 to the specified torque with the other hand.
14 • Bend the two lock tabs on the nut of inhibitor switch 14.

C
13
29861

[Inspection]
14
Check the electric conduction at wire connector D of inhibitor switch
14 using a tester.
< Connection chart >
B N C PL RL NL DL 2L LL

P p p p p

R p p

D 29862 N p p p p

D p p

2 p p

L p p

p p : Electric conduction between terminals

23-77
REPLACEMENT OF AUTOMATIC TRANSMISSION PARTS
28 28 Installation of oil seal

CAUTION k
After the oil seal 28 is removed, clean the surface of the exten-
sion housing of automatic transmission unit *a to which oil
seal is mounted.

• Apply grease on the lip section of oil seal 28.

• Use J oil seal installer to insert oil seal 28 all the way into the ex-
*a 29870 tension housing of automatic transmission unit *a.
CAUTION k
• Insert oil seal 28 evenly.
• Do not damage or deform the shape of oil seal 28.

29 29 Installation of torque converter

• Pour new automatic transmission fluid into torque converter 29
when the torque converter to be installed is new.
Automatic transmission fluid quantity : Approximately 2 dm3 {2 L}
• Apply automatic transmission fluid on front oil seal A, and mount
torque converter 29 on the oil pump.
B
CAUTION k
Be careful not to damage oil seal A when mounting torque
converter 29.

• Measure dimension B between the torque converter housing and

the set block of torque converter 29 to make sure that the torque
converter is inserted into the proper position.
Dimension B : 44 mm or more

A 29858

23-78
 23

MEMO

23-79
INSPECTION OF ELECTRIC PARTS
Inspection of power mode switch
• Check continuity as shown in the table below:
LED
(Night illumination)
PWR p p p p
ECO
p p Continuity between terminals
• If abnormality is found, replace the switch.
18622

Inspection of overdrive OFF switch

Free
• Check continuity as shown in the table below:
Lock
: BW : RW : BW : YW
: RW
Free p p
Lock p p

p p Continuity between terminals

• If abnormality is found, replace the switch.
: YW 37413

Inspection of P range switch

OFF
ON • Check continuity as shown in the table below:

ON p p
OFF p p

p p Continuity between terminals

• If abnormality is found, replace the switch.
07630

Inspection of automatic transmission fluid temperature switch

140 to 148 C • Place the automatic transmission fluid temperature switch in a con-
ON
OFF tainer containing rape oil. Change the oil temperature to check conti-
Approx. 120 C nuity of the switch (ON and OFF) within the specified temperature
range.
• If abnormality is found, replace the switch.

29869

Inspection of automatic transmission fluid thermostat switch (for

97 W 3-C operation of automatic transmission fluid fan motor)
ON
• Place the automatic transmission fluid thermostat switch in a contain-
OFF er containing rape oil. Change the oil temperature to check continuity
90-C or more
of the switch (ON and OFF) within the specified temperature range.
• If abnormality is found, replace the switch.
2 1

07806

23-80
 23
Inspection of relay (Normally open 4-pin)
• Check continuity and operation as shown in the table below:

Power supplied p p
p p
Power not supplied

p p Continuity between terminals

% * Terminal applied with DC24V
• If abnormality is found, replace the relay.

1
51227

Inspection of relay (Normally close 4-pin)

• Check continuity and operation as shown in the table below:

2
4 2 1 3 Power supplied p p
p p
4 Power not supplied
% *
1
p p Continuity between terminals
3 % * Terminal applied with DC24V
82759 • If abnormality is found, replace the relay.
Inspection of vehicle speed sensor 2
• Measure resistance between terminals a and b.
Standard value (at normal temperature) 560 to 680 Ω
2 1 • If the measurement is out of the standard value, replace the sensor.

38217

Inspection of automatic transmission temperature sensor

• Measure resistance between terminals a and e.
20°C Approx. 2.5 kΩ
Standard value 40°C Approx. 1.2 kΩ
(at normal tem-
perature) 60°C Approx. 0.6 kΩ
80°C Approx. 0.3 kΩ

• If the measurement is out of the standard value, or if the resistance

37422 does not change along with change of the oil temperature, replace
the sensor.

23-81
INSPECTION OF ELECTRIC PARTS
Inspection of automatic transmission fluid cooler fan motor
• Check if the automatic transmission fluid cooler fan motor operates
when battery voltage is applied between terminals a and b.
• If abnormality is found, replace the automatic transmission fluid cool-
er fan motor.

1 2

77411

4 Inspection of shift lock actuator

2 • Inspection the operation mode of shift lock actuator 1 with the power
3
1 source and switch status in he table below:
1 2
4 2: Brake switch
1 3 3: P range switch
4: Other load
L: Lock
UL: Unlock

Power source Switch status Operation mode

UL L 79597
Brake switch P range
IG a +B b Unlock UL Lock L
2 switch 3

p p p p p

p p p p
p p p p
p p p
p p p p
p p p
p p p
p p
IG: Starter switch ON power source
+B: Battery direct power source
• If abnormality is found, replace the shift lock actuator.

Inspection of solenoid valve

• Check resistance value between terminals.
Timing solenoid c– 50 ± 4 Ω
*
g– 50 ± 4 Ω
Standard value
Lock-up solenoid
*
Throttle solenoid b–f 5.3 Ω
(at 20°C)
Shift solenoid 1 d– 50 ± 4 Ω
*
h– 50 ± 4 Ω
Shift solenoid 2
*
37422
*: Automatic transmission case
• When the measurement value is out of the standard value, replace
the solenoid valve.

23-82
 23
Inspection of reverse buzzer
• Apply DC24V between terminals a and b and check if the buzzer
sounds.
• If abnormality is found, replace the buzzer.

07145

Inspection of converter
• When the voltage of 20 to 30 V is applied to terminal d with the volt-
age of 20 to 30 applied to terminal a or terminal c, check if voltage
of 10 w 2 V occurs at terminal b.
• If abnormality is found, replace the converter.

54538

23-83
PART MOUNTING POSITION

A15
A01 to 33 A05

A09
A01 A32 A07
A33

A17

A03

A04

A16

A28 A19 A24

A06
F29 F15 F1
F30 F16 F2
F31 F17 F3 A27
FUSE SPARE SPARE SPARE SPARE SPARE

F32 F18 F4
F33 F19 F5
F34 F20 F6 A25
F35 F21 F7 A18
F36
F37
F22
F23
F8
F9
A26
F38 F24 F10
F39 F25 F11 A20
F40 F26 F12 A29 A21 A02
PULLER

F41 F27 F13

F42 F28 F14
A22
A23

A30

79837

23-84
 23

A11
A07

A08

A12

A13

A01 Automatic transmission electronic control unit

A02 Accelerator position sensor
A03 Memory clear switch
A04 Diagnosis switch
A05 Power mode switch
A06 Fuse box A10
A07 Starter switch
A08 Key interlock solenoid
A09 Key interlock control unit A14
A10 Shift lock actuator
A11 Overdrive OFF switch
A12 P-range switch
A13 Converter
A14 Reverse buzzer
A15 Meter cluster
A16 Engine electronic control unit
A17 Multi-use tester-II connector
A18 Brake switch
A19 Relay box
A20 Diode<A/T1>
A21 Diode<A/T2>
A22 Diode<A/T3>
A23 Diode<A/T4>
A24 Diode<Starter>
A25 ATF cooler fan mortor relay
A26 Neutral start relay
A27 Stop lamp relay
A28 Back lamp relay
A29 Exhaust brake cut relay
A30 ABS relay
A31 -
A32 Pulse divider
A33 Connection of instrument panel harness and front chassis harness

A/T : Automatic transmission

ATF : Automatic transmission fluid
ABS : Anti-lock brake system
79838

23-85
PART MOUNTING POSITION

B01 to 10

B10
B05
B06

B08
B07

B03 B01

B02 B09

B04

B01 Terminal assembly

B02 Vehicle speed sensor 2
B03 Inhibitor switch
B04 ATF temperature switch
B05 Battery
B06 High current fuse box
B07 ATF thermostat switch
B08 ATF cooler fan mortor
B09 Vehicle speed sensor 1
B10 Connection of front chassis harness and rear chassis harness

ATF : Automatic transmission fluid

79839

23-86
 110
A07 A09
Electrical Starter switch Electrical
B A M F S Key interlock
A06 START control unit A10
Fuse box ON A08 Shift lock

KEY LOCK SOL+

ACC Key actuator

KEY LOCK SOL-

P-RANGE SW
(OFF) interlock
Electrical

STOP SW
LOCK solenoid
A02 A05

+24VB
3-RW
3-LW

3-BY
5-RL

GND
ACC
IG B

IG B
5-B
Accelerator To To tail A03 A04
Power mode switch
position sensor Gr13E cigarette lamp Memory Diagnosis
lighter relay clear switch switch

R
Y

B
L
F13

F17

F15

F16

F18

F19

F22

F31

F32
F6
PWR

F5
610 320 AN6A AM4A

BN1A

BS1A
ECO AP2A AN6A AN2A 2 3 1 6 5 4 2 1 3 4

94
Spare 1 1
AK8A 2 1 3 4 2 1 2

769
770
774
773
772
771

798
799
800
797
5

13

17

15

806

19

22

785

710

810
809
55
64
61
60
58
57

48
47
59
0.85-LR
AQ5A DD10A 7 8 1 6

5-RL 55

58
59
60
5-Y 218

770
769
2 5 1 4 3 1

0.85-R

WG
1.25-RY
733

815

783

747

722
786
789

790

YW

WY
GL
Y

0.85-YG

3-RW

LW

RG

YB

0.85-O

0.85-RL
0.85-RL
5-RL
0.85-LW
0.85-RL
3-BY
3-LW
0.85-RL

5-R

RG
BR

BR
YB

YB
3-RW

3-RW
3-LW

3-BY

Y
13

WG
BR
692
696
698
688
703

YG

GY
LG

LR
1.25-RY

B
B
GW
WL
BR

O
A01

P
Automatic transmission
electronic control unit

0.85-O 710
STARTER SW (M) 1
B 711
GND 2
BY 712
P RANGE 3
BG 713
N RANGE 4
CC12A

LY 714
L RANGE 6
YB 715
STARTER SW (M) 7
B 716
GND 8
RG 717
R RANGE 9
YG 718
D RANGE 10
YR 719
2 RANGE 11

L 452
EXH.BRK 1
GY 722
POWER MODE 5
LB 802
OVER DRIVE SW 6
CC16A

RB 78
BRK. SW 7
LG 783
DIAG SW 8
LW 725
ABS 11
GL 726
ATF TEMP SW 15

Lg 834
NE (+) 1
G 838
SP SENSOR 2 (+) 3
Y 826
SP SENSOR 1 (+) 4
Br 836
PWM 5
V 808
ATF (+) 6
YG 733
M CLEAR 7
P 734
DIAG LMP (WARNING) 9
BW 736
ST 11
RW 737
SOL2 12
CC26A

LG 738
SOL1 13
BL 842 SHIELD 840
SP SENSOR 2 (GND) 15
R 839
SP SENSOR 2 (-) 16
835

837

O 807
ATF (-) 20
GL 748
SIG 21
GY 451
EXH. BRK CUT 22
LR 745
SL (L/U DUTY SOL) 24
BY 787
SLT (-) 25
WY 788
SLT (+) 26
SHIELD

SHIELD

262
77

781
784
816
782

0.85-YG 171
0.85-LW 176
BR 693
BR 692

GW 698

450
452

829
831
828

830
832
827

806
777

780
778
777
776

765
768
767
766

451
445
446
449

178
YG 172
76
77
78

76
97

99
834
831

O 688

WL 696

P 703
GL 743
GR 449

836

743
812
811
813

5
100

WY

0.85-LR
0.85-O
0.85-O
B

3-RW
WB
WY

WB
WY
GR

RG

GR

RG

GR
GO
YG

GY
YG
YG
LW
RB

YR

3-RB
3-RL

RL
3-RL

RL

LB
Lg

LY
Br

W
G

G
LW

B
GL

2 1
3-B
B
B

4 8 3 8 6 11 13 10 13 17 6 AL2A
10 13 12 1 1 2 1 2 3 1 2 3 3 2 1 1 2 3 1 2 4 3 1 2 4 3 1 2 4 3 1 2 4 3 1 2 4 3 1 2 4
CC12B CC16A CC22A CC26A
G
G

CB16A PD3A PD3A PD3A PD3A AL2A AL4A AL4A AL4A AL4A AL4A AL4A
EXHAUST BRAKE CUT RELAY
SENSER SOURCE (+5V)-1

Multi-use
A16
ACCEL SENSOR-1 (SIG)
ACCEL SENSOR-2 (SIG)

PWM ACCEL OUT(SIG)

tester-ll Gr13E
IDLE UP CANCEL SW

Engine connector To V4
SENSOR GND-2
SENSOR GND-1

electronic A19 harness

A17 (A/T1) (A/T2) (A/T3) (A/T4) (Starter)
MUT-2 (K-Line)

Electrical
NE OUT (SIG)

control unit
ACCEL SW

ATF cooler Neutral start Stop lamp Back lamp Exhaust ABS relay Relay box
130 A20 A21 A22 A23 A24 fan motor relay relay relay relay brake cut relay
Brake A25 A26 A27 A28 A29 A30
Gr13E Diode
switch
A18
 Automatic transmission

B09 B01 Terminal assembly B02 B04

Electrical 401 A15 Meter cluster B03 ATF Back buzzer
Vehicle Vehicle
A12

temperature
solenoid
speed speed Inhibitor switch temperature

senor
ATF
P-range Electrical sensor 1 sensor 2 P
switch
A11 Intermittent

SLT
switch A14 R operation

solenoid
POWER SOURCE
A13 802

Lock up
Overdrive N circuit
Reverse

Solenoid 3

Solenoid 2

Solenoid 1
OFF switch Converter D
buzzer

25P OUT
8P OUT
OD 2
P R N D 2 L
P-SW NC

GND
OFF L 340
Bz Sound
+24VB

+ - - + gene-
IG B

ACT
RW
YW
BW

To back up ration
lamp RH
BC3A BB3A AL4A BB2A AU16A AU13A AU10A AU16A DG4A DG8A AR2D AA10A AA1A
3 1 3 1 2 1 3 2 4 1 2 7 4 6 1 2 8 9 6 5 4 2 1 1 3 2 4 2 6 5 1 3 8 4 7 1 2 8 9 7 6 5 4 3 2 1 1
AA3B
802
801

794
774
793

795
796
793
797

791
792

Electrical

756

286

726

734

735

762

763

761

760

759

758

757

256
255
257
258

128
129
127
126

100

101

102

103

106
107

116
112
114
113
104
117
115

122
3 1 2

99
94
YW
BW

BW
BR
YB

RL
LB

21
RW
WY

BW
RG

GR

RG
G

GY

BG

YG

GB

BG
YG
LW
B

GL

BY

YB

BY

GL

BY

LG

BY

YB

GL
LR

9
LB

YL
LY

LY
W
A33

G
R
P

RL
G

B
5-R 48 5-R 20

BM4A
1
5-Y 218 5-Y 18
3

19
3-B
3-B 805 3-B 93

AN6A
4
3-B 804 3-B 92
6

Electrical

19
1
6
BY 763 BY 112
14 130
BG 760 BG 113 Rear

3-B
RL
15

G
LY 757 LY 115 chassis
17
YB 785 YB 116 AA8A AW1A
18
0.85-LR 782 0.85-LR 121 4 7 1
RG 761
22
RG 114
B10 Front
B10

111
110
16

64
YG 759 YG 104 chassis
6
YR 758 YR 117

RL
19

3-B
AK22A (Black)

G
RL 767 RL 111
13
G 792 G 110
12
GO 781 GO 120
10
LR 745 LR 103
5
LG 738 LG 102
4
GR 780 GR 94
21
BW 736 BW 100
2
RW 737 RW 101
3
GL 755 GL 122
1
R 839 R 106
8
G 838 G 107
9
BL 841 BL 105 SHIELD 108
7

20

18
AK18A
LW 19 LW 5
4

5-R

5-Y
1 3
BM3A

120
125

121
124
FH11

FH1

FH3

GO

0.85-LR
0.85-B
B

92
93
21
3-B 100 3-B 21
BM2A

2
3-RB 776 3-RW 26 2 1 1 2
1

3-B
3-B
3-B
High current AA2A AB2A

26
fuse box

3-BR

60-BR
3-BR
3-RY

3-RY

60-BR
BY 787 BY 129
1

3-RW
B06

LW
WY 788 WY 128
DD6D

2
O 807 O 127
4
V 808 V 126 2 1 Electrical
5
AY2A AY1A S B ATF cooler 130
ATF fan motor
BY 442 BY 256 thermostat
5
AK6A

GL 17
4
GL 257 switch B08
YL 821 YL 258
3
Alternator
Starter relay
Starter B07
GL 824

Y 826
YL 821
BY 822

Battery
255

A33
B05
Front
W

2 6 7 8 Instrument
panel chassis
AK10A
VB

OUTPUT(25P)
SENSOR(SIG)
GND

Electrical
Electrical
To ABS To interlock To meter
To stop and hydraulic unit rear door cluster
tail lamp RH 401
Gr35E ABS Gr35E ABS
325 Electrical
Pulse divider
79836

A32

23-87
 25

GROUP 25 PROPELLER SHAFT

SPECIFICATIONS ................................................................................ 25-2

STRUCTURE AND OPERATION ........................................................ 25-2

TROUBLESHOOTING ......................................................................... 25-3

REMOVAL AND INSTALLATION OF PROPELLER SHAFT .............. 25-4

REAR PROPELLER SHAFT................................................................. 25-6

FRONT PROPELLER SHAFT ............................................................. 25-10

PROPELLER SHAFT BALANCING ADJUSTMENT ........................... 25-14

25-1
SPECIFICATIONS/STRUCTURE AND OPERATION
SPECIFICATIONS
Item Specifications
Propeller shaft Model P3
Pipe Outer diameter × wall thickness mm 82.6 × 2.3
Universal joint Spider outer diameter mm 21
Outer diameter mm 3
Needle bearing Length mm 15.3
Quantity 25
Sleeve yoke joint Spline diameter mm 36
Catalog No. 83A910CC3
Center bearing
Inner diameter × outer diameter mm 40 × 74

STRUCTURE AND OPERATION

Swing of Propeller Shaft
A: Lateral swing
B: Longitudinal swing
C: Fore-and-aft movement

The relative positions of the transmission, transfer, rear axle, and front
axle vary depending on the undulation of the road surface, and the vi-
bration and load carried when operating the vehicle.
The universal joint and the slip yoke joint are provided to absorb these
influences.

00815

Configuration of Propeller Shaft Connection

1 Transmission
6 7 5 2 Parking brake drum
3 Center bearing
4 Rear axle
5 Rear propeller shaft
6 Front propeller shaft (No.1)
1 2 3 4 7 Front propeller shaft (No.2)
78578

25-2
TROUBLESHOOTING 25
Symptoms Propeller Strange noise
shaft from propeller
vibrating shaft

Strange noise when starting or when cruising

Strange noise during normal running

Vibration at high speed

Vibration at low speed

Clanking noise
Possible causes

The flange yoke assembly direction is incorrect p

Excessive companion flange tightening torque p
Insufficient greasing p
Slip yoke joint
Excessive spline play p p
Excessive clearance in spider axial direction p p
Universal joint Insufficient greasing of needle bearing p
Worn needle bearing p p p
Insufficient greasing p
Seized, worn, or rotation faulty p p
Center bearing
Cushion rubber deteriorated or deformed p
Loose hanger mounting bolt p
Loose mounting bolt p p
Propeller shaft Bent p
Poor dynamic balance p
Transmission gear selection too high p

25-3
REMOVAL AND INSTALLATION OF PROPELLER SHAFT

7T
4T
8T

1T

9
5 6
T 2
T
3

79856

P Disassembly sequence
1 Nut 7 Nut
2 Nut 8 Nut
3 Rear propeller shaft L P25-6 9 Front propeller shaft (No. 1) L P25-10
4 Nut
5 Nut X: Non-reusable parts
6 Front propeller shaft (No. 2) L P25-10

P Assembly sequence
Follow the disassembly sequence in reverse.

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks

1 Nut (rear propeller shaft mounting) 100 to 120 {10 to 12} –

2, 5 Nut (propeller shaft mounting) 100 to 120 {10 to 12} –

4, 7 Nut (front propeller shaft mounting) 47 to 65 {4.8 to 6.6} –

8 Nut (front propeller shaft mounting) 100 to 120 {10 to 12} –

R Service procedure
3 6 9 Removal and installation of rear propeller shaft and
front propeller shaft
Be sure to make alignment marks A before removing the rear propeller
3 shaft 3 and the front propeller shaft 6, 9.
A

6, 9
A 71921

25-4
 25

MEMO

25-5
REAR PROPELLER SHAFT
PDisassembly sequence
1 Snap ring
2 Needle bearing
3 Flange yoke
4 Spider
5 Grease nipple
6 Retainer packing
7 Sealed packing
8 Grease nipple
9 Slip yoke joint
10 Rear propeller shaft

X: Non-reusable parts

71922

P Assembly sequence
Follow the disassembly sequence in reverse.

Repair kit: Universal joint spider kit

Service standards Unit: mm

Standard value
Location Maintenance item Limit Remedy
(Basic diameter In [ ])

1 to 4 Clearance of spider in axial direction 0 to 0.06 – Adjust

2, 4 Clearance between needle bearing and spider [21] 0.01 to 0.05 0.1 Replace

In rotation 0.01 to 0.09 0.3

direction Replace
9, 10 Spline play of slip yoke joint and
rear propeller shaft
In diameter 0.02 to 0.16 0.3
direction Replace

10 – 0.5 Repair or
Deflection of rear propeller shaft (center) replace

K Lubricant
Location Points of application Specified lubricant Quantity

Pack until
grease
5 Wheel bearing grease overflows
Supply via grease nipple [NLGI No. 2 (Li soap)] from needle
bearing oil
seal.

7 Wheel bearing grease

Sealed packing lip [NLGI No. 2 (Li soap)] As required

Pack until
grease
8 Supply via grease nipple Wheel bearing grease overflows
[NLGI No. 2 (Li soap)] from dust
plug

25-6
 25
0 Special tools Unit: mm
Location Tool name and shape Part No. Application

Universal joint tool set MB999024 Removal and

Installation of needle
A : Yoke assembly A : MB999025 bearing
B : Push rod B : MB999026
C : Guide C : MB999010
2

02823

R Service procedure
P Pre-disassembly inspection
Clearance in the spider axial direction
Press the needle bearing 2 downward firmly, and measure clearance
between snap ring 1 and needle bearing. If the measured value is high-
er than the standard value, adjust it by changing the thickness of the
snap ring.
(Available snap ring thicknesses and their combinations: The combina-
tions indicated by a solid line are preferred.)
Color Color
identifi- identifi-
71923 Part name Thickness cation Combination Thickness cation
mark mark

Snap ring 1.49 mm None 1.49 mm None

Snap ring 1.52 mm Black 1.52 mm Black

Snap ring 1.55 mm Blue 1.55 mm Blue

Snap ring 1.58 mm Yellow 1.58 mm Yellow

Snap ring 1.61 mm Purple 1.61 mm Purple

Snap ring 1.64 mm None 1.64 mm None

Snap ring 1.67 mm Black 1.67 mm Black

Snap ring 1.70 mm Blue 1.70 mm Blue

CAUTION k
For snap rings 1, as far as possible use rings of the same thick-
ness for both ends.

2 Needle bearing
[Removal]
• Put alignment marks on the needle bearing 2 and spider 4.
• Put alignment marks on the flange yoke 3, slip yoke joint 9 and rear
propeller shaft 10.
2
4 J:Universal joint tool set
9, 10
3 03207

25-7
REAR PROPELLER SHAFT
[Pressure-fitting]
J:Universal joint tool set

4
9, 10

03208

2 4 Clearance between needle bearing and spider

Measure the play in the diameter direction between the needle bearing
2 and the spider 4. If the measured value is higher than the limit, re-
2 place the defective part.

4 CAUTION k
Use the universal joint spider kit to make the replacement.

00231

6 7 Installation of retainer packing and sealed packing

• Apply grease to the inner periphery A of the sealed packing 7 and in-
stall as illustrated.
• Press retainer packing 6 onto slip yoke joint 9, and caulk the claw at
the eight points shown by B.

03135

8 Supplying grease via the grease nipple

Pack grease via the grease nipple 8 until the grease starts overflowing
from the dust plug A of the slip yoke joint 9.

03136

25-8
 25
9 10 Play between slip yoke joint and rear propeller shaft spline
• Measure the play A in the rotation direction between the slip yoke
joint 9 and the rear propeller shaft 10 at the spline ares. If the mea-
sured value in higher than the limit, replace the faulty parts.
• Measure the play B in the diameter direction between the slip yoke
joint 9 and the rear propeller shaft 10 at the spline area. If the mea-
sured value is higher than the limit, replace the faulty parts.

03138

10 Rear propeller shaft deflection

Measure the deflection on the rear propeller shaft 10 at the center. If the
measured value is higher than the limit, repair or replace the shaft.

CAUTION k
• To measure the deflection of the rear propeller shaft 10, turn it
one full revolution and read the dial gauge indicator. The deflec-
tion is one half of the indicated value.
03137 • When a press is used to make repairs, after the repair is com-
pleted check the welded areas for cracks.

25-9
FRONT PROPELLER SHAFT

12

8
9
14
10

13

1 10
2
9

6 15 11

7 5
4
8
15
3
P48629

P Disassembly sequence
1 Snap ring 7 Grease nipple 13 Cushion rubber
2 Needle bearing 8 Nut 14 Center bearing assembly
3 Flange yoke 9 Disc spring 15 Front propeller shaft
4 Snap ring 10 Companion flange
5 Needle bearing 11 Holder X: Non-reusable parts
6 Spider 12 Hanger

P Assembly sequence
Follow the disassembly sequence in reverse.

Repair kit: Universal joint spider kit

Service standards Unit: mm

Standard value
Location Maintenance item Limit Remedy
(Basic diameter In [ ])

– Clearance of spider in axial direction 0 to 0.06 – Adjust

2, 5, 6 Clearance between needle bearing and spider [21] 0.01 to 0.05 0.1 Replace

Repair or
15 Deflection of front propeller shaft (center) – 0.5
replace

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks

8 Nut (companion flange mounting) 290 to 390 {30 to 40} –

25-10
 25
K Lubricant
Location Points of application Specified lubricant Quantity

Pack until
Wheel bearing grease grease
7 Supply via grease nipple overflows
[NLGI No. 2 (Li soap)]
from spider
dust seal.

70 to 100%
Pack interior of center bearing assembly of capacity
14 Showa Shell Variant M3 (18 to 23 g)

Center bearing assembly seal lip area As required

0 Special tools Unit: mm

Location Tool name and shape Part No. Application

Universal joint tool set MB999024 Removal and

installation of needle
A : Yoke assembly A : MB999025 bearing
B : Push rod B : MB999026
2, 5 C : Guide C : MB999010

02823

R Service procedure
P Pre-disassembly inspection
2, 5
1, 4 Clearance in the spider axial direction
Press the needle bearing 2, 5 downward firmly, and measure clearance
between snap ring 1, 4 and needle bearing. If the measured value is
higher than the standard value, adjust it by changing the thickness of
the snap ring.
(Available snap ring thicknesses and their combinations: The combina-
tions indicated by a solid line are preferred.)
Color Color
identifi- identifi-
71923 Part name Thickness cation Combination Thickness cation
mark mark

Snap ring 1.49 mm None 1.49 mm None

Snap ring 1.52 mm Black 1.52 mm Black

Snap ring 1.55 mm Blue 1.55 mm Blue

Snap ring 1.58 mm Yellow 1.58 mm Yellow

Snap ring 1.61 mm Purple 1.61 mm Purple

Snap ring 1.64 mm None 1.64 mm None

Snap ring 1.67 mm Black 1.67 mm Black

Snap ring 1.70 mm Blue 1.70 mm Blue

CAUTION k
For snap rings 1, 4, as far as possible use rings of the same
thickness for both ends.

25-11
FRONT PROPELLER SHAFT
2 5 Needle bearing
[Removal]
• Put alignment marks on the needle bearing 2, 5 and spider 6.
• Put alignment marks on the flange yoke 3, and front propeller shaft
15.
2, 5
J:Universal joint tool set
6
15
3 03207

[Pressure-fitting]

J:Universal joint tool set

2, 5

6
15

03208

2 5 6 Clearance between needle bearing and spider

Measure the play in the diameter direction between the needle bearing
2, 5 and the spider 6. If the measured value is higher than the limit, re-
2, 5 place the defective part.

6 CAUTION k
Use the universal joint spider kit to make the replacement.

00231

9 9 Disc spring
Install the disc spring 9 with its convex side A facing nut.

A 02822

25-12
 25
11 13 Holder and cushion rubber
[Remover]
Make alignment marks A before removal.
13
B [Installation]
Install holder 11 and cushion rubber 13 aligning the alignment marks A.
The relative position to the front of the vehicle B is as illustrated.
A
11
B
03218

14 A 14 Center bearing assembly

• Inspect the center bearing assembly for leaking grease every 50,000
km or during the regular safety inspections. If a substantial grease
leak is found, pack grease into the housing A to 70 to 100% of capac-
ity (18 to 23 g).
• Apply grease to the seal lip B.

CAUTION k
B 02800 The bearing does not require greasing because it is sealed.

15 Front propeller shaft deflection

Measure the deflection of the front propeller shaft 15 at the center. If the
measured value is higher than the limit, repair or replace the shaft.

CAUTION k
• To measure the deflection of the front propeller shaft 15, turn it
15 one full revolution and read the dial gauge indicator. The deflec-
tion is one half of the indicated value.
02821 • When a press is used to make repairs, after the repair is com-
pleted check the welded areas for cracks.

25-13
PROPELLER SHAFT BALANCING ADJUSTMENT

(1) After correcting to the proper shaft deflection or replacing the flange yoke, universal joint, or related parts, measure
the balance of the completed propeller shaft assembly on a balancing machine and attach balance weights as re-
quired to correct the balance to within the permissible range.

(2) Use the polar coordinate method to correct dynamic balance.

(3) Permissible amount of imbalance for propeller shaft circumference

10 g or less/3,000 rpm (rear propeller shaft)
5 g or less/3,000 rpm (front propeller shaft)

(4) Correction procedure

• Balance weight attachment point

<Rear propeller shaft> A : Balance weight attachment point

B : Alignment marks

03240

<Front propeller shaft>

03239

25-14
 25
PAvailable balance weights
Part name Weight R

Balance weight 2g R31 mm

Balance weight 4g R31 mm

Balance weight 6g R31 mm

Balance weight 8g R31 mm

Balance weight 10 g R31 mm

Balance weight 12 g R31 mm

Balance weight 16 g R31 mm

Balance weight 24 g R33 mm

CAUTION k
• The maximum balance weight allowed for one point is 100 g.
• Use a combination that keeps the number of balance weights to
74274 a minimum.

25-15
 26

GROUP 26 FRONT AXLE

SPECIFICATIONS ................................................................................ 26-2

STRUCTURE AND OPERATION ........................................................ 26-2

ON-VEHICLE INSPECTION AND ADJUSTMENT

• Adjustment of Wheel Alignment ......................................................... 26-4
• Adjustment of Steering Angle ............................................................. 26-7
• Measurement of Side Slip .................................................................... 26-8

WHEEL HUB AND ROTOR, KNUCKLE .............................................. 26-10

26-1
SPECIFICATIONS/STRUCTURE AND OPERATION
SPECIFICATIONS
Item Specifications
Front axle Model F020Bi
Type Double wishbone independent suspension
Tread (reported specification dimensions) mm 1655

STRUCTURE AND OPERATION

1 Coil spring
2 Shock absorber
4 3 Suspension cross member
4 Upper arm
3 5 Knuckle
5 6 Lower arm
2 7 Leaf spring

1 The front axle is divided in two and the left

and right knuckles 5 to which the wheels are
attached are supported by the upper arm 4
and lower arm 7.

7
6

73990

26-2
 26
Wheel Hub and Rotor, Knuckle

4 5
3
2 8
7

1
6

6
6

19 7
8
18
10
9
17
10
12

13 11
16 15 14 11
4

73992

1 Hub bolt 11 Dust shield

2 Wheel hub 12 Oil seal
3 Disc rotor 13 Rotor
4 Knuckle 14 Inner bearing
5 Bracket 15 Bolt
6 Brake hose 16 Outer bearing
7 Eye bolt 17 Lock washer
8 Disc brake assembly 18 Hub cap
9 Brake pad wear indicator 19 Lock nut
10 Wheel speed sensor

26-3
ON-VEHICLE INSPECTION AND ADJUSTMENT
Adjustment of Wheel Alignment
Service standards Unit: mm
Location Maintenance item Standard value Limit Remedy
Toe-in (with tires on the ground) 0 to 6 – Adjust

Wheel Camber 0°30' – Adjust

–
alignment Caster 2°45' – Adjust
Kingpin inclination angle 12° – Replace

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
2 Lock nut (tie rod fastening) 120 to 150 {12 to 15} –
4 Nut (upper arm assembly installation) 180 to 240 {18 to 24} –

CAUTION k
• Be sure to measure the wheel alignment while the vehicle is
empty and level.
• Be sure that each part of the front axle has been serviced com-
pletely before adjusting the wheel alignment.

Before adjusting the wheel alignment, check for the following faults.
• Play in front wheel hub
• Play or looseness in the joint between the tie rod and the knuckle
• Play or looseness of the links between the upper and lower arms and
the knuckle.
• Looseness in any fasteners.
• Fatigued or damaged suspension cross members
• Incorrect tire pressure
• Defective steering related parts.

(1) Measurement and adjustment of toe-in

• Point the front wheels exactly forward.
• Put mark A on the left and right front tires at the height of the front
wheel axis and in the middle of the tire width.

00887

• Align the two points of the toe-in gauge B to the respective marks A
on the front tires. Measure the distance C between the marks at the
front of the vehicle.

00888

26-4
 26
• Rotate the tires 180° and measure the distance D between the marks
at the rear of the vehicle with the tires on the ground.
• Check if the difference between distances C and D is within the stan-
dard value.
Standard value: 0 to 6 mm

E: Front of the vehicle

06037

• If the measured value deviates from the standard value, with the tires
pointed forward, remove left and right clips 1, loosen lock nut 2, and
adjust the toe-in to the standard value by turning tie rod 3 with a
spanner wrench.
• After adjustment, tighten lock nut 2 to the specified torque.
Tightening torque: 120 to 150 N?m {12 to 15 kgf?m}

73993

(2) Measurement of camber

• Point the front wheels exactly forward.
• Remove the hub caps.
• Wipe off the grease from the knuckle end and attach camber/caster
kingpin gauge F to the knuckle.
• While keeping the bubble in level G centered, measure the camber
angle by reading the scale marker at the center of the bubble on
camber scale H. Follow this procedure to measure the camber an-
gles on the left and right sides.
00892 Standard value: 0° 30'

7 • When the camber deviates from the standard value, loosen the nut 4
5
and adjust the camber by adding to or reducing the camber shims 7
between the frame 5 and upper arm 6. There are 2 shim thicknesses,
1.2 mm and 2.3 mm.
• The standard shim thickness is 4.6 mm. Use 3 or fewer shims. 1 mm
4 of shim thickness changes the camber 0°10'. Increasing the shim
4 thickness reduces the camber.
• After adjustment, tighten the nut 4 to the specified torque.
Tightening torque: 180 to 240 N·m {18 to 24 kgf·m}
6 79601

26-5
ON-VEHICLE INSPECTION AND ADJUSTMENT
(3) Measure the caster and kingpin inclination angle
• Align turning radius gauges J. Prepare a platform K having the same
height as the turning radius gauges and place the platform under the
rear wheels so that the vehicle is kept level.
• Keep turning radius gauges J locked.
• Set the right and left front tires so that the center of the contact area
is in the center of the turn tables of the left and right turning radius
gauges J, then pull the parking brake lever.
L K
J 73985
CAUTION k
• If it is difficult to move the vehicle, jack it up and then set it on
the turning radius gauges J and platforms K as instructed
above.
• You must be sure to block the rear tires with chocks L before
jacking up the vehicle.

• Unlock turning radius gauge J and set the scale to 0°.

• As when measuring the camber as explained previously, attach cam-
ber/caster kingpin gauge F tightly to the front wheel hub and keep the
level bubble centered.
• Apply the brake to the front wheels and turn the steering wheel slow-
ly from the 0° point on the scale of turning radius gauge F until the di-
rection changes 20° to the left for the left front wheel and 20° to the
right for the right front wheel.

00894
CAUTION k
An accurate reading of the camber cannot be taken if the brake
is not applied to the front wheels because the tires might rotate
slightly.

• At the 20° point, align the bubbles in caster scale M and kingpin scale
N to 0° by turning the adjuster.

CAUTION k
Kingpin scale N has scales for the left and right, so use the left
scale when adjusting the left wheel, and use the right scale
when adjusting the right wheel.

• Turn the steering wheel slowly until the left front wheel changes its di-
rection 20° to the right or until the right front wheel changes its direc-
tion 20° to the left past the 0° point of the turning radius gauge F
scale. At this point read the scale marks at the center of the bubbles
on caster scale M and kingpin scale N. The scale marks indicate the
caster and kingpin inclination angles.
Standard values
Caster: 2°45'
Kingpin inclination angle: 12°

26-6
 26
Adjustment of Steering Angle
Service standards
Location Maintenance item Standard value Limit Remedy

Steering Inside 46° –

– Adjust
angle Outside 42° –

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
2 Lock nut (tie rod fastening) 120 to 150 {12 to 15} –

CAUTION k
Be sure wheel alignment adjustment is completed before ad-
justing the steering angle.

• Set the vehicle to the turning radius gauges and platform in the same
way as for caster and kingpin inclination angle measurement
(LP26-5).
• Turn the steering wheel to the left or right completely and form the
position where the turning radius gauge is aligned to 0°, adjust toe-in,
and in the same way remove left and right clips 1, loosen lock nut 2,
and then turn tie rod 3 with a spanner wrench, etc. At this time, turn
the right and left tie rods by the same amount.
• After adjustment, tighten lock nut 2 to the specified torque.
Standard value
Steering angle inside: 46°
Steering angle outside: 42°
73993 Tightening torque: 120 to 150 N?m {12 to 15 kgf?m}

26-7
ON-VEHICLE INSPECTION AND ADJUSTMENT
Measurement of Side Slip

CAUTION k
Be sure that wheel alignment adjustment is completed before
measuring the side slip.

• Point the front wheels exactly forward.

• While maintaining this position, slowly move the vehicle forward over
side slip tester A as slowly as possible.

CAUTION k
When measuring side slip, make sure the wheels point exactly
forward when the vehicle passes over side slip tester A. Do not
allow the wheels to veer to the side.
A 73986
• The side slip is indicated by side slip tester after the vehicle has
passed through the tester. Readjust the wheel alignment if slippage
is 3 mm or more per meter.

26-8
 26

MEMO

26-9
WHEEL HUB AND ROTOR, KNUCKLE

2
10

1 8 *b
14 17
9
13

18

3
5
4 19

6 *d
9 9
7
17
40
34
12 38 36
11
35
24
18 23
19
16
* a
37
22
21
15

39

*c

20
25
32
26
27
28

31

33 30
29
79878

26-10
 26
P Disassembly sequence
1 Brake pipe 24 Wheel hub and rotor assembly
2 Clip 25 Rotor
3 Bolt 26 Oil seal
4 Bolt 27 Inner bearing inner race
5 Clip 28 Inner bearing outer race
6 Bolt 29 Outer bearing outer race
7 Wheel speed sensor 30 Bolt
8 Bolt 31 Disc rotor
9 Eye bolt L Gr 35A
10 Brake hose 32 Hub bolt
11 Clip 33 Wheel hub
12 Brake hose 34 Spacer
13 Bolt 35 Bolt
14 Bracket 36 Dust shield
15 Bolt 37 Nut
16 Dust cover 38 Nut
17 Bolt 39 Nut
18 Bolt 40 Knuckle
19 Disc brake assembly
L Gr 35A
*a: Tie rod L Gr 37
20 Hub cap *b: Upper arm L Gr 33
21 Lock nut c: Lower arm L Gr 33
*d:
22 Lock washer
* Wear indicator harness L Gr 35A
23 Outer bearing inner race X: Non-reusable parts

CAUTIONk
• Be sure to keep dust, etc., out of the removed brake hoses 10 and 12 by putting plugs in their ends after re-
moval.
• Do not remove rotor 25 except for replacement.
• Do not disassemble disc rotor 31 or wheel hub 33 except when replacing them.

P Assembly sequence
Follow the disassembly sequence in reverse.

CAUTIONk
• When wheel hub and rotor assembly 24 is assembled to knuckle 40, do not damage oil seal 26 and rotor 25
press-fit at the end of wheel hub 33. If the rotor has an impact mark or its teeth are chipped, the signal of
wheel speed sensor 7 is abnormal, resulting in failure of assembly.
• After assembly, air in the brake system is relieved. L Gr 35A

26-11
WHEEL HUB AND ROTOR, KNUCKLE
Service standards
Location Maintenance item Standard value Limit Remedy
Tangential
force at
the hub
– Wheel hub bearing starting torque 1 to 3.5 N?m {0.10 to 0.35 kgf?m} –
bolt 8.8 to
28.4 N {0.9
to 2.9 kgf}

T Tightening torque Unit: N?m {kgf?m)

Location Parts to be tightened Tightening torque Remarks
3 Bolt (clip fastening) 12 ± 2.5 {1.25 ± 0.25} –
4 Bolt (clip fastening) 21.1 ± 4.4 {2.15 ± 0.45} –
6 Bolt (brake hose fastening) 11.3 ± 2.5 {1.15 ± 0.25} –
8 Bolt (brake hose fastening) 11.3 ± 2.5 {1.15 ± 0.25} –
9 Eye bolt (brake hose fastening) 22.1 ± 2.5 {2.25± 0.25} –
13 Bolt (bracket fastening) 21.1 ± 4.4 {2.15 ± 0.45} –
15 Bolt (dust cover fastening) 4.5 ± 1 {0.45 ± 0.1} –
17 Bolt (disc brake assembly fastening) 152 ± 25 {15.5 ± 2.5} –
18 Bolt (disc brake assembly fastening) 118 ± 19 {12.0 ± 2.0} –

Screw out approx. 45° Primary fastening 113 ± 15 {11.5 ± 1.5} –

21 (1/8 turn) after Secondary tightening
fastening the lock nut 59 {6} –
after slacking off
30 Bolt (disc rotor and wheel hub fastening) 85.8 ± 12 {8.75 ± 1.25} –
35 Bolt (dust shield fastening) 21.1 ± 4.4 {2.15 ± 0.45} –
37 Nut (tie rod fastening) 70 to 120 {7 to 12} –
38 Nut (upper arm fastening) 120 to 180 {12 to 18} –
39 Nut (lower arm fastening) 260 to 340 {26 to 34} –

K Lubricant
Location Points of application Specified lubricant Quantity
Wheel bearing grease
20 Hub cap 65 ± 10 g
[NLGI No.2 (Li soap)]
Pack the space between the rollers of the outer and Wheel bearing grease
23, 27 As required
inner bearing inner races. [NLGI No.2 (Li soap)]
Wheel bearing grease
26 Oil seal lip As required
[NLGI No.2 (Li soap)]
Wheel bearing grease
33 Pack interior space of wheel hub 210 ± 20 g
[NLGI No.2 (Li soap)]

26-12
 26
J Special tools Unit : mm
Location Tool name and shape Part No. Application
Hub cap wrench MB999108 Removal of hub cap

20

06046

Oil seal installer MB999097 Press-fitting of oil seal

(T90ST30) (Used in combination)

05619
24
Bearing installer MB999099
(T90ST26)

05621

Bearing installer MB999100 Press-fitting of inner and

(T90ST31) outer bearing outer races
(Used in combination)

05668
28, 29
Bearing installer MB999099
(T90ST26)

05621

Steering linkage puller MH990635 Tie rod removal

*a

05495

Ball joint puller MH062470 Upper and lower ball joint

removal

*b
*c
06714

26-13
WHEEL HUB AND ROTOR, KNUCKLE
R Service procedure
P Work after assembly
Wheel hub bearing starting torque
[Adjustment]
21 23 29 28 27
• Tighten lock nut 21 at the specified torque (primary tightening) while
24 turning wheel hub and rotor assembly 24, then slacken off.
• Turn wheel hub and rotor assembly 24 several times to smooth oper-
ation of outer bearings 23 and 29 and inner bearings 27 and 28, and
then retighten lock nut 21 at the specified torque (secondary tighten).
• Slacken off lock nut 21 by approximately 45° (1/8 turn) and fasten it
with a split pin. If the split pin and split hole do not align, slacken off
the lock nut slightly, making sure that there is no play in the axial di-
06049 rection.

[Measurement]
• Fasten spring balance A to hub bolt 32 and measure the tangential
32 force.
If the measured tangential force is the standard value, the starting
A torque conforms to the standard value. If the measured value is not
the standard value, adjust the starting torque of the wheel hub bear-
ing according to the procedure described above.
If the results show there is a fault, replace the outer and inner bear-
ings.
06050
CAUTION k
• Make sure the starting torque does not exceed the tangential
force.
• If the tangential force does not conform to the standard value,
readjust the starting torque.
• Make sure oil seal 26 is installed.
• Take the measurement with the disc brake assembly 19 re-
moved.

A 10 Brake hose removal and installation

First remove brake hose 10 from bracket A (on the frame), then remove
10 the brake hose from the disc brake B. For installation, follow this proce-
dure in reverse.
B

74553

26-14
 26
19 Installing the disc brake assembly’s brake pad wear indicator
harness
Tape the disc brake assembly 19 brake pad wear indicator harness d
*
from the wheel brake to the frame in the order illustrated in the diagram
A
5 and then fasten the harness with clip 5.
5
19
A: Frame
*d
73996

20 Hub cap removal

J: Hub cap wrench

20 06058

21 21 Lock nut removal and installation

LP26-14

06059

23 27 Packing grease in outer bearing inner race and inner bear-

ing inner race
A 23, 27
B Insert grease pump nozzle B in the space A between the rollers of out-
er bearing inner race 23 and inner bearing inner race 27 and sufficiently
pack with grease.
Apply grease to the roller outer surface of outer bearing inner race 23.

01000

26-15
WHEEL HUB AND ROTOR, KNUCKLE
25 Rotor
[Inspection]
25
Check for chipped teeth or deformed tooth A on rotor 25.

07679

C [Disassembly]

B: Steel plate
B
C: Gear puller

24

09934

[Installation]
D When rotor 25 is installed on hub and rotor assembly 24, heat the rotor
to approx. 150°C and assemble the rotor and the hub and rotor assem-
25 bly evenly with pipe D so that there may be no inclination.

24

06061

26 Oil seal installation

Apply grease to the lip A of oil seal 26 and install the seal.
26
a: Oil seal installer
b: Bearing installer
A

06062

28 Inner bearing outer race

[Removal]
A Use pin-punch A and drive out inner bearing outer race 28 evenly from
the three indented parts B in wheel hub 33.

28 33 06063

26-16
 26
[Installation]

a: Bearing installer
29 b: Bearing installer

33 06064

29 Outer bearing outer race

[Removal]
A Use pin-punch A and drive out outer bearing outer race 29 evenly from
the three indented parts B in the wheel hub 33.
33

29

06065

[Installation]

a: Bearing installer
b: Bearing installer
29

33
06066

32 32 Hub bolt installation

Hub bolt 32 is marked with “L” (left) or “R” (right) to indicate the side it is
to be installed on. Check this symbol before installing the bolt.

05490

40 Knuckle removal
*a 37
• Tie rod
*a area
J: Steering linkage puller

40

05503

26-17
WHEEL HUB AND ROTOR, KNUCKLE
• Upper arm *b area
*b
J: Ball joint puller

40

71579

• Lower arm c area

*
*c
J: Ball joint puller
40

71580

26-18
 27

GROUP 27 REAR AXLE

SPECIFICATIONS ................................................................................ 27-2

STRUCTURE AND OPERATION ........................................................ 27-3

TROUBLESHOOTING ......................................................................... 27-6

WHEEL HUB AND BRAKE DRUM ...................................................... 27-8

AXLE HOUSING .................................................................................. 27-18

REDUCTION AND DIFFERENTIAL ASSEMBLY................................. 27-22

27-1
SPECIFICATIONS
Item Specification
Rear axle Type Full floating shaft tube type
Model D033H
Type Single-reduction gear

Reduction Tooth shape Hypoid gear

4.111
Speed reduction ratio 5.285
5.714
Differential Tooth shape Straight bevel gear
Grade Gear oil API GL-5 SAE90
Gear oil
Oil quantity dm3 {L} 4.5 {4.5}

* Mass (reference) Kg Approx. 180 to 220

*: Mass depends on the vehicle model.

