Page 275 of 2890
8
.
Electrical
Wiring
Harness
and
Ground
Point
Connector
Connecting
to
No
.
Pole
Color
Area
No
.
Name
R156
B-2
B97
Bulkhead
wiring
harness
(S
.M
.J
.)
R4
1
Black
B-2
Parking
brake
switch
R5
2B-2
Select
lever
illumination
light
R6
2
Black
B-2
Shift
lock
solenoid
R7
2B-2P
position
switch
RS
2B-2
Seat
belt
switch
R9
1
Brown
B-3Front
door
switch
LH
R11
8
B-4D21
Rear
doorcord
LH
R12
1
Brown
B-2
Front
door
switch
RH
R14
8
B-2
D27
Rear
door
cord
RH
R15
8B-3
R57
Fueltank
cord
R16
1
Brown
A-3
Rear
door
switch
RH
R30
2
Black
B-2
Diode
(Rear
gale
latch
switch)
R46
2
B3
R67
Fuel
lankcord
R50
2
Green
B-2
890
Bulkhead
wiring
harness
R52
2
A-3
Room
light
R57
S
B-3
R15
Rear
wiring
harness
R58
6
A-3
Fuel
gaugemodule
&
fuel
pump
R59
2
B-4
Fuel
gauge
submodule
R67
2
B-3
R46
Rear
wiring
harness
R68
2B-3
Pressure
control
solenoid
valve
R69
I
2
A-3
Vent
control
solenoid
valve
non-coiorea
A
B
C
n
6
.
REAR
WIRING
HARNESS
AND
GROUND
POINT
1
I
2
I
3
I
4
2
~S
4
[D806]
B6M0695A
A
B
C
u
Page 276 of 2890
8
.
Electrical
Wiring
Harness
and
Ground
Point
Connector
Connecting
to
No
.
Pole
Color
Area
No
.
Name
R156
B-2
B97
Bulkhead
wiring
harness
(S
.M
.J
.)
R4
1
Black
B-2
Parking
brake
switch
R5
2B-2
Select
lever
illumination
light
R6
2
Black
B-2
Shift
lock
solenoid
R7
2B-2P
position
switch
RS
2B-2
Seat
belt
switch
R9
1
Brown
B-3Front
door
switch
LH
R11
8
B-4D21
Rear
doorcord
LH
R12
1
Brown
B-2
Front
door
switch
RH
R14
8
B-2
D27
Rear
door
cord
RH
R15
8B-3
R57
Fueltank
cord
R16
1
Brown
A-3
Rear
door
switch
RH
R30
2
Black
B-2
Diode
(Rear
gale
latch
switch)
R46
2
B3
R67
Fuel
lankcord
R50
2
Green
B-2
890
Bulkhead
wiring
harness
R52
2
A-3
Room
light
R57
S
B-3
R15
Rear
wiring
harness
R58
6
A-3
Fuel
gaugemodule
&
fuel
pump
R59
2
B-4
Fuel
gauge
submodule
R67
2
B-3
R46
Rear
wiring
harness
R68
2B-3
Pressure
control
solenoid
valve
R69
I
2
A-3
Vent
control
solenoid
valve
non-coiorea
A
B
C
n
6
.
REAR
WIRING
HARNESS
AND
GROUND
POINT
1
I
2
I
3
I
4
2
~S
4
[D806]
B6M0695A
A
B
C
u
Page 712 of 2890
1. Clutch System
Condition Possible cause and testing Corrective action
1. Clutch slip-
pageIt is hard to perceive clutch slippage in the early stage, but pay attention to the following symptoms.
(a) Engine revs up when shifting.
(b) High speed driving is impossible; especially rapid acceleration impossible and vehicle speed does not increase in
proportion to an increase in engine speed.
(c) Power falls, particularly when ascending a slope, and there is a smell of burning of the clutch facing.
Method of testing: Put the vehicle in stationary condition with parking brake fully applied. Disengage the clutch and
shift the transmission gear into the first. Gradually allow the clutch to engage while gradually increasing the engine
speed. The clutch function is satisfactory if the engine stalls. However, the clutch is slipping if the vehicle does not
start off and the engine does not stall.
(a) No clutch pedal play Readjust.
(b) No release lever end play Readjust.
(c) Clutch facing smeared by oil Replace.
(d) Worn clutch facing Replace.
(e) Deteriorated diaphragm spring Replace.
(f ) Distorted pressure plate or flywheel Correct or replace.
(g) Defective release bearing holder Correct or replace.
(h) Defective pedal and cable system Correct or replace.
2. Clutch
drags.As a symptom of this trouble, a harsh scratching noise develops and control becomes quite difficult when shifting
gears. The symptom becomes more apparent when shifting into the first gear. However, because much trouble of the
this sort is due to defective synchronization mechanism, carry out the test as described after.
Method of testing: Refer to DIAGNOSTIC DIAGRAM on page after.
