BRAKE PEDAL
BR-7
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1. Disconnect accelerator pedal position sensor harness connec-
tor.
2. Remove stop lamp switch from brake pedal assembly.
3. Remove snap pin and clevis pin from clevis of brake booster.
4. Remove nuts from brake pedal bracket, and remove brake pedal
assembly from vehicle.
5. Remove accelerator pedal from brake pedal assembly.
INSPECTION AFTER REMOVAL
• Check brake pedal upper rivet for deformation.
• Make sure that the lapping length of sub-bracket and slide plate is
at least 6.9 mm (0.272 in).
• Check brake pedal for bend, damage, and cracks on the welded
parts.
• Replace brake pedal assembly if any non-standard condition is
detected.
• Check clevis pin and plastic stopper for damage and deformation.
Replace clevis pin as necessary.
INSTALLATION
Installation is in the reverse order of the removal.
• After installing brake pedal assembly to vehicle, adjust brake pedal. Refer to BR-5, "
Inspection and Adjust-
ment" .
• After installing accelerator pedal, check accelerator pedal. Refer to ACC-3, "
Removal and Installation" .
SFIA2044E
SFIA2866E
SBR997
BR-20
< SERVICE INFORMATION >
BRAKE BOOSTER
1. Loosen lock nut to adjust input rod length so that the length B
satisfies the specified value.
2. Install spacer to brake booster and tighten spacer nut (brake
booster side) to the specified torque.
3. After adjusting length “B”, temporarily tighten lock nut to install
brake booster assembly to dash panel. At this time, make sure
to install a gasket between brake booster and vehicle.
CAUTION:
Be sure to install the gasket between brake booster and
vehicle.
4. Connect brake pedal to clevis of input rod with the clevis pin and snap pin.
5. Install brake pedal bracket nuts and tighten them to the specified torque.
6. Adjust the height and play of brake pedal. Refer to BR-5, "
Inspection and Adjustment" .
7. Tighten lock nut of input rod to the specified torque. Refer to "COMPONENTS" .
8. Install vacuum hose into brake booster. Refer to BR-21, "
Removal and Installation" .
9. Bleed air from brake system. Refer to BR-8, "
Bleeding Brake System" . Length “B” : 154 - 161 mm (6.06 - 6.34 in)
SGIA0060E
SERVICE DATA AND SPECIFICATIONS (SDS)
BR-33
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SERVICE DATA AND SPECIFICATIONS (SDS)
General SpecificationINFOID:0000000001703806
Brake PedalINFOID:0000000001703807
Unit: mm (in)
Check ValveINFOID:0000000001703808
Brake BoosterINFOID:0000000001703809
Vacuum type
Front Disc BrakeINFOID:0000000001703810
Unit: mm (in)
Front brake Brake model CLZ25VA
Cylinder bore diameter 57.2 mm (2.252 in)
Pad
Length × width × thickness125.6 mm × 46.0 mm × 9.5 mm
(4.945 in × 1.811 in × 0.374 in)
Rotor outer diameter × thickness 280 mm × 24.0 mm (11.02 in × 0.945 in)
Rear brake Brake model LT20D
Cylinder bore diameter 15.87 mm (0.625 in)
Lining
Length × width × thickness194.1 mm × 30.0 mm × 4.0 mm
(7.642 in × 1.181 in × 0.157 in)
Drum outer diameter 228.6 mm (9.000 in)
Master cylinder Cylinder bore diameter 22.22 mm (0.875 in)
Control valve Valve model Electric brake force distribution
Brake booster Booster model C255
Diaphragm diameter 255 mm (10.04 in)
Recommended brake fluid Refer to MA-10
.
Brake pedal free height (from dash panel top surface)A/T, CVT model 172.4 - 182.4 (6.79 - 7.18)
M/T model 162.3 - 172.3 (6.39 - 6.78)
Brake pedal depressed height
[under a force of 490 N (50 kg-f, 110 lb-f) with the engine running]A/T, CVT model 98 (3.86) or more
M/T model 90 (3.54) or more
Clearance between brake pedal lever and the threaded end of stop lamp switch 0.74 - 1.96 (0.0291 - 0.0772)
Pedal play3 - 11 (0.12 - 0.43)
Vacuum leakage
[at vacuum of – 66.7 kPa (– 500 mmHg, – 19.69 inHg]Within 1.3 kPa (10 mmHg, 0.39 inHg) of vacuum for 15 seconds
Vacuum leakage
[at vacuum of – 66.7 kPa (– 500 mmHg, –19.69 inHg)]Within 3.3 kPa (25 mmHg, 0.98 inHg) of vacuum for 15 seconds
Input rod installation standard dimension 154 - 161 mm (6.06 - 6.34 in)
Brake modelCLZ25VA
Brake padStandard thickness (new) 9.5 (0.374)
Repair limit thickness 2.0 (0.079)
CVT-180
< SERVICE INFORMATION >
TRANSAXLE ASSEMBLY
• When installing the cooler outlet tube (1) to the transaxle assembly
(2), align the cooler tube bracket (A) against the transaxle as
shown.
