
19. Pack drive ¯ange groove with grease, apply grease to O-ring
and mating surface of drive ¯ange, and install ¯ange.
20. Place snap ring in drive shaft groove. Choose snap ring so that
the gap between groove and snap ring is 0.4 mm (0.016 in) or
less.
Refer to SDS for selection of snap ring.
Front Wheel Alignment
Before checking front wheel alignment, be sure to make a prelimi-
nary inspection (Unladen*).
*: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand
tools and mats in designated positions.
PRELIMINARY INSPECTION
1. Check tires for wear and improper in¯ation.
2. Check wheel runout on outside and inside.
Wheel runout average
[(Outside runout value + Inside runout value) x 0.5]:
Refer to SDS (FA-27).
3. Check front wheel bearings for looseness.
4. Check front suspension for looseness.
5. Check steering linkage for looseness.
6. Check that shock absorbers work properly.
7. Check vehicle posture (Unladen).
CAMBER, CASTER AND KINGPIN INCLINATION
Camber, caster and kingpin inclination are preset at factory
and cannot be adjusted.
1. Measure camber, caster and kingpin inclination of both right
and left wheels with a suitable alignment gauge.
Camber, Caster and Kingpin inclination:
Refer to SDS (FA-27).
2. If camber, caster or kingpin inclination is not within
speci®cation, inspect front suspension parts. Replace damaged
or worn out parts.
SFA417A
SFA418AA
SFA356B
SFA894
ON-VEHICLE SERVICE
Front Wheel Bearing (Cont'd)
FA-8

General Speci®cations
Suspension typeRigid axle, leading arm and panhard rod with
coil spring
Strut type Double-acting hydraulic
Stabilizer bar Standard equipment
Inspection and Adjustment
WHEEL ALIGNMENT (Unladen*1)
Applied modelWagon Hardtop
Camber Minimum 0É (0.00É)
Degree minute
(Decimal degree)Nominal 0É30¢(0.50É)
Maximum 1É00¢(1.00É)
Left and right difference 45¢(0.75É) or less
Caster Minimum 3É00¢(3.00É) 3É20¢(3.33É)
Degree minute
(Decimal degree)Nominal 3É30¢(3.50É) 3É50¢(3.83É)
Maximum 4É00¢(4.00É) 4É20¢(4.33É)
Left and right difference 45¢(0.75É) or less
Kingpin inclination Minimum 13É45¢(13.75É)
Degree minute
(Decimal degree)Nominal 14É30¢(14.50É)
Maximum 15É15¢(15.25É)
Total toe-in Minimum 0 (0)
Distance (A þ B)
mm (in)Nominal 1 (0.04)
Maximum 2 (0.08)
Angle (left plus right)
Degree minute
(Decimal degree)Minimum 0¢(0.00É)
Nominal 5¢(0.08É)
Maximum 10¢(0.17É)
Wheel turning angle Minimum 33É00¢(33.00É)
Full turn*2Inside
Degree minute
(Decimal degree)Nominal 35É00¢(35.00É)
Maximum 35É00¢(35.00É)
Outside
Degree minute
(Decimal degree)Minimum 29É00¢(29.00É)
Nominal 31É00¢(31.00É)
Maximum 31É00¢(31.00É)
*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
*2: On power steering models, wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 lb) with engine idle.
WHEEL RUNOUT AVERAGE*
Wheel typeSteel Aluminum
6JJ-16 8JJ-16 6JJ-16 8JJ-16
Radial runout limit
mm (in)1.2
(0.047)0.8
(0.031)0.3
(0.012)0.3
(0.012)
Lateral runout limit
mm (in)1.2
(0.047)0.8
(0.031)0.3
(0.012)0.3
(0.012)
*: Wheel runout average = (Outside runout value + Inside runout value) x 0.5
SERVICE DATA AND SPECIFICATIONS (SDS)
FA-27

SAE J1930 Terminology List
All emission related terms used in this publication in accordance with SAE J1930 are listed. Accordingly, new
terms, new acronyms/abbreviations and old terms are listed in the following chart.
***: Not applicable
NEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM
Air cleaner ACL Air cleaner
Barometric pressure BARO ***
Barometric pressure sensor-BCDD BAROS-BCDD BCDD
Camshaft position CMP ***
Camshaft position sensor CMPS Crank angle sensor
Canister *** Canister
Carburetor CARB Carburetor
Charge air cooler CAC Intercooler
Closed loop CL Closed loop
Closed throttle position switch CTP switch Idle switch
Clutch pedal position switch CPP switch Clutch switch
Continuous fuel injection system CFI system ***
Continuous trap oxidizer system CTOX system ***
Crankshaft position CKP ***
Crankshaft position sensor CKPS ***
Data link connector DLC ***
Data link connector for CONSULT DLC for CONSULT Diagnostic connector for CONSULT
Diagnostic test mode DTM Diagnostic mode
Diagnostic test mode selector DTM selector Diagnostic mode selector
Diagnostic test mode I DTM I Mode I
Diagnostic test mode II DTM II Mode II
Diagnostic trouble code DTC Malfunction code
Direct fuel injection system DFI system ***
Distributor ignition system DI system Ignition timing control
Early fuel evaporation-mixture heater EFE-mixture heater Mixture heater
Early fuel evaporation system EFE system Mixture heater control
Electrically erasable programmable read only
memoryEEPROM ***
Electronic ignition system EI system Ignition timing control
Engine control EC ***
Engine control module ECM ECCS control unit
Engine coolant temperature ECT Engine temperature
Engine coolant temperature sensor ECTS Engine temperature sensor
Engine modi®cation EM ***
Engine speed RPM Engine speed
Erasable programmable read only memory EPROM ***
Evaporative emission canister EVAP canister Canister
SAE J1930 TERMINOLOGY LIST
GI-43

