1997 Terios j100

SECTION INDEX
DAIHATSU SECTION NAME SECTION
GENERAL INFORMATION GI
MAINTENANCE MA
J100 ENGINE MECHANICAL EM
EMISSION CONTROL EC
EFI SYSTEM EF
LUBRICATION SYSTEM LU
COOLING SYSTEM CO
IGNITION SYSTEM IG
STARTING SYSTEM ST
CHARGING SYSTEM CH
CLUTCH CL
MANUAL TRANSMISSION MT
AUTOMATIC TRANSMISSION AT
TRANSMISSION & TRANSFER TR
PROPELLER SHAFT PR
FRONT & REAR DIFFERENTIAL DF
FRONT AXLE & SUSPENSION FS
REAR AXLE & SUSPENSION RS
BRAKE (Including A.B.S) BR
STEERING SR
BODY BO
BODY ELECTRICAL (Including
and immobilizer system )
Airbag system
BE
HARNESS & WIRING DIAGRAM HW
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SERVICE MANUAL
DAIHATSU
J100
FOREWORD
This service manual describes the maintenance and servicing procedures for the Model
J100.
Applicable Model: J100

In this service manual, the entire portion is divided into 23 sections. Each section has an
index along with a table of contents at the beginning. For easier reference, the upper part
of each page bears the section title concerned.
All information used in this service manual was in effect at the time when the manual was
printed. However, the specifications and procedures may be revised due to continuing im-
provements in the design without advance notice and without incurring any obligation to
us.
Published in June, 1997
NO. 9710-JE
DAIHATSU MOTOR CO., LTD.
1997 DAIHATSU MOTOR CO., LTD.

All rights reserved. This material may not be reproduced or copied, in whole or in part, with-
out the written permission of Overseas Service Division of Daihatsu Motor Co., ltd.

DAIHATSU
GI
J100
GENERAL INFORMATION
IMPORTANT SAFETY NOTICE .................... GI 2

WARNINGS, CAUTIONS AND NOTES..... GI 2
HOW TO USE THIS MANUAL ...................... GI 4
CONTENTS OF EXPLANATION .............. GI 4
ABBREVIATION CODES ............................. GI 6
GENERAL SERVICE INSTRUCTION .......... GI 7
HANDLING INSTRUCTIONS ON
CATALYTIC CONVERTER ......................... GI 8
JACKING POINTS AND SUPPORTING
POINTS OF SAFETY STANDS ................. GI 9
MODEL VARIATION ..................................... GI13
CHASSIS SERIAL NUMBER STAMPED
POSITION ..................................................... GI14
MANUFACTURERS PLATE POSITION ....... GI14
CONTENTS OF MANUFACTURERS
PLATE....................................................... GI14
ENGINE NUMBER AND ENGINE TYPE
STAMPED POSITIONS...............................GI15
BODY COLOR INFORMATION ......................GI15
COLOR CODE IN THE WORLD ................GI16
TRIM CODE ....................................................GI16
JGI00001-00000
NO. 9710-JE

GI2
IMPORTANT SAFETY NOTICE

The vehicle is a machine comprising a great number of parts. Basically speaking, the vehicle is
potentially hazard. However, one can handle it safely if he has the required knowledge.
Correct service methods and repair procedures are very vital for assuring not only the safety and
reliability of a vehicle, but also the safety of service personnel concerned.
The methods and procedures contained in this manual describe in a general way the techniques
which the manufacturer has recommended. Thus, they will contribute to ensuring the reliability of
the products. The contents of the servicing operations come in a wide variety of ways. Moreover,
techniques, tools and parts necessary for each operation are different widely from each other.
This manual does not cover all details of techniques, procedures, parts, tools and handling instruc-
tions which are necessary for these operations, for such coverage is impossible. Hence, any one
who obtains this manual is expected first to make his responsible selection as to techniques, tools
and parts which are necessary for servicing the vehicle concerned properly. Furthermore, he must
assume responsibility for his actions in connection with his own safety.
Therefore, one should not perform any service if he is not capable of making responsible selection
and/or if he can not understand the contents herein described, for this manual has been prepared
for experienced service personnel.
WARNINGS, CAUTIONS AND NOTES

All these symbols have their specific purposes, respectively.
WARNING:
This symbol means that there is the possibility of personal injury of the operator himself or the
nearby workers if the operator fails to follow the operating procedure prescribed in this manual.
CAUTION:
This symbol means that there is the possibility of damage to the component being repaired if
the operator fails to follow the operating procedure prescribed in this manual.
NOTE:
To accomplish the operation in an efficient manner, additional instructions concerning the
operation are given in this section.
The following list describes general WARNINGS:
Always wear safety glasses for eye protection.
Use safety stands whenever a procedure requires you to be under the vehicle.
Be sure that the ignition switch is always in the OFF position, unless otherwise required by the
procedure.
Set the parking brake when working on the vehicle.
Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide.
Keep yourself and your clothing away from moving parts, when the engine is running, especial-
ly from the fan and belts.
To prevent serious burns, avoid contact with hot metal parts, such as the radiator, exhaust
manifold, tail pipe, catalytic converter and muffler.
Do not smoke while working on a vehicle.
To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before
beginning to work on a vehicle.
Keep hands and other objects clear of the radiator fan blades! The electric cooling fan is mounted
on the radiator and can start to operate at anytime by a rise in coolant temperature or turning ON
of the air conditioner switch in the case of vehicles equipped with an air conditioner. The electric
cooling fan is also mounted on the condenser for air conditioner and starts to operate anytime
when the air conditioner switch is turned ON. For this reason care should be taken to ensure that
the electric cooling fan motor is completely disconnected when working under the hood.

GI3
The UNITS used in this manual are showed as the SI UNIT (International System of Unit), and alter-
natively showed in the metric system.
Example
24.5 - 34.3 Nm (2.5 - 3.5 kgf-m)
JGI00002-00000

GI4
HOW TO USE THIS MANUAL
CONTENTS OF EXPLANATION
1. Schematic Diagram of Components
(1) The schematic diagram of components that appears at the beginning of each section describes the
nomenclature and installed conditions of each component. Furthermore the tightening torque is
posted in the figure.
(2) Those parts whose reuse is not permitted bear a mark for an identification purpose. Be certain
to replace these parts with new ones during the assembly.
(3) During the assembly, be sure to apply grease to those parts indicated by the mark in the figure.
(Example)
T : Tightening torque
Unit : Nm (kgf-m)
: Non-reusable parts
T : 11.80 - 17.7
(1.2 - 1.8)
q Brake master cylinder Ay

w Reservoir tank fill cap
e Reservoir tank cap spacer
r Reservoir tank diaphragm
t Switch operating float
y Master cylinder reservoir tank S/A
u Clamp
i Set bolt
o Gasket
!0 Gasket
!1 Master cylinder repair kit
JGI00003-00001
2. Servicing Procedure
(1) In principle, the servicing procedure is described in the following sequence given below: Removal
Inspection Installation, and Disassembly Inspection Assembly.
(2) The explanation covers detailed servicing methods, specifications and notes.
(3) The main point of each item explains the servicing section and servicing procedure, using illustrations.
(Example)
What to do How to do it
What to do and where
3. Brake tube installation

(1) Install the brake tube to the wheel cylinder temporarily
by hands.
(2) Tighten the brake tube to the wheel cylinder, using
the following SST. 09751-36011-000
SST: 09751-36011-000
JGI00004-00002

GI5
(4) The inspection in this manual describes only checking operation. Therefore, if you find any malfunc-
tion, replace any defective parts with new ones.
3. SST
For those operations which require the use of any SST, the SST numbers concerned are given in bold
letters.
4. Service Specifications
Service specifications are indicated in bold letters or enclosed by heavy lines. Be certain to confirm the
specifications concerned.
5. Tightening Torque
For those operations which require the control of tightening torque, the relevant tightening torque is
given in bold letters. Be certain to confirm the tightening torque concerned.
6. Definitions of Terms
Specified Value A value which represents the allowable range during the inspection
and adjustment.
Limit A maximum or a minimum limit which the value should not exceed or fall below.
JGI00005-00000

GI6
ABBREVIATION CODES
The abbreviation codes that appear in this workshop manual stand for the following, respectively.
Abbreviation code Original word Meaning
A/C Air Conditioner Refers to air conditioner.
A/T, AT Automatic Transmission Refers to automatic transmission
A/Y or Ay Assembly Refers to an assembled component comprising more than two single parts or sub-assembly
parts.
API American Petroleum The standards set forth by the American Petroleum Institute (abbreviated as API
Institute Classification) have been employed to evaluate and classify properties of various oils.
Engine oils for gasoline engines are classified as SD, SE, SF and so on, whereas engine oils
for diesel engines are classified as CC, CD and so on.
ECU Electronic Control Unit Refers to electronic control unit.
Electronic Refers to electronic fuel injection.
EFI Fuel Injection
F/L Fusible Link Refers to fusible link.
L.H.D. Left-Hand Drive Left-hand drive vehicle.
LH Left Hand Refers to left side.
M/T, MT Manual Transmission Refers to manual transmission.
MP Multipurpose Means that the following item has multi-purposes.
O/S Oversize In instances where fitting becomes too loose due to wear resulting from use for a long period
of time or due to frequent removal/installation operations, if the fitting part (e.g. piston) is
replaced with a part having larger dimensions, the other mating part may be put into use
again. Oversized parts denote those parts having larger dimensions compared with the
standard parts.
PR Ply Rating Represents strength of tires.
The larger the ply rating number, the stronger the tire strength.
R.H.D. Right-Hand Drive Right hand drive vehicle
RH Right Hand Refers to right side.
S/A Sub-Assembly Refers to a component comprising more than two single parts which are welded, staked, or
studded to each other to form a single component.
SAE Society of Automotive For example, automotive oils are designated as SAE so and so number.
Engineers These designation numbers have been set forth by the Society of Automotive Engineers in the
United States of America (SAE). The larger the SAE number, the higher the oil viscosity.
Conversely, the smaller the SAE number, the lower the oil viscosity.
SST Special Service Tool Refers to a tool designed for a specific purpose.
STD Standard When referring to automotive parts, standard represents those parts which have been
installed originally by the manufacturer and which have standard dimensions.
T Torque Refers to tightening torque.
U/S Under Size In the same manner as with the oversized parts, if fitting part (e.g. bush and bearing) is
replaced with a part having smaller bore dimensions, the other mating part may be put into
use again. Under sized parts denote those parts having smaller dimensions compared with
standard parts.
VSV Vacuum Switching
Refers to vacuum switching valve.
Valve
W/ With Denotes that the following part is attached.
ETR Electronic Tuning Radio which incorporates variable capacitance, etc. which varies the value according to an
Radio applied voltage or current.
JGI00006-00000
The abbreviation codes that appear in the figure stand for the following, respectively.
B Bolt S Screw
N Nut W Washer
JGI00007-00000

GI7
GENERAL SERVICE INSTRUCTION
1. Use fender covers, seat covers and floor sheets so that the vehicle may not get dirty or be scratched.
2. Jacking up
(1) When only the front section or rear section of the vehicle is jacked up, be sure to place chocks at
the wheels so as to insure safe operations.
(2) When the vehicle has been jacked up, be sure to support the vehicle at the specified section using
safety stands. (See page GI9)
3. Handling instructions related to battery.

(1) Before you start performing the electrical works, make certain to disconnect the battery ground
cable terminal from the negative () terminal of the battery.
NOTE:
Before disconnecting the battery ground cable terminal from the negative () terminal of the battery,
be sure to read out the diagnosis code of the EFI, Airbag and immobilizer system etc., if the vehicle
is equipped with such systems, when necessary.
After reconnecting the battery ground cable terminal to the negative terminal of the battery, be sure to
reset the watch or radio, if the vehicle is equipped with such equipment.
(2) When it becomes necessary to disconnect the battery power supply for the purpose of carrying out
checks or repairs, always disconnect the battery ground cable terminal from the negative terminal
of the battery first.
(3) To avoid damaging battery plates, after the terminal nut has been loosened, pull out the battery
ground cable terminal straight upward, rather than turning or prying the terminal.
NOTE:
Be sure to employ a battery terminal puller (commercially available) to remove the battery ground
cable terminal from the negative terminal of the battery, if encountered any difficulty.
(4) Clean the battery terminal posts or battery ground terminals, using a cloth. Never use a file or other
adhesive agents.
(5) When connecting the battery ground cable terminal to the battery, first the battery ground cable ter-
minal should be fitted onto the battery post with the attaching nut in a loose state.
Then, tighten the nut. Never tap the terminal onto the battery post, using a hammer or spanner wrench
or the like.
(6) As for the cover at the positive (+) terminal side, be sure to install it at the correct position.
4. Repairs of fuel system

(1) The EFI equipped vehicles employ a high fuel pressure. Therefore, the following notes should be
observed.
q Be sure to prevent the fuel from splashing with a cloth or the like, when the union bolt or other
connected section of the fuel line is loosened or slackened.
(2) When connecting/disconnecting the fuel line.
q Tighten each connecting section to the specified torque.
w Attach new specified clips to each connecting section.
e Be certain to place a suitable container or a cloth, etc. under the connected section of the fuel
line before disconnecting the fuel line.
r Before the fuel line is disconnected, be sure to release the inner pressure of the fuel tank by
detaching the fuel filler cap.
t Be sure to follow the instruction mentioned in the main text when disconnect or connect the
quick type connectors.
(3) Never work near open flames.
5. For increased work efficiency and improved accuracy, be sure to utilize SSTs (Special Service Tools) ef-
fectively.
JGI00008-00000

GI8
HANDLING INSTRUCTIONS ON CATALYTIC CONVERTER
WARNING:
When a great amount of unburnt gas is admitted into the catalytic converter, overheating is prone to
occur, resulting in a fire hazard.
To avoid such trouble in advance, be certain to observe the following precautions. Also, be sure to
explain such precautions to your customers.
1. Use only unleaded gasoline.
2. Avoid idling the engine for a prolonged length of time.

Do not run the engine continuously at idle speed for more than 20 minutes.
WARNING:
Immediately check and repair the vehicle if the fast idle speed or idle speed is unstable or the system
exhibits malfunction. Failure to observe this warning may result in a fire hazard.
3. Be sure to observe the following points when performing the spark jump tests.
(1) The spark jump test must be limited to cases where such test is absolutely necessary. Also, be sure
to finish the test in the shortest possible time.
(2) Be sure to shut off the fuel supply when performing the spark jump test in advance.
4. Do not run the engine when the fuel tank becomes nearly empty.
Failure to observe this caution will cause misfiring. Also, it will apply excessive load to the catalytic con-
verter, even leading to catalyst damage.
5. Do not dispose of the waste catalyst along with parts contaminated with gasoline or oil.
JGI0009-00000

GI9
JACKING POINTS AND SUPPORTING POINTS OF SAFETY STANDS
CAUTION:
Be sure to support the vehicle at the flat surface of the rocker panel.
Do not support the vehicle at the edge part rocker panel.
Jacking Points
Front side Differential mount bracket
Rear side Rear axle housing
Front side Rear side
Supporting points
Garage jack Garage jack
Supporting points of safety stands

Four supporting points are located at the right and left sides. (The supporting points have been
strengthened by spot-welding reinforcements. Never support the vehicle at points other than the
specified points.)
Supporting points of tow-post lift

Align the supporting pads of a two-post lift with the supporting points of safety stands, as indicated in
the figure above.
Supporting points of plate supporting type lift

A vehicle should be placed at the center of the supporting plates of the lift.
When lifting up the vehicle, be sure to support the front section of the vehicle.
JGI00010-00003

GI10
TOWING INFORMATION
When towing the model J100 follow the manner mentioned below.
CAUTION:
Never perform towing, using sling type equipment.
Failure to observe this caution may lead to severe damage on the vehicle body.
JGI00020-00000
Flat bed type

We recommend this as the most desirable method.
CAUTION:
Apply the parking brake securely.
Be sure to tie-down the vehicle body to the carrier,
using a tie-down wires. However, never apply exces-
sive force to each hook on the vehicle body, for vehicle
body may be severely damaged.
Wheel lift type
JGI00021-00008
Use a towing dolly when towing the vehicle with the front
wheels or rear wheels on ground.
WARNING:
Never allow anyone to be in the vehicle being towed.
CAUTION:
Be sure to secure the front or rear tires on the towing
dolly.
Never perform the towing, using sling type equipment.
Failure to observe this caution may severely damage
JGI00022-00009
the vehicle body.
Emergency towing
This manner can be employed if the vehicle is equipped with
a manual transmission and the road surface is hard and
smooth. In this case, be certain to follow the WARNING and
CAUTION mentioned below.
WARNING :
The driver in the vehicle to be towed should always
keep in mind that braking will require more force than
JGI00023-00010
usual when the engine is stopped, because the brake
booster is not functioning when the engine is stopped.

GI11
Never tow the vehicle at speed more than 30 km/h.

Turn the ignition switch of the vehicle to be towed in the ACC position during the towing. Never pull
out the key or turn the ignition switch to the LOCK position during the towing. Failure to observe this
warning will loose controllability, causing an accident.
Never tow the vehicle in this manner unless the wheels, axles, drive train, steering, and brakes are in
a good condition.
CAUTION:
Never tow an automatic transmission vehicle in this manner. Be sure to always use a towing dolly.
Always pull the hook in a straight-ahead direction to prevent it from being damaged. Never pull it
from side or in a vertical direction. Also, never pull it sharply.
Never connect the towing rope, cable or such to the parts other than the hooks provided on the vehi-
cle shell. Connection of the towing rope, cable or such to other pants than hooks may damage these
components
Ensure that the hooks are installed on the vehicle shell securely before towing.
1. Attach a sturdy rope, towing strap or cable to the towing hook.

2. A driver must ride in the vehicle being towed and control it.
3. Release the parking brake and shift the shift lever of manual transmission to the neutral position.
4. Select the center differential lock switch in the free position.
NOTE:
If you cannot start the engine, ensure that the center differential lock mechanism is free by jacking up
one of the wheels and making sure that the wheel turns freely.
Even if the indicator lamp in the combination meter shows that the differential lock is free, there is the
possibility that it is not free actually.
5. Set the ignition switch to the ACC position.

6. Perform the towing.
JGI00024-00000
DIAGNOSIS CONNECTOR
The diagnosis connector is provided under the instrument
panel at the drivers seat side as shown.
Terminal table
Terminal number and name
q IG For DS-21 o T (ITC)
e ABST !0 SIO For DS-21
r ECUT !1 EFIT
i REV !3 Body ground
!6 VF JGI00025-00011
1. Be sure to connect the following SST when utilizing this

connector, in order to prevent the terminals in the diagno-
sis connector from being damaged.
The shape of the SST end is the same as the diagnosis
connector.
SST: 09991-87401-000
JGI00026-00012

GI12
2. When measuring the engine tachometer, connect the fol-
lowing SST to the No.8 (REV) terminal of the above SST.
REV
SST: 09991-87402-000
JGI00027-00013
3. Utilize the following SST when connecting the terminals in

the SST for the diagnosis connector which is specified in
the main text.
SST: 09991-87403-000
CAUTION:
Never connect the terminals other than that specified in
the main text in each section. Failure to observe this
caution may lead to serlus damage or malfunction.
JGI00028-00014
4. Reference
(1) Output of diagnosis code of EFI system.
Connect the 11(EFIT) and 13 (Body ground)
(2) Output of diagnosis code of ABS system.
Connect the 4(ECUT) and 13 (Body ground)
(3) Switching to the test of ABS system. 1 2 3 4 5 6 7 8
Connect the 3(ABST) and 13 (Body ground) 9 10 11 12 13 14 15 16
(4) Vf output (oxygen sensor function)
Connect the 16(VF) and 13(body ground)
(5) Output of diagnosis code of air bag system.
Connect the 4(ECUT) and 13 (Body ground) JGI00029-00015
(6) To connect the tachometer

Connect a tachometer to 8(REV) terminal.
(7) Connection of the DS-21
Connect the DS-21 utilizing the following SST. The fol-
lowing SST is provided with the terminal for DS-21.
SST: 09991-87401-000
CAUTION:
Never connect the DS-21 in another way than that
manner specified.

GI13
MODEL VARIATION
Specification General AUS EC
Engine Handle position RHD LHD RHD RHD LHD
Grade Lo Hi Lo Hi Lo Hi Lo Hi Lo Hi
Model code J100RG J100LG J100RG J100RG J100LG
HC-EJ 5MT GMDE GMXE GMDE GMXE GMDEQ GMXEQ GMDEW GMXEW GMDEW GMXEW
4AT GPDE GPXE GPDE GPXE GPDEQ GPXEQ GPDEW GPXEW GPDEW GPXEW
JGI00011-00000
Explanation of vehicle model code

J1 0 0 L G - G M D E W
Model code
J1 : TERIOS
Drive system
0 : Four-Wheel Drive Vehicle (Full-time 4WD)
Engine type
Body type 0 : Type HC-EJ engine
G : Station
wagon Steering position
Number of doors L : Left-Hand Drive Vehicle
G : Five Door R : Right-Hand Drive Vehicle
Transmission Fuel supply

M : Five-speed Manual Transmission E : EFI-equipped Engine
P : Four-speed Automatic Transmission
Destination
Grade of model Non : General Specifications
D : Low grade W : European Specifications
X : High grade Q : Australian Specifications
JGI00012-00000

GI14
CHASSIS SERIAL NUMBER
STAMPED POSITION
Serial number
The chassis number is stamped on the cowl panel at the right
side in the engine compartment.
JGI00013-00004
MANUFACTURERS PLATE POSITION

The manufacturers plate is attached on the cowl panel.
Manufacturers
plate
JGI00014-00005
CONTENTS OF MANUFACTURERS PLATE
(1) General, Australian, Norwegian and Finnish specifications
q
w
e
r t
u
y !4 q Manufacturers name, Country
w Vehicle model
i e Chassis No.
r Engine type
o t Engine displacement
y Body colors
u Trim code
(2) European Specification (except for Norway and Finland) i Engine number
o Manufacturers name in Japanese
q !0 Gross vehicle weight
!1 Gross combination weight
!5 !2 Maximum permissible front axle weight
e !3 Maximum permissible rear axle weight
!4 Production month-year (Only for AUS spec.)
!0
!5 Authorized number of W.V.T.A.
!1 (Only for European specification.)
!2
!3
w
r y
JGI00015-00006

GI15
ENGINE NUMBER AND ENGINE TYPE
STAMPED POSITIONS
The engine number is stamped on the cylinder block.
Serial number
The engine type is indicated by embossed letters on the stamped
cylinder block. position
JGI00016-00007
BODY COLOR INFORMATION

Body color name Code
Silver metallic S07

Black metallic 6A5
Red mica metallic R24
Turquoise mica metallic B36
Purplish blue mica B38
Violet metallic P05
Two-tone color
NF7
Silver metallic / Silver metallic
Two-tone color NF2

Black metallic / Silver metallic
Two-tone color NF0

Red mica metallic / Silver metallic
Two-tone color
ND9
Turquoise mica metallic / Silver metallic
Two-tone color
NG1
Purplish blue mica / Silver metallic
Two-tone color
NG2
Violet metallic / Silver metallic
JGI00017-00000

GI16
COLOR CODE IN THE WORLD
Color code
Color name SPIES
DAIHATSU AKZO DUPONT ICI STANDOX
HECKER
Silver metallic S07 DAHS07 L8842 B127B 97076 S07
Black metallic 6A5 DAH6A5 G8742 A403B 96326 6A5
Red mica metallic R24 DAHR24 F2213 FCN6B 33273 R24
Turquoise mica metallic B36 DAHB36 F2855 HMG7B 55174 B36
Purplish blue mica B38 DAHB38 F3425 JNE4B 55603 B38
Violet metallic P05 DAHP05 F3426 JNE5B 40868 P05
White W09 DAHW09 K9344 XM48 16461 W09
Two-tone color S07 DAHS07 L8824 B127B 97076 S07
NF7
Silver metallic / Silver metallic S07 DAHS07 L8842 B127B 97076 S07
Two-tone color 6A5 DAH6A5 G8742 A403B 96326 6A5

NF2
Black metallic / Silver metallic S07 DAHS07 L8842 B127B 97076 S07
Two-tone color R24 DAHR24 F2213 FCN6B 33273 R24
NF0
Red mica metallic / Silver metallic S07 DAHS07 L8842 B127B 97076 S07
Two-tone color B36 DAHB36 F2855 HMG7B 55174 B36

Turquoise mica metallic / Silver metallic ND9
S07 DAHS07 L8842 B127B 97076 S07
Two-tone color B38 DAHB38 F3425 JNE4B 55603 B38
NG1
Purplish blue mica / Silver metallic S07 DAHS07 L8842 B127B 97076 S07
Two-tone color P05 DAHP05 F3426 JNE5B 40868 P05

Violet metallic / Silver metallic NG2
S07 DAHS07 L8842 B127B 97076 S07
Two-tone color W09 DAHW09 K9344 XM48 16461 W09
White / Silver metallic NC1
S07 DAHS07 L8842 B127B 97076 S07
JGI00018-00000
TRIM CODE
F C S5 Trim color code (Serial c
Serial code
Seat main material
F: Fabric
S: Gray
JGI00019-00000

DAIHATSU
MA
J100
MAINTENANCE
MAINTENANCE REQUIREMENTS ... MA 2 BRAKE MASTER CYLINDER ........ MA35

MAINTENANCE SCHEDULE ............ MA 3 MUFFLER AND EXHAUST PIPE ... MA37
SCHEDULE FOR SEVERE AUTOMATIC TRANSMISSION ..... MA37
DRIVING ..................................... MA 5 CLUTCH ....................................... MA38
MAINTENANCE OPERATION ........... MA 6 MANUAL TRANSMISSION,
ENGINE ............................................. MA 6 TRANSFER, FRONT AND REAR
COLD ENGINE OPERATION ........ MA 6 DIFFERENTIAL ........................... MA39
HOT ENGINE OPERATION .......... MA13 PROPELLER SHAFT ..................... MA40
CHASSIS ........................................... MA26 DRIVE SHAFT ............................... MA40
BRAKE FLUID .............................. MA26 WHEEL HUB NUT ........................ MA40
BRAKE PEDAL ............................. MA27 WHEEL BEARING ........................ MA40
PARKING BRAKE HANDLE .......... MA27 STEERING SYSTEM ..................... MA41
BRAKE HOSE & TUBE ................. MA28 WHEEL ALIGNMENT .................... MA42
FRONT BRAKE ............................. MA29 SHOCK ABSORBER ..................... MA43
REAR BRAKE ............................... MA32 SUSPENSION ARM, CONTROL
BRAKE BOOSTER HOSE ............. MA34 ARM & DUST COVER ................. MA43
JMA00001-00000
NO. 9710-JE

MA2
MAINTENANCE REQUIREMENTS
The scheduled maintenance service is important to ensure trouble-free, safe and economical driving.
Failure to perform the scheduled maintenance may cause an accident or serious damage.
If you conduct the periodical maintenance, Daihatsu car owners may reduce the chance of accidents or
car problems. Furthermore, it becomes possible for you to find at an earlier stage malfunctions which may
lead to serious damages. Consequently, potential vehicle damage can be prevented or the degree of the
damage can be minimized.
Therefore, all of the persons who are concerned with servicing the Daihatsu vehicles should offer the peri-
odical maintenance service to Daihatsu car owners in order that they may be protected from accidents or
unexpected problems.
To prevent malfunctions in advance, however, conducting the periodical maintenance service only is insuffi-
cient. It is essential that owners themselves perform maintenance, such as the pre-starting check de-
scribed in the owners manual, so that the vehicle exhibits no abnormal change or phenomenon. Hence,
please explain to owners about the necessity of maintenance performed by them. However, malfunction
may occur on those vehicles which are always checked by their owners. For instance, if a part instructed to
be replaced periodically should be used beyond the replacement intervals and the life of the part has ex-
pired, there are cases where malfunction occurs suddenly despite the fact that no malfunction has taken
place until yesterday. To prevent such malfunction in advance, be sure to replace parts recommended to
be replaced periodically at the specified replacement intervals.
This section describes those items of the scheduled maintenance service recommended by the Daihatsu
and their intervals. Be sure to observe the maintenance schedule.
JMA00002-00000

MA3
MAINTENANCE SCHEDULE
NOTE:
Perform the periodical maintenance at the specified mileage or the time whichever comes first, un-
less otherwise specified.
Continue to perform the periodical maintenance after 100,000 km (60,000 miles) at the same inter-
vals as before 100,000 km.
If the vehicle should be operated under severe driving conditions, operated occasionally, operated in
dusty areas, repeating short trip, operated under extremely cold climate and/or on salted roads, it is
necessary to perform some maintenance items more frequently than the regular maintenance sched-
ule.
This maintenance schedule prepared based on requirements mentioned in the owners manual
which are to be performed by the Daihatsu owner thoroughly.
Check or inspect. Change or replace.

1000 km 1 10 20 30 40 50 60 70 80 90 100
See
Section Item What to do Inspection interval 1000 miles 0.6 6 12 18 24 30 36 42 48 54 60
page
Years 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Cleaning
Air cleaner element Check MA6
Damage
Valve clearance Check & adjustment MA18
Engine oil & oil filter Change (Use API: SG or higher grade) Every 12,000 km MA13
Fuel filter Change Every 100,000 km MA9
Check
Crack
Fuel line & connections
Tightness Every 40,000 km MA8
(Including fuel hoses)
Leakage
Damage
Engine Coolant (Long-life coolant) Change Every two years MA23
Check
Drive belt
Tension
(Alternator, water pump,
Crack MA6
power steering)
Damage
Refer
Timing belt Change Every 100,000 km to EM
section.
Cleaning & check
Condition
Spark plug
Gap MA14
Damage
Ignition timing Check & adjustment MA21
Blow-by gas recirculation Check
hose (Positive crankcase Connection MA7
ventilation hose) Damage
Exhaust Check
emission Charcoal canister Function MA11
control Damage
system Evaporative emission hoses Change Every eight years MA12
Check
Exhaust pipe & muffler
Tightness MA37
mounting
Damage
* Replace every 10,000 km when API SF grade oil is used.

MA4
1000 km 1 10 20 30 40 50 60 70 80 90 100
See
page
Years 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Check
Free travel
Clutch Reserve travel MA38
Damage
Change
Manual transmission Oil MA39
Change
Automatic transmission Every 80,000 km MA37
Fluid
Automatic transmission Check
Power Every 40,000 km MA38
Oil cooler hose Crack, scratch, cut, twist and swelling
train
system Change
Transfer Oil MA39
Change
Differential (Front & Rear) Oil MA39
Check
Tightness
Propeller shaft Rattle MA40
Damage
Check
Drive shaft boot Damage MA40
Check
Function
Suspen-
Shock absorber Oil leakage (Shock absorber) MA43
sion Damage
system Check
Suspension arm (Front)
Control arm (Rear) Tightness MA43
Dust boots Damage
Check
Running
Wheel bearing Tightness MA40
system
Damage
Check
Free play (Steering wheel)
Steering linkage, gear box Tightness MA41
Rattle
Steering Damage
system
Check
Wheel alignment Toe-in MA42
Check
Fluid hose Every 4 years MA42
Crack, scratch, cut, twist and swelling

MA5
1000 km 1 10 20 30 40 50 60 70 80 90 100
See
page
Years 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Check
Free play (Brake pedal)
Brake pedal & Parking brake Reserve travel (Brake pedal) MA27
Working travel (Parking brake)
Check
Disc pad Wear MA29
Damage
Check
Brake hose, tube and P & B Leakage (Fluid level, connection)
Brake
valve Loose clamp MA28
system Damage
Brake fluid Change Every 2 years MA26
Check
Brake lining Wear MA32
Damage
Brake booster vacuum hose Check Every 4 years MA34
Check
Master & wheel cylinder Every 2 years MA35
Leakage
Chassis & Wheel hub nut, other bolts & Check
body nuts Tightness MA40
JMA00003-00000
SCHEDULE FOR SEVERE DRIVING

1000 km 1 10 20 30 40 50 60 70 80 90 100
See
page
Years 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Engine oil & oil filter Change Every 5,000 km MA13
Engine Check & cleaning Check and cleaning: Every 5,000 km
Air cleaner element Damage Replacement: Every 20,000 km MA6
Change
Exhaust Check
emission Tightness
control Exhaust pipe and mounting MA37
system Damage
Change
Manual transmission Every 25,000 km MA39
Fluid
Change
Power Automatic transmission Fluid Every 50,000 km MA37
train
system Change
Transfer Every 25,000 km MA39
Fluid
Change
Differential (Front & Rear) Every 25,000 km MA39
Fluid
Check
Steering
Steering linkage Tightness MA41
system
Damage
Check
Disc & disc pad Wear MA29
Brake Damage
system Check
Brake drum & lining Wear MA32
Damage
JMA00004-00000

MA6
MAINTENANCE OPERATION
ENGINE
COLD ENGINE OPERATION
1. Inspection of drive belt
(1) Visual inspection of drive belt
Visually check the belt for separation of the adhesive
rubber above and below the core, core separation
from the belt side, severed core, separation of the rib
from the adhesive rubber, cracks or separation of the
JMA00005-00001
ribs, torn or worn ribs or cracks in the inner ridges of
the ribs. Replace the drive belt, if necessary. : Measuring section for
tension and deflection
(2) Inspection of drive belt tension Idle pulley
Measure the amount of the drive belt deflection when With air
the midpoint of the drive belt between the alternator Vane conditioner
pump
and the water pump pulley or between the crankshaft pulley
pulley and vane pump pulley is pushed with a force of
98 N (10 kgf).
Idle pulley
Specified Belt Deflection
New Belt: Alternator and water pump 4 - 5 mm When without Crank shaft
Vane pump(Power steering) 8 - 11 mm air conditioner pulley
JMA00006-00002
Used Belt: Alternator and water pump 5 - 6 mm
Vane pump(Power steering) 11 - 14 mm
If necessary, adjust the drive belt tension.

(Refer to the EM or SR section.)
2. Inspection of air filter element

(1) Removal of air filter element
q Unlock the four clips.
w Gradually open the air filter case cover.
CAUTION:
Do not open the air filter case cover beyond what is
necessary to remove the air filter element. Failure to
observe this caution may lead to disconnection of the
rubber hoses.
e Take out the air filter element from the air filter JMA00007-00003
case.
(2) Replacement of air filter element
Replace the air filter element with a new one when the
replacement time arrives.
(3) Inspection of air filter element
Visually inspect the air filter element for being exces-
sively dirty, damage or oily.
Replace the air filter element, if necessary.

MA7
(4) Cleaning of air filter element
Clean the air filter element with compressed air.
First, blow compressed air from the back side of the
element thoroughly. Then, blow off the upper side of
the element.
WARNING:
Protect your eyes with safety goggles during the clean-
ing operation.
CAUTION:
The air pressure to be used for this cleaning operation JMA00008-00004
should not exceed 392.3 kPa (4.0 kgf/cm2).
Replace the air filter element, if the element is exces-

sively dirty.
(5) Installation of air filter element
q Install the air filter element in the air filter case cover.
NOTE:
Ensure that the air filter element faces in such a direc-
tion that the wider protrusion side comes to the air filter
case cover side.
w Close the air filter case cover.

e Latch the four clips properly.
3. Inspection of blow-by gas recirculation device

(1) Visually inspect the hoses for improper connections,
cracks, leak and damage.
NOTE:
Replace parts which exhibit damage as necessary.
(2) Remove the oil filler cap.

(3) Disconnect the blow-by gas hose from the throttle
body. JMA00009-00005
(4) Ensure that no resistance exists when you blow your

breath to the disconnected hose end (which was con-
nected to the throttle body).
If resistance is felt or no air continuity exists, check
blow-by gas hose and the cylinder head cover.
(5) Connect the blow-by gas hose to the throttle body.
(6) Install the oil filler cap securely.
(7) Disconnect the PCV hose which is connected to the
throttle body at the throttle body side.
(8) Ensure that heavy resistance exists when you blow
your breath from the disconnected hose end. JMA00010-00006
If no continuity exists or no resistance for air continuity

exists, replace or repair the cylinder head cover.
(Refer to the EM section for the cylinder head cover re-
placement.)
NOTE:
The orifice is built in the cylinder head cover. This pro-
cedure is required for ensuring the orifice function in
the cylinder head. If this orifice is plugged, correct en-
gine idle speed will not be obtained.
(9) Connect the PCV hose to the throttle body properly. JMA00011-00007

MA8
4. Inspection of fuel line and connection
(1) Visually inspect the fuel line including the fuel hose for
connecting condition, cracks, tightness, leakage and
damage.
If cracks or any other damage exists, repair or replace
the part as required.
(2) Check the connecting section of the fuel line for loose-
ness and leakage.
If looseness or leakage exists on the connected sec-
tions of the fuel line, repair or replace the parts as re-
quired. JMA00012-00008
(3) Ensure that the ignition switch is turned OFF.

(4) Open the relay box cover in the engine compartment.
(5) Remove the fuel pump relay from the relay box.
CAUTION:
Prevent dust or water, etc. from entering the connector.
Entering of dust, water or contamination of the termi-
nals in the fuel pump relay connector may cause fuel
pump malfunction or other serious malfunctions, due to
lowered insulation of each terminal.
(6) Connect the No. 1 and No. 2 terminals of the fuel

pump relay in the relay box with suitable wires or the
like as shown.
CAUTION:
Never deform or damage the terminals during the con-
nection.
Never make connection on a terminal except for those q
w
specified.
Even slight contact of the other terminal causes serious
trouble. e r
Prevent dust or water, etc. from entering the relay box. JMA00013-00009

nals in the relay box causes serious malfunction, due
to lowered insulation of each terminal.
(7) Turn ON the ignition switch.

(8) Ensure that no fuel leakage exists on the fuel line.
If fuel leakage exists, repair or replace the part as re-
quired.
(9) Turn OFF the ignition switch.

MA9
(10) Remove the wire from the fuel pump relay terminal in
the relay box.
CAUTION:
Never deform or damage the terminals during opera-
tion.
Never make connection between terminals except for
those specified. Fuel pump
Even slight contact of the other terminal causes serious relay
trouble.
Prevent dust or water, etc. from entering the relay box.
Entering of dust, water or contamination of the termi- JMA00014-00010

(11) Install the fuel pump relay into the relay box.
(12) Close the relay box cover.
5. Replacement of fuel filter

WARNING:
Never smoke or work near open flame.
Failure to observe this warning will cause fire.
Removal
(2) Open the fuel filler cap to release the inner pressure of the
fuel tank.
(3) Remove the fuel pump relay from the relay box in the en-
gine compartment. (See illustration above.) JMA00015-00011
CAUTION:
Never make connection on a terminal except for those
specified.
trouble.
Prevent dust or water, etc. from entering the relay box.
JMA00016-00000

MA10
(4) Start the engine and wait for a little while until the engine
stops.
(5) Turn off the ignition switch.
(6) Jack-up the vehicle and support it with safety stands.
(Refer to the GI section.)
(7) Detach the fuel hose clips.
WARNING:
Never reuse the used hose clips. Failure to observe
this warning may lead to fire.
(8) Disconnect the fuel hoses from the fuel filter and plug the JMA00017-00012
disconnected hoses and fuel pipes of the fuel filter with a

suitable plug or the like.
CAUTION:
Quite a large amount of fuel will flow out during fuel
hose disconnection. Therefore, be sure to plug the dis-
connected hose and pipes properly.
(9) Remove the fuel filter from the fuel filter clamp.
Installation
(1) Install the fuel filter to the fuel filter clamp as shown.
CAUTION:
Be sure to install the fuel filter in such direction that the
IN mark of fuel filter faces to fuel pump side and Engine side
Fuel pump side
OUT mark faces to fuel pump side.
Failure to observe this caution may lead to fuel filter
malfunction.
(2) Insert new hose clips to the fuel hoses.

(3) Connect the fuel hoses to the fuel filter until the fuel hose
end comes in contact with the fuel filter body .
(4) Place the new fuel hose clips at each point between the JMA00018-00013
pipe end and the spool. Then remove the clip holder to
secure the fuel hoses.
CAUTION :
Never reuse the used hose clips.
(5) Install the fuel filler cap.

(6) Checking of fuel leakage
Perform the inspection described in the Inspection of fuel
line and connection.
6. Inspection of charcoal canister

(1) Removal of charcoal canister
q Detach the hose bands from the hoses connected
to the charcoal canister.
CAUTION:
Never reuse the removed hose bands.
w Disconnect the rubber hoses from the upper side

of the charcoal canister.
NOTE:
Prior to the disconnection of the rubber hoses, put a Charcoal canister
tag on each of the rubber hoses so that they may be
reconnected correctly to the original position. JMA00019-00014

MA11
e Remove the engine undercover by removing the
six attaching bolts.
JMA00020-00015
r Disconnect the atmosphere side hose from the

frame.
t Remove the charcoal canister from the vehicle by
pulling up the charcoal canister case to unlock it
from the bracket.
y Remove the atmosphere side hose from the char-
coal canister.
JMA00021-00016
(2) Inspection of charcoal canister

q Visually inspect the charcoal canister case for A Throttle body B Fuel tank
cracks or damage. If any damage is found, re-
place the charcoal canister with a new one.
w Check the charcoal canister for air leakage. Ensure
that no air leakage exceeding 0.3 ml/min is present
when applying compressed air of 29.4 kPa
(0.3 kgf/cm2) into the fuel tank side pipe B with the
throttle body side A and atmosphere side C pipes
plugged. C Atmosphere
If air leakage exceeding the above-specified value JMA00022-00017
is present, replace the charcoal canister with a

new one.
e Ensure that no air continuity exists when you blow
into the purge side A pipe of the charcoal canister.
If air continuity exists, replace the charcoal canis-
ter with a new one.
r Check of charcoal canister for restriction
a. Ensure that air continuity exists to the atmos-
phere side C pipe, when you blow into the fuel
tank side pipe B while the purge side A pipe
is plugged.
If no air continuity exists, replace the charcoal
canister with a new one.
b. Ensure that air continuity exists when applying
a negative pressure to the purge side pipe A
by a MityVac.
If no air continuity exists, replace the charcoal
canister with a new one.

MA12
t Cleaning of charcoal canister
Clean the charcoal canister by blowing com-
pressed air of 294.2kPa (3.0 kg/cm2) into the fuel
tank side pipe B while holding the purge side of
the canister pipes A closed.
CAUTION:
Never attempt to wash the charcoal canister.
No activated carbon should come out during the test.
If activated carbon comes out, replace the charcoal
canister. JMA00023-00000
(3) Installation of charcoal canister

The installation procedure is basically reverse to the
removed procedure. Therefore, no illustration is given
in this installation procedure.
q Install the charcoal canister to the charcoal canis-
ter holder and lock it securely.
w Connect the atmosphere side hose to the charcoal
canister.
JMA00024-00018
e Install the engine undercover with the six attaching

bolts and tighten them securely.
JMA00025-00019
r Connect the rubber hoses and attach new hose

bands.
CAUTION:
Never reuse the removed hose band.
JMA00026-00020
7. Replacement of evaporative emission control hose

Replace the fuel evaporative emission control hoses with
new ones when the replacement interval arrives.
WARNING :
Replace the hose bands and clips with new ones.
Never reuse the removed hose bands and clips.
JMA00027-00021

MA13
HOT ENGINE OPERATION
1. Change of engine oil and oil filter
WARNING:
Protect your eyes by wearing safety goggles.
Never burn yourself with hot engine oil or hot engine
components during operation.
(1) Park the vehicle on a level surface.

(2) Check the oil level.
(3) Start the engine. JMA00028-00022
(4) Warm-up the engine to normal operating temperature.

(5) Place a suitable container under the oil drain plug.
(6) Remove the drain plug and gasket. Then, drain the en-
gine oil into the placed container completely.
(7) Remove the oil filler cap.
(8) Place a suitable container or such to under the oil filter.
(9) Slacken the oil filter with an oil filter wrench.
CAUTION:
Care must be exercised, for quite a large amount of en-
gine oil may flow out.
(10) Remove the oil filter by hand.

(11) Wipe off the engine oil from the oil filter attaching part
of the engine oil filter bracket.
(12) Thinly apply engine oil to the O-ring of a new oil filter.
(13) Screw in the oil filter by hand, until the O-ring of the oil
filter comes in contact with the oil filter installing sur-
face of the oil filter bracket.
(14) Tighten the oil filter three fourths to one complete turn,
JMA00029-00023
by hand or using the following SST.
SST: 09228-87201-000
CAUTION:
Never tighten the oil filter excessively. Failure to ob-
serve this caution will cause oil leakage or damage to
the oil pump, or the oil filter.
(15) Tighten the drain plug to the specified tightening

torque with a new gasket interposed.
Tightening Torque: 19.6 - 29.4 Nm (2.0 - 3.0 kgf-m)
JMA00030-00000
(16) Pour engine oil to the engine.

CAUTION:
Use API grade SG or higher grade oil.
Oil Capacity
With Oil Filter: 3.6 liters
Without Oil Filter: 3.4 liters
JMA00031-00024

MA14
(17) Pull out the oil level gauge and wipe off the engine oil. TEMP.
C 29
20
18 7 4 16 27 38
F 0 20 40 60 80 100
(18) Reinsert the oil level gauge as far as it will go. Engine oil
(19) Pull out the oil level gauge again. (4 stroke) *10W-30, 10W-40, 10W-50
(20) Ensure that the engine oil level is between the L and 20W-40, 20W-50
F levels on the oil level gauge.
5W-30
If the engine oil level is below the L level, replenish
the specified engine oil to the F level. 30
(21) Close the oil filler cap.

20
WARNING:
Securely close the oil filler cap to the cylinder head JMA00032-00025
cover. Failure to observe this warning will cause engine
seizure and fire.
Low level Full level
(22) Start the engine. JMA00000-00026
(23) Warm up the engine to normal operating temperature.

(24) Stop the engine.
(25) After a few minutes, slowly pull out the oil level gauge
and wipe off the engine oil.
(26) Reinsert the oil level gauge as far as it will go.
(27) Pull out the oil level gauge again and check to see if
the oil level is between F and L levels.
If the engine oil level is low, replenish the specified en-
gine oil to the F level of the oil level gauge.
(28) Reinsert the oil level gauge as far as it will go.
JMA00034-00000
2. Inspection of spark plug

Inspection of electrode
When a megger is available:
(1) Removal of air cleaner
q Disconnect the hoses connected to the air cleaner
case cover.
NOTE:
Prior to the disconnection of the rubber hose, put a tag
on each of the rubber hoses so that it may be recon-
nected correctly to the original position.
JMA00035-00027
w Displace the hose band of the air duct connected

to the throttle body.
e Unlock the four clips of the air cleaner case cover.
r Remove the air cleaner element.
t Remove the air cleaner case by removing the three
attaching bolts.
JMA00036-00028

MA15
(2) Removal of resistive cords and ignition coils
q Disconnect the resistive cord from the ignition coil.
w Remove the No. 1 and No. 3 resistive cords by dis-
connecting the connectors from the ignition coils
and spark plugs.
CAUTION:
Never disconnect the resistive cords by holding the DAIHATSU
16VALVE
cord section of the resistive cords.
e Disconnect the connectors from the ignition coils.

r Remove the ignition coils on the spark plugs of JMA00037-00029
No. 2 and No. 4 cylinders by removing the attach-

ing nuts.
(3) Measurement of insulation resistance

Measure the insulation resistance of each spark plug,
using a megger (Insulation resistance meter) and en-
sure that the measured insulation resistance of each
spark plug is more than the specified value.
Minimum Insulation Resistance: 20 MW
If the measured insulation resistance is less than

15 MW proceed to the step (4) onward.
If the measured insulation resistance is more than the
specified value, proceed to the step (4) onward except
the step (8). JMA00038-00030
When a megger is not available:

q Start the engine. Warm up the engine completely.
w Race the engine at 4000 rpm for five seconds.
e Stop the engine.
r Remove the air cleaner.(Refer to the removal of the
air cleaner.)
t Remove the resistive cords and ignition coils.
(Refer to the check and adjustment of the valve
clearance section for the removal of the ignition
coil and resistive cord.)
y Remove the spark plug, using a suitable spark JMA00039-00031
plug wrench or the following SST.

SST: 09268-87703-000
WARNING:
Be very careful not to get scalded with hot spark plugs,
since spark plugs are hot.
u Visually inspect the spark plug.

If the electrode is dry: Proceed to the step (6)
(Satisfactory)
If the electrode is wet: Proceed to the step (5).
MA16
(4) Removal of spark plug
(Refer to the step (3)6 above.)
(5) Visual inspection of spark plug
Visually inspect the spark plug for electrode wear,
damage in threads or insulation.
Replace the spark plug if it exhibits any damage.
Recommended Spark Plug:
DENSO NGK
K20TNR-S BKUR6EK
K22TNR-S BKUR7EK
CAUTION:
All four spark plugs used for one engine should have
the same heat range and be ones manufactured by the
same manufacturer.
Follow the information label in the engine compartment
for selecting the spark plugs. Failure to observe this
caution may cause problems.
JMA00040-00000
(6) Inspection of electrode gap

Measure the electrode gap, using a plug gap gauge. Spark
Electrode Gap: 0.9 - 1.0 mm plug
gap
If the electrode gap of a used spark plug is not within

the specification, replace the spark plug with a new
one.
If the electrode gap of a new spark plug is not within
the specification, adjust the gap by bending the base
of the ground electrode, being careful not to touch the
tip. JMA00041-00032
(7) Cleaning of spark plug

If the electrode has traces of wet carbon, dry the elec-
trode and clean it with a spark plug cleaner.
Air Pressure: Not to exceed 588.4 kPa (6 kgf/cm2)
Duration of Cleaning: Not more than 20 seconds.
NOTE:
If there is trace of oil, remove it with gasoline before the
spark plug is cleaned by the spark plug cleaner.
JMA00042-00033
(8) Inspection of spark plug insulation resistance

Ensure that the insulation resistance of the spark plug
is more than the specified value.
Minimum Insulation Resistance: More than 20 MW
If the insulation resistance is less than the specified

value, replace the spark plug with a new one.
CAUTION:
All four spark plugs used for one engine should have
the same heat range and be ones manufactured by the
same manufacturer. JMA00043-00034

MA17
(9) Installation of spark plug
Install the spark plugs. Tighten them to the specified
tightening torque, using a suitable spark plug wrench
or the following SST.
SST: 09268-87703-000
NOTE:
Since the insulator strength of a small spark plug is
comparatively smaller than that of a regular spark plug,
when tightening, be sure to use the tool exclusively JMA00044-00035
used for this application. Also, when tightening, never

use the wrench in a crooked way.
(10) Installation of ignition coils

Install the ignition coil on the No. 2 and No. 4 spark
plugs with the attaching nuts and tighten the nuts to
the specified tightening torque.
Tightening Torque: 8.5 Nm ( 0.85 kgf-m)
CAUTION:
Never damage the boot section of the ignition coils by
interfering with the cylinder head cover.
(11) Connect the ignition coil connectors to the ignition
coils properly.
(12) Connect the resistive cords to the spark plugs and ig-
nition coils properly as shown in the figure.
NOTE:
DAIHATSU
Never interfere the resistive cord with the ignition coils 16VALVE
and attaching nuts of the ignition coils.
Never bend or twist the resistive cord beyond what is
necessary.
JMA00045-00036
(13) Clamp the resistive cord to a clamp provided on the

ignition coil as shown.
(14) Installation of air cleaner
q Install the air cleaner case to the cylinder head
cover and throttle body with the three attaching
bolts and tighten the attaching bolts properly.
w Attach the hose band of the air cleaner duct which
is connected to the throttle body.
e Install the air cleaner element on the air cleaner
case.
r Install the air cleaner case cover and secure the JMA00046-00037
four clips.
t Connect the rubber hoses to the air cleaner case
cover.

MA18
3. Inspection and adjustment of valve clearance
The measurement and adjustment of the valve clearance
are carried out when each piston of the No. 1 and No. 4
cylinders is set to the top dead center at the end of com-
pression stroke.
WARNING:
Never burn yourself with hot engine components,etc.
during operation.
CAUTION:
The valve clearance adjustment is performed normally JMA00047-00038
when the engine is in a hot condition.

HOT engine condition denotes a condition in which
the cooling water temperature is 75 - 85C and the en-
gine oil temperature is above 65C.
However, when the engine has been overhauled, it is
necessary to adjust the valve clearances while the en-
gine is cold and to readjust the valve clearance in a hot
condition after warming up the engine.
(1) Warm up the engine thoroughly. (Only when neces-

sary.)
(2) Remove the air cleaner. w r
(Refer to the Inspection of spark plug section for re-
moval.) u y
(3) Remove the resistive cords and ignition coils.
(Refer to the removal of resistive cords and ignition coil t i
in the inspection of the spark plug section.)
(4) Disconnect the PCV hoses(blow-by gas hose) from the e
q
cylinder head cover.
(5) Remove the bolt attaching the timing belt cover to the
cylinder head cover. JMA00048-00039
(6) Loosen the eight attaching bolts (6 mm) shown in the

figure over two or three stages in the sequence in the
right figure.
(7) Remove the cylinder head cover by removing the at-
taching bolts.
CAUTION:
Never damage the spark plug grommets of the spark
plug tubes and cylinder head cover gasket during the
removal of the cylinder head cover.
JMA00049-00040
(8) Inspection and adjustment of valve clearances

CAUTION: Indicator
Before the adjusting screw is tightened with lock nuts,
apply engine oil to between the lock nut and the valve
rocker arm.
q Remove the engine undercover by removing the

six attaching bolts.
w Turn the crankshaft until the recessed mark on the
crankshaft pulley is aligned with the indicator mark Timing mark
on the timing belt cover. JMA00050-00041

MA19
e Check to see if the valve rocker arms of the No. 1
cylinder are free or are being pushed. According
to the table below, check and adjust the valve
clearance, using a thickness gauge.
JMA00051-00042
Pistion position 1 2 3 4
When valve rocker arms of No. 1 cylinder are free: Inkate ! !

(Piston of No. 1 cylinder is at top dead center under compression stroke) Exhaust ! !
When valve rocker arms of No. 4 cylinder are free: Inkate ! !

(Piston of No. 4 cylinder is at top dead center under compression stroke) Exhaust ! !
NOTE:
The O mark denotes those valves that can be adjusted under that setting.
Valve Clearance (HOT)
Intake: 0.25 0.05 mm
Exhaust: 0.33 0.05 mm
(Reference)
Valve Clearance (COLD)
Intake: 0.18 mm
Exhaust: 0.25 mm
Tightening Torque (Lock nut): 16.7 - 22.6 Nm (1.7 - 2.3 kgf-m)
r Turn the crankshaft 360 degrees (one turn).

t Proceed to check and adjust the remaining valve clearances.
JMA00052-00000
(8) Installation of cylinder head cover

q Wipe off the oil from the gasket attaching surface
of the cylinder head.
w Check the cylinder head cover gasket for evidence
of damage.
Replace the gasket, as required.
CAUTION:
Install the cylinder head gasket in such a direction that
the identification mark may come at the intake side.
e Check the rubber grommets of the spark plug JMA00053-00043
tubes for evidence of damage.

Replace the rubber grommet, as required.
(For replacement of the rubber grommet, refer to
the EM section of the service manual.)
r Install the cylinder head cover gasket on the cylin-
der head.
NOTE:
Install the cylinder head cover gasket in such a direc-
tion that the identification mark may come at the intake
side.

MA20
t Apply the Three Bond 1104 to the four points on
the cylinder head, as indicated in the figure.
JMA00054-00044
y Install the cylinder head cover on the cylinder

head.
NOTE:
Never damage the rubber grommets for the spark plug
tubes during the installation of the cylinder head cover.
Make sure that the rubber grommet is fitted over the
spark plug tube properly.
JMA00055-00045
u Install the attaching bolts of the cylinder head

cover and tighten them to the specified tightening w r
torque over two or three stages in the sequence
shown in the right figure. u y
t i
i Install the timing belt attaching bolts with wire
clamp and tighten them to the specified tightening e
q
torque.
JMA00056-00046
o Connect the PCV hoses(blow-by gas hose) to the

!0 Install the ignition coils and resistive cords to the
spark plugs and ignition coils.
(Refer to installation procedure described in the in-
spection of spark plug section.)
!1 Install the air cleaner assembly.
(Refer to installation procedure described in the in-
spection of spark plug section.)
4. Inspection and adjustment of ignition timing

(1) Start the engine.
(2) Warm up the engine.
REV
(4) Connection of tachometer
q Connect the following SST to the diagnosis con-
nector.
SST: 09991-87401-000
w Connect the tachometer to the REV (i) terminal of

the SST, in combination with the following SST.
SST: 09991-87402-000 JMA00057-00047

MA21
CAUTION:
Never allow the tachometer terminal to touch ground. It
could result in damage of the ignition system.
As some tachometer are not compatible with this igni-
tion system, it is recommended to confirm the compati-
bility with your unit before its use.
Care must be exercised to ensure that no connection is
made on terminals except for those specified.
malfunction. JMA00058-00000
(5) Connect a timing light to the resistive cord of the No. 1

cylinder (at the timing belt side)
(6) Connect the T (!1) terminal and E (!3) terminal in the T E
SST which was connected, using the following SST.

SST: 09991-87403-000
CAUTION:
made on terminals other than that specified.
malfunction. JMA00059-00048

(8) Ensure that the engine revolution speed is stable.
If the engine revolution speed becomes unstable, pro-
ceed to check ISC system.
(Refer to the EM section.)
(9) Check to see if the ignition timing mark of the crank-
shaft pulley is aligned with the indicator provided on
the timing belt cover, using a timing light.
If the ignition timing mark on the crankshaft pulley is TDC 0 BTDC 2 ATDC 2
not aligned with the indicator provided on the timing
belt cover, adjust the ignition timing by turning the cam JMA00060-00049
angle sensor attaching position.
(10) Adjustment of ignition timing

q Loosen the cam angle sensor attaching bolt.
w Adjust the ignition timing to the specified timing by turning the cam angle sensor.
e Tighten the cam angle sensor attaching bolt to the specified tightening torque.
Tightening Torque : 14.7 - 21.6 Nm (1.5 - 2.2 kgf-m)
r Ensure that the ignition timing is not disturbed by tightening of the attaching bolts of the cam
angle sensor.
Readjust the ignition timing, if the timing is not in the specified position.
(12) Remove the tachometer.
(13) Remove the SST from the diagnosis connector.
CAUTION:
Care must be exercised to ensure that no connection is made on terminals except for those speci-
fied.
Even slight contact of the other terminal causes serious malfunction.
(14) Check the idle speed.

(See the check of the idle speed procedure in this service manual.)
JMA00061-00000

MA22
5. Inspection of dashpot
(For automatic transmission-equipped model only)
Preparation to be made prior to idle speed adjustment
Check and adjust the ignition timing.
Check and adjust the idle speed.
Apply the parking brake fully.
Warm up the engine thoroughly.
All accessory switches are turned OFF.
(On those vehicles equipped with a day-light system, set the light control switch to the first stage, in
order to turn OFF the head lights.)
The air element is installed.
All vacuum hoses are connected properly.
Ensure that the intake system exhibits no gas leakage or air admission.
Ensure that there is no gas leakage.
Place the shift lever in the N or P range.
Place the steering wheel to the straight ahead position and do not operate it during the inspection.
JMA00062-00000
(1) Connection of tachometer

(Refer to the Inspection and adjustment of ignition timing section for the connection of tachome-
ter.)
CAUTION :
Never allow the tachometer terminal to touch ground. It could result in damage of the ignition system.
As some tachometers are not compatible with this ignition system, it is recommended to confirm the
compatibility with your unit before its use.
(2) Start and warm up the engine.

(3) Ensure that the adjusting screw of the dashpot is not in contact with the dashpot shaft when the en-
gine revolution is held at about 2400 100 rpm.
If the adjusting screw of the dashpot is in contact with the dashpot shaft, adjust the height of the ad-
justing screw.
(4) Ensure that the duration of time from dash pot adjusting screw contacts to the dash pot shaft to en-
gine revolution returns to idle speed is within specified value when the throttle lever released slowly
from the engine revolution at 3500 rpm.
Specified Duration: 0.5 - 5.0 seconds.
If the measured duration of time fails to meet with the specified value, replace the dashpot with a
new one.
(Refer to the EC section.)
JMA00063-00000

MA23
6. Change of engine coolant
WARNING:
Never open the radiator cap when the engine is still
hot.
CAUTION:
As regards water to be used as cooling water, use soft
water which does not contain salts of minerals, calci-
um, magnesium, and so forth.
If the coolant gets to the vehicle body, immediately JMA00064-00050
flush away the coolant, using fresh water.

Radiator cap
(1) Ensure that the coolant temperature is nearly the ambi-
ent temperature.
(2) Turn the radiator cap one step in an opening direction
(counterclockwise direction) until you feel the first
clicking.
(3) Lightly press the radiator cap two or three times to re-
lease the inner pressure of the radiator. Front
(4) Close the radiator cap. of vehicle Drain plug
(5) Place an adequate container under the drain plug. JMA00065-00051
(6) Drain the coolant by loosening the drain plug.
(7) Remove the radiator cap.
(8) Drain the coolant in the reserve tank.
(9) Close the drain plug, after draining the coolant.
(10) Fill the water to the radiator and reserve tank.
NOTE:
If the water level in the radiator drops, replenish the
water.
(12) Close the radiator cap.

(15) Cool down the water temperature to the ambient tem-
perature.
(16) Repeat the steps (1) through (15) two or three times.
(17) Ensure that the coolant temperature is nearly the ambi-
ent temperature.
(counterclockwise direction) until you feel the first re-
sistance. JMA00066-00052
lease the inner pressure of the radiator.
(21) Place an adequate container under the drain plug.
(22) Drain the water by loosening the drain plug.
(24) Drain the water in the reserve tank.
(25) Replace the O-ring of the radiator drain plug with a
new one, after draining the water.
(26) Install the radiator drain plug to the radiator securely.

MA24
(27) Slowly pour a proper amount of antifreeze solution into
the radiator in accordance with the instruction of the
manufacturer of antifreeze solution.
CAUTION:
Use a good brand of ethylene-glycol base antifreeze
solution.
Coolant Capacity:
Automatic Transmission: 5.3 liters
Manual Transmission: 5.4 liters
NOTE:
The amount above includes 0.6 liter for the reserve
tank. JMA00067-00000
(28) Fill the water to the radiator and reserve tank.

NOTE:
If the water level in the radiator drops, replenish the
water to the full level.
JMA00068-00053

(31) Ensure that no water leakage is present.
If water leakage is present, repair the water leakage.
(32) Warm up the engine thoroughly.
(34) Cool down the coolant temperature to the ambient
temperature.
(35) Ensure that the coolant level in the reserve tank will not
decrease.
If the coolant level in the reserve tank decreases ex-
cessively or no coolant remains in the reserve tank,
check the coolant level in the radiator to see whether
the coolant in the radiator is full or not. If not, replenish
the water to the radiator, and repeat the steps (30)
through (35) again.
(counterclockwise) until you feel the first resistance.
lease the inner pressure of the radiator.
JMA00069-00000

MA25
(39) Ensure that the concentration of antifreeze solution in
the radiator meets the instruction of the manufacturer
of antifreeze solution by a densitometer.
Adjust the concentration of the antifreeze solution in
the radiator according to the instruction of the manu-
facturer of the antifreeze solution, if the concentration
does not meet the instruction of the manufacturer of
the antifreeze solution.
JMA00070-00054
(40) Secure the radiator cap.

(41) Drain the water in the reserve tank.
(42) Pour the coolant which is mixed with antifreeze solu-
tion and water in accordance with the instruction of the
manufacturer of the antifreeze solution.
(43) Secure the reserve tank cap.
JMA00071-00055

MA26
CHASSIS
BRAKE FLUID
CHANGE
WARNING:
Do not mix the different kind and manufacture of brake fluid.
Recommended brake fluid:
FMVSS116 DOT3 or SAE J1703
CAUTION:
If the brake fluid is spilled inadvertently over the paint finish surface of the vehicle or the resin made
part, immediately wipe off the brake fluid and flush with fresh water.
Be sure to follow the draining order of each wheel cylinder. The draining should be performed from
the farthermost wheel cylinder from the brake master cylinder, one by one.
JMA00072-00000
1. Remove the brake bleeder plug cap. Front

2. Connect the suitable bleeder hose to the bleeder plug.
3. Prepare a suitable container and connect one end of the
bleeder hose in the container.
4. Depress the brake pedal and have a person hold it in a
depressed state.
5. Slacken the bleeder plug to drain the brake fluid by anoth-
er person and tighten the bleeder plug temporarily.
6. Repeat the steps 4 to 5 until the brake fluid in the reservoir
tank becomes zero.
However, at this state be very careful not to suck the air JMA00073-00056
into the brake line, except cases where draining of the Rear
brake fluid is required.
7. Replenish the new brake fluid into the reservoir tank and
maintain the brake fluid level in the reservoir tank at the
MAX level during the following operation.
8. Drain the old brake fluid or air from each brake line start-
ing from the farthest wheel cylinder from the master cylin-
der one by one following the manner mentioned in the
steps 4 to 5 repeatedly. JMA00074-00057
9. Tighten the air bleeder plugs to the specified tightening
torque.
10. Ensure that no air exists in the brake line by depressing

the brake pedal firmly.
If air is remaining in the brake line, perform the air bleed-
ing by following the procedure described in the steps 4 to
5 repeatedly, until air will be discharged. Then, tighten the
bleeder plug to the specified tightening torque.
11. Install the brake bleeder plug cap. JMA00075-00058

MA27
BRAKE PEDAL
FREE PLAY
1. Ensure that the ignition switch is turned OFF.
2. Depress the brake pedal more than five times to release
the vacuum saved in the brake booster.
3. Ensure that the specified free play exists on the brake
pedal by pushing the brake pedal lightly by hand.
Free Play: 0.5 - 2.0 mm 0.5 - 2.0 mm
If the free play is not within the specified value, adjust the
free play by adjusting the push rod length. JMA00076-00059
(Refer to the BR section.)
RESERVE TRAVEL
1. Place chocks at the wheels.
2. Place the transmission in the neutral position.
3. Start the engine.
4. Depress the brake pedal with an applying force of 300 N
(30 kgf).
CAUTION: 108.3 mm or more
At this stage the hand brake should not be applied.
JMA00077-00060
5. Measure the distance between the position where the

brake pedal pad upper surface is depressed and the floor
panel as shown.
6. Ensure that the reserve travel meets with the specification.
Reserve Travel: 108.3 mm or more
If the reserve travel fails to meet with the specification,

check/ adjust or repair the brake shoe clearance as nec-
essary.
(Refer to the BR section.) JMA00078-00000
PARKING BRAKE HANDLE

WORKING TRAVEL
1. Chock the wheels. Unlock
2. Ensure that the number of notches is within the specified Set
value when the parking brake handle is pulled with a force
of 196 N (20 kgf) by hand.
Specified Number of Notches: 5 to 7
Release
If the working travel fails to meet with the specification, ad-
just the parking brake handle working travel to the speci-
fied value. JMA00079-00061
(Refer to the BR section in this service manual.)

3. Ensure that the parking brake handle rachet operates
properly and retains the handle at each notch position
properly and will not be skipped or jumped.
If any trouble exists, replace the parking brake handle with
a new one.

MA28
INSPECTION OF EFFECTIVENESS
Check to see if the vehicle can be retained in a stationary state on a dry slope with a grade of 1/5 when the
parking brake is applied fully.
If not, check and repair the rear brake system.
JMA00080-00000
BRAKE HOSE & TUBE

LEAKAGE, LOOSE CLAMP AND DAMAGE
Inspect the following points. If any problem is found, repair them, as required.
1. Hoses and tubes for scratches or cracks.
2. Hoses for aging such as deformation or swelling.
3. Tubes for corrosion or rusting.
4. Tube clamps and related parts for tightness, rattle or damage.
5. Connection for fluid leakage.
6. Hoses for extreme bending, twisting or pulling.
Crack Scratch/Cut Twist Swelling
JMA00081-00062

MA29
FRONT BRAKE
COMPONENTS
q 83.4 4.9 : Tightening torque

(8.5 0.5) Unit : Nm (kgf-m)
!3

!2
!1 o
w !0 i
y
u
r
e
t
49.0 4.9
(5.0 0.5)
q Cylinder slide main pin

w Cylinder slide sub-pin
e Disc brake No. 1 pad
r Disc brake No. 2 pad
t Anti-squeal shim
y Shim
u Disc brake pad guide No. 2 plate
i Disc brake pad guide plate
o Disc brake cylinder mounting (R, L)
!0 Cylinder boot
!1 Front disc brake piston
!2 Piston seal
!3 Pin boot
JMA00082-00063
INSPECTION OF BRAKE PAD THICKNESS

1. Jack up the vehicle and support the vehicle with safety
stands.
2. Remove the front wheel.
3. Check the brake pad thickness through the inspection
hole provided on the caliper as shown.
Brake Pad Thickness:
Standard Thickness: 10 mm
Minimum Thickness: 1 mm
JMA00083-00064
If the brake pad thickness is less than the specified value

or the wear indicator emits a warning sound, replace the
brake pad with a new one.
CAUTION:
Be sure to replace the right and left side brake pads as
a set. Failure to observe this caution may lead to side
pull of the brake function.
4. Install the front wheel.

(Refer to FS section.)
MA30
INSPECTION OF FRONT BRAKE RUBBER PARTS AND
BRAKE PAD FOR DAMAGE
stands.
2. Remove the front wheel.
3. Remove the sub-cylinder slide pins.
JMA00084-00065
4. Turn up the disc brake assembly as shown.

CAUTION :
Never pull the brake hoses not more than necessary.
5. Ensure that no damage exists on the cylinder boot.

If any damage exists, replace the cylinder boots and pis-
ton seal with new ones as a set.
6. Ensure that no leakage of brake fluid exists from the disc
brake cylinder, piston and around the cylinder boot.
If any leakage exists, replace the piston seal and cylinder JMA00085-00066
boot with new ones.

7. Inspect the disc pads and disc brake pad-related parts

for damage.
If any damage is found, replace the damaged part, as re-
quired.
(Refer to the BR section for details.)
8. Ensure that no damage exists on the disc brake pad
guide plates, disc brake pad guide No. 2 plates, disc
pads, shims and anti-squeal shims.
If any damage exists, replace the damaged parts with
new ones.
9. Install the disc brake pad guide plates, disc brake pad JMA00086-00067
guide No. 2 plates, disc pads, shims and anti-squeal

shims as shown.
CAUTION :
Prior to installation, apply brake grease to the sliding
surface of the component parts.
10. Ensure that no damage exists on the pin boots.

If any damage is present, replace the pin boots with new
ones.

MA31
11. Ensure that the brake pads, anti-squeal shims and pad
guide plates are installed properly.
CAUTION:
Be very careful not to deform or lose the anti-squeal
shims.
12. Thinly apply the brake rubber grease to the sub-cylinder

slide pin boot.
JMA00087-00068
13. Turn over the disc brake assembly onto the disc brake
pads while pushing the pin boots of the sub-cylinder slide
pin by finger.
CAUTION :
Never pull the brake hoses not more than necessary.
Never damage the pin boots during the operation.
Never interfere with the disc brake cylinder assembly
with the brake pads and anti-squeal shims during the
installation
JMA00088-00069
14. Thinly apply the brake rubber grease to the sliding surface
of the sub-cylinder slide pin.
15. Install the sub-cylinder slide pin of the disc brake cylinder
assembly to the disc brake mounting.
CAUTION:
Be very careful not to damage the pin boot during the
assembly.
16. Tighten the sub-slide pin to the specified tightening

torque.
Tightening Torque: 44.1 - 53.9 Nm (4.5 - 5.5 kgf-m) JMA00089-00070
17. Depress the brake pedal more than 10 times.

18. Check to see if the brake disc can rotate smoothly.
19. Ensure that no abnormal sound is emitted or no drag ex-
ists when the wheel is rotated.
20. Install the front wheels with the attaching nuts and tighten
them evenly in two or three stages to the specified tighten-
ing torque.
Tightening Torque: 88.2 - 117.6 Nm
(9.0 - 12.0 kgf-m)
21. Check effectiveness of the brake with a brake tester.

JMA00090-00000

MA32
REAR BRAKE
COMPONENTS
: Tightening torque
!3 Unit : Nm (kgf-m)
9.8 2 (1.0 0.2) !6 !7 : Non-reusable parts
B !8 !5
!2 !4 !4
!5 !11 !5 !7
o
e i
61 7 (6.25 0.75)
r

!0
u
t y
q Brake drum subassembly

w Brake shoe hold down spring
e Shoe hold down spring pin
o r Tension No. 4 spring
w t Tension No. 3 spring
y Tension spring
q
u Automatic adjust lever (R, L)
i Parking brake shoe lever subassembly (R, L)
o Brake shoe assembly
!0 Parking brake shoe strut
!1 Rear wheel brake cylinder assembly
!2 Bleeder plug
!3 Brake backing plate subassembly
!4 Wheel cylinder boot
!5 Wheel brake cylinder piston
!6 Compression spring
!7 Cylinder cup
!8 Bleeder plug cap
JMA00091-00071
INSPECTION OF BRAKE LINING THICKNESS

1. Jack up the vehicle and support it with safety stands.
2. Remove the hole plug provided on the backing plate as
shown in the figure.
3. Inspect that the thickness of the brake shoe lining is more
than the specified value through the inspection hole.
Thickness of Brake Lining
Standard Thickness: 5 mm
JMA00092-00072
Replace the brake shoe, if the lining thickness is less than

the specified value.
If the brake lining is less than the specified value, check
the brake drum inner diameter.
4. Install the hole plug securely.
CAUTION:
Be sure to install the hole plug securely. Failure to ob-
serve this caution may lead to rear brake problems
owing to admission of dust, mud, water, etc.

MA33
INSPECTION OF WHEEL CYLINDER FOR LEAKAGE
2. Remove the wheels.
3. Release the parking brake fully.
4. Remove the rear brake drum from the rear axle hub by
pulling it out.
NOTE:
If any difficulty is encountered in removing the brake
drum, screw in the 8 mm bolts to the brake drum even-
ly. JMA00093-00073
The bolt hole is of the offset type. Therefore, after tight-

ening the bolt to a certain extent, make the brake drum
float evenly by lightly tapping the brake drum with a
plastic hammer or the like.
5. Ensure that no damage exists on the brake shoe lining

surfaces.
If any damage is found, replace the brake shoes with new
ones.
CAUTION :
Replacement should be performed for the right and left
side shoes as a set.
JMA00094-00074
6. Ensure that no brake fluid leakage exists around the wheel

cylinder boots.
Replace the piston cups and cylinder boots if brake fluid
leakage exists.
JMA00095-00000
7. Clean the attaching surface of the brake drum and rear

axle hub.
8. Install the brake drum on the rear axle hub.
9. Clean the attaching surface of the brake drums and
wheels.
10. Install the wheels and tighten the attaching bolts to the
specified tightening torque.
Tightening Torque: 103.0 14.7 Nm
(10.5 1.5 kgf-m)
11. Apply the brake pedal fully several times until the clicking
sound is emitted.
12. Ensure that the brake drum turns lightly without being
caught.
13. Check effectiveness of the rear brake with a brake tester. JMA00096-00075

MA34
BRAKE BOOSTER HOSE
COMPONENTS
: Tightening torque
LHD RHD
Unit : Nm (kgf-m)
o t : Non-reusable parts
i u e
u
B t 9.8 - 15.7
N
25.5 2.9 r (1.0 - 1.6)
t y t
(2.6 0.3)
r
w
e
t t y 25.5 2.9
9.8 - 15.7 (2.6 0.3)
q
N (1.0 - 1.6)
q Brake booster assembly
w Master cylinder push rod clevis
e Brake booster bracket gasket
w
r Union to connector tube
t Clip
q y Union
u Intake manifold tube clamp
i Intake manifold to connector tube
o Union to check valve hose
JMA00097-00076
CHECK OF VACUUM HOSE

1. Visually check vacuum hose for aging, cracks, scratches
or cut.
If any damage exists, replace the vacuum hose with a new
one.
2. Disconnect the vacuum hose from the brake booster.
3. Ensure that the negative pressure is retained when apply-
ing negative pressure to the disconnected hose.
If not, replace the vacuum hose with a new one.
JMA00098-00077
4. Ensure that the air continuity exists when air is blown into
the vacuum hose from the brake booster side.
If not, replace the vacuum hose with a new one.
5. Connect the vacuum hose to the brake booster.
6. Install new hose bands.
CAUTION :
Insert the vacuum hose up to the spool of the brake
booster.
JMA00099-00078

MA35
BRAKE MASTER CYLINDER
COMPONENTS
: Tightening torque
Unit : Nm (kgf-m)
t
B
q
12.7 2.5
(1.3 0.3)
r

r
B
7.9 - 11.7
(0.8 - 1.2)
y
q Brake master cylinder reservoir tank

w Reservoir filler cap
e Reservoir diagram
r Grommet
t Brake master cylinder assembly
y Tandem master cylinder repair kit
JMA00100-00079
INSPECTION OF BRAKE MASTER CYLINDER FOR FLUID

LEAKAGE
1. Ensure that no brake fluid leakage exists from the grom-
met sections on the brake master cylinder.
If leakage exists, replace the grommet with a new one.
2. Disconnect the connecter of the brake fluid level switch.
3. Drain the brake fluid from the master cylinder.
(Refer to the brake fluid change section.)
4. Place a suitable piece of cloth under the master cylinder
to prevent the brake fluid from being splashed on the JMA00101-00080
painted surface.
5. Disconnect the brake pipes from the master cylinder.
CAUTION:
If the brake fluid is spilled inadvertently over the paint-
finish surface of the vehicle or resin made parts, imme-
diately wipe off the brake fluid and wash with fresh
water.
6. Remove the master cylinder by removing the attaching

nuts.

MA36
7. Secure the master cylinder in a vise.
8. Ensure that no brake fluid leakage exists around the pis-
ton guide section of the brake master cylinder.
If any brake fluid leakage exists, replace the brake master
cylinder pistons with piston cups(repair kit) with new ones.
9. Clean the master cylinder attaching surface of the brake
booster.
10. Replace the O-ring of the brake master cylinder with a
new one.
CAUTION: JMA00102-00081
Never make scratches on the O-ring during the installa-

tion.
11. Thinly apply brake rubber grease to the O-ring on the

brake master cylinder.
12. Install the master cylinder to the brake booster with the at-
taching nuts. Then, tighten the attaching nuts evenly to the
Tightening Torque: 12.7 2.5 Nm (1.3 0.26 kgf-m)
WARNING: JMA00103-00082
Be sure to perform the adjustment of the brake booster
push rod height if any inner part of the master cylinder
has been replaced. (Refer to the BR section.)
Failure to observe this warning may lead to damage or
malfunction of the brake system.
13. Connect the brake pipes to the master cylinder and tight-
en the flare nuts to the specified tightening torque.
Tightening Torque: 13 - 18 Nm (1.3 - 1.8 kgf-m)
14. Connect the brake fluid level switch connector.

15. Perform the air bleeding of the brake system.
(Refer to the Brake fluid change section.)
16. Perform the brake performance test with a brake tester.

MA37
MUFFLER AND EXHAUST PIPE
DAMAGE & TIGHTNESS
1. Visually check that the exhaust pipes and mufflers for
damage and exhaust gas leakage. Also ensure that there
is no possibility of interference with any other parts.
WARNING
Never perform this check when the exhaust system is
hot.
Catalytic
converter
If any damage or gas leakage exists, repair or replace the
parts as necessary. JMA00104-00083
2. Check that the muffler support of the exhaust pipe and

muffler as well as their connecting section for looseness,
using a suitable wrench or rock them by hand.
WARNING:
Never perform this check when the exhaust system is
hot.
Be careful not to burn yourself during inspection.
If any damage or looseness is found, repair or replace

parts as necessary. JMA00105-00000
AUTOMATIC TRANSMISSION
FLUID CHANGE
1. Place a suitable container under the drain plug.
2. Drain the transmission fluid by removing the drain plug.
3. Install the drain plug with a new gasket interposed and
tighten the drain plug with the specified tightening torque.
CAUTION:
Never reuse the used gasket.
JMA00106-00084
4. Fill the specified automatic transmission fluid to the auto-

matic transmission.
Specified Automatic Transmission Fluid:
DEXRON @ or #
Capacity: 1.7 liters (Drain and refill)
5. Check the fluid level.

CAUTION:
Inspection should be performed when the fluid temperature is between 70 - 80C.
Be very careful not to scald yourself with hot transmission fluid or other parts in the engine compart-
ment.
(1) Park the vehicle on a level surface and apply the parking brake fully.
(2) With the engine idling, move the shift lever from the P range to the L range, and return it to the P
range.
(3) Pull out the dipstick and wipe it clean. Then insert the dipstick and pull it out again. Ensure that the
fluid level is between the upper and lower levels in the hot range of the oil level gauge.
If the fluid level is less than the lower level, add the specified automatic transmission fluid to the
upper level of the dipstick. Then, recheck the fluid leakage.
JMA00107-00000

MA38
CHECK OF OIL COOLER HOSE
Inspect the following points. If any problem is found, repair
them, as required.
1. Hoses and tubes for scratches or cracks.
2. Hoses for aging such as deformation and swelling.
3. Tubes for corrosion or rusting.
4. Tube clamps and related parts for tightness, rattle or dam-
age.
5. Connection for fluid leakage.
6. Hoses for extreme bending, twisting or pulling.
JMA00108-00000
CLUTCH
FREE PLAY
1. Lightly depress the clutch pedal by hand,until you feel re-
sistance. Then, measure the free play.
Specified Clutch Pedal Free Play: 15 - 30 mm
If the clutch pedal free play fails to meet with the specifi-
cation, adjust the clutch pedal free play to the specified 15 - 30 mm
value.
(Refer to the CL section.)
JMA00109-00086
RESERVE TRAVEL
2. Ensure that the difference of clutch pedal upper surface
Position clutch
height at clutch pedal depressed fully and clutch pedal just disengage
positioned at point where the clutch just disengage is con-
forms to the specified value.
Specified Reserve Travel: 25 mm or more 25 mm or more
Position
If the reserve travel fails to conform to the specification, depressed fully
adjust the reserve travel by adjusting the free play or re-
place the clutch disc, clutch cover and related damaged JMA00110-00087
parts, as required.

MA39
MANUAL TRANSMISSION, TRANSFER, FRONT
AND REAR DIFFERENTIAL
OIL CHANGE
1. Place a suitable container under the drain plug.
2. Drain the oil by removing the drain plug.
3. Remove the filler plug.
4. Reinstall the drain plug with a new gasket interposed and
tighten it to the specified tightening torque.
Tightening Torque Transmission
Manual Transmission:
JMA00111-00088
30 - 49 Nm (3.0 - 5.0 kgf-m)
Transfer:
30 - 49 Nm (3.0 - 5.0 kgf-m)
Front Differential:
49 9.8 Nm (5.0 1.0 kgf-m)
Rear Differential:
53.9 - 68 Nm (5.5 - 7.0 kgf-m)
5. Fill the specified oil, until the oil begins to overflow from
the oil filler hole.
Transfer
Specified Oil:
JMA00000-00089
Manual Transmission
Grade: API GL-3 or GL-4
Viscosity: SAE 75W-85 or 75W-90
Capacity: 2.2 liters (With transfer)
Transfer (For automatic transmission)
Capacity: 1.6 liters
Front Differential
Grade: API GL-5
Front differential
Viscosity: SAE 80W-90
Capacity: 0.7 liter JMA00000-00090
Rear Differential (Conventional)

Grade: API GL-5
Rear Differential (LSD)
Grade: API GL-5
Viscosity: SAE 80W-90 LSD
6. Install the filler plug with a new gasket interposed and Rear differential
tighten it to the specified tightening torque. JMA00000-00091
Tightening Torque
Manual Transmission:
30 - 49 Nm (3.0 - 5.0 kgf-m)
Transfer:
30 - 49 Nm (3.0 - 5.0 kgf-m)
Front Differential:
49 9.8 Nm (5.0 1.0 kgf-m)
Rear Differential:
53.9 - 68 Nm (5.5 - 7.0 kgf-m)

MA40
PROPELLER SHAFT
CHECK OF PROPELLER SHAFT
1. Ensure that no looseness exists on the attaching bolts of
the universal joint flange yokes which were connected to
the front, rear differential and propeller shaft, using a
torque wrench.
If any looseness exists, retighten the attaching bolts as re-

quired.
(Refer to the PR section.) JMA00112-00092
2. Ensure that no excessive play exists on the universal

joints.
If any excessive play exists, repair the universal joint by
replacing the spider kit or replace the propeller shaft with
a new one.
(Refer to the PR section.)
3. Ensure that no excessive play exists between the pro-
peller shaft and the transfer output shaft.
If excessive play is found, replace the front propeller shaft
and/or transfer output shaft as required.
DRIVE SHAFT
CHECK OF DUST BOOT
1. Inspect that the dust boot is free from damage or cracks.
If any damage exists, replace the boot with a new one.
(Refer to the FS section.)
2. Inspect that the dust boot bands are securely installed in
position properly.
If not, replace the boot bands with new ones.
JMA00113-00093
WHEEL HUB NUT

Inspect the wheel hub nuts for looseness, using a wheel hub
nut wrench.
JMA00114-00094
WHEEL BEARING
RATTLE
1. Ensure that the wheel bearings exhibit no excessive play
by rocking the tire in and out, up and down or forward and
backward while holding the tire by hands.
If excessive play is found, replace the wheel bearing with
a new one.
2. Ensure that no abnormal sound is emitted when the wheel
is rotated by hand.
If abnormal sound is emitted, perform a repair so that no
abnormal sound may be emitted. JMA00115-00095

MA41
STEERING SYSTEM
STEERING WHEEL FREE PLAY
1. Set the vehicle in a straight-ahead condition.
Play
2. Inspect the steering wheel free play by turning it lightly
with your fingers.
Specified Value: 10 mm MAX.
10 mm MAX.
If the free play fails to meet with the specification, adjust
the free play to the specified value.
(Refer to the SR section.)
JMA00116-00096
STEERING WHEEL RATTLE

Hold the steering wheel by your hands. Ensure that the steer-
ing wheel exhibits no excessive looseness or play by moving
it in an up-&-down direction, a right-&-left direction as well as
in a fore-&-aft direction.
If excessive play is found, repair the steering system.
JMA00117-00097
TIGHTNESS OF STEERING LINKAGE

Inspect the attaching sections for tightness or damage.
Tightening Torque:
Steering Wheel/Steering Main Shaft:
28 - 41 Nm (2.8 - 4.2 kgf-m)
Steering Main Shaft/Universal Joint:
25 - 34 Nm (2.5 - 3.5 kgf-m)
Universal Joint/Steering Pinion:
25 - 34 Nm (2.5 - 3.5 kgf-m)
JMA00118-00000
DAMAGE OF STEERING LINKAGE BALL JOINT DUST

BOOT
Inspect the dust boot of the tie rod end ball joint for cracks or
damage.
If any cracks or damage exists, replace the dust boot as nec-
essary.
JMA00119-00099
FLUID LEAKAGE OF STEERING GEAR BOX

1. Inspect the power steering device for fluid leakage.
2. Inspect the tightness of the power steering device.
TIGHTNESS OF STEERING GEAR BOX

Inspect the bolts of the gear box for looseness.
JMA00120-00000

MA42
POWER STEERING FLUID HOSE
Inspect the power steering fluid hose for aging, deformation,
cracks, scratches, cut, twist and swelling.
If any problem is found, replace the fluid hose with a new one.
CAUTION:
JMA00121-00101
WHEEL ALIGNMENT
TOE-IN CHECK
1. Ensure that the tires have been inflated with the specified
pressure.
(Refer to the Owners manual.)
2. Place the vehicle on a flat floor and place the steering
wheel to a straight ahead direction.
3. Attach a toe-in gauge to the rear side at the center point of A
each front tire at a height of tire center and put a mark on
each tire.
JMA00122-00102
4. Move the vehicle forward in a straight ahead direction Front

gradually until the marks put on the tires come to the front
side.
B
5. Attach the toe-in gauge to the front side, at the center
point of each front tire. Determine the difference in the
mark-to-mark distance between the first measurement and
the second measurement. This difference constitutes the
toe-in.
6. Ensure that the measured difference is within the specified A
value.
Specified Value: 0 1.5 mm JMA00123-00103
If the measured difference(toe-in) fails to meet with the

specification, adjust the toe-in to the specified value.

MA43
SHOCK ABSORBER
DAMAGE AND OIL LEAKAGE
Visually inspect each shock absorber for damage and oil
leakage.
If damage or oil leakage exists, replace the damaged part
with a new one.
(Refer to FS or RS section.)
JMA00124-00104
FUNCTION
Rock the vehicle in an up-&-down direction. Ensure that the
vehicle emits no abnormal noise and the shake will finish with-
in a few times.
If not, replace the shock absorber with a new one.
(Refer to FS or RS section.)
JMA00125-00105
SUSPENSION ARM, CONTROL ARM & DUST

COVER
DAMAGE OF SUSPENSION ARMS AND DUST COVER
Visually inspect the suspension arms and dust cover for dam-
age.
If damage exists, replace the damaged part with a new one.
TIGHTNESS OF SUSPENSION ARMS

Check the suspension arm connecting bolts and nuts for
JMA00126-00106
tightness.
If any looseness exists, tighten the attaching bolts and nuts to
the specified tightening torque.
DAMAGE AND TIGHTNESS OF CONTROL ARMS

1. Visually inspect the control arms for damage.
If damage exists, replace them with new ones.
(Refer to the RS section.)
2. Inspect the attaching bolts and nuts for tightness.
If any looseness exists, tighten the attaching bolts and
nuts to the specified tightening torque.

DAIHATSU
EM
J100
ENGINE MECHANICAL
ENGINE TUNE-UP .............................. EM 2 CYLINDER BORING ...................... EM 86

TIMING BELT ...................................... EM 10 REPLACEMENT OF REAR OIL
COMPONENTS .............................. EM 10 SEAL .......................................... EM 87
REMOVAL ...................................... EM 11 REPLACEMENT OF FRONT OIL
INSPECTION .................................. EM 15 SEAL .......................................... EM 87
INSTALLATION .............................. EM 17 REPLACEMENT OF CYLINDER
CYLINDER HEAD ............................... EM 24 BLOCK ....................................... EM 88
COMPONENTS .............................. EM 24 REPLACEMENT OF
INSTRUCTION PRIOR TO CRANKSHAFT ........................... EM 90
OPERATION ............................... EM 25 REPLACEMENT OF CONNECTING
CYLINDER HEAD REMOVAL ......... EM 25 RODS ......................................... EM 91
OVERHAUL OF CYLINDER HEAD .... EM 31 DISASSEMBLY OF OIL PUMP ....... EM 92
DISASSEMBLY OF CYLINDER ASSEMBLY OF OIL PUMP ............. EM 95
HEAD ......................................... EM 31 INSPECTION OF CRANKSHAFT
INSPECTION, CLEANING AND PULLEY ...................................... EM 97
REPAIRS OF CYLINDER HEAD INSPECTION OF WATER PUMP .... EM 97
COMPONENTS .......................... EM 32 INSPECTION OF WATER PUMP
CYLINDER BLOCK ............................. EM 60 PULLEY ...................................... EM 97
COMPONENTS .............................. EM 60 INSPECTION OF OIL PAN ............. EM 98
INSTRUCTION PRIOR TO INSPECTION OF FLYWHEEL ......... EM 98
OPERATION ............................... EM 61 INSPECTION AND REPLACEMENT
ENGINE REMOVAL ........................ EM 61 OF RING GEAR ......................... EM 98
DISASSEMBLY OF CYLINDER ASSEMBLY OF CYLINDER
BLOCK ....................................... EM 66 BLOCK ....................................... EM 99
INSPECTION OF EACH PART ........... EM 79 PREPARATION OF ENGINE
INSPECTION OF CYLINDER INSTALLATION .......................... EM112
BLOCK ....................................... EM 79 INSTALLATION OF ENGINE .......... EM115
INSPECTION OF PISTONS AND ENGINE SPECIFICATION ................... EM121
CONNECTING RODS ................ EM 80 ENGINE MECHANICALS ............... EM124
INSPECTION OF PISTONS ............ EM 81 SST (Special Service Tools) .............. EM126
ASSEMBLY/DISASSEMBLY OF TIGHTENING TORQUE ...................... EM128
PISTON & CONNECTING JEM00001-00000
ROD ........................................... EM 84
NO. 9710-JE

EM2
ENGINE TUNE-UP
NOTE:
The adjustments or checks of this section is performed normally when the engine is in a hot condi-
tion.
Hot engine condition denotes a condition in which the cooling water temperature is 75 - 85C and
the engine oil temperature is above 65C.
Warm up the engine thoroughly. However, do not perform the adjustment while the idle-up VSV is still
functioning.
Ensure that all accessory switches are turned OFF.
On the automatic transmission vehicle, the gear shift lever is placed in the [N] or [P] range.
On the manual transmission vehicle, the gear shift lever is placed in the neutral range.
Connect the engine revolution meter for measuring the engine revolution speed. If your engine revo-
lution meter is of such a type as to be connected to the negative terminal of the ignition coil, connect
the following SST to the diagnosis connector.
SST: 09991-87402-000

Set the steering wheel to the straight ahead direction.
Be sure that the removed parts for adjustment or checks should be reinstalled.
JEM00002-00000
1. Inspection of engine coolant

Check to see if coolant level is between the LOW and
FULL lines of the reserve tank.
If coolant level is near the LOW level or bellow the LOW
level, add the coolant up to the full level.
WARNING:
Never open the radiator cap when the engine is still FULL
hot. LOW
Failure to observe this caution will cause you to get
scalded.
JEM00003-00001
NOTE:
If no coolant is present in the reserve tank or the
coolant level is very low, check for water leakage, using
a radiator cap tester.
Here, the coolant refers to the coolant having an ade-
quate freezing protection rating.
Coolant Capacity:
Manual Transmission Vehicle: 5.4 liters
Automatic Transmission Vehicle: 5.3 liters
CAUTION:
Use a good brand of ethylene-glycol-base antifreeze
solution.
NOTE:
The amount above includes liter for reserve tank.
JEM00004-00000

EM3
2. Inspection of engine oil
(1) Oil quality check
Check the engine oil for deterioration, ingress of water,
discoloring and dilution.
NOTE:
Park the vehicle or a level surface.
The amount of oil between the L level and the F
level equals around one liter.
JEM00005-00002
(2) Oil level check

Ensure that the engine oil level should be between the
L and F level an the dipstick.
If the engine oil level is below the L level, replenish
the specified oil to the F level after oil leakage has
been checked.
Oil Capacity: Unit: liter
F level 3.3
L level 2.3
Oil capacity when oil filter replaced 3.5
JEM00006-00003
Full capacity 3.6
C 29 18 7 4 16 27 38
TEMP. F 20 0 20 40 60 80 100
NOTE: Engine oil

(4 stroke) 10W-30, 10W-40, 10W-50
Use API grade SF or higher multigrade viscosity, fuel
efficient oil. 20W-40, 20W-50
The amount of oil between the L level and the F 5W-30

level equals around one liter.
30
20
JEM00000-00004
3. Inspection of spark plugs
Recommended Spark Plug:

DENSO NGK
K20TNR-S, K22TNR-S BKUR6EK, BKUR7EK
NOTE:
All spark plugs should have the same head range and
be ones manufactured by the same manufacture.
JEM00007-00000

EM4
(1) Inspection of electrode
Measure the insulation resistance of the spark plug.
Minimum Insulation Resistance: 15 M
If the measured insulation resistance is less than the

specified value, replace the spark plug with a new one
after checking the electrode gap and cleaning the
spark plug.
WARNING:
Since the spark plugs are hot, care must be exercised
to avoid getting scalded. JEM00008-00005
(2) Inspection of electrode gap

Measure the electrode gap, using a plug gap gauge.
Electrode Gap: 0.9 - 1.0 mm

one.

(1) Visual inspection of the drive belt JEM00009-00006
Visually check the belt for separation of the adhesive

rubber above and below the core, core separation
from the belt side, severed core, separation of the rib
from the adhesive rubber, cracks or separation of the
ribs, torn or ribs or cracks in the inner ridges of the
ribs.
Replace the drive belt, if necessary.
(2) Inspection of the drive belt tension

Measure the amount of the drive belt deflection when JEM00010-00007
the midpoint of the drive belt between the alternator
and the water pump pulley is pushed with a force of Water pump pulley
98 N (10 kgf).
New Belt: 4 - 5 mm
[with a force of 10 kg applied at the
point shown in the figure.]
Used Belt: 5 - 6 mm
[with a force of 10 kg applied at the
point shown in the figure.] Alternator pulley
JEM00011-00008
If necessary, adjust the drive belt tension. Vane pump pulley

NOTE: Water pump pulley
New belt refers to a belt which has been used on a Air conditioner
compressor pulley
running engine for less than five minutes.
Used belt refers to a belt which has been used on a
running engine for more than five minutes or more.
After replacing the drive belt, check that it fits properly
in the ribbed grooves, especially in the places difficult
Idler pulley
to see. Alternator pulley
After installing a new belt, run the engine for about five Crankshaft pulley
minutes and then recheck the tension. JEM00012-00009

EM5
5. Inspection and adjustment of valve clearances
The measurement and adjustment of valve clearance are
carried out when each of the piston of the No. 1 and No. 4
cylinders is set to the top dead center at the end of com-
pression stroke.
NOTE:
The valve clearance adjustment is performed normally
when the engine is in a hot condition.
Hot engine condition denotes a condition in which the
cooling water temperature is 75 - 85C and the engine
oil temperature is above 65C.
However, when the engine has been overhauled, it is
necessary to adjust the valve clearances while the en-
gine is cold and to readjust the valve clearance in a hot
condition after warming up the engine.
JEM00013-00000
NOTE:
The O mark denotes those valves that can be adjust-
ed under that setting.
Valve Clearances (Hot)
Intake: 0.25 0.05 mm
Exhaust: 0.33 0.05 mm
(Reference)
Valve Clearances (Cold)
Intake: 0.18 mm
Exhaust: 0.25 mm
Tightening Torque (Lock nut): 16.7 - 22.6 Nm JEM00014-00010
Piston positions 1 2 3 4
When valve rocker arms of No. 1 cylinder are free: Intake

(Piston of No. 1 cylinder is at top dead center under compression strok) Exhaust
When valve rocker arms of No. 4 cylinder are free: Intake
(Piston of No. 4 cylinder is at top dead center under compression strok) Exhaust
JEM00015-00000

EM6
6. Inspection and adjustment of ignition timing
Check to see if the ignition timing mark of the crankshaft
pulley is aligned with the indicator of the timing belt cover
by using a timing light under the condition that the T termi-
nal has been connected with the ground terminal in the di-
agnosis connector by the following SST.
SST: 09991-87403-000
TDC 0 BTDC 2 ATDC 2
NOTE:
The ignition timing inspection or adjustment is per-
formed normally when the engine is in a Hot condi- JEM00016-00011
tion.
The Hot engine condition denotes a condition in
which the cooling water temperature is 75 - 85C and
the engine oil temperature is above 65C.
made on terminals except for those specified.
Even a slight contact with the other terminals will cause
serious malfunction.
If the ignition timing mark is not aligned with the indicator

of the timing belt cover, adjust the ignition timing by turn-
ing the cam angle sensor.
REFERENCE:
If the cam angle sensor is turned clockwise, the timing
will be advanced. Conversely, if the can angle sensor is
turned counterclockwise, the ignition timing will be re-
tarded.
JEM00017-00012
7. Inspection and adjustment of idle speed

Preparation to be made prior to idle speed adjustment.
The air cleaner element is installed.
All vacuum hoses are connected.
Ensure that the intake system exhibits no air leakage.
Ensure that the exhaust system exhibits no air leakage.
On the automatic transmission vehicle, the shift lever is placed in the [N] or [P] range.
On the manual transmission vehicle, the shift lever is placed in the neutral range.
Position the steering wheel to the straight-ahead direction.
NOTE:
Do not perform the engine idle speed adjustment, while the idle-up VSV is operating.
Prior to the adjustment of the idle speed, be sure to check that the idle-up VSV is not operating.
JEM00018-00000

EM7
Measure the engine idle speed, using a tachometer which
is connector to the REV terminal of the diagnosis con-
Diagnosis connector
nector.
NOTE:
Never allow the REV terminal to touch the ground. It
could result in damage of the ignition system.
As some tachometers are not compatible with this igni-
tion system, it is recommended to confirm the compati- Earth Tacho-meter
bility with your unit before its use. terminal terminal
Specified Idle Speed:
MT: 800 50 rpm JEM00019-00013
AT: 850 50 rpm
If the measured engine idle speed is not within the speci-

fied value, adjust the engine idle speed by turning the idle
adjusting screw placed at the throttle body.
NOTE:
When the idle adjusting screw is turned clockwise, the
idle speed will be decreased, whereas when the idle
adjusting screw is turned counterclockwise the idle
speed will be increased.
JEM00020-00014
8. Compression check
NOTE:
After completion of the engine tune-up, if the engine
exhibits lock of power, excessive oil consumption or
poor fuel economy, measure the cylinder compression
pressure.
JEM00021-00000
Measure the cylinder compression pressure for each

cylinder, using a compression gauge which is inserted
into the spark plug hole.
NOTE:
Depress the accelerator pedal fully while measuring
the compression pressure.
Always use a fully charged battery so that at least a
revolution speed of 300 rpm may be attained.
Compression Pressure:
1373 kPa (14 kgf/cm2)/at 300 rpm
Minimum Pressure: JEM00022-00015
1030 kPa (10.5 kgf/cm2)/at 300 rpm

Difference in Reading Between Cylinders:
147 kPa (1.5 kgf/cm2)/at 300 rpm

EM8
If the compression of one or more cylinders is low, pour a
small amount of engine oil into that cylinder through the
spark plug hole and measure the cylinder compression
again.
If adding oil helps the compression to improve,
chances are that the piston rings and/or cylinder bores
are worm or damaged.
If the pressure remains low after the operation has
been performed, the valves may be sticking or seated
un properly, or there may be leakage post the gasket.
JEM00023-00016
9. Checking of CO/HC concentrations

Preparation to be made prior to check of CO/HC concentrations.
Check and adjust the idle speed.
The air cleaner element is installed.
All pipes and vacuum hose are connected.
Ensure that the intake system exhibits no air leakage.
Ensure that the exhaust system exhibits no gas leakage.
On the automatic transmission vehicle, the shift lever is placed in the [N] or [P] range.
On the manual transmission vehicle, the shift lever is placed in the neutral position.
Position the steering wheel to the straight-ahead direction.
Be sure to prepare the CO/HC meter by following the instruction of its manufacturer, before it is
put into use.
NOTE:
This check is used only to determine whether or not the idle HC/CO emission complies with the regu-
lations.
Measure the HC/CO emission by inserting a sampling pipe of the HC/CO meter into the exhaust pipe.
Wait at least one minute before the measurement so as to allow the concentrations to stabilize.
Complete the measurement within three minutes.
If the HC/CO concentrations do not conform to the regulations, see the following table for possible
causes.

EM9
Trouble Shooting List
HC CO Problems Possible causes
1. Faulty ignition
Incorrect ignition timing
Fouled, shorted or improperly gapped spark plugs
High Normal Rough idle Open or crossed high tension cords
2. Incorrect valve clearance
3. Leaky exhaust valves
4. Leaky cylinder
Rough idle
High Low 1. Lean mixture causing misfire
(Fluctuation in HC reading)
1. Restricted air filter
2. Faulty EFI system
Faulty pressure regulator
Clogged fuel return line
Rough idle Defective water temp. sensor
High High
(Black smoke from exhaust) Defective air temp. sensor
Faulty throttle position sensor
Faulty pressure sensor
Faulty ECU
Faulty oxygen sensor
JEM00024-00000

EM10
TIMING BELT
COMPONENTS
o
y
r
w e
u FRONT
q Fan shroud y Timing belt upper cover

w Fan & fluid coupling u Timing belt lower cover
e V-ribbed belt i Timing belt tensioner subassembly
r Water pump pulley o Timing belt
t Crankshaft pulley assembly
JEM00025-00017

EM11
REMOVAL IG OFF
1. Disconnect the battery ground cable from the negative ()
terminal of the battery.
JEM00026-00018
2. Remove the engine undercover.
JEM00027-00019
3. Removal of fan and fluid coupling

(1) Drain the coolant by loosening the drain plug and the
radiator cap.
WARNING:
Never open the drain plug and the radiator cap when
the coolant is still hot.
Failure to observe this caution will cause you to get
scalded.
JEM00028-00020
(2) Disconnect the water hose from the radiator upper

side.
JEM00029-00021
(3) Loosen the attaching nuts of the fluid coupling.

(4) Remove the fan and the fluid coupling together with
the fan shroud by loosening the attaching bolts.
JEM00030-00000

EM12
4. Remove the power steering vane pump drive belt by loos-
ening the power steering vane pump attaching bolts.
5. Remove the alternator drive belt.
JEM00031-00022
6. Remove the crankshaft pulley.

NOTE:
Place the shift lever in the 4th gear position so as to
prevent the rotation of the crankshaft in the case of
manual transmission-equipped model.
On the automatic transmission vehicle, prevent the
crankshaft from being rotated by inserting a screwdriv-
er or the like into the ring gear at the rear end section
of the cylinder block.
JEM00032-00023
7. Disconnect the connector of the oil pressure switch and

loosen the attaching bolt of the oil pressure switch wire
bracket.
JEM00033-00024
8. Remove the timing belt cover by removing the attaching

bolts.
JEM00034-00025

EM13
9. Removal of timing belt
NOTE:
Prior to removal of the timing belt, put an arrow mark
indicating the normal rotating direction on the belt,
using a chalk or the like.
CAUTION: Mark showing

Do not try to pry the timing belt with a screwdriver or normal rotating
direction
the like during the removal or installation.
Do not allow the belt to come into contact with oil,
water or dust. JEM00035-00026
Do not bend the belt at a sharp angle or turn the belt

inside out, for it is very vulnerable to bending.
Do not utilize the tension of the timing belt pulley when
loosening the set bolt of the camshaft timing belt pulley.
(1) Rotate the crankshaft until the F mark of the crank- Indicator
shaft timing belt pulley is aligned with the indicator of F mark
the cylinder head cover.
JEM00036-00027
(2) Loosen the attaching bolt of the timing belt tensioner. Anti-vibration rubber
Move the tensioner to the left as far as it will go and
tighten the bolt temporarily.
Timing belt tensioner
JEM00037-00028
(3) Remove the timing belt.
JEM00038-00029

EM14
10. Removal of camshaft timing belt pulley
(2) Remove the cylinder head cover.
JEM00039-00000
(3) Removal of camshaft timing belt pulley

While preventing the camshaft timing belt pulley from
turning using a suitable iron rod, remove the three at-
taching bolts.
Then, remove the camshaft timing belt pulley.
JEM00040-00030
11. Removal of crankshaft timing belt pulley

(2) Removal of crankshaft timing belt pulley
q Remove the power train stiffener and prevent the
ring gear from turning with a suitable screwdriver
or the like.
JEM00041-00031
w While performing the operation described in the

step q, remove the set bolt of the crankshaft tim-
ing belt pulley.
JEM00042-00032
e Remove the crankshaft timing belt pulley.

NOTE:
If any difficulty is encountered in removing the crank-
shaft timing belt pulley, lightly screw in the set bolt of
the crankshaft timing belt pulley. Then, remove the pul-
ley, using the following SST.
SST: 09609-20011-000
SST
JEM00043-00033

EM15
(3) Remove the timing belt pulley flange.
JEM00044-00034
INSPECTION
1. Inspection of timing belt
CAUTION:
Do not bend, twist or turn the belt inside out.
Do not allow the belt to come into contact with oil,
water or steam.
JEM00045-00035
If there are damages, as shown in the figures, check the

following points and replace the timing belt, if necessary.
(1) Premature separation
Check for proper installation.
Check the timing belt cover gaskets for damage and
check for correct installation.
JEM00046-00036
(2) If the belt teeth are cracked or damaged, check to see

if the camshaft is seized.
,,,, ,,
, , ,,,
, ,, ,
JEM00047-00037
(3) If there is noticeable wear or cracks on the belt sur-

face, check to see if there are nicks on one side of the
idler pulley lock.
JEM00048-00038

EM16
(4) If there is wear or damage on only one side of the belt,
check the pulley flange.
, ,,, ,,
, , ,
,,,,,,,,,,
JEM00049-00039
(5) If there is noticeable wear on the belt teeth, check the

timing cover gasket for damage and check for correct
gasket installation. Check for foreign material on the
,,,,,,,
pulley teeth.
,,
JEM00050-00040
2. Inspection of camshaft timing belt pulley

(1) Measure the maximum width of the timing belt pulley,
using vernier calipers.
Wear Limit of Camshaft Timing Belt Pulley: 119.8 mm
If the measured value is less than the specified value,

replace the timing belt pulley with a new one.
JEM00051-00041
(2) Visually inspect the timing belt pulley for damage.

If any damage is present, replace the timing belt pul-
ley with a new one.
JEM00052-00042
3. Inspection of timing belt tensioner

If the timing belt tensioner is damaged, check to see if the
bearing exhibits an excessive play.
NOTE:
Check the timing belt pulleys for smooth turning.
Check the belt contact surface for damage.
If necessary, replace the idler pulley.

CAUTION:
Never wash the timing belt tensioner.
JEM00053-00043

EM17
4. Inspection of tension spring
(1) Check the free length of the spring
Free Length: 46.5 mm or less
(2) Check the tension of the spring at the specified instal-

lation length.
Specified Value:
29.4 3 N at 50.9 mm
If the tension does not conform to the specification, re-

place the spring. JEM00054-00044
5. Inspection of crankshaft timing belt pulley and flange

(1) Measure the maximum width of the timing belt pulley,
using vernier calipers.
Wear Limit of Crankshaft Timing Belt Pulley: 59.3 mm
If the measured value is less than the specified value,

replace the timing belt pulley with a new one.
JEM00055-00045
(2) Visually inspect the crankshaft timing belt pulley for

damage. If any damage is present, replace the crank-
shaft timing belt pulley.
JEM00056-00046
(3) Visually inspect the crankshaft timing belt pulley flange

for bend, wear and other damage.
If any damage is present, replace the crankshaft tim-
ing belt pulley flange.
JEM00057-00047
INSTALLATION
1. Installation of camshaft timing belt pulley
(1) Install the camshaft timing belt pulley on the camshaft
in such a way that the F mark can be seen and the
locating pin hole is aligned.
JEM00058-00000

EM18
(2) Install the attaching bolts of the camshaft timing belt
pulley, while preventing the pulley from turning by in-
serting an iron rod into the hole of the pulley.
NOTE:
Do not turn the camshaft independently.
Be very careful not to damage the gasket attaching
surface of the cylinder head.
The bolts and bolt holes should be dry during the tight-
ening. JEM00059-00048
2. Installation of crankshaft timing belt pulley

(1) Install the crankshaft timing belt pulley flange with its
recessed side facing toward the oil pump side
(Protrusion side facing toward the crankshaft timing
belt pulley side).
(2) Install the crankshaft timing belt pulley on the crank-
shaft by aligning it with the key groove.
(3) Install the set bolt of the crankshaft timing belt pulley.
JEM00060-00049
(4) Tighten the set bolt of the crankshaft timing belt pulley,
while preventing the ring gear from turning with a suit-
able screwdriver or the like.
NOTE:
Never allow the crankshaft to turn.
JEM00061-00050
3. Attach the tension spring to the timing belt tensioner.

Hang the tension spring hook on the pin. Assemble the
timing belt tensioner in place and install the bolt.
CAUTION:
Hang the spring hook securely on the pin groove.
Ensure that the pin at the oil pump is fitted into the pin
hole of the timing belt tensioner.
JEM00062-00051
4. Installation of timing belt

(1) Temporarily install the cylinder head cover.
JEM00063-00052

EM19
(2) Align the drilled mark of the camshaft timing belt pul- Indicator F mark
ley with the top surface line of the cylinder head.
(3) Align the drilled mark of the crankshaft timing belt pul-
ley with the indicator. Drilled mark
(4) Assemble the timing belt in such a way that the two
mating marks on the timing belt may be aligned with
the corresponding drilled marks on the crankshaft tim-
ing belt pulley and camshaft timing belt pulley.
CAUTION: Drilled mark
Do not allow the belt to come into contact with oil, Indicator
water or dust. JEM00064-00053
Do not try to pry the timing belt with a screwdriver or

the like.
When the timing belt is reused, there should exist 35
teeth of the belt between the drilled marks of the crank-
shaft timing belt pulley and camshaft timing belt pulley.
When the timing belt is reused, the arrow mark which
was put during the disassembly comes in a rotational
direction of the timing belt.
(5) Loosen the attaching bolt of the timing belt tensioner.

Apply tension to the timing belt. Temporarily tighten
the attaching bolt.
NOTE:
Ensure that the belt exhibits no slack at the tension
side of the belt (the side opposite to the tensioner).
JEM00065-00054
(6) Rotate the crankshaft 1.9 turns in the normal direction

so that the F mark of the camshaft timing belt pulley about 30 degrees
comes at a point three teeth in the camshaft timing belt
pulley before the indicator of the cylinder head cover.
NOTE:
At this time, never turn the crankshaft reversely.
Make sure that the belt is not tilted between the crank-
shaft timing belt pulley and the camshaft timing belt
pulley.
If the crankshaft should be reversed or the timing belt
should be tilted, turn the crankshaft two more turns. JEM00066-00055
(7) Make the tensioner free by loosening the attaching bolt

of the timing belt tensioner.
JEM00067-00056

EM20
(8) Turn the crankshaft further in the normal direction until
the F mark of the camshaft timing belt pulley is
aligned with the indicator of the cylinder head cover.
NOTE:
Never turn the crankshaft reversely.
Never turn the crankshaft beyond the point where the
F mark of the camshaft timing belt pulley is aligned
with the indicator.
If the crankshaft should be reversed or turned beyond
that point, temporarily tighten the tensioner attaching
bolt and repeat the operations from the step (5) on- JEM00068-00057
ward.
(9) Tighten the attaching bolt of the timing belt tensioner

to the specified torque.
JEM00069-00058
(10) Ensure that the drilled marks of the crankshaft timing Indicator F mark
belt pulley and camshaft timing belt pulley are aligned
with the corresponding indicators.
Drilled mark
If the drilled mark is not aligned with the indicator, re-
peat the operations from the step (2) onward.
Drilled mark
Indicator
JEM00070-00059
5. Checking of timing belt tension

When the midpoint of the belt at the tension side is
pushed 5 mm, ensure that the pushing force is within the
specified value.
Specified Pushing Force: Pushing force
7.8 - 15.7 N When belt is deflected 5 mm 7.8 - 15.7 N
If the belt does not conform to the specification, repeat the 5 mm

operations from the step 13 (4) onward.
JEM00071-00060
6. Install the timing belt lower cover and upper cover.

CAUTION:
Care must be exercised as to the length of each bolt.
JEM00072-00061

EM21
7. Install the oil pressure switch wire and tighten the wire
clamps.
8. Connect the oil pressure switch connector.
9. Install the crankshaft pulley with the attaching bolt. Tighten

the bolt to the specified torque. JEM00073-00063
NOTE:
Place the gear shift lever in the 4th gear position so as
to prevent the rotation of the crankshaft in the case of
manual transmission equipped model.
On the automatic transmission vehicle, prevent the
crankshaft from being rotated by inserting a screwdriv-
er or the like into the ring gear at the rear end section
of the cylinder block.
JEM00074-00062
10. Temporarily install the water pump pulley and the drive
belt.
11. Install the power steering vane pump drive belt and adjust
the belt tension.
NOTE:
Make sure that the V-ribbed belt is fitted properly in the
groove of each pulley.
Correct Wrong Wrong
JEM00075-00064
12. Install the fan and the fluid coupling together with the fan
shroud.
13. Tighten the fluid coupling attaching nuts.
JEM00076-00065
14. Tension adjustment Water pump pulley

(1) Screw in the adjusting bolt, until the deflection of the 98 N
drive belt meets the specification when you push the (10 kgf)
midpoint of the drive belt between the water pump pul-
ley and the alternator pulley by applying a force of Deflection
98.1 N (10 kgf).
Alternator pulley
JEM00077-00066

EM22
Specified Belt Deflection:
New Belt: 4.0 - 5.0 mm
With a force of 98.1 N (10 kgf) applied
to point indicated in figure
Used Belt: 5.0 - 6.0 mm
With a force of 98.1 N (10 kgf) applied
to point indicated in figure
NOTE:
The used belt denotes a belt which has been used for
more than five minutes after it was put into use. JEM00078-00067
(2) Tighten the alternator attaching bolts.

(3) Install the locking plate of the adjusting bolt.
CAUTION:
Be sure to install the locking plate securely. Failure to
observe this caution could cause falling of the adjusting
bolt.
JEM00079-00068
15. Ensure that the belt deflection meets the specification Water pump pulley
when the midpoint between the water pump pulley and 98 N
the alternator is pushed with a force of 98.1 N (10 kgf). (10 kgf)
(See step 14.)
If the deflection does not conform to the specification, per- Deflection
form the adjustment so that the specification may be satis-
fied.
Alternator pulley
JEM00080-00069
16. Tighten the fan shroud attaching bolts.

17. Connect the water hoses to the radiator.
JEM00081-00070
18. Tighten the drain plug and fill the coolant to the radiator
and reserve tank.
JEM00081-00071

EM23
19. Install the engine undercover and tighten the attaching
bolts.
JEM00083-00072
20. Connect the ground cable to the negative () terminal of

IG OFF
the battery.
JEM00084-00073

EM24
CYLINDER HEAD
COMPONENTS
@6
!7
!6
q
!5 !3
!8
e
w
!4 e
!3
@0 u
!2 @4
@1 !1
!0
o
r
i
t
y
@5
!9
Front
@2
@3
q Cylinder head cover !4 Camshaft timing belt pulley

w Camshaft !5 Spacer
e Valve rocker shaft !6 Grommet
r Valve guide !7 Oil filler cap
t Cylinder head !8 Gasket
y Oil seal !9 Timing belt upper cover
u Spark plug @0 Timing belt
i Valve @1 Timing belt tensioner
o Spring seat @2 Crankshaft timing belt pulley
!0 Valve stem oil seal @3 Crankshaft pulley
!1 Valve spring @4 Camshaft cap
!2 Valve spring retainer @5 Cylinder head gasket
!3 Valve rocker arm @6 Ignition coil
JEM00085-00074

EM25
INSTRUCTION PRIOR TO OPERATION
Install the fender cover to the fenders so that so scratch
may be made to the fenders.
Be sure to read the general information section of the ser-
vice manual.
JEM00086-00000
CYLINDER HEAD REMOVAL

1. Remove the battery and the battery carrier.
JEM00087-00075
2. Drain the coolant.

3. Remove the cooling fan with the fluid coupling and the fan
shroud.
4. Remove the radiator by loosen the attaching bolts.
JEM00088-00076
5. Removal of air cleaner.

(1) Remove the attaching bolt of the air intake hose.
(2) Remove the accelerator cable and the rubber hoses
from the throttle body.
(3) Release the clips of the air cleaner and remove the air
cleaner lower case with air intake hose and the filter el-
ement.
JEM00089-00077
(4) Remove the air cleaner lower case by loosen the at-
taching bolts.
JEM00090-00078

EM26
6. Remove the power steering vane pump from the engine.
Suspend the removed steering vane pump at body side,
using an adequate rope.
JEM00091-00079
7. Removal of alternator
(1) Remove the connector and the cable at the rear side
of the alternator.
(2) Remove the alternator with the belt tension adjusting
bar.
JEM00092-00080
8. Remove the timing belt.

JEM00093-00000
9. Removal of engine wire from cylinder head.

(1) Disconnect the connector of the engine wire from the
following parts.
q Ignition coils
w Injectors
e Pressure sensor
r Throttle position sensor
JEM00094-00081
t Intake air temperature sensor

y Idle-up VSV
u Water temperature sensor
i Oxygen sensor
o Cam angle sensor
JEM00095-00082

EM27
(2) Disconnect the harness clamps by unlocking the
clamps.
(3) Remove the engine harness from the cylinder head.
JEM00096-00083
10. Disconnect the water hoses
JEM00097-00084
11. Remove the surge tank stay No. 1, No. 2 and No. 3.
JEM00098-00085
12. Disconnect the fuel inlet hose and return hose.

CAUTION:
The fuel pressure at inside of the fuel line is approxi-
mately 284 kPa higher than the atmospheric pressure.
Therefore, be sure to gradually pull out the rubber hose
Inlet
so as to prevent fuel from splashing.
Return
JEM00099-00086
13. Disconnect the rubber hoses for brake booster and VSV.
JEM00100-00087

EM28
14. Removal of intake manifold
(1) Disconnect the plugged hose at the cylinder head.
JEM00101-00088
(2) Remove the attaching bolts and nuts of the intake

manifold by loosen them evenly over two or three
stage, following the sequence shown in the right fig-
ure. e y !0 !1 u
(3) Slowly detach the intake manifold from the cylinder
head while preventing the interference with other q w
parts. r i !2 o t
JEM00102-00089
15. Removal of exhaust manifold

(1) Remove the heat insulator by loosen the attaching
bolts.
JEM00103-00090
(2) Remove the oil level gauge.

(3) Remove the oil level gauge guide by loosen the at-
taching bolt.
JEM00104-00091
(4) Remove the front exhaust pipe from the exhaust mani-
fold.
JEM00105-00092

EM29
(5) Loosen the exhaust manifold attaching bolts and nuts
evenly over two or three stages in the sequence shown
in the right figure.
(6) Remove the exhaust manifold from the cylinder head
while preventing the interference with other parts.
JEM00106-00093
16. Remove the ignition coil and resistive cords from the cylin-
der head cover.
JEM00107-00094
17. Loosen the cylinder head cover attaching bolts evenly

over two or three stages in the sequence shown in the q t i e
right figure.
18. Remove the cylinder head cover.
r u y w
JEM00108-00095
19. Remove the camshaft pulley and cam angle sensor.

CAUTION:
Do not turn the camshaft independently.
Do not damage the cylinder head cover gasket surface.
JEM00109-00096
20. Loosen the valve rocker shaft attaching bolts.

21. Remove the valve rocker shaft together with rocker arms
from the cylinder head.
JEM00110-00097

EM30
22. Remove the rocker arms, spacers and wave washers from
the removed valve rocker shaft.
NOTE:
Arrange the removed parts in oder to so that their re-
spective original installation positions may be known
readily.
JEM00111-00098
23. Remove the camshaft bearing caps by removing the at-

taching bolts.
24. Remove the camshaft from the cylinder head.
JEM00112-00099
25. Loosen the cylinder head bolts evenly over two or three
stages in the sequence shown in the right figure.
NOTE:
Be certain to loosen the cylinder head bolts. Failure to
observe this caution will cause cracks or distortion of r y o u q
the cylinder head, even leading to engine seizure. w i !0 t e
JEM00113-00100
26. Remove the cylinder head bolts.

REFERENCE:
The bolts q and e are shorter the other bolt
Nominal Length of q and e: 110 mm
Nominal Length of other Bolts: 155 mm
JEM00114-00000
27. Remove the cylinder head from the cylinder block.

NOTE:
Place the cylinder head on two suitable wooden blocks
in oder that the cylinder head gasket surface may not
be damaged.
JEM00115-00101

EM31
OVERHAUL OF CYLINDER HEAD
DISASSEMBLY OF CYLINDER HEAD
1. Remove the water temperature sensor gauge from the
cylinder head.
2. Remove the engine hanger.
JEM00116-00102
3. Remove the valve spring retainer locks, using the follow-

ing SST.
SST: 09202-87002-000
SST
JEM00117-00103
4. Remove the valve springs.

NOTE:
Arrange the removed parts in order so that their in-
stalling positions may be known easily.
JEM00118-00104
5. Remove the valves.

NOTE:
JEM00119-00105
6. Remove the valve stem oil seal by your hand or using the
following SST.
SST: 09201-87704-000
JEM00120-00106

EM32
7. Remove the valve spring seats.
NOTE:
JEM00121-00107
8. Wash the disassembled parts except for electrical parts,

plastic parts and grease sealed bearings. Dry them by
blowing compressed air.
JEM00122-00108
INSPECTION, CLEANING AND REPAIRS OF

CYLINDER HEAD COMPONENTS
1. Cleaning of top of each piston and cylinder block
(1) Turn the crankshaft until each piston is brought to the
top dead center.
Using a gasket scraper, remove all carbon deposits
from the piston tops.
(2) Using a gasket scraper, remove any remaining gasket
material from the top of the cylinder block.
Blow carbon deposits, water and oil from the bolt
JEM00123-00109
holes.
WARNING:
Protect your eyes during the cleaning operation using
compressed air.
CAUTION:
Do not scratch the gasket surfaces of the piston and
cylinder block.
(3) Set the piston No. 1 to the top dead center.
2. Removal of gasket material

Using a gasket scraper, remove any remaining gasket ma-
terial from the cylinder head and manifold surfaces.
JEM00124-00110

EM33
3. Cleaning of combustion chamber
Using a wire brush, remove all carbon deposits from the
combustion chambers.
CAUTION:
Be careful not to scratch the cylinder head gasket con-
tact surfaces.
JEM00125-00111
4. Cleaning of valve guide bushings

Using a valve guide brush and solvent, clean all the valve
guide bushings.
JEM00126-00112
5. Cleaning of cylinder head

Using a soft brush and solvent, thoroughly clean the cylin-
der head.
JEM00127-00113
6. Inspection of cylinder head for flatness

Using a precision straight edge and a feeler gauge, check
the gasket surfaces contacting the cylinder block and
manifolds for warpage.
Maximum Surface Warpage
Cylinder Block Side: 0.10 mm
Intake Manifold Side: 0.10 mm
Exhaust Manifold Side: 0.10 mm
JEM00128-00114
If surface warpage of the cylinder block side exceeds the

maximum limit, replace the cylinder head.
JEM00129-00115

EM34
JEM00000-00116
7. Inspection of cylinder head for cracks

Using a dye penetrant, check the combustion chamber,
intake and exhaust ports, cylinder head surface and top of
the cylinder head for cracks.
If a crack is found, replace the cylinder head.
JEM00130-00117
8. Inspection of camshaft oil clearance

NOTE:
Prior to this oil clearance check, the camshaft should
be checked for bend in advance.
(1) Install the camshaft to the cylinder head.
JEM00131-00118
(2) Place a plastigage on each bearing.
Plastigauge
JEM00132-00119

EM35
(3) Install the bearing caps and rocker shafts. Tighten
them to the specified torque.
Tightening Torque
M10 Bolt: 28.4 - 36.3 Nm/Dry
M8 Bolt: 12.7 - 16.7 Nm/Dry
NOTE:
Each bearing cap bears a cap number.
The intake valve rocker shaft can be identified by the
recessed sections on it.
The valve rocker shaft should be installed in such a di- JEM00133-00120
rection that the side having a wider chamfer comes at

the timing belt side.
Ensure that the bolt holes and bolts are dry when tight-
ening the bolts. (Ensure that no oil or the like gets to
the bolt holes and bolts.)
(4) Remove the bearing caps and measure the oil clear-
ance.
Clearance
Specified Value: 0.035 - 0.076 mm
Allowable Limit: 0.17 mm
If the oil clearance exceeds the allowable limit, replace

the cylinder head and camshaft as a set.
NOTE:
After completion of the check, remove the plastigages.
Wash the camshaft and bearing caps in cleaning sol-
vent.
JEM00134-00121
9. Inspection of camshaft thrust clearance

(1) Apply engine oil to the camshaft journals.
JEM00135-00122

EM36
(2) Install the camshaft to the cylinder head. Install the
bearing caps and rocker shafts and tighten them to
the specified torque.
Tightening Torque
M10 Bolt: 28.4 - 36.3 Nm/Dry
M8 Bolt: 12.7 - 16.7 Nm /Dry
NOTE:
Each bearing cap bears a cap number.
recessed sections on it. JEM00136-00123
The valve rocker shaft should be installed in such a di-

rection that the side having a wider chamfer comes at
the timing belt side.
Ensure that the bolt holes and bolts are dry when tight-
ening the bolts. (Ensure that no oil or the like gets to
the bolt holes and bolts.)
(3) With a dial gauge attached to the camshaft, measure

the thrust clearance.
Thrust Clearance
If the camshaft thrust clearance exceeds the allowable

limit, replace the camshaft and cylinder head as a set.
Reference:
Cylinder Head Thrust Surface Width:
4.10 - 4.20 mm JEM00137-00124
Camshaft Thrust Surface Width:

3.95 - 4.00 mm
10. Inspection and grinding of valves

(1) Visually inspect the valve stem for seizure or damage.
NOTE:

If seizure or damage is found, replace the valve and

Seizure or

valve guide bush as a set.

damage

However, this replacement should be performed only

after the checks for the valve seat, valve stem and

guide bush have been finished.

The valve guide bush hole must be used for refacing
the valve seat. Hence, if the valve guide bush hole ex-
hibits any roughness due to seizure, etc., rectify the
hole with an adjustable reamer. JEM00138-00125

EM37
(2) Visually inspect the valve head for melting or damage.
If the valve head exhibits any melting or damage, re-
place the valve.
If the roughness on the contact surface can be cor-
rected, grind the valve seat contact surface with a
valve refacer.
Melting or damage
JEM00139-00126
(3) Grind the valves only enough to obtain a smooth con-

tact surface with the valve seat.
Valve Face Angle: 45.5
NOTE:
Make sure the valves are ground to the correct valve
face angle. 45.5
JEM00140-00127
(4) Visually inspect the valve stem end for abnormal wear.
Wear
JEM00141-00128
If the valve stem end exhibits abnormal wear, correct

the stem end with a valve refacer. However, this cor-
rection should be made within a limit of 2 mm from that
of standard length.
Reference:
Valve Length (STD)
Intake Valve: 112.8 mm
Exhaust Valve: 114.5 mm
NOTE:
Be very careful not to allow the valve to be overheated JEM00142-00129
during grinding.
(5) Inspect the valve head for its stock thickness. Stock
Minimum Stock Thickness thickness
Intake Valve: 0.8 mm Grinding
Exhaust Valve: 1.0 mm surface
If the stock thickness of the valve head is less than the

minimum stock thickness, replace it with a new one.
JEM00143-00130

EM38
11. Inspection and cleaning of valve seats
(1) Using a 45-degree valve seat cutter, reface the valve
seats. Remove only enough metal stock to clean the
seats.
45
(2) Apply a thin film of red lead (or white lead) to the valve
seat.
(3) Let the valve drop by its own weight onto the valve
seat two or three times.
(4) Take out the valve.
IN
JEM00144-00131
(5) Inspect the valve face and seat for the following items.
q Ensure that the valve seat contact surface of the
valve is continuous over the whole circumference.
If not, replace the valve.
w Ensure that the valve contact surface of the valve
seat is continuous over the whole circumference.
If not, reface the valve seat.
JEM00145-00132
e Measure the width of the contact surface of valve

seat.
Contact Surface of Valve Seat: 1.2 - 1.6 mm
If not, reface the valve seat. Center of valve

contact position
Seat contact width
JEM00146-00133
12. Refacing of valve seat

(1) Refacing procedure for intake valve seats
q Using a 45-degree cutter, recondition the rough-
ness on the valve-to-valve seat contact surface,
only enough to obtain a smooth surface. 45
IN
JEM00147-00134
w Using a 30-degree cutter, cut the valve seat in

such way that the circumference of the surface
refaced by the 45-degree cutter may become 29
0.1 mm 29 mm
JEM00148-00135

EM39
e Using a 70-degree cutter, cut the seat in such way
that the width, of the surface refaced by the 45-de-
gree cutter may became 1.4 mm.
,,
,,
1.4 mm (0.055 inch)
JEM00149-00136
r Using the 45-degree cutter, remove burrs pro-

duced during the refacing by the 30-degree and
70-degree cutters.
70
45
30
IN
JEM00150-00137
(2) Refacing procedure for exhaust valve seats

q Using a 45-degree cutter, recondition the rough-
ness on the valve-to-valve seat contact surface,
only enough to obtain a smooth surface.
45
JEM00151-00138
w Using a 20-degree cutter, cut the valve seat in

such a way that the circumference of the surface
refaced by the 45-degree cutter may become 25 mm
45
25 mm.
20
JEM00152-00139
e Using a 70-degree cutter, cut the valve seat in

such a way that the width of the surface refaced by
the 45-degree cutter may become 1.4 mm.
1.4 mm
45
JEM00153-00140

EM40
r Using the 45-degree cutter, remove burrs pro-
duced during the refacing by the 20-degree and
70-degree cutters. 70
45
20
EX
JEM00154-00141
13. Hand lapping of valves

(1) Perform hand lapping of the valves and valve seats,
using an abrasive compound.
(2) Clean the valves and valve seats after the hand lap-
ping of the valves.
JEM00155-00000
14. Inspection of valve recession

After the valve seat has been refaced, install the new
valve. Measure the distance between the cylinder attach-
ing surface of the cylinder head (attaching surface of the
cylinder head gasket) and the upper most section of the
valve. Ensure that the distance does not exceed the fol-
lowing maximum limit.
Maximum Limit
Intake Valve: 2.775 mm
Exhaust Valve: 6.026 mm
JEM00156-00142
If the recession exceeds the maximum limit, replace the

cylinder head.
15. Inspection of valve stem-to-guide bushing oil clearance

(1) Using a caliper gauge, measure the inner diameter of
the valve guide at six points.
Record the measured values.
JEM00157-00143
q Drive a new valve guide bush into position, until

the snap ring contacts the cylinder head, using the
following SST.
SST: 09201-87705-000
CAUTION:
Be very careful not to give an excessive impact during 09201-87705
the installation. Failure to observe this caution will re- -000
sult in valve guide bush cracks.
Care should be exercised not to detach the snap ring
due to driving the valve guide bush excessively. JEM00158-00144

EM41
w Using an adjustable reamer, ream the valve guide
bush to remove any burr or the like.
NOTE:
This reaming should be made only enough to remove
the burr or the like.
JEM00159-00145
e Inspection of oil clearance

Ensure that the oil clearance meets the specifica-
tions.
Oil Clearance
Specified Value:
Intake 0.030 - 0.055 mm
Allowable Limit:
Intake 0.08 mm
JEM00160-00146
(2) Exhaust valve guide bush

NOTE:
When the locating ring for the valve guide bush is lo-
cated 14 mm from the upper end of the valve guide
bush, replace the cylinder head.
JEM00161-00147
q Drive out the valve guide bush from the combus-

tion chamber side, using the following SST.
SST: 09201-87705-000
JEM00162-00148
(3) Using a micrometer, measure the diameter of the valve

stem at six points.
Record the measured values.
JEM00163-00149

EM42
(4) Calculation of oil clearance
Calculate the oil clearance of each valve according to
the following formula.
Oil clearance = Inner diameter of valve stem guide
Outer diameter of valve stem
Specified Oil Clearance
Intake Valve Side: 0.030 - 0.055 mm
Exhaust Valve Side: 0.035 - 0.060 mm
Allowable Limit
Intake Valve Side: 0.080 mm
Exhaust Valve Side: 0.090 mm
If the calculated oil clearance exceeds the allowable

limit, replace the valve guide bush and valve as a set.
JEM00164-00000
16. Replacement of valve guide bush

CAUTION:
Removal and installation of the valve guide bush Locating ring
should be carried out while the cylinder head tempera-
ture is 80C - 100C after heating it gradually.
(1) Intake valve guide bush

NOTE:
If the intake valve guide bush has been already in-
stalled with a locating ring, replace the cylinder head.
JEM00165-00150
q Drive out the valve guide bush from the combus-

tion chamber side, using the following SST.
SST: 09201-87705-000
NOTE:
Be very careful not to tap the cylinder head.
JEM00166-00151
w Drive a new valve guide bush into position, until

the snap ring contacts the cylinder head, using the
following SST.
SST: 09201-87705-000
CAUTION:
Be very careful not to give an excessive impact during
the installation. Failure to observe this caution will re-
sult in valve guide bush cracks.
Care should be exercised not to detach the snap ring
due to driving the valve guide bush excessively. JEM00167-00152

EM43
e Using an adjustable reamer, ream the valve guide
bush to remove any burr or the like.
NOTE:
This reaming should be made only enough to remove
the burr or the like.
JEM00168-00153
r Inspection of oil clearance

Ensure that the oil clearance meets the specifica-
tions.
Oil Clearance
Specified Value:
Exhaust 0.035 - 0.060 mm
Allowable Limit:
Exhaust 0.09 mm
JEM00169-00154
17. Inspection of valve springs

(1) Check the valve spring for squareness, using a steel
square. Not to exceed
1.6 mm
Maximum Squareness: 1.6 mm
If the squareness exceeds the maximum limit, replace

the valve spring.
JEM00170-00155
(2) Measure the valve spring for free length and spring
tension, using a spring tester.
Minimum Free Length
Pink Marked Spring: 43.9 mm
Orange Marked Spring: 46.1 mm
Minimum Tension/Installation Height
Pink Marked Spring: 244.9 N/38.0 mm
Orange Marked Spring: 208.9 N/38 mm
If the minimum free length and/or minimum tension is

less than the minimum limit, replace the valve spring. JEM00171-00156
Reference:
Standard Free Length
Pink Marked Spring: 45.2 0.5 mm
Orange Marked Spring: About 47.4 mm

EM44
(3) Check of valve spring edge surface for levelness 49 N
q Apply a load of 49 N to the valve spring on a
spring tester.
w Under the condition q above, insert a thickness
gauge at the arrowheaded point A at the right fig-
ure.
Here, the thickness gauge should measure 0.07
mm in thickness and 12.5 mm in width. Ensure that A
the tip-end of the thickness gauge will not reach
the center of the coil spring.
If the tip-end of the thickness gauge reaches the JEM00172-00157
center of the coil spring, replace the coil spring

with a new part.
18. Inspection of valve rocker arms and valve rocker shaft

(1) Visually inspect the valve rocker arm for cracks, Roughness
seizure or wear.
Replace the valve rocker arm, if necessary.
(2) If the valve rocker arm-to-cam contact surface is worn
excessively, replace the rocker arm.
JEM00173-00158
(3) Visually inspect the valve rocker shaft for cracks,

seizure or wear.
Replace the valve rocker shaft, if necessary.
IN
EX
JEM00174-00159
(4) Valve rocker shaft-to-valve rocker arm

Using a dial gauge, measure the inner diameter of
the valve rocker arm in two directions, 90 degrees
apart from each other.
Using a micrometer, measure the outer diameter of
the valve rocker arm attaching position of the valve
rocker shaft in two directions, 90 degrees apart
from each other.
Calculate the oil clearance by subtracting the rock-
er shaft diameter from the rocker arm diameter.
Oil Clearance JEM00175-00160

NOTE:
The measurement of the rocker shaft outer diameter
must be performed at the assembling position of each
rocker shaft.

EM45
Reference: Recess
Timing belt side
Identification of valve rocker shafts
On the intake valve rocker shaft, recesses for the spark
plug tube are provided.
Also, the oil grooves are provided very closely to the
bolt holes. IN
On the exhaust valve rocker shaft, the oil grooves are
located near the midpoint of the bolt holes.
Installing direction of valve rocker shaft
The valve rocker shaft should be installed in such a EX
way that the side having a wider chamfer comes at the JEM00176-00161
timing belt side.

Identification of valve rocker arm
The valve rocker arm comes in four kinds; two kinds
each for the intake side and exhaust side, as shown in
the right figure.
Specified dimensions of valve rocker shaft and valve
rocker arm
Outer Diameter of Valve Rocker Shaft:
No. 1 No. 2 No. 3 No. 4
19.468 - 19.488 mm
IN EX
Bore Diameter of Valve Rocker Arm:
19.500 - 19.521 mm JEM00177-00162
19. Inspection of valve rocker arm, spacer and wave washer

(1) Measure the free width of the spacer, using vernier
calipers.
Minimum Free Width: 22.0 mm
Replace the spacer whose free length is less than the min-
imum free width.
JEM00178-00163
(2) Visually inspect the wave washer for flattened condi-

tion or damage.
Replace the wave washer, if necessary.
20. Inspection of camshaft

(1) Checking camshaft for runout
Support the camshaft at its both ends with V-shaped JEM00179-00164
blocks. Set a dial gauge to the mid-point of the center
journal section of the camshaft. Turn the camshaft one
turn, making sure that the camshaft will not move in
the axial direction. Take a reading on the dial gauge
during the turning. Calculate the maximum runout, i.e.
the difference between the maximum and minimum
readings.
Maximum Runout: 0.03 mm
If the runout exceeds the maximum limit, replace the

camshaft. JEM00180-00165

EM46
(2) Checking of cam lobe height
Measure the cam lobe height, using a micrometer.
Specified Cam Lobe Height:
Intake: 33.434 - 33.634 mm
Exhaust: 33.17 - 33.37 mm
Minimum Limit:
Intake: 33.2 mm
Exhaust: 33.0 mm
JEM00181-00166
(3) Inspection of oil seal contact surface

Inspect the oil seal contact surface for abnormal wear.
Replace the camshaft if the contact surface exhibits
any abnormal wear.
JEM00182-00167
(4) Inspection of groove for driving cam angle sensor

Visually inspect to see if any damage is present at the
groove for driving the cam angle sensor.
Replace the camshaft if the groove exhibits any dam-
age.
NOTE:
If any damage is present, check the cam angle sensor
side, too.
JEM00183-00168
21. Inspection of manifold and surge tank

(1) Check the cylinder head attaching surface of the ex-
haust manifold for warpage, using a straightedge and
a thickness gauge.
Maximum Warpage Limit: 0.1 mm
If the warpage exceeds the maximum limit, replace the

exhaust manifold No. 1.
JEM00184-00169
(2) Check the contact surface of the intake manifold with

the cylinder head.
Maximum Warpage: 0.1 mm
JEM00185-00170

EM47
22. Check the valve spring seats, valve spring retainers and
valve retainer locks for damage and cracks.
If any damage is present, replace such faulty parts.
JEM00186-00171
23. Inspection of cylinder head cover

(1) Visually inspect the cylinder head cover gasket for
damage.
If any damage is present, replace the cylinder head
gasket with a new one.
Install the cylinder head gasket to the cylinder head
cover in such a direction that the identification mark
may face toward the intake manifold side.
JEM00187-00000
(2) Visually inspect the rubber grommets of the spark plug

tubes for damage.
Replace the rubber grommets, as required.
JEM00188-00172
Replacement of spark plug grommet

q Drive out the spark plug grommets, using the slot-
ted pin puller.
JEM00189-00173
w Install a new spark plug grommet, using the follow-

ing SST.
SST: 09268-87702-000
NOTE:
Make sure that the grommet is not tilted when it is dri-
ven into position.
Be sure to use a suitable wooden piece so as to pre-
vent the cylinder head cover from damage. 09388-87702-000
Be very careful not to damage the lip section of the
grommet. JEM00190-00174

EM48
ASSEMBLY OF CYLINDER HEAD
NOTE:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply new engine oil to all
sliding and rotating surfaces.
Replace all gaskets and oil seals with new ones.
JEM00191-00000
1. Assembly of cylinder head (When a new cylinder head is

installed:)
When a new cylinder head is installed, spark plug tubes
and a heater outlet tube have been furnished separately.
Assemble these parts, following the procedure given
below.
(1) Wash the cylinder head in cleaning solvent and dry it
with compressed air.
(2) Apply a thin film of the Three Bond 1377B to the cylin-
der head attaching surfaces for the spark plug tubes.
JEM00192-00176
(3) With a wooden piece or the like placed on the upper

end of the spark plug tube, drive the spark plug tube
into the cylinder head in such an extent that the dis-
tance between the spark plug tightening surface and
the upper end of the spark plug tube becomes
139 mm.
JEM00193-00177
NOTE:
Be very careful not to drive the spark plug too deeply.
Be very careful not to damage the upper end of the
spark plug tube.
When driving the spark plug tube into position, make
sure that the tube will not tilt in relation to the cylinder
head tube hole.
JEM00194-00178
(4) Put a mark at a point 45.0 1.0 mm from the forward

end of the heater outlet tube.
JEM00195-00179

EM49
(5) Apply a thin film of the Three Bond 1377B to the at-
taching section for the heater outlet tube on the cylin-
der head.
JEM00196-00180
(6) With a wooden piece interposed, drive the heater out-

let tube to the point marked in Step (4).
JEM00197-00181
(7) After completion of the operation, remove any oozed

bond, wooden chips and so forth.
JEM00198-00182
2. Install the valve spring seats to the cylinder head.
JEM00199-00183
3. Installation of valve stem oil seal

(1) Apply engine oil to the bore of the valve stem oil seal.
(2) Drive the valve stem oil seal into the valve stem guide
bush by hand.
NOTE:
When driving the oil seat, make sure that the oil seal is
not tilted.
Do not reuse any oil seal which was tilted or driven di-
agonally.
Hold the frame of the oil seal. Do not touch the rubber
section of the oil seal. JEM00200-00184

EM50
(3) Turn the oil seal slightly by hand to see if it can be
turned.
NOTE:
Never rotate the oil seal more than one turn, because
excessive turning may cause scratches on the oil seal.
If the oil seal can not be turned by hand, it means that
the oil seal has been tilted, driven diagonally or press-
fitted improperly.
Do not reuse any oil seal which was tilted or driven di-
agonally.
JEM00201-00185
4. Apply oil to the valve stem. Install the valve to the cylinder
head.
NOTE:
Care must be exercised as to the installing position. Do
not pull out the valve once it has been inserted.
If the inserted valve should be pulled out, replace the
valve stem oil seal with a new one.
Reference:
Identification of Valves
Engine Identification No. JEM00202-00186
HC-EJ r
5. Assembly of valve springs, valve spring retainers and

valve spring retainer locks
(1) Assemble the valve spring in such a way that the
painted side (the side having a larger pitch) comes at
the valve spring retainer.
JEM00203-00187
(2) Install the valve spring retainer to the valve spring.

Install the valve spring retainer locks while compress-
ing the valve spring retainer, using the following SST.
SST: 09202-87002-000
SST
JEM00204-00188

EM51
(3) After installing the valve spring retainer lock, lightly tap
the valve spring retainer with a hammer or the like so
as to ensure that the valve spring retainer locks are in-
stalled securely.
WARNING:
During this operation, care must be exercised to en-
sure that the valve spring retainer or retainer locks may
not be jumped out.
Protect your eyes with safety goggles during this oper-
ation.
JEM00205-00189
6. Clean and dry the cylinder block head bolt holes.

WARNING:
Protect your eyes with goggles when using com-
pressed air.
JEM00206-00190
7. Clean the cylinder block upper gasket surface. Install the

cylinder head gasket, while aligning it with the pin ring for Intake manifold side
locating use.
JEM00207-00191
8. Turn the crankshaft so that the crankshaft key groove may

come at the top position.
JEM00208-00192
9. Clean the threaded portion of the water temperature sen-

sor. Wind seal tape around the threaded portion and install
the sensor to the cylinder head.
NOTE:
The new water temperature sensor is coated with seal-
er. Therefore, if the sensor is replaced with a new one,
remove the sealer thoroughly before winding seal tape.
Moreover, be sure to clean the cylinder head side
threaded holes. JEM00209-00193

EM52
10. Install the cylinder head on the cylinder block.
JEM00210-00194
11. Coat each cylinder head bolt with a thin film of engine oil.
Using these bolts, install the cylinder head to the cylinder
block. Tighten the bolts evenly over two or three stages,
following the sequence shown in the right figure.
Tightening Torque: 58.8 - 66.7 Nm 7 5 2 4 10
9 3 1 6 8
NOTE:
Failure to tighten the bolts evenly may cause cracks
and distortion of the cylinder head, even leading to en-
gine seizure.
Make sure that all the bolts are torqued uniformly to a JEM00211-00195
constant value, also within the specified range.
12. Installation of camshaft and rocker shafts

(1) Wash and dry the holes for the camshaft cap attaching
bolts.
WARNING:
pressed air.
JEM00212-00196
(2) Liberally apply engine oil to the journal sections and

thrust bearing sections.
NOTE:
Be very careful not to allow any oil to flow into the bear-
ing cap attaching holes.
JEM00213-00197
(3) Assemble the camshaft on the cylinder head in such a

way that the locating pin for the camshaft timing belt
pulley comes exactly at the top position.
JEM00214-00198

EM53
(4) Apply the Three Bond 1104 to the camshaft cap No. 1
attaching section of the cylinder head at those points
shown in the right figure.
(5) Apply engine oil to the camshaft journal section.
NOTE:
Be very careful not to allow any oil to flow into the bear-
ing cap attaching holes.
No. 1
JEM00215-00199
(6) Install the camshaft bearing caps in the sequence of

embossed figures on the caps.
NOTE:
Before the camshaft bearing caps are installed, wipe
off any bond oozed from the camshaft cap No. 1.
JEM00216-00200
(7) Assemble the valve rocker arms and wave washers

onto the valve rocker shaft, while applying engine oil
liberally as shown in the right figure.
NOTE:
recessed sections on it.
The larger chamber end section of valve rocker shaft
faces toward the timing belt side.
JEM00217-00201
(8) Install the valve rocker shaft on the camshaft caps.

NOTE:
For easier installation, it is advisable to insert the
camshaft cap side of rocker arm first.
JEM00218-00202

EM54
(9) Clean the attaching bolts and dry them with com-
pressed air. Install them to the cylinder head through
the rocker shafts and camshaft caps. Tighten the bolts
evenly over two or three stages to the specified torque.
Tightening Torque
M10 Bolt: 28.4 - 36.3 Nm/Dry
M8 Bolt: 12.7 - 16.7 Nm/Dry
CAUTION:
Never exceed the specified tightening torque.
The bolts and bolt holes should be dry when tightening JEM00219-00203
the bolts.
WARNING:
Protect your eyes with safety goggles, when using
compressed air.
13. Install the spacers into between the intake valve rocker
arms on the rocker shaft.
JEM00220-00204
14. Apply engine oil to the lip section of the type T oil seal of
the camshaft.
15. Drive the oil seal into position, using the following SST.
SST: 09636-20010-000
CAUTION:
Be very careful not to tilt the oil seal against the attach-
ing hole of the camshaft oil seal.
16. Installation of the camshaft timing belt pulley.

(Refer to the Timing Belt section of the service manual.) JEM00221-00205
17. Install the cylinder head cover and tighten the attaching u q r y
bolts evenly two or three stages, following the sequence
t e w i
JEM00222-00206

EM55
18. Connect the connector to the water temperature sensor.
19. Install the ignition coil to the cylinder head cover and tight-
en it.
20. Connect the resistive cords between the ignition coil and
the spark plug.
IG coil for No. 2 cylinder No. 3 cylinder
IG coil for No. 4 cylinder No. 1 cylinder
JEM00223-00207
21. Installation of exhaust manifold

(1) Install the new exhaust manifold gasket in such a way Allow mark
that the arrow mark can be visible and it faces toward
the timing belt.
JEM00224-00208
(2) Install the exhaust manifold to the cylinder head.

NOTE: u w q t
Be very careful not to interfere with other parts.
(3) Install and tighten the attaching bolts and nuts evenly
over two to three stages, following the sequence in the y e r i
right figure.
JEM00225-00209
(4) Install a new O-ring to the oil level gauge guide.

CAUTION:
Do not reuse the O-ring.
(5) Insert the oil level gauge guide to the cylinder block.
CAUTION:
Be very careful not to damage the O-ring.
JEM00226-00000
(6) Install the exhaust manifold heat insulator to the ex-

haust manifold with the attaching bolts and nut.
JEM00227-00210

EM56
(7) Install and tighten the attaching bolt of the oil level
gauge guide.
(8) Insert the oil level gauge to the oil level gauge guide.
JEM00228-00211
(9) Connect the exhaust front pipe to the exhaust manifold

with a new gasket interposed.
CAUTION:
Do not reuse the used gaskets.
(10) Tighten the attaching bolts of the exhaust front pipe to

JEM00229-00212
22. Installation of intake manifold

(1) Install a new intake manifold gasket to the cylinder
head.
(2) Install the intake manifold to the cylinder head.
CAUTION:
Do not interfere with other parts.
(3) Install the attaching bolts and nuts of the intake mani-
fold.
NOTE:
Be sure to install the following parts interposed with the JEM00230-00213
attaching bolts and nuts of the intake manifold.

1. By-pass pipe
2. Oil pressure switch wire clamp
3. Power steering vane pump bracket. y t e w u
(4) Tighten the intake manifold attaching bolts and nuts i !1

evenly to the specified torque over two or three stages o !0 q r !2
in the sequence as indicated in the right figure.
JEM00231-00214
(5) Install the intake manifold stays and tighten the attach-
ing bolts.
(6) Install the engine wire ground terminal to the intake
manifold.
JEM00232-00215

EM57
(7) Connect the rubber hoses for brake booster and VSV.
(8) Connect the fuel inlet hose and return hose.
(9) Connect the water hose.
JEM00233-00216
(10) Installation of engine wire

q Connect the connector of the engine wire to the fol-
lowing parts.
a. Ignition coils
b. Injectors
c. Pressure sensor
d. Throttle position sensor
e. Intake air temperature sensor
f. Idle-up VSV
g. Oxygen sensor
h. Cam angle sensor JEM00234-00217
w Install the harness clamps to each bracket.
JEM00235-00218
(11) Install the timing belt.

(Refer to installation of timing belt section)
JEM00236-00000
(12) Install the alternator
JEM00237-00219

EM58
(13) Install the power steering vane pump
JEM00238-00220
(14) Install the acceleration cable to the throttle body and

adjust it.
A
B
JEM00239-00221
(15) Installation of air cleaner.

q Install the air cleaner lower case to the engine and
tighten the attaching bolts.
JEM00240-00222
w Install the air filter element to the air cleaner lower

case.
e Install the air cleaner upper case with the air duct
and fasten the clamp.
JEM00241-00223
r Tighten the air intake hose attaching bolt.

t Connect the rubber hoses to the air cleaner.
JEM00242-00000

EM59
(16) Install the battery carrier and the battery.
(17) Connect the battery cable to each terminals of the bat-
tery.
JEM00243-00224
(18) Fill the coolant

(Refer to CO section of this manual)
JEM00244-00000

EM60
CYLINDER BLOCK
COMPONENTS
w r i
e
@1
t o
y @3

u @2
!6
!0 !5
!1
!3 !2 !8
!4 !7
@4

@0
Front

!9
q Timing belt cover No. 1 !3 Crankshaft pulley

w Timing belt cover No. 2 !4 Crankshaft bearing
e Water pump assembly !5 Piston with pin
r Water pump gasket !6 Piston ring
t Dust seal !7 Connecting rod
y Oil pump assembly !8 Connecting rod bearing
u Oil seal !9 Oil pan
i Cylinder head gasket @0 Oil pump strainer
o Cylinder block @1 Rear end plate
!0 Crankshaft @2 Oil seal retainer
!1 Crankshaft timing belt pulley flange @3 Oil seal
!2 Crankshaft timing belt pulley @4 Crankshaft thrust bearing
JEM00245-00225

EM61
INSTRUCTION PRIOR TO OPERATION
Install the fender cover to the fenders so that no scratch
may be made to the fenders.
Be sure to read the general information section of the ser-
vice manual.
JEM00246-00000
ENGINE REMOVAL
2. Removal of engine hood
(1) Disconnect the windshield washer hose from the joint
section.
(2) Remove the hose from the clamp of the engine hood.
(3) Remove the hood, being very careful not to scratch
the body and hood.
3. Disconnect the wires of the positive (+) terminal from the
battery positive terminal. JEM00247-00226
4. Drain the coolant.

(Refer to the CO section of the service manual.)
5. Drain the engine oil.
(Refer to the MA section of the service manual.)
6. Removal of battery
(1) Remove the battery hold down clamp by removing the
two attaching nuts.
(2) Remove the battery from the battery carrier.
(3) Remove the wiring harness from the clamp section of
the battery carrier.
(4) Disconnect the engine wire harness clamp from the
battery carrier.
(5) Remove the battery carrier by removing the four at-
taching bolts.
JEM00248-00227
7. Remove the power steering vane pump from the engine.

Suspend the removed vane pump at the body side, using
an adequate rope.
JEM00249-00228

EM62
8. Remove the fan and fan shroud.
9. Remove the radiator.
JEM00250-00229
10. Remove the air cleaner.
JEM00251-00230
11. Remove the alternator.
JEM00252-00231
12. Remove the accelerator cable and rubber hoses.
A
B
JEM00253-00232
13. Disconnect the following connectors and remove the en-

gine wire
(1) Ignition coils
(2) Injectors
(3) Pressure sensor
(4) Throttle position sensor
(5) Intake air temperature sensor
(6) Idle-up VSV
(7) Water temperature sensor
(8) Oxygen sensor
(9) Cam angle sensor JEM00254-00233

EM63
JEM00000-00234
14. Disconnect the fuel inlet hose and return hose.

CAUTION:
The fuel pressure at inside of the fuel line is approxi-
mately 284 kPa higher than the atmospheric pressure.
Therefore, be sure to gradually pull out the rubber
Inlet
hoses so as to prevent fuel from splashing.
Return
JEM00255-00235
15. Disconnect the heater hoses.

CAUTION:
Be careful not to deform the heater inlet and outlet
pipes during disconnection. The heater core and pipe
are made copper.
NOTE:
Place a suitable container under the heater hose con-
necting section, for the coolant may flow out.
JEM00256-00236
16. Remove the charcoal canister from the engine compart-

ment.
17. Remove the clutch cable with bracket from the transmis-
sion.
JEM00257-00237
18. Removal of front exhaust pipe.

(1) Disconnect the attaching bolt and nuts of the exhaust
manifold.
(2) Disconnect the clamp of the front exhaust pipe.
JEM00258-00238

EM64
(3) Remove the bracket of the front exhaust pipe clamp
from the transmission.
(4) Remove the front exhaust pipe from the engine by dis-
connecting the attaching nuts of the main muffler.
JEM00259-00239
19. Remove the following stiffener from the engine and the
transmission.
(1) Engine stiffener RH
(2) Engine stiffener LH
(3) Power train stiffener
JEM00260-00240
20. Remove the starter from the engine by disconnecting the

attaching bolts.
21. Disconnect the attaching bolts of the engine with the
transmission.
JEM00261-00241
22. Disconnect the attaching bolts of the engine mounting

bracket.
JEM00262-00242
23. Take out the engine from the engine compartment.

CAUTION:
Be very careful not to allow the engine to hit to the ve-
hicle body and other parts.
JEM00263-00243

EM65
24. Place the engine on the suitable engine stand.
JEM00264-00000

26. Removal of cylinder head cover.
(1) Remove the ignition coils and resistive cords.
JEM00265-00244
(2) Remove the cylinder head cover attaching bolts.

(3) Remove the cylinder head cover. q t i e
r u y w
JEM00266-00245
27. Removal of cylinder head.

(1) Loosen the cylinder head attaching bolts evenly over
two or three stages in the sequence indicated in the
right figure.
NOTE: r y o u q
Be certain to loosen the cylinder head bolts evenly. w i !0 t e
Failure to observe this caution will cause cracks or dis-
tortion of the cylinder head, even leading to engine
seizure.
JEM00267-00246
(2) Remove the cylinder head bolts.

(3) Remove the cylinder head from the cylinder block.
JEM00268-00247

EM66
(4) Remove the cylinder head gasket.
(5) Remove any remaining gasket material from the gas-
ket surfaces of the cylinder head and cylinder block,
using the gasket scraper.
JEM00269-00248
DISASSEMBLY OF CYLINDER BLOCK

1. Remove the oil pressure switch and oil filter.
JEM00270-00249
2. Remove the air conditioner compressor bracket.

(Air conditioner equipped vehicle only)
JEM00271-00250
3. Remove the crankshaft timing belt pulley bolt.
JEM00272-00251
NOTE:
Prevent the ring gear from turning, using the following
SST.
SST: 09210-87701-000
SST
JEM00273-00252

EM67
4. Remove the crankshaft timing belt pulley.
JEM00274-00253
NOTE:
If the crankshaft timing belt pulley can not be removed
by hand, install the following SST with the crankshaft
timing belt pulley bolt interposed.
SST: 09609-20011-000
SST
JEM00275-00254
5. Remove the crankshaft timing belt pulley flange.
JEM00276-00255
6. Remove the tensioner and tension spring.
JEM00277-00256
7. Remove the water pump.

8. Remove the water pump gasket.
JEM00278-00000

EM68
9. Remove the alternator bracket.
JEM00279-00257
10. Remove the water inlet and thermostat.
JEM00280-00258
11. Remove the water hose for the throttle body.
JEM00281-00259
12. Remove the pressure plate and clutch disc. (M/T vehicle
only)
NOTE:
Prevent the pressure plate from turning, using the fol-
lowing SST.
SST: 09210-87701-000
SST
JEM00282-00260
13. Check of flywheel for runout (M/T vehicle only)

NOTE:
If the runout does not conform to the specification, con-
firm the tightening torque of the flywheel. Only case
where the tightening torque conforms to the specified
value, replace the flywheel.
JEM00283-00261

EM69
14. Loosen the attaching bolts of the flywheel or drive plate in
the sequence as indicated in the right figure. Remove the
flywheel or drive plate.
NOTE:
Prevent the flywheel from turning, using the following
SST.
SST: 09210-87701-000 q r
t
SST
e
w y
JEM00284-00262
15. Remove the rear end plate.
JEM00285-00263
16. Removal of oil pan

(1) Prepare two suitable wooden blocks. Place the cylin-
der block on those blocks.
NOTE:
Be very careful not to damage the piston head.
(2) Loosen the attaching bolts and nuts of the oil pan over
two or three stages. Pull out the bolts and nuts.
JEM00286-00264
(3) Separate the oil pan from the cylinder block by driving
the following SST into between the cylinder block and
the oil pan.
SST: 09032-00100-000
SST
JEM00287-00265
17. Remove the oil pan gasket.
JEM00288-00266

EM70
18. Remove the rear oil seal retainer.
JEM00289-00267
19. Remove the oil strainer.
Gasket
JEM00290-00268
20. Remove the oil pump.
JEM00291-00269
21. Measurement of connecting rod thrust clearance.

Measure the thrust clearance between the connecting rod
and the crankshaft, using a thickness gauge.
Thrust Clearance
Standard: 0.15 - 0.4 mm
Maximum: 0.45 mm
NOTE:
The thrust clearance should be measured while the
connecting rod is being pushed against either side of
the crankshaft in the axial direction. Measure the thrust JEM00292-00270
clearance at the opposite side.
If the clearance exceeds the specified value, replace the

connecting rod or the crankshaft, or both of them, refer-
ring to the width of the big end of the connecting rod in
the thrust direction and the side width of the crankpin jour-
nal.

EM71
Reference:
Width of big end of connecting rod in thrust direction Side width of crankpin
21.80 - 21.85 mm 22.0 - 22.2 mm
Crankshaft HC-EJ engine
A B
JEM00293-00271
22. Measurement of crankpin journal oil clearance

(1) Install the flywheel temporarily.
SST
JEM00294-00272
(2) Wipe off any oil from the side of the mate surface be-
tween the connecting rod bearing cap and the con-
necting rod. Daub a mate mark with an oily paint on
the side so that the parts can be assembled correctly
in the original combination.
(Also ensure that the cylinder number may be identi-
fied)
(3) Turn the crankshaft, until the connecting rod bearing
cap to be removed comes at the oil pan side.
JEM00295-00273
(4) Lock the flywheel to prevent the crankshaft from turn-

ing, using the following SST.
SST: 09210-87701-000
(5) Loosen the connecting rod bearing cap nuts evenly

over two or three stages. Then, remove the connecting
rod bearing cap nuts.
09210-87701-
000
JEM00296-00274

EM72
(6) Remove the bearing cap.
NOTE:
Replace the crankshaft if the crankpin journals exhibit
damages, such as seizure.
JEM00297-00275
(7) Place a plastigage on the crankpin journal.

NOTE:
Wipe off any oil from the crankpin journal.
JEM00298-00276
(8) Install the connecting rod cap, making sure that the
mate marks are lined up. Tighten the connecting rod
bearing cap nuts evenly over two or three stages to
NOTE:
When tightening of the bearing cap nuts, apply engine
oil to the bearing cap nuts. 09210-87701-
Prevent the crankshaft from turning, using the SST. 000
SST: 09210-87701-000 JEM00299-00277

rod bearing cap.
NOTE:
Prevent the crankshaft from turning, using the SST.
SST: 09210-87701-000
JEM00300-00278
(10) Measure the plastigage width at its widest point.

Oil Clearance: 0.020 - 0.044 mm
If the oil clearance fails to conform to the specified

value, measure the crankpin journal diameter and se-
lect a suitable connecting rod bearing or replace the
crankshaft.
(11) Remove the plastigage from the crankpin journal.
(12) Measure the oil clearances of the remaining crankpin
journals.
JEM00301-00279

EM73
23. Selection of connecting rod bearings
NOTE: Front mark
The replacement of the connecting rod bearings should
be performed after all inspections have been finished.
(1) Read the connecting rod big end bore code number.
NOTE:
The connecting rod big end bore code number comes
in three kinds of 4, 5 and 6. Connecting rod big end
bore code number
JEM00302-00280
(2) Measure the diameter of the crankpin journal.

The measurement should be performed at four points,
90 degrees spaced, for each crankpin journal at the A B Y
points shown in the right figure. The maximum value is
X X
regarded as the crankpin journal diameter.
However, if the variation in the measured diameters ex-
ceeds 0.044 mm, replace the crankshaft. 4 14 4 14 4 14 4 14 Y
Unit: mm
JEM00303-00281
(3) Select the connecting rod bearing or replace the crankshaft, based on the results of (1) and (2).
Connecting rod big end bore
Crankpin journal diameter Bearing classification number Remarks
code number
44.993 - 45.000 1
44.985 - 44.992 2
4
44.976 - 44.984 3
44.975 or less Crankshaft replacement
44.993 - 45.000 2
44.985 - 44.992 3
5
44.976 - 44.984 4
44.993 - 45.000 3
44.985 - 44.992 4
6
44.976 - 44.984 5
JEM00304-00000
24. Removal of pistons

(1) Remove all carbon deposits from the piston ring
ridges.
(2) Turn the crankshaft, until the connecting rod bearing
cap to be removed comes at the oil pan side.
JEM00305-00282

EM74
(3) Lock the flywheel to prevent the crankshaft from turn-
SST: 09210-87701-000

rod bearing cap nuts.
09210-87701-
000
JEM00306-00283
(5) Cover each connecting rod bolt with a short piece of

hose to protect the crankpin journal from damage.
JEM00307-00284
(6) Push out the piston and connecting rod assembly and
the upper bearing through the top of the cylinder
block.
JEM00308-00285
NOTE:
Arrange the disassembled pistons and connecting rod
in order so that their installation positions may be
known readily.
Care should be exercised so as not to damage the
bearings.
JEM00309-00286
25. Remove the flywheel.

NOTE:
Prevent the ring gear from turning with the SST.
SST: 09210-87701-000
SST
JEM00310-00287

EM75
26. Check of crankshaft thrust clearance
NOTE:
Measure the thrust clearance, using a dial gauge.
Thrust Clearance
If the thrust clearance exceeds the allowable limit, mea-

sure the width of the crankshaft thrust bearing contact sur-
face. If the measured value is less than 23.59 mm, replace
the thrust washer. If the measured value exceeds JEM00311-00288
23.59 mm, replace the crankshaft and thrust washer.

r i !0 t w
27. Check of crankshaft main journal oil clearance

(1) Gradually loosen the main bearing cap bolts over
three stages in the numerical sequence shown in the
figure. Remove the bearing cap bolts.
e u o y q
JEM00312-00289
(2) With the main bearing cap bolts inserted into the bolt
holes of the main bearing cap, wiggle the bearing cap
back and forth. Remove the bearing cap together with
the lower bearing.
NOTE:
Keep the lower bearing fitted to the main bearing cap.
Arrange the removed main bearing caps in order.
JEM00313-00290
(3) Lift off the crankshaft.

NOTE:
Be very careful not to allow the main bearings to be
mixed with the bearings of the other cylinders.
Remove the thrust washer.
If the main journal or crankshaft bearing exhibit dam-
ages, replace the crankshaft or crankshaft bearing as
necessary.
JEM00314-00291
(4) Clean the main journals and bearings, using cleaning

solvent. Blow them with compressed air.
WARNING:
Protect your eyes with safety goggles during the clean-
ing operation.
JEM00315-00000

EM76
(5) Check the main journals and bearings for pitting or
scratches.
If the main journals are damaged, replace the crank-
shaft.
If the main journal bearings are damaged, replace the
main journal bearings.
JEM00316-00292
(6) Install the main bearings to the cylinder block and

crankshaft main bearing cap.
NOTE:
Do not touch the metal surface of the bearing.
JEM00317-00293
(7) Support the both ends of the crankshaft with a V-block.

