GROUNDDISTRIBUTION
GROUND CONNECTTO CONN.
NO. CELLCORD
E37/E51 AIRBAG DIAGNOSIS SENSORUNIT(Single
E108 RS-SRS
air bag system)
BRAKE FLUIDLEVEL SWITCH E2EL-WARN
CLEARANCE LAMPLH E50EL-TAILIL
CLEARANCE LAMPRH E33EL-TAILIL
COOLING FANMOTOR-1 (1-modetype) E45 EC-COOLIFHA-A/C
COOLING FANMOTOR-1 (2-modetype-GA
E66 EC-COOLIF
HA-A/C
engine forEurope)
COOLING FANMOTOR-1 (2-modetype-ex-
E46 EC-COOLIF
HA-A/C
eept GAengine forEurope)
COOLING FANMOTOR-2 (1-modetype)
E39 EC-COOLIFHA-A/C
-
COOLING FANMOTOR-2 (2-modetype-GA
E67 EC-COOLiF
HA-A/C
engine forEurope)
COOLING FANMOTOR-2 (2-modetype-ex-
E40 EC-COOLIFHA-A/C
eept GAengine forEurope)
COOLING FANRELAY-1 E12
EC-COOLIFHA-A/C
COOLING FANRELAY-2 E17
EC-COOLIFHA-A/C
COOLING FANRELAY-3 E18EC-COOLIF
HA-A/C
DAYTIME LIGHTUNIT E119EL-DTRL
FRONT FOGLAMP LH E52EL-F/FOG
FRONT FOGLAMP RH
E36EL-F/FOG
FRONT TURNSIGNAL LAMPLH E53EC-TURN
FRONT TURNSIGNAL LAMPRH E32EC-TURN
FRONT WIPERANDWASHER SWITCH E113
EL-WIPER
FUEL FILTER SWITCH
E5EL-WARN
HEADLAMP AIMINGMOTOR UNITLH E48
EL-AIM
HEADLAMP AIMINGMOTOR UNITRH E35 EL-AIM
HEADLAMP LH E49EL-H/LAMP
EL-DTRL
HEADLAMP RH E34EL-H/LAMP
EL-DTRL
HEADLAMP WIPERMOTOR LH E44
EL-HLC
HEADLAMP WIPERMOTOR RH E41EL-HLC
IACV-FICD SOLENOID VALVE(LHDmodels
.
E65 EC-A/CCUTHA-A/C
with CD20 engine)
INHIBITOR SWITCH E222EC-PNP/SWAT-A
IT EL-START
NEUTRAL POSITION SWITCH E220EC-PNP/SW
POWER STEERING OILPRESSURE SWITCH
E3 EC-PST/SW
(RHO models withgasoline engine)
REAR FOGLAMP RELAY E20EL-R/FOG
REAR WIPER ANDWASHER SWITCH E112EL-WIP/R
REAR WIPER RELAY E15EL-WIP/R
SIDE TURN SIGNAL LAMP(Driver side) E1 EL-TURN
WASHER FLUIDLEVEL SWITCH E30EL-WARN
EL-20
I;)
1
CHECK INPUTSIGNAL CIRCUIT. NG
Repair harness orcon-
1. Stop engine.
--.
nectors.
2. Disconnect ECMharness connector
and heated oxygen sensorharness
connector.
3. Check harness continuity between
ECM terminal
@
or
@
and terminal
@.
Continuity shouldexist.
If OK, check harness forshort.
1
0K
CHECK HEATED OXYGEN SENSOR OK
Goto"CHECK
HEATER CIRCUIT.
--.
COMPONENT".
1. Reconnect harnessconnectors.
2. Start engine.
3. Check voltage between ECMterminal
@
(ForEurope andIsrael) or
@
(For Australia AfTmodels) and
ground withCONSULTor tester
under thefollowing conditions.
Voltage:
Engine speedisbelow 3,200rpm
Approximately OV
Engine speedisabove 3,200rpm
Battery voltage
NG
[!J
CHECK POWER SUPPLY. NG
Check thefollowing.
1. Stop engine.
~
•Harness connectors
2. Disconnect heatedoxygen sensor
aD,@
harness connector. •10A fuse
3. Turn ignition switch"ON".
•Harness foropen or
4. Check voltage between terminal
@
shortbetween heated
and ground. oxygensensorand
Voltage: Batteryvoltage fuse
If NG, repair harness or
OK connectors.