27-2
STRUCTURE AND OPERATION 27
Wheel hub & Brake drum
1 Inner oil seal
2 3 4 5 6 7 2 Spring spacer
3 Sensor holder
4 Wheel speed sensor
5 Inner bearing
6 Wheel hub
1 7 Hub bolt
8 Lock bolt
9 Rear axle shaft
8 10 Outer oil seal
11 Lock washer
12 Lock nut
9
13 Outer bearing
14 Axle housing
15 Rotor
10 16 Brake drum
17 Brake assembly

13 12 11

17 16 15 14
79581

27-3
STRUCTURE AND OPERATION
Reduction and Differential

1 2 3
25 4

24
5
23

6
22
21
7
20
8
19

18 9

10
17

16
11

15

12
14
13

79615

1 Companion flange 14 Differential case LH

2 Lock nut 15 Bearing cap
3 Dust cover 16 Lock plate
4 Oil seal 17 Adjust screw
5 Front bearing 18 Side bearing
6 Collar 19 Differential pinion
7 Rear bearing 20 Differential pinion washer
8 Pinion pilot bearing 21 Pinion spider
9 Lock ring 22 Differential carrier
10 Side gear 23 Reduction pinion
11 Side gear washer 24 Shim
12 Differential case RH 25 Bearing retainer
13 Reduction gear

27-4
 27

MEMO

27-5
TROUBLESHOOTING
Failure Condition Power transmission is faulty.

Oil leaks from the differential carrier and axle housing.

Abnormal noise when starting out and when shifting gear

The propeller shaft turns but the vehicle does not move.

Oil leaks from the companion flange assembly.

Abnormal noise when driving around curves.
Continuous abnormal noise while driving.

Tires drag when driving around curves.

Irregular abnormal noise while driving.
Remarks

Oil leaks from the axle shaft.

Likely Causes
The wheel hub bearing has seized up, is worn
p
or turns poorly.
The wheel hub bearing is damaged. p
The axle shaft mounting bolt is loose. p p
The axle shaft is broken. p
Wheel hub, axle The axle shaft is separated from the side gear
p
shaft, axle hous- spline.
ing The axle shaft and side gear spline backlash
p
is excessive.
The oil seal is defective. p
The axle housing is bent. p
The inspection plug or drain plug is loose. p
The air breather or vent plug is clogged. p p
Too much gear oil has been poured in. p
There is insufficient gear oil. p p
The oil seal is defective. p
The seal material is defective. p
The reduction & differential assembly mount-
p p
ing nuts and bolts are loose.
The differential carrier is cracked or damaged. p
The bearing cap mounting bolt is loose. p
The side bearing is seized up, worn or turns
p p
Reduction & poorly.
Differential Gears The side bearing is damaged. p
The side bearing pre-load adjustment is faulty. p
The reduction pinion or reduction gear is bro-
p p p p
ken down.
The reduction pinion or reduction gear is worn. p p
The reduction pinion or reduction gear is dam-
p
aged.
The reduction gear backlash is excessive. p
The reduction gear backlash or tooth contact
p
adjustment is faulty.

27-6
 27
Failure Condition Power transmission is faulty.

Oil leaks from the differential carrier and axle housing.

Abnormal noise when starting out and when shifting gear

The propeller shaft turns but the vehicle does not move.

Oil leaks from the companion flange assembly.

Abnormal noise when driving around curves.
Continuous abnormal noise while driving.

Tires drag when driving around curves.

Irregular abnormal noise while driving.
Remarks

Oil leaks from the axle shaft.

Likely Causes
The pinion bearing starting torque is faulty. p p
The lock nut is loose p p
The front and rear bearing are seized up. p
The front and rear bearing are worn. p
The front and rear bearing are damaged. p
The pinion pilot bearing is worn. p
The pinion pilot bearing is seized up or dam-
p
aged.
Reduction & The pinion shaft or pinion spider is damaged. p
Differential Gears
The reduction gear and differential case
p p
mounting bolts and nuts are loose.
The side gear backlash is excessive. p
The side gear or differential pinion is dam-
p p p p
aged.
The side gear or differential pinion is seized
p p
up.
The side gear or differential pinion is worn. p p
The side gear washer is worn or damaged. p p p

27-7
WHEEL HUB AND BRAKE DRUM

* 1

21
22
20

23

24
8
7
10
11 5
12
15
16 3

6
2
4
19
14

18

17

13 79849

P Disassembly sequence
1 Brake pipe 15 Rotor
2 Bolt 16 Nut
3 Rear axle shaft 17 Brake drum L Gr35A
4 Outer oil seal 18 Hub bolt
5 Bolt 19 Wheel hub
6 Lock washer 20 Sensor holder
7 Lock nut 21 Wheel speed sensor L Gr35E
8 Outer bearing inner race 22 Spring spacer
9 Wheel hub and brake drum assembly 23 Nut
10 Inner oil seal 24 Brake assembly L Gr35A
11 Inner bearing inner race : Axle housing L P27-18
*
12 Inner bearing outer race X: Non-reusable parts
13 Outer bearing outer race
14 Bolt

CAUTION k
• Be sure to plug the ends of the removed brake pipe 1 to prevent dust, etc., from getting into the pipe.
• Do not disassemble the brake drum 17 and wheel hub 19 except when replacing them.

27-8
 27
P Assembly sequence
Follow the disassembly sequence in reverse.

CAUTION k
• When installing the wheel hub and brake drum assembly 9 into the axle housing , do not damage the inner oil
seal 10, press-fitted into the top of wheel hub 19.
*
• After assembly, bleed the air from the brake system. L Gr35A

Service standards Unit: mm

Location Maintenance item Standard value Limit Remedy
Tangential
force at hub
2 to 3.9 N?m
– Starting torque of wheel hub bearing – bolt 18 to 35
{0.2 to 0.4 kgf?m} N {1.8 to 3.6
kgf}

Rear axle Deflection of shaft center 1 or less 2

3 Replace
shaft Deflection of flange face 0.03 or less 0.05

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
2 Bolt (rear axle shaft installation) 98 to 115 {10 to 12} –
5 Bolt (lock washer installation) 4.9 ± 1 {0.5 ± 0.1} –

Lock nut (wheel bearing Primary tightening 98 to 125 {10. to 13} –

7 installation: wheel bearing Secondary
pre-load adjustment) 29 to 39 {3 to 4} –
tightening
16 Nut (wheel hub and brake drum tightening) 345 ± 39 {35 ± 4}| –
23 Nut (brake assembly installation) 98 to 135 {10 to 14} –

K Lubricant
Location Points of application Specified lubricant Quantity
Wheel bearing grease
4, 10 Oil seal lip As required
[NLGI No. 2 (Li soap)]
Wheel bearing grease
7 Lock nut threads As required
[NLGI No. 2 (Li soap)]
Pack the space between the rollers of the outer and Wheel bearing grease
8, 11 As required
inner bearing inner races [NLGI No. 2 (Li soap)]
Wheel bearing grease
19 Pack interior space of wheel hub 370 ± 37 g
[NLGI No. 2 (Li soap)]

27-9
WHEEL HUB AND BRAKE DRUM
0 Special tools Unit : mm

Location Tool name and shape Part No. Application

Lock nut removal

7 Lock nut adjustment tool MB999150
and installation

05617

Hub puller
MB999070
components Wheel hub and
9 A : Hub puller body A : MB999071 brake drum assembly
B : MB999072 removal
B : Bolt
C : MB999073
C : Attachment

05618

MB999097
Oil seal installer
(T90ST30)

05619
Press-fitting of inner
10 oil seal (used in
combination)

Oil seal installer MH062607

06596

MB999097
OIl seal installer
(T90ST30)

Press-fitting of inner
05619
12 bearing outer race
(used in combination)

MB999098
Bearing installer
(T90ST05)

05621

27-10
 27
Location Tool name and shape Part No. Application

MB999097
Oil seal installer
(T90ST30)

Press-fitting of inner
05619
13 bearing outer race
(used in combination)

MB999098
Bearing installer
(T90ST05)

05621

R Service procedure
P Work after assembly
Starting torque of wheel hub bearing
[Adjustment]
• Tighten the lock nut 7 with the specified torque while turning wheel
hub and brake drum assembly 9 and then slacken off.
• Next, rotate the wheel hub and brake drum assembly 9 several turns
to smooth operation of outer bearings 8 and 13 and inner bearings
11 and 12 and then retighten lock nut 7 with the specified torque us-
ing J lock nut adjustment tool.
71435
• After adjustment, make sure there is no play in the axial direction.

• Insert lock washer 6 so that the flat area A fits onto the notch B of
spindle. Install two bolts 5 diagonally to lock nut 7 and then tighten
them with the specified torque.
• If lock nut 7 and the screw hole of lock washer 6 do not align, turn the
lock nut to slackening direction slightly to align them.

71436

27-11
WHEEL HUB AND BRAKE DRUM
[Measurement]
• Measure tangential force at the hub bolt 18 using a spring balance C.
When the measured tangential force conforms to the prescribed val-
ue, the staring torque conforms to the standard value.
When the measured value deviates from the prescribed value, adjust
C the starting torque of the wheel hub bearing according to the proce-
18 dure described above. If any fault is fund during adjustment, replace
outer bearings 8 and 13 and inner bearings 11 and 12.

71437 CAUTION k
• Make sure that the starting torque doe not exceed the upper lim-
it of the tangential force.
• If the tangential force is not the specified value, adjust the start-
ing torque again.
• Check after confirming that there is no drag on the brake lining
and brake drum 17.
• Inner oil seal 10 must be installed.
• Do not install outer oil seal 4 and real axle shaft 3.

3 Rear axle shaft

[Removal]
Screw-in the two installation bolts 2 of rear axle shaft 3 evenly to the two
screw holes A of the flange provided for disassembly. Then remove the
rear axle shaft.

06612

[Inspection]
• Deflection B of the shaft center
Measure the deflection at the center of rear axle shaft 3. If the mea-
sured value deviates from the limit, replace the rear axle shaft.
• Deflection of flange face C
If the measured value deviates from the standard value, replace rear
axle shaft 3.

NOTE
06613 To measure the deflection of rear axle shaft 3, turn it one full
revolution and read the dial gauge indicator. The deflection is
one half of the indicated value.

[Installation]
• Knock pin hole E of real axle shaft 3 in the second hole clockwise
from disassembly screw hole A.
• To install rear axle shaft 3, align knock pin D with knock pin hole E.

NOTE
• Lock pin hole E is not necessarily the hole on the protrusion of
the rear axle shaft 3 flange face as shown in the left illustration.
71438 The second hole counted clockwise from screw hole for disas-
sembly A is the knock pin hole E.

27-12
 27
4 Outer oil seal
[Removal]
To remove outer oil seal 4, use a pair of pliers and uniformly pull protru-
sion A of the outer oil seal circumference.

71439

[Installation]
Apply grease to lip area B of outer oil seal 4 and press-fit by hand with
the direction illustrated.

71440

7 Lock nut removal and installation

When installing lock nut 7 see LP27-11: Adjustment procedure for the
starting torque of the wheel hub bearing.

J: Lock nut adjustment tool

71441

8 11 Packing grease in the outer bearing inner race and inner

bearing inner race
Insert grease pump nozzle B into space A between the rollers of outer
bearing inner race 8 and inner bearing inner race 11 to pack grease.

01000

9 Wheel hub and brake drum assembly

[Removal]
• Remove wheel hub and brake drum assembly 9 using installation
bolt 2 of rear axle shaft 3.

CAUTION k
Be sure to pull the assembly straight out to prevent damage to
inner oil seal 10.

71442

27-13
WHEEL HUB AND BRAKE DRUM
D • If brake drum 17 has stepped wear A and wheel hub and brake drum
C assembly 9 cannot be removed, remove the cover of the backing
E plate and lift lever C with wire B of approx. φ2 mm. Turn adjuster D
B opposite to the arrow of the backing plate and expand the clearance
17
between the brake drum and brake shoe assembly E for removal.
• Correct brake drum 17 if any faults are found. L Gr 35A

[Installation]
After installing wheel hub and brake drum assembly 9, adjust the clear-
A
06630 ance between brake drum 17 and brake shoe assembly E. L Gr 35A

10 Installation of inner oil seal

A
[J oil seal installer installation]
Install bolt A (M10 × 1.25) into the J oil seal installer, set it into wheel
19 hub 19 to remove bolt A.

79867

Install inner oil seal 10 so that it is flush with the edge of wheel hub 19.

a: Oil seal installer

b: Oil seal installer
19

10
06723

12 Inner bearing outer race

[Removal]
Use punch bar A and drive out inner bearing outer race 12 uniformly
A from the three cut out sections B in wheel hub 19.

12 19

71915

[Press-fitting]

a: Oil seal installer

b: Bearing installer
12

19
71916

27-14
 27
13 Outer bearing outer race
[Removal]
Use pin- punch A and drive out outer bearing outer race 13 uniformly
A from the three cut out sections B in wheel hub 19.

13 19
71917

[Press-fitting]

a: Oil seal installer

b: Bearing installer
13
19

71918

16 Installation of nut
Tighten nut 16 at the specified torque and then caulk the nut to keep it
from turning.

16
06626

18 Installation of hub bolt

Hub bolt 18 is marked with “L” (left) or “R” (right) to indicate the side it is
to be installed on. Check this symbol before installing the bolt.

18

06098

27-15
WHEEL HUB AND BRAKE DRUM
21 21 22 Wheel speed sensor and spring spacer
A [Disassembly]
Press a flat plate at edge A of wheel speed sensor 21 to remove the
22 sensor from sensor holder 20.

20 CAUTION k
• If wheel speed sensor 21 is pinched with a prier, it may be dam-
aged. Do not pinch it.
79454 • When wheel speed sensor 21 is removed, applying force to the
wheel speed sensor such as “hitting” with a hammer, “prying”
with a screwdriver or “pulling” a harness may result in a cause
of disconnection. Never apply force.
• If wheel speed sensor 21 is smoothly removed, replace spring
spacer 22.

[Installation]
B • Insert spring spacer 22 into sensor holder 20 and push the spacer
20
until it hits stopper B.
22 • Insert wheel speed sensor 21.

22 CAUTION k
20 When wheel speed sensor 21 is removed, applying force to the
wheel speed sensor such as “hitting” with a hammer, “prying”
21
78746
with a screwdriver or “pulling” a harness may result in a cause
of disconnection. Never apply force.

27-16
 27

MEMO

27-17
AXLE HOUSING

x
12

15
1 *b
14 6

2
5
10
3 3
4

5
* a

8 13
7 9

11
79850

P Disassembly sequence
1 Inspection plug 11 U-bolt nut
2 Drain plug 12 U-bolt
3 Clip 13 Spring pad
4 Brake hose 14 Bump stopper
5 Packing 15 Axle housing
6 Nut
7 Nut
*a: Propeller shaft L Gr 25
8 Nut *b: Shock absorber L Gr 34
9 Bolt X: Non-reusable parts
10 Reduction and differential assembly L P27-22

CAUTION k
• Do not remove axle housing 15 unless it is faulty.
• Be sure to plug the ends of the removed brake hose 4 to prevent dust, etc., from getting into the hose.
• Refer to L Gr 35A for the procedure to drain brake fluid.

P Assembly sequence
Follow the disassembly sequence in reverse.

27-18
 27
CAUTION k
• Make sure that brake hose 4 is not twisted when installed.
• Be sure to bleed the air from the brake system after installation. L Gr 35A

Service standards Unit: mm

Location Maintenance item Standard value Limit Remedy
Outer bearing run-out 0.5 or less 1 Replace
15 Axle housing Difference before and after
1 or less 5 Replace
rotation at center

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Inspection plug 98 to 115 {10 to 12} –
2 Drain plug 98 to 115 {10 to 12} –
4 Brake hose installation (axle housing side) 13 to 17 {1.3 to 1.7} –
6 Nut (shock absorber installation) 26 to 33 {2.7 to 3.4} –
7 Nut (propeller shaft installation) 100 to 115 {10 to 12} –
8 Nut (reduction & differential assembly mounting) 69 to 93 {7 to 9.5} –
9 Bolt (reduction & differential assembly mounting) 83 to 108 {8.5 to 11} –
11 U-bolt nut (U-bolt installation) 127.5 to 166.7 {13 to 17} –

K Lubricant and/or sealant

Location Points of application Specified lubricant and/or sealant Quantity
Wheel bearing grease
12 U-bolt threads As required
[NLGI No.2 (Li soap)]
Reduction and differential assembly mounting sur-
15 THREEBOND 1215 As required
face of axle housing

0 Special tools Unit : mm

Location Tool name and shape Part No. Application

Reduction and
differential assembly
10 Differential carrier base MB999102
removal and
installation

06679

27-19
AXLE HOUSING
R Service procedure
P Service operations before removal and after installation
• Before removing any part, remove inspection plug 1 and drain plug 2
to drain gear oil from the axle housing 15.
• After installing all parts, fill axle housing with the specified amount of
gear oil from the inspection plug 1.
• Tighten inspection plug 1 and drain plug 2 with the specified torque.
1
15
2
06680

4 Brake hose removal and installation

Remove brake hose 4 from bracket A side (frame side or load sensing
valve side: option) first, then remove the brake hose from axle housing
15 side. To install the brake hose follow the disassembly sequence in
A 3 reverse.

15 4
5 06681

10 Reduction and differential assembly removal and installation

• Remove the lift pad from garage jack A and install the J differential
carrie base. After turning pin B to the dimensions as illustrated insert
and secure it with the bolt which secured the lift pad.
• Tighten the bolts in screw holes C (two positions) used for removing
reduction and differential assembly 10 uniformly, and remove the re-
duction and differential assembly.
M12 × 1.25mm

CAUTION k
Be sure to completely remove sealant from the installation sur-
face of the axle housing and carrier.
06682

27-20
 27
15 Axle housing
[Inspection]
• Horizontally support the inner bearing mating section at both ends of
the housing spindle of axle housing 15.
06683 • Set the dial gauge against outer bearing mating section A and turn
15 the housing 360° to measure the run-out.
• Set axle housing 15 at right angles using square C to measure B1.
After measuring B1, turn the axle housing 180° and measure B2.
06684 Then calculate the difference between B1 and B2.
• If the measured value exceeds the limit, replace axle housing 15.
[Sealant application]
E
• Apply sealant to reduction and differential assembly 10 installation
15
G surface of axle housing 15.
• For area D apply sealant linearly for the 2 positions that are symmet-
G
rical to an imaginary center line.
• Apply sealant so that it runs along the outer circumference of the
D notch in part E.

3 to 4 CAUTION k
After assembly, make sure that sealant is not oozing from the
mating surfaces.

G G
79873

27-21
REDUCTION AND DIFFERENTIAL ASSEMBLY

13

78583

P Primary work before disassembly

L P27-26

P Inspection before disassembly

L P27-26

P Disassembly sequence
1 Bolt 13 Differential gear 25 Lock ring
2 Lock plate 14 Differential gear washer 26 Pinion pilot bearing
3 Adjusting screw 15 Differential pinion washer 27 Rear bearing inner race
4 Bolt 16 Differential pinion 28 Final drive pinion
5 Bearing cap 17 Pinion spider 29 Oil seal
6 Side bearing outer race 18 Differential case, LH 30 Front bearing inner race
7 Side bearing inner race 19 Bolt 31 Front bearing outer race
8 Differential assembly 20 Pinion assembly 32 Rear bearing outer race
9 Bolt 21 Lock nut 33 Bearing retainer
10 Final drive gear 22 Dust cover 34 Shim
11 Bolt 23 Companion flange 35 Differential carrier
12 Differential case, RH 24 Collar
X: Non-reusable parts

27-22
 27
P Assembly sequence
Follow the disassembly sequence in reverse.

CAUTION k
Be sure when replacing any of the following parts to replace both it and its associated parts as a set:
• For bolt 4, bearing cap 5 or differential carrier 35, replace the differential carrier set.
• For final drive gear 10 or final drive pinion 28, replace the reduction gear set.
• For differential case, RH 12 and differential case, LH 18, replace the differential case set.

P Inspection and adjustment after assembly

L P27-27

Service standards Unit: mm

Location Maintenance item Standard value Limit Remedy
• Adjust using adjusting screw
6, 7 Starting torque of side bearing 2.0 to 2.9 N?m {0.2 to 0.3 kgf?m} – • Tangential force at 152 mm point
around periphery of differential
case: 26 to 38 N {2.6 to 3.9 kgf}
Deflection of rear surface of final Adjust or replace along with the gear
10 0.1 or less
drive gear set
Backlash between final drive gear Adjust or replace along with the gear
10, 28 0.20 or 0.28 0.50
and final drive pinion set
Play in rotating direction between
13 rear axle shaft and differential 0.05 or 0.15 0.50 Replace
gear spline
Backlash between differential
13, 16 0.15 or 0.20 0.50 Replace
gear and differential pinion
Clearance between differential
16, 17 0.17 to 0.27 0.50 Replace
pinion and pinion spider
• Adjust using collar
2.0 to 2.9 N?m • Tangential force around periphery
New parts –
{0.2 to 0.3 kgf?m} of bearing retainer: 34 to 52 N {3.5
to 5.3 kgf}
20 Starting torque of final drive pinion
• Adjust using collar
Reused 1.6 to 2.4N?m • Tangential force around periphery
– of bearing retainer: 27 to 41 N {2.8
parts {0.16 to 0.24 kgf?m}
to 4.2 kgf}

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Bolt (Adjusting screw to lock plate mounting) 20 to 26 {2.0 to 2.7} –
4 Bolt (Bearing cap mounting) 200 {20.5} –
Bolt (Final drive gear and differential case, LH
9 167 to 226 {17 to 23} –
mounting
Bolt (Differential case, LH and differential case, RH
11 83 to 113 {8.5 to 11.5} –
mounting
19 Bolt (Pinion assembly mounting) 67 to 90 {6.8 to 9.2} –
21 Nut (Companion flange mounting) 373 to 471 {38 to 48} –

27-23
REDUCTION AND DIFFERENTIAL ASSEMBLY
K Lubricant and/or sealant
Location Points of application Specified lubricant and/or sealant Quantity
10 Thread area of final drive gear LOCTITE 271 As required
11 Thread area of bolt LOCTITE 271 As required
Wheel bearing grease [NLG1 No.2
29 Lip area of oil seal As required
(Li soap)]
35 Pinion pilot bearing mounting surface of differential carrier LOCTITE 601 As required

J Special tools Unit : mm

Location Tool name and shape Part No. Application
Differential working base assembly
A: Attachment

RA F° G G
MB999034
RA A A: MB999040 • Maintenance work bench for reduction
R158 30° φ13 F C B: MB999036 and differential assembly
–
C: MB999037 • Flange stopper is used for installation
B D: MB999035 and removal of the companion flange
B: Holder 11 D E: MB999096
C: Holder
D: Working base
E: Flange stopper
E
40
10 20
05656

Removal of side bearing inner race

Adaptor MB999076 (Use in combination with available bear-
ing puller)

05658
7

Bearing installer MH061748 Installation of side bearing inner race

01039

Installation of pinion assembly

20 Bearing retainer gaide pin MH061745
(Use two)

01041

39.2

26 Pinion pilot bearing installer MH061976 Installation of pinion pilot bearing

45.2
01081

27-24
 27
Unit : mm
Location Tool name and shape Part No. Application

Pinion rear
bearing MB999045 Removal of rear bearing inner race
remover

02956
27

Pinion bearing installer MH061005 Installation of rear bearing inner face

01077

29 Oil seal installer MH061750 Installation of oil seal

01039

30 Pinion bearing installer MH061005 Installation of front bearing inner race

01077

31 Pinion bearing installer MH061977 Installation of front bearing outer race

01078

32 Pinion bearing installer MH061264 Installation of rear bearing outer race

01078

27-25
REDUCTION AND DIFFERENTIAL ASSEMBLY
R Service procedure
P Primary work before disassembly
Mount differential carrier 35 on differential working base assembly.
a: Attachment
b: Holder
c: Holder
d: Working base
e: Flange stopper

06750

P Inspection before disassembly

10
Perform inspection to find possible problems.
(1) Deflection of rear surface of final drive gear
Measure deflection at the point 132 mm (radius) away from the cen-
ter of final drive gear 10.

02945

(2) Backlash of final drive gear and final drive pinion

Measure at three points on the circumference of final drive gear 10.

06595

(3) Starting torque of side bearing

• Measure tangential force A at the φ 152 position (outer diameter) on
differential case, LH 18.
• If the measured tangential force is the standard value, the starting
A torque conforms to the standard value.

NOTE
Measure the starting torque within the backlash range.
18
06639

27-26
 27
(4) Tooth contact of final drive gear
Apply red lead primer to the surfaces of three or four teeth of final
drive gear 10, examine tooth contact by turning the gears a few
times.
B: Examine tooth contact using paper.

01045

P Inspection and adjustment after assembly

10 (1) Deflection of rear surface of final drive gear
Measure deflection at the point 132 mm (radius) away from the cen-
ter of final drive gear 10.

02945

(2) Backlash of final drive gear and final drive pinion

[Adjustment]
Adjust backlash using left and right adjusting screws 3 with the ad-
justed starting torques of side bearings 6, 7 unchanged.
Measure backlash at three points around the circumference of final
drive gear 10.

CAUTION k
Be sure, when adjusting screws 3 on one side are loosened, to
06771 tighten the other side by the same amount.

(3) Starting torque of side bearing

10
[Inspection]
Measure tangential force A at the φ152 position (outer diameter) on
differential case, LH 18.
3 If the measured tangential force is the standard value, the starting
A torque conforms to the standard value.

[Adjustment]
18 If the measured value deviates from the standard value, adjust it us-
06772 ing left and right adjusting screws 3.

CAUTION k
• Be sure to tighten left and right adjusting screws 3 by the same
amount of pitch.
• Adjust the backlash to within the standard backlash of final
drive gear 10.

27-27
REDUCTION AND DIFFERENTIAL ASSEMBLY
(4) Tooth contact of final drive gear
[Inspection]
Apply red lead primer to the surfaces of three or four teeth of final
drive gear 10, examine tooth contact by turning the gears a few
times.
B: Examine tooth contact using paper.

[Adjustment]
If tooth contact has deteriorated, adjust by increasing or decreasing
01045
backlash and shim 34.

NOTE
Be sure when replacing the gear because of abnormally worn
teeth to replace the reduction gear set of final drive gear 10 and
final drive pinion 28.

P Normal tooth contact at no load

<Final drive gear>
C: Heel
D: Toe
E: Face
F: Flank
G: Clearance

01046

<Final drive gear>

C: Heel
D: Toe
E: Face
F: Flank
G: Clearance

01047

Mainenance item Assembly standards

Lengthwise direction of tooth From center towards edge
Tooth contact position From center towards top of tooth for final drive gear and center
Vertical direction
At no load

for final drive pinion

Length Approximately 50 to 70% of tooth width
Tooth contact shape
Width Approximately 50 to 70% of tooth width
Degree of tooth contact It becomes weaker as it nears tooth root or tooth tip

NOTE
When tooth contact is near the toe at no load it becomes middle area contact at load.

27-28
 27
Adjustment of tooth contact
Method of adjustment Moving direction
Advance final drive pinion to final drive gear
Adjustment by adding or reducing shims

(Shims are added.)

Tooth contact moves toward-

stooth root.

Retard final drive pinion from final drive gear

(Shims are reduced)

Tooth contact moves towards

tooth tip

Advance final drive gear to final drive pinion center

(Less backlash) Tooth contact moves in length-wise
Adjustment using adjusting screw

direction of tooth
Leading edge: Nearer to toe and
slightly nearer to root of tooth
Trailing edge: Nearer to heel and
slightly nearer to top of tooth

Retard final drive gear from final drive pinion center Tooth contact moves in length-wise
(More backlash) direction of tooth
Leading edge: Nearer to heel and
slightly nearer to top of tooth
Trailing edge: Nearer to toe and
slightly nearer to root of tooth.

01048

5 Removal of bearing cap

Put alignment marks A on bearing cap 5 and differential carrier 35 to
distinguish left and right.

78584

27-29
REDUCTION AND DIFFERENTIAL ASSEMBLY
7 Side bearing inner race
[Removal]

CAUTION k
Be sure to keep side bearing 6, 7 separate so you do not mix up
left and right when installing them.

J: Adapter
06752

[Installation]

J: Bearing installer

06753

10 Final drive gear

[Removal]
Put alignment marks A on final drive gear 10 and differenatial case, LH
18.

06724

[Installation]
• Apply rust preventive evenly to the whole of bolts 9.
• Apply lock paint to thread area of all bolt holes B of final drive gear 10
and tighten bolts 9 at specified torque.

CAUTION k
• Be sure to let bolts 9 harden for least an hour, after installation,
before driving.
06754
• Furthermore, be sure to let bolts 9 harden for at least four hours
before running at full torque.

27-30
 27
11 Installation of bolt
• Apply rust preventive evenly to the whole of bolts 11.
• Apply lock paint to thread area of bolts 11 and tighten the bolts at
specified torque.

CAUTION k
• Be sure to let bolts 11 harden for at least an hour, after installa-
tion, before driving.
06755 • Furthermore, be sure to let bolts 11 harden for at least four
hours before running at full torque.

13 Play between differential gear and rear axle shaft spline area in
the rotating direction
If the measured value is higher than the limit, replace faulty parts.
A: Rear axle shaft
B: Play

01065

13 16 Backlash between differential gear and differential pinion

06773

20 Pinion assembly
[Removal]
Insert M12 × 1.25 mm bolts into two holes A provided for removing pin-
ion assembly 20, then tighten bolts uniformly until the pinion assembly
is removed.

06756

27-31
REDUCTION AND DIFFERENTIAL ASSEMBLY
[Inspection to starting torque after installation]
• Apply load B to companion flange 23 or tighten lock nut 21 at speci-
fied torque.
B: 30 KN {4000 kgf}
• Wind a wier around bearing retainer 33 (periphery: X114 mm) and
measure tangential force C.
Starting torque

New parts Reused parts

06757
Tangential force Starting torque Tangential force Starting torque
34 to 52 N 2.0 to 2.9 N?m 27 to 41 N 1.6 to 2.4 N?m
{3.5 or 5.3 kgf} {0.2 to 0.3 kgf?m} {2.8 to 4.2 kgf} {0.16 to 0.24 kgf?m}

CAUTION k
• Be sure to secure companion flange 23 before measurement.
• Be sure to remove oil seal 29 before measurement.

[Adjustment of starting torque]

If the measured value deviates from the standard value, replace collar
24 so that the tangential force conforms to the standard value.
Collar thicknesses:
15.600 to 16.200 mm (25 thicknesses available in 0.025 mm incre-
ments)

[Installation and adjustment]

Calculate the required number of shims by assigning the deviations
from the basic dimensions stamped on differential carrier 35 and pinion
assembly 20 and the deviation from the measured value to the expres-
sion below. Then, select shims 34.
: Point where basic dimension is stamped
*

02950

27-32
 27
Adjusting shim thicknesses: 0.1, and 0.2 mm
Expression
Shim thickness G = 0.5-a+b+c
a=Deviation from basic dimension D
b=Deviation from basic dimension E
c=Deviation from basic dimension F
Basic dimension
Location How to obtain deviation
(mm)
Shim
06758 0.5 –
quantity
The basic dimension multiplied by 100 is
D 203 stamped on the periphery of the differential
carrier flange
The basic dimension is stamped on the top
E 157
of the final drive pinion
Measure the deviation from F using a dial
gauge. However, if it is difficult to measure
F 46.5
the actual deviation, assume a value from 0
to 0.2 mm

[Installation]
• Apply lock paint to entire mounting surface H of pinion pilot bearing
26 of differential carrier 35.

CAUTION k
Be sure to let pinion assembly 20 harden for 30 minutes to two
hours. Wait three hours before running the vehicle, and if possi-
ble, wait 24 hours.
06774

• Assemble differential carrier 35 and pinion assembly 20 with their

alignment marks ‘‘ ’’ aligned.
J: Bearing retainer guide pin

02951

27-33
REDUCTION AND DIFFERENTIAL ASSEMBLY
24 to 28 Removal of collar, lock ring, pinion pilot bearing, rear
bearing inner race and final drive pinion
Using an appropriate cylinder A and press B, and remove collar 24,
lock ring 25, pinion pilot bearing 26, rear bearing inner race 27, and fi-
nal drive pinion 28 together.

06759

25 26 Lock ring and pinion pilot bearing

[Removal]

78585

[Installation]

CAUTION k
Be sure to mount pinion pilot bearing 26 retaining ring A on the
final drive pinion 28 side.

J: Pinion pilot bearing installer

06761

27 Rear bearing inner race

[Removal]
J: Pinion rear bearing remover

02959

27-34
 27
[Installation]
J: Pinion bearing installer

06762

29 Installation of oil seal

J: Oil seal installer

78586

30 Installation of front bearing inner race

J: Pinion bearing installer

78587

31 Front bearing outer race

[Removal]
Use pin-punch A and drive out front bearing outer race 31 evenly from
three indented parts B of bearing retainer 33.
C: Hammer

78588

27-35
REDUCTION AND DIFFERENTIAL ASSEMBLY
[Installation]
J: Pinion bearing installer

06766

32 Rear bearing outer race

[Removal]
Use pin-punch A and drive out rear bearing outer race 32 evenly from
three indented parts B of bearing retainer 33.
C: Hammer

78589

[Installation]
J: Pinion bearing installer

06768

27-36
 31

GROUP 31 WHEEL AND TIRE

SPECIFICATIONS................................................................................. 31-2

TROUBLESHOOTING .......................................................................... 31-3

WHEEL AND TIRE................................................................................ 31-4

31-1
SPECIFICATIONS

Air pressure kPa{kgf/cm2}

Tire size Applicable wheel
Front tire Rear tire
205/85R16-117/115L 575 {5.9} 425 {4.3} 16 × 5 1/2 K-115

31-2
TROUBLESHOOTING 31
Symptoms Tire tread wear-down

Feather-edge from outside to inside

Feather-edge from inside to outside

Dished wear (one or more spots)

Pitted wear (dented) all around

Both shoulders worn

Outside worn

Jagged wear
Center worn

Inside worn

Wavy wear
Possible causes
Over loading p
Insufficient p p p p p
Tire air pressure
Excessive p
Excessive p p
Toe-in
Too little p

Wheel alignment Excessive p

Camber
L Gr 26 Too little p
Toe-out excessive p p
Overall misalignment p p p p p p p p
Knuckle arm bent L Gr 26 p p p p

Left and right tie rod lengths different L Gr 26 p

Wheel balance incorrect p p p p
Wheel bearing loose L Gr 26, 27 p p p p
Ball joint loose L Gr 26 p

Tie rod end loose L Gr 37 p

Brake drum eccentric L Gr 35A p p

Axle bent <rigid> L Gr 27 p p

Upper arm, lower arm bent <independent suspension> L Gr 26 p p

Sudden starting, sudden braking or sharp turn p p
Left and right front wheel turning radius incorrect L Gr 26 p
Rough road p p

31-3
WHEEL AND TIRE

CAUTION k
Use right-hand threaded wheel nuts market “R” for right-side wheels and left-hand threaded wheel nuts
marked “L” for left-side wheels.

<Single tire>
P Disassembly sequence
1 Wheel nut
2 Tire assembly L P31-6
5 Hub bolt
6 Hub

P Assembly sequence
Follow the disassembly sequence in re-
verse.

71396

<Double tire>
P Disassembly sequence
1 Wheel nut (outer)
2 Tire assembly L P31-6
3 Wheel nut (inner)
4 Tire assembly L P31-6
5 Hub bolt
6 Hub

P Assembly sequence
Follow the disassembly sequence in re-
verse.

06835

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Wheel nut <Single tire> 441 to 539 {45 to 55} –
1 Wheel nut (outer) <Double tire> 441 to 539 {45 to 55} –
3 Wheel nut (inner) 441 to 539 {45 to 55} –

31-4
 31
R Service procedure
P Cleaning before installation
To prevent wheel nuts 1 and 3 and hub bolts 5 from becoming loose
and to prevent the parts to be mounted (tire assemblies 2 and 4 and
hub 6) from being damaged, remove rust, dust, additional coatings of
paint, and foreign matter from the following areas:

A: Hub bolt thread area

B: Wheel mounting surface of hub
C: Wheel spigot of hub
06706 D: Disc wheel mating surface
E: Disc wheel nut mounting surface
F: Wheel nut thread area
G: Wheel nut spherical area

31-5
WHEEL AND TIRE
Tire Assembly
P Disassembly sequence
1 Tire
3
2 Air valve
2 1
3 Disc wheel

P Assembly procedure
Follow the assembly sequence in reverse.

3 2

71401

Service standards Unit: mm

Location Maintenance item Standard value Limit Remedy
1 Tire lateral run-out (assembled condition) 3.5 or less – –
Levelness 0.4 or less – –
Disc wheel
3 <16 × 5 1/2 K-115> Lateral run-out 1.5 or less – –
Vertical run-out 1.5 or less – –

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
No air leak after
2 Air valve 12.8 ±1.4 {130 ±14}
tightening

R Service procedure
1 Tire deflection
[Inspection]
If the measured value exceeds the limit, correct as follows.

71398

31-6
 31
[Correction]
• Put chalk marks on tire 1, disc wheel 3, and hub bolt * (position A as
illustrated).
• Remove tire 1 from disc wheel 3.

3 1 71399

• Measure deflection of disc wheel 3. If the most deflective position is

near the chalk mark, reinstall tire 1 rotating it half a turn from the
chalk mark and tighten the nuts.
• Remeasure the deflection of tire 1.
• If the measured value exceeds the limit, replace tire 1 and disc wheel
3 together as an assembly.

71400

3 Disc wheel inspection

B (1) Flatness
A 3 • Measure the flatness at the specified position B from the center of
disc wheel 3.
Measure flatness at five equidistant points on the wheel.
C
A: Dial gauge
D
B: X160 mm, X250 mm
05996 C: Portable screw jacks (×4)
D: Surface plate

• If the measure value exceeds the limit, replace disc wheel 3.

(2) Deflection
E
If the measured value exceeds the limit, replace disc wheel 3.

G G F
E: Vertical deflection measuring point
F: Horizontal deflection measuring point
G: 10 mm

05997

31-7
 33

GROUP 33 FRONT SUSPENSION

SPECIFICATIONS ................................................................................ 33-2

STRUCTURE AND OPERATION ........................................................ 33-2

TROUBLESHOOTING ......................................................................... 33-3

PREPARATION WORK BEFORE FRONT SUSPENSION

REMOVAL AND INSTALLATION ........................................................ 33-4

LOWER ARM, COIL SPRING AND LEAF SPRING ............................ 33-6

UPPER ARM AND SUSPENSION CROSS MEMBER ........................ 33-10

SHOCK ABSORBER ........................................................................... 33-12

33-1
SPECIFICATIONS/STRUCTURE AND OPERATION
Specifications
Specifications
Item
Free height × wire diameter × outside diameter
Coil spring mm 308.0 × 19.3 × 128.6

Specifications
Item
Straight span × width × thickness
Leaf spring mm 1366 × 70 × 20.5

Specifications
Item
Model
Shock absorber C30SE

Structure and Operation

1 Coil spring
2 Shock absorber
3 Suspension cross member
4 Upper arm
5 Lower arm
6 Leaf spring

*: Knuckle

73896

• The front axle is divided into two and has right and left knuckles to each of which a wheel is attached to create an in-
*
dependently moving mechanism. The knuckle is supported by upper arm 4 and lower arm 5.

33-2
TROUBLESHOOTING 33
Symptoms

Impact shock transmitted from the road surface

Periodic jolts received from the road surface

Vehicle body is not level to the road surface

Ride is soft with gentle swaying

Excessive rolling while cruising

Wheel alignment is incorrect

Remarks

Noise is generated easily

Poor linearity
Possible causes

Damaged, fatigued p p
Coil spring
Bent p p
Cracked, damaged, fatigued p p
Bent p p
Leaf spring
Mount loose p p p
Bushing worn p p
Noticeable oil leak, decreased damping
p p
force
Shock absorber
Rubber bushing worn p p
Mount loose p p
Upper arm ball joint stud worn p p p
Ball joint stud worn p p p
Lower arm Bushing worn p p
Bushing seat worn p
Tires worn unevenly p p p
Tire Tires, wheels unbalanced p p L Gr31
Air pressure excessive p

33-3
PREPARATION WORK BEFORE FRONT SUSPENSION
REMOVAL AND INSTALLATION

73920

P Disassembly sequence
1 Apply chocks.
2 Contact the jack to the jack up plate of suspension lower arm mounting area and jack up.
3 Support the frame with rigid rack.
4 Remove the brake hose joint (on the frame).
5 Remove the brake pad wear indicator harness clamp and then remove the frame connector.
6 Remove the knuckle. L Gr26

CAUTION k
• Be sure to securely block the tires.
• Do not place the garage jack or rigid rack against the suspension cross member (other than jack up point).
• Put plugs in the ends of the removed brake hose to prevent dust from getting into it.
• Absolutely do not get under the vehicle while it is being jacked up.

P Assembly sequence
Follow the disassembly sequence in reverse.

CAUTION k
• Be careful not to twist the brake hose when installing it.
• After installing the brake hose, bleed the air from the brake system. L Gr35A

33-4
 33

MEMO

33-5
LOWER ARM, COIL SPRING AND LEAF SPRING

*b

7
9

2 T 12
7
6T 5T *a
14

11
1T 13
K
*c
8T

T 10 79606

P Disassembly sequence
1 Nut 10 Bolt
2 Leaf spring 11 Leaf spring bracket
3 Spring seat 12 Nut
4 Coil spring 13 Lower ball joint
5 Bolt 14 Lower arm
6 Bolt
7 Lower arm bushing *a: Knuckle L Gr26
8 Nut Upper arm L P33-10
9 Bump stopper
*b:
c: Shock absorber L P33-12
*
P Assembly sequence
Follow the disassembly sequence in reverse.

Service standards Unit: mm

Location Maintenance item Standard value Limit Remedy
9 Bump stopper height 50 to 56 – Replace
13 Play in lower ball joint axial direction 0.5 or less – Replace

33-6
 33
T Tightening torque Unit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks
1 Nut (leaf spring installation) 260 to 340 {26 to 35} –
5, 6 Bolt (lower arm installation) 410 to 550 {41 to 56} –
8 Nut (bump stopper installation) 90 to 120 {9.0 to 12} –
10 Bolt (leaf spring bracket installation) 110 to 140 {11 to 14} –
12 Nut (lower ball joint installation) 90 to 130 {9.5 to 13.0} –

K Lubricant
Location Points of application Specified lubricant Quantity
13 Lower ball joint dust cove lip Molybdenum disulfide grease As required

J Special tools
Location Tool name and shape Part No. Application

Coil spring removal

4 Spring compressor MH062471
and installation

05468

Bushing remover
Removing lower arm
7 A: Remover base MH062475
bushing
B: Arbor

06725

R Service procedure
2 Leaf spring
[Removal]
• Jack up the lower area A of the knuckle a and first remove the re-
bound stopper B of upper arm b.
*
*
• Remove the jack used above and with leaf spring 2 in an unloaded
state remove the leaf spring eye nut 1 and then remove the leaf
spring.

73923

4 Coil spring
[Removal]
Use the J spring compressor to compress coil spring 4. With the coil
spring compressed remove knuckle a and then remove the coil spring.
L Gr26
*

73924

33-7
LOWER ARM, COIL SPRING AND LEAF SPRING
7 Lower arm bushing
[Removal]
Remove lower arm bushing 7 from lower arm 14 using the J bushing
remover.

06726

[Press-fitting]
Press fit lower arm bushing 7 into lower arm 14 using the press to push
the flange with side A of the flange facing aft of the vehicle.

06727

9 Bump stopper inspection

Measure the height A of the bump stopper 9, and if the measured value
is less then the standard value, replace the bump stopper.

A : 50 to 56 mm

74721

13 Lower ball joint inspection

Measure the play A in the axial direction of lower ball joint 13, and if the
measured value is outside the standard value, replace the lower ball
joint.

06797

33-8
 33

MEMO

33-9
UPPER ARM AND SUSPENSION CROSS MEMBER

73925

P Disassembly sequence
1 Nut 6 Nut 11 Bolt
2 Adjuster shim L Gr26 7 Brake hose bracket 12 Bolt
3 Spacer 8 Bolt 13 Suspension cross member
4 Nut 9 Upper ball joint 14 Shim
5 Rebound stopper 10 Upper arm assembly

CAUTION k
The upper ball joint of upper arm assembly 10 is not disassembled.

P Assembly sequence
Follow the disassembly sequence in reverse.

Service standards Unit: mm

Location Maintenance item Standard value Limit Remedy
5 Rebound stopper height – 37 Replace
9 Upper ball joint start up torque 1 to 5 N?m {0.1 to 0.5 kgf?m} – Replace

33-10
 33
T Tightening torque Unit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks
1 Nut (upper arm assembly installation) 180 to 240 {18 to 24} –
4 Nut (rebound stopper installation) 19 to 28 {1.9 to 2.8} –
6 Nut (brake bracket installation) 80 to 110 {8 to 11} –
8 Bolt (upper bolt joint installation) 80 to 110 {8 to 11} –
11 Bolt (suspension cross member installation) 130 to 180 {13 to 18} –
12 Bolt (suspension cross member installation) 200 to 270 {20 to 27} –

K Lubricant
Location Points of application Specified lubricant Quantity
9 Lip of ball joint dust cover Molybdenum disulfide grease As required

J Special tools
Location Tool name and shape Part No. Application

Measuring the start up

9 Pre-load socket MB990326 torque of the upper arm
assembly upper ball joint

05315

R Service procedure
5 Rebound stopper inspection
Measure the height A of the rebound stopper 5, and if the measured
value is less than the standard value, replace the rebound stopper.

A : 37 mm
5
A

74714

9 Upper ball joint inspection

Measure the start up torque A of upper ball joint 9. If the measured val-
ue is outside the standard value, replace the upper arm assembly 10.

J: Pre-load socket

05316

33-11
SHOCK ABSORBER
P Disassembly sequence
T1
1 Lock nut
2 2 Nut
3
3 Washer
4 4 Rubber bushing
5 Rubber bushing
*b 6 Washer
7 Bolt
8 Shock absorber
*c
* e
*a: Lower arm
*b: Upper arm
c: Knuckle
*d:
* Leaf spring
*e: Coil spring
P Assembly sequence
Follow the disassembly sequence in re-
*d 5 verse.
*a 6

T7
79607

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Lock nut (shock absorber installation) 21 to 30 {2.1 to 3.1} –
7 Bolt (shock absorber installation) 19 to 28 {1.9 to 2.8} –

R Service procedure
8 Shock absorber installation
Tighten nut 2 so that shock absorber 8 protrudes from the lock nut 1 by
amount A.

A = 5 to 7 mm

79608

33-12
 34

GROUP 34 REAR SUSPENSION

STRUCTURE AND OPERATION ........................................................ 34-2

TROUBLESHOOTING ......................................................................... 34-3

PREPARATION WORK BEFORE REAR SUSPENSION

REMOVAL AND INSTALLATION ........................................................ 34-4

LEAF SPRING ASSEMBLY REMOVAL AND INSTALLATION ......... 34-6

LEAF SPRING ASSEMBLY ................................................................. 34-8

SHOCK ABSORBER ........................................................................... 34-10

STABILIZER ......................................................................................... 34-12

34-1
STRUCTURE AND OPERATION
Structure and Operation

74013

1 Leaf spring assembly

2 Shock absorber
3 Stabilizer

*a: Frame
*b: Rear axle
Leaf spring assembly 1 and shock absorber 2 are installed between frame a and rear axle b to support the vehicle
* *
body weight and absorb vibration and shock from the road surface to prevent them from being directly transmitted to the
vehicle body hereby protecting the vehicle body, and passengers, and the crew. In addition, irregular vibration from the
wheels is restrained to ensure driving stability. Stabilizer 3 is installed to prevent rolling.

34-2
TROUBLESHOOTING 34
Symptoms

Noise is easily generated when vehicle is loaded with passengers

Noise is easily generated when vehicle is empty

Impact shock transmitted from the road surface

Periodic jolts received from the road surface

Remarks

Ride is soft with gentle swaying

Excessive rolling while cruising

Possible causes

Cracked or damaged p
Damaged p
Leaf spring Spring hanger damaged p
U-bolts loose p
Rubber bushing worn p
Damaged bump stopper p
Excessive spring pin and shackle plate tightening torque p
Noticeable oil leak or decreased damping force p
Shock absorber Rubber bushing worn p
Mount loose p
Stabilizer Stabilizer deformed or bushing worn p
Tires worn unevenly p
Tire Tires and wheels unbalanced p L Gr31
Air pressure excessive p

34-3
PREPARATION WORK BEFORE REAR SUSPENSION
REMOVAL AND INSTALLATION

74582

P Disassembly sequence
1 Apply the chocks.
2 Jack up the rear axle with a garage jack.
3 Support the rear of the frame with rigid jacks.
4 Put alignment marks A on the rear axle companion flange and propeller shaft flange yoke and remove the nut
(connection between the rear axle and propeller shaft). L Gr25
5 Remove the brake hose joint (on the frame).

P Assembly sequence
Follow the disassembly sequence in reverse.

34-4
 34
CAUTION k
• Be sure to securely block the tires.
• Put plugs in the ends of the removed brake hose to prevent dust from getting into it. Be careful not to twist the
brake hose when installing it.
• After installing the brake hose, bleed the air from the brake system. L Gr35A, E
• Absolutely do not get under the vehicle while it is being jacked up.
• Continue to support the rear axle with the garage jack.