Measure the crankshaft runout with a dial gauge.
Allowable Limit of Runout: 0.06 mm
If the runout exceeds the allowable limit, replace the

crankshaft.
JEM00318-00294
(8) Place the crankshaft in the cylinder block.
JEM00319-00295
(9) Lay a strip of plastigage across each crankshaft main

journal.
JEM00320-00296

EM77
(10) Install the crankshaft bearing caps. Tighten the crank-
u e q t o
shaft bearing cap bolts evenly in the sequence indi-
cated in the right figure.
i r w y !0
JEM00321-00297
(11) Remove the main bearing caps with the lower bear-
ings fitted on them.
JEM00322-00298
(12) Measure the plastigage width at its widest point.

Oil Clearance: 0.024 - 0.042 mm
If the oil clearance fail to conform to the specified

value, measure the crankshaft main journal diameter
and select suitable connecting rod bearings or replace
the crankshaft.
(13) Remove the plastigage from the crankshaft main jour-
nals.
JEM00323-00299
28. Selection of crankshaft bearings

NOTE:
The replacement of the crankshaft bearings should be
performed after all inspections have been finished.
For the selection of the crankshaft bearing as a result
of the replacement of the crankshaft, refer to the sec-
tion under Replacement of Crankshaft. JEM00324-00000
(1) Read the cylinder block main journal diameter code

No. 5 Journal diam-
number. eter code number
NOTE:
No. 4 Journal diam-
The main journal diameter code comes in four kinds of eter code number
5, 6, 7 and 8. No. 3 Journal diam-
eter code number
No. 2 Journal diam-
eter code number
No. 1 Journal diam-
eter code number
JEM00325-00300

EM78
(2) Measure the diameter of the crankshaft main journals. Crankshaft
The measurement should be performed at four points,
90 degrees spaced, for each crankshaft main journal Y
at the points shown in the right figure. The maximum
X X
value is regarded as the crankshaft main journal diam-
eter.
However, if the variation in the measured diameters ex- 12 6 12 6 12 6 12 6 12 6 Y
ceeds 0.026 mm, replace the crankshaft.
Unit: mm
JEM00326-00301
(3) Select the crankshaft bearings or replace the crankshaft, based on the results of (1) and (2).
Crank main journal diameter
Main journal diameter code Bearing classification number Remarks
mm
49.995 - 50.000 1
49.989 - 49.994 2
5 49.983 - 49.988 3
49.976 - 49.982 4
49.995 - 50.000 2
49.989 - 49.994 3
6 49.983 - 49.988 4
49.976 - 49.982 5
49.995 - 50.000 3
49.989 - 49.994 4
7 49.983 - 49.988 5
49.976 - 49.982 6
49.995 - 50.000 4
49.989 - 49.994 5
8 49.983 - 49.988 6
49.976 - 49.982 7
JEM00327-00000

EM79
INSPECTION OF EACH PART
INSPECTION OF CYLINDER BLOCK
1. Removal of gasket material
Remove all gasket materials from the cylinder block.
2. Cleaning of cylinder block
Clean the cylinder block, using a soft brush and cleaning
solvent.
JEM00328-00303
3. Inspection of top surface of cylinder block

Using a precision straightedge and a thickness gauge,
check the surface contacting the cylinder head gasket for
warpage.
Maximum Warpage: 0.10 mm
If the warpage exceeds the allowable limit, replace the

cylinder block.
,,
JEM00329-00304
4. Inspection of cylinder bores

(1) Measure the bore diameter of each cylinder at the six
A
points shown in the right figure. Ensure that the differ-

ence between the maximum and minimum bore diam-
eters of each cylinder is within 0.1 mm. B
10 mm
If the difference between the maximum and minimum
values exceeds 0.1 mm, perform boring and/or honing Center
for the cylinder bore in accordance with the oversized
piston. 10 mm
The honing angle is 35 5. The surface coarse de-
gree is 1 - 4Z. JEM00330-00305
Reference:
The table below shows the cylinder bore diameter when
oversized pistons are used.
However, after the diameter of the replacement piston has
been measured, perform the finishing in accordance with
the piston diameter.
Standard O/S 0.25
76.000 - 76.030 mm 76.250 - 76.280 mm
(2) Measure the bore diameter of each cylinder at a posi-

tion shown in the right figure. The measured value is
regarded as the cylinder bore diameter.
45 mm
JEM00331-00306

EM80
5. Removal of cylinder ridges
If ridges are formed at the upper parts of the cylinder
bores, use a ridge reamer to remove the ridges.
JEM00332-00307
INSPECTION OF PISTONS AND CONNECTING

RODS
CAUTION:
The piston and piston pin are available only as a set so
that the oil clearance may become the specified value.
Therefore, if you replace a piston or a piston pin, be
sure to replace them as a set. Moreover, the piston and
piston pin should be handled at all times as a set. Care
must be exercised so that the piston or piston pin may
be mixed with other ones.
JEM00333-00000
1. Inspection of fit between piston and piston pin

Try to move the piston back and forth on the piston pin. If
any movement is felt replace the piston and piston pin as
a set.
NOTE:
When the piston is moved back and forth on the piston
pin, you may encounter hard movement. However, if
the piston moves smoothly without any binding, this fit-
ting of the piston is normal.
JEM00334-00308
Reference:
1. The oil clearance between the piston and piston pin is as
follows.
Specified Oil Clearance: 0.005 - 0.011 mm
NOTE:
In the case of a piston and piston pin assembly having
this degree of oil clearance, you will hardly feel exces-
sive play when you move the piston by your hands.
JEM00335-00000
2. Measurement of oil clearance

NOTE:
The oil clearance can be measured, following the pro-
cedure given below.
(1) When measuring oil clearance without disassembling:

Interpose the big end of the connecting rod between
V-blocks on a surface plate. Measure the play while
moving the piston, as indicated in the right figure.
JEM00336-00309

EM81
(2) When measuring oil clearance after disassembling:
q Measure the diameter of the whole circumference
at the positions A and B indicated in the right fig-
ure. The minimum dimension should be the piston
A B
pin hole diameter.
8 8
Unit: mm
JEM00337-00310
w Measure the diameter of the whole circumference

at the positions A and B indicated in the right fig-
ure. The maximum dimension should be the piston
pin outer diameter.
A B
8 8
Unit: mm
JEM00338-00311
2. Removal of piston rings

NOTE:
Arrange the removed piston rings in order so that their
installation positions may be known readily.
Do not expand the piston ring unnecessarily beyond
the required extent.
(1) Remove the piston rings No. 1 and No. 2, using a pis-
ton ring expander.
(2) Remove the oil ring side rails by hand.
(3) Remove the oil ring expander by hand. JEM00339-00312
INSPECTION OF PISTONS
1. Cleaning of pistons
(1) Remove the carbon deposits from the piston top, using
a gasket scraper or the like.
(2) Clean the piston grooves with a broken piston ring or a
groove cleaning tool.
NOTE:
Be very careful not to scratch the piston.
JEM00340-00313
2. Inspection of pistons
Visually inspect the piston for cracks, damage or seizure.
Replace the piston, if necessary.
JEM00341-00000

EM82
3. Measurement of piston diameter
(1) Measure the piston outer diameter horizontally at a
specified point shown bellow from the lower end of the
piston at right angles to the piston pin.
Specified Measuring Point H: 15 mm
(2) Calculation of piston-to-cylinder bore clearance

Subtract the measured piston outer diameter from the
H
measured cylinder bore diameter. Ensure that this pis-
ton-to-cylinder bore clearance is less than 0.045 mm.
Piston-to-Cylinder Bore Clearance JEM00342-00314

If the piston-to-cylinder bore clearance exceeds the al-

lowable limit, perform boring and honing the cylinder
bores so that the cylinder bore diameter may match
with the oversized piston.
JEM00343-00000
4. Inspection of piston ring groove side clearance

Measure the side clearances of the piston rings No. 1 and
No. 2 over the entire periphery of each groove, using a
thickness gauge.
The maximum measured value is regarded as the piston
ring side clearance.
JEM00344-00315
Piston ring side clearance

Specified value mm Allowable limit mm
Compression ring No. 1 0.03 - 0.07
0.12
If the piston side clearance exceeds the allowable limit, measure the piston ring thickness. Referring to the
piston ring standard thicknesses given below, replace the piston ring and/or piston so that the piston ring
side clearance may become less than the allowable limit.
JEM00345-00000
Piston ring specified thickness

Unit: mm
NOTE:
When replacing the piston rings, a set of piston rings for the engine should be replaced.
JEM00346-00000

EM83
5. Inspection of piston ring end gap
(1) Apply engine oil to the cylinder walls.
(2) Insert the piston rings into the cylinder bore.
(3) Using a piston, push down the piston ring to a point
110 mm from the cylinder block upper surface.
Piston ring
JEM00347-00316
(4) Measure the piston ring end gap, using a thickness

gauge or a feeler gauge.
JEM00348-00317
Piston ring end gap

Specified value mm Allowable limit mm
With T mark 0.27 - 0.37
Compression ring No. 1 0.7
With N mark 0.27 - 0.40
Compression ring No. 2 0.4 - 0.55 0.8
Shape of spacer A 0.2 - 0.60
Oil ring 1.0
Shape of spacer B 0.15 - 0.60
Oil ring spacer shape
Shape A Shape B
If the piston ring end gap exceeds the allowable limit, a set of piston rings for that engine should be re-
placed.
JEM00349-00318

EM84
ASSEMBLY/DISASSEMBLY OF PISTON & CONNECTING ROD
NOTE:
The piston and piston pin are handled as a set, for their oil clearance is controlled. Therefore, when
disassembling the pistons, care must be exercised so that the piston and piston pin may not be
mixed with other pistons or piston pins.
The piston disassembling should be performed only when any malfunction takes place and disas-
sembling is required. Failure to observe this caution may loosen the interference fit between the con-
necting rod and the piston pin, leading to an engine damage.
1. Disassembly of piston and connecting rod

Use the following SSTs for the disassembling operation.
SST: 09221-87704-000
09221-87705-000
JEM00350-00000
(1) Install the connecting rod in the following SST as

SST: 09221-87704-000
SST
JEM00351-00319
(2) Insert the longer SST into the piston pin hole. Press off
the piston, using a hydraulic press.
SST
SST
JEM00352-00320
2. Inspection of connecting rods

(1) Visually inspect the connecting rods for damage or
cracks.
(2) Check the connecting rod for bend and twist, using a
connecting rod aligner.
Maximum Bend: 0.05 mm Bend
Maximum Twist: 0.05 mm
Twist
If the bend and/or twist is greater than the maximum
limit, replace the connecting rod assembly.
JEM00353-00321

EM85
3. Inspection of piston pin-to-connecting rod interference fit
(1) Measure the outer diameter of the piston pin contact-
ing with the connecting rod, using a micrometer.
JEM00354-00322
(2) Measure the inner diameter of the connecting rod,

using a bore dial gauge.
(3) Determine the interference fit by subtracting the inner
diameter of the connecting rod from the outer diameter
of the piston pin.
Interference Fit: 0.015 - 0.044 mm
If the interference fit does not conform to the specifica-

tion, replace the connecting rod.
JEM00355-00323
4. Assembly of piston and connecting rod

Use the following SSTs for the assembling operation.
SST: 09221-87704-000
09221-87705-000 Piston pin
(1) Install the piston pin to the following SST in a way

SST: 09221-87705-000 SST
JEM00356-00324
(2) Install the piston and connecting rod in the SST in a

way shown in the right figure. Insert the SST installed
with the piston pin into the piston pin hole.
SST: 09221-87704-000 Front mark
09221-87705-000
NOTE:
The piston and connecting rod should be assembled in
such a way that the piston front mark and connecting
rod front mark come in the same direction.
JEM00357-00325
(3) Press the piston pin into the piston and connecting
rod, using a hydraulic press.
JEM00358-00326

EM86
(4) Remove the piston and connecting rod assembly from
the SST. Remove the SST from the piston pin.
JEM00359-00327
CYLINDER BORING
NOTE:
When the cylinder is bored, all cylinders should be
bored at the same time.
As for piston rings, use oversized piston rings.
JEM00360-00000
1. Measurement of cylinder bore diameter

Measure the diameter at a point 45 mm from the cylinder
upper surface in the direction shown in the right figure.
If the measured value exceeds 76.28 mm, replace the
cylinder block.
45 mm
JEM00361-00328
2. Determining cylinder finishing diameter

(1) Measure the diameter of the oversized piston to be
used, using a micrometer.
NOTE:
The measurement should be conducted at the speci-
fied skirt section from the piston lower end.
Perform the measurement horizontally, not in a tilted
state. JEM00362-00000
(2) Calculate the finishing dimension, as follows.

A: Piston diameter
B: Piston-to-cylinder bore clearance
0.025 - 0.045 mm
C: Honing allowance
0.02 mm
D: Finishing diameter
D=A+BC
JEM00363-00000

,,
EM87
,,
3. Hone the cylinder after the boring.
(1) Bore the cylinder, leaving a honing allowance of
0.02 mm.
,,
(2) Hone the cylinder. Honing angle
Honing Angle: 35 5 35 5
Surface Coarse Degree: 1 - 4Z
Surface coarse degree
1 - 4Z
JEM00364-00329
REPLACEMENT OF REAR OIL SEAL

(1) Removal of rear oil seal
Remove the rear oil seal from the rear oil seal retainer,
using a pin punch.
NOTE:
Be very careful not to damage the oil seal retainer.
JEM00365-00330
(2) Installation of rear oil seal

Drive a new rear oil seal into position, using the follow-
ing SST.
SST: 09223-41020-000
NOTE:
Care must be exercised to ensure that the oil seal is
not driven in a tilted state.
JEM00366-00331
REPLACEMENT OF FRONT OIL SEAL

(1) Removal of front oil seal
Remove the front oil seal from the oil pump, using a
pin punch.
NOTE:
Be very careful not to damage the oil pump during the
removal.
JEM00367-00332
(2) Installation of front oil seal

Drive a new front oil seal into position, using the follow-
ing SST.
SST: 09310-87102-000
JEM00368-00333

EM88
REPLACEMENT OF CYLINDER BLOCK
NOTE:
The cylinder block is furnished along with the pistons
as a set. Hence, make sure that each piston is installed
in the mated cylinder bore.
1. Wash the cylinder block using cleaning solvent.

2. Drive the oil orifice until it is recessed 3.0 1.0 mm from
the cylinder upper surface.
NOTE:
For driving this oil orifice, use an iron rod having an JEM00369-00334
outer diameter of 10 mm.

No. 5 Journal diam-
eter code number
3. Selection of crankshaft bearings No. 4 Journal diam-
(1) Read the crankshaft journal diameter code number of eter code number
the cylinder block. No. 3 Journal diam-
eter code number
No. 2 Journal diam-
eter code number
No. 1 Journal diam-
eter code number
JEM00370-00335
(2) Measure the main journal diameter of the crankshaft at Crankshaft

those points indicated in the right figure.
The measurement should be conducted in four di- Y
rections for each main journal, 90 degrees spaced,
X X
at those points indicated in the right figure.
(3) Select the crankshaft bearings in accordance with the
table next page. 12 6 12 6 12 6 12 6 12 6 Y
Unit: mm
JEM00371-00336

EM89
Crankshaft journal diameter Crankshaft bearing
Crankshaft jurnal hole code Remarks
mm classification No.
50.000 - 49.995 1
49.994 - 49.989 2
5 49.988 - 49.983 3
49.982 - 49.976 4
50.000 - 49.995 2
49.994 - 49.989 3
6 49.988 - 49.983 4
49.982 - 49.976 5
50.000 - 49.995 3
49.994 - 49.989 4
7 49.988 - 49.983 5
49.982 - 49.976 6
50.000 - 49.995 4
49.994 - 49.989 5
8 49.988 - 49.983 6
49.982 - 49.976 7
JEM00372-00000
4. Selection of pistons No. 1 Cylinder

(1) Read the cylinder block bore code number.
No. 4 Cylinder
bore code No.
No. 3 Cylinder
bore code No.
No. 2 Cylinder
bore code No.
No. 1 Cylinder
bore code No.
No. 2 Cylinder
No. 3 Cylinder No. 4 Cylinder
JEM00373-00337
(2) Select a piston having the same classification number

as the cylinder block bore code number.
NOTE:
The piston code number is stamped on the top of each
piston. Front
Outer
diameter
code No.
JEM00374-00338

EM90
REPLACEMENT OF CRANKSHAFT
(Replacement of the crankshaft only)
1. Wash the crankshaft using cleaning solvent. Dry it with
compressed air.
NOTE:
Make sure that the oil gallery exhibits no restriction due
to rust-proof oil.
As for the crankshaft for automatic transmission, drive
the rear end bush into the rear end of the crankshaft
with a brass rod so as to prevent damage to the bush.
JEM00375-00000
2. Selection of crankshaft bearings <Cylinder Block>

(1) Read the crankshaft journal diameter code number of Front No. 5 Journal
the cylinder block. diameter code No.
No. 4 Journal
diameter code No.
No. 3 Journal
diameter code No.
No. 2 Journal
diameter code No.
No. 1 Journal
diameter code No.
JEM00376-00339
(2) Read the crankshaft main journal diameter code num- <Crankshaft>
ber.
No. 5 Crank main journal code No.

JEM00377-00340
(3) Establish the crankshaft bearing classification number, using the table below.
Crankshaft Crankshaft journal
Cylinder block 1 2 3 4
Crankshaft journal 5 4 3 2 1
diameter code No.
6 5 4 3 2
7 6 5 4 3
8 7 6 5 4
JEM00378-00000
3. Selection of connecting rod bearings

(1) Read the crankpin journal diameter code number.
No. 1 Crankpin journal code No.

JEM00379-00341

EM91
Connecting rod
Front mark
Connecting rod big end

bore code No.
JEM00380-00342
(3) Establish the classification number of the connecting

rod bearing, using the table below.
Crankshaft Crankpin journal
diameter code No.
Connecting rod 1 2 3
Connecting rod big end 4 3 2 1
bore code No.
5 4 3 2
6 5 4 3
JEM00381-00000
REPLACEMENT OF CONNECTING RODS

1. Wash the connecting rods using cleaning solvent.
WARNING:
Be sure to protect your eyes, wearing goggles.
JEM00382-00000
2. Selection of connecting rod bearings <Crankshaft>

A B Y
X X
4 14 4 14 4 14 4 14 Y
Unit: mm
JEM00383-00343
(2) Measure the crankshaft pin diameter of the crankshaft <Crankshaft>

in four directions for each crankshaft pin, 90 degrees
spaced, at those points indicated in the right figure. A B Y
NOTE:
X X
The greatest value among the measured diameters is
regarded as the crankpin journal diameter.
However, if the difference among the measured values 4 14 4 14 4 14 4 14 Y
exceeds 0.044 mm, replace the crankshaft.
(3) Select the connecting rod bearing in accordance with Unit: mm

the table posted in next page. JEM00384-00344

EM92
Connecting rod big end bore Crankpin journal diameter Connecting rod bearing
Remarks
code No. mm classification No.
45.000 - 44.993 1
44.992 - 44.985 2
4
44.984 - 44.976 3
45.000 - 44.993 2
44.992 - 44.985 3
5
44.984 - 44.976 4
45.000 - 44.993 3
44.992 - 44.985 4
6
44.984 - 44.976 5
JEM00385-00000
DISASSEMBLY OF OIL PUMP

1. Detach the oil pump cover.
JEM00386-00345
2. Remove the front oil seal.
JEM00387-00346
3. Remove the oil pump rotor set.
JEM00388-00347

EM93
4. Pull out the cotter pin, while pushing the spring retainer
with nose pliers or the like.
NOTE:
Put an appropriate cloth, etc. on the retainer spring so
that it may not jump out.
JEM00389-00348
5. Remove the oil pump relief valve spring retainer, compres-

sion spring and oil pump relief valve.
NOTE:
Wash the disassembled parts in cleaning solvent.
JEM00390-00349
6. Inspection of each part

(1) Check the pump body for damage.
Replace the pump body if it exhibits damage.
JEM00391-00350
(2) Check the rotor set for damage.

Replace the rotor set if it exhibits damage.
JEM00392-00351
(3) Check the oil pump relief valve for damage.

Replace the relief valve if it exhibits damage. Also,
check to see if any damage is present at the relief
valve installation hole of the oil pump body.
JEM00393-00352

EM94
(4) Check the compression spring for damage. Also, mea-
sure its free length.
Specified Free Length: 57 mm
Replace the compression spring if it exhibits damage

or the free length is less than the specified valve.
JEM00394-00353
(5) Check the oil pump relief valve spring retainer for
damage.
Replace the retainer if it exhibits damage.
JEM00395-00354
(6) Apply engine oil to the oil pump relief valve. Insert the
oil pump relief valve into the oil pump body. Check to
see if the valve slides smoothly.
Replace the oil pump body if the valve fails to slide
smoothly.
JEM00396-00355
7. Measurement of body clearance, tip clearance and side

clearance
(1) Apply a thin film of engine to the rotor mate surface of
the oil pump body as well as to the rotor set. Assemble
the rotor set in the oil pump body in such a way that
the drilled mark may be seen from the outside.
JEM00397-00356
(2) Measure the body clearance between the oil pump

body and the outer rotor, using a thickness gauge.
Body Clearance: 0.20 - 0.28 mm
Replace the oil pump if the body clearance exceeds

JEM00398-00357

EM95
(3) Measure the tip clearance of the rotor set, using a
thickness gauge.
Tip Clearance: 0.16 - 0.24 mm
Replace the rotor set if the tip clearance exceeds the

specified value.
JEM00399-00358
(4) Measure the side clearance between the oil pump

body and the rotor set, using and a straightedge and a
thickness gauge.
Side Clearance: 0.035 - 0.085 mm
Replace the oil pump if the side clearance exceeds

JEM00400-00359
8. Check to see if any wear is present at the rotor set mate

surface of the pump cover.
Replace the oil pump cover if it exhibits wear.
JEM00401-00360
ASSEMBLY OF OIL PUMP

NOTE:
Wash those parts to be assembled in cleaning solvent.
Dry them using compressed air.
WARNING:
When you use compressed air, be sure to protect your
eyes,wearing goggles.
JEM00402-00000
1. Apply engine oil to the relief valve. Then, insert the relief
valve into the oil pump body.
2. Insert the compression spring and retainer into the oil
pump body.
NOTE:
Install the retainer in such a direction that its projected
side may come at the compression spring side.
JEM00403-00361

EM96
3. Insert a new cotter pin into the retainer while the retainer is
being compressed with pliers, etc. Split the end of the cot-
ter pin to form an anchor-like shape.
JEM00404-00362
4. Apply engine oil to the rotor set. Assemble the rotor set in
the pump body in such a direction that the drilled mark of
the rotor may be seen from the outside.
JEM00405-00363
5. Install the oil pump cover. Tighten the cover to the speci-
fied torque.
JEM00406-00364
6. Drive a new oil seal into position, using the following SST.
SST: 09310-87102-000
NOTE:
Be very careful not damage the oil pump during the in-
stallation.
Make sure that the oil seal is not driven into position in
a tilted state.
JEM00407-00365
7. Turn the rotor by hand. Ensure that the rotor turns smooth-
ly.
If the rotor will not turn smoothly, overhaul the oil pump.
NOTE:
The oil pump performance test procedure is described
in the LU section.
JEM00408-00366

EM97
INSPECTION OF CRANKSHAFT PULLEY
1. Visual inspection of crankshaft pulley Check damage
or cracks
(1) Check the crankshaft pulley attaching seat for defor-
mation, wear or cracks.
(2) Check the V-ribbed belt attaching surface for scratch-
es, deformation or wear.
Replace the crankshaft pulley, as required.
JEM00409-00367
INSPECTION OF WATER PUMP

1. Visually inspect the water pump.
(1) Mechanical seal section for evidence of water leakage
(2) Rotary fin of water pump for scratches, deformation or
cracks
(3) Water pump attaching surface for scratches
(4) Water pump pulley attaching seat for scratches or flat-
tened condition
Replace the water pump, as required.
JEM00410-00368
2. Check the water pump bearing and water pump pulley at-
taching section for excessive play.
Replace the water pump, if necessary.
JEM00411-00369
3. Turn the water pump by hand. Ensure that the water pump
turns smoothly.
Replace the water pump, if necessary.
JEM00412-00370
INSPECTION OF WATER PUMP PULLEY

1. Visual inspection of water pump pulley
(1) Inspect the water pump pulley attaching section for
deformation or wear.
(2) Inspect the V-ribbed belt attaching surface for defor-
mation or wear.
Replace the water pump pulley, if necessary.
Deformation or wear
JEM00413-00371

EM98
INSPECTION OF OIL PAN
Visually inspect the oil pan for damage or cracks.
Replace the oil pan, as required.
JEM00414-00372
INSPECTION OF FLYWHEEL
Inspect the flywheel for cracks or damage.
Replace the flywheel if it exhibits defects.
INSPECTION AND REPLACEMENT OF RING

GEAR
Inspect the ring gear for damage.
Replace the flywheel if it exhibits defects.
JEM00415-00373
CAUTION:
Never disassemble the flexible type flywheel by remov-
ing the flex-plate from the flywheel subassembly.
If the flywheel has undergone disassembling, it would
cause breakage of the flywheel due to unbalanced fly-
wheel mass, while the engine is running.
Never expose the flexible type flywheel to flame of a
burner, etc. If the flywheel is exposed to flame of a
burner, for example, at the time of replacement of the
ring gear, the quenched state of the flex-plate will be
weakened. This may lead to breakage during the en- JEM00416-00000
gine running.

EM99
ASSEMBLY OF CYLINDER BLOCK
NOTE:
As for those parts to be reassembled, wash them in
cleaning solvent (excluding those parts, such as
grease-sealed type bearings, dust seals and electrical
parts).
Then, dry them using compressed air.
Remove any remaining sealer, etc. from the threaded
portions of the switches and sensors.
WARNING:
pressed air. JEM00419-00000
1. Ensure that the straight pins are installed at the positions

of the front, rear and upper sides of the cylinder block, as
Front view Back view
indicated in the right figure. Also, ensure that the protru-
sion of each straight pin conforms to the specified amount B
given below.
Specified Amount of Protrusions
A: 4 0.5 mm
B: 8 1.0 mm
C: 7 1.0 mm
D: 3 1.0 mm A C D
E: 6.5 1.0 mm
If no straight pin is installed or its protrusion fails to con- Upper view

form to the specified value, replace the straight pin with a
new one.
Front
JEM00420-00377
2. Installation of crankshaft
(1) Install the bearings to the cylinder block and crank-
shaft bearing caps.
NOTE:
Do not touch with the front and back surfaces of each
bearing. Be sure to hold the bearing at its edge sur-
faces.
JEM00421-00378

EM100
(2) Lubricate the surface of each bearing with engine oil.
NOTE:
Do not touch with the front and back surfaces of each
bearing.
Never apply engine oil to the crankshaft bearing caps.
JEM00422-00379
(3) Install the crankshaft in the cylinder block.
JEM00423-00380
(4) Apply engine oil to the thrust washers. With the side
having the oil groove facing toward the crankshaft
side, insert each thrust washer between the crankshaft
main journal No. 3 and the cylinder block.
JEM00424-00381
(5) Apply engine oil to the crankshaft main journal sec-

tions.
NOTE:
Care must be exercised to ensure that no oil flows into
the bearing cap attaching bolt holes.
JEM00425-00382
(6) Install the crankshaft bearing caps with the arrow

u e q t o
marks facing toward the oil pump side and also in the
numerical sequence.
(7) Thinly apply engine oil to the crankshaft bearing cap
bolts. Tighten the bolts to the specified torque over two
or three stages in the sequence shown in the right fig-
ure.
i r w y !0
JEM00426-00383

EM101
3. Assembly of piston and connecting rod
Install the flywheel on the crankshaft temporarily.
NOTE:
Care must be exercised to ensure that no oil, etc. gets
to the bolts or bolt holes.
JEM00427-00384
(1) Install the oil ring spacer expander in the oil ring
groove. Ensure that the expander end may not line up
with the thrust direction nor with the axial direction.
NOTE:
Do not expand the spacer expander to an extent more
than necessary. Thrust
direction
End of
spacer
expander
JEM00428-00385
(2) Fit the upper rail into position in such a manner that it
is wound up while pushing the edge section of the oil
ring spacer expander with your thumb.
JEM00429-00386
NOTE:
Ensure that the rail end is deviated 90 degrees to the Lower rail end
left from the end of the oil ring spacer expander.
Do not expand the rail to an extent more than neces-
sary. 90
Thrust
direction 90
Upper rail end Spacer expander
JEM00430-00387
(3) Fit the lower rail into position in such a manner that it is
wound up.
NOTE:
Ensure that the rail end is deviated 90 degrees to the
right from the end of the oil ring spacer expander.
Do not expand the rail to an extent more than neces-
sary.
Make sure that the oil ring can be rotated smoothly.
JEM00431-00388

EM102
(4) Install the compression ring No. 2 with the stamped
mark of T, 2T, N or 2N facing upward, using a piston
ring expander.
NOTE:
Do not expand the piston ring to an extent more than
necessary.
(5) Install the compression ring No. 1 with the stamped

mark of T or N facing upward, using a piston ring ex-
pander.
JEM00432-00389
(6) Position the piston rings so that each ring end may
End of ring No. 2
come at the respective points as indicated in the right
figure. Lower rail
NOTE:
It is not necessarily required to follow strictly the right
figure. However, be sure that the ring end is not lined Thrust side Thrust side
up with the thrust direction. Also, each ring should be
deviated about 120 to 180 degrees from the adjacent Oil ring spacer
Upper rail
ring. expander
End of ring No. 1
JEM00433-00390
(7) Install the connecting rod bearings on the connecting

rod and connecting rod cap, making sure that your fin-
gers will not touch with the front and back surfaces of
the bearings.
JEM00434-00391
(8) Cut an appropriate vinyl hose to a suitable length. Fit

the vinyl hose to each connecting rod bolt sections.
JEM00435-00392
(9) Apply engine oil to the piston rings, piston pins, con-
necting rod bearings, cylinder walls and crankpin jour-
nals.
JEM00436-00393

EM103
(10) Compress the piston rings by means of the piston ring
compressor SST, making sure that the piston ring ends
will not move during the installation.
SST: 09217-87001-000
(11) Push the piston by hand into the cylinder bore with the
front mark facing toward the oil pump side.
NOTE:
Be very careful to avoid damaging the connecting rod
bearings during the installation.
Care must be exercised to ensure that the crankpin JEM00437-00394
journal is not scratched by the connecting rod.
(12) Push the piston by hand until the connecting rod

reaches the crankpin journal.
(13) Apply engine oil to the bearing surface of each con-

necting rod bearing.
NOTE:
Do not touch with the bearing front surface.
(14) Remove the vinyl hoses which were attached to the

connecting rod bolt sections.
JEM00438-00395
(15) Install the connecting rod cap with the front mark fac-
ing toward the oil pump side.
JEM00439-00396
(16) Prevent the crankshaft from turning, using the following

SST.
SST: 09210-87701-000
SST
JEM00440-00397

EM104
(17) Thinly apply engine oil to the connecting rod cap at-
taching nuts. Tighten the nuts to the specified torque
evenly over two or three stages.
(18) Perform the operations described in the steps (1)

through (17) for each cylinder.
JEM00441-00398
(19) Remove the flywheel.

(20) Remove the following SST.
SST: 09210-87701-000
SST
JEM00442-00399
4. Installation of oil pump

O-ring
(1) Apply the Three Bond 1207C to the oil pump installa-
tion surface of the cylinder block, as indicated in the
right figure.
(2) Replace the O-ring of the oil pump with a new part.
Three Bond 1207C
JEM00443-00400
(3) Apply engine oil to the inner surface of the oil seal.
Install the oil pump to the cylinder block. Perform tight-
ening to the specified torque.
JEM00444-00401
5. Installation of oil seal retainer

(1) Apply the Three Bond 1207C to the oil seal retainer in-
stallation surface of the cylinder block, as indicated in
the right figure.
Three Bond 1207C
JEM00445-00402

EM105
(2) Apply engine oil to the inner surface of the oil seal.
Install the oil seal retainer to the cylinder block.
Perform tightening to the specified torque.
JEM00446-00403
6. Install the oil strainer with a new gasket interposed.
Gasket
JEM00447-00404
7. Installation of oil pan

(1) Apply the Three Bond 1207C to the oil pan installation
surface of the cylinder block, as indicated in the right
figure.
Three Bond 1207C

JEM00448-00405
(2) Place the oil pan gaskets.

NOTE:
Ensure that the end section of the oil pan gasket is
overlapped at least 10 mm with the Three Bond 1207C.
JEM00449-00406
(3) Install the oil pan. Tighten the oil pan attaching nuts
and bolts to the specified torque over two or three
stages.
JEM00450-00407

EM106
8. Installation of rear end plate
Install the rear end plate to the cylinder block with two at-
taching bolts.
Tighten the attaching bolts to the specified torque.
JEM00451-00408
9. Installation of flywheel
(M/T vehicle only)
(1) Install the flywheel on the crankshaft with the spacer interposed.
(2) Application of flywheel bolt sealing material
q Wash the flywheel bolts. Then, degrease and dry them.
NOTE:
When degreasing the bolts, remove any oil completely, using a solvent such as a degreasing spray-
ing agent or alcohol.
CAUTION:
Make sure that no bond nor other foreign matter, such as dust, gets to the bolts.
Even when new bolts are used, be sure to perform this operation.
Be sure to interpose the spacer between the crankshaft and the flywheel.
w Check the flywheel bolts for damage. Replace any flywheel bolt which exhibits damage with a
new one.
CAUTION:
Even when a new bolt is used, be sure to perform the operation in the step (1).
e Clean the flywheel bolt threaded holes at the rear end section of the crankshaft. Degrease and
dry them.
CAUTION:
Make sure that no bond nor other foreign matter, such as dust, gets to the bolt threaded holes.
As for degreasing, wipe off any oil from the threaded portion with a cloth damped with alcohol.
Never allow alcohol to get to resin or rubber parts, specifically, the rear oil seal.
r Clean the bolt seating surface of the flywheel and degrease it.
NOTE:
As for degreasing, wipe the bolt seating surface with a cloth damped with alcohol.
Never allow alcohol to get to resin or rubber parts.
JEM00452-00000
t Apply two to three drops of the Three Bond 1324 to

the forward end of the threaded portion of each fly-
wheel bolt.
,,
Three bond
CAUTION:
If the Three Bond 1324 is applied excessively beyond
,,
the specified amount, the oil will penetrate up to the
bolt seating surface. This may cause loosening of the
bolts.
Never use bond sealers other than the designated one.
Never allow the bond sealer to get to resin or rubber
parts. JEM00453-00409

EM107
(3) Tighten the flywheel attaching bolts to the specified
torque in the sequence indicated in the right figure.
NOTE:
Prevent the crankshaft from turning at the ring gear
section, using the following SST. q t
SST: 09210-87701-000 r
e
w y
CAUTION:
When tightening the bolt, make sure that no bond is JEM00454-00410
present on the bolt seating surface.

If the bond oozes out, perform the operations again,
starting the step (2).
(4) Tighten the flywheel attaching bolts to the specified

torque in the sequence indicated in the right figure.
(5) Measure the flywheel runout, using a dial gauge.

Allowable Runout Limit: 0.1 mm
NOTE:
Replace the flywheel if its runout exceeds the allowable
limit.
JEM00455-00411
10. Installation of drive plate

(A/T vehicle only)
(1) Application of flywheel bolt sealing material
q Wash the flywheel bolts. Then, degrease and dry them.
NOTE:
When degreasing the bolts, remove any oil completely, using a solvent such as a degreasing spray-
ing agent or alcohol.
CAUTION:
Make sure that no bond nor other foreign matter, such as dust, gets to the bolts.
Even when new bolts are used, be sure to perform this operation.
w Check the flywheel bolts for damage. Replace any flywheel bolt which exhibits damage with a
new one.
CAUTION:
Even when a new bolt is used, be sure to perform the operation in the step (1).
e Clean the flywheel bolt threaded holes at the rear end section of the crankshaft. Degrease and
dry them.
CAUTION:
Make sure that no bond nor other foreign matter, such as dust, gets to the bolt threaded holes.
As for degreasing, wipe off any oil from the threaded portion with a cloth damped with alcohol.
EM108
Never allow alcohol to get to resin or rubber parts, specifically, the rear oil seal.
r Wash the centering plate. Then, degrease and dry it.

NOTE:
When degreasing the center plate, remove any oil completely, using a solvent such as a degreasing
spraying agent or alcohol.
Never allow the solvent to get to resin or rubber parts.
JEM00456-00000
t Apply two to three drops of the Three Bond 1324 to

the forward end of the threaded portion of each fly-
wheel bolt.
,,
Three bond 1324
CAUTION:
If the Three Bond 1324 is applied excessively beyond
,,
the specified amount, the oil will penetrate up to the
bolt seating surface. This may cause loosening of the
bolts.
Never use bond sealers other than the designated one.
Never allow the bond sealer to get to resin or rubber
parts. JEM00457-00412
(2) Install the drive plate and centering plate to the crank-
shaft end. Tighten the attaching bolts temporarily.
NOTE:
section, using the following SST.
SST: 09210-87701-000
JEM00458-00000
(3) Tighten the drive plate attaching bolts to the specified

torque in the sequence indicated in the right figure. q
r t
NOTE:
section, using the following SST.
e w
SST: 09210-87701-000
y
CAUTION:
When tightening the bolt, make sure that no bond is JEM00459-00413
present on the bolt seating surface.

If the bond oozes out, perform the operations again,
starting the step (1).
11. Assembling of clutch disc and pressure plate

(M/T vehicle only)
(1) Insert the following SST into the crankshaft rear end.
SST: 09301-87703-000
(2) Install the clutch disc.

JEM00460-00000

EM109
(3) Install the pressure plate, lining up the locating pin of
the pressure plate. Tighten the attaching bolts to the
specified torque.
09301-87601-000
JEM00461-00414
12. Install the water hose for the throttle body use to the cylin-
der block. Attach the hose bands.
JEM00462-00415
13. Install the thermostat in the cylinder block in such a way

that the jiggle pin section may come at the upper side. Jiggle pin
CAUTION:
Make sure to install the jiggle pin of the thermostat in
the correct direction. Failure to observe this precaution
may cause overheating.
Identification of Thermostat
Destination Identification color
European Cold spec. Green
General spec. Black JEM00463-00416
14. Install the water inlet.

JEM00464-00417
15. Install the alternator bracket.

JEM00467-00420

EM110
16. Installation of water pump
(1) Install a new water pump gasket on the cylinder block.
JEM00468-00421
(2) Install and tighten the water pump to the specified

torque.
NOTE:
When the stud bolts have been replaced, apply the
Three Bond 1377B to the threaded portion at the cylin-
der block side.
JEM00469-00422
17. Attach the tension spring to the timing belt tensioner.

Hang the tension spring hook on the pin. Assemble the
timing belt tensioner in place and install the bolt. Push the
tensioner to the alternator side as far as it will go. Tighten
the tensioner temporarily.
JEM00470-00423
18. Install the crankshaft pulley flange in such a way that its
recessed side may come at the cylinder block side.
JEM00471-00424
19. Install the crankshaft timing belt pulley.
JEM00472-00425

EM111
20. Install the crankshaft timing belt pulley attaching bolt.
Tighten the bolt to the specified torque.
NOTE:
Prevent the crankshaft from turning, using the following
SST.
SST: 09210-87701-000
JEM00473-00426
21. Install the air conditioner compressor bracket.

JEM00474-00427
22. Installation of oil filter

(1) Thinly apply engine oil to the oil seal of the oil filter.
JEM00475-00428
(2) Screw in the oil filter until the oil seal of the oil filter
comes in contact with the oil pump or the contact sur- ,, Oil seal
,,
,,
,,
face of the oil cooler.
JEM00476-00429
(3) Then, rotate the oil filter further one complete turn (360
degrees), using the following SST.
SST: 09228-87201-000
JEM00477-00430

EM112
23. Installation of oil pressure switch
(1) Clean the threaded portion of the oil pressure switch.
Wind seal tape around the threaded portion.
NOTE:
The new oil pressure switch is coated with sealer.
Hence, when the oil pressure switch is replaced with a
new one, first remove the sealer thoroughly. Then wind
the seal tape. Also, be sure to clean the threaded holes
at the oil pump side.
JEM00478-00431
(2) Tighten the oil pressure switch to the specified torque

using a long box wrench having a hexagonal hole.
JEM00479-00432
PREPARATION OF ENGINE INSTALLATION

1. Place the cylinder block on a suitable engine stand.
2. Clean and make dry the cylinder head bolt holes.
WARNING:
eyes, wearing goggles.
JEM00480-00433
2. Align the drilled mark of the crankshaft timing belt pulley

with the indicator of the oil pump.
JEM00481-00434
3. Place the new cylinder head gasket on the cylinder block.

Identification mark
JEM00482-00435

EM113
4. Turn the crankshaft, until the F mark of the camshaft tim-
ing belt pulley comes exactly at the top position.
JEM00483-00436
5. Install the cylinder head assembly on the cylinder block.

CAUTION:
Be very careful not to damage the cylinder head gasket
and cylinder head gasket attaching surface.
Never turn the crankshaft or camshaft independently
before installing the timing belt.
JEM00484-00000
6. Apply engine oil to the threaded portion of the cylinder

head bolts.
7. Install the bolts on the cylinder head.
CAUTION:
As for the two bolts at the distributor side, use the bolts
whose nominal length is 112 mm, which is shorter than
that of others. 7 5 2 4 10
9 3 1 6 8
8. Tighten the cylinder head bolts evenly over two or three
stages to the specified torque, following the sequence
JEM00485-00437
9. Installation of cylinder head cover

(1) Check the cylinder head cover gasket for damage.
Replace the cylinder head gasket if it is damaged.
(2) Replacement of cylinder head gasket
(Only case where such replacement is required;)
q Remove the cylinder head cover gasket from the
w Install a new cylinder head cover gasket in such a
way that the identification mark comes at the intake
manifold side of the cylinder head cover.
JEM00486-00438
(3) Check the spark plug tube grommet for damage.

Replace any grommet which exhibits damage.
JEM00487-00439

EM114
(4) Wipe off any oil from the cylinder head cover gasket
attaching surface of the cylinder head.
JEM00488-00440
(5) Install the cylinder head cover to the cylinder head.

CAUTION:
Be very careful not to damage the spark plug tube rub-
ber grommet during installation. JEM00489-00000
(6) Install the tighten the cylinder head cover attaching

bolts to the specified torque, following the sequence in
the right figure.
JEM00490-00441
(7) Install and tighten the ignition coils to the engine.

(8) Connect the resistive cords.
JEM00491-00442
10. Install the timing belt.

(Refer to the timing belt section)
JEM00492-00000

EM115
11. Install and tighten the engine mounting bracket with the
mounting to the engine.
12. Sling the engine, using a chain block.
JEM00493-00443
INSTALLATION OF ENGINE
1. Insert the engine to the engine compartment.
2. Joint the engine to the transmission and temporarily install
the transmission attaching bolt.
JEM00494-00444
3. Place the engine to the engine mounting section of the en-

gine support number.
4. Install and tighten the engine mounting attaching bolts.
NOTE:
Be very careful not to allow the engine to hit the vehicle
body and other parts.
JEM00495-00445
5. Install and tighten the transmission attaching bolts with the

power train stiffener bracket.
JEM00496-00446
6. Install the starter motor and starter motor attaching bolts.

JEM00497-00447

EM116
7. Install the clutch housing under cover to the transmission.
Tightening Torque: 49 - 68.6 Nm
JEM00498-00448
8. Install the engine stiffener to the engine and tighten it to

JEM00499-00449
9. Installation of exhaust pipe

(1) Install the front exhaust pipe to the exhaust manifold
with a new gasket interposed.
NOTE:
Do not reuse the used gasket.
JEM00500-00450
(2) Temporarily tighten the exhaust pipe attaching nut of

the exhaust manifold.
(3) Connect the front exhaust pipe to the main muffler with
a new gasket interposed.
(4) Tighten the attaching nuts to the specified torque.
JEM00501-00451
(5) Install the front exhaust pipe clamp bracket to the

transmission.
JEM00502-00452

EM117
(6) Clamp the front exhaust pipe to the clamp bracket.
(7) Tighten the front exhaust pipe attaching nuts of the ex-
haust manifold to the specified torque.
JEM00503-00453
10. Connect the power train stiffener between the engine .and
transfer.
Tighten the stiffener attaching bolts to the specified
torque.
JEM00504-00454
11. Connect the heater hose.

12. Connect the fuel inlet hose and return hose.
Inlet
Return
JEM00505-00455
13. Install the engine wire to the engine and connect the fol-
lowing connector.
(1) Ignition coils
(2) Injectors
(3) Pressure sensor
(4) Throttle sensor
(5) Intake air temperature sensor
(6) Idle-up VSV
(7) Water temperature sensor
JEM00506-00456
(8) Oxygen sensor

(9) Cam angle sensor
JEM00507-00457

EM118
14. Connect the starter wire to the starter motor.
15. Install the accelerator cable to the throttle body and adjust
it.
16. Connect the rubber hoses.
A
B
JEM00508-00458
17. Install the alternator to the engine and connect the con-
nectors.
SST
JEM00509-00459
18. Install the air cleaner to the engine.
JEM00510-00460
19. Installation of radiator

(1) Ensure that the radiator lower grommet exhibits no de-
formation or damage.
If any damage is existed, replace the radiator lower
grommet with new one.
JEM00511-00461
(2) Place the radiator into the radiator lower grommet.

(3) Ensure that the radiator upper grommet for damage.
Replace the radiator upper grommet with new one, if
any damage is present.
JEM00512-00462

EM119
(4) Secure the radiator by installing the radiator brackets
with the attaching bolts.
(5) Connect the radiator lower hose and cramp the hose
band.
JEM00513-00463
20. Install the cooling fan with the fluid coupling together with
the fan shroud.
Tighten the fluid coupling attaching nuts and the fan
shroud attaching bolts.
21. Adjust the alternator driver belt tension to the specified
value.
(Refer to timing belt section)
JEM00514-00464
22. Install the power steering vane pump drive belt and adjust
its belt tension.
JEM00515-00465
23. Connect the water hoses to the radiator.

JEM00516-00000
24. Installation of battery

(1) Install the battery carrier and tighten its attaching
bolts.
(2) Install the battery to the battery carrier.
(3) Secure the battery by installing the hold down clamp
with the attaching nuts.
JEM00517-00466

EM120
25. Installation of engine hood.
(1) Install the engine hood, being very careful not to
scratch the vehicle body and engine hood.
(2) Tighten the engine hood attaching bolts and adjust the
engine hood dimensions.
JEM00518-00467
(3) Connect the windshield washer hose to the joint sec-

tion.
JEM00519-00000
26. Fill the engine oil.

IG OFF
27. Fill the coolant to the radiator and reserve tank.
28. Connect the positive cable to the positive terminal of the
battery.
29. Connect the battery ground cable to the negative terminal
of the battery.
30. Perform the engine turn-up.
JEM00520-00468

EM121
ENGINE SPECIFICATION
Engine type
HC-EJ
Item
Type Petrol, 4-cycle
Mounting location Front
4-cylinder-in-line,
Cylinder No. and arrangement
mounted transversely
Combustion chamber type Pent roof type
Valve mechanism Belt-driven, SOHC
Bore stroke mm 76.0 71.4
Compression ratio 9.5 0.3
1372.9
Compression pressure kPa (kgf/cm2-rpm)
(14 - 300)
SAE net kW/rpm General specifications 61/6100
Maximum
output
European kW/rpm Australian specifications
DIN kW/rpm European specifications
SAE net Nm/rpm General specifications 105/5100
Maximum
Engine torque
European Nm/rpm Australian specifications
proper DIN Nm/rpm European specifications
Engine dimensions [Length width height] mm 630 510 655
Compression ring 2
Number of piston rings
Oil ring 1
Open BTDC 1
Intake
Close ABDC 39
Valve timing
Open BBDC 42
Exhaust
Close ATDC 2
Intake [HOT] 0.25
Valve clearance mm
Exhaust [HOT] 0.33
Manual
800 50
transmission
Idling speed rpm
Automatic
850 50
transmission
Blow-by gas recirculating system Closed type
Lubricating method Fully-forced feed method
Oil pump type Trochoid type
Oil filter type Fully-flow filter type, filter paper type
Lubricating
system Whole 3.6
When only oil is changed 3.3
Lubrication oil capacity liter
When oil and oil filter are
3.5
changed

EM122
Engine type
HC-EJ
Item
Cooling method V-ribed belt driven type
Radiator type Corrugation type forced circulation
Manual transmission 5.4
Coolant capacity
Cooling [Including 0.434 liter for liter
system reserve tank]
Automatic transmission 5.3
Water pump type Centrifugal type belt-driven type

Wax pellet type
Thermostat type
bottom-by-pass type
Type Filter unwoven fabric type
Air cleaner
Number 1
Capacity liter 46
Fuel tank
Location Underneath rear seat floor
Fuel pipe material Rubber and steel tube
Fuel pump type Electromotor type
Filter paper type
Fuel filter type
(Voltex type)
Fuel injection device Electronic type
Type of nozzle retainer With cushion rubber type
Electronic controlled
Nozzle type
Injector throttle type
Injection pressure
284 (2.9)
kPa (kgf/cm2)

EM123
Engine type
HC-EJ
Item
Voltage V 12 [Negative ground]
Full transistorized type (ESA)
Type
battery ignition type
TDC 0 2
Ignition timing with the check connector
connected with ground terminal
Ignition
Firing order 1-3-4-2
system
Manufacturer DENSO K20TNR-S, K22TNR-S
& Type NGK BKRU6EK, BKRU7EK
Spark plug Sparkplug DENSO 0.9 - 1.0
gap mm NGK 0.9 - 1.0
Engine
electrical Thread 1.25
system Type 36B20L
Battery
Capacity AH 28 Ah
Three-phase alternating
Type
current commuting type
Output MT 12 - 50
Alternator
V-A AT 12 - 55
Contact pointless type
Regulator type
(IC regulator type)
Type Magnet engaging type
Starter
Output V-kW 12 - 0.8
Radio noise suppressing device Resistive cord
JEM00521-00000

EM124
ENGINE MECHANICALS
Timing belt pulley Wear limit Camshaft 119.8 mm
Crankshaft 59.3 mm
Timing belt tension spring Free length 46.5 mm
Installation load 29.4 3 N at 50.9 mm (3.0 0.3 kg at 50.9 mm)
Camshaft Oil clearance 0.035 - 0.076 mm
(Cylinder head to camshaft)
Maximum limit 0.17 mm
Thrust clearance 0.1 - 0.25 mm
Fuel pump cam diameter
Minimum 42.65 mm
Fuel pump cam stroke
Standard 5.0 mm
Minimum 4.8 mm
Valve cam lobe height
Intake 33.434 - 33.634 mm
Exhaust 33.17 - 33.37 mm
Minimum limit
Intake 33.2 mm
Exhaust 33.0 mm
Maximum circle run out 0.03 mm
Cylinder head Warpage Cylinder block side 0.10 mm
Intake manifold side 0.10 mm
Exhaust manifold side 0.10 mm
Valve seat angle Intake 30 - 45 - 70
Exhaust 20 - 45 - 70
Valve contacting angle 45
Valve seat contacting width
Standard 1.4 mm
Allowance 1.2 - 1.6 mm
Maximum valve seat recession 0.5 mm
(Depth measured from cylinder head gas-

ket attaching surface to uppermost part of
a new valve inserted into position)
Intake 2.775 mm
Exhaust 6.026 mm
Valves Valve stem diameter Intake valve 6.560 - 6.580 mm
Exhaust valve 6.555 - 6.575 mm
Valve length Intake valve 112.8 mm
Exhaust valve 114.5 mm
Valve face angle 45.5
Valve stock thickness (Minimum)
Intake 0.8 mm
Exhaust 1.0 mm
Valve stem oil clearance
Intake Standard 0.030 - 0.055 mm
Maximum 0.080 mm
Exhaust Standard 0.035 - 0.060 mm
Maximum 0.090 mm

EM125
Valve springs Free length:
Standard Pink marked spring 45.2 0.5 mm
Orange marked spring About 47.4 mm
Minimum Pink marked spring 43.9 mm
Orange marked spring 46.1 mm
Installed tension at 38.0 mm
Pink marked spring 244.9 N (24.97 kgf)
Orange marked spring 208.9 N (21.3 kgf)
Maximum out-of squareness 1.6 mm
Valve rocker arm and Oil clearance Standard 0.012 - 0.053 mm
valve rocker shaft Maximum 0.08 mm
Valve rocker arm bore diameter 19.500 - 19.521
Valve rocker shaft outer diameter 19.468 - 19.488 mm
Valve rocker arm spacer Free width 22.00 mm
Exhaust manifold Warpage 0.1 mm
Intake manifold Warpage Cylinder head side 0.1 mm
Cylinder block Maximum cylinder head surface warpage 0.1 mm
Cylinder bore diameter
Standard 76.000 - 76.030 mm
O/S 0.25 76.250 - 76.280 mm
Bore honing angle 35 5
Coarse degree 1-4Z
Piston, piston pin and Piston-to-cylinder bore clearance
piston rings Standard 0.025 - 0.045 mm
Piston ring groove-to-piston ring side
clearance
Standard No. 1 Other than below 0.03 - 0.07 mm
No. 2 0.02 - 0.06 mm
Maximum 0.12 mm
Piston ring thickness
Standard No. 1 Other than below 1.17 - 1.19 mm
No. 2 1.47 - 1.49 mm
Piston ring end gap
Standard No. 1 With T mark 0.27 - 0.37 mm
With N mark 0.27 - 0.40 mm
No. 2 With 2T mark 0.40 - 0.55 mm
With 2N mark 0.40 - 0.55 mm
Oil Shape of spacer A 0.2 - 0.6 mm
Shape of spacer B 0.15 - 0.60 mm
Maximum No. 1 0.7 mm
No. 2 0.8 mm
Oil 1.0 mm
Piston pin-to-connecting rod inference fit 0.015 - 0.044 mm
Piston-to-piston pin clearance 0.005 - 0.011 mm
Flywheel Runout Maximum 0.1 mm
Connecting rod Big end thrust clearance Standard 0.15 - 0.4 mm
Maximum 0.45 mm
Maximum bend 0.05 mm
Maximum twist 0.05 mm
Crankshaft Crankpin journal oil clearance 0.020 - 0.044 mm
Main journal oil clearance 0.024 - 0.042 mm
Crankpin journal diameter 44.976 - 45.000 mm
Main journal diameter 49.976 - 50.000 mm
Thrust clearance Standard 0.02 - 0.22 mm
Runout Maximum 0.06 mm
JEM00522-00000

EM126
SST (Special Service Tools)
Shape Part No. and Name Purpose Remarks
09090-04010-000 Removal and installation of

engine
Engine sling device
09219-87202-000 Stand for engine overhaul This stand is to be used

in combination with
Engine overhaul stand engine overhaul
attachment.
09219-87101-000 Attaching engine to overhaul This attachment is to be

stand used in combination with
Engine overhaul attachment engine overhaul stand.
09210-87701-000 Preventing crankshaft from

turning
Flywheel holder
09609-20011-000 Removal of crankshaft timing

belt pulley
Steering wheel puller
09636-20010-000 Installation of camshaft oil

seal
Upper ball joint dust cover
replacer
09202-87002-000 Installation and removal of

valves
Valve cotter remover & replacer
09217-87001-000 Guiding piston during

insertion
Piston replacing guide
09223-41020-000 Installation of crankshaft rear

oil seal
Crankshaft rear oil seal replacer
09201-87704-000 Removal of valve stem oil

seals
Valve stem oil seal cover
09310-87102-000 Installation of crankshaft front

oil seal
Counter shaft front bearing
replacer
09221-87704-000 Removal and installation of This remover & replacer body is

piston pins to be used in combination with
Piston pin remover & replacer piston pin remover & replacer
body guide
09221-87705-000 Removal and installation of This remover & replacer guide is

piston pins to be used in combination with
Piston pin remover & replacer piston pin remover & replacer
guide body.

EM127
Shape Part No. and Name Purpose Remarks
09201-87705-000 Removal and installation of

valve guide bushes
Valve guide bush remover &
replacer
09301-87703-000 Assembling clutch
Clutch guide tool
09258-00030-000 Plugging rubber hoses
Plug set
09648-87201-000 Disconnecting drive shafts
Drive shaft replacer
09388-87702-000 Press-fitting of rubber

grommets
Transfer replacer
*1 09268-87704-000 Removal and installation of oil Only for oil

cooler (only for oil cooler- cooler-equipped vehicle
Oil cooler set bolt box wrench equipped vehicle)
09032-00100-000 Removal of oil pan
Oil pan seal cutter
09228-87201-000 Removal and installation of oil

filter
Oil filter wrench
*2 09268-87703-000 Removal and installation of

spark plugs
Plug wrench
*3 09991-87401-000 EFI system inspection

ABS system inspection
Wire engine control system Measure engine speed
inspection
*4 09611-87701-000 Disconnection of tie rod end
Tie rod end puller
JEM00523-00469
REFERENCE:
ESB-1 Handled by BANZAI Limited
Engine support bridge
JEM00524-00470

EM128
TIGHTENING TORQUE
Tightening torque
Tightening component
Nm kgf-m
Cylinder head Spark plug 14.7 - 21.6 1.5 - 2.2
Cylinder head Cylinder head cover 2.9 - 4.9 0.3 - 0.5
M10 28.4 - 36.3 2.9 - 3.7

Cylinder head Rocker shaft (camshaft cap)
M8 12.7 - 16.7 1.3 - 1.7
Cylinder head Cylinder block 58.8 - 66.7 6.0 - 6.8
Cylinder head Exhaust manifold 29.4 - 44.1 3.0 - 4.5
Cylinder head Intake manifold 14.7 - 21.6 1.5 - 2.2
Cylinder head Water outlet 14.7 - 21.6 1.5 - 2.2
Cylinder block Water inlet 5.9 - 8.8 0.6 - 0.9
Cylinder block Crankshaft main bearing cap 44.1 - 53.9 4.5 - 5.5
Cylinder block Oil pump 5.9 - 8.8 0.6 - 0.9
Cylinder block Rear oil seal retainer 5.9 - 8.8 0.6 - 0.9
Cylinder block Water pump 14.7 - 21.6 1.5 - 2.2
Cylinder block Transmission 49.0 - 68.6 5.0 - 7.0
Cylinder block Alternator bracket 34.3 - 49.0 3.5 - 5.0
Cylinder block Rear end plate 9.8 - 14.7 1.0 - 1.5
Crankshaft Flywheel 78.5 - 98.0 8.0 - 10.0
Crankshaft Drive plate 78.5 - 98.0 8.0 - 10.0
Crankshaft Crankshaft timing belt pulley 88.3 - 98.0 9.0 - 10.0
Camshaft Camshaft timing belt pulley 14.7 - 21.6 1.5 - 2.2
Connecting rod Connecting rod cap 34.3 - 44.1 3.5 - 4.5
Intake manifold Gas filter 11.8 - 19.6 1.2 - 2.0
Intake manifold Union bolt for brake booster 11.8 - 19.6 1.2 - 2.0
Intake manifold Plug screw 11.8 - 19.6 1.2 - 2.0
Intake manifold Delivery pipe 14.7 - 21.6 1.5 - 2.2
Intake manifold Rear stiffener 49.0 - 68.6 5.0 - 7.0
Exhaust manifold Front exhaust pipe 41.6 - 62.4 4.2 - 6.4
Engine mounting stiffener RH Transmission (MT) 29.4 - 44.1 3.0 - 4.5
Engine mounting stiffener LH Transmission 29.4 - 44.1 3.0 - 4.5

EM129
Tightening torque
Nm kgf-m
Oil pump Oil pressure switch 11.8 - 19.6 1.2 - 2.0
Oil pump body Oil pump cover 7.8 - 12.7 0.8 - 1.3
Oil pan 6.9 - 11.8 0.7 - 1.2
Water inlet Thermo control switch 24.5 - 34.3 2.5 - 3.5
Pressure plate 14.7 - 21.6 1.5 - 2.2
Lower member subassembly 48.1 - 89.2 4.9 - 9.1
Drive plate Torque converter 22.6 - 32.4 2.3 - 3.3
Power train stiffener Clutch housing under cover 6.9 - 9.8 0.7 - 1.0
A 29.4 - 44.1 3.0 - 4.5

Power train stiffener
B 14.7 - 21.6 1.5 - 2.2
Ball joint Steering knuckle 29.4 - 44.1 3.0 - 4.5
Lower arm bracket connecting rod 39.2 - 92.2 4.0 - 9.4
Water outlet Water temperature sensor 24.5 - 34.3 2.5 - 3.5
Front exhaust pipe Rear exhaust pipe 15.2 - 22.8 1.6 - 2.3
JEM00525-00000

DAIHATSU
J100 EC
EMISSION CONTROL SYSTEMS
COMPONENT LAYOUT .............................. EC 2

POSITIVE CRANKCASE VENTILATION
SYSTEM .................................................. EC 3
INSPECTION OF PCV HOSE &
CONNECTION ................................... EC 4
FUEL EVAPORATIVE EMISSION
CONTROL SYSTEM ............................... EC 5
DASHPOT (DP) SYSTEM (only for
automatic transmission models) .......... EC 8
THREE-WAY CATALYST (TWC)
SYSTEM .................................................. EC10
INSPECTION OF EXHAUST PIPE
ASSEMBLY ......................................... EC10
INSPECTION OF HEAT INSULATOR ...... EC10
THREE-WAY CATALYST ......................... EC11
SST (Special Service Tools) ...................... EC13
TIGHTENING TORQUE ............................... EC13
SERVICE SPECIFICATIONS ...................... EC13
JEC00001-00000
NO. 9710-JE

EC2
COMPONENT LAYOUT
[Manual transmission Vehicle]
Throttle body
Air cleaner Intake air pressure sensor
Idle-up VSV
Intake air
temperature
sensor
Fuel return hose
Throttle position sensor
To canister
JEC00002-00001
[Automatic transmission Vehicle]
Air cleaner Throttle body

Intake air pressure sensor
Idle-up VSV
Intake air
temperature
sensor
Fuel return hose
To canister
JEC00000-00002

EC3
POSITIVE CRANKCASE VENTILATION SYSTEM
The engine equipped with a sealed type blow-by gas recirculating system in order to prevent blow-by
gases generated inside the crankcase from being released into atmosphere.
When the no blow-by gases is generated in the cylinder, air in the cylinder head cover are ventilated by the
fresh air introduced from up stream of the throttle valve to down stream of the throttle valve through inside
of the cylinder head cover.
At this time, the flow rate of air is regulated by a jet provided at the cylinder head cover, thus stabilizing the
engine idle speed, if engine at the idling.
When the generating amount of the blow-by gases is small, the blow-by gases generated inside the
crankcase flow into the cylinder head cover side through the gas path of the cylinder block, oil in the blow-
by gases is separated by oil separator provided at the cylinder head cover.
Then, the blow-by gases in the cylinder head cover introducing to the cylinders through down stream of the
throttle body to be burnt there again in the cylinders.
At this time, the air flow rate of the blow-by gases is regulated by a jet provided at the cylinder head cover,
thus stabilizing the engine idle speed, if engine at the idling.
When the large amount of the blow-by gases are generated, the blow-by gases are flow into the cylinders
both through the upstream path and downstream path of the throttle valve.
Jet Jet
Crankcase gases Crankcase gases

Fresh air Fresh air
Blow-by gases amount is small Blow-by gases amount is large
JEC00003-00003

EC4
INSPECTION OF PCV HOSE & CONNECTION
Visual inspection of hoses and connections
Check the hoses and connections for cracks, leakage or
damage.
If any parts exhibit fault, replace or repair them, as required.
JEC00004-00004
Inspection of blow-by gas recirculation device

1. Disconnect the blow-by gas hose from the throttle body
side.
2. Ensure that a heavy resistance exists when you blow your
breath from the disconnected hose end.
If no resistance is felt, replace the cylinder head cover.
NOTE:
Slight air continuity normally exists.
JEC00005-00000
3. Connect a MityVac to the disconnected hose.

4. Ensure that air continuity exists without resistance when
air is sucked in the MityVac.
If no air continuity exists, replace the cylinder head cover.
5. Disconnect the MityVac from the disconnected hose.
6. Connect the blow-by hose to the throttle body.
JEC00006-00005

EC5
FUEL EVAPORATIVE EMISSION CONTROL SYSTEM
The fuel evaporative emission control system employs a charcoal canister type. The charcoal canister type
leads the fuel vapor into the charcoal canister which uses activated carbon to absorb HC emission. The ab-
sorbed HC emission is drawn into the throttle body to be burnt together with mixture in the combustion
chamber.
Purge port
Combustion chamber
Purging line
Throttle body
Fuel tank vapor line

Check valve 1
Check valve
Check valve 3
Check valve 2
Fuel tank
JEC00007-00006
Canister check valve Check

Pressure condition valve in
Engine condition Fuel Evaporative emission (HC)
in tank 1 2 3 safety
filler cap
Engine is running HC emission is absorbed by the charcoal

Closed Open Closed Closed
at idle condition canister.
High pressure in
tank
HC emission is sucked into the engine
Vehicle is running Open Open Closed Closed
through the charcoal canister.
Low vacuum Engine is running HC emission absorbed by the charcoal

Closed Closed Open Closed
pressure in tank at idle condition canister is returned to the tank.
If the vacuum pressure rises, even after the

check valve of charcoal canister has
High vacuum Engine is running
Closed Closed Open Open opened, the safety valve in the fuel filler
pressure in tank at idle condition
cap will open to prevent damage to fuel
tank
JEC00008-00000
Inspection of fuel vapor lines, fuel tank & filler cap

1. Visual inspection of fuel vapor lines and connections for loose connections, kinks or damage
If any damage is present, repair or replace the parts, as required.
2. Visual inspection of fuel tank
Check the fuel tank for deformation, cracks or fuel leakage.
If any damage is present, repair or replace the part, as required.
Replace the fuel tank cap, if any deformation is caused by the negative pressure in the fuel tank.
JEC00009-00000

EC6
3. Inspection of the fuel filler cap
Check the fuel filler cap and gasket for damage or defor-
mation.
Also check the air continuity with some resistance is exist-
ing on the fuel filler cap.
Replace the cap, if necessary.
NOTE:
If fuel tank deformed by negative pressure, be sure to
replace the fuel filler cap with new one after replacing
the fuel tank.
JEC00010-00007
4. Inspection of the charcoal canister

(1) Detach the hose band from charcoal canister.
(2) Disconnect the rubber hoses from charcoal canister.
NOTE:
Prior to disconnection of the rubber hose, put a tag on
each of the rubber hoses so that they may be recon-
nected correctly to the original position.
(3) Remove the charcoal canister from vehicle by pull up

the charcoal canister case.
JEC00011-00008
(4) Visually inspect the charcoal canister case for cracks A B

or damage.
If any damage is found, replace the charcoal canister
with new one.
(5) Check of charcoal canister for air leakage Ensure that
no air leakage is present when applying compressed
air of 29.4 kPa (0.3 kgf-cm2) into the fuel tank side pipe
B with carburetor side A and atmosphere side C
pipes plugged.
If air leakage is present, replace the charcoal canister C
with new one. JEC00012-00009
(6) Ensure that the no air continuity is exist when blowing

your breath into purge side A pipe of the charcoal
canister.
If air continuity is exist, replace the charcoal canister
with new one.
(7) Check of charcoal canister for restriction.
q Ensure that the air continuity is existing to the at-
mosphere side C pipe, when blow your breath into
the fuel tank side pipe B while the purge side A
pipe is plugged.
If no air continuity is exist, replace the charcoal
canister with new one.
w Ensure that the air continuity is existing when ap-
plying a negative pressure to the purge side pipe
A by the Mity Vac.
If no air continuity is exist, replace the charcoal
canister with new one.

EC7
(8) Cleaning of charcoal canister Clean the charcoal can-
ister by blowing compressed air of 294.2 kPa
(3.0 kg/cm2) into the fuel tank side pipe B while hold-
ing the purge side of canister pipes A closed.
NOTE:
Do not attempt to wash the charcoal canister.
No activated carbon should come out during the test.
If activated carbon comes out replace the charcoal
canister.
(9) Install the charcoal canister to vehicle.

(10) Reconnect the rubber hoses and attach the new hose
band.
JEC00013-00000

EC8
DASHPOT (DP) SYSTEM (only for automatic transmission models)
This system prevents the throttle valve from suddenly closing, thus reducing the CO and HC emissions.
JEC00014-00010
Conditions Throttle valve Dashpot

Idling Idle speed position Pushed in by return force of throttle lever.
Normal driving Opened position Pushed out by the diaphragm spring.
Slightly opens and then slowly closes to the idle
Deceleration Pushed in by return force of the throttle lever.
position
JEC00015-00000
Inspection and adjustment of dashpot (DP) system

1. Connection of tachometer
REV
Connect the tachometer to the engine (REV terminal, vehi-
cle side of connector), by connecting the following SST
between them.
SST: 09991-87402-000 Diagnosis check connector
for RHD vehicle

(LHD vehicles connecter is located
symmetrically opposite position.)
JEC00016-00011
2. Start and warm-up the engine.

3. Ensure that the adjusting screw of the dashpot is not con-
tact with dashpot shaft when the engine revolution speed
at 3500 rpm.
If adjusting screw of the dashpot is contact with the dash-
pot shaft, adjust the adjusting bolt height.
JEC00017-00012

EC9
4. Slowly release the throttle lever.
5. Ensure that the engine revolution within the specified
range.
Specified Engine Revolution
AT: 2400 100 rpm
If not adjust the engine revolution speed by adjusting

screw and repeat the step (3) to (5) again.
JEC00018-00000
6. On condition that engine revolution speed is 3500 rpm, re-

lease the throttle lever quickly.
Make sure that the engine revolution speed changes from
3500 rpm to idle speed within 0.5 - 5.0 seconds after
dashpot works.
7. Stop the engine.
8. Remove the tachometer.
9. Remove the SST from the REV terminal, vehicle side of
connector.
JEC00019-00000

EC10
THREE-WAY CATALYST (TWC) SYSTEM
In this three-way catalyst, the oxidation of carbon monoxide (CO) and the reduction of nitrogen oxides
(NOx) contained in exhaust gas can take place simultaneously. Thus, the three-way catalyst purifies the ex-
haust gas by converting its harmful component gas into harmless carbon dioxide (CO2), water vapor (H2O)
and nitrogen (N2).
JEC00020-00013
Exhausta gas component TWC Exhaust gas

HC, CO and NOx Oxidation and reducation CO2 H2O and N2
JEC00021-00000
INSPECTION OF EXHAUST PIPE ASSEMBLY

1. Check the connections for looseness or damage.
2. Check the clamps for weakness, bend or damage.
Catalytic
converter
JEC00022-00014
INSPECTION OF HEAT INSULATOR

1. Check heat insulator for damage.
2. Check for adequate clearance between the three-way cat-
alyst and heat insulator.
JEC00023-00015

EC11
THREE-WAY CATALYST
INSPECTION
1. Check the connection for looseness or damage.
2. Check the three-way catalyst for dents or damage.
JEC00024-00016
REMOVAL
WARNING:
Do not perform any operation while the exhaust pipe is
still hot.

JEC00025-00000
2. Remove the engine undercover, by removing the six at-

taching bolts.
JEC00026-00017
3. Separate the tail pipe assembly from the front exhaust

pipe assembly by removing the two bolts and nuts.
JEC00027-00018
4. Separate the front exhaust pipe assembly from the ex-

haust manifold by removing the three bolts and nuts.
NOTE:
When replace the catalytic converter, replace it as the
front exhaust pipe assembly.
JEC00028-00019

EC12
INSTALLATION
1. Install a new gasket to the front exhaust pipe and tail pipe.
JEC00029-00000
2. Install the front exhaust pipe assembly to the exhaust

manifold.
NOTE:
Mark sure that the front mark is located at front side.
JEC00030-00021
3. Tighten the attaching bolts and nuts for the three-way cat-
alyst at the tail pipe side.
JEC00031-00022
4. Install the engine undercover, by attaching the six bolts.
JEC00032-00023

EC13
Shape Part No. and name Purpose
09991-87402-000
Tacho pulse pick-up wire Connecting engine tachometer
09258-00030-000
Plugging rubber hoses.
Plug set
JEC00033-00024
TIGHTENING TORQUE
Tightening Torque
Nm kgf-m Remark
Cylinder head Exhaust manifold 29.4 - 44.1 3.0 - 4.5 Dry
Exhaust manifold Exhaust pipe 34.3 - 49.0 3.5 - 5.0 Dry
Exhaust manifold clamp 29.4 - 44.1 3.0 - 4.5 Dry
Exhaust pipe front Exhaust pipe rear 36.3 - 51.0 3.7 - 5.2 Dry
Exhaust pipe support 9.8 - 15.7 1.0 - 1.6 Dry
JEC00034-00000
SERVICE SPECIFICATIONS
Ignition timing B.T.D.C. 0 2/800 50 rpm (M/T)
B.T.D.C. 0 2/850 50 rpm (A/T)
Idle speed
Transmission type M/T A/T
Idle speed 800 50 rpm 850 50 rpm
Throttle positioner touch revolution 2400 100 rpm (A/T)
Throttle positioner operating time 0.5 - 5.0 seconds (A/T)

Compression pressure at 300 rpm Standard 1373 kPa (14.0 kgf/cm2)
Minimum 1030 kPa (10.5 kgf/cm2)
Difference between cylinders 147 kPa (1.5 kgf/cm2)
JEC00035-00000

DAIHATSU
J100
EF
EFI SYSTEM
SYSTEM DESCRIPTION .................... EF 2 DIAGNOSIS CODE NO. 43 ........... EF29

LOCATION OF ELECTRONIC DIAGNOSIS CODE NO. 44 ........... EF31
CONTROL PARTS ..................... EF 2 DIAGNOSIS CODE NO. 45 ........... EF33
SYSTEMATIC DIAGRAM ............... EF 2 DIAGNOSIS CODE NO. 51 ........... EF35
DIAGNOSIS SYSTEM .................... EF 3 DIAGNOSIS CODE NO. 52 ........... EF37
SUMMARY OF TROUBLE DIAGNOSIS CODE NO. 81 ........... EF39
SHOOTINGS ............................. EF 5 REPLACEMENT OF ECU .................. EF41
CAUTION FOR IMMOBILIZER- INSPECTION ................................. EF41
EQUIPPED VEHICLE ................. EF 6 CHARACTERISTICS OF ECU
PRECAUTIONS .................................. EF 7 OUTPUT (1) ............................... EF42
BASIC INSPECTION .......................... EF 9 CHARACTERISTICS ECU
WIRING DIAGRAM OF EFI OUTPUT (2) ............................... EF43
SYSTEM ..................................... EF 9 ECU REPLACEMENT .................... EF44
ARRANGEMENT OF EFI ECU INSPECTION OF IDLE-UP
TERMINAL ................................. EF10 CONTROL SYSTEM ....................... EF45
TROUBLE SHOOTING ACCORDING WIRING DIAGRAM ........................ EF45
TO DIAGNOSIS CODE ................... EF18 UNIT INSPECTION ........................ EF45
PREPARATION OF TROUBLE SYSTEM INSPECTION .................. EF46
SHOOTING WITH SST .............. EF18 INSPECTION OF FUEL SYSTEM ...... EF47
DIAGNOSIS CODE TABLE ............ EF19 FUEL TANK ................................... EF47
DIAGNOSIS CODE NO. 13 ........... EF20 FUEL PUMP ................................... EF48
DIAGNOSIS CODE NO. 21 ........... EF22 FUEL LINE ..................................... EF48
DIAGNOSIS CODE NO. 31 ........... EF25 SST (Special Service Tools) ............. EF49
DIAGNOSIS CODE NO. 42 ........... EF27 TIGHTENING TORQUE ...................... EF49
JEF00001-00001
NO. 9710-JE

EF2
SYSTEM DESCRIPTION
LOCATION OF ELECTRONIC CONTROL PARTS
Pressure sensor
EFI ECU
Throttle sensor
Relay Block
10
A
Injector Cam angle sensor
Oxygen sensor
JEF00002-00011
SYSTEMATIC DIAGRAM
Throttle
Speed sensor position
sensor VSV
N
Intake air
S
N
S
temp. Pressure
sensor sensor
IG key
Cam angle
sensor Aux. valve
Immobilizer
Ignition coil Injector

EFI ECU
Oxygen sensor
ECU
Fuel pump
Fuel pressure
M
regulator
Coolant temp.
Electrical sensor
load signal
Back up
Shift position
switch (A/T)
JEF00003-00021

EF3
DIAGNOSIS SYSTEM
DESCRIPTION
A self-diagnosis system is built in the ECU. If any abnormality
should occur in the signal systems of various sensors, the
self-diagnosis system memorizes the malfunction code num-
ber in the ECU. In respect to important abnormalities, the
check engine lamp at the instrument panel goes on, thus
warning the driver of the abnormality.
When the abnormality is cleared, the check engine lamp goes
out.
When the Test terminal of the diagnosis connector is connect- JEF00004-00031
ed with the earth terminal, the malfunction code number that

has been memorized in the ECU will be indicated in a form of
blinking of the check engine lamp in the instrument panel.
CHECK ENGINE LAMP

1. When the ignition switch is turned on, the check engine
lamp goes on.
(The engine is under a stopped state.)
2. When the engine starts, the check engine lamp goes off.
If the check engine lamp remains illuminated, it indicates
that the diagnosis system has detected system malfunc- JEF00005-00032
tion.
Diagnosis connector
READING OUT OF DIAGNOSIS CODE
1. Initial conditions
(1) Battery voltage of 11 volts or more
(2) Throttle valve fully closed
(3) All accessory switches turned OFF
2. Reading out of diagnosis code Test Earth
(1) Connect the terminal between the test terminal and the terminal terminal
earth terminal with a jump wire as indicated in the illus-
JEF00006-00033
tration.
(2) Turn the ignition switch to the ON position. At this
time, be careful not to start the engine.
(3) Read out the diagnosis code by observing the flashing
number of the check engine lamp.
NOTE:
When system malfunction was detected, go to page
EF18, TROUBLE SHOOTING ACCORDING TO DI-
AGNOSIS SYSTEM.
If the check engine lamp fails to blink, it is likely that the
JEF00007-00034
ECU is malfunctioning. Hence, proceed to the inspec-
tion of the diagnosis system circuit.

EF4
EXPLANATION OF DIAGNOSIS CODES
1. Indication of normal code 0.25 Sec.
Glowing
The engine check lamp glows for 0.25 second, 0.25 sec-
ond after the ignition switch has been turned ON. After a
lapse of 0.25 second, the check engine lamp again glows
for 0.25 second.
Then, this pattern will be repeated.
Extinguished
0.25 Sec.
JEF00008-00036
2. Indication of malfunction code

In case of malfunction code number 21
(1) When a single malfunction code is indicated:
0.5 Sec.
The diagnosis code is composed of two digits. These 0.5 Sec.
two numbers are indicated by blinking of the check 0.5 Sec.
engine lamp. Four seconds after the ignition switch Glowing
has been turned ON, the check lamp indicates first the
number of the tens digit of the diagnosis code by
glowing the same times as the number. The lamp Extinguished 4 Sec.
glows for 0.5 second each time and then it is extin-
1.5 Sec.
guished for 0.5 second. After a pause of 1.5 seconds,
the check lamp indicates the number of the units digit JEF00009-00037
of the diagnosis code by glowing the same times as

the number. The lamp glows for 0.5 second each time In case of malfunction code number 21 and 31
and then it is extinguished for 0.5 second. Then, this
pattern will be repeated after a pause of 4 seconds.
Glowing
(2) When plural malfunction codes are indicated:

In cases where plural malfunction codes have been
detected, the two-digit diagnosis codes are indicated Extinguished 2.5 Sec.
4 Sec.
in the sequence of the code number, starting from a
smaller number. Each diagnosis code is indicated in
JEF00010-00038
the above described pattern. A pause of 2.5 seconds
occurs between the outputs of respective diagnosis
codes, thus separating one from another. After all of
the plural diagnosis codes that have been detected
are indicated, the check engine lamp is extinguished
for four seconds. Then, the detected plural diagnosis
codes will be indicated again.
3. Canceling of diagnosis code IG OFF

To erase the diagnosis codes memorized in the ECU after
malfunctions have been repaired, disconnect the battery
ground cable from the negative () terminal of the battery
for at least 10 seconds with the ignition switch turned OFF.
[When ambient temperature is about 20C.]
NOTE:
After the diagnosis codes have been read, remove the
SST at the diagnosis connector.
JEF00011-00039

EF5
SUMMARY OF TROUBLE SHOOTINGS
NOTE:
Prior to the troubleshooting according to malfunction phenomena, conduct the basic inspections so
as to narrow down the possible causes for malfunctions. For instance, if the spark inspection of the
basic inspection proves to be normal, it can be assumed that the ignition system is functioning nor-
mally. Moreover, the information obtained during diagnosis through questions can help further narrow
down the possible causes.
Malfunction phenomena Poor starting Unstable idling Engine stalling Poor running
Hesitation during acceleration period

Engine stalls when accelerator pedal
place, combustion is not complete.
Engine stalls at time when vehicle

No initial combustion takes place.
Hard starting (during cold period)

Although initial combustion takes
Idle revolution speed is too high.

Hard starting (during hot period)
Idle revolution speed is too low.
Engine stalls during idling.

Fast idle is not effective.
Hunting during running

Hunting during idling
Unstable idling
Lack of output
is released.
moves off.
Knocking
Possible malfunctioning parts
Pressure sensor
Water temperature sensor
Intake air temperature sensor
Control system

Air conditioner switch
Oxygen sensor
Neutral start switch
Cam angle sensor
Fuel pump system
Fuel system
Pressure regulator
Fuel filter
Injector
IG coil
Ignition system
Spark plug
Resistive cord
Ignition timing
Idle-up VSV
Air intake
system
Throttle valve
Throttle body
Hose, etc., disconnected
Power supply
ECU power supply circuit

system
IG switch
Fuel pump relay
Main relay
JEF00012-00101

EF6
CAUTION FOR IMMOBILIZER-EQUIPPED
VEHICLE
1. The immobilizer system is formed by communication be-
tween the Immobilizer ECU and the EFI ECU by means of
the rolling code. The rolling code will be automatically re-
tained both in the immobilizer ECU and in the EFI ECU
when the engine is started once with the key of the immo-
bilizer system. The engine will not start if the rolling code
in the immobilizer ECU and EFI ECU are not identical.
Therefore, the engine will not start when using the EFI
ECU which was mounted before on another vehicle with
the immobilizer system without resetting the rolling code.
JEF00013-00102
2. Even when the EFI ECU has been replaced according to

the check results of the trouble shooting and the relevant
malfunction has been remedied, be sure to reinstall the
old EFI ECU so as to confirm that the malfunction was ob-
viously caused by the faulty EFI ECU.
NOTE:
Be sure to reset the rolling code in the EFI ECU and
Immobilizer ECU using a diagnosis tester (DS-21).
Furthermore, registration of the ignition key should be
performed when installing the EFI ECU which was
mounted on the vehicle equipped with the immobilizer
system to another vehicles.
Refer to the BE section of the service manual.
JEF00014-00103
3. However, the engine can start when using the EFI ECU
which was mounted on a vehicle without the immobilizer
system. However, after completion of the test where this
EFI ECU was used for the vehicle with the immobilizer sys-
tem, if this EFI ECU is returned to the original vehicle, the
engine of the original vehicle will not start any more.
JEF00015-00104

EF7
PRECAUTIONS
1. When resistance or voltage measurement is conducted at
the connector section, insert a measuring probe from the
back of the connector, being very careful not to damage
the harness to terminal connections.
In the case of water-proof type connectors, a measure-
ment is conducted at the connector section, while the
measuring probe is in contact with the terminal at the con-
nection side of the connector. Be very careful not to apply
any excessive force to the terminal at the connector side.
JEF00016-00201
As an alternative method, insert a male or femele terminal
into the connector terminal or connect an adequate at-
tachment.
2. The fuel line at the high-pressure side is pressurized to a
fuel pressure of about 284 kPa. Therefore, a large amount
of gasoline flows out when parts of the fuel line are discon-
nected. Hence, take the following countermeasures.
WARNING
Release the inner pressure of the fuel tank by remov-
ing the fuel filler cap in advance.
JEF00017-00202
3. Tachometer connection
Connect a tachometer probe to the measuring terminal of
the diagnosis connecter. Diagnosis connector
CAUTION:
This does not apply if your tachometer is a pick-up
type.
Never allow the tachometer probe to touch the ground,
for it could result in damage to the igniter and/or igni- Earth Tacho-meter
tion coil. terminal terminal
Some kinds of tachometers may not be suited for the
ignition system of the vehicle. Therefore, ensure that JEF00018-00203
your tachometer is compatible with the ignition system
of the vehicle.
4. Precautions during oxygen sensor handling
(1) Do not drop the oxygen sensor or hit it to other ob-
jects.
(2) Do not immerse the sensor in water or do not cool it by
water.
5. Do not open the cover of the ECU proper.
(Failure to observe this caution could cause ECU malfunc-
tion.)
JEF00019-00204
6. Before disconnecting or reconnecting the connector of the

ECU proper of the EFI system, be sure to turn off the igni-
tion switch and all accessory switches. Also, disconnect
the battery ground cable from the battery negative termi-
nal.
Failure to observe this caution could cause ECU malfunc-
tion.
7. Never apply strong impacts to the EFI parts. Pay utmost
attention during the installation/removal.
Especially, special caution must be exercised as to the
handling of the ECU. JEF00020-00205

EF8
8. When installing the battery, care must be exercised not to
mistake the battery polarity.
CAUTION:
A battery of 12 volts for automotive use must be used.
9. When the voltage or resistance of the ECU is measured

during the check, never touch terminals other than the
specified terminals. Failure to observe this caution could
cause ECU malfunction.
JEF00021-00207
10. When the system is checked on a rainy day, be very care-

ful not to allow water to get to connectors and/or terminals.
Also, when the engine compartment is washed, prevent
water from splashing the EFI-related parts and connec-
tors.
11. Every EFI part should be replaced as an assembly.
JEF00022-00208
12. When disconnecting or reconnecting the connector, care

must be exercised as to the following points.
(1) Carefully observe the shape of the lock prior to the dis-
connection/connection. Pull up.
(2) Release the lock. Then, disconnect the connector.
NOTE:
When disconnecting the connector, be sure to hold the
connector holder, not to pull the wire.
(3) Insert the connector, until the lock is engaged com-

pletely.
(4) Be sure to keep the number of disconnection/recon-
nection of the connector at a minimum level. JEF00023-00209
13. When the vehicle is equipped with wireless installations

(HAM, CB, etc.)
The ECU has been so designed that it is resistant to exter-
nal influence.
However, if a vehicle is equipped with a CB wireless instal-
lation and so forth (even if its output is only 10 W), it may
affect the ECU adversely. Therefore, observe the following
precautions.
(1) Install an antenna at a place as far away as possible JEF00024-00211
from the ECU.

The ECU is installed under the instrument panel.
Therefore, the antenna should be installed at the rear
of the vehicle.
(2) The antenna cord should be kept at least 20 cm away
from the engine wire. Never wind the antenna cord to-
gether with the engine wire with tapes.
(3) Adjust the antenna output correctly.
(4) Never install a wireless installation with a high output
on the vehicle.
JEF00025-00212

EF9
BASIC INSPECTION
WIRING DIAGRAM OF EFI SYSTEM
To heater resister
To A/C dual pressure SW
40 5
To heater relay
6
525354555657585960 616263 64
20212223242526272829303132
To off board connector
(SIO) To heater blower SW
Check engine lamp To head lamp fuse
CONNECTOR A
10
(Combination meter)
37
Idle up VSV
To head lamp
ECU Terminal
60
To defogger SW
Idle up VSV(for A/C)
36
58
3334353637383940 414243
1 2 3 4 5 6 7 8 9 10 11
To defogger
CONNECTOR B
62 63
Idle up VSV(for A/T)
59
#4
52
#2
20
31
A/C evap.
temp sensor
#3
32
3
#1
Injector
42 39
(T) Off board
connector
(VF)
Throttle
54
A/C relay
Position
sensor
26 1
A/C
10A Intake
Magnet manifold
23 24
pressure
M
clutch
sensor
Fuel
Fuel pump relay pumo Intake air
ECU IG
temp.
33
sensor
57
10A
43
Cooling
EFI main relay water
R/B
temp.
EFI sensor
25
11
15A
2
Oxygen
56
Back-up 10A
sensor
To radio
Off board
To ABS
connector
(REV)
41
Ignition coil Tacho Vehicle

meter speed
Engine
sensor
7
10A Ignition coil

21 53
29
Crank
angle
sensor
IG No. 1
IG No. 2
Main
ACC
64
ST
To A/T
neutral
38
starter SW
IG SW
To spark
plug
AM60A
R/B
A/T starter relay

Starter
F/L motor
JEF00026-00301

EF10
ARRANGEMENT OF EFI ECU TERMINAL
ECU Terminal
33 34 35 36 37 38 39 40 41 42 43 52 53 54 55 56 57 58 59 60 61 62 63 64
1 2 3 4 5 6 7 8 9 10 11 20 21 22 23 24 25 26 27 28 29 30 31 32
Connector B Connector A
CONNECTOR A
No. Contents of connection No. Contents of connection
20 E1 Sensor system ground 52 E2 Sensor ground
21 N+ Cam angle sensor (+) 53 N Cam angle sensor
22 Throttle position sensor (Idle) 54 PSW Throttle position sensor
23 VC Pressure sensor power supply 55
24 PIM Pressure sensor signal 56 Ox Oxygen sensor
25 THW Coolant temperature sensor 57 THA Intake air temperature sensor
26 KNK A/C lock sensor 58 VSV3 Idle up VSV (for A/C)
27 59 VSV2 Idle up VSV (for A/T)
28 ALT Alternator cut 60 VSV1 Idle up VSV (for electrical load)
29 IG2 Ignition signal (#2,#3 cylinder) 61
30 62 E01 Power supply system ground
31 #20 Injector (#2, #4 cylinder) 63 E02 Ignition system ground
32 #10 Injector (#1, #3 cylinder) 64 IG1 Ignition signal (#1, #4 cylinder)
CONNECTOR B
No. Contents of connection No. Contents of connection
1 MGC A/C Magnet clutch 33 FC2 Fuel pump relay (Without IMB.)
2 BAT Battery (Back-up power supply) 34 FC1 Fuel pump relay (With IMB.)
3 ACEV A/C Evaporator temp, sensor 35
4 36 DEF Defogger switch
5 ACSW A/C Switch 37 H/L Headlamp switch
6 BLW Heater blower 38 A/T Neutral start switch
7 SPD Vehicle speed sensor 39 T Test terminal
8 40 SIO Diagnosis tester
9 41 REV Engine speed signal
10 W Check engine lamp 42 VF VF monitor terminal
11 +B1 Power supply 43 +B2 Power supply
JEF00027-00302

EF11
Trouble shooting hints
1. In most cases, engine troubles are attributable to systems
other than the EFI system.
(1) Battery voltage, fuse blown or fusible link blown
(2) Body earth
(3) Fuel leakage, fuel filter clogged or fuel pump malfunc-
tioning
(4) Spark plugs faulty, spark plug wires faulty, distributor
faulty, igniter faulty, or ignition timing adjusted improp-
erly
(5) Admission of air JEF00028-00303
2. Most of troubles related to the EFI system are merely

caused by poor wire connections.
Ensure that connectors are connected securely.
Check connectors, being careful as to the following
points.
(1) Visually inspect that terminals are not bent.
(2) Ensure that connectors are securely connected and
locked.
(3) Check to see if the malfunction phenomenon takes JEF00029-00305
place when applying light vibration to the connector or
the wire connected to the connector.
3. If engine misfire takes place, the following measures

should be taken.
(1) Ensure that the battery terminals and so forth are con-
nected properly.
(2) Handle the spark plug wires carefully.
(3) After completion of repairs, ensure that the ignition coil
terminals and other ignition system wire are reconnect-
ed securely. JEF00030-00306
Check to see if diagnosis detects malfunction code.

1. Check of diagnosis code
When the engine starts, the check engine lamp in the
combination meter remains illuminated. It indicates that
the diagnosis has detected system malfunctions.
2. Read out the diagnosis code.
NOTE:
See page EF4.
When system malfunction has been detected, proceed
to page EF18, TROUBLE SHOOTING ACCORDING JEF00031-00309
TO DIAGNOSIS SYSTEM.
Check of power supply circuit

1. Check the fuses and fusible link.
If the fuses are blown out, be sure to perform the trouble
shooting.
JEF00032-00311

EF12
2. Check the EFI main relay.
(a) Turn the ignition switch to the ON position. Check to
see if the relay emits an operating sound.
JEF00033-00312
(b) Remove the EFI main relay from the relay box.
Check that there is continuity between the terminals 1 r w
and 2. q e
Specified Resistance: 40 - 100
(c) Check that there is continuity between the terminals 3

and 4 when a voltage of 12 V is applied to across the
terminals 1 and 2.
w r
NOTE: e q
Even when the trouble has not been solved by repair-
ing the relay, check the wire harness. JEF00034-00313
3. Check the fuel pump relay.

(a) When the ignition switch is set to the ON position,
check to see if the relay emits an operating sound.
(b) Remove the fuel pump relay from the relay box.
Check that there is continuity between the terminals 1
and 2.
Specified Resistance: 40 - 100
(c) Check that there is continuity between the terminals 3

and 4 when a voltage of 12 V is applied to across the
terminals 1 and 2.
JEF00035-00314
Check of ignition system

Diagnosis connector
1. Connect a timing light to the ignition wire of the No. 1
cylinder.
2. Check to see if the ignition timing mark on the crankshaft
pully is aligned with the indicator. Earth
Test terminal
Specified Value: 0 2 BTDC/ at Idle terminal
NOTE:
Remove the air cleaner case.
Connect the test terminal and the earth terminal with a
jump wire at the diagnosis connector. JEF00036-00319

EF13
3. Remove the spark plug(s).
4. Visually inspect the spark plug for electrode wear, thread
or insulator damage.
5. Measure the electrode gap, using a plug gap gauge.
Specified Value: 0.9 - 1.0 mm (NGK, DENSO)
NOTE:
If the gap will not conform to the specification, replace
the plug.
JEF00037-00320
6. Check if the resistance of the the spark plug distance

piece and the ignition wire is within the specification. q e
Spark Plug Distance Piece 1: 0.3 or less
Ignition Wire 2: 3.8 k
Ignition Wire 3: 5.6 k w
NOTE:
Remove the ignition coils from the cylinder head cover.
Then, remove the wire and distance piece.
JEF00038-00321
7. Check if the ignition coil resistance is within the specifica-

tion.
Secondary Coil: 13.6 - 2.0 k
Check of compression pressure JEF00039-00322
1. Temporarily remove the main relay and fuel pump relay.

2. Insert a compression gauge into the spark plug hole.
3. Depress the accelerator pedal fully.
4. While cranking the engine, measure the compression
pressure.
Minimum Value: 1030 kPa at 300 rpm
NOTE:
Always use a fully charged battery so that at least a
revolution speed of 300 rpm is attained.
JEF00040-00323
Check of fuel system

1. Using a sound scope, check to see if each injector emits
an operating sound when the engine is being started or
cranked.
NOTE:
If a sound scope is not available, apply a screwdriver
or the like to the injector. So you can feel an operating
vibration.
If the injector emits no operating sound, check the
wiring or connectors. Then, perform the following pro-
cedure. JEF00041-00331

EF14
2. Disconnect the injector connector of the engine wire.
3. Measure the resistance between the terminals of each in- Derivery pipe
jector.
Specified Resistance: 11 - 17 (at 20C)
NOTE:
If the resistance is not within the specification, replace
the injector.
If the resistance will conform to the specification, per- Injector
form the following procedure.
JEF00042-00332
4. Using a test lamp (12 V 6 W), check to see if the lamp will
be illuminated as shown in the illustration when the engine
is being started or cranked.
If not, check the wiring harness and ECU output.
Terminal of
engine wire
(Injector)
JEF00043-00333
5. Remove the fuel delivery pipe.

Remove the injectors.
6. Remove the injector grommet and O-ring.
NOTE:
Check to see if the injector grommet exhibits damage.
JEF00044-00334
7. Using the following SSTs, connect the injector, as indicat-

To fuel filter
ed in the figure. Insert the injector into the measuring SST (On the vehicle)
cylinder. (09268-87701)
Hose band
SST:
(1) 09268-87701-000
(2) 09268-87702-000 (09268-87702) SST SST(09283-87703)
(3) 09842-30070-000
Pressure regulator
SST(09842-30070)
To fuel return pipe
Battery (On the vehicle)
JEF00045-00335
NOTE:
O-Ring Grommet
Install a new grommet to the injector.
Install a new O-ring to the O-ring seal section.
Insulator
Attach the hose bands to the rubber hose connections.
Pressure regulator
Intake manifold
JEF00046-00336

EF15
8. Remove the fuel pump relay. Then, connect the terminal
r e
with a jump wire as shown in the illustration.
9. Turn the ignition switch to the ON position.
Relay
terminal
JEF00047-00337
10. Connect the SST wire to the battery terminal for 15 sec-
SST SST (09842-30070)
onds. (09268-87702)
11. Measure the amount of fuel collected in the measuring
cylinder.
Specified Amount of Fuel: Approx. 42 - 48 ml Vinyl
Variation Between Injectors: 5 ml or less pipe
Battery
JEF00048-00338
NOTE:
Attach a suitable vinyl hose to the tip-end of the injector
Conduct the measurement two or three times for each
injector.
Before the injector is pulled out, make certain to turn off
the ignition switch.
When removing the injector, use a suitable cloth or the
like so as to prevent fuel from splashing.
Prior to the test, perform air bleeding for the fuel hose.
JEF00049-00338
12. Ensure that no fuel is leaking from the injector nozzle when
SST SST (09842-30070)
the SST wire is removed from the battery terminal. (09268-87702)
Specification: Less than one drop of fuel per minute
NOTE:
If the leakage exceeds the specification, replace the in-
jector.
13. Turn off the ignition switch.

Battery
JEF00050-00339
14. Loosen the hose band at the fuel filter.

15. Connect a suitable fuel hose (about 2 meter long) to the
fuel filter.
16. Insert one end of the fuel hose in a measuring cylinder.
CAUTION:
The fuel pressure of the fuel line is approximately
284 kPa. Hence, be sure to gradually remove the pipe
Since the fuel will flow out, be certain to place a suit-
able container or cloth under the fuel filter so that no
fuel may get to the resin or rubber parts of the vehicle. JEF00051-00341

EF16
17. Remove the fuel pump relay. Then, connect the terminal
r e
with a jump wire as indicated in the illustration.
18. Turn the ignition switch to the ON position for 10 sec-
onds. Then, turn off the ignition switch.
Relay
terminal
JEF00052-00342
19. Measure the amount of fuel collected in the measuring

cylinder.
Specified Amount of Fuel: 230 ml or more
NOTE:
Check to see if the fuel lines and filter exhibit leakage,
deformation or choking.
JEF00053-00343
20. Remove the fuel pressure regulator from the fuel delivery
pipe. Then, install a fuel pressure gauge between the SST (09268-87701)
pressure regulator and the fuel pipe from the fuel filter as Hose bands
shown in the illustration. Hose bands
SST: 09268-87701-000
Hose band
09283-87703-000
SST (09283-87703)
To fuel filter
Pressure regulator
To fuel return pipe
JEF00054-00344

22. Check to see if the fuel pressure conforms to the specified
pressure.
Specified Value: 284 5 kPa
NOTE:
If the fuel pressure is less than the specification, check
the fuel pump and fuel pressure regulator.
JEF00055-00345

EF17
23. Check the idle revolution speed.
Diagnosis connector
(1) Connect a tachometer to the terminal of the diagnosis
connector.
(2) Check to see if the fast idle revolution speed is within
the reference value. Earth Tacho-meter
Reference Value: Around 1400 rpm/25C terminal terminal
NOTE:
The fast idle revolution speed can not be adjusted to
the specification. If the revolution speed will not con-
form to the reference value, perform the inspection of JEF00056-00346
the auxiliary air system, following the procedure given

Idle adjusting
below. screw
(3) Remove the air cleaner case from the throttle body. To
From
(4) Start the engine. Check that there is air continuity at the air cleaner manifold
auxiliary air port under the following conditions.
q Apply your finger to the auxiliary air valve port. Auxiliary Throttle valve
Ensure that the engine speed drops. air valve
port Auxiliary
w When the cooling water temperature is above air valve
70C, apply your finger to the auxiliary air port. Engine coolant
Ensure that the engine speed does not change. JEF00057-00347
NOTE:
If the auxiliary air system exhibits malfunction, replace
the throttle body.
(5) Check to see if the idle revolution speed conforms to

the specification when the engine water temperature is
higher than 80C.
Specified Value
M/T Vehicle: 800 50 rpm
A/T Vehicle: 850 50 rpm
NOTE:
If the revolution speed will not conform to the specifica-
tion, check the EFI ECU unit. See page EF41.
JEF00058-00348

EF18
TROUBLE SHOOTING ACCORDING TO IG OFF
DIAGNOSIS CODE
PREPARATION OF TROUBLE SHOOTING WITH
SST
The EFI unit can be checked by measuring the resistance or
voltage at the SST terminals.
CAUTION:
Be sure to memorize the malfunction code before dis-
JEF00059-00401
connecting the battery cable. Otherwise the maifunc-

tion code(s) will be erased by disconnecting the battery
code.
2. Disconnect the wire harness connectors from the EFI ECU

connectors at the cowl side of the passenger seat. EFI ECU
3. Connect the following SST between the wire harness con-
nectors and the EFI ECU connectors.
SST: 09842-87706-000
SST
32
29 30 31
26 27 28
23 24 25 61 62 63
64
21 22 58 59 60
18 19 20 55 56 57
15 16 17
12 13 14 53 54
50 51 52
47 48 49
9 10 11 44 45 46
6 7 8
4 5
1 2 3 41 42 43
39 40
36 37 38
33 34 35
JEF00060-00402
4. Reconnect the battery ground cable to the negative ()

CAUTION:
When disconnecting or reconnecting the EFI ECU con-
nectors, be sure to disconnect the battery ground cable
from the negative () terminal of the battery with the ig-
nition switch and all accessory switches in the off state.
When installing a new battery, care must be exercised
not to mistake the battery polarity. Failure to observe
this caution could cause ECU malfunction.
Before using the SST, be sure to check to see if short
or open wire exists between the terminals of the SST.
JEF00061-00403

EF19
DIAGNOSIS CODE TABLE
When the diagnosis system detects malfunctions, the check engine lamp will go on even if the diagnosis
connector test terminal is not connected to the earth terminal.
Code Number of flashing Diagnosis Diagnosis contents Trouble area See

No. item page
Engine When the engine revolution 1. Cam angle sensor & circuit
13 revolution signal is not inputted while the EF202
signal starter switch is on.
When the input signal from the 1. Oxygen sensor circuit
Oxygen
oxygen sensor shows too lean 2. Oxygen sensor
sensor
21 air-to-fuel ratio under certain EF22
signal
conditions:
Pressure When the input signal from the 1. Pressure sensor circuit
31 sensor pressure sensor becomes more 2. Pressure sensor EF257
signal than 4.9 V or less than 0.7 V.
Cooling When the engine cooling water 1. Water temp. sensor circuit
water temperature sensor circuit 2. Water temperature sensor
42 temperature becomes open or shorted. EF27
signal
Intake When the intake air temperature 1. Air temperature sensor circuit
43 air temp. sensor circuit becomes open or 2. Air temperature sensor EF29
signal shorted.
A/C evapo. When the A/C evaporator 1. A/C evaporator temperature

44 temperature temperature sensor circuit sensor circuit EF31
sensor exhibits open or short. 2. A/C evaporator temperature sensor
When the A/C switch is turned on, 1. A/C magnet clutch
the rotation signal from the A/C 2. A/C lock sensor circuit
A/C
45 compressor compressor becomes too low EF33
because of slipping of the magnet
clutch or overload.
When the A/C switch is turned on, 1. A/C switch circuit

the idle switch is turned off with 2. A/C switch
Switch the test terminal of the diagnosis 3. Idle switch circuit
51 EF35
signal connector shorted. However no 4. Throttle position sensor
memorizing will take place.
Vehicle When the vehicle speed sensor 1. Vehicle speed sensor circuit
speed signal circuit exhibits open wire or 2. Vehicle speed sensor
52 EF37
sensor or short circuit.
signal
When the rolling codes can not 1. Wire harness between the
be exchanged between the EFI Immobilizer ECU and EFI ECU
81 Immobilizer ECU and the immobilizer ECU 2. Immobilizer ECU EF39
signal or the rolling codes are not 3. EFI ECU
matched.
When the rolling codes can not 1. EFI ECU
be exchanged in the EFI ECU.
83 Immobilizer
signal EF39
JEF00062-00405

EF20
DIAGNOSIS CODE NO. 13
CAM ANGLE SENSOR & CIRCUIT
EFI ECU
62 21 53
Cam angle sensor

Z49
JEF00063-00501
When no cam angle sensor signal is inputted within 2 sec-

onds while the engine is being cranked by the starter
motor.
1. Check of cam angle sensor
(1) Disconnect the connector of the cam angle sensor.
(2) Check that there is the specified resistance between
the respective terminals of the cam angle sensor.
Specified Value: 205 - 255
NOTE:
If the resistance will not conform to the specification,
replace the signal generator. Refer to the IG section.
JEF00064-00502
(3) Temporarily remove the EFI main relay at the relay box.
(4) Check that there is a voltage between the terminals of
the cam angle sensor when the engine is being
cranked.
Specified Value: About AC 150 mV/300 R.P.M.
NOTE:
The generating voltage should be measured, using the
AC range of a volt meter.
If the measured value does not conform to the specifi-
cation, adjust the gap. See the IG section. JEF00065-00503

EF21
REFERENCE
(1) Prepare an oscilloscope.
(2) Connect a probe to the respective terminals.
(3) Check to see if a signal shown in the graph appears at
the terminals when the engine is being cranked.
NOTE:
If not, check the air gap of the signal generator.
Refer to the IG section of the service manual.
JEF00066-00504
3. Check the wire harness and ground earth.

(1) Check to see if the earth bolt exhibits looseness or
corrosion.
JEF00067-00506
(2) Connect the connector of the cam angle sensor and

the wire harness connector.
(3) Connect the SST.
NOTE:
SST
Refer to page EF18, Preparation of trouble shooting
with SST. 20 21 22
12 13 14 15 16 17 18 19
At this time, disengage the connector between the SST 44 45 46 47 48 49 50 51 52 53 54
and the EFI ECU.
(4) Measure the resistance between the SST terminals 21

and 53. JEF00068-00507
Specified Value: 205 - 255
NOTE:
If the trouble has not been solved by repairing the wire
harness or parts, then, proceed to page EF41,
Replacement of ECU.
JEF00069-00508

EF22
OXYGEN SENSOR & CIRCUIT
EFI ECU
56 42
J/C
X28
VF monitor
terminal
Z49
Oxygen
sensor
JEF00070-00511
The ECU detects malfunction when the input signal from

Diagnosis connector
the oxygen sensor shows too lean air-to-fuel mixture con-
tinuously for 2 seconds or more when the engine revolu-
tion speed is 1500 rpm or more and the engine is in a hot
condition. Test Earth VF
1. Inspection of oxygen sensor circuit terminal terminal terminal
(1) Warm up the engine completely.
(2) Connect the test terminal and the earth terminal with a
jump wire at the diagnosis connector.
(3) Measure the voltage between the VF terminal and the
earth terminal as indicated in the illustration. JEF00071-00512
Specified Voltage: 0 - 5 V
(4) While keeping the engine revolution speed at 5V

3000 rpm for about 2 minutes, count how many times
the pointer of the voltmeter swings within 10 seconds.
8 Times or more: Normal
0 - 7 Times: Proceed to the following steps.
0V
NOTE:
The throttle valve must be opened.
JEF00072-00513

EF23
REFERENCE
Diagnosis connector
(1) Prepare an oscilloscope.
(2) Connect a jump wire to the test terminal and the earth
terminal.
(3) Connect a probe to the VF terminal and the earth ter- Test Earth VF
minal. terminal terminal terminal
(4) Check to see if a signal shown in the graph appears at
the terminals while the engine is rotating at 3000 rpm.
JEF00073-00514
NOTE:
There are cases where the measurement can not be
conducted with a tester having a low reaction speed.
Therefore, use a tester having a high reaction speed or
oscilloscope.
If no voltage appears, check the oxygen sensor unit.
JEF00074-00515
2. Check of oxygen sensor

(1) Warm up the engine completely.
(2) Disconnect the connector of the oxygen sensor.
(3) Connect a voltmeter to the connector terminal of the
oxygen sensor.
(4) Hold the engine revolution speed for 2 minutes at
about 3000 rpm. At this time, ensure that the reading
of the voltmeter registers 0.45 V or more.
Oxygen
NOTE: sensor
When the oxygen sensor connector has been discon-
nected, an air-to-fuel mixture ratio of the engine will be- JEF00075-00516
come rich. The oxygen sensor therefore generates an

electromotive force of about 0.45 volts or more.
Replace the oxygen sensor with a new part, if the read-
ing will not register 0.45 V or more.
If the reading conforms to the specification, proceed to SST
the following procedure.
23 24 25 26 27 28 29 30 31 32
3. Check of wire harness 55 56 57 58 59 60 61 62 63 64
(1) Connect the SST between the ECU connectors and

the wire harness connectors. (See page EF18.)
(2) Ensure that the voltage between the SST terminals 56 JEF00076-00517
and 62 is the specified value while keeping the engine

revolution speed at 3000 rpm.
1.0 V
Specified Voltage: 0.2 - 1.0 V
NOTE: Judgment line

0.45 V
At this stage, remove the jump wire from the test termi-
nal and the earth terminal of the diagnosis connector.
0V
Oxygen sensor output

JEF00077-00518

EF24
(3) Perform the procedure given in the table, according to the measurement results.
Measured voltage Remedy

0V 1) Check the oxygen sensor circuit for open wire or short circuit.
Remedy causes for too-lean fuel mixture.
Pressure sensor
The measured voltage varies Pressure regulator
mainly within a range under Fuel line
0.45 V. Fuel filter
Fuel pump
Injector
The measured voltage varies
within a range of 0 - 1.0 V,
centering around 0.45 V.
However, the reaction speed the
Check the ECU. (Go to page EF41, REPLACEMENT OF ECU.)
is low.
(The pointer of the voltmeter
swings less than 8 times within
10 seconds.)
Remedy causes for too-rich fuel mixture.
The measured voltage varies Pressure sensor
mainly within a range above Fuel line
0.45 V. Pressure regulator
Injector
Remedy causes for too-rich fuel mixture.
Pressure sensor
1.0 V Fuel line
Pressure regulator
Injector
Check the oxygen sensor circuit for short circuit with other positive line.
More than 1.0 V
Repair or replace the wiring harness.
JEF00078-00519
NOTE:
If the trouble has not been solved by repairing the wire harness or parts, then, proceed to page
EF41, Replacement of ECU.
JEF00079-00520

EF25
PRESSURE SENSOR & CIRCUIT
EFI ECU
52 57 25 24 23
J/C
X44 X45 X46
Intake air Cooling Intake

temp. water manifold
sensor temp. pressure
sensor sensor
JEF00080-00521
When the pressure sensor becomes open or shorted:

1. Check the pressure sensor. SST
the wire harness connectors. 12 13 14 15 16 17 18 19 20 21 22
44 45 46 47 48 49 50 51 52 53 54
(2) Ensure that the voltage between the SST terminals 23
and 52 is within the specified value when the ignition SST
switch is turned to the ON position.
Specified Value: 4.5 - 5.5 V 23 24 25 26 27 28 29 30 31 32
55 56 57 58 59 60 61 62 63 64
NOTE:
If no voltage appears, check the ECU power supply cir- JEF00081-00522
cuit, ECU ground circuit and the wire harness.

SST
and 52 is within the following specified voltage when 12 13 14 15 16 17 18 19 20 21 22
the ignition switch is turned to the ON position. 44 45 46 47 48 49 50 51 52 53 54
Altitude Atmospheric SST

Voltage
(From sea level) m pressure kPa (mmHg)
0 101.3 (760) 3.30 - 4.0 V 23 24 25 26 27 28 29 30 31 32
55 56 57 58 59 60 61 62 63 64
500 95.5 (716) 3.10 - 3.8 V
1000 89.9 (674) 2.95 - 3.65 V JEF00082-00523

EF26
(4) Temporarily connect a vacuum gauge (The MityVac
may be used) to the negative pressure port of the VSV
so that the inner pressure of the intake manifold may
be measured. Next, start the engine and keep it idling.
At this time, ensure that the gauge reading and the
voltage across the SST terminals 24 and 52 satisfy the
following formula given below.
V = 0.004 P1 + 0.6
Where: JEF00083-00524
V = P sensor output during idling (V)

P1 = Intake manifold negative pressure during
idling (mmHg)
CAUTION:
Once the pressure sensor is removed from the intake
manifold, even for the purpose of inspection, never re-
use the pressure sensor. This is because the grommet
of the sensor will be damaged by the removal.
Grommet
NOTE:
If the measured voltage fails to drop by the specified
value, replace the pressure sensor.
If the measured voltage does not conform to the speci-
fications, check the wire harness. JEF00084-00525
If the trouble has not been solved by repairing of the

wire harness or parts, proceed to page EF41,
Replacement of ECU.

EF27
WATER TEMPERATURE SENSOR & CIRCUIT
EFI ECU
52 57 25 24 23
J/C
X31 X30

sensor sensor
JEF00085-00531

1. Check to see if the connector is connected properly. SST
2. Check of wire harness
(1) Connect the SST between the ECU connectors and 12 13 14 15 16 17 18 19 20 21 22
the wire harness connectors. 44 45 46 47 48 49 50 51 52 53 54

SST
and 52 is within the specified value when the ignition
switch is turned to the ON position.
23 24 25 26 27 28 29 30 31 32
55 56 57 58 59 60 61 62 63 64
NOTE: JEF00086-00532

fications, check the wire harness.
Measuring points
Voltage
Temperature C
20 2.450 0.15
80 - 90 0.318 0.01
JEF00087-00533

EF28
3. Check the water temperature sensor unit.
(2) Disconnect the connector of the water temperature
sensor.
(3) Drain the engine cooling water.
(4) Remove the water temperature sensor unit.
NOTE:
Be certain to perform the replacement and repairs of
the sensor only after the intake manifold has been re-
moved from the cylinder head.
JEF00088-00534
(5) Check that the resistance between the terminals X30

and X31 of the water temperature sensor is within the
specified value in the table. See page EF27.
NOTE: O ring
X31
harness or parts, proceed to page EF41, Replacement X30
Spring Case
For water
of ECU. temp. gauge Electric
conductor ring Insulator
Thermistor Thermistor
(For water temp. gage) (For engine control)
JEF00089-00535

EF29
INTAKE AIR TEMPERATURE SENSOR & CIRCUIT
EFI ECU
52 57 25 24 23
J/C
X34 X33

sensor sensor
JEF00090-00541

1. Check to see if the wire harness connectors are connected
properly.
2. Disconnect the connector of the intake air temperature
sensor.
NOTE:
Before the wire harness connector is disconnected, be
sure to turn off the ignition switch.
JEF00091-00542
3. Check that the resistance between the terminals X33 and

X34 of the intake air temperature sensor is within the spec-
ified value. X33
Temperature C Resistance k X34
40 1.140 0.3
20 2.450 0.5
0 5.880 1.5
JEF00092-00543

EF30
(1) Connect the SST between the ECU connectors and SST
the wire harness connectors.
(2) Check that the voltage between the SST terminals 52 12 13 14 15 16 17 18 19 20 21 22
44 45 46 47 48 49 50 51 52 53 54
and 57 is within the specified value when the ignition
switch is turned to the ON position. SST
Reference: 20C 1.8 - 2.9 V
23 24 25 26 27 28 29 30 31 32
55 56 57 58 59 60 61 62 63 64
JEF00093-00544
NOTE:
fications, check the wire harness.
If the diagnosis code No. 43 is flashing, most likely it
denotes that open wire occurs intermittently or the
shielding is poor.
Replacemeny of ECU.
JEF00094-00545

EF31
AIR CONDITIONER EVAPORATOR TEMPERATURE SENSOR & CIRCUIT
IG SW
ACC ACC
IG No. 1 IG1
IG No. 2 IG2
ST ST
Main MAIN
Engine
No. 2
10A
Heater
20A
R/B
13
1
F/L Radiator fan
pressure SW
F/L 1.25
EFI ECU
K02
Dual
Blower
motor
17 5 1
KP5 M
temperature
3
Evaporator
K30
Resister
sensor
K44
3
14
52
KK4
K05 K07
26 6
Magnet
clutch
20 K04 K06 K08
A/C SW
Blower
switch
fan motor
Water temp. SW
Radiator
M
Z21
5
JEF00095-00551
When the air conditioner evaporator temperature sensor

and circuit becomes open or shorted:
1. Check to see if the wire harness connectors are connected
properly.
2. Disconnect the connector of the evaporator temperature
sensor. KP5
NOTE:
Before the wire harness connector is disconnected, be KK4
sure to turn off the ignition switch.
JEF00096-00552
3. Check the resistance between the terminals.

Temperature C Resistance k
25 1.500 0.15
15 2.340 0.23
0 4.850 0.24
JEF00097-00553

EF32
(1) Connect the SST between the ECU connectors and SST
(2) Check that the voltage between the SST terminals 3 35 6 7 8
4
9 10 11
1 2
41 42 43
and 52 is within the specified value when the ignition 33 34 35 36
37 38 39 40
switch is turned to the ON position. SST

Reference: 20C 1.8 - 2.9 V 16 17 18 19 20
21 22
12 13 14 15 54
47 48 49 50 51 52 53
44 45 46
JEF00098-00554
NOTE:
fication, check the wire harness.
Replacement of ECU.
JEF00099-00555

EF33
AIR CONDITIONER LOCK SENSOR & CIRCUIT
IG SW
ACC ACC
IG No. 1 IG1
IG No. 2 IG2
ST ST
Main MAIN
Engine
No. 2
10A
Heater
20A
R/B
13
1
F/L Radiator fan
pressure SW
F/L 1.25
EFI ECU
K02
Dual
Blower
motor
17 5 1
KP5 M
temperature
3
Evaporator
K30
sensor
K44 Resister
3
14
52
KK4
K05 K07
26 6
Magnet
clutch
20 K04 K06 K08
A/C SW
Blower
Water temp. SW
switch
fan motor
Radiator
M
Z21
5
JEF00100-00556
When the ECU detects malfunction of the A/C lock sensor Vane pump pulley
circuit. Water pump pulley
1. Check the drive belt tension of the A/C compresser. Check Air conditioner
compressor pulley
the A/C compresser for sticking before checking the A/C
lock sensor circuit.
2. Check the connection of the A/C lock sensor connector.
NOTE:
This code will not be memorized.
Idler pulley
The diagnosis code will be indicated only when the test Alternator pulley
terminal is connected with the ground terminal. Crankshaft pulley
JEF00101-00557
3. Check the A/C lock sensor and circuit.

(1) Connect the SST between the ECU and the cowl wire. SST
(2) Check the output voltage across the SST terminals 26
and 20 when the A/C compresser is operating. 12 13 14 15 16 17 18 19 20 21 22
Specified Value: 0.1 - 3 V (Pulse signal) 44 45 46 47 48 49 50 51 52 53 54
SST
23 24 25 26 27 28 29 30 31 32
55 56 57 58 59 60 61 62 63 64
JEF00102-00558

EF34
(1) If the measured voltage is o volt, check the wiring be-
tween the ECU and the A/C lock sensor connector for
open wire or short circuit.
(2) Check the A/C lock sensor by measuring the output
voltage at the sensor connector.
JEF00103-00559
NOTE:
Replacement of ECU.
JEF00104-00560

EF35
SWITCHING SIGNAL CIRCUIT
IG SW
ACC ACC
IG No. 1 IG1
IG No. 2 IG2
ST ST
Main MAIN
To starter
Heater
20A
relay
coil
pressure SW
F/L 1.25
K02
Dual
Blower
motor
38 62
Neutral M
start
switch (A/T) K30
K44 Resister
EFI ECU
K05 K07
6
K04 K06 K08
A/C SW
Blower
switch
23
Throttle
position 54 Z21
5
sensor
20
JEF00105-00561
When the ECU detects malfunction of the switching cir- Diagnosis connector
cuit.
1. Check that the following wire harness connector or switch-
ing circuits are connected properly.
Earth
(1) Throttle position sensor circuit Test terminal
(2) A/C switch circuit terminal
(3) Neutral start switch circuit of the A/T.
NOTE:
This code will not be memorized.
The diagnosis code will be indicated only when the test
terminal is connected with the earth terminal as shown JEF00106-00562
in the illustration.
2. Check of wire harness and switches

the wire harness connectors. 10 11
4 6 7 8 9
5
(2) Check that there is continuity between the SST termi- 1 2 3
37 38 39 40 41 42 43
33 34 35 36
nals 62 and 38 when the A/T shift lever is shifted to the
P or N position.
30 31 32
26 27 28 29
23 24 25
61 62 63 64
58 59 60
55 56 57
JEF00107-00563

EF36
(3) Check the voltage between the SST terminals 20 and
23 when the throttle valve is opened and the ignition SST
switch is turned on.
Specified Value: 4.5 - 5.5 V 12 13 14 15 16 17 18 19 20 21 22
44 45 46 47 48 49 50 51 52 53 54
SST
23 24 25 26 27 28 29 30 31 32
55 56 57 58 59 60 61 62 63 64
JEF00108-00564
(4) Check the voltage between the SST terminals 20 and

54 when the throttle valve is fully closed and the igni-
tion switch is turned on.
Specified Value: 0.4 - 0.8 V SST
12 13 14 15 16 17 18 19 20 21 22
44 45 46 47 48 49 50 51 52 53 54
JEF00109-00565
(5) Check the voltage between the SST terminals 5 and 62

when the A/C switch is turned on.
Specified Value: Battery voltage
10 11
3 4 6 7 8 9
5
1 2
38 39 40 41 42 43
37
33 34 35 36
30 31 32
26 27 28 29
23 24 25
61 62 63 64
58 59 60
55 56 57
JEF00110-00566
(6) Turn off the ignition switch. Then, disconnect the con-
nector of the throttle position sensor.
(7) Check the resistance between the terminals PSW and
VC of the throttle position sensor.
Specified Value: 2.5 - 6.0 k
PSW
VC
JEF00111-00567
NOTE:
Replacement of ECU.
JEF00112-00568

EF37
VEHICLE SPEED SENSOR & CIRCUIT
EFI ECU
62 7
Combination meter
B11
Speedometer
cable
S
Vehicle
N
speed sensor
B10
JEF00113-00571

1. Check of the reed switch
(1) Remove the combination meter.
(2) Ensure that continuity occurs four times at the termi-
nals B10 and B11 of the combination meter while the
speedometer drive shaft completes a turn.
NOTE:
The sensor has been so constructed that its rotary
shaped-magnet rotates at the same revolution speed
as the speedometer cable turns ON/OFF reed switch,
thereby making it possible to input the vehicle speed to JEF00114-00572
the computer. Four pulses are generated as the

speedometer cable completes its one turn.

(1) Connect the SST between the ECU connectors and 4 6 7 8 9
5
10 11
1 2 3
the wire harness connectors. 33 34 35 36
37 38 39 40 41 42 43
(2) Check that the voltage between the SST terminals 7

and 62 is within the following specified value when the
vehicle moves and the ignition switch is turned to the 23 24 25
26 27 28 29
30 31 32
61 62 63 64
ON position. 55 56 57
58 59 60
Specified Value: 0 - 5 V for pulse signal JEF00115-00573

EF38
NOTE:
If the measured voltage is 0 volt, check that the wire
harness or connector is shorted.
If the measured voltage is still 5 volts, check that the
wire harness or connector exhibits open wire.
If the diagnosis code No. 43 is flashing, most likely it
shielding is poor.
Check to see if the earth bolt exhibits looseness or cor-
rosion.
If the trouble has not been solved by repairing the wire JEF00116-00574

Replacement of ECU.

EF39
IMMOBILIZER SIGNAL CIRCUIT
EFI ECU
62 40
IMMOBILIZER ECU
7
Diagnosis
connector
(DS-21)
Antenna
(IG key)
JEF00117-00581
When the rolling codes cannot be exchanged between the

EFI ECU
engine EFI ECU and the immobilizer ECU or the rolling Immobilizer ECU
codes are not matched.
(2) Remove the screws of the glove compartment sub-
assembly.
(3) Disconnect the connector of the Immobilizer ECU.
JEF00118-00582
(4) Check that continuity exists between the terminal 7

(Cowl wire side terminal of the Immobilizer ECU) and
terminal 40 (SST terminal). SST
If not, check the wire harness.
9 10 11
NOTE: 1 2 3 5 6 7 8
4
41 42 43
If the diagnosis code No. 43 is flashing, most likely it 37 38 39 40
33 34 35 36

shielding is poor. Immobilizer
If the trouble has not been solved by repairing the wire connector
(Wire harness side) 7
harness or connectors, then, proceed to the following
steps. JEF00119-00583

EF40
2. Check the Immobilizer system.
NOTE:
In cases where the ECU is replaced with a new EFI
ECU, be sure to use the master key to start the engine
for the first time. The engine will not start with a key
other than the master key. In cases where the ECU is
replaced with an EFI ECU other than a new one, the
engine will not start even if the master key is used.
For details, refer to the immobilizer manual. Master key
When the diagnosis code No. 81 occurs because of (black)
reasons other than abnormality of the wire harness, JEF00120-00585
most likely the immobilizer ECU is malfunctioning.

Refer to the immobilizer manual.

EF41
REPLACEMENT OF ECU
INSPECTION
NOTE:
Even when the replacement of the ECU is required in
previous checks, make sure that the ECU malfunction
has not been caused by factors other than the ECU by
carrying out the following checks. Then, proceed to re-
place the ECU.
The measurement of voltage should be conducted
while all of the connectors are connected. JEF00121-00701
CAUTION:
ECU, be sure to use the master key and connect the
test terminal with the earth terminal to start the engine
other than the master key.
In cases where the ECU is replaced with an EFI ECU
other than a new one, the engine will not start even if
the master key is used.
For details, refer to the immobilizer manual. JEF00122-00702
1. Install the SST. EFI ECU

See page EF18, Preparation of trouble shooting with
SST.
2. Measurement of voltage or resistance
(1) Measure the voltage or resistance between respective SST
terminals.
(2) Check to see if the measured voltage or resistance
conforms to the specifications in accordance with the 12 13 14
15 16 17
18 19 20 21 22
52 53 54
23 24 25
55 56 57
26 27 28
58 59 60
29 30
61 62
31 32
63 64
50 51
following CHARACTERISTICS OF ECU OUTPUT

47 48 49
9 10 11 44 45 46
6 7 8
4 5
1 2 3 41 42 43
39 40
36 37 38
33 34 35
table. JEF00123-00703

EF42
CHARACTERISTICS OF ECU OUTPUT (1)
Followings are standard voltage or resistance at ECU.
Item Standard
Terminal Condition Remedies
voltage or resistance
2 62 All times Battery voltage Check back-up fuse in the
relay box.
Power supply
11 62 Ignition switch is turned on. Battery voltage Check main relay in the
43 62 relay box.
20 All times 1 or less Check ground earth of
52 wiring harness.
Earth group
62
63
23 52 Ignition switch is turned on. 4.5 - 5.5 V Check ECU power supply.
Pressure 24 52 Ignition switch is turned on. Check pressure sensor.
3.3 - 4.0 V
sensor Atmospheric pressure is
101 kPa.
25 52 Ignition switch is turned on. 0.4 - 0.65 V Check cooling water
Water temp. After engine has warmed up temperature sensor.
sensor fully. (Cooling water
temperature is 80 - 90C.)
57 52 Ignition switch is turned on. Air 1.8 - 2.9 V Check air temp. sensor.
Intake air temp.
temperature sensor inside the
sensor
surge tank is 20 (68).
56 62 Engine is rotating at about Voltage varies within Check oxygen sensor.
Oxygen sensor 3000 r.p.m., after engine has 0.2 - 1.0 V
warmed up fully.
Cam angle 21 53 While the engine is being 0.1 - 0.3 V (AC range) Check crank angle sensor.
sensor cranked by the starter motor.
23 20 Ignition switch is turned on. 4.5 - 5.5 V
Ignition switch is turned on. 1.0 V or less
Throttle position Throttle valve is fully closed. Check throttle position
sensor 54 20 sensor.
Ignition switch is turned on. 3.5 - 4.1 V
Throttle valve is fully opened.
7 62 Ignition switch is turned on. Change in voltage Check speed sensor.
Vehicle speed When vehicle is moved. between 0.1 V and
sensor (Measured voltage changes 4 approx. 5 V
times for movement of 1.6 m)
Ignition coil 63 29 Ignition switch is turned on. 3 V or less Check ignition coil.
drive 63 64
Injector drive 31 62 Ignition switch is turned on. Approx. battery voltage Check injector(s).
32 62
33 62 Ignition switch is turned on. Approx. battery voltage Check fuel pump relay.
Fuel pump
or The terminal 34 is for
drive
34 62 immobilizer system.
42 62 Engine is rotating at about 1.8 - 3.2 V Check oxygen sensor.
VF monitor 3000 r.p.m. after engine has
warmed up fully.
Alternator 28 62 Engine is running. Approx. battery voltage Check alternator.
JEF00124-00704

EF43
CHARACTERISTICS ECU OUTPUT (2)
Standard
Item Terminal Condition Remedies
Headlamp switch is turned on. Approx. battery voltage Check headlamp fuse or
37 62 switch.
36 62 Ignition switch is turned on and Approx. battery voltage Check defogger fuse or
defogger switch is turned on. switch.
Electrical Ignition switch is turned on and 0.1 V or less Check heater blower
load heater blower switch is turned switch.
6 62 on.
Heater blower switch is Approx. battery voltage Check gauge fuse or heater
turned off. blower relay.
Ignition switch is turned on. 0.1 V or less Check tachometer.
Tachometer
signal 41 62 Engine is rotating at idling Approx. 6 V (AC range) Replace ECU.
speed.
Automatic When A/T shift lever is in P or 1 or less Check wire harness.
transmission 38 62 N range.
signal
5 62 When ignition SW is turned on Approx. battery voltage Check wire harness.
and A/C switch is turned on.
1 62 Engine is running at idling speed 3.0 V or less Check wire harness.
and A/C SW is turned on.
Air conditioner
signal 26 62 Engine is running at idling 0.1 V - 0.4 V Check wire harness.
speed and A/C switch is (AC range)
turned on.
3 62 Ignition SW is turned ON. 0.15 - 4.8 V Check wire harness.
60 62 Engine is running at idling 0.5 V or less Check wire harness.
speed and headlamp switch,
defogger switch or heater
Idle-up 59 62 Engine is running at idling 0.5 V or less Check wire harness.
VSV speed and headlamp switch,
control defogger switch or heater
58 62 Engine is running at idling 0.5 V or less Check wire harness.
speed and A/C switch is
turned on.
Test terminal 39 62 Ignition switch is turned on. 4.5 - 5.5 V Check ECU.
Check engine 10 62 Ignition switch is turned on. Approx. battery voltage Check wire harness.
lamp
JEF00125-00705
After completion of inspection

(1) Disconnect the ground cable terminal from the negative () terminal of the battery.
(2) Remove the SST by disconnecting its connectors from the ECU and engine wire connectors.
(3) Connect the wire harness connectors to the ECU.
(4) Reconnect the ground cable terminal to the negative () terminal of the battery.
JEF00126-00706

EF44
ECU REPLACEMENT IG OFF
1. Disconnect the ground cable terminal from the negative
() terminal of the battery.
2. Remove the glove compartment subassembly.
JEF00127-00707
3. Disconnect the wire harness connector from the ECU.

4. Remove the ECU by removing the attaching bolts and
nuts.
5. Install a new ECU.
CAUTION:
Never touch the bracket screws mounted on the ECU
proper. This tampering will cause an ECU malfunction.
6. Connect the wire harness connector to the ECU.

7. Install the glove compartment subassembly.
8. Connect the ground cable terminal to the negative () ter-
minal of the battery.
JEF00128-00708

EF45
INSPECTION OF IDLE-UP CONTROL SYSTEM
WIRING DIAGRAM
IG SW
ACC ACC
IG No. 1 IG1
IG No. 2 IG2
ST ST
Main MAIN
Engine
No. 2
10A
To starter relay
R/B
1
10A
EFI
18
Neutral
2 2 38 start
F/L 1.25
switch
F/L 2.0
Main
relay
6 19
13 EFI ECU VSV No. 3
Fuel
pump 33 58
relay
VSV No. 2
3 34
20
59
43
11 60
Fuel VSV No. 1
pump M
JEF00129-00901
UNIT INSPECTION
1. Remove the air cleaner case subassembly and its relevant
parts.
2. Disconnect the connector of the idle-up VSV.
3. Measure the resistance between the respective terminals
of the VSV.
X08
4. Ensure that the specified resistance exists between the
terminals described below. X09
Specified Value: 32 5
NOTE: JEF00130-00911
If the resistance will not conform to the specified value,

replace the idle-up VSV.
5. Apply a negative pressure of 13.3 kPa (100 mmHg) to the
VSV, using a MityVac or a vacuum pump.
6. Check to see if the negative pressure applied in the step 5
becomes zero when the battery voltage is applied to the
terminals of the VSV.
NOTE:
If not, replace the idle-up VSV.
JEF00131-00912

EF46
SYSTEM INSPECTION
VSV No. 1
1. Connect the SST between the EFI ECU connector and the
wire harness connectors. See page EF18.
2. With the engine running, measure the voltage between the
terminals 60 and 62 of the SST.
Condition Specified value
1 Until engine is warmed up fully after engine starting 26 27 28 29

30 31 32
23 24 25
from engine cold state. 61 62 63 64
58 59 60
55 56 57
2 Defogger switch is turned on. 0.5 V or less JEF00132-00941
3 Heater blower switch is turned on.

4 Headlamp switch is turned on. No. 1 No. 2
NOTE:
The measurement should not be performed when plur-
al conditions of those discribed above one met concur-
rently.
If the check results will not conform to the requirements
given in the table, check and repair those related sys-
tems.
JEF00133-00942
VSV No. 2
2. With the engine running, measure the voltage between the
terminals 59 and 62 of the SST.
Condition Specified value
Until engine is warmed up fully after engine starting
1 from engine cold state. 30 31 32
26 27 28 29
23 24 25
61 62 63 64
The shift lever has been moved from D, 2, L 55 56 57
58 59 60
2
or R to P or N. 0.5 V or less
JEF00134-00943
Defogger switch, heater blower switch and
3
headlamp switch have been turned on.
NOTE:
This VSV is equipped on A/T vehicles only.
If the check results will not conform to the requirements
given in the table, check and repair those related sys-
tems.
JEF00135-00944
VSV No. 3
2. With the engine running and air conditioner switch turned
on, measure the voltage between the terminals 58 and 62
of the SST.
Specified Value: 0.5 V or less
NOTE:
This VSV is used for the air conditioner system.
If the check results will not conform to the requirements 23 24 25
26 27 28 29
30 31 32
63 64
60 61 62
58 59
given in the table, check and repair those related sys- 55 56 57
tems. JEF00136-00945

EF47
INSPECTION OF FUEL SYSTEM
JEF00137-01001
FUEL TANK
UNIT INSPECTION
1. Check the fuel tank for deformation, cracks or fuel leak-
age.
2. Check the filler neck for damage or fuel leakage.
3. Check to see if the hose and tube connections are in-
stalled as shown in the right figure.
JEF00138-01002
4. Check to see if the fuel tank cap and gasket exhibit dam-
age.
NOTE:
If the fuel tank and its related parts exhibit any defect,
repair or replace the fuel tank.
Replace the gasket if it is damaged. Also, replace the
fuel tank cap if it exhibits damage.
JEF00139-01003

EF48
FUEL PUMP IG OFF
INSPECTION
See page EF14, Check of fuel system.
REMOVAL
2. Remove the fuel tank.
Refer to the BO section of the sevice manual.
WARNING:
Never allow any fire to be brought near the working JEF00140-01011
site.
3. Remove the fuel pump assembly.
INSTALLATION
1. Install a new fuel pump assembly to the fuel tank with a
new gasket interposed.
2. Tighten the attaching screws.
3. Install the fuel tank and its related parts to the body. JEF00141-01012
Refer to the BO section of the service manual.
FUEL LINE
REMOVAL & INSTALLATION OF QUICK CONNECTOR
WARNING:
Always keep fire away from the working site.
NOTE:
Always use a new gasket and a hose band (clip) when
replacing the fuel tank or components.
Each part should be tightened securely to the specified
torque. JEF00142-01013

EF49
Shape Part No. and name Purpose Remarks
09283-87703-000 * Inspection of injectors Used in combination

* Inspection of pressure with 09268-87702-000
Pressure regulator adapter regulator
* Inspection of fuel pressure
09268-87702-000 * Inspection of injectors Used in combination

* Inspection of pressure with 09283-87703-000
Injection measuring tool set regulator
* Inspection of fuel pressure
09268-87701-000 Inspection of fuel pressure
EFI fuel pressure gauge
09842-30070-000 Inspection of fuel injectors
EFI inspection wire
09991-87401-000 Measurement of engine

revolution speed
Engine control system Shorting terminal T
inspection wire
09991-87402-000 Measurement of engine

revolution speed
Tacho-pluse pick-up wire
09991-87403-000 Shorting terminal T
Diagnosis check wire
09842-87706-000 Inspection of computer

input/output voltage
EFI-II computer check
subharness
JEF00143-01101
TIGHTENING TORQUE
Tightening torque
Tightening components Remarks
Nm kgf-m
Ignition coil Cylinder head over 5.9 - 8.8 0.6 - 0.9
Spark plug Cylinder head 14.7 - 21.6 1.5 - 2.2
Cam angle sensor Cylinder head 14.7 - 21.6 1.5 - 2.2
Oxygen sensor Exhaust manifold 29.4 - 39.2 3.0 - 4.0
Cooling water temperature sensor Cylinder head 24.5 - 34.3 2.5 - 3.5
Intake air temperature sensor Intake head 29.5 - 39.2 3.0 - 4.0
Idle-up VSV Intake manifold 14.7 - 21.6 1.5 - 2.5
Delivery pipe Intake manifold 14.7 - 21.6 1.5 - 2.2
Fuel pump Intake manifold 1.5 - 2.5 0.15 - 0.25
JEF00144-01201

DAIHATSU
J100
LU
LUBRICATION SYSTEM
OIL PRESSURE WARNING ........................ LU 2

OIL PRESSURE CHECK ............................. LU 2
OIL PUMP .................................................... LU 3
COMPONENTS ...................................... LU 3
REMOVAL ............................................... LU 3
DISASSEMBLY ....................................... LU 4
ASSEMBLY ............................................. LU 7
INSTALLATION ....................................... LU 8
TIGHTENING TORQUE ............................... LU10
JLU00001-00001
NO. 9710-JE

LU2
OIL PRESSURE WARNING
1. Check to see if the oil pressure warning will be illuminated
when the ignition switch is turned on.
NOTE:
If the warning lamp will not go on, check to see if the
bulb in the combination meter is burnt out.
(Refer to the BE section of the service manual.)
If the warning lamp is illuminated when the engine has
started, perform the following checks.
(In advance, be sure to check that the engine oil is at a
JLU00002-00011
sufficient level.)
OIL PRESSURE CHECK

2. Disconnect the oil pressure switch connector.
3. Remove the oil pressure switch.
NOTE:
Use a hexagonal long box wrench for removal.
4. Install a suitable oil pressure gauge.

JLU00003-00101
5. Measuring of oil pressure

Start the engine and warm it up to the normal operating
temperature.
Ensure that the oil pressure is within the specification.
Specified Oil Pressure
At Idle Speed: 20 kPa or more
At 3000 rpm: 245 - 490 kPa
NOTE:
If the measured value fails to conform to the specified
value, check and repair the oil pump. JLU00004-00102
6.Stop the engine.

7.Remove the oil pressure gauge.
8.Clean the threaded portion of the oil pressure switch.
9.Wind seal tape around the threaded portion of the oil pres-
sure switch.
10. Install the oil pressure switch to the oil pump.
NOTE:
Use a hexagon long box wrench for the installation of JLU00005-00103
the oil pressure switch.
The new oil pressure switch is coated with sealer.
Therefore, when replacing the oil pressure switch with
the new one, remove the sealer thoroughly before
winding seal tape.
Be sure to clean the hole threads at the oil pump side
before installation of the oil pressure switch.
11. Connect the connector of the engine wire to the oil pres-
sure switch.
12. Start the engine and check it for oil leakage.
JLU00006-00104

LU3
OIL PUMP
COMPONENTS
Oil pump assembly
Oil filter
Oil pressure switch
Gasket
Oil strainer
JLU00007-00201
REMOVAL
NOTE:
In order to remove/install the oil pump, it is necessary
to remove the oil pan. For a reliable service, it is not
recommended to perform this operation with the engine
mounted on the vehicle. Therefore, this manual de-
scribes only for the operation that is to be performed
after the engine has been removed from the vehicle.
For the operations that precede the removal of the oil
pump, refer to the EM section of this manual. JLU00008-00202

LU4
1. Install the engine unit to the suitable engine stand.
Refer to EM section of the service manual.
2. Remove the oil filter element.
3. Remove the attaching bolts and nuts of the oil pan.
4. Separate the oil pan from the cylinder block.
JLU00009-00203
5. Remove the oil strainer by removing the attaching bolts.
JLU00010-00204
6. Remove the attaching bolts of the oil pump assembly

evenly.
7. Remove the oil pump from the cylinder block.
JLU00011-00205
DISASSEMBLY
1. Detach the oil pump cover by removing the attaching
screws.
JLU00012-00301
2. Remove the front oil seal.
Front oil seal

JLU00013-00302

LU5
3. Remove the oil pump rotor set.
JLU00014-00303
4. Pull out the cotter pin, while pushing the spring retainer
with nose pliers or the like.
NOTE:
Put an appropriate cloth, etc. on the retainer spring so
that it may not jump out.
5. Remove the oil pump relief valve spring retainer, compres-

sion spring and oil pump relief valve.
JLU00015-00304
6. Inspection of each part

(1) Wash the disassembled parts in cleaning solvent.
(2) Check the pump body for damage.
(3) Check the rotor set for damage.
(4) Check the oil pump relief valve for damage.
(5) Check the oil pump relief valve spring retainer for
damage.
NOTE:
Replace the each parts if it exhibits damage. JLU00016-00305
(6) Check the compression spring for damage. Also, mea-

sure its free length.
Specified Free Length: 57 mm
NOTE:
Replace the compression spring if it exhibits damage
or the free length is less than the specified value.
JLU00017-00306
(7) Apply engine oil to the oil pump relief valve. Insert the
oil pump relief valve into the oil pump body. Check to
see if the valve slides smoothly.
NOTE:
Replace the oil pump body if the valve fails to slide
smoothly.
JLU00018-00307

LU6
7. Measurement of body clearance, tip clearance and side
clearance
(1) Apply a thin film of engine oil to the rotor mate surface
of the oil pump body as well as to the rotor set.
Assemble the rotor set in the oil pump body in such a
way that the drilled mark may be seen from the out-
side.
JLU00019-00308
(2) Measure the body clearance between the oil pump

body and the outer rotor, using a thickness gauge.
Body Clearance: 0.20 - 0.28 mm
NOTE:
Replace the oil pump if the body clearance exceeds
JLU00020-00309
(3) Measure the tip clearance of the rotor set, using a

thickness gauge.
Tip Clearance: 0.16 - 0.24 mm
NOTE:
Replace the rotor set if the tip clearance exceeds the
specified value.
JLU00021-00310
(4) Measure the side clearance between the oil pump

body and the rotor set, using and a straightedge and a
thickness gauge.
Side Clearance: 0.04 - 0.08 mm
NOTE:
Replace the oil pump if the side clearance exceeds the
specified value.
JLU00022-00311
8. Check to see if any wear is present at the rotor set mate

surface of the pump cover.
NOTE:
Replace the oil pump cover if it exhibits wear.
JLU00023-00312

LU7
ASSEMBLY
NOTE:
Wash those parts to be assembled in cleaning solvent.
Dry them using compressed air.
WARNING:
eyes, wearing goggles. JLU00024-00411
1. Apply engine oil to the relief valve. Then, insert the relief
valve into the oil pump body.
2. Insert the compression spring and retainer into the oil
pump body.
CAUTION:
Install the retainer in such a direction that its projected
side may come at the compression spring side.
JLU00025-00412
3. Insert a new cotter pin into the retainer while the retainer is
being compressed with pliers, etc. Split the end of the cot-
ter pin to form an anchor-like shape.
JLU00026-00413
4. Drive a new oil seal into position if the oil seal exists dam-
aged, using a hydraulic press.
NOTE:
Be very careful not damage the oil pump during the re-
moval and the installation of the oil seal.
Make sure that the oil seal is not driven into position in
a tilted state.
JLU00027-00414
5. Apply engine oil to the rotor set. Assemble the rotor set in
the pump body in such a direction that the drilled mark of
Mark
the rotor may be seen from the outside.
JLU00028-00415

LU8
6. Install the oil pump cover. Tighten the cover to the speci-
fied torque.
JLU00029-00416
7. Turn the rotor by hand. Ensure that the rotor turns smooth-
ly.
If the rotor will not turn smoothly, overhaul the oil pump.
JLU00030-00417
INSTALLATION
1. Remove the gasket material of the sealer from the oil
pump and cylinder block.
2. Apply the Three Bond 1207-F (or 1207-C) to the oil pump
installation surface of the cylinder block, as indicated in
the illustration.
JLU00031-00511
3. Apply engine oil to the inner surface of the oil seal. O ring
4. Replace the O-ring of the oil pump with a new part.
JLU00032-00512
5. Install the oil pump to the cylinder block with the attaching
bolts.
CAUTION:
Be very careful not to damage the crankshaft oil seal
during the oil pump installation.
Be very careful not to drop the O-ring during the oil
pump installation.
JLU00033-00513

LU9
6. Install the oil strainer to the cylinder block with a new gas-
ket interposed.
Gasket
JLU00034-00514
7. Attach the oil pan gaskets to the cylinder block.

NOTE:
The oil pan gaskets are provided at two points; one at
the oil pump side and the other at the flywheel side. Fit
the protruding section of the gasket into the cut-out
section of the cylinder block.
JLU00035-00515
8. Apply the Three Bond 1207-F (or 1207-C) to the cylinder

block attaching section of the oil pan as shown in the right
figure.
NOTE:
Be sure to apply the Three Bond to both ends of the oil
pan gasket in such a way that the applied portions may
be overlapped.
Three Bond 1207C

JLU00036-00516
9. Install the oil pan to the cylinder block with the attaching
bolts and nuts.
10. Tighten the oil pan attaching bolts and nuts to the speci-
fied torque evenly over two or three stages.
JLU00037-00517

LU10
TIGHTENING TORQUE
Tightening torque
Nm kgf-m
Oil pressure switch
Oil pump 11.8 - 19.6 1.2 - 2.0
Oil pump cover

Oil pump 7.8 - 12.7 0.8 - 1.3
Oil pump Cylinder

block 5.9 - 8.8 0.6 - 0.9
Oil strainer
Cylinder block 14.7 - 21.6 1.5 - 2.2
Oil pan Cylinder

block 6.9 - 11.8 0.7 - 1.2
JLU00038-00801

DAIHATSU
J100
CO
COOLING SYSTEM
DESCRIPTION ................................... CO 2 INSPECTION OF WATER

RADIATOR ......................................... CO 3 PUMP-RELATED PARTS ........... CO11
RADIATOR CAP ............................ CO 3 INSTALLATION OF
RADIATOR RESERVE TANK ......... CO 3 WATER PUMP ........................... CO11
RADIATOR HOSES & PIPES ......... CO 4 THERMOSTAT ................................... CO13
FAN-EQUIPPED REMOVAL OF THERMOSTAT ....... CO13
FLUID COUPLING ......................... CO 5 INSPECTION OF
COOLING FAN ............................. CO 5 THERMOSTAT ........................... CO13
FLUID COUPLING WITH FAN ...... CO 5 INSTALLATION OF
WATER PUMP PULLEY ................. CO 6 THERMOSTAT ........................... CO14
THERMOSTAT ............................... CO 7 RADIATOR ......................................... CO15
PRECAUTIONS ................................. CO 8 CLEANING OF RADIATOR ........... CO15
CHECK & CHANGE OF INSPECTION OF RADIATOR ........ CO15
ENGINE COOLANT ....................... CO 8 REMOVAL OF RADIATOR ............ CO16
WATER PUMP ................................... CO10 INSTALLATION OF RADIATOR ..... CO17
COMPONENTS ............................. CO10 TIGHTENING TORQUE ..................... CO19
REMOVAL OF WATER PUMP ....... CO10 SERVICE SPECIFICATION ............... CO19
JCO00001-00000
NO. 9710-JE

CO2
DESCRIPTION
The cooling system is a water-cooled, forced-circulation type. Furthermore, it employs a fluid coupling fan.
The cooling system employs a bottom by-pass type in which the thermostat equipped with a by-pass valve
is provided at the inlet side.
The cooling system is composed of the radiator, water pump, thermostat, cylinder head, water jackets of
cylinder block, water hoses and their connecting parts.
The total capacity of the cooling water is approximately 5.4 L (for manual transmission models) and 5.3 L
(for automatic transmission models)
[HC-E Engine]
[View from left side]
[View from right side]
JCO00002-00001

CO3
RADIATOR
JCO00003-00002
Radiator specification
Item Specification
Fin pitch mm 1.6
Radiator water capacity L 1.66 (M/T) 1.54 (A/T)
Heat radiating rate W/h 48.3
Core dimensions (width height thickness) mm 572 425 27
JCO00004-00000
RADIATOR CAP
A pressure type radiator cap is installed at the upper part of
the radiator.
The radiator cap has two valves: a pressure regulating valve
and a negative pressure valve.
When the pressure of the cooling system exceeds a specified
limit, the rising pressure opens the pressure regulating valve
of the radiator cap. As a result, the coolant in the radiator
flows to the reserve tank.
JCO00005-00003
On the other hand, the negative pressure valve opens when

the inner pressure drops below the atmospheric pressure due
to a dropped water temperature after the engine has stopped.
Thus, the coolant returns from the reserve tank to the radiator.
Radiator cap specifications

Item Specifications
2
Radiator cap opening pressure kPa (kgf/cm ) 88.3 (0.9)
JCO00006-00004
RADIATOR RESERVE TANK

A reserve tank with an overflow hose is employed.
Specifications
Total capacity L 1.1 or more
F level 0.6
Cooling water capacity L FULL
L level 0.15 LOW
JCO00007-00005

CO4
RADIATOR HOSES & PIPES
These components come in four radiator hoses and two radiator pipe subassemblies.
Radiator hose No. 1 Radiator pipe No. 1 to radiator upper tank
No. 2 Radiator lower tank to inlet of cylinder block section
No. 4 Outlet at rear of cylinder head to radiator pipe No. 1
Radiator pipe No. 1 Radiator hose No. 4 to radiator hose No. 1
JCO00008-00000
Radiator
hose No. 4
(to water outlet)
[View from left side]

Radiator hose No. 1 Radiator pipe No. 1
Water inlet
Radiator hose
No. 2
[View from right side]
JCO00000-00006

CO5
FAN-EQUIPPED FLUID COUPLING
The fan-equipped fluid coupling with a temperature control
device is employed in order that the noise level may be re-
duced.
Furthermore, the drop in engine output due to the installation
of cooling fan has been kept to a minimum level.
JCO00009-00000
1. COOLING FAN
The fan made of propylene is a seven-blade fan.
JCO00010-00007
Specifications
Item Specification
Fan outer diameter mm 380
Number of blades 7
Type Axial flow
0.40 at 1000 rpm
Air flow rate m3/sec
0.85 at 2000 rpm
JCO00011-00000
2. FLUID COUPLING WITH FAN

The fluid coupling employs a two-stage temperature control
type.
The fluid coupling is available in two kinds. The optimum fluid
coupling can be selected and installed in accordance with
the vehicle specifications.
JCO00012-00000
Specifications
Specifications
Item
M/T A/T
Fluid coupling outer diameter mm 136
Fan revolution speed 1300 at 70C
rpm
(when the water pump revolution speed is 4000 rpm) 2500 at 80C 2900 at 80C
JCO00013-00000

CO6
Operation of coupling fan
During cold operation (Below about 55C)
When the cooling water temperature is low, the port is closed Port Operating
by the coupling divider. Consequently, the silicon oil will not Chamber
move into the operating chamber. Hence, the coupling body
remains at its low speed operation.
During hot operation

Spiral
(Above about 70C) Bimetal
When the spiral bimetal detects the temperature of the air
passing through the radiator, this rotates the coupling divider
integral with the bimetal shaft. As a result, the silicon oil flow-
ing out from the port enters into the operating chamber, thus
pushing the coupling rotor. Consequently, the coupling body
is rotated.
As is explained above, the revolution speed of the coupling
fan is switched over two stages. In this way, the output loss
due to the cooling fan has been kept at a minimum level and Coupling
the fan noise level has been reduced. Divider Coupling
Body
Coupling rotor
JCO00014-00008
3. WATER PUMP PULLEY

The water pump pulley is made of sheet metal. This pulley is
attached to the water pump pulley seat along with the fluid
coupling by means of four nuts.
All water pump pulleys use a V rib belt.
JCO00015-00000
Water pump
The water pump used for circulating the cooling water is in-
stalled at the front section of the cylinder block.
Specifications
Item Specifications
Type Centrifugal type
Delivery output
(When shaft revolution speed is 2000 rpm) L/min 35
Rotor outer diameter mm 62 JCO00016-00010

CO7
THERMOSTAT
The thermostat is a wax type with a bypass valve. The thermostat helps the engine to warm up quickly by
allowing the cooling water to be recirculated through the cylinder block and cylinder head without passing
through the radiator.
Furthermore, the thermostat is equipped with a jiggle pin which performs the air bleeding while the engine
is stopped. Also, the jiggle pin allows the temperature of the cooling water to rise quickly during the warm-
ing-up period.
Moreover, a baffle plate attached to the thermostat makes it possible to get better temperature sensing
characteristics.
Jiggle pin Jiggle pin
Position of
jiggle pin
(just top position)
jiggle pin
Baffle plate
JCO00017-00011
Thermostat specifications
Item Standard specifications Cold region specifications
Type Wax type
Valve opening temperature C 78 84
Valve full opening temperature C 91 97
JCO00018-00000

CO8
PRECAUTIONS
As regards water to be used as cooling water, use soft water which does not contain salts of minerals,
calcium, magnesium and so forth.
If the coolant gets to the vehicle body, immediately flush away the coolant using water.
Never open the radiator cap when the cooling water is hot.
WARNING:
The inside of the radiator is under a pressurized condition when the cooling water is hot. Therefore, if
the radiator cap should be removed, the cooling water will blow off, possibly causing injuries such as
scald.
JCO00019-00000
CHECK & CHANGE OF ENGINE Reserve

COOLANT tank cap
1. Check of coolant level

Check to see if the coolant level is between the LOW and
FULL lines of the reserve tank.
If the coolant level is near the low level or below the low Full line
FULL
level, add the coolant up to the full level. LOW
Low line
JCO00020-00012
2. Check of coolant quality

There should not be any excessive deposits of rust or
water scales around the radiator cap or the radiator filler
hole. Also, the coolant should be free of oil.
Change the coolant if it is excessively dirty or the time due
to change the coolant has already arrived.
WARNING:
Never open the radiator cap when the engine is hot.
JCO00021-00013
3. Change of engine coolant

WARNING:
Never open the radiator cap and/or the drain plug when
the engine is still hot. Care must be exercised to avoid
getting scalded.
JCO00022-00000
(2) Remove the engine under cover.

(3) Place an adequate container below the radiator drain
plug. Drain the coolant by removing the drain plug.
(4) Close the drain plug.
(5) Fill the system with water.
(6) Start the engine, and stop it.
(7) Repeat the steps (1) through (5) two to three times.
NOTE:
Replace the drain plug gasket with a new one.
JCO00023-00014

CO9
(8) Fill the radiator and reserve tank with antifreeze solu-
tion in accordance with the instructions of the manu-
facturer of the antifreeze solution.
CAUTION:
Use a Good brand of ethylene-glycol base antifreeze
solution.
Coolant Capacity (Vehicle with front heater):
5.3 liter (for automatic transmission)
5.4 liter (for manual transmission)
JCO00024-00015
(9) Fill the system with water.

(10) Start the engine. Check the coolant level. Add water,
as required.
(11) Tighten the radiator cap.
(12) Warm the engine. Afterwards, allow the coolant to cool
down to the atmospheric temperature. Recheck the
coolant level at the reserve tank. Add coolant to the full
level, as required.
If no coolant remains at all in the reserve tank, recheck
the coolant level in the radiator. Replenish the radiator
with water, as required. Replenish the reserve tank with JCO00025-00016
coolant up to the full level.

NOTE:
Here, the coolant refers to the mixture of water and an-
tifreeze that has been mixed in accordance with the in-
structions of the antifreeze manufacturer.
(13) Install the engine under cover with attaching bolts.

CO10
WATER PUMP
COMPONENTS
Dust seal : Non-reusable parts
Nut
B
Fluid Water pump
coupling pulley

Gasket
Water pump
Nut
JCO00026-00017
REMOVAL OF WATER PUMP

2. Remove the engine under cover.
3. Drain the coolant. (See page CO8.)
Open the radiator cap and drain plug, and allow the
coolant to drain into a container.
WARNING:
Never open the radiator cap and/or drain plug. When
the engine is hot.
JCO00027-00018

JCO00028-00019
5. Remove the water pump by removing the attaching bolts

and nuts of the water pump.
JCO00029-00020

CO11
INSPECTION OF WATER PUMP-RELATED PARTS
1. Check the water pump pulley for damage or deformation.
Replace the water pump if it exhibits damage or deforma-
tion.
JCO00030-00021
2. Visually inspect the water pump rotor for damage or defor-

mation.
Replace the water pump if the water pump rotor exhibits
damage or deformation.
JCO00031-00022
3. Ensure that the water pump rotates smoothly by hand.

Replace the water pump if it will not rotate smoothly.
JCO00032-00023
4. Check the water pump cover section of the cylinder block

for damage or wear.
Replace the cylinder block if the water pump cover sec-
tion exhibits damage or wear.
JCO00033-00024
INSTALLATION OF WATER PUMP

1. Remove the gasket material from the water pump in-
stalling surface of the cylinder block, using a gasket
scraper.
JCO00034-00000

CO12
2. Remove the gasket material from the water pump, using a
gasket scraper.
JCO00035-00025
3. Install a new gasket to the cylinder block.
JCO00036-00026
4. Install the water pump to the cylinder block. Tighten the

attaching bolts and nuts evenly over two or three stages to
Tightening Torque:
14.7 - 21.6 Nm (1.5 - 2.2 kgf-m)
NOTE:
After tightening bolts, ensure that the water pump ro-
tates smoothly by hand.
JCO00037-00027
5. Install the timing belt.

JCO00038-00028
6. Fill coolant.
(See page CO9.)
7. Install the engine under cover.
8. Connect the battery ground cable to the negative () ter-
JCO00039-00029

CO13
THERMOSTAT
REMOVAL OF THERMOSTAT
() terminal of battery.
2. Drain the coolant
(See page CO8.)
WARNING:
Never open the radiator cap and/or drain plug when the
coolant is hot.
JCO00040-00030
3. Remove the power steering vane pump assembly.

4. Remove the radiator hose No. 2 from the water inlet.
CAUTION:
Cover the alternator to prevent entering the cooling
water to the alternator.
JCO00041-00031
5. Remove the water inlet and the thermostat.
JCO00042-00032
INSPECTION OF THERMOSTAT
1. Ensure that the thermostat valve is closed completely at
room temperature 20C and the spring has no play.
Replace the thermostat if the valve is open or the spring
has a play.
JCO00043-00033
2. Check the rubber grommet of the thermostat for damage

or crack.
Replace the thermostat if the rubber grommet exhibits
damage or crack.
JCO00044-00034

CO14
3. Immerse the thermostat in water, and check the valve
opening temperature by heating the water gradually.
Valve opening
Specifications Valve lift
temperature C
Cold region 8.5 mm or more at
specifications 82 - 86
97C
Standard 8.5 mm or more at
76 - 80
specifications 91C
Replace the thermostat if the valve operation fails to con-

form to the specifications. JCO00045-00035
INSTALLATION OF THERMOSTAT
1. Assemble the thermostat in such a way that the jiggle pin
comes exactly at the top of the engine.
NOTE:
The thermostat should be installed in such a way the
jiggle pin may face upward. Failure to observe this cau-
tion may cause engine malfunction.
JCO00046-00036
2. Install the water inlet.

3. Install the power steering vane pump assembly into posi-

tion.
JCO00047-00037
4. Fill coolant.
(See page CO9.)
minal of battery.
6. Start the engine and check it for leakage.
Repair the leaky point if the leakage exists.
JCO00048-00038

CO15
RADIATOR
CLEANING OF RADIATOR
Using water or steam cleaner, remove mud and dirt from the
radiator core.
CAUTION:
When using a high pressure type cleaner, be careful
not to deform radiator core fins.
Keep a distance of more than 40 - 50 cm between the
radiator core and cleaner nozzle when the cleaner noz-
zle pressure is 2.9 - 3.4 MPa (30 - 35 kgf/cm2). Also, JCO00049-00039
the injection angle of pressurized water should be right
angles to the radiator.
INSPECTION OF RADIATOR
1. Check of radiator cap
(1) Check the radiator cap by means of a radiator cap
tester to see if the relief valve opens at a pressure of
74 - 103 kPa (0.75 - 1.05 kgf/cm2).
If the radiator cap does not conform to the specifica-
tion, replace the radiator cap.
WARNING:
Never open the radiator cap when the engine is hot.
JCO00050-00040
(2) Check the seal packing of the radiator cap for dam-
age.
Replace the radiator cap with a new one, if any dam-
age exists.
JCO00051-00041
(3) Lift the valve at the vacuum side with your fingers.
Ensure that the valve is functioning properly.
Replace the radiator cap with a new one, if the valve
fails to function.
JCO00052-00042

CO16
2. Check of cooling system for leakage
(1) Fill the radiator with coolant. Attach a radiator cap
tester.
(3) Apply a pressure of 118 kPa (1.2 kgf/cm2) to the cool-
ing system by means of a radiator tester.
If the pressure drops, check the hoses, radiator, water
pump and heater for evidence of leakage.
If no external leakage is found, check the heater core,
cylinder block, cylinder head, oil cooler and throttle
body for evidence of leakage. JCO00053-00043
Check the hoses for deterioration, cracks, bulge or

damage.
Replace the defective part(s) if necessary.
(4) Remove the radiator cap tester from the radiator.
WARNING:
Never remove the radiator cap tester when the coolant
temperature is high.
REMOVAL OF RADIATOR
1. Disconnect the battery ground cable terminal from the
negative () terminal of the battery.
2. Drain the coolant as follows:
WARNING:
Never open the radiator cap and/or drain plug when the
coolant is hot.
JCO00054-00044
(2) Remove the engine under cover.

(3) Place a suitable container below the radiator drain
plug. Drain the coolant by removing the drain plug.
(4) Tighten the drain plug.
3. Disconnect the two oil cooler hoses for the automatic JCO00055-000045
transmission. (A/T vehicle for European market only)

NOTE:
Receive the oil with a suitable container because the
torque converter oil flows out.
Prevent oil flowing by installing suitable plugs to the
disconnected hoses.
CAUTION:
Never reuse the oil cooler hoses and hose bands for
automatic transmission use. Failure to observe this
caution will cause the hoses to be disconnected. JCO00056-00046

CO17
4. Removal of radiator
(1) Temporarily detach the power steering vane pump.
(2) Remove the radiator hose No. 1 and the breather
hoses at radiator side.
CAUTION:
When the radiator hose is loosened, be sure to protect
the alternator because the coolant flows out.
(3) Disconnect the radiator hose No. 2 from the radiator

lower tank.
JCO00057-00047
(4) Remove the two attaching bolts of the radiator upper

tank.
(5) Remove the two attaching bolts of the fan shroud.
Then, disconnect the lock section of the fan shroud
from radiator.
(6) Remove the four attaching nuts of the cooling fan.
(7) Remove the fan shroud and the cooling fan at the
same time.
(8) Remove the radiator.
JCO00058-00048
JCO00000-00049
INSTALLATION OF RADIATOR
1. Radiator installation
(1) Place the radiator fan shroud to the cooling fan side.
(2) Install the radiator in the engine room.
NOTE:
Before attaching the fan shroud to the radiator, insert
the lock section of the fan shroud to the lower section
of the radiator.
JCO00060-00050
(3) Tighten the two attaching bolts of the radiator upper

tank.
(4) Tighten the two attaching bolts of the fan shroud.
JCO00061-00051

CO18
(5) Connect the radiator hose No. 1 and the breather
hoses to the radiator upper tank.
(6) Connect the radiator hose No. 2 to the radiator lower
tank.
JCO00062-00052
(7) Connection of oil cooler hoses (A/T vehicle for

European market only)
q Remove the oil cooler hoses.
w Wipe off any oil from the connecting section of the
oil cooler hoses.
e Connect new oil cooler hoses. Install new hose
clips.
CAUTION:
Never reuse the oil cooler hoses and hose clips.
Make sure that no oil or dirt gets to the connected sec-
tions. JCO00063-00053
Failure to observe this caution will cause the hoses to

be disconnected.
(8) Add automatic transmission oil

(See the Chassis Workshop Manual)
(9) Install the power steering vane pump.
JCO00064-00054
2. Fill the coolant.