It may be judged as insufficient disengagement of clutch if any noise occurs during this test.
(a) Excessive clutch pedal play Readjust.
(b) Excessive clutch release lever play Readjust.
(c) Worn or rusty clutch disc hub spline Replace clutch disc.
(d) Excessive deflection of clutch disc facing Correct or replace.
(e) Seized crankshaft pilot needle bearing Replace.
(f ) Malfunction of pedal and cable system Correct or replace.
(g) Cracked clutch disc facing Replace.
(h) Sticked clutch disc (smeared by oil or water) Replace.
3. Clutch chat-
ters.Clutch chattering is an unpleasant vibration to the whole body when the vehicle is just started with clutch partially
engaged.
(a) Improper clutch cable routing Correct.
(b) Adhesion of oil on the facing Replace clutch disc.
(c) Weak or broken torsion spring Replace clutch disc.
(d) Defective facing contact or excessive disc Replace clutch disc defection.
(e) Warped pressure plate or flywheel Correct or replace.
(f ) Loose disc rivets Replace clutch disc.
(g) Loose engine mounting Retighten or replace mounting.
(h) Improper adjustment of pitching stopper Adjustment.
11
2-10DIAGNOSTICS
1. Clutch System
Page 714 of 2890
1. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG
Test (1)
Disengage the clutch and shift quickly from neutral to reverse in idling condition.
Gear noise
Ye s
No
Sufficient disengagement of clutch
Test (2)
Shift to reverse after 0.5 to 1.0 sec of clutch disengagement.
Gear noise
Ye s
No
Defective transmission
or excessive clutch drag torque
[Cause]
1. Defective pilot bearing
2. Excessive disc deflection
3. Defective transmission
4. Defective clutch disc hub spline
Test (3)
Shift the gear N,R several times during disengaging clutch as test (2).
Gear noise
Ye s
No
Sticked clutch disc
[Cause]
1. Clutch disc smeared by oil
2. Clutch disc smeared by rust
3. Defective clutch disc hub spline
Clutch drags.
[Cause]
1. Cracked clutch disc facing
2. Damaged or worn clutch cover
3. Malfunction of clutch release system
4. Insufficient clutch release amount
5. Excessive clutch pedal play
13
2-10DIAGNOSTICS
1. Clutch System
Page 741 of 2890
A
16. Remove gear shift rod and stay from transmission.
17. Remove shift selector cable.
18. Remove bolts which install stabilizer clamp onto
crossmember.
19. Remove front drive shaft from transmission.
20. Remove nuts which hold lower side of transmission to
engine.
21. Place transmission jack under transmission.
22. Remove transmission rear crossmember.
23. Remove transmission.
28
2-11SERVICE PROCEDURE
3. Transmission
Page 747 of 2890
G3M0697
16) Remove gear shift rod and stay from transmission.
(MT model)
(1) Remove spring.
(2) Disconnect stay from transmission.
(3) Disconnect rod from transmission.
B2M0033A
17) Remove shift selector cable. (AT model)
(1) Disconnect shift selector cable from selector
lever.
(2) Remove cable bracket from body.
G2M0323
18) Remove bolts which install stabilizer clamps onto
crossmember.
G2M0324
19) Remove front drive shafts from transmission.
(1) Remove transverse link from housing.
(2) Lower transverse link.
G2M0325
(3) Remove spring pins and separate front drive shafts
from each side of the transmission.
CAUTION:
Discard removing spring pin. Replace with a new one.
34
2-11SERVICE PROCEDURE
3. Transmission
Page 749 of 2890
B: INSTALLATION
1. Install transmission to engine.
2. Install transmission rear crossmember.
3. Take off transmission jack.
4. Tighten nuts which hold lower side of transmission to engine.
5. Tighten bolt which holds right upper side of transmission to
engine.
AT model
6. Install torque converter to drive plate.
7. Remove special tools.
8. Install pitching stopper.
9. Install front drive shafts into transmission.
10. Install stabilizer clamps onto front crossmember.
11. Install gear shift rod and stay.
B
36
2-11SERVICE PROCEDURE
3. Transmission
Page 750 of 2890
B
AT model
12. Install shift selector cable to selector lever.
13. Install ATF level gauge guide, and connect ATF cooler hose
to pipe.
AWD model
14. Install propeller shaft.
15. Install exhaust system.
Heat shield cover [AWD]
Rear exhaust pipe [AWD]
Front exhaust pipe
Center exhaust pipe
16. Install transmission connector holder bracket.
AT model
17. Install ATF level gauge.
18. Connect connectors and cables.
19. Install starter.
20. Install air intake duct.
21. Connect battery ground cable.
22. Fill ATF. [AT]
23. Check selector lever operation. [AT]
24. Take off the vehicle from lift arm.
25. Check the vehicle on the road tester. [AT]
37
2-11SERVICE PROCEDURE
3. Transmission
