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GI-4< SERVICE INFORMATION >
PRECAUTIONS
• Replace oil seals, gaskets, packings, O-rings, locking wa shers, 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 com ponents which use microcomputers (such as ECM).
Static electricity may damage internal electronic components.
• After disconnecting vacuum or air hoses, atta ch 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.
• 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 tro uble codes, do not carelessly disconnect the harness
connectors which are related to the engine cont rol system and TCM (transmission control module)
system. The connectors should be disconnected on ly when working according to the WORK FLOW of
TROUBLE DIAGNOSES in EC, CVT, and AT sections.
Precaution for Three Way Catalyst INFOID:0000000004307348
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 (Unleade d Regular Gasoline Recommended) INFOID:0000000004307349
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. Do not use E-85
fuel (85% fuel ethanol, 15% unl eaded gasoline) unless the vehicle is specifically designed for E-85 fuel PBIC0190E
SGI234
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(i.e. Flexible Fuel Vehicle - FFV models). Using a fu
el other than that specified could adversely affect
the emission control devices and systems, and could also affect the warranty coverage validity.
Precaution for Multiport Fuel Inject ion System or Engine Control System INFOID:0000000004307350
• Before connecting or disconnecti ng 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 Hoses INFOID:0000000004307351
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 insertion length and orientation is correct. (If tube is equipped with hose
stopper, insert rubber hose into tube until it butts up against hose
stopper.)
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. SMA019D
SMA021D
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HFC-134a (R-134a) Service Procedure " for specific instructions.
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HOW TO USE THIS MANUAL
Description INFOID:0000000004307354
This volume explains “Removal, Disassembly, Inst allation, Inspection and Adjustment” and “Trouble Diag-
noses”.
Terms INFOID:0000000004307355
• 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 t hat should not be exceeded at inspection and adjustment.
Units INFOID:0000000004307356
• 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
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SYMBOLS
How to Follow Trouble Diagnosis INFOID:0000000004307360
DESCRIPTION NOTICE:
Trouble diagnoses indicate work procedures required to diagnose problems effectively. Observe the following
instructions before diagnosing.
1. Before performing trouble diagno ses, read the “Preliminary Check” , the “Symptom Chart” or the
“Work Flow”.
2. After repairs, re-check that the prob lem has been completely eliminated.
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 grease 2: Rubber grease : Brake fluid
Refer to GI section for additional symbol definitions.
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• Letter designations next to test meter probe indicate harness wire
color.
• Connector numbers in a single circle (e.g. M33) indicate harness
connectors.
• Connector numbers in a double circle (e.g. F211) indicate compo- nent connectors.
TYPE 2: Harness Wire Co lor and Connector Number are Shown in Text