Air mix door control (Automatic temperature control)
The air mix door is automatically controlled so that in-vehicle temperature is maintained at a predetermined
value by: The temperature setting, ambient temperature, in-vehicle temperature and amount of sunload.
Fan speed control
Blower speed is automatically controlled based on temperature setting, ambient temperature, in-vehicle
temperature, intake temperature, amount of sunload and air mix door position.
With FAN switch set to ``AUTO'', the blower motor starts to gradually increase air ¯ow volume.
When engine coolant temperature is low, the blower motor operation is delayed to prevent cool air from ¯ow-
ing.
Intake door control
The intake doors are automatically controlled by: The temperature setting, ambient temperature, in-vehicle
temperature, intake temperature, amount of sunload and ON-OFF operation of the compressor.
Outlet door control
The outlet door is automatically controlled by: The temperature setting, ambient temperature, in-vehicle
temperature, intake temperature and amount of sunload.
Magnet clutch control
The ECM (ECCS control module) controls compressor operation using input signals from the throttle position
sensor and auto ampli®er.
Self-diagnostic system
The self-diagnostic system is built into the auto ampli®er (LCU) to quickly locate the cause of problems.
RHA442G
DESCRIPTIONAUTO
Features (Cont'd)
HA-51

SYSTEM DESCRIPTION
Component parts
Fan speed control system components are:
1) Auto amp.
2) Fan control amp.
3) A/C LAN system (PBR built in mode door motor and air mix door motor)
4) In-vehicle sensor
5) Ambient sensor
6) Sunload sensor
7) Intake sensor
System operation
Automatic mode
In the automatic mode, the blower motor speed is calculated by the automatic ampli®er based on inputs from
the PBR, in-vehicle sensor, sunload sensor, intake sensor and ambient sensor. The blower motor applied
voltage ranges from approximately 5 volts (lowest speed) to 12 volts (highest speed).
The control blower speed (in the range of 5 to 12V), the automatic ampli®er supplies a gate voltage to the fan
control ampli®er. Based on this voltage, the fan control ampli®er controls the voltage supplied to the blower
motor.
Starting fan speed control
Start up from ``COLD SOAK'' condition (Automatic mode)
In a cold start up condition where the engine coolant temperature is below 50ÉC, the blower will not operate
for a short period of time (up to 150 seconds). The exact start delay time varies depending on the ambient
and engine coolant temperature.
In the most extreme case (very low ambient) the blower starting delay will be 150 seconds as described above.
After this delay, the blower will operate at low speed until the engine coolant temperature rises above 55ÉC,
at which time the blower speed will increase to the objective speed.
Start up from normal or ``HOT SOAK'' condition (Automatic mode)
The blower will begin operation momentarily after the AUTO button is pushed. The blower speed will gradu-
ally rise to the objective speed over a time period of 3 seconds or less (actual time depends on the objective
blower speed).
SHA006FB
TROUBLE DIAGNOSESAUTO
Blower Motor (Cont'd)
HA-87

