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GI-6
PRECAUTIONS
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Do not run engine when the fuel tank level is low, otherwise the engine may misfire, causing damage to
the catalyst.
Do not place the vehicle on flammable material. Keep flammable material off the exhaust pipe and the three
way catalyst.
Precautions for Fuel (Unleaded Regular Gasoline Recommended)EAS00209
Use unleaded regular gasoline with an octane rating of at least 87 AKI (Anti-Knock Index) number (Research
octane number 91).
CAUTION:
Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Using a fuel
other than that specified could adversely affect the emission control devices and systems, and could
also affect the warranty coverage validity.
Precautions for Multiport Fuel Injection System or Engine Control SystemEAS001ZD
Before connecting or disconnecting any harness connector for
the multiport fuel injection system or ECM:
Turn ignition switch to “OFF” position.
Disconnect negative battery terminal.
Otherwise, there may be damage to ECM.
Before disconnecting pressurized fuel line from fuel pump to
injectors, be sure to release fuel pressure.
Be careful not to jar components such as ECM and mass air
flow sensor.
Precautions for HosesEAS001ZE
HOSE REMOVAL AND INSTALLATION
To prevent damage to rubber hose, do not pry off rubber hose
with tapered tool or screwdriver.
To reinstall the rubber hose securely, make sure that hose inser-
tion length and orientation is correct. (If tube is equipped with
hose stopper, insert rubber hose into tube until it butts up
against hose stopper.)
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PRECAUTIONS
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HOSE CLAMPING
If old rubber hose is re-used, install hose clamp in its original
position (at the indentation where the old clamp was). If there is
a trace of tube bulging left on the old rubber hose, align rubber
hose at that position.
Discard old clamps; replace with new ones.
After installing plate clamps, apply force to them in the direction
of the arrow, tightening rubber hose equally all around.
Precautions for Engine OilsEAS001ZF
Prolonged and repeated contact with used engine oil may cause skin cancer. Try to avoid direct skin contact
with used oil.
If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible.
HEALTH PROTECTION PRECAUTIONS
Avoid prolonged and repeated contact with oils, particularly used engine oils.
Wear protective clothing, including impervious gloves where practicable.
Do not put oily rags in pockets.
Avoid contaminating clothes, particularly underpants, with oil.
Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regu-
larly.
First aid treatment should be obtained immediately for open cuts and wounds.
Use barrier creams, applying them before each work period, to help the removal of oil from the skin.
Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Prepa-
rations containing lanolin replace the natural skin oils which have been removed.
Do not use gasoline, kerosene, diesel fuel, gas oil, thinners or solvents for cleaning skin.
If skin disorders develop, obtain medical advice without delay.
Where practical, degrease components prior to handling.
Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face
shields; in addition an eye wash facility should be provided.
Precautions for Air ConditioningEAS0021N
Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to
MTC section "HFC-134a (R-134a) Service Procedure", "REFRIGETANT LINES" for specific instructions.
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GI-8
HOW TO USE THIS MANUAL
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HOW TO USE THIS MANUALPFP:00008
Description EAS001ZH
This volume explains “Removal, Disassembly, Installation, Inspection and Adjustment” and “Trouble Diag-
noses”.
TermsEAS001ZI
The captions WAR NIN G and CAUTION warn you of steps that must be followed to prevent personal
injury and/or damage to some part of the vehicle.
WAR NIN G indicates the possibility of personal injury if instructions are not followed.
CAUTION indicates the possibility of component damage if instructions are not followed.
BOLD TYPED STATEMENTS except WAR NIN G and CAUTION give you helpful information.
Standard value:Tolerance at inspection and adjustment.
Limit value:The maximum or minimum limit value that should not be exceeded at inspection and adjust-
ment.
UnitsEAS001ZJ
The UNITS given in this manual are primarily expressed as the SI UNIT (International System of Unit),
and alternatively expressed in the metric system and in the yard/pound system.
Also with regard to tightening torque of bolts and nuts, there are descriptions both about range and about
the standard tightening torque.
“Example”
Range
Standard
ContentsEAS001ZK
ALPHABETICAL INDEX is provided at the end of this manual so that you can rapidly find the item and
page you are searching for.
A QUICK REFERENCE INDEX, a black tab (e.g. ) is provided on the first page. You can quickly find
the first page of each section by matching it to the section's black tab.
