1988 Subaru XT Service Manual

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~-----------FOREWORD----------~~
This service manual has been prepared to provide SUBARU service personnel with the necessary informatio.n and
data for the correct maintenance and repair of SUBARU XT.
The manual includes the procedures for maintenance, disassembling, reassembling, inspection and adjustment of .
components and trouble-shooting for guidance of both the fully qualified and the less-experienced mechanics.
Please peruse and utilize this manual fully to ensure complete repair work for satisfying our customers by keeping
their vehicles in optimum condition. When replacement of parts during repair work is needed,.,e sure to use.
SUBARU genuine parts.
All information, illustrations and specifications contained in this manual are based on the latest product
information available at the time of publication approval.
We reserve the right to make changes at any time without prior notice.
FUJI HEAVY INDUSTRIES LTD.
How to use this manual
This service manual is divided into four volumes. Each volume consists of Section 1, Section 2, 3,Section 4, 5,
and Section 6 respectively.
Each chapter, beginning with the Engine section, is basically made up of the following five areas.
1. Mechanism and function
2. Specifications and service data
3. Component parts
4. Service procedure
5. Trouble-shooting
"ABBREVIATION LIST" is provided at the back page of quick reference index in each volume.
"ALPHABETICAL INDEX" is also provided at the last page in each volume.
This service manual applies to SUBARU XT, and explains all equipments including factory options. Therefore,
you may find some explanations for equipments not installed on the vehicle.
SUBARU,
©
8 and ~ are registered trademarks of FUJI HEAVY INDUSTRIES LTD.
Copyright 1987 FUJI HEAVY INDUSTRIES LTD. All rights reserved.
Not to be reptoduced in whole or in part without the prior written permission

of FUJI HEAVY INDUSTRIES LTD .. TOKYO JAPAN.
.- ,.
TABLE OF CONTENTS
1-1 Specifications
1-2 * * * * * * * * * * * *
[] GENERAL SECTION
1-3 General Information
1-4 Pre-Delivery Inspection
1-5 Periodic Maintenance Services
1-6 Special Tools
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QUICK REFERENCE INDEX .
[j] GENERAL SECTION

SPECIFICATIONS 1- 1
SUBARU • • • • • • • • • • • • 1-2
GENERAL INFORMATION 1-3
1988 PRE-DELIVERY INSPECTION 1 -4
PERIODIC MAINTENANCE SERVICES 1 -5

SPECIAL TOOLS 1 -6
SrERV~CE
MAINJUJAlL
ABBREVIATION LIST
AIC Air Conditioner GVWR Gross Vehicle Weight Rating
ACC Accessory HI High (Speed)
AIC pulley Air Conditioner compressor pulley HP Horse Power
ALT pulley Alternator pulley IG-COIL Ignition Coil
API American Petroleum Institute IG SWITCH Ignition Switch
Approx Approximately INT Intermittent (Wiper)
ASSY Assembly lIP Idler Pulley
ASV Air Suction Valve LH Left-hand
AT Automatic Transmission LO Low (Speed)
ATF Automatic Transmission Fluid LSD Limited Slip Differential
BILEV Bi-Ievel MPFI Multi Point Fuel Injection
BJ Bell Joint MT Manual Transmission
BP British Petroleum PCV Positive Crankcase Ventilation
BTDC Before Top Dead Center PHV Pressure Holding Valve
Calif. California PIN Parts Number
Carbo Carburetor PIS pulley Power Steering oil pump pulley
CP Complete RAD FAN Radiator Fan
CIP Crankshaft Pulley R-DEF Rear Defogger
CTR Center RH Right-hand
CVJ Constant Velocity Joint SAE Society of Automotive Engineers Inc.
CW Curb Weight SIR Single-range
DIFF Differential TC Torque Converter
DOJ Double Offset Joint TEMP GAUGE Temperature Gauge
DIR Dual-range TP Theft Prevention
DSPD Dry Single Plate Diaphragm VGR Variable Gear Ratio
ECS Electric Control System VIN Vehicle Identification Number
EGR Exhaust Gas Recirculation W/height control With height control
FF drive Front wheel drive (2WD) W/P pulley Water Pump pulley
FMVSS Federal Motor Vehicle Safety
Standards
INDEX
Air Cleaner ........... ...................................................... 1-4- 9 Inspect Brake Line and Check Operation of
Air Filter Elements Parking and Service Brake System ............... ........ 1-5-25
(Air cleaner, PCV air filter) ..................................... 1-5-16 Installation of Steering Components ..................... 1-4-15
Automatic Transmission Fluid ................................. 1-5-19 Jack Installation ......................................................... 1-4-10
Automatic Transmission Fluid (ATF) Level .......... 1-4-24 Lifting, Towing and Tie-down Points ..................... 1-3-18
Battery Fluid Level and Battery Lights and Switches ................................................. 1-4-13
Installation ................... ................................................ 1-4- 6 Lubricants ................................................................... 1-3-13
Brake Fluid .... ............................................... .............. 1-5-20 Operation of Indicator Lights and Gauges .......... 1-4-19
Brake Fluid Level and Brake Piping Power Steering Fluid Level..................................... 1-4-25
Installation .............. ............................................... ...... 1-4- 5 Precautions in Handling a Full-Time 4WD
Brake Lining and Drum ......... .................................. 1-5-24 Vehicle ............. ................... ................ ......... ................ 1-3- 3
Camshaft Drive Belt ..................... ........... ........... ...... 1-5- 6 Replace Engine Coolant and Inspect
Clutch and Hill-holder System .......................... ...... 1-5-28 Cooling System, Hoses and Connections ............ 1-5-12
Coolant Level and Cooling Fan Installation ......... 1-4- 6 Replace Fuel Filter and Inspect
Disc Brake Pad and Disc/Front and Rear Fuel System Hoses and Connections .................. 1-5-15
Axle Boots .................. .................. ............................. 1-5-22 Sealants and Adhesives .................. ......................... 1-3-16
Door Operation, Door lock and Regulator .......... 1-4- 4 Seat Adjuster and Seat Belts ................................ 1-4-11
Drive Belt(s) [Except Camshaft] Spark Plug .................................................................. 1-5-17
(Inspect drive belt tension) ...................................... 1-5- 3 Steering and Suspension .......... .............. ..... ........... 1-5-30
Driving Test ................................................... ............. 1-4-21 Tachometer, Radio, Clock, etc. .............................. 1-4-20
Engine Oil .... .............................. ........... ............ .......... 1-5- 9 Theft Prevention ........................................................ 1-3-11
Engine Oil Filter ...................... ....... ....... ..... ............... 1-5-11 Tightening Torque of Standard Bolts
Engine Oil Level ........................................................ 1-4- 7 and Nuts ..................................................................... 1-3-17
Exhaust Pipe and Muffler .... .............. ........... ........... 1-4-16 Tilt/Telescopic Steering Column ............................. 1-4-18
External Appearance and Equipment ......... ........... 1-4-27 Toe ............................................................................... 1-4-25
Fuel .............................................................................. 1-3-13 Transmission and Differential Gear Oil Level...... 1-4- 8
Fuel System for Leakage ............... ............... .......... 1-4-16 Transmission/Differential (Front and rear)
Fuses ........................................................................... 1-4-13 Lubricants (Gear oil) ................................................ 1-5-18
General Precautions ..................... ............................ 1-3- 2 Trunk lid, Rear Gate and Fuel Lid Operation ..... 1-4- 4
Grease on Front and Rear Wheel Bearings ....... 1-5-38 Underside .......................................... .......................... 1-4-26
Height Control System Vehicle Identification Numbers (V.I.N.) .................. 1-3- 7
..... Air (Pneumatic) Suspension Vehicle .............. 1-4-18 Water Leakage ........................................................... 1-4-27
Hood Operation ............ .................................... ......... 1-4- 3 Wheel Nuts for Looseness and Tire Inflation
Identification Number and Label Locations ........... 1-3- 9 Pressure ...................................................................... 1-4-11
Windshield Washer and Windshield Wipers ......... 1-4-10
SPECIFICATIONS
!55i1..l~1==I1..I XT . ................................................. ~~ .....
1988
• XT
1800 2700
MODEL FWD 4WD FWD 4WD

Full time 4WD Full time 4WD
DL GL GL GL XT6
XT6 XT6
MPFI MPFI MPFI MPFI MPFI MPFI MPFI

ITEM 5MT 5MT 4AT 5MT SIR 4AT 5MT SIR 4AT
Overall length mm (in) 4,510 (177.6)
Overall width mm (in) 1,690 (66.5)
Overall height mm (in) 1,255 (49.4) 1,330 (52.4) 1,255 (49.4) 1,335 (52.6)
Front Max. mm (in) 1,100 (43.3)
Leg room
Rear Min. mm (in) 665 (26.2)
Compartment Front mm (in) 950(37.4)
Head room
Rear mm (in) 875 (34.4)
Shoulder room mm (in) 1,340 (52.8)
Wheelbase mm (in) 2,465 (97.0)
en
Front mm (in) 1,435 (56.5) 1,420 (55.9) 1,445 (56.9) 1,435 (56.5) '1J
Tread
Rear mm (in) 1,425 (56.1 ) 1,440 (56.7) m
(")
Ground clearance mm lin) 120 (4.7) 155 (6.1) 125 (4.9) 165 (6.5)
Front
*1 640 *2 650 *2 705 *2 680 *3 810 *3 790 *3 825 "
(")
~
(1,410) (1,435) (1,555) (1,500) (1,785) (1,740) (1,820)
*1 435 *2 455 *2 455 *2 510 *3 460 *3 510 *3 515

U.S.A. Rear
(965) (1,000) (1,005) (1,125) (1,010) (1,125) (1,135) o
*1 1,075 *2 1,105 *2 1,160 *2 1,190 *3 1,270 *3 1,300 *3 1,340
z
Total
(2,375) (2,435) (2,560) (2,625) (2,795) (2,865) (2,955)
Curb weight
*1 640 *1 695 *1 670 *3 800 *3 785 *3 820
Front -
(1,405) (1,525) (1,4701 (1,765) (1,725) (1,805)
Weight *1 445 *1 450 *1 500 *3 455 *3 505 *3 510
kg lib)
CANADA Rear - (985) (995) (1,105) (1,000) (1,1151 (1,125)
*1 1,085 *1 1,145 *1 1,170 *3 1,255 *3 1,290 *3 1,330

Total -
(2,390) (2,520) (2,575) (2,765) (2,840) (2,930)
740 870 870 885 925 945 945
Front
11,630) (1,920) (1,920) (1,950) (2,040) (2,080) (2,080)
660 690 690 745 695 750 750

Gross vehicle weight Rear
(1,460) (1,520) (1,520) (1,640) (1,530) (1,660) 11,660)
1,400 1,560 1,560 1,630 1,620 1,695 1,695

Total
(3,090) (3,440) (3,440) (3,590) (3,570) (3,740) (3,740)
Seating capacity persons 2 4
*1: The weight of power steering is included.

"2: The weight of power steering and power window is included.
*3: The weight of air conditioner and cruise control is included.
1800 2700
DL GL GL GL XT6
XT6 XT6
Horizontally opposed, liquid cooled, 4-cylinder, Horizontally opposed, liquid cooled, 6-cylinder,
Engine type 4-stroke gasoline engine with multi-point 4-stroke gasoline engine with multi-point
fuel injection fuel injection
Valve arrangement Overhead camshaft type
Bore x stroke mm (in) 92 x 67 (3.62 x 2.64)
Displacement cm 3 (cu in) 1,781 (108.68) 2,672 (163.05)
Compression ratio 9.5:1
F i ri ng order 1-3-2-4 1-6-3-2-5-4
Ignition timing at idling speed BTDC/rpm *1 20° ± 2° /700 20° ± 2° /800 20° ± 2° /700 20° ± 2° /750
Idling speed at neutral, N or P position rpm 700 ± 100 800 ± 100 700 ± 100 750 ± 100
(BPR6ES-ll (or BPR5ES-l1, BPR7ES-ll) .......... NGK en
For U.S.A.: W20EPR-U11 (or W16EPR-Ul1, W22EPR-Ul1) ..... Nippondenso '"0
Spark plug Type and manufacturer
RN9YC-4 (or RN 11 YC-4) ...................... Champion m
For Canada: RN9YC-4 (or RN11 YC-4) .............. ........ Champion o
Maximum output HP/rpm 97/5,200 145/5,200
"o
Maximum torque N·m (kg-m, ft-Ibllrpm 139 (14.2, 103) /3,200 211 (21.5,156)/4,000 ~
o
Type 50D20R (MF) 65D23R (MF) 50D20R (MF) 75D23R (MF) 55D23R (MF) 75D23R (MF) z
Battery Reserve capacity (min.) 78 111 78 111 99 111
Cold cranking ampere (amp.) 306 420 306 490 356 490
Alternator 12V - 65A 12V - 90A
Clutch type DSPD TC DSPD TC DSPD TC
Transmission type *2 *3 *2 *3 *2 *3
1st 3.636 2.785 3.545 2.785 3.545 2.785
2nd 2.105 1.545 2.111 1.545 1.947 1.545

3rd 1.428 1.000 1.448 1.000 1.366 1.000
Gear ratio
4th 1.093 0.694 1.088 0.694 0.972 0.694
5th 0.885 - 0.871 - 0.780 -

Reverse 3.583 2.272 3.416 2.272 3.416 2.272
DSPD: Dry Single Plate Diaphragm "1: With gear in neutral position (MT) or "P" position (AT)
TC Torque Converter "2: 5-forward speeds with synchromesh and 1-reverse
"3: Full automatic, 4-forwards and l-reverse
1800 2700
Full time4WD Full time 4WD
DL GL GL GL XT6
XT6 XT6
ITEM SMT SMT 4AT SMT SIR 4AT 5MTS/R 4AT
Reduction gear Final Type of gear Hypoid

(Front drivel reduction Reduction gear ratio 3.700 3.900 3.700 3.900 3.700
Transfer Type of gear - Helical - Helical -

reduction Reduction gear ratio - 1.000 - 1.000 -
Reduction gear
(Rear drive) Type of gear - Hypoid - Hypoid
Final
reduction Reduction gear ratio - 3.700 - 3.900 3.700
Type Rack and pinion
Turns, lock to lock 4.8 3.S 3.2
Steering system
10.4 (34.1) [at tire]
Minimum turning circle m (ft) 9.7 (31.81 [at tire I , 10.8 (3S.41 [at bumper]
11.3 (37.11 [at bumper]
Front ·1 *2 ·1 *2
en
Suspension ""tJ
Rear *3 *4 *3 *4 m
(')
Service brake system Dual circuit hydraulic with vacuum suspended power unit
Front Ventilated disc brake
:!!
Brake (')
~
Rear Drum brake (Leading & trailing type) Disc brake
Parking brake Mechanical on front brake
o
Tire
Size 165SR13 185/70HR13
19S/60R14
85H
205/60R1487H z
Type Steel belted radial, Tubeless
*1: MacPherson strut type, Independent, Coil spring

*2: MacPherson strut type, Independent, Pneumatic suspension (CANADA: with height control)
*3: Semi-trailing arm type, Independent, Coil spring
"4: Semi-trailing arm type, Independent, Pneumatic suspension (CANADA: with height control)
1800 2700
DL GL GL GL XT6
XT6 XT6
Fuel tank Q (US gal, Imp gal) 60 (15.9, 13.2)
Engine
oil
l Upper level Q (US qt. Imp qt) 4.0 (4.2, 3.5) 5.0 (5.3, 4.4)
I Lower level Q (US qt, Imp qt) 3.0 (3.2, 2.6) 4.0 (4.2,3.5)
Transmission gear oil Q (US qt, Imp qt) 2.6 (2.7. 2.3) - 3.3 (3.5, 2.9) - 3.5 (3.7,3.1) -
Automatic transmission
Q (US qt. Imp qt) - 9.3 (9.8.8.2) - 9.3 (9.8, 8.2) - 9.5 (10.0,8.4)
Capacity fluid
AT differential gear oil Q (US qt, Imp qt) - 1.4 (1.5, 1.2) - ~1.4 (1.5, 1.2) - 1 .4 (1.5, 1.2)
4WD rear differential
gear oil
Q (US qt. Imp qtl - 0.8 (0.8,0.7) - 0.8 (0.8,0.7)
Power steering fluid Q (US qt. Imp qt) - 0.7 (0.7,0.6)

Engine coolant Q (US qt, Imp qt) 5.5 (5.8,4.8) 7 {7.4, 6.2} en
'1J
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GENERAL INFORMATION
Page
BUBARU
1988
GENERAL PRECAUTIONS ..•.••...•.......................
VEHICLE IDENTIFICATION NUMBERS (V.I.N.) ••......•..•.....
IDENTIFICATION NUMBER AND LABEL LOCATIONS. • • . . . • . . . .. 9.
2
7
THEFT PREVENTION. . . . . . . . . . . . . . . . • . . . . . . . . . • . . . . • . . . .. 11
RECOMMENDED FUEL, LUBRICANTS, SEALANTS AND
ADHESIVES ...............••.•....•.•................. 13
TIGHTENING TORQUE OF STANDARD BOLTS AND NUTS. . • . . . .. 17
LIFTING, TOWING AND TIE·DOWN POINTS .......•.•••.•..... 18
1-3 GENERAL INFORMATION
General Precautions Precautions while working

1) When jacking up the vehicle, be sure to use safety stands.
Precautions to take before starting service 2) When jacking up the front or rear end of the car body, be
sure to chock the tires remaining in contact with the ground.
1) Be sure to perform the jobs listed in the Periodic Mainte-
3) Keep the parking brake applied when working on the
nance Schedule.
vehicle. Set the shift lever to REVERSE when the parking
2) When a vehicle is brought in for maintenance, carefully
brake cannot be applied, such as when the brakes are being
listen to the owner's explanations of the symptoms exhibited
worked on.
by the vehicle. List the problems in your notebook, and refer
4) Keep the ignition key turned "OFF" if at all possible.
to them when trying to diagnose the trouble.
5) Be cautious while working when the ignition key is "ON";
3) All jewelry should be removed. Suitable work clothes
if the temperature in the engine compartment increases, the
should be worn.
cooling fan can start to operate.
4) Be sure to wear goggles.
6) While the engine is in operation, properly ventilate the
5) Use fender, floor and seat covers to prevent the vehicle
workshop.
from being scratched or damaged.
7) While the engine is in operation, be aware of any moving
6) Never smoke while working.
parts, such as the cooling fan and the drive belt.
7) 4WD models (Selective 4WD)
8) Keep your hands off any metal parts such as the radiator
exhaust manifold, exhaust pipe, and muffler, to preven~
When front wheels are jacked up or placed on test rollers
(= chassis dynamometer) for operation, be sure to set "4WD
burning yourself.
switch" to "OF F".
9) When servicing the electrical system or the fuel system,
In addition, disconnect harness connector for 4WD solenoid
disconnect the ground cable from the battery.
valve inside engine compartment.
10) When disassembling, arrange the parts in the order that
they were disassembled.
11) When removing a wiring connector, do not pull the wire
unit but remove the connector unit by holding it.
12) When removing a hose or tube, remove the clip first.
Then, pull the hose or tube while holding its end fitting.
13) Replace the gasket, O-ri ng, snap ring, lock washer, etc.
with new ones.
14) When tightening a bolt or nut, tighten it to the specified
torque.
15) When performing work requiring special tools, be sure to
use the designated ones.
16) After completing the work, make certain that the hoses,
tubes and wiring harnesses are securely connected.
Fig. 1 17) After completing the work, be sure to wash the vehicle.
8) Pneumatic suspension models w/height control .....

CANADA ,model only
These models are provided with height control mechanism.
Be sure to return the height control to "Normal" position
(low) and support the vehicle with a jack before getting under
it for servicing, etc. To check any system other than electrical
under the vehicle, disconnect cables from battery in advance.
2
Precautions in handling a full-time 4WD vehicle 2) Testing Procedures

(1) Jack-up Method
CD Equipment
• Speedometer tester ....................... 1
• Speedometer test • Garage jack ............................. 1
Generally, when testing the speedometer of a full-time 4WD • Safety stand ............................ 2
vehicle, even if the engine is running at a relatively slow speed, ® Precautions
releasing the clutch abruptly may still cause the vehicle to • Test the speedometer using the rear wheels.
jump off of the test machine. Be especially careful to avoid (Vehicle stability is better than with the front
this. wheels.)
1) Testing Methods
(1) Jack-up Method
The usual speedometer tester is used and the rear wheels
are tested with the front wheels raised off the ground and
the center differential locked.
~ /' + II/ +
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"
, - .......... - ..... i
\:
II
i \. . .
_..,~/ \. . . _",,/ :
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! { + ':!
Fig. 5 Setting on the speedometer tester
L1-408
• Place the garage jack and safety stands in their

L1·406
proper positions.
Fig. 3 Jack-up method
Also, in order to prevent the vehicle from slipping
due to vibration, do not place any wooden blocks
(2) Adapter Method or similar items between the safety stands and the
An adapter is installed between the vehicle's speedometer vehicle.
and cable, and testing is done using the usual speedometer
1
tester with the center differential operating. The vehicle's
speedometer will then indicate 1/2 actual wheel speed. IrAPprox.
80 mm 13.15 ;nl
Therefore, an adapter which doubles the speed is neces·
sary.
Front (J
L1·360
Fig. 6 Safety stand setting
L1·407
• Since the front wheels will also be rotating, do not
Fig. 4 Adapter method place anything near them. Also, make sure that
nobody goes in front of the vehicle.
Use the adapter method only when the jack-up method cannot • With the center differential locked, confirm that
be employed at the service garage. the differential lock indicator light is lit.
3
If the differential lock switch is in the "ON"
position. but the differential lock indicator light is
not on. rock the vehicle slightly forward or back-
ward to lock the differential.
Operate the differential lock switch before setting
the speedometer tester. Never operate the differ-
ential lock switch while the vehicle is on the free
rollers. (There is a chance that the vehicle may
jump off the rollers.) ~i11
-~ IL \
, Differential lock switch
Fig. 9 Adapter
L1-363
U\
\I i
®
•
Precautions
Do the testing with the differential lock cancelled.
Confirmation that the differential lock is cancelled
can be done with the differential lock indicator
light, but for this test, confirm with actual driving
that there is no braking phenomenon when turning
sharp corners at low speed.
L 1-409
Fig. 7 Differential lock switch
(®) =:~ DOOR LOCK ((!!) ::e DOOfI LOCK
"OFF" liON"
L1-518
Fig. 10 Differential lock indicator light
"OFF" "ON"
L 1-517 • Since the vehicle speedometer indicates 112 the
Fig. 8 Differential lock indicator light actual speed of the rotating wheels. be certain to
install an ADAPTER (499827100).
• For safety, start in second gear. Never make any

abrupt speed changes or maneuvers during the test.
)
(2) Adapter Method
CD Equipment
• Speedometer tester ....................... 1
• Wheel blocks ........................... 2
• ADAPTER (499827100) . . . . . . . . . . . . . . . 1
Since the speedometer detector is on the engine side of the

center differential, if the front wheels are locked, the vehicle's
speedometer will only indicate 1/2 the speed of the rear L1·412
wheels. Thus, an adapter which doubles the speed is necessary. Fig. 11 Adapter installation
4
• Do the test with the rear wheels on the speed- ® Adapter Installation Procedures
ometer tester rollers. a. Disconnect the speedometer cable from the
speedometer.
b. Connect the speedometer cable to the
ADAPTER gear box.
;;.. -- . ,
I, ,I
--
, ...... .....
II + jl + \ I
\ \ ..... _-,,: \'''' - ... ,/
L1408
Fig. 12 Setting on the speedometer tester
L 1-414
Fig. 14
• In order to prevent the vehicle from jumping off

c. Connect the speedometer to the ADAPTE R
the tester, be certain to apply the parking brake
speedometer cable.
and place wheel blocks in front of the front wheels.
Also, make sure that nobody goes in front of the
vehicle. Place the cable so that it does not get in the way when depress-
ing the accelerator pedal.
L1407
Fig. 13 Adapter method
Fig. 15
• For safety, start in second gear. Never make any

abrupt speed changes or maneuvers during the test.
• The center differential will be rotating faster than
normal. Check the transmission oil which also • Brake Test
serves as the center differential oil and add if oil When using the brake tester, do so with the differential lock
level is low. canceiled. Turn the differential lock switch off and make sure
• Keep maximum speed below 50 km/h (31 MPH) that the differential lock indicator light ("DIFF LOCK") has
and for less than 1 minute. gone off.
5
• Chassis Dynamometer Test 2) Towing with Front Wheels Raised

The propeller shaft must be removed and the vehicle made CD Turn the differential lock switch to the "OF F"
into front wheel drive. To undo the propeller shaft, do not position and make sure that the differential lock indicator
disconnect the front propeller shaft ASSY. Only disconnect light ("DIFF LOCK") has gone off. (Confirmation of
the rear propeller shaft ASSY and lock the center differential. differential lock cancellation.)
CV The center differential will be rotating faster than
When reconnecting the front and rear propeller shaft ASSV's, normal. Check the transmission oil which also serves as
align the matching marks very carefully. the center differential oil and add if oil level is low.
Tow at less than 30 km/h (19 MPH) .
• Tire Balance Test (On-car-machine) @ Do not tow for more than 50 km (31 miles).
For safety when doing the tire balance testing, disconnect the
propeller shaft and keep the center differential locked. Also,
do not drive the tires with the engine, but use the on-car- Transmission oil level check
machine to rotate the tires and do the balance testing.
a. In doing the testing, be sure to jack up both the left and

right sides and put wheel blocks behind the tires contacting
the ground.
b. Make sure that the transmission is in neutral gear position .
• Towing Towing distance within. Towing speed under

If the following conditions cannot be met, raise and support 50 km (31 miles) 30 km/h (19 MPH).
all four wheels to move the vehicle.
L1-41S
a. Before towing, check transmission oil and differential oil Fig. 17 Towing with front wheels raised
levels and top up to the specified level if necessary.
b. The ignition switch should be in the "ACC" position while
the vehicle is being towed. • Differential Lock Cancelling Method
1) Under normal circumstances, start the engine, turn the c.>
1) Rope Towing
differential lock switch off and, with the tires pointed straight,
CD Turn the differential lock switch to the "OFF"
move the vehicle either forward or backward.
;
•
position and make sure that the differential lock indicator 1
2) If the engine cannot be started, such as with a dead >
>
light ("DIFF LOCK") has gone off. (Confirmation of
battery or when the vacuum actuator is not working, raise the
differential lock cancellation.)
front (or rear) wheels and move the differential lock lever, on
CV When the vehicle has a large air spoiler skirt on it,
the right side of the transmission, towards the rear of the
wrap the tow rope with a rag to prevent the rope from
vehicle.
scratching the air spoiler.
Tow the vehicle with the engine off .
• The power steering will not be operating so the steering
will be stiff .
• The brake booster will not be operating so the braking
will be very weak.
• Front
L1-372
Fig. 18 Differential lock lever operation
Rag
L1-415
Fig. 16 Rope towing
6
• Towing
If the following conditions cannot be met, raise and sup-
port all four wheels to move the vehicle.
a. Before towing, check transmission oil and differential oil

... levels and top up to the specified level if necessary .
3... b. The ignition switch should be in the "ACC" position while
the vehicle is being towed.
., c. Never use the tie down tabs for towing .
FWD connector '
..
d. Remember that brake booster and power steering will not
work when the engine is "OFF". You will have to use greater ~'2615
I effort for the brake pedal and steering wheel. Fig. 19
• Also ensure that the FWD pilot light is on.
1) Rope towing
(1) Place the selector lever "N" position and put a spare
fuse inside the FWD connector. IT]
[ID
(2) Tow at less than 30 km/h (20 MPH). 1NJ
(3) Do not tow for more than 10 km (6 miles). [Q] IPOWER!
4 rn
[rJ 11HOLDI
• Before checking or servicing the car with the front wheels
raised or on rollers (brake tester, chassis dynamometer, ~
Iiil ~DOOA
W LOCK
etc.), always set the car in the FWD mode.
To set the car in the FWD mode, disconnect the 4WD /fu-LT1r.'f \
4WD
circuit by inserting a fuse in the FWD connector inside the (<l')
PARK ~
engine compartment. Also chock·the rear wheels firmly. If BAAKE'---
the car is left in the 4WD mode, it will surge abruptly

when the wheels turn, possibly damaging the transfer L 1-519
clutch.
Fig. 20
Vehicle Identification Numbers (V. I. N.)

1. Applicable V.I. N. in This Manual
DL (MPFI, 5MT) JF1AX422XJB 300001 and after

GL (MPFI, 5MT) JF1AX432*1 XJB 300001 and after
1800 cc Engine JF1AX432*1 XJC 300001 and after
GL (MPFI, 4AT)
4WD GL (MPFI, 5MT, Single-range) JF1*2AX732*1 XJD 300001 and after
XT6 (MPFI,4AT) JF1AX842*1XJC 300001 and after

FULL TIME 4WD XT6
2700 cc Engine JF1*2AX942*1 XJG 300001 and after
(MPFI, 5MT, Single-range)
FULL TIME 4WD XT6 (MPFI,4AT) JF1*2AX942*1 XJH 300001 and after
*1: For CANADA, "B" instead of "2"

*2: For CANADA, "2" instead of "1"
7
'----------------
2. The Meaning of V.I.N. •
Maker identifier
,C I
. - - - - - - - - - - - - - - - - - Veh icle attribute
JF1AX432XJB30000
II
. - - - - - - - - - - Vehicle identification
~------ Sequential number

300001 and after
' - - - - - - - - - - - - Plant of manufacture and transmission type
B Gunma manufacture - 5MT
C Gunma manufacture - AT
D Gunma manufacture - 4WD 5MT
G Gunma manufacture - Full-time 4WD MT
H Gunma manufacture - Full-time 4WD AT
' - - - - - - - - - - - - - Model year
J : 1988
~------------ Check digit
o thru 9 and X, varies
L - ._ _ _ _ _ _ _ _ _ _ _ _ _ Weight class and restraint type
2 3,001 to 4,000 Ib GVWR with passive restraint
B : 3,001 to 4,000 Ib GVWR without passive restraint
(For CANADA)
' - - - - - - - - - - - - - - - - - Model
2 DL model
3 GL model
4 GL-10 model
~--------------- Series and engine type

4 1800 cc engine
7 1800 cc engine 4WD
(model equipped with air suspension)
8 2700 cc engine
9 2700 cc engine 4WD
(model equipped with air suspension)
~--------------------Bodytype
X : XT
1 . . - - - - - - - - - - - - - - - - - - - - - Line
A: Fuji SUBARU L line
'-------------------------------Type of vehicle
1 : Passenger car
2 : Multipurpose passenger vehicle
' - - - - - - - - - - - - - - - - - - - - - - - - - - Manufacturer and make
Fuji Heavy Industries Ltd. SUBARU
8
Identification Number and label locations

1. Vehicle Identification Number 3. Transmission Serial Number
The vehicle identification number is stamped on the bulkhead The transmission number label is stuck on the upper surface of
panel of the engine compartment. main case (MT) or converter housing (AT).
( E:l I
~~ _______~_V~IN~----{
I
Transmission serial number
..::r-
~- l~ ~~.J----/.....J-~'
Ll-419
Fig. 21
2. Engine Serial Number

The engine serial number is stamped on the right side of the
crankcase at the front.
Transmission serial number
Fig. 22
/ L1-420
Fig. 23
Ll-421
Engine, transmission and vehicle identification numbers are

used for factory communications such as Technical informa·
tion, Service bulletins and other information.
9
4. Safety Certification Plate 6. Vehicle Identification Number Plate

Safety certification plate is stuck near the driver's side door
striker.
Fig. 26
L1·223
Fig. 24
7. Color Code Label
5. Vehicle Emission Control

Information Labels
Vehicle emission control information labels are stuck under
the engine hood.
Fig. 27
L 1-224
Fig. 25
10
Theft Prevention
The Theft Prevention (T.P.) label is stuck or V.I.N. is stamped on the main line installed parts shown below.
Additionally. the "R DOT" label is stuck or " t) R DOT" is stamped on the main spare parts shown below.
1. T.P. label and "R DOT" label

(A) T.P. label (8) "R DOT" label
L 1-424 L 1-425
~----------------------------~
For engine and transmission, "V.I.N." is stamped. For engine and transmission, "t) R DOT" is stamped.
Fig. 28
2. Location
CD @ ®
L1-426
Fig. 29
11
CD Front hood ® Rear quarter
LJL
(j) Trunk lid

@ Fender @ 3'~
~~
~
c
I~ --
__ --.:::,
~
~~bJ
® Door
@ Engine
2700 cc
@ Front bumper ® Transmission

• Manual Transmission
• Automatic Transmission
@ Rear bumper
@
Fig. 30
12
Recommended Fuel, Lubricants, Sealants and Adhesives

1. Fuel
The SUBARU engine is designed to give satisfactory engine performance and low exhaust emissions by using gasoline of 87
octane or higher. (Average of Research Octane Number and Motor Octane Number.)
Use unleaded gasoline only.
2. Lubricants
Lubricants Specifications Remarks
• Engine oil • API Classification:

SE or SF
• For SAE viscosity number, refer to the table below.
• Transmission and differ-

ential gear oil
• API Classification:
GL-5
• For SAE viscosity number, refer to the table below.
• 4WD rear differential
gear oil
• Automatic transmission
and power steering fluid
• DEXRON II (For power steering fluid)
Recommended fluid Manufacturer
B.P.
CALTEX
ATF CASTROL
Dexron II MOBIL
SHELL
TEXACO
• Limited Slip Differential • Genuine SUBARU LSD oil

(LSD) oil (Part No. 003304300)
• CYBRID power steering

fluid
• STEERING
Genuine SPECIAL POWER
FLUID
(Part No. K0209A0080)
• Coolant • Genuine SUBARU Coolant

(Part No. 000016218)
• For further coolant specifications, refer to the table
below.
(Anti-freeze, anti-corrosive
ethylene glycol base)
• Brake fluid • DOT3 or DOT4 •

•
FMVSS NO. 116
Avoid mixing brake fluid of different brands to
prevent the fluid performance from degrading.
• When brake fluid is added, be careful not to allow
any dust into the reservoir.
13
Lubricants Recommended Application Equivalent
FX clutch grease
(PIN 000040901 )
Spl ines of transm ission main shaft. --
Molylex No.2
(PIN 723223010)
BJ and DOJ joints of axle shafts. --
PBC Stopper plugs of the front disc brake
(PIN 003607000) caliper.
--
Brake caliper body (Piston, spindle
Silicone KS64
(PIN 003606010)
adjuster a-ring), battery terminals, --
distributor, hood latch, etc.
Control cables and carburetor linkages

Silicolube G·30M subject to cold weather, water-pump
(PIN 004404002) impeller, door latch, striker, battery
--
• Grease
terminals, etc.
Dow Corning Molykote No. 7439 Contacting surfaces of drum brake

(PIN 725191460) shoes and shoe clearance adjuster.
--
Niglube RX-2 Disc brake caliper (lever, connecting
(PIN 003606000) link and spindle head).
--
Valiant grease M-2 Steering gearbox (Both manual and
(PIN 003608001 ) power steering)
--
SUNLIGHT 2
(PIN 003602010)
Steering shaft bearing, bushing for
gear shift system, etc.
--
SUBARU CRC
• Spray lubricants
(PIN 004301003)
O2 sensor. --
14
API SAE viscosity No. and Applicable Temperature

ITEM Clas-
sifica-
tion (OF) -30 0 30 60 90
(oC) -34 -18 0 16 32
SE I 10W-30, 10W-40 I
• Engine oil or
SF
<: 5W-30
I
I
~
90
• Transmission and
I 85W
differential gear oil
.4WD rear differential
GL-5
< 80W I
gear oil
< 75W-90, *80W-90

> L1-513
Fig. 31
a. Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands. (Except engine oil)
b. When replacing engine oil, it does not matter if the oil to be added is a different brand from that in the engine, however use
oil having the API classification and SAE viscosity No. designated by Subaru.
c. SAE 50W·30 is not recommended for sustained high speed driving.
d. If vehicle is used in desert areas or areas with very high temperatures or for other heavy duty applications, the following
viscosity oils may be used:
30,40, lOW-50, 2OW-40, 2OW-50
e. *For differential gear oil (AT)
Coolant Specifications
SUBARU Specific gravity

Lowest atmospheric coolant-to-
Freezing point
anticipated temperature *water ratio at 10°C at 20°C at 30°C at 40°C at 50°C
(Volume) % (50°F) (68°F) (86°F) (104°F) (122°F)
Above-30°C (-22°F) 50 - 50 1.078 1.074 1.069 1.063 1.057 -36°C (-33°F)
* It is recommended that distilled water be used.
a. Avoid using any coolant or only water other than this designated type to prevent corrosion.
b. SUBARU's engine is aluminum alloy, so special care is necessary.
15
1-3 GENERAL INFORMATrON
3. Sealants and Adhesives
Recommended Application Equivalent
Mating surfaces of transmission cases, plugs,

Three Bond 1105 Dow Corning's
etc.
(PIN 004403010) No. 7038
Periphery of water pump mechanical seal.
Sealant Three Bond 1215 Flywheel bolts, mating surface of flywheel Dow Corning's
(PIN 004403007) housing, crank case and cam case. No. 7038
Starcalking B-33A Sealing against water and dust entry Butyl Rubber
(PIN 000018901) through weatherstrips, grommets, etc. Sealant
Weatherstrips and other rubber parts, 3M's

Cemedine 5430L plastics and textiles except soft vinyl EC-1770
parts. EC-1368
Soft vinyl parts, and other parts subject 3M's

to gasoline, grease or oil EC-776
Cemedine 540
(e.g., trim leather, gear shift boot, door EC-847
inner remote cover, etc.). EC-l022 (Spray Type)
Adhesive
Bonding metals, glass, plastic and rubber Armstrong's
Cemedine 3000 parts. Repairing slightly torn weather· Eastman
strips, etc. 910
Essex Chemical
Corp's Windshield to body panel. --
Urethane E
16
Tightening Torque of Standard Bolts and Nuts

(1) ENGINE & TRANSMISSION Unit: N'm (kg-m, ft-Ib)
Dia. x Pitch
5T 7T 9T lOT
(mm)
1.0 - 1.5 1.5 - 2.0 2.5 - 3.0 3.0 - 3.5

4 x 0.75
(0.105 - 0.155,0.8 - 1.1) (0.155 - 0.205,1.1 -1.5) (0.255 - 0.305, 1.8 - 2.2) (0.305 - 0.355, 2.2 - 2.6)
2.5 - 3.0 2.9 - 3.9 4.9 - 5.9 5.4 - 6.4
5 x 0.9
(0.255 - 0.305, 1.8 - 2.2) (0.30 - 0.40,2.2 - 2.9) (0.50 - 0.60, 3.6 - 4.3) (0.55 - 0.65, 4.0 - 4.7)
4.4 - 5.4 5.9 - 6.9 9.4 - 10.8 10 -12

6 x 1.0
(0.45 - 0.55, 3.3 - 4.0) (0.60 - 0.70, 4.3 - 5.1 ) (0.955 - 1.105, 6.9 - 8.0) (1.0 - 1.2, 7 - 9)
12 - 14 14.2 - 17.2 23 - 26 25 - 28
8 x 1.25
(1.2 - 1.4, S - 10) (1.45 - 1.75, 10.5 - 12.7) (2.3 - 2.7,17 - 20) (2.5 - 2.9,18 - 21)
25 - 28 30 - 36 46 -54 49.5 - 58.4

10 x 1.25
(2.5 - 2.9,18 - 21) (3.1 - 3.7, 22 - 27) (4.7 - 5.5, 34 - 40) (5.05 - 5.95, 36.5 - 43.0)
41 - 49 53 - 63 84 -98 88 - 106
12 x 1.5
(4.2 - 5.0, 30 - 36) (5.4 - 6.4, 39 - 46) (8.6 - 10.0,62 - 72) (9.0 - 10.8,65 - 78)
71 - 84 88 - 106 139 - 165 147 -175

14 xl.6
(7.2 - 8.6, 52 - 62) (9.0 - 10.8, 65 - 78) (14.2 - 16.8, 103 - 122) (15.0 - 17.8, 108 - 129)
(2) BODY Unit: N·m (kg-m, ft-Ib)
Dia. (mm) 4T 7T 9T
1.7 - 2.6
4
(0.17 - 0.27,1.2 - 2.0)
~ 5
2.9 - 5.9
(0.30 - 0.60, 2.2 - 4.3)
qp 6
5.4 - 9.3
(0.55 - 0.95, 4.0 - 6.9)
12.7 - 22.6 22.6 -42.2 31.4-51.0
~
8
(1.30 - 2.30, 9.4 - 16.6) (2.30 - 4.30,16.6 - 31.11 (3.20 - 5.20, 23.1 - 37.6)
27.5 - 47.1 51.0 - 86.3 62.8 - 107.9

10
(2.80 - 4.80,20.3 - 34.7) (5.20 - 8.80, 37.6 - 63.71 (6.40 - 11.00,46.3 - 79.6)
TC-002
52.0 - 85.3 88.3 - 156.9 117.7 - 196.1
Fig. 32 12
(5.30 - 8.70, 38.3 - 62.9) (S.OO - 16.00,65.1 - 115.7) (12.00 - 20.00, 86.8 - 144.7)
1.2 - 2.2
4
(0.12 - 0.22,0.9 - 1.6)
~ 5
2.5 - 4.4
(0.25 - 0.45, 1.8 - 3.3)
~ 6
4.4-7.4
(0.45 - 0.75, 3.3 - 5.4)
~ 8
9.8-17.7 17.7 - 31.4
(1.80 - 3.20, 13.0 - 23.1)
23.5 - 39.2
(2.40 - 4.00,17.4 - 28.9)
TC-003 (1.00 - 1.80,7.2 - 13.0)
Fig. 33 22.6 - 36.3 37.3 - 66.7 48.1 - 83.4

10
(2.30 - 3.70,16.6 - 26.8) (3.80 - 6.80, 27.5 - 49.2) (4.90 - 8.50, 35.4 - 61.5)
Including bolt or nut with
washer or spring washer 3S.2 - 64.7 68.6 - 117.7 88.3 - 147.1
12
only (4.00 - 6.60, 28.9 - 47.7) (7.00 - 12.00,50.6 - 86.8) (9.00 - 15.00,65.1 -108.5)
The mark is embossed on the bolt head as follows:

4T--4 9T-- 9
5T--5 1DT--1D
7T--7
17
Lifting, Towing and Tie-down Points

Be sure to lift, tow and tie-down the vehicle at the designated positions.
1. Garage Jack
I FRONT I
Crossmember (F)
Fig. 34
Fig. 35
a. When jacking up the vehicle, place chocks to hold wheels.

b. After jacking up the vehicle with garage jack, be sure to support the vehicle with safety stands for safety.
t8
2. Pantograph Jack
\\\ \ \\ )
\ \, \ \
il ) () (l () I
); /
/)
L1-430
Fig. 36
a. Never get under the vehicle while it is supported only by 3. Safety Stand
the jack. Always use safety stands to support body when you
have to get under the car. Be sure to lift vehicle at the same four positions as those of
b. Block the wheels diagonally using wheel chocks. pantograph jack.
c. Make sure the jack is set at the correct position on the
flange of side sill.
d. Be careful not to set the jack at the air flap portion.
L 1-014
Fig_ 37
19
4. Lift
L1-431
Fig. 38
a. Be sure to lift vehicle at the same four positions as those of

pantograph jack.
b. Be careful not to set the lift at the air flap portion.
5. Towing and Tie-down Hooks

Avoid towing another car using front towing hooks.
I Front I
o ICJ c::J1 o [
-~rl]dl~bD1t
3~B§?o~ggVt
JtC~n:~:IDl
Fig. 39
L1-432
Fig. 40
Hook for tie-down L1-433
20
PRE-DELIVERY INSPECTION
Page
SUBARU PRE·ROAD TEST INSPECTION. . . • . . . . . • • . . . • • . . . . • . . . • . • • •.

ROAD TEST INSPECTION ............•........•..•..•..... 19
3
POST·ROAD TEST INSPECTION ...............•.......•..... 24
1988
•
1-4 PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION TABLE

Page
I PRE·ROAD TEST INSPECTION I . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . .. 3
o 1. HOOD OPERATION. . . . . . . . . . . . • • • • • • . . • . • • • . . • • . • . . . . • • • • • • . • • . . • • • •• 3
o 2. DOOR OPERATION, DOOR LOCK AND REGULATOR...... . . . . . . . . . . . . . . . • . .. 4
o 3. TRUNK LID, REAR GATE AND FUEL LID OPERATION.. . . . . . . . . . . . . . . . . • • . •• 4
o 4. BRAKE FLUID LEVEL AND BRAKE PIPING INSTALLATION ..............•.... 6
o 6. BATTERY FLUID LEVEL AND BATTERY INSTALLATION. . . . . . . . . . . . • . . . . . . . .. 6
o 6. COOLANT LEVEL AND COOLING FAN INSTALLATION.. . . . . . . . . . . . . . . . . . . . .. 6
o 7. ENGINE OIL LEVEL. . . . . . . . . . . . . • . . . • . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . .. 7
o 8. TRANSMISSION AND DIFFERENTIAL GEAR OIL LEVEL ............•......... 8
I
o 9. BELT TENSION ... See p.3 in Chap. 1·6 ................................... .
9
010. AIR CLEANER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
011. JACK INSTALLATION ...... . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . .• 10
012. WINDSHIELD WASHER AND WINDSHIELD WIPERS. . . . . . . . . . . . . . . . . . . . . . . . . •. 10
0·13. WHEEL NUTS FOR LOOSENESS AND TIRE INFLATION PRESSURE .............. 11
014. SEAT ADJUSTER AND SEAT BELTS. . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11
015. FUSES............................................................. 13
o 16. LIGHTS AND SWITCHES ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 13
o 17. PREPARATION FOR UNDERSIDE INSPECTION ... See p. 18 in Chap. 1·3 .. . . . . . . . .. _
018. INSTALLATION OF STEERING COMPONENTS.... . . . . . . . . . . . . . . . . . . . . . . . . . .. 16
019. EXHAUST PIPE AND MUFFLER.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 16
020. FUEL SYSTEM FOR LEAKAGE.... . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . .. 16
o 21. HEIGHT CONTROL SYSTEM (Canada model) ... Air (Pneumatic) Suspension Vehicle. . . .. 18
o 22. TILTITELESCOPIC STEERING COLUMN .................................... 18
I ROAD TEST INSPECTION I ................................................. 19
o 1. OPERATION OF INDICATOR LIGHTS AND GAUGES .......................... 19
o 2. TACHOMETER, RADIO, CLOCK, ETC. ..... • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20
o 3. DRIVING TEST ..... . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . .. 21
I POST·ROAD TEST INSPECTION I ............................................. 24
o 1. IGNITION TIMING ... See p. 2 in Chap. 2·2 ................................. -
o 2. AUTOMATIC TRANSMISSION FLUID (ATF) LEVEL ........................... 24
o 3. POWER STEERING FLUID LEVEL ......•.................................
25
o 4. TOE ......... '..............•.....................................•
25
o 5. UNDERSIDE ...........................•...........................•26
o 6. WATER LEAKAGE ......................•............•.........•..... 27
o 7. EXTERNAL APPEARANCE AND EQUIPMENT ....................••..•.....• 27
PRE-DELIVERY INSPECTION 1-4
Pre-road Test Inspection

1. HOOD OPERATION 2. Check the condition of lock and adjust if necessary.
CHECK POINTS
1. Operation of hood release and lock

2. Condition of lock
3. Fitting of hood
1. Check the operation of hood release and lock.
I
Fig. 3
Fig. 1
L1-523
Fig. 4
-·_~------safetY lever
--------
L1-521
Fig. 2
Fig. 5
3
3. Check the hood fitting and adjust if necessary. 6. Check the auto·door locking operation.
L1-440
Fig. 6 Fig. 8
§J
2. DOOR OPERATION, DOOR LOCK AND §)
/ D ~~
'/Jf
REGULATOR
/ ~'~,~~~
CHECK POINTS / Pus~ thi~rt, to lock.
1.
2.
Door "open-close" operation
Operation of door release and lock
/
~OCk
,
i --;
\'\~~
\ \ \ ~~
""
/~ Red mark ' \ \ ~
/ lever
3. Loose or damaged parts J II
L1-524
4. Regulator handle's operation
5. Position of door window glass Fig. 9
6. Auto-door locking operation
2. Check the operation of door release and lock.
3. TRUNK LID, REAR GATE AND FUEL

LID OPERATION
, CHECK POINTS
Flap
1. Trunk lid, rear gate and fuel lid "open-close"
OM·1807 operation
Fig. 7 2. Operation of trunk lid, rear gate and fuel lid
release and lock
a. Do not use excessive force when pulling the outer handle. 3. Fitting of trunk lid, rear gate and fuel lid
b. If the lock cylinder does not function properly, it must be
replaced with a new one. However, if the door lock's opera-
tion is just unsmooth, it may be corrected by applying grease
or oil to the sliding surfaces.
'4
2. Check the operation of release and lock. 4. BRAKE FLUID LEVEL AND BRAKE
• Opener PIPING INSTALLATION
CHECK POINTS
1. Flu id level in brake reserve tank

2. Wiring of fluid leveller and its operation
3. Brake booster, master cylinder, hill holder
and pressure control valve for proper instal-
lation; brake pipe, brake hose and con-
nectors for proper fitting
4. Leakage in any of the above
Ll-443
Fig. 10
1. Inspect the fluid level and add if necessary.
• Trunk lid
Fig. 11 Fig. 13
• Models equipped with a trunk lid opener have an opener

cancel lever. With the lever in the "ON" position, make
sure that the opener lock cannot be released even if the • The fluid level must be kept at "MAX" level.
opener lever is pulled from the inside of the passenger
compartment. Also make sure that it can only be released • Recommended brake fluid
from the outside with the key. FMVSS No. 116, fresh DOT3 or 4 brake fluid
a. Do not mix different brands of brake fluid.

b. When adding brake fluid, be careful not to allow any dirt,
water, or oil around the fluid tank to enter it.
c. Never use engine oil, gear oil, or any mineral oil.
d. Use extreme care not to allow any water to get into the
fluid; water in the brake fluid will lower the fluid's boiling
point and cause vapor-lock.
e. Use special care not to spill any brake fluid on the vehicle's
painted surfaces, because it will quickly erode them. In case
of an accident, wipe it off as quickly and as cleanly as possible.
f. If too much brake fluid is missing, check the brake line for
possible leakage.
L 1·154
g. After adding brake fluid, any excess must be stored in a
Fig. 12 tightly sealed container.
5
2. Check the wiring of fluid leveller and its operation. 2. Check the specific gravity and recharge if necessary.
u..
Co
~
u 1.250
o N
1.230
1.220 - -- ---
1.190
1.130~~~--=-,,:"-,,-~--'::::c:~~~::-:-:-~~~
100% 75% 66% 50% 25%
~
\ Charging condition (%)
~ L1-526
Complete charge
A9-004
Fig. 14 Fig. 16
When checking the operation of leveller, use clean screwdriver a. Electrolyte is toxic; be careful handling the fluid.
or the like and be careful not to allow dirt or dust to get into b. Avoid contact with skin, eyes or clothing. Especially
the tank. contact with eyes, flush with water for 15 minutes and get
prompt medical attention.
c. Batteries produce explosive gasses. Keep sparks, flame,
5. BATTERY FLUID LEVEL AND BATTERY cigarettes away.
INSTALLATION d. After adding distilled water, run the engine and recharge
the battery to mix the additional water with the fluid. After
CHECK POINTS recharging, measure the fluid's specific gravity.
e. Be careful not to spill any battery fluid onto the vehicle.
1. Battery indicator sign f. Ventilate when recharging or using in enclosed space.
2. Specific gravity g, Prior to recharging, any corroded terminals should be
3. Battery terminals cleaned with a brush and common baking soda solution.
4. Battery installation and wiring h. When recharging the battery without removing it from the
vehicle, be sure to disconnect the cable from its negative
terminal.
1. Inspect indicator on battery. i. The battery should not be recharged with 10 A or more.
Blue .... OK
White ... Check electrolyte level.
1) If the level is anywhere between the upper
and lower I ines, recharge battery.
6. COOLANT LEVEL AND COOLING FAN
2) If the level is below the lower line, replace
battery.
INSTALLATION
CHECK POINTS
INDICATOR SIGN
1. Coolant level
2. Cooling fan motor and wiring
Blue @ C:>Blue 3. Water leakage and hose damage
O.K. OK
1. I nspect coolant level and add if necessary.

White--@ @::::>Red or white • Always inspect and add at reserve tank when engine is cold.
CHARGING CHARGING
NECESSARY NECESSARY Reserve tank is equipped with dark green cap which can be
removed with screwdriver.
L6-1219
Fig. 15 • The level must be kept at IJFU LL" level.
, 6
a. Use only genuine SUBARU Coolant (P/N000016218).

b. Avoid using only water any coolant or other than this
designated type to prevent corrosion.
c. SUBARU's engine is aluminum alloy, and so special care is
necessary.
d. If reserve tank is empty, check coolant level in engine. Add
coolant up to filler neck of engine, if necessary.
e. The radiator is of the pressurized type. Never attempt to
open the radiator cap when the coolant's temperature is high;
otherwise boiling water will spurt out. Be sure to wait until the
engine cools down before opening the radiator cap .
.-/When reserve tank is empty, Fig. 19

Q check engine.
(2) XT6
FULL
L 1·545
Fig. 17 Upper
level
3. Inspect for water leakage and hose damage.
When retightening the hose clamps, be careful not to over·

Lower
tighten them, as doing so could damage the hose. level
I~
Q) Oil level gauge
.~--\::::: L 1·527
7. ENGINE OIL LEVEL Fig. 20
Engine oil level

1. Inspect the engine oil level and add oil if necessary.
(1) Except XT6
::..upper
~Ievel Fig. 21
-;: Lower
level • The level should be within the specified range marked on
the gauge.
~_ _ _ _ _---=-~..:.==-=---,,--,-=-----<-_---!._ _ _ _L_1_.O_28---1 Shut the engine off if it is running, and wait at least five
Fig. 18 minutes before checking the oil level.
7
• Recommended oil
API
SAE viscosity No. and Applicable Temperature
Clas-
ITEM sifica-
(OF) -30 0 30 60 90
tion
(OC) -34 -18 0 16 32
• Engine oil SE I 10W-30,10W-4Q

I
<
SE
5W-30
I
L1445
Fig_ 22
a. SAE 5W·30 is not recommended for sustained high speed 1. Check the transmission gear oil level (MT) and add oil if
driving. necessary.
b. If vehicle is used in desert areas or areas with very high tem· • The level should be within the specified range marked on
peratures or for other heavy dry application, the following the gauge.
viscosity oils may be used"
"30, 40, 1OW-50, 20W-40, 20W·50" FWD Non-TURBO
c. When replenishing oil, it does not matter if the oil to be 4WD/FWD
added is a different brand from that in the engine, however, TURBO
use oil having the API classification and SAE viscosity No.
designated by SUBARU.
8. TRANSMISSION AND DIFFERENTIAL

Upper u.
GEAR OIL LEVEL u. _ level 0
_ Lower 0
CHECK POINTS level ...J
1. Level of transmission gear oil for manual L1-546

transmission
Fig. 23
2. Level of differential gear oil for automatic
transmission
3. Level of rear differential gear oil for 4WD
model.
'8
2. Check the differential gear oil level (AT) and add oil if • Recommended oil
necessary.
• The level should be with in the specified range marked on
the gauge.
API SAE Viscosity No, and Applicable Temperature

ITEM Classification (OF) -30 0 30 60 90
(oe) -34 -18 0 16 32
• Transmission and
•
differential gear
oil
4WD rear differ·
ential gear oil
GL·5
< I
I ssw
sow
90
I
3
<: 75W·90, ·Sow·go
:>
L 1-090
-Lower Fig. 26
level
L 144 7
~----------------------------------------~
a. Each manufacturer uses different base oils and additives.
Fig. 24 Thus, do not mix brands.
b. *For differential gear oil (AT).
10. AIR CLEANER
CHECK POINTS
1. Contamination of air cleaner element

2. Related parts
3. Check the rear differential gear oil level (4WD), and add 1. Check the air cleaner element for contamination or the
oil if necessary. presence of foreign matter.
1) Place the vehicle on level ground and check with the
engine stopped.
2) Remove the filler plug of the differential.
3) 011 level should be kept at the bottom of the filler hole.
4) If the oil level is below the bottom edge of the hole, add
oil up to the bottom edge.
5) After adding oil, securely tighten filler plug with alumi-
num gasket in place.
Fig. 27
a. The air cleaner element is a viscous type, which should not

~'-448 be washed or cleaned.
b. If the air cleaner element is broken or damaged, replace it
Fig. 25 with a new one.
9
r-r---==---------------==-------,
11. JACK INSTALLATION c==---::;;~---
.~---.=------------
1. Installed condition of jack
1. Check the installed condition of jack.
UCJ\ Fig. 29
2. Inspect the direction and quantity of windshield washer

fluid sprayed.
1) If the quantity of washer fluid ejected is insufficient:
L1449 Check the level of fluid in the reservoir, the nozzle for clogs
and the hose for twists, or other deformities. If these are all
Fig. 28
normal, suspect motor failure.
2) If the position at which washer fluid is ejected is wrong:
Using an eyeleteer or similar tool, adjust the direction of the
nozzle, be careful not to damage the nozzle hole.
3. Check the operation of windshield wiper and washer.
12. WINDSHIELD WASHER AND

WINDSHIELD WIPERS
CHECK POINTS
1. Installation of windshield washer tank

2. Checking of fluid level
3. Direction and quantity of windshield washer
fluid sprayed
4. Operation of windshield wiper and washer
L 1·529
1. Check the fluid level.
• If the level is not to the filler port level, add washer fluid Fig. 30
to the filler port level.
In areas where water freezes in winter, use SUBARU
windshield washer fluid (003406401) or an equivalent.
The relationship between fluid to water ratio and freezing
a. Before checking the windshield wiper, clean the windshield
point is as follows:
glass.
b. Do not operate the windshield wiper when the reservoir is
Fluid to water ratio (%) Freezing point °c [OF] empty.
c. Before operating the windshield wipers, be sure to eject
30 -12 [101 windshield washer fluid onto the windshield.
If the windshield is dry, the wipers' operating speed and angle
50 -20 [-41
of operation will be different from when it is wet.
100 -45 [-491 d. Do not operate the windshield washer continuously for
more than 10 seconds at a time.
'10
13. WHEEL NUTS FOR LOOSENESS AND 2. Check front seat operation.
TIRE INFLATION PRESSURE • Sliding
CHECK POINTS
1. Wheel nut tightening torque

2. Tire inflation pressure and tire specification
3. Damage to tire and rim
1. Check the wheel nut tightening torque.
Tightening torque:
78 - 98 N·m (8.0 - 10.0 kg-m, 58 - 72 ft-Ib)
When checking the wheel nuts, be sure to use a torque wrench,

and tighten the nuts to the specified torque. Fig. 32
• Reclining
Fig. 31
2. Adjust tire inflation pressure and check tire specification.

Fig. 33
After inspecting and adjusting the tire pressure, be sure to
replace the valve cap.
• Lumbar support
14. SEAT ADJUSTER AND SEAT BELTS
CHECK POINTS
1. Front and rear seats, and their facing

materials
2. Front seat operation
3. Rear seat folding operation
4. Seat belts and their fit
Fig. 34
11
• Lifter • Getting in and out of the rear seat
Fig. 35 Fig. 38
3. Check rear seat folding operation.
• Head restraints
Up-and-down
Lock release knob
(Unlock)
e
(Lock)
L1452
Fig. 36
• Fore-and-aft
L5-645
Fig. 39
4. Check seat belts and their fit.
The seat belt warning light on the instrument panel comes on

for approximately six seconds with the ignition-starter switch
"ON".
The warning chime sounds if the driver's lap belt is not
L 1453
fastened or the emergency release buckle of the automatic
shoulder belt is released.
Fig. 37 Make sure that the warning system works normally.
12
Automatic Shoulder Belt 16. LIGHTS AND SWITCHES

a. While inserting the shoulder belt into the emergency release
buckle, open and close the corresponding door to check that CHECK POINTS
the shoulder anchor moves smoothly without binding or play.
b. Check that the tongue releases when the emergency release 1. Visual inspection of lights (installation,
button is pressed, and that it latches properly with a click damage, dirty lenses, water inside, etc.)
when inserted. 2. Operation of all lights and switches
3. Horn operation
4. Operation of heater and ventilator
5. Removing the clip for room light switch
2. Check the operation of all Iights and switches.
Light switch
The light switch operates with the ignition switch turned
15. FUSES "ON".
The head Iights are raised or lowered and turned on or off
CHECK POINTS using this switch.
1. Fuse installation
2. Spare fuse
1. 2. Check fuse installation and spare fuse.
DON'T USE EXCEPT SPECIFIED FUSE
LOAD <J BATT
R·OEF
II ~I CHARGE
c:(
I.C)
.-4
c:(
HEATER
Fig. 41
L1·534
DR·LOCK
I I.C)
.-4
HEATER
Retractable headlight switch

c:(
I.C) STOP
..... ROOM This switch raises or lowers the headlights without the lights
being turned on or off.
c:(
I.C) PARKING The switch when pressed, raises the headlights to the set
.....
position.
Pressing it again lowers the lights and stores them away.
I
I~ I SPARE
I~ I SPARE
I~ I RAD. FAN
II~ I HEAD LH
I CATCHER
I~ I WIPER
II~ I HEAD RH
Ll·241
Fig. 40
Ll·535
Fig. 42
13
High/low beam switch Turn signal switch

Move the lever up or down. Once the turn is completed, the
When the light switch" iD" is turned ON, the headlights turn signal lever automatically returns. After a slight turn the
illuminate with high or low beam. Each time the lever is lever may not return and in this case, you should cancel it
pulled until it clicks, high or low beam is selected alternately. by hand.
When the headlights are on high beam, the indicator" iD " For a lane change, move the lever part way, then hold it there.
illuminates. The lever will return to its original position when it is released.
L1·538
Fig. 43
Fig. 45
Headl ight flasher switch

Illumination brightness control switch
To flash the headlights.
1. Pull the lever lightly toward you and release it, and the When light switch" :00:" orII 10" is ON, brightness of
lights are raised. the instrument lights, for heater control, and lighting switch
2. Pull the lever lightly again, and the high beam comes on. identification lights, wiper and washer switch, fan motor
The headlights lower automatically in about four seconds switch, etc., is adjusted by sliding the svvitch knob.
once the lever is released. If the lever is released after being As the knob slides toward right side, brightness reduces.
kept pulled for four or more seconds, headlights immediately
lower.
The lever will return automatically once it is released.
The headlight flasher works independently of the lights
switch.
Do not hold the lever for more than just a few seconds.
L1·539
Fig. 46
L1·536
Fig. 44
14
Hazard warning light switch 18. INSTALLATION OF STEERING

When the switch knob is pushed, all turn-signal lights flash as COMPONENTS
a hazard warning regardless of the ignition switch position
for use in an emergency stop with the ignition either off or on.
To stop flashing, push the opposite knob. CHECK POINTS
Turn signals do not function when the hazard warning switch
is on.
,. I nstallation of universal joints
2. Steering gear box for looseness, play, or
Avoid leaving the lights on for long time as it discharges the backlash, and boots for damage
battery. 3. Tie-rod and tie-rod end for proper installa-
tion, or damage
1. Check the universal joint for looseness.
Tightening torque:
21 - 26 N·m (2.1 - 2.7 kg·m, 15 - 20 ft·lb)
( rrr:-=================----;-L-:-'-4:-;'SO
Fig. 47
Fig. 49
Parking light switch
When the switch knob is pushed, the parking lights all go on
regardless of the ignition switch position.
When checking, turn IG switch to "ACC" position.
2. Check the gear box mounting bolt for looseness.
Tightening torque:
47 - 71 N'm (4.8 - 7.2 kg-m, 35 - 52 ft·lb)
( (~r-===============:-~I-;-:L';- :-4~S1
Fig. 48
Fig. 50
15
Carefully check the root portion of the boots, and the can· 20. FUEL SYSTEM FOR LEAKAGE
dition of the clip .
CHECK POINTS
3. Check the tie· rod end lock nut for looseness.
,. Installation of fuel hose and pipe. And
Tightening torque: condition of clamps
78 - 88 N·m (8.0 - 9.0 kg·m, 58 - 65 ft·lb) 2. Fuel system for leakage
1. Check the fuel and air breather pipes visually or by feeling

with your fingers from the underside. Retighten the clamps if
necessary.
a. When retightening the clamps, do not tighten them exces-

sively.
19. EXHAUST PIPE AND MUFFLER b. When checking the fuel system, use extreme care to prevent
accidental fires.
CHECK POINTS
2. Without starting the engine, turn the ignition switch to
the ON position, and operate the fuel pump to pressurize the
,. Exhaust system's installation
fuel system. Then check the fuel system for leakage.
2. Exhaust gas leakage.
Check the fuel hose's layout, and also search for interference
with other parts, twists, or damage, check the condition of the
1. Check the exhaust system's installation for looseness, clamps.
damage and possible interference with other parts.
When the engine is running, and for a short time after it is

stopped, the exhaust system remains very hot; use extreme
care and don't get burnt during this evolution.
Tightening torque:
Front exhaust pipe to engine
25 - 29 N·m (2.6 - 3.0 kg·m, 19 - 22 ft·lb)
Front exhaust pipe to rear exhaust pipe
13 - 23 N·m (1.3 - 2.3 kg·m, 9 - 17 ft·lb)
Rear exhaust pipe to muffler
42 - 52 N'm (4.3 - 5.3 kg·m, 31 - 38 ft-Ib)
Front exhaust pipe to bracket
25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-Ib)
Tail pipe cutter to muffler
29 - 39 N'm (3.0 - 4.0 kg·m, 22 - 29 ft·lb)
16
1. 1800 cc
Purge line
Vacuum line Throttle body
~lntake manifold
Fuel injector
Fuel delivery tine

2-way valve
Filler pips
Canister
L2-016
Fig. 51
2. 2700 cc
Purge line
Vacuum line ""§- Throttle body

~
Pressure
regulator Intake manifold
Fuel injector
Fuel delivery line Fuel filler cap

Tank evaporation
line 2·way valve
Filler pipe
Canister
Fuel return line

L 1-540
Fig. 52
17
21. HEIGHT CONTROL SYSTEM

(Canada model) ···· .. Air (Pneumatic)
Suspension Vehicle
CHECK POINTS
'(
f
1. Function of height control system (Manual

control)
<
(
1. Check the function of height control changeover.

r
...
1) Unload the car to establish "curb weight" condition. L 1-464
2) Start engine and turn height control switch to "NO R-
Fig. 53
MAL."
Ensure ground clearance is automatically set to the NORMAL
value as indicated in Chapter 4-1. 2. Check the operation of telescopic steering mechanism.
I
3) Check air suspension compressor to ensure it stops. Unlock lever B by turning it counterclockwise and check that
If it still is in operation, wait until it stops. steering wheel can be adjusted along the axial direction.
Lock lever B to ensure steering wheel is held in place.
The above procedure is required to determine whether or not,
car height control is in good order and should not be omitted.
4) After compressor stops, set height control switch to

"H IGH" and check the following:
a} Check if car attains the specified height within 30
seconds.
b) Check if the HIGH pilot lamp is on.
c) Check if compressor stops within 150 seconds after
setting height control switch to "H IGH."
5) Set height control switch to "NORMAL" after com-
pressor has stopped. Check if car returns to the specified
NORMAL position within 30 seconds.
6) If abnormality is noted in steps 1) through 5) above, refer
Fig. 54
to Chapter 4-1 and repair as necessary.
3. Check the operation of lift-up steering mechanism.

Pull knob on instrument panel to check if steering wheel lifts
22. TILT ITELESCOPIC STEERING up automatically. Push steering wheel down to check if it
locks in the original position. Ensure there is no free play in
COLUMN
the steering wheel.
CHECK POINTS
1. Operation of tilt steering mechanism

2. Operation of telescopic steering mechanism
3. Operation of lift-up steering mechanism
1. Check the operation of tilt steering mechanism.

Unlock lever A and ensure steering wheel moves up and down
smoothly for proper position adjustment.
Lock lever A to ensure steering wheel stays in place even when
an external force is applied to it from above or below.
Fig. 55
18
2. Check the operation of gauges.

Road Test Inspection Start the engine, and make sure that each gauge operates
normally.
1. OPERATION OF INDICATOR LIGHTS • Fuel gauge
AND GAUGES • Temperature gauge
• Voltmeter
• Oil pressure gauge, etc.
CHECK POINTS
1. Operation of indicator lights a. Perform this inspection with the gear shift lever in the
2. Operation of gauges neutral position.
3. Connecting the wiring harness connector (For automatic transmission models: Set the select lever in the
for clock, etc. [1-pole white connector "P" position.)
underneath the glove box] b. Set the parking brake.
c. Do not race the engine excessively.
I 1. Check the operation of indicator lights.

1) With the ignition switch turned to ON, make sure the
charge indicator light, oil pressure indicator light, brake fluid
level warning light, stop light failure warning light etc.
illuminate. Start the engine, and make sure all of these lights
go off.
The parking brake warning light should illuminate when the
parking brake lever is pulled and the ignition switch is in the
ON position.
It should go out when the parking brake lever is released.
2} Make sure that each indicator light operates normally and
corresponds to its respective device.
• Headlight beam indicator light
• Hazard warning indicator light
• Door ajar warning lights
• Rear gate ajar warning light
• Four-wheel drive indicator light
• Rear window defogger indicator light
• Low fuel indicator light
• Door lock indicator light
• Upshift indicator light
• Height control "HI" indicator light
• AT oil temperature warning light
• CHECK ENGINE light, etc.
• Power steering failure warning light
19
• Analog meter
@ ® ® (For full-time 4WD MT)
~h PSI 45
...."
,'3 4
,'2 "")"" 5 ".- ¢
6"'"
'#
~
:1
lSI
!CI mtJ
~
¢>
" 35
(Z)1i!iY .... 25
45 ,
"
1 5565 75
\,11/,
B5" #
95 .-
105 ......
I /
fi,r::
12v
o;;;::Q E3
fi~~ oO~LYI
"l!::r.
,,~ .~ 2. 7~-
KiIQlo lo[Q!Q[Q1
Q)
"0·' ~D([I "15
Iiiii~Lorl .e=
/fULLlI.f'
4"'0
MPH
0
115'"
125-
135':-
- FFUEL -
UNLEADED
~ ~ ,
8 .... (llJ~
.... L -
81111 0
~
...
. ®
I to
STOP BRAKE CHECK
ATOlL e::lICI-lARGE T EP-S
((l)'FLUID r....:Ec..:;NG:::.:.:IN.:.::E_ _ _~
. TEMP 1------' LAMP
® ® 1 Temperature gauge
2 Oil pressure gauge
® 3 Tachometer
4 Indicators
,."-.
'-v' ,\
\ , I I
55 65 75
I, I /
5 Speedometer
, 45 B5 " # 6 Voltmeter
, 35 95 ..- 7 Fuel gauge
........ 25 105 ...._ 8 Warning lights
101010101010101 -
TEMP
CD ----:-----4.
H~
---=~
"'5
.e=
MPH
o
IQIJKIIlQl
115-
'35... - ::
125::: fiF UNL:~:~D
OD~Y
..
9 Low fuel warning
light
-L~ ,
®
!~·-------T-----~·
I0 I G1CHARGE <O-OIL
STDP
LAMP
BRAKE
IO'FLUID
CH ECK
l..:.EN:.:::G~IN::...E_ - - - I
® ® Ll-541
Fig. 56
2. TACHOMETER, RADIO, CLOCK, ETC. • Radio

Check the operation according to "Owner's manual".
CHECK POINTS • Digital clock
Connect the wiring connector for the clock which is located
1. Operation of tachometer, radio, digital at the back side of the fuse box.
clock, cigarette lighter, etc. Make sure the clock is operating normally.
• Cigarette lighter
• Tachometer
To operate, push in the knob completely and wait for a
Race the engine two or three times, and check the tacho-
moment. The lighter will click out of holder automatically
meter's operation.
when ready to use.
Do not race the engine more than necessary.

CAUTION:
a. To avoid the possibility of being burned, do not hold the
,\ 3
\ , \
cigarette lighter in by hand. This may also cause damage to
the lighter heating element.
,'2 b. When replacing the knob, it is recommended that you use
.... only a genuine part. If you use either non-genuine parts or
x 1000 r/min any combination of parts different from original knob-and-
~1
socket combination, it may cause overheating due to a short
;~G=O circuit.
OM·1825
Fig. 57
20
Pedal play
0.5 - 2.5 mm
\ \
~~
(0.020 - 0.098 in)
OM·527
Fig. 58 Fig. 59
3) Perform the adjustment of operating rod ASSYas follows:

(1) Be sure engine is off. (No vacuum is applied to brake
booster. )
3. DRIVING TEST (2) There should be play between brake booster clevis
and pin at brake pedal installing portion.
CHECK POINTS (Depress brake pedal pad with a force of less than 10 N
[1 kg, 2 IbJ to a stroke of 0.5 to 2.5 mm [0.020 to 0.098
,. Operation of foot brake and parking brake inJ.)
2. Operation of hill holder
3. Operation of clutch and gear shift
4. Operation of selector lever (Automatic trans-
mission models only) Pin (Clevis)
5. Operation of 4WD selector lever (4WD Lock nut
models only)
6. Operation of steering and position of steer-
ing wheel
7. Operation of turn signal cancel cam
8. Operation of ventilation system and heater operating rod
Clevis (M/V)
9. Abnormal noises or vibration
, O. Operation of cru ise control
, 1. Function of automatic vehicle height con-
trol ..... Air (pneumatic) suspension vehicle
1. Check the foot and parking brakes' operation.

1) Drive on a dry, level, paved road, and apply normal
braking. Look for uneven or improper operation, or pulling
to one side.
L4·928
Be sure to perform this test in a safe area. Fig. 60
2) Press the brake pedal in two or three times, and keep it

fully depressed. Make sure that the brake can be kept that
(3) Depress the surface of brake pad by hand.
way for at least five seconds. Also check for air in the brake
(4) If there is no free play between clevis pin and clevis,
system, or brake fluid leakage.
loosen lock nut for operating rod and adjust operating
rod by turning in the direction that shortens it.
Brake pedal free play:
(5) After adjustment, make sure there is no brake drag·
0.5 - 2.5 mm (0.020 - 0.098 in)
ging.
21
4) Pull the parking brake lever completely out, and check its • If the vehicle does not start properly, it should be
operation. Also check the ratchet for normal functioning. corrected by following case A or case B.
Check the parking brake as follows: With the engine running, Case A: When the hill holder releases after the clutch
pull the parking brake lever completely out, and place the gear pedal is engaged (the eng ine tends to stall),
shift lever in 1st gear. Run the engine slightly faster than idle, loosen the adjusting nut gradually until
and engage the clutch. The engine should stall. smooth starting is possible.
If the parking brake is functioning normally, the engine will Case B: When the hill holder releases before the clutch
stall; if not, the vehicle will continue to roll. pedal engages (the vehicle slips down slightly),
tighten the adjusting nut so that the hill
holder releases after the clutch pedal engages
Parking brake lever stroke: (case A).
Standard: Then make adjustment as in case A.
3 - 4 notches/245 N (25 kg, 55 Ib)
Whenever turning the adjusting nut, prevent the pressure
holding valve cable from revolving as shown in the figure.
Fig. 61
L1470
Fig. 62
3. Check the operation of clutch and gear shifting.

2. Check the hill holder operation. 1) With the engine idling and the shift lever in neutral,
1) Inspect free play of clutch pedal by depressing the pedal gradually depress the clutch pedal, to see if it generates any
by hand. If it is out of the specified value, adjust it by turning abnormal noise.
adjusting nut on engine side end of clutch cable at release fork.
Carefully compare a normal clutch's operating sounds to the
dutch being tested.
Standard of free play:
At clutch pedal
2) Pull the parking brake lever completely out, and place
10 - 20 mm (0.39 - 0.79 in)
wheel chocks under the tires. Then depress the clutch pedal
At center of cable on clutch release fork
completely, and place the shift lever in 4th speed.
2 - 4 mm (0.08 - 0.16 in)
Raise engine rpms a little, gradually engage the clutch, and see
if the engine stalls.
If the engine stalls, it means that the clutch is not slipping.
Tightening torque (Adjusting nut):
5.4 - 9.3 N·m (0.55 - 0.95 kg-m, 4.0 - 6.9 ft-Ib)
a. Be sure to perform this test in a safe area.
2) Confirm stopping and starting performances by activating
b. Do not repeat this test.
hill holder on an uphill road of 3° or higher inclination.
Clutch pedal free play:
• If the vehicle does not stop, tighten adjusting nut of
10 - 20 mm (0.39 - 0.79 in)
pressure holding valve (PHV) cable.
22
1-;;~~I:::J~~::;;:7::::::;~rrr~~:::7~\\-1 a. Perform this check by depressing the clutch completely

while the vehicle is moving straight ahead.
b. Do not shift the drive selector lever when the wheels are
spinning or slipping.
5. Operation of steering and position of steering wheel.

1) Check the steering wheel for free play.
Steering wheel free play:

o- 25 mm (0 - 0.98 in)
Fig_ 63
Pedal play
10 - 20 mm -O.79i"~ OM-526
3) Remove the wheel chocks, and return the shift lever to

neutral, then check the gear shifting mechanism for excessive
play.
4) Drive the car at various speeds. While depressing the
clutch pedal completely, move the gear shift lever into each
position, and check for any unusual play or unusual resistance.
CD@) ® L 1-473
H-1
®®®
Fig. 66
OM-1878
Fig. 64
4. Operation of drive selector lever (Automatic transmission
models only).
Place the selector lever in each position, and make sure that
the pointer indicates the position of each range correctly.
The 1st hold switch operates when it is pushed while the selec-
2) With the car moving straight ahead, check for hard
tor lever is at the 2nd range.
steering, shimmy, or other abnormal ities.
3) Make a turn, and check for hard or heavy steering wheel
operation, or poor stability.
p -j-"'- 4) Make a right or left turn with the turn signal on, and make
R -.-e- sure that the turn signal switch returns automatically to the
~
ot
-~-,}-
OF F position when the steering wheel is retu rned to the
straight ahead position.
-~-{r-
6. Operation of ventilation system and heater.
-.--e-
1) While driving, move the control lever into each position,
... V and check the venti lation system's operation. Also check for
unusual vibration or noises.
2) Turn the temperature control dial and fan motor switch,
L1-543 and make sure that warm air is discharged into the compart-
Fig. 65 ment.
23
Temperature control lever
OM-2569
Fig. 67
7. Abnormal noises or vibration.

1) When starting the engine, and while driving the vehicle,
Post-road Test Inspection
check the engine, transmission, body, suspension, and steering 1. AUTOMATIC TRANSMISSION
system for any unusual noises or vibration. FLUID (ATF) LEVEL
Do this when idl ing the engine, accelerating, decelerating, and
running at low, middle and high speeds.
2) Depress the accelerator pedal, and make sure that the
engine rpms increase smoothly and that the vehicle accelerates • Level of ATF
smoothly.
3) While dri-ving, turn the steering wheel right and left to test
the vehicle's stability and response. The A TF should be maintained at the proper level as follows:
1) Drive the car several miles to bring the transm iss10n to the
Be sure to perform this test in a safe area. normal operating temperature. 60 to BO°C (140 to 176°F) is
normal.
2) Park the car on a level surface.
B. Check the operation of the cruise control according to 3) Place selector lever in the "P" position and idle the engine.
"Owner's manual". 4) Remove the level gauge and wipe it clean.
9. Check the function of automatic vehicle height resump- 5) Reinsert the level gauge completely.
tion. 6) Remove it again and note its reading.
(1) Move height control switch to "HIGH" while operat- If the fluid level is at the lower mark or below, add enough
ing car below 80 km/h (50 MPH) to see if HIGH pilot recommended automatic transmission fluid to bring the level
lamp comes on. to the high mark. ATF is added through the fluid level gauge
(2) Operate car at speed higher than 95 km/h (60 MPH) hole.
for at least five seconds to check if NORMAL pilot lamp
instead of HIGH pilot lamp comes on. Do not fill above the high mark level.
(3) Operate car at speed lower than 55 km/h (35 MPH)
for at least five seconds to check if HIGH pilot lamp
instead of "NORMAL" pilot lamp comes on again.
(4) Stop car and move height control switch to
"NORMAL." Check if car is set to the NORMAL height
position.
High mark
(5) If abnormality is noted in steps (1) through (4)
above, refer to Chapter 4-1 al1d repair as necessary.
Be sure to conduct driving tests using a chassis dynamometer Low mark

with front wheels set in operation (F F drive), or test on an
authorized race course or similar place.
L 1-544
Fig. 68
24
2. POWER STEERING FLUID LEVEL a. The available power steering fluid is the same as the auto-
matic transmission fluid. (Except XT6)
The available CYBRID POWER steering fluid is "SPECIAL
POWER STEERING FLUID". (XT6)
Be sure to use the recommended fluid .
• Level of power steering fluid b. When power steering fluid is added, be careful not to allow
any dust into the tank.
The power steering fluid should be maintained at a proper
level.
Check level as follows:
1) Drive the car several miles or kilometers to bring power
steering system up to the normal operating temperature of
about 60°C (140°F).
2) Park the car on a level surface and stop the engine.
3) Remove the level gauge and wipe it clean.
4) Reinstall the level gauge firmly.
5) Remove it again and read the level on the "HOT" side.
If the fluid level is at the lower level or below it, add
recommended power steering fluid up to the high level.
3. TOE
1) To check the toe, make sure that the vehicle has a full
fuel tank and that the spare tire, floor mats and service tool
A3-286
are in place. No other weight should be present.
Fig. 69 2) Place the vehicle on a flat, level surface, and set the front
wheels in the straight ahead position.
3) Mark a line at the center of the tread surface on each tire,
and then mark the front and rear end positions of both front
tires on the ground. Measure the distance between the right
When the fluid level is to be checked without warm ing up the and left tires at both the front and rear ends, and then check
power steering system [at approximately 21°C (70°F)1, read the toe by using the following equation:
the fluid level at the "COLD" position of the level gauge.
A
I Front
I
I
I t \,
I
, \I
I \ I
B
A3·285 A18-024
Fig. 70 Fig. 71
25
Toe L = B-A (In case of ilL" being positive: L = toe-in)

\In case of ilL" being negative: L = toe-out
~
FWD 4WD
Normal Minimum Maximum Normal Minimum Maximum
mm 3 (0.12) 3 (0.12) 5 (0.20) 2 (0.08) 8 (0.31)

0(0)
(in) IN OUT OUT OUT OUT
Service limit i---------- ----- - - --- - - - - ---- - - - - -.-- ---
Degree: per wheel 0° 0°09' IN 0°09' OUT 0°15' OUT 0°06' OUT 0°24' OUT
Toe
mm 1 (0.04) 1 (0.04) 5 (0.20) 4 (0.16) 6 (0.24)
0(0)
(in)
·Service standard i - - - - - - - - - - - - - - I-- - -
IN
_ OUT
........ - - . - -
OUT OUT
- - r- - - - - -
OUT
-.-..-....
Degree: per wheel 0° 0°03' IN 0°03' OUT 0°15' OUT 0°12' OUT 0°18' OUT
Service limit m/km (ft/mile) IN 5 - OUT 5 (IN 26 - OUT 26)

Side-slip with
one occupant
"Service standard m/km (ft/mile) IN 3 - OUT 3 (IN 16 - OUT 16)
"If the toe data is out of "SERVICE LIMIT", readjust it within "SERVICE STANDARD".
a. Before checking front wheel alignment with a sideslip 4. UNDERSIDE

tester, check the following:
(1) Left and right tires are the same type and size. CHECK POINTS
(2) Tires are inflated to specified pressure.
b. When driving over the sideslip tester, be sure to drive the 1. Leakage of engine oil, transmission gear oil,
vehicle slowly with the steering wheel fixed in the straight differential gear oil, etc.
ahead position. 2. Leakage of coolant
3. Leakage of brake fluid
4) If the measured toe or sideslip value is not within the 4. Loose suspension mountings or steering
standard range, adjust it as follows: mounting
(1) Loosen the lock nut on the right and left tie-rod ends,
and adjust the right and left tie-rods simultaneously.
Raise the vehicle body and perform these checks from the
underside by referring to the "Preparatory Steps for Underside
Turn both tie-rods equally to make the adjustment.
Inspection" instructions.
1. Visually check for any signs of engine oil, transmission
gear oil, differential gear oil, etc. leakage.
(2) Measure the amount of toe or sideslip, and if the
2. Visually check for any sign of coolant leakage.
measured value is within the specified range, tighten the
3. Visually check for any sign of brake fluid leakage.
tie-rod end lock nuts.
4. Check the suspension mounting and steering mounting for
any loose or unconnected parts.
Tightening torque (lock nut I :
78 - 88 N·m (8.0 - 9.0 kg-m, 58 - 65 ft·lb)
After completing the toe adjustment, check the steering wheel

for levelness when the vehicle is in the straight ahead position.
26
5. WATER LEAKAGE Before removing the protective agent, be sure to wash the
vehicle, because the painted surface may be scratched if the
surface is rubbed with sand or other hard particles which may
be attached to the protective agent.
• Water leakage by pouring water
• Check the whole vehicle body for stains, flaking, damage
caused by transportation, rust, dirt, cracks, or blistering.
1) Before performing the water leakage test, remove anything
that may obstruct the operation or which must be kept dry. a. It is better to determine an inspection pattern in order to
2) Close all of the windows completely, and then close all of avoid missing an area.
the doors tightly. Close the hood and trunk lid before starting b. It is desirable not to make corrections to the body paint
the test. unless absolutely needed. However, if any corrections are
3) Connect a hose to a tap, and spray water on the vehicle. required to remove scratches or rust, the area to be corrected
The rate of water discharge must be approx. 20 to 25 liters must be limited as much as possible. Re-painting and spray
(5.3 to 6.6 US gal, 4.4 to 5.5 Imp gal) per minute. When painting must be avoided whenever possible.
spraying water on areas adjacent to the floor and wheel house,
increase the pressure.
When directing water on areas other than the floor portion 2. Carefully check each window glass for scratches. Slight
and wheel house, decrease the pressure. But the force of water damage may be removed by polishing with cerium oxide.
must be made strong occasionally by pressing thr! end of the (Half-fill a cup with cerium oxide, and add warm water to it.
hose. Then agitate the contents until it turns to wax. Apply this
wax to a soft cloth, and pol ish the glass.)
Be sure to keep the hose at least 10 cm (3.9 in) from the 3. Check each portion of the vehicle body and underside
vehicle. components for the formation of rust. If rust is discovered,
remove it with #80 - #180 emery paper, and treat the surface
4) Check the following areas: with rust preventive. After this treatment is completed, flush
(1) Front window and body framework mating portion the portion thoroughly, and prepare the surface for repair
(2) Door mating portions painting.
(3) Glass mating portions
(4) Rear quarter windows mating portions Care should be taken not to apply paint, undercoating agent,
(5) Rear window and body framework mating portion anti-corrosive wax, etc. to the following parts of air-suspension
(6) Trunk lik mating portion equipped models while refinishing the undercarriage.
(7) Around roof drips (1) Diaphragm and rolling surfaces
(2) Air suspension compressor and dryer ASSY
If any dampness in the compartments is discovered after the
water has been applied, check all areas that may have possibly • Check each portion of the body and all of the chrome parts
contributed to the leak carefully.
for deformation or distortion. Also check each lamp lens
for cracks.
4. Check the following interior parts for contamination.
1) Instrument panel and meter glass
2) Glove box
6. EXTERNAL APPEARANCE AND 3) Sun visor
EQUIPMENT 4) Room mirror
5) Assist rail
CHECK POINTS 6) Roof trim
7) Door trim
1. Paint 8) Inner trim
2. Scratches or damage to glass 9) Front and rear seats
3. Rust formation 10) Luggage shelf
4. Contamination of interior parts 11) Floor mat
5. Installation of equ ipment 12) Others
1. Check the paint after removing the paint protective agent

and washing the vehicle.
27
If the meter glass is contaminated, wipe it gently with a clean

soft cloth that has been dampened with water. 00 not rub
the meter glass hard; otherwise, the transparent resin plate on
it may become cloudly due to the formation of scratches.
5. Check the interior and exterior equipment to make sure

that they are installed securely. Also make sure that the
equipment conforms to the veh icte's specifications.
Make sure that the spare tire, jack, spare key,

tools, owner's manual, warranty & service book-
let, etc. are all present.
28
PERIODIC MAINTENANCE SERVICES t1C~
Page
SUBARU SCHEDULE OF INSPECTION AND MAINTENANCE SERVICES. . . . ..

1. DRIVE BEL T(S) [EXCEPT CAMSHAFT]
2
(INSPECT DRIVE BELT TENSION) ..................•.... 3

2. CAMSHAFT DRIVE BELT .............................. 6
1988 3. ENGINE OIL .•.... . . . . . . . . . . . . . . . . . . . . . . . • . . . . • . . . .. 9
4. ENGINE OIL FILTER .•...........•.................... 11 •
5. REPLACE ENGINE COOLANT AND INSPECT COOLING
SYSTEM, HOSES AND CONNECTIONS ...................•. 12
6. REPLACE FUEL FILTER AND INSPECT FUEL SYSTEM
HOSES AND CONNECTIONS ..........•...........•...•. 15
7. AIR FILTER ELEMENTS (AIR CLEANER, PCV AIR FILTER) ... 16
8. SPARK PLUG ....................•................... 17
9. TRANSMISSION/DIFFERENTIAL (FRONT AND REAR)
LUBRICANTS (GEAR OIL). . . . . . . . . . . . . . . • . . . . . • . . . . . . .. 18
10. AUTOMATIC TRANSMISSION FLUID....... . . . . . • . . . . . . . .. 19
11. BRAKE FLUiD...... . . . . . . . . . . . • . . . . . . . . . . . • . . . . . . . .. 20
12. DISC BRAKE PAD AND DISC/FRONT AND
REAR AXLE BOOTS • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 22
13. BRAKE LINING AND DRUM...... . . . . . . . . . . . . . . . . . • . . .. 24
14. INSPECT BRAKE LINE AND CHECK OPERATION OF
PARKING AND SERVICE BRAKE SYSTEM ..............•.. 25
15. CLUTCH AND HILL-HOLDER SYSTEM ............. " . . . . . .. 28
16. STEERING AND SUSPENSION . . • . . . . . . . . . . . . . . . . . . . . . . .. 30
17. GREASE ON FRONT AND REAR WHEEL BEARINGS .•....... 38
1-5 PERIODIC MAINTENANCE SERVICES
Schedule of Inspection and Maintenance Services

Continue periodic maintenance beyond Symbols used R: Replace
96,000 km (60,000 miles) or 60 months I: Inspect, adjust, correct or replace if necessary
by returning to the first column of the P: Perform
maintenance schedule. (I) or (P) : Recommended service for safe vehicle operatio!'"
MAINTENANCE INTERVAL
[Number of months or km (miles), whichever occurs first.)
MAINTENANCE ITEM Months 7.5 15 22.5 30 37.5 45 52.5 60 REMARKS

x 1,000 km 12 24 36 48 60 72 84 96
x 1,000 miles 7.5 15 22.5 30 37.5 45 52.5 60
1 Drive belt(s) [Except camshaft) (Inspect drive belt tension) I R
2 Camshaft drive belt R
3 Engine oil R R R R R R R R See NOTE a).
4 Engine oil filter R R R R R See NOTE bl.
Replace engine coolant and inspect cooling system, hoses p

5 (P)
and connections
Replace fuel fi Iter and inspect fuel system hoses and
6 (P) P See NOTE c).
connections
7 Air filter elements (Air cleaner, PCV air filter) R R
8 Spark plug R R
Transmission/Differential (Front and Rear) lubricants
9 I See NOTE d).
(Gear oil)
FWD vehicle I
10 Automatic transmission fluid
4WD vehicle R R See NOTE e).
11 Brake fluid R R See NOTE f).
12 Disc brake pad and disc/Front and rear axle boots I I I I See NOTE g).
13 Brake lining and drum I I See NOTE g).
Inspect brake line and check operation of parking and

14 P P P P
service brake system
Adjust pedal free
15 Clutch and hill-holder system I I I I play at 1,600 km
(1,000 miles).
16 Steering and suspension I I I I See NOTE gl.
17 Grease on front and rear wheel bearings (I)
a. When the vehicle is used under severe driving conditions mentioned below*, the engine oil should be changed more often.
b. Change at first 12,000 km (7,500 miles) or 7.5 months, whichever occurs first. Afterwards, follow the table, i.e. change every 24,000 km
(15,000 miles) or 15 months, whichever occurs first.
c. When the vehicle is used in extremely cold or hot weather areas, contamination of the filter may occur and replacement of filter should be
performed as necessary.
d. When the vehicle is frequently operated under severe conditions, replacement should be performed every 48,000 km (30,000 miles).
e. When the vehicle is frequently operated under severe conditions, replacement should be performed every 24,000 km (15,000 miles).
f. When the vehicle is used under following areas, change fluid every 24,000 km (15,000 miles) or 15 months, whichever occurs first.
(1) High humid areas
(2) Mountainous areas
g. When the vehicle is used under severe driving conditions mentioned below*, inspection should be performed every 12,000 km (7,500 miles) or
7.5 months, whichever occurs first.
* Severe driving conditions:
(1) Repeated short distance driving (Item 3, 12 and 13 only)
(2) Driving on rough and/or muddy roads (Item 12, 13 and 16 only)
(3) Driving in dusty conditions
(4) Driving in extremely cold weather (Item 3 and 16 only)
(5) Driving in areas where roads salts or other corrosive materials are used. (Item 12, 13 and 16 only)
2
PERIODIC MAINTENANCE SERVICES 1-5
Drive Belt(s} MAINTENANCE INTERVAL

[Nu mber of months or km (miles), whichever occurs first]
[Except Camshaft] Months 7.5 15 22.5 30 37.5 45 52.5 60

(Inspect drive belt x 1,000 km 12 24 36 48 60 72 84 96
tension) x 1,000 miles 7.5 15 22.5 30 37.5 45 52.5 60
0 m
2) Check drive belt tensi.::>n and adjust it if necessary by
INSPECTION changing alternator installing position and/or idler pulley
installing position.
1) Replace belts, if cracks, fraying or wear is found.
1. 1800 cc model
Tension mm (in)/98 N (10 kg, 22 Ib)
Type Pulley arrangement
New belt Existing belt
8 -10 9 - 11
Basic model
(0.31 - 0.39) (0.35 - 0.43)
Power steering 6 - 7 *1 7-9

equipped model (0.24 - 0.28) (0.28 - 0.35)
Air conditioner 10-12*2

equipped model (0.39 - 0.47)
Power steering 6 - 8 *2
and air conditioner
(0.24 - 0.31)
equipped model
Figures in parentheses refer to the number of grooves in pulleys, * 1 Replace two belts simultaneously if the above fault
CIP : Crankshaft pulley PIS: Power steering oil pump pulley is found on one of the two belts.
WIP : Water pump pulley AIC : Air conditioner compressor pulley *2 When replacing belt with a new one, adjust its tension to the
AL T: Alternator pulley liP: Idler pulley specification and then readjust it to the same specification after
running engine for 5 minutes in consideration of its initial
Fig. 1
expansion. L1-477
3
2. 2700 cc model
Tension mm (in)/98 N (10 kg, 22 Ib)

Type Pulley arrangement
New belt Existing belt
(1)
8 -10 9 -11
Basic model
(0.31 - 0.39) (0.35 - 0.43)
Air conditioner 5.5 - 6.5 *2 6.5 -7.5

equipped model (0.217 - 0.256) (0.256 - 0.295)
Figures in parentheses refer to the number of grooves in pulleys. *1 Replace two belts simultaneously if the above fault
CIP : Crankshaft pulley AIC : Air conditioner compressor pulley is found on one of the two belts.
WIP : Water pump pulley liP: Idler pulley *2 When replacing belt with a new one, adjust its tension to the
AL T: Alternator pulley specification and then readjust it to the same specification after
running engine for 5 minutes in consideration of its initial
expansion.
Fig. 2 L1·551
2) Install new belt(s) and tighten alternator installing bolts

REPLACEMENT as to obtain the specified belt tension shown in the above
table.
3) Wipe off any oil or water on belts and pulleys.
(1) Except XT6
[A] Alternator drive belt(s) [8] Rear side belt (not driving alternator) on ve-
1) Loosen alternator mounting bolts and remove belt(s). hicles equipped with air conditioner.
1) Loosen bolt and special nut, securing idler pulley then
remove belt.
Fig. 3
Fig. 4
4
2) Attach new belt and apply proper tension to belt as 4) Tighten adjusting bolt by turning it counterclockwise.
shown above.
Tightening torque:
(2) XT6 4 - 6 N·m (0.4 - 0.6 kg-m, 2.9 - 4.3 ft-Ib)
1) Loosen lock nut. Using adjusting bolt, move idler pulley
in the direction that loosens belt.
2) Replace belt with a new one. Belt tension
3) Adjust belt adjusting bolt to tense belt properly. Then Belt tension
tighten lock nut. Gauge [with 98 N
(10 kg, 22 Ib) force]
Tightening torque:
34 - 44 N·m (3.5 - 4.5 kg-m, 25 - 33 ft-Ib) 637 -736 N 5.5 - 6.5 mm
New
(65 - 75 kg, 143 -165 Ib) (0.217 - 0.256 in)
441 - 637 N 6.5 -7.5 mm

Used
(45 - 65 kg, 99 - 143 Ib) (0.256 - 0.295 in)
Lock nut
Adjusting bolt * Tighten a new belt in two steps. Tighten first by applying
~
a force of 588 to 785 N (60 to 80 kg, 132 to 176Ib).
Then retighten to specified value after idling engine for
5 minutes.
CIP : Crankshaft pulley

WIP : Water pump pulley
AIC : Air conditioner compressor pulley
AL T: Alternator pulley
liP : Idler pulley
L 1-552
Fig. 5
5
B Camshaft Drive Belt

Months
[Number of months or km (miles), whichever occurs firstl
7.5 15 22.5 30 37.5 45 52.5 60
x 1,000 km 12 24 36 48 60 72 84 96
x 1,000 miles 7.5 15 22.5 30 37.5 45 52.5 60
m
(3) Remove crankshaft sprocket CPo
REPLACEMENT (4) Detach timing belt on the side of #2 and #4 cylin-
ders.
a. Before replacing timing belts, remove radiator fan.
b. Timing belts should be replaced when engine is cold.
c. Be extremely careful not to allow nuts, washers, and other
foreign matters to enter belt cover.
REMOVAL
Put arrow mark to indicate the direction in which belts move
before detaching belts.
,
INSTALLATION
1) Loosen water pump pulley nut until it can be turned with
fingers. Loosen the upper bolts @ and © by 1/2 turn in advance.
2) Loosen two alternator mounting bolts.
3) Detach V·belts. 1) Install timing belts:
4) Disconnect harness for oil pressure switch or oil pressure (1) Align center line of three lines scribed on flywheel
gauge. with timing mark on flywheel housing by moving fly-
5) Remove crankshaft pulley: wheel.
Loosen crank pulley bolt, and remove pulley. Use special tool (2) Align timing mark scribed on left-hand camshaft
"FLYWHEEL STOPPER CP" or "DRIVE PLATE STOPPER" sprocket with notch on belt cover.
to lock crank pulley.
Tool No. Tool Name ~ Timing mark

" ' \ Notch
498277000 FLYWHEEL STOPPER
498497000 DRIVE PLATE STOPPER
6) Remove water pump pulley and pulley cover by loosening

four 6 mm nuts.
7) Remove level gauge guide together with level gauge by
loosening one 8 mm bolt.
8) Remove right-hand and left-hand belt covers by loosening L1-258
eight 6 mm bolts. Fig. 6
9) Remove front belt cover by loosening eight 6 mm bolts.
10) Remove timing belts:
(1) Loosen bolts securing tensioner on the side of #1
and #3 cylinders, and move tensioner upward completely. (3) Attach No.2 timing belt to crankshaft sprocket, oil
Then temporarily tighten bolts. pump sprocket, idler CP, and camshaft sprocket in
Use special tool "TENSIONER WRENCH" (499007000) sequence. Be careful not to slacken belt.
to move up #2 and #4 side tensioner.
(2) Detach timing belt on the side of #1 and #3 cylin-
ders.
6
(4) Adjust tension of belt by loosening tensioner bolt (8) Be sure the three lines on flywheel and timing mark
@ by 1/2 turn. on camshaft sprocket are respectively positioned as
specified in steps (1) and (2) above.
(9) Rotate crankshaft clockwise one turn and align center
line of scribed three lines on flywheel with timing mark
on flywheel housing.
(10) Install crankshaft sprocket CPo
(11) Align timing mark of right-hand camshaft sprocket
with notch on belt cover.
(12) Attach timing belt to crankshaft sprocket and cam-
shaft sprocket. Be careful not to slacken belt_
(13) Loosen tensioner bolt @ 1/2 turn, and apply tension
to timing belt.
(14) Push timing belt with finger to ensure smooth move-
ment of tensioner.
(15) Using special tool "BELT TENSION WRENCH CP"
(499437000), apply the specified torque counterclock-
Fig. 7
wise to camshaft sprocket. Under this state, temporarily
tighten tensioner bolt @ and then temporarily tighten
bolt @.
(5) Push timing belt with finger and ensure tensioner

moves smoothly.
(6) Using special tool liBEL T TENSION WRENCH CP"
(499437000), apply the specified torque counterclock-
wise to camshaft sprocket. Under this state, temporarily
tighten tensioner bolt @ and then temporarily tighten
bolt ©.
Specified timing belt tension and torque to be applied to

camshaft sprocket
Torque to be appl ied

Belt tension
to camshaft sprocket
Fig. 8
147 - 245 N 24 - 25 N·m
(15 - 25 kg, 33 - 551b) (2.4 - 2.6 kg-m, 17 - 19 ft-Ib)
(16) Sequentially tighten bolts @ and @ to the specified

When specified belt tension is applied to timing belt, notch of torque.
special tool "BEL T TENSION WRENCH CP" will be aligned
with belt cover notch. Timing under tensioned state can be Tightening torque:
ascertained by this method. 17.2 - 20.1 N·m
(7) Sequentially tighten bolts @ and © to the specified (1.75 - 2.05 kg-m, 12.7 - 14.8 ft-Ib)
torque.
(17) Be sure the three lines on flywheel and timing mark
on camshaft sprocket are respectively positioned as
Tightening torque:
specified insteps (11) and ( 12) above.
17.2 - 20.1 N·m
2) Install front belt cover:
(1.75 - 2.05 kg-m, 12.7 - 14.8 ft-Ib)
Attach front and rear belt cover sealings, and timing belt cover
plug to front belt cover. Install it to cylinder block.
Be sure that no foreign matter such as nut, washer, etc. is left

inside the belt cover.
7
3) Install crank pulley:

Lock crank pulley using special tool "FLYWHEEL STOPPER Tightening torque:
CP" or "DRIVE PLATE STOPPER", and tighten crank pulley 89 - 107 N·m (9.1 - 10.9 kg-m, 66 - 79 ft-Ib)
bolt.
4) Install water pump pulley:
Assemble water pump pulley and pulley cover, and temporar-
ily tighten bolts.
5) Install oil level No.2 guide ASSY and oil level gauge CPo
Coat O-ring with engine oil when installing.
6) Install V-belts.
7) Tighten water pump pulley bolt to the specified torque.
Tightening torque:
9.1 - 10.5 N·m (0.93 - 1.07 kg-m, 6.7 -7.7 ft-Ib)
8) Connect harness to oil pressure switch or oil pressure

gauge and clamp harness to level gauge guide.
Crankshaft pulley l1-259
Fig. 9
8
II Engine Oil
Months
[Number of months or km (miles), whichever occurs first]
7.5 15 22.5 30 37.5 45 52.5 60
x 1,000 km 12 24 36 48 60 72 84 96
x 1,000 miles 7.5 15 22.5 30 37.5 45 52.5 60
m m m m m III m m
2) Open engine oil filler cap for quick draining of the engine
REPLACEMENT oil.
1) Drain engine oil by loosening engine oil drain plug.
Fig. 11
Fig. 10
3) Tighten engine oil drain plug after draining engine oil.
Tightening torque:
25 N·m (2.5 kg-m, 18 ft-Ib)
4) Fill engine oil through filler pipe up to upper point on

level gauge. Make sure that vehicle is placed level when
checking oil level. Use engine oil of proper quality and
viscosity, selected in accordance with the table below.
9
API SAE viscosity No. and Applicable Temperature

Clas-
ITEM sifica-
(oF) -30 0 30 60 90
tion
(OC) -34 -18 0 16 32
• Engine oil SE I 10W-30, 10W-40 I
<
SF
5W·30
I
L1-445
Fig. 12
The proper viscosity helps car get good cold and hot starting
by reducing viscous friction and thus increasing cranking
speed.
a. SAE 5W·JO is not recommended for sustained high speed

driving. Upper
b. If vehicle is used in desert areas or areas with very high
temperatures or for other heavy duty applications, the
following viscosity oils may be used:
"30,40, 10W·50, 20W·40, 2OW-50"

:Ilevel
Lower
level
c. When replenishing oil, it does not matter if the oil to be L '·028

added is a different brand from that in the engine, however, Fig. 13
use oil having the API classification and SAE viscosity No.
designated by SUBARU. Engine oil capacity:
Upper level
4.0£ (4.2 US qt, 3.5 Imp qt) (Except XT6)
5.0£ (5.3 US qt, 4.4 Imp qt) (XT6)
Lower level
3.0£ (3.2 US qt, 2.6 Imp qt) (Except XT6)
4.0 £ (4.2 US qt, 3.5 Imp qt) (XT6)
5) Close engine oil filler cap.

6) Start engine and warm it up for a time.
7) After stopping the engine, recheck the oil level. If neces·
sary, add oil up to the upper point on level gauge.
10
II Engine Oil Filter

Months
7.5 15 22.5 30 37.5 45 52.5 60
x 1,000 km 12 24 36 48 60 72 84 96
x 1,000 miles 7.5 15 22.5 30 37.5 45 52.5 60
mm m m m
REPLACEMENT
1) Remove oil filter with an oil filter wrench.

2) Get a new oil filter and apply a thin coat of engine oil to
the seal rubber.
3) Install oil filter by turning it with hand, being careful not
to damage seal rubber.
4) Tighten more approximately two thirds turn after the seal
rubber contacts the oil pump case. Do not tighten excessively,
or oil may leak.
5) After installing oil filter, run engine and make sure that no
oil is leaking around seal rubber.
The filter element and filter case are permanently joined; Fig. 14
therefore, interior cleaning is not necessary.
11
~ Replace Engine MAINTENANCE INTERVAL

[Nu mber of months or km (miles), whichever occurs first]
. . . Coolant and Inspect Months 7.5 15 22.5 30 37.5 45 52.5 60
Cooling System, Hoses x 1,000 km 12 24 36 48 60 72 84 96
and Connections x 1,000 miles 7.5 15 22.5 30 37.5 45 52.5 60
~ m
5) Remove drain plug on engine side, and drain coolant.
REPLACEMENT
1) Pull out the end of drain tube to the underside of body

from between undercover and skirt.
Fig. 17
Drain tube 6) Securely tighten engine side drain plugs.

Ll-261 7) Tighten radiator drain plug securely. (Drain tube may face
F'--;9-.- 1 5 - - - - - - - - - - - - - - - - - - - - downward.)
8) Install reserve tank to original position.
9) Carefully pour pr~pared coolant from radiator filler port
to neck of filler, then pour into reserve tank up to "FULL"
level.
Coolant capacity (Pour up to "FULL" level):

2) Place a container under drain tube, and loosen drain plug. Approx. 5.5Q (5.8 US qt, 4.8 Imp qt) (Except XT6)
3) Loosen radiator cap to drain coolant. Approx. 7 Q (7.4 US qt, 6.2 Imp qt) (XT6)
4) Drain coolant from reserve tank.
The SUBARU Genuine Coolant containing anti-freeze and
anti-rust agents is especially made for SUBARU engine, which
has an aluminum crankcase. Always use SU BARU Genuine
Coolant, since other coolant may cause corrosion.
10) Securely install radiator cap.

11) Run engine for more than five minutes at 2,000 to 3,000
rpm. (Run engine until radiator becomes hot in order to purge
air trapped in cooling system.)
12) Stop engine and wait until coolant temperature lowers.
Then open radiator cap to check coolant level and add coolant
up to radiator filler neck. Next, add coolant into reserve tank
up to "FULL" level.
Fig. 16 The radiator is of the pressurized type. Do not attempt to

open the radiator cap immediately after the engine has been
stopped.
12
13) After adding coolant, securely install radiator and reserve PROCEDURE TO ADJUST THE
tank caps. CONCENTRATION OF THE COOLANT
To adjust the concentration of the coolant according to
temperature, find the proper fluid concentration in the above
diagram and replace the necessary amount of coolant with an
undiluted solution of SUBARU genuine coolant (concentra-
RELATIONSHIP OF SUBARU COOLANT tion 50%).
CONCENTRATION AND FREEZING The amount of coolant that should be replaced can be deter-
TEMPERATURE mined using the following diagram,
The concentration and safe operating temerature of the
SUBARU coolant is shown in the following diagram. Measur-
ing the temperature and specific gravity of the coolant will (1) Except XT6
provide this information.
Necessary concentration of coolant
c- 5
.§ (5,3,4.4) r -_ _ _
~
1.100 Safe operating temperature
4
2 (4,2,3.5)
1.090
"C
1.080 ~ 3
.§ (3.2,2.6)
"C
~ 1.070 III
.c
'0 o 2
o
.:: 1.060
o
E(2,1,1.8)
co
> (1.049) '0
'~1.050 -------- o
1
e
CI
t)
'0 (1,1.0,9)
,S! 1.040 ...>
';;
~::J O~--~r-~~~~~~-L~~~--r
}1.030
o 10 20 30 40 50
Concentration of coolant in the vehicle cooling system %
1.020
Concentration of coolant in vehicle and quantity to be drained L2-049
1.010 Fig. 19
1.000 '---~-~~--1:--..L----::!01.--"'1:-'::0~--'20---'~3:'::0---'401.--5~0~.....I1
(32) (50) (68) (86) (104) (122)
Coolant temperature °c (OF) [Example]
L1479 Assume that the coolant concentration must be increased from
Fig. 18 30% to 40%. Find point A, where the 30% line of coolant
concentration intersects with the 40% curve of the necessary
coolant concentration, and read the scale on the vertical axis
of the graph at height A. The quantity of coolant to be
[Example] drained is 2.5 liters (2.6 US qt, 2,2 Imp qt). Drain 2,5 liters
(2.6 US qt, 2,2 Imp qt) of coolant from the cooling system
If the coolant temperature is 25°C (77°F) and its specific
and add 2.5 liters (2.6 US qt, 2.2 Imp qt) of the undiluted
gravity is 1.049, the concentration is 35% (point A), the safe
solution of SUBARU coolant.
operating temperature is -14°C (7°F) (point Bl. and the
If a coolant concentration of 50% is needed, drain all the
freezing temperature is -20°C (-4°F) (point C).
coolant and refill with the undiluted solution only.
13
(2) XT6
Cap relief pressure:
88 kPa (0.9 kg/cm 2 , 13 psi)
-;:; Necessary concentration of coolant
~ 7
.§ (7.4,6.2)
& 6
~ (6.3,5.3)
~ 5
al (5.3,4,4)
.~ 4
-0 (4.2, 3.5)
Q)
~ 3
::: (3.2,2.6)
c:
.g 2
8 (2.1, 1.8)
'0 1
·S> (1.1, 0.9)
c: A7·025
~ 0 ~--~--~~--~-+--~~~~~
a 10 20 30 40 50 Fig. 21
Concentration of coolant in the vehicle cooling system %
Concentration of coolant in vehicle and quantity to be drained
L1-555 5) Check the rad iator for leakage.
Inspect radiator for leakage using a cap tester and applying a
Fig. 20
pressure of 157 kPa (1.6 kg/cm 2 , 23 psi).
If a leakage is detected, repair or replace the radiator.
[Example]
Assume that the coolant concentration must be increased from
30% to 40%. Find point A, where the 30% line of coolant
concentration intersects with the 40% curve of the necessary
coolant concentration, and read the scale on the vertical axis
of the graph at height A. The quantity of coolant to be
drained is 3.5 liters (3.7 US qt, 3.1 Imp qt). Drain 3.5 liters
(3.7 US qt, 3.1 Imp qt) of coolant from the cooling system
and add 3.5 liters (3.7 US qt, 3.1 Imp qt) of the undiluted
solution of SUBARU coolant.
If a coolant concentration of 50% is needed, drain all the Fig. 22
coolant and refill with the undiluted solution only.
6)* If the coolant temperature exceeds 86.5 to 89.5°C (188

to 193°F) while radiator is not so hot, check thermostat.
(Except XT6)
If the coolant temperature exceeds 90 to 94°C (194 to 201°F)
INSPECTION while radiator is not so hot, check thermostat. (XT6)
7)* If thermostat does not open at 86.5 to 89.5°C (188 to
1) Check the radiator reserve tank and hoses for damage or 193°F), replace it with a new one. (Except XT6)
clogging. If thermostat does not open at 90 to 94°C (194 to 201 ° F),
2) Check the hose connections for leakage. replace it with a new one. (XT6)
3) Check the valve, spring and packing in the cap for damage. 8) If electric fan does not operate with coolant temperature
4) Check rubber seal on cap for tears, cracks or deterioration above 93 to 97°C (199 to 207°F), check thermoswitch or fan
after cleaning it. motor.
Install the cap on a tester and if cap does not hold or does not
release the specified pressure, replace cap. * Refer to Chap. 2-5.
14
. . Replace Fuel Filter and MAINTENANCE INTERVAL
ail Inspect Fuel System

Months 7.5 15 22.5 30 37.5 45 52.5 60

Hoses and Connections x 1,000 km 12 24 36 48 60 72 84 96
x 1,000 miles 7.5 15 22.5 30 37.5 45 52.5 60
1m m
(3) Remove the filter from the holder.
REPLACEMENT
a. Before starting the job, be sure to carry out the following .

• Place "No fire" signs near the working area.
• Disconnect ground cable from battery.
b. Be careful not to spill fuel on the floor.
MPFI
1) Removal
(1) Before removing the hose, filter, pump, etc., be sure
to release the fuel pressure, as follows:
• Disconnect the wiring connector of the fuel pump.
• Crank the engine for more than five seconds.
If the engine starts, let the engine run until it Fig. 23
stops.
• After turning IG switch OFF, connect the wiring
connector of the fuel pump. 2) Installation
(2) Loosen the screw of the hose clamp and pull off the (1) I nstall the filter to the holder.
hose from the filter. (2) Connect the hose as illustrated below:
Unit: mm (in)
25 - 30 (0.98 - 1.18)
r=:
--+--+-4 - 7 (0.16 - 0.28) --*--+--4 - 7 (0.16 - 0.28)
I... When fitting length When fitting length

is specified is not specified
A21-232
Fig. 24
(3) Tighten the hose clamp screw to the specified torque. holder. Correct the hose position by removing any twist
so that it will not interfere with the filter body or washer
Tightening torque: tank, before tightening the screw of the hose clamp.
1.0 - 1.5 N·m (0.1 - 0.15 kg-m, 0.7 - 1.1 ft-Ib)
(4) If the hose is damaged at the clamping portion, INSPECTION

replace the hose with a new one.
(5) If the hose clamp is too deformed, replace with a
new one. FUEL PIPING AND CONNECTIONS
(6) Fit the hose to the filter, then install the filter to the Check fuel piping and connections for leakage.
15
II Air Filter Elements MAINTENANCE INTERVAL

[Number of months or km (miles!, whichever occurs first)
(Air cleaner, PCV air Months 7.5 15 22.5 30 37.5 45 52.5 60
filter) x 1,000 km 12 24 36 48 60 72 84 96
x 1,000 miles 7.5 15 22.5 30 37.5 45 52.5 60
III III
REPLACEMENT
I MPFI\
Fig. 25
a. Do not attempt to clean the air cleaner element.

The filter paper of the element is wetted with a special
non-inflammable slow-evaporating viscous liquid. It is
resistant to cold weather and has a long service life. Dirt
adhering to this filter paper forms porous laminations with
the viscous liquid, which function as a filtration layer to
reduce dust penetration into the filter paper. If this filter
paper is cleaned, the filtration layer thus formed will be
lost along with the viscous liquid.
b. Under extremely dusty conditions, replace it more fre-
quently.
16
.spark Plug MAINTENANCE INTERVAL

[Number of months or km (miles). whichever occurs first!
Months 7.5 15 22.5 30 37.5 45 52.5 60
x 1,000 km 12 24 36 48 60 72 84 96
x 1,000 miles 7.5 15 22.5 30 37.5 45 52.5 60
III m
When installing spark plugs on cylinder head, tighten to the
REPLACEMENT specified torque.
Tightening torque:
Recommended spark plugs
18 - 24 N·m (1.8 - 2.4 kg-m, 13 - 17 ft-Ib)
For U.S.A.
NGK: BPR6ES-11
(or BPR5ES-11, BPR7ES-11)
Be sure to place the gasket between the cylinder head and
spark plug.
Nippondenso: W20EPR-U11
(or W16EPR-U11, W22EPR-U11)
Champion: RN9YC-4
(or RN11YC-4)
For Canada
Champion: RN9YC-4
(or RN11YC-4)
Spark plug gap

1.0 - 1.1 mm (0.039 - 0.043 in)
1.0 - 1.1 mm (0.039 - 0.043 in)
Spark plug thread

Dia. = 14 mm (0.55 in)
Pitch = 1.25 mm (0.0492 in)
A9-163
Fig. 26
17
II!I Transmission/ MAINTENANCE INTERVAL

[Number of months or km lmiles), whichever occurs first]
_ Differential (Front and Months 7.5 15 22,5 30 37.5 45 52.5 60
rear) Lubricants x 1,000 km 12 24 36 48 60 72 84 96
(Gear oil) x 1,000 miles 7.5 15 22,5 30 37.5 45 52,5 60
D
REAR 01 FFE.RENTIAL (4WO Vehicle)
INSPECTION
Remove plug of filler hole and check the oil level. Oil level
should be maintained fully to the filler hole.
MANUAL TRANSMISSION
If the oil level is below the mouth of filler hole, add some oil
Inspect the transmission gear oil level. If the oil level is at the up to the mouth.
lower point or below, add some oil through the oil level gauge
hole up to the upper point of gauge.
FWD Non-TURBO
4WD/FWD
TURBO
u.. Upper u..

-level
-lower
level
0
...J
~L1-448
Fig. 29
L 1-446
Fig. 27
Recommended oil
FRONT 01 FFERENTIAL
SAE VilCo.it~ No. end Applicabla Temptrature
(Automatic Transmission) ITEM
API
Classification {OFI -30 30
0 60 90
Oil ,level should be maintained between two points on the level

. {OCI -34 -18 0 16 32
3
. I
Tranlmisslon and 90
gauge. If the oil level is at lower point or below, add some oil differential gaar oil GL,5 I B&W
up to upper point. 4WD raar differential

gear oil < BOW
I
<: 75W,eo. 'sow,eo
>
a. Each oil manufacturer has its base oil and additives. Thus,
do not mix two or more brands.
b. * For differential gear oil (AT)
""
N
,..;
LL
- Upper
level
-lower
level
L1-556
Fig. 28
18
1'-1 Automatic MAINTENANCE INTERVAL

[Number of months or km (miles), whichever occurs first)
. . : . Transmission Fluid Months 7.5 15 22.5 30 37.5 45 52.5 60
x 1,000 km 12 24 36 48 60 72 84 96
x 1,000 miles 7.5 15 22.5 30 37.5 45 52.5 60
FWD vehicle
0
4WD vehicle
m m
INSPECTION
1) Drive vehicle several km (miles) to bring automatic trans-
REPLACEMENT
mission fluid (ATF) up to normal operating temperature.
Normal operating temperature is 60 to 80°C (140 to 176°F). 1) Drain fluid by removing drain plug after allowing the
2) Park vehicle on a level surface. engine to cool for 3 to 4 hours.
3) After selecting all positions (P, R, N, D, 2, 1), place
selector lever in lip" position and run engine on at idling
speed.
4) Remove level gauge and wipe it clean.
5) Reinsert the level gauge all the way.
6) Remove it again and note reading. If the fluid level is
below the center between high and low marks, add recom-
mended ATF until the fluid level is within the specified range
(above the center between high and low marks). When trans-
mission is hot, the level should be above the center of upper
and lower marks, and when it is cold, the level should be
below the center of these two marks.
ATF level gauge hole also serves as fluid filler.
Do not fill the fluid above upper point of level gauge. Fig. 31
2) Reinstall drain plug after draining fluid, and tighten it to

the specified torque.
Tightening torque:
25 N'm (2.5 kg-m, 18 ft-Ib)
High mark
a. Be sure to place a gasket between oil pan and drain plug.
b. Replace the gasket with new one.
Low mark
3) Fill ATF through the fluid level gauge hole.
Oil capacity:
L 1-557 1800 cc 9.3 Q (9.8 US qt, 8.2 Imp qt)
Fig. 30 2700 cc FWD 9.3Q (9.8 US qt, 8.2 Imp qt)
4WD 9.5Q (10.0 US qt, 8.4 Imp qt)
4) Run the vehicle until the ATF temperature rises to 60 to

Recommended automatic transmission fluid (ATF Dexron II) aooe (140 to 176°F) and then check the ATF level.
19
m
Brake Fluid [Number of months or km (milesl, whichever occurs first]
Months 7.5 15 22.5 30 37.5 45 52.5 60
x 1,000 km 12 24 36 48 60 72 84 96
x 1,000 miles 7.5 15 22.5 30 37.5 45 52.5 60
m m
a. Avoid mixing different brands of brake fluid to prevent
REPLACEMENT degrading the quality of the fluid.
b. Be careful not to allow dirt or dust to get into the reservoir
1) Either jack up the front end of vehicle and place a safety tank.
stand under it, or drive vehicle onto the pit and then jack up c. Use fresh DOTJ or 4 brake fluid when replacing or refilling
the front end. the fluid.
2) Remove both left and right front wheels. d. Always check to be sure a small amount of brake fluid is
3) Remove filler cap from brake fluid tank. in the tank while changing brake fluid.
Install one end of a vinyl tube onto the air bleeder of front e. The amount of brake fluid required is approximately
brake and insert the other end of the tube into a container to 270 mQ (9.1 US fl OZ, 9.5 Imp fl oz) for total brake system.
collect the brake fluid. f. Bleed air according to illustrated sequence.
To drain fluid into container, open the air bleeder and
repeatedly depress and release the brake pedal until a small Bleeding sequence CD . . . ® . . . ® -+ @
amount of fluid remains in the reservoir tank. Front right Rear right
Then tighten the bleeder screw.
® ®
Primary
Front left Rear left

A17-150
Fig. 33
5) Instruct your co-worker to depress the brake pedal slowly

Fig. 32 two or three times and then hold it depressed.
6) Loosen bleeder screw approximately 1/4 turn until a small
amount of brake fluid drains into container, and then quickly
a. The brake piping consists of a dual system, cross design. tighten screw.
The piping on the primary side connects the right front brake 7) Repeat steps 5) and 6) above until there are no air bubbles
and the rear left brake and the piping on the secondary side in drained brake fluid and new fluid flows through vinyl tube.
connects the left front brake and rear right brake.
b. For convenience and safety, it is advisable to have two men Add brake fluid as necessary while performing the air bleed
working. operation, in order to prevent the tank from running short of
c. Be careful not to spill brake fluid onto the painted surface. brake fluid.
d. Discard the drained brake fluid and do not reuse it.
8) After completing the bleeding operation, hold brake pedal
4) Refill reservoir tank with recommended brake fluid. depressed and tighten screw and install bleeder cap.
Recommended brake fluid: Tightening torque (Bleeder screw):

FMVSS No. 116, fresh DOT3 or 4 brake fluid 7 - 9 N·m (0.7 - 0.9 kg-m, 5.1 - 6.5 ft-Ib)
20
9) Bleed air from each wheel cylinder using the same pro- 10) Depress brake pedal with a force of approximately 294 N
cedures as described in steps 5) through 8) above. (30 kg, 66 Ib) and hold it there for approximately 20 seconds.
At this time check pedal to see if it shows any unusual move-
ment.
Visually inspect bleeder screws and brake pipe joints to make
sure that there is no fluid leakage.
11) Install wheels, and drive car for a short distance between
2 to 3 km (1 to 2 miles) to make sure that brakes are operating
properly.
Fig. 34
21
I!II Disc Brake Pad and MAINTENANCE INTERVAL
a.I Disc/Front and Rear [Number of months or km (miles), whichever occurs first]
Months 7.5 15 22.5 30 37.5 45 52.5 60

Axle Boots x 1,000 km 12 24 36 48 60 72 84 96
x 1,000 miles 7.5 15 22.5 30 37.5 45 52.5 60
D D D D
(
~
INSPECTION I REAR I .
<
t
[A] Disc Brake Pad and Disc (Front and Rear)

1) Jack up vehicle and support with rigid racks. Then remove
wheels.
2) Visually check pad thickness through inspection hole of
disc brake assembly. Replace pad if necessary.
IFRONT I /'
Inspection hole
~. L1-559
Fig. 37
Pad thickness including back metal mm (in)
Front Rear
Except XT6 18(0.71)

Standard 15 (0.59)
XT6 22 (0.87)
Fig. 35
Except XT6 6.5 (0.256)
Wear limit 7.5 (0.295)
Back metal XT6 8 (0.31)
Lining Wear limit Except XT6 1.5 (0.059)

(excluding 1.5 (0.059)
back metal) XT6 3 (0.12)
a. When replacing a pad, always replace the pads for both the
left and right wheels at the same time. Also replace pad clips
if they are twisted or worn.
b. The clip incorporated with pad is also used as a warning
device for worn pads. When wear occurs on the pad to such an
Thickness of pad L 1-171 extent that the clip comes into contact with the rotor, unusual
Fig. 36 noise (squeak) is produced. If such a noise is noticed, replace
the pads.
22
PERIODIC MAINTENANCE SERVICES
3) Disc rotor [B] Front and Rear Axle Boots
Check for wear and damage, and correct or replace if ab-
Inspect front and rear axle boots for deformation, damage or
normal.
failure. If faulty, replace them with new ones.
Brake disc thickness mm (in)
Front Rear
Except XT6 18 (0.71)

Standard 10 (0.39)
XT6 22 (0.87)
Except XT6 16 (0.63)

Wear limit 8.5 (0.33)
XT6 20 (0.79)
-
Th ickness of disc
r Fig. 40
-~. Ll-l72
Fig. 38
L1483
Disc rotor runout:
Limit: 0.10 mm (0.0039 in) Fig. 41
Measure the disc rotor runout at a point less than 5 mm (0.20

in) from the outer periphery of the rotor.
Ll-560
Fig. 39
23
III Brake Lining and Drum

Months
7.5 15 22.5 30 37.5 45 52.5 60
x 1,000 km 12 24 36 48 60 72 84 96
x 1 ,O~~ mil es 7.5 15 22.5 30 37.5 45 52.5 60
D D
2) Check brake drum for wear, dents or other damage.
INSPECTION If the inside surface of brake drum is streaked, correct the
surface with emery cloth (#200 or more). If it is unevenly
Inspect brake linings and drums of both sides of the rear brake worn, taperingly streaked, or the outside surface of brake
at the same time by removing brake drums. drum is damaged, correct or replace it.
1) Inspect brake shoes for damage or deformities and check
brake linings for wear. Brake drum inside diameter:
Standard:
Always replace both leading and trailing brake shoes for the 180 mm (7.09 in)
left and right wheels at the same time. Wear limit:
182 mm (7.17 in)
Brake lining thickness excluding back metal:
Standard:
4.5 mm (0.177 in)
Wear limit:
1.5 mm (0.059 in)
Thickness of
brake lining
(Exclude
back metal)
Measuring inside diameter
Ll-054
Fig. 43
3) If the deformation or wear of back plate, shoe, etc. are

Ll-053
notable, replace them.
Fig. 42 4) When the shoe return spring tension is excessively
weakened, replace it, taking care to identify upper and lower
springs.
5) If grease has leaked from brake drum, replace oil seal or
drum.
6) If drum bearing is abnormal or loose, replace it.
24
Inspect Brake Line and

II
~ Check Operation of Months 7.5 15 22.5 30 37.5 45 52.5 60
Parking and Service x 1,000 km 12 24 36 48 60 72 84 96
Brake System x 1,000 miles 7.5 15 22.5 30 37.5 45 52.5 60
Ii1 Ii1 m m
INSPECTION CHECKING
BRAKE LINE [A] Service Brake

1) Check scratches, swelling and/or traces of fluid leakage on 1) Check the free play of brake pedal by lightly depressing
brake hoses or pipe joints. the pedal with your finger with a force of less than 10 N (1 kg,
2Ib).
Brake pedal free play:

0.5 - 2.5 mm (0.020 - 0.098 in)
If the free play is out of specifications above, adjust the brake

pedal as follows:

booster. )
(2) There should be play between brake booster clevis
(Depress brake pedal pad with a force of less than 10 N
[1 kg 2 Ib] to a stroke of 0.5 to 2.5 mm [0.020 to 0.098
Fig. 44
inl.
Clevis pin
Clevis
Play at pin -----<...rio.-+----
'-- Pedal play

L 1·056
0.5 - 2.5 mm
Fig. 45 (0.020 - 0.098 in)
2) Check the possibility of adjacent parts interfering with

brake pipes/hoses during driving, and loose connections/
clamps.
3) Check any trace of fluid leakage, scratches, etc. on master
L4-928
cylinder, wheel cylinder, pressure control valve and hill-holder.
Fig. 46
When the brake fluid level in the reservoir tank is lower than
the specified limit, the brake fluid warning light on the instru-
ment panel will come on. (3) Depress the surface of brake pad by hand.
25
(4) If there is no free play between clevis pin and clevis, 4) Check to see if air is in the hydraulic brake line by the
loosen lock nut for operating rod and adjust operating feel of the pedal operation. If air appears to exist in the line,
rod by turning in the direction that shortens it. bleed it from the system.
5) Check for even operation of all brakes, using a brake
a. Make sure that the stop lamp operates normally. tester or by driving the vehicle for a short distance on a
b. After adjustment, make sure there is no brake dragging. straight road.
2) Adjust lining clearances of rear drum brake as follows.

[FWD only]
[B] Parking Brake
(1) Jack up vehicle to release tires and wheels slightly
from the ground. 1) After confirming the proper operation of brake pedal,
(2) Tighten adjusting screw on back side of rear brake pull parking brake lever with a force of approximately 245 N
drum fully until tire and wheel ceases to rotate. (25 kg, 55 Ib) to make sure lever still has a short length of
(3) Turn back adjusting screw by 180 and lining
0 stroke to go.
clearance will be 0.1 to 0.15 mm (0.004 to 0.0059 in).
(4) Be sure to rotate tire and wheel I ightly by hand. Parking brake lever stroke:
(5) Adjust lining clearance of another side rear brake Standard:
with the same manner. 3 - 4 notches/245 N (25 kg, 55 Ib)
Torque (Adjuster lock nut):
4.4 - 7.4 N·m (0.45 - 0.75 kg·m, 3.3 - 5.4 ft·lbl
2) If the parking brake lever pull is not within the above

specifications, adjust it as follows:
(1) Pull parking brake lever forcibly three to five times.
(2) Loosen the lock nut and change the setting of
adjuster until the play at point A is ato 0.5 mm (0 to
0.020 in).
Fig. 47
3) Measure the distance between brake pedal and floor when

the pedal is depressed with a force of approximately 294 N
(30 kg, 66 Ib).
Brake pedal reserve distance:

More than 120 mm (4.72 in)/294 N (30 kg, 66 Ib)
Fig. 49
(3) Make sure that vehicle stops on uphill road properly

Toe
board
by operating parking lever.
Pedal play
0.5 - 2.5 [C] Brake Servo System
(0.020 - 0.098)
1) With the engine off, depress the brake pedal several times
applying the same pedal force: Make sure the travel distance
should not change.
2) With the brake pedal depressed, start the engine: Make
sure the pedal should move slightly toward the floor.
Unit: mm (in) 211 (8.31) 3) With the brake pedal depressed, stop the engine and keep
L4-934
the pedal depressed for 30 seconds: Make sure the pedal height
Fig. 48 should not change.
26
4) Check valve is built into vacuum hose. Disconnect vacuum 5) Check vacuum hose for cracks or other damage.
hose to inspect fu ncti on of check va Ive.
Blow air into vacuum hose from its brake booster side end: When installing the vacuum hose on the engine and brake
Air must flow out of engine side end of hose. Next blow air booster, do not use soapy water or lubricating oil on their
into hose from engine side: Air should not flow out of hose. connections.
Replace both check valve and vacuum hose if check valve is
faulty. Engine side of vacuum hose is indicated by marking 6) Check vacuum hose to make sure it is tight and secure.
II<ENGINEI " as shown.
Brake
booster
Engine side side
• ~'.L.---------L-~---1-'NI ~~ •
L1-562
Fig. 50
27
I'-! Clutch and Hill-holder MAINTENANCE INTERVAL

~System Months 7.5 15 22.5 30 37.5 45 52.5 60
x 1,000 km 12 24 36 48 60 72 84 96
x 1,000 miles 7.5 H) 22.5 30 37.5 45 52.5 60
D D D D
INSPECTION AND ADJUSTMENT Tightening torque (Adjusting nut on release fork):

5.4 - 9.3 N'm (0.55 - 0.95 kg-m, 4.0 - 6.9 ft-Ib)
1) Inspect free play of clutch pedal by operating pedal by
hand. a. When replacing clutch cable vvith new one and/or making
If it is out of the specified value, adjust it by turning adjusting free play adjustment of clutch pedal, make adjustment of
nut on engine side end of clutch cable at release fork. hill-holder system without fail as follows.
b. After replacing clutch cable and/or pressure hold valve
Standard of free play: (PHV) cable with new one, depress clutch pedal about thirty
A t clutch pedal: (30) times as a running-in operation prior to this adjustment.
10 - 20 mm (0.51 - 0.79 in)
At center of cable on clutch release fork: 2) Confirm stopping and starting performance by activating
hill-holder on an uphill road of 3° or higher inclination.
FWD: 2 - 3 mm (0.08 - 0.12 in)
(1) If vehicle does not stop;
4WD: 3 - 4 mm (0.12 - 0.16 in)
Tighten adjusting nut of PHV cable.
Pedal play:
10 - 20 mm (0.39 - 0.79 in) Ll·060
Fig. 51 Fig. 53
Free play
(2) If vehicle does not start properly;

• Case A - When hill-holder is released later than engage-
ment of clutch (engine tends to stall):
Loosen adjusting nut gradually until smooth starting
is enabled.
• Case B - When hill-holder is released earlier than
engagement of clutch (vehicle slips down slightly):
Tighten adjusting nut so that hill-holder is released
later than engagement of clutch (status in Case A).
1 Lock nut
Then make adjustment the same as in Case A.
2 Adjusting nut
3 Release fork A20-051
a. Whenever turning adjusting nut, prevent PHV cable from
Fig. 52 revolving as following illustration.
28
b. Replace pressure hold valve (PHV), return spring of PHV

or PHV cable with new one, if they are defective and/or
damaged.
L'-470
Fig. 54
29
IIP!I Steering and MAINTENANCE INTERVAL

[Nu mber of months or km (miles), whichever occurs first 1
. . . Suspension Months 7.5 15 22.5 30 37.5 45 52.5 60
x 1,000 km 12 24 36 48 60 72 84 96
x 1,000 miles 7.5 15 22.5 30 37.5 45 52.5 60
D D 0 D
(3) Wheel runout ........ ..
INSPECTION Steering wheel should not show any sign of runout.
(4) Return factor ......... .
STEERING WHEEL Steering wheel should return to its original position after
1) Set steering wheel in a straight-ahead position, and check it has been turned and then released.
wheel spokes to make sure they are correctly set in their
specified positions. STEERING SHAFT JOINT
2) Lightly turn steering wheel to the left and right to deter- 1) Disconnect universal joint of steering shaft and check it
mine the point where front wheels start to move. for any play and yawing torque (at the point of the crossing
Measure the distance of the movement of steering wheel at the direction). Also inspect for any damage to sealing or worn
outer periphery of wheel. serrations.
Steering wheel free play:

o - 17 mm (0 - 0.67 in)
Fig. 56
L1473
Fig. 55
If the joint is loose, retighten the mounting bolts to the
specified torque.
3) Move steering wheel vertically toward the shaft to ascertain
if there is play in that direction. Tightening torque:
21 - 26 N·m (2.1 - 2.7 kg-m, 15 - 20 ft-Ib)
Maximum permissible play:
0.5 mm (0.020 in)
GEARBOX
4) Drive vehicle and check the following items during
1) With wheels placed on a level surface, turn steering wheel
operation. 0
90 in both the left and right directions.
(1) Steering force ..........
While wheel is being rotated, reach under vehicle and check for
The effort required for steering should be smooth and
looseness in gearbox.
even at all points, and should not vary.
(2) Pull to one side ........ ..
Tightening torque:
Steering wheel should not be pulled to either side while
47 - 71 N·m (4.8 - 7.2 kg-m, 35 - 52 ft-Ib)
driving on a level surface.
30
~
~ ~"g\=='=bd:=~~
~.nrnl' r\~/n n
Fig. 57 Fig. 59
2) Check boot for damage, cracks or deterioration. (3) From that position, turn back adjusting screw 15°
and then tighten lock nut securely.
Tightening torque:
29 - 49 N·m (3.0 - 5.0 kg-m, 22 - 36 ft-Ib)
Hold the adjusting screw with a wrench to prevent it from

turning while tightening the lock nut.
TIE-ROD
1) Check tie-rod and tie-rod ends for bends, scratches or
other damage.
2) Check connections of knuckle ball joints for play, inspect
for damage on dust seals, and check the free play of ball studs.
3) Make sure that the cotter pin is installed correctly in the
Fig. 58 castle nut of the tie-rod end.
3) With vehicle on a level surface, quickly turn steering wheel

to the left and right.
While steering wheel is being rotated, check the gear backlash.
If any unusual noise is noticed, adjust the gear backlash as
follows:
(1) Loosen gearbox mounting clamps, and slightly lower
gear box.
(2) Loosen lock nut by using Spanner (Special tool) and
tighten adjusting screw fully.
Tool No. Tool name

Fig. 60·
Manual SPANNER
925640000
steering (STEERING GEAR BOX)
Power SPANNER
926230000
steering (STEERING GEAR BOX)
POWER STEERING FLUID LEVEL
1) Place vehicle with engine "off" on the flat and level
SPANNER (926230000) can be also used for manual steering. surface.
31
2) Check the fluid level by removing filler cap of oil pump. • Except XT6
(1) Check at temperature 21°C (70°F) of fluid temper-
ature. Recommended fluid Manufacturer
B.P.
CAlTEX
CASTROl
ATF Dexron II
MOBil
SHEll
TEXACO
A3-285
Fig. 61
• XT6
Recommended fluid
(2) Check at temperature 60°C (140°F) of fluid temper- SPECIAL POWER STEERING FLUID
ature. IDEMITSU
[Parts No. K0209A0080]
Fluid capacity:
0.7£ (1.5 US pt, 1.2 Imp pt)
POWER STEERING FLUID FOR LEAKS

Inspect the underside of oil pump and gearbox for power
steering system, hoses, piping and their couplings for fluid
leaks.
A3-286
If fluid leaks are found, correct them by retightening their
Fig. 62 fitting bolts (or nuts) and/or replacing their parts.
a. Wipe the leakage fluid off after correcting fluid leaks, or a

wrong diagnosis is taken later.
b. Also pay attention to clearances between hoses (or pipings)
3) Fluid level should be maintained in the each specified and other parts when inspecting fluid leaks.
range on the indicator of filler cap.
If fluid level is at lower point or below, add fluid to keep the
level in the specified range of i nd icator.
If fluid level is at upper point or above, drain fluid to keep the
level in the specified range of indicator by using a syri.nge or
the like.
32
HOSES OF OIL PUMP FOR DAMAGES 1) A, 8 and C position of gearbox boot are fitted corre-
spondingly in A, 8 and C grooves of gearbox and the rod.
2) Clips are fitted outside of A, 8 and C positions of boot.
3) Projection of boot is fitted in hole on A groove of gearbox
to prevent boot rotating.
4) 800t does not have crack, hole.
Rotate Band C position of gearbox boot against twist of it

produced by adjustment of toe-in, etc.
In this case, never rotate A position of gearbox boot.
GEARBOX BOOTS (XT6)

Inspect both sides of gear box boots as follows, and correct
the defects if necessary.
Fig. 63
1 Clip (Small)
2 Clip (Large)
3 Boot L1-565
Fig. 64 Fig. 66
Check pressure hose and return hose of oil pump for crack,
swell or damage. Replace hose with new one if necessary.
1) A and B positions of gearbox boot are fitted correctly in
Prevent hoses from revolving and/or turning when installing A and 8 grooves of gearbox and rod.
hoses. 2) Clips are fitted outside of A and 8 positions of boot.
3) 800t does not have cracks or holes.
GEARBOX BOOTS (Except XT6)
Repair boot if twisted while adjusting toe-in.
Inspect both sides of gearbox boots as follows, and correct
the defects if necessary.
/
CD @
1 Clip (Small)
2 Clip (Middle)
3 Clip (Large)
4 Boot L 1-174
Fig_ 65
33
FITTING BOLTS AND NUTS (Except XT6) FITTING BOLTS AND NUTS (XT6)
Inspect fitting bolts and nuts of oil pump and bracket for Inspect fitting bolts and nuts of oil pump and bracket for
looseness, and retighten them if necessary. looseness, and retighten them if necessary.
Inspect and/or retighten them when engine is cold.
1 Cap
2 Strai ner
CD--q
3
4
5
6
Oil tank
a-ring
Pipe
Oil pump
®-, \
\
7 Bracket \
8 Pulley
@
Fig. 68
-..!---=-----@
Tightening torque:
Bolt A (four):
23 - 42 N·m (2.3 - 4.3 kg-m, 17 - 31 ft-Ib)
Bolt B:
23 - 37 N·m (2.3 - 3.S kg-m, 17 - 27 ft-Ib)
Nut C:
4.4 -7.4 N'm (0.45 - 0.75 kg-m, 3.3 - 5.4 ft-Ib)
Bolt D:
9.5 - 12.3 N·m (0.97 - 1.25 kg-m, 7.0 - 9.0 ft-Ib)
L 1-175
Bolt E (one):
Fig. 67 3.9 - 5.1 N·m (0.40 - 0.52 kg·m, 2.9 - 3.S ft·lb)
Tightening torque:
Nut A (one):
42 - 62 N·m (4.3 - 6:3 kg-m, 31 - 46 ft-Ib)
Bolt B (two): SUSPENSION SYSTEM
20 - 29 N·m (2.0 - 3.0 kg-m, 14 - 22 ft-Ib)
Bolt C (three): Care should be taken not to apply paint, undercoating agent,
18 - 22 N·m (1.8 - 2.2 kg-m, 13 - 16 ft-Ib) anti·corrosive wax, etc. to the following parts of air·suspension
Bolt D (three): equipped models while refinishing the undercarriage.
29 - 49 N·m (3.0 - 5.0 kg-m, 22 - 36 ft-Ib) (1) Diaphragm and rolling surfaces
(2) Air suspension compressor and dryer assembly
34
1) Play of front ball joint ...... Inspect every 24,000 km (2) When looseness is less than standard value, wipe off
(15,000 miles) or 15 months, whichever occurs first. old grease, apply the proper amount [about 3 g (0.11 oz))
(1) Jack up vehicle until front wheels are off ground of designated grease (SUNLIGHT 2, PIN 003602010),
as instructed in "Pre-Delivery Inspection." and install a new dust seal.
(2) Next, grasp bottom of tire and move it in and out.
If relative movement is observed between brake disc cover When transverse link ball joint has been removed or replaced,
and end of transverse link, ball joint may be excessively check toe-in (or side slip) of front wheel.
worn. If front wheel toe-in (or side slip) is not at specified value,
adjust according to chapter 4·1 so that toe-in conforms to
service standard.
3) Wheel alignment and ground clearance ...... Inspect

every 48,000 km (30,000 miles) or 30 months, whichever
occurs first.
(1) Unload cargoes and set vehicle in curb weight
(empty) condition.
(2) Then, check ground clearance of front and rear
suspensions to ensure that they are within specified
values.
Relative movement
(Adjusting procedure)
Ll-234
When ground clearance is out of standard, visually inspect
Fig. 69 following components and replace deformed parts .
• Suspensions components [Front: strut assembly, cross-
(3) Next, grasp end of transverse link and move it up and
member, transverse link, etc. Rear: shock absorber,
down. Relative movement between housing and transverse
inner arm, outer arm, etc.]
link boss indicates ball joint may be excessively worn.
• Body parts to which suspensions are installed.
When no components are deformed, adjust ground
clearance by replacing coil spring in the suspension whose
ground clearance is out of standard.
(3) Check alignment of front suspension to ensure that

following items conform to standard values provided in
chapters 4-1 and 4-3.
• Toe-in (or side slip)
J
-----71.,L:;;-I-fR=~± Relative movement • Camber angle
• Caster angle
Transverse link • Turning angle of tire
Ball joint
L1-235 (Adjusting procedure)
L..F-ig-.-~-O--------------------~ (a) Camber and caster angles are not adjustable. When
camber or caster angle does not conform to standard
value, visually inspect following components and 'replace
(4) If relative movement is observed in tests (2) and (3) deformed parts.
above, remove and inspect ball joint according to chapter • Suspension components [Strut assembly, crossmember,
4-1. If looseness exceeds standard, replace ball joint. transverse link, etc.]
• Body parts to which suspensions are installed.
2) Damage of dust seal ...... Inspect every 24,000 km (b) When toe-in (or side slip) is out of standard value,
(15,000 miles) or 15 months, whichever occurs first.
adjust by the method described in chapter 4-1 so that it
Visually inspect ball joint dust seal. If it is damaged, remove conforms to service standard.
ball joint as instructed in chapter 4-1 and measure looseness of (c) When right-and-Ieft turning angles of tire are out of
ball joint. standard, adjust to standard value by method described in
(1) When looseness exceeds standard value, replace ball chapter 4-3.
joint.
35
(4) Check alignment of rear suspension to ensure that (d) Adjust toe within service standard by repeating
following items are within standard values. steps in 2) and 3) above for for both right and left wheels.
• Toe-in (or side slip)
• Camber angle Camber angle
(a) Jack up rear of vehicle as shown in "Pre·Delivery
(Adjusting procedure) Inspection," and remove wheel whose camber angle is out
When toe (or side slip) or camber angle does not con- of standard.
form to standard value, visually inspect parts listed below. (b) Remove bolt linking lower end of shock absorber to
If deformation is observed, replace damaged parts. inner arm.
• Suspension components [Shock absorber, inner arm, (c) Then, loosen outer arm mounting bolts shown in
outer arm, crossmember, etc.] Fig.5.
• Body parts to which suspensions are installed. (d) If camber angle is excessive in ffi direction, use a
When no components are deformed, adjust alignment as piece of wood as a lever and change relative angle between
instructed below so that it conforms to service standard. inner arm and outer arm so that angle e formed by inner
arm and outer arm centerlines (Fig. 73) increases. Then,
Toe tighten outer arm mounting bolts.
(a) Jack up rear of vehicle as shown in "Pre-Delivery
Inspection," and remove rear wheels.
(b) Loosen outer arm mounting bolts. \cente, I;ne of inn., "m
Crossmember
Inner arm ASSY ©
--Center. line of outer arm
L 1-489
Fig. 73
L 1-487
Fig. 71
(e) If camber angle is excessive in 8 direction, use a
piece of wood as a lever and change relative angle between
(c) When toe-in (or side slip) is excessive, tighten outer
inner and outer arms so that angle 8 formed by inner arm
arm mounting bolts shown in Fig. 71 while pulling end of
and outer arm centerlines decreases. Then, tighten outer
spindle towards rear of vehicle (in direction of arrow in
arm mounting bolts.
Fig. 72). When toe-out (or side slip) is excessive, tighten
(f) Adjust camber angle to conform to service standard
outer arm mounting bolts while pushing end of spindle
by repeating steps 4) and 5) above.
toward front of vehicle (in opposite direction of arrow in
Fig. 72).
a. Adjusting toe (or side slip) results in a change in camber
angle, while adjusting camber angle causes a change of toe
(or side slip). Therefore, when either is adjusted, always check
Inner arm ASSY that the other remains within service standard.
b. After both toe (or side slip) and camber angle have been
adjusted within service standard, be sure to tighten bolts to
torque specified in chapter 4·1.,
4) Oil leakage of shock absorber ...... Inspect every 48,000

km (30,000 miles) or 30 months, whichever occurs first.
Remove tire and visually inspect shock absorber for oil leakage
Outer arm ASSY
as instructed in chapter 4-1. Replace shock absorber if oil leaks
excessively.
1.......-_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ L_1_-4_8_8-1 5) Tightness of bolts and nuts ....... Inspect every 48,000
Fig. 72 km (30,000 miles) or 30 months, whichever occurs first.
36
Check bolts shown in Figs. 74, 75 and 76 for looseness.
Retighten bolts to specified torque. Further, check that cotter Tightening torque N·m (kg-m, ft-Ib):
pin is in place as shown in Figs. 74 and 75. If not, install a new Tl: 38 - 50 (3.9 - 5.1,28 - 37) (Except XT6)
cotter pin. 64 - 83 (6.5 - 8.5, 47 - 61) (XT6)
T2: 88 - 103 (9.0 - 10.5,65 - 76)
T3: 118 - 147 (12.0 - 15.0,87 - 108)
T4: 74 - 88 (7.5 - 9.0, 54 - 65)
6) Dirt on and damage to rolling diaphragm ...... Inspect

every 24,000 km (15,000 miles) or 15 months, whichever
occurs first.
(1) After loosening wheel nuts, jack up vehicle until all
four wheels are off ground according to instructions in
"Pre-Delivery Inspection." Remove tires.
(2) Visually inspect rolling diaphragm. If dirty, remove
dirt from diaphragm. Be careful not to damage dia-
Cotter pin phragms.
L1-239
(3) Visually inspect rolling diaphragm. Replace dia-
Fig. 74 Front suspension (Except XT6) phragm if damaged. However, replacement is not required
if only fine scratches on diaphragm surface caused by
sand. These do not present a problem.
(4) Visually inspect rolling diaphragm for rust. If rusty,
remove rust and touch up.
When touching up diaphragm, be careful paint does not adhere

to diaphragm. (LoMr jack after touch-up paint has dried
completely. )
Fig. 75 Front suspension (XT6)
L1-240
Fig. 76 Rear suspension
37
Grease on Front and MAINTENANCE INTERVAL

[Number of months or km (miles!. whichever occurs first]
Rear Wheel Bearings Months 7.5 15 22.5 30 37.5 45 52.5 60
x 1,000 km 12 24 36 48 60 72 84 96
x 1,000 miles 7.5 15 22.5 30 37.5 45 52.5 60
[[I]
FRONT WHEEL BEARING (XT6)

INSPECTION
1) Jack up the front of vehicle.
2) While holding front wheel by hand, swing it in and out to
Inspect the condition of front and rear wheel bearing grease as
check bearing free play.
1
follows:
3) Loosen wheel nuts and remove front wheel.
4) If bearing free play exists in step 2) above, attach a dial
FRONT WHEEL BEARING (Except XT6)
gauge to hub and measure axial displacement in axial direc-
1) Raise front wheel with a jack, and remove wheel. Remove tion.
cotter pin from axle shaft and remove castle nut.
2) Remove hub & disc ASSY.
3) Remove oil seal from housing, and check the condition of
Service limit:
Straight-ahead position within 0.05 mm (0.0020 in)
I
bearing grease.
5) Remove bolts and self-locking nuts, and extract transverse
a. If either the grease appears to be white or if only a small link from front crossmember.
amount of grease remains, remove the bearing from the 6) While lightly hammering spring pin which secures D.O.J.
housing, clean it, and pack it with grease. to transmission spindle, remove it.
b. Discard the old seal and install a new one. 7) Extract D.O.J. from transmission spindle.
8) While supporting front drive shaft horizontally with one
hand, turn hub with the other to check for noise or binding.
If hub is noisy or binds, disassemble front axle and check
condition of oil seals, bearings, etc.
REAR WHEEL BEARING

[Except 4WD vehicle)
1) Apply parking brake, and loosen rear wheel nuts.
2) Jack up vehicle, support it with safety stands (rigid racks)
and remove rear tires and wheels.
3) Pry brake drum cap by screwdriver off drum.
L 1-177 4) Flatten lock washer and loosen axle nut, then remove lock
washer, lock plate and brake drum so as not to drop inner race
Fig. 77
of outer taper roller bearing.
Outer bearing, outer race of inner bearing and oil seal can be
4) Installation is in the reverse order of removal.
removed together with drum.
5) Check condition of bearing grease.
Tightening torque (Castle nut):
196 N·m (20 kg-m, 145 ft-Ib)
a. If either the grease appears to be white or if only a small
After tightening the castle nut to the specified torque, tighten amount of grease remains, remove the bearing hom the
additionally in one sixth (1/6) turn until both holes of bolt housing, clean it, and pack it with grease.
and castle nut align each other. b. Discard the old seal and install a new one.
Tightening torque (Hub to disc rotor bolts):

44 - 58 N·m (4.5 - 5.9 kg-m, 33 - 43 ft-Ib)
38
Tool No. Tool name

Outer bearin g \
925550000 HOUSING NUT WRENCH
15) Extract spindle inwardly by tapping it from outside with

a plastic hammer.
16) Remove oil seal.
17) Check condition of bearing grease.
Inner bearing
a. If either the grease appears to be white or if only a small
,
(
amount of grease remains, remove the bearing from the
'-
)
• Oil seal housing, clean it, and pack it with grease.
L1·176 b. Discard the old seal and install a new one.
Fig. 78
6) Apply approximately 4 g (0.14 oz) of grease to inner

bearing and 3 g (0.11 oz) to outer bearing.
Fill the hub of drum with approximately 30 g (1.060z) of
grease.
7) Install drum, inner race of outer bearing, lock plate, lock
washer and axle nut in this order onto the spindle. Inner oil seal
Be sure to use new lock plate and new lock washer without
fail.
L1-178
Fig. 79
REAR WHEEL BEARING 18) Apply grease of 20 to 30 g (0.71 to 1.06 oz) to bearing
[4WD vehicle] outer race in housing.
1) Apply parking brake. 19) Insert spindle from inside, and press inner race of outer
2) Remove rear wheel cap and cotter pin, and loosen castle bearing from outside by using a pipe of 35 mm (1.38 in) in
nut and wheel nuts. inner diameter while tapping it with a hammer.
3) Detach shock absorber from inner trailing arm.
4) Loosen locking bolts of crossmember outer bushing.
Apply grease sufficiently on the inner and outer bearing area.
5) Jack up vehicle, support it with safety stand (rigid racks)
20) Install ring nut to housing.
and remove rear tires and wheels.
6) Remove castle nut and brake drum.
Tightening torque:
7) Drive out spring pins of BJ and D.O.J. by using a steel
rod of 6 mm diameter. 172 - 221 N·m (17.5 - 22.5 kg·m, 127 - 163 ft·lb)
8) Remove BJ from spindle of trailing arm with trailing arm
lowered fully.
9) Remove rear exhaust pipe, muffler and exhaust cover in
that order.
10) Disconnect brake pipe from brake hose.
Fit air breather cap onto end of brake hose to prevent brake
fluid from pouring out.
11) Remove brake assembly from trailing arm.