CHECK OUTPUT SIGNALCIRCUIT. NG
Repair harness orcon-
1. Turn ignition switch"OFF".
-----...
nectors.
2. Disconnect ECMharness connector.
3, Check harness continuity between
terminal
G)
and ECM terminal
@
(For Europe andIsrael) orGill (For
Australia
AfT
models) .
Continuity shouldexist.
If OK, check harness forshort.
t
OK
SEF180R
SEF646P
SEF181R
~i5
cilltD
@:
ForAustralia NTmodels
@:
ForEurope andIsrael
TROUBLE
DIAGNOSIS FORNON-DETECTABLE ITEMS
Heated Oxygen Sensor(H02S) (Cont'd)
@
~
~
I;) ~i5
Il
ECM
'QcoNNECTORII
46 19
For Europe andIsrael, andGA15DE.L.J
engine models
Engineground
@,
@
----- \
~ ~
'1
\
.~
,~\ C/
Power steering",
fluid reservoir __\ ~
W~
:'C"",,
EC-192
WithoutVTC
Engine front
Unit: mm(in)
~(0.39)
~1-J--10 (0.39)
* -\
3 (0.12)
Z~
Liquid
gasket
SEM59BEA TIMING
CHAIN
Installation (Cont'd)
29. Apply liquidgasket torocker covergasket.
•
With VTC
Cylinderhead
'l:tJ
~ /2.0-3.0mm
Cylinder headfront cover
(0.079-0.118 In)
With
VTC
28. Apply liquidgasket tomating surfaces ofthe cylinder head
and cylinder headfrontcovers showninthe figure.
With VTC
Engine front
Unit: mm(in)
SEM091F
7~'\
\ ..... -4'
~-'?
~'0391
~10 (0.39)
*
--1
3 (0.12)
Zr.a
liquid
gasket
SEM111F
29.
Apply liquidgasket torocker covergasket.
Without VTC
With VTC
30.
Install rocker coverandtighten innumerical orderasshown
in the figure.
31. Install allspark plugsandleads.
32. Install engine frontmounting bracketandmounting.
33. Install frontexhaust tube.
34. Install frontundercover.
35. Install frontright.splash cover.
36. Install frontrightwheel.
37. Install aircleaner.
38. Install power steering pulleyandpump withbracket.
To check power steering fluid,refertoMA section ("Check-
ing Power Steering FluidandLines", "CHASSIS ANDBODY
MAINTENANCE").
39. Drive belts.
For adjusting drivebeltdeflection, refertoMA section
("Checking DriveBelts", "ENGINE MAINTENANCE").
EM-29
HOWTOUSE THIS MANUAL
ManualTransaxle/Transmission
Automatic Transaxle/
Transmission
Air Conditioner
Power Steering
Special Service Tools
Society ofAutomotive Engineers,
Inc.
Automatic Transmission Fluid
Drive range 1stgear
Drive range 2ndgear
Drive range 3rdgear
Drive range 4thgear
Overdrive
2nd range 2ndgear
2nd range 1stgear
1st range 2ndgear
1st range 1stgear
A/C
PIS
Tool SAE
ATF
0
1
O
2
0
3
0
4
00
2
2
2
1
1
2
1
1
•
The following
SYMBOLS ANDABBREVIATIONS
areused:
to;J,
l\tI
Tightening torque M/T
IE!
Shouldbelubricated withgrease. A/T
Unless otherwise indicated,use
recommended multi-purpose
grease.
Should belubricated withoil.
Sealing point
Checking point
Always replaceafterevery disas-
sembly.
Apply petroleum jelly.
Apply ATF.
Select withproper thickness.
Adjustment isrequired.
Service DataandSpecifications
Left-Hand, Right-Hand
Front, Rear
IE!
~
@
*
1I
SDS LH, RH
FR, RR
• The
UNITS
giveninthis manual areprimarily expressed asthe SlUNIT (International SystemofUnit),
and alternatively expressedinthe metric system andinthe yard/pound system.
"Example" Tightening torque:
59 -78 N'm (6.0-8.0 kg-m, 43-58 ft-Ib)
• TROUBLE DIAGNOSES
areincluded insections dealingwithcomplicated components.
• SERVICE DATAANDSPECIFICATIONS
arecontained atthe end ofeach section forquick reference
of data.
