
Adjusting Clutch Pedal
1. Adjust pedal height with pedal stopper.
Pedal height ``H*'':
195 - 205 mm (7.68 - 8.07 in)
*: Measured from surface of dash reinforcement panel to
pedal pad
2. Adjust pedal free play with master cylinder push rod or clutch
booster input rod. Then tighten lock nut.
Pedal free play ``A'':
1.0 - 3.0 mm (0.039 - 0.118 in)
Pedal free play means the following total measured at position
of pedal pad:
+Play due to clevis pin and clevis pin hole in clutch pedal.
+Play due to piston and push rod.
+Push or step on clutch pedal until resistance is felt, and check
the distance the pedal moves.
SCL788
SCL702
INSPECTION AND ADJUSTMENT
CL-5

Clutch Cover and Flywheel
INSPECTION
+Set Tool and check height and unevenness of diaphragm
spring.
Diaphragm spring height ``A'':
Model 240
37.5 - 39.5 mm (1.476 - 1.555 in)
+Check thrust rings for wear or damage by shaking cover
assembly up and down to listen for chattering noise, or lightly
hammering on rivets for a slightly cracked noise. Replace
clutch cover assembly if necessary.
+Check pressure plate and clutch disc contact surface for slight
burns or discoloration. Repair pressure plate with emery paper.
+Check pressure plate and clutch disc contact surface for defor-
mation or damage. Replace if necessary.
+Adjust unevenness of diaphragm spring with Tool.
Uneven limit:
0.7 mm (0.028 in)
+Check ¯ywheel and clutch disc contact surface for slight burns
or discoloration. Repair ¯ywheel with emery paper.
+Check ¯ywheel runout.
Maximum allowable runout:
Refer to EM section (``Inspection'', ``CYLINDER
BLOCK'').
SCL219-C
SCL466-A
SEM929A
CLUTCH DISC AND CLUTCH COVER
CL-14

jA
CHECK INJECTION TIMING.
1. Set No. 1 piston at TDC on its com-
pression stroke.
2. Remove injection tubes and air bleeder
on the back of injection pump.
3. Set dial gauge so its indicator points to
somewhere between 1.0 and 2.0 mm
(0.039 and 0.079 in) on the scale.
4. Turn crankshaft 1 turn clockwise and
check that dial gauge indicates the
same value again.
5. Turn crankshaft counterclockwise about
100 degrees, then turn crankshaft
clockwise slowly, and set dial gauge
indicator to 0 mm at the position it
stops.
6. Turn crankshaft clockwise and set the
injection timing mark on the crankshaft
pulley to the timing indicator.
7. Read plunger lift.
Plunger lift:
0.92 0.04 mm (0.0362 0.0016 in)
+When repeating the checking, start
with step 5.
NG
cOK
+Bleed air from fuel sys-
tem.
+After this inspection,
unnecessary diagnostic
trouble code No. might
be displayed.
Erase the stored
memory in ECM.
Refer to ``ON BOARD
DIAGNOSTIC SYSTEM
DESCRIPTION'' (EC-30)
and ``HOW TO ERASE
DTC'' (EC-30).
OK
INSPECTION END
ADJUSTING
1. If plunger lift is not within the speci®ed
value, adjust by turning injection pump.
+If indication is smaller than the speci-
®ed value, turn pump body away
from engine.
+If indication is larger than the speci-
®ed value, turn pump body towards
engine.
2. Tighten injection pump securing bolts
and nuts.
Nut:
: 16-21Nzm
(1.6 - 2.1 kg-m, 12 - 15 ft-lb)
Bolt:
: 22-29Nzm
(2.2 - 3.0 kg-m, 16 - 22 ft-lb)
3. Remove dial gauge and install air
bleeder with new washer.
4. Install injection tubes.
Flare nut:
: 22-25Nzm
(2.2 - 2.5 kg-m, 16 - 18 ft-lb)
5. Bleed air from fuel system.
Refer to ``DRAINING WATER'', ``Check-
ing and Replacing Fuel Filter and
Draining Water'' of ``ENGINE MAINTE-
NANCE'' in MA section.
cGo to.
SEF672V
SEF664V
SEF673V
SEF666V
.
.
.
TROUBLE DIAGNOSIS Ð Basic Inspection
Basic Inspection (Cont'd)
EC-47