(See page CO9.)
4. Start the engine and check it for leakage.
Repair the leaky point if leakage exists.
JCO00065-00055

CO19
TIGHTENING TORQUE
Tightening torque
Tightening component Remark
Nm kgf-m
Cylinder head Water temperature sensor 24.5 - 34.3 2.5 - 3.5 Dry
Cylinder block Water inlet 5.9 - 8.8 0.6 - 0.9 Dry
Cylinder block Water pump 14.7 - 21.6 1.5 - 2.2 Dry
Fluid coupling Water pump pulley Water pump 10 - 18 1.0 - 1.8 Dry
Cooling fan Fluid coupling 4.3 - 6.5 0.44 - 0.66 Dry
JCO00066-00000
SERVICE SPECIFICATION
Coolant capacity w/heater [Excluding 1.1 L for reserve tank] 5.4 L (M/T) 5.3 L (A/T)
Radiator cap Relief valve opening pressure
Standard 73.5 - 103.0 kPa (0.75 - 1.05 kgf/cm2 )
Minimum 58.8 kPa (0.6 kgf/cm2)
Thermostat Valve opening temperature
Cold region 82 - 86C
specifications
Standard 76 - 80C
specifications
Valve lift
Cold region 8.5 mm or more at 97C
specifications
Standard 8.5 mm or more at 91C
specifications
JCO00067-00000

DAIHATSU
J100
IGNITION SYSTEM IG
WIRING DIAGRAM ....................................... IG 2

SPARK TEST ................................................ IG 3
SPARK PLUG .......................................... IG 3
POWER SUPPLY ..................................... IG 4
IGNITION WIRE ....................................... IG 5
IGNITION COIL ....................................... IG 5
CAM ANGLE SENSOR ............................ IG 5
EFI ECU ................................................... IG 7
IGNITION TIMING ......................................... IG 9
TIGHTENING TORQUE ................................ IG10
SSTs ............................................................. IG10
JIG00001-00001
NO. 9710-JE

IG2
WIRING DIAGRAM
F/L 1.25 ACC

IG No. 1
IG No. 2
ST
IG SW
Main
F/L
FUSE 10A FUSE

10A
(Engine) (Back-up)
Ignition coil
(#1,#4 Cylinder)
Ignition coil
(#2,#3 Cylinder)
64 29 2
EFI ECU
21 53 7 41
Vehicle
speed
sensor
Tachometer
Cam angle
sensor
JIG00002-00011

IG3
SPARK TEST
SPARK PLUG
1. Remove the air cleaner case and relative parts.
2. Connect a timing light to the ignition wire of the No. 1
cylinder.
3. Ensure that the timing light flashes while the engine is
being cranked by the starter motor.
NOTE:
If the timing light will not flash, perform the following in-
spection. JIG00003-00101
4. Remove the ignition wire from the spark plug at the cylin-
der No. 1.
5. Connect a spark plug to the ignition wire.
6. Check ignition sparks while the engine is being cranked
by the starter motor.
WARNING:
Before performing this operation, check that no fuel is
spilled inside the engine compartment. Remove any
spilled fuel. Also, be sure to perform this operation at a
well-ventilated place where no volatile liquid, gas, etc.
JIG00004-00102
exist nearby.
NOTE:
If no ignition sparks occur, check power supply.
7. Remove the spark plug.
CAUTION:
When the operation of the step 7 is performed, care
must be exercised to avoid getting scalded, for the
spark plugs may be still very hot.
8. Cleaning of spark plug

NOTE:
If there are traces of oil, remove it with gasoline before
the spark plug is cleaned by the spark plug cleaner.
If the electrode has traces of wet carbon, dry the elec-
trode and clean it with a spark plug cleaner.
Air Pressure: Not to exceed 588 kPa
Duration: Less than 20 seconds
JIG00005-00103
9. Visually inspect the spark plug for electrode wear, thread

or insulator damage.
NOTE:
Replace the spark plug if it exhibits damage.
JIG00006-00104

IG4
10. Inspection of electrode gap
Measure the electrode gap, using the plug gap gauge.
Electrode Gap: See page IG9
NOTE:
one.
If the electrode gap of a new spark plug is not within
the specification, adjust the gap by bending the base of
the ground electrode, being careful not to touch the tip. JIG00007-00105
All four plugs should be the same heat range and be

ones manufactured by the same manufacturer.
11. Inspection of spark plug insulation resistance

More Than 20 M
NOTE:
If the insulation resistance is less than the specified
value, replace the spark plug.
JIG00008-00106
12. Install the spark plugs. Tighten them to the specified

torque.
13. Install the ignition coil with ignition wire to the cylinder
head cover.
14. Connect the ignition wire to the spark plug.
15. Install the air cleaner case and relative parts.
JIG00009-00107
POWER SUPPLY
1 2 3
2. Disconnect the connector of the ignition coil.
3. Measure the voltage between the terminals 1 and 3 of the
wire harness connector side when the ignition switch is
turned on.
Specified Value: Battery voltage
NOTE:
If the voltage is not the specified value, check the fuse
and wiring harness. JIG00010-00201
4. Connect a test lamp (12 V, 6 W) between the terminals 2

and 3 of the wire harness connector side. Check to see if 1 2 3
the lamp will illuminate while the engine is being cranked.
NOTE:
Under this condition, the test lamp flashes. If the test
lamp will not flash, check the outputs of the cam angle
sensor and EFI ECU. (Refer to the EF section of the
service manual.)
JIG00011-00202

IG5
IGNITION WIRE
3. Remove the ignition coil by removing the attaching nuts.
4. Disconnect the spark plug distance piece and the ignition
wire from the ignition coil.
NOTE:
Carefully remove the ignition wire from the spark plugs
and ignition coil by holding their rubber boots.
JIG00012-00301
5. Check that the ignition wire resistance is about same as

the specification.
q e
Ignition Wire 3: 5.6 k
NOTE: w
Spark plug distance piece 1: 0.3 (Cylinder No. 2
and No. 4)
Ignition wire 2: 3.8 k (Cylinder No. 3)
If the above inspection will conform to the specification,
perform the following procedure.
JIG00013-00302
IGNITION COIL
3. Remove the ignition coil by removing the attaching nuts.
4. Disconnect the spark plug distance piece and the ignition
wire from the ignition coil.
5. Check that the ignition coil resistance is within the specifi-
cation.
Secondary Coil: 13.6 2.0 k
NOTE: JIG00014-00401
For the primary coil, it is impossible to check the resis-

tance because it incorporates electronic parts.
CAM ANGLE SENSOR

2. Disconnect the connector of the cam angle sensor.
3. Measure the resistance between each terminal of the con-
nectors.
Specified Value: 230 25 (at 20C)
JIG00015-00501
4. Check to see if a signal shown in the graph appears at the

terminals when the engine is being cranked by the starter
motor.
NOTE:
When the voltage across the connector terminals is
measured during the engine cranking period, using an
oscilloscope, you will get wave forms as indicated in
the illustration, if the signal generator is functioning nor-
mally.
JIG00016-00502

IG6
5. Remove the cam angle sensor from the cylinder head by
removing the attaching bolt.
6. Remove the cam angle sensor cover.
7. Turn the shaft of the rotor, until the signal rotor faces to-
ward the signal generator.
8. At all four points, check to see if the air gap between the
signal generator and the signal rotor conforms to the
specified value.
Specified Air Gap: 0.2 - 0.4 mm
NOTE: JIG00017-00503
If the air gap fails to conform to the specified value, ad-

just the air gap.
9. Adjustment of air gap.

(1) Loosen the attaching screws of the signal generator.
(2) Adjust the air gap between the signal generator and
the signal rotor to specified value.
(3) Tighten the attaching screws of the signal generator.
JIG00018-00504
10. Install the cam angle sensor cover.

11. Install the cam angle sensor to the cylinder head. tighten
the attaching bolt.
JIG00019-00505
12. Check the ignition timing and adjust it, as required.

(See page IG9)
JIG00020-00506

IG7
EFI ECU
1. Check to see if diagnosis detect malfunction code.
(Refer to EF section of the service manual)
2. Connection of SST
(Refer to EF section of the service manual)
JIG00021-00701
NOTE:
The EFI unit can be checked by measuring the resis- IG OFF
tance or voltage at the SST terminals.
(1) Disconnect the battery ground cable from the negative

CAUTION:
Be sure to memorize the malfunction code before dis-
connecting the battery cable. Otherwise the malfunc-
tion code(s) is erased by disconnecting of the battery
code.
JIG00022-00702
(2) Disconnect the wire harness connectors from the EFI

ECU connectors at the upper side of the glove com-
EFI ECU
partment.
(3) Connect the following SST between the wire harness
connectors and the EFI ECU connectors.
SST: 09842-87706-000
SST
29 30 31 32
26 27 28
23 24 25 61 62 63 64
58 59 60
18 19 20 21 22 55 56 57
15 16 17
12 13 14 50 51 52 53 54
47 48 49
9 10 11 44 45 46
7 8
4 5 6
1 2 3 41 42 43
39 40
36 37 38
33 34 35
JIG00023-00703
(4) Reconnect the battery ground cable to the negative ()

CAUTION:
When disconnecting or reconnecting the EFI ECU con-
nectors, be sure to disconnect the battery ground cable
from the negative () terminal of the battery when the
ignition switch and all accessory switches are in the off
state.
When installing new battery, care must be exercised
not to mistake the battery polarity. Failure to observe
this caution could cause ECU malfunction.
Before using the SST, be sure to check to see if short
or open wire exists between the terminals of the SST.
JIG00024-00704
NOTE:
Even when the replacement of the ECU is required in
previous check, make sure that the ECU malfunction
has not been caused by factors other than the ECU by
carrying out the following checks. Then, proceed to re-
place the ECU.
The measurement of voltage should be conducted
while all of the connectors are connected. JIG00025-00705

IG8
CAUTION:
ECU, be sure to use the master key and connect the
test terminal with the earth terminal, to start the engine
other than the master key.
Refer to BE section of service manual. (Immobilizer
system)
In cases where the ECU is replaced with an EFI ECU
other than a new one, the engine will not start even if
the master key is used. JIG00026-00706
For details, refer to the immobilizer manual.
3. Measurement of the voltage or resistance

(1) Measure the voltage or resistance between each ter- SST
minal.
(2) Check that if the measured voltage or resistance con-
12 13 14 15 16 17 18 19 20 21 22
form to the specifications in accordance with the fol- 44 45 46 47 48 49 50 51 52 53 54
lowing table.
JIG00027-00707
CHARACTERISTICS OF ECU OUT PUT

Standard
Family Terminal Condition Remedies
Check back up fuse in the
2 - 62 All time Battery voltage
relay box
Power supply
11 - 62 Check main relay in the
Ignition switch is turned on Battery voltage
43 - 62 relay box
20
52 Check ground earth of
Earth group All time 1 or less
62 wiring harness
63
Cam angle While the engine is being
21 - 53 0.1 - 0.3 V (AC range) Check crank angle sensor
sensor cranked by the starter motor.
Ignition coil 63 - 29
Ignition switch is turned on. 3 V or less Check ignition coil
drive 63 - 64
JIG00028-00708
NOTE:
If the measured voltage or resistance is not conform to
the specified value, check the wiring harness.
Even when the trouble has not been solved by the re-
pair the wire harness or parts, replace the EFI ECU.
JIG00029-00709
After completion of the inspection

1. Disconnect the ground cable terminal from negative ()
2. Remove the SST by disconnecting its connectors from the
ECU and engine wire connectors.
3. Connect the wire harness connectors to the ECU.
4. Reconnect the ground cable terminal to the negative ()
terminal of the battery. JIG00030-00710

IG9
IGNITION TIMING Diagnosis connector
1. Connect the test terminal and the earth terminal with a
jumper wire of the diagnosis connector.
2. Connect a timing light to the ignition wire of the No. 1 Earth
Test
cylinder. terminal terminal
4. Check to see if the ignition timing mark of the crankshaft
pulley is aligned with the indicator of the timing belt cover,
using the timing light.
5. Adjust the ignition timing by turning the cam angle sensor,
JIG00031-00801
if the ignition timing mark is not aligned with timing belt
cover.
Ignition Timing: B.T.D.C. 0 2/Idle speed
6. Adjustment of ignition timing

(1) Loosen the cam angle sensor attaching bolts.
(2) Adjust the cam angle sensor installation angle by turn-
ing the cam angle sensor, until the ignition timing mark
of the crankshaft pulley is aligned with the indicator of
the timing belt cover.
JIG00032-00802
NOTE:
If the cam angle sensor is turned clockwise, the timing
will be advanced. Conversely, if the cam angle sensor
is turned counterclockwise, the ignition timing will be
retarded.
(3) Tighten the cam angle sensor attaching bolts to the

specified torque, making sure that the ignition timing is
not disturbed.
JIG00033-00802
Recommended spark plug

Manufacturer Type Electrode air gap
NGK BKUR6EK 0.9 - 1.0 mm
DENSO K20TNR-S 0.9 - 1.0 mm
JIG00034-00803

IG10
TIGHTENING TORQUE
Tightening torque
Nm kgf-m
Cam angle censor
14.7 - 21.6 1.5 - 2.2
Cylinder head
Spark plug Cylinder head 14.7 - 21.6 1.5 - 2.2

JIG00035-00901
SSTs
Shape Part number Part name Remarks
09842-87706-000 Inspection of computer

EFI computer check input/output voltage &
sub harness resistance
32
29 30 31
26 27 28
23 24 25 61 62 63
64
21 22 58 59 60
18 19 20 55 56 57
15 16 17 53 54
12 13 14 50 51 52
47 48 49
10 11 44 45 46
7 8 9
4 5 6 42 43
1 2 3 39 40 41
36 37 38
33 34 35
JIG00036-00902

DAIHATSU
J100
STARTING SYSTEM
ST
STARTING SYSTEM CIRCUIT .................... ST 2
STARTER MOTOR ....................................... ST 3
COMPONENTS ...................................... ST 3
SERVICING INSTRUCTIONS OF
STARTER ............................................ ST 4
IN-VEHICLE INSPECTION ...................... ST 4
REMOVAL ............................................... ST 5
PLANETARY TYPE STARTER
MOTOR .............................................. ST 5
INSTALLATION OF STARTER
MOTOR .............................................. ST19
SERVICE SPECIFICATIONS ....................... ST21
TROUBLE SHOOTING ................................ ST21
JST00001-00000
NO. 9710-JE

ST2
STARTING SYSTEM CIRCUIT
Ignition switch
Engine
ST Starter relay* ECU
#8
M/T vehicle only
Neutral start switch*

Fusible link
Planetary type
starter ST
B
Battery
(AT vehicle only)
* : AT vehicle only
JST00002-00001

ST3
STARTER MOTOR
COMPONENTS
0.8 kW, Planetary Type Starter Motor
!4
!5
!3
!1
For automatic
transmission vehicles !2
o !0
i
u
y
t
r
e
For manual !9
transmission vehicles
q w
!7
!6
!8
@4
@0
@1
@2 : Non-reusable parts
@5 @3 : Asbestos parts
q Bearing !0 Center bearing !9 Brush holder

w Drive housing !1 Magnet switch @0 O-ring
e Snap ring !2 Internal gear @1 Yoke
r Stop collar !3 Washer @2 O-ring
t Clutch !4 Planet carrier shaft @3 Plate
y Snap ring !5 Bearing @4 Planet gear
u Washer !6 End frame @5 Washer
i Drive lever !7 Bearing
o Bearing !8 Armature
JST00003-00002

ST4
SERVICING INSTRUCTIONS OF STARTER
1. When connecting the starter terminal or battery terminal, perform positive tightening so as to avoid poor
connection.
If poor connection should exist, it presents the hazard of serious danger that a large amount of current
flowing during starter operation can overheat the poor connection.
2. When removing the starter, first disconnect the negative ; terminal of the battery. Then, disconnect the
positive terminals (+B, ST) at the starter side. Since the battery voltage is always applied to the starter
+B terminal, failure to observe this removing sequence may lead to battery short, which is extremely
dangerous.
3. When installing the starter, install the starter in the clutch housing positively and be sure to tighten the
attaching bolts to the specified torque. Improper installation can cause premature wear of the teeth of
the pinion gear or ring gear and also can cause breakage of the clutch housing.
JST00004-00000
IN-VEHICLE INSPECTION
1. Place the shift lever to the neutral position. Apply the park-
ing brake lever.
2. Disconnect the ignition coil coupler so that the engine will
not start.
JST00005-00003
3. Set the ignition switch to the ST position. Check to see if

the engine cranks.
4. If the engine will not crank, perform the following checks.
Inspect the battery for damage. Charge the battery.
Perform harness continuity test.
5. If the starter motor still will not rotate even after the checks
above have been performed, remove the starter motor
and perform the unit check.
JST00006-00000

ST5
REMOVAL
JST00007-00000
2. Remove the battery and battery carrier.

(Refer to the GI Section of the service manual.)
4. Removal of starter motor attaching bolt
(1) Remove the upper side and lower side attaching bolt
from the under side of the vehicle.
JST00008-00004
5. Disconnection of two wires from starter

(1) Disconnect the starter terminal ST of the alternator wire
from the starter.
(2) Disconnect the starter terminal B of the alternator wire
from the starter.
6. Remove the starter motor.
JST00009-00005
PLANETARY TYPE STARTER MOTOR

UNIT CHECK OF PLANETARY TYPE STARTER MOTOR
CAUTION:
Each of the following tests must be performed within
three to five seconds. If you fail to observe this caution
and the starter should be energized for more than this
duration, the coil may be burnt out.
JST00010-00006
1. Pull-in test
(1) Disconnect the lead wire form the magnetic switch ter-
minal.
JST00011-00007

ST6
(2) Connect the negative () terminal of the battery to the
starter body and magnetic switch terminal.
JST00012-00008
(3) Connect the positive (+) terminal to the terminal ST.

Ensure that the pinion is pushed outward.
If the drive pinion fails to move out, replace the mag-
netic switch.
JST00013-00009
2. Hold-in test
After the check has been performed following the same
procedure as with the pull-in test, disconnect the negative
terminal of the magnetic switch terminal.
Ensure that the drive pinion is held in a pushed-out state.
If the drive pinion fails to be held, replace the magnetic
switch.
JST00014-00010
3. Inspection of plunger return

After the check has been performed following the same
procedure as with the hold-in test, disconnect the ground
terminal of the starter body. Ensure that the drive pinion is
drawn into the drive housing.
If the drive pinion fails to be drawn, replace the magnetic
switch.
JST00015-00011
4. No-load performance test

Connect the battery and an ammeter to the starter as
shown in the right figure. Ensure that the starter rotates
smoothly with the pinion moving out.
Measure the current the starter is drawing.
Specified Current: Less than 90A at 11.5V
NOTE:
Prior to the test, be sure to connect the lead wire to the
magnetic switch.
JST00016-00012

ST7
DISASSEMBLY OF PLANETARY TYPE STARTER MOTOR
1. Disconnect the lead wire from the magnetic switch.
JST00017-00013
2. Remove the attaching nut of the magnetic switch from the

drive housing.
JST00018-00014
3. Remove the magnetic switch from the drive housing.
JST00019-00015
4. Remove the two through bolts from the commutator end

frame.
JST00020-00016
5. Remove the yoke with armature and the drive lever from
the drive housing.
JST00021-00017

ST8
6. Separate the yoke with armature from the clutch with cen-
ter bearing.
7. Remove the O-ring.
JST00022-00018
8. Remove the end frame cover by removing the two screws.
JST00023-00019
9. Remove the brushes from the brush holder by lifting the

brush springs by means of nose pliers or the like.
NOTE:
Care must be exercised not to damage the brushes
during the removal.
10. Then, remove the armature from the yoke.
JST00024-00020
11. Removal of planetary gear

(1) Remove the plate for starter armature.
(2) Remove the three planetary gears.
(3) Remove the plate washer.
JST00025-00021
12. Remove the stop collar from the snap ring by tapping the
collar with a screwdriver or the like placed on it.
JST00026-00022

ST9
13. Detach the snap ring by prying it off with snap ring pliers.
Then, remove the collar.
JST00027-00023
14. Remove the clutch.
JST00028-00024
15. Detach the snap ring. Separate the center bearing from
the planetary carrier shaft.
JST00029-00025
16. Remove the internal gear by aligning the recessed section

provided at the outer periphery of the internal gear with
the protruded section provided at the inner periphery of
the center bearing.
JST00030-00026
INSPECTION OF PLANETARY TYPE STARTER MOTOR

Check of armature
1. Check of armature insulation
Ensure that no continuity exists between the commutator
and the armature coil, using an ohmmeter.
If continuity exists, replace the armature.
JST00031-00027

ST10
2. Check of commutator continuity
Check continuity between each adjacent segment of the
commutator, using an ohmmeter.
If no continuity exists between any adjacent segments, re-
place the armature.
JST00032-00028
Check of commutator
1. Check each contact surface of the commutator segments
with the brushes for burning.
If the surfaces are dirty or burnt, correct the commutator
surfaces, using abrasive paper (No. 400) or a lathe.
JST00033-00029
2. Check of commutator for circle runout

Support the armature at its both ends on a Vee block.
Check the commutator for circle runout, using a dial
gauge.
Circle Runout Limit: 0.05 mm
If the circle runout exceeds the allowable limit, turn down

the commutator on a lathe.
At this point, care must be exercised to ensure that the
commutator diameter is not less than the minimum re-
quirement diameter of 27 mm. JST00034-00030
3. Measurement of commutator diameter

Measure the commutator diameter by means of a microm-
eter or vernier calipers.
Standard Diameter: 28 mm
Minimum Diameter: 27 mm
If the commutator diameter is less than the minimum diam-

eter, replace the armature.
JST00035-00031
4. Check of commutator undercut

Measure the insulator groove depth between commutator
segments.
Minimum Depth: 0.2 mm
If the insulator groove depth becomes less than the limit

value, replace the commutator.
JST00036-00032

ST11
Check of field coil
1. Field coil continuity test
Perform field coil continuity test at a point between the
lead wire and the brush, using an ohmmeter.
If no continuity exists, replace the yoke.
JST00037-00033
2. Field coil short test

Perform field coil short test at a point between the brush
and the yoke proper, using an ohmmeter.
If no continuity exists, replace the yoke.
JST00038-00034
Check of brushes
1. Measurement of brush length
Measure the brush length, using vernier calipers.
Standard Length: 14 mm
Minimum Length: 11 mm 14 mm
11 mm
2. Replacement of brush.
If the length is less than the minimum requirement, replace
the brush holder or the yoke, as required.
JST00039-00035
3. Procedure for brush replacement

(1) Cut the brush lead wire at the terminal side.
NOTE:
Replacement can be made only for the two brushes at
the yoke side (positive (+) side). The brush at the nega-
tive () side should be replaced together with the brush
holder.
JST00040-00036
(2) Remove welding traces with a file or the like to correct

the brush terminal to the specified dimensions.
Specified Dimensions:
Thickness: 1.5 mm - 1.7 mm
Width: 5 mm
NOTE:
Be sure to remove the section of the brush termi-
nal as indicated in the right figure. Since the section to
be removed is narrow, be very careful not to damage
the field coil. JST00041-00037

ST12
(3) Stack the plate section of a replacement brush onto
the welding side of the lead wire. Make pressure con-
nection over the overlaid section by pinching it with
pliers.
NOTE:
Be sure to take out the brush lead wire in the correct
direction.
JST00042-00038
(4) Solder the pressure connection section. Correct the

section, using a file or the like, so that the section con-
forms to the dimensions, as indicated in the right fig-
ure.
NOTE:
1. When performing the soldering, heat the section to be
soldered thoroughly. Be very careful not to allow any
solder to flow into the positive side lead wire.
2. Be sure to allow solder in a sufficient amount to flow
into the inside of the plate.
3. Ensure that no solder oozes to the field side. JST00043-00039
Check of brush holder

1. Check of brush holder for insulation
Measure the insulation between the positive and negative
terminals of the brush holder, using an ohmmeter.
Insulation Resistance: 0.1 M or more
2. Replacement of brush holder.

If the insulation resistance is less than the specification,
replace the brush holder.
JST00044-00040
Check of brush spring

Measure the brush spring tension, using a spring scale.
Standard Tension: 15.7 N (1.6 kgf)
JST00045-00041
Check of clutch
1. Inspection of pinion gear and spline teeth
Check the teeth of the pinion gear and spline for wear or
damage.
If the teeth exhibit any damage, replace the clutch. Also,
inspect the flywheel ring gear for wear or damage.
JST00046-00042

ST13
2. Check of starter clutch
While holding the clutch, turn the pinion clockwise. Ensure
that the pinion turns smoothly.
Turn the pinion counterclockwise. Ensure that the pinion is
locked.
If the check results are unsatisfactory, replace the starter
clutch.
JST00047-00043
Check of magnetic switch

1. Plunger check
Push in the plunger with your fingers and release your fin-
gers. Ensure that the plunger returns quickly to the original
position. If the plunger exhibits poor returning or fails to re-
turn, replace the magnetic switch.
JST00048-00044
2. Pull-in coil open circuit test

Using an ohmmeter, ensure that continuity exists between
the terminal ST and terminal C.
If no continuity exists, replace the magnetic switch.
JST00049-00045
3. Hold-in coil open circuit test

Ensure that continuity exists between the terminal ST and
the switch body.
If no continuity exists, replace the magnetic switch.
JST00050-00046
Check of bearing
Center bearing
1. Measure the outer diameter of the center bearing sliding
section of the planetary carrier shaft.
Specified Value: 15 mm
JST00051-00047

ST14
2. Measure the inner diameter of the center bearing so as to
determine the clearance.
Specified Value: 0.04 mm
If the clearance exceeds the allowable limit, replace the

oilless bearing or the planetary carrier shaft.
JST00052-00048
3. Bearing replacement
(1) Remove the bearing, using a suitable tool in combina-
tion with a press or the like.
NOTE:
When pulling out the bearing, be sure to remove it from
the inside.
JST00053-00049
(2) Install the bearing, using a suitable tool in combination

with a press or the like.
NOTE:
When installing the bearing, be sure to install it from
the outside.
JST00054-00050
NOTE:
The bearing should be driven into position in such a
way that the bearing is recessed within 0.5 mm from
the edge of the center bearing.
JST00055-00051
End frame bearing

1. Measure the outer diameter of the end frame sliding sec-
tion of the armature shaft.
JST00056-00052

ST15
2. Measure the inner diameter of the end frame bearing so
as to determine the clearance.

oilless bearing or the armature.
JST00057-00053
(1) Remove the bearing, using a tap having an outer di-
ameter of 8 mm.
NOTE:
Be certain to clamp the end frame in a vise with a cloth
interposed so that no scratch may be made on the end
frame.
JST00058-00054
(2) Install a new bearing, using a suitable tool in combina-

JST00059-00055
Planetary carrier shaft bearing

1. Measure the outer diameter of the front sliding section of
the armature shaft.
JST00060-00056
2. Measure the inner diameter of the planetary carrier shaft

bearing so as to determine the clearance.

oilless bearing or the armature.
JST00061-00057

ST16
(1) Remove the bearing, using a tap having an outer di-
ameter of 8 mm.
NOTE:
Be certain to clamp the planetary carrier shaft in a vice
with a cloth interposed so that no scratch be made on
the planetary carrier shaft.
JST00062-00058
(2) Install a new bearing, using a suitable tool in combina-

JST00063-00059
NOTE:
The bearing should be driven into the position, as indi-
JST00064-00060
ASSEMBLY OF PLANETARY TYPE STARTER MOTOR
NOTE:
Use high-temperature grease to lubricate the bearings
and sliding parts when assembling the starter motor.
1. Install the internal gear by aligning the recessed section

provided at the outer periphery of the internal gear with
the protruded section provided at the inner periphery of
the center bearing.
JST00065-00061
2. Put the plate washer onto the planetary carrier shaft. Then,
install the center bearing to the planetary carrier shaft.
JST00066-00062

ST17
3. Install the plate washer in place.
Install the snap ring.
JST00067-00063
4. Install the clutch.
JST00068-00064
5. Install the stop collar and a new snap ring. Compress the
snap ring, using a vise or the like.
JST00069-00065
6. Tap the collar so that it may come onto the snap ring,
using a screwdriver.
JST00070-00066
7. Installation of planetary gear

(1) Install the plate washer.
(2) Install the three planetary gears.
(3) Install the plate for starter armature.
NOTE:
Be certain to install the plate, aligning with the mate
mark on the center bearing.
JST00071-00067

ST18
8. Install the yoke to the armature. Install the brushes to the
brush holder while lifting the brushes by means of nose
pliers or the like.
JST00072-00068
9. Install the commutator end frame, together with a new O-

ring, to the yoke by means of the two screws.
JST00073-00069
10. Install the drive lever and the clutch with center bearing to
the drive housing.
NOTE:
Apply high-temperature grease to the sliding section of
the drive lever.
Make sure to align the mate mark of the drive housing
with that of the yoke during the assembly.
JST00074-00070
11. Install the armature with yoke and a new O-ring to the
drive housing.
NOTE:
Make sure to align the mate mark of the center bearing
with that of the yoke during the assembly.
JST00075-00071
12. Install the two through-bolts.
JST00076-00072

ST19
13. While hooking the magnetic switch over the drive lever, in-
stall the magnetic switch onto the drive housing. Secure
the magnetic switch with the two nuts.
NOTE:
Be sure to install the rubber boot in the spring section
securely.
JST00077-00073
14. Connect the lead wire to the magnetic switch.
JST00078-00074
INSTALLATION OF STARTER MOTOR

1. Install the starter motor to the bell housing.
JST00079-00000
2. Tighten the lower side and upper side attaching bolt from
the under side of the vehicle.
JST00080-00075
3. Connect the starter terminal B of the alternator wire to the

starter.
4. Connect the starter terminal ST of the alternator wire to the
starter.
JST00081-00076

ST20
5. Jack up the vehicle. Remove the safety stands from the
vehicle. Then, remove the jack.
6. Install the battery and battery carrier.
7. Connect the ground cable terminal to the negative () ter-
JST00082-00000
8. Ensure that the starter motor rotates smoothly.

NOTE:
The battery should be in the full charged condition.
JST00083-00000

ST21
Reduction type starter Rating voltage and output power 12V 0.8 kW
motor
No-load characteristic at 11.5V
Amperage Less than 90A
Brush length
Standard 14.0 mm
Minimum 11.1 mm
Commutator
Outer diameter Standard 28 mm
Minimum 27 mm
Undercut depth
Standard 0.45 - 0.75 mm
Minimum 0.2 mm
Maximum circle runout 0.05 mm
15.7 N (1.6 kgf)

Spring installed load
JST00084-00000
TROUBLE SHOOTING
Problem Possible cause Remedies Page
Engine will not crank Battery not fully charged Check specific gravity of battery CH6
electrolyte.
Charge or replace battery.
Battery cables loose, corroded or worn Repair or replace cables. CH6
Neutral start switch faulty Adjust or replace Neutral start switch.
Fusible link blown Replace fusible link.

Starter faulty Repair starter. ST4
Ignition switch faulty Replace ignition switch.
Engine cranks slowly Battery not fully charged Check specific gravity of battery CH6
electrolyte.
Charge or replace battery.
Battery cables loose, corroded or worn Repair or replace cables.
Starter faulty Repair starter. ST4
Starter keeps running Starter faulty Repair starter. ST4

Ignition switch faulty Replace ignition switch.
Short in wiring Repair wiring.
Starter spins engine will Pinion gear teeth broken or faulty Repair starter. ST4
not crank starter
Flywheel teeth broken Replace flywheel.
JST00085-00000

DAIHATSU
J100
CHARGING SYSTEM
CH
OUTLINE OF CHARGING SYSTEM ........... CH 2
CHARGING SYSTEM CIRCUIT .................. CH 2
PRECAUTIONS ........................................... CH 3
IN-VEHICLE INSPECTION ......................... CH 3
ALTERNATOR ............................................. CH 9
SERVICE SPECIFICATIONS ...................... CH22
TROUBLE SHOOTING ............................... CH22
JCH00001-00000
NO. 9710-JE

CH2
OUTLINE OF CHARGING SYSTEM
An IC regulator type alternator is employed on this model.
Moreover, an alternator cut-off system is adopted on automatic transmission vehicles to shut off the alterna-
tor operation so that the startability of the engine may be enhanced when the ambient temperature is ex-
tremely low at the starting period.
This system is controlled by the EFI ECU.
JCH00002-00000
CHARGING SYSTEM CIRCUIT
Ignition switch Engine fuse
Gauge fuse
Charge lamp
EFI
ECU
For manual
transmission
vehicles
@8
For automatic
transmission
vehicles
Battery
B IG IG
P 0.5F
L L
F
MIC
JCH00003-00001

CH3
PRECAUTIONS
1. Prior to the inspection, make sure that the battery cables are connected securely.
2. When a quick charging operation is carried out, first be sure to disconnect the battery cables.
3. Never use a high-voltage insulation resistance tester for the purpose of conducting this inspection.
4. Under no circumstances should the battery cables be disconnected while the engine is rotating.
JCH00004-00000
1. Inspection of battery
<Reference>
First-aid treatment for dilute sulfuric acid
Nature of accident First-aid treatment
Immediately flush the affected area using a large amount of clean running water,
Acid gets to vehicle body.
until no acid content remains any more.
Immediately flush your eyes using a large amount of clean running water for at
* Acid gets into your eyes.
least 15 minutes with your eyes in open state.
Immediately flush the affected area using a large amount of clean running water,
* Acid gets to your skin or clothes. until no acid content remains any more. Afterwards, neutralize them with a soap.
Finally flush them with water.
Immediately flush the affected area using a large amount of water, until no acid
Acid is spilled. content remains any more. Afterwards, neutralize the area with slacked lime,
sodium or the like.
Immediately flush the mouth with clean water. Let him drink raw eggs. Milk or a
* Acid is swallowed. large amount of water. Let him lie quietly.
* After the aforesaid first-aid treatment has been done, call a physician immediately.
JCH00005-00000

(Refer to the MA section of the service manual.)
3. Check of fuses for continuity
Fusible link
Fusible link block
EFI No. 1 fuse
Engine fuse
Gauge fuse
4. Checking alternator wiring and listening for abnormal nois-
es
(1) Check to see if the alternator wire is connected prop-
erly to the alternator.
(2) Ensure that the alternator emits no abnormal noise
while the engine is running. JCH00006-00000
5. Check of charge warning lamp circuit

(1) Turn OFF all accessory switches.
(2) Start the engine and warm up the engine thoroughly.
Turn OFF the ignition switch.
(3) When the ignition switch is turned ON, ensure that the
charge warning lamp goes on.
(4) After the engine has started, ensure that the charge
warning lamp goes out.
If the warning lamp does not function as specified, trou-

bleshoot the warning lamp circuit. JCH00007-00002

CH4
6. Check of charging circuit under unloaded state
NOTE:
If a battery/alternator tester is available, connect such
tester to the charging circuit according to the manufac-
turers instructions of the alternator tester.
JCH00008-00000
(1) If a battery/alternator tester is not available, connect a

voltmeter and an ammeter to the alternator wiring and A
alternator as follows:
Disconnect the battery ground cable from the neg-
ative () terminal of the battery.
Connect an ammeter in series between the alterna-
tor wire terminal B and the alternator as indicated V
in the right figure. Terminal B

Connect the positive (+) terminal of a voltmeter to
the terminal B of the alternator as indicated in the
right figure. JCH00009-00003
Connect the negative () terminal of the voltmeter

to the engine ground.
Wind vinyl tape around each connection section so
as to prevent short.
Reconnect the battery ground cable to the nega-
tive terminal of the battery.
(2) Connection of SST

Install the following SST between EFI ECU and EFI
ECU connectors of the engine wire.
(Refer to the EF section of the service manual for in-
stallation of the SST.)
SST: 09842-87706-000
This terminal is not

used for this model
JCH00010-00004
(3) Checking the charging circuit as follows:

q Start the engine and warm it up. A
w Raise the engine speed from the idle speed to

2000 rpm.
e Ensure that the ammeter and voltmeter reading are
within the specified value.
Standard Amperage: Not to exceed 10 A. V
Standard Voltage: 13.6 - 14.4 Volts
If the voltage reading is greater than the standard volt-

age, replace the IC regulator. JCH00011-00005

CH5
For automatic transmission models, ensure that a voltage
of 4.0 volts or higher is applied to between the terminal Terminal F
@8 of the SST and the body ground.
If the specified voltage is not applied, check the wiring be-
tween the EFI ECU and the alternator as follows:
JCH00012-00006
a. Turn OFF the ignition switch.

b. Disconnect the battery ground cable terminal from the
negative terminal of the battery.
c. Disconnect the EFI ECU terminal of the SST from the
EFI ECU. (Do not disconnect the engine wire side con-
nector of the SST.)
d. Connect the battery ground cable terminal to the neg-
ative terminal of the battery.
e. Turn ON the ignition switch.
f. Ensure that a voltage of 4.0 volts or higher is applied
to between the terminal @8 of the SST and the body JGCH00013-00007
ground.
If the voltage between the terminal @8 of the SST and the
body ground is 2.5 volts or less, check the EFI computer
and its related circuits for short or open circuit.
<Reference>
The standard voltage between the terminal @8 of the SST
and the body ground is approximately equal to the battery
voltage.
7. Check of charging circuit under loaded state

(1) Start the engine. Maintain the engine speed at A
2000 rpm. Turn ON the high beams of the headlamps

and set the blower fan motor switch to the Hi position.
Take a reading of the ammeter.
Standard Amperage: 30 A or more
V
If the ammeter reading is less than 30 A, repair the al-

ternator.
(Refer to the overhaul of the alternator.)
NOTE: JCH00014-00008
When the battery is in a fully-charged state, the amme-

ter reading may be less than 30 A during the aforesaid
test.

CH6
Removal of battery
WARNING:
Never touch the battery terminals immediately after the
engine stopped.
Be certain to turn OFF the ignition switch.
Never allow any fire to be brought near the battery.
CAUTION:
Be very careful not to drop the battery or apply strong
vibration to the battery. JCH00015-00000
Terminals
1. Ensure that the ignition switch is turned OFF.
2. Disconnect the battery ground cable from the negative
3. Disconnect the positive cable terminal from the positive
terminal of the battery. Hold down
4. Remove the battery hold-down clamp. clamp
JCH00016-00009
5. Remove the battery.

JCH00017-00000
CLEANING AND INSPECTION OF BATTERY

1. Remove any rust from the battery terminals by means of a
wire brush, a fine abrasive paper, or sodium water and a
soft brush.
NOTE:
After the battery terminals have been cleaned, make
sure that no rust particle remains on the terminals.
JCH00018-00010
2. Using adhesive tape or the like, seal the vent hole of each
cell plug.
3. Flush the battery with clean water, using a soft brush.
4. Wipe off the battery surface using a cloth dampened with
clean water.
5. Dry the battery case surface.
JCH00019-00011

CH7
Battery capacity check
1. Reserve capacity check, using hydrometer
2. Reserve capacity check, using battery tester

CAUTION:
The battery tester should be operated in accordance
with the operating instructions of the service manual.
The battery to be check should be fully charged.
(1) Connect a battery tester to the battery.

(2) Check the battery capacity. JCH00020-00012
NOTE:
If the check results are not satisfactory, recheck the re-
serve capacity, after having checked the electrolyte
level and/or replenished distilled water. Then, charge
the battery until the battery capacity reaches the speci-
fied level.
Replace the battery with a new one, if the check results
are still unsatisfactory after the rechecking of the bat-
tery reserve capacity.
Battery recharging (Except Delco freedom battery)
CAUTION:
If the Delco Freedom Battery requires the recharging,
be sure to consult with the distributor or agent of Delco
Freedom Battery.

CH8
INSTALLATION OF BATTERY
1. Clean any dust from the battery carrier.
JCH00021-00013
2. Place the battery on the battery carrier in such a direction

Terminals
that the negative terminal of the battery may come at the
front side of the vehicle.
3. Install the battery hold-down clamp.
CAUTION:
Be very careful not to tighten the hold-down clamp ex- Hold down
cessively. clamp
NOTE:
Install the battery hold-down clamp in such a direction
that the hold-down clamp on the battery may come to JCH00022-00014
the straight position against the battery not in a tilted

state.
4. Connect the positive cable terminal to the battery positive

NOTE:
Ensure that the terminal at the wiring exhibits no rust or
the like.
If any rust is present, remove the rust, using a wire
brush or a fine abrasive paper.

CH9
ALTERNATOR
COMPONENTS
Generator cap
Alternator
assembly
Nut
Bolt Wave washer
Spacer
Alternator rotor assembly
Stud bolt
Drive end flame
assembly Bearing cover
Bearing
Bolt
Retainer plato
Alternator pulley
Bearing
Pulley lock nut

Bolt
Insulator terminal
Nut
Brush holder
Brush spring
Rear end cover
Brush
Generator regulator assembly
Rectifier holder
Bolt
Rectifier end frame
Alternator 50A for manual transmission vehicles and 55A for automatic transmission vehicles
JCH00023-00015

CH10
REMOVAL OF ALTERNATOR
terminal of the battery. Attaching bolt
2. Remove the generator cap.
3. Disconnect the terminal B of the alternator wire from the
alternator.
4. Disconnect the alternator connector of the alternator wire
from the alternator.
NOTE:
Generator cap
Be sure to disengage the lock of the connector before
disconnection. JCH00024-00016
5. Removal of alternator drive belt

(1) Remove the air conditioner drive belt.
(Refer to the air conditioner installation manual issued
by DENSO CO., LTD.)
(2) Remove the upper attaching bolt of alternator.
(3) Remove the engine undercover.

JCH00025-00017
(4) Remove the lower attaching bolt of the alternator.

(5) Take out the alternator from the vehicle.
JCH00026-00000
DISASSEMBLY OF ALTERNATOR
1. Remove the alternator pulley lock nut by means of an im-
pact wrench.
NOTE:
Be sure to use an impact wrench having a hexagonal
hole.
JCH00027-00018

CH11
2. Remove the alternator pulley.
JCH00028-00019
3. Remove the attaching nut of the terminal insulator. Nut

4. Pull out the terminal insulator.
5. Remove the three rear end cover attaching nuts. Terminal
6. Remove the terminal plate attaching bolt. insulator
7. Remove the rear end cover.
Rear end
cover
JCH00029-00020
8. Remove the brush holder by removing the two attaching

bolts.
JCH00030-00021
9. Remove the rectifier holder and regulator assembly at-

taching bolts.
10. Remove the regulator assembly.
11. Remove the rectifier holder.
JCH00031-00022
12. Remove the rectifier end frame assembly by removing the

four attaching nuts or two bolts and two nuts.
JCH00032-00023

CH12
13. Remove the wave washer from the alternator rotor assem-
bly.
JCH00033-00024
14. Remove the alternator rotor assembly from the drive end
frame assembly.
JCH00034-00025
INSPECTION OF ALTERNATOR
Rotor
1. Inspection of rotor for open circuit
Using an ohmmeter, check to see if the specified resis-
tance exists between the rotor slip rings.
Standard Resistance: 2.9 0.2 ohm
If the resistance does not conform to the specification, re-

place the rotor.
JCH00035-00026
2. Inspection of rotor for ground

Ensure that no continuity exists between the rotor slip
rings and the rotor core.
If continuity exists, replace the rotor.
JCH00036-00027
3. Inspection of slip rings

(1) Check to see if the slip ring surface exhibits rough-
ness, abnormal wear and/or burning.
Replace the rotor, if necessary.
JCH00037-00028

CH13
(2) Measure the outer diameter of the slip ring, using
vernier calipers.
Standard Diameter: 14.4 mm
Minimum Diameter: 14.0 mm
If the slip ring diameter is less than the minimum diam-

eter, replace the rotor assembly.
JCH00038-00029
Stator
1. Inspection of stator for open circuit
Using an ohmmeter, check to see if any open circuit of the
stator coil is present between the leads.
If no continuity exists, replace the end frame assembly.
JCH00039-00030
2. Inspection of stator for short circuit

Using an ohmmeter, check to see if any short circuit of the
stator coil is present between the coil lead and the drive
end frame.
If continuity exists, replace the drive end frame assembly.
JCH00040-00031
Brush and brush holder

1. Measurement of exposed brush length
Measure the exposed brush length, using a scale.
Standard Exposed Length: 10.5 mm
Minimum Exposed Length: 8.4 mm
If the exposed length is less than the minimum require-

ment, replace the brushes.
JCH00041-00032
2. Replacement of brushes (If necessary)

(1) Remove the brush and spring from the brush holder by
melting the solder by means of a soldering iron.
JCH00042-00033

CH14
(2) Install the brush cord in the brush holder with the
spring fitted in place.
JCH00043-00034
(3) Solder the brush cord in the brush holder in such a

way that the exposed length of the brush meets the
specification.
Standard Exposed Length: 10.5 mm
JCH00044-00035
(4) Ensure that the brush moves freely in the brush holder.
JCH00045-00036
(5) Cut off any excess remaining wire and apply an insula-
tion paint.
JCH00046-00037

CH15
Rectifier
NOTE:
Be sure to confirm the specification of the ohmmeter to
be used for inspection before putting it into use.
The current flow direction differs according to the de-
sign of an ohmmeter.
This manual is described, based on a digital tester
manufactured by DENSO Japan.
<Reference> JCH00047-00038
The measured resistance should be about the same as

those of other rectifiers, for the measurement results
differ according to the input voltage of each tester.
If the measured resistance of the rectifier differs more
than 20 percent, replace the rectifier holder.
1. Inspection of rectifier at positive side

(1) Ensure that continuity exists between the positive stud
bolt of the rectifier holder and the rectifier terminal by
connecting an ohmmeter as indicated in the right fig-
ure.
If no continuity exists, replace the rectifier holder.
(2) Ensure that no continuity exists between the positive

stud bolt of the rectifier holder and the rectifier terminal
by connecting an ohmmeter as indicated in the right
figure.
If continuity exists, replace the rectifier holder.
JCH00048-00039
2. Inspection of rectifier at negative side

(1) Ensure that continuity exists between each of the neg-
ative terminals of the rectifier holder and each rectifier
terminal by connecting an ohmmeter as indicated in
the right figure.
If no continuity exists, replace the rectifier holder.
JCH00049-00040
(2) Ensure that no continuity exists between each of the

negative terminals of the rectifier holder and each rec-
tifier terminal by connecting an ohmmeter as indicated
If continuity exists, replace the rectifier holder.
JCH00050-00041

CH16
Bearings
1. Inspection of front bearing
Ensure that the bearing turns smoothly.
Replace the bearing, if necessary.
JCH00051-00042
2. Replacement of bearing
(1) Remove the four screws and retainer plate.
JCH00052-00043
(2) Remove the front bearing from the drive end frame,
using a suitable socket wrench in conjunction with a
press.
CAUTION:
Be very careful not to damage the coil and stud bolts
during bearing removal.
JCH00053-00044
(3) Press a new front bearing into the drive end frame,
using a suitable socket wrench in conjunction with a
press.
CAUTION:
Be sure to hold the outer race of the new bearing dur-
ing installation. Holding of the inner race or side cover
will cause bearing damage.
JCH00054-00045
(4) Attach the retainer plate to the drive end frame with the
four screws.
JCH00055-00046

CH17
3. Inspection of rear bearing
Ensure that the bearing turns smoothly.
Replace the bearing, if necessary.
JCH00056-00047
4. Replacement of rear bearing

(1) Remove the rear bearing cover from the rotor, using
the armature bearing puller.
CAUTION:
Be very careful not to damage the fan during the re-
moval.
JCH00057-00048
(2) Place the parts on the rotor in the following order.

Spacer
New rear bearing
New bearing cover
(3) Press the assembled parts into the rotor, using a hy-
draulic press in combination with a suitable attach-
ment or following SST.
SST: 09236-00100-000
NOTE:
Care must be exercised so that the point where the JCH00058-00049
bearing is assembled to the rotor shaft may not deform

the bearing cover.
Therefore, be sure to select a suitable attachment to
assemble the bearing cover.
JCH00000-00050
5. Inspection/replacement of stud bolt

Visually inspect the thread portion of the stud bolt.
If any damage exists, replace the stud bolt.
JCH00059-00051

CH18
ASSEMBLY OF ALTERNATOR
1. Install the rotor in the drive end frame assembly.
JCH00060-00052
2. Installation of rectifier end frame on drive end frame

(1) Place the wave washer on the rear bearing.
(2) Install the rectifier end frame on the drive end frame
with the two bolts and two nuts or four attaching nuts.
CAUTION:
Be very careful not to damage the coil cord during the
installation.
JCH00061-00053
JCH00000-00054
3. Installation of rectifier holder, regulator assembly and

brush holder
(1) Attach the rectifier holder to the end frame with the coil
wires passed through the aperture of the rectifier hold-
er.
JCH00062-00055
(2) Wind the coil wires around the installing section of the
rectifier attaching bolt hole.
JCH00063-00056

CH19
(3) Connect the coil wires to the rectifier holder with the at-
taching screws.
(4) Install the rectifier holder and regulator assembly with
the attaching screws.
NOTE:
Make sure that the regulator assembly is installed
properly with the attaching screws as it works.
JCH00064-00057
(5) Install the brush holder in such a way that a gap of at

least 1 mm is provided between the brush holder and
the regulator assembly.
Secure the brush holder with the two screws.
JCH00065-00058
4. Installation of rear end cover

JCH00066-00000
(1) Install the rear end cover on the alternator. Nut

(2) Secure the rear end cover with the three attaching nuts
or screws. Terminal
(3) Install the terminal insulator. insulator
(4) Secure the terminal insulator attaching nut.
Rear end
cover
JCH00067-00059
5. Attach the pulley to the rotor shaft.
JCH00068-00060

CH20
6. Install the pulley lock nut by means of an impact wrench.
CAUTION:
Be sure to use an impact wrench having a hexagonal
hole.
Be sure to set the tightening torque of the impact
wrench as follows.
Tightening Torque: 110.5 Nm
JCH00069-00061
7. Ensure that the rotor turns smoothly.
JCH00070-00062
INSTALLATION OF ALTERNATOR
1. Insert the alternator from under side of the vehicle.
2. Install the alternator to the alternator bracket temporarily

with the attaching bolt.
JCH00071-00000
3. Install the upper attaching bolt of the alternator temporari-

ly.
4. Installation of alternator drive belt
Install the alternator drive belt to the engine properly.
CAUTION:
Make sure that the alternator drive belt is properly en-
gaged in the groove of each pulley.
JCH00072-00063

CH21
5. Tension adjustment of drive belt
(1) Install the following SST to the alternator and adjusting
bar as shown in the right figure.
SST: 09286-87701-000
(2) Adjust the drive belt tension to the specified value by

adjusting the nut of the SST.
New Belt: 4 - 5 mm
SST
[with a force of 10 kgf applied to the
point shown in the figure] JCH00073-00064
Used Belt: 5 - 6 mm
[with a force of 10 kgf applied to the
point shown in the figure]
NOTE:
As for definition of new belts and used belts, refer to
the MA section of the service manual.
(3) Tighten the alternator attaching bolts to the specified

torque.
(3.5 - 5.5 kgf-m) JCH00000-00066
(4) Remove the SST from the alternator and adjusting bar.
6. Connect the alternator connector of the alternator wire to

the alternator.
NOTE: Attaching bolt
Make sure that the lock of the connector is locked
properly after connection.
7. Connect the terminal B of the alternator wire to the alterna-

tor with the attaching nut.
8. Install the generator cap.
Generator cap
9. Reconnect the ground cable terminal to the negative ter-
minal of the battery. JCH00074-00065
10. Perform the in-vehicle inspection.

11. Install the right engine undercover.
12. Install the air conditioner drive belt.
(Refer to the air conditioner installation manual issued by
DENSO CO., LTD.)

CH22
Battery specific gravity (Except Delco Freedom battery) 1.25 - 1.27
Rated output Amperage 50A
Rotor coil resistance Resistance 2.9 at 20C (68F)
Alternator: Slip ring diameter Standard 14.4 mm
50A (For manual transmission vehicles) Minimum 14.0 mm
Brush exposed length Standard 10.5 mm
Minimum 8.4 mm
IC regulating voltage Hi level 14.1 - 15.2 volts
Rated output Amperage 55A
Rotor coil resistance Resistance 2.9 at 20C (68F)
Slip ring diameter Standard 14.4 mm
Alternator: Minimum 14.0 mm
55A (For automatic transmission vehicles) Brush exposed length Standard 10.5 mm
Minimum 8.4 mm
IC regulating voltage Hi level 14.1 - 15.2 volts
JCH00075-00000
TROUBLE SHOOTING
Problem Possible causes Remedies Page
Charge warning lamp will not Fuse blown Check gauge fuse. BE6
glow even if ignition switch is Lamp bulb burnt Replace bulb. BE Section
turned ON. Poor connection of wiring Repair poor connection of wiring. BE Section
Repair or replace.
Replace regulator assembly. CH3
Charge warning lamp will not Drive belt loose or worn Adjust or replace. MA6
go out even if engine has Battery cables loose, corroded Repair or replace cables.
started. or worn
Fuse blown Check gauge fuse.
Fusible link blown Replace fusible link.
IC regulator or alternator faulty Check charging system. CH3
Wiring faulty Repair or Replace.
JCH00076-00000

DAIHATSU
J100
CLUTCH
OUTLINE ..................................................... CL 2
CLUTCH SECTIONAL VIEW .................. CL 2
CL
CLUTCH PEDAL ADJUSTMENT ................ CL 3
PEDAL INSTALLATION HEIGHT ............ CL 3
ADJUSTMENT OF CLUTCH PEDAL
FREE TRAVEL ..................................... CL 3
CLUTCH PEDAL & CLUTCH CABLE ......... CL 4
1. Main points of clutch pedal
installation .......................................... CL 6
2. Main points of clutch cable
installation .......................................... CL 6
CLUTCH RELEASE MECHANISM ............. CL 7
COMPONENTS ...................................... CL 7
1. Operation prior to removal ................. CL 7
2. Main points of removal ....................... CL 7
3. Check ................................................. CL 8
4. Main points of installation ................... CL 9
5. Operation after installation ................. CL11
APPENDIX ................................................... CL12
SSTs (Special Service Tools) .................. CL12
SERVICE SPECIFICATIONS ................... CL12
TIGHTENING TORQUE .......................... CL12
JCL00001-00000
NO. 9710-JE

CL2
OUTLINE
1. The clutch mechanism has employed a cable-operated mechanical clutch. This clutch has adopted a
dry, single disc type diaphragm type which features easy operation and excellent serviceability.
2. The release mechanism employs a lever type featuring superb stroke efficiency and load efficiency, as
is the case with S100 series.
3. For improved cooling performance of the clutch friction surface, the clutch housing is provided with
cooling holes at its front and rear sides.
JCL00002-00000
CLUTCH SECTIONAL VIEW
Clutch cover
Diaphragm spring
Clutch release bearing
Clutch disc
Clutch release fork
JCL00003-00001

CL3
CLUTCH PEDAL ADJUSTMENT
PEDAL INSTALLATION HEIGHT
Loosen the lock nut. Adjust the pedal height by turning the
adjusting bolt. Adjusting bolt
Pedal Installation Height: 175 - 180 mm
(Distance from center of
pedal pad upper surface to
dash panel)
Lock nut
Lock Nut Tightening Torque: 11.8 - 27.4 Nm
(1.2 - 2.8 kgf-m)
Pedal height
175 - 180 mm
JCL00004-00002
ADJUSTMENT OF CLUTCH PEDAL FREE

TRAVEL
1. Pull the clutch outer cable toward the vehicle front, until
the clutch release bearing hub is brought into contact with
the diaphragm spring of the clutch cover.
2. Under the condition in the step 1, turn the adjusting nut in
such a way that the gap relative to the grommet (dimen-
sion (A) in the right figure) may be adjusted to 4 - 7 mm. (A)
3. Align the nearest groove of the adjusting nut with the pro-
trusion of the grommet, and secure it.
JCL00005-00003
4. Ensure that the free travel of the clutch pedal conforms to
the specification.
Clutch pedal free travel: 15 - 30 mm

CL4
CLUTCH PEDAL & CLUTCH CABLE
COMPONENTS
RHD : Tightening torque

FRONT
Unit : Nm (kgf-m)
3.9 - 6.9
(0.4 - 0.7) u
3.9 - 6.9
(0.4 - 0.7)
10.3 - 24.0
B (1.05 - 2.45) i
3.9 - 6.9
(0.4 - 0.7) B
r B
!0
B t
!0 N
e y
3.9 - 6.9
(0.4 - 0.7) !2
o
6.9 - 15.7 !1
w (0.7 - 1.6)
!3
q Clutch housing cover

w Clutch cable bracket
e Clutch cable bracket
r Clutch cable bracket
t Clutch cable bracket
y Clutch cable bracket (ABS vehicle only)
u Clutch release cable assembly
i Pedal shaft
o Spring
!0 Bush
!1 Clutch pedal subassembly
!2 Cushion
!3 Clutch pedal pad.
JCL00006-00004

CL5
LHD
e
FRONT
t
3.9 - 6.9
(0.4 - 0.7)
B
10.3 - 24.0 3.9 - 6.9

(1.05 - 2.45) B (0.4 - 0.7)
B
i B
y
N
r
u
w
!0
o
i
!1
6.9 - 15.7
B
(0.7 - 1.6)
q Clutch housing cover q

w Clutch cable bracket
e Clutch cable bracket
r Clutch cable bracket
t Clutch release cable assembly
y Pedal shaft
u Spring
i Bush
o Clutch pedal subassembly
!0 Cushion : Tightening torque
!1 Clutch pedal pad Unit : Nm (kgf-m)
JCL00000-00005

CL6
1. Main points of clutch pedal installation MP grease
(1) Apply MP grease to the points where the inner surface
of the clutch pedal subassembly is connected to the
clutch release cable assembly; the inner surface and MP grease
hook section of the torsion spring; and the inner/outer
surfaces of the bush.
NOTE: MP grease
Be very careful not to allow grease to get to the thread-
ed portion of the pedal shaft.
JCL00007-00006
2. Main points of clutch cable installation

(1) Pull the clutch release cable assembly into the vehicle
interior. Apply MP grease to the cable end section.
Install the assembly to the clutch pedal.
(2) Install the clutch release cable assembly to the clutch
re Clutch cable bracket (ABS vehicle only)
lease fork assembly in such a way that the end section
of the clutch release cable assembly is aligned with
the ellipse section of the clutch release fork assembly.
NOTE:
Be sure to install all clamps. JCL00008-00007
(3) Adjust the clutch pedal free travel.
(4) Install the clutch housing cover.

NOTE:
Be sure to install the clutch housing cover in the direc-
tion shown in the right figure.
JCL00009-00008

CL7
CLUTCH RELEASE MECHANISM
COMPONENTS
: Tightening torque 14.7 - 21.6

Unit : Nm (kgf-m) (1.5 - 2.2)
w
14.7 - 21.6 w
(1.5 - 2.2)
e
q
y
B r
t
u
MP grease
MP grease
FRONT
q Clutch release fork support
MP grease w Anti-rattle spring
e Clutch release fork
r Clutch release bearing hub
t Release bearing hub clip
y Clutch cover assembly
u Clutch disc assembly
JCL00010-00009
1. Operation prior to removal

(1) Remove the transmission assembly from the vehicle.
(Refer to the MT section.)
JCL00011-00000
2. Main points of removal

(1) Remove the clutch cover assembly and clutch disc as-
sembly, while preventing the ring gear from turning by
means of the following SST.
SST: 09210-87701-000
JCL00012-00010

CL8
3. Check
Clutch cover and diaphragm spring
Inspect the following parts. Replace any parts which exhibit
defects.
(1) Check the clutch pressure plate and the clutch disc
contracting surface of the flywheel for evidence of
wear or burns.
(2) Check the diaphragm spring lever for wear, corrosion
or damage.
JCL00013-00011
Clutch disc
(1) Check the clutch disc for wear.
Rivet Depth
Limit: 0.4 mm
JCL00014-00012
(2) Check the clutch disc for runout.

Runout
Limit:
(Longitudinal Runout): 1.0 mm
(Lateral Runout): 0.7 mm
JCL00015-00013
Release bearing
(1) Checking of release bearing for smooth turning. Turn
the release bearing while applying a force to the bear-
ing by your hand in the thrust direction. Ensure that
you feel no abnormal stiffness or binding.
(2) Check the release bearing hub for damage or wear.
Also, check to see if any damage or wear is present at
the clip contact surface and the housing sliding sec-
tion.
JCL00016-00014
Release bearing hub clip

(1) Check for wear or damage.
JCL00017-00015

CL9
Clutch release fork
JCL00018-00016
Anti-rattle spring
JCL00019-00017
Clutch release fork support

JCL00020-00018
4. Main points of installation

(1) Thinly apply EP grease to the clutch release fork or the
entire periphery of the sliding surface of the clutch re-
lease bearing hub assembly.
Apply grease
Apply grease
JCL00021-00019
(2) Install the release bearing hub clip to the clutch re-
Fork side
lease fork.
NOTE:
Be sure to assemble the release bearing hub clip in the
direction shown in the right figure.
Clip assembling
direction
JCL00022-00020

CL10
(3) Apply EP grease to the entire periphery of the sliding Apply grease
surface of the release fork support.
JCL00023-00021
(4) Apply EP grease to the entire inner periphery of the

clutch release bearing hub assembly. Install the clutch
release fork to the transmission.
Apply grease
JCL00024-00022
(5) Thinly apply EP grease to the spline section of the

clutch disc assembly. Apply grease
NOTE:
The grease should be applied from the clutch cover
side. Be sure to apply the grease as sparsely as possi-
ble so that no excess grease may ooze out to the fly-
wheel side.
Specified Amount: 0.1 - 0.2 g
JCL00025-00023
(6) With the clutch disc assembly placed at the center po-
sition by means of the following SST, install the clutch
disc assembly to the flywheel.
SST: 09301-87703-000
NOTE:
Be very careful not to mistake the installation direction
of the clutch disc assembly. SST
(7) Install the clutch cover assembly, aligning with the lo-
cating pins of the flywheel at three points. Tighten the JCL00026-00024
six bolts to the specified torque, while preventing the 1

flywheel from turning by means of the following SST. 6
SST: 09210-87701-000 4
NOTE:
As for the tightening sequence of the bolts, first tem-
porarily tighten the bolt (1). Then, fully tighten the bolts
in order of (2) - (3) - (1) - (4) - (5) - (6). (Here, any bolt 3
can be the bolt (1).) 2
5
JCL00027-00025

CL11
5. Operation after installation
(1) Check the diaphragm spring section for unevenness in
height, using the following SST. SST
SST: 09210-87701-000
Limit: 0.5 mm
JCL00028-00026
(2) If the check above reveals that the unevenness in

height exceeds its limit, correct the unevenness, using
the following SST.
SST: 09333-00016-000
SST
(3) Install the transmission assembly to the vehicle.
JCL00029-00027

CL12
APPENDIX
SSTs (Special Service Tools)
Illustration Tool No. Tool name
09210-87701-000 Flywheel holder
09301-87703-000 Clutch guide tool
09302-87702-000 Clutch diaphragm spring height gauge No.4
09333-00013-000 Clutch diaphragm spring aligner
JCL00030-00028
Unit : mm
Item Specified value Allowable limit Remark
Height Distance from upper

175 - 180
Clutch pedal surface of pedal to floor
Free travel 15 - 30
Longitudinal: 1.0
Run-out
Clutch disc Lateral: 0.7
Lining wear 0.4 Rivet depth
JCL00031-00000
TIGHTENING TORQUE
Tightening torque
Nm kg-m
Clutch cover Flywheel 14.8 - 21.5 1.5 - 2.2
Clutch release fork support Clutch housing 14.7 - 21.6 1.5 - 2.2
Clutch release cable Right stiffener plate 6.9 - 15.7 0.7 - 1.6
Clutch cable bracket attaching bolt 3.9 - 6.9 0.4 - 0.7
Clutch release cable Dash panel 3.9 - 6.9 0.4 - 0.7
Pedal shaft attaching nut 10.3 - 24.0 1.05 - 2.45
JCL00032-00000

DAIHATSU
J100
MANUAL TRANSMISSION
OUTLINE ............................................ MT 2 COMPONENTS ............................. MT28

SECTIONAL VIEW OF MANUAL COMPONENTS ............................. MT29
TRANSMISSION ....................... MT 2
SPECIFICATIONS ......................... MT 3
INSPECTION PRIOR TO
OPERATION .............................. MT30
MT
POWER FLOW ROUTE ..................... MT 4 DISASSEMBLY .............................. MT30
SHIFT CONTROL MECHANISM ....... MT 5 INSPECTION ................................. MT31
INSTALLATION/REMOVAL OF REPLACEMENT OF CONICAL
MANUAL TRANSMISSION ............ MT 6 SPRING WASHER ..................... MT33
COMPONENTS ............................. MT 6 INSPECTION ................................. MT33
DISASSEMBLY/ASSEMBLY OF ASSEMBLY .................................... MT33
MANUAL TRANSMISSION ............ MT10 OUTPUT SHAFT ................................ MT37
COMPONENTS (PART 1) .............. MT10 DISASSEMBLY .............................. MT37
NOTICE PRIOR TO INSPECTION ................................. MT37
OPERATION .............................. MT11 ASSEMBLY .................................... MT37
COMPONENTS (PART 1) .............. MT11 INSTALLATION ............................. MT37
COMPONENTS (PART 2) .............. MT12 INSTALLATION/REMOVAL OF SHIFT
COMPONENTS (PART 2) .............. MT13 CABLE & SELECT CABLE ........... MT46
REMOVAL OF TRANSFER COMPONENTS ............................. MT46
ASSEMBLY ................................ MT14 INSTALLATION/REMOVAL OF
DISASSEMBLY .............................. MT14 TRANSMISSION FLOOR SHIFT
INSPECTION ................................. MT17 ASSEMBLY .................................... MT48
SHIFT FORKS AND HEADS .......... MT17 COMPONENTS ............................. MT48
REPLACEMENT OF TYPE S OIL DISASSEMBLY/ASSEMBLY OF
SEAL ......................................... MT18 TRANSMISSION FLOOR SHIFT
SHIFT LEVER & SHIFT RELATED ASSEMBLY .................................... MT50
PARTS REPLACEMENT ............ MT18 COMPONENTS ............................. MT50
INPUT SHAFT .................................... MT20 APPENDIX ......................................... MT51
COMPONENTS ............................. MT20 SSTs (Special Service Tools) ........ MT51
COMPONENTS ............................. MT21 SERVICE SPECIFICATIONS ............. MT52
COUNTER GEAR .............................. MT28 TIGHTENING TORQUE ..................... MT55
JMT0000100000
NO. 9710-JE

MT2
OUTLINE
1. The manual transmission employs five gears on all vehicles.
2. The gear train arrangement uses the output reduction type. This design has made possible the follow-
ing features given below.
(1) The number of pair of gears which are idling during the engine idling has been reduced to only two
pairs (first gear and second gear). Consequently, the number of components emitting rattling noise
has been decreased and the mechanism loss has been reduced.
(2) For reduced mechanism loss, the counter gear is not rotating while the transmission is in neutral.
(3) The shift feeling has been further improved by reducing the inertial weight at the time of synchroniz-
ing gears.
JMT00002-00000
SECTIONAL VIEW OF MANUAL TRANSMISSION
Input gear
Reverse idler gear
Output reduction gear
Output shaft
Counter gear
Transfer input hub
Sub gears
JMT00003-00001

MT3
SPECIFICATIONS
Item Specifications
Engine type HC-EJ
Forward gears Constant-mesh type
Type
Reverse gear Selective sliding type
1st gear 4.059
2nd gear 2.045
3rd gear 1.376
Gear ratio
4th gear 1.000
5th gear 0.838
Reverse gear 4.128
Type SAE 75W-85 API GL-3 or GL-4
Oil used
Capacity liter 2.21 (including transfer)
JMT00004-00000

MT4
POWER FLOW ROUTE
The gear train has been so designed that the fourth gear makes direct connection, while the fifth gear
makes overdrive. Furthermore, as for the gear arrangement, the first gear, reverse gear, second gear, fifth
gear and output reduction are located in this sequence, counting from the front.
A 1st gear
2nd gear
3rd gear
4th gear
5th gear
Input shaft
A Reverse
Reverse idler gear

Counter gear
A-A cross-section
JMT00005-00002

MT5
SHIFT CONTROL MECHANISM
1. The shift control mechanism employs the remote control method in which two push-pull cables are
used, in the same way as with S100. Also, for improved shift feeling, an aluminum housing has been
adopted.
Select cable
Housing
Shift cable
Dust cover
JMT00006-00003

MT6
INSTALLATION/REMOVAL OF MANUAL TRANSMISSION
COMPONENTS
: Tightening torque
Unit : Nm (kgf-m)
29.4 - 44.1
29.4 - 44.1 49.0 - 68.6 (3.0 - 4.5)
(3.0 - 4.5) (5.0 - 7.0)
B
4
!5
B 7
B B 14.7 - 21.6
(1.5 - 2.2)
6
B B
31.4 - 47.0
(3.2 - 4.8) !3
29.4 - 44.1
(3.0 - 4.5)
29.4 - 44.1
!0 (3.0 - 4.5)
B !2 N !4 29.4 - 44.1
B (3.0 - 4.5) B
B B i
B
o
14.7 - 21.6 29.4 - 44.1
(1.5 - 2.2) (3.0 - 4.5)
!1
49.0 - 68.6
(5.0 - 7.0) B
26.0 - 48.5 w
(2.65 - 4.95) 29.4 - 44.1
(3.0 - 4.5)
B
q e
34.3 - 61.7
(3.5 - 6.3)
q Frame front lower crossmember i Power train stiffener

subassembly o Stiffener plate bracket
w Engine mounting rear insulator !0 Stiffener right plate
e Engine rear support member subassembly !1 Stiffener left plate
r Speedometer driver cable assembly !2 Clutch cover undercover
t Starter assembly !3 Transmission assembly with transfer
y Backup lamp switch harness !4 Engine mounting rear bracket
u Control cable bracket !5 Transmission control cable bracket
JMT00007-00004

MT7
1. OPERATION PRIOR TO REMOVAL
(1) Disconnect the negative () terminal of the battery.
(2) Suspend the engine by means of an engine support Tool
bridge.
NOTE:
Attach the hook to the engine hanger.
(3) Raise the vehicle with a lift.

(4) Drain the transmission oil.
(5) Remove the propeller shaft assembly and propeller
front shaft assembly. JMT00008-00005
(6) Remove the front exhaust pipe assembly.

(7) Remove the clutch cable.
(8) Remove the shift cable assembly and select cable as-
sembly.
2. MAIN POINTS OF REMOVAL

(1) Remove the front lower frame crossmember sub-
assembly. With the transmission assembly supported
by a transmission jack, etc., remove the attaching
bolts of the engine mounting rear insulator and engine
rear support member subassembly. Proceed to re-
move the engine rear support member subassembly.
JMT00009-00006
(2) Remove the stiffener right plate by removing the three

attaching bolts.
Stiffener right plate
JMT00010-00007
(3) Separate the stiffener left plate from the transmission

by removing the two attaching bolts.
(4) Remove the transmission assembly with transfer from
the vehicle by removing the five attaching bolts.
Stiffener left plate
JMT00011-00008

MT8
3. OPERATION AFTER REMOVAL
(1) Ensure that the locating pin is positioned securely at both the transmission and engine sides.
NOTE:
Make sure to replace the locating pin that has exhibited severely scored.
Locating pin (at engine side)
Engine side Transmission side
Locating pin
(at transmission side)
Engine side Transmission side
JMT00012-00009
4. MAIN POINTS OF INSTALLATION

(1) With the transmission assembly with transfer support-
ed by a transmission jack, etc., bring the surface of
the transmission in close contact with the surface of
the engine. Tighten the attaching bolts to the specified
torque.
Stiffener left plate
(2) Tighten the attaching bolts of the stiffener left plate.
JMT00013-00010
(3) Tighten the attaching bolts of the stiffener right plate.

NOTE:
Temporarily tighten the -marked bolts until the stiffen-

er plate is brought in close contact with the transmis-
sion. Securely tighten the -marked bolts.
Then, proceed to tighten the -marked bolts to the
specified torque.
Stiffener right plate

JMT00014-00011
(4) Install the power train stiffener in the direction as indi-

NOTE:

Temporarily tighten the -marked bolts. Securely tight-
en the -marked bolts. Then, proceed to tighten the re-
maining two bolts securely.

Identification mark
JMT00015-00012

MT9
(5) Tighten the attaching bolts of the engine mounting rear
insulator and engine rear support member subassem-
bly. Proceed to install the attaching bolts of the engine
rear support member subassembly to the body.
(6) Remove the transmission jack, etc. Install the front
lower frame crossmember subassembly.
NOTE:
For the tightening torque, refer to MT6.
JMT00016-00013
5. OPERATION AFTER INSTALLATION

(1) Install the shift cable assembly and select cable as-
sembly.
(2) Assemble the clutch release cable assembly to the
clutch release fork. Adjust the clutch free travel.
(3) Install the front exhaust pipe assembly.
(4) Install the propeller shaft assembly and propeller front
shaft assembly.
(5) Pour the transmission oil.
(6) Lower the vehicle.
(7) Remove the engine support bridge.
(8) Connect the negative () terminal of the battery.
JMT00017-00000

MT10
DISASSEMBLY/ASSEMBLY OF MANUAL TRANSMISSION
COMPONENTS (PART 1)
: Tightening torque
Unit : Nm (kgf-m)
18.6 - 30.4
(1.9 - 3.1)
24.5 - 39.2
(2.5 - 4.0)
!1
!2 @9
14.7 - 21.6
(1.5 - 2.2) !2
9 @7
7 8
@6
6
@8
!0
B !8
18.6 - 30.4 !9
(1.9 - 3.1) !8
!7

B
!6 @2 !8
!3 B
!4 !8
!5 18.6 - 30.4 14.7 - 21.6
B (1.9 - 3.1) @1 (1.5 - 2.2)
!8
14.7 - 21.6 !3
14.7 - 21.6 (1.5 - 2.2) !4 @5 !8
(1.5 - 2.2) 18.6 - 30.4
B !5
(1.9 - 3.1)
5 B
#0 !3
B
@0 !4
4 !5
2
B
@4
3
@3
q Clutch housing !6 5th & reverse shift fork shaft

w Type S oil seal !7 5th & reverse shift head
e Shift interlock plate !8 Slotted spring pin
r Tension spring !9 5th shift fork
t Reverse shift arm @0 3rd & 4th shift fork shaft
y Input shaft bearing lock plate @1 3rd & 4th shift head
u Reverse idler gear @2 3rd & 4th shift fork
i Reverse idler gear thrust washer @3 1st & 2nd shift fork shaft
o Reverse idler gear shaft @4 1st & 2nd shift fork
!0 Slotted spring pin @5 1st & 2nd shift head
!1 Hexagon bolt @6 Tight plug
!2 Gasket @7 Transmission case
!3 Gasket @8 Transmission magnet
!4 Compression spring @9 Backup lamp switch assembly
!5 Ball #0 Breather plug
JMT00018-00014

MT11
NOTICE PRIOR TO OPERATION
This section summarizes the main points of each section of the configuration drawings posted on those
pages previous to MT10, MT12, MT20 and MT28. The description is so arranged that the removal and
assembly may readily be understandable when the configuration drawings are referred to the contents
posted at the lower section of the page.
For more details, refer to the relevant pages.
JMT00019-00000
COMPONENTS (PART 1)
q Clutch housing The clutch housing is connected to the transmission case by means of eight bolts of M8
(R= 40 mm) and two bolts of M8 (R= 60 mm).
Tightening torque: 14.7 - 21.6 Nm (1.5 - 2.2 kgf-m)
w Type S oil seal Be sure to apply gear oil to the lip section when assembling. Press this oil seal by means
of a 35 mm dia. rod.
e Shift interlock plate Overall length = 23.25 - 23.55 mm
Length at inside = 17.7 - 17.9 mm
The same plate is used in common at two points.
r Tension spring The tension spring is provided between Items t and y.
t Reverse shift arm Ensure that the operating pin moves lightly and freely between the neutral position and
the 5th gear position.
The reverse shift arm is installed with three bolts of M8 (R= 20 mm).
y Input shaft bearing lock plate The input shaft bearing lock plate is installed with three bolts of M8 (R= 20 mm).
u Reverse idler gear Bush bore diameter d = 20.03 - 20.06 mm
Care must be exercised as to the correct assembling direction.
i Reverse idler gear thrust washer Nylon-made washer
o Reverse idler gear shaft D = 20 mm
This shaft is secured by means of the hexagon bolt !1.
!0 Slotted spring pin Ensure that the section protruding from the shaft is 2.5 mm or less.
!1 Hexagon bolt Black bolt, hexagon socket
Be sure to pull out this bolt when disassembling the transmission.
!2 Gasket
!3 Gasket
!4 Compression spring The same spring is used in common at three points.
L = 40 mm
This compression spring is secured by means of a bolt of M10 (R= 19 mm).
!5 Ball The same ball is used in common at four points, including the reverse restrict ball.
D = 7.9375 mm
!6 5th & reverse shift fork shaft This fork shaft is the longest one among the three shafts.
L = 265 mm, D = 13.0 mm
!7 5th & reverse shift head Width contacting with inner lever: 12.1 - 12.2 mm
Width contacting with reverse shift arm pin: 15.0 - 15.043 mm
!8 Slotted spring pin The same pin is used in common at six points.
D = 5 mm, L = 23 mm
!9 5th shift fork Thickness of rib section contacting with hub sleeve: 6.7 - 6.9 mm
@0 3rd & 4th shift fork shaft This shaft has the middle length among three shafts.
L = 259 mm, D = 13.0 mm
@1 3rd & 4th shift head Groove width at section contacting with shift inner lever: 12.1 - 12.2 mm
@2 3rd & 4th shift fork Thickness of rib section contacting with hub sleeve: 6.7 - 6.9 mm
@3 1st & 2nd shift fork shaft This fork shaft is the shortest one among the three shafts.
L = 224 mm, D = 13.0 mm
@4 1st & 2nd shift fork Thickness of section contacting with hub sleeve: 9.7 - 9.9 mm
(Only the 1st & 2nd shift fork is wider than other shift forks.)
@5 1st & 2nd shift head Groove width at section contacting with shift inner lever: 12.1 - 12.2 mm
@6 Tight plug This plug is not required to remove, unless exceptional situation, such as oil leakage, oc-
curs.
@7 Transmission case The clutch housing is connected to the transmission case with 10 bolts.
The transfer assembly is connected to the transmission case with 6 bolts.
@8 Transmission magnet This magnet is not secured with a bolt.
@9 Backup lamp switch assembly Tightening torque: 24.5 - 39.2 Nm (2.5 - 4.0 kgf-m)
#0 Breather plug Tightening torque: 14.7 - 21.6 Nm (1.5 - 2.2 kgf-m)
JMT00020-00000

MT12
COMPONENTS (PART 2)
: Tightening torque
Unit : Nm (kgf-m)
14.7 - 21.6 %8
#4 (1.5 - 2.2)
29.4 - 49.0
(3.0 - 5.0) B
%7
14.7 - 21.6 %2 %6
(1.5 - 2.2) #5
^0 $1
18.6 - 30.4 B
B 14.7 - 21.6 $2
(1.9 - 3.1) w $3
#6 (1.5 - 2.2) %3 %4
#1 $4
B #2
#7 %0 %1
#3 ^3
#8 176.4 - 215.8
%5
#9 (18.0 - 22.0)
%9
$7
$8
$6
^1 24.5 - 39.2
^2 (2.5 - 4.0) $9
$5
$0
#1 Torsion spring $8 Grooved pin

#2 Reverse restrict cam $9 Shift lever shaft subassembly
#3 Reverse restrict shaft %0 Radial ball bearing
#4 Select lever subassembly %1 Hole snap ring
#5 Grooved pin %2 Rear bearing retainer
#6 Control shaft cover %3 Transfer input hub
#7 Transmission case cover gasket %4 Conical spring washer
#8 Torsion spring %5 Lock nut
#9 Select inner lever %6 Needle roller bearing
$0 Output shaft %7 Extension housing gasket
$1 Reverse restrict pin holder %8 Transfer assembly
$2 Gasket %9 Type T oil seal
$3 Compression spring ^0 Type K oil seal
$4 Ball ^1 Gasket
$5 Transmission case ^2 W/head straight screw plug
$6 Shift inner lever ^3 Clamp
$7 Control shaft boot
JMT00021-00015

MT13
COMPONENTS (PART 2)
#1 Torsion spring Pay special attention to the assembling direction in the same way as with Item #2.
#2 Reverse restrict cam Pay special attention to the assembling direction during disassembly and assembly, for
the reverse restrict cam has the correct assembling direction to be observed.
#3 Reverse restrict shaft D = 8 mm, L = 7.15 mm
#4 Select lever subassembly Pay special attention to the assembling direction of the lever when Items #8 and #9 are
assembled.
#5 Grooved pin D = 6 mm, L = 22 mm
Drive this pin into position from the side where no groove is provided.
#6 Control shaft cover The transmission case cover is installed with a total of four bolts; two bolts of M8 and two
reamer bolts (olive green) of M8 with Item #7 interposed.
#7 Transmission case cover gasket (Non-asbestos)
#8 Torsion spring Pay special attention to the up-and-down direction of the spring during assembly.
#9 Select inner lever Width of section contacting with shift head: 14.88 - 14.98 mm
$0 Output shaft This shaft corresponds to the 4th gear.
$1 Reverse restrict pin holder Tightening torque: 29.4 - 49.0 Nm (3.0 - 5.0 kgf-m)
$2 Gasket
$3 Compression spring Free length: 24.00 mm
Length as installed: 17.00 mm
$4 Ball The same ball is used in common at four points, including the shift fork ball.
$5 Transmission case Description is made in the Components (part 1).
Apply Three Bond 1216 or 1217 to the mating sections with the clutch housing and ex-
tension housing.
$6 Shift inner lever Width of section contacting with shift head: 11.88 - 11.98 mm
Width of section contacting with select inner lever: 15.1 - 15.2 mm
$7 Control shaft boot Install this boot in such a way that the air bleeding section faces downward.
$8 Grooved pin D = 6 mm, L = 24 mm
$9 Shift lever shaft subassembly Pay special attention to the assembling direction of the lever during assembly.
%0 Radial ball bearing
%1 Hole snap ring This ring can be reused.
%2 Rear bearing retainer This retainer is installed with five bolts of M8 (R= 20 mm).
%3 Transfer input hub
%4 Conical spring washer Pay special attention to the correct installing direction during the assembly.
%5 Lock nut Width across flats of lock nut: 32 mm
Be sure to stake the lock nut after tightening.
%6 Needle roller bearing
%7 Extension housing gasket
%8 Transfer assembly The transmission case is connected to the transfer assembly by means of five bolts of
M10 (R= 40 mm) and two bolts of M10 (R= 210 mm).
%9 Type T oil seal The protruding dimension should be observed strictly at the time of installation to be 5
0.3 mm.
^0 Type K oil seal The seal inclination at the time of prese-fitting should be 1 or less.
Apply MP grease to the lip section.
^1 Gasket
^2 W/head straight screw plug Tightening torque: 24.5 - 39.2 Nm (2.5 - 4.0 kgf-m)
^3 Clamp
JMT00022-00000

MT14
REMOVAL OF TRANSFER ASSEMBLY
NOTE:
For disassembly of the transfer assembly, refer to 40 40
40
Section TR.
1. Remove the seven bolts indicated in the right figure.

NOTE:
The numeral in the right figure denotes the nominal
length of each bolt. (Unit: mm)
JMT00023-00016
2. Top the rib section of the transfer case. Then, pull out it to-
ward you.
3. Remove the extension housing gasket.
NOTE:
Never reuse the removed gasket.
4. Remove the needle roller bearing at the forward end of the 40

transmission output shaft. 210
40
210
JMT00024-00017
DISASSEMBLY
(A)
DISASSEMBLY OF SHIFT AND SELECT LEVER RELATED
PARTS
NOTE:
After the sifting feeling and continuity for the reverse
backup lamp switch have been checked.
1. Remove the clutch-related parts.

(Detach the engagement of the spring (A).)
JMT00025-00018
2. Remove the control shaft cover with gasket {(A) bolts are (A)
used for the reamer bolt}.
3. Remove the compression spring and ball of the reverse (A)
restrict pin holder (B) with the gasket. (B)
NOTE:
Disassemble the control shaft cover, as required.
Prior to the disassembly, drive out the grooved pin of
the shift lever shaft.
4. Remove the hexagon bolt (C) of the reverse idler gear (C)
shaft with the gasket. JMT00026-00019
NOTE:
This hexagon bolt is for securing the reverse idle shaft.
Hence, be sure to remove this bolt before the transmis-
sion is disassembled.

MT15
5. Pull out the shift lever subassembly and shift inner lever by
driving out the grooved pin.
6. Remove the reverse restrict cam (A), torsion spring (B)
and reverse restrict shaft (C) by removing the hexagon
bolt with the gasket.
NOTE:
The reverse restrict cam (A) has the correct assem-
bling direction to be observed during assembly.
Therefore, when disassembling the reverse restrict
cam, make sure to remember the assembling direction
in order that the part may be assembled correctly. JMT00027-00020
7. Remove the backup lamp switch assembly with the gasket.

NOTE:
Do not reuse the gasket removed above.
DISASSEMBLY OF TRANSMISSION CASE

NOTE:
Disassemble the transmission case after checking to
see if any variation in rotation exists between the input
and output shafts.
JMT00028-00000
1. Remove the 10 bolts of the transmission case, (including

the two bolts to be removed from the side of the clutch
housing).
NOTE:
Of those bolts that are installed from the clutch housing
side, one bolt is a hexagon socket head bolt due to a
reason in the production line. However, here it is per-
missible to install the same hexagonal bolt as other
bolts.
2. Tap the rib section of the transmission case. Then, pull it JMT00029-00021
out toward you.
3. Remove the lock nut by means of a deep socket.

NOTE:
Do not reuse the removed lock nut. Deep socket
[Reference]
Deep socket dimensions (Tool commercially available)
Width across flats: 32 mm Overall length: 100 mm
4. Remove the conical spring washer.

JMT00030-00022

MT16
5. Remove the transfer input hub.
6. Remove the rear bearing retainer and transmission mag-
net by removing the five bolts.
JMT00031-00023
7. Remove the hole snap ring with a snap ring expander.

8. Remove the output shaft from the transmission case.
JMT00032-00024
REMOVAL OF SHIFT FORK

NOTE:
Check the movement of reverse shift arm and contact
width between the shift fork and the rib sleeve.
Make sure that the shift fork is removed only after the
gear concerned is placed in neutral.
JMT00033-00000
1. Detach the tension spring (A).

2. Remove the compression spring and ball by removing the
hexagon bolt with the gasket (B).
3. Remove the 5th & reverse shift fork shaft by removing the
slotted spring pin of the shift fork and shift head.
NOTE:
When the slotted spring pin is driven out, a measure to (A)
sustain the reaction force for pulling out should be
taken at the opposite side.
(B)
JMT00034-00025
4. Remove the 1st & 2nd shift fork shaft and the 3rd & 4th
shift fork shaft progressively, following the procedure de-
scribed in the steps 2 through 3 above.
JMT00035-00026

MT17
REMOVAL OF INPUT SHAFT AND COUNTER GEAR
NOTE:
Confirm that each gear can be engaged properly.
1. Pull out the output shaft assembly with the needle roller
bearing, synchronizer ring and wave spring.
2. Remove the reverse shift arm by removing the three bolts.
3. Pull out reverse idler gear shaft, thrust washer and reverse
gear.
4. Remove the input shaft bearing lock plate by removing the
three bolts. JMT00036-00027
5. While holding both the input shaft and counter gear as-
sembly by your hands, pull out them in such a way that
they face toward the upper side.
INSPECTION
1. Measure the free length of the compression spring for shift
fork shafts and reverse restrict pin.
For shift fork shafts For reverse restrict pin
Free length 40 mm 24 mm
Load as installed: N (kgf) 47.33 N (4.83 kgf) 23.83 N (2.43 kgf)
Height as installed 30 mm 17 mm
2. Visually inspect the balls for deformation or scratches.

JMT00037-00028
3. Measure the contact width section between the select
inner lever shaft and shift heads.
Unit: mm
Select inner lever Shift inner lever heads
0.02 +0.2
Specified Value 15 0.12 15 +0.1
JMT00038-00029
SHIFT FORKS AND HEADS

INSPECTION
1. Measure the outer diameter of the shift fork shafts and
inner diameter of the case sides.
Unit: mm
Case sides Shaft sides
+0.043 0.050
Specified Value 13.0 +0 13.0 0.077
JMT00039-00030

MT18
2. Measure the contact width section between the shift
heads and the shift inner lever.
Unit: mm
Shift heads Shift inner lever
+0.1 0.02
Specified Value 12.1 +0 12 0.12
JMT00040-00031
REVERSE IDLER GEAR

1. Visually inspect the chamfered section of the reverse idle
gear for damage.
2. Measure the bore diameter of the reverse idle gear bush.
3. Measure the outer diameter of the reverse idle gear shaft.
Also, check its surface for scores, etc.
Unit: mm
(d) (D)
+0.061 +0
Specified Value 20 +0.032 20.0 0.013
JMT00041-00032
REPLACEMENT OF TYPE S OIL SEAL

1. Remove the Type S oil seal with a common screwdriver.
NOTE:
Do not reuse the removed Type S oil seal.
JMT00042-00033
2. Install a new Type S oil seal in the clutch housing, using

the SST given below.
SST: 09606-87201-000
SST
NOTE:
Prior to assembly, apply gear oil to the whole periphery
of the lip section.
JMT00043-00034
SHIFT LEVER & SHIFT RELATED PARTS

REPLACEMENT
REMOVAL
1. Remove the select lever boot.
2. Remove the tight plug (if necessary).
3. Remove the Type T oil seal.
NOTE:
Do not reuse the removed tight plug and oil seal.
JMT00044-00035

MT19
INSTALLATION
1. Install the new tight plug as shown in the right figure.
2. Install the new Type T oil seal as shown in the right figure.
3. Ensure that the protrusion section (A) of the Type T oil seal
conforms to the specified value.
Specified Value: 5 0.3 mm
CAUTION:
If the protrusion section (A) exceeds the specification
above (i.e. above 5.3 mm), it would cause oil leakage.
4. Check that continuity exists at the backup lamp switch assembly.

JMT00045-00000

MT20
INPUT SHAFT
COMPONENTS
: Selection parts
!3

2 !2
!1
1 !0
7
9
7
6
5
4
8 @1
@0
!5 !9
!8 !6
!4 !6
!7
q Shaft snap ring !2 Needle roller bearing

w Radial ball bearing (front) !3 3rd gear
e Input shaft !4 Synchronizer ring No. 1
r Split type needle roller bearing !5 Wave spring
t 5th gear !6 Synchromesh shifting key spring
y Synchronizer ring No. 1 !7 Synchronizer No. 2 hub assembly
u Synchromesh shifting key spring !8 Synchromesh shifting key
i Synchronizer No. 3 hub assembly !9 Shaft snap ring
o Synchromesh shifting key @0 Synchronizer ring No. 1
!0 Transmission hub sleeve stopper @1 Needle roller bearing
!1 Shaft snap ring
JMT00046-00036

MT21
COMPONENTS
q Shaft snap ring This is shared in common with the snap ring of Item !9. Thickness selection type snap
ring
w Radial ball bearing
e Input shaft Needle roller bearing rotating section: D = 31.971 - 31.991 mm, two points
Needle roller bearing rear end section: D = 19.966 - 19.984 mm
r Split type needle roller bearing The opening width of mating ends of the bearing should not exceed the shaft diameter +
5 mm during installation and removal.
The opening end should not exceed 37 mm.
-1
t 5th gear Bore diameter: 37.00 - 37.025 mm
Width: 27.82 - 27.88 mm
Thrust end play: 0.1 - 0.4 mm
y Synchronizer ring No. 1 Items y, !4 and @0 are used in common.
Clearance between the gear and the synchronizer ring: 0.95 - 1.35 mm
u Synchromesh shifting key spring Items u and !6 are used in common.
Make sure that no mating end of the spring comes in the same direction in assembly.
i Synchronizer No. 3 hub assembly Thickness at boss section: 12.37 - 12.43 mm
The sleeve is shared in common with Item !7 However, be very careful not to mix the
sleeve with others, for the hub and sleeve are assembled as a set.
Assemble the hub in such a way that the oil-groove side of the hub comes at the front,
namely the 5th gear side.
The sleeve has no correct assembling direction to be observed. However, be sure to
align the missing teeth provided at three points when the hub and sleeve are assem-
bled.
o Synchromesh shifting key Items o and !8 are used in common.
Therefore, a total of six pieces are used in common.
Thickness: 4.6 - 4.8 mm
!0 Transmission hub sleeve stopper Thickness: 7.19 - 7.25 mm
Assemble this retainer in such a way that the flat surface comes at the front; the oil-
groove side comes at the rear.
!1 Shaft snap ring This is shared in common with Item q of the counter gear.
Thickness selection type
!2 Needle roller bearing This is shared in common with Item u of the counter gear.
!3 3rd gear Bore diameter: 37.00 - 37.025 mm
Width: 37.95 - 37.98 mm
Number of gear teeth: 33
Outer diameter: 63.7
Thrust end play: 0.1 - 0.52 mm
!4 Synchronizer ring No. 1 Items y, !4 and @0 are used in common.
Clearance between the gear and the synchronizer ring: 0.95 - 1.35 mm
-2
!5 Wave spring This wave spring is provided between items !7 and @0
!6 Synchromesh shifting key spring Items u and !6 are used in common.
Make sure that no mating end of the spring comes in the same direction in assembly.
!7 Synchronizer No. 2 hub assembly Thickness at boss section: 18.52 - 18.58 mm
Assemble the hub in such a way that the oil-groove side of the hub comes at the front,
namely the 3rd gear side.
Be sure to align the missing teeth provided at three points when the hub and sleeve are
assembled. The sleeve has no correct assembling direction to be observed.
Width of shift fork groove: 7.05 - 7.12 mm
!8 Synchromesh shifting key Items o and !8 are used in common.
Therefore, a total of six pieces are used in common.
Thickness: 4.6 - 4.8 mm
!9 Shaft snap ring This is shared in common with the snap ring of Item q.
Thickness selection type
@0 Synchronizer ring No. 1 Items y, !4 and @0 are used in common.
Refer to Items y and !4.
@1 Needle roller bearing This needle roller bearing is located between the input shaft and the output shaft.
-1 When the snap ring !1 is removed, those parts r to !0 can be removed collectively.
-2 When the snap ring !9 is removed, those parts !2 to !8 can be removed collectively.
JMT00047-00000

MT22
INSPECTION PRIOR TO OPERATION
1. Measure the contact section of the shift forks for 3rd gear
(A), 5th gear (B) and with the hub sleeves.
Unit: mm
3rd gear (A) and 5th gear (B)
Fork Hub sleeve
0.1 +0.12
Allowable Limit 6.6 7.2
JMT00048-00037
2. Measure and record the thrust clearance for 3rd gear (C)
and 5th gear (D), using a feeler gauge.
Unit: mm
(C) (D)
Specified Value 0.10 - 0.52 0.10 - 0.40
NOTE:
Ensure that the thrust clearance is measured at several
points.
If the measured thrust clearance fails to conform to the JMT00049-00038
specification above, proceed to disassemble the input

shaft assembly.
DISASSEMBLY
1. Using soft jaws, clamp the input shaft assembly in a vice
so as to avoid the damage in the spline section.
2. Remove the selection type shaft snap ring at the rear side.
3. For reference at the time of installation, measure and
record the removed shaft snap ring.
JMT00050-00039
4. Remove the following parts, using the following SST.

SST: 09950-20017-000
NOTE:
The following parts can be removed by driving out the
input shaft by means of a press, with the 3rd gear sec-
tion sustained by the SST (09334-87301-000)
(1) Synchronizer No. 2 hub assembly

(2) Synchronizer ring No. 1
(3) 3rd gear JMT00051-00040
5. Remove the needle roller bearing.
6. Remove the selection type shaft snap ring.

record the removed shaft snap ring.
8. Remove the transmission hub sleeve stopper.
JMT00052-00041

MT23
9. Remove the following parts, using the following SST.
SST: 09950-20017-000
NOTE:
The following parts can be removed by driving out the
input shaft by means of a press, with the 5th gear sec-
tion sustained by the SST (09334-87301-000).

(3) 5th gear JMT00053-00042
10. Remove the split type needle roller bearing.

CAUTION:
When the split type needle roller bearing is removed,
make sure that the gap (B) at the opening of the needle
roller bearing will not exceed the outer diameter of the
input shaft by more than 5 mm.
JMT00054-00043

12. Measure and record the thickness of the removed snap
ring for the reference of installation.
13. Remove the radial ball bearing at the front side, using the
following SST.
SST: 09950-20017-000
JMT00055-00044
INSPECTION
1. Check the clearance between the gear tapered section
and the synchronizer rings.
JMT00056-00045
2. Measure the outer diameter of the input shaft at the sec-

tions (A), (B) and (C) as shown in the right figure.
3. Visually inspect the sections (A), (B) and (C) for scratch or
discoloration.
Unit: mm
Specified Value
0.009
(A) and (B) 32 0.029
0.016
(C) 20 0.034
JMT00057-00046

MT24
4. Measure the dimensions between the outer diameter of
the synchronizer No. 2 for 3rd (A) and synchronizer No. 3
for 5th (B) and bore diameter of both hub sleeves.
Unit: mm
Classifica- Identifica-
(A) and (B) Hub sleeve
tion tion
No. 2 57.78 - 57.84 57.871 - 57.97 Yellow
No. 1 57.68 - 57.74 57.771 - 57.87 None
No. 3 57.58 - 57.64 57.67 - 57.77 White
JMT00058-00047
CAUTION:
If any part which has exceeded the value specified in
the table above should be used, it would cause abnor-
mal noise. Therefore, be certain to replace those parts
as a set.
5. Measure the thickness of the synchronizer hub No. 2 (C)

and No. 3 (D).
Unit: mm
(C) (D)
Specified Value 18.55 0.03 12.4 0.03 JMT00059-00048
6. Measure the height of the transmission hub sleeve stop-

per.
(A) section:
+0.05 mm
Specified Value: 7.2 0.01 mm
JMT00060-00049
7. Measure the thickness and inner diameter of the 3rd and

3rd gear 5th gear
5th gears.
Unit: mm
3rd gear (A) 5th gear (B)
+0.025
Specified Value 37.0 +0
3rd gear (C) 5th gear (D)

Specified Value 37.95 0.03 27.85 0.03
JMT00061-00050
8. Measure the height of the synchromesh shifting key.

0.2 mm
NOTE:
All of the six shifting keys assembled in the input shaft
are common parts.
9. Visually inspect the synchromesh shifting key spring for

wear or damage.
JMT00062-00051

MT25
ASSEMBLY
NOTE:
Be sure to apply gear oil to the relevant parts at every
process.
Never reuse those parts bearing an asterisked mark
posted at the pages MT20 and 21.
JMT00063-00000
1. Install the split type needle roller bearing and apply gear
oil to it.
CAUTION:
When the split type needle roller bearing is installed,
make sure that the gap (B) at the opening of the needle
roller bearing does not exceed the outer diameter of
the input shaft by more than 5 mm.
JMT00064-00052
2. Install the 5th gear and synchronizer ring to the input

shaft.
3. Assemble the synchromesh shifting key and key spring to
the hub as shown in the illustration.
NOTE:
Make sure that no opening end of the shifting key
spring comes in the same direction in assembly.
Be sure to align the missing teeth provided at three
points when the hub and sleeve are assembled.
The same hub sleeve is used for both the 3rd gear and
4th gear. However, the hub differs in shape between JMT00065-00053
the 3rd gear and the 4th gear.
4. Ensure that the grooved section in the protrusion position

of the synchronizer No. 3 hub faces toward the front (i.e.
the 5th gear) side and press them, using the following
SST.
SST: 09310-87302-000
NOTE:
Make sure that the synchronizer ring is aligned with the
shifting key grooves (three points), while the synchro- JMT00066-00054
nizer No. 3 hub is being pressed.
5. Install the transmission hub sleeve stopper.

NOTE:
Ensure that the oil groove section of the 5th shifting
key retainer faces toward the 3rd gear side.
JMT00067-00055

MT26
6. Selection procedure for new shaft snap ring
(1) Using the table below, select a new shaft snap ring
having the same thickness as that measured at the
time of the removal, or the thinnest shaft snap ring.
Then, install the thus-selected snap ring on the shaft
snap ring installation groove of the input shaft.
(2) Measure the end play, using a feeler gauge as shown
(3) Select a snap ring shaft whose end play is zero or al-
most zero and that can be set readily, using the table
below. JMT00068-00056
(4) Again, ensure that the end play between the 5th shifting key retainer and the shaft snap ring con-
forms to the specified value.
End Play:
Specified Value: 0
Allowable Limit: Less than 0.16 mm
Unit: mm
Part No. Thickness Identification Part No. Thickness Identification
90045-20263 2.06 None 90045-20267 1.90 Brown
90045-20264 2.02 Brown 90045-20268 1.86 Blue
90045-20265 1.98 Blue 90045-20269 1.82 None
90045-20266 1.94 None 90045-20270 2.10 Brown
NOTE:
The shaft snap rings in the table above are the common parts as those used when the hub of the
counter gear is set.
JMT00069-00000
7. Install the needle roller bearing and apply gear oil.

8. Install the 3rd gear and synchronizer ring.
9. Assemble the synchromesh shifting key spring and shift-
ing key to the synchronizer No. 2 hub assembly.
NOTE:
For the handling of the hub sleeve, refer to the step 3
at page MT25.
10. Ensure that the oil grooved section (A) of the synchronizer
No. 2 hub assembly faces toward the 3rd gear side.
JMT00070-00057
NOTE:
Make sure that the wave spring is interposed between
the synchronizer hub No. 2 and the synchronizer ring in
advance of the synchronizer hub No. 2 pressing, using
the following SST.
SST: 09310-87302-000
JMT00071-00058

MT27
11. Selection procedure for new shaft snap ring
(1) For the selection procedure of the shaft snap ring,
refer to the step 6 at page MT26.
JMT00072-00059
(2) Again, ensure that the end play between the hub and the shaft snap ring conforms to the specified
value.
End Play:
Specified Value: 0
Unit: mm
90045-20271 2.06 None 90045-20275 1.90 Brown
90045-20272 2.02 Brown 90045-20276 1.86 Blue
90045-20273 1.98 Blue 90045-20277 1.82 None
90045-20274 1.94 None 90045-20278 1.78 Brown
NOTE:
The shaft snap rings in the table above are the common parts as those used at the front bearing sec-
tion of the input shaft.
JMT00073-00000
12. Press the radial ball bearing.

NOTE:
Be very careful not to drop and disassemble the syn-
chronizer ring and hub sleeve, while the radial ball
bearing is being pressed.
The assembling operation of the radial ball bearing
may be conducted first.
13. In the same manner of the step 11 above, install the selec-
tion type shaft snap ring.
JMT00074-00060

MT28
COUNTER GEAR
COMPONENTS
: Selection parts
q Shaft snap ring !2 Synchromesh shifting key

w Radial ball bearing !3 Synchronizer ring No. 3
e 1st gear thrust washer !4 Split type needle roller bearing
r Shaft snap ring !5 2nd gear
t 1st sub-gear !6 Conical spring washer
y Conical spring washer !7 2nd sub-gear
u Needle roller bearing !8 Shaft snap ring
i 1st gear !9 Counter gear
o Synchronizer ring No. 2 @0 Radial ball bearing
!0 Synchromesh shifting key spring @1 Shaft snap ring
!1 Synchronizer No. 1 hub assembly
JMT00075-00061

MT29
COMPONENTS
q Shaft snap ring Thickness selection type
w Radial ball bearing Assemble the bearing so that the side having a seal comes at the front.
e 1st gear thrust washer Thickness = 3.97 - 4.03 mm
Assemble the washer in such a way that the protruding side comes at the front; the oil-
groove side comes at the 1st gear side.
Thrust end play of 1st gear = 0.1 - 0.52 mm
r Shaft snap ring
t 1st sub-gear -1
Items r and !8 are used in common.
Items r to i are normally handled as assembled parts.
y Conical spring washer Items y and !6 are used in common.
u Needle roller bearing This bearing is shared in common with Item !2 of the input shaft.
i 1st gear Inner diameter: 37.00 - 37.025 mm
Effective thickness: 27.31 - 27.37 mm
Clearance with synchronizer ring: 0.95 - 1.35 mm
Limit: 0.9 mm
o Synchronizer ring No. 2 Not interchangeable with Item !3.
To distinguish this from Item !3, missing teeth are provided at three points.
!0 Synchromesh shifting key spring Make sure that no mating end comes in the same direction in assembly.
!1 Synchronizer No. 1 hub assembly The hub and sleeve (reverse gear) are assembled as a set.
Effective hub width: 26.97 - 27.03 mm
Assemble the hub assembly so that the side having a larger boss protruding dimension
comes at the front.
As for the sleeve (reverse gear), make sure that the shift fork groove comes at the front
side.
Shift fork groove width: 10.05 - 10.12 mm
-2
!2 Synchromesh shifting key Thickness = 5.0 - 5.2 mm, composed of 3 pieces.
!3 Synchronizer ring No. 3 Not interchangeable with Item o.
!4 Split type needle roller bearing This is shared in common with Item r of the input shaft.
The opening width of mating ends should not exceed 37 mm during installation and re-
moval.
!5 2nd gear Inner diameter: 37.00 - 37.025 mm
Effective thickness: 36.27 - 36.33 mm
Clearance with synchronizer ring: 0.95 - 1.35 mm
Limit: 0.9 mm
Thrust clearance: 0.1 - 0.4 mm
!6 Conical spring washer Items y and !6 are used in common. Assemble each part to the 2nd gear in such a way
that the portion having a wider spring diameter comes at the sub-gear side.
!7 2nd sub-gear Items !5 to !7 are serviced as assembled parts together with the ring !8.
!8 Shaft snap ring Items r and !8 are used in common.
!9 Counter gear Outer diameter of roller bearing rotating section: 31.971 - 31.991 mm
@0 Radial ball bearing
@1 Shaft snap ring This is used in common with Item !1 of the input shaft. Thickness selection type.
-1 When the snap ring q is removed, those parts up to i can be removed collectively.
-2 When the snap ring @2 is removed, those parts !0 to !8 can be removed collectively.
JMT00076-00000

MT30
INSPECTION PRIOR TO OPERATION
1. Measure the contact width section of the synchronizer No.
1 hub assembly (B) with the 1st & 2nd shift fork (A).
Unit: mm
(A) (B)
0.1 +0.12
Allowable Limit 9.6 10.2
2. Measure and record the thrust clearance for 1st gear (C)
and 2nd gear (D) as shown in the right figure.
NOTE:
Prior to disassembling, make sure to measure the
thrust clearance at several points.
If the measured thrust clearance exceeds the specified
value in the table below, proceed to disassemble the
counter gear.
Unit: mm
1st gear (C) 2nd gear (D)
Specified Value 0.10 - 0.52 0.10 - 0.40
JMT00077-00062
DISASSEMBLY
1. Using soft jaws, clamp the spline section of the counter
gear assembly in a vice so as to avoid damage.
record the removed selection type shaft snap ring.
JMT00078-00063
4. Remove the following parts by pressing the counter gear

by means of a suitable rod.
(1) Radial ball bearing
(2) 1st gear thrust washer
(3) 1st gear
(5) Needle roller bearing
NOTE:
The parts described above can be removed by press-
ing the counter gear, while the 1st gear is supported by
means of the following SST. JMT00079-00064
SST: 09334-87301-000

record the removed selection type shaft snap ring.
JMT00080-00065

MT31
7. Remove the following parts.
(3) 2nd gear with sub-gear
NOTE:
The parts described above can be removed by press-
ing the counter gear, while the 2nd gear (sub-gear sur-
face) is supported by means of the following SST.
SST: 09334-87301-000
JMT00081-00066
8. Remove the split type needle roller bearing.

CAUTION:
When the split type needle roller bearing is removed,
make sure that the gap (A) at the opening of the needle
roller bearing does not exceed the outer diameter of
the counter gear by more than 5 mm. Failure to ob-
serve this caution would cause abnormal noise from
the transmission.
JMT00082-00067
9. Remove the radial ball bearing at the rear side of the

counter gear, using the SST given below.
SST: 09306-87602-000
JMT00083-00068
INSPECTION
1. Measure the height of the synchromesh shifting spring
keys.
Specified Value: 5.1 0.1 mm
2. Visually inspect the spring for synchromesh shifting key

spring for damage or distortion.
JMT00084-00069
3. Measure the outer diameter of the counter gear at the sec-

tions (A) and (B).
Unit: mm
(A) (B)
0.009
Specified Value 32 0.029
4. Visually inspect the sections (A) and (B) for discoloration

and scratches.
JMT00085-00070

MT32
5. Measure the thickness of the 1st gear thrust washer.
JMT00086-00071
6. Measure the dimensions between the outer diameter of

the synchronizer No. 1 hub (A) and the bore diameter of
synchronizer hub sleeve (B).
[Reference information]
The parts (A) and (B) are available only as a set. An identi-
fication mark is applied to the end surface of the synchro-
nizer hub.
Unit: mm
Classifica- Identifica-
(A) (B)
tion tion
JMT00087-00072
No. 2 69.78 - 69.84 69.871 - 69.97 Yellow
No. 1 69.68 - 69.74 69.771 - 69.87 None
No. 3 69.58 - 69.64 69.67 - 69.77 White
CAUTION:
When replacing those parts (A) and (B), be sure to re-
place them as a set.
7. Measure the thickness (A) of the synchronizer No. 1 hub.

JMT00088-00073
8. Measure the inner diameter of 1st and 2nd gear.

Unit: mm 1st gear 2nd gear
1st gear (A) 2nd gear (B)
+0.025
Specified Value 37.0 +0
9. Measure the thickness of 1st and 2nd gear.

Unit: mm
1st gear (C) 2nd gear (D)
Specified Value 27.34 0.03 36.30 0.03
JMT00089-00074

MT33
REPLACEMENT OF CONICAL SPRING WASHER
1. Clamp the 1st gear together with the following SST in a
vice as shown in the right figure.
SST: 09350-32014-000
2. Remove the conical spring washer and sub-gear by re-

moving the shaft snap ring.
JMT00090-00075
INSPECTION
1. Measure the height of the conical spring washer.
2. Place a new conical spring washer (1) and sub-gear on

the 1st gear.
3. Ensure that the expanded side of the conical spring wash-
er faces toward the sub-gear side as shown in the right
figure.
JMT00091-00076
4. Install a new shaft snap ring by pressing the conical

spring washer, using the following SST.
SST: 09350-32014-000
JMT00092-00077
5. In the same manner of the operation stated above, re-

place the conical spring washer for the 2nd sub-gear.
6. Ensure that the expanded side of the conical spring wash-
er (1) for 2nd sub-gear faces toward the sub-gear side as
JMT00093-00078
ASSEMBLY
When assembling the counter gear, apply gear oil at each
step and assemble each part.
As for those parts which bear the marks at pages
MT28 and MT29, never reuse them.
1. Install the radial ball bearing at the rear side of the counter
gear, using a press in combination with the following SST
given below.
SST: 09310-87301-000
JMT00094-00079

MT34
2. Install the split type needle roller bearing.
CAUTION:
When the split type needle roller bearing is installed,
make sure that the gap (A) at the opening of the needle
roller bearing will not exceed the outer diameter of the
counter gear by more than 5 mm.
3. Apply gear oil to the outer periphery of the split type nee-
dle roller bearing and install the 2nd gear to the counter
gear.
JMT00095-00080
4. Place the synchronizer ring No. 3 into the synchronizer

No. 1 hub.
NOTE:
The external appearance of the synchronizer ring No. 3
{for 2nd gear (B)} differs from that of the synchronizer
ring No. 2 {for 1st gear (A)}, as evident from the right il-
lustration.
JMT00096-00081
5. Install the synchronizer ring No. 3 to the synchronizer

No. 1.
6. Assemble the synchromesh shifting key and synchromesh
shifting key spring to the synchronizer No. 1 hub assem-
bly.
NOTE:
During assembling, make sure that the mating ends of
the shifting key springs come at different positions.
When installing the hub and hub sleeve, be sure to
align three teeth-missing sections.
JMT00097-00082
7. Prior to pressing the synchronizer No. 1 hub assembly,

make sure that the protrusion section (A) of the hub faces
toward the front side. (The hub sleeve has a shift fork
groove.)
8. Apply gear oil to the tapered section of the 2nd gear.

9. Apply gear oil to the spline section.
10. Align the spline section. Press the synchronizer No. 2 hub
assembly by using the following SST.
SST: 09310-87302-000
NOTE:
While the synchronizer No. 2 hub assembly is being
pressed into the counter gear, make sure that the shift-
ing key assembled to the hub is aligned with the shift
key groove of the synchronizer ring. JMT00098-00083

MT35
11. Selection sequence of new shaft snap ring.
(1) Using the table below, select a new shaft snap ring
having the same thickness as that measured at the
time of removal, or the thinnest shaft snap ring.
Then, install the thus-selected shaft snap ring on the
shaft snap ring installation groove of the counter gear.
(2) Measure the end play, using a feeler gauge as shown
(3) Select a shaft snap ring whose end play is zero or al-
most zero and that can be set readily, using the table
below. Then, proceed to install it. JMT00099-00084
(4) Again, ensure that the end play conforms to the specified value.
End Play:
Specified Value: 0
Unit: mm
90045-20263 2.06 None 90045-20267 1.90 Brown
90045-20264 2.02 Brown 90045-20268 1.86 Blue
90045-20265 1.98 Blue 90045-20269 1.82 None
90045-20266 1.94 None 90045-20270 2.10 Brown
NOTE:
The shaft snap rings in the table above are the same as those used when the hub of the input shaft
is set.
JMT00100-00000
12. Install the needle roller bearing. Apply gear oil to the outer
periphery of the needle roller bearing.
13. Place the synchronizer ring No. 2 (the ring having missing
teeth).
14. Install the 1st gear with the sub-gear assembled.
15. Install the 1st gear thrust washer.
NOTE:
Ensure that the protrusion section (A) of the 1st gear
thrust washer faces toward the front side.
JMT00101-00085
16. Press the radial ball bearing, using the following SST.
SST: 09310-87301-000
NOTE:
Make sure that the radial ball bearing having a seal
faces toward the front.
JMT00102-00086

MT36
17. Selection sequence of new shaft snap ring
(1) For the selection procedure of the shaft snap ring,
refer to the step 11 at page MT35.
JMT00103-00087
(2) Ensure that the end play conforms to the specified

value.
End Play:
Specified Value: 0
Unit: mm
90045-20279 2.06 None 90045-20283 1.90 Brown
90045-20280 2.02 Brown 90045-20284 1.86 Blue
90045-20281 1.98 Blue 90045-20285 1.82 None
90045-20282 1.94 None 90045-20286 1.78 Brown
JMT00104-00000

MT37
OUTPUT SHAFT
DISASSEMBLY
1. Remove the radial ball bearing (for rear), using the follow-
ing SST.
SST: 09306-87602-000
JMT00105-00088
INSPECTION
1. Check the clearance between the synchronizer ring and
gear tapered section.
Specified Value 0.95 - 1.35 mm
2. Visually inspect the gear and spline section of the output

shaft for wear and damage.
JMT00106-00089
3. When you rotate the rear and center of the radial ball
bearing inner race with your fingers, as shown in the right
figure, they should be rotated smoothly without any bind-
ings.
JMT00107-00090
ASSEMBLY
1. Press the inner race of the radial ball bearing.
Ensure that the retaining section of the radial ball bear-
ing faces toward the rear side.
NOTE:
The radial ball bearing can be pressed by using either
the SST (09310-87302-000) or a pipe with which the
inner race can be pressed.
JMT00108-00091
INSTALLATION
1. While holding both the input shaft and counter gear as-
semblies by your hands, install them to the clutch housing.
NOTE:
Be careful not to damage the Type S oil seal during the
installation of the shafts.
JMT00109-00092

MT38
2. Attach the tension spring to the input shaft bearing lock
plate.
3. Tighten the input shaft bearing lock plate with the three
bolts.
4. Place the two pieces of the shift lock plates on the clutch
housing side.
JMT00110-00093
5. Assemble the reverse idler gear, shaft and thrust washer

to the clutch housing.
NOTE:
When installing, install the knock pin for use in prevent-
ing rotation of the idler gear shaft to the groove section
at the clutch housing side.
Make sure that the gear chamfer and thrust washer
(nylon) face upward (i.e. rear side).
JMT00111-00094
6. Tighten the reverse shift arm with the three bolts.

JMT00112-00095
7. Check of reverse shift arm for movement

With the idler gear pushed against the lower edge sur- A
face, check that the pin moves freely (drops by its own
weight) between the position A (neutral position) to the
position B (5th gear position).
B
Idler gear Reverse shift arm subassembly
JMT00113-00096
8. Assemble the tension spring.

NOTE:
Attach the spring to the recessed section of the arm
subassembly.
JMT00114-00097

MT39
CONFIRMATION OF LENGTH/SHAPE OF SHIFT FORK
AND SHIFT FORK SHAFT
9. The following three shift fork shafts differ in the overall
length, as shown in the right figure.
NOTE:
Be very careful not to make any wrong installation of
these shift fork shafts.
Unit: mm
Shift fork shafts Overall Length
(1) 1st & 2nd 224.00
(2) 3rd & 4th 259.00 JMT00115-00098
(3) 5th & Reverse 265.00
10. The shift forks and shift heads differ in the external view,
as shown in the right figure. Hence, be very careful not to
make any wrong installation of these shift forks and shift
heads.
(1) 1st & 2nd
(2) 3rd & 4th
(3) 5th & Reverse
NOTE:
It is advisable to install the shift fork shaft and fork tem-
porarily and confirm that the combination and direction
are right. Then, proceed to the operation. JMT00116-00099
INSTALLATION TO SHIFT FORK AND SHIFT FORK SHAFT

Apply gear oil to the required points. Perform the opera-
tions, following the procedure given below.
11. Temporarily drive a new slotted spring pin into all of the
shift forks and heads so that the slotted spring pin may be
driven easily during installation.
JMT00117-00100

MT40
12. Install the 3rd & 4th shift fork into the hub sleeve and insert
the 3rd & 4th shift fork shaft.
NOTE:
Make sure that the gear is in the neutral position.
In order to drive a new slotted spring pin smoothly, it is
advisable to prepare a guide pin whose outer diameter
is 4.0 mm and whose length is 50.00 mm.
Perform the operations, while confirming the assem-
bling direction of the shift fork and shift head and the
positional relationship with the gears.
As for the shapes and lengths of the shift fork shaft, JMT00118-00101
shift fork and shift head, refer to the steps 9 and 10 at

page MT39.
When driving a new slotted spring pin into position, a
measure to sustain the reaction force against the dri-
ving force should be taken at the opposite side of the
shift fork shaft.
13. Insert a guide pin or the like into the back side groove of
the shift fork, as the guide of installation for the slotted
spring pin.
14. Install a new slotted spring pin.
15. In the same manner as described in the steps 12 and 13,
insert the 3rd & 4th shift head.
16. Install the 1st & 2nd shift fork into the hub sleeve and in-
sert the 1st & 2nd shift fork shaft.
17. As for the installation of 1st & 2nd shift fork and shift head,
refer to the steps 12 and 13 described above.
JMT00119-00102
18. Insert the 5th & reverse shift head into the shift fork shaft.
19. As for the installation of the 5th & reverse shift fork and
shift head, refer to the steps 12 and 13 described above.
JMT00120-00103
20. Install the three balls and compression springs and tight-
en the three bolts with a new gasket interposed.
JMT00121-00104

MT41
21. Place the output shaft with the needle roller bearing, syn-
chronizer ring and wave spring.
NOTE:
Make sure to assemble the wave spring according to
the convex shape of the synchronizer ring. (See the
right figure.)
JMT00122-00105
22. Assemble the output shaft in the transmission case. Install

the hole snap ring by means of a snap ring expander.
JMT00123-00106
23. Assemble the transmission magnet.
JMT00124-00107
24. Install the rear bearing retainer. Tighten the retainer with
the five bolts.
JMT00125-00108
25. Assemble the transfer input hub.
JMT00126-00109

MT42
26. With the smaller diameter end placed at the nut side, as-
semble the conical spring.
NOTE: Conical spring Lock nut
Make sure that the conical spring is assembled in the
correct direction.
JMT00127-00110
27. Insert a deep socket into the output shaft.

[Reference]
Deep socket dimensions (Tool commercially available) Deep socket
Width across flats: 32 mm Overall length: 100 mm
28. Using soft jaws, clamp the periphery of the transfer input
hub in a vice so as to avoid damaging the hub.
Tighten a new lock nut with a torque wrench.
(18.0 - 22.0 kgf-m)
JMT00128-00111
29. Stake the new lock nut.

NOTE:
When staking the new lock nut, point a suitable staking
tool toward the output shaft axis center to lock securely,
as shown in the right upper figure.
Poor staking, such as shown in the right middle and
lower figures, may cause loosening of the lock nut.
JMT00129-00112
30. Clean the contact surface between the clutch housing and Apply liquid
the transmission case side, using solvent or the like. gasket
31. Apply the following bond to the transmission case surface
as shown in the right figure.
Specified Bond: Three bond 1216 or 1217
[Reference information]
Nozzle Inner Diameter: 0.9 mm
JMT00130-00113
32. Quickly install the transmission case.

33. Tighten the ten bolts between the transmission case side
and the clutch housing side.
34. With a new gasket interposed, tighten the hexagon bolt

(A) for reverse idler gear shaft.
(A)
JMT00131-00114

MT43
35. Install the clutch related parts.
JMT00132-00000
36. Install the shift lever boot and shift lever shaft correctly as Apply grease
shown in the right illustration.
CAUTION:
Ensure that the air bleeding section (A) of the boot
,
,,,
,,
faces toward the lower side.
,
NOTE: (A)
Apply MP grease to those points specified in the right
figure.
JMT00133-00115
37. Assemble the shift inner lever in the shift lever shaft sub-
assembly. Drive a new grooved pin into position with a
knock pin punch so that the shift inner lever may be se-
cured.
JMT00134-00116
NOTE:
When driving a new grooved pin into position, the pin
should be inserted from the smaller end of the taper.
JMT00135-00117
NOTE:
When driving the pin into position, be sure that the as- Inner lever
sembling is made in such a way that the installation
angle is displaced from the trace of the former pin.
Former pin
New pin
JMT00136-00118

MT44
38. Install the ball and compression spring and tighten the re-
verse restrict pin holder (B) with a new gasket interposed.
JMT00137-00119
39. Assemble the torsion spring, reverse restrict cam and re-
verse restrict shaft in the transmission case in this se- A
quence.
NOTE:
Make sure to attach the torsion spring securely at the
two points of the cam (the section A and the shift lever
shaft (the section B).
B
40. Install and tighten the washer based head hexagon bolt
with a new gasket used.
Tightening Torque: 18.6 - 30.4 Nm (1.9 - 3.1 kgf-m) JMT00138-00120
Standard
bolts
41. With a new gasket interposed, tighten the select lever
shaft subassembly with the four bolts.
NOTE:
Ensure that the reamer bolts (A) are placed as shown
Reamer
bolt (A)
JMT00139-00121
42. Install and tighten the backup lamp switch assembly with
a new gasket used.
NOTE: Clamp
Install the connector, using the drilled hole of the
clamp. Connector
Backup
lamp
JMT00140-00122
INSTALLATION OF TRANSFER ASSEMBLY

1. Install a new extension housing gasket to the rear edge
surface of the transmission case.
2. Install the needle roller bearing to the forward end of the
transmission output shaft.
JMT00141-00123

MT45
3. Install and tighten the transfer assembly with the seven
bolts.
Tightening Torque: 29.4 - 44.1 Nm (3.0 - 4.5 kgf-m) 40 40
40
NOTE:
The numeral in the right figure denotes the nominal
JMT00142-00124
40
210
210 40
JMT00000-00125

MT46
INSTALLATION/REMOVAL OF SHIFT CABLE & SELECT CABLE
COMPONENTS
14.7 - 21.6 : Tightening torque
(1.5 - 2.2) Unit : Nm (kgf-m)
8 : Non-reusable parts
2 B
9
14.7 - 21.6
B
(1.5 - 2.2)
2
7
B
14.7 - 21.6
7 (1.5 - 2.2)
6 3
3
4 4
5
6.9 - 9.8 1 5
B
(0.7 - 1.0)
q Cover, shift lever housing dust y Washer, plate

w Clamp u Clip
e Clip i Cable assembly, select
r Washer, plate o Cable assembly, shift
t Clip
JMT00143-00126

(1) Detach each clip with pliers or the like.
NOTE:
Care must be exercised to ensure that the pliers, etc.
will not touch with the cable section during the removal.
JMT00144-00127
(2) Remove the select cable assembly and shift cable as-
sembly.
NOTE:
Do not allow the ends of the shift and select cables to
be bent beyond 8 degrees. 8
8
JMT00145-00128

MT47
2. CHECK
(1) Check that the inner cables of the shift cable and se-
lect cable slide smoothly.
(2) Check for boot breakage, other damage or distortion.
Boot breakage
JMT00146-00129
3. MAIN POINTS OF INSTALLATION

(1) Insert the clips t and u until their upper edges be-
come flush with the upper edges of the bracket or the
retaining surface of the floor shift assembly.
NOTE:
Install the clips after the eye end has been installed
first.
Make sure that the clips are inserted in the correction
direction as indicated in the figure. Never insert them
reversely.
Never allow a hammer, etc. to tap the cable during the JMT00147-00130
clip installation. (If the cable should be tapped inadver-

tently, be certain to replace the cable with a new one.)
(2) When the shift cable is retained to the clamp w, retain

it to the H-shaped protector section of the shift cable.
JMT00159-00136
NOTE:
Care should be taken as to the correct direction of the
clamp w. (For the correct direction, see the right fig-
ure.)
JMT00160-00137

MT48
INSTALLATION/REMOVAL OF TRANSMISSION FLOOR SHIFT
ASSEMBLY
COMPONENTS
: Tightening torque
Unit : Nm (kgf-m)
1
8 6
7
3
14.7 - 21.6
B 4
(1.5 - 2.2)
4
5
2
5
6.9 - 9.8
(0.7 - 1.0)
q Knob, shift lever y Cable assembly shift

w Cover, shift lever housing dust u Cable assembly select
e Clip i Floor shift assembly, transmission
r Washer, plate o Boot, shift & select lever
t Clip
JMT00148-00131

(1) Detach the clips e and t, two each, with pliers or the
like.
NOTE:
Care must be exercised to ensure that the pliers, etc.
will not touch with the cable section during the removal.
JMT00149-00132

MT49
2. MAIN POINTS OF INSTALLATION Front
(1) Tighten the floor shift assembly with the attaching
bolts. r e
NOTE:
Be certain to tighten the attaching bolts in the se- w
q
quence specified in the right figure.
JMT00150-00133
(2) Install the shift cable assembly and select cable as-
sembly in the floor shift assembly. Secure them by
means of the clips.
NOTE:
Make sure that the clips are inserted in the correction
direction as indicated in the figure. Never insert them
reversely.
Never allow a hammer, etc. to tap the cable during the
clip installation.
Insert the clips until they become flush with the lower
edges of the cable retaining surface. JMT00151-00134
Install the clips after the eye end has been installed
first.

MT50
DISASSEMBLY/ASSEMBLY OF TRANSMISSION FLOOR SHIFT
ASSEMBLY
COMPONENTS
: Tightening torque
Unit : Nm (kgf-m)
!4
9.8 - 15.6
MP grease
(1.0 - 1.6)
1 MP grease
4 (Outer diameter,
5
6 !0 spherical sections)
N o
W
W !1
!3 !2 9
!3
o
8 9
!2
3
MP grease 7
39.2 - 49.0
2 (4.0 - 5.0)
39.2 - 49.0
(4.0 - 5.0)
q Support, control link i Lever subassembly, control select

w Bolt, washer based head hexagon o Bush
e Bolt, washer based head hexagon !0 Guide, control select lever
r Nut !1 Holder subassembly, shift lever
t Washer, spring !2 Ring, O
y Washer, plate !3 Bush
u Lever subassembly, shift !4 Boot, shift lever
JMT00152-00135
1. OPERATION PRIOR TO DISASSEMBLY

(1) Remove the transmission floor shift assembly.
2. MAIN POINTS OF ASSEMBLY

(1) Uniformly apply MP grease to the outer diameter and spherical section of the control select lever
guide !0, the sliding sections of the bushes o and !3, and the O-ring !2.
3. OPERATION AFTER ASSEMBLY

(1) Install the transmission floor shift assembly.
JMT00153-00000

MT51
APPENDIX
Shape Part No. Part name
09306-87602-000 Counter gear front bearing puller
09310-87301-000 Counter shaft front bearing replaer
09310-87302-000 Counter shaft rear bearing replacer
09334-87301-000 Transmission rear bearing anvil
TOYOTA Automatic transmission tool

09350-32014-000
set
09606-87201-000 Front hub bearing remover & replacer
09950-20017-000 Universal puller
JMT00154-00000

MT52
Unit: mm
Specified Value Allowable Limit
Free length 24.00
Free length of
compression spring for Load as installed: N (kgf) 28.83 (2.43)
reverse restrict pin
Height as installed: 17.00
Free length 40.00
Free length of
compression spring for Load as installed: N (kgf) 47.33 (4.83)
shift fork shaft
Height as installed: 30.00
+0
Outer Reverse idler gear shaft 20.0 0.013
Diameter +0.061
Inner Reverse idler shaft 20.0 +0.032
0.02
Outer Select inner lever 15 0.12
+0.2
Inner Shift inner lever 15.0 +0.1
0.050
Outer Shift fork shafts 13.0 0.077
Dimensions +0.043
Inner Case sides 13.0 +0
0.02
Outer Shift inner lever 12 0.12
+0.1
Inner Shift heads 12.1 +0
0.065
Outer Reverse restrict shaft 8 0.090
+0.16
Inner Reverse restrict cam 8 +0.07
Clearance between scynchronizer ring and gear 0.9 - 1.4 0.5
JMT00155-00000

MT53
AT THE INPUT SHAFT SIDE
Unit: mm
0.1
Contact width section between shift forks Shift forks 3rd & 5th 7 0.3 6.6
and synchronizer No. 2 & No. 3 hub
sleeves Hub sleeves 3rd & 5th 7 +0.12
+0.05 7.2
3rd 0.10 - 0.52

Thrust clearance
5th 0.10 - 0.40
Clearance between synchronizer rings and gears 0.95 - 1.35 0.90
0.009
(A) and (B) 32 0.029
Outer diameter of input shaft
0.016
(C) 20 0.034
Classification Identification
Outer diameter of No. 2 Yellow 57.78 - 57.84

hubs No. 1 None 57.68 - 57.74
Dimensions No. 3 White 57.58 - 57.64
No. 2 Yellow 57.871 - 57.97
Inner diameter of
hub sleeves No. 1 None 57.771 - 57.87
No. 3 White 57.67 - 57.77
No. 2 18.55 0.03
Thickness of synchronizer hubs
No. 3 12.40 0.03
+0.05
Thickness of transmission hub sleeve stopper 7.2 0.01
+0.025
Inner diameter 3rd and 5th gears 37.0 +0
Dimensions 3rd gear 37.95 0.03

Thickness
5th gear 27.85 0.03
0.2
Height of synchromesh shifting key 5 0.4
End play between the snap ring shaft and input shaft 0 Less than 0.16
JMT00156-00000

MT54
AT THE COUNTER SHAFT SIDE
Unit: mm
+0.12
Hub sleeve 10 +0.05 10.2
Contact width section between the synchronizer No. 1 hub
sleeve and 1st/2nd shift fork Shift fork 10
0.1
0.3 9.6
1st 0.10 - 0.52

Thrust clearance between gear and counter shaft
2nd 0.10 - 0.40
Height of shifting key 5.1 0.1
0.009
Outer diameter of countershaft (A) and (B) 32 0.029
Thickness of 1st gear thrust washer 4 0.03
Classification Identification
Outer diameter of No. 2 Yellow 69.78 - 69.84
synchronizer No. 1
hub No. 1 None 69.68 - 69.74
Dimensions No. 3 White 69.58 - 69.64
No. 2 Yellow 69.871 - 69.97
Inner diameter of
synchronizer No. 1 No. 1 None 69.771 - 69.87
hub sleeve
No. 3 White 69.67 - 69.77
+0.025
Inner 1st and 2nd gear 37.0 +0
Dimensions 1st 27.34 0.03
Thickness
2nd 36.30 0.03
Height of conical spring washer 2.01 1.04
End play between the snap ring shaft and countershaft Less than 0.16
JMT00157-00000

MT55
TIGHTENING TORQUE
Tightening components Nm kgf-m
Engine Clutch housing 49.0 - 68.6 5.0 - 7.0
Stiffener right Engine, Clutch housing 29.4 - 44.1 3.0 - 4.5
Stiffener left Engine, Clutch housing 29.4 - 44.1 3.0 - 4.5
Clutch housing undercover Clutch housing 14.7 - 21.6 1.5 - 2.2
Stiffener plate bracket Powertrain stiffener 29.4 - 44.1 3.0 - 4.5
Powertrain stiffener Transfer case 29.4 - 44.1 3.0 - 4.5
Lock nut Output shaft 176.4 - 215.8 18.0 - 22.0
Reverse restrict pin holder Transmission case 29.4 - 49.0 3.0 - 5.0
Transmission case cover Transmission case 14.7 - 21.6 1.5 - 2.2
Bolt for reverse restrict shaft Transmission case 18.6 - 30.4 1.9 - 3.1
Clutch housing Transmission case 14.7 - 21.6 1.5 - 2.2
Input shaft bearing lock plate Clutch housing 14.7 - 21.6 1.5 - 2.2
Reverse shift arm Clutch housing 14.7 - 21.6 1.5 - 2.2
Bolt for shift fork shaft Clutch housing 18.6 - 30.4 1.9 - 3.1
Rear bearing retainer Transmission case 14.7 - 21.6 1.5 - 2.2
Washer based head hexagon Transmission case 18.6 - 30.4 1.9 - 3.1
Backup lamp switch assembly Transmission case 24.5 - 39.2 2.5 - 4.0
Breather plug Clutch housing 14.7 - 21.6 1.5 - 2.2
W/head straight screw plug Transmission case 24.5 - 39.2 2.5 - 4.0
Transfer assembly Transmission case 29.4 - 44.1 3.0 - 4.5
Transmission control cable bracket Transfer case 29.4 - 44.1 3.0 - 4.5
Control cable bracket Transfer case 14.7 - 21.6 1.5 - 2.2
Control cable bracket Clamp 14.7 - 21.6 1.5 - 2.2
Shift lever housing dust cover Control link support 6.9 - 9.8 0.7 - 1.0
Control link support Floor 14.7 - 21.6 1.5 - 2.2
Floor shift washer based head hexagon bolt 39.2 - 49.0 4.0 - 5.0
Floor shift nut 9.8 - 15.6 1.0 - 1.6
JMT00158-00000

DAIHATSU
J100
J100
AUTOMATIC TRANSMISSION
OUTLINE ............................................. AT 2 REMOVAL AND INSTALLATION OF

SECTIONAL VIEW OF AUTOMATIC AUTOMATIC TRANSMISSION ....... AT40
TRANSMISSION ........................ AT 2 COMPONENTS ............................. AT40
SPECIFICATIONS .......................... AT 3 CONNECTION AND DISCONNECTION
TORQUE CONVERTER ...................... AT 4
CONSTRUCTION .......................... AT 4
OF OIL COOLER HOSES .............. AT44
COMPONENTS ............................. AT44
AT
OPERATION .................................. AT 4 DISASSEMBLY AND ASSEMBLY OF
POWER TRAIN MECHANISM ............ AT 5 AUTOMATIC TRANSMISSION ....... AT46
DESCRIPTION ............................... AT 5 COMPONENTS ............................. AT46
CONSTRUCTION .......................... AT 5 COMPONENTS (INNER PARTS) ... AT47
OPERATION .................................. AT 6 REMOVAL ...................................... AT48
HYDRAULIC PRESSURE CONTROL DISASSEMBLY AND ASSEMBLY OF
SYSTEM .......................................... AT11 COMPONENTS ......................... AT61
DESCRIPTION ............................... AT11 INSPECTION ................................. AT63
HYDRAULIC PRESSURE CIRCUIT ASSEMBLY .................................... AT67
DIAGRAM .................................. AT12 INSTALLATION AND REMOVAL
COMPONENTS ............................. AT13 OF CONTROL CABLE AND
CASE & COVER ................................. AT25 FLOOR SHIFT ................................ AT90
DESCRIPTION ............................... AT25 COMPONENTS ............................. AT90
ELECTRIC CONTROL SYSTEM ........ AT26 APPENDIX .......................................... AT92
OVERDRIVE SWITCH .................... AT26 SSTs (Special Service Tools) ......... AT92
SHIFT CONTROL MECHANISM ........ AT27 SERVICE SPECIFICATIONS .......... AT94
DESCRIPTION ............................... AT27 TIGHTENING TORQUE ................. AT95
COMPONENTS ............................. AT27 JAT00001-00000
PRELIMINARY CHECK ...................... AT28

TESTING ............................................. AT32
STALL TEST ................................... AT32
TIME LAG TEST ............................. AT33
HYDRAULIC PRESSURE TEST ..... AT33
RUNNING TEST ............................ AT37
ELECTRICRELATED TESTS ......... AT38 NO.9710-JE

AT2
OUTLINE
1. A hydraulic pressure control planetary gear type, four-speed automatic transmission with overdrive is
employed, which has been newly developed for FR vehicles with an engine mounted longitudinally.

2. The automatic transmission fluid has employed a DEXRON III which features excellent heat and oxida-
tion stability.
SECTIONAL VIEW OF AUTOMATIC TRANSMISSION
q w e r t y u i o !0
!1 !2 !3 !4 !5 !6 !7 !8 !9
q Torque converter !0 Output shaft

w Oil pump !1 Input shaft
e Direct clutch !2 Valve body
r Forward clutch !3 2nd brake band
t Rear clutch !4 Front planetary sun gear
y One-way clutch !5 Planetary short pinion
u 1st & reverse brake !6 Planetary output shaft
i Planetary long pinion !7 Intermediate shaft
o Rear planetary sun gear !8 Parking lock gear
!9 Governor drive gear
JAT00002-00001

AT3
SPECIFICATIONS
Item Specifications
Type Three-element, one-stage, two-phase type
Torque
Stall torque ratio/Stall revolution speed 2.0/1990 - 2540 rpm
converter
One-way clutch type Sprag type
Four forward speeds, one reverse gear,
Type planetary gear type
Wet type multiple clutch 3 set
Band type brake 1 set
Control element
Wet type multiple brake 1 set
One-way clutch 1 piece
Transmission
type 1st gear: 2.800 2nd gear: 1.540 3rd gear: 1.000
Gear ratio 4th gear: 0.700 Reverse gear: 2.333
Speedometer gear ratio 24/5
Oil pump Internal gear type
Fluid to be used ATF DEXRONR 3
Fluid capacity liter Except for EU: 4.2 liters , For EU: 4.29 liters
Except for EU: Water-cooled (radiator built-in type),
Cooling method For EU: Water-cooled (radiator built-in type)
plus air-cooled oil cooler separately mounted
Gear shift control method Governor and throttle pressure shift control method
Control
Automatic gear shift Four forward speeds, full automatic shift
system
Manual control pattern PRND2L (with overdrive switch)
JAT00003-00000

AT4
TORQUE CONVERTER
Stator
The torque converter employs a three-element, one-stage,
two- phase type converter, as has been hitherto employed.
CONSTRUCTION Front cover One-way

clutch
The torque converter consists of a front cover to which a drive
plate is attached, a pump impeller integral with the torque
converter cover, a turbine runner which is spline-fitted with the
input shaft at the transmission side, a stator, a one-way clutch
which supports the stator and so forth.
Turbine runner Pump impeller
JAT00004-00002
OPERATION
When the ratio of the turbine runner speed to the pump im-
peller speed is small, the fluid returning from the turbine run-
ner to the pump impeller flows in such a direction that pre- a b
4 100
vents the rotation of the pump impeller. Therefore, the installa-
tion of the stator helps converting the fluid flow in such a di- 80
rection that the pump impeller rotation is assisted. 3
The torque ratio becomes a maximum of about 2.0 when the
Torque ratio (t)
Efficiency ()
60
speed ratio is zero (at the time when the turbine runner is
stopped). The torque ratio at this time is called the stall 2
torque, whereas this stage is called the stall point. 40
Until the speed ratio reaches about 0.8, fluid transmission t
takes place, while increasing the torque. As the speed ratio 1
becomes greater, the torque ratio decreases. This stage is 20
called the torque converter range.
When the speed ratio becomes above about 0.8, the torque
ratio is maintained at about one, transmitting the same torque 0.2 0.4 0.6 0.8 1.0
without altering it. This stage is called the fluid coupling
Speed ratio (e)
range.
The efficiency rises in proportion to the speed ratio. After
a: Torque converter range
passing a certain point, however, the increase rate of the effi-
ciency starts to decline. This is because the fluid from the tur- b: Fluid coupling range
bine runner begins to strike the back side of the stator, thus e: Speed ratio = Turbine shaft revolution speed
preventing the fluid flow. Pump shaft revolution speed
Then, the one-way clutch of the stator operates, making the
t: Torque ratio = Turbine shaft torque
stator rotate. As a result, the increase rate of the efficiency Pump shaft torque
starts to increase again.
: Efficiency = Output horse power 100 (%)
Input horse power
JAT00005-00003

AT5
POWER TRAIN MECHANISM
DESCRIPTION
In the power train mechanism, the power that has been trans-
mitted from the engine to the input shaft of the transmission
through the torque converter is transmitted from various
clutches to the planetary gear, using reduction ratios optimum
for the running condition.
JAT00006-00000
CONSTRUCTION
Planetary Intermediate shaft
(1) Planetary gear short pinion
A Ravingeau type planetary gear is employed.
The following are the main components: Intermediate shaft, Planetary
front planetary sun gear, planetary short pinion, planetary long output shaft
pinion, rear planetary sun gear and planetary output shaft.
Rear planetary
The input section of the driving force at the planetary gear unit sun gear
section is composed of three systems: One is the intermedi-
ate shaft; another is the front planetary sun gear; and the third Front planetary Planetary long
sun gear pinion
is the rear planetary sun gear.
This input section is switched by making gear shifts. JAT00007-00004
Furthermore, the output section is the planetary output shaft.
(2) Shift control element

The shift control element consists of three kinds of wet type multiple-disc clutches, namely, the direct clutch
(C1), forward clutch (C2) and rear clutch (C3), as well as the 1st & reverse brake (B2) of the wet type multi-
ple-disc brake, the 2nd brake (B1) of the band type brake, and the one-way clutch (F). Moreover, the fol-
lowing table shows functions of each control element.
Functions of Each Shift Control Element

Shift control element Operations
Direct clutch (C1) Connects input shaft with front planetary sun gear.
Forward clutch (C2) Connects input shaft with rear planetary sun gear.
Rear clutch (C3) Connects input shaft with intermediate shaft.
2nd brake band (B1) Locks front planetary sun gear.
1st & reverse brake (B2) Prevents planetary carrier from rotating.
One-way clutch (F) Prevents planetary carrier from rotating counterclockwise.
JAT00008-00000

AT6
OPERATION
(1) Power Train Route
The input route of the power train has three routes: One is a route in which the power is transmitted from
the input shaft to the front planetary sun gear via the C1 clutch. Another is a route in which the power is
transmitted to the rear planetary sun gear via the C2 clutch. The other is a route in which the power is trans-
mitted to the intermediate shaft via the C3 clutch. Conversely, there is only one output route of the planetary
output shaft.
Moreover, the following table shows functions of each shift control element according to the transmission
gear.
B2
F
Planetary short pinion
Planetary long pinion
Front planetary sun gear

Output shaft
C2
C3
Planetary carrier
Input shaft
Rear planetary sun gear
Planetary output shaft
Intermediate shaft
C1 B1
JAT00009-00005
Table Showing Functions of Shift Control Elements

Shift position C1 C2 C3 B1 B2 F
P Parking
R Reverse
N Neutral
1st
D
2nd
3rd
4th (O/D)
1st
2 2nd
3rd
L 1st
JAT00010-00000

AT7
(2) and x ranges <1st gear> (without engine brake)
When the transmission is in the 1st gear with the shift lever set to the or x range, the forward clutch (C2)
is activated. Therefore, the rotating force of the input shaft is directly transmitted to the rear planetary sun
gear, thus transmitting a counterclockwise rotating force to the planetary short pinion.
Conversely, the planetary long pinion which is in mesh with the planetary short pinion receives a clockwise
rotating force and tries to rotate the planetary carrier counterclockwise. However, the rotation is prevented
by the function of the one-way clutch (F). Consequently, the planetary output shaft receives a clockwise ro-
tating force.
Planetary short pinion F
C2 Output shaft
Input shaft Planetary carrier

JAT00011-00006
(3) and x ranges <2nd gear>

When the transmission is in the 2nd gear, the forward clutch (C2) is activated. Therefore, the rotating force
of the input shaft is directly transmitted to the rear planetary sun gear, thus transmitting a counterclockwise
rotating force to the planetary short pinion.
Conversely, the front planetary sun gear is locked by the 2nd brake band (B1). As a result, the planetary
long pinion which is in mesh with the planetary short pinion receives a clockwise rotating force and re-
volves around the front planetary sun gear while rotating on its axis. Consequently, a clockwise rotating
force is transmitted to the planetary output shaft.

Output shaft
C2
Input shaft
B1
JAT00012-00007

AT8
(4) range <3rd gear>
When the transmission is in the 3rd gear, the direct clutch (C1) and forward clutch (C2) are activated.
Therefore, the input shaft, front planetary sun gear and rear planetary sun gear rotate in the same direction.
As a result, the planetary short pinion and planetary long pinion come in a locked state. Consequently, the
planetary output shaft receives a clockwise rotating force.

Output shaft
C2
C3
Input shaft
Planetary carrier
C1
JAT00013-00008
(5) range <4th gear>

When the transmission is in the 4th gear, the rear clutch (C3) is activated. The rotating force of the input
shaft is directly transmitted to the intermediate shaft, thus transmitting a clockwise rotating force to the
planetary carrier.
Conversely, the front planetary sun gear is locked by the 2nd brake band (B1). Therefore, the planetary
long pinion supported by the planetary carrier receives a clockwise rotating force and revolves around the
front planetary sun gear while rotating on its axis. Consequently, a clockwise rotating force is transmitted to
the planetary output shaft.

Output shaft
C3
Input shaft
Planetary carrier
B1 Intermediate shaft
JAT00014-00009

AT9
(6) range <1st gear>
The rotating force is transmitted in the same way as the 1st gear of the range, as previously explained.
However, the 1st & reverse brake (B2) operates to prevent the planetary carrier from rotating clockwise at
the time of engine braking.
In other words, at the time of driving with the range, the counterclockwise rotation of the planetary carrier
is locked by the function of the one-way clutch (F). Thus, the rotating force is transmitted to the planetary
output shaft.
However, at the time of engine braking, a reverse force is applied. As a result, the one-way clutch (F) will
not operate and the planetary carrier rotates idly. Therefore, in order to make the function of engine brake
possible, the planetary carrier is secured by operating the 1st & reverse brake (B2).
Planetary short pinion F

B2
Output shaft
C2
Input shaft
Planetary carrier
JAT00015-00010
(7) range <Reverse gear>

When the transmission is in the reverse gear, the direct clutch (C1) is activated, as shown in the figure
below. Therefore, the rotating force of the input shaft is directly transmitted to the front planetary sun gear.
Conversely, the planetary carrier is locked by the function of the 1st & reverse brake (B2). Therefore, the ro-
tating force transmitted to the front planetary sun gear makes the planetary long pinion rotate counterclock-
wise on its axis. Consequently, the counterclockwise rotating force is transmitted to the planetary output
shaft.
B2

Output shaft
Input shaft
Planetary carrier
C1
JAT00016-00011

AT10
(8) range
When shifted to the range, the parking cam is pushed out through the parking rod. Thus, the parking
cam pushes up the parking pawl. As a result, the parking lock pawl becomes engaged with the parking
lock gear. Consequently, locking is made.
Parking lock gear
Output shaft
Parking rod
Cam spring
Parking lock pawl
Parking cam
JAT00017-00012

AT11
HYDRAULIC PRESSURE CONTROL SYSTEM
DESCRIPTION
Utilizing the hydraulic pressure generated at the oil pump, the hydraulic pressure control system switches
fluid passages leading to each shift control element of the power train mechanism according to running
conditions, regulates the line pressure as well as lubricates each section of the transmission.
The following table shows operating conditions of the hydraulic pressure applied to each shift control ele-
ment in each shift position.
Table Showing Operating Conditions of Hydraulic Pressure
B1
Shift position C1 C2 C3 B2
B1 (Applied side) B1 (Released side)
P Parking
R Reverse
N Neutral
1st
D
2nd
3rd * *
4th (O/D)
2
1st
2nd
L 1st
*: In cases where hydraulic pressure is applied both to the applied side and to the released side, B1 is re-
leased by the difference in the pressure-receiving area.
JAT00018-00000

3-4 & select timing valve
AT12
Oil pan Servo control valve
Lubrication Cooler
Torque converter
B1 B1 relief valve
2-3 timing valve

Torque converter
B2 C3 C2 C1

2-4 timing valve
3-2 timing 4-3 timing

Throttle
valve valve
modulator
valve
HYDRAULIC PRESSURE CIRCUIT DIAGRAM
B1
accumulator
2-3 shift valve
3-4 shift valve

C2
accumulator
Governor
1-2 shift valve Strainer Throttle valve
Strainer
Modifier valve
L 2 DN R P
Manual valve
Regulator valve
Secondary regulator valve
Oil pump
Overdrive solenoid
JAT00019-00013
AT13
COMPONENTS
Oil pump driven gear
(1) OIL PUMP
A trochoid type gear oil pump has been adopted.
The oil pump consists of an oil pump body, an oil pump drive Oil pump drive
gear, and an oil pump driven gear. The oil pump drive gear, gear
which is driven by the torque converter, drives the oil pump
driven gear to send the automatic transmission fluid to the hy-
draulic pressure control system under a pressurized state.
Oil pump body
JAT00020-00014
(2) VALVE BODY

The valve body is mounted at the lower surface of the trans-
mission. It incorporates hydraulic pressure-regulating valves,
such as a throttle valve, a regulator valve, a modifier valve, a
secondary regulator valve, and a throttle modulator valve. It
also incorporates a manual valve, and valves that will switch
fluid passages of each shift valve, thus reducing gear shift im-
pacts of each timing valve, etc.
JAT00021-00015
1) Manual valve
The manual valve is interlocked with the shift lever by the con-
trol cable. According to the shift lever movement, the manual
valve switches the line pressure of each range. q w e
L 2 DN R P r t
Line pressure
(From regulator valve)
Range Circuit q w e r t
P
R
N
D
2
L
JAT00022-00016

AT14
2) Regulator valve
The regulator valve regulates the pressurized fluid sent from
the oil pump to a hydraulic pressure (line pressure) suited for
the running condition. q w e r
The forces applied to the valve are the spring force (force FS
pushing to the right side), line pressure r (the discharging
pressure from the oil pump y flowing via e) (force FL pushing
t y u i
to the left side), modifier pressure t (force FMF pushing to the
right side), and line pressure w (force FRL pushing to the right
side) which will be applied only when the shift lever is moved q Line pressure ( range)
to the range.
w Lubrication pressure (To secondary
Therefore, the line pressure y is regulated under the following regulator valve and torque converter)
conditions, thus becoming an optimum hydraulic pressure ery Line pressure (From oil pump
suited for the running condition. to manual valve and throttle valve)
1. Except range: FL = FS + FMF t Modifier pressure
2. range: FL = FS + FMF + FRL u Drain (To oil strainer)
i Drain
3) Modifier valve JAT00023-00017
The modifier valve regulates the modifier pressure which will

regulate the line pressure to an optimum pressure according
to the running condition (throttle opening angle).
The forces applied to the valve are the spring force (force FS Chamber B
pushing to the left side), force applied to the valve by the Chamber A
modifier pressure w when it enters the chamber A through e
the fluid passages inside the valve (force FMF pushing to the
right side), and throttle pressure q (force FTH pushing to the
left side).
In cases where the throttle opening angle is less than approxi-
q w
mately 25% with the shift lever set to a place other than the x
and ranges, the throttle pressure q flows into w without
being regulated. Therefore, the modifier pressure becomes q Throttle pressure
equal to the throttle pressure. Conversely, in cases where the (Except for x and ranges)
throttle opening angle is more than approximately 25%, the Line pressure
(x and ranges)
modifier pressure will be regulated under a condition of FMF =
FS + FTH. w Modifier pressure
When the shift lever is moved to the x or range, the
e Drain
line pressure will be applied to q. As a result, the modifier
pressure becomes a constant value, regardless of the throttle
opening angle.
JAT00024-00018

AT15
4) Secondary regulator valve
The secondary regulator valve regulates the lubrication pres-
sure to an optimum hydraulic pressure. Chamber A
q
pushing to the right side), and force pushing the valve by the
lubrication pressure q when it enters the chamber A through
the fluid passages inside the valve (force FLUB pushing to the
left side). Hence, the lubrication pressure will be regulated
under a condition of FLUB = FS.
w
q Lubrication pressure
(From regulator valve to torque converter)
w Drain (To oil strainer)
JAT00025-00019
5) Throttle valve & downshift plug

The throttle pressure is generated in proportion to the throttle
opening angle. Adjuster Spring Downshift plug
The forces applied to the throttle valve are the adjuster spring q w e
force (force FSA pushing to the right side), main spring force
(force FSM pushing to the left), and force generated by the dif-
ference in the pressure-receiving area after the throttle pres-
Chamber A r Main spring
sure q enters the chamber A through the fluid passages in-
Throttle valve
side the valve (force FTH pushing to the right side). As a result,
q Throttle pressure
the throttle pressure is regulated under a condition of FTH + FSA w Throttle pressure (Throttle opening
= FSM. Since the FSM becomes greater in proportion to the angle is 85% or more.)
throttle opening angle, the throttle pressure is in proportion to e Throttle pressure
r Line pressure
the throttle opening angle.
The downshift plug outputs the throttle pressure from w to the
Throttle pressure
shift valve when the throttle opening angle becomes 85%.

Then, this outputted pressure acts as a force counteracting
the governor pressure, thus raising the shifting point.
The throttle pressure e acts as a force pushing the downshift
plug to the left side, thus reducing the accelerator pedal ap-
plication force. Throttle opening angle
JAT00026-00020

AT16
6) 1-2 shift valve
The 1-2 shift valve allows or does not allow the hydraulic pressure be applied to the B1 (the applied side),
depending on conditions of the vehicle speed and throttle opening angle.
1. When shifted from 1st gear to 2nd gear:
When the shift lever is set to the or x range, the forces applied to the valve are the spring force
(force FS pushing to the right side), throttle pressure y (force FTH pushing to the right side), and gover-
nor pressure u (force FG pushing to the left side). When a condition of FG > FS + FTH is obtained, the
valve is moved to the left side. Thus, the line pressure w is applied to the B1 e (the applied side).
When the shift lever is moved to the range, the line pressure (force FL pushing to the right side) is ap-
plied to r and y from the manual valve. In this case, since a condition of FG < FS + FL is always ob-
tained, the valve will not move to the left side (The transmission will not be shifted to the 2nd gear).
Furthermore, at this time the line pressure r is applied through the fluid passages inside the valve and
q, thereby causing B2 to operate.
2. When shifted from 2nd gear to 1st gear:
In cases where the throttle opening angle is less than 85% with the shift lever set to the range other
than the range, the throttle pressure y will not be applied to the valve. Therefore, when a condition
of FG < FS is obtained, the valve moves to the right side. As a result, the hydraulic pressure will not be
applied to the B1 e (the applied side). (The shifting point comes to a speed lower than the shifting
point for 1st-to-2nd gear shifting.)
In cases where the throttle opening angle is more than 85% with the shift lever set to the range other
than the range (at the time of kick down), the throttle pressure (force pushing to the right side) is ap-
plied to t. Therefore, the valve moves to the right side under a condition of FG < FS + FTH (when the ve-
hicle speed is lower than a certain value).
When the shift lever is shifted to the range while running with the 2nd gear, the line pressure (FL) will
be applied to t. Therefore, the valve will not move to the right side, until a condition of FG < FS + FL is
satisfied. (The 2nd gear is held, until the vehicle speed decreases below a certain vehicle speed, so as
to prevent the engine from overrunning.)
<Except 2nd, 3rd and 4th gears> <2nd, 3rd and 4th gears>
r t y r t y
e u e u
q w q w
q To B2 t Line pressure ( range),

Throttle pressure ( and x ranges, throttle opening
w Line pressure angle of 85% or more)
(, x and ranges)
y Line pressure ( range), throttle pressure
e To B1 (Except for and x ranges)
r Line pressure ( range) u Governor pressure
JAT00027-00021

AT17
7) 2-3 shift valve
The 2-3 shift valve allows or does not allow the hydraulic pressure be applied to the C1, C3, and B1 (at the
released side), depending on conditions of the vehicle speed and throttle opening angle.
1. When shifted from 2nd gear to 3rd gear:
When the shift lever is set to the range, the forces applied to the valve are the spring force (force FS
pushing to the right side), throttle pressure y (force FTH pushing to the right side), throttle modulator
pressure u (force FTM pushing to the right side), and governor pressure i (force pushing to the left
side). When a condition of FG > FS + FTH + FTM is satisfied, the valve moves to the left side. Thus, the line
pressure from the 1-2 shift valve q is applied to the C1 and B1 via the servo control valve from w; and
to the C3 via the 2-3 timing valve.
When the shift lever is moved to the x or range, the line pressure (force FL pushing to the right side)
is applied to e, t and y from the manual valve. In this case, since a condition of FG < FS + FL is al-
ways satisfied, the valve will not move to the left side (The transmission will not be shifted to the 3rd
gear).
2. When shifted from 3rd gear to 2nd gear:
In cases where the throttle opening angle is less than 85% with the shift lever set to the range, the
throttle modulator pressure u will not be applied to the valve. Therefore, when a condition of FG < FS +
FTH is satisfied, the valve moves to the right side. As a result, the hydraulic pressure will not be applied
to the C1 w, B1 and C3. (The shift point comes to a speed lower than the 2nd-to-3rd gear shift point.)
In cases where the throttle opening angle is 85% or more with the shift lever set to the range, the
throttle pressure (force FKD pushing to the right side) is applied to t. Therefore, the valve is moved to
the right side when a condition of FG < FS + FKD + FKD is satisfied (when the vehicle speed is lower than
a certain value).
When the shift lever is shifted to the x or range while running with the 3rd gear, the line pressure (FL)
of the manual valve will be applied to e and t. Therefore, the valve will not move to the right side, until
a condition of FG < FS + FL is satisfied. (The 3rd gear is held, until the vehicle speed decreases below a
certain vehicle speed, so as to prevent the engine from overrunning.)
<Except for 3rd and 4th gears> <3rd and 4th gears>
qw r y u i qw r y u i
e t e t
q Line pressure , From 1-2 shift valve t Line pressure , From manual valve (x and ranges),
(2nd, 3rd and 4th gears) Throttle pressure , From throttle valve
(throttle opening angle of 85% or more)
w Servo control valve / To C1 and B1
2-3 timing valve / To C3 y Throttle pressure , From throttle valve
(Except for x and ranges)
e Line pressure , From manual valve Line pressure / From manual valve (x and ranges)
(x and ranges)
r To 2-4 timing valve u Throttle modulator pressure , From throttle modulator valve
i Governor pressure , From servo control

JAT00028-00022

AT18
8) 3-4 shift valve & 3-4 relay valve
3-4 relay valve
The relay valve changes the force applied to the shift valve, depending on the throttle opening angle.
The forces applied to the valve are the large spring force (force FS pushing to the left side), small spring
force (force FS pushing to the right side) and throttle pressure q (force FTH pushing to the right side).
In cases where the throttle opening angle is less than approximately 20%, a condition of FS FS + FTH is
satisfied. Consequently, the force applied to the shift valve becomes FS.
In cases where the throttle opening angle is between approximately 20% and 85%, a condition of FS FS +
FTH is satisfied. Then, the relay valve moves to the right side, coming into contact with the shift valve.
Consequently, the force applied to the shift valve becomes FS + FTH.
In cases where the throttle opening angle is more than 85%, the throttle pressure w (force FKD pushing to
the left side) is applied, thus satisfying a condition of FS + FKD > FS + FTH (FKD). As a result, the relay valve
returns to the left again. Consequently, the force applied to the shift valve becomes FS + FKD.
JAT00029-00000
3-4 shift valve

The 3-4 shift valve allows or does not allow the line pressure be applied to the servo control valve and C2,
depending on conditions of the vehicle speed, throttle opening angle and overdrive switch, so as to per-
form gear shifting between the 3rd gear and the 4th gear.
1. When shifting from 3rd gear to 4th gear:
The forces applied to the 3-4 shift valve are the force generated by the relay valve (force FR pushing to
the right side (= FS, or FS + FTH, or FS + FKD)), and governor pressure i (force FG pushing to the left
side).
When running at a low speed (FG < FR), the valve is located at the right side. Therefore, the line pressure
t will be applied to the servo control valve and C2 via r. However, when running at a high speed (FG
> FR), the valve moves to the left side. Consequently, the line pressure which was applied via r will be
drained. Thus, gear shifting to the 4th gear takes place.
Furthermore, when the overdrive is turned OFF, the line pressure (force FL pushing to the right side) is
applied to e. Therefore, a condition of FG < FS + FL is always satisfied. Consequently, the valve will not
move to the left side. (No gear shifting to the 4th gear will take place.)
2. When shifting from 4th gear to 3rd gear:
When the valve is located at the left side, the pressure-receiving diameter of the governor pressure i
becomes greater. As a result, the force (FG) pushing the valve to the left side also becomes greater.
Consequently, the 4th-to-3rd gear shift point comes at a speed lower than the 3rd-to-4th gear shift
point.
Furthermore, when the overdrive is turned OFF, the line pressure (force FL pushing to the right side) is
applied to e and u. However, since a condition of FG < FS + FL is always satisfied, the valve moves to
the right side (gear shifting to the 3rd gear takes place), regardless of the vehicle speed and throttle
opening angle.
<Except for 4th gear> <4th gear>
3-4 relay valve 3-4 shift valve 3-4 relay valve 3-4 shift valve
w e t u ii w e t u ii
Small spring Small spring
q Large spring r y q Large spring r y

q Throttle pressure , Throttle valve t Line pressure , From manual valve
(, x and ranges)
w Line pressure , From 2-4 timing valve (1st and 2nd gears)
Throttle pressure , From 2-4 timing valve y To B1
(Throttle opening angle of 85% or more)
u Line pressure , From overdrive solenoid
e Line pressure , From overdrive solenoid (When overdrive is turned OFF
(When overdrive is turned OFF with shift lever with shift lever set to
set to , x or range) , x or range)
r 3-4 & select timing valve / To C2 i Governor pressure , From governor valve
Servo control valve / To C1, B1
JAT00030-00023

AT19
9) Throttle modulator valve
The throttle modulator valve regulates the throttle modulator
pressure which is applied to the 2-3 shift valve as a force q w
counteracting the governor pressure. This throttle modulator
valve causes shifting to take place at a low vehicle speed
when the throttle is opened slightly; and at a high vehicle
speed when the throttle is opened widely. Furthermore, when
the throttle opening angle is less than approximately 10% and
no throttle pressure is being generated, this valve assures the e
difference in speed between the 2nd-to-3rd gear shift point
and the 3rd-to-2nd gear shift point (hysteresis).
In the , x and ranges, the line pressure is applied to e q Throttle pressure , From throttle valve
from the manual valve. This pressure flows into w, thus gener- (Except for x
ating the throttle modulator pressure. and ranges)
Line pressure , From manual valve
The forces applied to the valve are the spring force (force FS (x and ranges)
pushing to the right side), throttle pressure q (force FTH push-
ing to the right side), and throttle modulator pressure w (force w Throttle modulator pressure /
FTM pushing to the left side). Thus, the throttle modulator pres- To 2-3 shift valve
sure is regulated under a condition of FTM = FS + FTH. e Line pressure / From manual valve
(, x and ranges)
JAT00031-00024

AT20
10) Servo control valve
When gear shift takes place between the 3rd gear and the 4th gear, the servo control valve turns ON and
OFF the C1 pressure and B1 pressure (at released side) simultaneously.
Moreover, in order to prevent downshift from the 4th gear to the 2nd gear from taking place all at once (be-
cause it will apply a great torque to the forward clutch suddenly), the servo control valve causes downshift
to the 3rd gear to take place first. Then, the transmission is shifted to the 2nd gear.
When the transmission is in the 3rd gear, the forces applied to the valve are the spring force (force pushing
to the left side), line pressure o (force pushing to the left side) from the 3-4 shift valve, and the line pres-
sure q (force pushing to the right side) from the 2-3 shift valve.
When conditions for upshifting to the 4th gear are satisfied and the 3-4 shift valve is switched, the line pres-
sure o will be drained. Therefore, the valve moves to the right side. At this time, u and i are connected
to each other. Consequently, the pressure B1 u will be drained from the 3-4 shift valve via i. At the same
time, the pressure C1 w will be drained, too.
Moreover, although the vehicle speed decreases and conditions for switching the 2-3 shift valve (downshift
to the 2nd gear) are satisfied, the servo control valve allows the 2-3 shift valve be switched only after the 3-
4 shift valve has been switched (downshift to the 3rd gear has taken place). The servo control valve does
this by making the line pressure, instead of governor pressure, applied to the 2-3 shift valve from r.
<Except for 4th gear> <4th gear>
r t u i o r t u i o
q q w e y q q w e y
q Line pressure , From 2-3 shift valve (3rd and 4th gears) y Line pressure , From 2-3 shift valve (3rd and 4th gears)
w To C1 u To B1
To 3-4 & select timing valve
e Governor pressure (From governor valve)
r To 2-3 shift valve
i
o }
Line pressure , From 3-4 shift valve
(1st, 2nd and 3rd gears)
t Line pressure , From manual valve (, x and ranges)
JAT00032-00025

AT21
11) 3-4 & select timing valve
When upshift from the 3rd gear to the 4th gear takes place,
the 3-4 & select timing valve makes the turning OFF of the q
pressure C2 synchronized with the turning OFF of the pres-
sure B1, thus preventing the engine from racing and making
smooth shifting possible.
Orifice r t
When the transmission is in the 3rd gear, the forces applied to
the valve are the spring force (force FS pushing to the left
side), and line pressure q (pressure B1) (force pushing to w
the right side). Since a condition of FS < FL is satisfied, the y
valve is located at the right side. If the line pressure q (pres- e
sure B1) is turned OFF when upshifting to the 4th gear, the Check valve
valve moves to the left side. Also, r and t are connected to
each other simultaneously. In this way, the pressure C2 w will q Line pressure (pressure B1)
be quickly drained.
w From C2
e 3-4 shift valve / Drain
JAT00033-00026
12) 2-3 timing valve

When gear shift takes place between the 2nd gear and the 3rd gear, the 2-3 timing valve raises the pres-
sure C3 after the pressure C1 reaches a certain pressure.
When the transmission is in the 2nd gear with the shift lever set to the range, the forces applied to the
valve are the spring force (force FS pushing to the left side), and line pressure q (force FL pushing to the
right side) from the manual valve. Furthermore, since a condition of FS < FL is satisfied, the valve is located
at the right side. When upshifting from the 2nd gear to the 3rd gear takes place, the line pressure t (force
FL pushing to the left side) from the 2-3 shift valve is applied gradually via the orifice. As a result, at the
point when a condition of FS + FL > FL is satisfied, the valve moves to the left. At the same time, w and e
are connected to each other. Consequently, the line pressure w is applied to the C3 via e.
<D range, 1st and 2nd gears> <D range, except for 1st and 2nd gears>
q w e r t q w e r t
q Line pressure , From manual valve r Line pressure , From 3-4 shift valve (4th gear)
(, x and ranges)
t Line pressure , From 2-3 shift valve (3rd and 4th gears)
w Line pressure , From 2-3 shift valve
(3rd and 4th gears)
e To C3
JAT00034-00027

AT22
If upshift from the 2nd gear to the 4th gear takes place all at once (when making the C2 inoperative and the
C3 operative), the engine starts racing, for no load is applied temporarily. In order to avoid this, the 2-4 tim-
ing valve prevents the pressure C2 from being turned OFF (through shifting to the 3rd gear temporarily),
until the pressure C3 reaches a certain pressure.
When the transmission is in the 2nd gear with the shift lever set to the range, only the spring force (force
FS pushing to the left side) is applied to the valve. Therefore, the valve is located at the left side. In this
case, the line pressure from the manual valve is applied to the 3-4 shift valve via e as a force counteract-
ing the governor pressure.
If conditions for upshift to the 4th gear are satisfied and the 2-3 shift valve is switched (moved to the left
side), the line pressure q (pressure C3) (force FC3 pushing to the right side) starts to be applied. However,
the valve remains located at the left side, until a condition of FS < FC3 is satisfied. Therefore, since the line
pressure is applied to the 3-4 shift valve, the 3-4 shift valve cannot move to the left side. In other words, the
pressure C2 cannot be turned OFF and the transmission remains in the 3rd gear. When a condition of CS <
FC3 is satisfied and the valve moves to the right side, e and r are connected to each other and the line
pressure which was applied to the 3-4 shift valve will be drained. Consequently, the 3-4 shift valve moves
and upshifting to the 4th gear takes place.
When the overdrive is turned OFF (the overdrive solenoid is energized), the line pressure (force FL pushing
to the left side) is applied to t. Since a condition of FC3 < FS + FL is always satisfied, the valve will not move
to the right side (upshifting to the 4th gear will not take place).
<Except for 3rd and 4th gears> <3rd and 4th gears>
q
q
w e r t
w e r t
q Line pressure (Pressure C3) r Line pressure (x and ranges) From 2-3 shift valve
Throttle pressure
w Line pressure , From manual valve (opening angle of 85% or more)
(, x and ranges)
t Line pressure , From overdrive solenoid
e To 3-4 shift valve (When overdrive is turned OFF with , x or range)
JAT00035-00028
14) 3-2 timing valve q

When a downshift is made from the 3rd gear to the 2nd gear,
the change in the engine speed is relatively small during low- w
speed operation. However, the change in the engine speed is
great during high-speed operation, resulting in a strong shift
shock. The 3-2 timing valve is provided to reduce this shift
shock.
Spring Orifice control valve
q From Bl e
w To 2-3 shift valve
e Governor pressure
JAT00286-00257

AT23
When downshift from the 4th gear to the 3rd gear takes place
at a high speed, the 4-3 timing valve retards the rising speed e
r
of the line pressure (pressure C2), thus reducing shift im-
pacts. Orifice
pushing to the left side) and governor pressure w (force FG
q t
pushing to the right side). y u
When running at a low speed (FG < FS), the valve moves to the Check valve
left side, and y and u are connected to each other.
Therefore, the line pressure q from the 3-4 shift valve is w
quickly raised through the route of r / u / y / e.
When running at a high speed (FG > FS), the valve moves to q Line pressure , From 3-4 shift valve
the right side, and y and u are cut off. Therefore, the line (Except for 4th gear)
pressure q will be raised slowly through the route of t / w Governor pressure
orifice / e.
e 3-4 & select timing valve / To C2
JAT00036-00029
16) Overdrive solenoid

The overdrive solenoid makes the line pressure applied to the <When electric current is not
3-4 shift valve and 2-4 timing valve, thus preventing upshift to energized (Overdrive ON)>
the 4th gear from taking place. q
When the overdrive switch is turned ON (overdrive possible),
the solenoid is not energized, thus draining the line pressure w w
q.
When the overdrive switch is turned OFF (overdrive impossi-
ble), the solenoid is energized. As a result, the plunger is
pulled to close the fluid passage. Consequently, the line pres- <When electric current is energized
sure q is retained. (Overdrive OFF)>
q
w w
q Line pressure
(, x and ranges)
w Drain
JAT00037-00030
17) Accumulators
The accumulator has functions to relax the connecting of the
shift control elements and to reduce gear shift impacts. There
are two kinds of accumulators: One is for the forward clutch
(C2); and the other is for the 2nd brake band (B1). These are Accumulator B1
provided in the transmission case.
Accumulator C2
JAT00038-00031

AT24
(3) GOVERNOR VALVE
The governor valve is driven by the governor drive gear mounted on the output shaft. The governor valve
generates a governor pressure which is corresponding to the vehicle speed (output shaft revolution
speed).
The forces applied to the valve are the governor weight, centrifugal force of the governor inner weight
(force F1 pushing to the right side), centrifugal force of the governor valve (force F2 pushing to the right
side), and governor pressure w (force pushing to the left side).
When running at a low speed (spring force FS > F1), the governor pressure is regulated under a condition of
FG = F1 + F2. As the vehicle speed becomes high (FS < F1), the governor inner weight comes in contact with
the stopper. Consequently, the governor pressure is regulated under a condition of FG = FS + F2.
Governor valve
Governor pressure
Governor
inner weight
Governor weight
Governor shaft revolution speed

(vehicle speed)
w Governor pressure w Governor pressure

q Line pressure q Line pressure
<At low speed> <At high speed>

JAT00039-00032
(4) COOLING DEVICE

The automatic transmission fluid is cooled down by the oil cooler incorporated in the radiator.
On vehicles with the EU specifications, the fluid is once cooled down by the air-cooled oil cooler separately
mounted. Then, the fluid is sent to the oil cooler inside the radiator to be cooled down further.
This illustration shows specifications except

for the EU specifications
Oil cooler front hose
Front tube
A/T tubes
Oil cooler inlet hose
Oil cooler outlet hose
Engine side tubes
Oil cooler hoses
JAT00040-00033

AT25
CASE & COVER
DESCRIPTION
The case and cover consist of the transmission case, transmission case side cover, and transmission oil
pan.
For improved rigidity of the case, the transmission case is integrated with the converter housing.
Furthermore, liquid gasket featuring excellent sealing ability has been applied at the mating surfaces of
each case.
Transmission case
Transmission case side cover
Transmission oil pan
JAT00041-00034

AT26
ELECTRIC CONTROL SYSTEM
OVERDRIVE SWITCH
DESCRIPTION
The overdrive solenoid provided in the transmission valve body is energized (overdrive possible) by turning
ON (pushing) the overdrive switch incorporated in the shift lever. Also, the overdrive solenoid is non-ener-
gized (overdrive impossible) by turning OFF (releasing) the overdrive switch.
Gauge, back
10A
O/D OFF indicator
Overdrive relay
IG1
F/L AM
60A
Overdrive switch
O/D ON: Switch OFF
(Button pushed)
Battery O/D OFF: Switch ON Overdrive
(Button released) solenoid
JAT00042-00035
COMPONENTS
q Overdrive switch
w Overdrive relay
The overdrive relay is mounted on the floor shift assembly with
a bracket interposed.
Overdrive relay
e Overdrive solenoid
JAT00043-00036

AT27
SHIFT CONTROL MECHANISM
DESCRIPTION
1. The shift control mechanism has employed a remote control type, using a push-pull cable.
JAT00044-00037
COMPONENTS
(1) Shift lever assembly
The floor shift assembly has employed a six-position type having the , , , , x and positions.
Also, the overdrive switch is incorporated.
Overdrive switch
JAT00045-00038

AT28
PRELIMINARY CHECK Transmission warming-up method
1. Warm up the engine.
1. Check of transmission fluid level 2. If the vehicle runs for about 15 minutes at a speed
of 60 km/h or for about 30 minutes at a speed of 40
NOTE: km/h, the temperature of the fluid inside the
Prior to the fluid level check, be sure to run the vehicle transmission becomes about 80 10C.
until the engine and transmission have reached their Reference
normal operating temperature. When the engine is cold, if the engine is operated for
about 35 minutes at the idling speed after the engine
(Fluid temperature: 70 - 90C) has started, the temperature of the fluid inside the
transmission will rise to about 60 10C.
2. Check of engine idling speed.
Specified Value: 850 50 rpm
(a) Park the vehicle on a level surface. Apply the parking

brake.
(b) With the engine idling, smoothly move the shift lever all
through the ranges from P to L. Finally, return the shift
lever to the P range.
(c) Pull out the transmission fluid level gauge and wipe it
clean.
(d) Push it back fully into the tube.
(e) Pull it out and check that the fluid level is in the HOT
JAT00046-00039
range.
If the fluid level is too low, add the fluid.