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
Nut (connection between the rear axle and the propel-
4 100 to 120 {10 to 12} –
ler shaft)

34-5
LEAF SPRING ASSEMBLY REMOVAL AND INSTALLATION
P Disassembly sequence
1 U-bolt nut
14 2 2 U-bolt
3 U-bolt sheet
13 4 4 Bump stopper
5 Nut
6 Spring pin
16
7 Rubber bushing
* 8
9
Nut
Shackle plate
10 Spring shackle
11 Rubber bushing
12 Leaf spring assembly L P34-8
13 Nut
14 Bump stopper seat
15 Rear spring hanger
16 Rear shackle hanger
15 10
12
11
9 *: Rear axle L Gr27
8
CAUTION k
Do not remove the rear spring hanger
15 or rear shackle hanger 16 unless
5
they are faulty. L Gr41
3
P Assembly sequence
1 Follow the disassembly sequence in re-
verse.
7
6
79823

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 U-bolt nut (U-bolt mounting) 127.5 to 166.7 {13 to 17} –
5 Nut (Spring pin installation) 93.2 to 127 {9.5 to 13.0} –
8 Nut (Spring shackle installation) 93.2 to 127 {9.5 to 13.0} –
13 Nut (Bump stopper sheet installation) 12 to 15 {1.2 to 1.5} –

K Lubricant
Location Points of application Specified lubricant Quantity
Wheel bearing grease
2 U-bolt threads As required
[NLGI No.2 (Li soap)]

34-6
 34
R Service procedure
6 Spring pin installation
Install spring pin 6 into rear spring hanger 15 with indent A of the spring
pin fitted to protrusion B of the rear spring hanger.

74016

9 Shackle plate installation

Install shackle plate 9 with stamped facing the leaf spring.
mark

06126

34-7
LEAF SPRING ASSEMBLY
P Disassembly sequence
1 Collar
2
2 Center bolt
3 Rivet
4 Clip
5 Leaf spring

5 X: Non-reusable parts

1
P Assembly sequence
Follow the disassembly sequence in re-
verse.

4
3
79824

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
2 Center bolt 34 to 54 {3.5 to 5.5} –

R Service procedure
2 Center bolt
[Removal]
5 • Align the alignment mark A on the side of leaf spring 5.

71412

• Compress leaf spring 5 with a press, lever up the bent parts of clips 4
using a cold chisel, etc., and then remove center bolt 2.

4
5 2

71413

34-8
 34
[Installation]
• Align alignment marks A on the side of leaf springs 5, assemble the
2 component leaf springs, and then temporarily tighten center bolt 2.

71414

• Compress leaf springs 5 using a press, tighten the center bolt 2 at

the specified torque, then bend over clips 4 using a hammer, etc.

5 2
4

71415

3 Rivets
[Removal]
• Drill out caulked end A of rivet 3 and remove clip 4.

A
3 05732

[Installation]
B • Using riveting machine B, install clip 4 by caulking rivet 3.

05733

34-9
SHOCK ABSORBER
P Disassembly sequence
1 Nut
2 Rubber bushing
3 Shock absorber

P Assembly sequence
Follow the disassembly sequence in re-
verse.

74017

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Nut (shock absorber installation 26 to 33 {2.7 to 3.4} –

34-10
 34

MEMO

34-11
STABILIZER
P Disassembly sequence
1 1 Lock nut
2
3 2 Washer
3 Rubber bushing
4
4 Center ring washer
*a 5 Rubber bushing
6 Washer
7 Nut
8 Hanger
4 9 Clamp
T 5 10 Stabilizer bushing
11 6
11 Bolt
12 12 Retainer
13 Nut
7T 14 Bushing
8 15 Stabilizer bar
12
15 16 Nut
17 Stabilizer bracket
9
14
10
*a: Frame
*b: Leaf spring
T 13
P Assembly sequence
Follow the disassembly sequence in re-
verse.
17
* b

16
79605

Service standards Unit: mm

Location Maintenance item Standard value Limit Remedy
Lock nut (distance between the hanger end and nut
1 4 – Adjust
during tightening)
10 Stabilizer bushing installation position 635 ± 1.0 – Adjust

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
7 Nut (clamp and hanger installation) 17 to 26 {1.7 to 2.6} –
11 Bolt (retainer installation) 34 to 54 {3.5 to 5.5} –
13 Nut (stabilizer bar installation) 33 to 49 {3.4 to 5.0} –

34-12
 34
R Service procedure
1 8 Hanger installation
2 Tighten lock nut 1 so that the end of hanger 8 protrudes by the amount
3 of A.
4
A = 4 mm
*
4
a

5
6
8 73895

10 Stabilizer bushing
Align the end of stabilizer bushing 10 with the marking area A of stabi-
lizer bar 15 and install.

Dimension B: 635 ± 1 mm

74855

34-13
 35A

GROUP 35A BRAKE

SPECIFICATIONS ................................................................................ 35A-2

STRUCTURE AND OPERATION ........................................................ 35A-4

TROUBLESHOOTING ......................................................................... 35A-22

ON-VEHICLE INSPECTION AND ADJUSTMENT

• Brake Fluid Replacement ..................................................................... 35A-28
• Brake System Air Bleeding .................................................................. 35A-30
• Brake Pedal Free Play Inspection and Adjustment ............................ 35A-32
• Inspection and Adjustment of Clearance between Brake Pedal
and Floor Panel .................................................................................... 35A-32
• Disc Brake Pad Inspection and Replacement .................................... 35A-33
• Drum Brake Lining Thickness Inspection and Replacement ........... 35A-36
• Inspection of Clearance between Brake Drum and Lining ............... 35A-36
• Brake Booster Inspection .................................................................... 35A-37
• Exhaust Brake System Inspection ...................................................... 35A-41

VACUUM PUMP ................................................................................... 35A-42

BRAKE MASTER CYLINDER ............................................................. 35A-44

BRAKE PEDAL AND BRAKE BOOSTER .......................................... 35A-46

FRONT WHEEL BRAKE....................................................................... 35A-48

REAR WHEEL BRAKE......................................................................... 35A-52

EXHAUST BRAKE SYSTEM ............................................................... 35A-60

HYDRAULIC UNIT ................................................................................ 35A-64

35A-1
SPECIFICATIONS
Vacuum Pump
Item Specifications
Type Vane type
Discharge cm3 {mL} 90 {90}
Manufacturer MITSUBISHI ELECTRIC CORP.

Brake Master Cylinder

Item Specifications
Inner diameter mm X31.75

Front mm 16.0
Stroke
Rear mm 16.0
Manufacturer Bosch Automotive Systems

Brake Booster
Item Specifications
Type Vacuum, tandem type
Diaphragm diameter Inch X9 + X10
Manufacturer Bosch Automotive Systems

Front Wheel Brake

Item Specifications
Brake type Twin caliper type disc brake
Caliper piston Inner diameter mm X51.10

Disc rotor Outer diameter × thickness mm X293 × 40

Pad Thickness mm 14

Rear Wheel Brake

Item Specifications
Brake type Dual 2-leading type drum brake
Wheel cylinder Inner diameter mm X31.75

Brake drum Inner diameter mm X320

Brake lining Width × thickness mm 110 × 10.4

Brake shoe clearance adjustment system Auto adjustment system

Exhaust Brake
Control method Both electric and vacuum controlled type
Valve type Butterfly valve type

Hydraulic Unit L Gr35E

35A-2
 35A

MEMO

35A-3
STRUCTURE AND OPERATION
Brake System

2 4
1

5 7
3
6

:A
:B 7
:C 4

78496

1 Brake booster 8 Vacuum pump

2 Brake fluid tank 9 Hydraulic unit
3 Brake master cylinder
4 Front brake A: Fluid line
5 Vacuum tank B: Air line
6 Vacuum switch C: Hose
7 Rear brake
• The brake system is the vacuum servo brake for all wheels and the servo system has brake booster 1.
• Hydraulic unit 9 has the Anti-lock brake system Electronic control unit to control the Anti-lock brake system.
L Gr35E

35A-4
 35A
Vacuum Pump
1 Check valve assembly
2 Vane
3 Rotor
4 Housing

A: Inlet
B: Outlet

• The vacuum pump is installed on the

timing gear case and is rotated by the in-
jection pump gear or camshaft gear.
• Check valve assembly 1 is fitted to pre-
vent the atmospheric pressure and the
lubrication oil from flowing in reverse
from the vacuum pump to the vacuum
tank when the engine is stopped.

05224

P Operation
• Inside cylindrical housing 4, rotor 3 equipped with three vanes (mov-
able blades) 2 rotates, pressing the vanes against the inner surface
of the housing by centrifugal force.
• Since rotor 3 is eccentric with respect to housing 4, as the rotor ro-
tates the atmospheric pressure of the vacuum tank is drawn in from
inlet A and is discharged from outlet B by the gradual compression of
the air. This repetition of the suction, compression and exhaust
strokes generates a vacuum, which creates a near vacuum in the
vacuum tank.
• The engine oil that lubricates and cools the inside of housing 4 is re-
turned, along with compressed air, through outlet B to the oil pan.

71934

35A-5
STRUCTURE AND OPERATION
Brake Booster and Brake Master Cylinder<Tandem Brake Booster>

05248

<Brake Booster>
1 Front diaphragm 13 Push rod
2 Front diaphragm plate 14 Front shell
3 Front diaphragm 15 Diaphragm plate spring
4 Front diaphragm plate
5 Rear shell <Brake Master Cylinder>
6 Valve plunger 16 Primary piston
7 Poppet 17 Primary piston return spring
8 Poppet spring 18 Retainer
9 Valve return spring 19 Secondary piston
10 Operating rod 20 Secondary piston return spring
11 Valve body 21 Cylinder body
12 Center plate 22 Packing cup
• Compared with the single brake booster, the tandem brake booster with two separate vacuum chambers is smaller,
has a larger capacity, and a higher power boost performance.
• The brake master cylinder hydraulic system is separated into two independent hydraulic systems, which are the front
and rear brake systems. Accordingly when there is a leakage in one of the circuits, the safety mechanism allows for
emergency stopping power using the other undamaged brake system.

35A-6
 35A
P When brake pedal is depressed

05249
Brake booster action
• When the brake pedal is released, chamber C and chamber D are subjected to the vacuum created by the vacuum
pump.
• Depressing the brake pedal activates operating rod 10, which places poppet 7 in tight contact with the seat of valve
body 11.This action closes vacuum valve A, cutting the vacuum to chamber D.Depressing the brake pedal further sep-
arates valve plunger 6 from poppet 7 opening breather valve B permitting atmospheric air to flow into chamber D, pro-
ducing a pressure difference between chamber C and chamber D.
• The pedal depression force, boosted by the pressure difference between chamber C and chamber D, overcomes the
force of diaphragm plate spring 15,pushing diaphragm 1, 3 and push rod 13 and actuating the brake master cylinder.
Brake Master Cylinder Action
• Push rod 13 pushes in primary piston 16 and sec-
ondary piston 19, and packing cup 22 passes re-
turn port E generating hydraulic pressure in
chamber H, feeding the oil to the respective brake
systems.

K: To the front brake system

L: To the front brake system

05242

35A-7
STRUCTURE AND OPERATION
P When a fluid leak occurs in the front brake
system
• Depressing the brake pedal makes push rod 13
push in primary piston 16.However, if the brake
fluid in the front brake system leaks, hydraulic
pressure is not generated in the front brake sys-
tem.
• Depressing the brake pedal further makes prima-
ry piston 16 compress primary piston return
spring 17 and retainer 18 push against secondary
05243 piston 19 thus generation hydraulic pressure only
in the rear brake system.
L: Rear brake system

P When a fluid leak occurs in the rear brake sys-

tem
• Depressing the brake pedal makes push rod 13
push in primary piston 16 and secondary piston
19.Howevwe, if the brake fluid in the rear brake
system leaks, hydraulic pressure is not generated
in the rear brake system.
• Depressing the brake pedal further makes the
end of secondary piston 19 contact cylinder body
21 and primary piston 16 is pressed on creating
05244 pressure only in the front brake system.

K: To the front brake system

P When the brake pedal is released

05250

35A-8
 35A
Brake booster action
• When the brake pedal is depressed, atmospheric air flows into chamber D and on the other hand chamber C is sub-
jected to negative pressure generated by the vacuum pump.
• When the brake pedal is released, since the pressing force acting on the operating rod 10 also is released, valve
plunger 6 contacts poppet 7 tightly, closing breather valve B to cut off the flow of atmospheric air into chamber D.In ad-
dition, valve plunger 6 separates from body 11 to open vacuum valve A.Then, the negative pressure generated by the
vacuum pump creates a vacuum in chamber D, and the pressure difference between chambers C and D diminishes.
• This absence of a pressure difference between chambers C and D allows diaphragm 1, 3 to be pushed against the
rear shell 5 by the force of diaphragm plate return spring 15, and push rod 13 returns to its original position.

Brake master cylinder action

• When push rod 13 returns to its original position,
the force of the secondary piston return spring 20
immediately begins to return secondary piston
19. However, the brake fluid delivered from the
brake master cylinder cannot return quickly due
to the absence of a pressure difference between
chambers H and G.
• As secondary piston 19 begins to return, the
pressure in chamber H becomes lower than that
in chamber G, and this pressure difference de-
forms packing cup 22 to open a small passage J.
05246 Then the brake fluid in chamber G is drawn into
chamber H.
• When secondary piston 19 moves further to re-
turn to its original position, the pressure differ-
ence between chambers G and H is diminished,
and packing cup 22 closes the small passage
J.The hydraulic oil in the brake pipe flows from
chamber H to the reservoir tank via return port E.
• The same operation takes place also on the pri-
mary side.

05247

35A-9
STRUCTURE AND OPERATION
FRONT WHEEL BRAKE
1 Pad wear indicator
2 Disc rotor
3 Torque member
4 Outer pad
5 Inner pad
6 Caliper
7 Piston

• Twin floating caliper type is installed in the front

disc brake, and the inside of caliper 6 contains
one cylinder and one piston 7, and the outer pad
4 on the opposite side utilizes the reaction to
sandwich disc rotor 2 and generates a braking
force.
• Pad wear indicator 1 is installed in inner pad 5 to
notify the driver when outer pad 4 and the inner
pad need to be replaced.
05404
• The front disc brake has an automatic adjustment
mechanism that correctly adjusts the clearance
between disc rotor 2, outer pad 4, and inner pad 5
caused by wear each time brake is operated.

P Automatic adjustment mechanism Action

• When inner pad 5 is worn by amount A, piston 7 moves by wear
amount A over the elastic deformation amount C of seal B.

05407

• Piston 7 returns by the same amount as the seal B elastic deforma-

tion amount C to correct the clearance between inner pad 5 and disc
rotor 2.

D: Piston return amount

05408

35A-10
 35A
REAR WHEEL BRAKE

1 2 1 Back plate
2 Brake shoe assembly
3 Return spring
4 Wheel cylinder assembly
The rear drum brake assembly has a dual 2-leading
type brake. It has dual-action wheel cylinder assem-
bly 4, and the self servo action produces a great brak-
3 ing force by using brake shoe assembly 2 as the
leading shoes when the vehicle is traveling forwards
or backwards.
4
05476

P Wheel Cylinder Assembly

11 1 2 1 Spring
3
2 Piston cap
3 Body
10
4 Piston
5 Boot
7 6 Adjuster
7 Adjusting screw
6 8 Washer (thick)
9 Washer (thin)
4 5
4 10 Lever
5 9 8
11 Spring and fitting
79866

P Auto adjustment mechanism

• The wheel cylinder is equipped with an auto adjustment mechanism which adjusts automatically, maintaining the prop-
er shoe clearance if the brake lining becomes worn and the shoe clearance becomes markedly greater than the spec-
ified value when the brakes are applied while traveling in the forward direction.

35A-11
STRUCTURE AND OPERATION
Operation
4 • When the brake pedal is depressed, hydraulic
4 pressure from the master cylinder pushes out pis-
ton 4 and pulls spring and fitting 11. Therefore, le-
ver 10 turns around pin A together with the spring
and fitting.
7 B: Brake lining
C: Movement of lever
6 D: Push-out of piston assembly
D

A 10
11 B

6
D
74312

• When the clearance between the brake drum and

6
C brake lining B is the optimum, operation of the
10
brake pedal does not move lever 10 enough and
adjuster 6 does not turn.
C: Movement of lever

05391

35A-12
 35A
• When the clearance between the brake drum and
10 brake lining B is large, push-out of piston 4 is
6 large. Movement of lever 10 is accordingly large.
6 C 7
C: Movement of lever
E: Push-out of adjusting screw

• Lever 10 makes turning of adjuster 6 large and

the thread of adjuster pushes out adjusting screw
7, resulting in expansion of the brake shoe as-
sembly.

E
B 05390

<Before depressing pedal>

6
C
10

<When depressing pedal>

05402

<When pedal is released> • When the brake pedal is released, adjuster 6

maintains the turning position. Only lever 10 re-
6 C
turns to the position offset by one tooth. This opti-
mizes the clearance between the brake drum and
10
brake lining B.
C: Movement of lever

05392

35A-13
STRUCTURE AND OPERATION
Exhaust Brake System

72043

1 Fuse box 8 Butterfly valve

2 Meter cluster 9 Neutral switch
3 Exhaust brake indicator lamp 10 Exhaust brake switch
4 Air cleaner 11 Accelerator switch
5 Vacuum tank 12 Clutch switch
6 Exhaust brake 3-way magnetic valve 13 Exhaust brake cut relay <Automatic transmission>
7 Exhaust brake unit
• Butterfly valve exhaust brake unit 7 is fitted as an auxiliary brake for the foot brake.
• For the brake force, the exhaust brake uses the pressure that pushes back the piston in the exhaust stroke, that rises
in the exhaust pipe when the pipe is closed.
• When exhaust brake switch 10 is turned ON, the excitation of the coil in exhaust brake 3-way magnetic valve 6 causes
the breather valve to close and the vacuum valve to open which causes the vacuum in the vacuum tank 5 to act on ex-
haust brake unit 7 to close butterfly valve 8 and operate the exhaust brake.

35A-14
 35A
P Operation
Electrical System

72044
When exhaust brake switch 10 is turned ON, exhaust brake indicator lamp 3 within meter cluster 2 is lit, and exhaust
brake 3-way magnetic valve 6 for the exhaust brake is actuated.At this time if the clutch pedal or accelerator pedal is de-
pressed, the clutch switch 12 or the accelerator switch 11 goes OFF and the exhaust brake is released temporarily.
The exhaust brake is released when the transmission is in neutral (neutral switch 9 is ON), as when the vehicle is
stopped.
Furthermore, in the case of vehicles with automatic transmission, the exhaust brake is released by the operation of the
exhaust brake cut relay 13.

35A-15
STRUCTURE AND OPERATION
Exhaust Brake Unit (Power Chamber)
1 Cylinder shell
2 Spring
3 Diaphragm
1 4 Push rod
5 Butterfly valve
2

5 79628

35A-16
 35A

MEMO

35A-17
STRUCTURE AND OPERATION
Brake Warning System
P Vacuum system electric circuit and brake fluid level system electric circuit

3 4
1
F19

A
5

79889

1 Fuse box 6 Brake fluid level switch

2 Meter cluster 7 Vacuum switch
3 Vacuum warning lamp
4 Brake warning lamp A: To alternator
5 Parking brake switch

35A-18
 35A
Operation
P Vacuum system electric circuit
The vacuum system electric circuit is a warning circuit which senses
the vacuum in the vacuum tank and sends a warning.
• If the vacuum drops in the vacuum tank, the vacuum switch 7 goes
ON and the vacuum warning lamp 3 lights up.
P Brake fluid level system electric circuit
The brake fluid level system electric circuit is a warning circuit which
senses the brake fluid level in the brake fluid tank and sends a warn-
ing.
• If the brake fluid level in the brake fluid tank becomes low, the
brake fluid level switch 6 goes ON and the brake warning lamp 4
lights up.

35A-19
STRUCTURE AND OPERATION
P Wear Indicator System Electric Circuit <Front Wheel Brake>

74943

1 Fuse box 5 Multipurpose timing control and lighting and

2 Meter cluster alarm control
3 Disc brake warning lamp 6 Front pad wear indicator Left side
4 Relay box 7 Front pad wear indicator Right side

35A-20
 35A
Operation
The pad wear indicator system electric cir-
cuit is a warning circuit that when the brake
pads wear down pad wear indicators 6, 7
are disconnected by the disc rotor and this
is detected by Multipurpose timing control
and lighting and alarm control 5 which gives
the warning. When one of the pad wear in-
dicators 6, 7 is disconnected, Multipurpose
timing control and lighting and alarm control
5 operates and turns on disc brake warning
indicator lamp 3.

74944

35A-21
TROUBLESHOOTING
Wheel Brake
Symptoms One-sided Noise and
braking shudder
when brakes

Braking force difference between right and left

Braking shoe return slow after releasing brake pedal
are applies

Noise and shudder when brakes are applied

Continuous noise generated when

Noise generated when wheels are
rotating with vehicle jacked up
Brake pedal stroke reduced
Braking force insufficient
Braking force unstable

braking (at low speed)

Lock points different
One-sided braking
Possible causes

Air pressure uneven, etc. L Gr31 p

Tires
Right and left tire sizes different L Gr31 p
Wheel hub bearing adjusted incorrectly
p p
L Gr26, 27
Right and left wheel base difference excessive
p
L Gr26, 27
Axle
Wheel alignmen incorrect L Gr26 p
Trunnion bearing worn L Gr26
Upper or lower ball joint worn L Gr33
Backing plate ledge surface rough p p
Backing plate ledge surface catches
Backing plate deformed, mounted incorrectly p
Oil or water on brake lining or brake pad surface p p
Brake lining deteriorated or wrong material used p
Brake lining unevenly worn or surface roughened p
Brake lining or brake pad fading (surface deteriorated) p
Brake lining or brake pad completely worn out p
Wheel brakes
Powder from wear on brake lining or brake pad
Brake lining or brake pad worn
Brake lining or brake pad contact incorrect p p p
Brake lining ground radius irregular p
Wheel cylinder malfunctioning p p p p
Wheel cylinder piston cup defective
Shoe return spring fatigued or broken p p
Brake drum or disc rotor unevenly worn p

35A-22
 35A
Symptoms One-sided Noise and
braking shudder
when brakes

Braking shoe return slow after releasing brake pedal

Braking force difference between right and left
are applies

Noise and shudder when brakes are spplid

Continuous noise generated when

Noise generated when wheels are
rotating whis vehicle jacked up
Brake pedal stroke reduced
Braking force insufficient

braking (at low speed)

Braking force unstable

Lock points different

One-sided braking
Possible causes
Brake drum or disc rotor deformed p
Brake drum or disc rotor worn p
Brake drum or disc rotor surface rough p
Brake drum or disc rotor roughness excessive p
Brake drum or disc rotor surface has mirror-like surface
Brake drum cracked p
Wheel brakes Foreign particles in brake drum p
Brake drum deformed or eccentric
Disc rotor thickness uneven
Brake shoes deformed or broken p
Brake shoe twisted or tilted
Shoe hold down cup broken p
Moving parts greased insufficiently p
Brake pedal stroke faulty(45 mm or more at 490N{50 kgf}) p
Brake pedal adjusted incorrectly, excessive play p
Brake pedal return faulty
Brake pedal Brake pedal play inadequate
Linkage rusted or deformed
Return spring fatigued or broken
Brake booster operating rod pushing up
Brake fluid insufficient p
Brake fluid leaking p
Brake fluid system Air mixed in p
Vapor lock reduction p
Brake fluid return insufficient because brake pipe tightened excessively
Vacuum system Degree of vacuum reduced p
Brake booster Brake booster defective p p
Brake master Piston cup faulty p
cylinder Return port clogged

35A-23
TROUBLESHOOTING
Symptoms Brake
drums Brakes
over- squeaking
heating

Squeaking in new vehicle or after brake lining

Remarks

Brake pedal return faulty

One wheel overheating
All wheels overheating

Brakes squeaking

Brake shuddering
Action too severe
replacement

Brake drags
Possible causes

Air pressure is not uniform L Gr 31

Tires
Right and left tire sizes different L Gr 31
Wheel hub bearing adjusted incorrectly p p p L Gr 26, 27
Left and right wheel base difference excessive L Gr 26, 27
Axle Wheel alignment incorrect L Gr 26
Trunnion bearing worn p L Gr 26
Upper or lower ball joint worn p L Gr 33
Backing plate ledge surface rough p
Backing plate ledge surface catches p
Backing plate deformed, mounted incorrectly p
Oil or water on brake lining or brake pad surface
Brake lining deteriorated or wrong material used
Brake lining unevenly worn or surface roughened
Brake lining or brake pad fading (surface p
deteriorated)

Wheel brakes Brake lining or brake pad completely worn out

Powder from wear on brake lining or brake pad p
Brake lining or brake pad worn p
Brake lining or brake pad contact incorrect p
Brake lining ground radius irregular
Wheel cylinder malfunctioning p p
Wheel cylinder piston cup defective p p
Shoe return spring fatigued or broken p p
Brake drum or disc rotor unevenly worn

35A-24
 35A
Symptoms Brake
drums Brakes
over- squeaking
heating

Squeaking in new vehicle or after brake linig

Remarks

Brake pedal return faulty

One wheel overheating
All wheels overheating

Brakes squeaking

Brake shuddering
Action too severe
replacement

Brake drags
Possible causes
Brake drum or disc rotor deformed
Brake drum or disc rotor worn
Brake drum or disc rotor surface rough
Brake drum or disc rotorroughness excessive
Brake drum or disc rotor surface has mirror-like surface p
Brake drum cracked
Wheel brakes Foreign particles in brake drum
Brake drum deformed or eccentric p
Disc rotor thickness uneven p
Brake shoes deformed or broken p
Brake shoe twisted or tilted p
Shoe hold down cup broken
Moving parts greased insufficiently
Brake pedal stroke faulty(45 mm or more at 490N{50 kgf})
Brake pedal adjusted incorrectly, excessive play
Brake pedal return faulty p
Brake pedal Linkage rusted or deformed p
Return spring fatigued or broken p
Brake booster operating rod pushing up p
Brake pedal play inadequate p
Brake fluid insufficient
Brake fluid leaking
Air mixed in
Brake fluid system
Vapor lock reduction
Brake fluid return insufficient because brake pipe
p
tightened excessively and thereby deformed
Vacuum system Degree of vacuum reduced
Brake booster Brake booster defective p
Brake master Piston cup faulty p
cylinder Return port clogged p

35A-25
TROUBLESHOOTING
Exhaust brake
Symptoms

Exhaust brake does not release

Exhaust brake not working
Remarks

Possible causes

Degree of vacuum insufficient p

Vacuum system
Pipe crushed p
3-way magnetic valve Not working p p B Electrical
Valve assembly does not work p p
Exhaust valve assembly
Valve assembly shaft seized p p
Electrical system Electrical system faulty p p B Electrical

35A-26
 35A

MEMO

35A-27
ON-VEHICLE INSPECTION AND ADJUSTMENT
Brake Fluid Replacement
T Tightening torque Unit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks
1 Air bleeder 6.9 to 8.8 {0.7 to 0.9} –

CAUTION k
• If the brake fluid gets on a painted surface it will dissolve the
paint, so wipe it off immediately.
• Always use new Fuso genuine brake fluid (SAE J1703f or FM-
VSS No.116, DOT3). Mixing in different quality brake fluid or
mineral oil (gas oil, engine oil, gear oil, automatic transmission
fluid, etc.) the rubber components of the brake assembly to
swell which will result in brake dragging and inefficient braking.
• When filling the brake fluid, make sure dirt and water are not
mixed in.
• If a funnel is used, use a funnel made to be used with brake flu-
id.
• Add enough brake fluid so that the brake fluid tank level is al-
ways at “MAX.”
• Check that the old brake fluid has been replaced by the new
brake fluid by noting the color of the brake fluid that comes out.

<Front disc brake> [Replacement]

• Start the engine and let it idle until you have completed the brake flu-
id replacement.
• Attach vinyl pipes A to air bleeders 1 of the front disc brake, rear
wheel cylinder, and put one end of the pipes in container B.

1
A
B
12934

07529

35A-28
 35A
• Loosen air bleeders 1 and depress the brake pedal several times to
completely drain the brake fluid.
• Fill the new brake fluid up to the “MAX” level of the brake fluid tank,
depress the brake pedal repeatedly until the old brake fluid is com-
pletely replaced with new brake fluid, and when this work is complet-
ed tighten air bleeder 1 at the specified torque.

07530

07623
• Bleed the air from the brake system.
L P35A-30

35A-29
ON-VEHICLE INSPECTION AND ADJUSTMENT
Brake System Air Bleeding
<Anti-lock brake system> L Gr35E

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Air bleeder 6.9 to 8.8 {0.7 to 0.9} –

CAUTION k
• If the brake fluid gets on a painted surface it will dissove the
paint, so wipe it off immediately.
• Always use new Fuso genuine brake fluid (SAE J1703f or FM-
VSS No.116, DOT3). Mixing in different quality brake fluid or
mineral oil (gas oil, engine oil, gear oil, automatic transmission
fluid, etc.) the rubber components of the brake assembly to
swell which will result in brake dragging and inefficient braking.
• When filling the brake fluid, make sure dirt and water are not
mixed in.
• If a funnel is used, use a funnel made to be used with brake flu-
id.
• Add enough brake fluid so that the brake fluid tank level is al-
ways at “MAX.”

• Start the engine and let it idle until you have completed the brake flu-
id replacement.
• Attach vinyl pipes A to air bleeders 1 of the front disc brake, rear
<Front disc brake>
wheel cylinder, and put one end of the pipes in container B to bleed
air.

<Front brake system>

Right disc brake

Left disc brake

<Rear brake system>
1 Right wheel cylinder

A
Left wheel cylinder
B 12934

07532

35A-30
 35A
• Depress the brake pedal slowly several times, and with the brake
pedal depressed, loosen air bleeder 1 to discharge air together with
the brake fluid.After closing the air bleeder, release the brake pedal.

CAUTION k
Make sure you maintain the brake fluid at the “MAX” level of the
brake fluid tank because the brake fluid decreases during air
bleeding.

07530 • Repeat the above operation until air bubbles are no longer present in
the brake fluid discharged from air bleeder 1.
• When the discharged fluid is free of air bubbles, tighten air bleeder 1
at the specified torque.
• Make sure that the brake fluid level is at the “MAX” level of the brake
fluid tank, and depress the brake pedal several times to ensure that
the brake fluid does not leak from anywhere. then conduct a brake
test.

35A-31
ON-VEHICLE INSPECTION AND ADJUSTMENT
Brake Pedal Free Play Inspection and Adjustment
Service standards Unit: mm
Location Maintenance item Standard value Limit Remedy
– Brake pedal play 10 to 15 – Adjust

[Inspection]
Check if the brake pedal free play confirms to the standard value with
the engine stopped. If the measured value deviates from the standard
value, adjust the position of the brake pedal.

[Adjustment]
LP35A-46

10 to 15mm
06539

Inspection and Adjustment of Clearance between Brake Pedal and Floor Panel
Service standards Unit: mm
Location Maintenance item Standard value Limit Remedy
Clearance between brake pedal and floor
– 45 or more – Adjust
panel (with pedal depressed at 490N {50 kgf})

[Inspection]
Depress the brake pedal using 490 N{50 kgf} of force when the engine
is idling to check if the clearance between the brake pedal and the floor
conforms to the standard value. If the measured value deviates from the
standard value, adjust the position of the brake pedal.

[Adjustment]
LP35A-46

06540

35A-32
 35A
Disc Brake Pad Inspection and Replacement
Service standards Unit: mm
Location Maintenance item Standard value Limit Remedy
8, 11 Outer and inner pad thickness 14 4 Replace

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
4 Slide pin bolt 83 to 93 {8.5 to 9.5} –

K Lubricant
Location Points of application Specified lubricant Quantity
4 Slide pin bolt threads Brake fluid (SAE J1703f or FMVSS No.116, DOT3) As required

J Special tools Unit: mm

Location Tool name and shape Part No. Application

To separate the pistons

5 Piston expander MB990520 when the brake pads are
replaced

06815

[Inspection]
• When brake pad thickness A becomes approximately 4 mm, pad
warning indicator 1 makes contact with disc rotor 2 and is discon-
nected, which turns on brake warning light B in the meter cluster and
notifies the driver that the brake pads need to be replaced.

06816

35A-33
ON-VEHICLE INSPECTION AND ADJUSTMENT
• Inspect brake pad thickness A from inspection holes C to calipers 3.
If the brake pad thickness is below the limit replace the brake pads
with a single wheel kit.

06817
[Replacement]
• Remove bottom slide pin bolt 4, turn calipers 3 toward the top, and
secure them with a wire, etc.

CAUTION k
• When fastening calipers 3, be careful not to apply excessive
force on the brake hose or harness or to prevent them from fall-
ing.
• Rubber grease has been applied to slide pin bolt 4, so do not
wipe it off or get dust, etc., on it.
71935
• Inspect inside caliper 3 to see if brake fluid is leaking from piston 5 or
if piston boots 6 are damaged, and if any problems are found, re-
place the faulty parts.
• Remove the following parts.
7 Outer shim
8 Outer pad
9 Inner shim A
10 Inner shim B
11 Inner pad
12 Pad liner A
13 Pad liner B

71936

• Install pad wear indicator 1 to the pad kit’s inner pad 11 using clip 14
of the pad wear indicator kit.

71937
• Install the kit parts in the opposite sequence the old parts were re-
moved.
• The installation position of pad wear indicator 1 of inner pad 11 is the
disc rotor 2 inlet of caliper 3 when the vehicle is moving forward.

35A-34
 35A
• Clean torque member 15.
• Install pad liner A 12 and pad liner B 13 onto torque member 15.
• Install outer shim 7, inner shim A 9, and inner shim B 10 on outer pad
8 and inner pad 11.
• Install outer pad 8 and inner pad 11 onto torque member 15.

71938

• Use the J piston expander to press piston 5 inside caliper 3 to the

bottom of the caliper.

06824

• Return caliper 3 to its original position taking care not to damage pis-
ton boots 6.
• Thinly apply brake fluid to the outer circumference and threads of
slide pin bolt 4.
• When installing slide pin bolt 4, bleed the air from inside the bushing.
L P35A-48
• Tighten slide pin bolt 4 to the specified torque.
• Install the pad wear indicator 1 harness.
L Gr26
71939 • Inspect the drag torque.
L P35A-48
• Depress the brake pedal several times and then check that the level
of the brake fluid in the brake fluid tank is at “MAX.” If it is below this
level supply more brake fluid.

35A-35
ON-VEHICLE INSPECTION AND ADJUSTMENT
Drum Brake Lining Thickness Inspection and Replacement
Service standards Unit: mm
Location Maintenance item standard value Limit Remedy
Front – 4.0
2 Brake lining thickness Replace
Rear – 4.0

[Inspection]

CAUTION k
Be sure to inspect at two points for each wheel per side.

• Remove backing plate cover 1 and inspect the thickness of brake lin-
ing 2 via inspection hole A.
• If the thickness of brake lining 2 is below the limit, replace the brake
lining and the brake shoe assembly for that wheel as a unit.
06541
• After the inspection is completed, be sure to replace cover 1.

[Replacement]
L P35A-52

Inspection of Clearance between Brake Drum and Lining

Insert 0.2 mm feeler gauge A into inspection hole B of the back plate,
and make sure that you can move the gauge in and out feeling some re-
sistance. After this inspection, adjust the clearance if any abnormality is
found.
L P35A-37

08177

35A-36
 35A
Brake Booster Inspection
Service standards
Location Maintenance item standard value Limit Remedy
Air tightmess with no load (with vacuum meter at 67
kPa {500 mmHg} and engine stopped) Vacuum drop after 15 sec-
– Air tightmess with load (with brake pedal lightly de- onds should be 0.8 kPa {25 – Replace
pressed and vacuum meter at 67 kPa {500 mmHg} mmHg} or less.
and engine stopped)
Boosting action 3.9 MPa {40 kg/cm2}
(Fluid pressure with vacuum meter at 67 kPa (98 N {10 kgf})
– Replace
{500 mmHg} and brake pedal depressed at 8.8 MPa {90 kg/cm2}
specified foot pressure) (295 N {30 kgf})
–
No boosting action 0.2 MPa {2 kg/cm2}
(Fluid pressure after vacuum meter falls to 0 kPa (98 N {10 kgf})
– Replace
{0 mmHg} and brake pedal depressed at 1.5 MPa {15 kg/cm2}
specified foot pressure) (295 N {30 kgf})

[Inspection]
Two types of inspection can be used to inspect the brake booster oper-
ation. One is an inspection without a tester and the other an inspection
with a simple tester. Make sure that there is no fluid leak or damage at
the joints of the brake pipes and hoses before inspection.
(1) Inspection of check valve operation

CAUTION k
• Make sure that your saliva does not enter the check valve.
• Be sure to inspect the check valve both when opened and when
closed.
• Do not remove the check valve fitted to the vacuum hose.

Start the engine

06542

Stop the engine

Immediately after the engine is stopped, remove the clamps on the vacuum
pipe and the vacuum hose, and hold the vacuum hose in your mouth.

There is passage of air only

No passage of air by your
at the moment you inhale
blowing in (The valve is
and depress the brake pedal
closed.)
(The valve is open.).
YES NO YES NO

Good Faulty Good Faulty

35A-37
ON-VEHICLE INSPECTION AND ADJUSTMENT
(2) Inspection of brake booster operation

CAUTION k
Be sure, if the brake booster is faulty, to determine the quality of
the brake booster as an independent device by means of a
bench test specified by the maker’s service station. This is be-
cause the above inspection of the brake booster operation is
merely a simplified inspection. If any fault is found, hand the de-
vice over to the service station without disassembling it, and re-
place the entire assembly.

P Inspection method without a tester

If the brake booster is determined to be good by inspection 1 to 3 below,
its operation is normal. If any fault is detected in any of the three inspec-
tions, the following parts are likely to be faulty.
• Check valve
• Vacuum hose
• Brake booster
• Vacuum pump

[Inspection 1]
After one or two minutes of operation, stop the engine.

Depress the brake pedal using normal foot pressure.

The brake stoke is longest during the first brake application, but
becomes shorter gradually during the second and third applications.
YES NO

06543 Good Faulty

[Inspection 2]
Depress the brake pedal several times while the engine is stopped.

With the brake pedal depressed, start the engine.

The brake pedal goes down a little.

YES NO

Good Faulty
06544
[Inspection 3]
With the brake pedal depressed while the engine is running, stop
the engine.

The height of the brake pedal remains unchanged for approximately

30 seconds.
YES NO

Good Faulty

06545

35A-38
 35A
P Inspection with a simplified tester
• Air tightness inspection
• Before inspection, observe the operation of check valve 2 fitted to
vacuum hose 1.
LP35A-37
• Remove vacuum hose 1 from brake booster 3, place the end with-
out the white s mark on the brake booster and connect it to vacu-
um meter A. Connect another vacuum hose (without a built-in
check valve 2) between the vacuum meter and the brake booster.
Connect pressure gauges B and foot pressure meter C as illustrat-
ed, and bleed the air from the pressure gauges.
• If the results of the following two air tightness inspections are satis-
06546
factory, the operation is normal. If any fault is found during either or
the two inspections, the following parts are likely to be faulty.
• Vacuum hose
• Brake booster

[No-load air tightness inspection]

Start the engine and stop it when the vacuum meter indicates 67 kPa
{500 mmHg}

After the engine has stopped, the drop of the degree of vacuum for
approximately 15 seconds is 0.8 kPa {25 mmHg} or less.

YES NO

Good Faulty

[Loaded air tightness inspection]

Start the engine, depress the brake pedal lightly, and stop the engine when
the vacuum meter indicates 67 kPa {500 mmHg}.

After the engine has stopped, the drop of the degree of vacuum for
approximately 15 seconds is 0.8 kPa {25 mmHg} or less.

YES NO

Good Faulty

CAUTION k
Be sure, when you attach vacuum hose 1 to brake booster 3 af-
ter the inspection that the end without the white s mark faces
the brake booster.

35A-39
ON-VEHICLE INSPECTION AND ADJUSTMENT
P Inspection of characteristics
• Inspect characteristics after the air tightness inspection is finished.
• If the results of the following two inspections are good, the opera-
tion is normal. If any fault is found during either of the two inspec-
tions, the following parts are likely to be faulty.
• Vacuum hose
• Brake booster

[Boosting action inspection]

Start the engine, and when the vacuum meter indicates 67 kPa {500 mmHg}
and the brake pedal is depressed using the specified foot pressure, measure
the fluid pressure.

Fluid pressure
Foot pressure N {kg}
MPa {kg/cm2}
98{10} 3.9 {40}
295 {30} 8.8 {90}

YES NO
Good Faulty

[No boosting action inspection]

Stop the engine, and when the vacuum meter indicates 0 kPa {0 mmHg} and
the brake pedal is depressed using the specified foot pressure, measure the
fluid pressure.

Fluid pressure
Foot pressure N {kg}
MPa {kg/cm2}
98{10} 0.2 {2}
295 {30} 1.5 {15}

YES NO
Good Faulty

CAUTION k
Be sure when you attach vacuum hose 1 to brake booster 3 after
the inspection that the end without the white s mark faces the
brake booster.

35A-40
 35A
P Brake booster performance diagram
93{700}
9.8{1000}
80{600}
8.8{900}

Vacuum pressure kPa {mmHg}

7.8{800} 67{500}
Brake booster force pushing

6.9
{700}
the push rod kN {kgf}

5.9
{600}
4.9{500}
3.9{400}
2.9{300}
2.0{200}

1.0{100}

0 1.0{100} 2.0{200}
Force pushing the operating rod kN {kgf}
06549

Exhaust Brake System Inspection

[Inspection]
Turn the exhaust brake switch on, depress the accelerator pedal gradu-
ally, and make sure that when the engine revolution reaches 800 to 950
rpm, the exhaust brake operation indicator lamp within the meter cluster
goes off.
If any fault is found, adjust the accelerator switch.
[Adjustment]
• Turn the exhaust brake switch on, depress the accelerator pedal
gradually, and make sure that when the engine revolution reaches
800 to 900 rpm, the exhaust brake operation indicator lapm within the
meter cluster goes off.
• If the indicator light goes off when the engine revolution is 800 rpm or
less, adjust accelerator switch 2 by screwing it in.
• If the indicator light goes off when the engine revolution is 950 rpm or
more, adjust accelerator switch 2 by unscrewing it.

06550

35A-41
VACUUM PUMP
PDisassembly sequence
1 Check valve assembly
2 Bolt
3 O-ring
4 Cylinder
5 Vane
6 Rotor
7 O-ring
8 Flange

P: Positioning pin
X: Non-reusable parts
PAssembly sequence
Follow the disassembly sequence in re-
verse.
For removal and installation of the vacuum
pump, see B Gr11.

05412

Service standards
Location Maintenance item Standard value Limit Remedy
Degree of vacuum 90.6kPa {680mmHg} or more –
– Degree of pump vacuum Replace
Revolution 3000rpm –

T Tightening Torque Unit: N?m {kgf?m}

Location Parts to be tightening Tightening torque Remarks
2 Bolt (cylinder and flange installation) 8.8 ± 2 {0.9 ± 0.2} –

K Lubricant
Location Points of application Specified lubricant Quantity
3, 7 O-ring periphery Engine oil As required

35A-42
 35A

MEMO

35A-43
BRAKE MASTER CYLINDER

72048

P Disassembly sequence
1 Retaining ring 5 Clamp
*a: Brake booster support
2 Primary piston assembly 6 Connector *b: Brake booster and brake pedal
3 Set bolt 7 Cylinder body assembly
4 Secondary piston assembly

CAUTION k
• Be sure to use a brake fluid or vegetable oil, such as industrial alcohol, for cleaning.
• Be sure not to damage the inner surface of cylinder body 7.

P Assembly sequence
Follow the disassembly sequence in reverse.

Service standards Unit: mm

Location Maintenance item Standard value Limit Remedy
Primary piston assembly spring load
2 100 to 125 N {10.5 to 12.7 kgf} 97 N{9.9 kgf} Replace
(installed length 36.3)
Clearance between primary piston assembly and
2, 4, 7 0.02 to 0.10 0.2 Replace
secondary piston assembly, and cylinder body
Secondary piston assembly spring load
4 76 to 92 N {7.8 to 9.4 kgf} 72 N {7.3 kgf} Replace
(installed length 31.0)

35A-44
 35A
T Tightening Torque Unit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks
3 Set bolt 6.9 to 8.8 {0.7 to 0.9} –

K Lubricant
Location Points of application Specified lubricant Quantity
1 Retaining ring periphery Rubber grease As required

R Service procedure
4 Secondary piston assembly
[Removal]
• Using rod A, push in secondary piston assembly 4, then loosen set
bolt 3.

71613

• Put plugs D into brake fluid port B and discharge port C that leads to
the rear wheel brakes, then feed compressed air via discharge port E
to the front wheel brakes to extract the secondary piston assembly.

WARNING k
You must be careful not to feed air at too high a pressure or the
secondary piston assembly might be violently ejected. To avoid
danger, use compressed air at minimum pressure.

71614

[Installation]
Using rod A, push in secondary piston assembly 4, then tighten set bolt
3 at the specified torque.

71613

35A-45
BRAKE PEDAL AND BRAKE BOOSTER

71616

P Disassembly sequence
1 Nut 5 Bolt 9 Pedal pad
2 Clevis pin 6 Spring 10 Brake pedal
3 Brake booster 7 Collar 11 Stop lamp switch B Electrical
4 Nut 8 Bushing 12 Support assembly

CAUTION k
Do not disassembly brake booster 3 because it non-disassemble type.

P Assembly sequence
Follow the disassembly sequence in reverse.

Service standards Unit: mm

Standard value
Location Maintenance item Limit Remedy
Basic diameter in [ ]
7, 8 Clearance between collar and bushing [16] 0.02 to 0.26 0.50 Replace
Clearance between top of thread area of
10, 11 0.5 to 1.5 – Adjust
stop lamp switch and brake pedal stopper
Brake pedal installation height (height from
250 ± 3.0 – Adjust
10 pedal pad center to master cylinder center)
Brake pedal full stroke 144.3 – Adjust

35A-46
 35A
T Tightening torque Unit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks
1 Nut (brake booster installation) 8.8 to 14 {0.9 to 1.4} –
4 Nut (brake booster installation) 34 to 54 {3.5 to 5.5} –
11 Stop lamp switch 19 to 27 {1.9 to 2.8} –

K Lubricant
Location Points of application Specified lubricant Quantity
5 Sliding surfaces of bolt bushing Chassis grease [NLGI No.1 (Li soap)] As required

R Service procedure
P Post-assembly adjustment
• Brake pedal installation height adjustment
Turn operating rod B of brake booster 3 to adjust the height from the
center of pedal pad 9 to the center of master cylinder A so that it is
the standard height.
Then tighten nut C.

CAUTION k
Make sure, when brake pedal 10 is depressed fully, that operat-
ing rod B of brake booster 3 acts as stopper.

• Brake pedal full stroke inspection

mm
Make sure that the full stroke is at the standard value when brake
pedal 10 is depressed fully.
If there is a fault, adjust the brake pedal installation height.

• Brake pedal play inspection

LGr35A-32

mm

71617

0.5 to 1.5 mm 11 Stop lamp switch adjustment

Turn stop lamp switch 11 to adjust clearance between the top of the
thread of the stop lamp switch and the stopper of brake pedal 10 to the
standard value, and then fasten with lock nut A.

CAUTION k
Make sure, when brake pedal 10 is released, that stop lamp
switch 11 does not function as the stopper for the brake pedal.

71618

35A-47
FRONT WHEEL BRAKE
This illustration shows the left wheel disc brake as seen from the front.

74321

P Disassembly sequence
1 Slide pin bolt 9 Inner shim A 17 Pin boots
2 Piston boots 10 Inner shim B 18 Cap
3 Piston 11 Clip 19 Torque member
4 Piston seal 12 Pad wear indicator
5 Air bleeder 13 Inner pad
*: Disc rotor
L Gr26
6 Caliper 14 Pad liner A
7 Outer shim 15 Pad liner B X: Non-reusable parts
8 Outer pad 16 Bushing

CAUTION k
• When disassembling a component be sure to replace the rubber components with a seal kit.
• Do not get lubricants or greases on outer pad 8, inner pad 13, or the disc rotor surface.
*
• During assembly use the grease from the seal kit.

P Assembly sequence
19 17 16 15 14 1 18 Repair kits : Pad kit
Seal kit
13 12 11 10 9
Pad wear indicator kit
8 7
6 5 4
3 2
For information regarding front wheel brake removal and installation, see L Gr26.