12) Remove bolt holding inner bushing of inner trailing arm.
13) Remove three bolts, and take out inner arm.
14) Vise inner arm, and straighten staked portion of housing,
then remove ring nut by using HOUSING NUT WRENCH
(Special tool). Fig. 80
39
21) Lock the ring nut by staking a point on the housing

surface facing the ring nut groove.
Fig. 82
Fig. 81
Tightening torque (Back plate):

46 - 58 N·m (4.7 - 5.9 kg-m, 34 - 43 ft-Ib)
22) Install outer oil seal by using OIL SEAL INSTALLER
(Special tool).
Tool No. Tool name 26) Connect brake hose and brake pipe.
925530000 OIL SEAL INSTALLER
Be su re to renew the oil seal.
23) Install inner oil seal by using OIL SEAL INSTALLER

(Special tool).
24) Mount inner arm to vehicle body.
Tightening torque:
I nner bush bolt:
Fig. 83
74 - 93 N·m (7.5 - 9.5 kg-m, 54 - 69 ft-Ib)
I nner and outer arms connecting bolts:
118 - 147 N·m
(12.0 - 15.0 kg-m, 87 - 108 ft-Ib)
27) Temporarily fit brake drum, center piece, washer spring

and castle nut to spindle in this order.
25) Install rear brake assembly to inner arm, and connect
brake pipes etc.
a. Play on spindle is not a fault when mounting brake drum.
b. Don't confuse orientation of washer spring.
40
31) Drive spring pins into D.O.J.
a. Before driving in the spring pin, confirm alignment of the

holes.
b. Be sure to renew the spring pin to be driven in.
aint mark
Fig. 84
l
Nut side. • Center piece
side
Washer spring
1
2
3
4
Cotter pin
Castle nut
Washer spring
Center piece
A16·197
28) Bleed brake system. Fig. 86
a. Before bleeding brake system, check pedal play and brake

fluid level in reserve tank.
b. Bleed air from four wheels without fail.
29) Tighten castle nut, insert cotter pin and bend it firmly 32) Install wheels, outer arms, etc.
with foot brake applied to lock the wheel and axle. 33) Lower vehicle on the ground, and install lower end of
shock absorber.
Tightening torque:
196 N·m (20 kg-m, 145 ft-Ib)
After tightening castle nut to the specified torque tighten

further within 30° to align holes on nut and spindle.
30) Install packing to rear spindle, and mount D.O.J. or B.J.

on rear drive shaft onto spindle with trailing arm lowered all
the way.
When mounting, mate the spline teeth properly so that the

D.O.J. or B.J. and spindle spring pin hole will align.
Fig. 87
Tightening torque:
88 - 118 N·m (9 - 12 kg-m, 65 - 87 ft-Ib)
34) Check and adjust rear vehicle height and rear wheel align-
ment.
35) Tighten outer arm lock bolts.
For disc brake vehicle, inspect it in the same manner as drum

Fig. 85 brakes one.
41
SPECIAL TOOLS
Page
SUBARU ENGINE TOOLS 0 0 0 0 0 ••••• 0 •
MANUAL TRANSMISSION AND DIFFERENTIAL TOOLS ..........

• • • • • • • • • • • • • • • • • • • • • • • • • • • •• 2
4
AUTOMATIC TRANSMISSION AND DIFFERENTIAL TOOLS ...•... 9
1988 REAR WHEEL DRIVE SYSTEM (4WD MODELS) TOOLS ....•...•..

SUSPENSION TOOLS .. . . . . . • . . • . . . . . . . . . . . . . . . . . . . . . . . • ..
11
13
-
WHEELS AND AXLES TOOLS .............................. 14
STEERING SYSTEM TOOLS •..............•.•...••.....• 0 •• 16
BRAKES TOOLS .•..•..•..•...... 0 • • • • • • • • • • • • • • • • • • • • •• 19
AIR CONDITIONING SYSTEM TOOLS ..••••.................. 20
BODY TOOLS ........•..........•••..•...•............. 21
1-6 SPECIAL TOOLS
Engine Tools
398744300 398852100 399094310 399284300
PISTON GUIDE OIL SEAL INSTALLER PISTON PIN REMOVER ASSY PISTON PIN GUIDE
Used to install piston in cylinder. For press-fitting of intake and Used to remove piston pins by Used to install piston pin in piston
exhaust valve guide oil seals. inserting this tool through crank- and connecting rod.
case plug holes.
1800 cc model 1800 cc model
8 A5-155 ST-054 A5-143 A5-156
399762103 399762104 498027000 498037000
VALVE GUIDE REMOVER VALVE GUIDE REAMER CAMSHAFT HOLDER INSTALLER
For removing of valve guide. For reaming of valve guide. Used to hold camshaft when Used to install camshaft oil seal.
press-fitting distributor gear to
camshaft.
=---I~=
A5-147 A5-150 L1-093
498267100 498277000 498497000 499007000
CYLINDER HEAD TABLE FLYWHEEL STOPPER CP DRIVE PLATE STOPPER TENSIONER WRENCH
For replacing of valve guide. Used to stop rotation of flywheel Used to stop rotation of drive Used to hold up tensioner No.2
when loosening and tightening plate when loosening and when reducing timing belt tension.
crankshaft pulley bolt, etc. tightening crankshaft pulley bolt,
etc.
Manual transmission vehicle Automatic transmission vehicle 1800 cc model
Ll-094 L 1-095 Ll-096 L1-276
2
SPECIAL TOOLS 1-6
* 499017000 499037000 * 499097300 49920700
PISTON PIN GUIDE REMOVER & REPLACER CAMSHAFT SPROCKET

PISTON PIN REMOVER ASSY
WRENCH
Used.to install piston pin in piston Connecting rod bushing Used to remove pins by inserting Used to remove and install
and connecting rod. through crank-case plug holes. camshaft sprocket.
1800 cc model
A5-156 A5-389 A5-143 L1-187
499437000 * 499437100 499567000 * 499567100
BELT TENSION WRENCH CP BELT TENSION WRENCH CP INSTALLER INSTALLER
When installing timing belt, used When installing timing belt, used Used to install crankcase front oil Used to install crankcase front oil
to apply the specified torque to to apply the specified torque to seal. seal.
camshaft pulley so as to get the camshaft pulley so as to get the
specified belt tension. specified belt tension.
1800 cc model 2700 cc model 1800 cc model
L1-188 L1-188 Ll-100 L1-100
499587000 * 499817100 499987200 499990110
INSTALLER ENGINE STAND SOCKET WRENCH (17) SOCKET
Used to install cran kcase rear oil. Stand used for engine disassembly For retightening cylinder head. Oxygen (0 2 ) sensor.
and assembly. Two pieces are
needed. This tool can be made by
modifying the former one
(499817000). 1800 cc model
L1-102 L 1-103 Al0-133
* Newly adopted tool
3
1-6 SPECIAL TOOLS
899724100 899768603 * 13082AAOOO
VALVE SPRING PRESS ASSY VALVE GUIDE ADJUSTER BELT ADJUSTER STOPPER
Used to remove and install valve Used to install intake and exhaust Used to compress belt tensioner
spring. valve guides. rubber boot (of adjuster COMPL)
for easy installation of belt.
2700 cc model
A5-149 A5-149 L 1-568
Manual Transmission and Differential Tools

398406200 398791600 398791700 399295120
STAND REMOVER II REMOVER II STAND SET
Rear drive shaft. Straight pin (Transfer shifter Spring pin (5-speed) Transmission main case.
fork).
4WD
'~,~
f"
~
-.-
'-,
ST-144
I A12-174
I A12-174
1
2
3
4
STANDCP(399935120)
BOl T(016510600) ... 10x60mm
BOlT(016510700) ... 10x70mm
BOlT(016510400) ... 10x40mm
ST-169
4
SPECIAL TOOLS 1-6
399411700 399513600 399520105 399527700
INSTALLER INSTALLER SEAT PULLER SET
Reverse shifter rail arm. Extension rear oil seal. Roller bearing (Differential). Roller bearing (Differential).
4WD FWD 4WD
\U f
~0
@ @
, BOL T(B995214121
2 PULLEFH3995277021
3 HOLDER (3995277031
4 ADAPTER (3984977011
5 BOL T (S995201 071
A12-170 A13-196 A12-171 6 NUT (02100S0001 A14-075
399780104 399790110 498057000 498067000
WEIGHT INSTALLER OIL SEAL INSTALLER TRANSFER RACE PRESS
Preload on roller bearing. Roller bearing, (Differential) Transfer case oil seal. Transfer race.
Axle shaft oil seal.
FWD 4WD 4WD
A12-172 A12-175 L1-105 L1·108
498077000 498147000 498247001 498247100
5TH DRIVE GEAR REMOVER DEPTH GAUGE MAGNET BASE DIAL GAUGE
5th driven gear. Main shaft axial end play Backlash between side gear and Backlash between side geer and
adjustment pinion, pinion,
Hypoid gear backlesh. Hypoid gear backlash.
4WD
L1-109 ST-146 ST-156 ST-157
5
1-6 SPECIAL TOOLS
498427000 498517000 498787000 498787100
STOPPER REPLACER STOPPER MAIN SHAFT STOPPER
For securing the drive pinion shaft Drive pinion thrust plate and Transmission main shaft. Transmission main shaft.
ASSY and driven gear ASSY when needle bearing race.
removing the drive pinion shaft
ASSY lock nut (18 x 13.5).
4WD FWD FWD 4WD
L1·388 ST-151 A12-173 L1·110
498937000 499277000 499277100 499277200
TRANSMISSION HOLDER INSTALLER BUSH 1-2 INSTALLER INSTALLER
Transmission main shaft lock nut. Drive pinion. 1st driven gear thrust plate. For press fitting the 2nd driven
1st-2nd driven gear bush. gear, roller bearings, & 5th driven
gear onto the driven shaft.
4WD FWD 4WD 4WD
A12·296 L1·113 L 1·391
499747000 499747100 499787000 499797000
GUIDE CLUTCH DISC GUIDE WRENCH ASSY OIL SEAL INSTALLER
Clutch disc. Clutch disc. Differential side retainer. Differential side retainer oil seal.
FWD 4WD 4WD
ST-170 L1-114 L1·117 L1·118
6
SPECIAL TOOLS 1-6
499827000 499857000 499877000 499917100
PRESS REMOVER ASSY RACE 4-5 INSTALLER GAUGE ASSY 2
Oil seal (Speedometer). To remove the driven gear ASSY Needle bearing 4th and 5th races. Drive pinion shim.
5th gear. Transmission main shaft rear ball
bearing.
4WD 4WD FWD
,---j_._'~~(J)
1 Plate
2 Scale
ST -14 7 L 1-569 L 1-119 A1 2-188

499917500 499927000 499927100 499987300
DRIVE PINION GAUGE ASSY HANDLE HANDLE SOCKET WRENCH (50)
Drive pinion shim adjustment. Transmission main shaft. Transmission main shaft. To remove the driven gear ASSY
lock nut.
4WD FWD 4WD 4WD
A12-189 L1-121
898938600 899474100 899524100 899580100
HOLDER EXPANDER PULLER SET INSTALLER
Transmission main shaft. Snap ring Roller bearing (Differential). Transmission main shaft
(Transmission main shaft). Drive pinion, Ball bearing
(Rear drive shaft).
FWD 4WD FWD
A12-176 A12-178 A5-142 A12-179
7
1-6 SPECIAL TOOLS
899714110 899754110 899754112 899858600
RETAINER PRESS ASSY PRESS RETAINER II
Transmission main shaft, Transmission main shaft, Clutch release bearing holder. Transmission main shaft,
Drive pinion, Rear drive shaft. Needle bearing (transfer easel. (Except 4WD) Drive pinion.
Rear drive shaft
4WD FWD FWD
~ o i- i-.,,,,
~
Gu;d.
~
Press
A12·181 A12·182 A11·025 A12·183
899864100 899874100 899884100 899904100
REMOVER INSTALLER HOLDER REMOVER
Transmission main shaft, Transmission main shaft, Drive pinion, Rear drive shaft, Straight pin (Differential)
Drive pinion. Drive pinion, Extension ASSY
Transfer drive gear bushing.
~ q ~
c-
A12·184 A 12·185 A12·186 A12·187
899988608
SOCKET WRENCH (27)
Transmission main shaft (FWD)

Rear drive shaft (4WD)
~
A12·191
8
SPECIAL TOOLS 1-6
Automatic Transmission and Differential Tools

398437700 398573600 398603610 398643600
DRIFT 01 L PRESSURE GAUGE ASSY SOCKET GAUGE
Front oil seal for converter case. Oil pressure. Brake band. Used to adjust drive pinion.
• Oil pump clearance
• Total end play
0 ~ Q @ I 6
\
A14-046 A13-201 A13-209 A13-211
398673600 399520105 399703600 399780111
COMPRESSOR SEAT PULLER WRENCH
Snap ring for clutch piston Roller bearing (Differential) • Used to install band servo piston Axle shaft oil seal holder.
retainer. to case .
• Used with COMPRESSOR
(498677000).
~ Q ~ ~
I
4l
I
A13-208 A12-171 A13-186 A12-168
399790110 399893600 498247001 498247100
INSTALLER PLiER MAGNET BASE DIAL GAUGE
Roller bearing (Differential) Snap ring for spring retainer. Backlash of gears. Backlash of gears.
(6)
-
A 12-175
~
A13-207
~ ST-156
~ ST-157
9
1-6 SPECIAL TOOLS
498517000 498627000 498627100 498677000
REPLACER SEAT SEAT COMPRESSOR
Drive pinion front roller bearing. Snap ring for clutch piston spring Used to hold overrunning clutch Band servo piston.
retainer. piston retainer (return spring)
when installing snap ring.
4AT 4AT
ST-151
c A13-210 L1-502 L1-503
498897100 498937100 499095500 499247300
ADAPTER CP HOLDER REMOVER ASSY INSTALLER
Used when checking oil pressure, _ Used to tighten/loosen M30 lock • Used to extract axle drive shaft Drive pinion oil seal.
etc. nut for drive pinion. from differential ASSY .
• Used when measuring tooth • Used with INSTALLER
contact pattern. (499247300)
4AT 4AT 4AT 4AT
L 1-504 L 1-498 L 1-499 L 1-500
499267300 499577000 499787100 499787300
STOPPER PIN GAUGE WRENCH ASSY WRENCH
Used to align range selector Transfer end play. • Used to tighten/loosen M30 lock Manual shaft.
lever/inhibitor switch. nut for drive pinion .
• Used when measuring hypoid
gear backlash.
4AT 4AT 4AT 4AT
L1-508 L1-509 L1-501 L1-510
10
SPECIAL TOOLS 1-6
499827000 499897000 899524100 899580100
PRESS PLIERS PULLER SET INSTALLER
Speedometer shaft oil seal. Snap ring. Reduction driven gear. Ball bearing for rear drive shaft.
Cap
PUs.
g
ST-147 A13-519 A5-142 A12-179
Rear Wheel Drive System (4WD Models) Tools

397471600 398177700 398217700 398227700
HANDLE & DRIFT KIT INSTALLER ATTACHMENT SET WEIGHT
Front and rear bearing cup. Rear bearing cone. Differential case. Side bearing.
6
10_"=::;:1 ==::J~
<D
1 HANDLE (398477701 I
2 DRIFT(3984777021
3 DRIFT 2(398477703)
ST-143 A14-085 A14-084 A14-087
398237700 398417700 398427700 398437700
GAUGE DRIFT FLANGE WRENCH DRIFT
Side bearing. Oil seal. Companion Flange Oil seal.
o A 14-086 A14-045 A14{)43 A14-046
11
1-6 SPECIAL TOOLS
398457700 398467700 398487700 398507701
ATTACHMENT DRIFT DRIFT GAUGE
Side bearing retainer. Drive pinion, Pilot bearing, Side bearing cone. Pinion height adjustment.
Front bearing cone.
-~
\) ))
A 14-047
a I I
A14-049
Q
1\ 'I)
.....-
I
A14-088
Ir A14-080
(
l
!
398507702 398507703 398507704 398517700
DUMMY SHAFT DUMMY COLLAR BLOCK REPLACER
Pinion height and Preload Pinion height and Preload Pinion height and Preload Rear bearing cone.
adjustment. adjustment. adj ustment.
I
tl:r I I II • ( 0 @ ~\
-
A14-081 A14-082 A14-083 A14-076
398527700 399527700 399780104 899580100
PULLEY ASSY PULLER SET WEIGHT INSTALLER
Oil seal, Side bearing cup. Side bearing cone. Front bearing cone, Pilot bearing, Front bearing cone, Pilot bearing.
Companion flange.
~~~=
_- M1)o=
1
2
3
4
Li . \
® @
BOL Tl8995214121
PULLER (3995277021
HOLDER (3995277031
.
ADAPTER (3984977011
6
~
5 BO L T (8995201071
A14-044 6 NUT (0210080001 A14-075 A12-172 A12-179
12
SPECIAL TOOLS 1-6
899874100 899904100 925560000
INSTALLER STRAIGHT PIN REMOVER WRENCH
Companion flange. Differential pinion shaft lock pin. Differential spindle set bolt.
q I i
~
A12-185 A12-187 ST -032
Suspension Tools
I 926110000
COIL SPRING COMPRESSOR

926500000 926510000 926520000
ADAPTER SPANNER AIR PIPE REMOVER
Used to remove and install coi I Camber & caster gauge. Used to disassemble and assemble Used to disconnect air pipe from
spring. front strut ASSY or front air jOint.
suspension ASSY.
Except Air Suspension 1800 cc model For Air Suspension
E1-076 L1-122 L 1-123 L1-124
926940000 *927050000
3-WAY JOINT ASSY ADAPTER
Used as an adapter for gauge Camber & caster gauge_

manifold of air conditioning
system to measure pressure.
For Air Suspension 2700 cc model
~
~~ L1-434 L1-570
+ Newly adopted tool
13
1-6 SPECIAL TOOLS
Wheels and Axles Tools

921130000 925091000 925130000 *1 925220000
INSTALLER BAND TIGHTENING TOOL INSTALLER INSTALLER
Brake Drum Bearing (Outer) D.O.J. Boot Front axle shaft. Brake Drum Bearing (Inner)
B.J. Boot
FWD
'\ Jig for band
~
~ R
1 Shank
2 Base
~wrench [J
A16-052 A15-171 A16.()47 A16-151
925530000 925550000 926470000 *2 926480000 *2
INSTALLER WRENCH AXLE SHAFT PULLER AXLE SHAFT PULLER PLATE
Oil Seal Rear Axle Ring Nut Used to remove front axle shaft Same as plate 2 included in
or brake drum. AXLE SHAFT PULLER
(926470000) .
Available as spare parts.
4WD 4WD 1800 cc model
~
o~c::::,
o 0 0
A16-154 A16·053 L 1-125 L1-126
926490000
*1 AXLE SHAFT INSTALLER (922431000) *2 Former PU LLER (921122000)
can be used instead of this INSTALLER can be used instead of PULLER
INSTALLER (925130000). (926470000) by replacing its
plate 2 with PLATE (926480000)
Used to install bearing and oil 922431000
seal into front housing.
AXLE SHAFT INSTALLER
Used to install front axle shaft

into housing.
I f necessary. use a 41 mm wrenc h
to prevent rotation of installer
body.
EXTENSION AXLE
SHAFT INSTALLER ST-361
14
SPECIAL TOOLS 1-6
* 927060000 * 927070000 * 927080000 * 927090000
HUB PULLER AXLE SHAFT PULLER HUB STAND HOUSING STAND
Used to remove front hub. Used to remove front axle shaft. Used when disassembling and Used in combination with
assembling hub ASSY. BEARING PULLER (927100000)
to disassemble/reassemble housing
bearing.
2700 cc model 2700 cc model 2700 cc model 2700 cc model
L 1-575 L 1-576 L1-577

* 927100000 * 927110000 * 927120000 * 927130000
BEARING PULLER 01 L SEAL INSTALLER HUB INSTALLER EXTENSION AXLE SHAFT

INSTALLER
Used to disassemble/reassemble Used to install oil seal into Used as a bearing pad when Used in combination with AXLE
housing bearing. housing. pressing hub into place. SHAFT INSTALLER
(922431000) to install front axle
shaft on hub.
2700 cc model 2700 cc model 2700 cc model 2700 cc model
L1-579 L1·580 L1·581 L 1·582
* 927140000
AXLE SHAFT PULLER PLATE
Same as plate 2 included in AXLE

SHAFT PULLER (926470000).
Available as spare parts.
2700 cc model
L1·583
15
1-6 SPECIAL TOOLS
Steering System Tools

1. Manual Steering
925640000 *3 926530000 926540000
SPANNER BUSH A INSTALLER BUSH A REMOVER
Big end: Used to loosen and Used to install bush A into Used to remove bush A from
tighten the lock nut when adjust- steering gearbox unit. VGR (Variable Gear Ratio)
ing gear backlash of steering steering gearbox unit.
gearbox.
For VGR steering gearbox
A3-167 L 1-128 Ll-129
*3 SPANNER (926230000) for power steering can be used instead of this tool.
2. Steering Column
926720000 926730000 926740000
CLAMP INSTALLER STAND
Used when assembling steering Used to remove and install Used when disassembling and
column ASSY. steering boss of pipe ASSY. assembling steering column
Attach this tool to STAND. ASSY.
L 1-215 L 1-216 L1-217
16
SPECIAL TOOLS 1-6
3. Power Steering
925700000 925711000 *4 926200000 926210000
WRENCH PRESSURE GAUGE STAND ADAPTER A
Used to remove and install tie-rod. Oil pump. Used when inspection character- Used with PRESSURE GAUGE.
Apply this tool to rack. istic of gearbox ASSY and
disassembling it.
Vise this tool and secure gearbox
ASSY using gearbox clamps.
To Gauge
c'"=_="'=.--
.. -:s
A18-233 ST-175 L1-131
926220000 926230000 926240000 926250000
ADAPTER B SPANNER INSTALLER GUIDE
Used with PRESSURE GAUGE. For the lock nut when adjusting Oil seal of steering body ASSY. Fit this tool to the left side of
backlash of gearbox. rack when installing seal holder
Removal and installation of ASSY into steering body ASSY.
tie-rod. Measurement of rotating
resistance of gearbox ASSY.
INSTALLER A~
INSTALLER~,~
To Gauge L 1-132 L1-133

~INSTALLER C
L1-281 L 1-190
926260000 926290000 926300000 926310000
REMOVER REMOVER INSTALLER GUIDE
Seal holder snap ring. Used to remove dust seal, back-up Used to install dust seal, back-up Input shaft.
ring, V-packing and ball bearing ring and V-packing into valve
from valve housing. housing.
Used to install ball bearing into
valve housing
L 1-191 L1-194
L1-195 L1-196
*4 Interchangeable with former PRESSURE GAUGE (925710000).
17
1-6 SPECIAL TOOLS
926320000 926330000 926420000 *926970000
INSTALLER REMOVER PLUG INSTALLER
Attach this tool to the left side of Used to remove back-up ring and When oil leaks from pinion side of Oil seal of oil pump.
rack when press-fitting back-up oil seal from steering body. gearbox ASSY, remove pipe B
ring and oil seal to steering body from valve housing, attach this
ASSY. tool and check oil leaking points.
L1-197 L1-142
L1-198 L 1-496
926980000 * 927020000
GUIDE JIG MOTOR PUMP ASSY
Shaft and bearing ASSY of oil Used to over-haul MOTOR

pump. PUMP ASSY.
L 1-497 L1-571
18
SPECIAL TOOLS 1-6
Brakes Tools
925460000 925471000 925600000 926430000
WHEEL CYLINDER 11/16" DISC BRAKE CYLINDER DISC BRAKE PISTON
ADAPTER PULLER O·RING ADAPTER
WRENCH
Installing cup onto piston of rear Pressing cone spring (front disc Installing spindle O·ring (front disc Used with SPACER (926440000)
drum brake wheel cylinder brake). brake). to rotate front disc brake piston.
(size 11 /16 in).
Rear drum brake All models All models All models
-f------ -----Jd e I
(
A 17-163 ST·148 A17·160 L1·143
926440000
SPACER
Used as a set with WRENCH

(926430000l.
Attach this tool to WRENCH
using two 6-mm dia. bolts (length:
less than 15 mm l. All models
L 1·144
19
1-6 SPECIAL TOOLS
Air Conditioning System Tools

925770000 925790000 925800000 *6 925820000 *6
CLUTCH TIGHTENER HUB NUT TIGHTENER OIL SEPARATOR FLEXIBLE HOSE
For holding clutch hub. For tightening hub nut. For withdrawing oil from ~Used with 01 L SEPARATOR)
refrigeration system.
Cap Cap
~ ~ ~c.P
A26-045 A26-047 ST-176 ST-178
925840000 *6 925850000 *6 926120000 926130000
CLUTCH ARMATURE
DOUBLE UNION CONNECTOR PIPE SHAFTSEALINSTALLER REMOVER
(Used with OIL SEPARATOR) (Used with 01 L SEPARATOR) For removing and installing shaft For clutch disassembly.
seal.
. fjO~in9 EO-
@- ,--J
I § ~
ST-179 ST-180 L4-541 A26-046
926140000 926150000 926160000 926170000
SHAFT ROTATOR COVER PLATE REMOVER HEXAGON SOCKET (8 mm) FRONT COVER TIGHTENER
For assemble and rotation For cover plate removal. For elbow removal and For shell removal and
checking_ installation. installation.
I ::;:j © : ~ ()
m @).,
L4-542 L4-543 L4-544 L4-545
*6 Oil Separator Kit is composed of Oil Separator, Flexible Hose, Double Union and Connector Pipe.
20
SPECIAL TOOLS 1-6
926180000 926190000
HEXAGON SOCKET (10 mml INJECTOR NEEDLE
For cover end (R) removal and For discharging and charging gas.
installation.
~ Q:II]
L4·546 L4·547
Body Tools
925580000 925610000 926661000 927000000
PULLER WRENCH REMOVER ENGINE SUPPORT ASSY
Trim clip. Door hinge. Used to remove and install trunk For supporting engine.
torsion bar.
1800 cc model
ST -035 ST·166
o Ll·282 L1·511
927010000 * 927150000 * 927160000
BRACKET (ENGINE SUPPORT) ENGINE SUPPORT ASSY BRACKET (ENGINE SUPPORT)
Used together with ENGINE For supporting engine. Used together with ENGINE
SUPPORT ASSY. SUPPORT ASSY.
1800 cc model 2700 cc model 2700 cc model
L 1·512 L1·572 Ll·573

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Publication No. G 140BECD

Issued: July 1987 A
Printed in Japan M·4.2
~-----------FOREWORD------------~
This service manual has been prepared to provide SUBARU service personnel with the necessary information. and
The manual includE¥ the procedures for maintenance, disassembling, reassembling, inspection and adjustment of
their vehicles in optimum condition. When replacement of parts during repair work is needed, be sure to use
FUJI HEAVY INDUSTRIES LTD .
. - - - - - - - - - - - - - - - - - How to use this manual
This service manual is divided into four volumes. Each volume consists of Section 1, Section 2, 3, .Section 4,5,
Each chapter, beginning with the Engine section, is basically made up of the following five areas. JI
!
3. Component parts
A. Service procedure
5. Trouble-shooting
SUBARU,
©
8- and fj are registered trademarks of FUJI HEAVY INDUSTRIES LTD.
Copyright 1987 FUJI HEAVY INDUSTRIES LTD. All rights reserved.
Not to be reptoduced in whole or in part without the prior written permission

of FUJI HEAVY INDUSTRIES LTD., TOKYO JAPAN.
-- ---...-.-.
TABLE OF CONTENTS
1-1 Specifications
1-2 ** * * * ** * * ***
1-3 General Information
IT} GENERAL SECTION 1-4 Pre~Deliverylnspection
1-5 Periodic Maintenance Services
1~6 Special Tools
2-1 Emission Control System and Vacuum Fitting

2-2 On·Car Services
2-3 Engine
2-4 Engine Lubrication System
2-5 Engine Cooling System
[g] ENGINE SECTION 2-6 * ****** *** * *
2-7 Fuel Injection System
2-8 Fuel System
2-9 Exhaust System
2-10 Clutch
2-11 Engine and Transmission Mounting System
3-:1 Manual Transmission and Differential

~ TRANSMISSION AND 3-2 Automatic Transmission and Differential
DIFFERENTIAL SECTION 3-3 Transmission Control System
3-4 4WD System
4,....1 Suspension
4-2 Wheels and Axles
4,....3 Steering System
~ MECHANICAL COMPONENTS 4-4 Brakes
SECTION 4..;..5 Pedal System and Control Cables
4-6 Heater and Ventilator
4-7 Air Conditioning System
5-1 Body and Exterior
/ 5..;..2 Doors and Windows
~BODY SECTION
5-3 Seats, Seat Belts, and Interior -
5....:..4 Instrument Panel
6--1 Engine Electrical System

[§J ELECTRICAL- SECTION 6-2 Body Electrical Sy$iem
6-3 Wiring Diagram and Trouble-shooting
I
~
(
QUICK REFERENCE INDEX
~ ENGINE SECTION
EMISSION CONTROL SYSTEM 2-1
BUBARU AND VACUUM FITTING
ON-CAR SERVICES 2-2
ENGINE 2-3
1988 ENGINE LUBRICATION SYSTEM 2-4
ENGINE COOLING SYSTEM 2-5
SlERV~CIE ** * * * ** * * ** * 2-6
MANL»AIL FUEL INJECTION SYSTEM 2-7
FUEL SYSTEM 2-8
EXHAUST SYSTEM 2-9

CLUTCH 2-10
ENGINE AND TRANSMISSION 2 -11
MOUNTING SYSTEM
~ TRANSMISSION AND
DIFFERENTIAL SECTION
',. MANUAL TRANSMISSION 3-1
AND DIFFERENTIAL
AUTOMATIC TRANSMISSION 3-2

/ AND DIFFERENTIAL
TRANSMISSION CONTROL SYSTEM 3-3
4WD SYSTEM 3-4

-.
j
/
ABBREVIATION LIST
AAV Anti-Afterburning Valve KDLH Kick-Down Low Hold
ABDC After Bottom Dead Center LED Light Emitting Diode
AIC Air Conditioner Led. Light emitting diode
AID AnaloglDigital LH Left-hand
AI Air Injection LSD Limited Slip Differential
approx. approximately LlU Lock-Up
ASSY Assembly MPFI Multi Point Fuel Injection
ASV Air Suction Valve MPS Motor Power Steering
AT Automatic Transmission (Electronic-Controlled Motor Drive
ATC Automatic Temperature Controller Power Steering)
ATDC After Top Dead Center MP-T Multi-Plate-Transfer
ATF Automatic Transmission Fluid MT Manual Transmission
Batt. Battery 0.0 Outside Diameter or Overdrive
BBDC Before Bottom Dead Center OHC Over-Head Camshaft
BDC Bottom Dead Center OIP Oil Pump
BJ Bell Joint OP. Option
BTDC Before Top Dead Center OS Oversize
Cal California OVRIC Overrunning Clutch
Coolant temp. Coolant temperature O.W.C. One-Way Clutch
.. CP Complete pcs. pieces
CPU Central Processing Unit PCV Positive Crankcase Ventilation
CTR Center Pd Palladium
CIU Control Unit P.H.v Pressure Hold Valve
CVJ Constant Velocity Joint P.M Primary Main
bOJ Double Offset Joint Power TR Power Transistor
D/R Dual-range Press. SW Pressure Switch
D.S.v. Duty Solenoid Valve P.S Primary Slow
ECC Electronically Controlled Carburetor PTC heater Positive Temperature Coefficient
ECM Electronic Control Module heater
ECS Electric Control System Pt Platinum
E/G Engine REG Regulation
EGR Exhaust Gas Recirculation Rev. Reverse
Ex. port Exhaust port Rh Rhodium
FCV Float Chamber Ventilation RH Right-hand
FF Front drive Front engine SAC Sub Advance Control
FICO Fast Idle Control Device SAE Society of Automotive Engineers
FIL Fusible Link SMAB Secondary Main Air Bleed
FIP Fuel Pump S.M Secondary Main
FWD Froht Wheel Drive (= 2WDj sol. solenoid
gear UN gear Unit SIR Single-range
GND Ground STD Standard
H/A High Altitude St. Starter
HLA Hydraulic Lash Adjuster ST SW Starter Switch
lAS Idle Adjusting Screw TCU Transmission Control Unit
1.0. Inside Diameter TDC Top Dead Center
liD Idle Temp. valve Temperature valve
IG Ignition TRF/C Transfer Clutch
IG ON Ignition ON UIL (SIL) Up Shift Indicator Light
IG SW Ignition Switch US Undersize
1/0 InputlOutput VLC Vacuum Line Control
KD Kick-Down WOT Wide Open Throttle
r-
INDEX
Accumulator ... ............ ......... .............. ............ ...... ..... 3-2- 37 Front Exhaust Pipe ...................... ,... .... ..... ... ... .... .... 2-9- 4
Accumulator Control Valve .................................... 3-2- 29 Fuel Delivery, Return and Evaporation Lines .... 2-8- 11
Air Flow Meter ........................................................ 2-7- 18 Fuel Filler Pipe ........................................................ 2-8- 7
Air Flow Meter ........................................................ 2-7- 2 Fuel Filter ............. '" ................................................. 2-8- 9
Air-fuel Ratio Learning Control System .............. 2-7- 8 Fuel Injector ............................................................. 2-7- 25
Air Intake System ................................................... 2-7- 29 Fuel Injector ............................................................. 2-7- 9
Air Intake System ................................................... 2-7- 17 Fuel Meter Unit ....................................................... 2-8- 7
ATF Level ................................................................. 3-2-148 Fuel Pump ................................................................ 2-8- 10
ATF Temperature Sensor ...................................... 3-2- 54 Fuel Separator .... ... ....... ......... ........ ... ... ...... ........ ...... 2-1- 10
Automatic Transmission ......................................... 3-3- 10 Fuel Separator ......................................................... 2-8- 8
Auxiliary Air Valve ................................................... 2-7- 24 Fuel Tank .................................................................. 2-8- 6
Auxiliary Air Valve ................................................... 2-7- 6 High Clutch .............................................................. 3-2- 13
Band Brake .............................................................. 3-2- 14 High Clutch ............................. '" ....... ... ...... ... ... ........ 3-2-112
Brake Band .................. .... .......... .......... .... ............. ... 3-2-150 High Tension Cords ............................................... 2-2- 9
By-pass Air Control Valve ..................................... 2-7- 23 Hypoid Gear ............................................................. 3-2- 20
By-pass Air Control Valve ..................................... 2-7- 5 Ignition Control System ......................................... 2-1- 6
Camshaft and Valve Rocker ............................ ..... 2-3- 77 Ignition System ........................................................ 2-7- 6
Camshaft and Valve Rocker ................................. 2-3- 22 Ignition Timing ......................................................... ,2-2- 2
Canister ..................................................... '" ........ ..... 2-1- 9 Inhibitor Switch ................ ,....................................... 3-2-151
Center Differential & Extension ASSY Inhibitor Switch ........................................................ 3-2- 55
(Full-Time 4WD) ....................................................... 3-1- 55 Input Shaft ..................................... ,.... .... .... ........ ...... 3-2- 18
Clear Memory Mode ...... .... ..... ....... .............. ... ........ 2-7- 55 Intake Manifold ........................................................ 2-7- 15
Clutch Play Adjustment ......................................... 2-10- 5 Intake Manifold Vacuum ...................................... ,. ,2-2- 3
Control Valve Body ................................................. 3-2-105 Knock Sensor .......................................................... 2-7- 8
Coolant Thermosensor ........................................... 2-7- 29 Line Pressure Test ................................................. 3-2-162
Coolant Thermosensor ........................................... 2-7- 10 Lock-up Control - Mechanism ....... .......... ... ....... 3-2- 6
Cooling Fan and Fan Motor ................................. 2-5- 15 Lock-up Control - Operation ............................. 3-2- 8
Cooling System ................................................ ,...... 2-2- 7 Lock-up Control Valve ........................................... 3-2- 35
Crankcase Emission Control System .... ... ........ ... 2-1- 5 Low & Reverse Brake ........................................... 3-2- 16
Crankshaft and Piston ........................................... 2-3- 96 Manual Transmission ............................................ ,. 3-3- 7
Crankshaft and Piston ........................................... 2-3- 41 Manual Valve .................... ,. ... ... ... ... ...... ...... ...... ... ..... 3-2- 34
Cylinder Block ..................................... '" .... ... .... ...... 2-3- 33 Muffler Assembly ..................................................... 2-9- 6
Cylinder Block .................................................. ,. ..... 2-3- 86 Oil Leakage Check Points .................................... 3-2-149
Cylinder Head .......................................................... 2-3- 81 Oil Pump ................................................................... 2-4- 10
Cylinder Head ................................................... ,. ..... 2-3- 27 Oil Pump ........................... ,. .... .............. ... ...... ..... ...... 3-2- 9
Cylinder Head Bolts ............................................... 2-2- 9 Oil Pump Assembly ................................................ 3-2-106
D-check Mode ......................................................... 2-7- 54 Oil Pump Assembly ................................................ 2-2- 10
Differential ASSY (FWD) ........................................ 3-1- 78 One-way Clutch ....................................................... 3-2- 15
Differential ASSY (Selective 4WD) ....................... 3-1- 48 One-way Clutch Outer Race ................................ 3-2-116
Differential Case Assembly ................................... 3-2-117 Overall Transmission (Full-Time 4WD) ................ 3-1- 49
Differential Gear ......................... .... ......................... 3-2- 20 Overall Transmission (FWD) .................................. 3-1- 66
Differential Gear Oil Level.. ... ...... .... ...... ... ............. 3-2-149 Overall Transmission (Selective 4WD) ................. 3-1- 27
Drive Pinion Shaft ................................................. 3-2-109 Overrunning Clutch Control Valve ..................... ,. 3-2- 33
Drive Pinion Shaft ASSY (Full-Time 4WD) ......... 3-1- 61 Overrunning Clutch Reducing Valve ... .... ... ..... ..... 3-2- 33
Drive Pinion Shaft ASSY (FWD) .......................... 3-1- 73 Oxidation Catalyst ................................................... 2-1- 8
Drive Pinion Shaft ASSY (Selective 4WD) ......... 3-1- 44 Oxygen (0,) Sensor ............................................... 2-2- 6
Duty Solenoid C and Transfer Valve Body ....... 3-2-156 02 Sensor ................................................................. 2-7- 8
Engine Compression ............................................... 2-2- 3 PCV Valve ................................................................. 2-1- 5
Engine Idle Speed .................... .... ........... ... ...... ...... 2-2- 4 Pilot Valve ................................................................. 3-2- 34
Engine Idling Speed ............................................... 3-2-150 Pilot Valve (Transfer) .............................................. 3-2- 61
Evaporative Emission Control System ................ 2-1- 8 Planetary Gear ......................................................... 3-2- 18
Extension & Transfer Gear ASSY Power Indicator Light ........................................... ,. 3-2- 45
(Selective 4WD) ....................................................... 3-1- 42 Pressure Modifier Valve .......................... ,. ............. 3-2- 29
Fail-safe Function ................................................. '" 3-2- 52 Pressure Regulator ................................................. 2-7- 10
Forward Clutch Drum .. ............. .... ... ....... .......... ...... 3-2-113 Pressure Regulator ................................................. 2-7- 29
Forward Clutch & Overrunning Clutch ............... 3-2- 17 Pressure Regulator Valve ....................... ,. .......... ... 3-2- 28
Propeller Shaft ......................................................... 3-4- 14 Throttle Sensor .... ...... .......... .................. .......... ........ 3-2- 53
Radiator ..................................................................... 2-5- 13 Throttle Sensor ........................................................ 2-7- 4
Read Memory Mode ............................................... 2-7- 51 Time Lag Test ......................................................... 3-2-162
Rear Case & Shifter ASSY (FWD) ...................... 3-1- 71 Timing Belt and Belt Cover .................................. 2-3- 69
Rear Differential Assembly .................................... 3-4- 20 Timing Belt and Belt Cover .................................. 2-3- 17
Rear Exhaust Pipe .. ,............................................... 2-9- 5 Torque Converter Regulator Valve ...................... 3-2- 29
Reduction Drive Gear Assembly .......................... 3-2-104 Transfer Case & Shifter ASSY
Reduction Gear ....................................................... 3-2- 19 (Full-Time 4WD) ....................................................... 3-1- 57
Resistor ................................ ,.................................... 2-7- 25 Transfer Case & Shifter ASSY
Reverse Clutch ........................................................ 3-2-111 (Selective 4WD) ....................................................... 3-1- 43
Reverse Clutch ........................................................ 3-2- 12 Transfer Clutch ........................................................ 3-2-118
Road Test ................................................................. 3-2-164 Transfer Control Valve ........................................... 3-2- 61
Self-diagnosis System ............................................ 2-7- 33 Transfer Valve Body ...... ......................................... 3-2-120
Servo Charger Valve .... .... ......... ..... .... ...... ........ ...... 3-2- 36 Transmission Harness ............................................ 3-2-152
Servo Piston ............................................................ 3-2-116 Transmission Main Shaft ASSY (FWD) ............... 3-1- 75
Shift Solenoid, Duty Solenoid and Valve Transmission Main Shaft ASSY
Body .......................................................................... 3-2-153 (Selective 4WD) ....................................................... 3-1- 46
Shift Valve A and 4-2 Relay Valve .......... ............ 3-2- 32 Trouble Codes ......................................................... 2-7- 35
Shift Valve Band 4-2 Sequence Valve .............. 3-2- 31 Troubleshooting Chart for Self-diagnosis
Shuttle Shift Valve D .. .................... ...... .................. 3-2- 30 System ...................................................................... 2-7- 50
Shuttle Shift Valve S .............................................. 3-2- 34 Two-way Valve ........ ........ ............ ........ ..................... 2-1- 10
Solenoids .................................................................. 3-2- 54 Vacuum Fitting ......................................................... "2-1- 12
Specification Codes ................................................ 2-7- 35 Valve and Valve Spring .......... ............ .................... 2-3- 85
Speedometer Gear System ................................... 3-2- 21 Valve and Valve Spring .......................................... 2-3- 31
Stall Test .................................................................. 3-2-159 Vehicle Revolution Sensor .................................... 3-2-153
Tail Pipe Cutter ....................................................... 2-9- 7 Vehicle Revolution Sensor 1 .............. .......... ........ 3-2- 54
Thermometer ............................................................ 2-5- 12 Water Pump ............................................................. 2-5- 10
Thermostat ................................................................ 2-5- 12 Water Pump Assembly ........................................... 2-2- 14
Three-way Catalyst .................................................. 2-1- 8 1st Hold Indicator Light .......... ........ .............. ......... 3-2- 45
Throttle Body ........................................................... 2-7- 3 1st Reducing Valve ........ ................ ......................... 3-2- 36
Throttle Body ........................................................... 2-7- 21 3-2 Timing Valve ...................................................... 3-2- 36
Throttle Body ........................................................... 2-7- 13
EMISSION CONTROL SYSTEM AND
VACUUM FITTING
Page
SUBARU System Application

General Precautions
2
2
Schematic Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3
Crankcase Emission Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5
1988 DESCRIPTION ........................................ 5
INSPECTION ......................................... 6
Ignition Control System .................................... 6
Three·Way Catalyst ....................................... 8
Oxidation Catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8
Evaporative Emission Control System ........................... 8
DESCRIPTION ........................................ 8
INSPECTION ......................................... 10
Vacuum Fitting ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11
,
2-1 EMISSION CONTROL SYSTEM AND VACUUM FITTING
3) Check hose and wiring connections first.

System Application The most frequent cause of problems is simply a bad Connec·
There are thr.ee emission control systems which are as follows: tion in the wiring or vacuum hoses. Always make sure that
1) Crankcase emission control system connections are secure and correct.
2) Exhaust emission control system 4) Avoid coasting with the ignition turned off and prolonged
engine braking.
• Ignition control system
5) Do not damage parts.
• Front catalyst (Three-way catalyst)
(1) To disconnect vacuum hoses, pu II on the end, not the
• Rear catalyst (Oxidation catalyst)
middle of the hose.
3) Evaporative em ission control system
(2) To pull apart electrical connectors, pull on the con-
nector itself, not the wire.
(3) Be careful not to drop electrical parts, such as
sensors, or relays.
If they are dropped on a hard floor, they shou Id be
General Precautions replaced and not reused.
(4) When steam cleaning an engine, protect the distribu-
1) Know the importance of periodic maintenance services. tor, coil, air cleaner, and throttle body from water.
(1) Every service item in the periodic maintenance (5) When checking continuity at the wire connector, the
schedule must be performed. test bar should be inserted carefully to prevent terminals
(2)Failing to do even one item can cause the engine to run from bending.
poorly and increase exhaust emissions. 6) Use SUBARU genuine parts.
2) Determine if you have an engine or emission system 7) Record how hoses are connected before disconnecting.
problem. (1) When disconnecting vacuum hoses, use tags to
(1) Engine problems are usually not caused by the emis- identify how they should be reconnected.
sion control systems. (2) After completing a job, double check to see that the
(2) When troubleshooting, always check the engine and vacuum hoses are properly connected. See the "Vacuum
the ignition system first. connections label" under the hood.
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EMISSION CONTROL SYSTEM AND VACUUM FITTING 2-1
Crankcase Emission Control ®

System
DESCRIPTION
The positive crankcase ventilation (PCV) system is employed

to prevent air pollution which will be caused by blow-by gas
being emitted from the crankcase.
The system consists of a sealed oil filler cap, rocker covers
with an emission outlet and fresh air inlet, connecting hoses,
PCV valve and an air cleaner.
At the part throttle, the blow-by gas in the crankcase flows
--~ Fresh air
into the intake manifold through the connecting hose of
...... Blow-by gas
rocker cover on #2/#4 side, connecting hose of crankcase and
PCV valve by the strong vacuum of the intake manifold. - - Mixture of air and blow-by gas
Under this condition, the fresh air is introduced into the

crankcase through connecting hose of rocker cover on #1/#3 PCV valve 8 Connector
side, and drawn to the intake manifold through PCV valve 2 pev hose 9 Oil filler cap
together with the blow-by gas_ 3 Blow·by hose (RH) 10 Rocker cover (#1/#3)
4 Blow-by hose (LH) 11 Rocker cover (#2/#4)
At the wide open th rottle, a part of blow-by gas flows into
5 Blow-by hose (CTR) 12 Crankcase
the air cleaner through the connecting hose of rocker cover on 13 Connecting hose
6 I ntake duct
#1/#3 side and is drawn to the throttle body, because under 7 Intake manifold 14 Connecting hose
this condition, the intake manifold vacuum is not so strong as 15 Connector
to introduce all blow-by gases increasing with engIne speed Ll-039
directly through the PCV valve. Fig. 3 1800 cc
Under the special operating condition, such as steep right turn
driving, engine oil sometimes blows up into connecting hose or
rocker cover on #2/#4 side and flows into the intake manifold
by the force of the vacuum.
However, in this case, the connecting hose between intake
duct and connecting hose of rocker cover on #2/#4 side
reduces the vacuum to prevent th is.
Valve rocker cover

Valve rocker
cover
---.... Fresh air

...... Blow-by gas
- Mixture of air and blow-bY gas
L2-1257
Fig. 4 2700 cc
5
Battery
~I·~-~""-----·-"""-
Ignition switch
MPFI conteol uni~~i======----===j - ~n'",

Power transistor I
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- Distributor
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Coolant temper::r: ::nsor
L2-125~
Fig. 6 1800 cc
, - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - --1
I ,--------------------l
Battery
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Spark plug
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control valve
L _____________________ ,
Air flow
Power I
sensor
transistor
Coolant
temperature sensor
L2-1259
Fig.72700cc
7
Three-way Catalyst Oxidation Catalyst

The basic material of three-way catalyst is platinum (Pt) and The basic material is Palladium (Pd) and Rhodium (Rh).
rhodium (Rh), and a thin film of their mixture is applied onto A thin film of their mixture is applied onto honeycomb or
honeycomb or porous ceramics of an oval shape (carrier), porous ceramics of an oval shape (carrier), To avoid damaging
To avoid damaging the catalyst, only unleaded gasoline should the catalyst, only unleaded gasoline should be used.
be used. The catalyst is used to reduce HC, CO in exhaust gases.
The catalyst is used to reduce HC, CO and NOx in exhaust
gases, and permits simultaneous oxidation and reduction. To Evaporative Emission Control
obtain an excellent purification efficiency on all components
HC, CO and NOx, a balance shou Id be kept among the con-
System
centrations of the components. These concentrations vary
with the air-fuel ratio.
DESCRIPTION
The air-fuel ratio needs to be controlled to a value within the
very narrow range covering around the theoretical (stoichio-
The evaporative emission control system is employed to
metric) air-fuel ratio to purify the components efficiently.
prevent evaporative fuel from being discharged into ambient
The air-fuel ratio is controlled by the MPFI system.
atmosphere. This system includes a canister, two-way valve,
fuel separator, purge control solenoid valve, connecting lines,
Refer to 2-7 "FUEL INJECTION SYSTEM". etc.
Gasoline vapor evaporated from the fuel in the fuel tank is
introduced into the canister located in the engine compart-
ment through the evaporation line, and is absorbed on
activated carbon in it. A two-way valve and a fuel separator
are also incorporated on the tank fuel line.
,Coolant
~ temperature
r Air flow meter
Air duct
Throttle chamber
MPF I control
unit
Purge line
t Vacuum line
Fuel filler cap (Vacuum relief)
Purge control
solenoid valve
Two-way valve
Vapor volume
Tank vapor line
Canister
Fuel tank
Tank fuel volume

L2-1260
Fig_ 8 1800 cc
8
Purge control
solenoid valve
Throttle body
Fuel filler cap

Vacuum line (Vacuum relief)
Purge line Two-way valve
+--
Vapor volume
Tank vapor line
Canister - --~----
Fuel tank~
Fuel tank volume
L2-1261
Fig. 9 2700 cc
CANISTER
The purge control valve on the canister is controlled by the
intake manifold vacuum_ When the purge control valve is
opened, the absorbed vapor is introduced from the canister
into the throttle body.
When the engine is not running, the purge control valve is
closed by the return spring.
Purge vent
From fuel tank
Vacuum orifice:
0.4 mm (0.016 in)
Purge control valve
Activated
carbon
Fi Iter
100 mm (3.94 in)

L2-1262
Fig. 10
9
TWO-WAY VALVE FUEL CAP

The two-way valve is located in the fuel vapor line and func- The rei ief valve is adopted to prevent the development of
tions to control the pressure in the fuel tank. vacuum in the fuel tank which may occur in case of trouble in
When the fuel tank pressure is positive above a certain point, the fuel vapor line.
the valve A is open to perm it the fuel vapor to the canister, In normal condition, the filler pipe is sealed at ® and at the
and when the fuel tank pressure is negative below a certain packing pressed against the filler pipe end. As vacuum develops
point, the valve B is open to introduce fresh air into the fuel in the fuel tank, atmospheric pressure forces the spring down
tank. to open the valve; consequently air is led into the fuel tank
controlling the inside pressure.
~Handle
To canister
A10-084
Fig. 11
L2-1027
'\
Fig. 13
FUEL SEPARATOR
The fuel separator is to prevent liquid fuel from flowing into
the canister in case of abrupt cornering, etc.
To canister
INSPECTION
FUEL PIPING
Fuel separator
Check fuel piping and connections for leakage.
EVAPORATION LINE FROM FUEL TANK TO

CANISTER
1) Remove fuel filler cap.
2) Disconnect evaporation line at evaporation pipe CPo
3) Check for unobstructed evaporation line on fuel tank side
except for a little resistance due to 2-way valve by blowing air
into hose.
4) Check for unobstructed evaporation line on canister side
with no resistance by blowing air into hose.
TWO-WAY VALVE
1) Check for air passage with slight resistance due to the
valve by blowing air into the nipple on the side marked with
letters "To engine".
2) Repeat the same step on the other nipple.
L2-329 3) Check for the valve case with no crack. If cracked, replace
it with new one.
Fig. 12
10
\ Marked letters "To engine"

Usually (when the current is OFF), the plunger is forced
upwards by the spring force to close the passage between @
...
To canister
and ®, and to open the passage between ® and © .
When the current is ON in the solenoid, the plunger is
attracted downwards to open the passage between @ and ®,
@
..
and to close the passage between ® and ©.
To fuel tank
~~~ ® To canister purge
1 Valve "8" control valve
2 Valve "A"
3 Case
4 Spring
5 Retainer
A3·192
Fig. 14
PURGE LINE AND CANISTER

11 Disconnect the vacuum hose. Orally blow air through the
hose to ensure that air does not leak.
L2-331
21 Disconnect the purge hose. Orally blow air through the
hose to ensure that air does not leak. Fig. 15 1800 cc
3} Disconnect the evaporation hose from the fuel tank side.
Orally blow air through the hose to ensure that air flows.
Be careful not to suck on the hose as this causes fuel evapo·

rating gas to enter your mouth.
4) Check the exterior of the canister to ensure that it is not f----i

©
cracked or scratched. - - - + -EE£+-- - - - - +-~-+ ~
To intake manifold
~I-=========r---J...,
PURGE CONTROL SOLENOID VALVE
Check the resistance between To canister purge

NO control valve
(+) and (-I terminals. L2-1263
Standard resistance: Fig. 16 2700 cc
32.7 - 39.9n
~ YES
Check the resistance between
NO
(+) or (-) terminal and body. J Replace
Standard resistance: I I
1 Mn or more.
l YES
Check the vacuum passage for

opening and closing operation NO
while applying electric current
on both (+) and (-) terminals.
j YES
I Normal
I
11
Vacuum Fitting
Distributor
L2·1264
Fig. 17 1800 cc
4WD
MT
only
L2·1265
Fig. 18 2700 cc
12
ON-CAR SERVICES
Page
BUBARU IGNITION TIMING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • ..

ENGINE COMPRESSION. . . . . • . . . . . . . . . . . . . . . . . . . . . .. . . . . ..
2
3_
INTAKE MANIFOLD VACUUM. . . . . . . . . . . . . . . . . . . . . . . . • . . . .. 3
1988 ENGINE IDLE SPEED ....................................

OXYGEN (0 2 ) SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
4
6
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . .. 7
HIGH TENSION CORDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9
CYLINDER HEAD BOLTS ................................. 9
OIL PUMP ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10
WATER PUMP ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . •. 14
/
2-2 ON-CAR SERVICES
This chapter describes major inspection and service procedures If the timing is not correct, proceed to the next paragraph for
for the engine mounted on the body. For procedures not adjustment.
found in this chapter. refer to the service procedure section in
the applicable chapter. 1800 cc model 2700 cc model
Ignition Timing -------------

MIT 20° /700 20° /750
AIT 20° 1800 20° /750

INSPECTION AND ADJUSTMENT (BTDC/rpm)
BEFORE CHECKING AND ADJUSTING Ignition timing can be set when the test mode connector is
IGNITION TIMING connected and the idle switch is turned ON, regardless of
engine rpm. Do not check ignition timing while the connector
1) Warm up the engine. is disconnected and the switch is OFF.
2) Make sure that the idle contact of throttle sensor is ON
position. (Refer to "Chapter 2-7".)
3) Connect the test mode connector.
ADJUSTING IGNITION TIMING
a. The CHECK ENGINE warning light will come on. This does 1) Loosen the 6·mm bolts on the mounting plate of the
not indicate a problem. distributor.
b. Ignition timing must not be adjusted and cannot be 2) Turn the distributor housing. The timing is advanced
checked while the idle switch is off or the test mode connector when the distributor housing is turned clockwise and is
is disconnected. retarded when turned counterclockwise.
3) Tighten the bolts and make sure that the timing is correct.
CHECKING IGNITION TIMING
1) Set gear in neutral position (MT) or "N" or lip" position
(AT), and turn off the light.
2i To check the ignition timing. connect a timing light to #1
cylinder spark plug cord, adjust the engine idle speed to the
specification and illuminate the timing mark with the timing
light.
----------------------------------~L~2~-1066
Fig. 2
AFTER CHECKING AND ADJUSTING
Fig. 1
Be sure to disconnect the test mode connector.
2
ON-CAR SERVICES 2-2
Engine Compression Intake Manifold Vacuum
MEASUREMENT MEASUREMENT
1) After warming up the engine, turn off the ignition switch.
2) Make sure that the battery is fully charged. 1) Warm up the engine.
3) Remove all the spark plugs. 2) Disconnect the vacuum hose and install the vacuum gauge
4) Disconnect the harness connectors for injectors. to the hose fitting on the manifold.
5) Fully open the throttle valve. 3) Keep the engine at the idle speed and read the vacuum
6) Check the starter motor for satisfactory performance and gauge indication.
operation. By observing the gauge needle movement, the internal condi-
7) Crank the engine by means of the starter motor, and read tion of the engine can be diagnosed as described in Table
the maximum value on the gauge when the pointer is steady. below.
Hold the compression gauge tight against the spark plug hole.
8) Perform at least two measurements per cylinder, and

make sure that the values are correct.
1,157 (11.8,168)
1,079 (11.0, 156) .--------j
.~ ~dard i
c: : I
'"o'E 0
/ __
.~
II) I I
~I
en ...
~ a. Lirnit 961 (9.8,139)
-co 0E I I
I
~ u I 883 (9.0, 128)
I I
I I (rpm)
200 350
Engine speed
L2-308
Fig. 3
Difference between cylinders:

196 kPa (2.0 kg/cm 2 , 28 psi) or less
3
2-2 ON-CAR SERVICES
Diagnosis of engine condition by measurement of manifold vacuum
Vacuum gauge indication Possible engine condition
1. Needle is steady but lower than normal position. Leakage around intake manifold gasket or throttle cham·
This tendency becomes more evident as engine ber gasket.
temperature rises.
2. When engine speed is reduced slowly from higher Back pressure too high, or exhaust muffler clogged.
speed, needle stops temporarily when it is lowering
or becomes steady above normal position.
3. Needle intermittently drops to position lower than Leakage around cylinder.

normal position.
4. Needle drops slightly and intermittently from normal Leaking valves or irregular valve clearances.
position.
5. Needle drops suddenly and intermittently from Sticky valves.

normal position.
6. When engine speed is gradually increased, needle Weak or broken valve springs.
begins to vibrate rapidly at certain speed, and then
vibration increases as engine speed increases.
7. Needle vibrates above and below normal position in Incorrect idle adjustment.
narrow range.
Engine Idle Speed 1) Before inspection, ensure that the auxiliary air valve is
completely closed.
2) Adjust the idle speed by using the idle adjusting screw
INSPECTION AND ADJUSTMENT located on the throttle body.
1800 cc model MT 700 ± 100

Idle speed (rpm)
AT 800 ± 100
a. Make sure that the ignition timing is correctly adjusted
prior to this inspection. CO contents (%) 0.1, max
b. Set the gear position at "Neutral" for MT, or lip" or liN"
HC contents (ppm) 200, max
for AT.
c. Before inspecting the engine idle speed, ensure that:
(1) Vacuum hoses, blow·by hoses, rocker cover, oil filler
cap, etc. which are connected to the intake system, are
tight and secure.
(2) The engine has warmed up sufficiently and O2 sensor
has also been warmed up at an engine speed of 2,500 rpm
for approximately one minute after engine warm-up.
(3) Disconnect the purge hose(s) at the opposite side of
canister and then clog it(them).
L2-1401
Fig. 4
4
ON-CAR SERVICES 2-2
3) Inspecting the exhaust gas. The CO content adjusting screw of the air flow meter need
(1) After adjusting both ignition timing and idling speed, not be adjusted as the air·fuel ratio is feedback controlled.
check both the idle CO and HC contents in the exhaust
gas. (2) If the CO and HC contents are outside specifications,
check and correct the problem using the following chart
as a guide.
Troubleshooting
Faulty
Use of leaded
gasoline
Improper
idle CO I-L,.-------...---~~--L----cr--_,;:--l--------
contents
*2
Improper
compression
pressure
L2-1550
Fig. 5
*1: Check the MPFI system.

Connect a jumper wire and check to see if the CHECK 2700 cc model
ENGIN E warning light flickers with the engine at idle.
If it does, the MPFI-6ystem is functioning properly.
*2: Check the fuel pressure. Refer to Chapter 2·7 "Throttle Chamber Assembly".
*3: Check fuel injectors.
a: Remove the fuel injector and direct air at a pressure of
approximately 196 kPa (2 kg/cm2, 28 psi) to see if air
leaks at the nozzle tip. If air leaks, replace the injector.
b: The injector is faulty.
5
2-2 ON-CAR SERVICES
Oxygen (0 2 ) Sensor 4) Apply SUBARU CRC (004301003) to threaded portion

of oxygen (0 2 ) sensor again, and leave it for one minute or
more.
REPLACEMENT 5) Remove oxygen (0 2 ) sensor by using socket and wrench.
Oxygen (0 2 ) sensor is one of the important emission control When removing, do not force oxygen (02) sensor especially
parts. Therefore, replace it as follows only when it is damaged when exhaust pipe is cold; otherwise it will damage the
by external force, or if it seems to be out of order according exhaust pipe.
to troubleshooting etc.
REMOVAL
1) Disconnect oxygen (0 2 ) sensor cord.
2) Apply SUBARU CRC (004301003) or its equivalent to
INSTALLATION
threaded portion of oxygen (0 2 ) sensor, and leave it for one 1) Apply anti-seize compound ("SS-30" made by JET-LUBE
minute or more. Inc. in U.S.A. or its equivalent) only to threaded portion of
3) Loosen oxygen (0 2 ) sensor by turning it 10 to 40 degrees oxygen (0 2 ) sensor to make the next removal easier.
with SOCKET (499990110).
Never apply anti-seize compound to protector of oxygen (0 2)
sensor.
2) By using socket and torque wrench, install oxygen (0 2 )

sensor onto front exhaust pipe by tightening it to the specified
torque.
Torque [oxygen (02) sensor):

25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-Ib)
3) Securely connect oxygen (0 2 ) sensor cord.
Fig. 6
6
ON-CAR SERVICES 2-2
Cooling System
INSPECTION
SYSTEM COMPONENTS
Repair or replace parts which are found faulty.
1800 cc model
Loosen~ss, leak~~e at ~
connection positIOn ~,
.I\')~~
LDeformation, damage, rust
Bend of fin, clog, leakage~' I Damage, deterioration leakage

~
L2-1069
2700 cc model
~ ~.
/
/
/~<w ~==]~
_---
\' Looseness, leakage at connection position
~~\ \-0_---..
~~
/
/ ~ ~&> \-~ ' ....../1\ Damage, deterioration leakage

I 0 ~~/~,./ (?':~ // i\
~
, I ' \
,,1 ( / \
)(~/ ~ ~~. _.~ "I~ ~

I ' /
Bend of fin, clog, I . \

~ f~l)
'I
leakage 1
11 /, I II _', I .
'l
~ "
I il~ /~'Jl, f~~
~ J
/
1,1 /
0:
: ~ 4? ~~ _
~~~.. :,. f'(

r~~:" ~ ,J~1~~~
ill ~, ~/ ~f~)
~
I
11 );
%1 1 . . . " ,~ .
/ "~/
\ / Deformation, damage, rust
Voeformation, nOise, vibration, damage
L2-1403
Fig. 7
7
2-2 ON-CAR SERVICES
RADIATOR CAP OPENING PRESSURE

1) Attach radiator cap to tester.
2) Increase pressure until tester gauge pointer stops. Radiator
cap is functioning properly if it holds the service limit pressure
for five to six seconds.
A7-025
Fig. 8
Standard pressure:
78 - 98 kPa (0.8 - 1.0 kg/cm 2 , 11 - 14 psi)
Service limit pressure:
69 kPa (0.7 kg/cm 2, 10 psi)
Fig. 9
Be sure to remove foreign matter and rust from the cap in
advance; otherwise, results of pressure test will be incorrect.
a. Engine should be off.
b. Wipe water from check points in advance.
c. Be careful to prevent cooling wlter from spurting out when
removing tester.
d. Be careful also not to deform filler neck of radiator when
installing or removing tester.
COOLANT
1) Check coolant level.
When the engine is cool, check and add coolant on reserve
tank side.
Be careful not to confuse the reserve tank cap wh ich is green
WATER LEAKAGE FROM RADIATOR
and the window washer cap which is blue.
1) • Remove radiator cap, top off radiator, and attach (1) If coolant level is close to the "LOW" mark, add
tester to radiator in place of cap. (1800 cc model) genuine SUBARU Coolant up to the "FULL" mark.
• Remove filler cap, and attach tester to thermostat (2) If reserve tank is empty, check coolant level in
cover in place of cap. (2700 cc model) radiator and first add coolant up to filler necks in radiator.
2) Apply a pressure of 157 kPa (1.6 kg/cm2, 23 psi} to Then, perform step (1).
radiator to check if:
(1) Water leaks at/around radiator.
(2) Water leaks at/around hoses or connections. On 2700 cc model, coolant filler is located on top of engine.
8
ON-CAR SERVICES 2-2
(1800 cc model) Cylinder Head Bolts

~When reserve tank is empty,
Q check radiator (1800 cc engine only)
RETORQUING
After completing engine ASSY and mounting engine on car, be

FULL sure to retighten cylinder head bolts.
LOW 1) Warm up engine.
2} After engine has cooled down, remove right and left
valve rocker covers.
3) Loosen intake manifold mounting bolts next to cylinders
L1-155
No.1 and No.3 by 60°. Do not loosen the manifold mounting
(2700 cc model) When reserve tank is empty, bolts next to cylinders No.2 and No.4.
~ check radiator.
, ~Reservetank Do not loosen the mounting bolts more than 90°, or water
To engine ~, may leak.
FULL ( ali
LOW~ 4} Loosen bolt at position CD
in Figure, and apply oil to
~~ the thread. Repeat "loosen and tighten" operation four to
five times within the 60° range for a better fit, then tighten
bolt to the specified torque.
L2-1405 ® ®
Fig. 10
®
2) Replacement work.
Refer to 1-5 "Periodic Maintenance Services". ®
®
High Tension Cords
-;/®'----CD \
INSPECTION Retightening cylinder head bolts
L2·583
Fig. 11
Check for:
1) Damage to cords, deformation, burning or rust formation
of terminals.
2) Resistance values of cords.
Unit: [kn]
Apply oil here.
~ 1800 cc model 2700 cc model
Distributor cord 2.43 - 5.67 2.43 - 5.67
#1 cord 9.87 - 23.03 10.86 - 25.33
#2 cord 2.83 - 6.61 5.67 - 13.24
#3 cord 11.21 - 26.16 11.24 - 26.23
#4 cord 2.27 - 5.29 4.52 - 10.55

Bolt loosening engle and oiling position.
#5 cord - 11.43 - 26.68
L2·584
#6 cord - 2.60 - 6.07
Fig. 12
9
2-2 ON-CAR SERVICES
6) Lower the vehicle.

Specified torque: 7) Remove the radiator fan shroud.
64 N·m (6.5 kg-m, 47 ft-Ib) (1) Disconnect the fan motor connector.
(2) Remove the bolts from the upper side of the shroud.
Tool Part No. Tool Part Name
499987200 Socket wrench (17)
5) Similarly, retighten each bolt in sequence from ® to ®

as shown in Figure.
Finally, retighten bolt CD to the specified torque without
loosening.
6) After retightening right and left cylinder head bolts,
tighten mounting bolts of intake manifolds.
Fig. 14
Oil Pump Assembly 8) Remove the alternator and V-belt.
1800 cc model
REMOVAL
1) Open the front hood.

2) Disconnect the ground cable from the battery.
3) Position the lift arm and raise the vehicle with a jack.
4) Remove the undercovers.
5) Remove the bolts from the lower side of the radiator fan
shroud.
Fig. 15
Fig. 13
10
ON-CAR SERVICES 2-2
9) Remove the oil level gauge guide and disconnect the oil
pressure gauge harness.
10} Remove the water pump pulley.
11} Remove air intake boot.
12} Attach the. STOPPER [498277000 (MT}/498497000
{AT}] to flywheel or torque converter to prevent it from turn-
ing. Remove the crank pulley.
Fig. 18
Fig. 16
(2) Remove the right timing belt.

15) Remove the crankshaft sprocket.
16) Remove the left timing belt.
(1) Loosen the two bolts which secure the tensioner.
Move the tensioner in the direction which loosens it and
13) Remove the LH, R Hand F R belt covers, in that order. temporarily tighten the bolts.
14} Remove the right timing belt.
Draw an arrow on the left and right belts with a piece of chalk
to indicate the direction of advance.
TENsrONER WRENCH_------
_ _ _ (4990070001 ~
- - L2-827
Fig. 19
i ____
....,,\--~
.-----
L2-825
Fig. 17
Be careful not to scratch the crankshaft with a tensioner

(1) Loosen the two bolts which secure the tensioner. wrench.
Move the tensioner in the direction which loosens it and
temporarily tighten the bolts. (2) Remove the left timing belt.
11
2-2 ON-CAR SERVICES
17) Remove the belt idler. 7.) Install the left and right belt covers.
8) Install the oil level gauge guide.
9) Install the water pump pulley.
10) Install the alternator and V-belt, then adjust belt tension.
11) Install the radiator fan shroud and connect the connector.
12) Fasten the canister hose, etc. to the clamps.
13) Install the timing hole plug.
15) Connect the grou nd cable to the battery.
16) Start the engine.
17) Add engine oil to the oil pan.
18) Close the front hood and release the I ift arm.
L2-828
2700 cc model
Fig, 20
REMOVAL
18) Using the CAMSHAFT SPROCKET WRENCH
(499207000), remove the left camshaft sprocket.
19) Remove the belt cover No.2 (LH) and the rear belt cover.
3) Position the lift arm and raise the vehicle with a jack.
20) Remove the oil pump ASSY.
4) Remove the bolts from the lower side of the radiator and
condenser fan shroud.
REINSTALLATION
1) Install the oil pump ASSY.
Replace the gasket with a new one.
2) Install the belt cover (RR) and the belt cover No.2 (LH).
3) Install the camshaft sprocket on the right and left cam·
shafts. Lock the camshaft using the CAMSHAFT SPROCKET
WRENCH (499207000).
4) Install the timing belt. (Refer to Chapter "2·3.")
L2·1407
Timing belts should be replaced when engine is cold. Fig. 21
5) Install the belt cover (FR) on the cylinder block. 6) Disconnect the radiator and condenser fan motor connec-
Install the belt cover seals (F Rand R R) and the belt cover tor.
plug on the belt cover (FR) in advance. 7) Remove the bolts from the upper side of the shroud.
Before installing the belt cover (F R), check that there are no
bolts, washers, etc. left in the cover.
6) Install the crank pulley.

Lock the crank pulley using the STOPPER [49827700 (MT)/
498497000 (AT) 1•
Tightening torque:
93 - 103 N·m (9.5 - 10.5 kg-m, 69 - 76 ft·lb)
Sub fan shroud
Main fan sh roud
Apply a coat of engine oil to the crank pulley bolts before
installation. L2·1408
Fig. 22
12
ON-CAR SERVICES 2-2
8) Remove the radiator fan shroud ASSY. While moving (1) Loosen the two bolts wh ich secu re the tensioner.
condenser fan shroud ASSY in the direction in which radiator Move the tensioner in the direction which loosen it and
fan shroud ASSY was installed, lift it out. temporarily tighten the bolts.
9) Remove the pulser ASSY (A/C).
10} Loosen the tension pulley lock nut to release V-belt ten-
sion. When removing V-belt, check that adjuster bolt is turned
counterclockwise fully in the direction which loosens the belt.
Fig. 25
Fig. 23
(2) Remove the right timing belt.

16) Remove the crankshaft sprocket.
'7) Remove the left timing belt.
(1) Remove idler pulley.
(2) Remove plug rubber and then remove plug screw
11) Remove the alternator, alternator bracket and tension
from belt tension adjuster lower side.
pulley (RH).
12) Remove the water pump pulley.
13) Attach the STOPPER [49827700 (MT)/498497000
(AT)] to flywheel or torque converter to prevent it from
turning. Remove the crank pulley.
14) Remove the LH, RH and CTR belt covers in that order.
15) Remove the right timing belt.
Draw an arrow on the left and right belts with a piece of chalk
to indicate the direction of advance.
Fig. 26
(3) I nsert a flat-blade screwdriver into hole on bottom of

belt tension adjuster. Turn screw clockwise to compress
rubber boot. Install BELT ADJUSTER STOPPER
(13082AAOOO), then remove belt tension adjuster.
Fig. 24
13
2-2 ON-CAR SERVICES
Water Pump Assembly

I 1800 cc model I
REMOVAL

3} Drain the coolant completely.
4) Remove the alternator and V -belt.
5} Disconnect the radiator outlet hose.
Fig. 27
(4) Remove the left timing belt.

18) Remove the oil pump ASSY.
RE INSTALLATION
1) Install the oil pump ASSY.
Replace the gasket with a new one. Fig. 28
2) Install the timing belt. (Refer to Chapter "2-3.")
Timing belts should be replaced when engine is cold.
3) Install the belt cover on the cylinder block. 6) Disconnect the water by-pass hose from the pipe.
Lock the crank pulley using the STOPPER [49827700 (MT)I
498497000 (AT)].
Tightening torque:
89 - 107 N'm (9.1 - 10.9 kg-m, 66 - 79 ft·lb)
Apply a coat of engine oil to the crank pulley bolts before

installation.

6) Install the alternator bracket, tension pulley and alterna- L2-10B1
tor. Fig. 29
7) Install V-belt, then adjust belt tension. (Refer to Chapter
"2-3. ")
8) Install the condenser and radiator fan shroud and connect
the fan motor connectors.
9) Install the pulser ASSY (A/C)' 7) Unfasten clips which secure the oil pressure switch har-
10) Connect the ground cable to the battery. ness.
11) Add engine oil to the oil pan.
8) Remove the oil level gauge guide. •
9) Remove the water pump pulley.
13) Close the front hood and release the lift arm. 10) Using the stopper, remove the crank pulley.
14
ON-CAR SERVICES 2-2
11) Disconnect the water pipe.
2700 cc model
REMOVAL

2) Disconnect the ground cable from battery.
3) Drain the coolant completely.
4) Disconnect the radiator outlet hose and air vent tube.
Water pip.,e ~r
---------- rA,---L2-1082
\----
Fig. 30
12) Remove the LH, RH and FR belt covers, in that order.

13) Remove the water pump ASSY and timing plate.
-_______ Radiator outlet hose
====---===-----------
Fig. 32
5) Remove the pulser ASSY (A/C).

6) Remove the V·belt. (Refer to Chapter 2-2 "Oil Pump
L2-1083
Assembly".)
Fig. 31 7) Remove compressor, alternator and alternator bracket.
8) Disconnect the water by-pass hose and water pipe.
REINSTALLATION
1) Install the water pump ASSY and timing plate.
2) I nstall the F R, R H and ~H belt covers.

3) Connect the water pipe.
6) Install the oil level gauge guide.
7) Clamp the oil pressure switch harness clip.
8) Connect the water by-pass hose to the pipe.
9) Connect the radiator outlet hose. Fig. 33
10) Install the alternator and V·belt.
111 Add coolant in the radiator. 9) Remove the water pump pulley.
12) Connect the ground cable to the battery.
10) Using the STOPPER [49827700 (MT)/498497000 (AT)],
13) Start the engine and check the coolant level. remove the crank pulley.
14) Close the front hood and release the lift arm. 11) Remove the LH, RH and CTR belt covers, in that order.
15
2-2 ON-CAR SERVICES
12) Remove the water pump ASSY.

RE INSTALLATION
1) Install the water pump ASSY.
2) Install the CTR, RH and LH belt covers.

3) Connect the water pipe and water by-pass hose.
6) Install alternator bracket, alternator and compressor.
7) Install V-belt, then adjust belt tension. (Refer to Chapter
L2-1415
"2-3". )
8) Install the purser ASSY (A/C).
I
Fig. 34 9) Connect the radiator outlet hose and air vent tube.
10) Add coolant in the radiator.
11) Connect the grou nd cable to the battery.
12) Start the engine and check the coolant level.
13) Close the front hood and release the lift arm.
16
ENGINE
Page
BUBARU 1800 cc 2700 cc

MECHANISM AND FUNCTION... . . . • . • . . . • • • . . . . • . •• 2 53
1988
General ...................................... . 2
Valve Mechanism ....•••.........................
SPECIFICATIONS AND SERVICE DATA ...•............
Specifications ..........................•...•...
Service Data ..............................•...•
4
6
6
7
53
56
58
58
59
-
COMPONENT PARTS ............................. . 11 63
I Cylinder Block and Oil Pan ..................•...... 11
Crankshaft and Piston .....•.•.....•............... 12
63
64
Cylinder Head and Flywheel Housing ......•............ 13 65
Camshaft and Timing Belt ......................... . 14 66
Belt Cover ..............................•••..•. 15 67
Electrical Equipment ........................•.... 16 68
SERVICE PROCEDURE ........•.••...............• 17 69
General Precautions .•...•..•......•.............. 17 69
Timing Belt and Belt Cover •.....•.....•....•..•.... 17 69
Camshaft and Valve Rocker ........................ . 22 77
Cylinder Head ..........••....••...•............ 27 81
Valve and Valve Spring ............••.•.•••.....••. 31 85
Cylinder Block ....................••••....•.•... 33 86
Crankshaft and Piston ............................ . 41 96
TROUBLESHDOTING .•.•...................•...... 48 102
Engine Trouble in General ...........•.............. 48
Engine Noise .................................. . 51
2-3 ENGINE
1 800 cc Engine
MECHANISM AND FUNCTION
General weight and compact in construction. This engine also adopts
The SUBARU XT houses a horizontally-opposed 4-cylinder, the OHC (Over-Head Camshaft) system, hydraulic lash ad-
4-stroke cycle, liquid cooled OHC gasoline engine. This well- juster, and fuel injection system, attaining easier maintenances
balanced engine, adopting a horizontally opposed piston servicing, and reliability as well as low fuel consumption, low
arrangement, is made of an aluminium alloy, and is light noise and powerful performance.
Intake valve
Lash adjuster
Oil filler duct
Lash adjuster
Valve rocker-
Camshaft
Camshaft
Rocker cover
Camshaft case Camshaft case
Exhaust valve
Oil pan~ Cylinder block
L2-1037
Fig. 1
CYLINDER BLOCK CYLINDER HEAD

1) The cylinder block, made of an aluminium alloy, is light 1) The cylinder head, made of an aluminium alloy, forms a
weight and provides good heat conduction, and is divided into part of the bath-tub type combustion chamber which features
two portions, left-side half and right-side half, due to the higher combustion efficiency.
adoption of a horizontally opposed piston arrangement. 2) The intake and exhaust ports are laid out so as to
2) The rotor housing for the oil pump is built into the minimize resistance for the intake air and exhaust gases, and
cylinder block in order to reduce the total length of the they improve suction and discharge efficiencies.
engine.
3) The cylinder liner is a cast and dry type.
2
.....
ENGINE 2-3
HEAD GASKET CRANKSHAFT
1) The cylinder head gaskets are provided with wire rings at The crankshaft is made from special wrought iron which
the bore sections in order to increase pressure- and heat- provides sturdiness. All corners of the journals are processed
resistant properties as well as an effective seal. with "deep roll" treatment.
2) The oil passage is provided with an O-ring to improve The horizontally opposed engine configuration provides
sealing. greater strength against bending and torsional stresses wh ile
reducing the total length of the crankshaft.
CAMSHAFT CASE PISTON AND PISTON RING

11 The camshaft case holds the camshaft, and is an 1) The piston is cast from aluminum alloy which features a
aluminium die-\:asting. small thermal expansion rate. Its top land is provided with
2) The oil rei ief valve for the hydraulic lash adjuster is built valve rei ief and its skirt section has an elliptical, tapered design
into the cam case. to provide heat- and wear-resistance.
The oil filler duct is mounted on the right-hand camshaft case, The shaped piston and short piston pin effectively reduce the
and the distributor on the left-hand camshaft case. weight of the piston ASSY.
3) The camshaft case has a groove all around the cylinder 2) Three piston rings are used for each piston - two com-
head mating surface, and fluid packing is filled into this groove pression rings and one oil ring.
for sealing. These piston rings have small wall thickness to reduce weight
and oi I consumption.
OIL PAN
ROCKER COVER
The oil pan incorporates a double-layer baffle plate to stabilize
1) The rocker cover is a light-weight and compact aluminium the oil surface, and also improves rigidity along with reducing
die-casting. noise.
2) This rocker cover adopts a float-supporting system with a
rubber ring type gasket and an oil seal washer to reduce the
noise level.
3
2-3 ENGINE
Valve Mechanism
The valve mechanism adopts a timing belt driven over-head
camshaft (OHC) type. This OHC features reduced inertia mass
of the valve mechanism, and superior valve follow-up per-
formance from low to high engine speeds. The valve mecha-
nism is provided with the hydraulic lash adjusters for
maintenance-free and noiseless valve operation.
Camshaft RH
Intake valve
Camshaft sprocket
Camshaft LH
Camshaft sprocket
Timing belt LH
Idler
L2-788
Fig. 2
CAMSHAFT VALVE ROCKER AND VALVE LASH

1) The camshafts are made of special cast iron, and are ADJUSTER
completely treated with Lubrite except for the bearing 1) The rocker arms are special steel forgings having great
portions to improve initial fitting to the rocker arms. The strength and rigidity. Each arm is fitted with a sintered metal
cam rubbed surface is chilled to increase wear-resistance. tip to improve wear resistance.
2) The cam profile is specially designed for this OHC type, 2) The hydraulic valve lash adjuster eliminates the need for
and features higher output and less fuel consumption. valve clearance adjustment.
3) The cam base circle has an oil hole for lubricating the 3) The rocker arms and valve lash adjusters are common
rocker arm. The distributor drive gear is mounted on the between intake and exhaust valves.
left-hand camshaft.
4
ENGINE 2-3
Lash adjuster
Sintered alloy chip
L2-789
Fig. 3
VALVE AND VALVE SPRING

1) The valve has a small valve stem diameter [7 mm (0.28 in)
dia_l to reduce the valve weight. The variable pitch valve
spring is adopted to improve valve follow-up performance at
high engine speeds_
2) The valve has a large valve head diameter to increase
engine output.
TIMING BELT, TENSIONER AND SPROCKET

1) Two timing belts drive the left and right-hand camshafts.
The timing belt is composed of a core featuring great strength
1 Timing belt RH 5 Tensioner RH
and less elongation, canvas (tooth face portion) having superior 2 Timing belt LH 6 Tensioner LH
wear resistance, and highly heat-resistant rubber. 3 Crankshaft sprocket 7 Oil pump sprocket
2) The timing belt has special round teeth featuring positive 4 Camshaft sprocket 8 Idler
L2-996
engagement with sprocket teeth and smooth and low-noise
operation. The crankshaft sprockets, oil pump sprocket and Fig. 4
idler are made of sintered alloy_
3) The camshaft sprockets are made of sheet metal, and are TIMING BELT COVER
common between right and left. 1) The resin-mold timing belt cover, consisting of six pieces,
4) A grease-sealed type ball bearing is used in the tensioner. is used to protect the timing belt against dust and water.
The tensioner spring gives the timing belt an initial tension 2) Each of the left-hand and right-hand side covers has an
which is adjustable by loosening the tensioner mounting bolt. access hole for belt tensioner adjustment.
5
2-3 ENGINE
SPECIFICATIONS AND SERVICE DATA

SPECIFICATIONS
--------
Type
Valve arrangement
MPFI
Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine
Over-head camshaft type
Bore x Stroke mm (in) 92 x 67 (3.62 x 2.64)
Piston
cm 3 (cc, cu in) 1,781 (1,781,108.68)
displacement
Compression ratio 9.5
Compression pressure
1,157 (11.8,168)
(at 350 rpm) kPa (kg/cm 2 , psi)
UJ Number of piston rings Pressure ring: 2, Oil ring: 1

z
t!J Opening 16° BTDC
z Intake valve timing
UJ
Closing 60° ABDC
Opening 60° BBDC

Exhaust valve timing
Closing 16° ATDC
Idling speed
MT: 700 ± 100
( At neutral ) rpm
AT: 800 ± 100
(or N) or P position
,
Firing order 1~3-+2-+4
MT: 20°/700
Ignition timing BTDC/rpm
AT: 20°/800
6
ENGINE 2-3
SERVICE DATA
"0
(tI
Q) Surface warpage limit 0.05 mm (0.0020 in)
.r:.
...
Q) Surface grinding limit 0.3mm (0.012 in)
"0
C Standard height 90.6 mm (3.567 in)
>
U
....
Q) Refacing angle 90°
VI
Q)
>
Wear limit 0.5mm (0.020 in)
(tI
> Contacting width Intake 1.2 - 1.8 mm (0.047 - 0.071 in)

Exhaust 1.5 - 2.0 mm (0.059 - 0.079 in)
~ ~ Inner diameter 7.000 -7.015 mm (0.2756 - 0.2762 in)

';;'~ Protrusion above head 17.5 - 18.5 mm (0.689 - 0.728 in)
Head edge thickness STD Intake & Exhaust 1.3 mm (0.051 in)
Limit 0.8 mm (0.031 in)
Stem diameter Intake 6.950 - 6.965 mm (0.2736 - 0.2742 in)
Exhaust 6.945 - 6.960 mm (0.2734 - 0.2740 in)
Stem oil clearance STD Intake 0.035 - 0.065 mm (0.0014 - 0.0026 in)
Exhaust 0.040 - 0.070 mm (0.0016 - 0.0028 in)
Limit 0.15 mm (0.0059 in)
Overall length Intake & Exhaust 107.58 mm (4.2354 in)
Free length Outer spring 50.7 mm (1.996 in)

Inner spring 50.3 mm (1.980 in)
Squareness Outer spring 2.2mm (0.087 in)
Tension/spring height Outer spring 203.0 - 238.3 N
C'I (20.7 - 24.3 kg, 45.6 - 53.6 Ib)/
C
41.5 mm (1.634 in)
C.
'" 502.1 - 576.7 N
~
(tI
(51.2 - 58.8 kg, 112.9 - 129.7 Ib)/
> 31.5 mm (1.240 in)
I nner spring 88.3 - 101.0 N
(9.0 -10.3 kg, 19.8 - 22.7Ib)/
38.5 mm (1.516 in)
201.0 - 230.5 N
(20.5 - 23.5 kg, 45.2 - 51.8 Ib)/
28.5 mm (1.122 in)
STD: Standard
7
2-3 ENGINE
~
Outer diameter 21.380 - 21.393 mm (0.8417 - 0.8422 in)
VI
co ....
- CIl Cylinder head adjuster hole 1.0. 21.413 - 21.470 mm (0.8430 - 0.8453 in)
CIl+'
.2!::s
co .- Adjuster-to-hole clearance STD 0.020 - 0.090 mm (0.0008 - 0.0035 in)
>~ Limit 0.1 mm (0.004 in)
Surface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)
Surface grinding limit 0.4 mm (0.016 in)
Metal housing 1.0. 59.000 - 59.018 mm (2.3228 - 2.3235 in)
~ Oil seal hole 1.0. Front and center 59.000 - 59.030 mm (2.3228 - 2.3240 in)
u
0
J5 Rear 93.000 - 93.035 mm (3.6614 - 3.6628 in)
....
CIl Cylinder bore STD 91.985 - 92.015 mm (3.6214 - 3.6226 in)
'0
c Taper limit (0.0020 in)
0.050 mm
>-
u Out-of roundness limit 0.050 mm (0.0020 in)
Piston clearance STD 0.015 - 0.035 mm (0.0006 - 0.0014 in)
Limit 0.060 mm (0.0024 in)
Enlarging (boring) lim it 0.3 mm (0.012 in)
Outer diameter STD 91.970 - 91.980 mm (3.6209 - 3.6213 in)

c
0 0.25 mm (0.0098 in) OS 92.220 - 92.230 mm (3.6307 - 3.6311 in)
+'
c:
VI
0.50 mm (0.0197 in) as 92.470 - 92.480 mm (3.6405 - 3.6409 in)
Standard inner diameter of piston pin hole 20.999 - 21.009 mm (0.8267 - 0.8271 in)

c
a. Standard clearance between piston pin and hole in piston 0.001 - 0.015 mm (0.00004 - 0.00059 in)
c
+'
0 Degree of fit Piston pin must be fitted into position with
VI
c: thumb at 20°C (68°F).
Standard clearance between piston pin and hole in connecting rod 0- 0.022 mm (0 - 0.0009 in)
Width Top ring 1.17 - 1.19 mm (0.0461 - 0.0469 in)

Second ring 1.47 -1.49 mm (0.0579 - 0.0587 in)
Oil ring Combination ring
Rad ial wall th ick ness Top ring 3.2 - 3.4 mm (0.126 - 0.134 in)
Second ring 3.6 - 3.8 mm (0.142 -0.150 in)
Cl Piston ring gap Top & Second ring STD 0.2 - 0.35 mm (0.0079 - 0.0138 in)
...c Limit 1.5 mm (0.059 in)
c
0
+'
VI Oil ring STD 0.3 - 0.9 mm (0.012 - 0.035 in)
a::: Limit 2.0 mm (0.079 in)
Clearance between piston ring and Top ring STD 0.040 - 0.080 mm (0.0016 - 0.0031 in)
piston ring groove Limit 0.15 mm (0.0059 in)
Second ring STD 0.030 - 0.070 mm (0.0012 - 0.0028 in)
Limit 0.15 mm (0.0059 in)
Oil ring STD Omm (0 in)
Limit Omm (0 in)
STD: Standard OS: Oversize
8
ENGINE 2-3
Oistance between big end and small end hole 116.95 - 117.05 mm (4.6043 - 4.6083 in)
"0 Crank pin bore diameter 48.000 - 48.019 mm (1.8898 - 1.8905 in)
...0 Piston pin bore diameter 21.000 - 21.016 mm (0.8268 - 0.8274 in)
CI
t:
'B Q)
Width at big end 19.35 - 19.43 mm (0.7618 - 0.7650 in)
t: Side clearance STO 0.070 - 0.330 mm (0.0028 - 0.0130 in)
t:
8 Limit 0.4 mm (0.016 in)
Bend twist per 100 mm (3.94 in) in length Limit 0.10 mm (0.0039 in)
Thickness at center portion STO 1.485 - 1.490 mm (0.0585 - 0.0587 in)

CICI
t: t:
0.03 mm (0.0012 in) US 1.500 - 1.505 mm (0.0591 - 0.0593 in)
.~ '':
(,.)
Q)
~
Q)
0.05 mm (0.0020 in) US 1.510 -1.515 mm (0.0594 - 0.0596 in)
t:.o
t:'8
0.25 mm (0.0098 in) US 1.610 - 1.615 mm (0.0634 - 0.0636 in)
8 .. Oil clearance STO 0.010 - 0.054 mm (0.0004 - 0.0021 in)
Limit 0.10 mm (0.0039 in)
Bend limit 0.035 mm (0.0014 in)

Thrust clearance STO 0.010 - 0.095 mm (0.0004 - 0.0037 in)
Limit 0.30 mm (0.0118 in)
Crank journal outer diameter Front STO 54.957 - 54.972 mm (2.1637 - 2.1642 in)
0.03 mm (0.0012 in) US 54.927 - 54.942 mm (2.1625 - 2.1631 in)
0.05 mm (0.0020 in) US 54.907 - 54.922 mm (2.1617 - 2.1623 in)
0.25 mm (0.0098 in) US 54.707 - 54.722 mm (2.1538 - 2.1544 in)
Center sro 54.954 - 54.970 mm (2.1635 - 2.1642 in)
0.03 mm (0.0012 in) US 54.924 - 54.940 mm (2.1624 - 2.1630 in)
0.05 mm (0.0020 in) US 54.904 - 54.920 mm (2.1616 - 2.1622 in)
0.25 mm (0.0098 in) US 54.704 - 54.720 mm (2.1537 - 2.1543 in)
Rear STO 54.955 - 54.970 mm (2.1636 - 2.1642 in)
0.03 mm (0.0012 in) US 54.925 - 54.940 mm (2.1624 - 2.1630 in)
0.05 mm (0.0020 in) US 54.905 - 54.920 mm (2.1616 - 2.1622 in)
.....
'+-
~
0.25 mm (0.0098 in) US 54.705 - 54.720 mm (2.1537 - 2.1543 in)
.r.
~ '"t: Width at center portion 25.970 - 26.015 mm (1.0224 -1.0242 in)
u
...
('Q
Oil clearance Front & Rear STO 0.003 - 0.036 mm (0.0001 - 0.0014 in)
Limit 0.055 mm (0.0022 in)
Center STO 0.008 - 0.027 mm (0.0003 - 0.0011 in)
Limit 0.045 mm (0.0018 in)
Out-of roundness 0.030 mm (0.0012 in) or less
Grinding limit 0.250 mm (0.0098 in)
Crankpin outer diameter STO 44.995 - 45.010 mm (1.7715 - 1.7720 in)
0.03 mm (0.0012 in) US 44.965 - 44.980 mm (1.7703 - 1.7709 in)
0.05 mm (0.0020 in) US 44.945 - 44.960 mm (1.7695 - 1.7701 in)
0.25 mm (0.0098 in) US 44.745 - 44.760 mm (1.7616 - 1.7622 in)
Width 19.50 -19.68 mm (0.7677 - 0.7748 in)
Oil clearance STO 0.010 - 0.054 mm (0.0004 - 0.0021 in)
Limit 0.10 mm (0.0039 in)
STO: Standard OS: Oversize US: Undersize
9
2-3 ENGINE
Thickness Front & Rear sro 2.015 - 2.019 mm (0.0793 - 0.0795 in)
c:n 0,03 mm (0.0012 in) US 2,030 - 2,034 mm (0.0799 - 0.0801 in)
c:
.;:
C'CI
0.05 mm (0.0020 in) US 2.040 - 2.044 mm (0.0803 - 0.0805 in)
Q)
.0 0.25 mm (0.0098 in) US 2.140 - 2.144 m m (0.0843 - 0.0844 in)
~
C'CI
.r; Center STO 2.019 - 2.022 mm (0.0795 - 0.0796 in)
In
~
c: 0.03 mm (0.0012 in) US 2.034 - 2.037 mm (0.0801 - 0.0802 in)
...
u
C'CI
0.05 mm (0.0020 in) US 2.044 - 2.047 mm (0.0805 - 0.0806 in)
0.25 mm (0.0098 in) US 2.144 - 2.147 m m (0.0844 - 0.0845 in)
Width Center STO 25.920 - 25.960 mm (1.0205 - 1.0220 in)

Thrust clearance 0.030 - 0.260 mm (0.0012 - 0.0102 in)
Cam lobe height STO 39.75 - 39.85 mm (1.5650 -1.5689 in)
.::C'CI Wear limit 0.15 mm (0.0059 in)

.r; Cam journal outer diameter Front 37.964 - 37.980 mm (1.4946 -1.4953 in)
lIS
e
a Center
Rear
48.464 - 48.480 mm (1.9080 - 1.9087 in)
47.964 - 47.980 mm (1.8883 - 1.8890 in)
LH distributor 38.964 - 38.980 mm (1.5340 - 1.5346 in)
Limit 0.070 mm (0.0028 in)
Camshaft journal inner diameter Front (camshaft support inner 38.000 - 38.018 mm (1.4961 - 1.4968 in)
Q)
diameter)
'"C'CI
(J
+J
'+-
Center 48.500 - 48.518 mm (1.9094 - 1.9102 in)
C'CI
.r; Rear 48.000 - 48.018 mm (1.8898 - 1.8905 in)
'"
E
C'CI Distributor 39.000 - 39.018 mm (1.5354 - 1.5361 in)
u
Camshaft support depth of spigot 19.00 - 19.08 mm (0.7480 - 0.7512 in)
~ 1.0. 38.000 - 38.018 mm (1.4961 - 1.4968 in)

C'CI+-'
.r;'"
ec'
'" 0 0.0. 57.971 - 59.990 mm (2.2823 - 2.3618 in)
8~ Height of spigot 14.95 -15.00 mm (0.5886 - 0.5906 in)
S1D: Standard US: Undersize
10
ENGINE 2-3
COMPONENT PARTS
Cylinder Block and Oil Pan
1 Water by-pass hose
2 Service hole plug
3 Oil seal (Rear)
4 Oil separator cover gasket
5 Oil separator cover
6 Main gallery plug
7 Cylinder block O-ring
8 Back-up ring
9 Service hole plug
10 Oil pan gasket
11 Oil pan
12 Oil drain plug
13 Oil strainer @
14 O-ring
15 Oil strainer stay
16 Service hole plug
n Front engine hanger
18 Cylinder block plug
19 Oil seal (Front)
20 O-ring
22 Oil level gauge guide
23 Oil level gauge
24 Water pump pulley
25 Pulley cover
26 Water pump ASSY
27 Gasket
28 Timing plate
29 Seal
30 Oil pump ASSY
31 Oil pressure gauge
32
33
""
"
Tightening torque N·m (kg-m, ft-Ib)

T1: 4.4 - 5.4 (0.45 - 0.55, 3.3 - 4.0)
T2: 62 -76 (6.3 - 7.7, 46 - 56)
T3: 44 - 49 (4.5 - 5.0, 33 - 36)
T4: 23 - 26 (2.3 - 2.7, 17 - 20)
T5: [M10] 39 - 47 (4.0 - 4.S, 29 - 35)
[MSJ 23 - 26 (2.3 - 2.7,17 - 20)
T6: 9.1 - 10.5 (0.93 -1.07, 6.7 -7.7)
T7: 22 - 27 (2.2 - 2.S, 16 - 20)
Fig. 5 L2-1064
11
2-3 ENGINE
Crankshaft and Piston
1 Reinforcement 12 Oil ring

2 Drive plate 13 Crankshaft bearing (Front and rear) Tightening torque N·m (kg-m, ft-Ib)
3 Flywheel 14 Crankshaft bearing (Center)
T1: 69 - 75 (7.0 -7.6,51 - 55)
4 Ball bearing 15 Crankshaft pulley
5 Circlip
T2: 39 - 42 (4.0 - 4.3, 29 - 31)
16 V·belt
6 Piston pin 17 Crankshaft sprocket CP T3: 89 - 107 (9.1 - 10.9,66 -79)
7 Connecting rod 18 Crankshaft sprocket No.2
8 Connecting rod bearing 19 Woodruff key
9 Piston 20 Connecting rod cap
10 Top ring 21 Connecting rod cap bolt
11 Second ring 22 Connecting rod bearing
23 Crankshaft
Fig. 6 L2-1038
12
ENGINE 2-3
Cylinder Head and Flywheel Housing
1 Cylinder head (RH)

2 Cylinder head gasket
3 Engine hanger
4 Timing hole plug
5 Flywheel housing
6 Cylinder head (LH)
7 Cylinder head gasket
8 Exhaust valve
9 Intake valve
10 Intake valve oil seal
11 Exhaust valve oil seal
12 Valve lash adjuster
13 Valve rocker
14 Valve inner spring
15 Valve outer spring
16 Valve spring retainer
17 Valve spring retainer key
18 Housing cover

T1: 46 - 54 (4.7 - 5.5, 34 - 40)
/
T2: 34 - 40 (3.5 - 4.1,25 - 30)
T3: 60 - 68 (6.1 - 6.9, 44 - 50)
T4: 22 - 27 (2.2 - 2.8, 16 - 20)
T5: 17.2 - 20.-1 (1.75 - 2.05, 12.7 - 14.8)
L2-1276
Fig. 7
13
2-3 ENGINE
Camshaft and Timing Belt

1 Oil filler cap
2 Oil filler duct
3 Camshaft case (RH)
4 O·ring
5 Camshaft support
6 Timing belt (RH)
7 Oil seal
8 Camshaft sprocket
9 Camshaft (R H)
10 Oil relief valve
11 Oil relief spring
12 Oil relief pipe
13 Oil rei ief plug
14 Valve rocker cover gasket (RH)
15 Valve rocker cover (RH)
16 Camshaft case (LH)
17 Valve rocker cover gasket (LH)
18 Valve rocker cover (LH)
19 Distributor drive gear
20 Woodruff key
21 C<Jmslwft (LH)
22 Cilmshaft sprocket
23 Timing belt (LH)
24 Belt idler
25 Tensioner NO.2
26 Tensioner spring
27 Tensioner
• 28 Tensioner spring

T1: 17.2 - 20.1 (1.75 - 2.05, 12.7 - 14.81
T2: 23 - 26 (2.3 - 2.7,.17 - 20)
T3: 4.4 - 5.4 (0.45 - 0.55, 3.3 - 4.0)
T4: 9.1 - 10.5 (0.93 - 1.07,6.7 -7.7)
T5: 39 - 47 (4.0 - 4.8, 29 - 35)
T6: 6 - 7 (0.6 - 0.1, 4.3 - 5.11
L2-575
Fig. 8
14
ENGINE 2-3
Belt Cover
1 Belt cover spacer

2 Belt cover spacer No.2
3 Belt cover No.2 (RH)
4 Belt cover mount
5 Belt cover seal No.2 (RH)
6 Belt cover seal (RH)
7 Belt cover seal No.3 (LH)
8 Water pump seal
9 Belt cover seal (LH)
10 Belt cover (RR)
12 Belt cover seal (F R)
13 Belt cover seal (RR)
15 Belt cover No.2 (LH)
16 Belt cover (LH)
17 Belt cover plug
18 Belt cover (FR)
19 Belt cover (RH) Tightening torque N·m (kg-m, ft-Ib)
T: 4.4 - 5.4 (0.45 - 0.55,3.3 - 4.0)
L2-1277
Fig. 9
15
2-3 ENGINE
Electrical Eq ulpment
·
c.
J
(
1 Sp ark plug cord 1

2
3 Spark plug cord 2
4 Spark plug cord 3
5 S~ark plug cord 4
6 Distributor cord
Ignition coil
7 Distributor
8 Spark plug
9 Cover
10 Altern ator
11 starter bracket
12 Alternator
13 Nut plate
14 Ad·Justing bar
Tightening
T 1: 18torq ue (1N·m (k g-m, ft-Ib)
_ 24
8
T2: 36 _ 42 (3. - 2.4, 13 - 17)
7
T3: 16 _ 22 (1. -4.3,27 -31)
__ .6 - 2.2, 12 - 16)
L2-1278
Fig. 10
16
ENGINE 2-3
SERVICE PROCEDURE
General Precautions
• Before disassembling engine, install ENGINE STAND
499817100 x 2.
• All parts should be thoroughly cleaned, paying special
attention to the engine oil passages, pistons and bearings.
• Rotating parts and sliding parts such as piston, bearing and
gear should be coated with oil prior to ASSY.
• Be careful not to let oil, grease or coolant contact the
timing belt and clutch disc.
• All removed parts, if to be reused, should be reinstalled in
the original positions and directions.
L2-1042
• Gaskets and lock washers must be replaced with new ones.
I Liquid gasket should be used where specified to prevent

leakage.
Fig. 12
• Bolts, nuts and washers should be replaced with new ones

as required.
• Even if necessary inspections have been made in advance,
proceed with ASSY work while making rechecks.
7) Remove belt covers LH, RH and FR.
8) Removing timing belt
(1) Loosen tensioner mounting bolts on #1 cylinder by
1/2 turn.
(2) With tensioner fully turned to slacken belt, tighten
mounting bolts.
Timing Belt and Belt Cover
REMOVAL
1) Loosen water pump pulley mounting nuts or bolts.

2) Loosen two alternator mounting bolts, and detach V·belt.
[Except air conditioner equipped model]
3) Remove water pump pulley and pulley cover.
4) Disconnect lead from oil pressure switch.
6) Remove oil level gauge guide together with gauge.
6) Remove crankshaft pulley. To lock crankshaft, use
FLYWHEEL STOPPER [manual transmission model] or
DR IVE PLATE STOPPE R [automatic transmission model].
Fig. 13
(3) Mark rotating direction of timing belt, then remove

belt.
(4) Loosen tensioner No.2 mounting bolts on #2
cylinder by 1/2 turn.
(5) With tensioner fully rotated to slacken belt by using
TENSIONER WRENCH, tighten tensioner mounting bolts.
Cover TENSIONER WRENCH clamping tips with a rubber

hose or waste cloth to prevent crankshaft or pulley from being
Fig. 11 damaged.
17
2-3 ENGINE
a. Be careful not to let oil, grease or coolant contact the belt.
Remove quickly and thoroughly if this happens.
b. Do not bend the belt sharply. [The bending radius must be
greater than 60 mm (2.36 in).]
c. When replacing belt, be sure to replace both belts as a
matched set.
Fig. 14 60mm
(2.36 in)
(6) Remove crankshaft sprocket.

(7) Remove timing belt after marking rotating direction
of belt.
L2·176
(8) Remove crankshaft sprocket No.2.
9) Remove tensioner and tensioner No. 2 together with ten- Fig. 16
sioner spring.
10) Remove belt idler.
11) Remove camshaft sprockets by using CAMSHAFT
SPROCKET WRENCH.
TIMING BELT TENSIONER

1) Check tensioner roller for smooth rotation. Replace roller
if noise or excessive play is noted.
2) Measure the out·of·squareness of tensioner roller H. If it
exceeds 0.5 mm (0.020 in), replace roller.
Fig. 15
12) Remove right-hand belt cover No.2, left-hand belt cover

No.2 and belt cover R R.
L2-177
Fig. 17
INSPECTION
TIMING BELT
1) Check timing belt teeth for breaks, cracks, and wear.
If any fau It is found, replace belt. BELT IDLER
2) Check the condition of back side of belt; if any crack is Check idler for smooth rotation. Replace if noise or excessive
found, replace belt. pJ.ay is noted.
18
ENGINE 2-3
INSTALLATION
1) Install belt cover seal LH No.3 to cylinder block.

2) Install belt cover LH seal, belt cover No.4 LH seal, and
belt cover mount to belt cover RR, then install to cylinder
block.
Tightening torque:
4.4 - 5.4 N·m (0.45 - 0.55 kg·m, 3.3 - 4.0 ft·lb)
3) Install belt cover No.2 LH seal and belt cover mounts to

belt cover No.2 LH, then install to cylinder head and camshaft
case.
Fig. 19
Tightening torque:
4.4 - 5.4 N·m (0.45 - 0.55 kg·m, 3.3 - 4.0 ft·lb)
4) Install belt cover RH seal, belt cover No.2 RH seal, and

7} Installing tensioner No.2
belt cover mounts to belt cover No.2 RH, then install to
(1) Attach tensioner spring to tensioner No.2, then
cylinder head and camshaft case.
install the tensioner No.2 to cylinder block LH. Tighten
bolts temporarily by hand.
Tightening torque:
(2) Attach tensioner spring to bolt, tighten bolt @, then
4.4 - 5.4 N'm (0.45 - 0.55 kg·m, 3.3 - 4.0 ft-Ib)
loosen 1/2 turn.
(3) Raise tensioner No.2 using TENSIONER WRENCH
5) Install camshaft sprockets to right and left camshafts.
(499007000) until it stops, then tighten bolt @ tem·
To lock camshaft, use CAMSHAFT SPROCKET WR ENCH.
porarily.
Tighten bolts gradually in two or three steps until the specified
torque is attained.
Cover the tip of tensioner wrench with a rubber hose or waste
cloth to prevent crankshaft or pulley from being damaged.
Tightening torque:
9.1 - 10.5 N·m (0.93 -1.07 kg-m, 6.7 -7.7 ft·lb)
Fig. 20
Fig. 18
6) Installing tensioner
(1) Attach tensioner spring to tensioner, then install to 8} Install belt idler to cylinder block, using care not to turn
cylinder block RH. Tighten bolts temporarily by hand. over seal.
(2) Attach tensioner spring to bolt, tighten bolt @, and
then loosen 112 turn. Tightening torque:
(3) Push down tensioner until it stops, then tighten 39 - 47 N·m (4.0 - 4.8 kg-m, 29 - 35 ft-Ib)
temporarily bolt @.
19
2-3 ENGINE
9) Install timing belt. (4) Align timing mark on camshaft sprocket LH with
(1) Install sprocket No.2 and sprocket to crankshaft. notch in belt cover.
Sprocket No.2 can be identified by the absence of dowel pin.
L2-494
Fig. 24
Fig. 2-1 (5) Attach timing belt No.2 to crankshaft sprocket

No.2, oil pump sprocket, belt idler, camshaft sprocket, in
,~. that order, avoiding downward slackening of the belt.
_;""$ (2) Install crankshaft pulley to crankshaft, and tighten
bolt temporarily.
Timing belt No.2
Crankshaft pulley
L2-1050
~____________________________________
L2_-_10_4~7 F~25
Fig. 22
(6) Loosen tensioner No.2 tightening bolt @ by 1/2
turn to apply tension to belt.
(3) Align the center of three lines scribed on the flywheel
(7) Push timing belt by hand to ensure smooth move·
with timing mark on flywheel housing.
ment of tensioner.
Fig. 23 Fig. 26
20
ENGINE 2-3
(8) Apply the specified torque to camshaft sprocket in
Notch
cou"nterclockwise direction using BE L T TENSION
WRENCH. While applying torque, tighten tensioner No.2 Timing
bolt @ temporarily, then tighten bolt © temporarily. mark
When torquing sprocket, be extremely careful not to apply

excessive force to it. Excessive belt tension will greatly reduce
belt life.
Belt tension Torque to cam sprocket
147-245N 24 - 25 N·m
(15 - 25 kg, 33 - 55 Ib) (2.4 - 2.6 kg.m, 17 - 19 ft-Ib) Fig. 28
"
(13) Attach timing belt to crankshaft sprocket and cam·
shaft sprocket, avoiding slackening of belt on the upper
side.
L2·1053
(14) Loosen tensioner bolt @ 1/2 turn to apply tension

to belt.
(9) Tighten bolt @ and bolt ©, in that order, to the (15) Push timing belt by hand to ensure smooth ten-
specified torque. sioner movement.
Tightening torque:
17.2 - 20.1 N'm (1.75 - 2.05 kg·m, 12.7 - 14.8 ft·lb)
(10) Ascertain that flywheel timing mark and camshaft

sprocket LH timing mark are in their normal positions.
(11) Turn crankshaft one turn clockwise from the posi-
tion where timing belt No.2 was installed, and align the
center of three lines scribed on the flywheel with timing
mark on flywheel housing.
(12) Align timing mark on camshaft sprocket RH with
the notch in belt cover.
Fig. 30
21
2-3 ENGINE
(16) Apply the specified torque (same as camshaft 11) Install belt covers LH and RH.
sprocket LH) to camshaft sprocket RH in counterclock- 12) Insert crank pulley to crankshaft using FLYWHEEL
wise direction using BELT TENSION WRENCH. While STOPPER (498277000) [manual transmission modelJ or
applying torque, tighten tensioner No.2 bolt @ tem· DR IVE PLATE STOPPE R (498497000) [automatic transmis·
porarily, then tighten bolt ® temporarily. sion model) to lock crankshaft.
Tightening torque:
89 - 107 N· m (9.1 - 10.9 kg·m, 66 - 79 ft·lb)
13) Install water pump pulley and pulley cover to water pump
ASSY. and tighten nuts temporarily.
14) Install oil level gauge and gauge guide. Apply engine oil to
O·ring beforehand.
15) Connect lead to oil pressure switch.
16) Inst~11 V·belt and apply proper tension to the belt.
17) Tighten water pump pulley mounting nuts or bolts to the
specified torque.
Tightening torque:
Fig. 31 9.1 -10.5 N·m (0.93 -1.07 kg·m, 6.7 -7.7 ft·lb)
(17) Tighten bolt @ and bolt ®, in that order, to the

specified torque.
Tightening torque:
17.2 - 20.1 N·m (1.75 - 2.05 kg·m, 12.7 - 14.8 ft·lb)
(18) Make sure that flywheel timing mark and camshaft

sprocket RH timing mark are in their normal positions.
(19) Remove crankshaft pulley.
Do not remove sprocket with crankshaft pulley.
10) Install belt cover FR seal, belt cover RR seal, and belt
cover plug to belt cover FR. then install belt cover FR to
cylinder block.
Before installing belt cover, ensure that no foreign matter such

as nut or washer is in it.
Camshaft and Valve Rocker

REMOVAL
1) Removing distributor
(1) Disconnect spark plug cords from distributor.
(2) Remove distributor by removing mounting bolts.
2) Remove timing belt. belt cover and related parts. (Refer
to "Timing Belt and Belt Cover".)
3) Remove water pipe.
4) Remove oil filler duct.
Fig. 32 5) Remove PCV hoses from rocker cover.
22
ENGINE 2-3
6) Remove valve rocker covers and gaskets.
7) Remove camshaft cases, camshaft support, and camshaft
as a unit.
When removing camshaft case, valve rockers may come off.

To prevent them from being damaged, be sure to place waste
cloth or rubber mat under cylinder head.
L2·471
Fig. 35
3) Remove oil relief plug, then remove oil relief pipe, relief
valve spring, and relief valve.
Fig. 33
Relief valve
8) Remove valve lash adjusters from cylinder head.
a. Do not lay down removed adjusters; keep them erect.

b. Retain removed valve rockers and adjusters in the order of
"t:A:';O' ~ Oil relief pipe
Plug
their removal so that they can be reinstalled correctly.
L2-472
Fig. 36
INSPECTION
CAMSHAFT
1) Measure the bend, and repair or replace if necessary.
Limit:
0.025 mm (0.0010 in)
-1A-"-A~
8 ~ ~ rvalve rocker
a fj B fj ~ L2-149
Fig. 34
DISASSEMBLY
1) Remove camshaft support. L2-481
2) Remove camshaft. Fig. 37
23
~." (":(-
2-3 ENGINE
2) Check journal for damage and wear. Replace if faulty.
Item Front Center Rear LH distributor
Cam case journal hole 38.000 - 38.018 mm 48.500 - 48.518 mm 48.000 - 48.018 mm 39.000 - 39.018 mm
I.D. (1.4961 - 1.4968)*1 (1.9094 - 1.9102 in) (1.8898 - 1.8905 in) (1.5354 - 1.5361 in)
37.964 - 37.980 mm 48.464 - 48.480 mm 47.964 - 47.980 mm 38.964 - 38.980 mm

Camshaft journal 0.0.
(1.4946 -1.4953 in) (1.9080 -1.9087 in) (1.8883 - 1.8890 in) (1.5340 - 1.5346 in)
Clearance at Standard 0.020 - 0.054 mm (0.0008 - 0.0021 in)

journal 0.070 mm (0.0028 in)
Limit
* 1: Camshaft support I.D.
~".:'':~:ft Camshaft
6m'h'ftC'~
i Front i r---H--l----l
--r-----+,- t - - -++---+- -+--+---+- -+---+ *--
D
I
I
,
I
Center
uC
Rear Distributor (LH)
[p o
I
Center Rear Distri-

butor
[j --'----t---d U
(LH)
L2-1085
Fig. 38
3) Check cam face condition; remove minor faults by

grinding with oil stone. Measure the cam height H; replace if Identification mark A
the limit has been exceeded.
Identification mark C
Identification mark B
L2-993
Fig. 39
Identification Identification Identification Height H Wear limit

mark A mark B mark C mm (in) mm (in)
A 39.80 ± 0.05
0 1 0.15 (0.0059)
(1.5669 ± 0.0020)
24
ENGINE 2-3
4) Measure backlash between distributor drive gear and
distributor driven gear. If the limit is exceeded, replace
ASSEMBLY
distributor drive gear.
1) Press-fit oil seal into camshaft support by using
Backlash: INSTALLER (498037000), then attach O-ring.
Standard 2) Install oil relief valve, relief valve spring, oil relief pipe,
0.015 - 0.126 mm (0.0006 - 0.0050 in) and oil relief plug to camshaft case.
Limit
0.180 mm (0.0071 in) Tightening torque:
23 - 26 N·m (2.3 - 2.7 kg-m, 17 - 20 ft·lb)
5) Replace gear using a press and CAMSHAFT HOLDER
(498027000). 3) Install woodruff key to camshaft, then press-fit distributor
drive gear by using CAMSHAFT HOLDER (498027000).
4) Insert camshaft into camshaft case, and install camshaft
support.
VALVE ROCKER
If cam or valve contact surface of valve rocker is worn or Tightening torque:
dented, repair by removing the minimum necessary amount. 5.9 - 6.9 N·m (0.60 - 0.70 kg-m, 4.3 - 5.1 ft-Ib)
If worn heavily, replace valve rocker.
VALVE LASH ADJUSTER

1) With adjuster set in vertical position, push adjuster pivot
quick and hard by hand.
If pivot is depressed more than 0.5 mm (0.020 in), put INSTALLATION
adjuster in a container filled with light oil, and move plunger
up and down until the depression is less than 0.5 mm 1) Insert valve lash adjusters into cylinder head.
(0.020 in).
Be sure to insert each valve lash adjuster to its original
position. ..\.~ ':,
Ai
.ji~ ~
2) Apply grease to spherical surface and sliding SUrfaC(l~f
each valve rocker, then secure valve rockers to the respective
valve adjusters and valves.
Be sure to apply grease; otherwise, valve rocker will drop off.
...-1-- Valve lash adjuster
L2-482
Fig. 40
2) If pivot is depressed more than 0.5 mm (0.020 in) even

after repeating the above procedure, replace adjuster.
The new adjuster is provided with a pin which must be L2·806
removed before using. Fig. 41
25
2-3 ENGINE
3) Install D-ring to camshaft case by setting camshaft so that 6) Install PCV hoses.
camshaft straight pin is oriented as shown. 7) Install oil filler duct.
8) Install water pipe.
9) Install timing belt, belt cover and related parts. (Refer to
"Timing Belt and Belt Cover".)
10) Install distributor, proceeding as follows:
(1) Bring #1 cylinder piston to its top dead center on
compression stroke. Set camshaft sprocket to the position
shown in Figure.
Camshaft sprocket position

Flywheel position
Straight pin
L2-807
Fig. 42
4) Apply fluid packing (Three-bond 1215, or equivalent) to Timing mark

groove of each camshaft case, then install to cylinder head. L2-1058
Fig. 44
After installing, abundantly apply engine oil to sliding surfaces
of cam and valve rocker.
Tightening torque:
17.2 - 20.1 N·m (1.75 - 2.05 kg-m, 12.7 - 14.8 ft-Ib)
THREEBOND 1215
0.5 - 1 mm (0.020 - 0.039 in)
(2) Align distributor housing match mark with pinion
gear match mark to set #1 cylinder at igniting position.
L2-191
Fig. 43
L6-080
5) Attach gaskets to valve rocker covers, and install the
Fig. 45
covers to camshaft cases with rocker cover washers and bolts.
Be extremely careful not to cause oil to leak from mating faces

of valve rocker cover and camshaft case_
(3) Install distributor to camshaft case.
Tightening torque: (4) Connect lead wires_
4.4 - 5.4 N·m (0.45 - 0.55 kg-m, 3.3 - 4.0 ft-Ib) (5) Install plug cord and high-tension cord.
11) Install right and left belt covers.
::." 26
.~
ENGINE 2-3
Cylinder Head 7)
8)
Remove spark plugs.
Remove cylinder heads and gaskets from cylinder block.
9) Using VALVE SPRING PRESS ASSY (899724100),
REMOVAL compress the valve spring and remove the valve spring retainer
key. Remove each valve and valve spring.
1) Remove timing belt, belt cover and related parts.
(Refer to "Timing Belt and Belt Cover".) a. Mark each valve to prevent confusion.
b. Use extreme care not to damage the lips of the intake valve
2) Remove camshaft cases, lash adjuster and related parts.
(Refer to "Camshaft and Valve Rocker".)
oil seals and exhaust valve oil seals.
3) Remove bolt attaching alternator bracket to cylinder
head. [Except air conditioner model]
VALVE SPRING
4) Remove bolt attaching adjusting bar to cylinder head.
PRESS ASSY
[Except air conditioner model1
5) Remove bolts attaching intake manifold to cylinder head,
and then lift intake manifold from cylinder head.
L2-469
Fig. 48
Fig. 46
INSPECTION
6) Remove bolt attach ing water by·pass pipe bracket to
cylinder head. CYLINDER HEAD
1) Make sure that no crack or other damage exists. In
addition to visual inspection, inspect important areas by means
of red check.
2) Measure the warping of the cylinder head surface that
mates with crankcase by using a straight edge and th ickness
gauge.
If the warping exceeds 0.05 mm (0.0020 in), regrind the
surface with a surface grinder.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.3 mm (0.012 in)
Standard height of cylinder head:
Fig. 47 90.6 mm (3.567 in)
27
2-3 ENGINE
Uneven torque for the cylinder head nuts can cause warping.
When reassembling, pay special attention to the torque so as
to tighten evenly.
CYLINDER
HEAD TABLE
L2·474
Fig. 51
L2·473
Fig. 49
VALVE GUIDE
1) Check the clearance between valve guide and stem. The
clearance can be checked by measuring the outside diameter of
valve stem and the inside diameter of valve guide with outside
and inside micrometers respectively.
Specifications for valve stem and valve guide
0.035 - 0.065 mm
Standard clearance Intake
(0.0014 - 0.0026 in)
3) Inspect intake and exhaust valve seats, and correct the between valve guide
contact surfaces with valve seat cutter if they are defective or and valve stem 0.040 - 0.070 mm
Exhaust
when valve guides are replaced. (0.0016 - 0.0028 in)
Contacting width: W Limit of clearance between

0.15 mm (0.0059 in)
Intake valve guide and valve stem
1.2 - 1.8 mm (0.047 - 0.071 in) Standard inside diameter of 7.000 - 7.015 mm
Exhaust valve guide (0.2756 - 0.2762 in)
1.5 - 2.0 mm (0.059 - 0.079 in)
Wear limit of valve seat (measured in direction of valve 6.950 - 6.965 mm
Intake
axis): Standard diameter (0.2736 - 0.2742 in)
0.5 mm (0.020 in) for both intake and exhaust valves of valve stem 6.945 - 6.960 mm
Exhaust
(0.2734 - 0.2740 in)
2) If the clearance between valve guide and stem exceeds the

specification, replace guide as follows:
(1) Place cylinder head on CYLINDER HEAD TABLE
with the combustion chamber upward so that valve guides
enter the holes in CYLINDER HEAD TABLE.
(2) Insert VALVE GUIDE REMOVER into valve guide
and press it down to remove valve guide.
A5·052
Fig. 50
28
l
ENGINE 2-3
(6) Check the valve guide protrusion.
Valve guide protrusion: L

17.6 - 18.6 mm (0.689 - 0.728 in)
(7) Ream the inside of valve guide with VALVE GUIDE

REAMER (399762104). Gently rotate the reamer clock·
wise while pressing it lightly into valve guide, and return it
also rotating clockwise. After reaming, clean valve guide
to remove chips.
1 VALVE GUIDE REMOVER
(399762103) a. Apply engine oil to the reamer when reaming.
2 CYLINDER HEAD TABLE b. If the inner surface of the valve guide is torn, the edge of
(498267100) A5-289
the reamer should be slightly ground with an oil stone.
Fig. 52 c. If the inner surface of the valve guide becomes lustrous and
the reamer does not cut chips, use a new reamer or remedy the
(3) Turn cylinder head upside down and place VALVE reamer.
GUIDE ADJUSTER as shown in the figure.
(8) Recheck the contact condition between valve and
VALVE GUIDE ADJUSTER
(899768603) valve seat after replacing valve guide.
Valve guide
protrusion: L
INTAKE AND EXHAUST VALVE OIL SEAL
Replace oil seal with new one, if lip is damaged or spring is out
c L2-161
of place, or when the surfaces of intake valve and valve seat are
reconditioned or intake valve gu ide is replaced.
Press in oil seal to the specified dimension indicated in the
figure, using 01 L SEAL INSTALLER.
Fig. 53 •. Apply engine oil to oilllal before force·fitting.

b. Diffarentiate batween intake valva oil .aal and exhaust
(4) Before installing new valve guide, make sure that valve oilual by noting thair difference in height.
neither scratches nor damages exist on the inside surface
of the valve guide holes in cylinder head.
(5) Put new valve guide, coated with sufficient oil, in
QILSEAL
cylinder, and insert VALVE GUIDE REMOVER into INSTALLER
valve guide. Press in until the valve guide upper end is (398862100)
flush with the upper surface of VALVE GUIDE
ADJUSTER.
VALVE GUIDE REMOVER (399762103)
CYLINDER HEAD
TABLE (498267100)
L2·476
Fig. 55
CYLINDER
HEAD TABLE'
L2-475
Fig. 54
29
2-3 ENGINE
Unit: mm (in)
VALVE SPRING
PRESS ASSY
(899724100)
f--+--
(Intake side) (Exhaust lide)
L2·S80 L2-469
Fig. 56 Fig. 58
3) I~stall cylinder heads to cylinder block with new gaskets.

INSTALLATION
,) Install the oil sea.ls to th~ valve guides using 01 L SEAL

INSTALLER.
01 L SEAL INSTALLER
(398852100)
Fig. 59
CYLINDER HEAD
TABLE (498267100)
L2-476
Fig. 57
When tightening bolts, apply oil to the threads and tighten

them in two or three successive steps until the final tightening
2) Coat the stem of each valve with engine oil and insert is at the specified torque.
the valve into the valve guide, Attach the valve springs and In each step, tighten them in the specified sequence.
retainer. Then compress the valve springs using VALVE
SPRING PRESS and fit the valve spring retainer key. 1st step:
29 N·m (3.0 kg-m, 22 ft-Ibl
•. After installing, tap the valve spring retainers lightly with 2nd step:
B wooden hammer for better seating. 59 N·m (6.0 kg-m, 43 ft-Ib)
b. When inserting the valve into the valve guide, use special 3rd (final! step:
.\--(,
care not to damage the oil seal lip. 64 N'm (6.5 kg-m, 47 ft·lb)
'c. Be sure to install the valve springs with their close-coiled
end facing the seat on the cylinder head.
,
30
ENGINE 2-3
10) Install camshaft cases, lash adjustor and related parts.

sure to retighten cylinder head bolts.
(Refer to "2·2 ON·CAR SERVICES".)
L2·489
Fig. 60
4) Install spark plugs.
Tightening torque:
18 - 24 N·m (1.8 - 2.4 kg·m, 13 - 17 ft·lb)
5) Install b~lt attaching water by·pass pipe bracket to

cylinder head.
6} Install bolts attaching intake manifold collector to intake
manifold.
7) Install bolts attaching intake manifold to cylinder head.
Tightening torque: Valve and Valve Spring

18 - 22 N·m (1.8 - 2.2 kg-m, 13 - 16 ft·lb)
REMOVAL
1) Remove cylinder head from engine ASSY.

• (Refer to "Cylinder Head".)
2) Using VALVE SPRING PRESS ASSY, compress the valve
spring and remove the valve spring retainer- key. Remove each
valve and valve spring.
a. Mark each valve to prevent confusion.

b. Use extreme care not to damage the lips of the intake valve
oil seals and exhaust valve oil seals.
L2-1061 VALVE SPR ING

Fig. 61 PRESS ASSY
(899724100)
8) Install bolt attaching adjusting bar to cylinder head.
Tightening torque:
16 - 22 N·m (1.6 - 2.2 kg·m, 12 - 16 ft·lb)
9) Install bolts attaching alternator bracket to cyl inder head.

L2-469
Tightening torque:
Fig. 62
36 - 42 N'm (3.7 - 4.3 kg-m, 27 - 31 ft·lb)
31
2-3 ENGINE
3) Put a small amount of grinding compound on the seat
INSPECTION surface and lap the valve and seat surface. Also refer to
"Cylinder Head" 3) at this time. Install a new intake valve oil
INTAKE AND EXHAUST VALVE seal after lapping.
1) Inspect the flange and stem of valve, and replace if
damaged, worn, or deformed, or if "H" is less than the
VALVE SPRINGS
specified limit. 1) Check valve springs for damage, free length, and tension.
Replace valve spring if it is not to the specifications presented
below.
Head edge thickness: H
2) To measure the squareness of the valve spring, stand the
Intake & Exhaust
spring on a surface plate and measure its deflection at the top
Standard
using a try square.
1.3 mm (0.051 in)
Limit
0.8 mm (0.031 in)
Valve overall length:
Intake & Exhaust
107.58 mm (4.235 in) I
A5-062
Fig. 65
900 +1
-0
R 0.3 mm (0.012 in)
~
=
Outer spring Inner spring
A5-293
Free length 50.7 mm (1.996 in) 50.3 mm (1.980 in)
Fig. 63
203.0 - 238.3 N 88.3 - 101.0 N
(20.7 - 24.3 kg, (9.0 - 10.3 kg,
45.6 - 53.6 Ib)/ 19.8 - 22.7 Ib}/
Tension/ 41.5 mm (1.634 in) 38.5 mm (1.516 in)
2) If the contact surface of valve is damaged, or if the stem
spring
end is recessed, correct with a valve refacer, grinding as little as 502.1 - 576.7 N 201.0 - 230.5 N
height
possible. The contact surface should be at right angle with the (51.2 - 58.8 kg, (20.5 - 23.5 kg,
Valve axis. [Intake valve only] 11 2.9 - 129. 7 Ib )/ 45.2 - 51.8 Ib)/
31.5 mm (1.240 in) 28.5 mm (1.122 in)
Squareness 2.2 mm (0.087 in) 2.2 mm (0.087 in)
I
ASSEMBLY
Coat the stem of each valve with engine oil and insert
the valve into the valve guide. Attach the valve springs and
A5-061
SPRING PRESS (899724100) and fit the valve spring retainer
Fig. 64 key.
32
ENGINE 2-3
a. After installing, tap the valve spring retainers lightly with

a wooden hammer for better seating.
b. When inserting the valve into the valve guide, use special
care not to damage the oil seal lip.
c. Be sure to install the valve springs with their close-coiled
end facing the seat on the cylinder head.
Cylinder Block Fig. 67
REMOVAL \--h \~. , \~ Jj--(~-=JF\

DRIVE PLATE STOPPER (498497000)
I 1) Remove distributor and plug cord.

~\f--L\}tt\'1 u , \~~
Fig. 68

Fig. 66 12) Remove oil level gauge guide together with gauge.
13) Remove timing belt, belt cover and related parts. (Refer
to ''Timing Belt and Belt Cover".)
14) Remove water pump together with hose, pipe and timing
plate.
15) Remove oil pump by aligning notch in oil pump pulley
3) Remove alternator and V-belt. [Except air conditioner
with bolt position, then remove pump outer rotor from
equipped model)
cylinder block.
4) Removal of intake manifold ASSY
(1) Remove hoses and tubes from cylinder block side,
(2) Disconnect each harness.
(3) Remove intake manifold ASSY from engine,
5) Remove power steering oil pump bracket from cylinder
block. [Power steering model]
6) Remove alternator brackets and adjusting bar, [All except
air-conditioner models]
7) Remove air bleed hose,
10) Remove crankshaft pulley. To lock crankshaft, use
FLYWHEEL STOPPER (498277000) [manual transmission
L2-147
modelJ or DRIVE PLATE STOPPER (498497000) [automatic
transmission model], Fig. 69
33
2-3 ENGINE
16) Removing clutch cover and clutch disc. [All except

automatic transmission model] Piston pin
Be careful not to let oil, grease or coolant contact the clutch

disc.
17) Remove flywheel [manual transmission model] or drive

plate [automatic transmission model], and take out flywheel
housing with housing cover. To lock crankshaft, use FLY·
WHEEL STOPPER (498277000) or DRIVE PLATE STOPPER
(498497000).
18) Remove camshaft, valve rocker and related parts. (Refer PISTON PIN REMOVER
to "Camshaft and Valve Rocker".) L2-467
19) Remove cylinder heads and gaskets.
Fig. 71
20) Remove oil pan.
21) Remove oil strainer and strainer stays.
6} Similarly remove piston pins from #3 and #4 pistons.
Be careful not to confuse original combination of piston,

piston pin and cylinder.
7) Remove all of cylinder block connecting bolts except one

10-mm bolt under center journal. Loosen this 10-mm bolt
until it can be turned by hand. (Cylinder block connecting
bolts: six 1 O-mm bolts and six 8-mm bolts.)
DISASSEMBLY 8) Set up cylinder block so that #1 and #3 cyl inders are on
the upper side, then separate left-hand and right-hand cylinder
1) Remove oil separator cover. blocks.
2) Remove service hole plugs from cylinder block using
hexagon wrench (14 mm). When separating cylinder block, do not allow the connecting
3) Rotate crankshaft to bring #1 and #2 pistons to TDC rod to fall and damage the cylinder block.
position.
4) Remove piston circlip through service hole of #1 and #2 9) Remove coolant passage a-ring and back-up ring from
cylinders. left-hand cylinder block.
L2-468
Fig. 70 Fig. 72
5) Draw out piston pin from #1 and #2 pistons using 10) Remove front oil seal and rear oil seal from crankshaft.
PISTON PIN REMOVER (399094310). 11} Remove crankshaft together with connecting rod from
cylinder block.
34
l
ENGINE 2-3
12) Draw out each piston from cylinder block using wooden Measurement should be performed at a temperature of 20°C
bar or hammer handle. (68°F).
Do not confuse combination of piston and cylinder.
ttti7 (028 ;Ol_e.

Cylinder head mating surface
mm
A
Q : 33.5 mm (1.319 in) A: Thrust direction

B: Piston pin direction
/ L2·154
Fig. 74
AS·068
Fig. 73
13) Remove crankshaft bearings from cylinder block using

hammer handle.
a. Do not confuse combination of crankshaft bearings. Press

bearing at the end opposite to locking lip.
Cylinder bore
b. Do not confuse combination of crankshaft bearings.
gauge
L2·477
INSPECTION
Fig. 75
CYLINDER BLOCK
Check cylinder block for the following items, and correct or
replace if defective.
1} Check for cracks and damage visually. Especially, inspect
important parts by means of red check. Cylinder bore
2) Check the oil passages for clogging.
3} Inspect the crankcase surface that mates with cylinder 91.985 -92.015 mm
Standard diameter
head for warping by using a straight edge, and correct by (3.6214 - 3.6226 in)
grinding if necessary.
Standard 0.015 mm (0.0006 in)
Taper
Warping limit: Limit 0.050 mm (0.0020 in)
0.05 mm (0.0020 in)
Grinding limit: Standard 0.010 mm (0.0004 in)
0.4 mm (0.016 in) Out·of roundness
Limit 0.050 mm (0.0020 in)
Cylinder to piston 0.015 - 0.035 mm

Standard
clearance at 20°C ,(0.0006 - 0.0014 in)
CYLINDER AND PISTON (68°F)
0.060 mm (0.0024 in)
Limit
1) Measure the inner diameter of each cylinder in both the
thrust and piston pin directions at the heights shown in the
figure, using a cylinder bore gauge.
35
2-3 ENGINE
2) Boring and honing (3) If the cylinder inner diameter exceeds the following
(1) If the value of taper, out-of-roundness, or cylinder-to- enlarging limit after boring and honing, replace the
piston clearance measured exceeds the specified limit or crankcase.
if there is any damage on the cylinder wall, rebore it to
use an oversize piston. Immediately after reboring, the cylinder diameter may differ
from its real diameter due to temperature rise. Thus, pay
When any of the cylinders needs reboring, all other cylinders attention to this when measuring the cylinder diameter.
must be bored at the same time, and use oversize pistons. 00
not perform boring on one cylinder only, nor use an oversize Enlarging limit of cylinder inner diameter:
piston for one cylinder only. 0.30 mm (0.0118 in)
(2) Get four of the oversize pistons and measure the (4) Inspect the cyl inder bore for taper, out-of-roundness,
outer diameter of each piston at the height shown in the and diameter differences.
figure. (Thrust direction)
Measure ,the inner diameter of the cylinder when the tempera-
Measurement should be performed at a temperature of 20°C ture is 20°C (68°F).
0
(68 F).
Diameter difference between cylinders:
Piston outer diameter: 0.060 mm (0.0020 in) or lell
Standard
91.970 - 91.980 mm (3.6209 - 3.6213 in)
0.25 mm (0.0098 in) oversize
92.220 - 92.230 mm (3.6307 - 3.6311 in)
0.50 mm (0.0197 in) oversize
92.470 - 92.480 mm (3.6405 - 3.6409 in)
ASSEMBLY
1) Install ENGINE STANDS (499817100) to cylinder

blocks. When installing ENGINE STANDS, fit bolts to the
holes marked with "R" on the #1 and #3 cylinder sides, and
to the holes marked with ilL" on the #2 and #4 cylinder sides.
O(@) ] 2) I nstall crankshaft bearings to cylinder blocks.

3) Install crankshaft to left-hand cylinder block.
4) Fit a-ring and back-up ring to coolant passage of left-hand
cylinder block.
5) Apply fluid packing (Three-bond 1215, or equivalent) to
mating surface of cylinder block.
L2-813
Fig. 76
Apply liquid Packing along this line.
L2-582
Fig. 78
A5-071
Fig. 77
36
l
ENGINE 2-3
6) With left-hand cylinder block facing down, install right-
Top ring
hand cylinder block. After tightening bolts temporarily, lay Oil ring upper Oil ring lower
cylinder block down, then tighten bolts to the specified rail rail
torque.
Make sure a·ring is fitted correctly in groove. Second ring

Oil ring spacer
Tightening torque:
p:nvq
10 mm bolt
39 - 47 N'm (4.0 - 4.8 kg·m, 29 - 36 ft·lb)
8 mm bolt
23 - 26 N·m (2.3 - 2.7 kg·m, 17 - 20 ft·lb) Bend over pawl of upper rail
t
and attach to 3.5 mm (0.138 in) dia.
hole.
L2·1373
Fig. 81
9) Install pistons in cylinder as follows.
(1) Apply oil to the circumference of piston and the
L2·485 inner surface of cylinder.
Fig. 79 (2) With the #3 and #4 cylinders facing downwards, turn
crankshaft until the #1 and #2 connecting rod comes to
the bottom dead center. Then insert the #1 and #2 piston
into cylinder by using PISTON GUIDE (398744300).
If any of the pistons are reused, be sure to direct them in the

same way as before they were disassembled.
Fig. 80
7) Check thrust clearance of crankshaft.
Thrust clearance:
Standard
Fig. 82
0.010 - 0.095 mm (0.0004 - 0.0037 in)
Limit (3) Install piston pin and circlip through the service hole
0.3 mm (0.012 in) after aligning the service hole, piston pin hole, and
connecting rod small end with PISTON PIN GUIDE
(399284300) .
8) Position the gaps of the piston rings and oil ring as shown Circlip must be installed in correct direction with its end
in the figure. facing out.
37
2-3 ENGINE
12) Install oil separator cover with gasket placed in
between.
Tightening torque:
4.4 - 5.4 N·m (0.45 - 0.55 kg-m, 3.3 - 4.0 ft-Ib)
13) Install front oil seal to cylinder block using OIL SEAL
INSTALLER (499567000) or (499567100).
Coat the outside surface of oil seal with engine oil, and oil seal
lip with grease. Force-fit oil seal squarely into position.
Max. allowable out·of·squareness of oil seal:

0.2 mm (0.008 in)
(4) With #1 and #2 cylinders facing down, turn crank-

shaft until #3 and #4 piston connecting rods are at the
bottom dead center position. Similarly to #1 and #2
cylinders, install pistons, piston pins, and circiips to #3
and #4 connecting rods.
Install crankshaft bolt to turn crankshaft.
(5) Turn crankshaft, and check whether pistons are

assembled correctly.
10) Apply fluid packing (Fuji-bond C, or equivalent) to plugs,
and tighten it with aluminium gasket placed in between.
Tightening torque:
62 -76 N·m (6.3 - 7.7 kg-m, 46 - 56 ft-Ib) Fig. 85
11) Install rear oil seal to cylinder block using INSTALLER

(499587000).
INSTALLATION
Coat oil seal lips with grease.
Coat the outside surface of oil seal with engine oil.
1) Secure oil strainer to cylinder block with oil strainer stays.
2) install oil pan.
Max. allowable out-of-squareness of oil seal:
0.3 mm (0.012 in)
Tightening torque:
4.4 - 5.4 N'm (0.45 - 0.55 kg-m, 3.3 - 4.0 ft·lb)
3) Install cylinder heads to cylinder blocks with gaskets

placed between.
them in two or three successive steps until the final tightening
is at the specified torque.
In each step, tighten them in the specified sequence.
1st step:
29 N'm (3.0 kg-m, 22 ft·lb)
2nd step:
59 N'm (6.0 kg·m, 43 ft·lb)
3rd (final) step:
Fig. 84 64 N'm (6.5 kg·m, 47 ft-Ib)
38
ENGINE 2-3
9) Install oil pump ASSY, proceeding as follows:
(1) Thoroughly remove. excess fluid packing from rotor
housing of cylinder block.
(2) Apply a small amount of fluid packing (Three·bond
1215, or equivalent) to the portion indicated by arrow in
figure in cylinder block.
(3) Apply ample engine oil to rotor housing, then insert
outer rotor into rotor housing by setting it as shown.
(4) Set oil pump pulley as shown, and install oil pump
ASSY to cylinder block with gasket placed between. After
installing, make sure pulley can be rotated smoothly.
L2-489
Fig. 86
4) Install flywheel housing with housing cover and pitching

stopper bracket.
Tightening torque:
34 - 40 N·m (3.5 - 4.1 kg-m, 25 - 30 ft-Ib) Outer rotor direction
5) Install flywheel to crankshaft using FLYWHEEL

STOPPER (498277000) for locking crankshaft. [Manual
transm ission model]
Tightening torque:
69 - 75 N·m (7.0 - 7.6 kg-m, 51 - 55 ft-Ib)
Pulley direction
6) Install drive plate and reinforcement using DRIVE PLATE L2·187
STOPPER (498497000) for locking crankshaft. [Automatic Fig. 87
transmission model]
(5) Install oil pressure switch or oil pressure gauge to oil
Tightening torque: pump ASSY. Loosen oil pressure gauge lead clamping
69 - 75 N·m (7.0 - 7.6 kg-m, 51 - 55 ft-Ib) screw and route the lead on the side of #1 and #3
cylinders.
7} Position the clutch cover so that the "e" marks on the
0
flywheel and clutch cover are spaced 120 or more. Tightening torque:
Install clutch disc and clutch cover with bolts and spring 22 - 27 N·m (2.7 - 2.8 kg-m, 16 - 20 ft-Ib)
washers, aligning clutch disc with flywheel by inserting
CLUTCH DISC GUIDE (499747000) into needle bearing 10) Insert valve lash adjusters into cylinder head.
fitted in flywheel. [Manual transmission model]
Be sure to insert each valve lash adjuster to its original
Tightening torque: position.
16 N·m (1.6 kg-m, 12 ft-Ib)
11) Apply grease to spherical surface and sl iding surface of
8) Install seal to water pump, then install the water pump each valve rocker, then secure valve rockers to the respective
and timing plate to cylinder block with gasket placed between. valve adjusters and valves.
39
2-3 ENGINE
Be sure to apply grease; otherwise, valve rocker will drop off. 14) Attach gaskets to valve rocker covers, and install the
covers to camshaft cases with rocker cover washers and bo Its.
Be extremely careful not to cause oil to leak from mating faces

of valve rocker cover and camshaft case.
Tightening torque:
4.4 - 5.4 N·m (0.45 - 0.55 kg-m, 3.3 - 4.0 ft-Ib)
15} Install timing belt, belt cover and related parts. (Refer to
16) Install crank pulley to crankshaft using FLYWHEEL
Valve rocker STOPPER (498277000) [manual transmission model) or
DRIVE PLATE STOPPER (498497000) [automatic transmis-
L2-490
sion model) to lock crankshaft.
Fig. 88
12) Install O-ring to camshaft case by setting camshaft so that Tightening torque:
camshaft straight pin is oriented as shown. 89 - 107 N·m (9.1 - 10.9 kg-m, 66 - 79 ft·lb)
ASSY, and tighten bolts temporarily.
18} Install oil level gauge and gauge guide. Apply engine oil to
O-ri ng beforehand.
19) Install oil filler duct and bracket.
20) I nstall water by-pass pipe, hose, and water pipe_ Apply
coolant to O·rings beforehand.
21) Install air bleed hose_
22} Install alternator bracket, proceeding as follows. [All
except air conditioner model]
(1) Assemble bracket ® and bracket @ temporarily
. with bolt © so that these two parts contact each other.
L2-491
(2) Install assembled brackets ® and @ to engine, and
Fig. 89
hand-tighten bolts (E) and @.
13) Apply fluid packing (Three-bond 1215, or equivalent) to (3) Tighten bolt @ to the specified torque, then tighten
groove of each camshaft case, then install to cylinder head. bolt (E) to the specified torque.
(4) Tighten bolt © to the specified torque.
After installing, abundantly apply engine oil to sliding surfaces
of cam and valve rocker. Tightening torque:
Bolt ©
Tightening torque: 16 - 22 N·m (1.6 - 2.2 kg-m, 12 - 16 ft-Ib)
17.2 - 20.1 N-m (1.75 - 2.05 kg-m, 12.7 - 14.8 ft-Ib) Bolts @ and ®
36 - 42 N'm (3.7 - 4.3 kg-m, 27 - 31 ft-Ib)
HIREEBOND 1215
0.5 - 1 mm (0.020 - 0.039 in)
..
L2-191
Fig. 90
40
ENGINE 2-3
L6-080
Fig. 91 Fig. 93

(4) Connect lead wires.
(5) Install plug cord and high-tension cord.
28) I nstall right and left belt covers.
29) Remove ENGINE STAND (499817100).
30) Install air duct and boots.

(Refer to "2·2 ON·CAR SERVICES".)
23) Install power steering oil pump bracket to cylinder block.
[Power steering model]
24) Install harnesses.
25) Install hoses and tubes.
26) Install alternator to bracket, and tighten bolts temporarily.
[Except air conditioner model]
(1) Bring #1 cylinder piston to its top dead center on Crankshaft and Piston
shown in Figure.
DISASSEMBLY
Camshaft sprocket position
Flywheel position PISTON
1) Remove the piston rings using the piston ring expander.
L2-1058
Fig. 92
(2) Align distributor housing match mark with pinion L2-813

gear match mark to set #1 cylinder at igniting position. Fig. 94
41
2-3 ENGINE
2) Remove the oil ring by hand.
Arrange the removed piston rings in good order to prevent

confusion.
CONNECTING ROD
Remove connecting rod cap mounting nuts, and take out
connecting rod from crankshaft.
Arrange removed connecting rod and connecting rod cap in A5-072

good order to prevent confusion.
Fig. 95
The oil ring is a combined ring consisting of two rails and a
spacer in between. When installing, be careful not to make
misassembly.
INSPECTION
Top ring
PISTON AND PISTON PIN ~Rmark
1) Check pistons and piston pins for damage, cracks, and Second ring ~
rr
wear and the piston ring grooves for wear and damage.
upper rail
Replace if defective.
Oil ring Spacer
2) Measure the piston-to-cylinder clearance at each cyl inder
as instructed in CYLINDER AND PISTON. If any of the Lower rail
clearances is not to specification, replace the piston or bore A5-073

the cylinder to use an oversize piston.
3) Make sure that piston pin can be inserted into the piston
pin hole with a thumb at 20°C (68° F). Replace if defective.
Top ring
g-Nm",
Specifications for piston and piston pin:
.
~Nmark
Standard outer diameter of piston pin
20.994 - 21.000 mm (0.8265 - 0.8268 in) Second ring ~
e
Standard inner diameter of piston pin hole
20.999 - 21.009 mm (0.8267 - 0.8271 in) Upper rail
Standard clearance between piston pin and hole in Oil ring Spacer
piston Lower rail

0.001 - 0.015 mm (0.00004 - 0.00059 in)
Standard clearance between piston pin and hole in A5-074
connecting rod Fig. 96
o - 0.022 mm (0 - 0.0009 in) 2) Squarely place piston ring in cylinder and measure the
piston ring gap with a th ickness gauge.
PISTON RING
1) If piston ring is broken, damaged, or worn, or if its
--------- Top
ring
Standard
0.20 - 0.35 mm
(0.0079 - 0.0138 in)
Limit
1.5 mm
(0.059 in)
tension is insufficient, or when the piston is replaced, replace Second 0.20 - 0.35 mm 1.5 mm
Piston ring gap
piston ring with a new one of the same size as the piston. ring (0.0079 - 0.0138 in) (0.059 in)
"R" or liN" is marked on the end of the top and second rings. Oil ring 0.3 - 0.90 mm 2.0mm
When installing the rings to the piston, face this mark upward. rail (0.012 - 0.0354 in) (0.079 in)
42
ENGINE 2-3
o
o
)
1 Thickness gauge
L2·478
2 Connecting rod
A5-077
Fig. 97
3) Measure the clearance between piston ring and piston ring

groove with a th ickness gauge.
Before measuring the clearance, clean the piston ring groove

and piston ring.
-----------
Clearance
Top
ring
Standard
0.04 - 0.08 mm
Limit
0.15 mm
(0.0016 - 0.0031 in) (0.0059 in)
between piston
Second 0.03 - 0.07 mm 0.15 mm 1 Connecting rod
ring and piston
ring (0.0012 - 0.0028 in) (0.0059 in) 2 Thickness gauge
ring groove A5·078
Oil ring 0 0 Fig. 99
3) Install connecting rod fitted with bearing to crankshaft

and measure the side clearance (thrust clearance). Replace
connecting rod if the side clearance exceeds the specified limit.
Connecting rod side clearance:

Standard
0.070 - 0.330 mm (0.0028 - 0.0130 in)
Limit
0.4 mm (0.016 in)
A5-076
Fig. 98
CONNECTING ROD
1) Replace connecting rod, if the large or small end thrust
surface is damaged.
2) Check for bend or twist using a connecting rod aligner.
Replace connecting rod if the bend or twist exceeds the limit.
Thickness
gauge
Limit of bend or twist per 100 mm (3.94 in) in length:
L2-479
0.10 mm (0.0039 in)
Fig. 100
43
2-3 ENGINE
4) Inspect connecting rod bearing for scar, peeling, seizure,

melting, wear, etc.
5) Measure the oil clearance on individual connecting rod
bearings by means of plastigauge according to the following
procedure.
(1) Wipe off oil, dust. etc. on the surfaces to be measured.
(2) Cut the plastigauge to the width of the bearing, place
it on the crank pin parallel with the crankshaft axis, and
install connecting rod. Tighten connecting rod nuts to
41 N'm (4.2 kg-m, 30 ft-Ib).
During this measurement, do not allow relative movement

between the crankpin and connecting rod.
Fig. 101
(3) Remove connecting rod and measure the width of the
plastigauge with the scale printed on the plastigauge case.
If any oil clearance is not within specification, replace the
defective bearing with a new one of standard size or 6) Inspect bushing at connecting rod small end. and replace
undersize as necessary, and replace or recondition the if worn or damaged. Also measure the piston pin clearance at
crankshaft as necessary. (See the table below.) the connecting rod small end.
Connecting rod oil clearance: Standard clearance between piston pin and bushing in
Standard connecting rod:
0.010 - 0.054 mm (0.0004 - 0.0021 in) o - 0.022 mm (0 - 0.0009 in)
Limit
0.10 mm (0.0039 in) Replacement procedure is as follows.
(1) Remove bushing from connecting rod with
REMOVER & REPLACER (499037000) and press.
(2) Press bushing with REMOVER & REPLACER
Connecting rod bearing (499037000) after applying oil on the periphery of
bushing.
Thickness at center (3) Make two 3 mm (0.12 in) holes in bushing.
Bearing size
of bearing Ream the inside of bushing.
1.485 - 1.490 mm
Standard Bushing bore:
(0.0585 - 0.0587 in)
21.000 - 21.016 mm (0.8268 - 0.8274 in)
1.500 - 1.505 mm
0.03 mm (0.0012 in) undersize (4) After completion of reaming, clean bushing to
(0.0591 - 0.0593 in)
remove ch ips.
1.510 -1.515 mm
0.05 mm (0.0020 in) undersize
(0.0594 - 0.0596 in)
CRANKSHAFT AND CRANKSHAFT BEARING
1.610 -1.615 mm
0.25 mm (0.0098 in) undersize 1) Clean crankshaft completely and check for cracks by
(0.0634 - 0.0636 in)
means of red check etc., and replace if defective.
2) Measure the crankshaft bend, and correct or replace if it
exceeds the limit.
When measuring, place both the front and rear journals on

blocks located on a surface plate, and apply a dial gauge to the
center journal.
Crankshaft bend limit:

0.035 mm (0.0014 in)
44
ENGINE 2-3
3) Inspect the crank journal and crankpin for wear. If not to
specifications, replace bearing with an undersize one, and
replace or recondition crankshaft as necessary. When grinding
crank journal or crankpin, finish them to the specified dImen-
sions according to the undersize bearing to be used.
Crankpin and crank journal:

Out-of-roundness
0.03 mm (0.0012 in) or less
Taper limit
0.07 mm (0.0028 in)
Grinding limit
"""'----v blocks L2-169 0.25 mm (0.0098 in)
Fig. 102
Crank journal 0.0.

Crankpin 0.0.
Front Center Rear
44.995 - 45.010 mm 54.957 - 54.972 mm 54.954 - 54.970 mm 54.955 - 54.970 mm

Standard
(1.7715 - 1.7720 in) (2.1637 - 2.1642 in) (2.1635 - 2.1642 in) (2.1636 - 2.1642 in)
0.03 mm (0.0012 in) 44.965 - 44.980 mm 54.927 - 54.942 mm 54.924 - 54.940 mm 54.925 - 54.940 mm
undersize (1.7703 - 1.7709 in) (2.1625 - 2.1631 in) (2.1624 - 2.1630 in) (2.1624 - 2.1630 in)
0.05 mm (0.0020 in) 44.945 - 44.960 mm 54.907 - 54.922 mm 54.904 - 54.920 mm 54.905 - 54.920 mm
0.25 mm (0.0098 in) 44.745 - 44.760 mm 54.707 - 54.722 mm 54.704 - 54.720 mm 54.705 - 54.720 mm
Thickness gauge
L2-170 L2-480
Fig. 103 Fig. 104
4) Measure the thrust clearance of crankshaft at center

bearing. If the clearance exceeds the limit, replace bearing.
5) Inspect individual crankshaft bearings for signs of flaking,
Crankshaft thrust clearance seizure, melting, and wear.
Standard 6) Measure the oil clearance on each crankshaft bearing by
0.010 - 0.095 mm (0.0004 - 0.0037 in) means of plastigauge as follows:
Limit (1) Wipe off oil, dust, etc. on the surfaces to be measured.
0.3 mm (0.0118 in) (2) Install bearings in crankcase and set crankshaft in
position.
45
2-3 ENGINE
(3) Cut the plastigauge to the bearing width and place it

Dimensions of bearing
on journal parallel with the crankshaft axis. Be careful not
to put it on the oil hole or groove. Bring together the Th ickness of bearing at center
Crankshaft
crankcase halves and tighten bolts to the specified torque.
bearing size Front & Rear Center
During the work, the crankshaft must not be turned nor the
2.015 - 2.019 mm 2.019 - 2.022 mm
crankcase inverted. Standard
(0.0793 - 0.0795 in) (0.0795 - 0.0796 in)
Torque: 0.03 mm
2.030 - 2.034 mm 2.034 - 2.037 mm
39 - 47 N·m (4.0 - 4.8 kg-m, 29 - 35 ft-Ib) (0.0012 in)
(0.0799 - 0.0801 in) (0.0801 - 0.0802 in)
undersize
(4) Remove all bolts and separate crankcase. Measure the
plastigauge width with the scale printed on the plastigauge 0.05 mm
2.040 - 2.044 mm 2.044 - 2.047 mm
(0.0020 in)
case. (0.0803 - 0.0805 in) (0.0805 - 0.0806 in)
undersize
0.25 mm
2.140 - 2.144 mm 2.144 - 2. 147m m
(0.0098 in)
(0.0843 - 0.0844 in) (0.0844 - 0.0845 in)
undersize
ASSEMBLY
CRANKSHAFT
L2-172 1) Install connecting rod bearings on connecting rods and
Fig. 105 connecting rod caps.
Apply oil to the surfaces of the connecting rod bearings.

(5) If the measurement is not within the specification,
replace defective bearing with an undersize one, and 2) Install connecting rods and connecting rod caps on crank-
shaft with connecting rod bolts and nuts.
replace or recondition crankshaft as necessary.
Torque (Connecting rod nut):

Crankshaft oil clearance
39 - 42 N'm (4.0 - 4.3 kg-m, 29 - 31 ft-Ib)
0.008 - 0.027 mm with oil on threads
Center
(0.0003 - 0.0011 in)
Standard a. Position each connecting rod with the side marked f)
0.003 - 0.036 mm facing forward.
Front & Rear
(0.0001 - 0.0014 in) b. Each connecting rod has its own mating cap. Make sure
that they are assembled correctly by checking their matching
Center 0.045 mm (0.0018 in) number.
Limit
Front & Rear 0.055 mm (0.0022 in)
c. When tightening the connecting rod nuts, apply oil on the
threads.
46
ENGINE 2-3
2) Position the gaps of the piston rings and oil ring as shown
in the figure.
Mark fI
Top ring
Oil ring upper Oil ring lower
rail rail
Second ring
Oil ring spacer
L2-483
Fig. 106
rcnih:A Bend over pawl of upper rail
t
and attach to 3.5 mm (0.138 in) dia.
hole.
Matching number
A5·101 L2·1373
Fig. 107 Fig. 108
3) Install circlip to piston.

The circlip must be fitted to the end that faces inside of
crankcase when piston is inserted.
PISTON Circlip must be installed in correct direction with its end

facing out.
1) Install piston rings on pistons as follows.
Install oil ring spacer, upper rail and lower rail in this order by
hand. Then install second ring and top ring with a piston ring
expander.
Face this end outward.
Install one side first.
L2·581
Fig. 109
47
2-3 ENGINE
TROUBLESHOOTING
Engine Trouble in General
Symbols shown in the chart refer to No. TROUBLE
the possibility of reason for the trouble 1 Starter does not turn.
in order ("Very often" to "Rarely") r---
2 Initial combustion does not occur.
© - Very often r----
Engine will not
o - Sometimes 3 start. Initial combustion occurs.
t, - Rarely r----
4 Engine stalls after initial combustion.
S Rough idle and engine stall.
6 Low output, hesitation and poor acceleration.
7 Surging.
8
9
Engine does not return to idle.
Dieseling (Run-on).
I
10 Afterburning in exhaust system.
Knocking.
%
11
12 Excessive engine oil consumption.
13 Excessive fuel consumption.
TROUBLE No.
POSSIBLE CAUSE
1 2 3 4 5 6 7 8 9 10 11 12 13
STARTER
0 • Defective battery-to-starter harness.
t,
• Defective starter switch.
t, • Defective inhibitor switch.
0 t,
• Defective starter.
BATTERY
© • Poor terminal connection.
© • Run-down battery.
0 • Defective charging system.
© © © © © © © © © © © MPFI SYSTEM (See Chap. 2-7.)
IGNITION SYSTEM
0 0 0 © © © © © © © © • Incorrect ignition timing.
0 © 0 0 0 t, t,
• Defective distributor.
Disconnection of spark plug cord.
0 t, © 0 0 © 0 •
0 t, 0 0 • Defective ignition coil.
0 t, t, t, • Defective cord or wiring.
0 0 t, 0 t, 0 • Leakage of spark plug cord.
0 0 0 0 © • Defective spark plug.
0 0 0 © 0 © 6 0 0 • Incorrect cam timing.
1 2 3 4 5 6 7 8 9 10 11 12 13
48
ENGINE 2-3
TROUBLE No.
POSSIBLE CAUSE
1 2 3 4 5 6 7 8 9 10 11 12 13
INTAKE SYSTEM
0 0 © 0 0 © 0 0 © • Improper idle adjustment.
0 © © © /:, © • Loosened or cracked intake boot.
0 © © © /:, © • Loosened or cracked intake duct.
/:, © © © /:, © © • Loosened or cracked blow-by hose.
/:, © 0 © © 0 © • Loosened or cracked vacuum hose.
0 0 0 0 0 © • Defective intake manifold gasket.
0 0 0 0 0 © • Defective throttle body gasket.
/:, 0 0 0 0 0 • Defective PCV valve.
0 0 0 /:, 0 /:,
• Loosened oil filler cap.
/:, /:, © 0 0 © • Dirty air cleaner element.
FUEL LINE
© /:, /:, 0 0 • Defective fuel pump.
•
I 0
/:,
0
/:,
0
/:,
0
0
/:,
0
/:,
•
Clogged fuel line.
Lack of or insufficient fuel.
BELT
0 0 0 • Defective.
0 0 0 /:, 0 0 0 0 0 • Defective timing.
FRICTION
/:, • Seizure of crankshaft and connecting-rod bearing.
/:, • Seized camshaft.
/:,
• Seized or stuck piston and cylinder.
COMPRESSION
/:, /:, /:, 0 0 0 0 /:, 0 • Incorrect valve clearance.
/:, /:, /:, 0 0 /:, /:, /:,
• Loosened spark plugs or defective gasket.
/:, /:, /:, 0 0 /:, /:, /:,
• Loosened cylinder head nuts or defective gasket.
£:... £:... £:... 0 0 £:... 0 0 • Improper valve seating.
6- /:, /:, /:, /:, /:, /:, © /:, • Defective valve stem.
0 0 0 0 0 £:... £:... £:... • Worn or broken valve spring.
£:... £:... £:... 0 £:... £:... £:... © 0 • Worn or stuck piston rings, cylinder and piston.
0 0 0 © © © © 0 0 • Incorrect valve timing.
0 0 0 0 0 0 • Improper engine oil (low viscosity).
LUBRICATION SYSTEM
0 0 /:, £:... • Incorrect oil pressure.
0 • Loosened oi I pump attaching bolts and defective gasket.
0 • Defective oil filter seal.
0 • Defective crankshaft oil seal.
/:, 0 • Defective rocker cover gasket.
0 • Loosened oil drain plug or defective gasket.
0 • Loosened oil pan fitting bolts or defective oil pan.
1 2 3 4 5 6 7 8 9 10 11 12 13
49
2-3 ENGINE
TROUBLE No.
POSSIBLE CAUSE
1 2 3 4 5 6 7 8 9 10 11 12 13
COOLING SYSTEM
b. /::; 0 0 © • Overheating.
b. b. b. • O,,:er cooling.
OTHERS
© © b. /::; • Malfunction of Evaporative Emission Control System.
(See Chap. 2-1)
0 © • Stuck or damaged throttle valve.
b. 0 0 • Dashpot out of adjustment ..
b. 0 0 0 • Accelerator cable out of adjustment.
0 0 0 0 • FICO out of adjustment.
0 0 • Malfunction of FICO.
1 2 3 4 5 6 7 8 9 10 11 12 13
50
ENGINE 2-3
Engine Noise
In case of 1800 cc OHC engine, valve lash adjuster may make clicking noise once engine starts. It is normal if clicking noise
ceases after a few seconds.
If clicking noise continues after several seconds, check engine oil level and add oil if necessary. Then allow engine to idle for
10 to 20 minutes while- maintaining engine speed at 1,500 to 2,000 rpm.
Type of sound Condition Possible cause
Regular clicking Sound increases as engine speed increases. Valve mechanism is defective
sound. • Broken lash adjuster.
• Worn valve rocker.
• Worn camshaft.
• Broken valve spring.
_. • Worn valve lifter hole.
Heavy and dull Oil pressure is low. • Worn crankshaft main bearing.
metallic knock. • Worn connecting rod bearing
(big end).
Oil pressure is normal. • Loose flywheel mounting bolts.

• Damaged engine mounting.
High-pitched metallic Sound is noticeable when accelerating with an overload. • Accumulation

Ignition timing advanced.
knock.
(Engine knocking)
• of carbon inside
combustion chamber.
• Wrong spark plug.
• Improper gasoline.
Metallic knock when Sound is reduced when spark plug in noisy cylinder is • Worn crankshaft main bearing.
engine speed is
medium (1,000 to
shortened out. • Worn bearing at crankshaft
end of connecting rod.
2,000 rpm).
Knocking sound
when engine is
Sound is reduced when spark plug in noisy cylinder is
shortened out.
• Worn
ring.
cylinder liner and piston
operating under • Worn

Broken or stuck piston ring.
idling speed and • piston pin and hole at
engine is warm. piston end of connecting rod.
Sound is not reduced if each spark plug is shortened out • Unusually worn valve lifter.
in turn. • Worn cam gear.
• Worn camshaft journal bore in
crankcase.
Squeaky sound. • Insufficient alternator lubrica-

tion.
Rubbing sound. • Defective alternator brush and

rotor contact.
51
2-3 ENGINE
Type of sound Condition Possible cause
Gear scream when

starting engine.
• switch.
Defective ignition starter
• Worn ring gear and starter

pinion.
Sound like polishing • Defective

Loose drive belt.
glass with a dry cloth. • water pump shaft.
Hissing sound. • Air

Loss of compression.
• tem,leakage in air intake sys-
hoses, connections or
manifolds.
Timing belt noise. • Loose timing belt.

• Belt contacting case/adjacent
part.
Distributor gear noise. • Worn gear.
52
ENGINE 2-3
2700 cc Engine
General rangement, is made of an aluminium alloy, and is lightweight.
This engine also adopts the OHC (Over-Head Camshaft)
The SUBARU XT6 houses a horizontally-opposed 6-cylinder, system, hydraulic lash adjuster, and multi point fuel injection
4-stroke cycle, liquid cooled OHC gasoline engine. This well- system, attaining reliability as well as low fuel consumption,
balanced engine, adopting a horizontally opposed piston ar- low vibration and powerful performance.
L2-1279
Fig. 110
53
2-3 ENGINE
CYLINDER BLOCK
2} Four main journals are provided because of the 6-cylinder
1) The cylinder block, made of an aluminium alloy, is light- engine. These journals are lubricated through oil passages lo-
weight and provides good heat conduction, and is divided into cated in the right bank of the engine. The oil passage is en·
two portions, left-side half and right-side half, due to the larged to reduce oil resistance.
adoption of a horizontally opposed piston arrangement.
Cylinder block (RH) Main journal
Oil passage
L2·1280
Fig. 111
CYLINDER HEAD 2) The intake ports are independent types. The #1 and #3,
1) The cylinder head, made of an aluminium alloy, forms a and #2 and #4 exhaust ports are assembled types and the #5
part of the bath-tub type combustion chamber which features and #6 exhaust ports are independent types.
higher combustion efficiency.
Intake port
Exhaust port
Intake port
Exhaust port
(#2, #4, #6) (#1, #3, #5) L2-1281

Fig. 112
54
ENGINE 2-3
HEAD GASKET ROCKER COVER
The head gasket is finished with a silicon-based, cotton-like 1) The rocker cover is made from thin, die-cast aluminium
treatment at the oil coolant passages to improve sealing. and is equipped with an oil separator.
2) This rocker cover adopts a float-supporting system with a
CAMSHAFT CASE rubber ring type gasket and an oil seal washer to reduce the
noise level.
1) The camshaft case holds the camshaft, and is an alum i-
nium die-casting.
2) A rib connects the front journal and the mounting portion
of the cam support to strengthen the camshaft case.
3) An oil filler duct and distributor are built into the left Rocker cover
camshaft case.
4) An oil passage is provided in the camshaft case at the
mounting portion of the cam support. Bolt
5) The camshaft case has a floating design which uses O-rings
together with mounting bolts.
Front Rubber ring type gasket

L2-1283
Fig. 114
CRANKSHAFT
The crankshaft is supported by four bearings. Two crank pins
are used between adjacent crank journals.
These crank pins are located equally at an angle of 60° and are
(LH) (RH)
numbered #1, #6, #3, #2, #5 and #4 in the clockwise
direction.
L2-1282
Fig. 113 #6 #3
#1 #2
#4 #5
L2-1284
Fig. 115
55
2-3 ENGINE
CRANKSHAFT PULLEY Valve Mechanism
1) The crankshaft pulley is a damper type into which a
bushing is pressed. This results in reduced torsional vibration 1) The valve mechanism adopts a timing belt driven over-
which occurs in a long crankshaft. head camshaft (OHC) type.
2) The pulley is a one·stage type which is used with a six- 2) The valve mechanism is provided with the hydraulic lash
crested, ribbed V-belt to improve serviceability. Belt tension is adjusters for maintenance-free, noiseless valve operation.
adjusted by moving the screw on the belt-tension pulley. 3) The width of the left and right timing belts is designed to
accommodate loads.
The left timing belt is equipped with a belHension adjuster to
maintain constant tension.
Fig. 116
Camshaft sprocket
Camshaft
sprocket
Belt tension
Tensioner (RH) adjuster
Idler
Oil pump sprocket
L2-1286
Fig. 117
CAMSHAFT VALVE ROCKER AND VALVE LASH

1) The camshafts are made of special cast iron, and are ADJUSTER
completely treated with Lubrite except for the bearing 1) The rocker arms are special steel forgings having great
portions to improve initial fitting to the rocker arms. The strength and rigidity. Each arm is fitted with a sintered metal
cam rubbed surface is chilled to increase wear-resistance. tip to improve wear resistance.
2) The cam profile is specially designed for this OHC type, 2) The hydraulic valve lash adjuster eliminates the need for
and features higher output and less fuel consumption. valve clearance adjustment.
3) The cam base circle has an oil hole for lubricating the 3) The rocker arms and valve lash adjusters are common
rocker arm. The distributor drive gear is mounted on the between intake and exhaust valves.
left-hand camshaft.
56
ENGINE 2-3
VALVE AND VALVE SPRING

1) The valve has a small valve stem diameter [7 mm (0.28 in)
d ia.] to reduce the valve weight.
2) Both the intake and exhaust valve springs are non-linear-
pitch, double types.
3} The variable pitch valve spring is adopted to improve valve
follow-up performance at high engine speeds.
BELT TENSION ADJUSTER, TENSIONER

1) The belt tension adjuster is oil-filled and consists of a
spring and a special screw.
2) The adjuster used with the left timing belt automatically
adjusts and maintains belt tension.
3) The left belt tensioner is supported by a self-lubricating,
resin bearing.
Spring
Operation J:0')::;t;~f-- Shaft

The belt tension adjuster appl ies a constant load to the contact
portions and the arm and operates as follows:
• Operation in the direction of belt elongation
(1) If the left timing belt becomes loose, the adjuster
shaft turns counterclockwise by spring tension when Plug screw
L2-1287
viewed from the bottom.
(2) The rod wh ich meshes with the end of the adjuster Fig. 118
shaft is then tifted.
The rod is not turned by the bearing but moves only up
and down. A screw is used to connect the shaft and rod so that the ten-
(3) The cap, which is coupled to the rod with a cotter sioner arm can be pushed up easily and not pushed down.
pin, moves to push the tensioner arm up.
(4) When the force lowering the arm by belt tension and CAMSHAFT SPROCKET AND TIMING BELT
the force to raising the cap by spring tension are balanced,
1) The camshaft sprocket has special round teeth featuring
the shaft stops. This maintains constant belt tension.
positive engagement with belt teeth and smooth, low-noise
• Operation in the direction of belt contraction
operation.
(Absorbs a change in belt length with a change in tempera-
2) The timing belt is composed of a core featuring great
ture)
strength and less elongation, and a canvas (tooth face portion)
Basically, the belt-tension adjuster operates in the reverse
having superior wear resistance and highly heat-resistant
manner of belt elongation.
rubber.
3) A heavy load is applied to the left timing belt by the oil
pump. For this reason, this belt is 6 mm (0.24 in) wider than
the right belt.
TIMING BELT COVER

1) The resin-mold timing belt cover, consisting of five pieces,
is used to protect the timing belt against dust and water.
2) Right-hand side cover has an access hole for belt tensioner
adjustment.
57
2-3 ENGINE

SPECIFICATIONS
Horizontally opposed, liquid cooled, 6-cylinder,

Type
4-stroke gasoline engine with multi-point fuel injection
Valve arrangement Over-head camshaft type
Bore x Stroke mm (in) 92 x 67 (3.62 x 2.64)
Piston displacement cm 3 (cc, cu in) 2,672 (2,672, 163.05)
Compression ratio 9.5
Compression pressure (at 350 rpm)

1,157 (11.8, 168)
kPa (kg/cm 2 , psi)
w
Z Number of piston rings Pressure ring: 2, Oil ring: 1
(!)
z
w
Opening 12° BTDC
I ntake valve timing
Closing 60° ABDC
Opening 60° BBDC

Exhaust valve timing
Closing 16° ATDC
Idling speed
(At neutral ) rpm 750 ± 100
(or N) or P position
Firing order 1-+6-+3-+2-+5-+4
Ignition timing BTDC/rpm 20° /750
58
ENGINE 2-3
SERVICE DATA
..... Surface warpage limit 0.075 mm (0.0030 in)

Q)
"C"C
c ra Surface grinding limit 0.3 mm (0.012 in)
.- Q)
>...c
u Standard height 90.6 mm (3.567 in)
Refacing angle 90°

+-'
Q)
en Wear limit 0.5 mm (0.020 in)
Q)
>
iii Contacting width Intake 1.2 - 1.8 mm (0.047 - 0.071 in)
> Exhaust 1.5 - 2.0 mm (0.059 - 0.079 in)
Q) Q)
Inner diameter 7.000 - 7.015 mm (0.2756 - 0.2762 in)
1!~
ra :::l
>Cl Protrusion above head 17 - 18 mm (0.67 -0.71 in)
Head edge thickness Intake STO 1.3 mm (0.051 in)

Limit 0.8mm (0.031 in)
Exhaust STO 1.3 mm (0.051 in)
E Limit 0.8mm (0.031 in)
Q)
+-'
en Stem diameter Intake 6.950 - 6.965 mm (0.2736 - 0.2742 in)
Q)
~ Exhaust 6.945 - 6.960 mm (0.2734 - 0.2740 in)
ra
> Stem oil clearance STO Intake 0.035 - 0.065 mm (0.0014 - 0.0026 in)
(between valve guide and Exhaust 0.040 - 0.070 mm (0.0016 - 0.0028 in)
valve stem) Limit 0.15 mm (0.0059 in)
Overall length Intake & Exhaust 107.58 mm (4.2354 in)
Free length Outer spring 51.7 mm (2.035 in)

Squareness Outer spring 2.3mm (0.091 in)
I nner spring 2.2 mm (0.087 in)
Tension/spring height Outer spring 177.5 - 204.0 N
Cl
c
(18.1 - 20.8 kg, 39.9 - 45.9 Ib)/
0. 41.5 mm (1.634 in)
en
Q) 447.2 - 513.9 N
>
(ij (45.6 - 52.4 kg, 100.5 - 115.5 Ib)/
> 31.5 mm (1.240 in)
Inner spring 88.3 - 101.0 N
(9.0 - 10.3 kg, 19.8 - 22.7 Ib)/
38.5 mm (1.516 in)
201.0 - 230.5 N
(20.5 - 23.5 kg, 45.2 - 51.8 Ib)/
28.5 mm (1.122 in)
S10: Standard
59
2-3 ENGINE
.L:. Outer diameter 21.380 - 21.393 mm (0.8417 - 0.8422 in)

VI
~ "-
- IV Cylinder head adjuster hole 1.0. 21.400 - 21.441 mm (0.8425 - 0.8441 in)
_~t::
::l
~ ...... Adjuster-to-hole clearance STO 0.007 - 0.061 mm (0.0003 - 0.0024 in)
>~ Limit 0.1 mm (0.004 in)
Surface warpage limit (mating with cylinder head) 0.075 mm (0.0030 in)
Surface grinding limit 0.4 mm (0.016 in)
Metal housing 1.0. 59.000 - 59.018 mm (2.3228 - 2.3235 in)
..lIo::
t)
Oil seal hole 1.0. Front and center 59.000 - 59.010 mm (2.3228 - 2.3232 in)
0
:0 Rear 93.000 - 93.035 mm (3.6614 - 3.6628 in)
"-
IV Cylinder bore STO 91.985 -92.015 mm (3.6214 -3.6226 in)
"C
c::
Taper limit 0.050 mm (0.0020 in)
>.
u Out-of roundness limit 0.050 mm (0.0020 in)
Piston clearance STD 0.015 - 0.035 mm (0.0006 - 0.0014 in)
limit 0.060 mm (0.0024 in)
Enlarging (boring) limit 0.5mm (0.020 in)
Outer diameter STO 91.970 - 91.980 mm (3.6209 - 3.6213 in)

c 0.25 mm (0.0098 in) OS 92.220 - 92.230 mm (3.6307 - 3.6311 in)
....0
VI
Q: 0.50 mm (0.0197 in) OS 92.470 - 92.480 mm (3.6405 - 3.6409 in)
Standard inner diameter of piston pin hole 20.999 - 21.009 mm (0.8267 - 0.8271 in)

c::
'0. Standard clearance between piston pin and hole in piston 0.001 - 0.015 mm (0.00004 - 0.00059 in)
c::
....0 Oegree of fit Piston pin must be fitted into position with
VI
Q: thumb at 20°C (68°F).
Standard clearance between piston pin and hole in connecting rod 0- 0.022 mm (0 - 0.0009 in)
Width Top ring 1.17-1.19mm (0.0461 - 0.0469 in)

Second ring 1.47 - 1.49 mm (0.0579 - 0.0587 in)
Radial wall thickness Top ring 3.0 -3.2 mm (0.118 -0.126 in)
Second ring 3.6 - 3.8 mm (0.142 - 0.150 in)
01
c::
Piston ring gap Top & Second ring STD 0.2 - 0.35 mm (0.0079 - 0.0138 in)
"-
c Limit 1.5 mm (0.059 in)
....0
VI Oil ring STO 0.3 - 0.9 mm (0.012 - 0.035 in)
Q:
Limit 2.0mm (0.079 in)
Clearance between piston ring and Top ring STD 0.040 - 0.080 mm (0.0016 - 0.0031 in)
piston ring groove Limit 0.15 mm (0.0059 in)
Second ring STO 0.030 - 0.070 mm (0.0012 - 0.0028 in)
Limit 0.15 mm (0.0059 in)
Oil ring STO Omm (0 in)
Limit Omm (0 in)
STO: Standard as: Oversize
60
ENGINE 2-3
Oistance between big end and small end hole 116.95 -117.05 mm (4.6043 -4.6083 inl
'C Crank pin bore diameter 48.000 - 48.019 mm (1.8898 - 1.8905 inl
...
0
Piston pin bore diameter 21.000 - 21.016 mm (0.8268 - 0.8274 in)
01
c
....(.)
Width at big end 19.35 - 19.43 mm (0.7618 - 0.7650 in)
(1)
c: Side clearance STO 0.070 - 0.330 mm (0.0028 - 0.0130 in)
c
8 Limit 0.4 mm (0.016 in)
Bend twist per 100 mm (3.94 in) in length Limit 0.10 mm (0.0039 in)
Thickness at center portion STO 1.485 - 1.490 mm (0.0585 - 0.0587 in)

0101
c c 0.03 mm (0.0012 in) US 1.500 - 1.505 mm (0.0591 - 0.0593 in)
'';; .~
(.) III
(1) (1)
0.05 mm (0.0020 in) US 1.510 -1.515 mm (0.0594 - 0.0596 in)
coO
c'C 0.25 mm (0.0098 in) US 1.610 - 1.615 mm (0.0634 - 0.0636 in)
8e Oil clearance STO 0.010 - 0.070 mm (0.0004 - 0.0028 in)
Limit 0.10 mm (0.0039 in)

Limit 0.30 mm (0.0118 in)
Crank journal outer diameter Front STO 54.957 - 54.972 mm (2.1637 - 2.1642 in)
0.03 mm (0.0012 in) US 54.927 - 54.942 mm (2.1625 - 2.1631 in)
0.05 mm (0.0020 in) US 54.907 - 54.922 mm (2.1617 - 2.1623 in)
0.25 mm (0.0098 in) US 54.707 - 54.722 mm (2.1538 - 2.1544 in)
Center & Center II STO 54.954 - 54.970 mm (2.1635 - 2.1642 in)
:"..~.• _.,•.)di
0.03 mm (0.0012 in) US 54.924 - 54.940 mm (2.1624 - 2.1630 in)
0.05 mm (0.0020 in) US 54.904 - 54.920 mm (2.1616 - 2.1622 in)
, \
0.25 mm (0.0098 in) US 54.704 - 54.720 mm (2.1537 - 2.1543 in)
Rear STO 54.955 - 54.970 mm (2.1636 - 2.1642 in)
0.03 mm (0.0012 in) US 54.925 - 54.940 mm (2.1624 - 2.1630 in)
0.05 mm (0.0020 in) US 54.905 - 54.920 mm (2.1616 - 2.1622 in)
-
~
~
....
I II
II>
c
Width at center portion
0.25 mm (0.0098 in) US 54.705 - 54.720 mm (2.1537 - 2.1543 in)
25.970 - 26.015 mm (1.0224 - 1.0242 in)
...
u
III
Oil clearance Front & Rear STO 0.003 - 0.036 mm (0.0001 - 0.0014 in)
Limit 0.055 mm (0.0022 in)
Center & Center II STO 0.008 - 0.027 mm (0.0003 - 0.0011 in)
Limit 0.045 mm (0.0018 in)
Crankpin outer diameter STO 44.995 - 45.010 mm (1.7715 - 1.7720 in)
0.03 mm (0.0012 in) US 44.965 - 44.980 mm (1.7703 - 1.7709 in)
0.05 mm (0.0020 in) US 44.945 - 44.960 mm (1.7695 - 1.7701 in)
0.25 mm (0.0098 in) US 44.745 - 44.760 mm (1.7616 - 1.7622 in)
Width 19.50 - 19.68 mm (0.7677 - 0.7748 in)
Limit 0.10 mm (0.0039 in)
STD: Standard os: Oversize us: Undersize
61
2..3 ENGINE
Thickness Front & Rear STO 2.015 - 2.019 mm (0.0793 - 0.0795 in)
Cl
0.03 mm (0.0012 in) US 2.030 - 2.034 mm (0.0799 - 0.0801 in)
c::
.;: 0.05 mm (0.0020 in) US 2.040 - 2.044 mm (0.0803 - 0.0805 in)
III
CI)
.c 0.25 mm (0.0098 in) US 2.140 - 2.144 mm (0.0843 - 0.0844 in)
........
III Center & Center II STO 2.019 - 2.022 mm (0.0795 - 0.0796 in)
.L;
VI
~ 0.03 mm (0.0012 in) US 2.034 - 2.037 mm (0.0801 - 0.0802 in)
c::
...
u
III
0.05 mm (0.0020 in) US 2.044 - 2.047 mm (0.0805 - 0.0806 in)
0.25 mm (0.0098 in) US 2.144 - 2.147 mm (0.0844 - 0.0845 in)
Width Center STO 25.920 - 25.960 mm (1.0205 - 1.0220 in)

Limit 0.35 mm (0.0138 in)
Cam lobe height STO 39.64 - 39.74 mm (1.5606 -1.5646 in)
Wear limit 39.49 mm (1.5547 in)
........III Cam journal outer diameter Front 37.964 - 37.980 mm (1.4946 - 1.4953 in)
.L;
VI Center 48.464 - 48.480 mm (1.9080 - 1.9087 in)
E
III
u Center II 47.964 - 47.980 mm (1.8883 - 1.8890 in)
Rear 49.464 - 47.480 mm (1.9474 - 1.8693 in)
LH distributor 38.964 - 38.980 mm (1.5340 - 1.5346 in)
Limit 0.070 mm (0.0028 in)
Camshaft journal inner diameter Front (camshaft support inner *138.000-38.018mm (1.4961 -1.4968in)
CI)
diameter)
VI
III
(.) Center 48.500 - 48.525 mm (1.9094 - 1.9104 in)
........
III Center II 48.000 - 48.025 mm (1.8898 - 1.8907 in)
.L;
'"
E
I'tI
Rear 47.500 - 47.525 mm (1.8701 - 1.8711 in)
u Distributor 39.000 -39.013 mm (1.5354 -1.5359 in)
Camshaft support depth of spigot 19.00 - 19.08 mm (0.7480 - 0.7512 in)
':III
:= ....
...
1.0. 38.000 - 38.018 mm (1.4961 - 1.4968 in)
.L;O
VIa. 0.0. 57.971 - 59.990 mm (2.2823 - 2.3618 in)
Ea.
III ::::l
u'" Height of spigot 14.95 - 15.00 mm (0.5886 - 0.5906 in)
STD: Standard US: Undersize *1 Camshaft support I.D.
62
ENGINE 2-3
COMPONENT PARTS 1 Water by-pass hose

2 Service hole plug
3 Oil seal (Rear)
4 Oil separator cover gasket
5 Oil separator cover
6 Main gallery plug
7 Cylinder block O-ring
B Back-up ring
9 Service hole plug
10 Oil pan gasket
11 Oil pan
12 Oil drain plug
13 Oil strainer
14 O-ring
@ 15 Oil strainer stay
17 Gasket
O-ring
I
.~.0J.="""" ,~~
22 Oil level gauge guide
23 Oil level gauge
25 Cylinder block
@ 26 Water pump ASSY
27 Gasket
@,J 28 Oil pump ASSY
r'Ii:\;~j'
~ ' .. 29 Oil pressure gauge
@-Ojz",// -,
~~~@
@ : "'i; ~
I
I
Tightening torque N -m (kg-m, ft-Ib)