MAIN 12 CAUSES OF OVERHEATING
Engine Step Inspection item Equipment Condition Reference page
OFF 1+Blocked radiator
+Blocked radiator grille
+Blocked bumper+Visual No blocking Ð
2+Coolant mixture+Coolant tester 50 - 50% coolant mixture See ``RECOMMENDED
FLUIDS AND LUBRI-
CANTS'' in MA section.
3+Coolant level+Visual Coolant up to MAX level
in reservoir tank and
radiator ®ller neckSee ``Changing Engine
Coolant'', ``ENGINE
MAINTENANCE'' in MA
section.
4+Radiator cap+Pressure tester 78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0
kg/cm
2, 11 - 14 psi)See ``System Check''
``ENGINE COOLING
SYSTEM'' in LC section.
ON*
25+Coolant leaks+Visual No leaks See ``System Check''
``ENGINE COOLING
SYSTEM'' in LC section.
ON*
26+Thermostat+Touch the upper and
lower radiator hosesBoth hoses should be hot See ``Thermostat'' and
``Radiator'', ``ENGINE
COOLING SYSTEM'' in
LC section.
ON*
17+Cooling fan+CONSULT Operating See ``TROUBLE DIAG-
NOSIS FOR DTC 28'',
EC-113.
OFF 8+Combustion gas leak+Color checker chemical
tester 4 Gas analyzerNegative Ð
ON*
39+Coolant temperature
gauge+Visual Gauge less than 3/4
when drivingÐ
+Coolant over¯ow to res-
ervoir tank+Visual No over¯ow during driving
and idlingSee ``Changing Engine
Coolant'', ``ENGINE
MAINTENANCE'' in MA
section.
OFF*
410+Coolant return from res-
ervoir tank to radiator+Visual Should be initial level in
reservoir tankSee ``ENGINE MAINTE-
NANCE'' in MA section.
OFF 11+Cylinder head+Straight gauge feeler
gauge0.1mm (0.004 in) Maxi-
mum distortion (warping)See ``Inspection'', ``CYL-
INDER HEAD'' in EM
section.
12+Cylinder block and pis-
tons+Visual No scuffing on cylinder
walls or pistonSee ``Inspection'', ``CYL-
INDER BLOCK'' in EM
section.
*1: Turn the ignition switch ON.
*2: Engine running at 3,000 rpm for 10 minutes.
*3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes.
*4: After 60 minutes of cool down time.
For more information, refer to ``OVERHEATING CAUSE ANALYSIS'' in LC section.
TROUBLE DIAGNOSIS FOR ``OVER HEAT'' (DTC 28)
Cooling Fan (Overheat) (Cont'd)
EC-120

DIAGNOSTIC PROCEDURE
INSPECTION START
CHECK OVERALL FUNCTION.
1. Turn ignition switch ``ON''.
2. Check ``START SIGNAL'' in
``DATA MONITOR'' mode with
CONSULT.
--------------------------------------------------------------------------------------------------------------------------------------OR--------------------------------------------------------------------------------------------------------------------------------------
1. Turn ignition switch to ``START''.
2. Check voltage between ECM
terminal
V20and ground.
Voltage:
Ignition switch ``START''
Battery voltage
Except above
Approximately 0V
NG
cOK
INSPECTION END
CHECK INPUT SIGNAL CIRCUIT.
1. Turn ignition switch ``OFF''.
2. Disconnect ECM harness connector and
ignition switch harness connector.
3. Check harness continuity between ECM
terminal
V20and terminalV6.
Continuity should exist.
If OK, check harness for short to ground
and short to power.
OK
cNG
Check the following.
+Harness connectors
M52,F7
+7.5A fuse
+Fuse block
M3,E112
+Harness for open or short
between ECM and igni-
tion switch
If NG, repair open circuit or
short to ground or short to
power in harness or con-
nectors.
Disconnect and reconnect harness connec-
tors in the circuit. Then retest.
Trouble is not ®xed.
Check ECM pin terminals for damage and
check the connection of ECM harness con-
nector. Reconnect ECM harness connector
and retest.
INSPECTION END
IGN ``ON'' OFF
IGN ``START'' ONSEF625S
SEF109P
SEF785V
.
.
.
.
.
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Start Signal (Cont'd)
EC-164