THE CONTENTS are listed on the first page of each section.
THE TITLE is indicated on the upper portion of each page and shows the part or system.
THE PAGE NUMBER of each section consists of two or three letters which designate the particular sec-
tion and a number (e.g. “BR-5”).
THE SMALL ILLUSTRATIONS show the important steps such as inspection, use of special tools, knacks
of work and hidden or tricky steps which are not shown in the previous large illustrations.
Assembly, inspection and adjustment procedures for the complicated units such as the automatic tran-
saxle or transmission, etc. are presented in a step-by-step format where necessary.Outer Socket Lock Nut : 59 - 78 N-m (6.0 - 8.0 kg-m, 43 - 58 ft-lb)
Drive Shaft Installation Bolt : 44.3 N-m (4.5 kg-m, 33 ft-lb)
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Relation between Illustrations and DescriptionsEAS001ZL
The following sample explains the ralationship between the part description in an illustration, the part name in
the text and the service procedures.
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ComponentsEAS001ZM
THE LARGE ILLUSTRATIONS are exploded views (see the following) and contain tightening torques,
lubrication points, section number of the PA R T S C ATA L O G (e.g. SEC. 440) and other information neces-
sary to perform repairs.
The illustrations should be used in reference to service matters only. When ordering parts, refer to the
appropriate PA R T S C ATA L O G .
Components shown in an illustration may be identified by a circled number. When this style of illustration
is used, the text description of the components will follow the illustration.
SYMBOLS
1. Union bolt 2. Copper washer 3. Brake hose
4. Cap 5. Bleed valve 6. Sliding pin bolt
7. Piston seal 8. Piston 9. Piston boot
10. Cylinder body 11. Sliding pin 12. Torque member mounting bolt
13. Washer 14. Sliding pin boot 15. Bushing
16. Torque member 17. Inner shim cover 18. Inner shim
19. Inner pad 20. Pad retainer 21. Pad wear sensor
22. Outer pad 23. Outer shim 24. Outer shim cover
1: PBC (Poly Butyl Cuprysil) grease
or silicone-based grease2: Rubber grease : Brake fluid
Refer to GI section for additional symbol definitions.
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How to Follow Trouble DiagnosesEAS001ZN
DESCRIPTION
NOTICE:
Trouble diagnoses indicate work procedures required to diagnose problems effectively. Observe the following
instructions before diagnosing.
1.Before performing trouble diagnoses, read the “Preliminary Check”, the “Symptom Chart” or the
“Work Flow”.
2.After repairs, re-check that the problem has been completely eliminated.
3.Refer to Component Parts and Harness Connector Location for the Systems described in each
section for identification/location of components and harness connectors.
4.Refer to the Circuit Diagram for quick pinpoint check.
If you need to check circuit continuity between harness connectors in more detail, such as when a
sub-harness is used, refer to Wiring Diagram in each individual section and Harness Layout in PG
section for identification of harness connectors.
5.When checking circuit continuity, ignition switch should be OFF.
6.Before checking voltage at connectors, check battery voltage.
7.After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure
that all harness connectors are reconnected as they were.
HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES
1.Work and diagnostic procedure
Start to diagnose a problem using procedures indicated in enclosed test groups.
2.Questions and required results
Questions and required results are indicated in bold type in test group.
The meaning of are as follows:
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HOW TO USE THIS MANUAL
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3.Symbol used in illustration
Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem,
familiarize yourself with each symbol. Refer to "Connector Symbols" in GI Section and "KEY TO SYM-
BOLS SIGNIFYING MEASUREMENTS OR PROCEDURES" below.
4.Action items
Next action for each test group is indicated based on result of each question. Test group number is shown
in the left upper portion of each test group.
HARNESS WIRE COLOR AND CONNECTOR NUMBER INDICATION
There are two types of harness wire color and connector number indication.
TYPE 1: Harness Wire Color and Connector Number are Shown in Illustration
Letter designations next to test meter probe indicate harness
wire color.
Connector numbers in a single circle (e.g. M33) indicate har-
ness connectors.
Connector numbers in a double circle (e.g. F211) indicate com-
ponent connectors.a. Battery voltage → 11 - 14V or approximately 12V
b. Voltage : Approximately 0V → Less than 1V
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TYPE 2: Harness Wire Color and Connector Number are Shown in Text
KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES
SG I1 44 A
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