35A-48
 35A
Service standards Unit: mm
Location Maintenance item Standard value Limit Remedy
Immediately after brake pedal re- tangential 95 N
Drag torque 9.8N?m {1 kgf?m} or less –
lease (approx. 5 seconds later) force at {9.7 kgf}
(measure the
– the hub
tangential After rotating the disc rotor 10 67N
6.9N?m {0.7 kgf?m} or less – bolt posi-
force) times {6.8 kgf}
tion
8, 13 Outer pad and inner pad thickness 14 4 –
Run out (measure by
0.07 or less 0.10 Replace
* Disc rotor attaching to front axle)
Thickness 40 38 Replace

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Slide pin bolt 83 to 93 {8.5 to 9.5} Wet
5 Air bleeder 6.9 to 8.8{0.7 to 0.9} Wet

K Lubricant and/or sealant

Location Points of application Specified lubricant and/or sealant Quantity
Slide pin bolt threads Brake fluid (SAE J1703f or FMVSS No.166, DOT3) As required
1 Slide pin bolt pin outer periphery, bushing and con- As required
AMIX (pink)
nection area with pin boots
3 Piston boots outer periphery Brake fluid (SAE J1703f or FMVSS No.166, DOT3) As required
5 Apply to the air bleeder threads. AMIX (pink) As required

6 Caliper cylinder lip inner periphery AMIX (pink) As required

Entire bushing inner periphery and connection area As required
16 AMIX (pink)
with slide pin bolt
17 Connection area with the pin boots slide pin bolt AMIX (pink) As required
Torque member pin boots groove, entire main side As required
19 AMIX (pink)
guide hole, and cap seat surface

35A-49
FRONT WHEEL BRAKE
R Service procedure
P Drag torque measurement
Use spring balancer A to measure the tangential force at hub bolt B. If
the tangential force is at the specified value then the drag torque is at
the standard value.
If the measured value deviates from the stadard value, inspect the slid-
ing areas of piston seal 4 and piston 3.

06972

1 Slide pin bolt installation

Lightly apply metal rubber #20 on screw A, and grease (AMIX: pink) to
the joint D with slide periphery B, bushing groove C, and pin boots 17,
and then tighten to the specified torque.
Bleed the air from bushing 16 and the pin boots, and check that the
bushing and pin boots seals E are seated against bushing groove C of
slide pin bolt 1 and connection area D with the pin boots.

06970

2 to 4 Piston boots, piston, and piston seal installation

• Apply metal brake fluid to the piston 3 periphery, and insert piston
boots 2.
• Uniformly spread out the grease (red) applied to piston seal 4 and
seat it in the caliper 6 seal groove.
• Evenly apply grease (AMIX:pink) to caliper 6 cylinder lip A.
• Seat piston boots 2 caliper side seal in caliper 6 boots groove B and
then sloe press-fit piston 3.
• Check that piston boots 2 piston side seal is seated in piston 3 boots
06960
groove C.
7 to 10 13 Pad and shim installation
Be careful of the direction of each shim claw A.

71621

35A-50
 35A
16 Bushing installation
Use push rod A with an outer diameter of approximately 8 mm and in-
stall it in the torque member 19 guide hole.
Evenly apply grease (AMIX:pink) to the entire bushing 16 inner periph-
ery and connection area with slide pin bolt 1.

06962

17 Pin boots installation

Evenly apply grease (AMIX:pink) to the mounting surface with pin boots
17 slide pin bolt 1 and the entire inner periphery of torque member 19
guide hole A, and then install the pin boots on the torque member.

06963

35A-51
REAR WHEEL BRAKE
Rear Wheel Brake Assembly

13

71622

P Disassembly sequence
1 Return spring 10 Spacer
2 Shoe hold down cup 11 Bolt
3 Shoe hold down spring 12 Wheel cylinder assembly L P35A-58
4 Shoe hold down pin 13 Cover
5 Brake shoe assembly 14 Cover
6 Rivet 15 Backing plate
7 Brake lining
8 Brake shoe L Gr27
9 Pipe assembly
*: Brake drum

CAUTION k
• Make sure that oil or grease dose not stick to the lining surface of brake lining 7 and the inner surface of brake
drum .
*
• Be sure to wash and apply rubber grease to the thread area of the adjuster and the adjusting screw of wheel
cylinder assembly 12 when replacling brake lining 7. L P35A-58

P Assembly sequence
Follow the disassembly sequence in reverse.
For information regarding rear wheel brake removal and installation, see L Gr27.

35A-52
 35A
Service standards Unit: mm
Location Maintenance item Standard value Limit Remedy
1 instslled load of return spring (installed lenght: 190) 215 ± 22N {22 ± 2.2kgf} 175 N {18 kgf} Replace
7 Thickness of brake lining 10.4 4.0 Replace
Inner diameter 320
Brake drum *321 322 Replace or
* Cylindricity 0.05 0.20 replace

Shows the repair limit value

*
T Tightening torque Unit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks
9 Pipe assembly (Wheel cylinder assembly installation) 13 to 15 {1.3 to 1.5} –
11 Bolt (wheel cylinder assembly installation) 79 to 105 {8.1 to 11.0} –

K Lubricant
Location Points of application Specified lubricant Quantity
Contact surface between the backing plate ledge and As required
5, 15 shoe rim, wheel cylinder assembly anchor area of Brake grease AKB100
shoe web, and adjusting screw contact point

35A-53
REAR WHEEL BRAKE
R Service procedure
P Post-assembly adjustment
Initial setting of clearance between the brake drum and brake shoe as-
sembly
• Jack up the wheel to be adjusted and check if the wheel bearing is
loose.
• Insert 0.3 mm thickness gauge A through wear inspection hole B
and set brake shoe assembly 5 so that the gauge can be pulled
out and inserted with a fair amount of resistance.
• If resistance cannot be felt with thickness gauge A
00320 From adjustment hole E turn adjuster C in the direction of arrow
D to make the adjustment.
• If thickness gauge A cannot be inserted or the resistance is
large
Push up wheel cylinder lever G with approximately 2 mm diam-
eter wire F and then turn adjuster C in the opposite direction of
arrow D to make the adjustment.

• After setting the clearance to 0.3 mm, depress the brake pedal 2
or 3 times. When this is done the clearance between brake drum
06385 and brake shoe assembly 5 will be automatically adjusted to ap-
*
proximately 0.2 mm.
• Insert 0.2 mm thickness gauge A and check that it can be pulled
out and inserted with a fair amount of resistance. After checking, if
there are any problems then disassemble and inspect wheel cylin-
der assembly 12.
L P35A-58
• After adjustment be sure to replace covers 13 and 14.

CAUTION k
• Adjust both locations for each wheel.
• The backing plate arrow D position and direction varies depend-
06214
ing on the model.

1 Return spring
[Removal]
To remove retrun spring 1, place screwdriver A on the hook of the re-
turn spring and then pry and remove the return spring making use of
wheel cylinder assembly 12 adjusting screw B as a fulcrum.

05879

35A-54
 35A
[Installation]
Insert small Philips-hear screwdriver C into the hook of return spring 1
and insert the tip of the screwdriver into return spring installation hole D
of brake show assembly 5 to lever against the return spring while in-
stalling it.

07375

5 Brake shoe assembly inspection

Measure thickness A of brake lining 7, and if the measured value is low-
er than the limit, replace the brake linings for one axle as a unit of re-
placement.

01589

5 15 Brake shoe assembly and backing plate installation

Apply grease to the areas shown in the illustration.

06215

06216

35A-55
REAR WHEEL BRAKE

7 Brake lining
[Removal]
Drill out caulked ends A of rivets 6 on the sides of brake shoe 8 on a
drill press to remove brake lining 7.

05882

[Installation]
• Wash the surface of brake shoe 8 that mounts with brake lining 7 with
cleaning fluid and then dry it.
• Insert rivets 6 from the brake lining 7 side and caulk the rivets in se-
quence from the center of brake shoe 8 towards both ends.
CAUTION k
• Make sure the caulking load of rivet 6 is 21±1.0 kN{2100±100
kgf}.
• Caulk rivets 6 so that the clearance between brake shoe 8 and
00573
brake lining 7 is 0.05 mm or less around the rivets, 0.4 mm or
less on the side face, and 0.5 mm or less on the end face.
• Be sure to in inspect the contact of brake drum and brake lin-
*
ing 7 and correct irregularities on the brake linings if necessary.
The repair should be done with the brake shoe correctly assem-
bled.
• Be sure to use brake linings 7 with identical size and identifica-
tion mark.
• Be sure to replace all brake linings 7 of one axle whenever any
replacement is necessary.

Brake drum repair

*
If the cylindricity of brake drum is higher than the limit, or if the brake
*
drum is scored, repair the drum by machining to an acceptable limit.

CAUTION k
Machining of brake drum should be done with the wheel hub
*
attached as an integral object.

35A-56
 35A

MEMO

35A-57
REAR WHEEL BRAKE
Wheel cylinder assembly

X 12
15
2
3 K
1 17

16 T
4

14
11 X
K
13
K
9 K

10
8 K
7 K
6 K
5 K
K 79635

P Disassembly sequence
1 Spring 11 Boot
2 Spring and fitting 12 Piston assembly
3 Lever 13 Piston cap
4 Piston assembly 14 Piston
5 Adjust screw 15 Boot
6 Adjuster 16 Air bleeder
7 Washer (thin) 17 Body
8 Washer (thick)
9 Piston cap X: Parts which must not be reused.
10 Piston
P Assembly sequence
Follow the disassembly sequence in reverse order.

Repair kit: Wheel cylinder kit

Service Standard Unit: mm

Standard value
Location Maintenance item Limit Remedy
Basic diameter in [ ]
10, 14, 17 Clearance between piston and body [31.75] 0.02 to 0.08 0.2 Replace

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
16 Air bleeder 6.9 to 8.8 {0.7 to 0.9} –

35A-58
 35A
K Lubricant
Location Points of application Specified lubricant Quantity
5 Apply to the adjust screw threads Rubber grease Appropriate amount
6 Apply to the adjuster threads and sliding parts Rubber grease Appropriate amount
7, 8 Apply to both sides of the washer. Rubber grease Appropriate amount
9, 13 Apply to the piston cap sliding surface Rubber grease Appropriate amount
10, 14 Apply to the piston inside and sliding surfaces Rubber grease Appropriate amount
17 Apply to the boot mounting groove on the body. Rubber grease Appropriate amount

R Service procedure
1 Spring installation
Hang the closed end hook of the spring 1 on pin A of the body 17.

05587

7 8 Washer (thin), Washer (thick) Installation

Install the washer (thick) 8 with the black surface in the direction shown
in the illustration.

CAUTION k
10 If the direction, order and quantity of washer (thin) 7 and washer
(thick) 8 are mistaken, the shoe gap will not be adjusted correct-
8
ly, so be careful not to mistake these points.
7
78757

9 13 Piston cap installation

10, 14 9, 13 Install the piston cap 9 and 13 in the direction shown in the illustration.

CAUTION k
If the direction of the piston cap 9 and 13 is mistaken, it could
cause the brakes to function poorly and could cause the brake
fluid to leak, so be careful not to mistake the direction.

79631

35A-59
EXHAUST BRAKE SYSTEM
Exhaust brake unit
P Disassembly sequence
1 Bolt
2 Cover
3 Clevis pin
4 Nut
8 5 Clevis
6 Lock nut
7 Bearing
9
8 Connector
9 Power chamber
10 Nut
11 Lever
14 6 12 Bracket
7
13 Adjusting bolt
5 14 Valve assembly
3
NOTE
12 Since power chamber 9 is a non-disas-
sembly type, do not disassemble it.
13 10
4
P Assembly sequence
11
Follow the assembly sequence in reverse.
1 Removal and installation of exhaust brake
2 unit B Gr15
1

71623

Service Standard Unit: mm

Location Maintenance item Standard value Limit Remedy
Average value of upper/lower clearances between but-
terfly valve and body when the butterfly valve is com-
– 0.10 to 0.25 – Adjust
pletely closed (Degree of vacuum in power chamber: 87
to 93 kPa {650 to 700 mmHg})
Power chamber air tightness (Air tightness 15 seconds
9 63 kPa {475 mmHg}) or more – Replace
after negative pressure of 67 kPa {500 mmHg})

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Bolt (cover mounting) 4.9 to 6.9 {0.5 to 0.7} –
4 Nut (power chamber mounting) 9.8 to 16 {1.0 to 1.6} –
6 Lock nut (clevis fixing) 9.8 to 16 {1.0 to 1.6} –
8 Connector 9.8 {1.0} or more Wet
10 Nut (lever mounting) 9.8 to 16 {1.0 to 1.6} –

35A-60
 35A
K Sealant
Location Points of application Specified sealant Quantity
8 Connector thread THREEBOND 1211 As appropriate

R Service procedure
P Adjustment after assembly
[Full close adjustment]
Apply the negative pressure of 87 to 93 kPa {650 to 700 mmHg} to
D power chamber 9 and adjust clearances with adjusting bolt 13 so that
9
the average value of C and D between butterfly valve A and body B
C
may be the standard value.
13
B A Average value of clearance = C + D
2

05270

[Full open adjustment]

Adjust butterfly valve A of valve assembly 14 with adjusting bolt 13 to
A
be fully opened.

14
13
05269

9 5 Installation of clevis
Install power chamber 9 into bracket 12 and install the clevis so that cle-
5
vis 5 may be offset half of the lever 11 hole.
11

12

05257

9 8 Installation of connector
Install connector 8 on power chamber 9 to the angle as shown in the fig-
68 3 ure.

8 05267

35A-61
EXHAUST BRAKE SYSTEM
9 Air tightness inspection of power chamber
Provide piping as shown in the figure. Apply the negative pressure of 67
B
kPa {500 mmHg} to power chamber 9 and stop vacuum pump A.
15 seconds later, make sure that the value of vacuum gauge B is the
standard value. If the measurement value is out of the standard value,
A
9 replace the power chamber.

05268

35A-62
 35A

MEMO

35A-63
HYDRAULIC UNIT

11 5 4
9 6 3

8 2

7
12

13

8
11

10

78497

P Inspection before disassembly

Inspect function and operation of the hydraulic unit. L Gr35E.

P Disassembly sequence
1 Brake tube (Marking: White) 8 Bolt
2 Brake tube (Marking: None) 9 Cover
3 Brake tube (Marking: Pink) 10 Bolt
4 Brake tube (Marking: Orange) 11 Nut
5 Brake tube (Marking: Yellow) 12 Bracket
6 Brake tube (Marking: Blue) 13 Hydraulic unit
7 Anti-lock brake system harness

CAUTION k
• Plug removed brake tubes 1 to 6 and hydraulic unit 13 to prevent entry of dust.
• Hydraulic unit 13 cannot be disassembled. If abnormality is found, replace the assembly.

P Assembly sequence
Follow the assembly sequence in reverse.

35A-64
 35A
P Inspection after installation
Inspect function and operation of hydraulic unit 13. L Gr35E

CAUTION k
After installation, bleed air from the brake system and hydraulic unit 13. L Gr35A, E

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening Torque Remarks
1 to 6 Brake tube mounting 13 to 17 [1.3 to 1.7] –
8, 10 Bolt (cover and bracket mounting) 9.8 to 15 [1 to 1.5] –
11 Nut (hydraulic unit mounting) 9.8 to 15 [1 to 1.5] –

R Service procedure

4 1 to 6 Installation of brake tube

5 Install brake tubes 1 to 6 on hydraulic unit 13 as shown in the figure. An
identification symbol is stamped at the connecting part of the hydraulic
6 unit.
3 Identifica-
Brake tube Connection
tion symbol
1 2
Brake tube (Marking: White) 1 To brake master cylinder (rear) W
13
Brake tube (Marking: None) 2 To brake master cylinder (front) –
78498
Brake tube (Marking: Pink) 3 Front axle left wheel P
Brake tube (Marking: Orange) 4 Front axle right wheel O
Brake tube (Marking: Yellow) 5 Rear axle left wheel Y
Brake tube (Marking: Blue) 6 Rear axle right wheel B

B 7 Anti-lock brake system harness

[Removal]
• Press unlock pin B of connector lever A with finger and unlock it.
• Make sure that the lock is unlocked and push back connector lever A
to the arrow.

7
A 78499

• Make sure that connector lever A is completely returned and pull

connector C and remove Anti-lock brake system harness 7.

CAUTION k
If it is difficult to remove Anti-lock brake system harness 7, pull-
ing with undue force may damage connector C. Return connec-
tor lever A to the lock position and repeat the procedure.

7 A
C
79282

35A-65
HYDRAULIC UNIT
[Installation]
• Make sure that there is no foreign matter on connector C terminal.
C A • Set connector lever A at the position shown in the figure.

CAUTION k
If connector C is connected when connector lever A is not at the
position shown in the figure, the connector lever may be dam-
aged. Be sure to set the lever as shown in the figure.

78501

• Insert connector C of Anti-lock brake system harness 7 straight into

13 hydraulic unit 13.

7
78502

• Then, connector lever A turns by 208 to 308 in the arrow direction.

13 • The case surface of hydraulic unit 13 must be parallel D to the sur-
face of connector lever A shown in the figure.
D 20
to 30
A

7
79283

• Hold the center of connector lever A and turn the lever until "click"
13 noise is heard for locking.

A CAUTION k
• If connector lever A is turned with undue force when it is not
turned by 208 to 308, the connector lever may be damaged. Make
sure that the connector lever is turned by 208 to 308.
• If connector lever A is turned by holding the edge, the connec-
tor lever may be damaged. Turn the connector lever by holding
78504 the center.
• If connector C is not securely connected, the Anti-lock brake
system warning lamp may illuminate. If it illuminates, repeat the
assembly procedure again.

35A-66
 35E

GROUP 35E ANTI-LOCK BRAKE SYSTEM

(ABS)
SPECIFICATIONS ................................................................................ 35E-2

STRUCTURE AND OPERATION ........................................................ 35E-4

TROUBLESHOOTING
1. Inspection procedure ........................................................................... 35E-20
2. Connection of Multi-Use Tester II ........................................................ 35E-22
3. Reading and erasing diagnosis code ................................................. 35E-23
4. Cause of diagnosis code and inspection items ................................. 35E-25
5. Service data of Multi-Use Tester II ...................................................... 35E-32
6. Actuator test with Multi-Use Tester II ................................................. 35E-34
7. Inspection at Hydraulic Unit Connector ............................................. 35E-35
8. Action for temporary failure ............................................................... 35E-36

ON-VEHICLE INSPECTION AND ADJUSTMENT

1. Function inspection ............................................................................. 35E-38
2. Inspection of vehicle speed sensor signal wave with oscilloscope 35E-39
3. Inspection of hydraulic unit operation ............................................. 35E-40
4. Air bleeding .......................................................................................... 35E-42
5. Replacement of hydraulic unit or inspection after assembly/disassembly 35E-44

INSPECTION OF ELECTRIC PARTS .................................................. 35E-45

PART MOUNTING POSITION AND ELECTRIC WIRING DIAGRAM ...... 35E-48

35E-1
SPECIFICATIONS
Item Specifications
Control method (control equipment) No. of sensors and channels 4S4K: 4 sensors 4 channels (hydraulic unit)
Manufacturer ADVICS

* Hydraulic unit Rated voltage V DC24

Range of operating voltage V DC20 to 32
Manufacturer Bosch Automotive systems
Front 1 to 1.2 (resistance between terminals)
Coil resistance kq
100 or more (insulation resistance)
Wheel speed sensor
Manufacturer SUMITOMO ELECTRIC
Rear 1.4 w 0.2 (resistance between terminals)
Coil resistance kq
1000 or more (insulation resistance)

* The hydraulic unit has the Anti-lock Brake System Electronic Control Unit to control the Anti-lock Brake System.

35E-2
 35E

MEMO

35E-3
STRUCTURE AND OPERATION
1. General
The Anti-lock Brake System (ABS) prevents skid of tires due to wheel locking in quick braking or in braking on a slip-
pery road, and this brake system ensures constant vehicle body posture and directional stability.

1.1 Description of Anti-lock brake system

• Tires rotating on the road in normal driving tend to move the rotating direction. Therefore, the vehicle turns or moves to
the intended direction with the control of a driver.
However, when the brake pedal on a vehicle without Anti-lock brake system is fully depressed and wheels are locked,
the tendency to maintain the tire moving direction is lost and tires are only a piece of rubber in contact with the ground.
The vehicle skids in the direction where force is applied regardless of the tire direction.
In this way, vehicle body posture and directional stability are lost and vehicle cannot be controlled at a driver's will.
• In contrast, the vehicle with Anti-lock brake system reduces braking force of a wheel that tends to lock. This prevention
for locking can achieve a constant vehicle body posture and directional stability.

(1) Wheel lock at a curve on a slippery road

In braking at a curve on a slippery
road, locking of wheels results in loss
of directional stability even if the
steering wheel is turned. The vehicle
B may be out of the course by skidding.

A : Braking point (wheel lock)

B : Direction heading for
A
C : Direction of vehicle cannot be
C changed.

70659

(2) Wheel lock at a straight line on a slippery road

A
C

70660

When a vehicle tries to avoid a block ahead on a slippery road while applying the brake, locking of wheels results in loss
of directional stability even if the steering wheel is turned. The vehicle may not avoid a block.

A : Braking point (wheel lock)

B : Block
C : Direction of avoidance

35E-4
 35E
(3) Split mu
(wheel lock on a road that has different friction coefficients between right and left wheels)

B
A

70661

The tire in contact with the ground that has a smaller friction coefficient is slippery and the wheel locks first. A locked tire
causes imbalance of braking in slipping. The vehicle posture is lost as if one side braking occurred, and the steering
wheel is pulled.
In quick braking, a vehicle spins.
A : Braking point (wheel lock)
B : Slippery road
C : Non-slippery road

As explained above, the vehicle with Anti-lock brake system controls the braking force of each wheel to the optimum due
to function of the Anti-lock brake system and prevents locking of wheels. Therefore, a vehicle can be steered in quick
braking and a constant vehicle body posture and directional stability can be achieved without slipping and side skidding.

35E-5
STRUCTURE AND OPERATION
1.2 Control of Anti-lock brake system
• Anti-lock brake system controls the braking force so that the braking capacity may be the most effective based on the
slip ratio determined by wheel speed and vehicle speed.
• When a brake is applied, rotation of wheels is restricted and the vehicle speed is reduced. If rotation of wheels is re-
stricted, the vehicle tents to move forward with inertia force. Then, a difference occurs between the wheel speed and
the vehicle speed, resulting in slippage. The percentage of slippage is indicated by the slip ratio.

Vehicle speed - Wheel speed

Slip ratio (%) = u100
Vehicle speed

• Slip ratio of 0% means that there is no slippage between the wheel and the road. 100% means that the wheel is
locked.

• The figure shows variation of tire friction coefficients from

Friction coefficient curve for slip ratio
rotation to locking. When the brake is gradually applied to
1.0 tired rotating on the ground, tires start slipping while rotat-
Dry asphalt ing.
• When the brake is further applied, rotation is lost and only
slipping remains. This is locking status.
Friction coefficient

Wet asphalt • The figure shows that the friction coefficient is the maxi-
mum when the slip ratio is in the hatched area.
• In this way, the tire friction force of the tire is the maximum
when applied with a controlled force rather than depression
0.5
of the brake to the full.
Cornering force • In the vehicle with Anti-lock brake system, the braking force
Snow road is controlled with the hydraulic unit so that the friction coef-
ficient may be high in the hatched area without locking
wheels and that stable braking force may be achieved.
Frozen road
0
0 50 100
(Tire roll) Slip ratio(%) (Tire lock)
03049

35E-6
 35E
P Anti-lock brake system control characteristic diagram

Actual vehicle speed

Vehicle speed and Pseudo-actual vehicle speed

wheel speed
Wheel speed
Slip ratio set value
+b

Wheel acceleration/ 0
deceleration
-b

Signal from
hydraulic unit
Pressure
reduction
Hold

Pressure
increase

Brake hydraulic
pressure

AB C D
07734

Figure is the Anti-lock brake system control characteristic diagram that represents variation of the wheel speed, acceler-
ation/deceleration of wheel and brake hydraulic pressure with time after applying the brake.

• At point A, when the vehicle speed is reduced to set value -b of the wheel acceleration/deceleration, the hold signal is
issued from the hydraulic unit and the current brake hydraulic pressure is maintained.
The preliminary set pseudo-actual vehicle speed is also calculated in the hydraulic unit.
• At point B, when the vehicle speed is further reduced to set value -b of the slip ratio, it is judged that there may be a
risk of wheel lock. Pressure reduction signal is issued from the hydraulic signal to reduce the brake hydraulic pressure.
• When the wheel speed is recovered with the pressure reduction and the speed is over set value -b of the wheel accel-
eration/deceleration at point C, the hold signal is issued from the hydraulic unit and the current brake hydraulic pres-
sure is maintained.
• At point D, when the vehicle speed is further increased to set value +b of the wheel acceleration/deceleration, it is
judged that there may not be a risk of wheel lock. Pressure increase signal is issued from the hydraulic signal to in-
crease the brake hydraulic pressure.

As explained above, Anti-lock brake system repeats pressure increase, hold and pressure reduction and achieves a con-
stant braking force at the optimum slip ratio without locking tires.

35E-7
STRUCTURE AND OPERATION
1.3 Hydraulic unit
(1) Internal circuit
D C A

E F B

E F B A C D

25 24

19 20 21 22 1 2 3 4

17 9
16 8

18 23 14 10 5 6
11
15 7

13 12
78478

35E-8
 35E
1
Check valve 13 Reservoir 24 Damping orifice
(front axle right wheel) (rear system) (front system)
2 Solenoid valve 14 Plunger pump 25 Damping orifice
(front axle right wheel hold) (rear system) (rear system)
3 Check valve 15 Inlet valve A: From master cylinder
(front axle left wheel) (rear system) (front system)
4 Solenoid valve 16 Outlet valve B: From master cylinder
(front axle left wheel hold) (rear system) (rear system)
5 Solenoid valve 17 Damper C: To wheel brake
(front axle right wheel pressure reduction) (rear system) (front axle right wheel)
6 Solenoid valve 18 Solenoid valve D: To wheel brake
(front axle left wheel pressure reduction) (rear axle right wheel pressure reduction) (front axle left wheel)
7 Inlet valve 19 Solenoid valve E: To wheel brake
(front system) (rear axle right wheel hold) (rear axle right wheel)
8 Outlet valve 20 Check valve F: To wheel brake
(front system) (rear axle right wheel) (rear axle left wheel)
9 Damper 21 Solenoid valve
(front system) (rear axle left wheel hold)
10 Plunger pump 22 Check valve
(front system) (rear axle left wheel)
11 Motor 23 Solenoid valve
12 Reservoir (rear axle left wheel pressure reduction)
(front system)

The hydraulic unit controls Anti-lock brake system to turn ON/OFF the solenoid valve and motor 11.
The solenoid valve and the motor for each control are turned ON/OFF under the conditions in the table below:
Anti-lock brake system control
Front axle right wheel Front axle left wheel Rear axle right wheel Rear axle left wheel
Pressure Pressure Pressure Pressure Pressure Pressure Pressure Pressure
Hold Hold Hold Hold
reduction increase reduction increase reduction increase reduction increase
Front axle right
wheel pressure q u u s s s s s s s s s
reduction 5
Front axle right
q q u s s s s s s s s s
wheel hold 2
Front axle left
wheel pressure s s s q u u s s s s s s
reduction 6
Solenoid valve

Front axle left

s s s q q u s s s s s s
wheel hold 4
Rear axle right
wheel pressure s s s s s s q u u s s s
reduction 18
Rear axle right
s s s s s s q q u s s s
wheel hold 19
Rear axle left
wheel pressure s s s s s s s s s q u u
reduction 23
Rear axle right
s s s s s s s s s q q u
wheel hold 21
Motor 11 q
q : ON

u : OFF

35E-9
STRUCTURE AND OPERATION
(2) No operation of Anti-lock brake system (normal brake)

A D

4
3

: Brake pedal is depressed.

Figure indicates operation of
the front axle left wheel. : Brake pedal is released.

78479

• When the brake pedal is depressed and Anti-lock brake system is not operated, there is no control signal from the hy-
draulic unit to the solenoid valves 6 (front axle left wheel pressure reduction) and 4 (front axle left wheel hold). Sole-
noid valve 4 (front axle left wheel hold) is open and solenoid valve 6 (front axle left wheel pressure reduction) is closed.
• Brake hydraulic pressure A from the brake master cylinder runs through solenoid valve 4 (front axle left wheel hold)
and goes to wheel brake D for braking.
• When the brake pedal is released, brake pressure A from the brake master cylinder is reduced. The brake pressure
from wheel brake D runs through solenoid valve 4 (front axle left wheel hold) and check valve 3 (front axle left wheel)
and returns to the brake master cylinder.

35E-10
 35E
(3) Operation of Anti-lock brake system (pressure reduction)

A D

24
4
3
9

8
11
10
6

Figure indicates operation of

the front axle left wheel. 12
78480

• When the brake pedal is depressed and wheels tends to lock, control signal from the hydraulic unit is issued to sole-
noid valves 6 (front axle left pressure reduction) and 4 (front axle left wheel hold). Solenoid valve 6 (front axle left
wheel pressure reduction) is open and solenoid valve 4 (front axle left wheel hold) is closed.
• The hydraulic pressure from wheel brake D runs through solenoid valve 6 (front axle left wheel pressure reduction)
and goes to reservoir 12 (front system) for pressure reduction.
• When the control signal is sent to solenoid valve 6 (front axle left wheel pressure reduction) and solenoid valve 4 (front
axle left wheel hold) together with the control signal to motor 11, the plunger pump 10 (front system) is activated and
the reservoir brake pressure is returned to the master cylinder through inlet valve 7 (front system), outlet valve 8 (front
system), damper 9 (front system) and damping orifice 24 (front system).
• At this time, check valve 3 (front axle left wheel) is closed with brake hydraulic pressure A of the brake master cylinder
and the brake hydraulic pressure of the brake master cylinder is not sent to the wheel brake.

35E-11
STRUCTURE AND OPERATION
(4) Operation of Anti-lock brake system (hold)

A D

4
3

Figure indicates operation of

the front axle left wheel.

78481

• When hydraulic pressure D of the wheel brake needs to be held for control of Anti-lock brake system, the hold control
signal from the hydraulic signal is issued to solenoid valve 4 (front axle left wheel hold) and the closing brake hydraulic
pressure is maintained for solenoid valve 4 (front axle left wheel hold) and solenoid valve 6 (front axle left wheel pres-
sure reduction).
• At this time, check valve 3 (front axle left wheel) is closed with brake hydraulic pressure A of the brake cylinder.

35E-12
 35E
(5) Operation of Anti-lock brake system (pressure increase)

A D

Figure indicates operation of

the front axle left wheel.

78482

• When brake hydraulic pressure D of the wheel brake needs to be increased, the control signal from the hydraulic unit
is not issued from the hydraulic unit to solenoid valves 4 (front axle left wheel hold) and 6 (front axle left wheel pres-
sure reduction).
• Then, solenoid valve 4 (front axle left wheel hold) is open and 6 (front axle left wheel pressure reduction) is closed.
The status is the same as the non-operating status. Brake hydraulic pressure A generated with depression of the pres-
sure applies (increases pressure) to the wheel brake.

35E-13
STRUCTURE AND OPERATION
2. Electronic control system
2.1 System block diagram

Input signal Hydraulic unit

Wheel speed sensor Solenoid valve

(front axle left wheel) 1 (front axle left wheel)
Hold valve
Wheel speed sensor Pressure reduction valve
(front axle right wheel) 1
Anti-lock brake Solenoid valve
Wheel speed sensor system control (front axle right wheel)
(rear axle left wheel) 1 function Hold valve
(solenoid valve Pressure reduction valve
control function)
Wheel speed sensor
(rear axle right wheel) 1 Solenoid valve
(rear axle left wheel)
Hold valve
Stop lamp switch 2 Pressure reduction valve

Solenoid valve
(rear axle right wheel)
Hold valve
Pressure reduction valve

Motor Hydraulic pump

Motor power supply

Motor relay

Solenoid power source

Valve relay

Output signal

Anti-lock brake system

Failure diagnosis exhaust brake cut relay 3
function
Fail safe Anti-lock brake system
Self-diagnosis warning lamp 4
Multi-use tester II
communication
Multi-use tester II connector 5

35E-14
 35E
Information signal Part name Main function or operation

1 Wheel speed signal Wheel speed sensor Detection of wheel speed

2 Brake pedal depression signal Stop lamp switch Detection of brake pedal depression
Anti-lock brake system exhaust
3 Exhaust brake cut signal Exhaust brake cut for Anti-lock brake system operation
brake cut relay
Anti-lock brake system warning Error display and system check of Anti-lock brake sys-
4 Lamp ON signal
lamp tem
Communication with Multi-use tester II and display/
5 Communication signal Multi-use tester II connector
erasing of diagnosis code

35E-15
STRUCTURE AND OPERATION
2.2 Anti-lock brake system control function
The hydraulic unit always monitors the signal from the wheel speed sensor (4 sensors). When it is judged that wheels
are locked, the signal of hold, pressure reduction or pressure increase is sent to each wheel.

(1) Anti-lock brake system fail safe

If abnormality has occurred on Anti-lock brake system, illumination of the warning lamp warns a driver. The Anti-lock
brake system control is cancelled and operated as a normal brake (status without ).

(2) Anti-lock brake system and exhaust brake

Braking with the exhaust brake may simulate a status of wheel lock on a slipper road. When the exhaust brake is oper-
ated during operation of Anti-lock brake system, it is difficult to control the brake in Anti-lock brake system.
Therefore, when Anti-lock brake system is operated, the system cancels the exhaust brake even if the exhaust brake
switch is ON. When the Anti-lock brake system control is canceled, the exhaust brake starts operation again.

(3) Wheel speed sensor

• Wheel speed sensor 1 detects rotation of each wheel and sends the
signal to the hydraulic unit. The sensor body is a electromagnetic
pickup type that has coil around the permanent magnet.
• Rotor 2 is a ring gear type. Protrusions are uniformly distributed on
the vertical line to the sensor. When the wheel rotates and protru-
sions of the rotor crosses the sensor magnetic flux, potential differ-
2 ence generated on the coil is AC voltage in proportion to the wheel
1
rotation and the signal is sent to the hydraulic unit.

51147

35E-16
 35E

MEMO

35E-17
STRUCTURE AND OPERATION
3. Terminal layout of hydraulic unit

14 13 12 11 10 9 8 7 6 5
2 1
24 23 22 21 20 19 18 17 16 15
4 3
34 33 32 31 30 29 28 27 26 25

79585

HYDRAULIC UNIT : EP34A

Terminal Terminal Terminal Terminal
Connection Connection
No. name No. name
1 VGND Grounding (valve ground) 18 BRK Stop lamp signal
2 VB Battery (valve power source) 19 s s
3 MGND Grounding (motor ground) 20 s s
4 MB Battery (motor power source) 21 s s
5 IG Starter switch M terminal (hydraulic unit) 22 s s
Wheel speed sensor
6 DIAG Diagnosis switch 23 RR GND
(rear axle right wheel) (ground)
Wheel speed sensor
7 s s 24 RL GND
(rear axle left wheel) (ground)
8 ABS W/L Anti-lock brake system warning lamp 25 s s
Anti-lock brake system exhaust brake cut relay
9 EXH IN 26 s s
(monitor)
Anti-lock brake system exhaust brake cut relay
10 EXH OUT 27 s s
(output)
11 s s 28 s s
Wheel speed sensor
12 FR SIG 29 TXRX Multi-use tester II connector
(front axle right wheel) (signal)
Wheel speed sensor
13 FR GND 30 s s
(front axle right wheel) (ground)
Wheel speed sensor
14 RR SIG 31 s s
(rear axle right wheel) (signal)
Wheel speed sensor
15 s s 32 FL SIG
(front axle left wheel) (signal)
Wheel speed sensor
16 MODE Multi-use tester II connector 33 FL GND
(front axle left wheel) (ground)
Wheel speed sensor
17 MCL Memory clear switch 34 RL SIG
(rear axle left wheel) (signal)

35E-18
 35E

Hydraulic unit

Wheel speed sensor

Starter switch M contact (front axle left wheel)
IG FL SIG
5 32

FL GND
33

Wheel speed sensor

(front axle right wheel)
FR SIG
VB 12
2
MB 4 FR GND
13

Wheel speed sensor

Battery (rear axle left wheel)
RL SIG
34

RL GND
Warning lamp relay 24
ABS W/L 8
Wheel speed sensor
(rear axle right wheel)
RR SIG
14
Anti-lock brake system
warning lamp RR GND
23
Anti-lock brake system
exhaust brake cut relay
EXHOUT
Starter 10
switch
M

Engine erectronic EXHIN 9

control unit
Exhaust brake
3-Way magnetic valve
TXRX
29
Multi-use tester-II
Stop lamp switch
16 MODE connector

Stop lamp relay

Stop lamp
BRK VGND
18 1
MGND
Diagnosis switch DIAG 6 3

Memory clear switch MCL

17

79846

35E-19
TROUBLESHOOTING
1. Inspection procedure

Failure diagnosis function

• When the starter switch is turned ON, the system always checks if each sensor is faulty or not. If a sensor is diag-
nosed faulty, a warning lamp is displayed in the meter cluster to notify a driver. The faulty area is memorized and the
back mode starts.

Warning lamp display for abnormality detection

System error

• The memorized faulty area can be retrieved as a diagnosis code with the Multi-use tester II or the diagnosis switch.

NOTE
• The battery voltage must be 22V or more.
• Check if connectors of the harnesses or parts are loose. When a connector is removed, remove it 20 sec-
onds later after the starter switched is set to the lock position.
• After repair, delete the diagnosis code with the Multi-use tester II or the memory clear switch.
• In principle, inspection is performed with the starter switch set to the lock position. Some work may be per-
formed with the switch set to ON position. In this case, be careful for short-circuit between each connector
terminal and the body.
• Resistance values of components are affected with the temperature and the tester accuracy. The value may
not always be within the range of the standard value. The inspection value in this manual is in accordance
with the condition of normal temperature (10 to 35!C).
• When a faulty status is removed, acceptance for automatic reset from the backup mode may vary depending
on the diagnosis code (abnormal location). When the status is recovered, the warning lamp goes off.
• When a faulty status is removed and automatic reset is achieved, the diagnosis code of the faulty area is
memorized in the past code of the hydraulic unit.
• If a failure has occurred at a location where automatic reset cannot be made, clear the memory of the diag-
nosis code for resetting from the backup mode. L P35E-23

35E-20
 35E
Inspection flow chart
With the Multi-use tester II, the system can be effectively inspected.
The system inspection type can be classified into the following with categories of failure types and diagnosis code
types.
• Inspection for each diagnosis code (failure diagnosis code) memorized in the hydraulic unit
• Action for temporary failure

Receipt of vehicle

Reading diagnosis code

Using Multi-use tester II L P35E-23
Not using Multi-use tester II L P35E-23

Normal code
Abnormal code output Normal code Disable communication
output after erasing
output with Multi-use tester II

Find the cause of the diagnosis Inspection for temporary

code and perform inspection. failure L P35E-36
L P35E-25

When the communication is not available with all other systems,

it is highly possible that the diagnosis circuit is faulty. When
communication is disabled with this system only, the power
Driving test circuit (including grounding circuit) of this system or the
diagnosis output circuit may be disconnected.

If a diagnosis code has occurred during a driving test, find the cause of the diagnosis code again
and perform inspection. L P35E-25
If the diagnosis code memorized in the hydraulic unit before a driving test did not appear in the
driving test, actions for a temporary failure are taken together with the inspection for the
diagnosis code.

Erasing diagnosis code

Using Multi-use tester II L P35E-23
Not using Multi-use tester II L P35E-24

35E-21
TROUBLESHOOTING
2. Connection of Multi-use tester II

J Special tools
Location Tool name and shape Part No. Application

s Multi-use tester II MB991496 Inspection of system

19492

Multi-use tester II harness Power supply to Multi-use tester II and

s MK327601
(for communication) communication with vehicle electric parts

19141
19141

s ROM pack (MRT-E10) MH062867 Hydraulic unit inspection control data

19493

Memory card (mounted on

s MB991500 Data writing
Multi-use tester II body)

20538

The Multi-use tester II is used as the circuit

s Multi-use tester II harness MB991499
tester.

20536

Connection of Multi-use tester II

• Set the starter switch to the lock position.
• Connect the b Multi-use tester II harness to the a Multi-use tester
II and insert the c ROM pack.
• Connect Multi-use tester II connector A (16 poles) to connector B
(16 poles).
A
c NOTE
b 1 2 3 4 5 6 7 8

a B 9 10 11 12 13 14 15 16 Refer to the Multi-use tester II operation manual for operation

A
procedures of the Multi-use tester II.
29385

35E-22
 35E
3. Reading and erasing diagnosis code

In reading and erasing the diagnosis code, there are two methods; method to use the Multi-use tester II and method not
to use the Multi-use tester II.

(1) Method to use Multi-use tester II

P Diagnosis code
• Turn ON the starter switch.
• Operate the Multi-use tester II to display the current diagnosis
code and the past diagnosis code. Find the faulty area.

P Erasing diagnosis code

• Turn ON the starter switch.
• Operate the Multi-use tester II to erase all diagnosis codes memo-
rized in the hydraulic unit.

(2) Method not to use Multi-use tester II

(Method with diagnosis switch and memory clear switch)

P Display of diagnosis code

• Turn ON the starter switch.
• Remove diagnosis switch 1.
• Display the diagnosis code by flashing of warning lamp 2.

77426

78487

35E-23
TROUBLESHOOTING
P Reading diagnosis code
10 place digit 1 place digit • Read the diagnosis code with the flashing count and time of warning
lamp 2.
ON • The flashing time of the 10 place digit is different from that of the 1
place digit.
• 10 place digit: Interval of 1.2 seconds
OFF • 1 place digit: Interval of 0.4 second
• The diagnosis code is displayed in the sequence of the 10 place digit
1.2 1.2 and the 1 place digit. The code that begins with 0 for the 10 place
0.4
digit indicates only the 1 place digit.
Opening of 0.4
• One diagnosis code is displayed three times repeatedly in the as-
diagnosis switch
0.4 cending order.
• If there is no new code, the display returns to the first code and the
ON same display is repeated three times.
1st display (diagnosis code 12)
• When diagnosis switch 1 is connected, the hydraulic unit stops
2nd (ends) display of the code immediately.
OFF
display
2.4 2.8 2.8 2.8 NOTE
13705 When the system is normal, 01 code is displayed.

P Current and past diagnosis codes

• After reading the current diagnosis code (with diagnosis switch 1 dis-
connected), disconnect memory clear switch 3. Warning lamp 2
starts flashing.
• This flashing displays the current and the past diagnosis codes.
1 Check faulty area with identification of the code.

3 77202

78487

P Erasing diagnosis code

With diagnosis switch 1 connected, disconnect (open) memory clear
1 second 3 seconds switch 3 for 1 second or more and connect it again. This erases all diag-
or more
nosis codes memorized in the electronic control unit.
NOTE
Connection • Note that the diagnosis code can be erased only with operation
of memory clear switch 2.
Open The diagnosis code
• If you do not want to erase all diagnosis codes after the diagno-
is erased here.
sis code is displayed, set the starter switch to the OFF position
02739
with memory clear switch 3 disconnected and connect the mem-
ory clear switch.

35E-24
 35E
4. Cause of diagnosis code and inspection items

4.1 Diagnosis code list

Screen display of Multi-use tester II

Reference section
Diagnosis code Message
11 FR SENSOR
12 FL SENSOR
L P35E-26
13 RR SENSOR
14 RL SENSOR
21 FR SENSOR SIG
22 FL SENSOR SIG
23 RR SENSOR SIG L P35E-27
24 RL SENSOR SIG
31 BATT VOLT ERR
35 EXB CUT RLY
41 FR VALVE
42 FL VALVE L P35E-28
43 RR VALVE
44 RL VALVE
51 VALVE RLY
52 MOTOR RLY L P35E-29
53 MOTOR ERR
63 ECU ERR
L P35E-30
64 ILLEGAL WHEEL
65 LONG ABS L P35E-31

35E-25
TROUBLESHOOTING
4.2 Diagnosis code occurrence conditions and inspection items

Perform maintenance based on the diagnosis code occurrence conditions and probable causes.

11 FR SENSOR
12 FL SENSOR
13 RR SENSOR
14 RL SENSOR
Diagnosis codes 11 to 14 are displayed when the hydraulic unit judges that resistance of each wheel
Code occurrence condi- speed sensor is abnormal.
tion [Reset condition] [When there is no abnormality after the starter switch is turned from ON to OFF, resetting is normally
completed.]
Action with Electronic Anti-lock brake system control is stopped.
control unit

Display of warning lamp

• Harness disconnection and short-circuit • Inspection with service data of Multi-use tester II
between hydraulic unit and wheel speed L P35E-32
sensor No. 11: Measurement of wheel speed (front axle
• Faulty wheel speed sensor right wheel)
• Faulty hydraulic unit No. 12: Measurement of wheel speed (front axle left
wheel)
No. 13: Measurement of wheel speed (rear axle right
wheel)
Probable cause No. 14: Measurement of wheel speed (rear axle left
and wheel)
inspection item • Inspection at hydraulic unit connector
L P35E-35
01 : Measurement of wheel speed sensor resis-
tance
• Inspection of wheel speed sensor unit
L P35E-45 Inspection of electric parts
• Circuit check between hydraulic unit and wheel
speed sensor
L P35E-51 Electric wiring diagram

35E-26
 35E

21 FR SENSOR SIG
22 FL SENSOR SIG
23 RR SENSOR SIG
24 RL SENSOR SIG
Diagnosis codes 21 to 24 are displayed when the hydraulic unit judges that resistance of each wheel
Code occurrence condi- speed sensor is abnormal.
tion [Reset condition] [When there is no abnormality after the starter switch is turned from ON to OFF, resetting is normally
completed.]
Action with Electronic
Anti-lock brake system control is not stopped.
control unit

Display of warning lamp

• Harness disconnection and short-circuit between • Inspection with service data of Multi-use
hydraulic unit and wheel speed sensor tester II L P35E-32
• Foreign matter on wheel speed sensor No. 11: Measurement of wheel speed (front
• Faulty wheel speed sensor or foreign matter on axle right wheel)
wheel speed sensor No. 12: Measurement of wheel speed (front
• Impact mark or chipped teeth of rotor axle left wheel)
• Excessive sensor gap due to failure of wheel bear- No. 13: Measurement of wheel speed (rear
axle right wheel)
ing
No. 14: Measurement of wheel speed (rear
Probable cause • Faulty hydraulic unit axle left wheel)
and • Inspection at hydraulic unit connector
inspection item L P35E-35
01 : Measurement of wheel speed sensor
resistance
• Inspection of wheel speed sensor unit
L P35E-45 Inspection of electric parts
• Inspection of rotor L P35E-39
• Circuit check between hydraulic unit and
wheel speed sensor
L P35E-51 Electric wiring diagram

31 BATT VOLT ERR

Code occurrence condi- Diagnosis codes 31 is displayed when the hydraulic unit voltage is low or excessive.
tion [Reset condition] [When the voltage is normal, resetting is normally completed.]
Action with Electronic
Anti-lock brake system control is not stopped.
control unit

Display of warning lamp

• Harness disconnection and short-circuit between • Inspection with service data of Multi-use
hydraulic unit and starter switch (M terminal) tester II L P35E-32
• Faulty starter switch No. 15: Measurement of power supply volt-
• Low battery voltage age from starter switch (M terminal)
• Faulty hydraulic unit • Inspection at hydraulic unit connector
Probable cause L P35E-35
and
inspection item 02 : Power voltage of hydraulic unit
• Inspection of starter
L P35E-45 Inspection of electric parts
• Circuit check between hydraulic unit and
starter switch (M terminal)
L P35E-51 Electric wiring diagram

35E-27
TROUBLESHOOTING

35 EXB CUT RLY

Diagnosis code 35 is displayed when the hydraulic unit judges that the monitor power of the Anti-lock
Code occurrence condi- brake system exhaust brake cut relay is abnormal.
tion [Reset condition] [When there is no abnormality after the starter switch is turned from ON to OFF, resetting is normally
completed.]
Action with Electronic
Only exhaust brake cut function is inhibited.
control unit

Display of warning lamp

• Harness disconnection and short-circuit between • Inspection with service data of Multi-use
hydraulic unit and Anti-lock brake system exhaust tester II L P35E-32
cut relay No. 22 and 23: Operation check of Anti-lock
• Faulty Anti-lock brake system exhaust brake cut brake system exhaust brake
relay cut relay
Probable cause • Inspection of Anti-lock brake system exhaust
and • Faulty hydraulic unit
brake cut relay unit
inspection item
L P35E-45 Inspection of electric parts
• Circuit check between hydraulic unit and
Anti-lock brake system exhaust brake cut re-
lay
L P35E-51 Electric wiring diagram

41 FR VALVE
42 FL VALVE
43 RR VALVE
44 RL VALVE
Diagnosis codes 41 to 44 are displayed when the hydraulic unit judges that voltage of each solenoid
Code occurrence condi- valve is abnormal.
tion [Reset condition] [When there is no abnormality after the starter switch is turned from ON to OFF, resetting is normally
completed.]
Action with Electronic
Anti-lock brake system control is stopped.
control unit

Display of warning lamp

• Harness disconnection (blown fuse) between hy- • Inspection with service data of Multi-use
draulic unit and battery (+) tester II L P35E-32
• Faulty hydraulic unit No. 41: Inspection of solenoid valve
No. 42: Inspection of solenoid valve
No. 43: Inspection of solenoid valve
Probable cause No. 44: Inspection of solenoid valve
and No. 45: Inspection of solenoid valve
inspection item No. 46: Inspection of solenoid valve
No. 47: Inspection of solenoid valve
No. 48: Inspection of solenoid valve
• Circuit check between hydraulic unit and bat-
tery (+)
L P35E-51 Electric wiring diagram

35E-28
 35E

51 VALVE RLY
Diagnosis code 51 is displayed when the hydraulic unit judges that voltage of the solenoid relay (valve
Code occurrence condi- relay) is abnormal.
tion [Reset condition] [When there is no abnormality after the starter switch is turned from ON to OFF, resetting is normally
completed.]
Action with Electronic
Anti-lock brake system control is stopped.
control unit

Display of warning lamp

• Harness disconnection (blown fuse) between hy- • Inspection with service data of Multi-use
draulic unit and battery (+) tester II L P35E-32
Probable cause
• Faulty hydraulic unit No. 31: Inspection of valve relay
and
• Circuit check between hydraulic unit and bat-
inspection item
tery (+)
L P35E-51 Electric wiring diagram

52 MOTOR RLY
Diagnosis code 52 is displayed when the hydraulic unit judges that voltage of the motor relay is abnor-
Code occurrence condi- mal.
tion [Reset condition] [When there is no abnormality after the starter switch is turned from ON to OFF, resetting is normally
completed.]
Action with Electronic
Anti-lock brake system control is stopped.
control unit

Display of warning lamp

• Harness disconnection (blown fuse) between hy- • Inspection with service data of Multi-use
draulic unit and battery (+) tester II L P35E-32
Probable cause
• Faulty hydraulic unit No. 32: Inspection of motor relay
and
• Circuit check between hydraulic unit and bat-
inspection item
tery (+)
L P35E-51 Electric wiring diagram

53 MOTER ERR
Diagnosis code 53 is displayed when the motor is sticking or when the hydraulic unit judges that volt-
Code occurrence condi- age of the motor relay is abnormal.
tion [Reset condition] [When there is no abnormality after the starter switch is turned from ON to OFF, resetting is normally
completed.]
Action with Electronic
Anti-lock brake system control is stopped.
control unit

Display of warning lamp

• Harness disconnection (blown fuse) between hy- • Inspection with service data of Multi-use
draulic unit and battery (+) tester II L P35E-32
Probable cause
• Faulty hydraulic unit No. 32: Inspection of motor relay
and
• Circuit check between hydraulic unit and bat-
inspection item
tery (+)
L P35E-51 Electric wiring diagram

35E-29
TROUBLESHOOTING

63 ECU ERR
Code occurrence condi- Diagnosis code 63 is displayed when the hydraulic unit judges that the internal circuit is abnormal.
tion [Reset condition] [After normal resetting, the starter switch is turned ON again.]
Action with Electronic
Anti-lock brake system control is stopped.
control unit

Display of warning lamp

Probable cause
and Faulty hydraulic unit s
inspection item

64 ILLEGAL WHEEL
Diagnosis code 64 is displayed when the hydraulic unit judges that difference of each wheel speed is
present due to difference of tire diameter size.
Code occurrence condi- In driving at the vehicle speed of 30 km/h or more, the difference of each wheel has been out of the nor-
tion [Reset condition] mal range (+10% to -45% of vehicle speed).
[When all wheel speeds are detected until the speed reaches 10 km/h after the starter switch is turned
from OFF to ON, resetting is normal.]
Action with Electronic
Anti-lock brake system control is stopped.
control unit

Display of warning lamp

• Harness disconnection and short-circuit between • Inspection with service data of Multi-use
hydraulic unit and wheel speed sensor tester II L P35E-32
• Faulty wheel speed sensor No. 11: Setting of wheel speed (front axle
• Different tire size right wheel)
• Abnormally low tire air pressure No. 12: Setting of wheel speed (front axle
• Faulty hydraulic unit left wheel)
No. 13: Setting of wheel speed (rear axle
right wheel)
No. 14: Setting of wheel speed (rear axle left
wheel)
Probable cause * The minimum display speed is 2 km/h.
and • Inspection at hydraulic unit connector
inspection item
L P35E-35
01 : Measurement of wheel speed sensor
resistance
• Inspection of wheel speed sensor unit
L P35E-45 Inspection of electric parts
• Circuit check between hydraulic unit and
wheel speed sensor
L P35E-51 Electric wiring diagram
• Inspection of tire size L Gr31
• Inspection of tire air pressure L Gr31

35E-30
 35E

65 LONG ABS
Diagnosis code 65 is displayed when continuous operation of Anti-lock brake system is present for the
Code occurrence condi- specified time.
tion [Reset condition] [When the normal sensor output is received during driving after the starter switch is turned from OFF to
ON, resetting is normally completed.]
Action with Electronic
Anti-lock brake system control is stopped.
control unit

Display of warning lamp

• Harness disconnection and short-circuit between • Inspection with service data of Multi-use
hydraulic unit and wheel speed sensor tester II L P35E-32
• Faulty wheel speed sensor No. 11: Setting of wheel speed (front axle
• Impact mark or chipped teeth of rotor right wheel)
• Backlash of rotor from wheel bearing No. 12: Setting of wheel speed (front axle
• Faulty of hydraulic unit left wheel)
No. 13: Setting of wheel speed (rear axle
right wheel)
Probable cause No. 14: Setting of wheel speed (rear axle left
and wheel)
inspection item • Inspection at hydraulic unit connector
L P35E-35
01 : Measurement of wheel speed sensor
resistance
• Inspection of wheel speed sensor unit
L P35E-45 Inspection of electric parts
• Inspection of rotor L P35E-39
• Circuit check between hydraulic unit and
wheel speed sensor
L P35E-51 Electric wiring diagram

35E-31
TROUBLESHOOTING
5. Service data of Multi-use tester II

Screen display of Multi-use tester II.