DIAGNOSTIC PROCEDURE
INSPECTION START
CHECK OVERALL FUNCTION.
1. Turn ignition switch ``OFF''.
2. Disconnect charge air temperature sen-
sor harness connector.
3. Connect 150Wresistor to charge air
temperature sensor harness connector.
4. Start engine and keep engine speed at
2,000 rpm.
5. Make sure that charge air cooler fan
operates.
NG
cOK
INSPECTION END
CHECK POWER SUPPLY.
1. Stop engine.
2. Disconnect charge air cooler fan relay.
3. Turn ignition switch ``ON''.
4. Check voltage between terminals
V2,
V5and ground with CONSULT or
tester.
Voltage: Battery voltage
OK
cNG
Check the following.
+Harness connectors
M21,E127
+10A fuse
+15A fuse
+Fuse block
M2
+Harness for open or
short between charge air
cooler fan relay and
fuses
If NG, repair harness or
connectors.
CHECK GROUND CIRCUIT.
1. Turn ignition switch ``OFF''.
2. Disconnect charge air cooler fan motor
harness connector.
3. Check harness continuity between relay
terminal
V3and motor terminalV1,
motor terminal
V2and engine ground.
Continuity should exist.
If OK, check harness for short to
ground and short to power.
OK
cNG
Check the following.
+Harness connectors
E127,M21
+Harness connectors
M50,F5
+Harness for open or
short between charge air
cooler fan relay and
charge air cooler fan
motor
+Harness for open or
short between charge air
cooler fan motor and
engine ground
If NG, repair open circuit or
short to ground or short to
power in harness or con-
nectors.
jA
SEF710V
SEF798V
SEF712V
SEF799V
SEF711V
.
.
.
.
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Charge Air Cooler Fan Control (Cont'd)
EC-180

DIAGNOSTIC PROCEDURE
INSPECTION START
CHECK OVERALL FUNCTION.
1. Turn ignition switch ``ON''.
2. Check ``WARM UP SW'' signal
in ``DATA MONITOR'' mode with
CONSULT.
Heat up switch is ``ON'': ON
Heat up switch is ``OFF'': OFF
--------------------------------------------------------------------------------------------------------------------------------------OR--------------------------------------------------------------------------------------------------------------------------------------
2. Check voltage between ECM
terminal
V59and ground under
the following condition.
Voltage:
Heat up switch is ``ON''
Battery voltage
Heat up switch is ``OFF''
Approximately 0V
NG
cOK
INSPECTION END
CHECK POWER SUPPLY.
1. Turn heat up switch ``OFF''.
2. Turn ignition switch ``OFF''.
3. Disconnect heat up switch harness con-
nector.
4. Turn ignition switch ``ON''.
5. Check voltage between terminal
V6
and ground with CONSULT or tester.
Voltage: Battery voltage
OK
cNG
Check the following.
+Fuse block
M3
+10A fuse
+Harness for open or
short between heat up
switch and fuse
If NG, repair harness or
connectors.
CHECK INPUT SIGNAL CIRCUIT.
1. Turn ignition switch ``OFF''.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM
terminal
V59and terminalV5.
Continuity should exist.
If OK, check harness for short to
ground and short to power.
OK
cNG
Check the following.
+Harness connectors
M51,F6
+Harness for open or
short between heat up
switch and ECM
If NG, repair open circuit or
short to ground or short to
power in harness or con-
nectors.
jA
SEF804V
SEF805V
SEF806V
SEF807V
.
.
.
.
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Heat Up Switch (Cont'd)
EC-185