T1: 4.4 - 5_4 (0.45 - 0.55, 3.3 - 4.0)
T2: 62 - 76 (6.3 -7.7, 46 - 56)
T3: 39 - 44 (4.0 - 4.5, 29 - 33)
T4: 17.2 - 20.1 (1.75 - 2.05,12.7,- 14.8)
T5: [M10l 39 - 47 (4.0 - 4_8, 29 - 35)
[Mal 23 - 26 (2.3 - 2.7, 17 - 20)
T6: 9.1 - 10.5 (0.93 - 1.07,6.7 - 7.7)
T7: 22 - 27 (2.2 - 2.8,16 - 20) .
Fig. 119
2-3 ENGINE
Crankshaft and Piston
1 Reinforcement
2 Drive plate
3 Flywheel
4 Ball bearing
5 Circlip
6 Piston pin
7 Connecting rod
8 Connecting rod bearing
9 Piston ®
10 Top ring
11 Second ring
12 Oil ring
"'-
13 Crankshaft bearing "'-
14 Crankshaft "'-
15 Crankshaft pulley "- '-
16 V-belt 1
17 Crankshaft sprocket CP ®
18 Crankshaft sprocket No.2
19 Woodruff key
20 Connecting rod cap
21 Connecting rod cap bolt
22 Connecting rod bearing
I

Tl: 69 -75 (7.0 -7.6, 51 - 55)
T2: 39 - 42 (4.0 - 4.3,29 - 31)
T3: 89 - 107 (9.1 - 10.9,66 - 79)
Fig. 120 L2-1289

Cylinder ~H~e=a=d:-~--_~EN~G~INNE
~.:--------~~
and Flywheel H ouslng 2-3
~
?~®
I
I
i
I
I
~ CYI~nder head (RH)

Cylinder head
3 En. gasket
glne hanger
4 Cable bracket
65 Flywh
. ee I housing
7 CYI~nder head (LH)
Cy Ilnder head
8 Exh gasket
aust valve
9 Intake valve
10
11 Intake
E h valve oil seal
x aust val .
12 Valve I ve oil seal
13 Val ash adjuster
ve rocker
14 Valve·
15 Val Innerspring
16 V ve outer spring
(jJ)
17 V alve
I sprin g retainer
® ave sprin
18 Guide (" g retainer key
@
@@ 7
@
.
19 . Intake)
Gu,d, loxh8u")
Tightening torque N·m (k

T1: 46 _ 54 (4 g-m, ft-Ib)
T2: 34 _ 40 (3:~
T3: 60 _ 68 (6
=5.5, 34 - 40)
4.1,25 - 30)
.1 - 6.9, 44 ~ 50)
Fig. 121 L2-1290
65
2-3 ENGINE
Camshaft and Timing Belt

~@& @ 1 Oil filler cap 7 Oil seal
/--
/'
/'
/' 2 a-ring 8 Camshaft sprocket
~, 3 Camshaft case (RH) 9 Camshaft (RH)
4 a-ring 10 Oil relief valve
Camshaft support 11 Oil relief spring
Timing belt (RH) 12 Oil relief pipe
13 Oil relief plug
14 Valve rocker cover gasket (RH)
15 Valve rocker cover (RH)
16 Camshaft case (LH)
17 Valve rocker cover gasket (LH)
18 Valve rocker cover (LH)
19 Distributor drive gear
20 Woodruff key
21 Camshaft (LH)
22 Camshaft sprocket
23 Timing belt (LH)
24 Belt idler
25 Tensioner
26 Belt tension adjuster
27 Tensioner
28 Tensioner spring
Tightening torque N·m (kg·m, ft-Ib)

T1: 17.2 - 20.1 (1.75 - 2.05,12.7 - 14.8)
® T2: 23 - 26 (2.3 - 2.7, 17 -20)
T3: 4.4 - 5.4 (0.45 - 0.55, 3.3 - 4.0)
T4: 11 -13 (1.1 -1.3,8 - 9)
T5: 39 - 47 (4.0 - 4.8, 29 - 35)
T6: 6 -7 (0.6 - 0.7, 4.3 - 5.1)
L2-1291
Fig. 122
66
ENGINE 2-3
Belt Cover
./
./
/'
/'
./
./
/'
/'
./
./
1 Belt cover (RH)

2 Belt cover (LH)
3 Belt cover (eTR)
4 Belt cover No.2 (RH)
5 Belt cover No.2 (LH)
6 Belt cover seal
Tightening torque N'm (kg-m, ft-Ib)

T: 4.4 - 5.4 (0.45 - 0.55, 3.3 - 4.0)
L2-1292
Fig. 123
67
.1
2-3 ENGINE
Electrical Equipment
1 Spark plug cord

2 Starter
3 Knock sensor
4 Distributor
5 Ignition coil
6 Cover
7 Nut plate
8 Alternator
9 Engine hanger
10 Alternator bracket
11 Cover
12 Tensioner pulley
Tightening torque N·m (kg·m, ft·lb)

T1: 22 - 27 (2.2.- 2.8, 16 - 20)
T2: 18 - 24 (1.8 - 2.4, 13 - 17)
T3: 4 - 6 (0.4 - 0.6, 2.9 - 4.3)
T4: 34 - 44 (3.5 - 4.5, 25 - 33)
L2·1293
Fig. 124
\
68
L
ENGINE 2-3
SERVICE PROCEDURE
General Precautions 4) Remove water pump pulley.
5) Remove crankshaft pulley. To lock crankshaft, use F L Y-
WHEEL STOPPER [manual transmission model] or DRIVE
• Before disassembling engine, install ENGINE STAND
PLATE STOPPER [automatic transmission model].
(499817100) x 2.
Place a 5 em (2.0 in) high wooden block under the ENGINE

STAND at four places so that the oil pan does not touch the
floor.
• Drain coolant and engine oil.

• All parts should be thoroughly cleaned, paying special
attention to the engine oil passages, pistons and bearings.
• Rotating parts and sliding parts such as piston, bearing and
gear should be coated with oil prior to ASSY.
• Be careful not to let oil, grease or coolant contact the
timing belt and clutch disc.
• All removed parts, if to be reused, should be reinstalled in
the original positions and directions. Fig. 126
• Gaskets and lock washers must be replaced with new ones.
Liquid gasket should be used where specified to prevent
leakage.
• Bolts, nuts and washers should be replaced with new ones
as required.
• Even if necessary inspections have been made in advance,
proceed with ASSY work while making rechecks.
Timing Belt and Belt Cover

REMOVAL
1) Loosen water pump pulley mounting bolts. Fig. 127

2) Loosen two alternator mounting bolts.
3) Loosen the tension pulley lock nut to release V-belt ten-
sion. When removing V-belt, check that adjuster bolt is turned 6) Disconnect lead from oil pressure switch.
cou nterclockwise fully in the direction wh ich loosens the belt. 7) Remove oil level gauge gu ide together with gauge.
Oil level gauge guide
Fig. 125 Fig. 128
69
2-3 ENGINE
8) Remove belt covers RH, LH and eTR. 10) Remove tensioner R H.

11) Remove crankshaft sprocket.
Belt cover (LH) 12) Removing timing belt LH.
Belt cover (RH) (1) Remove idler pulley.
Belt cover (CTR)

L2-1296
Fig. 129
9) Removing timing belt R H.

Fig. 132
(1) Loosen tensioner mounting bolts on #1 cylinder by
1/2 turn.
(2) With tensioner fully turned to slacken belt, tighten
mounting bolts. (2) Remove plug rubber.
Fig. 130 Fig. 133
(3) Mark rotating direction of timing belt, then remove (3) Remove plug screw from ~elt tension adjuster lower
belt. side.
Belt tension adjuster
,~ Tensioner
L2·1301
Fig. 131 Fig. 134
70
ENGINE 2-3
(4) I nsert a standard screwdriver into the hole in the bot· After removing belt tension adjuster, reinstall plug screw in the
tom of belt tension adjuster. Turn the screw clockwise to bottom.
loosen belt tension and install BE LT ADJUSTE R STOP·
PER (13082AAOOOl. Remove the left belt tensioner. 15} Remove camshaft sprocket R Hand LH.
L2·1305
Fig. 135 Fig. 138
(5) Remove timing belt after marking rotating direction 16) Remove belt cover No.2 R Hand LH.
of belt.
Belt cover No.2 (LH)
L2-1306
Fig. 139
Fig. 136
13) Remove crankshaft sprocket No.2 and idler pulley.

14) Remove belt tension adjuster.
INSPECTION
Oc TIMING BELT
o~
1} Check timing belt teeth for breaks, cracks, and wear.
If any fault is found, replace belt.
2} Check the condition of back side of belt; if any crack is
Oc found, replace belt.
a. Be careful not to let oil, grease or coolant contact the beit.

Remove quickly and thoroughly if this happens.
b. Do not bend the belt sharply.
Fig. 137
71
2-3 ENGINE
TIMING BELT TENSIONER Belt cover No.2 (RH)
1) Check tensioner roller for smooth rotation. Replace roller
if noise or excessive play is noted.
2) Measure the out-of-squareness of tensioner roller H. If it
exceeds 0.5 mm (0.020 in), replace roller.
L2·177
Fig. 141
Fig. 142
2) Install camshaft sprockets to right and left camshafts.
Tightening torque:
11 -13 N·m (1.1 -1.3 kg-m, 8 - 9 ft-Ib)
BELT IDLER 3) I nstall belt tension adjuster.

(1) Remove plug screw from belt tension adjuster lower
Check idler for smooth rotation. Replace if noise or excessive side.
play is noted.
INSTALLATION
1) I nstall belt cover No.2 R Hand LH.
Tightening torque: Belt tension adjuster

L2-1309
4.4 - 5.4 N'm (0.45 - 0.55 kg-m, 3.3 - 4.0 ft-fb)
Fig. 143
72
L
ENGINE 2-3
(2) I nsert a standard screwdriver into the hole in the bot-
tom of belt tension adjuster. Turn the screw clockwise to
compress rubber boot. Then install BELT ADJUSTER
STOPPER (13082AAOOOO).
The clip furnished as a spare part can be used in place of BELT

ADJUSTER STOPPER.
L2-1312
Fig. 146
4) Install plug rubber.
BELT ADJUSTER
STOPPER
L2-1310
Fig. 144
(3) Using a syringe, add engine oil through air vent hole
on top of rubber boot until it overflows.
L2-1313
Fig_ 147
5) Install idler pulley.
Tightening torque:
39 - 47 N·m (4.0 - 4.8 kg-m, 29 - 35 ft-Ib)
L2-1311
Fig. 145
(4) Install plug screw.
Be sure to use a new plug screw gasket.
(5) I nstall belt tension adjuster.
Tightening torque:
23 - 26 N·m (2.3 - 2.7 kg·m, 17 - 20 ft-Ib)
Fig_ 148
73
2-3 ENGINE
6) I nstall crankshaft sprocket No.2 to crankshaft. (4) I nstall left tensioner. Check that it moves smoothly
after installation.
Sprocket No.2 can be identified by the absence of dowel pin.
Tightening torque:
7) Install timing belt LH. 39 - 47 N·m (4.0 - 4.8 kg-m, 29 - 35 ft-Ib)
(1) Align the center of three lines scribed on flywheel
with timing mark on flywheel housing.
L2·1317
Fig. 152
Fig. 149
(2) Align timing mark on camshaft sprocket LH with

notch in belt cover.
(5) Remove BELT ADJUSTER SroPPER from belt-ten-
sion adjuster.
Fig. 150
(3) Install timing belt from the crankshaft side. Be care·

Fig. 153
fu I not to loosen it.
a. Check that the end of left tensioner arm conta~ts

top of belt tension adjuster.
b. Make sure that flywheel timing mark and camshaft
sprocket LH timing mark are in their normal posi·
tions.
8) Install timing belt RH.

(1) Turn crankshaft one turn clockwise from the position
where timing belt LH was installed and align the center of
three lines scribed on the flywheel with timing mark on
flywheel housing.
(2) Align timing mark on camshaft sprocket RH with the
Fig. 151 notch in belt cover.
74
, ENGINE 2-3
(5) I nstall timing belt from the crankshaft side. Be care-
ful not to loosen it.
(6) Loosen tensioner RH tightening bolt @ by 1/2 turn
to apply tension to belt.
(7) Apply the specified torque to camshaft sprocket R H
Timing in counterclockwise direction using BELT TENSION
mark WRENCH (499437100). While applying torque, tighten
tensioner RH tightening bolt @ temporarily, then tighten
bolt ® temporarily.
L2·1319
Fig. 154
(31 Temporarily tighten bolts ® and @ while moving

the right tensioner down in the direction of the arrow.
Loosen bolt ®180°.
Fig. 157
.).
When torquing sprocket, be extremely careful not to apply
L2-1320
excessive force to it. Excessive belt tension will greatly reduce
Fig. 155 belt life.
Belt tension Torque to cam sprocket

(4) I nstall crankshaft sprocket to crankshaft.
147 -245N 24 - 25 N·m
(15 - 25 kg, 33 - 551b) (2.4 - 2.6 kg-m, 17 - 19 ft-Ib)
(8) Tighten bolt @ and bolt ®, in that order, to the

specified torque.
Tightening torque:
23 - 26 N·m (2.3 - 2.7 kg-m, 17 - 20 ft-Ib)
L2-1321 Make sure that flywheel timing mark and camshaft sprocket
Fig. 156 RH timing mark are in their normal positions.
75
2-3 ENG1NE
9) Install belt cover CTR. 17) Install V-belt and apply proper tension to the belt.
(1) Loosen belt tension pulley lock nut.
(2) Turn adjusting bolt to adjust belt tension.
The belt tightens when the bolt is turned clockwise and
vice versa.
Fig. 158
Fig. 160
10) Install crankshaft pulley to crankshaft using FLYWHEEL
STOPPER (498277000) [manual transmission model] or
DRIVE PLATE STOPPER (498497000) [automatic transmis-
~
sion model] to lock crankshaft. H: mm On)/ Tension:
98 N (10 kg, 22 Ib) N (kg,lb)
When tightening bolt, apply engine oil to the threads, then 637 -736
New belt 5.5 - 6,5 (0.217 - 0.256)
tighten. (65 - 75, 143 - 165)
441 - 637
Tightening torque: Existing belt 6.5 - 7,5 (0.256 - 0.295)
(45 - 65,99 - 143)
89 - 107 N·m (9.1 - 10.9 kg-m.
, 'I
66 - 79 ft-Ib)
11) Install oil level gauge guide.

(3) Tightel?-Iock nut.
Tightening torque:
4.4 - 5.4 N·m (0.45 - 0.55 kg-m, 3.3 - 4.0 ft-Ib) Tightening torqOe:
34 - 44 N·m (3.5 - 4.5 kg-m, 25 - 33 ft-Ib)
12) Install water pipe. Apply coolant to O-ring beforehand.
13) Install water pump pulley to water pump ASSY, and (4) After adjusting belt tension, turn adjusting bolt coun-
tighten nuts temporarily. terclockwise to lock.
14) Install belt covers RH and LH.
15) Install compressor (A/C). Tightening torque:
16) Install alternator. 4 - 6 N·m (0.4 - 0.6 kg-m, 2.9 - 4.3 ft-Ib)
When replacing belt with a new one, adjust its tension to the
specification, then readjust it to the same specification after
running engine for 5 minutes in consideration of its initial ex-
pansion.
18) Tighten water pump pulley mounting bolts.
Fig. 159
76
L - __
ENGINE 2-3
Camshaft and Valve Rocker DISASSEMBLY
REMOVAL 1) Remove camshaft support.

2) Remove camshaft.
1} Removing distributor Camshaft case

(1) Disconnect high-tension cords from spark plug.
(2) Remove distributor by removing mounting bolts.
4) Remove PCV hoses from rocker cover.
5) Remove valve rocker covers.
6) Remove camshaft cases, camshaft support, and camshaft
as a unit.
Support
When removing camshaft case, valve rockers may come off. To L2-1328
prevent them from being damaged, be sure to place waste Fig. 163
cloth or rubber mat under cylinder head.
3) Remove oil relief plug, then remove oil relief pipe, relief
Camshaft case valve spring, and relief valve.
~=-------~------
INSPECTION
L2-1326
Fig. 161
CAMSHAFT
7} Remove valve lash adjusters from cylinder head.
1) Measure the bend, and repair or replace if necessary.
a. Do not lay down removed adjusters; keep them erect. Limit:

b. Retain removed valve rockers and adjusters in the order of 0.025 mm (0.0010 in)
their removal so that they can be reinstalled correctly.
Lash adjuster
L2-1327 L2-1329
Fig. 162 Fig. 164
77
.. ~
2-3 ENGINE
2) Check journal for damage and wear. Replace if faulty.
G=Lnnn
" " .. l Center Center II Rear Distributor (LH)
*UJLtUlJJ
I I I I - i I
I I I 1 I I I I
li Camshaft
'"PPO" Camshaft
: Front:
Center
L2·1395
Fig. 165
Item Front Center Center" Rear Distributor LH
38.000
Cam case journal hole 48.500 - 48.525 mm 48.000 - 48.025 mm 47.500 - 47.525 mm 39.000 - 39.013 mm
- 38.018 mm*'
1.0. (1.9094 - 1.9104 in) (1.8898 - 1.8907 in) (1.8701 -1.8711 in) (1.5354 - 1.5359 in)
(1.4961 -1.4968 in)
37.964 - 37.980 mm 48.464 - 48.480 mm 47.964 - 47.980 mm 47.464 - 47.480 mm 38.964 - 38.980 mm
Camshaft journal 0.0.
(1.4946 - 1.4953 in) (1.9080 - 1.9087 in) (1.8883 - 1 .8890 in) (1.8687 - 1.8693 in) (1.5340 - 1.5346 in)
Clearance at Standard 0.020 - 0.054 mm (0.0008 - 0.0021 in)

journal
Limit 0.070 mm (0.0028 in)
* 1: Camshaft support I.D.
3) Measure thrust clearance between camshaft and camshaft

support. If the limit is exceeded, replace camshaft support.
Thrust clearance:
Standard
0.03 - 0.26 mm (0.0012 - 0.0102 in)
Limit
0.35 mm (0.0138 in)
Fig. 166
78
ENGINE 2-3
4) Check cam face condition; remove minor faults by grind-
Backlash:
ing with oil stone. Measure the cam height H; replace if the
Standard
limit has been exceeded.
0_015 - 0.126 mm (0.0006 - 0.0050 in)
Limit
Height H mm (in) Wear limit mm (in)
0.180 mm (0.0071 in)
39.69 ± 0.05
39.49 (1.5547) 6) Replace gear using a press and CAMSHAFT HOLDER
(1.5626 ± 0.0020)
(498027000) .
VALVE ROCKER
If cam or valve contact surface of valve rocker is worn or
dented, repair by removing the minimum necessary amount. If
worn heavily, replace valve rocker.
VALVE LASH ADJUSTER

Stand adjuster vertically. Push pivot portion forcefully to
check that no air is in the adjuster.
L2-1331
Fig_ 167 The new adjuster is provided with a pin which must be re-
moved before using.
(New adjuster)
5) Measure backlash between distributor drive gear and
distributor driven gear. If the limit is exceeded, replace distrib-
utor drive gear.
Pivot
a. Measure backlash after assembling the engine because cam-

shaft must be prevented from turning. L2-1333
b. Attach a dial gauge to distributor driven gear rotate rotor to Fig. 169
measure backlash.
ASSEMBLY
1) Press-fit oil seal into camshaft support by using I N~J A L-

LER (498037000), then attach a-ring. -,;:
Apply oil to a-ring beforehand. Y
2) Install oil relief valve, relief valve spring, oil relief pipe,
and oil relief plug to camshaft case.
L2-1332 Tightening torque:

23 - 26 N·m (2.3 - 2.7 kg-m, 17 - 20 ft-Ib)
Fig. 168
79
2-3 ENGINE
Oil relief pipe CP
L2·1334
Fig. 170 Fig. 172
<
3) Install woodruff key to camshaft, then press-fit distribu- C
t""
tor drive gear by using CAMSHAFT HOLDER (498027000)
and PRESS (899754112). 3) Apply fluid packing (Three-bond 1207B or-equivalent) to
groove of each camshaft case, then install to cylinder head.
PRESS
(899754112) Tightening torque:
23 - 26 N·m (2.3 - 2.7 kg-m, 17 - 20 ft-Ib)
I
...J I
Camshaft
CAMSHAFT HOLDER
(49802700)
L2·1335
Three·bond
Fig. 171
#1~207B 0
4) Insert camshaft into camshaft case, and install camshaft f

support. 0.5 -1.0mm
(0.020 - 0.039 in) L2-1337
Tightening torque: Fig. 173

5.9 - 6.9 N·m (0.60 - 0.70 kg-m, 4.3 - 5.1 ft-Ib)
Apply oil to the surfaces of camshaft case journal hole, cam-

shaft journal hole and camshaft support oil seal lip. After installing, abundantly apply engine oil to sliding surfaces
of cam and valve rocker_
INSTALLATION 4) Attach gaskets to valve rocker covers, and install the
1) Insert valve lash adjusters into cylinder head. covers to camshaft cases with rocker cover washers and bolts.
5) Install pev hoses.
6) Install timing belt, belt cover and related parts.
Be sure to insert each valve lash adjuster to its original posi-
(Refer to "Timing Belt and Belt Cover".)
tion.
7) Install oil filler duct.
2) Apply grease to spherical surface and sliding surface of 8} Install water pipe.
each valve rocker, then secure valve rockers to the respective 9) Install distributor, proceeding as follows:
valve adjusters and valves. (1) Bring #1 cylinder piston to its top dead center on
compression stroke. Set camshaft sprocket to the pO$ition
Be sure to apply grease; otherwise, valve rocker will drop off. shown in Figure.
80
ENGINE 2-3
Timing mark
L2-1338 L2-1340
Fig. 174 Fig. 176
(2)· Align distributor housing match mark with pInion

gear match mark to set #1 cYlinder at igniting position.
6) Remove water by-pass pipe to cylinder head.
7) Remove alternator bracket to cylinder head.
I Matching
mark
L2-1339
Fig. 175 L2-1341
Fig. 177
(4) Connect lead wires.
8) Remove spark plugs.
11) Install right and left belt covers.
9) Remove cylinder heads from cylinder block.
Loosen cylinder head bolts in two or three steps, in the order

shown in figure below, and remove them.
Cylinder Head
REMOVAL
1) Remove timing belt, belt cover and related parts.

(Refer to "Timing Belt and Belt Cover"')
2) Remove camshaft cases, lash adjuster and related parts.
3) Remove alternator.
4) Remove compressor (A/C).
5) Remove bolts attaching intake manifold to cylinder head, L2-1342
and then lift intake manifold from cylinder head. Fig. 178
81r
2-3 ENGINE
10) Using VALVE SPRING PRESS ASSY (899724100), com- 3) Inspect intake and exhaust valve seats, and correct the
press the valve spring and remove the valve spring retainer key_ contact surfaces with valve seat cutter if they are defective or
Remove each valve and valve spring_ when valve guides are replaced.
Mark each valve to prevent confusion. W (contacting width):

Intake
VALVE SPRING 1.2 - 1.8 mm (0.047 - 0.071 in)
PRESS ASSY Exhaust
(899724100) 1.5 - 2.0 mm (0.059 - 0.079 in)
Wear limit of valve seat (measured in
direction of valve axis):
0.5 mm (0.020 in) for both intake and exhaust valves
L2-1343
Fig. 179
INSPECTION
CYLINDER HEAD A5-052

Fig. 181
1) Make sure that no crack or other damage exists. In ad-
dition to visual inspection, inspect important areas by means
of red check.
2) Measure the warping of the cylinder head surface that
mates with cylinder block by using a straight edge and thick-
ness gauge. VALVE GUIDE
If the warping exceeds 0.075 mm (0.0030 in), regrind the sur- 1) Check the clearance between valve guide and stem. The
face with a surface grinder. clearance can be checked by measuring the outside diameter of
valve stem and the inside diameter of valve guide with outside
Warping limit: and inside micrometers respectively.
0.075 mm (0.0030 in)
Grinding limit:
Specifications for valve stem and valve guide
0.3 mm (0.012 in)
0.035 - 0.065 mm
Standard clearance Intake
(0.0014 - 0.0026 in)
between valve guide
and valve stem 0.040 - 0.070 mm
Exhaust
(0.0016 - 0.0028 in)
Limit of clearance between

0.15 mm (0.0059 in)
valve guide and valve stem
Standard inside diameter of 7.000 - 7.015 mm

valve guide (0.2756 - 0.2762 in)
6.950 - 6.965 mm
Intake
Standard diameter (0.2736 - 0.2742 in)
Thickness gauge of valve stem 6.945 - 6.960 mm
L2-1344
Exhaust
(0.2734 - 0.2740 in)
Fig_ 180
82
ENGINE 2-3
2) If the clearance between valve guide and stem exceeds the VALVE GUIDE REMOVER
specification, replace guide as follows: (399762103)
(1) Place cylinder head on CYLINDER HEAD TABLE
with the combustion chamber upward so that valve guides
enter the holes in CYLINDER HEAD TABLE.
(2) Insert VALVE GUIDE REMOVER into valve guide
and' press it down to remove valve guide.
VALVE GUIDE REMOVER .~

(399762103) ~OOO~
t ~~O O~~:;l~3
c:e;a;; Ol9
4~~ ~. c?aY~l
0 0 L2-1346
Fig. 184
~~~.. O~j? &'U;

(6) Check the valve guide protrusion.
\\~o
~(O)If:J ( . Valve guide protrusion: L
\ ~ 17 - 18 mm <0.67 - 0.71 in)
/'i CYLINDER HEAD
..
.~ ,@
/ TABLE (498267100) L2-1345
(7) Ream the inside of valve guide with VALVE GUIDE
Fig. 182 REAMER (399762104). Gently rotate the reamer clock-
wise while pressing it lightly into valve guide, and return it
. also rotating clockwise. After reaming, clean valve guide
to remove chips.
(3) Turn cylinder head upside down and place VALVE a. Apply engine oil to the reamer when reaming.
GU IDE ADJUSTE R as shown in the figure. b. If the inner surface of the valve guide is torn, the edge of
the reamer should be slightly ground with an oil stone.
c. If the inner surface of the valve guide becomes lustrous and
the reamer does not cut chips, use a new reamer or remedy the
.'
reamer.
Valve guide
protrusion: L (8) Recheck the contact condition between valve and
valve seat after replacing valve guide.
c
INTAKE AND EXHAUST VALVE OIL SEAL
Replace oil seal with new one, if lip is damaged or spring is out
of place, or when the surfaces of intake valve and valve seat are
reconditioned or intake valve guide is replaced.
Press in oil seal to the specified dimension indicated in the
L2-161
figure, using OIL SEAL INSTALLER.
Fig. 183
OIL SEAL
INSTALLER
(398852100)
(4) Before installing new valve guide, make sure that

neither scratches nor damages exist on the inside surface
of the valve guide holes in cylinder head.
(5) Put new valve guide, coated with sufficient oil, in
cylinder, and insert VALVE GUIDE REMOVER into
valve guide. Press in until the valve guide upper end is
flush with the upper surface of VALVE GUIDE L2-1347
ADJUSTER.
Fig. 185
B3
2-3 ENGINE
a. Apply engine oil to oill8al bafore force-fitting.

b. Differentiate betwa.n intake valve oil pal and exhaust
valve oill8al by noting their difference in haight.
Unit: mm (in)
~n {~ 13.0
} (0.612)
LC==t==:=:u
t
~ Fig. 188- CD
L2·1568
(Intake side) (Exhaust lida)

c. Be careful as there are two types of bolts.
L2·680
Bolt position Color Bolt length
Fig. 186
CD,®,@,@ Silver 118.5 mm (4.665 in)
Others Yellow 132.5 mm (5.217 in)

INSTALLATION
1) Install the oil seals to the valve guides using OIL SEAL
INSTALLER (398852100).
2) Coat the stem of each valve with engine oil and insert
the valve into the valve guide. Attach the valve springs and
SPR ING PRESS and fit the valve spring retainer key.
VALVE SPRING
PRESS ASSY
(899724100)
Fig. 188-(fy
(1) Tighten all bolts in two steps in the order indicat~

above: .
1st step: 39 N·m (4.0 kg·m, 29 ft-Ib)

2nd step: 64 N·m (6.5 kg-m, 47 ft-Ib)
L2·1343
Fig.t87 (2) Loosen all bolts at least 90° in reverse order.
(3) Tighten all bolts to specified torque.
After installing, tap the valve spring retainers lightly with a Tightening torque:
wooden hammer for better seating: 60 - 68 N·m (6.1 - 6.9 kg-m, 44 - 50 ft-Ib)
3) Install cylinder heads to cylinder block with new gaskets.

4) Install spark plugs.
5) I nstall bolt attaching water by-pass pipe bracket to cylin·
a. When tightening bolts, apply oil to the threads.
der head.
b. Be sure to install washers with their convex/chamfered sides
6) Install bolts attaching intake manifold to cylinder head.
facing bolt heads.
7) Install bolts attaching alternator bracket to cylinder head.
84
ENGINE 2-3
8) Install camshaft cases, lash adjustor and related parts.
9) Install timing belt, belt cover and related parts.
(Refer to "Timing Belt and Belt Cover".)

(Refer to "2-2 ON-CAR SERVICES".)
Valve and Valve Springs 900 + 1

-0
R = 0.3 mm (0,012 in)
REMOVAL
A5·293
1) Remove cyl inder from engine ASSY. Fig. 190

(Refer to "Cylinder Head".)
2) Using VALVE SPRING PRESS ASSY, compress the valve 2) If the contact surface of valve is damaged, or if the stem
spring and remove the valve spring retainer key. Remove each end is recessed, corre.€t with a valve refacer, grinding as little as
valve and valve spring. possible.
Mark each valve to prevent confusion.
VALVE SPRING
PRESS ASSY
(899724100)
A5·061
Fig. 191
L2·1343 VALVE SPRINGS

~--------------------------------~--------
Fig. 189 1) Check valve springs for damage, free length, and tension.
Replace valve spring if it is not to the specifications presented
below.
2) To measure the squareness of the valve spring, stand the
INSPECTION spring on a surface plate and measure its deflection at the top
using a try square,
INTAKE AND EXHAUST VALVE

1) Inspect the flange and stem of valve, and replace'if dam·
aged, worn, or deformed, q~ if "H" is Jess than the specified
limit.
H
Valve Overall length
Standard Limit
1.3 mm 0.8mm 107.58 mm

Intake
(0.051 in) (0.031 in) (4:235 in)
1.3 mm 0.8mm 107.58 mm

Exhaust
(0.051 in) (0.031 in) (4.235 in)
Fig. 192
85
2-3 ENGINE
Outer spring I nner spring
3)
----------
Free length 51.7 mm (2.035 in) 50.3 mm (1.980 in) 4)
Remove alternator and V·belt.
Removal of intake manifold ASSY
(1) Remove hoses and tubes from cyl inder block side.
177.5 - 204.0 N 88.3 - 101.0 N (2) Disconnect each harness.
(18.1 - 20.8 kg, (9.0 - 10.3 kg, (3) Disconnect knock sensor harness.
39.9 - 45.9 Ib)/ 19.8 - 22.7 Ib)/ (4) Remove intake manifold ASSY from engine.
Tension/ 41.5 mm (1.634 in) 38.5 mm (1.516 in)
spring
height 447.2 - 513.9 N 201.0 - 230.5 N
(45.6 - 52.4 kg, (20.5 - 23.5 kg,
100.5 - 115.5 Ib)/ 45.2 - 51.8 Ib)/
31.5 mm (1.240 in) 28.5 mm (1.122 in)
Squareness 2.3 mm (0.091 in) 2.2 mm (0.087 in)
ASSEMBLY
Coat the stem of each valve with engine oil and insert the valve
L2·1340
into the valve guide. Attach the valve springs and retainer.
Then compress the valve springs using VALVE SPRING Fig. 194
PRESS (899724100) and fit the valve spring retainer key.
After installing, tap the valve spring retainers lightly with a

wooden hammer for better seating. 5) Remove alternator brackets.
6) Remove PCV connector and harness clamp.
PCV connector
Harness clamp
Cylinder Block
REMOVAL
1) Remove distributor and plug cord.

Fig. 195

9) Remove crankshaft pulley. To lock crankshaft, use FLY·
WHEEL STOPPER (498277000) [manual transmission
model] or DRIVE PLATE STOPPER (498497000) [auto-
matic transmission model] .
11) Remove oil level gauge guide together with gauge.
13) Remove water pump together with hose.
Fig. 193
86
ENGINE 2-3
17) Remove camshaft, valve rocker and related parts.

18) Remove cylinder heads and gaskets.
19) Remove oil pan.
Fig. 196
14) Remove oil pump by aligning notch in oil pump pulley

with bolt position, then remove pump outer rotor from
Fig. 199
cylinder block.
Do not remove oil strainer from cylinder block.
DISASSEMBLY .
1) Remove oil separator cover.

Oil separator
.~
iI
I
L2·1352
Fig. 197
15) Remove flywheel [manual transmission model) or drive

plate [automatic transmission model), and take out flywheel
housing with housing cover. To lock crankshaft, use FL Y- L2-1355
WHEEL STOPPER (498277000) or DRIVE PLATE STOPPER Fig. 200
(498497000).
16) Remove flywheel housing. 2) Remove service hole plugs from cylinder block.
L2·1353
Fig. 198 Fig. 201
87
2-3 ENGINE
3) Rotate crankshaft to bring #1 and #2 pistons to BDC

position.
To turn crankshaft, turn crankshaft pulley bolt and not the

crankshaft pulley.
4) Remove piston circlip through service hole of #1 and #2

cylinders.
Fig. 204
8) Set up cylinder block so that #1, #3 and #5 cylinders are
j Long nose
on the upper side, then separate left-hand and right-hand
cylinder blocks.
pliers
L2-1357 When separating cylinder block, do not allow the connecting
Fig. 202
rod to fall and damage the cylinder brock.
5) Draw out piston pin from #1 and #2 pistons using

PISTON PIN REMOVER.
L2-1360
Fig. 205
9) Remove coolant passage G-ring and back-up ring from

cylinder block.
~PISTON PIN REMOVER

~ (499097300) L2-1358
Fib. 203
6) Turn crankshaft and remove #5 & #f3 and #3 & #4 in a

manner similar to removal of #1 and #2.
7) Remove all cylinder block connecting bolts except one L2-1361
bolt of #3 cylinder. Fig. 206
88
ENGINE 2-3
10) Remove front oil seal and rear oil seal from crankshaft.
11) Remove crankshaft together with connecting rod from
INSPECTION
cylinder block.
CYLINDER BLOCK
Check cylinder block for the following items, and correct or
1) Check for cracks and damage visually. Especially, inspect
important parts by means of red check.
2) Check the oil passages for clogging.
3) Inspect the cylinder block surface that mates with cyl-
inder head for warping by using a straight edge, and correct by
grinding if necessary.
Warping limit:
0.075 mm (0.0030 in)
"'. L2·1362
Grinding limit:
Fig. 207 0.4 mm (0.016 in)
12) Draw out each piston from cylinder block using wooden,,,,
bar or hammer handle.
L2·1365
Fig. 210
CYLINDER AND ~TON

1) Measure the inner dia,neter of each cyl inder in both the
Fig. 208 thrust and piston pin directions at the heights shown in the
figure, using a cylinder bore gauge.
13) Remove crankshaft bearings from cylinder block using Measurement should be performed at a temperature of 20°C
hammer handle. (68°F).
Cylinder bore
gauge
L2·1364 L2·1366
Fig. 209
89
2-3 ENGINE
Cylinder bore
91.985 - 92.015 mm
Standard diameter
(3.6214 - 3.6226 in)
Taper Urn it 0.050 mm (0.0020 in)
Out-of-round Limit 0.050 mm (0.0020 in)
Cyli nder-to-piston 0.015 - 0.035 mm

Standard
(0.0006 - 0.0014 in)
clearance at
20°C (68°F)
Limit 0.06 mm (0.0024 in)
2) Boring and honing

Fig. 213
(1) If the value of taper, out-of-roundness, or cylinder-to-
piston clearance measured exceeds the specified I imit or
if there is any damage on the cylinder wall, rebore it to Piston outer diameter:
use an oversize piston. Standard
91.970 - 91.980 mm (3.6209 - 3.6213 in)
When any of the cylinders needs reboring, all other cylinders 0.25 mm (0.0098 in) oversize
must be bored at the same time, and use oversize pistons. Do 92.220 - 92.230 mm (3.6307 - 3.6311 in)
not perform boring on one cylinder only, nor use an oversize 0.50 mm (0.0197 in) oversize
piston for one cylinder only. 92.470 - 92.480 mm (3.6405 - 3.6409 in)
(2) Get six of the oversize pistons and measure the outer (3) If the cylinder inner diameter exceeds the following
diameter of each piston at the height shown in the figure. enlarging limit after boring and honing, replace the cyl-
(Thrust direction) inder block.
Measurement should be performed at a temperature of 20° C Immediately after reboring, the cylinder diameter may differ
(68° F). from its real diameter due to temperature rise. Thus, pay
attention to this when measuring the cylinder diameter.
Enlarging limit of cylinder inner diameter:

0.5 mm (0.020 in)
L2·1367
ASSEMBLY
Fig. 212
1) Install ENGINE STANDS (499817100) to cylinder
blocks. When installing ENGINE STANDS, fit bolts to the
holes marked with HR" on the #1, #3 and #5 cylinder sides,
and to the holes marked with "L" on the #2, #4 and #6
cylinder sides.
2) Install crankshaft bearings to cylinder blocks.
3) Install crankshaft to left-hand cylinder block.
Apply engine oil to sliding surfaces of crankshaft journal and

crankshaft bearing.
90
'-_. -
-
ENGINE 2-3
Make sure D·ring is fitted correctly in groove.
Tightening torque:
10 mm bolt
39 - 47 N·m (4.0 - 4.8 kg-m, 29 - 35 ft·lb)
8 mm bolt
23 - 26 N·m (2.3 - 2.7 kg-m, 17 - 20 ft·lb)
L2-1369
Fig. 214
4) Fit G-ring and back-up ring to coolant passage of left-hand

cylinder block.
L2-1372
Fig. 217
7) Position the gaps of the piston rings and oil ring as shown
in the figure.
Back-up ring
L2-1370
Fig. 215 Top ring

5) Clean mating surfaces of cylinder block using thinner. rail rail
Apply liquid packing (Three Bond 1215 or equivalent) to the

mating surface (one side only).
Second ring
Be careful not to extend liquid packing to coolant and oil pas- Oil ring spacer
sages.
p:nVd I
Bend over pawl of upper rail
. and attach to 3.5 mm (0.138 in) dia.
hole.
'
Oil passage and coolant passage

L2-1371
Fig. 216
6) With left·hand cylinder block facing down, install right-

hand cylinder block. After tightening bolts temporarily, lay L2-1373
cylinder block down, then tighten bolts to the specified Fig. 218
torque.
91
2-3 ENGINE
8) Install pistons in cylinder as follows:
(1) Apply oil to the circumference of piston and the ~ =~~:~~~s end
inner surface of cylinder.
(2) With the #5 and #6 cyl inders facing downwards, turn
Long nose pliers
i::'
crankshaft until the #3 and #4 connecting rod comes to
the bottom dead center. Then insert the #4 piston into
cylinder by using PISTON GUIDE (398744300).
L2-1376
Fig. 221
Fig. 219 (5) Circlips must be installed in the order of #3, #1, #2,
#5 and #6 pistons.
(6) Turn crankshaft, and check whether piston and cir-
cI ip are assembled correctly.
9) Apply fluid packing (Three-bond 1205 or equivalent) to
plugs, and tighten it with aluminium gasket placed in between.
(3) Install piston pin through the service hole after align- Tightening torque:
ing the service hole, piston pin hole, and connecting rod
62 -76 N·m (6.3 -7.7 kg-m, 46 - 56 ft-Ib)
small end with PISTON PIN GU IDE (499017000).
Fig. 220 Fig. 222
(4) Install circlips through the service hole, using long- 10) Install front oil seal to cylinder block using INSTALLER
nosed pliers. (499567100).
Circlip must be installed in correct direction with its end Coat the outside surface of oil seal with engine oil and oil seal
facing out. lip with grease. Force·fit oil seal squarely into position.
92
ENGINE 2-3
Fig. 223 Fig. 225
INSTALLATION
1) Install oil pan.
111 Install rear oil seal to cylinder block using INSTALLER
(499587000) . Tightening torque:
4.4 - 5.4 N·m (0.45 - 0.55 kg-m, 3.3 - 4.0 ft-Ib)
Coat the outside surface of oil seal with engine oil, and oil seal
lip with grease. Force-fit oil seal squarely into position. 2) Install cylinder heads to cylinder blocks with gaskets
placed between.
them in two successive steps until the final tightening is at the
specified torque.
INSTALLER (Refer to "Cylinder Head".)
Fig. 224
L2-1348
Fig. 226
12) Install oil separator cover with gasket placed in be-
tween.
Tightening torque:
4.4 - 5.4 N·m (0.45 - 0.55 kg-m, 3.3 - 4.0 ft-Ib)
Tightening torque:
13) Install flywheel housing.
60 - 68 N·m (6.1 - 6.9 kg-m, 44 - 50 ft·lb)
Tightening torque:
34 - 40 N·m (3.5 - 4.1 kg-m, 25 - 30 ft-Ib)
93
2-3 ENGINE
3) Install flywheel to crankshaft using FLYWHEEL

STOPPER (498277000) for locking crankshaft. [Manual
transm iss ion model)
Tightening torque:
69 - 75 N'm (7.0 - 7.6 kg-m, 51 - 55 ft-Ib)
4) Install drive plate and reinforcement using DRIVE PLATE

STOPPER (498497000) for locking crankshaft. [Automatic
transmission model)
Rotor housing
Tightening torque:
69 - 75 N'm (7.0 - 7.6 kg-m, 51 - 55 ft-Ib)
5) Position the clutch cover so that the "e" marks on the

0
flywheel and clutch cover are spaced 120 or more.
Install clutch disc and clutch cover with bolts and spring
Outer rotor direction
washers, aligning clutch disc with flywheel by inserting
CLUTCH DISC GUIDE (499747000) into needle bearing
fitted in flywheel. [Manual transmission model)
Tightening torque:
14.2 - 17.2 N'm
(1.45 - 1.75 kg-m, 10.5 - 12.7 ft-Ib)
6) Install seal to water pump, then install the water pump Pulley direction
L2-187
to cylinder block with gasket placed between. Fig. 227
7) Install oil pump ASSY, proceeding as follows:
(1) Thoroughly remove. excess fluid packing from rotor
8) Insert valve lash adjusters into cylinder head.
housing of cylinder block.
(2) Apply a small amount of fluid packing (Three-bond Be sure to insert each valve lash adjuster to its original
1207B or equivalent) to the portion indicated by arrow in position.
figure in cylinder block.
9) Apply grease to spherical surface and sliding surface of
Remove any Three Bond 1207B which protrudes into rotor each valve rocker, then secure valve rockers to the respective
chamber. valve adjusters and valves.
Be sure to apply grease; otherwise, valve rocker will drop off.

(3) Apply ample engine oil to rotor housing, then insert
10) Apply fluid packing (Three-bond 1207B or equivalent) to
outer rotor into rotor housing by setting it as shown.
groove of each camshaft case, then install to cylinder head.
(4) Set oil pump pulley as shown, and install oil pump
ASSY to cylinder block with gasket placed between. After
installing, make sure pulley can be rotated smoothly. Tightening torque:
23 - 26 N-m (2.3 - 2.7 kg-m, 17 - 20 ft-Ib)
Apply grease to oil pump gasket to prevent dislocation fro-m

the groove. After installing, abundantly apply engine oil to sliding surfaces
of cam and valve rocker.
11) Attach gaskets to valve rocker covers, and install the
covers to camshaft cases with rocker cover washers and bolts.
Tightening torque:
4.4 - 5.4 N·m (0.45 - 0.55 kg-m, 3.3 - 4.0 ft-Ib)
94
1...
ENGINE 2-3
13) Install crank pulley to crankshaft using FLYWHEEL
STOPPER (498277000) [manual transmission model] or
DR IVE PLATE STOPPER (498497000) [automatic transmis-
sion model] to lock crankshaft.
Tightening torque:
89 - 107 N'm (9.1 - 10.9 kg-m, 66 - 79 ft-Ib)
ASSY, and tighten bolts temporarily.
15) Install oil level gauge and gauge gu ide. Apply engine oil to
O-ring beforehand.
16) Install oil filler duct and bracket. Intake manifold L2-1383
17) I nstall water by-pass pipe, hose, and water pipe. Apply
coolant O-rings beforehand.
Fig. 230
18) Install knock sensor.
22) Install harnesses.
Tightening torque: 23) Install hoses and tubes.
22 - 27 N·m (2.2 - 2.8 kg-m, 16 - 20 ft-Ib) 24) Install alternator to bracket, and tighten bolts tem-
porarily.
19) I nstall alternator brackets.
(1) Bring #1 cyl inder piston to its top dead center on
shown in Figure.
Fig. 228
20) Install PCV connector and harness clamp.
L2-1338
PCV connector Fig. 231
(2) Align distributor housing match mark with pinion

Harness clamp gear match mark to set #1 cylinder at igniting position.
Matching
mark
Fig. 229
21). Install intake manifold ASSY.
Tightening torque:
L2-1339
18 - 22 N·m (1.8 - 2.2 kg-m, 13 - 16 ft-Ib)
Fig. 232
95
2-3 ENGINE
(4) Connect lead wires. INSPECTION
26) Install right and left belt covers. PISTON AND PISTON PIN
27) Remove ENGINE STAND.
1) Check pistons and piston pins for damage, cracks, and
wear and the piston ring grooves for wear and damage.
Replace if defective.
Crankshaft and Piston 2) Measure the piston-to-cylinder clearance at each cylinder
as instructed in CYLINDER AND PISTON. If any of the
DISASSEMBLY clearances is not to specification, replace the piston or bore
the cylinder to use an oversize piston.
PISTON 3) Make sure that piston pin can be inserted into the piston
pin hole with a thumb at 20°C (6So F). Replace if defective.
1) Remove the piston rings using the piston ring expander.
Specifications for piston and piston pin:

Standard outer diameter of piston pin
20.994 - 21.000 mm (0.8265 - 0.8268 in)
Standard inner diameter of piston pin hole
20.999 - 21.009 mm (0.8267 - 0.8271 in)
Standard clearance between piston pin and hole in
piston
0.001 - 0.015 mm (0.00004 - 0.00059 in)
Standard clearance between piston pin and hole in
connecting rod I
o - 0.022 mm (0 - 0.0009 in)
L2·B13
Fig. 233 If burr is created on piston pin hole when removing circlip,
2) Remove the oil ring by hand. carefully remove it so that piston pin can move.
Arrange the removed piston rings in good order to prevent

confusion.
PISTON RING
CONNECTING ROD 1) If piston ring is broken, damaged, or worn, or if its
Remove connecting rod cap mounting nuts, and take out tension is insufficient, or when the piston is replaced, replace
connecting rod from crankshaft. piston ring with a new one of the same size as the piston.
fiR;' is marked on the end of the top and second rings. When
installing the rings to the piston, face this mark upward.
"R" mark
Second ring
L2-1385
Fig. 234
Arrange removed connecting rod and connecting rod cap in L2-1386

good order to prevent confusion. Fig. 235
96
ENGINE 2-3
The oil ring is a combined ring consisting of two rails and a 3) Measure the clearance between piston ring and piston ring
spacer in between. When installing, be careful not to make groove with a thickness gauge.
misassembly.
Before measuring the clearance, clean the piston ring groove
and piston ring.
Top ring
~ Standard limit
Top 0.04 - 0.08 mm 0.15 mm

Second ring Clearance ring (0.0016 - 0.0031 in) (0.0059 in)
between piston
Second 0.03 - 0.07 mm 0.15 mm
~upperrail ring and piston
Oil ring ring (0.0012 - 0.0028 in) (0.0059 in)
ring groove
~spacer
Oil ring 0 0
Lower rail
L2-1549
Fig. 236
I
L2-1387
Fig. 238
2) Squarely place piston ring in cylinder and measure the
piston ring gap with a th ickness gauge.
------=----- Top
ring
Standard
0.20 - 0.35 mm
(0.0079 - 0.0138 in)
Limit
1.5mm
(0.059 in)
Second 0.20 - 0.35 mm 1.5mm

Piston ring gap
ring (0.0079 - 0.0138 in) (0.059 in)
Oil ring 0.3 - 0.90 mm 2.0mm

rail (0.012 - 0.0354 in) (0.079 in)
o CONNECTING ROD
1) Replace connecting rod, if the large or small end thrust
surface is damaged.
2) Check for bend or twist using a connecting rod aligner.
Replace connecting rod if the bend or twist exceeds the limit.
o
) Limit of bend or twist per 100 mm (3.94 in) in length:
L2·478 0.10 mm (0.0039 in)
Fig. 237
97
2-3 ENGINE
4) Inspect connecting rod bearing for scar, peeling, seizure,
melting, wear, etc.
5) Measure the oil clearance on individual connecting rod
bearings by means of plastigauge according to the following
procedure.
(1) Wipe off oil, dust, etc. on the surfaces to be measured.
(2) Cut the plastigauge to the width of the bearing, place
it on the crankpin parallel with the crankshaft axis, and
install connecting rod. Tighten connecting rod nuts to
the specified torque.
Tightening torque:
1 Thickness gauge 39 - 42 N·m (4.0 - 4.3 kg-m, 29 - 31 ft-Ib)
2 Connecting rod
A5-077
During this measurement, do not allow relative movement

between the crankpin and connecting rod.
(3) Remove connecting rod and measure the width of the

plastigauge with the scale printed on the plastigauge case.
If any oil clearance is not within specification, replace the
defective bearing with a new one of standard size or
undersize as necessary, and replace or recondition the
crankshaft as necessary. (See the table below.)
Connecting rod oil clearance:

1 Connecting rod
Standard
2 Thickness gauge 0.010 - 0.070 mm (0.0004 - 0.0028 in)
A5-078 Limit
Fig. 239 0.10 mm (0.0039 in)
3) Install connecting rod fitted with bearing to crankshaft

and measure the side clearance (thrust clearance). Replace
connecting rod if the side clearance exceeds the specified limit_
Connecting rod side clearance:

Standard
0.070 - 0.330 mm (0.0028 - 0.0130 in)
Limit
0.4 mm (0.016 in)
L2-1389
Fig_ 241
Fig. 240
98
ENGINE 2-3
3) Inspect the crank journal and crankpin for wear. If not to
Connecting rod bearing specifications, replace bearing with an undersize one, and
Thickness at center replace or recondition crankshaft as necessary. When grinding
Bearing size crank journal or crankpin, finish them to the specified dImen-
of bearing
sions according to the undersize bearing to be used.
1.485 - 1 .490 mm
Standard
(0.0585 - 0.0587 in) Crankpin and crank journal:
Out-of-roundness
1.500 - 1.505 mm 0.03 mm (0.0012 in) or less
(0.0591 - 0.0593 in)
Grinding limit
1.510 -1.515 mm 0.25 mm (0.0098 in)
0~05 mm (0.0020 in) undersize
(0.0594 - 0.0596 in)
1.610 - 1.615 mm
(0.0634 - 0.0636 in)
6) Inspect bushing at connecting rod small end, and replace

if worn or damaged. Also measure the piston pin clearance at
the connecting rod small end.
Standard clearance between piston pin and bushing in

connecting rod:
o - 0.022 mm (0 - 0.0009 in)
L2-1391
CRANKSHAFT AND CRANKSHAFT BEARING Fig. 243
1) Clean crankshaft completely and check for cracks by

means of red check etc., and replace if defective.
2) Measure the crankshaft bend, and correct or replace if it
exceeds the limit. 4) Measure the thrust clearance of crankshaft at center
bearing. If the clearance exceeds the limit, replace bearing.
When measuring, place both the front and rear journals on
blocks located on a surface plate, and apply a dial gauge to the Crankshaft thrust clearance
center journal. Standard
0.010 - 0.095 mm (0.0004 - 0.0037 in)
Crankshaft bend limit: limit
0.035 mm (0.0014 in) 0.3 mm (0.0118 in)
L2-1390
Fig. 242 Fig. 244
99
2-3 ENGINE
5) Inspect individual crankshaft bearings for signs of flaking, During the work, the crankshaft must not be turned nor the
seizure, melting, and wear. crankcase inverted.
6) Measure the oil clearance on each crankshaft bearing by
means of plastigauge as follows:
Torque:
(1) Wipe off oil, dust, etc. on the surfaces to be measured.
39 - 47 N'm (4.0 - 4.8 kg·m, 29 - 35 ft·lb)
(2) Install bearings in crankcase and set crankshaft in
position.
(3) Cut the plastigauge to the bearing width and place it
on journal parallel with the crankshaft axis. Be careful not
to put it on the oil hole or groove. Bring together the
crankcase halves and tighten bolts to the specified torque.
Crank journal 0.0.

Crankpin 0.0.
Front Center, Center II Rear
44.995 - 45.010 mm 54.957 - 54.972 mm 54.954 - 54.970 mm 54.955 - 54.970 mm

Standard
(1.7715 -1.7720 in) (2.1637 -2.1642 in) (2.1635 - 2.1642 in) (2.1636 - 2.1642 in)
0.03 mm (0.0012 in) 44.965 - 44.980 mm 54.927 - 54.942 mm 54.924 - 54.940 mm 54.925 - 54.940 mm
0.05 mm (0.0020 in) 44.945 - 44.960 mm 54.907 - 54.922 mm 54.904 - 54.920 mm 54.905 - 54.920 mm
0.25 mm (0.0098 in) 44.745 - 44.760 mm 54.707 - 54.722 mm 54.704 - 54.720 mm 54.705 - 54.720 mm
(4) Remove all bolts and separate crankcase. Measure the (5) If the measurement is not within the specification,
plastigauge width with the scale printed on the plastigauge replace defective bearing with an undersize one, and
case. replace or recondition crankshaft as necessary.
Crankshaft oil clearance
0.008 - 0.027 mm
Center & Center II
(0.0003 - 0.0011 in)
Standard
0.003 - 0.036 mm
Front & Rear
(0.0001 - 0.0014 in)
Center & Center II 0.045 mm (0.0018 in)

Limit
Front & Rear 0.055 mm (0.0022 in)
Fig. 245
100
ENGINE 2-3
Dimensions of bearing
Crankshaft Thickness of bearing at center

bearing size Front & Rear Center & Center II
2.015 - 2.019 mm 2.019 - 2.022 mm

Standard
(0.0793 - 0.0795 in) (0.0795 - 0.0796 in)
0.03 mm
2.030 - 2.034 mm 2.034 - 2.037 mm
(0.0012 in)
(0.0799 - 0.0801 in) (0.0801 - 0.0802 in)
undersize
0.05 mm L2-1394
2.040 - 2.044 mm 2.044 - 2.047 mm
(0.0020 in)
(0.0803 - 0.0805 in) (0.0805 - 0.0806 in) Fig. 246
undersize
0.25 mm
2.140 - 2.144 mm 2.144 - 2.147 mm
(0.0098 in)
(0.0843 - 0.0844 in) (0.0844 - 0.0845 in)
undersize
PISTON
1) Install piston rings on pistons as follows.
Install oil ring spacer, upper rail and lower rail in this order by
hand. Then install second ring and top ring with a piston ring
expander.
2) Position the gaps of the piston rings and oi I ri ng as shown
in the figure.
Top ring
rail rail
ASSEMBLY
CRANKSHAFT Second ring

Oil ring spacer
1) Install connecting rod bearings on connecting rods and
connecting rod caps.
Apply oil to the surfaces of the connecting rod bearings.
2) Install connecting rods and connecting rod caps on crank-

shaft with connecting rod bolts and nuts.
p:IT!;:q Bend over pawl of upper rail
f
and attach to 3.5 mm 10.138 in) dia.
hole.
Torque (Connecting rod nut):
39 - 42 N·m (4.0 - 4.3 kg-m, 29 - 31 ft-Ib)
with oil on threads
a. Position each connecting rod with the side marked f)

facing forward.
b. Each connecting rod has its own mating cap. Make sure
that they are assembled correctly by checking their matching
number.
c. When tightening the connecting rod nuts, apply oil on the L2-1373
threads. Fig. 247
101
2-3 ENGINE
3) Install circlip to piston.
The circlip must be fitted to the end that faces inside of TROUBLESHOOTING
crankcase when piston is inserted.
Refer to "1800 cc Engine TROUBLESHOOTING".
Circlip must be installed in correct direction with its end
facing out.
)
Face this end outward.
Install one side first.
Fig. 248
102
l
ENGINE LUBRICATION SYSTEM
Page
MECHANISM AND FUNCTION.... . . . . . . . . . . . . . . . . . . . . . . . . .. 2
SUBARU General. . . . . . . . . . . . . . . • . . . . . . . . . . • . . . . . . . . . . • . . . . . . .. 2
Lubrication Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2
Oil Pump ............................................ 5
1988 Oil Pressure Switch (Oil Pressure Indicator Light Equipped Model Only) . .. 5 _
Oil Pressure Gauge ...................................... 5
SPECIFICATIONS AND SERVICE DATA. . . . . . . . . . . . . . . . . . . . . .. 7
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . .. 7
SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8
COMPONENT PARTS .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9
Oil Pump ............................................ 9
SERVICE PROCEDURE .................................... 10
Oil Pump ............................................ 10
TROUBLESHOOTING ........................•............ 13
2-4 ENGINE LUBRICATION SYSTEM

General
The engine lubrication system is a fully-pressurized full-flow If the filtering capacity of the oil filter deteriorates, oil is sent
filter type. The lubricating oil is pressurized by a trochoid oil directly to the main gallery through the oil bypass valve_ If the
pump with a built-in oil relief valve and oil bypass valve*. This oil pressure rises in the oil circuit, excess oil is returned to the
oil pump is driven by the crankshaft at a speed ratio of 1: 1 oil pump through the oil relief valve.
through a timing belt.
*: The oil bypass valve is non-disassembling type.
Lubrication Lines
1800 cc Engine
Lubrication lines
Crankshaft
#1 connecting 1-_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _---,
front main
rod bearing
bearing
Crankshaft #2&#3
r- center main r--- connecting
bearing rod bearing
Crankshaft
rear main L......a. #4 connecting ~-----------------..
.------ rod bearing
bearing
.------.l~ ~ .J l
Cylinder
#1 & #3
Oil filter block main
gallery
f-
~'___ca_m_ _....JI~----------~
-------:
: ' - -_ _ _....J
i I
l
I
I
#1 &#3
camshaft
H!~~h!f~ l
r-- ,--_be_a_rin-=g,---,I
Bypass
valve
j #1 &#3
camshaft
case
- '---------' l1 JI Camshaft
support ~----------~
4
#1&#3 H
cylinder head
H LA gallery
#1 & #3
H LA
Relief
valve
Relief
pipe
L...----...J
~
I
I Oil strainer I
rl #2& #4
'--_ca_m____~J~----------~
~~~h~f~ I
#2&#4
#2& #4
camshaft r-- -1 bearing
'------=---'
r
4 camshaft r-- Camshaft I~ __________+-I
I I case support I
-1
Oil pan
4
#2&#4
cylinder head
#2&#4
HLA
Relief Relief ~
valve pipe
HLA gallery ~
L2-1251
Fig. 1
1..-
ENGINE LUBRICATION SYSTEM 2-4
Engine lubricating system

Cam case
Cyl inder block Cylinder
head
HLA gallery
(Hydraulic lash
adjuster)
...
~
~
connecting
rod
l::
.....
connecting
rod
...
+-
.....
O-ring
Cam support
LH
RH
Oil bypass valve
Oil pressure switch
L2-064
Fig. 2
3
2700 cc Engine
Lubrication lines
L2·1252
Fig. 3
Engine lubricating system

Cam case
~-----------~I.------
HLA gallery Cylinder block Cylinder
(Hydraulic lash adjuster) head
~
I
I
Rocker arm
Oil relief
I
Relief valve
Cam support
RH LH
L2·1253
Fig. 4
l
Oil Pump The inner rotor has four projections and the outer rotor has
five depressions. As the inner rotor rotates inside the outer
The oil pump is a small pump which sucks lubricant from the rotor, the clearance between the two rotors constantly varies.
oil pan, and pressurizes it to send it to each section subjected The oil is pumped in accordance with this clearance change.
to friction. The trochoid pump is small and features a simple construction
The trochoid pump consists of a pump casing with one lube oil which experiences fewer problems.
inlet and one outlet, and an inner and outer rotor.
Inner rotor
Suction stroke Transfer stroke Del ivery stroke Delivery stroke

drive side
Fig. 5
Oil Pressure Switch Oil Pressure Gauge

(Oil Pressure Indicator Light Equipped Construction
Model Only) GAUGE SECTION
The gauge section consists of a bimetal, pointer and scale
The oil pressure switch is attached to the oil pump case. It plate. The bimetal is wound with heat wire. The pointer moves
monitors the oil pressure and turns on or off the oil pressure in response to bending of the bimetal.
indicator light in the combination meter.
The oil pressure switch consists of a diaphragm, which is
operated by oil pressure, a set of contacts, which are opened
or closed by diaphragm movement, and a spring, which deter·
mines when the contacts open depending on the oil pressure.
It is enclosed by a housing similar in design to a hexagonal nut
molded with phenol resin and a terminal.
CD®®@@ Temperature
compensating
bimetal
Terminal
L2-1564
Fig. 7 Construction of the gauge section
SENDER SECTION
This section consists of a diaphragm, point arm, contact points
and a heat-wire-wound bimetal. The diaphragm is displaced by
1 Contacts 4 Molded portion oil pressure and the point arm conveys diaphragm displace-
2 Diaphragm 5 Terminal
ment to the contacts.
3 Spring A6'()11
It is completely enclosed by a cover equipped with a positive
Fig. 6 terminal.
5
3) When oil pressure is applied:
Temperature
compensating (1) The diaphragm expands in response to oil pressure so
bimetal that it pushes up the point arm forcefully. The point arm
then contacts the contact point (on the bimetal side).
(2) At this point, when the ignition switch is turned ON
to open the contact point, the bimetal bends consider-
ably. I n other words, cu rrent flows for a long period of
time.
(3) However, after current flows through the heat wire
for a certain period of time (until the bimetal reaches a
certain temperature), the point will open to interrupt the
Point arm current flow. As the bimetal cools, the contact point
Bimetal closes again.
L2-1565
(4) Thus, the contact point closes and opens in response
Fig. 8 Construction of the sender section
to the temperatu re of the bimetal. That is, the tempera-
ture in relation to oil pressure. I n other words, the bimetal
maintains a certain temperature in response to oil pres-
sure.
Operation (5) Similar to the bimetal of the sender section, the bi-
metal of the gauge section bends as its temperature in-
1) When no oil pressure is applied, contact points open creases. This causes the gauge pointer to deflect.
slightly.
8 ...
Ignition
Ignition switch
switch
Point arm
Bimetal
Battery..L ~~~L-Point arm Diaphragm
1 t
Diaphragm t
Oil pressure applied
No oil pressure L2-1567

applied
L2-1566 Fig. 10 Oil pressure applied
Fig. 9 No oil pressure applied
2) When oil pressure is low:

(1) The point arm is held by the diaphragm and lightly Operating precautions
contacts the contact point of the bimetal.
(2) When the ignition switch is turned ON, current flows 1) Do not apply battery voltage directly to the gauge or
through the gauge section and heat wire of the sender sec- sender section. Otherwise, the heat wire may burn or the bi-
tion. Because of low point contact pressure, heat gener- metal twist.
ated by low current allows the bimetal to bend so that the 2) Connect the terminals firmly.
contact points open. If an erroneous indication is noted, check wiring for ground-
(3) The contact points (on the sender side) open rapidly. ing, the terminal for looseness, and the gauge for operation.
Since the temperature of the bimetal (on the gauge side) 3) Do not ground or short the midpoint of the wiring. Other-
does not increase, the bimetal hardly bends and the point- wise, problems similar to those indicated in 1) above may
er does not move. occur.
4) Do not drop the gauge/sender section and do not allow it
to strike adjacent parts.
6
SPECIFICATIONS AN D SERVICE DATA

SPECIFICATIONS
- 1800 cc model 2700 cc model
Lubrication method Forced feed, full flow filtration, splash type
Pump type Trochoid type
2.0 Q/min (2.1 US qt/min, 5.0 Q/min (5.3 US qt/min,

Discharge - Pressure 1.8 Imp qt/minl - 98 kPa 4.4 Imp qt/min) - 98 kPa
Discharge (1.0 kg/cm 2 , 14 psi) (1.0 kg/cm 2 , 14 psi)
performance I
Speed 550 rpm
Oil temperature 75 - 85°C (167 - 185°F)
31.2 Q/min {8.24 US gal/min, 40 Q/min (10.6 US gal/min,

Oil pump Discharge - Pressure 6.86 Imp gal/min) - 294 kPa 8.8 Imp gal/min) - 392 kPa
Discharge (3.0 kg/cm 2 , 43 psi) (4.0 kg/cm 2 , 57 psi)
performance II
Speed 5,000 rpm
Oil temperature 75 - 85°C (167 - 185°F)
Pressure at which 392 - 441 kPa {4.0 - 4.5 441 - 490 kPa (4.5 - 5.0
Oil relief valve
valve starts to open kg/cm2, 57 - 64 psi) kg/cm 2 , 64 - 71 psi)
Pressure at which
Oil bypass valve 147 kPa (1.5 kg/cm 2 , 21 psi)
valve starts to open
Type Paper, cartridge type

Oil filter
Filtration area 0.137 m2 (1.47 sq ftl
Upper level 4.0 Q (4.2 US qt, 3.5 Imp qt) 5.0 Q (5.3 US qt, 4.4 Imp qt)
Engine oil capacity
Lower level 3.0 Q (3.2 US qt, 2.6 Imp qt) 4.0 Q (4.2 US qt, 3.5 Imp qt)
Type Immersed contact point type -
Voltage 12V -
Warning light 12V - 3.4 W or less -
Pressure at which 14.7 - 24.5 kPa (0.15 - 0.25
-
Oil pressure switch* switch closes kg/cm 2 , 2.1 - 3.6 psi)
Pressure at which 14.7 - 24.5 kPa (0.15 - 0.25

-
switch opens kg/cm2, 2.1 - 3.6 psi)
981 kPa (10 kg/cm 2 , 142 psi)

Proof pressure -
or more
Type B imeta I type
Oil pressure gauge Voltage 12V
Pressure range 0- 785 kPa (0 - 8 kg/cm2, 0 - 114 psi)
*Oil pressure ind icator light equipped model only
7
SERVICE DATA
1800 cc model 2700 cc model
Inner rotor outer diameter 35.65 - 35.70 mm (1.4035 - 1.4055 in)
Outer rotor outer diameter 49.95 - 50.00 mm (1.9665 - 1.9685 in)
13.89 - 13.91 mm 18.89-18.91 mm

A (0.7437 - 0.7445 in)
(0.5468 - 0.5476 in)
13.90 - 13.92 mm 18.90 - 18.92 mm

Inner and outer rotor height B
(0.5472 - 0.5480 in) (0.7441 - 0.7449 in)
13.91 - 13.93 mm 18.91 - 18.93 mm

C
(0.5476 - 0.5484 in) (0.7445 - 0.7453 in)
7.97 - 8.00 mm 2.97 - 3.00 mm

Oil pump case projection height
(0.3138 - 0.3150 in) (0.1169- 0.1181 in)
Oil pump
Rotor housing depth 21.96 - 22.04 mm (0.8646 - 0.8677 in)
STD 0.05 - 0.16 mm (0.0020 - 0.0063 in)

Side clearance between inner or outer
rotor and crankcase limit 0.18 mm (0.0071 in)
STD 0.10 - 0.18 mm (0.0039 - 0.0071 in)

Case clearance between outer rotor
and crankcase limit 0.22 mm (0.0087 in)
Free length 47.1 mm (1.854 in) 52.2 mm (2.055 in)
I nstalled length 33.5 mm (1.319 in) 38.9 mm (1.531 in)

Relief valve spring
3.88 - 4.28 kg 6.15 - 6.75 kg
Load when installed
(8.56 - 9.44 Ib) (13.56 - 14.88 Ib)
Reference pressure with oil pump equipped on the engine is as follows:
Condition 1800 cc model 2700 cc model
Oil temperature 100°C (212°F)
Cooling fan OFF
Engine oil 10W-30 (SAE)
206 - 304 kPa 382 - 490 kPa

2,000 rpm
(2.1-3.1 kg/cm2,30-44 psi) (3.9 - 5.0 kg/cm 2 , 55.- 71 psi)
Engine speed
353 - 441 kPa 481 - 569 kPa
4,000 rpm
(3.6 - 4.5 kg/cm 2 , 51 - 64 psi) (4.9 - 5.8 kg/cm2, 70 - 82 psi)
8
ENGINE LU BRICATION SYSTEM 2-4
COMPONENT PARTS
Oil Pump
Tightening torque N·m

2 _(kg·m,
3.8, 23ft·lb)
_ 27)
T1: 31 - 37 (3. 1 13 _ 15)
T2: 18 - 21 (1.8 - ~'8' 16 _ 20)
T3: 22 - 27 (2.2 - 4'5' 29 _ 33)
T
4: 39 - 44 (4.0 - . 0' 55 3.3 _ 4.0)
T5: 4.4 5 .4 (0.45 - . ,
1 Oil level gauge ,

2 Oil level gau ge gUide
3 O-ring
4 Oil filler cap
5 Oil filler duct
6 Gasket
7 Oil filter
8 Oil pump ASSY
9 Gasket
1o OH strainer
, stay
11 Oil stramer
12 Oil strainer stay 2
13 O-ring
14 Gasket
15 Plug
16 Oil pan
17 Oil pump pulley
18 Oil seal
19 Oil pump case
lightpress~re
20 indicat0'l
Oil pressure switch } (Oil eqUippe d model)
21
22 Plug
Oil pressure ga g
u e I(Oil pressure gaugeJ
equipped model @
23 Plug
0'1 relief valve ,
24 OilI relief va Ive spnng
25 f 'l..@-
o
I !
26 Plug 'nner rotor

I! '
27 Oil pump ~uter rotor
28 Oil pump
29 O-ring
L2-1254
Fig_ 11
9
SERVICE PROCEDURE
Oil Pump INNER ROTOR
Check the outside diameter of the inner rotor shaft portion,
and replace it if worn or damaged.
REMOVAL
Outside diameter of inner rotor shaft portion:
1) Drain engine oil. 35.65 - 35.70 mm (1.4035 - 1.4055 in)
2) Remove belt covers and camshaft drive belts. (See Section
2-3 "Engine".)
OUTER ROTOR
Before removing camshaft drive belts, be sure to loosen oil Check the outer rotor, and replace if worn or damaged.
pump pulley mounting nut.
Outside diameter of outer rotor:
3) Remove oil pump mounting bolts, and detach oil pump 49.95 - 50.00 mm (1.9665 - 1.9685 in)
together with oil filter from cylinder block.
OIL PUMP CASE CLEARANCE

Measure the clearance between the outer rotor and the
cylinder block rotor housing.
If the clearance exceeds the limit, replace the rotor.
Case clearance:
Standard
Limit
0.10 - 0.18 mm (0.0039 - 0.0071 in) I
0.22 mm (0.0087 in)
Fig. 12
4) Remove oil pump outer rotor from cylinder block.
DISASSEMBLY
1) Remove oil filter from oil pump.

2) Remove a-ring.
3) Remove oil pressure gauge or oil pressure switch.
4) Remove oil pump pulley, and draw out oil pump inner Fig. 13
rotor.
5) Remove oil relief valve plug, and take out spring and ball.
01 L PUMP SI DE CLEARANCE
1) Measure total height of case projection (H1) plus oil pump
inner and outer rotors (H2).
INSPECTION
Wash the disassembled parts, check them for the following

items, and repair or replace if defective.
10
3) Calculate side clearance (C) using the following equation:
C;L-(Hl+H2)
Side clearance: C
Standard
0.05 - 0.16 mm (0.0020 - 0.0063 in)
Limit
0.18 mm (0.0071 in)
4) If side clearance value (C) is larger than "limit" shown

below, replace pump inner and outer rotors with the suitable
ones selected from following table.
L2-069
I nner and Outer Rotor Height (H2)
Fig. 14
Marking 1800 cc 2700 cc
2) Measure depth (L) of rotor housing bore in cylinder block.
13.89 - 13.91 mm 18.89 - 18.91 mm
A
(0.5468 - 0.5476 in) (0.7437 - 0.7445 in)
13.90 - 13.92 mm 18.90 - 18.92 mm

B
(0.5472 - 0.5480 in) (0.7441 - 0.7449 in)
13.91 - 13.93 mm 18.91 - 18.93 mm

C
(0.5476 - 0.5484 in) (0.7445 - 0.7453 in)
Height of case projection: H1

1800 cc model
I Depth gauge
7.97 - 8.00 mm (0.3138 - 0.3150 in)
2700 cc model
2.97 - 3.00 mm (0.1169 - 0.1181 in)
Fig. 15 Depth of rotor housing: L
21.96 - 22.04 mm (0.8646 - 0.8677 in)
OIL RELIEF VALVE

" Check the valve for fitting condition and damage, and the
relief valve spring for damage and deterioration. Replace the
parts if defective.
Inner rotor
Relief valve spring
Free length
1800 cc model: 47.1 mm (1.854 in)
2700 cc model: 52.2 mm (2.055 in)
I nsta lied Ie ngth
1800 cc model: 33.5 mm (1.319 in)
2700 cc model: 38.9 mm (1.531 in)
Load when installed
1800 cc model:
3.88 - 4.28 kg (8.56 - 9.44 Ib)
2700 cc model:
6.15 - 6.75 kg (13.56 - 14.88 Ib)
Fig. 16
11
01 L PUMP CASE
ASSEMBLY AND INSTALLATION
Check the oil pump case for worn shaft hole, clogged oil
passage, worn rotor chamber, cracks, and other faults.
Assembly and installation is in the reverse order of removal
procedure.
Observe the following:
OIL SEAL 1) Replace the a-ring and gaskets with a new one.
Check the oil seal lips for deformation, hardening, wear, etc. 2) Coat rubber seal of oil filter with engine oil before
and replace if defective. installing the oil filter.
3) Tighten oil filter an extra 2/3 turn after rubber seal
contacts pump case. Do not tighten excessively.
12
TROUBLESHOOTING
Before troubleshooting, make sure that the engine oil level is correct and no oil leakage exists.
~ Trouble Possible cause Corrective action
1) Oil pressure Cracked diaphragm Replace.

switch failure Oil leakage within switch Replace.
Clogged oil filter Replace.
Malfunction of oil bypass valve Clean or replace.
-(I.) Malfunction of oil relief valve Clean or replace.

~
2) Lowoil
0 1. Warning light Clogged oil passage Clean.
E pressure
~ remains on.
(I.)
a. Excessive tip clearance and side
a. Replace.
::::l
clearance of oil pump rotor and gear
C'
(I.)
+-'
.r::.
Clogged oil strainer or broken pipe Clean or replace.
.QI
"- Insufficient engine oil Replenish.
0
+-'
('CI
.~ 3) No oil pressure Broken pipe of oil strainer Replace.

~
c:
(I.)
"-
Stuck oil pump drive gear and rotor Replace.
::::l
VI
VI
(I.)
"-
1) Burnt-out bulb Replace.
c. 2. Warning light
-
(5 does not go 2) Poor contact of switch contact points Replace.
on.
3) Disconnection of wiririg Repair.
1) Poor contact at terminals Repair.

3. Warning light
2) Defective wiring harness Repair.
flickers
momentarily. Check for the same possible
3) Low oil pressure
causes as listed in 1.-2)
1) Poor contact at terminals Repair.
2) Deformed bimetal Replace.

4. Oil pressure
a;
"'0 gauge indio 3) Binding of needle pointer Repair.
0
E cation is
"'0 erroneous. 4) Contaminated points Replace.
(I.)
c.
.9- Check for the same possible
::::l 5) Low oil pressure
C' causes as listed in 1.-2)
(I.)
(I.)
OJ
::::l 1) Needle pointer out of place Repair.
co
OJ
~ 2) Heat wire disconnection

::::l Replace.
VI
VI
~ 5. Oil pressure
c. 3) Disconnection of wiring Repair.
.- gauge does not
0 deflect. 4) Cracked sensor diaphragm Replace.
Check for the same possible

5) Low oil pressure
causes as listed in 1.-2)
13
ENGINE COOLING SYSTEM
Page
BUBARU MECHANISM AND FUNCTION.............................. 2

General ...............•............................. 2
Cooling Lines .................•.................•..... 2
Thermostat ...................•................•......
1988 Thermometer .................•.......................
SPECIFICATIONS AND SERVICE DATA ...................... .
Specifications ........................................ .
Service Data .......................................... 5
COMPONENT PARTS . • . . . . . . . . . . • . . . . . . . . . . . • . . . . . . . . . . .. 6
Water Pump ......•....•.....•.................•..•... 6
Radiator and Cooling Fan .,.,", ..... ,." ... , .... ,', .... ,' 8
SERVICE PROCEDURE, , ..•• , , , , , , , , . , , , • , , , ......• , ...... 10
Water Pump ., ..........•.. ,',.,.,""""", ..... ,... 10
Thermostat .•............... , .. , , . , • , ......... , . . . . . .. 12
Thermometer ....... , .. , .......... , •••.•.•... ,',...... 12
Radiator ..•.... , ......... , . , , . . • . • . . . . . . • . . . . • . . . . . .. 13
Cooling Fan and Fan Motor ., .... , ..... , .•....•.... , .... , .. 15
TROUBLESHOOTING ................•.................... 16
2-5 ENGINE COOLING SYSTEM

General
The engine cooling system consists of a cross-flow radiator.
a reserve tank. an electric motor fan, a water pump, a thermo-
stat, and a thermometer.
--- -- -- Thermostat
l
~
--
-- I Thermostat case
1
Fll
I
Cylinder block (Right)
Cyl inder jacket (R ight)
Cylinder head
(Right)
Pl t
t - Intake manifold
I •
Radiator
-- Water pump
I - - --
--- Cylinder block (Left)
Cyl inder jacket (Left)
- - - -- - - -- - - - - --- -
-- Cylinder head
(Left)
~
- - - --
+
f- - -- 1
r --
By-pass circuits I
I
I
1
1
t
Throttle body
(Preheating)
1=- I
I
I
I
I I Heater r
--- I
I
I
_J
L2-1266
Fig. 1
2} 2nd step ... With thermostat opened

Cooling Lines When the coolant temperature is above 88° C (190° F). the
This cooling system operates in three steps depending on the thermostat opens and the coolant flows through the radiator
where it is cooled.
temperature of the coolant flowing through the cooling
circuit. 3) 3rd step ... With electric cooling fan operating
1) 1 st step ... With thermostat closed When the coolant temperature rises above 95°C (203°Fl. the
Q
At coolant temperature of below B8°C (190 F), the thermo· thermoswitch is turned on and the electric cooling fan rotates.
stat remains closed and the coolant flows through the bypass
and heater circuits.
This permits the engine to warm up quickly.
2
Thermostat 2700 cc model

The thermostat is a wax·pellet type. It is equipped with a main
1800 cc model valve and a sub-valve. Before the main valve opens, the sub-
The thermostat is powered to open the valve by a totally- valve opens to prevent abrupt pressure variations.
enclosed wax pellet which expands with increased tempera-
ture. It provides the sure open·close operation of the valve
and features high durability.
Valve 7 Rubber piston ®

2 Spring 8 Semifluid
3 Piston 9 Diaphragm
® 1 Valve 6 Stopper
2 Spring
4 Guide 10 Wax
3 Sub valve
7 Piston ®
5 Jiggle pin 11 Temperature 8 Dust seal valve
6 Teflon sheet sensing case 4 Sub spring 9 Wax element
5 Stop ring
L2·1267
Fig. 3
A7·078 Thermometer
Fig. 2 The thermometer is installed on the intake manifold and
monitors the temperature of the coolant in the engine to
activate the temperature gauge in the combination meter.
The thermometer includes a thermistor, lead wire, spring,
terminal plate and resin body, completely sealed by a threaded
case which is integralwith a hexagon nut.
For ECM For temperature

gauge
Lead wire
Thermistor element I
Thermistor element II A7·102

Fig. 4
3

SPECIFICATIONS
Cooling system Electric fan + Forced cooling water circulation system

Model 1800 cc 2700 cc
Total coolant capacity 5.5 Q (5.8 US qt, 4.8 Imp qt) 7.0 Q (7.4 US qt, 6.2 Imp qt)
Type Centrifugal impeller type
7 Q/min (7.4 US qt!min, 20 Q!min (21.1 US qt/min,

Discharge
6.2 Imp qt!min) or more 17.6 Imp qt!min) or more
Discharge
performance Pump speed - 1,000 rpm - 0.29 m Aq 3,000 rpm - 2m Aq
I total water head (0.95 ft Aq) (7 ft Aq)
Water temperature 75 - 85°C (167 - 185°F)
50 Q (13.2 US gal, 11.0 Imp gal)/ 160 Q (42.3 US gal, 35.2 Imp gal)/
Water pump Discharge
min or more min or more
Discharge
performance Pump speed- 4,000 rpm - 5.0 m Aq 8,000 rpm - 16 m Aq
II total water head (16.4ftAq) (52 ft Aq)
Water temperature 75 - 85°C (167 - 185°F)
Impeller diameter 66 mm (2.60 in) 62 mm (2.44 in)
Number of impeller vanes 5
Pump pulley diameter 90 mm (3.54 in) 88 mm (3.46 in)
Type Wax pellet type
Sub-valve 86 - 90°C
(187 - 194°F)
Starts to open 86.5 - 89.5°e (188 - 193°F)
Main valve 90 - 94°C
(194 - 201°F)
Thermostat
Fully opens 100°C (212°F) 102°C (216°F)
Sub-valve 1.5 mm (0.059 in)

Valve lift 8.5 mm (0.335 in)
Main valve 6.5 mm (0.256 in)
Sub-valve 14 mm (0.55 in)

Valve bore 31 mm (1.22 in)
Main valve 33 mm (1.30 in)
Type Bimetal type

Thermoswitch
Operation temperature ON: 92 - 98°C (198 - 208°F) Differential: 5 _9°C (9 -16°F)
4
Motor 120 W or les 140 W or less

Electric fan
Fan dia. 280 mm (11.02 in) 340 mm (13.39 in)
Type Cross-flow, pressurized type
49.893 kW (42,900 kcal/h, 56.522 kW (48,600 kcal/h,

Radiation capacity
170,227 BTU/h) 192,845 BTU/h)
670 x 332 x 16 mm 645 x 322 x 32 mm

Radiator Core dimensions
(26.38 x 13.07 x 0.63 in) (25.39 x 12.68 x 1.26 in)
Pressure range in which cap valve is Above 78 - 98 kPa (0.8 - 1.0 kg/cm2, 11 -14 psi)
open Below -4.9 to -9.8 kPa (-0.05 to -0.1 kg/cm 2 , -0.7 to -1.4 psi)
Fins Corrugated fin type
Reserve tank Capacity 1.3 Q (1.4 US qt, 1.1 Imp qt) 2.3 Q (2.4 US qt, 2.0 Imp qt)
SERVICE DATA
Clearance between impeller and case 0.5 - 0.9 mm (0.020 - 0.035 in)
Water pump Distance between pulley attaching surface of hub 103.6 - 104.2 mm 113.8 - 114.2 mm
and pump case surface, which mates with gasket (4.08 - 4.10 in) (4.48 - 4.50 in)
5
COMPONENT PARTS
Water Pump
1800 cc model
,,
I
I
I
CD __ ...J
®,-~
1 Thermostat cover
2 Gasket
3 Thermostat
4 Water by-pass pipe
J()
5 Seal
/:..\& -- 6 Gasket
8 Water pump ASSY
9 O-ring
10 Water pipe
,@ I 12 Pulley cover
--~® 'x<J~
13 Water pump hub
14 Water pump case
15 Water pump shaft
\ ,OY 16
17
18
19
Water pump mechanical seal
Water pump plate
Water pump impeller
Water pump clip
J({(\I /
L_ (~h@-D/ / ' Tightening torque: N·m (kg-m, ft-Ibl

T: 9.1 - 10.5 (0.93 - 1.07,6.7 - 7.7)
L2-1268
Fig. 5
6
2700 cc model
~I
I
I " "
I
CD
~\
®
1 Thermostat cover
2 Filler cap
3 Gasket
4 Thermostat
5 Air vent pipe
6 Water by-pass pipe
7 Water pipe
8 Q-ring
9 Gasket
11 Water pump ASSY
13 Water pump hub
14 Water pump shaft
15 Water pump clip
(J)
16 Seal
17 Water pump case
18 Water pump mechanical seal
19 Water pump plate
20 Water pump impeller
Tightening torque: N-m (kg-m, ft-Ib)

T: 9.1 - 10.5 (0.93 - 1.07,6.7 - 7.7)
Fig. 6 L2-1269
7
Radiator and Cooling Fan

1800 cc model
CD
}3l~~ @-----v I
"-
I'
1 "~
1
@[
~
9
® ~,
- '" I
-- I
uctJ
j 1
~i'
- I
I
@I
I
®
® ~: I
I
j
Tightening torque: N'm (kg-m, ft-Ib)

T1: 10 -18 (1.0 -1.8, 7 -13)
T2: 7.3 - 7.7 (0.74 - 0.79,5.4 - 5.7)
T3: 9.3 - 10.8 (0.95 - 1.1,6.9 - 8.0)
~-@ Radiator inlet hose
~G
J
2 Plug [AT only]
J
I 3 Packing [AT only]
4 Radiator
J
I
5 O-ring
6
'<~'>~
J Thermoswitch
I
I
7 Drain hose
I 8 Radiator packing
I 9 Drain guide
I
I I 10 Drain cock
I
I
I
..-
/1
J
1..---
- ...... ..,.
..,.
..,.
11
12
Radiator cap
Radiator cushion
!.,- J .;> 13 Radiator spacer
I 14 Radiator cushion
1
15 Radiator outlet hose
16 Overflow hose
17 Reserve tank
18 Reserve tank cap
19 Fan & motor
@
~ 20 Shroud
L2-1270
Fig. 7
8
2700 cc model @ GI
I
CD
I
/
I
/ (j)
l..... .......
....................
®~
®
/
/
1 Radiator inlet hose ",-1 I
I ......;
2 Filler cap
3 Bracket
4 Reserve tank
5 Thermo switch
6 O-ring
7 Overflow hose
8 Radiator outlet hose
9 Radiator cap
10 Oil cooler hose (AfT)
11 Drain cock
12 Drain guide
13 Drain hose
14 Radiator
15 Fan & motor
16 Shroud
17 Fan & motor (A/C)
18 Shroud (A/C)
------------------------------- @
@ Tightening torque: N·m (kg-m, ft-Ib)
T1: 10 - 18 (1.0 - 1.8, 7 - 13)
T2: 7.3 -7.7 (0.74 - 0.79,5.4 - 5.7)
T3: 9.3 -10.8 (0.95 -1.1, 6.9 - 8.0)
Fig. 8 T4: 5 -10 (0.5 -1.0,3.6 -7.2) L2-1271
9
SERVICE PROCEDURE
Water Pump
REMOVAL
1) Drain coolant and disconnect the radiator outlet hose,
water by-pass hose and air vent hose (2700 cc model only)
from the water pump.
2) Loosen pulley nuts so that they can be turned by hand.
3) Loosen alternator ASSY mounting bolts (1800 cc model).
Loosen belt tensioner pulley locking nut (2700 cc model).
4) Remove drive belt.
5) Remove front belt cover. Refer to 2-3 "Engine Disassem-
bly" for procedures.
Be careful not to spill coolant on drive belt. If spilled, wipe Fig. 10

clean immediately.
51 Remove shaft, impeller, and mechanical seal from water
DISASSEMBLY pump case as a unit.
a.Oo not disassemble water pump unless absolutely necessary. Do not press the shaft, or the bearings will be damaged. Press
It is advisable to replace water pump ASSY. the bearing outer race.
b. In case of disassembling water pump, be sure to check
"run out" of water pump hub after assembling. If it is outside 61 Remove impeller from shaft with a press.
specifications, replace water pump ASSY.
1) Remove water pump pulley.

2) Insert a screwdriver into the slit in water pump case and
lift end of water pump clip.
INSPECTION
1) Clean all the disassembled parts thoroughly.

2) Inspect the pump shaft for wear, damage, and operation.
3) Inspect the impeller surface that contacts the mechanical
seal for wear and damage.
4) Inspect the mechanical seal and plate for wear, crack and
damage.
5) Inspect the other parts for crack, wear and damage, and
L2-1035
Fig. 9
ASSEMBLY
o
1) Heat water pump case to a temperature of 80 to 100 e,
3) Extract water pump clip with pliers. (176 to 212°FI, and press shaft into bore in water. pump
4) Using a press, drive hub from water pump ASSY. case. Do not press any section other than outer race.
10
l
L2·568
Fig. 11 Fig. 13
5) Before pressing, apply oil on the pump shaft.

Support the impeller side of the pump shaft end and install
Be su re to install a new mechanical seal. the hub by using a press until the distance "L" between the
pump case surface, which mates with the gasket, and the
2} Press the seal into the pump case with the carbon washer pulley attaching surface of the hub becomes specified value.
of the seal facing the impeller.
3) Apply coolant on the sliding surface between mechanical After pressing water pump hub into place, measure "run out".
seal and impeller. If it exceeds 0.05 mm (0.0020 in), replace water pump ASSY.
With a thin coat of oil on the shaft surface, install the impeller
onto the pump shaft with a press.
"L":
1800 cc model 103.6 - 104.2 mm (4.08 - 4.10 in)
2700 cc model 113.8 - 114.2 mm (4.48 - 4.50 in)
~'\'J.,~=~q~~-Impeller
L2-054
Fig. 12
L2·569
Fig. 14
4) Check for the following clearance after installation and

correct if defective.
Clearance between impeller and pump case: 6) looking through slit in water pump case, ensure that
0.5 - 0.9 mm (0.020 - 0.035 in) groove on water pump case is aligned with groove on outer
surface of shaft.
Insert water pump clip into grooves and drive it into place
with a plastic hammer.
11
Be careful not to deform the clip. Immerse the thermostat and a thermometer in water. Raise
water temperature gradually, and measure the temperature and
valve lift when the valve begins to open and when the valve is
fully opened. During the test, agitate the water for even tem-
perature distribution. The measurement should be to the
specification.
Starts to open Fully opens
86.5 - 89.Soe
1800 cc 100°C (212°F)
(188 - 193°F)
Sub- 86 - 90°C
Water pump valve (lS7 - 194°F)
case 2700 cc 102°C (216°F)
L2-570 Main 90 - 94°C
Fig. 15 valve (194 - 201°F)
7) Rotate water pump shaft by hand. It should turn

smoothly without emitting noise.
INSTALLATION
Installation is in the reverse order of removal procedures.

1) Replace the gasket with a new one_ 1 Thermometer
I
2) After reinstalling the water pump, adjust the drive belt 2 Thermostat
tension and run the engine to make sure that neither water A7-021
leakage nor abnormal noise exists. Fig. 16
Thermostat Thermometer
REMOVAL AND INSTALLATION INSPECTION
1) Remove the thermostat case cover and gasket, and pull 1) To test the thermometer, connect the gauge section and
out the thermostat_ the sensor unit in series_
2) Install the thermostat in the intake manifold, and install 2) The thermometer performance data are shown below.
the thermostat cover together with a gasket.
Temperature Resistance
a. When reinstalling the thermostat, use a new gasket.
b. The thermostat must be installed with the jiggle pin [120°C (24SoF) J 14.9 - 17.3n
upward. (1800 cc model only)
100°C (212°F) 26.2 - 29.3n
sooe (176°F) 47.5 - 56.Sn
INSPECTION [50°C (122°F)) 133.9 - 178.9n
Replace the thermostat if the valve does not close completely

at an ambient temperature or if the following test shows
unsatisfactory resu Its.
12
Sending
unit
Voltage regulator
IIncorporated in gauge ASSY)
A7·023 L2·1031
Fig. 17
...
')
PRECAUTIONS FOR HANDLING
1) When testing, do not apply battery voltage directly to the

temperature gauge or sensor unit, because these two parts are
designed to be connected in series. Fig, 18
I If the battery voltage is applied to only one of them, the

heating wire on gauge or thermistor may be damaged.
2) Connect the wire firmly to the terminals. When the gauge
4) Disconnect oil cooler's inlet and outlet hoses at radiator
location (A/T model).
reading is abnormal, inspect not only the gauge but also the
grounding wire or the terminal for loose connections.
Catch both coolant and oil remained in the hoses into con·
3) Use care not to short or ground the terminals or wirings,
tainers.
otherwise troubles described in 1) may occur.
4) Use care not to drop or strike either the gauge or unit,
5) Disconnect main harness connector from thermoswitch.
since these are precision products.
5) Make sure that the gauge needle indicates C when the
ignition switch is not turned on.
Radiator
L2·1273
REMOVAL Fig. 19
1) Disconnect ground cable from battery terminal.

2) Drain coolant.
3) Loosen hose clamps and disconnect both inlet and outlet 6) Disconnect lead wire connector from fan motor.
hoses from radiator.
13
(2700 cc model only) Cap valve opening pressure:

a. Disconnect lead wire connector from sub (condenser)
Positive pressure side
fan motor.
78 - 98 kPa
b. Remove lower and upper bolts holding shrouds (sub
(0.8 - 1.0 kg/cm 2 t 11 - 14 psi)
and main fan) to radiator. Negative pressure side
-4.9 to -9.8 kPa
(-0.05 to -0.1 kg/cml, -0.7 to -1.4 psi)
INSTALLATION
1) Attach radiator mounting cushions to pins on the lower

side of radiator.
-==
L2-502
Main fan shroud
Fig. 21
L2-1274
~) Fit ~ushions, ~n lower side of radiator, into holes on body
Fig. 20 Side and Install radiator.
c. Remove sub and main fan shroud with motor ASSY.

7) Remove two radiator mounting bolts.
8) Lift radiator up and away from vehicle with radiator cap
facing up to prevent remaining coolant from spilling.
I INSPECTION
Fig. 22
Check all removed parts and replace if defective.
1) A clogged radiator should be cleaned.
3) Tighten two radiator mounting bolts.
2) A deteriorated hose should be replaced.
3) Check the valve opening pressure of the pressure cap with
Tightening torque:
a cap tester. If the pressure is out of specification, replace the
10 - 18 N·m (1.0 - 1.8 kg-m, 7 - 13 ft-Ib)
cap ASSY.
14
4) Install sub and main fan shroud on radiator (2700 cc Cooling Fan and Fan Motor
model only).
Tightening torque: REMOVAL

Lower and upper bolt
7.3-7.7 N·m 1) Disconnect ground cable from battery terminal.
(0.74 - 0.79 kg-m, 5.4 - 5.7 ft-Ib) 2) Disconnect lead wire connector.
3) Remove bolts holding shroud to radiator and detach
5) Connect main harness connector to thermoswitch. shroud.
6} Connect lead wire connector to fan motor.
7) Connect both inlet and outlet hoses to radiator with
marked sides facing up and tighten with hose clamps.
Be careful not to twist hoses.

-
8) Connect both inlet and outlet hoses to radiator's oil
cooler and tighten with hose clamps (A/T model).
9) Pour coolant into radiator.
10) Connect ground cable to battery term inal.
Fig. 23
4) Remove fan motor mounting nuts and detach fan motor

from shroud.
Do not separate fan motor and fan as they are balanced

properly.
INSTALLATION

1) Before installing cooling fan motor, apply a coat sealant
to threads and tighten nuts.
Tightening torque:
Fan motor to shroud
7.3 -7.7 N·m
(0.74 - 0.79 kg-m, 5.4 - 5.7 ft-Ib)
2) Make sure cooling fan does not come into contact with
shroud when installed.
3) After installation, make sure there is no unusual noise or
vibration when fan is rotated.
15
TROUBLESHOOTING
Trouble Possible cause Corrective action
Over-heating a. Insufficient coolant. Replenish coolant, inspect for leakage, and

repair.
b. Loose drive belt. Adjust drive belt tension.
c. Oil on drive belt. Replace.
d. Malfunction of thermostat. Replace.
e. Malfunction of water pump. Repair or replace.
f. Clogged coolant passage. Clean.
g. Improper ignition timing. Adjust.
h. Clogged or leaking radiator. Clean or repair, or replace.
i. Improper engine oil. Replace.
j. Air-fuel mixture too thin. Inspect and repair fuel system.
k. Excessive back pressure in exhaust system, Clean or replace.
I. Insufficient clearance between piston and Adjust or replace.
cylinder.
m. Improper valve clearance. Adjust.
n. Slipping clutch. Repair or replace.
o. Dragging brake. Adjust.
p. Improper transmission oil. Replace.
q. Defective thermostat. Replace.
r. Malfunction of electric fan. Replace thermoswitch or motor.
Over-cooling a. Atmospheric temperature extremely low. Partly cover radiator front area.
b. Defective thermostat, Replace.
Coolant leaks a. Loosened or damaged connecting units on Repair or replace.

hoses.
b. Leakage from water pump. Repair or replace.
c. Leakage from intake manifold. Repair or replace.
d. Leakage around cylinder head gasket. Retighten cylinder head nuts or replace gasket.
e. Damaged or cracked cylinder head and Repair or replace.
crankcase.
f. Damaged or cracked thermostat case, Repair or replace.
g. Leakage from radiator. Repair or replace.
Noise a. Defective drive belt. Replace.

b. Defective electric fan. Replace.
c. Defective water pump bearing. Replace.
d. Defective water pump mechanical seal. Replace.
16
FUEL INJECTION SYSTEM
Page
BUBARU MECHANISM AND FUNCTION. . . . . . . . . . . . . . . . . • . . . . . . . . . . ..

General. . . . . . . . . . . . . . . • • • . . • . • . . . . . . . . . . . . . . . . . . . . . ..
2
2
Air Flow Meter .....•.................................• 2
1988 Throttle Body .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .•

By-pass Air Control Valve ......................•..........
3
5
Auxiliary Air Valve ..................................... .
Ignition System .............•................•.........
Air-Fuel Ratio Learning Control System ••......................
O2 Sensor ..................•.........................
Fuel Injector ..........••..............................
Dropping Resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . .. 10
Coolant Thermosensor . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . .. 10
Pressure Regulator ..........•.••..•..................... 10
SCHEMATIC DRAWING .........•......................... 11
1800 cc Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11
2700 cc Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12
COMPONENT PARTS ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 13
Throttle Body and EGR Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 13
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15
Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17
Precautions in Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 18
Air Flow Meter ........................................ 18
Throttle Body .. . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 21
By·pass Air Control Valve .....•........................... 23
Auxiliary Air Valve. . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . .. 24
Fuel Injector and Resistor ........•........................ 25
Coolant Thermosensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 29
Pressure Regulator ...................................... 29
Air Intake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 29
TROUBLESHOOTING .....................•............... 30
General Troubleshooting Table . . . . • . . . . . . . . . . . . . . . . . . . . . . . .. 30
Self-diagnosis System .................................... 33
Troubleshooting Chart for Self-diagnosis System .................. 50
2-7 FUEL INJECTION SYSTEM

General Air Flow Meter
The Multi Point Fuel Injection (MPFI) system is a system
The MPFI system employs a hot-wire type air flow meter.
that supplies the optimum air-fuel mixture to the engine for
This air flow meter converts the amount of air taken into the
all the various operating conditions through the use of the
engine into an electric signal by utilizing the heat transfer
latest electronic technology.
phenomenon between the incoming air and a heating resistor
With this system fuel, which is pressurized at a constant
(hot wire) located in the air intake.
pressure, is injected into the intake air passage of the cylinder
The features of this flow meter type are as follows:
head. The injection quantity of fuel is controlled by an inter-
1) High-altitude compensation is made automatically.
mittent injection system where the electro-magnetic injection
2) Quick response.
valve (fuel injector) opens only for a short period of time,
3) There are no moving parts.
depending on the quantity of air required for one cycle of
operation. In actual operation, the injection quantity is 4) It is compact.
determined by the duration of an electric pulse applied to the
fuel injector and this permits simple, yet highly precise meter-
ing of the fuel.
Further, all the operating conditions of the engine are con-
verted into electric signals, and this results in additional
features of the system, such as large improved adaptability,
easier addition of compensating element, etc. The MPFI
system also has the following features:
1) Reduced emission of harmful exhaust gases.
2) Reduced in fuel consumption.
3) Increased engine output.
4) Superior acceleration and deceleration.
Hot wire
5) Superior startability and warm-up performance in cold
weather since compensation is made for coolant and intake
air temperature.
Air flow
L2-889
Fig. 1
2
FUEL INJECTION SYSTEM 2-7
Throttle Body Turning the idle adjust screw on the idle bypass passage can
change the air flow to adjust the number of revolutions in
In response to the depressing stroke of the throttle pedal, the idling. Further, to prevent the number of revolutions from
throttle body opens/closes its valve to regulate the air volume decreasing while the air conditioner is turned on, the fast idle
to be taken in the combustion chamber. Negative pressure bypass passage is provided which has the valve operated by
(positive pressure at supercharging) generated according to the the fast idle solenoid.
opening of the throttle valve is applied to the pressure port
The fast idle engine rpm can be adjusted by turning the
for canister purge. This pressure is used for controlling canister fast idle adjusting screw.
purge.
1800 cc model
During idling, the throttle valve is almost fully closed and the
air flow through the throttle body is less than that passing
through the carburetor. More than half of the air necessary for
idling is supplied to the intake manifold via the idle bypass
passage.
adjusting screw
Idle by-pass passage
screw
L2-1086
Fig_2
2700 cc model
During idling, the throttle valve is almost fully closed and the
air flow through the throttle body is less than that passing
through the carburetor.
More than half of the air necessary for idling is supplied to the
intake manifold via the by-pass air control valve.
And the by-pass air control valve properly controls the number
of revolutions in idling, so it does not need to be adjusted.
3
THROTTLE SENSOR SYSTEM 2700 cc model
A throttle position sensor is provided with a potentiometer
and idle switch interlocked with the throttle valve shaft is
~
utilized. 1 Power (Sensor)
This throttle position sensor sends the MPF I control unit a 2 Sensor signal
potentiometer output signal corresponding to the opening of ,..
the throttle valve and an idle switch signal that turns ON only 3 Power (Idle switch)
-
when the throttle is opened nearly to the idle position. 4 GND
Using these signals, the MPF I control unit precisely controls
the air-fuel ratio during acceleration and deceleration as wetl
as idling.
1800 cc model
4 Power (Idle switch)
3 GND
2 Power (Sensor)
Sensor signal
L2·1467
Fig. 4
Throttle sensor
L2·1087
Fig. 3
4
By-pass Air Control Valve 2) When the engine is cold, the by·pass passage opens widely
to allow more air to pass through. This speeds engine warm-up.
3) Variations in engine idling rpm over time and/or among
products (= engines) are compensated for.
(2700 cc model only)
4) When the throttle valve closes (= dash pot function), a
The by·pass air control valve is regulated by a signal transmit· sudden drop in engine rpm is prevented to improve driving
ted from the MPFI control unit. It finely controls the flowrate performance.
of air passing through the by·pass passage, allowing the engine
to run at optimum speed under various conditions. This in a. When battery voltage drops momentarily, the by-pass
turn results in stabilized exhaust gas emission, improved fuel valve sometimes activates to increase idling speed to 9DO rpm.
economy and better performance. This is not a problem.
1) The by·pass passage opens partially while the engine idles. b. Before the engine is warmed up (coolant temperature:
When the engine is loaded (the air conditioner is turned ON, above BDoe (176°F)), idling speed between the N or Prange
for example), the by-pass passage opens wider to let more air and the 0 range sometimes differs. However, this is not a
pass through. This maintains specified engine idling rpm. problem because it assists in rapidly warming up the engine.
Air flow sensor
By-pass passage Ignition switch
rr----~------~~-,
MPF I control -=- Battery

unit
1
Air cleaner
Throttle body
Intake manifold
Various sensor signals
Engine rpm 1
Low air flow rate
lin low-load, idling operation)
U-ring washer
Commutator
Coil
Magnet
Shaft
High air flow tate
.-lIJT-J+-- Core
(in high·load, idling operation)
.. Housing
::~ O·ring
V
,
.
R eturn spring
Slider
Slider housing
Control valve operation
Fig. 5 Idling rpm control system
5
Auxiliary Air Valve Ignition System

The ignition system is composed of a battery, an ignition coil,
The auxiliary air valve is used to increase air flow when the
a distributor, spark plugs, knock sensor, MPF I control unit
engine is started up at a low temperature and the following
and wires.
warmup is performed. It consists of the coiled bimetal, the
The crank angle sensor built-in distributor detects the refer-
bimetal-operated shutter valve, and the electric heater ele-
ment for bimetal. The passing air flow (at start-up) is increased ence crank angle and the positioned crank angle. Electronic
signal of both angles is transmitted to MPF I control unit which
as the temperature becomes lower. After start-up of the
is used in common by fuel injection system.
engine, the heating is performed by the heater to which
current is supplied from the fuel pump relay circuit. Thereby, The MPFI control unit calculates the spark advance angle and
determines the spark timing.
the shutter valve turns gradually to decrease the air flow. After
a certain elapsed time, the shutter valve is closed. The electronic signal of spark timing determined by control
unit is transmitted to the power transistor where it makes
the primary circuit to ignition coil, whereby high voltage
current is generated in the secondary circuit.
The high voltage of secondary circuit is distributed to the
spark plug of each cylinder and discharged there.
UNDER NORMAL OPERATING CONDITIONS

The spark advance angle is calculated from the following three
factors.
1) Engine speed compensation.
2) Advance when starting the engine.
3) Advance in all driving conditions except starting the
engine, after engine speed exceeds the present value.
Rotary valve
WHEN KNOCKING OCCURS
.....
AIR IN
-.... AIR OUT
A signal is transmitted from the knock sensor to the MPF I
control unit. The MPFI control unit then retards spark timing
Valve fulcrum to prevent engine knocking.
Knocking is Advance
eliminated. gradually.
L2-1089
Fig. 6
6
1800 cc model
,----
I
--- - - --~PF 1 00""01 u~;~~i= =====----==1- ~",o,
Power transistor I
I
I Auxiliary air valve
r--------------' :
I---------------~
Ignition coil
I 'fl\
L - - - J Coolant temperature sensor L2-1258
Fig. 7
2700 cc model
r--- --- ------ - - - - - - - - - - - - - - -- - - - - - l
I r--------------------l
Battery
I I r-----------------, Spark plug
I I I I
I I I I
Ignition switch
I
I
I
I
I
I
I
J
I
I
I
I
I
____ J I
_____ -.J
MPFI
I-
I
I
By-pass air
control valve
K"o<k ""'0' LHf ,-
,-
L _____________________ ~
Air flow
Power I
sensor
transistor
Coolant
temperature sensor
L2-1259
Fig. 8
7
KNOCK SENSOR
O 2 Sensor
The knock sensor is installed on the cylinder block, and senses The 0] sensor is mounted on the center exhaust pipe between
knocking signals from each cylinder. the turbocharger and the rear exhaust pipe. It is used to sense
This knock sensor is a piezo-electric type which converts oxygen concentration in the exhaust gas. If the fuel ratio is
knocking vibrations into electric signals. leaner than the stoichiometric ratio in the mixture (Le. ex-
It consists of a piezo-electric element, weight, and case. cessive amount of air), the exhaust gas contains more oxygen.
If knocking occurs in the engine, the weight in the case To the contrary, if the fuel ratio is richer than the stoichio-
moves causing the piezo-electric element to generate a voltage. metric ratio, the exhaust gas hardly contains oxygen.
Therefore, examination of the oxygen concentration in ex-
haust gas makes it possible to show whether the air/fuel ratio
is leaner or richer than the stoichiometric ratio.
The 0 1 sensor has a zirconia tube (ceramic) which generates
voltage if there is a difference in oxygen concentration be-
tween the inside and outside of the tube. Platinum is coated
on the inside and outside of the zirconia tube for the purpose
of catalysis and electrode provision. The hexagon screw on
the outside is grounded to the exhaust pipe, and the inside
is connected to the MPFI control unit through the harness.
Piezoelectr ic ity
L2-893
Fig. 9
Air-Fuel Ratio Learning

Control System L2-241
Fig. 10
This system has been developed to stabilize the quality of the
hot-wire type air flow meter and fuel injector and to maintain
their original performance by correcting their qualitative
variation and aging.
By learning the feedback control amount of the O2 sensor, the
system controls the control unit to automatically set a coeffi- When rich air-fuel mixture is burnt in the cylinder, the oxygen
cient of correction; thereby, the fuel injector always ach ieves in the exhaust gases reacts almost completely through the
fuel injection under the optimum condition. catalytic action of the platinum coating on the surface of the
zirconia tube. This results in very large difference in the
oxygen concentration between the inside and outside, and
the electromotive force generated is large.
When a lean air-fuel mixture is burnt in the cylinder, oxygen
remains in the exhaust gases even after the catalytic action,
and this results in small difference in the oxygen con-
centration. The electromotive force is very small.
8
The difference in oxygen concentration changes greatly in the 1800 cc model
vicinity of the optimum air-fuel ratio, and hence the change
in the electromotive force is also large. By inputting this
Coil
information into the MPFI control unit, the air-fuel ratio of
the supplied mixture can be determined easily. The O2 sensor
does not generate much electromotive force when the tem-
perature is low. The characteristics of the electromotive force
stabilize at temperatures of approximately 300 to 400°C
(572 to 752°F).
L2-1469
Fig. 12
2700 cc model
A21-224
Large Theoretical air-fuel
ratio
To be judged
as rich
t Comparison
- - - r . - - ___vo_ltage
L2-1470
Fig. 13
Small _ Air-fuel _ Large

Small ratio
A21-225
Fig. 11
Fuel Injector
The fuel injector injects fuel according to the valve open
signal received from the MPF I control unit.
The nozzle is attached on the top of the fuel injector. The
needle valve is lifted by the solenoid coil through the plunger
on arrival of the valve open signal.
Since the injection opening, the lifted level of needle valve
and the regulator-controlled fuel pressure are kept constant,
the amount of fuel to be injected can be controlled only by
the valve open signal from the MPF I control unit.
At the fuel inlet of the injector, the filter is mou nted to pre-
vent dust from entering.
On the 2700 cc model, a high resistor is built into the fuel
injector to etim inate a separate dropping resistor.
9
Dropping Resistor Pressure Regulator

The pressure regulator is divided into the fuel chamber and
the spring chamber by the diaphragm as illustrated below. Fuel
The dropping resistor serves as a voltage control to maintain is fed to the fuel chamber through the fuel inlet connected
optimum injector driving current. with the injector. A difference in pressure between the fuel
chamber and the spring chamber connected with the intake
manifold causes the diaphragm to be pushed down, and fuel
is fed back to the fuel tank through the return line.
By returning fuel so as to balance the above pressure differ-
ence and the spring force, the fuel pressure is kept at a con-
stant level 250.1 kPa (2.55 kg/cm2, 36.3 psi) against the in-
Coolant Thermosensor take manifold pressure.
The coolant thermosensor is equipped on the waterpipe which (1800 cc model)
is made of aluminum alloy. Its thermistor changes resistance
with respect to temperature.
To the MPFI control unit, the thermosensor sends the coolant
temperature signal which is decisive for the fuel volume to be
injected.
¢:> Fuel inlet
Diaphragm
Diaphragm
c:~ Chamber
2.5
III
u To intake manifold
c:
~ A21-218
'ij
a: Fig. 15
L--_ _.l--_ _ _ _ Temp. °c (oF)
-20 0 40 80
(-4)(321 (104) (176) (2700 cc model)
20 60
(68) (140)
A21-227 To intake manifold t
Fig. 14
Diaphragm
Valve . . :~om fuel

Injector
L2-1472
Fig. 16
10
."
...
OJ
-"
~.
o
o
C')
C')
3
-- --
~--
(speed sensor)--- - ---1-- ~=:~
J Rela = I
-.
y i 8.
~
J II !I~~'- -
-
:
~I;
- =iI
F:'::~ ::~
IGcoil
( IG. SW } - -
B::JII' '
" I
r - -)::::=~ i L___ ~_
.0' .."
~I C
( Starter SW ) - - - !
.= Power m
transistor r-
Z
~
( Neutral SW)-- I
Z
or Inhibiter SW
==--~;;~~~-----~-~ ~~t~kangle
- D,,,,'butm G> '-
m
(')
!ii ~ sensor i
-i
~:~
Ii oZ
Ii
il ~
en
-i
II m
s:
• i F====:-J
UI ___ I + _____ ~,
"9.~1CI Solenoid valve
Orifice I From
.
I
-.A I fuel tank
----'
rJ :=J
0.0'"''
rf',)
N
--..
r= --- .
(speed ~mo'}----j I -l--~-M-P~~-! ~'
-----r--~
I Relay ,
8
n
n
3
8.
-I- _ ---_ -- _--- -- ====.-.: ===:: I
::tjfrE~ ~£r.'~ ' :-7=-:1- --~~-T-!i
. - CuOn':ilttrol - I S!.
" 0::0
~-~'I~-~ ~ L__~
, , IG coil with
C"-,G.SW B>=- --t -r---/iJ i !,FueIPUF==m
~~- !il'I',rr~- _L_ -k ~~~~~~o~~ I~~:',

p ,-
(Sto".' I ,,,n,;,,o,
~I
~-
~.~~ III IIII', LDi~nosiS
11"1 -~'I '
j~mper !!'- i !~ :.
-===,1'1 i i , ~ : : _____I '-.~Distributor
_, ."
- -~!
(NeutralSW only
. I,I, I"., with crank C
"N" "P" 1'1' I , =1- II _ _ _ .. _ . __ _ angle sensor m
r-
p",,-
(
( c~~ditioner
range SW -
A· }-
-~"
L
I Air
~
Th,ottl.
_
sensor
~bf;~~~===f~~=~;;r
regulator .
'I
Z
c....
~:1ill valv~_ ==~(r:: r-I+~~-I--II-'
"i: L - control m
Air flow meter. , , ,I ()
with hot wire II;, -I
sensor
t: '1 oZ
en
-<
, ~
m
~
Injector
containing
01
.E:'~ Solenoid
resistor
Temp.
L-----~~valve
sensor
I · From fuel tank
Oxygen
sensor
------fJ ~er
Oxidation
catalyst
COMPONENT PARTS
Throttle Body and EGR Valve
1800cc model
~,~ @
@
«V. ""
1 Throttle sensor
2 Throttle body ASSY
3 GasKet
4 FICD solenoid valve
5 Spring
6 Plunger
Q
I I 7 Throttle body
8 Throttle adjusting screw
9 Throttle lever
10 Throttle cam (Accelerator cable)
11 Throttle cam (Cruise control cable)
12 Throttle cam
13 Dash pot
",./ '........ lJ
,,- -" " ">
,,/ ," Q QV
,
{tI
"~~ ~~
--- ~~ I
I
. ;~a
"\..~'"
___ >
I /
I /"
I //
~, ',< ---
@lZt
1",
C~~~
~ L2·1473
Fig. 19
13
2700cc model
CD
//
/r
?"" ,
\ "/ ~
r".:'...a:::"tJ / ,
/
/
®
1 Throttle sensor
2 Throttle body ASSY
3 Gasket
4 Throttle body
5 Throttle adjust screw
6 Throttle cam
7 Throttle cam (Accelerator cable)
8 Throttle cam (Cruise control cable)
9 Throttle lever
®
I
I
I
I
I
I
I
r', I
I' I
I " I
I '-..J
I
I
I
, I
" I
'-J
Fig. 20 L2-1474
14
Intake Manifold
1800cc model 1 Gasket
2 Intake manifold collector
3 Fuel pipe ASSY AH
4 Pressure regulator
5 Fuel pipe ASSY LH
6 Vacuum pipe ASSY
7 Purge control solenoid
valve
/1 8 Auxiliary air valve
/ I
.-'
9 EGA solenoid valve
CD I
10 Coolant thermosensor
11 Gasket
12 Thermometer
® 13 Water pipe
14 Fuel injector
® ._-;-, CD 15 Holder plate

Insulator
16
17 Holder
18 Seal
19 Intake manifold
20 Gasket
/
/1
~ ' ........ ~
I
,I .-'
/
@'-~~7 I
@
I
@ @
L2-1475
Fig. 21
15
2700cc model
CD
~""~~
1 Intake manifold cover
2 Fuel pipe cover RH
3 By-pass air control valve
4 Intake manifold collector
5 Gasket
6 Fuel pipe cover LH
7 Fuel pipe ASSY
8 Pres$ure regulator
9 Fuel pipe RH
- ttl 10
11
Union bolt
Fuel pipe
r~~~J
12 Fuel pipe ASSY
V_, l 13
14
Purge control solenoid valve
\ ~:-]~ "" ' , i~p

Q'ring
15 Fuel injector
·-\' 16 Insulator
~
. 0 '~ . 17 Gasket
C::t
1
(I ~
® 18
19
Intake manifold RH
Gasket
~~
20 Water pipe
® 21 Coolant thermosensor
~: ~ 22
23
Fuel pipe LH
Gasket
~I
l.t 24 Intake manifold LH
25 Gasket
L2·1476
Fig. 22
16
Air Intake System
CD
\
~--
--
1 Flange nut
2 Air intake duct
3 Lower case
4 Air cleaner element
5 Gasket
6 Upper case
7 Flange nut
8 Bolt
9 Washer
10 Spacer
11 Grommet
12 O·ring @
13 Air flow meter ASSY
14 Hose clamp
15 Air intake boot
Fig. 23 L2·1477
17
SERVICE PROCEDURE
Precautions in Servicing Air Flow Meter
1) Never connect the battery in reverse polarity.
• The MPFI control unit will be destroyed instantly. INSPECTION
• The fuel injector and other part will be damaged in just
a few minutes more. 1) Check for leaks or damage in the connection between the
2) Do not disconnect the battery terminals while the engine air intake boot and air flow meter. Repair any defect noted.
is running. 2) Remove the connectors from the air flow meter, the air
• A large counter electromotive force will be generated in intake boot, and the air flow meter for the air cleaner case in
the alternator, and this voltage may damage the electronic the order stated.
parts such as MPFI control unit, etc. 3) Check the exterior of the air flow meter for damage.
3) Before disconnecting the connectors of each sensor and 4) Check for foreign matter. water. or oil in the air passages,
the MPFI control unit, be sure to turn off the ignition switch. especially in the by-pass. If any abnormality is noticed. replace
• Otherwise, the MPFI control unit may be damaged. the air flow sensor.
4) The connectors to each sensor in the engine compartment 5) If no defect is found in the visual checks above. conduct
and the harness connectors on the engine side and body side the following inspections.
are all designed to be waterproof. However, it is still necessary (1) Turn the ignition switch OFF (engine off).
to take care not to allow water to get into the connectors (2) Attach the air flow meter to the air cleaner.
when washing the vehicle, or when servicing the vehicle on a (3) Disconnect the air flow meter connector, and remove
rainy day. the rubber cover from the connector.
5) Every MPFI-related part is a precision part. Do not drop Conduct the following checks by attaching the tester
them. check pins to the connector terminals on the side from
6) Observe the following cautions when installing a radio in which the rubber cover has been removed.
MPFI equipped models.
a. The antenna must be kept as far apart as possible
from the control unit.
b. The antenna feeder must be placed as far apart
as possible from the MPF I control unit and MPF I harness.
c. Carefully adjust the antenna for correct matching.
d. When mounting a large power type radio, pay special
attention to items a. thru c. above.
• Incorrect installation of the radio may affect the operation
of the MPF I control unit.
7) Before disconnecting the fuel hose, disconnect the fuel I
Air flow meter
pump connector and crank the engine for more than five
seconds to release pressure in the fuel system. If engine starts
during this operation, run it until it stops.
I
I
Rubber cover
Air flow meter connector (Body side)
LgR: Burn·off signal

R : Power supply
S : GND
SR : GND
W : Sensor signal
L2-901
Fig. 24
18
(4) Measure resistance between the body and ground (8) Attach the positive lead of a tester to signal terminal
terminals (B) and (BR). (W) and the negative lead to the ground terminal (BR).
Measure the voltage across the two terminals.
Specified resistance:
lOn, max. Specified voltage:
1- 2V
If resistance is greater than lOn, check the harness and
internal circuits of the control unit for discontinuity, and If voltage is outside specifications, replace the air flow
the ground terminal on the intake manifold for poor meter.
contact.
L2-1099
Fig. 27
Fig. 25
(9) Remove the air flow meter from the air cleaner.
(The air intake boot need not be removed.)
(5) Turn the ignition switch ON (engine off). (10) Blow air from the air cleaner side to check if voltage
(S) Connect the air flow meter connector. across terminals (W) and (BR) is greater than that meas-
(7) Measure voltage across power terminal (R) and the ured in step (8) above. If not, replace the air flow meter.
body.
Specified voltage:
10V, min.
If voltage is outside specifications, check the condition of

the parts (battery, fuse, control unit harness, connector,
etc.) in the power line.
L2-1100
Fig. 28
(11) Install the air flow meter on the air cleaner.

