N20161
F
1/2
E1
2 3
Z05730 1
3
42
5
BE1217 Ie±5±1±A
BatteryWarning Light
Ignition
Switch
N20213
1 3
N20214
1
3
N20215
Engine coolant temperature gauge
Ignition
Switch
BatterySender
Gauge
± BODY ELECTRICALCOMBINATION METER
BE±49
2269 Author: Date:
6. INSPECT FUEL SENDER GAUGE RESISTANCE
Measure the resistance between terminals 2 and 3 for each
float position.
Float position mm (in.)Resistance (W)
F: Approx. ±91.1 (±3.587)Approx. 3.0
1/2: Approx. ±34.2 (±1.346)Approx. 31.7
E: Approx. 30.8 (1.213)Approx. 110.0
If resistance value is not as specified, replace the sender
gauge.
7. INSPECT FUEL LEVEL WARNING LIGHT
(a) Disconnect the connector from the sender gauge.
(b) Connect terminals 1 and 3 on the wire harness side con-
nector.
(c) Turn the ignition switch ON, check that the warning light
lights up.
If the warning light does not light up, test the bulb or inspect wire
harness.
8. INSPECT FUEL LEVEL WARNING SWITCH
(a) Apply battery positive voltage between terminals 1 and 3
through a 3.4±W test bulb, check that the bulb lights up.
HINT:
It takes a short time for the bulb to light up.
(b) Submerge the switch in fuel, check that the bulb goes out.
If operation is not as specified, replace the sender gauge.
9. INSPECT ENGINE COOLANT TEMPERATURE RE-
CEIVER GAUGE OPERATION
(a) Disconnect the connector from the sender gauge.
(b) Turn the ignition switch ON and check that the receiver
gauge needle indicates COOL.
Z15788
Engine coolant temperature gauge
Ignition
Switch
BatteryWire Harness SideTest Bulb
(3.4 W)
N20216
C
B
A
N21646
Z14205
Warning Light
Ignition
Switch
Battery
1 BE±50
± BODY ELECTRICALCOMBINATION METER
2270 Author: Date:
(c) Ground terminal on the wire harness side connector
through a 3.4±W test bulb.
(d) Turn the ignition switch ON, and check that the bulb lights
up and the receiver gauge needle moves to the hot side.
If operation is as specified, replace the sender gauge.
Then, recheck the system.
If operation is not as specified, measure the receiver gauge re-
sistance.
10. INSPECT ENGINE COOLANT TEMPERATURE RE-
CEIVER GAUGE RESISTANCE
Measure the resistance between terminals.
Tester connectionResistance (W) *
A ± BApprox. 175.7
A ± CApprox. 54.0
B ± CApprox. 229.7
*: This circuit includes the diode.
HINT:
Connect the test leads so that the current from the ohmmeter
can flow according to the above order.
If resistance value is not as specified, replace the receiver
gauge.
11. INSPECT ENGINE COOLANT TEMPERATURE SEND-
ER GAUGE RESISTANCE
Measure the resistance between the terminal and gauge body.
Temperature °C (°F)Resistance (W)
50 (122.0)274
120 (248.0)26.4
If resistance value is not as specified, replace the engine cool-
ant temperature sender gauge.
12. INSPECT LOW OIL PRESSURE WARNING LIGHT
(a) Disconnect the connector from the warning switch and
ground terminal on the wire harness side connector.
(b) Turn the ignition switch ON and check that the warning
light lights up.
If the warning light does not light up, test the bulb.
N06640
BE1217
Warning Light
Ignition
Switch
Battery
N02346
OFF
ON
1 2
N01212
BE1217
Warning Light
Ignition
Switch
Battery
± BODY ELECTRICALCOMBINATION METER
BE±51
2271 Author: Date:
13. INSPECT LOW OIL PRESSURE SWITCH
(a) Disconnect the connector from the switch.
(b) Check that continuity exists between terminal and ground
with the engine stopped.
(c) Check that no continuity exists between terminal and
ground with the engine running.
HINT:
Oil pressure should be over 24.5 kPa (0.25 kgf/cm
2, 3.55 psi).
If operation is not as specified, replace the switch.
14. INSPECT BRAKE SYSTEM WARNING LIGHT
(a) Disconnect the connector from the brake fluid warning
switch.
(b) Release the parking brake pedal.
(c) Connect the terminals on the wire harness side of the lev-
el warning switch connector.
(d) Start the engine, check that the warning light lights up.
If the warning light does not light up, test the bulb or wire har-
ness.
