
CONSULT Inspection Procedure
SELF-DIAGNOSIS PROCEDURE
1) Turn ignition switch OFF.
2) Connect CONSULT to Data Link Con- nector for CONSULT.
1) Start engine.
2) Drive vehicle over 30 km/h (19 MPH) for at least one minute.
1) Stop vehicle with engine runningand touch ``START'' on CONSULT
screen.
2) Touch ``ABS''.
3) Touch ``SELF-DIAG RESULTS''.
+ The screen shows the detected mal-
function and how many times the igni-
tion switch has been turned since the
malfunction.
Make the necessary repairs following the
diagnostic procedures.
After the malfunctions are repaired, erase
the self-diagnostic results stored in the
control unit by touching ``ERASE''.
Check warning lamp for deactivation after
driving vehicle over 30 km/h (19 MPH) for
at least one minute.
Test the ABS in a safe area to verify that it
functions properly.
Note: ``SELF-DIAG RESULTS'' screen shows the detected malfunction and how many times the ignition switch has been turned since the mal-
function.
SBR195E
SBR455D
SBR080E
SST412B
SBR950C
.
.
.
.
.
.
TROUBLE DIAGNOSES
BR-51

Diagnostic Procedure 10 (ABS does not work.)
CHECK WARNING LAMP ACTIVATE.
- ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Does the ABS warning lamp activate?
No
cYe s Carry out self-diagnosis.
Refer to BR-47, 51.
Go toin Diagnostic Procedure 8,
BR-67.
Note: ABS does not work when vehicle speed is under 10 km/h (6 MPH).
Diagnostic Procedure 11 (Pedal vibration and
noise)
INSPECTION START
- ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1. Apply brake.
2. Start engine.
3. Does the symptom appear only when engine is started?
No
cYe s Carry out self-diagnosis.
Refer to BR-47, 51.
CHECK IF SYMPTOM APPEARS.
- ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Does the symptom appear when electrical
equipment switches (such as headlamp)
are operated?
Ye s
cNo Go toin Diagnostic
Procedure 8, BR-67.
CHECK WHEEL SENSOR.
- ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Check wheel sensor shield ground. For
location of shield ground, refer to wiring
diagram and ``HARNESS LAYOUT'' in EL
section.
OK
cNG Repair wheel sensor.
CHECK HARNESS CONNECTOR.
- ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Check ABS actuator and electric unit pin
terminals for damage or the connection of
ABS actuator and electric unit harness
connector.
Reconnect ABS actuator and electric unit
harness connector. Then retest.
SAT797A
.
.
.
.
TROUBLE DIAGNOSES FOR SYMPTOMS
BR-68

Note: ABS may operate and cause vibration under any of thefollowing conditions.
+ Applying brake gradually when shifting or operating
clutch.
+ Low friction (slippery) road.
+ High speed cornering.
+ Driving over bumps and pot holes.
+ Engine speed is over 5,000 rpm with vehicle stopped.
Diagnostic Procedure 12 (Warning lamp does
not come on when ignition switch is turned
ON.)
CHECK FUSE.
- ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Check 10A fuse
28. For fuse layout, refer
to POWER SUPPLY ROUTING in EL sec-
tion.
OK
cNG Replace fuse.
CHECK WARNING LAMP ACTIVATE.
- ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Disconnect ABS actuator and electric unit
connector.
Does the warning lamp activate?
No
cYe s jA(Go to next page.)
CHECK HARNESS FOR SHORT.
- ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1. Disconnect ABS actuator and electric unit connector.
2. Check voltage between ABS actuator and electric unit connector
E18(body
side) terminal j
21and ground.
Battery voltage should not exist.
OK
cNG Repair harness or connec-
tor.
CHECK COMBINATION METER.
- ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Check combination meter. Refer to
WARNING LAMPS in EL section.
SBR205E
SBR186E
SBR144EB
.
.
.
TROUBLE DIAGNOSES FOR SYMPTOMS
Diagnostic Procedure 11 (Pedal vibration and
noise) (Cont'd)
BR-69

Body Front End
+When removing or installing hood, place a cloth or other padding on front fender panel and cowl top. This
prevents vehicle body from being scratched.
+Bumper fascia is made of plastic. Do not use excessive force and be sure to keep oil away from it.
+Hood adjustment: Adjust at hinge portion.
+Hood lock adjustment: After adjusting, check hood lock control operation. Apply a coat of grease to hood
locks engaging mechanism.
+Hood opener: Do not attempt to bend cable forcibly. Doing so increases effort required to unlock hood.
REMOVAL Ð Front bumper assembly
V1Remove front guard bar. Refer to ``EXTERIOR'' for details, BT-26.
V2Remove left and right headlamp wipers (on models with headlamp wipers).
V3Remove clips securing front grille and remove the front grille.
V4Remove screws and bolts securing left and right front bumper side bracket.
V5Remove bolts securing bumper lower to engine under cover.
V6Remove bolts securing left and right front bumper stay upper (without winch).
V7Remove bolts securing left and right front bumper stay side.
V8Extract bumper assembly.
SBT518
BODY END
BT-4