(12) Start the engine.
(13) Warm up the engine until the coolant temperature
reaches approximately 80°C (17SoF).
(14) Drive at speed greater than 24 km/h (15 MPH) for
Fig. 26 at least one minute.
19
(15) Race engine above 2,000 rpm. (17) Turn the ignition switch OFF. Check if 12 volts are
(16) While idling the engine, monitor voltage across present across the terminal LgR and the body for one
terminal (LgR) of the air flow meter connector and the second shortly after the ignition switch has been turned
body. (OV under normal operating conditions is OK.) OFF. If not, check the harness from the control unit to
the air flow meter for discontinuity.
Fig. 29
Air flow meter
Control unit
38 LgR
12 R
5 e
2~L---------------------------------------------------------~
27~~-----I
35 ® Fuse No. 11
39 GW 1------+---+---<>"""....,o---oEljIG
(f}e
®
I I I I It'l I I: 1I ~
GEl
@ Ignition relay @) Diode
L2·1202
Fig. 30
20
Throttle Body 4) If the above standards are not satisfied, loosen the screws
(two) securing the throttle switch to the throttle body, and
1800cc model turn the throttle switch main body until the correct adjust·
ment is obtained.
INSPECTION AND ADJUSTMENT
THROTTLE SENSOR
Throttle
body
Connector
(Throttle
To @ sensor side)
L2·1102
Control unit Fig. 32
r - - - - , LW
251---------'
16 BA
W
211-----------'
22 B
@(Black)
II t III Ittl
@<BlaCk)
III t I.~ I till

L2·1103
Fig. 31
Idle contact
Throttle opening signal
Before checking the idle contact, remove the intake duct.
1) Measure resistance between terminals @ and ®.
Insert a thickness gauge between the stopper screw of the
throttle body and the stopper (portion @ I. and check for Specified resistance:
continuity between ( @ and @). 6 -18 kn
1)· Make sure that @ and @ are conducting when the
throttle is closed fully. If resistance is outside specifications, replace the sensor.
2) Make sure that @ and @ are conducting when the 2) Measure resistance between terminals ® and CD.
thickness of gauge is 0.55 mm (0.0217 in) (this corresponds to
throttle opening of 1.5°). Specified resistance:
3) Make sure that @ and @ are not conducting when the 5.8 - 17.8 kn (Throttle valve fully closed)
thickness is 0.92 mm (0.0362 in) (this corresponds to a 1.5 - 5.1 kn (Throttle valve fully opened)
throttle opening of 2.5°).
Ensure that resistance changes smoothly between the fully-
closed and fully-opened throttle positions. If resistance is
outside specifications, replace the sensor.
21
2700cc model
TH RaTTLE SENSOR
To @
Fig. 33
DASH POT (Black)

1) Warm-up the engine sufficiently, and check that the idle Control unit
speed is as specified. 16 BR
2) Under the non-loaded state, turn the throttle lever by 25 LW

22~B~ _ _ _ _ _ _....J
hand and increase engine speed until the end of the dash pot
21 W
is off the throttle cam.
3) Gradually return the throttle lever, and read the engine
rpm when the throttle cam contacts the end of the dash pot. @(Black)
Engine rpm 2,800 - 3,400 rpm Ii! I'll ttl

® (Black)
III t 1,& I I III

4) If the engine rpm is not within this range, loosen the lock
nut of the dash pot, and turn the dash pot until this specifi-
cation is satisfied. After adjustment, tighten the lock nut
securely.
L2-1478
5) After adjustment, race the engine and make sure the idle
speed returns correctly to the idle speed as the throttle is Fig. 34
released.
1) Disconnect the th rottle sensor connector.

2) Insert a thickness gauge [0.35 mm (0.0138 in), 0.75 mm
(0.0295 in)] between the stopper screw and throttle lever
[portion G], and measure resistance between terminals (3) and
(4) of throttle sensor.
5 kn, max
[When gauge thickness is 0.35 mm (0.0138 in))
1 Mn,min
[When gauge thickness is 0_75 mm (0.0295 in)]
22
By-pass Air Control Valve

Throttle body
[2700cc model only]
INSPECTION
Throttle lever
By-pass air
Control unit control valve
~---------:~:: ~~~
5Sf-------------'-'-'-i
YL
L2-1479 5 9 f - - - - - - + - - - - - -"""--1 3 1_~_j
Fig. 35
@)~
@@
L2-1481
Fig. 37
1) Disconnect the connector from the by-pass air control

valve.
3) Measure resistance between terminals (1) and (4 Measure resistance between terminals (1) and (2) of by-pass air
control valve.
Specified resistance;
3-7kn Specified resistance:
9.5 -11.5 n
4) Measure resistance between terminals (2) and (4
4.2 - 15 kn (Throttle valve fully closed)
0.1 - 11 kn (Throttle valve fully opened)
[Differential: 4 kn]
Ensure that resistance changes smoothly between the fully

closed and fully opened throttle positions. If resistance is out-
side of speCifications, replace the sensor.
Fig. 38
2) Measure resistance between terminals (2) and (3) of by-

pass air control valve.
8.5 -10.5 n
Fig. 36
23
3) Measure resistance between terminal (2) and valve body,

and between terminal (3) and valve body,
Infinity ( 00 ) n
If resistance is outside of specifications, replace the by. pass

air control valve.
Fig. 40
Fig. 39
2) As the engine Is started, the auxiliary air valve Is heated by
the built-In heater and its shutter valve closes gradually. This
causes the engine rpm to be lowered gradually until the
specified idling rpm is reached.
If the engine speed will not drop to the idling rpm smoothly,
the heater circuit or the heater power supply circuit may be
faulty. In this case, perform the following checks;
(1) Check the resistance value of the auxiliary air valve.
Disconnect the connector of the auxiliary air valve and
measure the resistance between the two terminals, using
a circuit tester.
Auxiliary Air Valve Resistance value must be other than zero (0)
and infinity (00).
[1800cc model only]
If the resistance is zero (0) or infinity (00), replace the
INSPECTION auxiliary air valve with a new one.
1) Pinch the hose connecting the air intake duct and

auxiliary air valve and observe how the engine speed changes.
State of engine Engine speed

Engine idle speed drops as
When engine is cold
the hose is pinched.
Reduction in engine speed
When engine is hot
is within 100 rpm.
When pinching the hall, cover it with I rubber pllte or the

like for protection. Fig. 41
24
(2) Check source voltage.
Disconnect the connector of the auxiliary air valve, and
check voltage on the harness side.
Voltage (when engine is running):

Over 12V
If the voltage is OV or lower than 12V, check the harness

and connector for condition.
(\\~ L2-1111
Fig_ 42
3) If item 2) above is normal but only item 1) is faulty,
the cause may be as follows:
Cause of trouble Symptom Remedy
1 Sticking of shutter valve of auxiliary

air valve.
• cold.
Engine stalls easily when engine is
(Sticking in closed direction)

Replace auxiliary air
valve.
2 Sticking of shutter valve of auxiliary
air valve.
• during
Engine rpm does not lower smoothly
warm-up operation.
(Sticking in open direction) • Engine rpm remains high.
3 Clogged air passage. Same as CD Check air passage, such as

hose, etc. and clean.
2) Disconnect each fuel injector connector.

Fuel Injector and Resistor Measure resistance between the terminals of each injector.
1800cc model
2-3n
INSPECTION If resistance is greater than 1 Mn, the affected circuit is

broken. If 0 fl, the circuit is shorted. Replace the injector.
Using a stethoscope or a long-type screwdriver, make sure of
operating noise (clicking sound) of each injector (when idling
or cranking engine). If this operating noise cannot be heard on
any injector:
1) Disconnect the control unit connector.
Measure voltage across the body and terminals 49 (W), 50 (W),
51 (WL) and 52 (WL) of control unit connector (body side),
respectively.
Specified voltage:
12V
If voltage is below lOV in any line, the affected harness from

the battery to the control unit through the resistor and
injector is broken or shorted. Fig. 43
25
3) Measure voltage across power terminals of each injector 5) Measure voltage across terminal 5 (R) of body harness
connector and the body. connector and the body.
Specified voltage: Specified voltage:

12V 12V
If voltage is less than 10 V, the harness from the battery to the

injector through the resistor is discontinued or shorted.
~1.---....L..-=<I _
Resistor connector
I
II L-.......J I
Fig. 46
Fig. 44
4) Disconnect the connector from the resistor.

Measure resistance between terminals Wand B of the resistor.
5.8 - 6.5rl
If resistance is outside specifications, replace the resistor.
Fig. 45
26
1800 cc
Fuel injector Fuel injector Fuel injector Fuel injector
No.1 No.2 No.3 No.4
®
Control unit (Black)
W
49
W
50
WL
51
WL
52
ciIQ) (Black)
~
Fusible link
®
(Black) 1--~1---4
Resistor
L2-1471
Fig. 47
2700cc model 2) Disconnect each fuel injector connector.

Measure resistance between the terminals of each injector.
INSPECTION
Using a stethoscope or a long-type screwdriver, make sure of Approx. 13.8 fl
operating noise (clicking sound) of each injector.
If this operating noise cannot be heard on any ir.jector: If resistance is greater than 1 Mfl, the affected circuit is
1) Disconnect the control unit connector. broken. If 0 fl, the circuit is shorted. Replace the injector.
Measu re voltage across the body and term inals 49 (W), 50 (W),
51 (WRl, 52 (WR), 53 (WY) and 54 (WY) of control unit con-
nector (body side), respectively.
Specified voltage:
12V
If voltage is below 10V in any line, the affected harness from

the battery to the control unit through the resistor and
injector is broken or shorted.
Fig. 48
27
3) Measure voltage across power terminals of each injector
connector and the body.
Specified voltage:
12V
If voltage is less than 10 V, the harness from the battery to the

injector is discontinued or shorted.
Fig. 49
2700 cc
Fuel injector
® @) @ @) @) @)
No.1 No.2 No.3 No.4 No.5 No.6
Control unit @)
51 WR WR WR
52 WR WR WL
53 WY WY WY
54 WY WY WG
49 W W W
50 W W WB
R RV
@ (Black) R R
~ R
® @ L2-1486
Fig. 50
28
2) When checking with the engine stopped
Coolant Thermosensor Set the diagnosis jumper for checking the MPFI system to ON,
and then turn ON the key switch. This will cause the fuel
INSPECTION pump to operate intermittently. Measure the fuel pressure in
this state.
Put the thermosensor in water of various temperatures and
measure the resistance between terminals using a circuit Standard:
tester. Fuel pump ON
If the resistance value is too much out of these ranges, replace Approx. 255 kPa (2.6 kg/cm 2 , 37 psi)
the thermosensor with a new one. Fuel pump OFF
Approx. 226 kPa (2.3 kg/cm 2 , 33 psi)
Water temperature
Resistance value
°c (oF)
-10 (14) 7 - 11.5 kn
20 (68) 2 -3 kn
50 (122) 700 - 1,000n
Air Intake System

Pressure Regulator Air Cleaner Assembly
The pressure regulator adjusts the fuel pressure to 250.1 kPa REMOVAL AND INSTALLATION
I (2.55 kg/cm 2 , 36.3 psi) compared to the intake manifold
pressure.
1) Disconnect connector from air flow meter.
2) Remove engine harness from clip.
INSPECTION 3) Loosen hose clamps securing air intake boot, and remove
air intake boot connecting with air flow meter.
Disconnect the fuel hose at the pressure regulator connecting 4) Remove air cleaner ASSY mounting bolts.
portion and install a fuel gauge. 5) Move air cleaner ASSY toward engine, and take it out
from body.
a. Before disconnecting the fuel hose, first disconnect the fuel
pump connector and crank the engine (more than five Installation is in the reverse order of removal procedure.
seconds) to release the pressure in the fuel system. If the
engine is started by this cranking, run it until it stops.
b. Be sure to clamp the hose at the connecting portion.
1) When checking with the engine running Chamber Assembly

(1) Measure the fuel pressure when the engine is at idle
speed.
REMOVAL AND INSTALLATION
Standard:
1) Remove mud guard.
177 - 206 kPa (1.8·2.1 kg/cm 2 , 26 - 30 psi)
2) Remove washer tank.
3) Remove nuts, and remove chamber ASSY from body.
(2) Race the engine, and make sure the fuel pressure
increases correspondingly. Installation is in the revene order of removal procedure.
29
TROUBLESHOOTING
General Troubleshooting Table
*: The CHECK ENGINE light blinks.
*1: The CHECK ENGINE light blinks when contact is resumed during inspection (although poor contact is present in the 0-
check).
*2: The CHECK ENGINE light lights when the mixture is leaner than that specified and does not light (U-check) or blink (0-
check) when the mixture is richer.
*3: The CHECK ENGINE light lights when abnormality is detected in the D-check mode if the idle switch persistently remains
off with the acclerator pedal released.
Symbols shown in the table refer to the TROUBLE
degree of possibility of the reason for 1 No initial combustion
the trouble ("Very often" to "Rarely"). -
Engine will
© : Very often 2 Initial combustion occurs.
- not start
o : Sometimes 3 Engine stalls after initial combustion.
6: Rarely 4 Rough idle and engine stall
u: Occurs only in extremely
low temperatures 5 Inability to drive at constant speed
6 Inability to accelerate and decelerate
7 Engine does not return to idle.
8 Afterburning in exhaust system
9 Knocking
%§
10 Excessive fuel consumption
11
U CHECK EN- U-check mode & read memory mode
r-- GINE light
D operation D-check mode
TROUBLE No. #
POSSIBLE CAUSE
1 2 3 4 5 6 7 8 9 10 U D
AIR FLOW METER
U © 6 6 0 ON ON • Connector not connected
6 © © © © 0 6 ON *1 • Poor contact of terminal
U © 6 0 6 ON ON • Short circuit
U © 6 6 0 ON ON • Discontinuity of wiring harness
0 0 0 0 6 © 0 *2 *2 • Performance characteristics unusual
COOLANT THERMOSENSOR
U 0 U 0 0 0 0 ON ON • Connector not connected
6 6 © 0 0 © 6 0 ON *1 • Poor contact of terminal
U 0 U 0 0 0 0 ON ON • Short circuit
U 0 U 0 0 0 0 ON ON • Discontinuity of wiring harness
U 0 U 0 © © © *2 *2 • Performance characteristics unusual
IDLE SWITCH OF THROTTLE SENSOR
0 © © OFF ON • Connector not connected
0 0 ON *1 • Poor contact of terminal
0 6 0 ON ON • Short circuit
6, 0 OFF ON • Discontinuity of wiring harness
0 OFF *3 • Improper adjustment
1 2 3 4 5 6 7 8 9 10 U D
#: CHECK ENGINE light
30
TROUBLE No. #
POSSIBLE CAUSE
1 2 3 4 5 6 7 8 9 10 U 0
THROTTLE SENSOR
© © ON ON • Connector not connected
© © © ON *, • Poor contact of terminal
6. © © ON ON • Short circuit
© © ON ON • Discontinuity of wiring harness
0 0 6. 0 © © OFF * • Performance characteristics unusual
PRESSURE REGULATOR
0 0 © © © 0 6. *2 *2 • Sensing hose not connected
6. 0 0 © OFF * • Fuel pressure too high
0 0 0 © © © © *2 *2 • Fuel pressure too low
FUEL INJECTOR
e.g (~) 0 0 0 0 0 ON *1 • Connector not connected
0 0 0 © © 0 ON ON • Poor contact of terminal
© © 0 0 0 0 ON ON • Short circuit
© © 0 0 0 0 0 ON ON • Discontinuity of wiring harness
6. 0 0 6. 0 0 6. 0 *2 *2 • Performance characteristics unusual
6. 0 6. 6. 0 0 6- *2 *2 • Clogged filter
6. 0 0 0 0 0 6. *2 *2 • Clogged nozzle
0 OFF * • Stuck open
0 0 0 OFF * • Slight leakage from seat
CRANK ANGLE SENSOR
© ON ON • Connector disconnected
0 0 © © © 0 0 ON *1 • Poor contact of terminal
© ON ON • Short circuit
© ON ON • Discontinuity of wiring harness
POWER TRANSISTOR OF IGNITION COIL
© OFF * • Connector not connected
0 0 © © © 0 OFF * • Poor contact of terminal
© OFF * • Short circuit
© OFF * • Discontinuity of wiring harness
AIR REGULATOR [1800 cc model only]
© OFF * • Connector not connected
0 © 0 OFF *
• Short circuit
© OFF * • Discontinuity of wiring harness
KNOCK SENSOR [2700 cc model only]
© ON ON • Connector not connected
0 0 ON ON • Short circuit
© ON ON • Discontinuity of wiring harness
1 2 3 4 5 6 7 8 9 10 U D
31
2. . 7 FUEL INJECTION SYSTEM
TROUBLE No. #
POSSIBLE CAUSE
1 2 3 4 5 6 7 8 9 10 11 U D
AIR CONTROL VALVE [2700 cc model only]

0 6, © ON ON • Connector not connected
6, 0 © ON *1 • Poor contact of terminal
0 0 ON ON • Short circuit
0 6, © ON ON • Discontinuity of wiring harness
© © OFF * • lAS improperly adjusted
© © ON * • Stuck open
0 0 © OFF * • Stuck closed
ENGINE GROUNDING
0 ON • Disconnecting of engine grounding terminal at intake
manifold
© © 0 © © © ON *1 • Poor contact of engine grounding terminal
0 ON • Discontinuity of wiring harness for engine grounding
1 2 3 4 5 6 7 8 9 10 11 U D
32
Self-diagnosis System SELF-DIAGNOSIS FUNCTION

The MPF I control unit executes the computational pro-
General cessing on the input information received from various sensors
and produces the output information for driving the fuel
The self-diagnosis system detects and indicates a fault in
injector, fuel pump, etc.
various inputs and outputs of the complex electronic con-
Along with this computational processing, it reads out all the
trol. The warning lamp (CHECK ENGINE light) on the instru-
input/output information to examine matching with the pre-
ment panel indicates occurrence of a fault or trouble, and also
determined levels (proper values or ranges). If a predetermined
the light emitting diode (LED) in the control unit indicates
level is not satisfied, i.e., a fault is found, the warning lamp is
a trouble code.
Further, against such a failure of sensors as may disable the signaled to a driver. In this fashion, the self·diagnosis function
drive, the fail-safe function is provided to ensure the minimal is performed.
driveability.
FAIL·SAFE FUNCTION
For the part which has been judged faulty in the self-diagnosis,
the MPFI control unit generates the associated pseudo signal
(only when convertible to electric signal) and carries out the
computational processing. In this fashion, the fail-safe
function is performed.
Function of Self-diagnosis
The self-diagnosis function has four modes: U-check mode,
Read memory mode, D-check mode and Clear memory mode.
Two connectors (Read memory and Test mode) and two
Fig. 51
lamps (CHECK ENGINE light and O 2 monitor) are used. The
connectors are for mode selection and the lamps monitor the
type of problem.
RELATIONSHIP BETWEEN MODES AND CONNECTORS

RL ~\ ( 4 ~rQ . ~.~
Mode Engine Read memory connector Test mode connector
U-check Ignition ON DISCONNECT DISCONNECT
Read memory Ignition ON CONNECT DISCONNECT
D-check Ignition ON DISCONNECT CONNECT
Clear memory Ignition ON (engine on) CONNECT CONNECT
U·CHECK MODE when the vehicle's monitor lamps are off). It is most effective
in detecting poor contact or loose connections of connectors,
The U-check is a user·oriented mode in which only the MPFI
harnesses, etc.
components necessary for start-up and drive are diagnosed. On
occurrence of a fault, the warning lamp (CHECK ENGI N E
D·CHECK MODE
light) is lighted to indicate to the user that the dealer's inspec·
tion is necessary. The diagnosis of other parts which do not This mode is used by the dealer to check the entire MPF I
give significant adverse effect to start-up and drive are ex- system and detect faulty parts.
cluded from this mode in order to avoid unnecessary un-
easiness to be taken by the user. CLEAR MEMORY MODE
This mode is used by the dealer to clear the trouble code from
READ MEMORY MODE the memory after the affected part is repaired.
This mode is used by the dealer to read past problems (even
33
Basic Operation of Self-diagnosis System

NO TROUBLE 0: CONNECT X: DISCONNECT
Read memory Test mode CHECK O2 monitor

Engine Remarks
connector connector ENGINE light lamp
ON X X OFF O 2 monitor
2 ON 0 X OFF O2 monitor
Vehicle specification
** code is outputted when
*3 ON X 0 OFF
OFF -+ Blink CHECK ENGINE light
is OFF.
All memory stored in
*4 control unit is cleared
ON 0 0 OFF -+ Blink OFF
after CHECK EN-
GINE light blinks.
OFF Vehicle spec if i-
5 0 X ON
(Ignition switch ON) cation code
Before starting the
OFF Vehicle specifi-
6 X X ON engine, the self-
(Ignition swit·ch ON) cation code diagnosis system
OFF Vehicle specifi- assumes the engine to
7 X 0 ON be in NO TROUBLE
condition.
OFF Vehicle specifi-
8 0 0 ON
TROUBLE
Read memory Test mode CHECK O2 monitor

Engine Remarks
connector connector ENGINE light lamp
9 ON X X ON Trouble code
Trouble code
10 ON 0 X ON
(memory)
**
*11 ON X 0 Trouble code Vehicle specification
OFF -+ ON
code is outputted when
** . CHECK ENGINE light
*12 ON 0 0 Trouble code
OFF-+ON is OFF.
OFF Trouble code

13 0 X ON
(Ignition switch ON) (memory)
STALL
14 X X ON Trouble code
(Ignition switch ON)
STALL
15 X 0 ON Trouble code
STALL
16 0 0 ON Trouble code
*: Ignition timing is set to 20 BlOC (when the engine is on, test mode connector is connected, a:nd idle switch is ON).
0
**: CHECK ENGINE light remains off until engine is operated at speed greater than 2,000 rpm for at least 40 seconds.
34
List of Trouble Codes
Trouble code Item

u- D-
Page
check check
11 Crank angle sensor (No reference pulse) 0 0 71
Starter switch (Continuously in ON position or continuously in OF F position

12 0 0 73
while cranking)
13 Crank angle sensor (No position pulse) 0 0 74

*76
14 Fuel injectors * #1 and #2, **#5 and #6 (Abnormal injector output) 0 0 **77
*78
15 Fuel injectors *#3 and #4, **#1 and #2 (Abnormal injector output) 0 0 **79
21 Water temperature sensor (Open or shorted circuit) 0 0 80
**22 Knock sensor (Open or shorted circuit) 0 0 81
23 Air flow meter (Open or shorted circuit) 0 0 82
**24 By-pass air control valve (Open or shorted circuit) 0 0 83
**25 Fuel injectors #3 and #4 (Abnormal injector output) 0 0 84

*85
31 Throttle sensor (Open or shorted circu it) 0 0 **86
32 O 2 sensor (Abnormal sensor signal) 0 0 87
33 Car-speed sensor (No signal is present during operation) 0 0 88

-
Purge control solenoid valve (Solenoid switch continuously in ON or OFF
35 - 0 89
"'"""--,
position)
41 System too lean 0 0 90
42 Idle switch (Abnormal idle switch signal in relation to throttle sensor output) - 0 91
51 Neutral switch (No signal is present) - 0 92
* 1800 cc model ** 2700 cc model
List of Specification Codes
MT
-------- 49-state and Canada
California
1800 cc model
05
06
2700 cc model
01
02
49-state and Canada 07 03

AT
California 08 04
35
How to Read Trouble Codes (Flashing)

The O 2 monitor lamp flashes the code corresponding to the
faulty part.
The long segment (1.2 sec on) indicates a "ten", and the short
segment (0.2 sec on) signifies a "one".
Example:
When only one part has failed: _II -II

lO.2-t11 \ ~0.2J
Flashing code 12
(unit: second)
1.2ffn1.8
0.3 0.3
When two or more parts have failed:

Flashing codes 12 and 21
_II __ I _II
(unit: second)
L~~~~:L2~L~,.J
0.3 0.3 0.3 0.3 0.2
L2-848
Fig. 52
36
MPFI System Layout

1800 cc model
Read memory connector @

Test mode connector ®
MPF I control unit
®®®@
Inhibitor switch (AT)@

-Neutral switch (MT) @
FICO solenoid ®
Throttle sensor @
®
Auxiliary air valve
Resistor (Engine control) ® Crank angle sensor ®

I Resistor (AT control) ® Ignition coil @
Fusible link ®
Air flow meter ®
Fuel injector
Fuel injector @@
Temperature sensor ®
Oil pressure switch @
Front
Fig. 55 L2-1489
41
2700 cc model
Read memory connector @

Test mode connector @
Fuel pump
Inhibitor switch (AfT) @

. Neutral switch (MT) @
Throttle sensor @
Knock sensor @
By-pass air control valve @
Crank angle sensor @ .
Resistor (AT control) ®
Ignition coil @
Fusible link @
Air flow meter ®

Battery
Fuel injector ~@@

Temperature sensor @ Thermo meter @
Oil pressure switch @ Purge control solenoid @
Front
Fig. 56 L2·1490
42
Connector Terminal
CONTROL UNIT CONNECTOR [1800 cc model]
® (Black)
r-1
@(Black)
r-J
10 9 8 7 6 5 4 3 2 1 42 41 40 39 38 37
20 19 18 17 16 15 14 13 12 1 1 48 47 46 45 44 43
® (Black)
r-1
@(BlaCkl
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
Fig. 57
1 YR Check connector 32 Br Test mode connector

2 W Air flow meter (signal) 33 LgW Read-memory connector
3 GL Purge control solenoid 34 - -
GY Neutral switch (MT) 35 WR Control unit power (input)
4
YL Inhibitor switch (AT) 36 - -
5 B Air flow meter (ground) 37 WY Ignition output (power transistor)
6 LB Fuel pump relay 38 LgR Air flow meter (burn-off «utput)
7 R Crank angle sensor (power) 39 GW Self-shutoff output
8 ''-8 Crank angle sensor (reference) 40 RY CHECK ENGINE light
9 WB Water temperature sensor 41 - -
10 BR Ground 42 RB AIC cut control
11 - - 43 WY Ignition output (power transistor)
12 W Air flow meter (power) 44 RL Check connector
13 - - 45 GB Check connector
14 YW I nhibitor switch (AT) 46 L Check connector
15 Lg I nhibitor switch (AT) 47 R Trouble code output
16 BR Throttle sensor (ground) 48 W O2 sensor
17 W Crank angle sensor (position signal) 49 W Fuel injector #1, #2
18 - - 50 W Fuel injector #1, #2
19 BW I gnition switch signal 51 WL Fuel injector #3, #4
20 BR Ground 52 WL Fuel injector #3, #4
21 W Throttle sensor (power supply) 53 - -
22 B Throttle sensor (signal) 54 - -
23 L Air conditioner signal 55 W Fuel pump control
24 ~'¢' I~Yn Starter signal 56 B G rou nd (ignition)
25 LW Idle switch signal 57 B Ground (ignition)
26 - - 58 - -
27 WR Control unit power (input) 59 G Auxiliary air valve control

28 BY Specification code 60 BR Ground (fuel injector)
29 YR Car-speed sensor 61 BR Ground (fuel injector)
30 BR I dentification of AT and MT 62 R Power (fuel injector)
31 - - 63 - -
43
CONTROL UNIT CONNECTOR [2700 cc model]
® (Black)
Ii
@(Black)
r-1
10 9 8 7 6 5 4 3 2 1 42 41 40 39 38 37
20 19 18 17 16 15 14 13 12 11 48 47 46 45 44 43
® (Black)
r-1
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
L2-910
Fig. 58
1 YR Check connector 32 Sr Test mode connector

2 W Air flow meter (signal) 33 LgW Read-memory connector
3 GL Purge control solenoid 34 - -
GY Neutral switch (MT) 35 WR Control unit power (input)
4
YL I nhibitor switch (AT) 36 R Knock sensor
5 S Air flow meter (ground) 37 WY Ignition output (power transistor)
6 LS Fuel pump relay 38 LgR Air flow meter (burn-off output)
7 R 'Crank angle sensor (power) 39 GW Self-shutoff output
8 G ~ Crank angle sensor (position signal) 40 RY CHECK ENGINE light
9 WS Water temperature sensor 41 - -
10 BR Ground 42 RB AIC cut control
11 - - 43 WY Ignition output (power transistor)
12 R Air flow meter (power) 44 RL Check connector
13 - - 45 GB Check connector
14 YW I nhibitor switch (AT) 46 L Check connector
15 Lg I nhibitor switch (AT) 47 R Trouble code output
16 SR Throttle sensor (ground) 48 W O 2 sensor
17 W Crank angle sensor (reference) 49 W Fuel injector #5, #fl
18 - - 50 W Fuel injector #5, #fl
19 SW Ignition switch signal 51 WR Fuel injector #1, #2
20 SR Ground 52 WR Fuel injector #1, #2
21 W Throttle sensor (power supply) 53 WY Fuel injector #3, #4
22 B Throttle sensor (signal) 54 WY Fuel injector #3, #4
23 L Air conditioner signal 55 S Fuel pump control
24 BW (M~) Starter signal 56 S Ground (ignition)
BY (AT
25 LW Idle switch signal 57 S Ground (ignition)
26 - - 58 YR By-pass air control
27 WR Control unit power (input) 59 YL By-pass air control
28 - - 60 BR Ground (fuel injector)
29 YR Car-speed sensor 61 BR Ground (fuel injector)
30 SR Identification of AT and MT 62 R Power (fuel injector)
31 LS Specification code 63 Br Power steering control
44
Engine-to-body harness connector (body side) ... C[ID

[1800 cc model]
1 WB Water temperature sensor
2 BR Ground
3 - -
4 W Fuel injector #2
5 BR Ground
7 WL Fuel injector #4
8 - -
9 WL Fuel injector #3
L2·1491
10 - Shield
11 B Ground
Fig. 59 12 G Auxiliary air valve
13 GL Purge control solenoid
14 - -
15 BR Ground
16 BY Specification code signal
Engine-to-body harness connector (body side) ... c§Q) (Black)

[1800 cc model]
1 SR Ground
2 YB Oil pressure
3 W Fuel injector #1 (power)
4 YG Water temperature gauge
5 RB Fuel injector #2 (power)
6 L Air conditioner signal
7 LW Idle switch (signal)
8 R Fuel injector #3 (power)
9 W Throttle sensor (power)
L2·912 10 RL Fuel injector #4 (power)

Fig. 60
11 L Auxiliary air valve
12 B Throttle sensor
13 BR Throttle sensor (ground)
14 B Ground
15 BW Solenoid (power)
16 SR Ground
45
Engine-to-body harness connector (body side) . .. § (Black)
[2700 cc model]
1 SR Ground
2 SR Ground
4 WR Fuel injector #1
6 WR Fuel injector #2
7 WY Fuel injector #3
8 B Ground
9 B Ground
L2-912
10 WY Fuel injector #4 (signal)
Fig. 61
11 R Fuel injector (power)
12 R Fuel injector (power)
13 YG Water temperature gauge
14 YB Oil pressure
15 R Knock sensor
16 - Shield
Engine-to-body harness connector (body side) ... @

[2700 cc model]
1 BR Ground
2 SR Ground
3 WB Water temperature sensor
4 - -
5 GL Purge control solenoid
6 BW Pu rge control solenoid
L2·1492 7 BR Throttle sensor (ground)
8 W Throttle sensor (power)

Fig. 62
9 B Throttle sensor (signal)
10 LW Idle switch (signal)
11 - -
12 SR Ground
46
Air flow meter connector . .. ® (Black)
1 LgR Control unit (burn-off output)
2 *w Control unit (power)

**R
3 B Ground (control unit)
L2-913 4 BR Ground (intake manifold)

Fig. 63
5 W Control unit (sensor signal)
6 - --
* 1800 cc model ** 2700 cc model
Ignition coil (power transistor) . .. @ (Black)
1 BW Power supply
2 WY Control unit (ignition control signal)
L2-860
Fig. 64
Crank angle sensor . .. C§D (Black)
1 SR Control unit (ground)
2 *S Control unit (position signal)

**G
3 W Control unit (reference signal)
4 R Control unit (power supply)
Fig. 65 * 1800 cc model ** 2700 cc model
Dropping resistor . .. ® (Black)

[1800 cc model only]
~
2 - --
~ 3 RL Fuel injector #2
L2-917 4 R Fuel injector #3

Fig. 66
5 R Power
6 RS Fuel injector #4
47
Fuel injector. .. ® @D @@IV@)@

[1800 cc model]
#1 #2 #3 #4
Control unit (fuel injector
1 W WB WR WL
L2-918 control)
Fig. 67
2 RW RB R RL Power (dropping resistod
[2700 cc model]
#1 #2 #3 #4 #5 #fJ
Control unit (fuel injec-
1 WR WL WY WG W WR
tor control)
2 RY R RY R RY R Power
By-pass air control valve ... @

[2700 cc model only]
1 YL Control unit (Close signal)
2 BW Power
3 YR Control unit {Open signal)
L2-1493
Fig_ 68
Auxiliary air valve. .. @ (Sky blue)

[1800 cc model only] 1 B Control unit (Auxiliary air control)
2 L Power
L2·918
Fig. 69
48
Throttle sensor. .. @ (Black)
[1800 cc model]
1 G Control unit (sensor signal)
2 W Control unit (power)

L2-1115
Fig. 70 3 B Control unit (ground)
4 LW Control unit (idle switch)
[2700 cc model]
1 BW Control unit (power)
2 GB Control unit (sensor signal)
3 GY Control unit (idle switch)
4 B Control unit (ground)
Purge control solenoid valve I I I ®

1 GL Control unit (purge control)
2 BW Power
Fig. 71
L2-856
Water temperature sensor ... @
1 WB Control unit (sensor signal)
2 BR Ground
L2-918
Fig. 72
Fuel pump relay ... @) (Brown)
r,T,i 1 BW Power (ignition)
rrGj 2 R Power
L2-859 3 LB Control unit

Fig. 73
4 L Fuel pump and auxiliary air valve
Ignition relay. .. ® (Black)
r,T,i 1 GW Power (ignition)

rrGj 2 R Power
L2·859
3 B Ground
Fig. 74
4 WB Control unit
49
Troubleshooting Chart for Self-diagnosis System

Basic Troubleshooting Procedures
Trouble occurs. I
Read memory mode. I

I
Trou ble code No trouble code
designated designated
D-check mode
I
No trouble code Trouble code
designated designated
~
~
Check harness/connectors Troubleshoot in accordance Check mechanical trouble in
affected by trouble code with trouble code. * accordance with troubleshoot-
outputted in read memory ing charts (Chapters 2-7 and
mode. ** --- - 2-3),
Trouble code
(See page 56.)
designated
I
Repair. I Repair.
D-check mode t----

No trouble code
designated
Clear memory mode. J
*. When more than one trouble code is outputted, begin troubleshooting with the smallest trouble code number and proceed
to the next higher code.
After correcting each problem, conduct the D·check and ensure that the corresponding trouble code no longer appears.
**: When more than one trouble code is outputted, check all related harness connectors, starting with that corresponding to
the smallest trouble code number and proceeding to the next higher code.
50
READ MEMORY MODE
WHEN VEHICLE IS RETURNED TO DEALER BECAUSE ECS LAMP LIGHTS
Vehicle returned to dealer
Turn ignition switch OFF.
Connect read memory connector.
Turn ignition switch ON (engine off).
Check if CHECK ENGINE light

illuminates.
YES
Check 0 1 monitor lamp.
Vehicle specification code is indi- Trouble code is indicated. No trouble code is indicated.
cated.
Confirm trouble code. Disconnect read memory connector.

Check if trouble code coincides with
vehicle specifications.
YES Disconnect read memory connector. Check if ground terminal is

open or disconnected and/or
Disconnect read memory connector. if there is mechanical trouble.
Conduct D-check. NO
YES
Trouble in other than self-diegnosis
system. Repair harness or terminal and/or Replace control unit.
[See Chapters 2-3 (paga 48) and related part.
2-7 (page 30).)
51
Disconnect all connectors from con-

trol unit.
Check if more than 7 V are present

YES Poor contact of terminal 40 or faulty
across terminal 40 (RY) of connector
control unit.
(body side) and body.
NO
Replace CKEC1< ENGINE light.
Turn ignition switch ON (engine offl.
Check if more than 7 V are present

NO
across terminal 40 IRY) of control Replace faulty harness.
unit connector (body side) and body.
YES
Connect 1111 connectors to control

unit.
NO
Check if CHECK ENGINE light
illuminates.
YES
System OK.
52
T
Check if system erroneously
detects MT in place of AT.
NO Check if system erroneously
detects AT in place of MT.
NO
YES YES
Turn ignition switch OFF, Turn ignition switch OFF,
Disconnect control unit con- Disconnect control unit con-

nector, nector,
Check if continuity exists Check if continuity exists

Faulty harness or
between terminal 30 (BR) of NO between terminal 30 (BR) of NO I
incorrect harness -I Repair control unit.
connector (body side) and connector (body side) and
connection.
body. body.
YES
~
Repair harness,
YES
Poor contact of terminal 30 or Incorrect harness connection.

f~~~tycontrol unit, Repair harness.
J
Check if display erroneously
YES NO
shows "Cal" in place of ~
"49-state" ,
~
Turn ignition switch OFF. ')
•
Turn ignition switch OFF, )
Disconnect control unit con- Disconnect control unit con-

nector. nector.
Faulty harness,
incorrect harness
Check if continuity exists Check if continuity exists
NO J NO connection or poor
between terminal 28 (BY)
(body side) and body.
-I Faulty control unit. I between terminal 28 (BY)
(body side) and body,
contact of body-to-
~
engine harness con-
nection,
YES YES
Incorrect engine harness con-

Repair control unit. J
Poor contact of terminal 28 or
nection, faulty control unit,
Repair engine harness.
53
D-CHECK MODE
Start engine.
Warm up engine. •
+
Turn ignition switch OFF. )
+
Connect test mode connector.
+
Turn ignition switch ON (engine offl. )
j NO
Check if CHECK ENG INE light turns A (See page 52.)
on.
• YES
Check fuel pump noise. l Inaudible or I Check fuel pump and associated
continuously audible systems.
+Pump operates intermittently.
,- - Depress accelerator pedal completely.
Return it to the half-throttle position
and hold it there for two seconds.
Then release the pedal completely. r Turn ignition switch OFF.
\
+ +
Start engine. ) Disconnect test mode connector.
NO J
I Check if CHECK ENGINE light goes
lOut. +
Was trouble code present in read YES
• YES memory mode?
Race engine with throttle fully
opened.
I ! NO
t System of self-diagnosis is OK.
~
Drive at speed greater than 8 km/h
(5 MPH) for at least one minute.
When other trouble is still present,

+
I Warm up engine above 1,500 rpm.
see item "General Troubleshooting
Table".
•
Check if CHECK ENGINE light blinks. l
YES
~
NO
JNO Check if affected part has already YES
C
I Check if CHECK ENGINE light been corrected.
I illuminates.
• YES
I Confirm trouble code.
J NO
* Check harness and connector of

affected trouble code.
+ (See page 56.)
* Check trouble codes sequentially.
*: When more than one trouble code is outputted, sequentially check the trouble codes, starting with the smallest code number.
After correcting each trouble, reconduct D-check and make sure the corresponding trouble code is no longer present
If another trouble code is outputted, carry out troubleshooting again.
54
CLEAR MEMORY MODE
~
Start engine.
Warm up engine.
•
( Turn igni~ion * switch OFF.
- ~
Connect test mode connector.
•
Connect read memory connector.
•
Turn ignition switch ON (engine off). )
*
CHECK ENGINE light turns ON.
t YES
NO
o (See page 52.)
Depress the accelerator pedal com-

pletely. Return it to the half-throttle
position and hold it there for two
seconds. Then release accelerator
pedal completely.
~
Start engine.
•i
CHECK ENGINE light goes out.
YES
I NO
Race engine at full-throttle.
t
Drive at speed greater than 8 km/h
(5 MPH) for at least one minute.
t
Warm up engine above 1,500 rpm.
J NO / Check if CHECK ENGINE light '\ NO

Check if CHECK ENGINE light blinks. I
turns ON.
~ YES • YES
( ) l..-
I Confirm trouble code.
t +
Disconnect test mode and read
memory connectors.
r Sequentially check trouble codes. I
~
+
After sequential checks, go to
End I D-check mode again. I
55
Checking Harnesses and Connectors 2) When terminals are considered to be open:

(1) Method of determining "OK" or "Faulty":
Related to Trouble Codes a. Pull out the terminal from the connector (body
side).
When a trouble code is outputted in the read memory mode
b. Insert this terminal (female) into the terminal
but not in the D·check mode, check the affected harness and
(male) of the connector (control unit).
connector terminal as described below.
c. Check "pull" force required to disconnect the
female terminal from the male terminal.
CHECKING TERMINALS OF CONTROL UNIT
If the terminal is loose, it is "faulty".
CONNECTOR (BODY SIDE)
(2) When terminals are faulty:
1) When terminals are not locked securely, insert into con- Pinch the terminal using a pair of nose pliers. If the
nectors until they lock. terminal is still loose, replace it or the harness ASSY.
SYMPTOMS RESULTING FROM POOR CONTACT OF CONTROL UNIT CONNECTOR TERMINALS

AND RELATED TROUBLE CODES
Terminal Lead Trouble

Symptom resulting from poor terminal contact
1')10'- color code
1 YR - No change occurs.
2 W 23 Engine stalls during idle. It can be restarted. Problems do not occur while driving.
3 GL 35 No change occurs.
4 YL or GY - No change occurs.
Engine runs at low speed and sometimes stalls during idle. It can be started but idle
5 B -
speed is low.
Engine stalls during idle. It cannot be restarted if affected circuit remains opened.
6 L8 - Engine lacks power while driving.
Engine stalls during idle. Shock is felt. Engine lacks power (poor acceleration) while
7 R 11
driving.
8
*8 *11
Engine stalls during idle. Shock is felt. Engine lacks power while driving.
I
**G **13
SI ight shock is felt while engine is cold but is not felt after warm-up. Driving perform-
9 WB 21
ance is affected while engine is cold but is not affected after warm-up.
10 BR - No change occurs.
11 - -
*w
12 23 Engine stalls during idle. It can be restarted. Problems do not occur while driving.
**R
13 - - -
14 YW - No change occurs.
15 GY - No change occurs.
16 BR - No ch ange occu rs.
* 1800 cc model only

** 2700 cc model only
56

No. color code
*13
17 W Engine stalls during idle. Shock is felt. Engine power while driving.
**11
18 - - -
Engine stalls du ring idle. It cannot be restarted. Shock is felt if poor intermittent
19 BW -
contact occurs while driving.
21 W 31 Shock is not felt. Engine acceleration is poor.
22 B 31 Shock is not felt. Engine acceleration is poor.
23 L - No change occu rs.
BW (MT) CHECK ENGINE light comes on and soon goes out when starting engine.
24 12
BY (AT) There is no problem.
25 LW - No change occurs.
26 - -
27 WR - No change occurs.
*28 BY - No change occurs.
29 YR 33 No change occurs.
**31 LB - No change occurs.
32 Br - No change occurs.
33 LgW - No change occurs.
34 - -
35 WR -
**36 R 22 Change rarely occurs. Engine sometimes knocks.
37 WY - No change occurs.
38 LgR - No change occurs.
39 GW - No change occurs.
40 RY - No change occurs.
41 - -
42 RB - No change occurs.
43 WY - No change occurs.
44 RL - No change occurs.

**. 2700 cc model only
57

No. color code
45 GB - No change occurs.
46 L - No change occurs.
47 R - No change occurs.
48 W - No change occurs.
* 14 Engine stalls during idle. I t cannot be restarted if there is poor contact of affected
49 W
**25 connection. Shock is felt if poor intermittent contact occurs while driving.
* 14 Engine stalls during idle. I t cannot be restarted if there is poor contact of affected
50 W
**25 connection. Shock is felt if poor intermittent contact occurs while driving.
*WL *15 Engine stalls during idle. I t cannot be restarted if there is poor contact of affected
'51
**WR **14 connection. Shock is felt if poor intermittent contact occurs while driving.
*WL *15 Engine stalls during idle. I t cannot be restarted if there is poor contact of affected
52
**WR **14 connection. Shock is felt if poor intermittent contact occurs while driving.
Engine stalls during idle. It cannot be restarted if there is poor contact of affected
**63 WY 15
connection. Shock is felt if poor intermittent contact occurs while driving.
Engine stalls during idle. If cannot be restarted if there is poor contact of affected
**54 WY 15
Engine stalls du ring idle. I t cannot be restarted if there is poor contact of affected
55 W -
56 B - No change occurs.
57 B - No change occurs.
**58 YR 24 No change occurs.
**59 YL 24 Engine stalls occasionally.
62 R - No change occurs.
**63 Br - Difficulty in engine starting while engine is cold.

** 2700 cc model only
58
Troubleshooting for Engine Starting Failure
1. GROUND & CONTROL UNIT POWER SUPPLY
Control unit
SR
10
BR
20
R
61
BR
60
57~----------------------------------------~
56 B
_62!--'-'R_ _ _ _ _ _ _ _ _---j
Fusible link
27 WR ~R---------~~>C~-----o(BB
35 WR
19I-'B:..:.W'-------------l r-B_W---O----...D--.--o(B IG
39 GW Fuse No. 11
®it
tI
=
® 1::1••1J 1 I I I 1 @ @
~
t!E g]
Ignition relay Diode
~
@CrTITIJ
L2-1192
Fig. 75
Turn ignition switch OFF. ) Check if right intake manifold ground YES
I Tighten bolts.
terminal is grounded properly. I I
~
Disconnect control unit connector.
l NO
Check if connector between body
~
YES
J
harness and engine harness is discon-
nected.
Connect properly.
I
Check if resistance is less than 10 n
between body and terminals 10 (BA),
20 (BA). 60 (BA), 61 IBA), 56 (B)
NO
I---
~ NO
and 57 IB) of connector (body side), Aepair harness.

respect ivel y.
~ YES
Check if at least 10V are present
Turn ignition switch ON (engine off). )
.1
I
across body and terminals 27 (WA), NO Check battery terminals, fuse, igni-
35 (WA). 62 IR) and 19 (BW) of I tion relay and ignition switch.
connector (body sidel.
~
~
OK
YES
I Repair harness. I
Power supply and grounding circuits
are OK.
- +
59
2. IGNITION CONTROL SYSTEM
Control unit
7
B
A
*B, **G
A
**G, *S
r--
b!!d Crank angle
~sensor
W W
17
BA BA
20 '--
WY
37
WY 1
c§D~
43 *S, **G
® IBI8Ck'1' t
*S **G
(Black)
I.RI I' :I I !I I I ® WY Ignition coil
~
(Power
BW
J transistor)
@(Slack)
®
WY
WY
F~se ~. ~ ffi IG '§I@IBI.,k'
BW
Y
FI
L2·1494
Fig. 76 *. 1800 cc model **: 2700 cc model
Turn ignition switch OF F

(engine off).
Crank engine and chack with timing

light if ignition occurs.
NO
Disconnect crank angle sensor can·

nector of distributor.
60
III
~
Check if voltage across body and

terminal (R) of crank angle sensor
connector (body side) is greater than
10V.
NO
- terminal 7 (R) of control unit can·
nector is greater than 10 V.
NO
YES l YES
Repair harness.

NO terminal 8 (W) of control unit can· NO
terminal (*8, **G) is greater than 4V'j
nectar is greater than 4V. -
~
YES
YES I ,••
Repair herness .
•
~ Check if voltage across body and
terminal (W) is greater than 4 V.

I NO terminal'7 (W) of control unit can· NO
J nectar is greater than 4 V.
YES
[ Connect crank angle sensor can-

i YES
Repair harness.
nectar.
J
~
[ Disconnect 2-pole connector from ~
ignition coil power transistor.
J Check if terminal is open or discon· I NO
J Replace control unit.
I J J
•
nected . l
1 YES
l Repair terminal or harness. J
*. l800ccmodel **. 2700 cc model
61
!
Turn ignition switch ON Check voltage between 2-pole
(engine ofO. connector power terminal
I
---
NO
(BW) at IG coil power tran- I Repair open harness.
~
t
sistor and car body is greater
than 10V.
Check if monitor voltage
repeats to become 0 V and 5 V
when crankshaft is turned
~ YES
slowly (do not crank with NO I Replace crank angle Check voltage between IG coil
starter) while monitoring
voltage between control unit
I sensor. I 1-) terminal and car body is
greater than 10 V.
NO
J Replace IG coil.
I
position signal terminalS
and car body.
~
it
.-
,
~
c.:..,\oJ
, )
I
! YES
~ YES , Disconnect 2-pole connector

at IG coil power transistor.
Check if monitor voltage
repeats to become OV and 5V
when crankshaft is turned by !
I
NO .1 Replace crank angle
starter while monitoring Check if voltage varies syn-
voltage between control unit
l sensor.
chronously with engine revolu-
reference signal terminal tions when cranking while
YES
17 (W) and car body. monitoring voltage between J Replace IG coil.
I
2-pole connector signal termi·
~ YES nal (WY) at IG coil power
transistor and car body.
Connect 2-pole connector at
IG coil power transistor. ~ NO
1
Connect injector connector.
Repair harness or replace con-
trol unit.
l
Turn ignition switch ON
(engine off).
62
3. FUEL PUMP CIRCUIT

Fuel injector Fuel injector Fuel in~ector
1800 cc model fuel injector
~
No.1 No.2
Throttle r-- r-- ~
In® 1r1@l
~IBI'Ck) ~IBI'Ck) ~,~, ~ In@)
IBlack)
@)
~t (B~k)
9~W~B~______________________~ r---r-r-r-----_+~------+_r_----_+_+~
\6
22
BA
B
-~ B
21 W
W
49 W
50~
51 WL
52~ ~~r_----------~----+_----~~~
55 W r---------~~~--------------~
6 LB
®II t II I 1'1"1
@)
~
'-----
Fuel pump
L2-1497
FUll injectOr
2700 cc model Fuel injKtQf
No.1
Fl,lel injector
No.2
Fuel injectOt"
NO.3
fuel injector
No.4
Fuel injector
No.5 Nc>. I>
Throttle
senSor
@
~
Control unit
@)
IBlack)
9 WB
16 BA
GB
22 8
BW
21 W @)
51 WA WA
52 WA WA
53 WY WY
54 WY WY
W
49 W
W
50 W
A AY
55 B
6 LB A A
Fuse No, 11
,----<Y''VO---+---<> EB IG
I rl:><}---+--o EB B
Fuel pl,.lmp Fuel pump reiay

L2-1495
Fig. 77
63
Check if fuel pump emits hiss-

ing noise every 1.5 seconds.
YES
Disconnect test mode connec·

tor.
[1800 cc model]
Check if fuel injector emits
operating sound while cranking.
[2700 cc model]
NO
[1800 cc model] [2700 cc model]
Disconnect control unit con· Disconnect control unit con-

nector. nector.
Check if voltage across body Check if voltage across body

and terminals 49 (W), 50 (W), and terminals 49 (W), 50 (W), NO
NO
51 (WL) and 52 (WL) of con- 51 (WR), 52 (WR), 53 (WY) and I--_~
nector (body side) is greater 54 (WY) of connector (body
than 10 V. side) is greater than 10 V.
Check if terminals are open or Check if terminals are open or

YES Repair faulty
disconnected, or if there is disconnected, or if there is
terminal.
poor contact. poor contact.
64
ED
l NO
Check if fuel pump relay clicks every
1.5 seconds. III
! YES
Check if voltage across terminal 55

(W) of control unit and body changes YES
from 0 - 10V alternately every
.1 Replace control unit.
J
1.5 seconds.
~ NO
Disconnect fuel pump connector.
l
Check if voltage across terminal (Ll
of connector (body side) and body NO .1 Repair harness from fuel pump to
changes from 0 - 1OV alternately I relay. J
every 1.5 seconds.
~ YES
Check if resistance between terminal

(W) of connector (body side) and NO
terminal 55 (W) of control unit is
-t Repair harness.
I
on.
l YES
Replace fuel pump.
65
NO
-r
(LS) of control unit connector and
body changes from 0 - 10V (mini-
mum) alternately every 1.5 seconds.
YES
Check if voltage across terminal (R)

NO
~ Repair harness from battery to relay.
of fuel pump relay and body is
greater than 10 V.
J
YES
Replace relay.
L YES .1 Check if terminal 6 is open or discon- 1 YES j

I Check if voltage is greater than 10V.
J -l nected. J I
Repair terminal.
I
NO
JNO
I Replace control unit.
J
Check if voltage across terminal (LS)
YES J Repair harness from relay to control
greater than 10 V. I unit. J
NO
Check if voltage·across terminal (SW)

greater than 10 V.
YES
t Replace relay.
J
NO
Repair harness from battery to relay.
66
[1800 cc model]
Disconnect control unit can·

nectar.
Check if resistance between

terminals 21 (W) and 16 (BR)
of connector (body side) is
6 - '8 kn, and between termi· NO Disconnect throttle sensor
nals 16 (BR) and 22 (B) is connector.
5.8 - 17.8 kn (Throttle closed)
and 1.5 - 5.1 kn (Throttle
open).
YES terminals CID and @ of can·
nector (throttle sensor side) is
YES
Check if resistance between 6 - 18 kn, and between termi·
Disconnect water temperature NO
sensor.
terminal 9 (WB) and body is nals CD and ® is 5.8-
100n - 20kn. 17.8kn (Throttle closed) and
1.5 - 5.1 kn (Throttle open).
YES
NO
Turn ignition switch ON.
terminals of connector (sensor
Replace throttle sensor.
side) is 100n - 20kn.
NO
Check if fuel pressure is OK.
NO
(Saa "Inspection of Pressure Repleee pressure reguletor.
Regulator".)
YES
Replece water tempereture Replace control unit.

sansor.
67
Disconnect control unit con·

nector.

terminals 21 (W) and 16 (BR)
of connector (body side) is
3 - 7 kn, and between termi- NO Disconnect throttle sensor
nals 16 (eR) and 22 (B) is connector.
4.2 - 15 kn (Throttle closed)
and 0.1 - 11 kn (Throttle
open). [Differential: 4 kOl
YES terminals CD and @ of con·
nector (throttle sensor side) is
YES
Disconnect water temperature NO Check if resistance between 3 - 7 kn, and between termi-
sensor. terminal 9 (WB) and body is nalsCV and @is 4.2 - 15
1000 - 20kO. kn (Throttle closed) and
0.1 - 11 kn (Throttle open).
[Differential: 4 knl
terminals of connector !sensor
side) il 1000 - 20kO.
NO
Check if fuel prellur. il OK.
NO
(St. ",n,pection of Pr...ur.
"Iliulltor".)
".pllc. wlt.r t.mp.rlturt

IInlor.
68
[1800 cc model]
Check if resistance between terminals

NO
of each injector (injector side) is
2-3n.
YES
Check if voltage across body and each

power terminal (RW, RB, R or RL) YES
of connectorlengine harness side) is
greater than 10 V.
NO

NO
(W) and each terminal (B) of connec-
tor (resistor side) is 5.8 - 6.5 n.
YES
Check if voltage across terminal 5 (R)

NO Repair harness from battery to
of connector (body side) and body is
resistor.
greater than 10 V.
YES
Repair harness from resistor to

injector.
69
III [2700 cc model]
t
Disconnect all injector connectors.
~
NO J Replace faulty injector.
of each injector (injector side) is -I
13 - 14.5 n.
~ YES
Check if voltage across body and Ich
each power terminal (R. RY) of YES
connector (engine harness side) is ;
I Repair harness.
I I
greater than 10 V.
~ NO
Disconnect engine harness connector
from body harness connector.
~
Check if voltage across terminal (R)
NO I connector
Repair harness from engine harness
of body harness connector and body
is greater than 10 V. I to injector. I
~ YES
Repair harness from battery to

body harness connector.
70
TROUBLE CODE (11): CRANK ANGLE SENSOR
Crank angle sensor

Control unit
0B ooG
I
j: "G'iD
°B,,'G
~
®
~
£OS.:G
(Black)
L1 IJ RI I I I I I @ wR
ISRI I wi I I I I I (Black)
L2-1496
Fig. 78 *. 1800 cc model **. 2700 cc model
I Check if trouble code is out· l NO

Check terminals of con·
trol unit connector.
Check if voltage across termi·
nal (W) of crank angle sensor NO
putted in D·check mode.
I (See page 56.1 r--t-' connector (body side) and
l1li
! YES
body is greater than 4 V.
~ YES
Turn ignition switch OFF
(engine off).
!
Disconnect test mode
nal (R) of connector (body
side) and body is greater than
10V.
NO
11&
~ YES
connector.
~
I Check if engine starts. I YES
Check terminals (j),
@ and ® of control
unit connector for poor
Check if continuity exists be·
tween terminal (BR) of con·
NO
l1li
nector (body side) and body.
contact.
~ NO (See page 56.1
~ YES
( Turn ignition switch OFF. ) Check if female terminal of YES
Repair terminal
or replace body
I ! connector (body side) is open.
~ NO
harness.
Disconnect crank angle sensor

connector.
I Replace crank angle sensor.
~
(engine off).
71
-l
(W) of control unit and body is
NO
1 - - - -.....( Turn ignition switch OF F. )
greater than 4 V.
! YES l
Check terminal 17 for poor contact I1------..4
YES ,...---------,
Repair terminal or harness. I
Body harneslopen.
Replace harness.
I (open or disconnection).
I
I Replace control unit. j
-
Check if voltage across terminal 7 (RI
of control unit and the body is
NO
greater than 10 V.
YES
Check terminal 7 for poor contect
Repair terminal or harness.
Body harness open. (open or disconnection}.
Replace harness.
NO
Replace control unit.
-
Check jf continuity exists between
terminal 20 (BR) of control unit and
NO
I
the body.
YES
Check terminel 20 for poor contact
Repair terminal Or harness.
Body harness open. (open or disconnection).
Replace harness.
NO
72
TROUBLE CODE (12): STARTER SWITCH
Control unit
W
24 BW [MT], BY (AT] BW
®FwITi
(Black)~
Fusible link
L2-1l95
Fig. 79
Check if trouble code is

outputted in D·check
mode.
NO
Check terminals of control
unit.
(See page 56.!
i
(Turn ignition switch OFF.
+YES ~ YES
lengine off).
Check if fuse blows. Replace fuse.
I
~ NO
~ Check if resistance between
Disconnect test mode ignition switch terminal (R)
connector. and terminal 24 of
control unit is less than
~ Repair harness. I
•
(engine off).
10n.
~ YES
Replece ignition switch.
•
Check if voltage across
terminal 24 (BW or BY) of NO
-( Turn ignition switch OFF.
control unit and the body
is less than 2 V.
~
Disconnect ignition switch
• YES
connector.
Dilconnect crank angle
senIor connector.
•
( •
(engine offl.
~
terminal 24 of con- NO
•
terminal 24 of con·
~
NO
10- trol unit and the body is
trol unit and the body is
less than 2V.
greater than 4 V.
~ YES
• YES
Repair harness.
Replace ignition switch.

~
73
TROUBLE CODE (13): CRANK ANGLE SENSOR
Crank angle sensor

Control unit
os
~
O'G
®
I :~I~'.-°s, ··G
"G'iD
-B,··O
~
I" ~
(Black)
I I IJ IR I I I I I I <§J) wA
IBAI I Iwl I I I I I (Black)
L2-1496
Fig. 80 *. 1800 cc model **. 2700 cc model
I Check if trouble code is out· I NO

Check terminals of con-
trol unit.
Check if voltage across term i-
nal *8. **G of crank angle sen- NO
putted in D-check mode.
I (See page 56.) ~ sor connector (body side) and Ell
1 YES
the body is greater than 4 V.
Turn ignition switch OFF ~ YES

(engine off).
Check if voltage across termi-
~
nal R of connector (body side) NO
and the body is greater than lIB
~
10V.
connector.
I ~ YES
l
I Check if engine starts. I YES
Check terminals (j).
® and ® of control
unit conneCtor for poor
Check if continuity exists be-
tween terminal BR of connec-
NO
III
!
tor (body side) and body.
contact.
(
NO

(See page 56.)
l YES
Repair terminal
Check if the female terminal of YES
~
or replace body
connector (body side) is open.
harness.
I Disconnect crank angle sensor 1 NO

connector.
I Replace crank angle sensor.
!
(engine off).
74

NO
of control unit and body is greater J Turn ignition switch OFF. )
than 4V.
~ YES 1
Check terminal (8) for poor contact l YES J I
Body harness open.
Replace.
__ Repair terminal or harness.
II-----~
~ NO
I Replace control unit. J
Check if voltage across terminal 7 (R)

NO
of control unit and the body is ~_ _ _--eo-(J Turn ignition switch OFF.
\.
greater than 10 V.
~ YES
Check terminal 7 for poor contact I YES --.,.1
11-----..J
I
J
Body harness open. (open or disconnection 1.
Replace body harness.

J
1111
1
,
Check if continuity exists between
NO (
terminal 20 (BR) of control unit and Turn ignition switch OFF.
body.
l YES
Check terminal 20 for poor contact I YES ...lJ
jl-------II--;:- Repair terminal or harness. I
Body harness open.
Replace.
! NO
I Replace control unit. J
75
TROUBLE CODE (14): FUEL INJECTOR [1800cc model]
Fuel injector Fuel injector

No.1 No.2
® @)
(Slack) (Slack)
Control un it
"~---...-------.----=-I
!OI-"-----'
Fusible link
Resistor
(Slack)
L2-1498
Fig. 81
Check if trouble code is out·

I NO
Check terminals of
control unit.
--1 Disconnect fuel injector con-
nectors #1 and #2.
(See page 56.)
l YES
!
Turn ignition switch OFF Check if resistance between
(engine off). terminals of fuel injector is
NO
i Replace fuel injector.
2-30.
l
! YES
connector. Check if voltage across body

Repair harness from
and power terminals (RW) and NO
l
fuel injector to con·
(RS) of connector (body side)
trol unit.
is greater than 10 V.
Disconnect control unit con-
nector. ! YES
! Disconnect resistor connector.
Check if voltage across body

and terminals 49 (WI and 50 NO ~
(WI of connector (body side) Check if resistance between
is greater than 10V. terminals (W) and (S's) of con· NO
i Replace resistor.
! YES
nector (resistor side) is 5.7 -
6.50.
Check if terminals 49 and 50

are open or disconnected.
YES
J
L R ' term .Ina I.
epatr l YES

~ NO nal 5 (RI of connector (body
NO Repair harness from
battery to resistor.
Replace control unit. 10V.
! YES
Repair harness from resistor to

fuel injector.
76

NO.5 No.6
c@) @
(Black) (Black)
Control unit
49 W w W
50 W w WB
r -______ ~R~ rR~Y ____________________ ~
~ ______ ~R~ ~R~ ________________________________ ~
f-----c:>O<I---o <3j B
L2·1499
Fig. 82
Check terminals of
putted in D·check mode.
NO
control unit.
rl Disconnect fuel injector con·
nectors #5 and #6.
J
(See page 56.)
YES
Turn ignition switch OFF Ch~ck

!
if resistance between
NO
(engine off). terminals of fuel injector is cl Replace fuel injector.
13 - 14.5!l.
~ ~ YES
Aepair harness from
and power terminals (A) and NO
l
fuel injector to con-
lAY) of connector (body side)
trol unit.
nector. l YES
1
Disconnect engine harness
connector from body harness
connector.
and terminals 49 (W) and 50 NO
(W) of connector (body side)
is greater than 10 V. l
~ YES
terminal (AI of body harness NO Repair harness from
connector and body is greater battery to body
Check if terminals 49 and 50 YES than 10 V . harness connector.
. , Repair terminal.
are open or disconnected.
! NO
l YES
Aepair harness from engine

harness connector to injector.
77

No.3 No.4
@
(Black)
Control unit
51 WL
52 WL
@ (Black)
~ ®®
~
~
Aesistor (Black)
L2-1500
Fig. 83
Check terminals of
r-1
Check if trouble code is out- NO Disconnect injector connectors
control unit.
putted in D·check mode. #3 and #4.
(See page 56.)
1 YES

1
NO
(engine off). terminals of each injector is _I Aeplace fuel injector.
2 - 3,n.
1
l YES

Aepair harness from
and power terminals (AI and NO
l (AL) of connector (body side)

is greater than 10V.
fuel injector and
control unit.

nector. ! YES
! Disconnect resistor connector.

and terminals 51 (WL) and 52
(WL) of connector (body side)
NO 1
is greater than 10 V. terminals (W) and (B's) of con· NO I .
nector (resistor side) is 5.7-
I Aeplace reSistor.
I
~ YES 6.5,n.
Check if terminals 51 and 52 YES

rI A ' term .lOa I.
epalr ~ YES
are open or disconnect.
~ NO nal 5 (A) of connector (body
NO Aepair harness from
battery to resistor.
Aeplace control unit. 10V.
1 YES
Aepair harness from resistor to

fuel injector.
78

No, 1 No.2
® @J)
(Black)
Control unit <§)
51 WR WR WR
52 WR WR WL
R RY
R R
Fusible link
(j1B
@) @
L2-1501
Fig. 84

NO
Check terminals of
control unit.
rl Disconnect injector connectors
#1 and #2.
!
(See page 56.1
YES

!
NO
(engine off). terminals of each injector is 1 Replace fuel injector.
13 - 14.5 n.
1
~ YES
Repair harness from
and power terminals (R) and NO
~
fuel injector and
(RY) of connector (body side)
control unit.
nectar. ~ YES
!
connector from body
harness connector.
and terminals 51 (WR) and 52 NO
(WR) of connector (body side)
~ YES
~ YES
terminal (R) of body harness NO Repair harness from
connector and body is greater battery to body
Check if terminals 51 and 52 YES than 10 V. harness connector.
1l R ' termlna
epalr . I.
!
! NO
YES
Repair harness from engine

Replace control unit. harness connector to injector.
79
TROUBLE CODE (21): WATER TEMPERATURE SENSOR
Control unit Water temperature

sensor
9~W~B~ ________________________________ ~W~B~
WB
®
® (Black)
E @
L2·1502
Fig. 85 *. 1800 cc model * •. 2700 cc model
Check terminals of
Check if trouble code is out- NO Disconnect water temperature
control unit.
putted in D·check mode. sensor.
(See page 56.)
YES

NO Replace water tem-
(engine off). terminals on sensor side is
perature sensor.
100.11 - 20kn.
YES
connector. Check if continuity exists be-
ND Repair engine
tween terminal SR of connec-
harness.
tor (body side) and body.
Turn ignition switch OFF. YES
Connect water temperature

sensor.
nector.
Disconnect engine-to-body
harness connector.
NO
terminal 9 (WB) and body is
lOOn - 20kn.
YES terminal (WB) of connector NO Repair engine
(engine side) and body is harness.
Check female terminal 9 for lOOn - 20kn.
poor contact.
YES
YES
Repair body harness.
80
TROUBLE CODE (22): KNOCK SENSOR [2700cc model]
Control unit @D Knock stnlor
I "II---"'--·--------lD w II
@t2\
V:'!!:!J
(Black)
@IBlack)
1.1 t III I II
L2·936
Fig. 86
Check if trouble code is outputted in NO .1 Check terminals of control unit.

D·check mode. -I (See page 56.) I
~ YES
( Turn ignition switch OFF

(engine off).
!
Disconnect telt mode connector.
!
!
Check if resistance batween terminal
36 IR) of connector (body side) and
YES _I
·l
Check if terminal 36 is open or discon·1
nected_
YES
J Repair tarminal or harness. I
body is 532 - 588kO. 1
J NO
! NO
Disconnect knock sensor connector.

I
!
YES .1 Repair harness from knock sensor to
of connector (knock sensor side) and
body is 532 - 588 kO.
·l control unit. I
! NO
Replace knock sensor.
81
TROUBLE CODE (23): AIR FLOW METER
Air flow meter
Control unit
38 ~W **R
12~~--~----------------------------------------J
~(BlaCk)
'@(Blacklill I I IBI I IWJ I
19R "W, ""R
@(Blackll III 1\1 I L2·1198

Fig, 87 ... 1800 cc model **. 2700 cc model
Check terminals of control
~
Check if trouble code is out- unit.
(See page 56.)
• YES
Disconnect air flow meter con-
,
nector.
(engine off) .
C •
,
Remove rubber cover from air
flow meter connector.

connector.

NO I~ Check if terminal 5 is open or YES
terminal S of air flow meter
connector and body is less
than 10n.
1--+ terminal 5 of control unit and
body is less than 10 n.
disconnected.
t NO
Repair terminal or
harness. I
YES • YES
Repair harness.
Check if resistance between Check if ground terminal at

~
NO
terminal (SR) of connector intake manifold is grounded ~ Repair harness.
and body is less than 10 n. properly.
, YES , YES
Turn ignition switch ON Tighten bolt.
(engine off).
t
Check if voltage across termi· Check if voltage across termi-
---- ~
NO
nal ("W, **R) and body is nal 12 of control unit and Repair harness.
greater than 10 V. body is greater than 10 V.
t YES , NO
,
Connect air flow meter con- Check if terminal 12 is open YES
Repair term inal or harness.
nector. or disconnected.
+NO
Check if voltage across termi· NO Replace control unit.
nals (WI and '(BR) of air flow
meter is 1 - 2V.
t YES Replace air flow meter.
J
Disconnect air flow meter from
air cleaner. Blow air into air
flow meter to check if voltage
between terminals (W) and
~ Replace air flow meter.
I
(SR) changes.
t YES
Check if voltage across termi- YES YES
Check if terminal 2 is open or
nal 2 (WI of control unit con· Repair terminal or harness.
disconnected.
nector and body is 1 - 2V.
+NO , NO
Repair harness.
I
82
TROUBLE CODE (24): BY-PASS AIR CONTROL VALVE
~P
ContrOl unit CD ® @ By·pass air control valve
YL YL
59 3
58
YR YR t--
1
BW t--
2
C§]) ~
TIO
BW BW
~
(i)
IG
L2·1503
Fig. 88
Check if trouble code is outputted in NO Check terminals of control unit.

D-check mode.
, YES
(See page 56.)
J
(engine off).
1
Disconnect test mode connector.
j
,

(engine off).
1
Check if voltage between control
unit connector (body side) by·pass
NO Disconnect bY'pass air control
air terminal (YR) and car body, and
bY'pass air terminal (YLl and car valve connector.
body is greater than 10 v.
1
1 YES Check if voltage between terminal
Repair harness from
Disconnect bY'pass air control (BW) of control valve connector NO
battery to control
valve connector. (body side) and car body is greater
valve.
than 10 V.
1
Check if resistance between terminals 1. YES
CD and ® of control valve is 9.5 -
11.5 .n, and between terminals ®
NO ... Replace bY'pass
air control
CD and ® of control valve is 9.5 - NO Replace bY'pass
air control
and @ is 8.5 -10.5.n. valve. 11.5 .n and between terminal ® and
valve.
1 YES
® is 8.5 - 10.5.n.
Remove by-pass air control valve , YES
,
from engine, and disconnect hoses.
Connect control valve connector.

I Repair terminals.
I
t
Make sure the valve moves when Replace by-pass
NO
ignition switch is turned ON and air control
OFF. valve.
1 YES
83

No.3 No.4
@ @])
(Black) (Black)
Control unit
53 WV ~w~v________________~
~ wv rW~G~__________________~________~
A rA~Y __________________~
~ __~A~ rA~ ______________________________~
@ (Black) Fusible link
~
L2-1504
Fig. 89

putted in o.check mode.
NO
Check terminals of
control unit.
r--I Dis,connect injector connectors
#3 and #4.
(See page 56.)
! YES
!
NO
(engine off). terminals of each injector is I Aeplace fuel injector.
13 -14.5 n.
1
Disconnect test moda
l YES

Aepair harness from
and power terminals (A) and NO
!
Disconnact control unit con-
(RY) of connector (body side)
fuel injector and
control unit.
nector. ~ YES
!
connector from body harness
connector.
and terminals 53 (WY) and 54 NO
(WY) of connector (body side)
! YES
! YES
Check if voltage across terminal
(A) of body harness connector
NO Repair harness from
battery to body
Check if terminals 53 and 54 YES and body is greater than 10 V. harness connector.
II R ' terminal.
epalr .
!
J NO
YES
Repair harness from engine

Replace control unit. harness connector to injector.
84
TROUBLE CODE (31): THROTTLE SENSOR [1800cc model]
Throttle sensor
Control unit
To @
@(Black)
BR
16r-------------------------------~
w
21r-------------------------------~
22 B
® (Black) ® (Black)
fI II I,J II I I filII I IItf L2·1116

Fig. 90
Check if trouble code is outputted in NO I Check contrOl unit terminals.

D·check mode. 1 (See page 56.) I
1 YES

(engine off).
1
Disconnect test mode connector. )
1
1
21 (W) and 16 (BRI of connector
(body side) is 6 - 18kn, and between YES I Check if terminals 21. 16 and 22 are I NO
~! Replace control unit.
terminals 22 (B) and 16 (BR) is 5.8 - I open or disconnected.
I I
17.8kn (throttle closed) and 1.5 -
5.1 kn (throttle open). 1 YES
1 NO I Repair terminal or harness. I

Disconnect throttle sensor connector.
!
® (BI and ® (W) of connector
!throttle sensor sidel is 6 - 18 kn,
and between terminals ®(BI and
YES I Repair harness from throttle sensor
CD (G) is 5.8 -17.8 kn !throttle
I to control unit. I
closedl and 1.5 - 6.1 kn (throttle
open).
~ NO
85
TROUBLE CODE (31): THROTTLE SENSOR [2700cc model]
Throttle sensor
To @
Control unit
~ (Black)
BR
16r-----------------------------~
22 B
21 W
Iii I i,J i 1Iii I I I I±I 1'1"1

L2·1505
Fig. 91
J Check control unit terminals.

Check if trouble code is outputted in
D-check mode.
NO
-I (See page 56.) j
1 YES

(engine off).
1
C Disconnect test mode connector. )
1
1
21 (W) and 16 (BRI of connector
(body sidel is 3 - 7 kn, and between YES J Check if terminals 21,16 and 22 are l NO
terminals 22 (BI and 16 (BRI is 4.2- l open or disconnected.
J
--.l Replace control unit.
I
15 kn (throttle closedl and 0.1 -
11 kn (throttle open!. ! YES
1 NO l Repair terminal or harness.

J
~
CD (BW) and @ (B) of connector
(throttle sensor sidel is 3 - 7 kn,
and between terminals @ (GB) and
YES c I Repair harness from throttle sensor
@ (BI is 4.2 - 15 kn (throttle I to control unit. I
closed) and 0.1 - 11 kG (throttle
open).
~ NO
86
TROUBLE CODE (32): 0 7 SENSOR
Control unit
°2 sensor
48r~w~----------------------------------------------~w~~[Jr----~
I I
® (Black)
@e
(Black)
IA I ±I I
L2-1506
Fig. 92
Check if trouble code is outputted in NO I Check terminals of control unit.

D·check mode. -] (See page 56.1 I
l YES

(engine off).
1
Disconnect telt mode connector.
1
( Turn ignition switch ON
(engine offl.
I
Disconnect 02 sensor connector.
~°
Is voltage between 1 sensor connec·
YES I Replace 0l sensor.
tor of body harness and car body
greater than 0.1 V 7
I I
~ NO
Check if voltage between control unit
connector O 2 sensor signal terminal NO I Check if terminal 48 (WI is open or l NO
(WI and car body is greater than I disconnected. I
.~ Replace control unit. I
0.1 V.
~ YES
1 YES
I Repair terminal. I
Repair harness.
87
TROUBLE CODE (33): SPEED SENSOR
Combination
meter
Control unit
29 VR
*@(Black)
@(Black)
**
Fig. 93
I II II II !vAl ®
*. 1800 cc model
L2·940
**: 2700 cc model
Check if trouble code is out- Check terminals of control unit.

putted in D·check mode. (See pege 56.)
YES

(engine off).

connector.

(engine on).
Check if voltage fluctuates

above and below 2V by slowly
moving the car while monitor· YES
ing voltage across speed signal
terminal 29 (YR) of control
unit and body.
NO
f
nal 29 (YR) of control unit NO Turn ignition switch OFF
connector and body is greater (engine off).
than 2V.
YES
Disconnect combination meter.
Disconnect combination meter.

Is voltage between combina- terminal 29 (VR) of control NO Replace car speed
tion meter connector car speed YES Replace car speed unit connector and body is less sensor.
signal terminal (VR) and car 1----..4 sensor. than 10n.
body greater than 2V? ' - - - - - - - - -.....
YES
NO
Repair harness.
Repair harness.
88
TROUBLE CODE (35): PURGE CONTROL SOLENOID VALVE
Control unit
@or @) (Black) Purge control
solenoid valve
3~G~L~ ____________________________ ~
GL
BW
® (Black)
I 1 I f II 11 '1 ®
0
1I Fuse No. 11
r------c~r---~EB IG
L2·1507
Fig. 94
Check if trouble code is out· NO Check terminals of control

putted in D·check mode. unit.
(See page 56.)
, YES
Connect test mode connector .
•
(engine off).
t
nal3 (GL) of control unit and YES
Raplace control unit.
body alternates above and
below 6 V every 1.5 seconds.
, NO
Check if voltege ecross termi· YES J
nel (GL) and body is greater
than 6V.
(engine off). I
nector. I
t NO
Disconnect purge control
solenoid valve connector.
Repair tarminel or harness.
YES I
I
•
Check if terminel (OL) is open
or disconnected.
I
, NO
~ l Replace control unit. I
nal (BW) of connector (body NO I NO •
side) and body is greater than 1 Check if fuse is blown. Repair harness. I
10V. i YES
• YES Replace fuse.
Replace NO Check if resistance between
solenoid ~
solenoid valve terminals is less
velve. than 100n.
y YES
Replace NO Check if resistance between
solenoid
valve.
each solenoid valve terminal
and body is greater than 1 MO.
+
Check if resistance between NO
• YES
terminal 3 (G L) of control unit
and body is less than 100n.
--l Repair harness. I
,
Connect purge control solenoid
valve connector. +YES
Disconnect control unit can-

nector. )--
89
TROUBLE CODE (41): SYSTEM
Trouble code (41) indicates that the mixture is too lean.

When another trouble code is not outputted, all system com·
ponents are electrically in good order.
Check the following:
CD Injector nozzles (for clogging)
® Fuel pressure
® Performance characteristics of water temperature sensor
If the above three are OK, check the following:
@ Drive some distance after replacing the air flow meter.
If still no good, proceed to ®.
@ Replace fuel injectors and drive some distance.
If still no good, proceed as follow:
® Replace control unit.
90
TROUBLE CODE (42): IDLE SWITCH
Throttle s e n s 0 : t J
(Idle switch)
1800 cc
~ 4321
model
To
® ~'"
Control unit ~
~(Black)
[ : : ~: D~-----\
C
I I 111.J :1: : I I I l1 111 I

[@.] 2700 cc
model
~
]
L2·1508
Fig. 95
Check if trouble code is outputted in NO _I Check terminals of control unit.

D-check mode. I (See page 56.' I
YES

(engine off).
( Disconnect test mode connector. )
Disconnect control unit connector-

terminals 25 (LW) of connector
(body side) and body when accelera· YES _I Check if terminal 25 is open or dis- NO
1 I Replace control unit.
tor pedal is released and does not I connected. I
1
exist when accelerator pedal is
depressed. ~ YES
NO I Repair terminal or harness. I

Check if continUity exists between

terminals @ and @ of connector NO J Adjust throttle sensor as outlined in
(throttle sensor side) when accelera- I Chapter 2-7 on page 21. I
tor pedal is released.
~
YES
I Check if continuity exists when I NO J Replace throttle sensor.
I j
accelerator pedal is released. j
I I YES
Check if there is no continuity when NO
J
accelerator pedal is depressed.
I
YES
Repair harness.
91
TROUBLE CODE (51): NEUTRAL SWITCH [MT]
clontrol u n i l t @ Neutral switch
~:~:: -----IDI----------=---iI LJ I L
,:
@(Black) @)~
~L9Y
I I"VI I I I
(Black)
I'AII f 1
L2·1201
Fig. 96
Check if trouble code is outputted in I NO J Check terminals of control unit.

Q·check mode. -I (See page 56.) I
~ YES
(engine offl.
C
t
Disconnect test mode cohnector. )
1
Disconnect control unit connector .
. ~
terminal 4 of connector (body side)
and body when switch is in Neutral
YES J Check if terminal 4 is open or dis· I NO
J Replace control unit. 1
t connected. J
and does not exist in any other posi·
tion.
~ YES
t NO I Repair terminal or harness.
I
Disconnect neutral switch connector.
!
terminals of neutral switch when
switch is in Neutral and does not
J Replace neutral switch.
I I
exist when switch is in any other
position.
~ YES
Repair harness.
92
FUEL SYSTEM
Page
MECHANISM AND FUNCTION .•. . . . . . . . . . . . . . . . . . . . . . . . . . .. 2
SUBARU Fuel Lines .••.....•.•....•..•.•............•......... 2
Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3
SPECIFICATIONS AND SERVICE DATA.... . . . . . . . . . . . . . . . . . .. 3
1988 COMPONENT PARTS ..................... . . . . . . . . . . . . . . .. 4
SERVICE PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6
Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6
Fuel Meter Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7
Fuel Filler Pipe ......................•................. 7
Fuel Separator . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8
Fuel Filter. . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . .. 9 _
Fuel Pump ........................................... 10
Fuel Delivery, Return and Evaporation Lines. . . . . . . . . . . . . . . . . . . .. 11
TROUBLESHOOTING ..................................... 13
2-8 FUEL SYSTEM

Fuel Lines
Fuel is delivered from the fuel tank to the fuel pump via the 2700 cc model, a fuel damper is located in the center of the
filter inside the tank. It is then delivered to the fuel injectors delivery hose to absorb pulsations produced by the fuel in-
via the fuel filter. jectors and the pressure regulator. Thus, vibration resulting
Part of the fuel is returned by the pressure regulator. On the from fuel pulsation is not transmitted to the passenger com-
partment.
Purge line
Vacuum line ,--__§_ Throttle body
regu lator"'- .
~ Intake manifold
Fuel injector
2·way valve
Fuel separator
I Filler pipe
Canister
Fuel damper (2700 cc only)

Filter L2-1239
Fig. 1
2
FUEL SYSTEM 2-8
Fuel Tank
It is provided with a chamber which prevents interruption of
fuel flow during cornering.

SPECIFICATIONS
Capacity 60 Q (15.9 US gal, 13.2 Imp gal)

Fuel tank
Location Under rear floor
Type Electromagnetic pin roller
422 - 490 kPa

Discharge pressure
(4.3 - 5.0 kg/cm 2 , 61 - 71 psi)
Fuel pump
95 Q (25.1 US gal, 20.9 Imp gal)/H min.
Discharge flow
[12 Vat 299.1 kPa (3.05 kg/cm 2 , 43.4 psi) 1
Fuel filter Cartridge type
Fuel separator Capacity 1,250 mQ (42.3 US fl OZ, 44.0 Imp fl OZ)
3
2-8 FUEL SYSTEM
COMPONENT PARTS
Fuel Tank ®
®--
•u
•
® CD @
'ft.~~~""
, 1J... .... ,.,'" C;c.t ......
'(~ .....
<"
, it-,
'" 'P....... .... . .
I
f;'_':.''''1 ,"" ,
..................... 'j
~® , ') I
§ !I
1'1
1 I I
II I I I't4'\ I I I
gr-I!.Y
111 I
I
I
I
I
I
I
I I '-
~@ ...... , ,
'-"
, ... ...
... ......
~ ... ... ....... ...
....
...........
... .... ....
: @ .................. ,:: ..... ,
I
, .......... ,
@ I
, .....' ~ .....
................
q
.... ... ... '" )
'- t
I
I
I
!..
~'
1 Evaporation hose
2 Evaporation pipe
3 Fuel separator
4 Fuel separator bracket
5 Hose protector
6 Grommet
7 Fuel meter harness .... .....
8 Fuel meter unit
9 Gasket
10 Filler cap
11 Ring
12 Packing
13 Filler pipe
14 Filler hose
15 Filler hose protector
16 Air-vent hose Tightening torque N·m (kg-m, ft-Ib)
17 Fuel delivery hose
T1: 1.8 - 3.1 (0.18 - 0.32,1.3 - 2.3)
18 Fuel return hose
19 Evaporation pipe T2: 13 - 23 (1.3 - 2.3, 9 -17)
20 Evaporation hose
Fig. 2 21 Fuel tank L2-1001
4
FUEL SYSTEM 2-8
Fuel Lines
@1]
1 Fuel pump 11 Fuel return pipe
I
I
• 2
3
Fuel delivery hose
Fuel delivery pipe
12
13
Pipe stay
Evaporation tube
4 Pump bracket 14 Fuel return hose
~ 5 Spacer 15 Fuel center pipe ASSY
Ei 6 Cushion 16 Canister
C"~ ~ ~ I
7 Pump bracket 17 Saucer
8 Fuel filter 18 Canister bracket
@ 9 Filter bracket 19 2-way valve
10 Evaporation pipe 20 Fuel damper
Fig. 3 L2·1241
5
2-8 FUEL SYSTEM
SERVICE PROCEDURE
a. Before starting the job, be sure to carry out the following. 7) While holding fuel tank, remove six mounting bolts from
1) Place "No fire" signs near the working area. fuel tank and dismount it.
2) Disconnect ground cable from battery.
b. Be careful not to spill fuel on the floor. a. Two men are required to perform step 7) above.
b. Have a helper support fuel tank, as shown in the figure,
when disconnecting fuel meter harness or evaporation tube.
Fuel Tank
REMOVAL
1) Remove muffler and rear differential ASSY. (4WD model

only)
2) Remove fuel filler cap and drain fuel from fuel tank.
3) Remove fuel filler pipe protector.
/
Fuel fi lIer pi pe
Fig. 6
8) Disconnect harness connector from fuel meter unit.

9) Loosen clips, disconnect evaporation tube, and dismount
fuel tank.
Fig. 4
4) Remove clamp and disconnect fuel filler hose from fuel

filler pipe.
5) Remove clamp and disconnect air vent hose from fuel
filler pipe.
6) Loosen clips and disconnect delivery hose, return hose
and evaporation tube from fuel tank.
Evaporation hose
INSTALLATION

1) When installing fuel tank, have a helper hold fuel tank
while connecting hoses, tubes and harness connector.
2) Before tightening fuel tank mounting bolts, make sure
hoses, harnesses, etc. are not caught between fuel tank and car
Fig. 5 body.
6
FUEL SYSTEM 2-8
3) Install hose and tube holddown clips at positions indi-
cated in the figure.
Fuel Filler Pipe
REMOVAL
1) Completely drain fuel from fuel tank.

2) Remove right rear tire.
3) Open fuel filler flap and remove filler cap.
4) Remove three screws holding packing in place.
5) Remove fuel filler pipe protector.
L/2 6) Remove clips and disconnect fuel filler hose and air vent
hose from fuel filler pipe.
/
Fig. 8
L = 25 - 30 mm
(0.98 - 1.18 in)
E2-036
II
Fuel Meter Unit
REMOVAL
1) Remove floor mat from luggage compartment.

2) Remove access hole lid. Fig. 10
3) Disconnect harness connector from fuel meter unit.
7) Disconnect fuel filler pipe from underside of car.
INSTALLATION
1) Hold fuel filler flap open.

2) Insert fuel filler pipe into hole in fuel saucer from the
inner side of apron. Align holes in fuel filler pipe neck and
packing and tighten screws.
Fig. 9
4) Remove five nuts and detach fuel meter unit.

Tapping screw
INSTALLATION
Filler cap
1) Be sure to alternately tighten fuel meter unit mounting
nuts in a criss-cross fashion.
2) Apply a sealant to the edge of access hole lid before L2-029
installation. Fig. 11
7
2-8 FUEL SYSTEM
3) If edges of rubber packing are folded toward the inside, 5) Remove fuel separator from bracket.
straighten it with a standard screwdriver. 6) Disconnect tube from fuel separator.
4) Insert fuel filler hose approximately 25 to 35 mm (0.98 to
1.18 in) over the lower end of fuel filler pipe and tighten
clamps. Do not allow clips to touch protector and air vent
pipe.
5) Insert air vent hose approximately 25 to 30 mm (0.98 to
1.18 in) into the lower end of air vent pipe and tighten with
clips, as shown in figure.
L = 25 - 30 mm (0.98 -1.18 in)
L2-032
Fig. 14
INSTALLATION
Air vent tube L2-030
Fig. 12 Installation is in the reverse order of removal procedures.

1) When connecting tube between fuel separator and pipe,
6) Install protector together with fuel filler pipe. Check to be
insert until it butts up against nipple on the separator side, and
sure clamp for filler hose and clip for air vent hose do not
insert the other end up to the marked position on the pipe
touch apron.
side.
2) Install fuel separator on bracket such that the pipe can
run through the hollowed section of separator.
Fuel Separator
REMOVAL
1) Remove right trim from luggage compartment.
2) Remove hose protector.
3) Remove fuel separator and bracket as a unit. Be sure not
to scratch the inner side of car body.
4) Disconnect evaporation tube from pipe held to bracket.
Fig. 15
3) Be sure to insert evaporation tube approximately 15 to

20 mm (0.59 to 0.79 in) into pipe on bracket. Install clips in
Fig. 13 a direction which does not touch other tubes.
8
FUEL SYSTEM 2-8
Fuel Filter INSTALLATION
REMOVAL 1) Connect the hose as illustrated below:
1) The fuel system is pressurized. Before removing the hose,

filter, pump, etc., be sure to release the fuel pressure, as
follows:
(1) Disconnect the wiring connector of the fuel pump.
(2) Crank the engine for more than five seconds.
If the engine starts, let the engine run until it stops.
(3) After turning IG switch to OFF, connect the wiring
-+-t- 4 -7 (0.16 - 0.28)
connector of the fuel pump. When fitting length

is specified
2) Loosen the screw of the hose clamp and pull off the hose
from the filter.
3) Remove the filter from the holder.
25 - 30 (0.98 - 1.18)
-01--+-4 - 7 (0.16 - 0.28)

When fitting length is
not speci f ied
Unit: mm (in)
A21·232
Fig. 16 Fig. 17
2) Tighten the hose clamp screw to the specified torque.
Tightening torque:
1.0 . 1.5 N·m (0.1 -0.15 kg·m, 0.7 . 1.1 ft·lb)
3) If the hose is damaged at the clamping portion, replace

INSPECTION
the hose with a new one.
4) If the hose clamp is too deformed, replace with a new
1) Check the inside of the filter for dirt and water sediment. one.
2) If the filter is clogged or cracked, or if the replacement 5) Fit the hose to the filter, then install the filter to the
interval has been reached, replace the filter. holder. Correct the hose position by removing any twist so
3) If water is found in the filter, shake the filter with its inlet that it will not interfere with the filter body or washer tank,
port facing down, to expel the water. before tightening the screw of the hose clamp.
9
2-8 FUEL SYSTEM
Fuel Pump INSTALLATION
1 ) If the pump and damper have been removed from the

REMOVAL
pump bracket, tighten the mounting bolts to the specified
torque_
1) Release the pressure of the fuel system.
2) Install the hose using the same procedure as that ex-
plained in "Fuel Filter".
Refer to "REMOVAL 1)" in Fuel Filter. 3) Install the pump bracket in position to the vehicle body,
and secure it with bolts.
2) Keep the pump harness connector disconnected.
3) Jack up the vehicle. Use care not to drop the spacer of the cushion rubbe.r.
4) Clamp the middle portion of the thick hose connecting
the pipe (coupling) and pump. Prevent the fuel from flowing
4) Install the hose.
out of the fuel tank.
5) Connect the pump harness connector.
6) Run the pump and check for fuel leaks.
Do not bend the hose sharply; otherwise, it may be damaged.
5) Loosen the hose clamp, and disconnect the hose.

6) Remove three pump bracket mounting bolts, and remove
the pump together with the pump dam~er. ..
,," "
L2-613
Fig. 19
L2-612
Fig. 18
INSPECTION
1) Connect the leads to the harness connector, and apply a

12-volt power supply to check whether the pump operates.
a. Keep the battery apart from the pump as far as possible.

b. Be sure to turn the 12 V supply ON and OFF on the
battery side.
c. Do not run the pump for a long time under non-loaded
condition.
10
FUEL SYSTEM 2-8
Fuel Delivery, Return and Evaporation Lines

REMOVAL
1) Under body floor, detach fuel deliver'll hoses, return

hoses, evaporation tubes and 2-way valves_
2_way valve
li Evaporation hose
:.=-:-- = = = ==_-
._r.~.o.~~-::---o----=-~~--
0. -=--.-::;:::;---
~ ~
Evaporation hose
Return hose
Delivery hose
Delivery hose
Evaporation hose
Return hose
Fuel tan="
L2-1240
Fig. 20
,
,
;
11
2-8 FUEL SYSTEM
2) In engine compartment, detach fuel delivery hoses, return
hoses, evaporation tubes and canister.
Evaporation hose (vacuum line)
Evaporation hose (main purge line)
Delivery hose
Return hose
. . Pressure regulator .~-
v-:_-+ Fuel)!!iector _---./ _ _ _ _ _ _ _Evaporation hose (to fuel tank)
:O~:::::=~----.-._j -"
Evaporation hose
L2·1242
Fig. 21
.
'(
INSTALLATION
Install in the reverse order of removal. 3) Insert evaporation tube into evaporation pipe by approx.
1) Connect delivery hose to delivery pipe with an overlap 15 mm (0.59 in) and position a clip with approx. 8 mm (0.31
of 25 to 30 mm (0.98 to 1.18 in).
2) Connect delivery hoses and fuel return hose to fuel tank,
in) from hose end.
4) When installing 2·way valve, install it with its "TO
I
fuel pump and fuel filter until they reach the base of each ENGINE" mark facing downward.
pipe. 5) Be sure to inspect hoses and their connections for any
leakage of fuel.
12
FUEL SYSTEM 2-8
TROUBLESHOOTING
Trouble and possible cause Corrective action
--
1. Insufficient fuel supply to the injector
1) Fuel pump will not operate.

0 Defective terminal contact. Inspect connections, especially ground, and tighten
securely.
0 Trouble in electromagnetic or electronic circuit Replace fuel pump.
parts.
2) Lowering of fuel pump function. Replace fuel pump.
3) Clogged dust or water in the fuel filter. Replace fuel filter, clean or replace fuel tank.
4) Clogged or bent fuel pipe or hose. Clean, correct or replace fuel pipe or hose.
5) Air is mixed in the fuel system. Inspect or retighten each connection part.
6) Clogged or bent air breather tube or pipe. Clean, correct or replace air breather tube or pipe.
7) Fuel damper will not operate. Replace.
8) Damaged diaphragm of pressure regulator. Replace.
2. Leakage or blowout fuel
1) Loosened joints of the fuel pipe. Retightening.

2) Cracked fuel pipe, hose and fuel tank. Replace.
3) Defective welding part on the fuel tank. Replace.
4) Defective drain packing of the fuel tank. Replace.
5) Clogged or bent air breather tube or air vent tube. Clean, correct or replace air breather tube or air vent
tube.
3. Gasoline is smelling inside of compartment
1) Loosened joints at air breather tube, air bent tube and Retighteni ng.
fuel filler pipe.
2) Defective packing air tighteness on the fuel saucer. Correct or replace packing.
3) Cracked fuel separator. Replace separator.
4. Defective fuel meter indicator
I 1) Defective operation of fuel meter unit. Replace.

2) Defective operation of fuel meter. Replace.
5. Noise
1) Large operation noise or vibration of fuel pump. Replace.
a. When the vehicle is left unattended for an extended period of time.

1) Water may accumulate in the fuel tank. To prevent water condensation, top off the fuel tank or drain the fuel completely.
2) Also drain water condensation from the fuel filter.
13
2-8 FUEL SYSTEM
b. Refilling the fuel tank.

1) Refill the fuel tank while there is still some fuel left in the tank.
c. Protecting the fuel system against freezing and water condensation.
1) Cold areas
In snow-covered areas, mountainous areas, skiing areas, etc. where ambient temperatures drop below DoC (32°F), throughout
the winter season, use an anti-freeze solution in the cooling system.
Refueling will also complement the effect of anti-freeze solution each time the fuel level drops to about one-half.
After the winter season, drain water which may have accumulated in the fuel filter and fuel tank in the manner same as that
described under the Moderate Areas.
2) Moderate areas
When water condensation is noticed in the fuel filter, drain water from both the fuel filter and fuel tank or use a water
removing agent (or anti-freeze solution) in the fuel tank.
• Observe the instructions, notes, etc., indicated on the label affixed to the anti-freeze solution (water removing agent)
container before use.
14
EXHAUST SYSTEM
Page
SUBARU COMPONENT PARTS ....•...... . . . . . . . . . . . . . . • . . . . . . • . . . ..

SERVICE PROCEOURE ............•.......................
2
4
Front Exhaust Pipe ............•........•.....••......... 4
Rear Exhaust Pipe ...................•........•.•••.....• 5
1988 Muffler Assem bly ...................................... " 6
Tail Pipe Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7
-
2-9 EXHAUST SYSTEM
CO.MPONENT PARTS
1800 cc model
-..,
-- -- --
-- I
I
I
-- -- --
I
I
I
-- I
--- --- ---

,- I
I
\
\ I
\ I
1
2
Muffler ASSY
Gasket
\
-- ®\
I
_-~J
3 Rear exhaust pipe (4WD)
4 Rear exhaust pipe (FWD)
5 Gasket
6 Cushion
7 Spring
8 Boit
9 Gasket
10 O 2 sensor
11 Front exhaust pipe
12 Bracket (FWD MT)
13 Bracket (4WD MT) _---.-1
14 Bracket (FWD AT)
15 Bracket (4WD AT)
16 Tail pipe cutter ® 0
-~~
(
I
I
I
I
I
I
I
I ~
I
I ~_
I- _
: ------- 0)J®
L-~
-.,I
I
-'
DETAILII A II
Tightening torque N.m (kg-m, ft·lb)

T1: 42 - 52 (4.3 - 5.3,31 - 38)
T2: 25 - 34 (2.5 - 3.5, 18 - 25)
T3: 13 - 23 (1.3 - 2.3, 9 - 17)
T4: 25 - 29 (2.6 - 3.0, 19 - 22)
Fig. 1 L2·1006
2
EXHAUST SYSTEM 2-9
2700 cc model
CD a _~ Tightening torque: N·m (kg-m, ft-lb)

T1:
T2:
42 -
25 -
52 (4.3 -
34 (2.5 -
5.3, 31 - 38)
3.5, 18 - 25)
\
I
(? \
\'l
@ T3:
T4:
13 -
25 -
23 (1.3 -
29 (2.6 -
2.3, 9 - 17)
3.0, 19 - 22)
-~'
(-~\ L'~
'\ ~
_~- 0~~\)
@ '\
'V'@ (l)~~-~/\
\~ 5
<:
1 Muffler Assy
2 Gasket
3 Rear exhaust pipe
4 Gasket
5 Cushion
6 Spring
7 Bolt
8 Gasket
9 0, sensor
10 Front exhaust pipe
11 Bracket (AT)
12 Bracket (MT)
13 Tail pipe cutter
DETAIL "A"
Fig. 2 L2·1234
3
2-9 EXHAUST SYSTEM
SERVICE PROCEDURE ,
Front Exhaust Pipe
3) Disconnect front and rear exhaust pipes.
REMOVAL 4) Disconnect front exhaust pipe and bracket.
1) Disconnect O2 sensor harness. 5) While holding front exhaust pipe with one hand, remove
2) Loosen (do not remove) nuts which hold front exhaust nuts which hold front exhaust pipe to exhaust port. Front
pipe to exhaust port of engine. exhaust pipe can then be disconnected.
1800 cc model
Bracket
0, sensor
L2-1008
Fig. 3
2700 cc model
~
Gasket
oo?
~
0,
.I
Bracket
L2-1235
Fig. 4
4
EXHAUST SYSTEM 2-9
INSTALLATION

1) Be sure to install a new gasket at exhaust port.
2) Use only nuts specified by the manufacturer.
3) Do not remove gasket placed between front and rear
exhaust pipes. When front exhaust pipe needs to be replaced,
gasket must be also replaced.
Fig. 6
3) Remove rear exhaust pipe from rubber cushion. To

facilitate its removal, apply a coat of SUBARU CRC5·56
(004301003) to it in advance.
Rear Exhaust Pipe

REMOVAL
INSTALLATION
1) Disconnect rear exhaust pipe from front exhaust pipe.
1) Temporarily connect rear exhaust pipe and muffler
ASSY.
2) Temporarily connect rear exhaust pipe and front exhaust
pipe.
3) Insert exhaust pipe bracket into rubber cushion. To
facilitate insertion, apply a coat of SUBARU CRC5·56
(004301003) to the mating area of rubber cushion in advance.
4) Adjust clearances between temporarily installed parts and
tighten to specified torque.
Be sure to install bolts, springs, and self-locking nuts in the

order indicated in the figure. Alwavs install new self-locking
nuts.
Fig. 5
Gasket
2) Disconnect rear exhaust pipe from muffler ASSY. To

prevent damaging bumper or rear skirt by muffler, wrap a Front . . . .
cloth around tail pipe.
L ~Bolt
Self.locking nut Spring
L2-011
Fig. 7
5
2-9 EXHAUST SYSTEM
Muffler Assembly
REMOVAL INSTALLATION
1) Remove bolts and self-locking nuts which hold rear
exhaust pipe to muffler ASSY to prevent damage to bumper Installation is in the reverse order of removal procedures.
or rear skirt by muffler wrap a cloth around tail pipe.
2) Remove left and right rubber cushions from muffler Be sure to install new self-locking nuts and gaskets.
ASSY, and detach muffler ASSY.
Exhaust System
ADJUSTMENT
1) After installing exhaust system parts, check to make sure

clearances between parts and car body are larger than specified
values.
2) If any clearance is not, loosen all connections.
3) Adjust where necessary to obtain proper clearance.
4) Tighten all connections to specified torque.
Fig. 8
1800 cc model Unit: mm (in)
Rear skirt
More than 10 (0.39) A
AD [MT] B.J2.. [MT] 80 [AT]
More than 17 (0.67) More than 12 (0.47)

More than 17 (0.67)
More than 12 (0.47)
l2-1236
Fig. 9
6
EXHAUST SYSTEM 2-9
2700 cc model Unit: mm (in)
Crossmember
More than 10 (0.39) A B
An [MT] en [MT] en [AT]
More than 17 (0.67) More than xx (xxx)
L2-1238
Fig. 10
Tail Pipe Cutter

2) Tighten clamp bolt to specified torque.
REMOVAL
Tightening torque:
Loosen clamp bolt and remove tail pipe cutter from tail pipe. 29 - 39 N·m (3.0 - 4.0 kg·m, 22 - 29 ft·lb)
Be sure there is at least 25 mm (0.98 in) of clearance between

INSTALLATION rear skirt and tail pipe.
1) Put tail pipe cutter onto tail pipe until it touches a projec-
tion.
Tail pipe cutter
Clamp bolt
L2-422
Fig_ 11
7
CLUTCH
Page
MECHANISM AND FUNCTION. . . . . . . . . . • • • . • . . . . . . . . . . . . . .. 2
SUBARU SPECIFICATIONS AND SERVICE DATA....................... 3
COMPONENT PARTS .••.•••.•••• • • • • • • • • • • • . • • • • • • . • • . . •• 4
SERVICE PROCEDURE. . . . . . . . . • . . . . . . . • . . . . . . . • . . . . • • • . •• 5
1988 TROUBLESHOOTING .•.....•....••.••..••.............••. 10
-
2-10 CLUTCH

Cross Sectional View
FWD 4WD
Release lever
Flywheel ASSY
Clutch disc
Clutch disc
Transmission Transmission
main shaft main shaft
--+l!-a:lI"I-
Release bearing-- Release bearing

ASSY
Bearing holder~
O'~ t
~~ ..
L2-321 L2·430
~------------------------------~~
Fig. 1 Fig. 2
2
CLUTCH 2-10

SPECIFICATIONS
FWD 4WD
Item
0.0. mm (in) 244 (9.61) 266 (10.47)
Thickness mm (in) 5 (0.20) 6 (0.24)
Clutch Pressure plate 0.0. mm (in) 202 (7.95) 228 (8.98)

cover
Pressure plate 1.0. mm (in) 128 (5.04) 147 (5.79)
1800 cc 350 (172)

Diaphragm set load kg (Ib) 350 (172)
2700 cc 500(1,103)
Facing material Woven Woven
Clutch 200 x 130 x 3.5 225 x 150 x 3.5

0.0. x 1.0. x thickness mm (in)
disc (7.87 x 5.12 x 0.138) (8.86 x 5.91 x 0.138)
Spline 0.0. mm (in) 23.2 (0.913) 25.2 (0.992)

(No. of teeth) (23) (25)
Clutch release lever ratio 2.0 3.0
Release bearing Grease-packed ball bearing Grease-packed self-aligning
SERVICE DATA
Clutch pedal Full stroke mm (in) 138 -152 (5.43 - 5.98)
Stroke mm (in)
FWD 17 - 18 (0.67 - 0.71)
4WD 25.5 - 27 (1.004 - 1.063)
Release lever
Play at release lever center mm (in)
FWD 2 - 3 (0.08 - 0.12)
4WD 3 -4 (0.12 -0.16)
Depth of rivet head mm (in)

Standard 1.4 (0.055)
Limit of sinking 0.3 (0.012)
Clutch disc
Limit for deflection mm (in) 0.7 (0.028)
at R = 95 (3.74) . " . FWD
R = 107 (4.21) .... 4WD
3
2-10 CLUTCH
COMPONENT PARTS
®'---.'I
@ -------:=-~(k::mn~1ft.lb): )
- 17. 2 (1.45 -1 . 7,~5::.,..:..:.:..:..-._ _ __
Tightening torq ue N·m g-. 105- 12.7
T: 14.2
CD
~'\
(1.'1
® .-
~/'
®
ble bracket
1 Clutch ca I bracket
2 Clutch cab e lever sealing
3 Clutch release
4 Pivot "
5 Retainer spring
6 Clutch re Iea se lever
7 Clip "ng holder

8 Release bearl
bearing
9 Release lever sealing
10 Clutch relea~e
11 Retainer spring
12 Pivot lever
13 Clutch release bearing ASSY
14 Clutch release
15 Clutch cover
16 Clutch disc
17 Snap ring "
Fig. 3 18 PHV cable Pin L2-571
4
CLUTCH 2-10
SERVICE PROCEDURE
Precautions
ON-CAR SERVICE
When reinstallation, pay attention to the following items.
1) Check the routing of clutch cable for smoothness.
CLUTCH CONTROL
2) Excessive tightness or looseness of clutch cable have a had
Clutch Play Adjustment influence upon the cable durability.
3) Apply grease sufficiently to the connecting portion of
1) Remove release lever return spring from lever.
clutch pedal.
2) Adjust spherical nut so that the play is with in the spec·
4) Apply grease sufficiently to the release lever portion.
ified value at the lever end (center of spherical nut).
5) Position clutch cable through the center of toe board hole
and route it smoothly. Adjustment is done by moving the
Take care not to twist the cable during adjustment. outer cable.
6) Make sure not to make clutch chattering at starting
forward or rearward. If clutch chattering occurs, readjust so
Play
that the bend of clutch outer cable becomes flatter.
Full stroke
REMOVAL
1) Clutch cover CP and clutch disc CPo
Lock nut a. Take care not to allow oil on the clutch disc facing.
b. Do not disassemble either clutch cover CP or clutch disc
.------Clutch release lever
CPo
All·013
Fig. 4 2) Release bearing hoder and clutch release lever.
Unit: mm (in)
I FWD I
~ Play Full stroke
1) Two clips from lever
2-3 17 - 18 2) Release bearing holder
FWD 3) Retainer spring from pivot
(0.08 - 0,12) (0.67 - 0.71)
4WD -
.
,
3-4 25.5 - 27
4) Clutch release lever and sealing
"~-,,,", . (0.12 -0:16) (1.004 - 1.063)

4WD
1 I
1) Two cI ips from lever
Check 2) Release bearing ASSY
3) Retainer spring from pivot
1) Upon completion of adjustment, securely lock spherical 4) Clutch release lever and sealing
nut with lock nut.
2) Install return spring on lever. IJ.e careful not to deform clutch lever & holder clip and clutch
fever retaining spring.
Hook the long hook side of the return spring with the lever.
(4WD)
3) Depress clutch pedal to assure there is no abnormality in

the clutch system.
5
2-10 CLUTCH
INSPECTION
Inspect all the disassembled parts for wear or damage, and repair or replace if necessary.
No. Parts Inspection Corrective action
Clutch disc CPo (1) Wear of facing Measure the depth of rivet head from
the surface of facing. Replace if
facings are worn locally or worn down
to less than the specified value.
Depth of rivet head
Standard value 1.4 mm (0.055 in)
limit of sinking 0.3 mm (0.012 in)
Do not wash clutch disc with any

cleaning fluid.
(2) Hardened facing Correct by using emery paper or

replace.
(3) Oil soakage on facing Replace clutch disc and inspect trans-
mission front oil seal, transmission
case mating surface, engine rear oil seal
and other points for oil leakage.
(4) Deflection of facing If deflection exceeds the specified

value at the outer circumference of
facing, repair or replace.
Limit for deflection

0.7 mm (0.028 in)
at R = 95 mm (3.74 in)
... FWD
R = 107 mm (4.21 in)
... 4WD
Deflection limit: Dial gauge
~Ol~~
~ @9r~ =
Fw~~~6E V/J"r--,ICI\
(499747000)
4WD:
r----,
(499747100) A11.Q03
Fig. 5
(5) Worn spline, loose rivets and

Replace.
torsion spring failure.
6
CLUTCH 2-10
2 Clutch cover CP. Visually check for the following items

without disassembling.
1) Loose thrust rivet CD. Repair or replace.
2) Damaged or worn bearing contact
area at center of diaphragm spring ®.
3) Damaged or worn disc contact
surface of pressure plate ®.
4) Loose strap plate setting bolt @.
5) Worn diaphragm sliding surface
®.
A12-437
Fig. 6
3 Clutch release bearing. (1) Smoothness of rotation

Rotate bearing applying pressure in Repair or replace.
Since this bearing is grease- thrust direction.
sealed and is of a non-
lubrication type, do not (2) Wear and damage of holder sur- Repair or replace.
wash with gasoline or any face contacting with lever.
solvent when servicing the Replacing of clutch release bearing
clutch. (FWD only)
1) Remove bearing out of holder.
2) Press bearing.
Do not depress outer race.

(3) 4WD
Check the bearing ASSY for smooth
movement by applying force in the
radial direction.
Holding bearing case,

apply force in the
radial direction.
Stroke: approx.
1.6mm
(0.063 in)
A11·007
1 PRESS (899754112)
2 Bearing (Clutch release)
3 Holder (Release bearing)
L2·216
Fig. 7 Fig. 8
4 Clutch release lever. Check lever pivot portion and the Repair or replace.
point of contact with holder for wear.
7
2-10 CLUTCH
5 Flyweel CP (1) Damage of facing. Replace.
Since this bearing is grease- (2) Smoothness of rotation Repair or replace.

sealed and is of a non-
lubrication type, do not
Rotate ball bearing applying pressure
in thrust direction. I Pressing of ball bearing I
wash with gasoline or any Press bearing into flywheel until
solvent. bearing end surface is flush with fly-
wheel.
Do not press inner race.
r-----
t--
-r------
- - - - 7 Flush surfaces
~/ ~
Crankshaft side- - '-----c
Di ~
- !:2
E
E
o
--1<-----'- co
~~
Discrimination
groove
A12-438
Fig. 9
8
CLUTCH • 2-10
(3) Install holder (FWD) or bearing ASSY (4WD) and

INSTALLATION fasten it with two clips.
(4) Install clutch release lever sealing.
1) Install clutch release lever and release bearing holder 2) Insert GUIDE (499747000) for FWD or (499747100) for
(FWD) or bearing ASSY (4WD). 4WD into clutch disc CP and install them on flywheel by
inserting the end of Guide into pilot bearing.
Before or during assembling, lubricate the following points
with a light coat of grease. Install clutch cover CP on flywheel and tighten bolts to the
a. Inner groove of release bearing holder. specified torque.
b. Contact surface of lever and pivot.
c. Contact surface of lever and holder. Tightening torque:
d. Transmission main shaft spline. (Use grease containing 142 - 17.2 N·m
molybdenum disulphide.) (1.45 -1.75 kg-m, 10.5 - 12.7 ft-Ib)
a. When installing the clutch cover on the flywheel, position

the clutch cover so that there is a gap of 12110 or more
between "0" marks on the flywheel and clutch cover.
("0" marks indicate the directions of residual unbalance.)
b. Note the front and rear of the clutch disc when installing.
c. Tighten clutch cover installing bolts gradually.
Each bolt should be tightened in a crisscross fashion to the
specified torque.
3) After remounting engine and transmission on body, make

adjustment with the nut at the lever end so that the clutch
release lever end play is 2 to 3 mm (0.08 to 0.12 in) for FWD
L-_ _ _ _ _ --=______-===-___--.:L=2~·2:....:.1___J7 and 3 to 4 mm (0.12 to 0.16 in) for 4WD.
Fig. 10
(1) Install retainer spring into lever. Take care not to twist the cable during adjustment.
(2) While pushing lever to pivot and twisting it to both
sides, fit retainer spring onto the constricted portion of 4) Install release lever return spring.
pivot.
Hook up the long hook side of the return spring with the lever
Confirm that retainer sprinB is securely fitted by seeing (4WD).
through the main case hole.
9
2-10 CLUTCH
TROUBLESHOOTING
Condition Possible cause and testing Corrective action
1. Clutch It is hard to perceive clutch slippage in the early stage, but pay attention to the following symptoms.
slippage
(a) Engine revs up when shifting.
(b) High speed driving is impossible; especially rapid acceleration impossible and vehicle speed does
not increase in proportion to an increase in engine speed.
(c) Power falls, particularly when ascending a slope, and there is a smell of burning of the clutch facing .
• Method of testing:
Put the car in stationary condition with parking brake fully applied. Disengage the clutch and shift
the transmission gear into the first. Gradually allow the clutch to engage while gradually increasing
the engine speed. The clutch function is satisfactory if the engine stalls. However, the clutch is
slipping if the car does not start off and the engine does not stall.
(a) No clutch pedal play Readjust.
(b) No release lever end play Readjust.
(c) Clutch facing smeared by oil Replace.
(d) Worn clutch facing Replace.
(e) Deteriorated diaphragm spring Replace.
(f) Distorted pressure plate or flywheel Correct or replace.
(g) Defective release bearing holder Correct or replace.
(h) Defective pedal and cable system Correct or replace.
2. Clutch As a symptom of this trouble, a harsh scratching noise develops and control becomes quite difficult
drags when shifting gears. The symptom becomes more apparent when shifting into the first gear. However,
because much trouble of this sort is due to defective synchronization mechanism, carry out the test as
described after.
• Method of testing:
Refer to diagnostic diagram on page after.
It may be judged as insufficient disengagement of clutch if any noise occurs during this test.
(a) Excessive clutch pedal play Readjust.

(b) Excessive clutch release lever play Readjust.
(c) Worn or rusty clutch disc hub spline Replace clutch disc.
(d) Excessive deflection of clutch disc facing Correct or replace.
(e) Seized crankshaft pilot needle bearing Replace.
(f) Malfunction of pedal and cable system Correct or replace.
(g) Cracked clutch disc facing Replace.
(h) Sticked clutch disc (smeared by oil or water) Replace.
10
CLUTCH 2-10
Condition Possible cause and testing Corrective action
3. Clutch Clutch chattering is an unpleasant vibration to the whole body when the vehicle is just started with clutch
chatters partially engaged.
(a) Improper clutch cable routing Correct.
(b) Adhesion of oil on the facing Replace clutch disc.
(c) Weak or broken torsion spring Replace clutch disc.
(d) Defective facing contact or excessive disc Replace clutch disc.

deflection
(e) Warped pressure plate or flywheel Correct or replace.
(f) Loose disc rivets Replace clutch disc.
(g) Loose engine mounting Retighten or replace mounting.
(h) Improper adjustment of pitching stopper Adjustment.
4. Noisy Examine whether the noise is generated when the clutch is disengaged, engaged, or partially engaged.
clutch
(a) Broken, worn or un lubricated release bearing Replace release bearing.
(b) Insufficient lubrication of pilot bearing Apply grease.
(c) Loose clutch disc hub Replace clutch disc.
(d) Loose torsion spring retainer Replace clutch disc.
(e) Deteriorated or broken torsion spring Replace clutch disc.
5. Clutch When starting the vehicle with the clutch partially engaged, the clutch engages suddenly and the car jumps
grabs instead of making a smooth start.
(a) Grease or oil on facing Replace clutch disc.
(b) Deteriorated cushioning spring Replace clutch disc.
(c) Worn or rusted spline of clutch disc or main Take off rust, apply grease or replace clutch
shaft disc or mainshaft.
(d) Deteriorated or broken torsion spring Replace clutch disc.
(e) Loose engine mounting Retighten or replace mounting.
(f) Deteriorated diaphragm spring Replace.
11
2-10 CLUTCH
Diagnostic Diagram of Clutch Drags
Test (1) I Disengage the clutch and shift quickly from neutral to reverse in idling condition
Gear noise
I No
Sufficient disengagement of clutch
I I
Yes
Test (2) Shift to reverse after 0.5 to 1.0 sec of clutch disengagement. _I
1
Gear noise l No Defective transmission or excessive

r I clutch drag torque
[Cause]
1. Defective pilot bearing
2. Excessive disc deflection
3. Defective transmission
4. Defective clutch disc hub spline
Yes
Test (3) I Shift the gear N -.

+- R several times during disengaging clutch as test (2) 1
Gear noise I No
Stuck clutch disc
1 I I
[Cause]
1. Clutch disc smeared by oil
2. Clutch disc smeared by rust
3. Defective clutch disc hub spline
"
Yes
Clutch drags
1
[Cause]
1. Cracked clutch disc facing
2. Damaged or worn clutch cover
3. Malfunction of clutch release system
4. Insufficient clutch release amount
5. Excessive clutch pedal play
12
ENGINE AND TRANSMISSION
MOUNTING SYSTEM
Page
SUBARU COMPONENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2

Engine Mounting ....................................... 2
Transmission Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3
1988 SERVICE PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

General Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 18
This chapter applies to the 2700 cc model. For service procedures regarding the
1800 cc model, refer to section 2·11 of the 1987 Service Manual.
2-11 ENGINE AND TRANSMISSION MOUNTING SYSTEM
COMPONENT PARTS
Engine Mounting
"t
1 Front engine mounting bracket
2 Front cushion rubber
3 Front crossrnember
4 Torque converter
5 Drive plate
6 Buffer rod
7 Buffer rod bush
8 Rubber bush
9 Buffer rod bracket (engine side)
10 Buffer rod bracket (body side)
3 Tightening torque: N·m (kg-m;ft-Ib)

T1: 23 - 36 (2.3 - 3.7! 17 - 27)
T2: 20 - 33 (2.0 - 3.4, 14 - 25)
T3: 46 - 54 (4.7 - 5.5, 34 - 40)
T4: 23 - 26 (2.3 - 2.7, :t7 - 20)
T5: 38 - 68 (3.9 - 6.9, 28 - 50)
T6: 44 - 54 (4.5 - 5.5, 33 - 40)
T7: 23 - 33 (2.3 - 3.4,17':" 25)
L2-1416
Fig. 1
2
ENGINE AND TRANSMISSION MOUNTING SYSTEM 2-11
Transmission Mounting
MT Model
1 Pitching stopper rod

2 Pitching stopper bush
3 Rubber bush
4 Pitching stopper bracket
(4WD) 6
(FWD)
6 Rear cushion rubber
7 Rigid crossmember
8 Cushion
9 Mounting plate
10 Crossmember
-~
11 Cushion
12 Plate
13 Rear crossmember
@
Tightening torque: N·m (kg·m, ft·lb)

'.-"f".
T1: 18 - 31 (1.8 - 3.2, 13 - 23)
T2: 88 - 118 (9.0 - 12.0,65 - 87) ,
I
~
T3: 27 - 47 (2.8 - 4.8, 20 - 35)
T4: 46 - 54 (4.7 - 5.5, 34 - 40)
T5: 44 - 54 (4.5 - 5.5,33 - 40)
T6: 37 - 67 (3.8 - 6.8, 27 - 49)
"
T7: 37 - 67 (3.8 - 6.8, 27,- 49)
'.
L2·1417
Fig. 2
...
AT Model
•
1 Pitching stopper bush

2 Pitching stopper rod
3 Rubber bush
4 Pitch ing stopper bracket
5 Rear cushion rubber LH (4WD)
6 Rear cushion rubber RH (4WD)
7 Rear cushion rubber (FWD)
8 Cushion rubber stopper (4WD)
9 Rear crossmember ASSY
10 Plate
11 Mounting bolt
/
/
/'
/
/'
/'
/'
/'
/
/
/
/
Tightening torque: N·m (kg-m, ft-lb)

T1: 18 - 31 (1.8 - 3.2, 13 - 23)
T2: 27 - 47 (2.8 - 4.8, 20 - 35)
T3: 46 - 54 (4.7 - 5.5, 34 - 40)
T4: 13 - 23 (1.3 - 2.3, 9 - 17)
T5: 20 - 33 (2.0 - 3.4, 14 - 25)
T6: 37 - 67 (3.8 - 6.8, 27 - 49)
17: 23 - 26 (2.3 - 2.7, 17 - 20)
18: 44 - 54 (4.5 - 5.5, 33 - 40)
19: 53 - 67 (5.4 - 6.8, 39 - 49) L2·1418
Fig. 3 I
4
SERVICE PROCEDURE
All descriptions in this chapter apply to the 2700 cc model. section 2-11 "Engine and Transmission Mounting System" of
For service procedures regarding the 1800 cc model, refer to the 1987 Service Manual.
Procedure Chart for Removing and Installing Engine and Related Parts
REMOVAL Open front hood and support with a stay.
• Reduce fuel pressure.

• Drain coolant.
• Disconnect ground cable from battery and engine side.
Disconnect hoses, harness connectors and cables.
Remove exhaust system (front exhaust pipe).
Remove air intake system.
Disconnect flexible hoses (A/C),
Remove cooling system

(: Radiator ASSY
Heater hoses (IN and OUT)
(AfT)
,
I Disconnect drive plate from torque converter.
I
Remove buffer rod mounting bolts to engine side.
Disconnect engine mount from front crossmember.
Remove nuts which hold lower side of engine to transmission. I

Support engine with a lifting device and wire ropes.
Remove bolts which hold upper side of engine to transmission.
Support transmission with a garage jack.

I
I Remove engine.
J
5
INSTALLATION Install engine to transmission and tighten engine to transmission

nuts and bolts.
Remove garage jack and wire rope.
(A/T)
I
•
Tighten torque converter mounting bolts.
J
Tighten front engine mount nuts.
Install buffer rod to engine side.
Install exhaust system (front exhaust pipe).
Connect flexible hoses (A/C).
Install cooling system.

(: Heater hoses (IN and OUT)
Radiator ASSY
Fill cooling system with coolant. *

Install air intake system.
*
Connect cables, hoses and harness connectors.
Connect ground cable to battery terminal and engine side.
Check and correct coolant and oil levels.
This flowchart shows the main procedure for removing and installing the engine and its related parts. For details, refer to the
text.
6
Procedure Chart for Removing and Installing Transmission and Related Parts
REMOVAL
I ,
Open front hood and support with a stay.
I
I Disconnect ground cable from battery and transmission side.
I
I
I Disconnect cables, harness connectors and hoses.
I
I Disconnect torque converter from drive plate. I
I Disconnect pitching stopper rod from bracket. I

I Remove bolts which hold upper side of engine to transmission. I
Set the special tool.
Remove exhaust system (front exhaust pipe).
(4WD)
t
I Remove propeller shaft.
J
I
Remove gear shift system.
•
Disconnect axle shaft from drive shaft on each side .
•
Remove nuts which hold lower side of engine to transmission.
(AfT)
I •
Disconnect oil cooler hoses. I
Place transmission jack under transmission.
,
Remove rear cushion rubber mounting nuts and rear cross·
member.
r Remove transmission. I
7
INSTALLATION
Install transmission to engine and temporarily tighten engine to transmission nuts.
Install rear cushion rubber and rear crossmember.
Tighten engine to transmission nuts on the lower side.
Remove transmission jack.
Remove special tool.
I Install axle shaft to axle drive shaft.

I
t
I
•
•
,
Install transverse link temporarily to front crossmember .
Temporarily install stabilizer to transverse link.
I
I Lower car to floor. I
t
Tighten transverse link·to·front crossmember mounting bolt and I
I transverse link·to·stabilizer mounting bolt.
t
I Install gear shift system. I
(4WD)
•
I Install propeller shaft.
1
(AfT)
•
I Connect oil cooler hoses.
1
I Connect engine and transmission.
, 1
I Install pitching stopper and bracket.
l
(AID
•
I Install and tighten torque converter mounting bolts.
I Connect hoses, harness connectors and cables. I
~
I Install exhaust system (front exhaust pipe).
I
~
I Connect ground cable to battery and transmission side. I
~
I Check transmission oil level. I
I Check ATF with engine idling • I
t
I Start engine and recheck oil level. 1
This flowchart shows the main procedures for removing and installing the transmission and its related parts. For details, refer to
the text.
8
General Precaution 2) Reduce fuel pressure.

(1) Raise car positioned at side sill location.
1) Remove or install engine and transmission in an area (2) Disconnect fuel pump wiring connector.
where chain hoists, lifting devices, etc. are available for ready
use.
2) Be sure not to damage coated surfaces of body panels
with tools or stain seats and windows with coolant or oil.
Place a cover over fenders, as required, for protection.
3) Prior to starting work, prepare the following:
Service tools, clean cloth, containers to catch coolant and oil,
wire ropes, chain hoist, transmission jacks, etc.
4) Lift up or down car when necessary. Make sure to support
the correct positions. (Refer to Chapter 1-3 "General Informa-
tion".)
Fig. 5
Engine
REMOVAL
(3) Lower car to floor.
1) Open front hood and support with a stay. (4) Start engine.
(5) After engine has stopped, crank engine for approxi-
mately five seconds and then turn ignition switch to OFF.
(6) Raise car again.
(7) Connect fuel pump wiring connector.
3) Drain coolant.
(1) Loosen drain cock.
Fig. 6
(2) Lower car to floor.

L2-1123
(3) Place a container to catch coolant.
Fig. 4
(4) Loosen radiator cap.
4) Disconnect ground cable from battery and engine side.
9
2-11 ENGINE AND TRANSMISSION ty10UNTING SYSTEM
5) Disconnect the following hoses.

• Canister hoses and hose bracket
• Fuel hoses (delivery, return and evaporation lines)
Place a container to catch fuel from fuel hoses.
• Brake booster vacuum hose

• Diff. lock vacuum hose (MIT Full-Time 4WD)
.
(
Fig. 7
10
6) Disconnect the following harness connectors. Also remove • Alternator connector and terminal
clips. • Compressor connector (A/C)
• Engine wiring harness connectors • Pulser coil connector (A/C)
• O2 sensor connector • Engine ground terminal
• By-pass air control valve connector • Radiator fan motor connector
• High-tension cord (to ignition coil) • Thermoswitch connector
• Distributor connector (to crank sensor) • Condenser fan motor connector (A/C)
L2-1427
I :, .,- ~
user cOl/Engine ground.J
connector' termina,Jl1V\
.-------:~~-y-:~/---~ lV C~~1429
Fig. 8
11
7) Disconnect the following cables.
• Accelerator cable
• Cruise control cable (Cruise control model)
• Hill-holder cable (MIT)
Disconnect hill-holder cable at connection on clutch release

fork side, and remove cable clamps.
Hill-holder cable clamps
L2-1432
Fig. 9
12
8) Remove front exhaust pipe. 10) Disconnect flexible hoses. (Refer to 4-7 "Air Conditioning
System".)
(1) Raise car.
(1) Discharge refrigerant at low-pressure service valve.
(2) Disconnect front exhaust pipe from engine.
(2) Disconnect flexible hoses (low- and high-pressure
hoses) from compressor side and remove clamp.
Remove all nuts except one. (This nut is used to temporarily
hold exhaust pipe.)
(3) Disconnect front-to-rear exhaust pipe connection.

(4) Disconnect front exhaust pipe at transmission and
hanger locations.
(5) Remove the nut which was used to temporarily hold
exhaust pipe in step (1) above, and disconnect front
exhaust J::ipe.
Fig. 12
---
Fig. 10
L2-1433
Plug the opening to prevent foreign matter from entering.
11) Remove radiator ASSY.

(1) Remove radiator and condenser fan shroud.
(2) Disconnect radiator hoses (IN and OUT) and reservoir
hose.
Place a container to catch coolant
(3) Disconnect oil cooler hoses (IN and OUT) from

radiator side. (AfT)
9) Remove air intake boot, upper air cleaner case and Plug the opening hoses to prevent oil from flowing out
element, disconnect air flow meter connector.
I '
--&.J 'kI,I"",,
\ I' 'I
~M L2-1436
~------------------------------~
Fig. 11 Fig. 13
13
(4) Remove the bolts from the upper side of the radiator, 14) Remove buffer rod mounting bolts to engine side.
then remove the radiator.
~-1441
L-_________________________________
~_.1_4_38~ n~ 17
Fig. 14
12) Disconnect heater hoses (IN and OUT).

15) Remove nuts which hold engine mount to front cross-
member.
a. Catch remaining coolant
b. Be sure to disconnect heater hoses from engine side.
Fig. 18
Fig. 15
13) Remove timing hole plug and remove four bolts which 16) Remove nuts which hold lower side of engine to trans-
hold torque converter to drive plate. ~ mission.
====
Fig. 16 Fig. 19
14
17) Support engine with a lifting device and wire ropes. 19) Support transmission with a garage jack.
Transmission case
L2·1159
Fig. 20
Fig. 22
Before moving engine away from transmission, cbeck to

be sure no work has been overlooked. Doing this is very
important in order to facilitate re-installation and because
transmission lowers under its own weight.
18) Remove bolts which hold upper side of engine to trans-

mission.
20) Remove engine itself.

(1) Slightly raise engine.
(2) Raise transmission with a garage jack.
(3) Move engine in the direction of the arrow in the
figure.
Move engine in axial direction until main:shaft is withdrawn

from clutch cover. (MIT)
L2·1445
L -______________________________________ ~ L2·1446
Fig. 21 Fig. 23
15
(4) Slowly lifting engine away from engine compartment. 3) Tighten torque converter mounting bolts. (A/T)
(1) Align torque converter with drive plate at mounting
Be careful not to damage adjacent parts or body panels with holes.
crank pulley, oil pressure gauge, etc. (2) While cranking engine, tighten bolts securely - one at
a time.
Be careful not to drop bolts into torque converter housing.
Tightening torque:
23 - 26 N·m (2.3 - 2.7 kg·m, 17 - 20 ft-Ib)
(3) Install timing hole plug.

4) Tighten front engine mount nuts.
Be sure to tighten front rubber cushion mounting bolt in the

innermost elliptical hole in the front crossmember.
Tightening torque:
Fig. 24 38 - 68 N·m (3.9 - 6.9 kg·m, 28 - 50 ft·lb)
INSTALLATION
1) Install engine to transmission.

• (AfT) Position engine in engine compartment and align it
with transmission.
Be careful not to damage adjacent parts or body panels with =--)

crank pulley, oil pressure gauge, etc. L2-276
Fig. 25
• (MfT) Rotate crank pulley two or three turns until main-
shaft and clutch disc are properly engaged at their
splines.
a. Apply a small amount of grease to splines of mainshaft in

advance.
b. Be careful not to strike mainshaft against diaphragm springs 5) Install buffer rod to engine side, and tighten mounting
to prevent deformation or damage. bolts.
2) Tighten engine-to-transmission nuts and bolts.

Tightening torque:
(1) Temporarily tighten bolt to hold the right upper side.
(2) Temporarily tighten bolt to hold starter to engine. 20 - 33 N·m (2.0 - 3.4 kg-m, 14 - 25 ft·lb)
(3) Remove garage jack and set front engine mount on
6) Install front exhaust pipe.
crossmember.
(4) Remove wire rope. a. Be sure to use new gasket.
(5) Raise car and tighten nuts on the lower side.
b. Position front exhaust pipe in hanger bracket, and properly
(6) Lower car to floor and tighten nuts and bolts in step align it with adjacent parts.
(1) and (2) above.
c. Tighten all parts in numerical sequence, as shown in figure
below, to specified torque.
Tightening torque:
46 - 54 N·m (4.7 - 5.5 kg-m, 34 - 40 ft-Ib)
16
10) Fill cooling system with coolant.

11) Install air cleaner element, upper case and air intake boot.
12) Connect air flow meter connector.
13) Connect accelerator cable and adjust its tension using
adjusting nut.
a. Be careful not to bend the cable bracket

b. Check to be sure that throttle lever opens to full-throttle.
14) Connect cruise control cable. (Cruise control model)

15) Connect hill-holder cable to clutch release fork. (M/T)
After connecting, test operation of hill-holder on an upgrade.
Fig. 26 16) Connect the following hoses.

• Fuel hoses (delivery, return and evaporation lines)
• Canister hoses and hose bracket
Tightening torque: • Brake booster vacuum hose
Front exhaust pipe to cylinder head: • Diff. lock vacuum hoses (MIT Full-Time 4WD)
25 - 29 N·m (2.6 - 3.0 kg-m, 19 - 22 ft-Ib) 17) Connect the following harness connectors and hold with
Front exhaust pipe to hanger bracket: clips where necessary.
25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-Ib) • Engine wiring harness connectors
Front exhaust pipe to rear exhaust pipe: • O2 sensor connector
13 - 23 N·m (1.3 - 2.3 kg-m, 9 - 17 ft-Ib) • By-pass air control valve connector
• High-tension cord
Also check to be sure there is no gas leakage after installation • Distributor connector (to crank sensor)
is completed. • Alternator connector and terminal
• Compressor connector (A/C)
7) Connect flexible hoses. (Refer to 4-7 "Air Conditioning • Pulser coil connector (A/C)
System".) • Engine ground terminal
(1) Connect flexible hoses (low- and high-pressure hoses). • Radiator fan motor connector
• Thermo switch connector
Tightening torque: • Condenser fan motor connector (A/C)
15 - 25 N'm (1.5 - 2.5 kg-m, 11 - 18 ft-Ib) 18) Connect ground cable to battery terminal and engine side.
19) Check and correct coolant and oil levels.
(2) Charge refrigerant into system.
Use only genuine SUBARU coolant and recommended oil.
After charging refrigerant, test operation of air conditioning
system.
8) Connect both I N and OUT heater hoses.

9) Install radiator ASSY.
• Radiator
• Radiator hoses (IN and OUT), reservoir hose
• Oil cooler hoses (I N and OUT) (A/T)
• Radiator fan shroud
• Condenser fan shroud
Tightening torque:
Radiator mounting bolt:
10 - 18 N'm (1.0 - 1.8 kg-m, 7 - 13 ft-Ib)
Radiator fan shroud bolt:
7.3 -7.7 N'm (0.74 - 0.79 kg-m,
5.4 - 5.7 ft-Ib)
Condenser fan shroud bolt:
5 - 10 N'm (0.5 - 1.0 kg-m, 3.6 - 7.2 ft-Ib)
17
Transmission
REMOVAL
1) Open front hood and support with a stay.
L2-1123
Fig. 27
2) Disconnect ground cable from battery and transmission

side.
18
L2-1451
~~
'_~~~ Diff.lock vacuum
Fig. 28
3) Remove clutch cable and hill-holder cable. (MIT) • Transmission cord connector (back-up and diff. lock
4) Remove meter cable. indicator light switch) (Full-Time 4WD)
5) Disconnect the following harness connectors. 6) Disconnect the following hoses .
(AIT) • Diff. lock vacuum hose (MIT Full-Time 4WD)
• O2 sensor connector
• Transmission harness connector Remove clip band which secures air breather hose to pitching
• Inhibitor switch connector stopper in advance. (A/T)
• Revolution sensor connector (4WD)
(MIT)
• O2 sensor connector
• Neutral switch connector
19
7) Remove starter from transmission case. 11) Remove engine-to-transmission mounting bolt on the right
8) Remove air intake boot. side.
Fig. 29 Fig. 32
9) Remove timing hole plug and four torque converter

attaching bolts. (AfT)
Be careful not to slip wrench off bolt. It may strike and 12) Set the special tool.
damage bolt head. (1) Raise the car.
(2) Remove buffer rod from engine and, body side
bracket.
(3) Install ENGINE SUPPORT BRACKET (927160000)
to the body side bracket of buffer rod ASSY.
(4) Install ENGINE SUPPORT (927150000).
Fig. 30
10) Disconnect pitching stopper rod from bracket.
Fig. 31 Fig. 63
20
Before attaching ENGINE SUPPORT to ENGINE SUPPORT ~\

BRACKET and front crossmember, connect adjuster to buffer ~\
rod ASSY bracket (on engine side).
13) Remove front exhaust pipe.

(1) Disconnect front exhaust pipe from engine.
Remove all nuts except one. (This nut is used to temporarily

hold exhaust pipe.)
(2) Disconnect front-to-rear exhaust pipe connection.

(3) Disconnect front exhaust pipe at transmission and
hanger locations. L2-1171
(4) Remove the nut which was used to temporarily hold
exhaust pipe in step (1) above, and disconnect front
Fig. 35 - ®
exhaust pipe.
15) Remove gear shift system, as follows:

(MIT)
(1) Remove spring.
(2) Disconnect stay CP from transmission.
(3) Disconnect rod CP from transmission.
(A/T)
(1) Disconnect cable from select lever.
(2) Loosen nut which holds cable to bracket.
(3) Disconnect cable while moving inhibitor switch to
2nd position.
Fig. 34
14) Remove propeller shaft. (4WD)
a. Before removing propeller shaft, scribe alignment marks on

connections of rear differential companion flange and pro-
peller shaft.
b. Plug the opening at rear of extension to prevent oil from
flowing out.
L2-1173
K==~~=§~~=L2-1169 Fig. 36
Fig. 35 - CD
21
16) Disconnect axle shaft from drive shaft on each side. 17) Remove engine-to-transmission mounting nuts.
(1) Loosen upper bolt and nut from plate which secures
transverse link to stabilizer, and remove lower bolt.
Separate transverse link and stabilizer.
L
L
\_-
l
I-
e
I
t l
Fig. 39
'---_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _--=L:.::..2._14_6--..J2 18) Disconnect oil cooler hoses. (AIT)

Fig. 37
Place a container to catch oil.
(2) Remove hand brake cable bracket from transverse

link",
(3) 'Remove bolt holding transverse link to crossmember
on each side.
(4) Lower transverse link.
(5) Remove spring pin and separate axle shaft from drive
shaft on each side.
Fig. 40
19) Place transmission jack under transmission.
Always support transmission case with a transmission jack.