Condition for inspection Judgement criteria
No. Item name Data
11 FR SPEED . km/h
12 FL SPEED . km/h
Driving at constant speed Synchronous with speedometer
13 RR SPEED . km/h
14 RL SPEED . km/h
15 BATT VOLTAGE . V Starter switch is ON. 20 to 30V
Brake pedal is depressed. ON
21 BRAKE SW ON/OFF
Brake pedal is released. OFF
Anti-lock brake system exhaust brake cut relay
is operated. (Actuator test No. 22 is performed ON
22 EXB CUT RLY ON/OFF with Multi-use tester II.)
Anti-lock brake system exhaust brake cut relay
OFF
is operated.
Anti-lock brake system exhaust brake cut relay
ON
is operated.
23 EXB MONITOR ON/OFF Anti-lock brake system exhaust brake cut relay
is operated. (Actuator test No. 22 is performed OFF
with Multi-use tester II.)
Anti-lock brake system warning lamp is ON.
(Actuator test No. 23 is performed with Multi- ON
24 ABS LAMP ON/OFF use tester II.)
Anti-lock brake system warning lamp is OFF. OFF
Diagnosis switch is open. OPEN
25 DIAGNOSIS SW OPEN/CLOSE
Diagnosis switch is closed. CLOSED
Memory clear switch is open. OPEN
26 DIAG. RESET SW OPEN/CLOSE
Memory clear switch is closed. CLOSED
Valve relay is operated. ON
31 VALVE RLY ON/OFF
Valve relay is not operated. OFF
Motor is operated. ON
32 MOTOR RLY ON/OFF
Motor is not operated. OFF
Solenoid valve (front right pressure reduction)
is operated. (Actuator test No. 11 is performed ON
41 FR s DV ON/OFF with Multi-use tester II.)
Solenoid valve (front right pressure reduction)
OFF
is not operated.

35E-32
 35E

Screen display of Multi-use tester II.

Condition for inspection Judgement criteria
No. Item name Data
Solenoid valve (front right hold) is operated.
(Actuator test No. 11 is performed with Multi-use ON
42 FR s HV ON/OFF tester II.)
Solenoid valve (front right hold) is not operated. OFF
Solenoid valve (front left pressure reduction) is op-
erated. (Actuator test No. 12 is performed with ON
43 FL s DV ON/OFF Multi-use tester II.)
Solenoid valve (front left pressure reduction) is not
OFF
operated.
Solenoid valve (front left hold) is operated. (Actua-
ON
tor test No. 12 is performed with Multi-use tester II.)
44 FL s HV ON/OFF
Solenoid valve (front left pressure reduction) is not
OFF
operated.
Solenoid valve (rear right pressure reduction) is op-
erated. (Actuator test No. 13 is performed with ON
45 RR s DV ON/OFF Multi-use tester II.)
Solenoid valve (rear right pressure reduction) is not
OFF
operated.
Solenoid valve (rear right pressure hold) is operat-
ed. (Actuator test No. 13 is performed with Multi- ON
46 RR s HV ON/OFF use tester II.)
Solenoid valve (rear right hold) is not operated. OFF
Solenoid valve (rear left pressure reduction) is op-
erated. (Actuator test No. 14 is performed with ON
47 RL s DV ON/OFF Multi-use tester II.)
Solenoid valve (rear left pressure reduction) is not
OFF
operated.
Solenoid valve (rear left hold) is operated. (Actuator
ON
48 RL s HV ON/OFF test No. 14 is performed with Multi-use tester II.)
Solenoid valve (rear left hold) is not operated. OFF

35E-33
TROUBLESHOOTING
6. Actuator test with Multi-use tester II

Screen display of Multi-use tester II

Operation check method
No. Item name
11 FR ABS MV ON
12 FL ABS MV ON
Function check of hydraulic unit L P35E-38
13 RR ABS MV ON
14 RL ABS MV ON
21 ABS MOTOR ON Check with motor operation noise (for 2 seconds).
22 EXB CUT RLY ON Check with relay operation noise (for 2 seconds).

23 ABS LAMP ON Check with Anti-lock brake system warning lamp ON (for 2
seconds).

35E-34
 35E
7. Inspection at hydraulic connector
This inspection checks if each signal of the hydraulic unit is correctly transferred with harnesses and connectors on the
vehicle. In this way, the inspection assists troubleshooting.
Numbers and 01 in 02 the table correspond to the reference number in “4. Cause of diagnosis code and inspec-
tion items” .

No. Item Reference section

01 Wheel speed sensor resistance
L P35E-35
02 Power voltage of hydraulic unit

Harness connector on vehicle

5 6 7 8 9 10 11 12 13 14
1 2
15 16 17 18 19 20 21 22 23 24
3 4
25 26 27 28 29 30 31 32 33 34

79587

Inspection procedure
CAUTION k
• Never touch terminals not inspected. Be careful for short-circuit between terminals with a tester.
• Since the harness connector on the vehicle has a lock mechanism, observe the assembly/disassembly pro-
cedures.

Check item Measuring method

01 [Condition]
Wheel speed sensor resis- • Turn OFF the starter switch.
tance • Disconnect the connector and check resistance with the harness and the connector on the vehicle.
[Judgement criteria]
Front axle right wheel: Between terminals E and R
Front axle left wheel: Between terminals V and B
Rear axle right wheel: Between terminals T and F
Rear axle left wheel: Between terminals N and G
1 to 3 k q or more

02 [Condition]
Power voltage of hydraulic • Turn ON the starter switch.
unit • Disconnect the connector and check voltage with the harness on the vehicle.
[Judgement criteria]
Between terminals r s : 5s1
Power voltage: 20 to 30V

35E-35
TROUBLESHOOTING
8. Action for temporary failure
A temporary failure often occurs under particular conditions. When the
conditions are examined, it is easy to find the cause. To examine condi-
tions of a temporary failure, driving situation, weather, frequency and
phenomenon of a failure should be questioned in detail to a customer.
The failure phenomenon is reproduced.
Then, check if the failure is attributable to vibration, temperature or oth-
er factors based on the failure situation.
When it is judged that the failure is attributable to vibration, perform the
following inspections on an individual connector and check if the failure
02597 occurs.

• Swing a connector gently up/down or left/right.

• Swing a wiring harness gently up/down or left/right.
• Swing a sensor or device gently with hand.
• Swing a wiring harness gently at a movable part like a suspension.

Parts for inspection here are connectors or individual parts that appear
in the probable causes or inspection procedures on the inspection pro-
cedures for the output diagnosis code.

02598

02599

35E-36
 35E

MEMO

35E-37
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Inspection for function

Perform the following inspections. If abnormality is found, be sure to

check it with the J Multi-use tester II referring to troubleshooting.

(1) Inspection while vehicle is not in motion

• Depress the brake pedal and check for fluid leak from the hydraulic
unit, brake pipe and connector.
• If fluid leak from the hydraulic unit is found, replace the hydraulic unit.
If fluid leak from the brake pipe or the connector, retighten the area.

(2) Inspection on brake tester

• Check braking force of each wheel on the brake tester with the same
procedure as on a normal vehicle.
• If abnormality is found, check the wheel brake unit, service brake
system and hydraulic unit.

(3) Drive a vehicle and check the Anti-lock brake system operating
condition.

NOTE
Perform the driving test at a safe place where there are no other
vehicles or persons.

• Perform the driving test with an unloaded vehicle.

• Affix white tape A at the sides of tires so that rotation of front and rear
wheels may be visible.
• Set the starter switch from LOCK to ON position. Make sure that the
warning lamp illuminates and that the lamp goes off a few seconds
later.
• Drive a vehicle at the speed of 20 to 30 km/h and apply the brake
quickly. Make sure that all wheels are not locked.

A 70677

35E-38
 35E
2. Inspection of wheel speed sensor signal waveform with oscilloscope
Impact mark or chipped teeth on the rotor cannot be checked with a
tester. Use an oscilloscope for inspection.

NOTE
Use an oscilloscope with the function that can record a wave-
form.
• Jack up the wheel for measurement and remove the connector of the
wheel speed sensor.
• Connect the terminal of the oscilloscope to the removed connector
terminal and rotate the wheel at a constant speed. Check for impact
mark or chipped teeth on the rotor with a waveform of the oscillo-
scope.
Normal waveform • Cause of impact mark or chipped teeth on the rotor
(No impact mark or chipped teeth on the rotor) • When the hub and brake drum assembly (drum brake) or the hub
and rotor assembly (disk brake) is installed on the axle, impact mark
or chipped teeth on the rotor is often caused by hitting of the rotor
press-fit at the hub end with the axle, resulting in impact mark or
chipped teeth. Therefore, attention must be paid in such a way that
the rotor may not hit other parts when the hub and brake drum as-
sembly (drum brake) or the hub and rotor assembly (disk brake) is in-
stalled on the axle.
• When the width of a waveform is compared with other waveforms
03122 and it is obviously narrow, there may be an impact mark or chipped
Abnormal waveform teeth.
(Impact mark or chipped teeth on the rotor) • In this case, check the rotor visually.

51148

35E-39
ON-VEHICLE INSPECTION AND ADJUSTMENT
3. Operation check of hydraulic unit

Operation check with Multi-use tester II

• Jack up the vehicle and support it with a rigid truck or put the vehicle
on the brake tester roller for inspection.

WARNING k
• The roller of the brake tester and the tires must be dry during the
test.
• When the front brake is tested, apply the parking brake. When
the rear brake is tested, place scotches to lock the front wheels.

• Release the parking brake and feel the drag force of brakes at each
wheel.
Read the value of brake drag force when the brake tester is used.
• Set the start switch to the LOCK position and connect the Multi-use
tester II.
• Make sure that the transmission is at the neutral position. Start the
engine.

NOTE
When the hydraulic unit is not functioning due to fail-safe, the
actuator of the Multi-use tester II cannot be tested.

• Operate the Multi-use tester II to start the actuator forcibly.

• Turn a wheel with hand check variation of braking force when the
brake pedal is depressed.
These steps are shown on the following diagram:

35E-40
 35E

Depression
Pedal operation
Release

ON
Hold valve
OFF
Solenoid valve
ON
Pressure
reduction OFF
valve
ON
Motor
OFF

Lock
Check of braking force
Drag feel
when the pedal
is free
1 second
Start of Multi-use tester II actuator test
(either one of item Nos. 11 to 14) 78489

• If abnormality is found after inspection, actions are take according to

the "Judgement table" below.

Judgement table (actuator test with Multi-use tester II)

Multi-use Judgement
Item No. tester II Operation Cause Action
display Normal Failure
(1) Depress the brake pedal to Braking Wheels are Clogging in the brake Check and clean the
FR ABS lock wheels. force is not locked line other than the brake line.
11
MV ON (2) Select the wheel for inspection lowered for when the hydraulic unit
with the Multi-use tester II and 6 seconds brake pedal is
operate the actuator forcibly. from the depressed. Clogging in the hy- Replace the hydraulic
FL ABS (3) Turn the selected wheel with a lock status. draulic circuit of the unit.
12 brake tester or hand to check
MV ON hydraulic unit
variation of braking force.
Braking force Incorrect piping of Correct the piping.
RR ABS is not lowered. hydraulic unit brake
13
MV ON pipe

Faulty solenoid valve Replace the hydraulic

RL ABS
14 of hydraulic unit unit.
MV ON
• Set the starter switch to the LOCK position after inspection and re-
move the Multi-use tester II.

35E-41
ON-VEHICLE INSPECTION AND ADJUSTMENT
4. Air bleeding

• At normal air bleeding or replacement of the hydraulic unit, brake fluid is filled at the secondary side (operation circuit)
of the hydraulic unit. Air bleeding must be performed only at the primary side (normal circuit).
• If the system is operated with inclusion of air at the primary side, air may enter the secondary side. Air bleeding at the
secondary side must be performed using the Multi-use tester II.
• If the system is operated with inclusion of air at the secondary side, air may enter the primary side. Air bleeding at both
the primary side and the secondary side must be performed.
(1) Air bleeding at primary side

COUTIONk
Remove the power fuse of the hydraulic unit
• When the battery connection s is removed, do
or remove the battery connection s.
not connect the battery until air bleeding at the
primary side is completed. If the battery is con-
nected, air may be included at the secondary
side due to operation of the system. Air bleed-
Open the brake bleeder.
ing at the secondary side must also be per-
formed.
• If it is necessary to connect the battery before
Repeat depression and release of the brake
pedal slowly and run sufficient amount of the air bleeding, remove the power fuse of the hy-
brake fluid. draulic test.
• If air bleeding is found at the primary side due
to elongated travel of the brake pedal, air may
Tighten the brake bleeder. be included at the secondary side. Air bleeding
at the secondary side must also be performed.

After pumping the brake pedal a few times,

Complete the work in the thick line for each wheel in
maintain the depression status.
the sequence below:
Front axle right wheel
Open the brake bleeder.
Front axle left wheel

Discharge the brake fluid.

Rear axle right wheel

Rear axle left wheel

Air is included in the Air is not included in
brake fluid. the brake fluid.

Tighten the brake bleeder to the specified torque.

Connect the power fuse of the hydraulic unit

or the battery.

Perform initial check of the system.

The hydraulic unit operates (for 3 seconds).

Air bleeding at the primary side is completed.

35E-42
 35E
(2) Air bleeding at the secondary side

COUTIONk
Air bleeding at primary side (normal air bleeding)
• Do not perform the actuator test (Anti-lock
brake system operation) with the Multi-use
tester II continuously. Abnormal heating of
Depress the brake pedal. Anti-lock brake system motor valves may re-
sult in damage to the hydraulic unit.
• Do not perform the actuator test with the
Multi-use tester II during air bleeding at the
Perform the actuator test with the Multi-use
tester II while the brake pedal is depressed. primary side. Air at the primary side may be
L P35E-34 moved to the secondary side.
• Perform air bleeding of the axle (another
Operate the solenoid valve. *
wheel) that completed the actuator test.

Perform the actuator test with the Multi-use tester

Release the brake pedal after operation of II and complete the work in the thick line for each
the solenoid valve. wheel in the sequence below.

Front axle right wheel [Display No. 11 FR ABS

MV ONrtY]
Perform air bleeding at the primary side
(normal air bleeding).
(Air bleeding of the axle wheel that completed Front axle left wheel [Display No. 12 FL ABS
the actuator test) MV ONrtY]

Rear axle right wheel [Display No. 13 RR ABS

MV ONrtY]

Rear axle left wheel [Display No. 14 RL ABS

Air is included in the Air is not included in
MV ONrtY]
brake fluid. the brake fluid.

Tighten the brake Tighten the brake

bleeder and release bleeder to the
the pedal. specified torque.

Completion air bleeding at the primary and the secondary sides

35E-43
ON-VEHICLE INSPECTION AND ADJUSTMENT
5. Inspection after replacement or assembly/disassembly of hydraulic unit

Check operation of the hydraulic unit. L P35E-40

COUTIONk
• Incorrect piping may result in malfunction of the brake. Be
sure to check operation when the hydraulic unit is re-
placed or assembled/disassembled.
• The harness connector on the vehicle has a lock mecha-
nism. Connect it referring to the assembly/disassembly
procedures.
L Gr35A

35E-44
INSPECTION OF ELECTRIC PARTS 35E
Inspection of stop lamp switch
• Check continuity according to the table below:
2.5 w 0.5mm 1 2
1
OFF
ON q q

ON OFF Continuity between terminals

2 • If abnormality is found, replace the stop lamp switch.

07071

Inspection of relay (normally open 4-pin)

• Check continuity and operation according to the table below:
1 2 3 4
2 No power supply q q
4 2 1 3
r s q q
4 Power supply
1 r s
3 Continuity between terminals
r s Terminal applied with 24V
00432
• If abnormality is found, replace the relay.

Inspection of relay (normally close 4-pin)

• Check continuity and operation according to the table below:
1 2 3 4
2
4 2 1 3 q q
No power supply
＋− q q
4
1 Power supply
r s
3
82759 Continuity between terminals
r s Terminal applied with 24V
No continuity between terminals.
• If abnormality is found, replace the relay.

Inspection of wheel speed sensor

<Front> A
NOTE
Ball piece B is magnetized with the magnet built in wheel speed
sensor A. It tends to attract metal parts, but do not allow attrac-
B
tion.

07666

<Rear>

A
07690 35E-45
INSPECTION OF ELECTRIC PARTS
<Front> Perform the following inspection. If abnormality is found, replace the
wheel speed sensor. L Gr26, 27

A (1) Resistance between terminals of wheel speed sensor

Front 1 to 1.2 kq
Standard value
Rear 1.4 w 0.2 kq

07667

<Rear>

31750

<Front> (2) Insulation resistance of wheel speed sensor A

(body C and terminals)
Front 100 kq or more
Standard value
Rear 1000 kq or more
C

09940
<Rear>

31751

(3) Disconnection
If disconnection is found, remove the harness clamp from the vehicle
and check for temporary disconnection by bending or straightening the
harness at the clamp. Also check the terminal connection at the con-
nector.

31296

35E-46
 35E
Hydraulic unit

• An individual part cannot be inspected with ease. Therefore, accep-

tance is indirectly judged by checking the harness and the peripheral
parts of each system.
• If peripheral parts have no abnormality and the system has abnor-
mality, replace the hydraulic unit.

35E-47
PART MOUNTING POSITION AND ELECTRIC WIRING DIAGRAM

A 01 to 16 A06
A17 A01
A15

A07

A08

A02
A10
A16

A11

F29 F15 A05

F19 F5
F6

A09

F25

A04 A03
A02 A16

A01 Starter switch A09 Diode

A02 Fuse box A10 Diagnosis switch
A03 Anti-lock brake system A11 Memory clear switch
exhaust brake cut relay A12 -
A04 Anti-lock brake system A13 -
warning lamp relay A14 -
A05 Stop lamp relay A15 Connection of instrument panel harness and chassis harness
A06 Meter cluster A16 Relay box
A07 Multi-use tester- II connector A17 Automatic transmission electronic control unit
A08 Stop lamp switch

79847

35E-48
 35E
B 01 to 09
B04

B03
B09
B06
B07
B02

B01

B08

B05

B01 Wheel speed sensor (front-axle left wheel)

B02 Wheel speed sensor (front-axle right wheel)
B03 Wheel speed sensor (rear-axle left wheel)
B04 Wheel speed sensor (rear-axle right wheel)
B05 Hydraulic unit
B06 Battery
B07 High-current fuse box
B08 Hydraulic unit connector
B09 Connection of chassis and rear chassis harness

90164

35E-49
35E-50
<Manual transmission>
Iustrument panel Chassis Rear chassis

START
Wheel speed sensor Wheel speed sensor
ON
A01 ACC
B09
B01 B02 0.5-W 364 (SHIELD NO.3) 3 0.5-W 116 (SHIELD NO.3)
2
B03

AB2A
LOCK

AB3A
Starter switch front-axle front-axle 0.5-B 365 (SHIELD NO.3)
2 0.5-B 115 (SHIELD NO.3)
1 (rear-axle left wheel)
S F M A B left wheel right wheel 0.5-BG 369 1 0.5-BG 116

AP2A 0.5-W 359 (SHIELD NO.4) 0.5-W 112 (SHIELD NO.4)

B04

AB2A
1 1

AB3A
1 2 0.5-B 360 (SHIELD NO.4) 0.5-B 111 (SHIELD NO.4)
2 2 (rear-axle right wheel)
AB2A AB2A 0.5-BL 368 0.5-BL 112
5-RL 55 5-Y 218 3
2 1 2 1

5-R 48

0.5-W 354 (SHIELD NO.1)

0.5-B 355 (SHIELD NO.1)

0.5-W 349 (SHIELD NO.2)

0.5-B 350 (SHIELD NO.2)
To flasher and cornering relay B05

361
366
5-R 48 F6 10A W6 W6
330 Hydraulic unit
R 47 F5 10A 0.5-Y 5 B08
A02 110 RL 57 F15 10A YG 15 0.5-BW 358
23 Wheel speed sensor(ground)(for rear-axle right wheel)

356

351
RL 61 F19 10A 0.5-LW 19
Fuse box 0.5-YR 357
14 Wheel speed sensor(signal)(for rear-axle right wheel)
5-RL 67 F25 10A WY 25 WY 25 0.5-BY 363
To spare 24 Wheel speed sensor(ground)(for rear-axle left wheel)
RL 165 F29 10A GB 166 0.5-YL 362 34 Wheel speed sensor(signal)(for rear-axle left wheel)
3-B 100 0.5-BR 348 0.5-BR 348 Wheel speed sensor(ground)(for front-axle right wheel)
13
0.5-WR 347 0.5-WR 347 Wheel speed sensor(signal)(for front-axle right wheel)
12
130
0.5-BL 353 0.5-BL 353 33 Wheel speed sensor(ground)(for front-axle left wheel)
6
A16 Relay box
A15 0.5-WL 352 0.5-WL 352
32 Wheel speed sensor(signal)(for front-axle left wheel)

0.5-LB 178 0.85-GB 166 0.5-GB 342 0.5-GB 342 5 Starter switch terminal M(hydraulic unit power supply)
A03 3
0.5-LB 178
13
AL4A

0.5-LW 176 12 0.5-LB 346 0.5-LB 346 10 Anti-lock brake system exhaust brake cut relay(output)
4
Anti-lock brake system

AK14A( Bl ue)
1 0.5-YG 172 0.5-L 177 11 0.5-L 345 0.5-L 345 Anti-lock brake system exhaust brake cut relay(moniter)
9
exhaust brake cut YG 171 0.5-WY 182 0.5-WY 372 0.5-WY 372

EP34A
2 10 18 Stop lamp relay(signal)
relay
0.5-V 168 0.5-V 168 0.5-V 344 0.5-V 344 Anti-lock brake system warning lamp
3 9 8
A04
AL4A

0.5-B 170 0.5-LY 179 0.5-LY 370 0.5-LY 370

4 1 16 Multi-use tester-Ⅱ connector
0.5-RL 169
Anti-lock brake system 2 0.5-GL 180 0.5-GL 375 0.5-GL 375
Multi-use tester-Ⅱ connector
0.5-WY 182

0.5-GB 167 7 29
1 0.5-O 184 0.5-O 343 0.5-O 343
warning lamp relay 4 6 Diagnosis switch
0.5-R 183 0.5-R 371 0.5-R 371
3 17 Memory clear switch
0.5-WB 75
A05 3
AL4A

4 0.5-W 99 0.5-W 99 325

0.5-Y 97
Stop lamp relay 1
0.5-Y 5 To stop lamp sensor
0.5-B 367
2

0.5-B 367
0.5-B 186 0.5-B 186 0.5-O 184

A10 Diagnosis switch

3-RW 341
2 Battery(valve power supply)
3-LW 374 Battery(motor power supply)
4
BN1A

0.5-B 185 0.5-B 185 0.5-R 183

AU13A

11 0.5-RL 169
A06 401 ABS
4
LW 286
1 3-B 340 1 Ground(valve ground)
3-B 373 Ground(motor ground)
3
Meter cluster A11 Memory clear switch

0.5-B 367
0.5-LY 179
0.5-GL 180

16

3-B 340
3-B 373
0.5-B 812
13
CB16A

A07 12
0.5-B 811
Multi-use tester-Ⅱ connector 0.5-GL 743 A15
10
0.5-LW 813 5-R 48 5-R 20 10 10 130
B08
1 1

AJ4A
Hydraulic unit connector

3-RW 341
3-LW 374
5-Y 218 5-Y 18
3

5-R 20
5-Y 18
BM2A

0.5-WB 75 3-B 100 3-B 21

A08 2
AL2A

1 3 1 1 2
0.5-B 262 0.5-B 262 14 13 12 11 10 9 8 7 6 5
Stop lamp switch
2 BM3A BM2C
B07 2 1
130

FH3 60A

FH1 40A

FH8 30A
FH9 30A
High-current 24 23 22 21 20 19 18 17 16 15
fuse box 4 3
10 34 33 32 31 30 29 28 27 26 25
110
0.5-LW 176

0.5-GL 743

AK20A

0.5-LW 19 0.5-LW 5 40-BY

5 125
To exhaust brake + -
To alternator 8
magnatic valve
Gr13E
- + ：Erectrical

79776
Iustrument panel Chassis
B06 Battery
35E-51
35E-52
<Automatic transmission>
Iustrument panel Chassis Rear chassis

START
Wheel speed sensor Wheel speed sensor
ON
A01 ACC
B09
B01 B02 0.5-W 364 (SHIELD NO.3) 3 0.5-W 116 (SHIELD NO.3)
2
B03

AB2A
LOCK

AB3A
Starter switch front-axle front-axle 0.5-B 365 (SHIELD NO.3)
2 0.5-B 115 (SHIELD NO.3)
1 (rear-axle left wheel)
S F M A B left wheel right wheel 0.5-BG 369 1 0.5-BG 116

AP2A 0.5-W 359 (SHIELD NO.4) 0.5-W 112 (SHIELD NO.4)

B04

AB2A
1 1

AB3A
1 2 0.5-B 360 (SHIELD NO.4) 0.5-B 111 (SHIELD NO.4)
2 2 (rear-axle right wheel)
AB2A AB2A 0.5-BL 368 0.5-BL 112
5-RL 55 5-Y 218 3
2 1 2 1

5-R 48

0.5-W 354 (SHIELD NO.1)

0.5-B 355 (SHIELD NO.1)

0.5-W 349 (SHIELD NO.2)

0.5-B 350 (SHIELD NO.2)
To flasher and cornering relay B05

361
366
5-R 48 F6 10A W6 W6
330 Hydraulic unit
R 47 F5 10A 0.5-Y 5 B08
A02 110 RL 57 F15 10A YG 15 0.5-BW 358
23 Wheel speed sensor(ground)(for rear-axle right wheel)

356

351
RL 61 F19 10A 0.5-LW 19
Fuse box 0.5-YR 357
14 Wheel speed sensor(signal)(for rear-axle right wheel)
5-RL 67 F25 10A WY 25 WY 25 0.5-BY 363
To spare 24 Wheel speed sensor(ground)(for rear-axle left wheel)
RL 165 F29 10A GB 166 0.5-YL 362 34 Wheel speed sensor(signal)(for rear-axle left wheel)
3-B 100 0.5-BR 348 0.5-BR 348 Wheel speed sensor(ground)(for front-axle right wheel)
13
0.5-WR 347 0.5-WR 347 Wheel speed sensor(signal)(for front-axle right wheel)
12
130
0.5-BL 353 0.5-BL 353 33 Wheel speed sensor(ground)(for front-axle left wheel)
6
A16 Relay box
A15 0.5-WL 352 0.5-WL 352
32 Wheel speed sensor(signal)(for front-axle left wheel)

0.5-LB 178 0.85-GB 166 0.5-GB 342 0.5-GB 342 5 Starter switch terminal M(hydraulic unit power supply)
A03 3
0.5-LB 178
13
AL4A

0.5-LW 176 12 0.5-LB 346 0.5-LB 346 10 Anti-lock brake system exhaust brake cut relay(output)
4
Anti-lock brake system

AK14A( Bl ue)
1 0.5-YG 172 0.5-L 177 11 0.5-L 345 0.5-L 345 Anti-lock brake system exhaust brake cut relay(moniter)
9
exhaust brake cut YG 171 0.5-WY 182 0.5-WY 372 0.5-WY 372

EP34A
2 10 18 Stop lamp relay(signal)
relay
0.5-V 168 0.5-V 168 0.5-V 344 0.5-V 344 Anti-lock brake system warning lamp
3 9 8
A04
AL4A

0.5-B 170 0.5-LY 179 0.5-LY 370 0.5-LY 370

4 1 16 Multi-use tester-Ⅱconnector
0.5-RL 169 0.5-GL 180 0.5-GL 375 0.5-GL 375
Anti-lock brake system 2 Multi-use tester-Ⅱconnector
0.5-WY 182

0.5-GB 167 7 29
1 0.5-O 184 0.5-O 343 0.5-O 343 Diagnosis switch
warning lamp relay 0.5-R 183
4
0.5-R 371 0.5-R 371
6
3 17 Memory clear switch
0.5-WB 75
A05 3
AL4A

4 0.5-W 99 0.5-W 99 325

0.5-Y 97
Stop lamp relay 1
0.5-Y 5 To stop lamp sensor
0.5-B 367
2

0.5-B 367
0.5-B 186 0.5-B 186 0.5-O 184
0.5-WB 76
A09 3
PD3A

2
0.5-WY 77
0.5-RB 78
A10 Diagnosis switch
3-RW 341
Diode 1 2 Battery(valve power supply)
3-LW 374 Battery(motor power supply)
4
BN1A

0.5-B 185 0.5-B 185 0.5-R 183

AU13A

11 0.5-RL 169
A06 401 ABS
4
LW 286
1 3-B 340 1 Ground(valve ground)
3-B 373 Ground(motor ground)
3
Meter cluster A11 Memory clear switch

0.5-B 367
0.5-LY 179
0.5-GL 180

16

3-B 340
3-B 373
0.5-B 812
13
CB16A

A07 12
0.5-B 811
Multi-use 0.5-GL 743 A15
10
tester-Ⅱ 0.5-LW 813 5-R 48 5-R 20 10 10 130
B08
1 1
connector AJ4A Hydraulic unit connector

3-RW 341
3-LW 374
5-Y 218 5-Y 18
3

5-R 20
5-Y 18
BM2A

0.5-WB 77 3-B 100 3-B 21

A08 2
AL2A

1 3 1 1 2
0.5-B 262 0.5-B 262 14 13 12 11 10 9 8 7 6 5
Stop lamp switch
2 BM3A BM2C
B07 2 1
130

FH3 60A

FH1 40A

FH8 30A
FH9 30A
High-current 24 23 22 21 20 19 18 17 16 15
0.5-LW 725

fuse box 4 3
0.5-RB 78

10 34 33 32 31 30 29 28 27 26 25
110
0.5-GL 743

7 11
AK20A

0.5-LW 19 0.5-LW 5 40-BY

CC16A 5 125
+ -
To alternator 8
Gr23 Gr13E - + ：Erectrical
Automatic transmission
A17 electronic control unit 79777
Iustrument panel Chassis
B06 Battery
35E-53
 36

GROUP 36 PARKING BRAKE

SPECIFICATIONS ................................................................................ 36-2

STRUCTURE AND OPERATION ........................................................ 36-2

TROUBLESHOOTING ......................................................................... 36-4

ON-VEHICLE INSPECTION AND ADJUSTMENT

• Adjustment of Parking Brake Shoe Clearance and Ratchet Bar
Pulling Stroke ........................................................................................ 36-5

PARKING BRAKE CONTROL ............................................................. 36-6

PARKING BRAKE ASSEMBLY .......................................................... 36-8

BACKING PLATE AND SHOE ASSEMBLY ....................................... 36-10

36-1
SPECIFICATIONS / STRUCTURE AND OPERATION
SPECIFICATIONS
Item Specifications

Type Propeller shaft internal expanding type brake

Brake
Operation method Mechanical cable type

Type Dual-servo type

Parking brake assembly Drum inner diameter mm X190

Lining width × Thickness mm 45 × 4.0

STRUCTURE AND OPERATION

Parking Brake Control
1 Parking brake ratchet bar
2 Parking brake cable
1 3 Parking brake assembly

74258

Parking Brake Ratchet Bar

1 1 Support
2
2 Ratchet bar
3 Ratchet pole

A: Handle
B: Idle rotation angle
C: Lock release range
D
3 A D: Release button

• The idle rotation angle B at handle A of

ratchet bar 2 prevents inadvertent return of
the ratchet bar.
• To release the lock status, set handle A of
ratchet bar 2 into lock release range C
while pressing release button D and disen-
B gage ratchet pole 3 from ratchet bar 2.
C Then return the ratchet bar.
79840
79840

36-2
 36
Parking Brake Assembly
1 Parking lever
2 Strut
3 Shoe return spring
4 Parking brake drum
5: Shoe and lining assembly

• Pulling the parking brake ratchet bar pulls the parking brake cable,
which in turn pulls parking brake lever 1 installed the parking brake
03569 body, operating shoe and lining assembly 5.
• Activation of parking lever 1 expands one shoe and lining assembly 5
via strut 2, the parking lever itself expands to the other shoe and lin-
ing assembly. Therefore, both shoe and lining assemblies function as
leading shoes.
• When the ratchet bar (parking lever) is returned, the repercussive
force of shoe return spring 3 releases the brake.

36-3
TROUBLESHOOTING
Symptoms

Parking brake does not release smoothly (dragging)

Parking brake does not release
Remarks

Possible causes

Inner cable stretched or damaged p p

Parking brake cable Inner cable rusted p
Inner spring of wire fatigued or broken p
Ratchet bar and ratchet pawl are engaged incorrectly p
Parking brake ratchet bar Pulling stroke insufficient p p
Pulling stroke excessive p
Shoe clearance insufficient p
Shoe clearance excessive p
Parking brake drum inner surface deformed or warped p
Parking brake assembly Parking brake drum inner surface greasy or oily p
Lining worn unevenly p
Lining surface greasy or oily p
Shoe return spring fatigued or broken p

36-4
ON-VEHICLE INSPECTION AND ADJUSTMENT 36
Adjustment of Parking Brake Shoe Clearance and Ratchet Bar Pulling Stroke
Service standards Unit: mm

Location Maintenance item Standard value Limit Remedy

– Brake shoe clearance 0.2 to 0.25 – Adjust

4 Ratchet bar pulling stroke 80 to 120 – Adjust

(Operating force: 295 N {30 kgf}
Clearance between outer cable and lock nut
7 (when the outer cable is pulled at 59 to 98N {6 to 3 to 7 – Adjust
10 kgf}.

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks

6 Lock nut 19 to 27 {1.9 to 2.8} –

(1) Shoe clearance

When parking lever 1 is released, turn adjuster 2 in the expansion direc-
tion using a screwdriver inserted through the shoe adjusting hole of the
parking brake drum, and then return 8 to 10 notches from the position
where shoe 3 is in close contact with the drum. Then, the shoe clear-
ance will be the standard value.
A: Contraction
B: Expansion
Standard value: 0.2 to 0.25 mm
03599

(2) Ratchet bar pulling stroke

Adjust the adjusting nut of the parking brake cable so that the ratchet
bar pulling stroke C is the standard value when parking brake ratchet
bar 4 is pulled from the released position by an operating force of 295 N
{30 kgf}.
Operate the ratchet bar two or three times after adjusting to verify the
pulling stroke to make sure that the parking brake is operating properly
and that the parking brake drum does not drag when the parking brake
is released.
74260
Standard value: 80 to 120 mm
[Adjustment]
• Tighten adjusting nut 5 until mark D can be seen.
• Tighten lock nut 6 to the position of adjusting nut 5.
• Tighten lock nut 6 at the specified torque.
Tightening torque: 19 to 27 N?m {1.9 to 2.8 kgf?m}
• Check clearance E when the outer cable of parking brake cable 7 is
pulled by an operating force of 59 to 98 N {6 to 10 kgf}.
E: 3 to 7 mm

03602

36-5
PARKING BRAKE CONTROL

74261

P Disassembly sequence
1 Parking brake ratchet bar L P36-7
2 Parking brake cable

*: Parking brake assembly L P36-8

P Assembly sequence
Follow the disassembly sequence in reverse.

36-6
 36
Parking Brake Ratchet Bar
PDisassembly sequence
2 1 Push nut
2 Pin
6K 3 Ratchet pawl
1
4 Ratchet spring
5 Push nut
3 6 Pin
11 5
7 Return spring
10
8 Ratchet bar
4 9 Parking brake switch B Electrical
9
10 Grommet
12 11 Clip
12 Support
7

8 PAssembly sequence
Follow the disassembly sequence in re-
verse.

79841

K Lubricant
Location Points of application Specified lubricant Quantity

6 Sliding areas between pin and ratchet bar Wheel bearing grease [NLGI No.2 (Li soap)] As required

R Service procedure

8 Ratchet bar inspection

8
• Check that the several operation ranges (turning angles) of ratchet
bar 8 are as shown in the illustration.
B A • Check that ratchet bar 8 is smoothly operated without any hitch.
A: Horizontal, set position
C
B: Free play ±5°
C: Idle rotation angle (41°30’)
D D: Unlocked range (120° or higher)
78596

36-7
PARKING BRAKE ASSEMBLY
P Disassembly sequence
1 Nut
2 Lock nut
3 O-ring
4 Dust plug
5 Parking brake drum
6 Companion flange
7 Bolt
8 Backing plate and shoe assembly
LP36-10

*a: Propeller shaft L Gr25

*b: Parking brake cable L P36-6
X: Not reusable parts

P Assembly sequence
Follow the disassembly sequence in re-
verse.
03607

Service standards Unit: mm

Location Maintenance item Standard value Limit Remedy

+ 0.2
Inner diameter X190 X191
0
Squareness 0.05 or less –

5 Parking brake Concentricity X0.1 to less – Replace

drum
Cylindrical accuracy 0.05 or less –

0.49 N?m {50 gf?cm}

Static rotation imbalance –
or less

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks

1 Nut (propeller shaft installation) 100 to 115 {10 to 12} –

2 Lock nut (companion flange installation) 245 to 345 {25 to 35} –

7 Bolt (Backing plate and shoe assembly installa- 52 to 67 {5.3 to 6.8} –

tion)

36-8
 36
J Special tools Unit: mm
Location Tool name and shape Part No. Application

6 Flange puller MH061848 Companion flange removal

03618

R Service procedure
6 Companion flange removal

J: Flange puller

03609

36-9
BACKING PLATE AND SHOE ASSEMBLY
P Disassembly sequence
1 Shoe return spring
2 Washer
3 Strut spring
4 Shoe hold down cup
5 Shoe hold down spring
6 Shoe hold down pin
7 Adjuster
8 Adjuster spring
9 Strut
10 Retainer
11 Parking lever
K
12 Shoe and lining assembly
13 Backing plate

*a: Retainer
K *b: Parking brake cable L P36-6
03405

P Assembly sequence
Follow the disassembly sequence in reverse.

CAUTION k
• Keep surface of shoe and lining assembly 12 free from grease, etc.
• If shoe and lining assembly 12 has been replaced with a new part, check the correctness of contact with the
parking brake drum.

Service standards Unit:mm

Location Maintenance item Standard value Limit Remedy
Installed load of shoe return spring 59 ± 5.9 N 49 N
1 Replace
(installation length 67.1) {6 ± 0.6 kgf} {5 kgf}
Installed load of strut spring 29 ± 2.9 N 26 N
3 Replace
(installed length 49) {3 ± 0.3 kgf} {2.7 kgf}
Installed load of shoe hold down spring 78 ± 7.8 N 71 N
5 Replace
(installed length 15.5) {8 ± 0.8 kgf} {7.2 kgf}
Installed load of adjust spring 59 ± 5.9 N 49 N
8 Replace
(installed length 78.2) {6 ± 0.6 kgf} {5 kgf}
12 Lining thickness 4 1.4 Replace

K Lubricant
Location Points of application Specified lubricant Quantity

7 Contact surface of both ends of adjuster with shoe Brake grease AKB100 As required
and lining assembly

13 Anchor pin area ledge face (6 locations) of backing Brake grease AKB100 As required
plate

36-10
 36
R Service procedure
7 13 Applying grease to adjuster and backing plate
• Apply grease to contact surface C between both ends of adjuster 7
and shoe and lining assembly 12.
• Apply grease to area D of the anchor pin and ledge face E (6 loca-
tions) of backing plate 13.

B B

03567

12 Inspection of shoe and lining assembly

Measure thickness A of the lining. If the measured value is lower the
limit, replace shoe and lining assembly 12.

14921

36-11
 37

GROUP 37 STEERING
SPECIFICATIONS ................................................................................ 37-2

STRUCTURE AND OPERATION ........................................................ 37-3

TROUBLESHOOTING ......................................................................... 37-9

ON-VEHICLE INSPECTION AND ADJUSTMENT

• Power Steering Oil Replacement ........................................................ 37-11
• Bleeding of Power Steering System ................................................... 37-11
• Steering Wheel Play ............................................................................. 37-12
• Steering Wheel Play, Vibration and Pulling ....................................... 37-12
• Power Steering System Performance Verification Test .................... 37-13

STEERING SYSTEM ............................................................................ 37-14

STEERING COLUMN SUBASSEMBLY .............................................. 37-18

BEVEL GEAR ...................................................................................... 37-22

POWER STEERING BOOSTER ASSEMBLY ..................................... 37-26

POWER STEERING OIL PUMP .......................................................... 37-34

POWER STEERING OIL TANK ........................................................... 37-37

POWER STEERING OIL LINE ............................................................. 37-38

37-1
SPECIFICATIONS
Item Specifications
Type 2-spoke Type
Steering wheel
Outer diameter mm 400
Steering shaft Type Universal joint type (high tilt type)
Manufacturer KOYO SEIKO CO., LTD
Type Rack and pinion type
Model Integral type
Power steering
booster Gear ratio (rack stroke/
47.72
pinion revolution)
Rack stroke mm 188
Mass (without oil) kg 15.45
Manufacturer KOYO SEIKO CO., LTD
Type Spiral gear type
Bevel gear
Gear ratio 1.27
Mass kg 5.5
Manufacturer NIPPON POWER STERING CO., LTD
Type Vane type
Discharge amount
9.6 {9.6}
cm3 {mL}/rotation
Regulated flow
7 {7}
Power steering oil Volume dm3 {L}/min
pump
Regulated pressure(relief
valve) MPa {kgf/cm2} 9.3 +0.2 +2
–0.3 {95 –3 }

Permissible
600 to 6500
revolution rpm
Mass (without drive gear
1.71
and oil) kg

37-2
STRUCTURE AND OPERATION 37
Steering System
1 Steering wheel
2 Steering column subassembly
1
3 Horn contact
4 Combination switch
2 5 Bevel gear
6 Intermediate shaft
7 Power steering booster
8 Input shaft
9 Pinion gear
10 Rack gear
6

5 Pinion gear 9 is installed at the end of input shaft 8

that is linked to intermediate shaft 6, the pinion gear
7 is meshed with rack gear 10 to convert the rotation
movement of the pinion gear to the horizontal move-
9 ment by the rack gear.

10

74302

• The steering wheel 1 is an impact absorption type,

so if a large force is applied to steering wheel in an
accident the steering wheel will deform to absorb
the shock and lessen the injury to the driver’s tor-
so.
• Shifting lock lever A from lock position B to release
position C produces high tilt D. In this way the
structure of steering column subassembly 2 allows
driver to adjust steering column to obtain the opti-
mum driving position.
• Horn contact 3 is connected to combination switch
4.

74276

37-3
STRUCTURE AND OPERATION
Power Steering System
1 Power steering oil tank
1
2 Power steering oil pump
3 Power steering booster

2 : Oil flow

79818

Bevel Gear
1 Reduction gear (input side)
2 Top plug
3 Oil seal
4 Dust cover
5 Needle bearing
6 Lock nut
7 Spacer
8 Bearing
9 Bearing
10 Oil seal
11 Reduction gear (output side)
12 Lock nut
13 Gear box
14 Bolt
15 Adjustment bolt
16 End cover
17 Lock nut
18 Spacer
19 Bearing

06836

37-4
 37
Power Steering Booster

74666

1 Input shaft 8 Rack gear D: Oil pressure adjustment section

2 Torsion bar 9 Piston E: Cylinder chamber
3 Bearing 10 Dowel pin F: Cylinder chamber
4 Rotary valve 11 Pin G: From oil pump
5 Pinion gear 12 Bushing H: To oil tank
6 Bearing 13 Stopper J: To cylinder chamber
7 Yoke spring K: To cylinder chamber

Rotary valve 4 is the central part of the power steering booster. Torsion bar 2 allows the steering reaction force and valve
return to operate lightly and smoothly at low speed and ensures stable steering feeling even at high speed.

37-5
STRUCTURE AND OPERATION
P Straight-ahead drive operation
When steering torque is not applied by the steering wheel, input shaft 1
is not activated and remains in neutral. At this time, pressurized oil from
the oil pump flows through the input shaft and the hole of rotary valve 4
and then returns to the oil tank without flowing into cylinder chambers E
and F.

