Page 1969 of 3061

PRECAUTIONS
GI-3
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General PrecautionINFOID:0000000003531471
• Do not operate the engine for an extended period of time without
proper exhaust ventilation.
Keep the work area well ventilated and free of any flammable
materials. Special care should be taken when handling any flam-
mable or poisonous materials, such as gasoline, refrigerant gas,
etc. When working in a pit or other enclosed area, be sure to prop-
erly ventilate the area before working with hazardous materials.
Do not smoke while working on the vehicle.
• Before jacking up the vehicle, apply wheel chocks or other tire
blocks to the wheels to prevent the vehicle from moving. After jack-
ing up the vehicle, support the vehicle weight with safety stands at
the points designated for proper lifting before working on the vehi-
cle.
These operations should be done on a level surface.
• When removing a heavy component such as the engine or tran-
saxle/transmission, be careful not to lose your balance and drop
them. Also, do not allow them to strike adjacent parts, especially
the brake tubes and master cylinder.
• Before starting repairs which do not require battery power:
Turn off ignition switch.
Disconnect the negative battery terminal.
• If the battery terminals are disconnected, recorded memory of
radio and each control unit is erased.
• Battery posts, terminals and related accessories contain lead and
lead compounds. Wash hands after handling.
• To prevent serious burns:
Avoid contact with hot metal parts.
Do not remove the radiator cap when the engine is hot.
• Dispose of or recycle drained oil or the solvent used for cleaning
parts in an appropriate manner.
• Do not attempt to top off the fuel tank after the fuel pump nozzle
shuts off automatically.
Continued refueling may cause fuel overflow, resulting in fuel spray
and possibly a fire.
• Clean all disassembled parts in the designated liquid or solvent
prior to inspection or assembly.
• Replace oil seals, gaskets, packings, O-rings, locking washers,
cotter pins, self-locking nuts, etc. with new ones.
• Replace inner and outer races of tapered roller bearings and needle bearings as a set.
• Arrange the disassembled parts in accordance with their assembled locations and sequence.
• Do not touch the terminals of electrical components which use microcomputers (such as ECM).
Static electricity may damage internal electronic components.
• After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection.
• Use only the fluids and lubricants specified in this manual.
• Use approved bonding agent, sealants or their equivalents when required.
SGI285
SGI231
SEF289H
SGI233
Page 1970 of 3061

GI-4
< SERVICE INFORMATION >
PRECAUTIONS
• Use hand tools, power tools (disassembly only) and recommended
special tools where specified for safe and efficient service repairs.
• When repairing the fuel, oil, water, vacuum or exhaust systems,
check all affected lines for leaks.
• Before servicing the vehicle:
Protect fenders, upholstery and carpeting with appropriate covers.
Take caution that keys, buckles or buttons do not scratch paint.
WARNING:
To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness
connectors which are related to the engine control system and TCM (transmission control module)
system. The connectors should be disconnected only when working according to the WORK FLOW of
TROUBLE DIAGNOSES in EC and AT sections.
Precaution for Three Way CatalystINFOID:0000000003531472
If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To
prevent this, follow the instructions.
• Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst.
• When checking for ignition spark or measuring engine compression, make tests quickly and only when nec-
essary.
• 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.
Precaution for Fuel (Unleaded Premium Gasoline Required)INFOID:0000000003531473
Use unleaded premium gasoline with an octane rating of at least 91 AKI (Anti-Knock Index) number (Research
octane number 96).
If unleaded premium gasoline is not available, unleaded regular gasoline with an octane rating of at least 87
AKI number (Research octane number 91) can be used, but only under the following precautions:
• have the fuel tank filled only partially with unleaded regular gasoline, and fill up with unleaded premium gas-
oline as soon as possible.
• avoid full throttle driving and abrupt acceleration.
However, for maximum vehicle performance, the use of unleaded premium gasoline is recommended.
CAUTION:
Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Do not use E-85
fuel (85% fuel ethanol, 15% unleaded gasoline) unless the vehicle is specifically designed for E-85 fuel
(i.e. Flexible Fuel Vehicle - FFV models). Using a fuel other than that specified could adversely affect
the emission control devices and systems, and could also affect the warranty coverage validity.
PBIC0190E
SGI234
Page 1971 of 3061

PRECAUTIONS
GI-5
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Precaution for Multiport Fuel Injection System or Engine Control SystemINFOID:0000000003531474
• 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 injec-
tors, be sure to release fuel pressure.
• Be careful not to jar components such as ECM and mass air flow
sensor.
Precaution for HosesINFOID:0000000003531475
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 of hose insertion
length and clamp orientation. (If tube is equipped with hose stop-
per, insert rubber hose into tube until it butts up against hose stop-
per.)
HOSE CLAMPING
• If old rubber hose is re-used, install hose clamp in its original posi-
tion (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.
SGI787
SMA019D
SMA020D
SMA021D
Page 1972 of 3061

GI-6
< SERVICE INFORMATION >
PRECAUTIONS
• After installing leaf spring clamps, apply force to them in the direc-
tion of the arrow, tightening rubber hose equally all around.
Precaution for Engine OilsINFOID:0000000003531476
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). Prepara-
tions 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.
Precaution for Air ConditioningINFOID:0000000003531477
Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to
ATC-150, "
HFC-134a (R-134a) Service Procedure" for specific instructions.
SMA022D
Page 1973 of 3061

HOW TO USE THIS MANUAL
GI-7
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PHOW TO USE THIS MANUAL
DescriptionINFOID:0000000003531478
This volume explains “Removal, Disassembly, Installation, Inspection and Adjustment” and “Trouble Diag-
noses”.
Te r m sINFOID:0000000003531479
• The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal injury
and/or damage to some part of the vehicle.
WARNING 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 WARNING 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 adjustment.
UnitsINFOID:0000000003531480
• 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.
“Example”
Relation between Illustrations and DescriptionsINFOID:0000000003531481
The following sample explains the relationship between the part description in an illustration, the part name in
the text and the service procedures.Outer Socket Lock Nut : 59 - 78 N-m (6.0 - 8.0 kg-m, 43 - 58 ft-lb)
SAIA0519E
Page 1974 of 3061

GI-8
< SERVICE INFORMATION >
HOW TO USE THIS MANUAL
Contents
INFOID:0000000003531482
•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 section
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 transaxle
or transmission, etc. are presented in a step-by-step format where necessary.
ComponentINFOID:0000000003531483
•THE LARGE ILLUSTRATIONS are exploded views (see the following) and contain tightening torques, lubri-
cation points, section number of the PARTS CATALOG (e.g. SEC. 440) and other information necessary to
perform repairs.
The illustrations should be used in reference to service matters only. When ordering parts, refer to the appro-
priate PARTS CATALOG.
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.
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.
SFIA2959E
Page 1975 of 3061

HOW TO USE THIS MANUAL
GI-9
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SYMBOLS
How to Follow Trouble DiagnosisINFOID:0000000003531484
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.
SAIA0749E
Page 1976 of 3061

GI-10
< SERVICE INFORMATION >
HOW TO USE THIS MANUAL
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:
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
SAIA0256E
a. Battery voltage → 11 - 14V or approximately 12V
b. Voltage : Approximately 0V → Less than 1V