Wiring Diagram Ð H/AIM Ð .....................................71
PARKING, LICENSE AND TAIL LAMPS......................73
Wiring Diagram Ð TAIL/L Ð/Type A .........................73
Wiring Diagram Ð TAIL/L Ð/Type B.........................75
STOP LAMP..................................................................77
Wiring Diagram Ð STOP/L Ð/Type A ......................77
BACK-UP LAMP............................................................78
Wiring Diagram Ð BACK/L Ð/LHD Models..............78
Wiring Diagram Ð BACK/L Ð/RHD Models .............79
REAR FOG LAMP.........................................................80
Wiring Diagram Ð R/FOG Ð ....................................80
TURN SIGNAL AND HAZARD WARNING LAMPS.....81
Wiring Diagram Ð TURN Ð/Type A .........................81
Wiring Diagram Ð TURN Ð/Type B .........................83
Trouble Diagnoses.....................................................85
Electrical Components Inspection .............................85
ILLUMINATION..............................................................86
Schematic ..................................................................86
Wiring Diagram Ð ILL Ð ..........................................87
INTERIOR ROOM LAMP Ð With Timer Ð.................93
System Description ....................................................93
Schematic ..................................................................94
Wiring Diagram Ð ROOM/L Ð/LHD Models ............95
Wiring Diagram Ð ROOM/L Ð/RHD Models............98
Trouble Diagnoses...................................................100
MAP AND VANITY MIRROR LAMPS.........................101
Wiring Diagram Ð INT/L Ð.....................................101
METER AND GAUGES...............................................102
System Description ..................................................102
Combination Meter ..................................................103
Wiring Diagram Ð METER Ð/LHD Models............104
Wiring Diagram Ð METER Ð/RHD Models ...........106
Meter/Gauge Operation and Odo/Trip Meter
Segment Check in Diagnosis Mode ........................108
Flexible Print Circuit (FPC) ......................................109
Trouble Diagnoses................................................... 110
Electrical Components Inspection ........................... 114
COMPASS AND THERMOMETER............................. 116
System Description .................................................. 116
Wiring Diagram Ð COMPAS Ð .............................. 117
Trouble Diagnoses................................................... 118
Calibration Procedure For Compass ....................... 119
WARNING LAMPS......................................................121
Schematic ................................................................121
Wiring Diagram Ð WARN Ð ..................................123
Electrical Components Inspection ...........................134
WARNING CHIME.......................................................135
System Description ..................................................135
Wiring Diagram Ð CHIME Ð/LHD Models.............136
Wiring Diagram Ð CHIME Ð/RHD Models ............137
Trouble Diagnoses...................................................138
Electrical Components Inspection ...........................140FRONT WIPER AND WASHER..................................141
System Description ..................................................141
Wiring Diagram Ð WIPER Ð/With Intermittent
Wiper........................................................................142
Removal and Installation .........................................143
Washer Nozzle Adjustment .....................................144
Washer Tube Layout ...............................................144
REAR WIPER AND WASHER....................................145
System Description ..................................................145
Wiring Diagram Ð WIP/R Ð/LHD Models ..............146
Wiring Diagram Ð WIP/R Ð/RHD Models .............148
Trouble Diagnoses...................................................150
Removal and Installation .........................................151
Washer Nozzle Adjustment .....................................151
Washer Tube Layout ...............................................152
Check Valve .............................................................152
HEADLAMP WIPER AND WASHER..........................153
Wiring Diagram Ð HLC Ð ......................................153
Electrical Components Inspection ...........................154
Removal and Installation .........................................154
Washer Tube Layout ...............................................154
Check Valve .............................................................154
HORN...........................................................................155
Wiring Diagram Ð HORN Ð...................................155
CIGARETTE LIGHTER................................................156
Wiring Diagram Ð CIGAR Ð ..................................156
CLOCK.........................................................................157
Wiring Diagram Ð CLOCK Ð .................................157
REAR WINDOW DEFOGGER.....................................158
System Description ..................................................158
Wiring Diagram Ð DEF Ð/LHD Models .................159
Wiring Diagram Ð DEF Ð/RHD Models ................161
Trouble Diagnoses...................................................163
Electrical Components Inspection ...........................164
Filament Check ........................................................164
Filament Repair .......................................................165
WIPER DEICER...........................................................166
System Description ..................................................166
Wiring Diagram Ð DEICER Ð................................167
AUDIO..........................................................................168
Wiring Diagram Ð AUDIO Ð/LHD Models .............168
Wiring Diagram Ð AUDIO Ð/RHD Models ............170
Trouble Diagnoses...................................................172
CATS (Code) System/RHD .....................................173
NATS Audio Link/LHD .............................................174
AUDIO Ð CD AUTO CHANGER Ð...........................176
Wiring Diagram Ð CD/CHG Ð/LHD Wagon ..........176
Wiring Diagram Ð CD/CHG Ð/LHD Hardtop .........177
Wiring Diagram Ð CD/CHG Ð/RHD Wagon ..........178
Wiring Diagram Ð CD/CHG Ð/RHD Hardtop ........179
Trouble Diagnoses...................................................180
AUDIO ANTENNA.......................................................181