• The captions
WARNING
and
CAUTION
warnyouofsteps thatmust befollowed toprevent personal
injury and/or damage tosome partofthe vehicle.
WARNING
indicatesthepossibility ofpersonal injuryifinstructions arenotfollowed.
CAUTION
indicatesthepossibility ofcomponent damageifinstructions arenotfollowed.
BOLD TYPED STATEMENTS
except
WARNING
and
CAUTION
giveyouhelpful information.
GI-8
CONTENTS(Cont'd.)
CHASSIS ANDBODY MAINTENANCE 45
Checking ExhaustSystem .45
Checking ClutchFluidLevel andLeaks .45
Checking ClutchSystem .45
Checking MfTOil .45
Changing MfTOil 46
Checking
AfT
Fluid Level .46
Changing
AfT
Fluid .47
Checking BrakeFluidLevel andLeaks 47
Checking BrakeSystem .47
Changing BrakeFluid .47
Checking BrakeBooster, VacuumHoses,
Connections andCheck Valve ~48
Checking DiscBrake .48
Checking DrumBrake .49
Balancing Wheels 49
Ti re Rotation 50
Checking SteeringGearandLinkage 50
Checking PowerSteering FluidandLines 50
Lubricating Locks,Hinges andHood Latches 51
Checking SeatBelts, Buckles, Retractors,
Anchors andAdjusters 51
Checking BodyCorrosion 52
GA
SERVICE DATAANDSPECIFICATIONS
(505)53
Engine Maintenance 53
SR
SERVICE DATAANDSPECIFICATIONS
(505)54
Engine Maintenance 54
CD
SERVICE DATAANDSPECIFICATIONS
(505)55
Engine Maintenance 55
SERVICE DATAANDSPECIFICATIONS
(505)56
Chassis andBody Maintenance 56
PRE-DELIVERYINSPECTIONITEMS
Shown belowarePre-delivery InspectionItemsrequired forthe new vehicle. Itis recommended that
necessary itemsotherthanthose listedherebeadded, payingdueregard tothe conditions ineach
country.
Perform applicable itemsoneach model. Consult textofthis section forspecifications .
UNDER HOOD-engine off
o
Radiator coolantlevelandcoolant hosecon-
nections forleaks
o
Battery fluidlevel, specific gravityandcondi-
tions ofbattery terminals
o
Drive beltstension
D
Fuel filter forwater ordusts, andfuel lines
and connections forleaks
[] Engine oillevel andoilleaks
D
Clutch andbrake reservoir fluidlevel and
fluid lines forleaks
o
Windshield andrear window washerand
headlamp cleanerreservoir fluidlevel
D
Power steering reservoir fluidlevel andhose
connections forleaks
ON INSIDE ANDOUTSIDE
D
Remove frontspring/strut spacer(Ifapplica-
ble)
D
Operation ofall instruments, gauges,lights
and accessories
o
Operation ofhorn(s), wiperandwasher
[] Steering lockforoperation
[] Check airconditioner forgas leaks
o
Front andrear seats, andseat belts foroper-
ation
n
All moldings, trimsandfittings forfitand
alignment
[J
Allwindows foroperation andalignment
n
Hood, trunklid,door panels forfitand align-
ment
[1
Latches, keysandlocks foroperation
rl
Weatherstrips foradhesion andfit
[l
Headlamp aiming
I~ Tighten wheelnuts(Inc. inner nutsifapplica-
ble)
IJ Tire pressure (Inc.spare tire)
Il
Check frontwheels fortoe-in
IJ Install clock/voltmeter/room lampfuse(If
applicable)
~ Install deodorizing filtertoair purifier (If
applicable)
~ Remove wiperbladeprotectors (Ifapplicable)
UNDER
BODY
o
Manual transmission/transaxle, transferand
differential gearoillevel
D
Brake andfuel lines andoil/fluid reservoirs
for leaks
D
Tighten boltsandnuts ofsteering linkageand
gear box,suspension, propellershaftsand
drive shafts
~ Tighten rearbody boltsandnuts (Models with
wooden bedonly)
ROAD TEST
D
Clutch operation
D
Parking brakeoperation
[J
Service brakeoperation
D
Automatic transmission/transaxle shifttiming
and kickdown
[] Steering controlandreturnability
o
Engine performance
D
Squeaks andrattles
ENGINE OPERATING ANDHOT
D
Adjust idlemixture andspeed (andignition
timing*1)
n
Automatic transmission/transaxle fluidlevel
~ Engine idlingandstop knob operation (Diesel
only)
FINAL INSPECTION
n
Install necessary parts(outside mirror,wheel
covers, seatbelts, mat,carpet ormud flaps)
[1
Inspect forinterior andexterior metaland
paint damage
[] Check forspare tire,jack, tools (wheel
chock), andliterature
n
Wash, cleaninterior andexterior
"1: Not required onmodels withadirect ignition system
~ :Not appiicable tothis model.