+All dimensions indicated in ®gures are actual ones.
+When using a tracking gauge, adjust both pointers to equal length. Then check the pointers and gauge
itself to make sure there is no free play.
+When a measuring tape is used, check to be sure there is no elongation, twisting or bending.
+Measurements should be taken at the center of the mounting holes.
+An asterisk (*) following the value at the measuring point indicates that the measuring point on the other
side is symmetrically the same value.
+The coordinates of the measurement points are the distances measured from the standard line of ``X'', ``Y''
and ``Z''.
Engine Compartment
MEASUREMENT
SBF874GD
SBT560
BODY ALIGNMENT
BT-49

Clutch Booster
INSPECTION
Hoses and connectors
+Check condition of vacuum hoses and connections.
+Check vacuum hoses and check valve for air tightness.
Vacuum hose check valve
1. Remove the vacuum hose.
2. Blow air through one end (booster side) of the vacuum hose
and make sure that air passage continuity exists.
3. Blow air through the other end (engine side) of the vacuum
hose and make sure that air passage continuity does not exist.
Check valve
1. Remove the vacuum hose.
2. Check the condition of the check valve using a handy vacuum
pump.
V1V2
Vacuum pump connected to the
engine sideVacuum pump connected to the booster
side
No vacuum pressure is applied.Vacuum drop is less than 1.3 kPa (13
mbar, 10 mmHg, 0.39 inHg) at a vacuum
pressure of þ66.7 kPa (þ667 mbar, þ500
mmHg, þ19.69 inHg).
SCL772
SCL782
SCL783
HYDRAULIC CLUTCH CONTROL
CL-9

General Speci®cations
CLUTCH CONTROL SYSTEM
Type of clutch control Hydraulic
CLUTCH MASTER CYLINDER (with clutch
damper)
Unit: mm (in)
Inner diameter 17.46 (11/16)
CLUTCH OPERATING CYLINDER
Unit: mm (in)
Inner diameter 20.64 (13/16)
CLUTCH BOOSTER
Unit: mm (in)
Type M45
Diaphragm diameter 114.3 (4.50)
Check valve type Built-in hose type
CLUTCH DISC
Model 240
Engine RD28ETi
Facing size
(Outer dia. x inner dia. x thick-
ness)
mm (in)240 x 160 x 3.5
(9.45 x 6.30 x 0.138)
Thickness of disc assembly with
load
mm (in)/N (kg, lb)7.7 - 8.1 (0.303 - 0.319)/
8,336 (850, 1,874)
CLUTCH COVER
Model 240
Engine RD28ETi
Destination Ð
Full load
N (kg, lb)5,835 - 6,620
(595 - 675, 1,312 - 1,488)
Inspection and Adjustment
CLUTCH PEDAL
Unit: mm (in)
Pedal height ``H*''195 - 205
(7.68 - 8.07)
Pedal free play ``A''
(at pedal pad)1.0 - 3.0 (0.039 - 0.118)
*: Measured from surface of melt sheet to pedal pad
CLUTCH BOOSTER
Unit: mm (in)
Output rod length ``A'' 1.30 - 1.55 (0.0512 - 0.0610)
Input rod length ``B'' 130 (5.12)
CLUTCH DISC
Unit: mm (in)
Model 240
Wear limit of facing sur-
face to rivet head0.3 (0.012)
Runout limit of facing 0.7 (0.028)
Distance of runout
check point (from
the hub center)115.0 (4.53)
Maximum backlash of
spline (at outer edge of
disc)1.0 (0.039)
CLUTCH COVER
Unit: mm (in)
Model 240
Diaphragm spring height ``A''37.5 - 39.5
(1.476 - 1.555)
Uneven limit of diaphragm
spring toe height0.7 (0.028)
SERVICE DATA AND SPECIFICATIONS (SDS)
CL-16

Precautions
+Before connecting or disconnecting the ECM harness
connector, turn ignition switch OFF and disconnect nega-
tive battery terminal. Failure to do so may damage the ECM
because battery voltage is applied to ECM even if ignition
switch is turned off.
+When connecting ECM harness connector, tighten secur-
ing bolt until the gap between orange indicators disap-
pears.
: 3.0 - 5.0 Nzm (0.3 - 0.5 kg-m, 26 - 43 in-lb)
+When connecting or disconnecting pin connectors into or
from ECM, take care not to damage pin terminals (bend or
break).
Make sure that there are not any bends or breaks on ECM
pin terminal, when connecting pin connectors.
+Before replacing ECM, perform Terminals and Reference
Value inspection and make sure ECM functions properly.
Refer to EC-54.
+If MIL illuminates or blinks irregularly when engine is
running, water may have accumulated in fuel ®lter. Drain
water from fuel ®lter. If this does not correct the problem,
perform speci®ed trouble diagnostic procedures.
+After performing each TROUBLE DIAGNOSIS, perform
``OVERALL FUNCTION CHECK'' or ``DTC (Diagnostic
Trouble Code) CONFIRMATION PROCEDURE''.
The DTC should not be displayed in the ``DTC CONFIRMA-
TION PROCEDUREº if the repair is completed. The ``OVER-
ALL FUNCTION CHECK'' should be a good result if the
repair is completed.
SEF289H
SEF308Q
SEF291H
MEF040D
SEF051P
PRECAUTIONS AND PREPARATION
EC-6