Fluid To Be Used: DEXRON III
Full Capacity: Approx. 4.2 R (For EU: 4.29 R)
Drain and Refill: Approx. 1.7 R (For EU: 1.74 R)
CAUTION:
Do not overfill the fluid.
NOTE:
If it is necessary to check the fluid level at a low tem-
perature (20 - 30C), e.g. at the time of fluid change,
first adjust the fluid level so that it may become within H C
the COLD level. Then, recheck the fluid level under the
hot conditions.
If the fluid level fails to reach the cold level on the fluid
level gauge, be sure to check the transmission for fluid H range C range
leakage. Also, pull out the fluid level gauge and check
the fluid for contamination or smell of fluid burning.
JAT00047-00040
3. Check of fluid condition

If the fluid smells burning or it presents a black appear-
ance, change the fluid.
4. Change of transmission fluid
(1) Remove the drain plug with the gasket. Drain the fluid.
NOTE:
JAT00048-00041

AT29
(2) With a new gasket interposed, tighten the drain plug
securely.
(3) Add new fluid through the filler tube.

Fluid To Be Used: DEXRON III
Full Capacity: Approx. 4.2 R (For EU: 4.29 R)
Drain and Refill: Approx. 1.7 R (For EU: 1.74 R)
(4) Start the engine. Move the shift lever to all positions
from P through L. Then, move it to the P position.
(5) With the engine idling, check the fluid level. Add fluid
up to the COLD level on the fluid level gauge.
(6) Check the fluid level at the normal fluid operating tem-
perature (70 - 90C). Add the fluid, as required.
JAT00049-00000
5. Adjustment of throttle cable

The purpose of this adjustment is to make the full open
state of the throttle link of the throttle body at the engine
side equal to the full-open position of the throttle valve in-
side the transmission.
NOTE:
Do not perform the adjustment, using the attaching nut
A
of the throttle link at the engine side. The nut A in the
right figure is secured with bond.
JAT00050-00043
(1) Remove the neutral start switch.

(2) Reset the automatic adjusting mechanism, following
the procedure given below. Hexagonal
NOTE: w staked section
When turning the casing cap with pliers or the like, be
sure not to apply a lateral force. If a lateral force should Casing cap
be applied, it may damage (break) the casing cap sec- q
tion.
Circlip
1) Turn the casing cap about 60 to 90 degrees. (The
circlip will be expanded.) JAT00051-00044
NOTE:
When turning the casing cap with pliers or the like, be
sure to clamp the hexagonal staked section of the cas-
ing cap.
2) Pull the casing cap, until it is brought into contact

with the stopper.

AT30
3) Turn the casing cap in the reverse direction of the
step 1). (The circlip will be closed so that the cas-
ing cap may be secured.)
JAT00052-00045
(3) Fully depress the accelerator pedal or turn the throttle

link at the engine side, until it comes in contact with
the full-open stopper.
At this time, ensure that the free play of the throttle
cable has been automatically adjusted by listening to
a clicking sound.
(4) Install the neutral start switch assembly.
(See the step 7.)
JAT00053-00000
6. Inspection of neutral start switch

Using an ohmmeter, check the continuity of the terminals
for each switch position shown in the table below.
Terminal
E R RB P N D 2 L
Range P D 2 R
L RB E N
P
R
N
D
2
L
If the continuity does not conform to the specifications, re-
place the switch.
JAT00054-00046
7. Adjustment of neutral start switch

(1) Move the shift lever to the range.
(2) Remove the attaching bolts of the control cable and
control shaft lever subassembly.
(3) Remove the control shaft lever subassembly.
JAT00055-00000

AT31
(4) Install the SST. Check that the gauge section of the
SST is aligned with the scribed line of the neutral start
SST
switch.
SST: 09302-87201-000
(5) If they are not aligned with each other, loosen the bolt.
Then, perform the adjustment by turning the switch
section so that they may be aligned. Tighten the bolt to
the specified torque. Scribed line
JAT00056-00047
NOTE:
Do not use an impact wrench to tighten the securing
bolt of the neutral start switch.
(6) Remove the SST. Install the control shaft lever sub-
assembly.
(7) In cases where the operation in (5) has been per-

formed, confirm the operation of the control shaft lever,
following the procedure given below:
1) With the control shaft lever set to the range,
move it approximately 2 to 3 mm toward the Excessive play
range by your hand. At this time, ensure that the
control shaft lever fully returns to the range.
2) If the lever will not return to the range, once
loosen the securing bolt of the neutral start switch.
After performing the adjustment, retighten the bolt.
(8) Install the control cable, making sure that the backlash
will not be deviated to one side.
JAT00057-00048
8. Check of shift lever position

(1) Move the shift lever from the range to each range.
Ensure that the shift lever button and shift lever can be
operated smoothly with a positive detent feeling at
each range. Check that the position indicator functions
properly.
(2) Start the engine. Ensure that the vehicle moves for-
ward when you move the shift lever from the range
to the , x and ranges, respectively. Make sure
that the vehicle moves backward when you move the
shift lever to the range. JAT00058-00049
(3) With the ignition switch set to the ON position, move

the shift lever from the to range and from the
to range while depressing the brake pedal.
e mark: Shift can be made only while shift lever but-
ton is being pushed
a mark: Shift can be made without pushing shift
lever button
(4) With the ignition switch turned ON and the shift lever
placed in the range, check that the back-up lamp
goes on and the reverse warning buzzer is set off.

AT32
TESTING
CAUTION:
Perform the stall test at the normal fluid operating temperature (70 - 90C).
Do not conduct this test continuously for more than five seconds.
Wait at least one minute before the switching is made from the range to the range.
Be sure to turn OFF the air conditioner (if equipped so on).
JAT00059-00000
STALL TEST
1. Place chocks at the wheels of the vehicle.
2. Connect an engine tachometer. Apply the parking brake.
4. While strongly depressing the brake pedal by your left foot, move the shift lever to the and ranges,
respectively. Then, depress the accelerator pedal fully by your right foot. At this time, quickly read the
engine revolution speed.
NOTE:
Do not conduct this test continuously for more than five seconds.
There must be an interval of at least one minute between the range and the range.
Specified Value: 1990 - 2540 rpm
REFERENCE:
If the stall revolution speed fails to conform to the specified value, most likely the following malfunc-
tions are taking place.
Although the stall revolution speed in the range is
Insufficient engine output
the same as that in the range, they are lower than
Faulty torque converter stator one-way clutch
Although the stall revolution speed in the range is Insufficient transmission fluid amount
the same as that in the range, they are higher than Low line pressure
the specified value. Slipping of forward clutch, direct clutch and 1st &
reverse brake, and malfunction of one-way clutch
Low line pressure
The stall revolution speed in the range is higher
Slipping of forward clutch, and malfunction of one-way
than the specified value.
clutch
The stall revolution speed in the range is higher Low line pressure
than the specified value. Slipping of direct clutch and 1st & reverse brake
JAT00060-00000

AT33
TIME LAG TEST
1. Apply the parking brake and place chocks at the wheels of the vehicle.
3. While depressing the brake pedal, move the shift lever from the range to the range; and from the
range to the range at the idle speed. At this time, measure the time elapsed from shifting until a
shock is felt.
NOTE:
If the time lag is to be measured consecutively, be sure to put a one-minute interval between the
tests.
Conduct the test several times. Obtain the mean value.
Specified Value:
: 1 second or less
: 1 second or less
REFERENCE:
If the time lag fails to conform to the specified value, most likely the following malfunctions are taking
place.
The time lag when shifted from the range to the Forward clutch slipping
range is longer than the specified value. Low line pressure
The time lag when shifted from the range to the Direct clutch slipping
range is longer than the specified value. 1st & reverse brake slipping
Low line pressure
JAT00061-00000
HYDRAULIC PRESSURE TEST

1. Articles to be prepared
Shape Part number, nomenclature
09325-87201-000
SST A/T pressure gauge No. 1 adapter
Pressure gauge for automatic

transmission fluid
Instrument
Oil pressure gauge adapter

Grease DEXRON III
JAT00062-00050

AT34
2. Plug position for hydraulic pressure test
Pressure B2
Throttle pressure
Governor
Pressure C3
Pressure C1
Pressure B1 Pressure C2 Test plug tightening torque

6.9 - 9.8 (0.7 - 1.0)
Pressure B1 range pressure
Unit: Nm (kgf-m)
JAT00063-00051
3. Installation procedure for pressure gauges

NOTE:
Be sure to use new gaskets for the SST and instrument.
Never reuse the test plugs.
(1) Remove the test plug and install the pressure gauge.
NOTE:
Be very careful not to allow the pressure gauge to interfere with the front propeller shaft.
(2) Start the engine and warm up the transmission (fluid temperature 70 - 90 C). Check the fluid level.
Also, check each section for fluid leakage.
4. Measurement procedure for each hydraulic pressure

q Throttle pressure, range pressure, pressure C1, pressure C2 and pressure B2
(1) Apply the parking brake and place chocks at the wheels of the vehicle.
(3) Strongly depress the brake pedal by your left foot. With the shift lever moved to the range, range,
and range, respectively, operate the accelerator pedal by your right foot. At this time, measure each
hydraulic pressure.
w Pressure B1
(1) Jack up the four wheels. Then, support the vehicle by rigid racks.
(3) With the shift lever moved to the range and x range, gradually depress the accelerator pedal.
Measure the hydraulic pressure after upshift to the 2nd gear takes place. However, in cases where the
shift lever is set to the range, measure the hydraulic pressure at the time when the accelerator pedal
is released.
e Pressure C3 and pressure B1
(1) Jack up the four wheels. Then, support the vehicle by rigid racks.
(3) With the shift lever moved to the range, gradually depress the accelerator pedal so that upshift to the
3rd gear may take place. Then, measure the hydraulic pressure at the time when the accelerator pedal
is released.
JAT00064-00000

AT35
r Governor pressure
(1) Drive the vehicle onto a speedometer tester.
(3) With the shift lever moved to the range, gradually depress the accelerator pedal. Measure the hy-
draulic pressure at each vehicle speed.
Specified Value
Item Measurement condition Specified value (kPa {kg/cm2})

Idling revolution condition 29 {0.3} or less
Throttle pressure
Stall revolution condition 598 - 637 {6.1 - 6.5}
Idling revolution condition 530 - 628 {5.4 - 6.4}
range pressure
C2
C1, B2
431 - 530 {4.4 - 5.4}
Line pressure
B2 Idling revolution condition 1265 - 1363 {12.9 - 13.9}

B1, C3 3rd gear with accelerator pedal OFF 530 - 628 {5.4 - 6.4}
2nd gear with accelerator pedal OFF 530 - 628 {5.4 - 6.4}
B1
x 2nd gear 902 - 1000 {9.2 - 10.2}
30 km/h 49 - 147 {0.5 - 1.5}
Governor pressure
60 km/h 167 - 265 {1.7 - 2.7}
JAT00065-00000

AT36
REFERENCE:
If each hydraulic pressure fails to conform to the specified value, most likely the following malfunc-
tions are taking place.
1. Oil pump faulty

2. Oil strainer clogged
3. Faulty O-ring of oil strainer
4. Improper adjustment of throttle cable
All line pressures fail to conform to the specified value.
5. Faulty valve body assembly
Loose connecting bolt of valve body
Faulty modulator valve
6. Improper throttle pressure
Leakage or clogging at circuit of the clutch or brake
pressure concerned
Only a certain clutch or brake pressure fails to conform
Faulty piston accumulator of the clutch or brake
to the specified value.
pressure concerned
Shift valve faulty
2. Manual valve faulty, or improper adjustment of position
Faulty manual valve, or improper adjustment of position
range pressure fails to conform to the specified value.
Leakage or clogging of range pressure circuit
2. Improper line pressure
1. Improper adjustment of throttle cable
2. Throttle cable detached or broken
Throttle pressure fails to conform to the specified value.
Faulty throttle valve
Leakage or clogging of throttle pressure circuit
1. Faulty governor valve assembly
Governor pressure fails to conform to the specified value.
Leakage or clogging of governor pressure circuit
JAT00066-00000

AT37
RUNNING TEST
NOTE:
Be sure to confirm safety on the road when conducting the running test.
Make sure that the fluid temperature is in a normal running condition (70 - 80 C).
1. range test
(1) Move off the vehicle with the shift lever set to the range. Check to see if upshift and downshift
take place between the 1st gear and the 2nd gear; between the 2nd gear and the 3rd gear; and be-
tween the 3rd gear and the 4th gear (overdrive). Also, check to see if each shift point conforms to
the specified value. Furthermore, check that there is no abnormal shock and slipping, etc.
(2) While driving the vehicle with the shift lever set to the range and the transmission in the 4th gear
(overdrive), 3rd gear, and 2nd gear, respectively, perform the kick-down operation. At this time,
check to see if kick-down takes place from the 4th gear (overdrive) to the 3rd gear, from the 3rd
gear to the 2nd gear; and from the 2nd gear to the 1st gear. Also, check to see if the vehicle speed
range during which kick-down is possible conforms to the specified value. Furthermore, check that
there is no abnormal shock or slipping, etc.
(3) When the overdrive switch is turned OFF while driving the vehicle in the 4th gear (overdrive), ensure
that the downshift from the 4th gear (overdrive) to the 3rd gear takes place.
2. x range test
(1) Move off the vehicle with the shift lever set to the x range. Check to see if upshift and downshift
take place between the 1st gear and the 2nd gear. Also, check to see if each shift point conforms to
(2) Move off the vehicle with the shift lever set to the x range. At this time, ensure that upshift from the
1st gear to the 2nd gear takes place and that no upshift to the 3rd gear will take place.
(3) While driving the vehicle with the shift lever set to the x range and the transmission in the 2nd gear,
perform the kick-down operation. Check to see if kick-down takes place from the 2nd gear to the 1st
gear. Also, check to see if the vehicle speed range during which kick-down is possible conforms to
(4) When the shift lever is shifted to the x range while driving the vehicle with the shift lever set to the
range and the transmission in the 3rd gear, check that downshift from the 3rd gear to the 2nd
gear takes place and engine brake is applied. Also, check to see if the shift point conforms to the
specified value.
3. range test
(1) Move off the vehicle with the shift lever set to the range. At this time, ensure that no upshift to the
2nd gear will take place.
(2) When the shift lever is shifted to the range while driving the vehicle with the shift lever set to the
range and the transmission in the 3rd gear, check that downshifts from the 3rd gear / the 2nd
gear / the 1st gear take place and engine brake is applied. Also, check to see if the shift point
conforms to the specified value.
JAT00067-00000

AT38
4. range test
(1) Park the vehicle on a grade (approximately 5 degrees or more) in a climbing state and move the
shift lever to the range. Then, release the parking brake. At this time, check that the parking lock
mechanism functions and the vehicle will not move.
(2) Park the vehicle in a descending state, and perform the same check as stated above.
(3) Under conditions above, move the shift lever from the range to other ranges. At this time, check
to see if the vehicle moves.
Specified Value
Throttle opening angle Range Gear shifting Vehicle speed (km/h)
1st / 2nd 31.6 - 47.6
2nd / 3rd 67.6 - 83.6
3rd / 4th 107.8 - 123.8
100 %
4th / 3rd 89.4 - 105.4
3rd / 2nd 60.7 - 76.7
2nd / 1st 24.5 - 40.5
4th / 3rd 12.0 - 28.0
0%
3rd / 1st 6.3 - 22.3
x, 3rd / 2nd 85.6 - 101.6
0 - 100%
2nd / 1st 33.7 - 49.7
JAT00068-00000
ELECTRIC-RELATED TESTS
OVERDRIVE SYSTEM
q Wiring diagram
Gauge, back
10A
O/D OFF
indicator Overdrive relay
IG1
F/L AM
60A
Overdrive switch
O/D ON: Switch OFF
(Button pushed)
Battery O/D OFF: Switch ON Overdrive
(Button released) solenoid
JAT00069-00052

AT39
w Unit inspection
Overdrive switch
1. When the overdrive switch is turned ON (overdrive possi- 3 1
4 2
ble), check that no continuity exists between the terminals
q and w of the connector in the right figure. Also, when
the overdrive switch is turned OFF (overdrive impossible),
check that continuity exists between the same terminals.
JAT00070-00053
Overdrive relay
1. Measure the resistance between the terminals q and w.
e
Specified Value: Approx. 70 w
2. Ensure that no continuity exists between the terminals q q

and e.
3. When the battery voltage is applied across the terminals
q and e, ensure that continuity exists between the termi-
nals q and w. Overdrive relay
JAT00071-00054
Overdrive solenoid
1. Measure the resistance between the terminal of the over- Terminal
drive solenoid connector and the ground (transmission
case).
Specified Value: 24 - 27.2
JAT00072-00055

AT40
REMOVAL AND INSTALLATION OF AUTOMATIC TRANSMISSION
COMPONENTS
: Tightening torque
Unit : Nm (kgf-m)
e t
29.4 - 39.2 q
(3.0 - 4.0)
6.9 - 9.8 B

(0.7 - 1.0)
B
29.4 - 39.2
6.9 - 9.8 (3.0 - 4.0) w
(0.7 - 1.0)
r
B
u 49.04 - 68.64
(5.0 - 7.0)
B
y
29.4 - 44.1
(3.0 - 4.5)
78.45 - 98.07 B
(8.0 - 10.0) !2
B B
26.0 - 48.5
14.7 - 21.6
(2.65 - 4.95)
o B (1.5 - 2.2)
!1
!3 14.7 - 21.6 29.4 - 44.1
(1.5 - 2.2) (3.0 - 4.5)
MP grease
!4
!0 B
29.4 - 44.1 i
(3.0 - 4.5)
B
34.3 - 61.7
(3.5 - 6.3)
q Ground wire o Power train stiffener

w Vacuum hose !0 Bolt (torque converter drive plate)
e Neutral start switch connector !1 Engine rear support member subassembly
r Overdrive solenoid connector with engine mounting rear insulator
t Speedometer drive cable assembly !2 Transmission assembly with transfer assem-
y Oil cooler hose bly
u Bolt (tube bracket transmission) !3 Torque converter assembly
i Front lower frame crossmember subassem- !4 Drive plate & ring gear subassembly
bly
JAT00073-00056

AT41
1. Operations prior to removal
(1) Disconnect the negative () terminal of the battery.
(2) Disconnect the throttle cable at the engine side.
(3) Drain the automatic transmission fluid.
(4) Remove the propeller front shaft.
(5) Remove the propeller shaft.
(6) Remove the front exhaust pipe.
(7) Remove the starter assembly.
(8) Disconnect the control cable at the transmission side.
JAT00074-00000

(1) Disconnect the neutral start switch connector and Neutral start switch
overdrive solenoid connector. connector
Overdrive
solenoid
connector
JAT00075-00057
(2) Support the engine, using an engine supporting

bridge. Remove the engine rear support member sub-
assembly with the rear engine mounting rear insulator.
(3) Support the transmission assembly with the transfer,
using a transmission jack, etc. Remove the transmis-
sion assembly with the transfer.
NOTE:
Be very careful not to deform the oil pan during the re-
moval.
JAT00076-00058
3. Check
(1) Check the drive plate for runout.
Limit: 0.25 mm
JAT00077-00059
(2) Install the torque converter to the drive plate. Check

the shaft for runout, using the following SST.
SST: 09351-87203-000
Limit: 0.30 mm
NOTE:
Be very careful not to drop the torque converter during
the operation.
SST
JAT00078-00060

AT42
(1) Insert the torque converter assembly into the transmis-
sion assembly. Ensure that the torque converter has
been inserted securely.
Specified Value: Dimension A is 28 mm or more.
(Dimension A: Dimension between
edge surface of housing and drive
plate installation seat of torque con-
verter)
JAT00079-00061
(2) Install the transmission assembly with the transfer.

1) Face the reference hole (elongated hole) of the
drive plate downward.
2) Support the transmission assembly with a trans-
mission jack, etc. Then, connect the transmission
assembly to the engine.
NOTE:
Be very careful not to dent the oil pan during the opera-
Reference hole
tion.
JAT00080-00062
NOTE:
Before securely tightening the bolts and nuts (engine
transmission), make sure that the torque converter
turns lightly. If the torque converter will not turn lightly, it
means that the torque converter is deviated from the
specified position. Therefore, remove the transmission Ensure that the
torque converter
and securely insert the torque converter into the speci- assembly rotates
fied position. (If the bolts and nuts are tightened se- lightly.
curely with the torque converter deviated from the
specified position, there will be the possibility that the
oil pump be damaged.) JAT00081-00063

(5.0 - 7.0 kgf-m)
(3) Install the bolts (drive plate torque converter).

1) First, tighten the bolt in the reference hole (elongat-
ed hole) of the drive plate.
NOTE:
Never use bolts other than the bolt indicated in the right
(22)
20
figure. (If those bolts longer than the specified bolt

should be used, it would lead to improper tightening or
deformation of the inner shape of the converter, thus
resulting in hampering the functions.) (2)
14 0.3
JAT00082-00064

AT43
(4) Install the power train stiffener. Tighten the bolts in the (D)
following sequence.
1) Temporarily tighten the bolt (A).
2) Securely tighten the bolts in the sequence of the
bolt (B), bolt (A), bolt (E), bolt (F), bolt (C), and bolt
(D). (C)
REFERENCE:
If any difficulty is encountered in inserting the bolts (E)
(A)
and (F), loosen the bolt (a) before the operation.
(B)
JAT00083-00065
Tightening Torque:
M10 29.4 - 44.1 Nm (3.0 - 4.5 kgf-m)
M8 14.7 - 21.6 Nm (1.5 - 2.2 Kgf-m)
(a)
(E)
(F)
JAT00084-00066
5. Operations after installation

(1) Install the starter assembly.
(2) Install the control cable assembly at the transmission side.
(3) Install the front exhaust pipe.
(4) Install the propeller shaft.
(5) Install the propeller front shaft.
(6) Connect the throttle cable at the engine side.
(7) Fill automatic transmission fluid.
(8) Perform the basic check and adjustment.
JAT00085-00000

AT44
CONNECTION AND DISCONNECTION OF OIL COOLER HOSES
COMPONENTS
1. Operations prior to removal
(1) Remove the center engine undercover. (Except EU specifications)
Remove the center engine undercover, radiator grill and front bumper cover. (EU only)
: Tightening torque
Unit : Nm (kgf-m)
29.4 - 39.2
(3.0 - 4.0)
6.9 - 9.8
(0.7 - 1.0) B
6.9 - 9.8
(0.7 - 1.0) B
29.4 - 39.2
q (3.0 - 4.0)
29.4 - 44.1
(3.0 - 4.5) B
To radiator
EU specifications
e

r
Specifications
other than

*

EU specifications B
B
To radiator B
B
FRONT 6.9 - 9.8

6.9 - 9.8 (0.7 - 1.0)
(0.7 - 1.0) u
y r
B
*
q Oil cooler hose 6.9 - 9.8
w Oil cooler inlet hose (0.7 - 1.0) To radiator
e Oil cooler outlet hose
r Oil cooler front hose
t Oil cooler front inlet hose i
t
y Oil cooler assembly
u Transmission oil cooler bracket
i Clamp
JAT00086-00067

AT45
Table showing identification of oil cooler hose
Length (mm) Remarks

q Oil cooler hose 125
w Oil cooler inlet hose 246
e Oil cooler outlet hose 189
r Oil cooler front hose Moulded hose
t Oil cooler front inlet hose Moulded hose
JAT00087-00000
(1) Completely degrease the hose connecting section. Insert

new oil cooler hoses q, w, e, r and t up to the second
q,w,e r,t
stage spools of the oil cooler tube and the union at the oil
cooler side, while making sure that those hoses may not Second stage spool Second stage spool
be twisted. Then, attach the clip, while aligning it with the
edge of the marking. However, the oil cooler front hoses
(moulded hoses) r and t should be connected in such
a way that the marking faces just downward of the vehicle.
Marking Marking
JAT00088-00068
3. Operations after installation

(1) Check the automatic transmission fluid level. Replenish
the fluid, as required.
(2) Install the center engine undercover. (Except EU speci-
fications)
Install the center engine undercover, front bumper
cover and radiator grill. (EU only)
JAT00089-00000

AT46
DISASSEMBLY AND ASSEMBLY OF AUTOMATIC TRANSMISSION
COMPONENTS
: Tightening torque
Unit : Nm (kgf-m)
9.8 - 15.7
(1.0 - 1.6)
@5 14.7 - 21.6 29.4 - 44.1

(1.5 - 2.2) (3.0 - 4.5)
14.7 - 21.6
(1.5 - 2.2) B
6.9 - 9.8
(0.7 - 1.0) B N B 29.4 - 44.1
#0 (3.0 - 4.5)
@6 B @9
B
i
@7
6.9 - 9.8
B
(0.7 - 1.0) #2
t 6.9 - 9.8
#1 (0.7 - 1.0)
B
u
6.9 - 9.8
(0.7 - 1.0) !3
y
@8 !2
B
!1
22.5 - 30.4
(2.3 - 3.1) !0
!6 o
@2 @1 N
r 6.9 - 9.8
e (0.7 - 1.0) @4
B
q w !8
!7 @3 !5
B
!9
!4
B @0
6.9 - 9.8 19.6 - 29.4 6.9 - 9.8

(0.7 - 1.0) (2.0 - 3.0) (0.7 - 1.0)
q T-type oil seal !8 Transmission magnet

w O-ring !9 gasket
e Stator shaft & oil pump assembly @0 W/head straight screw plug
r Clutch drum oil seal ring @1 Oil strainer subassembly
t Transmission case subassembly @2 O-ring
y Transmission case side cover subassembly @3 Transmission brake band assembly
u Transfer assembly @4 Transmission brake band adjusting anchor
i Needle roller bearing bolt
o Hole snap ring @5 Throttle cable assembly
!0 Governor cover @6 Neutral start switch assembly
!1 O-ring @7 Transmission control shaft lever subassem-
!2 Governor body assembly bly
!3 Ball @8 Power train stiffener
!4 O-ring @9 Control cable bracket
!5 Transmission oil filler tube subassembly #0 Throttle cable clamp
!6 Transmission oil level gauge subassembly #1 Breather plug No. 1
!7 Transmission oil pan assembly #2 Breather plug No. 2
JAT00090-00069

AT47
COMPONENTS (INNER PARTS)
!5
!3
!2
!0
o
i !4
u
y !1
t
@4
e
w @3
@2
q
@0
r @5
!8
@1
!9
!7
!6
q Clutch drum thrust washer @0 Brake cushion plate

w Direct clutch assembly @1 Planetary gear assembly
e Thrust needle roller bearing @2 Thrust needle roller bearing
r Thrust bearing race @3 Planetary output shaft subassembly
t Forward clutch assembly @4 Radial ball bearing
y Thrust needle roller bearing @5 Output shaft assembly
u Intermediate shaft subassembly
i Thrust needle roller bearing
o Thrust bearing race
!0 Forward clutch hub
!1 Thrust needle roller bearing
!2 2nd brake drum
!3 Planetary sun gear subassembly
!4 Thrust needle roller bearing
!5 Rear planetary sun gear subassembly
!6 Hole snap ring
!7 One-way clutch
!8 Brake plate
!9 Brake disc
JAT00091-00070

AT48
REMOVAL
1. Remove the bolt of the transmission oil filler tube sub-
assembly.
2. Pull out the transmission oil filler tube subassembly toward
upside.
3. Remove the O-ring from the transmission oil filler tube
subassembly.
NOTE:
Never reuse the removed O-ring.
JAT00092-00071
4. Remove the breather plug (A) and union bolts (B) (for oil
cooler). (B)
NOTE: (A)
Never reuse the removed gaskets. (B)
5. Remove the clamp (C) for the throttle cable. (C)
JAT00093-00072
6. Removal of governor valve

(1) Remove the hole snap ring, using standard snap ring
pliers.
(2) Remove the governor cover with the O-ring installed,
using standard pliers.
(3) Remove the O-ring from the governor cover.
NOTE:
JAT00094-00073
(4) Remove the governor body assembly from the trans-

mission case. (A)
(5) Remove the ball (A), using a standard magnet hand.
JAT00095-00074
7. Detach the connector (A) of the solenoid wire assembly

from the clamp of the control cable bracket.
8. Removal of neutral start switch assembly
(1) Remove the control cable bracket by removing the two
bolts.
(2) Detach the connector (B) (of the neutral start switch) (B)
from the clamp of the control cable bracket.
(A)
JAT00096-00075

AT49
(3) Remove the transmission control shaft lever sub-
assembly by removing the nut.
(4) Remove the neutral start switch assembly by removing
the bolt.
JAT00097-00000
9. Remove the nine inspection plugs from the transmission.

NOTE:
Never reuse the removed plugs.
JAT00098-00076
10. Remove the power train stiffener.
JAT00099-00077
11. Removal of transfer assembly 35 35

NOTE:
For the disassembling procedure of the transfer, refer
to the TR section.
35 35
(1) Remove the seven bolts indicated in the right figure.
NOTE: 170
The numerals in the right figure denote the nominal
length of each bolt. (Unit: mm) 35
170
(2) Tap the rib section of the transfer case. Then, pull it out JAT00100-00078
toward you.
12. Remove the needle roller bearing at the forward end of the
output shaft assembly.
JAT00101-00079

AT50
13. Remove the transmission oil pan assembly by removing
the fourteen bolts.
CAUTION:
Do not turn over the transmission, for this will contami-
nate the valve body with foreign materials deposited at
the bottom of the oil pan.
NOTE:
Never reuse the removed oil pan assembly.
JAT00102-00080
14. Check of pan for particles

Remove the transmission magnet and use them to collect
any steel chips. Inspect the oil pan for any chips and par-
ticles collected on the magnet. Inspect them carefully to
find out the type of wear of the transmission.
Steel (magnetic) ... Wear of bearing, gear and plate
Brass (nonmagnetic) ... Wear of bush
JAT00103-00081
15. Disconnect the throttle cable from the throttle valve cam.
16. Remove the throttle cable attaching bolt.
17. Pull out the throttle cable from the transmission case.
18. Remove the O-ring of the throttle cable.
NOTE:
JAT00104-00082
19. Disconnect the connector of the solenoid wire assembly

indicated by the arrow mark in the right figure.
JAT00105-00083
20. Remove the oil strainer subassembly by removing the 48.5 48.5 (A)
three bolts.
NOTE:
Be sure to remove the bolts evenly and uniformity.
The numerals in the right illustration indicate the nomi-
nal length of the bolt.
21. Disconnect the valve body tube (A).

48.5
JAT00106-00084

AT51
22. Remove the O-ring by sticking a needle into the O-ring for
the oil strainer which has been installed at the valve body
side.
NOTE:
Be very careful not to scratch the valve body when O-ring
sticking the needle into the O-ring.
Needle
JAT00107-00085
23. Remove the manual detent spring by removing the two

bolts.
40
NOTE: 12
Be sure to remove the bolts evenly and uniformity.
The numerals in the right illustration indicate the nomi-
JAT00108-00086
24. Remove the valve body assembly. $0 $0

NOTE:
Be sure to remove the bolts evenly and diagonally. @0
The numerals in the right illustration indicate the nomi- $0
@0
nal length of the bolt. @0
@0
@0
JAT00109-00087
25. Remove the compression spring of the B1 accumulator

piston.
26. Lightly hold the arrow-headed section of the accumulator
No. 1 piston.
27. Remove the piston with the accumulator seal No. 1 and )
(A
No. 2 rings installed by applying compressed air into the
oil hole (A).
NOTE:
Be sure to put on protection goggles since oil may
splash when using compressed air.
JAT00110-00088
28. Remove the accumulator No. 2 piston with the seal No. 1
ring installed and compression spring.
JAT00111-00089

AT52
29. Remove the roller for manual valve lever shaft subassem-
bly, using a standard magnet hand.
JAT00112-00090
30. Remove the solenoid wire assembly attaching bolt.

31. Pull out the the solenoid wire assembly from the transmis-
sion case.
JAT00113-00091
32. Removal of 2nd brake piston assembly

(1) Remove the lock nut of the transmission brake band
adjusting anchor bolt.
(2) Remove the transmission brake band adjusting anchor
bolt, using a standard screwdriver or the like.
NOTE:
Never reuse the removed anchor bolt.
JAT00114-00092
(3) Remove the hole snap ring, using snap ring pliers in SST(B)
combination with the following SSTs.
SST: 09202-87002-000 ..... (A)
09202-87002-0A0 ..... (B)
(4) Gradually loosen the SSTs (A) and (B) above, until the
compression spring for the 2nd coast brake piston is
released fully. Then, remove the SSTs. SST(A)
NOTE:
In cases where the 2nd coast brake piston will not
come out, slightly loosen the SSTs above. Then, apply JAT00115-00093
a light impact by means of a plastic hammer to remove

the 2nd coast brake piston.
(5) Remove the 2nd brake piston assembly and compres-

sion spring.

AT53
33. Remove the slotted spring pin, using a pin punch and a
hammer.
NOTE:
When removing the slotted spring pin, be very careful
not to drop it into the transmission case.
Never reuse the removed slotted spring pin.
34. Pull out the manual valve lever shaft subassembly.
JAT00116-00094
35. Remove the manual valve lever by aligning the cut-out

groove of the manual valve lever (B) with the protruding (A)
section of the parking lock rod (A). (B)
JAT00117-00095
36. Remove the parking lock cam support and parking lock
rod subassembly by removing the three bolts.
JAT00118-00096
37. Remove the roller for the one-way clutch outer race, and
compression spring by removing the bolt.
JAT00119-00097
38. Measure the input shaft end play, using a dial gauge in
conjunction with the following SST.
SST: 09351-87210-000
NOTE:
Be sure to record the measured value for a guide dur-
ing the assembly.
JAT00120-00098

AT54
39. Remove the T type oil seal, using the following SST.
SST: 09308-10010-000
NOTE: SST
Never reuse the removed oil seal.
JAT00121-00099
40. Remove the seven bolts of the stator shaft & oil pump as-
sembly.
NOTE:
Be sure to remove the bolts evenly and diagonally.
Never loosen any bolt other than the specified ones in
the right figure.
JAT00122-00100
41. Remove the stator shaft & oil pump assembly with the O-
ring installed, using the following SST. SST
SST: 09820-00021-000
42. Remove the O-ring from the stator shaft & oil pump as-
sembly.
NOTE:
JAT00123-00101
43. Remove the two clutch drum oil seal rings.

NOTE:
Never reuse the removed oil seal rings.
JAT00124-00102
44. Remove the clutch drum thrust washer (resin made) from
the direct clutch.
NOTE:
If no thrust washer (resin made) is provided on the di-
rect clutch, make sure that the thrust washer is in-
stalled at the stator shaft & oil pump assembly side.
JAT00125-00103

AT55
45. Remove the direct clutch together with the forward clutch
at the same time.
46. Remove the direct clutch from the forward clutch.
JAT00126-00104
47. Remove the thrust needle roller bearing from the forward
clutch.
48. Remove the thrust bearing race from the forward clutch.
JAT00127-00105
49. Removal of intermediate shaft subassembly

(1) Remove the thrust needle bearing from the intermedi-
ate shaft subassembly.
(2) Remove the intermediate shaft subassembly.
JAT00128-00106
(3) Remove the thrust needle bearing from the intermedi-

JAT00129-00107
50. Removal of forward clutch hub and 2nd brake drum

(1) Remove the thrust bearing race from the forward
clutch hub.
JAT00130-00108

AT56
(2) Remove the 2nd brake drum (together with the forward
clutch hub).
JAT00131-00109
(3) Remove the rear planetary sun gear subassembly from

the 2nd brake drum.
(4) Remove the thrust needle bearing from the rear plane-
tary sun gear subassembly.
JAT00132-00110
(5) Remove the forward clutch hub from the 2nd brake
drum.
(6) Remove the thrust needle bearing from the 2nd brake
drum.
JAT00133-00111
(7) Remove the planetary sun gear assembly from the 2nd
brake drum.
JAT00134-00112
51. Remove the transmission brake band assembly.
JAT00135-00113

AT57
52. Measurement of 1st & reverse brake end play
(1) Turn over the transmission case.
JAT00136-00114
(2) Measure the 1st & reverse brake end play, using a
standard feeler gauge.
NOTE:
Be sure to record the measured value for a guide dur-
ing the assembly.
The tightness which you encounter during this inser-
tion/withdrawal of the feeler gauge should be virtually
the same as the tightness which you would encounter
during the thickness adjustment of the valve rocker JAT00137-00115
arm.
53. Removal of planetary gear and one-way clutch

(1) Remove the hole snap ring, using snap ring pliers.
(2) Remove the planetary gear assembly with the one-way
clutch installed.
JAT00138-00116
(3) Remove the one-way clutch from the planetary gear

assembly.
JAT00139-00117
54. Removal of 1st & reverse brake

(1) Move the brake discs, brake plates and brake cushion
plate as a set in such a way that they face toward the
front side.
(2) Remove the discs, plates and cushion plate in the fol-
lowing order.
D = Brake disc, P = Brake plate
B = Brake cushion plate
D/P/D/P/D/P/D/P/B
JAT00140-00118

AT58
(3) Remove the thrust needle roller bearing (A) from the
(A)
planetary output shaft subassembly.
JAT00141-00119
55. Removal of transmission case side cover (A)

(1) Remove the nine bolts and oil guide plate (A). 85
NOTE: 85
The numerals in the right figure denote the nominal 35
length of each bolt. 85
Never reuse the removed three bolts (B).
(2) Remove the transmission case side cover, using a

plastic hammer.
NOTE: (B)85 (B)35
(B)35 85 35
Lightly apply an impact to the right and left sides of the JAT00142-00120
transmission case side cover, using a plastic hammer,

when removing the cover.
Be very careful not to scratch the oil seal lip by the
spline of the output shaft when removing the transmis-
sion case side cover.
56. Remove the output shaft assembly.
JAT00143-00121
57. Remove the torsion spring.

58. Remove the parking lock pawl.
59. Remove the parking lock pawl shaft.
JAT00144-00122

AT59
60. Removal of planetary output shaft subassembly
(1) Tap the planetary output shaft subassembly lightly,
using a plastic hammer, until the planetary output shaft
subassembly becomes free.
(2) Remove the planetary output shaft subassembly from
the transmission case side.
JAT00145-00123
(3) Remove the hole snap ring, using snap ring pliers.
(4) Remove the radial ball bearing.
NOTE:
If any difficulty is encountered in removing the radial
ball bearing, remove it by applying a light impact from
the inside of the transmission case, using a suitable
brass bar in combination with a plastic hammer.
JAT00146-00124
61. Disassembling of first & reverse brake piston

(1) Temporarily install the removed B2 inspection plug to
the transmission case.
JAT00147-00125
(2) Assemble the following SSTs and set them to the trans-
mission case to remove the first & reverse brake return
spring.
SSTs: 09351-87201-000
09351-87707-000
09351-87709-000
09351-87710-000
NOTE:
To prevent the first & reverse brake return spring seat
from being deformed, be sure to stop pressing when JAT00148-00126
the first & reverse brake return spring seat has been
lowered 1 to 2 mm from the shaft snap ring installation
position.
(3) Remove the shaft snap ring, using snap ring pliers.
NOTE:
Be very careful not to deform the shaft snap ring by
spreading it excessively.
(4) Remove the first & reverse brake return spring.

JAT00149-00127

AT60
(5) Hold the first & reverse brake piston, using the follow-
ing SSTs (to prevent the piston from being tilted when
removing the piston).
SSTs: 09351-87201-000 SST
09351-87707-000
09351-87709-000
09351-87710-000
(6) While applying compressed air of 392 - 784 kPa (4 -

8 kgf/cm2) from the oil hole indicated in the right figure,
gradually loosen the bolt of the SST and remove the JAT00150-00128
first & reverse brake piston.

(7) Remove the outer O-ring of the first & reverse brake
piston.
NOTE:
JAT00151-00129
(8) Remove the inner O-ring of the first & reverse brake
piston.
NOTE:
JAT00152-00130

AT61
DISASSEMBLY AND ASSEMBLY OF COMPONENTS
COMPONENTS
: Tightening torque
Unit : Nm (kgf-m)
6.9 - 9.8
t
(0.7 - 1.0)
q Transmission case e Transmission case side cover subassembly

w T type oil seal r D type oil seal
t Breather plug
JAT00153-00131
1. Disassembly and assembly of transmission case

(1) Remove the type T oil seal, using a standard screw-
driver.
NOTE:
JAT00154-00132

AT62
(2) Assemble a new type T oil seal, using the following
SST.
SST: 09301-87702-000
JAT00155-00133
2. Disassembly and assembly of transmission case side

cover subassembly
(1) Remove the type D oil seal, using the following SST.
SST: 09309-87502-000
NOTE:
JAT00156-00134
(2) Assemble a new type D oil seal, using the following

SST.
SST: 09309-87203-000
(3) Tighten the breather plug to the specified torque.

JAT00157-00135

AT63
INSPECTION
COMPONENTS
i
u
y
(C)
r
(B) (E)
e
w (D)
(A) (F)
q
!2
!0
!4
!3
!1
q Direct clutch assembly !0 Brake plate

w Forward clutch assembly !1 Brake disc
e Brake band assembly !2 Brake cushion plate
r Intermediate shaft subassembly !3 Planetary gear assembly
t Forward clutch hub !4 Planetary output shaft subassembly
y 2nd brake drum (A) - (F) Thrust needle roller bearing
u Planetary sun gear subassembly Visually inspect each part for wear and dam-
i Rear planetary sun gear subassembly age.
o One-way clutch
JAT00158-00136

AT64
1. Brake band assembly
If the lining of the brake band is exfoliated or discolored, or
even a part of the printed number is defaced, replace the
brake band.
NOTE:
When the brake band assembly is replaced, be sure to
check the band contacting surface at the 2nd brake
drum side.
If the contacting surface is damaged or discolored, be
sure to replace the 2nd brake drum together with the
band. JAT00159-00137
Before assembling a new brake band, soak it in the

ATF for at least two hours.
2. Direct clutch assembly

Check of piston stroke of direct clutch
(1) Install the clutch drum thrust washer (resin made) to the oil
pump.
(2) Install the direct clutch on the oil pump.
NOTE:
Be very careful not to scratch the clutch drum oil seal
ring of the oil pump. JAT00160-00138
(3) Secure the direct clutch, using the following SST in combi-
nation with a press, to such an extent that the direct clutch
will not move in an up-&-down direction. SST (B)
(4) Install the following SSTs to the dial gauge.
SST: 09351-87203-000 ... (B)
09527-87301-000 ... (A)
NOTE:
Make sure that the SST (09351-87203-000) installed to Piston
the dial gauge is in contact at right angles with the di- JAT00161-00139
rect clutch outer piston. Make sure that the SST is not
in contact with any part other than the piston.)
(5) Measure the direct clutch piston stroke while applying and
releasing compressed air 392 - 784 kPa (4 - 8 kgf/cm2)
through the section (A) as shown in the right figure.
SST: 09527-87301-000, 09351-87203-000
Piston Stroke: 1.22 - 1.53 mm
If the piston stroke is greater than the maximum, re-

place the direct clutch with a new one. JAT00162-00140
Perform the measurement at several points.
Before assembling a new direct clutch, soak it in the
ATF for at least two hours.

AT65
(6) While pressing the direct clutch flange with a force of 9.8 -
29.4 N (1.0 - 3.0 kgf), using the following SST (A) in com-
bination with a suitable pushable gauge, measure the end
play between the direct clutch flange and the snap ring,
using a flat thickness gauge (B).
Specified Value: 0.93 +0.15mm
0.16mm
SST: 09306-87302-000 ... (A)
JAT00163-00141
(7) Confirmation of turning effort of clutch disc

Insert the input shaft (forward clutch) and rotate it. At this
time, ensure that the clutch disc rotates lightly.
JAT00164-00142
(8) Measure the bush inner diameter of the direct clutch pis-
ton subassembly, using an inner caliper gauge.
NOTE:
Ensure that the measurement should be performed at
several points.
If the measured value exceeds the allowable limit, re-
place the direct clutch drum subassembly with a new
one. JAT00165-00143
If the measured value exceeds the allowable limit of

the bush inner diameter, check the bush contacting
surface of the stator shaft of the oil pump assembly. If
the contacting surface is scratched or discolored, re-
place the stator shaft & oil pump assembly with a new
one, too.
3. Forward clutch assembly

Operation check of forward clutch piston
(1) Secure the input shaft on a vice with aluminum sheets
interposed.
NOTE:
Be very careful not to score the bush contacting sur-
face of the input shaft.
Air
blowing
(2) Blow compressed air of 392 - 784 kPa (4 - 8 kgf/cm2) hole
into the fluid hole of the input shaft indicated in the
right figure. At this time, check that the piston slides
smoothly. JAT00166-00144

AT66
Operation check of rear clutch piston
(1) Blow compressed air of 392 - 784 kPa (4 - 8 kgf/cm2)
into the fluid hole of the input shaft indicated in the
right figure. At this time, check that the piston slides
smoothly.
Air blowing
hole
JAT00167-00145
Confirmation of rotating weight of clutch disc

(1) Install the thrust needle bearing to the forward clutch.
REFERENCE:
Dimensions of thrust needle roller bearing:
clutch side
Outer diameter: 32 mm
Forward
Inner diameter: 16.5 mm
Thickness: 4.1 mm
Needle roller bearing

JAT00168-00146
(2) Assemble the intermediate shaft subassembly and ro-

tate it. Ensure that the clutch No. 3 disc rotates lightly.
JAT00169-00147
(3) Assemble the thrust needle bearing and thrust bearing Thrust needle bearing
race to the intermediate shaft subassembly.
REFERENCE:
Dimensions of thrust needle bearing:
Thickness: 4.1 mm
Thrust bearing race

JAT00170-00148
(4) Assemble the forward clutch hub and rotate it. Ensure
that the clutch No. 2 disc rotates lightly.
JAT00171-00149

AT67
4. One-way clutch
Hold the one-way clutch and turn the planetary gear assem-
bly.
NOTE:
Ensure that the one-way clutch turns freely when
turned counterclockwise. Also, ensure that it is locked
when turned clockwise.
JAT00172-00150
5. Thrust bearing specifications

Be sure to install the thrust bearings in the correct direction
and position.
NOTE:
Since the following six bearings have been staked at
the race side, these bearings can not be removed from
the race.
Approx
Unit: mm
A B C D E F
Outer diameter 35.7 32 32 46.5 35.7 46.5
Inner diameter 22.7 16.5 16.5 25.0 22.7 25.0
Thickness 2.8 4.1 4.1 5.0 2.8 5.0
JAT00173-00000
ASSEMBLY
1. Assembly of 1st & reverse brake piston
(1) Coat new O-rings with ATF.
(2) Install the new O-rings (B) to the first & reverse brake
piston
NOTE:
Be sure to install the (A) section of the new O-rings
faces toward the first & reverse brake piston side, for
the O-ring has a D-type shape.
JAT00174-00151
(3) Apply ATF to the outer periphery of the first & reverse
brake piston.
(4) Apply ATF to the inserted section of the first & reverse
brake piston of the transmission case.
(5) Insert the first & reverse brake piston into the transmis-
sion case.
JAT00175-00152

AT68
(6) Install the first & reverse brake piston, using the follow-
ing SSTs.
SSTs: 09351-87201-000
09351-87707-000
09351-87709-000
09351-87710-000
NOTE:
When installing the first & reverse brake piston, care
must be exercised to ensure that the O-ring may not be
deviated from the specified position and may not be JAT00176 -00153
scratched.
(7) Remove the aforesaid SST from the transmission case.

(8) Place the first & reverse brake return spring.
JAT00177-00000
(9) Compress the first & reverse brake return spring (seat
section), using the following SSTs.
SSTs: 09351-87201-000
09351-87707-000 SST
09351-87709-000
09351-87710-000
NOTE:
To prevent deformation, be sure to stop tightening the
SST when the first & reverse brake return spring has
been lowered 1 to 2 mm from the snap ring installation JAT00178-00154
groove.
(10) Install the shaft snap ring, using snap ring pliers.
NOTE:
Do not expand the ring excessively.
Make sure that the end gap of the shaft snap ring is not
aligned with the stopper section of the spring retainer
claw.
JAT00179-00155
(11) Remove the B2 inspection plug.
JAT00180-00156

AT69
2. Measure the inner diameter of the planetary output shaft
subassembly, using an inner caliper gauge.
NOTE:
Perform the measurement at several points. Calculate
the mean value.
If the measured value exceeds the allowable limit, re-
place the planetary output shaft subassembly with a
new one. Moreover, when replacing the planetary out- JAT00181-00157
put shaft subassembly, be sure to check the bush con-

tacting surface of the intermediate shaft for scratch or
discoloration. If the contacting surface is scratched or
discolored, replace the intermediate shaft with a new
part.
3. Assembly of planetary output shaft subassembly

(1) Install the radial ball bearing to the transmission case,
using the following SST.
SST: 09310-87301-0000
(2) Assemble the hole snap ring into the groove of the
transmission case, using snap ring pliers.
NOTE:
Replace any scored or deformed hole snap ring with a
new one.
JAT00182-00158
(3) Insert the planetary output shaft subassembly into the

transmission case as far as it will go.
(4) Install the planetary output shaft subassembly, using

the following SST in combination with a hammer.
SST: 09506-87303-000
JAT00183-00159
4. Install the parking lock pawl shaft to the transmission

case.
5. Install the parking lock pawl.
6. Install the torsion spring, as indicated in the right figure. (B)
NOTE:
Push the parking lock pawl toward the direction (B) and
release it. At this time, make sure that the parking lock
pawl returns to the original position by the reaction
force of the torsion spring.
JAT00184-00160

AT70
7. Install the output shaft assembly.
NOTE:
Securely insert the output shaft assembly into the
spline of the planetary output shaft assembly.
JAT00185-00161
8. Installation of transmission case side cover

(1) Apply the Three Bond 1281B to the entire periphery of
the transmission case without any discontinuation, as tire
(En ery)
R7
indicated in the right figure. 5
2. riph R5
pe

R5

Details of bolt
hole section at
asterisked marks

JAT00186-00162
(2) Assemble the transmission case side cover to the (A)

transmission case. Tighten the nine bolts. 85
Among the nine bolts, one bolt should be tightened to- 85
gether with the oil guide plate (A). 35
Tightening Torque: 14.7 - 21.6 Nm (1.5 - 2.2 kgf-m) 85
NOTE:
The numerals in the right figure denote the nominal
length of each bolt.
Make sure that new bolts are used at the three sec- (B)35
(B)85
85
(B)35
35
tions (B). JAT00187-00163
Be very careful not to scratch the oil seal lip by the

spline of the output shaft when installing the transmis-
9. Install the thrust needle roller bearing to the planetary out-

put shaft subassembly.
Reference Value:
Thrust needle roller bearing dimensions
Outer Diameter: 46.5 mm
Inner Diameter: 25 mm
Thickness: 5 mm
NOTE:
Be sure to install the (B) section of the thrust needle
roller bearing in such a way that it faces toward the out-
put shaft assembly side. JAT00188-00164

AT71
10. Install the planetary gear assembly.
NOTE:
Ensure that the planetary gear assembly rotates
smoothly.
JAT00189-00165
11. Installation of first & reverse brake

(1) Install the brake cushion plate.
NOTE:
Ensure that the stamped mark O of the brake cushion
plate faces toward the upper side.
JAT00190-00166
(2) Install the plates and discs in the following order. Disc
P = Brake plate, D = Brake disc Plate
P/D/P/D/P/D/P/D
Brake cushion plate
NOTE:
Before assembling new discs, soak them in the ATF for
at least two hours.
Be sure to align the cut-out section of the brake plate
with the protruding section of the transmission when in-
stalling the brake plate.
JAT00191-00167
(3) Coat the sliding section of the one-way clutch and Transmission
planetary gear assembly with the ATF. case
(4) Install the one-way clutch. One-way clutch
NOTE: assembly
Ensure that the one-way clutch with the snap ring faces
toward the upside.
Align the cut-out section at the inside of the transmis-
sion case with the protruding section provided with the
groove (O mark) of the one-way clutch.
JAT00192-00168
(5) Measure and record the thickness of the hole snap

ring.
NOTE:
Replace any scratched or deformed hole snap ring with
a new part.
JAT00193-00169

AT72
(6) Install the hole snap ring to the grooved section of the
transmission case.
JAT00194-00170
12. Measurement of first & reverse brake end play

(1) Turn over the transmission case.
JAT00195-00171
(2) Measure the first & reverse brake end play, using a flat
thickness gauge.
NOTE:
The tightness which you encounter during this inser-
tion/withdrawal of the flat thickness gauge should be
virtually the same as the tightness which you would en-
counter during the thickness adjustment of the valve
rocker arm.
JAT00196-00172
If the measured end play fails to conform to the speci-

fied value above, select a snap ring from the right lower
table, using the following calculation formula. Then, in-
stall it.
JAT00197-00173
Calculation formula
A=B-C+D Snap ring thickness
Part No.
Unit: mm
A = Thickness of snap ring to be selected
(Refer to the right table.) Measured value of end 1.97 - 2.03 90045-21119-000
play
B = Measured value of end play 2.22 - 2.28 90045-21120-000
C = Specified value of end play
D = Thickness of snap ring that has been 2.48 - 2.53 90045-21121-000
already installed
2.72 - 2.78 90045-21123-000
JAT00198-00000

AT73
13. Installation of transmission brake band assembly-related SST(B)
parts
(1) Install the compression spring to the second brake
piston assembly.
(2) Install the 2nd brake piston assembly to the transmis-
sion case together with the compression spring.
(3) While compressing the 2nd brake piston with the fol-
lowing SSTs, install the hole snap ring, using snap ring SST(A)
pliers.
SSTs: 09202-87002-000 ... (A)
09202-87202-0A0 ... (B) JAT00199-00174
(4) Install a new brake band adjusting anchor bolt to the

transmission.
NOTE:
Be sure to tighten the anchor bolt, until the head sec-
tion of the anchor bolt appears at the inside of the
transmission case, as indicated in the right figure.
JAT00200-00175
(5) With the brake band assembly contracted, assemble

the band while aligning its recessed section with the
head of the brake band anchor bolt and with the head
of the 2nd coast brake piston rod.
NOTE:
Before assembling the brake band assembly, soak it in
the ATF for at least two hours.
JAT00201-00176
14. Assembly of forward clutch hub and 2nd brake drum

(1) Measure the bush bore diameter of the rear planetary
sun gear subassembly.
Allowable limit: 15.568 mm
NOTE:
The measurement should be performed at several
points. Determine the mean value.
If the bore diameter exceeds the allowable limit, re-
place the rear planetary sun gear subassembly. JAT00202-00177
When replacing the rear planetary sun gear subassem-

bly, be sure to check the bush contacting surface of the
intermediate shaft subassembly. If the contacting sur-
face is scored or discolored, replace the intermediate
shaft subassembly, too, with a new one at the same
time.

AT74
(2) Assemble the thrust needle roller bearing to the rear
planetary sun gear subassembly.
NOTE:
Make sure that the thrust needle roller bearing is as-
Gear side
sembled in the correct direction.
REFERENCE:
Dimensions of thrust needle roller bearing
Outer diameter: 35.7 mm
Thickness: 2.8 mm JAT00203-00178
(3) Assemble the rear planetary sun gear subassembly to

the planetary gear assembly.
NOTE:
Apply ATF to the bush section.
JAT00204-00179
(4) Measure the bush bore diameter of the planetary sun

gear subassembly.
NOTE:
The measurement should be performed at several
points. Determine the mean value.
If the bore diameter exceeds the allowable limit, re-
place the planetary sun gear subassembly.
When replacing the planetary sun gear subassembly, JAT00205-00180
be sure to check the bush contacting surface of the

rear planetary sun gear subassembly. If the contacting
surface is scored or discolored, replace the rear plane-
tary sun gear subassembly with a new one, too, at the
same time.
(5) Assemble the planetary sun gear subassembly to the

planetary gear assembly.
NOTE:
Apply ATF to the bush section.
JAT00206-00181

AT75
(6) Assemble the thrust needle roller bearing to the 2nd
brake drum.
NOTE:
Drum side
REFERENCE:
Outer diameter: 46.5 mm
Inner diameter: 25 mm
Thickness: 5 mm JAT00207-00182
(7) Assemble the forward clutch hub to the 2nd brake

drum.
(8) Assemble the 2nd brake drum to the transmission
case.
JAT00208-00183
15. Assembly of intermediate shaft subassembly

(1) Assemble the thrust needle roller bearing and thrust
of intermediate shaft
bearing race to the intermediate shaft subassembly.
Clutch hub side

NOTE:
REFERENCE:
Inner diameter: 16.5 mm JAT00209-00184
Thickness: 4.1 mm
(2) Assemble the intermediate shaft subassembly.

NOTE:
Be sure to apply ATF to the intermediate shaft sub-
assembly before assembling.
JAT00210-00185
16. Assemble the thrust needle roller bearing to the intermedi-

NOTE:
Intermediate
shaft side
REFERENCE:
Dimensions of thrust needle roller bearing:
Thickness: 4.1 mm JAT00211-00186

AT76
17. Align the pawls of the clutch disc of the forward clutch
with each other.
18. While aligning the pawls of the clutch disc of the forward
clutch with the groove of the forward clutch hub and with
the groove of the intermediate shaft subassembly, assem-
ble these parts.
JAT00212-00187
19. Measure the height of the forward clutch between the in-
stallation section of the oil pump and the thrust bearing
race of the forward clutch, using the following SST.
SST: 09351-87208-000
Specified Value: Approx. 54 mm
NOTE:
If the actually measured value is less than the specified
value, there is the possibility that the pawl section of
the forward clutch disc is not fitted in the groove of the
forward clutch hub. Be sure to perform the operation of JAT00213-00188
the step 15-(2) again and recheck the specified dimen-

sion.
20. Turn the forward clutch clockwise and counterclockwise.
At this time, ensure that the forward clutch turns lightly
and the 2nd brake drum makes a relative movement with
the forward clutch.
JAT00214-00189
21. Installation of direct clutch

(1) Measure and record the thickness of the thrust bearing
race. (A)
(2) Install the thrust bearing race (A).
JAT00215-00190
(3) Install the direct clutch.

(4) Install the direct clutch to the 2nd brake drum while
turning the direct clutch clockwise and counterclock-
wise.
JAT00216-00191

AT77
(5) Confirm the height of the oil pump attaching surface
from the upper surface of the direct clutch, using the
following SST.
SST: 09351-87208-000
Specified Height: Approx. 22 mm
NOTE:
If the actually measured value is less than the specified
height, there is the possibility that the two pawls of the
clutch disc are not fitted into the groove of the forward
clutch. Be sure to perform the operation of the step (4) JAT00217-00192
above again.
22. Inspection of stator shaft & oil pump assembly

(1) Inspection of oil pump operation
Ensure that the oil pump drive gear rotates smoothly,
SST: 09351-87206-000
NOTE:
Be sure to insert the flat sections (2 points) of the SST
into the flat sections of the oil pump drive gear. JAT00218-00193
(2) Measure the inner diameter of the oil pump bush sec-
tion, using an inner caliper gauge.
Unit: mm
Specified value Allowable limit
Front side 15.50 - 15.522 15.572
Rear side 21.100 - 21.121 21.171
JAT00219-00194
NOTE:
Perform the measurement at several points. Calculate
the mean value.
If the actually measured value exceeds the allowable
limit, replace the stator shaft & oil pump assembly with
a new one.
When replacing the stator shaft & oil pump assembly,
be sure to check the bush contacting surface of the
input shaft subassembly. If the contacting surface is
scratched or discolored, replace the input shaft sub-
assembly with a new one, too, at the same time. JAT00220-00195
23. Check of input shaft end play

(1) Apply a small amount of vaseline to the protruding
sections (2 points) of the clutch drum thrust washer.
JAT00221-00196

AT78
(2) Install the clutch drum thrust washer by aligning its
protruding section with the recessed section of the oil
pump assembly.
NOTE:
Be sure to apply vaseline in a small amount enough to
prevent the clutch drum thrust washer from dropping.
JAT00222-00197
(3) Apply a small amount of vaseline to the race side of

the thrust needle roller bearing.
NOTE:
Be sure to apply vaseline in a small amount enough to
prevent the thrust needle roller bearing from dropping.
JAT00223-00198
(4) Install the thrust needle roller bearing to the oil pump
assembly.
NOTE:
Ensure that the section (A) of the thrust needle roller
bearing race faces toward the oil pump assembly side.
Reference Value:
Thrust needle roller bearing dimensions
Inner Diameter: 22. 7 mm
Thickness: 2.8 mm
JAT00224-00199
(5) Install the following SST to the transmission case.

SST: 09351-87207-000
SST
JAT00225-00200
(6) Align the attaching holes (sections (A)) of the stator

shaft & oil pump assembly with the SST that has been
installed at the step (5).
JAT00226-00201

AT79
(7) Apply the ATF to the outer periphery of the stator shaft
& oil pump assembly.
(8) Install the stator shaft & oil pump assembly to the
transmission case.
NOTE:
Be very careful not to damage or twist the O-ring dur-
ing the installation of the stator shaft & oil pump as-
sembly.
JAT00227-00202
(9) Tighten the seven bolts of the stator shaft & oil pump
assembly.
NOTE:
Be sure to tighten the bolts alternately and diagonally.
JAT00228-00203
(10) Measure the input shaft end play with a dial gauge
and the following SST.
SST: 09351-87210-000
NOTE:
If the measured end play exceeds the specified value,
remove the stator shaft & oil pump assembly and the
direct clutch from the transmission case. Then, select
the thickness of the thrust bearing race from the right
lower table. Proceed to perform the operations of the JAT00229-00204
steps from 21-(2) to 23-(10). Thrust Bearing Race Availability

Thrust bearing race
Part No.
thickness Unit: mm
1.55 - 1.65 35789-87208-000
1.95 - 2.05 35789-87209-000
2.35 - 2.45 35789-87210-000

JAT00230-00000

AT80
24. Assembly of stator shaft & oil pump assembly
(1) Coat a new O-ring of the stator shaft & oil pump as-
sembly with the ATF.
(2) Install the two new clutch drum oil seal rings to the sta-
tor shaft & oil pump assembly.
NOTE:
Do not spread the new oil seal rings excessively.
(3) Coat a new O-ring of the stator shaft & oil pump as-
sembly with the ATF.
(4) Install the new O-ring to the stator shaft & oil pump as- JAT00231-00205
sembly.
(5) Assemble the stator shaft & oil pump assembly, follow-
ing the procedure given in the steps 23-(1) through 23-
(9).
(6) Install a new T-type oil seal, using the following SST.
SST: 09310-87301-000 SST
NOTE:
Make sure that the T-type oil seal is in contact at right
angles with the stator shaft & oil pump assembly when
installing the oil seal.
JAT00232-00206
25. Install the roller, compression spring and bolt to the trans-
mission case in this order.
JAT00233-00207
26. Assemble the manual valve lever subassembly to the

parking lock rod subassembly in advance.
NOTE:
Apply ATF to the arrow-headed section indicated in the
right figure.
JAT00234-00208

AT81
27. Install the parking lock rod subassembly and parking lock
pawl cam support, as indicated in the right figure. Tighten
(C)
the three bolts.
Tightening Torque: 14.7 - 17.7 Nm (1.5 - 1.8 kgf-m) (B)
NOTE:
Tightening should be made in the following sequence:
(A) (Tighten temporarily.) / (B) (Tighten securely.) / (A)
(C) (Tighten securely.) / (A) (Tighten securely.)
JAT00235-00209
28. Installation of manual valve lever shaft assembly

(1) Install the manual lever shaft subassembly.
NOTE:
Care must be exercised so that the lip of the oil seal
may not be scratched when installing the shaft.
(2) Install a new slotted spring pin, using a pin punch and
a hammer.
NOTE:
Be sure to positively install the new slotted spring pin,
until it becomes flush with the edge surface of the man- JAT00236-00210
ual valve lever.
29. Install the solenoid wire assembly to the transmission

case.
NOTE:
Apply ATF to the outer periphery of the O-ring of the
solenoid wire assembly. Care must be exercised so
that the O-ring may not be caught in when inserting it.
JAT00237-00211
30. Adjustment of brake band

(1) Set the brake band parallel to the 2nd brake drum.
JAT00238-00212
(2) Tighten the brake band adjusting anchor bolt, until the
E-ring (A) of the 2nd coast brake piston slightly floats.
(3) At the time when the E-ring of the 2nd coast brake pis-
ton floats, stop tightening the brake band adjusting an-
chor bolt.
JAT00239-00213

AT82
(4) Under the condition of the step (3) above, loosen the
brake band anchor bolt 3.2 turns counterclockwise (di-
rection (A)).
JAT00240-00214
(5) Install the nut to the brake band anchor bolt.

(6) While holding the brake band anchor bolt by means of
a screwdriver or the like, tighten the nut.
JAT00241-00215
31. Install the roller for the manual valve lever shaft subassem-
bly as illustrated in the right figure.
NOTE:
Make sure that the roller edge surface is lower than the
transmission case edge surface.
JAT00242-00216
32. Assembly of C2 accumulator piston

(1) Measure the free length and outer diameter of the C2
accumulator compression spring.
Reference Value:
Free Length: 85.8 mm
JAT00243-00217
(2) Apply ATF to a new C2 accumulator seal No. 1 ring.

Then, assemble the ring to the accumulator No. 2 pis-
ton.
NOTE:
Do not expand the oil seal ring beyond the minimum
extent needed for assembly.
Be sure to align the opening ends with each other after
assembling.
Seal ring
JAT00244-00218

AT83
(3) Assemble the compression spring and accumulator
No. 2 piston to the transmission case.
JAT00245-00219
33. Assembly of B1 accumulator piston

(1) Measure the free length and outer diameter of the B1
accumulator compression spring.
Reference Value:
Free Length: 50.5 mm
Outer Diameter: 20 mm
JAT00246-00220
(2) Coat the A section of the new accumulator seal No. 1

and No. 2 ring with ATF.
(3) Install the accumulator seal No. 1 and No. 2 ring to the
accumulator No. 1 piston.
NOTE:
Do not spread the seal ring end excessively.
JAT00247-00221
(4) Install the accumulator No. 1 piston to the transmission

case.
(5) Install the compression spring.
JAT00248-00222
34. Assembly of valve body

(1) Ensure that the manual valve operates smoothly with-
out any binding.
(2) Set the manual valve to the neutral position, using the
following SST.
SST: 09351-87211-000
JAT00249-00223

AT84
(3) Install the valve body assembly with the aforesaid SST
to the transmission case.
NOTE:
Ensure that the protrusion of the manual valve lever (A)
and grooved section of the manual valve (B) are
matched securely.
(B)
(A)
JAT00250-00224
(4) Tighten the bolts of the valve body assembly. $0 $0

@0
NOTE: $0
@0
The numeral in the right illustration indicates the nomi- @0
If the bolt is tightened with any oil getting to the bolts
threaded portion, it may cause the bolt looseness.
Therefore, be sure to clean the bolt threaded portion by @0
@0
applying compressed air.
Care must be exercised so that the wire may not be JAT00251-00225
caught in between the transmission case and the valve

body assembly.
(5) Connect the connector of the solenoid wire assembly.
JAT00252-00226
35. Tighten the (A) bolt firstly with the aforesaid SST. Then,
proceed to tighten the (B) bolt of the manual detent
spring. (B) (A)
NOTE:
The numeral in the right figure indicates the nominal
length of the bolt.
(A) = 12 mm (B) = 40 mm
Be sure to tighten the bolts alternately.
JAT00253-00227
36. Assembly of oil strainer

(1) Coat a new O-ring (A) with ATF.
(2) Install the new O-ring to the groove section of the valve
body.
O-ring
JAT00254-00228

AT85
(3) Apply ATF to the O-ring contact section of the oil 48.5 48.5 (A)
strainer.
(4) Install the valve body tube (A).
(5) Install the oil strainer with the 3 bolts.
NOTE:
The numeral in the right illustration indicates the nomi-
nal length of the bolt. 48.5
JAT00255-00229
37. Assembly of throttle cable

(1) Coat a new O-ring with the ATF.
(2) Install the new O-ring to the throttle cable.
(3) Insert the throttle cable to the transmission case.
(4) Tighten the throttle cable with a bolt.
(5) Connect the throttle cable to the throttle valve cam.
JAT00256-00230
38. Assembly of oil pan

(1) Place the transmission magnet in the protrusion (A) of
the transmission oil pan assembly.
(A)
Transmission magnet
JAT00257-00231
(2) Apply the Three Bond 1281B to the entire periphery of

the oil pan without any discontinuation, as indicated in
the right figure.
NOTE:
Be very careful not to get oil to the application surface.
3.8 mm
JAT00258-00232
(3) Install the new transmission oil pan assembly with the
14 bolts.
NOTE:
When installing the transmission oil pan, be very care-
ful not to allow the oil pan to come in contact with any
inside part.
JAT00259-00233

AT86
39. Clean the contact surface between the transmission case
side cover subassembly and the transfer assembly, using 1 mm
solvent or the like.
40 Apply the following bond to the transmission case side
cover subassembly surface as shown in the right figure.
Specified Bond: Three bond 1216 or 1217
NOTE:
Be sure to apply the bond to the entire periphery with-
out any discontinuation.
JAT00260-00234
41. Install the needle roller bearing to the forward end of the
output shaft assembly.
JAT00261-00235
42. Install the transfer assembly. Tighten the seven bolts. 35

35
NOTE:
The numerals in the right figure denote the nominal 35 35
170
35
170
JAT00262-00236
43. Tighten nine new inspection plugs to the transmission

case.
JAT00263-00237
44. Adjustment of neutral start switch

(1) Temporarily tighten the bolt of the neutral start switch
assembly.
JAT00264-00238

AT87
(2) Place the transmission control shaft lever subassem-
bly.
(3) Push the transmission control shaft lever subassembly
toward the front side (ie: range)
(4) Back off the lever two notches to the NEUTRAL posi-
tion
(5) Remove the transmission control shaft lever sub-
assembly. P
D N R
JAT00265-00239
(6) Install the following SST

SST: 09302-87201-000 SST
(7) Adjust the neutral start switch assembly until the neu-
tral basic line should be aligned with the SST above.
(8) Tighten the bolt.
Scribed line
JAT00266-00240
45. Tighten the transmission control shaft lever subassembly

with a nut.
JAT00267-00241
46. Install the control cable bracket. Tighten the two bolts.
47. Secure the connectors of the neutral start switch assembly

(B) and solenoid wire assembly (A), respectively, to the
control cable bracket. (B)
(A)
JAT00268-00242
48. Installation of governor valve.

(1) Place the ball into the transmission case side cover.
JAT00269-00243

AT88
(2) Coat the whole of governor body assembly with ATF.
(3) Install the governor body assembly into the transmis-
JAT00270-00244
(4) Coat a new O-ring with ATF.

(5) Install the new O-ring to the governor cover.
(6) Install the governor cover to the transmission case
side cover.
NOTE:
Be very careful not to damage the new O-ring during
installation.
JAT00271-00245
(7) Install the hole snap ring, using standard pliers.

NOTE:
Make sure that the hole of the snap ring comes in the
slant line section indicated in the right figure when as-
sembling.
2 mm-dia. hole
JAT00272-00246
49. Assemble the union bolts (B) with a new gasket inter-
posed. (B) (B)
Tightening Torque: 29.4 - 39.2 Nm (3.0 - 4.0 kgf-m) (A)
(B)
50. Tighten the breather plug (A).
Tightening Torque: 6.9 - 9.8 Nm (0.7 - 1.0 kgf-m) (C)
51. Assemble the clamp (C) for the throttle cable. Tighten the
bolt to the specified torque.
Tightening Torque: 6.9 - 9.8 Nm (0.7 - 1.0 kgf m)
JAT00273-00247

AT89
52. Coat a new O-ring with the ATF.
53. Install the new O-ring to the transmission oil filler tube sub-
assembly.
NOTE:
Be very careful not to twist or damage the O-ring dur-
ing the installation of the transmission oil filler tube sub-
assembly.
54. Insert the transmission oil filler tube subassembly to the

transmission case.
55. Tighten the transmission oil filler tube subassembly with JAT00274-00248
the bolt.
56. Install the power train stiffener. Tighten the bolts in the fol-
lowing sequence.
(1) Temporarily tighten the bolt (A) and bolt (D).
(2) Securely tighten the bolt (B).
(D)
(3) Tighten the bolts in the sequence of the bolt (A), bolt
(D) and bolt (C).
Tightening Torque: 29.4 - 44.1 Nm (3.0 - 4.5 kgf-m) (A)
(C)
(B)
JAT00275-00249

AT90
INSTALLATION AND REMOVAL OF CONTROL CABLE AND FLOOR
SHIFT
COMPONENTS
: Tightening torque
Unit : Nm (kgf-m)
w
q
B
14.7 - 21.6
(1.5 - 2.2)
S
B B 14.7 - 21.6
e
(1.5 - 2.2)
B
9.8 - 15.7
(1.0 - 1.6)
B
6.9 - 9.8
(0.7 - 1.0)
q Console rear box assembly

w Console panel with shifting hole vessel
e Control cable assembly
JAT00276-00250

NOTE:
Be very careful not to rock the control cable end (both
shift lever side and transmission side) beyond 8 de-
grees. Also, never apply any load to it. 8
8
JAT00277-00251
(1) Remove the control cable assembly.

1) First, confirm that a white mark for identifying the Vehicle upper side mark
upper side and lower side is put on the upper side
of the cable end. Then, remove the control cable
assembly at the transmission side. If the mark is
erased, put a mark.
JAT00278-00252

AT91
2. Check
(1) Check that the inner cable of the control cable assem-
bly slides smoothly. Also, check that the control cable
assembly exhibits no damage and deformation, such
as rapture of the boot.
Rapture of boot
JAT00279-00253

(1) Install the control cable assembly.
1) Move the shift lever and transmission control shaft
lever to the range.
L P
2 D N R
JAT00280-00254
2) Connect the control cable (at the shift lever side) to

the floor shift assembly so that the flange section of
the collar may come at the lever side. Then, secure
the control cable with the clip. Flange
section
JAT00281-00255
3) Install the control cable end at the transmission

side to the transmission control shaft lever assem- Vehicle upper side mark
bly, while making sure that the white mark for iden-
tifying the upper side and lower side comes at the
upper side.
JAT00282-00256

AT92
APPENDIX
09302-87201-000 Neutral start switch adjusting gauge
Automatic transmission pressure gauge

09325-87201-000 No. 1 adapter
09202-87002-000 Valve cutter remover & replacer
09301-87702-000 Clutch guide tool
09308-10010-000 Oil seal puller
09309-87203-000 4M/T friction dumper No. 2 replacer
09309-87502-000 4M/T friction dumper No. 2 replacer
09310-87301-000 Countershaft front bearing replacer
09527-87301-000 Rear axle shaft bearing remover
09820-00021-000 Alternator rear bearing puller
09306-87302-000 Counter gear front bearing puller

AT93
09350-87202-000 Automatic transmission tool set
09351-87201-000 Piston spring No. 1 compressor
09351-87203-000 Dial gauge attachment
09351-87206-000 Oil pump driver
09351-87207-000 Oil pump guide
09351-87208-000 Direct & forward clutch measure
09351-87210-000 Dial gauge stand base
09351-87211-000 Manual valve setting tool
09350-87704-000 Automatic tool set
09351-87707-000 Piston spring No. 1 compressor
09351-87709-000 Brake piston rod
09351-87710-000 Brake piston plate
JAT00283-00257

AT94
Unit: mm
Items Specified value Allowable limit
Free play of input shaft 0.28 - 0.92
Bush bore diameter of direct clutch drum subassembly 44.000 - 44.025 44.075
Stroke of direct clutch piston 1.22 - 1.53
End play of direct clutch 0.77 - 1.08
End play of 1st & reverse brake 1.04 - 1.41
Bush bore diameter of planetary sun gear subassembly 22.020 - 22.038 22.088
Bush bore diameter of rear planetary sun gear subassembly 15.500 - 15.518 15.568
Bush bore diameter of planetary output shaft subassembly 12.000 - 12.018 12.068
Bush bore diameter of stator shaft Front side 15.500 - 15.522 15.572
& oil pump assembly Rear side 21.100 - 21.121 21.171
Dimensions of compression spring Free length 85.8
for accumulator C2 piston Outer diameter 18.3
Dimensions of compression spring Free length 50.5
for accumulator B1 piston Outer diameter 20.0
The number in brackets < > denotes the reference value.

JAT00284-00000

AT95
TIGHTENING TORQUE
Tightening torque
Tightening components
Nm kgf-m
Drive plate Crankshaft 78.45 - 98.07 8.0 - 10.0
Transmission Engine direct-connecting bolt 49.04 - 68.64 5.0 - 7.0
Torque convertor Drive plate 29.4 - 44.1 3.0 - 4.5
M8 14.7 - 21.6 1.5 - 2.2
Power train stiffener Engine, Transmission
M10 29.4 - 44.1 3.0 - 4.5
Starter shaft & oil pump Transmission case 6.9 - 9.8 0.7 - 1.0
Nut (for brake band anchor bolt) Transmission case 22.5 - 30.4 2.3 - 3.1
Roller, bolt for securing spring Transmission case 6.9 - 9.8 0.7 - 1.0
Parking lock pawl cam support Transmission case 14.7 - 17.7 1.5 - 1.8
Valve body Transmission case 6.9 - 9.8 0.7 - 1.0
Manual detent spring Transmission case 6.9 - 9.8 0.7 - 1.0
Transmission oil pan Transmission case 6.9 - 9.8 0.7 - 1.0
Inspection plugs Transmission case 6.9 - 9.8 0.7 - 1.0
Breather plug Transmission case 6.9 - 9.8 0.7 - 1.0
Throttle cable Transmission case 6.9 - 9.8 0.7 - 1.0
Clamp for throttle cable Transmission case 6.9 - 9.8 0.7 - 1.0
Oil strainer Transmission case 6.9 - 9.8 0.7 - 1.0
Unions (for oil cooler) Transmission case 29.4 - 39.2 3.0 - 4.0
Neutral start switch Transmission case 14.7 - 21.6 1.5 - 2.2
Transmission control shaft lever Manual shaft lever 9.8 - 15.7 1.0 - 1.6
Control cable bracket Transmission case side cover 14.7 - 21.6 1.5 - 2.2
Transmission oil filter tube Transmission case 6.9 - 9.8 0.7 - 1.0
Transmission case Transmission case side cover 14.7 - 21.6 1.5 - 2.2
Breather plug Transmission case side cover 6.9 - 9.8 0.7 - 1.0
Solenoid wire assembly Transmission case 6.9 - 9.8 0.7 - 1.0
Transmission Transfer 29.4 - 44.1 3.0 - 4.5
Control cable Transmission control shaft lever 6.9 - 9.8 0.7 - 1.0
Drain plug Oil pan 19.6 - 29.4 2.0 - 3.0
Oil cooler Oil cooler bracket 6.9 - 9.8 0.7 - 1.0
Power train stiffener Transmission, Transfer 29.4 - 44.1 3.0 - 4.5
JAT00285-00000

DAIHATSU
J100
TRANSFER
DESCRIPTION ............................................. TR 2
CENTER DIFFERENTIAL SYSTEM ......... TR 2
OPERATION OF CENTER
DIFFERENTIAL LOCK SYSTEM ......... TR 2
IN-VEHICLE INSPECTION .......................... TR 4
COMPONENTS ........................................... TR 5
REMOVAL .................................................... TR 5 TR
DISASSEMBLY ............................................ TR 8
INSPECTION ............................................... TR10
ASSEMBLY .................................................. TR15
INSTALLATION ........................................... TR17
SSTs ............................................................ TR20
TIGHTENING TORQUE ............................... TR20
JTR00001-00000
NO. 9710-JE

TR2
DESCRIPTION
A driving system equipped with a center differential is em- Transmission Transfer
ployed.
Engine
Center differential
Rear differential
Front differential
JTR00002-00101
CENTER DIFFERENTIAL SYSTEM

The input power from the transmission of the driving system is
always distributed to the front and rear wheels. The transfer
system employs a negative pressure-driving actuator type,
with a center differential lock mechanism.
The negative pressure which has been taken from the intake
manifold is transmitted to a diaphragm type actuator provided
inside the transfer case.
JTR00003-00102
The negative pressure is controlled by two VSVs. For im-

proved response of the actuator, these VSVs have been in-
stalled in the engine compartment.
JTR00004-00103
OPERATION OF CENTER DIFFERENTIAL LOCK SYSTEM

Differential lock switch
VSV2 (green)
Check valve Indicator lamp
Chamber A
IG S/W
Chamber B
VSV1 (blue)
To intake Lock Free

manifold
Actuator for transfer
Differential case
Differential
clutch hub
JTR00005-00110

TR3
1. When center differential lock switch is turned off. To intake
(1) The VSV1 and VSV2 become unenergized. Thus, the manifold
VSV1 is connected to the air filter side. As a result, the VSV2 Check Differential
transfer actuator chamber B becomes equal to the at- (green) valve lock switch
mospheric pressure.
Chamber B
Free
Chamber A
VSV1
(blue)
JTR00006-00111
(2) On the other hand, the intake manifold negative pres- To intake
sure is transmitted to the check valve, VSV2, and then, manifold
transfer actuator chamber A. Consequently, the differ- VSV2 Check Differential
(green) valve lock switch
ential clutch hub assembly of the transfer moves back-
ward. In this way, the center differential is switched to
Chamber B
a free state.
Free
VSV1 Chamber A
(blue)
JTR00007-00112
2. When center differential lock switch is turned on. To intake

(1) A electric current flows into the VSV1 and VSV2. Thus, manifold
the intake manifold negative pressure is transmitted to VSV2 Check Differential
the check valve, VSV1, and then, transfer actuator (green) valve lock switch
chamber B.
Chamber B
Lock
VSV1 Chamber A
(blue)
JTR00008-00113
(2) On the other hand, the VSV2 is connected to the air fil- To intake
ter. As a result, the transfer actuator chamber A be- manifold
comes equal to the atmospheric pressure. VSV2 Check Differential
(green) valve lock switch
Consequently, the differential clutch hub assembly of
the transfer moves forward, thus engaging with the dif-
Chamber B
ferential case subassembly. In this way, the center dif-
ferential becomes in a locked state. Lock
VSV1 Chamber A
(blue)
JTR00009-00114

TR4
2. Check to see if the indicator will illuminate when the differ-
ential lock switch is turned on.
NOTE:
If not, check the indicator valve.
3. Turns off the differential lock switch.
JTR00010-00201
4. Disconnect the pipe A. Then, Connect a MityVac to the

pipe A.
6. Check to see if the MityVac indicates a negative pressure
while keeping the engine revolution speed at idling.
Pipe A
JTR00011-00202
7. Connect the MityVac to the diaphragm with a suitable

pipe.
8. Set the MityVac to 200 mmHg manually.
9. Hold the negative pressure of the MityVac at 200 mmHg
for about 10 seconds.
NOTE:
If the diaphragm exhibits damage, deterioration and so
forth, the negative pressure will rapidly return to posi-
tive pressure.
JTR00012-00203
10. Disconnect the pipe B.

11. Connect the MityVac to the pipe B. Pipe A
12. Start the engine. Turns on the differential lock switch.
13. Check to see if the MityVac indicates a negative pressure
while keeping the engine revolution speed at idling.
Pipe B
JTR00013-00204
14. Connect the MityVac to the diaphragm with a suitable

pipe.
15. Set the MityVac to 200 mmHg manually.
16. Hold the negative pressure of the MityVac at 200 mmHg
for about 10 seconds.
NOTE:
If the diaphragm exhibits damage, deterioration and so
forth, the negative pressure will rapidly return to posi-
tive pressure.
JTR00014-00205

TR5
COMPONENTS
Transfer oil Hanger T type oil seal Diaphragm cylinder cover
supply right pipe
Tube
Transfer No. 2 Transfer shift shaft
oil plate B
Transfer oil sub-assembly
supply left pipe E ring Slotted
B B
T type K type pin
oil seal Filler plug O ring
oil seal Front drive
shift link lever Slotted
Drain plug sub-assembly pin
E ring
Oil seal B Gasket Ball
Compression Transfer fork
Hale snap
B spring shaft
ring
Transfer rear case Transfer gear
Transfer oil plate shift head
Shaft snap
ring Transfer diff. rock
Transfer control shift fork
Transfer case
shaft washer Compression
Differential case spring Needle roller
Differential pinion
thrust washer sub-assembly Transfer bearing
T type oil seal Differential clutch hub
pinion Radial ball
Transfer output bearing
rear shaft
Transfer front drive Speedometer
Shaft snap drive gear
gear bearing
ring
inner race Lock nut
B Needle roller Bearing
bearing Differential Radial ball
side gear bearing
Differential
pinion shaft
Differential No. 2 case Transfer output
sub-assembly Differential Transfer front
side gear drive gear front shaft
Differential Transfer front Radial ball
: Non-reusable parts side gear thrust washer drive chain bearing
JTR00015-00301
REMOVAL
1. Remove the transmission & transfer assembly from the ve-
hicle. Refer to MT and AT section of the service manual.
2. Remove the transfer from the transmission by removing
the attaching bolts.
NOTE:
JTR00016-00401
3. Drive off the slotted pin of the transfer fork shaft.
JTR00017-00402

TR6
4. Remove the speedometer shaft sleeve by removing the
bolt.
JTR00018-00403
5. Remove the drain plug. Rib section

6. Remove the filler plug. Filler plug
7. Remove the transfer case by removing the attaching bolts.
NOTE:
While lightly tapping the transfer case at the rib sec-
tions, using a plastic hammer or the like, remove the
transfer case.
Rib Drain
section plug
JTR00019-00404
8. Remove the transfer output front shaft with the radial ball
bearings.
JTR00020-00405
9. Detach the snap ring of the speedometer drive gear.

10. Remove the speedometer drive gear.
JTR00021-00406
11. Remove the lock nut of the radial ball bearing in the trans-
fer output rear shaft.
NOTE:
Release the staking of the lock nut, using a suitable
chisel and a hammer.
Prior to loosen the nut, grab the shaft by the vise with
the soft metal for not rotating.
(Be careful not to damage the shaft.)
Never reuse the removed nut.
JTR00022-00407

TR7
12. Remove the radial ball bearing in combination with the
gear, using the following SST.
SST: 09306-87602-000
JTR00023-00408
13. Remove the transfer output rear shaft with differential gear.
JTR00024-00409
14. Remove the ring retainer of the bearing.

15. Remove the radial ball bearing with the transfer clutch
inner hub from the transfer case.
JTR00025-00410
16. Drive off the slotted pin of the transfer gear shift head.
17. Remove the E ring.
E ring
JTR00026-00411
18. Remove the following parts.

(1) Transfer fork shaft
(2) Compression spring
(3) Transfer control shaft washer
(4) Shaft snap ring
(5) O ring
(6) Transfer differential lock shift fork
(7) Transfer clutch outer hub
(8) Transfer gear shift head
JTR00027-00412

TR8
19. Remove front drive shift link lever sub-assembly and E
ring.
JTR00028-00413
20. Remove the diaphragm cylinder cover.
JTR00029-00414
21. Remove the transfer shift shaft sub-assembly from the di-
aphragm cylinder.
JTR00030-00415
DISASSEMBLY
SST SST
1. Disassemble the transfer clutch inner hub and the radial
ball bearing, using the following SST in conjunction with a
press.
SST: 09310-87102-000
09253-87202-000
SST SST
Ring retainer Bearing

JTR00031-00501
2. Disassemble the following parts.

(1) Transfer front drive gear
(2) Needle roller bearing
(3) Transfer front drive gear bearing inner race
JTR00032-00502

TR9
3. Disassemble the rear bearing from the transfer output front
drive shaft, using the following SST in conjunction with a
press.
SST: 09253-87101-000
09301-87601-000
JTR00033-00503
4. Disassemble the front bearing from the transfer output

front drive shaft, using the following SST in conjunction
with a press.
SST: 09253-87101-000
JTR00034-00504
5. Remove the transfer output rear shaft and needle roller

bearing from the differential case sub-assembly, using the
following SST, in conjunction with a press.
SST: 09238-87202-000
JTR00035-00505
6. Push the differential pinion shafts by pushing it with your

fingers.
JTR00036-00506
7. Remove the differential case No. 2 case sub-assembly.
JTR00037-00507

TR10
8. Remove the following parts from the differential case.
(1) Differential side gear No. 2
(2) Differential side gear
JTR00038-00508
(3) Differential pinion shafts

(4) Differential pinions
(5) Differential pinion thrust washers
JTR00039-00509
INSPECTION
1. Bearings
Visually inspect the roller and roller guide surface for
seizure due to poor oil lubrication and so forth.
JTR00040-00601
2. Needle roller bearings

Check the roller outer periphery of the needle roller bear-
ing for damage by scratching it by your fingernails. Also,
visually inspect the roller outer periphery for seizure due to
poor oil lubrication or use of deteriorated oil.
JTR00041-00602
3. Check the fitting section (A) and spline section (B) of the
transfer output rear shaft and the spline section (C) of the
transfer output front shaft for damage or abnormal wear.
B
C
JTR00042-00603

TR11
4. Visually inspect the transfer front drive gear and the trans-
fer output front shaft gear for damage or wear.
JTR00043-00604
5. Visually inspect the transfer front drive chain for damage

or wear.
JTR00044-00605
6. Check the contact surface between the differential lock

shift fork (A) and the transfer clutch outer hub (B).
Unit: mm
Specified value Allowable limit (A)
0.1
(A) 7 0.2 6.7
+0.06
(B) 7.2 +0 7.3
(B)
JTR00045-00606
7. Measure the outer diameter of the shaft and socket sec- A

tion.
If the measured valve does not conform to the specifica-
tion, replace the parts. B
Also inspect the snap ring for damage or wear.
Unit: mm
0
(A) 12 0.1 11.8
(B) 12 0
0.1 11.8
Outer diameter of the shaft 14 0.13
0.063 JTR00046-00607
8. Visually inspect the transfer shift shaft for damage or wear.

NOTE:
Also inspect the diaphragm for damage.
JTR00047-00608

TR12
9. Visually inspect the transfer gear shift head for damage or
wear
NOTE:
Also inspect the ball and compression spring for dam-
age or wear.
JTR00048-00609
10. Measure the outer diameter of the transfer fork shaft.

If the measured value does not conform to the specifica-
tion, replace the shaft.
Also inspect the compression spring and the transfer con-
trol shaft washer for damage or wear.
Unit: mm
+0
Specified value 12 0.043
JTR00049-00610
11. Measure the outer and inner diameter of the transfer front
drive gear bearing inner race. Unit: mm
Inner +0.02
26 +0.002 26.020
diameter
Outer 0
diameter 38 0.014 38.986
JTR00050-00611
12. Visually inspect the differential pinion for damage or wear.

13. Visually inspect the differential side gear for damage or
wear.
JTR00051-00613
14. Measure the thickness of the differential pinion thrust

washer.
Unit: mm
Specified value 0.8 0.06
Allowable limit 0.74
JTR00052-00614

TR13
15. Visually inspect the differential case sub-assembly for
damage or wear.
JTR00053-00615
16. Measure the outer diameter of the differential pinion shaft.

17. Measure the inner diameter of the differential pinion.
Unit: mm
Inner +0.06
Pinion 15 +0.03 15.06
diameter
Pinion Outer 0.016
15 0.043 14.943
Shaft diameter
JTR00054-00617
18. Measure the inner diameter of the transfer front and rear
output shaft bearing.
NOTE:
If the measured value does not conform to the specifi-
cation, replace the transfer case.
Unit: mm
Inner diameter specified value
.0
Output front shaft Front 25 0.010
bearing Rear .0
17 0.008
.0
Output rear shaft Front 50 0.012 JTR00055-00618
bearing Rear 25
.0
0.010
19. Visually inspect the type T oil seal in the diaphragm cylin-
der for damage or wear.
NOTE:
Replace the oil seal if it exhibits damage or wear.
JTR00056-00619
20. Visually inspect the type K oil seal of the front drive shift
link lever for damage or wear.
NOTE:
JTR00057-00620

TR14
21. Visually inspect the type T oil seal of the transfer output
rear shaft for damage or wear.
NOTE:
SST: 09308-10010-000
09309-87201-000
JTR00058-00621
22. Visually inspect the transfer rear drive output shaft inner oil
seal for damage or wear.
NOTE:
JTR00059-00622
23. Visually inspect the type T oil seal of the transfer output
front shaft for damage or wear.
NOTE:
SST: 09308-10010-000
09309-87201-000
JTR00060-00623

TR15
ASSEMBLY
NOTE:
Prior to the assembly, clean the transfer case and the
parts by removing any dirt or the like. And then, apply
gear oil to the all parts.
1. Press the radial ball bearing (Front) to the transfer output

front shaft.
JTR00061-00701
2. Press the radial ball bearing (Rear) to the transfer output

front shaft, using the following SST.
SST: 09238-87202-000 SST
JTR00062-00702
3. Press the radial ball bearing to the transfer inner hub,

SST: 09388-20010-000 SST
NOTE:
Make sure that the groove section of the redial ball
bearing comes upper side.
Groove
section
JTR00063-00703
4. Install the differential side gear to the differential case.

Machine
5. Install the differential pinion shafts, the differential pinions ground side
and the differential pinion thrust washers to the differential
case No. 2.
NOTE:
Make sure that the machine-ground side of the differ-
ential pinion shaft section faces toward differential side
gear.
Differential
Differential case
case No. 2
JTR00064-00705
6. Align the pinion shafts and shaft holes. Then, Insert the
differential case sub-assembly to the differential case
No. 2.
JTR00065-00706

TR16
7. Push the pinion shaft in the shaft hole with finger to the dif-
ferential case outside so as to the transfer output rear
shaft can go through.
Shaft hole
JTR00066-00707
8. Install the new snap ring to the transfer output rear shaft.
Snap ring
JTR00067-00708
9. Install the needle roller bearing to the transfer output rear

shaft with applying the gear oil for not to fall off.
Oil: API GL-3, SAE75W-85
JTR00068-00709
10. Insert the transfer output front shaft with the needle roller
bearing to the differential case assembly, using a press.
NOTE:
Make sure that the transfer output rear shaft rotates
smoothly when inserting has been done.
JTR00069-00710

TR17
INSTALLATION
1. Install the transfer shift shaft sub-assembly to the di- Groove
aphragm cylinder. section
2. Install the front drive shift link lever to the transfer case.
NOTE:
Make sure that the drive shift link lever is fitted securely
in the groove.
Shaft
JTR00070-00802
3. Install the diaphragm cylinder cover to the diaphragm

cylinder and tighten the bolts.
JTR00071-00803
4. Install the radial ball bearing with the transfer clutch inner
hub to the transfer case.
5 Install the snap ring to the radial ball bearing.
NOTE:
Make sure that the snap ring is fitted securely in the
groove.
JTR00072-00805
6. Insert the transfer output rear shaft and center differential

assembly to the transfer clutch inner hub.
7. Install the transfer clutch outer hub to the transfer clutch
inner hub.
8. Install the differential lock shift fork to the transfer clutch
outer hub.
9. Insert the transfer fork shaft with the compression spring
and transfer control shaft washer to the differential lock
shift fork.
10. Insert the transfer fork shaft with the transfer differential
lock shift fork. to the transfer case. JTR00073-00810
11. Install the compression spring and ball to the transfer gear
shift head.
12. With the ball pushed down by means of a suitable rod
from the hole section of the head, insert the transfer gear
shift head to the transfer fork shaft.
13. Drive new slotted pin to the transfer gear shift head.
Install the new E ring.
Slotted pin
E ring
JTR00074-00813

TR18
14. Insert the transfer front drive gear to the transfer output
rear shaft.
15. Install the transfer output front shaft with the chain to the
transfer case.
NOTE:
Prior to the installation, make sure that the chain is set
to the both gears.
(After the installation, the chain will not be able to set.)
JTR00075-00815
16. Install the radial ball bearing to the transfer output rear
shaft.
17. Install new lock nut to the transfer output rear shaft and
tighten the lock nut.
Tightening Torque:
225.6 - 264.8 Nm (23.0 - 27.0 kgf-m)
NOTE:
When staking the lock nut, point a suitable staking tool
toward the transfer output rear shaft axis center and
stake to lock nut securely. JTR00076-00817
Prior to install new lock nut, grab the shaft by the vise
with the soft metal for not rotating.
18. Insert the speedometer drive gear to the transfer output

rear shaft.
19. Install new snap ring of the speedometer drive gear.
NOTE:
Make sure that the snap ring is fitted securely in the
groove.
JTR00077-00819
20. Install new O ring to the transfer fork shaft.

NOTE:
Prior to the installation of a new O ring, wind a suit-
able vinyl sheet around the transfer fork shaft and
apply gear oil to the O ring installing section.
JTR00078-00820
21. Apply the liquid gasket interposed, assemble the transfer (A)
case and transfer case No. 2 by tapping it evenly and
lightly at the rib sections (A), (B) and (C) by means of a
22. Tighten the transfer case with the bolts.
NOTE:
Be sure to tighten the bolts evenly and diagonally. (B)
Prior to the tightening of the bolts, apply Three Bond (C)
1216 to the threaded portions of the bolts. JTR00079-00822

TR19
23. Apply gear oil to the O ring prior to the insertion of the
speedometer shaft sleeve.
24. Insert the speedometer shaft sleeve into the output shaft
bearing rear retainer.
25. Tighten the speedometer sleeve lock plate with a bolt.
26. Tighten the transfer drain plug with new gasket.

JTR00080-00825
27. Install the transfer assembly to the transmission. (Refer to

the MT or AT section of the service manual.)
28. Fill the transfer with oil.
29. Tighten the transfer filler plugs with new gasket.
JTR00081-00828

TR20
SSTs
Shape Part No. and name Purpose See page
09253-87101-000
Transfer output Removal of bearing TR9
front shaft bearing anvil
09238-87202-000 Removal of output rear

Transfer output shaft TR9
front shaft rear bearing replacer Assembling bearing TR15
09253-87202-000
Transfer clutch Removal of bearing TR8
inner hub bearing anvil
09301-87601-000
Removal of bearing TR9
Tool, clutch guide
09306-87602-000
Transfer output Removal of bearing TR7
rear shaft bearing replacer
09308-10010-000
Removal of oil seal TR14
Oil seal puller
09309-87201-000
Transfer output Assembling oil seal TR14
shaft oil seal replacer
09310-87102-000
inner hub bearing puller
09388-20010-000
inner hub bearing replacer
JTR00082-00901
TIGHTENING TORQUE
Tightening torque
Tightening components Reference
Nm kgf-m
Diaphragm cylinder cover Diaphragm cover 14.7 - 21.6 1.5 - 2.2
Radial ball bearing Transfer output rear shaft 225.6 - 264.8 23.0 - 27.0
Transfer case Transfer case No. 2 14.7 - 21.6 1.5 - 2.2
Speedometer sleeve Transfer case 5.9 - 8.8 0.6 - 0.9
Transfer filler plug Transfer case 29.4 - 49.0 3.0 - 5.0
Transfer drain plug Transfer case 29.4 - 49.0 3.0 - 5.0
JTR00083-00902

DAIHATSU
J100
PROPELLER SHAFT
COMPONENTS ........................................... PR 2
IN-VEHICLE INSPECTION .......................... PR 3
REMOVAL ................................................... PR 3
INSPECTION ............................................... PR 4
INSTALLATION ........................................... PR 5
TIGHTENING TORQUE ............................... PR 7
JPR00001-00000
PR
NO. 9710-JE

PR2
COMPONENTS
Front W
B
60.3 9.5 (6.15 0.95)
Rear
W
B
q
60.3 9.5 (6.15 0.95)
36.8 7.3 (3.75 0.75)
q Propeller shaft assembly

: Tightening torque
Unit : Nm (kgf-m)
JPR00002-00001

PR3
Ensure that the universal joint section of the propeller shaft ex-
hibits no excessive play by turning it by your hand in up-and-
down and right-and-left directions.
If any excessive play exists, replace the propeller shaft with a
new one.
JPR00003-00002
REMOVAL Front
1. Jack up the vehicle and support it with safety stands. (As
for the jacking-up points and supporting points for safety
Mating marks
stands, refer to the GI section in this service manual.)
2. Put mate marks on the flange yoke and companion flange,
respectively.
JPR00004-00003
Rear
Mating marks
JPR00000-00004
3. Remove the two attaching bolts of the center support

bearing and support the center bearing with a suitable
hanger or jack, etc., so that no bending force may be ap-
plied to the center support. (For rear propeller shaft)
CAUTION:
Never apply the bending force to the center bearing
and No. 2 joint of the rear propeller shaft.
JPR00005-00005
4. Loosen the attaching bolts of the flange yoke evenly.

5. Remove the propeller shaft assembly by removing the at-
taching bolts and disconnect it from the transfer case.
NOTE:
Prior to disconnection of the propeller shaft from the
transfer case, drain the transfer oil from the transfer
case or prepare a suitable oil stopper and install it im-
mediately after disconnection of the propeller shaft, for
quite large amount of the transfer oil will flow out.
JPR00006-00006

PR4
INSPECTION
Front & rear
1. Check the propeller shaft for evidence of damage or
bend.
Limit of bend: 0.5 mm
JPR00007-00007
2. Check the spider bearing cup-fitting section for damage.
JPR00008-00008
3. Check the flange yoke and sleeve yoke.

(1) Inspect to see whether any damage is present at the
differential drive pinion companion flange-contact sec-
tion A.
(2) Check the oil seal sliding section B for damage or
wear.
(3) Check the spline C for damage or wear.
(4) Fit the sleeve yoke onto the sliding spline of the trans-
mission output shaft.
Ensure that the spline exhibits no looseness in the ro-
tating direction and the sleeve can slide freely in the JPR00009-00009
axial direction on the spline.

4. Check the universal joint for looseness as follows:
(1) Check the spider for looseness in an axial direction.
(2) Check the spider for looseness in a right-angled-direc-
tion.
(3) Check the spider for smooth rotation.
If any damage is found, replace the propeller shaft with a
new one.
JPR00010-00010

PR5
5. Check of universal joint preload Front
(1) Hook a spring scale at the bolt hole of the flange yoke
as well as at the sleeve yoke end.
(2) Gently pull the spring scale to measure the starting
torque.
Starting Torque: 0.029 - 1.47 Nm (0.003 - 0.15 kgf-m)
Replace the propeller shaft, if the preload fails to meet the

specified value.
JPR00011-00011
Rear
JPR00000-00012
INSTALLATION
1. Apply the specified transmission fluid to both the inner
and outer sides of the sleeve.
Specified Gear Oil
Propeller shaft
assenbly
2. Insert the propeller shaft assembly into the output shaft of
the transfer case.
CAUTION:
JPR00012-00013
Never insert the propeller shaft to the transfer case by
force. Failure to observe this caution may damage the
bush or oil seal in the transfer case.
3. Assemble the propeller shaft while aligning it with the mat-

ing mark put on the companion flange of the differential.
(As for the illustration, refer to the disassembling proce-
dure.)
CAUTION:
Never insert the propeller shaft into the transfer case
by force. Failure to observe this caution may damage
the bush or oil seal in the transfer case.
JPR00013-00000

PR6
4. Install the propeller shaft yoke flange to the flange of the
differential with new four attaching bolts with washers.
CAUTION :
Be sure to clean the attaching surface of the yoke and
flange properly. Failure to observe this caution may
lead to propeller shaft vibration or damage, etc.
5. Tighten the attaching bolts evenly over two or three stages

to the specified tightening torque.
JPR00014-00000
6. Temporarily install the center support with two attaching

bolts.
JPR00015-00014
7. Ensure that the clearance between the center bearing

support rubber and the dust cover is within the specified Center bearing
value. support rubber
Specified clearance: 6 mm or more at installation.
If the clearance fails to meet the specified value, adjust

the clearance by adjusting the center support attaching
position.
8. Tighten the attaching bolts to the specified tightening

torque evenly in two or three stages.
9. Check and fill the specified transfer oil to the transfer

case.
(Refer to the TR section.)
10. While turning the propeller shaft, ensure that the propeller
Dust cover
shaft turns smoothly without exhibiting abnormal noise
and/or binding.
11. Jack down the vehicle and check the clearance between
the center support rubber and the dust cover.
12. Ensure that the clearance between the center bearing JPR00016-00015
support rubber and the dust cover is within the specified
value.
Specified clearance: 10 mm or more

the clearance by adjusting the center support attaching
position. Then, tighten the attaching bolts to the specified
tightening torque.

PR7
TIGHTENING TORQUE
Tightening torque
Nm kgf-m
Propeller shaft flange Differential flange 60.3 9.5 6.15 0.95
Center bearing support Body 36.8 7.3 3.75 0.75
JPR00017-00000

DAIHATSU
J100
FRONT & REAR DIFFERENTIAL
FRONT DIFFERENTIAL .............................. DF 2

COMPONENTS ...................................... DF 2
REAR DIFFERENTIAL ................................ DF 3
COMPONENTS ...................................... DF 3
IN-VEHICLE SERVICE ................................ DF 4
REPLACEMENT OF FRONT AND
REAR DIFFERENTIAL COMPANION
FLANGE OIL SEALS .......................... DF 4
REPLACEMENT OF FRONT
DIFFERENTIAL SIDE OIL SEAL ......... DF 7
REMOVAL ............................................... DF 9 DF
DISASSEMBLY ............................................ DF11
INSPECTION ............................................... DF16
ASSEMBLY .................................................. DF18
INSTALLATION ........................................... DF25
SSTs ............................................................. DF28
TIGHTENING TORQUE ............................... DF30
JDF00001-00000
NO. 9710-JE

DF2
FRONT DIFFERENTIAL
COMPONENTS
@6
@3
@4 @2

@5 !4
w
@4 q
t @2
!5 @3
!7 e
117.7 + 19.5
!8 (12.0 + 2.0)
B
@1
!6
r
i t
83.4 + 4.8 y
(8.5 + 0.5) !6 t
u
t
49.1 + 9.7
(5.0 + 1.0)
11.3 + 1.4
!9 !2 o (1.15 + 0.15)

!3
@0 !3
!0
20.6 + 2.9
(2.1 + 0.3) !1
B
36.8 + 7.3
(3.75 + 0.75) : Tightening torque
@1 Unit : Nm (kgf-m)
q Drive pinion companion flange subassembly !5 Bearing

w Plate washer !6 Tapered roller bearing (rear outer)
e T type oil seal !7 Differential case
r Tapered roller bearing (rear inner) !8 Differential ring gear
t Shim !9 Differential front carrier assembly
y Differential drive pinion bearing spacer @0 Front axle housing cover subassembly
u Tapered roller bearing (front inner) @1 Tapered roller bearing (rear inner)
i Differential drive pinion @2 Differential pinion
o Breather plug @3 Differential side gear thrust washer
!0 Differential carrier @4 Differential side gear
!1 Differential bearing cap @5 Differential pinion shaft
!2 W/head straight screw plug @6 Differential case assembly
!3 T type oil seal @7 Front differential carrier support bracket
!4 Lock nut
JDF00002-00001

DF3
REAR DIFFERENTIAL
COMPONENTS
@3 : Tightening torque
Unit : Nm (kgf-m)
q
46.6 7.3 (4.75 0.75)
@1
w
!3 !0
o i
!5 u

!4
e i
r
!2
o
!1
117.7 19.6 (12.0 2.0) !0
y
@2
r
@0
!7 e
!9 t
!6
B
!8 83.4 4.9 (8.5 0.5)
q Differential cap bearing !3 Drive pinion companion flange subassembly

w Differential case assembly !4 T type oil seal
e Shim !5 Tapered roller bearing
r Radial ball bearing !6 Shim
t Differential ring gear !7 Drive pinion bearing spacer
y Differential case !8 Tapered roller bearing
u Differential pinion shaft !9 Differential drive pinion
i Differential pinion @0 Shim
o Differential side gear @1 Front tapered roller bearing outer race
!0 Side gear thrust washer @2 Rear tapered roller bearing outer race
!1 Lock nut @3 Differential carrier
!2 Plate washer
JDF00003-00002

DF4
IN-VEHICLE SERVICE
REPLACEMENT OF FRONT AND REAR DIFFERENTIAL COMPANION FLANGE OIL
SEALS
NOTE:
This section describes the replacement procedure both for the front and rear companion flange oil
seals. Therefore, some descriptions and figures may not be applicable or differ from each other.
1. Jack up the vehicle and support it with safety stands. (As for the jacking-up points and support points
for safety stands, refer to the GI section.) JDF00004-00000
Front
2. Drain the differential oil by removing the drain plug and
gasket.
CAUTION:
Do not reuse the used gasket.
JDF00005-00003
Rear
Filler plug
Drain plug
JDF00000-00004
3. Disconnect the propeller shaft from the companion flange

of the front or rear differential.
CAUTION:
Sling the companion flange of the propeller shaft at the
body side with a suitable string or the like to prevent
the unnecessary force from applying to the spider sec-
tion of each universal joint or the center bearing section
of the front propeller shaft.
JDF00006-00000
4. Release the staking of the lock nut, using a suitable chisel

and a hammer.
JDF00007-00005

DF5
5. Loosen the lock nut of the companion flange while pre- Front
venting the companion flange from turning, using the fol-
lowing SST in combination with a long box wrench or the
like.
SST: 09330-87301-000
6. Remove the lock nut and plate washer.

CAUTION:
Never reuse the removed lock nut and plate washer.
SST
JDF00008-00006
Rear
SST
JDF00000-00007
7. Remove the drive pinion companion flange subassembly.
NOTE:
If any difficulty is encountered in removing the compan-
ion flange, use the following SST.
SST: 09950-20017-000
JDF00009-00008

SST: 09308-10010-000
CAUTION:
Do not reuse the used oil seal.
JDF00010-00009

DF6
9. Clean the T type oil seal attaching surface with a piece of
cloth or the like.
10. Thinly apply the lithium soap base multi-propose grease to
the lip section of the T type oil seal.
11. Install a new T type oil seal, using the following SST.
SST: 09635-20010-000
CAUTION:
Drive the T type oil seal until the outer surface of the T
type oil seal becomes flush with the flange surface of
the front differential. JDF00011-00010
12. Install the drive pinion companion flange subassembly, a

new washer plate and a new lock nut.
13. Tighten the new lock nut to the specified tightening torque
while preventing the companion flange from turning, using
the following SST.
SST: 09330-87301-000
14. Stake the lock nut to the recessed part of the drive pinion
shaft, using a suitable chisel or the like properly.
CAUTION:
Make sure that the lock section of the nut is positively
staked down to the bottom of the drive pinion groove.
Failure to observe this caution may lead to looseness.
15. Connect the propeller shaft.

(Refer to the PR section)
16. Install and tighten the drain plug with a new gasket inter-
posed.
Tightening Torque:
Front 39.3 - 58.8 Nm (4.0 - 6.0 kgf-m) JDF00012-00011
Rear 53.9 - 68.6 Nm (5.5 - 7.0 kgf-m)
Front
17. Remove the oil filler plug.

18. Fill the specified differential oil from the oil filler plug hole.
Specified differential oil
Grade : API GL-5 (Front & rear)
Viscosity: SAE 80W-90 (Standard)
: SAE 80W-90 LSD (For LSD)
Capacity: 0.7 liters (Front)
1.55 liters (Rear)
JDF00013-00012
NOTE:
The specified oil level is 0 to 5 mm from the lower end Rear
Filler plug
of the oil filler hole.
5 mm
19. Install the oil filler plug with a new gasket interposed and or less

Tightening Torque:
Front 39.3 - 58.8 Nm (4.0 - 6.0 kgf-m)
Rear 53.9 - 68.6 Nm (5.5 - 7.0 kgf-m)
Drain plug
20. Jack down the vehicle.
21. Ensure that no oil leakage exists. JDF00014-00013

DF7
REPLACEMENT OF FRONT DIFFERENTIAL SIDE
OIL SEAL
1. Jack up the vehicle and support it with stands. (As for the
jacking-up points and support points for safety stands,
refer to the GI section.)
2. Remove the front wheels.
3. Drain the differential oil by removing the drain plug and
gasket.
CAUTION:
Do not reuse the removed gasket.
JDF00015-00014
4. Remove the tie rod end attaching castle nut lock clip.
5. Remove the tie rod end attaching castle nut.
6. Disconnect the tie rod end from the steering nuckle, using
the following SST.
SST: 09611-87701-000
JDF00016-00015
7. Remove the lock clip of the castle nut for the lower arm.
8. Remove the castle nut for the lower arm.
9. Disconnect the lower arm from the steering nuckle, using
the following SST.
SST: 09611-87701-000
CAUTION:
Be sure to protect the speed sensor rotor and sensor
from damage, using a piece of cloth or the like.
JDF00017-00016
10. Loosen both sides of the suspension support attaching

nuts.
CAUTION:
Never reuse the used nut.
JDF00018-00017
11. Disconnect the front drive shaft assembly from the front
differential, using the following SST.
SST: 09648-87201-000
JDF00019-00018

DF8
SST: 09308-00010-000
JDF00020-00019
13. Clean the oil seal attaching surface of the front differential.
14. Apply the lithium soap base multi-purpose grease to the
lip section of the new oil seals.
15. Install a new T type oil seal, using the following SST.
SST: 09636-20010-000
16. Apply the lithium soap base multi-purpose grease to the

oil seal attaching surface of the drive shafts.
17. Connect the drive shafts to the front differential carrier. JDF00021-00020
CAUTION:
Never made scratch on the oil seal during the connec-
tion of driver shaft.
18. Replace the suspension attaching nuts with new ones.

19. Tighten the new suspension attaching nuts evenly until the
tightening torque reaches the specified tightening torque.
CAUTION:
Never reuse the used nut. JDF00022-00021
20. Connect the lower arms to the steering knuckles with a

new attaching castle nut and tighten it to the specified
tightening torque.
21. Install new clips securely.

NOTE:
Never reuse the used clips.
22. Connect the tie rod end to the steering knuckle with a new JDF00023-00022
attaching castle nut and tighten it to the specified tighten-

ing torque.
23. Install a new clip.

CAUTION:
Never reuse the removed clip.
24. Install and tighten the drain plug with a new gasket inter-
posed.
DF9
25. Remove the filler plug and gasket. Front
26. Fill the differential oil from the filler plug.
Specified differential oil
Grade: API GL-5
NOTE:
The specified oil level is 0 to 5 mm from the lower end
of the oil filler hole.
JDF00024-00023
27. Install and tighten the filler plug with a new gasket inter- Front
posed. 5 mm
Tightening Torque: 39.3 - 58.8 Nm (4.0 - 6.0 kgf-m) or less
28. Install the front wheels.

30. Inspect the front wheel alignment.
31. Ensure that no oil leakage exists.
JDF00025-00024
REMOVAL
NOTE:
This section describes the removal procedure both for the front and rear differentials. Therefore,
some descriptions and figures may not be applicable or differ from each other.
1. Jack up the vehicle and support it with safety stands. (As for the jacking-up points and support points
for safety stands, refer to the GI section.)
2. Remove the front and/or rear wheels.
3. Drain the differential oil by removing the drain plug and gasket.
CAUTION:
4. Disconnect the tie rod end from the steering knuckle. (For front differential)
(Refer to the procedure described in REPLACEMENT OF FRONT DIFFERENTIAL SIDE OIL SEAL.)
5. Disconnect the lower arm from the steering knuckle. (For front differential)
6. Loosen the suspension support attaching nuts. (For front differential)
CAUTION:
Never reuse the suspension support attaching nuts.
7. Pull out the front drive shaft assembly from the differential carrier assembly, using the following SST.
SST: 09611-87701-000
8. Remove the propeller shaft assembly. (Refer to the PR section.)
CAUTION:
Prior to the disconnection of the propeller shaft from the transfer case, drain the transfer oil or pre-
pare the oil stopper to prevent the transfer oil from flowing out and install it immediately after discon-
necting the propeller shaft from the transfer case.
JDF00026-00000

DF10
9. Support the differential carrier, using a suitable engine
hanger, transmission jacks or the like.
10. Remove the three attaching bolts of the differential carrier
support bracket and differential carrier assembly.
(Only for front differential.)
11. Remove the differential carrier assembly by removing JDF00027-00025
three attaching bolts of the differential carrier support

bracket mount.
12. Remove the front axle housing cover by removing the at-
taching bolts.
NOTE:
Be sure to place a suitable container under the front
axle housing connected sections, for a large amount of
the differential oil may flow out.
JDF00028-00026
13. Remove the rear axle shaft assembly. (Refer to the RS

section.)
(Only for rear differential.)
14. Remove the propeller shaft assembly. (Refer to the PR
section.)
15. Loosen the attaching bolts of the differential carrier as-
sembly evenly.
16. Remove the rear differential carrier assembly by removing
the attaching bolts. JDF00029-00027

NOTE:
It should be noted that a large amount of oil may flow
out. Hence, prior to the disconnecting of the differential
carrier, place a suitable container under the connected
section between the differential and the rear axle hous-
ing.

DF11
DISASSEMBLY SSTB
1. Place the differential carrier removed from the vehicle on a

disassembly stand.
SST: 09219-87202-000 A
09548-87201-000 B
SSTA
JDF00030-00028
2. Inspection before disassembly

(1) Checking of ring gear runout
Ensure that the ring gear runout is within the specified
value, using a dial gauge.
Maximum limit: 0.1 mm or less
If the ring gear runout fails to meet the specified value,

retighten the ring gear attaching bolt evenly after loos-
ening the bolts evenly or replace the ring gear and
drive pinion as a set.
JDF00031-00029
(2) Checking of ring gear backlash

Ensure that the backlash of the ring gear is within the
specified value.
Ring gear backlash: 0.08 - 0.15 mm
NOTE:
If the measured backlash fails to meet the specified
value, replace the ring gear and drive pinion as a set.
(3) Ensure that the backlash of the side gear is within the JDF00032-00030
specified value.
Side pinion backlash: 0.025 - 0.10 mm
CAUTION:
Be sure to employ the shims which have the same
thickness at the right and left side.
NOTE:
If the measured backlash fails to meet the specified
value, adjust the backlash with the thrust washer thick-
ness. JDF00033-00031
(4) Measure the preload of the drive pinion.

Preload: 0.59 - 0.98 Nm (0.06 - 0.1 kgf-m)
NOTE:
If the measured preload fails to meet the specified
value, adjust the preload by selecting the thickness of
shims.
(5) Check of tooth contact between ring gear and pinion

(Refer to page DF21) JDF00034-00032

DF12
3. Remove the T type oil seals, using the following SST.
SST: 09308-00010-000
(For front differential)
SST
JDF00035-00033
4. Put mating marks (paint or the like) on the bearing caps Mating marks
and differential carrier.
NOTE:
Machining process should be carried out with carrier
and cap as a set. Arrange the removed bearing caps in
order.
5. Remove the bearing caps by removing the four attaching

bolts.
JDF00036-00034
Mating marks
JDF00000-00035
6. Remove the shims and differential case assembly from the

carrier. Shims
CAUTION: Shims
Be sure to keep the shims installed at the right and left
sides separately as a reference value for assembly.
JDF00037-00036
7. Remove the side bearings, using the following SST.

SST: 09950-20017-000
JDF00038-00037

DF13
8. Put mating marks on the differential case and ring gear.
9. Loosen the differential ring gear attaching bolts evenly.
CAUTION:
Be sure to loosen the attaching bolts evenly. Failure to
observe this caution may damage the ring gear or the
differential case.
10. Remove the differential ring gear by removing the eight at-
taching bolts.
NOTE: Mating marks
If any difficulty is encounter in separating the ring gear JDF00039-00038
from the differential case, lightly tap the ring gear even-
ly, using a plastic hammer or the like.
11. Remove the differential pinion, differential side gear and

differential thrust washer from the differential case.
(Except LSD)
CAUTION:
Arrange the removed differential side gears and thrust
washeres as a set.
Never disassemble the LSD. The inner parts are not
available as spare parts.
JDF00040-00039
12. Release the staking of the lock nut, using a chisel and a
hammer. (Refer to the procedure described in REPLACE-
MENT OF FRONT DIFFERENTIAL COMPANION FLANGE
OIL SEAL.).
13. Loosen the companion flange attaching nut while prevent-
ing the companion flange from turning, using the following
SST. (Refer to the procedure described in (REPLACE-
MENT OF FRONT DIFFERENTIAL COMPANION FLANGE
OIL SEAL.).
JDF00041-00000
14. Remove the lock nut and plate washer.

CAUTION:
Do not reuse the used lock nut and plate washer.
15. Remove the drive pinion companion flange subassembly,

using the following SST. (Refer to the procedure described
in REPLACEMENT OF FRONT DIFFERENTIAL COMPAN-
ION FLANGE OIL SEAL.).
SST: 09950-20017-000
JDF00042-00000

DF14
16. Remove the T type oil seal, using the following SST. Front
SST: 09308-10010-000
SST
JDF00043-00040
Rear
SST
JDF00000-00041
17. Remove the differential drive pinion spacer and shims

Front
from the differential carrier, using a hydraulic press or tap-
ping the drive pinion, using a hydraulic press.
CAUTION:
Never drop the drive pinion on the floor.
Be very careful not to damage the threaded section of
the drive pinion.
NOTE:
Measure the thickness of the removed shims for the
reference value at assembly. JDF00044-00042
Rear
JDF00000-00043
18. Remove the tapered roller bearing from the drive pinion,
using the following SST or the like.
SST: 09950-87701-000
SST
JDF00045-00044

DF15
19. Remove the front and rear tapered roller bearing outer Front
races and shims, using a press in combination with the
following SST.
SST: 09608-87501-000 SST SST
(Use No. 2 and No. 5 in the above component, in case
front differential.)
(Use No. 3 and No. 5 in the above component, in case
rear differential.)
CAUTION:
Care must be exercised so that the outer race may not JDF00046-00045
be tilted during removal. Rear
NOTE: SST
Measure the thickness of the removed shim for the ref- SST
erence value at assembly.
Be sure to remove the smaller sized bearing outer race
first, otherwise some SST can not utilized.
JDF00000-00046

DF16
INSPECTION
Inspect each section of the following parts for any sign of q
damage, wear or excessive looseness. Replace any parts
which exhibit defects. w
1. Differential drive pinion & ring gear
(1) Gear teeth q
(2) Spline portion w of drive pinion
(3) Bearing fitting section e e
CAUTION:
Replace the drive pinion and ring gear as a set, if any
JDF00047-00047
damage is found on either drive pinion or ring gear.
2. Differential side gear, differential pinion and differential

pinion shaft
JDF00048-00048
3. Differential case
e
(1) Side gear boss contact sections q t
(2) Pinion contact section w w
(3) Ring gear attaching section e
(4) Side bearing press-fitting section r
(5) The differential case proper t
r r
q
JDF00049-00049
4. Bearings
Turn the bearings lightly. Ensure that the tapered roller
bearing (front and rear) and bearing (differential side) ro-
tate smoothly without any binding or abnormal noise.
CAUTION:
Replace the front and rear bearings as a set, if any
damage is found on any bearing.
JDF00050-00050
5. Drive pinion companion flange

(1) Oil seal contact section q q
(2) Spline section w
JDF00051-00051

DF17
6. Differential carrier Front q e
(1) Side bearing fitting sections q w
(2) Tapered roller bearing outer race fitting sections w
(3) Oil seal inserting section e
(4) Carrier cover attaching section r
(5) The differential case proper t
w r t
JDF00052-00052
Rear
q
w e
w r t
JDF00000-00053
7. Inspection of the LSD (Limited Slip Differential)

(For LSD only)
(1) Install the rear axle shaft to a vise.
(2) Connect the differential case to the rear axle.
(3) Connect the rear axle shaft to the differential case.
(4) Install the wheel hub nut to one of the hub bolt with a
suitable spacer interposed.
(5) Install the torque wrench to the hub nut.
(6) Ensure that the starting torque (a reading of the torque
wrench at time when it is turned) is within the specified
value. JDF00053-00054
Starting torque: 49.0 9.8 Nm (5.0 1.0 kgf-m)
If the specified measured starting torque fails to meet

the specified value, replace the differential case with a
new one.
NOTE:
The distance from the shaft center to the hub bolt cen-
ter is 57.15 mm. When measuring the starting torque
with a torque wrench, the reading of the torque wrench
should be compensated using this value.

DF18
ASSEMBLY Front
1. Installation of differential drive pinion

(1) Install the shim which was assembled or a shim having SST
SST
the same thickness with the one which was assembled
as well as the front and rear tapered roller bearing
outer races to the differential carrier, using the follow-
ing SST in combination with a hydraulic press.
SST: 09608-87501-000
(Use No. 7 of the above SST in case front differential.)
(Use No. 7 and 8 of the above SST in case rear differ-
JDF00054-00055
ential.)
Rear
CAUTION:
If any problem is found on the shims, replace the shims
SST SST
with new ones which have the same thickness with the
former one.
Never apply a force beyond 19.6 kN (2000 kgf) during
the installation.
Care must be exercised so that the race may not be
tilted during the press-fitting operation.
(2) Install the tapered roller bearing to the differential drive JDF00000-00056
pinion, using the following SST in combination with a

hydraulic press.
SST: 09515-10010-000
JDF00055-00057
(3) Install the drive pinion shaft assembly, drive pinion and
companion flange to the differential carrier temporarily.
CAUTION:
Liberally apply the specified differential oil to the ta-
pered roller bearings.
Do not assemble the drive pinion shaft bearing spacer
and shims at this moment.
JDF00056-00058
(4) Press the drive pinion shaft tapered roller bearing into
position, using a hydraulic press.
CAUTION:
Never apply excessive force to the bearings during
pressing.
Ensure that no excessive force is applied to the bear-
ings by turning the differential carrier.
JDF00057-00059

DF19
(5) Install the washer plate and lock nut for drive pinion
companion flange subassembly.
SST
CAUTION:
Apply the specified differential oil to the threaded por-
tion of the lock nut and drive pinion before the installa-
tion.
Do not install the spacer, shim and T type oil seal at
this moment.
JDF00058-00060
(6) Tighten the lock nut until the preload of the tapered
bearings becomes the following specified value while
preventing the companion flange from turning, using
the following SST.
SST: 09330-87301-000
Preload: 0.59 - 0.98 Nm (0.06 - 0.1 kgf-m)
NOTE:
Be sure to turn the companion flange several turns to
stabilize the bearing contacting condition before mea-
suring the preload. JDF00059-00061
2. Assembly of differential case

(1) Liberally apply the specified differential oil to the slid-
ing surfaces of all component parts.
(2) Install the side gear thrust washer, side gear, pinion
and pinion shaft to the differential case.
JDF00060-00062
(3) Ensure that the backlash of the differential side gear is

within the specified value with a dial gauge.
Backlash: 0.025 - 0.1 mm
If the backlash is not within the specified value, select

a suitable washer from the spare parts mentioned
below.
Thrust washer availability: 0.8 mm
0.9 mm
1.0 mm
JDF00061-00063

DF20
CAUTION:
Be sure to adjust the backlash in such a manner that
the thickness of the thrust washers at both sides
should be the same or differ not more than 0.1 mm.
(4) Install the differential gear to the differential case while

aligning the mating marks put at the disassembly pro-
cedure.
(5) Install and tighten the attaching bolts evenly to the
specified tightening torque. Mating marks
Tightening Torque: 78.5 - 88.2 Nm (8.0 - 9.0 kgf-m) JDF00062-00064
(6) Install the radial ball bearings into position, using a hy-
SST
draulic press in combination with the following SST.
SST: 09309-87201-000
3. Inspection and adjustment of ring gear backlash

(1) Install the differential case assembly to the differential
carrier. Also, install shims having the same thickness JDF00063-00065
as the one that was assembled to the back side of the

differential gear tooth.
CAUTION:
Apply the specified differential oil to the sliding surface
of the component parts.
Be sure to assemble the differential case assembly to
the differential case while pushing the differential case
assembly against the inserted shim side.
(2) Install the differential bearing caps with bolts to the dif-
ferential carrier according to the mating marks which JDF00064-00066
were put during the disassembling.

CAUTION:
Be sure to push the differential case assembly against
the inserted shim side when assembling the bearing
cap.
(3) Tighten the attaching bolts evenly to the specified tigh-

tening torque.
(4) While applying a dial gauge perpendicular to the tooth JDF00065-00067
surface of the differential ring gear, secure the flange

of the driving pinion. Under this condition, measure the
backlash by moving the ring gear.
Specified value: 0.08 - 0.15 mm
CAUTION:
The measurement should be performed at three or
more points on the circumference of the ring gear.
In cases where a backlash is too large, increase shims.
Conversely, in cases where a backlash is too small, de-
crease shims. JDF00066-00068

DF21
(5) Adjust the backlash to the specified value by selecting
suitable shims from spare part, if the backlash fails to
meet the specified value.
Shim availability: 0.15 mm
0.20 mm
0.25 mm
0.50 mm
(6) Note the selected shim thickness.
4. Adjustment of play of differential case assembly in axial JDF00067-00069
direction
(1) Remove the bearing cap.
(2) Measure the clearance between the bearing at the ring
gear tooth surface side and the differential carrier,
using a thickness gauge. Select and insert shims so
that the clearance may become the specified value.
Specified Value: 0 - 0.05 mm
NOTE:
If any difficulty is encountered in assembling shims,
first insert shims at the back gear tooth surface side. JDF00068-00070
Then, insert shims at the back side by lightly tapping

the back side, using a plastic hammer.

0.20 mm
0.25 mm
0.50 mm
(3) Note the selected shim thickness.

(4) While aligning the mating marks that were put during
the disassembling, assemble the differential bearing JDF00069-00071
cap. Gradually tighten the four bolts evenly to the

(5) Ensure that the ring gear runout is within the specified
value. (Refer to page DF11.)
If the ring gear runout fails to meet the specified value,
retighten the attaching bolts of the ring gear evenly
after loosening them once or replace the ring gear and
drive pinion gear as a set.
JDF00070-00072
5. Check and adjustment of tooth contact condition with ring

gear and drive pinion.
Apply blue lead to the gear teeth. Turn the flange to check
the tooth contact between the ring gear and the drive pin-
ion.
CAUTION:
Be sure to turn the flange in both the forward and back-
ward directions and check the tooth contact pattern at
several points.
JDF00071-00073

DF22
JDF00000-00074
6. Adjustment of drive pinion bearing preload

(1) Remove the differential bearing caps by removing the attaching bolts and differential case with the
shims. (Refer to the disassembly procedure.)
NOTE:
Be sure to keep the removed shims at the right and left sides separately for reassembly.
(2) Loosen the lock nut of the drive pinion while preventing the companion flange from turning, using
the following SST. (Refer to the disassembly procedure.)
SST: 09330-87301-000
(3) Remove the lock nut.

(Refer to the disassembly procedure.)
(4) Remove the companion flange from the pinion shaft, using the following SST in combination with an
adjustable wrench or the like.
SST: 09950-20017-000
(5) Remove the drive pinion from the differential carrier, using a hydraulic press or lightly tapping the
drive pinion, using the plastic hammer.
(6) Remove the outer race of the tapered roller bearing. (Pinion gear side.)
JDF00072-00000
(7) Assemble the drive pinion spacer and shims having

the same thickness as those measured during the disassembling to the drive pinion.
NOTE:
Replace the shims to new ones which have the same thickness with former shims, if they are dam-
aged.
JDF00073-00000

DF23
(8) Install the drive pinion shaft assembly, drive pinion and
companion flange to the differential carrier temporarily.
(9) Press the drive pinion shaft bearing into position, using
a hydraulic press.
CAUTION:
Never apply excessive force to the bearings during
pressing.
Ensure that the no excessive force is applied to the
bearings by turning the differential carrier.
JDF00074-00075
(10) Apply the specified differential oil to the threaded sec-

tion of the drive pinion and lock nut.
(11) Install the plate washer and lock nut. Then, tighten the
lock nut to the specified tightening torque while pre- SST
venting the companion flange from turning, using the
following SST.
(Refer to the assembly procedure.)
SST: 09330-87301-000
Tightening torque: 98.1 - 137.2 Nm
(10.0 - 14.0 kgf-m)
JDF00075-00076
(12) Ensure that the preload is within the specified value, Front
using a torque wrench.
Preload: 0.59 - 0.98 Nm (0.6 - 1.0 kgf-m)
If the measured preload fails to meet the specified

value, select suitable preload adjusting shims from the
spare parts. Then, repeat the preload adjustment, until
the specified preload is obtained.
0.30 mm
0.40 mm JDF00076-00077
0.50 mm Rear
7. Installation of drive pinion oil seal

(1) Remove the drive pinion shaft lock nut while prevent-
ing the companion flange from turning, using the fol-
SST
lowing SST. (Refer to the assembly procedure.)
SST: 09330-87301-000
(2) Remove the companion flange, using the following

SST in combination with a suitable adjusting wrench.
(Refer to the disassembling procedure.)
JDF00077-00078
SST: 09950-20017-000
8. Assembly of companion flange

(1) Install a new T type oil seal to the differential case,
using the following SST. SST
SST: 09635-20010-000
CAUTION:
Apply lithium soap base multi purpose grease to the lip
section of the oil seal.
Make certain to drive the oil seal into position so that it
becomes flush with the edge surface of the housing. JDF00078-00079

DF24
(2) Install the companion flange subassembly, washer
plate and lock nut.
(3) Tighten the lock nut to the specified tightening torque
while preventing the companion flange from turning, SST
SST: 09330-87301-000
(10.0 - 14.0 kgf-m)
(4) Turn the drive pinion shaft several times.

JDF00079-00080
(5) Ensure that the preload is within the specified value.

If not, adjust the preload to the specified value by re-
placing the adjusting shims, as required.
(6) Stake the lock nut to the recessed section of the drive
pinion shaft by a chisel of the like.
CAUTION:
Make sure that the lock section of the lock nut is posi-
tively staked down to the bottom of the driving pinion
groove.
Never damage the threaded section of the drive pinion
shaft. JDF00080-00081
9. Installation of front axle housing cover

(1) Degrease the surface of the front axle housing cover
attaching surface and front axle housing cover.
(2) Apply the specified seal adhesive to the front axle
housing cover attaching surface.
Seal adhesive: Three bond 1216 or equivalents
(3) Install the front axle housing cover with attaching bolts
and tighten them evenly to the specified tightening JDF00081-00082
torque.
SST
10. Installation of drive shaft oil seal
(1) Install new T type oil seals to the differential case,
SST: 09635-20010-000
(2) Apply the lithium soap base multi-purpose grease to

the lip section of the T type oil seals. JDF00082-00083

DF25
INSTALLATION
(Front differential)
1. Install the differential carrier assembly and differential sup-
port bracket with the attaching bolts.
2. Tighten the bolts to the specified tightening torque.
Tightening Torque: Differential carrier
68.6 - 83.4 Nm
(7.0 - 8.5 kgf-m)
Differential support
34.3 - 61.8 Nm
JDF00083-00084
(3.5 - 6.3 kgf-m)
3. Install the propeller shaft to the front differential with the at-
taching bolts and tighten them to the specified tightening
torque.
(Refer to PR section)
4. Insert the drive shaft assembly into the differential carrier

assembly. (Refer to the procedure described in Replace-
ment of Front differential side Oil Seal and FS section.)
CAUTION:
Apply lithium soap base multi-purpose grease to the lip
JDF00084-00085
section of the differential side oil seal.
5. Tighten the new attaching nut of the suspension support

to the specified tightening torque.
JDF00085-00086
6. Install the lower arm to the steering nuckle and tighten the
castle nut to the specified tightening torque.
(Refer to the procedure described in Replacement of
Front differential side oil seal.)

8. Install the tie rod end to the steering knuckle and tighten
the castle nut to the specified tightening torque.

tighten the drain plug to the specified tightening torque.
Tightening Torque:
Front 39.3 - 58.8 Nm (4.0 - 6.0 kgf-m) JDF00086-00000

DF26
11. Fill the specified differential oil from the filler plug.
(Refer to the REPLACEMENT OF FRONT DIFFERENTIAL
COMPANION FLANGE OIL SEAL section.)
12. Install the filler plug with a new gasket interposed and
Tightening Torque:
Front 39.3 - 58.8 Nm (4.0 - 6.0 kgf-m)

15. Ensure that no trouble persists. JDF00087-00087
(Rear differential)
Application of
1. Apply liquid gasket to the mating surface of the rear axle bond sealer
housing cover.
(1) Degrease the surface of the rear differential attaching
surface or the rear axle housing.
(2) Apply the specified seal adhesive to the rear axle.
Seal adhesive: Three bond 1217 or equivalents
2. Install the rear differential carrier assembly with the attach-

ing bolts. JDF00088-00088
3. Tighten the attaching bolts to the specified tightening
torque evenly.
4. Install the propeller shaft assembly. (Refer to the PR sec-

tion.)
5. Install the rear axle shaft. (Refer to the RS section.)
tighten the drain plug to the specified tightening torque.
JDF00089-00000
7. Fill the specified differential oil from the filler plug.

Specified differential oil Filler plug
Grade : API GL-5
Viscosity : SAE 80W-90 (Standard)
SAE 80W-90 LSD (For LSD)
Capacity : 1.55 liters
Drain plug
JDF00090-00089

DF27
8. Install the filler plug with a new gasket interposed and
9. Install the rear wheel.

11. Ensure that no trouble is persists.
JDF00091-00000

DF28
SSTs
09515-10010-000 Rear axle bearing replacer
09309-87201-000 Transmission bearing replacer
09608-87501-000 Axle hub & drive pinion bearing tool set
09635-20010-000 Lower ball joint dust cover replacer
09548-87201-000 Differential overhaul attachment
09330-87301-000 Drive pinion flange holding tool
09611-87701-000 Tie rod end puller
09648-87201-000 Drive shaft replacer
09636-20010-000 Upper ball joint dust cover replacer
09219-87202-000 Engine overhaul stand

DF29
09950-20017-000 Universal puller
09950-87701-000 Bearing pulling attachment
JDF00092-00090

DF30
TIGHTENING TORQUE
Tightening torque
Tightening compartment
Nm kgf-m
Drive pinion companion flange subassembly lock nut 98.1 - 137.2 10.0 - 14.0
Drain plug (Front) 39.3 - 58.8 4.0 - 6.0
(Rear) 53.9 - 68.6 5.5 - 7.0
Oil filler plug (Front) 39.3 - 58.8 4.0 - 6.0
(Rear) 53.9 - 68.6 5.5 - 7.0
Suspension support attaching nut 28.4 - 42.2 2.9 - 4.3
Lower arm steering knuckle 44.1 - 58.8 4.5 - 6.0
Tie rod end steering knuckle 39.2 - 53.9 4.0 - 5.5
Differential gear differential case 78.5 - 88.2 8.0 - 9.0
Differential bearing cap differential carrier 29.5 - 44.1 3.0 - 4.5
Front axle housing cover front axle 17.7 - 23.5 1.8 - 2.4
Differential carrier differential support bracket 68.6 - 83.4 7.0 - 8.5
Differential support bracket frame
Differential carrier frame 34.3 - 61.8 3.5 - 6.3
JDF00093-00000

DAIHATSU
J100
FRONT AXLE & SUSPENSION
WHEEL ALIGNMENT ......................... FS 2 SUSPENSION LOWER ARM ............. FS17

PREPARATION .............................. FS 2 REMOVAL ...................................... FS17
FRONT AXLE AND SUSPENSION .... FS 4 INSPECTION ................................. FS17
COMPONENTS ............................. FS 4 REPLACEMENT OF SUSPENSION
FRONT AXLE ..................................... FS 5 LOWER ARM BUSH .................. FS18
REMOVAL ...................................... FS 5 REPLACEMENT OF SUSPENSION
DISASSEMBLY .............................. FS 7 LOWER ARM BALL JOINT
INSPECTION ................................. FS 8 DUST COVER ............................ FS18
ASSEMBLY .................................... FS 9 INSTALLATION .............................. FS19
INSTALLATION .............................. FS10 DRIVE SHAFT .................................... FS20
FRONT STABILIZER BAR ................. FS12 COMPONENTS ............................. FS20
REMOVAL ...................................... FS12
DISASSEMBLY .............................. FS12
REMOVAL ...................................... FS20
DISASSEMBLY .............................. FS21
FS
INSPECTION ................................. FS12 INSPECTION ................................. FS22
ASSEMBLY .................................... FS13 ASSEMBLY .................................... FS23
INSTALLATION .............................. FS13 REPLACEMENT OF TRANSFER
SHOCK ABSORBER AND OIL SEAL ................................... FS25
SPRING .......................................... FS14 INSTALLATION .............................. FS25
REMOVAL ...................................... FS14 TIGHTENING TORQUE ...................... FS26
DISASSEMBLY .............................. FS14
INSPECTION ................................. FS15
ASSEMBLY .................................... FS15
INSTALLATION .............................. FS16
JFS00001-00000
NO. 9710-JE

FS2
WHEEL ALIGNMENT
PREPARATION
Prior checks
1. Inspect the wear of tires.
2. Inspect the air pressure of the tires.
NOTE:
Perform the check on a level floor.
Make sure that the same makers tires having the
same size are mounted.
Keep the vehicle in an unloaded state. Unloaded JFS00002-00001
state denotes a condition where the fuel tank is full, a
spare tire is mounted, standard tools and a jack are
mounted at correct storage locations.
Tire Size: 205/70R15 95S
Pressure: 180 kPa (1.8 kgf/cm2)
3. Inspect the runout of tires.

Maximum Limit: 2 mm in a right-and-left direction
1.4 mm in an up-and-down direction
NOTE:
The measurement should be conducted within five min-
utes after the vehicle has been run for at least 30 min-
utes at a speed of 60 to 80 km/h.
JFS00003-00002
4. Ensure that the no looseness are exists on the bolts and

nuts on the related parts of the front axle and steering link-
age.
5. Check of related sections of the front axle and steering
linkage for excessive play
(1) Jack up the vehicle and support it with safety stands.
(Refer to GI section.)
(2) Ensure that no excessive play are exists on the con-
necting sections of the each front axle and steering
linkage by rocking the tire alternately in-and-out or
push and pull while holding the upper and lower parts JFS00004-00003
of the tire.

FS3
Camber, Caster and Kingpin angle
Specified Value
Camber 030 45
Caster 235 1
Kingpin angle 1345 1
NOTE:
No adjustment can be made for the camber, caster and
kingpin angle. Therefore, if the camber, caster or king-
pin angle fails to meet the specified value, check that JFS00005-00004
no damage or deformation exists on the frame or cor- Front

rect the frame, as required.
B
Toe-in, Turning radius
Specified Value:
Toe-in 0 1.5 mm
Turning Radius In 3828 +120
240
+130
Out 3324 230
A
NOTE: JFS00006-00005
If the toe-in or turning radius fails to meet the specified
value, perform the adjustment, following the procedure
given below, so that both the toe-in and turning radius A B B A
may conform to the specified values.
Front
JFS00000-00006
Adjustment of Toe-in and Turning radius

1. Loosen the lock nuts of the tie-rod ends.
2. Perform the toe-in and turning radius adjustment by turn-
ing the tie-rod ends.
CAUTION:
When adjusting the toe-in, the tie-rods at the right and (a)
left sides should be turned by the same amount.
Make the length (a) indicated in the illustration equal
between the right and left sides. If the length differs be-
tween the right and left sides, a difference occurs in the
wheel turning angle between the right and left sides. JFS00007-00007
3. Tighten the lock nut.


FS4
FRONT AXLE AND SUSPENSION
COMPONENTS
: Tightening torque
Unit : Nm (kgf-m)
q
N
28.4 - 42.2
37.8 - 56.4 N (2.9 - 4.3)
(3.85 - 5.75)
w
t
i
12.7 - 23.5
(1.3 - 2.4) y
B
N
12.7 - 23.5 !2
(1.3 - 2.4) !3
o
!0 !3
!2
!1 101.9 - 152.9
u
!4 (10.4 - 15.6)
B
!2 !6
12.7 - 23.5 !3
(1.3 - 2.4) !2 N
!7 !9
!8
!5
@0
B @1
B @2 @3
117.6 - 176.4
117.6 - 176.4
(12.0 - 18.0)
(12.0 - 18.0)
!2 N
39.2 - 53.9
!3
(4.0 - 5.5)
!2
N 196.6 - 29.4
12.7 - 23.5 (20.0 - 3.0)
(1.3 - 2.4)
q Bearing dust cover !3 Bush

w Front suspension support !4 Stabilizer link rod
e Bearing !5 Suspension lower arm
r Front spring upper seat !6 Steering knuckle
t Front spring bumper !7 Bearing
y Front spring !8 Snap ring
u Front shock absorber !9 Disc brake dust cover
i Front stabilizer bracket sub-assembly @0 Front axle hub
o Front stabilizer bar @1 Washer
!0 Stabilizer bush @2 Front wheel adjusting lock cap
!1 Stabilizer bracket @2 Cotter pin
!2 Washer
JFS00008-00008

FS5
FRONT AXLE
REMOVAL
3. Remove the attaching bolts of the disc brake assembly.
4. Suspend the disc brake assembly with suitable string.
JFS00009-00009
5. Remove the brake disc.

NOTE:
Remove the brake disc by screw-in the two bolts (M8
1.25) evenly to the bolt holes provided on the brake
disc, if any difficulty is encountered.
JFS00010-00010
6. Inspection of wheel bearing

(1) Ensure that no excessive looseness exists between the
drive shaft and axle hub.
(2) Ensure that the free play with in the specified value,
using the dial gauge as shown.
Axial Free Play: Not more than 0.05 mm
If the free play is exceeds the allowable limit, replace

the wheel bearing.
JFS00011-00011
7. Inspection of axle hub

Ensure that the axle hub runout is with in specified value,
using dial gauge.
Runout Limit: Not more than 0.05 mm
If the runout exceeds the allowable limit, replace the axle

hub.
NOTE:
Measure the runout at a point of the axle hub outer
edge. JFS00012-00012
8. Removal of front axle hub

(1) Remove the cotter pin, then remove the front wheel ad-
justing lock cap.
(2) Remove the nut while preventing the front hub from
turning, using the following SST.
SST: 09511-87202-000
CAUTION:
Prevent the hub bolt from damage by installing the suit-
able hub nut or the like, when using the SST. JFS00013-00013

FS6
(3) Pull out the front axle hub sub-assembly with inner
bearing race, using the following SST.
SST: 09520-00031-000
CAUTION:
Never reuse the removed bearing.
SST
JFS00014-00014
9. Remove the sensor mounting bracket with the skid control

sensor from the steering knuckle by removing the attach-
ing bolts.
(Only for vehicles equipped with ABS.)
10. Removal of steering knuckle JFS00015-00015
(1) Disconnection of tie-rod end from steering knuckle

q Remove the clip.
w Loosen the castle nut until the upper end of the
castle nut becomes flash with the end of the
threaded section of the lower ball joint.
e Disconnect the tie-rod end from the steering
knuckle, using the following SST.
SST: 09611-87701-000
r Disconnect the tie-rod end from the steering

knuckle by removing the castle nut. JFS00016-00016
CAUTION:
Never make damage on the threaded section of ball
joint during the disconnection using the SST.
(2) Disconnection of suspension lower arm from steering

knuckle
q Remove the clip.
w Loosen the castle nut until the upper end of the
castle nut becomes flash with the end of the
threaded section of the lower ball joint.
e Disconnect the suspension lower arm from the JFS00017-00017
steering knuckle, using the following SST.

SST: 09611-87701-000
r Disconnect the suspension lower arm from the

steering knuckle by removing the castle nut.
CAUTION:
Never make damage on the threaded section of ball
joint during the disconnection using the SST.

FS7
(3) Disconnection of shock absorber from steering knuck-
le
q Remove the attaching nuts of the steering knuckle
to shock absorber.
NOTE:
Never reuse the removed bolt and nut.
w Disconnect the front shock absorber from the

steering knuckle.
JFS00018-00018
DISASSEMBLY
Front axle hub
1. Wrench out the bearing dust cover from the front axle hub,
using screwdriver or the like.
JFS00019-00019
2. Remove the inner bearing race (outer side) from the front
axle hub, using the following SST.
SST: 09950-20017-000
CAUTION:
JFS00020-00020
3. Drive out the hub bolts from the front axle hub, using a
JFS00021-00021
Steering knuckle
1. Remove the disc brake dust cover, using a suitable brass
bar or the like in combination with suitable hammer.
NOTE:
Never remove the disc brake dust cover unless its re-
placement is required.
JFS00022-00022

FS8
2. Removal of front axle bearing.
(1) Detach the hole snap ring, using snap ring pliers.
Hole snap ring
JFS00023-00023
(2) Remove the bearing from the steering knuckle, using a

following SST in combination with the hydraulic press.
SST
SSTs: 09544-10010-000
09252-10010-000 (Use the 09550-10012-000
that is a part of the set.) 09506-87302-000
CAUTION:
SST
JFS00024-00024
INSPECTION
Front axle hub
Visually check front axle hub for crack, deformation or exces-
sive wear.
Ensure that no damage is exits on the serration section of the
front axle hub.
If any damage is exists replace the front axle hub with new
one.
JFS00025-00025
Steering knuckle
Visually check steering knuckle for crack, deformation or any
other damages.
Ensure that no damage exists on the bearing attaching sec-
tion.
If any damage is exists replace the steering knuckle with new
one.
JFS00026-00026

FS9
ASSEMBLY
Front axle hub
Install the hub bolt to the front axle hub by tapping it with suit-
able hammer.
JFS00027-00027
Steering knuckle
1. Installation of disc brake dust cover
Press the disc brake dust cover until it comes in contact
with the steering knuckle, using the following SSTs in com- SST
bination with the hydraulic press.
SSTs: 09506-87302-000
09718-87702-000 SST
CAUTION:
Ensure that the disc brake dust cover is press-fitted to
the steering knuckle positively by ensuring the dust JFS00028-00028
cover properly contacts with the steering knuckle.

Be sure to assemble the brake dust cover to steering
knuckle in such position, as indicated in the figure.
13 0.5
JFS00029-00029
2. Installation of front axle bearing

(1) Press a new bearing into the steering knuckle, using
the following SSTs in combination with hydraulic press.
SSTs: 09310-87302-000
09506-87302-000
(2) Install a new hole snap ring, using snap ring pliers.
CAUTION:
Never reuse the used snap ring.
JFS00030-00030

FS10
INSTALLATION
1. Press the front axle hub into the steering knuckle sub-as-
sembly using the following SST in combination with hy-
draulic press.
SST: 09559-10010-000, 09252-10010-000 (Use the
09550-10012-000 that is a part of the set.)
NOTE:
Press in the steering knuckle into the axle hub after the
axle hub placed on the SST 09506-87302-000.
JFS00031-00031
2. Install the steering knuckle after insert the drive shaft to

the steering knuckle as follows.
(1) Connection of shock absorber to steering knuckle
q Connect the steering knuckle on the shock ab-
sorber lower bracket.
w Install the new bolts and nuts, then tighten the
bolts and nuts to specified tightening torque.
(10.4 - 15.6 kgf-m)
CAUTION: JFS00032-00032
Be sure to tighten the attaching nuts when tightening.
(2) Connection of tie-rod end to steering knuckle

q Connect the tie-rod end to the steering knuckle
with the castle nut. Then, tighten the castle nut to
w Install the clip to the castle nut.

CAUTION:
Never adhere a grease or oil, etc. to the taper section JFS00033-00033
of the lower ball joint.
Never make any damage on the dust cover of the ball
joint.
(3) Connection of suspension lower arm to steering

knuckle
q Connect the suspension lower arm to the steering
knuckle with the castle nut. Then, tighten the castle
nut to specified tightening torque.
JFS00034-00034
w Install the clip to the castle nut.
CAUTION:
Never adhere a grease or oil, etc. to the taper section
of the lower ball joint.
Never made any damage on the dust cover of the ball
joint.
3. Install the sensor mounting bracket with the skid control

sensor to the steering knuckle.
JFS00035-00035

FS11
4. Tightening of drive shaft end nut
Inside Outside
(1) Install the conical washer to the drive shaft.
(2) Install the nut and tighten the nut to specified tighten-
ing torque while prevent the front axle hub from turn-
SST: 09511-87202-200
(20.0 3.0 kgf-m)
Serrated section
CAUTION:
Be sure to install the conical washer in the correct di- JFS00036-00036
rection.
(3) Install the front wheel adjusting lock cap to the nut.
(4) Install a new cotter pin.
CAUTION:
Bend the legs of the cotter pin, as indicated in the fig-
ure.
When bending the cotter pin, make sure that the cotter
pin is not protruding from the head of the bolt.
JFS00037-00037
5. Install the brake disc to the front axle hub.

6. Install the disc brake assembly to the steering knuckle.
(9.2 - 13.8 kgf-m)
7. Install the wheel with hub nuts and tighten the hub nut fully
by hand.
9. Tighten the hub nut to specified tightening torque.
(9.0 - 12.0 kgf-m) JFS00038-00038

FS12
FRONT STABILIZER BAR
REMOVAL
2. Remove the stabilizer bar end lower nut.
CAUTION:
3. Remove the bush and washer.

4. Remove the stabilizer bracket from the stabilizer bracket JFS00039-00039
sub-assembly.
5. Remove the stabilizer bar.
DISASSEMBLY
1. Remove the stabilizer bar end upper nut.
CAUTION: Nut Washer
Never reuse the removed nut. Bush
2. Remove the bush, washer and stabilizer link rod from the Washer
stabilizer bar.
JFS00040-00040
INSPECTION
Bush
Ensure that no damage such as crack, wear, deterioration,
aging and/or so forth.
Stabilizer bar
Visually inspect that no damage or wear is exists on the stabi-
lizer bracket.
Stabilizer bracket
Visually inspect that no damage or wear is exists on the stabi-
lizer bracket.
Stabilizer bush
Ensure that no damage such as crack, wear, deterioration,
aging and/or so forth.
Stabilizer link rod

Ensure that the no wear, bent, damage on threaded section.
If any damage is exists replace the damaged part as re-
quired.
JFS00041-00041

FS13
ASSEMBLY
1. Install the washer and bush to the stabilizer link rod.
2. Install the stabilizer link rod to the stabilizer bar. Nut Washer
3. Install the bush and washer to the stabilizer link rod. Then, Bush
tighten the stabilizer bar end upper nut.
CAUTION: Washer
Be sure to assemble the bush and washer as shown in
the right figure.
JFS00042-00042
INSTALLATION
1. Install the stabilizer link rod, washer and bush to the sus-
pension lower arm with the attaching nuts as shown in the Washer A
right figure. Then, tighten the stabilizer bar end lower nut Bush
temporary.
Washer A
CAUTION:
Be sure to insert the protrusion section on the washer Bush
Washer B
B to the hole provided on the stabilizer bracket on the
Bush
suspension lower arm.
Washer A
JFS00043-00043
2. Attach the bushes to the stabilizer bar.

CAUTION:
Be sure to attach the bushes to the stabilizer bar in
such manner that the bushes should be attached on
the mark provided on the stabilizer bar during installa-
tion.
Marker
3. Install the stabilizer bar to the stabilizer bracket sub-as-
sembly by installing the stabilizer bracket with the attach-
ing bolts. Then, tighten the attaching bolts to specified
tightening torque. JFS00044-00044
4. Tighten the stabilizer bar end lower nut.

JFS00045-00045

FS14
SHOCK ABSORBER AND SPRING
REMOVAL

3. Remove the brake hose bracket from the shock absorber
lower bracket by removing its attaching nut.
JFS00046-00046
4. Remove the skid control sensor harness bracket from the

shock absorber lower bracket by removing its attaching
bolt.
5. Remove the attaching nuts of the shock absorber lower
bracket which is connected to the steering knuckle.
CAUTION:
JFS00047-00047
6. Remove the attaching nuts of the suspension support at

the front fender apron.
CAUTION:
7. Remove the attaching nuts and bolts of the shock ab-

sorber lower bracket which is connected to the steering
knuckle.
NOTE:
Never reuse the removed nuts.
Be sure to prevent the drive shaft boot from the dam- JFS00048-00048
age, using the suitable piece of cloth or the like.
DISASSEMBLY
1. Compress the coil spring, using the following SST.
SST: 09727-87701-000 or
09727-30020-000
2. Secure the front shock absorber in a vice.

3. Remove the bearing dust cover.
4. Remove the nut.
JFS00049-00049
CAUTION:
Never remove the nut by applying impacts to it, using
an impact wrench or the like.
5. Remove the front suspension support.

6. Remove the bush and front spring upper seat.
7. Remove the coil spring and spring bumper.

FS15
INSPECTION
CAUTION:
Replace the parts with new one, if any damage or mal-
function is found in following inspections.
Suspension support
Visually check that deformation, rust, crack nor other damage
are not exists and also check that no damage is exists on the
threaded portion of the stud bolts.
Spring upper seat

Ensure that the spring upper seat is free from crack, rupture,
deformation aging, wear and other damage.
Bumper
Ensure that the bumper is free from crack, rupture, deforma-
tion aging, wear and other damage.
Bearing
Ensure that the bearing is turns freely without any pulling.
Coil spring JFS00050-00050
Ensure that the coil spring is free from deformation, deteriora-

tion, crack or other damage.
Shock absorber
Ensure that the shock absorber piston operates smoothly
without any rattling, shock or abnormal resistance or noise by
pulling and pushing the piston rod.
WARNING:
Release the gas completely before discarding the
JFS00051-00051
shock absorber.
Cut-out
ASSEMBLY
1. Insert the spring bumper to the piston rod.
2. Compress the coil spring, using the following SST.
SST: 09727-87701-000 or
09727-30020-000
3. Install the coil spring which is compressed with SSTs to

the shock absorber.
4. Install the front spring upper seat to the shock absorber JFS00052-00052
piston rod.
5. Install the bearing to the shock absorber piston rod.
6. Install the front suspension support.
CAUTION:
Be sure to align the cut-out section of the front suspen-
sion support with the protrusion section of piston rod
during the assembly.

FS16
7. Temporarily attach the new piston end nut.
8. Hold the front suspension support in a vice.
CAUTION:
Never apply the excessive force to the suspension sup-
port.
9. Tightening the piston end nut to specified tightening

torque.
(3.85 - 5.75 kgf-cm)
JFS00053-00053
10. Install the bearing dust cover.

11. Remove the SSTs which is compress the coil spring while
aligning coil spring end with the recessed section provid-
ed on the each of the upper and lower seats.
JFS00054-00054
INSTALLATION
1. Install the suspension support to the fender apron with the
new attaching nuts.
2. Tighten the suspension support attaching nuts to speci-
fied tightening torque.
Tightening Torque: 28.4 - 42.2 Nm (2.9 - 4.3 kgf-cm)
JFS00055-00055
3. Connect the shock absorber to the steering knuckle.

(Refer to the FS10.)
4. Install the skid control sensor harness bracket to the JFS00056-00056
shock absorber lower bracket.

5. Install the brake hose bracket to the shock absorber with
the attaching bolt.
6. Install the wheel with hub nuts and tighten them fully by
hand.
8. Tighten the hub nut to specified tightening torque. (Refer
to the FS11.)
9. Perform the inspection of the front wheel alignment. (Refer
to the WHEEL ALIGNMENT section.) JFS00057-00057

FS17
SUSPENSION LOWER ARM
REMOVAL
3. Remove the front stabilizer bar. (Refer to the STABILIZER
section.)
4. Remove the stabilizer bracket sub-assembly from the sus-
pension member.
JFS00058-00058
5. Remove the skid control sensor from the sensor mounting

bracket. (Only for vehicles equipped with ABS.)
6. Disconnection of suspension lower arm
(1) Disconnect the suspension lower arm from the steer-
ing knuckle. (Refer to the FS6.)
(2) Loosen the attaching nuts of the shock absorber to the
suspension lower arm.
(3) Remove the lower side attaching bolt and nut of shock
absorber. JFS00059-00059
CAUTION:
Never reuse the removed bolts and nuts.
(4) Remove the attaching bolts and nuts of the suspen-

sion lower arm to suspension member.
CAUTION:
Never reuse the removed bolts.
(5) Remove the suspension lower arm from the suspen-

sion member.
INSPECTION
Suspension lower arm
1. Ensure that the ball joint dust cover is free from rupture,
crack, aging, deformation and other damages.
2. Ensure that the ball joint is operates smoothly without any
rattle.
3. Visually inspect that no damage or wear exists on the sus-
pension lower arm.
If any damage is exists replace the damaged part with
new one.
JFS00060-00060

FS18
REPLACEMENT OF SUSPENSION LOWER ARM
BUSH
1. Remove the bush, using a suitable tool in combination 25 mm
Front side 35 mm
with a hydraulic press.
NOTE:
Use a suitable tool, such as a tool indicated in the fig-
ure.
35 mm
Rear side
2. Apply the Samper 115 to a new bush (Only for the front
60 mm
side bush.). Then, press-fit the bush in the suspension
lower arm, using a suitable tool in combination with a hy- JFS00061-00061
draulic press.
CAUTION:
Never apply the pressure to the inner sleeve of the
bush.
Be sure to install the front side bush in such positions Front
that the both flange section of the bush properly posi-
tioned as shown. 15 15
Be sure to install the rear bush to suspension lower 15 15
arm in such positions that the holes provided on the
bush align with the position as shown.
Be sure to install the rear side bush outer sleeve to JFS00062-00062
suspension lower arm in such positions that the edge

of the rear side bush outer sleeve be comes flash with
the attaching hole edge of the suspension lower arm.
REPLACEMENT OF SUSPENSION LOWER ARM

BALL JOINT DUST COVER
1. Remove the dust cover, using a screwdriver or the like.
NOTE:
Never remove the dust cover, unless its replacement is
required due to the damage or deterioration. JFS00063-00063
2. Pack the specified amount of multi purpose grease to in-

side of the dust cover.
Amount of Multi Purpose Grease: 4 0.5 cc
3. Install the new dust cover to suspension lower arm by

using following SST in combination with a hydraulic press.
SST: 09618-87301-000
JFS00064-00064

FS19
INSTALLATION
1. Install the suspension lower arm to the suspension mem-
Suspension
ber with the attaching bolts and nut. member
2. Tighten the attaching bolts and nut to specified tightening
193 5
torque.
(12.0 - 18.0 kgf-m)
CAUTION:
Be sure to tighten the bolts and nut while locating the
suspension lower arm in position as show. JFS00065-00065
3. Connect the shock absorber to the steering knuckle.

4. Connect the suspension lower arm and steering knuckle.
5. Install the skid control sensor to the sensor mounting
6. Install the stabilizer bracket sub-assembly to the suspen-
sion member. (Refer to the STABILIZER section.)
7. Install the stabilizer. (Refer to the STABILIZER section.)
8. Install the wheel with hub nuts and tighten the hub nut fully JFS00066-00066
by hand.
to the FS11.)
11. Perform the inspection of the front wheel alignment.
(Refer to the WHEEL ALIGNMENT section.)

FS20
DRIVE SHAFT
COMPONENTS
q

u i
w
e
r
t
y
i
o
o i
q Snap ring i
w Inboard joint
e Snap ring
r
t !0
y
u Snap ring
i Boot band
o Boot
!0 Outboard joint
JFS00067-00067
REMOVAL
(Refer of the GI section.)
3. Drain the transmission oil. (Refer to the MA section.)
4. Remove the disc brake assembly. (Refer to the FS5.)
5. Remove the brake disc. (Refer to the FS5.)
6. Remove the skid control sensor from the sensor mounting
bracket. (Only for the vehicles equipped with ABS.)
7. Remove the cotter pin.
8. Remove the adjusting lock cap. JFS00068-00068
9. Remove the drive shaft end nut and washer. (Refer to the
FS5.)
10. Disconnect the tie-rod end from the steering knuckle.
(Refer to the FS6.)
11. Disconnect the suspension lower arm from the steering
knuckle. (Refer to the FS6.)
12. Disconnect the shock absorber from the steering knuckle.
(Refer to the FS7.)
13. Remove the steering knuckle with the front axle hub from
the drive shaft.
14. Disconnect the drive shaft from the transfer, using the fol-
lowing SST.
SST: 09648-87201-000
JFS00069-00069

FS21
DISASSEMBLY
Inboard joint side
1. Pry up the boot band clip with a screwdriver.
NOTE:
Be very careful not to damage the boot.
JFS00070-00070
2. Remove the snap ring, using a screwdriver or the like.
JFS00071-00071
3. Remove the front axle inboard joint sub-assembly from

shaft.
4. Remove the balls.
JFS00072-00072
5. Remove the snap ring, using snap ring pliers.
JFS00073-00073
6. Remove the inner race, using the following SST.