Do not place support under oil pan; otherwise oil pan may be
damaged. (A/T)
Fig. 38
a. Use REMOVER 2 (398791700) to remove spring pin.

b. Discard old spring pin and install new one. Transmission jack
C. Be sure to remove axle shaft from drive shaft by pushing L2·1177
the rear oftire outward. Fig. 41
22
20) Remove rear cushion rubber mounting nuts, and rear 22) Remove transmission.
crossmember.
a. Move transmission jack toward rear until mainshaft is with·
drawn from clutch cover. (MIT)
b. Move torque converter and transmission as a unit away
from the engine. (4AIT)
Torque converter
L2-1461
Fig. 44
INSTALLATION
L--_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
L2_.1_1_79....J 1) Install transmission to engine and temporarily tighten
Fig. 42 engine·to·transmission mounting nuts.
a. Gradually raise transmission with a transmission jack until

mainshaft is aligned with clutch disc at their splines. Engage
them at splines. If they are not aligned properly, rotate crank·
shaft as required. (MIT)
b. Be sure not to strike mainshaft against clutch cover. (MIT)
2) I nstall rear crossmember to rear cushion rubber.
21) Turn ENGINE SUPPORT adjuster counterclockwise to

raise the front of engine slightly.
Align rear cushion rubber guide with rear crossmember guide
hole and tighten nuts. (A/T)
Fig. 45
23
9) Temporarily install stabilizer to transverse link.

Tightening torque (Cushion rubber nut): 10) Install hand brake cable bracket to transverse link.
(A/T FWD):
13 - 23 N·m (1.3 - 2.3 kg·m, 9 - 17 ft·lb) Tightening torque:
(AIT 4WD, MIT): 10 - 16 N·m (1.0 - 1.6 kg-m, 7 - 12 ft·lb)
27 - 47 N·m (2.8 - 4.8 kg-m, 20 - 35 ft-Ib)
11) Lower car to floor.
3) Install rear crossmember to car body. 12) Tighten transverse link-to·front crossmember mounting
bolt, transverse link-to-stabilizer mounting bolt.
Be careful not to damage threads.
Tighten nuts with the tires placed on the ground when the
Tightening torque (Rear crossmember bolt): vehicle is not loaded.
(AIT)
53 - 67 N·m (5.4 - 6.8 kg·m, 39 - 49 ft·lb) Tightening torque:
(MIT) Transverse link to front crossmember
(Front) : (self·locking nut):
59 - 69 N·m (6.0 - 7.0 kg·m, 43 - 51 ft-Ib)
88 - 118 N·m (9.0 - 12.0 kg·m, 65 - 87 ft-Ib)
(Rear): Transverse link to stabilizer:
20 - 29 N·m (2.0 - 3.0 kg·m, 14 - 22 ft·lb)
37 - 67 N'm (3.8 - 6.8 kg-m, 27 - 49 ft·lb)
13) Raise car.
4) Tighten engine-to-transmission nuts on the lower side.
14) Install gear shift system.
(MIT)
Tightening torque: (1) Connect rod CP to transmission.
46 - 54 N·m (4.7 - 5.5 kg·m, 34 - 40 ft·lb) (2) Install spring.
(3) Connect stay CP to transmission.
5) Remove transmission jack. (AfT)
6) Remove ENGINE SUPPORT and ENGINE SUPPORT (1) Tighten nut which holds cable to bracket.
BRACKET, and install buffer rod to brackets. (2) Connect cable to select lever.
7) Install axle shaft to axle drive shaft and drive spring pin
into place. When connecting table to select lever, set the location of the
a. Use new spring pin. select lever and inhibitor switch to "N".
b. Be sure to align two shafts at chamfered holes and engage
Tightening torque:
shaft splines.
Rod CP (MIT)
Chamfered hole 9 - 15 N·m (0.9 - 1.5 kg-m, 6.5 - 10.8 ft·lb)
Stay CP (MIT)
14 - 22 N·m (1.4 - 2.2 kg-m, 10 -16 ft·lb)
Cable to bracket (A/T)
13 - 23 N·m (1.3 - 2.3 kg-m, 9 - 17 ft·lb)
Cable to select lever (AIT)
10 -18 N·m (1.0 -1.8 kg·m, 7 -13 ft·lb)
After completion of the fitting, make sure that the lever

operates smoothly all across the operating range. (A/T)
15) Install propeller shaft. (4WD)

L2-592
Fig. 46 Align marks and connect propeller shaft to rear differential.

8) Install transverse link temporarily to front crossmember
Tightening torque:
by using bolt and self-locking nut.
Propeller shaft to rear differential
a. Align bolt holes using a cross-head screwdriver, insert bolt 24 - 32 N·m (2.4 - 3.3 kg-m, 17 - 24 ft·lb)
Center bearing location
into holes from the front side.
34 - 44 N·m (3.5 - 4.5 kg-m, 25 - 33 ft-Ib)
b. Use new self-locking nut.
24
16) Connect oil cooler hoses. (AfT) 24) Connect meter cable.
17) Connect engine and transmission, and tighten bolt on the
right side. Manually tighten cable nut all the way and then turn it
approximately 30° more with a wrench.
Tightening torque:
46 - 54 N·m (4.7 - 5.5 kg-m, 34 - 40 ft-Ib) 25) Connect clutch cable and hill-holder cable. (MIT)
18) I nstall starter. After connecting, test operation of hill-holder on an upgrade.
Tightening torque: 26) Install front exhaust pipe.

Upper bolt:
46 - 54 N·m (4.7 - 5.5 kg-m, 34 - 40 ft-Ib) a. Be sure to use new gasket.
Lower nut: b. Position front exhaust pipe in hanger bracket, and align it
30 - 36 N·m (3.1 - 3.7 kg-m, 22 - 27 ft-Ib) with adjacent parts.
c. Tighten all parts in numerical sequence, as shown in figure
19) Install pitching stopper. below, to specified torque.
Tightening torque
Transmission side:
44 - 54 N-m (4.5 - 5.5 kg-m, 33 - 40 ft-Ib)
20) Install and tighten torque converter mounting bolts.

(AfT)
(1) Align torque converter with drive plate at mounting
holes.
(2) While manually cranking engine, tighten torque
converter-to-drive plate mounting bolts securely - one at
-----.
a time.
Be careful not to drop bolts into torque converter housing. L2-1433
Fig. 47
Tightening torque:
23 - 26 N·m (2.3 - 2.7 kg-m, 17 - 20 ft-Ib)
(3) Install timing hole plug. Tightening torque:

21) Install air intake boot. Front exhaust pipe to engine:
22) Connect the following hoses. 25 - 29 N·m (2.6 - 3.0 kg-m, 19 - 22 ft-Ib)
• Diff. lock vacuum hose (MfT Full-Time 4WD) Front exhaust pipe to bracket:
25 - 34 N·m (2.6 - 3.5 kg-m, 19 - 25 ft-Ib)
Secure air breather hose to pitching stopper with a clip band. Front exhaust pipe to rear exhaust pipe:
13 - 23 N·m (1.3 - 2.3 kg-m, 9 - 17 ft-Ib)
23) Connect the following harness connectors.
(A/T) Also check to be sure there is no gas leakage after installation
• O 2 sensor connector is completed.
• Transmission harness connector
• Inhibitor switch connector 27) Connect ground cable to battery and transmission side.
• Revolution sensor connector (4WD) 28) Check transmission oil level.
(MIT) Add gear oil if necessary.
• O 2 sensor connector 29) Check ATF with engine idling.
• Neutral switch connector If lower than the specified level, stop engine and add ATF.
• Back-up light switch connector (FWD) (A/T)
• Transmission cord connector (back-up and diff. lock 30) Start engine and re-check oil levels.
indicator light switch) (Full-Time 4WD)
25
MANUAL TRANSMISSION AND
DIFFERENTIAL
Page
SUBARU MECHANISM AND FUNCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

Cross Sectional View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
2
2
Reverse Check Mechanism .........•...................•.. , 3
Full·Time 4WD ...........•......•.•................... 4
1988 SPECIFICATIONS AND SERVICE DATA ..•.•................ " 9
COMPONENT PARTS ...•.........•.•.•................... 14
SERVICE PROCEDURE ................•................... 27
Selective 4WD • . . . • . . • . . . . . . . . . . . • . • . . . . . . . . . . . . . . . . . . . 27
Full-Time 4WD ..•..•............•••.•................. 49
FWD ....•....................•••............ , .•.... 66
TROUBLESHOOTING ...................................•. 80
3-1 MANUAL TRANSMISSION AND DIFFERENTIAL
M'ECHANISM AND FUNCTION

Cross Sectional View
FWD
L3-090
Fig. 1
4WD
• Selective 4WD (Single-range)
L3-855
Fig. 2
• Full-Time 4WD (Single-range)
L3-884
Fig. 3
2
MANUAL TRANSMISSION AND DIFFERENTIAL 3-1
Reverse Check Mechanism ® Position at Fig. 5-(1), (2) and (3)

,@ Position at Fig. 5-(4)
COMPONENT PARTS
CD
(5) (j)
Reverse check sleeve
r CJ) ASSY
(1) Reverse accent shaft
(~ Reverse check cam
(4) Reverse return spring
(5) Reverse check spring
(6) Reverse check plate
(j) Snap ring Arrow view "Z" @ L3-101
(Q) Reverse accent spring
@ Ball Fig. 6
@ O-ring
(\}) Selector arm CONSTRUCTION
@ Select adjust shim
L3·096 • The sleeve CD is bolted to the transmission case. The shaft
® is inserted in the sleeve CD. On the smaller-diameter
Fig. 4 side (right side in Fig. 4) of this shaft ®, the cam @ is
loosely mounted so that it can rotate, and the sleeve CD
holds the cam in place with its stepped part.
CD @ The spring @, which is inserted in the shaft ® presses
the shaft to the left. Further, the spring @ is placed in
between the cam @ and sleeve CD, which forces the cam
@ to the left and in the direction of rotation. Both springs
are held down with the plate @ that is attached to the
sleeve CD with the snap ring (j) . The shaft ® has a groove
for reverse accent, in which the ball ® and spring ® are
put through a hole drilled in the sleeve CD .
OPERATION
(1) Neutral position (2) 5th position • As shown in Fig. 5, the sleeve CD and shaft ® have a
L3-097 L3-098
notch, and the arm @ is placed between the notches.
The position of the arm @ shown in Fig. 4 is the neutral
position (hereafter referred to as ® position). The point
where the arm stops when moved to the left is the 1st and
2nd position. Opposite this, the point where the arm stops
when moved to the right is the 5th and reverse position.
Fig. 5 shows the section A-A in Fig. 4, and Fig. 6 the view
Z in Fig. 4.
1) When 5th and reverse side is selected
The arm @ pushes the shaft ® and cam @ simultaneously
and moves to the 5th and reverse side, as shown in [Fig. 5-
(3) 5th .... Neutral position (4) Reverse position (1 ) ] .
L3-099
Section A-A L3-100 2) When shift is made to 5th
As shown in [Fig. 5-(2)], the arm @ moves to the 5th side
Fig. 5
pushing the shaft ®. When the arm @ pulls out of the cam
@, the cam is returned to the original position by the spring
@.
3) When shift is made from 5th to reverse
As shown in [Fig. 5-(3)], the arm @ moves to the reverse
side pushing the shaft ® and runs against the cam ® that has
already returned. The cam @ has, as shown in [Fig. 6], a
stopper, which hits against the plate @' Thus, the cam @
can[1ot rotate further. Accordingly, the arm @ comes to a
3
stop at a point where it has turned the cam @ to a certain 2) The center differential features the reliable bevel gear
degree (i.e.,® position), and the cam @ is pushed back to design. It distributes the torque to both front and rear dif-
the ® position by the shaft® (i.e., the spring (@). ferentials and performs the differential action between the
4) When shift is made to reverse fron~ and rear axle shafts.
From the position shown in [Fig. 5-(1)), the arm (j]) again 3) In order to minimize the size of the transfer section, a
moves to the 5th and reverse side. When the shift is made to triple-shaft structure with two hollow shafts is adopted. These
reverse, the arm (j]) moves to the reverse position while push- are located at the center differential power input section and
ing the shaft® and cam @ together. at the output section from which power is transmitted to the
front and rear wheels. Major parts such as the transmission
case, main shaft, front differential and others are interchange-
able.
4) The center differential is equipped with a built-in mechan-
Full-Time 4WD ical locking mechanism. It is locked or unlocked by the
vacuum actuator with engine vacuum when the differential
CONSTRUCTION lock switch on the console box inside the cabin is operated.
1) The full-time 4WD transmission is designed on the basis of 5) When the center differential is locked, the drive shaft is
the selective 4WD model. A center differential unit and lock- coupled directly to the front and rear wheels. This provides a
ing mechanism have been added to the rear end transfer maximum drive equivalent to that of the 4WD mode of the
section. The overall length of the transmission is unchanged. selective 4WD model.
The transmission case is unchanged

from that of the former model.
Main shaft
From engine
·C,",'h~
Pinion
Front reduction gear
Drive pinion
Vacuum actuator Center differential

Ignition switch lock selector lever
Solenoid valve
.1 Hollow shaft
.\
L.....-If\-_ _ _ _...J ~ Center differential lock switch
Intake manifold
L3-494
Fig_ 7
4
Differential lock sleeve

Transfer driven gear
Center differential
Transfer drive gear
Drive pinion shaft
L3..a85
Fig. 8
5
OPERATION OF CENTER DIFFERENTIAL AND rear wheels is absorbed through the action of this differential
POWER TRANSMITTING MECHANISM unit.
3) The torque or driving force thus transmitted and dis-
1) Engine torque is transmitted to the clutch and main shaft.
tributed is then transferred to the axle shafts and tires via the
It is then transmitted to the hollow driven shaft after being
front and rear final drives.
multiplied by the respective speed gears.
4) When the car is going straight ahead, the drive pinion and
2) The rear end of the hollow driven shaft is coupled directly
transfer drive gear rotate as a unit. When making a turn, tight
to the pinion of the center differential via the pinion shaft,
corner braking is avoided by the action of the center differen-
and torque is transmitted equally to the front and rear final
tial.
drives. Any difference in rotating speed between the front and
Power transmission when the car is going straight ahead (When driving in 5th gear)
Center differential
Clutch lock selector
Input shaft
To rear axle
Center differential
To front wheel
Drive pinion
Power from the engine is transmitted as follows:
Center
r1 Rear bevel
gear
Drive pinion
Front
differential
Hollow
driven shaft
f-- Pinion shaft
- differential
pinion
r-
Front bevel Transfer Transfer Rear
'--
gear
f-- drive gear - driven gear '-- differential
L3496
Fig. 9
6
Power transmission when front wheel or rear wheel is

locked (when driving in 5th gear)
Power is transmitted as follows:
With front wheel locked With rear wheel locked
Th is does not rotate because

the front wheels are locked. This does not rotate because
the rear wheels are locked.
In either case, the output shaft is driven at a speed twice that of the hollow input shaft.
L3-327
Fig. 10
5) When the center differential lock switch is operated and

the center differential lock is activated, the differential gear
coupled to the front and rear drive shafts does not function.
If the front or the rear wheel slips, torque is transmitted to the
remaining wheel by the center differential lock, so that the
car can maneuver off the slippery surface, or get out of mud.
The suction vacuum of the engine is utilized to activate the
vacuum actuator to changeover the locking mechanism.
7
Operation of differential lock

Intake manifold
Differential lock OFF
r+---, r~'--'wr-Power to ignition
Solenoid valve
Solenoid valve
Ditt. lock l e v e r - - - r - - - - - _
L. (with. ditto in operati~n)
(with difl. "locked")
Ditt. lock shaft --~--~:::::~~~w=

A
i?~~
Vacuum actuator
Transfer drive gear
Transfer drive gear ~--Difl. "unlocked"

A-A
Difl. lock f o r k - - - - - - - ' L---Difl. lock sleeve L3-859

Fig. 11
Intake manifold
Differential lock ON
M - - - r~"-".vr--Power to ignition
Solenoid valve
(with ditto "locked")
Solenoid valve
Ditt.lock lever--.::-----·-_ L. (wit~ difl. in operati.on)
Difl. lock shaft_~-------

Vacuum actuator
Transfer drive gear
Transfer drive gear-----~ - - - D i f l . "locked"
Difl. lock fork-------~ ' - - - - Ditt. lock sleeve

L3-860
Fig. 12
8

SPECIFICATIONS
~
4WD
FWD
Selective 4WD, SIR Full-time 4WD, SIR
Type 5-forward speeds with synchromesh and 1-reverse
1st 3.636 (40/11 ) 3.545 (39/11 ) 3.545
2nd 2.105 (40/19) 2.111 (38/11) 1.947
Transmission gear ratio 3rd 1.428 (40/28) 1.448 (42/29) 1.366

(Tooth number of gear)
4th 1.093 (35/32) 1.088 (37/34) 0.972
5th 0.885 (31/35) 0.871 (34/39) 0.780
Reverse 3.583 (43/23/12) 3.416 (41/26/12) 3.416
Type of gear Hypoid

Front
reduction Final
Gear ratio
gear 3.700 (37/10) 3.900
(Tooth number of gearl
Type of gear - Helical

Transfer
Gear ratio
Rear (Tooth number of gearl
- 1.000 (34/34)
reduction
gear Type of gear - Hypoid
Final
Gear ratio
(Tooth number of gearl
- 3.700 (37/10) 3.900 (39110)
Type and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)
Front
Tooth Bevel gear 14
differential
number
Bevel pinion 10
Straight bevel gear

Type and number of gear - (Bevel pinion: 2,
Bevel gear : 2)
Center
differential
Tooth Bevel gear - 14
number
Bevel pinion - 10
Straight bevel gear

Type and number of gear - (Bevel pinion: 2, Bevel gear: 2)
Rear
differential
Tooth Bevel gear - 14
number
Bevel pinion - 10
3.3l1 (3.5 US qt, 3.5l1 (3.7 US qt,

Transmission oil capacity 2.6l1 (2.7 US qt, 2.3 Imp qt)
2.9 Imp qt) 3.1 Imp qt)
Rear differential gear oil capacity - 0.8l1 (1.7 US pt, 1.4 Imp pt)
9
SERVICE DATA
4WD FWD
DIFFERENTIAL ASSEMBLY DIFFERENTIAL ASSEMBLY

Bevel gear to pinion backlash Bevel gear to pinion backlash
0.13 - 0.18 mm (0.0051 - 0.0071 in) 0.13 - 0.18 mm (0.0051 - 0.0071 in)
Washer (38.1 x 50 x t) Washer (35.1 x 45 x t)
Part No. Thickness mm (in) Part No. Thickness mm (in) Part No. Thickness mm (in) Part No. Thickness mm (in)
0.925 - 0.950 1 .025 - 1 .050 0.925 - 0.950 1 .000 - 1 .025

803038021 803038023 803135011 803135014
(0.0364 - 0.0374) (0.0404 - 0.0413) (0.0364 - 0.0374) (0.0394 - 0.0404)
0.975 - 1.000 0.950 - 0.975 1 .025 - 1 .050
803038022 803135012 803135015
(0.0384 - 0.0394) (0.0374 - 0.0384) (0.0404 - 0.0413)
0.975 - 1 .000
803135013
(0.0384 - 0.0394)
Pinion shaft to axle drive shaft clearance
o - 0.2 mm (0 - 0.008 in)
Pinion shaft to axle drive shaft clearance
Snap ring (Outer-28) 0- 0.2 mm (0 - 0.008 in)
Part No. Thickness mm (in) Part No. Thickness mm (in) Snap ring (Outer-26)
805028011 1.05 (0.0413) 805028012 1.20 (0.0472) Part No. Thickness mm (in) Part No. Thickness mm (in)
805026010 1.05(0.0413) 031526000 1.20 (0.0472)

Drive pinion adjustment
Drive pinion shim

Drive pinion adjustment
Part No. Thickness mm (in) Part No. Thickness mm (in)
Drive pinion shim
32295AA030 0.150 (0.0059) 32295AA070 0.250 (0.0098)
32295AA040 0.175 (0.0069) 32295AA080 0.275 (0.0108) Part No. Thickness mm (in)
32295AA050 0.200 (0.0079) 32295AA090 0.300 (0.0118)
32295AA060 0.225 (0.0089) 32295AA100 0.500 (0.0197) 441967111 0.15 (0.0059)
441967112 0.175 (0.0069)
441967113 0.20 (0.0079)
441967114 0.225 (0.0089)
441967115 0.25 (0.0098)
441967116 0.275 (0.0108)
441967117 0.30 (0.0118)
441967118 0.50 (0.0197)
REVERSE IDLER GEAR SHAFT ASSEMBLY REVERSE IDLER GEAR SHAFT ASSEMBLY
Adjustment of reverse idler gear CP position Adjustment of reverse idler gear CP position
Reverse idler gear CP to transmission case (LH) wall clearance Reverse idler gear CP to transmission case (LH) wall clearance
1.5 - 3.0 mm (0.059 - 0.118 in)
6.0 - 7.5 mm (0.236 - 0.295 in)
Reverse shifter lever CP Reverse shifter lever CP
Part No. Mark Remarks Part No. Mark Remarks
32820AAOOO 0 Further from case wall 440627101 1 Further from case wall
32820AA010 No mark Standard 440627102 2 or No mark Standard
32820AA020 2 Closer to the case wall 440627103 3 Closer to the case wall
10
4WD FWD
After installing a suitable reverse shifter lever, adjust reverse idler gear- After installing a suitable reverse shifter lever, adjust reverse idler gear-
to-transmission case wall clearance to within 0 to 0.5 mm (0 to 0.020 to-transmission case wall clearance to within 0 to 0.5 mm (0 to 0.020
in) using washers. in.) using washers.
Washer (20.5 x 26 x t) Washer (15.5 x 21 x t)
Part No. Thickness mm (in) Part No. Thickness mm (in) Part No. Thickness mm (in) Part No. Thickness mm (in)
803020151 0.4 (0.016) 803020154 1.9 (0.075) 0.6 - 0.8 1.8 - 2.0
803015081 803015084
803020152 1.1 (0.043) 803020155 2.3 (0.091) (0.024 - 0.031) (0.071 - 0.079)
803020153 1.5 (0.059) 1.0 - 1.2 2.2 - 2.4
803015082 803015085
(0.039 - 0.047) (0.087 - 0.094)
1.4 - 1.6
803015083
(0.055 - 0.063)
DRIVE PINION SHAFT ASSEMBLY DRIVE PINION SHAFT ASSEMBLY

Select suitable shifter forks so that both coupling sleeve and reverse Select suitable shifter forks so that both coupling sleeve and reverse
driven gear are positioned in the center of their synchromesh driven gear are positioned in the center of their synchromesh
mechanisms. mechanisms.
1st-2nd sh ifter fork CP 1st-2nd shifter fork CP
Approach to 1st gear by 0.2 mm Approach to 2nd gear 0.2 mm

32804AA031 1 32804AA001 1
(0.008 in) (0.008 in)
32804AA041 No mark Standard 32804AA011 No mark Standard
Approach to 2nd gear by 0.2 mm Approach to 1st gear 0.2 mm
32804AA051 3 32804AA021 3
(0.008 in) (0.008 in)
3rd4th shifter fork CP 3rd4th shifter Fork CP
32810AA031 Approach to 4th gear by 0.2 mm Approach to 4th gear by 0.4 mm

1 32810AA110 1
*32810AA060 (0.008 in) (0.016 in)
32810AA041 Approach to 4th gear by 0.2 mm
No mark Standard 32810AA120 2
*32810AA070 (0.008 in)
32810AA051 Approach to 3rd gear by 0.2 mm 32810AA130 No mark Standard
3
*32810AA100 (0.008 in) Approach to 3rd gear by 0.2 mm
32810AA140 4
(0.008 in)
* Full-time 4WD Approach to 3rd gear by 0.4 mm
32810AA150 5
(0.016 in)
5th shifter fork CP
Part No. Mark Remarks

5th shifter fork CP
32812AA005 Approach to 5th gear by 0.2 mm
1 Part No. Mark Remarks
*32812AA060 (0.008 in)
32812AA015
No mark Standard Approach to gear side by 0.2 mm
*32812AA070 32812AA032 1
(0.008 in)
32812AA025 Become distant from 5th gear by
3 32812AA042 No mark Standard
*32812AA100 0.2 mm (0.008 in)
Become distant from gear side by
32812AA052 3
0.2 mm (0.008 in)
* Full-time 4WD
Rod end clearance
A: 3rd4th - 5th
Rod end clearance
0.6 - 1.4 mm (0.024 - 0.055 in)
A & B: 0.3 - 1.6 mm (0.012 - 0.063 in)
B: 1st-2nd - 3rd4th
0.5 - 1.5 mm (0.020 - 0.059 in)
11
4WD FWD
PRELOAD ADJUSTMENT OF THRUST BEARING

Drive pinion spacer
Part No. Length mm (in)
32288AAOOO 121.35 t 0.02 (4.7775 t 0.0008)

32288AA010 121.50 t 0.02 (4.7835 t 0.0008)
32288AA020 121.65 t 0.02 (4.7894 ± 0.0008)
Differential bevel gear sleeve
38956AAOOO 18.925 t 0.01 (0.7451 t 0.0004)

38956AA010 18.950 t 0.01 (0.7461 t 0.0004)
38956AA020 18.975 t 0.01 (0.7470 t 0.0004)
38956AA030 19.000 t 0.01 (0.7480 t 0.0004)
38956AA040 19.025 t 0.01 (0.7490 t 0.0004)
38956AA050 19.050 t 0.01 (0.7500 t 0.0004)
38956AA060 19.075 t 0.01 (0.7510 t 0.0004)
FINAL GEAR ASSEMBL V FINAL GEAR ASSEMBL V

Hypoid gear backlash: Hypoid gear backlash:
0.13 - 0.18 mm (0.0051 - 0.0071 in) 0.13 -.0.18 mm (0.0051 - 0.0071 in)
TRANSFER CASE ASSEMBL V REAR CASE ASSEMBL V
Main shaft rear plate Main shaft rear plate
Dimension "A" mm On) Part No. Mark. Dimension "A" mmOn) Part No. Mark
4.00 - 4.13 (0.1575 - 0.1626) 32294AA040 1 4.50 - 4.63 (0.1772 - 0.1823) 441347001 T81-1
3.87 - 4.00 (0.1524 - 0.1575) 32294AA050 2 4.37 - 4.50 (0.1720 - 0.1772) 441347002 T81-2
Neutral position adjustment Neutral position adjustment
Reverse accent shaft Reverse accent shaft
Part No. Mark Remarks Part No_ Mark Remarks
32188AA020 A Neutral position is closer to 1st. 32188AA040 1 Neutral position is closer to 1st.
32188AA002 B Standard 32188AAOll 2 Standard
32188AA030 C Neutral position is closer to reverse. 32188AA050 3 Neutral position is closer to reverse.
Reverse check plate adjustment Reverse check plate adjustment
Reverse check plate Reverse check plate
Part No. Mark Angle (J Remarks Part No. Mark Angle (J Remarks
32189AAOOO 0 28° Arm stops closer to 5th gear. 32189AAOOO 0 28° Arm stops closer to 5th gear.
32189AA010 1 31° Arm stops closer to 5th gear. 32189AA010 1 31° Arm stops closer to 5th gear.
33189AA020 2 34° Arm stops in the center. 33189AA012 2 34° Arm stops in the center.
32189AA030 3 37° Arm stops closer to reverse gear. 32189AA030 3 37° Arm stops closer to reverse gear.
32189AA040 4 40° Arm stops closer to reverse gear. 32189AA040 4 40° Arm stops closer to reverse gear.
12
4WD FWD
Snap ring to ball bearing side clearance:

o - 0.1 mm (0 - 0.004 in)
Snap ring (Inner-56)
Part No. Thickness mm (in)
805156020 1.735 - 1.765 (0.0683 - 0.0695)

805156021 1.815 - 1.845 (0.0715 - 0.0726)
805156022 1.895 - 1.925 (0.0746 - 0.0758)
CENTER DIFFERENTIAL & EXTENSION ASSY

0- 0.2 mm (0 - 0.008 in)
Snap ring (I nner-80)
805180020 1.72 - 1.78 (0.0677 - 0.0701)

805180030 1.87 - 1.93 (0.0736 - 0.0760)
805180040 2.02 - 2.08 (0.0866 - 0.0819)
Backlash adjustment
axial movement: 0.4 - 0.6 mm (0.016 - 0.024 in)
Differential bevel washer
38960AA001 0.95 -1.05 (0.0374 - 0.0413)

38960AA011 1.15 - 1.25 (0.0453 - 0.0492)
38960AA021 1.35 - 1.45 (0.0531 - 0.0571)
38960AA031 1.55 - 1.65(0.0610 - 0.0650)
38960AA041 1.75 - 1.85 (0.0689 - 0.0728)
38960AA051 1.95 - 2.05 (0.0768 - 0.0807)

0- 0.2 mm (0 - 0.008 in)
Snap ring (Outer-50)
805050030 1.97 - 2.03 (0.0776 - 0.0799)

805050040 2.12 - 2.18 (0.0835 - 0.0858)
805050050 2.27 - 2.33 (0.0894 - 0.0917)
13
(")
I Tightening sequence I
Size Torque
...-4
Q) 0
All models
:::J
~
8 mm bolt @-@
23 - 26 N·m
(2.3 - 2.7 kg·m.
17 - 20 ft·lb)
_.en
en
3 '"U
0
CD-@ 36 - 42 N·m _.
en
Z
10 mm bolt (3.7 - 4.3 kg·m. 0
@-@ 27 - 31 ft·lb) :::J m ~
Z }>
3: -f Z
_.
Q) C
}>
~
Tightening torque: N·m (kg-m, ft-Ib)
1
4WD
I
:::J r
T1: 41 - 47 (4.2 - 4.8,30 - 35)
(') ~
@ Q) :D :0
en -f }>
@@, ~
~
CD en Z
(J)
(j'i@'l ~
~cv
~,~
(J)
(J)
~\
oz
}>
z
o
o
."
."
1 Transmission case ASSY
m
@'@ :0
2 Gasket "~I m
3 Drain plug Z
4 Snap ring (OUn
Speedometer driven gear
@.@..d, ~
5 ,, }>
6 Stud r
7 Speedometer shaft
8 Snap ring (OUT)
9 Oil seal
10 Radio ground cord
11 Clip
12 Oil level gauge
14 Clip
15 Oil gauge guide
16 Oil seal
Rear Case
1 Rear case
Tightening torque: N·m (kg-m, ft~b) 2 Oil guide
T1: 6.4 (0.65,4.7) 3 Case gasket
4 Oil seal
T2: 18 (1.8 , 13)
5 Back-up light switch ASSY
T3: 23 - 26 (2.3 - 2.7, 17 - 20) 6 Gasket
7 Transmission hanger
8 Neutral switch ASSY
Fig. 14 L3-886
15
Transfer Case and Transfer Control System

Selective 4WD

T1: 18 (1.8, 13)
T2: 25 (2.5, 18)
T3: 10 (1.0,7)
T4: 20 (2.0, 14)
T5: 16 (1.6, 12)
T6: 5 (0.5, 3.6)
1 Transfer case CP
2 Oil guide
3 Needle bearing race
5 Oil seal
6 Gasket
7 Transfer cover
8 Cover gasket
9 Back·up light switch ASSY
(j)
10 Gasket
@ 11 Oil seal
12 Support
13 Stay
14 Transfer shifter fork CP
15 Transfer shifter rod
16 Spring
17 Spring pin
18 Ball
20 Transfer shifter shaft
26 Ball
28 Clip
30 Spring
32 Spring pin
33 Oil seal
34 Clevis pin
35 Snap pin
36 Transfer shifter lever
37 Neutral switch ASSY
38 Actuator
39 Cable ASSY
40 4WD vacuum switch ASSY
41 Check valve
Fig. 15 L3-895
16
Full-Time 4WD
CD
(
® @
~~
)
I
® * Selective parts
1 Actuator ASSY
2 Check valve
4 Vacuum hose connector
5 Vacuum switch ASSY
6 Transfer cover
(j) 7 Transfer cover gasket
8 Transfer gear set
® 9 Transfer case CP
10 Oil seal
Snap ring (lnner-72)

Needle bearing
Cable ASSY
Back·up light switch ASSY
Neutral switch ASSY
(MPFI)
16 Differential lock shaft
17 Differential lock fork
18 Spring pin
19 Differential lock rod
20 Oil guide
21 Lock nut
22 Lock washer
*23 Snap ring (I nner·56)
24 Ball bearing
25 Gasket
26 Oil seal
27 Spring pin
28 Lever CP
29 Clevis pin
30 Snap pin
31 Bracket CP
32 Boot B
33 Harness stay CP (1800 cc)
L3·887
Fig. 16
17
Extension
Selective 4WD
1 Extension CP
2 Dust cover
3 Washer
4 Sleeve
5 Synchronizer hub
6 Rear d rive shaft
7 Spacer
8 Bushing
9 Transfer driven gear
11 Lock nut
12 Lock washer
13 Snap ring (IN)
14 Ball bearing
15 Oil seal
Tightening torque: N'm (kg-m, ft-Ib) 16 Ball bearing
T1: 37 (3.8,27) 17 Gasket
T2: 18 (1.8, 13) 18 4WD switch ASSY
T3: 78 (8.0, 58)
Fig. 17 L3-435
18
Extension and Center Differential

Full-Time 4WD
* Selective parts
1 Snap ring (I nner-37)

2 Needle bearing
3 Extension CP
4 Oil seal
5 Dust cover
6 Shifter bracket
7 Extension cover
8 Gasket
9 Transfer gasket
*10 Snap ring (Outer-50)
11 Ball bearing
*12 Snap ring (Inner-80)
13 Differential lock sleeve
/-1
;' I
I
I
I
I
I
;'
/
/
;'
/
/
/
/
/ I
" I
~
/
I
/
/ "" )
I
I
./ I
I
"
(j]) 14 Needle bearing

I 15 Hexagon socket head bolt
I
16 Transfer gear set
~
17 Center differential pinion shaft
18 Differential bevel pinion
19 Differential bevel gear
*20 Washer
@ 21 Center differential case
22 Plug
23 Gasket
24 Spring
25 6.350 ball
L3-888
Fig. 18
19
Shifter Fork and Shifter Rod

*Selective parts G@
*2
3
*4
1st-2 nd fork rod
1st-2nd shifter fork CP
3rd4th fork rod
3rd4th shifter fork CP
@®~
*5 5th shifter fork CP
6 Reverse fork rod
*7 Reverse shifter lever CP
8 Reverse fork rod arm
9 Shifter fork screw
10 I nterlock plunger
11 Interlock plunger ®
o
12 Spring
13 Checking ball spring
*(jj
~@
14 Checking ball plug
15 Selector arm
16 Shifter arm CP (4WD)
®
f /, /
17 Shifter arm CP (FWD)
18 Reverse accent spring I
19 Reverse checking sleeve I
20 Reverse checking cam ®
21 Reverse checking spring
22 Reverse return spring @ /// //1
*23 Reverse accent shaft ~ I() /.-" I
*24 Reverse check plate / ' /.-" I
25 Snap ring (IN) 1/
26 O-ring © tJ
27 Adjusting select shim /"
28 Straight pin @
29 Ball
30 Ball
31 Bolt & washer ASSY
32 Snap ring (OUT)
33 Gasket
34 Gasket
35 Filler
36 1st-2nd fork rod
*37 1st-2nd shifter fork CP
38 3rd4th fork rod
*39 3rd4th shifter fork CP *@
*40 5th shifter fork CP FWD
41 Reverse fork rod
*42 Reverse shifter lever CP
43 Reverse fork rod arm
44 Interlock plunger
45 Snap ring (OUT)
Tightening torque: N-m (kg-m, ft-Ib)

T1: 20 (2, 14)
T2: 10 (1,7)
Fig_ 19 L3-334
20
Transmission Main Shaft

FWD
"Selective parts
1 Oil seal
2 Needle bearing
3 Transmission main shaft
4 Woodruff key
5 5th needle bearing race
6 Needle bearing
7 Baulk ring
8 Synchronizer spring
9 Synchronizer hub
10 Coupling sleeve
11 3rd4th gear set
12 Shifting insert
13 4th gear thrust washer
14 Ball bearing
"15 Main shaft rear plate
16 5th gear set
17 Lock washer
18 Lock nut
*19 Washer
9 20 Reverse idler gear CP
21 Straight pin
® ([j)
22 Reverse idler gear shaft
7

T1: 73 - 84 (7.4 - 8.6, 54 - 62)
L3·251
Fig. 20
21
AII4WD
* Selective parts
2 Transmission main shaft

3 Oil seal
4 Needle bearing
5 Shifting insert
6 Baul k ring
7 Synchronizer spring
(j) 8 Synchronizer hub
9 Coupling sleeve
10 3rd-4th gear set
11 Needle bearing race
@ 12 4th gear thrust washer
13 Ball bearing
14 5th gear thrust washer
15 5th needle bearing race
*16 Main shaft rear plate
17 5th gear set
18 Synchronizer hub
19 I nsert stopper plate
20 Lock washer
21 Lock nut
22 Washer
23 Reverse idler gear CP
24 Straight pin
25 Reverse idler gear shaft

T1: 118(12.0,87)
Fig. 21
L3·5Q0
22
Drive Pinion Shaft

FWD @
/1
/ I
I
I
I
I
/' )
/ /'
/
,/ /
,/ ,/
,/
,/
./
/'
,/
/
,/
,/
./
,,- /
./ /
/ /
/
/
,,-
/
,/
./
./
/
r *Selective parts
I
I *15 Drive pinion shim
1 Drive pinion shaft
I 16 Ball bearing
2 Key
I 3 Roller bearing 17 5th gear thrust washer
I 4 1st gear thrust washer 18 5th needle bearing race
I 5 Needle bearing 19 5th driven gear
I 6 1st·2nd needle bearing race 20 Baulk ring
V,/ 7 1st driven gear 21 Synchronizer spring
8 1st-2nd baulk ring 22 Synchronizer hub
9 1st-2nd synchronizer spring 23 Shifting insert
10 1st-2nd synchronizer hub 24 Coupling sleeve
11 1st-2nd shifting insert 25 Insert guide
12 Reverse driven gear 26 I nsert stopper plate
Tightening torque: N'm (kg-m, ft-Ib) 13 2nd driven gear 27 Lock washer
14 3rd4th driven gear 28 Lock nut
T1: 26 - 32 (2.7 - 3.3,20 - 24)
T2: 78 (8.0, 58)
Fig. 22 L3·177
23
Selective 4WD
13 2nd driven gear CP

• Selective parts 14 3rd-4th driven gear
·15 Drive pinion shim
Drive pinion shaft 16 Ball bearing
1
17 5th driven gear
2 Key
18 Drive pinion collar
3 Woodruff key
19 Transfer drive gear
4 Roller bearing
20 5th needle beari ng race
5 1st gear thrust washer
21 Needle bearing
6 1st-2nd driven gear bushing
22 Lock washer
7 1st driven gear CP
23 Lock nut
8 1st-2nd baulk ring
9 1st-2nd synchronizer spring 24 1st driven gear spring
10 1st-2nd shifting insert 25 Washer
11 1st-2nd synchronizer hub 26 Snap ring (Outer)
12 Reverse driven gear 27 2nd driven gear spring

T1: 26 - 32 (2.7 - 3.3, 20 - 24)
T2: 112 - 124 (11.4 - 12.6,82 - 91)
Fig_ 23 L3-889
24
Full-Time 4WD ;' I

/1
I
I
I
I
I
I ®
)
;'
I
I
I
I
I
I
, /
/
/
;'
/'
I
I
* Selective parts
I
;'
)
/'
@ /
;'
;'
/
/' 1st driven gear
/
11
/ 12 Needle bearing
/'
13 Woodruff key
14 Key
15 Driven shaft
16 Lock nut
17 Lock washer
20 Roller bearing
*21 Drive pinion shim
22 2nd driven gear bush
23 2nd driven gear
24 Washer
25 Lock nut
26 Lock washer
*27 Differential bevel gear
sleeve
Drive pinion collar *28 Drive pinion spacer
2 Roller bearing 29 Thrust bearing
3 Needle bearing 30 Washer
4 Thrust bearing 31 Drive pinion shaft
5 Washer 32 3rd-4th driven gear
6 Balk ring 33 5th driven gear
7 Reverse driven gear 34 1 st driven gear spring
8 Spring 35 Washer
9 1 st-2nd synchronizer hub 36 Snap ring (Outer)
10 Insert 37 2nd driven gear spring
Fig. 24 L3-868
25
Differential
• Selective parts
1 Hypoid gear set (FWD)

2 Hypoid gear set
(Selective 4WD)
3 Pinion shaft
4 Straight pin
*5 Washer
6 Differential bevel gear
14
15 Retainer lock plate
16 Hypoid gear set
(Full time 4WD)
Tightening torque: N·m (kg·m, ft-Ib)

T1: 57 - 67 (5.8 - 6.8, 42 - 49)
T2: 25 (2.5, 18)
Fig. 25 L3-890
26
SERVICE PROCEDURE
The vehicle models listed after the description of each service 3) Removing actuator & cable ASSY
procedure indicate the vehicle models to which that procedure Using REMOVER II (398791600), drive out spring pin (5.2 x
28) connecting transfer shifter shaft and transfer shifter lever
applies. If an item does not list any vehicle model, it applies to
on the right side of transfer case. Remove transfer shifter lever
all models.
from transfer shifter shaft. Remove snap pin and extract 8-mm
clevis pin. Then, remove cable from transfer shifter lever.
Remove five 8-mm bolts & washers (three on actuator and two
on cable) and remove actuator & cable ASSY.
Transfer shifter shaft CP
Spring pin (5.2 x 28)
[A] Selective 4WD Cable end

[1] Overall Transmission
Clevis pin
DISASSEMBLY
Transfer shifter lever CP
The following job should be followed before disassembly;

• Clean oil, grease, dirt and dust from transmission.
• Remove drain plug to drain oil. After draining, retighten L3·253
it as before.
Fig. 27
• Replace gasket with a new one.
Tightening torque:
41 - 47 N·m (4.2 - 4.8 kg-m, 30 - 35 ft-Ib)
4) Removing transfer cover
Remove transfer cover by loosening four bolts.
1) Attach transmission to TRANSMISSION STAND SET
(399295120).
2) Remove release lever and clutch release bearing.
(1) Remove two clutch sleeve clips from transmission
Transfer cover
front, and then clutch release bearing.
(2) Remove release dust cover. Next, remove release lever
retainer spring from release lever by pushing release lever
from outside main case, and take out lever.
Be careful not to deform clutch sleeve clips and release lever

retainer spring.
L3·501
Fig. 28
5) Removing straight pin in transfer shifter fork CP

Using REMOVER II (398791600), drive out straight pin
(5 x 25).
6) Removing transfer shifter rod and transfer shifter fork
0
Extract transfer shifter rod by turning it 180 • Remove
L3·338 transfer shifter fork. Also remove ball (6.35) and checking ball
Fig. 26 spring from transfer case.
27
a. When taking out fork, move reverse checking sleeve 2 to 10) Remove transfer case plug with gasket and then remove
3 mm (0.08 to 0.12 in) toward outside by loosening it. reverse accent spring and ball (7.1438).
b. Be careful not to dr~p ball when removing transfer shifter
rod.
Transfer shifter fork CP
Spring Tra nsfer sh ifter rod
L3-502
L3.256 Fig. 32
~----------------------------------------~
Fig. 29
7) Removing bolts from extension 11) Remove the two bolts from reverse check sleeve ASSY
Remove seven bolts from extension. and move the sleeve ASSY until it rotates freely.
Extension
LReverse check sleeve

L3·111
L3·503
Fig. 30
Fig. 33
8) Removing extension and transfer gear ASSY

Remove extension & transfer gear ASSY.
9) Removing transfer shifter shaft 12) Removing shifter fork screw from selector arm
Remove shifter fork screw securing selector arm to shifter arm
Extract transfer shifter shaft from the right side of transfer
case. CPo
Fig. 31
L3·257
Fig. 34
---- L3·204
28
13) Removing transfer case and shifter ASSY

Loosen eight bolts, and remove transfer case and shifter ASSY
from transm iss ion case by tapping with a plastic hammer.
14) Removing bearing mounting bolts
Remove four bolts mounting ball bearing behind drive pinion
shaft ASSY.
L3-258
Fig. 37
18) Removing drive pinion shaft
Drive pinion shaft ASSY
Remove drive pinion shaft ASSY from LH transmission.
Use a hammer handle, etc. to remove if too tight.

L3-208
I I
Fig. 35
15) Remove main shaft rear plate_

16) Putting vinyl tape around axle drive shafts
Put vinyl tape around splines of right and left axle drive shafts
to prevent damage to oil seals.
Fig. 38
19) Removing transmission main shaft ASSY
Remove main shaft ASSY from LH transmission case.
20) Removing differential ASSY
Remove differential assembly from transmission case.
a. Be careful not to confuse right and left roller bearing outer

races.
b. Be careful not to damage retainer oil seal.
Fig. 36
17) Separating transmission case

Separate transmission case into right and left cases by loosen-
ing seventeen coupling bolts.
Work with nuts facing upward.
Fig. 39
29
21) Removing 5th shifter fork 24) Removing reverse idler gear
Remove spring pin from 5th shifter fork by driving with Pullout straight pin and reverse idler gear shaft. Then, remove
STRAIGHT PIN REMOVER 2 (398791700). reverse idler gear CP and washer (15.5 x 21 x T).
When pulling out straight pin, wash off oil and blow air on it
for easy removal.
Fig. 40
Fig. 42
22) Removing checking ball plugs

Remove three checking ball plugs from main case.
25) Removing arm and rod
There are spring and ball inside. Replace gasket with a new Remove outer snap ring, and pUllout reverse shifter rod arm
one. from reverse fork rod. Then take out ball, spring and interlock
plunger from rod.
23) Removing fork and rod And then remove rod.
Using STRAIGHT PIN REMOVER 2 (398791700), drive out
spring pins from 1-2 shifter fork CP and 3-4 shifter fork CP, When pulling out reverse shifter rod arm, be careful not to let
and remove 3-4 fork rod and 3-4 shifter fork CPo Then, pull ball pop out of arm.
out 1-2 fork rod and remove 1-2 shifter fork CPo
26) Remove reverse shifter lever.
When removing rod, keep other rods in neutral. Also, when 27) Removing differential side retainer ASSY
pulling out spring pin, remove it toward inside of case so that Using WRENCH ASSY (499787000)' remove differential side
it may not hit against case. retainer ASSY from transmission case.
'----_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _--=L~3-_=2_15::..J A 12-020

F~_41 F~_43
30
28) Removing speedometer driven gear 4) Balk ring

Remove outer snap ring and pull out speedometer driven gear. Replace the ring in the following cases:
Next, remove speedometer shaft CP and washer (12.5 x 15.5 • When the inner surface and end face are damaged.
x 1) from main case. • When the ring inner surface is abnormally or partially
worn down.
• If the gap between the end faces of the ring and the
gear splined part is excessively small when the ring is
pressed against the cone.
• When the contact surface of the synchronizer insert is
scored or abnormally worn down.
Synchronizer ring
Limit: 0.5 mm (0.020 in)
L3·216
Fig. 44
A12-254
Fig. 45
INSPECTION
Disassembled parts should be washed clean first and then

inspected carefully.
1) Bearings 5) Insert (shifting)
Replace bearings in the following cases: Replace the insert if deformed, excessively worn, or defective
• Bearings whose balls, outer races and inner races are in any way.
broken or rusty. 6) Oil seal
• Worn bearings. Replace the oil seal if the lip is deformed, hardened, damaged,
• Bearings that fail to turn smoothly or make abnormal worn, or defective in any way.
noise when turned after gear oil lubrication. 7) a-ring
The ball bearing on the rear side of the drive pinion Replace the a-ring if the sealing face is deformed, hardened,
should be checked for smooth rotation before the drive damaged, worn, or defective in any way.
pinion ASSY is disassembled. In this case, because 8) Gearshift mechanism
a preload is working on the bearing, its rotation feels Repair or replace the gearshift mechanism if excessively worn,
slightly qragging unlike the other bearings. bent, or defective in any way.
• Bearings having other defects. 9) Differential gear
2) Bushing (each gear) Repair or replace the differential gear in the following cases.
Replace the bushing in the following cases: (1) The hypoid drive gear and drive pinion shaft tooth
(1) When the sliding surface is damaged or abnormally surfaces are damaged, excessively worn, or seized.
worn. (2) The roller bearing on the drive pinion shaft has a
(2) When the inner wall is abnormally worn. worn or damaged roller path.
3) Gears (3) There is damage, wear, or seizure of the differential
(1) Replace gears with new ones if their tooth surfaces bevel pinion, differential bevel gear, washer, pinion shaft,
are broken, damaged, or excessively worn. and straight pin.
(2) Correct or replace if the cone that contacts the balk (4) The differential case has worn or damaged sliding
ring is rough or damaged. surfaces.
(3) Correct or replace if the inner surface or end face
is damaged.
31
Apply grease to plunger to prevent it from falling.
ASSEMBLY
® Plug
Replace gaskets with new ones. Position ball (7.1438). spring and gasket in reverse shifter rod
hole on L. H. transmission case, and tighten checking ball plug.
1) Assembling parts in transmission case (LH).
CD Interlock plunger (5.56 x 19.6) Tightening torque:
Position two interlock plungers (5.56 x 19.6) in holes on the 20 N·m (2 kg-m, 14 ft-Ib)
inner wall of left transmission case, one interlock plunger in
hole between 1-2 and 34 fork rod holes, and one interlock
plunger in hole between 3-4 and reverse fork rod holes.
o
o
Through hole
~~~©J
L3-259
Fig. 48
L3-349
Fig. 46
@ Adjustment of reverse idler gear CP position

® Reverse idler gear CP Move reverse sh ifter rod toward REV side. Adjust so clear-
Position reverse shifter lever CP in L.H. transmission case. ance between reverse idler gear CP and L.H. transmission case
Install reverse idler CP and reverse idler gear shaft, and secure wall is 6.0 to 7.5 mm (0.236 to 0.295 in). using reverse shifter
with straight pin (6 x 411). lever CPo
Be sure to install reverse idler shaft from the rear side.
~ L3-350
Fig. 49
Fig. 47 Reverse shifter lever CP
Part No. No. Remarks

® Reverse fork rod and reverse fork rod arm.
Install reverse arm fork spring, ball (5.5563) and interlock 32820AAOOO 0 Further from case wall.
plunger (5.56 x 19.6) to reverse fork rod arm. Insert reverse
fork rod into hole in reverse fork rod arm, and hold it with 32820AA010 - Standard.
outer snap ring using ACCENT BALL INSTALLER (39941
32820AA020 2 Closer to case wall.
1700).
32
® Clearance adjustment
After installing a suitable reverse shifter lever CP, shift into
Neutral. Adjust so clearance between reverse idler gear CP and
L.H. transmission case wall is 0 to 0.5 mm (0 to 0.020 in),
using washer(s).
REMOVER 2
(398791600)
Fig. 51
a. Set other rods to Neutral.

b. Make sure interlock plunger (5.56 x 19.6) is on the 3-4 fork
rod side.
Fig. 50
(4) Install 5th shifter fork CP onto the rear of reverse
fork rod. Align holes in the two parts and drive straight
pin into place.
@ Plug
Position balls (7.1438 mm dia.), checking ball springs and
gaskets into 3-4 and 1-2 rod holes, and install plugs.
Washer (20.5 x 26 x t)
803020151 0.4 (0.016)
803020152 1.1 (0.043)
803020153 1.5 (0.059)
803020154 1.9 (0.075)
803020155 2.3 (0.091)
(j) Rod and fork L3-352

(1) Install interlock plunger (3 x 11.9) onto 3-4 fork rod. Fig. 52
Apply a coat of grease to plunger to prevent it from falling.
(2) Install 3-4 fork rod into 3-4 shifter fork CP via the
hole on the rear of L.H. transmission case. Align the holes Tightening torque:
in rod and fork, and drive straight pin (6 x 22) into these 20 N·m (2 kg-m, 14 ft-Ib)
holes using STRAIGHT PIN REMOVER (398791600).
a. Set reverse fork rod to Neutral.

b. Make sure interlock plunger (installed before) is on the
reverse fork rod side.
(3) Install 1-2 fork rod into 1-2 shifter fork CP via the
hole on the rear of L.H. transmission case. Align the holes
in rod and fork, and drive straight pin (6 x 22) into these
holes using STRAIGHT PIN REMOVER (398791600).
33
2) Alignment marks/figures on hypoid gear set.
Adjust clearance to zero
A12'()74
A12-413 Fig. 55
Fig. 53 (5) The thickness of shim shall be determined by adding
the value indicated on drive pinion to the value indicated
The upper figure on drive pinion is the match number for com- on the gauge. (Add if the figure on drive pinion is pre-
bining it with crown gear. The lower figure is for shim adjust- fixed by + and subtract if the figure is prefixed by -.)
ment. If no lower figure is shown, the value is zero. The figure Select one to three sh ims from the next table for the
on crown gear indicates a number for combination with drive value determined as described above and take a shim
pinion. thickness which is closest to the said value.
3) Adjustment of drive pinion shim Drive pinion shim

(1) Place drive pinion shaft on transmission main case
(R.H.) without shim and tighten drive pinion.
32295AA030 0.150 (0.0059)
Tightening torque:
26 - 32 N·m (2.7 - 3.3 kg-m, 20 - 24 ft-Ib) 32295AA040 0.175 (0.0069)
32295AA050 0.200 (0.0079)

(2) Inspection and adjustment of GAUGE ASSY
(499917500). 32295AA060 0.225 (0.0089)
a. Loosen the two bolts and adjust so that the scale
indicates 0.5 correctly when the plate end and the 32295AA070 0.250 (0.0098)
scale end are on the same level.
32295AA080 0.275 (0.0108)
b. Tighten two bolts.
32295AA090 0.300 (0.0118)
1 Plate 32295AA100 0.500 (0.0197)

2 SCALE (899914105)
4) Differential ASSY
Install differential ASSY onto L.H. transmission case.
A12'()73
Fig. 54
(3) Position the gauge by inserting the knock pin of

gauge into the knock hole in the transmission case.
(4) Slide the drive pinion gauge scale with finger tip and
read the value at the point where it matches with the end
face of drive pinion. Fig. 56
34
a. Wrap the left and right splined sections of axle shaft with d. Be careful not to drop oil seal when installing RH trans·
vinyl tape to prevent scratches. mission main case.
b. Be careful not to fold the sealing lip of oil seal. e. Make sure straight pin is positioned in hole in needle
bearing's outer race.
5) Transmission main shaft ASSY
Install needle bearing and oil seal onto the front of trans- 6) Install drive pinion with shims selected before into trans-
mission main shaft ASSY, and position in LH transmission mission case.
case.
Ensure that the knock pin of the case is fitted into the hole in
a. Wrap clutch splined section with vinyl tape to prevent the bearing outer race.
damage to oil seal.
b. Apply grease (Unilube #2 or equivalent) to the sealing 7) Selection of suitable 1st-2nd, 3rd-4th and 5th shifter fork
lip of oil seal. CPs.
c. Align the end face of seal with surface A of LH trans· Set transmission main shaft ASSY and drive pinion shaft
mission main case when installing oil seal. ASSY in position (so there is no clearance between the two
when moved all the way to the front). Select suitable 1st-2nd,
3rd-4th and 5th shifter fork CP's so that coupling sleeve and
reverse driven gear are positioned in the center of their
synchronizing mechanisms.
A12-099
Fig. 57
1 st-2nd shifter fork CP 3rd-4th shifter fork CP 5th shifter fork CP
Part No. No. Remarks Part No. No. Remarks Part No. No. Remarks
Moves 0.2 mm Moves 0.2 mm Moves 0.2 mm

32810AA031 32812AA004 (0.008 in) closer to
32804AA031 1 (0.008 in) closer to 1 (0.008 in) closer to 1
*32810AA060 *32812AA060
1st gear 4th gear 5th gear
Positions in the 32810AA041 Positions in the 32812AA014 Positions in the

32804AA041 - center *32810AA070
- center *32812AA070
- center

32810AA051 32812AA024
32804AA051 3 (0.008 in) closer to 3 (0.008 in) closer to 3 (0.008 in) closer to
*32810AA100 *32812AA 100
2nd gear 3rd gear 5th gear
* Full-time 4WD
35
9.5 Reverse driven gear

(0.374)
1 st driven
2nd driven
gear CP
gear CP
'-----c:. _ _ _ _ _ _ _ _ _ L3-143
Unit: mm (in) L3-869
Fig. 58 1st-2nd shifter fork Fig. 61
9) Wipe off grease, oil and dust on the mating surfaces of

transmission cases with white gasoline, and apply liquid gasket
(Fuji Bond "C" or equivalent), and then put case (RH) and
(LH) together.
10) Tighten 17 bolts with bracket, clip, etc. in the following
sequence.
Unit: mm (in) L3-141

Fig. 59 3rd-4th shifter fork
5th drive gear • 10 mm bolt

A12-369
Fig. 62
Tightening torque:
8 mm bolt
23 - 26 N·m (2.3 - 2.7 kg-m. 17 - 20 ft-Ib)
10 mm bolt
36 - 42 N·m (3.7 - 4.3 kg-m. 27 - 31 ft-Ib)
L3-142
Fig. 60 5th shifter fork
a. Insert bolts from the bottom and tighten nuts at the top.
b. Put cases together so that drive pinion shim and input shaft
holder shim are not caught up in between.
c. Confirm that counter gear and speedometer gear are
meshed, and high-low shifter shaft is inserted perfectly.
8) Inspection of rod end clearance
Measure rod end clearances A and B. If any clearance is not 11} Tighten ball bearing attaching bolts at the drive pinion
within specifications, replace rod of fork as required. rear.
A: 3-4 - 5 0.6 - 1.4 mm (0.024 - 0.055 in) Tightening torque:

26 - 32 N·m
B: 1-2 - 3-4 0.5 - 1.5 mm (0.020 - 0.059 in) (2.7 - 3.3 kg-m, 20 - 24 ft-Ib)
36
12) Backlash adjustment of hypoid gear and preload adjust- e. Turn in the retainer on the upper side additionally by
ment of roller bearing. Y2 to 1 notch in order to apply preload on taper roller
a. Place the transmission with case (LH) facing down- bearing.
ward and put WEIGHT (399780104) on bearing cup. f. Tighten temporarily both the upper and lower lock
b. Screw retainer ASSY into case (LH) from the bottom plates and mark both holder and lock plate for later
with WRENCH (499787000). Fit HANDLE (499927100) readjustment.
on the transmission main shaft. Shift gear into 5th and g. Turn transmission main shaft dozens of turns while
turn the shaft several times. Screw in the retainer while tapping around retainer lightly with plastic hammer.
turning HANDLE until a slight resistance is felt on h. Set DIAL GAUGE (498247100) and MAGNET BASE
WRENCH. (498247001). Insert the needle through transmission oil
This is the contact point of hypoid gear and drive pinion drain plug hole so that the needle comes in contact with
shaft. Repeat the above sequence several times to ensure the tooth surface at a right angle and check the backlash.
the contact point.
Backlash:
0.13 - 0.18 mm (0.0051 - 0.0071 in)
:;/\ WRENCH (499787000)
A12-106
Fig. 63
MAGNET BASE
c. Remove weight and screw in retainer without D-ring on (498247001 )
the upper side and stop at the point where slight A12-512
resistance is felt. Fig. 65
At this point, the backlash between the hypoid gear and drive
pinion shaft is zero. 13) Checking tooth contact of hypoid gear.
Apply a uniform thin coat of red lead on both tooth surfaces
of 3 or 4 teeth of the hypoid gear. Move the hypoid gear back
WRENCH (499787000)- and forth by turning the transmission main shaft until a
definite contact pattern is developed on hypoid gear, and
judge whether face contact is correct. If it is incorrect, make
the following correction.
a. Tooth contact is correct.
A12-510
Fig. 64
d. Fit lock plate. Loosen the retainer on the lower side by
1Y, notches of lock plate and turn in the retainer on the
upper side by the same amount in order to obtain the
Coast side
backlash.
The notch on the lock plate moves by Yz notch if the plate is A12-114
turned upside down. Fig. 66
37
b. Backlash is excessive. e. The drive pinion shim selected before is too thin.
To reduce backlash, loosen holder on the upper side (case Increase its thickness.
R.H. side) and turn in the holder on the lower side (case
L.H. side) by the same amount.
A12·113
Fig. 70
A12·110
Fig. 67
c. Backlash is insufficient.
To increase backlash, loosen holder on the lower side 14) After checking the tooth contact of hypoid gears, remove
(case L.H. side) and turn in the holder on the upper side the lock plate. Then loosen retainer until the a'ring groove
(case R.H. side) by the same amount. appears. Fit a·ring into the groove and tighten retainer into
the position where retainer has been tightened in.
Tighten lock plate.
Tightening torque:
22 - 27 N·m
(2.2 - 2.8 kg·m, 16 - 20 ft·lb)
Carry out this job on both upper and lower retainers.
15) Selecting of main shaft rear plate.

Using DEPTH GAUGE (498147000), measure the amount (A)
'--_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _. ;. A;..:.1.:.2·. .:.1. ;. 11.;.; of ball bearing protrusion from transmission main case surface
Fig. 68 and select the proper plate in the following table.
d. The drive pInion shim selected before is too thick.

Reduce its thickness. Dimension A mm (in) Part No. Identification
4.0 - 4.13
32294AA040 1
(0.1575 -0.1626)
3.87 - 4.0
32294AA050 2
(0.1524 - 0.1575)
Before measuring, tap the end of main shaft by the plastic

hammer lightly in order to make the clearance zero between
the main case surface and the moving flange of bearing.
A12·112
Fig. 69
38
18) I nstall ball (7.1438), reverse accent spring, aluminum

A
gasket and plug in that order.
L3-147
Fig. 71
L3-502
Fig. 73
16) Transfer case & shifter ASSY

Secure transfer case & shifter ASSY to transmission case with
Tightening torque:
eight bolts.
10 N·m (1.0 kg·m, 7 ft·lb)
Tightening torque:
19) Neutral position adjustment
25 N·m (25 kg·m, 18 ft·lb)
(1) Shift gear into 3rd gear position.
(2) Shifter arm turns lightly toward the 1st/2nd gear side
Be sure gasket is positioned on the rear of the case.
but heavily toward the reverse gear side because of the
function of the return spring, until arm contacts the
17) Tighten selector arm.
stopper.
Secure selector arm to shifter arm CP with shifter fork screw.
(3) Make adjustment so that the heavy stroke (reverse
Shifter arm CP should be caught by pawl of rod.
side) is a little more than the light stroke (1st/2nd side).
(4) To adjust, remove bolts holding reverse check sleeve
Tightening torque:
ASSY to the case, move sleeve ASSY outward, and place
10 N'm (1.0 kg·m, 7 ft·lb)
adjustment shim (0 to 1 ea.) between sleeve ASSY and
case to adjust the clearance.
Be careful not to break D'ring when placing shim(s).
One shim's thickness: 0.15 mm (0.0059 in)

0.30 mm (0.0118 in)
• When shim is removed, the neutral position will move
closer to reverse; when shim is added, the neutral
position will move closer to 1st gear.
• If shims alone cannot adjust the clearance, replace
reverse accent shaft and re·adjust.
Reverse accent shaft
Fig. 72 Part No. Mark Remarks
Neutral position is closer

32188AA020 A
to 1st gear.
32188AA002 No Standard
mark
Neutral position is closer
32188AA030 C
to reverse gear.
39
20) Reverse check plate adjustment.
Shift shifter arm CP to "5th" and then to reverse to see if
reverse check mechanism operates properly. Also check to Extension
see if arm returns to Neutral when released from the reverse

position. If arm does not return properly, replace reverse
check plate.
Reverse check plate
Part No. No. Angle (J Remarks
Arm stops closer to

32189AAOOO 0 28°
"5th". L3-111
Arm stops closer to Fig. 75

32189AA010 1 31 °
"5th" .
22) Installing transfer shifter fork
32189AA020 2 34° Standard
Install transfer shifter fork to coupling sleeve and align the
Arm stops closer to cutout section of fork with arm of transfer shifter shaft.
32189AA030 3 37°
reverse.
Apply a coat of oil to nylon pawl of fork.
Arm stops closer to
32189AA040 4 40°
reverse. 23) Installing spring and ball
Install checking ball spring and ball (6.35) in transfer case.
Be careful not to drop ball and spring into transfer case.
24) Installing transfer shifted rod

Insert transfer shifter rod into bore in the upper center of
extension with the cutout section facing the front. Pass it
through transfer shifter fork while positioning ball and spring
in the hole at the center of transfer case.
Align the hole in transfer shifter fork with that in shifter rod
and drive spring pin (5 x 25) into the holes.
Identification No. a. Be sure each end of spring pin protrudes slightly beyond
the holes when installing.
L3·149
b. Position ball with the cutout section of shifter rod facing
Fig. 74 down. Be careful not to drop the ball.
c. To avoid scratching oil seal, apply a coat of oil to shifter
rod before installing.
Bracket section of transfer shifter fork

21) Install extension with transfer gasket and tighten bolts.
Tightening torque:
34 - 40 N·m
(3.5 - 4.1 kg-m, 25 - 30 ft-Ib)
While installing, the gears (transfer drive and driven) should

engage each other.
L3·260
Fig. 76
40
(3) While applying vacuum pressure, turn turnbuckle in
Transfer shifter rod the direction that shortens cable until it no longer turns.
Ball 0
Then, back off turnbuckle 180 and tighten two lock nuts
to the specified torque.
Tightening torque:
5 N'm (0.5 kg-m, 3.6 ft-Ib)
Spring
(4) Operate actuator to ensure that shifting from front-
wheel drive to 4-wheel drive is smooth.
Vacuum pump
L3-261
Fig. 77
25) Installing actuator & cable ASSY

Connect the end of cable and shifter lever with an 8-mm clevis
pin and secure with a snap pin. Secure actuator to the left side
of transmission case with three 8-mm bolts & washers. Secure
cable plate to transfer case with two 8-mm bolts & washers. L3-263
All bolts should be tightened to the specified torque. Fig. 79
Tightening torque: 27) Install transfer cover with gasket and tighten bolts.
16 N'm (1.6 kg-m, 12 ft-Ib)
Tightening torque:
18 - 22 N'm (1.8 - 2.2 kg-m, 13 - 16 ft-Ib)
Transfer shifter lever CP
Transfer cover
o
~"pi"
L3-262
Fig. 78
L3-501
Fig. 80
26) Adjustment of cable

(1) Connect transfer shifter lever to transfer shifter shaft.
Align the hole in transfer shifter lever with that in shifter 28) Release lever
shaft and drive spring pin into the holes. (1) Install retaining spring on release lever.
(2) Connect a hose to pipe on the outside of actuator and (2) Secure release lever pivot to LH transmission case.
apply vacuum pressure until cable is shortened as much as
possible. Tightening torque:
16 N·m (1.6 kg-m, 12 ft-Ib)
Use a vacuum pump or intake manifold to create vacuum.
41
(3) Push release lever against pivot. With the lever held in 4) Install ball bearing onto rear drive shaft with INSTALLER
that position, twist it to the left and right so that retaining (899580100) and RETAINER (899714100).
spring moves onto the stepped surface on the 'rear of
pivot. (Proper positioning of retaining spring can be
checked through access window on the case.)
(4) Install release bearing sleeve ASSY, and hold with
two clutch sleeve clips.
(5) Install dust release cover onto the case. 1 INSTALLER
(899580100)
2 RETAINER
(899714100)
[2] Extension & Transfer Gear ASSY
DISASSEMBLY
L3-150
1) Remove 4WD switch ASSY with a spanner, etc.
Fig. 81
Replace aluminum gasket with a new one.
2) Using a snap-ring pliers, remove snap ring (Inner-68) from 5) Install rear drive spacer, synchronizer hub and sleeve onto
extension. rear drive shaft.
3) Remove rear drive shaft by tapping from the rear with an
aluminum bar.
4) Put sleeve coupling in drive position, and remove locknut
(18 x 10.5) with the TOP-THIRD DRIVEN GEAR HOLDER
(899884100) .
Remove caulking before taking off locknut.
5) Using the REMOVER (899864110) and REPLACER

(398517700), remove ball bearing (20 x 52 x 15).
6) Remove 4th gear thrust washer, transfer driven gear and
coupling sleeve from rear drive shaft.
7) Using the REMOVER (899714110) and TRANSMISSION
MAIN SHAFT REMOVER (899864100)' remove following A12-229
parts from rear drive shaft. Fig. 82
• Rear shaft driven bushing
• Transfer synchronizer hub
• Rear drive spacer 6) I nstall transfer driven gear bush ing onto rear drive
• Ball bearing (28 x 68 x 18) shaft with INSTALLER (899874100) and RETAINER
(899714100).
7) Install coupling sleeve, transfer driven gear and thrust
washer onto rear drive shaft.
8) Install ball bearing onto rear drive shaft with PRESS
ASSEMBLY ASSY (899754112) and RETAINER (899714100).
9) Shift sleeve t'o the drive position and tighten lock nut with
1) Install oil seal (35 x 50 x 11) onto the rear of extension HOLDER (899884100) and SOCKET WRENCH (899988608).
CP using INSTALLER (399513600).
2) Install transfer rear oil seal onto extension CP using 01 L Tightening torque:
SEAL INSTALLER (498057200). 73 - 84 N·m
3) Instal14WD switch ASSY on extension CPo (7.4 - 8.6 kg-m, 54 - 62 ft-Ib)
Tightening torque: Stake the lock nut at four positions after tightening.
18 N·m (1.8 kg-m, 13 ft-Ib)
10) Hammer rear drive shaft into extension with a plastic
Do not forget to install aluminum washer. hammer. And fit snap ring to the groove inside of extension.
42
[3] Transfer Case & Shifter ASSY ASSEMBLY
1) Install needle bearing race into bore in transfer case.

DISASSEMBLY
Be careful not to damage stopper on transfer case.
1) Pull out shifter arm CP and selector arm from transfer
case.
2) Install back lamp switch ASSY and neutral switch ASSY
2) Remove oil guide from transfer case.
on transfer case.
3) Remove back-up light switch ASSY and neutral switch
ASSY.
Tightening torque:
18 N·m (1.8 kg-m, 13 ft-Ib)
a. Some models are not equipped with neutral switch ASSY.
b. Replace aluminum gasket with a new one. a. Some models are not equipped with neutral switch ASSY.
b. Do not forget to install aluminum washer.
4) Remove reverse check sleeve ASSY by loosening 6-mm
bolt and washer ASSY in two places. 3) Install oil seal (18 x 28 x 7) into bore in transfer case
using OIL SEAL INSTALLER (498057000).
a. Be careful not to damage Q-ring fitted in reverse check 4) Install oil guide.
sleeve.
b. 0 to 3 shim(s) are inserted between reverse check sleeve Make sure oil guide is secure and tight.
and transfer case. Be careful not to break them.
5) Assembling reverse check sleeve ASSY.
5) Disassembling reverse check sleeve ASSY. CD Install reverse accent shaft, check cam, return spring
and check spring onto reverse check sleeve.
Be sure the bent section of reverse check spring is positioned

in the groove in check cam.
L3-870
Fig. 83
CD Using a standard screwdriver, remove snap ring (inner

L3-870
28).
Fig. 84
Replace snap ring with a new one if deformed or weakened.
® Remove reverse check plate.

® a. Hook the bent section of reverse check spring
@ Take out return reverse spring and reverse check
over reverse check plate.
spring.
b. Rotate cam so that the protrusion of reverse
® Take out reverse check cam.
check cam is at the opening in plate.
@ Take out reverse accent shaft. c. With cam held in that position, install plate onto
® Remove O-ring (35.4 x 1.5).
reverse check sleeve and hold with snap ring (Inner-
28).
d. Position O-ring (35.4 x 1.5) in groove in sleeve.
43
[4] Drive Pinion Shaft ASSY

Cam
Reverse check
DISASSEMBLY
1) Loosen locknut (22 x 13) using SOCKET WRENCH (35)

(499987003) and HOLDER (899884100).
Snap ring (IN)
Plate
L3-144 SOCKET WRENCH

(499987003)
Fig. 85
a. Make sure the cutout section of reverse accent shaft is Drive pinion shaft ASSY
aligned with the opening in reverse check sleeve.
b. Spin cam by hand for smooth rotation. HOLDER (899884100)
If it does not return properly, replace reverse check spring.
c. Move cam and shaft all the way toward plate and release.
L3-123
If cam does not return properly, replace reverse check spring;
if shaft does not, check for scratches on the inner surface of Fig. 86
sleeve. If sleeve is in good order, replace spring.
d. Select a suitable reverse check plate by referring to
"Neutral Position Adjustment."
2) Using TRANSMISSION SHAFT REMOVER (899864100)
and REMOVER (899714110). remove 5th needle bearing race,
6) a. Install reverse check sleeve ASSY onto transfer case needle bearing (32 x 42 x 25.8), and transfer drive gear.
and tighten with two bolt & washers. 3) Remove drive pinion collar.
4) Remove 5th driven gear using 5TH DRIVEN GEAR
Tightening torque: REMOVER (498077000) and a press.
10 N·m (1.0 kg-m, 7 ft-Ib) 5) Remove woodruff key (5 x 6.5 x 1.6).
6) Using REMOVER (899714110) and a press, remove ball
b. Install shifter arm CP into the partition from the front bearing (28 x 74 x 28) and 3rd and 4th driven gear.
while inserting selector arm into the opening in sleeve
ASSY. Pass shaft through hole in selector arm until its
end comes out of the rear of transfer case. Tool No. Tool name
Apply a coat of gear oil to shifter arm CPo Also make sure oil 899714110 REMOVER
seal (18 x 28 x 7) is positioned properly.
7) Press oil seal (15 x 25 x 2) completely into the right 7) Remove 2nd driven gear CPo
boss section of transfer case. 8) Using REMOVER (899714110) and a press, remove 1st
8) Press oil seal (13 x 22 x 6) completely into bore for trans- driven gear CP, 2nd gear bushing, and gear & hub ASSY.
fer shifter rod at rear of transfer case.
9) Insert transfer shifter shaft into the right side of transfer Remove key before removing 2nd gear bushing.
case from inside.
9) Using 5th driven gear remover and a press, remove 1st
gear bushing, 1st driven gear thrust plate, and roller bearing
(41 x 71 x 23).
Replace roller bearing (41 x 71 x 23) with a new one if this

disassembly is performed.
44
ASSEMBLY -----=--
1) Assemble gear & hub ASSY.
CD
1 INSTALLER (499877000)
1 st gear side 2 INSTALLER (499277100)
2nd gear side 31st-2nd driven gear bushing ®
l""'--@
F lush surface
A12454
Fig. 89
Stepped surface
4) Install 1st driven gear, 1st-2nd balk ring and gear & hub
L3-357
ASSY (already assembled in previous step) to drive pinion
Fig. 87 shaft.
Align ring groove with insert.

0
Position open ends of springs 120 apart.
5) Install 1st-2nd driven gear bushing to drive pinion shaft.
2) Drive roller bearing onto drive pinion shaft and

1st driven gear thrust washer using 1ST-2ND BUSHING
INSTALLER (499277100) and 4TH-5TH RACE INSTALLER
(499877000).
1 INSTALLER (499877000)
2 INSTALLER (499277100)
31st-2nd driven gear bushing
CD
1 INSTALLER (499877000)
2 INSTALLER (499277100)
31st driven gear thrust washer
A12455
Fig. 90
A12453
6) Install 2nd driven gear, 1st-2nd balk ring and key to drive
Fig. 88 pinion shaft. Then, install 4th-3rd driven gear using the same
tools as above.
Tool No. Tool name
3) Install driven gear bushing (42) onto drive pinion shaft 499277100 INSTALLER (1st-2nd bushing)
using the same tools as in step (2) above.
499877000 INSTALLER (4th-5th race)
Bushing may be installed with either side up.
7) Install ball bearing (29 x 74 x 38) to drive pinion shaft
using 1ST-2ND BUSHING INSTALLER (499277100).
Ball bearing may be installed without using the tool. There

should be no problem.
45
8) Install woodruff key (5 x 6.5 x 1.5) to the rear section of [5] Transmission Main Shaft ASSY
drive pinion shaft. Using 1ST-2ND BUSHING INSTALLER
(499277100) and press, install 5th driven gear.
DISASSEMBLY
a. Face 5th driven gear in the correct direction.
1) Put vinyl tape around main shaft splines to protect oil seal
Face this surface having groove from damage. Then pull out oil seal and needle bearing by
to the rear side hand.
2) Remove locknut.
HOLDER (498937000)
L3-135
Fig. 91
SOCKET WRENCH
(499987003)
Transmission main
shaft ASSY
b. Be careful not to dislocate woodruff key while installing
5th gear. L3-126
9) Install drive pinion collar and transfer drive gear. Then, Fig. 92
install 5th needle bearing race using 4TH-5TH RACE
INSTALLER (499877000) and a press.
10) Install needle bearing and lock washer, then tighten lock
nut to the specified torque.
Tool No. Tool name 3) Remove insert stopper plate, sleeve and hub ASSY No.2,
balk ring, 5th drive gear CP, and needle bearing (32 x 36 x
499987003 SOCKET WRENCH (35) 25.7).
4) Using TRANSMISSION MAIN SHAFT REMOVER
899884100 HOLDER
(899864100), REMOVER (899714110), and a press, remove:
• 5th needle bearing race
• 5th gear thrust washer
Tightening torque: • Ball bearing (25.5 x 65 x 31)
112 - 124 N·m (11.4 - 12.6 kg-m, 82 - 91 ft-Ib) • 4th gear thrust washer
• 4th drive gear CP
Secure lock nut in two places. • Sleeve and hub assembly
• Balk ring
• 3rd drive gear CP
46
ASSEMBLY
Groove
1) Assemble sleeve & hub ASSY for 3rd-4th and 5th.
Two holes for ~.

discrimination q;
(3rd4th hub) •
t'e'e'
o L3·132
G
Fig. 95
L3·358
5) Drive ball bearing onto the rear section of transmission
Fig. 93 main shaft using REMOVER (899714110), 4TH-5TH RACE
6) Using REMOVER (899714110), 4TH-5TH RACE
One hole for~'
di scrim i nation INSTALLER (499877000) and a press, install the following
(5th hub) parts onto the rear section of transmission main shaft.
t'e'~
o Face thrust washer in the correct direction.
Fig. 94
G L3-359
Face this surface
to 5th gear side
2) In~tall 3rd drive gear CP, balk ring, and sleeve & hub
ASSY for 3rd4th needle bearing (32 x 36 x 25.7) on trans· L3·133
mission main shaft. Fig. 96
Align groove in balk ring with shifting insert.

3) Install 4th needle bearing race onto transmission
7) Install the following parts to the rear section of trans-
main shaft using REMOVER (899714110), INSTALLER
mission main shaft.
(499877000) and a press.
• Needle bearing (32 x 36 x 25.7)
4) Install balk ring, needle bearing (32 x 30 x 25.7). 4th
• 5th drive gear
drive gear CP and 4th gear thrust washer to transmission main
shaft. • Balk ring
• Sleeve & hub ASSY
• Insert stopper plate
Face thrust washer in the correct direction.
• Lock washer (22 x 38 x 2)
• Tighten lock nuts (22 x 13) to the specified torque using
SOCKET WRENCH (499987003) and TRANSMISSION
MAIN SHAFT HOLDER (498937000).
47
4) Pull out pinion shaft, and remove differential bevel pinion
Tightening torque:
and gear and washer (38.1 x 50 x t).
112 -124 N'm (11.4 -12.6 kg·m, 82 - 91 ft·lb)
5) Remove roller bearing.
a. Align groove in balk ring with shifting insert.

b. Be sure to fit pawl of insert stopper plate into 4·mm dia
hole in the boss section of synchronizer hub.
PULLER ASSY
(399527700)
A12'()38
Pawl Fig. 99
Insert stopper plate

L3-871
Fig. 97
c. Secure lock nuts in two places after tightening.

ASSEMBLY
1) Install bevel gear and bevel pinion together with washers,

[6] Differential ASSY and insert pinion shaft.
Face the chamfered side of washer toward gear.

DISASSEMBLY
1) Remove right and left snap rings from differential, and

then remove two axle drive shafts.
During reassembly, reinstall each axle drive shaft in the same

place from which it was removed.
2) Loosen twelve bolts and remove hypoid drive gear.

3) Drive out straight pin from differential ASSY toward
crown gear.
Pinion shaft
A12-261
Fig. 100
2) Measure backlash between bevel gear and pinion. If it is

not within specifications, install a suitable washer to adjust it.
1 REMOVER (899904100) /~~ (1 Standard backlash:
~.cq\, .~
0.13 - 0.18 mm (0.005 - 0.0071 in) I
A12'()36
Be sure the pinion gear tooth contacts adjacent gear teeth
Fig. 98 during measurement.
48
6) Position drive axle shaft in differential case and hold it

Washer (38.1 x 50 x t)
with outer snap ring (28). Make sure clearance between the
Part No. Thickness mm (in) shaft and case is within specifications.
803038021 0.925 - 0.950 (0.0364 - 0.0374) Clearance:

0- 0.2 mm (0 - O.OOS in)
803038022 0.975 - 1.000 (0.0384 - 0.0394)
803038023 1.025 - 1.050 (0.0404 - 0.0413) If it is not within specifications, replace snap ring with a
suitable one.
Snap Ring (Outer-28)
805028011 1.05 (0.0413)
805028012 1.20 (0.0472)
A12·262
Fig. 101
3) Align pinion shaft and differential case at their holes, and

drive straight pin into holes from the crown gear side, using
STRAIGHT PIN REMOVER (899904100).
A12-070
lock straight pin after installing. Fig. 103
4) Install roller bearing (40 x 80 x 19.75) to differential case.
Be careful because roller bearing outer races are used as a set.
[SJ Full-Time 4WD

[1] Overall Transmission
DISASSEMBLY
1 INSTALLER (499277100)
2 2 ADAPTER (398497701)
The following job should be followed before disassembly;
A12-067 • Clean oil, grease, dirt and dust from transmission.
Fig. 102 • Remove drain plug to drain oil. After draining, retighten it
as before.
5) Install crown gear to differential case using twelve bolts. • Replace gasket with a new one.
Tightening torque: Tightening torque:

57 - 67 N'm (5.S - 6.8 kg-m, 42 - 49 ft-Ib) 41 - 47 N·m (4.2 - 4.S kg-m, 30 - 35 ft·lb)
49

(399295120).
Fig. 106 Actuator ASSY
Fig. 104
4) Remove transfer cover.
5) Remove plug from extension and take out spring and
ball.
6) Removing rear cover and bracket CP
2) Remove release lever and clutch release bearing. Remove the five 10-mm bolts from the rear cover.
3) Removing actuator & cable ASSY
CD Remove snap pin from the transfer shifter rod side
and remove clevis pin.
L3·891
Fig. 107 Removing rear cover
Fig. 105 Cable ASSY 7) Removing extension ASSY

CD Remove the ten bolts which secure extension ASSY.
® Remove the three 8 mm bolts and detach the dif·

ferential lock cable bracket.
@ Remove the three 8 mm bolts from the actuator side
and remove actuator & cable ASSY.
L3-506
Fig. 108
50
® Remove center differential & extension ASSY. 13) Remove main shaft rear plate.
L3-892 L3-873
Fig. 109 Fig. 112
8) Remove plug with gasket, reverse accent spring and ball. 14) Put vinyl tape around axle drive shafts.
9) Remove two bolts and loosen reverse check sleeve ASSY. 15) Separate transmission case.
16) Remove drive pinion shaft ASSY.
Use a hammer handle, or similar item, remove if too tight.
17) Remove transmission main shaft ASSY.

18) Remove differential ASSY.
a. Be careful not to confuse right and left roller bearing outer

races.
b. Be careful not to damage retainer oil seal.
Fig. 110 19) Remove 5th shifter fork.

20) Remove three checking ball plugs from main case.
10) Remove shifter fork screw securing selector arm to shifter There is a spring and ball inside. Replace gasket with a new
arm CPo one.
11) Remove transfer case and shifter ASSY.
12) Remove bearing mounting bolts. 21) Remove fork and rod.
When removing rod, keep other rods in neutral. Also, when

pulling out spring pin, remove it toward inside of case so that
it may not hit against case.
22) Remove reverse idler gear.

23) Remove reverse shifter rod arm and rod.
When pulling arm, be careful not to let ball pop out of arm.
24) Remove reverse shifter lever.

25) Remove differential side retainer.
26) Remove speedometer driven gear.
Fig. 111
51
2) Alignment marks/figures on hypoid gear set.
INSPECTION
See p. 34
See p. 31
3) Adjustment of drive pinion shim.
ASSEMBLY See p. 34
Replace gaskets with new ones. 4) Install differential ASSY.
1) Assembling parts in transmission case (LH). a. Wrap the left and right splined sections of axle shaft with
CD Interlock plunger vinyl tape to prevent scratches.
® Reverse idler gear CPo b. Be careful not to fold the sealing lip of oil seal.
® Reverse fork rod and reverse fork rod arm.
@ prug for Rev-5th 5) Install transmission main shaft ASSY.
@ Adjustment of reverse idler gear CPo position.
See p. 35
See p. 32
6) Install drive pinion shaft ASSY with selected shims.
® Clearance adjustment
Ensure that the knock pin of the case is fitted into the hole in
See p. 33 the bearing outer race.
(j) Rod and fork 7) Selection of suitable 1st-2nd, 3rd-4th and 5th shifter fork
® Plugs for 3-4 and 1-2. CPs.
1st-2nd shifter fork CP 3rd-4th shifter fork CP 5th shifter fork CP
Part No. No. Remarks Part No. No. Remarks Part No. No. Remarks

32804AA031 1 (0.008 in) closer to 32810AA080 1 (0.008 in) closer to 32812AA060 1 (0.008 in) closer to
1st gear 4th gear 5th gear
Positions in the Positions in the Positions in the

32804AA041 - center
32810AA070 - center
32812AA070 - centel'
Moves 0.2 mm Moyes 0.2 mm Moves 0.2 mm

32804AA051 3 (0.008 in) closer to 32810AA100 3 (0.008 in) closer to 32812AA100 3 (0.008 in) closer to
2nd gear 3rd gear 5th gear
8) Inspect rod end clearance.

See p. 36 Tightening torque:
g) Apply liquid gasket and put cases (RH/LH) together. 8 mm bolt
10) Tighten 17 bolts to i:he tightenir.g torque in the following 23 - 26 N·m (2.3 - 2.7 kg-m, 17 - 20 ft-Ibl
sequence. 10 mm bolt
36 - 42 N·m (3.7 - 4.3 kg-m, 27 - 31 ft-Ibl
holder shim are not caught up in betvveen.
meshed, and high·low shifter shaft is inserted perfectly.
11) Tighten ball bearing attaching bolts at the drive pinion

rear.
121 Backlash adjustment of hypoid gear and preload adjust-
ment of roller bearing.
* 10 mm bolt
~_ _ _ _ _ _ _ _ _ _ _ _ _ _ _-.:A-.:..:1-=.2--=.36=-.J9 a. Use new special tool "STOPPER (498427000)".
Fig. 113
52
L3·373
Fig. 114 Fig. 116
b. See p. 37
13) Checking tooth contact of hypoid gear. 19) Neutral position adjustment.
See p. 37 See p. 39
14) Fit a·ring into the groove of retainer and tighten it into 20) Reverse check plate adjustment.
the position where retainer has been tightened.
See p. 40
21) Installing center differential & extension ASSY.
15) Selection of main shaft rear plate. CD Install transfer shifter rod on extension with a clip.
® Install center differential & extension on transfer
See p. 38 case.
16) Install transfer case & shifter ASSY to transmission case.
While aligning differential lock sleeve, install transfer case.
Fig. 117
L3·508
Fig. 115
® Tightening the extension
Tighten the ten 10·mm bolts to secure extension.
17) Tighten selector arm.

Tightening torque:
18) Install in following order ba", reverse accent spring,
37 ± 3 N·m (3.8 ± 0.3 kg-m, 27.5 ± 2.2 ft-Ib)
aluminum gasket and plug.
53
L3-510
Fig. 118 Fig. 120
@ Install ball, spring and gasket in extension and tighten 25) Installing actuator & cable ASSY
plug. Install on the case (left) with the three bolts. Also install
cable plate with the two bolts.
Tightening torque:
19.6 ± 1.5 N'm (2.0 ± 0.15 kg-m,14.5 ± 1.1 ft-Ib) Tightening torque:
15.7 ± 1.5 N·m (1.6 ±0.15 kg-m, 11.6 ± 1.1 ft-Ibl
22) Installing extension cover and shifter bracket
Secure cover and shifter bracket to extension with the five
bolts.
Tightening torque:
33 ± 3 N·m (3.4 ± 0.3 kg-m, 24.6 ± 2.2 ft-Ib)
Fig. 121
261 Adjusting cable length

CD Move differential lock lever to the center differential
lock side while turning main shaft.
Fig. 119
23) Install transfer cover with gasket and tighten bolts.

24) Installing differential lock bracket
Tighten with the three bolts.
Tightening torque:
15.7 ± 1.5 N·m (1.6 ± 0.15 kg-m, 11.6 ± 1.1 ft-Ib)
Fig. 122
54
® Connect a hose to the pipe outside the actuator.

Apply vacuum (using Mighty Bag, etc.) through the hose
to pull the cable forward.
Fig. 125
2S) Install release lever.

L3-513
Fig. 123
@ Align the bore in differential lock lever with the hole

at the end of cable using a turnbuckle, and secure with an
S-mm clevis pin and snap pin.
@) Turn the turnbuckle 1S0° in the compression di rec-
tion and tighten the two lock nuts to the specified torque.
[2] Center Differential & Extension ASSY
Tightening torque:
5 N·m (0.5 kg·m, 3.6 ft·lb) DISASSEMBLY
1) Remove snap ring (Outer·50) from center differential

bearing.
2) Press out center differential ASSY.
Do not reuse ball bearing.
L3-514
Fig. 124
27) Checking operation of transfer shifter rod

Apply vacuum -26.7 to -33.3 kPa (-200 to -250 mmHg,
-7.S7 to -9.S4 inHg) through pipes located on the inside and
outside of the actuator to check that transfer shifter rod L3-389
moves smoothly from the differEtntial lock position to the dif· Fig. 126
ferential unlock position, and vice versa.
If transfer shifter rod does not move properly, check condition 3) Remove snap ring (lnner'SO) and remove ball bearing
of rod, lever, bracket, transfer sleeve and gears. Repair or (50 x SO x 10).
replace faulty parts.
Do not reuse ball bearing.
55
L3-390 L3-392
Fig_ 127 Fig. 129
2) Installing center differential ASSY

4) Disassembling center differential
CD Remove the eight socket bolts (8 x 16 x 12)_
CD Position differential bevel washer and bevel gear in
center differential case.
® Separate transfer drive gear and differential case.
® Attach differential bevel pinion to center differential
Remove the shaft, two pinions, bevel gear, washer, and
pinion shaft and insert the assembled unit into the case.
needle bearings (41 x 46 x 13; 2 sets of two halves).
Note the locations of both sets of needle bearings so that they

can be reassembled in their original positions.
Pinion shaft
L3-393
Fig. 130
® Attach the two needle bearing halves (41 x 46 x 13)
to the groove in pinion shaft. Install transfer drive gear
and tighten with the eight socket bolts (8 x 16 x 12).
Fig. 128
Tightening torque:
25 ± 2 N·m (2.5 ± 0.2 kg·m, 18.1 ± 1.4 ft·lb)
ASSEMBLY
Always replace needle bearing halves in their original positions.
1) Attach ball bearing (50 x 80 x 10) to extension and install
snap ring (Inner-80).
Select a suitable snap ring so that side clearance between snap
ring and ball bearing is 0 to 0.2 mm (0 to 0.008 in).
Snap Ring (Inner-80)
Part No_ Thickness mm (in)
805180020 1.75 ± 0.03 (0.0689 ± 0.0012)
805180030 1.90 ± 0.03 (0.0748 ± 0.0012)
805180040 2.05 ± 0.03 (0.0807 ± 0.0012)

L3·394
Fig. 131
56
® Backlash adjustment 4) Installing snap ring (Outer-50)

Set up a dial gauge as shown in Figure below. Select a Select a snap ring so that side clearance between snap ring
differential bevel washer so that pinion shaft can move and ball bearing is 0 to 0.2 mm (00 to 0.008 in).
0.40 to 0.60 mm (0.0157 to 0.0236 in) in the axial direc-
tion. Snap Ring (Outer-50)
805050030 2.00 ± 0.03 (0.0787 ± 0.0012)
805050040 2.15 ± 0.03 (0.0846 ± 0.0012)
805050050 2.30 ± 0.03 (0.0906 ± 0.0012)
L3·395
Fig. 132
Differential Bevel Washer
38960AAOOO 1.0 ± 0.05 (0.0394 ± 0.0020)

38960AA100 1.2 ± 0.05 (0.0472 ± 0.0020)
Fig. 134
38960AA200 1.4 ± 0.05 (0.0551 ± 0.0020)
38960AA300 1.6 ± 0.05 (0.0630 ± 0.0020)
38960AA400 1.8 ± 0.05 (0.0709 ± 0.0020)
38960AA500 2.0 ± 0.05 (0.0787 ± 0.0020) [3] Transfer Case & Shifter ASSY
3) Using INSTALLER, press center differential into place.

DISASSEMBLY
Tool No. Tool name
1) Pull out shifter arm CP., selector arm, and reverse check
922340000 INSTALLER
sleeve ASSY from transfer case.
2) Remove oil guide from transfer case.
Support socket bolt location with a press_
Center differential
L3-396
Fig. 133 Fig. 135
57
3) Remove CD back-up light switch, ® neutral switch and 5) Using REMOVER 2, drive out straight pin (5 mm dia. x
® differential lock pilot switch. 25) through the hole for differential lock switch. Remove
fork, differential lock shaft and lock sleeve.
Tool No. Tool name
398791600 REMOVER 2
Differential
~
Fig. 136 lock rod
61o....z..... Difi",",'"
lock shaft
L3-881
Fig. 138
4) Using REMOVER 2, drive out straight pin (5 mm dia. x
25). Remove differential lock lever ASSY.
Tool No. Tool name
398791600 REMOVER 2
6) Place splined end of transfer driven gear in a vise. Unlock
lock plates and remove lock nuts (30 x 12).
a. Use soft vise jaws (such as aluminum plates, etc.) when

placing driven gear in vise.
b. Use a hex. socket wrench whose width across flats is
30mm.
L3-401
Fig. 137
L3-403
Fig. 139
58
7) Press out transfer driven gear.

ASSEMBLY
Tool No. Tool name
1) Press needle bearing (58 x 72 x 16) into the bore in trans-
899580100 REMOVER fer case and secure with snap ring (lnner-72).
Tool No. Tool name
498175400 INSTALLER
499755502 INSTALLER
L3·404
Fig. 140
L3-405
8) Remove snap ring (Inner-56) and press out ball bearing Fig. 141
(22 x 56 x 16).
Tool No. Tool name
899754112 PRESS
2) Install ball bearing (22 x 56 x 16) using a press and
Do not reuse ball bearing. INSTALLER and install snap ring (Inner-56).
Tool No. Tool name
9) Remove snap ring (lnner-72). Remove needle bearing 899874100 INSTALLER

(58 x 72 x 16) using INSTALLER and a press.
Tool No. Tool name
398663600
499755502
SNAP RING PLIERS
INSTALLER
\
L3-406
Fig. 142
59
3) Select a snap ring so that side clearance between snap ring 5) Install lock washer (20 x 30 x 3). Place splined end of
(Inner-56) and ball bearing is 0 to 0.1 mm (0 to 0.004 in). transfer driven gear in a vise and tighten lock nut (30 x 12) to
the specified torque. Lock lock nut at four points.
Snap Ring (Inner-56)
Tightening torque:
Part No. Thickness mm (in) 78 ± 6 N·m (8 ± 0.6 kg-m, 57.9 ± 4.3 ft-Ib)
805156020 1.75 ± 0.015 (0.0689 ± 0.0006)
805156021 1.83 ± 0.015 (0.0720 ± 0.0006)
805156022 1.91 ± 0.015 (0.0752 ± 0.0006)
L3409
Fig. 145
L3407
Fig. 143
6) Install differential lock shaft, lock sleeve, fork and rod in

that order. Drive straight pin (5 mm dia. x 25) into place
4) Install transfer driven gear using PRESS and INSTALLER. through the hole for differential lock switch using REMOVER
2.
Tool No. Tool name
Tool No. Tool name
899580100 INSTALLER
398791600 REMOVER 2
899754112 PRESS
a. Note the direction of the check ball groove in the rod.
Be careful because press support is unstable. b. Face dog clutch of differential lock sleeve toward the rear.
VJ~ /
/
L3408 L3-41 0
L -____ ~~~ ________ ~ __ ~ ____ ~~ ______ ~
Fig. 144 Fig. 146
60
7) Install differential lock lever. Drive straight pin (5 mm dia. [4] Drive Pinion Shaft ASSY
x 28) into place using REMOVER 2.
Tool No. Tool name DISASSEMBLY

398791600 REMOVER 2
8) Install ® differential lock pilot switch, ® neutral switch 1) Drive pinion ASSY
and G) back·up light switch. (1) Straighten lock nut at staked portion. Remove the
lock nut using HOLDER and STOPPER.
Tightening torque:
25 ± 2 N·m (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft·lb) J!Iij~lbrf.::::-'-::::----:::::~- HOLDER (899884100)
STOPPER (498427000)
Fig. 149
(RH)
Fig. 147
Harness color G) RY (two harnesses)

® LgYand B
® RY (two harnesses)
(2) Withdraw drive pinion from driven shaft ASSY.
9) Position reverse check sleeve ASSY in the case.
Remove differential bevel gear sleeve G), drive pinion
10) Position shifter arm in the case and install selector arm.
spacer ®, two washers ® (25 x 37.5 x 4), thrust bearing
@ (25 x 37.5 x 3)' needle bearing @ (25 x 30 x 20),
Apply gear oil to shifter arm. Check that oil seal (18 x 28 x 7)
drive pinion collar ®, needle bearing (J) (30 x 37 x 23)
engages properly. and thrust bearing @ (33 x 50 x 3).
11) I nstall transfer oil guide.

®
I
Off
Tightening torque:
@
10 N'm (1 kg·m, 7 ft-Ib)
©
©
CD Q L3·413
Fig. 150
Fig. 148
61
(3) Remove roller bearing and washer (33 x 50 x 5) using

REMOVER and PRESS.
I
,.
t:::-
" JI
~
()-
(\)
- :::>
~
REMOVER
ID (498077000)
~ Fig. 153
~~
~ c::-:".... L3·414
Fig. 151
(3) Remove woodruff key.
(4) Remove roller bearing (42 x 74 x 40) and 3rd & 4th
driven gear using REMOVER.
2) Driven gear ASSY
Attach a cloth to the end of driven shaft (on the frictional

side of thrust needle bearing) during disassembly or reassembly
to prevent damage.
(1) Straighten lock nut at staked portion. Remove the

lock nut using SOCKET WRENCH 50 and HOLDER.
HOLDER
(899884100 )
L3-417
Fig. 154
(5) Remove the key.

(6) Remove 2nd driven gear ASSY.
(7) Remove 1st driven gear, 2nd gear bushing, gear and
hub using REMOVER and PRESS.
L3-415
Fig. 152
(2) Remove 5th driven gear using REMOVER.
L3-418
Fig. 155
62
(3) Install 2nd driven gear, 1st-2nd baulk ring and insert
ASSEMBLY onto driven shaft. After install ing key on driven shaft,
install 3rd-4th driven gear using INSTALLER and PRESS.
1) Assemble gear & hub ASSY.
F lush surface INSTALLER

(499277200)
Stepped surface
L3-420
L3-357 Fig. 158

~----------------------------------------~
Fig. 156
(4) I nstall a set of roller bearing (42 x 74 x 40) onto the
driven shaft using INSTALLER and PRESS.
2) Driven shaft ASSY

(1) Install 1st driven gear, 1st-2nd baulk ring and gear
& hub ASSY onto driven shaft. INSTALLER
(2) Install 2nd driven gear bushing onto driven shaft (499277200)
using INSTALLER and PRESS.
Attach a cloth to the end of driven shaft to prevent damage.
L3-421
Fig. 159
(5) Position woodruff key in groove on the rear of driven

shaft. Install 5th driven gear onto drive shaft using
INSTALLER and PRESS.
L3-419
INSTALLER
Fig. 157
(499277200)
L3-422
Fig_ 160
63
(6) Install lock washer (42 x 53 x 2). Install lock nut 3) Drive pinion shaft ASSY
(42 x 13) and tighten to the specified torque using (1) Install roller bearing onto drive pinion. Install washer
SOCKET WRENCH (50). (33 x 50 x 5) using INSTALLER and PRESS.
Tightening torque:
245 ± 10 N·m (25 ± 1 kg-m, 181 ± 7 ft-Ib)
SOCKET WRENCH
(499987300)
o-!---INSTALLER
(499277100)
L3-425
Fig. 163
L3·423
When installing roller bearing, note its directions (front and
Fig. 161 rear) because knock pin hole in outer race is offset.
____- - - - Roller beari ng
a. Stake lock nut at two points.

b. Check that starting torque of roller bearing is 0.1 to 1.5
N·m (1 to 15 kg-cm, 0.9 to 13.0 in-Ib).
Spring balancer
' - - - - Knock pin hole L3-426
Fig. 164
(2) Install thrust bearing (33 x 50 x 3) and needle bearing

(30 x 37 x 23). Install driven shaft ASSY.
L3-424
Fig. 162
L3-427
I
Fig. 165
64
(3) Install drive pinion collar T, needle bearing~2) (2) Using HOLDER, measure starting torque while
(25 x 30 x 20), washer .]j (215 x 37.5 x 4), thrust tightening lock nut to the specified torque.
bearing @) (25 x 37.5 x 3), washer .• ~ (25 x 37.5 x 4),
drive pinion spacer (§) and differential bevel gear sleeve Tightening torque:
(V in that order. 118 ± 8 N·m (12 ± 0.8 kg-m, 86.8 ± 5.8 ft-Ib)
Be careful because spacer must be installed in proper direction.

Starting torque:
0.3 - 0.8 N·m (3 - 8 kg-em, 2.6 - 6.9 in-Ib)
Stake the lock nut at four points.
L3-428
Fig. 166
4) Adjust thrust bearing preload.
(1) After completing steps 1) through 4) above, select a
spacer and sleeve so that dimension H is zero through
visual check. Position washer (18.3 x 30 x 4) and lock Fig. 169
washer (18 x 30 x 2) and install lock nut (18 x 13.5).
Drive pinion spacer Sleeve
(3) If starting torque is not within specified limit, select

new spacer or sleeve and recheck starting torque.
Starting torque Dimension H Spacer /sleeve
Low Small Select thicker one.

"A"
High Large Select thinner one.
L3-429
Fig. 167
Drive Pinion Spacer
32288AAOOO 121.35 ± 0.02 (4.7775 ± 0.0008)
32288AA010 121.50 ± 0.02 (4.7835 ± 0.0008)
32288AA020 121.65 ± 0.02 (4.7894 ± 0.0008)
L3-430
Fig. 168 Detail "A"
65

Differential Bevel Gear Sleeve
(399295120).
Part No. Length mm (in) 2) Remove release lever and clutch release bearing.
(1) Remove two clips and release bearing holder.
38956AAOOO 18.925 ± 0.01 (0.7451 ± 0.0004) (2) Remove dust cover, release lever retainer spring and
clutch release lever.
38956AA010 18.950 ± 0.01 (0.7461 ± 0.0004)
38956AA020 18.975 ± 0.01 (0.7470 ± 0.0004) Be careful not to deform clips and retainer spring.
38956AA030 19.000 ± 0.01 (0.7480 ± 0.0004) 3) Remove rear case and shifter ASSY.
4) Remove four bolts holding ball bearing behind drive
38956AA040 19.025 ± 0.01 (0.7490 ± 0.0004) pinion shaft ASSY.
38956AA050 19.050 ± 0.01 (0.7500 ± 0.0004) 5) Putting vinyl tape around axle drive shafts.
6) Separate transmission case into right and left cases by
38956AA060 19.075 ± 0.01 (0.7510 ± 0.0004) loosening seventeen coupling bolts.
7) Remove drive pinion shaft ASSY from LH transmission.
[5] Transmission Main Shaft ASSY Use a hammer claw, etc. to remove if too tight.
See p. 46 8) Remove transmission main shaft ASSY from LH transmis-

sion case.
91 Removing differential ASSY
Remove differential ASSY from transmission case.
[6] Differential ASSY a. Be careful not to confuse right and left roller bearing outer
races.
See p. 48 b. Be careful not to damage retainer oil seal.
10) Removing 5th shifter fork

Remove spring pin from 5th shifter fork.
Tool No. Tool name
398791700 STRAIGHT PIN REMOVER
11) Removing checking ball plugs

Remove three checking ball plugs from main case.
[C] FWD
There is a spring and ball inside. Replace gasket with a new
[1] Overall Transmission (FWD) one.
12) Removing fork and rod

DISASSEMBLY Remove 3-4 shifter fork and 3-4 fork rod by loosening shifter
fork screw. Drive out spring pin from 1-2 shifter fork CP with
The following job should be followed before disassembly; STRAIGHT PIN REMOVER "2" (398791700), and remove
• Clean oil, grease, dirt and dust from transmission. fork CP and 1-2 fork rod.
• Remove drain plug to drain oil. After draining, retighten
it as before. When pulling out rod, keep other rod in neutral. Also, turn
• Replace gasket with a new one. 3rd-4th rail 90° and remove it in order not to drop plunger.
Tightening torque: 13) Removing reverse idler gear

41 - 47 N'm (4.2 - 4.8 kg·m, 30 - 35 ft-Ibl Pull out straight pin and reverse idler gear shaft. Then remove
reverse idler gear CP and washer.
66
When pulling out straight pin, wash off oil and blow air on it ell Install reverse idler gear and reverse idler gear shaft
for easy removal. and retain with knock pin.
14) Removing arm and rod

Remove outer snap ring and pullout reverse shifter rod arm
with ball, spring and interlock plunger from rod. Then take
out rod.
When pulling out reverse shifter rod arm, be careful not to let
ball pop out of arm.
15) Removing differential side retainer ASSY

Using WRENCH ASSY (499787000), remove differential side
1 Reverse idler gear
retainer ASSY from transmission case.
2 Shaft
3 Knock pin
In FWD, this work can be done with WRENCH CP A12483
(399780111). Fig. 171
16) Removing speedometer driven gear

Remove outer snap ring and pull out speedometer driven gear.
Next, remove speedometer shaft CP and washer from main
case.
® Install reverse fork rod and reverse fork rod arm.
INSPECTION
See p. 31
ASSEMBLY
1 Arm (reverse fork rod)
Replace gaskets with new ones. 2 INSTALLER (399411700)
A12-141
1) Assembling parts in transmission case (LH). Fig. 172
G) Install two plungers into case.
Be sure to insert the correct plunger.

Apply grease to plunger to prevent it from falling.
1st-2nd shifter rod
Reverse shifter rod
Reverse shifter rail arm A12-277

Fig. 170
67
® For reverse shifter rail, install ball, spring and gasket ® Clearance adjustment
into case and tighten plug.
Tightening torque:
18.1 -21.1 N·m
(1.85 - 2.15 kg·m, 13.4 - 15.6 ft·lb)
) i
~. Fig. 175
1 Plug I I
2 Gasket
3 Spring CD
4 Ball
A12·250
Fig. 173
Washer (15.5 x 21 x t mm)

@ Adjustment of reverse idler gear CP position.
0.6 - 0.8
803015081
Clearance: (0.024 - 0.031)
1.5 - 3.0 mm (0.059 - 0.118 in)
1.0 - 1.2
803015082
(0.039 - 0.047)
1.4 - 1.6
803015083
(0.055 - 0.063)
1.8 - 2.0
803015084
(0.071 - 0.079)
2.2 - 2.4
803015085
(0.087 - 0.094)
1 Clearance: 1.5 - 3.0 mm

(0.059-0.118in)
2 Reverse idler gear
A12'()84
Fig. 174 (J) Install rod and fork
• Interlock plunger (3 x 11.9)
• Fork rod for 3-4, 1-2 and 5th
• Shifter fork for 3-4, 1-2 and 5th
® Install ball, checking ball spring, gasket and plug for
Reverse shifter lever 3-4 and 1-2.
2) Alignment marks/figures on hypoid gear set
Part No. Mark Remarks
440627101 1 Recedes from the case wall See p. 34
440627102 No mark Standard 3) Adjustment of drive pinion shim
440627103 3 Moves to the case wall See p. 34
68
Drive pinion shim 3rd-4th shifter fork

I denti fi cati on
Part No. Remarks
441967111 0.15 (0.0059) Mark
441967112 0.175 (0.0069) Moves 0.4 mm (0.016 in)

32810AA110 1
toward 4th gear
441967113 0.20 (0.0079) Moves 0.2 mm (0.008 in)
32810AA120 2
toward 4th gear
441967114 0.225 (0.0089)
32810AA130 No mark Standard
441967115 0.25 (0.0098)
Moves 0.2 mm (0.008 in)
32810AA 140 4
441967116 0.275 (0.0108) toward 3rd gear
Moves 0.4 mm (0.016 in)
441967117 0.30 (0.0118) 32810AA150 5
toward 3rd gear
441967118 0.50 (0.0197)
Use GAUGE ASSY (499917101) 5th shifter fork CP
Identification
4) I nstall differential ASSY onto LH transmission case. Part No. Remarks
Mark
a. Wrap the left and right splined sections of axle shaft with Moves 0.2 mm (0.008 in)
32812AA032 1
vinyl tape to prevent scratches. toward gear side
b. Be careful not to fold the sealing lip of oil seal.
5) Install transmission main shaft ASSY. Recedes 0.2 mm (0.008 in
32812AA052 3 from gear side
See p. 35
6) Install drive pinion shaft with shims selected before into

transmission case. Reverse driven gear
1st driven gear 2nd driven gear
Ensure that the knock pin of the case is fitted into the hole in 9.5 mm
the bearing outer race. (0.374 in)
7) Selection of suitable 1st-2nd, 3rd4th and 5th shifter fork

CPs.
1st-2nd shifter fork CP
Identification Irr--I...,=::::!==:;;:;t:===~",< A 12.097

Part No. Remarks
Mark Fig. 176 1st-2nd shifter fork
Moves 0.2 mm (0.008 in)

32804AA001 1
toward 2nd gear
32804AA021 Moves 0.2 mm (0.008 in)

3
toward 1st gear
69
9) Wipe off grease, oil and dust on the mating surfaces of

transmission cases with white gasoline, and apply liquid gasket
(Fuji Bond "C" or equivalent), and then put case (RH) and
9.5mm 9.5mm (LH) together.
(0.374 in) (0.374 in) . 10) Tighten 17 bolts with bracket, clip, etc. in the following
4th drive gear
sequence.
A12-Q96
Fig. 177 3rd-4th shifter fork
Coupling sleeve ·10 mm bolt A12·369

Fig. 180
Tightening torque:
8 mm bolt
23 - 26 N·m (2.3 - 2.7 kg-m, 17 - 20 ft-Ib)
10 mm bolt
36 - 42 N·m (3.7 - 4.3 kg-m, 27 - 31 ft-Ib)
L3-434
Fig. 178 5th shifter fork

holder shim are not caught up in betvveen.
meshed, and high-low shifter shaft is inserted perfectly.
8) Inspection of rod end clearance
------
Unit: mm (in) 11) Tighten ball bearing attaching bolts at the drive pinion
shaft rear.
A B 12) Backlash adjustment of hypoid gear and preload adjust-
ment of roller bearing.
0.3 -1.6 0.3 - 1.6
Clearance
(0.012 - 0.063) (0.012 - 0.063)
a. WRENCH CP (399780111) can be used instead of
WRENCH ASSV (499787000).
b. Use HANDLE CP (499927000) instead of HANDLE
(499927100).
c. See p. 37
13) Checking tooth contact of hypoid gear.
See p.37
14) Fit O-ring into the groove of retainer and tighten it into
the position where retainer has been tightened.

A12425
Fig. 179 15) Selection of main shaft rear plate.
70
[2] Rear Case & Shifter ASSY

A
DISASSEMBLY
1) Pull out shifter arm CPo

2) Loosen two 6·mm bolts and remove rear case oil guide.
3) Remove back lamp switch ASSY and neutral switch
ASSY.
Replace aluminum gasket with a new one.
A12·270 4) Remove filler with gasket from transmission rear case.

'-F-ig-.-::1-=-8-=-1--------------------J Then remove reverse accent spring and ball (7.1438).
5) Remove reverse check sleeve ASSY.
6) Disassembling reverse check sleeve ASSY.
Dimension A Discrimination
Part Number
mm (in) stamp
ASSEMBLY
4.50 - 4.63
441347001 T81·1
(0.1772 - 0.1823) 1) Install oil seal (18 x 30 x 6) into bore on the back of rear
case using a plastic hammer.
4.37 - 4.50
441347002 T81·2
(0.1720 - 0.1772) Apply a coat of gear oil to the mating surface and sealing lip
of oil seal beforehand.
16) Install rear case & shifter ASSY. 2) Install oil guide on rear case, and tighten with two 6·mm
bolts.
Tightening torque:
23 - 26 N'm (2.3 - 2.7 kg·m, 17 - 20 ft·lb)
Tightening torque:
17) Neutral position adjustment
6.4 N'm (0.65 kg·m, 4.7 ft·lb)
Reverse accent shaft

Rear case oi I guide
I denti ficati on
Part No. Remarks
Mark
Neutral position is
32188AA040 1 closer to 1st gear.
Neutral position is
32188AA050 3 closer to reverse gear.
L3·167
Fig. 182
See p. 39
18) Reverse check plate adjustment.
See p. 40
19) Install clutch release lever and clutch release bearing.
71
3) Assembling reverse check sleeve ASSY. a. Make sure the cutout section of reverse accent shaft is
CD Install reverse accent shaft, check cam, return spring aligned with the opening in reverse check sleeve.
and check spring onto reverse check sleeve. b. Spin cam by hand for smooth rotation.
If it does not return properly, replace reverse check spring.
Be sure the bent section of reverse check spring is positioned c. Move cam and shaft all the way toward plate and release.
in the groove in check cem. If cam does not return properly, replace reverse check spring;
if shaft does not, check for scratches on the inner surface of
sleeve. If sleeve is in good order, replace spring.
d. Select a suitable reverse check plate by referring to
Sleeve "Neutral Position Adjustment."
~Shaft
lfrb ~R","," 'P'~: 4) Install reverse check sleeve ASSY to rear case, and tighten
with bolts and washers.
R"~'" ~",k':!(J; ~yIJ

Tightening torque:
10 N'm (1.0 kg-m, 7 ft-Ib)
spring Plate?
Snap ring
L3-870
Fig. 183
L3-168
CV a. Hook the bent section of reverse check spring Fig. 185

over reverse check plate.
b. Rotate cam so that the protrusion of reverse
check cam is at the opening in plate. 5) Install ball (7.1438)' reverse accent spring aluminum
c. With cam held in that position, install plate onto gasket, and plug in that order.
reverse check sleeve and hold with snap ring (Inner-
Tightening torque:
28).
d. Position a-ring (35.4 x 1.5) in groove in sleeve. 10 N'm (1.0 kg·m, 7 ft·lb)
Cam
Plate
L3·144 L3·169
~----------------------------------~
~1~ ~1M
72
6) Install back lamp and neutral switch ASSY on rear case.

Tool No. Tool name
Tightening torque: 899714110 REMOVER

18 N·m (1.8 kg·m, 13 ft·lb)
5) Remove 1st needle bearing inner race and gear and hub
a. Do not forget to install aluminum washer. ASSY.
b. Some models are not equipped with neutral switch ASSY.
7) Install shifter arm CP onto rear case.
Apply a coat of gear oil to arm CPo Also make sure oil seal is
positioned in place.
1 REPLACER (498517000)
2 Race
A12-031
Fig. 187
[3] Drive Pinion Shaft ASSY
DISASSEMBLY
1) Remove locknut (22) from drive pinion with SOCKET

WRENCH (35) (4999870031. HOLDER (8998841001. and a
vice.
2) Remove following parts:

ASSEMBLY
• Insert stopper plate
• Insert guide 1) Assemble gear & hub ASSY.
• Sleeve and hub ASSY
• Balk ring 1 st gear side
• 5th driven gear 2nd gear side
• Needle bearing (29 x 33 x 25.8)
3) Using REMOVER (899714110), TRANSMISSION MAIN
SHAFT REMOVER (899864100), and a press, remove: Flush surface
• Ball bearing (27 x 70 x 35)

• 4th and 3rd driven gear
Stepped surface
4) First remove 2nd driven gear and needle bearing (39 x 44
x 23.8) using REMOVER (899714110). Then, using a press,
remove 1st driven gear, 2nd needle bearing inner race, and gear L3-357
and hub ASSY. Fig. 188
Remove key before removing 2nd needle bearing inner race. 0

73
2) Assemble sleeve & hub ASSY. 5) Install needle bearing, 1st driven gear, 1st-2nd ring and
gear & hub ASSY subassembled before.
Make sure bent sections of springs on both sides are kept 180 0
apart and hooked at hub's holes. Take care so that 1st-2nd synchronizer ring groove is in line
with the insert.
L3·166
Fig. 189 A12-059
Fig. 192
3) Fit roller bearing in drive pinion shaft. Install 1st driven 6) Install needle bearing inner race.
gear thrust plate.
1 INSTALLER (899580100)
1 INSTALLER (899580100) 2 INSTALLER (499277000)
3 Needle bearing inner race
2 INSTALLER (499277000)
31st driven gear thrust plate
.....r-::Io._@
A12455
A12453 Fig. 193

Fig. 190
7) Install needle bearing, 2nd driven gear.
8) Install key into the groove on drive pinion shaft and
4) Install needle bearing race. install 3rd-4th driven gear.
1 INSTALLER (899580100)
2 INSTALLER (499277000)
3 Needle bearing inner race
1-=---00
r-=-I.-_@
1 INSTALLER (899580100)
2 4th-3rd driven gear
A12454 A12-062
Fig. 191 Fig. 194
74
9) Install ball bearing with the following special tool(s):
INSTALLER (899874100) and/or INSTALLER (899580100).
';
l. _. "~
~ ____ 11 : '
__ .... _,'. _~ .. _......... ,......... _......... ,

8@@)O.Geti®
9 B 7
I
6
'f 4 3 2 "
5
I ! ! '--1..-......1
In.tlll ing order
A12-140
Fig. 197
A12'()63
Fig. 195 12) Tighten lock nut-22 with SOCKET WRENCH
(499987003) and HOLDER (899884100).
Tightening torque:
Some ball bearings may be installed in the drive pinion shaft 73 - 84 N·m (7.4 - B.6 kg·m, 64 - 62 ft·lb)
without press tightness, but it causes no problem in practical
operation.
Stake the lock nut at 2 points.
10) Install 5th driven gear thrust washer and then, install 5th
needle bearing inner race.
[4] Transmission Main Shaft ASSY
CD DISASSEMBLY
®
1) Put vinyl tape around main shaft splines to protect oil
seal from damage. Then pull out oil seal and needle bearing by
hand.
2) Removing locknut
Remove locknut (18 x 10).
1 INSTALLER (899874100)
25th needle bearing inner race
A 124 77 Remove caulking before taking off locknut.
~----------------------------------~~~
Fig. 196
11) Install needle bearing, 5th driven gear, rings, sleeve & hub
ASSY, insert guide, insert stopper plate, lock washer and lock
nut.
1 HOLDER
(898938600)
2 SOCKET WRENCH
(899988608)
A12-145
Fig. 198
75
3) Removing 5th drive gear 3) Install 3rd drive gear, ring and sleeve & hub ASSY sub-
Remove 5th drive gear using REMOVER (899714110) and assembled before_
TRANSMISSION MAIN SHAFT REMOVER (899864100)_
4) Remove woodruff key. Take care so that the insert is in line with the ring groove.
5) Remove the following parts;
• Ball bearing (23 x 58 x 27) 4) Install 5th needle bearing race.
• 4th drive gear
• Sleeve and hub assembly
• 3rd drive gear CP
1 INSTALLER (899874100)
2 Race
3 RETAINER (899714110) A12-050
Fig. 201
1 REMOVER (899864100)
5) Install ring, 4th drive gear and 4th drive gear thrust
2 RETAINER (899714110)
A12-027 washer.
Fig. 199
ASSEMBLY
1) Assemble sleeve & hub ASSY.
Make sure bent sections of springs on both sides are kept 1800
apart and hooked at hub's holes.
A12.Q51
Fig. 202
Pay attention to the assembling direction.
L3-166
Fig. 200
Before assembling main shaft, apply transmission oil to needle

bearing, ball bearing and bushings sufficiently.
2) Install 5th needle bearing race with the following special

tools. 4th gear side
INSTALLER (899874100)
A12-260
RETAINER (899714110) Fig. 203
76
6) Install ball bearing. a. When reassembling a snap ring, always replace it with a new
one.
b. Select a suitable snap ring from the following table so that
the play in the axial direction is 0 to 0.05 mm (0 to 0.0020
in).
8) Assemble woodruff key and then 5th drive gear.
1 INSTALLER (899874100)
2 Bear'lng
3 RETAINER (899714110)
A12'()53
Fig. 204
7) Assemble snap ring with PRESS ASSY (899754110).
1 RETAINER (899714110)
2 INSTALLER (899754112) A12475
Fig. 206
When assembling key, pay attention to the groove.
9) Tighten lock nut.
1 PRESS ASSY (899754110) Tightening torque:

2 Snap ring 73 - 84 N·m
3 Guide A 12'()54 (7.4 - 8.6 kg-m, 54 - 62 ft-Ib)
Fig. 205
805022010 2.45 (0.0965)

805022011 2.48 (0.0976)
805022012 2.51 (0.0988)
805022013 2.54 (0.1000)
805022014 2.57 (0.1012)
1 HOLDER (898938600)
805022015 2.60 (0.1024) 2 SOCKET WRENCH (899988608)
A12·145
805022016 2.63 (0.1035) Fig. 207
805022017 2.66 (0.1047)
805022018 2.69 (0.1059)
After tightening the lock nut, stake it.
805022019 2.85 (0.1122)
805022030 2.42 (0.0953)
805022031 2.39 (0.0941)
77
[5] Differential ASSY
DISASSEMBLY
1) Remove right and left snap rings from differential, and

then remove two axle drive shafts.
During reassembly, reinstall each axle drive shaft in the same

place from which it was removed.
2) Loosen ten bolts and remove hypoid drive gear. A12·262

3) Using STRAIGHT PIN REMOVER (899904100), drive Fig. 209
out straight pin from differential ASSY toward crown gear.
4) Pullout pinion shaft, and remove differential bevel pinion
and gear and washer (35.1 x 45 x t). Washers (35.1 x 45 x t mm)
5) Remove roller bearing with puller ASSY (899524100).
0.925 - 0.950
803135011
(0.0364 - 0.0374)
0.950 - 0.975
803135012
(0.0374 - 0.0384)
0.975 - 1.000
803135013
(0.0384 - 0.0394)
ASSEMBLY 803135014
1.000 - 1.025
(0.0394 - 0.0404)
1) Install differential bevel gears and differential pinions 1.025 - 1.050

together with washers on differential case, and then insert 803135015
(0.0404 - 0.0413)
pinion shaft.
3) Align the pinion shaft hole with the holes on differential

case and drive straight pin by tapping lightly with hammer
from the hypoid gear side. Finally drive pin until it falls in
about 1 mm (0.04 in) with REMOVER (899904100).
Stake the hole portion after driving it into the differential

case.
4) Install bearing cone on differential case with INSTALLER

(399790110) and SEAT (399520105).
A 12·261
Fig. 208 Notice that the cups of roller bearings are provided as a set
2) Measure backlash between gear and pinion.

If the backlash is inappropriate, make adjustment by using
proper washers.
Standard backlash:
0.13 - 0.18 mm (0.0051 - 0.0071 in)
78
2 SEAT (399520105)
A 12-067 A 12-070
~--------------------------------------~
Fig. 210 Fig. 211
5) Install hypoid gear on case.

Outer snap ring
Tightening torque: Part No. Thickness mm (in)
57 - 67 N·m (5.8 - 6.8 kg-m, 42 - 49 ft-Ib)
1.00 - 1.10
805026010
6) Install axle drive shafts and lock it with snap rings. Select (0.0394 - 0.0433)
proper snap ring so that the clearance between pinion shaft 1.15-1.25
and tip of axle drive shaft is within the specified range. 031526000
(0.0453 - 0.0492)
Standard clearance:
0- 0.20 mm (0 - 0.0079 in)
79
TROUBLESHOOTING
Condition and possible cause Corrective action
1. Gears are difficult to intermesh.

The cause for difficulty in shifting gears can be classified into two kinds: one is malfunction of the gear shift system
and the other is malfunction of the transmission.
However, if the operation is heavy and engagement of the gears is difficult, defective clutch disengagement may also
be responsible. Check whether the clutch is correctly functioning, before checking the gear shift system and trans-
mission.
(a) Worn, damaged or burred chamfer of internal Replace.

spline of sleeve and reverse driven gear.
(b) Worn, damaged or burred chamfer of spline of Replace.
gears.
(c) Worn or scratched bushings. Replace.
(d) Incorrect contact between synchronizer ring and Correct or replace.
gear cone or wear.
2. Gear slips out.

(1) Gear slips out when coating on rough road.
(2) Gear slips out during acceleration.
(a) Defective pitching stopper adjustment. Adjust.
(b) Loose engine mounting bolts. Tighten or replace.

(c) Work fork shifter, broken shifter fork rail spring. Replace.
(d) Worn or damaged ball bearing. Replace.
(e) Excessive clearance between splines of synchro- Replace.
nizer hub and synchronizer sleeve.
(f) Worn tooth step of synchronizer hub (respon- Replace.
sible for slip-out of 3rd gear).
(g) Worn 1st driven gear, needle bearing and race. Replace.
(h) Worn 2nd driven gear, needle bearing and race. Replace.
(i) Worn 3rd drive gear and bushing. Replace.
(j) Worn 4th drive gear and bushing. Replace.
(k) Worn reverse idler gear and bushing. Replace.
3. Unusual noise from transmission.

If an unusual noise is heard when the car is parked with its engine idling and if the noise ceases when the clutch is
disengaged, it may be considered that the noise comes from the transmission.
(a) Insufficient or improper lubrication. Lubricate or replace with specified oi I.

(b) Worn or damaged gears and bearings. Replace.
If the trouble is only wear of the tooth surfaces,

merely a high roaring noise will occur at high speeds,
but if any part is broken, rhythmical knocking sound
will be heard even at low speeds.
80
Condition and possible cause Corrective action
4. Broken differential (case, gear, bearing, etc.)

Abnormal noise will develop and finally it will become impossible to continue to run due to broken pieces obstructing
the gear revolution.
(a) Insufficient or improper oil. Disassemble differential and replace broken components
and at the same time check other components for any
(b) Use of vehicle under severe conditions such as
excessive load and improper use of clutch. trouble, and replace if necessary.
(c) Improper adjustment of taper roller bearing. Readjust bearing preload and backlash and face contact of
(d) Improper adjustment of drive pinion and crown gears.
gear.
(e) Excessive backlash due to worn differential side Add recommended oil to specified level. Do not use
gear, washer or differential pinion. vehicle under severe operating conditions.
(f) Loose crown gear clamping bolts.
5. Differential and hypoid gear noises.

Troubles of the differential and hypoid gear always appear as noise problems.
Therefore noise is the first indication of the trouble.
However noises from the engine, muffler, tire, exhaust gas, bearing, body, etc. are easily mistaken for the differential
noise. Pay special attention to the hypoid gear noise because it is easily confused with other gear noises. There are
following four kinds of noises.
(1) Gear noise when driving:
If noise increase as vehicle speed increases it may be due to insufficient gear oil, incorrect gear engagement,
damaged gears, etc.
(2) Gear noise when coasting:
Damaged gears due to maladjusted bearings and incorrect shim adjustment.
(3) Bearing noise when driving or when coasting:
Cracked, broken or damaged bearings.
(4) Noise which mainly occurs when turning:
Unusual noise from differential side gear, differential pinion, differential pinion shaft, etc.
(a) Insufficient oil Lubricate.
(b) Improper adjustment of crown gear and drive Check tooth contact.
pinion.
(c) Worn teeth of crown gear and drive pinion. Replace in a set.
(d) Loose roller bearing. Readjust bearing preload.
Readjust crown gear to drive pinion backlash and check
tooth contact.
(e) Distorted crown gear or differential case. Replace.
(f) Worn washer and differential pinion shaft. Replace.
81
AUTOMATIC TRANSMISSION AND
DIFFERENTIAL
Page
SUBARU MECHANISM AND FUNCTION

[I] Cross Sectional View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2
2
[gJ Electronic Control System Schematic ........................ , 4
1988 @J Construction and Features of Each Component ....... . . . . . . . . . .. 5

0J Power Transmission System '" . . . . . . . . . . . . . . . . . . . . . . . . . . .. 63
§] Fluid Passages ........................................ 73
[§J Range Select Mechanism ................................. 75
[ZJ Parking Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 76
SPECIFICATIONS AND SERVICE DATA ....................... 77
[I] Specifications ........................................ 77
[gJ Location and Dimension of Adjusting Parts. . . . . . . . . . . . . . . . . . . .. 79
@J Location and Installing Direction of Thrust Needle Bearing and Washer .. 81
COMPONENT PARTS ..................................... 82
[I] General Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 92
[gJ Disassembly of Overall Transmission ......................... 94
@J Disassembly, Inspection and Assembly of Each Component .......... 104
0J Assembly of Overall Transmission ........................... 121
[I] Troubleshooting for Electrical Transmission Control System .......... 139
[gJ Preliminary Inspection ................................... 145
@J Troubleshooting Chart ................................... 146
0J 0 n-Car Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
§] Performance Test ...................................... 159
c.vI
EJ ~ I\)
Torque converter case Oil pump Brake band Overrunning clutch
m
()
Oil pump drive shaft Oil pump housing High clutch One-way clutch (3-4)
o I
~
Input shaft Transmission case - Front planetary gear Reduction drive shaft
o(I)
(I)
»
Z
Torque converter Rear planetary gear
Forward clutch One-way clutch (1-2) fn (J) »

~ c
(1)
(')
Reduction drive gear
_.
r+
»
-I
o
o z ~
:::l
Q) o ~
(')
<
_.
(1)
"'Tl
C -I
:D
~ Z »
Z
() (J)
--i
-
o
~
(J)
z (J)
oz
»z
o
o
"'Tl
"'Tl
m
:D
m
Z
-I
»
r
Hypoid drive gear J Oil pan Parking gear

Drive pit:1ion shaft
r
Ctl
~
o Torque converter section Final reduction section Automatic transmission section

~
Torque converter case High clutch Overrunning clutch
Oil pump drive shaft Oil pump housing Front planetary gear Low & Rev. brake
Transmission case Rear planetary gear One-way clutch (1-2)
Torque cnl'Vf!rt'>r-~
Forward clutch Reduction drive shaft
One-way clutch (3-4) Reduction drive gear
Transfer clutch
»
c
-I
Rear drive shaft o
~
~
()
-I
JJ
»Z
(J)
~
(J)
(J)
oz
»
z
o
o
""
m
JJ
m
Z
-I
Reduction driven gear
»
r
Drive pinion shaft Oil pan Control valve Parking gear
Hypoid drive gear
Torque converter section Final reduction section Automatic transmission section Transfer section
CAl
I
I\)
3-2 AUTOMATIC TRANSMISSION AND DIFFERENTIAL
Electronic Control System Schematic
,~\'"
r-- 1--=i"I":'
,'\
--r'~--'
'
--=-=-===-:: .-. ------

1+
v
Vehicle revolution
-t
~o~~
sensor 2
---=---~
(built in meter)
: 1st hold indicator light
1st hold switch
C>
'------- ,- ,~--.../ ~--1--
2nd range indicator light
Transmission control signal Power indicator light
i I
Inhibitor switch Sh ift solenoid~ 1
I Line pressure solenoid
(Duty solenoid A) l
ATF temperature Shift solenoid·2
Idle switch
Cruise control unit sensor
Owrrunning clutch
Cruise signal Throttle opening
sensor
Engine revolution
signal
Vehicle revolution
sensor 1
(installed in trans-
mission)
solenoid
(Shift solenoid-3)
Lock-up solenoid
(Duty solenoid B)
r
Dropping
resistor
1
I
AfT control unit (FWD)
1
L3-580
Fig. 3
1
4WD I
Vehicle revolution r-- --

u=r;g+
:tI~
sensor 2
(built-in meter)
1st hold indicator light
: f "\
0 • -=
'st hold switch
II'
! 11. It..Jt-
2nd range indicator light
FWD switch u
'----..----'
T Transmission control signal
Power indicator light
ATF temp. warning light
r I
I nhibitor switch Shift solenoid-'
I Line pressure solenoid
(Duty solenoid A) I
ATF temperature Sh ift solenoid-2
Idle switch
Cruise control unit sensor
r
Overruning clutch solenoid
Cruise signal Throttle opening
sensor
Engine revolution
signal
Vehicle revolution
sensor'
(Installed in
transmission)
(Shift solenoid-31
Lock-up solenoid
(Duty solenoid B)
r
Dropping
resistor
l
Transfer pressure
solenoid
IOutY solenoid CI
AfT control unit (4WO)

I
L3-581
Fig. 4
4
AUTOMATIC TRANSMISSION AND DIFFERENTIAL 3-2
When the impeller rotates, centrifugal force pushes out oil
Construction and Features which then enters the turbine. The oil flows along the turbine
of Each Component blade and exerts force on the blade. This causes the turbine
to rotate and power is transmitted to the input shaft.
3-1 Torque Converter If turbine speed is below impeller speed, the oil leaving the
turbine flows in the direction impeding impeller rotation (a in
Fig. 6). This direction is then changed by the stator so that
the oil will assist impeller rotation (b in Fig. 6). With this
action, the torque is multipl ied.
The stator is subject to reverse torque when it changes the
direction of oil flow, hence it must be secured to the casing.
As turbine speed increases and approaches impeller speed, the
oil from the turbine begins to push directly on the back of
the stator blade. (This changeover point is called the "coupling
point".) If the stator is still fixed under this condition, the oil
flow will be impeded by the stator. To avoid this, the stator
is mounted to the case via a one·way clutch so that it can
rotate freely in the same direction as the impeller and turbine.
L3·582
Fig. 5
Construction and Function

3) PERFORMANCE
1) CONSTRUCTION
Torque converter range Coupling range
• The torque converter is composed of impeller, turbine, I
I
stator, and lock·up clutch. It is filled with oil; therefore it Stall·torque ratio
2.55
must not be disassembled. I
I
I
• The impeller is directly coupled to the crankshaft via a Torque ratio
2.0 100
drive plate. A sleeve for driving the oil pump, which is the
source of the hydraulic pressure for the automatic trans· Torque ratio Efficiency (%)
mission, is welded to the rear of the impeller.
• The turbine transmits multiplied engine torque in the 1.0 50
torque converter range, unmultiplied engine torque in the
coupling range, or engine torque itself directly through the
lock·up clutch to the automatic transmission via the input
L -_ _ _~-~~O
shaft spline fitted to the internal spline of the turbine hub. o Speed ratio 0.5 1.0 L3·584
• The stator incorporates a Sprague type one·way clutch.
Fig. 7
The stator is spline·fitted to the oil pump cover via the
inner race of the one·way clutch, and secured to the torque
converter case. The performance curve of the torque converter is shown in
Fig. 7. The torque ratio, speed ratio, and efficiency respec·
2) FUNCTION
tively are represented by the following equations.
Rotating direction
Turbine shaft torque
To rq ue rati 0 = -,--...,..,--,---,----'---
Impeller shaft torque
Turbine shaft speed
Speed ratio
Impeller shaft speed
Turbine-11'''-''·-~1 Impeller
Efficiency Output horse·power x 100 (%)
Stator Input horse·power
The torque multiplication range with stator fixed is called the

"torque converter range". The range in which the stator
rotates together with the impeller and turbine is called the
"coupling range". In this coupling range, the torque converter
'--_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _L_3_.5_8_3-' functions similarly to the fluid coupling,.and the torque is not
Fig. 6 Function of torque converter multiplied. When the speed ratio is zero (0), that is, the
5
condition in which the impeller shaft (engine side) alone when in full throttle, the torque ratio of the turbine shaft and
rotates and the turbine shaft does not rotate, is called the impeller shaft is at a maximum. The torque ratio at this point
"stall point" (the vehicle is at a standstill). At this stall point, is called the "stall torque ratio", and the engine speed is called
the stall speed.
4) LOCK-UP CONTROL - MECHANISM
~L---1L-::::::::::r~~~_---_---lmpeller cover
Lock-up clutch
Impeller
Torsional damper
_~l._I--ilL--ff---Turbine
Friction washer & wave spring
LJ.\-_-ff----Stator
Drive plate
One-way clutch
crankShaft~
L3·586
Fig. 8
The control unit controls the 50 Hz duty control (pulse width The duty control solenoid is operated by applying on-off
modulation) solenoid by changing its on/off time ratio. The voltage pulses; and the percentage modulation is used to
lock-up control valve actuated by this solenoid switches the indicate its performance. This percentage modulation is also
oil passages, and controls the hydraulic pressure applied to called the duty ratio, which is represented by the following
the lock-up clutch. expression.
Pulse Width Modulation Duty ratio = ON . ON t~m:F' x 100 (%) = AB x 100 (%)
time + time
VO,,,,,ONTIll The repetition period A is defined as follows:
Period A = ON time + OFF time
OFF EJA .1- - Pulse width modulation meims variation of duty ratio while
keeping period A constant .
• Hydraulic preuure is controlled by changing the ratio of B/A .
• Period A IS constant. (Frequency IS 50 Hz)
ON
Duty ratio 25 % ~
ON
Dutyratio50%~
ON OFF
outyratio75%_
I AOFt
~ ---+- Time (tl
L3-587
Fig. 9
6
Content of lock-up control
Control content Remarks
Lock-up control (1) Normal • Lockup on/off characteristics are set for
Fully·open
control each range, gear position and pattern by
throttle opening and vehicle speed. 2nd 3rd 4th
Lock-up on • Fuel consumption, power performance I q:::: I

I LU I LU LU
Duty ratio 95% and shift characteristics are taken into
Lock-up off
Duty ratio 5%
account.
Range Mode
Normal
Purpose
Lower fuel consumption Fully-clo5ed

I
OPEN:
if('
(
I
/
/
/
/
I
I
/
/
/
/
/
/
/
0 Vehicle speed
D
Power Higher performance L3-588
Fig. 10
• Lock-up non-operation condition

1) ATF temperature 40°C (104°F) or
lower.
2) 1st speed, N, R, P.
3) During gear shifting.
4) When throttle is fully closed. If V>
140 km/h (87 MPH), lock-up operates
even when throttle is fully closed.
5) Rapid accelerator pedal depression.
(2) Smooth When switching from lock-up off to lock-up

control on, oil pressure for "lock-up apply" is
changed gradually to ensu re smooth lock-up
operation.
7
5) LOCK-UP CONTROL - OPERATION
Lock-up control valve
Lock-up apply circu it
Lock-up release circ I

!I'I'"--::::=o Lock-up duty pressure
or pilot pressure
. (8) (A)
D rain
Vehicle speed
Throttle opening Pi lot pressure
Engine speed
ATF temperature
sensor signal
Range signal
Filter
AfT control unit
Plunger
Duty solenoid 8 (lock-up)

L3-589
Fig. 11
The lock-up control valve is pushed downward by torque into the lock-up release circuit. On the other hand, the lock-up
converter REG pressure and pilot pressure. It is pushed up- apply circuit is connected to the oil cooler in the radiator.
ward by lock-up duty pressure and spring force. Accordingly, the relationship between "lock-up release pres-
sure lock-up apply pressure" is established. As a result, the
(1) During Lock-up Operation lock-up piston is forced to separate from the impeller cover,
Oil pressure at the lock-up control duty solenoid valve is and power is transmitted from impeller to turbine to input
drained (duty ratio 95%) by a signal from the automatic trans- shaft, as with an ordinary torque converter coupling.
mission control unit so that no lock-up duty pressure is
developed and the lock-up control valve remains in condition
(A). As a result, hydraulic oil flows into the lock-up apply (3) During Smooth Control
circu it. On the other hand, the lock-up release circuit drains.
When the lock-up clutch activates, the clutch partially engages.
This causes a pressure differential across the lock-up piston.
Lock-up apply pressure increases smoothly to engage the lock-
The piston is then forced against the impeller cover and turned
up clutch.
as an integral unit with the cover. Thus, power from the engine
is directly transmitted to the transmission input shaft. That
is, the transmission is directly coupled to the engine.
(4) Non-Lack-up Operation During "1st Speed",
(2) During Non-Lack-up Operation "N", "R" and "P"
In this mode, the lock-up control duty solenoid is driven at In this mode of operation, pilot pressure is generated, and the
a 5% duty ratio. This causes the lock-up duty pressure (pilot lock-up control valve is set to condition (8) where lock-up
pressure) to be generated. With this pressure, the lock-up is inoperative.
control valve is set to condition (8), and hydraulic oil flows
8
3·2 Oil Pump 2) OPERATION
(1) The automatic transmission fluid (ATF) is drawn through

1) CONSTRUCTION
the oil strainer mounted under the control valve ASSY, and is
routed to the transmission case, to the oil pump housing, and
to the oil pump cover. It then goes to the suction port of
section A shown in the Figure.
(2) The ATF sucked into section A rotates in the direction of
the arrow (driven directly by engine). and is compressed at the
delivery side of section B. It is then discharged.
(3) The discharged ATF flows from the oil pump cover to the
oil pump housing, It then goes to the transmission case, the
control valve and to the regulator valve, thus serving as
hydraulic oil and lubricating oil for the torque converter,
valves, clutch and brake.
Oil pump housing (4) As engine speed increases, the delivery rate of the vane
pump also increases.
L3-592
(5) Feedback pressure from the regulator valve is appl ied to
Fig. 12
section C in the Figure. The cam ring position (the amount of
eccentricity) is controlled by this pressure so that the pump
The vane pump is housed in the oil pump housing. It consists delivery rate remains constant at speeds exceeding the preset
of a rotor, vanes, vane rings, cam ring, control piston, return pump speed.
spring, seal ring and oil pump cover. (6) As the cam ring position changes, the suction volume at
Hydraulic pressure (feedback pressure) from the oil passage (2) section A varies. In this manner, the pump delivery volume is
of the pressure regulator valve is appl ied to the back of the controlled.
control piston.
9
a-ring
Bolt
Friction ring
Oil pump cover

Oil pump housonu ______
Line pressu re
t ~ Line pressure
Rev. clutch pressure
CD rg:i:\:i:J Feedback pressure
Pressure
Vane ring (Both side)
- -..........-++-t- regulator
valve
To torque counverter
reg. valve
Drain
Retainer
Control pisto
Cam ring
Vane
Rotor
(B) Delivery port
(A) Suction port

Fulcrum
Fig. 13
L3-593
10
3-3 Transmission
The planetary gear train uses two sets of simple planetary multi-plate brake, and two sets of one-way clutches (one-way
gears (front planetary gear and rear planetary gear), four sets clutch 1-2 and one-way clutch 3-4) in order to allow shifting
of multi-plate clutches (reverse clutch, high clutch, forward of four forward speeds and one reverse speed.
clutch, and overrunning clutch), one brake band, one set of
Brake band Overrunning clutch Low & Rev. brake
Forward cl utch One-way clutch (3-4) One-way clutch (1-2)
Input
High clutch hub Front sun gear Front planetary gear Rear planetary gear
L3-594
Fig. 14
11
The advantage of the planetary gear system is that it is

1) OPERATING PRINCIPLE
compact because it has only one center shaft. The gear ratio
Internal gear can be changed by simply locking or releasing or rotating
certain portions, unlike the manual transmission that requires
changing gear engagement.
The construction of the planetary gear is shown above. The
Planetary Sun gear
sun gear is located at the center, and each of the pinion gears
carrier
revolves around the sun gear while rotating on its axis. These
gears are all enclosed in a large ring, called the internal gear.
Each pinion gear is supported by a planetary carrier, so that
the pinion gears revolve an equal amount in the same direction.
As mentioned above, the planetary gear consists of four
elements: the sun gear, pinion gears, internal gear, and
planetary carrier. The gears are shifted by imposing certain
L3-595
conditions on two of the following three elements: sun gear,
Fig. 15 Planetary gear internal gear, and planetary carrier.
The automatic transmission uses a planetary gear system The clutches and brakes are used to impose the conditions on
instead of the parallel shaft (two shaft~) gear system adopted the planetary gear set.
in the manual transmission.
2) CONSTRUCTION AND FUNCTION OF EACH ELEMENT
(1) Reverse clutch
w@
1 Reverse clutch drum 8 Snap ring

2 Lip seal 9 Dish plate
3 Reverse clutch piston 10 Driven plate
4 Lathe cut seal ring 11 Drive plate
5 Spring 12 Retaining plate
6 Spring 13 Snap ring
7 Spring retainer 14 High clutch drum
L3·596
Fig. 16
12
During operation During non-operation
Hydraulic pressure is applied to the reverse clutch pistonCD
from the control valve when shifting in reverse. The drive
plate ell and driven plate ® are connected by this pressure,
and engine power from the high clutch drum ® is transmitted
to the front sun gear.
L3·598
Fig. 18
When the shift lever is in any position other than reverse, no
hydraulic pressure is applied to the reverse clutch piston CD.
Hence the drive plate and driven plate are separated, and no
power is transmitted.
L3-597
The check ball ell is built into the clutch piston. This check
Fig. 17 Operation of reverse clutch ball releases oil pressure from the clutch piston while the drum
rotates idle. It thus avoids buildup of residual pressure in the
clutch drum and a resultant half-engaged clutch, which may
otherwise be caused by centrifugal oil pressure.
(2) High clutch
High clutch drum 8 Drive plate

2 Lathe cut seal ring 9 Driven plate (Thicker)
3 High clutch piston 10 Retaining plate
4 Lathe cut seal ring 11 Snap ring
5 Spring retainer CP 12 Thrust needle bearing
6 Snap ring 13 High clutch hub
7 Driven plate (Thinner)
L3-599
Fig. 19
In 3rd and 4th speed operation, hydraulic pressure is applied plates) are connected by this hydraulic pressure, and engine
to the high clutch from the control valve and another hydrau- power from the input shaft is transmitted to the front
lic pressure controller. The clutch plates (drive and driven planetary carrier through the high clutch hub.
13
(3) Band brake One end of the brake band is secured to the transmission case
via the brake band adjusting screw.
• Construction When no hydraulic pressure is applied to the servo piston from
ci
_~__ _
~- ~::..:::",
Rev, . c, lutch drum
~" Lock nut
' W h
the hydraulic pressure controller, the servo piston and band
servo piston 0.0. are forced downward by the return spring,
as shown in (A) of the Figure.
When hydraulic pressure 2A is applied to the servo chamber
(II), it causes the band servo piston to come into contact with
~"~'
i" ~," -- , as er
~., "'i
the stepped portion of the band servo piston stem, thereby
''\: M - a-ring
\W~ pushing the band servo piston stem upward to state (B). Under
\;;t ', ., ------- Brake band adjusting screw this condition, the brake band slowly tightens the reverse
'~""
\\0- '" clutch drum and fixes the front sun gear of the front planetary
, \\\--,------ Brake band ASSY
\w", ',(
',p, ', .. gear. (2nd speed state)
------~.!,~ ',',- ~Strut Next, when the release pressure 3R to the servo chamber (I)
// ....of'
',_', ___
/?~~~~"" Band servo piston stem and the hydraulic operating pressure 2A to the servo chamber
(II) are applied simultaneously, the band servo piston is
.l' ',:" "' .~./~, Return piston spring
/#"l / \',I", """,
pushed downward by the force of the return spring and the
:;;;;;/,/.. .~j "",0,,;-:=- ,;-~

pressure difference between chamber (I) and chamber (II),
Band servo piston (1-2)
caused by the difference in operating areas of the band servo
'-"'~'" .~~ r: =-, Retainer pistons. Under this condition, state (A) is resumed, and the
~.-\lL~;lf .1-
--'-"""1"1,",,'" --- " ~I brake band loosens and releases the reverse clutch drum.
_~~O_O~'~"~iO"
(3rd speed state)
_
Retainer
Band servo piston a.D. return spri ng
0.0. (3-4)
L3-600
Fig. 20
The band brake consists of a flex type brake band, a band (A) (e) L3-602
brake adjusting mechanism, two servo pistons, two retainers, Fig. 22
two return springs, a stem, a strut, and others. The band brake
can be adjusted as installed on the vehicle .
• Function
t,
When hydraulic pressure 4A is applied to the servo chamber ,I
(III) under the 3rd speed condition, the band servo piston
0.0. is brought into contact with the retainer installed at the
Band servo piston
lower end of the band servo piston stem. Hence, the stem is
~,~:::r::=zt- Release pressure pushed upward. As a result, state (e) is ach ieved where the
3R
brake band slowly tightens the reverse clutch drum and fixes
Hydraulic operating the front sun gear of the front planetary gear. (4th speed state)
pressure 2A
Drain -r"t;ii;t,............ t1 The accumulator is built into the transmission case as shown
in the Figure. When hydraulic pressures 2A, 3R, and 4A are r
applied from the hydraulic control unit to the respective
servo chambers, the hydraulic shock loads are absorbed by the
accumulator. This is because the accumulator piston moves
slowly, and the brake band is tightened or released slowly.
Fig. 21 This results in smooth gearshift operation.
14
Accumulator
piston
Spring
L3-603
Fig. 23
~
Band servo piston Band servo piston Return spring Return spring
Retainer I.D.
(1-2) O.D. (3-4) O.D. (1-2) (3-4)
mm (in) mm (in) mm (in) N (kg, Ib) N (kg, Ib)
70 - 30 70 - 30 - 64 147 (15,33) 98 (10,22)

2700 cc 64 (2.52)
(2.76 -1.18) (2.76 -1.18 - 2.52) (at setting) (at setti ng)
64 - 30 64 - 30 - 64 147(15,33) 98 (10,22)
1800 cc 57 (2.24)
(2.52 - 1.18) (2.52 - 1.18 - 2.52) (at setting) (at setting)
(4) One-way clutch Sprague
The one-way clutch (O.w.C.) is a Sprague type. Two clutches

are used. One is mounted between the one-way clutch outer
race and the rear internal gear ASSY. The other is located
between the forward clutch drum and the one-way clutch
inner race.
The former O.W.C. (3-4) is provided to prevent counterclock-
wise rotation (as viewed from the front) of the rear internal
gear ASSY of the rear planetary gear during 1st, 2nd and 3rd Outer race
speeds of the "D" range, "3" range, "2" range and "1st hold".
At the 4th speed of the "D" range, therefore, the rear internal Inner race
gear ASSY rotates clockwise so that the O.W.C. rotates freely
As viewed from the front of body L3-604
to ensure smooth transition between 3rd and 4th speeds.
On the other hand, the latter O.w.C. (1-2) is provided to Fig. 24
prevent counterclockwise rotation (as viewed from the front)
of the forward clutch ASSY during 1st speed of the "D" range
and 1st speed of the "3" range. Therefore, when shifting from
1st speed of the "D" range or "3" range to 2nd speed, the One-way clutch One-way clutch
Item
(1-2) (3-4)
forward clutch ASSY rotates clockwise. As a result, the
O.W.C. now rotates freely ensuring smooth transition between No. of Sprague 34 28
1st and 2nd speeds.
Width of O.w.C. 10 mm (0.39 in) 15mm (0.59 in)
15
(5) Low & reverse brake The piston, dish plate, drive plate, driven plate, retaining plate
and snap ring are mounted directly to the transmission case.
• Construction The spring retainer which is integral with the spring is secured
to the inner race of the transmission case engagement surface.
Transmission case
• Function
~~:::::=~o- Lip seal During 1st speed of the "2" range and 1st speed of the "1st
hold", and reverse, hydraulic pressure from the hydraulic
Dish plate pressure controller is applied to the low & reverse piston. This
pressure causes the drive plate and driven plate to engage, and
------
Piston the forward clutch to be fixed.
Bolt 2700 cc 1800 cc
Lathe cut seal ring No. of drive plates 6 4
No. of driven plates 6 4

Clutch spring
retainer mm (in) 148 (5.83) 148 (5.83)
a.D.
Forward clutch drum Piston
I.D. mm (in) 73 (2.87) 73 (2.87)
L3-605
Fig. 25
16
(6) Forward clutch & overrunning clutch

• Construction
Forward clutch piston

Lip seal
Snap ring Drift ball
Forward clutch drum
Overrunning clutch piston
Dish plate
lip seal Snap ring
Retainer Plate
Snap ring O.W.C. (1-2)
Bushing Needle bearing
Sleeve Lathe cut ring
Return spring Snap ring
Drive plate Outer race
Drive pi
(II)
Driven plate L3-918

Fig. 26
The forward clutch drum is manufactured by pressing sheet • Function

metal. The clutch drum, outer race and sleeve are welded
When hydraulic pressure is applied to the pressure chamber (I)
together by the electron beam welding technique. This clutch
from the hydraulic pressure controller during forward opera-
drum accommodates two multi-plate clutches (forward clutch
tion in the "0", "3", "2" range or "1st hold", the forward
and overrunning clutch). The overrunning clutch piston is
clutch piston forces the overrunning clutch piston. This causes
mounted on the internal periphery of the forward clutch
the drive and driven plates of the forward clutch to engage
piston for common use of the return spring and reduction in
while causing the drive and driven plates of the overrunning
size.
clutch to slide forward.
A groove is provided on the outside of the retaining plate and
~
Overrunning
Forward clutch driven plate of the overrunning clutch in which the forward
clutch
clutch piston sl ides.
No. of drive plates 5 3 When hydraulic pressure is appl ied to the pressure chamber
(II) from the hydraulic pressure controller during "3" range,
No. of driven plates 5 3 "2" range or "1 st hold" operation, the forward clutch piston
is forced onto the side of the forward clutch drum. The over-
0.0. mm (in) 147 (5.79) 133 (5.24)
running clutch piston, however, is moved to the left by the
Piston
1.0. mm (in) 73 (2.87) 75 (2.95) hydraulic pressure. This causes the drive and driven plates of
the overrunning clutch to engage. When this occurs, the out-
side splines of the overrunning clutch retaining plate and
driven plate fit into the internal spline grooves of the forward
clutch. This allows power to be transmitted between the over-
running clutch hub and the forward clutch drum.
17
(7) Planetary gear Two sets of simple planetary gears are used to allow gear
shifting from 1st speed to 4th speed or to reverse. Both the
front and rear planetary gear carriers are made from pressed
steel which is electron-beam welded to other structural
members. The front planetary gear has three pinions while the
rear planetary gear has four pinions. Both are part of an
Front planetary carrier
integral unit, and disassembling is not allowed.
Snap ring
Overrunning
clutch hub
OW.C.
outer race
Rear internal
gear ASSY
Rear carrier ASSY

thrust washer
L3·607
Fig. 27
3-4 Input Shaft
-===...,/
r
O-ring groove
fitting surface fitting surface
r_-__r,--trr_--_-==b=...H_i9_h_C_I_ut""fc=;hrd_ru_m_ _rr-.:::-d:::.=....R...,e,a_r_su_n.......gear
Turbine hub Drain circuit for Lubricating circuit

fitting surface lock-up mechanism
L3-608
Fig. 28
The input shaft front end is spline-fitted to the torque con- roll pin. The torque converter side of the shaft becomes the
verter turbine hub. The rear end is spline-fitted to the high drain circuit for the lock-up mechanism. The other side
clutch drum and rear sun gear. Power from the torque con- becomes the lubricating circuit for the planetary gears and
verter is transmitted to the high clutch drum and rear sun gear. high clutch.
The input shaft is hollow. A seal is fitted inside the shaft by a
18
3-5 Reduction Gear

< FWD> Ball bearing
(
I
Reduction drive gear shaft
Parking gear
Roller bearing
Reduction
driven gear
Drive pinion shaft
L3-609
Fig. 29
<4WD> Ball bearing Reduction drive gear Transfer clutch hub
Seal ring
Reduction drive gear shaft
Drive pin ion shaft
L3-610
Fig. 30
19
Engine power is transmitted from the rear planetary carrier to 3-6 Final Reduction Gears
the reduction drive shaft and the reduction drive gear. In a
The hypoid drive gear is mounted to the cast iron oil pump
FWD vehicle, power is then transmitted to the final gear
housing by double taper roller bearings. The hypoid driven
through the reduction driven gear and drive pinion. In a 4WD
gear and the differential are mounted to the differential case.
vehicle, power transmission to the front wheels is the same as
Both ends rotate and are supported by taper roller bearings in
a FWD vehicle. Power to the rear wheels is transmitted from
the converter case.
the transfer cl utch hub, welded to the side of the reduction
drive gear, and passes through the transfer clutch (multi-plate
clutch), to the rear drive shaft -+ propeller shaft -+ rear differ-
ential -+ rear wheel.
1) HYPOI D GEAR
/ Oil pump housing Lock washer Transmission case
Bolt
Oil seal holder
Drive pinion
shaft
! Reduction driven
gear
Lock nut
Lock nut
Bolt
Double taper roller bearing

Hypoid
drive gear L3·612
Fig. 31
The front end of the drive pinion shaft is supported by the 2) DIFFERENTIAL GEAR
double-taper roller bearing on the oil pump housing. The rear
end is supported by two roller bearings on the transmission
Differential bevel pinion
case and extension case (rear case for FWD vehicle). The Bolt
double-taper roller bearing is preloaded by tightening the lock
Pinion shaft
nut to a specified torque via the collar. The tooth contact of
the hypoid gear is adjusted by changing the shim thickness
between the double-taper roller bearing flange and oil pump
housing.
The rear end of the drive pinion shaft is spline-fitted to the
reduction driven gear, which is secured with a lock nut. The
external helical spline has a length, and the reduction driven
gear is force-fitted to this shaft end.
-------
No. of drive pinion shaft
teeth
No. of hypoid drive gear

2700 cc
10
37
1800 cc
10
39
Left-hand
differential case
Diameter of hypoid
mm (in) 170 (6.69) 170 (6.69)
drive gear
L3-613
Hypoid offset mm (in) 23 (0.91) 23 (0.91)
Fig. 32
20
The differential bevel gear is locked to the axle shaft by a clip. The speedometer drive gear is mounted directly on the differ-
ential case, and the flexible cable is led from the right side of
the converter case. With this arrangement, the speedometer
drive and driven gears are properly lubricated.
3-7 Hydraulic Control System

The hydraulic control system consists of an oil pump, control
Pull-off load in the valve bodies, clutches, brakes and connecting passages and
direction of arrow: 1,177 N (120 kg, 265 Ib) pipes. When it is activated manually, or automatically by the
L3·614
electronic control system, it hydraulically controls the gear-
Fig. 33 shifting mechanism.
3) SPEEDOMETER GEAR SYSTEM
.?
o
C
~
Converter case
+0 Speedometer shaft
,....
,
fJ
0 Oil seal
['\l C\j
'ft::~l£---- Washer
Snap ring
Speedometer
driven gear
l::i-- Speedometer
drive gear
L3-615
Fig. 34
21
UPPER VALVE BODY
1 Pressure regulator valve

2 Pressure regulator plug
3 Pressure regulator sleeve plug
4 Pressure modifier valve
5 Pilot valve
7 Accumulator control plug
8 Accumulator control sleeve
9 Manual valve
10 Shift valve A
® 11 Sh ift valve B
I 12
13
Shuttle sh ift valve B
Overrunning clutch control valve
14 4·2 relay valve
15 4-2 sequence valve
16 Servo charger valve
17 3·2 timing valve
18 "1" reducing valve
19 Overrunning clutch reducing valve
20 Torque converter relief valve
21 Lock-up control valve
22 Lock-up control plug
23 Lock-up control sleeve
24 Shuttle sh ift valve D
LOWER VALVE BODY
Fig. 35 L3-919
22
(2) Valve Body Configuration
< Upper valve body>

Lock·up--- Torque converter
contro I f-6-Eqp--l.n...J..L.J-.:;=='V
regu lator valve
valve
Pressure regulator
valve
-'-"""-'-- Pressure modifier valve

o
Pilot valve --~-~~~a--::
o Accumulator control valve
o0 o
, . -_ _ _---l
o o -lli~~~~E~ Shuttle duty shift valve

o
4·2 sequence valve
4·2 relay valve =-=t-=-:~- Shift valve A
Overrunning clutch control valve
8~j(~~g~ Overrunning clutch

reducing valve
00
L3·920
Fig. 36
< Lower valve body> Manual valve
~~~~- 3·2 timing valve
fiE~~~~~:t Servo charger valve
L3·921
Fig. 37
23
3-2
(3) Related Parts (1)

AUTOMATIC TRANSMISSIO=N~A~N=D===
"d 1 (shift),
DIFFERENTIAL
___ ==-__
Solenoid ASSY Solenoid-2 (shift) "
" d WI"th Solenol Solenoid-l (shift)
The control ( valve body is"d fltte
3 (overrunning clute h) , Duty
So h Solenoid-3
lenoid 2 s I"ft) , SolenOi olenoid B (loc k -u p) and an
solenol"d A (line
" pressur e) , Duty s (overrunning clutch)
ATF temperature sensor"
Duty solenol"d B (lock-up)
L3-618
" 39 Upper surface a f control valve

Fig.
L3-617
" 38 Lower sur,~ace of control valve

F Ig.
< Upper valve body> < Lower valve body>
Strainer location
Nine steel ball location
L3-922
Fig. 40
24
FRONT REAR
.-- -.
Transmission case
Manual shaft Detent spring
L3-622
Fig. 41
< Pipe names>

No. Description Hydraul ic circuit
CD Oil cooler outlet pipe Cooling line from control valve to oil cooler inside radiator
CV Transfer control pipe Line-pressure supply line to transfer control valve
@ Reverse clutch pressure pipe Accumulator circuit of reverse clutch pressure
@ 4A pressure pipe 4A pressure circuit
® 3R pressure pipe 3A pressure circuit
® Forward clutch pressure pipe Supply line to N -+ D accumulator
(J) Pilot pressure pipe Pilot pressure supply line to shuttle shift valve S
@ Pressure-modifier pressure pipe Supply line to pressure modifier accumulator
25
2) FUNCTION OF EACH VALVE
Name Function
• Pressure regulator valve Regulates the pressure of oil delivered from the oil pump to an optimum level (line
• Pressure regulator plug pressure) corresponding to vehicle running conditions.
• Pressure regulator sleeve plug
Pressure modifier valve An auxiliary valve for the pressure regulator valve. This valve adjusts pressure used
to regulate I ine pressure to an optimum level corresponding to running conditions.
Pressure modifier accumulator Smoothes the pressure regulated by the pressure modifier valve to prevent pulsation
piston in line pressure.
Pilot valve Creates the constant pressure (pilot pressure) necessary to control line pressure,
lock-up, overrunning clutch, 3-2 timing, and gearshift operations from line pressure.
• Accumulator control plug Adjusts accumulator back pressure to correspond to running conditions.
• Accumulator control sleeve
Manual valve Delivers line pressure to each circuit corresponding to the selected position.
~ircuit CD CV ®
Range~
P
R o
PRND32
N , ! I' I I
o o
B)
3 o
Fig. 42
2 o o L3-924
When the valve is set in the "line pressure no delivery" position, the pressure is
relieved.
Shift valve A Simultaneously changes three different oil passages using shift solenoid 1 output
pressure corresponding to such operating conditions as vehicle speed and throttle
opening. Combined with shift valve B, this valve permits automatic shifting of
1st ~ 2nd ~ 3rd ::t 4th speeds.
Shift valve B Simultaneously changes three different oil passages using shift solenoid 2 output
pressure corresponding to such operating conditions as vehicle speed and throttle
opening. Combined with shift valve A, this valve permits automatic shifting of
1st ~ 2nd ~ 3rd t: 4th speeds.
Shuttle shift valve S Changes the 3-2 timing control and overrunning clutch control oil passages corre-
sponding to the throttle opening. When the throttle is wide open, the overrunning
clutch becomes inoperative to prevent interlocking at 4th speed.
Overrunning clutch control valve Changes oil passages so as to prevent simultaneous operation of the overrunning
clutch when the brake band is actuated at 4th speed. (Operation of overrunning
clutch at 04 speed results in interlocking.)
26
Name Function
4-2 relay valve Memorizes the 4th speed position, and prevents gear sh!fting from 4th to 3rd to
2nd speeds due to combined operation of the 4-2 sequence valve, shift valve A and
shift valve B when shifting down from 4th to 2nd speeds.
4-2 sequence valve Inhibits release of band servo operating pressure acting at 4th speed until the high
clutch operating pressure and band servo release pressure (same hydraulic circuit)
are drained when shifting down from 4th speed to 2nd speed.
Servo charger valve The 2nd speed band servo actuating hydraulic circuit has an accumulator and
one-way orifice for relieving shift shock when shifting from 1st speed to 2nd speed.
The servo charger valve is installed to ensure sufficient oil flow when shifting down
from 4th to 2nd speed, or from 3rd to 2nd speed. It operates at 3rd or higher
speeds and supplies the 2nd speed band servo actuating pressure by bypassing the
one-way orifice.
3-2 timing valve When shifting down from 0 3rd to 0 2nd speed, the timing valve retards the release
of band-servo pressure and creates a temporary neutral condition so that vehicle
speed can be changed smoothly.
"1" Reducing valve Reduces the low & reverse brake operating pressure so as to relieve engine braking
shock when changing from "2" range 2nd speed to 1st speed.
Overrunning clutch reducing Reduces the operating pressure applied to the overrunning clutch so as to relieve
valve engine braking shock. In the "2" and "3" ranges, line pressure is applied to the
valve to raise the pressure adjusting point, thereby increasing engine braking
capacity.
Torque converter regulator valve Prevents excessive rise of torque converter pressure.
• Lock-up control valve Controls the operation of the lock-up function.