•
MA-5
PERIODICMAINTENANCE (ExceptforEurope)
Chassis andBody Service
Abbreviations: I
=
Inspect andcorrect orreplace asnecessary, RReplace, L
=
Lubricate.
MAINTENANCE OPERATION MAINTENANCE
INTERVAL
km x1,000 10
20 30 40
5060 70
80Refer-
Perform eitheratnumber ofkilometers (miles)or
ence
months, whichever comesfirst. (Miles
x1,000) (0.6)(6)(12) (18) (24)(30)(36) (42)(48)
page
Months 612 1824
3036 42
48
Underhood andunder vehicle
Brake, clutch
&
automatic transaxlefluidoroil (For
level
&
leaks)* MA-47,
45, 46
Brake fluid* R
RMA-47
Brake booster
vacuum
hoses,connections
&
check
valve
MA-48
Power steering fluid
&
lines (For
level
&
leaks)
""
I'
"
MA-50
Brake, clutch
&
exhaust systems MA-47,
45
Manual transaxle oil(For level
&
leaks)*
"
I'
I' I'
MA-45
MA-50
Steering gear
&
linkage, axle
&
suspension parts
&
drive
shafts* I'
FA-5
RA-4
Outside andInside
Wheel alignment,
If
necessary, rotate
&
balance wheels MA-49
FA-6
Brake pads,disc
&
other brake components* MA-48
Brake linings, drums
&
other brake components MA-49
Locks, hinges
&
hood latch* L'
LL' LL'
LL'
LMA-51
Seat belts, buckles, retractors, anchors
&
adjuster MA-51
BR-11,
Foot brake, parking brake
&
clutch (Forfreeplay, stroke
&
operation)
I'
I'
I'
I'
37
CL-5
Air bag system See
NOTE (1) RS-11
NOTE: (1)Inspect atthe first 10years, andthen every 2years.
*
Maintenance itemswith
"*"
should beperformed morefrequently accordingto"Maintenance UnderSevere Driv-
ing Conditions".
*:
Except
for
Australia models
MA-8
PERIODICMAINTENANCE (ForEurope)
Chassis andBody Services
Abbreviations: R
=
Replace. Inspect,andcorrect orreplace asnecessary.
MAINTENANCE OPERATION
MAINTENANCEINTERVAL
Steering gear
&
linkage, axle
&
suspension parts
&
exhaust system*
OutsideandInside
Wheel alignment (Ifnecessary, rotate
&
balance wheels)
Brake pads,disc
&
other brake components*
Brake linings, drums
&
other components*
Headlamp aiming
Foot brake, parking brake
&
clutch (Forfreeplay, stroke
&
operation)
Annually120
Reference page
(72)
48
MA-47,45MA-46
R MA-47
MA-48
MA-50
MA-47,45 MA-45
MA-50, 45,FA-5,
RA-4
FA-7
MA-49, FA-6
MA-48
MA-49 EL-75
BR-11, 37,CL-5
MA-52 RS-11
90
(54)
36
R
60
See NOTE (1)
(36)
24
30
(18)
12
km
x1,000
(Miles x1,000)
Months
Underhood andunder vehicle
Perform
eitheratnumber ofkilometers (miles)ormonths,
whichever comesfirst.
Brake booster vacuum hoses,connections
&
check valve
Brake
&
clutch oil(For level
&
leaks)*
Automatic transaxlefluid(Forlevel
&
leaks)*
Brake f1uid*
CHASSIS
ANDBODY
Power steering fluid
&
lines (Forlevel
&
leaks)
Brake
&
clutch systems
Manual transaxle oil(For leaks)*
Drive shafts*
Air bag system
Body
corrosion
NOTE:
*
Maintenance itemswith
"*"
should beperformed morefrequently accordingto"Maintenance undersevere driving
conditions" .
(1) Inspect atthe first 10years andthen every 2years.
MA-12