SST: 09950-20017-000
7. Remove the cage from the shaft.
JFS00074-00074

FS22
8. Wind vinyl tape to the splined section of the shaft so that
the boot may not be damaged during the removal.
9. Remove the boot. vinyl tape
JFS00075-00075
Outboard joint side

1. Pry up the boot band clip with a screwdriver.
2. Remove the boot.
NOTE:
Outboard joint is non-disassembling parts.
Be very careful not to damage the boot.
JFS00076-00076
INSPECTION
Ball sub-assembly
Visually check that no damage such as crack excessive wear
or any other damage.
Shaft and outboard joint

Ensure that the outboard joint operates smoothly with out any
rattle or pulling.
Inboard joint
Visually check that no damage such as crack excessive wear
or any other damage.
Boot
Ensure that the boot is free from damage such as crack, dete-
rioration, aging or any other damage.
If any damage is exists replace the damaged part with new
one.
JFS00077-00077

FS23
ASSEMBLY
Outboard joint side
1. Wind vinyl tape to the spline section of the inboard joint
shaft, so that the boot may not be damaged during the in-
stallation.
2. Install the boot to outboard joint in position as shown.
3. Install the new boot band (smaller diameter side) on the
outboard joint.
JFS00078-00078
4. Pack the specified amount of specified grease into out-

board joint.
Specified Amount of Grease: 65 10 g
CAUTION:
The grease for outboard joint should be use specified
grease only which is supplied with the spare parts.
5. Install and tie-up the new boot band (Larger diameter

side) in place.
JFS00079-00079
Inboard joint side

1. Temporarily install the boot and boot band (smaller diame-
ter side).
2. Remove the vinyl tape that was wound around the splined
portion.
3. Install the cage to the shaft.
NOTE:
The cage should be inserted in the direction indicated
in the figure.
JFS00080-00080
4. Install the inner race, using the following SST.

SST: 09309-87201-000
SST
JFS00081-00081
5. Install the new snap ring to the shaft, using a snap ring pli-
ers.
CAUTION:
Ensure that the snap ring installed in the groove prop-
erly after installation.
JFS00082-00082

FS24
6. Assemble the inner race and cage, and install the ball.
While holding the ball to prevent it from dropping, assem-
ble the inboard shaft subassembly.
JFS00083-00083
7. Install the snap ring to the inboard joint.

CAUTION:
Ensure that the snap ring installed in the groove prop-
erly after installation.
JFS00084-00084
8. Tie-up the smaller side boot band.

CAUTION:
Place the boot in position as shown. (Refer to the
FS23.)
9. Pack the specified amount of grease into inboard joint.

Specified Amount of Grease: 75 10 g
CAUTION:
The grease for inboard joint should be use specified
grease only which is supplied with the spare parts. JFS00085-00085
10. Install and tie-up the new band (Larger diameter side) in
place.

FS25
REPLACEMENT OF TRANSFER OIL SEAL
Replace the oil seal, as required. (For the replacement proce-
dure, refer to the TR section.)
JFS00086-00000
INSTALLATION
1. Apply chassis grease to the whole serrated section of the
front drive shaft at the outboard joint side.
2. Connect the inboard joint section of the front drive shaft
into the transfer.
NOTE:
Apply lithium soap base multi purpose grease to the lip
section of the oil seal.
Never made scratch on the oil seal during the installa-
tion of the drive shaft.
JFS00087-00086
3. Install the steering knuckle with front axle hub to the drive
shaft.
4. Connect the steering knuckle to the shock absorber with
attaching bolts and nuts. (Refer to the FS10.)
5. Connect the suspension lower arm to the steering knuck-
le. (Refer to the FS10.)
6. Connect the tie-rod end to the steering knuckle. (Refer to
the FS10.)
7. Install the drive shaft end washer and nut. (Refer to the
FS11.)
8. Install the adjusting lock cap. JFS00088-00087
9. Install the new cotter pin. (Refer to the FS11.)

10. Install the skid control sensor to the sensor mounting
11. Install the brake disc to the steering knuckle.
12. Install the disc brake assembly to the steering knuckle.
13. Fill the specified transmission oil to the transfer. (Refer to
the TR section.)
14. Install the wheel with hub nuts and tighten the hub nut fully
by hand.
to the FS11.)
17. Perform the inspection of the front wheel alignment.
(Refer to the WHEEL ALIGNMENT section.)

FS26
TIGHTENING TORQUE
Components Nm kgf-m
Wheel hub nut 88.2 - 117.6 9.0 - 12.0
Steering knuckle Suspension lower arm 44.1 - 58.8 4.5 - 6.0
Suspension lower arm Member 117.6 - 176.4 12.0 - 18.0
Stabilizer link Suspension lower arm 12.7 - 23.5 1.3 - 2.4
Shock absorber Steering knuckle 101.9 - 152.9 10.4 - 15.6
Stabilizer bracket Stabilizer bracket sub-assembly 12.7 - 23.5 1.3 - 2.4
Shock absorber piston end nut 37.8 - 56.4 3.85 - 5.75
Suspension support Front fender apron 28.4 - 42.2 2.9 - 4.3
Stabilizer bracket sub-assembly Frame 12.7 - 23.5 1.3 - 2.4
Drive shaft Front axle hub 196.6 29.4 20.0 3.0
Tie-rod end lock nut 59.8 - 89.2 6.1 - 9.1
Tie-rod end Steering knuckle 39.2 - 53.9 4.0 - 5.5
Steering knuckle Speed sensor bracket 6.9 - 9.8 0.7 - 1.0
Speed sensor bracket Speed sensor 6.9 - 9.8 0.7 - 1.0
Steering knuckle Disc brake assembly 90.2 - 135.3 9.2 - 13.8
JFS00089-00000

FS27
09309-87201-000 Replacer
09310-87302-000 Replacer
09506-87302-000 Replacer
09511-87202-00 Stopper, brake drum
09520-00031-000 Puller, axle shaft
09611-87701-000 Puller, tie-rod end
09648-87201-000 Replacer, drive shaft
09718-87702-000 Replacer, front disc
09722-87702-000 Attachment, camber
09727-87701-000 Compressor, spring
09950-10012-000 Tool set, replacer
09950-20017-000 Puller, universal
JFS00000-00088

DAIHATSU
J100
J100
REAR AXLE & SUSPENSION
REAR AXLE & SUSPENSION ........... RS 2 REAR AXLE SHAFT .......................... RS13
COMPONENTS ............................. RS 2 REMOVAL ..................................... RS13
PRIMARY INSPECTION ................ RS 3 DISASSEMBLY .............................. RS14
SHOCK ABSORBER ......................... RS 4 INSPECTION ................................. RS15
REMOVAL ..................................... RS 4 ASSEMBLY .................................... RS15
INSPECTION ................................. RS 4 INSTALLATION .............................. RS17
INSTALLATION .............................. RS 4 REAR AXLE SHAFT HOUSING ........ RS18
LATERAL CONTROL ROD ................ RS 6 REMOVAL ..................................... RS18
REMOVAL ..................................... RS 6 DISASSEMBLY .............................. RS19
INSPECTION ................................. RS 6 INSPECTION ................................. RS20
INSTALLATION .............................. RS 7 ASSEMBLY .................................... RS20
UPPER CONTROL ARM ................... RS 9 INSTALLATION .............................. RS21
REMOVAL ..................................... RS 9 TIGHTENING TORQUE ...................... RS23
INSPECTION ................................. RS 9 SST...................................................... RS23
INSTALLATION .............................. RS 9
LOWER CONTROL ARM ................... RS11
JRS00001-00000
RS
REMOVAL ..................................... RS11
INSPECTION ................................. RS11
INSTALLATION .............................. RS12
NO. 9710-JE

RS2
REAR AXLE & SUSPENSION
COMPONENTS
: Tightening torque
Unit : Nm (kgf-m)
q
w
49.0 - 88.3
(5.0 - 9.0)
e 6.9 - 15.7
(0.7 - 1.6)
t
y o !1 73.5 - 93.1
r i N (7.3 - 9.5)
u B
y B
t !0 !3
!4
N !5
!4
!3
B N
53.9 - 78.5
!2 (5.5 - 8.0)
B
N @0
B
!6
B
N !8 @1
@2
N
B @3
!6
@4
!7 B
!8 73.5 - 107.9 @5
B
(7.3 - 11.0)
!9
@6
q Upper rear spring seat !4 Bush

w Rear spring bumper !5 Shock absorber
e Coil spring !6 Bush
r Under rear spring seat !7 Upper control arm
t Plate !8 Bush
y Bush !9 Lower control arm
u Collar @0 Backing plate
i Lateral control rod @1 Rear axle shaft bearing inner retainer
o Dynamic dumper @2 Rear axle shaft bearing
!0 Bush @3 Shim
!1 Stay @4 Rear axle shaft bearing outer retainer
!2 Rear axle shaft housing @5 Rear axle shaft
!3 Plate @6 Hub bolt
JRS00002-00001

RS3
PRIMARY INSPECTION
Inspection of tire & wheel
1. Check that the wheel exhibits no breakage, cracks, dent,
and so forth.
2. Check the tire for wear, breakage and cracks. Also, check
that no foreign substance is embedded into the tire.
3. Inspect the air inflation pressure of the tires.
4. Inspect the runout of the tires. (Refer to the FS section.)

JRS00003-00000
Inspection of wheel bearing free play

2. Remove the rear wheels.
3. Perform the free play measurement at a point of the hub
edge with a dial gauge.
4. If the free play exceeds the allowable limit, replace the
rear axle bearing.
Allowable Limit
Axial Direction: 0.8 mm or less
Vertically Against Axial Direction: 0.1 mm or less JRS00004-00002
Inspection of rear axle shaft runout

3. Remove the brake drum. (Refer to the BR section.)
4. Perform the runout measurement at a point of the axle hub
outer edge.
5. If the runout exceeds the allowable limit, change the rear
axle shaft.
Runout Limit : 0.2 mm JRS00005-00003

RS4
SHOCK ABSORBER
REMOVAL
3. Remove the shock absorber attaching nuts.
NOTE:
At this stage, do not take out the bolt.
4. Lift the rear axle carrier, using a garage jack, so that no JRS00006-00004
tension may be applied to the shock absorber attaching
bolt. Under this condition, remove the shock absorber at-
taching bolt.
5. Remove the plates, bushes and shock absorber from the
shock absorber attaching stud bolt.
INSPECTION
Shock absorber
Check that the shock absorber exhibits no oil leakage nor
major scores by observing its external appearance.
Extend and contract the shock absorber by your hands.
During this operation, ensure that the shock absorber moves 305 mm
smoothly and that there is no abnormal resistance or rattle. 496 mm
Ensure that the maximum and minimum lengths conform to
the specified values.
Specified Length: Min: 305 mm
Max: 496 mm JRS00007-00005
If any damage or malfunction is exists, replace the part with

new one.
Upper bush and Plate

Bush
Check that the bush exhibits no breakage cracks, defor-
mation, and so forth.
Plate
Check that the plate exhibits no deformation, warpage,
and so forth. JRS00008-00006
Plate Bush Bush Plate

If any damage is exists, replace the part with new one.
INSTALLATION
1. Install the plate and bush to the shock absorber attaching
stud bolt.
Vehicle side Nut
CAUTION:
Assemble the plate and bush as indicated in the figure.
Sock absorber
JRS00009-00007

RS5
2. Install the shock absorber to the shock absorber attaching
stud bolt.
3. Install the bush and plate to the shock absorber attaching
stud bolt.
CAUTION:
Assemble the plate and bush, as indicated in the figure
in Step 1.
4. Temporarily tighten the shock absorber attaching nut.
JRS00010-00008
5. Lift the rear axle carrier, using a garage jack, so that the
installation section of the shock absorber may be aligned
with that of the lower control arm. Under this condition, in-
stall and temporarily tighten the shock absorber attaching
bolt.
CAUTION:
Make sure that the threaded portions of the bolts face
toward the vehicle outside.
JRS00011-00009
6. Install the rear wheels.

(9.0 - 12.0 kgf-m)

8. Rock the vehicle in an up-and-down direction several
times so that the suspension may be settled.
9. Tighten the sock absorber attaching bolt and nuts.
JRS00012-00010

RS6
LATERAL CONTROL ROD
REMOVAL
2. Remove the lateral control rod.
CAUTION:
Never reuse the removed nuts.
JRS00013-00011
3. Remove the dynamic dumper from the lateral control rod.
JRS00014-00012
INSPECTION
Lateral control rod
Check that the lateral control rod exhibits no warpage, defor-
mation and major scores.
If any damage is exists, replace the damaged part with new

one.
Check that the bush exhibits no cracks, breakage, deforma-
tion, and so forth.
Replace any abnormal bush.
JRS000015-00013
Dynamic dumper
Check that the rubber section exhibits no cracks, deforma-
tion, and so forth.

one.
JRS00016-00014
Bush, Plate and collar

Bush
Check that the bush exhibits no cracks, deformation, and
so forth.
Plate and collar
Check that the bush and collar exhibit no deformation,
warpage, and so forth.

one.
JRS00017-00015

RS7
Replacement of lateral control rod bush
1. Remove the bush, using a suitable tool in combination
25mm
35mm
with a hydraulic press.
NOTE:
Use a suitable tool, such as a tool indicated in the fig-
ure.
JRS00018-00016
R
2. Apply the Samper 107 to a new bush. Then, press-fit the
B
bush in the lateral control rod, using a suitable tool in com-
bination with a hydraulic press.
CAUTION:
Be very careful not to apply pressure to the inner
sleeve of the bush. Make sure that the difference in di-
mensions at the sections A and B is within 1 mm during
the press-fitting, as indicated in the figure.
A
JRS00019-00017
INSTALLATION
1. Install the dynamic dumper to the lateral control rod.
JRS00020-00018
2. Install the plate and bush to the lateral control rod attach-
ing stud bolt.
Plate
CAUTION:
Assemble the plate and bush, as indicated in the fig- Bush
ure.
Cdor
Bush
Plate Nut
JRS00021-00019
3. Install the lateral control rod to the lateral control rod at-
taching stud bolt. (Lower control arm attaching side)
4. Install the collar, bush and washer to the lateral control rod
attaching stud bolt. (Lower control arm attaching side.)
CAUTION:
Assemble the collar, bush and plate, as indicated in the
figure in Step 2.
5. Temporarily tighten the lateral control rod attaching nut.

(Lower control arm attaching side)
JRS00022-00020

RS8
5. Temporarily install the lateral control rod to the reinforce-
ment.
CAUTION:
Make sure that the threaded portions of the bolts face
toward the vehicle outside.
JRS00023-00021

8. Tighten the lateral control rod attaching nuts.
Tightening Torque:
Rear axle shaft housing side:
49.0 - 88.3 Nm (5.0 - 9.0 kgf-m)
Reinforcement side:
73.5 - 93.1 Nm (7.5 - 9.5 kgf-m)
JRS00024-00022

RS9
UPPER CONTROL ARM
REMOVAL
3. Retain the rear axle shaft housing, using a garage jack,
etc.
JRS00025-00023
4. Remove the speed sensor wire from the bracket at the

upper control arm. (Only for vehicles equipped with ABS)
5. Remove the upper control arm.
JRS00026-00024
INSPECTION
Upper control arm
Check that the upper control arm exhibits no warpage, defor-

one.
tion, and so forth.
JRS00027-00025
Replacement of upper control arm bush

For the replacement procedure for the bush, refer to the pro-
cedure for the lateral control rod bush, for the replacement
5mm
procedure is the same. However, care must be exercised so

that the difference in dimensions at the sections A and B of
the bush may become within 1 mm. Also, make sure that the
B
slit assumes the position indicated in the figure during the

press-fitting.
A
JRS00028-00026
INSTALLATION
1. Temporarily install the upper control arm.
CAUTION:
With regard to the bolts connecting the upper control
and rear axle shaft housing, make sure that the thread-
ed portions of the bolts face toward the vehicle outside.
JRS00029-00027

RS10
2. Install the rear wheels. (Refer to the RS5.)
5. Tighten the upper control arm attaching bolt and nut.
Tightening Torque:
73.5 - 107.9 Nm (7.5 - 11.0 kgf-m)
JRS00030-00028

RS11
LOWER CONTROL ARM
REMOVAL
3. Remove the brake cable from the bracket at the lower
control arm.
4. Loosen the bolts and nuts at the following sections: Lower
control arm shock absorber, lower control arm rear
axle shaft housing, and lower control arm body. JRS00031-00029
5. Lift the rear axle carrier, using a garage jack, so that no
tension may be applied to each bolt that has been loos-
ened in Step 4. Then, remove the lower control arm by re-
moving the bolts and nuts.
INSPECTION
Lower control arm
Check that the lower control arm exhibits no warpage, defor-

one.
tion, and so forth.
JRS00032-00030
Replacement of lower control arm bush

For the replacement procedure for the bush, refer to the pro-
B
cedure for the lateral control rod bush, for the replacement
procedure is the same.
A
JRS00033-00031

RS12
INSTALLATION
1. Temporarily install the lower control arm attaching bolts
and nuts.
CAUTION:
As regards the bolts connecting the lower control arm
to the shock absorber, and the lower control arm to the
rear axle shaft housing, make sure that the threaded
portions of the bolts face toward the vehicle outside.

3. Jack down the vehicle. JRS00034-00032

5. Tighten the lower control arm attaching bolts and nuts.
Tightening Torque:
lower control arm shock absorber :
53.9 - 78.5 Nm (5.5 - 8.0 kgf-m)
lower control arm rear axle shaft housing :
73.5 - 107.9 Nm (7.5 - 11.0 kgf-m)
lower control arm body :
73.5 - 107.9 Nm (7.5 - 11.0 kgf-m)
6. Connect the brake cable to the bracket at the lower control arm.
JRS00035-00000

RS13
REAR AXLE SHAFT
REMOVAL
3. Drain the rear differential oil. (Refer to the DF section.)
JRS00036-00033
4. Remove the rear brake drum. (Refer to the BR section.)
JRS00037-00034
5. Remove the rear axle shaft bearing outer retainer attach-

ing nuts, using the box wrench through the hole on the
rear axle hub.
JRS00038-00035
6. Remove the rear axle shaft assembly, using the following

SST.
SST : 09520-00031-000
CAUTION:
Be very careful not to damage the oil seal of the rear
axle shaft housing when removing the rear axle shaft.
7. Remove the shim.

CAUTION:
Never make damage on the shim during removal. JRS00039-00036

RS14
DISASSEMBLY Hand grinder
1. Clamp the rear axle shaft in a vice.
2. Grind off the rear axle shaft bearing inner retainer, using a
hand grinder or the like.
WARNING:
Be sure to observe the operation instructions by the
hand grinder manufacturer.
Be sure to wear goggles during the grinding operation.
CAUTION:
When grinding the retainer with a grinder, if the bearing JRS00040-00037
should be ground inadvertently, most likely the bearing

may break off during the vehicle running, (because this
bearing is a critical part that sustains fully the vehicle
weight.) Also a defective bearing could result in poor
sealing. Therefore, be certain to replace the bearing
with a new one.
Likewise, when the bearing inner race should be
ground inadvertently, also be sure to replace it with a
new one.
3. Split the retainer with a chisel and a hammer.

WARNING:
Before splitting the retainer with a chisel, be sure to
wear protective goggles and gloves.
4. Pull out the rear axle shaft bearing with the rear axle shaft
bearing inner retainer.
5. Remove the rear axle shaft outer retainer from the rear
axle shaft.
JRS00041-00000
6. Drive out the hub bolts from the rear axle shaft, using a
CAUTION:
Never reuse the removed hub bolts.
JRS00043-00040

RS15
INSPECTION
Rear axle shaft
1. Place the rear axle shaft on a V-block.
2. Ensure that the runout at the flange end surface is within
the allowable limit.
Maximum Allowable Limit: 0.2 mm
NOTE:
This maximum allowable runout does not include the
runout caused by roughness on the flange surface.
If the flange surface exhibits roughness, finish the sur- JRS00044-00041
face with an abrasive paper or the like.
3. Ensure that the runout at the center unmachined section is

within the allowable limit.
Maximum Allowable Limit: 1.5 mm
JRS00045-00042
4. Ensure that the rear axle shaft spline section exhibits no

damage, such as cracks and/or wear.
5. Ensure that the oil seal contact surface or rear axle shaft
exhibits no damage, such as cracks, scores and/or rust.
If any damage is exists, replace the damaged part with

new one.
JRS00046-00043
ASSEMBLY
1. Install the hub bolt to the rear axle shaft.
JRS00047-00044
2. Install the rear axle shaft bearing outer retainer to the rear
axle shaft.
3. Install the rear axle shaft bearing to the rear axle shaft,
using a hydraulic press.
SST
JRS00048-00045

RS16
4. Installation of rear axle shaft bearing inner retainer.
Inner retainer
(1) Heat the retainer to 150 15C in an oil bath. 150C
NOTE:
Perform this operation promptly before the retainer
temperature drops. Oil bath
When the temperature exceeds 150 15C, the sur-
face of the retainer will be turned to yellow. In this case,
be careful not to heat the retainer any further.
WARNING:
Special attention must be paid not to burn yourself. JRS00049-00046
(2) Install a new retainer to the rear axle shaft, using a hy-
draulic press.
JRS00050-00000
Replacement of rear axle shaft housing oil seal

1. Remove the rear axle shaft housing oil seal, using the fol-
lowing SST.
SST : 09308-00010-000
JRS00051-00048
2. Install a new oil seal to the rear axle shaft housing, using
the following SST.
SST : 09517-12010-000
CAUTION:
Make sure that the oil seal assumes the position indi-
cated in the figure. 4.80.5
3. Apply lithium-based multi purpose grease to the lip sec-

tion of the installed oil seal.
JRS00052-00049

RS17
INSTALLATION
1. Apply Three BondR 11040 or relevant to both sides of the
shim, as indicated in the figure.
CAUTION:
Do not apply sealer to the drain hole.
As regards the rear axle shaft bearing shim, the thick-
ness of the shim has been determined according to the
thickness of the backing plate. Therefore, be sure to
select a shim having the same thickness as that of the
removed shim. (For selection of the rear axle bearing
shim, refer to the BR section.) JRS00053-00050
2. Install the rear axle shaft bearing shim to the backing

plate.
3. Install the rear axle shaft to the rear axle shaft housing.
CAUTION:
Be very careful not to damage the rear axle shaft hous-
ing oil seal by the spline section of the rear axle shaft.
Care must be exercised so that the rear differential
may not be damaged when inserting the rear axle
shaft. Never insert it forcibly.
JRS00054-00051
4. Tighten the attaching nuts of the rear axle shaft.

5. Install the brake drum to the backing plate.

6. Fill the differential oil. (Refer to the DF section.)
JRS00055-00052

RS18
REAR AXLE SHAFT HOUSING
REMOVAL
1. Drain the brake fluid. (Refer to the BR section.)
4. Drain the differential oil. (Refer to the DF section.)
5. Remove the brake drum. (Refer to the BR section.)
6. Remove the rear axle shaft. (Refer to the REAR AXLE
SHAFT section.) JRS00056-00053
7. Disconnect the brake tube from the backing plate.
CAUTION:
Since the brake fluid flows out, be very careful not to
get the fluid to your hands. Also, care must be exer-
cised so that the fluid may not get to other parts.
8. Remove the ABS sensor from the backing plate. (Only for
vehicles equipped with ABS)
9. Remove the backing plate from the rear axle housing.

NOTE:
If any difficulty is encountered in removing the backing
plate, prior to the removal, lightly tap the backing plate,
using a plastic hammer or the like.
Leave the backing plate suspended, as indicated in the
figure.
JRS00057-00054
10. Remove the rear propeller shaft. (Refer to the PR section.)
JRS00058-00055
11. Disconnect the brake tube from the brake hose at the rear
axle shaft housing.
CAUTION:
Since the brake fluid flows out, be very careful not to
get the fluid to your hands. Also, care must be exer-
cised so that the fluid may not get to other parts.
12. Disconnect the brake hose from the bracket by removing

the E-ring.
JRS00059-00056

RS19
13. Remove the lateral control rod and upper control arm so
that the rear axle shaft housing may be retained by the
lower control arm and shock absorber. (Refer to the LAT-
ERAL CONTROL ROD, UPPER CONTROL ARM section.)
14. Retain the rear axle shaft housing with a garage jack, etc.
Under this condition, remove the shock absorber and
lower control arm.
15. Remove the coil spring.
JRS00060-00057
16. Take out the rear axle shaft housing.
JRS00061-00058
17. Remove the rear spring bumper from the body.

18. Remove the upper rear spring seat from the body.
JRS00062-00059
DISASSEMBLY
1. Remove the under rear spring seat from the rear axle shaft
housing.
2. Remove the brake tube from the rear axle shaft housing.
JRS00063-00060
3. Remove the breather plug oil deflector from the rear axle
shaft housing.
4. Remove the rear differential carrier assembly from the rear
axle shaft housing. (Refer to the DF section.)
JRS00064-00061

RS20
INSPECTION
Rear axle shaft housing
Check that the external appearance of the rear axle shaft
housing exhibits no major dent and scores. Also, check that
the lateral control rod attaching stud bolt exhibits no scores.

one.
Replace the oil seal, if necessary. (For the changing proce-
dure, refer to the RS16.)
JRS00065-00062
Coil spring
Ensure that the coil spring is free from deformation, deteriora-
tion, crack or other damage.

one.
JRS00066-00063
Upper and under rear spring seats and rear spring bumper
Ensure that the upper and under rear spring seats and rear
spring bumper free from cracks, deterioration, aging and
other damage.

one.
JRS00067-00064
ASSEMBLY
1. Install the rear differential carrier assembly to the rear axle
shaft housing. (Refer to the DF section.)
2. Install the breather plug oil deflector to the rear axle shaft
housing.
JRS00068-00065
3. Install the brake tube to the rear axle shaft housing.

4. Install the under rear spring seat to the rear axle shaft
housing.
JRS00069-00066

RS21
INSTALLATION
1. Install the rear spring bumper to the body.
2. Install the upper rear spring seat to the body.
JRS00070-00067
3. Put the coil spring on the spring seat. Then, lift the rear
axle shaft housing to an appropriate height, using a
garage jack or the like.
NOTE:
Set the coil spring in such a way that the marking
comes at the lower side, as viewed from the rear side
of the vehicle.
Be sure to insert the coil spring into the specified posi-
tion when lifting the rear axle shaft housing, using a
garage jack.
JRS00071-00068
4. Temporarily install the lateral control rod, upper control

arm, lower control arm and shock absorber.
5. Install the rear propeller shaft. (Refer to the PR section.)
JRS00072-00069
6. Connect the brake hose to the bracket with the E-ring.

7. Connect the brake tube to the brake hose
JRS00073-00070
8. Installation of backing plate

(1) Apply silicon bond No. 1212 or relevant to the housing
end, as indicated in the figure.
(2) Install the backing plate to the rear axle shaft.
JRS00074-00071

RS22
9. Install the rear axle shaft. (Refer to the REAR AXLE
SHAFT section.)
10. Connect the brake tube to the backing plate.
Tightening Toque : 12.8 - 17.6 Nm (1.3 - 1.8 kgf-m)
11. Connect the brake hose to the bracket of the upper con-
trol arm.
12. Install the ABS sensor to the backing plate.
JRS00075-00072
13. Install the brake drum.
JRS00076-00073
14. Fill the differential oil. (Refer to the DF section.)

15. Install the rear Wheel. (Refer to the RS5.)
18. Securely tighten the attaching bolts and nuts of the lateral
control rod, upper control rod, lower control rod and shock
absorber. (For the tightening torque and tightening proce-
dure, refer to the relevant sections.)
19. Fill the brake oil. (Refer to the MA section.)
JRS00077-00000

RS23
TIGHTENING TORQUE
Components Nm kgf-m
Shock absorber Body 53.9 - 78.5 5.5 - 8.0
Shock absorber Lower control arm 53.9 - 78.5 5.5 - 8.0
Lateral control rod Dynamic dumper 6.9 - 15.7 0.7 - 1.6
Lateral control rod Rear axle shaft housing 49.0 - 88.3 5.0 - 9.0
Lateral control rod Stay 73.5 - 93.1 7.5 - 9.5
Upper control arm Body 73.5 - 107.9 7.5 - 11.0
Upper control arm Rear axle shaft housing 73.5 - 107.9 7.5 - 11.0
Lower control arm Rear axle shaft housing 73.5 - 107.9 7.5 - 11.0
Lower control arm Body 73.5 - 107.9 7.5 - 11.0
Rear axle shaft Backing plate 53.9 - 68.6 5.5 - 7.0
At the rear axle
Brake tube Brake hose 12.8 - 17.6 1.3 - 1.8 shaft housing
Brake tube Backing plate 12.8 - 17.6 1.3 - 1.8
JRS00078-00000
SST
09520-00031-000 Puller, rear axle shaft
09308-00010-000 Puller, oil seal
09517-12010-000 Replacer, oil seal
JRS00079-00000

DAIHATSU
J100
BRAKES
BASIC CHECK ............................................ BR 2

BRAKE PEDAL ........................................... BR 5
BRAKE MASTER CYLINDER .................... BR 7
BRAKE BOOSTER ..................................... BR13
FRONT BRAKE ........................................... BR16
REAR BRAKE ............................................. BR22
PARKING BRAKE ....................................... BR30
PROPORTIONING VALVE .......................... BR33
BRAKE HOSE ............................................. BR34
ANTI-LOCK BRAKE SYSTEM ................... BR36
JABS CIRCUIT DIAGNOSIS ..................... BR37
ABS RELATED CONNECTORS ............... BR38
ABS CIRCUIT CONNECTION TABLE ...... BR40
PRECAUTIONS ......................................... BR42
TROUBLE SHOOTING HINTS .................. BR44
HOW TO PROCEED TROUBLE
SHOOTING ............................................ BR45
BR
DIAGNOSIS CODE CHECK ...................... BR46
UNIT INSPECTION & REPLACEMENT .... BR70
TIGHTENING TORQUE ............................ BR91
SSTs .......................................................... BR92
JBR00001-00000
NO. 9710-JE

BR2
BASIC CHECK
BRAKE PEDAL
1. Ensure that the brake pedal height is with in specified
valve by measuring the brake pedal height.
Specified Value: 162.8 mm (*155.8 mm)
CAUTION:
* Mark denote brake pedal height between upper sur- Cushion
face of brake pedal pad and upper surface of protrude
section of floor panel.
2. Pedal height adjustment Pad
(1) Disconnect the connector from the stop lamp switch.
(2) Slacken the nut of the stop lamp switch and screw out the
stop lamp switch, until the brake pedal has a free travel.
(3) Slacken the lock nut of the brake pedal clevis. Turn the
push rod so as to adjust the pedal height to the speci-
fied value.
(4) Tighten the lock nut of the brake pedal clevis to the
JBR00002-00001
(5) Screw in the stop lamp switch, until the clearance betw-
een the brake pedal cushion and the edge of the thread-
ed portion of the stop lamp switch becomes 1.5 mm.
(6) Tighten the lock nut of the stop lamp switch to the
(7) Connect the connector of the stop lamp switch.Then,
proceed to the brake pedal free play check.
3. Pedal free play check Pedal free play
(1) After turning off the engine, depress the brake pedal JBR00003-00002
several times so that no vacuum may remain in the
brake booster.
(2) Measure the brake pedal free play by pushing the brake
pedal lightly by hand. Here, the brake pedal free play
means the distance from a point where the brake pedal
is free to a point where you begin to feel a resistance.
Specified Value: 0.5 - 2 mm
(3) Ensure that the free play is within the specified value.
If the brake pedal free play fails to meet the specified
value, adjust the brake pedal free play to the specified Lock nut
value.
4. Pedal free play adjustment
(1) Slacken the nut of the brake pedal clevis.
(2) Turn the push rod so as to adjust the pedal free play to
Specified Value: 0.5 - 2 mm
(3) Tighten the lock nut of the brake pedal clevis.

(4) Ensure that the brake pedal height is within the speci-
fied value and the stop lamp functions properly. JBR00004-00003

BR3
5. Pedal reserve travel check
(1) Start the engine and run the engine at idling.
(2) Depress the brake pedal with a pedal applying force
of 300 N (30kgf) with the parking brake lever returned.
(3) Measure the distance between the upper surface of
brake pedal pad center and the upper surface of pro-
trude section of floor panel.
Specified Value: 85 mm or more
JBR00005-00004
BOOSTER
IN-VEHICLE CHECK
1. Booster air-tight performance check
(2) Turn off the engine after a few minutes.
(3) Ensure that the position of the brake pedal height pro-
gressively rises every time the brake pedal is de-
pressed. 3rd application
2nd application
If the position of the brake pedal rises progressively at 1st application
the second and third applications, it indicates the
brake booster is functioning properly. JBR00006-00005
CAUTION:
Be sure to keep intervals of each application of the
brake pedal at least five seconds or more between the
first and second applications as well as the second and
third applications.
2. Booster air-tight performance check under loaded condi-

tion While the engine The pedal is held
is running. for 30 seconds
(1) Start the engine. after the engine
(2) Depress the brake pedal fully. is stopped.
(3) Turn off the engine while depressing the brake pedal.
(4) Ensure that the brake pedal height remains un-
changed for more than 30 seconds. It indicates that
the booster is functioning properly. Bad
JBR00007-00006
3. Booster operation check

(1) Depress the brake pedal several times under the en-
gine stopped state, until the brake pedal height will no
longer change (to release the vacuum pressure re-
tained in the brake booster).
(2) Ensure that the height of the brake pedal will go down
when the engine is started while keeping the depress-
ing force of the brake pedal unchanged.
It indicates that the booster is functioning properly.
JBR00008-00007

BR4
4. Booster air-tight performance check under loaded condition
(1) Connect a negative pressure gauge to the booster, 4
5
3
using a T or Y pipe joint. 2 6
(2) Start the engine with the brake pedal depressed with a 1 7
x100mmHg
T pipe joint
force of 200 N.
(3) Stop the engine when the negative pressure exceeds
500 mmHg.
(4) Ensure that the negative pressure retained in the brake
booster will not drop 25 mmHg or more for 15 seconds
since the engine is stopped.
It means that the air tightness is proper. If not, check air JBR00009-00008
leakage of the check valve in the brake booster hose.
AIR BLEEDING
1. Fill and maintain the brake fluid level in the reservoir tank
at the upper level during the operation.
NOTE:
finish surface of the vehicle or resin-made parts, imme-
diately wipe off the brake fluid and flush with fresh water.
When drain the brake fluid, do not fill brake fluid into
the reservoir tank. JBR00010-00009
Front
2. Connection of vinyl hose to bleeder plug of wheel cylinder
Connect a suitable vinyl or rubber hose to the bleeder
plug of the wheel cylinder and submerge one end of the
vinyl or rubber hose in a container filled with the brake
fluid. Connect the other end of the vinyl hose to the wheel
cylinder bleeder plug of the vehicle.
NOTE:
Start the air bleeding operation at the wheel cylinder
which is located at the furthermost point from the mas-
ter cylinder. JBR00011-000010
Rear
3. Air bleeding
(1) Perform the operation by two persons. One person
should depress the brake pedal slowly and hold it in a
depressed state.
(2) While depressing the brake pedal, the other person
slackens the bleeder plug 1/3 through 1/2 turn to drain
the brake fluid. Then, tighten the bleeder plug tem-
porarily.
(3) Repeat the steps (1) and (2) above, until bubbles are
no longer observed in the fluid. JBR00012-00011
NOTE:
It may require more time than the ordinary brake sys-
tem if the vehicle is equipped with ABS.
(4) Tighten the bleeder plug securely to the specified tighten-

ing torque.
4. Checking of brake fluid leakage

Ensure that no brake fluid leakage exists on the brake line
when the brake pedal is depressed fully.
BR5
BRAKE PEDAL
COMPONENTS
N
B
N
B
q Brake pedal subassembly

w Brake pedal pad
e Cushion NOTE:
r Brake pedal bracket : The brake pedal shaft installed from right
t Brake pedal shaft side when model with left hand drive.
y Pedal bracket stay Contrary, the brake pedal shaft installed
u Bush from left side when model with right hand
i Spring drive.
JBR00013-00012
REMOVAL
1. Remove the instrument panel. (Only when the brake pedal bracket removal is required)
(Refer to the BO section.)
2. Disconnect the connector from the stop lamp switch while unlocking its lock.
3. Remove the stop lamp switch by screwing it out.
4. Disengage the clutch cable from the clutch pedal. (Only for models with manual transmission.)
5. Remove the clip and pin from the brake pedal clevis.
6. Disconnect the wire harness clamp from the brake pedal bracket.
7. Remove the brake pedal bracket by removing the attaching bolts and nuts.
8. Remove the brake pedal by removing its attaching bolts and nuts.
7. Remove the spring from the brake pedal.
8. Remove the bushes from the brake pedal.
9. Remove the brake pedal pad and cushion from the brake pedal.
JBR00014-00000

BR6
10. Inspect the following parts.
Damage or deformation
N
Wear or damage
Wear or damage
Wear or damage
Wear or damage
Bend or twist
Damage or deformation
JBR00015-00013
INSTALLATION
1. Apply the specified grease to those points indicated in the
right figure. Both inside and
Specified Grease: outside
Lithium soap base multi-purpose grease
2. Install the cushion, brake pedal pad, bushes and spring to Inside
the brake pedal.
Both inside and
outside
JBR00016-00014
3. Install the brake pedal on the brake pedal bracket.

4. Install the brake pedal to the brake pedal bracket while connecting the spring end to the brake pedal
bracket with the brake pedal shaft and nut. Then, tighten the nut to the specified tightening torque.
5. Apply the lithium soap base multi-purpose grease to the clevis pin contacting surface of the brake
pedal.
6. Connect the clevis to the brake pedal with the pin and install the clip to the pin securely.
7. Install the brake pedal bracket to the body with the pedal bracket stay, attaching bolts and nuts.
8. Screw in the stop lamp switch to the brake pedal bracket. (Refer to the Brake pedal section.)
9. Perform the check and adjustment of the brake pedal. (Refer to the Brake pedal section.)
10. Install the instrument panel. (Refer to BO section.)
11. Check that no abnormal noise is emitted when the brake papal is depressed.
JBR00017-00000

BR7
BRAKE MASTER CYLINDER
COMPONENTS
B
q
For conventional model only.

y
NOTE: For ABS model
q Brake master cylinder reservoir tank

w Reservoir filler cap
e Reservoir diaphragm
r Grommet
t Brake master cylinder assembly
y Tandem master cylinder repair kit
JBR00018-00015
REMOVAL
1. Disconnect the connector of the brake fluid level switch.
2. Drain the brake fluid from the master cylinder.
(Refer to the Air bleeding section for procedure.)
3. Disconnect the brake pipes from the master cylinder.
CAUTION:
finish surface of the vehicle or resin-made parts, imme-
water.
JBR00019-00016

BR8
4. Remove the master cylinder from the brake booster.
NOTE:
The O-ring is installed on the master cylinder.
It may be hard to remove the master cylinder from the
brake booster.
5. Secure the master cylinder to a vise.
JBR00020-00017
6. Remove the slotted pin of the master cylinder reservoir

tank, using a suitable knock pin punch.
7. Pull out the brake master cylinder reservoir tank from the
master cylinder.
JBR00021-00018
8. Remove the grommets from the master cylinder or reser-

voir tank.
JBR00022-00019
9. Remove the set bolt and gasket while the pistons are
being pushed fully by means of a suitable bar.
(Only when equipped)
NOTE:
Do not push the piston rapidly in order to prevent the
brake fluid from splashing.
JBR00023-00020
10. Using snap ring pliers, detach the snap ring while the pis-
tons are being pushed by means of a suitable bar.
JBR00024-00021

BR9
11. Remove the piston No. 1 from the master cylinder.
CAUTION:
Remove the piston straight, being very careful not to
scratch the cylinder bore.
12. Remove the piston No. 2 by lightly applying compressed

air at the brake pipe hole.
WARNING:
Be sure to protect your eyes by wearing safety gog-
gles, when using compressed air.
JBR00025-00022
CAUTION:
Never score the cylinder bore during the removal of the
piston No. 2.
Remove the piston in a straight direction.
NOTE:
Be sure to prevent the brake fluid from splashing, using
a piece of cloth or the like.
13. Inspect the following parts. If any problem is found, repair them, as required.
Damage, deformation Damage, deformation

or deterioration or deterioration
Cylinder bore for

uneven wear
Damage, deformation
or deterioration
Damage or deterioration Damage or corrosion
JBR00026-00023
ASSEMBLY
1. Wash the master cylinder and components with washing
solvent and dry them with compressed air.
WARNING:
JBR00027-00024

BR10
2. Thinly apply brake rubber grease to the lip section of the
cups of the piston No. 2 assembly.
3. Install the piston No. 2 into the master cylinder.
JBR00028-00025

cups and O-ring on the piston No. 1 assembly.
5. Install the piston No. 1 assembly into the master cylinder.
6. Install a new snap ring while pushing the piston No. 1 into
the master cylinder, using snap ring pliers.
WARNING:
Never reuse the removed snap ring.
JBR00029-00026
7. Install the set bolt of the piston No. 2 assembly to the mas-
ter cylinder with a new gasket interposed while pushing
the piston No. 2.
JBR00030-00027
8. Thinly apply brake rubber grease to the grommets.

9. Install the grommets to the master cylinder.
JBR00031-00028
10. Install the brake master cylinder reservoir tank to the mas-
ter cylinder.
11. Secure the master cylinder reservoir tank to the master
cylinder by installing a new slotted pin.
CAUTION:
Never reuse the used slotted pin.
JBR00032-00029

BR11
INSTALLATION
1. Check the clearance between the master cylinder and the
brake booster push rod.
(1) Prepare the following SSTs.
SST: 09730-87401-000
09737-87003-000q
09733-87401-000w
09731-87401-000e
09732-87401-000r
09734-87401-000t
09735-87401-000y JBR00033-00000
O-ring
(2) Assemble the components of the above SSTs as fol-
lows.
q Install the O-ring (w) to the O-ring groove of the
adjusting rod(q).
w Install the attachment (e) on the adjusting rod
(q). Attachment
e Thinly apply the brake rubber grease to the outer
surface of the attachment (e).
JBR00034-00030
(3) Install the O-ring (t) and O-ring (y) to the adapter
(r) and apply the brake rubber grease to the O-rings.
(4) Install the adapter (r) to the brake booster.
Adapter
JBR00035-00031
(5) Attach the SST assembled in step (2) on the master

cylinder.
(6) Turn the adjusting rod to adjust the clearance between
the SST and the piston rod end to zero.
JBR00036-00032
(7) Set the SST on the brake booster as shown.

Attachment
NOTE:
Apply brake rubber grease to the attaching section of
the SST.
Push
rod
(8) Connect a Mity Vac to the brake booster.
(9) Apply a vacuum of 500 mmHg to the booster housing,
using the Mity Vac.
Adapter
(10) Ensure that the clearance between the SST and the
piston rod is zero by turning the adjusting rod lightly.
JBR00037-00033

BR12
WARNING:
Be sure to adjust the clearance properly. Failure to ob-
serve this warning may lead to brake system problem.
NOTE:
the clearance between the SST and the push rod of the
brake booster to zero, by turning the adjusting tip pro-
vided at the top of the push rod of the brake booster.
JBR00038-00000
(11) Adjustment of brake booster push rod height

Adjust the brake booster push rod height while de-
pressing the brake pedal fully.
(12) Ensure that the clearance between the push rod and
the SST is zero.
WARNING:
Be sure to adjust the clearance properly. Failure to ob-
serve this warning may lead to brake system problem.
(13) Remove the SST from the brake booster.

(14) Remove the Mity Vac from the brake booster. JBR00039-00034
(15) Connect the vacuum hose to the brake booster.

2. Thinly apply brake rubber grease to the oil seal on the
master cylinder piston shaft.
3. Install the master cylinder to the brake booster with attach-
ing nuts. Tighten the attaching nuts evenly to the specified
tightening torque.
WARNING:
Be sure to perform the adjustment of the brake booster
push rod height, if any inner part of the master cylinder JBR00040-00000
has been replaced.

Failure to observe this warning may lead to damage or
malfunction of the brake system.
4. Temporarily connect the brake pipes to the master cylin-

der and tighten the flare nuts to the specified tightening
torque.
JBR00041-00035
5. Connect the brake fluid level switch connector.

6. Perform air bleeding for the brake system.
7. Ensure that no fluid leakage exists on the brake system.
8. Perform the checks and adjustments of the brake pedal
height. (Refer to the brake papal section.)
9. Check the brake fluid leakage on the brake system.
JBR00042-00036

BR13
BRAKE BOOSTER
COMPONENTS
RHD
e

t
N
r

t y q
LHD

r t
u
i
u

t t
y
o

e

t
q Brake booster assembly

w Master cylinder push rod clevis w
e Brake booster bracket gasket
r Union to connector tube q
t Clip
y Union
u Intake manifold tube clamp
i Intake manifold to connector tube
o Union to check valve hose
JBR00043-00037
REMOVAL
1. Remove the brake master cylinder.
(Refer to the Brake master cylinder section for removal.)
CAUTION:
If the brake fluid is spilled inadvertently over the paint
finish surface of the vehicle or resin part, immediately
wipe off the brake fluid and wash with fresh water.
2. Remove the vacuum hose from the vehicle.
JBR00044-00038

BR14
3. Remove the instrument finish lower panel by removing the
two attaching bolts.
JBR00045-00039
4. Remove the clip of the push rod clevis pin.

5. Remove the push rod clevis pin.
6. Loosen the brake booster attaching nuts evenly.
7. Remove the brake booster attaching nuts.
8. Remove the brake booster from the dash panel.
CAUTION:
Be very careful not to deform the brake tubes during
the removal of the brake booster.
INSPECTION JBR00046-00040
1. Inspection of check valve (vacuum hose)

Engine side
Check that continuity exists from the booster side to the
engine side. Also, check that no continuity exists from the
engine side to the booster side.
If the inspection results are not satisfactory, replace the
vacuum hose.
2. Inspection of booster push rod-to-master cylinder clear-
ance
Check the clearance of the brake booster push rod.
(Refer to the Brake master cylinder section.)
JBR00047-00041
INSTALLATION
1. Install the brake booster to the dash panel with a new
brake booster bracket gasket interposed.
2. Install the attaching nuts and tighten them to the specified
tightening torque.
CAUTION:
Care must be exercised so that the brake tubes may
not be interfered with the brake pedal during the instal-
lation. JBR00048-00000
3. Connect the clevis and brake pedal with the clevis pin.
If any difficulty is encountered in installing the clevis pin,
loosen the lock nut of the clevis and adjust the length of
the push rod of the brake booster by turning the brake
booster push rod or clevis.
4. Apply chassis grease to the sliding surface of the compo-
nents.
5. Install a new clip to the clevis pin.
6. Perform the check and adjustment of the brake pedal.
(Refer to the Brake pedal section.) JBR00049-00042

BR15
6. Install the instrument finish lower panel and install two at-
taching screws.
7. Install the brake master cylinder.
(Refer to the brake master cylinder section for installation.)
CAUTION:
Be sure to follow the installation procedure for the
brake master cylinder described in the above men-
tioned section. Failure to observe this caution may lead
to serious accidents or problems.
8. Perform the air bleeding.

(Refer to BR4.)
9. Check the brake performance with a four-wheel brake
tester.
JBR00050-00000

BR16
FRONT BRAKE
COMPONENTS
!3

!2
o
w
!1
!0 y i
r
e
q Main cylinder slide pin t

w Sub-cylinder slide pin
e Disc brake No. 1 pad
r Disc brake No. 2 pad
t Anti-squeal shim
y Shim
u Disc brake pad guide No. 2 plate
i Disc brake pad guide plate
o Disc brake cylinder mounting (R, L)
!0 Cylinder boot
!1 Front disc brake piston
!2 Piston seal
!3 Pin boot
JBR00051-00043
INSPECTION
stands. (Refer to the GI section.)
3. Check the pad thickness through the inspection hole pro-
vided at the disc brake caliper as shown.
Specified Thickness: 10 mm
If the brake pad thickness is less than the specified value

or the wear indicator emits a warning sound, replace the JBR00052-00044
brake pad with a new one.

CAUTION:
Be sure to replace the right and left side brake pads as
a set. Failure to observe this caution may lead to side
pull of the brake function.

BR17
REMOVAL
NOTE:
The replacement procedure of the brake pads is not
mentioned in this service manual. Refer to the proce-
dure which is necessary to replace the brake pads.

stands. (Refer to the GI section.)
3. Drain the brake fluid from the front brake line. JBR00053-00000
(When only necessary. Refer to the Air bleeding section.)
4. Disconnect the brake hose from the disc brake cylinder by

removing the union bolt and gasket. (When necessary)
5. Loosen the cylinder slide pins.
6. Remove the cylinder slide sub pin.
JBR00054-00045
7. Turn up the disc brake assembly as shown.

CAUTION:
Be very careful not to pull the brake hoses more than
necessary.
8. Remove the disc brake cylinder assembly from the disc

brake cylinder mounting.
JBR00055-00046
9. Detach the following parts from the disc brake cylinder

mounting.
(1) Disc brake pad
(2) Anti-squeal shims No. 1 and No. 2
(3) Brake pad guide plates No. 1 and No. 2
10. Inspection of brake pad-related parts
Ensure that the disc brake pad-related parts are free from
damage, deformation, deterioration or corrosion.
If any damage is found, replace the damaged part with a
new one.
CAUTION: JBR00056-00047
Replace the brake pad when damage or uneven wear

exists.
Replace the right and left side brake pads as a set
when replacing the brake pads. Failure to observe this
caution may lead to side pull of the brake function.
Be sure to perform the brake pad replacement one side
by one side. Failure to observe this caution may cause
the piston to jump out.

BR18
11. Ensure that the disc rotor thickness is more than that
specified value by means of vernier calipers.
Inspect the disc rotor thickness.
Specified Thickness: 16 mm
JBR00057-00048
12. Inspection of disc rotor runout

(1) Secure the disc rotor with hub nuts properly.
CAUTION:
Be sure to use suitable hub nuts if the hub is of a deco-
rated type.
(2) Ensure that the wheel bearings exhibit no looseness.

If an excessive play is found, replace the wheel bear-
ings.
(3) Ensure that the disc rotor runout is within the specified
value, using a dial gauge. JBR00058-00049
Maximum disc runout: 0.10 mm
CAUTION:
Be sure to check the runout at a point 10 mm inward
from the outer edge of the disc rotor.
If the measured runout exceeds the allowable limit, re-

place the disc with a new one.
13. Remove the pin boots from the disc brake cylinder mount-
ing.
14. Remove the disc brake cylinder mounting by removing the
attaching bolts.
15. Remove the disc rotor.
Disassembly of front disc brake cylinder assembly JBR00059-00050
1. Removal of brake piston

Apply compressed air gradually to the brake hose con-
necting hole of the disc brake cylinder assembly while a
piece of cloth is placed at the piston end side, in order to
prevent the piston from getting damaged and to prevent
the brake fluid from splashing.
WARNING:
Utmost care must be exercised so that your fingers or
hands may not be pinched by the piston end.
Be sure to protect your eyes by wearing safety goggles
when using compressed air. JBR00060-00051

BR19
2. Remove the cylinder boot from the cylinder.
JBR00061-00052
3 Detach the piston seal from the cylinder, using a suitable

minor screwdriver or the like.
CAUTION:
Be very careful not to score the cylinder bore wall, etc.
during the removal.
Assembly of front disc brake cylinder assembly

JBR00062-00053
NOTE:
The assembly procedure is basically reverse to the dis-
assembly procedure. Therefore, some illustrations are
not mentioned in this installation procedure.
Please refer to the illustration mentioned in the disas-
sembly procedure if any difficulty is encountered.
JBR00063-00000
1. Assembly of front brake cylinder assembly

(1) Wash the disc brake cylinder and related parts, except
rubber parts, with washing solvent and dry them with
compressed air.
WARNING:
If any damage, deformation, deterioration or wear exists
on the components, replace the parts with new ones.
CAUTION:
Replace the rubber parts with new ones.
(2) Thinly apply brake rubber grease to the cylinder wall

and the piston seal. JBR00064-00054
(3) Insert the piston seal to the groove in the disc brake
cylinder.
(4) Thinly apply brake rubber grease to the piston and
boot.
(5) Install the outer end of the boot to the groove in the
cylinder.
(6) Insert the piston into cylinder through the boot, making
sure that the piston is not tilted during the installation.
WARNING:
Never score or damage the piston seal, boots, piston
and cylinder during the installation. JBR00065-00055

BR20
(7) Insert the outer end of the boot to the groove provided
on the piston properly.
CAUTION:
Never score or damage the boots.
(8) Install the cylinder main pin to the disc brake cylinder
assembly by hand.
JBR00066-00056
INSTALLATION
NOTE:
The installation procedure is basically reverse to the removal procedure. Therefore, some illustra-
tions are not mentioned in this installation procedure.
Please refer to the illustration mentioned in the disassembly procedure if any difficulty is encoun-
tered.
JBR00067-00000
1. Install the disc rotor on the front hub.

CAUTION:
Be sure to clean the disc rotor attaching surface of the front hub and disc rotor before assembly.
2. Install the disc brake cylinder mounting with the attaching bolts and tighten the attaching bolts to the
Tightening Torque: 90.2 -135.3 Nm (9.2 - 13.8 kgf-m)
3. Thinly apply the brake rubber grease to the pin boots.

4. Install the pin boots to the disc brake cylinder mounting.
NOTE:
Install the sub-cylinder slide pin boot, using the sub-cylinder slide pin.
5. Install the disc brake pad guide plates on the disc brake cylinder mounting.
6. Install the brake pads, anti-squeal shims and shims to the disc brake cylinder mounting.
7. Thinly apply the brake rubber grease to the sliding surface of the cylinder slide main pin.
8. Install the disc brake cylinder assembly to the disc brake cylinder mounting.
9. Turn over the disc brake assembly onto the disc brake pads, anti-squeal shims and shim while the pin
boots of the sub-cylinder slide pin are being pushed by fingers.
CAUTION:
Be very careful not to pull the brake hoses more than necessary. (When the brake hose is not dis-
connected)
Be very careful not to damage the pin boots during the assembly.
Care must be exercised so that the brake cylinder may not be interfered with the disc brake pads,
anti-squeal shims and shim during the installation.
JBR00068-00000

BR21
10. Thinly apply the brake rubber grease to the sliding surface
of the sub-cylinder slide pin.
11. Install the sub-cylinder slide pin of the disc brake cylinder
assembly to the disc brake mounting.
CAUTION:
Be very careful not to damage the pin boot during the
assembly.
JBR00069-00057
12. Tighten the main and sub cylinder slide pins to the speci-
Tightening Torque:
Main: 78.5 - 88.3 Nm (8.0 - 9.0 kgf-m)
Sub: 44.1 - 53.9 Nm (4.5 - 5.5 kgf-m)
13. Connect the brake hose to the disc brake cylinder assem-
bly by the union bolt with new gaskets interposed.
14. Tighten the union bolt to the specified tightening torque.
NOTE:
Make sure that the brake hose is not twisted or
stretched.
After completion of the installation, turn the steering
wheel from lock to lock position. Make sure that the
brake hose is not interfered with other parts.
15. Perform the air bleeding for the brake line.

(Refer to the Air bleeding section.)
16. Ensure that no fluid leakage is present on the brake hose
connected section and parts between the disc brake
cylinder and the disc brake piston.
18. Depress the brake pedal more than 10 times.
19. Check to see if the brake disc can rotate smoothly.
20. Ensure that no abnormal sound is emitted or no drag ex-
ists when the wheel is rotated.
21. Check the brake performance with a brake tester.
JBR00070-00000

BR22
REAR BRAKE
COMPONENTS
: Tightening torque
Unit : Nm (kgf-m)
9.8 2 (1.0 0.2) !3

!6
!2
B !4 !5
!5 !5 !2 !4
!1
e o
61 7 (6.25 0.75) i
r

!0 u

t y
o w
q Brake drum subassembly
w Shoe hold-down spring & retainer
e Shoe hold-down spring pin q
r Tension No. 4 spring
t Tension No. 3 spring
y Tension spring
u Automatic adjust lever (R, L)
i Parking brake shoe lever (R, L)
o Brake shoe assembly
!0 Parking brake shoe strut
!1 Cylinder assembly
!2 Cylinder cap
!3 Brake backing plate subassembly
!4 Wheel cylinder boot
!5 Wheel brake cylinder piston
!6 Compression spring
!7 Cylinder cup
JBR00071-00058
REMOVAL
1. Remove the hole plug at the inspection hole provided on
the backing plate.
2. Inspect that the thickness of the brake shoe lining is more
than the specified value, through the inspection hole.
Standard thickness: 5.0 mm
Minimum thickness: 1.0 mm
JBR00072-00059

BR23
DISASSEMBLY
2. Drain the brake fluid from the rear brake line.
(Refer to the Air breeding section.)
4. Release the parking brake fully.
5. Remove the rear brake drum from the rear axle hub by
pulling it out.
NOTE:
If any difficulty is encountered in removing the brake JBR00073-00060
drum, screw in the 8mm bolts to the brake drum evenly.

The bolt hole is offset. Therefore, after tightening the
bolt to a certain extent, lightly tap the brake drum,
using a plastic hammer or the like, so that the brake
drum may be lifted up evenly.
6. Check the brake drum inner diameter, using suitable

vernier calipers.
Specified Diameter: 228.6 mm
If the diameter exceeds the specified value, replace the

brake drum with a new one.
JBR00074-00061
7. Check the brake shoe thickness, using suitable vernier

calipers or ruler.
Specified Thickness: 5.0 mm
If the diameter exceeds the specified value, replace the

brake drum with a new one.
8. Check the brake shoe for seizure or abnormal wear, etc.
If any damage exists, replace the brake shoe with a new
one.
JBR00075-00062
9. Remove the tension No. 4 spring, using the following SST.

SST: 09703-30010-000
JBR00076-00063

BR24
10. Remove the shoe hold-down spring pin retainers and
springs from the shoe hold-down spring pins.
11. Remove the shoe hold-down spring pins.
12. Detach the brake shoes from the backing plate.
13. Remove the leading side brake shoe from the tension
No. 3 spring.
14 Remove the tension No. 3 spring.
15. Remove the parking brake shoe strut from the brake shoe.
JBR00077-00064
16. Disconnect the parking brake cable from the parking

brake shoe lever.
NOTE:
If any difficulty is encountered in disconnecting the
parking brake cable from the parking brake shoe lever,
loosen the parking brake lever adjusting nut fully.
JBR00078-00065
17 Remove the tension spring.

18. Remove the automatic adjuster lever from the brake shoe
by removing the E-ring.
CAUTION:
Never reuse the removed E-ring.
E-ring
JBR00079-00066
19. Remove the parking brake shoe lever and parking brake
lever pin from the brake shoe by extracting the C-ring,
using outside nose pliers or the like.
CAUTION:
Never reuse the removed C-ring.
JBR00080-00067
20. Remove the wheel cylinder boots, wheel cylinder pistons

with the cup and compression spring from the wheel cylin-
der.
21. Remove the piston cup and boots from the wheel cylinder
pistons.
JBR00081-00068

BR25
22. Disconnect the brake pipe from the wheel cylinder by dis-
connecting the flare nut, using a flare nut wrench.
23. Remove the wheel cylinder by removing the attaching
bolts.
JBR00082-00069
24. Disconnect the parking brake cable from the backing

plate by removing the two attaching bolts.
25. Remove the wheel speed sensor by removing the attach-
ing bolt. (Only when equipped)
26. Remove the backing plate.
JBR00083-00070
INSPECTION
1. Inspect the components with point mentioned in figure.
If any damage is found, replace the damaged parts with new ones.
Backing plate
Wear / rust / warpage / damage
Wheel cylinder
Rusting / wear / cracks
Parking brake lever pin Brake shoe

Rusting / wear / damage Wear :
Brake lining thickness
Specified thickness: 5.0 mm
Allowable limit: 1.0 mm
Rusting / crack / burning
adhesion of oil
Shoe hold-down
spring pin
Wear / rust
Spring
wear / rust /
stretching Spring
Wear / rusting / stretching
Parking brake shoe strut

Wear / damage
Brake drum
Wear / rusting / cracks / damage
JBR00084-00071

BR26
2. Checking of brake lining contacting condition with brake
drum
(1) Apply powder of chalk to the brake drum. Then, check
the brake lining surface contacting condition with the
brake drum by rubbing the brake lining in the brake
drum.
If the contacting condition of the brake lining with
brake drum is poor, grind the brake lining surface with
abrasive paper or the like.
CAUTION:
Replace the brake lining with a new one if an excessive JBR00085-00072
uneven contact exists.

Ensure that the brake lining thickness is within the
specified value after grinding.
(2) Make sure that the contacting condition of the brake

lining is sufficient after grinding the brake lining.
(3) Clean the brake lining and brake drum after perform-
ing the checking of the brake lining contacting condi-
tion.
INSTALLATION
CAUTION:
Be sure to apply brake grease to the metal and metal sliding surfaces, unless otherwise specified.
NOTE:
Please refer to the illustration mentioned in the removal procedure if any difficulty is encountered.
JBR00086-00000
1. Installation of backing plate

Refer to the RS section for installation of the backing plate.
Be sure to select the correct shim when the backing plate
is replaced with a new one in the manner described as fol-
lows.
Selection of shim
(1) Measure the thickness of the new backing plate.
(2) Select the shim from the following table which corre-
sponds to the thickness of the new backing plate.
Rear axle bearing retainer gasket (shim)

JBR00087-00073
Thickness of backing plate Thickness of shim
2.650 - 2.790 0.15
2.505 - 2.650 0.30
2.410 - 2.505 0.40
2. Install the backing plate with the selected shim.

(Refer to the RS section for installation.)
3. Connect the parking brake cable to the brake backing
plate with two attaching bolts and tighten them to the
BR27
4. Thinly apply brake grease to the sliding portions of the
parking brake shoe lever.
5. Install the parking brake shoe lever to the trailing side
brake shoe with the parking brake lever pin together with
a new C-ring. Then, retract the C-ring with pliers or the
like.
WARNING:
Never reuse the removed C-ring.
JBR00088-00074
6. Connect the automatic adjuster lever to the parking brake

lever pin. Then, install the new E-ring.
7. Install the tension spring to the brake shoe and automatic
adjuster lever.
E-ring
JBR00089-00075
8. Clean the backing plate thoroughly.

9. Connect the parking brake cable to the backing prate with
two attaching bolts and tighten them to the specified tight-
ening torque.
JBR00090-00076
10. Install the wheel cylinder to the backing plate with attach-
ing bolts and tighten the attaching bolts to the specified
tightening torque.
11. Connect the flare nut of the brake tube to the wheel cylin-
der fully by hand and tighten the flare nut to the specified
tightening torque.
12. Assemble new piston cups and rubber boots to the pis- JBR00091-00077
tons.
piston cup.
WARNING:
Never install the piston cups in a wrong direction.
Failure to observe this warning may lead to brake fluid
leakage or serious brake malfunction.

BR28
14. Install the compression spring and wheel cylinder pistons
with the wheel cylinder boots to the wheel cylinder.
NOTE:
Loosen the bleeder plug fully before installing the
wheel pistons.
JBR00092-00078
15. Apply brake grease to the six brake shoe contacting

points on the backing plate, one point each on the wheel
cylinder pistons and two points on the brake lining anchor.
WARNING:
Be careful not to allow lubricants, such as grease or oil
etc., to get to the wheel cylinder boot or brake shoe lin-
ing.
JBR00093-00079
16. Connect the parking brake cable to the parking brake

shoe lever.
17. Install the rear side brake shoes on the backing plate with the shoe hold-down pin, spring and retainer.
18. Connect the tension spring to the back side of the brake shoe.
19. Connect the other side of the brake shoe to the tension spring.
20. Thinly apply brake grease to the sliding section of the parking brake shoe strut.
JBR00094-00000
21. Install the other side of the brake shoe to the backing plate with the shoe hold-down pin, spring and re-
tainer while placing the parking brake shoe strut in position.
22. Install the tension No. 4 spring to the brake shoes, using the following SST.
SST: 09921-00010-000
23. Clean the brake drum contacting surface of the rear axle hub and axle hub contacting surface of the
brake drum properly.
24. Install the brake drum to the rear axle hub.
CAUTION:
Never allow the brake drum to interfere with the brake shoe during the installation.
Make sure that the parking brake lever strut is retracted fully before the installation.
25. Install the rear wheels.

Tighten the attaching hub nuts to the specified tightening torque.
Tightening Torque: 103.0 14.7 Nm (10.5 1.5 kgf-m.)
26. Perform air bleeding. (Refer to the Air bleeding section.)

27. Apply the parking lever several times, until the clicking sounds emitted from the rear brake will stops.
JBR00095-00000

BR29
Reference:
Manual adjusting method of brake shoe-to-drum clear-
ance
NOTE:
The illustration shows the brake at the right hand side.
The brake at the left hand side is symmetric to the
brake at the right hand side.
(1) Remove the adjusting hole plug provided on the back- E Adjusting hole
ing plate. B A (Backing plate side)
(2) Turn the adjusting wheel by a flat screwdriver (A) in- JBR00096-00080
serted from the adjusting hole in the direction (C) as

shown in the figure, until the brake shoe comes in con-
tact with the brake drum.
(3) Turn back the adjusting wheel in the direction (D) by
the screwdriver (A) while pushing up the adjusting
lever with the L-shaped head bar (E), until the brake
drum turns without dragging.
(4) Install the adjusting hole plug to the backing plate.
28. Adjust the working travel of the parking brake lever.
(Refer to the Parking brake section for adjustment.)
29. Check the brake performance with a four-wheel brake
tester.

BR30
PARKING BRAKE
COMPONENTS
q : Tightening torque
Unit : Nm (kgf-m)
S
B
18.1 3.4 (1.85 0.35) B
B 7.3 1.5 (0.75 0.15)

r
B
B
B
B
B
e q Rear console box assembly
w Parking brake lever assembly
e Parking brake left cable assembly
r Parking brake right cable assembly
JBR00097-00081
INSPECTION
1. Pull up the parking brake control handle several times and
place it to fully-returned position.
2. Ensure that the parking brake control handle travel is 5 to
7 notches when the parking brake control handle in pulled
up with a force of 196 N (20 kgf).
If the number of the notches fails to meet the specified
numbers, adjust the parking brake control handle travel to
JBR00098-00082
ADJUSTMENT
1. Depress the brake pedal fully several times and ensure
that the parking control lever travel fails to meet the speci-
fied notches.
2. Remove the rear console box by removing the two attach-
ing screws.
JBR00099-00083

BR31
3. Adjust the parking brake control handle travel to the spec-
ified number of notches by turning the adjusting nut of the
parking brake pull rod.
Specified Value: 5 - 7 notches
CAUTION:
Be sure to use a hexagon socket (box) wrench for ad-
justment to prevent the adjusting nut from being dam-
aged.
4. Install the rear console box with the two attaching screws. JBR00100-00084
REMOVAL
1. Remove the rear console box by removing the two attach-
ing screws. (Refer to the BO section.)
JBR00101-00085
2. Remove the adjusting nut from the parking brake pull rod.
3. Disconnect the connector from the parking brake switch.
4. Remove the parking brake control handle by removing the
two attaching bolts.
JBR00102-00086
5. Remove the parking brake pull rod by disconnecting the

parking brake cables from the parking brake pull rod.
6. Lift up the vehicle and support the vehicle with safety
stands.
(Refer to the GI section for supporting section of the safety
stands.)
7. Disconnect the parking brake cable assembly from the
brake backing plate.
(Refer to the rear brake section.)
8. Remove the parking brake cable by removing the attach-
ing bolts of the parking brake cable and its clamps.
9. Remove the clamps from the parking brake cable assem-
bly.
JBR00103-00000

BR32
INSPECTION
Inspect the components with the following point. Replace any damaged parts.
JBR00104-00087
INSTALLATION
NOTE:
Please refer to the illustration mentioned in the removal procedure, if any difficulty is encountered.
1. Install the parking brake cable to the vehicle with the attaching bolts of the parking brake cable and its
clamps.
2. Connect the parking brake cable assembly to the brake backing plate. (Refer to the rear brake section.)
3. Lift down the vehicle.
4. Connect the parking brake cables to the parking brake pull rod.
5. Install the parking brake handle assembly to the floor panel while connecting the parking brake pull rod
to the parking brake handle assembly and tighten the attaching bolts to the specified tightening torque.
6. Install the adjusting nut.

7. Connect the connector of the parking brake switch.
8. Perform the adjustment of the parking brake lever. (Refer to the adjustment section.)
9. Install the rear console box with the two attaching screws. JBR00105-00000

BR33
PROPORTIONING VALVE
COMPONENTS
Up
Front Left
JBR00106-00088
INSPECTION
Inspect the proportioning valve function with a four-wheel brake tester.
1. Place the vehicle on the four-wheel brake tester.
2. Ensure that the rear wheels will not be locked before the front wheels are locked.
If the rear wheel will be locked simultaneously or before the front wheels are locked, replace the propor-
tioning valve with a new one.
JBR00107-00000
REPLACEMENT
1. Open the engine hood.
2. Drain the brake fluid from the brake line.
3. Remove the battery and battery carrier. (For RHD vehicle)
4. Disconnect the brake tubes from the proportioning valve.
5. Remove the proportioning valve by removing the attaching bolts.
JBR00108-00000
INSTALLATION
1. Install a new proportioning valve with the bolts and tighten them to the specified tightening torque.
2. Connect the brake tubes to the proportioning valve fully by hand.

3. Tighten the flare nut to the specified tightening torque.
4. Perform the air bleeding for the brake system.

5. Perform the brake performance test with a four-wheel brake tester. JBR00109-00000

BR34
BRAKE HOSE
COMPONENTS
q r !0
u
t
o !1
y i
e q Front brake No. 8 tube

w Front flexible hose
e Rear brake No. 1 tube
r Front brake No. 6 tube
t Front brake No. 7 tube
w y Front brake No. 9 tube
u Front brake No. 1 tube
i Rear brake No. 6 tube
o Rear flexible hose
!0 Rear brake No. 5 tube
!1 Hose
JBR00110-00089
INSPECTION
Inspect the brake hose for following points and replace it with a new one if any damage exists.
Crack Scratch/Cut Twist Swelling
JBR00111-00090
REPLACEMENT
Front brake hose
1. Drain the brake fluid from the brake system.
2. Disconnect the flare nut of the brake pipe from the brake
hose, using a flare nut wrench.
3. Disconnect the brake hose from the clamp by removing
the E-ring.
NOTE:
Never reuse the used E-ring.
JBR00112-00091

BR35
4. Disconnect the brake hose from the disc brake cylinder assembly by removing the union bolts and
washers.
CAUTION:
Do not reuse the used washers.
5. Remove the brake hose by removing the attaching bolt of the clamp bolts.
6. Install the brake hose with the clamp bolt and tighten the clamp bolt to the specified tightening torque.
7. Connect the brake hose to the disc brake cylinder assembly with the union bolt with a new gasket inter-
posed. JBR00113-00000
8. Tighten the union bolt to the specified tightening torque.

9. Connect the brake hose to the bracket and secure it by in-

stalling a new E-ring.
CAUTION:
Be sure to connect the E-ring in such a manner that the
E-ring is securely inserted in the groove provided on
the brake hose end properly.
JBR00114-00092
10. Connect the flare nut of the brake pipe to the brake hose
fully by hand.
11. Tighten the flare nut to the specified tightening torque.

13. Ensure that no brake fluid leakage exists.
Rear brake hose

1. Drain the brake fluid from the brake system.
2. Disconnect the flare nut of the brake pipes from the brake
hose, using a flare nut wrench.
3. Remove the brake hose from the clamps by removing the
E-rings.
WARNING:
Never reuse the used E-rings.
4. Connect the brake hose to the brackets and secure it by

installing new E-rings.
WARNING: JBR00115-00093
Never reuse the used E-ring.

Be sure to connect the E-ring in such a manner that the E-ring is securely inserted in the groove pro-
vided on the brake hose end properly.
5. Connect the flare nuts of the brake pipes to the brake hose fully by hand.
6. Tighten the flare nuts to the specified tightening torque.

8. Ensure that no brake fluid leakage exists.
BR36
ANTI-LOCK BRAKE SYSTEM
SYSTEM OUTLINE
The ABS is a brake system to prevent the wheels from locking which may cause the vehicle to slip. For this
purpose, the ABS assures proper braking forces at all times by maintaining the coefficient of friction be-
tween the tires and the road surface to an optimum level through controlling the hydraulic pressure of each
of the front right, front left and rear wheels. In this way, the controllability or steerability of the steering wheel
is assured even under sudden braking/hard braking, except for the case of over-speeding or sharp turning
in a corner.
ABS ECU
Controlling the actuator based on signals
from each speed sensor and gravity sensor.
Actuator
Controlling the hydraulic pressure
in each wheel cylinder under
control of ABS ECU.
Rear vehicle speed sensors

Front vehicle speed sensors Detecting wheel speed.
Detecting wheel speed.
ABS warning lamp

Warning the driver of malfunction of
the system by illumination of this lamp. Gravity sensor
Indicating the diagnosis code at Detecting the gravity being
inspection. applied to the vehicle.
NOTE: LHD model

JABS00002-00001

BR37
JABS CIRCUIT DIAGNOSIS
ABS fuse
Back-up fuse ABS ECU 1 1

38 BAT +BS +BM GND
AM IG SW(IG2) ECU IG fuse MR MR 4
1 18 +B 4 4
SR SR
36 ECUT 5 5
t rq r q
Diagnosis
Tail fuse STOP fuse connector Body ground
14 ABST solenoid
stop lamp relay
switch 11 SIO Motor relay
e w e w
37 STP R+ 3 3
Front vehicle speed R+

BS BM
sensor (right) 2 2
6 FR+
stop 7 FR
lamp Front vehicle speed
sensor (left) 12 10
26 FL+ AST
BS BM
AST 24 11
Battery
27 FL SFRH
SFRH 8 4
Rear vehicle speed
SFRR
sensor (right) SFRR 29 8
31 RR+
SFLH M
32 RR SFLH 1 3
Rear vehicle speed
SFLR
sensor (left) SFLR 2 7 BS
9 RL+
SRH Inspection
10 RL SRH 22 1 diode
SRR WA
SRR 23 5
2 GND MT
9 13
IG GS1 3 35 GS1 Actuator
Body ground
GS2 4 15 GS2
Gravity
sensor MT 25
GST 6 13 GST
GGND 1 34 GGND
WA 41 Gauge fuse
19 GND ABS Warning lamp
40 GND
Body ground
JABS00003-00002

BR38
ABS RELATED CONNECTORS
EFI ECU
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22
Ignition switch
IG2
1 2 3
4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Vehicle speed sensors
1 2 2 1
SFRH SFLH SRH SRH SFLH SFRH
4 3 2 1 1 2 3 4
5 6 7 8
8 7 6 5
1 2 2 1
SRR SFLR SFRR
SFRR SFLR SRR
BM GND GND BM
1 2 2 1
10 9 1 2
13 12 11 3 4 5
AST BS MT 1 2 2 1
MT BS AST
Actuator connector
Actuator
1 1 2
2 (WA)
2 2
Stop lamp switch 1 1 (BS)

Inspection diode
+BS BS +BM BM GGND IG
1 2 1 2 1 2
3 4 5 3 4 5 6
3 4
R+ GND SR GS1 GS2 GST
R+ MR ABST ECUT
w q w q
2 1
SIO Ground
6 5 4 3
Diagnosis connector
t r e r e
Solenoid relay Motor relay Gravity sensor
ABS00004-00003

BR39
SST (Sub - harness)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1 2 3 4 5 6 7 8 9 10 11
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 22 23 24 25 26 27 28 29 30 31 32
MT
12 13 14 15 16 17 18 19 20 21
33 34 35 36 37 38 39 40 41 42
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22
SST (Diagnosis connector)
14 36
Body ground.
For DS - 21
(To diagnosis connector) (For inspection side)
ABS00000-00004

BR40
ABS CIRCUIT CONNECTION TABLE
ABS ECU Terminal Terminal No.
SST (Sub-harness) name ABS actuator
No. Terminal connected to Gravity sensor
Solenoid relay
Motor relay
Speed sensor
Front Rear
RH LH RH LH Others
1 SFLH terminal of actuator SFLH e
2 SFLR terminal of actuator SFLR u
3 R+ terminal of motor and solenoid relay R+ e e
4 MR terminal of motor relay MR r
5 SR terminal of solenoid relay SR t
6 Front right speed sensor (+) FR+ w
7 Front right speed sensor () FR q
8 SFRH terminal of actuator SFRH r
9 Rear left speed sensor (+) RL+ q
10 Rear left speed sensor () RL w
11 SIO terminal diagnosis connector SIO Diagnosis connector *1
12 NIL
13 GST terminal of gravity sensor GST y
14 ABST terminal of diagnosis connector ABST Diagnosis connector *1
15 GS2 terminal of gravity sensor GS2 r
16 NIL
17 NIL
18 Ignition switch (IG 2) +B Ignition switch (IG 2) *2
19 Body ground GND Body ground *3
20 *Internal check use only D/G Never touch !! *4
21 NIL
22 SRH terminal of actuator SRH q
23 SRR terminal of actuator SRR t
24 AST terminal of actuator AST !1
25 MT terminal of actuator MT !3
26 Front left speed sensor (+) FL+ w
27 Front left speed sensor () FL q
28 NIL
29 SFRR terminal of actuator SFRR i
30 NIL
31 Rear right speed sensor (+) RR+ q
32 Rear right speed sensor () RR w
33 NIL
34 GGND terminal of gravity sensor GGND q
35 GS1 terminal of gravity sensor GS1 e
36 ECUT terminal of diagnosis connector ECUT Diagnosis connector *1
37 Stop lamp switch STP Stop lamp switch *2

BR41
ABS ECU Terminal Terminal No.
SST (Sub-harness) name ABS actuator
No. Terminal connected to Gravity sensor
Solenoid relay
Motor relay
Speed sensor
Front Rear
RH LH RH LH Others
38 Back-up fuse BAT Back-up fuse *3
39 NIL
40 Body ground GND Body ground *3
41 ABS warning lamp WA Combination meter *2
Inspection diode
42 NIL
BS !2 w Inspection diode
BM !0 w
GND o Body ground *3
+BS, +BM q ABS fuse *3
+B w ECU IG fuse *3
GND r Body ground *3
*1 : Refer to page ABS3 and 4.
*2 : Refer to BE section.
*3 : Refer to HW section.
*4 : CAUTION:
Never touch and connect anything to this terminal. Failure to observe this caution may lead to ABS ECU malfunction.
ABS00005-00000

BR42
PRECAUTIONS
1. The ABS system has a self-diagnosis function. The ECU memorizes abnormality as diagnosis codes
which are occurring at present or occurred in the past.
Memorized diagnosis codes are erased when the power supply is disconnected. Therefore, be sure to
read out diagnosis codes before starting any operations.
CAUTION:
Be sure to read out diagnosis codes of the EFI system before disconnecting the power supply.
Failure to observe this caution will erase memorized diagnosis codes.
2. The components of the ABS system are precise and delicate. Therefore, never apply any excessive im-
pact during the removal, inspection and installation.
CAUTION:
Never use components to which an impact is applied by dropping or hitting with other objects.
3. Never perform the inspection of the ABS system when the vehicle is wet, such as after running in rain or
snow and after washing, in order to prevent water or dust, etc. from being admitted into the ABS and re-
lated connectors.
4. Never allow water and dust, etc. to enter into the ABS and related connectors.
5. Never allow water, etc. to come in contact with the ABS components installed in the cabin and their
connectors.
6. Prevent water from coming in contact with the ABS related parts and connectors during washing.
7. Prior to replacing the ABS ECU, thoroughly perform the trouble shooting for possible items other than
the ABS ECU. The ABS ECU is a reliable, but an expensive part.
Even when the ABS ECU is replaced according to the check results of the trouble shooting and the rele-
vant trouble has been remedied, be sure to reinstall the old ABS ECU so as to confirm that the malfunc-
tion was obviously caused by the faulty ABS ECU.
8. Never try to remove the ABS ECU cover and touch the screws on the ABS ECU proper.
9. Ensure that the components of the brake system are installed properly and so that no brake fluid leak-
age exists before performing the trouble shooting of the ABS.
10. Ensure that no excessive rattle exists on each of the wheel bearings before performing the trouble
shooting of the ABS.
11. When installing a wireless installation (HAM, CB, Telephone, etc.) :
The ABS ECU has been so designed that it is resistant to external influence.
However, if a vehicle is equipped with a wireless installation, such as CB, HAM, telephone and so forth,
(even if its output is only 10 W) it may affect the ABS ECU adversely. Therefore, observe the following
precautions.
Install the antenna at a place as far away as possible from the ABS ECU and related harnesses.
The antenna cord should be kept at least 30 cm from the ABS ECU and its related harnesses.
The antenna cord should not be routed in parallel to ABS related harnesses.
Adjust the antenna output correctly.
Never install a wireless installation with a high output into the vehicle.
Never use or place a handy telephone near the components of the ABS and its related harnesses.
12. When disconnecting or connecting connectors:
Prevent dust, water and foreign material, etc. from being admitted into the ABS related connectors
when disconnecting or connecting the connectors. Failure to observe this caution may cause seri-
ous malfunction, due to lowering the insulation of each terminal.
Never damage or lose the gasket or seal of connectors during disconnection or connection.
Be sure to confirm the shape of the lock and release the lock properly before disconnecting the
connectors.
Never damage the rubber protector of connectors during disconnection or connection.
JABS00006-00000

BR43
13. Circuit tester
For trouble shooting, use a volt/ohmmeter whose internal resistance is more than 10 k ohm, whose
resolution is 0.1 V or more and 0.5 ohm or more, and whose accuracy is 0 2 % or more.
Use of a volt/ohmmeter which has lower specifications than those described above for trouble
shooting may lead to wrong diagnosis or mis-judgement.
14. Never deform the terminals of connectors by applying an excessive force when checks are performed
by attaching the probe electrodes of the volt/ohmmeter to the terminals.
Prevent such damage by utilizing SSTs effectively.
15. Be sure to disconnect the ground cable from the negative terminal of the battery before disconnecting
the connector of the wire harness from the ABS ECU. Failure to observe this caution may lead to ABS
ECU damage.
JABS00007-00000

BR44
TROUBLE SHOOTING HINTS
1. Most of troubles related to the electrical system of the ABS
are merely caused by poor connections.
Ensure the following points carefully before and during the
inspection.
(1) Visually inspect that the terminals are not damaged or
bent.
(2) Ensure that connectors are securely connected and
locked.
(3) Ensure that the measured continuity or resistance will
JABS00008-00005
not be changed when light vibration is applied to the
connector or the wire harness connected to the related
circuit of presumable parts of trouble.

BR45
HOW TO PROCEED TROUBLE SHOOTING
The trouble or malfunction of the brake system mainly originates in the mechanical systems, such as the
brake pedal, brake booster, brake master cylinder, P valve, wheel cylinders and brake fluid line, or electri-
cal systems, such as the ABS actuator, wheel speed sensors, gravity sensor, ABS ECU and ABS related
wiring harness.
This manual describes mainly trouble shooting of the electrical system of the ABS control systems on the
premise that the brake mechanical systems are functioning normally.
Hence, when the brake system is encountered with any trouble, make sure that the trouble does not origi-
nate in the mechanical systems of the brake systems.
To proceed the trouble shooting, first perform the diagnosis check. Then, if any of the diagnosis codes
other than the normal codes is outputted, perform the trouble shooting according to the diagnosis codes.
When no diagnosis code is outputted even if malfunction phenomena exists, perform the trouble shooting
according to the malfunction phenomena.
The following diagram shows the basic procedure for the trouble shooting.
Actual approach may differ if you have much experience on this system. However, it is recommended to
perform the trouble shooting according to this procedure.
JABS00009-00000
Entry of malfunctioning vehicle to service shop
Get thorough information from the customer about conditions and circumstances under which the
problem takes place.
Grasp the situation where the problem takes place.
Check diagnosis codes. ABS warning lamp malfunctioning.

(Refer to the diagnosis code check.)
Erase the diagnosis codes.
Perform the confirmation of trouble phenomena.
Check diagnosis codes. No diagnosis code memorized.

(Refer to the diagnosis code check.)
Diagnosis code is memorized.

Perform the trouble shooting according to the diagnosis code.
Perform the basic inspection.

1. Check the battery voltage.
2. Check the power supply and ground circuits for the ABS ECU.
Perform the trouble shooting according to the trouble phenomena.
If the trouble persists:

Perform the confirmation test.
Finish
JABS00010-00000

BR46
DIAGNOSIS CODE CHECK
1. Checking of ABS warning lamp
(1) Ensure that the ABS warning lamp will glow for about
three seconds after the ignition switch is turned ON,
and, then, the warning lamp goes out.
NOTE:
Proceed to trouble shooting according to the trouble
O/D
OFF
phenomenon if the ABS warning lamp fails to meet the

condition above.
JABS00011-00006
2. Output of diagnosis codes

(1) Remove the inspection diode from the connector.
JABS00012-00007
(2) Connect the following SST to the diagnosis connector.

SST: 09991-87401-000
(3) Connect the ECUT and GND terminals in the SST with
the following SST.
SST: 09991-87403-000
ECUT
CAUTION:
Never connect the terminal other than that specified.
Even slight contact of the other terminals causes serius GND
malfunction. JABS00013-00008
Normal code
(4) Turn ON the ignition switch.
(5) Read out the diagnosis code(s) by observing the num-
ber of blinking of the ABS waning lamp.
NOTE:
When plural malfunctions codes are memorized, the ON
code will be outputted starting from a smaller code OFF
number at intervals of 2.5 seconds. 0.25 0.25
After completion of one cycle, the same codes will be
outputted again at intervals of 4 seconds. Unit : Second
JABS00014-00009
Single code : 11 Plural code : 11 and 13
0.5
ON ON
OFF OFF
0.5
1.5
4 4.0 1.5 2.5 1.5 4.0
unit : Second
JABS00000-00010

BR47
DIAGNOSIS CODE TABLE
CODE NO. Diagnosis items Diagnosis contents Timing of diagnosis Presumable causes of trouble
11 Solenoid relay Open wire All time
Immediately after Solenoid relay
12 Solenoid relay Short circuit ignition switch is turned Solenoid relay-related harness
ON.
Immediately after
13 Motor relay Open wire ignition switch is turned Motor relay
ON. Motor relay-related harness
14 Motor relay Short circuit All time
Right front
21
solenoid valve
Open wire or short Solenoid valve in actuator
Left front
22 circuit
All time Solenoid valve-related harness
solenoid valve
Rear solenoid
23
valve
Right front vehicle
31
speed sensor
32
Left front vehicle Open wire or short
speed sensor circuit Vehicle speed sensors
speed sensor All time Vehicle speed sensor-related
Right rear vehicle
33 speed sensor signal harness
Left rear vehicle

34 speed sensor
When running at 20
37
Front vehicle speed
Speed sensor signal km/h or more after Front vehicle speed sensors and
sensor ignition switch is turned related harness
ON.
Power supply Low voltage

41
voltage (Low) When running (10 V or less) Battery
Alternator
High voltage Power supply-related harness
Power supply
42 All time (18 V or less)
voltage (High)
When repeating stop
43 Gravity sensor and start. Function Gravity sensor
Open wire or short Gravity sensor

44 Gravity sensor All time circuit Gravity sensor-related harness
49 Stop lamp
Stop lamp switch All time Open wire
Stop lamp-related harness
Immediately after Motor in actuator
51 Motor ignition switch is Function in voltage
Motor-related harness
turned ON.
JABS00015-00000
Erasing procedure for diagnosis codes
CAUTION:
There are four methods to erase diagnosis codes, as mentioned below. However, if the diagnosis
codes are erased by the brake pedal method, normally diagnosis codes of the EFI system also will
be erased when the power supply of the vehicle is shut off.
Therefore, be sure to read out the diagnosis codes of the EFI system before disconnecting the power
supply.
Disconnection of the power supply is required when disconnecting the connector of the wire harness
from the ABS ECU.
JABS00016-00000

BR48
1. Erasing procedure by brake pedal
SST: 09991-87401-000 ECUT
(2) Connect the ECUT and GND terminals in the SST ter-
minal with the following SST.
SST: 09991-87403-000
Ground
CAUTION:
Never connect the terminals other than that specified,
for even slight contact of other terminals may lead to JABS00017-00011
serius malfunction or damage.
(3) Turn ON the ignition switch.(Never start the engine.)

(4) Depress the brake pedal more than 8 times within 5 Five seconds
seconds.
(5) Ensure that the normal code is indicated by the ABS
warning lamp.
(7) Remove the SST (jump wire) from the SST(sub har- Eight times
ness).
(8) Turn on the ignition switch. JABS00018-00012
(9) Ensure that the ABS warning lamp remains extin-

guished after a lapse of three seconds.
If the ABS warning lamp remains illuminated, repeat
the operation above again.
(11) Remove the SST from the diagnosis connector.
2. Erasing diagnosis codes by utilizing the ABST terminal

SST: 09991-87401-000
(2) Turn ON the ignition switch.(Never start the engine.)

(3) Repeat the connection and disconnection of ABST ABST
and GND terminals in the SST four times within eight
seconds, using the following SST.
SST: 09991-87403-000
CAUTION: E
Never connect the terminals other than that specified,
for even slight contact of other terminals may lead to
serius malfunction or damage. JABS00019-00013

guished.
(6) Remove the SST (sub harness) from the diagnosis O/D
OFF
connector.
JABS00020-00014

BR49
3. Erasing diagnosis codes by removing back-up fuse
(1) Ensure that the ignition switch is turned OFF. Back-up fuse
(2) Remove the back-up fuse from the relay block, using
the fuse puller, and install it again after a lapse of more 10A
than 10 seconds.
CAUTION:
Be sure to read out diagnosis codes of the EFI system
before disconnecting the back-up fuse.
When a radio, a cassette stereo, etc. are installed, it
should be noted that it may take more than ten sec-
onds to delete the diagnosis codes. JABS00021-00015
(3) Turn on the ignition switch.

guished after a lapse of three seconds.
4. Erasing diagnosis codes by disconnecting the negative terminal of battery ground cable from the bat-
tery negative terminal.
(2) Disconnect the negative terminal of the battery ground cable from the battery negative terminal for
more than 10 seconds. Then, connect the negative terminal of the battery ground cable to the nega-
tive terminal.
CAUTION:
Be sure to read out diagnosis codes of the EFI system before disconnecting the negative terminal of
the ground cable from the battery negative terminal.

(4) Ensure that the ABS warning lamp remains extinguished after a lapse of three seconds.
If the ABS warning lamp remains illuminated, repeat the operation above again.
JABS00022-00000

BR50
TROUBLE SHOOTING ACCORDING TO DIAGNOSIS CODES
TROUBLE SHOOTING ACCORDING TO DIAGNOSIS CODE
DIAGNOSIS CODE No. 11 JUDGMENT SOURCE:
Comparing voltage being applied to across terminals +B and AST
DIAGNOSIS ITEM Solenoid relay
of ABS ECU between the ON condition and the OFF condition of
DIAGNOSIS CONTENTS Open wire solenoid relay
ABS fuse
Body
AM fuse ECU IG fuse MR 4
18 +B ground
Ignition SR 5 +BS MR +BM
switch Solenoid
Motor relay
relay
R+ BS
R+ 3 BM
BS BM
To gravity AST 24
sensor ABS SFRH 8
Battery ECU SFRR 29
SFLH 1 M Inspection diode
SFLR 2
SRH 22
SRR 23
Actuator
WA 41 Gauge fuse
ABS warning lamp
JABS00023-00016
Checking points
1. Solenoid relay
2. ABS fusible link for open wire.
3. Wire harness between battery and terminal +BS of solenoid relay for open wire or short circuit.
4. Wire harness between battery and terminal +BM of motor relay for short circuit.
5. Wire harness between terminal BS of solenoid relay and terminal BS of actuator, including wire harness
up to terminal BS of diode for open wire or short circuit.
6. Circuits in actuator for open wire or short circuit.
7. Wire harness between terminal AST of actuator and terminal AST of ABS ECU for open wire or short cir-
cuit.
8. Wire harness between SFRH, SFRR, SFLH, SFLR, SRH and SRR terminals of actuator and the same ter-
minals of ABS ECU for short circuit.
9. Wire harness between terminal R+ of ABS ECU and terminal R+ of solenoid relay, between terminal SR
of ABS ECU and terminal SR of solenoid relay, and between terminal R+ of ABS ECU and terminal R+
of motor relay for open wire or short circuit.
10. ABS ECU
JABS00024-00000

BR51
Checking procedure
BAD
1. Check solenoid relay. Replace solenoid relay.
(Refer to unit check.)
OK
BAD
2. Check ABS fusible link. Replace fusible link.
(Refer to BE section.)
OK
BAD
3. Check power supply to terminal +BS of solenoid relay. Check the harness between battery and
terminal +BS of solenoid relay or terminal +BM
OK of motor relay for open wire or short circuit.
4. Check drive circuit of solenoid relay. Repair it, as required.
Ensure that solenoid relay emits an operating
sound when ignition switch turned ON. NO
Check harness between
terminal R+ of ABS ECU and
OK
BAD terminal R+ of solenoid relay,
5. Check harness between terminal BS of solenoid Repair or replace the harness. between terminal R+ of ABS
relay and terminal BS of actuator, including wire ECU and terminal R+ of motor
harness up to terminal BS of inspection diode relay, and between terminals
for open wire or short circuit. SR of ABS ECU and terminals
SR of solenoid relay for open
OK wire or short circuit.
BAD
6. Check harness between terminal AST of Repair or replace the harness. BAD
actuator and terminal AST of ABS ECU for
open wire or short circuit. Check ABS ECU.
OK
BAD
7. Check harness between each of terminals SFRH, Repair or replace the harness.
SFRR, SFLH, SFLR, SRH and SRR of actuator
and each of terminals SFRH, SFRR, SFLH, SFLR,
SRH and SRR of ABS ECU for short circuit.
OK
BAD
8. Check actuator unit internal circuit. Replace actuator.
OK
BAD
9. Check ABS ECU. Replace ABS ECU.
JABS00025-00000

BR52
DIAGNOSIS ITEM Solenoid relay Monitoring the voltage being applied to terminal AST of the
ABS ECU when solenoid relay is turned off.
DIAGNOSIS CONTENTS Short circuit
ABS fuse
+BM
Body
18 +B SR ground
Ignition SR 5
switch Solenoid BS
relay Motor relay
BS
R+ 3 +BM
BS 12 BM
AST 10
To gravity AST 24 11
sensor ABS SFRH 8 4

Battery ECU
SFRR 29 8
SFLH 1 3
M Inspection diode
SFLR 2 7
SRH 22 1
SRR 23 5
9 13
Actuator
WA 41 Gauge fuse
ABS warning lamp
JABS00026-00017
Checking points
1. Solenoid relay
2. Wire harness between terminal GND of solenoid relay and body ground for open wire.
3. Wire harness between terminal AST of actuator and terminal AST of ABS ECU for short circuit with posi-
tive circuit.
4. Wire harness between terminal SR of solenoid relay and terminal SR of ABS ECU for short circuit with
ground circuit.
5. ABS ECU
JABS00027-00000
Checking procedure
BAD
1. Check solenoid relay. Replace solenoid relay.
OK
BAD
2. Check circuit between terminal GND of solenoid relay Repair or replace the wire harness.
and body ground for open wire.
OK
BAD
3. Check wire harness between terminal SR of solenoid relay Repair or replace the wire.
and terminal SR of ABS ECU for short circuit with body ground.
OK
BAD
4. Check circuit between terminal AST of actuator and terminal Repair or replace the wire.
AST of ABS ECU for short circuit with positive circuit.
OK
BAD
JABS00028-00000

BR53
DIAGNOSIS CODE No. 13
JUDGMENT SOURCE:
DIAGNOSIS ITEM Motor relay Monitoring voltage being applied to across terminals +B and MT
of ABS ECU with motor relay turned ON.
DIAGNOSIS CONTENTS Open wire
ABS fuse

18 +B
Ignition SR 5 +BS MR +BM Body ground
switch Solenoid Motor
relay relay
R+ BS R+ BM
R+ 3
BS BM
To gravity
sensor SFRH 8
Battery ABS SFRR 29
ECU SFLH 1 M
SFLR 2
SRH 22
SRR 23
Actuator MT
GND
MT 25
JABS00029-00018
Checking points
1. Motor relay
2. ABS fusible link
3. Wire harness between battery and terminal +BM of motor relay for open wire or short circuit.
4. Wire harness between battery and terminal +BS of solenoid relay for short circuit with body ground.
5. Wire harness between terminal BM of motor relay and terminal BM of actuator for open wire or short circuit.
6. Circuits in actuator between terminal BM and terminal MT, and between terminal BM and terminal GND
for open wire or short circuit.
7. Wire harness between terminal MT of actuator and terminal MT of ABS ECU for open wire or short circuit.
8. ABS ECU
JABS00030-00000
Checking procedure
BAD
1. Check motor relay. Replace solenoid relay.
OK
BAD
2. Check ABS fusible link. Replace fusible link.
OK
BAD
3. Check power supply to terminal +BM of motor relay. Check the harness between battery and
terminal +BM of motor relay or terminal +BS of
OK
solenoid relay for open wire or short circuit.
4. Check drive circuit of solenoid relay. Repair it, as required.
Ensure that the motor relay emits an operating sound
NO
when ignition switch is turned ON. Check harness between
OK terminal R+ of ABS ECU
BAD and terminal R+ of motor
5. Check harness between terminal BM of motor relay Repair or replace the harness.
relay, and between
and terminal BM of actuator for open wire or short circuit.
terminal MR of motor
OK relay and terminal MR of
6. Check harness between terminal MT of actuator and BAD ABS ECU for open wire
Repair or replace the harness. or short circuit.
terminal MT of ABS ECU for open wire or short circuit.
OK OK
BAD
7. Check actuator unit. Replace actuator. Check ABS ECU.
(Refer to unit check.) (Refer to unit check.)
OK
BAD
(Refer to unit check.) JABS00031-00000

BR54
DIAGNOSIS ITEM Motor relay Comparing voltage being applied to across +B and MT terminals
of ABS ECU with motor relay turned OFF.
DIAGNOSIS CONTENTS Short circuit
ABS fuse

18 +B
Ignition M +BM
switch
Motor relay
R+ 3 BM
BM
To gravity
sensor SFRH 8
Battery ABS SFRR 29
ECU SFLH 1 M
SFLR 2
SRH 22
SRR 23
Actuator MT
GND
MT 25
JABS00032-00019
Checking points
1. Motor relay
2. Wire harness between terminal MR of motor relay and terminal MR of ABS ECU for short circuit with
body ground.
3. Wire harness between terminal BM of motor relay and terminal BM of motor for short circuit with positive
circuit.
4. Wire harness between terminal MT of actuator and terminal MT of ABS ECU for short circuit with posi-
tive circuit.
5. Circuits in actuator between terminal BM and terminal MT or between terminal BM and terminal GND for
short circuit with positive circuit.
6. ABS ECU JABS00033-00000
Checking procedure
BAD
1. Check motor relay. Replace solenoid relay.
OK
BAD
2. Check wire harness between terminal MR of ABS ECU and Check the harness between battery and terminal
terminal MR of motor relay for short circuit with body ground. +BM of motor relay or terminal +BS of solenoid relay
for open wire or short circuit. Repair it, as required.
OK
NO
3. Check drive circuit of solenoid relay. Check harness between
Ensure that the motor relay emits an operating sound terminal MR of ABS ECU
when ignition switch is turned ON. and terminal MR of motor
OK relay for short circuit.
BAD
4. Check harness between terminal BM of motor relay and Repair or replace OK
terminal BM of actuator for short circuit with positive circuit. the harness.
Check ABS ECU.
OK (Refer to unit check.)
BAD
5. Check harness between terminal MT of actuator and terminal Repair or replace
MT of ABS ECU for short circuit with positive terminal. the harness.
OK
BAD
6. Check actuator unit. Replace actuator.
OK
BAD
7. Check ABS ECU.
Replace ABS ECU
(Refer to unit check.) JABS00034-00000

BR55
DIAGNOSIS CODE No. 21, 22 and 23 JUDGMENT SOURCE:
Monitoring the voltage being applied to ABS ECU through each of
DIAGNOSIS ITEM Solenoid valve solenoid valves and standard resistance are identified with the
DIAGNOSIS CONTENTS Open wire or short circuit prememorized value in the CPU of ABS ECU.
12 10
AST 24 11
SFRH 8 4
SFRR 29 8
ABS SFLH 1 3
M
ECU SFLR 2 7
SRH 22 1
SRR 23 5
9 13
Actuator
JABS00035-00020
Checking points
1. Solenoid valve circuit in actuator.
2. Wire harness between respective terminals AST, SFRH, SFRR, SFLH, SFLR, SRH and SRR of actuator
ABS ECU for open wire or short circuit.
3. ABS ECU
JABS00036-00000
Checking procedure
BAD
1. Check actuator circuit. Replace actuator.
OK
BAD
2. Check wire harness between respective terminals AST, SFRH, Repair the wire harness.
SFRR, SFLH, SFLR, SRH and SRR for open wire or short circuit.
OK
BAD
JABS00037-00000

BR56
DIAGNOSIS CODE No. 31 32 33 34 37
R L R L Both sides
JUDGMENT SOURCE:
DIAGNOSIS ITEM Front Rear Front Monitoring sensor circuit voltage.
Vehicle speed sensor Monitoring difference of input signal from each sensor.
Monitoring missing of input signal from each sensor.
Open wire or short circuit
DIAGNOSIS CONTENTS Abnormal input signal
FR sensor
6 FR+
7 FR
FL sensor
26 FL+
27 FL ABS
RR sensor ECU
31 RR+
32 RR
RL sensor
9 RL+
10 RL
NOTE:
R: Right side
L: Left side
JABS00038-00021
Checking points
1. Speed sensors
2. Speed sensor rotor for damage
3. Wire harness of each speed sensor for open wire or short circuit with body ground.
4. Clearance between speed sensor and sensor rotor.
5. Excessive rattle of wheel bearings.
6. ABS ECU
JABS00039-00000
Checking procedure
BAD
1. Check speed sensor. Clear or replace speed sensor.
OK
BAD
2. Check speed sensor rotor. Clear or replace speed sensor rotor.
OK
BAD
3. Check wire harness between terminals FR + and -, Replace wire harness.
between terminals FL + and -, between terminals RR +
and -, and between terminals RL + and - of ABS ECU and
each sensors for open or short circuit with body ground.
OK
BAD
4. Check clearance between speed sensor and sensor rotor. Adjust clearance.
OK
BAD
5. Check wheel bearing for Replace wheel bearing.
excessive rattle.
OK
BAD
JABS00040-00000

BR57
DIAGNOSIS CODE No. 41 or 42
JUDGMENT SOURCE:
DIAGNOSIS ITEM Power supply voltage When power supply voltage to terminal +B of the ABS ECU
becomes 10 volts or less or 18 volts or more.
DIAGNOSIS CONTENTS Abnormal power supply voltage
Back-up fuse
38 BAT
Ignition switch IG2
18 +B
ECU IG fuse
AM fuse
To gravity sensor
Battery ABS
ECU
19 GND
Body 40 GND
Ground
JABS00041-00022
Checking points
1. Battery
2. Charging system (Alternator with IC regulator)
3. AM fusible link
4. Ignition switch
5. ECU IG fuse
6. Following circuits
Battery to fusible link
Fusible link to ignition switch
Ignition switch to ECU IG fuse
ECU IG fuse to terminal +B of the ABS ECU
ECU IG fuse to terminal IG of the Gravity sensor
Battery to terminal +BS of solenoid relay and terminal +BM motor relay
7. ABS ECU JABS00042-00000
Checking procedure
BAD
1. Check battery voltage. Charge or replace the battery.
(Refer CH section in this service manual.)
OK
BAD
2. Check charging system. Repair charging system.
(Refer to CH section.)
OK
BAD
3. Check the following parts or wire harnesses for open wire or short circuit. Repair or replace the
Battery to fusible link wire harness
Fusible link to ignition switch
Ignition switch to ECU IG fuse
ECU IG fuse to terminal +B of the ABS ECU
ECU IG fuse to terminal IG of the Gravity sensor
Battery to terminal +BS of solenoid relay and terminal +BM of motor relay
OK
BAD
JABS00043-00000

BR58
DIAGNOSIS ITEM Gravity sensor Monitoring if output signal of gravity sensor meets
predetermined output form.
DIAGNOSIS CONTENTS Abnormal output signal
Monitoring if output signal of gravity sensor meets
DIAGNOSIS ITEM Gravity sensor predetermined output form.
When wire harness between each of terminals GS1, GS2, GST and
DIAGNOSIS CONTENTS Open wire or short circuit GGND of gravity sensor and ABS ECU becomes open of shorted.
ABS fuse
To solenoid relay
& motor relay
AM fuse ECU IG fuse
38 +B
Ignition
switch
ABS
ECU
IG GS1 35 GS1
Gravity GS2 15 GS2
sensor GST 13 GST
GGND 34 GGND
JABS00044-00023
Checking points
1. Gravity sensor
2. Power supply to terminal IG of gravity sensor.
3. Wire harness between respective terminals GS1, GS2, GST and GGND terminals of gravity sensor and
the same terminal of ABS ECU for short circuit or open wire.
4. ABS ECU
JABS00045-00000
Checking procedure
BAD
1. Check power supply to IG terminal of Check and repair the related part(s).
gravity sensor from ignition switch.
OK
BAD
2. Check wire harness between each of Replace the wire harness.
terminals GS1, GS2, GST and GGND of
gravity sensor and ABS ECU for open
wire or short circuit.
OK
BAD
3. Check gravity sensor function. Replace gravity sensor.
(Refer to unit inspection.)
OK
BAD
JABS00046-00000

BR59
DIAGNOSIS CODE No. 49
JUDGMENT SOURCE:
DIAGNOSIS ITEM Stop lamp switch Monitoring brake lamp circuit
DIAGNOSIS CONTENTS Open wire
Tail fuse Stop lamp switch

Stop fuse
37 STP
ABS
ECU
Stop
Battery lamp
JABS00047-00024
Checking points
1. Stop lamp
2. Stop lamp circuit
3. ABS ECU
JABS00048-00000
Checking procedure
NO
1. Check of stop lamp circuit Repair brake lamp circuit.
Ensure that the stop lamp glows when brake pedal is depressed.
OK
BAD
2. Check wire harness between stop lamp switch and terminal STP of Repair or replace the wire harness.
ABS ECU for open wire or short circuit.
OK
BAD
JABS00049-00000

BR60
DIAGNOSIS ITEM Actuator pump motor Monitoring voltage at terminal MT of actuator when actuator
pump motor is turned OFF.
DIAGNOSIS CONTENTS Operation
BS BM
AST 24
SFRH 8
SFRR 29
ABS SFLH 1 M
ECU SFLR 2
SRH 22
SRR 23
Actuator GND MT
MT 25
JABS00050-00025
Checking points
1. Actuator pump motor circuit
2. Wire harness between terminal GND of actuator and body ground for open wire.
3. ABS ECU
4. Wire harness between terminal MT of actuator and terminal MT of ABS ECU.
JABS00051-00000
Checking procedure
BAD
1. Check wire harness between terminal GND of actuator and body Repair circuit or replace wire harness.
ground for open wire.
OK
BAD
2. Check wire harness between terminal MT of actuator and terminal Repair circuit or replace wire harness.
MT of ABS ECU for open wire or short circuit.
OK
BAD
3. Check resistance between terminal BM and terminal MT of actuator. Replace actuator.
Specified resistance 33 (at 20 C)
OK
BAD
OK
5. Replace actuator.
JABS00052-00000

BR61
TROUBLE SHOOTING ACCORDING TO TROUBLE PHENOMENA
TROUBLE SHOOTING ACCORDING TO TROUBLE PHENOMENON
TROUBLE PHENOMENA Flow chart number
1. ABS warning lamp remains illuminated immediately after ignition switch is turned ON. 1
2. ABS warning lamp will not glow immediately after ignition switch is turned ON. 2
3. ABS warning lamp will start blinking immediately after ignition switch is turned ON. 3
4. ABS warning lamp is illuminated while driving. 4
5. Side pull of brake 4
6. Poor effectiveness 4
7. ABS operates under normal braking. 4
8. ABS operates just before vehicle stops under normal braking. 4
9. Brake pedal vibrates excessively. 4
10. Wheel locks frequently under ABS operation. 4
11. Starting of ABS operation is late. 5
12. Brake pedal working travel is too small. 6
13. Brake pedal working travel is too large. (Reserve travel is too small.) 7
JABS00053-00000

BR62
TROUBLE SHOOTING PROCEDURE FLOW CHART NUMBER 1
PHENOMENA: ABS warning lamp remains illuminated.
AM fuse ECU IG fuse

18 +B
Ignition
switch
To solenoid relay
ABS ECU
BS Inspection diode
WA ABS warning lamp
Battery WA 41 Gauge fuse

Combination meter
JABS00054-00026
Checking point
1. Abnormal input voltage to ABS ECU.
2. Wire harness between terminal WA of ABS ECU and ABS warning lamp for short circuit with body
ground.
3. Wire harness between terminal WA of ABS ECU and diode for short circuit with body ground.
4. Solenoid relay
5. ABS ECU
1. Remove the inspection diode from inspection connector.

NO
2. Ensure that the ABS warning lamp remains illuminated even Check solenoid relay and related circuit.
three seconds after ignition switch is turned ON. (Refer to unit inspection.)
Remain illuminated
Malfunction code
3. Check diagnosis code. Perform trouble shooting
(Refer to diagnosis code check.) according to diagnosis code.
Lamp remains illuminated.
4. Connect the following SST between ABS ECU and connectors
connected to ABS ECU. (Refer to unit check of ABS ECU
section.)
SST: 09842-87401-000

BAD
6. Ensure that the voltage at terminal !8+B of the SST is within Check power supply to terminal +B of
specified value when engine is started. ABS ECU for following points.
Specified value: 10 - 17 volts 1. EFI IG fuse for burn-out
2. Ignition switch
OK 3. Wire harness of related circuit for open
7. Turn Off the ignition switch. wire or short circuit.
4. Charging system.
8. Disconnect the SST connectors from the ABS ECU.

NO
9. Check to see if ABS warning lamp goes on when ignition Check EFI ECU.
switch is turned ON. (Refer to unit check.)
Lamp remains illuminated.
BAD
10. Check wire harness between ABS warning lamp and terminal Repair or replace wire harness.
WA of the ABS ECU or inspection diode connector for short
circuit with body ground.
JABS00055-00000

BR63
PHENOMENA: ABS warning lamp will not glow after ignition switch is turned ON.
Ignition switch
Fusible link
To solenoid relay
ABS ECU
Inspection diode
ABS warning lamp

19 GND
40 GND WA 41
Combination Gauge fuse Battery
meter
JABS00056-00027
Presumable causes for trouble

1. ABS warning lamp bulb for burnout.
2. Gauge fuse burnout.
3. Circuit between battery and combination meter for open wire.
4. Circuit between combination meter and terminal WA of ABS ECU or inspection diode for open wire.
5. Warning lamp circuit in the combination meter for open for open wire.
6. Diode rapture
1. Remove the inspection diode.

2. Disconnect the connector of wire harness from the ABS ECU.
(Refer to the unit inspection of the ABS ECU.)
3. Connect the following SST to disconnected connector of the
ABS ECU. (Refer to the unit inspection of the ABS ECU.)
SST: 09842-87401-000
CAUTION: Check and repair the following points.

Never connect the connector of SST to the ABS ECU. 1. Power supply to combination meter.
2. ABS warning lamp for burnout.
4. Connect the terminals WA and GND of the SST. 3. ABS warning lamp circuit in
combination meter for open wire.
NO 4. Wire harness between combination lamp
5. Ensure that the ABS warning lamp is illuminated when the and terminal WA of ABS ECU for open
ignition switch is turned ON. wire.
YES
BAD
6. Check inspection diode. Replace check diode.
6. Check ABS ECU.

JABS00057-00000

BR64
PHENOMENA: ABS warning lamp blinks immediately after ignition switch is turned ON.
ABS ECU
To solenoid relay
Diagnosis
connector Inspection diode
36 ECUT
ABS warning lamp
14 ABST WA 41 Gauge fuse

Combination
meter
JABS00058-00028
Checking point
Wire harness between each of terminals ECUT #6 and ABST !4 of ABS ECU and diagnosis connector
for short circuit with body ground.
ABS ECU
1. Disconnect the connector of wire harness from the ABS ECU.

(Refer to the unit inspection of the ABS ECU.)
NO
2. Ensure that no continuity exists between terminals ECUT and Repair or replace wire harness.
ABST of diagnosis connector with body ground.
YES
3. Check ABS ECU.
JABS00059-00000

BR65
PHENOMENA: ABS warning lamp remains illuminated while driving.
Side pull of brake
Poor effectiveness
ABS operates under normal braking.
ABS operates just before vehicle stops under normal braking.
Brake pedal vibrates excessively.
Wheel locks frequently under ABS operation.
JABS00060-00000
Checking points
Wheel speed sensors and related wire harness
Gravity sensor and related wire harness
ABS ECU
Malfunction code
1. Check diagnosis code. Perform trouble shooting according to
(Refer to diagnosis code check.) diagnosis code.
Normal code
BAD
2. Check speed sensor and gravity sensor by sensor Repair according to diagnosis code of
check function. sensor check function.
(Refer to sensor check function.)
OK
4. Disconnect the connector connected to ABS ECU.

(Refer to the unit inspection of ABS ECU.)
5. Connect the following SST to connector which was
disconnected from ABS ECU.
(Refer to unit inspection of ABS ECU.)
SST: 09842-87401-000
CAUTION:
Never connect the connector of SST to the ABS ECU.
NO
5. Ensure that continuity or measured resistance will not be Check and repair the related circuits.
changed when vibration is applied to each connector of
sensor circuits.
YES
6. Check ABS ECU.
JABS00061-00000

BR66
PHENOMENA: Starting of ABS operation is late.
IG SW ECU IG fuse
AM
F/L Tail
fuse ABS ECU
GS1 GS1 IG
Stop Stop
GS2 GS2 Gravity
fuse lamp
SW GST GST sensor
GGND GGND
37 STP FR+
FR
Battery Stop
lamp FL+
Speed
FL sensors
RR+
RR
RL+
RL
JABS00062-00029
Malfunction code
Normal code
2. Disconnect the connector connected to ABS ECU.
(Refer to the unit inspection of ABS ECU.)
3. Connect the following SST to connector which was
disconnected from ABS ECU.
(Refer to unit inspection of ABS ECU.)
SST: 09842-87401-000
CAUTION:
Never connect the connector of SST to the ABS ECU.
NO
4. Ensure that a voltage of 8 volts or more is applied to terminal Check and repair the circuits between
STP of the ABS ECU when brake pedal is depressed. terminal STP and stop lamp switch.
OK
BAD
5. Check speed sensor by sensor check function. Repair according to diagnosis code of
(Refer to sensor check function.) sensor check function.
OK
5. Check ABS ECU.
JABS00063-00000

BR67
PHENOMENA: Brake pedal working travel is too small
NOTE:
No consideration has been taken for function of each wheel cylinder in this procedure.
BAD
1. Ensure that the ABS warning lamp is extinguished three Perform trouble shooting according to
seconds after ignition switch is turned ON. trouble phenomenon.
YES
Malfunction code
Normal code
3. Ensure that the brake fluid will flow out from each wheel
cylinder when the same operation as the air bleeding is OK
Check abnormality in each wheel
performed. cylinder system.
(Refer to air bleeding section.)
BAD
4. Loosen the flare nuts of brake fluid inlet pipes of actuator
connected to the master cylinder.
NO
5. Ensure that the brake fluid will flow out when brake pedal Check abnormality in brake pedal and
is depressed. master cylinder.
CAUTION:
Depress the brake pedal gradually, otherwise quite a large
amount of the brake fluid will flow out.
(Refer to caution in air bleeding section.)
OK
6. Tighten the loosened brake fluid inlet pipes.
OK
7. Loosen the flare nut of brake fluid pipes on actuator Check brake pipes and hoses between
connected to each wheel cylinder. actuator and wheel cylinder, including
(Refer to unit inspection.) P valve.
8. Ensure that the brake fluid will flow out flow each outlet
pipe when brake pedal is depressed.
CAUTION:
Depress the brake pedal gradually, otherwise quite a large
amount of the brake fluid will flow out.
(Refer to caution in air breeding section.)
NO
9. Replace the actuator with a new one.
JABS00064-00000

BR68
PHENOMENA: Brake pedal working travel is too large. (Reserve travel is too small.)
BAD
1. Ensure that the ABS warning lamp is extinguished Perform trouble shooting according to
three seconds after ignition switch is turned ON. trouble phenomenon.
OK
Malfunction code
Normal code
3. Check that no reserve travel exists on brake pedal when brake pedal is depressed.
No reserve travel exists. Reserve travel exists.
BAD
4. Perform unit check of brake actuator. Replace brake actuator.
OK
5. Check master cylinder, wheel cylinders and P valve
including fluid leakage.
JABS00065-00000
BASIC CHECK
To perform the diagnosis properly, be sure to perform the basic check before carrying out the specified in-
spection to ensure whether the power supply circuit and ground circuit of the ABS ECU are proper or not.
Back-up fuse
38 BAT
ECU IG fuse
18 +B
AM fuse Ignition
switch
ABS ECU SST terminal
Battery
19 GND
40 GND 18 19
38 40
JABS00066-00030
1. Ensure that the voltage applying to the ABS ECU is within the specified value, using a volt meter.
Specified voltage: 10 - 18 volts
2. Connection of the SST

(1) Disconnect the negative terminal of the ground cable from the battery negative terminal.
CAUTION:
Be sure to read out the diagnosis code of the EFI system before disconnecting the negative terminal
of the ground cable from the battery negative terminal.
JABS00067-00000

BR69
(2) Remove the glove compartment box by removing the
glove compartment hinge. (Refer to the BO section.)
(3) Disconnect the connector of the wire harness which is
connected to the ABS ECU.
(4) Connect the following SST to the connectors of the
wire harness disconnected from the ABS ECU.(Refer
to the unit inspection of ABS ECU.)
SST: 09842-87401-000
CAUTION:
Never connect the connectors of the SST to the ABS JABS00068-00031
ECU proper.
3. Connect the negative terminal of the ground cable to the

battery negative terminal.
4. Turn on the ignition switch.
NOTE:
Never start the engine.
JABS00069-00032
5. Ensure that the battery voltage is applied between the ter-

SST terminal
minal +B and the body ground, and between the terminal
BAT and the body ground, using a specified circuit tester.
If the battery voltage is not applied, check the power sup-
ply circuit for open wire or short circuit.
6. Turn off the ignition switch. +B GND
7. Ensure that the battery voltage is applied between the ter- 18 19
minal BAT of the SST and the body ground. 38 40
If no battery voltage applied, check the back-up power BAT GND
supply circuit for open wire or short circuit.
8. Ensure that continuity exists between each of the terminals JABS00070-00033
GND of the SST and the body ground.

If no continuity exists, repair or replace the wire harness.
9. Disconnect the negative terminal of the ground cable from
the battery negative terminal.
10. Disconnect the connector of the wire harness from the
connector of the SST.
11. Connect the connector of the wire harness to the ABS
ECU.
12. Connect the negative terminal of the ground cable to the

BR70
UNIT INSPECTION & REPLACEMENT
NOTE:
The inspection of each sensor circuit should be performed by reoffering to the ABS RELATED CON-
NECTORS and ABS CIRCUIT CONNECTION TABLE.
Utilize the following SST effectively by reoffering to the unit inspection of the ABS ECU.
SST: 09842-87401-000
Never connect the connector of the SST to the ABS ECU during the inspection of continuity. Failure
to observe this note may lead to wrong diagnosis results.
JABS00071-00000
SOLENOID RELAY
2. Remove the solenoid relay from the dash panel by removing the attaching bolt.
3. Disconnect the connector of the wire harness connected to the solenoid relay.
NOTE:
The solenoid relay is installed on the dash panel around the front center side of the front right seat.
JABS00072-00000
4. Ensure that continuity exists between the terminals BS and

GND of the solenoid relay.
If no continuity exists, replace the solenoid relay with a
new one.
5. Ensure that the resistance between the terminals R+ and
SR within the specified value.
Specified resistance: 80 W (at 20 C)
If the measured resistance fails to meet the specified

value, replace the solenoid relay with a new one. NOTE: LHD model
JABS00073-00034
6. Ensure that continuity exists between the terminals +BS

and BS when the battery voltage is applied across the
terminals R+ and SR. BS +BS
w q NC
4
If no continuity exists, replace the solenoid relay with a 2

new one. NO 1
7. Install the solenoid relay to the dash panel with the attach-
ing bolt. 3 5
8. Connect the connector of the wire harness to the solenoid

t r e
relay. SR GND R+
JABS00074-00035

BR71
MOTOR RELAY
2. Remove the motor relay from its bracket while unlocking
the lock provided on its bracket.
3. Disconnect the connector of the wire harness connected
to the motor relay.
4. Ensure that the resistance between the terminals R+ and
MR is within the specified value.
Specified resistance: 62 ohm (at 20 C)
If the measured resistance fails to meet the specified JABS00075-00036
value, replace the motor relay with a new one.

BM +BM
5. Ensure that continuity exists between the terminals +BM w q MR +BM
and BM of the motor relay when the battery voltage is ap- 3 1
plied across the terminals R+ and MR.
If no continuity exists, replace the motor relay with a new
one.
6. Connect the connector of the wire harness to the motor r e
4 2
relay. R+ MR
R+ BM
7. Install the motor relay to its bracket.
JABS00076-00037
SENSOR CHECK BY SENSOR CHECK FUNCTION

OF THE ABS ECU
NOTE:
The sensor check function of the ABS ECU checks the
output signal (voltage) and its conditions of each speed
sensor and gravity sensor.
Therefore, you may judge whether sensors are proper
or not by this function when the ABS ECU is function-
ing properly.
Carefully follow the instructions mentioned below, in
particular, the instructions regarding the operation of
the ignition switch. Failure to observe this NOTE may
lead to wrong diagnosis results.
JABS00077-00000
1. Ensure that the ignition switch is turned off.

2. Connect the following SST to the diagnosis connecter.
SST: 09991-87401-000
3. Connect the terminal ABST with the ground terminal in the

inspection connector of the SST, using the following SST.
SST: 09991-87403-000
CAUTION:
Never connect the connector other than that specified. ABST
Even slight contact of terminals other than that speci-
fied will lead to malfunction of the ABS, EFI and/or E
other systems. JABS00078-00038

BR72
4. Turn ON the ignition switch.
CAUTION:
Never turn off the ignition switch until the sensor check
by the sensor function is completed.
5. Ensure that the ABS warning lamp will indicate the ABS
ECU code number once immediately after the ignition
NOTE:
There is no problem even if the ABS ECU code is not
outputted. JABS00079-00000
6. Ensure that the ABS warning lamp blinks at intervals of

0.13 second.
<Reference>
This shows that the ABS ECU is in the test mode.
0.13 second
7. Drive the vehicle at a speed between 45 km/h and 80
km/h. Then, maintain the driving speed for one second or
more. Blinking form of test mode
WARNING:
Be sure to perform the test driving in a safe place. JABS00080-00039
CAUTION:
Keep the steering wheel in a straight-ahead direction at
the time of starting and stopping.
Never made tire slipping during the test driving.
If phenomenon appears under the high speed driving,
drive the vehicle at a speed of 80 km/h or more and
keep the driving speed for one second or more after
performing the test driving above.
8. Stop the vehicle.

NOTE:
Never turn off the ignition switch.
9. Connect the terminals ECUT and GND of the SST.

10. Read out the diagnosis code indicated by the blinking of
the ABS warning lamp.
NOTE:
The ABS warning lamp blinks at intervals of 0.25 sec- ECUT
ond when the malfunction code is not memorized.
The ABS warning lamp indicates the malfunction code
GND
by blinking at intervals of 0.5 second. There is an inter- JABS00081-00067
val of 1.5 seconds between the first digit and the sec-
ond digit.
The ABS warning lamp blinks at intervals of the 2.5
seconds between codes when plural codes are memo-
rized.
The ABS warning lamp repeats blinking at intervals of
4 seconds after all memorized malfunction codes are
outputted.
When plural codes are memorized, the ABS warning
lamp indicates diagnosis codes, starting from a smaller
number.
BR73
Diagnosis code table
NOTE:
Be sure to perform trouble shooting including its related wire harness hand and connectors of pre-
sumable parts mentioned in the table above.
Code
Output from of diagnosis code Diagnosis contents Presumable causes
No.
Nil Normal No trouble on sensor systems

0.25 sec.
Speed sensor
Lack of output voltage of Sensor rotor
71
front right side speed sensor Clearance between sensor and sensor rotor
0.5 1.5 sec.
sec. Wheel bearing
Speed sensor
72 Clearance between sensor and sensor rotor
front left side speed sensor
1.5 sec. Wheel bearing
Speed sensor
73 Clearance between sensor and sensor rotor
rear right side speed sensor
Speed sensor
74 rear left side speed sensor Clearance between sensor and sensor rotor
Speed sensor
Excessive variation of output
Sensor rotor
75 voltage of front right side
Clearance between sensor and sensor rotor
1.5 sec. speed sensor
Deterioration of sensor tip and/or sensor rotor
Speed sensor
Sensor rotor
76 voltage of front left side speed
1.5 sec. sensor
Speed sensor
Sensor rotor
77 voltage of rear right side
1.5 sec. speed sensor
Speed sensor
Sensor rotor
78 voltage of rear left side speed
sensor
1.5 sec. Deterioration of sensor tip and/or sensor rotor
79 Gravity sensor function Gravity sensor

1.5 sec.
JABS00082-00000

12. Remove the SST (jump wire) from the SST (sub-harness.)
NOTE:
All memorized codes will be erased when the ignition switch is turned off or the jump wire between
the terminals ABST and the ground terminal is removed.
13. Remove the SST from the diagnosis connector.

14. Perform the unit inspection for parts mentioned in the table above as presumable cause and their relat-
ed harnesses.
JABS00083-00000

BR74
GRAVITY SENSOR
: Tightening torque
w Unit : Nm (kgf-m)
6.9 - 9.8 B
(0.7 - 1.0)
S
q Rear console box assembly
w Console panel
e Gravity sensor
JABS00084-00040
NOTE:
The function check of the gravity sensor should be performed by the sensor check function.
The following procedure applies only to the inspection of attaching conditions, removal and installation.
1. Removal of rear console box

(2) Remove the console box by removing the two attaching bolts and screw grommets. (Refer to BO
section.)
NOTE:
Change the shift lever position while removing the center console box in the case of automatic trans-
mission-equipped model. JABS00085-00000
2. Inspection of gravity sensor for installation condition

Check the gravity sensor for the following points.
Connector connecting condition.
Gravity sensor installing condition.
Ensure that the gravity sensor attaching bolts are tight-
ened properly and the gravity sensor is seated on the
floor panel properly.
Also, check that the wire harness for the gravity sensor
is not interfered with the gravity sensor.
If any trouble exists, repair or replace the gravity sen- JABS00086-00041
sor or the wire harness.
3. Removal of gravity sensor

(1) Remove the gravity sensor attaching bolts.
(2) Disconnect the two wire harness clamps from the bracket of the gravity sensor.
(3) Disconnect the connector from the gravity sensor.
4. Installation of gravity sensor
(1) Connect the connector of the wire harness to the gravity sensor.
(2) Connect the two wire harness clamps to the bracket of the gravity sensor.
JABS00087-00000

BR75
(3) Install the gravity sensor to the floor panel with two attaching bolts in such a direction that the con-
nector provided on the gravity sensor faces toward backward.
CAUTION:
Never install the gravity sensor in a reverse direction. The gravity sensor can be installed in both di-
rections. Failure to observe this caution may make the gravity sensor inoperative.
Never pinch the wire harness of the gravity sensor at the front side of the gravity sensor during the
installation.
Be sure to clean the contacting surfaces of the gravity sensor and floor panel before installing the
gravity sensor.
(2) Tighten the attaching bolts evenly in two or three stages to the specified tightening torque.
5 Install the center console boxes with two attaching bolts and screw grommets. (Refer to BO section.)
JABS00088-00000
FRONT SPEED SENSOR
NOTE:
The check of the speed sensor is basically carried out by the sensor check function.
: Tightening torque
w
Unit : Nm (kgf-m)
B
6.9 - 9.8
(0.7 -1.0) q
6.9 - 9.8
(0.7 -1.0)
B B
q Front fender liner

w Speed control front sensor
e Sensor mounting No. 1 bracket
JABS00089-00042
1. Checking of air gap

Ensure that the air gap between the sensor tip and the
sensor rotor is within the specified value.
Air gap: 0.7 0.5 mm
If the air gap fails to meet the specified air gap, replace
the speed sensor, knuckle or sensor rotor(drive shaft), as
required. (Refer to FS section.)
JABS00090-00043

BR76
2. Checking of sensor rotor
Inspect the sensor rotor for the following points.
Ensure that the sensor rotor is pressed in on the drive
shaft properly, is free from damage and is not contami-
nated by foreign materials.
Ensure that the wheel bearing has no excessive play.
If any trouble exists, clean, repair or replace the sensor

rotor (drive shaft) or wheel bearing, as required. (Refer to
FS section.)
JABS00091-00000
3. Removal of front speed sensor

(1) Remove the fender liner. (Refer to BO section.)
(2) Disconnect the wire harness side connector from the
sensor connector.
(3) Remove the front speed sensor by removing the at-
taching bolts.
4. Inspection of speed sensor JABS00092-00044
(1) Ensure that the front speed sensor resistance is within

the specified value, using an ohmmeter.
Specified resistance: 1.1 0.2 k W (at 20C)
(2) Ensure that the tips of the speed sensors are free from
damage or contamination with foreign materials. 2 1
Clean the tips of the speed sensors, if they are conta-
minated.
5. Installation of front speed sensor
CAUTION:
Be sure to clean the contacting surfaces of the speed JABS00093-00045
sensors and speed sensor before the installation.

Never twist the speed sensor harness during the instal-
lation and check that the checked line has not been
twisted.
6. Install the speed sensor to the vehicle with the attaching

bolts and tighten them to the specified tightening torque.
Tightening torque:
Speed sensor harness clamp to inner fender:
6.9 - 9.8 Nm (0.7 - 1.0 kgf-m)
Speed sensor to knuckle:
6.9 - 9.8 Nm (0.7 - 1.0 kgf-m)
7. Install the fender liner. (Refer to BO section.)

BR77
REAR SPEED SENSOR
NOTE:
The check of the speed sensor is basically carried out by the sensor check function.
q Speed control rear left sensor 6.9 - 9.8 (0.7 -1.0)
w Speed control rear right sensor B
q w
6.9 - 9.8
N B
6.9 - 9.8 (0.7 -1.0)
(0.7 -1.0) B
B
: Tightening torque
Unit : Nm (kgf-m)
JABS00094-00046
1. Remove the rear wheels. (Refer to RS section.)

2. Checking of air gap.
(1) Remove the rear wheel. (Refer to RS section)
(2) Ensure that the air gap between the sensor tip and the
sensor rotor (brake drum) is within the specified value.
Air gap: 1.8 1.0 mm
If the air gap fails to meet the specified air gap, re-
place the speed sensor, brake backing plate (refer to
RS section.) or sensor rotor (brake drum), as required.
(3) Install the rear wheel. (Refer to RS section.) JABS00095-00047
3. Checking of sensor rotor (brake drum.)

(1) Remove the rear wheel. (Refer to RS section.)
(2) Ensure that the sensor rotor is free from damage and
contamination with foreign materials. Also, check that
no excessive free play exists on the wheel bearings.
If any trouble exists, clean, repair or replace the sen-
sor rotor(brake drum) or wheel bearing, as required.
(3) Install the rear wheel. (Refer to RS section.)
JABS00096-00048
4. Inspection of speed sensor

CAUTION:
Never remove the rear speed sensor from the vehicle,
unless its replacement is required.
No spare part of the sensor wire clamp is available.
2 1
(1) Disconnect the connector of the rear speed sensor
from the connector of the wire harness.
(2) Ensure that the rear speed sensor resistance is within
the specified value, using an ohmmeter.
Specified resistance: 1.1 0.2 k W (at 20C) JABS00097-00049

BR78
(3) Ensure that the tips of the speed sensors are free from damage or contamination with foreign mate-
rials.
Clean the tips of the speed sensors, if they are contaminated.
(4) Connect the connector of the rear speed sensor to the connector of the wire harness.
5. Removal of speed sensor
NOTE:
Refer to the illustration shown in page BR77.
(1)
Turn off the ignition switch.
(2)
Disconnect the connector of the speed sensor from the connector of the wire harness.
(3)
Disconnect the sensor harness clamp by removing the attaching bolts.
(4)
Disconnect the sensor harness clamp form the floor panel by retracting its lock sections, using a
minor screwdriver or the like.
(5) Remove the speed sensor by removing the attaching bolt.
6. Installation of speed sensor
(1) Clean the attaching surface of the speed sensor and backing plate.
(2) Install the speed sensor with the attaching bolt and tightening it to the specified tightening torque.
(3) Connect the sensor harness clamp to the floor panel and ensure that the locking section is properly
engaged by pulling it lightly.
(4) Connect the sensor harness clamp with the attaching bolts and tighten them to the specified tight-
ening torque.
(5) Connect the connector of the speed sensor to the connector to the wire harness.
(6) Check the speed sensor by performing the sensor check function of the ABS.
JABS00098-00000

BR79
ABS ACTUATOR
WARNING:
Be sure to prevent foreign substances from being admitted into the brake actuator. Failure to observe
this warning may lead to serius brake malfunction.
: Tightening torque
r Unit : Nm (kgf-m)
u 15.5 2.5 (1.59 0.26)
N e
4.3 - 6.5 (0.44 - 0.66)
i
N
w
q
N 4.3 - 6.5 (0.44 - 0.66)

q Nut 15.2 - 23.0 (1.55 - 2.35) o
w Nut y
B
e Nut
r Brake tube clamp
t Brake warning relay t
assembly
y Relay bracket
B
u Brake tube
i Brake actuator assembly B B
o Actuator No.1 bracket assembly
15.2 - 23.0 (1.55 - 2.35)
JABS00099-00050
1. Check of continuity and resistance

(1) Disconnect the negative terminal of the ground cable
from the negative terminal of the battery.
NOTE:
Be sure to read out the diagnosis code of the ABS and
EFI before disconnecting the battery power supply.
(2) Remove the glove compartment box by removing the

glove compartment door hinge. (Refer to BO section.)
(3) Disconnect the connector of the wire harness from the
ABS ECU. JABS00100-00051
(4) Connect the following SST to the connector of the wire
harness which was connected to the ABS ECU.
SST: 09842-87401-000
NOTE:
Never connect the connector of the SST to the ABS
ECU.

BR80
(5) Remove the inspection diode. (Refer to the inspection diode section)
(6) Remove the motor relay. (Refer to the motor relay section.)
(7) Ensure that the resistance or continuity between the respective terminals is within the specified
value, as shown in the table below.
NOTE:
Resistance values in the following table below denote values at an ambient temperature of 20C.
If any one of resistance or continuity fails to meet the specification in the following table, replace the
actuator with a new one.
JABS00101-00000
Terminal table of SST and connector terminals

SFRH SFLH SRH BM GND 1 2 3 4 5 6 7 8 9 10 11
+BM BM
22 23 24 25 26 27 28 29 30 31 32 2
1 2
4 3 2 1
10 9
3 4
8 7 6 5 13 12 11 1
12 13 14 15 16 17 18 19 20 21
R+ MR
33 34 35 36 37 38 39 40 41 42
SFRR SFLR SRR MT BS AST
Actuator connector SST terminals Motor relay connector Inspection diode
JABS00000-00052
Terminal to be checked or measured

Resistance
Terminal No. (Actuator) 1 3 4 5 7 8 9 10 11 12 13
5 0.25
plus wiring
resistance
2.2 0.2
plus wiring
Terminal to be resistance
checked 33 0.2
plus wiring
resistance
wiring
resistance
SST terminal 22 1 8 23 2 29 19 24
Motor relay 2
Inspection diode 2
If the measured resistance or continuity fails to meet the specified value, perform the unit inspection after
the actuator is removed by referring to the table above, in order to clarify that the trouble originated in the
wire harness or the actuator unit.
JABS00102-00000
(8) Install the motor relay. (Refer to the motor relay section.)
(9) Install the inspection diode. (Refer to the inspection diode section.)
(10) Remove the following SST from the connector of the wire harness which was connected to the ABS
ECU.
NOTE:
Never connect the connector of the SST to the ABS ECU.
(11) Connect the connector of the wire harness to the ABS ECU.
(12) Install the glove compartment box by installing the glove compartment box retainer. (Refer to BO
section.)
(13) Connect the negative terminal of the ground cable from the negative terminal of the battery.
JABS00103-00000

BR81
2. Check of fluid lines in actuator
CAUTION:
Be sure to prevent the brake fluid from coming in con-
tact with the painted surface and resin parts, using a
piece of cloth or the like. If the brake fluid comes in
contact with the painted surface and resin parts, imme-
water.
JABS00104-00053
(1) Loosen the brake pipes connected to the actuator

from the master cylinder.
(2) Ensure that the brake fluid will flow out without resis-
tance when the brake pedal is depressed.
CAUTION:
Be sure to depress the brake pedal gradually, other-
wise a quite large amount of brake fluid will splash out.
If no brake fluid flows out, check the fluid leakage or in-
ternal leakage in the master cylinder.
JABS00105-00054
(3) Tighten the flare nuts to the specified tightening

torque.
Tightening torque: 15.5 2.5 Nm (1.59 0.26 kgf-m)
(4) Loosen the brake pipes connected to the actuator

from the wheel cylinders.
(5) Ensure that the brake fluid will flow out without resis-
tance when the brake pedal is depressed.
CAUTION:
Be sure to depress the brake pedal gradually, other-
wise a quite large amount of brake fluid will splash out.
If no brake fluid flows out, replace the actuator with a

new one, after inspecting the P valve for fluid continu-
ity.
(6) Tighten the flare nuts to the specified tightening
torque.
Tightening torque: 15.5 2.5 Nm (1.59 0.26 kgf-m) JABS00106-00000
3. Function check of actuator

(1) Preparation before inspection
q Check the brake system, using a brake tester.
If any trouble exists, repair it, as required.
w Jack up the vehicle and support it with safety
stands.
(Refer to GI section for supporting position of the
safety stand.)
e Release the parking brake.
r Place the shift lever in the neutral position.
t Ensure that the wheels turn properly. LABS00107-00055

BR82
y Disconnect the negative terminal of the ground
cable from the negative terminal of the battery.
NOTE:
Be sure to read out the diagnosis code of the EFI sys-
tem before disconnecting the power supply to the vehi-
cle.
u Disconnect the connector of the wire harness con-

nected to the ABS ECU.
i Connect the following SST to the connector of the
wire harness disconnected from the ABS ECU. LABS000108-00056
SST: 09842-87401-000
NOTE:
Never connect the connector of the SST to the ABS
ECU.
o Connect the negative terminal of the ground cable

to the negative terminal of the battery.
(2) Inspection of left side front wheel

CAUTION: q wer t
Never connect the terminal to other terminals than that
specified. Failure to observe this caution may lead to
serius trouble including fire.
!8 !9
q Connect the terminals No. 1 and 2 to terminal No. 19.
w Connect the terminals No. 4 and 5 to terminals
No. 40. $0
e Connect the terminals No. 3 to terminals No. 18.
LABS00109-00057
r Ensure that the front side left wheel will be locked

when the brake pedal is depressed.
t Ensure that the locked state of the front side left

wheel will be released and the wheel turns freely,
also, ensure that the brake pedal will rise up slight-
ly when the ignition switch is turned ON while de- LABS00110-00058
pressing the brake pedal.

CAUTION:
Never leave the ignition switch in the ON state for 15
seconds or more.
Failure to observe this caution will make the actuator
inoperative.
y Turn off the ignition switch immediately after the in-

spection.
If the actuator is not functioning as specified
above, replace the actuator with a new one. LABS00111-00059

BR83
y Remove the jump wire in the SST terminals.
NOTE:
Proceed to check the remaining right and rear wheels as mentioned in step (3).
u Disconnect the negative terminal of the ground cable from the negative terminal of the battery.
i Remove the SST from the connector of the wire harness.
o Connect the connector of the wire harness to the ABS ECU.
10. Connect the negative terminal of the ground cable to the negative terminal of the battery.
LABS00112-00000
(3) Inspection of right side front wheel and rear wheels

CAUTION:
The terminals of the SST shown in this step are to be connected for each inspection.
However, the step-by-step procedure is not given in this step. The inspection procedure of the right
side front wheel and rear wheels is the same as the left side front wheel, except terminals to be con-
nected in the SST. Therefore, follow the procedure mentioned in Inspection of left side front wheel,
except terminals in the SST to be connected.
LABS00113-00000
q Right side front wheel

Connect the terminals No. 8 and 29 to terminal 19. e r t i
Connect the terminals No. 4 and 5 to terminal No.
40.
Connect the terminals No. 3 and 18. @9
!8 !9
$0
LABS00114-00060
w Rear wheels
Connect the terminals No. 22 and 23 to terminal er t
19.
Connect the terminals No. 4 and 5 to terminal No.
40. @2 @3
Connect the terminals No. 3 and 18. !8 !9
$0
LABS00115-00061
4. Function check of actuator using DS-21

(1) Preparation before inspection
q Check the brake system, using a brake tester.
w Jack up the vehicle and support it with safety
stands.
(Refer to GI section for supporting position of the
safety stand.)
e Release the parking brake.
r Place the shift lever to the neutral position.
t Ensure that the wheels turn properly.
LABS00116-00000

BR84
(2) Inspection
(Refer to the service manual of DS-21 for more details.)
q Connect the DS-21 to the diagnosis connector,
SST: 09991-87401-000
w Select the function of the actuator drive.

NOTE:
When selecting of the actuator drive, release the secu-
rity function of DS-21.
JABS00117-00062
e Ensure that the wheels turn properly.

r Ensure that the wheels will be locked when the brake pedal is depressed.
t Ensure that the locked state of the front side left wheel will the released and the wheel turns
freely. Also, ensure that the brake pedal will rise up slightly when the function of the front side left
wheel actuator is performed by DS-21.
y Perform the remaining inspection of the front side right wheel and rear wheels one by one, fol-
lowing the steps q to t mentioned above.
JABS00118-00000
5. Removal of ABS actuator

NOTE:
Refer to the illustration in page BR79
(1) Removal of motor relay

q Disconnect the connectors of the wire harness from the motor relay.
w Remove the motor relay by unlocking the lock on its bracket.
e Remove the motor relay bracket.
(2) Drain the brake fluid from the brake system.
(3) Remove the brake tube clamp.
(4) Disconnect the brake pipes from the actuator.
CAUTION:
Prevent dust or other foreign substances from being admitted into the actuator and brake line.
Failure to observe this caution may lead to serius brake problem.
(5) Remove the actuator by removing the attaching nuts.

CAUTION:
Never deform the brake pipes during the removal of the actuator.
(6) Removal of ABS actuator bracket

q Disconnect the brake pipe from the brake pipe clamp.
w Disconnect the brake pipe (connected from the front inlet P valve to the actuator) from the P
valve.
CAUTION:
Prevent dust or other foreign substances from being admitted into the brake line.
Failure to observe this caution may lead to serius brake problem.
e Remove the ABS actuator bracket with the brake pipe by removing the attaching bolts.
JABS00119-00000

BR85
6. Installation of ABS actuator
NOTE:
The installation procedure is basically procedure in the
reverse order of the removal procedure. Therefore,
some illustrations are omitted from the installation pro-
cedure. Refer to the illustration in the removal proce-
dure if any difficulty is encountered.
JABS00120-00000
(1) Installation of ABS actuator bracket

q Insert the brake pipe (connected from the P valve
to the front inlet of the actuator) in the brake actua-
tor bracket as shown.
w Install the ABS actuator bracket by installing the at-
taching bolts and tighten the attaching bolts to the
specified tightening torque evenly.
e Connect the brake pipe to the P valve temporarily

by your hand. JABS00121-00063
(2) Install the actuator with the attaching nuts and tighten
them to the specified tightening torque.
CAUTION:
Never deform the brake pipes during the removal of the
actuator.
(3) Connect the brake pipes to the actuator and tighten

the flare nuts of the brake pipes which are connected
to the actuator and P valve to the specified tightening
torque.
Tightening torque: 15.5 2.5 Nm (1.59 0.26 kgf-m)
CAUTION:
Prevent dust or other foreign substances from being
admitted into the actuator and brake line.
Failure to observe this caution may lead to serius brake
problem.
(4) Fill the brake fluid to the brake system.

(5) Ensure that no brake fluid leakage exists.
(6) Installation of motor relay
q Install the motor relay bracket with the attaching
bolts.
w Connect the motor relay to the motor relay bracket
and ensure that the lock is properly engaged.
e Connect the connectors of the wire harness to the
motor relay.
JABS00122-00000

BR86
ABS ECU
COMPONENTS
q Glove compartment subassembly
w Skid control computer assembly : Tightening torque
Unit : Nm (kgf-m)
8.3 1.4 (0.85 0.15)

B
B B
8.3 1.4 (0.85 0.15) q
JABS00123-00064
CAUTION:
Be sure to read out the diagnosis code of the ABS and
EFI systems before disconnecting the battery power
supply. Failure to observe this caution will erase the
memorized diagnosis codes.
Be sure to perform the unit inspection of the ABS ECU
at the battery voltage between 10 to 14 volts when the
ignition switch is turned ON.
Use correct measuring instrument for inspection.
(Refer to BR42.)
JABS00124-00000
1. Disconnect the negative terminal of the ground cable from

the negative terminal of the battery.
2. Remove the glove compartment box by removing the re-
tainer. (Refer to BO section.)
ABS ECU.
4. Connect the following SST between the ABS ECU and the
connector of the wire harness.
SST: 09842-87401-000
5. Connect the negative terminal of the ground cable to the JABS00125-00065

6. Measure the voltages under the condition specified in the
table below and perform the trouble shooting of the part(s)
related to the wire harness and connection as mentioned
in the table below.
NOTE:
All specifications mentioned in the following table de-
note values at a temperature under 20-25 C.
Be sure to perform the trouble shooting including its re-
lated wire harness and connectors of presumable parts
mentioned in the following table.
BR87
Terminal to be connected Specified value Measuring condition Presumable cause
Zero volt Ignition switch OFF Actuator
1 (SFLH) - 40 (GND) Solenoid relay
Battery voltage Ignition switch ON After ABS warning lamp is extinguished.
2 (SFLR) - 40 (GND)
Battery voltage Ignition switch ON After ABS warning lamp is extinguished. Solenoid relay
Zero volt Ignition switch OFF Solenoid relay
3 (R+) - 40 (GND)
Battery voltage Ignition switch ON Motor relay
Zero volt Ignition switch OFF

Battery voltage Ignition switch ON When motor relay is turned ON
4 (MR) - 40 (GND) Motor relay
When motor is operating, for
Battery voltage Ignition switch ON example, short duration immediately
after ignition switch is turned ON.
5 (SR) - 40 (GND) Solenoid relay
Zero volt Ignition switch ON When solenoid relay is turned ON
6 (FR+) - 40 (GND)
1.0 - 3.0 volts Ignition switch ON Front right speed
Zero volt Ignition switch OFF sensor
7 (FR) - 40 (GND)
1.0 - 3.0 volts Ignition switch ON
8 (SFRH) - 40 (GND)
8 (RL+) - 40 (GND)
1.0 - 3.0 volts Ignition switch ON Front left speed
10 (RL) - 40 (GND)
13 (GST) - 40 (GND) Gravity sensor
Zero volt Ignition switch ON
14 (ABST) - 40 (GND) Diagnosis connector
Battery voltage Ignition switch ON
15 (GS2) - 40 (GND) Gravity sensor
18 (IG2) - 40 (GND) Ignition switch
19 (GND) - 40 (GND)
Zero volt Ignition switch ON Body ground
19 (GND) - Body ground Continuity Ignition switch OFF
22 (SRH) - 40 (GND)
23 (SRR) - 40 (GND)
24 (AST) - 40 (GND)
Battery voltage Ignition switch ON Solenoid relay
Actuator
25 (MT) - 40 (GND) Zero volt Ignition switch ON Motor relay
Battery voltage Ignition switch ON During motor relay is ON

BR88
26 (FL+) - 40 (GND)
1.0 - 3.0 volts Ignition switch ON Front left speed
27 (FL) - 40 (GND)
29 (SFRR) - 40 (GND)
Battery voltage Ignition switch ON After ABS warning lamp is extinguished. Motor relay
31 (RR+) - 40 (GND)
1.0 - 3.0 volts Ignition switch ON Rear right speed
32 (RR) - 40 (GND)
34 (GGND) - 40 (GND)
Zero volt Ignition switch ON
Gravity sensor
35 (GS1) - 40 (GND)
3.0 - 6.0 volts Ignition switch OFF
36 (ECUT) - 40 (GND) Diagnosis connector
Stop lamp switch
37 (STP) - 40 (GND) Zero volt Ignition switch ON Stop lamp
Battery voltage When brake pedal is depressed
Battery voltage Ignition switch OFF
38 (BAT) - 40 (GND) Back-up fuse
Body ground
40 (GND) - Body ground Zero volt Ignition switch ON
Continuity Ignition switch OFF
ABS warning lamp
41 (WA) - 40 (GND) (Combination lamp)
Battery voltage Ignition switch ON After ABS warning lamp is extinguished.
JABS00126-00000

BR89
8. Disconnect the negative terminal of the ground cable from the negative terminal of the battery.
9. Disconnect the SST connectors from the ABS ECU.
10. Measure resistance or continuity between the SST terminals specified in the table below and perform
the trouble shooting for the part(s) related to the wire harness including the connectors mentioned in
the table below.
NOTE:
All specifications mentioned above denote values at a temperature of under 20 - 25C.
@6 (FL+) - @7 (FL) 1.0 - 1.4 kW 20% Front left speed sensor
y (FR+) - u (FR) 1.0 - 1.4 kW 20% Front right speed sensor
o (RL+) - !0 (RL) 1.0 - 1.4 kW 20% Rear left speed sensor
#1 (RR+) - #2 (RR) 1.0 - 1.4 kW 20% Rear right speed sensor
Front left fluid pressure
w (SFLR) - $0 (GND) 2.0 - 2.4 kW 20% retaining solenoid valve
Front right fluid pressure
@9 (SFRR) - $0 (GND) 2.0 - 2.4 kW 20% retaining solenoid valve
Rear fluid pressure retaining
@3 (SRR) - $0 (GND) 2.0 - 2.4 kW 20%
solenoid valve
Ignition switch turned OFF.
Rear fluid pressure reducing
@2 (SRH) - $0 (GND) 4.75 - 5.25 W 20%
solenoid valve
Front left fluid pressure
q (SFLH) - $0 (GND) 4.75 - 5.25 W 20% reducing solenoid valve
Front right fluid pressure
i (SFRH) - $0 (GND) 4.75 - 5.25 W 20% reducing solenoid valve
t (SR) - e (R+) 80 W 20% Solenoid relay
r (MR) - e (R+) 62 W 20% Motor relay
@4 (AST) - $0 (GND) 33 W 20% Monitor resistance
@5 (MT) - $0 (GND) 32 W 20% Motor
JABS00127-00000
11. Disconnect the connectors of the wire harness from the SST.
12. Connect the connectors of the wire harness to the ABS ECU.
13. Install the glove compartment box. (Refer to BO section.)
15. Perform the final check, using a four-wheel brake tester or on the road test.
WARNING:
The road test should be carried out at a safe place.
JABS00128-00000

BR90
Replacement of ABS ECU
(Refer to the illustration in page BR86.)
1. Disconnect the negative terminal of the ground cable from the negative terminal of the battery.
CAUTION:
Be sure to read out the diagnosis code of the ABS and EFI systems before disconnecting the battery
power supply.
2. Remove the glove compartment box by removing its retainer. (Refer to BO section.)
3. Disconnect the connector of the wire harness from the ABS ECU.
4. Disconnect the wire harness clamp from the ABS ECU bracket by retracting the mushroom section of
the clamp.
5. Remove the ABS ECU by removing the two attaching bolts.
6. Install the ABS ECU with two attaching bolts.
7. Connect the wire harness clamp to the ABS ECU connector.
8. Connect the connectors of the wire harness to the ABS ECU.
9. Install the glove compartment box by installing its retainer. (Refer to BO section.)
JABS00129-00000
INSPECTION DIODE
1. Remove the check diode from the connector of the wire
harness.
2. Ensure that continuity exists between the terminals of the

inspection diode. Also, ensure that no continuity exists be- JABS00130-00066
tween the terminals when the attaching order of the tester

probes is reversed, using an ohmmeter. (Refer to the
BR38.)
Replace the inspection diode if it fails to meet the specifi-
cation.
NOTE:
The current flow direction of the ohmmeter differs, de-
pending on its design.
3. Install the inspection diode to the connector of the wire

harness. JABS00131-00000
STOP LAMP SWITCH

Check the stop lamp switch function.
(Refer to the BE section for inspection.)
JABS00132-00000

BR91
TIGHTENING TORQUE
Tightening components Nm kgf-m
Brake pedal clevis 25.5 2.9 2.6 0.3
Bleeder plug 6.9 - 9.8 0.7 - 1.0
Piston stopper bolt master cylinder 7.9 - 11.7 0.8 - 1.2
Master cylinder brake booster 12.7 2.5 1.3 0.3
Brake pipe master cylinder 12.7 - 17.7 1.3 - 1.8
Brake booster dash panel 9.8 - 15.7 1.0 - 1.6
Disc brake cylinder mounting disc rotor 90.2 - 135.3 9.2 - 13.8
Main and sub cylinder slide pins 19.6 - 29.4 2.0 - 3.0
Wheel cylinder backing plate 7.5 - 11.5 0.8 - 1.2
Flare nut wheel cylinder 12.7 - 17.6 1.3 - 1.8
Rear wheel hub nut 103.0 14.7 10.5 1.5
Parking brake cable clamp 5.8 - 8.8 0.6 - 0.9
Parking brake handle assembly floor panel 14.7 - 21.6 0.15 - 0.2
Proportioning valve body 5.9 - 9.8 0.6 - 1.0
Flare nut 12.7 - 17.6 1.3 - 1.8
Brake hose clamp bolt 6.9 - 15.7 0.7 - 1.6
Brake hose disc brake cylinder assembly 26.5 - 34.3 2.7 - 3.5
Gravity sensor floor panel 6.9 - 9.8 0.7- 1.0
Speed sensor harness clamp inner fender 6.9 - 9.8 0.7 - 1.0
Speed sensor knuckle 6.9 - 9.8 0.7 - 1.0
Speed sensor fender epron 6.9 - 9.8 0.7 - 1.0
ABS actuator ABS actuator bracket 4.3 - 6.5 0.44 - 0.66
Brake pipe ABS actuator 15.5 2.5 1.59 0.26
ABS actuator bracket fender epron 15.2 - 23.0 1.55 - 2.35
Flare nut 15.5 2.5 1.59 0.26
Skid control computer assembly body 8.3 1.4 0.85 0.15
JABS00133-00000

BR92
SSTs
Shape Part name Part name Remarks
09730-87401-000 Brake booster gauge set
09737-87003-000 (Gauge)
09733-87401-000 (O-ring)
09731-87401-000 (Attachment)
09732-87401-000 (Adapter)
09734-87401-000 (O-ring)
09735-87401-000 (O-ring)
09703-30010-000 Brake shoe return spring tool
09921-00010-000 Spring tension tool
09991-87401-000 Engine control system inspection wire
09842-87401-000 ABS computer check sub-harness
09991-87403-000 Diagnosis check wire
JABS00134-00068

DAIHATSU
J100
J100
STEERING
IN-VEHICLE INSPECTION ................ SR 2 REMOVAL ..................................... SR12

STEERING WHEEL ....................... SR 2 DISASSEMBLY .............................. SR13
POWER STEERING INSPECTION ................................. SR14
DRIVE BELT .............................. SR 2 ASSEMBLY .................................... SR15
POWER STEERING FLUID ............ SR 3 INSTALLATION .............................. SR16
STEERING WHEEL (PP TYPE) ......... SR 7 STEERING GEAR .............................. SR17
COMPONENTS ............................. SR 7 COMPONENTS ............................. SR17
REMOVAL ..................................... SR 7 REMOVAL ..................................... SR18
DISASSEMBLY .............................. SR 8 DISASSEMBLY .............................. SR19
ASSEMBLY .................................... SR 8 INSPECTION ................................. SR23
INSTALLATION .............................. SR 8 ASSEMBLY .................................... SR24
STEERING WHEEL INSTALLATION .............................. SR34
(AIRBAG TYPE) ............................. SR 9 VANE PUMP ....................................... SR36
COMPONENTS ............................. SR 9 COMPONENTS ............................. SR36
REMOVAL ..................................... SR 9 REMOVAL ..................................... SR36
DISASSEMBLY .............................. SR10 DISASSEMBLY .............................. SR37
ASSEMBLY .................................... SR10 INSPECTION ................................. SR37
INSTALLATION .............................. SR10 ASSEMBLY .................................... SR38 SR
CHECK AFTER INSTALLATION .... SR11 SERVICE SPECIFICATIONS ............. SR40
STEERING COLUMN & SSTs.................................................... SR41
INTERMEDIATE SHAFT ................ SR12 TIGHTENING TORQUE ...................... SR43
COMPONENTS ............................. SR12 JSR00001-00000
NO. 9710-JE

SR2
STEERING WHEEL
Check for rattle
Move the steering wheel in an axial direction and/or in a per-
pendicular direction so as to ensure that no looseness and/or
excessive play is present. SRS AIRBAG
If any looseness and/or excessive play is present, check the

steering wheel for improper installing condition. Repair any
defective parts. JSR00002-00001
Check for free play

1. Set the steering wheel to a straight- ahead state.
2. Turn the steering wheel clockwise and counterclockwise. Free play
Max 10 mm
Measure the steering wheel movement at the circumfer-
ence of the steering wheel which is registered before the
steering tires start to be steered. Ensure that this steering
wheel play is not more than the specified value.
If not, check each joint section for excessive play. If the joints JSR00003-00002
are satisfactory, replace the steering gear assembly.

If the joint sections exhibit defects, such as excessive play, re-
place the defective parts.
Check of turning effort

Check of turning effort of steering wheel with vehicle in its sta-
tionary state
While the engine is idling and with the vehicle in its stationary
state, measure the force required to turn the steering wheel
from the straight-ahead position.
Specified Value: Not to exceed 5.4 Nm (0.55 kgf-m) JSR00004-00003
If the turning effort is fails to meet with specified value, check

tire pressure, quality of fluid etc., or check and overhaul the
power steering systems as necessary.
POWER STEERING DRIVE BELT

Visual inspection
Inspect the drive belt for damage.
Visually check the belt for separation of the adhesive rubber
above and below the core, core separation from the belt side,
severed cord, separation of the rib from the adhesive rubber,
cracks or separation of the ribs, torn ribs or cracks in the inner
ridges of the ribs. Replace the drive belt, if necessary.
JSR00005-00004

SR3
Check of drive belt tension
Measuring point
Ensure that the amount of the drive belt deflection within
Vane pump Vane pump
specified value, by depressing the midpoint of the drive belt pulley pulley Idler
pulley
between the vane pump and crank shaft pulley (vehicles
Air
equipped without air conditioner) or vane pump and air condi- Idler conditioner
pulley
tioner pulley (vehicles equipped with air conditioner) is
pushed with a force of 98 N (10 kgf). Crank shaft Measuring Crank shaft
pulley point pulley
New belt: 8 - 11 mm
Used belt: 11 - 14 mm With air conditioner Without air conditioner
JSR00006-00005
Adjust the drive belt deflection by means of adjusting bolt, if

the deflection is failes to meet with the specified value.
NOTE:
Prior to the check, ensure that the drive belt is applied
correctly on the pulley.
The new belt refers to that belt driven not more than
five minutes on the engine.
The used belt refer to that belt driven more than five
minutes on the engine.
JSR00007-00006
POWER STEERING FLUID

Check of fluid level
1. Park the vehicle on a level floor.
2. Stop the engine. MAX
3. Ensure that the power steering fluid level within specified MIN
HOT
COLD
MAX
MIN
level at the reservoir tank.
NOTE:
Hot range denotes that when the fluid temperature is
between 40 to 80 degrades.
Cold range denotes that when the fluid temperature is
between 0 to 40 degrades. JSR00008-00007
When the fluid level does not conform to the specifica-

tion, check the fluid leakage or component parts for
malfunction. Then, add the specified powersteering
fluid to specified level as necessary.
Check of fluid properties

1. While the vehicle is in its stationary state and the engine
is idling, turn the steering wheel from lock to lock position
in both right and left directions.
2. Visually inspect the fluid inside the reservoir tank.
NOTE:
If the fluid is foamy or exhibits whitish cloudiness,
most likely the fluid is lacking. Hence, perform air
bleeding and adjust the fluid level.
If foreign matters, such as dirt, are mixed in the fluid,
be certain to change the fluid. JSR00009-00000

SR4
Fluid change
1. Jack up the vehicle and support it with the safety stands.
2. Place the suitable container to under the return hose at re-
serve tank side.
3. Disconnect the return hose from the reservoir tank so as to
allow the fluid to flow out.
4. Start the engine. (Never race the engine.)
5. Turn the steering wheel from lock to lock position in both
the right and left directions.
CAUTION: JSR00010-00008
To prevent vane pump seizure, be sure to drain the

fluid as shortest as possible without raising the engine
revolution speed.
6. Stop the engine.
7. Fill the reservoir tank with fluid.

Power Steering Fluid: ATF DEXRONII
8. Start the engine and run it idly. When the fluid starts to flow
out from the return hose side, immediately stop the en-
gine.
9. Repeat the steps 7 and 8 above, until air no longer injects
from the return side.
10. Connect the return hose to the reservoir tank.
12. Perform air bleeding for the power steering system. (Refer
to step Air bleeding for the power steering system men-
tioned below.)
JSR00011-00000
Air bleeding for the power steering system

1. Check the fluid level of the reservoir tank.
NOTE:
If the fluid is lacking, add the specified fluid to the maxi-
mum level in the reservoir tank.
2. Run the engine at a speed below the fast idle speed. Turn
the steering wheel up to the lock position in either the right
or left direction. Hold this locked state for about two to
three seconds. Next, turn the steering wheel up to the op-
posite lock position. Hold this locked state for about two to JSR00012-00009
three seconds. Repeat this operation two to three times.

NOTE:
Be certain to turn the steering wheel quickly.
If the fluid temperature is low, most likely the fluid re-
mains foamy. Hence, prior to the bleeding operation, be
certain to warm the fluid up to 40 to 70C by turning the
steering wheel repeatedly with the vehicle in its station-
ary state.
Check the fluid level of the reservoir tank during the
bleeding operation. If the drop in fluid level is more
than 5 mm, recheck the piping for fluid leakage. JSR00000-00010

SR5
3. While turning the steering wheel with the vehicle in its stationary state, check that the power steering
system is operating properly or it emits no abnormal noise, etc. Perform this check with the engine run-
ning at over 3000 rpm.
NOTE:
If the following abnormalities are encountered during this check, check each part of the power steer-
ing system for sign of leakage. Again repeat the operations described in the step (2) afterward. If the
trouble persists even these steps have been followed, replace faulty components of the power steer-
ing system.
The fluid exhibits whitish cloudiness when the engine revolution speed is rising quickly.
The steering operation is not smooth and also emitting abnormal noise.
The change in fluid level exceeds 5 mm between a time when the engine is running and a time when
the engine is stopped or between a time when the power steering is operating and a time when the
power steering is stopped.
The power steering system emits abnormal noise during the running (when the front wheels are turn-
ing).
JSR00013-00000
Check of power steering fluid pressure

1. Drain the fluid from the power steering system. (Refer to the Fluid change section.)
2. Disconnect the pressure feed hose with gasket from the vane pump by disconnecting the union bolt
which is bolted in the air control valve. (Refer to the SR36.)
3. Connect the two end of the following SST to vane pump.
(1) Connect the one end of the SST to vane pump.
(2) Connect the other end of the SST to pressure feed hose with gasket using the union bolt.
SST: 09990-87704-000
(Use the attachments (PSG-FJL, 2ST) for connection of the oil pressure gauge to the vane pump and pres-
sure feed hose as shown bellow.)
To union bolt
IN FJL
To pressure gauge
2ST
FJL
To pressure gauge OUT

2ST
To vane pump
JSR00014-00011

SR6
CAUTION:
Never connect the IN and OUT side hoses of the oil pressure gauge in wrong way. Failure to ob-
serve this caution may lend to damaging the oil pressure gauge.
Never bend or twist the hoses and tubes forcibly.
Never close the valve of the oil pressure gauge at this moment.
4. Perform the filling of fluid (Refer to the Fluid change section.) and the air bleeding (Refer to the Air
bleeding for the power steering system section.).
5. Warm up the power steering fluid, until its temperature rises above 50C.
6. Measurement of hydraulic pressure generated by vane pump
While the engine is idling, measure the hydraulic pressure generated by the vane pump by closing the
valve of the oil pressure gauge fully.
Specified Pressure: 5786 kPa (59 kgf/cm2) or more
If the hydraulic pressure is low, replace the vane pump assembly with new one.
CAUTION:
Never close the valve of oil pressure gauge not more than 10 seconds during measurement.
7. Check of pressure difference under unloaded state

(1) Open the pressure gauge valve fully.
(2) Determine the difference in pressure between a time when the engine revolution speed is 1000 rpm
and a time when it is 3000 rpm.
Specified Value: Not to exceed 294 kPa (3 kgf/cm2)
NOTE:
If the difference in hydraulic pressure exceeds the specified value, replace the vane pump assembly.
Never operate the steering wheel during the measurement.
8. Measurement of hydraulic pressure at gear housing side

(1) While the engine is idling, open the pressure gauge valve fully.
(2) Ensure that the oil pressure gauge reading is more than that specified during steering wheel turns
lock to lock positions from the steering wheel turns fully in right and left positions.
Specified Value: 5.4 MPa +0.5 +5
0 (55 0 kgf/cm )
2
If the hydraulic pressure is lower than that specified at either side of the right or the left, overhall the
steering gear assembly.
9. Drain the fluid from the power steering system. (Refer to the Fluid change section.)
10. Remove the oil pressure gauge (SST).
JSR00015-00000
11. Connect the pressure feed hose to the vane pump, by union bolt with new gasket interposed.
12. Perform the filling of fluid (Refer to the Fluid change section.) and the air bleeding (Refer to the Air
bleeding for the power steering system section.).
13. Ensure that no fluid leakage is exists from the fluid pipe connected sections of power steering systems
under engine operated and when turning the steering wheel.
JSR00016-00000

SR7
Check of air control valve
1. Ensure that there is no air continuity exists between port
A and port B of the air control valve in the right figure
when steering wheel not operated under engine at idling
state.
2. Ensure that there is air continuity exists between port A
and port B of the air control valve in the right figure when
steering wheel turns fully in right or left direction under en-
gine at idling state.
NOTE:
Be sure to perform the above check with the air control JSR00017-00012
valve in the vane pump assembly.
STEERING WHEEL (PP TYPE)

COMPONENTS
r
: Tightening torque
Unit : Nm (kgf-m) e
w
S
y
t
0.49 - 0.98
(0.05 - 0.10)
q
JSR00018-00013
REMOVAL
negative () terminal of the battery.
2. Hold the steering wheel pad sub-assembly at its lower
end by your fingers. Then, detach the upper side of the
w q q
steering wheel pad sub-assembly by pulling it toward your
w
side. w
NOTE:
Be careful not to break the claw of the steering wheel
pad by pulling it excessively.
JSR00019-00014
3. Remove the horn harness and lock nut.

4. Remove the steering wheel.
CAUTION:
Never tap the shaft, using a hammer or the like, when
removing the steering wheel from the shaft. If any diffi-
culty is encountered in removing the steering wheel,
use a steering wheel puller to remove it.
JSR00020-00015

SR8
DISASSEMBLY
1. Remove the horn button contact plate.
2. Remove the steering wheel cover from the steering wheel.
ASSEMBLY
1. Install the steering wheel cover to the steering wheel.
2. Install the horn button contact plate to the steering wheel.
JSR00021-00016
INSTALLATION
1. Install the steering wheel to the steering wheel cover. Apply grease
2. Apply rubber grease on the indicated area in the right fig-
ure.
JSR00022-00017
3. Ensure that the vehicle is in a straight-ahead state. Then,

install the steering wheel assembly to the steering shaft.
NOTE:
Make sure that the steering wheel is installed, making
an angle of 15 from the neutral position.
Never tap the shaft, using a hammer or the like, when
installing the steering wheel to the shaft.
4. Install and tighten the lock nut. Then, connect the horn
harness.
Tightening Torque: 27.5 - 41.2 Nm (2.8 - 4.2 kgf-m) JSR00023-00018
5. Install the steering wheel pad.