06990

P Steering operation
Turning the steering wheel rotates input shaft 1, causing rotary valve 4
to close the oil feed passage to cylinder chamber F. This produces a
pressure difference between cylinder chambers E and F which causes
piston 9 to move and facilitates rotation of input shaft (pinion gear
5).The illustration shows right-turn steering and should be reversed left-
turn steering.

06991

P Operation when hydraulic circuit faulty

Pinion gear 5 has stopper 13 to prevent excessive twisting of torsion bar
2, and when there is trouble in the hydraulic circuit this stopper makes
the input shaft 1 transmit the rotational force of the steering wheel di-
rectly to the pinion gear to provide a safety mechanism that makes
manual steering possible.

06992

37-6
 37
Power Steering Oil Pump

79622

1 Cam ring 7 Bearing 13 Shaft

2 Vane 8 Oil seal 14 Connector
3 Rotor 9 Side plate 15 Relief valve assembly
4 Pin 10 Bolt 16 Flow control spring
5 Gear 11 Cover 17 Bolt
6 Snap ring 12 Suction connector 18 Body

37-7
STRUCTURE AND OPERATION
Relief Valve Assembly
P Flow control valve assembly
(1) Oil pump rotating at low speed
Since pressure generated from pressure chamber A is low when the oil
pump is rotating at low speed, the hydraulic pressure in chamber B is
also low. Therefore, relief valve assembly 15, which is pressed by the
spring force of flow control spring 16, is not activated.

C: Direction of rotation
D: To the power steering booster

06802

(2) Oil pump rotating at medium or high speed

Since pressure generated from pressure chamber A is high when the
oil pump is rotating at medium or high speed, the hydraulic pressure in
chamber B is also high. This will activate relief valve assembly 15, over-
coming the spring force of flow control spring 16, and open port E, mak-
ing excess oil return to the inlet port to adequately regulate the flow of
oil to power steering booster D.

06803

P Operation of relief valve

When the steering is at lock-to-lock, pressure in chambers B and F in-
creases and overcomes the spring force of relief spring G and opens re-
lief valve J, which was closed by steel ball H. Thus, if the pressure in
chamber F decreases, the relief valve closes again.

06804

37-8
TROUBLESHOOTING 37
Symptoms

Steering wheel angle insufficient or different

Steering wheel play excessive and unstable

Oil pump hydraulic pressure abnormal

Steering wheel pulls to one side
Steering wheel operation heavy

Steering wheel self-return poor

Steering wheel does not turn

Remarks

Steering wheel vibration

between right and left

Oil pump squeaks

Oil pump gurgles

Oil pump growls

Oil leaking
Possible causes
Insufficient amount of oil p p
Air bled insufficiently p p
Power system faulty

Oil viscosity unsuitable p

Hydraulic circuit is clogged p
Power steering booster faulty p p p p p p
Power booster installed incorrectly p p p
Tie rod end ball stud movement incorrect p
Tie rod end ball stud excessive play p p
Steering shaft universal joint abnormally worn,
p p
damaged, or lubrication is poor
Intermediate shaft universal joint abnormally worn,
p p
damaged, or lubrication is poor
Steering wheel right and lest turning center is off center p
Bevel gear rotation torque adjustment is incorrect p p p
Upper arm or lower arm ball joint lubrication is
Defects in front axle, front suspension, etc.

p p
poor
Upper arm or lower arm ball joint is worn or
p p p
damaged
L Gr33
Upper arm or lower arm bushing is worn p
Upper arm or lower arm installation is incorrect p
Upper arm or lower arm is deformed p p
Shock absorber attenuation power is insufficient p L Gr33
Knuckle deformed p p
Wheel hub bearing worn or damaged p p p p
Front wheel alignment is faulty (toe-in, chamber, L Gr26
p p p p
caster)
Steering angle adjustment is incorrect. p p

37-9
TROUBLESHOOTING
Symptoms

Steering wheel angle insufficient or different

Steering wheel play excessive and unstable

Oil pump hydraulic pressure abnormal

Steering wheel pulls to one side
Steering wheel operation heavy

Steering wheel self-return poor

Steering wheel does not turn

Remarks

Steering wheel vibration

between right and left

Oil pump squeaks

Oil pump gurgles

Oil pump growls

Oil leaking
Possible causes
Oil pump body faulty p
O-ring, oil seal faulty p
Bolt tightened incorrectly p
Maximum generated hydraulic pressure
Oil pump faulty

p
insufficient
Oil line is crushed or clogged p
Air lock in oil pump p
Oil pump interior seized p p p
Mounting bolt or nut loose p
Pump body faulty p
Valve operates incorrectly p
Oil tank

Oil tank leaking due to overflowing p

faulty

Oil tank leaking due to air lock p

Left and right wheel base difference excessive p
Propeller shaft run out excessive p L Gr25
Rear axle housing bent p
Final drive gear and final drive pinion damaged L Gr27
p
Other malfunctions

or engaged incorrectly
Tire pressure insufficient p
Tire pressure excessive p
Tire wear difference between right and left ex-
p
cessive
L Gr31
Tire outer diameter difference between right and
p
left
Front tire pitching and rolling, static balance or
p
dynamic balance faulty
Braking one sided p L Gr35A

37-10
ON-VEHICLE INSPECTION AND ADJUSTMENT 37
Power Steering Oil Replacement
T Tightening torque Unit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks
2 Feed tube 12 to 18 {1.2 to 1.8} –

[Draining]
• Jack up the front wheels.
• Release pressure tube 2 on the power steering booster rack housing
1 side.
• Turn the steering wheel fully right and left repeatedly to drain the hy-
draulic oil from the power steering booster.
• After draining the hydraulic oil, tighten feed tube 2 at the specified
torque.
Tightening torque: 12 to 18 N?m {1.2 to 1.8 kgf?m}
74667

CAUTION k
When removing feed tube 2, clean around the ports and prevent
the entrance of debris, dust, etc.

[Filling]
L P37-11

Bleeding of Power Steering System

K Lubricant
Location Points of application Specified lubricant Quantity
Filler cap
Automatic transmission fluid
– Power steering oil tank level gauge between MIN
(DEXRON or DEXRON II TYPE)
and MAX

CAUTION k
Since power steering pump seizure may be caused, do not hold
the steering wheel steered to the right or left limit with the en-
gine running for more than 15 seconds.

• Pour hydraulic oil into the power steering oil tank to the mouth of
strainer A.
• With the engine stopped, jack up the front wheels and turn the steer-
ing wheel fully right and left repeatedly.When the oil level has
07236
dropped, add oil to maintain the oil level within range B.

37-11
ON-VEHICLE INSPECTION AND ADJUSTMENT
CAUTION k
• Check the oil level without screwing on filler cap C.

• Start the engine and letting it idle, turn the steering wheel fully right
and left repeatedly. When the oil level has dropped, add the hydraulic
oil to maintain the oil level within range B. Repeat these steps until
the oil level does not drop.
• If there is an abnormal noise, air is still in the system. Turn the steer-
ing wheel several times to raise the hydraulic oil temperature to ap-
proximately 60 to 80°C, then stop the engine and wait for
approximately 5 minutes.
• Lower the front wheels and turn the steering wheel several times. If
there is no noise, bleeding is completed.
• When bleeding is finished, check the oil level of the tank and the pipe
and hose connections for leaks.

Steering Wheel Play

Service standards Unit: mm
Location Maintenance Item Standard value Limit Remedy
Steering wheel play (measure at the
– 0 to 25 – Replace
periphery of the steering wheel)

Point the wheels directly forward, start the engine and gently turn the
steering wheel right and left to measure the play at the periphery. If the
play deviates from the standard value, adjust the tightening, and inspect
the bevel gear total rotational torque (LP37-22) and power steering
booster total rotational torque (L P37-28).

74281

Steering Wheel Play, Vibration and Pulling

• Move the steering wheel up and down, forward and back, and right
and left to check for play.
• Drive the vehicle at low speed and check if the steering wheel vi-
brates, pulls to one side, is abnormally hard to turn, or has poor re-
turn.

74282

37-12
 37
Power Steering System Performance Verification Test
Service standards
Location Maintenance item Standard value Limit Remedy
Steering system hydraulic pressure (with hands off
–
steering wheel) 0.5 MPa {5 kgf/cm2} – Repair

Maximum
+200 kPa
Relief set pressure (measure with engine speed at {2 kgf/cm2}
–
1000 to 1500 rpm and stop valve closed) 9.3 MPa {95 kgf/cm2} Minimum
Replace
–300 kPa
{–3 kgf/cm2}

Verify that the power steering booster and the power steering oil pump
are operating properly by testing the following items.

CAUTION k
• Connect the stop valve A and oil pressure gauge B to the oil
pump 2 output side as shown in the illustration.
• Because power steering pump 2 seizure is caused, do not close
stop valve A for more than 15 seconds.
• If the oil pressure is higher than 0.5 MPa {5 kgf/cm2} with engine
74669 idling and the steering wheel free, inspect power steering boost-
er 1 and hydraulic circuit for clogging.

Test item Test procedure Assembly standards

Verification of smooth
Jack up the front wheels and turn steering wheel fully left and right. Smooth operation throughout test
operation
• Install oil pressure gauge B capable of measuring above 10.8 MPa
{110 kgf/cm2} and stop valve A, then bleed the air.
Measurement
• With the engine idling, turn the steering wheel right and left several
conditions
times to raise the oil temperature to 50 to 60°C.
• With the engine idling, fully open stop valve A.
Measurement of hy-
• Measure oil pressure with hands off steering wheel. 0.5 MPa {5 kgf/cm2}
draulic oil pressure
Measurement of relief • Gradually increase engine speed and maintain it at 1000 to 1500 Relief set pressure
pressure rpm and close stop valve A to measure the maximum oil pressure. 9.3 MPa {95 kgf/cm2}

37-13
STEERING SYSTEM

5
6T

7 4

13
16
T 12
8 17
3
25
1

9
23 T
14
16

11 XT 15
24 18
10 K T
22

21

20

19 T
X
30 29 28

*
27
T
26 T X 26 X
T
31 X

79819

37-14
 37
P Removal sequence
1 Column cover outer lower 18 Band
2 Column cover outer upper 19 Nut
3 Column cover inner lower 20 Dust cover
4 Column cover inner upper 21 Dust cover
5 Horn pad 22 Dust cover
6 Nut 23 Bolt
7 Steering wheel assembly 24 Bolt
8 Horn spring 25 Steering column subassembly L P37-18
9 Contact plate 26 Nut
10 Cover assembly 27 Nut
11 Steering wheel 28 Bevel gear L P37-22
12 Screw 29 Intermediate shaft
13 Combination switch B Electrical 30 Oil pipe
14 Bracket 31 Power steering booster L P38-28
15 Thread cutting bolt
16 Starter switch B Electrical : Knuckle
*
17 Spring X: Non-reusable parts

P Installation sequence
Follow the removal sequence in reverse.

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
6 Nut (steering wheel assembly installation) 39 to 49 {4 to 5} –
12 Screw (combination switch installation) 2.9 {0.3} –
15 Thread cutting bolt (Starter switch installation) 13 to 16 {1.3 to 1.6} –
Nut (steering column subassembly and bevel gear
19 53 to 65 {5.3 to 6.5} –
installation)
Bolt (floor side steering column subassembly instal-
23 17 to 26 {1.7 to 2.6} –
lation)
Bolt (instrument panel side steering column subas-
24 17 to 26 {1.7 to 2.6} –
sembly installation)
26 Nut (intermediate shaft installation) 54 to 66 {5.4 to 6.6} –
27 Nut (bevel gear installation) 70 to 85 {7.0 to 8.5} –

K Lubricant
Location Points of application Specified lubricant Quantity
Contact area of combination switch and horn con- Wheel bearing grease
10 As required
tact in cover assembly [NLGl No.2 (Li soap)]

37-15
STEERING SYSTEM
R Service procedure
5 Horn pad removal
• Insert a flat head screwdriver into the gap between steering wheel
assembly 7 and horn pad 5 shoulder A and B and pry them up by the
driver until there is a “catch release sound” that indicates the horn
pad connection can be removed.
• Slide your fingers into the lifted up horn pad 5 to remove the horn
pad.

24551

7 Steering wheel assembly installation

Align the slits A of the steering wheel assembly 7 and the tabs B of
combination switch 8 cancel cam to install.

19063

15 16 Thread cutting bolt, starter switch

[Removal]
• After removing bracket 14, drill a hole of 5.5 to 6.0 mm diameter and
10 to 15 mm depth on cutting surface A of thread cutting bolt 15 for
mounting starter switch 16.
• Screw in screw extractor B counterclockwise and then pull out thread
cutting bolt 15.

07241

[Installation]
• With new thread cutting bolt 15, tighten starter switch 16 at the spec-
ified torque to cut the head off the bolt.
• After installing bracket 14, verify operation of the steering lock func-
tion of starter switch 16.

07242

37-16
 37
23 24 Bolt installation
Bolts 23 and 24 differ in shape. Do not mix when installing them.

CAUTION k
Thread area A of bolt 23 is elliptical to facilitate grounding of the
horn circuit.

07243

25 Installation of steering column subassembly

When the steering column subassembly 25 spline is removed, position
it the same as yoke direction A.
A

25
A
79820

25 28 29 31 Removal and installation of steering column subas-

25
A sembly, bevel gear, intermediate shaft, and power
steering booster
A Be sure to make alignment marks A before removing steering column
29
A subassembly 25, bevel gear 28, intermediate shaft 29, and power steer-
ing booster 31.
28

31
07003

29 Intermediate shaft installation

Check the shaft length A and identification color B (power steering
booster side) of the intermediate shaft 29 and install.

A :365mm
B :White

07004

37-17
STEERING COLUMN SUBASSEMBLY

1T

1T

23
22 T K

21 2

22 T K
13

24

T10 5T
11
K15 19 T
20

18

X
6
12
19
7
T 25
6
17
K 16
14
K 12
X

K8

79821

37-18
 37
P Disassembly sequence
1 Nut 11 Lock lever 21 Clevis pin
2 Support bracket 12 Split pin 22 Bolt
3 Spring seat 13 Return spring 23 Column support upper
4 Steering column assembly 14 Return spring 24 Telescopic shaft assembly
5 Nut 15 Snap ring 25 Column support lower
6 Stopper 16 Cam
7 Bearing spacer 17 Lock plate X : Non-reusable parts
8 Grease nipple 18 Wave washer
9 Steering shaft assembly 19 Bolt
10 Nut 20 Lever support

P Assembly sequence

4 3 2 1
24 23
22 21 20 19 18 17 16 15 14 13 12 11 10
4: 25 5
9 8 7 6

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Nut (support bracket installation) 17 to 26 {1.7 to 2.6} –
Nut (Steering shaft assembly and telescopic shaft
5 53 to 65 {5.4 to 6.6} –
assembly installation)
10 Nut (lock lever installation) 4 to 6{0.4 to 0.6} –
19 Bolt (lever support installation) 7 to 10 {0.7 to 1.0} –
Bolt (column support upper and column support
22 15 to 20 {1.5 to 2.0} –
lower installation)

K Lubricant and/or sealant

Location Points of application Specified lubricant and/or sealant Quantity
Wheel bearing grease
8 Inject from a grease nipple As required
[NLGI No.2 (Li soap)]
Wheel bearing grease
14 Return spring washer sliding areas As required
[NLGI No.2 (Li soap)]
Wheel bearing grease
15 Snap ring lever support sliding areas As required
[NLGI No.2 (Li soap)]
Wheel bearing grease
17 Lock plate return spring sliding clevis pin and cam sliding areas As required
[NLGI No.2 (Li soap)]
THREEBOND Thread Lock Super
Bolt threads As required
103Q or LOCTITE 271
22
Wheel bearing grease
Sliding areas with bolt column support upper As required
[NLGI No.2 (Li soap)]

37-19
STEERING COLUMN ASSEMBLY
R Service procedure
6 Stopper installation
Install stoppers 6 onto steering shaft assembly 9 in the direction as il-
lustrated so that bearing spacer 7 is sandwiched between the stoppers.

11310

9 Steering shaft assembly

[Removal]
Before removing steering shaft assembly 9, be sure to make alignment
marks A.

[Installation]
Install the steering shaft with direction of yokes B of the telescopic shaft
assembly 24 and steering shaft assembly 9 in alignment or at a phase
angle of 90°.
07255

11 Lock lever installation

• Install lock lever 11 so it is within dimension A when locked.
• After installing lock lever 11, make sure that the lever operates
smoothly (operating force less than 49 N {5 kgf}. With the lever free,
make sure that high tilt operates smoothly.)

06998

12 Split pin installation

Bend split pin 12 to the direction as illustrated.

07246

16 Cam installation
Adjust lever support 20 so that the top surface A of cam 16 is within the
dimension of lock plate 17 dimension B and then install the cam.

18759

37-20
 37
21 Clevis pin installation
Install clevis pin 21 on column support upper 23 so that dimension A is
obtained.

07000

37-21
BEVEL GEAR

K22
2

K K

K
74674

P Disassembly sequence
1 Dust cover 8 Spacer 15 Lock nut
2 Lock nut 9 Adjustment bolt 16 Bearing
3 Oil seal 10 End cover 17 Reduction gear (output side)
4 Needle bearing 11 Spacer 18 Bearing
5 Top plug 12 Bearing 19 Gear box
6 Bolt 13 Reduction gear (input side)
7 Lock nut 14 Oil seal X : Non-reusable parts
P Assembly sequence
4
13 12
17 16
15 11 5 2 14 6 3 1
19 18
10 9 8 7

37-22
 37
Service standards
Location Maintenance item Standard value Limit Remedy
Reduction gear (output side) rotational torque 0.05 to 0.15 N?m
– Adjust
(no oil seal) {0.5 to 1.5 kgf?cm}
Reduction gear (input side) rotational torque 0.29 to 0.49N?m
– – Adjust
(no oil seal) {3 to 5 kgf?cm}
Reduction gear (input side) total rotational 0.39 to 0.59 N?m
– Adjust
torque (with oil seal) {4 to 6 kgf?cm}

TTightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
2 Lock nut (top plug installation) 78 to 118 {8 to 12} –
6 Bolt (end cover installation) 20 to 29 {2 to 3} –
7 Lock nut (adjustment bolt installation) 20 to 29 {2 to 3} –

K Lubricant and/or sealant

Location Points of application Specified lubricant and/or sealant Quantity
1 Fill inside of dust cover Molybdenum disulfide grease As required
2 Lock nut fastening area THREEBOND 1104 As required
3 Oil seal lip Molybdenum disulfide grease As required
4 Needle bearing Molybdenum disulfide grease As required
8 Spacer vertical sliding areas Molybdenum disulfide grease As required
End cover lock nut fastening area THREEBOND 1211 As required
10
End cover gear box joining surfaces THREEBOND 1211 As required
14 Oil seal lip Molybdenum disulfide grease As required
Fill reduction gear (output side) lock nut area inside 10 g
Molybdenum disulfide grease
the gear box or more
19
Fill reduction gear (input side, output side) 60 g
Molybdenum disulfide grease
engagement area inside the gear box or more

J Special tools Unit: mm

Location Tool name and shape Part No. Application
Pre-load socket

Measuring reduction
13, 17 MB991006
gear rotational torque

06838

Socket wrench

Lock nut removal and

15 31691-12400
installation

06839

37-23
BEVEL GEAR
R Service procedure
P Reduction gear rotational torque adjustment
[Output side]
• Tighten and adjust lock nut 15 so that the reduction gear (output
side) 17 rotational torque A is the standard value.

J: Pre-load socket

CAUTION k
Adjust without the reduction gear (output side) 17 oil seal 14 be-
74675
ing installed.
[Input side]
• Tighten and adjust top plug 5 and install lock nut 2 so that the reduc-
tion gear (input side) 13 rotational torque B is the standard value.

J: Pre-load socket

CAUTION k
Adjust without top plug 5 oil seal 3 being installed.

74676

[Total]
• After adjusting the above rotational torque, assemble all remaining
parts.
• Tighten and adjust adjustment bolt 9 so that reduction gear (input
side) 13 total rotational torque C is the standard value.
• After rotating reduction gear (input side) 13 10 times, check that the
total rotational torque C is the standard value.

74677

3 14 Oil seal installation

Apply grease to oil seals 3 and 14 lip area A and press fit them.

06844

5 Top plug removal and installation

Remove or install lock nut 2 using spanner wrench A (width accross
flats 52 mm) while holding top plug 5 with spanner wrench B (width
across flats 36 mm).

74678

37-24
 37
15 Lock nut removal and installation
J: Socket wrench

74679

16 18 Bearing installation
Install bearings 16 and 18 in the direction illustrated.

06846

19 Filling gear box with grease

• Fill lock nut area A of reduction gear (output side) 17 inside gear box
19 with grease.
• Fill the engagement areas of reduction gears (output side, input side)
17 and 13 in gear box 19 with grease.

06847

37-25
POWER STEERING BOOSTER ASSEMBLY

T2
3T

*b

10

9
T1 *a
7
8

T6
5

4T

79822

P Disassembly sequence
1 Nut 8 Mount rubber, LH
2 Return tube 9 Mount rubber, RH
3 Pressure hose 10 Power steering booster L P37-28
4 Bolt
5 Clamp *a: Knuckle
6 Bolt
7 Clamp, RH
*b: Suspension cross member

P Installation sequence
Follow the removal sequence in reverse.

37-26
 37
T Tightening Torque Unit: N?m {kgf?m}
Location Part to be tightened Tightening torque Remarks
1 Nut (power steering booster tie rod installation) 68 to 118 {7 to 12} –
2 Return tube 39 to 49{4 to 5} –
3 Pressure hose 29 to 39 {3 to 4} –
4 Bolt (clamp left installation) 88 to 118 {9 to 12} –
6 Bolt (clamp left installation) 88 to 118 {9 to 12} –

J Special tools
Location Tool name and shape Part No. Application
Ball joint puller

Power steering boost-

10 MH062478
er tie rod removel

05495

R Service procedure
10 Power steering booster tie rod removal

J: Ball joint puller

05503

37-27
POWER STEERING BOOSTER ASSEMBLY

74308

P Disassembly sequence
1 Dust cover 14 Rack support plug 27 Oil seal
2 Tie rod end 15 Rack support spring 28 O-ring
3 Lock nut 16 Rack support 29 Rack bushing
4 Clip 17 Dust cover 30 Piston ring
5 Band 18 Bolt 31 O-ring
6 Dust boots 19 Oil seal 32 Rack
7 Booster assembly 20 Seal ring 33 Oil seal
8 Inner ball joint assembly 21 Pinion and valve assembly 34 Backup washer
9 Feed tube 22 Bearing 35 Rack housing
10 O-ring 23 Oil seal
11 End plug 24 Valve housing X : Non-reusable parts
12 Lock nut 25 Snap ring
13 Lock nut 26 End housing

37-28
 37
P Assembly sequence

7 6 5 4 3 2 1

29 28 27 24 23 22
7: 26 25
32 31 30 21 20 19
18 17 16 15
35 34 33
14 13 12 11 10 9 8

Service standards
Location Maintenance item Standard value Limit Remedy
0.7 to 1.6 N?m
Booster assembly total rotational torque – –
{7 to 16 kgf?cm}
7
2 to 4.9 N?m
Booster assembly tie rod swivel torque – –
{20 to 50 kgf?cm}

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
3 Lock nut (tie rod end installation) 120 to 150 {12 to 15} –
8 Inner ball joint assembly 117.6 to 147 {12 to 15} –
9 Feed tube 12 to 18 {1.2 to 1.8} –
11 End plug 49 to 69 {5 to 7} –
12 Lock nut (pinion and valve assembly installation) 20 to 29 –
13 Lock nut (Rack support plug installation) 49 to 69 {5 to 7} –
Slack of approximately 25° after tightening the rack
14 4.9 {0.5} –
support plug
18 Bolt (valve housing installation) 20 to 29 {2 to 3} –

K Lubricant and/or sealant

Location Points of application Specified lubricant and/or sealant Quantity
1 Fill the inside of the dust cover and apply to the lip Molybdenum disulfide grease As required
Inner ball joint assembly dust boots installation
8 Toshiba Silicone TSM650 As required
groove
11 End plug threads THREEBOND 1104 As required
13 Lock nut threads THREEBOND 1104 As required
Wheel bearing grease
19 Oil seal lip As required
[NLGI No.2 (Li soap)]
Wheel bearing grease
21 Pinion and valve assembly shaft As required
[NLGI No.2 (Li soap)]
Wheel bearing grease
23 Oil seal lip and upper surface As required
[NLGI No.2 (Li soap)]
Wheel bearing grease
27 Oil seal lip As required
[NLGI No.2 (Li soap)]
Wheel bearing grease
33 Oil seal lip As required
[NLGI No.2 (Li soap)]

37-29
POWER STEERING BOOSTER ASSEMBLY
J Special tools
Location Tool name and shape Part No. Application
Pre-load socket

Booster assembly total

7 MB991006 rotation torque mea-
surement

06838

R Service procedure
2 Tie rod end installation
Install tie rod end 2 so that the inner ball joint assembly 8 tie rod length
is the dimension illustrated A.

A :187.4 -20 mm

CAUTION k
Loosen clip 4, install the inner ball joint assembly 8 tie rod with
07006
temporary length, and after installation on the vehicle adjust the
toe-in and check the steering angle.

7 Booster assembly inspection

• Hold booster assembly 7 in a vise inserting protection plates (copper
or aluminum) A.
• Remove the dust boots 6 from booster assembly 7 and measure the
total rotational torque.

J: Pre-load socket

• Measure the total rotational torque at 180° turns right and left from
71717
the central position of booster assembly 7 with the speed of 1 rota-
tion every 4 to 6 seconds.
• Strongly swivel the inner ball joint assembly 8 tie rod C 10 times and
measure swivel torque (swivel resistance) direction tie rod end 2
downward.
• When the swivel torque is below the standard value but there is no
play in the tie rod axial direction and the tie rod can be swiveled
smoothly it can still be used.

07008

37-30
 37
8 Inner ball joint assembly installation
After tightening inner ball joint assembly 8 to rack 32, caulk the two A
areas.

07009

11 End plug installation

Apply sealant to the end plug 11 threads A and after tightening use a
punch to caulk the two locations on circumference B.

07010

14 Rack support plug installation

• Apply sealant to the rack support plug 14 threads A and tighten to
the specified tightening torque. Then slack off the plug by approxi-
mately 25° and tighten lock nut 13.
• Check the booster assembly total rotational torque.
L P37-30

07011

19 23 Oil seal installation

• Install oil seals 19 and 23 as illustrated and apply grease to lip area
A.
• Apply grease to the top surface B of oil seal 23.

07012

25 26 Snap ring and end housing removal

Turn the opposing flats portion of end housing 26 to the right, extend
snap ring 25 from the rack housing 35 opening, after the end comes out
turn it to left, remove the snap ring, and remove the end housing.

07013

37-31
POWER STEERING BOOSTER ASSEMBLY
27 Oil seal installation
Install oil seals 27 in rack bushing 29 as illustrated and after applying
grease to lip area A install into rack housing 35.

07014

33 Oil seal installation

After inserting backup washer 34 into rack housing 35 apply grease to
oil seal 33 lip area A and install it as illustrated.

07015

37-32
 37

MEMO

37-33
POWER STEERING OIL PUMP

X
13 X
14
2
17
X
12 T 16 X 1T
15 11
X10

18

9
19

23
22 X 3

T 6 4
20

24
25 X
21
X 8

26 7
74625

P Disassembly sequence
1 Bolt 10 O-ring 19 Flow control spring
2 Cover assembly 11 Side plate 20 Bolt
3 Pin 12 Connector assembly 21 Suction connector
4 Cover 13 O-ring 22 O-ring
5 Cartridge assembly 14 O-ring 23 Body assembly
6 Vane 15 O-ring 24 O-ring
7 Rotor 16 O-ring 25 O-ring
8 Cam ring 17 Connector 26 Body
9 Side plate assembly 18 Flow control valve assembly
X : Non-reusable parts

CAUTION k
The flow control valve assembly 18 and body 26 cannot be disassembled.

37-34
 37
P Assembly sequence
Follow the disassembly sequence in reverse order.

Repair kit: Seal repair kit

Service Standard Unit: mm

Location Place inspected Standard value Limit Remedy
Uneven wear on the rotor and vane sliding
4
surfaces of the cover
– 0.05 Replace
*
6, 7 Clearance between the vane and rotor 0.01 0.06 Replace
Uneven wear on the rotor and vane sliding
11 – 0.05 Replace
surfaces of the side plate *
Clearance between the flow control valve
18, 23 0.01 to 0.02 0.03 Replace
assembly and body assembly *
19 Flow control spring free length 36.5 33.5 Replace

* :Parts with a mark are replaced with the power steering pump assembly.
T Tightening Torque Unit: N?m {kgf?m}
Location Place Tightened Tightening Torque Remarks
1 Bolt (cover assembly installation) 22 to 26 {2.2 to 2.7} –
12 Connector assembly 49 to 69 {5.0 to 7.0} –
20 Bolt (suction connector installation) 7.8 to 11.8 {0.8 to 1.2} –

R Major Maintenance Points

4 3 Pin installation
• Install the pin 3 so that it is the distance from the cover 4 shown in
the illustration.
A: 14.5 mm
3

P50146

6 6 Vane installation
• Install the vane 6 in the rotor 7 so that the rounded end faces toward
the outside.

Outside
7

P50147

37-35
POWER STEERING OIL PUMP
8 Cam ring installation
• Install the cam ring 8 in the body assembly 23 so that it is facing the
direction shown in the illustration.
8

23
P50389

B 18 Flow control valve assembly airtightness check

18 • Close off port A of the flow control valve assembly 18 with a finger.
• Apply air pressure (390 to 490 kPa {4 to 5 kgf/cm2}) to port B.
• Check if air is leaking from port C.
• If there is any trouble, replace the power steering oil pump assembly.

C
A
P50150

37-36
POWER STEERING OIL TANK 37
P Disassembly sequence
1 Packing
2 Filler cap
3 Strainer
4 Screw
5 Filter
6 Packing
7 Tank

X : Non-reusable parts

P Assembly sequence
Follow the disassembly sequence in re-
verse.

74296

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
4 Screw (filter installation) 1.3±0.3 {0.13±0.03} –

37-37
POWER STEERING OIL LINE
P Removal sequence
1 Nut
2 Pressure hose
3 Supply hose
4 Rubber hose
5 Supply pipe
6 Rubber hose
7 Power steering pipe
8 Rubber hose
9 Return pipe
10 Return tube
11 Pressure pipe
12 Pressure tube
13 Return tube

a: Power steering oil tank

*b:
* Power steering oil pump
*c: Power steering booster
74682

P Installation sequence
Follow the removal sequence in reverse.

CAUTION k
Be sure to bleed out the air when the oil line was removes. LP37-11

T Tightening Torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Nut (pressure hose installation) 16 to 24 {1.6 to 2.4} –
2 Pressure hose (pressure hose connection) 29 to 39 {3 to 4} –
Pressure tube (connection with pressure hose and
12 29 to 39 {3 to 4} –
power steering booster)
Return tube (connecting with power steering boost-
13 39 to 49 {4 to 5} –
er)

R Service procedure
2 Pressure hose installation
Install pressure hose 2 so that notch A contacts the suction connector
of power steering oil pump b.
*

07250

37-38
 41

GROUP 41 FRAME

SPECIFICATIONS ................................................................................ 41-2

STRUCTURE AND OPERATION ........................................................ 41-2

FRAME INSPECTION AND REPAIR ................................................... 41-2

41-1
SPECIFICATIONS/STRUCTURE AND OPERATION/FRAME INSPECTION AND REPAIR

SPECIFICATIONS
Item Specifications
Frame model Ladder type
side member cross section shape channel shape section

STRUCTURE AND OPERATION

1 Cross member
2 Mounting bracket
5 3 Side member
4 4 Shock absorber bracket
1 5 Spare tire hanger

1
79816
74019

FRAME INSPECTION AND REPAIR

: Bolt (M10 × 1.25)
: Bolt (M12 × 1.25)

TT
T
T T
T
T T
T
T
T

T
T T

T
T T

79817
79603

41-2
 41
T Tightening torqueUnit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks
– Bolt ( area bolt: M10 × 1.25) 59 to 78 {6 to 8} –
– Bolt ( area bolt: M12 × 1.25) 98 to 115 {10 to 12} –

R Service procedure
P Frame cleaning
Carefully remove mud, grease, rust, etc. that is stuck to the outer and
inner surfaces of the frame.

P Inspection for frame deformation

If any fault, such as a deformation, is found, repair the frame.

P Inspection for cracks in frame

• Remove the paint from any areas that are seemingly faulty and care-
fully inspection them.
• If visual inspection is difficult, inspect using color contrast penetration
examination or another methods.
If a crack is found, repair as follows.

P Frame crack repair

• With the vehicle unloaded, level the frame.
• Drill a hole, about twice the thickness of the frame, 10 mm from the
end of the crack.

CAUTION k
If a crack is found inside the frame, drill holes at both ends of
the crack.

00238

• If the edges of the crack are not flush, make them flush with each
other.

00240

41-3
FRAME INSPECTION AND REPAIR
• Using a grinder, etc., grind a 90° V-section channel down to two-
thirds of the frame thickness and then weld the channel closed.

CAUTION k
• Do not use gas welding because the high temperature produced
alters the material properties and weakens the welded area. Be
sure, therefore, to use electric welding.
• Be sure to remove the negative terminal of the battery and then
ground the welder near the area to be welded to prevent a re-
00241 versed flow of current from the welder which might burn out
electrical components.
• Be sure to cover any inflammable materials, such as pipelines,
wiring harnesses, rubber parts, and the fuel tank, that are near
the welding site.
• Be sure to use low-hydrogen type coated CO2 and arc welding
electrodes for welding to prevent harmful defects such as un-
dercutting, blow holes, etc.
• Be sure to preheat the area to be welded to approximately 50 to
350°C before welding when the workshop temperature is below
0°C.
00343
• Be sure to protect mountings, such as main sills, that can be
damaged by heat by using heat insulators, etc.

• Next, grind a V-section channel, as described above, on the opposite

side of the weld and them weld the channel closed. At the same time,
weld closed the holes at both ends of the crack.

CAUTION k
In colds areas, heat the welded area to approximately 200°C
after welding.

41-4
 41
• After welding, grind bead A at right angles B to remove shaded area
C as illustrated and grind the area flat.

CAUTION k
Finish the surface so that the frame thickness is identical to the
original thickness.

00243

[Repairing cracks caused by rivets or bolt holes]

• To make the edges of the holes flush at the cracked area, temporarily
tighten bolt D in the hole.
• Weld cracked point E at least 20 mm from the center of the bolt. For
information regarding the welding method, refer to the above-men-
tioned procedures for repairing cracks. L P41-3
• After removing the bolt and making the edges flush, weld remaining
area F and fill the hole.
• After drilling a hole in the filled area, install a rivet or bolt.
00244

[Repairing using reinforcement plate]

• To prevent concentrated stress from being produced at both ends G
of the reinforcement plate, weld the plate with angle H at both ends
opened 30° or less. Do not weld area J.

J : 20 mm

• The reinforcement plate must have enough strength for the cracked
area.
00245
CAUTION k
• Thickness of reinforcement plate: Same as the frame thickness.
• Reinforcement plate material: SAPH440 (hot-rolled sheet steel
for automobiles), SS400 (sheet steel for general construction),
or those with equivalent strength.

• After welding, heat the shaded area to 600 to 700°C.

K : 50 mm

CAUTION k
Use heat insulators to protect mountings, such as the main
sills, that can be damaged by heat.

00246

41-5
FRAME INSPECTION AND REPAIR
P Inspection for loose rivets
• Gently tap the rivet head using an inspection hammer and judge the
condition by checking the vibration using the tip of you finger or by lis-
tening to the sound.
• Rust between rivet and frame indicates that the rivet is loose.
CAUTION k
Be sure to replace loose rivets with new ones because they can
break or cause cracking of the frame in the area around the rivet
00247 hole, causing accidents.

P Rivet repair
• When removing rivets, use a center punch to make an indent in the
center of the rivet head and then drill out the rivet using drill A or re-
move the rivet by grinding off its head.

B: Incorrect
C: Correct

00248 CAUTION k
Be careful not to damage the rivet hole.

• When riveting, first clamp both plates tightly near the rivet hole using
a clamp to eliminate gaps between plates.
• Using a riveting machine, press-fit the rivet (cold rivet).

CAUTION k
If riveting is impossible, ream the rivet hole, drive in a reamer
bolt, fully tighten the nut, and then weld it in place.
A flange bolt and flange nut should be used for the reamer bolt
and nut.
00249
P Inspection for loose bolts and nuts
• Inspect the mounting bolts in all areas for looseness. Loose bolts
should be tightened at the specified torque.
L P41-2

41-6
 55

GROUP 55 HEATER AND AIR

CONDITIONER

SPECIFICATIONS ................................................................................ 55-2

STRUCTURE AND OPERATION ........................................................ 55-4

TROUBLESHOOTING ......................................................................... 55-12

ON-VEHICLE INSPECTION AND ADJUSTMENT

• V-belt inspection and Adjustment ....................................................... 55-16
• Refrigerant level inspection ................................................................. 55-16
• Charging Refrigerant ............................................................................ 55-17
• Adding Refrigerant ............................................................................... 55-19
• Refrigerant Discharge .......................................................................... 55-20

CONNECTING AIR CONDITIONER PIPING ........................................ 55-21

COMPRESSOR AND TENSION PULLEY............................................ 55-22

AIR CONDITIONER PIPING ................................................................ 55-24

CONDENSER ASSEMBLY .................................................................. 55-26

EVAPORATOR ASSEMBLY AND COOLER DUCTS ......................... 55-28

HEATER CONTROL ............................................................................ 55-32

AIR DUCT ............................................................................................. 55-35

HEATER UNIT, DUCT ASSEMBLY AND

BLOWER ASSEMBLY ......................................................................... 55-36

HEATER PIPING .................................................................................. 55-40

REAR HEATER AND HEATER PIPING .............................................. 55-42

Refer to the B MITSUBISHI ROSA BM370 - E Cooler Service Manuals regarding maintenance of the compressor,
the condenser assembly, and the evaporator assembly.

55-1
SPECIFICATIONS
Item Specifications
Damper switching method Manual cable type
System
Refrigerant type HFC134a
MITSUBISHI HEAVY
Manufacturer
INDUSTRIES LTD
Model MSC 90BA
Compressor Ejection amount cm3 {mL}/1 rotation 90 {90}
assembly
Lubrication oil SUN PAG 56

Magnetic Rated voltage V 24

clutch Power consumption W 45
MITSUBISHI HEAVY
Manufacture
INDUSTRIES LTD
Condenser Rated voltage V 24
assembly
Blower fan mm X270 × 2 pieces
3/min
Blower power m 65
MITSUBISHI HEAVY
Manufacturer
Receiver INDUSTRIES LTD
Capacity dm3 {L} 0.5 {0.5}
MITSUBISHI HEAVY
Manufacturer
INDUSTRIES LTD
Evaporator Rated voltage V 24
assembly
Blower fan mm X270 ×4
Blower power m3/min 27

55-2
 55
Item Specifications
Manufacturer DENSO
Temperature control system Air mixing type
Fan motor type Sirocco fan type
Standard voltage V 24
Heater unit
Heat radiation W {kcal/h} 4660 ± 465 {4000 ± 400}
Air capacity m3/h 240 ± 24
Blower speed rpm 3450 ± 345
Power consumption W 120 or less
Blower type Sirocco fan type
Blower Standard voltage V 24
assembly
Fan outer diameter mm X140

Fan motor type Sirocco fan type

Standard voltage V 24
Heat radiation W {kcal/h} 3775 ± 375 {3250 ± 325}
Rear heater
assembly Air capacity m3/h 220 ± 22
Blower speed rpm 2950 ± 300
Power consumption W 70 ± 7

55-3
STRUCTURE AND OPERATION
Air Conditioner Schematic Diagram

74497

1 Compressor 9 Liquid pipe

2 Suction hose 10 High-pressure service valve
3 Discharge hose 11 Liquid pipe
4 Low-pressure pipe 12 Receiver
5 Evaporator assembly 13 Condenser assembly
6 Low-pressure service valve 14 High-pressure switch
7 Liquid pipe 15 High-pressure pipe
8 Sight glass 16 Engine

55-4
 55
Air Conditioner System

1
3

74607

1 Cooler duct 4 Air conditioner relay panel

2 Condenser 5 Compressor
3 Evaporator 6 Air conditioner control panel

• When air-conditioner control panel 6 is operated, compressor 5 begins working, the refrigerant passes into condenser
2 where it is liquefied, and is then sent to evaporator 3.
• Evaporator 3 is connected to cooler duct 1 which discharges cool air via the outlet grill.
• Temperature control is performed by air-conditioner control panel 6 thermo switch.
• The cooling capacity is keep constant by engaging and disengaging the clutch of compressor 5 by the thermo in evap-
orator 3.

NOTE
For details regarding the specifications and service procedures, etc., for compressor 5, condenser 2, and the
evaporator 3, refer to “MITSUBISHI ROSA BM370-E Cooler Service Manual”.

55-5
STRUCTURE AND OPERATION
Front Air Duct

74502

1 Heater duct 8 Center duct 14 Side defroster duct RH

2 Heater duct 9 Center defroster duct 15 Heater unit
3 Blower assembly 10 Center defroster duct 16 Fan
4 Duct assembly 11 Defroster duct 17 Damper (DEF)
5 Passenger face duct 12 Defroster duct 18 Damper (FOOT)
6 Center face duct 13 Side defroster duct LH 19 Damper (FACE)
7 Driver face duct

Outside air (entering) Inside air (circulating) Air from filters

(inside cleaning unit and
heater)

Air (FACE) Air (DEF) Air (FOOT)

The switching operation of the heater control assembly opens and closed dampers 17, 18, and 19 or the heater unit 15 to
the inside or outside air being introduced through the blower assembly 3. The resultant air flow is as shown in the dia-
gram.

55-6
 55
PMode switching
1 Lever
2 Mode switching control wire
3 Damper (DEF)
4 Lever
5 Lever
6 Lever
7 Damper (FOOT)
8 Lever
9 Lever
10 Damper (FACE)
11 Heater unit

A: Guide
• The three dampers, damper 3 (DEF), damper 7
(FOOT), and damper 10 (FACE), move simulta-
neously and independently to switch modes.
• The opening of damper 3 is controlled by lever
4; this damper performs switching to the DEF
circuit. Note that lever 5 is connected to lever 4,
and these two levers can move the damper to its
74610
fully open, half open, or fully closed positions.
• The opening of damper 7 is controlled by lever
8; this damper performs switching to the FOOT
circuit. NOte that because lever 9 is connected
to lever 8, and also because lever 9 movers
along the guide A, the opening condition of the
damper is also influenced by whatever mode the
system is currently operating in.
• The opening of damper 10 is controlled by lever
1; this damper performs switching to the FACE
circuit.
• Lever 6 is connected to all of the levers that move
the 3 dampers and can be used to control the mo-
tion of the dampers.
• Lever 6 is moved in a mechanical fashion using the
mode switching control wire 2.

74611

55-7
STRUCTURE AND OPERATION
P Air-mix switching
1 Damper
2 Heater core
3 Lever
4 Lever
5 Lever
6 Lever
7 Air-mix control wire
8 Heater unit

A: Warm air
B: Cool air

• The opening of the damper 1 is controlled

by lever 3, temperature adjustment is per-
formed by modifying the opening of this
damper to change the amount of warm air
A from the heater core 2 and cool air B,
which doesn’t pass through the heater
74612 core, in the air-mix.
• Lever 4 is connected to lever 3 and is used
to control its movement.
• Lever 4 is moved in a mechanical fashion
by transferring the motion of the air-mix
control wire 7 via lever 5 and lever 6.

55-8
 55
P Inside/outside air switching
1 Inside/outside air switching control wire
2 Lever
3 Rod
4 Lever
5 Lever
6 Damper
7 Blower assembly

A: Inside air
B: Outside air
• The opening of the damper 6 is controlled by le-
ver 5; this damper is used to switch suction from
inside air A to outside air B and vice-verse.
• Lever 4 is connected to lever 5 and is used to
control its movement.
• Lever 4 is moved in a mechanical fashion by
transferring the motion of the inside/outside air
switching control wire via lever 2 and rod 3.
74613

55-9
STRUCTURE AND OPERATION
Heater System Diagrams
1 Heater unit
2 Engine

A: Hot water piping

74614

• The heater system is a hot water system that uses the cooling water (hot water) circulated by engine 2.

55-10
 55
Heater and Rear Heater System Diagrams
1 Heater unit
2 Engine
3 Water valve
4 Rear heater assembly

A: Hot water piping

74616

• The heater and rear heater system is a hot water system that uses the cooling water (hot water) circulated by engine 2.
• When using this system leave open water valve 3 in the engine compartment.

55-11
TROUBLESHOOTING
Air Conditioner System
Symptoms

Inside/outside air switching is not possible.

Discharge port switching is not possible.

There is a draft from the discharge port.

Air cannot leave the discharge port.

Temperature cannot be adjusted.

Air conditioner is not effective.
Remarks

Heater is not effective.

Possible causes

B MITSUBISHI
Compressor seizure p ROSA BM370-E
Cooler
Fuse blown p p
Harness, connector defective p p p p p p
B Electrical
Ground defective p p p p p p
Air conditioner relay contacts fused, coil disconnected, short circuit p
Condenser fan motor coil disconnected, short circuit p
Condenser fan relay contacts fused, coil disconnected, short circuit p
Insufficient coolant p p
Air conditioner piping blockage, loose piping, faulty connection p
Cooler duct connection defective p
Condenser clogged p
Condenser core collapse, foreign objects present p B MITSUBISHI
ROSA BM370-E
Receiver clogged, drying agent defective p Cooler
Evaporator clogged p

55-12
 55
Front Heater
Symptoms

Air volume cannot be adjusted

Remarks

Defroster is not effective.

Heater is not effective.
No warm air.
Possible causes

Fuse blown p
Harness, connector defective p
B Electrical
Fan switch operation defective p p
Ground defective p
Foreign object catching fan p p
Fan motor operation defective p p p
Heater core clogged p
V-belt incorrectly adjusted p
Water pump operation defective p
Thermostat doesn’t close p B Gr14
Cooling system defective p
Insufficient cooling water p
Air-mix damper operation defective p
Gap between internal components and floorboard mount area p
Gaps around the body p
Duct connection defective p
Control damper operation defective p
Air flow box clogged by foreign objects p
Register operation defective p
Defroster hose warped, bent, connection defective p
Defroster duct incorrectly attached p
Foreign objects have fallen into defroster duct p
Heater control wire incorrectly adjusted p

55-13
TROUBLESHOOTING
Rear Heater
Symptoms

Air volume cannot be adjusted

Remarks

Heater is not effective.

No warm air.
Possible causes
Fuse blown p
Harness, connector defective p
B Electrical
Rear heater switch operation defective p p
Ground defective p
Foreign object catching fan p p
Fan motor operation defective p p p
Water valve closed p
Heater core clogged p
V-belt incorrectly adjusted p
Water pump operation defective p
Thermostat doesn’t close p B Gr14
Cooling system defective p
Insufficient cooling water p
Gap between internal components and floorboard mount area p
Gaps around the body p
Register operation defective p

55-14
 55

MEMO

55-15
ON-VEHICLE INSPECTION AND ADJUSTMENT
V-belt inspection and Adjustment
B Gr14

Refrigerant level inspection

Inspection of the refrigerant level is carried out at the sight glass 1 (re-
frigerant inspection window) located along the piping at the rear-right of
the vehicle. The coolant’s flow condition is examined visually and an
1 evaluation is made under the conditions listed below.
• Engine speed: 1400 rpm
• Air conditioner switch: ON
• Fan switch: HI
• Temperature control lever: Maximum cooling position
• Inside/ outside air switching: inside air
• Doors: Fully open
79848
• Door glass: Fully open

CAUTION k
Operation of the air conditioner without any refrigerant present
will result in breakdown of the compressor.

Normal Insufficient coolant Almost no coolant

Condition at sight
glass

06552 06553 06554

Almost transparent. Even if Bubbles can be seen A foggy liquid is flowing quite
bubbles are seen, they constantly. White or slowly.
disappear whenever the transparent bubbles may be
engine speed increases or present.
decreases.
Conditions at high and High-pressure pipe is hot; High-pressure pipe is hot; Hardly any temperature
low-pressure pipes low-pressure pipe is cold. low-pressure pipe is slightly difference can be felt between
There is a marked difference cold. the high-pressure pipe and
in temperature. low-pressure pipes.

55-16
 55
Charging Refrigerant
Work sequence

Complete installation of vehicles’s air conditioner system

Attach refrigerant changer

Start vacuum evacuation

Complete vacuum evacuation

NG
Confirm system is airtight Tighten pipe connections further
OK
Change refrigerant until it reaches its saturation pressure
NG
Check for gas leaks
OK
Change refrigerant up to the specified level

Completion of work

1 Gauge manifold
2 Low-pressure valve
3 High-pressure-side valve
4 Charge hose
5 Low-pressure side service valve
6 Charging hose
7 High-pressure side service valve
8 Charging hose
9 Adapter valve
10 Vacuum pump
11 Service can valve
12 Service can
13 Compressor

74509

This flow chart must be followed when charging the refrigerant.

Attach refrigerant charger.

Close the low-pressure side valve 2 and the high-pressure side valve 3.