• When installing the transaxle to the engine, align the matching mark on the drive plate with the matching
mark on the torque converter alignment stud.
• When securing the transaxle to the engine, attach the bolts in
accordance with the following standard.
• When installing the drive plate to torque converter nuts, tighten
them temporarily. Then tighten the nuts to the specified torque.
• After completing installation check for fluid level, fluid leakage, and the positions of CVT. Refer to MA-19,
"Checking CVT Fluid", CVT-171, "Adjustment of CVT Position" and CVT-171, "Checking of CVT Position".
• When replacing the CVT assembly, erase EEP ROM in TCM. Refer to CVT-8, "
Service After Replacing TCM
and Transaxle Assembly".
WCIA0618E
Bolt No. 1 (Transaxle to engine) 2 (Engine to transaxle)
Number of bolts 2 7
Bolt length
“A” mm (in)55 (2.17) 50 (1.97)
Tightening torque
N·m (kg-m, ft-lb)62 (6.3, 46)
WCIA0619E
Converter nuts: : 51 N·m (5.2 kg-m, 38 ft-lb)
WCIA0616E
ENGINE CONTROL SYSTEM
EC-23
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*1: This sensor is not used to control the engine system under normal conditions.
*2: This signal is sent to the ECM through CAN communication line.
*3: ECM determines the start signal status by the signals of engine speed and battery voltage.
SYSTEM DESCRIPTION
The amount of fuel injected from the fuel injector is determined by the ECM. The ECM controls the length of
time the valve remains open (injection pulse duration). The amount of fuel injected is a program value in the
ECM memory. The program value is preset by engine operating conditions. These conditions are determined
by input signals (for engine speed and intake air) from the crankshaft position sensor (POS), camshaft position
sensor (PHASE) and the mass air flow sensor.
VARIOUS FUEL INJECTION INCREASE/DECREASE COMPENSATION
In addition, the amount of fuel injected is compensated to improve engine performance under various operat-
ing conditions as listed below.
• When starting the engine
• During acceleration
• Hot-engine operation
• When selector lever is changed from N to D (A/T and CVT models)
• High-load, high-speed operation
• During deceleration
• During high engine speed operation
MIXTURE RATIO FEEDBACK CONTROL (CLOSED LOOP CONTROL)
The mixture ratio feedback system provides the best air/fuel mixture ratio for driveability and emission control.
The three way catalyst (manifold) can then better reduce CO, HC and NOx emissions. This system uses air
Sensor Input Signal to ECM ECM function Actuator
Crankshaft position sensor (POS)
Engine speed*
3
Piston position
Fuel injection
& mixture ratio
controlFuel injector Camshaft position sensor (PHASE)
Mass air flow sensor Amount of intake air
Engine coolant temperature sensor Engine coolant temperature
Air fuel ratio (A/F) sensor 1 Density of oxygen in exhaust gas
Throttle position sensor Throttle position
Accelerator pedal position sensor Accelerator pedal position
Park/neutral position (PNP) switch Gear position
Battery
Battery voltage*
3
Knock sensor Engine knocking condition
EPS control unit
Power steering operation*
2
Heated oxygen sensor 2*1Density of oxygen in exhaust gas
Air conditioner switch
Air conditioner operation*
2
Wheel sensor
Vehicle speed*2
PBIB3020E
ON BOARD DIAGNOSTIC (OBD) SYSTEM
EC-63
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tified codes can be identified by using the CONSULT-II or GST. A DTC will be used as an example for how to
read a code.
A particular trouble code can be identified by the number of four-digit numeral flashes. The “zero” is indicated
by the number of ten flashes. The “A” is indicated by the number of eleven flash. The length of time the
1,000th-digit numeral flashes on and off is 1.2 seconds consisting of an ON (0.6-second) - OFF (0.6-second)
cycle. The 100th-digit numeral and lower digit numerals consist of a 0.3-second ON and 0.3-second OFF
cycle. A change from one digit numeral to another occurs at an interval of 1.0-second OFF. In other words, the
later numeral appears on the display 1.3 seconds after the former numeral has disappeared.