NOTE:
Be careful not to break the claw at the back side of the
steering wheel pad by pushing it excessively.
w q q
w
6. Connect the battery ground cable to the negative terminal w
of the battery.
JSR00024-00019

SR9
STEERING WHEEL(AIRBAG TYPE)
COMPONENTS
w
e
w
S
r q
5.2 - 9.5
(0.53 - 0.97)
: Tightening torque
Unit : Nm (kgf-m)
JSR00025-00020
REMOVAL
1. Turn OFF the ignition switch and disconnect the battery
cable from the negative () terminal of the battery.
2. Set the steering wheel to a straight-ahead position.
Remove the attaching bolts (TORX bolt) at the right and
left sides of the steering wheel cover side.
WARNING:
Be sure to start the operation 60 seconds after the
power supply is cut off. Failure to observe this warning
may cause unexpected deployment of the airbag owing
to impacts, etc. during the removal. JSR00026-00021
Never bring your face, arms and body to the front of

the steering wheel during the removal.
If the pad assembly is dropped or damaged during the
removal or the storage, be sure to dispose of the pad
assembly according to the disposal procedure. Be sure
to mount a new pad assembly to the vehicle.
CAUTION:
It should be noted that, when the negative () terminal
of the battery is disconnected, the memory of the ECU
control of other systems will be erased at the same JSR00000-00022
time.
3. Separate the pad and steering wheel from the top of the
pad assembly. Disconnect the connector for the airbag
and connector for the horn provided at the reverse side of
the pad assembly.
WARNING:
Never resume the operation within 60 seconds after
the power supply has been cut off, during which the
backup condenser is discharged.

SR10
4. After the connector is disconnected, remove the pad as-
sembly from the steering wheel.
WARNING: GOOD DANGER
Be sure to place the removed pad assembly with the
pad surface facing upward. The pad assembly placed
with the pad surface facing downward is potentially
hazard. Failure to observe this caution may cause un-
expected deployment of the airbag, resulting in scat-
tered pad assembly. Furthermore, store the pad as-
sembly at a low place close to the ground level where
no heat source (100C or less) exists in close proximity. JSR00027-00023
5. Ensure that the steering wheel is set to a straight-ahead

position.
6. Remove the lock nut.
7. Detach the connector from the clamp.
CAUTION:
Care must be exercised so that the connector may not
be caught in when removing the steering wheel.
JSR00028-00024
DISASSEMBLY
Remove the steering wheel cover by removing the attaching
screws.
ASSEMBLY
Install the steering wheel cover by installing the attaching
screws.
JSR00029-00025
INSTALLATION
PRECAUTION:
It should be noted that wrong installation of the steering
roll connector may pose potential hazard, for it may
break the wire and also prevent proper turning of the
steering wheel.
1. Ensure that the front wheels are set to the straight-ahead

position.
JSR00030-00000
2. Turn the steering roll connector clockwise, until it is

locked.
CAUTION:
The steering roll connector makes five turns at the
maximum. Hence, when the steering roll connector is
connected to the steering wheel, be sure to set the
steering roll connector to the midpoint of the rotation.
3. Back off the steering roll connector about 2.5 turns coun-
terclockwise from the locked position. Align the center
mark. Temporarily secure the steering roll connector, using
a tape, so that it may not move. JSR00031-00026

SR11
4. Ensure that the vehicle is in a straight-ahead state. Then,
install the steering wheel assembly to the steering shaft.
CAUTION:
Make sure that the steering wheel is installed, making
an angle of 15 from the neutral position.
5. Turn the steering wheel about 60 in a right-and-left direc-

tion two or three times so as to positively fit the cancella-
tion pin of the multi-use lever switch to the cutout section
of the steering wheel boss section.
6. Install and tighten the lock nut. JSR00032-00027
7. Installation of steering wheel pad assembly

(1) Ensure that the ignition switch is set to the OFF or ACC
position.
(2) Set the horn connector at the roll connector side to the
connector holder of the steering wheel.
(3) Join the horn connector at the pad assembly side to
the connector that has been set in Step (2).
(4) Join the connectors for the squib at the roll connector
side and pad assembly side together so as to make JSR00033-00028
double locking.
(5) With the double locking side of the connector for the
squib which has been set in Step (4) facing down-
ward, set the connector for the squib to the connector
holder of the steering wheel while sliding it.
(6) Set the harness for the squib leading to the roll con-
nector to the lower part of the connector holder.
8. Temporarily install the pad assembly to the steering wheel,
making sure that it exhibits no excessive rattle.
9. Tighten the TORX bolts (at two points) provided at the
side of the steering wheel proper to the specified tighten- JSR00034-00029
ing torque.
CHECK AFTER INSTALLATION

1. Ensure that steering wheel operates smoothly with out any
pulling and abnormal resistance by turning the steering
wheel to the right and left sides, respectively, as far as it
will go.
2. Connect the negative () terminal of the battery ground
cable to the negative terminal of the battery terminal.
3. Ensure that the horn is set off by pushing the horn button.
4. Ensure that the airbag warning lamp illuminates for six
seconds immediately after turn ON the ignition switch.
JSR00035-00000

SR12
STEERING COLUMN & INTERMEDIATE SHAFT
COMPONENTS
t
: Tightening torque
Unit : Nm (kgf-m)
y
3.9 - 6.9 14.7 - 21.6

(0.4 - 0.7) (1.5 - 2.2)
9.8 - 15.7
(1.8 - 1.6)
24.5 - 34.5
(2.5 - 3.5)
r
q Steering column assembly
w Dust cover retainer
e Dust cover
r Intermediate shaft
24.5 - 34.3 t Steering column upper bracket with switch
(2.5 - 3.5) y Ignition switch
JSR00036-00030
REMOVAL
1. Disconnect the negative () terminal of the battery ground
cable from the negative () terminal of the battery.
(Refer to the STEERING WHEEL section.)
3. Remove the instrument panel lower finish panel.
4. Remove the steering column lower cover.
JSR00037-00031
5. Remove the intermediate shaft and steering column con-

necting bolt.
JSR00038-00032

SR13
6.Disconnect the connector for the ignition switch.
7.Remove the steering column attaching bolts and nuts.
8.Remove the steering column upper cover.
9.Disconnect the connector for the multi-use lever switch, air
bag (if equipped) and immobilizer (if equipped).
10. Remove the steering column by removing the attaching
bolt.
CAUTION:
Be very careful not to scratch the dust cover when re-
moving the steering column.
JSR00039-00033
11. Removal of intermediate shaft

(1) L.H.D. vehicle
Remove the air intake duct from the air cleaner case.
R.H.D. vehicle
Remove the battery and battery carrier.
(2) Remove the intermediate shaft and steering gear pin-
ion connecting bolt.
(3) Remove the intermediate shaft from the steering gear.
JSR00040-00034
12. Remove the dust cover retainer and dust cover from the
dash panel by removing attaching bolts.
JSR00041-00035
DISASSEMBLY
1. Remove the multi-use lever switch assembly by loosening
the two attaching screws.
NOTE:
On airbag-equipped vehicles, the multi-use lever switch
should be removed with the roll connector attached.
2. Remove the antenna coil.(If equipped.) JSR00042-00036
NOTE:
For the replacement of the antenna coil on immobilizer-
equipped vehicles, refer to the BE section.
Stop pin
3. Remove the ignition key cylinder from the steering column
upper bracket with the switch.
Ignition key
NOTE: cylinder
Set the ignition key to the ACC position and push the
stop pin. Then, draw out the cylinder.
Set to ACC
This operation can be performed on the vehicle if the
steering column cover is removed beforehand. JSR00043-00037

SR14
4. Remove the ignition switch from the steering column
upper bracket by removing the attaching screw.
NOTE:
This operation can be performed also on the vehicle.
5. Removal of the steering column upper bracket. JSR00044-00038
NOTE:
Perform this operation only when it becomes neces-
sary to replace the steering column upper bracket
alone.
(1) Remove the steering column upper bracket by remove

the head section of the attaching bolt, using a drill.
(2) Remove the upper bracket from the steering column
tube.
(3) Screw-out the thread part of the attaching bolt from the
steering column upper bracket. JSR00045-00039
INSPECTION
Steering column dust cover and retainer
Ensure that the steering column dust cover and dust cover re-
tainer free from cracks, deterioration, aging, deformation and
other damage.

one
JSR00046-00040
Intermediate shaft (collapsible type and rigid type)

Measure the length of intermediate shaft.
If the length is shorter than the specified length excessively, replace it with a new one.
Ensure that the intermediate shaft exhibits no defect, such as excessive play or rattle at the spline section
and excessive play or rattle at the joint section of the universal joint.
CAUTION:
Never drop the collapsible type intermediate shaft nor apply strong impacts to it. Failure to observe
this caution may lead to loss of the impact-absorbing function.
Specified Length:
L.H.D. 368 mm R.H.D 363 mm
JSR00047-00041

SR15
Steering column assembly
Ensure that the length of the steering column assembly is not less than specified value by measuring the its
length.
If the length is shorter than the specified length excessively, replace it with a new one.
Ensure that the steering column assembly exhibits no defect, such as excessive play at the spline section.
CAUTION:
Never drop the collapsible type steering column assembly nor apply strong impacts to it. Failure to
observe this caution may lead to loss of the impact-absorbing function.
Specified Length:
Rigid type 708.6 mm Collapsible type 701 mm
JSR00048-00042
ASSEMBLY
1. Install the steering column upper bracket to the steering
column tube with new attaching bolt and tighten it until it
with break off.
2. Install the ignition switch to the steering column upper
bracket with attaching screws.
NOTE:
Before installing the ignition switch, set the protrusion
of steering column upper bracket with the groove inside
the ignition switch each other.
JSR00049-00043
3. Install the ignition key cylinder to the steering column

upper bracket. Then, ensure that the stop pin of the igni-
tion key cylinder is hooked at the hole of the column upper
bracket.
NOTE:
Before installing the ignition key cylinder, set the igni-
tion key position to the ACC. Then, set the pawl groove
inside the steering column upper bracket with the pro-
trusion of ignition key cylinder.
JSR00050-00044
4. Install the multi-use lever switch assembly to the steering

column with the attaching screw.
JSR00051-00045

SR16
INSTALLATION
1. Install the dust cover to the retainer.
2. Install the dust cover retainer to the dash panel with the at-
taching bolts.
3. Insert the steering column to the dust cover hole.

4. Attaching the steering column upper cover on the steering
column.
5. Install the steering column temporarily with the attaching
bolts and nuts. JSR00052-00046
6. Connect the intermediate shaft between the steering col-

umn shaft and steering gear pinion while aligning the tooth
less section of the steering column shaft and universal
joint of the intermediate shaft during the assembly. Then,
tighten the attaching bolts to the specified tightening
torque.
JSR00053-00047
7. Tighten the steering column attaching bolts and nuts.

Tightening Torque:
Bolt: 14.7 - 21.6 Nm (1.5 - 2.2 kgf-m)
Nut: 9.8 - 15.7 Nm (1.0 - 1.6 kgf-m)
8. Connect the connectors.
JSR00054-00048
9. Install the steering column lower cover.

10. Install the instrument panel lower finish panel.
11. Install the steering wheel.(Refer to the STEERING WHEEL
section.)
12. Connect the battery ground cable terminal to the negative
JSR00055-00049

SR17
STEERING GEAR
COMPONENTS
: Tightening torque 19.6 - 29.4

Unit : Nm (kgf-m) (2.0 - 3.0)
w 14.7 - 21.6
(1.5 - 2.2)
r
!3
!4 w
o t
!5 y
!6 i
u
!7
!8
!9
@0
@1
19.6 - 29.4
@2 (2.0 - 3.0)
!0
!1
!2
59 - 79
(6.0 - 8.0) @3
@4
@6 @5
@7
@8
#3
88 - 118
(9.0 - 12.0)
#1 #2
@9
59.8 - 89.2 #0
(6.1 - 9.1)
Apply Molybdenum Disulphide Lithium Base Grease

Apply Power Steering Fluid
Apply Silicone Grease
q Turn pressure tube !2 Bearing guide nut @3 Rack guide seat

w Union seat !3 Clip @4 Rack guide
e Dust cover !4 Rack boot @5 Spring
r Control valve housing !5 Boot band @6 Rack guide spring cap
t O-ring !6 Cylinder end stopper @7 Lock nut
y Oil seal !7 O-ring @8 Steering rack
u Bearing !8 Bush @9 Claw washer
i Control valve !9 Oil seal #0 Rack end
o Ring @0 Oil seal #1 Seal ring
!0 Oil seal @1 Spacer #2 O-ring
!1 O-ring @2 Rack housing #3 Tie rod end
JSR00056-00050

SR18
REMOVAL
1. Drainage of power steering fluid
(See page SR4, Fluid change.)
2. Remove the intermediate shaft. (See page SR12.)
3. Affix a tape or the like to the pinion section of the steering
gear so as to prevent the body, etc., from being damaged
during the removal of the steering gear assembly.
JSR00057-00051
4. Disconnect the return tube and pressure feed hose at the

union section of the steering gear assembly.
JSR00058-00052

(Refer to the GI section.) SST
8. Separation of tie-rod end
(1) Remove the clip, then remove the castle nut from the
tie-rod end.
(2) Separate the tie-rod end from the steering knuckle,
SST: 09611-87701-000
JSR00059-00053
CAUTION:
Never made damage to boot and threaded portion dur-
ing disconnection by the SST.
9. Remove the bracket retaining the pressure feed hose and

return tube.
10. Remove the steering gear assembly mounting bolts.
11. Take out the power steering gear assembly from the vehi-
cle.
NOTE:
Remove the tape which was affixed in Step 3. JSR00060-00054

SR19
DISASSEMBLY
PRECAUTION
Never reuse non-reusable parts. (Failure to observe this caution may cause serious accidents.)
Prior to the disassembly, be sure to wipe off any sand or mud adhering to the outside of the power
steering gear assembly so that they may not get into the inside during the disassembly and assembly.
When disassembling and assembling, do not use gloves. These operations should be performed by
bare hands.
Be sure to always arrange the disassembled parts in order and protect them from dust, etc.
Prior to the assembling of each part, be sure to wash the part completely and dry it. Then, apply the
ATF DEXRONII. As for aluminum and rubber sections, never wash them with alkaline chemicals. Also,
never wash rubber parts, such as O-rings and oil seals, with cleaning solvent (white gasoline, etc.).
Liberally apply the ATF DEXRONII to sliding surfaces and rotating sections before assembling them.
When securing a part in a vice, be sure to interpose aluminum plates.
Be very careful not to scratch oil seals, O-rings and so forth during the installation.
Prior to the application of seal agents, be sure to wipe off thoroughly the old seal agent remaining at the
seal section. Then, wash the seal section with white gasoline and dry it.
When using compressed air, be sure to wear protective goggles.
JSR00061-00000
1. Removal of turn pressure tube

Remove the turn pressure tubes from the rack housing as-
sembly, using the following SST.
SST: 09633-00020-000
CAUTION:
If the steering rack is moved with the turn pressure
tube removed, residual fluid may splash.
Therefore, care must be exercised so that no fluid may
get to your eyes.
JSR00062-00055
NOTE:
Be very careful not to scratch the spool section during
the removal of the tube.
2. Remove the union seats from the cylinder tube side turn
pressure tube attaching hole.
3. Remove the bracket and grommet from the steering gear JSR00000-00056
housing.
4. Secure the power steering gear assembly with a vice,
SST: 09612-00012-000
NOTE: SST
When the SST is installed to the power steering gear
assembly, a gap will be formed. At this time, be very
careful not to damage the rack housing by excessively
tightening the attaching nuts of the SST.
Be sure to evenly tighten the attaching nuts of the SST. JSR00063-00057

SR20
5. Removal of tie rod end
Mating mark
(1) Put a mating mark on the tie rod end and steering rack
end.
(2) Remove the tie rod end by loosening the lock nut.
JSR00064-00058
6. Removal of steering rack boots

(1) Remove the steering rack boot bands.
NOTE:
Never reuse the removed steering rack boot bands.
Be very careful not to damage the boots during the re-
moval of the steering rack boot bands.
(2) Remove the clips by means of a pair of pliers.

(3) Remove the steering rack boots from the steering rack
end sub-assemblies while compressing the boots by
means of a screwdriver or the like. JSR00065-00059
NOTE:
When removing the steering rack boots, care must be
exercised so that no overstroke and so forth may take
place due to the steering racks displacement.
When removing the steering rack boots, be very careful
not to apply impacts to the boots.
7. Removal of steering rack end sub-assemblies

(1) Secure the ball joint section of the steering rack end
with a vice.
(2) Release the staked part of the claw washer, using a JSR00066-00000
chisel.
NOTE:
Be very careful not to damage the steering rack.
Never reuse the removed claw washer.
When removing the claw washer, be very careful not to
apply impacts to the steering rack.
(3) Remove the steering rack end sub-assemblies from

the steering rack, using the following SST and a
wrench.
SST: 09922-10010-000 (Width across flats: 30 mm) JSR00067-00060
NOTE:
After removing the tooth side steering rack end, put the
turning-preventing cutout section provided at the tooth
side of the rack in a vice. Then, remove the steering
rack end at the opposite side.
8. Remove the claw washer from the removed steering rack

end sub-assembly.

SR21
9. Remove the lock nut for the rack guide spring cap, using
the following SST.
SST: 09922-10010-000
(Width across flats: 42 mm)
24 mm
10. Remove the rack guide spring cap, using the following
SST.
SST: 09612-10020-000
(Width across flats: 24 mm)
42 mm
11. Remove the rack guide spring, rack guide and rack guide JSR00068-00062
seat.
12. Put a mating mark on the control valve housing and rack
housing.
13. Remove the control valve housing by removing attaching
bolts.
14. Remove the O-ring from the valve housing.
JSR00069-00063
15. Removal of control valve

(1) Put the control valve housing in a vice.
(2) Affix a tape or the like to the pinion section of the steer-
ing gear so as to prevent the pinion section from being
SST
damaged.
(3) Remove the bearing guide nut, using the following
SST.
SST: 09631-20060-000
(4) Remove the O-ring from the bearing guide nut.

JSR00070-00064
16. Remove the dust cover.

17. Remove the control valve by tapping it, using a plastic
hammer or the like.
JSR00071-00065
18. Remove the cylinder end stopper, using the following SST.
SST: 09631-20090-000
SST
JSR00072-00066

SR22
19. Removal of rack and cylinder side rack oil seal
(1) Insert a 20 mm-dia. bar or a suitable tool from the rack
housing side. Remove the cylinder side rack oil seal
and rack together, using a press.
(2) Remove the oil seal from the rack.
JSR00073-00067
20. Removal of the rack housing side rack oil seal PRESS
(1) Insert a 27 mm-dia. remover or a suitable tool from the
rack housing side. Remove the rack oil seal and spac-
er at the rack housing side, using a press. Rack housing 27.5 mm
Bar
Rack cylinder 27 mm
Spacer
Oil seal
26 mm
JSR00074-00068
21. Removal of steering rack oil seal ring and O-ring

(1) Cut off the seal ring No. 2 from the rack sub-assembly
by means of a cutter or the like.
NOTE:
When cutting off the seal ring No. 2, be very careful not
to scratch the ring groove and side surface.
(2) Remove the O-ring from the rack sub-assembly by

means of a small screwdriver or the like.
NOTE:
Never reuse the removed O-ring. JSR00075-00069
22. Remove the bearing guide nut oil seal, using a 32 mm-dia.
remover or a suitable tool (e.g. 22 mm socket wrench) in
combination with a press. 32 mm
JSR00076-00070
23. Remove the control valve housing oil seal and bearing,
using a 27 mm-dia. remover or a suitable tool in combina-
tion with a press. Bar
Oil seal
Bearing
Control valve
housing
JSR00077-00071

SR23
24. Remove the seal rings of the power steering control valve
sub-assembly by cutting them by means of a cutter or the Seal ring
like.
NOTE:
When cutting the seal rings, be very careful not to
scratch the seal ring grooves and side surface.
JSR00078-00072
INSPECTION
Power steering rack
1. Check the tooth surface for wear and damage.
2. Ensure that the bend of the rack is within the specified
value, using V-blocks and a dial gauge.
Bend: 0.15 mm
NOTE:
The bend should be measured at the center of the
rack.
JSR00079-00073
Radial ball bearing of control valve housing

Turn the bearing by your hands. At this time, ensure that the
bearing exhibits no binding and emits no abnormal noise.
Also, check to see if the bearing rotates smoothly.
JSR00080-00074
Control valve
Turn the bearing by your hands. At this time, ensure that the
bearing exhibits no binding and emits no abnormal noise.
Also, check to see if the bearing rotates smoothly.
Check that the gear section and serration section have no
scores.

one.
JSR00081-00075
Control valve housing

Check to see if the turn pressure tube attaching hole is not
clogged or scored.
Check that the control valve housing inner section has no
scores.

one.
JSR00082-00076

SR24
Rack housing assembly
Check to see if the turn pressure tube attaching hole is not
clogged or scored.
Check that the external and inner sections exhibit no major
scores and dents.

one.
JSR00083-00077
Cylinder end stopper

Check that the external and inner sections exhibit no major
scores and dents.

one.
JSR00084-00078
Boot
Check the boot for rapture, deformation and major scores.

one.
JSR00085-00079
ASSEMBLY
1. Assembly of power steering rack sub-assembly
(1) Attach a new O-ring to the ring groove of the rack sub-
assembly.
NOTE:
Do not expand the O-ring excessively.
When attaching the O-ring, apply power steering fluid
to the O-ring.
Care must be exercised so that the O-ring may not be
twisted during the installation. Also, be very careful not
to scratch the O-ring. JSR00086-00080
(2) Lightly rub a new seal ring No. 2 with your fingers so
as to expand the ring. Then, attach the ring to the ring
groove of the rack sub-assembly.
JSR00087-00081

SR25
NOTE:
Do not expand the seal ring excessively.
When attaching the ring, apply power steering fluid to
the seal ring.
Be very careful not to twist the seal ring during the in-
stallation. Also, at most care must be exercised so as
not to scratch the ring by your finger nails during the in-
stallation.
After completion of the installation, be sure to apply
power steering fluid to the ring groove again.
JSR00088-00082
(3) Hold the expanded seal ring by your hand and con-
tract it so that the ring may be bedded in.
JSR00089-00083
2. Installation of rack housing side rack oil seal

Insert the spacer and oil seal in this order from the cylin-
der tube side, using the following SSTs in combination with
a press.
SST: 09631-00020-000
09631-12020-000
SST
JSR00090-00084
3. Installation of rack cover tube to power steering rack sub-

assembly
(1) Pack lithium base grease to the bottom land of the
steering rack tooth.
NOTE:
Care must be exercised so that the ventilation hole of
the steering rack may not be restricted with grease.
(2) Apply power steering fluid to the steering seal ring

No. 2.
JSR00091-00085

SR26
(3) Installation of rack cover tube
Rack Cover Tube (SST): 09612-87101-000
q Prepare the rack cover tube and a sheet of paper.

NOTE:
The rack cover tube is used to protect the oil seal. Any
damage on the tube surface will cause oil leakage.
Therefore, prior to use, be sure to check that no burr
nor cracks are present at the tube surface before it is
contracted.
JSR00092-00086
w Cut the rack cover tube (SST) 3 cm greater than

the length that covers the power steering rack
tooth surface and port.
e Cut a sheet of paper having thickness virtually the
same as that of a newspaper in such a way that
the width may cover the tooth surface and the
length may become equal to that of the rack cover
tube.
NOTE:
Paper is used to prevent the tooth pattern of the rack
from remaining on the rack cover tube when it is con- JSR00093-00000
tracted.
r Install the paper in such a way that it covers the

tooth surface of the power steering rack sub-as-
sembly.
t Install the rack cover tube on the power steering
rack sub-assembly in such a way that the folds of
the rack cover tube come at points indicated in the
right figure.
JSR00094-00087
y Contract the rack cover tube by blowing air with a

dryer or the like. At this time, blow air from the sec-
tion A toward section B at the back of the rack
tooth surface of the rack cover tube which is in-
stalled to the power steering rack sub-assembly. In
this way, ensure that air inside the rack cover tube
flows into the side B.
NOTE:
Be sure to contract the back side of the tooth surface. If
the tooth surface side of the power steering rack
should be contracted, the tooth pattern at the tube will JSR00095-00088
make the tube removal difficult.

SR27
u Turn the rack cover tube 180 degrees.
i Contract the rack cover tube at the back side of
the tooth with a dryer in the same manner with the
operation above.
o Pull out the paper installed to the power steering
rack sub-assembly.
NOTE:
If the paper breaks, pull out the tube once and remove
the paper. Install the tube again to the power steering
rack sub-assembly.
JSR00096-00089
!0 Fully warm up the forward end of the power steer-

ing rack only with a dryer. After warming-up, imme-
diately push the forward end into the threaded hole
of the rack end while twisting the tube.
NOTE:
Do not contract the rack cover tube at the tooth surface
of the power steering rack sub-assembly.
!1 Ensure that the rack cover tube surface exhibits no

protrusion or edge.
NOTE:
If any protrusion or edge exists, remove it by warming
up the tube by means of a dryer, etc. and contracting it.
Do not contract the rack cover tube at the tooth surface
of the power steering rack sub-assembly.
JSR00097-00090
!2 Ensure that the power steering cylinder tube oil

seal spacer can be passed smoothly without any
binding.
NOTE:
Prior to this check, ensure that no burr exists at the
inner periphery of the spacer.
This check is performed so as to confirm that the inner
side of the spacer will not scrape the rack cover tube
surface during the assembly of the power steering rack
sub-assembly.
JSR00098-00091
!3 Ensure that no damage, such as scratch, exists on

the rack cover tube surface.

SR28
4. Install the rack into the cylinder.
5. Installation of cylinder tube side rack oil seal
(1) Put the rack housing in a vice, using the following SST.
SST: 09612-00012-000
(2) Install the cylinder tube side oil seal to the rack.
(3) Install a new O-ring to the cylinder end stopper.
(4) Insert the cylinder end stopper while pushing the oil SST
seal, using the following SST.
SST: 09631-20090-000
JSR00099-00092
6. Remove the rack cover tube installed to the power steer-

ing rack sub-assembly.
7. Air tightness test
(1) Install the SST to the union section of the steering rack
housing assembly.
SST: 09631-12071-000
NOTE:
Install the SST with a packing interposed.
(2) Connect a MityVac to the SST. JSR00100-00093
Apply a negative pressure of about 52 kPa (0.53

kgf/cm2) and keep it for about 30 seconds.
Ensure that the reading of the MityVac will not change.
NOTE:
If any air leakage exists, replace the oil seals.
8. Assembly of power steering control valve

(1) Apply power steering fluid to a new seal ring No. 1.
Push the ring from the smaller-diameter side to the
center of the larger-diameter side so as to expand the
ring.
SST: 09631-20070-000
NOTE:
Thoroughly wash the SST. Make sure that the SST is
not scratched. Also, make sure that no dust adheres to
the SST. JSR00102-00095
Do not expand the ring unnecessarily.

Be sure to expand evenly the entire periphery of the
ring.
Be very careful not to scratch the ring.
(2) With the seal ring attached to the SST, insert the SST
into the control valve sub-assembly from the direction
indicated in the right figure. Attach the expanded seal
rings to the seal ring grooves of the control valve sub-
assembly.
JSR00103-00096

SR29
(3) Hold the seal rings attached to the control valve sub-
assembly with your fingers and contract it so that the
rings may be bedded in.
NOTE:
Be very careful not to scratch the edge surface and
outer periphery of the ring by your finger nails.
JSR00104-00097
(4) Apply power steering fluid to the seal rings again.

Contract the rings further, using the following SST,
while settling the ring in place.
SST: 09631-20081-000
NOTE:
Thoroughly wash the SST. Make sure that the SST is
not scratched. Also, make sure that no dust adheres to
the SST.
Apply power steering fluid to the inside of the SST.
JSR00105-00098
9. Assembly of control valve housing

(1) Install the oil seal, using the following SST or a 32 mm-
dia. remover or a suitable tool in combination with a
press.
SST
(2) Install the bearing, using the following SST or a
34 mm-dia. remover or a suitable tool in combination
with a press.
SST: 09608-30012-000 (Part No. of set)
09608-04020-000 (Bar)
09630-24013-000 (Part No. of set)
09620-24030-000 (Spacer) JSR00106-00099
36 mm
Control valve
housing
Bearing
Oil seal
32 mm
JSR00000-00100
(3) Install the oil seal to the bearing guide nut, using the
following SST in combination with a press.
(4) Install a new O-ring to the bearing guide nut. SST
SST: 09608-30012-000 (Part No. of set)
09608-04020-000 (Bar)
09631-22070-000 (Replacer)
SST
JSR00107-00101

SR30
(5) Insert the control valve to the control valve housing.
NOTE:
To prevent the oil seal damage, wind a vinyl tape on
the serration part of the control valve shaft.
SST
(6) Install the oil seal to the control valve shaft.

(7) Install the bearing guide nut, using the following SST.
SST: 09631-20060-000
JSR00108-00102
(8) Stake the guide nut.

(9) Install a new O-ring to the control valve housing.
(10) Install the dust cover to the control valve housing.
JSR00109-00103
10. Installation of power steering control valve housing

(1) Apply power steering fluid to the ring section of the
power steering control valve.
(2) Assemble the power steering control valve sub-assem-
bly to the steering rack housing.
NOTE:
During this assembling, make sure that the steering
rack is engaged with the pinion of the control valve by
turning the control shaft in a right-&-left direction, using
the following SST.
SST: 09616-00010-000 JSR00110-00104
11. Assemble the rack guide seat to the rack guide.

12. Install the rack guide with the rack guide seat to the steer-
24 mm
ing gear housing.
13. Install the rack guide spring.
14. Temporarily tighten the rack guide spring cap.
42 mm
JSR00111-00105
15. Adjustment of total pre-load

(1) Tighten the rack guide spring cap to the specified
torque, using the following SST.
SST: 09922-10010-000 SST
Tightening Torque: 14.5 Nm (1.5 kgf-m)
(2) From the condition (1), back off the rack guide spring
cap about 12 degrees.
JSR00112-00106

SR31
(3) Move the steering rack one or two times in the full
stroke by turning the control valve shaft, using the fol-
lowing SST, so that steering rack may be bedded in. SST
SST: 09616-00010-000
NOTE:
Make sure that the rack end surface will not enter into
each end surface of the rack housing sub-assembly.
Care must be exercised so that no overstroke takes
place.
JSR00113-00107
(4) Loosen the steering rack guide spring cap, using the
following SST, until the rack guide spring no longer op-
erates.
SST: 09612-10020-000 SST
NOTE:
Loosen the cap to the extent that the steering rack end
surface moves smoothly when pushing it by your hand.
JSR00114-00108
(5) Tighten the steering rack guide spring cap progres-

sively, until the pre-load may become the specified
value when the control valve shaft is being turned, SST
using the following SSTs.
SSTs: 09616-00010-000 (Steering gear pinion)
09612-10020-000 (Rack guide spring cap) SST
Specified Pre-load: 0.78 - 1.54 Nm
(0.08 - 0.16 kgf-m)/during turning
JSR00115-00109
(6) Apply Three Bond 1141 to the threaded portion of the

lock nut (for rack guide spring cap) and to the end
surface of the rack housing side. SST
Tighten it to the specified torque, using the following
SSTs.
SSTs: 09922-10010-000 (Width across flats: 42 mm) SST
09612-10020-000 (Rack guide spring cap)
Tightening Torque: 59 - 79 Nm
(6.0 - 8.0 kgf-m)
JSR00116-00110
(7) Turn the control valve shaft, using the following SST.
Ensure that the pre-load during turning comes within
the specified range. SST
SST: 09616-10020-000
Specified Pre-load: 0.78 - 1.54 Nm
(0.08 - 0.16 kgf-m)/during turning
JSR00117-00111

SR32
16. Check the rack hole.
JSR00118-00112
17. Attach a new claw washer to the steering rack in the direc-
tion indicated in the right figure.
NOTE:
Be sure to align the pawl of the claw washer with the
cut-out section of the steering rack.
JSR00119-00113
18. Install the steering rack end sub-assembly to the steering

rack assembly. Tighten it to the specified torque.
SSTs: 09922-10010-000 (Width across flats: 30 mm)
NOTE: SST
Be very careful not to twist the steering rack during
tightening.
JSR00120-00114
19. Secure the ball joint section of the steering rack end sub-
assembly with a vice. Stake the claw washer, using a ham-
mer in combination with a brass bar or the like.
NOTE:
Positively stake the two points of the claw washer.
Be very careful not to apply impacts to the steering
rack.
Be very careful not to tighten the ball joint section ex-
cessively. Failure to observe this caution may cause
deformation of the ball joint section.
JSR00121-00115
20. Apply silicone grease into the rack boot groove of the
steering rack end sub-assembly.
Specified Grease: Silicone grease
(Three Bond TB1855)
JSR00122-00116

SR33
21. Install new steering rack boot bands to the steering rack
housing sub-assembly.
22. Install the steering rack boots to the steering rack end
sub-assembly.
23. Stake the installed steering rack boot bands.
JSR00123-00117
24. Install the clips to the steering rack end sub-assembly.

CAUTION:
Make sure that the knob of the clip comes in the range
indicated in the figure when installing the clip.
231
JSR00124-00118
25. After the steering rack boots have been installed, move
the steering rack in the full stroke several times using the
following SST. Ensure that the boots exhibit no abnormal SST
dent or bulge.
Also, ensure that the boots are not caught-in.
SST: 09616-00010-000
JSR00125-00119
26. Install the union seats into the rack housing tube.
NOTE:
Be very careful not to insert the union seat in a wrong
direction.
27. Install the right and left turn pressure tubes to the rack
housing cylinder, using the following SST.
SST: 09633-00020-000
JSR00126-00120
28. Install the grommet to the steering rack housing.

29. Install the bracket to the grommet.
NOTE:
The rack housing and rack cylinder grommets differ in
shape.
Hence, be sure to assemble the grommets correctly.
Rack cylinder Rack housing

grommet grommet
JSR00127-00121

SR34
30. Install the tie rod ends to the steering rack ends according Mating mark
to the mating marks that were put during the removal, ex-
cept for the installation of a new part.
Tighten the nut to the specified torque.
(6.1 - 9.1 kgf-m)
NOTE:
Make sure that the tie rod end is installed in the correct
direction.
JSR00128-00122
INSTALLATION
1. Attach the power steering gear assembly to the front sus-
pension cross member sub-assembly from the right.
(On left-hand drive vehicles, attach the power steering
gear assembly from the left side.)
2. Install the bracket retaining the pressure feed hose and re-
turn tube.
JSR00129-00123
3. Attach the tie-rod end to the steering knuckle and tighten

the nut.
(4.0 - 5.5 kgf-m)
4. Install the clip.
JSR00130-00124
5. Install the engine undercover.

6. Install the front wheel.
8. Connect the return tube and pressure feed hose at the
union section of the steering gear assembly.
JSR00131-00125
9. Connect the intermediate shaft between the steering col-

umn shaft and the steering gear pinion.
NOTE:
Make sure that the non-spline section of the steering
column shaft is aligned with the opening section of the
universal joint of the intermediate shaft during the as-
sembly.
JSR00132-00126

SR35
10. Fill the power steering fluid. (See page SR3.)
11. Perform the air bleeding. (See page SR4.)
12. Adjust the wheel alignment. (Refer to the FS section.)
JSR00133-00000

SR36
VANE PUMP
COMPONENTS
: Tightening torque
Unit : Nm (kgf-m)
q
39.2 - 49.0
(4.0 - 5.0) r
w N
y
B
B
34.3 - 49.0
(4.0 - 5.0)
q Vacuum hose
w Pressure feed hose
e Return tube
r Air control valve
t Drive belt
y Collar
u Vane pump assembly
JSR00134-00127
REMOVAL
1. Drain the power steering fluid. (See page SR3.)
2. Disconnect the return tube from the suction pipe.
3. Disconnect the vacuum hose from the air control valve.
JSR00135-00128
4. Remove the union bolt with the air control valve from the
vane pump, using the following SST.
SST: 09617-22030-000
5. Remove the pressure feed hose.
JSR00136-00129

SR37
6. Remove the adjusting bolt, collar and plate nut.
NOTE:
While removing the adjusting bolt, be very careful not
to drop the spacer and the plate nut on the floor.
7. Remove the vane pump mounting bolt.

8. Remove the vane pump drive belt.
9. Remove the vane pump.
JSR00137-00130
DISASSEMBLY
1. Remove the pulley from the vane pump.
JSR00138-00131
2. Remove the bracket from the vane pump.

3. Remove the suction pipe from the vane pump.
4. Remove the O-ring from the suction pipe.
JSR00139-00132
5. Remove the air control valve from the union bolt.

6. Remove the union seat from the union bolt.
JSR00140-00133
INSPECTION
VANE PUMP
Check that the external section exhibits no major scores and
dents.
Check that no oil leakage is present.
If any damage is exists, replace the damage part with now

one.
JSR00141-00134

SR38
AIR CONTROL VALVE
dents.
For operation check, see page SR7.
If any damage is exists, replace the damage part with new

one.
JSR00142-00135
VANE PUMP PULLEY

dents.

one.
JSR00143-00136
SUCTION PIPE
Check the suction pipe for scores and rapture.

one.
JSR00144-0000137
ASSEMBLY
1. Install the union seat to the union bolt.
NOTE:
Make sure that the union seat be installed in a correct
direction.
2. Install the air control valve to the union bolt.

Tightening Torque : 32 - 42 Nm (3.2 - 4.2 kgf-m)
JSR00145-00138
3. Install the O-ring to the suction pipe.

4. Install the suction pipe to the vane pump.
5. Install the bracket to the vane pump.

JSR00146-00139

SR39
6. Install the pulley to the vane pump.
JSR00147-00140
7. Temporarily install the vane pump with the vane pump

mounting bolt.
8. Install the vane pump drive belt. (Refer to the SR2.)
9. Temporarily tighten the adjusting bolt.
10. Adjust the belt tension. Then, tighten the adjusting bolt
and vane pump mounting bolt.
(For the adjusting method of the belt tension, see page
SR3.)
Tightening Torque:
Adjusting bolt: 34.3 - 49.0 Nm (3.5 - 5.0 kgf-m)
Mounting bolt: 34.3 - 49.0 Nm (3.5 - 5.0 kgf-m) JSR00148-00141
11. Connect the return tube to the suction pipe.

12. Connect the pressure feed hose by means of the union
bolt with the air control valve, using the following SST.
SST: 09617-22030-000
13. Connect the vacuum hose to the air control valve.
JSR00149-00142

SR40
Item Specified value Remarks
Vane pump When new belt is used: 8 - 11 mm
drive belt When pushed with a force of 98 N
tension When used belt is used: 11 - 14 mm
Hydraulic pressure generated With oil pressure gauge valve
by vane pump 5.4+0.5 +5 2
0 MPa (55 0 kgf/cm ) at 500 rpm
closed
Pressure difference that occurs
Difference in pressure under
Oil pressure Within 490 kPa (5 kgf/cm2) between 1000 rpm and 3000 rpm
unloaded state
of engine speed
Hydraulic pressure at gear With steering gear in fully-locked
5.4+0.5 +5 2
0 MPa (55 0 kgf/cm ) at 500 rpm
housing state
Turning effort of steering wheel with vehicle in

Not to exceed 5.4 Nm (0.55 kgf-m)
stationary state
Pre-load of steering gear input shaft 0.78 - 1.57 Nm (8 - 16 kgf-cm) While rotating:
JSR00150-00000

SR41
SSTs
09611-87701-000 Tie-rod end puller
09990-87704-000 P/S pressure gauge
09612-00012-000 Rack and pinion steering rack housing stand
09633-00020-000 Power steering hose nut wrench
09922-10010-000 Steering rack end wrench
09617-22030-000 Worm bearing adjusting screw lock nut wrench
09612-10020-000 Hexagon wrench
09616-00010-000 Steering pinion bearing adjusting socket
09631-12020-000 Handle
09631-20090-000 Cylinder end stopper nut wrench
09608-30012-000 Front hub and drive pinion bearing set
09608-0420-000 Handle
09631-00020-000 Handle

SR42
09630-24013-000 Steering rack oil seal tool set
09620-24030-000 Valve cap bearing replacer
09631-20070-000 Seal ring guide
09631-20081-000 Seal ring tool
09631-20060-000 Bearing guide nut wrench
09631-22070-000 Oil seal replacer
09631-12071-000 Steering rack oil seal test tool
09612-87101-000 Rack tube cover
JSR00151-00143

SR43
TIGHTENING TORQUE
Components Nm kgf-m
Steering wheel Steering shaft 25.7 - 41.2 2.8 - 4.2
Steering Wheel Steering wheel pad (Air bag type) 5.2 - 9.5 0.53 - 0.97
Steering column Instrument panel reinforthment (bolt) 14.7 - 21.6 1.5 - 2.2
Steering column Instrument panel reinforthment (Nut) 9.8 - 15.7 1.8 - 1.6
Dust cover retainer Dash panel 3.9 - 6.9 0.4 - 0.7
Steering column Intermediate shaft 24.5 - 34.3 2.5 - 3.5
Inter mediate shaft Steering gear 24.5 - 34.3 2.5 - 3.5
Steering rack housing Control valve housing 14.7 - 21.6 1.5 - 2.2
Turn pressure tube Control valve housing 19.6 - 29.4 2.0 - 3.0
Turn pressure tube Steering rack cylinder 19.6 - 29.4 2.0 - 3.0
Rack guide housing Lock nut 59 - 79 6.0 - 8.0
Pressure feed hose Control valve housing 39.2 - 49.0 4.0 - 5.0
Control valve housing Bearing guide nut 19.6 - 29.4 2.0 - 3.0
Steering rack Rack end 88 - 118 9.0 - 12.0
Rack end Tie rod end 59.8 - 89.2 6.1 - 9.1
Tie-rod end Steering knuckle 39.2 - 53.9 4.0 - 5.5
Vane pump Pump stay 34 - 52 3.52 - 5.28
Vane pump Pulley 33 - 53 3.4 - 5.4
Vane pump Air control valve 39.2 -49.0 4.0 - 5.0
Air control valve Union bolt 32 - 42 3.2 - 4.2
Vane pump bracket Engine 34.3 - 49.0 3.5 - 5.0
Drive belt adjusting bolt 34.3 - 49.0 3.5 - 5.0
Steering gear assembly Front suspension cross member sub-assembly 53.9 - 81.4 5.5 - 8.3
JSR00152-00000

DAIHATSU
J100
BODY
ALIGNMENT ADJUSTMENTS ................... BO 2

FRONT BUMPER ........................................ BO 7
FRONT FENDER ........................................ BO11
REAR BUMPER .......................................... BO13
FENDER LINER .......................................... BO16
HOOD & HOOD LOCK CONTROL
CABLE .................................................... BO18
FUEL LID OPENER .................................... BO22
ROOF DRIP MOLDING ............................... BO24
ROOF RAIL & ROOF END SPOILER ......... BO25
REMOVABLE ROOF ................................... BO28
INSTRUMENT PANEL ................................ BO30
FRONT SEAT .............................................. BO37
REAR SEAT ................................................ BO39
SEAT BELT ................................................. BO40
FRONT DOOR ............................................ BO44
REAR DOOR ............................................... BO52
BACK DOOR ............................................... BO59
TRIM & GARNISH ....................................... BO64
WINDOWS ................................................... BO70 BO
FUEL TANK ................................................ BO82
ACCELERATOR PEDAL ............................. BO91
EXHAUST PIPE .......................................... BO93
ENGINE MOUNTING INSULATOR ............. BO94
TIGHTENING TORQUE .............................. BO96
JBO00001-00000
NOTE:
When the tightening torque values are not given, refer to the tightening torque table for general standard bolts to find the re-
quired tightening torque values.
NO. 9710-JE

BO2
ALIGNMENT ADJUSTMENTS
m
400 m
mm
200
u
y
r
r
i
w
e q
q Specified value y Specified value

Gap: 4.4 1.5 mm Gap: 5.2 1.5 mm
Lateral deviation: Not to exceed 1.5 mm Lateral deviation: Not to exceed 1.5 mm
Difference between right and left sides: Difference in height: 5.9 1.5 mm
Not to exceed 1.5 mm u Specified value
w Specified value Gap: 5.2 1.5 mm
Gap: 4.7 1.5 mm Lateral deviation: Not to exceed 1.5 mm
Lateral deviation: Not to exceed 1.5 mm Difference in height: 7.2 1.5 mm
Difference in height: 0 1.5 mm i Specified value
e Specified value Gap: 7.8 1.5 mm
Gap: 7.6 1.5 mm Difference between right and left sides:
Difference between right and left sides: Not to exceed 2.0 mm
Not to exceed 2.0 mm Difference in height: 5.2 1.5 mm
Difference in height: 2.9 1.5 mm
r Specified value
Gap: 5.5 1.5 mm
Lateral deviation: Not to exceed 1.5 mm
Difference in height: 0 1.5 mm
t Specified value
Gap: 4.7 1.5 mm
JBO00002-00001

BO3
1. Gap adjustment
Engine hood
(1) Loosen the bolts attaching the engine hood to the en-
gine hood hinge and adjust the engine hood alignment
to the specified value mentioned below.
Specified Value:
Gap: 4.4 1.5 mm
Difference Between Right and Left Sides:
Not to exceed 1.5 mm
Lateral Deviation: Not to exceed 1.5 mm
JBO00003-00002
(2) Tighten the engine hood attaching bolts properly.
2. Adjustment of difference in height

(1) Loosen the bolts attaching the hood lock to the radia-
tor supports.
(2) Adjust the hood lock attaching position to adjust the
difference in height to the specified value.
At the same time adjust the height of the hood cushion
rubber so that the clearance between the engine hood
and the cushion rubbers may become zero and the
height at the right and left sides may become the JBO00004-00003
same.
Specified Value of Difference in Height:
Not more than 1.5 mm
ADJUSTMENT OF FRONT DOOR AND REAR

DOOR SST
1. Gap adjustment
(1) Front door
q Loosen the attaching bolts of the door hinges,
JBO00005-00004
SST: 09812-00010-000
CAUTION:
Never scratch the painted surface of the body during
the operation.
w Perform the adjustment by changing the attaching

position of the front door hinges to the body.
e Tighten the attaching bolts of the door hinge, using
the following SST.
SST: 09812-00010-000
r Adjust the door lock striker, as required.
(2) Rear door

q Loosen the attaching bolts of the door hinge.
position of the rear door hinges to the body.
e Tighten the attaching bolts of the door hinge.
r Adjust the door lock striker, as required.
JBO00006-00005

BO4
Front
(1) Front/Rear door hinge side.
q Loosen the bolts attaching the door to the door
hinges.
position of the front door to the door hinges.
e Tighten the bolts attaching the door to the door
hinge.
JBO00007-00006
Rear
JBO00000-00007
(2) Front/Rear door lock striker side.

q Loosen the screws of the lock striker.
w Perform the adjustment of the lock striker by tap-
ping it lightly with a hammer to change the attach-
ing position of the lock striker.
e Tighten the attaching bolts of the lock striker.
JBO00008-00008

BO5
ADJUSTMENT OF BACK DOOR ALIGNMENT
q Specified value
Gap: Door hinge section 10.4 2.0 mm
Difference in height: 1.8 2.0 mm
100 mm
100 mm
w w Specified value
Gap: 2.0 1.5 mm
e r Difference in height: 1.5 1.5 mm
e Gap: 6.8 1.5 mm
t Lateral deviation: Not to exceed 1.5 mm
r Gap: 6.8 1.5 mm
t Gap: 7.3 2.0 mm
JBO00009-00009
1. Gap Adjustment
(1) Loosen the attaching bolts of the hinge to the back
door.
(2) Perform the adjustment by changing the attaching po-
sition of the door panel.
If any difficulty is encountered in adjusting the attach-
ing position of the back door due to lack of adjusting
allowance, perform the adjustment by loosening the
nuts attaching the back door hinge to the vehicle shell
after the three grommets of the roof head lining are re-
moved. JBO00010-00010
NOTE:
Be very careful not soil or bend the roof head lining
during the loosening of the nuts attaching the hinge to
the vehicle shell.
(3) Tighten the attaching bolts of the hinge to the back

door.

BO6
(1) Remove the rear bumper.
(Refer to the rear bumper section.)
(2) Remove the right hand side rear combination lamp.
(3) Remove the rear bumper filler by removing the attach-

ing bolts.
(4) Loosen the attaching bolts of the back door lock strik-
er.
(5) Adjust the difference in height by changing the attach-
ing position of the back door lock striker. JBO00011-00011
(6) Tighten the attaching bolts of the back door lock strik-
er.
3. Back door lock striker side

(1) Loosen the screws of the lock striker.
(2) Perform the adjustment of the lock striker by tapping it
lightly with a hammer to change the attaching position
of the striker.
(3) Tighten the attaching bolts of the striker.
JBO00012-00012
4. Adjustment of back door lower female stopper

(1) Loosen the attaching bolts of the back door lower fe-
male stopper to just only move the back door lower fe-
male stopper.
(2) Close the back door slowly.
(3) Open the back door slowly.
(4) Tighten the attaching bolts of the back door down fe-
male stopper.
(5) Ensure that the back door down female stopper is not
interfered with the down male stopper by repeating the
opening and closing operations of the back door. JBO00013-00013

BO7
FRONT BUMPER
COMPONENTS
y
u
i
y
e
!9 r
w
q w
@0
o
!1 !2
!0
!4
!5
!6
!7 !3
!8
q Front bumper cover !1 Front turn signal lamp lens

w Front bumper guard base No. 1 bracket !2 Bulb
e Front bumper guard right bracket !3 Front fog & turn lamp assembly
r Front bumper guard left bracket !4 Turn cord
t No. 1 clip !5 Bulb
y Radiator grill assembly !6 Fog cord
u Retainer !7 Bulb
i Grill retainer !8 Front fog & turn lamp lens
o Front bumper guard garnish subassembly !9 Front bumper right bracket
!0 Front turn signal lamp assembly @0 Front bumper left bracket
JBO00014-00014

BO8
REMOVAL
1. Removal of front fog & turn signal lamp assembly (Only for
front bumper guard garnish equipped model.)
(1) Remove the fog lamp attaching screws.
(2) Remove the fog lamps by disconnecting its connec-
tors.
JBO00015-00015
2. Remove the under fender bracket by removing the attach-

ing tapping screw and clip. (Both sides)
JBO00016-00016
3. Removal of radiator grill Turn in a right

(1) Turn the clips 90 degrees, using a phillips screwdriver. or left direction.
(Four clips at the upper side of the radiator grill.)
90 90
JBO00017-00017
(2) Remove the radiator grill assembly while unlocking the

locking section of the four clips and one retainer.
Lock clip Retainer Lock clip
JBO00018-00018
4. Removal of front turn signal lamps (On model without front

bumper guard garnish.)
(1) Remove the attaching screw of the front turn signal
lamps.
CAUTION:
Be very careful not to scratch the lamps during the re-
moval and installation.
(2) Remove the front turn signal lamp by disconnecting

the connector.
JBO00019-00019

BO9
5. Remove the attaching bolts of the front bumper cover. (On
model without the front bumper guard garnish.)
6. Remove the front bumper cover. (On model without the
front bumper guard garnish.)
7. Remove the front bumper bar reinforcement by removing
the attaching bolts. (On model without the front bumper
guard garnish.)
JBO00020-00020
8. Remove the front bumper cover by removing the five at-

taching bolts. (Only model equipped with the front bumper
guard garnish.)
JBO00021-00021
9. Remove the front bumper guard garnish by removing the

attaching screws. (On model with the front bumper guard
garnish.)
10. Remove the front bumper guard base bracket by remov-
ing the attaching bolts. (On model with the front bumper
guard garnish.)
JBO00022-00022
INSTALLATION
NOTE:
Basically the installation procedure is reverse to the removal procedure. Therefore, illustrations are
not given in this installation procedure. Refer to the illustrations in the removal procedure in cases
where any difficulty is encountered.
1. Install the front bumper guard base brackets with the attaching bolts. (On model with the front bumper
guard garnish.)
2. Install the front bumper guard garnish to the front bumper cover with the attaching screws. (On model
with the front bumper guard garnish.)
3. Install the front bumper cover with the five attaching bolts. (Only model equipped with the front bumper
guard garnish.)
4. Install the front bumper bar reinforcement with the attaching bolts. (Only model without the front bumper
guard garnish.)
5. Install the front bumper cover with the attaching bolts. (Only model without the front bumper guard gar-
nish.)
6. Installation of front turn signal lamps (Only model without the front bumper guard garnish.)
(1) Connect the connector of the front turn signal lamps.
(2) Install the attaching screw of the front turn signal lamps.

BO10
7. Installation of radiator grill
(1) Ensure that the clips and retainer are installed properly. Also, ensure that no damage exists.
If any damage exists or the clip or retainer is missing, replace the clips or retainer with a new one.
(2) Install the radiator grill by connecting the retainer and four clips.
(3) Lock the clips by turning the head section of the clip, using a phillips screwdriver. (Four portions)
8. Install the under fender bracket by installing the attaching tapping screw and grommet. (Both sides)
9. Installation of front fog & turn signal lamp (Only model equipped with the front bumper guard garnish.)
(1) Connect the connectors of the wire harness to the fog lamps.
(2) Install the fog lamp with the attaching screws.
JBO00023-00000

BO11
FRONT FENDER
COMPONENTS
q Hood subassembly
w Hood silencer
w e Clip
r r Headlamp cover to hood seal (R, L)
e t Clip
y
e y Hood to front end panel seal
t
u Hood front protector
u i Front fender subassembly (R, L)
o Front fender liner
!0 Clip
i !1 Over fender
i
!1
!0
JBO00024-00023
REMOVAL
1. Remove the front bumper cover.
(Refer to the front bumper section.)
2. Remove the front mudguard by removing the three attach-
ing bolts.
3. Remove the front fender liner attaching screw grommets.
(Refer to the front fender liner section.)
JBO00025-00024

BO12
4. Remove the over fender from the fender panel by discon-
necting the retainers while retracting the lock section,
using a nosepliers or the like.
5. Remove the side turn signal lamp.
6. Remove the front fender subassembly by removing the

five attaching bolts.
A-A
JBO00026-00025
INSTALLATION
NOTE:
1. Install the front fender subassembly with the attaching bolts and tighten them properly.
2. Install the side turn signal lamp.
3. Installation of over fender

(1) Ensure that the retainers are installed properly and there is no damage.
If any damage exists, replace the retainer with a new one.
(2) Install the over fender to the front fender by connecting the retainers on the over fender to the front
fender.
(3) Ensure that the retainers are locked properly.
4. Install the front fender liner. (Refer to the fender liner section.)
5. Install the front mudguard with the three attaching bolts.
6. Install the front bumper. (Refer to the front bumper section.)
JBO00027-00000

BO13
REAR BUMPER
COMPONENTS
e
r
i
t o !0 !1
q
t
y
u
q Rear bumper cover u Quarter panel mudguard subassembly

w License plate bracket base i Back-up lamp and/or rear fog lamp
e Rear bumper filler o Rear combination lamp socket
r Rear bumper right protector !0 Bulb
t Lower back panel cover !1 Rear lamp lens
y License plate lamp assembly
JBO00028-00026
REMOVAL
1. Remove the rear bumper filler and quarter panel mud-
guard (when equipped) by removing the attaching screw
grommets.
2. Remove the rear bumper cover attaching bolt. (Both sids)
JBO00029-00027
3. Removal of back-up lamp(s) and rear fog lamp (when

equipped)
(1) Remove the attaching screw.
(2) Remove the back-up lamp assembly(s) and rear fog
lamp (when equipped) by disconnecting their connec-
tor.
JBO00030-00028

BO14
4. Remove the license plate lamps by retracting the lock
sections of the license plate lamps from the rear bumper
cover.
5. Disconnect the license plate lamps from the connectors.
JBO00031-00029
6. Remove the rear bumper cover and license plate bracket

base (when equipped) by removing the eight attaching
bolts.
JBO00032-00030
7. Remove the lower back panel cover and air vent.

(If necessary.)
JBO00033-00031
8. Removal of rear combination lamp
(1) Remove the two attaching bolts and one screw.

(2) Remove the rear combination lamp by disconnect the
connector of the wire harness.
JBO00034-00032
9. Remove the rear bumper filler by removing the two attach-

ing bolts.
JBO00035-00033

BO15
INSTALLATION
NOTE:
1. Install the rear bumper filler with the two attaching bolts.
2. Installation of rear combination lamp
(1) Connect the connector of the wire harness to the rear combination lamp.
(2) Install the two attaching bolts and one screw.
3. Install the lower back panel cover and air vent. (If it has been removed.)
4. Install the rear bumper cover and license plate bracket base (when equipped) with the eight attaching
bolts.
5. Install the rear bumper cover attaching screws to the fender covers and body panel at both sides.
6. Connect the license plate lamps to the connectors.
7. Install the license plate lamp(s) to the rear bumper cover and ensure that the lock section of the license
plate lamps is engaged to the rear bumper cover.
8. Install the back-up lamp(s) and rear fog lamp.
(1) Connect the connector of the wire harness to the back-up lamp(s) and fog lamp (when equipped).
(2) Install the back-up lamp(s) and fog lamp (when equipped) with the attaching screw.
9. Install the rear bumper filler and quarter panel mudguard with the attaching screw grommets.
JBO00036-00000

BO16
FENDER LINER
COMPONENTS
t e
q Front fender liner

w Clip
e Front fender mudguard subassembly
r Grommet
t Front bumper bracket
JBO00037-00034
REMOVAL
1. Remove the front fender mudguard subassembly by re-
moving the three attaching bolts.
JBO00038-00035
2. Remove the under fender bracket by removing the grom-

met and tapping bolt.
JBO00039-00036

BO17
3. Remove the screw grommet for the tapping bolts by cut-
ting off the hem section of the grommet as shown.
,
,
,
,
,
Cut
Screw
grommet
JBO00040-00037
4. Remove the ten screw type grommets by screwing them

out.
5. Remove the front fender liner.
JBO00041-00038
INSTALLATION
NOTE:
1. Install the front fender liner with the ten screw grommets.
NOTE:
Insert the fender liner into between the fender panel and the over fender at the three screw grommet
installing positions.
Install the three screw grommets for tapping bolts to the lower side of the fender liner.
2. Install the under fender bracket with the attaching grommet and tapping screw.
3. Install the front fender mudguard with the three attaching bolts.
JBO00042-00000

BO18
HOOD & HOOD LOCK CONTROL CABLE
COMPONENTS
r
w q
y
q Hood lock control cable assembly

w Hood lock assembly
e Hood hinge assembly (R, L)
r Hood support rod
t Hood support clamp
y Clip
JBO00043-00039
Removal of engine hood

1. Disconnect the window washer hose from the window
washer nozzle(s), clamps of the engine hood and clamp.
JBO00044-00040
2. Remove the window washer nozzles from the engine hood

by retracting the lock sections of the window washer noz-
zles.
JBO00045-00041

BO19
3. Remove the insulator, the hood-to-front end panel seal and
the head lamp cover-to-hood seal by removing the attach-
ing retainers.
JBO00046-00042
4. Place cloths under the engine hood in order to prevent the

painted surface from being damaged.
5. Loosen the attaching bolts of the engine hood which are
connected to the hood hinges.
6. Remove the engine hood by removing the attaching bolts
while supporting the engine hood securely.
JBO00047-00043
7. Removal of engine hood hinge

(1) Remove the front fender.
(Refer to the front fender section.)
(2) Remove the engine hood hinge by removing the at-
taching bolts.
JBO00048-00044
Installation of the engine hood

NOTE:
1. Installation of engine hood hinge

(1) Install the engine hood hinge with the attaching bolts.
(2) Install the front fender. (Refer to the front fender section.)
2. Place a piece of cloth under the engine hood in order to prevent the painted surface from being dam-
aged.
3. Install the engine hood with the attaching bolts while supporting the engine hood securely.
4. Tighten the bolts attaching the engine hood to the hood hinges temporarily.
5. Remove the cloth.
6. Perform the adjustment of the engine hood alignment.
7. Install the insulator, the hood-to-front end panel seal and the head lamp cover-to-hood seal with the at-
taching clips.
8. Install the window washer nozzles to the engine hood.
9. Install the window washer hoses to the engine hood.
10. Connect the window washer hoses to the window washer nozzle. Tighten the attaching bolts of the en-
gine hood which are connected to the hood hinges. JBO00049-00000

BO20
Removal of hood lock and hood lock control cable
1. Remove the radiator grill.
2. Remove the front fender liner.
3. Removal of hood lock assembly
(1) Remove the three attaching bolts of the hood lock as-
sembly.
(2) Remove the hood lock assembly by disconnecting the
hood control cable.
JBO00050-00045
4. Remove the cowl side trim board assembly.

(Refer to the trim & garnish section.)
5. Release the control cable from the clamps.
Front apron member

Extension apron fender side
To upper cowl side
Apron front fender
B
A
Wire harness
A
Clamp Control cable
Clamp
Cross section A - A Apron fender (Clamped together with wire harness)
JBO00051-00046
6. Remove the two attaching bolts of the hood lock control

handle bracket.
7. Remove the cowl side trim board subassembly. (Refer to
the BO section.)
8. Remove the hood lock control cable assembly from the
vehicle.
NOTE:
For easier operation to reinstall the hood lock control
cable, connect a suitable string to the end of the hood
lock control cable before the removal.
JBO00052-00000

BO21
Installation of hood lock and hood lock control cable
NOTE:
1. Insert the hood lock control cable assembly to the front fender side from the cabin and route it as
shown.
2. Install the hood lock control cable handle with the attaching bolts and tighten them properly.
3. Install the cowl side trim board assembly. (Refer to the trim & garnish section.)
4. Connect the hood lock control cable to the clamps provided in the fender liner as shown.
5. Connect the hood lock control cable to the hood lock assembly.
6. Install the hood lock assembly with the three attaching bolts.
7. Perform the adjustment of the engine hood alignment.
(Refer to the engine hood alignment.)
8. Install the front fender liner.
9. Install the radiator grill.
Hood lock assembly Radiator upper support Upper part of headlamp
Viewed from Arrow B

Grommet
Vehicle interior Harness
C Marking
C
Control cable
B
Grommet
Cross section C - C
JBO00053-00048

BO22
FUEL LID OPENER
COMPONENTS
A or B section
C
RHD
K
G
A (RHD)
L
D
Up
Right w
Front
LHD
B (LHD)
F
Floor carpet
Center pillar lower garnish
Harness
Up Up
Right
Inside
w Front
G sectional view E sectional view
Up
w
Front w
Right
Up
Harness Harness
Front
e
F section K and L C and D
sectional view sectional view
q Back door lock open lever subassembly

w Fuel lid lock control cable subassembly
e Fuel filler opening lid lock subassembly
JBO00054-00049

BO23
REMOVAL
1. Remove the front drivers seat. (Refer to the front seat sec-
tion.)
2. Remove the rear seat. (Refer to the rear seat section.)
(Left hand drive vehicle only.)
3. Remove the right side rear door scuff plate assembly.
4. Remove the right side deck side trim. (Refer to the trim &
garnish section.)
5. Turn over the floor carpet.
6. Remove the back door lock open lever subassembly by JBO00055-00050
removing the attaching bolt.

7. Disconnect the fuel lid lock control cable from the back
door lock open lever subassembly.
8. Remove the fuel filler opening lid lock subassembly from

the fuel inlet box by removing the attaching nut.
JBO00056-00051
9. Disconnect the fuel lid lock control cable from the fuel filler
opening lid lock subassembly.
10. Remove the fuel lid control cable from the vehicle.
JBO00057-00052
INSTALLATION
NOTE:
1. Route the fuel lid lock control cable in the vehicle.

2. Connect the fuel lid lock control cable to the fuel filler opening lid lock subassembly.
3. Install the fuel filler opening lid lock subassembly to the fuel inlet box with the attaching nut.
4. Connect the fuel lid lock control cable to the back door lock open lever subassembly.
5. Install the back door lock open lever subassembly with the attaching bolts.
6. Place the floor carpet on the floor. (Refer to the trim & garnish section.)
7. Install the right side deck side trim. (Refer to the trim & garnish section.)
8. Install the right side rear door scuff plate. (Refer to the trim & garnish section.)
9. Install the rear seat. (Refer to the rear seat section.)
10. Install the front drivers seat. (Refer to the front seat section.)
JBO00058-00000

BO24
ROOF DRIP MOLDING
COMPONENTS
q
w
q Roof drip side finish right molding

w Roof drip side finish left molding
JBO00059-00053
REMOVAL
1. Remove the rear combination lamp. Retainer
2. Removal of roof drip molding

Pull up the roof drip molding from the rear side gradually.
Then remove the molding by pulling it backward to disen-
gage the retainer on the molding from the pin on the roof
panel. Pin
NOTE:
Do not reuse the removed roof drip molding.
JBO00060-00054
INSTALLATION
NOTE:
Do not reuse the removed roof drip molding.
1. Connect the retainer on the roof drip molding to the pin on the roof panel and insert the front end of the
roof drip molding into the weatherstrip of the front windshield glass.
2. Insert the roof drip molding by push it to the groove on the roof panel.
3. Install the rear combination lamp assembly.
JBO00061-00000

BO25
ROOF RAIL & ROOF END SPOILER
COMPONENTS
r y
w
t
u
r
q Right roof rack assembly

w Clip
e Rear right roof rack assembly
r Clip
t Left roof rack assembly
y Rear spoiler subassembly
u Stop center lamp assembly
i Rear spoiler No. 1 cover
JBO00062-00055
REMOVAL Hexagon wrench

1. Remove the attaching screw of the front roof rack covers
by a hexagon wrench.
2. Pull out the front roof rack covers.
JBO00063-00056
3. Remove the clip, using a clip remover.

CAUTION:
Be sure to prevent the painted surface of the roof panel
from being scratched by inserting a piece of cloth into Clip
between the clip remover and the roof panel as shown.
JBO00064-00057

BO26
: Tightening torque
w Unit : Nm (kgf-m)
Vehicles not equipped with roof end spoiler
q Roof rack subassembly (front side) e

w Roof rear rack subassembly
e Roof rack assembly
q
7.1 1.1 (0.7 0.1)
Vehicles equipped with roof end spoiler

w
q Roof rear rack subassembly q
w Rear spoiler subassembly
e Roof rack assembly e
7.1 1.1 (0.7 0.1)
JBO00000-00058
4. Remove the roof lining.

5. Remove the six bolts attaching the rear spoiler and roof rear rack. (Model equipped with rear spoiler.)
6. Disconnect the retainer on the rear spoiler from the roof panel. (Model equipped with rear spoiler.)
7. Gradually lift up the rear spoiler. Then disconnect the connector of the wire harness from the connector
of the high mount stop lamp. (Model equipped with high mount stop lamp.)
8. Remove the rear spoiler with the roof rear racks from the roof panel. (Model equipped with rear spoiler.)
9. Remove the roof rack assembly at each side by removing the three of the five attaching nuts of the roof
rack assembly.
10. Remove the roof rear rack from the rear spoiler subassembly by removing the attaching nuts. (Model
equipped with rear spoiler.)
NOTE:
Do not damage the harness of the high mount stop lamp during the removal.
11. Remove the high mount stop lamp from the rear spoiler by removing the attaching screws. (Model
equipped with rear spoiler and high mount stop lamp.)
12. Separate the roof rack from roof rear rack. (Model equipped with roof rack without rear spoiler.)
13. Remove the clips from the rear spoiler subassembly. (Model equipped with rear spoiler.)
JBO00065-00000

BO27
INSTALLATION
NOTE:
1. Install the three clips to the rear spoiler subassembly. (Model equipped with rear spoiler.)
2. Install the high mount stop lamp to the rear spoiler with the attaching screws. (Model equipped with rear
spoiler and high mount stop lamp.)
3. Install the roof rear racks to the rear spoiler subassembly with the attaching nut. (Model equipped with
rear spoiler.)
4. Install the each side of roof rack assembly with the five or three attaching nuts.
5. Install the rear spoiler with the roof racks to the roof panel with the attaching nuts. (Model equipped with
with rear spoiler.)
NOTE:
Be sure to connect the connector of the wire harness to the connector of the high mount stop lamp.
(Model equipped with high mount stop lamp.)
Ensure that the retainer is connected to the roof panel properly.
6. Install the roof lining. (Refer to the trim & garnish section.)
7. Install the clip for the front roof rack covers to the roof panel.
8. Insert the front roof rack cover from the front side. Ensure that the front roof rack cover is engaged with
the clip properly.
9. Install the attaching screw of the front roof rack cover, using a hexagon wrench.
JBO00066-00000

BO28
REMOVABLE ROOF
COMPONENTS
r
!0
y
w
!2 N S q Removable roof rock garnish
S t
!1 w Removable roof rock handle assembly
e Removable roof rock base assembly
S r Removable roof panel assembly
!4
!3 t Removable roof auxiliary left director catch
assembly
y Roof window deflector panel assembly
u Sunroof opening trim molding
i Removable roof inner weatherstrip
o Removable roof trim
!0 Removable roof outer weatherstrip
!1 Removable roof left hinge
e !2 Removable roof right hinge
N !3 Removable roof hinge left case
!4 Removable roof hinge right case
q
B
JBO00067-00059
REMOVAL
1. Remove the removable sunroof. (Refer to the owners manual.)
2. Remove the removable roof lock garnish by removing the two attaching bolts.
3. Remove the removable roof lock handle assembly by removing the attaching screws.
4. Remove the removable roof lock base assembly from the removable roof panel by removing the attach-
ing nuts.
5. Remove the removable roof trim by removing the retainers.
6. Remove the removable roof hinges from the removable roof panel by removing the attaching screws.
7. Remove the removable roof outer weather strip from the roof panel.
8. Remove the sunroof opening trim molding and removable roof inner weatherstrip.
9. Remove the roof headlining. (Refer to the trim & garnish section.)
10. Remove the roof window deflector panel assembly by removing the two attaching nuts.
11. Remove the removable roof hinge case by removing the attaching screws.
JBO00068-00000

BO29
INSTALLATION
NOTE:
1. Install the removable roof hinge case with the attaching screws.
2. Install the roof window deflector panel assembly with the two attaching nuts.
3. Install the roof headlining. (Refer to the trim & garnish section.)
4. Install the sunroof opening trim molding and removable roof inner weatherstrip.
5. Install the removable roof outer weatherstrip to the roof panel.
6. Install the removable roof hinges to the removable roof panel with the attaching screws.
7. Install the removable roof trim with the retainers.
8. Install the removable roof lock base assembly to the removable roof panel with the attaching nuts.
9. Install the removable roof lock handle assembly with the attaching screws.
10. Install the removable roof lock garnish with the two attaching bolts.
11. Install the removable sunroof. (Refer to the owners manual.)
JBO00069-00000

BO30
INSTRUMENT PANEL
COMPONENTS
@7
@8
@9
@6
@5
@4 o
@3
i e
r
u y q
w
t
y
#0
!0
!2
!1
#1
#0
!5 !6
u
!3 @2
#2 !4
!7
#7
!8
@0
!9
@1
q Instrument panel subassembly !8 Shifting hole flame

w Instrument panel center register assembly !9 Console panel
e Instrument panel hole No. 3 cover @0 Rear console box assembly
r Instrument panel hole No. 2 cover @1 Rear console box support bracket
t Instrument panel hole No. 1 cover @2 Glove compartment door lock subassembly
y Instrument panel No. 2 register assembly @3 Instrument panel mounting bracket sub-
u Clip assembly
i Instrument cluster finish panel subassembly @4 Instrument panel to floor bracket
o Air bag assembly (Passenger) @5 Instrument panel No. 1 brace subassembly
!0 Cash box @6 Heater to register center duct subassembly
!1 Instrument panel finish lower panel @7 Side ventilator right duct subassembly
!2 Radio tuner opening cover @8 Defroster nozzle assembly
!3 Instrument cluster finish center panel as- @9 Side ventilator left duct subassembly
sembly #0 Bracket
!4 Glove compartment subassembly #1 Glove compartment door striker
!5 Glove compartment door hinge #2 Front ash receptacle retainer subassembly
!6 Glove compartment cushion #3 Front ash receptacle box
!7 Shifting hole cover
JBO00070-00060

BO31
REMOVAL
2. Remove the front seats. (Refer to the front seat section.)
3. Removal of console box assembly
(1) Remove the rear console box assembly by removing
the two attaching screws.
JBO00071-00061
(2) Remove the shift lever knob from the shift lever.
(Only for manual transmission vehicle.
(3) Remove the console panel by removing the two at-

taching bolts and two clips.
JBO00072-00062
4. Remove the instrument panel finish lower panel by remov-

ing the two attaching screws. Then unlock the lock on the
instrument panel finish lower panel by pulling it out while
holding the instrument panel.
JBO00073-00063
5. Remove the steering column assembly.

(Refer to the SR section for more details of the removal
and installation of the column assembly.)
(1) Disconnect the steering column assembly-related con-
nectors.
(2) Remove the four attaching bolts of the steering column
assembly.
JBO00074-00064
6. Remove the two attaching screws of the instrument cluster
finish panel subassembly.
7. Pull out the instrument cluster finish panel subassembly
from the instrument panel to disengage the locks provided
on the instrument cluster finish panel subassembly.
8. Remove the instrument cluster finish panel subassembly.
9. Removal of various switches
(1) Push out the various switches from the inside of the in-
strument panel.
(2) Disconnect the switches from the connector.
(3) Put the switch connectors into the inside of the instru-
ment panel. JBO00075-00065

BO32
10. Removal of combination meter assembly
(1) Remove the three attaching bolts.
JBO00076-00066
(2) Gradually raise the combination meter assembly.

(3) Disconnect the connectors and speedometer cable
from the combination meter assembly.
NOTE:
Refer to the BE section for more details.
(4) Remove the combination meter.
JBO00077-00067
11. Remove the glove compartment subassembly by remov-

ing the glove compartment door hinge, using a clip re-
mover.
JBO00078-00068
12. Removal of instrument cluster finish center panel assem-

bly
(1) Pull out the cigarette lighter heater.
(2) Remove the two attaching screws of the instrument
cluster finish center panel.
(3) Remove the front ash receptacle box from the front ash
receptacle retainer subassembly.
(4) Unlock the two locks provided on the instrument clus-
ter finish center panel assembly. Then, remove the in-
strument cluster finish center panel assembly.
JBO00079-00069
(5) Disconnect the cigarette lighter connector.

(Refer to the BE section for removal of the cigarette
lighter.)
JBO00080-00070

BO33
13. Remove the three attaching screws of the heater control
panel assembly.
radio tuner or cassette player.
15. Disconnect the antenna cable from the radio tuner.
16. Remove the radio tuner opening cover, radio tuner or cas-
sette player by removing the attaching screws.
JBO00081-00071
17. Removal of cowl side trim board assembly (Both sides)

(Refer to the trim and garnish section.)
JBO00082-00072
18. Removal of front door pillar garnish (Both sides)

(1) Remove the front door opening molding.
(2) Disconnect the door trim retainers provided on the
front door pillar garnish by disengaging the retainers,
using a clip remover or the like.
(3) Remove the front pillar garnish from the front pillar.
JBO00083-00073
19. Remove the instrument panel hole covers No. 1, No. 2 and
No. 3 from the instrument panel, using a minor screwdriver
or the like.
CAUTION:
Be very careful not to scratch the instrument panel and
hole covers No. 1, No. 2 and No. 3 during the removal.
JBO00084-00074

connector of the airbag. (For front passenger airbag
equipped model only. Refer to the BE section for the cor-
rect manner of disconnection.)
CAUTION:
Be sure to disconnect this connector by referring to the
BE section. Failure to observe this caution may lead to
serious malfunction.
JBO00085-00075

BO34
21. Remove the instrument panel subassembly by removing
If any difficulty is encountered in removing the attaching
bolt of the rear hood lock control handle attaching bracket
of the instrument panel, prior to the removal of the instru-
ment panel, remove the hood lock control handle bracket
by removing the two attaching bolts.
CAUTION:
Be sure to remove the two attaching bolts of passenger
side airbag, if model equipped with passenger side
airbag. JBO00086-00000
22. Remove the front ash receptacle retainer by removing the

attaching screws.
JBO00087-00076
23. Remove the heater-to-register center duct subassembly

by removing the five attaching screws.
JBO00088-00077
24. Removal of airbag at front passenger seat side

(Only for model equipped with front passenger seat side
airbag)
WARNING:
Be sure to follow the instruction mentioned in the
airbag section in the BE section of the service manual
before performing the removal of the front passenger
seat airbag.
(1) Remove the two attaching nuts of the front passenger

seat airbag assembly. JBO00089-00078
(2) Remove the front passenger seat airbag assembly

from the instrument panel by unlocking the locks pro-
vided on the airbag assembly.
25. Removal of instrument panel center register assembly by

removing the attaching screws.
JBO00090-00079

BO35
26. Remove the register assembly No. 2 of the instrument
panel by unlocking the lock section on the instrument
panel assembly.
CAUTION:
Do not enlarge the attaching portion of the instrument
panel more than necessary to remove the register.
27. Remove the defroster nozzle assembly and side defroster

duct subassembly (right and left) from the cowl panel and
bracket by removing the attaching screws and bolt.
28. Removal of instrument panel reinforcement assembly JBO00091-00080
(Only when equipped)

(1) Disconnect the relay box from the bracket by removing
attaching bolt, while unlocking the lock of the relay
box. Bolt
Disconnect the wire clamps and antenna cable from
the reinforcement.
(2) Remove the instrument panel reinforcement assembly
by removing the attaching bolts and nut.
JBO00092-00081
INSTALLATION
NOTE:
not given in this installation procedure. Refer to the illustration in the removal procedure in cases
1. Installation of instrument panel reinforcement assembly (Only when equipped)

(1) Install the instrument panel reinforcement assembly with the attaching bolts and nuts.
(2) Install the relay box to its bracket.
2. Install the defroster nozzle assembly and side defroster duct subassembly with the attaching screws
(right and left) to the cowl panel and bracket.
3. Install the register assembly No. 2 of the instrument panel to the instrument panel subassembly.
CAUTION:
Do not enlarge the instrument panel more than necessary.
4. Install the instrument panel center register assembly to the instrument panel subassembly with the at-
taching screws .
5. Installation of front passenger seat side airbag
WARNING:
Be sure to refer to the handling instruction mentioned in the BE section before performing the instal-
lation of the front passenger seat side airbag. Failure to observe this warning may lead to serious
trouble or malfunction.
(1) Install the front passenger seat side airbag assembly to the instrument panel and ensure that the
locks on the front passenger seat side airbag assembly are locked to the instrument panel properly.
(2) Install the two attaching nuts of the front passenger seat side airbag and tighten them securely.
6. Install the heater-to-register center duct subassembly with the attaching screws.
7. Install the front ash receptacle retainer with the attaching screws.
8. Install the instrument panel subassembly with the attaching bolts.
CAUTION:
Be sure to tighten the attaching bolts of passenger side airbag to the specified tightening torque, if
model equipped with passenger side airbag.
BO36
9. Connect the connector of the wire harness to the connector of the front passenger airbag.
WARNING:
Be sure to refer to the instruction in the BE section. Failure to observe this warning may lead to seri-
ous trouble or malfunction.
10. Install the instrument panel hole covers No. 1, No. 2 and No. 3 to the instrument panel.
11. Installation of front door pillar garnish (Both sides)
(1) Ensure that the clips of the front pillar garnish are installed properly.
(2) Insert the protrusion section of the front pillar garnish provided at its lower side to the pillar hole.
(3) Insert the locator on the front pillar garnish into the front pillar.
(4) Push in the front pillar garnish to engage the retainers with the front pillar.
(5) Install the front door opening trim.
12. Install the cowl side trim board assembly. (Both sides) (Refer to the trim and garnish section.)
13. Install the radio tuner or cassette player by installing the attaching screws.
14. Connect the antenna cable to the radio tuner.
15. Connect the connector of the wire harness to the radio tuner or the cassette player.
16. Connect the heater control panel assembly and install it to the instrument panel by installing the attach-
ing screws.
17. Installation of instrument cluster panel assembly
(1) Connect the cigarette lighter connector to the cigarette lighter.
NOTE:
Refer to the BE section for installation of the cigarette lighter.
Prior to the installation, ensure that the retainer clips are installed on the instrument cluster assembly.
(2) Insert the instrument cluster panel assembly into the instrument panel and ensure that the retainers
are locked properly.
(3) Insert the cigarette lighter heater.
18. Install the front ash receptacle box to the ash receptacle retainer subassembly.
19. Install the glove compartment subassembly with the clip, using a clip remover.
20. Installation of combination meter assembly
(1) Connect the connectors and speedometer cable to the combination meter assembly.
NOTE:
Refer to the BE section for more details.
(2) Install the combination meter into the instrument panel.

(3) Install and tighten the three attaching bolts.
21. Installation of various switches
(1) Pull out the switch connectors from each switch attaching hole of the instrument panel.
(2) Connect the switches to the connector securely.

(3) Install the various switches to the instrument panel.
22. Install the steering wheel with the steering column tube subassembly by means of the four attaching
bolts securely. (Refer to the SR section.)
23. Install the instrument panel finish lower panel and secure it with the two attaching screws.
24. Installation of console box assembly
(1) Install the console panel with the two attaching bolts and two clips.
(2) Install the shift lever knob to the shift lever. (Only for manual transmission vehicle.)
(3) Install the rear console box assembly with the two attaching screws.
25. Install the front seat. (Refer to the front seat section.)
26. Connect the negative terminal of the battery ground cable to the negative terminal of the battery.
27. Ensure that the all switchs are functioning properly and no abnormal noise is emitted.
JBO00093-00000

BO37
FRONT SEAT
COMPONENTS
: Tightening torque
Unit : Nm (kgf-m)
Right side
25.4 4.9 (2.5 0.5)
JBO00094-00082
REMOVAL
1. Disconnect the seat belt warning light switch connector.
(Only for seat belt warning-equipped vehicle)
2. Move the front seat to the most rearward position.
3. Remove the attaching bolts of the front seat.
JBO00095-00083
4. Move the front seat to the most forward position.

5. Remove the attaching bolts of the front seat.
6. Remove the front seat assembly from the vehicle.
CAUTION:
Care must be exercised so that the front seat assembly
may not be interfered with other parts.
JBO00096-00084

BO38
INSTALLATION
1. Place the front seat on the attaching surface on the floor while aligning the protrusions of the front seat
with the holes on the floor panel.
2. Install the attaching bolts temporarily.
3. Move the front seat to the most forward position and tighten the attaching bolts temporarily.
CAUTION:
Make sure that the both inner and outer tracks are locked properly before tightening the attaching
bolts.
4. Move the front seat to the most rearward position.

CAUTION:
Make sure that the both inner and outer tracks are locked properly before tightening the attaching
bolts.
5. Tighten the inner side attaching bolts to the specified tightening torque.
7. Move the front seat to the most forward position.

9. Tighten the outer side attaching bolts to the specified tightening torque.
10. Connect the seat belt warning light switch connector.

(Only for seat belt warning-equipped vehicle)
11. Ensure that the seat slide locks are properly engaged with both rails by sliding the front seat in a for-
ward direction with a force of 98 N (10 kgf) and in a rearward direction with a force of 49 Nm (5 kgf-m).
If the seat slide locks are not engaged properly, repair the seat slide lock or reinstall the rear seat, as re-
quired.
JBO00097-00000

BO39
REAR SEAT
COMPONENTS
: Tightening torque
Unit : Nm (kgf-m)
19.5 4.5 (2.0 0.5)
5.5 1.5 (0.6 0.2)
19.5 4.5 (2.0 0.5)
19.5 4.5 (2.0 0.5)
JBO00098-00085
REMOVAL
1. Remove the rear seat cushion by removing the two attaching bolts.
2. Separate the deck board carpet from the rear seat by disconnecting the velcro-tape sections.
3. Remove the rear seatback by removing the three attaching bolts.
4. Remove the rear seatback center hinge by removing the three attaching bolts.
JBO00099-00000
INSTALLATION
1. Install the rear seatback center hinge with the attaching bolts and tightening them to the specified tight-
ening torque.
2. Install the rear seatback with the three attaching bolts and tighten the attaching bolts to the specified
tightening torque.
3. Install the rear seat cushion with the two attaching bolts and tightening them to the specified tightening
torque.
4. Fold the rear seat.

5. Ensure that the mechanism of the rear seat operates properly.
JBO00100-00000

BO40
SEAT BELT
FRONT SEAT BELT
9 2 (0.9 0.2) : Tightening torque

Unit : Nm (kgf-m)
40.5 12.5 (4.2 1.3)
2.5 1.0 (0.3 0.1)

If the threaded portion is damaged,
use an oversized ET screw.
40.5 12.5 (4.2 1.3)

Tightening should be made, aligning
with the turning-preventive bead.
40.5 12.5 (4.2 1.3)
Turning-preventive beads
JBO00101-00086
FRONT SEAT BELT

REMOVAL
1. Remove the center pillar lower garnish.
2. Open the seat belt attaching bolt cover.
3. Remove the front seat belt shoulder belt guide by remov-
ing the attaching bolts. Screw
4. Remove the seat belt anchor attaching bolts
5. Remove the seat belt retractor by removing the attaching
bolt and screw.
JBO00102-00087
6. Removal of inner seat belt

(1) Remove the front seat. (Refer to the front seat section.)
(2) Remove the inner seat belt by removing its attaching
bolts.
JBO00103-00088

BO41
INSPECTION
1. Ensure that the seat belt will not be locked until the seat 45
belt retractor is tilted more than 15 degrees in all direc-
tions from the installed angle.
Also, ensure that the locked state is retained when the re-
tractor is tilted 45 degrees or more.
2. Ensure that the seat belt will be locked when the seat belt
is pulled out quickly.
3. Ensure that no scratch, wear or any other damage exists
on the seat belts.
If any damage is found, replace the seat belt with a new JBO00104-00089
one.
CAUTION:
Never attempt to disassemble the retractor.
After the anchor bolts have been tightened, make sure
that each anchor can move in a circumferential direc-
tion of the bolt.
Ensure that the belt in the installed state can be pulled
out smoothly and also it can be retracted smoothly in
position.
INSTALLATION
1. Installation of inner seat belt
(1) Install the inner seat belt with the attaching bolt and tighten the attaching bolt to the specified tight-
ening torque.
(2) Install the front seat. (Refer to the front seat section.)
2. Install the front seat retractor with the attaching screw.
3. Install the front seat retractor attaching bolt and tighten the attaching bolt to the specified tightening
torque.
4. Install the seat belt anchor with the attaching bolts and tighten the attaching bolts to the specified tight-
ening torque.
CAUTION:
Be sure to install the seat belt end anchor while aligning it with the locating embossed mark on the
floor panel.
5. Install the front seat belt guide with the attaching screws.
6. Close the upper seat belt anchor bolt cover.
7. Install the center pillar lower garnish. (Refer to the trim & garnish section.)
JBO00105-00000

BO42
REAR SEAT BELT
: Tightening torque
Unit : Nm (kgf-m) 40.5 12.5 (4.2 1.3)
40.5 12.5 (4.2 1.3)
40.5 12.5 (4.2 1.3)
Turning-preventive beads
40.5 12.5 (4.2 1.3)

Tightening should be made, aligning
with the turning-preventive bead.
JBO00106-00090
REMOVAL
1. Remove the rear seatback.
(Refer to the rear seat section for the removal procedure.)
2. Remove the deck board assembly.
(Refer to the trim & garnish section for the removal procedure.)
3. Remove the rear door scuff plate assembly.
4. Remove the deck side trim.
5. Open the rear seat belt upper anchor bolt cover.
6. Remove the attaching bolt of the seat belt upper anchor.
7. Remove the rear seat belt retractor by removing the attaching bolts.
8. Remove the rear seat inner belt assembly and center seat belt by removing the attaching bolts.
JBO00107-00000

BO43
INSPECTION
1. Ensure that the seat belt will not be locked until the seat 45
belt retractor is tilted more than 15 degrees in all direc-
tions.
Also, ensure that the locked state is retained when the re-
tractor is tilted 45 degrees or more.
2. Ensure that the seat belt will be locked when the seat belt
is pulled quickly.
3. Ensure that no scratch, wear or any other damage exists
on the seat belts.
If any damage is found, replace the seat belt with a new JBO00108-00091
one.
CAUTION:
Never attempt to disassemble the retractor.
After the anchor bolts have been tightened, make sure
that each anchor can move in a circumferential direc-
tion of the bolt.
Ensure that the belt in the installed state can be pulled
out smoothly and also it can be retracted smoothly in
position.
INSTALLATION
1. Install the rear seat inner belt assembly and center seat belts with the attaching bolt. Then, tighten the
attaching bolt to the specified tightening torque.
2. Install the rear seat belt retractor with the attaching bolt and tighten it to the specified tightening torque.
3. Install the rear seat belt upper anchor with the attaching bolt and tighten it to the specified tightening
torque.
4. Close the seat belt anchor bolt cover of the rear seat belt upper anchor.
5. Install the deck side trim. (Refer to the trim & garnish section for the installation procedure.)
6. Install the rear door scuff plate assembly. (Refer to the trim & garnish section for the installation proce-
dure.)
7. Install the rear seat belt end anchor with the attaching bolts and tighten them to the specified tightening
torque.
8. Install the deck board assembly. (Refer to the trim & garnish section for the installation procedure.)
9. Install the lower back trim. (Refer to the trim & garnish section for the installation procedure.)
10. Install the rear seat. (Refer to the rear seat section for the installation procedure.)
JBO00109-00000

BO44
FRONT DOOR
COMPONENTS
POWER WINDOW
@0
!9 POWER LOCK
q #6
w
!0 o
i @7
@1
!7 #7
!2
#8 @2
t y
@3
#6 !8 @4
#3 @5
#4 @6
!4 !6
@7
#5 !3 !5
!1
e
u
@8
r
#2 @9
#1
#0
q Front door glass subassembly @0 Front door glass outer weatherstrip

w Front door glass run @1 Front door outside handle assembly
e Front door outside panel @2 Front door lock link No 1 silencer
r Front door panel subassembly @3 Front door open control link assembly
t Front door front lower frame subassembly @4 Front door lock striker plate subassembly
y Lock retainer @5 Front door locking button
u Door trim bracket @6 Door lock control knob holder
i Clip @7 Front door lock assembly
o Front door lower frame bracket garnish @8 Door pull handle
!0 Outside rear view mirror @9 Front door inside handle subassembly
!1 Front door service hole cover #0 Front door window handle assembly
!2 Front door weatherstrip #1 Shaft snap ring
!3 Front door glass inner weatherstrip assembly #2 Door vent window control handle plate
!4 Cushion #3 Front door check assembly
!5 Front door trim retainer #4 Front door upper hinge assembly
!6 Front door trim panel assembly #5 Front door lower hinge assembly
!7 Front door glass outer weatherstrip #6 Front door window regulator subassembly
!8 Front door rear lower frame subassembly #7 Lock cylinder
!9 Retainer #8 Lock cylinder pad
JBO00110-00092

BO45
DISASSEMBLY
1. Unlock the shaft snap ring of the front door window handle
assembly by inserting a piece of cloth between the handle
and the door vent window control handle plate. Then, pull
the inserted cloth alternately so as to unlock the shaft
snap ring.
2. Remove the front door window handle, shaft snap ring and
door vent window control handle plate.
JBO00111-00093
3. Remove the front door inside handle subassembly attach-

ing screw.
4. Remove the front door pull handle by removing the attach-
ing screw.
5. Unscrew the front door locking button.
6. Unlock the inside door handle from the front door and in-
sert it into the front door trim panel assembly.
JBO00112-00094
7. Remove the front door lower frame bracket garnish by

pulling it out to disengage the retainers provided on the
bracket, using a clip remover.
JBO00113-00095
8. Unlock the nail section of the front door inside handle sub-
assembly from the front door panel and insert it into the
front trim panel assembly.
9. Disengage the retainers provided on the rear side of the
front door trim panel assembly by pulling out one by one
from the door panel.
CAUTION:
Be sure to disconnect the retainers, using a clip re-
mover.
Failure to observe this caution may bend the front door
trim panel assembly or cause cracks on the front door JBO00114-00096
trim panel assembly.
10. Pull up the front trim panel assembly to disengage it from

the front door panel.
power window switch. (Only for power window-equipped
model.)
12. Remove the front door trim panel assembly from the front
door panel.
JBO00115-00097

BO46
13. Remove the front door inside handle subassembly by dis-
connecting the front door open control link.
14. Remove the door trim bracket by removing the attaching
screws.
15. Remove the speaker by removing the three attaching
screws. (Only when equipped.)
16. Remove the front door service hole cover from the front
door panel.
CAUTION:
Never reuse the service hole covers. Failure to observe
this caution may lead to water leakage. JBO00116-00098
17. Removal of outside rear view mirror

connector of the outside rear view mirror. (Only for re-
mote control mirror-equipped model.)
(2) Remove the three attaching nuts of the outside rear
view mirror while holding the outside rear view mirror
by hand.
(3) Remove the outside rear view mirror. Connector
JBO00117-00099
18. Remove the door lock control knob holder from the door
trim panel assembly.
19. Remove the power window control switch by removing the
attaching screws. (Only for power window-equipped
model.)
20. Remove the front door glass weatherstrip assembly from
the front door trim panel assembly by straightening the
protrusion sections on the front door glass weatherstrip
assembly.
JBO00118-00100
21. Remove the attaching bolts of the front door front lower
frame assembly. Then, remove the front lower frame as-
sembly.
JBO00119-00101
22. Removal of front door glass subassembly

(1) Install the front door window handle assembly tem-
porarily.
(2) Place the front door glass attaching bolts in position at
the holes provided on the front door panel by turning
the front door window handle.
(3) Remove the bolts attaching the front door glass to the
front door regulator subassembly.
JBO00120-00102

BO47
23. Remove the front door glass subassembly.
JBO00121-00103
24. Disconnect the connector of the front door wire harness

from the power window motor. (For model equipped with
power window)
25. Remove the front door window regulator subassembly by
removing the attaching bolts.
26. Remove the front door rear lower frame subassembly by
removing the attaching screw and bolt.
JBO00122-00104
27. Removal of front door lock assembly

(1) Disconnect the front door open control link from the
front door outside handle assembly.
(2) Disconnect the front door open control link assembly
from the front door lock assembly.
(3) Remove the front door lock cylinder and lock cylinder
pad by removing the lock retainer.
(4) Remove the front door outside handle assembly by re-
moving the attaching nuts.
JBO00123-00105

door lock control motor. (For model equipped with
central door lock.)
(6) Remove the front door lock assembly by removing the
attaching screws.
JBO00124-00106
28. Remove the front door glass outer weatherstrip from the
front door panel by unlocking the front door glass weath-
erstrip grips.
29. Remove the front door glass run.
JBO00125-00107

BO48
30. Remove the cowl side trim board. (Refer to the trim & gar-
nish section.)
31. Disconnect the connector of the wire harness (cowl wire)
from the connector of the wire harness (front door wire).
32. Disconnect the various clamps of the wire harness from
the front door.
(For models equipped with power window, central door
lock and/or speaker.)
33. Remove the front door wire from the inside of the front
door by removing the grommet section of the front door
wire. JBO00126-00220
34. Remove the front door garnish by retracting the mushroom

section of the retainers.
CAUTION:
The front part of the garnish is affixed with a two-faced
adhesive tape.
Therefore, be very careful not to bend the garnish dur-
ing the removal of the front part of the garnish.
B-B
JBO00127-00108
35. Remove the front door check assembly by removing the

attaching bolts.
36. Remove the front fender.
(Refer to the front fender section for the removal proce-
dure.)
37. Remove the front door by removing the attaching bolts of
the front door hinges while holding the front door securely.
JBO00128-00109
38. Remove the front door upper and lower hinges from the
front door by removing the attaching bolts.
JBO00129-00110

BO49
ASSEMBLY
NOTE:
Basically the assembling procedure is reverse to the disassembling procedure. Therefore, illustra-
tions are not mentioned in this assembling procedure. Refer to the illustrations in the disassembling
procedure in cases where any difficulty is encountered.
1. Install the front door upper and lower hinges to the front door with the attaching bolts.
2. Install the front door to the vehicle shell with the attaching bolts while holding the front door securely
and adjust the front door alignment. (Refer to the section under the adjustment of front door and rear
door alignment.)
3. Install the front fender.
(Refer to the front fender section for the installation procedure.)
4. Install the door check assembly with the attaching bolts.
5. Installation of front door garnish.
(1) Affix a two-faced adhesive tape to the front part of the front door garnish.
(2) Install the front door garnish to the front door panel by connecting the retainers and ensure that the
retainers are engaged securely.
NOTE:
If the installation is performed in a cold wether, hear the front door panel to about 40C before the in-
stallation.
6. Installation of front door wire.

(Only for model equipped with power window, central door lock and speaker, For the details, refer to the
BE section.)
(1) Install the front door wire to the front door and connect the wire harness clamp to the front door
panel.
(2) Route the front door wire through the front door panel and hole provided on the body shell.
(3) Secure the front door wire grommets to the front door and body shell.
(4) Connect the connector of the wire harness to the connector of the front door wire.
(5) Install the cowl side trim board. (Refer to the trim & garnish section.)
7. Install the front door glass run.

8. Install the front door glass outer weatherstrip to the front door panel and ensure that the front door glass
weatherstrip grips are engaged with the front door panel securely.
9. Installation of front door lock assembly
(1) Install the front lock assembly to the front door panel with the attaching screws and bolt. (Only for
central door lock-equipped model.)
(2) Connect the connector of the wire harness to the door lock control motor.
(3) Install the front door outside handle assembly with the attaching nuts.
(4) Install the front door lock cylinder and lock cylinder pad by installing the lock retainer.
(5) Connect the front door open control link assembly to the front door lock assembly.
(6) Connect the front door open control link to the front door outside handle assembly.
10. Install the front door rear lower frame subassembly by installing the attaching screw and bolt and insert
the front glass run into the front floor rear lower frame subassembly.
11. Install the front door regulator subassembly with the attaching bolts.
12. Connect the connector of the front door wire harness to the power window motor. (For model equipped
with power window.)
13. Install the front door glass subassembly into the front door panel.
14. Install the front door window regulator handle assembly temporarily and align the attaching bolt holes of
the front door window with the regulator by adjusting the height of the regulator.
15. Install the front door glass to the front regulator subassembly by installing the attaching bolts.
16. Insert the front door frame assembly into the front door panel and insert the front glass run into position.
17. Install the front door front frame assembly with the attaching bolts.
18. Install the front door glass outer weatherstrip assembly to the front door trim panel assembly by bend-
ing the nail sections of the front door glass outer weatherstrip.
BO50
19. Install the power window control switch by installing the attaching bolt. (For power window-equipped
model.)
20. Install the door control lock knob holder to the front door trim panel assembly.
JBO00130-00000
21. Installation of front door service hole cover

(1) Affix a butyl tape at the groove provided around the front door panel, as shown.
(2) Attach the service hole cover on the butyl tape, as shown.
CAUTION:
Care must be exercised so that the joint section of the butyl tape may come at the upper section. If
the joint section of the tape comes at the lower side of the door, it may cause water leakage.
The butyl tape should be routed just under the water drain holes. Failure to observe this caution may
lead to collection of water, resulting in rust formation.
Never reuse the front door service hole cover. Failure to observe this caution may lead to water leak-
age.
Be sure to route the front door open control link for front door inside handle subassembly.
A B
C Cover
Reference for cover
Cover assembling
Align with bead.
Align with bead. Section B
Section A
C-C
JBO00131-00111

BO51
22. Install the door trim bracket with the attaching screws.
23. Connect the front door inside handle subassembly to the front door open control link.
24. Installation of outside rear view mirror
(1) Install the outside rear view mirror with the three attaching nuts.
(2) Connect the connector of the front door wire harness to the connector of the remote control mirror.
(For remote control rear view mirror-equipped model.)
(3) Connect the clamp of the wire harness to the door panel.
25. Connect the connector of the front door wire harness to the power window switch. (For power window-
equipped model.)
26. Insert the front door inside handle subassembly into the front door trim panel assembly.
27. Hang the front door trim panel assembly on the front door panel.
28. Connect the front door trim panel assembly to the front door panel by connecting the retainers on the
front door trim panel assembly.
29. Connect the front door inside handle to the front door panel and install the attaching screw.
NOTE:
An oversize screw is available as a spare part for cases where the ordinary screw becomes loose.
30. Install the front door pull handle to the front door with the attaching screw.
NOTE:
An oversize screw is available as a spare part for cases where the ordinary screw becomes loose.
31. Install the shaft snap ring to the front door window handle.
NOTE:
Install the shaft snap ring to the front regulator handle in such a direction that the open end faces to-
ward the handle side.
32. Install the front door window handle to the window regulator with the door vent window control handle
plate.
33. Install the front door lower fame bracket garnish.
34. Screw in the front door locking button.
JBO00132-00000

BO52
REAR DOOR
COMPONENTS
q
e
POWER LOCK
!2
@2
u
!3 !1
@3
w #1 y
@0 @1
!8
#1 @4
!4 !9
!0
u @2
#0 @5
#2 t
r !5
!6
@9
o @6
@8
!7 @7
i
q Rear door glass subassembly !7 Rear door locking control link subassembly
w Rear door glass outer weatherstrip !8 Rear door locking link clamp
e Rear door glass run !9 Rear door locking silencer
r Rear door outside panel @0 Rear door lock link clamp
t Rear door panel subassembly @1 Door lock striker plate subassembly
y Rear door weatherstrip @2 Rear door lock assembly
u Door trim retainer @3 Rear door open control link
i Rear door trim board subassembly @4 Rear door glass inner weatherstrip assembly
o Rear door service hole cover @5 Door pull handle
!0 Hole cover @6 Rear door inside handle
!1 Rear door window guide subassembly @7 Rear door window handle assembly
!2 Rear door rear lower frame seal @8 Shaft snap ring
!3 Rear door outside handle assembly @9 Door vent window control handle plate
!4 Rear door check assembly #0 Door trim No. 1 bracket
!5 Rear door locking button #1 Rear door upper hinge assembly
!6 Door lock control knob holder #2 Rear door lower hinge assembly
JBO00133-00112

BO53
DISASSEMBLY
Removal of rear door trim panel assembly
1. Unlock the shaft snap ring of the rear door window regula-
tor handle assembly by inserting a piece of cloth between
the rear door window regulator handle and the door vent
window control handle plate. Then, pull the inserted cloth
alternately so as to unlock the shaft snap ring.
2. Remove the rear door window regulator handle, shaft
snap ring and door vent window control handle plate.
JBO00134-00113
3. Remove the attaching screws of the rear door inside han-

dle assembly.
4. Unscrew the rear door locking button.
5. Remove the door pull handle by removing the attaching
screw.
JBO00135-00114
6. Disengage the retainers provided on the back side of the

rear door trim panel assembly.
7. Unlock the nail section of the rear door inside handle sub-
assembly from the rear door panel. Then, insert it into the
rear door trim panel assembly.
8. Remove the rear door trim panel assembly from the rear
door panel by hang it off.
9. Remove the door trim No.1 bracket by removing the at-
taching bolts.
10. Remove the rear door inside handle subassembly by dis-
connecting it from the rear door open control link assem- JBO00136-00115
bly.
11. Remove the rear door service hole cover from the rear
door panel.
CAUTION:
Never reuse the removed service hole cover.
JBO00137-00116
12. Remove the rear door glass weatherstrip assembly from

the rear door trim panel assembly by straightening the
protrusion section on the rear door glass weatherstrip as-
sembly.
13. Remove the door control knob holder from the door trim
panel panel assembly.
JBO00138-00117

BO54
14. Disconnect the rear door harness clamp from the door
panel.
(For the central door lock and/or speaker-equipped vehi-
cle.)
15. Disconnect the connector of the rear door wire harness
from the door control motor assembly.
(For the central door lock and/or speaker-equipped vehi-
cle.)
JBO00139-00118
16. Remove the rear lower frame seal of the rear door by dis-
engaging the retainers from the rear door panel, using a
clip remover or the like.
JBO00140-00119
17. Remove the rear door window guide subassembly by re-

moving the attaching bolts.
JBO00141-00120
18. Removal of rear door glass subassembly

(1) Install the rear door window handle assembly tem-
porarily.
(2) Align the rear door glass attaching bolts with the holes
provided on the rear door panel by turning the rear
door window handle.
(3) Remove the attaching bolts of the rear door glass from
the rear door window regulator subassembly.
JBO00142-00121
19. Remove the rear door glass subassembly from the rear
door panel.
JBO00143-00122

BO55
20. Remove the rear door glass outer weatherstrip from the
rear door panel by disconnecting the rear door glass
weatherstrip clip from the rear door panel.
21. Remove the rear door glass run.
22. Remove the rear door window regulator handle assembly
by removing the attaching bolts.
JBO00144-00123
23. Disconnect the door control link from the rear door outside
handle assembly.
24. Remove the rear door outside handle assembly by remov-
ing the attaching nuts.
25. Disconnect the rear door open control link assembly from
the rear door lock assembly.
26. Remove the rear door lock assembly.
JBO00145-00124
27. Remove the rear door lock assembly by removing the

three attaching screws and one bolt. (For door control
motor-equipped vehicles.)
28. Remove the rear door lock assembly from the rear door
panel.
JBO00146-00125
29. Removal of rear door garnish

(1) Remove the attaching screws of the rear door garnish
which is installed to the outside molding No. 2 retainer.
(2) Remove the rear door garnish by removing the retain-
ers.
JBO00147-00126
30. Remove the outside molding No. 2 retainer by removing

JBO00148-00127

BO56
31. Remove the center pillar lower garnish. (Refer to the trim &
garnish section.) (Only for model equipped with central
door lock and/or speaker.)
32. Disconnect the connector of the rear door wire from the
wire harness. (Only for model equipped with central door
lock and/or speaker.)
33. Remove the rear door wire by disconnecting the rear door
wire clamp from the rear door panel while retracting the
lock section of the various clamps and disconnect the rub-
ber grommet from the body shell and rear door panel.
(Only for model equipped with central door lock and/or JBO00149-00221
speaker.)
34. Remove the rear door check assembly by removing the
attaching bolts.
35. Remove the rear door by removing the attaching bolts.
36. Remove the rear door hinges from the rear door by remov-
ing the attaching bolts.
JBO00000-00128
ASSEMBLY
NOTE:
Basically the assembling procedure is reverse to the disassembling procedure. Therefore, some il-
lustrations are not mentioned in this assembling procedure. Refer to the illustrations in the disassem-
bling procedure in cases where any difficulty is encountered.
1. Install the rear door hinges to the rear door with the attaching bolts.
2. Install the rear door by installing the attaching bolts of the rear door hinges while holding the rear door
securely and adjust the rear door alignment. (Refer to the section under the adjustment of front door
and rear door alignment.)
3. Install the rear door check assembly by installing the attaching bolts.
4. Install the rear door wire harness to the rear door through the body shell and rear door panel and set
the rubber grommets to the body shell and rear door panel.
(Only for model equipped with central door lock and/or speaker.)
5. Connect the rear door wire clamps to the rear door panel.
6. Connect the connector of the rear door wire to the wire harness.
7. Install the center pillar lower garnish. (Refer to the trim & garnish section.)
8. Install the outside molding No. 2 retainer to the rear door by installing the attaching bolts.
9. Installation of rear door garnish
(1) Ensure that the retainers are installed on the rear door garnish properly.
(2) Affix a two-faced adhesive tape at the front part of the rear door garnish.
(3) Install the rear door garnish to the rear door panel by connecting the retainers securely.
(4) Install the rear door garnish to the outside molding No. 2 retainer by installing the attaching screws.
10. Install the rear door lock assembly with the three attaching screws and one bolt. (For central door lock-
equipped model.)
11. Install the rear door open control link assembly to the rear door panel and connect it to the rear door
lock control assembly.
12. Install the rear door outside handle assembly with the two attaching nuts securely.
13. Connect the door control link to the rear door outside handle assembly.
14. Install the rear door glass run.

BO57
15. Install the rear door glass outer weatherstrip to the rear door panel by connecting the rear door glass
weatherstrip clip to the rear door panel.
16. Install the rear door regulator subassembly with the attaching bolts.
17. Install the rear door window regulator handle temporarily.
18. Align the position for the rear door glass attaching bolts with the hole on the rear door panel.
19. Install the rear door glass subassembly to the rear door panel.
20. Install the attaching bolts of the rear door glass to the rear door window regulator subassembly.
21. Install the rear door window guide subassembly into the rear door panel and connect the rear window
glass run to the rear door window guide subassembly.
22. Install the rear door window guide subassembly to the rear door panel while inserting the rear door win-
dow glass into the glass run.
23. Install the rear door lower frame seal by connecting its retainers to the rear door panel assembly.
24. Connect the connector of the rear door wire to the door control motor assembly.
25. Install the rear door glass weatherstrip assembly to the rear door trim panel assembly by bending the
protrusion sections on the front door glass weatherstrip assembly.
JBO00150-00000
26. Installation of rear door service hole cover

(1) Affix a butyl tape to the groove provided around the rear door panel as shown.
CAUTION:
Care must be exercised so that the joint section of the butyl tape may come at the upper section. If
the joint section of the tape comes at the lower side of the door, it may cause water leakage.
The butyl tape should be routed just under the water drain holes. Failure to observe this caution may
lead to collection of water, resulting in rust formation.
(2) Affix the front door service hole cover, as shown.

NOTE:
Pass the rear door open control link through the front door service hole cover during the assembly.
Cover assembling reference
A B
Align with beads. Align with beads.
Cover Cover
Section A Section B
Align with butyl location.
JBO00151-00129

BO58
27. Install the door trim No. 1 bracket with the attaching bolts.
28. Connect the rear door inside handle subassembly to the rear door open control link assembly.
29. Ensure that the retainers are installed on the back side of the rear door trim panel assembly properly.
30. Pass the rear door inside handle subassembly through the rear door panel while holding the rear door
trim panel assembly slightly.
31. Install the rear door trim panel assembly on the rear door panel while aligning the rear door lock control
link position.
32. Engage the retainers provided on the rear side of the front door trim panel assembly by pressing the
position where retainers are installed.
33. Hang the nail section provided on the rear door inside handle subassembly to the rear door panel and
secure the attaching screws.
NOTE:
An oversize screw is available.
34. Install the attaching screw of the door lock control knob holder securely.
35. Screw in the rear door locking button.
36. Close the window glass fully.
37. Install the snap ring to the rear door window regulator handle assembly in such a direction that the
open ends of the snap ring face toward the arm side of the window regulator handle assembly.
38. Attach the door vent window control handle plate in such a direction that the recessed side faces to-
ward the front door trim panel assembly side.
39. Insert the window handle assembly to the regulator in such a way that the tilt angle is 30 degrees from
the horizontal.
40. Ensure that the rear door mechanism operates properly.
41. Check and adjust the rear door alignment.
(Refer to the section under the adjustment front door and rear door alignment.)
JBO00152-00000

BO59
BACK DOOR
COMPONENTS
: Tightening torque
Unit : Nm (kgf-m) @7
: Non-reusable parts @6
@5
i !0
!3 @3
u
!1
!4 !6 !7
@2
!5
!8
e r !2
w
!9
@0
@1
t
y
19.6 - 29.4
(2.0 - 3.0)
@4 q
@9
#0
#1
@8 o
6.9 - 15.7
(0.7 - 1.6)
q Back door weatherstrip !7 Back door handle assembly

w Retainer !8 Back door lock assembly
e Back door trim board !9 Door lock striker plate assembly
r Back door service hole cover @0 Back door down male stopper
t Hole plug @1 Back door down female stopper
y Cushion @2 Cushion
u Clip @3 Back door panel subassembly
i Back door hinge cover @4 W/motor back door lock assembly
o Spare wheel cover tray (only for model @5 Rear wiper motor assembly
equipped) @6 Rear wiper link cap
!0 Rear wiper blade rubber @7 Rear wiper arm assembly
!1 Rear wiper blade assembly @8 Spare wheel carrier assembly
!2 Lower hinge assembly @9 Nut
!3 Upper hinge assembly #0 Spare wheel cover (only for model
!4 Door check pin equipped)
!5 Back door check base #1 Spare wheel carrier protector cushion
!6 Back door check assembly (only for model equipped)
JBO00153-00130

BO60
DISASSEMBLY
1. Removal of spare wheel
(1) Remove the spare wheel by removing the attaching
bolts.
(2) Remove the spare wheel cover tray by removing the
four attaching bolts. (For model equipped with spare
wheel carrier.)
JBO00154-00131
(3) Remove the spare wheel carrier assembly by remov-

ing the four attaching bolts.
JBO00155-00132
2. Remove the rear wiper arm by removing the attaching nut.

(Only for rear wiper-equipped model. Refer to the BE sec-
tion for the removal procedure.)
JBO00156-00133
3. Remove the back door trim board by disengaging the re-

tainers provided on the back side of the back door trim
board, using a clip remover.
JBO00157-00134
4. Remove the back door service hole cover from the back
door panel subassembly.
NOTE:
Failure to observe this note may lead to water leakage.
JBO00158-00135

BO61
5. Disconnect the connectors of the rear wiper motor and
door lock control switch.
(Only for models equipped with such equipment. Refer to
the BE section for the removal procedure.)
6. Remove the rear wiper motor by removing the attaching
bolts.
(Only for rear wiper-equipped model. Refer to the BE sec-
tion for the removal procedure.)
JBO00159-00136
7. Removal of back door handle assembly

(1) Disconnect the back door open control link from the
back door handle assembly.
(2) Remove the back door handle assembly by removing
the two attaching nuts.
8. Removal of back door lock cylinder
(1) Disconnect the back door lock control link from the
back door lock cylinder.
(2) Remove the back door lock cylinder and lock cylinder
pad by removing the lock retainer.
JBO00160-00137
9. Disconnect the connector of the central door lock.

(Only for central door lock-equipped model)
10. Remove the back door lock assembly by removing the
three attaching bolts.
JBO00161-00138
11. Remove the back door lower male stopper by removing

the two attaching bolts.
12. Disconnect the clamps of the wire harness from the back
door panel.
13. Disconnect the rear window washer hose and plug the
disconnected hose. JBO00162-00139
14. Disconnect the connector of the back door wire harness

from the rear window defogger.
15. Disconnect the connector of the high mount stop lamp
from the back door wire harness.
16. Remove the deck side trim. (Refer to the trim & garnish
section.)
17. Disconnect the connector of the rear door wire harness
from the connector of the wire harness.
18. Remove the back door wire harness from the body shell
and back door by disconnecting the grommets on the
back door wire harness. JBO00163-00140

BO62
19. Remove the back door check assembly by removing the
attaching bolts.
JBO00164-00141
20. Remove the right hand side rear combination lamp and
rear bumper filler.
(Refer to the rear bumper section)
21. Remove the back door by removing the attaching bolts of

the back door hinge.
22. Remove the hinges from the back door by removing the
attaching bolts.
JBO00165-00142
ASSEMBLY
NOTE:
Basically the assembling procedure is reverse to the disassembling procedure. Therefore, illustra-
tions are not mentioned in this assembling procedure. Refer to the illustrations in the disassembling
procedure in cases where any difficulty is encountered.
1. Installation of back door panel subassembly

(1) Install the back door hinges (upper & lower) to the back door panel with the attaching bolts.
(2) Install the back door to the vehicle shell with the attaching bolts securely.
(3) Adjust the back door alignment.
(Refer to the section under the adjustment of back door alignment.)
(4) Install the back door check assembly with the attaching bolts.
2. Install the right hand side rear combination lamp and rear bumper filler.
(Refer to the rear bumper section)
3. Install the rubber grommets of the back door wire harness to the back door panel and body shell.
4. Connect the connector of the rear door wire harness to the connector of the wire harness (body side.).
5. Install the deck side trim. (Refer to the trim & garnish section.)
6. Install the high mount stop lamp.
7. Connect the connector of the high mount stop lamp and/or rear window defogger.
(For model equipped with such equipmemt.)
8. Connect the rear door wire harness clamps to the rear door panel.
9. Connect the window washer hose.
10. Install the back door lower male stopper with the two attaching bolts.
(Refer to the section under the adjustment of back door alignment.)
11. Install the back door lock assembly with the attaching screws.
12. Connect the connector of the door lock control motor. (Only for central door lock-equipped model)
13. Installation of back door lock cylinder
(1) Install the back door lock cylinder and lock cylinder pad with the attaching lock retainer.
(2) Connect the back door lock control link to the back door lock cylinder.
14. Installation of back door handle assembly
(1) Install the back door handle assembly with the two attaching nuts.
(2) Connect the back door open control link to the back door handle assembly.

BO63
15. Install the rear wiper motor with the attaching bolts.
(Only for rear wiper-equipped model. Refer to the BE section for the installation procedure.)
16. Connect the connectors of the rear wiper motor and door lock control switch.
(Only for models equipped with such equipment. Refer to the BE section for the installation procedure.)
JBO00166-00000
17. Installation of back door service hole cover

CAUTION:
Never reuse the used service hole cover.
(1) Affix a butyl tape to the groove provided around the back door panel.
(2) Affix the back door service hole cover as shown.
Cover assembling reference
Align with beads. Align with beads.

B
A
Section A Section B
JBO00167-00143
18. Ensure that the back door trim retainers are installed properly.
19. Install the back door trim to the back door and ensure that the retainers are connected to the rear door
panel properly.
20. Install the rear wiper arm with the attaching nut.
(Only for rear wiper-equipped model. Refer to the BE section for the installation procedure.)
21. Installation of spare wheel
(1) Install the spare wheel carrier assembly with the four attaching bolts and tighten them to the speci-
(2) Install the spare wheel cover tray with the four attaching bolts and tighten them to the specified
tightening torque.
(3) Install the spare wheel to the spare wheel carrier with the attaching bolts.
JBO00168-00000

BO64
TRIM & GARNISH
COMPONENTS
!6
!6
!7
w
e r
w t w
!3
!8 w
q !1 w
!9 w w
!2 !4
w w
w w
u !0 w
w w w w
!5 (CL)
!5 (CX) y
w
i o
@0
q Front pillar garnish (R, L) !1 Center pillar lower garnish (R, L)

w Retainer !2 Rear door scuff plate assembly (R, L)
e Center pillar upper garnish (R, L) !3 Deck side trim (R, L)
r Roof side inner garnish (R, L) !4 Lower back trim
t Clip !5 Deck board assembly
y Rear floor rear carpet !6 Roof silencer
u Cowl side trim right board assembly !7 Roof headlining assembly
i Cowl side trim left board assembly !8 Sun roof opening trim molding
o Rear floor front carpet !9 Sun roof headlining
!0 Front door scuff plate (R, L) @0 Floor carpet assembly
JBO00169-00144

BO65
REMOVAL
1. Remove the front and rear seats.
(Refer to the front and rear seat section.)
2. Removal of front door scuff plate
(1) Disconnect the four retainers provided under the scuff
plate by pulling them up straight.
(2) Remove the front scuff plate.
JBO00170-00145
3. Removal of cowl side trim board assembly

(1) Disconnect the retainers of the cowl side trim board
from the body panel, using a clip remover or the like.
(2) Pull out the cowl side trim board assembly rearward to
disengage it from the locator.
JBO00171-00146
4. Removal of rear door scuff plate assembly

(1) Remove the attaching clips of rear door scuff plate.
(2) Gradually disconnect the retainers provided under the
scuff plate by lifting them up.
(3) Remove the rear door scuff plate.
JBO00172-00147
5. Removal of center pillar lower garnish

(1) Disconnect the retainers of the center pillar lower gar-
nish, using a clip remover or the like.
(2) Remove the center pillar lower garnish while lifting it
upward.
6. Removal of center pillar upper garnish

(1) Remove the front seat outer belt shoulder anchor.
(Refer to the seat belt section for the removal proce- JBO00173-00148
dure.)
(2) Disconnect the retainers of the center pillar upper gar-
nish, using a clip remover or the like.
(3) Remove the center pillar upper garnish.
7. Removal of the front floor carpet assembly and rear floor
front carpet.
(Only when necessary.)
(1) Remove the rear console box assembly and console
panel. (Refer to instrument panel section for removal.)
(2) Remove the front floor carpet assembly by removing
the attaching clip and rear floor front carpet. JBO00174-00149

BO66
8. Removal of front pillar garnish
(1) Disconnect the clips provided on the back side of the
front pillar garnish, using a clip remover or the like.
(2) Remove the front pillar garnish.
JBO00175-00150
9. Removal of lower back trim

(1) Unlock the clips by pushing the central part of the
clips one notch.
(2) Remove the clips from the lower back trim.
(3) Remove the lower back trim.
10. Remove the deck board assembly by removing the at-
taching bolts.
JBO00176-00222
11. Removal of deck side trim

(1) Remove the rear seat outer belt anchor.
(Refer to the seat belt section.)
(2) Unlock the clips by pushing the central part of the
clips one notch.
(3) Remove the deck side trim by carefully disconnecting
the three spring clips installed at the rear door side.
(4) Remove the luggage room lamp connector.
(Only for luggage room lamp-equipped model. Refer
to the BE section.)
JBO00177-00151
12. Remove the rear floor rear carpet.

13. Removal of roof side inner garnish
(1) Remove the rear seat outer belt anchor assembly.
(Refer to the seat belt section for the removal proce-
dure.)
(2) Disconnect the retainers of the roof side inner garnish
by pulling it out, using a clip remover.
(3) Remove the roof side inner garnish.
JBO00178-00152
14. Remove the assist grip assembly by removing the attach-

ing screws.
NOTE:
Open the cover for assist grip attaching screws, before
removing the attaching screws, if the model equipped
with the assist grip attaching screw cover.
JBO00179-00153

BO67
15. Removal of inner rear-view mirror assembly and visor as-
sembly
(1) Disconnect the visor assembly from the visor holder.
(2) Remove the visor assembly by removing the two at-
taching screws.
(3) Remove the visor holder by removing the attaching
screws.
(4) Remove the room lamp cover.
(5) Remove the two attaching screws of the inner rear-
view mirror.
(6) Remove the inner rear-view mirror by disconnecting its JBO00180-00154
connector.
16. Remove the removable roof assembly.
(Refer to the removable roof section.)
17. Remove the roof headlining assembly by removing the at-

taching retainer.
CAUTION:
Be very careful not to smear the roof headlining during
the removal.
Be very careful not to bend the roof headlining during
the removal.
Never reuse the damaged grommet.
JBO00181-00155
18. Tear off the roof silencer from the roof panel.
(Only when necessary)
NOTE:
Never reuse the removed silencer pad.
JBO00182-00156

BO68
INSTALLATION
NOTE:
Basically the assembling procedure is reverse to the disassembling procedure. Therefore, some il-
lustrations are not mentioned in this assembling procedure. Refer to the illustrations in the disassem-
bling procedure in cases where any difficulty is encountered.
1. Sticking of roof silencer pad

(1) Clean the roof silencer attaching surface of the roof panel.
(2) Apply adhesive agent to the roof silencer.
CAUTION:
Ensure that the adhesive agent be applied to at least 90% of the roof silencer. Failure to observe this
caution may lead to producing echo or resonance noise from the roof panel.
(3) Stick the roof silencer pad to the roof panel.

2. Install the roof headlining with the attaching retainer.
CAUTION:
Never reuse the damaged retainer.
Be very careful not to bend the roof headlining during the installation.
Be very careful not to smear the roof headlining during the installation.
Make sure that each connector is located at the lamp attaching section.
3. Install the removable roof assembly. (Refer to the removable roof section.)
4. Installation of inner rear-view mirror and visor assembly
(1) Connect the connector of the roof wire to the inner rear-view mirror.
(2) Install the inner rear-view mirror with the two attaching screws.
(3) Install the room lamp cover.
(4) Install the visor holder with the attaching screw.
(5) Install the visor assembly with the two attaching screws.
(6) Connect the visor assembly to the visor holder.
5. Install the assist grip assembly with the attaching screws.
6. Place the front floor carpet in position and install the clip.
7. Install the rear floor front carpet and rear floor rear mat in position.
8. Install the child restraint anchorage. (Only for vehicles with the Australian specifications)
9. Installation of roof side inner garnish

(1) Ensure that the door trim retainers are properly installed on the back side of the roof side inner gar-
nish.
(2) Install the roof side inner garnish by engaging the retainer with the body shell. To engage the retain-
er with the body shell, lightly tap the retainer attached position of the roof side inner garnish surface
horizontally by hand.
CAUTION:
Be sure to tap the back side of the retainer attaching position horizontally by hand. Failure to observe
this caution may damage the retainer or other related parts.
10. Installation of deck side trim

(1) Connect the luggage room lamp connectors to luggage room lamp. (Refer to BE section of the in-
stallation procedure.)
(2) Install the deck side trim.
(3) Push back the central part of the retainer one click from the position where the central part is flush
with the outer part.
(4) Install the retainer and lock the retainer by pushing the central part of the retainer until its upper sur-
face becomes flush with the outer part of the retainer.
(5) Install the rear seat outer belt assembly.
(Refer to the seat belt section for the installation procedure.)
BO69
11. Install the deck board assembly by installing the attaching bolts.
12. Installation of lower back trim
(1) Place the lower back trim in position.
(2) Push back the central part of the retainer one click from the position where the central part is flush
with the outer part.
13. Installation of front pillar garnish
(1) Ensure that the clips are installed properly.
(2) Insert the lower end of the front pillar garnish into the hole of the front pillar.
(3) Install the front pillar garnish by engaging the retainers with the front pillar.
14. Installation of center pillar upper garnish
(1) Ensure that the retainers are installed properly.
(2) Install the center pillar upper garnish to the center pillar and ensure that the retainers are engaged
properly.
(3) Install the front seat outer belt shoulder anchor. (Refer to the seat belt section for the removal proce-
dure.)
15. Install the center pillar lower garnish.
16. Installation of rear door scuff plate assembly
(2) Install the rear door scuff plate. Ensure that the retainers are engaged properly.
(3) Secure the door scuff plate installing the attaching clips.
17. Installation of cowl side trim board assembly
(2) Insert the cowl side trim into the retainers from the back side of the vehicle.
(3) Connect the retainer on the cowl side trim to the body panel.
18. Installation of front door scuff plate
(2) Install the front door scuff plate. Ensure that the retainers are connected securely.
19. Install the front and rear seat. (Refer to the front and rear seat section.)
JBO00183-00000

BO70
WINDOWS
COMPONENTS
q
w
r y
y
r
q Windshield glass dam

w Windshield glass
e Windshield outside molding
r Cowl top ventilator louver (R, L)
t Hood to cowl top weatherstrip
y Windshield glass stopper
JBO00184-00157
REMOVAL
1. Preparation prior to removal
(1) Remove the front pillar garnish & roof headlining. (Refer to the trim & garnish section.)
(2) Remove the instrument panel. (Refer to the instrument panel section.)
(3) Remove the wiper arms. (Refer to the BE section.)
(4) Remove the hood-to-cowl top weatherstrip.
(5) Remove the cowl top ventilator louver by removing the attaching retainers.
(6) Remove the windshield outside moulding.
JBO00185-00000
(7) Protection of paint surface around windshield glass

Protective tape
Protect the paint surface around the windshield glass
by applying a protective tape or the like.
CAUTION:
To protect the paint surface, be sure to apply a protec- Roof headlining
tive tape to the inside of the edge (groove around the
window attaching surface) as far as it will go.
Be sure to protect both cabin and outside surface.
JBO00186-00158

BO71
2. Cut off the windshield glass adhesive by a cutter knife or
the like to make a small hole, in order to pass a piano wire
through the hole.
CAUTION:
Be very careful not to damage the paint surface and
windshield by the cutter knife or the like.
NOTE:
Change the position of the hole to be made if any diffi-
culty is encountered, because spacers or retainers are
installed at some parts. JBO00187-00159
For quicker operation, make a hole on the adhesive

agent with a heated wire.
CAUTION:
Be very careful not to get scalded during the operation.
3. Pass the piano wire through the adhesive agent.

4. Hold both ends of the piano wire by pliers or the like and
cut off the adhesive by pulling the piano wire one side to
the other.
NOTE:
Some parts are hard to be cut off, because spacers or
retainers are built in between the glass and the body
panel.
5. Remove the windshield glass.

6. Remove the remaining material of the stopper and dam
from the windshield glass frame.
JBO00188-00160
7. Clean the adhesive applying part of the windshield glass

frame and windshield glass as follows.
CAUTION: Adhesive agent
Degrease the blade of a cutter knife before it is put into
use.
The surface of the adhesive agent that was cut by the

piano wire should be made flat by means of a cutter knife,
while leaving a thin layer of the adhesive material.
JBO00189-00161

BO72
INSTALLATION
1. Affix locating stoppers to the windshield glass as shown in the figure below.
Along body
Along body
surface
surface
Align both ends with cut-out sections.
12.6
12.6
Unit: mm
JBO00190-00162
2 Affix a windshield glass dam of the windshield glass to the position shown in the figure below.
3. Apply the primer for the windshield glass frame and/or windshield glass to under the adhesive agent
applying portion if the adhesive agent has been removed completely.
NOTE:
Do not apply the primer when adhesive materials remain on the windshield glass frame or windshield
glass. Be sure to apply the adhesive agent three minutes after the primer has been applied.
4. Apply the adhesive agent to the positions shown in the figure below.
Apply the adhesive agent in such a way that the cross section of the applied agent may measure 8 mm
in base length and 12 mm in height.
Hook section
12
72
Dam
Adhesive agent 35 2
Glass
The ends of the dam should be butted at
* around the center of the lower section. Unit: mm
JBO00191-00163

BO73
5. Install the glass, using suction rubbers. Push the entire
glass surface lightly so that the glass may fit completely.
NOTE:
At this time, assembling should be performed while the
marks of the tinted section of the glass are aligned with
the windshield glass stoppers.
JBO00192-00164
6. Using a spatula or the like, correct the adhesive agent

which has oozed out to the peripheral section of the glass,
as shown in the right figure. Glass Adhesive agent
7. Affix the windshield outside molding.
Dam
JBO00193-00165
8. Cure the adhesive agent completely.

NOTE:
Observe the curing time of the adhesive agent speci-
fied by its manufacturer.
CAUTION:
Do not move the vehicle until the adhesive agent of the
windshield cures completely.
As for the following operations, refer to the front wind-

shield wiper section on the BE section.
9. Install the cowl top ventilator louver.
10. Install the hood-to-cowl top weatherstrip.
11. Install the front windshield wiper arms.
12. Ensure that no water leakage exists.
If any water leakage is found, repair it, as required, or re-
fix the front windshield glass. JBO00194-00000

BO74
QUARTER WINDOW GLASS
COMPONENTS
e
w
r
r
q
q Quarter window glass

w Quarter window glass molding
e Quarter window glass clip
r Quarter window glass spacer
JBO00195-00166
REMOVAL
Protective
1. Preparation prior to removal tape
(1) Remove the roof side inner garnish.
(2) Protection for paint surface around windows
Protect the paint surface around the windows by ap-
plying a protective tape or the like.
CAUTION:
To protect the paint surface, be sure to apply a protec-
window attaching surface) as far as it will go. JBO00196-00167
2. Cut off the window glass adhesive by a cutter knife or the

like to make a small hole, in order to pass a piano wire
through the hole.
CAUTION:
window by the cutter knife or the like.
NOTE:
installed at some parts.
CAUTION:

BO75
3. Pass a piano wire through the adhesive agent.
4. Hold both ends of the piano wire by pliers or the like and
cut off the adhesive by pulling the piano wire one side to
the other.
NOTE:
panel.
JBO00197-00168
5. Remove the window.

6. Remove the remaining material of the stopper and dam
from the window frame. Adhesive agent
7. Clean the adhesive applying part of the window frame and
window glass as follows.
CAUTION:
use.

piano wire should be made flat by means of a cutter knife, JBO00198-00169
while leaving a thin layer of the adhesive material.

3
INSTALLATION
1. Affix clips to the quater window glass as follows. Clip 2
(1) Install the clips to the holes on the body panel. 3
(2) Remove the protective sheet of the clip.
(3) Place the quater window glass to the body at a loca-
tion as shown.
(4) Ensure that the clips are sticked to the quater window 3 Clip
glass. Unit: mm
(5) Remove the quater window glass from the body. JBO00199-00170
(6) Ensure that the clips are sticked to the correct position
of the quater window glass as shown.
Alo face
sur
ng
51 ody
b
.5
d y
39.3ng bo
Alo ace
f
sur
91.3
27
Along body surface
Unit: mm
JBO00200-00171

BO76
2. Affix the quater window glass molding to the quater window with a two-faced tape.
3. Affix the spacers in position as shown in the figure below.
4. Apply the primer for the window frame or window to under the adhesive agent applying portion if the
adhesive agent has been removed completely.
NOTE:
Do not apply the primer when adhesive materials remain on the window frame or window glass. Be
sure to apply the adhesive agent three minutes after the primer has been applied.
in its base length and 12 mm in height.
13
13.
5
Spacer
End of glass
A - A cross-section
B - B cross-section
13.5
B
A
C
18
A B 46
C 25
13.5 F
F
End of glass
120
E D
13.5
C - C cross-section
F - F cross-section
E D
Spacer (Affix it in parallel Panel Flange
with side outer.) Clip
Spacer
3
10
32.5
13.5
7
13.5
E - E cross-section D - D cross-section
Unit: mm
JBO00201-00172
6. Install the glass by inserting the clips into the holes on the body side. Push the entire glass surface
lightly so that the glass may fit completely.
NOTE:
Observe the curing time of the adhesive agent specified by its manufacturer.
CAUTION:
Do not move the vehicle until the adhesive agent of the window cures completely.
8. Install the roof side inner garnish. (Refer to the trim & garnish section of the service manual.)
If any water leakage is found, repair it, as required, or refit the quarter window glass.
JBO00202-00000

BO77
BACK DOOR WINDOW
COMPONENTS
r-2 e : Non-reusable parts
r-1
t
w
y y
q Back door trim board

w Back door hinge cover
e Back door glass
r-1 Back door glass adhesive dam
(On vehicles without spoiler)
r-2 Back door upper weatherstrip
(On vehicles with spoiler)
q t Back window glass clip
y Back window glass spacer
JBO00203-00173
REMOVAL
1. Preparation prior to removal
(1) Remove the back door hinge cover by disconnecting
the retainers, using a clip remover.
(2) Remove the back door trim board and service hole
cover. (Only for model equipped with the rear wiper.) JBO00204-00174
(Refer to the back door section.)

(3) Remove the back door window wiper arm and wiper
motor. (Only for model equipped with the rear wiper.)
(Refer to BE section.)
(4) Disconnect the connectors of the rear window defog-
ger from the back door window. (Only for model
equipped with the rear window defogger.) (Refer to the
back door section.)
(5) Remove the high mount stop lamp. (Only for model
equipped with the high mount stop lamp.)
JBO00205-00000

BO78
(6) Protection for paint surface around windows
Protective tape
Protect the paint surface around the windows by ap-
plying a protective tape or the like.
CAUTION:
To protect the paint surface, be sure to apply a protec-
window attaching surface) as far as it will go.
JBO00206-00175
2. Cut off the window glass adhesive by a cutter knife or the

like to make a small hole, in order to pass a piano wire
through the hole.
CAUTION:
window by the cutter knife or the like.
NOTE:
installed at some parts.
CAUTION:
JBO00207-00000
3. Pass a piano wire through the adhesive agent.

4. Hold the both ends of the piano wire by pliers or the like
and cut off the adhesive by pulling the piano wire one side
to the other.
NOTE:
panel.
5. Remove the window. JBO00208-00176
6. Remove the remaining material of the clips, spacer and

dam from the window frame.
7. Clean the adhesive applying part of the window frame and Adhesive agent
window glass as follows.
CAUTION:
use.

piano wire should be made flat by means of a cutter knife,
while leaving a thin layer of the adhesive material. JBO00209-00177

BO79
INSTALLATION
1. Affix the clips of the back door window glass as follows.
(1) Install the clips to the holes on the back door panel.
(2) Remove the protective sheet of the clip.
(3) Place the back door window glass to the body in such a location as shown.
(4) Ensure that the clips are sticked to the back door window glass.
(5) Remove the back door window glass from the back door.
10.4
A
Clip Clip
A-A
NOTE:
Care must be exercised so t
2 hat the gaps at the right and
left sides may become equal.
Unit: mm
JBO00210-00178
(6) Ensure that the clips are sticked to the correct position of the quater window glass as shown.
surfa body
Along 5
ce
23
48
Along b
od
surface y 48.6
ody
Along b
su rf a c e
Alon ce
surfa
141.2 ody
gb
Unit: mm
JBO00211-00179

BO80
2. Affix the spacers in position as shown in the figure below.
3. Affix the dam in position as shown in the figure below.
4. Apply the primer for the window frame and/or window to under the adhesive agent applying portion if
the adhesive agent has been removed completely.
NOTE:
Do not apply the primer when adhesive materials remain on the window frame or window glass. Be
sure to apply the adhesive agent three minutes after the primer has been applied.
in its base length and 12 mm in height.
6. Affix the weatherstrip to the upper edge of the back door glass as shown in the figure below.
* : Along body surface
16.5
A
*
A 27
Spacer *
78.4
149
* * B *7
20
25
20
* B
25
*
5 16.5 16.5
Back door outer
Back door glass
Back door glass
Dam
Weatherstrip
Back door inner Back door inner Back door outer
Cross-section A - A
(On vehicles without rear spoiler) Cross-section A - A
(On vehicles with rear spoiler)
Back door glass

Dam application procedure
149
12
25
58
*(From edge of glass)

58
8
*(From edge of glass)
Back door outer
Cross-section B-B
Unit: mm
JBO00212-00180
7. Install the glass by inserting the clips into the holes on the
back door side. Push the entire glass surface lightly so
that the glass may fit completely.
NOTE:
Observe the curing time of the adhesive agent speci-
fied by its manufacturer.
CAUTION:
Do not move the vehicle until the adhesive agent of the
window cures completely. JBO00213-00181

BO81
9. Install the roof side inner garnish. (Refer to the trim & garnish section of the service manual.)
If any water leakage is found, repair it, as required, or refit the quarter window glass.
NOTE:
Be sure to seal the back door window wiper attaching hole before checking.
11. Remove the protective tape from around the windows.

12. Install the back door hinge cover by connecting the retainers.
13. Install the high mount stop lamp. (Only for model equipped with the high mount stop lamp.)
14. Connect the connectors of the rear window defogger to the back door window. (Only for model
equipped with the rear window defogger.) (Refer to the back door section.)
15. Install the back door window wiper arm and wiper motor. (Only for model equipped with the rear wiper.)
(Refer to the BE section.)
16. Install the back door trim board and service hole cover. (Only for model equipped with the rear wiper.)
(Refer to the back door section.)
JBO00214-00000

BO82
FUEL TANK
COMPONENTS
B 2.5 - 5.0
(0.25 - 0.5)
: Tightening torque
Unit : Nm (kgf-m) i
2.5 - 5.0
(0.25 - 0.5)

!0 S
2.5 - 5.0
(0.25 - 0.5)
y

r o
B

w !1
t

e
u
q Drain plug
w Fuel tube (emission)
e Fuel tube (return)
r Fuel tube (main)
t Fuel tank sub inlet hose
y Breather hose
u Fuel tank assembly 65 (0.66)
i Fuel pump assembly with motor and bracket q
o Fuel tank breather tube subassembly No. 2 B
!0 Fuel cut-off valve assembly 17.0 - 22.0
!1 Shut valve (1.7 - 2.2)
JBO00215-00182
REMOVAL
WARNING:
Never work near open flame or never smoke near the
working site of fuel-related components.
1. Draining of fuel from fuel tank

(1) Remove the fuel filler cap.
JBO00216-00183
(2) Place a suitable container under the fuel drain plug.

(3) Drain the fuel to the container by removing the fuel
drain plug.
CAUTION:
JBO00217-00184

BO83
(4) Install the fuel drain plug with new gasket interposed
and tighten it to specified tightening torque.
(When fuel tank is reused.)
Tightening torque: 65 Nm (0.66 kgf-m) Gasket
CAUTION:
Be sure to clean the gasket attaching surface of fuel
tank and fuel drain plug before installation.
Never over tighten the fuel drain plug.
JBO00218-00185
2. Remove the fuel pump relay.

3. Start the engine and leave it until engine stopped.
5. Install the fuel pump relay to relay box.
6. Disconnect the negative terminal of the ground wire from
the battery negative terminal.
Fuel pump relay

JBO00219-00186
7. Disconnection of fuel tubes.

(1) Remove the hose bands. Then, disconnect the fuel
hoses form the fuel pipes.
JBO00220-00187
(2) Disconnect the quick connector of the fuel hose from the
fuel pipe while retracting the retainer as shown in the fig-
ure.
CAUTION:
Never use any tools during disconnection.
Never reuse the removed fuel hose (quick connector)
again. Failure to observe this caution may lead to fuel
leakage.
JBO00221-00188
8. Remove the breather hose and fuel tank inlet hose from
the fuel inlet pipe assembly by loosening the hose bands.
CAUTION:
JBO00222-00189

BO84
9. Disconnect the connector of the wire harness from the fuel
pump with motor and bracket located upper side of fuel
tank while unlocking the lock on the connector.
JBO00223-00190
10. Support the fuel tank with suitable jack or bench.

11. Remove the fuel tank by removing the four attaching bolts.
JBO00224-00191
12. Removal of the fuel hoses from the fuel pump with motor
and bracket (fuel pump assembly) by following manner.
(1) Disconnect the main fuel hose from fuel pump assem-
bly by pull it out while retracting the retainer as shown.
CAUTION:
Never reuse the removed fuel hose again. Failure to
observe this caution may lead to fuel leakage.
(2) Remove the fuel main hose from fuel tank by unlocking
the main hose from the hose clips.
(3) Remove the retainer for quick connector from the fuel JBO00225-00192
pump assembly.
(4) Disconnection of the fuel return hose
q Hold the checker as shown.
w Turn the checker to 90 degree in clockwise direc-
tion while pushing the checker to connector side.
JBO00226-00193
e Pull out the fuel hose from fuel pump assembly

while pushing the checker to connector side.
(5) Remove the fuel return hose from the fuel tank by un-
locking the fuel return hose from the hose clamps.
(6) Remove the checker for quick connector from the fuel
tank assembly.
JBO00227-00194

BO85
13. Remove the fuel pump assembly and gasket by removing
the attaching screws evenly
CAUTION:
Never reuse the removed gasket again. Failure to ob-
serve this caution may cause to fire.
JBO00228-00195
14. Remove the fuel hose from the check valve by removing
the hose clamp.
15. Remove the fuel pipe from the fuel tank by unlocking the
fuel pipe from the hose clamps.
JBO00229-00196
16. Remove the check valve by removing the attaching

screws.
CAUTION:
JBO00230-00197
17. Disconnect the fuel tank sub inlet hose from the fuel tank
by loosening the hose clamp.
18. Remove the shut valve from the fuel inlet pipe.
19. Disconnect the breather hose from the fuel tank breather
No. 2 tube by loosening the hose clamp.
20. Remove the fuel tank breather No. 2 tube with gasket.
CAUTION:
JBO00257-00223
INSPECTION
NOTE:
Be sure to check the electrical parts by referring the BE
section.
1. Inspect all component parts for any crack, deformation,

aging, deterioration or other damage.
If any damage is found, replace the damaged part with
new one.
JBO00231-00000

BO86
2. Inspection of the check valve
(1) Connect the suitable rubber hose to check valve.
(2) Ensure that the air continuity is exists when check
valve in installed angle.
If no air continuity is exists, replace the check valve
with new one.
(3) Ensure that the no air continuity is exists when check
valve tilted 90 degrees or before 90 degrees.
If air continuity is exists, replace the check valve with
new one.
JBO00232-00198
INSTALLATION
NOTE:
Installation procedure are basically reverse procedure
of the removal procedure. Therefore, no illustration
shown in this installation procedure. Refer to the illus-
tration shown in the removal procedure when any diffi-
culty is encountered.
1. Installation of the check valve

(1) Clean the attaching surface of the fuel tank, check
valve and new gasket.
(2) Install the check valve to the fuel tank by installing the
attaching screws with new gasket interposed. Then,
tighten the attaching screws to specified tightening
torque evenly.
Tightening Torque: 2.5 - 5.0 Nm ( 0.25 - 0.5 kgf-m)
CAUTION:
Never reuse the used gasket again.
JBO00258-00000
2. Connect the fuel hoses to the fuel tube (for emission).

Then, attach the new hose bands as shown.
3. Connect the fuel tube (for emission) with fuel hoses to the
fuel pipe clamp on the fuel tank.
4. Connect the fuel hose (for emission) to the check valve
and secure the fuel hose with new hose band.
5. Connect the fuel pipe to fuel pipe clamp securely.
0-3 2-7
Unit: mm
6. Installation of the fuel pump assembly JBO00233-00199
(1) Clean the attaching surface of the fuel tank, fuel pump
assembly and new gasket.
(2) Install the fuel pump assembly to the fuel tank while
aligning the protruding section of the fuel pump with
the hole on the bracket by installing the attaching
screws with new gasket interposed. Then, tighten the
attaching screws to specified tightening torque evenly.
CAUTION:
Never reuse the used gasket again. JBO00234-00200

BO87
7. Connection of the fuel hoses to fuel pump assembly
(1) Connection of the fuel main tube
q Clean the fuel main pipe on the fuel pump assem-
bly.
w Apply the few drops of engine oil to the fuel pipe.
e Connect the new fuel hose to the fuel pipe until
clicking sounds emits from the retainer.
JBO00235-00201
r Remove the checker from the quick connector.

Pull this up
JBO00236-00202
t Ensure that the connector is connected properly

by pull the connector from the fuel pipe lightly.
(2) Connect the fuel main tube to the fuel pipe clamps in-
stalled on the fuel tank securely.
JBO00237-00203
(3) Connection of the fuel return tube

q Ensure that the checker of the quick connector is
installed on the quick connector as shown.
w Clean the fuel return pipe on the fuel pump assem-
bly.
e Apply the few drops of engine oil to the fuel pipe.
JBO00238-00204
r Connect the new fuel hose to the fuel pipe until

clicking sounds emits twice.
JBO00239-00205

BO88
t Hold the checker as shown and connect the nail
sections of checker to the quick connector.
y Ensure that the connector is connected properly
(4) Connect the fuel return tube to the fuel pipe clamps
installed on the fuel tank securely.
JBO00240-00206
8. Connect the fuel return tube and emission tubes to the fuel
hoses and attach the new hose clamps properly as
shown.
0-3 2-7
Unit: mm
JBO00241-00207
9. Clean the fuel tank breather No. 2 tube and its attaching
surface of fuel tank thoroughly.
10. Install the fuel tank breather No. 2 tube to the fuel tank by
the attaching bolts with the new gasket interposed.
CAUTION:
Never reuse the used gasket again. Failure to observe
this caution may lead to fuel leakage.
11. Tighten the attaching bolts of the fuel tank breather No. 2
tube to specified tightening torque.
Tightening Torque: 2.5 - 5.0 Nm (0.25 - 0.5 kgf-m) JBO00242-00224
12. Connect the breather hose to fuel tank breather No. 2

tube.
Then, attach the new hose band as shown.
0-3 2 - 15
Unit: mm
JBO00258-00208
CAUTION:
Hose clamp should be tighten until attaching bolt base
contact with the spacer.
Spacer
JBO00243-00209

BO89
13. Install the shut valve to the fuel inlet securely.
14. Connect the fuel tank sub inlet hose with new hose band
to the fuel tank temporary.
15. Install the fuel tank to the floor panel with the four attach-
ing bolts and tighten the attaching bolts to specified tight-
ening torque evenly while supporting the fuel tank with
suitable stand or the like.
JBO00244-00000
16. Connection of fuel tubes.

(1) Connect the fuel hoses to the fuel pipes and attach the
new hose bands. (Refer to the illustration in step 8.)
(2) Connection of fuel main tube (Refer to the step 7.)
q Clean the fuel main pipe on the fuel pump assem-
bly.
w Apply the few drops of engine oil to the fuel pipe.
e Connect the new fuel hose to the fuel pipe until
clicking sounds emits from the retainer.
r Remove the checker from the quick connector.
t Ensure that the connector is connected properly JBO00259-00225
(3) Connect the breather hose with new hose band to the
fuel inlet and tighten the hose band securely. (Refer to
the step 12.)
CAUTION:
(Refer to illustration in step 12.)
(4) Connect the fuel tank sub inlet hose to fuel inlet with
new hose band as shown and tighten the hose bands
Tank side Inlet side
securely.
CAUTION: Tank
10 - 1 2-9 2 - 15 0-3
Unit: mm
JBO00260-00226
17. Connect the connector of the wire harness to the fuel

pump with motor and bracket located upper side of fuel
tank and ensure that lock is locked properly.
18. Connect the negative terminal of the ground wire to the
19. Fill the fuel tank with the fuel.
20. Close the fuel filler cap.
21. Start the engine and ensure that the no fuel leakage ex-
ists.
JBO00261-00000

BO90
REMOVAL OF FUEL INLET
CAUTION:
Be sure to drain the fuel from the fuel tank before re-
moving the fuel inlet when fuel filled-up more than half
in the fuel tank.
1. Remove the fuel tank cap assembly.

2. Disconnect the fuel hose and fuel breather hose by re-
moving the hose bands.
3. Remove the fuel tank filler pipe protector by removing the JBO00245-00211
attaching three grommet.

NOTE:
Two screw type grommet can be loosened by turning
the screw section 90 degree to counter clockwise.
Upper section grommet can be removed by pull it out
while retracting the lock sections on the grommet.
4. Remove the fuel inlet by removing the two attaching bolts.

5. Remove the fuel tank filler pipe shield from the fuel inlet
box.
JBO00246-00212
INSTALLATION OF FUEL INLET

Install the components in the reversed order of the removal
procedure.
1. Install the fuel tank filler pipe shield to the fuel inlet box.
2. Install the fuel inlet with the two attaching bolts and tighten
the attaching bolts to specified tightening torque.
(0.64 - 0.96 kgf-m)
3. Install the fuel tank cap assembly.

4. Connect the fuel hose and fuel breather hose. Then, se-
cure it with attaching new hose bands.
CAUTION:
contacts with the spacer. (Refer to page BO88.)
5. Install the fuel tank filler pipe protector with the attaching
three grommets.
JBO00247-00000

BO91
ACCELERATOR PEDAL
COMPONENTS
RHD LHD
u q
i q
o e
r
y
y
w q Accelerator cable
t w w Accelerator pedal
r r
e e Accelerator pedal support bracket
r Bush
t Accelerator link rod return spring
r t y Cushion
u Clamp
i Clamp
o Clamp
JBO00248-00214
INSPECTION OF ACCELERATOR PEDAL

Ensure that the accelerator pedal operates smoothly without being caught or interference.
If any problem is found, replace the damaged accelerator pedal related part, as required.
REMOVAL
1. Disconnect the accelerator cable assembly from the accelerator pedal.
2. Remove the accelerator pedal support bracket by removing the attaching bolt.
3. Remove the accelerator cable assembly after disconnecting the cable from throttle body side (Refer to
the EM section.)
DISASSEMBLY
1. Remove the retainer from the accelerator pedal.
CAUTION:
Never reuse the removed retainer again.
2. Pull out the accelerator pedal slightly. Then, unlock the accelerator link rod return spring from the accel-
erator pedal.
3. Remove the accelerator pedal from the accelerator pedal support bracket.
4. Remove the accelerator link rod return spring and bushs from the accelerator pedal support bracket.
5. Remove the cushion from the accelerator pedal support bracket.
ASSEMBLY
1. Install the cushion from the accelerator pedal support bracket.
2. Thinly apply the chassis grease to accelerator link rod return spring and bushs.
3. Install the accelerator link rod return spring and bushs to the accelerator pedal support bracket.
4. Connect the accelerator pedal to the accelerator pedal support bracket half way.
5. Connect the accelerator link rod return spring to the accelerator pedal.
6. Connect the accelerator pedal to accelerator pedal support bracket completely.
7. Install the retainer to accelerator pedal.
8. Ensure that the retainers is securely installed on the accelerator pedal.
JBO00249-00000

BO92
INSTALLATION
1. Install the accelerator cable assembly and connect the cable to the throttle body side (Refer to the EM
section of the service manual.)
2. Install the accelerator pedal assembly to the floor panel with attaching bolts and tighten the attaching
bolts to the specified tightening torque.
3. Connect the accelerator cable assembly to the accelerator pedal while aligning protrusion on the accel-
erator cable grommet with the recessed sections of accelerator pedal.
4. Adjust the accelerator pedal free play to specified value by adjusting the free play of accelerator inner
cable at throttle body side.
Accelerator pedal free play: 3.0 - 5.0 mm
CAUTION:
Be sure to connect the accelerator cable assembly to the cable clamp properly.
Be sure to adjust the free play of the cable in an axial direction by referring to the EM section of the
service manual.
Clamp
Clamp
Throttle body Clamp
Accelerator pedal Accelerator pedal
Plane view
Clamp
Clamp
Clamp
Throttle body
Accelerator
pedal
Accelerator pedal
Frontal view
JBO00250-00216

BO93
EXHAUST PIPE
COMPONENTS
y
: Tightening torque
Unit : Nm (kgf-m)
t
q
24.0 - 56.4
(2.45 - 5.75)
r w
e
t q Tail pipe assembly

w Exhaust front pipe assembly
15.2 - 22.8 e Exhaust pipe support bracket No. 1
(1.6 - 2.3) r Exhaust pipe gasket
39.2 - 53.9 29.4 - 44.1 t Muffler support No. 2
(4.0 - 5.5) (3.0 - 4.5) y Exhaust pipe heat insulator No. 3
JBO00251-00217
REMOVAL
2. Separate the tail pipe from the exhaust manifold by removing the two attaching nuts.
3. Remove the tail pipe by disconnecting the muffler supports.
4. Remove the gasket between front pipe and tail pipe.
5. Remove the exhaust pipe support from the exhaust pipe and exhaust pipe support No. 1 by removing
the attaching bolt and nut.
6. Remove the exhaust pipe support No. 1 bracket from the transfer case by removing the attaching bolts.
7. Remove the front pipe from the exhaust manifold by removing the attaching nuts and bolt.
8. Remove the exhaust pipe gasket.
INSTALLATION
1. Install the new exhaust pipe gasket to the exhaust front pipe.
2. Install the front pipe to the exhaust manifold with the attaching nuts and bolt. Then, tighten the attaching
nuts and bolt to specified tightening torque.
Tightening Torque (Exhaust manifold Front exhaust pipe): 39.2- 53.9 Nm (4.0 - 5.5 kgf-m)
3. Install the exhaust pipe support No. 1 bracket to transfer case with the attaching bolts and tighten the
attaching bolts to specified tightening torque.
4. Secure the front exhaust pipe to the exhaust pipe support No.1 bracket with the exhaust pipe bands.
Then, tighten the attaching bolt and nut to specified tightening torque.
5. Install the new exhaust pipe gasket to the front pipe.

6. Install the tail pipe by connecting the muffler supports.
7. Connect the tail pipe to the front pipe with the two attaching nuts and tighten the attaching nuts to spec-
ified tightening torque.

9. Ensure that the no exhaust gas leakage is exists.
JBO00252-00000

BO94
ENGINE MOUNTING INSULATOR
COMPONENTS
: Tightening torque
Unit : Nm (kgf-m)
34.3 - 61.8 34.3 - 61.8

(3.5 - 6.3) 7 3 mm (3.5 - 6.3)
RH 7.5 +2
2.5 mm
LH 5.5 +2
2.5 mm
21.6 - 39.2
(2.2 - 4.0)
21.6 - 39.2
(2.2 - 4.0)
1.0 mm
REAR
5.3 +1.5
21.6 - 39.2
(2.2 - 4.0)
JBO00253-00218

BO95
INSPECTION
Ensure that the clearance of each mounting is within the specified value, as shown in the figure.
If the clearance fails meet with the specified value mentioned in the figure, replace the part with a new one
or adjust the clearance by changing the attaching position.
REMOVAL/INSTALLATION
1. Lift up the engine and transmission slightly, using an engine lifter and/or transmission jack, etc.
2. Remove the engine mountings.
3. Install a new engine mounting with the attaching bolts and nuts.Then, tighten the attaching bolts and
nuts to the specified tightening torque as mentioned in the figure.
4. Remove the engine lifter and/or transmission jack, etc from the engine and transmission.
5. Ensure that the clearance of the engine mountings are within the specified value.
If the clearance fails to meet the specified value, loosen the attaching bolts of the engine mountings at-
taching position. Then, tighten the attaching bolts to the specified tightening torque mentioned in the
figure.
6. Ensure that the clearance of each mountings are within the specified value as mentioned in the figure
above.
NOTE:
Check the alignment of the vehicle shell or the engine mounting member if the clearance fails to
meet the specified value after replacing the engine mounting.
JBO00254-00000

BO96
TIGHTENING TORQUE
Tightening torque determination procedure for general standard bolts and nuts
1. Tightening torque determination procedure for bolts
Determine the strength division of the bolt concerned from the table below. Then, locate the tightening
torque in the tightening torque table.
2. Tightening torque determination procedure for nuts
Determine the tightening torque in the same way as described above, based on the mating bolt.
3. Identification
Identification of strength division by checking bolts them selves Identification by part number
Kind Shape of head (How to determine strength division) Hexagonal bolt
(Strength division) Bolt without flange Bolt with flange An example of 9 1 1 1 1 - 4 0 6 2 0
part number Nominal
4 4 length (mm)
Nominal
4 T
diameter (mm)
Strength division
Nominal diameter
5
5 T Nominal length
JBO00000-00219
6
6 T

7
7 T
JBO00255-00000
4. Tightening torque table for general standard bolts

Standard tightening torque {Nm (kgf-m)}
Strength division Nominal diameter Pitch
(mm) (mm) Bolt without flange Bolt with flange
6 1.0 5.4 (0.55) 5.9 (0.6)
8 1.25 13 (1.3) 14 (1.45)
10 1.25 25 (2.6) 28 (2.9)
4 T
12 1.25 47 (4.8) 53 (5.4)
14 1.5 74 (7.6) 83 (8.5)
16 1.5 113 (11.5)
6 1.0 6.4 (0.65)
8 1.25 16 (1.6)
5 T 10 1.25 32 (3.3)
12 1.25 59 (6.0)
14 1.5 91 (9.3)
16 1.5 137 (14.0)
6 1.0 7.8 (0.8) 8.8 (0.9)
8 1.25 19 (1.95) 20.5 (2.1)
6 T 10 1.25 39 (4.0) 43 (4.4)
12 1.25 72 (7.3) 79 (8.1)
14 1.5 109 (11.0) 123 (12.5)
6 1.0 11 (1.1) 12 (1.2)
8 1.25 25 (2.6) 28 (2.9)
10 1.25 52 (5.3) 58 (5.9)
7 T
12 1.25 9.5 (9.7) 103 (10.5)
14 1.5 147 (15.0) 167 (17.0)
16 1.5 225 (23.0)
JBO00256-00000

DAIHATSU
J100
BODY ELECTRICAL SYSTEM
GENERAL DESCRIPTION ........................ BE 2

POWER SUPPLY ....................................... BE 6
IGNITION KEY SWITCH ........................... BE 8
COMBINATION METER ............................ BE 9
HEAD LAMP .............................................. BE 15
HEAD LAMP LEVELING ........................... BE 18
FRONT FOG LAMP ................................... BE 19
STOP LAMP .............................................. BE 20
BACK UP LAMP ........................................ BE 21
REAR FOG LAMP ..................................... BE 22
TAIL LAMP & LICENSE PLATE LAMP .... BE 24
INTERIOR LAMP & LUGGAGE ROOM
LAMP ..................................................... BE 25
HAZARD WARNING & HORN .................. BE 27
HATER & VENTILATION ........................... BE 29
POWER DOOR LOCK ............................... BE 32
POWER WINDOW ..................................... BE 34
WIPER & WASHER ................................... BE 36
DEFOGGER .............................................. BE 39
CIGARETTE LIGHTER ............................. BE 41
REAR VIEW MIRROR ............................... BE 43
ITC SYSTEM ............................................. BE 45 BE
SRS AIR BAG SYSTEM ............................ BE 52
IMMOBILIZER SYSTEM ........................... BE 91
SSTs (Special service tools) ................... BE104
TIGHTENING TORQUE ............................. BE104
JBE00001-00001
NO. 9710-JE

BE2
GENERAL DESCRIPTION
HANDLING PRECAUTION
General instructions
1. Never pull the connectors or step on them during the wire
harness transport or assembly.
(Prevention of pulling-out of terminals, connector cracks,
deformation and so forth.)
JBE00002-00002
2. Care must be exercised to ensure that no scratch is made

to the wire harness by burrs or edges during the wire har-
ness transport or assembly.
(Prevention of scratches to the outer trim, electrical insula-
tors and so forth.)
3. Clamping method
In the case of resin clamps, ensure that the clamp section
is fitted in the body hole. Harness
JBE00003-00003
NOTE:
Ensure that the clamp will not be detached when it is
pulled lightly in the arrow-headed direction.
(Prevention of interference due to the detachment of
the clamp)
In the case of metal sheet welded clamps, be sure to
assemble the harness in such a way that the harness
(Correct) (Wrong)
will not come in contact with the welded surface.
(Prevention of wire harness damage due to welding
burrs)
JBE00004-00004
In case that the locating guide of the clamp position or

the clamp mark is clamped, make sure that the clamp Clamp guide
is located within the guide. As for the clamp at the
clamp mark section, ensure that the clamping is made
at a point within 10 mm.
Clamping should be
made at a point
between these points.
JBE00005-00005
(Prevention of slackness or interference)

Clamp mark
Clamping is made at a point

within 10 mm (0.39 inch).
JBE00006-00006

BE3
4. Terminals and connectors
Perform the connection of connectors positively.
Connector with lock; Ensure that the locking is made.
Connector without lock; Connect the connector positively
until it stops.
JBE00007-00007
Retention by screws
When the tightening torque is specified, be sure to ob-
serve the specification strictly.
Terminal is bent.
(The tightening torque is posted in the table separately.)
Ensure that the staked section may not come on the as-
sembling surface.
After completion of the tightening operation, lightly pull out (Correct) (Wrong)
the terminal. Ensure that there is no slackness.
When performing other operations, care must be exer-
cised to ensure that no connected connector is detached
by pulling out the wire harness forcibly. JBE00008-00008
5. Work procedure for tightening-up type resin clamps

When the tightening-up type resin clamps are employed,
do not use any pliers, cutting pliers or the like.
<Reason>
Prevention of clamps being cut or scratched
Resin clamp Tool
JBE00009-00009
WIRE SIZE & COLOR CODE Code Gr Br B

For identification purpose, each wire has its own color. Color Gray Brown Black
Each color bears a code as described in the right table.
Code W R G
These codes are used in the wiring diagram and will be
helpful during trouble shooting. Color White Red Green
Code Y L O
Color Yellow Blue Orange
Code P Lg V
Color Pink Light green Violet
JBE00010-00010
The wire color comes in two kinds: single color and com-
posite color. In the case of single color, the whole outer
coat of the harness is of a single color.
In the case of composite color, a fine line of the second W
White
color is drawn on the harness basic color.
In this case, the code is composed of the basic color Black
code which comes first and the second color code which
comes after a hyphen. W-B
White
JBE00011-00011

BE4
WARNING:
The wire diameter and capacity of each harness have
been determined to assure the normal operation of the
electrical system.
Hence, do not take power for accessories carelessly
through the original wiring harness. Failure to observe
this caution may cause system malfunction or fire.
JBE00012-00012
2A 3.00 W-R
Color code
Nominal section
Wire type
JBE00013-00013
Section area Diameter Permissible

Nominal section
(mm) (mm) current (A)
0.5 0.56 1.0 9
0.85 0.88 1.2 12
1.25 1.28 1.5 15
2.00 2.09 1.9 20
3.00 3.29 2.4 27
JBE00014-00014
OPERATION OF LOCK TYPE CONNECTOR

Conventional type
Pull up
The lock type of the connector comes in a push release type, Press down
a pull release type, a spring lock type, an one-way lock type
and so on.
After confirming the shape of the lock, unlock the lock.
Disconnect the connector white holding the connector by
hand.
NOTE:
Never pull the harness during the disconnection.
Be sure to pull out the connector straight so as not to
damage the terminal.
Pull up
Release the
lock by
suitable
tool
JBE00015-00015

BE5
Double lock type
The double lock type connector has been adopted for air bag Spring 2nd lock
system to prevent unexpected troubles such as poor connect-
ing. Pin
NOTE:
1st
Disconnection and connection of each connector lock
should be kept at a minimum level. If unnecessary dis-
connection or connection is repeated, it may cause un-
expected troubles such as poor continuity and chatter-
ing.
JBE00016-00017
TERMINAL REMOVAL & INSTALLATION

Removal of terminal
<Housing lance type>
Insert a miniature screwdriver through the opening section of
the connector into between the locking lug and the terminal.
While prying up the locking lug with the screwdriver, pull the Housing lance type
terminal backward.
Lance
<Metal lance type>
While pushing the lance with the screwdriver, pull the terminal
backward. Metal lance type
JBE00017-00018
Installation of terminal
<Housing lock type>
Push the terminal into the protruding section of the connector,
until the lock is engaged completely. Lightly pull the harness
to assure that the locking has been made completely.
<Metal lance type>
Insert the terminal into the connector, until lance is locked
completely. Lightly pull the harness to assure that the locking
has been made completely.
JBE00018-00019
INSPECTION
Tester (Volt/ohmmeter)
For the inspection, use a tester having an internal resistance
of more than 10 kW/V.
Use of a tester with a low internal resistance may cause
wrong measurement or secondary troubles. V
A
W
JBE00019-00020

BE6
POWER SUPPLY
JUNCTION BLOCK
The junction block assembly is located underneath the steering post at the drivers seat side.
Turn SW (Dimmer Lo)

Turn SW (Dimmer Hi)
Turn SW (Hazard)
Turn SW (RLSW)
Turn SW (Earth)
Turn SW (+IG)
Turn SW (RH)
Turn SW (RF)
Turn SW (LH)
29 36 58
49 50 48
Turn SW (L)
77
50
70
53
64
58
49
48
74
13
36
40
74 70 64
82 Horn, Hazard (Sub)
33 Horn +B
53 13
60 Front turn lamp RH
B L
Flasher 61 Side turn lamp RH
E relay 71 Head lamp Hi RH
27 43
75 Head lamp Lo RH
57 8 80 63 69 4
71 30
42 66 67 72 75 33 61 60 82
socket
Head RH 10 A 41 Clearance lamp RH
Lighting SW (L) 29 30 Head lamp RH +B
Head LH 10 A
31 Head lamp LH +B
Tail 10 A 72 Head lamp Hi LH
Tail SW (L) 40 76 Head lamp Lo LH
21 10
42 Clearance lamp LH
31 41
Fog 10 A 67 Side turn lamp LH
66 Front turn lamp LH
Tail SW (+) 77 46 Fog lamp SW +B

34 Key SW (+)
5 Meter +B
6 Cowl IG
44 Meter illumination +B
11 54 76
Horn, Hazard fuse 79
Door lock 15 A 54 Key SW (L)
At junction block side

Tail FL (L) 32 39 Door lock relay +B
44 46 39 20 73
56 34 37
37 Stop SW +B
Stop 10 A 26 Electric mirror +B
Earth 47
28 Power supply (Option)
EFI Main relay 19 20 EPS ECU
ECU IG 10 A
IG SW (IG2) 18 68 Turn indicator LH
Air bag 10 A 62 Turn indicator RH
14
Sub fuse (Air bag) 22 11 Rear wiper SW +B
Power window SW +B 16 73 High beam indicator
Defogger 15 A
IG SW (IG1) 1 14 Defogger SW +B
Power 30 A 56 Courtesy SW (+)
62 68
28 26
6 5
65 Hazard SW (LH)
Wiper, Turn 20 A 59 Hazard SW (RH)
38 Room lamp +B
Gauge, Back 10 A 45 Heater illumination +B
45 59 65 52
35 38 51
35 Hazard SW +B
Sub fuse (Heater) 17 9 Front wiper motor
12 Hazard SW +IG
7 Back lamp SW
15 Heater motor +B
3 Ignition coil +B
Engine 10 A e a 2 Diagnosis check +B
c Warning
81 Air bag ECU power supply
buzzer
24 55 12 9 78
f 51 Hazard SW (L)
ACC 15 A d b 52 Hazard SW (RLSW)
79 47
19 32
2 3 81 7
IG SW (ACC) 23 25 Cigarette lighter +B

24 Radio +B
55 Reverse SW (L)
78 Air bag ECU
22 17 23 16
1
Air bag ECU (Sub) 21
Gauge, Back (Sub) 80
Rear turn lamp LH 69

Rear turn lamp RH 63
27
43
57
Rear wiper motor 10
8
Courtesy SW (+)
15
25
18
Back lamp SW
Tail lamp +B
ACC (Sub)
IG Coil +B
10A
H/L LH
wbh vij
82600-87402
NOTICE USE THE DESIGNATED FUSES ONLY.
10A 10A 10A

FOG SPARE H/L RH

t H O X y A wbh viEj
10A 15A 10A
w q [YOgp B
TAIL SPARE STOP

e [ X y A X g b v
15A 10A
DEFOG ECU IG
f t H K
30A 20A 10A
POWER WIPER/TURN AIR BACK
p [ C p [/ ^ [ G A [ o b N
10A 15A
GAUGE/BACK DOORLOCK
Q [ W^ o b N h A b N
10A 15A
ENGINE
G W
ACC
A N Z T Protruding section
JBE00020-00101

BE7
RELAY BLOCK
The relay block is located near the battery in the engine compartment.
q Heater 20A q w e r t
w Back-up 10A
e EFI 15A
r Horn-Hazard 15A
HORN-HAZ
BACK UP
t Magnet clutch 10A
MGC
FUEL
HTR
15A
20A
10A
15A
10A
EFI
y Fuel pump relay y PUMP
u Starter relay (for A/T)
i EFI main relay
o Heater relay u (S T) EFI HTR MGC !0
!0 Magnet clutch relay (for air conditioner)
!1 F/L AM 60A AM (ABS) TAIL HEAD
!2 F/L ABS 50A 60A 50A 40A 30A
!3 Tail lamp 40A
!4 Head lamp 30A
i o
!1 !2 !3 !4
F/L AM 60A Relay block side

M8 Nut 1 IG SW (AM)
Starter relay
1 2
21 Starter (+B)
22 Neutral SW
23 IG SW (ST) 6 5
Heater relay
Heater 20A 4 3
14 Blower motor (+B)
15 Blower SW (Lo)
16 Fuse Gauge/Back
7 8 9
Magnet clutch relay 13 Fuse ECU IG
MGC 10A 10 11 12
12 A/C compressor
11 EFI ECU (MGC)
13 14
15 16
EFI main relay
EFI 15A
3 EFI ECU (+B)
4 Earth
22 23
Fuel pump relay
5 Fuel pump (+B)
6 EFI ECU (F/P)
21
F/L ABS 50A
2 ABS relay (+B)
Head lamp 30A
7 Lighting SW (+B)
Tail 40A
8 Tail SW (+B)
Horn, Hazard 15A
9 Horn, Hazard (+B)
Back up 10A
10 EFI ECU (BATT)
JBE00021-00102

BE8
IGNITION KEY SWITCH
WIRING DIAGRAM
Ignition SW
ACC
IG No. 1
IG No. 2
ST
F/L AM 60A
IG2 IG1 ACC
AM ST
Main
Battery
To Starter
JBE00022-00201
Removal
1. Turn off the ignition key switch.
3. Remove the instrument lower panel and steering column
lower cover.
4. Disconnect the connectors of the ignition switch.
5. Disconnect the immobilizer antenna terminal, if equipped.
JBE00023-00202
UNIT INSPECTION
Ensure that continuity exists between the respective terminals
as indicated in the continuity table.
AM ACC IG1 IG2 ST ACC IG1 IG2
LOCK
ST AM
ACC
ON Switch side
START
JBE00024-00203

BE9
COMBINATION METER
CONSTRUCTION
q
r
q Meter assy, Combination w

w Glass, Front
e Plate, window
r Gauge, water temperature & Fuel
t Speedometer
y Tachometer
u Plate, Circuit meter
JBE00025-00301

BE10
WIRING DIAGRAM
Illumination
B13
L
C3
2 C2
D
C1
N
C5 H26 C1
P
Connector C
C4 H25
R H24
C10
H29
H27
C6 Starter relay coil
10 P
M20
Air bag B6 Air bag ECU

warning H28 C10
circuit
A12 EFI ECU

H52 B1
(At wire harness side)

Seat belt SW
X01
A13 H05
Connector B
WB0
B3 EFI ECU T37
H61
13 P
H22
ABS B5 ABS ECU H20
Z83
Oil pressure SW X03
B4 F19
Tail Tail C21 B13
40A SW Parking brake SW
AUS. only
Brake fluid level SW F21 A1
B7 A10 Z08
Gauge
Center diff. lock
10A _ +
A9 Alternator L
Connector A
Turn flasher relay
16 P
Acc
O20
IG1
ST
A14 G06
R N58
A1
H80
B12 L J/B earth H77
A2 A10
A15 A16
Rear fog switch
A13
F/L AM60A
EC only
Reed switch
EFI ECU B11
Fuel sender
B8
F/L 2.0 B9
Temperature sender
B10 Gauge earth
JBE00026-00302

BE11
Removal of combination meter
1. Pull of the hazard warning switch knob.
2. Remove the instrument cluster finish panel from the instru-
ment panel by removing the screws.
3. Remove the attaching screws of the combination meter
assembly.
4. Disconnect the speedometer cable and wire harness cou-
pler at the back side of the combination meter assembly.
5. Remove the combination meter assembly.
JBE00027-00303
SPEED SENSOR
1. With a circuit tester set to the ohmmeter range, connect
the circuit tester between the terminal B10 and B11.
2. Turn the speedometer drive shaft.
3. Check to see if continuity exists.
NOTE:
The continuity should be 4 times per each revolution of
the speedometer drive shaft.
JBE00028-00304
FUEL RECEIVER GAUGE

1. Jack up the vehicle.
2. Disconnect the connector from the fuel sender gauge/fuel
pump assembly by the fuel tank.
3. Under this condition, turn on the ignition switch.
4. Ensure that the pointer of the receiver gauge returns to the
position E.
O/D
OFF
JBE00029-00305

6. Connect the connector between the terminal H23 and H57
through a test lamp (12 V - 3.4 W).
7. Under this condition, turn on the ignition switch.
8. Ensure that the pointer of the receiver gauge rises gradu-
ally and resisters the position F. H57 H23
10. Ensure that the pointer of the receiver gauge remains sta- ZC6 P06
tionary and registers the position F.
NOTE: Connector at floor harness side
If not, check the wire harness and the fuel sender JBE00030-00306
gauge. With tachometer
Unit check
1. Remove the combination meter. B8
B10 B7
2. Measure the resistance between the terminals.
B8
Specified Resistance: B7 - B8 approx. 127 W
B10
B7 - B10 approx. 286 W B7
B8 - B10 approx. 160 W
JBE00031-00307

BE12
FUEL SENDER GAUGE
1. Jack up the vehicle.
sender gauge/fuel pump assembly by the fuel tank.
3. Connect a circuit tester between the terminal H23 and H23 H57

H57.
4. Ensure that the resistance conforms to the standard value P06 ZC6
for float position specified in the table.
Float position Resistance (W) Connector at fuel tank
sub harness side
F 32 JBE00032-00308
E 120 7
Replacement
1. Remove the fuel tank.
WARNING:
Never allow any fire to be brought near the working
site.
2. Remove the fuel sender gauge by removing the screws.

