Page 24 of 1226
Removal and Installation
1. Rotate crankshaft so intake cam nose for No. 1 cylinder facesstraight up when viewed through oil ®ller cap mounting hole.
2. Rotate crankshaft approximately 240É counterclockwise.
3. Remove vacuum pump.
CAUTION: Loosen mounting nuts equally and gradually.
Always remove mounting nuts by pushing to keep the
vacuum pump from jumping up.
Do not disassemble vacuum pump.
4. Install the vacuum pump in the location from which it was removed with cam nose set in position.
SBR319E
RD28 engine models
Vacuum pump
17 - 22 (1.7 - 2.2 kg-m, 12 - 16 ft-lb)
Rocker cover gasket
Rocker cover
VACUUM PUMP
BR-20
Page 198 of 1226

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
Page 408 of 1226

Bulb Replacement
The headlamp is a semi-sealed beam type which uses a replace-
able halogen bulb. The bulb can be replaced from the engine com-
partment side without removing the headlamp body.
+Grasp only the plastic base when handling the bulb. Never
touch the glass envelope.
1. Disconnect the battery cable.
2. Turn the bulb retaining ring counterclockwise until it is free from
the headlamp re¯ector, and then remove it.
3. Disconnect the harness connector from the back side of the
bulb.
4. Remove the headlamp bulb carefully. Do not shake or rotate
the bulb when removing it.
5. Install in the reverse order of removal.
CAUTION:
Do not leave headlamp re¯ector without bulb for a long period
of time. Dust, moisture, smoke, etc. entering headlamp body
may affect the performance of the headlamp. Remove head-
lamp bulb from the headlamp re¯ector just before a replace-
ment bulb is installed.
Aiming Adjustment
When performing headlamp aiming adjustment, use an aiming
machine, aiming wall screen or headlamp tester. Aimers should be
in good repair, calibrated and operated in accordance with respec-
tive operation manuals.
If any aimer is not available, aiming adjustment can be done as
follows:
For details, refer to the regulations in your own country.
a. Keep all tires in¯ated to correct pressures.
b. Place vehicle and tester on one and same ¯at surface.
c. See that there is no-load in vehicle (coolant, engine oil
®lled up to correct level and full fuel tank) other than the
driver (or equivalent weight placed in driver's position).
CAUTION:
Be sure aiming switch is set to ``0'' when performing aiming
adjustment on vehicles equipped with headlamp aiming con-
trol.
SEL995K
SEL466V
HEADLAMP Ð Conventional Type Ð
EL-63
Page 884 of 1226

Self-diagnosis
INTRODUCTION AND GENERAL DESCRIPTION
The self-diagnostic system diagnoses sensors, door motors,
blower motor, etc. by system line. Refer to applicable sections
(items) for details. Shifting from normal control to the self-diagnos-
tic system is accomplished by starting the engine (turning the igni-
tion switch from ``OFF'' to ``ON'') and pressing ``
'' switch for at
least 5 seconds. The ``
'' switch must be pressed within 5 sec-
onds after starting the engine (ignition switch is turned ``ON''). This
system will be canceled by either pressing
(AUTO) switch or
turning the ignition switch ``OFF''. Shifting from one step to another
is accomplished by means of turning temperature dial clockwise or
counterclockwise, as required.
Additionally shifting from STEP 4 to AUXILIARY MECHANISM is
accomplished by means of pushing
(fan) switch.
(Ignition switch OFF®ON)
Within 5 seconds after starting engine (ignition
switch is turned ``ON''), press
switch for
at least 5 seconds.
STEP 1 Ð LEDs and LCD are checked.
m
Left turnRight turn
STEP 2 Ð Input signals from each sensor are
checked.
m
Left turnRight turn
STEP 3 Ð Mode and intake door motor posi-
tion switch is checked.Ignition switch: OFFc
or(AUTO) switch: ONSelf-diagnostic function is canceled.m
Left turnRight turn
Note
STEP 4 Ð Actuators are checked.
m
AUXILIARY MECHANISM Ð Temperature set-
ting trimmerNote:
For STEP 4, engine must be running for
compressor to operate.
.
.
.
.
.
.
TROUBLE DIAGNOSESAUTO
HA-63
Page 885 of 1226
STEP-BY-STEP PROCEDURE
Turn ignition switch ON.
Set in self-diagnostic mode. Within 5 sec-
onds after starting engine (ignition switch is
turned ``ON''.), press
switch for at
least 5 seconds.
STEP 1 - LEDs AND LCD ARE CHECKED.
Do all LEDs and LCD illuminate?
Ye s
cNo
Malfunctioning
switch, LED or LCD.
Replace A/C auto amp.
Turn temperature dial clockwise.
Advance to self-diagnosis STEP 2?
Ye s
cNo
Malfunctioning temperature
dial.
Replace A/C auto amp.
Turn temperature dial counterclockwise.
Return to self-diagnosis STEP 1?
Ye s
cNo
Malfunctioning temperature
dial.
Replace A/C auto amp.
Turn temperature dial clockwise.
jA
(Go to next page.)
RHA526G
RHA527G
.
.
.
.
.
.
.
.
TROUBLE DIAGNOSESAUTO
Self-diagnosis (Cont'd)
HA-64
Page 889 of 1226
AUXILIARY MECHANISM: Temperature setting trimmer
The trimmer compensates for differences in range of 3ÉC between
temperature setting (displayed digitally) and temperature felt by
driver.
Operating procedures for this trimmer are as follows:
+Begin Self-diagnosis STEP 4 mode.
+Press
(fan) switch to set system in auxiliary mode.
+Turn temperature dial clockwise or counterclockwise as
desired. Temperature will change at a rate of 1ÉC each time a
switch is pressed.
When battery cable is disconnected, trimmer operation is can-
celed. Temperature set becomes that of initial condition, i.e.
0ÉC.
RHA581G
TROUBLE DIAGNOSESAUTO
Self-diagnosis (Cont'd)
HA-68
Page 902 of 1226

Air mix door control speci®cation
COMPONENT DESCRIPTION
The air mix door motor is attached to the heater unit. It rotates so
that the air mix door is opened or closed to a position set by the
auto ampli®er. Motor rotation is then conveyed through a shaft and
the air mix door position is then fed back to the auto ampli®er by
PBR built-in air mix door motor.
CONTROL LINKAGE ADJUSTMENT
Air mix door (Water cock)
1. Install air mix door motor on heater unit and connect it to main
harness.
2. Set up code No.
in Self-diagnosis STEP 4. Refer to HA-67.
3. Move air mix door lever by hand and hold it in full cold position.
4. Attach air mix door lever to rod holder.
5. Make sure air mix door operates properly when changing from
code No.
toby pushing DEF switch.
Full cold Full hot
6. Set up code No.in Self-diagnosis STEP 4.
7. Attach water cock cable to air mix door linkage and secure with
clip.
8. Rotate and hold water cock lever AND plate in the full cold
position (CLOCKWISE completely).
9. Attach water cock cable to plate and secure with clip (white
mark on cable housing should be centered under the retaining
clip).
10. Check that water cock operates properly when changing from
code No.
toby pushing DEF switch. (After several
cycles, water cock lever should be midpoint of plate opening
when code No.
is set.)
RHA690G
RHA696G
SHA522E
TROUBLE DIAGNOSESAUTO
Air Mix Door Motor (Cont'd)
HA-81