Firmly connect charging hose 4 to the low-pressure side service valve 5.

Firmly connect charging hose 6 to the high-pressure side service valve 7.

Firmly connect charging hose 8 to the adapter valve 9.

55-17
ON-VEHICLE INSPECTION AND ADJUSTMENT
Vacuum drawing procedure

Open the low-pressure side valve 2 and the high-pressure side valve 3.

Open the adapter valve 9.

Start-up the vacuum pump 10.

Continue drawing a vacuum for at least 10 to 15 minutes. Then close the adapter valve 9.

Stop the vacuum pump 10.

CAUTION k
The adapter valve 9 must be closed before the vacuum pump 10 is stopped

Open the low-pressure side valve 2 and the high-pressure side valve 3.

Hold in this condition for 5 minutes. Confirm that the indicator arrow on the gauge mani-
fold 1 is not moving towards 0.

Complete the vacuum drawing procedure

Refrigerant charging procedure

Remove the adapter valve 9 from the vacuum pump 10 while still in the closed condition.
Attach it now to the service can valve 11.

Open service can valve 11; then open the adapter valve 9.

Start-up the vacuum pump 10.

Continue drawing a vacuum for over 10 to 15 minutes. Then close adapter valve 9.

Open the low-pressure side valve 2 and add the refrigerant as a gas.

CAUTION k
Be sure to keep service can upright when charging it, so vapor is used rather than liquid. If
liquid refrigerant enters the system, compressed liquid might damage compressor 13.

When the service can 12 is empty, close the adapter valve 9, replace the empty service
can with a new one, and repeat the procedure above.

If the air conditioner pressure balances during the charging procedure, start the engine,
turn the air conditioner switch ON, activate the compressor, and continue to charge the
refrigerant to the specified amount.

CAUTION k
Check the refrigerant level through the sight glass, installed in the piping. LP55-16

55-18
 55
Adding Refrigerant
4 Charging hose
5 Low-pressure side service valve
7 High-pressure side service valve
9 Adapter valve
11 Service can valve
12 Service can
13 Compressor

74510

This flow chart must be followed when adding refrigerant.

Firmly connect charging hose 4 to the low-pressure side service valve 5 while adapter
valve 9 is still in its closed condition.

CAUTION k
If charging hose 4 is connected to the high-pressure side service valve 7, a reverse flow of
refrigerant will be started creating the danger that damage may be caused to the service can
12 and the charging hose 4.

Open and close adapter valve 9 to release any air trapped inside the charging hose 4.

Attach service can 12 while the service can valve 11 is still in its closed condition.

CAUTION k
Be sure to keep service can upright when adding refrigerant, so vapor is used rather than
liquid. If liquid refrigerant enters the system, compressed liquid might damage compressor
13.

Open the service can valve 11; then open the adapter valve 9.

Start the engine.

Set the desired temperature to the coldest possible temperature, turn the air
conditioner switch ON, and activate the compressor 13.

Add the refrigerant while constantly confirming its quantity from the sight glass on the
piping LP55-16

After the refrigerant has been added, close the adapter valve 9 and the service can valve
11. Following this, remove the charging hose 4 and the service can 12.

If there is any refrigerant remaining in the service can 12, store it with the service can
valve 11 closed until the next time that it is needed.

55-19
ON-VEHICLE INSPECTION AND ADJUSTMENT
Refrigerant Discharge
4 Charging hose
5 Low-pressure side service valve
9 Adapter valve
13 Compressor

74511

This flow chart must be followed when discharging refrigerant.

With the air conditioner ON, increase the engine speed to 1400 rpm. Keep at this speed
for approximately 30 minutes to return the oil.

Stop the engine.

Firmly connect the charging hose 4 to the low-pressure side service valve 5 while the
adapter valve 9 is still in its closed condition.

Insert the adapter valve 9 into the container. Open the valve little by little to avoid splash-
ing oil, and drain refrigerant.

Return the oil collected in the container to compressor 13.

55-20
CONNECTING AIR CONDITIONER PIPING 55
1 Pipe or hose
2 O-ring
3 Nut
4 Union

A: Refrigeration oil application region

X: Non-reusable parts

07329

K Lubricant
Location Points of application Specified lubricant Quantity
1 Apply to the outer sides of the ends of pipes and hoses. Refrigerant machine oil PAG56 As required
2 Apply all around the O-ring Refrigerant machine oil PAG56 As required

Care should be taken regarding the following items when connecting air conditioner pipes and hoses. Fastening torques
are noted in the maintenance outlines for the relevant device or component.

CAUTION k
• The connection area is sealed with the O-ring 2. Care must be taken to ensure that this component is not dam-
aged by twisting.
• The O-ring 2 is a special part for used with refrigerant HFC134a and it cannot be reused. O-ring should be pro-
cured from your area’s Service Station.
• A double wrench must be during connection. Secure the union 4 first, then tighten the nut 3 to the specified
torque. Since tightening at the union will cause the pipe 1 to deform resulting in possible coolant leaks, the
union itself is not tightened.

55-21
COMPRESSOR AND TENSION PULLEY

74618
P Removal sequence
1 Bolt 11 Sleeve 21 Compressor LH
2 V-belt B Gr14 12 Pulley assembly 22 Stay
3 Bolt 13 Washer 23 Compressor bracket
4 V-belt B Gr14 14 Shaft 24 Pipe stay
5 Tension pulley assembly 15 Washer 25 Connector clip A
6 Sleeve 16 Tension pulley bracket 26 Compressor RH
7 Pulley assembly 17 Bolt 27 Connector clip B
8 Washer 18 Suction hose 28 Compressor bracket
9 Shaft 19 Discharge hose
10 Washer 20 Pipe stay

P Installation sequence
Follow the removal sequence in reverse.

55-22
 55
T Tightening torque Unit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks
17 Bolt (Suction and discharge hose mounting) 19.6 to 29.4 {2.0 to 3.0} –

K Lubricant
Location Points of application Specified lubricant Quantity
18 Apply to the outer side of the end of suction hoses. Refrigeration oil PAG56 As required
19 Apply to the outer side of the end of discharge hoses. Refrigeration oil PAG56 As required

R Service procedure
P Preparation work before removal
The coolant must be removed from the system before the discharge
hoses 19 and the suction hoses 18 can be removed.
LP55-20

21 26 Compressor inspection
If any problem such as faulty compressor unit operation or oil leaks
from the oil seal area A are identified, and overhaul should be carried
out at your nearest service station.

74515

55-23
AIR CONDITIONER PIPING

*c

7 T K

2T
KT 9

10

KT 8
* b

K
K
T T 2T
T
2 3
T 5
1 4 TK

2T

T2
KT 6
2T
3 TK

5 TK
*a T 1 79814
74621

P Disassembly sequence
1 Bolt 7 Low-pressure pipe
2 Bolt 8 Liquid pipe
*a: Compressor
LP55-22
assembly

3 Discharge hose 9 Liquid pipe *b: Condenser assembly

4 High-pressure pipe 10 Sight glass LP55-26
5 Suction hose c: Evaporator assembly
*
6 Low-pressure pipe LP55-28

P Installation sequence
Follow the removal sequence in reverse.

55-24
 55
T Tightening torque Unit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks
1 Bolt (Suction and discharge hose mounting) 19.61 to 29.42 {2.0 to 3.0} –
2 Bolts (pipe and hose mounting) 4.9 to 6.9 {0.5 to 0.7} –
Discharge hose tightening
3 19.61 to 24.52 {2.0 to 2.5} –
(high pressure pipe side)
High pressure pipe tightening
4 34.3 to 39.2 {3.5 to 4.0} –
(condenser assembly side)
Suction hose tightening
5 29.42 to 34. 32 {3.0 to 34.32} –
(low pressure pipe side)

Low pressure pipe tight- Middle portion 63.7 to 93.2 {6.5 to 9.5} –
6
ening Low pressure pipe side 63.7 to 93.7 {6.5 to 9.5} –
Low pressure pipe tightening
7 63.7 to 93.2 {6.5 to 9.5} –
(evaporator assembly side)
Condenser assembly
11.8 to 14.7 {1.2 to 1.5} –
side
8 Liquid pipe tightening
Middle portion 19.61 to 24.52 {2.0 to 2.5} –
Sight glass side 11.8 to 14.7 {1.2 to 1.5} –
Middle portion 11.8 to 14.7 {1.2 to 1.5} –
9 Liquid pipe tightening
Sight glass side 11.8 to 14.7 {1.2 to 1.5} –

K Lubricant
Location Points of application Specified lubricant Quantity
3 to 9 Apply to the outer sides of the ends of pipes and hoses Refrigeration oil PAG56 As required

R Service procedure
P Preparation work before removal
The coolant must be removed from the system before hoses and pipes
can be removed.
LP55-20

3 to 9 Connection pipes and hoses

air conditioner piping connection LP55-21

55-25
CONDENSER ASSEMBLY

74517

P Removal sequence
1 Insulator
*a: High-pressure pipe
2 Lower panel *b: Low-pressure pipe
3 Insulator
4 U-bolt B MITSUBISHI ROSA BM370-E Cooler
*c: Liquid pipe
5 Receiver B MITSUBISHI ROSA BM370-E Cooler X: Non-reusable parts
6 Condenser
B MITSUBISHI ROSA BM370-E Cooler

P Installation sequence
Follow the removal sequence in reverse.

55-26
 55
T Tightening torque Unit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks

*a Condenser and high-pressure pipe mounting 34.3 to 39.2 {3.5 to 4.0} –

*b Receiver and low-pressure pipe mounting 11.8 to 14.7 {1.2 to 1.5} –

K Lubricant
Location Points of application Specified lubricant Quantity

*a Apply to the outer side of the end of the high-pressure pipe Refrigeration oil PAG56 As required

*b apply to the outer side of the end of the liquid pipe Refrigeration oil PAG56 As required

R Service procedure
P Preparation work before removal
The coolant must be removed from the system before the high-pressure
pipe a and the liquid pipes b and c can be removed.
* * *
LP55-20

6 Condenser inspection
Clean the condense 6 fin area A of any clogging caused by dirt, dust, or
the like. Use a spatula or its equivalent to repair any distortion of the
fins.

00693

*a *b *c Connecting pipes
Air conditioner piping connection LP55-21

55-27
EVAPORATOR ASSEMBLY AND COOLER DUCTS

74518

P Removal sequence
1 Front inner duct LH 13 Inside duct assembly RH
2 Front inner duct RH 14 Cooler duct inner sheath LH
3 Cooler duct cover LGr63 15 Cooler duct inner sheath RH
4 Air outlet grill LGr63 16 Drain hose
5 Cooler duct LH LGr63 17 Drain port
6 Cooler duct RH LGr63 18 Bracket
7 Air outlet duct LH 19 Evaporator assembly
8 Air outlet duct RH B MITSUBISHI ROSA BM370-E Cooler
9 Outside duct LH
10 Outside duct RH
11 Panel
12 Inside duct assembly LH

P Installation sequence
Follow the removal sequence in reverse.

55-28
 55
K Lubricant
Location Points of application Specified lubricant Quantity
16 Apply to the drain hose (RH) floor penetration area Cemedine 366E As required
Apply to the connecting portions of the evaporator assem-
19 Refrigeration oil PAG56 As required
bly's low pressure pipe and liquid pipe.

R Service procedure
P Preparation work before removal
The coolant must be removed from the system before the low-pressure
pipe a and the liquid pipes b can be removed. LP55-20
* *
16 Installing the drain hose (RH)
The floor penetration area of the drain hose (RH) 16 must be sealed se-
curely using sealant A.

71870

19 Removing the evaporator assembly

• Disconnect the body harness from connectors A.

71494

55-29
EVAPORATOR ASSEMBLY AND COOLER DUCTS
• Pull out drain hose 16.

74520

• Disconnect the low-pressure pipe B and the liquid pipe C.

74521

• Remove all fixing bolts, then remove the bracket 18 and the evapora-
tor assembly 19.

CAUTION k
The evaporator assembly 19 must be supported as it may fall
when its fixing bolts are removed.
19
D: Bracket

D
18

79815

55-30
 55

MEMO

55-31
HEATER CONTROL

74523

P Removal sequence
1 Harness 6 Front heater switch
2 Heater control assembly 7 Rear heater switch
3 Mode switching control wire
4 Inside/outside air switching control wire a: Heater unit assembly L P55-36
*b:
5 Air-mix control wire
* Blower assembly L P55-36
CAUTION k
This procedure cannot be completed without removing the center panel. Refer to the relevant section of the in-
strument panel documentation regarding this, and proceed with the removal of the panel. LGr63
P Installation sequence
Follow the removal sequence in reverse.

55-32
 55
R Service procedure
3 Installing the mode switching control wire
• Move the wind exit lever A for the heater control assembly 2 to the
t (DEF) position.
• Move the mode switching damper lever B for the heater unit assem-
bly a to the DEF position.
*
• Connect the mode switching control wire 3 to the mode switching
damper lever B while still in this condition, and secure firmly with the
wire clip C.

74623

4 Installing the inside/outside air switching control wire

• Move the inside/outside air switching control lever A for the heater
control assembly 2 to the m position. (RECIRC: inside air)
• Move the inside/outside air switching damper lever B for the blower
assembly b to the RECIRC position.
*
• Connect the inside/ outside air switching control wire 4 to the inside/
outside air switching damper lever B while still in this condition, and
secure firmly with the wire clip C.

74624

55-33
HEATER CONTROL
5 Installing the air-mix control wire
• Slide the temperature control lever A for the heater control assembly
2 to the MAX HOT position (maximum heating) on the extreme right.
• Move the air-mix damper lever B for the heater unit assembly a to
*
the MAX HOT position.
• Connect the air-mix control wire 5 to the air-mix damper lever B while
still in this condition, and secure firmly with the sire clip C.

74625

55-34
AIR DUCT 55

74525

P Removal sequence
1 Heater duct 8 Defroster duct
2 Heater duct 9 Defroster duct
3 Passenger face duct 10 Center defroster duct
4 Drive face duct 11 Center defroster duct
5 Center face duct 12 Center duct
6 Side defroster duct LH
7 Side defroster duct RH
*: Heater duct
P Installation sequence
Follow the removal sequence in reverse.

55-35
HEATER UNIT, DUCT ASSEMBLY AND BLOWER ASSEMBLY

74628

P Removal sequence
1 Screw 7 Bolt
2 Duct assembly 8 Hose clamp
3 Bolt 9 Heater unit
4 Blower assembly
5 Blower register *a: Water hose L P55-40, 42
6 Drain hose
*b: Water hose L P55-40, 42
NOTE
When installing the water hose, to be sure that no connection mistakes are made, mark the water hose a at
*
the front of the vehicle with white.
P Installation sequence
Follow the removal sequence in reverse.

Service standards Unit: mm

Location Maintenance item Standard value) Limit Remedy
+5
Water hose insertion amount (φ24 )
*a, *b 25 0 – Repair

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Screw (duct assembly mounting) 1.96 to 3.43 {0.2 to 0.35} –
3, 7 Bolt (heater unit and blower assembly mounting) 11.2 ± 20% {1.14 ± 20%} –

55-36
 55
K Sealant
Location Points of application Specified sealant Quantity

*a, *b Water hose connector Hermeseal No.201 As required

R Service procedure
9 Heater unit
[Removal]
• Drain the cooling water.
A: Radiator drain plug

71862

• Remove the battery body ground

71507

• Mark water hose a at the front of the vehicle with white as shown by
*
B in the illustration.
• Loosen hose clamp 8 and remove hoses a and b.
* *
• Remove the connector and then remove the heater unit.

74629

• Apply sealant C to water hoses a and b.

* *
NOTE
Install hose
*a with the white marking in the front of the vehicle

74630

55-37
HEATER UNIT, DUCT ASSEMBLY AND BLOWER ASSEMBLY
Water hose installation
*a *b
Insert water hoses a and b the specified amount and tighten them
*
down with hose clamp 8.
*

74631

55-38
 55

MEMO

55-39
HEATER PIPING

74638

P Removal sequence
1 Hose clamp 5 Water hose
2 Nut 6 Water pipe
3 Bolt 7 Water pipe assembly
4 Water hose
*: Heater unit L P55-36
NOTE
1. Water hose 5 and water pipe assembly 7 in the engine compartment are marked with white and yellow, respec-
tively, so pay attention to these markings so as not to make installation mistakes.
2. When removing the heater connection, mark the water hose 4 at the front of the vehicle with white so as not to
make a mistake during installation.

P Assembly sequence
Follow the removal sequence in reverse.

55-40
 55
Service standards Unit: mm
Location Maintenance item Standard value) Limit Remedy
+5
4 Water hose insertion amount (φ24) 25 0 – Repair

5 Water hose insertion amount (φ35) 35 +5 – Repair

0

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
2 Nut (water pipe installation) 3.9 to 5.9 {0.4 to 0.6} –
3 Bolt (water pipe installation) 9.8 to 15 {1.0 to 1.5} –

K Sealant
Location Points of application Specified sealant Quantity
4, 5 Water hose connector Hermeseal No.201 As required

R Service procedure
4 5 Water hose installation
Insert water hoses 4 and 5 the specified amount A and tighten them
with hose clamp 1.
+5
A: 25 0 mm: Water hose 4 (X24)

+5
35 0 mm: Water hose 5 (X35)

74631

5 7 Water hose and water pipe assembly installation

Water hose 5 and water pipe assembly 7 in the engine compartment
are marked with white and yellow, respectively, so pay attention to these
markings so as not to make installation mistakes.
A: White
B: Yellow
C: No marking

74634

55-41
REAR HEATER AND HEATER PIPING

*
K To engine
8
1
From
engine 1
5T
9
8 K

5T
1
1 4T 1 4T
K 7 1
8 9
K
1
1

1 7 K K 3

10 2T
4T

4T 1 7
1
6T
K
K 7
3 7 K
10 1
K K 1 6T

3 7
1 1
2T
10
2T 1 1 10
7 K 6T

7 K
1 6T 7
1 K
K 7
6T
1 K
7 1 10
1 1 7 K
11 1 10
1
K 7
6T

6T
1
7
1
K 79621

P Removal sequence
1 Hose clamp 7 Water hose
2 Nut 8 Water hose
3 Rear heater assembly 9 Water pipe
4 Nut 10 Water pipe
5 Bolt 11 Water valve
6 Nut
*: Heater unit L P55-36

55-42
 55
NOTE
1. Water hose 8 and water pipe 9 connections in the engine compartment are marked with white and yellow, re-
spectively, so pay attention to these markings so as not to make installation mistakes.
2. When removing the parts, mark water hose 7 with white so as not to make a connection mistake during instal-
lation. The marking locations are as follows.
• Rear heater assembly 3: Water hose at back of vehicle
• Heater unit : Water hose at front of vehicle
*
P Assembly sequence
Follow the removal sequence in reverse.

Service standards Unit: mm

Location Maintenance item Standard value Limit Remedy
+5
7 Water hose insertion (X24) 25 0 – Correct

+5
8 Water hose insertion (X35) 35 0 – Correct

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
2 Nut (rear heater assembly mounting) 8.8 to 2.7 {0.9 to 1.3} –
4 Nut (water pipe installation) 3.9 to 5.9 {0.4 to 0.6} –
5 Bolt (water pipe installation) 9.8 to 15 {1.0 to 1.5} –
6 Nut (water pipe installation) 4.9 to 6.9 {0.5 to 0.7} –

K Sealant
Location Points of application Specified sealant Quantity
Apply to rear heater assembly mounting surface and
3 Cemedine 369 As required
mounting holes
7, 8 Apply to each connection area on water hoses Hermeseal No.201 As required

55-43
REAR HEATER AND HEATER PIPING
R Service procedure
3 Rear heater assembly
[Removal]
• Remove coolant water

A: Radiator drain plug

71862

• Disconnect the battery’ body ground.

71507

• Make a white mark C on the water hose 7 that is nearest to the rear
of the vehicle B.
• Loosen the hose clamp 1 and disconnect the hose.

74531

• Release the fixing nut 2 and the body harness connector D from the
underfloor section.
• Push the heater harness grommet E and the harness connector from
under the floor into the vehicle, and remove the rear heater assembly
3.

CAUTION k
Do not tug on the heater harness F from the inside of the vehi-
cle.
74532

55-44
 55
[Installation]
3 • Apply sealant G to the surfaces for mounting the rear heater assem-
bly 3, the heater bracket H. Sealant G will also be needed at the
mounting holes in the harness grommet E.

E
H

G
G
H

G
71869

• Apply sealant J to the connection area of the water hose 7.

CAUTION k
Make sure to install the water hose 7 with the white marking
closer to the rear of the vehicle B.

74533

7 8 Water hose installation

Insert water hoses 7 and 8 the specified amount A and tighten them
with hose clamp 1.

+5
A: 25 0 mm: Water hose 4 (X24)

+5
35 0 mm: Water hose 5 (X35)

74631

8 9 Water hose and water pipe installation

Water hose 8 and water pipe 9 in the engine compartment are marked
with white and yellow, respectively, so pay attention to these markings
so as not to make installation mistakes.

A: White
B: Yellow
C: No marking
74634

55-45
 63

GROUP 63 BODY

SPECIFICATIONS ................................... 63-2 FRONT AND REAR WINDOW

GLASS ....................................... 63-78
STRUCTURE AND OPERATION ........... 63-4
SAFETY WINDOW GLASS ................... 63-82
TROUBLESHOOTING .......................... 63-22
SIDE WINDOW GLASS
ON-VEHICLE INSPECTION <SLIDING WINDOW> ............................. 63-86
AND ADJUSTMENT <FIXED WINDOW> ................................. 63-90
• Front Door Fitting Adjustment ............... 63-28
• Side Door <Folding> Fitting FRONT BUMPER .................................. 63-94
Adjustment ........................................... 63-30
• Side Door <Swing> Fitting REAR BUMPER .................................... 63-96
Adjustment ........................................... 63-31
GARNISH .............................................. 63-97
• Emergency Door Fitting
Adjustment ........................................... 63-34
INSTRUMENT PANEL .......................... 63-98
• Fuel Lid Fitting Adjustment .................... 63-36
FRONT HEAD LINING ........................ 63-102
FRONT DOOR ....................................... 63-38
CENTER HEAD LINING ...................... 63-104
SIDE DOOR
<FOLDING> ............................................. 63-44 REAR HEAD LINING .......................... 63-106
<SWING> ................................................. 63-48
OUTSIDE REAR
EMERGENCY DOOR ............................ 63-56 VIEW MIRROR ........................ 63-108

AUTOMATIC DOOR SYSTEM FRONT WIPERS

<FOLDING DOOR:VACUUM TYPE> ...... 63-64 AND WASHER ........................ 63-110
<SWING DOOR:ELECTRIC TYPE> ........ 63-70
SEAT BELT
(DRIVER’S SIDE) ............................ 63-114

63-1
SPECIFICATIONS
Front Door
Opening angle 67°
Glass operating system Sash slide type
Lock system Pin fork type
Inner lock system Push-pull type

Glass
Item Type Thickness (mm)
Windshield glass Tinted laminated glass 5.0
Rear window glass Tempered and tinted glass 4.0
Sliding window Tempered and tinted glass 5.0
Side window glass
Fixed window Tempered and tinted glass 5.0
Swing door Tempered and tinted glass 3.5
Side door glass
Folding door Tempered and tinted glass 3.5
Emergency door Tempered and tinted glass 4.0
Safety window glass Tempered and tinted glass 3.5

63-2
 63
Door Engine <Swing door: Electrically operated>
Item Specifications
Voltage range during use V 22 to 30
Temperature range during use °C -30 to 60
Angle of rotation ° 139 or greater
Maximum rotational torque N?m {kgf?m} 98 or higher {10 or higher}
Rated load torque N?m {kgf?m} 2.94{0.3}
Door opening and closing time sec 3.0 to 4.5
Rated operating current under load
10 or lower
(When the rated voltage at room temperature is 26 V) A

Door Engine <Folding door: Vacuum operated>

Item Specifications
Solenoid valve V-W 20 - 10.7
Stroke mm 175
Output N{kgf}/kPa{mmHg} 735 {75}/60 {450}
Cylinder assembly
Displacement dm3{L} 2.1 {2.1}
Airtightness (At -96kPa{-720mmHg}for a single cylinder)
Within2 {15}/15
kPa{mmHg}/sec
Tank capacity dm3{L} 16 ± 5% {16 ± 5%}
Reservoir tank Airtightness (At 60 kPa{450 mmHg}) kPa{mmHg}/h 13 {100} or less/12
Check valve operation pressure kPa{mmHg} 5.3 {40} or less
Set pressure (vacuum) kPa{mmHg} 67 ± 1.3 {500 ± 10}
Pressure difference (valve open pressure-valve closed pressure)
Limiting valve Within 4 {30}
kPa{mmHg}
Airtightness kPa{mmHg}/h Within 6.7 {50}/12

63-3
STRUCTURE AND OPERATION
BODY
1 Front body assembly
2 Front floor assembly
4 3 Roof assembly
4 Side body assembly, right
5 5 Rear body assembly
3 6 Body frame assembly
7 Side body assembly, left

1
6

7
2

74365

The vehicle body and chassis from an integral unit. Since the body shares all of the load the vehicle structure is light and
strong.
The press-formed or roll-formed body frame and outer panels are made of this steel plates and are joined together by
spot welding, etc.

Front Door Locking System

1 Inner lock knob
2 Lock rod
3 Striker
4 Key cylinder lever
5 Outer handle assembly
6 Inner handle assembly
7 Clip

74749

63-4
 63
Side Door <Folding> Locking System
1 Side door
2 Rod
3 Door lock assembly
5
4 Stopper
5 Stopper cover
4 6 Key cylinder

74367

63-5
STRUCTURE AND OPERATION
Side Door <Swing> Locking System

1 2

3 10
5
7

6
8
11
9
12

79775

1 inside handle 7 Latch assembly

2 Cover 8 Striker
3 Inside lock knob 9 Shim
4 Key cylinder 10 Latch assembly
5 Link assembly 11 Striker
6 Link assembly 12 Shim

63-6
 63
Emergency Door Locking System
1 Stopper assembly
2 Rod assembly
3 Lock assembly
4 Lock assembly
1 5 Catch

79802

63-7
STRUCTURE AND OPERATION
Front Wiper and Washer

1 7 1 7

C C

*b C C
8
9
A

D D

12 D D
11 10

1
*b *a
*b
*a 11

5
14 10
6
2
4 13

C-C D-D 79869

63-8
 63
1 Wiper arm assembly 11 Strap
2 Bolt 12 Washer tank
3 Link assembly 13 Grommet
4 Seal rubber 14 Washer nozzle
5 Nut
6 Nut A: View from outside cab
7 Blade assembly B: View from inside cab
8 Wiper motor bracket
9 Wiper motor
*a: Front body
10 Washer hose *b: Windshield weather strip

63-9
STRUCTURE AND OPERATION
Front Wiper and Washer Electric Circuit

71940

1 Fuse box 6 Wiper motor

2 Relay box 7 Washer motor
3 Wiper relay (HIGH) 8 Combination switch
4 Wiper relay (LOW) 9 Wiper and washer switch
5 Interval wiper relay 10 Wiper interval control switch
Wiper and washer operation is controlled by interval wiper relay 5. For details about the multipurpose timing control and
lighting and alarm control units, refer to B Electrical.

63-10
 63
When wiper is operating at LOW speed
When wiper and washer switch 9 is in posi-
tion Lo, wiper relay (LOW) 4 is activated,
wiper motor 6 rotates and the wiper oper-
ates at low speed.

71941

When wiper is operating at HIGH speed

When wiper and washer switch 9 is in posi-
tion HI, the current flows in the following di-
rection and the wiper operates at high
speed.

Fuse box 1 Wiper relay(HIGH) 3

Wiper and washer switch 9

Ground
Interval wiper relay 5 (RLY)

Because of this, wiper relay (HIGH) 3 starts

operating and the following circuit is formed.

Interval wiper relay 5 (MTR)

Wiper relay(LOW) 4
Wiper relay(HIGH) 3
Wiper motor 6 Ground

71942

63-11
STRUCTURE AND OPERATION
When wiper is operating intermittently
• When wiper and washer switch 9 is in
position INT, circuit B is connected and
circuit C is formed between interval wip-
er relay 5 (RLY) and wiper relay (LOW)
4.
• Because of this wiper relay (LOW) 4 is
activated, wiper motor 6 rotates and the
wiper starts intermittent operation at low
speed. (Interval between intermittent op-
eration depends on data recorded in the
multipurpose timing control unit.)
• In the case of a vehicle equipped with
wiper interval control switch 10, the in-
terval between intermittent operation is
determined by interval wiper relay 5 af-
ter it detects a change in the current in-
side circuit D caused by changes made
to the resistance inside the switch.

71943

Washer interlock wiper operation

• When wiper and washer switch 9 is in
position WASH, washer motor 7 oper-
ates.
At the same time circuit E is connected
so interval wiper relay 5 detects that the
washer switch is on.
• After an interval equivalent to the wash-
er interlocking delay time recorded in in-
terval wiper relay 5, circuit C is
connected, wiper relay (LOW) 4 is acti-
vated,wiper motor 6 rotates and the wip-
er starts operating at low speed.
• When the washer switch is turned off, af-
ter an interval equivalent to the washer
interlocking time, circuit C is shut off
and the wiper stops.

71944

63-12
 63

MEMO

63-13
STRUCTURE AND OPERATION
Auto door system <Folding door: vacuum type>
P Wiring diaguram

2
1

8
7
3
9 10

6
11

5 78200

1 Fuse box 7 Accelerator interlock

2 Time lag relay 8 Auto door electronic control unit
3 Door engine 9 Auto - Manual select switch
4 Neutral switch 10 Micro switch
5 Auto door switch 11 Emergency switch
6 Parking brake switch A: To alternator L terminal

63-14
 63
P Vacuum piping

5
7

2
1 9
4
3

6
12 11 10

78581

G
H

J 74376

63-15
STRUCTURE AND OPERATION

1 Vacuum pump A: ON
2 Engine B: OFF
3 Limiting valve C: Air
4 Reservoir tank D: Open
5 Door engine E: Close
6 Valve unit F: Piston rod
7 Valve A G: From exhaust brake unit
8 Valve B H: From vacuum tank
9 Valve C J: From vacuum pump
10 Brake booster
11 Clutch booster
12 Vacuum tank
• The auto door system is configured from the door engine 5, auto door switch, vacuum piping, limiting valve 3 and other
components and is linked to the door by the piston rod F.
• Operating the auto door switch causes vacuum to be supplied to the door engine 5, which operates the cylinder rod
and opens and closes the door.

63-16
 63
Auto door system <Swinging door: electric type>

A 2

10
9

8
11 3

12

4
6 5
78628

1 Fuse box 8 Accelerator interlock

2 Door switch 9 Auto Manual select switch
3 Door engine 10 Auto door electronic control unit
4 Door lockout actuator 11 Micro switch 1
5 Buzzer 12 Micro switch 2
6 Parking brake switch
7 Auto door switch A: To alternator L terminal

63-17
STRUCTURE AND OPERATION

74374

• The auto door system is configured form the door engine 3, the auto door switch 8 and other components. The door
engine's link B is linked to the swing door C.
• Operating the auto door switch 8 turns the swing door arm C, opening or closing the door.
• The hand lever, installed under the step and interlocked with the lever on the inside door engine, allows to open the
swing door manually at an emergency.

63-18
 63
Accelerator interlock
1 Accelerator interlock assembly
2 Accelerator pedal
3 Shaft
1 2
• The accelerator interlock assembly 1 is mounted under
the accelerator pedal 2.
• The accelerator interlock assembly 1 is linked to the
auto door system.
3 • When the side door is opening, the shaft 3 moves,
making it impossible to depress the accelerator pedal
2.

74377

63-19
STRUCTURE AND OPERATION
Emergency Locking Retractor Type Seat Belt

74945

63-20
 63
1 Tongue stopper 9 Sensor spring
2 Emergency locking retractor assembly 10 Lock arm
3 Spindle 11 Clutch
4 Locking gear 12 Buckle assembly
5 Mechanism lever 13 Tongue plate
6 Mechanism weight 14 Webbing
7 Pawl 15 Plate
8 Ratchet gear

CAUTION k
• This section only describes the emergency locking retractor type seat belt.
• Absolutely do not disassemble emergency locking retractor assembly 2.

P Webbing detecting lock

• When the vehicle is subjected to a sudden impact,
such as a collision, webbing 14 drawn out accord-
ing to the movement of the passenger, and spindle
3 rotates.
• As the rotation of spindle 3 is higher than that
specified value, the force of sensor spring 9 can no
longer retain lock arm 10. Then, the arm is pulled
out from the specified position and is locked by
clutch 11.
• If spindle 3 further rotates, clutch 11 lifts pawl 7 to
lock with ratchet gear 8, making spindle rotation
impossible.

P Body detecting lock

• When the body is tilted excessively, mechanism
weight 6 is tilted, engaging mechanism lever 5 with
locking gear 4, locking it.
• If spindle 3 further rotates, clutch 11 operates as
described above, and the spindle cannot rotate.
07371

63-21
TROUBLESHOOTING
Entire Body
Symptoms

Body or steering wheel high-frequency vibration

Body shimmy (pitching and rolling vibration)
Remarks

(above 20 Hz) or noise

Possible causes
Body mounting loose, play p p
Body-related
Body installation faulty p p
Cross axes angle of propeller shaft excessive due to increased tilt caused by
p
deteriorating engine mounting
Engine-related B Gr11
Engine installation faulty p
Intake and exhaust system installation faulty p
Transmission-related Transmission installation faulty p L Gr22, 23
Propeller shaft run out excessive p
Universal joint worn excessively p
Slip yoke joint spline play p
Propeller shaft-related Center bearing play excessive p L Gr25
Cross axes of mounting dimension excessive due to deteriorated center
p
bearing cushion rubber
Cross axes angle of propeller shaft excessive due to increased drive shaft tilt
p
caused by too many passengers riding
Front axle-related Axle seat resonance p L Gr26
Reduction gear engaged incorrectly p
Rear axle-related L Gr27
Differential gear engaged incorrectly p
Wheel and tire run out excessive p
Wheel and tire unbalanced p
Wheel and tire-related L Gr31
Size and kind of tire unequal p
Wheel mounting surface warped p
Suspension-related Leaf spring friction between leaves excessive p L Gr33, 34
Brake drum unbalanced p
Brake-related Brake drum eccentric p L Gr35A
Disc brake rotor eccentric p

63-22
 63
Door Lock
Symptoms

Door does not lock when door lock knob is pressed

Door does not open using outside door handle

Door does not open using inside door handle

Door does not lock when key is turned

Door inside handle self-return poor

Door does not open using lever
Door does not shut completely
Remarks

Door and body interference

Possible causes
Door installation faulty p p
Striker installation faulty p
Door latch rod deformed p p p p p
Door latch rod removed p p p p p
Front door
Door latch rod interference p p p p p
Key cylinder deformed p p
Joint screw installation faulty p
Inside door handle spring fatigued p
Door installation faulty p p
Side door
Stopper installation faulty p
<folding>
Door lock faulty p p
Door installation faulty p p
Striker installation faulty p
Door latch rod deformed p p p p p
Side door
Door latch rod removed p p p p p
<swing>
Door latch rod interference p p p p p
Key cylinder deformed p
Remote control faulty p p p p
Door installation faulty p p
Catch installation faulty p
Lock assembly or door lock controller deformed p p
Emergency door
Lock assembly or door lock controller removed p p
Lock assembly or door lock controller interference p p
Key cylinder deformed

63-23
TROUBLESHOOTING
Automatic Door System <Folding Door: Vacuum>
Symptoms

Start is poor when door is closed

Door does not shut completely
Door does not open and close
Remarks

Door does not open

Possible causes
Fuse blown p
B Electrical
Door open switch faulty p
Starter switch is not in the “ON” position p p
Door locked p p
Cylinder assembly change lever is in “manual” position p p
Cylinder assembly defective p p
Door upper roller and guide rail contact faulty p
Cylinder assembly installation position faulty p p
Dead point in start position p
Stroke is insufficient p
Cushion O-ring is worn p
Door hinge faulty p
Vacuum pressure is not transmitted to door p
Solenoid valve is not energized p
Solenoid valve does not change p

63-24
 63
Automatic Door System <Swing door: Electric>
Symptoms

Buzzer sounds but door does not open or close

Door does not shut completely
Door does not open and close

Door opens but does not shut

Door shuts but does not open

Remarks

Buzzer does not sound

Does not lock out

Possible causes
Fuse blown p
Harness or connector faulty p p p
B Electrical
Door open switch faulty p p p
Buzzer faulty p
Microswitch faulty p p p
Motor faulty p
Control box faulty p p p p p p p
Door engine change lever is in “manual” position p
Open/close capability (vehicle slant angle 12° is exceeded) p
Vehicle lock faulty p p p
Door fitting faulty p
The parking brake lever is not pulled up or the gear shift lever is not in neutral p
Door lock out actuator faulty p p

63-25
TROUBLESHOOTING
Wiper and Washer
Symptoms

Wiper intermittent operation does not work

Abnormal noise during wiper operation

Wiper blade stop position incorrect

Wiper does not work with washer

Washer fluid spraying insufficient

Washer fluid does not spray out

Washer motor does nor work
Remarks

Wiper operation inadequate

Wiper does not work

Wiper does not stop

Possible causes
Wiper motor faulty p p p p
Washer motor faulty p p p
Wiper and washer switch faulty p p p p p
Multipurpose timing control faulty p p B Electrical
Wiper relay faulty p p
Fuse, high-current fuse blown p p
Wire broken or connection faulty p p p p p
Wiper motor crank arm set position incorrect p
Wiper link, wiper arm connection faulty p
Wiper blade faulty p p
Wiper arm defective p
Washer hose twisted p
Washer hose connection faulty p
Washer nozzle clogged p p
Washer fluid insufficient p

63-26
 63
Emergency Door
Problems

Look system does not

Door cannot be opened with inner handle.

Door cannot be opened with inner handle.

operate.
Outer handle is heavy to move.
Inner handle is heavy to move.
Remarks

Lock knob operation

key operation
Possible causes

Defomed rod p p
Door lock controller Disconnected rod p p p p
Rod interference p p
Defomed or dameged door lock cylinder p
Faulty door lock actuator p p B Electrical
Faulty contact in connecter, open circuit in herness, faulty grounding p p B Electrical
Improper inner handle adjutment p
Improper inner handle adjutment p

63-27
ON-VEHICLE INSPECTION AND ADJUSTMENT
Front Door Fitting Adjustment
T Tightening torque Unit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks
2 Bolt (door hinge installation) 17 to 26 {1.7 to 2.6} –
6 Screw (striker installation) 9 to 14 {0.9 to 1.4} –

Adjust front door fitting at door hinge and striker. (For door fitting dimen-
sions see L P63-29)

(1) Hinge adjustment

After adjusting door hinge 1, tighten bolt 2 at the specified torque.

71206

(2) Striker adjustment

3 • Use shim 5 to adjust the engagement between door lock latch 3 and
5 striker 4 within the illustrated range.
4 6 • After adjustment, tighten screw 6 at the specified torque.

12 mm

71207

63-28
 63
Door Fitting Dimensions

A B
C C B 6.8 w 1 mm

A-A

6 w 1 mm

B-B

6 w 1 mm 7 w 1 mm

C-C
D-D

79803

63-29
ON-VEHICLE INSPECTION AND ADJUSTMENT
Side Door <Folding> Fitting Adjustment
Door Fitting Dimensions

74755

63-30
 63
Side Door <Swing> Fitting Adjustment
T Tightening torque Unit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks
3 Bolt (pillar side arm bracket installation) 34 to 55 {3.5 to 5.5} –
4 Bolt (step side arm bracket installation) 17 to 26 {1.7 to 2.6} –
7 Bolt (door side arm bracket installation) 34 to 55 {3.5 to 5.5} –
9 Nut (guide arm tightening) 19 to 28 {1.9 to 2.8} –

The side door <swing> fitting is adjusted using the swing door arm, arm
bracket, and guide arm.
(For door fitting dimensions see L P63-33)

(1) Vertical adjustment

• After adjusting pillar arm bracket 1 and step arm bracket 2, tighten
bolts 3 and 4 at the specified torque.

CAUTION k
The adjustment range for the arm bracket is ±2mm, so when an
adjustment greater than this needs to be made, make the adjust-
ment by changing the number of shims.

71209

• Remove step side arm bracket 2 and adjust the fitting using shim 5.

71210

63-31
ON-VEHICLE INSPECTION AND ADJUSTMENT
(2) Front and back direction adjustment
After adjusting door side arm bracket 6, tighten bolt 7 at the specified
torque.
Adjustment range: ±2.5mm

71211

(3) Door front and back direction position adjustment

Loosen nut 9 of guide arm 8 and after adjustment retighten the nut at
the specified torque.

71212

(4) Door vertical position adjustment

After adjusting step side arm bracket 2, tighten bolt 4 at the specified
torque.
Adjustment range: ±2.5mm

71213

63-32
 63
Door Fitting Dimensions

74387

63-33
ON-VEHICLE INSPECTION AND ADJUSTMENT
Emergency Door Fitting Adjustment
T Tightening torque Unit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks
2 Bolt (hinge assembly installation) 16 to 25.5 {1.7 to 2.6} –
6 Bolt (upper catch installation) 4 to 6 {0.4 to 0.6} –
9 Bolt (lower catch installation) 4 to 6 {0.4 to 0.6} –

Emergency door fitting adjustment is conducted by adjusting the hinge

assembly and the upper and lower catches. (For the door fitting dimen-
sions see L P63-35)
(1) Hinge assembly adjustment
• After adjusting hinge assembly 1, tighten bolt 2 at the specified
torque.
Adjust the clearance between the emergency door and the hinge as-
sembly.

74389

(2) Upper and lower catch

• Adjust the engagement between upper catch 3 and door lock 4 using
shim 5 so that is within the illustrated range.
• After adjustment tighten bolt 6 at the specified torque.
• Adjust the door lock so that the engagement between lower catch 7
and door lock 8 is within the illustrated range.
• After adjustment tighten bolt 9 at the specified torque.

74390

63-34
 63
Door Fitting Dimensions

74391

63-35
ON-VEHICLE INSPECTION AND ADJUSTMENT
Fuel Lid Fitting Adjustment
The fuel lid 1 fittings are adjusted using the
door hinge 2 and hook 3.
• Adjust door hinge 2 and hook 3 so that
the clearance between the body and lid
1 is 5mm all the way around, and then
tighten screw 4.

74756

63-36
 63

MEMO

63-37
FRONT DOOR
Door Hinge and Striker

8
3 T 7
6

T 5
4 10
T
2

11
12

74396

P Removal sequence
1 Door harness 7 Striker
2 Bolt 8 Shim
3 Door assembly L P63-40 9 Weather strip
4 Bolt 10 Weather strip
5 Door hinge 11 Grommet
6 Screw 12 Door switch B Electrical

P Installation sequence
Follow the removal sequence in reverse.

CAUTION k
For the door fitting adjustment see L P63-28

63-38
 63
T Tightening torque Unit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks
2 Bolt (Door assembly installation) 17 to 25 {1.7 to 2.6} –
4 Bolt (Door hinge installation) 17 to 25 {1.7 to 2.6} –
6 Screw (Striker installation) 9 to 14 {0.9 to 1.4} –

63-39
FRONT DOOR
Door Assembly (Double Sliding Window)

26

27

X
30
31 30
32

28

29

25
20
18 19
23
24

17
21
18
24
17 33

20
10
11 T
19 22 12
13

1
8

9
16 5 14
2 7T

T 15 3
4

X6

74399

63-40
 63
P Disassembly sequence
1 Handle 12 Screw 24 Clip
2 Weather strip 13 Door latch assembly 25 Window assembly
3 Weather strip 14 Inner side panel 26 Sash
4 Door trim 15 Bolt 27 Sash
5 Waterproof cover 16 Door check assembly 28 Sash
6 Butyl rubber tape (Sundine 60 or Aishin 17 Lock assembly 29 Run channel
Tape 60) 18 Plate 30 Glass
7 Bolt 19 Catch 31 Center seal
8 Outer handle assembly 20 Plate 32 Weather strip
9 Cover 21 Joint cover 33 Front door assembly
10 Inner lock knob 22 Trim
11 Bushing 23 Butyl rubber tape X : Non-reusable parts

P Assembly sequence
Follow the disassembly sequence in reverse.

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
7 Bolt (outer handle assembly installation) 4 to 6 {0.4 to 0.6} –
12 Screw (door latch assembly installation) 4 to 6 {0.4 to 0.6} –
15 Bolt (check assembly installation) 4 to 6 {0.4 to 0.6} –

R Service procedure
2 Weather strip installation
Insert the protruding part A of weather strip 2 into front door assembly
33 to install.

71229

63-41
FRONT DOOR
5 Waterproof cover installation
When installing waterproof cover 5, apply butyl rubber tape 6 all the
way along the groove.

5 5mm

74398

25 Window assembly removal

30
• After removing joint cover 21 and trim 22, move glass 30 right and
left and remove upper and lower installation clips 24.

24

30

24

74547

• Use knife A, etc., to remove the adhered surface of window assembly

25.
A

25

74400

63-42
 63
• Remove window assembly 25 by pushing it toward the outside.

25

74401

63-43
SIDE DOOR <FOLDING>

74763

P Disassembly sequence
1 Bolt 10 Hinge assembly 19 Door pull handle
2 Bracket 11 Hinge assembly (with handle) 20 Weather strip
3 Plate 12 Stopper bracket 21 Side door glass
4 Bearing 13 Weather strip (pillar side) 22 Weather strip (butyl rubber, Nitto
5 Bearing 14 Weather strip (door side) Sealant No.687)
6 Check plate 15 Door lock assembly 23 Shaft
7 Bolt 16 Stopper 24 Side door panel
8 Stopper 17 Plate 25 Weather strip
9 Cover 18 Seal rubber 26 Stopper

P Assembly sequence
Follow the disassembly sequence in reverse.

CAUTION k
For door fitting adjustment see L P63-30

63-44
 63
T Tightening torque Unit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks
1 Bolt (bracket installation) 3.9 to 5.9 {0.4 to 0.6} –
7 Bolt (stopper installation) 3.9 to 5.9 {0.4 to 0.6} –

K Lubricant and/or sealant

Location Points of application Specified lubricant and/or sealant Quantity
2, 23 Bracket and shaft rotating areas Chassis grease [NLGl No.1 (Li soap)] As required
4, 5, 23 Bearing and shaft rotating areas Chassis grease [NLGl No.1 (Li soap)] As required
6 Bearing contact surface Chassis grease [NLGl No.1 (Li soap)] As required
25 Weather strip right and left adhesion surfaces CEMEDINE 575 As required

R Service procedure
6 Check plate adjustment
• Bearing 5 on the rear of the side door and shaft 23 act at check plate
6 to prevent the door from closing when it is open.
• If the area of contact between the check plate and the shaft is insuffi-
cient, adjust by inserting liner B between the plate and rail A.

C: Door shaft side

71792

8 15 Side door locking system adjustment

Adjust the number of shims A so that the contact area between stopper
8 and door lock assembly 15 is 6 to 7 mm.

74764

63-45
SIDE DOOR <FOLDING>
20 21 Weather strip and side door glass
[Removal]
Pry up lip area B of weather strip 20 using screwdriver A, then push out
and remove side door glass 21 from the door.

71249

[Installation]
• Install weather strip 20 on side door glass 21.

71250

• Overlap strong string C in the door installation groove of weather

strip 20 as shown by D in the illustration.
• Apply soapy water E to weather strip 20 and fit side door glass 21
correctly into the side door.

71251

• Firmly pushing side door glass 21 from the outside and pulling one
end of string C from inside the cab to fit the cab side installation
groove of weather strip 20 into the flange part of the side door.

71252

63-46
 63
• Pull string C in the numerical order as illustrated and at the same
time tap the side door glass 21 from the outside with a rubber-head-
ed mallet to stabilize.

F: Approximately 100 mm from the starting point of straight line

G: Up to the end of straight line

71253

22 Weather strip (butyl rubber, Nitto Sealant No.687) installation

Install weather strip (butyl rubber, Nitto Sealant No.687) 22 around the
flange face of the side door.

71254

25 Weather strip installation

A: Apply adhesive (CEMEDINE 575)

71255

63-47
SIDE DOOR <SWING>
Guide Arm and Swing Door Arm

5 T
6

T3
4

15 14 T

15
17
14 T
16 T
12
7T
T 11
10

8 18

T7
9

T3
4

T1

2
13

79600
P Removal sequence
1 Bolt 7 Bolt 13 Door assembly L P63-50
2 Guide arm assembly 8 Arm bracket (step side) 14 Bolt
3 Bolt 9 Shim 15 Striker
4 Arm bracket (door side) 10 Cushion rubber 16 Bolt
5 Bolt 11 Nut 17 Door check
6 Arm bracket (pillar side) 12 Swing door arm 18 Plate

P Installation sequence
Follow the disassembly sequence in reverse.