JBE00033-00309
Installation
1. Place a new gasket on the fuel tank.
WARNING:
Be sure to replace the fuel sender gauge gasket with
new one. Failure to observe this caution may cause
fire.
2. Install the fuel sender gauge to the fuel tank.

3. Install the fuel tank to the body. JBE00034-00310

Cowl wire side
WATER TEMPERATURE RECEIVER GAUGE

In-Vehicle inspection
1. Disconnect the connector of the engine wire harness from
the cowl wire harness at the back side of the glove com-
partment.
Engine wire side

JBE00035-00311
2. Ground the terminal at the cowl wire harness side through

a test lamp (12 V - 3.4 W).
3. Turn on the ignition switch. Ensure that the test lamp goes
on and the pointer of the receiver gauge starts to rise
gradually.
H21
Cowl wire side

JBE00036-00312

BE13
4. Remove the combination meter, measure the resistance
With tachometer
between the terminals.
Resistance: B7 - B9: approx. 54 W
B7 - B10: approx. 177 W B7
B9 - B10: approx. 231 W B10
B9
B9 B7
B10
JBE00037-00313
WATER TEMPERATURE SENDER GAUGE

In-Vehicle inspection
1. Disconnect the connector of the engine wire harness from
the cowl wire harness at the back side of the glove com-
partment.
2. Under this condition, turn on the ignition switch. Ensure
that the pointer of the receiver gauge indicates lowest po-
sition. O/D
OFF
O/D
OFF
JBE00038-00314
3. Turn off the ignition switch, Ground the terminal at the en-
gine wire harness side through a circuit tester.
4. Ensure that the resistance conforms to the standard value
in the table.
NOTE:
(Engine wire side)
If not, check the wire harness and the water tempera-
ture sender gauge.
Temperature (C) Resistance (W)
H20
50 190 - 260
115 24 - 28 JBE00039-00315
15
Unit check 16
1. Remove the engine cylinder head.
Refer to the EM section of the service manual. For water
2. Remove the sender gauge. temp. gauge
3. Measure the resistance between the terminals as in the il-
lustration.
Thermistor
(For water temp. gage)
Thermistor
(For engine control)
JBE00040-00316
4. Clean the threaded portion of new water temperature

sender gauge. Wind seal tape around the threaded por-
tion.
5. Install the sender gauge.
JBE00041-00317

BE14
LOW OIL PRESSURE WARNING
Unit inspection
1. Disconnect the connector from the warning switch.
2. Connect a ohm meter. Ensure that continuity exists be-
tween the oil pressure switch terminal and the ground
while the engine is stopped, whereas no continuity exists
while the engine is running.
NOTE:
If not, replace the unit.
Refer to the LU section of the service manual.
JBE00042-00318
BRAKE FLUID LEVEL WARNING

Unit inspection
1. Disconnect the connector.
2. Connect an ohm meter.
3. Remove the reservoir tank cap. Press down the float with a
clean rod. Ensure that continuity exists.
NOTE:
As for a rod to be used for pressing down the float, be
sure to thoroughly clean it. Special care must be exer-
cised to ensure that no dust nor water gets into the
reservoir. JBE00043-00319
PARKING BRAKE WARNING

Unit inspection
1. Disconnect the connector from the parking brake switch.
2. Ensure that the parking brake warning lamp or brake
warning lamp goes on when ground the terminal at the
harness side.
3. Ensure that continuity exists between the terminal and the
body earth when the parking brake lever is pulled up
ward.
JBE00044-00320
REAR FOG LAMP WARNING

Refer to rear fog lamp system.
JBE00045-00321
SEAT BELT WARNING

Unit inspection
1. Disconnect the connector of the seat belt buckle.
2. Ensure that the seat belt warning glows when short the
terminal at the harness side and the body earth.
3. Ensure that continuity exists between the terminals of the
buckle side.
4. Ensure that no continuity exists when insert the tongue
plate into the buckle until it clicks. Z40 H58
JBE00046-00322

BE15
HEAD LAMP
WIRING DIAGRAM
F/L ABS 50A ABS
Head lamp 30A H/L
Tail 40A TAIL
Back up 10A B/U
Horn, Hazard 15A HRN/HAZ
ACC ACC
IG No. 1 IG1
F/L AM 60A
IG No. 2 IG2
ST ST
IG SW
Main MAIN
Z02 A22 Multi-use lever SW

Wire F/L 2.0
Lighting SW
Head lamp
Pass
L H
SW
A61 Head lamp
ZM7
A17
leveling unit LH
A18 A23
AA4 AA3 AA5 Junction block
A63
Battery
Head lamp RH
Head lamp LH
AA6
0
A69 1
2
Head lamp
leveling SW
3
A98 A01 A05 4
High beam
indicator ZM9
(Combination A56
meter )
H
A54 Head lamp
Head lamp LH ZM8
leveling unit RH
L
H
Head lamp RH
L
JBE00047-00401
HEAD LAMP SWITCH (with air bag system)

Unit inspection
Disconnect the connector for multi-use lever switch. Ensure
that continuity exists between the respective terminals in ac-
cordance with the following continuity table.
JBE00048-00402
HM HS ED TB S (RF+) (RF) D1 D2 L.H.D R.H.D

HF Ho L F R L F R Ho
OFF HL INT EW W +1 +2 WBWS WS WB +2 +1 W EWINT
HU
HF ED Z02 BH RF
+ CJ6
BT HM A17 HS A18 F+ D2 A23
I HL
S CE2 TB CE1 RF CJ7 D1 A22
HU
RF CJ7 D1 A22 S CE2 TB CE1

HF F+ A23 BT HM A17 HS A18
D2
II HL BH RF
+ CJ6 ED Z02
HU With air bag specification (at lighting SW side)
JBE00049-00403

BE16
HEAD LAMP SWITCH (without air bag system)
CE1 CE2
Unit inspection
Disconnect the connector for multi-use lever switch. Ensure W WS +2 +1
that continuity exists between the respective terminals in ac- A18 HS S HM
A17
cordance with the following continuity table. D2 D1 TB BH Ho
A23
HM HS ED TB S D1 D2 A22 F L WB ED
Z02
HF BT R F+
OFF HL
HU
Without air bag specification (at lighting SW side)
HF
JBE00050-00404
I HL
HU
HF
II HL
HU
JBE00051-00405
Aiming adjustment
Perform the following operation in advance.
1. Seat one person (weighing about 75 kg) at the drivers
seat. kPa
2. Set the tire inflation pressure to the specified values. Tire Tire air pressure
size Front Rear
3. Ensure that a spare tire, tools, a jack are mounted at the
205/70R15 200
specified points.
4. Check to see if the engine oil, transmission oil, window
washer fluid, etc. are filled to the specified levels. Fill
them, as required. Further more, fuel in the tank is filled
up. JBE00052-00406
5. Rock the vehicle in up-&-down and right-&-left directions

so that the suspensions may support the load evenly and
the vehicle may assume the proper vehicle posture.
NOTE:
In case of a vehicle which has the head lamp leveling
system, perform this aiming adjustment with the level-
ing control switch set to the 0 position.
JBE00053-00407
6. Setting of reference points on screen

(1) Measure the center height H of the head lamps. Dark side Center of Dark side 15
headlamp lens
(At 3 m from lens surface)
36 mm H
Center height of
Draw an adjustment line on the screen at;

headlamp lens
F
headlamp lens
F
L.H.D. vehicle:
headlamps
Center of
Center of
31 mm below the center height H

R.H.D. vehicle:
31 mm below the center height H
Ground level
Vehicle with head lamp leveling system:
36 mm below the center height H L.H.D Vehicle
JBE00054-00408

BE17
NOTE:
Keep the engine speed at 1500 rpm or more during the Center of
15 Dark side Dark side
headlamp lens
aiming adjustment.
36 mm H
Center height of
headlamp lens
F
headlamp lens
F
(2) Draw a vertical straight line on the screen at each cen-
headlamps
Center of
Center of
ter of the head lamps on both right and left sides.
Thus, establish each intersection F made by the ver-
tical center line and the adjustment line. Ground level
R.H.D Vehicle
JBE00055-00409
(3) Ensure that the optical axis moves down ward when
the head lamp leveling switch is turned 0-1-2-3-4.
Position Stroke
01 28 mm
12 28 mm
23 28 mm
34 28 mm
NOTE: JBE00056-00410
The head lamp leveling system functions only when the

head lamp switch is turned on.

BE18
HEAD LAMP LEVELING
WIRING DIAGRAM
Head lamp 30A

F/L 2.0
Lighting SW
Head lamp
Pass
L H SW
A61 Head lamp

ZM7
A17
leveling unit LH
A18 A23
Head lamp RH A63
Head lamp LH
AA6
0
A69 1 Head lamp
2 leveling SW
3
A98 A01 A05 4
High beam
indicator ZM9
(Combination A56
meter )
H
A54 Head lamp
Head lamp LH ZM8
leveling unit RH
L
H
Head lamp RH
L
JBE00057-00501
HEAD LAMP LEVELING SWITCH

Unit inspection
1. Remove the head lamp leveling switch by pushing it with
your fingers at the back side of the instrument panel.
2. Disconnect the connector of the wire harness.
3. Remove the switch assembly from the instrument panel.
JBE00058-00502
4. Ensure the resistance between the respective terminals

conforms to the following specifications.
Between A69 and ZM9 (Position 0); Approx. 2.0 kW
Between A69 and ZM9 (Position 3); Approx. 1.4 kW AA6 A69 ZM9
Between AA6 and ZM9 (Each position);
Approx. 2.4 kW Switch side
JBE00059-00503

BE19
FRONT FOG LAMP
WIRING DIAGRAM
F/L ABS 50A ABS
Head lamp 30A H/L
Tail 40A TAIL
Back up 10A B/U
ACC ACC
IG No. 1 IG1
IG2
F/L AM 60A
IG No. 2
ST ST
IG SW
Main MAIN
Tail SW
(Multi-use
lever)
Wire F/L 2.0
Junction block
CM1
10 A
Fog
Battery
CE7
C23
Front fog lamp
SW
C24
C26 C25
Front fog lamp LH Front fog lamp LH
ZD3 ZD2
JBE00060-00601
FRONT FOG LAMP SWITCH

Unit inspection
1. Pull out the switch assembly from the instrument panel.
Disconnect the connector. C23
2. Ensure that the continuity exists between the terminals of C24

the front fog lamp switch while the switch is turned on.
Harness Switch
JBE00061-00602

BE20
STOP LAMP
WIRING DIAGRAM
F/L ABS 50A ABS

Head lamp 30A H/L
Tai 40A TAIL
Back up 10A B/U
ACC ACC
IG No. 1 IG1
IG2
F/L AM 60A
IG No. 2
ST ST
IG SW
Main MAIN
Junction block OF2

Wire F/L 2.0
10 A
Stop
E28
E10
Stop lamp SW
Battery
E11
RH
Stop lamp
LH
Stop lamp
E15 E14 E16 stop lamp

High mounted
Z06 Z05 Z68
JBE00062-00701
STOP LAMP SWITCH

Unit inspection
1. Disconnect the connector of the stop lamp switch. (at the
brake pedal arm) E10
2. Ensure that continuity exists between the terminals when
the brake pedal is depressed.
E11
3. Ensure that no continuity exists between the terminals
when the brake pedal is not depressed.
JBE00063-00702
Removal and installation

Refer to the BR section of the service manual.
JBE00064-00703

BE21
BACK UP LAMP
WIRING DIAGRAM
F/L ABS 50A ABS

Head lamp 30A H/L
Tail 40A TAIL
Back up 10A B/U
ACC ACC
IG No. 1 IG1
IG2
F/L AM 60A
IG No. 2
ST ST
IG SW
Main MAIN
Junction block N59 Junction block N59

Wire F/L 2.0
Gauge
Gauge
/Back
10 A
/Back
10 A
Buzzer
G21 G21 D39

G02 G02
lamp SW
Back-up
start SW
Neutral
[M/T model] [A/T model]
Battery
G03 G03
G05 G04
G05 G04 H28
Back-up Back-up
lamp LH lamp RH Back-up Back-up Indicator
lamp LH lamp RH (Combination
G16 G15 meter)
G16 G15 Z08
JBE00065-00801
BACK UP LAMP SWITCH

Unit inspection
(Manual transmission)
1. Disconnect the connector of the back up lamp switch. (on G02
the transmission case)
G03
shift lever of the manual transmission is shifted to the re-
verse position.
JBE00066-00802
(Automatic transmission)
1. Disconnect the connector of the transmission neutral
switch. (on the transmission case)
shift lever of the automatic transmission is shifted to the re- G03
verse position.
G02
JBE00067-00803

BE22
REAR FOG LAMP
WIRING DIAGRAM
F/L ABS 50A ABS

Head lamp 30A H/L
Tail 40A TAIL
Back up 10A B/U
ACC ACC
IG No. 1 IG1
IG2
F/L AM 60A
IG No. 2
ST ST
IG SW
Main MAIN
C39
lamp SW
Rear fog
Wire F/L 2.0
C38
Junction block
N59 F70 D58 D61
Back
Gauge
10 A
Buzzer
Battery
D19 D71
Courtesy SW
CJ6
RF SW
(Multi-use lever)
CJ7
C40 H80
Rear fog lamp indicator
Rear fog lamp (Combination meter)
C64 Z08
JBE00068-00901
REAR FOG LAMP SWITCH

Unit inspection
Disconnect the connector. C38
2. Ensure that the rear fog lamp warning glows when ignition C39
switch turns on and short the terminals at the harness
side.
If not glows the warning, check the wire and meter assem-
bly. Harness Switch
3. Ensure that the continuity exists between the terminals of
the rear fog lamp switch while the switch is turned on. JBE00069-00902

BE23
REAR FOG LAMP WARNING BUZZER
In-vehicle inspection
1. Ensure if the warning buzzer is set off under the conditions
given following table.
Ignition Rear fog lamp
Front door Buzzer
SW SW
On Set off
Open
Off
OFF / Acc
On
Close
Off JBE00070-00904
On
Open
Off
ON
On
Close Off
2. If not, check the wiring harness and warning buzzer.

JBE00071-00905
Unit inspection
1. Disconnect the connectors and remove the junction block
by removing attaching bolts.
2. Apply a battery voltage to the terminal 17 (+) and the ter- 79 47
19 32
minal 47 ().
25
3. Check that the warning buzzer will set off when the battery 15
(+) (or the terminal 47) is connected to the terminal 54
with a jump wire. + 16 23 17 22
1 18
62 68 14 11 54
6 5 44 46 39 20 73
28 26 56 34 37 40 77
53 13 29 36 58
74 70 64 49 50 48
76 31
42 66 67 72
2 3 81 7 45 59 65 52
41 71 30
24 55 12 9 78 35 38 51
75 33 61 60 82
JBE00072-00906

BE24
TAIL LAMP & LICENSE PLATE LAMP
WIRING DIAGRAM
F/L ABS 50A ABS

Head lamp 30A H/L
Tail 40A TAIL
Back up 10A B/U
Horn,Hazard 15A HRN/HAZ
ACC ACC
IG No. 1 IG1
F/L AM 60A
IG No. 2 IG2
ST ST
IG SW
Main MAIN
Tail SW
CE1
CE2
Wire F/L 2.0
Junction block
CM1
10 A
Tail
Buzzer
CA1 H78 C06 C80 C09

Battery
Heater control illumination
License plate lamp LH
License plate lamp RH
Clearance lamp RH
Floor console illumination
Meter illumination
Tuner illumination
Clearance lamp LH
Tail lamp RH
C19 CE0 C28 C12 C08 C07 C10
Tail lamp LH
C21 C17 C16
Z23 Z08 ZR8 Z28 Z06 Z78 Z79 Z05 Z27
JBE00073-01001
TAIL LAMP SWITCH L.H.D R.H.D

Unit inspection Ho L F R L F R Ho
Disconnect the connector of the multi-use lever switch. INT EW W +1 +2 WB WS WS WB +2 +1 W EWINT
Ensure that continuity exists between the respective terminals

in accordance with the following continuity table. ED Z02 BH RF
+ CJ6
BT HM A17 HS A18 F+ D2 A23
S CE2 TB CE1 RF CJ7 D1 A22

RF CJ7 D1 A22 S CE2 TB CE1

F+ D2 A23 BT HM A17 HS A18
BH RF
+ CJ6 ED Z02
With air bag specification (at lighting SW side)

JBE00074-01002
TB S
CE1 CE2
HF
OFF HL W WS +2 +1
HU A18 A17
HS S HM
HF D2 D1 TB BH Ho
A23
I HL F L WB ED
A22 Z02
HU
BT R F+
HF
II HL
HU Without air bag specification (at lighting SW side)
JBE00075-01003

BE25
INTERIOR LAMP & LUGGAGE ROOM LAMP
WIRING DIAGRAM
F/L ABS 50A ABS

Head lamp 30A H/L
Tail 40A TAIL
Back up 10A B/U
F/L AM 60A ACC ACC
IG No. 1 IG1
IG No. 2 IG2
ST ST
IG SW
Main MAIN
J/B
& Back
Gauge
10 A
10 A
Stop
Buzzer
F/L 2.0
Room lamp
On Off
lamp
Luggage room
Door
Courtesy SW
Courtesy SW
Courtesy SW
courtesy SW
Back door
Courtesy SW
FR RH
FR RH
FR RH
FR RH
JBE00076-01101
INTERIOR LAMP SWITCH

Unit inspection
1. Lightly pry the lens to detach it and pull out the bulb
straight. V
2. Turns on the ignition switch.
3. Ensure if the voltage exists between the terminals when in-
terior lamp switch is located to the respective position.
Interior lamp switch position
Left Center Right
Front door Battery Battery JBE00077-01102
open voltage voltage

Front door Battery
close voltage

BE26
LUGGAGE ROOM LAMP SWITCH
Unit inspection
1. Lightly pry the lens to detach it and pull out the bulb
straight.
2. Turns on the ignition switch.
3. Ensure if the voltage exists between the terminals when
the rear gate is opened.
Rear gate open Battery voltage V
Rear gate close
JBE00078-01104
JBE00000-01105

BE27
HAZARD WARNING & HORN
WIRING DIAGRAM
F/L ABS 50A ABS
Head lamp 30A H/L
Tail 40A TAIL
Back up 10A B/U
ACC ACC
IG No. 1 IG1
F/L AM 60A
IG No. 2 IG2
ST ST
IG SW
Main MAIN
Multi-use
Junction block lever SW
Wire F/L 2.0
Turn / Wiper
N59 F66 F32 Turn
F48
F70 20 A F65 F47
Hazard
Flasher relay
LH F60
Horn E02
RH
F64 F62 LH
Battery
F63 F61
RH
E03
F04 F55
F44 F52
F53 F43
F54 F06 E19
Front turn lamp RH

Side turn lamp RH
Side turn lamp LH
Front turn lamp LH
indicator lamp RH
Turn signal
Rear turn lamp RH
Rear turn lamp LH
Horn SW
indicator lamp LH
Turn signal
F05 F11 F09 F19 F07 F16 F14 F21
Z06 ZM6 ZM3 Z08 Z05 ZM5 ZM4 Z08
JBE00079-01201
HAZARD WARNING SWITCH L.H.D F62 F60 F61 F62 F60 F61 R.H.D
Unit inspection
Ho L F R L F R Ho
1. Disconnect the connector of the multi-use lever switch.
INT EW W +1 +2 WB WS WSWB +2 +1 W EWINT
2. Ensure that continuity exists between the respective termi-
nals in accordance with the following continuity table. ED F47 BH RF
+
F32 BT HM HS F+ D2
F48
Hazard F L R BT BH F+ S TB RF
D1
L F48 RF D1 S TB

F32 BT HM
F+ D2 HS
OFF N F47
BH RF
+ ED
R
With air bag specification (at lighting SW side)
ON
JBE00080-01202
W WS +2 +1
HS S HM
F47
D2 D1 TB BH Ho
F60 F L WB ED
BT R F+
F62
F32 F61 F48
Without air bag specification (at lighting SW side)

JBE00000-01203

BE28
FLASHER RELAY
Unit inspection Flasher
1. Remove the combination meter. Then remove the flasher relay
unit at the bracket of the cowl panel.
2. Disconnect the connector of the flasher unit.
JBE00081-01211
3. Ensure if the voltage exists the respective terminals at wire

harness connector when ignition switch is turned on.
4. Ensure if the voltage exists the terminal when hazard
switch is turned on. L
5. Connect the flusher unit to the wire harness connector.
E B V
Under the condition, if the flusher unit will not work, then
the unit is failure.
JBE00082-01212

BE29
HATER & VENTILATION
WIRING DIAGRAM
F/L ABS 50A ABS
Head lamp 30A H/L
Tail 40A TAIL
Back up 10A B/U
EFI 15 A
A/C 10 A
Heater 20 A
ACC ACC
IG No. 1 IG1
IG No. 2 IG2
F/L AM 60A
ST ST
IG SW
Main MAIN
Junction block N59
Gauge
Relay block
/Back
10 A
K12
Wire F/L 2.0
EFI main
A/C relay
relay
Heater
relay
H79 H67
Air conditioner
SW
A/C SW KC6
OC9 K23 KG9 K11 K13
KV2
K02
Battery
motor
Heater blower
KP1
K18 KU9
A/C VSV
Magnet clutch
M K99
K30
K19
Resistor
KV1
SW
Dual pressure
KP6
K07
K44
K05
EFI ECU XQ6 XN4 XS0
VSV3 KNK MGC
K04 K06 K08
KP7
SW
Heater blower
E2 ACEV ACSW BLW
ZQ4 XP8 XS4 XK3
Z21
KK4 KP5
Thermistor
JBE00083-01301
BLOWER SWITCH
Unit inspection
1. Remove the instrument cluster finish center panel.
2. Remove the radio opening cover.
3. Remove the attaching screws of the heater control panel
assembly.
(Refer to the BO section of the service manual)
4. Disconnect the connector of the blower switch and the air
conditioner switch.
5. Disconnect the control cables from the heater unit.
6. Remove the heater control panel assembly from the instru- JBE00084-01302
ment panel.
7. When the blower switch is set to each stage, ensure that
continuity exists between the respective terminals as indi- K08 C19 Z23
cated in the table below.
K04 K06 Z21
Z21 K08 K06 K04
OFF
L
M
H JBE00085-01303

BE30
8. Ensure that each of the air outlet control lever, air intake
Green Brown
control lever and temperature control lever is functioning
smoothly with a positive dent feeling.
NOTE:
If not, apply a rubber grease to the points or replace Gray
the control panel assembly.
JBE00086-01304
Brown Green
Gray
JBE00000-01305
BLOWER RESISTER
Unit inspection
K07 K05
1. Connect the connector of the the blower resistance.
2. Ensure that resistance between the respective terminals
conforms to the following specifications.
Between Terminal K44 and K07: 3.35 W
K44
JBE00087-01311
VENTILATION SYSTEM
Face
DEF
Film type
rotary door position
Foot Film type
Face Bi-level Foot Foot/DEF DEF
Lever position
JBE00088-01321

BE31
Adjustment of ventilation control Air outlet Blower Air inlet mode
1. Ensure that the control levers move in a right-and-left di- control lever fan switch selector lever
rection without stiffness and binding over the full range of VENT mode RECIRC mode
each lever.
OFF
A/C
COOL mode A/C

Temperature switch
L.H.D control lever
JBE00089-01331
2. Set the air outlet control lever to the VENT mode. Clamp
the outer cable while pulling the outer cable toward VENT
side.
JBE00090-01332
3. Set the temperature control lever to the COOL mode.

Clamp the outer cable while pushing the outer cable to-
ward COOL side.
JBE00091-01333
4. Set the air inlet mode selector lever to the RECIRC mode. With A/C With out A/C
Clamp the outer cable while pulling the outer cable toward
RECIRC side. Stopper
Stopper
JBE00092-01334
5. After completion of the adjustments in the steps 2 through

4, set the blower switch to the most highest position.
FOOT mode
Check the following items.
(1) When the VENT mode is selected, ensure that no air VENT mode DEF mode
leaks from the foot side outlet and defroster.
(2) When the DEF mode is selected, ensure that no air
leaks from the foot side outlet and register. OFF
A/C
(3) When the FOOT mode is selected, ensure that no air
leaks from the register. if not, readjust the control lever.
JBE00093-01335

BE32
POWER DOOR LOCK
WIRING DIAGRAM
IG SW
ACC ACC
IG No. 1 IG1
IG No. 2 IG2
ST ST
Main MAIN
Door lock
15A
F/L AM 60A
3 ITC
4
(Door rock
control relay) Control
1 2 6 SW
(Passenger's side)
(Driver's side)
Rear door RH
Rear door LH
Front door
Front door
Rear gate
PTC
PTC
PTC
PTC
PTC
M M M M M
Door lock motor
JBE00094-01401
DOOR LOCK CONTROL SWITCH

Unit inspection
1. Remove the door trim-related parts.
JBE00095-01402
3. When the door lock switch is set to the LOCK and UN-
LOCK positions, respectively, ensure that continuity be-
tween the terminals of the door lock switch conforms to
the requirements as indicated in the table below.
Terminal q w 1
LOCK 2
UNLOCK
JBE00096-01403

BE33
DOOR LOCK MOTOR
Unit inspection
1. Detach the door locking knob from the control link.
2. Remove the door trim-related parts.
3. Remove the link-related parts. Motor
4. Remove the attaching screws of the lock assembly.
5. Take out the lock assembly.
6. Apply a voltage of 12 V between the following two termi-
Door lock
nals. Ensure that the plunger operates in accordance with control SW
the table below.
JBE00097-01404
Terminal
q w
Operation direction
LOCK : ;
UNLOCK ; :
DOOR CONTROL RELAY

See page BE45, ITC.
JBE00098-01405

BE34
POWER WINDOW
WIRING DIAGRAM
F/L ABS 50A ABS
Head lamp 30A H/L
Tail 40A TAIL
Back up 10A B/U
ACC ACC
IG No. 1 IG1
IG2
F/L AM 60A
IG No. 2
ST ST
IG SW
Main MAIN
Junction block N59
POWER
Wire F/L 2.0
30 A
PD4
Master SW P22
Sub SW
P29 P30 P31
Battery
Cancel
Z61
P42 P43
P23 P24 P27 P28
Power window motor Power window motor

(Passengers seat side) (Drivers seat side)
M P25 M P26
P44 P45
JBE00099-01501
DRIVERS SEAT SIDE SWITCH

Unit inspection (Left hand drive)
1. Remove the switch by means of suitable wooden peace.
2. When the switch is operated, ensure that continuity be- P28 P27
tween the terminals conforms to the requirements as indi- P22 P24 Z61 P23
Drivers seat side Window Passengers (master) Switch side

lock
P22 P23 P24 Z61 switch P22 P27 P28 Z61
UP
UP JBE00100-01502
manual
OFF
ON
OFF DOWN
UP
DOWN
OFF
OFF
DOWN
auto DOWN

BE35
Unit inspection (Right hand drive)
2. When the switch is operated, ensure that continuity be-
tween the terminals conforms to the requirements as indi- P37 P38 P33 P32
cated in the table below. P28 P27 P22 Z61 P23 P24
Drivers seat side Window Passengers (master)
lock
P22 P23 P24 Z60 switch P22 P27 P28 Z60 Switch side
UP
UP
manual
OFF
ON JBE00101-01504
OFF DOWN
UP
DOWN
OFF
OFF
DOWN
auto DOWN
FRONT PASSENGERS SEAT SIDE SWITCH

Unit inspection
2. When the switch is operated, ensure that continuity be-
tween the terminals conforms to the requirements as indi- R22 R27 R23
Power window switch
P42 P29 P30 P31 P43 Switch side
UP
JBE00102-01506
OFF
DOWN
LR
POWER WINDOW MOTOR
Unit inspection
1. Remove the door trim assembly, service hole cover and
remove the door window regulator. PW
1. Connect the positive (+) terminal of the battery to the con-
nector PW of the power window motor; the negative ()
terminal to the connector LR. Ensure that the motor rotates
clockwise, as viewed from the driving shaft side.
2. Connect the positive (+) terminal of the battery to the con-
nector LR of the power window motor; the negative () ter-
minal to the connector PW. Ensure that the motor rotates
counterclockwise, as viewed from the driving shaft side.
PW LR
Clockwise : ;
Counterclockwise ; :
JBE00103-01508

BE36
WIPER & WASHER
WIRING DIAGRAM
F/L ABS 50A ABS
Head lamp 30A H/L
Tail 40A TAIL
Back up 10A B/U
ACC ACC
IG No. 1 IG1
F/L AM 60A
IG No. 2 IG2
ST ST
IG SW
Main MAIN
Junction block N59
Wire F/L 2.0
Wiper
/ Turn
20 A
I01
Front wiper F66 I65 I66 I67

washer SW I10
I03
Front Washer
INT I29
motor
Battery
I28 I31
M W 2 1
Rear wiper
M
washer SW
Rear wiper
motor
OFF INT
ZQ9
Z14 I60 I57 I56 I41

I54 Z18 I30
I26
I20 I18 I24 I22
Front wiper Rear Washer
motor M motor
M
ZN0
JBE00104-01601
Adjustment of wiper arm and washer nozzle

Inspect the wiping area and stationary position of the wiper blade.
Projection zone f50
A: 15 - 25 mm (Except for AUS.),

27- 37 mm (AUS. only)
E: Tightening torque; 14.7 - 25.5 Nm
Center line
0
42
240
E 240
0
42
JBE00105-01602

BE37
WIPER MOTOR
Unit inspection
1. Low speed operation check +1
+2
(1) Connect the terminal +1 to the positive : terminal of
the battery; the body to the negative ; terminal of the B S
battery. Ensure that the wiper operates at the low
speed 1
+
JBE00106-01604
2. High speed operation check

(1) Connect the terminal +2 to the positive : terminal of
the battery; the body to the negative ; terminal of the +1
+2
battery. Ensure that the wiper operates at the high
speed. B S
JBE00107-01605
3. OFF operation check

With the wiper motor body connected to the negative ;
terminal of the battery, perform the following checks. +1
+2
(1) Connect the terminal B to the positive : terminal of
the battery. B S
(2) Operate the wiper at the low speed by connecting the
terminal +1 to the positive : terminal of the battery.
+
JBE00108-01606
(3) Under the operating conditions in the step (2), discon-

nect the terminal +1 to as to interrupt the wiper motor
operation. +1
+2
B S
JBE00109-01607
(4) Connect the terminal +1 to the terminal S. Ensure that

the wiper operates and stops at the automatic stop-
ping position. +1
+2
B S
JBE00110-01608

BE38
Adjustment of rear wiper arm Center line
Inspect the wiping area and stationary position of the wiper
blade.
Tightening Torque: 4 - 7 Nm 135
Projection zone f50
Defogger line
+10
0
JBE00111-01609
REAR WIPER MOTOR

Unit inspection
1. Remove the back door trim.
NOTE:
See BO section of service manual.
2. Connect the battery negative terminal () to the wiper

motor body. Also connect the battery negative terminal to
the motor connector () and battery positive terminal (+) to
the motor connector (+), as indicated in the right figure.
Ensure that the wiper motor functions. JBE00112-01610
3. Ensure that the wiper motor stops at the automatic stop-

ping position when the battery negative () terminal is dis-
connected from the wiper motor negative () connector.
I29 I30
Rear wiper motor
JBE00113-01611
REAR WIPER SWITCH

Unit inspection
1. Push the switch from back side while releasing the lock of
the switch, remove the switch toward your side.
3. Ensure that continuity exists between the respective termi-
nals, as indicated in the table below.
Z18 I31 I28 I54
OFF
Wiper ON JBE00114-01612
Washer ON
I28 I54
I31 Z18
JBE00000-01613

BE39
DEFOGGER
WIRING DIAGRAM
F/L ABS 50A ABS

Head lamp 30A H/L
Tail 40A TAIL
Back up 10A B/U
F/L AM 60A ACC ACC
IG No. 1 IG1
IG No. 2 IG2
ST ST
IG SW
Main MAIN
J/B
F/L 2.0
Defogger
15 A
K27
SW
Rear defogger
Defogger
K28 Z42
JBE00115-01701
DEFOGGER WIRE Push

NOTE: Tester probe by your finger
(1) When wiping the glass surface, use a soft, dry cloth.
Move the cloth along the wire. Be careful not to dam-
age the wire.
(2) Never use washing agent or glass cleaner which con-
tains abrasive compound.
(3) Wrap the tip end of the tester probe with foil strip so
that the tester probe causes no damage on the heat
wire during the voltage measurement. Heat wire Foil strip
JBE00116-01702
(4) Check the voltage by pushing the foil strip against the
heat wire with your finger, as indicated in the figure.
Open wire check

1. Turn on the ignition key switch.
2. Turn on the defogger switch so as to energize defogger
wire.
3. Check the voltage at the center section of each heat wire.
Voltage Judgment criteria
Approx. 5 V Good (No open wire)
Approx. 10 V or 0 V Open wire JBE00117-01703

BE40
REFERENCE:
Open wire
If the voltage is 10 V, it means that open wire exists be- Good
tween the center of the wire and the end of the positive 46V
: side. If the voltage is 0 V, it means that open wire ex-
ists between the center of the wire and the end of the Open
earth side. + wire
10 V
Volt Open
meter wire
0V
JBE00118-01704
Locating point of open wire

1. Connect the positive : terminal of the voltmeter to the
positive : side of the defogger wire. Open wire
2. Slide the voltmeters negative ; terminal wrapped with foil 0 volt Several volts
strip on the defogger wire from its positive : side to its +
negative ; side.
3. The voltmeter reading changes from 0 V to several volts at
the point where open wire exists.
JBE00119-01705
Repairing point of open wire

1. Clean the point of open wire with white gasoline. Repair agent
2. Affix masking tapes to both upper and lower portions of
the point to be repaired.
3. Stir repair agent (Du Pont Paste No. 4817) thoroughly.
Apply a small amount of the repair agent to the repairing
point, using a fine brush. Open wire
4. Two to three minutes later, peel off the masking tapes.
5. Do not energize the defogger wire within 24 hours after
the repair. Masking tapes
JBE00120-01706
DEFOGGER SWITCH
Unit inspection
1. Remove the instrument panel finish lower panel.
2. Remove the defogger switch by pushing it with your fin-
gers at the back side of the instrument panel.
3. Disconnect the connector of the defogger switch.
4. Remove the defogger switch from the instrument panel.
NOTE:
The indicator of the defogger in the combination meter
will glow when the rear window defogger switch is
turned on. JBE00121-01707
5. Ensure that continuity exists between the terminal Z27 and

the terminal Z28 when the switch is turned on.
6. Check to see if the bulb is burnt out. K27
K28 Z42
JBE00122-01708

BE41
CIGARETTE LIGHTER
WIRING DIAGRAM
ACC ACC
IG No. 1 IG1
IG No. 2 IG2
ST ST
IG SW
Main MAIN
F/L AM 60A
J/B R02
ACC
15 A
RC7
Cigarette lighter R15
Z31
JBE00123-01801
In-vehicle inspection
1. Push the cigarette lighter. Ensure that the heater section is
heated and glows red.
2. Ensure that the heater section returns to the original posi-
tion about 18 seconds.
If not, replace the cigarette lighter.
JBE00124-01802
Removal
1. Remove the retaining screws of the instrument cluster fin-
ish center panel.
2. Pull out the instrument cluster finish center panel from the
instrument panel.
3. Disconnect the connector from the cigarette lighter as-
sembly.
NOTE:
JBE00125-01803

BE42
4. Turn about 2 and pull out 10 mm the cigarette lighter as-
sembly. Then turn back about 2 (align the embossed at
the connector side) and pull out the cigarette lighter as-
sembly from the cigarette lighter bezel.
5. Remove the cigarette lighter.
JBE00126-01804
Installation
1. Align the embossed and insert the cigarette lighter assem-
bly to the bezel.
2. Connect the connector of the cigarette lighter assembly.
3. Install the instrument cluster finish center panel with the
retaining screws.
JBE00127-01805
WARNING:
The cigarette lighter has such construction that the
heater is energized when the lighter section is pushed- Temperature
in, resulting in a red-heated heater. When the heater fuse
becomes red-heated, the bimetal that is retaining the
lighter section will open because of the heat, thereby
pushing out the heater unit. As a result, the energizing
of the heater ceases. Down
side
Bimetal
JBE00128-01807
A temperature fuse is attached to the terminal of the

electric fuse so as to prevent over-heating of the fuse
in the event that the lighter can not pop out due to
some reasons. make sure to install this temperature
fuse at the underside of the terminal so that the circuit
may be cut off when the temperature fuse is melt down.
JBE00129-01808

BE43
REAR VIEW MIRROR
WIRING DIAGRAM
ACC ACC
IG No. 1 IG1
IG No. 2 IG2
ST ST
IG SW
Main MAIN
F/L AM 60A
R02 J/B
15 A
ACC
RC7
B Rear view mirror SW
E
C MV MH
C VL VR HL HR
Rear view mirror Rear view mirror
unit (Left side) unit (Right side)
C C
M M M M
V H V H
JBE00130-01901
REAR VIEW MIRROR SWITCH

Disconnect the connector.
2. Ensure that the continuity exists between the respective SWITCH CONNECTOR
terminals in accordance with the following continuity table. HR VR VL VL VR HR
E B C HL HL C B E
JBE00131-01902
Mirror Left Right

Terminal
Switch B E VL C HL B E VR C HR
position
MIRROR HARNESS
UP
V C H H C V
DOWN
LEFT
RIGHT
JBE00132-01903

BE44
REAR VIEW MIRROR UNIT
Unit inspection
1. Remove the front door trim assembly.
2. Disconnect the connector of the door mirror.
3. Apply a voltage of 12 V between the following two termi-
nals.
4. Ensure that the mirror operates in accordance with the
table below.
JBE00133-01904
Right door
C VR HR
mirror Operation
Terminal
Left door direction
C VL HL
mirror
; : UP
: ; Down VR HR
VL C HL
Connection
; : Left
: ; Right
JBE00134-01905

BE45
ITC SYSTEM
For enhanced safety of the motor vehicle, the ITC (Integrated
Timer Controller) is controlled by an ECU which has the con-
trol system interlocked with the following functions.
1. Impact-detecting door unlocking system
2. All-door locking, interlocked with door lock button at dri-
vers seat side.
3. Room lamp timer
JBE00135-04000
4. Impact-detecting door unlocking system

In the event that an impact beyond the specified value is
applied to the vehicle. all of the doors are unlocked three
seconds after the impact detection. Furthermore, when
the vehicle speed drops to 0 km/h within 10 seconds after
the impact detection, the hazard lamp are start to flash.
When the switches of room lamp is set to position in which
the lamp is interlocked with the door, the room lamp will go
on simultaneously as the hazard lamp goes on. The im-
pact is detected in all around horizontal directions.
JBE00136-04001
5. All-door locking, interlocked with door lock button at dri-

vers seat side
All of the doors, including the back door, can be locked Unlock
and unlocked, interlocked with the door lock button switch
at the drivers seat side.
Lock
JBE00137-04002
6. Room lamp timer

OFF
When any door is opened with the ignition switch turned DOOR ON
off, the room lamp goes on. When all of the doors are
closed, each lamp gradually dims, until it is finally extin-
guished. Namely, the lamp keeps approximately 75% of
the original brightness for 3 seconds after the door is
closed. For the next 2 seconds, the lamp is illuminated
with an approximately 50% of brightness. The lamp goes
out 5 seconds after the door is closed. When ignition
switch is turned on while the lamp is dimming, the extin-
guished lag of the lamp is suspended. JBE00138-04003
However, this function operates only when the switch of

the room lamp is set to position in which the lamp is illumi-
nated in interlocking with the door. Moreover, when the ig-
nition switches set to the ON position, this function will not
operate.
In order to prevent the battery from being discharged, if
the door remains opened for 10 minutes with the ignition
switch turned off, the room lamp will go out. Afterwards,
when the door is closed and again opened, the lamp goes
on, and the same function operates.

BE46
Collision sensor
The collision sensor is mounted in front of the air bag ECU. Air bag ECU Collision sensor
JBE00139-04005
Internal construction of collision sensor

The sensor consists of a weight for impact detection and elec-
tric contact points. Contact
points
Weight
JBE00140-04006
Moreover, the electric circuit is made up of a switch and a re-

sistor which are connected in parallel. A voltage of five volts is
always applied to both ends of the circuit from the ECU. QC8
Therefore, in cases where the wire harness between the sen-
sor and the ECU exhibits an open wire, an electric current
flowing into the resistor will be shut off. As a result, the sensor
judges that the circuit including the wire harness exhibits
open wire, then setting off the buzzer. QC9
Collision sensor
JBE00141-04007
In cases where the sensor circuit is shorted, no distinction

can be made between the case where the circuit is shorted
and the case where the switch is turned ON due to the func-
tion of the collision sensor. In the case of the short circuit,
however, the ON condition of the switch lasts longer.
Consequently, the ECU judges that it is an abnormality.
Utmost care must be exercised when a sensor is installed. If

the sensor is dropped, the sensor cannot be used even if its
external appearance exhibits no abnormality.
JBE00142-04008
The ITC ECU is mounted on the bracket of the cowl side inner
panel at its passengers seat side.
ITC ECU
JBE00143-04009

F/L ABS 50A ABS
Head lamp 30A H/L
Tail 40A TAIL
Back up 10A B/U
ACC ACC
IG No. 1 IG1
IG No. 2 IG2
ST ST
IG SW
CIRCUIT DIAGRAM
Main MAIN
Junction block OF2 N59 F70 N59 CA2
F/L AM 60A

Buzzer
20 A
Stop 10 A
Wiper/Turn
Door lock 15 A
Gauge 10 A
Wire F/L 2.0

Q17 H67 F65 F66 E44
RH LH
Battery
Courtesy SW
HZD TRN
RH LH
Turn signal lamp OFF
Room lamp
Flasher relay
Multi-use lever ON DOOR

SW
Turn signal indicator
ITC ECU Q47 QB3 QC7 QB7 QB5 QC4 QB9 QC5 QB4 QB6
+B IG1 CHZD T/H CHR CHL CFL FL+ DCSD CRL
Buzzer
SPD CS1 CS UKS E1 ULM LKM T
Q34 QC3 QC2 QB8 ZT3 Q51 Q50 QC1
ITC ECU connector (wire harness side) Door lock Diagnosis connector
D motor
CHL FL+ T/H T IG1 E1 LKM ABS ECU IMB
CSD M IG REV
S
Collision T T W
N
C
N
CHR CFL CRL UKS SPD CS1 +B CS ULM ITC
S
HZD sensor SIO E VF
Vehicle
M T
M
Door lock SW
speed sensor
M
JBE00144-04010
BE47
BE48
TROUBLE-SHOOTING
When there is an open wire or a short in the collision sensor of ECU
the impact-detecting system, a warning buzzer provided in
the ITC ECU is set off, emitting a continuous sound for five
seconds.
NOTE:
In the case of an open wire with the ignition switch
turned on, if the open wire state continues to exist for
200 ms or more, the buzzer is set off. The impact-de-
Buzzer
tecting function alone will not function, until the open
wire state is eliminated. JBE00145-04011
In the case of short circuit with the ignition switch

turned on, if the short continues to exist for 2 seconds
or more, the buzzer is set off. The impact-detecting
function alone will not function, until the short circuit
state is eliminated.
Operation checking method by shorting terminal T (test

terminal)
The operations of the following systems can be checked by
connecting the test terminal provided at the check connector
to the earth terminal with a jump wire.
Vehicle speed sensor
Room lamp system
Hazard lamp system
JBE00146-04013
(1) Set the switch for the room lamp to the door position in OFF
which the switch is interlocked with the door DOOR ON
opening/closing.
(2) Warm up the engine. Drive the vehicle at a speed of
15 km or more.
(3) Stop the vehicle.
NOTE:
Apply the parking brake. In the case of automatic trans-
mission-equipped vehicles, move the shift lever to the
P range.
JBE00147-04014
(4) Connect the test terminal for ITC to the earth terminal
with a jump wire, as shown in the figure. Diagnosis connector
NOTE: ABS ECU IMB
IG REV
After the vehicle has stopped, do not turn off the igni- T T W
ITC E
tion switch. Keep the engine idling. T
SIO VF
Jump wire
JBE00148-04015

BE49
(5) The hazard lamp flashes. At the same time, the room
lamp is illuminated.
NOTE:
If the lamp will not go on, check the wire harness and
unit itself. If they are satisfactory, disconnect the jump
wire. This completes the check.
JBE00149-04016
Malfunctions observed during operation check

OFF
1. When room lamp will not go on: DOOR ON
(1) Check to see if the switch of the room lamp is set to
the position in which the switch is interlocked with the
door opening/closing.
(2) Check to see if the lamp fuse has open wire.
(3) Check to see if the lamp bulb is burnt out.
(4) When the ignition switch is turned off, check to see if
the room lamp goes on properly in accordance with
switching.
JBE00150-04017
(5) Turn off the ignition switch. Disconnect the connector

for ITC ECU from the wire harness connector. ITC ECU connector (wire harness side)
D
(6) With a circuit tester set to the ohmmeter range, con- CHL FL+ T/H T
CSD
IG1 E1 LKM
nect the circuit tester to between the terminal SPD of CHR CFL
C
CRL UKS SPD CS1 +B CS ULM
HZD
the connector at the vehicle wire harness side and the
body earth.
JBE00151-04018
(7) Move the vehicle one meter by pushing it. During this
moving, check that the pointer of the ohmmeter Vehicle
speed sensor
moves.
S
N
WARNING:
S
Be sure to turn off the ignition switch.
NOTE:
If no abnormality is found in the checks (1) through (7),
the harness or ITC ECU is regarded as faulty. Replace
the harness or ITC ECU.
JBE00152-04019
2. When hazard lamp will not flash:

(1) Turn off the ignition switch and turn on the hazard
switch. Check that the hazard lamp flashes properly.
(2) If the hazard lamp will not flash, check the hazard
lamp circuit and switch.
(3) Check to see if there is open wire in the horn/hazard
lamp fuse.
(4) Check to see if the multi-use lever switch connector is
fit properly. Hazard switch
(5) Check to see if the flasher relay is functioning properly.
JBE00153-04020

BE50
REFERENCE:
When the buzzer provided in the junction block is set
off when the door is opened even if the ignition switch Second stage
has been turned off, there is the possibility that the fol-
lowing switches given below are turned on. Check
these switches.
(1) Rear fog lamp switch
(2) Lighting switch First stage
JBE00154-04021
Check to be performed when buzzer is set off with ignition

Collision sensor
switch turned on
(1) Turn off ignition switch.
(2) Disconnect the connector of the crash sensor sub-har-
ness. Measure the resistance between the terminals of
the crash sensor, using a circuit tester.
Specified Value: 2.2 kW
NOTE:
If there is no open wire nor short, connect the connec-
tor of the crash sensor sub-harness and connector of JBE00155-04022
the vehicle wire harness to their original positions.

ITC ECU connector (wire harness side)
D
(3) Disconnect the ITC ECU connector from the connector CHL FL+ T/H T
CSD
IG1 E1 LKM
at the vehicle wire harness side. CHR CFL

C
HZD
(4) Measure the resistance across the terminals CS1 and
CS of the connector at the vehicle wire harness side,
using a circuit tester.
NOTE:
If there is no open wire nor short circuit, the ITC ECU is
regarded as faulty. Replace the ITC ECU.
JBE00156-04023
Malfunction of power door lock

NOTE:
When each door can not be locked in interlocking with
Junction block
the door lock button at drivers seat, proceed to the fol-
lowing checks. Relay block
(1) Check to see if the tail fuse (40 A) or door lock fuse
(15 A) has open wire.
(2) Turn off the ignition switch. Disconnect the ITC ECU
connector from the connector at the vehicle wire har-
ness side. JBE00157-04024
ITC ECU connector (wire harness side)

D
(3) With a circuit tester set to the voltmeter range, connect CHL FL+ T/H T
CSD
IG1 E1 LKM
the circuit tester to between the terminal +B of the CHR CFL
C
HZD
connector at the vehicle wire harness side and the
body earth, as shown in the figure. Check to see if the V
battery voltage is applied.
NOTE:
The battery voltage is applied to this terminal at all
times regardless of the ON/OFF state of the ignition
switch. JBE00158-04025

BE51
(4) With a circuit tester set to the ohmmeter range, con-
nect the circuit tester to between the terminal UKS of ITC ECU connector (wire harness side)
D
the connector at the vehicle wire harness side and the CHL FL+ T/H T
CSD
IG1 E1 LKM
body earth, as shown in the figure. Check to see if CHR CFL
C
HZD
continuity exists.
NOTE:
This terminal has no continuity when the door lock but-
ton at drivers seat is locked. Conversely, this terminal
has continuity when the door lock button at the drivers
seat is not locked.
If this check reveals abnormality, check the door lock JBE00159-04026
control switch and wire harness.

Wire harness side
(5) Connect the ITC ECU connector with the connector at

the vehicle wire harness side. (Connect the connec-
tors that were disconnected at Step (2) into the original
positions.)
(6) Disconnect the door lock motor connector at the door
side whose locking is inoperative from the connector
at the vehicle wire harness side. Connect a circuit
tester in its voltmeter mode, as shown in the figure.
JBE00160-04027
(7) Turn on the ignition switch and lock or unlock the door
lock button at the drivers seat. Check to see if the volt-
meter registers the battery voltage. If there is abnor-
mality, check the wire harness.
NOTE:
The current during the locking state flows in the re-
verse direction, as opposed to the current during the
unlocking state. JBE00161-04028
(8) If there is no abnormality in the check at Step (7),

Rock motor
apply the battery voltage directly to the door lock
motor terminal to see if the door lock functions.
CAUTION:
Never let the current flow for ten seconds or more con-
tinuously.
NOTE:
If the lock motor has no abnormality, the ITC ECU is re- 12V
garded as faulty. Replace the ITC ECU.

JBE00162-04029

BE52
SRS AIR BAG SYSTEM
IMPORTANT SAFETY NOTICE
All information used in this service manual was in effect at the time when the manual was approved for
printing. However, the specifications and procedures may be revised due to continuing improvements in
the design without advance notice and without incurring any obligation to us.
The procedures contained in this manual describe in a general way the techniques which the manufacturer
has recommended. Thus, they will contribute to ensuring the reliability of the products. The contents of the
servicing operations come in a wide variety of ways. This manual does not cover all details of techniques,
procedures, parts, tools and handling instructions which are necessary for these operations, for such cov-
erage is impossible. Hence, any one who obtains this manual is expected first to make his responsible se-
lection as to techniques, tools and parts which are necessary for servicing the vehicle concerned properly.
Furthermore, he must assume responsibility for his actions in connection with his own safety. Therefore, one
should not perform any service if he is not capable of making responsible selection and/or if he can not un-
derstand the contents herein described, for this manual is prepared for experienced service personnel.
JBE000163-05000
TECHNICIAN SAFETY INFORMATION

WARNING:
When removing and installing the air bag assembly, the
technician should stand whenever possible on the side
of the air bag assembly. Air bag unit Steering whell pad assembly
During installation or replacement, do not bump the (passengers side)
Roll connector
area near the ECU unit of the SRS air bag, using an
impact wrench, a hammer or the like.
Whenever the ignition switch is on, or has been turned
off for only less than three minutes, be carefully not to
bump the ECU unit of the SRS air bag, for the air bag
could accidentally deploy and cause damage or in-
juries.
Never measure the resistance of the inflator squib easi- Air bag ECU
ly. This may cause the air bag to deploy, thus causing JBE00164-05001
serious injuries to the operators and other people in the

surrounding.
CAUTION:
Before scrapping any air bag assembly or the vehicle
which contains the air bag, the air bag assembly must
be deployed.
Do not disassemble the SRS air bag unit. It has no ser-
viceable parts.
VEHICLE PREPARATION FOR SERVICING JBE00165-05002
CAUTION:
Do not install a used air bag assembly from another
car. When repairing, use only a new air bag assembly.
Do not replace the original steering wheel with a steer-
ing wheel of any other design, since it will make impos-
sible proper installation of the air bag.
Do not use any air bag assembly or air bag ECU unit
which was subjected to water damage or shows signs
of being dropped or improperly handled, such as dents,
cracks and deformation.
JBE00166-05003

BE53
SYSTEM DESCRIPTION
This air bag system is a supplemental device to protect pas-
sengers in the event of a frontal collision. The drivers seat is
provided with an air bag and a seat belt. The front passenger
seat is provided with a seat belt and optional air bag, whereas
the rear passenger seat is provided with seat belts only.
If the vehicle undergoes a frontal collision and the system de-
tects it and the impact exceeds a specified value, the air
bags deploy to reduce the impact to the passengers.
JBE00167-05004
This air bag system is composed of the following main parts. Air bag warning light
Air bag ECU (Computer) Drivers air bag and inflator
G sensor (built in the air bag ECU)
Safing sensor (built in the air bag ECU)
Air bag unit (consists of Inflator and bag)
Steering roll connector Front
Warning lamp passengers air
bag and inflator
Control unit
JBE00168-05005
Air bag ECU & sensor

Metal diaphragm
The air bag ECU is located under the console panel.
G sensor and a safing sensor are provided as sensors which +

0
sense the deceleration in the event of collision. The crash +

sensor is incorporated in the logic circuit of the air bag ECU.

The G sensor calculates the deceleration, based on the mag- Piezoelectric ceramics
nitude of a potential difference, when the impact waves vi- +
Compression

brates the sensor during the collision. +
Tension
JBE0169-05006
The safing sensor is placed on the circuit board inside the

Safing sensor
ECU case. If a deceleration exceeding the specified value is
applied to the sensor by the impact, the inertia force of the
pendulum overcomes the reaction force of the spring. As a re-
sult, the pendulum moves to the switch side, thereby closing
the contact points of the switch.
Contact point
JBE00170-05007
As regards the system operation, the ECU calculates the de- IG 1

Diode
celeration detected by the G sensor and compares it with the IG 2 circuit Squib
Back-up Safing (Drivers
specified value. If the ECU has judged that a collision is tak- condenser sensor seat side)
ing place, it outputs an ignition signal. If the safing sensor is DC-DC
circuit
turned on at this time, an electric current which is necessary
Ignition
for the ignition is supplied to the air bag inflator. transistor
CPU diagnosis
The air bag ECU has a backup power supply consists of a G sensor collision
backup condenser and voltage set-up circuit. evaluation
Ignition
transistor Squib
(Passengers
seat side)
JBE00171-05008

BE54
Air bag unit
The air bag for the drivers seat is accommodated in the steer- Gas Door pad cover
generator
ing wheel pad assembly. Bag
Squib
The air bag for the front passenger seat is accommodated in
the instrument panel. Each air bag is assembled integral with
the inflator module. Filter
The inflator module consists of a squib, gas generator and so
forth.
Ignition
Coolant Inflator module
JBE00172-05009
Steering roll connector

The steering roll connector is installed to the multi-use lever
switch section. It is so designed that there may be no faults,
such as poor contacts, compared with a slip ring method.
This is because the wiring is kept connected even though the
steering wheel is turned.
Roll connector
JBE00173-05010
Warning lamp
The warning lamp warns the driver of abnormality of the sys-
tem.
This lamp, which is located inside the combination meter, tells
the driver of abnormality by going on the lamp.
When the engine starts, this lamp is made to go on for six
seconds so that the lamp can be checked for open wire of the
lamp filament. If the lamp keeps going on for more than six
seconds, it is considered abnormal.
In the event of abnormality, the diagnosis code can be read,
using the air bag ECU inspection terminal of the check con- JBE00174-05011
nector under the steering column. This malfunction diagnosis

circuit makes it possible to find out malfunctioning sections
quickly.
Air bag fuse

The air bag fuse is located inside the fuse block.
The fuse provides power supply for the air bag ECU via the
ignition switch. Furthermore, the ECU has a dual construction
that its power supply can be furnished from the engine fuse
side, too, in the event of failure of the air bag fuse.
JBE00175-05012
Wire harness and connector of air bag system

All wire harnesses and connectors related to the air bag sys-
tem are colored yellow uniformly. The following sections have
connectors with special functions.
1. Terminal double locking mechanism
2. Terminal short mechanism
3. Connector double lock mechanism
4. Incomplete fitting detecting mechanism
JBE00176-05013

BE55
Terminal double locking mechanism
This mechanism is provided with all connectors. Spacers
The connector is of a two-piece construction consisting of a
housing and a spacer. The terminal holding is double-locked Housings
by the lance (primary one) and the spacer (secondary one).
JBE00177-05014
Terminal short mechanism

This mechanism is provided at the connector between the
computer and the inflator (squib). Short circuit bridge Contact point
A short spring plate is provided inside the connector. When
the connector is disconnected, the terminal at the power sup- When opening
ply side of the squib and the terminal at the earth side are
shorted automatically, thereby preventing generation of a po- Terminal
tential difference between both terminals. When connecting
JBE00178-05015
Connector double locking mechanism

This mechanism is provided at the steering roll connector. Spring 2nd lock
For improved reliability of connection, connectors (male and
female connectors) are double locked with each other. It is so Pin
constructed that, when the primary lock is not made, the sec-
1st
ondary lock can not be made because a protrusion hinders lock
the locking.
JBE00179-05016
Incomplete fitting detecting mechanism

This mechanism is provided at the connector for the air bag Air bag ECU terminal
ECU. This mechanism detects electrically whether the con- Short circuit bridge
nector is connected completely or not. When the connector is (Incomplete
fit completely, the detecting pins at the IN and OUT sides are fitting)
Lock
connected through a resistor, allowing an extremely small
amount of current to flow to the computer. In this way, the fit-
ting condition is monitored.
When the connector is connected, the detecting pins are in-
serted along a tilted section provided at the inner wall of the
connector. When the connector is inserted completely, the de- JBE00180-05017
tecting pins are disengaged from the tilted section, and con-
tact the terminal.
Malfunction diagnosis function Diagnosis connector

Several items are available as the diagnosis items, including
the normal code.
When the system is encountered with an abnormality, the
computer memorizes the relevant abnormality item. All mal-
function codes are retained until the malfunction codes are
erased by the malfunction record erasure procedure or
through transmission with the diagnosis tester (DS21). JBE00181-05018

BE56
STEERING WHEEL PAD (AIR BAG UNIT FOR THE DRIVER) & STEERING ROLL
CONNECTOR
COMPONENTS
w
e
w
S
r q
q Steering wheel pad assembly

w Steering wheel pad set plate
e Steering wheel
r Steering wheel cover
JBE00182-05019
REMOVAL
1. Turn off the ignition switch and detach the negative () ter- IG OFF
minal of the battery cable from the battery terminal.
2. Set the steering wheel to a straight-ahead position.
Remove the attaching bolts (TORX) at the right and left
sides of the steering wheel cover side.
WARNING:
may cause unexpected deployment of the air bag JBE00183-05020
owing to impacts, etc. during the removal.

the steering wheel during the removal.
If the pad assembly is dropped or damaged during the
removal or the storage, be sure to dispose of the pad
assembly according to the disposal procedure. Be sure
to mount a new pad assembly to the vehicle.
CAUTION:
of the battery is detached, the memory of the ECU con- JBE00184-05021
trol of the other system will be erased at the same time.
3. Separate the pad assembly and steering wheel.

Disconnect the connector for the air bag and connector
for the horn provided at the reverse side of the pad as-
sembly.
WARNING:
Never resume the operation within 60 seconds after
the power supply has been cut off, during which the
backup condenser is discharged.
JBE00185-05022

BE57
4. After each connector is disconnected, remove the pad as-
sembly from the steering wheel.
WARNING: GOOD
Be sure to place the removed pad assembly with the
pad surface facing upward. The pad assembly placed
with the pad surface facing downward is potentially
hazard. Failure to observe this caution may cause un-
expected deployment of the air bag, resulting in scat-
tered pad assembly. Furthermore, store the pad as-
sembly at a low place close to the ground level where
no heat source (80C or more) exists in close proximity. JBE00186-05023
5. Ensure that the steering wheel is set to a straight-ahead

position.
6. Remove the lock nut of the steering wheel.
8. Remove the instrument finish lower panel by the removing
attaching screws.
9. Remove the steering column lower cover by the removing
attaching screws.
10. Disconnect the connector and detach the wiring harness
from the clamp. JBE00187-05024
11. Remove the multi-use lever switch by removing the attach-

ing screws.
NOTE:
There are cases where the multi-use lever switch can
not be removed from the steering column upper cover,
unless the steering column is lowered by temporarily
loosening the attaching bolts of the column.
INSTALLATION
PRECAUTION: JBE00188-05025
It should be noted wrong installation of the steering roll
connector may pose potential hazard, for it may break
the wire and also, prevent proper turning of the steer-
ing wheel.
1. Ensure that the front wheels are set to the straight-ahead

position.
2. Secure the steering roll connector to the multi-use lever
switch with screws. JBE00189-05026
3. Turn the steering roll connector clockwise, until it is

locked.
CAUTION:
The steering roll connector makes five turns at the
maximum. Hence, when the steering roll connector is
connected to the steering wheel, be sure to set the
steering roll connector to the midpoint of the rotation.
4. Back off the steering roll connector about 2.5 turns coun-
terclockwise from the locked position. Align the center
mark. Temporarily secure the steering roll connector, using Align the mark.
a tape, so that it may not move. JBE00190-05027

BE58
5. Install the steering wheel assembly to the steering shaft
and tighten the lock nut.
Specified Torque: 27.5 - 41.2 Nm
JBE00191-05028
6. Installation of pad assembly

(1) Connect the connector.
(2) Secure the pad assembly to the steering wheel assem-
bly with the TORX bolt.
Specified Torque: 5.2 - 9.5 Nm
7. Set the steering column upper cover to the steering col-

umn assembly.
8. Tighten the steering column assembly attaching bolts.
9. Connect the air bag connector. Clamp the wiring harness.
10. Install the steering column lower cover. JBE00192-05029
11. Install the instrument finish lower panel.

1. Turn the steering wheel to the right and left sides, respec-
tively, as far as it will go. Ensure that no malfunction exists.
2. Connect the negative () terminal of the battery cable to
the battery terminal.
3. Ensure that the horn is set off by pushing the horn button.
4. Turn on the ignition switch. Ensure that the air bag warning
lamp illuminates for six seconds.
JBE00193-05030

BE59
AIR BAG UNIT (FRONT PASSENGERS SEAT SIDE)
COMPONENTS
q Air bag unit

q
(Passengers seat side)
w Glove box
e Clip
JBE00194-05031
REMOVAL
1. Turn off the ignition switch and detach the negative () ter-
IG [OFF]
2. Remove the grove box by removing a hinge pin.
3. Disconnect the connector which connects the wire har-
ness of the air bag unit and the cowl wire.
JBE00195-05032
WARNING:
may cause unexpected deployment of the air bag
the air bag unit during the removal.
If the air bag unit is dropped or damaged during the re-
moval or the storage, be sure to dispose of the unit ac-
cording to the disposal procedure. Be sure to mount a
new unit to the vehicle. JBE00196-05033
CAUTION:
of the battery is detached, the memory of the ECU con-
JBE00197-05034

BE60
4. Remove the air bag unit assembly from the instrument
panel by removing attaching bolts and nuts.
WARNING:
Be sure to place the removed air bag unit with the pad
surface facing upward. The unit placed with the pad
surface facing downward is potentially hazard. Failure
to observe this caution may cause unexpected deploy-
ment of the air bag, resulting in scattered air bag unit.
Furthermore, store the unit at a low place close to the
ground level where no heat source (80C or more) ex-
ists in close proximity. JBE00198-05035
INSTALLATION
Nut
1. Install the air bag unit to the instrument panel and tighten
the bolts and nuts. Bol
t
Specified Torque for the Bolt: 6.7 - 9.5 Nm
2. Connect the connector.

3. Install the grove box.
JBE00199-05036

1. Ensure that the pad of the air bag unit fits properly to the
instrument panel.
lamp illuminates for six seconds.
JBE00200-05037

BE61
AIR BAG ECU
COMPONENTS
q Console box
w Console panel bezel
e Console panel
r Air bag ECU
r
e
JBE00201-05038
REMOVAL
1. Turn off the ignition switch and detach the negative () ter-
IG [OFF]
WARNING:
may cause unexpected deployment of the air bag
CAUTION:
It should be noted that, when the negative () terminal JBE00202-05039
of the battery is detached, the memory of the ECU con-
Connector
2. Remove the rear console box by removing attaching
screws.
3. Pull off the console panel bezel.
4. Remove the console panel by removing attaching bolts
and clips.
5. Disconnect the connector from the air bag ECU.
6. Remove the air bag ECU by removing attaching bolts.
Air bag ECU
WARNING:
Disconnect the connector in advance. JBE0203-05040
INSTALLATION
1. Install the air bag ECU.
2. Connect the connector.
3. Install the console panel.

lamp illuminates for six seconds. JBE00204-05041

BE62
CIRCUIT DIAGRAM
ACC ACC
IG No. 1 IG1
IG No. 2 IG2
ST ST
IG SW
Main MAIN
F/L AM 60A
Junction block N59 N60

Air bag ECU connector
(at wire harness side)
Gauge/Back
Engine
Air bag
10 A
10 A
10 A
P P+ SIO W D D+ T
H67 T45 N31
Warning lamp E1 A B IG2 IG1

(Combination meter) H61
Air bag ECU
Battery
IG 1
Diode
IG 2 circuit
Back-up Safing
condenser sensor
DC-DC Squib
T37
circuit (Drivers
W seat side)
D+
TC
To diagnosis D
connector (ECU T) G sensor
Ignition
transistor P+
SIO CPU diagnosis
To diagnosis Interface collision P
evaluation Ignition
connector (SIO) transistor
(Diagnosis connector) Diagnosis Squib
code memory (Passengers
ABS ECU IMB seat side)
IG REV E1
T T W
ITC E VF
SIO
T
JBE00205-05042
DIAGNOSIS CHECK
CONFIRMATION PROCEDURE FOR DIAGNOSIS CODES
1. Turn on the ignition switch.
2. If the air bag warning lamp goes on for approximately six
seconds and goes out afterward, the system is functioning
properly.
NOTE:
If the lamp will not go on at this time, refer to page
BE63.
JBE00206-05043
3. If the warning lamp keeps illuminated for more than six Diagnosis connector
seconds, it means a certain system malfunctioning is
being detected. Proceed to the following operations.
4. Connect the test terminal (ECU-T) and the earth terminal
(E) of check connector with a jump wire. Test terminal Earth
(ECU-T) terminal (E)
5. Confirm the diagnosis code by reading the number of
flashing of the air bag warning lamp.
JBE00207-05044

BE63
Reading of malfunction codes (diagnosis codes)
In case of malfunction codes number 21 and 31
When two or more malfunction codes are outputted, the
codes are indicated in the sequence of the code numbers, 0.5 Sec.
starting form a smaller number, with a four-second distin- 0.5 Sec.
1.5 Sec.
guished period interposed between codes. Glowing
After a lapse of four seconds, the malfunction codes are indi-
cated by the repetition of a 0.5-second glowing period and a
0.5-second extinguished period. If the code is a two-digit
number, a 1.5-second extinguished period is interposed be- Extinguished
tween the units digit and the tens digit. 2.5 Sec. 4 Sec.
JBE00208-05045
Canceling procedure for records of diagnosis codes 1 0.4 Sec.

1. The diagnosis codes can be canceled by connecting re- 1 0.4 Sec.
1 0.4 Sec.
peatedly the test terminal (ECU-T) with the earth terminal Terminal 1 0.4 Sec.
On
(E) at the intervals shown in the figure.
Off
Glowing 50m Sec
Warning
lamp
Extinguished
Cancel code.
JBE00209-05046
2. When the malfunction has been remedied and the system

has resumed, the normal code shown in the figure is indi- 0.25 Sec.
Glowing
cated.
NOTE:
The cancellation procedure for the malfunction record
can not be applied to the cancellation of the record of
the malfunction for the ECU internal circuit.
(Diagnosis codes number 61 and 62)
Extinguished
0.25 Sec.
JBE00210-05047
ABNORMAL ILLUMINATION OF WARNING LAMP

When warning lamp will not go on: Terminals
If the warning lamp will not go on when the ignition switch is
turned on, check the following items.
(1) Battery for defects or insufficient charge
(2) Battery cable for poor connection
(3) Warning lamp bulb for being burnt out Hydrometer
(4) Gauge fuse for open wire
(5) Cowl wire harness between warning lamp and air bag
ECU for abnormality
(6) Warning lamp relay for malfunction JBE00211-05048
NOTE:
When the gauge fuse has open wire, other warning
lamps will not go on.
JBE00000-05049

BE64
1. Check of cowl wire harness
(1) Turn off the ignition switch and wait for 60 seconds.
(2) Remove the console panel. Disconnect the connector Connector
at the vehicle wire harness side from the air bag ECU
connector.
(3) Turn on the ignition switch. Check to see if the warning
lamp goes on.
NOTE:
When there is open wire in the wire harness between
the warning lamp circuit inside the combination meter Air bag ECU
and the ECU, the warning lamp remains illuminated. JBE00212-05050
Combination meter 13-pin connector

(4) If the warning lamp will not go on in the condition (3), it (at wire harness side)
is likely that the harness of warning lamp is shorted.
Remove the combination meter and disconnect the
B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
13pin connector. Measure the resistance of harness
(cowl wire) across the terminal (B6) and body earth.
(5) If it might be shorted, replace the harness. Then turn
on the ignition switch. Check to see if the warning
lamp goes on.
JBE00213-05051
2. Check of air bag warning lamp relay

If the air bag warning lamp will not go on in the condition
(5) above, it means the relay is malfunctioning. Replace
the relay.
When warning lamp will not go out:

If the warning lamp will not go out even if about six seconds
have elapsed after the ignition switch was turned on, malfunc- JBE00214-05052
tion is most likely taking place in the system. However, as for
the following items given below, the malfunction codes can not
be read by the reading procedure for the malfunction code al-
ready described before, and the warning lamp will remain illu-
minated. At this time, proceed to the following inspection.
1. Malfunction of power supply circuit of air bag ECU

(2) Remove the console panel. Disconnect the connector
at the vehicle wire harness side from the air bag ECU.
(3) Set the range of the circuit tester to the voltmeter JBE00215-05053
mode. Connect the tester to the terminals of the con-

nector at the wire harness side. (at wire harness side)
(4) Switch on the ignition switch and take a reading of the
voltage. 1 2 3 4 5 6 7 8
NOTE:
If the specified voltage (12 V) is applied across the ter- 9 10 11 12 13 14 15 16 17 18
minal 17 or 18 and the terminal 10, the power supply E1 IG1
circuit is regarded as normal and proceed to the next
IG2
step.
If the specified voltage is not applied, check the wiring
route including the connector and fuse for open wire. JBE00216-05054

BE65
2. Check of warning lamp circuit
NOTE:
If the warning lamp circuit has open wire, the warning
lamp will remain illuminated. This malfunction is record-
ed as the malfunction code 16 of the air bag ECU.
However, as long as the warning lamp circuit has open
wire, the diagnosis code can not be indicated and the
warning lamp remains illuminated. JBE00217-05055
at the vehicle wire harness side from the air bag ECU. Connector
Air bag ECU

JBE00218-05056
(3) Set the range of the circuit tester to the voltmeter

mode. Connect the tester to the terminals of the con- (at wire harness side)
nector at the wire harness side. W
NOTE:
If the specified voltage (5.5 0.5 V) is applied across 1 2 3 4 5 6 7 8
the terminal 5 and the terminal 10 (body earth) circuits
9 10 11 12 13 14 15 16 17 18
except the ECU are regarded as functioning normally.
E1 V
JBE00219-05057
3. Replacement of air bag warning lamp relay

(1) Remove the combination meter from the instrument
panel.
(2) Check to see if there is open wire or damage at the cir-
cuit panel at the back side of the combination meter.
(3) Replace the air bag warning lamp relay inside the
combination meter.
(4) Then, perform the check of (3) and check that the
lamp goes out.
NOTE:
After completion of repairing the malfunction, read out JBE00220-05058
the malfunction codes and cancel them to complete the

Diagnosis connector
operation.
(5) Connect the wire harness connector to the ECU as it

was connected before. Perform code cancellation and Test terminal Earth
re-reading. Make sure that the malfunction has been
remedied.
JBE00221-05059

BE66
TROUBLE SHOOTING
When proceeding with operations for a malfunctioning vehicle, it is imperative to confirm the malfunction
phenomena actually before pinpointing the causes. In order to reproduce the malfunction phenomena, col-
lecting information from the customer is of great importance.
WARNING:
The aforesaid describes general notes. In the air bag system, there are some cases where the mal-
function phenomena can not be reproduced due to the characteristics of the system. Therefore, any
wrong operations during checks and repairs may cause the air bag to function accidentally and de-
ploy. Please observe the notes and perform the operations according to the instructions given in the
manual.
JBE00222-05060
LIST OF MALFUNCTION CODES

Code Timing at time of
Malfunction detection No.
No. Malfunctioning sections
11 At all times Abnormal Power supply voltage
14 At all times IG1 has open wire.
15 At all times IG2 has open wire.
16 Initial period Abnormal warning lamp illumination circuit
21 At all times Squib of air bag at drivers seat side has open wire.
22 At all times Circuit of squib of air bag at drivers seat side is shorted.
31 At all times Squib of air bag at front passengers seat side has open wire.
32 At all times Circuit of squib of air bag at front passengers seat side is shorted.
41 At all times Upstream circuit of squib of air bag is grounded to earth.
42 At all times Power supply voltage is applied to upstream circuit of squib of air bag.
61 Initial period Squib was operated. (Air bag was deployed.)
62 Initial period/ Air bag ECU malfunctioning
At all times
JBE00223-05061
CAUTION:
After carrying out the trouble shooting according to diagnosis codes, cancel the diagnosis codes by
following the code canceling method described at page BE63.
Even though the malfunction has been remedied, the code is not canceled automatically.
JBE00224-05062

BE67
When diagnosis code 11,14 or 15 is indicated:
Possible cause for malfunction: Abnormal power supply volt-
age to the air bag system.
1. Battery check
Turn off the ignition switch. Measure the voltage across the
battery terminals and ensure that the voltage is 12 V or
more.
2. Check of charging circuit

Hydrometer
(1) After starting the engine, disconnect the battery cable
terminal from the negative terminal of the battery. JBE00225-05063
(2) Measure the voltage between the negative terminal of

the disconnected battery cable and the battery posi- Terminals
tive terminal.
NOTE:
The voltage should be 14.5 V or more at the engine
revolution speed of 2000 rpm. Hydrometer
(3) Check to see if the battery cable is connected proper-

ly.
JBE00226-05064
3. Check of wire harness and fuse
Ignition SW Engine
ACC fuse
IG No. 1 18 IG1
IG No. 2
1 2 3 4 5 6 7 8
ST 17 IG2
Air bag 9 10 11 12 13 14 15 16 17 18
F/L
Main
fuse Air bag ECU
E1 IG2 IG1
10 E1
Battery
JBE00227-05065
at vehicle wire harness side from the air bag ECU. Connector
Air bag ECU

JBE00228-05066

BE68
With the circuit tester set to the voltmeter mode, con-
nect the tester between the connector terminal at the
vehicle wire harness side and body earth.
Between terminal 18 (IG1) and body earth: V
Battery voltage
Between terminal 17 (IG2) and body earth: !8 IG1
Battery voltage
!7 IG2
If the battery voltage is not applied to each terminal,

pull off and check the air bag fuse and engine fuse. JBE00229-05067
Engine Air bag ECU

(4) If the fuse is melt down, connect the tester between Ignition SW fuse
ACC
the connector terminal at the vehicle wire harness side IG No. 1 18 18 IG1
IG No. 2
and body earth with the tester set to the ohmmeter ST 17 17 IG2
range. Air bag
Between terminal 18 (IG1) and body earth: fuse
No continuity exists. 10 10 E1
Between terminal 17 (IG2) and body earth:
No continuity exists.
If it might be shorted, replace the harness. If not, re- JBE00230-05068

check after replacing the fuse. Engine Air bag ECU
Ignition SW fuse
ACC
(5) If the fuse is not melt down, connect the tester be- IG No. 1 18 18 IG1
tween the connector terminal at the vehicle wire har- IG No. 2
17 17 IG2
ST
ness side and fuse terminal with the tester set to the
Air bag
ohmmeter range. fuse
Between terminal 18 (IG1) and Engine fuse terminal
10 10 E1
(at the fuse block): Continuity exists.
Between terminal 17 (IG2) and Air bag fuse terminal
(at the fuse block): Continuity exists.
JBE00231-05069
If it might have open wire, replace the harness. If not,
re-check the battery and charging circuit.

BE69
When diagnosis code 16 is indicated:
Possible cause for malfunction: Abnormality in warning lamp illuminating circuit
NOTE:
When this code is memorized, it indicates that open wire has taken place in the warning lamp circuit
even though it occurred temporarily. However, if this code is now indicated, it means the circuit (wire
harnesses, connectors, etc.) has been remedied to the normal condition.
JBE00232-05070
1. Check of wire harness and connector
Ignition SW Engine Air bag ECU

ACC fuse
IG No. 1 18 IG1
IG No. 2
ST 17 IG2
Air bag
F/L
Main
fuse
Warning B6 5 W
B7
Gauge/Back lamp circuit
fuse 10 E1
Battery
1 2 3 4 5 6 7 8
B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
9 10 11 12 13 14 15 16 17 18
E1 IG2 IG1
Air bag ECU connector Combination meter 13-pin connector
(at wire harness side) (at wire harness side)
JBE00233-05071
at the vehicle wire harness side from the air bag ECU Connector
connector.
(3) Take out the combination meter from the instrument
panel. Disconnect the 13-pin connector from the com-
bination meter.
Air bag ECU

JBE00234-05072
(4) Connect a circuit tester to the wire harness connectors Combination meter 13-pin connector
between the terminal (B6) to the combination meter (at wire harness side)
side and the terminal (5) to the ECU side with the cir-
B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
cuit tester set to the ohmmeter mode. Check continuity
between these terminals. Give light vibration to the
wire harness or connector between the air bag ECU
and the combination meter by hand. Check to see if (at wire harness side)
any change is observed in the ohmmeter.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18
JBE00235-05073

BE70
Possible cause for malfunction: Open wire in squib of air bag
at drivers seat side
WARNING:
The squib of the air bag consists of a filament of about
2 ohms. Therefore, there is the possibility that a current
which is big enough to cause deployment flows when
the circuit tester is connected in its ohmmeter mode.
Hence, never measure the resistance of the squib easi-
ly just because the code 21 is indicated. This may
cause the air bag to deploy, thus causing serious in- JBE00236-05074
juries to the operators and other people in the sur-

rounding.
1. Check of wiring harness and connector
Ignition SW Steering roll Squib

Engine Air bag ECU (Drivers
ACC connector
fuse seat side)
IG No. 1 18 IG1 D+ 7 F2 f2
F1 f1
IG No. 2
ST 17 IG2
Air bag
F/L
Main D 6 G1 g1 G2 g2
fuse
10 E1
Battery
D D+
+
+ +
1 2 3 4 5 6 7 8 F1 f1 F2
G1 g1 G2
9 10 11 12 13 14 15 16 17 18

Air bag ECU connector Wire harness connector Roll connector Roll connector
(at wire harness side) (To roll connector) (To wire harness) (To drivers side squib)
JBE00237-05075
NOTE:
When there is poor connection between the air bag
ECU and the squib, the code 21 is indicated, too. Connector
at the vehicle wire harness side from the air bag ECU.
NOTE:
When the connector is disconnected from the air bag
ECU, the connector terminals 6 and 7 at the harness Air bag ECU
side are shorted automatically by the short circuit JBE00238-05076
bridge.
(3) Remove the steering pad assembly (air bag unit) from
the steering wheel.
CAUTION:
The pad assembly is installed to the steering wheel by
means of TORX bolts.
A pad assembly which was dropped previously can not
be used again. Therefore, extreme care must be exer-
cised as to its handling.
JBE00239-05077

BE71
(4) Disconnect the pad assembly connector from the roll
connector. Also disconnect the connector for the horn.
WARNING: GOOD
When storing the steering pad assembly (air bag unit),
be sure to place it with the pad surface facing upward
on a flat place which is not exposed to direct sun rays.
Sparks of welding, etc. shall be kept away from the
storing place. Also, the storing place shall be away
from the storing place for water, oil, grease, etc.
JBE00240-05078
(5) Connect the circuit tester to the roll connector terminal

Air bag ECU Squib
with the tester set to the ohmmeter range. Ensure that Steering roll (Drivers
there is no open wire between the wire harness and Cowl wire connector seat side)
the connector. D+ 7 7 F1 f1 F2 f2
Between terminal 7 (D+) and F2 (+):
Continuity exists. D 6 6 G1 g1 G2 g2
Between terminal 6 (D) and G2 ():
Continuity exists.
(6) If there is no open wire, connect both ends of the roll

connector terminal with a jump wire to short them. JBE00241-05079
Air bag ECU

(7) Connect the connector at the vehicle wire harness Steering roll Jump wire
side and the air bag ECU that were disconnected at connector
Step (2). D+ 7 F1 f1 F2
(8) Turn on the ignition switch and take a reading of the di-
D 6 G1 g1 G2
agnosis code.
CAUTION: IG ON
If the code 22 (short circuit of squib circuit) is indicated, ECUT
it proves indirectly that there is open wire in the squib Diagnosis
of the steering pad assembly (air bag unit). Therefore, connector E
replace the steering pad assembly. JBE00242-05080
After the replacement, cancel the diagnosis code and
confirm that the code 21 is not outputted any more.
2. Confirmation of open wire of squib

CAUTION:
To check an electric circuit for open wire, it is an ac-
cepted practice to perform measurement with an ohm-
meter. However, it is dangerous to use this method to
check the squib for open wire, because this method
may cause an accidental explosion. In the preceding
step, it has been confirmed that there is no open wire
in the circuits other than the squib. Before you proceed
to the disposing procedure for the steering pad assem-
bly described later, it is, however, necessary to prove
directly that there is open wire in the squib. As for this
procedure, refer to page BE83. JBE00243-05081
3. Installation of steering pad assembly

JBE00244-05082

BE72
Possible cause for malfunction: Circuit of squib of air bag at drivers seat side is shorted.
NOTE:
The squib of the air bag consists of a filament of about 2 ohms. In order to detect open wire or short
circuit in the squib circuit, a small amount of current is flown at all times from the air bag ECU.
Therefore, when this code is indicated, it means that an abnormally large amount of current flowed in
the squib circuit of the air bag at the drivers seat for a certain reason. Therefore, the ECU judges
that the resistor of the squib (filament or wire harness) is shorted.
JBE00245-05083
WARNING:
Never measure directly the resistance of the squib to
see if the squib is shorted or not, using a circuit tester.
Failure to observe this warning may cause the air bag
to deploy accidentally, thus causing injuries to the oper-
ators and other people in the surrounding.
JBE00246-05084
1. Check of wiring harness
Ignition SW Steering roll Squib

Engine Air bag ECU (Drivers
ACC connector
fuse seat side)
IG No. 1 18 IG1 D+ 7 F2 f2
F1 f1
IG No. 2
ST 17 IG2
F/L
Main Air bag D 6 G1 g1 G2 g2

fuse
10 E1
Battery
D D+
+
+ +
1 2 3 4 5 6 7 8 F1 f1 F2
G1 g1 G2
9 10 11 12 13 14 15 16 17 18
Roll connector
Air bag ECU connector Wire harness connector Roll connector (To drivers
(at wire harness side) (To roll connector) (To wire harness) side squib)
JBE00247-05085
(1) Turn off the ignition switch and wait for about 60 sec-
onds.
the steering wheel.
CAUTION:
A steering pad assembly which was dropped previous-
ly can not be used again. Therefore, extreme care
must be exercised not to drop it.
JBE00248-05086

BE73
(3) Disconnect the connector of the steering pad assem-
bly from the roll connector. Also disconnect the con-
nector for the horn. GOOD
WARNING:
Also the storing place shall be away from water and
rain.
JBE00249-05087

at the vehicle wire harness side from the air bag ECU. Wooden or
(5) Using a wooden or plastic piece, raise the short circuit plastic piece
bridge at the sections 6 and 7 of the connector at the
vehicle wire harness side which was removed from the D D+
ECU. In this way, disconnect the shorted contact 6 7
points.
Short circuit
bridge
JBE00250-05088
(6) With the circuit tester set to the ohmmeter mode, con-
nect the tester to the roll connector terminal. Check to Air bag ECU Steering roll
see if any short circuit exists in the circuits from the air connector
bag ECU to the roll connector via the wire harness. D+ 7 7 F1 f1 F2
Between terminal F2 (+) and G2 ():
No continuity exists. D 6 6 G1 g1 G2
Cowl wire
JBE00251-05089
(7) If the wiring harness is shorted, it is necessary to know

whether the faulty point is attributable to the inside of Steering roll
Cowl wire connector
the roll connector. To this end, disconnect the coupling
connector of the roll connector and the wire cowl. D+ 7 7 F1 f1 F2
Then, perform check with a circuit tester as was de- D 6 6 G2
G1 g1
scribed in Item (6) above.
Between terminal F1 (+) and G1 ():
Air bag
Between terminal f1 (+) and g1 (): ECU
JBE00252-05090
If a short circuit is found, replace the faulty part with a

new one.
NOTE:
At this time, turn the steering wheel in a right-and-left
direction and ensure that there is no change in the indi-
cation of the circuit tester.

BE74
(8) Replacement of roll connector
WARNING:
When replacing the roll connector, refer to BE-57.
Failure to observe this warning may hamper the turning
function of the steering wheel or cut the wiring of the
roll connector. Therefore, extreme care must be paid.
NOTE:
As for the steering wheel installation procedure, refer to
the SR section of the service manual.
JBE00253-05091
(9) Replace the wire harness if it exhibits any fault.

NOTE:
The wiring harness for the air bag can be identified by
its external color of yellow.
JBE0254-05092

Possible cause for malfunction: Squib of air bag at front pas-
senger seat side has open wire.
WARNING:
The squib of the air bag consists of a filament of about
2 ohms. Therefore, there is the possibility that a current
which is big enough to cause deployment flows when
the circuit tester is connected in its ohmmeter mode.
Hence, never measure the resistance of the squib easi-
ly just because the code 31 is indicated. This may
cause the air bag to deploy accidentally, thus causing
serious injuries to the operators and other people in the JBE00255-05093
surrounding.
1. Check of wiring harness and connector

ACC fuse
IG No. 1 18 IG1
IG No. 2
ST 17 IG2
Air bag
F/L
Main
fuse
P+ 3 H h
10 E1 P 2 J j
Squib
Battery
(Passengers
P P+ seat side)
+
1 2 3 4 5 6 7 8 H
J
9 10 11 12 13 14 15 16 17 18
Air bag ECU connector Vehicle side connector

(at wire harness side) (To passengers side squib)
JBE00256-05094

BE75
NOTE:
When there is poor connection between the air bag
ECU and the squib, the code 31 is indicated, too. Connector
(2) Remove the console box. Disconnect the connector at
the vehicle wire harness side from the air bag ECU.
NOTE:
ECU, the connector terminals 2 and 3 are shorted au- Air bag ECU
tomatically by the short circuit bridge. JBE00257-05095
(3) Disconnect the connector which connects the wire 2nd lock
harness of the air bag unit and the wire cowl.
NOTE:
1st
When the connector is disconnected from the air bag lock
unit, the connector terminals (h) and (j) are shorted au-
tomatically by the short circuit bridge.
Airbag unit side

JBE00258-05096
(4) Connect the circuit tester to the connector terminal at Air bag ECU Squib
the wire cowl side with the tester set to the ohmmeter Cowl wire (Passengers
range. Ensure that there is no open wire in the wire seat side)
P+ 3 3 H h
harness.
Between terminal 3 (P+) and H (+):
P 2 2 J j
Continuity exists.
Between terminal 2 (P) and J ():
Continuity exists.
JBE00259-05097
(5) If there is no open wire, connect both ends of the con- Air bag ECU
nector terminal with a jump wire to short them. Jump wire
(6) Connect the connector at the vehicle wire harness Cowl wire
P+ 3 H
side and the air bag ECU connector that were discon-
nected at Step (2).
P 2 J
(7) Turn on the ignition switch and take a reading of the di-
agnosis code. IG ON
ECUT
Diagnosis
connector E
JBE00260-05098
CAUTION: Diagnosis connector

If the code 32 (short circuit of squib circuit) is indicated,
it proves indirectly that there is open wire in the squib
of the air bag unit in the front passenger seat side.
Therefore, replace the air bag unit. Test terminal Earth
JBE00261-05099

BE76
2. Confirmation of open wire of squib
CAUTION:
To check an electric circuit for open wire, it is an accepted practice to perform measurement with an
ohmmeter. However, it is dangerous to use this method to check the squib for open wire, because this
method may cause an accidental explosion. In the preceding step, it has been confirmed that there is
no open wire in the circuits other than the squib. Before you proceed to the disposal procedure for the
air bag unit described later, it is necessary to prove directly that there is open wire in the squib. As for
this procedure, refer to page BE83.
JBE00262-05100

Possible cause for malfunction: Circuit of squib of air bag at front passenger seat side is shorted.
NOTE:
The squib of the air bag consists of a filament of about 2 ohms. In order to detect open wire or short
circuit in the squib circuit, a small amount of current is flown at all times from the air bag ECU.
Therefore, when this code is indicated, it means that an abnormally large amount of current flowed in
the squib circuit of the air bag in the drivers seat for a certain reason. Therefore, the ECU judges
that the resistor of the squib (filament or wire harness) is shorted.
JBE00263-05101
WARNING:
Never measure directly the resistance of the squib to
see if the squib is shorted or not, using a circuit tester.
Failure to observe this warning may cause the air bag
to deploy accidentally, thus causing injuries to the oper-
ators and other people in the surrounding.
JBE00264-05102

BE77
1. Check of wiring harness

ACC fuse
IG No. 1 18 IG1
IG No. 2
ST 17 IG2
Air bag
F/L
Main
fuse
P+ 3 H h
10 E1 P 2 J j
Squib
Battery
(Passengers
seat side)
P P+
+
H
1 2 3 4 5 6 7 8
J

9 10 11 12 13 14 15 16 17 18
Vehicle side connector
Air bag ECU connector (To passengers
(at wire harness side) side squib)
JBE00265-05103
onds.
(2) Remove the console panel. Disconnect the coupling of
the connector of the air bag ECU and the connector at P P+
the vehicle wire harness side. Wooden or 2 3
(3) Using a wooden or plastic piece, raise the short circuit plastic piece
bridge at the sections 2 and 3 of the connector at the
vehicle wire harness side which were removed from Short circuit
the ECU. In this way, disconnect the shorted contact bridge
points.
JBE00266-05104
(4) Disconnect the connector which connects the wire Air bag ECU
harness of the air bag unit and the wire cowl. Cowl wire h
(5) Connect the circuit tester to the connector terminal at
P+ 3 3 H j
the wire cowl side with the tester set to the ohmmeter
range. Ensure that there is no short in the wire har-
P 2 2 J
ness.
(6) If there is no short, disconnect the circuit tester.
Connect the air bag ECU connector and the connector
at the vehicle wire harness side as connected before.
JBE00267-05105
(7) Turn on the ignition switch and take a reading of the di- Diagnosis connector
agnosis code.
NOTE:
If the code 31 (open wire of squib circuit) is not indicat-
ed, the air bag ECU is likely malfunctioning. Test terminal Earth
JBE00268-05106

BE78
Possible cause for malfunction: Upstream circuit of squib of air bag at drivers seat side and/or passen-
gers seat side is grounded to earth.
NOTE:
When this code is indicated, it means that the squib circuit of the air bag is grounded for a certain
reason.
Air bag ECU Steering roll Squib
connector (Drivers
Ignition SW Engine seat side)
ACC fuse D+ 7 F1 f1 F2 f2
IG No. 1 18 IG1
IG No. 2
ST 17 IG2 D 6 G1 g1 G2 g2
Air bag Squib
F/L
Main
fuse (Passengers
H h seat side)
P+ 3
10 E1
P 2 J j
Battery
+
P P+ D D+ + + +
F1 f1 F2
H
1 2 3 4 5 6 7 8 G2
G1 g1 J

9 10 11 12 13 14 15 16 17 18 Roll connector Vehicle side connector
Wire harness connector Roll connector (To drivers (To passengers
Air bag ECU connector (To roll connector) (To wire harness)
(at wire harness side) side squib) side squib)
JBE00269-05107
1. Check of wiring harness at the drivers seat side

onds.
the steering wheel.
CAUTION:
Any steering pad assembly which was dropped previ-
ously can not be used again. Therefore, extreme care
must be exercised as to its handling.
JBE00270-05108

bly from the roll connector. Also disconnect the con-
nector for the horn. GOOD
WARNING:
Sparks of welding, etc. shall be kept away from the
storing place. Also the storing place shall be away from
the storing place for oil, grease, etc.
JBE00271-05109
(4) Disconnect the connector at the vehicle wire harness

6 7
side from the air bag ECU connector.
NOTE:
ECU, the connector terminals 6 and 7 (the squib circuit
for the air bag of the drivers seat) are shorted automat- Short circuit
ically by the short circuit bridge. bridge
Connector
Air bag ECU
JBE00272-05110

BE79
(5) Connect a circuit tester to the roll connector terminal
and the body earth with the tester set to the ohmmeter
range.
NOTE:
The wire harness of both terminals of the roll connector
is connected at the ECU side connector as was ex-
plained before. If there is continuity between the bodies
at this item (5), disconnect the connection between
both terminals by raising temporarily the short circuit
bridge terminal of the ECU side connector with a wood- Body earth
en piece or the like. In this way, determine which termi- JBE00273-05111
nal has been grounded.

2nd lock
(6) If the wiring harness is shorted with the body earth, it
is necessary to know whether the faulty point is attrib-
1st
utable to the inside of the roll connector. To this end, lock
disconnect the coupling connector of the roll connec-
tor and the wire cowl. Then, perform check with a cir-
cuit tester as was described in Item (5) above. If a
short circuit is found, replace the faulty part with a new
one. Roll connector side
JBE00274-05112
(7) Replacement of roll connector

WARNING:
When replacing the roll connector, refer to BE57.
Failure to observe this warning may hamper the turning
function of the steering wheel or cut the wiring of the
roll connector. Therefore, extreme care must be paid.
NOTE:
As for the steering wheel installation procedure, refer to
the SR section of the service manual.
JBE00275-05113
(8) Replace the wiring harness if it exhibits any fault.

NOTE:
The wiring harness for the air bag can be identified by
its external color of yellow.
JBE00276-05114
2. Check of wiring harness at the passengers seat side

2 3
onds.
(2) Disconnect the connector at the vehicle wire harness
side from the air bag ECU.
NOTE: Short circuit
When the connector is disconnected from the air bag bridge
ECU, the connector terminals 2 and 3 (the squib circuit
for the air bag in the passengers seat) are shorted au- Connector
tomatically by the short circuit bridge. Air bag ECU
JBE00277-05115

BE80
(3) Disconnect the connector which connects the wire
2nd lock
1st
lock
Airbag unit side

JBE00278-05116
(4) Connect a circuit tester between the connector termi-

nal at the wire cowl side and the body earth with the Wire cowl side
tester set to the ohmmeter range.
NOTE:
The wire harness of both terminals of the connector is
connected at the ECU side connector as was explained
before. If there is continuity between the bodies at this
item (4), disconnect the connection between both ter-
minals by raising temporarily the short circuit bridge Body earth
terminal of the ECU side connector with a wooden
piece or the like. In this way, determine which terminal JBE00279-05117
has been grounded.

Short circuit bridge Airbag unit side
(5) If there is no abnormality in the wire harness in the pre- Terminal

vious item (4), check to see if the connector terminal at
the air bag side is connected with the body earth.
WARNING:
Both terminals of the connector at the air bag side are
connected with the short circuit bridge. Therefore, the
tester probe terminal should be connected in such a
Body earth
way that this bridge may not be disconnected. If this
JBE00280-05118
short circuit bridge is disconnected and the tester volt-
age is applied to the terminals, the air bag may be de-
ployed accidentally.

BE81
Possible cause for malfunction: Power supply voltage is applied to upstream circuit of squib of air bag at
drivers seat side and/or passengers seat side.
WARNING:
When this code is indicated, it indicates that the upstream ignition driver is turned on for a certain
reason. Under this condition, the air bag is deployed as soon as the safing sensor at the downstream
circuit is turned on. Hence, when this code is indicated, immediately turn off the ignition key switch
and proceed to the following steps.
JBE00281-05119
Air bag ECU Steering roll Squib

connector (Drivers
Ignition SW Engine seat side)
ACC fuse D+ 7 F1 f1 F2 f2
IG No. 1 18 IG1
IG No. 2
ST 17 IG2 D 6 G1 g1 G2 g2
F/L
Main Air bag

fuse
P+ 3 H h
10 E1
Battery
P 2 J j
Squib
(Passengers
seat side)
P P+ D D+ +
+ + +
F1 f1 F2 H
1 2 3 4 5 6 7 8
G1 g1 G2 J

9 10 11 12 13 14 15 16 17 18
Wire harness connector Roll connector Roll connector Vehicle side connector
Air bag ECU connector (To roll connector) (To wire harness) (To drivers (To passengers
(at wire harness side) side squib) side squib)
JBE00000-05120
1. Checking procedure of air bag at the drivers seat side

onds.
the steering wheel.
CAUTION:
The steering pad assembly is installed to the steering
wheel by means of TORX bolts.
A steering pad assembly which was dropped previous-
ly can not be used again. Therefore, extreme care
must be exercised as to its handling. JBE00282-05121

bly from the roll connector. Also disconnect the con- GOOD
nector for the horn.
WARNING:
When storing the steering pad assembly, be sure to
place it with the pad surface facing upward on a flat
place which is not exposed to direct sun rays. Sparks
of welding, etc. shall be kept away from the storing
place. Also the storing place shall be away from the
storing place for oil, grease, etc. JBE00283-05122

BE82
(4) With a circuit tester set to the voltmeter mode, connect
the roll connector terminal and the body earth.
(5) Turn on the ignition switch. Check if the voltmeter reg-
isters approximately the battery voltage.
NOTE:
Measure the voltage of each connector terminal.
(6) Replacement of air bag ECU

NOTE:
As for this procedure, refer to item 3, Replacement of Body earth
air bag ECU. JBE00284-05123
2nd lock
2. Checking procedure of air bag at the passengers seat
side
(1) Turn off the ignition switch and wait for about 60 sec- 1st
onds. lock
(2) Disconnect the connector which connects the wire
(3) Connect a circuit tester between the connector termi-

nal at the wire cowl side and the body earth with the Airbag unit side
circuit tester set to the voltmeter mode. JBE00285-05124
(4) Turn on the ignition switch. Check if the voltmeter reg-

isters the battery voltage. Wire cowl side
NOTE:
Measure the voltage of each connector terminal.
(5) Replacement of air bag ECU

NOTE:
As for this procedure, refer to item 3, Replacement of
air bag ECU. Body earth
JBE00286-05125
3. Replacement of air bag ECU
NOTE: Diagnosis connector
The code 42 is indicated when the vehicle was subject-
ed to a light impact which was not big enough to cause
the air bag to deploy and, therefore, the upstream igni- Test terminal Earth
tion circuit functioned temporarily. In such case, the (ECU-T) terminal (E)
ECU resumes the normal operation later. Hence, the
ECU can be used again by canceling the code accord-
ing to the diagnosis code canceling method. When the
output of this code is attributable to causes other than
the malfunctioning ECU, no voltage has been applied
JBE00287-05126
to the circuit during the check of the preceding item
1.(4), (5) or item 2.(3), (4).
(1) If the battery voltage is applied to the terminal during

the check of the preceding item 1.(4), (5) or item 2.(3),
(4), the ECU is regarded as malfunctioning. (The ECU
can not resume its normal operation regardless of
causes.) It is necessary to replace the air bag ECU.
(2) As for the replacing procedure of air bag ECU, refer to
page BE61.
JBE00288-05127

BE83
NOTE:
This code is outputted when the air bag system were
operated. This diagnosis code can not be canceled and
the air bag ECU can not be used again. It is necessary
to replace them.
WARNING:
Refer to the disposal procedure for the air bag at DIS-
POSAL PROCEDURE FOR AIR BAG.
JBE00289-05128

Possible cause for malfunction: Malfunction of ECU
NOTE:
This code indicates that the ECU is malfunctioning.
This diagnosis code can not be canceled. Therefore,
the air bag ECU can not be used again. It is necessary
to replace the air bag ECU.
CAUTION:
The G sensor is built in the air bag ECU. If the ECU is
dropped once, the reliability of CPU and G sensor can JBE00290-05129
not be assured. Therefore, the air bag ECU can not be

used again. Extreme care must be exercised as to its
handling.
DISPOSAL PROCEDURE FOR AIR BAG

Disposal of vehicles with air bag system
WARNING:
When disposing the vehicles with the air bag system,
deploy the air bag while it is mounted on the vehicle.
JBE00291-05130
1. Disposal procedure for air bag in drivers seat

(1) Turn off the ignition switch. Wait for 60 seconds.
IG [OFF]
(2) Prepare a 12-V battery for automotive use.

at the vehicle wire harness side from the air bag ECU. JBE00292-05131
(4) Using a pincette or a screwdriver having a slim end,

remove the short circuit bride at the terminals 6 and 7 Short circuit
bridge
of the disconnected connector.
(5) Prepare two wires for automotive use, each of which
measures more than six meters long.
WARNING:
Connect the end of one wire with the end of the other
wire so that they may be shorted.
Connector
(6) Connect the wires prepared in Step (5) above to the Air bag ECU
connector terminals 6 and 7. JBE00293-05132

BE84
WARNING: 6 7
This connecting operation to the connector should be
performed by one person, not by a joint work of plural
operators, so as to avoid mistakes.
During this operation, there is the possibility that the air Wire
bag may be deployed accidentally. Therefore, be sure
to give a warning to other persons so that they may get
out of the vehicle or may be kept away from the area
five meters from the vehicle. Connector
Air bag ECU
JBE00294-05133
(7) The shorted section of the wires should be kept five

meters or more away from the vehicle, as shown in the
figure.
CAUTION:
Be sure to give a warning to other persons about a big
noise that will be emitted at the time of the air bag de-
ployment.
The window glass should be closed in advance.
NOTE:
Concerning the description of open wire of the JBE00295-05134
squibpage BE71 and BE76, be sure to temporarily

measure a resistance wires as right figure.
(8) Disconnect the wires that have been shorted. Connect

one wire to the positive terminal of the battery; the
other wire to the negative terminal of the battery, there-
by deploying the air bag.
NOTE:
There is no need for identifying the polarity of the bat-
tery.
JBE00296-05135
WARNING:
Immediately after the deployment of the air bag, the ve-
hicle interior is filled with gas. Therefore, start the oper-
ation after gas is diffused.
Since the metal section of the gas generator is ex-
tremely hot, leave it at least for thirty minutes to allow it
to cool naturally.
(9) After the deployed air bag cools down completely, it

shall be sealed in a bag to be disposed.
WARNING:
Be sure to wear protective goggles and gloves during
this operation. After completion of the operation, gargle
and wash your hands. If you feel any abnormality in
your respiratory organs, follow the instruction of a doc-
tor.
JBE00297-05137

BE85
2. Disposal procedure of air bag at front passenger seat
(1) Turn off the ignition switch. Wait for 60 seconds.
(2) Prepare a 12-V battery for automotive use. IG [OFF]
JBE00298-05138

Short circuit
at the vehicle wire harness side from the air bag ECU bridge
connector.
(4) Using a pincette or a screwdriver having a slim end,
remove the short circuit bride at the terminals 2 and 3
of the disconnected connector.
(5) Prepare two wires for automotive use, each of which
measures more than six meters long. Connect the end
of one wire with the end of the other wire so that they Connector
may be shorted. Air bag ECU
JBE00299-05139
(6) Connect the wires prepared in Step (5) above to the 2 3

connector terminals 2 and 3.
WARNING:
This connecting operation to the connector should be
performed by one person, not by a joint work of plural
Wire
operators, so as to avoid mistakes.
During this operation, there is the possibility that the air
bag may be deployed accidentally. Therefore, be sure
to give a warning to other persons so that they may get Connector
out of the vehicle or may be kept away from the area Air bag ECU
five meters from the vehicle. JBE00300-05140
(7) The shorted section of the wires should be kept five

meters or more away from the vehicle, as shown in the
figure.
CAUTION:
ployment.
The window glass should be closed in advance.
JBE00301-05141

BE86
(8) Disconnect the wires that have been shorted. Connect
one wire to the positive terminal of the battery; the
other wire to the negative terminal of the battery, there-
by deploying the air bag.
NOTE:
tery.
WARNING:
Immediately after the deployment of the air bag, the ve-
hicle interior is filled with gas. Therefore, start the oper- JBE00302-05142
ation after gas is diffused.

Since the metal section of the gas generator is ex-
to cool naturally.
(9) After the deployed air bag cools down completely, it

shall be sealed in a bag to be disposed.
WARNING:
and wash your hands. If you feel any abnormality in JBE00303-05144
tor.
Disposal of air bag unit

CAUTION:
It is the best to dispose the air bag when they are in-
stalled in the vehicle. However, if it is unavoidable to
perform the pre-treatment for disposal for the unit itself,
follow the procedure given below.
JBE00304-05145
NOTE:
Items to be prepared
(1) 12-V battery for automotive use
12V
JBE00305-05146
(2) Two wires for automotive use, each measuring at least

10 meters long
An alligator clip is connected to each end of these
wires.
WARNING:
Connect the end of one wire with the end of the other
wire so that they may be shorted.
No switch shall be installed to these wires so as to pre-
vent accidents.
JBE00306-05147

BE87
(3) Protective goggles and gloves
(4) A bag for disposal
JBE00307-05148
(5) A spacious place whose radius is at least 10 meters

CAUTION:
Do not perform the pre-treatment for disposal for the air
bag on a windy or rainy day.
m
10
JBE00308-05149
1. Disposal procedure for air bag in drivers seat (steering

wheel pad)
IG [OFF]
(1) Turn off the ignition switch. Disconnect the negative
terminal of the battery from the vehicle cable terminal.
JBE00309-05150
(2) Turn off the ignition switch and wait at least for 60 sec-
onds. Remove the steering wheel pad assembly from
the steering wheel.
NOTE:
The steering wheel pad assembly is installed to the
steering wheel by means of TORX bolts.
JBE00310-05151
(3) Disconnect the connector of the steering wheel pad

Roll connector
assembly from the roll connector. Disconnect the con-
nector for horn. Connector
for horn
Connector
for squib
JBE00311-05152

BE88
WARNING:
When storing the steering pad assembly temporarily,
be sure to place it with the pad surface facing upward GOOD
Also the storing place shall be away from water and
rain.
JBE00312-05153
(4) Cut the wires at the squib connector of the steering

pad assembly. Remove the covering of each end of
the two cut wires about 10 mm.
WARNING: m
Connect the sections each other whose wire coverings 10 m
have been removed so that they may be shorted.
Cut out
JBE00313-05154
(5) Place the steering pad assembly at the center of the

prepared place. At this time, the pad surface should
face upward.
(6) Disconnect the shorted squib wires of the steering pad
assembly. Connect the alligator clip attached to the
end of the prepared 10m-long wire to each squib wire.
JBE00314-05155
(7) Place the prepared 12-V battery for automotive use at

a corner of the place. Bring nearby the shorted ends
of the wires which is extended from the steering pad
assembly.
WARNING:
ployment.
JBE00315-05156
(8) Disconnect the wire ends that have been shorted.

Connect one wire to the positive terminal of the bat-
tery; the other wire to the negative terminal of the bat-
tery, thereby deploying the air bag.
NOTE:
tery.
JBE00316-05157

BE89
(9) Since the metal section of the gas generator is ex-
to cool naturally. After the deployed air bag cools
down completely, it shall be sealed in a bag to be dis-
posed.
WARNING:
tor. JBE00317-05158
2. Disposal procedure of air bag in front passenger seat

IG [OFF]
(1) Turn off the ignition switch. Disconnect the vehicle bat-
tery cable terminal from the negative terminal of the
battery.
JBE00318-05159
2nd lock
Disconnect the connector which connects the wire
1st
lock
Airbag unit side

JBE00319-05160
(3) Remove the air bag unit assembly in the front passen-
ger seat.
NOTE:
Before removing the air bag unit assembly in the front
passenger seat, remove the instrument panel. As for
this procedure, refer to the section BO.
JBE00320-05161
WARNING:
When storing the air bag unit assembly in the front pas-
senger seat temporarily, be sure to place it with the pad
surface facing upward on a flat place which is not ex-
posed to direct sun rays. Also the storing place shall be
away from water and rain.
JBE00321-05162

BE90
(4) Cut the wires at the squib connector of the air bag unit
assembly. Remove the covering of the ends of the two
cut wires about 10 mm.
WARNING: m
Connect the sections each other whose wire coverings 10 m
have been removed so that they may be shorted.
Cut out
JBE00322-05163
(5) Place the air bag unit assembly at the center of the
prepared place. At this time, the pad surface should
face upward.
(6) Disconnect the shorted squib wires of the air bag unit
assembly. Connect the alligator clip attached to the
end of the prepared 10m-long wire to each squib wire.
JBE00323-05164
(7) Place the prepared 12-V battery for automotive use at

a corner of the place. Bring nearby the shorted ends
of the wires which is extended from the air bag unit as-
sembly.
WARNING:
The pad assembly should be secured by piled up tires,
as shown in the figure.
ployment.
JBE00324-05165
(8) Disconnect the wire ends that have been shorted.

Connect one wire to the positive terminal of the bat-
tery; the other wire to the negative terminal of the bat-
tery, thereby deploying the air bag.
NOTE:
tery.
JBE00325-05166
(9) Since the metal section of the gas generator is ex-

to cool naturally. After the deployed air bag cools
down completely, it shall be sealed in a bag to be dis-
posed.
WARNING:
tor. JBE00326-05167

BE91
IMMOBILIZER SYSTEM
COMPONENTS LAYOUT
Immobilizer ECU EFI ECU
JBE00327-06001
OUTLINE
This system consists of a transponder-built-in key, an antenna coil, an immobilizer ECU and EFI ECU.
In the immobilizer system for EFI gasoline engine, if the key ID code can not be collated or the rolling code
is not matched with each other, the EFI ECU stops the ignition and fuel injection, thereby stopping the en-
gine operation. The key ID code is a transponder intrinsic code, whereas the rolling code takes a different
value every time the engine is started. This code is renewed and memorized in the EFI ECU and immobiliz-
er ECU as the rolling code for the next starting.
JBE00328-06002

BE92
WIRING DIAGRAM
F/L ABS 50A ABS

Head lamp 30A H/L
Tail 40A TAIL
Back up 10A B/U
ACC ACC
IG No. 1 IG1
IG2
F/L AM 60A
IG No. 2
ST ST
IG SW
Main MAIN
Junction block N60 R02
ECU IG
Wire F/L 2.0
10 A
ACC
15 A
QB2 RC8
Immobilizer ECU QA0 QA1 QA2
IG ACC +B
SIO Coil (+) Coil () GND T W

Battery
QA3 QA4 QA5 QA6 QA8 QA7
Antenna coil
IG ABS ECU IMB REV

To EFI ECU T T W
ITC E VF
SIO
T
COL E COL ACC +B
+B ACC E
+ + Diagnosis connector
IG SIO T COL IND COL T SIO IG
IND

Wire harness side connector Immobilizer ECU connector
JBE00329-06003
COMPONENTS
1. Ignition key
The vehicle with the immobilizer system is provided with
three ignition keys; one black-covered master key and
two gray-covered sub keys. The transponder is built in
the cover of each of the three keys. Each key has a differ-
ent recorded ID code.
In this system, the operation/releasing of the system can
Transponder
be performed by comparing and collating the ID code
with the data memorized in the immobilizer ECU.
Although two sub keys are provided for the vehicle, up to JBE00330-06004
three keys can be registered, as required, by means of the

sub key registration function of the master key.

BE93
CAUTION:
The master key has the following functions. Utmost care must be paid as to its handling.
a. Using the master key (black cover), it is possible to perform the new registration and renewal of
the sub keys.
b. The black covered key is memorized as the master key at the time of factory shipment. However,
if the immobilizer ECU memory has been cleared at time of repairs, etc., the key used first to start
the engine will be registered as the master key in the immobilizer ECU.
This point should be kept in mind.
JBE00331-06005
2. Antenna coil
The antenna coil is provided at the circumference of the
ignition key cylinder. The antenna coil energizes the
transponder built in the ignition key. Also, the antenna coil
receives the ID code that is sent from the transponder and Antenna coil
will send it to the immobilizer ECU.
If any metal shielding, such as a key holder ring, exists
between the ignition key and the antenna coil, or if there is
open wire in the antenna coil or its circuit, it becomes im-
possible to read the ID code of the ignition key, thus being
unable to start the engine. JBE00332-06006
3. Immobilizer ECU
The immobilizer ECU collates the ID code sent from the
key transponder with the ID code recorded in the immobi-
lizer ECU. Only when the ID codes are matched with each
other, the immobilizer ECU sends the signal of continua-
tion of engine operation to the EFI ECU.
In order to memorize the ID code, the immobilizer ECU
employs a non-volatile ROM that retains the memorized
data even when the battery or backup fuse is disconnect-
ed. JBE00333-06007
Therefore, when you erase the ECU memory and register

the master key ID code newly, you have to erase the mem-
ory, using the diagnosis system (DS-21).
4. EFI ECU
In addition to the hitherto-employed functions as the con-
ventional engine control unit, the EFI ECU has the func-
tions as the immobilizer function whereby the ignition and
fuel injection are stopped if the ID codes can not be collat-
ed in the immobilizer ECU or in instances where the rolling
JBE00334-06008
codes can not be collated between the immobilizer ECU
and the EFI ECU.

BE94
TROUBLE-SHOOTING
TROUBLE-SHOOTING HINTS
Before checking the immobilizer system, check the diagnosis code of the EFI system to determine whether
the malfunction is caused by the immobilizer system or by the EFI system.
CAUTION:
In the immobilizer system, the system is composed with the same rolling code shared in common
among the ignition key, immobilizer ECU and EFI ECU. Hence, if the immobilizer ECU and/or EFI
ECU are replaced with that of another vehicle during the checking of the immobilizer ECU or EFI sys-
tem, the immobilizer system will be regarded as malfunctioning. Therefore, do not replace the immo-
bilizer ECU and/or EFI ECU with that of another vehicle unnecessarily.
If you have to replace the immobilizer ECU and/or EFI ECU, erase the rolling codes memorized in
the immobilizer ECU and EFI ECU. Then, register the ID code of the ignition key to the immobilizer
ECU.
Refer to service manual, Ref. No.9031.
DESCRIPTION
A self-diagnosis system is built in the ECU. If any abnormality should occur in the immobilizer system, the
self- diagnosis system memorizes the malfunction phenomenon in the ECU in the form of malfunction code
number.
When the test terminal of the check connector is connected with the ground terminal, the malfunction code
number that has been memorized in the ECU will be indicated in a form of blinking of the check lamp in the
SST.
This memorized malfunction code number is erased when the battery ground cable is disconnected from
the negative () terminal of the battery or when the backup fuse in the relay block assembly is disconnect-
ed with the ignition key switch turned off.
JBE00335-06009
READ OUT OF DIAGNOSIS CODE Diagnosis connector

1. Connect the test terminal of the check connector with the
ground terminal, using a jump wire.
2. Connect a check lamp between the terminals as illustra-
tion. Test terminal Earth
NOTE:
Prepare the following SST.
SST: 09991-87211-000
CAUTION:
As for the check lamp, make sure to use a LED (light JBE00336-06010
emitting diode) type. Bulb type check lamp is not suit-

Check lamp (LED)
able for this system.
3. Set the ignition switch to the ON position.

4. Read the diagnosis code by observing the number of
ABS ECU IMB
blinking of the indicator lamp. IG
T T W
REV
ITC E VF
SIO
T
Jump wire
Diagnosis connector
JBE00337-06011

BE95
EXPLANATION OF DIAGNOSIS CODE
1. Indication of normal code 0.25 Sec.
Glowing
The check lamp glows for 0.25 second, 0.25 second later
after the ignition switch has been turned ON. After a lapse
of 0.25 second, the check lamp again glows for 0.25 sec-
ond. Then, this pattern will be repeated.
Extinguished
0.25 Sec.
JBE00338-06012
2. Indication of malfunction code In case of malfunction code number 21

When a single malfunction code is indicated:
0.5 Sec.
The diagnosis malfunction code is composed of two 0.5 Sec.
digits. Those two numbers are indicated by blinking of 0.5 Sec.
the check lamp. Four seconds later after the ignition Glowing
switch has been turned on, the check lamp indicates
first the number of the tens digit of the diagnosis code
by blowing the same times as the number. The lamp Extinguished 4 Sec.
glows for 0.5 second each time and then it is extin-
1.5 Sec.
guished for 0.5 second. After a pause of 1.5 seconds,
the check lamp indicates the number of the units digit JBE00339-06013
of the diagnosis code by glowing the same times as

the number. In case of malfunction code number 21 and 31
The lamp glows for 0.5 second each time and then it is
extinguished for 0.5 second. Then, this pattern will be Glowing
repeated after a pause of 4.0 seconds.
When plural malfunction codes are indicated:

In cases where plural malfunction codes have been Extinguished 2.5 Sec.
4 Sec.
detected, the two-digit diagnosis codes are indicated
in the sequence of the code number, starting from a
JBE00340-06014
smaller number. Each diagnosis code is indicated in
above described pattern. A pause of 2.5 seconds oc-
curs between the outputs of respective diagnosis
codes, thus separating one from the others. After all of
the plural diagnosis codes that have been detected
are indicated, the check lamp is extinguished for four
seconds. Then, the detected plural diagnosis codes
will be indicated again.
3. Canceling of diagnosis code

IG OFF
To erase the diagnosis codes memorized in the ECU after
malfunctions have been repaired, disconnect the battery
ground cable from the negative () terminal of the battery
for at least 10 seconds with the ignition switch turned off.
JBE00341-06016

BE96
TABLE OF DIAGNOSIS CODES
Code Number of glowing of
Diagnosis item Diagnosis contents
No. check lamp
Malfunction of transponder When there is no reply from key transponder after the
coil has energized key transponder.
12 (This diagnosis code is cleared if ID code can be
read normally next time.)
Unmatching of ID codes When immobilizer ECU determines that an attempt
was made to start engine, using an unregistered key:
21
Unregistered ID codes When transponder code to immobilizer ECU is

unregistered:
23
(Code to backup RAM is not memorized.)
Abnormality of registration mode At time of registration of sub key, terminal T is not

31 connected to ground, or an attempt is made to make
registration, using a sub key.
(Code to backup RAM is not memorized.)
Faulty communication between When a signal of non-matching of code is received at
41 immobilizer ECU and EFI ECU time of communication with EFI ECU:
Non-matching of codes
Faulty communication between When reply of code has not been received within
42 immobilizer ECU and EFI ECU specified time from EFI ECU at time of
When there is no reply of code: communication with EFI ECU:
JBE00342-06020

1. Normal code is outputted.
NOTE:
Normal code is being outputted from immobilizer ECU. In this case, the followings are possible causes.
1. Open wire or short between immobilizer ECU and EFI
ECU
2. Immobilizer ECU malfunctioning
3. EFI system malfunctioning
No
Diagnosis code No. 81 of EFI ECU is indicated.
Yes
Check wiring harness that there is continuity between

immobilizer ECU (terminal 7) and EFI ECU (terminal 40).
OK NG
There is abnormality in EFI ECU and EFI system.
Check EFI system, referring to EF section.
Replace immobilizer ECU with a new one. Register key Repair or replace communication line between
newly. immobilizer ECU and EFI ECU.
JBE00343-06021

BE97
2. Diagnosis code No.12 is indicated.
NOTE:
Diagnosis code No. 12 is indicated. In this case, the followings are possible causes.
1. Poor contacts in ECU connector or terminal
2. Open wire or short in antenna coil or harness
3. Key transponder malfunctioning
Check that connector of immobilizer ECU is connected NG Connect connector properly. Start engine again.
properly.
NG
OK
Disconnect connector of immobilizer ECU. Check that NG Repair or replace antenna coil and harness between
there is continuity between terminals No. 3 and No. 9. antenna coil and ECU.
OK
Start engine, using master key or other sub key. NG Transponder which was used for first starting is faulty.
Make a new sub key and register if, or use another key.
NG
JBE00344-06022
There is abnormality in immobilizer ECU.

Replace ECU with a new one. Register key again.
NG
All key transponders are faulty.

Make keys newly and register keys again.
3. Diagnosis code No. 21 is indicated

NOTE:
Diagnosis code No. 21 is indicated. Refer to service manual, 9031.
Start engine again, using master key. OK ID code of key that was used for first starting is not
registered.
NG Register key, using registration funcion of master key.
Clear memories of immobilizer ECU and EFI ECU. OK Registration for master key and sub keys have been done
Register key again in key registration mode. properly.
Start engine again. Release key registration mode. Use vehicle under this
state.
NG
JBE00345-06023

Replace ECU with a new one. Register key newly.

BE98
4. Diagnosis code No. 23 is indicated.
Diagnosis code No. 23 is indicated.
Start engine again, using master key. OK ID code of key that was used for first starting is not
registered.
NG Register key, using registration funcion of master key.
Register master key and sup keys in key registration OK Registration for master key and sub keys have been done
mode. Start engine again. properly.
Release key registration mode. Use vehicle under this
NG state.

JBE00346-06024
5. Diagnosis code No. 31 is indicated.
Diagnosis code No. 31 is indicated.
Check that terminal T of immobilizer is connected with NG Connect terminal T of immobilizer with ground properly.
ground properly. Register sub key again. Start engine.
OK NG OK
Sub key have been registered properly.

Release key registration mode. Use vehicle under this
state.
OK
Check that master key is used properly in key registration NG Register sub key again, using master key.
mode. Start engine.
OK NG JBE00347-06025


BE99
6. Diagnosis code No. 41 is outputted.
NOTE:
Diagnosis code No. 41 is outputted. There are cases that this code is outputted when the
EFI ECU or immobilizer ECU is borrowed from other
vehicles.
Check that there is continuity between terminal No. 7 of NG Repair or replace communication line between immobilizer
immobilizer ECU and terminal No. 40 of EFI ECU. ECU and EFI ECU.
OK
Connect terminal T of check connector with ground. Start OK Register sub keys again.
engine, using master key. There is possibility that EFI ECU or immobilizer ECU has
been changed.
NG
Check that diagnosis code No. 81 of EFI system is No There is abnormality in EFI ECU and EFI system.
indicated. Check EFI system by referring to EF section.
Yes JBE00348-06026


BE100
7. Diagnosis code No. 42 is outputted.
Diagnosis code No. 42 is outputted.
Check that there is continuity between terminal No. 7 of NG Repair or replace communication line between immobilizer
immobilizer ECU and terminal No. 40 of EFI ECU. ECU and EFI ECU.
OK
OK
Connect terminal T of check connector with ground. Start Register sub keys again.
engine, using master key.
NG
Check that diagnosis code No. 81 of EFI system is No

indicated.
Yes
There is abnormality in EFI ECU and EFI

system.
Check EFI system by referring to EF
section.
JBE00349-06027


BE101
FUNCTION CHECK OF IMMOBILIZER SYSTEM
The function check of the immobilizer system can be performed by doing the following two checks.
1. Ensure that the engine starts by using the master key and sub key.
2. Ensure that the engine will not start with a key without the transponder.
In the check 1., the system can be checked easily by using the master key and sub key.
Now we explain that the check can be made in the following method as one of the check method of 2.
JBE00350-06030
Checking procedure
1. Wind a piece of aluminum foil or the like at around the
resin section of the key of the vehicle concerned.
(The aluminum foil shuts off the magnetic field, thus pre-
venting the transponder from being energized.)
JBE00351-06031
2. Start the engine with the key wound up with the aluminum
foil. Check that the engine will not start.
JBE00352-06032
3. Install the check lamp to the diagnosis connector.

Check lamp (LED)
Connect the jump wire between Test terminal and earth
terminal. Ensure that the diagnosis code No.12 is out-
putted.by the indicator lamp.
IG ABS ECU IMB REV

T T W
ITC E VF
SIO
T
Jump wire
Diagnosis connector
JBE00353-06033
4. After confirming the diagnosis code of immobilizer system

IG OFF
and EFI system, erase the diagnosis code No. 81 memo-
rized in the EFI ECU by removing the terminal () of the
battery.
JBE00354-06034

BE102
5. Ensure that the diagnosis code No.81 has been erased
and that the normal code is being outputted. Remove the
check lamp and jump wire from the diagnosis connector.
JBE00355-06035
REPLACEMENT AND INSTALLATION OF ANTENNA COIL

IG OFF
JBE00356-06036
2. Remove the instrument lower finish panel and steering col-

umn lower cover by loosening the attaching screws.
3. Loosen the steering column attaching bolts.
4. Remove the steering column upper cover.
5. Disconnect the connector of the antenna coil and remove
the wire band.
6. Removal of antenna coil.
(1) Loosen the antenna coil attaching screw.
(2) Remove the antenna coil from the ignition key cylinder.
7 Attach a new antenna coil to the ignition key cylinder and
tighten the attaching screw. JBE00357-06037
8. Attach a new wire band.
9. Connect the connector of the antenna coil.

10. Install the steering column upper cover.
11. Tighten the steering column attaching bolts and nuts.
Tightening Torque:
Nut, lower side 9.8 - 15.7 Nm
Bolt, upper side 14.7 - 21.6 Nm
JBE00358-06038
12. Install the steering column lower cover and instrument

lower finish panel with attaching screws.
JBE00359-06039

BE103
REGISTRATION OF SUB KEYS
The vehicle is provided with one master key and two sub
keys. However, up to three sub keys can be memorized in
the immobilizer ECU by using the sub key registration
function of the master key.
CAUTION:
The master key (black) has the sub key registration
function. Hence, be very careful not to lose or damage
the master key.
If the master key is lost or damaged, it is imperative to
erase the memory of the immobilizer ECU and to re- JBE00360-06040
register the master key and sub keys, using the diag-
Diagnosis connector
nosis system (DS-21).
(1) Connect the jump wire between test terminal and earth
terminal. Test terminal Earth
JBE00361-06041
(2) Start the engine, using the master key.

When the engine starts, the key registration mode is
assumed.
(3) Stop the engine. Within ten seconds after the engine
stopped, start the engine with the sub key.
When the engine starts, this sub key is memorized in
the immobilizer ECU.
(4) To register the next sub key, repeat the steps (1)
through (3).
CAUTION:
In the key registration mode, the memories of all sub JBE00362-06042
keys are erased. It is, therefore, imperative to register

the all sub keys when a new key is added.
(5) After all sub keys have been registered, remove the
jump wire from the diagnosis connector.
(6) Ensure that the engine starts with all keys.
JBE00363-06043

BE104
SSTs (Special service tools)
Shape Part No. Part name Use Remarks
To read the diagnosis

codes for checking
09991-87211-000 Diagnosis check wire BE94
ECU input/output
signals
JBE00364-07001
TIGHTENING TORQUE
Tightening torque
Tightening component Remarks
Nm kgf-m
Water temp. sender gauge Cylinder block 24.5 - 34.3 2.5 - 3.5
Fuel sender gauge Fuel tank 1.5 - 2.5 0.15 - 0.26
Steering column Support brackect (Lower side) 9.8 - 15.7 1.0 - 1.6 Nut
Steering column Support brackect (Upper side) 14.7 - 21.6 1.5 - 2.2 Bolt
Steering wheel Steering shaft 27.5 - 41.2 2.8 - 4.2
Steering wheel Steering wheel pad assembly 5.2 - 9.5 0.53 - 0.97 TORX bolt
Passengers side air bag Instrument panel 6.7 - 9.5 0.68 - 0.97 Bolt
JBE00365-07002

DAIHATSU
J100
HARNESS & WIRING DIAGRAM
GENERAL DESCRIPTION ....................... HW 2 O/D OFF SWITCH & DIFFERENTIAL

HANDLING PRECAUTION ................. HW 2 LOCK SWITCH ............................... HW26
WIRE SIZE & COLOR CODE .............. HW 3 WIRING HARNESS .................................. HW27
INSPECTION ...................................... HW 4 CONTENTS OF HARNESS
OPERATION OF LOCK TYPE DIAGRAM ....................................... HW27
CONNECTOR ............................... HW 6 WIRE, ENGINE ................................... HW28
TERMINAL REMOVAL WIRE, ENGINE, No.2 .......................... HW30
& INSTALLATION ......................... HW 6 WIRE, FRONT DOOR
ABBREVIATION CODE ....................... HW 7 (DRIVERS SEAT/RHD) ................... HW32
CIRCUIT DIAGRAM ................................. HW 9 WIRE, FRONT DOOR
STARTER & ALTERNATOR ................ HW 9 (PASSENGERS SEAT/RHD) ........... HW34
EFI SYSTEM ........................................ HW10 WIRE, FRONT DOOR
ABS SYSTEM ...................................... HW11 (DRIVERS SEAT/LHD) ................... HW36
AIR BAG SYSTEM .............................. HW12 WIRE, FRONT DOOR
IMMOBILIZER SYSTEM ...................... HW13 (PASSENGERS SEAT/LHD) ........... HW38
ITC SYSTEM ....................................... HW14 WIRE, REAR DOOR ............................ HW40
COMBINATION METER ...................... HW15 WIRE, BACK DOOR, No.1 .................. HW42
HEAD LAMP ....................................... HW16 WIRE, FLOOR (RHD) .......................... HW44
TAIL LAMP .......................................... HW17 WIRE, FLOOR (LHD) .......................... HW46
FRONT FOG LAMP, REAR FOG WIRE, FLOOR, No.3 (RHD) ................ HW48
LAMP & STOP LAMP ...................... HW18 WIRE, FLOOR, No.3 (LHD) ................. HW50
TURN, HAZARD & HORN ................... HW19 WIRE, COWL, RH (EC/RHD, AUS) ...... HW52
BACK-UP LAMP ................................. HW20 WIRE, COWL, RH (General/RHD) ....... HW54
INTERIOR LAMP ................................. HW21 WIRE, COWL, RH (EC/LHD) ............... HW56
HEATER & AIR CONDITIONER .......... HW22
POWER WINDOW .............................. HW23
WIRE, COWL, RH (General/LHD) ....... HW59
WIRE, COWL, LH (EC/RHD, AUS) ...... HW62
HW
WIPER, WASHER & WIRE, COWL, LH (General/RHD) ....... HW65
DEFOGGER .................................... HW24 WIRE, COWL, LH (EC/LHD) ............... HW68
ACCESSORY (REAR VIEW MIRROR WIRE, COWL, LH (General/LHD) ....... HW70
JHW00001-00001
& CIGARETTE LIGHTER) ............... HW25

HW2
GENERAL DESCRIPTION
HANDLING PRECAUTION
General instructions
1. Never pull the connectors or step on them during the wire
harness transport or assembly.
(Prevention of pulling-out of terminals, connector cracks,
deformation and so forth) Harness
2. Care must be exercised to ensure that no scratch is made
to the wire harness by burrs or edges during the wire har-
ness transport or assembly. JHW00002-00002
(Prevention of scratches to the outer trim, electrical insula-
tors and so forth)
3. Clamping method
In the case of resin clamps, ensure that the clamp section
is fitted in the body hole.
NOTE:
Ensure that the clamp will not be detached when it is
pulled lightly in the arrow-headed direction. (Correct) (Wrong)
(Prevention of interference due to the detachment of
the clamp)
JHW00003-00003
In the case of metal sheet welded clamps, be sure to

assemble the harness in such a way that the harness Clamp guide
will not come in contact with the welded surface.
(Prevention of wire harness damage due to welding
burrs)
In case that the locating guide of the clamp position or
the clamp mark is clamped, make sure that the clamp
is located within the guide. As for the clamp at the Clamping should be
clamp mark section, ensure that the clamping is made made at a point
at a point within 10 mm. between these points.
JHW00004-00004
(Prevention of slackness or interference)

Clamp mark
Clamping is made at a point

within 10 mm (0.39 inch).
JHW00005-00005
4. Terminals and connectors

Perform the connection of connectors positively.
Connector with lock Ensure that the
locking is made.
Connector without lock Connect the connector
positively until it stops.
JHW00006-00006

HW3
Retention by screws
When the tightening torque is specified, be sure to
observe the specification strictly.
(The tightening torque is posted in the table Terminal is bent.
separately.)
Ensure that the staked section may not come on the
assembling surface.
(Correct) (Wrong)
After completion of the tightening operation, lightly pull
out the terminal. Ensure that there is no slackness.
When performing other operations, care must be
exercised to ensure that no connected connector is JHW00007-00007
detached by pulling out the wire harness forcibly.
5. Work procedure for tightening-up type resin clamps

When the tightening-up type resin clamps are employed,
do not use any pliers, cutting pliers or the like.
<Reason>
Prevention of clamps being cut or scratched
Resin clamp Tool
JHW00008-00008
WIRE SIZE & COLOR CODE Code Gr Br B

For identification purpose, each wire has its own color. Color Gray Brown Black
Each color bears a code as described in the right table.
Code W R G
These codes are used in the wiring diagram and will be
helpful during trouble shooting. Color White Red Green
Code Y L O
Color Yellow Blue Orange
Code P Lg V
Color Pink Light green Violet
JHW00009-00009
The wire color comes in two kinds: single color and

composite color. In the case of single color, the whole
outer coat of the harness is of a single color.
In the case of composite color, a fine line of the second W
color is drawn on the harness basic color. White
In this case, the code is composed of the basic color
Black
code which comes first and the second color code
which comes after a hyphen.
W-B
White
JHW00010-00010
WARNING:
The wire diameter and capacity of each harness have
been determined to assure the normal operation of the
electrical system.
Hence, do not take power for accessories carelessly
through the original wiring harness. Failure to observe
this caution may cause system malfunction or fire.
JHW00011-00011

HW4
2A 3.00 W-R
Color code
Nominal section
Wire type
JHW00012-00012
Section area Permissible

Nominal section Diameter (mm)
(mm) current (A)
0.5 0.56 1.0 9

0.85 0.88 1.2 12
1.25 1.28 1.5 15
2.00 2.09 1.9 20
3.00 3.29 2.4 27
JHW00013-00013
INSPECTION
Tester (Volt/ohmmeter)
For the inspection, use a tester having an internal resistance
of more than 10 kilo ohm/V.
Use of a tester with a low internal resistance may cause
V
wrong measurement or secondary troubles. A

JHW00014-00014
Conventional type connector

When resistance measurement and/or voltage measurement
is conducted at the connector section, insert the measuring
probe from the back of the connector, being very careful not
to damage the harness-to-terminal connections.
JHW00015-00015
Water-proof type connector

When resistance measurement and/or voltage measurement
is conducted at the connector section, bring the measuring
probe into contact with the terminal at the connection side of
the connector.
Be very careful not to apply excessive force to the terminal at
the connector side. Failure to observe this caution may
deform the terminal, causing poor continuity.
As an alternative method, insert a male or female terminal into
the connector terminal or connect an adequate attachment.
JHW00016-00016

HW5
INSPECTION OF CIRCUIT WITH TESTER
If a diode is built in the circuit, perform continuity test by
changing the polarities of the measuring terminals.
In case of a general type tester, ensure that continuity exists
when the negative () lead of the tester is connected to the
positive (+) side of the diode; the positive (+) lead of the
tester to the negative () side of the diode. Also ensure that no
continuity exists when the polarities are changed.
JHW00017-00017
Since some testers have different polarities, be sure to read

the instruction manual of a tester to be used for the check
before using it.
JHW00018-00018
The inspection procedure for light emitting diodes (LED) is the

same as normal diodes. However, there may be cases where
the LED emits no light, unless a tester with LED check mode
is used. If an adequate tester is not available, apply the
battery voltage to the LED and ensure that the LED emits
light. JHW00019-00019
INSPECTION OF SHORT CIRCUIT

(1) Remove a melt fuse or fusible link.
(2) Disconnect all connectors for loads being applied to the Test lamp
melt fuse.
IG switch
(3) Connect a test lamp at the position where the melt fuse or
fusible link was installed.
(4) Search for the short circuit by providing the minimum Short A
conditions which make the test lamp glow.
(5) Perform repairs or wiring harness replacement, as
required. Fuse
Short B
Example
Short section Connecting conditions

A Ignition switch is turned ON.
B Ignition switch and switch A are turned ON. Short C
Battery
Ignition switch, switch A and switch B are turned ON
C with relay energized.
JHW00020-00020

HW6
OPERATION OF LOCK TYPE CONNECTOR
Disconnection Pull up
Press down
The lock type of the connector comes in a push release type,
a pull release type, a spring lock type, an one-way lock type
and so on.
After confirming the shape of the lock, unlock the lock.
Disconnect the connector while holding the connector by
hand.
NOTE:
Never pull the harness during the disconnection.
Be sure to pull out the connector straight so as not to
damage the terminal. Pull up
Connection
Perform the connection until the lock is completely engaged.
After the connection has been made, ensure that the lock is
engaged positively.
NOTE: Release the
lock by
Be sure to connect the connector straight so as not to suitable
damage the terminal. tool
JHW00021-00021
NOTE:
Disconnection and connection of each connector
should be kept at a minimum level. If unnecessary
disconnection or connection is repeated, it may cause
unexpected troubles such as poor continuity and
chattering.
JHW00022-00022
TERMINAL REMOVAL & INSTALLATION

Removal of terminal
Insert a miniature screwdriver through the opening section of
the connector into between the locking lug and the terminal.
While prying up the locking lug with the screwdriver, pull the Housing lance type
terminal backward.
Lance
<Metal lance type>
While pushing the lance with the screwdriver, pull the terminal Metal lance type
backward. JHW00023-00023
Installation of terminal
Push the terminal into the protruding section of the connector,
until the lock is engaged completely. Lightly pull the harness
to assure that the locking has been made completely.
<Metal lance type>

Insert the terminal into the connector, until lance is locked
completely. Lightly pull the harness to assure that the locking
has been made completely. JHW00024-00024

HW7
ABBREVIATION CODES
The abbreviation codes that appear in this service manual stand for the following, respectively.
ACC: Accessory
ACT: Actuator FUL: Fuel
A/C: Air conditioner F/WP: Front wiper
ALT: Alternator F/WSH: Front washer
AMP: Amplifier GND: Ground
ANTN: Antenna HAZ, HZD: Hazard
AT, A/T: Automatic transmission H BM: High beam
BATT: Battery H-LP: Head lamp
B/DR: Back door HR, HL: Horizontal (Right hand, Left hand)
BK/LP, B/L: Back-up lamp HTD: Heated
BLR: Blower HTR: Heater
BNDR: Binder H.M: High mount
BRK: Brake IDUP, I/UP: Idle up
BST: Boost IG: Ignition
B/U, B/UP: Back-up ILM: Illumination
BUZ, BZR: Buzzer IMB,
CAST: Cassette, Cassette tape player IMMOBI: Immobilizer
CHG: Charge IND: Indicator
CIG: Cigarette lighter INJ: Injector
CLA: Clearance ITC: Integrated timer controller
CLT: Clutch LEV: Level, Leveling
COL: Coil LGHNG: Lighting
COM: Common, Combination LGT: Light
CON: Connector LH: Left hand
CON, CTR: Control LOK: Lock
CS: Collision sensor LP: Lamp
CTY: Courtesy LTR: Lighter
CWL: Cowl LUG: Luggage
DEF: Defroster LVLIG: Leveling
DIF, DIFF: Differential J/B: Junction block
DIM: Dimmer J/C: Junction
DIOD: Diode MAG, MG: Magnet
DIS: Distributor MAI: Main
D/L: Door lock MAS: Master
DR: Door MET: Meter
ECU: Electronic control unit MGC: Magnet clutch
ENG, E/G: Engine MIR: Mirror
ETH: Earth MLT: Multi-
EVP: Fuel evaporative control system MO, MTR: Motor
EXG: Exhaust gas NSS: Neutral start switch
FD: Fender O/D: Over drive
FR: Front O/D CUT: Over drive cut, over drive off
FRRH: Front door (RH) O/LEV: Oil level
FRLH: Front door (LH) PK: Parking
F/P: Fuel pump PKB: Parking brake
F.L, F/L: Fusible link PMNT: Permanent
PRES: Pressure
JHW00025-00025

HW8
PSI: Position
P/W: Power window
PU: Pulse
R/B: Relay block
RDFN: Radiator fan
RDI: Radiator
RESSTR: Resistor
REV: Revolution
RLY: relay
RH: Right hand
RNG: Range
RR: Rear
RRLH: Rear door (LH)
RRRH: Rear door (RH)
RTL: Retractable
R/TRN: Rear turn signal lamp
R/WIP: Rear wiper
SB: Seat belt
SID: Side
SLD, SOL: Solenoid
SP, SPR: Speaker
SPD: Speed
SSR: Sensor
ST: Starter
SW: Switch
T/F: Transfer
THA: Air thermometer
THEMSTR: Thermistor
THRM: Thermometer
THRTL: Throttle
THW: Water thermometer
TML, TMNL: Terminal
TL: Tail lamp
TRN: Turn
U/L: Unlock
ULSW: Unlock switch
VR, VL: Vertical (Right hand, Left hand)
VSV: Vacuum switching valve
WIP: Wiper
WRG, WRN: Warning
WSH: Washer
WTOW: Wire to wire
JHW00026-00026

F/L ABS 50A ABS
Head lamp 30A H/L
Tail 40A TAIL
Back up 10A B/U
ACC ACC
IG No. 1 IG1
IG No. 2 IG2
ST ST
IG SW
Main MAIN
CIRCUIT DIAGRAM

F/L AM 60A
STARTER & ALTERNATOR
For M/T
M15
For M/T
Junction block N59
Wire F/L 2.0

R/B
10 A
Starter relay
Engine
M14 M07
O20
To EFI ECU
To EFI ECU
Battery
(for A/T)
O18 O19
B IG
P N
M02 L O21
To Charge lamp (Meter)
OD9
Neutral starter
SW only for A/T
Motor
Starter
STARTER ALTERNATOR
JHW00027-00101
HW9
HW10
EFI SYSTEM
To heater resister
SW
5
SIO AC
To A/C dual pressure SW
BLW
To heater relay
525354555657585960 616263 64
20212223242526272829303132
6
To off board connector
To heater blower SW
40
(SIO)
Check engine lamp To head lamp fuse
CONNECTOR A
W
(Combination meter)
10
H/L
Idle up VSV
37
ECU Terminal
VSV1
To head lamp
60
To defogger SW
Idle up VSV(for A/C)
DEF
VSV3
36
3334353637383940 414243
1 2 3 4 5 6 7 8 9 10 11
58
To defogger
CONNECTOR B
E1 E01 E02
Idle up VSV(for A/T)
62 63
VSV2
59
52
#4
E2
#20
20
31
#2
A/C evap.
temp sensor
#3
ACEV
#10
3
32
#1
Injector
39
(T) Off board
VF T
(VF) connector
28
42
ALT
Alternator
PSW
A/C relay Throttle

KNK MGC
Position
54
1
sensor
A/C
26
Intake
24
10A
VC PIM
Magnet manifold
pressure
M
clutch
34
sensor
FC2 FC1
Fuel
23
Fuel pump relay pumo Intake air

ECU IG
temp.
sensor
THA
33
10A
57
To warning
+B2
Cooling lamp
43
EFI main relay water

R/B
temp.
THW
EFI sensor
BAT +B1
25
11
15A
Oxygen
OX
2
Back-up 10A
sensor
56
To radio
Off board
To ABS
connector
REV
(REV)
41
Ignition coil Tacho Vehicle

meter speed
Engine
sensor
SPD
10A Ignition coil

N+ N
IG2
Crank
21 53
angle
29
sensor
IG No. 1
IG No. 2
IG1
Main
ACC
ST
To A/T
64
neutral
A/T
starter SW
38
IG SW
To spark
plug
AM60A
R/B
A/T starter relay

Starter
Wire F/L 2.0 motor
JHW00028-00102

HW11
ABS SYSTEM
ABS F/L
Back-up fuse ABS ECU 1 1

38 BAT +BS +BM GND
AM IG SW(IG2) ECU IG fuse MR MR 4
1 18 +B 4 4
SR SR
36 ECUT 5 5
t rq r q
Diagnosis
Tail fuse STOP fuse connector Body ground
14 ABST solenoid
stop lamp relay
switch 11 SIO Motor relay
e w e w
37 STP R+ 3 3
Front vehicle speed R+

BS BM
sensor (right) 2 2
6 FR+
stop 7 FR
lamp Front vehicle speed
sensor (left) 12 10
26 FL+ AST
BS BM
AST 24 11
Battery
27 FL SFRH
SFRH 8 4
Rear vehicle speed
SFRR
sensor (right) SFRR 29 8
31 RR+
SFLH M
32 RR SFLH 1 3
Rear vehicle speed
SFLR
sensor (left) SFLR 2 7 BS
9 RL+
SRH Inspection
10 RL SRH 22 1 diode
SRR WA
SRR 23 5
2 GND MT
9 13
IG GS1 3 35 GS1 Actuator
Body ground
GS2 4 15 GS2
Gravity
sensor MT 25
GST 6 13 GST
GGND 1 34 GGND
WA 41 Gauge fuse
19 GND ABS Warning lamp
40 GND
Body ground
JHW00029-00103

F/L ABS 50A ABS
Head lamp 30A H/L
HW12
Tail 40A TAIL

Back up 10A B/U
ACC ACC
AIR BAG SYSTEM
IG No. 1 IG1
IG No. 2 IG2
ST ST
IG SW
Main MAIN
Junction block N59 N60 Air bag ECU connector
F/L AM 60A

10 A
10 A
10 A
T10 T09 T44 T26 T12 T11 T28
Air bag
Engine
Gauge/Back
Wire F/L 2.0

Warning lamp H67 T45 N31
(Combination meter) H61 T14 A B T02 T01
Air bag ECU
Battery
T01 IG 1
Diode
T02 IG 2 circuit Back-up Safing
T37 condenser sensor
T26 W D+ T11
T28 TC Squib D
To diagnosis connector D T12
(ECU T) Ignition
G sensor transistor P+ T09
T44 SIO CPU diagnosis
To diagnosis connector Interface P T10 Squib P
collision Ignition
(SIO) evaluation
Diagnosis transistor
(Diagnosis connector) code memory
ABS ECU IMB E1

IG REV
T T W T14
ITC E VF
SIO
T
JHW00030-00104
F/L ABS 50A ABS
Head lamp 30A H/L
Tail 40A TAIL
Back up 10A B/U
ACC ACC
IG No. 1 IG1
IMMOBILIZER SYSTEM

IG No. 2 IG2
ST ST
IG SW
Main MAIN
Junction block N60 R02
F/L AM 60A
10 A
15 A
ACC
ECU IG
QB2 RC8
Immobilizer ECU connector
Wire F/L 2.0

Immobilizer ECU QA0 QA1 QA2
IG ACC +B QA2 QA1 QA4 QA6
SIO Coil (+) Coil () GND T W QA0 QA3 QA8 QA5 QA7
Battery
QA3 QA4 QA5 QA6 QA8 QA7
Antenna coil
IG ABS ECU IMB REV

To EFI ECU T T W
ITC E VF
SIO
T
Diagnosis connector
JHW00031-00105
HW13
F/L ABS 50A ABS
Head lamp 30A H/L
Tail 40A TAIL
Back up 10A B/U
ITC SYSTEM
HW14
ACC ACC
IG No. 1 IG1
IG No. 2 IG2
ST ST
IG SW
Main MAIN
Junction block OF2 N59 F70 N59 CA2
F/L AM 60A
Buzzer
20 A
Stop 10 A
Wiper/Turn
Door lock 15 A
Gauge 10 A

Wire F/L 2.0
Q17 H67 F65 F66 E44
RH LH
Battery
Courtesy SW
HZD TRN
RH LH
Turn signal lamp OFF
Room lamp
Flasher relay
Multi-use lever
Turn signal indicator
ON DOOR
SW
ITC ECU Q47 QB3 QC7 QB7 QB5 QC4 QB9 QC5 QB4 QB6
+B IG1 CHZD T/H CHR CHL CFL FL+ DCSD CRL
Buzzer
SPD CS1 CS UKS E1 ULM LKM T
Q34 QC3 QC2 QB8 ZT3 Q51 Q50 QC1
ITC ECU connector (wire harness side) Door lock Diagnosis connector
D motor
CHL FL+ T/H T IG1 E1 LKM ABS ECU IMB
CSD M IG REV
S
Collision T T W
N
C
N
CHR CFL CRL UKS SPD CS1 +B CS ULM ITC
S
HZD sensor SIO E VF
Vehicle
M T
M
Door lock SW
speed sensor
M
JHW00032-00106
HW15
COMBINATION METER
Illumination
B13
L
C3
2 C2
D
C1
N
C5 H26 C1
P
Connector C
C4 H25
R H24
C10 H29
H27
C6 Starter relay coil
10 P
M20
Air bag B6 Air bag ECU

warning H28 C10
circuit
A12 EFI ECU

H52 B1
(At wire harness side)

Seat belt SW
X01
A13 H05
Connector B
WB0
B3 EFI ECU T37
H61
13 P
H22
ABS B5 ABS ECU H20
Z83
Oil pressure SW X03
B4 F19
Tail Tail C21 B13
40A SW Parking brake SW
AUS. only
Brake fluid level SW F21 A1
B7 A10 Z08
Gauge
Center diff. lock
10A _ +
A9 Alternator L Connector A
Turn flasher relay
16 P
Acc
O20
IG1
ST
A14 G06
R N58
A1
H80
B12 L J/B earth H77
A2 A10
A15 A16
Rear fog switch
A13
F/L AM60A
EC only
Reed switch
EFI ECU B11
Fuel sender
B8
F/L 2.0 B9
Temperature sender
B10 Gauge earth
JHW00033-00107

F/L ABS 50A ABS
Head lamp 30A H/L
HEAD LAMP
HW16
Tail 40A TAIL

Back up 10A B/U
ACC ACC
IG No. 1 IG1
IG No. 2 IG2
ST ST
IG SW
Main MAIN
F/L AM 60A

L H
Pass
Head lamp
Lighting SW
SW
A61 Head lamp
Wire F/L 2.0

ZM7
A17
leveling unit LH
A18 A23
A63
AA6
Battery
0
A69 1
2
Head lamp
leveling SW
Head lamp LH
Head lamp RH
3
A98 A01 A05 4
High beam
indicator ZM9
(Combination A56
meter )
H
A54 Head lamp
Head lamp LH ZM8
leveling unit RH
L
Head lamp RH
L
JHW00034-00108
HW17
TAIL LAMP & LICENSE PLATE LAMP
MAIN
ACC
TAIL
HRN/HAZ
ABS
B/U
H/L
IG1
IG2
ST
Clearance lamp RH
C10
Z27
Tail lamp RH
C07
Z05
Buzzer
License plate lamp RH
C16
Z79
C09 License plate lamp LH
C17
Z78
Tail lamp LH
C08
C80
Z06
Clearance lamp LH
Tail SW Tail
C12
CM1
Z28
C06
10 A
Tuner illumination
H78
C28
Floor console illumination

Junction block
CE0
ZR8
CA1
Meter illumination
40A
Horn,Hazard 15A
10A
50A
Head lamp 30A
IG No. 1
IG No. 2
Main
ACC
C21
Z08
ST
F/L ABS
Back up
Heater control illumination

Tail
IG SW
C19
Z23
F/L AM 60A
Wire F/L 2.0 Battery
JHW00035-00109

HW18
FRONT FOG LAMP, REAR FOG LAMP & STOP LAMP
MAIN
ACC
TAIL
HRN/HAZ
ABS
B/U
H/L
IG1
IG2
High mounted
ST
stop lamp
E16
Z68
E11
Stop lamp
OF2
E10
E28
Stop RH
E14
Z05
Junction block 10 A
Stop lamp SW
Stop lamp
LH
E15
Z06
RF SW
Rear fog lamp
(Multi-use lever)
D71
D61
CJ7
C40
C64
CJ6
Rear fog
lamp SW
D58
C38
Rear fog lamp indicator

C39
(Combination meter)
F70
H80
Z08
Gauge Courtesy SW
Buzzer
Back
D19
N59
10 A
Front fog lamp LH

Tail SW
(Multi-use Front fog lamp
C25
ZD2
lever) SW
Fog
CM1
CE7
C24
C23
10 A Front fog lamp LH

Horn,Hazard 15A
10A
40A
50A
Head lamp 30A
IG No. 1
IG No. 2
Junction block
Main
ACC
C26
ZD3
ST
F/L ABS
Back up
Tail
IG SW
F/L AM 60A
Battery
Wire F/L 2.0
JHW00036-00110

F/L ABS 50A ABS
Head lamp 30A H/L
Tail 40A TAIL
Back up 10A B/U
ACC ACC
IG No. 1 IG1
IG No. 2 IG2
ST ST
IG SW
Main MAIN

TURN, HAZARD & HORN
F/L AM 60A
Multi-use
Junction block lever SW
Turn / Wiper
N59 F66 F32 Turn
F48
F70 20 A F65 F47
Hazard
Wire F/L 2.0

Flasher relay
LH F60
Horn E02
RH
F64 F62 LH
Battery
F63 F61
RH
E03
F04 F55
F44 F52
F53 F43
F54 F06 E19
F05 F11 F09 F19 F07 F16 F14 F21

Horn SW
Turn signal
Turn signal
Side turn lamp RH
Front turn lamp RH
Rear turn lamp RH
Side turn lamp LH

indicator lamp RH
Z06 ZM6 ZM3 Z05 ZM5 ZM4 Z08
Front turn lamp LH

Z08
Rear turn lamp LH

indicator lamp LH
JHW00037-00111
HW19
HW20
F/L ABS 50A ABS

BACK-UP LAMP
Head lamp 30A H/L

Tail 40A TAIL
Back up 10A B/U
ACC ACC
IG No. 1 IG1
IG No. 2 IG2
ST ST
IG SW
Main MAIN

F/L AM 60A
Buzzer
10 A
10 A
/Back
/Back
Gauge
Gauge
[M/T model] [A/T model]
Wire F/L 2.0

G21 G21 D39
G02 G02
Neutral
Back-up
start SW
lamp SW
G03 G03
Battery
G05 G04
G05 G04 H28
Back-up Back-up
lamp LH lamp RH Back-up Back-up Indicator
lamp LH lamp RH (Combination
G16 G15 meter)
G16 G15 Z08
JHW00038-00112
HW21
INTERIOR LAMP
MAIN
ACC
TAIL
HRN/HAZ
ABS
B/U
H/L
IG1
IG2
ST
Luggage room
lamp
Stop
10 A
Gauge Back door

& Back courtesy SW
10 A
Courtesy SW
FR RH
Buzzer
Courtesy SW
J/B
FR RH
Room lamp Courtesy SW

Horn,Hazard 15A
10A
50A
Head lamp 30A
40A
FR RH
IG No. 1
IG No. 2
Door
Off
Main
ACC
ST
F/L ABS
Back up
Courtesy SW
On
Tail
FR RH
IG SW
F/L AM 60A
F/L 2.0
JHW00039-00113

F/L ABS 50A ABS
Head lamp 30A H/L
Tail 40A TAIL
Back up 10A B/U
HW22
EFI 15 A
A/C 10 A
Heater 20 A
ACC ACC
IG No. 1 IG1
IG No. 2 IG2
ST ST
IG SW
Main MAIN
Junction block N59
F/L AM 60A
HEATER & AIR CONDITIONER
Relay block

K12
10 A
/Back
Gauge
relay
H67
relay
H79
Heater
EFI main
A/C SW
Wire F/L 2.0

KC6
A/C relay
SW
OC9 K23 KG9 K11 K13

KV2
K02
KP1
Air conditioner
K18 KU9
motor
Battery
M K99
A/C VSV
K30
K19 Heater blower
Magnet clutch
KV1
SW
Resistor
KP6
K07
K44
K05
EFI ECU XQ6 XN4 XS0

VSV3 KNK MGC
K04 K06 K08
Dual pressure
KP7
SW
E2 ACEV ACSW BLW

ZQ4 XP8 XS4 XK3
Z21
Heater blower

KK4 KP5
Thermistor
JHW00040-00114
F/L ABS 50A ABS
Head lamp 30A H/L
Tail 40A TAIL
POWER WINDOW
Back up 10A B/U

ACC ACC
IG No. 1 IG1
IG No. 2 IG2

ST ST
IG SW
Main MAIN
Junction block N59
F/L AM 60A
30 A
POWER
PD4
Wire F/L 2.0

Master SW P22
Sub SW
P29 P30 P31 Cancel
Z61
Battery
P42 P43
P23 P24 P27 P28
Power window motor Power window motor

(Passenger's seat side) (Driver's seat side)
M P25 M P26
P44 P45
JHW00041-00115
HW23
F/L ABS 50A ABS
HW24
Head lamp 30A H/L

Tail 40A TAIL
Back up 10A B/U
ACC ACC
IG No. 1 IG1
IG No. 2 IG2
ST ST
IG SW
Main MAIN
F/L AM 60A

WIPER, WASHER & DEFOGGER
20 A
Wiper
15 A
/ Turn
I01
Defogger
Wire F/L 2.0

Front wiper F66 I65 I66 I67 K98
washer SW I10 K27
SW
I03
INT I29
I28 I31
motor
Battery
M W 2 1
M
Rear defogger
OFF INT K28 Z42
Front Washer
motor
ZQ9
Rear wiper
Rear wiper
washer SW
Z14 I60 I57 I56 I41 Defogger K29
I54 Z18 I30
I26
I20 I18 I24 I22
Front wiper Rear Washer
M motor
motor
M
ZN0 ZZ6
JHW00042-00116
F/L ABS 50A ABS
Head lamp 30A H/L
Tail 40A TAIL
Back up 10A B/U
ACC ACC
IG No. 1 IG1
IG No. 2 IG2

ST ST
IG SW
Main MAIN
Junction block R02
Junction block R02
F/L AM 60A
15 A
ACC
ACC
15 A
RC7
Rear view mirror SW RC7
Wire F/L 2.0

B
E
C MV MH
Battery
Cigarette lighter R15
C VL VR HL HR
Rear view mirror Rear view mirror
unit (Left side) C C unit (Right side)
ACCESSORY (REAR VIEW MIRROR & CIGARETTE LIGHTER)
Z31
M M M M
V H V H
JHW00043-00117
HW25
HW26
O/D OFF SWITCH & DIFFERENTIAL LOCK SWITCH
MAIN
ACC
TAIL
HRN/HAZ
ABS
B/U
H/L
IG1
IG2
ST
VD8
VD9
Transfer VSV 2
Gauge
VD2
VD1
VD6
VD7
H67
N59
/Back
10 A
Junction block
Differential Transfer VSV 1

lock SW
H77
Indicator
lamp
Over Drive off Over Drive off

relay solenoid
H37
V73
V72
V74
Gauge
H35
H61
N59
H67
ZJ3
H52
/Back
10 A
Junction block
O/D OFF Over Drive SW

Indicator
lamp
Horn,Hazard 15A
10A
50A
Head lamp 30A
40A
IG No. 1
IG No. 2
Main
ACC
ST
F/L ABS
Back up
Tail
IG SW
F/L AM 60A
Wire F/L 2.0 Battery
JHW00044-00118

HW27
WIRING HARNESS
10 9
3 4
5 5
7 8
JHW00045-00200
CONTENTS OF HARNESS DIAGRAM

WIRE NAME WIRE NAME
1 WIRE, ENGINE 7 WIRE, FLOOR
2 WIRE, ENGINE, No.2 8 WIRE, FLOOR, No.3
3 WIRE, FRONT DOOR (DRIVER'S SIDE) 9 WIRE, COWL, RH
4 WIRE, FRONT DOOR (PASSENGER'S SIDE) 10 WIRE, COWL, LH
5 WIRE, REAR DOOR
6 WIRE, BACK DOOR, No.1
JHW00046-00201

HW28
WIRE, ENGINE
From To From To
Location Terminal Terminal Location Location Terminal Terminal Location
MET (CHG) O20 O21 ALT (L) E/G J/C1 (E10) #1K N81 IG COIL NO2 (ECUE)
E/G WP BNDR1 (01) #BA O19 ALT (IG) Connect to X38~X46 X99 THROTTLE SSR (VC)
E/G WP BNDR1 (01) #BA N76 J/B FUSE ENG (L1) Connect to X53~X96 X98 FUL INJ NO4 ()
E/G WP BNDR1 (01) #BA N05 IG COIL (+) Connect to X51 X55 FUL INJ NO3 ()
E/G WP BNDR1 (01) #BA N53 IG COIL NO2 (+) E/G WP BNDR2 (01) #CA XF2 I/UP VSV2 (+)
ALT (IG) O19 XQ4 EFI ECU (ALTC) I/UP VSV2 () XF3 X10 EFI ECU (VSV2)
MET THRM G (+) H20 H21 THRM SENDER (+) 82121-87402
MET OIL PRES () H05 H06 OIL PRESS SW (B)