15. INSPECT BRAKE FLUID LEVEL WARNING SWITCH
(a) Remove the reservoir tank cap and strainer.
(b) Disconnect the connector.
(c) Check that no continuity exists between the terminals with
the switch OFF (float up).
(d) Use syphon, etc. to take fluid out of the reservoir tank.
(e) Check that continuity exists between the terminals with
the switch ON (float down).
(f) Pour the fluid back in the reservoir tank.
If operation is not as specified, replace the switch.
16. INSPECT PARKING BRAKE SWITCH
(a) Check that continuity exists between the terminal and
switch body with the switch ON (switch pin released).
(b) Check that no continuity exists between the terminal and
switch body with the switch OFF (switch pin pushed in).
If operation is not as specified, replace the switch or inspect
ground point.
17. INSPECT WASHER FLUID LEVEL WARNING LIGHT
(a) Disconnect the connectors from the level warning switch
and parking brake switch.
(b) Connect terminals on the wire harness side connector of
the level warning switch connector.
(c) Remove the GAUGE fuse and turn the ignition switch ON,
and check that the warning light comes on.
If the warning light does not light up, test the bulb.
R00954
Stop Light
Switch
Push Rod
Pedal HeightBR0YH±01
R00935
Pedal Freeplay
± BRAKEBRAKE PEDAL
BR±5
2028 Author: Date:
BRAKE PEDAL
ON±VEHICLE INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
152.0 ± 162.0 mm (5.984 ± 6.378 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Disconnect the connector from the stop light switch.
(b) Loosen the stop light switch lock nut and remove the stop
light switch.
(c) Loosen the push rod lock nut.
(d) Adjust the pedal height by turning the pedal push rod.
(e) Tighten the push rod lock nut.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
(f) Install the stop light switch and turn it until it lightly con-
tacts the pedal stopper.
(g) Push in the brake pedal 5±15 mm (0.20±0.59 in.), turn the
stop light switch to lock the nut in the position where the
stop light goes off.
(h) Connect the connector to the stop light switch.
(i) After installation, push in the brake pedal 5±15 mm
(0.20±0.59 in.), check that stop light lights up.
(j) Connect the connector to the stop light switch.
(k) After adjusting the pedal height, check the pedal freeplay.
3. CHECK PEDAL FREEPLAY
(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the booster.
(b) Push in the pedal by hand until the resistance begins to
be felt, then measure the distance.
Pedal freeplay: 1 ± 6 mm (0.04 ± 0.24 in.)
HINT:
The freeplay to the 1st resistance is due to the play between the
clevis and pin. This is magnified up to 1 ± 6 mm (0.04 ± 0.24 in.)
at the pedal.
If incorrect, check the stop light switch clearance.
If the clearance is OK, then troubleshoot the brake system.
Stop light switch clearance:
0.5 ± 2.4 mm (0.020 ± 0.094 in.)
BR2237
BR0AK±03
BR2238
1st3rd
2nd
GOOD
NO GOOD
± BRAKEBRAKE BOOSTER ASSEMBLY
BR±17
2040 Author: Date:
BRAKE BOOSTER ASSEMBLY
ON±VEHICLE INSPECTION
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine off
and check that there is no change in the pedal reserve
distance.
(b) Depress the brake pedal and start the engine. If the pedal
goes down slightly, operation is normal.
2. AIR TIGHTNESS CHECK
(a) Start the engine and stop it after 1 or 2 minutes. Depress
the brake pedal several times slowly.
If the pedal goes down farthest the 1st time, but gradually rises
after the 2nd or 3rd time, the booster is air tight.
(b) Depress the brake pedal while the engine is running, and
stop the engine with the pedal depressed. If there is no
change in the pedal reserve travel after holding the pedal
for 30 seconds, the booster is air tight.
CH02U±01
Z11577
Except Maintenance±Free Battery
Z11556
Maintenance±Free Battery
Voltmeter
± CHARGING (5S±FE)CHARGING SYSTEM
CH±1
1748 Author: Date:
CHARGING SYSTEM
ON±VEHICLE INSPECTION
CAUTION:
Check that the battery cables are connected to the
correct terminals.
Disconnect the battery cables when the battery is giv-
en a quick charge.
Do not perform tests with a high voltage insulation re-
sistance tester.
Never disconnect the battery while the engine is run-
ning.
1. CHECK BATTERY ELECTROLYTE LEVEL
Check the electrolyte quantity of each cell.
Maintenance±Free Battery:
If under the lower level, replace the battery (or add distilled wa-
ter if possible). Check the charging system.