CAUTION k
For the door fitting adjustment see L P63-31

63-48
 63
T Tightening torque Unit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks
1 Bolt (guide arm assembly installation) 17 to 25 {1.7 to 2.6} –
3 Bolt (arm bracket installation) 34 to 55 {3.5 to 5.5} –
5 Bolt (arm bracket installation) 34 to 55 {3.5 to 5.5} –
7 Bolt (arm bracket installation) 17 to 26 {1.7 to 2.6} –
11 Nut (cushion rubber installation) 34 to 50 {3.4 to 5.0} –
14 Bolt (striker installation) 8.8 to 14 {0.9 to 1.4} –
16 Bolt (door check installation) 4 to 6 {0.4 to 0.6} –

R Service procedure
13 Door assembly installation
• Align the window bottom line of the door window and side window.
• Align the body surface and door surface so that the door projection at
points A and B is 0 mm.
• Install the arm bracket so that clearance C is equal on both the right
and left.

74403
• Open the door assembly 13 fully, then adjust the position of the cush-
ion rubber 10 so that the effective opening width between the door
front end D and the front end of the entrance pillar E is 620 mm, and
the amount of protrusion of the door from the body is 154 mm. Adjust
by the number of washers F used.

CAUTION k
At this time cushion rubber 10 should contact entrance pillar G.

71239

11
12
F
10

79599
• Adjust the check plate H so that door check J does not ride up on the
protruding area of check plate H.

71240

63-49
SIDE DOOR <SWING>
Door Assembly

74404

P Disassembly sequence
1 Molding 13 Latch assembly
2 Glass clip 14 Latch assembly
3 Side door glass 15 Cover
4 Window dam 16 Inside lock knob
5 Trim edge 17 Sublink assembly
6 Clip 18 Link assembly
7 Trim 19 Key cylinder
8 Waterproof film 20 Swing door panel
9 Vent cover 21 Weather strip
10 Butyl rubber tape (Sundine 60 or Aishin 22 Weather strip
Seal Tape 60)
11 Outside handle X : Non-reusable parts
12 Inside handle

P Assembly sequence
Follow the disassembly sequence in reverse.

63-50
 63
K Lubricant and/or sealant
Location Points of application Specified lubricant and/or sealant Quantity
Primer: Glass clip surface Yokohama Rubber RC-50E As required
2 Primer: Side door glass surface Yokohama Rubber GM-78 As required
Glass clip and side door glass adhesion Yokohama Rubber WS-30 As required
Cleaner: Glass surface Sika Cleaner 205 As required
3
Glass adhesion surface Sika Flex 250PC As required

R Service procedure
1 Molding installation
• Wedge side door glass 3 into the groove in molding 1.
• Reinforce the corner with tape A.

74405

2 Glass clip installation

• Apply primer A (Yokohama Rubber RC-50E) to the adhesion surface
of glass clip 2.
• Apply primer C (Yokohama Rubber GM-78) to the adhesion surface
of side door glass 3.

CAUTION k
Primer dry time
A: Longer than 3 minutes and within 24 hours
74406
B: Longer than 5 minutes and within 24 hours

• After the primer is dry, adhere glass clip 2 to side door glass 3 with
adhesive B (Yokohama Rubber WS-30)
3 Side door glass
[Removal]
Insert a cutting machine or cutter knife A between the side door glass 3
and the frame to separate the adhesive. At this time cut so that the re-
maining adhesive layer is approximate 1 mm thick.

74407

63-51
SIDE DOOR <SWING>
[Installation]

CAUTION k
When conducting window installation work, refer to the precau-
tion items for using adhesive (Sika Flex 250PC) and take due
care when handling the adhesive.

• Remove adhesive A, etc., that is adhered to swing door panel 20 and

side door glass 3 and clean them. In addition, if there is damage to or
corrosion on the paint coating, repair it.
Clean the entire adhesion surface with unleaded gasoline and let the
surface dry for 3 minutes or more.

74408

• Glue window dam 4 all the way around swing door panel 20.

74409

• Apply Sika Cleaner No.1 A to the adhesion surface of swing door

panel 20 and side door glass 3 and let it sit for 5 to 10 minutes.

CAUTION k
• Carefully apply cleaner on the spot welds and sheet joints.
• After applying cleaner do not touch the surface with bare hands
or get lubricants or greases on the surface.

74410

63-52
 63
• Apply adhesive A (Sika Flex 250PC) along window dam 4.

74411

• Glue side door glass 3 and swing door panel 20 so that glass clips 2
enter the three holes on the side door glass.

74412

5 Trim edge installation

Appropriately cut trim edge 5 (L=2550) and install trim edge 5 so that
the joint is at center A of the door.

74413

8 9 Waterproof film and vent cover installation

When installing waterproof film 8 and vent cover 9, tape with butyl rub-
ber tape (Sundine 60 or Aishin Seal Tape 60) 10 using the dimensions
shown in the illustration.

74414

63-53
SIDE DOOR <SWING>
Precautions for using adhesive (Sika Flex 250PC) during work
This section covers the general precautions for using adhesive and
cleaner. Refer to the appropriate sections for information regarding re-
moval work procedure, and work instructions during window removal
and installation.

(1) When removing windows and window assembly A, use piano wire
or cutting machine B, etc., to cut the adhesive C while leaving a ap-
proximate 1 mm thick layer of adhesive.

D: Window dam

74736

(2) Coat areas where the paint has come off with primer VP209. In ad-
dition, if the glass ceramic membrane has come off, coat the area
with black primer and repair it.

A: Side window assembly

B: Window assembly adhesive surface

74737

(3) Clean the body side and window adhesive surface with unleaded
gasoline and let them dry for more than 3 minutes.

(4) After applying Sika Cleaner 205, let dry for 5 to 10 minutes.

A :Side window assembly

B :Window assembly adhesive surface
CAUTION k
• Carefully apply cleaner on the spot welds and sheet joints.
• After applying cleaner do not touch the surface with bare hands
or get lubricants or greases on the surface.
74738

63-54
 63
(5) Apply adhesive A (Sika Flex 250PC) following the precautions given
below.
CAUTION k
1. Apply the adhesive so that the adhesive application cross sec-
tion forms a triangle that has a bottom 8mm wide and a height of
12mm.
2. Be careful when starting application, stopping application, or
when applying to corners because it is easy for the adhesive not
to flow continuously or for too much to be applied.
74735
3. Because this is a quick hardening adhesive, work on one win-
dow at a time, and make the time period from the start of adhe-
sive application until the window is glued in within 8 minutes.
4. Because the adhesive is urethane and has poor compatibility
with silicon sealer, when using silicon sealer, use it in an area
1m or more away from the adhesive and in a sufficiently venti-
lated area.

(6) Use suction cups A, etc., to lift the window to keep the surface ap-
plied with cleaner clean.
CAUTION k
If you touch the cleaner applied surface with bare hands or get
lubricants or greases on the surface, then reapply the cleaner.

74415
(7) Quickly remove adhesive that is oozing out of the joint before it
dries, and clean the outside of the joint with unleaded gasoline.

63-55
EMERGENCY DOOR
Door Check, Hinge, Catch

74418
P Disassembly sequence
1 Bolt 7 Catch
2 Door check 8 Shim
3 Bolt 9 Bolt
4 Hinge 10 Stopper
5 Door assembly L P63-58 11 Weather strip
6 Bolt 12 Weather strip

P Installation sequence
Follow the disassembly sequence in reverse.
63-56
 63
CAUTION k
For door fitting adjustment see L P63-34

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Bolt (door check installation) 4 to 6 {0.4 to 0.6} –
3 Bolt (hinge installation) 16.6 to 25.5 {1.7 to 2.6} –
6 Bolt (catch installation) 4 to 6 {0.4 to 0.6} –
10 Bolt (stopper installation) 4 to 6 {0.4 to 0.6} –

63-57
EMERGENCY DOOR
Door Assembly

1
6
K
2 5
X
7

K 11

3
10
9
8

79804
P Disassembly sequence
1 Door pull handle 7 Weather strip (butyl rubber, Nitto
2 Cover Sealant No.687)
3 Door trim 8 Weather strip (inner)
4 Edge molding 9 Weather strip (outer)
5 Weather strip 10 Lever cover
6 Glass 11 Door panel assembly L P63-62
X: Non-reusable parts

P Assembly sequence
Follow the disassembly sequence in reverse.

63-58
 63
K Sealant
Location Point of application Specified sealant Quantity
4 Door body and molding contact area CEMEDINE 560 As required
5 Weather strip and glass contact area CEMEDINE CS3061-6AL As required

R Service procedure
4 Edge molding installation
50 mm 50 mm 50 mm
When installing edge molding 4, apply CEMEDINE 560 A to the edge,
and then install edge molding at the dimensions shown in the illustra-
tion.
217 mm

70 mm
4
A

74420

5 6 Weather strip and glass

[Removal]
Push glass 6 outside the door while lifting up lip area B of weather strip
A 5 using a screw driver A.
5

B
6

71258

[Installation]
5 • Install weather strip 5 onto glass 6 and at this time apply sealer A
5 (CEMEDINE CS3061-AL) and be careful that the sealer does not
ooze outside weather strip.
6
6
A

5
74421

63-59
EMERGENCY DOOR
• Overlap strong string C in the door installation groove of weather
5 strip 5 as shown by D in the illustration.
• Apply soapy water E to weather strip 5 and fit glass 6 correctly into
6
the emergency door.

5
71260

• Firmly pushing glass 6 from the outside and pulling one end of string
C from inside the cab, fit the cab side installation groove of weather
strip 5 into the flange part of the emergency door.
6
5

C
71252

• Pull string C in the numerical order illustrated and at the same time
tap glass 6 from the outside with a rubber-headed mallet to stabilize.
G 6
F: Approximately 100 mm from the starting point of straight line
G: Up to the end of straight line

71262

7 Weather strip (butyl rubber, Nitto Sealant No.687) installation

Install weather strip (butyl rubber, Nitto Sealant No.687) 7 all around the
flange face of the emergency door.

71263

8 9 10 Weather strip and lever cover

[Removal]
• Remove weather strip (inner) 8.
10
• Push out and remove lever cover 10 from the door.

[Installation]
9
• Install weather strip (inner) 8 all around, cutting it somewhat longer at
the joint than necessary.
8
71264 CAUTION k
Make sure not to pull weather strip (inner) 8 excessively when
installing it or it will shrink later and create a gap.

63-60
 63

MEMO

63-61
EMERGENCY DOOR
Door Panel Assembly (Door Locking System)
PDisassembly sequence
1 Knob cover
3 K 2 Lock knob
1 4 3 Insulator
2
4 Lock assembly
5 Inner handle
6 Outer handle
7 Bracket
K 11 9 8 Door lock actuator BElectrical
9 Retainer
5 10 Door lock cylinder
11 Door lock controller
10 12 Door panel

PAssembly sequence
Follow the disassembly sequence in reverse.

PInspection and adjustment after

8 6 Instration L P63-35
K
12
78629

Service standards Unit: mm

Location Maintenance item Standard value Limit Remedy
5 Play in inner handle 0 to 12 - Adjustment or replace
6 Play in outer handle 0 to 5 - Adjustment or replace
Distance between rod end of door lock Inner handle side 15 - Adjustment
11
controller and center of regulate pin Outer handle side 7.5 - Adjustment

K Lubricant and / or sealant

Location Points of application Specified lubricant and / or sealant Quantity
3 Bonding surface of insulator CEMEDINE 180 As required
8 Rotating sliding surface Permalube DL-12 As required
11 Rotating sliding surface Wheel bearing grease [NLGI No.2 (Li soap)] As required

R Service procedure
P Inspection and adjustment after installation
(1) Inspection and adjustment of play in inner handle
A 11
• Check to see if play in inner handle 5 conforms to the standard value.
5 • If the amount of play deviates from the standard value, adjust the
play in the inner handle by turning regulate pin B of rod A that links
inner handle 5 with door Iock controller 11.
B • lf an abnormality is found, replace inner handle 5 or door lock control-
ler 11.
0 to 12 mm
78647

63-62
 63
(2)Inspection and adjustment of play in outer handle
6 • Check to see if play in outer handle 6 conforms to the standard value.
• If the amaunt of play deviates from the standard value, adjust the
play in the outer handle by turning regulate pin B of rod A that links
outer handle 6 with door lock controller 11.
11 • If an abnormality is found, replase inner handle 6 or door lock con-
0 to 5 mm troller 11.
A
B
78648

3 Installation of insulater
4 B 3 • Appy adhesive (CEMEDINE 180) to the slits on insulators 3.
• Install insulators 3 to lock assembly 4, making sure that installation
4 intervals B are about the same.
3 B
A

B 3
A 78630

15 mm 11 Installation of door lock controller

11
• By turning regulate pin A of door lock controller 11, adjust the dis-
tance between the end of rod B and the center of the regulate pin is
as shown in the diagram.
A B

B
A
7.5 mm
78659

63-63
AUTOMATIC DOOR SYSTEM <FOLDING DOOR:VACUUM TYPE>

T
*d
12
1 2

10

13 T 8
T9
14 7
6

4 T
9 3 K
5

10
*a
10
T9 *b 11
10
15 10
9 11
T 79805

P Removal sequence
1 Clevis pin 11 Vacuum pipe
2 Cylinder cover 12 Bolt
3 Plate 13 Bolt
4 Bolt 14 Reservoir tank (vacuum)
5 Tail bracket 15 Limiting valve
6 Solenoid valve
7 Cylinder assembly L P63-68 *a: Exhaust brake unit
8 Door bracket assembly
9 Bolt
*b: Vacuum tank
c: Vacuum pump
*
10 Vacuum hose *d: Side door assembly L P63-44

P Installation sequence
Follow the removal in reverse.

63-64
 63
T Tightening torque Unit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks
4 Bolt (Tail bracket mounting) 9 to 14 {0.9 to 1.4} –
9 Bolt (Vacuum pipe mounting) 4 to 6 {0.4 to 0.6} –
Bolt (Reservoir tank front bracket and reservoir tank
12 10 to 15 {1.0 to 1.5} –
mounting)
Bolt (Reservoir tank rear bracket and reservoir tank
13 10 to 15 {1.0 to 1.5} –
mounting)

K Sealant
Location Point of application Specified sealant Quantity
After connecting harness, pack into space between har-
Silicone sealant BM30 As required
3 ness and grommet
Between plate and board CEMEDINE CX-4117(B) As required

R Service procedure
P Pre-installation inspection and adjustment
Side door operation inspection
• Check that the door moves smoothly when operated by hand before
beginning installation work.
• If the door does not open and close smoothly, inspect door areas A
through F and correct any problems. L P63-30

A: Upper bearing
B: Door bracket
C: Lower bearing
71809 D: Hinges
E: Door end rubbers
F: Guide rollers

P Checks and adjustments after installation

Cylinder assembly adjustment
7
Adjust the cylinder assembly so that the clearance between micro
switch stay B and cam C is as shown in the illustration when the rod A
on the cylinder assembly 7 is in the maximum extension position.

C
A
10w2mm 78245

63-65
AUTOMATIC DOOR SYSTEM <FOLDING DOOR:VACUUM TYPE>
7 Cylinder assembly installation
7
8 Check that cylinder assembly 7 installation surface is flat and without
depressions or rises. If there are depressions or rises, repair so that the
surface is flat.
CAUTION k
If cylinder assembly 7 is installed without the depressions or
rises being repaired, the door will not open and close smoothly.

71285

• Determine the temporary position for installing plate 3, tail bracket 5,

and door bracket assembly 8 in relation to the mounting hole of the
cylinder assembly, and open and close the door repeatedly to make
0
sure there is sufficient stroke (171 -2 mm).

71811

7 • After having made sure the door can be properly opened and closed
using the above temporary installation positions, lock tail bracket 5
and set adjustment assembly A.

71287

• Open the door and pull out clevis B of cylinder assembly 7 to the fully
7 closed position.
8 • Install cylinder assembly by aligning it with door bracket assembly 8
so that the bracket is positioned midway along the course of play C of
clevis in the vertical direction.

71288

63-66
 63
• Loosen the nuts of the clevis of cylinder assembly 7 and door bracket
assembly 8 and adjust so that when the door is opened and closed,
7
the dimensions are as shown in the illustration.

1 to 2 mm

0 mm

74765

• After installation, supply air to cylinder assembly 7, insert the clevis

pin into door bracket assembly 8 and secure it with the cotter pin.
• Move the door manually once again to make sure it is operating
smoothly and there is sufficient stroke.
CAUTION k
With the first supply of air, cylinder assembly 7 might start oper-
ating suddenly. Before applying air, make sure the area around
the door is safe.

10 11 Vacuum hose and vacuum pipe installation

Install vacuum hose 10 and vacuum pipe 11 so that the insertion length
is 20 mm and secure them with hose clip A.

71290

63-67
AUTOMATIC DOOR SYSTEM <FOLDING DOOR:VACUUM TYPE>
Cylinder Assembly

71291

P Disassembly sequence
1 Front hose 8 Stud bolt 15 Packing
2 Time lag relay 9 Adjustment assembly 16 O-ring
3 Solenoid valve 10 O-ring 17 Piston rod
4 Microswitch 11 O-ring 18 Packing
5 Rod stay 12 Cylinder tail 19 O-ring
6 Cam 13 Clevis 20 Cylinder head
7 Rod 14 Boots 21 Cylinder shell
X : Non-reusable parts

P Assembly sequence
Follow the disassembly sequence in reverse.
Repair kit: O-ring set

CAUTION k
Clean cylinder tail 12, piston rod 17, cylinder head 20, and cylinder shell 21 with cleaning oil before assembly.

63-68
 63
K Lubricant
Location Point of application Specified lubricant Quantity
10, 11, Multipurpose grease
O-ring As required
16, 19 [NLGI No.2 (Li soap)]
12, 17, Multipurpose grease
Sliding area of cylinder interior As required
20, 21 [NLGI No.2 (Li soap)]
Multipurpose grease
15, 18 Packing As required
[NLGI No.2 (Li soap)]

Automatic Door System Inspection

(1) Opening and closing door and operation of switches and devices.
Door swich Neutral Parking Valve Valve Valve Automatic door
State of door
position switch switch A B C actuator
Closed OPEN OFF OFF OFF ON OFF Fixes door at
closed position
Open OFF OFF ON OFF OFF Fixes door at
closed position
Open/Closed OFF ON ON OFF ON Opens door
ON OFF
ON ON
Closed OPEN n OFF OFF OFF ON OFF Fixes door at
NEUTRAL closed position
Open (automatic re- OFF OFF ON OFF OFF Fixes door at
turn) closed position
Open/Closed OFF ON ON OFF OFF Fixes door
ON OFF after operation
ON ON stop
Open/Closed CLOSE OFF OFF OFF ON ON Closes door
OFF ON
ON OFF
ON ON
Open/Closed CLOSEn OFF OFF OFF ON OFF Fixes door
NEUTRAL OFF ON after operation
ON OFF stop
ON ON
(2) Accelerator interlock operating conditions (when engine is rotating)
Automatic door Accelerator
Neutral switch Parking switch key position State of door
actuator interlock
OFF OFF ON Open Disabled from Operates
* Closed opening Does not operate
ACC Open
Closed
ON ON Open Enabled to open
Closed
ACC Open
Closed
ON OFF ON Open
Closed
ACC Open
Closed
ON ON Open
Closed
ACC Open
Closed
s s OFF s Allows to operate s
manually

*In case of A/T vehicles, the neutral switch is off with the selector lever in P or N range.
63-69
AUTOMATIC DOOR SYSTEM <SWING DOOR:ELECTRIC TYPE>

*a
2

T1
*b

12

9 7
8
11 10
T T
5
6
3
4T

79806

P Removal sequence
1 Bolt 8 E-ring
2 Door lockout actuator L P63-73 9 Link collar
3 lever 10 Bolt
4 Bolt 11 Nut
5 Handle assembly 12 Door engine L P63-74
6 Grommet a: Swing door arm L P63-48
7 Door engine cover
*b: Side door trim L P63-50
*
P Installation sequence
Follow the removal sequence in reverse.

63-70
 63
T Tightening torque Unit: N?m {kgf?m}
Location Parts to be tightened Tightening torque Remarks
1 Bolt (Door lockout actuator installation) 3.9 to 5.9 {0.4 to 0.6} –
4 Bolt (Handle assembly installation) 3.9 to 5.9 {0.4 to 0.6} –
10 Bolt (Door engine installation) 17 to 25 {1.7 to 2.6} –
11 Nut (Door engine installation) 17 to 25 {1.7 to 2.6} –

R Service procedure
P Pre-installation inspection and adjustment
Side door operation adjustment
• Check that the door moves smoothly when operated by hand before
beginning installation work.
• If the door does not open and close smoothly, inspect door areas A
through D and correct any problems. L P63-33

A: All weather strips

B: Door latch
C: Guide arm
74425 D: Door arm installation area

P Post-installation inspection and adjustment

(1) Side door operation adjustment
• After installation check the door to see if it moves smoothly when op-
12
erated by hand.

A: Toward the front of the vehicle

B: When the door is closed
C: When the door is opened
D: Door engine arm
E: Entrance pillar
71269

63-71
AUTOMATIC DOOR SYSTEM <SWING DOOR:ELECTRIC TYPE>

12 (2) Microswitch operation adjustment

Bend microswitch A and lever B and when the switch sounds with a
“click” sound adjust the clearance between door C and front entrance
pillar D within the range of 40 to 50 mm.

E: Area around door lock

71270

71271

2 Door lockout actuator removal

• Remove side door trim b.
LP63-50
*
• Remove rod clip A and remove the connection with remote control B.
• Remove installation bolt 1 and remove door lockout actuator 2.

71272

8 E-ring removal
Remove E-ring 8 and then remove door engine 12 and swing door arm
assembly a.
*
12

8
71273

12 Door engine installation

Check that the door engine 12 installation surface is flat and without de-
pressions or rises. If there are depressions or rises, repair so that the
surface is flat.
CAUTION k
If the door engine is installed without the depressions or rises
12 being repaired, the door will not open and close smoothly.

74426

63-72
 63
Door Lockout Actuator
P Disassembly sequence
1 E-ring
2 Link
3 Wave washer
4 Motor bracket
5 Adapter harness
6 Lockout motor

P Assembly sequence
Follow the disassembly sequence in re-
verse.
CAUTION k
If E-ring 1 or wave washer 3 are worn
or deteriorated, replace them with new
parts.

71275

63-73
AUTOMATIC DOOR SYSTEM <SWING DOOR:ELECTRIC TYPE>
Door Engine

71276

P Disassembly sequence
1 E-ring 8 Collar 15 Grommet
2 Joint pin 9 Dog 16 Box bracket
3 Link 10 Arm collar 17 Control box
4 Link collar 11 Rubber cover 18 Motor (24V)
5 Plate 12 Wire harness set 19 Gear box assembly
6 Arm 13 Separator
7 Plate spring 14 Lead handle

P Assembly sequence
Follow the disassembly sequence in reverse.

63-74
 63
Automatic Door System Inspection
(1) Door opening and closing, switch, and instrument operation
Automatic Door Parking brake Brake indicator Door lockout Door open/ Starter
door switch switch switch lamp actuator close switch
OPEN OFF OFF Does not turn on Lock Does not open ON
OPEN ON ON Turns on Operates Opens ON
OPEN ON OFF Does not turn on Operates Opens ON
CLOSE OFF Lock Closes ON

Door switch ON Door open

OFF Door close
Parking brake ON Pull lever (brake operates)
switch OFF Return lever (brake releases)

(a) Buzzer
When the automatic door switch is set to OPEN or CLOSE, a buzzer is activated, and the door starts operation after
about 1 second.

(b) Automaticx Manual change microswitch

The microswich is linked with the lead handle mounted on the door engine.
When the lead handle is set to the MANUAL position, the door can be opened and closed manually.

(c) Door lock system

Even if the door is locked (with the key from the outside of the vehicle or by pressing the lock button in the vehicle),
the door lock can be automatically disengaged by setting the automatic door switch to OPEN as long as the lead han-
dle is at the AUTOMATIC position (Automatic x Manual change microswitch at AUTOMATIC position).

(2) Accelerator interlock operating conditions (when engine is rotating)

Automatic door Accelerator
Neutral switch Parking switch Key position State of door
actuator interlock
OFF OFF ON Open Disabled from Operates
* Closed opening Does not operate
ACC Open
Closed
ON ON Open Enabled to open
Closed
ACC Open
Closed
ON OFF ON Open
Closed
ACC Open
Closed
ON ON Open
Closed
ACC Open
Closed
s s OFF s Allows to operate s
manually

*In case of A/T vehicles, the neutral switch is off with the selector lever in P or N range.

63-75
AUTOMATIC DOOR SYSTEM <SWING DOOR:ELECTRIC TYPE>
(3) Flow chart

<When open> <When closed>

Starter switch Starter switch

Automatic door Automatic door

switch OPEN switch CLOSE

Warning buzzer
Is the gear in NO sounds for 1 second
neutral or the parking
brake pulled?

Warning buzzer Is door before NO

sounds for 1 second completely open to
completely open
zone?

Door cannot be
Door lock released YES
opened
Door high-speed Door low-speed
operation operation
Door low-speed
operation

Is an Is an
excessive YES
excessive
Is an load applied load applied
exessive YES
load applied
NO
NO
Stops at that time Stops at that time
Completely opens Completely opens
and the buzzer and the buzzer
and stops continues to sound and stops
continues to sound

Has 5 seconds Has 5 seconds

passed after the passed after the
NO emergency stop? emergency stop? NO

YES YES

63-76
 63
(4) Timing Chart

<A> <B>

C J

D D
1 second

F 1 second
E

G G K
F

H L M

78580

A: Opening time G: Low speed

B: Closing time H: Fully open position
C: Auto door switch “Open” J: Auto door switch “Close”
D: Warning buzzer K: High speed
E: Lockout L: Before fully closed
F Motor M: Fully closed position

63-77
FRONT AND REAR WINDOW GLASS

K
K K
7
8 3 K
2

6
6

X
5 X
4

7 1
8
K
K
5
X
78598
P Disassembly sequence
1 Front window glass assembly 6 Rear window glass assembly
2 Weather strip 7 Weather strip
3 Front window glass 8 Rear window glass
4 Weather strip (Nittoh sealant No. 687)
5 Weather strip (Orotex BM 4 x 8) X : Non-reusable parts

P Preparation before assembly

L P63-79

P Assembly sequence
Follow the disassembly sequence in reverse.

K Sealant
Location Point of application Specified sealant Quantity
2, 3 Contact surfaces of weather strip and front window glass CEMEDINE CS3061-6AL As required
7, 8 Contact surfaces of weather strip and rear window glass CEMEDINE CS3061-6AL As required

63-78
 63
R Service procedure
P Preparation before assembly
• Remove adhesive and weather strips 4, 5 remaining on the mounting
surface on the body, and clean the surface with unleaded gasoline.
(Let it dry for at least 3 minutes.)
• Repair paint damage and rust on the mounting surface of the body, if
any.
• When reusing front window glass 3 and rear window glass 8, remove
adhesive and weather strips 4, 5 from the glass and clean the mount-
ing surfaces with unleaded gasoline. (Let it dry for at least 3 minutes.)
1 Front window glass assembly
2 [Removal]
While lifting lip section A of weather strip 2, push front window glass as-
1
sembly 1 toward the outside.
B: Screwdriver
B
A

78604

[Installation]
• Insert a strong cord C into the body-side mounting groove of weather
strip 2, providing cord overlapping section D as shown in the dia-
2 gram.

C 78607

• Press front window glass assembly 1 strong force from the outside of
the vehicle, and pull the end of cord C from the inside to engage the
inside mounting groove of weather strip 2 with the flange lip section
of the body.

1
2

C
00032

C • Pull out cord C in the order indicated in the diagram. At the same
time, tap with a rubber hammer from the outside of the vehicle to set
front window glass assembly 1 securely into place.
F E: Approx. 100 mm from the end of straight section
F: End of straight section

00033

63-79
FRONT AND REAR WINDOW GLASS
2 Installation of weather strips
2 A: Inside vehicle
B: Outside vehicle
3
3

A B 78608

5 4 Installation of weather strip (Nittoh sealant No. 687)

4 Install weather strip 4 (Nittoh sealant No. 687) on the entire perimeter of
the section of the body to which front window glass assembly 1 is at-
tached.
4

78606

5 Installation of weather strip (Orotex BM 4 x 8)

120 mm 120 mm Install weather strip 5 (Orotex BM 4 x 8) to the sections of the body indi-
cated in the diagram to which front window glass assembly 1 is at-
120 mm 120 mm tached.

5
5
78605

6 Rear window glass assembly

The service procedure is the same as for front window glass assembly
1. L P63-79

7 Installation of weather strips

7
A: Inside vehicle
8 B: Outside vehicle
8

B A 78557

63-80
 63

MEMO

63-81
SAFETY WINDOW GLASS
P Disassembly sequence
1 Safety window glass
2 Window dam
3 Lock fastener
4 Safety window glass
5 Lock fastener
: Body
1 K *
X: Non-reusable parts

4 K
5 NOTE
*
K X Do not remove lock fastener 5 unless
they need to be replaced.
2
3 P Preparation before assembly
X
X L P63-82
78599

P Assembly sequence
Follow the disassembly sequence in re-
verse.
K Sealant
Location Point of application Specified sealant Remarks
Entire perimeter of body contacting surface of safety window glass
Sika Cleaner 205 As required
assembly.
1
Entire perimeter of body contacting surface of safety window glass
Sika Flex 250PC As required
assembly.
4 Repair of ceramic coat on safety window glass. Sika Primer 206G+P As required
Entire perimeter of safety window glass assembly contacting surface
Sika Cleaner 205 As required
of body.
*
Repair of paint damage and peeling on body. Sika Primer VP209 As required

R Service procedure
P Preparation before assembly
• Remove adhesive and window dam 2 remaining on the mounting
surface on body , and clean the surface with unleaded gasoline.
*
(Let it dry for at least 3 minutes.)
• Repair paint damage and peeling on the mounting surface of body
* with the primer (Sika Primer VP209).
• When reusing safety window glass 4, remove adhesive from the
glass and clean the mounting surface with unleaded gasoline. (Let
it dry for at least 3 minutes.)
• If the ceramic coating has been removed from the safety window
glass 4, apply the primer (Sika Primer 206G+P) to repair.

63-82
 63
1 Safety window glass assembly
5 3 [Removal]
4 Cut and separate adhesive A from window dam 2 located between
safety window glass 4 and body , and remove safety window glass as-
B *
A sembly 1.

2 B: Cutting machine

78609 CAUTION k
To prevent scratches on safety window glass 4 and body ,
*
leave a layer of about 1 mm of window dam 2 and adhesive A on
the safety window glass.

[Installation]
• Apply cleaner C (Sika Cleaner 205) on the mounting surface of body
to which safety window glass assembly 1 is attached, and leave it
*
for 5 to 10 minutes to dry.
CAUTION k
• Smoothen any dents, dimples and ridges at joints on body , by
*
carefully applying cleaner C (Sika Cleaner 205).
• Do not touch the applied cleaner with hand or allow oil or
grease to adhere. If the applied cleaner is touched or contacts
* C 78627
oil or grease, safety window glass assembly 1 cannot be ad-
hered securely. When this happens, repeat the cleaner applica-
tion procedure.

• Apply adhesive A (Sika Flex 250PC) on safety window glass assem-

2 bly 1 along window dam 2. In this step, observe the following cau-
tions.
A
WARNING k
Adhesive A (Sika Flex 250PC) is made of urethane. Mixing it
with other silicon sealants or using in a workplace where other
silicone sealants are used can produce a harmful gas.
1

78562
NOTE
• Apply adhesive A (Sika Flex 250PC) continuously and evenly on
the entire perimeter, making sure that the adhesive forms a tri-
angular cross-sectional shape as shown in the diagram.
• Since adhesive A (Sika Flex 250PC) hardens quickly, be sure to
complete the installation (described in the following section) of
safety glass assembly 1 within 8 minutes from the time of adhe-
sive application.

63-83
SAFETY WINDOW GLASS
• lnstaIl safety window glass assembly 1 by pressing it lightly, making
5 sure that lock fasteners 3 engage securely with lock fasteners 5.

3 CAUTION k
• Do not touch applied cleaner C (Sika Cleaner 205) or allow oil or
grease to adhere. If the applied cleaner is touched or contacts
oil grease, safety window glass assembly 1 cannot be adhered
securely. When this happens, repeat the cleaner application pro-
1 cedure.
* C • lf adhesive A (Sika Flex 250PC) extends from safety window
2 glase assembly 1, remove the excess adhesive before it hardens
and clean with unleaded gasoline.
A
3
5
4
5
3
A
2
78617

2 Installation of window dam

• Apply cleaner A (Sika Cleaner 205) on safety window glass 4, and
15 mm leave for 5 to 10 minute to dry.
CAUTION k
4 Do not touch applied cleaner A (Sika Cleaner 205) or allow oil or
grease to adhere. If the applied cleaner is touched or contacts
oil or grease, safety window glass assembly 1 cannot be ad-
A hered securely. When this happens, repeat the cleaner applica-
78602 tion procedure.

• Adhere window dam 2 to the section of safety window glass 4 applied

with cleaner A(Sika Cleaner 205) .
2

4
A
2

78610

3 Installation of lock fasteners

3
30 mm

14 mm
3
78603

63-84
 63
5 Installation of lock fasteners
Install lock fasteners 5 on body at locations corresponding to the po-
*
sitions of lock fasteners 3 on safety window glass 4.

63-85
SIDE WINDOW GLASS < SLIDING WINDOW >

K
1 6
4
3

4
2

K 5

12
K
18
17 K X
16 X 11
K 7
14 21
16
K
20
18

22
17 K X K 19
20 7
X K 15 11
10
21
13 9
K 22 10
X K 19 8
7

9 10
8
10
8

78600

63-86
 63
P Disassembly sequence
1 Joint cover 13 Weather strip
2 Trim joint 14 Weather strip
3 Trim 15 Weather strip
4 Clip 16 Run channel
5 Side window assembly (near assistant seat) 17 Spacer
6 Side window assembly 18 Spacer
7 Glass assembly 19 Spacer
8 Connector assembly 20 Stopper
9 Lock assembly 21 Lock plate
10 Glass 22 Sash assembly
11 Center seal assembly
12 Weather strip X : Non-reusable parts

P Preparation before assembly

LP63-87

P Assembly sequence
Follow the disassembly sequence in reverse.

K Sealant
Location Points of application Specified sealant Quantity
5, 6 Body contacting surface of side window assembly Butyl rubber tape (Orotex 380 or equivalent) As required
13 to 15 Weather strip joint CEMEDINE 650 As required
17 to 19 Sash contacting surface of spacer Prime (Sumitomo 3M K-500) As required

R Service procedure
P Preparation before assembly
• Remove butyl rubber tape remaining on side window assemblies 5, 6
and body side.
• Clean side window assemblies 5, 6 and body side with isoprophyl al-
cohol.
• Repair paint damage and rust on the mounting surface of the body, if
any.

1 to 3 Installation of Joint covers, trim joints and trims

1, 2, 3 Install joint cover 1, trim joint 2 and trim 3, making sure that longer
flange A is positioned inside the vehicle.
A NOTE
Make sure the joint of trim 3 is not located at the clip 4 installa-
tion position.

78612

63-87
SIDE WINDOW GLASS < SLIDING WINDOW >
4 Installation of clips
150 mm 150 mm
150 mm
4

5
150 mm

150 mm 150 mm
50 mm 50 mm
150 mm " " " " 150 mm

150 mm " " 150 mm

78601

5 6 Side window assembly (assistant seat side) and side win-

B
dow assemblies
A [Removal]
5, 6 • Using a sharp knife, cut butyl rubber tape B which is securing side
window assemblies 5, 6 to body A.

NOTE
Make sure butyl rubber tape B is cut completely, If not, side win-
dow assemblies 5, 6 are difficult to detach.
78611

• Position glass assembly 7 or glass A at the center, and press the up-
per section of side window assembly 5, 6 toward the outside to re-
5, 6
move.

7, 10 74434

[Installation]
• Attach butyl rubber tape B to the entire perimeter of the body con-
tacting surface of side window assemblies 5, 6. Make sure the tape
joint is at the bottom.
• Install side window assemblies 5, 6 to the body.

B 5, 6
78565

63-88
 63
7 10 Removal of glass assembly and glass
Hold sash assembly 22 securely, and lift the upper section of the sash
assembly to remove glass assembly 7 or glass 10.

22

7, 10
78568

12 10 mm 12 Installation of weather strip

22

78569

A 13 to 15 Installation of weather strips

14
Glue joint sections of weather strips 13, 14, 15 securely with adhesive
A.
15

A 13 78613

63-89
SIDE WINDOW GLASS < FIXED WINDOW >

K 4
1

X 8

K 10
7
X K
K 6

5 3

9
K

78571
78571
P Disassembly sequence
1 Joint cover 7 Weather strip
2 Trim 8 Weather strip
3 Clip 9 Spacer
4 Side window assembly 10 Sash assembly
5 Weather strip
6 Glass X : Non-reusable parts

P Preparation before assembly

L P63-91

P Assembly sequence
Follow the disassembly sequence in reverse.

K Sealant
Location Point of application Specified sealant Quantity
4 Body contacting surface of side window assembly Butyl rubber tape (Orotex 380 or equivalent) As required
5 to 7 Contact surfaces of weather strip and glass Sunstar Penguin Seal 960 As required
9 Sash assembly contacting surface of spacer Prime (Sumitomo 3M K-500) As required

63-90
 63
R Service procedure
P Preparation before assembly
• Remove butyl rubber tape remaining on side window assembly 4 and
body side.
• Clean side window assembly 4 and body side with isoprophyl alcohol.
• When reusing glass 6, remove sealant from the glass and clean the
mounting surface with unleaded gasoline. (Let it dry for at least 3
minutes.)
• Repair paint damage and rust on the mounting surface of the body, if any.

1 2 Installation of joint cover and trim

1, 2 Install joint cover 1 and trim 2, making sure that longer flange A is posi-
tioned inside the vehicle.
A NOTE
Make sure the joint of trim 2 is not located at the clip 3 installa-
tion position.

78576

3 Installation of clips
50 mm 50 mm
150 mm 150 mm

150 mm 150 mm
< Most end part >
50 mm 50 mm

50 mm 50 mm
78575

B 4 Side window assemblies

[Removal]
4 • Using a sharp knife, cut butyl rubber tape B which is securing mount
4 side window assembly 4 to body A.

NOTE
Make sure butyl rubber tape B is cut completely, If not, side win-
dow assembly 4 is difficult to detach.

78572

63-91
SIDE WINDOW GLASS < FIXED WINDOW >
• Press the upper section of side window assembly 4 toward the out-
side to remove.

78624

[Installation]
• Attach butyl rubber tape B to the entire perimeter of the body con-
4 tacting surface of side window assembly 4. Make sure the tape joint
is at the bottom.
• Install side window assembly 4 to the body.

78574

6 Glass
6
A [Removal]
• Remove weather strip 5, and detach glass 6.
5 7
[Installation]
• Apply sealant A to the contact surfaces of weather strips 5, 7 and
glass 6, and install.
10
78577

10 mm 8 8 Installation of weather strip

10

78614

63-92
 63

MEMO

63-93
FRONT BUMPER

*a 5T

5T
*
c

3T

5 T
T 2

6
1 4 *
b

79870

63-94
 63
P Disassembly sequence
1 Molding 7 Headlamp bracket
2 Bolt
3 Bolt *a: Radiator grille
4 Headlamp bezel Cornering and clearance lamps B
5 Bolt
*b:
c : Headlamps B Electrical
Electrical
*
6 Front bumper assembly

P Assembly sequence
Follow the disassembly sequence in reverse.

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
Bolt (headlamp bezel, headlamp, and bracket in-
2, 3 4 to 8 {0.4 to 0.8} –
stallation)
Bolt (headlamp bracket and front bumper assembly
5 9 to 14 {0.1 to 1.4} –
installation)

63-95
REAR BUMPER

74454

P Removal sequence
1 Grommet
2 Bracket
3 Rear bumper assembly

a: Cross member
*b:
* Rear pillar
P Installation sequence
Follow the removal sequence in reverse.

63-96
GARNISH 63
P Removal sequence
1 Rear garnish
2 Trim clip
3 Weather strip

74455

R Service procedure
3 Weather strip installation
• Glue weather strip 3 (use appropriate division) on the body at the po-
sitions shown in the illustration.

74456

63-97
INSTRUMENT PANEL
Lower Panel

*
5

4 2
7
8

74457

P Disassembly sequence
1 Cigarette lighter 7 Lower side panel
2 Ashtray 8 Fuse box lid
3 Center lower panel 9 Washer tank lid
4 Lower panel bracket
5 Idle control knob L P63-100
6 Driver’s lower panel
*: Instrument panel

P Assembly sequence
Follow the disassembly sequence in reverse.

63-98
 63
Area around Meter

2
3
1

74458
P Disassembly sequence
1 Switch 5 Automatic air control panel B Electrical
2 Center upper panel assembly
3 Meter cluster B Electrical
4 Radio and cassette deck B Electrical
*: Instrument panel L P63-100

P Assembly sequence
Follow the disassembly sequence in reverse.

63-99
INSTRUMENT PANEL
Instrument Panel

2
T4
5

11 T

12

T
7
T9
T11
10

7
7 T
7 T
T

74459

63-100
 63
P Disassembly sequence
1 Instrument panel bracket 8 Center frame support
2 Oil tank lid 9 Bolt
3 Glove box 10 Instrument panel support bracket
4 Bolt 11 Bolt
5 Instrument panel 12 Instrument panel frame
6 Air outlet grill
7 Bolt

P Assembly sequence
Follow the disassembly sequence in reverse.

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
4 Bolt (instrument panel installation) 5.3 ± 1 {0.54 ± 0.1} –

7 Bolt (center frame support installation) 4.71 ± 1 {0.48 ± 0.1} –

9 Bolt (instrument panel support bracket installation) 4.71 ± 1 {0.48 ± 0.1} –

11 Bolt (instrument panel frame installation) 11.2 ± 2 {1.14 ± 0.2} –

63-101
FRONT HEAD LINING

P Removal sequence
1 Molding clip
2 End cap
3 Head lining molding
4 Glove box lid
5 Glove box
6 Spring nut
7 Front head lining
8 Head lining support rail
9 Front head lining bracket

X : Non-reusable parts

P Installation sequence
Follow the removal sequence in reverse.

74460

R Service procedure
P Preparatory work before removal
• Remove clock A, air outlet grill B, mirror C, sun visor D, etc.
CAUTION k
• The mirror and sun visor are fastened by the same screws as
front head lining 7.
• For clock removal see B Electrical

74775

E: Flat head screwdriver

71331

63-102
 63

3 Head lining molding removal

• Lowering head lining molding 3 will bring molding clip 1 into view, so
cut it off using scissors or a cutter knife.

B: Center head lining

CAUTION k
When cutting off the molding clip 1 be careful not to damage the
head lining.
71333

4 5 Glove box lid and glove box removal

• Open glove box lid 4 and remove the top installation screws.

71335

• Remove the screws and then remove glove box lid 4 and glove box 5.

74464

9 Front head lining bracket removal

71337

63-103
CENTER HEAD LINING
PRemoval sequence
1 Molding clip
2 End cap
6 3 Head lining molding
4 Cooler duct cover
5 Line light
6 Center head lining
7 Clip
6 8 Cooler duct
9 Cooler duct sheet
5
1X
X : Non-reusable parts
2
PInstallation sequence
3
9 Follow the removal sequence in reverse.

79807

R Service procedure
P Preparatory work before removal
• Remove room lamp A, speaker B, rack C, air outlet grill D, etc.
CAUTION k
• For room lamp and speaker removal see B Electrical

74776

63-104
 63
E: Flat head screwdriver

71331

3 Head lining molding removal

• Lowering head lining molding 3 will bring molding clip 1 into view, so
cut it off using scissors or a cutter knife.

B: Roof bow

CAUTION k
When cutting off the clip be careful not to damage the head lin-
ing.
71341

4 Cooler duct cover removal

A: Flat head screwdriver

74467

6 Center head lining removal

Remove center head lining 6 from trim support rail A and then remove it
from the roof.

74468

8 9 Cooler duct and cooler duct sheet removal

• Remove screw A and open the cooler duct 8.
• Remove clip 7 and remove cooler duct sheet 9 from the body.

74469

63-105
REAER HEAD LINING

P Removal sequence
1 Molding clip
8 2 End cap
3 Head lining molding
4 Christmas tree clip
5 Rear head lining cover
8 3 1X 6 Rear head lining
2 7 7 Spring nut
6
8 Head lining support rail

X : Non-reusable parts

P Installation sequence
Follow the removal sequence in reverse.

5
4

79808

R Service procedure
P Preparatory work before removal
A: Flat head screwdriver
B: Air outlet grill

71331

3 Head lining molding removal

• Lowering head lining molding 3 will bring molding clip 1 into view, so
cut it off using scissors or a cutter knife.

A: Center head lining

CAUTION k
When cutting off the clip be careful not to damage the head lin-
ing.
71333

63-106
 63
5 Rear head lining cover removal
Remove the installation screw and then remove rear head lining cover 5.

71350

63-107
OUTSIDE REAR VIEW MIRROR
Driver’s Side Mirror Stay
1 P Disassembly sequence
1 Mirror
2 Stay
P Assembly sequence
Follow the disassembly sequence in reverse.

74475

R Service procedure
2 Stay installation
Align alignment mark A as shown in the illustration and install stay 2.

2 74476

63-108
 63
Assistant Driver’s Side Mirror Stay
P Disassembly sequence
1 Mirror
1 2 Under mirror
3 Stay

* : Front panel
2
P Assembly sequence
Follow the disassembly sequence in re-
verse.

*K

74479

K Sealant
Location Point of application Specified sealant Quantity

All edge of front panel notch and screw installation hole OROTEX 725FX As required
*
R Service procedure
3 Stay installation
Align alignment mark A as illustrated and install stay 3.

74480

63-109
FRONT WIPERS AND WASHER

K
9
12

T 8 14 15
7
6
16
1 10

13 KX

11

17
4

5 3

74484

P Disassembly sequence
1 Nut 11 Motor bracket
2 Wiper arm and blade assembly 12 Wiper link assembly
3 Wiper blade 13 Washer nozzle assembly
4 Blade rubber 14 Grommet
5 Wiper arm 15 Cable strap
6 Pivot cap 16 Tube
7 Not 17 Washer tank motor assembly B Electrical
8 Collar
9 Seal rubber X : Non-reusable parts
10 Wiper motor B Electrical

CAUTION k
Before disassembling parts 10 to 12 and 14 to 16, remove the instrument panel to allow access to them.
L P63-98

P Assembly sequence
Follow the disassembly sequence in reverse.

63-110
 63
Service standards Unit: mm
Location Maintenance item Standard value Limit Remedy
Driver’s side 7.06 ± 0.5N {0.72 ± 0.05kgf} – Replace
5 Wiping force of wiper arm
Passenger side 6.17 ± 0.5N {0.63 ± 0.05kgf} – Replace

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
7 Nut (wiper link assembly installation) 11.8 ± 2 {1.2 ± 0.2} –

K Sealant
Location Points of application Specified sealant Quantity
9 Entire seal rubber installation area CEMEDINE 366 Deluxe As required
13 Entire washer nozzle installation area CEMEDINE 366 Deluxe As required

R Service procedure
2 Wiper arm and blade assembly installation
Install wiper arm and blade assembly 2 so that the distance from the
end of weather strip A is 38 ± 5mm on the driver’s side and 52 ± 5mm
on the passenger side.
A

2 38 w 5 mm 52 w 5 mm
71365

5 Wiper arm inspection

Measure the wiping force of wiper arm 5 when in the illustrated position.
If the measured value deviates from the standard value replace the wip-
er arm.

06156

63-111
FRONT WIPERS AND WASHER
13 Washer nozzle assembly
[Inspection]
• Inspect washer nozzle assembly 13 to make sure it is not clogged.
• If jet hole A is clogged, clean it using wire B (φ0.9 mm diameter or
less).

71366

[Removal]
• Grip washer nozzle assembly 13 with pliers C.
• While pulling, bend claw D and remove washer nozzle assembly 13
taking care not to damage body outer panel E.
• Remove tube 16.

71946

[Installation]
• Replace washer nozzle assembly 13 with a new one.
• Connect tube 16 and install washer nozzle assembly 13.

71947

[Adjustment]
• Make sure that washer fluid spreading target positions H are 400 mm
H from the edge of weather strip F as illustrated.

H • If washer fluid spreading target positions H deviate from this dimen-

sion, adjust angle of jet hole A of washer nozzle assembly 13 using
400 mm

wire B.
CAUTION k
Be careful not to damage jet hole of the washer nozzle.
13 13
F

13
71367

63-112
 63

MEMO

63-113
SEAT BELT (DRIVER’S SIDE)

3T

6
4 1T
T

7T
8

79809

P Removal sequence
1 Bolt 4 Bolt 7 Bolt
2 Shoulder anchor cover 5 Screw 8 Buckle
3 Bolt 6 ELR (Emergency Locking Retractor)

P Installation sequence
Follow the removal sequence in reverse.

CAUTION k
The ELR (Emergency Locking Retractor) 6 must never be disassembled.

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks
1 Bolt (floor anchor installation) 34.3 to 53.9 {3.5 to 5.5} –

3 Bolt (shoulder anchor installation) 34.3 to 53.9 {3.5 to 5.5} –

4 Bolt (ELR installation) 34.3 to 53.9 {3.5 to 5.5} –

7 Bolt (buckle installation) 34.3 to 53.9 {3.5 to 5.5} –

63-114
 JULY 2003
654