• Lock-up control plug Smoothes the transition between the lock-up state and release state.
• Lock-up control sleeve
Shuttle shift valve 0 Changes the oil passage so that output pressure to the duty solenoid B (lock-up)
will be applied to the lock-up valve in the "0" range 2nd, 3rd, or 4th speed.
(Lock-up at 1st speed is inhibited.)
at 1st speed is inhibited.)
* Lock-up control is not actuated if the lock-up solenoid does not generate output
pressure when signaled from the control unit, even if the vehicle is in the "0"
range 2nd, 3rd, or 4th speeds.
27
3) OPERATION OF EACH VALVE

(1) Pressure Regulator Valve
In the regulator valve, force "F L" generated by oil pump

pressure (line pressure) acts to the right, while force "FMF"
generated by the pressure modifier pressure, force "F RIC" and
spring force "Fs" act to the left.
If FL becomes larger than FM F + F R/C + Fs, the valve moves
toward the right, and passage CD communicates with passage
ell. Hydraulic pressure is then applied to the control piston
of the oil pump, decreasing the oil pump discharge pressure.
As a result, oil pump pressure is adjusted to maintain an
equilibrium between FL and FMF + F R/C + Fs.
With this valve, the discharge pressure of the oil pump is
adjusted to an optimum pressure (line pressure) corresponding
to the running conditions of the vehicle, so that oil pump
driving energy loss is reduced and gearshift shock is rei ieved.
Line pressure
pressure
Line pressure
x piston
Fs (Spring force)
F L (Force of line pressure) FMF (Force of pressure modifier pressure)
FR/C (Force of reverse clutch pressure)
To oil pump To torque converter

control piston regulator valve L3·625
Fig. 43
28
(2) Torque Converter Regulator Valve (3) Pressure Modifier Valve

Torque converter pressure is applied to the valve as a force The force of the P L duty pressure, which is pulse-width
pushing the valve to the right. If the force generated by torque modulated by the line pressure duty solenoid, and spring
converter pressure becomes greater than the spring force, the pressure push the valve to the right. Meanwhile, oil entering
valve moves toward the right, and torque converter pressure is through the oil passage CD
passes through the orifice and
relieved. Accordingly, torque converter pressure will not enters the chamber @, pushing the valve to the left. The pilot
exceed the set pressure 686 kPa (7 kg/cm 2 , 100 psi). pressure entering from passage ® to chamber ® also pushes
the valve to the left. Accordingly, oil pressure from the passage
CD is regulated to obtain equilibrium in the valve. This is the
pressure modifier pressure.
Line pressure This pressure modifier valve serves as a pilot valve for the
pressure regulator valve. It is used to create the pilot pressure
needed to regulate line pressure to an optimum level corre-
sponding to the driving conditions of the vehicle.
To pressu re regu lator valve
+----
Torque converter pressure: front portion
To L/U CONT
X Line pressure
Pilot pressure
FT IC (Force of torque
converter pressure)
---I~~I Fs (Spring force)
x
FPL SOL
(Force of PL
FMF (Force of pressure
L3·626 duty pressure)
I+--modifier pressure)
Fig. 44
Fs
(Spring force)
-----j~~ To pressure regulator valve
L3-627
Fig. 45
(4) Accumulator Control Valve

The force of the P L duty pressure, which is pulse-width-
modulated by the Iine pressure duty solenoid and the spring
force push the valve to the right. Meanwhile, the force of the
oil coming from the oil passage CD
into the chamber @
pushes the valve to the left. The oil pressure from passage CD
is adjusted to maintain an equilibrium of forces in the valve,
and this pressure is used as the accumulator back pressure.
This valve adjusts accumulator back pressure corresponding to
running conditions, thereby reducing gearshift shock.
29
Control unit
Line pressure
solenoid
PL duty pressure
Accumulator piston ) Pilot pressure
Upper: after shifting gear
( Lower: before shifting gear
"0" range pressure X
FR SOL
(Force of PL duty pressure) ACCUM
(Force of accumulator control pressure)
Spring force
To accumulator
L3-628
Fig. 46
(5) Shuttle Shift Valve 0

To lock-up control valve
The 2A pressure pushes the valve to the right, while the spring
force pushes the valve to the left .
• In 1st speed, and in "N", "R", or "P" range:
The shuttle shift valve is in condition (b). The pilot pressure
flows to the lock-up control valve and keeps the torque
converter lock-up clutch in the unlocked position (i.e., the
condition of torque converter coupling).
• In 2nd, 3rd, or 4th speed:
The shuttle shift valve D is in condition (a). The lock-up
duty pressure is routed to the lock-up control valve, and control valve
keeps the torque converter in the lock-up (direct-connec-
Lock-up duty pressure
tion) position.
(Force of 2A
Fs
(Spring force) t
pressure)
To forward To lock-up
control valve control valve
L3-925
Fig. 47
30
(6) Shift Valve Band 4-2 Sequence Valve When shifting down from 4th to 2nd, the 4-2 relay pressure
oi I flows from the passage ®. It then flows to the 4-2
sequence valve via passage ®.
Shift valve B
• In 3rd or 4th speed: Shift solenoid 2 pressure is OFF.
The shift solenoid 2 pressure pushes shift valve B to the left, Because no shift solenoid 2 pressure is generated, the valve
while spring force pushes the valve to the right. remains in condition (b), and oil pressure from passage @
• In 1st or 2nd speed: Shift solenoid pressure is ON. serves as the operating pressure for 3 R and Hie via passage
Shift valve B is in condition (a). When "2" range 1st speed ®.
or hold range 1st speed is selected, the oil from passage CD
flows to the low & reverse brake from passage ® via shift
valve A.
3R pressure
//A'""''''''''' t~
_ To H/C
(a)I~§61.II.1
(a)
(b) (b)
§WA=~~
pressure B pressure
4-2 relay "D" range 1st reducing 4-2 relay pressure

X
-
(Force by
3R pressure)
Fs (Spring force) FSOL Fs (Spring force)
(Force by
shift
solenoid
pressure)
To 4-2 sequence To H/C To shift A
ro shift A valve
valve L3-630
Fig. 48
4-2 sequence valve

The 3R pressure pushes the valve to the right, while the spring
force pushes the valve to the left. (When shifting down from
4th to 2nd.)
The valve remains in condition (b) as long as 3R pressure
exists. In this condition, the 4-2 relay pressure (line pressure)
flows from passage (j). It then flows to shift valve A from
passage ®.
31
(7) Shift Valve A and 4-2 Relay Valve • In 1st or 4th speed: Shift solenoid 1 pressure is ON.
The valve is in condition (D). In F2 range 1st speed, or
Shift valve A hold range 1st speed, oil from passage CD
is applied to the
The pressure from the solenoid 1 pushes the valve to the left, L&R/B from oil passage @. In 4th speed position, oil
wh ile spring force pushes the valve to the right . pressure from passage ® is applied to the servo 4A
• In 2nd or 3rd speed: Shift solenoid 1 pressure is OFF. chamber through oil passage (j).
The valve is in condition (a). Oil pressure from passage ®
is applied to the servo 2A chamber from oil passage ® .
• In 4th to 2nd shift down:
Oil from oil passage ® is applied to the servo 4A chamber
and 4·2 relay valve through passage (j) if 3R 4A pressure
exists.
"0" range 4-2 sequence

From shift To shift
From shift 2A pressure
(a)~~_ _ (a)
(b) (b)
pressure
Sh ift soleniod
1 pressure
4A
"0" range
pressu re
4·2 sequence Shift
valve 6
"0" range pressure X
Fs FSOLl Fs
(Spring force) (Force of (Spring force)
sh ift solenoid
pressure 1)
4A 2A To valve A
L3·631
Fig. 49
4-2 relay valves

The force generated by 4A pressure pushes the valve to the
left, while the spring force pushes the valve to the right. When
shifting from 4th to 2nd, status (a) is attained if 4A pressure
exists. Oil from passage @ is routed to the 4·2 sequence valve
via shift valve B from oil passage ®.
32
(8) Overrunning Clutch Control Valve Under conditions other than coasting, oil flows into passage
@, and the valve is set in condition (a). In 4th speed, the oil
During coasting, no oil flows into passage @, and the valve
is set to condition (b) by spring force. Oil from passage @
from passage CD exerts pressure on the servo 4A chamber via
passage ®.
exerts pressure on the overrunning clutch via the overrunning
clutch reducing valve from passage ®.
1st reducing "D" range pressure
(a)
(b)
4A pressure Pilot pressure or overrunning

To overrunning clutch solenoid pressure
clutch reducing valve
OV/C
(Force of 1st
reducing pressure)
1st
L 4A
,..-------11-----+--.
To overrunning clutch reducing valve
(Force of pilot pressure)

Fp
Fs----+I
(Spring force) FOVR/CSOL
(Force of overrunning clutch
solenoid pressure)
From shift x. "D" range pressure

valve B (From manual valve)
L3-926
Fig. 50
(9) Overrunning Clutch Reducing Valve

"3" range pressure
"0" range
Oil from the overrunn ing clutch control valve to passage ®
exerts the overrunning clutch pressure to chamber CD
via
orifice @, and pushes the valve to the right. If overrunning
clutch pressure exceeds spring force, the valve moves further
to the right. This releases the overrunning clutch pressure. As
a result, overrunning clutch pressure is maintained at a con-
stant level.
L _ _ _ _..;:;.-=~_To overrunning clutch

"3" range
In addition to the forces mentioned above, the valve is also "0" range pressure
pushed to the left by the force of oil coming from the manual PL ("3" range pressure)
valve into the chamber ®. Accordingly, overrunning clutch
pressure is adjusted at a higher level than that of "D" range.
FOVR/C REC _ - - - Fs (Spring force)
(Force of overrunning
clutch reducing
pressure)
To overrunning clutch
L3-633
Fig. 51
33
(10) Shuttle Shift Valve S (11) Pilot Valve

"0", "3" range The valve is pushed to the right by pilot pressure, and is
The valve is pushed to the right by spring force, and is pushed pushed to the left by spring force. If pilot pressure force
to the left by the "D" and "3" range pressure. exceeds spring force, the valve moves to the right, and pilot
When the throttle opening is small (Fs> F D ), the valve is set pressure is released. Accordingly, pilot pressure is maintained
in condition (a). Overrunning clutch solenoid pressure (shift at a constant level.
solenoid 3 pressure) from passage ® is then appl ied to the
overrunning clutch control valve via passage ®. Engagement
of the overrunning clutch is controlled by this pressure.
When the throttle opening is large (Fs < F D ), the valve is set Li ne pressu re
in condition (b). Accordingly, pilot pressure from passage CD
is applied to the overrunning clutch control valve via passage
® . This pressure prevents the overrunning clutch from engag-
ing. The oil coming from passage ® exerts pressure on the
3-2 timing valve via passage ® .
"2" range
The "2" range pressure is applied to the valve, setting the valve
in condition (a). In this state, engagement of the overrunning
clutch can be controlled by the overrunning clutch solenoid
pressure (shift solenoid 3 pressure). Line pressure
Fp (Force of
To overrunning clutch
control valve
To 3-2 timing valve -
pilot pressure)
- Fs (Spring pressure)
(a)
(b)
L3-635
Fig. 53
(From manual valve)
pressure
Pilot
Overrunning FD [Force of "D",
pressure
clutch
pressure
(12) Manual Valve
(Spring force) Rotary motion of the range select lever is changed into re-
Fs ciprocating motion of the manual valve by the manual lever.
FII pressure, In "P", "R", "N", "D", "3", and "2" positions, the manual
(Force of "2" condition (b)]
valve is set respectively so that line pressure ® is distributed
range pressu re) '-----+----+---t--'
to the following line pressure circuits:
Overrunning
"P" range:
3-2 timing
valve clutch control Line pressure ® - @ - d r a i n
valve
L3-927
"R" range:
Line pressure ®-®~ reverse clutch
Fig. 52
L- low & reverse brake
"N" range:
Line pressure ® ---------0__ None
34
"0" range & "3" range: "2" range:
Line pressure @-CD forward clutch 1st hold
4-2 relay valve Line pressure ®---r-CD-same as "0" range
shuttle shift valve S L ® -r- 1st reducing valve
shift valve A L- Same as "2" range
shift valve B
overrunning clutch control When the valve spool is set in a position where no line pressure
valve is delivered from port @, pressure at ports CD, ® and @
"2" range: is drained from port @.
Line pressure @-r--CDtsame as "0" range
L-® shuttle shift valve S
overrunning clutch reduc-
ing valve
Line pressure "R" range pressure
2 3 0 R P
I I I I I
"2" range "0", "3" range

pressure pressure
L3-928
Fig. 54
(13) Lock-up Control Valve

The lock-up control valve is pushed to the right by the torque
converter REG pressure and the pilot pressure. Meanwhile, it is
pushed to the left by the lock-up duty pressure and spring
pressure.
When lock-up is operating: [A)
No lock·up duty pressure is generated, and the valve is set [B)
in condition (A). Oil flows to the torque converter AP side,

applying lock-up.
In smooth control: ~o::::::::=~ Torque converter
~ REG pressure
Torque converter REG pressure is controlled by the lock-up Lock-up apply circuit
duty pressure. Hence, the force applied to the lock-up

Lock-up release circuit
clutch is controlled for smooth lock-up clutch engagement.
Torque converter pressure
When lock-up is not operating:
Lock-up duty pressure is generated. The valve is set in
FT/C REG (Force of torque
condition (B). Oil flows into the torque converter REG converter release pressure)
FL/U SOL (Force of lockup duty pressure)
side, making the lockup inoperative. Fp (Force of pilot pressure)
Fs (Spring force)
In 1st speed "N", "R", and "0" range:
Pilot pressure is generated. The valve is set in condition (B), To torque converter REG To torque converter AP
and lock-up is inoperative.
L3-637
Fig_ 55
35
(14) 1st Reducing Valve (15) 3-2 Timing Valve

This valve is pushed to the left by the oil in chamber ® When shifting from "0" range 3rd to "0" range 2nd:
coming from passage CD.
If the oil pressure exceeds spring This valve switches the 3R pressure releasing time.
pressure, the valve moves to the left, and the oil is drained. When oil passes through orifice A only:
Hence, the 1st reducing pressure remains constant. The valve is set in condition (B), and the 3R release oil
passes through orifice A. Hence, release time is prolonged.
When oil passes through both orifice A and valve:
The valve is in condition (A), and the 3R release oil passes
1 st reducing pressure through orifice A and the valve. Hence, release time is
(To L & R brake via shift valve A.B}
shortened.
Overrunning clutch solenoid pressure

(Shift solenoid pressure}
+
"2" range pressure
"2" range pressure
Fs F1st RED
(Spri ng force} (Force of 1st
reducing pressure}
3 R rei ease p ressu re
3R release pressure
1st reducing pressure
F oVRte SOL (Force of
overrunning clutch solenoid
pressure or shift solenoid Fs
(Spring force}
Fig. 56
L3-638 3 pressure}
..
To shift B valve L3-929

Fig. 57
(16) Servo Charger Valve

When shifting from "0" range 3rd to "0" range 2nd:
In "D" range 3rd speed, the valve is in condition (A). Passage
CD communicates with chamber ®. If the 3R pressure
exceeds spring pressure, the valve shifts to condition (B),
where passage ® communicates with chamber ®. Accord-
ingly, the valve will remain in condition (B) as long as 2A
pressure exists. This means that oil can be fed to the servo 2A
chamber without passing through the orifice. Thus, it is
possible to quickly compensate for the oil drained through
the servo 3R chamber. This prevents engine racing while
downshifting.
36
(17) Accumulator
The job of the accumulator is to lessen the shock when shift-
ing gears. The accumulators used in the present system are the
2A, 3R and 4A accumulators. They are located, respectively,
in the 2nd apply pressure circuit, 3rd release pressure circuit
and 4th apply pressure circuit to lessen shifting shocks. An
N-D accumulator is also provided to reduce shock in selecting.
In addition to electronic control of line pressure, the 2A, 3R
and 4A accumulators provide electronic control over the
resistance of the accumulators, which serve as shock absorbers
in the Iine pressure passages, according to sh ifting conditions.
To servo 2A
If oil pressure is suddenly applied to the clutch without using
an accumulator, the clutch will not engage smoothly, causing
an uncomfortable shock. Further, while oil pressure increases
2A pressure smoothly in mechanical types of accumulators, the way it
increases is constant. Accordingly, they cannot cope with
various operating conditions. For these reasons, in this full-
F2A (Force of 2A
-
range, electronically-controlled automatic transmission, the
pressure)
Fs (Spring force) resistance of the accumulators is electronically-controlled to
F3R (Force of 3R correspond to operating conditions. This always assures the
pressure)
optimum, smooth increase of oil pressure when it is appl ied
To servo 2A chamber to the clutch.
L3-640
Fig. 58
• Electronically-eontrolled accumulator system (2A accumulator)
Clutch piston
Upper part: After shifting )
Accumulator piston ( Lower part: Before sh ifting
l"SigMIp~e~s~r; th;t dete;:-min~;- ~

: the resistance of the accumulator I
I piston to operating oil pressure. :
) It is electronically-controlled by I
// I a line pressure solenoid so that it I
I / : becomes optimum for the I
r--------------, I / Ls~i~i~g .:~~t~~. ______ J
I Oil pressure (line pressure) I I /
I
I that operates the clutch I Accumulator control
:'-piston
_ _ _to
_engage
____ the_clutch
_ _ _ ..J I pressure
I
I
I
I Control unit
I
:- Oilpresru;:;TIiM~ressure) that - ~ Throttle pressu re

I exerts pressure on the accumulator I
I piston until it reaches equilibrium. I
I The oil pressure applied to the clutch I
I piston smoothly increases to this I
I pressure.
L _ _ _ _ _ _ _ _ _ _ _ _ _ JI
Pilot pressure
L3-826
Fig. 59
37
The four accumulators are arranged in series under the trans-
• Control of clutch operating oil pressure by an
mission case, in the order of 4A, 2A, 3R and N-D from the
electronically-controlled accumulator
front side.
When an accumulator is not used,

oil pressure rises rapidly.
\/---~-...,..-
.-
'0 /
/ Clutch operating oil pressure
/
/ optimized for operating
I. conditions by electronic
When an electronically- control
controlled accumulator
is used, the increase in
oil pressure can be
freely requlated.
Time
L3-827
Fig. 60
4A accumulator 2A accumulator 3R accumulator N-D accumulator L3-828
Fig. 61
38
3-8 Electronic-Hydraulic Control System

1) OUTLINE
The electronic-hydraulic control system consists of various
sensors and switches, a transmission control unit and the
hydraulic controller including solenoid valves. The system
controls the transmission proper including shift control, lock-
up control, overrunning clutch control, line pressure control,
auto pattern select control and shift timing control. It also
controls the 4WD transfer clutch. In other words, the system
detects various operating conditions from various input signals
and sends output signals to shift solenoids 1, 2 and 3 and duty
solenoids A, Band C (a total of six solenoids for 4WD and five
solenoids for FWD).
Electronic control I/O functions
INPUT r_L~I~n~i~~~u~_ -,
I -
ON OFF I
IThrottle opening sensor I
I
Sh ift solenoid 1 I
: Two solenoid are combined
I ON-OFF
I I
Shift solenoid 2 J
) : for 1st to 4th speeds.
Iidle switch I : I
Transmission
I Vehicle revolution
I
Sh ift solenoid 3
ON-OFF
I
I{I 3-2 shift timing control
Engine brake control
sensor 1 I
Built in meter I I
I
IVehicle revolution 2 I
DutY solenoid A
J
: Line pressure control
I I
Ignition pulse I
I Engine speed I I
Duty solenoid B II : Lock-up control
I I
IATF temperature sensor Control unit
I
I
Duty solenoid C I I 4WD transfer control (4WD)
P, R, N, D, 3,2
I Inhibitor switch
r-s.:----- ~
~
2nd range monitor

...J
Lights when 2nd range

I J , is selected
I Lights when 1st hold

[1st hold I
1st hold monitor
I, is selected
I FWD switch i Pattern monitor I I Lights at power pattern

(4WD)
!
lBattery voltage I ATF temperature
monitor :JI , Lights when ATF
temperature is high (4WD)
---------
I Cru ise control signal Lamp output
I
L3-641
Fig. 62
39
(1) Input Signal Name and Function
Signal name Major function
Throttle sensor Detects th rottle opening and determines shift point, line pressure and lock-up
vehicle speed according to engine load.
Vehicle revolution sensor 1 Detects vehicle speed. This signal is used to control shifting, lock-up,line pressure,
(mounted to transmission) and transfer clutch.
Vehicle revolution sensor 2 FWD ... Used as backup in case of failure of vehicle revolution sensor 1.
(built-in meter) 4WD ... Used to control transfer clutch and as backup in case of failu re of vehicle
revolution sensor 1.
Ignition pulse Detects engine speed. This signal is used for lock-up clutch smooth, control at lock-
up and to prevent engine overrunning at "2" range "1st hold".
Inhibitor switch Used to determine shifting and line pressure for respective ranges "P", "R", "N",
"0", "3", and "2".
Idle (lID) switch Detects throttle closing. This signal is used for lock-up release, and for line pressure
control.
Cruise switch (cruise control) Detects operation of cruise control, and expands "4th" operating range.
4th cut switch (cruise control) Causes forced release of "4th" from cruise control unit if large difference exists
between set vehicle speed and actual speed when cruise is selected.
ATF temperature sensor Detects ATF temperature. This signal is used for inhibition of lock-up, release of
OD and detection of ATF temperature.
"1st hold" switch Used to maintain the transmission in 1st when going up or down steep hills, running
on sand, mud, or slippery surfaces.
FWD switch Used to change the driving mode from 4WD to FWD. Also used to adapt the vehicle
to FWD tester roller. Changeover from 4WD to FWD can be accomplished by
inserting a fuse into the fuse holder. (4WD only)
40
(2) Output Signal Name and Function
Signal name Function
Sh ift solenoids 1, 2 Controls sh ift stage by turning solenoid ON/OFF. Relationship between solenoid
operation and shifting stage is shown in Table below. When shifting, timing is con-
trolled for each solenoid to reduce shock.
Shift solenoid 3 Controls 3-2 shift timing and overrunning clutch operation. Shift timing is con-
(Overrunning clutch) trolled by controlling release speed of oil pressure to reduce shock while down-
shifting. The overrunning clutch is controlled so that it will operate during coasting
to apply engine brake.
Duty solenoid A Regulates the line pressure according to driving conditions.

(line pressure)
Duty solenoid B Regulates the hydraulic pressure of the lock-up clutch and operates in three modes
(lock-up) (open, smooth and lock-up).
Duty solenoid C Regulates the hydraulic pressure of the transfer clutch and controls the driving
(transfer pressure) force to the rear drive shaft.
"Power" indicator light Indicates whether the shift pattern is "Normal" or "Power". The indicator lights
in power mode. This light is also used for "self-diagnosis".
"2nd range" indicator light Lights when the "1st hold switch" turned OFF in "2" range.
"1st hold" indicator light Lights when 1st speed is achieved with the "1st hold switch" turned ON and shift
lever set to "2" range.
ATF temperature warning light Lights when ATF becomes hot (exceeds a set temperature level). (4WD only)
(3) Relationship Between Solenoid Operation and Shift Position
Shift position Shift solenoid 1 Shift solenoid 2 Shift ratio
0 0 1st
X 0 2nd
"D" range
X X 3rd
0 X 4th
0 0 1st
"3" range X 0 2nd
X X 3rd
0 0 1st
1st hold released X 0 2nd
X X 3rd
"2" range
0 0 1st
1st hold appl ied X 0 2nd
X X 3rd
0: Energized X : Not energized
41
2) CONTROL SYSTEM
FWD
Engine speed ~----------,

~===ln:h:ib:i:to:r:s:w:it:C:h===~~ - - - - - - - --, :
I I
1st hold ,witch
L -______________ ~
~-------,I I
I
I
I r- -- - -1 2nd range indicator light
I I
Battery voltage
L -______________ ~ ~----,I
I
I
I
I
I
I
I
I
I
r--
I
-1 151 hold indicator light
I
L _ _C_r_u_i,_e_c_o_n_tr_o_1'_i_gn_a_I_ _ ...JI- --1 I
I
I I
;-~ Power indicator light
I I I
------------------l
--------,
I
I
I
I
I
r ____ ...J
L-----
l
I
I
I
I
~ Planetary gear
"0>c ~
Multi~plate clutch
"c -Iii'" Multi-plate brake
's,
w
c ""::> ~
c. Brake band
~ E One-way clutch
0
f-
0;
c
c:::;> ";: '""
-.
: Power transmitting route .c !!
'" :§
~
c -Iii'" ">
: Hydraulic pressure control
circuit
e
LL ">
.~
:§ ~==============~§."
0 '"c "::>
- -- ~ u:
~~
: Mechanical signal
- -- . : Electrical signal
i=
L3-642
Fig. 63
42
2) CONTROL SYSTEM
4WD
~_n _ _ _ _ _ _ _ _ --,
FWD switch
I
Engine speed
~ _____ - _n-, I
1 1
Inhibitor switch ~ -- -- - ---I I I ~ - - -

I i ht
- - 1L._A_T_F_t_e_m_p_er_"_tu_re_w_"'_n_in_9__9__ _ _ _ _ _- '
I I
1st hold switch
r------ 1 I
I I
I I
I
I
I
I
I
I
I
,----1
I
2nd gear indicator light
~----------------~
Battey voltage ~----l I I I
r - - - ~L_1_s_t_hO_I_d_in_d_ic_a_to_'_1i_9h_t_ _ _ _ _ _- '
I I 1 I
r--i I
1
1 I I I
I I I
I
I ~I_p_o_w_e'_i_nd_i_ca_t_o_'_'i 9_h_t _ _ _ _ _ _ _ _ _ _
Cruise control signal
1 1
I I 1 1 I 1 .J
--------,
~ ~
Planetary gear :§ ~
8,
1i,; ~
~
0 Multi-plate clutch § ~ .!Eiii
.~
~
..,
Multi-plate brake .~
.~ ~gj
UJ Brake band ~
-;; .: .c.
One-way clutch
-0-
.~ 0 t- ~
"',;
c::C> :Power transmitting route .:: ~

.g ~
-& ~ .~
~ : Hydraulic pressure ~ ii c:~================lg~
_
control circuit
.... : Mechanical signal
~
;;
c
ii
h
--~: Electrical signal
~
'--------------
L3-643
Fig. 64
43
(1) Functions and Control Items
Control item Description of control
Normal shift control Upshifting and downshifting are set for each range, gear position and
• Normal pattern pattern according to throttle opening and vehicle speed.
'0
...
....
• Power pattern
I:: When cruise control is set, 4th gear operating range is expanded.
0 Control with cruise control
...
~
U
[V ~ 40 km/h (25 MPH)]
.r:,
(/)
.... ATF low temperature control Shifting into 4th gear is prevented when ATF temperature is below
co
a> the preset value.
<!)
1st hold control 1st hold range is limited only when selector lever is in "2" and 1st hold
switch is ON.
Normal lock·up control Lock-up ON/OFF is set for each range, gear position, and pattern
0.
::J-
~g
• "Normal": "D" range only according to throttle opening and vehicle speed. (Basically lock-up is
g I:: • "Power" : R, 3, 2 ranges OF F during gear shifting.)

-18
Smooth control Smooth lock-up is performed when lock-up is switched on.
Ol Engine brake control Overrunning clutch is operated according to range, vehicle speed, and
I::
I:: cruise control signals in order to apply engine brake properly.
e... I::
::J.r:,'O
t:~p 3-2 timing control Th is control speeds the release of servo piston pressure 3R when
0
I::
~::JI::
U "08 shifting down from 3rd to 2nd, thereby preventing engine racing.
I::
0
'in a> Ordinary control Line pressure is regulated according to throttle opening, vehicle speed
,!!! ....
E ::J and range signals.
(/) l:l
a>_
I::
.... 0
....co 0. .... Shifting control Line pressure is reduced when shifting to lessen shifting shock .
I- a>'"
I:: I::
._ 0
-IU Starting control Line pressure is at a minimum so as to reduce engine cranking load.
Power pattern control Power pattern is selected when throttle opening speed exceeds the
I::
.... (POWER light ON) preset value.
£lco-
0.0 .... When throttle opening is less than the preset value, normal pattern is
U'"
Normal pattern control
.- I::
-:a 0 resumed immediately if vehicle speed ~ 60 km/h (37 MPH), or within
E U three seconds if vehicle speed < 60 km/h (37 MPH).
0'"
... U
::J~
«~ ATF temperature Power pattern is selected if ATF temperature is above the preset value.
Shift step control ON/OFF timing for shift solenoid is controlled.
'0 When shifting, the lock-up clutch is temporarily released .

...
....
I::
Lock-up control
0
U When shifting down, the overrunning clutch is temporarily disconnected
Ol
Overrunning clutch control
I::
(3rd to 2nd: small throttle to reduce shifting shock.
'E
';:; opening in coasting,
...
..... 2nd to 1st: in coasting)
.r:,
(/)
Line pressure control When shifting, line pressure is controlled to the optimum level so as to
reduce shifting shock.
44
Control item Description of control
Ordinary transfer control Transfer oil pressure is regulated according to the throttle opening angle
and vehicle speed.
- ....Q) 0....
VI
C
~
.... .c:
....C0
(,)
1st hold control
Slip control
Transfer oil pressure is increased.
Immediately after detecting a sl ip, transfer oil pressure is controlled to

Cl~ the same pressure as "1 st hold".
3:::l (This control is canceled if V ~ 60 km/h (37 MPH), or when throttle is
vu
closed fully.)
Control in turns Transfer oil pressure is reduced after detecting the turn.
(2) Power Indicator Light (3) 1st Hold Indicator Light

The automatic transmission equipped vehicle is capable of The 1st hold indicator light lights when 1st speed is attained
automatically selecting two driving patterns; a normal pattern with the 1st hold switch set to ON and AfT selector lever set
suitable for ordinary driving and a power pattern suitable for to "2" range. See the following table:
driving uphill or rapid acceleration. The power indicator light
lights when the power pattern is selected. See the table below: 1st hold indi-
Selector 1st hold SW
Vehicle speed cator light
lever position
Selector Changeover from ON/OFF
Power i nd icator
lever normal pattern to
light ON/OFF Below 50 km/h
position power pattern ON
(31 MPH)
Pattern is changed • "Normal" pattern: "2" range ON
automatically accord- OFF Over 50 km/h
OFF
"D" range (31 MPH)
ing to depression of • "Power" pattern:
accelerator pedal. ON o km/h
Other than
ON (0 MPH) to OFF
"2" range
Max. speed
o km/h
Other than
OFF (0 MPH) to OFF
"2" range
Max. speed
45
3) A/T CONTROL UNIT conditions of the veh icle. It then sends control signals to each
solenoid according to the preset gearshift characteristic data,
The AfT control unit is mounted to the side face. It's front
lock-up operation' data, and transfer clutch torque data (duty
faces the wheel arch with the left side toward the rear seat.
ratio).
It receives various sensor signals and determines the running
~
Shift-
Line· Engine Self-
Gearshift Lock-up pattern 4WD Fail-safe
pressure brake diagnosis
control control selection control function
control control function
Item control
Throttle sensor 0 0 0 0 0 0 0 0
Vehicle revolution
sensor 1
(output shaft revolution 0 0 0 0 0 0 0 0
sensor mounted to
transmission)
Vehicle revolution IOnsor 2 (Note 1) (Note 1) (Note 1) (Note 1) (Note 1)

0 0
(built into meter panel) 0 0 0 I 0 0
~
Ignition pulse 0 0 0 0
"c. 0
(Noae 2)
-= Inhibitor switch 0 0 0 0 0
(Note 2)
1st hold switch 0 0 0
0
ATF temperature sensor 0 0 0 0 0 0
(Note 2)
Idle switch 0 0 0 0
0
Set signal 0 0
Cruise
control "4th" range
rele..e signal
0 0
(Note 3)
FWD switch 0
0
Shift solenoid 1 0 0 0
Shift solenoid 2 0 0 0
Duty solenoid A
0 0 0
(line pressure)
Duty solenoid B
0 0 0
(lock-up)
:;
S- Overrunning clutch
0 0 0 0
0" solenoid
Duty solenoid C
0 0 0
(transfer)
ATF temperature
0
warning light
Power indicator light 0 0

1st hold indicator light 0
2 range indicator light 0
NOTES: (1) Provided as spare for car-speed sensor 1 (mounted to transmission)

(2) Used as the diagnosis starting condition. If self-diagnosis does not begin. there is trouble somewhere in
the system_
(3) Used to display trouble history_
I
(1) Shift Pattern Select Control Changeover from
Selector
Shift pattern is selectable automatically between a normal normal to power Meter indication
position
pattern suitable for ordinary economy running and a power pattern
pattern suitable for climbing uphill or rapid acceleration.
Performed automati- • Normal pattern:
In the power pattern, the shift down point and shift up point
cally corresponding OFF
are set higher than those of the normal pattern. "0" range
to accelerator pedal • Power pattern:
When the power pattern is selected, the POWER indicator light
depression. ON
in the meter lights up.
46
< Normal pattern > < Power pattern>
r-
t
I
I
I
I
Cl 1-2
c: I
c: 50 50
I
~ I
o
(
o L-~L-L-L--L~__~__~__~__~__~~
o 20 40 60 80 100 120 140 160 180 o 20 40 60 80 100 120 140 160 180
(0) (12) (25) (37) (50) (62) (75) (87) (99) (112) (0) (12) (25) (37) (50) (62) (75) (87) (99) (112)
Vehicle speed km/h (MPH) Vehicle speed km/h (MPH)
L3-645
Fig. 65 Shift characteristics
Shift pattern changeover conditions Changeover to power

pattern is easier
CD Normal pattern to power pattern 4
Large
Select lever "D" range
t
Accelerator depression speed Greater than set value *
- * Depending on throttle opening and vehicle speed, 16 areas as

I shown in the figure are set. Accelerator depression speed for
pattern changeover is set for each area.
When the accelerator depression speed exceeds this set value,
the pattern changes from normal to power. Small '--____-'--____- L -_ _ _ _---'-_ _ _ _ ~
Low _ Vehicle speed - - High L3-646
Fig. 66
47
CV Power pattern to normal pattern

The power pattern is shifted to the normal pattern, depending
on car speed. Shifting to the normal pattern is determined by
the throttle position as shown in Figure below. Time lag in
shifting is also determined by car speed. The maximum time 100~-~-"-Tr-----r----r'~I,,-r--~-'~r-~
lag is 3 seconds. I
I
,...--' --'
I
1_2
Large ~---~--------r-----,------, I
I
t Power I
I
I
I
Throttle I
I
opening
I
(
I
I
I
I
~ I
I
Small I
Low- Vehicle speed -High I
I
L3-825 O~LiL-L-~-LL-__L-__L-__L-__~~~~
o 20 60 80 100 120 140 160 180
Fig. 67 (0) (12) (37) (50) (62) (75) (87) (99) (112)
Vehicle speed km/h (MPH)
(2) Shift Control

Gearshifting is controlled in response to driving conditions,
according to the shift point characteristic data, as shown in L3-647
the following diagram, stored in the AfT control unit. Fig. 68
Solenoids are operated at the proper time corresponding to
the shift pattern, throttle opening, and vehicle speed for 0 0
When oil temperature is below approximately 10 C (50 F),
smooth shifting.
the vehicle cannot be shifted to the 4th range.
48
Shift clutches
~----------------l
: I
« co
Q)
Q)
> >
m m>
...
>
:= :;
.l: .l:
(/) (/)
,00;
L_~~[joId2J Sensors
. ,------------,
• Throttle opening I
• Vehicle speed I
I ~' Vehlcl~
.
I revolution
AfT I I~Mor
~.
Clutch fluid
control
<~======~ I
unit
I
Shift command Determination of optimum L __________ J I
signals gear position (incl. selection
of shift pattern)
Solenoid 1 Solenoid 2
1st 0 0
Clutch 2nd X 0
actuating
AfT 3rd X X
4th 0 X
CD Control unit activates both solenoids 1 and 2 in response

Solenoid to throttle and vehicle speed signals.
CV Shift valve moves in response to solenoid operation,
supplying/interrupting clutch pressure to the line.
® Gears are shifted by ON-OFF operation of both solenoids
as indicated in Table above.
*When clutch pressure is supplied to the line.
L3·930
Fig. 69 Shift valve operation system
49
(3) 3-2 Timing Control At this point, the servo piston moves to release oil pressure
from the 3rd release chamber (3R) and apply oil pressure to
When shifting from 3rd to 2nd, the high clutch is disengaged.
the 2nd apply chamber. This causes the brake band to be
At the same time, oil pressure (which releases the brake band) applied. In other words, high clutch "release" and brake band
is also released from the servo piston 3rd release chamber
"application" are properly timed by electronic control. Th is
(3R).
eliminates engine rev·up under no load or hesitation.
Se rvo piston 3rd

release chamber High clutch
apply pressu re
.---p
oi I pressu re
Timing control
solenoid (shift
solenoid 3)
AfT
control
unit
L3-931
Fig. 70
• When the 3-2 timing valve conducts, oil pressure applied • When the 3-2 timing valve does not conduct, oil pressure
to the 3rd release chamber is quickly released through appl ied to the 3rd release chamber is slowly released
passage @. through passage @ (provided with an orifice).
50
(4) Line-pressure Control

CD Ordinary line-pressure control and starting control
Control piston ~ Feedback pressure

(moves on the fulcrum in
the direction of the arrow o Line pressure
by feedback pressure to
move cam ring)
," ---- -- .... ------,

I
r
I
Cam ring I
(moves on the fulcrum in I
the direction of the arrow Torque converter oil pressure
by control piston to change
the amount of eccentricity X
with respect to rotor)
Pressure regulator valve
Fulcrum
- -
Oil pan
l Throttle pressure
Line pressure
x
AfT
Rotor control
(engages with oil pump drive shaft unit
and turns in response to engine speed)
ATF temperature sensor

Range signal
Vehicle speed
Throttle position
L3-932
Fig. 71
51
® Shifting control (Line-pressure control) ing operating conditions.
In other words, line pressure decreases to match the selected
Oil pressure which engages shift clutches (to provide 1st
through 4th speeds) is electronically controlled to meet vary- shift position, minimizing shifting shock.
_ Line pressure (Clutch operating pressure)

o Pilot pressure Signal pressure to
control line pressure)
1(
~ Th ro ttl e pressure
and shift valve
I Shift clutches
I m Accumulator control pressure switching
Transie nt oil pressure Accumulator

to oper ate cI utches
t
t Accumulator control
Solenoids 1 and 2
pressure
~
( Shift select valve)
r Shift valve
F~~(
I
(
Manual shift valve)
operated through
select lever
I Manual valve I ~ I Accumulator control valve
I
Drain
Li ne pressure 0 ptimally t r-------- --,
--J.'U.....,i) _ ,,
I Duty solenoid A I
regu Iated for cI utch operation
r- ------- -------- f----------- I
I Pressure regulator valve

.. Throttle pressure (also
serves as a signal to optimally l~ ·t I
Line pressure
t
regulate line pressure under
varying operating conditions)
~ .~
built up by
oil pump
Drain 8.
0
~;f;"
t Pilot pressure t '0
'0
c
( Oil pump ) Pilot pressure
.- ~'"
r-
Suction t
I Control unit
[)
, ( Oil tank
I
, l io n Throttle " positi
I I L ______________________ - - - - - - - - - - .., accelerator pedal I
\ \.\ I depressing speed, I
, I I
)._~ I etc. I
I ,
L _______ .JI
I
L3-933
Fig. 72
• Electronic control of clutch oil pressure in summary (5) Fail-safe Function N

a. Solenoids activate through the control unit which receives A fail-safe function is provided to maintain driveability even
various control signals (throttle signal, etc.) if trouble should occur in the vehicle revolution sensor,
b. Control signals are converted into throttle pressure, which throttle sensor, inhibitor switch, or any of the solenoids.
is transmitted to the pressure regulator valve. CD Vehicle revolution sensor
c. The pressure regulator valve optimally regulates line pres- A dual speed-sensing system is used. The speed signal is taken
sure (built-up by oil pump) in response to throttle pressure, from the transmission (output shaft revolution sensor) and
matching varying operating conditions. also from a sensor built into the speedometer. Even if one
sensor system fails, the vehicle can be controlled normally
with the other sensor system.
® Throttle sensor
If throttle sensor becomes faulty, throttle will be set to the
predetermined position. (In all ranges, throttle is set to the 5/8
position.)
52
® Inhibitor switch @ Sol 1 (shift) and sol. 2 (shift)
If two signals are inputted due to inhibitor switch failure, If trouble occurs in either solenoid, the other one is turned
the vehicle can be driven under the following priority. OFF to attain the following gear setting to allow vehicle
D > N (P) > > >
R 3 2 operation. Should trouble occur in both solenoids, the
Same as with "2nd" range if "1st hold" switch is faulty. hydraulic circuit operates mechanically.
Normal state Faulty solenoid 1 Faulty solenoid 2 Faulty solenoids 1,2

Shift position
1 2 Gear 1 2 Gear 1 2 Gear 1 2 Gear
0 0 1st - O~X 3rd O~X - 3rd - - 3rd
X 0 2nd - O~X 3rd X - 3rd - - 3rd

"D" range
X X 3rd - X 3rd X - 3rd - - 3rd
0 X 4th - X 3rd O~X - 3rd - - 3rd
0 0 1st - ~X 3rd O~X - 3rd - - 3rd
"3" range X 0 2nd - O~X 3rd X - 3rd - - 3rd
X X 3rd - X 3rd X - 3rd - - 3rd
0 0 1st - O~X 3rd O~X - 3rd - - 3rd

1st hold switch
released
X 0 2nd - O~X 3rd X - 3rd - - 3rd
X X 3rd - X 3rd X - 3rd - - 3rd

"2" range
0 0 1st - ~X 3rd O~X - 3rd - - 3rd
1st hold switch
X 0 2nd - O~X 3rd X - 3rd - - 3rd
operated
X X 3rd - X 3rd X - 3rd - - 3rd
0: Energized X : Non-energized Failed
® Duty sol. A (Line pressure) 4) THROTTLE SENSOR

If duty solenoid A fails, the solenoid is turned OFF and line
The throttle sensor provides electrical signals corresponding to
pressure is raised to maximum to enable vehicle operation.
the throttle opening. It has the following characteristics. The
® Duty sol. B (Lock-up)
throttle opening and accelerator depression speed are detected
If duty solenoid B fails, the solenoid is turned OF F and lock-
by th is throttle sensor output.
up is released_
(J) Sol. 3 (Overrunning clutch)
If the overrunning clutch solenoid fails, the solenoid is turned
OFF. The overrunning clutch will engage so that the engine 4.5+---~~
brake will be applied when reducing vehicle speed.

@ Duty sol. C (Transfer) Output
When the duty solenoid C becomes inoperative, it turns OFF. voltage
This causes maximum oil pressure to be applied to the transfer (V)
clutch so that the power is always transmitted to rear axles.
O.5+-------~--------------------~~
(Direct-coupling 4WD)
Throttle opening (Degree)

L3-649
Fig. 73
53
5) VEHICLE REVOLUTION SENSOR 1

(MOUNTED INSIDE THE TRANSMISSION)
[FWD]
The vehicle revolution sensor (output shaft rotation sensor) is
i
Resistance
mounted to the transmission case (front to the reduction
driven gear). This sensor outputs a pulse signal which is trans-
mitted to the AfT control unit where it is converted to vehicle
speed.
[4WD]
The vehicle revolution sensor (output shaft rotation sensor) is Temperature -
mounted to the extension case (from the outside of the case). L3-653
The sensor outputs a pulse signal which is transmitted to the
Fig. 76
AfT control unit where it is converted to vehicle speed.
The transfer clutch drum is connected directly to the rear
wheel driving propeller shaft. Vehicle revolution sensor 1 on
the 4WD model detects rear-wheel speed.
7) SOLENOIDS
1) SOL. 1 (Shift) and SOL. 2 (Shift)
These solenoids are mounted to the control valve. They are
turned ON or OFF according to signals sent from the AfT
control unit. The gear positions are changed according to the
ON and OFF condition of these solenoids.
IUPPER I
Solenoid-2 (shift)
L3-651 Solenoid-1 (shift)
Fig_ 74 Solenoid-3
(overrunning clutch)
6) ATF, TEMPERATURE SENSOR

This sensor is mounted to the control valve in the transmission.
It detects temperature change as an analog electrical signal.
The output characteristics of the sensor are shown below.
I LOWER I Duty solenoid B (lock-up)
ATF temperature
sensor
L3-652 L3-654
Fig. 75 Fig. 77
54
2) DUTY SOL. A (Line pressure) and DUTY SOL.B (Lock-up) 8) INHIBITOR SWITCH
These solenoids are mounted to the control valve. They repeat
The inhibitor switch assures safety when starting the engine.
ON and OFF at 50 Hz (0.02 sec period)* according to signals
This switch is mounted on the right side of the transmission
sent from the A/T control unit to open/close the drain circuit,
case, and is operated by the range selector lever.
thereby controlling the oil pressure to a specified level.
When the selector lever is set to "P" or "N", the electrical
*: A duty cycle type solenoid is used. It is capable of con-
circuit is connected in the inhibitor switch and the starter
trolling the ON/OFF time ratio in one cycle over the entire
circuit is energized for cranking the engine.
range from 0 to 100%. For example, a duty ratio of 50
When the selector lever is "R", "0", "3", "2", or "1st hold"
means 0.01 sec of ON period and 0.01 sec of OFF period
range, the electrical circuit is disconnected in the inhibitor
in one cycle of 0.02 sec.
switch. Hence engine cranking is disabled. In the "R" range,
the backup light circuit is completed in the switch, and the
backup lights come on.
~ Duty ratio 50 In addition to the above function, the inhibitor switch in-
corporates a circuit for detecting the selected range position
ON
and sending the range signal to the A/T control unit.
0.01
0.01
OFF~ ~
0.02
50 cycles per second
L3-655
Fig. 78
L3-657
Fig. 80
3) SOL. 3 (Overrunning clutch)
This solenoid is also mounted to the control valve. It is turned
ON or OFF according to the signal sent from the A/T control
~
unit. This operation controls the engagement and disengage- NO.
1 2 3 4 5 6 7 8 9 10 12
ment of the overrunning clutch.
'0
P~S:
4) DUTY SOL. C (Transfer) Lg
8 Y8 YW
GY
8, GW 8W
LgR
G
8Y
This solenoid is mounted to the transfer control valve on the TION
G* YLl\ GR *
side face of the extension case. It repeats ON and OFF at P 0- f.o 0- t-o
50 Hz (0.02 sec period) according to signals from the A/T
R
control unit. This operation opens and closes the drain circuit
to control transfer oil pressure. N 0 -0 0- t-o
0 ..(')
3 0- e{)
2
* 1800 cc model
\"Duty solenoid C (Transfer)
L3-656 L3-968
Fig. 79 Fig. 81
55
3-9 4WO Transfer Unit (Full-time 4WO)

1) OUTLINE
This 4WD transfer unit is an electronically controlled MP-T The sensors and transmission control unit are also used in
type, full-time, four-wheel driving system which is unique to common for gearshift control, lock-up control and hydraulic
SUBARU vehicles_ -It consists of a transfer hydraulic control pressure control.
system composed of various sensors, a transmission control
unit, duty solenoids and a combination of hydraulic multi-
plate clutches.
Transmission control unit
Throttle opening sensor
Input AID
Battery voltage interface converter
Circuit I
circuit
ATF temperature sensor

L: __ ~_~
I I
Vehicle revolution sensor 1

(rear wheel rpm)
Vehicle revolution sensor 2 Transfer

(front wheel rpm) clutch
CPU
Input
Range signal interface
circuit
I I Memory
Idle switch
1st hold switch

I I
I
Constant voltage
~
I I
I
source
Forced FWD switch
~-------'
L3-659
Fig. 82
56
PI LOT V -t---t-- - - -
Line
pressure
SOL
Transfer pressure
L3·934
Fig. 83
57
2) MAJOR COMPONENTS AND THEIR FUNCTIONS
Component name Function
Sensor Throttle opening sensor Detects throttle opening. This signal is used for determining the transfer
oil pressure.
Battery voltage Detects battery voltage. Used for voltage compensation of duty solenoid.
ATF temperature sensor Detects ATF temperature. Used for temperature compensation of duty
solenoid.
Vehicle revolution sensor 1 Detects rear-wheel speed. 30 pulses are generated per rotation of propeller
shaft. This signal is used for determining the transfer oil pressure.
Vehicle revolution sensor 2 Detects front-wheel speed. Four pulses are generated per rotation of
speedometer cable. Th is signal is used for determining the transfer oil
pressure.
Inhibitor switch Detects selected range signal. Used for determining the transfer oil
pressure.
Idle switch Used to release control when "slip" is detected.
Forced FWD switch Detects FWD mode. Releases transfer clutch.
1st hold switch When 1st hold range is selected increases the transfer oil pressure.
Actuator Duty solenoid C This solenoid is operated by a signal sent from transmission control unit
with duty ratio of 5 to 95% at driving frequency of 50 Hz. This solenoid
controls the transfer clutch hydraulic pressure.
Transmission control unit Computes the duty ratio according to signals sent from various sensors,
and issues a signal to the duty solenoid for driving.
58
3) 4WD TRANSFER UNIT (1) Transfer Clutch (Multi-plate clutch)

The transmission control unit has duty ratios memorized in
The transfer unit consists of a hydraulic multi-plate clutch and advance according to running conditions. In order to obtain
a transfer hydraulic control system incorporating a duty the optimum transfer torque for the running condition, the
solenoid valve. It is housed in the extension case together oil pressure that is applied to the drive plates and driven plates
with the bearings, rear drive shaft, etc. is controlled by applying oil pressure to the transfer piston
from the transfer oil pressure control device including the
duty solenoid.
Also, the transfer clutch drum and rear drive shaft are joined
to each other by welding. The rear drive shaft has drilled oil
passages for transfer clutch control and also for lubrication of
extension bushing and ball bearing in it.
1 Snap ring
2 Pressure plate
® 3 Drive plate
4 Driven plate
-1 5 Thrust need Ie beari ng
I Snap ring
6
I
I
I
I
I ®
@ I
I
I
@I
I ---
)
7 Spring retainer CPo

8 Lathe cut seal ring
9 Transfer clutch piston
11 Needle bearing
12 Rear drive shaft
13 Ball'bearing
14 Seal ring
15 Reduction drive gear
L3-661
Fig. 84
59
(2) Transfer Oil Pressure Control Device

The transfer valve body is bolted to the side of the extension
case through two gaskets and one separate plate.
Operating oil for the transfer valve body is routed to the
extension case through a pipe connecting the discharge circuit
of the oil pump on t~e front of the transmission case to the
rear of the case. It is then delivered to the oil pressure circuit
provided in the plane on which the transfer valve body is
mounted.
This line pressure is reduced to a fixed level by the pilot valve,
and becomes the initial pressure of the duty solenoid C.
Li ne pressure is also del ivered to the transfer control valve,
where it is regulated by duty pressure variations to control the
oil pressure so that optimum rear torque distribution is
obtained according to running conditions.
1 Revolution sensor (4WD)

2 Pilot valve pipe
3 Duty sol. C (transfer)
4 Gasket
5 Plate
6 Fi Iter
7 Gasket
8 Roller bearing
9 Extension case
10 Bushing
11 Oil seal
12 Dust seal
L3-662
Fig. 85
60
• Pilot valve (transfer) • Transfer control valve

The pilot pressure acts on the valve to force it to the right, and The duty pressure, which is controlled by pulse amplitude
the spring acts to force the valve to the left. Therefore, when modulation by duty solenoid C, acts on the valve as a force
pilot pressure exceeds the force of the spring, the valve moves pressing it to the right. On the other hand, oil entering from
to the right and drains the pilot pressure so that it does not the oil passage CD flows through the throttle inside the valve
exceed the fixed level. into the oil chamber ®, where it acts as a force pressing the
valve to the left together with the spring. Therefore, oil
Line pressure
entering from the oil passage CD is regulated so as to be
balanced by the forces acting in both directions and becomes
the transfer clutch control oil pressure.
Line pressu re
Line pressure
Transfer clutch pressure
Fp
(Pilot pressure)
Fs
x Line pressure
(Force of spring)
Fs
Pilot pressure F T/F SOL

(Duty pressure
L3-663 controlled by (Force of transfer
duty solenoid C ) , L . - - - - - + - - - - - - ' clutch pressure)
Fig. 86
To transfer clutch
L3-664
Fig_ 87
61
4) 4WD TRANSFER CONTROL
------
OJ Basic control
Type of control
Regulates transfer oil pressure

in response to throttle position
and vehicle speed.
Gear position
1st thru 4th and

reverse
g
Normal control
Remarks
.:s...~
..,
.....,c
.,..,
::T
.,..,
'C
;::;.
<
0 50 100
Fig. 88 Duty ratio (%) L3-935
m Control in 1st
hold range
Increases transfer oil pressure
(as compared with basic
1st hold range
-
control OJ .)
m Control during
"slip" detection
Returns transfer oil pressure
to the same as in 1st hold
1st thru 4th and
reverse
Release:
At more than set vehicle
range immediately after "slip" speed and fully closed
detection. throttle
[I] Control in turns Decreases transfer oil pressure 1st thru 4th and
upon detection of vehicle reverse -
turns.
62
~ Power Transmission System

4-1 Gearshifling Mechanism
1. OPERATION OF EACH GEARSHIFT MEMBER
I~ Rev./C BIB High/C FWD/C

OWC
(3-4)
OVR/C Lo I
Rev'!B
OWC
(1-2)
0
0 0 0
0
1ST
£i
0 0 0
I,
2ND
0 0 0
c
0
0 i~
I y-
3RD O 0 0
-;::; _~l
e I ,
~
0
~
4TH
0 0 0
.!!
....0u
.,
1ST 0 0 0
;;j ++
0 ++ 2ND 0 0 0
3RD 0 0 0 0
1ST 0 0 0 0
~+
0 2ND
~ *1 0 0 0 0
I~
3RD 0 0 0 0
B
c
....
1ST
Q *1 0 0 0 0
::I Ol
~ (1st\
.!l c
u- H~D 2ND *1
.&. --
~
0 0 0 0
.... "0
-- C
~
en.&.
. • ~
3RD 0 0 0 0
Only when selector lever is in "2" and 1st hold button is ON_
* 1: For prevention of over-revolution
L3-1029
Fig. 89
63
Power Transmission System
SCHEMATIC DRAWING
Gearsh ift Member 1st ("2" and " 1st hold" ) OverrunnIng oI""h,-\
Fo rward ,'"'' '- - , , - l.ow 80 reverse brake Forward ,"""h-, , Lo w 8. re~ e"e brake
High oI'"",h-,
Aeverw oI""h-,
, -, ,",.,"" clutch ( 1-2)
'--- One-way clu tch (3-4)

'--_,'""'N" clutch (3-4 )
'--- R,,, $U" gear

'--_ .,,,, p\a!1etafY car rier
_ INPUT
_ INPUT ' - - Fro." sun gear
o OU TPUT
D OUTPUT
_ LOCKED '-- F"," '''''''''Y carrier LOCKED

ICOMPONENT
DCOMPONENT LJ. l021 LJ.l023
"N" and "P" Tra nsmIssion 1st ("0" and "3")
'--- D,,,·,.,, clu rch 11-2)
' - - One- way clutCh (3-4 )

'--I '''M gear
_ INPUT _ INPUT
D OU TPUT D OUTPUT
LOC KED LOCKED
DCOMPONENT LJ.l022 o COMPONENT LJ.l024
2,d ("0" • "3" • "2"
and "ht hold")
Bal'ld .n,"-, Band Bu.' - ,
' - - OverruI'Inlng clutch ("2 " and "In hold" onlyl
(3-4)
_ INPUT _ INPUT
D OUTPUT C l OUTPUT
_ LOCKED _ LOCKED
I I COMPONENT
L3-1027
Overrunni"'9 clutch
3rd ("0" , "3", "2" ("3", "2" and "ht hold " onlvl -~ , - - Low & reyerS/! brake
and "lst hold")
,,,,., clutch (3,4 )
_ INPUT
_ INPUT
C ] OUTPUT
D OUTPUT
LOCKED
_ LOCKED
C ] COMPONENT
DCOMPONENT L3- 1026 L3- 1028
~ 1st 2nd 3rd 4th Rev.
Input member (0 (0 eee eB 8-B

Output member
8---e 8---e 8---e e--e e--e
Fixed member
e-e G G G X
Free member
G eB G G G
Gear ratio 2.785 1,545 1.000 0.694 2.272
Abbr.
FS Front sun gear
RS Rear sun gear
Fe Front planetary carrier
Re Rear planetary carrier
FI Front internal gear
RI Rear internal gear
L3·669
Fig. 90
64
4-2 Power Train

The gear train consists of two sets of planetary gears, four sets
of multi-plate clutches, one brake band, one set of multi-plate
brake and two sets of one-way clutches.
Reverse clutch (Operates while moving in reverse.) High clutch (Operates at 3rd and 4th speeds.)
Brake band (Contacts at 2nd and 4th speeds.) Front planetary gear
Rear planetary gear
Input shaft Forward clutch
Low & reverse brake

Low one-way clutch
(1-2)
From engine To propeller shaft
Transfer clutch
Electronic oil presSure

control mechanism
L3-671
Fig. 91
1) N RANGE AND PRANGE

1) N range
Because both the forward clutch and reverse clutch are in the
release positions, the power of the input shaft is not trans-
mitted to the drive pinion or the rear drive shaft.
2) Prange
All controls do not operate, just as in the N range. The
parking pawl interlocked with the selector lever meshes with
the parking gear to mechanically hold the output shaft
stationary, thus locking the power train.
65
2) FI RST SPEED OF 0 OR 3 RANGE (0,,3,) • While coasting, the rear internal gear turns normally and
the one-way clutch (3-4) is released and idles. Therefore,
• When the throttle is open wide, as during acceleration in
no power is transmitted and the engine does not provide
the low-speed range, the forward clutch, one-way clutch
braking action.
(3-4) and one-way clutch (1-2) operate to prevent the rear
internal gear from turning in the reverse direction.
Operating condition of parts Power flow (in acceleration)
• Forward clutch Applied • Input shaft
• One-way clutch (3-4) Operating

•
+
Rear sun gear
• One-way clutch (1-2) Operating
~
• Rear pinion gear
• , ~
Rear planetary carrier
•
~
Drive pinion
• Reduction gear
I
•
,
Transfer clutch
+ J
• Front differential • Rear differential
Front planetary gear Rear planetary gear Only counterclock-

- wise rotation is locked
One-way clutch (3-4) One-way clutch (1-2)
B"-=-- ~ Note: _ Locked
~ C Dlnput
rPower flow: : Power flow: _ Output
, :A-+B 'B-+C
, ---------, r r-------'
~-------- --------l r ~ r
:f
I
I nput Shaft~, Rear internal gear lOne-way clutch (3-4)
One-way clutch (1-2)

I Transfer clutch
I
I
I
I
Reduction gear
Front differential
Rear planetary gear
L3-672
Fig. 92
66
3) SECOND SPEED OF 0, 3, 2, OR 1ST increases in proportion to the rotation of the rear internal
HOLD RANGE (0 2,32,22, 1ST HOLD2) gear compared with the first speed .
• During acceleration, the forward clutch is applied and • Since the rear internal gear turns normally while coasting,
connects the front planetary gear to the internal gear the one-way clutch (3-4) is released and idles. Accordi ngly,
through the one-way clutch (3-4). Power is transmitted reverse power is not transmitted to the engine and engine
from the input shaft to the rear sun gear, turning the rear braking is not provided.
planetary carrier (i.e. front internal gear). • During deceleration at "2" or "1 st hold" range, the over-
Also, since the band brake is applied and the front sun gear running clutch operates to check idling of the one-way
is locked, the rear internal gear turns normally through the clutch (3-4). Reverse power is transmitted to the engine,
front planetary carrier and the forward clutch and one-way providing engine braking action.
clutch (3-4) that are connected to that carrier. Thus, speed
•
•
•
Brake band
Forward clutch
:
:
:
Applied
Applied
Operating
Input shaft
,
Rear sun gear
t
• Overrunning clutch : Applied Rear pinion gear
("2" and "1 st hold" ranges only) ~
I
R
e d '
uctlon f
d'rive shaft
t
Front internal gear
~
Reducti}n gear Front pinion gear
I t
t t Front planetary carrier
Drive pinion Transfer
clutch
t
Forward clutch
Fro)t differential
f t
Rear
differential
Rear
f
in~ernal gear
Front planetary gear Rear planetary gear Note:

_ Locked
~
~ One-way clutch (3-41 One-way clutch (,-21
o
o
o
0 r:& : Power flow:
~
:
o
_
Component
Input
Output
I B~A'
'---------.., r------..J
L.. _____ - - - ____ - -- -l I Front internal gear
,, Rear internal gear
Input shaft ~ ,
I r _ Rear pinion gear
: / One-way clutch (3-4)

Front differential
\\ '''"'','''"''"
Reduction gear
Rear sun gear

L3-673
Fig_ 93
67
4) THIRD SPEED OF 0, 3, 2, OR 1ST HOLD gear rotate normally as a unit.
RANGE (03, 33, 23, 1ST HOLD3) • While coasting at "0", because the rear internal gear turns
• During acceleration, the high clutch is applied and the input normally, the one-way clutch (3-4) idles in a released state .
shaft and front planetary carrier are connected. Further, Thus, reverse power is not transmitted to the engine and
the forward clutch and one-way clutch (3-4) operate to engine braking action is not provided.
connect the front planetary carrier to the rear internal gear. • During deceleration, at "3", "2" or "1st hold" range, the
Power is transmitted from the input shaft to the rear sun overrunning clutch is applied and checks the reverse rota-
gear and rear internal gear. The rear sun gear and rear tion of the one-way clutch (3-4).
internal gear turn normally at the same speed. Therefore, Thus, reverse power is transmitted to the engine and engine
the rear planetary carrier, rear sun gear and rear internal braking is performed.
• High clutch : Applied Input shaft

I
• Forward clutch : Applied
H"Igh clutch f t
Rear sun gear
• One-way clutch (3-4) : Operating
t
• Overrunning clutch : Applied Front planetary carrier
("3", "2" and "1 st hold" ranges only) t
Forward clutch
~
"t
Rear Internal gear
I
J
Rear Pin Ion gear
~
t
Reduction gear
I
t
Drive pinion
+
Transfer clutch
t
Front differential
t
Rear differential
--
Front planetary gear Rear planetary gear
@~
~ One-way clutch 13-4) One"way clutch 11-2)
:'\ 0 ~ ~ Note: _ Locked
o 0 '-"A ~ 0 Input
o Power flow: B _ A : _ Output
I
L__________ ~~-_-.:_~=~-: ~
I r
r------ J
I
I I I I
Input shaft Rear planetary carrier ~ I I I Forward clutch
I I I I
High clutch : I
I
I
I
I
I
I
Transfer clutch
Front differential Front planetary carrier
L3-674
Fig. 94
68
5) D-RANGE FOURTH SPEED (D4 ) When the front planetary carrier turns normally, because
the front sun gear is held stationary by the brake band, the
• During acceleration, the high clutch is applied and connects
speed of the front internal gear increases and is delivered
the input shaft to the front planetary carrier. Also, the
to the meshing reduction drive shaft in normal rotation.
forward clutch is applied, but it runs idle due to the one·
• While coasting, because power transmission does not go
way clutch (3·4) and takes no part in power transmission.
through the one-way clutch, reverse power is transmitted
Power is transmitted from the input shaft to the front
to the engine and engine braking is performed.
planetary carrier by the function of the high clutch.
• High clutch : Applied • Input shaft
• Brake band : Contracted ~

• Forward clutch Applied • High clutch
(Takes no part in power transmission.) ~

• Front planetary carrier
•
•
,
~
Front pinion gear
Front internal gear

~
• Rear planetary carrier
~
• Reduction drive shaft
+
• Reduction gear
I
+ +
• Drive pinion • Transfer clutch
t
• •
Front differential • Rear differential
@
~ ~o One-way clutch (3-4) One-way clutch (1-2)
o 0 0
o
~o 3
Constant free rotating
~
r
Note: 1IIIIIIII
D
_Output
Locked
Input
, ,speed: A >B I
L________ __ ~~-_-~~=~-; ~ r------.J

I
Input shaft High clutch I Front internal gear
I
Front differential
L3-675
Fig. 95
69
6) 2-RANGE FIRST SPEED OR 1ST HOLD engine braking is performed.

FIRST SPEED (2" 1ST HOLD) • The low & reverse brake operates in place of the one-
way clutch (1-2) and locks the rear internal gear.
• During acceleration, the forward clutch and overrunning
clutch are applied and the front planetary carrier and rear • In coasting and deceleration, low & reverse brake and
overrunning clutch are operating, so that reverse power is
internal gear are connected. Also, the low & reverse brake is
transmitted to the engine and engine braking action is
applied so that the front planetary carrier and internal gear
provided.
remain stationary.
The power flow is the same as in the first speed of "0",
"3" and "2" range (except for the following points) and
• Forward clutch Applied • Input shaft
• One-way clutch (3-4) Applied (in acceleration) ~

• Overrunning clutch Applied
• Rear sun gear
~
• Low & reverse brake Operating • Rear pinion gear
t
• Rear planetary carrier
t
• Reduction gear
I
~ i
• Drive pinion • Transfer clutch
+ ~
Front planetary carrier Rear planetary carrier
Note:
III Locked
Input shaft
I
I
I
L ________
Overrunning
~--------,
--------l
clutch
I
I
I
I
I
I
I
I
-
0 Input
Output
Forward clutch I Low & reverse brake

I I
One-way cI utch (1-2)
Front differential Drive pinion

L3-802
Fig_ 96
70
7) R RANGE gear. Also, the low & reverse brake operates to lock the front
planetary carrier. Therefore, when the front sun gear turns
The reverse clutch is applied and power is transmitted from
normally, the front internal gear slows and reverses.
the input shaft through the reverse clutch to the front sun
Operating condition of parts Power flow
• Reverse clutch Applied • Input shaft
• Low & rev.erse brake Operating

•
+
Reverse clutch
+
• Front sun gear
~
• Front pinion gear
~
• Front internal gear
t
• Reduction drive shaft
+
• Reduction gear
I
• +
Drive pinion • •
Transfer clutch
+ ~
~ O"~34) O~"21 Note:
fill Locked
I nput shaft
I
I
I
L ________
o
IL.
--------l
_ _ _ _ _ _ _ _ -,
Front internal gear~

I
I
I
I
: Operating
I (Takes
.
r' transmission.)
: Power
I A -+ B
flo~:
I
I
no ______ .JI
part In power

-
D Input
Output
Forward one·way clutch

Row", ,r""h \ I I
I
I Low & reverse brake
I One·way cI utch ('·2)
I
Transfer clutch
Front differential
Drive pinion L3·803
Fig. 97
71
Fluid Passages
Oil pump housing Oil pump cover
'" "m, MO'"' .~_~

~
pressur.
Reverse clutch pressure
OH pump outlet pressur• .1
Transmission ca. Transmission c. . LH sida
4A pressure brake pressure
Oil pump
outlet port
Transmission c. . RH lida
, '
Front lubriC~~~: III ~)""\\- High clutch pressure
0~Rever.. clutch pr...ur.
J
l~~~= Overrunning clutch
' [ J ; ; I COOI.::et prMsure pressure
Oi I pump inlet port
LLoCk-uP apply pressure Overrunning clutch pressure
/Lock-uP
. release pressure
L3·950
Fig. 98
73
1 P range and N range
IlttIII _ .... _
~
.... 0 L....
.... Shunle ball changes 011 passage
One· way ball blocks 011 passage 10

one·way only
x DraIn
,'"'' . ~
•
"
o..", _ _ c
OFF
Oul~ __ ,.;...;,~._ _ _ _ _ _;
localion 01 manual valve differs for N and P ranges.

_
_
_
une pressure
Pressure·mo<ilirer pressur6
PlIOI pressure
_
_
OverrunnIng clulch pressure
., reducIng pressure
: :
- oUly·A pressure
outy·C pressure
0 11 pomp cOnlfOl pfeSSUle _
Trans/er dUIch pressure
Torque convener pressure
Cooler pressure
_ AccumulalOr control pressure Lubrrcanl pressure
2 R range
One -way ball blocks 0,1 passage 10

one -w ay only
x Drain
-
• Oullea
,_... '''. ~ .
OFF
_ line ,)fCSSlJrc
_ Prcssorc -mO(l!Irc! pressure _ OvcmJl'llllflg ClutCh pressure

_ PrlOI pressure _ I reduCing pressure
- Duly A pressure
Duty-C pressure
Orl pump conlfol pressure _
Tr81lsler clutch pressure
TorQue convener pressure

Coolor ",ossure
_ Accumilla tor oonl.ol pres.sure Lubncanl pressule
, !
3 First speed of D or 3 range
ShulIlo b all c hangos 011 "assaoo
One way ball blOCks 011 pass ago to

one w ay only
Oranl
antl co
, h.r'lf
dlJlc.n
, " " " ' . d",,;"
OFF
• "' ..... '0 mod""!'

'I"' lOCUm"'.'",
•
-
~I ')~I
location 01 manual valve differs for J and 0 ranges .

_ Lme pressure
_
_
Pfcssure·modl foel pressure
P,IOI pressure
_
_
o.,.crrunnmo ClutCh pressure
I" leduClng pressure
: \0,:
DUl y-A pressure Tlanster clu lCh pfossule
Dul yC prcssufil Torque convenor pressure
011 Dump conUol p ressure _ Coote, pressurc
_ Acculfluhuor conllo1 pressure Lu b ucanr oreSSl/fO
'3 )... 1 3~t
4 Second speed of D or 3 range
Shu We ball chan ges 011 passage
One -way ball bloc~s 011 pa ssag e to

one-way only
• Oflhce
"
SerYtl C"'''U''
~'"
Pre .....e 11000,1>11'

-.......10'''' ,
ON OFF ON
location ot m anual valve differs l or 3 and 0 ranges _
_ line pressure
u'J I
_
_
PfessUfe modl t. er pressure
1'1101 pressure
_
_
Overrunl1lng Clutch pr essure
1- rl!dlll;mg pressurc
: :r:J=
- Duty A pressure
Duty C pressure
a,l pump comrol pressure _
Ttonslcf clutch pre ssure
TorQUO convortCI I)rcssure
Cooler pressure
_ Accumulator can uo! pressure LubllC<lnt pressure
5 Second speed of 0 or 3 range al lock-up
...~ L.........
0 Shunle ball changes 0,1 passage
One-way ball blocks 011 passage to

one-w ay only
x Dram
• O""eo
,,," "'~
& ,.....:t,.. 1>t1 ~ 8

,
ON ON
loca tion of manual valve diflers lor J and 0 ranges.
:
_ line pressure
#~ :
-- Pressure· mo(lII,er pressure
P,io! pressure
-- Over,unnll1g Cl utch pressUf c
I reduCing P'{lSSUIC
I!::::l ~
- Duly·A plC5su.e
Duly C pressure
Transfer Clutch pressure
conve ner pressute
-
TOICIU6
0,1 pump con\fol pressure Cooler pressure
- Accumulmo. comlol pleSStn e lubncam pressure

6 Third speed of 0 or 3 range
Shunle ball chaoges 0,1 paSStlgc
One·Wily ball blocks 011 passage 10

one way only
x O'a,n
- O"Ile(!
I~gh
& ,eve,.. ",~ I ",
Location of manual valve dille.s for 3 and 0 ranges.

_ l ono pressu re
_
_
Pressure mOOl1lc. pressure
1'1101 pressure
_
_
Ovcrrunnll19 clu tch pressure
1 reduCing pressure
;jJ
u :
! :
- Duly·A pressure
Ouly-C pressure
0,1 pump comlol pressure
_
_
Trllnsfcr Clu tCh pressure
Torque convefler pres sure

Cooler pres sure
_ Acc\Jmullll01 con nol pressure lubllCc, nt pressule
7 Third speed of D or 3 range at lock-up
Bond"""", . " .
Shuttle ball changes 011 passage
One -way ball blocks 0,1 passage to

one_w ay only
••
, • ••• m~
0..1y utvOl<l C
"
ON
OFF OFF ON
Loca tion of manual valve diffe rs for 3 and 0 ra nges.
-- Lme pressure
Pressure·mod,hcl pressure _ OveHunnmg clu tch pressure
- P,IOI pressure _ 1 reducing pressure
- Duly-A pressure
Duly -C pressure
011 pump conuol PlIilSSU'C _
Transter clu tch ()rossure
Torque converter pressure
Cooler pressure
- Accumulator COnllol pressure lubncam pressure

8 0 range fourth speed
Shunle ball changes Otl passage
One·way ball blocks 0,1 passage 10

one-w ay only
D,aln
-- Onlice
.
",," .., ,
.. ~
I'l101 ... 1Wr
_ line pressure
-- Pressure mochhm pressure

P,IOI pressure
-- Oveflunn,ng clu tch pressure
., rcdUCInCJ pressure
- OUIV-A pressure
OuIV' C prossure
- Translc' clulCh pressure
Torque convener pressure
-
0,1 pump conlrol pressure
Accumulator contrOl pressure
- Cooler pressure
Lubrocant pressure
9 D range fourth speed at lock-up
--'0'--
..., - ShullIc ball changes 0,1 passa ge
One-w ay ball blocks 011 pass age 10

one -way onlv
x Dr am
- O"lIce
.......
• 2 """""f'IC~
,
ON
-- Lmc pressure
PlessuJe -moddlcr pressure
-- Ovcuunnrng clu tCh lJ,essure
- PlIOI pressure
Dulv·A pressure
-
1 redUCing pressure
Tlansler clu tch pressure
•
DUIV' C pressure Torque COflVC. tCI pressure

0,1 pump conl 101 pressure
A(;(;umulalor carlltal pressure
- Cooler pressure
LubnClln l pressure
10 First speed of 2 range or 1st hold range
~0 L......
-- .-
Shunlc ball changes 011 passage
One way ball blocks 011 passage to

one way only
x Dram
--
--~
....-
,.
o y <I'
I
~ ,==='il .... - . - t... _
'" '
.-
_.-
lOC ~ ....
----
_.
Pi- ..... ,
ON ON OFF
_ Lillo I)fossure
-- Prcssure-modlher pressure
Pilot pressure
-- OWlJfunOll1D cl ulCh pressure
1 roducmg pressure
- 0tJ1Y A pressure
Duty C preS$l,Jre
lronster clu tCh prossu'e
T()fqUft convCrler prCS$I.Ire
-
0,1 pump control pressure
Accumulator 0001101 pressure
- ~el pressuro
lubncant pressure
11 Second speed of 2 range or 1st hold at lock-up
~
......
0 L......
..... Shuttle ball changes 0,1 passlIgc
One-w ily ball blocks 011 passage 10

one-wily only
Dram
••
."'''
.-
"'_omv/tl'OI
.....'.-mod,'..'
_ line pressure
_ Pressurc·modlher pressure _ Overrunning clu tch pressure
_ 1'1101 pressure _ 1 redUCing pressure
Duly·A pressure _ Transter clulCh pressure

DUly-C pressure Torque converter pressure
0,1 pump comrol p.essure _ Cooler pressure
_ Accumulator comfot pressure Lubncant pressure
12 Third speed of 2 range or 1s1 hold at lock-up
... -."'~,
...,,--l0 L..........
...... .- Shull1e ball changes 011 passage
One-w ay ball blocks 0.1 passage 10

one-way onl ~
x Dram
- Oullce
& ' ....,... bt.~

, co" ,ch
PootI' .,. ....
ON
,
OFF
_ lme pressure
_ Pressuro-mOd,j,er pre ssure _ OvcllunnlOg Clu tch pressure
_ Pilot pressure _ 1 rO'duClI19 pre ssure
- Dl.lly·A pressure
Duly·C pressure
0 ,1 pump com.ol pressure
_
_
Transler clu tch preSSl.lre
Torclue co,wer ter pressure
Cooler pressure
_ Accumulator co.wOI 1)'eS$Ur e Lutmcanl pressure
Transmission ca .. Transmission ca ..
Overrunning clutch pressure relief valve
Forward clutch pressure
relief valve
Forward clutch
Overrunning
/ clutch pressure pipe
Relief
valve body
Rear view
Extension ca .. Transmission ca ..
Transfer clutch pressure Overrunning

clutch pressure
Forward
clutch pressure
Transfer clutch pressure Overrunning clutch pressure

Line pressure (4WD only)
Transfer clutch pressure
L3-951
Fig.99 Transmission case
74
A manual plate and manual lever are attached to the manual
[§] Range Select Mechanism shaft. The manual plate is fan-shaped and is provided with six
grooves on its edge corresponding to shift ranges (from "P" to
"2"). A detent spring roller fits into the groove corresponding
to the range selected. This regulates effort required to operate
The range select mechanism consists of a select lever (on the the select lever.
floor/center console in the driver's compartment). push-pull A hydraUlically controlled manual valve is installed on the
cable, linkages, manual valve, parking pawl, etc. lower pin of the manual lever. It slides in response to rotation
When the select lever is moved either forward or backward, the of the manual shaft, thereby selecting an oil passage inside the
push-pull cable moves in the corresponding direction. This lower valve body in response to the position (P, R, N, D, 3
turns the manual shaft by way of the range select lever. At or 2) of the select lever.
this point, the pin at the end of the range select lever turns the A parking rod located on the upper portion of the lever
inhibitor switch arm to transmit a range signal to the control mechanically holds the output shaft when the select lever is
unit. sh ifted to "P".
,/')
---/
,/'--<\)\/'
) Propeller shaft
"\ X
/
Extension case
Reduction
\ \
(
\
~\ j
I
. . ->.,\,....~-1\'-,- Transmission case
'f p a grpawl
k / .' n
Parking pawl shaft
Range select lever Parking rod
Manual lever
/
/ / t? Forward direction
Fig. 100
75
With this arrangement, when the parking rod moves backward,

[Z] Parking Mechanism the cam moves to the back of the parking pawl and the "V"
groove of the actuator. The parking pawl turns in the direction
of the parking gear using the parking pawl shaft as a pivot. It
then engages with the parking gear groove.
If the end of the parking pawl rides over the tooth of the
The end of the parking pawl engages mechanically with the parking gear so that the parking cam does not move midway
gear groove of the parking gear. This gear is spline-fitted to between the pawl and actuator, the parking rod will move to
the drive pinion shaft. "P". This compresses the parking spring so that the parking
When the select lever is set to "P", the manual lever connected cam is ready to move to "P". Under this condition, if the
to the manual shaft turns, moving the parking rod backward. vehicle moves slightly, the parking gear will rotate to engage
A cam and spring are installed on the rear of the parking rod. the pawl completely.
The parking cam slides freely on the parking rod. The parking Except for the P range, the parking pawl is tensed by the
rod and cam contact the "V" groove of the actuator (secured parking pawl return spring in the direction that moves away
to the transmission case) and the back of the parking pawl. from the parking gear.
Parking actuator
Parking rod
Parking pawl
return spring
Parking pawl
Parking rod ."--+-.L- _ _ __
ViewY
Parking cam
Parking spring
(slides on parking rod)
Parking rod
Fig. 101
76

[] Specifications
1800 cc
I 2700 cc
Type Symmetric, 3-element, single stage, 2 phase torque converter coupling

....
........Q) Stall torque ratio
Q)
>
c:
2.4 - 2.5
I 2.2 - 2.3
0
u Nominal diameter 246 mm (9.69 in)
Q)
::J
....C' Stall speed (at sea level) 2,450 - 2,850 rpm 2,400 - 2,800 rpm
0
I- I
One-way clutch Sprag type one-way clutch
Type 4-forward, 1-reverse, double-row planetary gears
Multi-plate clutch 4 sets
Multi-plate brake 1 set

Control element
Band brake 1 set
One-way clutch (sprag type) 2 sets
1st 2.785
2nd 1.545
Gear ratio 3rd 1.000
c:
0 4th 0.694
'Vi
VI
'EVI
c:
0 Reverse 2.272
c: 'Vi
co
........ .~
E Front sun gear 33
.!:! VI
....co c:
co
....
E I- Front pinion 21
....::J
0
« Tooth number of planetary

Front internal gear 75
gear
Rear sun gear 42
Rear pinion 17
Rear internal gear 75
-
P
R
N
D
Selector pattern
3
2
-
1 1ST HOLD I
77
1800 cc 2700 cc
P (Park) Transmission in neutral, output member immovable,

and engine start possible
R (Reverse) Transmission in reverse for backing
N (Neutral) Transmission in neutral, and engine start possible
Selector position D (Drive) Automatic gear change 1st ~ 2nd ~ 3rd ~ 4th
Transmission
3 (3rd) Automatic gear change 1st ~ 2nd ~ 3rd
2 (2nd) Automatic gear change 1st ~ 2nd *"" 3rd

1st Hold 1st gear locked
(Deceleration 3rd -+ 2nd -+ 1st possible)
Control method Hydraulic remote control
Type Variable-capacity type vane pump
Oil pump Driving method Driven by engine
Number of vanes 9 pieces

Automatic
transmission Electronic/hydraulic control
Type [Four forward speed changes by electrical signals
of car speed and accelerator (throttle) opening]
Automatic transmission fluid (ATF)
Hydraulic Fluid DEXRON II
control
FWD: 9.32
(9.8 US qt, 8.2 Imp qt)
Fluid capacity 9.32 (9.8 US qt, 8.2 Imp qt)
4WD: 9.52
(10.0 US qt, 8.4 Imp qt)
Lubrication system Forced feed lubrication with oil pump

Lubrication
Oil Automatic transmission fluid (above-mentioned)
Cooling Cooling system Liquid-cooled cooler incorporated in radiator
Inhibitor switch 11 poles
Harness Transmission harness 11 poles 10 poles
Resolution sensor - 3 poles
Transfer clutch - Hydraulic multi-plate clutch
Control method - Electronic, hydraulic type
The same Automatic trans mis-

Transfer
Lubricant - sion fluid used in Automatic
transmission
1st reduction gear ratio 1.000 (47/47)
Front drive 3.900 (39/10) 3.700 (37/10)

Final gear ratio
Rear drive - 3.700 (37/10)
FWD: 0.869 (20/23)

Final Speedometer gear ratio 0.840 (21/25) 4WD: 0.840 (21/25)
reduction
Lubrication oil API, GL-5
Front drive 1.42 (3.0 US pt, 2.5 Imp pt)

Oil capacity
Rear drive - 0.82 (1.7USpt, l.4lmppt)
ATF cool- 1.454 kW (1,250 kcal/h, 4,960 BTU/h)

Radiation capacity
ing system
78
~ Location and Dimension of Adjusting Parts
L3-1033
Fig_ 102
79
No. Part Name Part Number Dimension mm (in) Application
1 CONTROL PISTON 31235AAOOO -0.030 -0.0012 -0.023 -0.0009 Adjusting side clearance of
13.5 -0.037 (0.5315 _0.0015),13.5 -0.030 (0.5315 -0.0012)'
-030 oil pump
-0.016 -0.0006) -0.009 -00004
13.5 -0.023 (0.5315 _0.0009,13.5 -0.016 (0.5315 -0:0006)
2 CAM RING 31241AAOOO 17 -0.010 (0 6693 -0.0004) 17 -0.003 (06693 -0.0001) Adjusting side clearance of
-030 -0.017' -0.0007' -0.010' -0.0004 ' oil pump
17 +0.004 (0 6693 +0.0002) 17 +0.011 (0 6693 +0.0004)
-0.003' -0.0001' +0.004' +0.0002
3 VANE (Oil pump) 31243AAOOO 17 -0.030 (0 6693 -0.0012) 17 -0.023 (0 6693 -0.0009) Adjusting side clearance of
-030 -0.037' -0.0015 ' -0.030' -0.0012 ' oil pump
17 -0.016 (0 6693 -0.0006) 17 -0.009 (06693 -0.0004)
-0.023' -0.0009' -0.016' -0.0006
4 ROTOR (Oil pump) 31240AAOOO 17 -0.030 (0 6693 -0.0012) 17 -0.023 (06693 -0.0009) Adjusting side clearance of
-030 -0.037' -0.0015 ' -0.030' -0.0012 ' oil pump
17 -0.016 (06693 -0.0006) 17 -0.009 (0 6693 -0.0004)
-0.023' -0.0009 ' -0.016' -0.0006
5 THRUST WASHER 31299AAOOO 0.7,0.9,1.1,1.3,1.5,1.7,1.9 Adjusting end play of reverse

(Reverse clutch) - 060 (0.028,0.035,0.043,0.051,0.059,0.067,0.075) clutch drum
6 BEARING RACE 803031021 0.8, 1.0, 1.2, 1.4, 1.6, 1.8, 2.0 Adjusting total end play
- 27 (0.031,0.039,0.047,0.055,0.063,0.071,0.079)
7 RETAINING PLATE 31567AAOOO, 4.6,4.8,5.0,5.2,5.4 (0.181,0.189,0.197,0.205,0.213) Adjusting clearance of reverse

020 - 050 clutch
8 RETAINING PLATE 31567AA190 3.6, 3.8, 4.0, 4.2, 4.4, 4.6, .4.8, 5.0 Adjusting clearance of high
- 260 (0.142,0.150,0.157,0.165,0.173,0.181,0.189,0.197) clutch
9 RETAINING PLATE 31567AA010, 8.0,8.2,8.4,8.6,8.8,9.0,9.2 Adjusting clearance of forward

060 - 110 (0.315,0.323,0.331,0.339,0.346,0.354,0.362) clutch
10 RETAINING PLATE 31567AA120 8.0, 8.2,8.4,8.6,8.8,9.0,9.2 Adjusting clearance of over-

- 180 (0.315,0.323,0.331,0.339,0.346,0.354,0.362) running clutch
11 RETAINING PLATE 31667AA180 6.5,6.8,7.1,7.4,7.7,8.0,8.2,8.4, Adjusting clearance of

No.2 - 250 (0.256,0.268, 0.280,0.291,0.303,0.315,0.323,0.331 ) low & reverse clutch
12 PRESSURE PLATE 31593AA150 3.3,3.7,4.1,4.5 (0.130,0.146,0.161,0.177) Adjusting clearance of transfer

(Front) -180 clutch
13 THRUST BEARING 806535020 3.8,4.0,4.2,4.4, 4.6,4.8, 5.0 Adjusting end play of transfer
(35 x 53 x T) -090 (0.150,0.157,0.165,0.173,0.181,0.189,0.197) clutch
14 SHIM 31288AAOOO 0.15 (0.0059) Adjusting end play of reduction

(Reduction gear) drive gear
15 WASHER 803038021 0.95, 1.00,1.05 (0.0374,0.0394,0.0413) Adjusting backlash of

(38.1 x 50 x T) -023 differential bevel gear
16 DRIVE PINION 31451AA050 0.15, 0.175, 0.2, 0.225, 0.25, 0.275 Adjusting drive pinion
SHIM - 100 (0.0059, 0.0069, 0.0079, 0.0089, 0.0098,0.0108) height
80
~ Location and I nstalling Direction of Thrust Needle

Bearing and Washer
@ CD
I~
@ @ © ® ® ® § @
~ ~
~I !l'I ~
~
(: :'
~ ~ f,;i ~
~ Ii
~I
~ ~ II' l ~
~, I~
~ ~
L3·954
Fig. 103
81
COMPONENT PARTS
Torque Converter and Converter Case
2 Oi I level gauge
3 O-ring
4 Oil seal
5 Snap ring
6 Washer
7 Speedometer shaft
8 Clip
9 Bushing
10 Oil pump shaft
11 Bushing
13 Seal pipe
14 Speedometer driven gear
15 Snap ring
17 Drain plug
18 Oil seal
I
I
I
I
I
I
I
I
I
)
~®
19 Bushing
20 Torque converter case
21 Torque converter
22 O-ring
23 Spring pin
24 Input shaft
25 Seal

T1: 44 ± 3 (4.5 ± 0.3, 32.5 ± 2.2)
T2: 33 ± 3 (3.4 ± 0.3, 24.6 ± 2.2)
T3: 39 ± 3(4.0 ± 0.3,28.9 ± 2.2)
Fig. 104 L3-807
82
Differential Case

T1: 57 - 67 (5.8 - 6.8, 42 - 49)
T2: 23 - 26 (2.3 - 27, 17 - 20)
I
I
I
I
I
l
"'-
"'-
'-
"'-
"'-
'-
'-..
'-
"-
',]
I 1 Crown gear
I 2 Straight pin
I 3 Pinion shaft
4 Differential case (RH)
I
5 Differential case (LH)
I Taper roller bearing
*: Selective parts
6
I 7 011 seal (LH)
I 8 O-ring
I 9 Differential side retainer
I 10 Circlip
'J 11
12
Axle shaft
Oil seal (RH)
13 Speedometer drive gear
*14 Washer
15 Differential bevel pinion
Fig. 105 16 Differential bevel gear L3-808
83
Oil Pump

T1: 25 ± 2 (2.5 ± 0.2, 18.1 ± 1.4)
T2: 39 ± 3 (4.0 ± 0.3, 28.9 ± 2.2)
T3: 33 ± 3 (3_4 ± 0.3, 24.6 ± 2.2)
T4: 13 ± 1 (1.3 ± 0.1, 9.4 ± 0.7)
T5: 7 ± 1 (0.7 ± 0.1, 5.1 ± 0.7)
T6: 113 ± 5 (11.5 ± 0.5, 83.2 ± 3.6)
*®
*: Selective parts ./
./
/
./
1 Retainer /
./ //1
./
/ 1
2 Return spri ng I
I
3 Pin I
4 Friction ring I
5 O-ring I
I
*6 Cam ring C) I
7 Vane ring ~-____ ()(J C) I
*8 Vane
*9 Rotor \) ~o L:::::JO :
10 Bushing C) C):
11 Oil pump cover
*12 Thrust washer
Cl I
I
13 Seal ring (R) I
14 Seal ring (H) I
15 Thrust needle bearing )

* 16 Thrust washer ./
17 Air breather hose ./

19 Roller bearing
*20 Shim
21 Test plug
22 Oil pump housing
23 Pin
24 Side seal
*25 Control piston
26 Plane seal
27 Gasket
28 O-ring
29 Oil seal (
30 Oil seal retainer I
I
31 Drive pinion collar I
32 Lock washer I
33 Lock nut I
I
34 O-ring 1,./
Fig. 106 L3-1017
84
Transmission Case, Transmission Cover and Control Device
*: Selective parts
1 Ai r breather hose
2 Oil level gauge
3 Oil charge pipe
4 Inhibitor switch
5 Range select lever
6 Manual shaft
7 Manual plate
8 Manual lever
9 Snap ring
10 Plug
11 O-ring
12 Oil seal
13 Releaf valve
14 Pipe
15 Roller bearing
16 Transmission cover (FWD)
17 Parking support
18 Parking rod
19 Return spring
20 Shaft
21 Parking pawl
22 Inlet pipe
23 Outlet pipe
24 Spring
25 O-ring
26 Accumulator piston (N-D)
27 O-ring
28 O-ring
29 Accumulator piston (2-3)
30 Spring
31 O-ring
33 O-ring
34 Spring
35 O-ring
37 O-ring
38 Spring
39 Magnet
40 Gasket
41 Oil pan
*42 Shim
43 Detent spring
44 Pipe
Tightening torque: N·m (kg·m, ft-Ib)

T1: 3.4 ± 0.5 (0.35 ± 0.05, 2.5 ± 0.4)
T2: 39 ± 3 (4.0 ± 0.3,28.9 ± 2.2)
T3: 30.9 ± 3.4 (3.15 ± 0.35, 22.8 ± 2.5)
T4: 6 ± 1 (0.6 ± 0.1, 4.3 ± 0.7)
T5: 25 ± 2 (2.5 ± 0.2, 18.1 ± 1.4)
T6: 3.9 ± 0.5 (0.4 ± 0.05, 2.9 ± 0.4)
T7: 13 ± 1 (1.3 ± 0.1, 9.4 ±0.7)
T8: 8±1 (0.8±0.1,5.8 ±0.71
T9: 6.4 ± 0.5 (0.65 ± 0.05, 4.7 ± 0.4)
Fig. 107 L3-81 0
85
Control Valve and Harness Routing

)~ "-
~/
~/ 14
1 Clip
2 Clip
3 Transmission harness
4 a-ring
5 Duty sol. A (Line-pressure)
6 Sol. Assy
7 Upper valve body
8 Ball
9 Upper separator plate
10 Lower separator plate
~--t-(j) 11 Lower valve body
I 12 Duty sol. B (Lock-up)
I 13 Pipe
I
14 Revolution sensor (FWD)
@I
I
, 0'
/,®
I
, I
,-,., -@
Tightening torque: N'm (kg-m, ft·lb)

T1: 7 ± 1 (0.7 ± 0.1, 5.1 ± 0.7)
T2: 8 ± 1 (0.8 ± 0.1, 5.8 ± 0.7)
Fig. 108 L3-811
86
*: Selective parts
1 Brake band
I 2 Reverse clutch drum
I 3 Lip seal
~ 4
5
Piston
Lathe cut seal ring
6 Spring
7 Spring
8 Spring retainer
9 Snap ring
10 Dish plate
11 Driven plate
12 Drive plate
*13 Retaining plate
14 Snap ring
15 Lock nut
16 Brake band adjusting screw
17 Strut
@ 18 Band servo piston stem
19 Spring
@ 20 Lathe cut seal ring
21 Band servo piston (1-2)
22 O-ring
@ 23 Retainer
24 O-ring
~® 25 Spring
"-
~ @ 26
27
Retainer
Circlip
,,-,~® 28 Lathe cut sea' ri ng
,,, 30
31
O-ring
0.0. servo retainer
,,,
32 Snap ring
1--/
T: 25 - 28 (2.5 - 2.9,18 ± 21)
®
Fig. 109 L3-812
87
High Clutch and Planetary Gear
*: Selective parts
1 High clutch drum

3 Piston
6 Snap ring
7 Driven plate (Thinnarl
8 Drive plate
9 Driven plate (Thickerl /
/
*10 Retaining plata /
/
11 Snap ring /
12 Thrust needla bearing /
/
13 High clutch hub
14 Thrust naedle bearing / "
/
Front sun gear /
15 /
16 Thrust needle bearing / "
/
/
/
/
/
/
/
/ " ®
/
/r
/
/
/
/
/
/ /-1
/ I
/
I
/ " I
I
/ I
/
/ I
/
/ I
/ )
/
( /
/
I /
/
I /
/
I /
/
I /
~
@I /
/
I /
/
/
/
I
I
I /
/
/
/
/
I
/
I /
I /
1 /
17 Front planetary carrier v/ (
/
18 Thrust needle bearing

I
19 Rear sun gear
20 Thrust needle bearing I
21 Rear planetary carrier I
22 Thrust needle bearing I
23 Rear internal gear
I
24 Thrust washer
I
25 Snap ring I
26 One-way clutch (3-4) I
27 One-way clutch outer race (3-4) I
28 Overrunning clutch hub I / '"
\/ /
Fig. 110 L3-813
88
Forward Clutch and Low & Reverse Brake
1 Snap ring
*2 Retaining plate
3 Drive plate
4 Driven plate
5 Dish plate
6 Snap ring
*7 Retaining plate
® 8 Drive plate
9 DriVltn plate
10 Dish plate
11 Snap ring
12 Spring retainer
-1
13 Spring
./
I
I 14 Lathe cut seal ring
./// ® 15 Overrunning piston
/
/
/
16 Lip seal
/
./ 11 17 Forward piston
/
18 Lip seal
./
/ 19 Lathe cut seal ring
/
./ 20 Forward clutch drum
./
/
/
/
/
./
./ ./
/
/ /
(
I
I
I
I
I
I
I
I
I I
l---./ I
)
./
./
./
/
./
/
./
/ 21 Needle bearing
./
./ 22 Snap ring
./
./ 23 One-way clutch (1-2)
./
/ ./ 24 Snap ring
/
./
./ / 25 Snap ring
./
( / *26 Retaining plate
I 27 Drive plate
28 Driven plate
29 Dish plate
31 Needle bearing
32 Seal ring

34 One-way clutch inner race (1-2)
36 Socket bolt
37 Low & reverse piston
39 Lip seal
T: 25 ± 2 (2.5 ± 0.2, 18.1 ± 1.4)
Fig. 111 L3-814
89
Reduction Gear
1 Seal ring
2 Bushing
3 Reduction drive shaft
4 Plug
5 Ball bearing
7 Snap ring
9 Reduction driven gear
10 Lock washer
11 Lock nut
13 Ball bearing
14 Snap ring

T: 98 ± 5 (10 ± 0.5, 72.3 ± 3.6)
Fig. 112 L3-815
90
Transfer and Extension

®
/1
/' I
® I
I
I
I
I /-1
I /' I
I I
I I
I I
@I I
) I
/' I
/' I
I
I
/' I
/'
/' )
/
/'
/' /'
/' /'
/
/' /'
/ /'
/'
( /
/'
I /'
/'
I /'
'~V
/'
/'
~ /'~/' /'
/'
/'
/'
*@ /
/'
/
/'
/
/'
/'
(
I
I
I *: Selective parts
1 Snap ring
*2 Pressure plate
3 Drive plate
4 Driven plate
*5 Thrust needle bearing
6 Snap ring
7 Spri ng retai ner CP
9 Transfer clutch piston
11 Needle bearing
12 Rear drive shaft
13 Ball bearing
14 Seal ring
15 Revolution sensor (4WD)
16 Pilot valve pipe
17 Duty sol. C (transfer)
18 Gasket
19 Plate
20 Filter
21 Gasket
Tightening torque: N'm (kg-m, ft-Ib) 22 Roller bearing
23 Extension case
T1: 7±1(0.7±0.1,5.1±0.7)
24 Bushing
T2: 8 ± 1 (0.8 ± 0.1, 5.8 ± 0.7) 25 Oil seal
T3: 25 ± 1 (2.5 ± 0.1,18.1 ± 0.7) 26 Dust seal
T4: 13±1 (1.3±0.1,9.4±0.7)
Fig. 113 L3-816
91
SERVICE PROCEDURE
(4) Complete the job from cleaning to completion of
[IJ General Precaution assembly as continuously and speedily as possible in order
to avoid occurrence of secondary troubles caused by dust.
When disassembling or assembling the automatic transmission
When stopping the job unavoidably cover the parts with
observe the following instructions. '
clean chamois or nylon cloth to keep them away from
1) Workshop
any dust.
Provide a place that is clean and free from dust. Principally
(5) Use kerosene, white gasoline or the equivalent as
the conventional workshop is suitable except for a dusty place.
washing fluid.
In a workshop where grinding work, etc. which produces fine
Use always new fluid for cleaning the automatic transmis-
particles is done, make independent place divided by the vinyl
sion parts and never reuse. The used fluid is usable in
curtain or the equivalent.
disassemble and assemble work of engine and manual
2) Worktable
transmission.
The size of 1 x 1.5 m (40 x 60 in) is large enough to work, and
(6) Although the cleaning should be done by dipping into
it is more desirable that its surface be covered with flat plate
the washing fluid or blowing of the pressurized washing
like iron plate which is not rusted too much.
fluid, the dipping is more desirable. (Do not rub with a
3) Cleaning of exterior
brush.) Assemble the parts immediately after the cleaning
(1) Clean the exterior surface of transmission with steam
without exposure to the air for a while. Besides in case of
and/or kerosene prior to disassembly, however it should
washing rubber parts, perform the job quickly not to dip
be noted that vinyl tape be placed on the airbreather or
them into the washing fluid for long time.
oil level gauge to prevent infiltration of the steam into the
(7) Apply the automatic transmission fluid (ATF) onto
transmission and also the cleaning job be done away from
the parts immediately prior to assembly, and the specified
the place of disassembly and assembly.
tightening torque should be observed carefully.
(2) Partial cleaning wi II do, depending on the extent of
(8) Use vaseline if it is necessary to hold parts in the
disassembly (such as when disassembly is limited to some
position when assembling.
certain parts).
(9) Drain ATF and differential gear oil into a saucer so
4) Disassembly, assembly and cleaning
that the conditions of fluid and oil can be inspected.
(1) Disassemble and assemble the transmission while
(10) Do not support axle drive shaft, stator shaft, input
inspecting the parts in accordance with the Trouble-
shaft or various pipes when moving transmission from one
shooting.
place to another.
(2) During job, don't use gloves.
(11) Always discard old oil seals and bushings, and install
Don't clean the parts with rags: Use chamois or nylon
new ones.
cloth.
(12) Do not reuse old pipes, gaskets, plugs (1/8"), spring
(3) Pay special attention to the air to be used for
pins, etc. .
cleaning.
Install new ones.
Get the moisture and the dust rid of the air as much as
(13) Be sure to replace parts which are damaged, worn,
possible.
scratched, discolored, etc.
Be careful not to scratch or dent any part while checking
for proper operation with an air gun.
92
SECTIONS THAT CAN BE DETACHED/ASSEMBLED
Section A ... YES

Section B ..• YES
Section C ... YES
Section 0 ... YES

Section E ... YES
Section F .•. YES
LJ.833
Fig. 114
93
Disassembly of Overall rr?I::'\

Torque converter
Transmission
1. External Parts
1) Place the transmission unit on a workbench, with the oil
pan facing down.
Be careful not to bend or damage external parts.
2) Remove the drain plug, and drain differential oil. Tighten

the plug temporarily after draining.
Fig. 117
5) Remove the input shaft.
Be careful not to scratch the bushing.
L3·523
Fig. 115
3) Remove the drain plug, and drain automatic transmission

fluid (ATF). Tighten the plug temporarily after draining.
L3-526
Fig. 118
6) Remove the pitching stopper bracket.
Pitch i n9 stopper brae ket
Fig. 116
4) Extract the torque converter.
a. Extract the torque converter horizontally. Be careful not to

scratch the bushing inside the oil pump shaft.
b. Note that oil pump shaft also comes out. Fig. 119
94
7) Disconnect the air breather hose. 10) Remove clips from the harnesses.
No. of hoses 4WD: 2 No. of harnesses 4WD: 3
FWD: 1 FWD: 2
Air breather hose (Converter case)
Air breather hose

(Transmission case)
L3-528
L -____________________________________ ~ L3-531
Fig_ 120 Fig_ 123
8) Remove the oil charger pipe, and remove the O-ring from
the flange face. Attach the O-ring to the pipe.
2. Separation of Converter Case and

Transmission Case Sections
a. Separate these cases while tapping lightly on the housing.

b. Be careful not to damage the oil seal and bushing inside the
converter case by the oil pump cover.
Oil charge pipe
Fig_ 121
9) Remove the oil cooler inlet and outlet pipes.
L3-532
Fig_ 124
Outlet pipe
L3-530
Fig_ 122
95
3. Separation of Transmission Case and 2) Remove the reduction driven gear:

(1) Straighten the staked portion, and remove the lock
Extension Sections (4WD)/
nut.
Transmission Cover Sections (FWD)
1) Remove the revolution sensor. (4WD) Set the range selector lever to "P".
L3·533 driven gear L3·536
Fig. 125 Fig. 128

2) While pulling the extension slightly, disconnect the con·
nector for the duty solenoid C (transfer). (2) Using the PULLER SET (899524100)' extract the
reduction driven gear.
Transmission
case section Drill two holes in the puller.
Extension case
L3·534
Fig. 126
(0.35) dia. Unit: mm(in)
3) Separate both sections. L3·537
Fig. 129
4. Transmission Case Section
1) Remove the reduction drive gear ASSY. 3) Remove the parking pawl, return spring and shaft.
Reduction drive
gear ASSY
L3·535 L3·538
~--------------------------------------~
Fig. 127 Fig. 130
96
4) Remove the revolution sensor. (FWD)
Keep the sensing element in the transmission case.

Oil pan
5) Loosen the taper roller bearing mounting bolts.
L3·541
Fig. 133
L3·539 8) Remove the oil cooler outlet pipe.

Fig. 131
Be careful not to twist the pipe.
6) Place two wooden blocks on the workbench, and stand

the transmission case with its rear end facing down.
a. Be careful not to scratch the rear mating surface of the

transmission case.
b. Note that the parking rod and drive pinion protrude from
the mating surface.
L3·542
Fig. 134
9) Disconnect the harness connectors for the solenoids and

duty solenoids and the ground cord.
For Duty sol. A
m==-+r:-i7-For Sol. 2 (shift)

L3·540
Fig. 132 For - Sol. 1 (shift)

- Sol. 3 (shift)
For Duty sol. B
For ATF temp.

7) Remove the oil pan and gasket. sensor
L3-543
Tap the corners of the oil pan when removing. Fig. 135
97
10) Remove the oil strainer. 12) Remove three accumulator springs.
L3·544 L3·546
~------------------------------------~
Fig. 136 Fig. 138
13) Loosen the reverse clutch drum lightly by turning the

adjusting screw. Then remove the oil pump housing.
Be careful not to damage D-ring on oil strainer.
Be careful not to lose the total end play adjusting thrust
11) Remove the control valve body. washer.
Oil pump housing
L3·547
Fig. 139
14) Loosen the brake band adjusting screw, and take out the
strut.
~ Short bolt (Yellow) 11 pes
• Long bolt (Black) 8 pes
L3·1014
Fig. 137
L3·548
Fig. 140
98
15) Remove the brake band and reverse clutch. 18) Take out the front sun gear.
Contract the brake band with a clip.
Reverse clutch
Front sun gear
Brake band
L3-552
Fig. 144
L3·549
Fig. 141
19) Take out the front planetary carrier.

16) Take out the high clutch.
Front planetary carrier
High clutch
L3-553
~___________________________________
L3_·5_5~O Fi~ 145
Fig. 142
17) Take out the high clutch hub. 20) Take out the rear planetary carrier and rear sun gear.
Rear sun gear

High clutch hub
L3·551 L3-554
Fig. 143 Fig. 146
99
21) Take out the rear internal gear. 24) Take out the forward clutch drum.
Rear internal gear
Forward clutch drum
L3-555 L3-558
Fig. 147 Fig. 150
25) Take out the low & reverse brake section.

22) Take out the one-way clutch outer race.
(1) Remove the snap ring. Then remove the retaining
plate, drive plates, driven plates, and dish plates as a unit.
L3-556
Fig. 148
Fig. 151
(2) Turning the case upside down, take out the one-way
23) Take out the overrunning clutch hub. clutch inner race and spring retainer CPo
L3-557 L3-560
Fig. 149 Fig. 152
100
(3) Take out the low & reverse piston by applying com-
pressed air.
Fig. 155
L3-561
Fig. 153
28) Remove the range select lever.
29) Remove the detent spring.
26) After removing the snap ring (inner), take out the servo
piston by applying compressed air from the release pressure
side.
Hold the servo piston with a rag so that it will not be ejected
with the air pressure. In this case, do not allow your finger to
be pinched between the pipe and retainer.
L3-564
Fig. 156
30) Remove the parking rod together with the manual lever.
Then remove the manual shaft by pulling off the straight pin.
Be careful not to damage the lips of the press-fitted oil seal in

the case.
Fig. 154
27) Apply compressed air from the operating pressure side,

and take out accumulator (3-4), accumulator (1-2), accumu-
lator (2-3), and accumulator (N-D).
Fig. 157
101
31) Remove the inhibitor switch. 2) Remove the differential side retainer.
Hold the differential case ASSV by hand to avoid damaging

retainer mounting hole of the converter case and speedometer
gears.
3) Extract the axle shaft.
Do not reuse the circlip.
L3-566
Fig. 158
32) Remove the transmission harness.
Be careful not to damage the cord insulation.
L3-569
Fig. 161
4) Remove the differential case ASSY.

L3-567
Fig. 159 a. Remove the seal pipe if it is attached. (Reusing is not
allowed.)
b. Be careful not to damage the retainer mounting hole of the
converter case and the speedometer gears.
5. Converter Case Section 5) Remove the snap ring. Then remove the speedometer
1) Wrap the axle-shaft serration with vinyl tape. driven gear.
Fig_ 160 Fig_ 162
102
6) Tap out the speedometer shaft to the outside of the case,

and remove the oi I seal.
Transfer pipe
L3·573
Fig. 165
Fig. 163
3) Remove duty solenoid C and the transfer valve body.
a. Take out the inlet filter.

b. Do not damage the O-ring.
6. Extension Section
1) Take out the transfer clutch by lightly tapping the end of
the rear drive shaft.
Duty sol. C
Be careful not to damage the oil seal in the extension.
L3-574
Transfer clutch
Fig. 166
4) Take out the roller bearing.
L3·572
Fig. 164 PULLER ASSY

(398527700)
Roller bearing
2) Remove the transfer pipe.
Be careful not to bend the pipe.

L3-575
Fig. 167
103
~ Disassembly, Inspection 4) Using a press, remove the ball bearing.
and Assembly of Each

Component
Reduction drive shaft
1. Reduction Drive Gear Assembly

Ball bearing
DISASSEMBLY
1) Take out the seal rings.
Be careful not to damage the seal rings. L3-578
Fig. 170
INSPECTION
Make sure that each component is free of harmful gouges,

cuts, or dust.
L3-576 ASSEMBLY
Fig. 168
1) Press-fit the ball bearing and reduction drive gear to the
shaft.
2) Take out the snap ring (out).
Be careful not to damage the splines. Reduction drive gear
3) Using a press, remove the reduction drive gear.

Ball baaring
I
Reduction drive shaft
L3·579
Fig. 171
2) 4WD: Fit the snap ring securely in the snap ring groove
on the shaft.
FWD: Press-fit the ball bearing using a press, then fit the snap
L3-577 ring to the snap ring groove on the shaft.
- -_- 1 6 - 9 - - - - ' - - - - - - - - - - - - - - - . . . J
L- 3) Attach two seal rings.
F i9
To make subsequent assembly easier, apply vaseline to the

grooves of the shaft and to the exterior of the seal ring.
104
2. Control Valve Body 3) Separate the upper valve body and lower valve body.
a. Do not lose the nine (9) steel balls contained in the upper
DISASSEMBLY valve body.
b. Do not lose an orifice and a strainer contained in the lower
1) Remove the following parts from the upper valve body. valve body.
(1) Solenoid ASSY (shift 1-2-3) c. Remove the upper-lower valve body tightening bolts. Then
(2) Duty solenoid A (line pressure) remove two locating bolts. ( .. )
Solenoid ASSY Solenoid-2 (shift) During ordinary servicing, clean the control valve bodies in
Solenoid-l (shift) this condition, without further disassembly.
Solenoid-3 In the event of a seized clutch or other problem, disassemble
(overrunning clutch) the control valve bodies further, and clean the component
parts.
INSPECTION
L3-618
Fig. 172
Make sure that each component is free of harmful gouges,
cuts, or dust.
2) Remove the following parts from the lower valve body.

(1) Duty solenoid B (lock-up)
(2) ATF temperature sensor
ATF temperature Duty solenoid 8 (lock-up)

sensor _
L3-956
Fig. 173
105
ASSEMBLY
Reverse the d isassembly sequence, pay ing attention to the

following points:
a. Be sure to properly position the steel balls, orifice and

strainer.
< Upper valve body> < Lower valve body>
Strainer location
Nine steel ball location
L3-922
Fig. 174
b. Tighten two locating bolts. Then tighten the upper-lower

valve body tightening bolts.
Tightening torque: 65 ft-Ib)

7 9 N'm (0.7 - 0.9 kg-m, 5.1 - .
3. Oil Pump Assembly

Oil seal retainer
DISASSEMBLY
L3·676
1) Remove the oil seal retainer. . Fig. 175

Also remove the O-ring and oil seal (air breather).
106
2) Remove the oil pump cover. 5) Remove two seal rings (R) and two seal rings (H).
Lightly tap the end of the stator shaft to remove the cover.
INSPECTION
Oil pump cover 1) Make sure that each component is free of harmful gouges,
cuts, and dust.
2) Selection of oil pump components (rotor, vanes, control
piston and cam ring):
(1) Using a micrometer, measure the height ofthe rotor,
vanes, control piston and cam ring in at least four posi·
tions. (Measure the height at one place for each of the
nine vanes.)
L3·677
a. Remove the control piston seals when measuring.
b. Remove the friction ring from the cam ring when measur·
Fig. 176
ing.
3) Remove the retainer and return spring. Then remove the

rotor, two vane rings and nine vanes.
L3·680
Fig. 179
L3·678
Fig. 177
(2) Using a depth gauge, measure the depth of the oil

4) Remove the cam ring and control piston. pump housing from the contact/sliding surface of the
Also remove the O'ring, friction ring, two side seals, and plain above·mentioned component parts in the same manner as
seal. above.
Control piston
'--_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _-'L=..:3:....-6;:.:7....::..J9 L3·681
~1m ~.~
107
(3) Make sure that the clearances are within the specified 3) Install the return spring and retainer between the housing
wear limits. If the wear limit is exceeded, select pump and cam ring.
components so that the standard clearance can be
obtained.
Wear limit Standard value
Rotor, control 0.054 mm 0.030 - 0.044 mm

piston, vanes (0.0021 in) (0.0012 - 0.0017 in)
0.034 mm 0.010 - 0.024 mm

Cam ring
(0.0013 in) (0.0004 - 0.0009 in)
Select vanes which are the same height as the rotor.

L3-684
Fig. 183
ASSEMBLY
1) Coat both the O-ring and friction ring with vaseline and
attach to the cam ring. Then fit them into the oil pump
housing.
4) Install the control piston to the oil pump housing.
Fit the seal in the piston groove, with the red seals facing the
top side. (Two side seals and one plain seal are attached.)
Friction ring
L3-682
Fig. 181
L3-685
2) Install the vane ring, rotor, vanes, and vane ring into the
housing in this sequence. Fig. 184
5) Set the rotor at the center of the housing bore. Apply

ATF abundantly to each rotary portion.
6) Install the oil pump cover.
Tightening torque:
L3-683 25 ± 2 N·m (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft-Ib)
Fig. 182
108
a. Align both pivots with the pivot holes of the cover, and 2) Using a press, separate the rear roller bearing and outer
install the cover being careful not to apply undue force to the race from the shaft.
pivots.
b. After assembling, turn the oil pump shaft to check for
smooth rotation of the rotor.
L3-688
Fig. 187
Oil pump cover
L3-686
Fig. 185
Install the oil seal retainer and seal rings (R) and (H) after
adjusting the drive pinion backlash and tooth contact. 3) Using a press, separate the front roller bearing from the
shaft.
Front roller bearing
4. Drive Pinion Shaft
DISASSEMBLY
1) Straighten the staked portion of the lock nut, and remove

the lock nut while locking the rear spline portion of the shaft.
L3-689
Then pull off the drive pinion collar.
Fig. 188
Remove the D·ring
Drive pinion
collar
WRENCH (499787100)
INSPECTION
Make sure that all component parts are free of harmful cuts,
HOLDER (498937100)
gouges, and other faults.
L3-687
Fig. 186
109
ASSEMBLY
1) Measure dimension" A" of the drive pinion shaft. WRENCH

(499787100)
HOLDER
(498937100)
L3-692
Fig. 191
L3·690
5) Measure the starting torque of the bearing.
Fig. 189 Make sure the starting torque is within the specified range.
If out of the allowable range, replace the roller bearing.
Starting torque:
0.3 - 2.0 N·m (3 - 20 kg-cm, 2.6 - 16.4 in-Ib)
2) Using a press, force·fit the roller bearing in position.
Do not change the relative positions of the outer race and

bearing cone.
Drive pinion shaft
L3-693
Fig. 192
L3·691
6) Stake the lock nut securely at two places.
Fig. 190
7) Measure dimension "8" of the drive pinion shaft.
3) After fitting the O-ring to the shaft, attach the drive

pinion collar to the shaft. 8e careful not to damage the D-
ring.
4) Tighten the lock washer and lock nut.
Actual tightening torque:

113 ± 5 N·m (11.5 ± 0.5 kg-m, 83.2 ± 3.6 ft-Ib)
a. Pay attention to the orientation of lock washer.

b. When using special tool WRENCH (499787100) and torque
L3-694
wrench, tighten it to 88 N·m (9 kg-m, 65 ft-Ib).
Fig. 193
110
8) Determine the thickness t (mm) of the drive pinion shim. 5. Reverse Clutch
t = 6.5 ± 0.0125 - (8 - A~ DISASSEMBLY
The number of shims must be three or less. 1) Remove the snap ring, and take out the retaining plate,
drive plates, driven plates, and dish plate.
• Available drive pinion shims 2) Using the COMPRESSOR (398673600), INSTALLER
(398177700) and PLiER (399893600), remove the snap ring
and take out the spring retainer and springs.
31451AA050 0.15 (0.0059) 3) Take out the piston by applying compressed air.
31451AA060 0.175 (0.0069)
31451AA070 0.2 (0.0079) INSPECTION
31451AA080 0.225 (0.0089)
0.25 (0.0098) 1) Drive plate facing for wear and damage
31451AA090
2) Snap ring for wear, return spring for breakage or setting,
31451AA100 0.275 (0.0108)
and spring retainer for deformation
3) Lip seal and lathe cut seal ring for damage
4) Piston check ball for operation
ASSEMBLY
1 Reverse clutch drum 8 Snap ring

2 Lip seal 9 Dish plate
3 Reverse clutch piston 10 Driven plate
4 Lathe cut seal ring 11 Drive plate
5 Spring 12 Retai n ing plate
6 Spring 13 Snap ring
7 Spring retainer 14 High clutch drum
L3-596
Fig. 194
111
1) Using the same special tools as those used in disassembling, 6. High Clutch
assemble piston the return springs, spring retainer and snap
ring. DISASSEMBLY
2) Assemble the dish plate, driven plates, drive plates and
retaining plate in that order and attach the snap ring. 1) Remove the snap ring, and take out the retaining plate,
drive plates, and driven plates.
Pay attention to the orientation of the dish plate.
2) Using the COMPRESSOR (398673600). INSTALLER
(398177700), and PLIERS (399893600), remove the snap
3) Checking operation:
ring and take out the spring retainer CPo
Apply compressed air intermittently to the oil hole, and check
3) Apply compressed air to the clutch drum to remove the
the reverse clutch for smooth operation.
piston.
4) Measuring clearance (Retaining plate selection).
Standard value:
0.5 - 0.8 mm (0.020 - 0.031 in)
Allowable limit: 1.2 mm (0.047 in)
INSPECTION
Before measuring clearance, place the same thickness of shim
on both sides to prevent retaining plate from tilting. 1) Drive plate facing for wear and damage
2) Snap ring for wear, return spring for setting and breakage,
and spring retainer for deformation
• Available retaining plates 3) Lathe cut rings (large) (small) for damage
Part No. Thickness mm (in) 4) Piston check ball for smooth operation
31567AAOOO 4.6 (0.181)

31567AA020 4.8 (0.189)
31567AA030 5.0 (0.197)
31567AA040 5.2 (0.205)
31567AA050 5.4 (0.213) ASSEMBLY
1 High clutch drum 8 Drive plate

2 Lathe cut seal ring 9 Driven plate (Thicker)
3 High clutch piston 10 Retaining plate
4 Lathe cut seal ring 11 Snap ring
5 Spring retainer CP. 12 Thrust needle bearing
6 Snap ring 13 High clutch hub
7 Driven plate (Thinner)
L3-599
Fig. 195
112
1) Using the same special tools as those used in disassembling, 2) Remove the retaining plate, drive plates, driven plates and
assemble the piston, spring retainer CP, and snap ring. dish plate. (Forward clutch)
2) Install the driven plate (thin), drive plates, driven plates, 3) Remove the snap ring from the forward clutch drum.
and retaining plate in that order. Then attach the snap ring.
3) Checking operation:
Apply compressed air intermittently to the oil hole, and check
the high clutch for smooth operation.
4) Measuring clearance (Retaining plate selection).
Standard value:
1.8 - 2.2 mm (0.071 - 0.087 in)

on both sides to prevent retaining plate from tilting.
L3·696
Fig. 197
• Available retaining plates
4) Remove the retaining plate, drive plates, driven plates and
31567AA190 3.6 (0.142) dish plate. (Overrunning clutch)
31567AA200 3.8 (0.150) 5) Compress the spring retainer, and remove the snap ring
31567AA210 4.0 (0.157) from the forward clutch, by using SEAT (498627100) and
31567AA220 4.2 (0.165) COMPRESSOR (398673600).
6) Install the one·way clutch inner race to the forward clutch
31567AA230 4.4 (0.173)
drum, and apply compressed air to remove the overrunning
31567AA240 4.6 (0.181) piston and forward piston.
31567AA250 4.8 (0.189)
31567AA260 5.0(0.197)
One-way clutch
inner race
7. Forward Clutch Drum
DISASSEMBLY
L3·697
1) Remove two snap rings from the forward clutch drum.
Fig. 198
7) Remove the one·way clutch after taking out the snap ring.
8) Remove the needle bearing after taking out the snap ring.
INSPECTION
1) Drive plate facing for wear and damage

2) Snap ring for wear, return spring for setting and breakage,
and snap ring retainer for deformation
L3·695 3) Lip seal and lathe cut ring for damage
Fig. 196 4) Piston and drum check ball for operation
113
ASSEMBLY
Forward clutch piston
Snap ring
Overrunning clutch piston
Dish plate
Lip seal Snap ring
Retainer Plate
Snap ring O.W.C.
Bush Needle bearing
Sleeve Lathe cut-ring
Return spring Snap ring
Drive plate Outer race
Drive p
Driven plate L3·957
Fig. 199
1) Fit the forward piston and overrunning piston to the 2) Set the springs and retainer on the piston with a press and
forward clutch drum. attach the snap ring.
Align the forward piston cut·out portion with the spline of the
drum.
COMPRESSOR
(398673600)
SEAT
(498627000)
Snap ring
Forward piston
Forward clutch L3-700

drum
Fig. 201
Overrunning piston
L3-699
Fig. 200
114
3) Install the· dish plate, driven plates, drive plates, and Before measuring clearance, place the same thickness of shim
retaining plate, and secure with the snap ring. (Overrunning on both sides to prevent retaining plate from tilting.
clutch)
Pay attention to the orientation of the dish plate. If the clearance is out of the specified range, select a proper
retaining plate so that the standard clearance can be obtained.
(Forward clutch)
31567AA010 8.0 (0.315)

31567AA060 8.2 (0.323)
31567AA070 8.4 (0.331)
Dish plate 31567AA080 8.6 (0.339)
~·=F-.7 31567AA090 8.8 (0.346)

31567AA100 9.0 (0.354)
{}.
L3-701
Fig. 202 (Overrunning clutch)
31567AA120 8.0 (0.315)

4) Install the dish plates, driven plates, drive plates, and
31567AA130 8.2 (0.323)
retaining plate, and secure with the snap ring. (Forward clutch)
31567AA140 8.4 (0.331)
Pay attention to the orientation of the dish plate. 31567AA150 8.6 (0.339)
31567AA160 8.8 (0.346)
31567AA170 9.0 (0.354)
Snap ring
31567AA180 9.2 (0.362)
8) Install the needle bearing, and secure with the snap ring.
Dish plate
Needle bearing
L3-958
Fig. 203
5) Install the snap ring (for front planetary carrier).

6) Check the forward clutch and overrunning clutch for
operation.
Set the one-way clutch inner race, and apply compressed air
L3-704
for checking.
7) Checking clearance: Fig. 204
~
Standard value Allowable limit
mm (in) mm (in) 9) Install the one-way clutch (1-2) and plate, and secure with
the snap ring.
0.45 - 0.85
Forward clutch 1.6 (0.063)
(0.0177 - 0.0335)
Set the inner race. Make sure that the forward clutch is free in
1.0 - 1.4 the clockwise direction and locked in the counterclockwise
Overrunning clutch 2.0 (0.079)
(0.039 - 0.055) direction, as viewed from the front of the vehicle.
115
Free One-way clutch

9. Servo Piston
inner race
(Locked) DISASSEMBLY
Forward ---;,;o.../:
clutch drum 1) Remove the spring.
2) Remove the band servo piston (3-4).
3) While compressing the retainer from above, remove the
snap ring. Then remove the retainer, spring and stem.
4) Take out the band servo piston (1-2).
INSPECTION
L3-959
1) Check each component for harmful cuts, damage, or other
Fig_ 205 faults.
2) Check the O-ring and lathe cut ring for damage.
8. One-Way Clutch Outer Race ASSEMBLY

DISASSEMBLY
Remove the snap ring. Then remove the one-way clutch (3-4).
INSPECTION
Check the sliding surface and one-way clutch (3-4) for any 1 Band servo piston stem
harmful cuts, damage, or other faults. 2 Spring
3 Lathe cut seal ri ng
ASSEMBLY 5 Lathe cut seal ring
6 O-ring
7 Retainer
Assemble the one-way clutch (3-4), and secure with the snap 8 O-ring
ring. 9 Spring
10 Retainer
11 Snap ring
Pay attention to the orientation of the one-way clutch (3-4).
Confirm: 14 O-ring
Assemble the rear internal gear, and secure the outer race. 15 0.0. servo retainer
Make sure that the internal gear is locked in the clockwise 16 Snap ring
direction, and free to rotate in the counterclockwise direction.
L3-822
Fig. 207
1) Install the band servo piston (1-2) to the retainer, and

insert the stem.
2) Put the spring and retainer on the piston. Fit the snap
ring securely while compressing the spring.
3) Install the band servo piston (3-4).
4) Install the spring securely to the band servo piston (1-2).
a. Many different O-rings and lathe cut rings are used. Be

careful not to confuse them when installing.
Fig. 206 b. Be careful not to damage O-rings and lathe cut rings.
116
10. Differential Case Assembly 3) Pull out the straight pin and shaft, and remove the differ-
ential bevel gear, washer, and differential bevel pinion.
DISASSEMBLY
1) Using a press, remove the taper roller bearing.
Be careful not to damage the speedometer drive gear.
Differential case (RH)

L3-708
Fig. 210
L3·706
Fig. 208 INSPECTION
Check each component for harmful cuts, damage, and other

faults.
2) Secure the case in a vise and remove the crown gear

tighten ing bo Its, then separate the crown gear, case (R H) and
case (LH). ASSEMBLY
1) Install the washer, differential bevel gear, and differential

bevel pinion in the differential case (RH). Insert the pinion
shaft, and fit the straight pin.
~ro\: Make sure that the case (RH) is staked in order to lock the
straight pin.
In
I l - - - - \ - - - - . . . l . Differential case (RH)
'---------( 2) Install the washer and differential bevel gear to the differ-
ential case (LH). Then put the case over the differential case
Differential case (LH)
L1-
(R H). and connect both cases.
3) Install the crown gear and secure by tightening the bolt.
,------------I L3 707 Standard tightening torque:

Fig. 209 57 - 67 N·m (5.8 - 6.8 kg-m, 42 - 49 ft-Ib)
4) Measurement of backlash (Selection of washer).