Except Maintenance±Free Battery:
If under the lower level, add distilled water.
2. Except Maintenance±Free Battery:
CHECK BATTERY SPECIFIC GRAVITY
Check the specific gravity of each cell.
Standard specific gravity:
1.25 ± 1.29 at 20°C (68°F)
If the specific gravity is less than specification, charge the bat-
tery.
3. Maintenance±Free Battery:
CHECK BATTERY VOLTAGE
(a) After having driven the vehicle and in the case that 20
minutes have not passed after having stopped the en-
gine, turn the ignition switch ON and turn on the electrical
system (headlight, blower motor, rear defogger etc.) for
60 seconds to remove the surface charge.
(b) Turn the ignition switch OFF and turn off the electrical sys-
tems.
(c) Measure the battery voltage between the negative (±)
and positive (+) terminals of the battery.
Standard voltage: 12.5 ± 12.9 V at 20°C (68°F)
If the voltage is less than specification, charge the battery.
Z18811
Maintenance±Free Battery
Type A
Type B
Blue White Red
OK Charging
NecessaryInsufficient
Water
GREEN EYE DARK EYECLEAR EYE or
CHARGED DISCHARGED ADD WATERLIGHT YELLOW
Z00015
Z00038
DENSOBorroughs
CH0086
CORRECTWRONG CH±2
± CHARGING (5S±FE)CHARGING SYSTEM
1749 Author: Date:
HINT:
Check the indicator as shown in the illustration.
4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND
FUSES
(a) Check that the battery terminals are not loose or cor-
roded.
If the terminals are corroded, clean the terminals.
(b) Check the fusible link, H±fuses, M±fuse and fuses for
continuity.
5. INSPECT DRIVE BELTS
(a) Visually check the drive belt for excessive wear, frayed
cords etc.
If any defect has been found, replace the drive belt.
HINT:
Cracks on the rib side of a drive belt are considered acceptable.
If the drive belt has chunks missing from the ribs, it should be
replaced.
(b) Using a belt tension gauge, measure the belt tension.
Belt tension gauge:
DENSO BTG±20 (95506±00020)
Borroughs No. BT±33±73F
Drive belt tension:
w/ A/C New belt
Used belt165 ± 25 lbf
110 ± 10 lbf
w/o A/C New belt
Used belt125 ± 25 lbf
95 ± 20 lbf
If the belt tension is not as specified, adjust it.
HINT:
ºNew beltº refers to a belt which has been used less than
5 minutes on a running engine.
ºUsed beltº refers to a belt which has been used on a run-
ning engine for 5 minutes or more.
After installing a belt, check that it fits properly in the
ribbed grooves.
Check with your hand to confirm that the belt has not
slipped out of the groove on the bottom of the pulley.
Z03473
BatteryVoltmeter
Generator Ammeter
Disconnect Wire
from Terminal B
B
± CHARGING (5S±FE)CHARGING SYSTEM
CH±3
1750 Author: Date:
After installing a new belt, run the engine for about 5 min-
utes and recheck the belt tension.
6. VISUALLY CHECK GENERATOR WIRING AND
LISTEN FOR ABNORMAL NOISES
(a) Check that the wiring is in good condition.
(b) Check that there is no abnormal noise from the generator
while the engine is running.
7. CHECK CHARGE WARNING LIGHT CIRCUIT
(a) Warm up the engine and then turn it off.
(b) Turn off all accessories.
(c) Turn the ignition switch ºONº. Check that the charge warn-
ing light is lit.
(d) Start the engine. Check that the light goes off.
If the light does not go off as specified, troubleshoot the charge
light circuit.
8. INSPECT CHARGING CIRCUIT WITHOUT LOAD
HINT:
If a battery/generator tester is available, connect the tester to
the charging circuit as per manufacturer's instructions.
(a) If a tester is not available, connect a voltmeter and amme-
ter to the charging circuit as follows:
(1) Disconnect the wire from terminal B of the genera-
tor, and connect it to the negative (±) tester probe
of the ammeter.
(2) Connect the positive (+) tester probe of the amme-
ter to terminal B of the generator.
(3) Connect the positive (+) tester probe of the voltme-
ter to terminal B of the generator.
(4) Ground the negative (±) tester probe of the voltme-
ter.
(b) Check the charging circuit as follows:
With the engine running from idling to 2,000 rpm, check
the reading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage: 13.5 ± 15.1 V
If the voltmeter reading is more than standard voltage, replace
the voltage regulator.