A change from one trouble code to another occurs at an interval of 1.8-second OFF.
In this way, all the detected malfunctions are classified by their DTC numbers. The DTC 0000 refers to no mal-
function. (See EC-9
)
How to Erase Diagnostic Test Mode II (Self-diagnostic Results)
The DTC can be erased from the back-up memory in the ECM by depressing accelerator pedal.
Refer to "How to Erase Diagnostic Test Mode II (Self-diagnostic Results)".
•If the battery is disconnected, the DTC will be lost from the backup memory within 24 hours.
•Be careful not to erase the stored memory before starting trouble diagnoses.
OBD System Operation ChartINFOID:0000000001702577
RELATIONSHIP BETWEEN MIL, 1ST TRIP DTC, DTC, AND DETECTABLE ITEMS
• When a malfunction is detected for the first time, the 1st trip DTC and the 1st trip freeze frame data are
stored in the ECM memory.
• When the same malfunction is detected in two consecutive trips, the DTC and the freeze frame data are
stored in the ECM memory, and the MIL will come on. For details, refer to EC-46, "
Two Trip Detection Logic".
• The MIL will go off after the vehicle is driven 3 times (driving pattern B) with no malfunction. The drive is
counted only when the recorded driving pattern is met (as stored in the ECM). If another malfunction occurs
while counting, the counter will reset.
• The DTC and the freeze frame data will be stored until the vehicle is driven 40 times (driving pattern A) with-
out the same malfunction recurring (except for Misfire and Fuel Injection System). For Misfire and Fuel Injec-
tion System, the DTC and freeze frame data will be stored until the vehicle is driven 80 times (driving pattern
PBIB3005E
FUEL INJECTOR
EC-521
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FUEL INJECTOR
Component DescriptionINFOID:0000000001703059
The fuel injector is a small, precise solenoid valve. When the ECM
supplies a ground to the fuel injector circuit, the coil in the fuel injec-
tor is energized. The energized coil pulls the ball valve back and
allows fuel to flow through the fuel injector into the intake manifold.
The amount of fuel injected depends upon the injection pulse dura-
tion. Pulse duration is the length of time the fuel injector remains
open. The ECM controls the injection pulse duration based on
engine fuel needs.
CONSULT-II Reference Value in Data Monitor ModeINFOID:0000000001703060
Specification data are reference values.
PBIA9664J
MONITOR ITEM CONDITION SPECIFICATION
B/FUEL SCHDL See EC-127
.
INJ PULSE-B1• Engine: After warming up
• Air conditioner switch: OFF
• Shift lever: P or N (A/T, CVT),
Neutral (M/T)
•No loadIdle 2.0 - 3.0 msec
2,000 rpm 1.9 - 2.9 msec
DRIVE BELTS
EM-13
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DRIVE BELTS
ComponentINFOID:0000000001702474
Checking Drive BeltsINFOID:0000000001702475
WARNING:
Be sure to perform this step when the engine is stopped.
• Make sure that the indicator (notch on fixed side) of drive belt auto-tensioner is within the possible use range
(A).
NOTE:
• Check the drive belt auto-tensioner indication when the engine is cold.
• When new drive belt is installed, the indicator (notch on fixed side) should be within the range (B).
• Visually check entire drive belt for wear, damage or cracks.
• If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt.
Tension AdjustmentINFOID:0000000001702476
Belt tension is not necessary, as it is automatically adjusted by drive belt auto-tensioner.
Removal and InstallationINFOID:0000000001702477
REMOVAL
1. Hold the hexagonal part (A) of drive belt auto-tensioner (1) with
a wrench securely. Then move the wrench handle in the direc-
tion of arrow (loosening direction of tensioner).
CAUTION:
Never place hand in a location where pinching may occur if
the holding tool accidentally comes off.
2. Insert a rod such as short-length screwdriver approximately 6
mm (0.24 in) in diameter into the hole (B) of the retaining boss to
fix drive belt auto-tensioner.
3. Remove drive belt.
INSTALLATION
1. Generator 2. Drive belt auto–tensioner 3. Crankshaft pulley
4.A/C compressor (models with A/C)
Idler pulley (models without A/C)5. Water pump 6. Drive belt
A. Possible use range B. Range when new drive belt is installed C. Indicator
PBIC3137J
PBIC3936E