Measure the gear backlash by inserting a dial gauge through
the access window of the case.
Standard value:
0.13 - 0.18 mm (0.0051 - 0.0071 in)
117
Measure the backlash by applying a pinion tooth between two

bevel gear teeth.
~~~-----------=~ ~\ ,
L3·709
~ DIAL GAUGE Fig. 213
(498247100)
"--- L3·823
Fig. 211
2) Using a press, remove the ball bearing.
Do not reuse the bearing.

5) Install the speedometer drive gear. Then force·fit the
taper roller bearing with a press.
Be sure to position correctly the locking end of the speed-

Ball bearing
ometer drive gear.
DRIFT (398487700)
("""'J!..!.L~:---Taper roller bearing

Fig. 214
3) Remove the snap ring, and take out the pressure plate,
L3·824
drive plates, and driven plates.
Fig. 212
11. Transfer Clutch
DISASSEMBLY
Snap ring
1) Remove the seal ring.

L3·711
Be careful not to damage the seal ring. Fig. 215
118
4) Remove the snap ring, and take out the spring retainer CPo
PLiER
(399893600) COMPRESSOR COMPRESSOR
(398673600) (398673600)
SEAT
(498627000)
SEA T (498627000)
)~'---'== Snap ring
~ Spring retainer CP L3-714

A I J / ~-712 Fig. 218
Fig. 216
3) Install the driven plates, drive plates, and pressure plate,
and secure with a snap ring.
4) Apply compressed air to see if the assembled parts move
smoothly.
5) Apply compressed air to the rear drive shaft to remove
the piston.
L3-715
Fig. 219
L -________________________________________
L3-713
~
5) Check the clearance:

Fig. 217 Standard value:
0.2 - 0.9 mm (0.008 - 0.035 in)
If the clearance is not within the specified range, select a

INSPECTION proper pressure plate.
1) Check the drive plate facing for wear and damage. Before measuring clearance, place the same thickness of shim
2) Check the snap ring for wear, return spring for permanent on both sides to prevent pressure plate from tilting.
set and breakage, and spring retainer for deformation.
3) Check the lathe cut ring for damage.
• Available pressure plates

ASSEMBLY Part No. Thickness mm (in)
31593AA150 3.3 (0.130)

1) Install the lathe cut seal ring to the I.D./O.D. of the 31593AA160 3.7 (0.146)
transfer clutch piston.
31593AA170 4.1 (0.161)
2) Install the piston and spring retainer, and secure with a
snap ring. 31593AA180 4.5 (0.177)
119
6) Press-fit the ball bearing_ 12. Transfer Valve Body
DISASSEMBLY
bearing
L3-717
Fig_ 220
L3-719
Fig_ 222
1) Remove the plate. Then remove the spring and pilot valve
7) Coat the seal ring with vaseline, and install it in the seal together.
ring groove of the shaft. 2) Remove the straight pin and pry out the plug with a
screwdriver. Then extract the spring and transfer clutch valve
Do not expand the seal ring excessively when installing. together.
Be careful not to damage the valve and valve body.
I
INSPECTION
Seal ring Check each component for harmful cuts, damage, or other
faults.
L3-718
Fig_ 221
ASSEMBLY
To assemble, reverse the removal sequence.
Make sure the valve slides smoothly after assembling.
120
~ Assembly of Overall 4) Force-fit the oil seal to the converter case.
Transmission
1. CONVERTER CASE SECTION
1) Check the appearance of each component and clean.
Make sure each part is free of harmful cuts, damage, and other
faults.
2) Install the washer and snap ring to the speedometer shaft,

and set the oil seal. Then force-fit the shaft to the converter
case.
Fig. 225
5) Install the differential ASSY to the case, paying special

attention not to damage the speedometer gears (drive and
driven) and the inside of the case (particularly, the differential
side retainer contact surface).
6) Install the snap ring to the axle shaft, insert the shaft into
the differential assembly, and tap it into position with a
plastic hammer.
L3·720
Fig. 223
Thrust play:
Approx. 0.3 mm - 0.5 mm (0.012 - 0.020 in)
3) Install the speedometer driven gear to the speedometer

shaft, and secure with a snap ring.
a. If no play is felt, check whether the shaft is fully inserted.
If shaft insertion is correct, replace the axle shaft.
b. Be sure to use a new snap ring.
7) Wrap vinyl tape around the splined portion of the axle

shaft.
8) Install the oil seal and outer race (taper roller bearing) to
the differential side retainer. Then screw in the retainer after
coating the threads with oil.
a. Pay attention not to damage the oil seal lips.

b. Do not confuse the RH and lH oil seals.
c. Keep the O-ring removed from the retainer.
9) Using the HANDLE (499787000), screw in the retainer

L3·721
until light contact is felt.
Fig. 224
Screw in the RH side slightly deeper than the lH side.
121
10) Hypoid gear backlash adjustment and tooth contact check

(1) Assemble the drive pinion assembly to the oil pump
~WRENCH
housing. ____~___.'---"';>(' (499787100)
a. Be careful not to bend the shims. HOLDER

(498937100)
b. Be careful not to force the pinion against the housing bore.
L3-726
Fig. 228
(5) Tighten the LH retainer until contact is felt while

rotating the shaft. Then loosen the RH retainer. Keep
tightening the LH retainer and loosening the RH retainer
until the pinion shaft can no longer be turned. This is the
"zero" state.
Fig. 226 (6) After the "zero" state is established, back off the LH
retainer 3 notches and secure it with the locking tab. Then
(2) Tighten four bolts to secure the roller bearing. back off the RH retainer and retighten until it stops.
Repeat this procedure several times. Tighten the RH
Tightening torque: retainer 1 3/4 notches further. This sets the preload.
39 ± 3 N·m (4.0 ± 0.3 kg-m, 28.9 ± 2.2 ft-Ib) Finally, secure the retainer with its locking tab.
Turning the retainer by one tooth changes the backlash about

0.05 mm (0.0020 in).
(7) Turn the drive pinion several rotations and check

to see if the backlash is within the standard value.
Backlash:
0.13 - 0.18 mm (0.0051 - 0.0071 in)
After confirming that the backlash is correct, check the

L3-724 tooth contact.
Fig. 227
I WRENCH (499787100)
(3) Install the oil pump housing assembly to the con- I
verter case, and secure evenly by tightening four bolts.
Tightening torque:
/
33 ± 3 N·m (3.4 ± 0.3 kg-m, 24.6 ± 2.2 ft-Ib)
a. Thoroughly remove the liquid gasket from the case mating

surface beforehand.
b. Use an old gasket or an aluminium washer so as not to
damage the mating surface of the housing.
DIAL GAUGE (498247100) L3-727
(4) Rotate the drive pinion several times.
Fig. 229
122
(8) Apply red lead evenly to the surfaces of three or contact pattern.
four teeth of the crown gear. Rotate the drive pinion in If tooth contact is improper, readjust the backlash or
the forward and reverse directions several times. Then shim thickness.
remove the oil pump housing, and check the tooth
Checking item Contact pattern Corrective action
Correct tooth contact

Tooth contact pattern slightly
sh ifted toward toe under no-load
rotation.
(When loaded, contact pattern
moves toward heel.)
Face contact
Backlash is too large.
This may cause noise and chipping at Increase thickness of drive pinion hight
tooth ends. adjusting shim in order to bring drive
pinion close to crown gear.
Flank contact
Backlash is too small.
This may cause noise and stepped wear Reduce thickness of drive pinion hight
on surfaces. adjusting shim in order to move drive
pinion away from crown gear.
Toe contact Adjust as for flank contact.

(Inside end contact)
Contact area is small. This may cause

chipping at toe ends.
Heel contact Contact area is small. Adjust as for face contact.

(Outside end contact) This may cause chipping at heel ends.
Fig. 230 A13·164
123
(9) If tooth contact 'is correct, mark the retainer position 14) Install the oil seal retainer taking care not to damage the
and loosen it. After fitting the O-ring, screw in the oil seal lips. Then secure with three bolts.
retainer to the marked position. Then tighten the lock
plate to the specified torque. Make sure the D·ring is fitted correctly in position.
Tightening torque: Tightening torque:

23 - 26 N·m (2.3 - 2.7 kg-m, 17 - 20 ft-Ib) 7 ± 1 N·m (0_7 ± 0.1 kg-m, 5.1 ± 0.7 ft·lb)
11) Install the seal pipe to the converter case.
Be sure to use a new seal pipe.
Oil seal retainer

L3-732
Fig. 233
L3-729
Fig_ 231
15) Apply vaseline to the groove on the oil pump cover, and
install two (R) seal rings and two (H) seal rings.
12) Install two oil seals to the oil seal retainer with IN-
a. Fit the seal ring after compressing, and rub vaseline into
STALLER (499247300). the seal ring to avoid expansion.
b. The "R" seal ring has a large diameter, while "H" has small
a. Pay attention to the orientation of the oil seals. diameter.
b. Be careful not to damage the seal lips. If any damage is
found, replace with a new one.
13) Attach the O-ring to the oil seal retainer with vaseline.
Install the seal to the oil pump housing bore.
L3-733
Fig. 234
16) Install the rubber seal to the converter case.

L3-731
Fig_ 232 Be careful not to lose the rubber seal.
124
2. TRANSMISSION CASE 4) Assemble the manual lever and parking rod to the inside
shaft, and secure with a nut.
1) Press-fit the roller bearing to the transmission case.
Tightening torque:
39 ± 3 N·m (4.0 ± 0.3 kg-m, 28.9 ± 2.2 ft-Ib)
DRIFT
(398487700)
Roller bearing
L3-735
Fig. 235
L3-738
2) Using a plastic hammer, force-fit the oil seal.
Fig. 238
5) Install the detent manual spring.
Position the spring so that its center is aligned with the center
of the manual plate.
Tightening torque:
6 ± 1 N'm (0.6 ± 0.1 kg-m, 4.3 ± 0.7 ft-Ib)
Fig. 236 6) Install the lathe cut seal ring and lip seal to the 1.0./0.0.
of the low & reverse piston. Then install the piston into the
case with a press.
3) Install the manual plate and shaft, and secure with a
spring pin.
a. Be careful not to tilt the piston when installing.
a. Be careful not to damage the oil seal lip. b. Be careful not to damage the lip seal.
b. After installation, make sure of smooth movement.
L3-739
Fig. 237 Fig. 239
125
7) Install the one-way clutch inner race. 8) Install the band servo sub ASSY.
(1) Using a press, install the thrust needle bearing to the 9) Press the 0.0. servo retainer into position, and secure
inner race. with a snap ring.
COMPRESSOR
(498677000)
INSTALLER
(398497701 )
Inner race
L3-740
L -_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
~
L3-742
F~-240 F~-242
* Perform the following operations with the transmission case

set vertically on wooden blocks_
10) Installation of the low & reverse brake:

Use the PU LLER ASSY (398527700) when removing.
(2) Install four seal rings.
Apply vaseline to the groove of the inner race and to the seal
ring after installation, so that the seal ring will not expand.
(3) Place the spring retainer CP on the inner race. Install Transmission case
the spring to the recessed portion of the piston. Then
tighten eight socket head bolts from the rear side of the
transmission case.
Dish plate
Tightening torque:
25 ± 2 N·m (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft-Ib) Piston
Be sure to tighten evenly. Bolt
Lathe cut seal ring
Clutch spring
retainer
Forward clutch
L3-605
Fig. 243
L3-741
(1) Install two dish plates, driven plates, drive plates, and
Fig. 241 a retaining plate, and secure with a snap ring.
126
a. Pay attention to,the orientation of the dish plate. (2) Installation is complete when the drum recedes
b. Driven plate } 1800: 4 2.5 mm (0.098 in) from the inner race surface.
Drive plate 2700: 6
2.5 mm (0.098 in)
c. Dish plate 1800: 2
Forward clutch drum
2700: 1
(2) Apply compressed air intermittently to check for

operation.
Inner race L3·746

Fig. 245
13) Assemble the overrunning clutch hub.
a. Join the thrust needle bearing* and thrust washer with

L3·744
vaseline, and then install them together.
Fig. 244 b. Make sure that the splines are engaged correctly.
(3) Check the clearance (Selection of retaining plate)
Standard value:
1.1 -1.7 mm (0.043 -0.067 inl
Allowable limit: 2.7 mm (0.106 inl

on both sides to prevent retaining plate from tilting.
• Available retaining plates

Thrust washer
Thrust needle bearing
31667AA180 6.5 (0.256) L3·747
31667AA190 6.8 (0.268) Fig. 246

31667AA200 7.1 (0.280)
14) Install the one-way clutch outer race ASSY.
31667AA210 7.4 (0.291)
31667AA220 7.7 (0.303) Make sure the forward clutch splines are engaged correctly.
31667AA230 8.0 (0.315)
31667AA240 8.2 (0.323) rc:t;/
Forward clutch
31667AA250 8.4 (0.331) c\
J
11) Install the thrust needle bearing to the inner race.
J
Refer to @] "Location and installing direction of thrust
needle bearing and washer" for the orientation of the bearing.
Carefully check the orientation of all parts indicated by an
asterisk * in the following pages.)
12) Install the forward clutch drum ASSY.

(1) Install carefully while rotating the drum slowly L3·74S
paying special attention not to damage the seal ring. Fig. 247
127
15) Assemble the rear internal gear.

(1) Join the thrust needle bearing* and thrust washer to
the gear with vaseline, and install the gear while rotating
it.
(2) Securely engage the bearing with the dog of the over-
running clutch hub.
Installation is complete when the snap ring top surface of the

forward clutch drum recedes approximately 3.5 mm (0.138
in).
3.5 mm (0.138 in) ~ Front
Overrunning clutch hub L3-751
Fig. 250
18) Install the front planetary carrier.

Attach the thrust needle bearings * to both sides of the carrier
with vaseline. Install the carrier carefully, while aligning with
the splines of the forward clutch drum, and while rotating the
pinion.
Rear internal gear

bearing L3-749 Forward clutch
drum Front planetary
Fig_ 248 carrier
16) Install the rear planetary carrier.

Attach the thrust needle bearing * to the inside of the carrier
with vaseline. Then install the carrier while rotating slowly.
L3-752
Fig. 251
19) Install the front sun gear.

Attach the thrust needle bearing * to the gear, and install the
gear while turning slowly.
L3-750
Fig. 249
17) Install the rear sun gear.

L3-753
Install the gear with the oil hole facing up. Fig. 252
128
20) Install the high clutch hub. 22) Install the reverse clutch ASSY.
Attach the thrust needle bearing * to the hub with vaseline and
install the hub by correctly engaging the splines of the front Engage the high clutch outer spline with the reverse clutch
planetary carrier. spline and the front sun gear with the cut-out portion of the
reverse clutch drum correctly when installing.
Reverse clutch
ASSY
Thrust needle
High
hub 0
Fig. 253
t~~~~ L3·754
L3-756
Fig. 255
21) Install the high clutch ASSY. 23) Install the brake band ASSY.
Correctly engage the high clutch hub and clutch splines. a. Be careful not to damage the brake band when installing.
b. Install the strut to the band servo piston stem. Then tighten
it temporarily to avoid tilting the band.
Brake band
High clutch ASSY
L3·755
Fig. 254
L3-757
Fig. 256
129
24) Adjustment of total end play

(1) Measure the distance from the transmission case
mating surface to the recessed portion of the high clutch
drum, and the distance to the top surface of the reverse
clutch drum.
L3-758
Fig. 257
130
(2) Measure the distance from the oil pump housing with needle bearing, and to the thrust surface of the
mating surface to the top surface of the oil pump cover reverse clutch.
L3-759
Fig_ 258
(3) Equation for calculation Unit: mm I t = (M + 0.4) - m - (0.55 to 0.9)
...
________T_=__
(L_+_0_._4)_-
__Q_-_(0_._25__
to_0_.5_5_)______ ~1_ ~----------------------------------~
t: Th ickness of thrust washer
T: Thickness of bearing race M: Depth of top surface of reverse clutch drum from
L: Depth of the recess of high clutch drum from case case mating surface
mating surface m: Height of reverse clutch thrust surface from housing
Q: Height of top surface of the oil pump cover with mating surface.
needle bearing from the mating surface of the housing 0.4: Thickness of gasket
0.4: Thickness of gasket 0.55 to 0.9: Total end play standard value
0.25 to 0.55: Total end play standard value Part No. Thickness mm (in)
31299AAOOO 0.7 (0.028)

31299AA010 0.9 (0.035)
803031021 0.8 (0.031) 31299AA020 1.1 (0.043)
803031022 1.0 (0.039) 1.3 (0.051)
31299AA030
803031023 1.2 (0.047) 1.5 (0.059)
31299AA040
803031024 1.4 (0.055) 31299AA050 1.7 (0.067)
803031025 1.6 (0.063) 31299AA060 1.9 (0.075)
80303102{) 1.8 (0.071)
25) Install the oil pump housing ASSY.
803031027 2.0 (0.079)
(1) After completing end play adjustment, insert the
bearing race * in the recess of the high clutch. Attach the
thrust washer to the oil pump cover with vaseline.
131
(2) After correctly installing the gasket to the case

mating surface, carefully install the oil pump housing
ASSY. Be careful to avoid hitting the drive pinion against
the inside of the case.
a. Be careful not to damage the seal ring.

b. Be sure to use a new gasket. Rubber seal
L3-763
Fig. 261
Oil pump
2) Install the converter case ASSY to the transmission case
housing ASSY
ASSY, and secure with six bolts and four nuts.
Tightening torque:
33 ± 3 N·m (3.4 ± 0.3 kg-m, 24.6 ± 2.2 ft-Ib)
Gasket
L3-761
When installing, be careful not to damage the converter case
Fig. 259 bushing and oil seal.
(3) Install both parts with dowel pins aligned. Make sure 4. INSTALLATION OF CONTROL VALVE
no clearance exists at the mating surface. AND OIL PAN
1) Install four accumulators.
Any clearance suggests a damaged seal ring.
Be careful not to confuse the springs and installation positions.
(4) Secure the housing with two nuts.
Tightening torque:
33 ± 3 N·m (3.4 ± 0.3 kg-m, 24.6 ± 2.2 ft-Ib)
Fig. 262
Spring spec.
mm(in)
Fig. 260 Accumulator

Outer diameter Free length
spring
3. CONNECTION OF CONVERTER CASE
AND TRANSMISSION CASE 1-2 28.5 (1.122) 44.5 (1.752)
1) Apply proper amount of liquid gasket (Three-bond
2-3 20.5 (0.807) 31.0 (1.220)
#1215) to the entire converter case mating surface.
3-4 17.3 (0.681) 43.7 (1.720)
Make sure that the rubber seal and seal pipe are fitted in posi-
tion. N-D 17.8 (0.701) 36.5 (1.437)
132
2) Install and route the transmission harness.
Be careful not to damage the harness. Oil strainer
3) Install the control valve ASSY.

(1) Set the select lever in range "2".
(2) Install the control valve by engaging the manual valve
and manual lever, then tighten the 19 bolts.
Tightening torque:
8 ±1 N.m (0.8 ± 0.1 kg-m, 5.8 ± 0.7 ft-Ib)
L3·769
Fig. 264
5) Secure five connectors.
For Duty Sol. A
r==-+T-:+r- For Sol. 2 (shift)
For. Sol. 1 (shift)

• Sol. 3 (shift)
For Duty Sol. B
For A TF temp.
sensor
L3·543
Fig. 265
6) Install the oil cooler outlet pipe, and secure with two
~ Short bolt (Yellow) 11 pes
bolts.
. . Long bolt (Black) 8 pes
Tightening torque:
8 ± 1 N'm (0.8 ± 0.1 kg·m, 5.8 ± 0.7 ft·lb)
L3·1014
Fit the pipe into position. Be careful to avoid twisting.
Fig. 263
7) Install the oil pan.
a. Be careful not to pinch the harness roll the gasket. (1) Attach the magnet at the specified position.
b. Tighten the control valve mounting bolts evenly.
4) Install the oil strainer to the control valve. Be careful not

to cut or break the a·ring. Then tighten bolts.
Tightening torque:
8 ± 1 N·m (0.8 ± 0.1 kg·m, 5.8 ± 0.7 ft·lb)
L3·772
Fig. 266
133
(2) With gasket inserted, secure the oil pan by tightening 6. CONNECTION BETWEEN EXTENSION CASE
20 bolts. AND TRANSMISSION CASE
1) Install the revolution sensor to the transmission case with
Tightening torque:
one bolt. (FWD model only)
3.9 ± 0.5 N·m (0.4 ± 0.05 kg-m, 2_9 ± 0.4 ft-Ib)
Tightening torque:
Tighten the bolts evenly. 7 ± 1 N·m (0.7 ± 0.1 kg-m, 5.1 ± 0.7 ft-Ib)
2) Install the reduction driven gear.

3) Install the parking pawl and shaft, set the select lever in
the "P" range and tighten the drive pinion lock nut.
Tightening torque:
98 ± 5 N·m (10 ± 0.5 kg-m, 72.3 ± 3.6 ft-Ib)
After tightening, stake the lock nut securely.
4) Install the reduction drive gear ASSY.
Insert it fully into position until the bearing shoulder bottoms.
Fig. 267
5) Adjustment of extension end play:
(1) Measure the distance from the transmission case
mating surface to the reduction drive gear end surface.
FWD model: Measure the distance from the transmission case

mating surface to the bearing end face.
5. EXTENSION CASE
1) Install the filter in the extension case.
Pay attention to the orientation of the filter.
2) Install the transfer clutch valve ASSY, and secure with

four bolts.
Tightening torque:
8 ± 1 N·m (0.8 ± 0.1 kg-m, 5.8 ± 0.7 ft-Ib)
a. Be su re to tighten the going lead with one of these bolts.

b. Be sure to use a new gasket.
3) Install the pipe, and clamp securely.

4) Install the transfer clutch assembly to the case.
a. Be careful not to damage the seal rings.

b. Insert the clutch assembly fully into position until the
bearing shoulder bottoms.
134
Rear drive shaft
L3·961
Fig. 268
(2) Measure the distance from the extension case mating

surface to the rear drive shaft end face.
806535020 3.8 (0.150)
FWD model: Measure the distance from the cover case mating 806535030 4.0 (0.157)
surface to the bearing mounting surface. 806535040 4.2 (0.165)
806535050 4.4 (0.173)
(3) Calculation equation: Unit (mm) 806535060 4.6 (0.181)
806535070 4.8 (0.189)
T = (L + 0.4) - Q - (0.05 to 0.25)
806535090 5.0 (0.197)
T: Thickness of thrust bearing
6) Installation of extension case 4WD, cover case FWD and
(FWD model: Thickness of AI washer)
transmission case.
L: Distance of rear drive shaft end face from
4WD model:
extension case mating surface
(1) Attach the selected thrust needle bearing* to the end·
(FWD model: Depth of bearing mounting surface of reduction drive gear with vaseline.
face from cover case mating surface)
(2) Set the parking return spring.
Q: Height of reduction drive gear end surface
(3) Remove the transfer clutch from the extension case.
from transmission case mating surface
Set the needle bearing on the reduction drive shaft and
(FWD model: Height of bearing end face
then install transfer clutch to the transfer clutch hub.
from transmission case mating surface)
0.4: Thickness of gasket Be sure to engage the spline teeth correctly.
0.05 to 0.25: Standard value of end play
135
(4) With gasket inserted between them, install the exten-
sion case to the transmission case. (Be sure to use a new
gasket.)
a. After inserting the extension case halfway, connect the

connector for duty sol. C. Be careful not to jam the cord in
the case.
b. Be careful not to damage the rear drive shaft seal ring.
(5) Tighten bolts to secure the case.
Tightening torque:
25 ± 2 N·m (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft-Ib)
Fig. 269
FWD model:
(1) Attach the selected aluminum washer to the cover
case with vaseline. (3) With the selector lever set to "N" adjust the inhibitor
(2) Set the parking return spring. switch so that the hole of range selector lever is aligned
(3) With gasket inserted between them, install the cover with the inhibitor switch hole.
case to the transmission case.
a. Be sure to use a new gasket.

b. Install the case while ensuring proper alignment of the
bearing, parking shaft, and reduction driven gear.
(4) Tighten bolts to secure the case. ~.
c>
Tightening torque: i
t
25 ± 2 N·m (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft-Ib) !
STOPPER PIN
(499267300) ~~~~~~~~~~~
L3-780
Fig. 270
(4) With hole aligned, tighten three bolts to secure the

inhibitor switch.
r
Tightening torque:
3.4 ± 0.5 N·m (0.35 ± 0.05 kg-m, 2.5 ± 0.4 ft-Ib)
7. INSTALLATION OF EXTERIOR PARTS
3) Clip the following cords and harness:
1) Install the revolution sensor. (4WD only) (1) Transmission harness
(2) Inhibitor switch cord
Tightening torque:
(3) Revolution sensor cord (4WD only)
7 ± 1 N·m (0.7 ± 0.1 kg-m, 5.1 ± 0.7 ft-Ib)
4) Install the oil cooler outlet pipe.
2) Installation and adjustment of inhibitor switch: Tightening torque:

(1) Install the inhibitor switch to the transmission case. 30.9 ± 3.4 N·m (3.15 ± 0.35 kg-m, 22.8 ± 2.5 ft-Ib)
Fit the projecting portion of the switch in the recessed
portion of the case, and tighten three bolts temporarily.
5) Install the oil cooler inlet pipe.
(2) Insert the range selector lever into the shaft, and
tighten the nut. Tightening torque:
25 ± 2 N·m (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft-Ib)
Tightening torque:
39 ± 3 N·m (4.0 ± 0.3 kg-m, 28_9 ± 2.2 ft-Ib) Be sure to use a new aluminum washer.
136
6) Install the oil charge pipe. (2) Holding the torque converter assembly by hand,
carefully install it to the converter case. Be careful not
Tightening torque: to damage the bushing. Also, to avoid undue contact
30.9 ± 3.4 N·m (3.15 ± 0.35 kg·m, 22.8 ± 2.5 ft·lb) between the oil pump shaft bushing and stator shaft
portion of the oil pump cover.
Be careful not to damage the Q·ring. (3) Rotate the shaft lightly by hand to engage the splines
securely.
7) Adjustment of brake band:
13.5 - 15.5 mm
(1) After tightening the brake band adjusting screw to (0.531 - 0.610 in)
9 N.m (0.9 kg-m, 6.5 ft-Ib) torque, back it off three turns. Torque converter normal protrusion
Then secure with a lock nut.
Lock nut tightening torque:

25 - 28 N·m (2.5 - 2.9 kg-m, 18 - 21 ft-Ib)
When tightening the lock nut, be careful not to turn the

adjusting screw.
8) Install the pitching stopper. L3-963
Fig. 272 Protrusion of torque converter

Tightening torque:
39 ± 3 N·m (4.0 ± 0.3 kg-m, 28.9 ± 2.2 ft-Ib)
13) Add oil:
9) Tighten the drain plugs.

Specified quantity Q (US qt, Imp qt)
Diff.
Tightening torque:
1.3 - 1.5 (1.4 - 1.6, 1.1 - 1.3)
Diff.
ATF
44 ± 3 N·m (4.5 ± 0.3 kg-m, 32.5 ± 2.2 ft-Ib)
FWD: 9.3 (9.8, 8.2)
ATF
4WD: 9.5 (10.0,8.4)
25 ± 2 N·m (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft-Ib)
After adding oil, insert the oil level gauge into the oil inlet.
10) Install the air breather hose.
11) Insert the input shaft while turning lightly by hand.
Input shaft
--+--1-- Normal protrusion

28 - 33 mm (1.10 - 1.30 in) L3-962
Fig.271 Inserting input shaft
Be careful not to damage the bushing.
12) Install the torque converter assembly.

(1) Install the oil pump shaft to the torque converter.
Make sure the clip fits securely in its groove.
137
TROUBLESHOOTING
GENERAL NOTES 2) Troubleshooting should be conducted by rotating with
1) Problems in the electronic-controlled automatic transm is- simple, easy operations and proceeding to complicated, dif-
sion may be caused by failure of the engine, the electronic ficult operations. The most important thing in troubleshooting
control system, the transmission proper, or by a combination is to understand the customer's complaint, and distinguish be-
of these. These three causes must be distinguished clearly tween the three causes.
when troubleshooting. 3) The general flow of troubleshooting is shown below:
OJ Read the self-diagnostic code. Read the trouble code on the "POWER" indicator, and per-
form operation according to the code.
Preliminary inspection. Check the following items:

• Fluid level
• Idling speed
• Inhibitor switch
• Shift linkage
• Fluid leakage, etc.
@] Troubleshooting chart
~ ~
m IOn-car service I rID IPerformance testj
~ ~
[§J Off-car service See "Service Procedure".
138
~
EJ
:0
(")-1
® /FWDI
(p cb cb Cf.l
AT OIJ /POWERI/1HOLDI [II
I I
29 30
25~----------------------~
Ignition coil
Z
C)
o
o ~
::1 0
r+r:
TEMP ' - - - l 13
» ~ C-
L------l27 C) O -
4~~-_-_-_-_-_-~--~---hif~~ :0 -C»
»
t:> Ignition switch
'--------~23
L----------------------128 15 I I , I
Idle switch
» (/)~
3: c-;
~------------~--------------------------~18
11 I I
t/------~
I ,
Throttle sensor <en0
0
o
~-HJ O+-.--~--------------------------__13
r+r+
C» _. ~
~~~~ {j~ ~top

switch \! light
~o+_~1___---l10
~
3~ ~
()
7! FWD switch Q)
::l rrr - - - - - - - - --...,... Speed sensor No.1 -;
Fuse r-
1----------------~6 3 ..L------------~·:7'---t'""1¥l101f'.~....J
16 H.!.'';'" _________ ~
(in transmission)
:0
~ r-----------~8
~.
,)"
m »Z
~
':' Battery
--'-
Cruise
control
unit 771!
~.-----4'-"":"""j-+-------------I
Speed sensor No.2

5
::l
n
o
::!
Q.
17~-------------------------__.
i.-n-----------~ r- - - -
-
C»
C")
(j)
~
12~L:~:-------------~:7:--Ir_~~~
1
(in combination meter)
D-l'--------------l9
c:
::l
;:;.
::;
..... _---------...., ./
ATF temp. sensor
_.
r+
~
C")
(j)
(j)
J.; 1st hold switch (")

C
35!-------------------+J'J'ff'--R,v
36 '""' --<
Shift solenoid No. 1
, Shift solenoid No.2

Q) oz
~[e] $~cb~ ®~ $rn »
21 ~--------------------_:_,J'1~IO'"~~ Shift solenoid No.3
-I
'-----'-n
P 34 ~ Duty solenoid A ~ z
~~~~--~--~~-?---~----------_;14
IIlR 1 33 ~ J (Line pressure)
Q)
::1
o
, 26 L.:.:..:.J Dropping resistor
22!--------........:...:......~-----+J'"'vv----. I
Duty solenoid B
(Lock-up) en o
~N~-------~~--~---?---------~19
~D~-------------~---?----------~20 24 ,''""' ~ Duty solenoid C 3 "'Tl
"'Tl
31 (Transfer clutch)
~. m
F3~--------------41--------~1 L_ _. :0
32'1----'J GND m
~2~--------------__12 o Z
'-+_-' Range switch ::1 -;
»
r
c.v
I
I\)
2) FUNCTION OF SELF-DIAGNOSIS • Shift solenoid No.1

• Shift solenoid No.2
(1) Self-diagnosis Items
• Shift solenoid No.3
The following items can be checked for improper operation • Duty solenoid A (Line-pressure)
using the self-diagnosis system. • Duty solenoid B (Lock-up)
• Vehicle-revolution sensor No.1 (on transmission) • Duty solenoid C (Transfer clutch)
• Vehicle-revolution sensor No.2 (in combination meter) • Throttle sensor
(2) Troubleshooting Chart

Trouble Possible cause
l2J No shift CD
ell
Shift solenoid No.1 and/or No.2
• Severed or short circuit
Speed sensor No.1 and No.2
@
• Defective or severed
Power source and grounding
l2J Shift point too high or too low CD Throttle sensor

• Defective, severed or short circuit
ell Speed sensor No.1
L:J No up-shift to overdrive (after warm-up) CD Range switch

ell ATF temp sensor
@
Cruise control unit
• Operation unusual or short circuit
~ No back-up (after warm-up) CD Duty solenoid B

ell ATF temp sensor
@
Ignition pulse
@
• Severed wire harness
Idle switch
~ No engine braking effect at "3" range CD Shift solenoid NO.3

ell Throttle sensor
@
Range switch
~ Excessive shift shock CD Duty solenoid A
ell
Throttle sensor
~ Excessive tight corner braking CD Duty solenoid C

ell Throttle sensor
@
• Defective, severed or short circu it
Speed sensor No.1
140
(3) Indication of Malfunctioning Self-diagnosis (4) Checking the Trouble History

Items
Trouble history of self-diagnosis items is indicated on the
Malfunctioning self-diagnosis items are indicated on the POWER indicator in terms of "trouble codes" using the
POWE R indicator in terms of "trouble codes". following method CD or ® as applicable.
CD 4WD .... Insert fuse into FWD switch.
FWD ® FWD .... Ground self-diagnosis terminal of check connector
4WD
..-..
HEIGHT [B]
[g
(17-pin connector),
CONT.HI [EjJ
I
[QJ POWER I
~
~ [Z] 11 HOLOI
() 0
,------, 000 R
Ci\il~LOCK
II FUllTIMEI \
4WD
(®)~
PI RK'---------'
BRAKE
L3-965
Fig. 274
L3-966
Indicator signal is as follows:
Fig. 276
ON
(a) NG
,
,
, I
OFF 2.0 I I
I"
I
~I
I
;.-- 0.25
8.0
I
I
:... ~I
ON
(b) OK
OFF
J ,I 2.0
,
,.-
I
I
~I
ON I
Ignition
key
OFF
J
L3-781
Fig. 275 POWER indicator signal (unit: second)
Warning can be noticed only when the ignition switch is initil-

Iy turned to ON.
141
(5) Calling up Trouble Codes Low battery voltage will cause faulty operation of the di-
A malfunctioning self-diagnosis item can be determined using
agnosis system. Therefore, always be sure to check the battery
the procedure outlined in the flowchart below.
voltage first.
I START I
Warm up engine
I I
I Turn the ignition switch OFF

I
I Turn the ignition switch ON
I
Power light or
I Check if POWER lights up

~ circuit faulty
TCU fauly
OK
I Turn the ignition switch ON

I
t
1 NG
I Check trouble history.
I
OK
Shift into "D" range
I Turn the 1-Hold switch ON
t
I
I Turn the ignition switch ON T
t
Shift into "3" range
I Turn the 1-Hold switch OFF
t
Shift into "2" range
I Turn the 1-Hold switch ON
t
Depress the accelerator pedal halfway
I . (Turn the Idle switch OFF)

The system YES t
is operating
normally.
1 Check if POWER normal blinking (no malfun9tion) I
NO
~ 1
I Trouble code I I Once every 0.125 seconds blinking
I No lighting up
I
I 1
The system faulty
I
I
Self-diagnosis faulty
(Low battery voltage)
1 Range switch, 1-Hold
switch or each circuit
faulty
142
(6) How to Read Trouble Code sec) blink means its own faulty system code.
In case of malfunction, trouble code will be observed by the Example: Shift solenoid No.1 fault
specified signal of POWER indicator. The sequence of blinking
shows each faulty system and the term of long segment (0.6
Shift solenoid No. 3 - - - - - - - - - - - . ~---- Duty solenoid B
Shift solenoid No. 2 - - - - - - - - - - . ~-- Duty solenoid C (4WD only)
Shift solenoid No.1 - - - - - - - - , ATF Temp. sensor
Ignition pulse
Throttle sensor ~
ON
Speed sensor No.2
Sp,,' ""'0' No.1 1 I [

Duty solenoid A
j A.PH'
OFF -,....------4
: I I I : I I I I I I I I I I
25 2 1111 11 1 11 11 11 11 11 11 11 ,1,
I
I. . -I.
I
~.
I
-I- -I- -I- ~ -I- -I- -t- + ... -I- -I- -I
r
Unit: second
1
ONJLJL
ON r--l I
OFF OFF~ U
0.1
-I
I
I-
0.9
I
•
0.6
.. .0.4 .I,
1
,
I I
f- ~ Unit: second
Normal system Faulty system
L3-782
Fig. 277
143
(7) Troubleshooting for Electronic Control System
Check diagnosis code

I I
t Defective sensor
Speed sensor No.1
I NG
Severed wire harness or short circuit
I I
t OK Defective sensor
Speed sensor No.2 I NG
Severed wire harness or short circu it
I I
J OK
Defective sensor
Throttle sensor I NG
I I
t OK
Severed solenoid or short circuit
Shift solenoid No.1 I NG
I I
! OK
Shift solenoid No.2 I NG
I I
t OK
Severed solenoid or short circu it
Shift solenoid No.3
I NG
I I
t OK
Duty solenoid B I NG
I I
t OK Severed solenoid or short circu it
I NG
I Duty solenoid C
I
t OK Defective sensor
ATF Temp sensor I NG
I I
t OK
I NG Severed wire harness

I Ignition pulse
I
i OK Severed solenoid or short circu it
Duty solenoid A I NG
I I
t OK
END
I I
144
(8) Cancelling the Trouble Code

Preliminary Inspection
Trouble codes are cancelled after self-diagnosis; however,
those in the trouble history remain in the memory of the No. Item to check Judgment standard
control unit after the ignition switch is turned OFF. After
repairs, a trouble code can be cancelled by turning the ignition 1. Idling rpm 1800 cc 800± 100 rpm
switch OF F and disconnecting the connector from the control
2700 cc 750±loorpm
unit.
2. Idling boost More than -53.3 kPa
(intake manifold) (-400mmHg,
-15.75 inHg)
3.* Stall rpm 1800 cc

2,450 - 2,850 rpm
2700 cc
2,400 - 2,800 rpm
4. Operation of linkage Throttle valve must

between accelerator open and close fully in
pedal and throttle body response to accelerator
pedal movement.
5. Inhibitor switch Must be in good

circuit condition.
6. ATF Must be maintained at

specified level.
7. Differential gear oil Must be maintained at

specified level.
8. ATF leakage Must not occur at A TF

cooling circuit or other
parts.
9. Oil leakage Must not occur from

any part of transmission.
* Check before engine is adjusted.
145
~ Troubleshooting Chart
Reference No.
Symptom Probable cause
On-car check Unit check
Starter runs in R, 0 or 2 range, but 1,2,6,7,9

not in P or N range. Transmission exterior parts:
Noise is emitted in N or Prange. 72,65,31 40 1. Inhibitor switch out of adjustment

2. Faulty inhibitor switch
Noise (shudder) is emitted when 72 3. Faulty control unit
car starts. 4. Faulty car-revolution sensor 1
5. Faulty car-revolution sensor 2
Noise is emitted in 0 1 range. 73 37,60,61 6. Select cable out of adjustment
Noise is emitted in O2 range. 73 37,60,61 7. Faulty select lever
8. FWD fuse remains installed
Noise is emitted in 0 3 range. 73 37,61 9. Faulty starter motor or harness
10. Faulty throttle sensor
Noise is emitted in 0 4 range. 73 37,60,61 11. Faulty 1st hold switch
Engine stalls while shifting to any 23, 76 77
range. Parts inside oil pan:
Engine stalls in P range and driving 42 12. Faulty N-D accumulator

in N range. 13. Faulty 2A accumulator
14. Faulty 4A accumulator
Shock is felt when shifting from N 70,12,23,3 15. Faulty 3R accumulator
to 0 range. 16. Faulty ATF temperature sensor
17. Clogged strainer
Lengthy time lag when shifting 23,32a 41 18. Faulty duty solenoid A
from N to 0 range. 19. Faulty duty solenoid B
Shock is felt when shifting from N 23, 14, 70 20. Faulty shift solenoid 1
to R range. 21. Faulty shift solenoid 2
22. Faulty shift solenoid 3
Lengthy time lag when shifting from 23 49,51 23. Valve sticking
N to R range. 24. Faulty detent spring
25. Faulty manual plate
Car does not move in any range 72,17,23 64,65,56,57, 25a. Faulty strainer seal
though engine revs up. 33, 34, 35, 36,
60,40 Parts inside extension case:
Engine stalls in all ranges. 62 26. Faulty transfer clutch
27. Transfer valve sticking
Car does not move in R range 23 49,51 28. Transfer pilot valve sticking
though engine revs up. 29. Faulty transfer pipe
Engine stalls in R range. 42,48 30. Faulty duty solenoid C
31. Noisy duty solenoid C
Car does not move in 0 or 3 range 53,54 32a. Faulty forward clutch rei ief ball
though engine revs up. 32b. Faulty overrunning clutch relief
ball
Car does not move in 0, 3 or 2 range 41,32a
though engine revs up.
146
Reference No.
Engine stalls in D, 3 or 2 range. 52

Parts inside differential case:
Car does not move in D, 3 or 2 range 23,3 54
though engine revs up. 33. Drive pinion broken
34. Crown gear broken
Poor acceleration: 35. Axle shaft broken
• High stall rpm 72,23 41,51 36. Differential gear broken
•• Proper
Low stall rpm
stall rpm (Poor accelera- 3,23
76,66,40
46,48
37. Poor/improper contact of final
gear
tion in D, 3 or 2 range) 38. Faulty seal pipe
• Proper stall rpm (Poor accelera- 23 46,48,44 39. Faulty speedometer gear
tion in R range)
Parts inside transmission:
No shifts:
• 1-+2 3,23 47 40. Oil pump seized or broken or
• 2-+3 3,23 45 foreign matter in pump
• 3-+4 3,23,16 47 41. Forward clutch slippage
• K/D 3,10 42.
43.
Forward clutch seized
Overrunning clutch slippage
No engine braking in: 44. Overrunning clutch seized
• 3 range only 3,23,10 45. High clutch slippage
• 3, 2 or 1 range 32b 43 46. High clutch seized
• 1 range only 3,23 49 47. Band & servo slippage
Erroneous shift points 3,23,10 47 48. Band seized
49. Low & reverse brake slipping
No lock-up operation 3,23,16,10 68 50. Low & reverse brake seized
51. Reverse clutch slippage
No power mode in D range 3, 10 52. Reverse clutch seized
Power mode not released in D range 3,10 53. Faulty O.w.C. (1-2)
54. Faulty O.w.C. (3-4)
Parking brake failure: 55. Faulty double oil seal
• No braking 6, 7 62 56. I nput shaft broken
• Dragging or failure to release 6, 7 62 57.
58.
Reduction drive shaft broken
Planetary gear broken
Unusual select force: 59. Reduction gear broken
• Considerable effort required 7,24,25 60. Poor/improper contact of
• No or light effort required 24,25 planetary gear
Fluid overflow 61. Poor/improper contact of
reduction gear
• ATF 74
62. Faulty parking brake mechanism
• Differential oil 75
Unusual changes in differential oil 38,55

level
Odor from oil supply pipe 70 41,43,45,47

49,51
147
Reference No.
Abnormal ities during shifting:

Other parts:
• Shock in 1 2 shift
~ 3,23,13,10,
70,76 63. Faulty torque converter ring gear
• Slippage ~
in 1 2 shift 3,23,13,10 47 64. Faulty drive plate
~ 3, 23, 10, 70,
15, 76
47,45 65. Improper installation of drive
plate
• Slippage ~
in 2 3 shift 3,23,15,10 47,45
66. Torque converter or owe burned
~ 3, 23, 10, 70,
14, 76
43 or broken
67. Worn parts in torque converter
• Slippage ~
in 3 4 shift 3,23, 14, 10 47 68. Lock-up facing worn
• Shock in D3 23 shift
Shock in ~ 3,23, 10,70 43,47 69. Faulty lock-up damper
~shift 3,23,10,70 43 70. Deterioration of ATF
• ~ 3,23,10,70 49,43 71. Deterioration of differential oil
Shock is felt when accelerator pedal 3,23,10,76 69, 77
72. ATF level too low
73. Differential oil level too low
is released at medium speed or above.
74. ATF level too high
Vibration in straight-forward driving 3 69, 77 75. Differential oil level too high
76. Poor engine performance
Select lever slips out of detents 6,24,25 77. Lock-up clutch seized
during acceleration or on rough
roads.
During 4WD operation:

• Vibration in tight corner 4, 70, 10, 3, 11 29, 26, 27, 28,
30
• Front tires slip on start. 5,10,3,11 29,26,27,28,
30
• Failure to shift into FWD mode 3,10,8 26, 27, 28, 29,
30
~ On-Car Service
After running, idle the engine for one or two minutes before
measurement.
1. ATF LEVEL
1) Raise the ATF temperature to 60 to 80 e (140 to
0
3) If the fluid level is below the center between upper and
176°F). [This temperature may be attained by running a dis- lower marks, add the recommended ATF until the fluid level
tance of 5 to 10 km (3 to 6 miles)). is found within the specified range (above the center between
upper and lower marks). When the transmission is hot, the
The level of ATF varies with fluid temperature. Pay attention level should be above the center of upper and lower marks,
to the fluid temperature when checking oil level. A change in and when it is cold, the level should be found below the center
the ATF level by oil temperature is shown in the following of these two marks.
figure.
Use care not to exceed the upper limit level.
2) Ensure the vehicle is level. After selecting a" positions (P,
R, N, D, 3, 2), set the selector lever in "P" range. Measure
fluid level with the engine idling.
148
• ATF level
1) ATF level varies with temperature as shown in figure.
a-ring
Remember that the addition of fluid to the upper limit mark
when the transmission is cold will result in the overfilling of
fluid.
2) Fluid temperature rising speed
• By idling the engine ll.
Time for rising temperature to 60°C (140°F) with atmos- - Upper
pheric temperature of O°C (32°F): More than 25 minutes level
-~m
( Reference)
Time for temperature rise to 30°C (86°F) with atmospheric
temperature of O°C (32°F): Approx. 8 minutes W
level
• By running the vehicle L3-785

Time for temperature rise to 60°C (140°F) with atmos- Fig_ 279
pheric temperature of O°C (32°F): More than 10 minutes
3) Method for checking fluid level upon delivery or at
periodic inspection.
Check fluid level after a warm-up run of approx. 10 minutes.
During the warm-up period, the automatic transmission
functions can also be checked. Thread portion
Oil supply opening

40 (Tapered face)
30
20
'0
~.
~=~1r
"Ho<" "PO' lowl . . _
E'
'" L3-786
lo~,
20
Fig. 280
30
"Cold" I,wl . . [ 0
~\ 2~
~68)
do
(861
40 sO
(104) (122)
sO
(140)
7~
058)
sO
(176)
~
(194)
ATF temperature"C (OF)
L3-784
Fig_ 278 3. OIL LEAKAGE CHECK POINTS
It is difficult to accurately determine the precise position of
a oil leak, since the surrounding area also becomes wet with
oil. The places where oil seals and gaskets are used are as
2. DIFFERENTIAL GEAR OIL LEVEL follows:
1) Ensure the vehicle
<Jointing portion of the case>
Do not check the oil level nor add oil to the case with the • Transmission case and oil pump housing jointing portion
front end of the vehicle jacked up; this will result in an in- • Converter case and oil pump housing jointing portion
correct reading of the oil level. • Transmission case and transmission cover jointing portion
(FWD)
2) Check whether the oil level is between the upper (F) and • Transmission case and extension case jointing portion
lower (L) marks. If it is below the lower limit mark, add oil (4WD)
until the level reaches the upper mark.
Converter housing
• Engine crankshaft oil seal
• Torque converter impeller sleeve oil seal
• ATF cooler pipe connector
• Torque converter
149
Converter case 4. ENGINE IDLING SPEED

• Converter case Excessively low engine idling rpm will lead to rough engine
• Axle shaft oil seal operation and excessively high idling rpm will lead to a sudden
• O-ring on the outside diameter of axle shaft oil seal holder shift shock or creeping when shifting from N to D or R.
• O-ring on the differential oil gauge
• Differential oil drain plug
• Speedometer cable mounting portion Idling rpm for automatic transmission cars (N or Prange):
• Location of steel balls 1800: 800±100 rpm
2700: 750±100 rpm
Oil pump housing
• Oil pump housing (Defective casting)
• O-ring on the test plugs 5. BRAKE BAND
• Checking blind plugs
If the following abnormal shifting conditions are noted in a
• Differential gear breather
road test, the brake band must be adjusted.
Automatic transmission case

• Shift state and adjustment
• Transmission case (Defective casting) 1) The 2nd gear state and 4th gear state can be achieved but:
• Mating surface of oil pan • the engine rpm increase excessively shifting up from 2nd to
• O-ring on the test plugs 3rd.
• Checking blind plugs (steel balls) • a shift delay (over 1 sec) accompanies at kickdown from
• Oil supply pipe connector 3rd to 2nd.
• ATF cooler pipe connector and gasket If any of these problems occurs, it is attributable to excessive
• Oil pan drain plug clearance between the reverse clutch drum and brake band:
• O-ring on the transmission harness holder Tighten the adjust screw by turning it clockwise.
• O-ring on the oil pump plugs 2) The 2nd gear state and 4th gear state can be achieved,
• ATF breather but:
• Shift lever oil seal • a braking phenomenon is noted when shifting up from 2nd
to 3rd.
Extension case If this phenomenon is noted, it is attributable to excessively
• Extension case (Defective casting) small brake band clearance: Loosen the adjust screw by
• O-ring on the revolution sensor turning it counterclockwise.
• Rear drive shaft oil seal 3) When accelerating, direct shift up from 1st to 3rd occurs:
• Checking blind plugs (steel ball) . . . . . . . . . . . . . . . . ' . . . . . . . Excessively large clearance.
• O-ring on the test plug When shifting up from 2nd to 3rd, tire slip occurs:
. . . . . . . . . . . . . . . . . . . . , .. Excessively small clearance.
Transmission cover
• Transmission cover (Defective casting)
The point listed above should be checked for fluid leak.
Checking method is as follows:
(1) Place the vehicle in the pit, and check whether the
leaking oil is ATF or not. The ATF is wine red in color,
and can be discriminated easily from engine oil and gear
oil.
(2) Wipe clean the leaking oil and dust from a suspectable
area, using a noninflammable organic solvent such as
carbon tetrach loride.
(3) Run the engine to raise the fluid temperature, and set
the selector lever to "D" in order to increase the fluid
pressure and quickly detect a leaking point.
L3-787
Fig. 284
150
<Inspection>
(1) Separate the cable end from the range select lever.
Lock nut
?Iearance f!!
Increases. ~
Clearance
decreases.
Adjusting screw
L3-967
Fig_ 281 Clearance control
• Adjustment of the adjusting screw Fig_ 282

1) Using a socket wrench, immobilize the end of the 10 mm
screw projecting on the left side of the transmission case, and (2) Using a circuit tester, check continuity in the con-
loosen the nut with a double-end wrench. nectors (for P, R, N, 0, 3 and 2 ranges) at the inhibitor
I n the case of occurrence of problems 1) and 2) mentioned switch.
previously, perform the adjustment by loosening or tightening
~PO:~
the nut within a range of 3/4 turn from this state. NO. 1 2 3 4 5 6 7 8 9 10 12
L, GY LgA
B YB YW B' GW BY BW G
Tool No. Tool Name TlON
G" YLl< GR M
398603610 SOCKET WRENCH

P 0- ro 0- -0
R -0 0 -0
Do not loosen excessively; otherwise, the band strut on the N 0 -0 .0- -0
servo piston will drop off_ 0 0 0
2) In case of the occurrence of problem 3) mentioned pre- 3 0- ~
viously, perform the adjustment as follows: 2
Adjusting procedure: Tighten adjust screw to 9 N·m (0.9 kg-m,
*1800 cc model L3-968
6.5 ft-Ib) torque, then back off three turns.
Fig. 283
Do not tighten the adjusting screw with an excessively large
torque.
Also check that continuity in ignition circuit does not exist
3) With the adjusting screw immobilized, tighten the lock when selector lever is in R, D, 3 and 2 ranges.
nut to 26±2 N·m (2.7±0.2 kg-m, 20±1.4 ft-Ib) torque.
6. INHIBITOR SWITCH
The inhibitor switch allows the back-up lights to turn on when
the select lever is in the R range and the starter motor to start
when the lever is in the N or P range. It also monitors the
input signal electronically controlled for each range and turns (3) Check if there is continuity at equal points when the
0
on the corresponding range light on the instrument panel. select lever is turned 1.5 in both directions from the N
When light operation, driving condition or starter motor range.
operation is erroneous, first check the shift linkage for im- If there is continuity in one direction and the continuity
proper operation. If the shift linkage is functioning properly, in the other or if there is continuity at unequal points,
check the inhibitor switch_ adjust the inhibitor switch.
151
p
Continuity
does not
R
V '
#
} exist.
N CJ
o
- - - _ _I: 5
I .5'
1Continuity
exists.
D Continuity
does not
exist.
3
L3·969
Fig. 285 Fig. 286
(5) Repeat the above checks. If the inhibitor switch is

<Adjustment> determined to be "faulty," replace it.
(1) Loosen the three inhibitor switch securing bolts.
(2) Shift the select lever to the N range.
(3) Insert STOPPER PIN (499267300) as vertical as
7. TRANSMISSION HARNESS
possible into the holes in the inhibitor switch lever and 1) Check resistance and/or continuity in sensor, solenoid
switch body. and ground circuits at connector.
(4) Tighten the three inhibitor switch bolts. 2) Also check terminals for shortcircuits.
Tightening torque: a. Remove oil pan before checking continuity between multi-
2.0 - 2.5 N·m connector and 2-pin or 1-pin connector.
(0.20 - 0.26 kg-m, 1.4 - 1.9 ft-Ib) b. Remove extension before checking continuity between
duty solenoid C and 1-pin connector.
10
w (FWD)
Vehicle-speed sensor
(FWD)
I
B (FWD only)
6
W
5 Temperature
.>t
(J
B (* GB) sensor
.!!! (*8 ) 9
III
2B
C 3
-'9-
(;
(*9) 8
GB
GY
~GND
--
0 11 I Line pressure solenoid
GB
(J
B 2 Lock-up solenoid
Q) LY
c: 7
c: L Shift "'" solenoid
0
~ LB
:E 4 I Shift "3" solenoid
::l
~ LG
1 Shift "2" solenoid
GR Duty solenoid C
12
(4WD only)
* 1800 cc
L3-971
Fig. 287
152
• Standard values
Part name Resistance (n) Shielded (GNO)
Vehicle-revolution sensor Approx.600
100 - 6 k,
Temperature sensor
2.5 k/20°C (6SoF)
Tester
Line-pressure solenoid Approx.3
Lock-up solenoid Approx.10
Shift solenoid 1 Approx.25

L3-973
Fig. 289
Duty solenoid C Approx. 10
If part is faulty, its resistance value will be different from the

standard value indicated above.
1. SHIFT SOLENOID, DUTY SOLENOID AND

VALVE BODY
• Removal
1) Clean transm ission e~terior.
2) Drain ATF completely.
8. VEHICLE REVOLUTION SENSOR

1) Disconnect connector.
ATF drain plug

/ /5-
P----- ~ L3-974
Fig. 290
Fig. 288 Tighten ATF drain plug after draining ATF.
Tightening torque:
2) Connect tester to connector. 25 ± 2 N·m (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft-Ib)
3) Drive vehicle at approx. 10 km/h (6 MPH).
4) Check that tester registers approx. 1 volt. 3) Remove oil pan and gasket.
For reference: Approx. 500 n resistance between revolution
sensor connectors. Drain oil into a container
153
4) Disconnect solenoid valve connectors. Be careful because oil flows from oil strainer.
Remove connectors from clips and disconnect connectors at
5 places. 7) Remove valve body.
(1) Remove 8 long bolts (Black).
For Duty Sol. A (2) Remove 11 short bolts (Yellow).
1Jj~+J.;:-P.r- For Sol. 2 (shift) Be careful because oil flows from valve body.
For Sol. 1 (shift)
For Duty Sol. B
~:r::<~WbWLL For A TF temp. sensor

L3·543
Fig. 291
5) Remove duty solenoid B.

L3-978
(1) Remove the four bolts.
(2) Remove solenoid. Fig. 294
8) Remove shift solenoids 1, 2, and 3, and duty solenoid A.
Solenoid ASSY
Solenoid-l (shift)
Solenoid-3
(overrunning clutch)
Fig. 292
6) Remove oil strainer.

(1) Disconnect oil pipe by removing the two bolts.
(2) Remove four bolts and oil strainer.
L3·618
Fig. 295
• Installation
1) Install duty solenoid B (lock-up).
L3·544 Tighten bolts shown by solid arrows. The two bolts and
Fig. 293 brackets shown by arrows" • " must be tightened later.
154
4) Install oil strainer.

Also install oil pipe and harness connector bracket.
Tightening torque:
2.9 ± 0.5 N·m (0.3 ± 0.05 kg-m, 2.2 ± 0.4 ft-Ib)
L3-980
Fig. 296
2) Install solenoid valves.
(1) Sh ift solenoids, 1, 2 and 3.
(2) Duty solenoid A (line pressure).
L3-544
Solenoid ASSY
Fig. 299
Solenoid·1 (shift)
5) Connect harness connectors at 5 places.
Solenoid·3
(overrunning clutch) (1) Connect connectors of same color.
(2) Secure connectors to valve body using clips.
For Duty Sol. A
rn~;-r,;-j7-- For Duty Sol. 2 (shift)
For Sol. 1 (shift)

Sol. 3 (shift)
L3·618
Fig. 297 For Duty Sol. B
3) Install valve body.
Tightening torque:
8 N·m (0.8 kg-m, 5.8 ft-Ib) For A TF temp. sensor
L3·543
• Secure accumulator springs using vaseline. Fig. 300

• Align manual valve connections. 6) Install oil pan & gasket.
• Tighten duty solenoid B (lock-up) bracket and two bolts
(also used to tighten valve body). Tightening torque:
3.9±0.5 N·m (0.4±0.05 kg-m, 2.9±0.4 ft-Ib)
L3-982
Fig. 298 L3-985

Fig. 301
155
7) Add and check A TF . 3) Remove exhaust pipe (F).
(1) Disconnect O2 sensor connector.
(2) Remove bolts shown by arrows in Figure.
direction
11 '
L3·986
Fig. 302
Fig. 305
4) Remove propeller shaft.
2. DUTY SOLENOID C AND TRANSFER Before removing propeller shaft, scribe alignment marks on
VALVE BODY propeller shaft and rear differential coupling.
• Removal
1) Remove transmission pitching stopper.
Fig. 306
L3·987 5) Remove rear crossmember.
Fig. 303 (1) Support transmission using a transmission jack and
raise slightly.
2) Raise car and drain ATF. (2) Remove bolts and nuts as shown in Figure.
I
)
ATF drain plug_
/F L3-974
Fig.30l
156
6) Remove revolution sensor. 8) Remove duty solenoid C & transfer valve body from ex·
tension.
(1) Remove transfer clutch drum.
L3-992
Fig. 308
7) Remove extension & gasket. L3·995
(1) Remove gear select cable nut. Fig. 311
(2) Move gear select cable so that extension bolts can be
removed.
(2) Remove clamp which secures pipe.

(3) Remove bolts.
Fig. 309
(3) Remove bolts.
(4) Remove extension and disconnect duty solenoid C
connector.
a. Use a container to catch oil flowing from extension.

b. Do not force extension back before disconnecting solenoid
connector. Otherwise, harness may be damaged. L3-996
Fig. 312
• Installation
1) Install duty solenoid C & transfer valve body.
(1) Install duty solenoid C & transfer valve body.
(2) Install pipe and clamp.
Tightening torque:
8 ± 1 N·m (0.8 ± 0.1 kg-m, 5.8 ± 0.7 ft-Ib)
Fig. 310
157
(3) Install clutch drum.
Duty solenoid C
(Transfer)
L3-992
L -_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~L~3~-9~97~ Fi~315
Fig. 313
2) Install extension. 4) Install rear crossmember.

(1) Connect connector. (1) Tighten bolts.
(2) Tighten 11 bolts.
Tightening torque:
Tightening torque: 37 ± 10 N·m (3.8 ± 1.0 kg-m, 27 ± 7 ft-Ib)
25 N·m (2.5 kg-m, 18 ft-Ib)
(2) Lower and remove transmission jack.
(3) Connect gear shift cable.
Fig. 316
Fig. 314
5) Install propeller shaft.
Tightening torque:
N·m (kg-m, ft-Ib)
3) Install revolution sensor. A 21.1 ± 3.4 (2.15 ± 0.35, 15.6 ± 2.5)
B 39±10(4.0±1.0,29±7)
Tightening torque:
8 N·m (0.8 kg-m, 5.8 ft-Ib) Align marks on propeller shaft and rear differential coupling.
158
/
o /1
//
"--_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _--=L:.::3-=-9;::90:..J L3-987

Fig. 317 Fig. 319
10) Replenish ATF and check oil level. Check for leaks.
6) Install exhaust pipe F.
Tightening torque: ~ Performance Test

N·m (kg-m, ft-Ib)
C 27 ± 7 (2.8 ± 0.7, 20.3 ± 5.1)
D 29 ± 5 (3.0 ± 0.5,21.7 ± 3.6) • NECESSARY TEST GAUGES
E 14 ± 4 (1.4 ± 0.4, 10.1 ± 2.9) 1) Tachometer (It is desirable to be able to read to 50 rpm.)
2) Vacuum gauge (It is used for measuring intake manifold
---------------------
---- vacuum.)
3) OIL PRESSURE GAUGE (398573600).
4) OIL PRESSURE ADAPTER (498897100).
5) Stop watch.
1. STALL TEST
The stall test is of extreme importance in diagnosing the con-
dition of the automatic transmission and the engine. It should
be conducted to measure the engine stall speeds in all shift
ranges except the P and N ranges.
Purposes of the stall test

Fig. 318 1) To check the operation of the automatic transmission
clutch and brake band.
2) To check the operation of the torque converter.
3) To check engine performance.
7) Lower and remove jack.
8) Connect the following parts: Test Methods
(1) O 2 sensor connector • Preparations before test
(2) Revolution sensor connector
(3) Multi-connector
CD Check that throttle valve opens fully.
9) Install transmission pitching stopper.
® Check that engine oil level is correct.
@ Check that coolant level is correct.
Tightening torque:
@ Check that A TF level is correct.
N'm (kg-m, ft-Ib)
@ Check that differential gear oil level is correct.
52 ± 15 (5.3 ± 1.5,38 ± 11) (Body side)
® Increase ATF temperature to 60 - 80°C (140 - 176°F) by
idling the engine for approximately 30 minutes (with
49 ± 5 (5.0 ± 0.5, 36.2 ± 3.6) (Engine side)
select lever set to "N" or "P").
159
1) Install an engine tachometer at a location visible from the 5) When the engine speed is stabilized, read that speed quick·
driver's compartment and mark the stall speed range on the Iy and release the accelerator pedal.
tachometer scale. 6) Shift the select lever to Neutral, and cool down the engine
2) Place the wheel chocks at the front and rear of all wheels by idling it for more than one minute.
and engage the parking brake. 7) Record the stall speed.
8) Perform the stall tests with the select lever in the 3, 2 and
R ranges.
a. Do not continue the stall test for MORE THAN FIVE

SECONDS at a time (from closed throttle, fully open throttle
to stall speed reading). Failure to follow this instruction causes
the engine oil and ATF to deteriorate and the clutch and brake
band to be adversely affected.
Be sure to cool down the engine for at least one minute after
each stall test with the select lever set in the P or N range and
with the idle speed lower than 1,200 rpm.
b. If the stall speed is higher than the specified range, attempt
Wheel chock
to finish the stall test in as short a time as possible, in order to
L3·1004
prevent the automatic transmission from sustaining damage.
Fig. 320
3) Move the manual linkage to ensure it operates properly, Stall speed (at sea level):
and shift the select lever to the D range. 1800 cc
4) While forcibly depressing the foot brake pedal, gradually 2,450 - 2,850 rpm
depress the accelerator pedal until the engine operates at full 2700 cc
throttle. 2,400 - 2,800 rpm
P
R
N
D ~
3
2
Brake pedal Accelerator
pedal
L3·1005
Fig. 335 Stall test
160
Interpretation of stall test results
Stall speed
Assessment Cause Remarks
(at sea level)
Higher than
2,850 rpm
Slippage of automatic transm"is-
sion clutch, brake band, etc_
• speed
Low line pressure (If stall
is higher than speci-
* 1: Slippage of reverse clutch/
low & reverse brake can be
(1800 cc) (Further stall tests are not fied range at any shift posi- judged by road tests.
or necessary.) tion). If engine compression can
2,800 rpm • One-way clutch slippage. be used as a brake with
(2700 cc) (If stall speed is higher than select lever in the 1 range,
specified range only in the reverse clutch is slipping; if
D range.) it cannot be used, low &
• Slippage of Forward clutch. reverse brake is slipping.
(If stall speed is higher than
specified range in D, 3, 2,
1ST Hold range.
• * 1: SI ippage of low &
reverse brake or reverse
clutch.
(If stall speed is higher
than specified range
only in the R range.)
2,450 - 2,850 • Control members are in • One-way clutch can be

rpm good order in the D, 3, 2 checked for condition by
(1800cc) and R ranges. road tests. * *
or
2,400 - 2,800
• Engine in good order.
rpm
(2700 cc)
Lower than • Throttle not fully opened.

2,450 rpm
(1800 cc)
• Erroneous engine operation
or torque converter one-
or way clutch slippage.
2,400 rpm
(2700 cc)
** Road test • Acceleration is not properly One-way clutch slippage. *3: Abnormal temperature
made up to 50 km/h *3: One-way clutch jamming. rise occurs.
(31 MPH). Erroneous engine operation.
• Car speed does not attain
more than 80 km/h
(50 MPH).
• Operation is not proper at
all car speeds.
161
2. TIME LAG TEST 2) Line pressure measurement (under heavy load)

If the shift lever is shifted while the engine is idling, there will
be a certain time elapse or lag before the shock can be felt.
a. Before measuring line pressure, apply both foot and parking
This is used for checking the condition of the forward clutch,
brakes with all wheels chocked (Same as for "stall" test condi-
reverse clutch, low & reverse brake, forward one-way clutch
tions).
and low one-way clutch
b. Measure line pressure for 5 to 10 seconds. Before measuring
it again, idle the engine for 2 to 5 minutes.
CAUTION: c. Before measuring line pressure, always shift the lever
(a) Perform the test at normal operation fluid temperature from "0" to "2".
(50 to BO°C or 122 to 176°F). d. Maintain the temperature of ATF at approximately 60 to
(b) Be sure to allow a one minute interval between tests. BO°C (140 to 176°F) during measurement. (ATF will reach
(c) Make three measurements and take the average value. the above temperature after idling the engine for approxi-
mately 30 minutes with the shift lever in "N" or "P".)
Measure time lag
Measuring the line pressure
1) Fully apply the parking brake.
1) Temporarily attach the 01 L PRESSURE GAUGE
(398573600) to a suitable place in the driver's compartment,
Check idling speed (A/C OFF)
remove the blind plug located in front of the toeboard and
"N" range: 1800: 800 ± 100 rpm
pass the hose of the GAUGE (398573600) to the engine
2700: 750 ± 100 rpm
compartment.
3) Shift the shift lever from "N" to "D" range.
Using a stop watch, measure the time it takes from shifting
the lever until the shock is felt.
Time lag: Less than 1.2 seconds
4) In same manner, measure the time lag for "N" -+ "R".
Time lag: Less than 1.5 seconds
Evaluation
1) If "N" -+ "D" time lag is longer than specified:
• Line pressure too low \\
• Forward clutch worn 1 Pressure gauge hose
• Low one-way clutch not operating properly 2 Hole in toe board (blank cap hole)
2) If "N" -+ "R" time lag is longer than specified: 3 Brake pedal
A13-223
• Line pressure too low
• Reverse clutch worn Fig. 322
• Low & Rev. clutch worn
3. LINE PRESSURE TEST

If the clutch or the brake band shows a sign of slippage or 2) Remove the test plug and install OIL PRESSURE GAUGE
shifting sensation is not correct, the line pressure should be ADAPTER (498897100) instead.
checked.
• Excessive shocks during upshifting or shifting takes place at
a higher point than under normal circumstances, may be
due to the line pressure being too high.
• Slippage or inability to operate the car may, in most cases,
be due to loss of oil pressure for the operation of the
clutch, brake band or control valve.
1) Line pressure measurement (under no load)
a. Before measuring line pressure, jack-up front wheels

(front-wheel-drive model) or all wheels (4-wheel drive model).
b. Maintain temperature of ATF at approximately 60 to
BO°C (140 to 176°F) during measurement. Test plug location
L3-1006
(ATF will reach the above temperature after idling the engine
for approximately 30 minutes with shift lever in "N" or "P".) Fig. 323
162
3) Start the engine and warm it up by driving the car for at Measuring transfer clutch pressure
least 10 to 15 minutes.
Check transfer clutch pressure in accordance with the follow-
4) Stop the engine. Connect the OIL PRESSURE ADAPTER
ing chart in the same manner as with line pressure.
(498897100) and the tip end of the GAUGE (398573600).
5) Check line pressure in accordance with the following
chart.
< Standard line pressure>

Unit: kPa (kg/cm 2 , psi)
I~
Min. line pressure Max. line pressure
600 - 800 rpm Stall rpm
441 - 569
P
(4.5 - 5.8,64 - 82)
-
588 - 686 1,422 - 1,589 L3-1007

R (6.0- 7.0, (14.5 - 16.2,
Fig. 324
85 - 100) 206 - 230)
441 - 569 Unit: kPa (kg/cm 2 , psi)

N -
(4.5 - 5.8, 64 - 82) FWD mode
4WD mode
1,128 - 1,255 High pressure High pressure
441 - 569 Low pressure
D (11.5 - 12.8, side
(4.5 - 5.8, 64 - 82) side side
164-182)
Range 600-800 rpm Stall rpm Stall rpm
1,128 - 1,255
441 - 569
3 (11.5 - 12.8, 49 -78 716 - 785
(4.5 - 5.8,64 - 82)
164 - 182) R (0.5 - 0.8, (7.3 - 8.0, 0(0,0)
7 - 11) 104 - 114)
1,128 -1,255
441 - 569
2 (11.5 -12.8, 49 -78 716-785
(4.5 - 5.8,64 - 82)
164 - 182) D (0.5 -0.8, (7.3 - 8.0, 0(0,0)
7 - 11) 104-114)
Accelerator
Fully-closed FUlly-open
pedal Accelerator
Fully-closed Fully-open Fully-open
pedal
If oil pressure is not produced or if it does not change in the

4WD mode, the duty solenoid C or transfer valve assembly
may be malfunctioning. If oil pressure is produced in the FWD
mode, the problem is similar to that in the 4WD mode.
163
4. ROAD TEST Speed change characteristics
Road tests should be conducted to properly diagnose the con- The standard speed change characteristics are indicated in the
dition of the automatic transmission_ following table.
When performing test, do not exceed posted speed limit.
1800 cc
~
Throttle fully-open km/h (MPH)
1-+2 2-+3 3-+4 4-+3 3-+2 2-+1
50±2_5 94±2.5 144±2.5 134±2.5 84±2.5 40±2.5

NORMAL
(31±2) (58±2) (89±2) (83±2) (52±2) (25±2)
D range
56±2.5 104±2.5 155±2.5 145±2.5 94±2.5 45±2.5
POWER
(35±2) (65±2) (96±2) (90±2) (58±2) (28±2)
56±2.5 104±2.5 94±2.5 45±2.5

3 range
(35±2) (65±2)
- - (58±2) (28±2)
1st hold S/W 56±2.5 104±2.5 94±2.5 45±2.5

OFF (35±2) (65±2)
- - (58±2) (28±2)
2 range
1st hold S/W 56±2.5 104±2.5 94±2.5 50±2.5
ON (35±2) (65±2)
- - (58±2) (31±2)
~
Throttle fully-closed km/h (MPH)
1-+2 2-+3 3-+4 4-+3 3-+2 2-+1
15±2.5 30±2.5 45±2.5 40±2.5 15±2.5 10±2.5

NORMAL
(9±2) (19±2) (28±2) (25±2) (9±2) (6±2)
D range
15±2.5 30±2.5 50±2.5 40±2.5 20±2.5 10±2.5
POWER
(9±2) ( 19±2) (31±2) (25±2) (12±2) (6±2)
15±2.5 30±2.5 20±2.5 10±2.5

3 range
(9±2) (19±2)
- - (12±2) (6±2)
1st hold S/W 15±2.5 104±2.5 94±2.5 10±2.5

OFF (9±2) (65±2)
- - (58±2) (6±2)
2 range
1st hold SIW 56±2.5 104±2.5 94±2.5 50±2.5
(35±2) (65±2)
- - (58±2) (31±2)
ON
164
2700 cc
~
Throttle fully-open km/h (MPH)
1-+2 2-+3 3-+4 4-+3 3-+2 2-+1
55±2.5 107±2.5 165±2.5 156±2.5 98±2.5 45±2.5

NORMAL
(34±2) (66±2) (103±2) (97±2) (61±2) (28±2)
Orange
55±2.5 107±2.5 165±2.5 156±2.5 98±2.5 45±2.5
POWER
(34±2) (66±2) (103±2) (97±2) (61±2) (28±2)
55±2.5 107±2.5 98±2.5 45±2.5

3 range
(34±2) (66±2)
- - (61±2) (28±2)
1st hold S/W 55±2.5 105±2.5 100±2.5 45±2.5

OFF (34±2) (65±2)
- - (62±2) (28±2)
2 range
1st hold S/W 57±2.5 105±2.5 100±2.5 40±2.5
ON (35±2) (65±2)
- - (62±2) (25±2)
~
Throttle fully-closed km/h (MPH)
1-+2 2-+3 3-+4 4-+3 3-+2 2-+1
13±2.5 18±2.5 38±2.5 33±2.5 15±2.5 10±2.5

NORMAL
(8±2) (11±2) (24±2) (21±2) (9±2) (6±2)
Orange
17±2.5 30±2.5 55±2.5 40±2.5 20±2.5 10±2.5
POWER
( 11±2) (19±2) (34±2) (25±2) (12±2) (6±2)
17±2.5 30±2.5 20±2.5 10±2.5

3 range
(11±2) (19±2)
- - (12±2) (6±2)
1st hold S/W 17±2.5 105±2.5 100±2.5 10±2.5

OFF
- - (62±2) (6±2)
(11±2) (65±2)
2 range
1st hold S/W 57±2.5 105±2.5 100±2.5 40±2.5
ON (35±2) (65±2)
- - (62±2) (25±2)
Shift characteristics 2) Kick down should activate properly.

3) When the select lever is shifted from the 0 range to the
Pay careful attention to ensure the shift is made smoothly at 3 or 2 range, shifting should be made as 3 -+ 2 -+ 1. Engine
the proper car speed at which shifting begins. compression can be utilized as a brake at 2 and 1st hold range.
1) Shifting shocks are encountered or smooth shifting does 4) With the shift lever in the 2 range, shifting should be made
not occur.
as 1 -+ 2 -+ 3 smoothly.
2) Shifting occurs slowly in response to the condition of the 5) When pushing 1st hold switch, shifting should be made as
engine throttle.
1 -+ 2 or 3 -+ 2 -+ 1.
The above two problems are due to incorrect line pressure or 6) The select lever should be locked when placed in the P
other factors involved in line pressure.
range.
In road tests, if any abnormality is noticed, it is necessary to
Checking for shift patterns adjust the brake band. If by inspection the brake band is in
1) In the 0 range, shifting should be made as 0 1 -+ O2 -+ 0 3 good order, check the servo piston for any sign of oil leakage
-+ 0 4 smoothly and vice versa; it should not be made in the R from the seal.
range.
165
AUTOMATIC SHIFT CHARACTERISTICS

1800 cc
32/32 I
4th L/U
ON ,
I
28/32 r---J
/
24/32
20/32
01
c:
.
'c
.t:0.
a
16/32 ---Upshift
.t:
e - - - - Downshift
I-
12/32 - - - - Lock-up off
- - - Lock-up on
8132
4/32
0 20 40 60 80 100 120 140 160

I I I I I
I I I I I I I I I
I
I I
(0) (10) (20) (30) (40) (50) (60)(70) (80) (90) (100)
Vehicie speed km/h (MPH)
L3-791
Fig. 325 "D" range (Normal pattern)
32/32
I
"'
28/32
24/32
01
.
.!:
c:
0.
20/32
..
a
-;:;
Upshift
§ 16/32 - - - - Downshift
.t:
I-
- - - - Lock-up off
12/32 - - - Lock-upon
8/32
4/32
0 20 40 60 80 100 120 140 160

I
I I I
I
I
I
I I I
I I
I I I
t I
(0) (10) (20) (30) (40) (50) (60) (70) (80) (90) (100)
Vehicie Speed km/h (MPH)
L3-792
Fig. 326 "D" range (Power pattern)
166
32/32
28/32
24/32
C> I
.!: 20/32 l-r-2
c:
8.0 I
Upshift
~ I
e
.<=
16/32 I - - - - Downshift
l- I
I - - - - Lock-up off
12/32 r -- - - Lock-up on
I
I
8132 I
I
I
4/32 I
I
I
0
0 20 40 60 80 100 120 140 160
I I
I
I
I
I
I
I I I
I
I
I
I
I
I I
(0) (10) (20) (30) (40) (50) (60) (70) (80) (90) (100)
Vehicie speed km/h (MPH)
L3-793
Fig. 327 "3" range
32/32
I I
I I
I I
28/32 r-~ I
I I
24/32
, I
1
I
I
I
1.L2
12 3
C>
c: I I
·c 20/32 2.-+-3
8. I
0 / I
~ I I
e 16/32
.<=
I Upshift
l- I - - - - Downshift
I
12/32 {
8132
4/32
0
0 20 40 60 80 100 120 140 160
I I
I
I
I
I
I
I I I
I
I
I
I
I
I I
(0) (10) (20) (30) (40) (50) (60) (70) (80) (90) (100)
L3-794
Fig. 328 "2" range (1st hold switch OFF)
167
32/32 I
I
28/32
I
I
1 f- 2 12-f+ 3
I
24/32 2+t- 3
g'
1 20/32
o
.!!
~
~ 16/32 - - - - Upshift
... l-t2 - - - - Downshift
I
12/32 I
I
I
8132 I
I
I
4/32 I
I
o ~ _____ ____ !
~ ~I-L _ _ _ _ _ _ _ _ _ __
o 20 40 60 80 100 120 140 160

I I
I
I I
I
I Iii I ' i 'i I
(01 (101 (201 (301 (401 (501 (601 (701 (801 (901 (1001
Vehicle speed km/h (MPHI
L3-795
Fig. 329 "2" range (1st hold switch ON)
2700 cc
32/32 I I
I I
I
,- _ _ _ ..JI
28/32 r-.J
I /
I 2 /
24/32 1 ~2 1
2+r3 2
I I
/
/ /
Upshift
I /
'c'"
c 20/32 - - - - Downshift
(
.. I
..
0.
0
I
t= 16/32
e
~
I
~
l-
I
I
12/32
I
I
I
8/32 (
I
I
4/32
0
0 20 40
, 60 80 100 120 140 160 180
i i
I I
i I I
I
i I I
i
I
I I i I I
(0) (10) (20) (30) (40) (50) (50) (70) (SO) (90) (100) (110)
"0" range (Normal pattern) L3-1oo8
Fig. 330 "0" range (Normal pattern)
168
32/32 I
I
I
28/32
,r-..J
I
24/32 I
I
1-+-2 - - - Upshift
I
20/32 I - - - - Downshift
I
c:n
I
.~ 16/32 I
I
~ t
.,0 I
~ 12/32 I
.J:.
I
l- I
8/32
I
I
I
I
4/32 I
I
I
0
0 20 40 60 80 100 120 140 160 180
I I
I I I I I i I I I i ' i 'i I , I
(0) (10) (20) (30) (40) (50) (60) (70) (80) (90) (100) (110)
"0" range (Power pattern) L3-1009
Fig. 331 "0" range (Power pattern)
I 32/32 I
I
I
28/32 ,..._..J
I
I
I
24/32 I
I ---Upshift
I
20/32 - - - - Downshift
1.1-2 2..!- 3
c:n
.S I
.,<: I
C. 16/32 I 2 3
.,0 (
"E
e
.J:.
I- 12/32
I
I
I
8/32 I
I
I
4/32 I
I
...... J
0
0 20 40 50 80 100 120 140 160 180
I i! I I i I I I I' I 'I ' , I I I
(0) (10) (20) (30) (40) (50) (60) (70) (80) (90) (100) (110)
"2" range (1st hold switch OFF) L3-1010
Fig. 332 "2" range (1st hold switch OFF)
169
32/32
,I
28/32 I
I
1~2 24 3
24/32
- Upshift
1- - 2 2 .... 3
20/32 - - - - Downshift
en
..
.!:
c:
0. 16/32r
..
0
;::;
....
e
.J:. 12/32
I-
8132 r-
4/321-
0
I I
Vehicle speed kmlh (MPH)
0
I
(0)
I
(10)
.
20
I
(20)
40
I
•
(30)
60
• I
(40)
80
I
(50)
100
I
120
I
140
(60) (70) (80) (90)
I. ..
•
160
I
(100)
•.
180
(110)
"2" range (1st hold switch ON) L3-1011
Fig. 333 "2'- range (1st hold switch ON)
32/32 I 3rd I 3rd
2nd
OFF
+-i 2nd OFF,
ON -,
ON
4th
ON
28/32 ,
I rJ
I I
I /
24/32 I /
I I
- - - Lock-up ON
I /
20/32 I / - - - - Lock-upOFF
en
I /
.!: /
c: I
~ /
~
..
0 16/32
I
J I /
e / /
I
.J:.
I- 12/32 I / /
/ /
I / /
I / /
8132 I I /
,,
1((
(
, ,,
4/32 I
I
OL-----~~~~--------------------------------------------
Vehicle speed kmlh (MPH)
o 20 40 60 80 100 120 140 160 180
(~O)
I ••
(6) (10; (20)' (:J» '(.w) (60;
(710)' (liO)
I
(90) (100) (110)
Lock-up (Normal pattern) LJ.1012
Fig. 334 Lock-up (Normal pattern)
170
I
I I
28/32 I
I 3rd /
I OFF I
24/32 2nd ..-J -'
OFF I 2nd I
I ON I - - - Lock-up ON
I I
20/32 - - - - Lock-up OFF
I I
I I
I
/
'"c:
.!: 16/32 I I
Q)
I
0-
0 I I
/
...
~
12/32 I /
e
.r.
I
I- I /
I /
8/32 (
I /
( I
I (
I I
4/32 I
I I
I I
o~-----~--~--~~----------------~------------------------
o 20 40 60 80 100 120 140 160 180
(b) (1'0; (20) I do) '(40) (~O) (60; (7'0) , (80) ;9'0) (1bo) (11~)
Lock-up (Power pattern)
L3-1013
Fig. 335 Lock-up (Power pattern)
Check for the 4WD function 3) If oil pressure is normal but "tight-corner braking"
occurs:
If "tight-corner braking" occurs when the steering wheel is
Check the transfer control valve for sticking, and the transfer
fully turned at low speed:
clutch facing for wear.
1) Determine the applicable trouble code and check the cor-
(Refer to Disassembly and Inspection of the Transmission.)
responding duty solenoid C (transfer) for improper operation.
2) If the solenoid is operating properly, check transfer clutch
pressure.
171
TRANSMISSION CONTROL SYSTEM ~C~
Page
SUBARU MECHANISM AND FUNCTION . . • . • • • . • • • • • • • . • • . . • . . • . . • . •.

4WD Shift Mechanism (Selective 4WD) • . . • . . . • . . . . . . . . . . . • . . . ..
2
2
Konb and Switch (MT, Selective 4WD) . . . . . . . . . . . • . • • . . • . . • . . .. 4
1988 COMPONENT PARTS . . • • . . • . . • • • . • • • • . . . • . . . • • . . . . . . . . . ..

Manual Transmission . . . . . • . . • • • • • . • . • • . • . • • • . • . . . . • . • . . ..
5
5
Automatic Transmission ••••......••..••......•........... 6
SERVICE PROCEDURE. . . . . • • . . • . • . . • • . . . . . • . • • . • . . . . . . . .. 7
Manual Transmission. . . . . . . . . • . . . . . . . • . • • . • • . . . . • . • . . . • .• 7
Automatic Transmission .....•....••...•....•.......•••••. 10
-
3-3 TRANSMISSON CONTROL SYSTEM

4WD Shift Mechanism (Selective 4WD)
Shifting from front-wheel to 4-wheel drive or vice versa is accomplished by utilizing the intake manifold vacuum pressure.
In Front-Wheel Drive
@ 4WD Pilot lamp switch

Intake manifold vacuum Diaphragm
Lever (transfer shifter)
(j) Rear drive shaft
4WD solenoid valve I

(Atmospheric pressure)
Check valve
® 4WD pilot lamp

CD 4WD switch (PULL)
___0--+--'---- Power source
@ Intake manifold
L3-235
Fig. 1
When the 4WD switch button CD

is pulled out with the engine At this point, the power from the engine is not transferred to
on, the FW[) solenoid valve ®
is energized and the valve ® the rear drive shaft (j) and thus the vehicle is in front-wheel
opens. This admits the intake manifold @ vacuum pressure drive. The 4WD pilot lamp ® in the combination meter
to the vacuum chamber so that the diaphragm is pulled in the remains off because the 4WD pilot lamp switch ® is not
direction of the arrow. turned on.
2
TRANSMISSON CONTROL SYSTEM 3-3
In 4-Wheel Drive
® 4WD pilot lamp switch

Transfer fork
7
Diaphragm Intake manifold vacuum @Transfer rod
Lever (transfer shifted
(Atmospheric
pressure)
Check valve
CD 4WD switch (PUSH) 4WD pilot lamp
--0--+-_--- Power source
CE' Intake manifold

L3-236
Fig. 2
When the 4WD switch button CD is pushed in with the engine in that direction. This causes the FWD-4WD selector clutch ®
on, the 4WD solenoid valve @ is energized and the valve @ to engage the spline of the transfer gear so that the vehicle is
opens. At this time, the vacuum pressure from the intake set in 4-wheel drive. In 4-wheel drive, the 4WD pilot lamp
manifold @ enters the valve so that the diaphragm inside switch ® turns on the 4WD pilot lamp ®in the combination
the vacuum chamber is pulled in the direction of the arrow. meter. Changing from 4-wheel drive to front-wheel drive is
The transfer rod @ connected to the diaphragm also moves accomplished by pushing the 4WD switch button CD·
3
Knob and Switch

(MT, Selective 4WD)
1) Construction
The switch is soldered to the cord and is held to the knob with
a screw. The cord is routed along the groove in the knob.
The knob is secured to the lever with a spring pin.
2) Operation
When the switch is pressed to ON, the car is set to the 4WD
mode; when it is pressed again, the car is set to the FWD mode.
Depress
-Switch ASSY
Cord ASSY
Knob
Lever CP
Knob groove
L3462
Fig. 3
4
COMPONENT PARTS
Manual Transmission
(~~-+----CD

T1: 9 - 15 (0.9 - 1.5,6.5 - 10.8)
T2: 14 - 22 (1.4 - 2.2,10 - 16)
1 Switch ASSY (Selective 4WD)

2 Grip (Selective 4WD)
3 Grip (FWD/Full-Time 4WD)
4 Spring pin
5 Gearshift cover
e---@~
o-----@
6
7
8
9
10
Bushing
Rubber bushing
Nylon bushing
Spacer
Boot plate
11 Boot
~
12 Holder
13 Lever CP
e)--@ 14
15
Bushing
Spring
g ®
16
17
Lock wire
Dust seal
p~
18 Plate CP
@) 19 Bushing
20 Cushion
21 Cush ion rubber
22 Spring
G 23
24
Joint CP
Bushing
@ 25 Boss CP
26 Spring pin
27 Bracket CP (Selective 4WD)
28 Rubber bushing
29 Stay CP
30 Spri ng plate
31 Bracket CP
® (FWD/Full-Time 4WD)
I 32 Spacer (FWD/Full-Time 4WD)
I
33 Spring bracket CP
i ® ~ (FWD/Full-Time 4WD)
,
:
(Except
Selective 4WD) @
r I
QD
34
35
Rod CP
Spring (FWD)
~-----------------------~ -[2]
Fig. 4 L3463
5
3-3
Automatl"c Transmis
TRANSMISSON
. CONTROL SYSTEM
sion
1 Cover
Tightening~t:or;qu:-'-;,::~---- 2 Button
T1: 13 _ 2;(1~':. ~kg-m, ft-Ib) 3 Spring
4 Grip
T2: 10 _ 18 ( .3,9-17) 5 Spring pin
1.0 -18 7
: 9 _ 15 (0.9 _ 1 ., - 13) 6 Indicator ASSY
T3
T4: 1.3 _ 2.6 (0 .5,6.5 - 10.8) 7 Selector lever
T5: 4.4 _ 7.4 (0.13 - 0.27, 0.9 - 2 0) 8 Spring
____ .45 - 0.75, 3.3 - 5:4) 9 Connector
10 Bushing
11 Washer
12 Snap pin
13 Boot
14 Spring pin
15 Spacer
16 PlateCP
17 Cable
~: Inhibitor switch
Bracket
Fig. 5 L3-464
6
SERVICE PROCEDURE
Manual Transmission 5) Remove the bolt to take off the stay CP from the trans·
mission.
6) Remove the bolt to disconnect the rod from the joint.
ON-CAR SERVICE 7) Remove the nut to take off the gearshift lever ASSY from
the body.
Confirm the following: (Selective 4WD vehicle only)
1) The switch activation stroke of the lever CP is 5 mm
(0.20 in). ON-operation force is not more than 14.7 N (1.5 kg,
3.3 Ib). There is no binding.
2) A single push of the switch turns on 4WD mode and an
additional push returns to FWD mode.
REMOVAL
1) Remove the console box. (Selective 4WD)

2) Disconnect the connector for 4WD switch. (Selective
4WD)
Fig. 9
3) Remove the rear exhaust pipe.
DISASSEMBLY
1) Disconnect the rod from the gearshift lever ASSY.
Fig. 6
4) Remove the spring between joint CP and bracket CPo
L3469
Fig. 10
L3467
Fig. 8
7
2) Remove the following parts from the rod CP both sides. 5) Remove the following parts from the lever:
CD Spacer CD Cushion
® Bushing (Rubber) ® Bushing
@ Bushing (Nylon) @ Plate CP
@ Dust seal
® Locking wire
) {@
E3
-----~
/
G o--®
(§)--@
I @
~~
(ii'I
L3470
~
I
Fig. 11 I I
L ______ -' G- CD L3472
Fig. 13
3) Remove the cushion rubber.
4) Remove two nuts to disconnect the lever from the stay 6) Remove the following parts from the stay CPo
CPo (FWD/Full·Time 4WD)
CD Bushing
® Spacer
@ Spring bracket CP
@ Bracket CP
Stay CP
L3471
Fig. 12
L3473
Fig. 14
8
(Selective 4WD) 3) Assemble the plate CP and dust seal.
CD Bushing (1) Tighten with the locking wire [1 mm (0.04 in) dia.J
® Washer to the extent that the dust seal will not come off.
® Spring plate (2) Direct the locking wire end toward the plate side so
@ Bracket CP as not to damage the dust seal.
@
®
CD
Stay CP
L3475
L3474
Fig. 16
Fig. 15
4) Mount the following parts on the lever.

CD Dust seal
® Bushing
CHECK • Apply grease [SUNLIGHT No.2 (003602010) or
equivalent] to the inner surface of the bushing.
Check the following parts for deformation, damage, and wear. ® Cushion
Repair or replace any defective parts. Determine defective 5) Mount the above-mentioned lever on the stay CPo
parts by comparing with new parts. (1) Apply sealant on the stay CP su rface mating with the
CD Bushing plate, not at a place inside the bolt hole and where sealant
® Cushion will fall into the hollow.
® Spacer Sealant: Butyl rubber tape [1.5 mm (0.059 in) dia.J
@ Dust seal (2) Mount the plate CP on the stay CPo
® Link, rod, and lever
® Joint CP Tightening torque:
(J) Spring 14 - 22 N.m (1.4 - 2.2 kg-m, 10 - 16 ft-Ib)
@ Wiring harness (Selective 4WD)
ASSEMBLY
1) Clean all parts before assembly.

2) Mount the following parts on the stay CPo
(FWD/Full-Time 4WD)
CD Bushing
® Spacer
® Spring bracket CP
@ Bracket CP
(Selective 4WD)
CD Bushing L3476
® Washer Fig. 17
® Spring plate
@ Bracket CP
9
(3) After assembling, check that the lever moves smooth· 8) Check that there is no excessive play and that the parts
Iy. move smoothly.
(4) Mount the cushion rubber on the stay CPo
Tightening torque:
Stay CP to cushion rubber
9 - 15 N·m (0.9 - 1.5 kg-m, 6.5 - 10.8 ft-Ib)
6) Mount the following parts on the rod CP both sides. INSTALLATION

CD Bushing (Rubber)
® Bushing (Nylon) 1) Mount the rod CP at the joint on the transmission.
@ Spacer • Insert the bolt from the lower side.
(1) Apply grease [SUNLIGHT No.2 (003602010) or
equivalent] to the inner and side surfaces of the bushings Tightening torque:
when installing the spacers. 9 - 15 N'm (0.9 - 1.5 kg·m, 6.5 - 10.8 ft-Ib)
(2) Mount the chrome·plated (silver) spacer at the lever
end and the galvanized (yellow) spacer at the transmission 2) Mount the bracket CP on the transmission.
end.
(3) The rod should be installed in the direction shown in Tightening torque:
the figure below. 14 - 22 N:m (1.4 - 2.2 kg-m, 10 - 16 ft-Ib)
3) Mount the gearshift lever ASSY on .the body.
FRONT Tightening torque:

14 - 22 N·m (1.4 - 2.2 kg-m, 10 - 16 ft-Ib)
4) Mount the spring between joint CP and bracket CPo
For FWD models, the hook shape of the spring differs at each
end. The longer hook end should be attached at the joint
CPo
o
L3492 5) Connect the connector for 4WD switch. (Selective 4WD)
Fig. 18 6) Install the console box. (Selective 4WD)
7) Check that the lever moves smoothly.
7) Connect the rod CP to the lever.
8) Install the exhaust pipe (rear).
Tightening torque:
9 - 15 N·m (0.9 - 1.5 kg-m, 6.5 - 10.8 ft-Ib)
Rocking torque:
2.7 N·m (0.28 kg-m, 2.0 ft-Ib) or lower
Automatic Transmission
REMOVAL
Rocking torque
1) Remove the cable ASSY.
(1) Separate cable from transmission lever.
L3477 (2) Remove cable clamp from transmission case.
~----------------------------------------~
Fig. 19
10
A ~N
DISASSEMBLY
Cable 1) Remove the following parts from the lever assembly.

• Grip
• Indicator ASSY
L3-478
Fig. 20 Grip
(3) Disconnect cable from selector lever.

iI
Indicator ASSY
Fig. 21
(4) Remove the cable ASSY from bracket by removing L3-481

mounting nuts. Fig. 23
2) Remove the hand brake cover.
3) Remove the console box. (Refer to 5·3 console box.)
4) Disconnect the illumination light connector and 1-HOLD
switch connector. 2) Drive out the spring pin to the position where it is
5) Remove the selector lever ASSY. detached from the guide plate of plate CP as shown in figure.
Be careful not to damage the connected parts.
Illumination light
connector
I
1 Guide plate
2 Spring pin
3 Selector lever
installing bolt
Fig. 22 4 Boot
5 Rod
L3-482
Remove body and plate CP while removing butyl rubber seal. Fig. 24
11
3) Remove selector lever installing bolt and detach the boot 2) Confirm the following parts for operating condition
by pushing it from underneath, then disconnect the selector before assembly.
lever from plate CPo (1) Sliding condition of the button in the grip ... they
should be moved smoothly.
Do not remove the bushings from selector lever. (2) Insertion of the grip on the selector lever ... When
pushing the grip on selector lever by hand, the screw holes
should be aligned in line.
(3) Operation of the selector lever and rod ... they should
be moved smoothly.
(4) Insertion of the spacer into the selector lever ... it
should be inserted lightly by fingers.
ASSEMBLY
1) Clean all disassembled parts.

2) Assemble rod to selector lever.
A 19.027 (1) Apply grease on both sliding part ends of rod and
L..F-ig-.-2-5--------------------=-..:...=.....J spring, then insert them into selector lever.
4) Install the grip and button to the selector lever tempo-

Apply grease
rarily, and drive the spring pin out from rod, taking care not Selector lever
to make damage on connected parts.
Load
Selector leVer\ • Rod
•
Rod -.j~- [3.5 - 3.8 mm
(0.138 -0.150 in) dia.l I
L3-484
Fig. 27
/
(2) Match the oblong hole of selector lever and the spring
pin hole of rod.
Spring pin
(3) Press the spring pin into the selector lever and rod
L3-483 from side opposite arm.
Fig. 26 In order to prevent the spring pin from contacting with
the guide plate of plate CP, stop the spring pin at the same
level of selector lever outer surface as shown in figure.
INSPECTION Rod
Spring pin
1) Inspect the removed parts by comparing with new ones
. . Press
for deformation, damage and wear. Correct or replace if defec-
: 0
tive.
: : ---------Selector lever
CD Rubber bushing o 0
CV Selector lever rod

@ Boot
@ Plate CP
® Spring
Arm
® Button
(J) Grip L3-485
@ Indicator ASSY Fig. 28
12
3) Assemble the following parts to selector lever. (2) Insert the boot into the plate by pushing boot edge
with fingers.
CD Spring
Apply grease to prevent noise.
® Rubber bushing
® Boot
Coat grease on sliding surface of the boot. Push ~
~
@) Spacer
Coat grease on the surface of spacer.
@ Connector
@ Washer
W Snap pin I nsert groove into
the plate firmly.
A19'()32
Fig. 31
(3) Drive in the spring pin to the same level as selector
_LW
IJ-----@
® lever outer surface.
Selector lever
Guide plate
L3-486 Spring pin
Fig. 29
I <If'
('
4) Assemble selector lever to plate CPo
(1) Install the selector lever to the plate CP, and insert
L3-487
the bolt. Tighten flange nut to the specified torque.
Fig. 32
Tightening torque (Flange nut):
9 - 15 N·m (0.9 - 1.5 kg-m, 6.5 - 10.8 ft-Ib)
5) Assemble indicator to plate CPo
Tightening torque (Flange screw):

1.3 - 2.6 N·m (0.13 - 0.27 kg-m, 0.9 - 2.0 ft-Ib)
1 Flange nut
2 Spacer
3 Bolt
4 Plate CP
2
@
A 19'()81
Fig. 30
Fig. 33
13
6) Assemble the grip cover, spring, and button to selector
lever.
(1) Apply grease on the sliding part of the grip and
button, and spring.
(2) Insert the spring and button into the grip and then
drive in the spring pin.
Butyl rubber
(sealing agent)
Grip L3-490
Fig. 35
(2) Set the location of the select lever at "N".

2) Connect the cable ASSY.
(1) Set the location of the selector arm of the transmis-
sion at "N".
L3-489 (2) Pass the inner cable through the selector arm pin and
Fig. 34 then connect it using a washer and snap pin.
(3) Attach the cover on the grip.

(4) Insert the grip on the select lever, then tighten screws
to the specified torque with the torque driver.
Tightening torque:
1.3 - 2.6 N·m (0.13 - 0.27 kg-m, 0.9 - 2.0 ft-Ib)
5 to 6 mm (0.20 to 0.24 in) length screw should be used.

Fig. 36
7) After the completion of fitting, transfer the select lever
to range "P" - "2", pressing the button of the grip; then
(3) Attach the outer cable to transmission case with
check whether the indicator and select lever agree, whether the
bolts.
pointer and position mark agree and what the operating force
(4) Insert the thread portion of the other inner cable end
is.
into the connector hole of the selector lever, and fix the
other outer cable end to the bracket.
INSTALLATION
1) Mount the select lever ASSY onto the car body.

(1) Apply Butyl rubber (sealing agent) between the select
lever through the hole in the car body and the threaded
fitting hole, and use six bolts for fitting.
Tightening torque:
4.4 -7.4 N·m (0.45 - 0.75 kg-m, 3.3 - 5.4 ft-Ib)
Fig. 37
14
3) Adjust the inner cable length. 4) After completion of the fitting, make sure that the lever
(1) Push select lever arm in the "W" direction with a operates smoothly all across the operating range.
force of 2.0 - S.9 N (0.2 - 0.7 kg, 0.4 -" 1.5 Ib) until 5) Connect the harnesses and check the following items.
nut ® contacts the connector. (1) The engine starts operating when it is in positions "P"
and "N", but not in other positions.
(2) The back-up lamp is lit when it is in position "R",
but not in other positions.
----t..--Arm (3) The above starting and lighting are not performed at
the same time.
•
(4) Check that select lever does not move from "N" to
"R" without pushing the button.
W (5) Check that select lever does not move from "R" to
"P" without pushing the button.
(S) Check that select lever does not move from "P" to
"R" without pushing the button.
(7) Check that select lever does not move from "3" to
Connector "2" without pushing the button.
L3491 S) Fit the console.
Fig. 38
(2) While firmly grasping nut ® with a wrench, tighten

nut @.
Tightening torque:
13 - 23 N·m (1.3 - 2.3 kg·m, 9 - 17 ft·lb)
15
4WD SYSTEM
Page
MECHANISM AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2
SUBARU Propeller Shaft . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . • . . • . . .. 2
Rear Differential ....................•.................. 3
Limited Slip Differential (LSD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4
1988 SPECIFICATIONS AND SERVICE DATA. . . . . . . . . . . . . . . . . . . . . .. 1
COMPONENT PARTS ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11
Rear Differential Mounting System ........................... 11
Propeller Shaft and Drive Shaft . . . . . . . . . . . . . . • . . . . . . • . . . . • . .. 12
Rear Differential Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 13
SERVICE PROCEDURE ...•..............................•. 14
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14
On-Car Services ........................................ 16
Rear Differential Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20
TROUBLESHOOTING _.................................... 31
-
3-4 4WD SYSTEM

Propeller Shaft
The propeller shaft is of three-joint type to accommodate
high-speed operations. The joint is provided with shell-cup
bearings which do not require maintenance.
Center bearing ASSY

2 Front propeller shaft ASSY
3 Rear propeller shaft ASSY
4 Companion flange
5 Washer
6 Stake nut
7 Bolt
8 Spring washer
9 Nut
L3-182
Fig. 1
2
4WD SYSTEM 3-4
Rear Differential
A hypoid drive gear with a nominal diameter of 160 mm
(6.30 in) is used and the drive pinion shaft is supported on
three bearings, the bearing preload being adjusted by a
selective spacer and washer. The drive pinion height is adjusted
by selecting washers located at the drive pinion neck using
Dummy Shaft and Gauge.
L3-049
1 Drive pinion nut 14 Differential case
2 Companion flange 15 Side gear
3 Front oil seal 16 Side gear thrust washer
4 Pilot bearing 17 Pinion mate gear
5 Spacer 18 Pinion mate gear washer
6 Front bearing 19 Pinion mate shaft
7 Bearing preload adjusting washer 20 Pinion shaft lock pin
8 Bearing preload adjusting spacer 21 Side beari ng
9 Rear bearing 22 Side bearing retainer
10 Pinion height adjusting washer 23 Side bearing retainer O-ring
11 Drive pinion 24 Side bearing retainer shim
12 Differential carrier 25 Rear cover
13 Drive gear 26 Rear cover gasket
Fig. 2
3
3-4 4WD SYSTEM
Limited Slip Differential (LSD)

Outline The LSD uses two units of friction clutch to join the right and
left rear axle shafts to the differential case, and is built into
The LSD (Limited Slip Differential) is installed on the rear the differential case.
differential of four-wheel drive vehicles, improving running
performance on rough roads. It permits the inner and outer a. Even though a noise may be heard while steering, it is not
wheels to rotate different amounts when turns are made, just faulty.
as in general differentials. In addition, the LSD provides the b. Never turn on the engine while the tire on one side is jacked
following features: up as the vehicle may start to move.
1) When one front and one rear wheel, diagonal to each c. If the tire on one side is in the mud and the tire is spinning,
other, slip on snow-covered roads and driving force cannot be the vehicle can get out of the mud by depressing the
delivered, or when one rear wheel is caught in a ditch and accelerator pedal. To keep the engine running at a high speed
runs idle, the LSD delivers strong torque to the other wheel adversely affects the LSD and should be avoided.
so that the veh icle can run normally. d. If, in an emergency, a different sized tire (temporary tire,
2) Even if the vehicle bumps with one rear wheel off the etc.) is used for the rear tire, it adversely affects the LSD. It is
road such as when driving on rough terrain, gravel or snow- necessary to replace that tire with the same sized tire
covered roads, the LSD assures easy straightforward drive- immediately.
ability by its limited differential function.
Structure
, ,
.----------------------...)\ ' '----------_._-
\@(j) @ @ fs\'
'\ ~ \ilj
,
A 14'()99
1 Crown gear bolt 9 Side gear

2 Differential case, left 10 Pinion
3 Thrust washer 11 Pinion shaft
4 Friction plate 12 Differential case, right
5 Friction disc 13 Cross recessed countersunk head screw
6 Spring plate 14 Ring gear
7 Spring disc 15 LSD kit ... Consists of 1 to 13
A14·100 8 Pressure ring
Fig, 3
4
4WD SYSTEM 3-4
The LSD uses the type called "LOK-O-MATIC" and consists Torque of the differential case is delivered to the pressure ring
of V-shaped cams and a multiple disc clutch_ linked to the differential case through four lugs and thus they
The cross pinion shaft (j]) with V -shaped cams at the tips is turn together. When the pressure ring is going to rotate in the
supported by the V -shaped grooves provided in the pressure direction of the arrows in Fig. 4, torque is transmitted to the
ring ®. The pressure ring ® is fitted into the grooves in the pinion shaft supported by the V-shaped cams, and the pressure
differential case @ by means of four peripheral lugs so that ring receives its reaction force. This reaction force pushes the
it can slide in the axial direction. Further, the pinions @ and pressure ring open right and left and acts as the pressing load
side gear ® are meshed with one another inside the pressure in the multiple disc clutch.
ring.
P = F cot 8
The friction plates @ and spring plate ®, each having four
peripheral lugs to be fitted into the differential case @, and Since 8 is constant, the clutching load P is proportional to F
the friction discs ® and spring disc (j), each having four or the torque of the differential case.
inner lugs to be fitted on the side gear ® are placed
alternately as shown in figure so that they can slide in the 2) OPERATIONS IN VARIOUS RUNNING
axial direction. All these parts are combined to form a clutch. CONDITIONS
The spring plate ® and spring disc (j) function as a coned 1) When right and left wheels turn at equal speed
disc spring and produce initial torque. To adjust the axial During normal straight-road driving where the right and left
clearance, the thrust washers @ are inserted between the side wheels run at an equal speed, the differential case and side
gears ® and differential cases CV and @. With this arrange- gears rotate together, just as in conventional differentials. As
ment, thrust of the side gears is prevented from acting on the a result, driving torque is transmitted equally to the right and
pressure ring. left side gears.
Operation
1) PRINCIPLE OF OPERATION
The load required for the clutch to couple the differential case
with the side gears is produced on the contact surfaces
between the V-shaped cams of the pinion shaft and the
pressure rings' V-shaped cuts. This load is proportional in size
to the torque transmitted from the differential case.
Direction of
rotation
t 2F
ressu re ri ng
F F
A14-102
F: Reaction force produced when pressure ring rotates Fig_ 5

pinion shaft in direction of rotation.
P: Axial reaction force that pressure ring receives from
pinion shaft; it acts as clutch load.
2) When tight and left wheels turn at different speeds
In conventional differentials, if one wheel slips in the mud, it
A 14-101
causes a considerable decrease in the friction between the
Fig. 4 wheel and road surface and therefore in the transfer torque.
5
3-4 4WD SYSTEM
The conventional differential always delivers the same amount Therefore, more torque is transmitted to the slower turning
of torque to each wheel. If one wheel slips, the other wheel wheel than to the faster wheel.
loses driving torque.
On the other hand, in the Iimited slip differential, if the right
wheel slips, as shown in Fig. 6, the right side gear tends to
Torque Ratio of Right to Left Wheels
turn faster than the differential case. However, because the If one wheel slips, it causes a difference between the slipping
clutch holds the right side gear in a braked state, a portion of and non-slipping wheels in the amount of torque transmitted
torque is transmitted from the right side gear to the differ· to them. However, the torque ratio between the two wheels in
ential case through the clutch, as shown by the broken line. this case is constant and called a "transfer ratio". This transfer
In the other nonslipping wheel, while the left side gear rotates ratio is expressed by the following equation:
at low speed, the differential case turns at high speed. Thus,
torque is delivered from the differential case to the left side Rt = ..!.h..
gear through the clutch. Ts
Rt: Transfer ratio
TL : Low-speed wheel torque
T s: High-speed wheel torque
Transfer ratio is indicated by a value based on the ratio of the
low-speed wheel torque to the high-speed wheel torque.
Because the conventional differential delivers an equal amount
of torque to each wheel, the transfer ratio Rt is 1.
In LSD, the transfer ratio, 1 < Rt < 00, can be obtained by
selecting the clutch coefficient that determines the torque
amount of the clutch .
..
~
~
...
o
II
1
1~t<--t--+-r-
oJ
High-speed wheel torque Ts
A14-104
Fig. 7
A14·103
Fig. 6
Oil
As a result, in addition to the torque delivered to the left side Use only genuine SUBARU LSD oil to obtain the best per-
gear from the pinions, an additional amount of torque is formance from the LSD.
transmitted to the left side gear which flows from the right
side gear via the clutch, differential case, left clutch and left SUBARU LSD oil
side gear in the order named. Given that torque in the direc- (Showa Sekiyu LSD oil #90)
tion in which the differential case turns is plus and that in the Part No. 003304300
reverse direction is minus, the amount of torque delivered to
the low-speed wheel, T L, is calculated by:
T L = (+ Side gear torque) + (+ Clutch torque) = To + T c Service Procedures for LSD

The amount of torque delivered to the high-speed wheel, Ts ,
The component parts of LSD kit (See Fig. 3) are not available
is given by:
as piece parts.
Ts = (+ Side gear torque) + (- Clutch torque) = To - Tc Therefore, it is not recommended to disassemble LSD kit.
6
4WD SYSTEM 3-4

SPECIFICATIONS
• Rear final reduction gear ratio
~
2700
1800
AT MT
Type of gear Hypoid
Gear ratio 3.900 (39/10)

3.700 (37/10) 3.700 (37/10)
(Number of gear teeth)
• Propeller shaft
Engine model 1800 2700
Type Standard 3-joint type Vibration-proof, 3-joint type
621 (24.45) ... MT

1st shaft, Q1 621 (24.45)
501 (19.72) ... AT
Jo int-to-jo int length mm (in)
2nd shaft, Q 2 744 (29.29)
1st shaft 63.5 x 1.6 (2.500 x 0.063)

Outside dia. of tube
mm (in)
x thickness 2nd shaft 50.8 x 2.3 (2.000 x 0.091)
Type Involute spline , -,r-.

Sleeve yoke
0.0. x No. of teeth x module 25 mm (0.98 in) x 24 x 1.0
Standard 3-joint type
L3·075
Fig. 8
7
3-4 4WD SYSTEM
Vibration-proof, 3-joint type
Rubber
L3-076
Fig. 9
• Drive shaft
Engine model Joint size Shaft dia. D Distance between boots, L
1800 82AC 22 mm (0.87 in) 223.5 mm (8.80 in)
2700 87AC 22.2 mm (0.874 in) 223.2 mm (8.79 in)
Black or Green Green

(Black) (Black)
~~.DL~~
) 2700 cc model
L3-318
Fig. 10
8
4WD SYSTEM 3-4
SERVICE DATA
Rear Front & rear bearing preload at New bearing 19.6 - 28.4 N
differential companion flange bolt hole (2.0 - 2.9 kg, 4.4 - 6.4 Ib)
Used bearing 8.34 - 16.67 N
(0.85 - 1.7 kg, 1.87 - 3.75Ib)
Preload adjusting washer length Part No.

383705200 2.59 mm (0.1020 in)
383715200 2.57 mm (0.1012 in)
383725200 2.55 mm (0.1004 in)
383735200 2.53 mm (0.0996 in)
383745200 2.51 mm (0.0988 in)
383755200 2.49 mm (0.0980 in)
383765200 2.47 mm (0.0972 in)
383775200 2.45 mm (0.0965 in)
383785200 2.43 mm (0.0957 in)
383795200 2.41 mm (0.0949 in)
383805200 2.39 mm (0.0941 in)
383815200 2.37 mm (0.0933 in)
383825200 2.35 mm (0.0925 in)
383835200 2.33 mm (0.0917 in)
383845200 2.31 mm (0.0909 in)
Preload adjusting spacer length Part No.

383695201 56.2 mm (2.213 in)
383695202 56.4 mm (2.220 in)
383695203 56.6 mm (2.228 in)
383695204 56.8 mm (2.236 in)
383695205 57.0 mm (2.244 in) .
383695206 57.2 mm (2.252 in)
Pinion height adjusting washer thickness Part No.

383495200 3.09 mm (0.1217 in)
383505200 3.12 mm (0.1228 in)
383515200 3.15 mm (0.1240 in)
383525200 3.18mm (0.1252 in)
383535200 3.21 mm (0.1264 in)
383545200 3.24 mm (0.1276 in)
383555200 3.27 mm (0.1287 in)
383565200 3.30 mm (0.1299 in)
383575200 3.33 mm (0.1311 in)
383585200 3.36 mm (0.1323 in)
383595200 3.39 mm (0.1335 in)
383605200 3.42 mm (0.1346 in)
383615200 3.45 mm (0.1358 in)
383625200 3.48 mm (0.1370 in)
9
3-4 4WD SYSTEM
Rear 383635200 3.51 mm (0.1382 in)

differential 383645200 3.54 mm (0.1394 in)
(continued) 383655200 3.57 mm (0.1406 in)
383665200 3.60 mm (0.1417 in)
383675200 3.63 mm (0.1429 in)
383685200 3.66 mm (0.1441 in)
Side gear to thrust washer clearance 0.1 - 0.2 mm (0.004 - 0.008 in)
Side gear thrust washer thickness Part No.
383445201 0.75 - 0.80 mm (0.0295 - 0.0315 in)
383445202 0.80 - 0.85 mm (0.0315 - 0.0335 in)
383445203 0.85 - 0.90 mm (0.0335 - 0.0354 in)
Side bearing standard width 20.00 mm (0.7874 in)

Side bearing retainer shim thickness Part No.
383475201 0.20 mm (0.0079 in)
383475202 0.25 mm (0.0098 in)
383475203 0.30 mm (0.0118 in)
383475204 0.40 mm (0.0157 in)
383475205 0.50 mm (0.0197 in)
Drive gear to drive pinion backlash 0.10 - 0.20 mm (0.0039 - 0.0079 in)
Drive gear runout on its back surface Limit 0.05 mm (0.0020 in)
Oil capacity 0.8Q (1.7 US pt, 1.4 Imp pt)
.
10
4WD SYSTEM 3-4
COMPONENT PARTS
Rear Differential Mounting System
@-_J
CD
~
~@
I
I ~
I
I
I
1 Bracket CP (L.H.)
2 Stopper
3 Bushing
4 Washer
5 Packing
6 Spring pin
7 Drive shaft ASSY
8 Bolt CP
9 Packing Tightening torque: N·m (kg·m, ft-Ib)
10 Spindle T1: 69 - 78 (7 - 8, 51 - 58)
11 Differential ASSY T2: 44 - 54 (4.5 - 5.5, 33 - 40)
12 Breather cap T3: 24 - 32 (2.4 - 3.3, 17 - 24)
13 Bracket ASSY
14 Differential mount member ASSY
T4: 31 - 36 (3.2 - 3.7,23 - 27)
15 Bracket CP (R.H.) T5: 39 - 49 (4 - 5, 29 - 36)
Fig. 11 L3-455
11
3-4 4WD SYSTEM
Propeller Shaft and Drive Shaft
1 Front propeller shaft ASSY

2 Center bearing ASSY
3 Rear propeller shaft ASSY
4 Companion flange
5 Washer
6 Baffle plate (BJ side)
7 Baffle plate (DOJ side)
8 DOJ ASSY
9 Snap ring
10 Circlip
11 Protector
12 Boot band
13 DOJ boot
14 BJ boot
15 BJ & shaft unit
/'
-1
I
/
/'
/'
/'
/
/'
/
/'
/
/'
/
/
/'
/
/'
( /
/'
/'
/'
/'
/'
/'
/ (j])
/
/
/
I /'
I / @
1---/ ®

T1: 245 - 294 (25 - 30, 181 - 217)
T2: 24 - 32 (2.4 - 3.3, 17 - 24)
T3: 34 - 44 (3.5 - 4.5, 25 - 33)
® Disassemble and reassemble the rear drive shaft using the same
procedure as for the front axle shaft.
Fig. 12 L3-456
12
4WD SYSTEM 3-4
Rear Differential Assembly

* Selective parts

T1: 167 - 196 (17.0 - 20.0,123 - 145)
T2: 19 - 25 (1.9 - 2.6, 14 - 19)
T3: 93 -113 (9.5 -11.5, 69 - 83)
T4: 9 - 12 (0.9 - 1.2,6.5 - 8.7)
Side gear 12 Pilot bearing 23 Bolt (8x20x14 mm)

2 Pinion mate gear 13 Front oil seal 24 Pinion shaft lock pin
3 Pinion crown gear set 14 Companion flange 25 Bolt (11 x18x11 mm)
4 Differential case 15 Self·locking nut *26 Side gear thrust washer
5 Pinion mate gear washer 16 S ide bear i ng 27 Rear cover
*6 Pinion height adjusting washer 17 Side bearing retainer 28 Stud bolt
7 Rear bearing 18 Differential carrier 29 Plug
*8 Bearing preload adjusting spacer 19 Side oil seal 30 Plug CP
*9 Bearing preload adjusting washer 20 Pinion mate shaft 31 Bolt (10x30x18 mm)
10 Front bearing 21 Side bearing retainer a·ring
11 Spacer *22 Side bearing retainer sh im
Fig. 13 L3·848
13
3-4 4WD SYSTEM
SERVICE PROCEDURE
3) Remove propeller shaft from transmission.
Propeller Shaft
Check the following points with propeller shaft installed in
vehicle.
1) Joints and connections
Check for looseness.
2) Splines and bearing locations
(1) Turn propeller shaft by hand to see if abnormal free
play exists at splines. Also move yokes to see if abnormal
free play exists at spiders and bearings.
(2) Turn rear wheels by hand to check for "runout" of
propeller shaft.
L3·053
REMOVAL
Fig. 16
1) Remove the four bolts which hold propeller shaft to rear
differential. a. Be sure to use an empty oil can to catch oil flowing out
when removing propeller shaft.
b. Be sure not to damage oil seals and the frictional surface of
sleeve yoke.
c. Be sure to plug the opening in transmission after removal of
propeller shaft.
DISASSEMBLY
Before removing center bearing, check its condition. If it does

L3·051 not operate smoothly or if there is any free play or leakage,
remove as follows:
Fig. 14
1) Put aligning marks on affected parts.
2) Remove the two bolts which hold center bearing to car

body.
Center bearing
L3-054
Fig. 17
2) Remove bolts which hold front propeller shaft to rear

Fig. 15 propeller shaft.
14
4WD SYSTEM 3-4
3) Place companion flange in a vise and remove stake nut. • Joints for unsmooth operation or abnormal noise
• Center bearing for free play. noise or unsmooth operation
• Oil seals for abnormal wear or damage
Companion flange
INSTALLATION
1) Install center bearing onto front propeller shaft.

2) Install washer to center bearing.
Apply a coat of grease to both surfaces of washer before

installation.
L3-055 Recommended grease:

Molybdenum disulfide grease
Fig. 18
3) Align marks and install companion flange.
Be sure not to hold propeller shaft pipe portion in the vise. 4) Tighten stake nut until center bearing is set in position.
4) Drive out companion flange with a puller or press. Be sure to install new stake nut.
Before disassembling, put aligning mark on affected parts. Tightening torque:

245 - 294 N·m (25 - 30 kg-m. 181 - 217 ft-Ib)
5) Lightly tap the head of front shaft with a copper hammer
until center bearing is removed. Stake the nut after tightening.
5) Align marks and connect front and rear shafts.
Tightening torque:
24 - 32 N'm (2.4 - 3.3 kg-m, 17 - 24 ft-Ib)
6) Insert sleeve yoke into transmission and attach center

bearing to car body.
Copper hammer
Tightening torque:
34 - 44 N'm (3.5 - 4.5 kg-m, 25 - 33 ft-Ib)
Center bearing
L3·056
Fig. 19
Be careful not to damage the thread portion.

Center beari ng
INSPECTION
Check the following and replace faulty parts if necessary.

• Tube surfaces for dents or cracks .,~~~
&t.~
• Splines for deformation or abnormal wear
• Tubes for runout exceeding 0.6 mm (0.024 in)
Measure runout with a dial gauge at the center of front and

rear shaft tubes. Fig. 20
15
3-4 4WD SYSTEM
7) Connect flange yoke and rear differential. 5) Remove self-locking nut while holding companion flange
with FLANGE WRENCH (398427700).
Tightening torque:
24 - 32 N·m (2.4 - 3.3 kg-m, 17 - 24 ft-Ib)
A14·059
Fig. 23
Fig. 21 6) Extract companion flange with a puller.
On-Car Services
REPLACING FRONT OIL SEAL
1) Drain gear oil.

2) Jack up rear wheels and support the vehicle body with
rigid racks. A 14·060
3) Detach propeller shaft from companion flange.
4) Measure turning resistance of companion flange. Fig. 24
Measure turning resistance after making sure that the com-

panion flange turns smoothly. 7) Remove oil seal.
1 Companion flange 1 PULLER ASSY

(398527700)
2 Spring balance
A14-058 2 Oil seal A14-007
Fig. 22 Fig. 25
16
4WD SYSTEM 3-4
8) Fit a new oil seal.
A16-180
A14-008 Fig. 27
Fig_ 26
6) Detach BJ from spindle of trailing arm with trailing arm
lowered fully and detach DOJ from differential spindle and
then remove drive shaft ASSY_
9) Install companion flange_ 7) Loosen differential spindle set bolt by using WRENCH
10) Tighten self-locking nut within the specified torque range (925560000) and remove spindle with packing.
so that the turning resistance of companion flange becomes 8) Remove oil seal.
the same as that before replacing oil seal.
Torque (Drive pinion nut):

167 - 196 N'm (17.0 - 20.0 kg-m, 123 - 145 ft-Ib)
PULLER ASSY (398527700)
~
11) Reassembling procedure hereafter is the reverse of the
disassembling.
REPLACING SIDE OIL SEAL A14-010
Fig. 28
1) Remove two bolts which fix the upper portion of shock
absorber to the body in unladen condition_ 9) Drive in a new oil seal with DR I FT (398437700)
2) Loosen both wheel nuts.
3) Jack up the vehicle and support it with rigid racks_ Apply chassis grease between the oil seal lips.
4) Remove wheels.
5) Drive out spring pins of BJ and DOJ by using 6 mm 10) Reassembling procedure hereafter is the reverse of the
(0.24 in) diameter of steel rod. disassembly.
17
3-4 4WD SYSTEM
Using the different rear differential ASSY causes the drive line
IDENTIFICATION OF REAR
and tires to "drag" or emit abnormal noise when 4WD is
DIFFERENTIALS selected.
When replacing a rear differential ASSY, select the correct one
according to the following table.
Gear ratio Identification mark Part number Label stuck on rear differential
PART
NUMBER 722011012
3.700 WL 722011012 GEAR RATIO 3. 7 00
G FUll HEAVY INDUSTRIES LTD. WL
LSD ~~~ 3.700

722011002
PART NO.
3.700
T 7 :;t 1" )L.o (;I: ;(IIull. LSD:;t 1" )L.o
WM 722011002 >a-O.8£;iJ....L"Cf~\.'o
(With LSD)
use BUBARU LSD OIL]
[ capacity 0 .8 £ 7 ~spt )(1.
1.4 Imppt
f) FUJI HEAVY INDUSTRIES LTD. WM
~~R~BER622006022
* 3.900 WP 622006022 GEAR RATIO 3.900

G FUll HEAVY INDUSTRIES LTD. WP
LSD22011
~~~ 3.900
GA022
PART NO.
3.900 T7:;t1" )L.o(;I: ;(II ll. LSD:;t1")L.o
U
* WR 22011GA022
(With LSD) >a-O.8t;iJ.... L "cr ~ \.'0
use SUBARU LSD OIL]
[ capacity 0 . 8 £ (1. 7 ~spt )
1.4lmppt
f) FUJI HEAVY INDUSTRIES LTD. WR
mul______-~~ I~-
* 2700 cc model L3·849
Fig. 29
Locati: of painted
identification code
::= I.
' -_ _ _--L..J Location of label
Fig. 30 L3-059
18
4WD SYSTEM 3-4
GEAR RATIOS OF REAR DIFFERENTIALS CHECKING FOR GEAR RATIOS
Engine
model MT AT Rear differential
Work procedures differ between LSD and non-LSD, as follows:
1800 3.700 3.700 WLorWM 1) LSD
2700 3.900 3.700 WL, WM, WP or WR (1) Set the selective 4WD and full-time 4WD (AT) models
in the FWD mode. Turn the diff. lock switch of the full-
If the painted identification code cannot be read clearly or if time 4WD (MT) model to OFF.
the label is torn off, its type can be determined as follows:
To set the full-time 4WD (AT) model in the FWD mode
CHECKING FOR LSD OR NON-LSD install a spare fuse in the FWD fuse holder located in front of
1) Set the selective 4WD and full-time 4WD (AT) models in the strut on the left side of the engine compartment.
the FWD mode. Turn the diff. lock switch of the full-time
4WD (MT) model to OFF. (2) Raise both rear wheels, not one wheel.
(3) Mark both tire and propeller shaft with a piece of
To set the full-time 4WD (AT) model in the FWD mode, install chalk so that the number of tire rotations can be counted.
a spare fuse in the FWD fuse holder located in front of the (4) Slowly and exactly turn the tire ten complete rota-
strut on the left side of the engine compartment. tions to see how many turns the propeller shaft makes.
If propeller shaft makes 37 turns, gear ratio is 3.700.
If it makes 39 turns, gear ratio is 3.900.
2) Non-LSD
(1) Set the selective 4WD and full-time 4WD (AT) models
in the FWD mode. Turn the diff. lock switch of the full-
time 4WD (MT) model to OFF.
To set the full-time 4WD (AT) model in the FWD mode

install a spare fuse in the FWD fuse holder located in front of
the strut on the left side of the engine compartment.
(2) Raise only right rear wheel. (If both left and right
wheels are raised, keep the left one stationary.)
(3) Mark the tire's lowest position and the propeller
Fig. 31 shaft with a piece of chalk so that the number of tire
2) Raise one or both rear wheels with a jack. rotations can be counted exactly.
(4) Slowly turn the tire clockwise until propeller shaft
3) Manually turn tire to check for rotating condition of tire.
• When one wheel is raised: rotates exactly 6 complete turns. At this point, check the
location of the chalk mark on the tire.
Tire turns smoothly . . . . . . . . . . . . . . . . Non-LSD
If the mark is at position "A" in the figure below, gear
Tire turns but requires considerable effort. . . .. LSD
ratio is 3.700; if it is at "8", gear ratio is 3.900 .
• When both wheels are raised:
80th tires turn in opposite direction to
each other . . . . . . . . . . . . . . . . . . . . . . . Non-LSD
If the above procedures are followed, rear differential can also
80th tires turn in the same direction . . . . . . . . LSD
be identified as to its type and other related information.
Rear wheel at R.H. side
Mark [Use this mark (balance weight)

as a guide when rotating]
I
Propeller shaft
A
After rotat i ng propel! er shaft Initial position of mark

six turns B L3-060
Fig. 32
19
3-4 4WD SYSTEM
Rear Differential Assembly DISASSEMBLY
DISMOUNTING 1) Inspection before disassembling

To detect real cause of trouble, inspect the following items
before disassembling.
1) Remove the two bolts which hold the upper end of shock
(Refer to "ASSEMBLY" for inspection procedures.)
absorber to car body. Car should be in an unloaded condition.
(1) Tooth contact of hypoid drive gear and pinion, and
2) Loosen wheel nuts on left and right wheels.
backlash.
3) Raise car with a jack and support it with a rigid rack.
(2) Runout of drive gear at its back surface.
(3) Turning resistance of drive pinion.
2) Disassembling
(1) Set ATTACHMENT (398217700) on vise and install
the differential assembly to Attachment.
L3-057
ATTACHMENT
(398217700)
A14-061
4) Remove wheels.
5) Remove spring pins from DOJ and BJ with a 6 mm
(0.24 in) diameter of steel rod. Next, lower trailing arm ASSY (2) Drain gear oil by removing plug.
all the way; remove BJ from spindle on the trailing arm side (3) Remove spindles by loosening bolts with WRENCH
first, then DOJ on the differential side. Remove drive shaft (925560000).
ASSY. (4) Remove rear cover by loosening retaining bolts.
6) Remove propeller shaft ASSY.
a. Prepare an oil can and cap since the transmission oil flows
out from the extension at removing propeller shaft ASSV.
b. When removing propeller shaft ASSV, pay attention not to
damage the sliding surfaces of rear drive shaft (extension)
spline, oil seal and sleeve yoke.
c. Insert the cap into the extension to prevent transmission oil
from flowing out immediately after removing the propeller
shaft ASSV.
7) Support differential assembly with jack and remove two

self-locking nuts at the center of differential mount member
ASSY. A14-012
8) Remove four self-locking nuts fixing differential ASSY to
Fig. 35
bracket ASSY (F).
9) Dismount differential ASSY by lowering jack.
(5) Mark right and left side bearing retainers in order to
identify them at reassembly. Remove side bearing retainer
attaching bolts, set ATTACHMENT (398457700) to
differential case, and extract right and left side bearing
retainers with a puller.
20
4WD SYSTEM 3-4
Each shim, which is installed to adjust the side bearing preload, (8) Extract bearing cone with PULLER SET
should be kept together with its mating retainer. (399527700).
a. Set Puller so that its claws catch the edge of the bearing
cone.
ATTACHMENT
b. Never mix up the right and left hand bearing cups and
(398457700)
cones.
Do not attempt to disassemble the parts unless necessary.
Side bearing retainer o L3-458
Fig. 36
(6) Pu II out differentia I case.
Be careful not to permit the teeth to contact the case. L3-460
Fig. 39
. ,,
(9) Remove drive gear by loosening drive gear bolts.
Differential case
Drive gear
Fig. 37
(7) When replacing side bearing, pull bearing cup from

side bearing retainer.
L3-461
Fig. 40
(10) Drive out pinion shaft lock pin from drive gear side.
The lock pin is staked at the pin hole end on the differential
1 PULLER ASSY case; do not drive it out forcibly before unstaking it.
(398527700)
2 Bearing cup
A14-015
Fig. 38
21
3-4 4WD SYSTEM
1 Rear bearing cone

2 REPLACER
(398517700)
A14-018 A14-063
Fig. 41 Fig. 43
(16) Remove front oil seal from differential carrier.

(11) Draw out pinion mate shaft and remove pinion mate (17) Remove pilot bearing together with front bearing
gears, side gears and thrust washers. cone.
The gears as well as thrust washers should be marked or kept

separated left and right, and front and rear.
(12) Hold companion flange with FLANGE WRENCH

(398427700) and remove drive pinion nut.
(13) Extract the companion flange with a puller.
(14) Press the end of drive pinion shaft and extract it
together with rear bearing cone, preload adjusting spacer
and washer.
® ®
1 DRIFT (398467700)
Hol.d the drive pinion so as not to drop it. 2 Rear bearing cup
3 Front bearing
4 Pilot bearing A14-021
Fig. 44
DRIFT (398467700)
(18) When replacing bearings, tap front bearing cup and
rear bearing cup in this order out of case by using a brass
bar.
A14-019
Fig. 42
(15) Remove rear bearing cone from drive pinion by

supporting cone with REPLACE R (398517700). Tap alternately with brass bar.
Place the replacer so that its center-recessed side faces the A 14-022
pinion gear. Fig. 45
22
4WD SYSTEM 3-4
INSPECTION
Wash all the disassembled parts clean, and examine them for
wear, damage, or other defects. Repair or replace defective
parts as necessary.
1) Drive gear and drive pinion
(1) If abnormal tooth contact is evident, find out the
cause and adjust to give correct tooth contact at assembly.
Replace the gear if excessively worn or incapable of
adjustment.
(2) If crack, score, or seizure is evident, replace as a set.
Slight damage of tooth can be corrected by oil stone or A14-023
the Iike.
2) Side gear and pinion mate gear Fig. 46
(1) Replace if crack, score, or other defects are evident
on tooth surface.
(2) Replace if thrust washer contacting surface is worn or
seized. Slight damage of the surface can be corrected by
oil stone or the like.
3) Bearing
Replace if seizure, peeling, wear, rust, dragging during rotation, 2) Adjusting preload for front and rear bearings.
abnormal noise or other defect is evident. Adjust the bearing preload with spacer and washer between
4) Thrust washers of side gear and pinion mate gear front and rear bearings. Pinion height adjusting washer has
Replace if seizure, flaw, abnormal wear or other defect is nothing to do with this adjustment. The adjustment must be
evident. carried out without oil seal.
5) Oil seal (1) Press front and rear bearing cups into differential
carrier.
Replace if deformed or damaged, and at every disassembling.
6) Differential carrier
Replace if the bearing bores are worn or damaged.
7) Differential case
Replace if its sliding surfaces are worn or cracked.
8) Companion flange
Replace if the oil seal Iip contacting surfaces have flaws.
HANDLE & DRIFT KIT

(397471600)
ASSEMBLY
A14-024
1) Precautions for assembling Fig. 47

(1) Assemble in the reverse order of disassembling.
Check and adjust each part during assembly.
(2) Keep the shims and washers in order, so that they are
not misinstalled.
(3) Thoroughly clean the surfaces on which the shims,
washers and bearings are to be installed.
(4) Apply gear oil when install ing the bearings and thrust
washers. (2) Insert DUMMY SHAFT (398507702) with pinion
(5) Be careful not to mix up the right and left hand cups height adjusting washer and rear bearing cone fitted on it
of the bearings. into carrier_
(6) Replace the oil seal with new one at every dis-
assembly. Apply chassis grease between the lips (*) when Reuse the used washer if they show normal tooth contact
installing the oil seal. pattern when checked before disassembly.
23
3-4 4WD SYSTEM
Pinion height adjusting washer

Preload adjusting spacer
Preload adjusting washer
DUMMY COLLAR DUMMY SHAFT

(398507703) (398507702)
A14'()25 A14-065
~--------------------------------------~
Front & rear bearing preload
For new bearing:

19.6 - 28.4 N (2.0 - 2.9 kg. 4.4 - 6.4 Ib)
(3) Then, install preload adjusting spacer and washer, at companion flange bolt hole
front bearing cone, DUMMY COLLAR (398507703).
companion flange, washer and drive pinion nut_ For used bearing:
(4) Turn Dummy Shaft with hand to make it seated, and 8.34 -16.67 N (0.85 -1.7 kg, 1.87 - 3.75Ib)
tighten drive pinion nut while measuring the preload with at companion flange bolt hole
spring balance as shown in the figure_ Select preload
adjusting washer and spacer so that the specified preload Preload adjusting washer
is obtained when nut is tightened to the specified torque.
a. Be careful not to give excessive preload.
b. When tightening the drive pinion nut, lock Dummy Shaft 383705200 2.59 (0.1020)
with BLOCK (398507704) as illustrated here. 383715200 2.57 (0.1012)
383725200 2.55 (0.1004)
383735200 2.53 (0.0996)
383745200 2.51 (0.0988)
383755200 2.49 (0.0980)
383765200 2.47 (0.0972)
383775200 2.45 (0.0965)
383785200 2.43 (0.0957)
383795200 2.41 (0.0949)
383805200 2.39 (0.0941 )
383815200 2.37 (0.0933)
383825200 2.35 (0.0925)
383835200 2.33 (0.0917)
383845200 2.31 (0.0909)
1 BLOCK (398507704)
2 DUMMY SHAFT (398507702) A 14-064
Preload adjusting spacer
Fig. 49
383695201 56.2 (2.213)

Torque (Drive pinion nut): 383695202 56.4 (2.220)
167 - 196 N'm (17.0 - 20.0 kg-m, 123 - 145 ft-Ib) 383695203 56.6 (2.228)
383695204 56.8 (2.236)
383695205 57.0 (2.244)
383695206 57.2 (2.252)
24
4WD SYSTEM 3-4
3) Adjusting drive pinion height Pinion height adjusting washers
Adjust drive pinion height with washer installed between rear
bearing cone and the back of pinion gear. Part No. Thickness mm (in)
(1) Install Dummy Shaft, Collar and Gauge, as shown in
the figure, and apply the specified preload on the bearings. 383495200 3.09 (0.1217)
(Refer to 2) Adjusting preload for front and rear 383505200 3.12 (0.1228)
bearings. ) 383515200 3.15 (0.1240)
383525200 3.18 (0.1252)
At this time, install a pinion height adjusting washer which is 383535200 3.21 (0.1264)
temporarily selected or the same as that used before. 383545200 3.24 (0.1276)
383555200 3.27 (0.1287)
383565200 3.30 (0.1299)
383575200 3.33 (0.1311)
CD ® RH N
@ 383585200 3.36 (0.1323)
383595200 3.39 (0.1335)
383605200 3.42 (0.1346)
383615200 3.45 (0.1358)
383625200 3.48 (0.1370)
383635200 3.51 (0.1382)
383645200 3.54 (0.1394)
383655200 3.57 (0.1406)
383665200 3.60 (0.1417)
1 DUMMY COLLAR (398507703) 383675200 3.63 (0.1429)
Pinion height
2 DUMMY SHAFT (398507702) 3.66 (0.1441)
adjusting washer 383685200
3 GAUGE (398507701)
A14·027
4) Install the selected pinion height adjusting washer on

drive pinion, and press the rear bearing cone into position with
(2) Measure the clearance N between the end of Gauge INSTALLER (398177700).
and the end surface of Dummy Shaft by using a thickness
gauge.
Make sure there is no clearance between the case and Gauge.
(3) Obtain the thickness of pinion height adjusting

washer to be inserted from the following formula, and
replace the temporarily installed washer with this one.
T = To + N - (H x 0.01) - 0.20 (mm)
where
T = Thickness of pinion height adjusting washer (mm)
To = Thickness of washer temporarily inserted (mm) 1 Drive pinion
N = Reading of thickness gauge (mm) 2 INSTALLER (398177700) A14·066
H = Figure marked on drive pinion head
(Example of calculation)
To = 2.20 + 1.20 = 3.40 mm
N =0.23 mm H = +1,
T = 3.40 + 0.23 - 0.01 - 0.20 = 3.42 5) Insert drive pinion into differential carrier, install the
Result: Thickness = 3.42 mm previously selected preload adjusting spacer and washer.
Therefore use the washer 383605200. 6) Press·fit front bearing cone into carrier.
25
3-4 4WD SYSTEM
10) Install self-locking nut.
CD
(V--t-...
1 INSTALLER (899580100)
2 DUMMY COLLAR (398507703) FLANGE WRENCH
3 WEIGHT (399780104) A14-067 (398427700)
Fig. 53 A14-092
Fig. 56
7) Insert spacer, then press-fit pilot bearing with WEIGHT
(399780104) and INSTALLER (899580100).
Torque (Drive pinion nut}:

167 - 196 N'm (17.0 - 20.0 kg-m, 123 - 145 ft-Ib)
11) Assembling differential case

Install side gears and pinion mate gears, with their thrust
washers and pinion mate shaft, into differential case.
Apply gear oil on both sides of the washer and on the side gear
shaft before installing.
1 INSTALLER (899580100) Insert the pinion mate shaft into the differential case by
2 Pilot bearing A 14-068 aligning the lock pin holes.
~----------------------------------------~
Fig. 54
(1) Measure the clearance between differential case and
the back of side gear.
8) Fit a new oil seal with DRIFT (398417700). (2) Adjust the clearance as specified by selecting side gear
thrust washer.
Apply grease between the oil seal lips. (Refer to 1) Precautions
for assembling.) • Side gear back clearance:
0.1 - 0.2 mm (0.004 - 0.008 in)
9) Press-fit companion flange with INSTALLER
(899874100) and WEIGHT (399780104).
Side gear thrust washer
Part No. Thickness mm lin)
383445201 0.75 - 0.80 (0.0295 - 0.0315)

383445202 0.80 - 0.85 (0.0315 - 0.0335)
383445203 0.85 - 0.90 (0.0335 - 0.0354)
(3) Check the condition of rotation after applying oil to

the gear tooth surfaces and thrust surfaces.
(4) After driving in pinion shaft lock pin, stake the both
1 INSTALLER (899874100)
2 Companion flange
sides of the hole to prevent pin from falling off.
A14-069
(5) Install drive gear on differential case.
Fig. 55
26
4WD SYSTEM 3-4
(2) When replacing differential case, differential carrier,

Torque (Drive gear bolt): side bearing, and side bearing retainer, obtain the right
93 -113 N·m (9.5 -11.5 kg-m, 69 - 83 ft-Ib) and left retainer shim thickness from the following
formulas.
Tighten diagonally while tapping the bolt heads.
12) Before installing side bearing, measure the bearing width

by using a dial gauge, WEIGHT (398227700) and GAUGE
(398237700).
Standard bearing width:

20.00 mm (0.7874 in)
Set the dial gauge needle to zero, using a standard bearing or

block of specified height in advance.
A14·073
Fig. 59
T, (Left) = (A + C + G, - D) x 0.01 + 0.76 - E (mm)

T2 (Right) = (B + 0 + G 2 ) x 0.01 + 0.76 - F (mm)
T, & T 2: Thickness of left and right side bearing
1 WEIGHT (398227700) retainer shim (mm)
2 GAUGE (398237700) A&B Number marked on differential carrier.
3 Side bearing A14·071 C&D Number marked on differential case.
E&F Difference of width of left and right side
Fig. 57
bearing from standard width 20.0 mm, ex-
pressed in a unit of 0.01 mm.
For example, if the bearing measured width
13) Press side bearing cone onto differential case with is 19.89 mm, value of E or F is as follows.
DRIFT (398487700) and ADAPTER (398497701) included 20.00 - 19.89 = 0.11 (E or F)
in PULLER SET (399527700). G, & G 2 : Number marked on side bearing retainer.
C&D
Side bearing
retainer
1 DRIFT (398487700)
G
2 ADAPTER (398497701) A 14-072 A14-074
14) Adjusting side bearing retainer shims If a number is not marked, regard it as zero.
(1) The drive gear backlash and side bearing preload can
be determined by the side bearing retainer sh im thickness. Use several shims to obtain the calculated thickness.
27
3-4 4WD SYSTEM
Side bearing retainer shims The correct shims are as follows
Thickness Q'tv
Part No. Thickness mm (in) 0.25 x 1 = 0.25
0.50 x 1 =0.50
383475201 0.20 (0.0079)
Total shim thickness = 0.75 mm
383475202 0.25 (0.0098)
383475203 0.30 (0.0118)
(3) Install the differential case ASSY into differential
383475204 0.40 (0.0157)
carrier in the reverse order of disassembling.
383475205 0.50 (0.0197)
(4) Fit the selected shims and a·ring on side bearing
retainer and install them on differential carrier with the
arrow mark on the retainer directed as shown in Figure.
Example of calculation
Ex.1 Be careful that side bearing cup is not damaged by bearing
A = 5, B = 5, C = 3, D = 3, G, = 4, G2 = 1, roller.
E = 0.10 mm, F 0.15 mm
Left side
T, = (A +C + G, - D) x 0.01 +0.76- E
= (5 + 3 + 4 - 3) x 0.01 + 0.76 - 0.10
= 0.09 + 0.76 - 0.10
= 0.75 mm
The correct shims are as follows
Thickness Q'tv
0.25 x 1 =0.25
0.50 x 1 =0.50
Total shim thickness =0.75 mm
Right side
T2 = (B + D + G2 ) x 0.01 +0.76- F A14·031
= (5 + 3 + 1) x 0.01 + 0.76 - 0.15
= 0.09 + 0.76 - 0.15 Fig. 61
=0.70 mm
The correct sh ims are as follows (5) Tighten side bearing retai ner bolts.
Thickness Q'tv
0.20 x 1 =0.20 On vehicle with LSD, apply a coat of Three Bond 1215 (PIN
0.50 x =0.50 004403007) to threads.
Total shim thickness = 0.70 mm
Ex.2 Torque (Side bearing retainer):
A = 2, B = 3, C = 0, D = 3, G, =2, G2 = 3, 9 - 12 N'm (0.9 - 1.2 kg-m, 6.5 - 8.7 ft-Ib)
E = 0.22 mm, F = 0.10 mm
(6) Measure the drive gear·to·drive pinion backlash.
Left side
If the reading is not within the specified range, correct bV
T, = (A + C + G, - D) x 0.01 + 0.76 - E
decreasing the shim thickness on one side and increasing
= (2 + 0 + 2 - 3) x 0.01 + 0.76 - 0.22
the shim thickness on the other side the same amount.
= 0.01 + 0.76 - 0.22
Total shim thickness must be the same to maintain proper
= 0.55 mm
preload.
The correct shims are as follows
Thickness Q'ty Backlash:
0.25 x 1 = 0.25 0.10 - 0.20 mm (0.0039 - 0.0079 in)
0.30 x =0.30
Total shim thickness =0.55 mm
Right side
T 2 = (B + D + G 2 ) X 0.01 + 0.76 - F
=(3+3+3)xO.01 +0.76-0.10
= 0.09 + 0.76 - 0.10
=0.75 mm
28
4WD SYSTEM 3-4
15) Checking and adjusting tooth contact of drive gear.
(1) Paint evenly both sides of three or four teeth on
drive gear with red lead. Check the contact pattern after
rotating drive gear several revolutions back and forth until
definite contact pattern develops on drive gear.
(2) When the contact pattern is incorrect, readjust
according to the instructions given in "Tooth contact
pattern".
Be sure to wipe off red lead completely upon completion
of adjustment.
(3) After completing the above adjustment, install oil
seal in side bearing retainer.
A14-032
a. Use DRIFT (398437700) to press the oil seal into position.
Fig. 62
b. Apply chassis grease between the oil seal lips.
(4) Install rear cover.
(7) At the same time, measure the turning resistance of

Torque (Rear cover bolt):
drive pinion. Compared with the resistance when differ-
19 - 25 N·m (1.9 - 2.6 kg-m, 14 - 19 ft-Ib)
ential case is not installed, if the increase of the
resistance is not within the specified range, readjust side
bearing retainer shims.
Turning resistance increase:

.J. 0.1 - 0.6 N'm (1 - 6 kg-cm, 0.9 - 5.2 in-Ib)
..,
~ (8) Recheck drive gear-to-pinion backlash after readjust-
MOUNTING
ing shims.
(9) Check the drive gear runout on its back surface, and
1) Raise differential ASSY using a jack. Remount the
make sure pinion and drive gear rotate smoothly.
differential assembly by temporarily tightening four self-
locking nuts at the front and two self-locking nuts at the rear.
Limit of runout:
2) Install other parts in the reverse order of dismounting.
0.05 mm (0.0020 in)
3) After installation fill differential carrier with gear oil to
the upper plug level.
Oil capacity:
0.8Q (1.7 US pt, 1.4 Imp pt)
Dial gauge
A14-033
Fig. 63
29
3-4 4WD SYSTEM
TOOTH CONTACT PATTERN
Condition Contact pattern Adjustment
Correct tooth contact
Tooth contact pattern slightly

shifted toward toe under no ~~
load rotation.
(When loaded, contact pattern
moves toward heel.)
-
Face contact
Backlash is too large.
4
-
-+t? ~
~
This may cause noise and chip- Increase thickness of drive pinion height
ping at tooth ends. adjusting washer in order to bring drive pinion
closer to drive gear center.
Flank contact
Backlash is too small.

4(1 +~ y ')
This may cause noise and Reduce thickness of drive pinion height
stepped wear on surfaces. adjusting washer in order to move drive pinion
away from drive gear.
Toe contact
$ .. ~ ¥ ~
Contact area is small. Adjust as for flank contact.

This may cause chipping at toe
ends.
Heel contact
£f
-
-+~
:& 0
Contact area is small. Adjust as for face contact.
This may cause chipping at heel
ends.
A13-164
Fig. 64
30
4WD SYSTEM 3-4
TROUBLESHOOTING
Rear Differential
Symptom and possible cause Remedy
Oil leakage
• Worn, scratched, or incorrectly seated front or side Repair or replace.

oil seal. Scored, battered, or excessively worn sliding
surface of companion flange.
• Clogged or damaged air breather. Clean, repair or replace.
• Loose bolts on differential spindle or side retainer, or Tighten bolts to specified torque. Replace a-ring.
incorrectly fitted a-ring.
• Loose rear cover attach ing bolts or damaged gasket. Tighten bolts to specified torque. Replace gasket and
apply liquid packing.
• Loose oil filler or drain plug. Retighten and apply liquid packing.
• Wear, damage or incorrectly fitting for spindle, side Repair or replace.
retainer and oil seal.
Seizure
Seized or damaged parts should be replaced, and also other parts should be thoroughly checked for any defect and
,:;: should be repaired or replaced as required.
'i
• Insufficient backlash for hypoid gear. Readjust or replace.

• Excessive preload for side, rear, or front bearing. Readjust or replace.
• Insufficient or improper oil used. Replace seized part and fill with specified oil to specified
level.
Damage
Damaged parts should be replaced, and also other parts should be thoroughly checked for any defect and should be
repaired or replaced as required.
• Improper backlash for hypoid gear. Replace.

• Insufficient or excessive preload for side, rear, or Readjust or replace.
front bearing.
• Excessive backlash for differential gear. Replace gear or thrust washer.
• Loose bolts and nuts such as drive gear bolt. Retighten.
• Damage due to overloading. Replace.
Noises when starting or shifting gears

Noises may be caused by differential ASSY, universal joint, wheel bearing, etc. Find out what is actually making noise
before disassembly.
• Excessive backlash for hypoid gear. Readjust.

• Excessive backlash for differential gear. Replace gear or thrust washer.
• Insufficient preload for front or rear beari ng. Readjust.
• Loose self-locking nut. Tighten to specified torque.

• Loose bolts and nuts such as side bearing retainer Tighten to specified torque.
attaching bolt.
31
-,
3-4 4WD SYSTEM
Symptom and Possible cause Remedy
Noises when cornering
• Damaged differential gear. Replace.
• Excessive wear or damage of thrust washer. Replace.
• Broken pinion mate shaft. Replace.
• Seized or damaged side bearing. Replace.
Gear noises
Since noises from engine, muffler, transmission, propeller shaft, wheel bearings, tires, and body are sometimes mistaken
for noises from differential ASSY, be careful in checking them. Inspection methods to locate noises include coasting,
accelerating, cruising, and jacking up all four wheels. Perform these inspections according to condition of trouble.
When listening to noises, shift gears into four wheel drive and fourth speed position, trying to pick up only differential
noise.
• Improper tooth contact of hypoid gear. Readjust or replace hypoid gear set.
• Improper backlash for hypoid gear. Readjust.
• Scored or chipped teeth of hypoid gear. Replace hypoid gear set.
• Seized hypoid gear. Replace hypoid gear set.
• Improper preload for front or rear bearings. Readjust.
• Seized, scored, or chipped front or rear bearing. Replace.
• Seized, scored, or chipped side bearing. Replace.
• Vibrating differential carrier. Replace.
Propeller Shaft
Trouble and possible cause Remedy
Vibration of propeller shaft

Vibration is caused by propeller shaft during operation and is transferred to vehicle body. Generally vibration increases
in proportion to vehicle speed.
• Worn or damaged universal joint needle bearing. Replace.
• Unbalanced propeller shaft due to bend or dent. Replace.
• Loose installation of propeller shaft. Retighten.
• Worn or damaged center bearing and damaged center

mounting rubber.
Replace.
Tapping when starting and noise while cruising, caused by propeller shaft.
• Worn or damaged universal joint. Replace.
• Worn spline of sleeve yoke. Replace.
• Loose installation of propeller shaft. Retighten.
• Loose installation of joint. Adjust snap ring.
• Worn or damaged center bearing and damaged center

mounting rubber.
Replace.
Vibration while cruising may be caused by an unbalanced tire, improper tire inflation pressure, improper wheel alignment, etc.
32
Publication No. G140BE C2>
";1!
IssuEfd: July 1987 A
Printed in Japan M-4.2
FOREWORD
This service manual has been prepared to provide SUBARU service personnel with the necessary information and
The manual includes the procedures for maintenance, disassembling, reassembling, inspection and adjustment of
components and trouble-shooting for guidance of both the fully qualified and the less-experiencedmechanics.
information available a t the time of publication approval.
I FUJI HEAVY INDUSTRIES LTD.

I
This service manual is divided into four volumes. Each volume consists of Section 1, Section 2, 3, Section 4, 5,
3. Component parts
5. Trouble-shooting
I
SUBARU, and @ are registered trademarks of FUJI HEAVY INDUSTRIES LTD.

© Copyright 1987 F U J I HEAVY INDUSTRIES LTD. All rights reserved.
Not to be reproduced in whole or in part without the prior written permission

TABLE OF CONTENTS
4- 1 Suspension
4- 2 Wheels and Axles
4-3 Steering System
4-5 Pedal System and Control Cables

4- 6 Heater and Ventilator
BODY SECTION
ELECTRICAL SECTION
MECHANICAL COMPONENTS
SECTION
SUBARU
SERVICE
MANUAL
BODY SECTION
ABBREVIATION LIST
A/C Air Conditioner F RH Front Right-hand
ALR Automatic Locking Retractor F sus Front suspension
approx approximately GND Ground
ASSY Assembly hex hexagon
AT Automatic Transmission ID Inside Diameter
BI-LEV Bi-level IG Ignition
BJ Bell Joint IMACA International Mobile Air Conditioning
BP British Petroleum Association Inc.
B power Battery power ISC ldle Speed Control
Carb Carburetor K/D Kickdown
CGR Constant Gear Ratio LH Left-hand
CIRC Circulation LWR Lower
CP Complete MPFl Multi Point Fuel Injection
CTR F LH Center Front Left-hand MT Manual Transmission
CTR R Center Rear PCD Pitch Circle Diameter
CVJ Constant Velocity Joint Pd Discharge pressure
DEF Defroster PHV Pressure Hold Valve
dia Diameter P/N Parts Number
DOJ Double Offset Joint Ps Suction pressure
E/A Energy Absorbing R-12 Refrigerant-1 2
E/G Engine R DPV Rear Dual Proportioning Valve
EGI Electronic Controlled Gasoline RH Right-hand
Injection RL Rear left
ELR Emergency Locking Retractor R LH Rear Left-hand
..
ERB Emergency Release Buckle RQ Rear Quarter
Ex Example RR Rear right
F/C Fresh/Circulation SD Side
FFV Fast Fill Valve S/R Single Range
FICD Fast ldle Control Device SV plate Suction Valve plate
FL Front left TDC Top Dead Center
F LH Front Left-hand UPR Upper
FMVSS Federal Motor Vehicle Safety Standard VGR Variable Gear Ratio
FR Front right 4WD D/R 4-Wheel Drive Dual Range
4WD S/R 4-Wheel Drive Single Range
INDEX
Air Bleeding ............................................................... 4-4-45 Heater Unit ................................................................. 4-6-10
Air (Pneumatic) Suspension .................................... 4-1- 4 Hill-Holder ................................................................... 4-4- 7
Air Tank Assembly ................................................... 4-1-43 Hill-Holder ................................................................... 4-4-18
Auto-Door Lock Actuator ........................................ 5-2-14 Hill-Holder ................................................................... 4-4-42
Auto-Door Lock Switch ........................................... 5-2-14 Hill-Holder ................................................................... 4-4-50
Automatic Shoulder Belt .......................................... 5-3-24 Hood Lock ................................................................. 5-1-23
Blower Assembly ....................................................... 4-6-10 Hood Lock Release Cable ...................................... 5-1-24
Brake Booster ........................................................... 4-4- 5 Inner Remote Assembly .......................................... 5-2- 9
Brake Booster ........................................................... 4-4-17 Inner Trim ................................................................... 5-3- 8
Brake Booster ........................................................... 4-4-37 Inner Trim ................................................................... 5-3-19
Brake Fluid Level Indicator ..................................... 4-4-45 Instrument Panel ....................................................... 5-4- 4
Brake Hose ................................................................ 4-4-40 Key Lock ....................................................... ............. 5-2- 9
Checker ....................................................................... 5-2- 8 (Manual Steering System) ....................................... 4-3-31
Compressor ................................................................ 4-7-23 Master Cylinder ......................................................... 4-4- 2
Compressor Clutch ................................................... 4-7-23 Master Cylinder ......................................................... 4-4-36
Compressor & Drier Assembly .............................. 4-1-42 Master Cylinder (Except XT6) ................................ 4-4-15
Condenser .................................................................. 4-7-35 Master Cylinder for XT6 .......................................... 4-4-16
Console Box .............................................................. 5-3-18 Microswitch ................................................................ 4-7-40
Control Valve (Power Steering Gearbox) ............. 4-3-52 Motor Pump & Power Controller .......................... 4-3-75
Cover and Molding .. ...... ................ .......... ....... .......... 5-1-37 Mud Guard ................................................................. 5-1-36
Disc Brake .................................................................. 4-4- 2 Mud Guard R ............................................................ 5-1-36
Door and Hinge ........................................................ 5-2- 7 Oil Pump (Power Steering System) ...................... 4-3-60
Door Glass ................................................................. 5-2-12 Outer Handle .............................................................. 5-2-10
Door Latch ................................................................. 5-2- 9 Outer Weatherstrip .................................................... 5-2-10
Door Sash .................................................................. 5-2-13 Pad Wear Indicator ................................................... 4-4- 2
Door Striker ............................................................... 5-2-14 Parking (Hand) Brake ............................................... 4-4-19
Door Weatherstrip ..................................................... 5-2-10 Parking (Hand) Brake ............................................... 4-4-44
Electronic-controlled Motor Drive Power Pedal ............................................................................ 4-5- 6
Steering ....................................................................... 4-3- 5 Pocket ......................................................................... 5-4- 5
Entire Brake System ................................................ 4-4-48 Power Steering System (Except for XT6) ........... 4-3-15
Evaporator .................................................................. 4-7-37 Power Steering System for XT6 ............................ 4-3-17
Exhaust Cover ........................................................... 5-1-36 Pressure Switch ........................................................ 4-7-40
Flexible Hose ............................................................. 4-7-38 Proportioning Valve .... ............................. .................. 4-4- 5
Fluid Line (Power Steering System) ..................... 4-3-70 Proportioning Valve ................................................... 4-4-41
Front Air Suspension Assembly ............................ 4-1-39 Pulser Amplifier ......................................................... 4-7-41
Front Axle .................................................................. 4-2- 2 Rear Air Suspension Assembly ............................. 4-1-41
Front Axle .................................................................. 4-2- 9 Rear Axle .................................................................... 4-2- 4
Front Axle .................................................................. 4-2-13 Rear Axle .................................................................... 4-2-11
Front Ball Joint .......................................................... 4-1-33 Rear Axle (FWD) ....................................................... 4-2-24
Front Bumper ............................................................ 5-1-25 Rear Axle (4WD) ....................................................... 4-2-26
Front Crossmember .................................................. 4-1-32 Rear Bumper ............................................................. 5-1-27
Front Disc Brake ...................................................... 4-4-12 Rear Coil Spring ....................................................... 4-1-36
Front Disc Brake ...................................................... 4-4-20 Rear Disc Brake ....................................................... 4-4-13
Front Fender ........ ....................... ..... ................ .......... 5-1-35 Rear Disc Brake ....................................................... 4-4-30
Front Seat ... ............. ............. ...... .......................... ..... 5-3- 2 Rear Drum Brake ...................................................... 4-4-33
Front Seat .................................................................. 5-3-12 Rear Drum Brake (FWD) ......................................... 4-4-14
Front Stabilizer .......................................................... 4-1-31 Rear Quarter Glass ........ .................... ......... ............. 5-2-23
Front Strut Assembly .... ........................................... 4-1-27 Rear Seat ................................................................... 5-3- 4
Front Suspension ...................................................... 4-1- 2 Rear Seat ................................................................... 5-3-12
Front Suspension Assembly ................................... 4-1-25 Rear Suspension ....................................................... 4-1- 3
Glass Stopper ............................................................ 5-2-1'3 Rear Suspension Assembly .................................... 4-1-34
Ground Clearance Measuring Rearview Mirror ......................................................... 5-1-36
(4WD Models Only) .................................................. 4-1-24 Rear Window Glass .................................................. 5-2-23
Gusset ......................................................................... 5-2-13 Receiver Drier ............................................................ 4-7-36
Heater Control (Control Wing, Temperature Relay and Fuse ......................................................... 4-7-39
Control Lever and Fan Switch Lever) .................. 4-6-11 Replacement of Brake Fluid ................................... 4-4-46
Roof Weatherstrip .... ...... .... ...... .......... ............ ........... 5-2-11 Torsion Bar ................................................................ 5-1-24
Sealing Cover ...... ,...................................................... 5-2- 8 Trim Cushion and Trim Back
Seat Belts ............ ,.......................................... ,........... 5-3- 5 (1800 cc DL model) ................................................. 5-3-13
Seat Belts ................................................................... 5-3-14 Trim Panel .................................................................. 5-2- 7
Stabilizer ..................................................................... 5-2-11 Trunk Lid .. ........ .......... ...... ............ ........ .............. ........ 5-1-24
Steering Column ........................................................ 4-3- 3 Trunk Lid Lock Assembly and Key Cylinder .. ..... 5-1-25
Steering Column ........................................................ 4-3-13 VGR (Variable Gear Ratio) Gear Box .................. 4-3- 2
Steering Column ........................................................ 4-3-18 Wheel and Tire .......................................................... 4-2-29
Steering Gearbox Window Regulator ..................................................... 5-2-12
(Manual Steering System) ....................................... 4-3-31 Windshield ................................................................... 5-2-20
Steering Gearbox
(Power Steering System) ............................... :......... 4-3-41
FOREWORD
components and trouble-shooting for guidance of both the fully qualified and the less-experiencedmechanics.
information available a t the time of publication approval.
I FUJI HEAVY INDUSTRIES LTD.