Combination meter........................................EL-102
Combination switch .........................................EL-57
Combustion chamber replacement ................EM-32
Compass .......................................................EL-116
Compression pressure ...................................EM-10
Compressor special service tool ......................HA-6
Connecting rod...............................................EM-47
Connecting rod...............................................EM-51
Connector inspection .......................................GI-17
Console box - See Instrument panel ..............BT-11
Control lever (Transfer) .....................................TF-9
Control sleeve position sensor .......................EC-86
Coolant mixture ratio ......................................MA-11
Coolant replacement ......................................MA-14
Cooling circuit (engine) .....................................LC-9
Cooling fan control .......................................EC-112
Cooling fan motor .........................................EC-120
Cooling fan relay ..........................................EC-120
Cooling fan......................................................LC-15
Counter gear (M/T).........................................MT-10
Counter gear (Transfer) ..................................TF-11
Coupling sleeve (M/T) ....................................MT-10
Crankcase emission control system -
See Positive crankcase ventilation.............EC-21
Crankcase ventilation system - See
Positive crankcase ventilation ....................EC-21
Crankshaft position sensor (TDC)................EC-143
Crankshaft ......................................................EM-50
Cylinder block ..........................................EM-45, 48
Cylinder head .................................................EM-28
D
D/LOCK - Wiring diagram .............................EL-205
DEF - Wiring diagram ...................................EL-159
DEICER - Wiring diagram.............................EL-167
DTRL - Wiring diagram ...................................EL-67
Data link connector for Consult......................EC-36
Daytime light system.......................................EL-65
Diagnosis sensor unit .....................................RS-12
Diagnostic trouble code (DTC) for
ECCS OBD system ....................................EC-30
Differential carrier assembly...........................PD-31
Differential carrier disassembly ......................PD-14
Differential gear oil replacement ....................MA-22
Dimensions ......................................................GI-38
Dome light - See Interior lamp .......................EL-93
Door glass .........................................................BT-9
Door lock ...........................................................BT-9
Door mirror ......................................................BT-46
Door trim .........................................................BT-18
Door, front .........................................................BT-9
Door, rear ........................................................BT-10
Drive belt inspection ......................................MA-12
Drive chain (Transfer) .....................................TF-11
Drive pinion diff. inspection ............................PD-19
Drive pinion height .........................................PD-27
Drive shaft (front) ............................................FA-23
Dual pressure switch ......................................HA-11Dual pressure switch ......................................HA-97
E
ECCS basic inspection...................................EC-46
ECCS circuit diagram .....................................EC-11
ECCS component parts location ......................EC-8
ECCS on board diagnostic system ................EC-30
ECCS symptom matrix chart..........................EC-48
ECCS system diagram and chart ..................EC-12
ECCS-D control module .........................EC-54, 110
ECM input/output signal .................................EC-54
ECTS - Wiring diagram ..................................EC-78
EGR control (EGRC) - solenoid valve .........EC-155
EGR control valve ........................................EC-161
EGRC/V - Wiring diagram ............................EC-155
Electric governor ....................................EC-95, 148
Electric sunroof .............................................EL-186
Electrical diagnoses.........................................GI-20
Electrical unit.................................................EL-321
Electrical units location .................................EL-269
Electronic fuel injection pump ........................EC-27
Engine compartment .......................................BT-49
Engine coolant temperature sensor
(ECTS) ........................................................EC-78
Engine oil ®lter replacement ..........................MA-14
Engine oil precautions .......................................GI-4
Engine oil replacement ..................................MA-13
Engine outer component parts ........................EM-8
Engine removal ..............................................EM-43
Engine room - See Engine
compartment ...............................................BT-49
Engine serial number ......................................GI-37
Exhaust system inspection ............................MA-20
Exhaust system ................................................FE-3
Exterior ............................................................BT-26
F
FCUT - Wiring diagram ................................EC-129
FTS - Wiring diagram ...................................EC-134
Fan control amp. ............................................HA-88
Final drive disassembly ..................................PD-14
Final drive removal and installation................PD-11
Finisher, interior - See Trim ............................BT-14
Floor trim .........................................................BT-14
Flow charts ......................................................GI-30
Fluids................................................................MA-9
Flywheel (clutch).......................................CL-13, 14
Flywheel runout..............................................EM-52
Fog lamp, rear ................................................EL-80
Fork rod (M/T) ................................................MT-12
Front axle ........................................................FA-10
Front bumper ....................................................BT-4
Front case (Transfer) ......................................TF-10
Front disc brake .............................................BR-20
Front door .........................................................BT-9
ALPHABETICAL INDEX
IDX-3

ENGINE LUBRICATION &
COOLING SYSTEMS
SECTION
LC
CONTENTS
PRECAUTIONS AND PREPARATION............................1
Liquid Gasket Application Procedure ..........................1
Special Service Tools ..................................................2
ENGINE LUBRICATION SYSTEM..................................3
Lubrication Circuit ........................................................3
Oil Pressure Check......................................................3
Oil Pump ......................................................................4
Oil Cooler .....................................................................7
Oil Jet...........................................................................7
Turbocharger ...............................................................8
ENGINE COOLING SYSTEM..........................................9
Cooling Circuit .............................................................9System Check..............................................................9
Water Pump ...............................................................10
Thermostat .................................................................12
Radiator .....................................................................14
Re®lling Engine Coolant ............................................14
Cooling Fan (Crankshaft driven) ...............................15
Cooling Fan (Motor driven)........................................15
Radiator (Aluminum type) ..........................................16
Overheating Cause Analysis .....................................20
SERVICE DATA AND SPECIFICATIONS (SDS)..........21
Engine Lubrication System ........................................21
Engine Cooling System .............................................21
LC

Liquid Gasket Application Procedure
a. Use a scraper to remove all traces of old liquid gasket from
mating surfaces and grooves. Also, completely clean any oil
from these areas.
b. Apply a continuous bead of liquid gasket to mating surfaces.
(Use Genuine Liquid Gasket or equivalent.)
+For oil pan, be sure liquid gasket diameter is 3.5 to 4.5 mm
(0.138 to 0.177 in).
+For areas except oil pan, be sure liquid gasket diameter is
2.0 to 3.0 mm (0.079 to 0.118 in).
c. Apply liquid gasket around the inner side of bolt holes (unless
otherwise speci®ed).
d. Assembly should be done within 5 minutes after coating.
e. Wait at least 30 minutes before re®lling engine oil and engine
coolant.
SEM164F
AEM080
PRECAUTIONS AND PREPARATION
LC-1