E/G WP BNDR3 (01) #DA ZQ4 EFI ECU (E2)
E/G WP BNDR3 (01) #DA KK4 A/C THEMSTR ()
MG CLT L SSR (B) KU9 XN4 EFI ECU (KNK)
E/G BNDR1 (E01) #0A KV1 MG CLT L SSR (E)
A/C I/UP VSV () K19 XQ6 EFI ECU (VSV3)
E/G J/C1 (E09) #IJ ZU2 IG COL SLD E (2)
E/G J/C1 (E06) #1F ZU4 IG COL SLD E (4)
IG COIL () N07 XS5 EFI ECU (IG1)
IG COIL NO2 () N54 XS6 EFI ECU (IG2)
EFI ECU (VC) X38 X46 EFI PRES SSR (VC)
CAM POSI SSR (N +) N66 XS1 EFI ECU (N +)
CAM POSI SSR (N ) N74 XS2 EFI ECU (N )
E/G BNDR1 (E01) #0A Z0B CAM POSI SLD (E01)
EFI ECU (OX) X27 X28 O2 SSR (+)
E/G BNDR1 (E01) #0A ZT6 O2 SSR SLD (E2)
EFI ECU (THW) X29 X30 EFI TH W SSR (+)
E/G WP BNDR3 (01) #DA X31 EFI TH W SSR ()
EFI ECU (THA) X32 X33 EFI TH A SSR (+)
E/G WP BNDR3 (01) #DA X34 EFI TH A SSR ()
EFI ECU (AUX1) XP0 XT2 RESISTOR1 (+)
EFI ECU (PIM) X43 X45 EFI PRES SSR (PIM)
E/G WP BNDR3 (01) #DA X44 EFI PRES SSR ()
EFI ECU (PSW) XL3 XT0 THRTL PSI SW (PSW)
E/G WP BNDR3 (01) #DA XT1 THRTL PSI SW ()
E/G WP BNDR3 (01) #DA XT3 RESISTOR1 ()
E/G BNDR1 (E01) #0A Z48 EFI ECU (EI)
EFI ECU (E01) Z47 Z50 ENG EARTH (E)
E/G J/C1 (E02) #1B ZX6 EFI ECU (E02)
E/G J/C1 (E11) #1L XK7 EFI ECU (PST)
E/G J/C1 (E01) #1A Z50 ENG EARTH (E)
E/G BNDR1 (E01) #0A Z49 ENG EARTH (E)
EFI ECU (VSV1) XH3 X09 I/UP VSV ()
E/G WP BNDR2 (01) #CA X08 I/UP VSV (+)
E/G WP BNDR2 (01) #CA X50 FUL INJ NO1 (+)
E/G WP BNDR2 (01) #CA #HD COWL R BNDR3 (04)
for LHD vehicle
E/G WP BNDR2 (01) #CA #RL COWL LH J/C9 (11)
for RHD vehicle
FUL INJ NO2 () X53 X96 EFI ECU (#20)
E/G WP BNDR2 (01) #CA X52 FUL INJ NO2(+)
FUL INJ NO1 () X51 X56 EFI ECU (#10)
E/G J/C1 (E07) #1G N80 IG COIL NO1 (ECUE)

WIRE, ENGINE
PRESS SSR
IG COIL #1, #4
X44 X45 X46
IN AIR SSR
N05 N07 N80 ZU4
X33
X34 FUL INJ
NO.3 THROTTLE
SSR
X55 X54
X99 XT1 XT0

THRM SDR & SW FUL INJ NO.2
FUL INJ NO.4 BNDR NO.2
X30 X31 #BA X53 X52
H21
CAM POSI SSR
X98 X97
N66 N74 Z0B #DA BNDR
NO.4
EFI ECU E/G

Z48 XS1 X38 X43 X29 XN4 XQ4 XS6 X96 X56 IG COIL #2, #3
O2 SSR
ZQ4 XS2 XL3 XK7 X27 X32 XQ6 X10 XH3 Z47 ZX6 XS5
ZT6 X28 N53 N54 N81
TO COWL WIRE RH ZU2
#RL
(RHD)
N76 K19 KK4
#HD
XPO O20 H05 H20 (LHD)
FUL INJ NO.1
X51 X50
J/C
#1L #1A #1F #1G
#0A #1B #1J #1K E/G EARTH
BNDR NO.1 8 8 O19
RESISTOR O21
ALT IG
Z50 Z49
XT2
XT3
X09 X08 #CA BNDR NO.3
XF3 XF2 I/U VSV 1
I/U VSV 2 A/T
H06 KV1 KU9
OIL PRESS SW A/C LOCK SSR
82121-87402
HW29
HW30
WIRE, ENGINE No. 2
From To
Location Terminal Terminal Location
R/B (+B) OC3 OD8 BATTERY (+)
R/B (+B) OC3 O18 ALT (B)
BATTERY () OD7 OE1 BATTERY (BODY)
BATTERY () OD7 OE0 BATTERY (M/T)
BATTERY (+B) OD2 OD9 STARTER (+B)
STARTER (ST) M02 M14 ST RLY (L)
F/L 2.0 OB5 OR6 F/L 2.0
82122-87401

WIRE, ENGINE No. 2
BODY EARTH

6 OE1
TO R/B ALT B
TO R/B, COWL 6 O18
8 OC3 M/T EARTH
M14 OE0 10
BATT (-)
OD7 8
OD9
ST B
OD8
M02
ST
OB5
OD2
F/L
BATT (+)
OB6 6
82122-87401
HW31
HW32
WIRE, FRONT DOOR (DRIVERS SEAT SIDE/RHD)
From To
COWL RH J/C5 (08) #GH R26 E MIRROR RH (C)
E MIRROR SW (VR) R19 R24 E MIRROR RH (V)
E MIRROR SW (HR) R21 R25 E MIRROR RH (H)
RADIO (SPR +) R10 R11 SP FR RH (+)
RADIO (SPR ) R12 R13 SP FR RH ()
D/L CTR RLY (ULSW) Q02 Q25 D/LOCK SW (U/L +)
COWL RH J/C1 (E04) #2D ZS1 D/LOCK SW (E)
COWL LH J/C4 (14) #FU Q66 D/L MTR FR D (LOK +)
COWL LH J/C4 (15) #FV Q65 D/L MTR FR D (U/L +)
COWL RH J/C1 (E05) #2E Z61 P/W MAS SW (E)
COWL RH J/C3 (04) #ED P22 P/W MAS SW (B)
P/W MAS SW (M/U +) P23 P25 P/W MTR FRRH (U +)
P/W MAS SW (M/D +) P24 P26 P/W MTR FRRH (D +)
P/W MAS SW (PU +) P27 P29 P/W SW FR P (U +)
P/W MAS SW (PD +) P28 P30 P/W SW FR P (D +)
P/W MAS SW (RLU +) P37 P39 P/W SW RRLH (U +)
P/W MAS SW (RLD +) P38 P40 P/W SW RRLH (D +)
P/W MAS SW (RRU +) P32 P34 P/W SW RRRH (U +)
P/W MAS SW (RRD +) P33 P35 P/W SW RRRH (D +)
82151-87401

P/W SW

P32 P33 P38 P37
P24 P23 Z61 P22 P27 P28
P/W MOTOR
P25
P26
DOOR LOCK SW
TO COWL MIRROR RH
WIRE RH Q25
SPEAKER ZS1
P35 P34 R13 R25 R26 R24
P40 P39 R11
WIRE, FRONT DOOR (DRIVERS SEAT SIDE/RHD)
TO COWL WIRE RH
#ED #2D Q02
#2E P30 P29 R12 R10 Q66 Q65
#FV #FU R21 #GH R19
D/L MOTOR
HW33
82151-87401
82151 87401
HW34
WIRE, FRONT DOOR (PASSENGERS SEAT SIDE/RHD)
From To
COWL RH J/C5 (09) #GJ R27 E MIRROR LH (C)
E MIRROR SW (HL) R20 R23 E MIRROR LH (H)
E MIRROR SW (VL) R18 R22 E MIRROR LH (V)
RADIO (SPL ) R08 R09 SP FR LH ()
RADIO (SPL +) R06 R07 SP FR LH (+)
COWL RH J/C4 (12) #FM Q28 D/L MTR FR P (LOK +)
COWL RH J/C4 (09) #FJ Q27 D/L MTR FR P (U/L +)
COWL RH J/C3 (05) #EE P31 P/W SW FR P (B)
P/W SW FR P (M/D +) P43 P45 P/W MTR FR P (D +)
P/W SW FR P (M/U +) P42 P44 P/W MTR FR P (U +)
82152-87401

P/W SW
P43 P30 P31 P42 P29
P/W MOTOR
P45
P44
MIRROR RH
SPEAKER
R09 R23 R27 R22
R07
WIRE, FRONT DOOR (PASSENGERS SEAT SIDE/RHD)
TO COWL WIRE LH D/L MOTOR

#EE #FJ #FM
P28 P27 R08 R06 Q28 Q27
R20 #GJ R18
82152-87401
HW35
HW36
WIRE, FRONT DOOR (DRIVERS SEAT SIDE/LHD)
From To
CWL LH J/C3 (12) #KM R27 E MIRROR LH (C)
D/L CTR RLY (ULSW) Q02 Q25 D/LOCK SW (U/L +)
COWL LH J/C1 (E04) #6D ZS1 D/LOCK SW (E)
COWL LH J/C3 (16) #KQ Q66 D/L MTR FR D (LOK +)
COWL LH J/C3 (15) #KP Q65 D/L MTR FR D (U/L +)
COWL LH J/C1 (E05) #6E Z61 P/W MAS SW (E)
COWL LH J/C4 (07) #LG P22 P/W MAS SW (B)
P/W MAS SW (M/U +) P23 P25 P/W MTR FRRH (U +)
P/W MAS SW (M/D +) P24 P26 P/W MTR FRRH (D +)
82152-87402

P/W SW

P27 P28
P23 Z61 P24 P22
P/W MOTOR
P26
P25
DOOR LOCK SW
MIRROR RH
Q25
SPEAKER ZS1
R09 R23 R27 R22
R07
WIRE, FRONT DOOR (DRIVERS SEAT SIDE/LHD)
TO COWL WIRE LH D/L MOTOR

#LG #5D Q02
#6E P30 P29 R08 R06 Q66 Q65
#KP#KQR20 #KM R18
HW37
82152-87402
82152 8740
HW38
WIRE, FRONT DOOR (PASSENGERS SEAT SIDE/LHD)
From To
COWL LH J/C3 (13) #KN R26 E MIRROR RH (C)
RADIO (SPR +) R10 R11 SP FR RH (+)
RADIO (SPR ) R12 R13 SP FR RH ()
COWL LH J/C3 (09) #KJ Q28 D/L MTR FR P (LOK +)
COWL LH J/C3 (06) #KF Q27 D/L MTR FR P (U/L +)
COWL LH J/C4 (08) #LH P31 P/W SW FR P (B)
P/W SW FR P (M/D +) P43 P45 P/W MTR FR P (D +)
P/W SW FR P (M/U +) P42 P44 P/W MTR FR P (U +)
82151-87402

P/W SW
P43 P30 P31 P29 P42
P/W MOTOR
P44
P45
MIRROR RH
SPEAKER
R13 R25 R26 R24
R11
WIRE, FRONT DOOR (PASSENGERS SEAT SIDE/LHD)
TO COWL WIRE RH D/L MOTOR

#LH #KF #KJ
P28 P27 R12 R10 Q28 Q27
R21 #KN R19
82151-87402
HW39
HW40
WIRE, REAR DOOR
From To
FLOOR J/C2 (13) #WN Q30 D/L MTR RRRH (LOK +)
FLOOR J/C2 (09) #WJ Q29 D/L MTR RRRH (U/L +)
P/W MAS SW (RRU +) P32 P34 P/W SW RRRH (U +)
P/W MAS SW (RRD +) P33 P35 P/W SW RRRH (D +)
FLOOR J/C1 (09) #SJ P36 P/W SW RRRH (B)
P/W SW RRRH (M/U +) P46 P48 P/W MTR RRRH (U +)
P/W SW RRRH (M/D +) P47 P49 P/W MTR RRRH (D +)
82153-87401

HW41
WIRE, REAR DOOR
TO FLOOR WIRE
#WN P32 #SJ
#WJ P33
P/W MOTOR
P48
P49
P47 P35 P36 P34 P46
P/W SW
D/L MOTOR
Q29 Q30
82153-87401

HW42
WIRE, BACK DOOR, No. 1
From To
FLOOR BNDR 2 (01) #UA E16 H. M. STOP LP (+)
BODY EARTH (RRRH) Z07 Z68 H. M. STOP LP ()
RR WIP MTR (+) I29 I67 J/B F/WP TRN (L3)
RR WIP MTR () I30 I31 RR WIP SW (B)
COWL LH J/C6 (05) #NE K29 DEF (+)
FLOOR BNDR1 (E01) #AA Z07 BODY EARTH (RRRH)
RADIO (SSR +) R28 R32 RR SP RH (+)
RADIO (SSR ) R29 R33 RR SP RH ()
RADIO (SRL ) R31 R35 RR SP LH ()
RADIO (SRL +) R30 R34 RR SP LH (+)
FLOOR J/C2 (12) #WM Q76 B/DR LOCK SW (LOK +)
FLOOR J/C 2 (08) #WH Q77 B/DR LOCK SW (U/L +)
FLOOR BNDR 2 (01) #UA E16 H. M. STOP LP (+)
BODY EARTH (RRRH) Z07 Z68 H. M. STOP LP ()
RR WIP MTR (+) I29 I67 J/B F/WP-TRN (L3)
FLOOR BNDR1 (E01) #AA K07 BODY EARTH (RRRH)
FLOOR J/C2 (08) #WH Q77 B/DR LOCK SW (U/L +)
82184-87401

WIRE, BACK DOOR, No. 1

TO
DEFOGGER D/L
MOTOR RR WIPER BK SP RH
TO BRAKE MTR
Z68 E16 K29 R33
LAMP WIRE BODY EARTH
Q77 Q76 R32
I30 I29
6 Z07
BK SP LH TO FLOOR WIRE
R35 #AA #WM #WH #NE #UA
R34 R30 R31 R28 R29 I67 I31
#AA #WH #UA

#WM I67 #NE I31
TO FLOOR WIRE
HW43
82184-87401
HW44
WIRE, FLOOR (RHD)
From To From To
COWL RH J/C5 (12) #GM C40 RR FOG LP (+) FLOOR J/C2 (11) #WL Q32 D/L MTR RRLH (LOK +)
FLOOR BNDR1 (E01) #AA C64 RR FOG LP () FLOOR J/C2 (07) #WG Q31 D/L MTR RRLH (U/L +)
FLOOR BNDR3 (02) #VB D19 J/B CTY SW (+1) COWL RH J/C4 (13) #FN #WK FLOOR J/C2 (10)
FLOOR J/C1 (08) #SH C80 J/B TL LH (+) COWL RH J/C4 (10) #FK #WF FLOOR J/C2 (06)
FLOOR J/C1 (05) #SE C08 TAIL LP LH (+) FLOOR J/C1 (11) #SL P41 P/W SW RRLH (B)
FLOOR J/C1 (06) #SF C16 LICENSE LP R (+) P/W MAS SW (RLU +) P37 P39 P/W SW RRLH (U +)
FLOOR J/C1 (04) #SD C07 TAIL LP RH (+) P/W MAS SW (RLD +) P38 P40 P/W SW RRLH (D +)
FLOOR BNDR1 (E01) #AA Z05 RR COM LP RH () P/W MAS SW (RRU +) P32 P34 P/W SW RRRH (U +)
FLOOR BNDR1 (E01) #AA Z79 LICENSE LP R () P/W MAS SW (RRD +) P33 P35 P/W SW RRRH (D +)
FLOOR BNDR1 (E01) #AA Z06 RR COM LP LH () COWL RH J/C3 (10) #EK #SK FLOOR J/C1 (10)
FLOOR J/C1 (06) #SF C16 LICENSE LP R (+) FLOOR J/C1 (09) #SJ P36 P/W SW RRRH (B)
FLOOR BNDR1 (E01) #AA Z79 LICENSE LP R () FUSE ACC (L5) RD1 RD2 ACC PLUG (B)
FLOOR J/C1 (07) #SG C17 LICENSE LP L (+) FLOOR BNDR1 (E01) #AA ZZK ACC PLUG (E)
FLOOR BNDR1 (E01) #AA Z78 LICENSE LP L () FUEL PUMP (E) ZC6 ZZ7 BODY EARTH ()
COWL LH J/C9 (06) #RF #UA FLOOR BNDR2 (01) F/P RLY (L) PD6 P06 FUEL PUMP (+)
FLOOR BNDR2 (01) #UA E14 STOP LP RH (+) COWL RH J/C1 (E03) #2C ZZ0 BODY EARTH ()
FLOOR BNDR2 (01) #UA E15 STOP LP LH (+) 82161-87401
FLOOR BNDR2 (01) #UA E33 H. M. STOP LP (SPR +)

FLOOR BNDR1 (E01) #AA Z69 H. M. STOP LP (SPR )
FLOOR BNDR2 (01) #UA E16 H. M. STOP LP (+)
FLOOR BNDR3 (02) #VB D06 CTY SW FR RH (+)
FLOOR BNDR3 (02) #VB D08 CTY SW RR RH (+)
FLOOR BNDR3 (02) #VB D09 CTY SW RR LH (+)
FLOOR BNDR3 (02) #VB D07 CTY SW FR LH (+)
FLOOR J/C1 (01) #SA G03 BACK LP SW ()
FLOOR J/C1 (02) #SB G04 BACK LP RH (+)
FLOOR J/C1 (03) #SC G05 BACK LP LH (+)
FLOOR BNDR1 (E01) #AA G15 BACK LP RH ()
FLOOR BNDR1 (E01) #AA G16 BACK LP LH ()
J/B R/TRN LP (LH +) F04 F05 RR TRN LP LH (+)
J/B R/TRN LP (RH +) F06 F07 RR TRN LP RH (+)
COWL LH J/C5 (06) #MF D67 LUG ROOM LMP (B)
FLOOR BNDR3 (02) #VB D68 LUG ROOM LMP (L)
FLOOR BNDR1 (E01) #AA ZB2 LUG ROOM LMP (E)
FLOOR BNDR3 (02) #VB D69 CTY SW BACK (+)
MET FUEL G (+) H22 H23 FUEL SENDER (+)
FUEL SENDER () H57 ZZ0 BODY EARTH ()
FLOOR BNDR1 (E01) #AA Z40 SEAT BELT SW ()
MET SB WRN () H56 H58 SEAT BELT SW (+)
FLOOR BNDR1 (E01) #AA ZZ7 BODY EARTH ()
RADIO (SRR ) R29 R33 RR SP RH ()
RADIO (SRR +) R28 R32 RR SP RH (+)
FLOOR J/C2 (13) #WN Q30 D/L MTR RRRH (LOK +)

J/C 2 BODY EARTH
#WF #WG #WK #WL
#WH #WJ #WM #WN ZZ7 ZZ0
RR COM RH
6 6
C07 E14
F07 Z05
WIRE, FLOOR (RHD)
RR Q SP RH

R33
R32
CTY SW ACC
BNDR TO BACK RD2
J/C 1 RR SK (+)
NO.1 #AA DOOR WIRE
#SJ #SK #SA #SB #SD #SE #SF ZZK
D08 E16 Q77 Z07
D06 P36 P34 Q30 #SL #SC #SG #SH Z69 E33
#UA I30 K29 I29 Q76
#VB P35 Q29 ACC SK (-)
CTY SW BNDR TO BRAKE
BNDR NO.3 FR LAMP WIRE
TO RR NO.2 G04 C40
H58 Z40 B/L RH G15 C64
RR FOG
DOOR
SEAT BELT WIRE RH
SW
PD6 #GM #2C #FK R30 H22 #NE G03 H56
P38 P37 #EK P33 P32 #FN R31 R28 R29 I31 #RF #MF H57 H23
ZC6 P06
TO COWL C80RD1 I67 TO COWL
F04 F06 D19 TO FUEL PUMP & GAUGE
WIRE WIRE RR COM LH
TO J/B
C08 E15
F05 Z06
RR Q SP LH TO RR DOOR WIRE LH LICENSE RH EC
R35 C16
P41 P39 Q32 Z79
R34 P40 Q31
LICENSE LP C16
Z79
ROOM L/P
C17
D67 D68 ZB2 D07 Z78
CTY SW FL LICENSE LH EC
D69
D09
G05
CTY SW BACK G16
CTY SW RL
B/L LH
82161-87401
HW45
HW46
WIRE, FLOOR (LHD)
From To From To
FLOOR BNDR3 (02) #VB D19 J/B CTY SW (+1) COWL LH J/C3 (07) #KG #WF FLOOR J/C2 (06)
COWL LH J/C4 (12) #LM C40 RR FOG LP (+) FLOOR BNDR1 (E01) #AA ZZK ACC PLUG (E)
FLOOR BNDR1 (E01) #AA C64 RR FOG LP () FUSE ACC (L5) RD1 RD2 ACC PLUG (B)
FLOOR J/C1 (08) #SH C80 J/B TL LH (+) F/P RLY (L) PD6 P06 FUEL PUMP (+)
FLOOR J/C1 (04) #SD C07 TAIL LP RH (+) FUEL PUMP (E) ZC6 ZZ7 BODY EARTH ()
FLOOR J/C1 (06) #SF C16 LICENSE LP R (+) COWL LH J/C1 (E03) #6C ZZ0 BODY EARTH ()
FLOOR J/C1 (07) #SG C17 LICENSE LP L (+) FLOOR BNDR1 (01) #AA ZZ27 BODY EARTH ()
FLOOR J/C1 (05) #SE C08 TAIL LP LH (+) 82161-87402
FLOOR BNDR1 (E01) #AA Z05 RR COM LP RH ()

FLOOR BNDR1 (E01) #AA Z79 LICENSE LP R ()
FLOOR BNDR1 (E01) #AA Z78 LICENSE LP L ()
FLOOR BNDR1 (E01) #AA Z06 RR COM LP LH ()
COWL RH J/C3 (02) #EB #UA FLOOR BNDR2 (01)
FLOOR BNDR2 (01) #UA E14 STOP LP RH (+)
FLOOR BNDR2 (01) #UA E15 STOP LP LH (+)
FLOOR J/C1 (06) #SF C16 LICENSE LP R (+)
FLOOR BNDR1 (E01) #AA Z79 LICENSE LP R ()
FLOOR BNDR2 (01) #UA E33 H. M. STOP LP (SPR +)
FLOOR BNDR1 (E01) #AA Z69 H. M. STOP LP (SPR )
FLOOR BNDR2 (01) #UA E16 H. M. STOP LP (+)
FLOOR BNDR3 (02) #VB D07 CTY SW FR LH (+)
FLOOR BNDR3 (02) #VB D06 CTY SW FR RH (+)
FLOOR BNDR3 (02) #VB D08 CTY SW RR RH (+)
FLOOR BNDR3 (02) #VB D09 CTY SW RR LH (+)
FLOOR J/C1 (01) #SA G03 BACK LP SW ()
FLOOR J/C1 (02) #SB G04 BACK LP RH (+)
FLOOR BNDR1 (E01) #AA G15 BACK LP RH ()
FLOOR J/C1 (03) #SC G05 BACK LP LH (+)
FLOOR BNDR1 (E01) #AA G16 BACK LP LH ()
J/B R/TRN LP (LH +) F04 F05 RR TRN LP LH (+)
J/B R/TRN LP (RH +) F06 F07 RR TRN LP RH (+)
COWL RH J/C5 (07) #GG D67 LUG ROOM LMP (B)
FLOOR BNDR3 (02) #VB D68 LUG ROOM LMP (L)
FLOOR BNDR1 (E01) #AA ZB2 LUG ROOM LMP (E)
FLOOR BNDR3 (02) #VB D69 CTY SW BACK (+)
FUEL SENDER () H57 ZZ0 BODY EARTH ()
MET FUEL G (+) H22 H23 FUEL SENDER (+)
COWL RH J/C6 (05) #XE K29 DEF (+)
RADIO (SRR +) R28 R32 RR SP RH (+)
RADIO (SRR ) R29 R33 RR SP RH ()
FLOOR J/C2 (I3) #WN Q30 D/L MTR RRRH (LOK +)
FLOOR J/C2 (11) #WL Q32 D/L MTR RRLH (LOK +)
FLOOR J/C2 (07) #WG Q31 D/L MTR RRLH (U/L +)
COWL LH J/C3 (10) #KK #WK FLOOR J/C2 (10)

J/C 2 BODY EARTH
#WF #WG #WK #WL
#WH #WJ #WM #WN ZZ7 ZZ0
RR COM RH
6 6
C07 E14
F07 Z05
WIRE, FLOOR (LHD)
TO RR DOOR WIRE RH
Q30
Q29
RR Q SP RH

D06 R33
R32
CTY SW FR
BNDR CTY SW RD2 ACC SK (+)
J/C 1 NO.1 RR
#SA #SB #SD #SE #SF #AA
D08 E16 Q77 Z07 ZZK ACC SK (-)
#SC #SG #SH Z69 E33
#UA I30 K29 I29 Q76
TO TO J/B BNDR TO BRAKE

TO BACK DOOR WIRE
COWL C80RD1 I67 NO.2 LAMP WIRE
F04 F06 D19
WIRE TO COWL WIRE G04 B/L RH
G15
#6C #KG R30 H22 #XE G03
#KK #LM R31 R28 R29 I31 #EB #GG PD6
TO FUEL PUMP & GAUGE
H57 H23
ZC6 P06
BNDR NO.3
#VB
LICENSE RH EC
CTY SW RL CTY SW BACK C16
Z79
D09 D69
LICENSE LP C16
Z79
C17
D67 D68 ZB2 Z78
ROOM L/P LICENSE LH EC
CTY SW FL D07 Q32 R35 C40 G05

Q31
RR Q SP LH C64 G16
B/L LH
C08 E15 R34
F05 Z06
RR FOG
TO RR DOOR WIRE LH
RR COM LH
HW47
82161-87402
HW48
WIRE, FLOOR, No. 3 (RHD)
From To
COWL LH J/C9 (07) #RG WT0 ABS ECU (BLS)
COWL LH J/C8 (13) #QN WT1 ABS ECU (WLAS)
ABS P SSR RL () WA3 W66 ABS ECU (RL 0)
ABS P SSR RL (+) WA2 W52 ABS ECU (RL 1)
ABS ECU (RR 1) W50 W98 ABS P SSR RR (+)
ABS ECU (RR 0) W64 W99 ABS P SSR RR ()
COWL LH J/C5 (11) #ML WS9 ABS ECU (BAT)
ABS ECU (GND 1) ZP0 ZY5 BODY EARTH (E)
ABS G SSR (GGND) WQ6 WV5 ABS ECU (GGND)
ABS ECU (GST) WP8 WQ1 ABS G SSR (GST)
ABS ECU (GS 2) WQ0 WQ3 ABS G SSR (GS 2)
ABS ECU (GS 1) WP9 WQ2 ABS G SSR (GS 1)
COWL LH J/C7 (11) #PL WQ5 ABS G SSR (+IG)
COWL LH J/C3 (13) #KN WW9 ABS ECU (EXI)
Connect to #PL~WQ5 W48 ABS ECU (IGN)
COWL LH J/C7 (06) #PF WV2 ABS ECU (TC)
COWL LH J/C6 (09) #NJ WV0 ABS ECU (SIO)
OFFBOARD CON (ABST) VN9 WK6 ABS ECU (TS)
82163-87401

WIRE, FLOOR, No. 3 (RHD)

ABS SSR RH
G SSR W98 W99
WQ6 WQ5
TO COWL WIRE WQ2 WQ3 WQ1
#ML #KN #PL
#NJ #RG #PF VN9 #QN
ABS ECU
W52 W66 WVO WP8 WK6 WQ0 WW9 W48 ZP0 WA2 WA3
W50 W64 WV5 WP9 WV2 WT0 WS9 ZP1 WT1
ABS SSR LH
6
ZY5
ABS EARTH
HW49
82163-87401
HW50
WIRE, FLOOR, No. 3 (LHD)
From To
COWL RH J/C3 (03) #EC WT0 ABS ECU (BLS)
COWL RH J/C9 (02) #ES WT1 ABS ECU (WLAS)
ABS P SSR RL () WA3 W66 ABS ECU (RL0)
ABS P SSR RL (+) WA2 W52 ABS ECU (RL1)
ABS ECU (RR1) W50 W98 ABS P SSR RR (+)
ABS ECU (RR0) W64 W99 ABS P SSR RR ()
COWL RH J/C5 (12) #GM WS9 ABS ECU (BAT)
ABS G SSR (GGND) WQ6 WV5 ABS ECU (GGND)
ABS ECU (GST) WP8 WQ1 ABS G SSR (GST)
ABS ECU (GS 2) WQ0 WQ3 ABS G SSR (GS 2)
ABS ECU (GS 1) WP9 WQ2 ABS G SSR (GS 1)
COWL RH J/C7 (11) #YL WQ5 ABS G SSR (+IG)
COWL RH J/C7 (06) #YF WV2 ABS ECU (TC)
COWL RH J/C6 (09) #XJ WV0 ABS ECU (SIO)
OFFBOARD CON (ABST) VN9 WK6 ABS ECU (TS)
Connect to #YL~WQ5 W48 ABS ECU (IGN)
82163-87402

WIRE, FLOOR, No. 3 (LHD)
ABS SSR RH

W98 W99
TO COWL WIRE
#GM #YL
#XJ #EC #YF VN9 #ES
ABS ECU
W52 W66 WVO WP8 WK6 WQ0 W48 ZP0 WA2 WA3
W50 W64 WV5 WP9 WV2 WT0 WS9 ZP1 WT1
ABS SSR LH
6
ZY5
WQ6 WQ5
ABS EARTH WQ2 WQ3 WQ1
G SSR
82163-87402
HW51
HW52
WIRE, COWL, RH (EC/RHD AUS.)
From To From To From To
Location Terminal Terminal Location Location Terminal Terminal Location Location Terminal Terminal Location
IG SW (AM) O12 O31 F/L AM (L) COWL LH J/C8 (08) #QH M07 ST RLY (COL ) F/P RLY (L) PD6 P06 FUEL PUMP (+)
IG SW (ACC) R01 R02 FUSE ACC (B) STARTER (ST) M02 M14 ST RLY (L) F/P RLY (COL ) PD7 XU4 EFI ECU (FC1)
IG SW (IG1) N01 N59 J/B IG1 (+) FR WSH SW (L) I60 ZQ9 FR WSH MTR () ABS P SSR FR (+) WA4 W67 ABS ECU (FR1)
IG SW (IG2) N30 N60 J/B IG2 (+) COWL R BNDR1 (E05) #4E Z14 BODY EARTH (CTIR) ABS P SSR FR () WA5 W53 ABS ECU (FR0)
M/FUSE TAIL (L) OF1 OF2 J/B M/F TAIL (L) FR WIP MTR (S) I24 I41 INT RLY (INT) COWL R BNDR1 (E08) #4H ZG3 ABS MAI RLY (SWNG)
J/B TL SW (+) CA2 CE1 TAIL LP SW (B) COWL RH J/C5 (06) #GF I10 FR WIP SW (+) COWL RH J/C2 (E04) #3D ZN9 ABS MTR ()
LGHTNG SW (B) A22 O69 M/FUSE H/L (L) FR WIP MTR (LO) I18 I56 FR WIP SW (1) ABS ACT (MT) WK1 WS5 ABS ECU (MS)
TAIL LP SW (L) CE2 CM1 J/B TL SW () FR WIP MTR (HI) I20 I57 FR WIP SW (2) COWL R BNDR4 (02) #JB WK2 ABS ACT (BS)
FUSE HORNHZD (L) F69 F70 J/B HORN HZD (L) COWL RH J/C5 (07) #GG R17 E MIRROR SW (C) ABS MTR RLY (L) WS4 WW1 ABS ACT (BM)
J/B H-LP SW () AA5 A23 LGHTNG SW (L) COWL R BNDR1 (E11) #4L ZN2 E MIRROR SW (E) COWL R BNDR3 (02) #HB WS0 ABS MAI RLY (SWNO)
J/B DIM (HI) AA3 A17 DIM SW (HI) COWL RH J/C5 (09) #GJ R27 E MIRROR LH (C) COWL RH J/C3 (08) #EH WS1 ABS MTR RLY (COL +)
J/B DIM (LO) AA4 A18 DIM SW (LO) COWL RH J/C5 (08) #GH R26 E MIRROR RH (C) COWL R BNDR3 (03) #HC WS3 ABS MTR RLY (B)
R-LP RH (LO) A08 A99 J/B H-LP LOR () E MIRROR SW (VR) R19 R24 E MIRROR RH (V) COWL R BNDR4 (01) #JA WG2 ABS DIODE ()
J/B H-LP HIR () AA1 A07 H-LP RH (HI) E MIRROR SW (VL) R18 R22 E MIRROR LH (V) COWL LH J/C8 (12) #QM WG1 ABS DIODE (+)
COWL RH J/C4 (01) #FA A05 FUSE H-LP RH (L) E MIRROR SW (HL) R20 R23 E MIRROR LH (H) ABS MTR RLY (COL ) WS2 WS6 ABS ECU (PCO)
COWL R BNDR1 (E04) #4D Z02 DIM SW (E) E MIRROR SW (HR) R21 R25 E MIRROR RH (H) ABS MAI RLY (COL ) WR7 WS7 ABS ECU (REL)
COWL RH J/C5 (10) #GK CJ7 MLT SW R/FOG () COWL LH J/C7 (02) #PB R16 E MIRROR SW (B) COWL RH J/C3 (09) #EJ WV3 ABS ECU (R +)
COWL RH J/C4 (02) #FB A06 H-LP RH (B) RADIO (SPR +) R10 R11 SP FR RH (+) ABS ECU (AST) WV4 WW2 ABS ACT (AST)
MLT SW R/FOG (+) CJ6 D71 JB R/FOG WNG (BZRB) RADIO (SPR ) R12 R13 SP FR RH () ABS ACT (SFRH) WW3 WX1 ABS ECU (SFRH)
COWL RH J/C5 (11) #GL H80 MET RR FOG (IND +) COWL L J/C10 (09) #LT Q25 D/LOCK SW (U/L +) ABS ACT (SFLH) WW4 WX2 ABS ECU (SFLH)
COWL RH J/C5 (12) #GM C40 RR FOG LP (+) COWL LH J/C2 (E04) #7D ZS1 D/LOCK SW (E) ABS ACT (SRH) WW5 WX3 ABS ECU (SRH)
COWL RH J/C4 (04) #FD A54 H-LP LEV ACT (RH +) COWL RH J/C4 (12) #FM Q28 D/L MTR FR P (LOK +) ABS ACT (SFRR) WW6 WX4 ABS ECU (SFRR)
COWL RH J/C4 (03) #FC AA6 H-LP LEV SW (+) COWL RH J/C4 (13) #FN #WK FLOOR J/C2 (10) ABS ACT (SFLR) WW7 WX5 ABS ECU (SFLR)
COWL RH J/C5 (01) #GA A56 H-LP LEV ACT (RH 0) COWL RH J/C4 (10) #FK #WF FLOOR J/C2 (06) ABS ACT (SRR) WW8 WX6 ABS ECU (SRR)
COWL RH J/C5 (03) #GC A69 H-LP LEV SW (LH 0) COWL RH J/C4 (09) #FJ Q27 D/L MTR FR P (U/L +) COWL RH J/C3 (07) #EG WR8 ABS MAI RLY (COL +)
COWL R BNDR1 (E10) #4K ZM9 H-LP LEV SW (LHE) COWL RH J/C4 (08) #FH Q51 ITC ECU (ULM) COWL R BNDR3 (01) #HA OC6 F/L ABS (L)
COWL RH J/C5 (02) #GB A63 H-LP LEV ACT (LH 0) COWL RH J/C4 (11) #FL Q50 ITC ECU (LKM) COWL R BNDR4 (03) #JC WR9 ABS MAI RLY (SWC)
COWL RH J/C2 (E05) #3E ZM8 H-LP LEV ACT (RH E) COWL RH J/C3 (06) #EF PD4 FUSE P/W (L) COWL R BNDR1 (E01) #4A #8A COWL L BNDR1 (E01)
J/B CLA LP (RH +) C09 C10 CLA LP RH (+) COWL RH J/C3 (05) #EE P31 P/W SW FR P (B) COWL RH J/C1 (E02) #2B #4B COWL R BNDR1 (E02)
COWL RH J/C2 (E02) #3B Z27 CLA LP RH () P/W MAS SW (PU +) P27 P29 P/W SW FR P (U +) COWL RH J/C1 (E01) #2A #3A COWL RH J/C2 (E01)
COWL RH J/C5 (04) #GD E32 TRN SW (B) COWL RH J/C1 (E05) #2E Z61 P/W MAS SW (E) COWL RH J/C1 (E03) #2C ZZ7 BODY EARTH ()
COWL RH J/C5 (18) #GZ F47 MULTI SW (HAZ +) COWL RH J/C3 (04) #ED P22 P/W MAS SW (B) COWL LH J/C9 (05) #RE E11 STOP LP SW ()
COWL RH J/C5 (16) #GX F65 J/B TRN SW (+B) P/W MAS SW (FD +) P28 P30 P/W SW FR P (D +) STOP LP SW (+) E10 E28 FUSE STOP (L)
COWL RH J/C5 (17) #GY QC7 ITC ECU (CHZD) MAG CLT (+) KP1 K23 A/C RLY (L) P/W MAS SW (RRD +) P33 P35 P/W SW RRRH (D +)
MULTI SW (HAZ ) F48 QB7 ITC ECU (T/H) A/C I/UP VSV () K19 XQ6 EFI ECU (VSV3) P/W MAS SW (RRU +) P32 P34 P/W SW RRRH (U +)
J/B TRN SW () F67 QC5 ITC ECU (FL +) COWL RH J/C4 (05) #FE K18 A/C I/UP VSV (+) P/W MAS SW (RLD +) P38 P40 P/W SW RRLH (D +)
COWL R BNDR1 (E03) #4C Z63 J/B EARTH (1) COWL RH J/C4 (06) #FF OC9 EFI MAIN RLY (L) P/W MAS SW (RLU +) P37 P39 P/W SW RRLH (U +)
COWL RH J/C5 (15) #GW F60 TRN SW (RL +) A/C RLY (COL ) KG9 XS0 EFI ECU (MGC) COWL LH J/C4 (15) #FV Q65 D/L MTR FR D (U/L +)
COWL RH J/C5 (13) #GU F68 J/B TRN SW (RLSW) COWL LH J/C4 (12) #LM K13 HTR RLY (COL ) COWL LH JC4 (14) #FU Q66 D/L MTR FR D (LOK +)
COWL RH J/C5 (14) #GV QB9 ITC ECU (CFL) HTR BLR MTR (+) K02 K11 HTR RLY (L) COWL RH J/C3 (15) #EP P36 P/W SW RRRH (B)
TRN SW (LH) F62 F64 J/B TRN (LH) J/B F/GGE-BK (L) H79 K12 HTR RLY (COL +) IG SW (AM) O12 O31 F/L AM (L)
TRN SW (RH) F61 F63 J/B TRN (RH) COWL RH J/C3 (01) #EA #KL COWL LH J/C3 (11) IG SW (ACC) R01 R02 FUSE ACC (B)
COWL RH J/C5 (05) #GE F66 J/B TRN SW (IG) COWL RH J/C3 (02) #EB VD6 DIFLOCK VSV1 (+) IG SW (IG1) N01 N59 J/B IG1 (+)
SID TRN LP R (+) F16 F43 J/B S/TRN LP (RH+) COWL RH J/C3 (03) #EC VD8 DIF LOCK VSV2 (+) IG SW (IG2) N30 N60 J/B IG2 (+)
SID TRN LP R (+) F14 F52 J/B F/TRN LP (RH) COWL R BNDR1 (E06) #4F VD9 DIFLOCK VSV2 () 82131-87403
COWL RH J/C2 (E01) #3A ZM5 SID TRN LP R () COWL R BNDR1 (E07) #4G VD7 DIFLOCK VSV1 ()
COWL RH J/C2 (E02) #3B ZK4 FR TRN LP RH() IMMOBI ECU (COL +) QA4 QB0 IMMOBI ANTN (COL +)
HORN RH (+) E02 E43 J/B HORN (+B) IMMOBI ECU (COL ) QA5 QB1 IMMOBI ANTN (COL )
HORN RH () E03 E19 HORN SW (+) COWL LH J/C5 (07) #MG C90 FUSE BK/UP (L)
COWL LH J/C3 (07) #KG G08 BRK O/LEV SW (+) J/B FS ECU IG (B1) N52 OC8 EFI MAIN RLY (COL +)
COWL RH J/C2 (E03) #3C Z11 BRK O/LEV SW () COWL RH J/C2 (E03) #3C ZS7 RB EFI M RLY (E)
IG SW (ST) M01 M15 ST RLY (COL +) COWL RH J/C4 (07) #FG #RH COWL LH J/C9 (08)

HW53
WIRE, COWL, RH (EC/RHD AUS.)
PD6 PD7
ABS DIODE & CHECK OC9 ZS7 R/B 3-2 FR TURN RH
R/B 3-1
OC6 O31 F14
WG1 HORN E02 ZM4
WG2
ABS ACT HORN E03
WS3 WS4 EARTH
6 #3D CLEARANCE RH
WS1 WS2
EARTH J/C
C10
ABS RLY 2 FENDER RH #3A #3B #3C #3E
Z27
HEAD LAMP RH
TO E/G A08
WW5 WW4 WW3 WIRE M02 A07 A06
ABS ACT 1 WW8 WW7 WW6 NO.2
TO COWL WIRE LH A R/B 1 F69 OF1 O69
K23 KG9 C90
Q28 ZQ9 K02
Q27 #QH I18 I24 I20 #LM ZN9 WW1
#8A KP1 XS0 XQ6 H79 ABS ACT 2 K11 OC8
ZM8 A56 A54
WW2 WK2 WK1
K12 K13
H-LP LVL RH
R/B 2-1
T/F VSV 2 T/F VSV 1
M15 M07
VD8 VD6 BRAKE FLUID
VD9 VD7 LEVEL SW R/B 2-2
G08
Z11 WA5 WA4
EARTH J/C
J/C 4
TO COWL WIRE LH B COWL RH A/C VSV ABS SSR FRRH
P29 R10 R12 R23 #MG P31 K18
#2A #2B #2C #2E
#KG #RH P30 R22 R27 #PB #KL XU4 K19
TO COWL WIRE LH ITC
#LT Q51 #7D
Q50 QB9 QC7 QC5 QB7
#FG #FF #FE #FD #FC #FB #FA BDR-EARTH TO FLOOR WIRE
#FV #FK #FJ #FH #FU #FN #FL #FM #4A #4B #4C #4D
#4E #4F #4G #4H #WF ZZ7 C40 P06
#4K #4L #WK P34 P35 P36 P39 P40
TO COWL WIRE LH ABS F16 ZM5
WV4 W67 W53 WS6 SIDE TURN RH
WS5 WV3 H80 A63 WX2 WX5
WX1 WX4 WS7 WX3
WX6 #QM QA5 QA4 #RE E28
MIRROR SW J/C 3
R18 R19 R21 #EE #ED #EH #EG #EA
R20 R17 R16 ZN2 E10 #EF #EP #EJ #EC #EB
E11
J/C 5
#GL #GJ #GG #GE #GD #GA STOP LP SW
#GK #GM #GH #GF #GC #GB
H-LP LVL SW F70
OF2 N52
ZM9 A69 AA6
J/B F
P32 P33
TURN SW 2 J/C 11
P37 P38
E19 F61 F60 F62 IMMOBI #GY #GX #GU
Z14 I60 I56 I57 I10 I41
ABS RLY 1 #GZ #GW #GV TO FR DOOR
ANTENNA N59 N60
WS0 WR9
PD4 R02
WIRE RH B
WR8 ZG3 WR7 QB0 QB1
TURN SW 1 J/B E
Q25 ZS1 P22
F47 F48 F32
R11 R13 P27 P28 Z61
CJ6 CJ7 CE2 A17 Z02
R24 R26 R25 Q66 Q65
N30 N01 R01 AA4 AA3 F64 F67 F68 Z63 TO FR DOOR WIRE RH
O12 M14 A05 AA1 C09 D71 F66 AA5 F65 F63
F52 F43 E43 A99 CM1 CA2
IG SW (M/T)
J/B D-1 J/B A
A18 CE1 A22 A23
#JA #JB #JC
N30 N01 R01
TURN SW 3 #HA#HB#HC O12 M01
IG SW (A/T)
BNDR-4
BNDR-3
87131-87403

HW54
WIRE, COWL, RH (General/RHD)
From To From To From To
Location Terminal Terminal Location Location Terminal Terminal Location Location Terminal Terminal Location
IG SW (AM) O12 O31 F/L AM (L) RADIO (SPR ) R12 R13 SP FR RH () COWL RH J/C3 (07) #EG WR8 ABS MAI RLY (COL +)
IG SW (ACC) R01 R02 FUSE ACC (B) COWL RH J/C4 (12) #FM Q28 D/L MTR FR P (LOK +) COWL R BNDR3 (01) #HA OC6 F/L ABS (L)
IG SW (IG1) N01 N59 J/B IG1 (+) COWL RH J/C4 (13) #FN #WK FLOOR J/C2 (10) COWL R BNDR4 (03) #JC WR9 ABS MAI RLY (SWC)
IG SW (IG2) N30 N60 J/B IG2 (+) COWL RH J/C4 (10) #FK #WF FLOOR J/C2 (06) COWL R BNDR1 (E01) #4A #8A COWL L BNDR1 (E01)
M/FUSE TAIL (L) OF1 OF2 J/B M/F TAIL (L) COWL RH J/C4 (09) #FJ Q27 D/L MTR FR P (U/L +) COWL RH J/C1 (E02) #2B #4B COWL R BNDR1 (E02)
J/B TL SW (+) CA2 CE1 TAIL LP SW (B) COWL RH J/C3 (06) #EF PD4 FUSE P/W (L) COWL RH J/C1 (E01) #2A #3A COWL RH J/C2 (E01)
LGHTNG SW (B) A22 O69 M/FUSE H/L (L) COWL RH J/C3 (05) #EE P31 P/W SW FR P (B) COWL RH J/C1 (E03) #2C ZZ7 BODY EARTH ()
TAIL LP SW (L) CE2 CM1 J/B TL SW () COWL RH J/C3 (04) #ED P22 P/W MAS SW (B) IG SW (AM) O12 O31 F/L AM (L)
FUSE HORNHZD (L) F69 F70 J/B HORN HZD (L) COWL RH J/C1 (E05) #2E Z61 P/W MAS SW (E) IG SW (ACC) R01 R02 FUSE ACC (B)
J/B H-LP SW () AA5 A23 LGHTNG SW (L) P/W MAS SW (PU +) P27 P29 P/W SW FR P (U +) IG SW (IG1) N01 N59 J/B IG1 (+)
J/B DIM (HI) AA3 A17 DIM SW (HI) P/W MAS SW (PD +) P28 P30 P/W SW FR P (D +) IG SW (IG2) N30 N60 J/B IG2 (+)
J/B DIM (LO) AA4 A18 DIM SW (LO) MAG CLT (+) KP1 K23 A/C RLY (L) P/W MAS SW (RRD +) P33 P35 P/W SW RRRH (D +)
H-LP RH (LO) A08 A99 J/B H-LP LOR () A/C I/UP VSV () K19 XQ6 EFI ECU (VSV3) P/W MAS SW (RRU +) P32 P34 P/W SW RRRH (U +)
J/B H-LP HIR () AA1 A07 H-LP RH (HI) COWL RH J/C4 (05) #EF K18 A/C I/UP VSV (+) P/W MAS SW (RLD +) P38 P40 P/W SW RRLH (D +)
COWL RH J/C4 (01) #FA A05 FUSE H-LP RH (L) COWL RH J/C4 (06) #FF OC9 EFI MAIN RLY (L) P/W MAS SW (RLU +) P37 P39 P/W SW RRLH (U +)
COWL R BNDR1 (E04) #4D Z02 DIM SW (E) A/C RLY (COL ) KG9 XS0 EFI ECU (MGC) COWL LH J/C4 (15) #FV Q65 D/L MTR FR D (U/L +)
COWL RH J/C4 (02) #FB A06 H-LP RH (B) COWL LH J/C4 (12) #LM K13 HTR RLY (COL ) COWL LH J/C4 (14) #FU Q66 D/L MTR FR (LOK +)
COWL LH J/C5 (03) #MC C25 FR FOG LP RH (+) HTR BLR MTR (+) K02 K11 HTR RLY (L) COWL RH J/C3 (15) #EP P36 P/W SW RRRH (B)
COWL RH J/C2 (E05) #3E ZD2 FR FOG LP RH () J/B F/GGE-BK (L) H79 K12 HTR RLY (COL +) COWL L J/C10 (09) #LT Q25 D/LOCK SW (U/L +)
J/B CLA LP (RH +) C09 C10 CLA LP RH (+) COWL RH J/C3 (01) #EA #KL COWL LH J/C3 (11) COWL LH J/C2 (E04) #7D ZS1 D/LOCK SW (E)
COWL RH J/C2 (E02) #3B Z27 CLA LP RH () COWL RH J/C3 (02) #EB VD6 DIFLOCK VSV1 (+) COWL RH J/C4 (08) #FH Q51 ITC ECU (ULM)
COWL RH J/C5 (04) #GD F32 TRN SW (B) COWL RH J/C3 (03) #EC VD8 DIFLOCK VSV2 (+) COWL RH J/C4 (11) #FL Q50 ITC ECU (LKM)
COWL R BNDR1 (E03) #4C Z63 J/B EARTH (1) COWL R BNDR1 (E06) #4F VD9 DIFLOCK VSV2 () COWL RH J/C5 (18) #GZ F47 MULTI SW (HAZ +)
TRN SW (LH) F62 F64 J/B TRN (LH) COWL R BNDR1 (E07) #4G VD7 DIFLOCK VSV1 () COWL RH J/C5 (16) #GX F65 J/B TRN SW (+B)
TRN SW (RH) F61 F63 J/B TRN (RH) J/B FS ECUIG (B1) N52 OC8 EFI MAIN RLY (COL +) COWL RH J/C5 (17) #GY QC7 ITC ECU (CHZD)
COWL RH J/C5 (05) #GE F66 J/B TRN SW (IG) COWL RH J/C2 (E03) #3C ZS7 RB EFI M RLY (E) MULTI SW (HAZ ) F48 QB7 ITC ECU (T/H)
SID TRN LP R (+) F16 F43 J/B S/TRN LP (RH +) COWL LH J/C5 (07) #MG C90 FUSE BK/UP (L) J/B TRN SW () F67 QC5 ITC ECU (FL +)
FR TRN LP RH (+) F14 F52 J/B F/TRN LP (RH) COWL RH J/C4 (07) #FG #RH COWL LH J/C9 (08) COWL RH J/C5 (15) #GW F60 TRN SW (RL +)
COWL RH J/C2 (E01) #3A ZM5 SID TRN LP R () F/P RLY (L) PD6 P06 FUEL PUMP (+) COWL RH J/C5 (13) #GU F68 J/B TRN SW (RLSW)
COWL RH J/C2 (E02) #3B ZM4 FR TRN LP RH () F/P RLY (COL ) PD7 XU4 EFI ECU (FC1) COWL RH J/C5 (14) #GV QB9 ITC ECU (CFL)
HORN RH (+) E02 E43 J/B HORN (+B) ABS P SSR FR (+) WA4 W67 ABS ECU (FR1) COWL LH J/C9 (05) #RE E11 STOP LP SW ()
HORN RH () E03 E19 HORN SW (+) ABS P SSR FR () WA5 W53 ABS ECU (FR0) STOP LP SW (+) E10 E28 FUSE STOP (L)
COWL LH J/C3 (07) #KG G08 BRK O/LEV SW (+) COWL R BNDR1 (E08) #4H ZG3 ABS MAI RLY (SWNC) 82131-87423
COWL RH J/C2 (E03) #3C Z11 BRK O/LEV SW () COWL RH J/C2 (E04) #3D ZN9 ABS MTR ()
STARTER (ST) M02 M14 ST RLY (L) ABS ACT (MT) WK1 WS5 ABS ECU (MS)
IG SW (ST) M01 M15 ST RLY (COL +) COWL R BNDR4 (02) #JB WK2 ABS ACT (BS)
COWL LH J/C8 (08) #QH M07 ST RLY (COL ) ABS MTR RLY (L) WS4 WW1 ABS ACT (BM)
FR WSH SW (L) I60 ZQ9 FR WSH MTR () COWL R BNDR3 (02) #HB WS0 ABS MAI RLY (SWNO)
FR WIP MTR (S) I24 I41 INT RLY (INT) COWL RH J/C3 (08) #EH WS1 ABS MTR RLY (COL +)
COWL RH J/C5 (06) #GF I10 FR WIP SW (+) COWL R BNDR3 (03) #HC WS3 ABS MTR RLY (B)
FR WIP MTR (LO) I18 I56 FR WIP SW (1) COWL R BNDR4 (01) #JA WG2 ABS DIODE ()
FR WIP MTR (HI) I20 I57 FR WIP SW (2) COWL LH J/C8 (12) #QM WG1 ABS DIODE (+)
COWL RH J/C5 (07) #GG R17 E MIRROR SW (C) ABS MTR RLY (COL ) WS2 WS6 ABS ECU (PCO)
COWL R BNDR1 (E11) #4L ZN2 E MIRROR SW (E) ABS MAI RLY (COL ) WR7 WS7 ABS ECU (REL)
COWL RH J/C5 (09) #GJ R27 E MIRROR LH (C) COWL RH J/C3 (09) #EJ WV3 ABS ECU (R +)
COWL RH J/C5 (08) #GH R26 E MIRROR RH (C) ABS ECU (AST) WV4 WW2 ABS ACT (AST)
E MIRROR SW (VR) R19 R24 E MIRROR RH (V) ABS ACT (SFRH) WW3 WX1 ABS ECU (SFRH)
E MIRROR SW (VL) R18 R22 E MIRROR LH (V) ABS ACT (SFLH) WW4 WX2 ABS ECU (SFLH)
E MIRROR SW (HL) R20 R23 E MIRROR LH (H) ABS ACT (SRH) WW5 WX3 ABS ECU (SRH)
E MIRROR SW (HR) R21 R25 E MIRROR RH (H) ABS ACT (SFRR) WW6 WX4 ABS ECU (SFRR)
COWL LH J/C7 (02) #PB R16 E MIRROR SW (B) ABS ACT (SFLR) WW7 WX5 ABS ECU (SFLR)
RADIO (SPR +) R10 R11 SP FR RH (+) ABS ACT (SRR) WW8 WX6 ABS ECU (SRR)

HW55
WIRE, COWL, RH (General/RHD)
PD6 PD7
OC9 ZS7 R/B 3-2
FR TURN RH
R/B 3-1 F14
ABS DIODE & CHECK HORN E02
ZM4
OC6 O31
WG1 HORN E03

WG2 ABS ACT
EARTH CLEARANCE RH ZD2 C25
TO COWL WIRE LH A EARTH J/C
Q28 ZQ9 K02 ABS RLY 2
WS3 WS4 6 #3D FENDER RH C10 FR FOG RH
Z27
Q27 #QH I18 I24 I20 #LM WS1 WS2
#8A #MC KP1 XS0 XQ6 H79 #3A #3B #3C #3E
WW5 WW4 WW3 TO E/G

ABS ACT 1 WW8 WW7 WW6 WIRE NO.2
M02
A08
TO COWL WIRE LH B R/B 1 F69 OF1 O69
A07 A06
P29 R10 R12 R23 #MG P31
ABS ACT 2 K23 KG9 C90
#KG #RH P30 R22 R27 #PB #KL XU4 HEAD LAMP RH
T/F T/F ZN9 WW1
K11 OC8
VSV 2 VSV1 WW2 WK2 WK1 R/B 2-1 K12 K13
TO COWL WIRE LH ITC
VD8 VD6
#LT Q51 #7D
EARTH J/C VD9 VD7
Q50 QB9 QC7 QC5 QB7 R/B 2-2 M15 M07
COWL RH
G08
#2A #2B #2C #2E Z11 WA5 WA4
BRAKE FLUID LEVEL SW ABS SSR FRRH

TO COWL WIRE LH ABS A/C VSV
WV4 W67 W53 WS6
K18
WS5 WV3 WX2 WX5
WX1 WX4 WS7 WX3
J/C 4 K19
WX6 #QM #RE E28 BDR EARTH TO FLOOR WIRE
#4A #4B #4C #4D
#4F #4G #4H #WF ZZ7 P06
#4L #WK P34 P35 P36 P39 P40
#FG #FF #FE #FB #FA F16 ZM5
#FV #FK #FJ #FH #FU #FN #FL #FM SIDE TURN RH
J/C 5
#GJ #GG #GE #GD E10

#GH #GF E11
STOP
#EE #ED #EH #EG #EA
LP SW #EF #EP #EJ #EC #EB
MIRROR SW J/C 11
F70
R18 R19 R21 #GY #GX #GU
OF2 N52
R20 R17 R16 ZN2 #GZ #GW #GV TO FR DOOR WIRE RH B
J/B F J/C 3 P32 P33
P37 P38
N59 N60
ABS RLY 1 PD4 R02
WS0 WR9 J/B E

WR8 ZG3 WR7 N30 N01 R01
O12 M01 IG SW (AT)
Q25 ZS1 P22
R11 R13 P27 P28 Z61
R24 R26 R25 Q66 Q65
N30 N01 R01 AA4 AA3 F64 F67 F68 Z63 TO FR DOOR WIRE RH
O12 M14 A05 AA1 C09 F66 AA5 F65 F63
F52 F43 E43 A99
#JA #JB #JC IG SW (M/T) CM1 CA2
I56 I57
CE1
I41 I60 #HA#HB#HC J/B D-1 J/B A
A17 A18
E19 F47 CE2 A22 A23
Z02 I10 F62 F60
F48 F61 F32
BNDR-4
BNDR-3
TO TURN SW
82131-87423

HW56
WIRE, COWL, RH (EC/LHD)
From To From To From To From To
Location Terminal Terminal Location Location Terminal Terminal Location Location Terminal Terminal Location Location Terminal Terminal Location
IG SW (AM) O12 O31 F/L AM (L) COWL RH J/C6 (02) #XB XQ2 EFI ECU (REV) RADIO (SRR ) R29 R33 RR SP RH () COWL RH J/C7 (05) #YE VN8 OFFBOARD CON (ECUT)
LGHTNG SW (B) A22 O69 M/FUSE H/L (L) COWL RH J/C6 (01) #XA N58 MET (REV) FUSE ACC (L1) RC6 R04 RADIO (+B) OFFBOARD CON (VF) VN6 X21 EFI ECU (VF)
M/FUSE TAIL (L) OF1 OF2 J/B M/F TAIL (L) COWL RH J/C6 (03) #XC VN5 OFFBOARD CON (REV) COWL RH J/C5 (10) #GK C30 RADIO (B/UP) J/B FUSE ENG (L2) N78 VL2 OFFBOARD CON (IG)
FUSE HORNHZD (L) F59 F70 J/B HORN HZD (L) COWL RH J/C4 (01) #FA H67 J/B MET (+) COWL RH J/C1 (E05) #2E Z30 RADIO (E) COWL RH J/C6 (07) #XG XT8 EFI ECU (SIO)
IG SW (AM) O12 O31 F/L AM (L) COWL RH J/C4 (02) #FB H61 MET (IG) RADIO (SPR +) R10 R11 SP PR RH (+) COWL RH J/C7 (04) #YD XS3 EFI ECU (T)
HI BEAM IND (+) A10 A98 J/B H BM IND (+) MET OIL PRES () H05 H06 OIL PRES SW (B) RADIO (SPR ) R12 R13 SP FR RH () COWL RH J/C6 (10) #XK QA3 IMMOBI ECU (SIO)
H-LP RH (LO) A08 A99 J/B H-LP LOR () COWL RH J/C3 (05) #EE G06 MET BRK WNG () COWL LH J/C3 (09) #KJ Q28 D/L MTR FR P (LOK +) A/B ECU (SIO) #TL #XL COWL RH J/C6 (11)
J/B H-LP HIR () AA1 A07 H-LP RH (HI) COWL RH J/C3 (06) #EF G08 BRK O/LEV SW (+) COWL LH J/C3 (06) #KF Q27 D/L MTR FR P (U/L +) COWL RH J/C6 (09) #XJ WV0 ABS ECU (SIO)
COWL RH J/C5 (02) #GB A06 H-LP (B) COWL RH J/C3 (07) #EG G07 PK BRK SW (+) COWL LH J/C4 (08) #LH P31 P/W SW FR P (B) A/B ECU (TC) #TJ #YH COWL RH J/C7 (08)
COWL RH J/C5 (01) #GA A05 FUSE H-LP RH (L) COWL R BNDR2 (E07) #5G ZJ3 O/D CUT SW (E) P/W MAS SW (PU +) P27 P29 P/W SW FR P (U +) COWL RH J/C7 (07) #YG QA8 IMMOBI ECU (T)
COWL LH J/C4 (11) #LL H80 MET RR FOG (IND +) COWL RH J/C8 (06) #ZF H35 O/D CUT SW (B) P/W MAS SW (PD +) P28 P30 P/W SW FR P (D +) COWL RH J/C7 (06) #YF WV2 ABS ECU (TC)
RR FOG SW (+) C38 D58 J/B KEY SW (+) COWL RH J/C8 (05) #ZE H52 O/D OFF IND (DI ) HTR BLR MTR (+) K02 K11 HTR RLY (L) OBD2 #TK T28 A/B ECU (T)
RR FOG SW () C39 D61 J/B K/WNG (BUZB) COWL RH J/C8 (07) #ZG V74 O/D CUT RLY (COLL) COWL RH J/C4 (11) #FL K13 HTR RLY (COL ) OBD2 (SIO) #TM T44 A/B ECU (SIO)
COWL LH J/C4 (02) #LB A56 H-LP LEV ACT (RH 0) O/D CUT SOL (+) H37 V73 O/D CUT RLY (L) A/C RLY (COL ) KG9 XS0 EFI ECU (MGC) MET (EFI) X01 X02 EFI ECU (W)
COWL RH J/C5 (04) #GD A54 H-LP LEV ACT (RH +) COWL RH J/C4 (04) #FD V72 O/D CUT RLY (B) MAG CLT (+) KP1 K23 A/C RLY (L) EFI ECU (AUX1) XP0 XT2 RESISTOR1 (+)
COWL RH J/C2 (E03) #3C ZM8 H-LP LEV ACT (RH E) STARTER (ST) M02 M14 ST RLY (L) COWL R BNDR3 (01) #HA OC9 EFI MAIN RLY (L) E/G WP BNDR2 (01) #CA #HD COWL R BNDR3 (04)
COWL RH J/C8 (13) #ZN C28 RADIO (ILM +) MET A/T IND (L) H24 H62 A/T NSS (L) COWL R BNDR3 (05) #HE K18 A/C I/UP VSV (+) COWL R BNDR3 (02) #HB XR4 EFI ECU (+B1)
J/B MTR ILM (B) CA1 C19 HTR CON ILM (+) MET A/T IND (2) H25 H63 A/T NSS (2) A/C I/UP VSV () K19 XQ6 EFI ECU (VSV3) COWL R BNDR3 (03) #HC XV0 EFI ECU (+B2)
MET (ILM +) C21 H78 J/B MET ILM (+) MET A/T IND (D) H26 H64 A/T NSS (D) E/G WP BNDR3 (05) #DE KK4 A/C THEMSTR () F/P RLY (COL ) PD7 XU4 EFI ECU (FC1)
COWL R BNDR2 (E03) #5C Z23 HTR CON ILM (E) MET A/T IND (N) H27 H65 A/T NSS (N) A/C THEMSTR (+) KP5 XP8 EFI ECU (ACEV) COWL RH J/C2 (E03) #3C ZS7 RB EFI M RLY (E)
COWL R BNDR1 (E03) #4C Z08 MET EARTH (E) MET A/T IND (P) H29 H66 A/T NSS (P) COWL RH J/C4 (08) #FH K44 HTR RESSTR (+) COWL RH J/C5 (09) #GJ XR3 EFI ECU (BAT)
COWL RH J/C2 (E02) #3B Z27 CLA LP RH () COWL RH J/C8 (09) #ZJ M20 A/T IND DIOD (B) COWL RH J/C4 (07) #FG K04 HTR BLR SW (H) J/B FS ECUIG (B1) N52 OC8 EFI MAIN RLY (COL +)
COWL RH J/C8 (12) #ZM C10 CLA LP RH (+) COWL RH J/C8 (08) #ZH M07 ST RLY (COL ) HTR RESSTR (M & M1) K05 K06 HTR BLR SW (M, M1) F/P RLY (L) PD6 P06 FUEL POMP (+)
COWL RH J/C8 (11) #ZL C09 J/B CLA LP (RH +) COWL R BNDR2 (E09) #5J Z53 A/T NSS (E) COWL RH J/C4 (12) #EM XK3 EFI ECU (BLW) COWL RH J/C1 (E02) #2B Z83 MET SPD (E)
COWL RH J/C8 (14) #ZP CE0 FLOOR ILM (+) IG SW (ST) M01 M15 ST RLY (COL +) COWL RH J/C4 (10) #FK K08 HTR BLR SW (L) COWL RH J/C6 (06) #XF XH6 EFI ECU (DEF)
COWL R BNDR2 (E05) #5E ZR8 FLOOR ILM () J/B F/WSH MO (+) I01 I03 FR WSH MTR (+) COWL RH J/C1 (E04) #2D Z21 HTR BLR SW (E) COWL RH J/C5 (03) #GC XH7 EFI ECU (H/L)
COWL RH J/C (01) #EA E11 STOP LP SW () FR WSH SW (L) I60 ZQ9 FR WSH MITR () J/B F/GGE-BK (L) H79 K12 HTR RLY (COL +) COWL R BNDR2 (E11) #5L XR9 EFI ECU (FAN)
STOP LP SW (+) E10 E28 FUSE STOP (L) FR WIP MTR (HI) I20 I57 FR WIP SW (2) COWL RH J/C4 (05) #FE KC6 A/C SW (+B) COWL RH J/C8 (10) #ZK XQ5 EFI ECU (A/T)
COWL RH J/C3 (02) #EB #UA FLOOR BNDR2 (01) FR WIP MTR (LO) I18 I56 FR WIP SW (1) COWL RH J/C4 (13) #FN KV2 A/C SW IND () A/B ECU (IG2) #TA T45 FUSE A/B (L1)
COWL RH J/C5 (06) #GF D02 ROOM LP (+) FR WIP MTR (S) I24 I41 INT RLY (INT) A/C D/PRS SW () KP7 XS4 EFI ECU (ACSW) FUSE A/B (L) #TB T02 A/B ECU (IG2)
COWL RH J/C5 (05) #GE E44 J/B F/STOP (L2) FR WIP MTR (+B) I22 I65 J/B F/WP-TRN (L1) A/C D/PRS SW (+) KP6 K99 A/C SW () A/B ECU (IG1) #TH N31 J/B FUSE ENG (L)
FLOOR J/C1 (01) #SA G03 BACK LP SW () RR WSH SW (B) I28 I66 J/B F/WP-TRN (L2) COWL RH J/C4 (06) #FF K30 HTR BLR MTR () FUSE E/G (L) #TG T01 A/B ECU (IG1)
BACK LP SW (+) G02 G21 J/B BACK LP (SW +) RR WIP MTR () I30 I31 RR WIP SW (B) COWL RH J/C4 (09) #FJ K07 HTR RESSTR (L) A/B ECU (W) #TE T37 MET (A/B)
BACK LP SW (+) G02 G21 J/B BACK LP (SW +) COWL R BNDR1 (E04) #4D Z18 RR WIP SW (E) COWL RH J/C4 (03) #FC VD1 DIFLOCK SW (B) MET A/B IND () #TF T26 A/B ECU (W)
COWL RH J/C8 (01) #ZA G03 BACK LP SW () RR WSH MTR (+) I26 I54 RR WSH SW (L) COWL RH J/C3 (11) #EL VD8 DIFLOCK VSV2 (+) COWL L J/C1 (E05) #TD T14 A/B ECU (E1)
FLOOR J/C1 (01) #SA #ZB COWL RH J/C8 (02) COWL RH J/C2 (E05) #3E ZN0 RR WSH MTR (E) COWL R BNDR1 (E06) #4F VD9 DIFLOCK VSV2 () A/B ECU (E1) #TC #2C COWL RH J/C1 (E03)
COWL RH J/C8 (04) #ZD H28 MET A/T IND (R +) DEF SW (B) K27 K98 J/B FUSE DEF (L) COWL R BNDR1 (E07) #4G VD7 DIFLOCK VSV () A/B ECU (D +) T11 T24 A/B SQUIB (D +)
COWL RH J/C8 (03) #ZC D39 J/B R/WNG (BUZ +) COWL R BNDR1 (E05) #4E Z42 DEF SW (E) COWL RH J/C3 (12) #EM H77 DIFLOCK IND (+) A/B ECU (D ) T12 T25 A/B SQUIB (D )
TRN IND LH (+) F19 F54 J/B TRN IND (LH) COWL RH J/C6 (04) #XD K28 DEF SW (L) COWL RH J/C3 (09) #EJ VD2 DIFLOCK SW (L) A/B ECU (PS +) T09 T42 A/B SQUIB (P +)
SID TRN LP R (+) F16 F43 J/B S/TRN LP (RH +) COWL RH J/C6 (05) #XE K29 DEF (+) COWL RH J/C3 (10) #EK VD6 DIFLOCK VSV (+) A/B ECU (PS ) T10 T43 A/B SQUIB (P )
FR TRN LP RH (+) F14 F52 J/B F/TRN LP (RH) COWL LH J/C3 (13) #KN R26 E MIRROR RH (C) COWL RH J/C7 (09) #YJ QB2 J/B IMMB ECU (IG) COWL R BNDR1 (E01) #4A #8A COWL L BNDR1 (E01)
TRN IND RH (+) F21 F55 J/B TRN IND (RH) E MIRROR SW (VR) R19 R24 E MIRROR RH (V) COWL RH J/C7 (10) #YK QA0 IMMOBI ECU (IG) COWL RH J/C1 (E02) #2B #4B COWL R BNDR1 (E02)
COWL RH J/C2 (E02) #3B ZM4 FR TRN LP RH () E MIRROR SW (HR) R21 R25 E MIRROR RH (H) COWL RH J/C5 (08) #GH C90 FUSE BK/UP (L) COWL RH J/C1 (E01) #2A #3A COWL RH J/C2 (E01)
COWL RH J/C2 (E01) #3A ZM5 SID TRN LP R () COWL RH J/C7 (01) #YA RC8 FUSE ACC (L3) COWL RH J/C5 (11) #GL QA2 IMMOBI ECU (+B) COWL RH J/C1 (E03) #2C #5A COWL R BNDR2 (E01)
HORN RH () E03 E19 HORN SW (+) COWL RH J/C7 (02) #YB R16 E MIRROR SW (B) COWL RH J/C7 (03) #YC QA1 IMMOBI ECU (ACC) COWL RH J/C2 (E05) #3E ZS1 D/LOCK SW (E)
HORN RH (+) E02 E43 J/B HORN (+B) FUSE ACC (L2) RC7 R15 CIG LTR (+) IMMOBI ECU (COL +) QA4 QB0 IMMOBI ANTN (COL +) J/B HAZ SW (RH) F49 QB5 ITC ECU (CHR)
COWL RH J/C5 (07) #GG D67 LUG ROOM LMP (B) COWL R BNDR2 (E06) #5F Z31 CIG LGT (E) IMMOBI ECU (COL ) QA5 QB1 IMMOBI ANTN (COL ) J/B HAZ SW (LH) F50 QC4 ITC ECU (CHL)
E/G J/C1 (E05) #1E #2A COWL RH J/C1 (E01) RADIO (SPL ) R08 R09 SP FR LH () COWL R BNDR1 (E09) #4J QA6 IMMOBI ECU (E) COWL RH J/C4 (15) #FW QB3 ITC ECU (IG1)
E/G WP BNDR1 (01) #BA N76 J/B FUSE ENG (L1) RADIO (SPL +) R06 R07 SP FR LH (+) OFFBOARD CON (ABST) VN9 WK6 ABS ECU (TS) FUSE D/LOCK (L) Q17 Q47 ITC ECU (+B)
MET (CHG) O20 O21 ALT (L) RADIO (SRL +) R30 R34 RR SP LH (+) COWL R BNDR2 (E02) #5B ZS4 OFFBOARD CON (E) COWL RH J/C2 (E06) #3F ZT3 ITC ECU (E1)
MET THRM G (+) H20 H21 THRM SENDER (+) RADIO (SRL ) R31 R35 RR SP LH () IMMOBI ECU (IND) QA7 VN7 OFFBOARD CON (IMBW) OFFBOARD CON (ITCT) VP3 QC1 ITC ECU (T)
MET FUEL G (+) H22 H23 FUEL SENDER (+) RADIO (SRR +) R28 R32 RR SP RH (+) COWL RH J/C6 (08) #XH VL0 OFFBOARD CON (SIO) ITC ECU (CS1) QC3 QC8 ALL RNG SSR (+)

HW57
From To From To
ITC ECU (CS ) QC2 QC9 ALL RNG SSR () COWL R BNDR1 (E08) #4H ZG3 ABS MAI RLY (SWNC)
D/LOCK SW (U/L +) Q25 QB8 ITC ECU (UKS) ABS P SSR FL (+) WA0 W65 ABS ECU (FL1)
COWL RH J/C4 (18) #FZ X03 MET (SPSR) ABS P SSR FL () WA1 W51 ABS ECU (FL0)
COWL RH J/C4 (17) #FY X04 EFI ECU (SPD) COWL R BNDR4 (01) #FR OC6 F/L ABS (L)
COWL RH J/C4 (16) #FX Q34 ITC ECU (SPD) COWL RH J/C9 (05) #EV WR8 ABS MAI RLY (COL +)
ROOM LP (DR) D03 QB6 ITC ECU (CRL) COWL R BNDR5 (02) #GS WR9 ABS MAI RLY (SWC)
J/B CTY SW (+2) D72 QB4 ITC ECU (DCSD) COWL RH J/C9 (02) #ES WT1 ABS ECU (WLAS)
COWL R J/C 11 (02) #NN QB9 ITC ECU (CFL) COWL RH J/C3 (13) #EN WW9 ABS ECU (EX1)
COWL R J/C 11 (05) #NR QC7 ITC ECU (CHZD) 82131-87405
J/B TRN SW () F67 QC5 ITC ECU (FL +)

MULTI SW (HAZ ) F48 QB7 ITC ECU (T/H)
COWL LH J/C3 (05) #KE Q51 ITC ECU (ULM)
COWL LH J/C3 (08) #KH Q50 ITC ECU (LKM)
A/B ECU (IG2) #TA T45 FUSE A/B (L1)
FUSE A/B (L) #TB T02 A/B ECU (IG2)
A/B ECU (IG1) #TH N31 J/B FUSE ENG (L)
FUSE E/G (L) #TG T01 A/B ECU (IG1)
A/B ECU (W) #TE T37 MET (A/B)
MET A/B IND () #TF T26 A/B ECU (W)
COWL L J/C1 (E05) #TD T14 A/B ECU (E1)
A/B ECU (D +) T11 T24 A/B SQUIB (D +)
A/B ECU (E1) #TC #2D COWL RH J/C (E04)
A/B ECU (D ) T12 T25 A/B SQUIB (D )
COWL LH J/C7 (08) #PH #TJ A/B ECU (TC)
COWL LH J/C6 (11) #NL #TL A/B ECU (SIO)
OBD2 (ECUT) #TK T28 A/B ECU (T)
OBD2 (SIO) #TM T44 A/B ECU (SIO)
ABS P SSR FR (+) WA4 W67 ABS ECU (FR1)
ABS P SSR FR () WA5 W53 ABS ECU (FR0)
COWL RH J/C5 (12) #GM WS9 ABS ECU (BAT)
COWL RH J/C2 (E04) #3D ZN9 ABS MTR ()
ABS ACT (MT) WK1 WS5 ABS ECU (MS)
COWL R BNDR5 (01) #GR WK2 ABS ACT (BS)
ABS MTR RLY (L) WS4 WW1 ABS ACT (BM)
COWL R BNDR4 (03) #FT WS0 ABS MAI RLY (SWNO)
COWL RH J/C9 (04) #EU WS1 ABS MTR RLY (COL +)
COWL R BNDR4 (02) #FS WS3 ABS MTR RLY (B)
COWL R BNDR5 (03) #GT WG2 ABS DIODE ()
COWL RH J/C9 (03) #ET WG1 ABS DIODE (+)
COWL RH J/C9 (01) #ER WB0 MET ABS IND ()
ABS MTR RLY (COL ) WS2 WS6 ABS ECU (PCO)
ABS MAI RLY (COL ) WR7 WS7 ABS ECU (REL)
COWL RH J/C9 (06) #EW WV3 ABS ECU (R +)
ABS ECU (AST) WV4 WW2 ABS ACT (AST)
ABS ACT (SRFRH) WW3 WX1 ABS ECU (SFRH)
ABS ACT (SRH) WW5 WX3 ABS ECU (SRH)
ABS ACT (SFLH) WW4 WX2 ABS ECU (SFLH)
ABS ACT (SFRR) WW6 WX4 ABS ECU (SFRR)
ABS ACT (SFLR) WW7 WX5 ABS ECU (SFLR)
ABS ACT (SRR) WW8 WX6 ABS ECU (SRR)
COWL RH J/C (11) #YL W48 ABS ECU (IGN)

HW58
WIRE, COWL, RH (EC/LHD)
R/B 3-2
ABS DIODE & CHECK PD6 PD7
OC9 ZS7
WS3 WS4
WG1 R/B 3-1
ABS RLY 2 FR TURN RH
WS1 WS2 WG2 HORN
OC6 O31 F14
E03 E02
ZM4
ABS ACT
ABS ACT 1 EARTH
FR WSH MTR 6 #3D
ZQ9
WW5 WW4 WW3 CLEARANCE RH
WW8 WW7 WW6 C10
I03
EARTH J/C Z27 HEAD LAMP RH
RR WSH MTR FENDER RH A08
#3A #3B #3C #3E #3F A07 A06
ZN0 ZN9 WW1
TO COWL TO
TO COWL I26 WW2 WK2 WK1
WIRE LH D E/G WIRE NO.2
WIRE LH A ABS
#LH KP6 R21 R09 R07 P27 T/F VSV 1 M02 ZM8 A56 A54
I41 #KJ I60 VD8 T/F ACT 2
WA0 WA1 R16 #KN R19 P28 KP7 G08 VD6 VD9
I56 #KF #LL #LB I57 E10
FR WIPER MTR VD7
VSV 2 H-LP LVL RH
E19 #8A E11 A22 F69 OF1 O69
I20 I18 R/B 1 K23 KG9 C90
TO COWL WIRE LH M/T O12 M14 KP1 QB1QB0
I24 I22
M15 M07 K11 OC8 R/B
A/C VSV R/B 2-1 K12 K13 2-2
TO COWL WIRE LH A/T O12M01 K18 WA5 WA4
K19
ABS SSR FRRH
J/C 3 A/B P SQUIB J/C 9
ZS1 #KE Q25
F48 F67 #NR #NN#KH #EE #EG #EA #EC #EJ #EL #EN #EV #EU #ER
#EF #EB #EK #EM T42 T43 #EW #ET #ES
TO COWL WIRE LH ITC
F16 ZM5
J/B B-3 J/B F
#SA K29 H23 R34 THERMISTOR ABS SIDE TURN RH
RC7 F70
RC7 OF2 N52 P06 D67 #UA I30 R33 R32 R35 J/C 6 BNDR-5 J/C 8 RLY 1
KP5 #ZA #ZC #ZL #ZN #ZF #ZG #ZK
#XA #XC #XD #XF #XG #XJ #XL #FR #FS #FT #GR #GS #GT
TO #XB #XE #XH #XK #NL
KK4 #ZB #ZD #ZM #ZP #ZE #ZH #ZJ
WS0 WR9 #DEXQ6 #BA #IE
WR8 ZG3 WR7 #CA H21H06 O21 XT2
FLOOR WIRE J/C 7
J/B B-1 #4A #4B #4C #4D TO
RC8 D72 D58 E28 TO E/G WIRE
#4E #4F #4G #4H
D03 D02 ROOF
H79 H67 H78 Q17 QB2 A98 #4J
BNDR-4 WIRE Q28Q27 P31
F55 F54 K98 I66 D61 TO
R11 R13 P29 P30
#YA #YC #YJ #YL #YD #YF #YH QA2 QA1 QA4 QA6 WX2 WX5 WV3 WS6 WS7 W67 W53 WX1
#YB #YK #YE #YG #PH IMMOBI #2A #2B #2C #2D #2E W48 WW9 WS9
R24 R26 R25 FR DOOR WIRE RH
F50 F49 CA1 G21 N31 N76 N78 BNDR-1 QA0 QA3 QA8 QA5 QA7 WX3 WX6 WV4 WS5 W65 W51 WX4
ECU WT1 WK6 WV2 WT0 WV0
E44 T45 I65 I01 D39RC6
#HA#HB #HC#HD J/C 4
#HE
#GA #GB #GE #GG#GH #GK #GM EARTH J/C ABS ECU TO FLOOR WIRE NO.3
J/B B-2 #GC #GD #GF #GJ #GL K02 BLOWER
J/C 5 K30 MTR COWL RH QC4 QC5 QB7 QC1 QB4 QB3 ZT3 Q50 XS0 XR3 XP8 XS4 XK3 X04 XP0 XR9 X02 XR4
A05 AA1 C09 QB5 QB9 QC7 QB6 QB8 Q34 QC3 Q47 QC2 Q51 XU4 XH6 XH7 XQ5 XS3 XT8 XQ2 X21 XV0
F52 F43 E43 A99 #FA #FB #FC #FD #FE #FW #FF #FG #FH
BNDR-3 #FJ #FK #FL #FM #FN #FX #FY #FZ K05 ITC ECU EFI ECU
J/B D-1 K44 K07 BLOWER RESISTOR
CTR DIFF VD1 T24 A/B WTOW 1 A/B ECU D&P NTRL ST SW
C39 C38 #TA #TE DIAGNOSIS
VD2 T25 #5A #5B #5C #5E
LOCK RR FOG #5F #5G #5J
T10 T09 T44 T26 T12 T11 T28 G03 H63 H64 H66 O/D OFF SOLENOID
SW A/B D #TC #TH #TL #TJ #5L
VL2 VN9 VN8 VN7 VN5 H65 Z53 G02 H62
T14 T02 T01 H37
SQUIB VP3 VL0 ZS4 VN6 A B
A/B ECU D
A/B WTOW 3 #TK #TM #TG #TD
#TF #TB BNDR-2 KV2 KC6 K99 A/C SW T44 T26 T12 T11 T28
A/B WTOW 4
METER 13 A/B WTOW 2 T14 T02 T01
A B
C21 F19 X03 Z83 H20 H22 H61 T37 WB0 H05 X01 H52 Z23 C19 K08
Z21 K06 K04
BLOWER SW G02
METER 10 G03
R10 R06 R04 C30
H28 M20 H27 H29 H24 H25 H26 BK/LP SW
R12 R08 Z30 C28
O/D OFF SW
METER 16 RADIO & CAST 1 & ILLUMI.
A10 H77 H80 N58 G06 O20 Z08 F21 G SSR
R28 R30 ZR8CE0 V74 O/D
R29 R31 QC9 QC8
H35 ZJ3 V72 V73 OFF RLY
K27 I54 I28 CIGAR Z31 RADIO & CAST 2
Z42 K28 Z18 I31 LIGHTER R15 PKB
RR DEF RR WIPER G07
SW SW
82131-87405

HW59
WIRE, COWL, RH (General/LHD)
IG SW (AM) O12 O31 F/L AM (L) COWL RH J/C (05) #EE G06 MET BRK WNG () COWL LH J/C3 (09) #KJ Q28 D/L MTR FR P (LOK +) COWL RH J/C2 (E03) #3C ZS7 RB EFI M RLY (E)
LGHTNG SW (B) A22 O69 M/FUSE H/L (L) COWL RH J/C3 (06) #EF G08 BRK O/LEV SW (+) COWL LH J/C3 (06) #KF Q27 D/L MTR FR P (U/L +) COWL RH J/C5 (09) #GJ XR3 EFI ECU (BAT)
M/FUSE TAIL (L) OF1 OF2 J/B M/F TAIL (L) COWL RH J/C3 (07) #EG G07 PK BRK SW (+) COWL LH J/C4 (08) #LH P31 P/W SW FR P (B) J/B FS ECUIG (B1) N52 OC8 EFI MAIN RLY (COL +)
FUSE HORNHZD (L) F69 F70 J/B HORN HZD (L) COWL R BNDR2 (E07) #5G ZJ3 O/D CUT SW (E) P/W MAS SW (PU +) P27 P29 P/W SW FR P (U +) F/P RLY (L) PD6 P06 FUEL PUMP (+)
IG SW (AM) O12 O31 F/L AM (L) COWL RH J/C8 (06) #ZF H35 O/D CUT SW (B) P/W MAS SW (PD +) P28 P30 P/W SW FR P (D +) COWL RH J/C1 (E02) #2B Z83 MET SPD (E)
HI BEAM IND (+) A10 A98 J/B H BM IND (+) COWL RH J/C8 (05) #ZE H52 O/D OFF IND (DI ) HTR BLR MTR (+) K02 K11 HTR RLY (L) COWL RH J/C6 (06) #XF XH6 EFI ECU (DEF)
H-LP RH (LO) A08 A99 J/B H-LP LOR () COWL RH J/C8 (07) #ZG V74 O/D CUT RLY (COLL) COWL RH J/C4 (11) #FL K13 HTR RLY (COL ) COWL RH J/C5 (03) #GC XH7 EFI ECU (H/L)
J/B H-LP HIR () AA1 A07 H-LP RH (HI) O/D CUT SOL (+) H37 V73 O/D CUT RLY (L) A/C RLY (COL ) KG9 XS0 EFI ECU (MGC) COWL R BNDR2 (E11) #5L XR9 EFI ECU (FAN)
COWL RH J/C5 (02) #GB A06 H-LP RH (B) COWL RH J/C4 (04) #FD V72 O/D CUT RLY (B) MAG CLT (+) KP1 K23 A/C RLY (L) COWL RH J/C8 (10) #ZK XQ5 EFI ECU (A/T)
COWL RH J/C5 (01) #GA A05 FUSE H-LP RH (L) STARTER (ST) M02 M14 ST RLY (L) COWL R BNDR3 (01) #HA OC9 EFI MAIN RLY (L) COWL R BNDR1 (E01) #4A #8A COWL L BNDR1 (E01)
COWL RH J/C8 (13) #ZN C28 RADIO (ILM +) MET A/T IND (L) H24 H62 A/T NSS (L) COWL R BNDR3 (05) #HE K18 A/C I/UP VSV (+) COWL RH J/C1 (E02) #2B #4B COWL R BNDR12 (E02)
J/B HTR ILM (B) CA1 C19 HTR CON ILM (+) MET A/T IND (2) H25 H63 A/T NSS (2) A/C I/UP VSV () K19 XQ6 EFI ECU (VSV3) COWL RH J/C1 (E01) #2A #3A COWL RH J/C2 (E01)
MET(ILM +) C21 H78 J/B MET ILM (+) MET A/T IND (D) H26 H64 A/T NSS (D) E/G WP BNDR3 (05) #DE KK4 A/C THEMSTR () COWL RH J/C1 (E03) #2C #5A COWL R BNDR2 (E01)
COWL R BNDR2 (E03) #5C Z23 HTR CON ILM (E) MET A/T IND (N) H27 H65 A/T NSS (N) A/C THEMSTR (+) KP5 KP8 EFI ECU (ACEV) COWL RH J/C2 (E05) #3E ZS1 D/LOCK SW (E)
COWL R BNDR1 (E03) #4C Z08 MET EARTH (E) MET A/T IND (P) H29 H66 A/T NSS (P) COWL RH J/C4 (08) #FH K44 HTR RESSTR (+) J/B HAZ SW (RH) F49 QB5 ITC ECU (CHR)
COWL RH J/C2 (E02) #3B Z27 CLA LP RH () COWL RH J/C8 (09) #ZJ M20 A/T IND DIOD (B) COWL RH J/C4 (07) #FG K04 HTR BLR SW (H) J/B HAZ SW (LH) F50 QC4 ITC ECU (CHL)
COWL RH J/C8 (12) #ZM C10 CLA LP RH (+) COWL RH J/C8 (08) #ZH M07 ST RLY (COL ) HTR RESSTR (M & M1) K05 K06 HTR BLR SW (M, M1) COWL RH J/C4 (15) #FW QB3 ITC ECU (IG1)
COWL RH J/C8 (11) #ZL C09 J/B CLA LP (RH +) COWL R BNDR2 (E09) #5J Z53 A/T NSS (E) COWL RH J/C4 (12) #FM XK3 EFI ECU (BLW) FUSE D/LOCK (L) Q17 Q47 ITC ECU (+B)
COWL RH J/C8 (14) #ZP CE0 FLOOR ILM (+) IG SW (ST) M01 M15 ST RLY (COL +) COWL RH J/C4 (10) #FK K08 HTR BLR SW (L) COWL RH J/C2 (E06) #3F ZT3 ITC ECU (E1)
COWL R BNDR2 (E05) #5E ZR8 FLOOR ILM () J/B F/WSH MO (+) I01 I03 FR WSH MTR (+) COWL RH J/C1 (E04) #2D Z21 HTR BLR SW (E) OFFBOARD CON (ITCT) VP3 QC1 ITC ECU (T)
COWL RH J/C3 (01) #EA E11 STOP LP SW () FR WSH SW (L) I60 ZQ9 FR WSH MTR () J/B F/GGE-BK (L) H79 K12 HTR RLY (COL +) ITC ECU (CS1) QC3 QC8 ALL RNG SSR (+)
STOP LP SW (+) E10 E23 FUSE STOP (L) FR WIP MTR (HI) I20 I57 FR WIP SW (2) COWL RH J/C4 (05) #FE KC6 A/C SW (+B) ITC ECU (CS ) QC2 QC9 ALL RNG SSR ()
COWL RH J/C (02) #EB #UA FLOOR BNDR2 (01) FR WIP MTR (LO) I18 I56 FR WIP SW (1) COWL RH J/C4 (13) #FN KV2 A/C SW IND () D/LOCK SW (U/L +) Q25 QB8 ITC ECU (UKS)
COWL RH J/C5 (06) #GF D02 ROOM LP (+) FR WIP MTR (S) I24 I41 INT RLY (INT) A/C D/PRS SW () KP7 XS4 EFI ECU (ACSW) COWL RH J/C4 (18) #FZ X03 MET (SPSR)
COWL RH J/C5 (05) #GE E44 J/B F/STOP (L2) FR WIP MTR (+B) I22 I65 J/B F/WP-TRN (L1) A/C D/PRS SW (+) KP6 K99 A/C SW () COWL RH J/C4 (17) #FY X04 EFI ECU (SPD)
FLOOR J/C1 (01) #SA G03 BACK LP SW () RR WSH SW (B) I28 I66 J/B F/WP-TRN (L2) COWL RH J/C4 (06) #FF K30 HTR BLR MTR () COWL RH J/C4 (16) #FX Q34 ITC ECU (SPD)
BACK LP SW (+) G02 G21 J/B BACK LP (SW +) RR WIP MTR () I30 I31 RR WIP SW (B) COWL RH J/C4 (09) #FJ K07 HTR RESSTR (L) ROOM LP (DR) D03 QB6 ITC ECU (CRL)
BACK LP SW (+) G02 G21 J/B BACK LP (SW +) COWL R BNDR1 (E04) #4D Z18 RR WIP SW (E) COWL RH J/C4 (03) #FC VD1 DIFLOCK SW (B) J/B CTY SW (+2) D72 QB4 ITC ECU (DCSD)
COWL RH J/C8 (01) #ZA G03 BACK LP SW () RR WSH MTR (+) I26 I54 RR WSH SW (L) COWL RH J/C3 (11) #EL VD8 DIFLOCK VSV2 (+) COWL R J/C11 (02) #NN QB9 ITC ECU (CFL)
FLOOR J/C1 (01) #SA #ZB COWL RH J/C8 (02) COWL RH J/C2 (E05) #3E ZN0 RR WSH MTR (E) COWL R BNDR1 (E06) #4F VD9 DIFLOCK VSV2 () COWL R J/C11 (05) #NR QC7 ITC ECU (CHZD)
COWL RH J/C8 (04) #ZD H28 MET A/T (ND (R +)) DEF SW (B) K27 K98 J/B FUSE DEF (L) COWL R BNDR1 (E07) #4G VD7 DIFLOCK VSV1 () J/B TRN SW () F67 QC5 ITC ECU (FL +)
COWL RH J/C8 (03) #ZC D39 J/B R/WNG (BUZ +) COWL R BNDR1 (E05) #4E Z42 DEF SW (E) COWL RH J/C3 (12) #EM H77 DIFLOCK IND (+) MULTI SW (HAZ ) F48 QB7 ITC ECU (T/H)
TRN IND LH (+) F19 F54 J/B TRN IND (LH) COWL RH J/C6 (04) #XD K28 DEF SW (L) COWL RH J/C3 (09) #EJ VD2 DIFLOCK SW (L) COWL LH J/C3 (05) #KE Q51 ITC ECU (ULM)
SID TRN LP R (+) F16 F43 J/B S/TRN LP (RH +) COWL RH J/C6 (05) #XE K29 DEF (+) COWL RH J/C3 (10) #EK VD6 DIFLOCK VSV (+) COWL LH J/C3 (08) #KH Q50 ITC ECU (LKM)
FR TRN LP RH (+) F14 F52 J/B F/TRN LP (RH) COWL LH J/C3 (13) #KN R26 E MIRROR RH (C) COWL RH J/C5 (08) #GH C90 FUSE BK/UP (L) COWL LH J/C5 (03) #MC C25 FR FOG LP RH (+)
TRN IND RH (+) F21 F55 J/B TRN IND (RH) E MIRROR SW (VR) R19 R24 E MIRROR RH (V) COWL RH J/C7 (09) #YJ QB2 J/B IMMB ECU (IG) COWL RH J/C2 (E06) #3F ZD2 FR FOG LP RH ()
COWL RH J/C2 (E02) #3B ZM4 FR TRN LP RH () E MIRROR SW (HR) R21 R25 E MIRROR RH (H) OFFBOARD CON (ABST) VN9 WK6 ABS ECU (TS) FUSE FOG (L) CE7 C23 FR FOG LP SW (B)
COWL RH J/C2 (E01) #3A ZM5 SID TRN LP R () COWL RH J/C7 (01) #YA RC8 FUSE ACC (L3) COWL R BNDR2 (E02) #5B ZS4 OFFBOARD CON (E) COWL LH J/C5 (01) #MA C24 FR FOG LP SW (L)
HORN RH () E03 E19 HORN SW (+) COWL RH J/C7 (02) #YB R16 E MIRROR SW (B) COWL RH J/C6 (08) #XH VL0 OFFBOARD CON (SIO) COWL LH J/C5 (02) #MB C26 FR FOG LP LH (+)
HORN RH (+) E02 E43 J/B HORN (+B) FUSE ACC (L2) RC7 R15 CIG LTR (+) COWL RH J/C7 (05) #YE VN8 OFFBOARD CON (ECUT) ABS P SSR FR (+) WA4 W67 ABS ECU (FR1)
COWL RH J/C5 (07) #GG D67 LUG ROOM LMP (B) COWL R BNDR2 (E06) #5F Z31 CIG LGT (E) OFFBOARD CON (VF) VN6 X21 EFI ECU (VF) ABS P SSR FR () WA5 W53 ABS ECU (FR0)
E/G J/C1 (E05) #1E #2A COWL RH J/C1 (E01) RADIO (SPL ) R08 R09 SP FR LH () J/B FUSE ENG (L2) N78 VL2 OFFBOARD CON (IG) COWL RH J/C5 (12) #GM WS9 ABS ECU (BAT)
E/G WP BNDR1 (01) #BA N76 J/B FUSE ENG (L1) RADIO (SPL +) R06 R07 SP FR LH (+) COWL RH J/C6 (07) #XG XT8 EFI ECU (SIO) COWL RH J/C2 (E04) #3D ZN9 ABS MTR ()
MET (CHG) O20 O21 ALT (L) RADIO (SPL +) R30 R34 RR SP LH (+) COWL RH J/C7 (04) #YD XS3 EFI ECU (T) ABS ACT (MT) WK1 WS5 ABS ECU (MS)
MET THRM G (+) H20 H21 THRM SENDER (+) RADIO (SRL ) R31 R35 RR SP LH () COWL RH J/C6 (09) #XJ WV0 ABS ECU (SIO) COWL R BNDR5 (01) #GR WK2 ABS ACT (BS)
MET FUEL G (+) H22 H23 FUEL SENDER (+) RADIO (SRR +) R28 R32 RR SP RH (+) COWL RH J/C7 (06) #YF WV2 ABS ECU (TC) ABS MTR RLY (L) WS4 WW1 ABS ACT (BM)
COWL RH J/C6 (02) #XB XQ2 EFI ECU (REV) RADIO (SRR ) R29 R33 RR SP RH () MET (EFI) X01 X02 EFI ECU (W) COWL R BNDR4 (03) #FT WS0 ABS MAI RLY (SWNO)
COWL RH J/C6 (01) #XA N58 MET (REV) FUSE ACC (L1) RC6 R04 RADIO (+B) EFI ECU (AUX1) XP0 XT2 RESISTOR1 (+) COWL RH J/C9 (04) #EU WS1 ABS MTR RLY (COL +)
COWL RH J/C6 (03) #XC VN5 OFFBOARD CON (REV) COWL RH J/C5 (10) #GK C30 RADIO (B/UP) E/G WP BNDR2 (01) #CA #HD COWL R BNDR3 (04) COWL R BNDR4 (02) #FS WS3 ABS MTR RLY (B)
COWL RH J/C4 (01) #FA H67 J/B MET (+) COWL RH J/C1 (E05) #2E Z30 RADIO (E) COWL R BNDR3 (02) #HB XR4 EFI ECU (+B1) COWL R ENDR5 (03) #GT WG2 ABS DIODE ()
COWL RH J/C4 (02) #FB H61 MET (IG) RADIO (SPR +) R10 R11 SP FR RH (+) COWL R BNDR3 (03) #HC XV0 EFI ECU (+B2) COWL RH J/C9 (03) #ET WG1 ABS DIODE (+)
MET OIL PRES () H05 H06 OIL PRES SW (B) RADIO (SPR ) R12 R13 SP FR RH () F/P RLY (COL ) PD7 XU4 EFI ECU (FC1) COWL RH J/C9 (01) #ER WB0 MET ABS IND ()

HW60
From To
ABS MTR RLY (COL ) WS2 WS6 ABS ECU (PCO)
ABS MAI RLY (COL ) WR7 WS7 ABS ECU (REL)
COWL RH J/C9 (06) #EW WV3 ABS ECU (R +)
ABS ECU (AST) WV4 WW2 ABS ACT (AST)
ABS ACT (SFRH) WW3 WX1 ABS ECU (SFRH)
ABS ACT (SRH) WW5 WX3 ABS ECU (SRH)
ABS ACT (SFLH) WW4 WX2 ABS ECU (SFLH)
ABS ACT (SFRR) WW6 WX4 ABS ECU (SFRR)
ABS ACT (SFLR) WW7 WX5 ABS ECU (SFLR)
ABS ACT (SRR) WW8 WX6 ABS ECU (SRR)
COWL RH J/C7 (11) #YL W48 ABS ECU (IGM)
COWL R BNDR1 (E08) #4H ZG3 ABS MAI RLY (SWNC)
ABS P SSR FL (+) WA0 W65 ABS ECU (FL1)
ABS P SSR FL () WA1 W51 ABS ECU (FL0)
COWL R BNDR4 (01) #FR OC6 F/L ABS (L)
COWL RH J/C9 (05) #EV WR8 ABS MAI RLY (COL +)
COWL R BNDR5 (02) #GS WR9 ABS MAI RLY (SWC)
COWL RH J/C9 (02) #ES WT1 ABS ECU (WLAS)
COWL RH J/C3 (13) #EN WW9 ABS ECU (EX1)
82131-87425

HW61
WIRE, COWL, RH (General/LHD)
R/B 3-2
ABS DIODE & CHECK PD6 PD7
OC9 ZS7
WS3 WS4 R/B 3-1

ABS RLY 2 WG1
FR TURN RH
WS1 WS2 WG2
OC6 O31
HORN
E02 F14
E03
ZM4
ABS ACT
ABS ACT 1 EARTH
FR WSH MTR 6 #3D ZD4 C25
ZQ9
WW5 WW4 WW3 CLEARANCE RH
WW8 WW7 WW6 C10
FR FOG RH
I03
EARTH J/C Z27
RR WSH MTR FENDER RH
ZN0 ZN9 WW1 #3A #3B #3C #3E #3F
TO TO I26 WW2 WK2 WK1
T/F TO
COWL WIRE LH D COWL WIRE LH A
VSV 1 ABS ACT 2 E/G WIRE A08
#LH KP6 R21 R09 R07 P27 I41 #KJ I60 C26 I20 I18 VD8 T/F NO.2 M02
A07 A06
WA0 WA1 R16 #KN R19 P28 KP7 G08 I56 #KF I57 E10
FR WIPER MTR I24 I22 VD6 VD9 VSV 2
E19 #8A E11 A22 VD7 F69 OF1 O69
HEAD LAMP RH
KP1
R/B 1 K23 KG9 C90
TO COWL WIRE LH M/T O12 M14
K11 OC8
M15 M07
K12 K13
A/C VSV R/B 2-1
TO COWL WIRE LH A/T O12M01
R/B 2-2
K18 WA5 WA4
K19
TO COWL WIRE LH ITC ABS SSR FRRH
ZS1 #KE Q25 J/C 3 J/C 9
F48 F67 #NR #NN#KH #EE #EG #EA #EC #EJ #EL #EN #EV #EU #ER
#EF #EB #EK #EM #EW #ET #ES
J/C 6
F16 ZM5
J/B B-3 J/B F TO FLOOR WIRE
#SA K29 H23 R34 THERMISTOR ABS SIDE TURN RH
F70
OF2 N52 P06 D67 #UA I30 R33 R32 R35 J/C 8
RC7 KP5 RLY 1
#XA #XB #XC #XD #XE #XF #MA #MB #MC #FR #FS #FT #GR #GS #GT #ZA #ZC #ZL #ZN #ZF #ZG #ZK
KK4 WS0 WR9 #DEXQ6 #BA #IE
#XG #XH #XJ #ZB #ZD #ZM #ZP #ZE #ZH #ZJ
WR8 ZG3 WR7 #CA H21H06 O21 XT2
J/B B-1 #4A #4B #4C #4D
RC8 D72 E28 #4E #4F #4G #4H
TO TO E/G WIRE TO
D03 D02 ROOF
H79 H67 H78 CE7 Q17 QB2 A98 WIRE FLOOR
BNDR-4 BNDR-5 Q28Q27 P31
F55 F54 K98 I66 WIRE NO.3 R11 R13 P29 P30
#YA #YJ #YL #YF WX2 WX5 WV3 WS6 WS7 W67 W53 WX1
W48 WW9 WS9 R24 R26 R25
F50 F49 CA1 G21 N76 N78 #YB #YE J/C 7 #2A #2B #2C #2D #2E
BNDR-1 WX3 WX6 WV4 WS5 W65 W51 WX4 WT1 WK6 WV2 WT0 WV0
E44 I65 I01 D39RC6 BNDR-3 J/C 4 TO FR DOOR WIRE RH
#HA#HB #HC#HD J/C 5 #GA #GB #GE #GG#GH #GK #GM
EARTH J/C ABS ECU
J/B B-2 #HE #GC #GF #GJ K02
K30 COWL RH QC4 QC5 QB7 QC1 QB4 QB3 ZT3 Q50 XS0 XR3 XP8 XS4 XK3 X04 XP0 XR9 X02 XR4
A05 AA1 C09 QB5 QB9 QC7 QB6 QB8 Q34 QC3 Q47 QC2 Q51
F52 F43 E43 A99
BLOWER MTR XU4 XH6 XH7 XQ5 XS3 XT8 XQ2 X21 XV0
#FA #FB #FC #FD #FE #FW #FF #FG #FH
#FJ #FK #FL #FM #FN #FX #FY #FZ K05 ITC ECU EFI ECU
J/B D-1 K44 K07 BLOWER RESISTOR
VD1 NTRL ST SW
C24 C23 DIAGNOSIS
VD2 #5A #5B #5C #5E
O/D OFF SOLENOID
CTR DIFF FR FOG SW #5F #5G #5J G03 H63 H64 H66
VL2 VN9 VN8 VN5 H65 Z53 G02 H62
#5L H37
LOCK VP3 VL0 #YD ZS4 VN6
BNDR-2 KV2 KC6 K99 A/C SW

METER 13
C21 F19 X03 Z83 H20 H22 H61 WB0 H05 X01 H52 Z23 C19 K08
Z21 K06 K04 BLOWER SW
G02
METER 10 G03
R10 R06 R04 C30
H28 M20 H27 H29 H24 H25 H26 BK/LP SW
R12 R08 Z30 C28
O/D OFF SW
RADIO & CAST 1 & ILLUMI.
A10 H77 N58 G06 O20 Z08 F21 G SSR O/D OFF RLY
R28 R30 ZR8CE0 V74
QC9 QC8
METER 16 R29 R31 H35 ZJ3 V72 V73
K27 I54 I28 Z31 RADIO & CAST 2
Z42 K28 Z18 I31 R15 CIGAR LIGHTER
RR DEF RR WIPER G07
SW SW
PKB
82131-87425

HW62
WIRE, COWL, LH (EC/RHD & AUS.)
COWL LH J/C9 (02) #RB A02 H-LP LH (B) COWL LR J/C4 (01) #LA H67 J/B MET (+) RADIO (SRL ) R31 R35 RR SP LH () COWL LH J/C7 (05) #PE VN8 OFFBOARD CON (ECUT)
COWL LH J/C9 (01) #RA A01 FUSE H-LP LH (L) COWL LH J/C3 (06) #KF G06 MET BRK WNG () RADIO (SRL +) R30 R34 RR SP LH (+) COWL LH J/C6 (08) #NH VL0 OFFBOARD CON (SIO)
J/B H-LP LOL () AA0 A04 H-LP LH (LO) COWL LH J/C3 (08) #KH G07 PK BRK SW (+) RADIO (SPL +) R06 R07 SP FR LH (+) COWL L BNDR2 (E02) #9B ZS4 OFFBOARD CON (E)
J/B H-LP HIL () AA2 A03 H-LP LH (HI) COWL LH J/C3 (07) #KG G08 BRK O/LEV SW (+) RADIO (SPL ) R08 R09 SP FR LH () COWL L J/C10 (01) #KR Q17 FUSE D/LOCK (L)
HI BEAM IND (+) A10 A98 J/B H BM IND (+) COWL LH J/C4 (04) #LD V72 O/D CUT RLY (B) COWL RH J/C4 (12) #FM Q28 D/L MTR FR P (LOK +) COWL L J/C10 (02) #KS Q47 ITC ECU (+B)
RR FOG SW (+) C38 D58 J/B KEY SW (+) O/D CUT SOL (+) H37 V73 O/D CUT RLY (L) COWL RH J/C4 (09) #FJ Q27 D/L MTR FR P (U/L +) OFFBOARD CON (ABST) VN9 WK6 ABS ECU (TS)
RR FOG SW () C39 D61 J/B K/WNG (BUZB) COWL LH J/C8 (07) #QG V74 O/D CUT RLY (COLL) COWL RH J/C3 (05) #EE P31 P/W SW FR P (B) COWL LH J/C6 (09) #NJ WV0 ABS ECU (SIO)
COWL RH J/C5 (11) #GL H80 MET RR FOG (IND +) COWL LH J/C8 (06) #QF H35 O/D CUT SW (B) P/W MAS SW (PU +) P27 P29 P/W SW FR P (U +) COWL LH J/C7 (06) #PF WV2 ABS ECU (TC)
COWL LH J/C3 (01) #KA C06 J/B CLA LP (LH +) COWL L BNDR2 (E07) #9G ZJ3 O/D CUT SW (E) P/W MAS SW (PD +) P28 P30 P/W SW FR P (D +) COWL LH J/C5 (08) #MH XR3 EFI ECU (BAT)
COWL LH J/C3 (03) #KC C28 RADIO (ILM +) COWL LH J/C8 (05) #QE H52 O/D OFF IND (DI ) HTR BLR MTR (+) K02 K11 HTR RLY (L) COWL LH J/C9 (09) #RJ XR4 EFI ECU (+B1)
J/B HTR ILM (B) CA1 C19 HTR CON ILM (+) COWL LH J/C8 (09) #QJ M20 A/T IND DIOD (B) COWL LH J/C4 (12) #LM K13 HTR RLY (COL ) COWL LH J/C9 (10) #RK XV0 EFI ECU (+B2)
MET (ILM +) C21 H78 J/B MET ILM (+) COWL LH J/C8 (08) #QH M07 ST RLY (COL ) A/C D/PRS SW () KP7 XS4 EFI ECU (ACSW) E/G WP BNDR2 (01) #CA #RL COWL LH J/C9 (11)
COWL LH J/C3 (02) #KB C12 CLA LP LH (+) MET A/T IND (P) H29 H66 A/T NSS (P) A/C D/PRS SW (+) KP6 K99 A/C SW () MET (EFI) X01 X02 EFI ECU (W)
COWL LH J/C2 (E02) #7B Z28 CLA LP LH () MET A/T IND (N) H27 H65 A/T NSS (N) COWL LH J/C4 (07) #LG K04 HTR BLR SW (H) COWL L BNDR2 (E11) #9L XR9 EFI ECU (FAN)
COWL L BNDR2 (E03) #9C Z23 HTR CON ILM (E) MET A/T IND (D) H26 H64 A/T NSS (D) COWL LH J/C4 (08) #LH K44 HTR RESSTR (+) EFI ECU (AUX1) XP0 XT2 RESISTOR1 (+)
COWL L BNDR1 (E03) #8C Z08 MET EARTH (E) MET A/T IND (2) H25 H63 A/T NSS (2) HTR RESSTR (M & M1) K05 K06 HTR BLR SW (M, M1) COWL LH J/C9 (03) #RC XH7 EFI ECU (H/L)
COWL L BNDR2 (E05) #9E ZR8 FLOOR ILM () MET A/T IND (L) H24 H62 A/T NSS (L) COWL LH J/C4 (10) #LK K08 HTR BLR SW (L) COWL LH J/C6 (06) #NF XH6 EFI ECU (DEF)
COWL LH J/C3 (05) #KE CE0 FLOOR ILM (+) COWL L BNDR2 (E09) #9J Z53 A/T NSS (E) COWL LH J/C4 (11) #LL XK3 EFI ECU (BLW) COWL RH J/C4 (07) #FG #RH COWL LH J/C9 (08)
COWL LH J/C9 (04) #RD A61 H-LP LEV ACT (LH +) MULTI SW (HAZ ) F48 QB7 ITC ECU (T/H) COWL LH J/C1 (E04) #6D Z21 HTR BLR SW (E) COWL L J/C10 (11) #LV X04 EFI ECU (SPD)
COWL LH J/C2 (E05) #7E ZM7 H-LP LEV ACT (LH E) J/B TRN SW () F67 QC5 ITC ECU (FL +) E/G WP BNDR3 (05) #DE KK4 A/C THEMSTR () COWL L J/C10 (12) #LW X03 MET (SPSR)
COWL RH J/C5 (02) #GB A63 H-LP LEV ACT (LH 0) KEYLESS KEY (1) #E1 D61 J/B K/WNG (BUZB) A/C THEMSTR (+) KP5 XP8 EFI ECU (ACEV) COWL L J/C10 (10) #LU Q34 ITC ECU (SPD)
COWL LH J/C9 (06) #RF #UA FLOOR BNDR2 (01) KEYLESS KEY (2) #E2 D14 IG KEY SW () A/C RLY (COL ) KG9 XS0 EFI ECU (MGC) COWL LH J/C1 (E02) #6B Z83 MET SPD (E)
COWL LH J/C9 (05) #RE E11 STOP LP SW () IG KEY SW (+) D13 D58 J/B KEY SW (+) A/C I/UP VSV () K19 XQ6 EFI ECU (VSV3) COWL LH J/C8 (10) #QK XQ5 EFI ECU (A/T)
STOP LP SW (+) E10 E28 FUSE STOP (L) FR WIP MTR (HI) I20 I57 FR WIP SW (2) MAG CLT (+) KP1 K23 A/C RLY (L) F/P RLY (COL ) PD7 XU4 EFI ECU (FC1)
COWL LH J/C5 (05) #ME D02 ROOM LP (+) FR WIP MTR (LO) I18 I56 FR WIP SW (1) J/B F/GGE-BK (L) H79 K12 HTR RLY (COL +) A/B ECU (IG2) #TA T45 FUSE A/B (L1)
ROOM LP (DR) D03 QB6 ITC ECU (CRL) FR WIP MTR (S) I24 I41 INT RLY (INT) COWL LH J/C4 (05) #LE KC6 A/C SW (+B) FUSE A/B (L) #TB T02 A/B ECU (IG2)
COWL LH J/C5 (04) #MD E44 J/B F/STOP (L2) FR WIP MTR (+B) I22 I65 J/B F/WP-TRN (L1) COWL LH J/C4 (06) #LF K30 HTR BLR MTR () A/B ECU (IG1) #TH N31 J/B FUSE ENG (L)
COWL L J/C10 (04) #KU D72 J/B CTY SW (+2) FR WSH SW (L) I60 ZQ9 FR WSH MTR () COWL LH J/C4 (09) #LJ K07 HTR RESSTR (L) FUSE E/G (L) #TG T01 A/B ECU (IG1)
COWL L J/C10 (05) #KV QB4 ITC ECU (DCSD) J/B F/WSH MO (+) I01 I03 FR WSH MTR (+) COWL LH J/C4 (13) #LN KV2 A/C SW IND () A/B ECU (W) #TE T37 MET (A/B)
BACK LP SW (+) G02 G21 J/B BACK LP (SW +) RR WSH SW (B) I28 I66 J/B F/WP-TRN (L2) COWL LH J/C4 (03) #LC VD1 DIFLOCK SW (B) MET A/B IND () #TF T26 A/B ECU (W)
FLOOR J/C1 (01) #SA G03 BACK LP SW () RR WIP MTR () I30 I31 RR WIP SW (B) COWL LH J/C3 (12) #KM H77 DIFLOCK IND (+) COWL L J/C1 (E05) #TD T14 A/B ECU (E1)
BACK LP SW (+) G02 G21 J/B BACK LP (SW +) COWL L BNDR1 (E04) #8D Z18 RR WIP SW (E) COWL RH J/C3 (01) #EA #KL COWL LH J/C3 (11) A/B ECU (E1) #TC #6E COWL LH J/C1 (E05)
COWL LH J/C8 (03) #QC D39 J/B R/WNG (BUZ +) RR WSH MTR (+) I26 I54 RR WSH SW (L) COWL LH J/C3 (10) #KK VD2 DIFLOCK SW (L) A/B ECU (D +) T11 T24 A/B SQUIB (D +)
COWL LH J/C8 (01) #QA G03 BACK LP SW () COWL LH J/C2 (E03) #7C ZN0 RR WSH MTR (E) COWL LH J/C7 (09) #PJ QB2 J/B IMMB ECU (IG) A/B ECU (D ) T12 T25 A/B SQUIB (D )
COWL HL J/C8 (02) #QB #SA FLOOR J/C1 (01) DEF SW (B) K27 K98 J/B FUSE DEF (L) COWL LH J/C7 (10) #PK QA0 IMMOBI ECU (IG) A/B ECU (PS +) T09 T42 A/B SQUIB (P +)
COWL LH J/C8 (04) #QD H28 MET A/T IND (R+) COWL LH J/C6 (04) #ND K28 DEF SW (L) COWL LH J/C5 (07) #MG C90 FUSE BK/UP (L) A/B ECU (PS ) T10 T43 A/B SQUIB (P )
SID TRN LP L (+) F11 F44 J/B S/TRN LP (LH +) COWL LH J/C6 (05) #NE K29 DEF (+) IMMOBI ECU (COL +) QA4 QB0 IMMOBI ANTN (COL +) ABS ACT (MT) WK1 WS5 ABS ECU (MS)
FR TRN LP LH (+) F09 F53 J/B F/TRN LP (LH) COWL L BNDR1 (E05) #8E Z42 DEF SW (E) IMMOBI ECU (COL ) QA5 QB1 IMMOBI ANTN (COL ) ABS MTR RLY (COL ) WS2 WS6 ABS ECU (PCO)
COWL LH J/C2 (E04) #7D ZM6 SID TRN LP L () COWL RH J/C5 (09) #GJ R27 E MIRROR LH (C) COWL L BNDR1 (E06) #8F QA6 IMMOBI ECU (E) ABS MAI RLY (COL ) WR7 WS7 ABS ECU (REL)
COWL LH J/C2 (E02) #7B ZM3 FR TRN LP LH () E MIRROR SW (HL) R20 R23 E MIRROR LH (H) COWL LH J/C7 (03) #PC QA1 IMMOBI ECU (ACC) COWL RH J/C3 (09) #EJ WV3 ABS ECU (R +)
TRN IND LH (+) F19 F54 J/B TRN IND (LH) E MIRROR SW (VL) R18 R22 E MIRROR LH (V) COWL LH J/C5 (10) #MK QA2 IMMOBI ECU (+B) ABS ECU (AST) WV4 WW2 ABS ACT (AST)
TRN IND RH (+) F21 F55 J/B TRN IND (RH) COWL LH J/C7 (01) #PA RC8 FUSE ACC (L3) J/B FUSE ENG (L2) N78 VL2 OFFBOARD CON (IG) ABS ACT (SFRH) WW3 WX1 ABS ECU (SFRH)
MET (CHG) O20 O21 ALT (L) COWL LH J/C7 (02) #PB R16 E MIRROR SW (B) OFFBOARD CON (VF) VN6 X21 EFI ECU (VF) ABS ACT (SFLH) WW4 WX2 ABS ECU (SFLH)
E/G WP BNDR1 (01) #BA M76 J/B FUSE ENG (L1) FUSE ACC (L2) RC7 R15 CIG LTR (+) COWL LH J/C7 (04) #PD XS3 EFI ECU (T) ABS ACT (SRH) WW5 WX3 ABS ECU (SRH)
COWL LH J/C5 (06) #MF D67 LUG ROOM LMP (B) COWL L BNDR2 (E06) #9F Z31 CIG LGT (E) COWL LH J/C6 (07) #NG XT8 EFI ECU (SIO) ABS ACT (SFRR) WW6 WX4 ABS ECU (SFRR)
MET THRM G (+) H20 H21 THRM SENDER (+) FUSE ACC (L1) RC6 R04 RADIO (+B) IMMOBI ECU (IND) QA7 VN7 OFFBOARD CON (IMBW) ABS ACT (SFLR) WW7 WX5 ABS ECU (SFLR)
MET FUEL G (+) H22 H23 FUEL SENDER (+) COWL LR J/C5 (09) #MJ C30 RADIO (B/UP) COWL LH J/C7 (07) #PG QA8 IMMOBI ECU (T) ABS ACT (SRR) WW8 WX6 ABS ECU (SRR)
COWL LH J/C6 (01) #NA N58 MET (REV) COWL LH J/C1 (E03) #6C Z30 RADIO (E) COWL LH J/C6 (10) #NK QA3 IMMOBI ECU (SIO) ABS P SSR FL (+) WA0 W65 ABS ECU (FL1)
COWL LH J/C6 (02) #NB XQ2 EFI ECU (REV) RADIO (SPR +) R10 R11 SP FR RH (+) COWL LH J/C7 (08) #PH #TJ A/B ECU (TC) ABS P SSR FL () WA1 W51 ABS ECU (FL0)
COWL LH J/C6 (03) #NC VN5 OFFBOARD CON (REV) RADIO (SPR ) R12 R13 SP FR RH () COWL LH J/C6 (11) #NL #TL A/B ECU (SIO) COWL LH J/C9 (07) #RG WT0 ABS ECU (BLS)
COWL LH J/C4 (02) #LB H61 MET (IG) RADIO (SRR ) R29 R33 RR SP RH () OBD2 (ECUT) #TK T28 A/B ECU (T) COWL LH J/C7 (11) #PL W48 ABS ECU (IGN)
MET OIL PRES () H05 M06 OIL PRES SW (B) RADIO (SRR +) R28 R32 RR SP RH (+) OBD2 (SIO) #TM T44 A/B ECU (SIO) COWL LH J/C8 (11) #QL WB0 MET ABS IND ()

HW63
From To
COWL LH J/C8 (12) #QM WU7 CHK TML ABS (STIM)
ABS P SSR FR () WA5 W53 ABS ECU (FR0)
ABS P SSR FR (+) WA4 W67 ABS ECU (FR1)
COWL LH J/C8 (13) #QN WT1 ABS ECU (WLAS)
COWL LH J/C5 (11) #ML WS9 ABS ECU (BAT)
COWL LH J/C3 (13) #KN WW9 ABS ECU (EXI)
COWL LH J/C1 (E02) #6B #8B COWL L BNDR1 (E02)
COWL LH J/C1 (E01) #6A #7A COWL LH J/C2 (E01)
COWL R BNDR1 (E01) #4A #8A COWL L BNDR1 (E01)
COWL LH J/C1 (E03) #6C #9A COWL L BNDR2 (E01)
FUSE A/B (L) #TB T02 A/B ECU (IG2)
A/B ECU (IG1) #TH N31 J/B FUSE ENG (L)
COWL L J/C1 (E05) #TD T14 A/B ECU (EI)
A/B ECU (E1) #TC #6E COWL LH J/C1 (E05)
A/B ECU (D +) T11 T24 A/B SQUIB (D +)
A/B ECU (D ) T12 T25 A/B SQUIB (D )
COWL LH J/C7 (08) #PH #TJ A/B ECU (TC)
COWL RH J/C4 (08) #FR Q51 ITC ECU (ULM)
COWL RH J/C4 (11) #FL Q50 ITC ECU (LKM)
COWL L J/C10 (08) #LS QB8 ITC ECU (UKS)
COWL L J/C10 (09) #LT Q25 D/LOCK SW (U/L +)
COWL LH J/C2 (E04) #7D ZS1 D/LOCK SW (E)
COWL LH J/C2 (E03) #7C ZT3 ITC ECU (E1)
OFFBOARD CON (ITCT) VP3 QC1 ITC ECU (T)
ITC ECU (CS ) QC2 QC9 ALL RNG SSR ()
ITC ECU (CSI) QC3 QC8 ALL RNG SSR (+)
COWL RH J/C5 (17) #GY QC7 ITC ECU (CHZD)
COWL RH J/C5 (14) #GV QB9 ITC ECU (CFL)
J/B HAZ SW (LH) F50 QC4 ITC ECU (CHL)
J/B HAZ SW (RH) F49 QB5 ITC ECU (CHR)
J/C4 (ITC) #E5 QB3 ITC ECU (IG1)
82132-87405

HW64
WIRE, COWL, LH (EC/RHD & AUS.)
FR TURN LH
F09
HEAD LAMP LH ZM3 CLEARANCE LH
A04
TO COWL WIRE RH B TO COWL WIRE RH ITC
C12
A03 A02
Z28
KP6 KP7 DUAL PS SW #EE C90 R20 R13 R11 P27 ZS1 #FH Q25
H-LP LVL LH PD7 #EA R16 #GJ R18 P28 #FG G08 F48 F67 #GY #GV #FL
ZM7 A63 A61 MAGNET CLUTCH

KP1 TO COWL WIRE RH A WS2 WA5 WA4 WW2
K11 I60 #FM WW7 WW4 #GB #GL #EJ WK1 TO COWL WIRE RH ABS
K13 I57 I41 I56 M07 #FJ WW5 WR7 WW6 WW3
EARTH J/C FENDER LH FR WSH K12 K19 KG9K23 #4A E10 E11 QB0 QB1 WU7 WW8
MTR RR WSH
#7A #7B #7C #7D #7E J/C 10
ZQ9 ZN0 MTR
I03 I26 FR WIPER
I20 I18
I24 I22 MOTOR
IMMOBI ECU #LU #LV #LW #KU #KV #LS #LT
#LF #LG #LH #KS #KR #E1 #E2
ABS SSR FENDER LH #KM #KK #KH #KF #KE #KC #KA QA2 QA1 QA4 QA6
J/C 3 #KN #KL #KG #KB QA0 QA3 QA8 QA5 QA7
WA1 WA0
J/C 9 J/C 7
J/C 5
#PA #PJ #PL #PF #PH
SIDE TURN LH BLOWER MTR #PB #PC #PK #PE #PG
A/B P
F11 ZM6 #RA #RC #RH #RK #RF #RG
SQUIB K02 A/B WTOW 4
#RB #RD #RJ #RL #RE J/C 8 J/C 6 K30 #MD #MF #MG#MJ #ML
#QA #QC #QM #QN #QJ #QH #QE KP5 #TK #TM #TG #TD
D03 D02 T42 T43 #ME #MH#MK
KK4 A/B WTOW 2
#QB #QD #QL #QK #QG #QF K05 BLOWER
TO ROOF THERMISTOR K44 K07 RESISTOR #TF #TB
WIRE #NA #NC #ND #NF #NG #NJ #NL A/B WTOW 1 # K29 H23 R34 TO
#NB #NE #NH #NK #9A #9B #9C D67 #UA I30 R33 R32 R35 FLOOR WIRE
BLOWER SW #TA #TE KEY SW
#9E #9G #9J
#6A #6B #6C #6D #6E Z23 C19 K08 J/C 4 BNDR-2 #9F #9L D13 D14
RC7
J/B B-3
EARTH J/C Z21 K06 K04
TO FR DOOR WIRE LH #TC #TH #TL #TJ
Q28 Q27 P31 COWL LH A/C SW RC8 D72 D58 E28
R07 R09 P29 P30 #DE XQ6 #BA KV2 KC6 K99
A/B WTOW 3 H79 H67 H78 Q17 QB2 A98 J/B B-1
R22 R27 R23 #CA H21 H06 O21 XT2 #LA #LB #LC #LD #LJ #LK #LL BNDR-1 F55 F54 K98 I66 D61
W48 WW9 WS9 #LE #E5 #LM #LN VL2 VN9 VN8 VN7 VN5 #8A #8B #8C #8D
WT1 WK6 WV2 WT0 WV0 TO E/G WIRE RADIO & R28 R30 VP3 VL0 #PD ZS4 VN6 T24 #8E #8F A01 AA0
WX2 WX5 WV3 WS6 WS7 W67 W53 WX1
CAST 2 R29 R31 DIAGNOSIS T25 AA2 F44 F53 C06 J/B D-2
TO WX3 WX6 WV4 WS5 W65 W51 WX4
FLOOR WIRE NO.3 A/B ECU D&P RR FOG SW A/B D SQUIB VD1
XS0 XR3 XP8 XS4 XK3 X04 XP0 XR9 X02 XR4 VD2
QC4 QC5 QB7 QC1 QB4 QB3 ZT3 Q50 ABS ECU R10 R06 R04 C30 T10 T09 T44 T26 T12 T11 T28 C39 C38
XU4 XH6 XH7 XQ5 XS3 XT8 XQ2 X21 XV0 F50 F49 CA1 G21 N31 N76 N78
QB5 QB9 QC7 QB6 QB8 Q34 QC3 Q47 QC2 Q51 R12 R08 Z30 C28 CTR DIFF J/B B-2
E44 T45 I65 I01 D39 RC6
EFI ECU T14 A B T02 T01 I54 I28 LOCK
ITC ECU RADIO & CAST 1 Z18 I31
Z31 RR WIPER SW K27 A10 H77 H80 N58 G06O20 Z08 F21
R15 Z42 K28
CIGAR LIGHTER T44 T26 T12 T11 T28 METER 16
RR DEF SW
T14 T02 T01 H28 M20H27 H29 H24 H25 H26
A B
A/B ECU D METER 13 METER 10
C21 F19 X03 Z83 H20 H22 H61 T37 WB0 H05 X01 H52
G03 H63 H64 H66
G07
K65 Z53 G02 H62
PKB
NTRL ST SW
H37
O/D OFF SOLENOID
V74 QC9 QC8 G02

ZR8 CE0
V72 V73 G SSR G03
H35 ZJ3
O/D OFF RLY O/D OFF SW & BK/LP SW
ILLUMINATION
82132-87405

HW65
WIRE, COWL, LH (General/RHD)
COWL LH J/C9 (02) #RB A02 H-LP LH (B) COWL LH J/C4 (02) #LB H61 MET (IG) P/W MAS SW (PD +) P28 P30 P/W SW FR P (D +) COWL LH J/C1 (E02) #6B Z83 MET SPD (E)
COWL LH J/C9 (01) #RA A01 FUSE H-LP LH (L) COWL LH J/C4 (04) #LD V72 O/D CUT RLY (B) MTR BLR MTR (+) K02 K11 MTR RLY (L) COWL L BNDR2 (E11) #9L XR9 EFI ECU (FAN)
J/B H-LP LOL () AA0 A04 H-LP LH (LO) O/D CUT SOL (+) H37 V73 O/D CUT RLY (L) COWL LH J/C4 (12) #LM K13 MTR RLY (COL ) COWL LH J/C8 (10) #QK XQ5 EFI ECU (A/T)
J/B H-LP HIL () AA2 A03 H-LP LH (HI) COWL LH J/C8 (07) #QG V74 O/D CUT RLY (COLL) A/C D/PRS SW () KP7 XS4 EFI ECU (ACSW) MET OIL PRESS () H05 H06 OIL PRES SW (B)
HI BEAM IND (+) A10 A98 J/B H BM IND (+) COWL LH J/C8 (05) #QE H52 O/D OFF IND (DI ) A/C D/PRS SW (+) KP6 K99 A/C SW () COWL L J/C10 (11) #LV K04 EFI ECU (SPD)
COWL LH J/C3 (01) #KA C06 J/B CLA LP (LH +) COWL LH J/C8 (06) #QF H35 O/D CUT SW (B) COWL LH J/C4 (07) #LG K04 HTR BLR SW (H) COWL L J/C10 (12) #LW X03 MET (SPSR)
FUSE FOG (L) CE7 C23 FR FOG LP SW (B) COWL L BNDR2 (E07) #9G ZJ3 O/D CUT SW (E) COWL LH J/C4 (08) #LH K44 HTR BESSTR (+) COWL L J/C10 (10) #LU Q34 ITC ECU (SPD)
COWL LH J/C3 (03) #KC C28 RADIO (ILM +) COWL LH J/C8 (09) #QJ M20 A/T IND DIOD (B) NTR RESSTR (M & M1) K05 K06 HTR BLR SW (M, M1) COWL L J/C10 (01) #KR Q17 FUSE D/LOCK (L)
J/B HTR ILM (B) CA1 C19 HTR CON ILM (+) COWL LH J/C8 (08) #QH M07 ST RLY (COL ) COWL LH J/C4 (10) #LK K08 HTR BLR SW (L) COWL L J/C10 (02) #KS Q47 ITC ECU (+B)
MET (ILM +) C21 H78 J/B MET ILM (+) MET A/T IND (P) K29 H60 A/T NSS (P) COWL LH J/C4 (11) #LL XK3 EFI ECU (BLW) ROOM LP (DR) D03 QB5 ITC ECU (CRL)
COWL LH J/C3 (02) #KB C12 CLA LP LR (+) MET A/T IND (N) K27 H65 A/T NSS (N) COWL LH J/C1 (E04) #6D Z21 HTR BLR SW (E) COWL L J/C10 (04) #KU D72 J/B CTY SW (+2)
COWL LH J/C2 (E02) #7B Z28 CLA LP LH () MET A/T IND (D) H26 H64 A/T NSS (D) E/G WP BNDR3 (05) #DE XK4 A/C THEMSTR () COWL L J/C10 (05) #KV QB4 ITC ECU (DCSD)
COWL L BNDR2 (E03) #9C Z23 HTR CON ILM (E) MET A/T IND (2) H25 H63 A/T NSS (2) A/C THEMSTR (+) KP5 XP8 EFI ECU (ACEV) COWL L J/C10 (13) #LX #F3 MLT MET (SPD)
COWL LH J/C5 (02) #MB C26 FR FOG LP LH (+) MET A/T IND (L) H24 H62 A/T NSS (L) A/C RLY (COL ) KG9 XS0 EFI ECU (MGC) COWL LH J/C4 (14) #LY #F2 MLT MET (IG)
COWL LH J/C2 (E05) #7E ZD3 FR FOG LP LH () COWL L BNDR2 (E09) #9J Z53 A/T NSS (E) A/C I/UP VSV () K19 XQ6 EFI ECU (VSV3) ABS ACT (MT) WK1 WS5 ABS ECU (MS)
COWL L BNDR1 (E03) #8C Z05 MET EARTH (E) FR WIP MTR (HI) I20 I57 FR WIP SW (2) MAG CLT (+) KP1 K23 A/C RLY (L) ABS MTR RLY (COL ) WS2 WS6 ABS ECU (PCO)
COWL LH J/C5 (03) #MC C25 FR FOG LP RH (+) FR WIP MTR (LO) I18 I56 FR WIP SW (1) J/B F/GGE-BK (L) H79 K12 HTR RLY (COL +) ABS MAI RLY (COL ) WR7 WS7 ABS ECU (REL)
COWL LH J/C5 (01) #MA C24 FR FOG LP SW (L) FR WIP MTR (S) I24 I41 INT RLY (INT) COWL LH J/C4 (05) #LE KC5 A/C SW (+B) COWL RR J/C3 (09) #EJ WV3 ABS ECU (R+)
COWL L SNDR2 (E05) #9E ZR8 FLOOR ILM () FR WIP MTR (+B) I22 I65 J/B F/WP-TRN (L1) COWL LH J/C4 (01) #LA H67 J/B MET (+) ABS ECU (AST) WV4 WW2 ABS ACT (AST)
COWL LH J/C3 (05) #KE CE0 FLOOR ILM (+) FR WSH SW (L) I60 ZQ9 FR WSN MTR () COWL LH J/C4 (06) #LE K30 HTR BLR MTR () ABS ACT (SFRH) WW3 WX1 ABS ECU (SFRH)
COWL LH J/C9 (06) #RF #UA FLOOR BNDR2 (01) J/B F/WSH MO (+) I01 I03 FR WSH MTR (+) COWL LH J/C4 (09) #LJ K07 HTR RESSTR (L) ABS ACT (SFLH) WW4 WX2 ABS ECU (SFLH)
COWL LH J/C9 (05) #RE E11 STOP LP SW () RR WSH SW (B) I28 I66 J/B F/WP-TRN (L2) COWL LR J/C4 (13) #LM KV2 A/C SW IND () ABS ACT (SRH) WW5 WX3 ABS ECU (SRH)
STOP LP SW (+) E10 E28 FUSE STOP (L) RR WIP MTR () I30 I31 RR WIP SW (B) COWL LH J/C4 (03) #LC VD1 DIFLOCK SW (B) ABS ACT (SFRR) WW6 WX4 ABS ECU (SFRR)
IG KEY SW (+) D13 D58 J/B KEY SW (+) COWL L BNDR (E04) #8D Z18 RR WIP SW (E) COWL LH J/C3 (12) #KM H77 DIFLOCK IND (+) ABS ACT (SFLR) WW7 WX5 ABS ECU (SFLR)
COWL LH J/C5 (05) #ME D02 ROOM LP (+) RR WSH MTR (+) I26 I54 RR WSH SW (L) COWL RH J/C3 (01) #EA #KL COWL LH J/C3 (11) ABS ACT (SRR) WW8 WX6 ABS ECU (SRR)
COWL LH J/C5 (04) #MD E44 J/B F/STOP (L2) COWL LH J/C2 (E03) #7Q ZN0 RR WSH MTR (E) COWL LH J/C3 (10) #KK VD2 DIFLOCK SW (L) ABS P SSR FL (+) WA0 W65 ABS ECU (FL1)
BACK LP SW (+) G02 G21 J/B BACK LP (SW +) DEF SW (B) K27 K98 J/B FUSE DEF (L) J/B FUSE ENG (L2) N78 VL2 OFFBOARD CON (IG) ABS P SSR FL () WA1 W51 ABS ECU (FL0)
FLOOR J/C1 (01) #5A G03 BACK LP SW () COWL LH J/C6 (04) #ND K28 DEF SW (L) OFFBOARD CON (VF) VN6 X21 EFI ECU (VF) COWL LH J/C9 (07) #RG WT0 ABS ECU (BLS)
BACK LP SW (+) G02 G21 J/B BACK LP (SW +) COWL LH J/C6 (05) #NE K29 DEF (+) COWL LH J/C7 (04) #PD XS3 EFI ECU (T) COWL LH J/C7 (11) #PL W48 ABS ECU (IGN)
COWL LH J/C8 (03) #QC D39 J/B R/WNG (BUZ +) COWL L BNDR1 (E05) #8E Z42 DEF SW (E) COWL LH J/C6 (07) #NG XT8 EFI ECU (SIO) COWL LH J/C8 (11) #QL WB0 MET ABS IND ()
COWL LH J/C8 (01) #QA G03 BACK LP SW () COWL RH J/C5 (09) #GJ R27 E MIRROR LH (C) COWL LH J/C7 (08) #PH #TJ A/B ECU (TC) COWL LH J/C8 (12) #QM WU7 CHK TML ABS (STIM)
COWL LH J/C8 (02) #QB #SA FLOOR J/C1 (01) E MIRROR SW (HL) R20 R23 E MIRROR LH (H) COWL LH J/C8 (11) #NL #TL A/B ECU (SIO) ABS P SSR FR () WA5 W53 ABS ECU (FR0)
COWL LH J/C8 (04) #QD H28 MET A/T IND (R +) E MIRROR SW (VL) R18 R22 E MIRROR LH (V) OBD2 (ECUT) #TK T28 A/B ECU (T) ABS P SSR FR (+) WA4 W67 ABS ECU (FR1)
SID TRN LP L (+) F11 F44 J/S S/TRW LP (LH +) COWL LH J/C7 (01) #PA RG8 FUSE ACC (L3) OBD2 (SIO) #TM T44 A/B ECU (SIO) COWL LH J/C7 (09) #PJ QB2 J/B IMMB ECU (IG)
FR TRN LP LH (+) F09 F53 J/B F/TRN LP (LH) COWL LH J/C7 (02) #PB R16 E MIRROR SW (B) COWL LH J/C7 (05) #PE VN8 OFFBOARD CON (ECUT) COWL LH J/C8 (13) #QN WT1 ABS ECU (WLAS)
COWL LH J/C2 (E04) #7D ZM6 SID TRN LP L () FUSE ACC (L2) RC7 R15 CIG LTR (+) COWL LH J/C6 (08) #NH VLO OFFBOARD CON (SIO) COWL LH J/C5 (11) #ML W59 ABS ECU (BAT)
COWL LH J/C2 (E02) #7B ZM3 FR TRN LP LH () COWL L BNDR2 (E06) #9F Z31 CIG LGT (E) COWL L BNDR2 (E02) #9B ZS4 OFFBOARD CON (E) COWL LH J/C3 (13) #KN WW9 ABS ECU (EXI)
TRN IND LH (+) F19 F54 J/B TRN IND (LH) FUSE ACC (L1) RC5 R04 RADIO (+B) OFFBOARD CON (ABST) VN9 WK5 ABS ECU (TS) A/B ECU (IG2) #TA T45 FUSE A/B (L1)
TRN IND RH (+) F21 F55 J/B TRN IND (RH) COWL LH J/C5 (09) #MJ C30 RADIO (B/UP) COWL LH J/C6 (09) #NJ WV0 ABS ECU (SIO) FUSE A/B (L) #TB T02 A/B ECU (IG2)
E/G WP BNDR1 (01) #BA N76 J/B FUSE ENG (L1) COWL LH J/C1 (E03) #6C Z30 RADIO (E) COWL LH J/C7 (06) #PF WV2 ABS ECU (TC) A/B ECU (IG1) #TH N31 J/B FUSE ENG (L)
MET (CHG) O20 O21 ALT (L) RADIO (SPR +) R10 R11 SP FR RR (+) COWL LH J/C5 (08) #MH XR3 EFI ECU (BAT) FUSE E/G (L) #TG T01 A/B ECU (IG1)
COWL LH J/C5 (06) #MF D67 LUG ROOM LMP (B) RADIO (SPR ) R12 R13 SP FR RH () COWL LH J/C5 (07) #MG C90 FUSE BK/UP (L) A/B ECU (W) #TE T37 NET (A/B)
MET THRM G (+) H20 H21 THRM SENDER (+) RADIO (SRR ) R29 R33 RR SP RR () COWL LH J/C9 (09) #RJ XR4 EFI ECU (+B1) MET A/B IND () #TF T26 A/B ECU (W)
MET FUEL G (+) H22 H23 FUEL SENDER (+) RADIO (SRR +) R28 R32 RR SP RH (+) COWL LH J/C9 (10) #RK XV0 EFI ECU (+B2) COWL L J/C1 (E05) #TD T14 A/B ECU (E1)
COWL LH J/C6 (01) #NA N58 MET (REV) RADIO (SRL ) R31 R35 RR SP LH () E/G WP BNDR2 (01) #CA #RL COWL LH J/C9 (11) A/B ECU (E1) #TC #6E COWL LH J/C1 (E05)
COWL LH J/C6 (02) #NB XQ2 EFI ECU (REV) RADIO (SRL +) R30 R34 RR SP LH (+) FUEL CUT (+) #F4 PD7 F/P RLY (COL ) A/B ECU (D +) T11 T24 A/B SQUIB (D +)
COWL LH J/C6 (03) #NC VN5 OFFBOARD CON (REV) RADIO (SPL +) R06 R07 SP FR LH (+) FUEL CUT () #F5 XU4 EFI ECU (FGI) A/B ECU (D ) T12 T25 A/B SQUIB (D )
COWL LH J/C3 (06) #KF G05 MET BRK WNG () RADIO (SPL ) R08 R09 SP FR LH () MET (EFI) X01 X02 EFI ECU (W) A/B ECU (PS +) T09 T42 A/B SQUIB (P +)
COWL LH J/C3 (08) #KH G07 PK BRK SW (+) COWL RH J/C4 (12) #FM Q28 D/L MTR FR P (LOK +) EFI ECU (AUX1) XP0 XT2 RESISTOR1 (+) A/B ECU (PS ) T10 T43 A/B SQUIB (P )
COWL LH J/C3 (07) #KG G08 BRK O/LEV SW (+) COWL RR J/C4 (09) #FJ Q27 D/L MTR FR P (U/L +) COWL LH J/C9 (03) #RC XH7 EFI ECU (H/L) COWL LH J/C1 (E02) #6B #8B COWL L BNDR1 (E02)
MET EXG WRN () Y01 Y02 EXG TEMP SSR (+) COWL RH J/C3 (05) #EE P31 P/W SW FR P (B) COWL LH J/C8 (06) #NF XR6 EFI ECU (DEF) COWL LH J/C1 (E01) #6A #7A COWL LH J/C2 (E01)
MET SB WRN () H56 H58 SEAT BELT SW (+) P/W MAS SW (PD +) P27 P29 P/W SW FR P (U +) COWL RH J/C4 (07) #FG #RH COWL LH J/C9 (08) COWL R BNDR1 (E01) #4A #8A COWL L BNDR1 (E01)

HW66
From To
COWL LH J/C1 (E03) #6C #9A COWL L BNDR2 (E01)
FUSE A/B (L) #TB T02 A/B ECU ((IG2)
A/B ECU (IG 1) #TH N31 J/B FUSE ENG (L)
COWL L J/C1 (E05) #TD T14 A/B ECU (EI)
A/B ECU (EI) #TC #6E COWL LH J/C1 (E05)
A/B ECU (D+) T11 T24 A/B SQUIB (D+)
A/B ECU (D ) T12 T25 A/B SQUIB (D)
COWL LH J/C7 (08) #PN #TJ A/B ECU (TC)
COWL L J/C10 (03) #KT Q70 K/DEL ENT SR (+B)
COWL L J/C10 (06) #KW #JR KEYLESS ENTY (CS)
KEYLESS ENTY (KLSW) #JT Q69 K/DEL ENT SR (SIG)
KEYLESS ENTY (ULS) #JS #LR COWL L J/C10 (07)
COWL LH J/C2 (E05) #7E ZD5 K/DEL ENT SR (E)
MULTI SW (HAZ ) F48 QB7 ITC ECU (T/H)
J/B TRN SW () F67 QC5 ITC ECU (FL +)
KEYLESS KEY (1) #E1 D61 J/B K/WNG (BUZB)
KEYLESS KEY (2) #E2 D14 IG KEY SW ()
KEYLESS KEY (3) #E3 #E4 KEYLESS KEY (4)
COWL RH J/C4 (08) #FH Q51 ITC ECU (ULM)
COWL RH J/C4 (11) #FL Q50 ITC ECU (LKM)
COWL L J/C10 (08) #LS QB8 ITC ECU (UKS)
COWL L J/C10 (09) #LT Q25 D/LOCK SW (U/L +)
COWL LH J/C2 (E04) #7D I08 D/LOCK SW (E)
COWL LH J/C2 (E03) #7C ZT3 ITC ECU (EI)
OFFBOARD CON (ITCT) VP3 QC1 ITC ECU (T)
ITC ECU (CS ) QC2 QC9 ALL RNG SSR ()
ITC ECU (CS1) QC3 QC8 ALL RNG SSR (+)
COWL RH J/C5 (17) #GY QC7 ITC ECU (CHZP)
COWL RH J/C5 (14) #GV Q89 ITC ECU (CFL)
J/B HAZ SW (LH) F50 QC4 ITC ECU (CHL)
J/B HAZ SW (RH) F49 QB5 ITC ECU (CHR)
J/C4 (ITC) #E5 QB3 ITC ECCU (IG1)
82132-87401

HW67
WIRE, COWL, LH (General/RHD)
FR TURN LH
F09
FR FOG LH ZM3 CLEARANCE LH
TO COWL WIRE RH B TO COWL WIRE RH ITC
C12
ZD3 C26
Z28
KP6 KP7 DUAL PS SW #EE C90 R20 R13 R11 P27 ZS1 #FH Q25
HEAD LAMP LH PD7 #EA R16 #GJ R18 P28 #FG G08 F48 F67 #GY #GV #FL
A04
A03 A02
MAGNET CLUTCH
KP1 TO COWL WIRE RH A WS2 WA5 WA4 WW2
K11 I60 #FM WW7 WW4 #EJ WK1
K13 I57 I41 I56 M07 #FJ WW5 WR7 WW6 WW3 TO COWL WIRE RH ABS
EARTH J/C FENDER LH FR WSH PR WSH K12 K19 KG9K23 C25 #4A E10 E11 WU7 WW8
#7A #7B #7C #7D #7E MTR MTR
ZQ9 ZN0 FR WIPER MTR
I03 I26
I20 I18
I24 I22
#LU #LX #LV #LW #KU #KV#KW #LR #LS #LT
J/C 3 #LF #LG #LH #KS #KR #KT #E1 #E2 #E3 J/C 10
#KM #KK #KH #KF #KE #KC #KA
#KN #KL #KG #KB
WA1 WA0
ABS SSR FENDER LH J/C 9
#PA #PJ #PL #PD #PF #PH

A/B P BLOWER MTR #PB #PE
F11 ZM6 #RA #RC #RH #RK #RF #RG SQUIB K02 A/B W TO W4 J/C 7
#RB #RJ #RL #RE J/C 8 J/C 5 K30
SIDE TURN LH KP5 A/B W #TK #TM #TG #TD #MA #MB #MD #MF #MG#MJ #ML
J/C 5
D03 D02 #QA #QC #QM #QN #QJ #QH #QE #MC #ME #MH
T42 T43
#QB #QD #QL #QK #QG #QF KK4 BLOWER K05 TO W2
THERMISTOR RESISTOR
K44 K07 #TF #TB
TO ROOF A/B W TO W1 M58 # K29 H23 R34 TO
#NA #NC #ND #NF #NG #NJ #NL
WIRE BNDR 2 D67 #UA I30 R33 R32 R35
BLOWER SW
#NB #NE #NH
#9A #9B #9C #TA #TE KEY SW FLOOR WIRE
#9E #9G #9J D13 D14
#6A #6B #6C #6D #6E EARTH J/C Z23 C19 K08 J/C 4 #9F #9L RC7
J/B B-3
Z21 K06 K04
TO FR DOOR WIRE LH COWL LH #TC #TH #TL #TJ
A/C SW RC8 D72 D58 E28
Q28 Q27 P31
R07 R09 P29 P30 #DE XQ6 #BA #JR #JS
KV2 KC6 K99
A/B W TO W3 #8A #8B #8C #8D H79 H67 H78 CE7 Q17 QB2 A98 J/B B-1
#CA H21 H06 O21 XT2 ZD5 Q69 #EA Q70 #LA #LB #LC #LD #LJ #LK #LL #8E F55 F54 K98 I66 D61
R22 R27 R23
W48 WW9 WS9 RADIO & CAST 2 #LE #E5 #LY #LM #LN VL2 VN9 VN8 VN5
WT1 WK6 WV2 WT0 WV0 TO E/G WIRE KEYLESS ECU VP3 VL0 ZS4 VN6 T24 A01 AA0
R28 R30
R29 R31 T25 AA2 F44 F53 C06 J/B D-2
TO DIAGNOSIS VD1
BNDR 1
FLOOR WIRE NO.3
WX2 WX5 WV3 WS6 WS7 W67 W53 WX1 A/B ECU D&P A/B D SQUIB VD2
XS0 XR3 XP8 XS4 XK3 X04 XP0 XR9 X02 XR4 WX3 WX6 WV4 WS5 W65 W51 WX4
QC4 QC5 QB7 QC1 QB4 QB3 ZT3 Q50 R10 R06 R04 C30 CTR DIFF C24 C23
XU4 XH6 XH7 XQ5 XS3 XT8 XQ2 X21 XV0 T10 T09 T44 T26 T12 T11 T28
F50 F49 CA1 G21 N31 N76 N78
QB5 QB9 QC7 QB6 #JT QB8 Q34 QC3 Q47 QC2 Q51 ABS ECU R12 R08 Z30 C28 LOCK FR FOG SW E44 T45 I65 I01 D39 RC6
J/B B-2
EFI ECU T14 T02 T01
ITC ECU RADIO & CAST 1 A B I54 I28
Z18 I31
EXT SSR Z31
R15
RR WIPER SW K27 A10 H77 H56 N58 G06O20 Y01 Z08 F21
FUEL CUT Y02 CIGAR LIGHTER Z42 K28
#F2
T44 T26 T12 T11 T28 METER 16
#F4 #F5
RR DEF SW
#F3 H28 M20H27 H29 H24 H25 H26
T14 A B T02 T01
TO MLT MET METER 13 METER 10
A/B ECU D
PKB C21 F19 X03 Z83 H20 H22 H61 T37 WB0 H05 X01 H52
G03 H63 H64 H66
G07
K65 Z53 G02 H62
NTRL ST SW
H37
O/D OFF SOLENOID
V74 QC9 QC8 G02

ZR8 CE0
V72 V73 G SSR G03
H35 ZJ3
O/D OFF RELAY O/D OFF SW & ILLUMINATION BK/LP SW
82132-87401

HW68
WIRE, COWL, LH (EC/LHD)
From To From To
IG SW (ACC) R01 R02 FUSE ACC (B) E MIRROR SW (HL) R20 R23 E MIRROR LH (H)
IG SW (IG1) N01 N59 J/B IG1 E MIRROR SW (HR) R21 R25 E MIRROR RH (H)
IG SW (IG2) N30 N60 J/B IG2 (+) COWL LH J/C3 (12) #KM R27 E MIRROR LH (C)
IG SW (AM) O12 O31 F/L AM (L) COWL L BNDR1 (E11) #8L ZN2 E MIRROR SW (E)
J/B TL SW (+) CA2 CE1 TAIL LP SW (B) RADIO (SPL ) R08 R09 SP FR LH ()
TAIL LP SW (L) CE2 CM1 J/B TL SW () RADIO (SPL +) R06 R07 SP FR LH (+)
J/B H-LP SW () AA5 A23 LGHTNG SW (L) ITC ECU (UKS) QB8 Q25 D/LOCK SW (U/L +)
LGHTNG SW (B) A22 O69 M/FUSE H/L (L) COWL LH J/C3 (06) #KF Q27 D/L MTR FR P (U/L +)
J/B H-LP LOL () AA0 A04 H-LP LH (LO) COWL LH J/C3 (09) #KJ Q28 D/L MTR FR P (LOK +)
J/B H-LP HIL () AA2 A03 H-LP LH (HI) COWL LH J/C3 (08) #KH Q50 ITC ECU (LKM)
J/B DIM (HI) AA3 A17 DIM SW (HI) COWL LH J/C3 (05) #KE Q51 ITC ECU (ULM)
J/B DIM (LO) AA4 A18 DIM SW (LO) COWL LH J/C3 (07) #KG #WF FLOOR J/C2 (06)
COWL LH J/C4 (12) #LM C40 RR FOG LP (+) COWL LH J/C3 (10) #KK #WK FLOOR J/C2 (10)
COWL L BNDR1 (E04) #8D Z02 DIM SW (E) COWL LH J/C4 (08) #LH P31 P/W SW FR P (R)
COWL LH J/C4 (11) #LL H80 MET RR FOG (IND +) COWL LH J/C4 (09) #LJ PD4 FUSE P/W (L)
COWL LH J/C4 (10) #LK CJ7 MLT SW R/FOG () COWL LH J/C4 (07) #LG P22 P/W MAS SW (B)
COWL LH J/C3 (01) #KA A01 FUSE H-LP LH (L) P/W MAS SW (PU +) P27 P29 P/W SW FR P (U +)
COWL LH J/C3 (02) #KB A02 H-LP LH (B) P/W MAS SW (PD +) P28 P30 P/W SW FR P (D +)
MLT SW R/FOG (+) CJ6 D71 JB R/FOG WNG (BZRB) COWL LH J/C1 (E05) #6E Z61 P/W MAS SW (E)
COWL LH J/C3 (04) #KD A61 H-LP LEV ACT (LH +) MAG CLT (+) KP1 K23 A/C RLY (L)
COWL LH J/C3 (03) #KC AA6 H-LP LEV SW (+) A/C D/PRS SW () KP7 XS4 EFI ECU (ACSW)
COWL LH J/C4 (03) #LC A69 H-LP LEV SW (LH 0) A/C D/PRS SW (+) KP6 K99 A/C SW ()
COWL LH J/C4 (01) #LA A63 H-LP LEV ACT (LH 0) IMMOBI ECU (COL ) QA5 QB1 IMMOBI ANTN (COL )
COWL L BNDR1 (E10) #8K ZM9 H-LP LEV SW (LHE) IMMOBI ECU (COL +) QA4 QB0 IMMOBI ANTN (COL +)
COWL LH J/C4 (02) #LB A56 H-LP LEV ACT (RH 0) ABS P SSR FR (+) WA0 W65 ABS ECU (EL1)
COWL LH J/C2 (E05) #7E ZM7 H-LP LEV ACT (LH E) ABS P SSR FL () WA1 W51 ABS ECU (FL0)
J/B CLA LP (LH +) C06 C12 CLA LP LH (+) COWL R BNDR1 (E01) #4A #8A COWL L BNDR1 (E01)
COWL LH J/C2 (E02) #7B Z28 CLA LP LH () COWL LH J/C1 (E02) #6B #8B COWL L BNDR1 (E02)
COWL LH J/C4 (04) #LD F32 TRN SW (B) COWL LH J/C1 (E01) #6A #7A COWL LH J/C2 (E01)
COWL L BNDR1 (E03) #8C Z63 J/B EARTH (1) COWL LH J/C1 (E03) #6C ZZ7 BODY EARTH ()
TRN SW (LH) F62 F64 J/B TRN (LH) COWL RH J/C3 (01) #EA E11 STOP LP SW ()
TRN SW (RH) F61 F63 J/B TRN (RH) STOP LP SW (+) E10 E28 FUSE STOP (L)
SID TRN LP L (+) F11 F44 J/B S/TRN LP (LH +) COWL R J/C11 (04) #NQ F65 J/B TRN SW (+B)
FR TRN LP LH (+) F09 F53 J/B F/TRN LP (LH) COWL R J/C11 (06) #NS F47 MULTI SW (HAZ +)
COWL LH J/C2 (E04) #7D ZM6 SID TRN LP L () COWL R J/C11 (05) #NR QC7 ITC ECU (CHZD)
COWL LH J/C2 (E02) #7B ZM3 FR TRN LP LH () COWL R J/C11 (01) #NM F68 J/B TRN SW (RLSW)
COWL LH J/C4 (05) #LE F66 J/B TRN SW (IG) COWL R J/C11 (03) #NP F60 TRN SW (RL +)
HORN RH () E03 E19 HORN SW (+) COWL R J/C11 (02) #NN QB9 ITC ECU (CFL)
COWL RH J/C3 (06) #EF G08 BRK O/LEV SW (+) MULTI SW (HAZ ) F48 QB7 ITC ECU (T/H)
COWL LH J/C2 (E03) #7C Z11 BRK O/LEV SW () J/B TRN SW () F67 QC5 ITC ECU (FL +)
IG SW (ST) N01 M15 ST RLY (COL +) D/LOCK SW (E) ZS1 #3E COWL RH J/C2 (E05)
COWL LH J/C4 (06) #LF I10 FR WIP SW (+) COWL LH J/C3 (15) #KP Q65 D/L MTR FR D (U/L +)
COWL L BNDR1 (E05) #8E Z14 BODY EARTH (CTIR) COWL LH J/C3 (15) #KQ Q66 D/L MTR FR D (LOK +)
FR WIP MTR (HI) I20 I57 FR WIP SW (2) 82132-87409
FR WIP MTR (LO) I18 I56 FR WIP SW (1)

FR WSH SW (L) I60 ZQ9 FR WSH MTR ()
FR WIP MTR (S) I24 I41 INT RLY (INT)
COWL RH J/C7 (02) #YB R16 E MIRROR SW (B)
COWL LH J/C3 (11) #KL R17 E MIRROR SW (C)

HW69
WIRE, COWL, LH (EC/LHD)
FR TURN LH
F09
ZM3 DUAL PS SW
KP6 KP7
CLEARANCE LH
HEAD LAMP LH C12
A04 Z28 MAGNET CLUTCH
A03 A02
KP1
HEAD LAMP LEVEL LH

ZM7 A63 A61
J/C 4
#LA #LC #LD #LF #LH #LJ #LL
EARTH J/C COWL LH
#LB #LE #LG #LM #LK
#6A #6B #6C #6E
EARTH J/C FENDER LH
BDR-EARTH TO COWL WIRER RH A
#7A #7B #7C #7D #7E
#8A #8B #8C #8D
TO FLOOR WIRE ZQ9 Q28 I24
#8E #8K #8L
E28 I20 A56 H80 Q27 I18
#WF ZZ7 O69 #EA #4A E03
C40 #WK QA4QA5 K23
WA1 WA0 G08
Z11
ABS SSR FENDER LH BRAKE FLUID
LEVEL SW TO COWL WIRE RH
M15O31
F11 ZM6
SIDE TURN LH
QB8 Q51 #3E
Q50 QB9 QC7 QC5 QB7
P29 R06 R08 R25 K99 P31 TO COWL WIRE RH ITC

#EF XS4 P30 R24 R26 #YB W51 W65
E10
TO COWL WIRE RH D
E11
N30 N01 R01
STOP LP SW O12 M01
R18 R19 R21
J/C 11 IG SW R20 R17 R16 ZN2
#KL #KM #KN #KD #KC #KB #KA #NS #NR #NM
#KJ #KH #KK #KQ #KP #KG #KF #KE #NQ #NP #NN AUTO MIRROR SW
QB0 QB1
ZM9 A69 AA6
Q66 Q65 P22 IMMOBI ANTENNA
R07 R09 P27 P28 Z61 HEAD LAMP LEVEL SW
R22 R27 R23 ZS1 Q25
J/C 3
TO FR DOOR WIRE LH AA4 AA3 F64 F67 F68 Z63

N59 N60 D71 F66 AA5 F65 F63
PD4 R02 CM1 CA2
J/B E
A01 AA0
J/B A A23 A22 CE1 A18
F61 F60 F62 E19
I41 I10 I57 I56 I60 Z14
AA2 F44 F53 C06
TURN SW 3 F32 F48 F47 TURN SW 2
J/B D-1 Z02 A17 CE2 CJ7 CJ6
TURN SW 1
82132-87409

HW70
WIRE, COWL, LH (General/LHD)
From To From To
IG SW (ACC) R01 R02 FUSE ACC (B) COWL LH J/C3 (05) #KE Q51 ITC ECU (ULM)
IG SW (IG1) N01 N59 J/B IG1 (+) COWL LH J/C3 (07) #KG #WF FLOOR J/C2 (06)
IG SW (IG2) N30 N60 J/B IG2 (+) COWL LH J/C3 (10) #KK #WK FLOOR J/C2 (10)
IG SW (AM) O12 O31 F/L AM (L) COWL LH J/C4 (08) #LH P31 P/W SW FR P (B)
J/B TL SW (+) CA2 CE1 TAIL LP SW (B) COWL LH J/C4 (09) #LJ PD4 FUSE P/W (L)
TAIL LP SW (L) CE2 CM1 J/B TL SW () COWL LH J/C4 (07) #LG P22 P/W MAS SW (B)
J/B H-LP SW () AA5 A23 LGHTNG SW (L) P/W MAS SW (PU +) P27 P29 P/W SW FR P (U +)
LGHTNG SW (B) A22 O69 M/FUSE H/L (L) P/W MAS SW (PD +) P28 P30 P/W SW FR P (D +)
J/B H-LP LOL () AA0 A04 H-LP LH (LO) COWL LH J/C1 (E05) #6E Z61 P/W MAS SW (E)
J/B H-LP HIL () AA2 A03 H-LP LH (HI) MAG CLT (+) KP1 K23 A/C RLY (L)
J/B DIM (HI) AA3 A17 DIM SW (HI) A/C D/PRS SW () KP7 XS4 EFI ECU (ACSW)
J/B DIM (LO) AA4 A18 DIM SW (LO) A/C D/PRS SW (+) KP6 K99 A/C SW ()
COWL L BNDR1 (E04) #8D Z02 DIM SW (E) ABS P SSR FL (+) WA0 W65 ABS ECU (FL1)
COWL LH J/C5 (02) #MB C26 FR FOG LP LH (+) ABS P SSR FL () WA1 W51 ABS ECU (FL0)
COWL LH J/C2 (E05) #7E ZD3 FR FOG LP LH () COWL R BNDR1 (E01) #4A #8A COWL L BNDR1 (E01)
COWL LH J/C3 (01) #KA A01 FUSE H-LP LH (L) COWL LH J/C1 (E02) #6B #8B COWL L BNDR1 (E02)
COWL LH J/C3 (02) #KB A02 H-LP LH (B) COWL LH J/C1 (E01) #6A #7A COWL LH J/C2 (E01)
J/B CLA LP (LH +) C06 C12 CLA LP LH (+) COWL LH J/C1 (E03) #6C Z27 BODY EARTH ()
COWL LH J/C2 (E02) #7B Z28 CLA LP LH () COWL RH J/C3 (01) #EA E11 STOP LP SW ()
COWL LH J/C4 (04) #LD F32 TRN SW (B) STOP LP SW (+) E10 E28 FUSE STOP (L)
COWL L BNDR1 (E03) #8C Z63 J/B EARTH (1) COWL R J/C11 (04) #NQ F65 J/B TRN SW (+B)
TRN SW (LH) F62 F64 J/B TRN (LH) COWL R J/C11 (06) #NS F47 MULTI SW (HAZ +)
TRN SW (RH) F61 F63 J/B TRN (RH) COWL R J/C11 (05) #NR QC7 ITC ECU (CHZD)
SID TRN LP L (+) F11 F44 J/B S/TRN LP (LH +) COWL R F/C11 (01) #NM F68 J/B TRN SW (RLSW)
FR TRN LP LH (+) F09 F53 J/B F/TRN LP (LH) COWL R J/C11 (03) #NP F60 TRN SW (RL +)
COWL LH J/C2 (E04) #7D ZM6 SID TRN LP L () COWL R J/C11 (02) #NN QB9 ITC ECU (CFL)
COWL LH J/C2 (E02) #7B ZM3 FR TRN LP LH () MULTI SW (HAZ ) F48 QB7 ITC ECU (T/H)
COWL LH J/C4 (05) #LE F66 J/B TRN SW (IG) J/B TRN SW () F67 QC5 ITC ECU (FL +)
HORN RH () E03 E19 HORN SW (+) D/LOCK SW (E) ZS1 #3E COWL RH J/C2 (E05)
COWL RH J/C3 (06) #EF G08 BRK O/LEV SW (+) COWL LH J/C3 (15) #KP Q65 D/L MTR FR D (U/L +)
COWL LH J/C2 (E03) #7C Z11 BRK O/LEV SW () COWL LH J/C3 (16) #KQ Q66 D/L MTR FR D (LOK +)
IG SW (ST) M01 M15 ST RLY (COL +) 82132-87431
COWL LH J/C4 (06) #LF I10 FR WIP SW (+)

FR WIP MTR (HI) I20 I57 FR WIP SW (2)
FR WIP MTR (LO) I18 I56 FR WIP SW (1)
FR WSH SW (L) I60 ZQ9 FR WSH MTR ()
FR WIP MTR (S) I24 I41 INT RLY (INT)
COWL RH J/C7 (02) #YB R16 E MIRROR SW (B)
COWL LH J/C3 (11) #KL R17 E MIRROR SW (C)
COWL LH J/C3 (12) #KM R27 E MIRROR LH (C)
COWL L BNDR1 (E11) #8L ZN2 E MIRROR SW (E)
ITC ECU (UKS) QB8 Q25 D/LOCK SW (U/L +)
COWL LH J/C3 (06) #KF Q27 D/L MTR FR P (U/L +)
COWL LH J/C3 (09) #KJ Q27 D/L MTR FR P (LOK +)
COWL LH J/C3 (08) #KH Q50 ITC ECU (LKM)

HW71
WIRE, COWL, LH (General/LHD)
FR TURN LH
F09
FR FOG LH ZM3 DUAL PS SW
ZD3 C26 KP6 KP7
CLEARANCE LH
HEAD LAMP LH C12
A04 Z28
MAGNET CLUTCH
A03 A02
KP1
J/C 4
#LD #LF #LH #LJ EARTH J/C COWL LH
#LE #LG
#6A #6B #6C #6E
EARTH J/C FENDER LH
BDR EARTH TO COWL WIRE RH A
#7A #7B #7C #7D #7E
#8A #8B #8C #8D
#MB ZQ9 Q28 I24
TO FLOOR WIRE #8L
E28 I20 Q27 I18
#WF ZZ7 O69 #EA #4A E03
K23
ABS SSR FENDER LH #WK
WA1 WA0 G08

Z11
BRAKE FLUID LEVEL SW TO COWL WIRE RH
SIDE TURN LH
M15O31
F11 ZM6
QB8 Q51 #3E

Q50 QB9 QC7 QC5 QB7
P29 R06 R08 R25 K99 P31 TO COWL WIRE RH ITC

#EF XS4 P30 R24 R26 #YB W51 W65
TO COWL WIRE RH D
E10
E11
STOP LP SW
IG SW R18 R19 R21
J/C 3 J/C 11 R20 R17 R16 ZN2
N30 N01 R01
#KL #KM #KN #KB #KA #NS #NR #NM
O12M01 AUTO MIRROR SW
#KJ #KH #KK #KQ #KP #KG #KF #KE #NQ #NP #NN
Q66 Q65 P22

R07 R09 P27 P28 Z61
R22 R27 R23 ZS1 Q25
AA4 AA3 F64 F67 F68 Z63
TO FR DOOR LH N59 N60 F66 AA5 F65 F63
PD4 R02 CM1 CA2
J/B E
AO1 AA0
J/B A
AA2 F44 F53 CO6 I56 I57 I41 I60
CE1
A17 A18
J/B D-1 E19 F47 CE2 A22 A23
Z02 I10 F62 F60
F48 F61 F32
TO TURN SW
82132-87431

1997 Terios j100

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SECTION INDEX

DAIHATSU SECTION NAME SECTION

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Applicable Model: J100

Published in June, 1997

1997 DAIHATSU MOTOR CO., LTD.

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IMPORTANT SAFETY NOTICE .................... GI 2

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IMPORTANT SAFETY NOTICE

WARNINGS, CAUTIONS AND NOTES

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q Brake master cylinder Ay

3. Brake tube installation

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3. Handling instructions related to battery.

4. Repairs of fuel system

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1. Use only unleaded gasoline.

2. Avoid idling the engine for a prolonged length of time.

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Garage jack Garage jack

Supporting points of safety stands

Supporting points of tow-post lift

Supporting points of plate supporting type lift

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Flat bed type

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Never tow the vehicle at speed more than 30 km/h.

1. Attach a sturdy rope, towing strap or cable to the towing hook.

5. Set the ignition switch to the ACC position.

1. Be sure to connect the following SST when utilizing this

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3. Utilize the following SST when connecting the terminals in

(6) To connect the tachometer

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Explanation of vehicle model code

Transmission Fuel supply

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MANUFACTURERS PLATE POSITION

CONTENTS OF MANUFACTURERS PLATE

(1) General, Australian, Norwegian and Finnish specifications

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BODY COLOR INFORMATION

Silver metallic S07

Two-tone color NF2

Two-tone color NF0

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Two-tone color 6A5 DAH6A5 G8742 A403B 96326 6A5

Two-tone color B36 DAHB36 F2855 HMG7B 55174 B36

Two-tone color P05 DAHP05 F3426 JNE5B 40868 P05

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MAINTENANCE REQUIREMENTS ... MA 2 BRAKE MASTER CYLINDER ........ MA35

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Check or inspect. Change or replace.