I
This service manual is divided into four volumes. Each volume consists of Section 1, Section 2, 3, Section 4, 5,
3. Component parts
5. Trouble-shooting
I
SUBARU, and @ are registered trademarks of FUJI HEAVY INDUSTRIES LTD.

© Copyright 1987 F U J I HEAVY INDUSTRIES LTD. All rights reserved.
Not to be reproduced in whole or in part without the prior written permission

TABLE OF CONTENTS
4- 1 Suspension
4- 2 Wheels and Axles
4-3 Steering System
4-5 Pedal System and Control Cables

4- 6 Heater and Ventilator
BODY SECTION
ELECTRICAL SECTION
MECHANICAL COMPONENTS
SECTION
SUBARU
SERVICE
MANUAL
BODY SECTION
ABBREVIATION LIST
A/C Air Conditioner F RH Front Right-hand
ALR Automatic Locking Retractor F sus Front suspension
approx approximately GND Ground
ASSY Assembly hex hexagon
AT Automatic Transmission ID Inside Diameter
BI-LEV Bi-level IG Ignition
BJ Bell Joint IMACA International Mobile Air Conditioning
BP British Petroleum Association Inc.
B power Battery power ISC ldle Speed Control
Carb Carburetor K/D Kickdown
CGR Constant Gear Ratio LH Left-hand
CIRC Circulation LWR Lower
CP Complete MPFl Multi Point Fuel Injection
CTR F LH Center Front Left-hand MT Manual Transmission
CTR R Center Rear PCD Pitch Circle Diameter
CVJ Constant Velocity Joint Pd Discharge pressure
DEF Defroster PHV Pressure Hold Valve
dia Diameter P/N Parts Number
DOJ Double Offset Joint Ps Suction pressure
E/A Energy Absorbing R-12 Refrigerant-1 2
E/G Engine R DPV Rear Dual Proportioning Valve
EGI Electronic Controlled Gasoline RH Right-hand
Injection RL Rear left
ELR Emergency Locking Retractor R LH Rear Left-hand
..
ERB Emergency Release Buckle RQ Rear Quarter
Ex Example RR Rear right
F/C Fresh/Circulation SD Side
FFV Fast Fill Valve S/R Single Range
FICD Fast ldle Control Device SV plate Suction Valve plate
FL Front left TDC Top Dead Center
F LH Front Left-hand UPR Upper
FMVSS Federal Motor Vehicle Safety Standard VGR Variable Gear Ratio
FR Front right 4WD D/R 4-Wheel Drive Dual Range
4WD S/R 4-Wheel Drive Single Range
SUSPENSION
-
Page
SUBARU *1MECHANISM AND FUNCTION........... . . . . . . . . . . . . . . .. 2

SPECIFICATIONS AND SERVICE DATA .................... 13
COMPONENT PARTS .................................. 16
1988 SERVICE PROCEDURE FOR CONVENTIONAL SUSPENSION ..... 20

Inspection and Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20
Ground Clearance Measuring (4WD Models Only) ............... 24
Front Suspension Assembly ............................. 25
Front Strut Assembly ................................. 27
Front Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 31
Front Crossmember .................................. 32
Front Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 33
Rear Suspension Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 34
Rear Coil Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 36
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 38
*1*2SERVICE PROCEDURE FOR AIR (PNEUMATIC) SUSPENSION ... 39
General Precautions .................................. 39
Front Air Suspension Assembly. . . . . . . . . . . . . . . . . . . . . . . . . .. 39
Rear Air Suspension Assembly ........................... 41
Compressor & Drier Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . .. 42
Air Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 43
*1TROUBLESHOOTING .................................. 44
*1 Canada models are equipped with a height control function. Also refer to the
87MV manual.
*2 In this topic are described the different points of the air (pneumatic) suspension
from the explanations described in the above topic. Accordingly, use this topic
together with the above topic.
4-1 SUSPENSION

Front Suspension
(~J 1 Strut mount

2
3
Damper strut
Housing
4 Front crossmember
CD 5 Transverse link
6 Ball joint
7 Leading rod
8 Stabilizer
L4·1359
Fig. 1
The front suspension is a strut·type independent suspension, by nut at the outer end, and inner end is fitted to the front
with cylindrical double·action oil damper and coil spring [or crossmember through the cushion rubber.
air spring for air (pneumatic) suspension). The leading rod is bolted at the outer end to the transverse
The top of oil damper is mounted to the body through the link and the inner end of leading rod is connected to the
cushion rubber, which has resulted in elimination of any leading rod bracket through the cushion rubber. Both front
vibration and improved passenger comfort cooperating with crossmember and leading rod bracket are bolted to the vehicle
other rubbers. body.
This type also maintains a wide distance between the upper The stabilizer is attached to the front crossmember through
and lower supporting points and makes adjustment of the the cushion rubbers and its ends are connected to the
camber or caster unnecessary. transverse links through the rubber bushings.
The transverse link has a maintenance free ball joint installed
2
SUSPENSION 4-1
Rear Suspension
Outer arm
Stabilizer (installed on some models)
~ Shock absorber and coil spring

[or air spring for air (pneumatic)
suspension 1
L4-1360
Fig. 2
The rear suspension is of semi-trailing arm type independent One end of inner arm is bolted to crossmember through bush-
suspension, with cylindrical double-action oil damper and ing, and another end bolted with outer arm is mounted to
coil spring [or air spring for air (pneumatic) suspension). body through shock absorber ASSY.
Crossmember is installed to body frame with brackets at both The certain models have a stabilizer installed to inner arm via
ends via bushings. bushings.
3
4-1 SUSPENSION
Air (Pneumatic) Suspension

This system maintains constant ground clearance regardless Operation
of vehicle load. For this purpose air volume in each air spring
is adjusted according to a signal from a vehicle height sensor Ground clearance "constant"
which is installed in each air spring. When the ground clearance becomes smaller than the preset
level due to an increase in load, the vehicle height sensor built
into each rolling diaphragm type air spring issues a "low"
signal. If this condition lasts for a certain period of time, the
Features control unit judges that the ground clearance is low, and opens
the solenoid valve to send compressed air to the air spring
The air spring (ground clearance maintaining) adopted on
from the air tank (-arrow mark). As the ground clearance
the 4WD veh icle provides good riding comfort and stabilized
increases, the "low" signal from the sensor disappears, and the
driving even on rough roads.
control unit closes the solenoid valve. The ground clearance is
1) The air spring is adopted in place of the conventional
thus always held at a constant level.
metal spring to improve riding comfort.
If the pressure in the air tank drops, t~e tank pressure switch
2) A constant wheel stroke is available irrespective of the
operates the compressor until the pressure returns to the
load, and this results in reduced bumping shock on irregular specified level.
surfaces of the road.
If the ground clearance becomes larger than the preset level
3) The variable damping force mechanism built into the air
due to a load reduction, the sensor issues a "high" signal, and
spring keeps the damping force low to assure good riding
opens the solenoid valve of the respective air spring to allow
comfort while the wheel stroke is small. When the wheel
air to be released from the air spring (-----arrow mark). As
stroke increases, the damping force is made larger to improve
the ground clearance lowers, the "high" signal from the sensor
driveability on rough surfaces. This increase in damping force
disappears, and the control unit closes the solenoid valve.
also improves stability during high speeds.
4) The vehicle posture can always be maintained constant, so
that the light axis of the headlight will be maintained constant.
\'
SUSPENSION 4-1
1 Solenoid valve
2 Solenoid valve
3 Drier
4 Air discharge solenoid valve
5 Compressor
6 Air charge solenoid valve
7 Air tank
8 Pressure switch
9 Control un it
10 Shock absorber
11 Rolling diaphragm
12 Vehicle height sensor
10 _ _ Air circuit
[
_ A i r charge J
- - Electrical circuit ~- - Air discharge
L4-116
Fig. 3
Fusible link Fuse
Fusible link Fuse

31 30 Solenoid valve (Front-Right)
18
Ignition switch Solenoid valve (Front-Left)

Warning light in meter 15
2
Solenoid valve (Rear-Right)
16
Solenoid valve (Rear-Left)

17
.~
c:
8 ;:,
Vehicle height sensor (5 Solenoid valve (Air discharge)
~ Battery 35 ... 11
...
• •I
I
(Front-Right) ~====e===~ 27 c:
0
7 u
I Vehicle height sensor
19
( Front-Left) 36
1 ~====~====j
26 12
Vehicle height sensor 5
(Rear-Right) 23
25 Compressor Compressor
4 relay motor
Vehicle height sensor
L----t=====i 28
~~""'---------'1
(Rear-Left) 34 33
PresSu re switch
20
Connector (unit)
L4-1361
Fig. 4 Electrical circuit
5
4-1 SUSPENSION
Construction
The air suspension system consists of the following.
• A warning light which illuminates in case of trouble.
• Four vehicle height sensors (each built into its respective air
spring) which detect proper vehicle height for each wheel.
• Six solenoid valves.
• A control unit which opens and closes the solenoid valves
in proper order and procedure by judging the signals from
the vehicle height sensors.
• An air tank and an electric compressor which is operated
by the pressure switch.
• A drier and air piping.
Solenoid valve
Front suspension
Control unit
(Located under front left seat)
Air tank
L4·1362
Fig. 5 Air suspension layout
6
SUSPENSION 4-1
r--l
, ,
I JJ==
To front and rear
solenoid valve
-n-,.--,~"'1r -~
Air tank
@ 2 Pressure switch
3 Solenoid valve
@ 4 Compressor
5 Drier
\
CD ® CD ® ®
L4-998
Fig. 6 Air tank, compressor and drier
WARNING Light
The control unit registers a system malfunction when either of
the following conditions occurs. The warning light will blink
and subsequent control operations will stop.
a) When both HIGH and LOW signals are simultaneously
transm itted by one height-control sensor.
b) When control unit continuously sends a signal to the same
solenoid valve and compressor relay for 10 minutes due to EP"S !
air leakage or other problem_ C Warning light
L4-1363
Fig. 7 Indicator
7
4-1 SUSPENSION
Vehicle height sensor Solenoid valve (control valve)

Vehicle height sensor consists of reed switch and magnet. The This valve is operated according to a signal from control unit
reed switch is fixed on a body side part of air suspension when air is charged or discharged for air suspension.
ASSY and magnet is fixed on a wheel side part of it. Height
signal is generated according to the relation between the
positions of reed switch and magnet.
Solenoid valve
-----
~Magnet
Reed switch
Bracket
L4-121
Vehicle height sensor
Fig. 10
The shape of bracket differs according to the installing

Fig. 8 position.
Drier
Drier dries air which flows through the drier to air tank or
each air spring with silica gel in order to prevent freeze of
water in air pipe. Silica gel is refreshed by dry air when
discharging.
A residual pressure valve is provided so that the diaphragm can
always be held in the expanded state, hence a residual pressure
of 98 kPa (1 kg/cm 2 , 14 psi) remains in the air chamber even
Control unit after air discharge operation is completed.
The control unit receives signals from the veh icle height
sensors and others, and controls the solenoid valve of each air Silica gel
suspension as well as the compressor. The microcomputer
adopted in this control unit permits each wheel to be con-
trolled independently so as to obtain the optimum perform- Compressor
ance according to the loaded condition of the vehicle.
Air tank
or each air
spring
L4-122
Fig. 11
Air tank
Pressure switch and solenoid valve for air charge are incorpo-
L4-851 rated in air tank. The air tank is filled with compressed air of
F- ; g . - . - 9 - - - - - - - - - - - - - - - - - - - - - - - - - '
L 755 to 941 kPa (7.7 to 9.6 kg/cm2, 109 to 137 psi).
8
SUSPENSION 4-1
Pressure switch
If the pressure in the air tank rises, the pressure sensitive disc
pushes the guide pin up to open the moving contact, and the
switch is opened. When the pressure drops. the switch is
closed.
Pressure sensitive disc r-Moving contact

/
Guide pin
L4-1292
Fig. 12
9
4-1 SUSPENSION
Front and rear air suspension assemblies
Both air suspension ASSYs adopt air springs in place of the
conventional metal springs. A housing is provided on the
outside of the shock absorber, which can be stroked through
the function of the roll ing diaphragm.
:: ::
Strut mount
Helper
=
~~~~il~~~;~j
-II,;~~~:.4:- - - ---,.
:_\;/JV---\
Magnet
SOlenoid valve
Rolling diaphragm
Housing
Shock
absorber
Rolling diaphragm
Piston rod
Housing bracket
Front air suspension ASSY

Rear air suspension ASSY
Fig. 13
10
SUSPENSION 4-1
Air Pipe VARIABLE DAMPING FORCE MECHANISM

The air pipe is made of nylon, and the joint at the front strut This mechanism senses the wheel stroke position and gener-
is composed of a cap, air bushing, and O-ring. The air pipe is ates an optimum damping force in accordance with the road
secured by tightening the cap to the specified torque to crush and driving conditions.
the end of the air bushing.
Features
• Excellent riding comfort is assured when driving on general
paved surface, since the damping force is kept low when the
wheel stroke change is small.
• Both higher maneuverability on rough surfaces and in-
Air bushing creased stability at high speeds are assured, since the
damping force increases as the wheel stroke becomes large.
Cap Construction and operation

A metering pin is set up at the bottom center in the damper,
O-ring
which slides in a bore drilled in the axis of the piston rod.
L4-1293 A in the Figure indicates the condition where a hard damping
Fig. 14 force is being generated. Based on the same principle as the
conventional gas-charged damper, the dam ping force is gener-
ated by the orifice in the piston and the disc valves provided
All other joints adopt a quick joint whose construction is over and under the piston.
shown below. B in the Figure shows the condition where a soft damping
force is being generated. During this condition, the clearance
produced between the th in diameter portion of the metering
pin and the rod also serves as an oil passage (flow route
marked with *). hence damping force is smaller than that
generated in condition A.
L4-128
Fig. 15
11
4-1 SUSPENSION
Piston rod
Outer tube
I nner tube
Piston
Disc valve ~
~~~~ nn
:~: ~ :..:::
..
::::
..
.. ::::..
:.;.
Metering pin
Thin diameter I
portion ~
Fat diameter
portion
A. Oil flow for hard damping force B. Oil flow for soft damping force
L4·126
Fig. 16
12
SUSPENSION 4-1

SPECIFICATIONS
CONVENTIONAL SUSPENSION
1800 cc FWD 2700 cc FWD
Stabilizer Bar diameter mm (in) 19 (0.75) 20 (0.79)
Coil diameter mm (in) 130 (5.12)

Coil
spring Coefficient of spring
25.5 (2.6, 146) 30.4 (3.1, 174)
N/mm (kg/mm, Ib/in)
Front
suspension Outer cylinder length mm (in) 322.5 (12.70) 319 (12.56)
Piston rod diameter mm (in) 20 (0.79) 22 (0.87)

Damper
strut Damping force Expansion 981 (100,221)
[at the piston speed]
: N (kg, Ib) Compression 490 (50, 110)
Stabilizer Bar diameter mm (in) 16 (0.63)
Coil diameter mm (in) 78 (3.07)

Coil
spring Coefficient of spring
31.4 (3.2,179)
N/mm (kg/mm, Ib/in)
Rear Outer cylinder length mm (in) 279 (10.98)
suspension
Piston rod diameter mm (in) 12.5 (0.492)
, Shock
absorber Damping force 981 (100,221)
Expansion
[at the piston speed
0.3 m (1.0 ttl/sec]
Compression 490 (50, 110)
N (kg, Ib)
AIR (PNEUMATIC) SUSPENSION
Front Rear
1800 cc 2700 cc 1800 cc 2700 cc
Stabilizer Bar diameter mm (in) 19 (0.75) 20 (0.79) 20 (0.79)
Piston rod diameter mm (in) 20 (0.79) 22 (0.87) 12.5 (0.492)
1,372 1,177
Expansion 1,177 (120,265)
(140,309) (120,265)
Air Hard
Damping force
suspension [at the piston speed Compression 588 (60, 132) 588 (60, 132)
CP 0.3 m (1.0 ft)/sec]
Expansion 686 (70, 154) 981 (100,221) 981 (100,221)
N (kg, Ib) Soft
Compression 490 (50, 110) 490 (50, 110)
13
4-1 SUSPENSION
WHEEL ALIGNMENT
FWD 4WD
1800 2700 1800 2700

0
Camber (common difference: to° 45') 0 0°40' 0°50'
Caster (common difference: ±0045') 4° 05' 3°25' 3°30'
No~mal Minimum Maximum Normal Minimum Maximum
3 (0,12) 3 (0,12) 5 (0,20) 8 (0.31) 2 (0.08)

mm (in) 0(0)
IN OUT OUT OUT OUT
Service limit
--~~------ ------ ------ ------ ------- ------
0
~----
Toe Degrees: per wheel 0° 0°09' IN 0°09' OUT 0°15' OUT 0 24' OUT 0°06' OUT
1 (0.04) 1 (0.04) 5 (0.20) 6 (0.24) 4 (0.16)

mm (in) 0(0)
Service IN OUT OUT OUT OUT
Front standard *3 ----------- ------ - - - - - - 1 --------1 - - - - - - - ------..., ------
Degrees: per wheel 0° 0°03' IN 0°03' OUT 001S' OUT 001S' OUT 0°12' OUT
Service limit m/km (ft/mile) IN S -OUTS (iN 26- OUT26)

Side slip with
one occupant Service
m/km (ft/mile) IN 3 - OUT 3 (iN 16 - OUT 16)
standard *3
226+ 12 216 +12 248 +12 253+ 12

-22 -22 -22 -22
Grou nd clearance * 1 mm (in)
(8.90 ~g:~~) (8.50~g:~~) (9.76~:~~) (9.96 ~g:~~)
Camber (common difference: to° 45') 0

0
_0° 10'
----- Normal
0(0)
Minimum
3 (0.12) IN
Maximum
3 (0.12) OUT
mm (in)
Service limit ---------- ------------- - - - - - - - - - - - - - ------------
0 0
Toe Degrees: per wheel 0° 0 09' IN 0 09' OUT
mm(in) 0(0) 2 (O.OS) IN 2 (0.08) OUT

Rear Service --------- ~--~~~------
~-~~------- -----------
standard' 3 Degrees: per wheel 0° 0°06' IN 0°06' OUT
Side slip with one occupant m/km (ft/mile) INS - OUT 5 (I N 26 - OUT 26)
203 +10 200 +10 2S0 +10 248 +10

-20 -20 -20 -20
Grou nd clearance *2 mm(in)
(7.99~:~~) (7 .87 ~g:~~) (9.S4 ~g:~~) (9.76 ~g:~~)
*1 Measure the ground clearance at center of front end face of the transversa link attaching bolt.
*2 Measure the ground clearance at lower face of the crossmember.
*3 If the inspection date is out of "SERVICE LIMIT", readjust within "SERVICE STANDARD".
A A
•
Front
•
Front
B
B
B - A = Toe-in A - B = Toe-out
(l = Toe-out angle (per wheel)
(l = Toe-in angle (per wheel) A15-179 A15-180
Fig. 17 Toe-in Fig. 18 Toe-out
14
SUSPENSION 4-1
SERVICE DATA
CONVENTIONAL SUSPENSION
Front strut Piston rod deflection Limit 0.8 mm (0.031 in)/20 N (2 kg, 4 Ib)
AIR (PNEUMATIC) SUSPENSION
Recommended grease NOK 5EALUB 5-4

Recommended O-ring NOK material; A980
.,
15
4-1 SUSPENSION
COMPONENT PARTS
Conventional Suspension
Tightening torque: N'm (kg-ni, ft-Ib)

Tl: 51 - 67 (5.2 - 6.8, 38 - 49)
T2: 26 - 36 (2.7 - 3.7, 20 - 27)
T3: 64 - 83 (6.5 - 8.5, 47 - 61)
T4: 23 - 42 (2.3 - 4.3, 17 - 31)
T5: 78 - 98 (8.0 -10.0, 58 -72)
T6: 59 - 69 (6.0 -7.0,43 - 51)
T7: 20 - 29 (2.0 - 3.0,14 - 22)
T8: 39 (4.0, 29)
T9: 78 - 98 (8.0 - 10.0,58 - 72)
TlO: 21 - 28 (2.1 - 2.9,15 - 21)
Tl1: 113 -132 (11.5 -13.5,83 - 98)
I
i
I....
I
"- I
"'...j
1 Cap
2 Strut mount
3 Spacer
4 Upper spring seat
5 Rubber seat
6 Dust cover
7 Helper
8 Coil spring
9 Damper strut
10 Plate CP
11 Housing
12 Ball joint
13 Transverse link
14 Bushing
15 Leading rod bracket
16 Plate
17 Leading rod CP
18 Stabilizer plate
19 Bushing
20 Spacer
21 Stabilizer ASSY
22 Stabilizer clamp
23 Stabilizer bushing
24 Jack-up plate
25 Crossmember CP
Fig. 19 Front suspension
16
SUSPENSION 4-1
Tightening torque: N·m (kg.m, ft·lb)

T1: 18 - 25 (1.8 - 2.6, 13 - 19)
T2: 10 - 20 (1.0 - 2.0, 7.2 - 14.5)
T3: 88 - 127 (9.0 - 13.0,65 - 94)
T4: 88 - 118 (9.0 - 12.0,65 - 87)
T5: 18 - 22 (1.8 - 2.2,13 - 16)
T6: 69 - 118 (7.0 - 12.0,51 - 87)
T1: 88 - 103 (9.0 - 10.5,65 - 76)
T8: 69 - 88 (7.0 - 9.0, 51 - 65)
T9: 118 - 147 (12.0 - 15.0, 87 - 108)
T10: 127 - 147 (13.0 - 15.0, 94 - 108)
T11: 74 - 88 (7.5 - 9.0, 54 - 65)
~(FWD) Upper rubber plate

1
2 Upper rubber
3 Bracket CP
4 Lower rubber
(4WD) 5 Collar
I"
~~
6 Spring seat plate
7 Upper spri ng seat
""-, "'-, 8 Rubber seat
@~ "" ,,> Helper ASSY
,/'@ 0 V0 /-'~~"~
9
10
11
Coil spring
Shock absorber CP
*12 Rear stabilizer
13 Inner arm ASSY
14 Inner bushing
15 Rear stabilizer bushing
~",
16 Rear stabilizer clamp
'/,</""'/;' 17 Rear bushing
~
18 Uppar stopper
19 Front bushing
20 Crossmember CP
21 Bracket
22 Lower stopper
23 Outer bushing
24 Outer arm ASSY
* Air suspension vehicle only
Fig. 20 Rear suspension L4.1294
17
4-1 SUSPENSION
Air (Pneumatic) Suspension

I FRONT I T1: 5 -15 (0.5 -1.5,3.6 -11)
T2: 51 - 67 (5.2 - 6.8, 38 - 49)
T3: 26 - 36 (2.7 - 3.7, 20 - 27)
T4: 18 - 25 (1.8 - 2.6,13 -19)
T5: 10 - 20 (1.0 - 2.0, 7 -14)
T6: 5.4 - 9.3 (0.55 - 0.95, 4.0 - 6.9)
1 Front air suspension

2 Strut mount
3 Flange nut
4 O-ring
5 Bushing
I
f 6 Cap
f
f 7 Rear air suspension
f 8 Solenoid valve
f
9 Plate (upper rubber)
10 Upper rubber
11 Bracket
12 Lower rubber
13 Collar
14 Plate (upper)
CD
"-
"-
"-
,, ,
"
Fig. 21 Front and rear air suspension L4-1366
18
SUSPENSION 4-1
~@
I
I
I
~i i
~,
\\ ~
\ ,,)
~,
II "
,..-... ~ _ _ '"
® ®
1 Air tank
~ Pressure switch
Bracket
4 Solenoid valve (air ch
5 C
ompressor b arge)
6 Co racket
mpressor
7 Drier
8 Front air suspen '
9 Sol slon
10 enoid valve
Strut mount ca
® 11 Rear ' p
12 Prot air suspension
\
ector
\
\
\
\
\
\
\
\
\
--:~-------
\
Tightening torq'
T1 : 11 _ 13
ue.(1 N'm
1 (k g-m, ft-Ib)
T2:5.4-93(' -1.3,8-9)
T3: 10 _ 18 (1~05~ ~ 0.95,4.0 - 6.9)
T4: 5 _ 8 (0.5 0 .8,7- 13)
.8,3.6 5.8)
Fig. 22 L4-1010
19
4-1 SUSPENSION
SERVICE PROCEDURE FOR CONVENTIONAL

SUSPENSION
Inspection and Adjustment
The following chart outlines the basic inspection and adjustment procedures for the entire front suspension system. Regarding
specific procedures for individual parts, refer to the applicable instructions set forth in this manual.
• Front Suspension
Item to be checked Description Remarks
Vehicle posture
Park the vehicle on a level, solid surface, and check for lateral inclina- Visual inspection
tion of the vehicle.
a. Make sure that all tires are inflated to the specified pressure.
Coil spring b. If any noticeable lateral vehicle inclination is detected visually,
determine whether it is due to permanent deformation of coil spring(s),
improper body alignment, or other factors.
c. If vehicle inclination (to either side) is due to permanent deforma-
tion of coil spring, remove the coil spring and replace it.
d. Replace the coil spring if it is cracked, broken or damaged.
Damping Force/Noise
Rock the left side of the vehicle up and down, and then rock the right Visual and tactile
side, to check for noise or variances in vehicle posture. inspection
If the up-and-down movement (when hands have been released)

continues longer than usual or if any abnormal noise is detected, check
the condition of the strut itself.
Refer to instructions for inspection procedures.
Damper strut Oil leakage
Check for oil leaks at or around the lower portion of the strut and oil
seal ASSY.
It is normal for a trace of oil to be oozing at the oil seal ASSY.
Cracks, Damage or Deformation

Check the outer shell for any cracks, damage or deformation. Replace
the dust cover if it is damaged.
20
SUSPENSION 4-1
Preliminary Inspection
Before checking/adjusting front wheel alignment, be sure to make a
prior inspection of the following points and repair/replace the damaged
portions/parts as necessary.
• Tire pressure
• Wear or damage of tires
• Wheel balance
• Looseness on suspension
• Looseness and smooth operation on axle Iinkage and connection
• Looseness and smooth operation on steering Iinkage and connection
• Shock absorber operation and oil leakage
• Damage, deformation etc. on body attaching portion of suspension,
axle and steering linkage and connection
• Vehicle height [It is recommended that the difference of vehicle
height between the front and rear ends, or the left and right sides is
less than 10 mm (0.39 in) in the unloaded condition.)
• Stain, rust, grease leakage etc. on front end parts
Toe Adjustment
Inflate all tires to the specified pressure, and park the vehicle Toe gauge
(unloaded) on a level, solid surface.
Loosen both the left and right lock nuts CD. If the toe is not within
the specified value when measured with a toe gauge, turn the left and
right tie rods @ equal amounts until the toe is within the specified
range.
Wheel alignment
L4-1367
Fig. 23
Torque (lock nut):

78 - 88 N-m (8 - 9 kg-m, 58 - 65 ft-Ib)
a. If the tie-rod and the tie-rod end have been disassembled, assemble
these parts in advance so that the toe is near the specified range.
b. Both the left and right tie-rods are right-hand threaded. To increase
toe-in, turn both tie-rods counterclockwise equal amounts (as viewed
from the outside of the vehicle).
c. Always adjust the toe after steering angle adjustment.
d. Refer to the "Specifications" for the specified toe.
21
4-1 SUSPENSION
Camber and Caster

Neither camber nor caster can be adjusted. To measure camber and Turning radius gauge
caster, place the wheel to be measured on the turning radius gauge CD. Alignment gauge
and make sure the vehicle is level. Set ADAPTER @ (926500000) ADAPTER
into the center of the wheel. and then install the alignment gauge (1). (926500000)
Wheel alignment
(continued)
A15·147
Fig. 24
a. Refer to the "Specifications" for the camber and caster values.

b. If the camber or caster measurement is not within the specified
range, check for body alignment, deformed transverse link or faulty
parts. Repair or replace the parts, if necessary.
Looseness
Check each mounting portion of the following for looseness and inspect
the castle nuts for missing cotter pins.
(1) Strut mount to vehicle body (8) Transverse link to front
(2) Damper strut piston rod to strut crossmember
mount (9) Crossmember to body
(3) Damper strut to housing (10) Stabilizer to front
(4) Housing to ball joint crossmember
(5) Ball joint to transverse link (11 ) Stabilizer to transverse
(6) Transverse link to leading rod link
(7) Leading rod to leading rod bracket (12) Leading rod bracket to
Entire front
body
suspension Cracks. Damage or Deformation
Check the following parts for cracks. damage or deformation. Visual inspection
(1) Crossmember (front) (5) Transverse link
(2) Damper strut (6) Leading rod
(3) Housing (7) Stabilizer
(4) Ball joint (8) Leading rod bracket
Rubber Parts
Check the following parts for deterioration, cracks or damage. Visual inspection
(1) Strut mount (4) Transverse link bushing
(2) Damper strut dust cover (5) Leading rod bushing
(3) Ball joint boot (6) Stabilizer bushing
22
SUSPENSION 4-1
• Rear Suspension
Vehicle posture
Park the vehicle on a level, solid surface, and check for lateral inclina- Visual inspection
tion of the veh icle.
a. Make sure that all tires are inflated to the specified pressure.
Coil spring b. If any noticeable lateral vehicle inclination is detected visually,
determine whether it is due to permanent deformation of coil spring(s),
improper body alignment, or other factors.
c. If vehicle inclination (to either side) is due to permanent deforma-
tion of coil spring, remove the coil spring and replace it.
d. Replace the coil spring if it is cracked, broken or damaged.
Damping Force/Noise
Rock the left side of the veh icie up and down, and then rock the right Visual and tactile
side, to check for noise or variances in vehicle posture. inspection
If the up-and-down movement (when hands have been released)

continues longer than usual or if any abnormal noise is detected, check
the condition of shock absorber itself.
Refer to instructions for inspection procedures.
Shock absorber Oil leakage
Check for oil leaks at or around the lower portion of shock absorber
and oil seal.
It is normal for a trace of oil to be oozing at the oil seal.
Cracks, Damage or Deformation

Check the outer shell for any cracks, damage or deformation. Replace
dust cover or bushings if damaged.
23
4-1 SUSPENSION
ADJUSTING PROCEDURE OF REAR e

and outer arm so that angle formed by inner arm and outer
SUSPENSION ALIGNMENT arm centerlines (Fig. 27) increases. Then, tighten outer arm
mounting bolts.
Toe
1) Jack up rear of vehicle as shown in "Pre-Delivery Inspec-
Center line of inner arm
tion", and remove rear wheels.
2) Loosen outer arm mounting bolts.
Cross member
Center line of outer arm
Fig. 27
L1-489 ..
Outer arm ASSY
5) If camber angle is excessive in 8 direction, use a piece of
wood as a lever and change relative angle between inner and
L 1-487
outer arms so that angle 8 formed by inner arm and outer arm
Fig. 25 centerlines decreases. Then, tighten outer arm mounting bolts.
3) When toe-in is excessive, tighten outer arm mounting bolts 6) Adjust camber angle to conform to service standard by
shown in Fig. 25 while pushing end of spindle towards rear of repeating steps 4) and 5) above.
vehicle (in direction of arrow in Fig. 26). When toe-out is
excessive, tighten outer arm mounting bolts while pulling end a. Adjusting toe results in a change in camber angle, while
of spindle toward front of vehicle (in opposite direction of adjusting camber angle causes a change of toe. Therefore,
arrow in Fig. 26). when either is adjusted, always check that the other remains
within service standard.
b. After both toe and camber angle have been adjusted within
Inner arm ASSY service standard, be sure to tighten bolts to the specified
torque.
Ground Clearance Measuring
(4WD Models Only)
Ground clearances of front and rear suspensions of 4WD
vehicles can be measured according to the following proce-
Outer arm ASSY
dure.
L1-488
a. Before measuring the ground clearance, check air pressure
Fig. 26
of the all tires and adjust to the specified pressure if necessary.
b. Place the vehicle under unloaded condition on the flat
4) Adjust toe within service standard by repeating steps in 2) ground.
and 3) above for both right and left wheels.
Front Ground Clearance
Camber Vehicle Specified ground clearance
1) Jack up rear of vehicle as shown in "Pre-Delivery Inspec- +12
tion", and remove wheel whose camber angle is out of 255_ mm
22
18004WD
standard.
2) Remove bolt linking lower end of shock absorber to inner
(10.04~g:~; in)
arm.
+12
3) Then, loosen outer arm mounting bolts shown in Fig. 25. 253_ mm
22
4) If camber angle is excessive in @ direction, use a piece of 27004WD
(996 +0.47. )
wood as a lever and change relative angle between inner arm . -0.87 In
24
SUSPENSION 4-1
Check the ground clearance by measuring between front end Front Suspension Assembly
of transverse link attaching bolt and ground.
REMOVAL

2) Apply parking brake.
3) Loosen front wheel nuts.
and remove front wheels.
5) Release parking brake.
6) Remove parking brake cable bracket from transverse link.
Front ground
clearance
L4-1296
Fig. 28
If ground clearance is out of the specified range in the above

table, replace the coil spring.
,\ ~
. Parking brake cable ____
bracket
Rear Ground Clearance Fig. 30
Vehicle Specified ground clearance

7) Disconnect parking brake cable end.
+10
250_ mm (1) Remove outer cable cI ip.
20
18004WD (2) Disconnect the cable end from the caliper lever.
(9 84 +0.39. )
. -0.79 In
+10
248_ mm
20
27004WD
+0.39.
(9.76_ . In)
0 79
Measure the ground clearance (from lowest point of cross·

member pipe to the ground).
Fig. 31
8) Disconnect brake hose from brake pipe at apron bracket.

Rear ground
clearance
a. Fit air bleeder cap onto brake pipe to prevent brake fluid
from pouring.
L4·180
b. When removing or installing flare nut, use flare nut wrench
Fig. 29 without fail.
2i
4-1 SUSPENSION
9) Drive out spring pin of D.O.J. at inner end by using a 14) Pull out cotter pin and remove castle nut. Then dis-
steel rod of 6 mm (0.24 in) diameter. connect the ball stud of tie-rod end ball joint from housing.
L4-137
Fig. 32 Fig. 35 Installing tie-rod end
10) Disconnect the end of stabilizer from transverse link. 15) Loosen nuts connecting strut mount to body, then pull
D.O.J. out of differential spindle, and remove front suspension
ASSY from body.
Fig. 33
L4·138
Fig. 36
11) Remove leading rod from leading rod bracket.
12) Disconnect transverse link bush from front crossmember.
INSPECTION
Check the removed parts for any wear, damage and cracks, and
correct or replace if defective.
INSTALLATION
L4-136
Fig. 34
a. Carry out the specified adjustments for control system.
b. Be sure to measure wheel alignment after installing suspen·
sian.
c. Replace cotter pins and axle shaft spring pins with new
13) Take out transverse link along with leading rod. ones when installing.
26
SUSPENSION 4-1
1) Install strut mount to body. 8) Connect stabilizer end bracket to transverse link.
Torque: Torque:
26 - 36 N·m (2.7 - 3.7 kg-m, 20 - 27 ft·lb) 20 - 29 N·m (2.0 - 3.0 kg-m, 14 - 22 ft-Ib)
2) Align the spring pin holes of D.O.J. and differential 9) Attach brake hose to apron bracket by using clip, and
spindle, and insert D.O.J. to differential spindle. then connect brake hose to brake pipe.
Torque:
13 - 18 N·m (1.3 - 1.8 kg-m, 9 - 13 ft·lb)
10) Install parking brake cable bracket to transverse link.
Torque (Bolt):
10 - 16 N·m (1.0 - 1.6 kg-m, 7 - 12 ft-Ib)
11) Install parking brake outer cable by attaching outer cable

clip to brake caliper.
Install the parking brake cable end to the caliper lever.
12) Bleed air from brake system.
13) Install wheels.
Fig. 37
Torque (wheel nut):
3) Install leading rod to leading rod bracket according to the 78 - 98 N'm (8 - 10 kg-m, 58 - 72 ft-Ib)
following procedure.
(1) Install a bush to leading rod. 14) Lower vehicle and tighten self-lock nut which installs
(2) Install leading rod to leading rod bracket, besides transverse link to crossmember.
install a bush, a plate and a self-lock nut.
(3) Tighten self-lock nut. Torque (self-lock nut):
59 - 69 N'm (6.0 -7.0 kg-m, 43 - 51 ft-Ib)
Torque:
78 - 98 N·m (8.0 - 10.0 kg-m, 58 - 72 ft-Ib)
Self-lock nut should be replaced with new one whenever it is

removed.
4) Connect D.O.J. and differential spindle by driving spring

pin in.
a. Make sure that the holes are aligned before driving the
spring pin in.
b. When driving the spring pin in, always use new one.
Front Strut Assembly
5) Install transverse link temporarily to crossmember by
using bolt and self-lock nut.
REMOVAL
6) Install tie-rod end ball joint to the housing knuckle arm.
Torque (Castle nut): 1) Disconnect ground cable from battery.

25 - 29 N'm (2.5 - 3.0 kg-m, 18 - 22 ft-Ib) 2) Apply parking brake.
After tightening the nut to the specified torque, adjust groove 4) Jack up vehicle, support it with safety stands (rigid racks)
on the nut and hole on the ball joint by retightening the nut and remove front wheels.
from 0 to 60 degrees. 5) Release parking brake.
6) Disconnect brake hose from caliper body.
7) Then install new cotter pin into the hole, and bend it
firmly. Use brake hose cap to prevent brake fluid from pouring.
27
4-1 SUSPENSION
2) Set the strut ASSY to COIL SPRING COMPRESSOR.
a. Be sure to use the special tool in order to avoid an accident.

b. Set the projections of COIL SPRING COMPRESSOR to
the inner diameter side of coil spring.
L4-892
Fig. 38
7) Pull out brake hose securing clip and detach brake hose
from damper strut bracket. L4-140
8) Remove bolt which connects damper strut to housing. Fig. 40
9) Remove bolt which connects damper strut bracket to
housing.
10) Pull strut out of housing gradually and carefully with
housing ASSY placed downward. 3) Compress the coil spring by carefully turning the coil
spring compressor handle.
If strut is rusted, apply sufficient "CRC" on housing and strut (Compress the spring until it comes off the strut upper seat
before pulling strut out. surface.)
4) Loosen the nut that connects the strut mount and the
11) Remove nuts clamping strut mount to body. rod.
12) Remove strut ASSY from body.
Fit SPANNER (926510000) into the holes ofspring seat, and
loosen the nut using a 17 mm box wrench.
DISASSEMBLY
1) Mount COIL SPRING COMPRESSOR (926110000) to a

vice.
SPANNER
(926510000)
COIL SPRING COMPRESSOR

(926110000)
L4-141
Projection
Fig. 41
5) Remove the strut mount and other minor parts.
Use care not to drop spacer.
6) Return carefully the coil spring compressor handle to the

E4-110
original position, and take out the coil spring and strut after
Fig. 39 making sure that the spring has been stretched fully.
28
SUSPENSION 4-1
Take out the coil spring, using care not to cause the spring to Coil spring
contact the strut rod. One having permanent strain should be replaced with a new
one. When vehicle posture is uneven, although there are no
considerable reasons like tire puncture, uneven loading, etc.,
check coil spring for its free length, cracks, etc., referring to
specifications, and replace it with a new one if defective.
INSPECTION
Helper
Check the disassembled parts for cracks, damage and wear, and
replace with new parts if defective. Replace it with new one if cracked or damaged.
Damper strut
1) Check for oil leakage.
2) Move the piston rod up and down to check its smooth ASSEMBLY
operation without any binding.
3) Deflection of piston rod
Measure the deflection as follows: 1) Compress the coil spring with COIL SPRING COMPRES·
Fix the outer shell and fully extend the rod. Set a dial gauge SOR (926110000).
at the end of the rod, and apply a weight of ±20 N (±2 kg,
±4 Ib) to the threaded portion. Read the dial gauge indication. Make sure that the vertical installing direction of coil spring is
The amplitude of the gauge needle pointer is the deflection of as shown below.
the rod.
Flat (top side)

Limit of deflection:
Less than 0.8 mm (0.031 in)
If the deflection is greater, replace the strut.
20N (2kg, 41b)
(:~)
Inclined (bottom side)
L4-142
Fig, 43
10mm (O.39in)
Hold outer shell stationary

2) Set the coil spring correctly so that its end face fits well
into the spring seat as shown.
A15-091
Fig, 42
Strut mount
1) Check rubber part for creep, cracks and deterioration, and
replace it with new one if defective.
2) If distortion is found on its connecting surface to body,
replace it with a new one.
Dust cover A 15'()98
If any cracks or damage are found, replace it with a new one. Fig, 44
29
4-1 SUSPENSION
3) Install helper and dust cover to the piston rod.
4) Pull the piston rod fully upward, and install rubber seat INSTALLATION
and spring seat.
5) Install sleeve to the piston rod. Install the strut ASSY in the reverse sequence of the removal
6) Install strut mount to the piston rod, and tighten the procedure.
self·lock nut temporarily.
Be sure to bleed air from brake system.
Be sure to use a new self-lock nut.
7) Loosen COIL SPRING COMPRESSOR carefully. Tightening torque:

8) While fixing the spring seat with SPANNER (926510000) Nut (Strut mount to body)
tighten the self-lock nut with a box wrench. 26 - 36 N'm (2.7 - 3.7 kg-m, 20 - 27 ft-Ib)
Bolt (Damper strut bracket to housing)
Tightening torque: and
51 - 67 N'm (5.2 - 6.8 kg-m, 38 - 49 ft·lb) Bolt (Damper strut to housing)
38 - 50 N·m (3.9 - 5.1 kg-m, 28 - 37 ft-Ib)
Disc brake union bolt
15 - 21 N·m (1.5 - 2.1 kg-m, 11 - 15 ft-Ib)
Wheel nut:
78 - 98 N·m (8.0 - 10.0 kg-m, 58 - 72 ft-Ib)
SPANNER
(926510000)
L4-141
Fig. 45
30
SUSPENSION 4-1
Front Stabilizer
Fig. 46
~/.",h Leading rod bracket
B - Bracket
Stabilizer
"'-
Leading rod
.~
l----- -+
I '
~~~~.~ )
L4.1369
Fig. 47
31
4-1 SUSPENSION
REMOVAL
1) Jack up the front part of the vehicle.

2) Remove the plate bolt securing the stabilizer to the
transverse link at the end of the stabilizer.
3) Remove the plate from the transverse link.
4) Remove the bolt securing the clamp (stabilizer bush) to
the crossmember (front).
5) Remove the clamp and bush from the stabilizer.
6) Remove jack-up plate of crossmember (front). and remove
the stabilizer.
L4-1370
Fig. 48
INSTALLATION 11) Remove nuts attaching engine mount cushion rubber to

crossmember.
12) Remove self-lock nuts connecting steering torque rod and
To install, reverse the removal procedure.
pinion shaft.
13) Lift engine ASSY by approx. 10 mm by using chain block.
a. Be sure the crossmember (front) side bush is brought up
14) Remove crossmember installing nuts with crossmember
fully to the bent portion of the stabilizer.
supported by jack, and remove crossmember downward
b. Fit each bush securely, and tighten bolts with the tires
gradually along with steering gearbox.
placed on the ground when the vehicle is not loaded.
c. Tightening torque
Stabilizer to transverse link: INSTALLATION

20 - 29 N·m (2.0 - 3.0 kg-m, 14 - 22 ft-Ib)
Stabilizer clamp to crossmember (front):
21 - 28 N'm (2.1 - 2.9 kg-m, 15 - 21 ft-Ib)
a. The clamping nuts for crossmember and transverse link
bushing should be tightened with tires on the ground.
b. When removing crossmember downward, be careful that
steering torque rod does not interfere with DOJ boot.
Front Crossmember c. Tightening torque
Transverse link bushing to crossmember:

REMOVAL 59 - 69 N·m (6.0 - 7.0 kg-m, 43 - 51 ft-Ib)
Stabilizer to bush:
1) Disconnect ground cable from battery. 21 - 28 N'm (2.1 - 2.9 kg-m, 15 - 21 ft-lb)
2) Apply parking brake, and remove spare tire and wheel. Tie-rod end to housing:
3) Loosen front wheel nuts. 25 - 29 N·m (2.5 - 3.0 kg-m, 18 - 22 ft-Ib)
4) Jack up vehicle, support it with safety stands (rigid racks). Front cushion rubber to crossmember:
and remove front tires and wheels. 20 - 32 N'm (2.0 - 3.3 kg-m, 14 - 24 ft-Ib)
5) Release parking brake. Torque rod ASSY to pinion shaft:
6) Remove air cleaner ASSY and pitching stopper rod. 21 - 26 N'm (2.1 - 2.7 kg-m, 15 - 20 ft-Ib)
Cross member to body:
Fit a cap onto carburetor to prevent illside of bore from 78 - 98 N·m (8.0 - 10.0 kg-m, 58 - 72 ft-Ib)
becoming dusty.
7) Remove parking brake cable bracket from transverse link.

8) Remove cotter pin and castle nut on tie-rod end, and
detach the ball stud from knuckle arm.
9) Remove front exhaust pipe.
10) Remove transverse link from front crossmember.
32
SUSPENSION 4-1
Front Ball Joint
L4·781
Fig. 51
L4·854
Fig. 49 (3) Calculate play [j from the following formula.
[j = Q2 - Q,
(4) When play ti is larger than the following figure,
replace with a new one.
REMOVAL
FRONT BALL JOINT
1) Jack up the front part of the veh icle, and remove the Specified play for replacement: [j
wheels. More than 0.3 mm (0.012 in)
2) Pull out the cotter pin from the ball stud, remove the
castle nut, and remove the ball stud from the transverse link. 2) When play ti is smaller than the specified value, visually
3) Remove the bolt securing the ball joint to the housing. inspect the dust seal.
4) Remove the ball joint from the housing. 3) If the dust seal is damaged, remove it and wipe off any
deteriorated grease with a clean cloth.
4) Next, replace with an appropriate quantity of specified
grease (SUNLIGHT 2; PIN 003602010). about 3 g (0.11 oz),
INSPECTION then mount a new dust seal.
1) Measure play ti of ball joint by the following procedures.

Replace with a new one when the play exceeds the specified
value. INSTALLATION
(1) With 686 N (70 kg, 154 Ib) loaded in the direction
shown in the figure, measure dimension Q,. 1) Install ball joint onto housing.
Torque (Bolt):
38 - 50 N'm (3.9 - 5.1 kg-m, 28 - 37 ft-Ib)
a. The ball joint and boot that have been removed must be
checked for wear, damage or cracks, and any defective part
must be replaced.
b. Do not apply grease to tapered portion of ball stud.
2) Connect ball joint to transverse link.
Torque (Castle nut):

L4·780 39 N·m (4.0 kg-m, 29 ft-Ib)
Fig. 50
0
3) Retighten castle nut further within 60 until a slot in
castle nut is aligned with the hole in ball stud end, then insert
(2) With 686 N (70 kg, 154 Ib) loaded in the direction new cotter pin and bend it around castle nut.
shown in the figure, measure dimension Q2. 4) Install front wheels, and lower vehicle.
33
4-1 SUSPENSION
7) Remove brake hose from brake pipe at inner arm side
Rear Suspension Assembly bracket (on both sides).
a. Insert air bleeder cap to brake hose end to prevent brake

fluid from pouring.
REMOVAL b. Whenever removing or installing flare nut, use suitable flare
nut wrench only.
1) Remove the two bolts attaching shock absorber upper end
to body.
At this time, vehicle should be in the unloaded condition.
Fig. 53
8) Support rear crossmember at its center with a jack.
L4-147
~--~

3) Loosen rear wheel nuts.
and remove rear wheels.
5) (4WD only) Remove following parts and detach rear drive
system.
(1) Spring pins at both ends of drive shaft.
--_/
Using a steel bar of 6 mm (0.24 in) diameter, gradually drive
out spring pins. Fig. 54
(2) Rear axle shafts on both sides - Remove outer

9) Remove bolts holding rear crossmember at both ends.
D.O.J. of drive shaft from spindle (inner arm side) by
pushing inner D.O.J. of drive shaft fully toward rear
differential and pushing inner arm downward. Then
remove inner D.O.J. from differential spindle.
(3) Proper shaft
(Refer to chapter 3-4, "4WD System").
(4) Support rear differential with jack.
(5) Self-lock nuts connecting rear differential mounting
member to body.
(6) Rear differential - Remove 4 nuts installing rear
differential at its front end to rear crossmember, and
carefully dismount rear differential.
6) Remove a part of exhaust system parts so as not to
interrupt the dismounting of the rear suspension ASSY.
(Refer to chapter 2-9 "Exhaust System".)
Fig. 55
34
SUSPENSION 4-1
10) Lower jack gradually and draw out from beneath vehicle • How to check for damage and cracks
body with rear suspension ASSY on it. If damage or cracks cannot be confirmed vi sua II y, check the
following areas using the dye check method.
Put dismounted rear suspension ASSV on soft material (rag, (1) The areas where paint has been peeled off.
corrugated paper, tire, etc.) to prevent brake backplate and/or (2) The areas where rust has formed.
brake drum from being damaged.
DISASSEMBLY ASSEMBLY
1) Install temporarily outer arm to crossmember.

2) Fit inner arm to crossmember and insert the connecting
bolt, then tighten new nut temporarily.
3) Tighten bolts connecting the inner and outer arms tem-
porarily.
4) Stabilizer equipped vehicle only:
Fit stabilizer to inner arm, and tighten stabilizer brackets with
bolts.
Torque:
18 - 22 N·m (1.8 - 2.2 kg-m, 13 - 16 ft-Ib)
'--_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _L4_-_8_55-' 5) Install shock absorber to inner arm at lower end of shock
Fig. 56 FWD as example absorber temporarily.
1) Remove rear floating bush at both ends of rear cross-

member. INSTALLATION
2) Remove shock absorber from inner arm at lower end of
shock absorber.
3) Stabilizer equipped vehicle only: To install, reverse the removal procedure.
Remove stabilizer clamp bolts.
Remove stabilizer from inner arm. a. Bolts for bush portions should be tightened with arms held
in unloaded vehicle condition.
Bushes on the removed stabilizer should be left as they are, in b. After installation, check and adjust the following:
order to readily mate them with clamps in re·fitting the (1) Air bleeding of brake system
stabilizer. (2) Rear wheel alignment
c. Tighten bolts and nuts to the specified torque.
4) Remove bolt connecting outer arm to crossmember, and
also bolts connecting outer arm to inner arm.
5) Remove inner arm from crossmember. Inner arm to outer arm:
(1) Remove nut. 127 - 147 N·m (13.0 - 15.0 kg·m, 94 - 108 ft-Ib)
(2) Pull out bolt from the crossmember bracket. Inner arm to crossmember:
69 - 88 N'm (7.0 - 9.0 kg-m, 51 - 65 ft-Ib)
Shock absorber to inner arm:
88 - 118 N·m (9.0 - 12.0 kg-m, 65 - 87 ft-Ib)
INSPECTION
Check the removed parts as follows, and if a fault is detected

Flare nut (Brake hose to brake pipe):
on any part, replace with a new one.
13 - 18 N'm (1.3 - 1.8 kg-m, 9 - 13 ft-Ib)
1) Check for wear, damage, deformation, or cracks.
Wheel nut:
2) Check the threads of bolts, nuts, and mating parts for
78 - 98 N·m (8.0 - 10.0 kg-m, 58 - 72 ft·lb)
deformation or damage.
See "COMPONENT PARTS" for the tightening torque
3) Check the bottom part or oil seal portion of the shock
of the suspension parts.
absorber for oil leakage.
Other parts except the above must be tightened with the
4) Be sure to replace the spring pin for the drive shaft with a
torque value described in the associated chapter.
new one when reassembling.
35
4-1 SUSPENSION
6) Extract the body fitting bracket, plate and upper spring
Rear Coil Spring seat as a whole from rod.
7) Return carefully the coil spring compressor handle to the
REMOVAL original position, and take out the coil spring and shock
absorber after making sure that the spring has been stretched
1) Remove coil spring as a part of shock absorber ASSY fully.
coupled with shock absorber.
2) Mount COIL SPRING COMPRESSOR (926110000) to a Take out the coil spring, using care not to cause the spring to
vice. contact the shock absorber rod.
8) Extract helper ASSY from shock absorber CPo
COIL SPRING
COMPRESSOR
(926110000)
INSPECTION
Shock absorber complete

1) Check for oil leakage from bottom of damper and oil seal.
If oil leaks from damper bottom, replace. If oil leakage from
oil seal reaches spring seat, replace. Oil stains around oil seal
E4-110 are permissible, therefore replacement is unnecessary.
'":F:-:-ig-.-:5:-::7:--------------------~ 2) Ascertain recovery of the shock absorber rod by pushing
it into the base. If the recovery is unusually slow or has
hitches, replace with a new one.
3) Check the lower bush for deformation or loss and replace
3) Set shock absorber ASSY to COIL SPRING COMPRES· if defective.
SOR. 4) Check the shock absorber itself, spring seat portion and
rod end bolt portion for damage or deformation.
a. Be sure to use the special tool in order to avoid an accident.
b. Set the projections of COIL SPRING COMPRESSOR to the Coil spring
inner diameter side of coil spring. Check for breakage or unusual rust.
Helper assembly
Check dust cover and helper for deformation or abnormal
wear (holes).
COIL SPRING COMPRESSOR Parts fitted to the upper portion

(926110000)
Check for deformation or damage.
Projection
I
INSTALLATION
L4-156
Fig. 58 To install, reverse the removal procedure.
a. Make sure that the coil spring is mounted with the flat end
downward.
4) Compress the coil spring by carefully turning the coil
spring compressor handle.
(Compress the spring until it comes off the spring seat surface.)
5) Remove the rod connecting nuts (double nuts).
36
SUSPENSION 4-1
A·A
OUT IN
Fig. 59
Upper side end face
of coil spring L4·158
Fig. 60
b. Take care of the vertical installing direction of upper and
lower rubbers.
c. Take care of the installing direction of bracket CPo
d. Be careful that rubber seat does not extrude from spring
seat (above figure).
e. Set coil spring correctly so that its end face fits well into
upper spring seat as shown in above figure.
37
4-1 SUSPENSION
Troubleshooting
1) Improper vehicle posture or improper ground clearance
Possible causes Countermeasures
(1) Permanent distortion or breakage of coil spring Replace.

(2) Unsmooth operation of shock absorber Replace.
(3) Installation of wrong inner arm Replace with proper parts.
(4) Deformation of inner arm Replace.
2) Poor ride comfort

1) Large rebound shock.
2) Rocking of vehicle continues too long after running over bump and/or hump.
3) Large shock in bumping.
(1 ) Breakage of coil spring Replace.

(2) Overinflation pressure of tire Adjust.
(3) Improper ground clearance Adjust or replace coil springs with new ones.
(4) Fault in operation of shock absorber Replace.
(5) Damage or deformation of shock absorber lower end Replace.
bushing
(6) Unsuitability of maximum and/or minimum length of Replace with proper parts.
shock absorber
(7) Deformation or loss of bushing Replace.
(8) Deformation or damage of helper ASSY Replace.
3) Noise
(1) Wear or damage of shock absorber component parts Replace.

(2) Damage or deformation of shock absorber lower end Replace.
bushing
(3) Loosening of outer arm installing bolt Retighten to the specified torque.
(4) Deformation or loss of bushing Replace.
(5) Loosening of inner arm installing bolt to crossmember Retighten to the specified torque.
bracket
(6) Unsuitability of maximum and/or minimum length of Replace with proper parts.
~hock absorber
(7) Breakage of coil spring Replace.

(8) Loosening of each bolt and/or nut Retighten to the specified torque.
38
SUSPENSION 4-1
SERVICE PROCEDURE FOR AIR (PNEUMATIC)

SUSPENSION
In this section are described the different points of the air Front Air Suspension Assembly
(pneumatic) suspension from the explanations described in the
section of conventional suspension. Accordingly, use this
section together with the section of conventional suspension. REMOVAL

T: 5 - 15 (0.5 - 1.5,3.6 - 10.8)
General Precautions
1) Be sure to support the vehicle with a jack before getting
under it for servicing. To check any system, other than elec-
trical, under the vehicle, disconnect cables from battery in
Vehicle body
advance. Th is prevents the auto leveler from being activated
to take up increase or decrease in wheel reaction while the
ignition switch is ON.
2) When reassembling, do not reuse O-rings. Also be sure not
to damage O-ring and O-ring contact surfaces such as O-ring
groove. Apply grease to O-rings when reassembling.
Recommended grease and O-ring:

Grease NOK SEAlUB S-4
O-ring NOK Material A980
Harness length to clip: Vehicle height sensor

3) Do not apply an undercoating for local rust prevention to 210 mm (8.27 in) harness
L4-161
the air bags (roll ing diaphragm surface and cylinder surface
with which the diaphragm is in rolling contact) and the air Fig. 61
compressor.
This is because, when the damper oil temperature increases
due to running on rough roads, the generated heat melts the
undercoating, which makes it easier to trap dust, dirt, and Air pipe
sand on the surface, reSUlting in damaged diaphragm. The
undercoating on the air inlet of the compressor can also block
/OT'--Bushing
the vent.
4) When welding vehicle body, be sure to cover air pipe and
air spring diaphragm so that welding sputter will not attach to CaP
these pa rts.
5) When replenishing battery electrolyte, be careful not to
have electrolyte come in contact with air pipe.
6) At transportation, retighten the ratchet another 2-3
notches with tie-down wire tightened up. (Retightening of one
!(I It~~~" .,,~"
I disassembly.)
End of strut
notch is recommended for the all models of conventional coil

springs.) Make sure O-ring is free from foreign
matter such as dirt and dust. L4-162
The tighter tension is recommended because of its lower spring
constant as compared with that of the coil spring. Fig. 62
39
4-1 SUSPENSION
1) Disconnect air pipe. Clip sensor harness 210 mm (8.27 in) from front air suspen-
2) Remove mud guard. sion ASSY to avoid twisting.
3) Remove vehicle height sensor harness from clip.
4) Disconnect harness coupler. Harness length to cl ip:
Other procedures are the same as those used for removal of 210 mm (8.27 in)
standard type strut ASSY.
DISASSEMBLY
Strut mount can be removed from air suspension CP, using

SPANNER (926510000).
Disassembling air suspension CP is not allowed. L4·164

Fig. 64
4) Fit O·ring to the end of strut rod, then insert air pipe into
Strut mount
O-ring for connection.
a. Insertion length of air pipe (L): 13 mm (0.51 in) or more.

Front air suspension CP
L4·163
Fig. 63
a. Before removing strut mount, make sure that air has been
discharged from air spring.
b. Be careful not to damage diaphragm.
L4-165
Fig. 65
b. Before inserting air pipe, make sure D·ring is free from any
ASSEMBLY AND INSTALLATION foreign matter such as dirt and dust, and apply a thin coat of
grease to D-ring.
1) Using SPANNER (926510000), install strut mount to
(Discard old D·ring when disassembling.)
front air suspension CPo
c. Install air pipe in correct direction.
(Correct position in straight ahead position of vehicle is shown
Tightening torque:
below.)
51 - 67 N'm (5.2 - 6.8 kg-m, 38 - 49 ft-Ib)
2) Install front air suspension ASSY to vehicle body. Refer

to reassembly procedure of a standard type strut ASSY.
3) Secure vehicle height sensor harness with clip.
40
SUSPENSION 4-1
To disconnect, pull off air pipe while opening claw of collet

by using AIR PIPE REMOVER (926520000).
4) Pull out vehicle height sensor harness from access hole of
body, and disconnect harness coupler.
Other procedures are the same as those used for removal of a
standard type damper.
Be extremely careful not to damage diaphragm.

T: 5 - 15 (0.5 - 1.5,3.6 - 10.8)
L4-166
Fig. 66 DISASSEMBLY
a. Before disassembling rear air suspension ASSY, be sure to

discharge air from air spring.
b. Disassembling air suspension CP is not allowed.
Rear Air Suspension Assembly

REMOVAL
1) Remove rear apron protector.
2) Remove rear solenoid valve from rear air suspension Reverse the removing and disassembling procedures. Observe
ASSY. the following:
3) When replacing solenoid valve, disconnect air pipe from
solenoid valve. This figure shows
left-hand air sus-
Body
--,
• pension ASSV .
Right-hand air
suspension ASSY
is symmetrical to
this figure .
•
Front of vehicle
Tire.
L4-169
Fig. 68
AIR PIPE REMOVER
(926520000)
a. Be sure to install upper rubber and lower rubber to their

proper directions.
b. Be sure to install bracket CP in correct direction.
c. Be careful not to damage or scratch D-ring and D-ring
contacting surface. Make sure D-ring is free from any foreign
matter, and coat with grease when assembling.
L4-168
(Discard old D-rings when disassembling.)
d. Arrange vehicle height sensor harness, solenoid valve lead
Fig. 67 wire, and air pipe as shown in the Figure.
41
4-1 SUSPENSION
DISASSEMBLY
Disassemble compressor & drier ASSY to compressor, drier,

and bracket by removing bolts, etc.
a. Disassemblv of both compressor and drier is not allowed.

If trouble should occur, replace faulty unit as an ASSY.
b. Make sure that O-rings are free from foreign matter such as
dirt and dust, and coat with grease before reassembling.
L4-170
Fig. 69
Compressor & Drier Assembly

REMOVAL

T1: 5 - 8 (0.5 - 0.8, 3.6 - 5.8)
T2: 3 - 5 (0.3 - 0.5, 2.2 - 3.6)
L4-857
Fig. 71
( I •.
1\ __ Inserting position 0
f 0 ASSEMBLY AND INSTALLATION
\_ ~hese five pipes is not
Important.
ql L4-856 Reverse the sequence of removal and disass~mbly procedures.
Fig. 70 Observe the following:
Make sure that O-rings are free from foreign matter such as
1) Remove front left wheel.
dirt and dust, and coat with grease before reassembling.
2) Remove front half portion of mud guard.
3) Using AIR PIPE REMOVER (926520000). disconnect
five air pipes from drier.
4) Remove coupler.
5) Remove compressor & drier ASSY from engine compart-
ment by loosening four nuts.
42
SUSPENSION 4-1
Air Tank Assembly DISASSEMBLY
REMOVAL a. When removing pressure switch or solenoid valve from air

tank, discharge air from the tank gradually. Be extremely
careful because air tank contains highly pressurized air.
b. When replacing pressure switch or solenoid valve, removal
Bolt of air tank from vehicle body is unnecessary.
o
Reverse the sequence of removal and disassembly procedures.

a. When installing O-ring, make sure it is free from any foreign

matter such as dirt and dust, and then coat with grease. Be
careful not to damage O-ring.
Air tank CP b. When installing pressure switch, be sure to apply grease to
its thread portion and tighten it to the specified tightening
O-'i"9/~
L preSSU:!:WitCh
torque.

T1: 13 - 23 (1.3 - 2.3, 9 - 17)
T2: 5.4 - 9.3 (0.55 - 0.95, 4.0 - 6.9)
T3: 11 -13 (1.1 -1.3,8 - 9)
T4: 10 - 18 (1.0 - 1.8,7 -13)
L4-173
Fig. 72
1) Using AIR PIPE REMOVER (926520000). remove air

pipe from solenoid valve, then remove solenoid valve coupler.
2) Remove left-hand turn signal light from front bumper.
3) Remove air tank ASSY by loosening one bolt and two
nuts.
43
4-1 SUSPENSION
TROUBLESHOOTING
Symptom Trouble Cause Ref.
Car Ignition Front or rear of car rises if car is Improper sea ling of affected air suspension
A7
height switch left as it is. solenoid valve or tank solenoid valve
increases. OFF
Ignition Front or rear of car rises Faulty vehicle height sensor

switch abnormally.
Faulty control unit
ON
Bl
Broken solenoid valve coil/air discharge
solenoid valve coil of affected air suspension
Faulty electrical circuit
Sticking solenoid valve/air discharge solenoid

I
Al0, A14
valve of affected air suspension
Clogged air line A9
Car Ignition Front of car height decreases when Air leakage from air pipe or joint on top of
Al
height switch car is left as it is. strut mount
decreases. OFF
Air leakage from front solenoid valve A7
Air leakage from front air suspension ASSY A4
Rear of car height decreases when Air leakage from rear solenoid valve or faulty
A7
car is left as it is. seal
Air leakage from rear air suspension ASSY A4
Ignition Front or rear of Compressor does

B3
switch car is not operate.
ON abnormally low.
Compressor Car returns to the Air leakage from tank
A5
operates. NORMAL position ASSY
when left
unattended with Air leakage from air
A2
ignition switch ON line
for 5 minutes.
Car returns to the Faulty vehicle height

NORMAL position sensor
when left
Faulty control unit
unattended with
Bl
ignition switch ON Broken solenoid valve
for 5 minutes. coil
Fau Ity electrical circu it
Sticking solenoid valve Al0
Clogged air line A9
Air leakage from air

A2
line
44
SUSPENSION 4-1
Compressor mal- Compressor keeps on running. Vehicle height See "Car

functions. (When engine is in operation, lowers if left alone height
compressor keeps running over with ignition switch decreases."
8 minutes if left alone without off for over 15
getting in and out of vehicle.) minutes.
Vehicle height does Faulty pressure switch

not lower even
if left alone with Faulty control unit
ignition switch off Defective compressor
for over 15 minutes. relay B2
Defective electric
I circuit
Faulty compressor
Tank solenoid valve

Al0
broken or sticking
Air leaks from tank

A5
ASSY
Air line leaks air or

A2,A9
clogs
Compressor operates frequently. When ignition See "Car

(When engine is in operation, switch is off, height
compressor operates frequently if vehicle height decreases."
left alone without getting in and lowers if left alone
out of vehicle for over 5 minutes.) for over 15 minutes.
When ignition Faulty pressure switch

switch is off,
Faulty control unit
vehicle height does B2
not lower even if Defective electric
left alone for over circuit
15 minutes.
Air leakage from tank
A5
ASSY
Compressor will not operate. Compressor malfunctioning

(If compressor operates frequently
and its temperature rises, circuit Faulty pressure switch
B3
breaker will operate to stop com- Faulty control unit
pressor; if left as it is for some ti me
and its temperature drops, it will Defective electric circuit
restart.)
45
4-1 SUSPENSION
WARNING light WARNING light blinks when Vehicle height sensor malfunctioning
blinks. ignition switch is turned on.
Faulty control unit 84
(Warning of system
failure.! Defective vehicle height sensor
WARNING light blinks after more Compressor malfunctioning

than 10 minutes passed with
Faulty solenoid valve 85
ignition switch turned on.
Faulty control unit
Air leaks from tank ASSY A5
Air line leaks air or clogs A2,A9
46
SUSPENSION 4-1
81)
Do sOlenoid
Check voltage valve and com·
Is No. 12 or across control unit pressor operate when
No. 18, 19 (1800 cc No terminal CD (® IG) and t -__
Y_es___-icorresponding terminals ~_Y_es____
Canada modal only) terminal fJ (ground) is of control unit are
fuse blown? over 10V when ignition grounded?
switch is on. (Confirm by operat·
ing nOise.)
Yes No
FR CD, FL. ]
No RR e, RL"
Air charge41,
[ Air discharge . ,
Check and repair short circuit Check IG power and ground Compressor relay ~
and replace fuse. circuit for breaks (A 13).
Solenoid valve, compreS$or

and compressor relay are
defective as single units (A8,
Al0, All, A14) or their
wiring faulty (A 131.
47
4-1 SUSPENSION
Check if
right front suspension
lowers when terminals CD
and. of control unit
are simultaneously grounded.
Vehicle height does
Similarly, conduct tests on Faulty solenoid valves
Yes No not lower at any I-Y;",e;;.,;s'--_ _~ (A8, A10) or clogged
the following terminals:
single wheel.
• and" ... Left front air line (A9).
suspension
• and CD ... Right rear
suspension
• and • . . . Left rear
suspension
Yes
• Measurement method (for the right front suspension)

(1) Check that voltage across terminals. and fj) -GND is approximately 5 volts.
Remove No. 18, 19 (1800 cc (2) Check that voltage across terminals. and fj) is approximately 0 volts.
Canada model only) fuse and (3) Slowly raise the car with a jack until voltage across terminals. and flI) changes
turn ignition switch ON. from 0 to 5 volts.
(4) Check that voltage across terminals. and fj) is approximately 5 volts.
(5) Slowly raise the car with a jack until voltage across terminals 0 and fj) changes
from 5 to 0 volts.
unit terminals (in combination) (6) Check that voltage across terminals. and fj) is approximately 5 volts.
corresponding to the suspension Each strut must also be checked in a similar manner.
to be tested while raising the
car with a jack.
(Unit: Approx. volts)
Right front Left front Right rear Left rear

suspension suspension suspension suspension
Terminal
combination
.++fj) 0++fj) e++fj) "++fj) fj++fj) .++fj) fj++fj) "++fj)
L (LOW) 0 5 0 5 0 5 0 5
Set height 5 5 5 5 5 5 5 5
H (HIGH) 5 0 5 0 5 0 5 0
Check that
all test results
No Check vehicle No
are satisfactory as indi- Replace affected strut.
height sensor.
cated in Table
at right.
Stroke the appropriate front or rear air suspension ASSY and
check continuity between terminals of coupler at end of
O.K. height control sensor harness protruding from the air suspen-
Yes
sion ASSY. If test results are as shown below, there are no
(Electrical system is O.K.)
problems.

Check air lines (A2, A1O),
pressure switch (A3) and air
tank ASSY (A5).
48
SUSPENSION 4-1
Extension Compression
Suspension unit
..
Continuity between
~-L
(red) and (white)
terminals
Continuity between ------- -
(blue) and (white)
terminals
Solid line Continuity exists
Broken line Continu ity does not exist
Front Rear
Red Blue
L4·1372
Fig. 73
49
4-1 SUSPENSION
82)
Test resu Its

as per Charts A2
Yes
and A5 revealed air Repair faulty parts.
lea kage or clogged
line.
No
Check if Turn ignition switch OFF,

compressor stops remove No. 18,19 (1800 cc
No
when 2·pole connector Canada model only) fuse and
of pressure switch is turn ignition switch ON.
disconnected.
Yes Check if
No Seized compressor relay contacts
compressor
or shorted compressor ci rcu it 8.
Connect air pressu re gauge. stops.
(See A2.)
Yes
Connect air charge solenoid
valve illand compressor ~
to GND. Increase air pressure Check if
to 10 atm. Then disconnect there is continuity Yes Wiring between compressor relay
solenoid valve and compressor between terminal (A) and control unit shorted.
from GND. and GND.
Connect air discharge solenoid

No A
valve lIDto GND. Reduce air
pressure until pressure does not
change. Then disconnect
solenoid valve from GND.
Check if Connector of compressor

air pressure relay (Female side)
No increases to at least Fig. 74 L4-1300
.-----...0( 9 atm. when air charge Check if
solenoid valve [l] there is continuity Yes Wiring between pressure switch
is connected between terminal (B) and control unit shorted.
to GND. and GND.
Faulty air charge Connector of pressure
solenoid valve or Yes switch (Female side)
wiring (AB or A 13), No
or clogged air pipe
between air charge
solenoid valve Replace control unit.
and drier.
L4-1373
Faulty pressure switch or
wiring (A 13) shorted. Fig. 75
50
SUSPENSION 4-1
B3)
Check if
No. 12 and No. 18,
Repair shorted circuit
19 (1800 cc Canada
and install fuse(s).
model only) fuses
are O.K.
Yes
No
Ground compressor termi-
nal (0). Refer to Fig. 76
(Terminal Arrangement).
Yes
Fau Ity compressor or
Check if wiring in compressor
No
compressor power circuit or wiring Faulty pressure switch or
rotates. between compressor broken wiring between
and relay broken. control unit and pressure
switch.
Yes
Ground compressor termi-

nal (A). Refer to Fig. 76
(Terminal Arrangement).
Fau Ity compressor or

No
compressor broken wiring in com-
rotates. pressor relay circuit.
Yes
Brok~n wiring in com-

pressor power ci rcu it.
Check if Connector of compressor
No control unit ground
compressor relay (Female side)
circuit or ground wiring
rotates.
of compressor relay
contacts.
Yes
Ground control unit termi-

4D and 41. 4D and
nals
Fig. 76 l4-1302
•. 4D and., 4D and
• simultaneously, and
lower car height.
51
4-1 SUSPENSION
B4)
Disconnect
right front veh icle
height sensor connector while
WARNING light is blinking. No Faulty right front vehicle height sensor.
Turn ignition switch OFF Replace.
and then ON to check if
WARNING light blinks
again.
Yes
Disconnect
left front veh icle
height sensor connector.
No Faulty left front vehicle height sensor.
Turn ignition switch OFF and
Replace.
then ON to check if
WARNING light
links again.
Yes
Disconnect
right rear veh icle
No Faulty right rear vehicle height sensor.
Replace.
then ON to check if
WARNING light
blinks again.
Yes
Disconnect
left rear vehicle
No Faulty left rear vehicle height sensor.
Replace.
then ON to check if
WARNING light
links again
Remove control
unit. Check if body
No Faulty wiring.
connector terminals of vehicle
Repair so that wire is not grounded.
height sensors are
grounded.
Yes
Faulty control unit. Replace.
52
SUSPENSION 4-1
85)
(1) Connect pressure gauge.

(2) Remove left front mudguard.
height of affected
suspensions increases when:
• Right front solenoid valve illand
compressor []] are grounded
simu Itaneously.
• Left front solenoid valve[IJ and
compressor []] are grounded
simultaneously. No Faulty solenoid valve (Charts A8. A9
• Right rear solenoid valve@] and and A 10) or clogged air line.
compressor ~ are grounded
simultaneously. and
0
•
cOmpressor m
Left rear solenoid valve
simultaneously.
and
are grounded
(Also check that pipes are

clean and free from
obstacles.)
Yes
Increase pressure to 8 to 10 atm. with

compressor [§Jand air charge solenoid
valves (one at a time) grounded.
Disconnect
compressor @] and air
charge solenoid valves (one
Yes
at a time) from ground and check Air leakage from air line (Chart A2).
if pressure drop exceeds 0.5 atm.
when left unattended for
10 minutes.
No
Check if
pressure drop exceeds
Yes
0.5 atm. when air charge solenoid Air leakage from air tank.
valve alone is
grounded.
No
Refer to Chart B 1.
53
4-1 SUSPENSION
INSPECTION
-(;:{ Pressu re gauge
3·way joint
A 1) Air leaks from air pipe above strut mount
FL
L4·1303
Fig. 78
L4·174
Fig. 77
6) If the pressure drop exceeded 0.5 atm. [in step 4) above),
go to step 7) below.
7) Disconnect one of the air lines connected to the struts at
the drier. In its place, connect a pressure gauge as shown in
Check air pipe and joints (shown by arrow) for air leaks. Soap figure below.
water or SUBARU CRC (004301003) may be used, but no 8) Method of connecting pressure gauge (ex. 2)
soap water must be applied to ball bearing inside the strut • Using the REMOVER, disconnect the air line leading to the
mount. air suspension ASSY at the drier outlet.
• Connect the gauge manifold and the 3-WAY JOINT as a
A2) Air leakage from air line unit between the drier outlet and the disconnected end of
the air pipe.
The following special service tools are available:
• 3-WAY JOINT ASSY (926940000) consists of:
(1) 3-WAY JOINT . . . . . . . . 1 FL FR
(2) AIR PIPE . . . . . . . . . . . 2 (3 sets)
Use a commercial gauge manifold. Pressure gauge &
1) Connect a pressure gauge to the right front solenoid valve 3-way joint &
(for example). See Fig. 79. RL blind plug
2) Remove the left front mudguard.
(Blind plug)
3) Ground the air charge solenoid valve and increase solenoid
valve pressure to 5 to 6 atm.
4) Leave the solenoid valve unattended for 10 minutes. Then
check for a pressure drop. If the pressure drop does not exceed
0.5 atm., the solenoid valve is functioning properly.
5) Method of connecting pressure gauge (ex. 1) L4-1304
• Using the REMOVER, disconnect the air pipe leading to Fig. 79
the compressor at the right front solenoid valve.
• Connect the gauge manifold and the 3-WA Y JO INT as a
unit between the solenoid valve and the disconnected end
of the air pipe.
9) Repeat steps 3) and 4) above.
10) If check results are O.K. repeat steps 7) and 8).
11) Repeat steps 7) through 10) to check the remaining struts.
If any particular strut does not show a pressure drop, the
affected air line is leaking.
54
SUSPENSION 4-1
A3) Pressure switch A5) Air leakage from air tank assembly
1) Connect a pressure gauge. 1) Connect a pressure gauge.
2) Ground the air charge solenoid valve and compressor [§J . 2) Ground the air charge solenoid valve. Read the pressure
3) Apply a pressure of 9 to 10 atm, to the solenoid valve to gauge 5 seconds after grounding the solenoid valve.
check that the pressure switch turns OFF. If it does not turn 3) Wait about 10 minutes.
OFF, the pressure switch is faulty or its circuit is broken. 4) Repeat step 2) and check that the pressure drop is less
4) Ground the air charge solenoid valve and the discharge than 0.5 atm.
solenoid valve.
5) Check that the pressure switch turns ON when less than AS) Vehicle height sensor
8.5 atm. pressure is applied to the solenoid valve. (If the Compress and extend front or rear air suspension ASSY, and
pressure switch does not turn ON, it is faulty or its circuit is
check with a tester if continuity exists between connector
broken.
terminals of vehicle height sensor harness coming out of air
suspension ASSY. Air suspension ASSY is in good condition
A4) Air leaks from air suspension assembly if continuity exists as follows.
Rear air suspension ASSY Front air suspension ASSY
t t=
Extension Compression
.. Suspension unit
II
Continuity between
(red) and (white) _ _ ___ _
terminals
Continuity between
(blue) and (white) - - - - - - - - -
terminals
Solid line Continuity exists
•
Broken line - - - continuity does not exist
L4·1374
Fig, 81
Front Rear
Blue
L4401
Fig. 80
White
L4·178
Fig. 82 Arrangement of connector terminals

Remove front or rear air suspension ASSY, and apply air into
it. Put air suspension ASSY in water, and check for air leaks
at places indicated by arrow.
a. Do not apply water to strut mount ball bearing. Apply

SUBARU eRe (004301003) etc. to check for air leaks.
b. After checking, thoroughly remove water from each portion
of air suspension ASSV by applying compressed air.
55
4-1 SUSPENSION
When checking vehicle height sensor at body harness side A7) Poor sealing or air leak from solenoid valve
connector to control unit, disconnect connector from control
With compressed air applied to front or rear air suspension
unit and check for continuity between terminals. The corre-
ASSY or air tank, disconnect air pipe from air joint, which is
spondence between terminals is as shown below. far from the above parts, by using AIR PIPE REMOVER
(926520000)' and check for air leaks.
~
"NORMAL"
Low High Also check solenoid valve for air leaks.
position
(Blue) (Red)
Location (White)
AS) Break in solenoid valve
Front· Right Ci)
• • Apply 12 volts to coupler and check whether operating noise
Front· Left
• .• •., is heard. Or check whether there is continuity between
terminals with a tester .
Rear.Right
Rear· Left
•
8 fJ . A9) Clogging in air line
Oleck each air line for clogging. Repair bent or twisted air
pipe.
YL
OR
L Br LW RY YR A 10) Sticking of solenoid valve
GY
CD Height control unit y 36353433 313029 VA OF! RW
Check that height of affected suspensions decreases when each
G LR GW RW W
set of the following parts are grounded.
OR
R
OR
Lg
1)
• Right front solenoid valve
valve
ITJ and air discharge solenoid
LgW
OR
YB LgR GB YW RWOARY
• Left front solenoid valve [gJ and air discharge solenoid
valve
® Height control unit 20*-':1.~,.*"17'*,c:'.E15¥*=¥,,*.,:::1,-R B
B 1::: • Right rear solenoid valve ~ and air discharge solenoid
valve
RL YG YL BR BY
GW
L4-1375 • Left rear solenoid valve @] and air discharge solenoid valve
Fig. 83 Control unit connector and terminal Also check that a sound (air-discharge) is heard when both the
air discharge and the air charge valve are grounded.
2) If height of a particular suspension does not decrease,
disconnect the air pipe from the air joint on the solenoid
valve side of the affected strut. Use the PIPE REMOVER
Vehicle height sensor consists of four self-holding reed
(926520000) to disconnect the air pipe.
switches, whose connections are made as shown in following Apply 12 volts across the connector terminals of the solenoid
figure. valve. (No polarity is established.)
3) When height decreases in step 2) above, the air pipe is
Red
; Hi,h
faulty and must be replaced. When height does not decrease,
the solenoid valve is malfunctioning and must be replaced.
I ~
"NORMAL" position If the front strut solenoid valve is faulty, also check the air
pipe for clogging.
Switch 1 White
~
A 11) Malfunction of compressor
..... Low
Apply 12 volts to compressor to see if it operates.
~ Compressor motor contains a circuit breaker. So when motor
Switch 2 temperature rises too high, the circuit breaker stops the motor
to prevent it from burning up. If this happens, leave com-
Blue
pressor alone, and it will return to normal condition when it
L4-1376
cools down.
Fig. 84
56
SUSPENSION 4-1
A 12) Check on compressor relay 2) Terminal arrangement

(1) For wheel solenoid valve checks
Compressor relay has terminal arrangement as shown in the
Ground the following terminals.
figure.
A check on compressor relay should be made by applying
,\SOI'OOld wlw
EB 12 volts to terminal S, grounding terminal A, and checking
if continuity exists between terminals C and D. Also, check ' \ Solenoid valve
that continuity between terminals C and D does not exist
without applying EB 12 volts to terminal B.
Terminal arrangement Circuit diagram
,
\m
FR
\ [l]
FL
RR [J] RL @]
,
n
c ®
A 0 lsolenoid valve
rI-] Solenoid valve (Female)

L4-1379
U-V B C
Fig. 87
@ @
3) 4-pole connector (for use with compressor relay)
L4-1377
Fig. 85
[5J
A13) Check on electric circuit Co mpressor
Electric circuit should be checked with a load (such as solenoid
valve and control unit) disconnected from the part in which
continuity is to be examined.
As for signal wires other than power lines, check continuity
and also check whether voltage is not applied to them and also
whether they are not grounded.
L4-1307
Fig. 88
4) Connector for air discharge or charge solenoid valve

A14) Air suspension check connector Ground the following terminals after connecting female and
1) Connector locations male connectors.
Connector location for t Front

checking intake and e_x_h_au_s-t---_ _
solenoid valves
(Inside of left
fended
Front strut (RH)
(Female) (Female)
4-Pole Connector location for checking

connector location wheel solenoid valve
L4-1378 L4-1380
Fig. 86 Fig. 89
57
~
~ ~
~
~ RW
5 *: 2700 engine model

Fuse box
~
....o ~
Battery Fusible
link
j~85'!1 3W 1 3BW
~'tr~'NT~B Air
,." .
solenoid
.,.".".....,
disc:t.rvesolenoid
®~
III
a 4 1](0'''.1 2WB @
rrD~r~Tr
1~15W!8W* @
lit ~B'
~
3B
0.85Lg ... ~ OOD
@-RL ~8rw
-
~ r- O.85Lg @!Blackl
~.
G
rf~~~n21
O.85Lg LgA
j; ®B Br LW RV VR
GV 28 2 625
V 3635 .33 RW
*2WB
Ignition switch LR GW RLg
ON ST .2WB LgR LgR
B,
B,W
IG GW
Lg
RB
3W~ RL
t::1:!l::l-3B RW
RY
@(Black)
en
® YR c
® @) 'G,""' {rTtr-rI'II~III) @) en
R,Y
"'0
01
00
Combination meter ~
1111111r
11111'1
.
-<
BY
8A
L B YW
12 8 21 20 "
15143511 1
GY GB RY
28 5233118
J4 3 251622
RY
YG
VR
m
Z
$1~ en
RY T RG G YL LB LR GL LW GW
~ ,n YW
GY
oz
~
LR
LB
R
YR
YG Y-G--
BY BY
BR BR
YL YL
GW GW
@r
GB GB
RY
{IUIII) I
RY (Bluel
LW
GL
YB
LW
GL
YB
G
L
®
{l,JIII n
I
RG RG
B
r
<§) LoW
M®~ 1:«~11
o.
-M ~:;:. ~~ ®~: @)~

viR (Brown) L -< • VB __ LgR GB VW RWOR RV
~ = ~~ CI r G'I
ri
Y~:$
til
-< r
~
BY r "r
O.85lg
®B@) a
12 III '" -< r 15 U> " 0
GW 0B5L9~ RyQ ! @ ~1181u.l!t!151
i§j: I 112111+-RB
BG • BY YG EEJB GB 5 3 ® RL YG YL IBR BY
2L 28
Ground =
0.85Lg
ffi B YG EB sl9
O.B5Lg BG YL
® GW GL RG ~ ~ GW
@(Black)
Pneumatic Front Ro" Ru, Front

Front
suspension pneumatic pneumatIC pneumatIC
pneumat,,; pneumatIc
relay suspenSIon suspension suspenSIon sUsp8I'I$ion suspension
solenoid (LH) solenoid (RH) solenoid (RH) IRHI (RH)
!
....~
WHEELS AND AXLES
Page
SUBARU
1988
MECHANISM AND FUNCTION... . . . . . . . . . . . . . . . . . . . . . . . . . .. 2
Front Axle ..............•..•...................•..•.. 2
Rear Axle . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . ..
SPECIFICATIONS AND SERVICE DATA... . . . . . . . . . . . . . . . . . . .. 6
SPECIFICATIONS. . . . . . . . . . . . . . . • . . • • . . . • • . • • . . . . . . . . .. 6
4.
SERVICE DATA....................................... 8
COMPONENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9
Front Axle ........................................... 9
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11
SERVICE PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . .. 13
Front Axle ........................................... 13
Rear Axle (FWD) ....................................... 24
Rear Axle (4W D) ............. . . . . . . . . . . . . . . . . . . . . . . . . .. 26
Wheel and Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . • . . . . . . .. 29
4-2 WHEELS AND AXLES
MECHANISM AND· FUNCTION

Front Axle
Because Front Wheel Drive system is adopted on the vehicle, Since the drive shaft employs constant velocity joints, it
drive shafts are front axle shafts. The inboard end of the provides with smooth, even revolution of drive wheel without
axle shaft is connected to the differential via a constant vibration.
velocity joint (double offset joint: DOJ) which provides The disc hub is engaged to BJ spindle by means of serration
flexible capabilities in the longitudinal direction while the and secured by a castle nut and cotter pin via a center piece
outboard end is supported by ball bearings located inside and washer spring.
the housing via a bell joint (BJ) which features a large operat· After front axle parts have been repaired, toe·in should be
ing angle. adjusted.
1 Disc brake ASSY

2 Disc cover
3 Ball bearing
4 Housing
5 Axle shaft ASSY
6 Oil seal
7 Spacer
(j) 8 Center piece
9 Washer spring
10 Castle nut
11 Cotter pin
12 Hub and disc ASSY
L4'{)92
Fig. 1 Except XT6
2
WHEELS AND AXLES 4-2
CD
I
1 Disc rotor
2 Disc cover
3 Tapered roller bearing
4 Housing
5 Axle shaft ASSY ® @
6 Oil seal
7 Snap ring
8 Washer
9 Castle nut
10 Adjusting cap
11 Cotter pin
L4-1321
Fig. 2 XT6
3
Rear Axle
FWD ... The rear ax Ie spindle is welded on the rear trailing ASSY (disc brake models) is serrated and held to the spindle
arm, and the brake drum (drum brake models)/hub & with a castle nut and cotter pin.
disc ASSY (disc brake models) is attached to the The brake drum/hub is provided with a fitting section for the
spindle via the taper roller bearings. disc wheel in order to prevent eccentric installation of the disc
4WD ... The rear axle spindle is supported by bearings located wheel and vibration in high-speed operations.
inside the housing welded to the rear trailing arm.
The brake drum (drum brake models)/hub & disc
• FWD drum brake vehicle • FWD disc brake vehicle

@
@
@ @
® ®
• 4WD drum brake vehicle • 4WD disc brake vehicle
1 Taper roller bearing 8 Castle nut

2 Spacer 9 Cotter pin
3 Oil seal 10 Washer spring
4 Lock washer 11 Center piece
5 Drum cap 12 Hub and disc ASSY
6 Axle nut 13 Spindle
7 Washer 14 Bearing ASSY L4-397
Fig. 3 Except XT6
4
• FWD disc brake vehicle • 4WD disc brake vehicle
/
®
1 Tapered roller bearing 9 Cotter pin

2 Spacer 10 Washer spring
3 Oil seal 11 Center piece
4 Washer 12 Disc rotor
5 Drum cap 13 Hub
6 Axle nut 14 Spindle
7 Lock washer 15 Bearing ASSY
8 Castle nut
L4-1322
Fig. 4 XT6
5

SPECIFICATIONS
• TIRE & WHEEL SIZE

Front and Rear Spare
Model Rim offset
Rim offset P.C.D.
Tire size Rim size Tire size Rim size
mm (in) mm (in) mm(in)
DL 165SR13
140
5Jx13 T125/70D14 4Tx14 50 (1.97)
GL 185/70H R13 (5.51)
FWD
100
XT6 195/60R1485H 5-1/2JJx14 43 (1.69)
(3.94)
45 (1.77)
140
GL 185/70H R13 5Jx13 T135/70D15 4Tx15 53 (2.09)
(5.51)
4WD
100
XT6 205/60R1487H 5-1/2JJx14 46 (1.81)
(3.94)
liT-type" tire for temporary use is used as a spare tire.
• TIRE INFLATION PRESSURE

kPa (kg/cm 2 , psi)
Except XT6 196 (2.0,28)

Front tire
XT6 226 (2.3, 33)
Rear tire 196 (2.0, 28)
Spare tire T-type 412 (4.2, 60)
• FRONT AXLE SHAFT ASSEMBLY

DOJ
Type of axle shaft Shaft diameter (D)
Model
ASSY mm (in) Cooling groove No. of spline teeth
87AC-23 23
With
87AC-25 25
Except XT6 23.8 (0.937)
95AC-23 23
With
95AC-25 25
95AC-25 28 (1.10)
XT6 With 25
100AC-25 25.4 (1.000)
6
Proper use of front axle' shaft ASSY 95AC-23 and
95 AC-25
95AC axle shaft is available in two different sizes to suit the
CW I
103 mm (4.06 in) differential spindle in the transmission; DOJ spline 23 teeth
type [spline dia. 27 mm (1.06 in) dia.] and DOJ spline 25
teeth type [spline dia. 30 mm (1.18 in) dia.]. These shafts
L
must be used properly according to the "Application Table".
II When replacing a single DOJ unit or axle shaft ASSY, carefully
o check the actual vehicle to avoid improper use of axle shaft.
BJ DOJ
The axle shafts 95AC-23 and 95AC-25 can be distinguished by
the different shape of the DOJ small end as shown in the
figure.
L4-1474
Fig. 5 Improper combination of transmission spindle and DOJ spline

will result in the following faulty conditions.
a. 87AC-23, 95AC-23 combined with thick spindle [30 mm
Application table
(1.18 in) dia.]:
The axle shaft cannot be installed because the DOJ spline
FWD 4WD
diameter is small [27 mm (1.06 in) dia.].
Power unit b. 87AC-25, 95AC-25 combined with thin spindle [27 mm
MT AT MT AT (1.06 in) dia.] :
A large play will be formed between DOJ and spindle. (Fitting
Multi-Point
Fuel Injection
XT6
87AC-23 87AC-25 87AC-23
100AC-25
1/
95AC-25
the DOJ to spindle is too loose.) At the time of vehicle's
starting the spring pin will break, and a large noise will be
generated, then the vehicle will fail to go forward (FWD mode)
as the front differential rotates idly.
~wo4ID.Irrm"1 1fm'-~----,-I~ 87AC-25
-mrmm~I'L-~[__,----11~ 95AC-25
100AC-25
BJ DOJ
* Identification paddings
L4-1470
Fig. 6
7
SERVICE DATA
Item Standard
I Service Limit
Rear wheel bearing 8.34 - 14.22 N

Preload (Starting force when measured at hub bolt)
(FWD only) (0.85 - 1.45 kg, 1.87 - 3.20 Ib)
Wheel balancing Dynamic unbalance Less than 6 g (0.21 oz)
Balance weight part number
For steel wheel Weight g (oz) For aluminum wheel

723141010 10(0.35) 23141GA470
723141020 20 (0.71) 23141GA490
723141030 30 (1.06) 23141 GA510
723141040 40 (1.41) 23141GA530
723141050 50 (1.76) 23141GA550
723141060 60' (2.12) 23141GA570
723141070 5 (0.18) 23141GA460
723141080 15 (0.53) 23141GA480
723141090 25 (0.88) 23141GA500
723141100 35 (1.23) 23141GA520
723141110 45 (1.59) 23141GA540
723141220 55 (1.94)
8
COMPONENT PARTS
Front Axle
1. Except XT6
1 Cotter pin
2 Castle nut
3 Washer spring
4 Center piece
5 Hub
6 Brake disc
7 Disc cover
8 Oil seal
9 Ball bearing
10 Spacer
11 Housing
12 Axle shaft ASSY
13 Spring pin

Tl: 196 (20, 145)
T2: 44 - 58 (4.5 - 5.9, 33 - 43)
T3: 6 -14 (0.6 -1.4,4.3 -10.1)
T4: 49-69(5.0-7.0,36-51)
L4-098
Fig. 7
9
WHEELS AND AXLES~_ __
4~-2~_ _ _ _ _
2. XT6
=
Tightening torque~4S)
. N·m (kg-m, ft-Ib)
T1: 196 (20, 18 7 -13)
18 (1 0 - . ,
T2: 10 -7 8 (S'O _ 8.0,36 _ 58)
T3: 49 - . 4 _ 10)
T4: 6- 14 {O.6 - 1.4, _____
10
Rear Axle
1. FWD (Except XT6)

Tl: 46 - 58 (4.7 - 5.9,34 - 43)
T2: 78 - 98 (8.0 - 10.0,58 -72)
1 O-ring
2 Spacer
3 Oil seal
4 Taper roller bearing
5 Brake drum
6 Washer
7 Lock washer
8 Axle nut
9 O-ring
10 Drum cap
11 Disc cover
12 Brake disc
13 Hub
@ L4-398
Fig. 9
2. 4WD (Except XT6)
1 Disc cover
2 Brake disc
3 Hub
4 Center piece
5 Cotter pin
6 Washer spring
7 Castle nut
8 Brake drum
9 Ring nut
10 Spindle
11 Oil seal
12 Bearing ASSY

Tl: 46 - 58 (4.7 - 5.9, 34 - 43)
T2: 78 - 98 (8.0 - 10.0,58 - 72)
T3: 196 (20, 145)
T4: 172 - 221 (17.5 - 22.5, 127 - 163)
L4-399
Fig. 10
11
--- -
3.
1 O-ring
r htening torque: N·m 5(kg-m,9 34 ft-Ib)
_ 43) 2 Spacer
Ig T1: 46 - 58 (4_7 - 1·00 58 -72) 3 Oil seal .
T2: 7~8-=-....:.:.
98 _ (8_0_
- _._, 4 Taper ro lIer bearing
5 Brake drum
6 Washer
7 Lock washer
8 Axle nut
9 O-ring
10 Drum cap
11 Disc cover
12 Disc rotor
13 Hub
®
®
1 Disc cover
2 Disc rotor
3 Hub
4 Center p.iece
5 Cotter pin .
6 Washer spring
7 Castle nut
8 Brake drum
9 Ring nut
10 Spindle
11 Oil seal
12 Bearing ASSY
( 9 34-
ue· N·m 5kg-m,
T " htening torq. ft-Ib)
43)
~'"
F~", Ig T 8 (47 - . , 2)
. .., 1: 46 - 5 . 00 58 _ 7
T2· 78 - 98 (8.0 - 1 . , )
: 196 (20,145) 25 127 _ 163
T3. 172- 221 (17.5 _ 2 . ,
T4:
Fig. 11-2
12
a. Do not expand the slit of housing more than 4 mm

SERVICE PROCEDURE (0.16 in).
b. If housing is hard to remove from strut, lightly tap hub &
Front Axle disc with spare tire.
Housing (Except XT6) 12) Remove castle nut, washer spring and center piece on axle
shaft, and take out hub & disc ASSY.
REMOVAL 13) Remove disc cover.
14) Attach PULLER (926470000) to housing and drive axle
1) Disconnect ground cable from battery. shaft out of housing toward engine at the bearing location.
3) Remove front wheel cap and cotter pin, and loosen castle When inner bearing and/or inner oil seal are/is left on axle
nut and wheel nuts. shaft, remove them/it with a puller.
4) Jack up vehicle, support it with safety stands (rigid racks),
and remove front tires and wheels.
5) Release parking brake.
6) Pull out parking brake cable outer clip from caliper.
7) Disconnect the parking brake cable end from caliper lever.
8) Loosen two bolts, and remove the disc brake ASSY from
housing.
Keep the removed disc brake ASSY suspended from strut with
string.
PULLER (926470000)
L4-103
Fig. 13
15) Disengage transverse link ball joint from housing and

detach housing.
L4-101
~;,
~)-1
Fig. 12 I
DISASSEMBLY
In ner oil seal

9) Remove two bolts which connect housing and damper
strut.
10) Remove cotter pin and castle nut, and disconnect tie-rod
end ball joint from the housing knuckle arm by using a puller.
11) Disconnect strut from housing by opening slit of housing
and by lowering housing gradually with care of not damaging
Bearing
BJ boot.
L4-104
Fig. 14
13
1) Move spacer in radial direction with a finger.
Press
2) Hold an aluminum or brass bar against inner race of
bearing.
Lightly tap the bar with a plastic hammer to drive bearing out
of housing together with oil seal.
a. Do not tap bearing with a steel hammer, otherwise the

bearing will be damaged.
b. Tap evenly along entire periphery of bearing inner race.
1 Housing 3 Bearing(Outer)
2 PUNCH 4 DIE A16-160
Fig. 16
3) Turn upside down housing, and apply about 10 to 13 g

(0.35 to 0.46 oz) of bearing grease into inside of housing.
4) Insert spacer.
A16-158
Fig. 15
3) Pull out spacer.

4) Hold an aluminum or brass bar against outer race or inner
race of bearing.
Lightly tap the bar with a plastic hammer to drive bearing out 1 Spacer
of housing together with oil seal. 2 Housing
3 DIE
a. Tap evenly along entire periphery of bearing outer race or A16-196
inner race. Fig. 17

b. Do not reuse the oil seal.
5) The other beari ng is pressed in as shown in figure.
ASSEMBLY
Press is necessary in assembling.

1) Set housing on DIE (INSTALLER: 926490000). @
2) Set bearing onto PUNCH (INSTALLER: 926490000) and
gradually press it into housing till outer race of bearing comes 1 PUNCH
to contact with housing stopper. 2 Bearing(inner)
3 DIE
A16-162
Fig. 18
14
6) Set housing on DIE.
Apply sufficient grease to oil seal lip.
INSTALLATION
7) Insert outer oil seal into the groove of PUNCH so that the
oil seal lip faces the groove, and gradually press it into housing
1) Fit housing onto axle shaft and attach spacer of
till the face of PUNCH comes to contact with bearing outer
INSTALLER (925130000 or 922430000) on outer bearing
race.
inner race taking care not to damage the oil seal lip.
Then, connect the rod of INSTALLER to the thread of axle
shaft so that housing does not drop off from axle shaft.
2) Install transverse link ball joint to housing.
Tightening torque:
29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft·lb)
3) Turn the handle while holding the rod end by means of

spanner, thus housing is pushed in.
1 PUNCH 3 Housing
2 Oil seal(Outer) 4 DIE
A16-163
Fig. 19
Do not confuse outer oil seal \/\lith the inner since their outside
diameters differ as follmNs:
Outer oil seal. .... 72 mm (2.83 in) dia.
Inner oil seal ..... 76 mm (2.99 in) dia.
8) Turn upside down housing and set it on PUNCH.

9) Insert inner oil seal into the groove of DIE so that the oil L4·106
seal lip faces the groove, and gradually press it into housing. Fig. 21
4) Connect damper strut and housing by installing two bolts.
Tightening torque:
29 - 39 N·m (3.0 - 4.0 kg·m, 22 - 29 ft-Ib)
DIE
5) Connect tie-rod end ball joint and housing knuckle arm.
Tightening torque (Castle nut):

PUNCH
25 - 29 N'm (2.5 - 3.0 kg-m, 18 - 22 ft-Ib)
After tightening to the specified torque, further tighten castle

0
A16-164 nut within 60 to align holes of castle nut and ball stud.
Fig. 20 Then insert cotter pin into ball stud and bend it around castle
nut.
6) Install disc cover to housing.
Tightening torque:
6 -14 N·m (0.6 -1.4 kg-m,4.3 -10.1 ft-Ib)
7) Install hub & disc ASSY onto axle shaft.
15
Be sure to insert (press) hub & disc ASSY onto axle shaft until
the end surface of hub contacts ball bearing.
If the ASSY is hard to press, rotate it to locate the point
where it is easily pressed.
8) Install disc brake ASSY to housing by two bolts.

~aint mark
Tightening torque:
1 Cotter pi n
49 - 69 N·m (5.0 - 7.0 kg-m, 36 - 51 ft·lb)
Nut side .~. Center piece side 2
3
Castle nut
Washer spring
4 Center piece
Washer spring
A16·197
Fig. 24
12) Install wheels and wheel caps.

13) Put down vehicle from rigid racks.
14) Connect ground cable with negative terminal of battery.
L4·101
Fig. 22
9) Connect parking brake cable to brake ASSY.

Housing (XT6)
REMOVAL
1) Remove cotter pin and castle nut which secure tie-rod end
ball joint to housing knuckle arm.
2) Using a puller, disconnect tie rod end ball joint from
housing knuckle arm.
3) Remove 10-mm bolt. Extract trasverse link ball joint
from houisng.
4) Remove two bolts which connect housing and damper
strut, and disconnect strut from housing.
L4·036
Fig. 23

11) Fit center piece, washer spring and castle nut in this order
onto axle shaft and tighten castle nut to the specified torque,
then insert a new cotter pin and bend it around castle nut.
After tightening the nut to the specified torque, retighten

further within 30 0 until a slot of the castle nut is aligned to
the hole in the axle shaft.
Tightening torque:
196 N·m (20 kg-m, 145 ft-Ib)
Fig. 25
16
4) Remove two bolts which secure disc cover. Remove disc
DISASSEMBLY
cover.
5) Using a standard screwdriver, remove outer and inner oil
1) Using HUB STAND (927080000), support housing & hub
seals.
ASSY securely.
2) Attach HUB PULLER (927060000) to housing and drive
Do not use old oil seals.
hub bearing out.
L4·1326 L4-1464
Fig. 26 Fig. 28
6) Using pliers, remove snap ring.

7) Using HOUSING STAND (927090000), ~:,~.housing
securely. .,
8) Using BEARING PULLER (927100000), press inner race
to drive out outer bearing.
3) If bearing inner race remains in the hub, remove it a a. Do not remove outer race unless it is faulty.
suitable tool (commercially available). b. Discard outer race after removal.
c. Do not replace inner or outer race separately: always
replace as a unit.
L4-1463
Fig. 27
L4-1465
Fig. 29
a. Remove oil seal. Cut it off with shears to facilitate removal.

b. Be careful not to scratch polished area of hub.
c. Be sure to install inner race on the side of outer race from 9) Loosen bolts which secure tone wheel to hub. RemovetClne,
which it was removed. wheel.
,·17
10) Using HUB STAND (927080000) and a hydraulic press,

drive hub bolts out.
Be careful not to hammer hub bolts. This may deform hub.
HUB STAND
(927080000)
.0
iO
L4-1467
Fig. 32
a. Always press outer race when installing bearing.

L4-1466 b. Be careful not to remove plastic lock from inner race when
Fig. 30
installing bearing.
c. Charge bearing with new grease when outer race is not
I
removed.
5) Install snap ring in its groove.
Make sure to install it firmly to groove.

ASSEMBLY 6) Using OIL SEAL INSTALLER (927110000), press outer
oil seal until it contacts circlip.
1) Attach hub COMPL to HUB STAND (927080000) se-
curely. OIL SEAL INSTALLER
2) Using a hydraulic press, press new hub bolts into place. (927110000)
a. Use 12 mm (0.47 in) dia. holes in HUB STAND to prevent Snap ring
bolts from tilting.
b. Be sure to press hub bolts until their seating surfaces con·
tact the hub.
HOUSING STAND
(927090000)
L4·1468
Fig. 33
7) Invert HOUSING STAND and housing.

8) Using OIL SEAL INSTALLER (927110000), press inner
oil seal until it contacts the bottom of housing.
9) Apply sufficient grease to oil seal lip.
L4-1472
Specified grease
Fig. 31 SHELL XSG·6459
3) Clean dust or foreign particles from inside the housing. a. If specified grease is not available, remove bearing grease
4) Using HOUSING STAND (927090000) and BEARING and apply AutoRex A instead.
PULLER (927100000), press a new bearing into place. b. Do not mix different types of grease,
18- .
10) Install disc cover to housing using two bolts. 4) Jack up vehicle, support it with safety stands (rigid racks),
and remove front tires and wheels.
Tightening torque: 5) Release parking brake.
10 - 18 N·m (1.0 - 1.8 kg-m, 7 - 13 ft-Ib) 6) Remove parking brake cable bracket from transverse link.
7) Drive out spring pin of DOJ.
11) Attach hub COMPL to HUB STAND (927080000) se-
curely. Do not reuse spring pin.
12) Clean dust or foreign particles from the polished surface
of hub. 8) Remove disc brake ASSY, and disconnect damper strut,
13) Using HUB INSTALLER (927120000), press bearing into tie-rod end and transverse link from housing. (Refer to
hub by driving inner race. "REMOVAL" of "Housing".)
9) Remove axle shaft from differential spindle along with
housing.
10) Remove housing from axle shaft by using PU LLER
(926470000).
a. Be sure not to scratch boot when removing axle shaft

ASSY.
b. Do not apply excessive force to differential case when
removing axle shaft.
I
o
L4-1469
Fig. 34
Tightening torque:
DISASSEMBLY
38 - 50 N·m (3.9 - 5.1 kg-m, 28 - 37 ft-Ib)
15) Connect damper strut and housing using two bolts. 1) Straighten bent claw of larger end of DOJ boot.
2) Loosen band by means of screwdriver or pliers with care
Tightening torque: of not damaging boot.
64 - 83 N·m (6.5 - 8.5 kg-m, 47 - 61 ft-Ib)
Front Axle Shaft
Several kinds of front axle shaft ASSY are available. When

replacing a single DOJ unit or axle shaft ASSY, select the
correct one according to "SPECIFICATIONS AND SERVICE
DATA".
A16·198
REMOVAL
Fig. 35

2) Apply parking brake. 3) Remove boot band on the small end of DOJ boot in the
3) Remove front wheel cap and cotter pin, and loosen castle same manner.
nut and wheel nuts. 4) Remove the larger end of DOJ boot from DOJ outer race.
19
5) Pry and remove round circlip located at the neck of DOJ 3) BJ (Bell Joint)
outer race with a screwdriver. Check seizure, corrosion, damage and excessive play.
4) Boot
Check for wear,warping, breakage or scratches.
5) Grease
Check for discoloration or fluidity.
A 16-018
Fig. 36
6) Take out DOJ outer race from shaft ASSY.

7) Wipe off grease and take out balls and move cage to the
boot side. ASSEMBLY
a. To remove the cage from the inner race, turn the cage by a
Use specified grease.
half pitch to the track groove of the inner race and shift the
cage.
Specified grease for constant velocity joint:
b. Disassemble exercising care not to lose balls (6 pcs). Molylex No.2 (PIN 623029980)
c. The grease is a special grease (grease for constant-velocity
joint). Do not confuse with other greases.
1) Install BJ boot in specified position, and fill it with 60
to 70 g (2.12 to 2.47 oz) of specified grease.
8) Remove C-type snap ring, which fixes inner race to shaft,
2) Place DOJ boot at the center of shaft.
by using special pliers.
9) Take out DOJ inner race.
Be sure to wrap shaft splines with vinyl tape to prevent boot
10) Take off DOJ cage from shaft and remove DOJ boot.
from scratches.
Be sure to wrap shaft splines with vinyl tape to prevent boot 3) Insert DOJ cage onto shaft.
from scratches.
Insert the cage with the cut-out side facing the shaft end, since
11) Remove BJ boot in the same procedure as steps 1) to 3).
the cage has an orientation.
12) Thus, disassembly of axle is completed, but BJ is unable
to be disassembled.
INSPECTION
Check the removed parts for damage, wear, corrosion and etc.
If faulty, repair or replace.
1) DOJ (Double Offset Joint) Cut-out portion
Check seizure, corrosion, damage, wear and excessive play.
2) Shaft A16·200
Check excessive bending, twisting, damage and wear. Fig. 37
20
4) Install DOJ inner race on shaft and fit C-type snap ring 9) Align the outer race track and ball positions and place in
with special pliers. the part where shaft, inner race, cage and balls are previously
installed, and then fit outer race.
Confirm that the C-type snap ring is completely fitted in the
shaft groove.
1 Outer race
2 Grease
A16-019
Fig. 40
A16-199
Fig. 38
10) Install circlip in the groove on DOJ outer race.
a. Assure that the balls, cage and inner race are completely
fitted in the outer race of DOJ.
5) Install cage, which was previously fitted, to inner race b. Exercise care not to place the matched position of circlip
fixed upon shaft. in the ball groove of outer race.
c. Pull the shaft lightly and assure that the circlip is complete-
Fit the cage with the protruded part aligned with the track on ly fitted in the groove.
the inner race and then turn by a half pitch.
CD @
1 Inner race
2 Cage
A16-022
Fig. 39
Fig. 41
6) Apply the specified grease 20 to 30 g (0.71 to 1.06 oz) on 11) Add 20 to 30 g (0.71 to 1.06 oz) of specified grease to the
the cage pocket. DOJ's interior.
7) Insert six balls into the cage pocket. 12) Apply an even coat of the specified grease [20 to 30 g
8) Fill 20 to 30 g (0.71 to 1.06 oz) of specified grease into (0.71 to 1.06 oz)] to the entire inner surface of boot. Also
the interior of DOJ outer race. apply grease to shaft.
21
13) Install DOJ boot taking care'Wpt to twist it.
INSTALLATION (Except XT6)
a. The inside of the larger end of DOJ boot and the boot
groove shall be cleaned so as to be free from grease and other
substances. 1) Insert axle shaft into housing and attach spacer of
b. When installing DOJ boot, position outer race of DOJ at INSTALLER (925130000 or 922431000) on outer bearing
center of its travel. inner race taking care not to damage the oil seal lip.

14) Put a band through the clip and wind twice in alignment
with band groove of boot. Tightening torque:
29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-Ib)
Use a new band.
15) Pinch the end of band with pliers. Hold the clip and 3) Connect the rod of INSTALLER to the thread of axle
tighten securely. shaft and turn the handle while holding the rod end by means
of a spanner, thus axle shaft is pulled in.
When tightening boot, exercise care so that the air within the 4) Align the spring pin holes of DOJ and differential spindle.
boot is appropriate. 5) Connect DOJ and differential spindle by driving spring pin
in.
16) Tighten band by using BAND TIGHTENING TOOL
(925091000). a. Make sure that the holes are aligned before driving the
spring pin in.
a. Tighten band until it cannot be moved by hand. b. When driving the spring pin, always use new one.
b. Former BAND TIGHTENING TOOL (925090000) is inter-
changeable vvith this 925091000.
BAND TIGHTENING TOOL

(925091000)
Fig. 43
A16-201
Fig_ 42
6) Connect damper strut to housing, and tighten two bolts.
17) Tap on the clip with the punch provided at the end of Tightening torque:
BAND TIGHTENING TOOL. 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-Ib)
Tap to an extent that the boot underneath is not damaged. 7) Install disc cover on housing.
18) Cut off band with an allowance of about 10 mm (0.39 in) Tightening torque:
left from the clip and bend this allowance over the clip. 6 - 14 N·m (0.6 - 1.4 kg-m, 4.3 - 10.1 ft-Ib)
19) Fix up boot on BJ in the same manner.
8) Install hub & disc ASSY to axle shaft.
22
L4-111
Fig. 44 Fig. 45
9) Install or connect disc brake ASSY, parking brake cable, 5) Install transverse link temporarily to crossmember by
center piece, washer spring, axle nut, cotter pin, brake hose using a bolt and self-locking nut; then tighten self-locking nut
and tie rod end referring to "INSTALLATION" of "Housing". which installs transverse link to cross member.
10) Install wheels and tighten wheel nuts.
11) Install wheel caps in position. Torque (self-locking nut):
12) Put down vehicle from rigid racks. 93 -113 N·m (9.5 - 11.5 kg-m, 69 - 83 ft-Ib)
13) Connect ground cable with negative terminal of battery.
Self-locking nut should be replaced with a new one whenever
it is removed.
6) I nstall tie-rod end ball joint to the housing knuckle arm.
Torque (Castle nut):

25 - 29 N·m (2.5 - 3.0 kg-m, 28 - 22 ft-Ib)
After tightening the nut to the specified torque, adjust groove

on the nut and hole on the ball joint by retightening the nut
from 0 to 60 degrees.
7) After then, install new cotter pin into the hole, and bend
INSTALLATION (XT6)
it firmly.
8) Engage brake caliper lever with parking brake cable.
1) Insert BJ (bell joint) into hub splines. 9) I nstall the outer parking brake cable.
10) Install parking brake cable bracket to transverse link.
Be careful not to damage inner oil seal lip. 11) Pull parking brake lever.
12) Tighten axle nut.
2) Using AXLE SHAFT INSTALLER (922431000) and
EXTENSION (927130000), pull bell joint into place. Tightening torque:
196 N'm (20 kg-m, 145 ft-Ib)
Do not hammer axle shaft when installing bell joint.
Before tightening axle nut, raise vehicle with a jack, remove
3) Install a washer on the threaded portion of BJ (bell joint) wheel and apply parking brake. Do not tighten axle ,.t with
and temporarily tighten axle nut. wheels on the ground. Otherwise, bearing may be damaged.
4) Align the spring pin holes of DOJ and differential spindle,
then insert DOJ into differential spindle. 13) After tightening axle nut, locate adjusting cap so that
cotter pin can be driven into place while turning axle nut with-
0
a. Make sure that the holes are aligned before driving the in 15 •
spring pin in. 14) Drive cotter pin into place.
b. When driving the spring pin, always use new one. 15) Spread cotter pin to lock axle nut.
23
Rear Axle (FWD) 7) Remove outer race of outer bearing from drum.
The text describes the procedures for drum brake equipped INSPECTION
vehicle. Take similar procedures as the above for disc brake
equipped vehicle.
Clean the removed parts and check them for wear, damage and
corrosion. If faulty, repair or replace.
REMOVAL AND DISASSEMBLY

1) Apply parking brake, and loosen rear wheel nuts.
and remove rear tires and wheels. 1) Press outer race of inner bearing into drum using TAPER
3) Pry brake drum cap by screwdriver off drum. ROLLER BEARING INSTALLER (925220000) and a press.
4) Flatten lock washer and loosen axle nut, then remove lock
washer, washer and brake drum so as not to drop inner race of
outer bearing.
Outer races of outer bearing and inner bearing, and oil seal can
be removed together with drum.
5) Pry up spacer with a screwdriver and remove spacer and
inner bearing inner race with a gear puller.
A16-204
Fig. 48
2) Apply sufficient grease to oil seal lip. Install oil seal into
drum until its outer end is flush with the drum surface.
3) Press outer race of outer bearing into drum using TAPER
ROLLER BEARING INSTALLER (921130000) and a press.
A16·172
Fig. 46
6) Remove outer race of inner bearing from drum. Remove

•
oil seal at this time.
A16·205
Fig. 49
1 Outer race of inner bearing

4) Apply approximately 4 g (0.140z) of grease to inner
2 Outer race of outer bearing bearing and 3 g (0.11 oz) to outer bearing.
A16·203 Fill the boss of drum with approximately 30 g (1.06 oz) of
Fig. 47 grease.
24
5) Install spacer and inner race of inner bearing onto the
spindle of trailing arm.
Stepped surface of the spacer must be faced toward the
bearing.
Spring balance
A16-177
Fig. 52
inner bearing
2 Spacer
3 O-ring A16-206
Starting force when measured at hub bolt:
8.34 - 14.22 N (0.85 - 1.45 kg, 1.87 - 3.20 Ib)
Fig. 50
Make sure there is no free play in the bearing.

6) Install drum, inner race of outer bearing, washer, lock
washer and axle nut in this order onto the spindle. 3) Bend lock washer.
Be sure to use new lock washer without fail.
ADJUSTING REAR WHEEL BEARING
1) Temporarily tighten axle nut with tightening torque of

49 N·m (5 kg-m, 36 ft-Ib), and then turn drum back and forth
alternately several times to properly seat bearing and ascertain
bearing stability.
A16-202
Fig. 53
4) After installing O-ring to drum cap, install cap to brake

drum by lightly tapping with plastic hammer.
a. Do not use steel hammer etc.

b. Be so re to use new D-ring.
A16-176
Fig. 51
2) Turn back nut 1/8 to 1110 in order to obtain correct

starting torque. Measure the starting force as shown.
25
Rear Axle (4WD) I INSPECTION
Check the removed parts for wear and damage.

For 4WD model, dismount inner arm of trailing arm from If defective, replace with a new one.
vehicle body before removing and installing rear axle.
a. If a bearing is faulty, replace it as the bearing set.
The text describes the procedures for disc brake equipped b. Be sure to replace oil seal at every overhaul.
vehicle.
REMOVAL

INSTALLATION
2) Remove rear wheel cap and cotter pin, and loosen castle
nut and wheel nuts.
3) Detach shock absorber from inner arm. 1) Install inner race of inner bearing onto the spindle, and
4) Loosen lock bolts of crossmember outer bush. install outer races of inner bearing and outer bearing and
5) Jack up vehicle, support it with safety stand (rigid racks). spacer by using press.
6) Remove rear wheels.
7) Drive out spring pins of DOJ and BJ by using a steel rod Don't confuse orientation of bearing outer races.
of 6 mm (0.24 in) diameter.
8) Remove BJ from spindle of trailing arm with trailing arm 2) Apply grease of 20 to 30 g (0.71 to 1.06 oz) to bearing
lowered fully, then remove DOJ from differential spindle. outer race in housing.
3) Insert spindle from inside, and press inner race of outer
Disassembly and reassembly procedure of rear drive shaft is bearing from outside by using a pipe of 35 mm (1.38 in) in
inner diameter while tapping it with a hammer.
the same as that of front drive shaft.
9) Remove castle nut loosened previously and brake disc. Apply grease sufficiently on the inner and outer bearing area.
10) Disconnect brake pipe from brake hose at inner arm
bracket. 4) Install ring nut to housing by using WRENCH
(925550000) .
Fit air breather cap onto end of brake hose to prevent brake
fluid from pouring out. Tightening torque:
172 - 221 N·m (17.5 - 22.5 kg-m, 127 - 163 ft-Ib)
11) Remove brake ASSY from trailing arm.
12) Remove bolt holding inner bush of inner arm.
13) Remove three bolts which connect inner arm and outer
arm, and take out inner arm.
14) Vise inner arm, and straighten staked portion of ring
nut, then remove ring nut by using special tool WRENCH
(925550000) .
15) Extract spindle inwardly by lightly tapping it from
outside with a plastic hammer.
16) Remove outer oil seal from inner arm housing. /
17) Insert spindle from out side of housing, and extract outer
race of inner bearing, spacer and outer bearing by pushing
inner race of outer bearing through the spindle by a press.
18) Remove inner race of inner bearing from spindle by using
a press.
Fig. 54
26
5) Lock the ring nut by staking a point on the housing
surface facing the ring nut groove.
Fig. 57
Fig. 55
11) Temporarily fit brake disc, center piece, washer spring and
castle nut to spindle, in this order.
6) Install outer oil seal by using special tool INSTALLER
(925530000). a. Play on spindle experienced, when mounting brake disc is
not a fault.
Be su re to renew the oil seal. b. Don't confuse orientation of washer spring.
7) Install inner oil seal by using special tool INSTALLER

(925530000).
8) Mount inner arm to vehicle body.

9) Install rear brake ASSY to inner arm, and connect brake
pipes etc. ~aint mark
1 Cotter pin
.~. Center piece side

2 Castle nut
Nut side 3 Washer spring
4 Center piece
Washer spring
A16-197
Fig. 58
12) 'Bleed brake system.
a. Before bleeding brake system, check pedal play and brake

fluid level in reserve tank.
b. Bleed air from four wheels without fail.
L1-491
Fig. 56 13) Tighten castle nut, insert cotter pin and bend it firmly
with foot brake applied to lock the wheel and axle.
Tightening torque:
Tightening torque (Back plate': 196 N·m (20 kg-m, 145 ft-Ib)
46 - 58 N·m (4.7 - 5.9 kg-m, 34 - 43 ft-Ib)
After tightening castle nut to the specified torque, tighten
10) Connect brake hose and brake pipe. further within 30° to align holes on nut and spindle.
27
14) Install packing to differential spindle. 17) Drive spring pins into DOJ and BJ respectively.
15) Engage DOJ of rear drive shaft to differential spindle.
a. Before driving in the spring pin, confirm alignment of the
a. When mounting, mate the spline teeth properly so that the holes.
spring pin holes of DOJ and spindle will align. b. Be sure to use new spring pin.
b. When mounting the rear drive shaft ASSY, take care not
to mount the DOJ and BJ oppositely.
DOJ
A16-106
Fig. 61
18) Install wheels, outer arms, etc.

19) Lower vehicle. to the ground, and install lower end of
shock absorber to inner arm.
70.5 mm
t - - - t - t-I-t-t--+ (2.776 in)
dia.
BJ
L4-1115
Fig. 59
16) Install packing to rear spindle, and mount BJ of rear

drive shaft onto rear spindle with trailing arm lowered all the
way.
Fig. 62
Tightening torque:
88 - 118 N·m (9 - 12 kg-m, 65 - 87 ft-Ib)
20) Check and adjust rear vehicle hight and rear wheel align-
ment.
Fig. 60
28
Wheel and Tire Installation

Align the valve hole in the wheel cap with the valve on the
See "SPECIFICATIONS AND SERVICE DATA" for: wheel and secure the wheel cap by tapping four points (shown
• Combination of tire and wheel in Figure) by hand .
• Tire inflation pressure
CENTER CAP (XT6)
Wheel Cap Removal
HALF CAP Insert a screwdriver into access hole and pry center cap.
Removal
Pry off the half cap with a screwdriver inserted into openings
in the cap.
Slot for flat-blade screwdriver

L4-1471
Removal Installation Fig. 65
L4-1056
Installation
Fig. 63
After aligning notch in center cap with that of aluminum
wheel, push center cap into place. When not properly aligned,
Installation
center cap cannot be installed properly because its protrusion
Attach the half cap to the disc wheel. Using the palm of your rides over the wheel.
hand, turn it clockwise until it stops. (The cap will stop when
turned approximately 20° after the pawl engages the nut.)
FULL CAP
Removal
Pry off the full cap with a screwdriver inserted between open-
ings in the cap.
Wheel and Tire

1) Deformation or damage on the rim can cause air leakage.
Check the rim flange for deformation, crack, or damage, and
repair or replace as necessary.
2) Take stone, glass, nail etc. off the tread groove.
Hit 3) Replace tire:
Screwdriver
• when large crack on side wall, damage or crack on
tread is found .
L4-1205 • when the "tread wear indicator" appears as a solid
Fig. 64 band across the tread.
29
Wheel Balancing
,
Tread wear indicator
\
1) Proper wheel balance may be lost if the tire is repaire.d or
if it wears. Check the tire for dynamic balance, and repair as
necessary.
1
.. .... - 2) To check for dynamic balance, use a dynamic balancer.
Drive in the balance weight on both the top and rear sides of
... - the rim.
I
3) Some types of balancer can cause damage to the wheel.
Use an appropriate balancer when adjusting the wheel balance.
Tire tread 4) Use genuine balance weights.
A16-045 Parts No. for Parts No. for

Weight g (oz)
steel wheel aluminum wheel
Fig_ 66
723141010 10(0.35) 23141GA470
723141020 20 (0.71) 23141GA490
723141030 30 (1.06) 23141GA510
When replacing a tire, make sure to use only the same siz~, 723141040 40 (1.41) 23141GA530
construction and load range as originally installed. AVOId
723141050 50 (1.76) 23141GA550
mixing radial, belted bias or bias tires on the vehicle.
723141060 60 (2.12) 23141GA570
723141070 5 (0.18) 23141GA460
723141080 15 (0.53) 23141GA480
723141090 25 (0.88) 23141GA500
723141100 35 (1.23) 23141GA520
723141110 45 (1.59) 23141 GA540
723141220 55 (1.94)
Aluminum Wheel
Allowable dynamic unbalance:
6 g (0.21 oz) at rim flange
INSPECTION
Inspection for aluminum wheels is basically the same as the

one for steel wheels. However, check the rim flange for cracks
or damage, and replace (not repair) aluminum wheel if air
leakage is found.
PRECAUTIONS
Installation of Wheel Assembly to vehicle
Aluminum wheels are easily scratched. To maintain their 1) Attach the wheel to the hub by aligning the wheel bolt
appearance and safety, observe the following:
hole with the hub bolt.
1) Do not damage aluminum wheels during removal, dis-
2) Temporarily attach the wheel nuts to the hub bolts.
assembly, installation, wheel balancing, etc. After removing (In the case of aluminum wheel, use SUBARU genuine wheel
aluminum wheels, place them on a rubber mat, etc. nut for aluminum wheeL)
2) While vehicle is being driven, be careful not to ride 3) Manually tighten the nuts making sure the wheel hub hole
over sharp obstacles or allow aluminum wheels to contact is aligned correctly to the guide portion of hub.
the shoulder of the road. 4) Tighten the wheel nuts in a diagonal selection to the
3) When installing tire chain, be sure to install it properly specified torque. Use a wheel nut wrench.
not to have a slack; otherwise it may hit wheel while driving.
4) When washing aluminum wheel, use neutral synthetic
Wheel nut tightening torque:
detergent and water. Avoid using the cleanser including
abrasive, hard brushes or an automatic car washer. 78 - 98 N'm (8 - 10 kg-m, 58 - 72 ft-Ib)
30
a. Tighten the wheel nuts in two or three steps by gradually nT-type" Tire
increasing the torque and working diagonally, until the speci·
fied torque is reached. For drum brake models, excess liT-type" tire for temporary use is prepared as a spare tire.
tightening of wheel nuts may cause wheels to "judder".
b. Do not depress the wrench with a foot; Always use both a. Keep the inflation pressure at 412 kPa (4.2 kg/cm 2 , 60 psi)
hands when tightening. at all times.
c. Make sure the bolt, nut and the nut seating surface of the b. When the wear indicator appears on the tread su rface,
wheel are free from oils. replace the tire with a new one.
c. Do not use a tire chain with the "T·type" tire. Because of
the smaller tire size, a tire chain will not fit properly and will
5) If a wheel was removed for replacement or for repair of a
result in damage to the vehicle and the tire.
puncture, retighten the wheel nuts to the specified torque
d. When using a T·type tire:
after running 1,000 km (600 miles).
• Do not drive at a speed greater than 80 km/h (50 MPH).
• Drive as slowly as possible and avoid running over bumps.
• Do not drive with 4WD engaged.
Tire Rotation • Replace it with a conventional tire as soon as possible since
this "T·type" tire is only for temporary use.
If tires are maintained at the same positions for a long period
of time, uneven wear results. Therefore, they should be
pediodically rotated.
This lengthens service life of tires.
a. When rotating tires, replace unevenly worn or damaged

tires with new ones.
b. Since "T·type" tire for temporary use is prepared as a spare
tire, tire rotation is as folioVIIS.
Fig. 67
31
STEERING SYSTEM
Page
SUBARU MECHANISM AND FUNCTION. . . . . . . . . . . . . • . . . . . . . . . . . . . • ..

SPECIFICATIONS AND SERVICE DATA. . . . . . . . . . . . . . . . . . . . . .. 10
2
•
COMPONENT PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 13
1988 SERVICE PROCEDURE. . . . . . . . . . . . . . . . . . . • . . • . . . . . . . . . . . .. 18

Steering Column. . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 18
Steering Gearbox (Manual Steering System) . . . . . . . . . . . . . . . • . . . . .. 31
Steering Gearbox (Power Steering System) ...................... 41
Control Valve (Power Steering Gearbox) . . . . . . . . . . • . . . . . . . . . • . .. 52
Oil Pump (Power Steering System) . . . . • • . . . . . . . . . . . . . . . . . . . . .. 60
Fluid Line (Power Steering System) . . . . . • . . • . . . . . • . . . . . . . . . . .. 70
Motor Pump & Power Controller . . • . . . . • . . . . . . . • . . . . • . • . . . . .. 75
TROUBLESHOOTING ..............••.•••••..••.••.......• 83
4-3 STEERING SYSTEM

VGR (Variable Gear Ratio)
Gearbox
The variable gear ratio (VG R) gearbox is adopted on some
manual steering models to reduce steering effort when making
a full turn. This VGR gearbox adopts different rack tooth
shapes between the straight-ahead position and the fully
turned position. This varies the pitch circle diameter of the
pinion which engages with the rack teeth so as to provide a
solid steering feel when steering in the straight ahead position
and a light steering feel during turns.
I Variable Gear Ratio (VGR) type I
I
~ 30
~
Cl
c:
'0,
c:
(II
~
-10
20
10
Q /
u Rack stroke
Straight Full turning
I Constant Gear Ratio (CGR) type I
~ 30
~ 20
~ 10
'g. 0 f------------1
~--1O Rack stroke
U
Straight Full turning
L4-223
Fig. 1
The gear ratio is approx. 20 in the straight ahead position and

approx. 25 in the full turn position.
2
STEERING SYSTEM 4-3
TELESCOPIC CONSTRUCTION
Steering Column
When the telescopic lever on the steering wheel spoke is
The steering column is a tilt and telescopic type in which the turned, the lock shaft inside the telescopic shaft moves in
position of the steering wheel can be adjusted up and down axial direction by thread lead. This causes the lock key to, be
and back and forth. For better control and visibility, the released from or pressed against the steering shaft, so that the
service switches are arranged on a control wing overhanging position of the steering wheel is axially adjusted or secured.
the steering column. The control wing can tilt up and down It is adjustable up to 35 mm (1.38 in) with reference to the
and moves back and forth with the steering column. In standard position.
addition, the combination meter moves up and down as a unit
with the steering column.
Further, a pop-up mechanism with a memory is provided.
Operating the pop-up knob permits the steering wheel to be
popped up higher than the uppermost tilt position. The
steering wheel returns to its original position when pulled
down_
A CYBRID power steering sensor system is located on the
lower part of the steering column.
Unit: mm (in)
35
(1.38)
Pivot point
2 Lock pin
3 Standard position
4 Tilt lever
5 Telescopic lever
6 Steering shaft
7 Lock key
8 Lock shaft
9 Telescopic shaft
10 Telescopic lever ®
11 Threaded portion
12 Steering sensor (XT6 only)
L4-1400
Fig. 2
3
4-3 STEERING SYSTEM
TI LT AND POP-UP CONSTRUCTION

The steering column is designed so that it can be either raised
or lowered. The pivot point is at the flexible supporting
portion to the body, at the lower end of the steering column.
This permits the steering wheel to be adjusted 32 mm (1.26 in)
upwards and 20 mm (0.79 in) downwards. By operating the
tilt lever, the tilt bracket on the steering column is loosened
or tightened allowing the steering wheel to be adjusted or
secured.
Further, when the knob on the instrument panel is pulled,
the lock pin connected to the knob with a cable is pulled out
of the fit hole in the column inner bracket and the balance
spring built into the column forces the steering wheel to pop
up 64 mm (2.52 in) above the standard position. And then
steering column locks at original position when steering wheel
is pulled down.
I nner bracket Lock pin
/
/
Tilt bracket
/
Tilt lever L-- --~I--L __ ~--'-' __ I
Knob
Cable
Instrument panel
L4-691
Fig. 3
4
STEERING SYSTEM 4-3
Electronic- Controlled Moter In other words, this system is a car-speed sensing type which
reduces "assist" force as car speed increases. It automatically
Drive Power Steering selects four driving modes according to average car speed and
frequency of steering operation.
System Configuration These modes include high-speed driving, suburban driving,
winding-road driving and city-driving. The motor will not
The electronic-controlled motor drive power steering system
activate when not steering at car speeds below 10 km/h (6
detects both car speed and frequency of steering operation. It
activates the motor to supply the required amount of oil to MPH).
the gear box through a command from the controller and pro-
vides "assist" force in relation to car speed.
Signal
controller t - - - - - - - ,
+
Battery
Ignition switch
Alternator
Engine
Pump driven by
electric motor
Speed sensor
Sensor steering
Power steering gearbox

L4·1401
Fig. 4
5
4-3 STEERING SYSTEM
Tilt steering ASSY
Hose ASSY
Motor pump
Power controller
Steering gearbox ASSY Steering sensor
L4-1402
Fig. 5
Electronic Control Logic Configuration 1) Initial diagnosis

In the initial diagnosis mode, current flowing through the
The electronic control logic configuration of the electronic- warning lamp system, engine signal system and electric motor
controlled motor drive power steering system included both an system is checked.
initial diagnostic function and a normal processing function to
monitor input and output signals transmitted by various parts. Ignition switch ON
It includes a self-diagnosis function by which warning lamps
are activated to indicate a problem. It also has a self-check
Checking warning lamp for operation
function. Malfunctioning systems can be determined by the
operation (blinking) of the warning lamp in the "check"
mode. Start the engine
Checking engine input signals,

and operation of motor and controller
Warning lamp Warning lamp

comes on does not come on
Operation (blinking) of warning
lamp is read to determine Normal processing
a malfunctioning system. Constant monitor is conducted
of system operation
6
STEERING SYSTEM 4-3
2) Normal processing (4) Assist control function
Upon completion of the initial diagnosis, normal processing Q) Car speed greater than 10 km/h (6 MPH)
controls steering in response to car speed and steering fre- "Duty" is determined by both car speed and driving
quency. mode.
(1) Diagnosis and fail-safe function ® Car speed less than 10 km/h (6 MPH)
The operation of the signal controller, power controller, When a steering pulse is entered, "Duty" will be
signal system and motor power supply is monitored at all 100%. If no pulse (for steering) is entered thereafter,
times. If a problem occurs, the warning lamp (located in "Duty" will decrease gradually.
the combination meter) comes on to warn the driver. The (5) Relaxation function (when is OFF)
fail-safe function activates, depending on the type of A great shock will be felt on the steering wheel if "Duty"
problem, and current flow to the motor is controlled to is abruptly decreased to "0". The "Duty" is decreased by
maintain proper steering. 1 degree every 0.5 seconds*2.
*2: 1 deg. = (2.5 to 3.5%)
3) Other functions
(1) Sub-fan control
S " . \\~ \,I:

O""tb
I", ¢(/ ¢
,45
.. \ \ ~51 6'5 '7~ I I
85/, (18
When the steering wheel is turned very quickly at speeds
PS, 45 .... 2
5',./ ( ........ 35 95 '" 12v
vom below 10 km/h (6 MPH), the sub fan is turns OFF.
, 6" \ ]5 ; ~D.
-1 ~\.... ~ ~ 1!3
"bo': )(1000r/min
-~\\) "'5
105_
When speed increases to 10 km/h (6 MPH) and the steer-
:J ~~O 7-1;;'~ -
- 115-
TEM'
4,
H
0=
~
'""'0
II]
8 : )
_
~'/ J
~
MPH
@
IQ[IDilj
125_
135:
,
6.. F
C:::Q) au
'UEC
tJNLEADt-D
'UECONlY
ing wheel is turned slowly, the sub fan comes ON again.
(2) "Runaway" detection function
When the microcomputer runs away of if the internal
\ power supply drops below the specified voltage, the
Warning lamp
microcomputer will reset*3.
*3: Refers to restoration of the microcomputer to a state
in which the power is initially turned ON.
L4-1403
Fig. 6
System Check Mode
1) Self-check procedures
Ignition OFF
(2) The following functional checks are conducted con-
stantly during normal processing.
CD When current in excess of 100 A flows to the Connect check terminal to GND.
motor for more than 10 seconds, the warning lamp
comes on. "Duty" will then decrease to "0."
® When power supply greater than 9 V continues Start the engine.
for at least 1 second, the warning lamp comes on.
"Duty*! " will gradually decrease. When the normal Drive the car at least 10 meters (33 ft.)
power supply is restored, the warning lamp goes out.
"Duty" will then be controlled.
0
@ When the engine stops, the warning lamp comes Turn steering wheel at least 90 •
on. "Duty* 1" will then gradually decrease. After

restarting, the warning lamp goes out. "Duty" will be Wait for 15 seconds.
controlled again.
@ If no pulses are emitted when speed exceeds 25
km/h (16 MPH), the car-speed sensor system will Disconnect check terminal from GND.
register a "malfunction". The steering force im-
mediately before the malfunction is maintained.
*1: Refers to a "relaxation" function (when is OFF).
(3) Relaxation function for changes in driving modes
"Duty" differs with driving modes. If "Duty" changes
abruptly in response to a change in driving mode, a shock
is felt on the steering wheel. To prevent this, "Duty" is
gradually decreased by 1 degree every 0.1 seconds*2.
7
4-3 STEERING SYSTEM
Determination by blinking pattern of warning lamp How to read blinking pattern

ex.: 1. All systems are in good condition
Start pulse output only
1 second (ON) 1 second (ON)
~ ...... Pulse pattern to be repeated

1 second (OFF)
2. Car-speed pulse system is in no-good condition

...... Pulse pattern to be repeated
Start pulse Car speed NG
3. Car speed pulse system is in no-good condition and current flow to motor exceeds 100 A
...... Pulse pattern to be repeated
Start pulse Car speed NG Motor current 100A NG L4-1453
Fig. 7
Diagnostic items in the check mode
Item to check Description Operation pattern of warning lamp Flowchart
No signal is transmitted from

Engine input system Does not come on
EGI control unit
Car-speed signal less than 5

Car-speed pulse system
pulses ~
Break in temperature sensor
Steering pulse system
circuit ~
Harness system
(Temperature sensor
operation)
Break in heater drive circuit JLJlJl.JL.-
Harness system (Heater Motor current less than 5 A
drive circuit operation) (Motor does not rotate) ~
Refer to
Current flow to motor 6-3.
Motor current greater than 100 A for at
least 10 seconds
Signal-controller power
Motor current supply below 9 V for at least
1 second.
~
Power supply
Power controller Inability to control
Systems are in good condition --'LJL
8
STEERING SYSTEM 4-3
Construction 3) Power controller

This controller regulates current flow to the motor pump
1) Steering sensor ASSY in response to instructions emitted by the signal con-
This sensor receives a pulse signal corresponding to the steering troller. It is located by the motor pump on the duct COMPL.
operation. It is constructed with a slit plate placed between in the engine compartment.
the photo couplers. The slit plate rotates as a unit with the It is equipped with a current sensor, which monitors current
column shaft. The sensor is located at the bottom of the flow through the power controller, a unit which prevents
column shaft, on the inside of the toe-board. reception of external noise (radio noise, etc.), and a power
transistor to control current flow.
Column pipe
/ Column ,haft
Sensor plate Power controller
Photo couplers
L4-1406
Fig. 10
4) Signal controller
This controller contains a 4-bit microcomputer. It is located
between the rear quarter inner panel and the inner trim. It
receives signals from the car-speed sensor to detect both car
speed and steering operation and controls the operation of the
motor pump ASSY. Since it is a car-speed-sensitive unit, it
L4-1404 serves to reduce steering "assist" as speed increases. It also has
Fig. 8 an automatic selective function for high-speed operation,
suburban driving, winding-road driving, and city-driving
2) Motor pump ASSY modes.
The motor pump ASSY is located on the duct COMPL. in the
engine compartment. An electrical motor rotates the oil pump
in place of the engine-drive unit. With this motor ASSY, high
viscosity steering fluid is quickly warmed in cold weather
below -20°C (_4°F) immediately after the engine starts. As a
result, proper steering performance is maintained.
Cap
Strainer
L4-1407
II--IN
Fig. 11
I
Electrical motor
Heater
L4-1405
Fig. 9
9
4-3 STEERING SYSTEM

Specifications
1800 ee 2700 ce
Minimum turning circle 9.7 m (31.8 ft) 10.4m (34.1 ft)
Steering angle (Inside - Outside) 38° - 34.5° 36° - 32°

Whole Steering wheel diameter 370 mm (14.57 in)
System
Overall gear Manual
steering
VGR*1 20.0 - 25.0 (4.8) -
ratio (Turns,
lock to lock)
Power steering 17.0 (3.5) 17.0 (3.2)
Manual steering Rack and pinion -

Type
Power steering Rack and pinion, Integral
Gearbox
Backlash o (Automatically adjustable)
Valve (Power steering system) Rotary valve
Type Vane pump
Oil tank Installed to pump
5.9 cm 3 1.8 cm 3
Output
(5.9 ce, 0.360 cu in)/rev. (1.8 ce, 0.110 cu in)/rev.
6,375 kPa
TURBO & MPFI
(65 kg/cm 2,924 psi) 6,865 kPa
Relief pressure
4,413 kPa (70 kg/cm 2, 995 psi)
Pump Others
(Power (45 kg/cm2, 640 psi)
steering
Drooping in response to Electronic control, car-speed
system) Hydraulic flux control
engine revolution sensing type
7 liters Max 4.8 liters

700 rpm
(7.4 US qt, 6.2 Imp qt)/min. (5.1 US qt, 4.2 Imp qt)/min.
Hydraulic flux
3,000 rpm
2.5 liters Min a
liters
(2.6 US qt, 2.2 Imp qt)/min. (0 US qt, 0 Imp qt)/min.
Range of revolution 500 - 7,000 rpm 0- 2,800 rpm
Revolving direction Clockwise
Name ATF DEXRON II SPECIAL STEERING FLUID

Working
Fluid (Power 0.28 liters 0.25 liters
Oil tank
steering (0.6 US pt, 0.5 Imp pt) (0.5 US pt, 0.4 Imp pt)
Capacity
system) 0.7 liters 0.7 liters
Total
(1.5 US pt, 1.2 Imp pt) (1.5 US pt, 1.2 Imp pt)
*1 Variable Gear Ratio
10
STEERING SYSTEM 4-3
Service Data
ITEM STANDARD
I SERVICE LIMIT
Steering wheel Free play 0- 25 mm (0 - 0.98 in)
Inner tire & wheel 1800 cc 36°30' - 39°30'

2700 cc 34°30' - 37°30'
Turning angle
Outer tire & wheel 1800 ce 33° - 36°
2700 ce 30° 30' - 33° 30'
Clearance between steering wheel and 2 - 4 mm (0.08 - 0.16 in)

Steering shaft
column cover
Rack shaft Bend limit (Run-out) 0.2 mm (0.008 in)

Pinion Free play limit 0.3 mm (0.012 in)
Steering gearbox Rotating torque Within 30 mm (1.18 in) from rack center at straight-
(Manual steering ahead position:
system) Less than 0.9 N.m (0.09 kg-m, 0.7 ft-Ib)
Maximum allowable value:
1.4 N·m (0.14 kg-m, 1.0 ft-Ib)
Sliding resistance 1800 ec 304 N (31 kg, 68 Ib) or less

2700 cc 284 N (29 kg, 64 Ib) or less
Rack shaft play in radial direction

Right-turn steering 0.15 mm (0.0059 in) or less
Left-turn steering Horizontal movement:
0.3 mm (0.012 in) or less
Vertical movement:
0.15 mm (0.0059 in) or less
Steering gearbox
(Power steering Input shaft In radial direction 0.18 mm (0.0071 in) or less
system) play In axial direction 0.1 mm (0.004 in) or less
Turning resistance Within 30 mm (1.18 in) from rack center at

straight-ahead position:
1800 cc Less than 11.18 N (1.14 kg, 2.51 Ib)
2700 cc 10.20 N (1.04 kg, 2.29 Ib)
Maximum allowable value:
1800 cc 12.7 N (1.3 kg, 2.9 Ib)
2700 cc 11.67 N (1.19 kg, 2.62 Ib)
Pulley shaft Radial play 0.4 mm (0.016 in) or less

Axial play 0.9 mm (0.035 in) or less
Oil pump Pulley D itch deflection 1.0 mm (0.039 in) or less
(Power steering Resistance to rotation 9.22 N (0.94 kg, 2.07 Ib) or less
system for 1800 ec)
Regular pressure 981 kPa (10 kg/cm 2 , 142 psi) or less
Relief pressure and working pressure 5,884 - 7,355 kPa
(60 - 75 kg/cm 2 , 853 - 1,067 psi)
11
r
4-3 STEERING SYSTEM
ITEM STANDARD SERVICE LIMIT

I
Regular pressure 981 kPa (10 kg/em 2, 142 psi) or less
Motor pump
Relief pressure and working pressure 6,669 - 7,355 kPa
(Power steering
(68 - 75 kg/cm2, 967 - 1,067 psi)
system for 2700 cc)
Continuous output rating of motor 140W
Belt line (Power Belt tension Refer to 1. Drive Belt(s) [Except Camshaft] in
steering system) chapter 1·5.
I n standstill with engine idling on 31.4 N (3.2 kg, 7.1 Ib) or less
Steering wheel concrete road
efforts (Power
I n standstill with engine stalled on 93.2 N (9.5 kg, 20.9 Ib) or less (1800 cc)
steering system)
concrete road 118 N (12 kg, 26 Ib) or less (2700 cc)
• Recommended Power Steering Fluid (Except XT6)
B.P. B.P. Autran DX
CAlTEX Texamatic Fluid 6673 Dexron
CASTROl CASTROl TO Dexron
MOBil Mobil ATF220
SHEll Shell ATF Dexron
TEXACO Texamatic Fluid 6673 Dexron
• Recommended Power Steering Flu id (XT6)
IDEMITSU Special Power Steering Fluid
12
STEERING SYSTEM 4-3
COMPONENT PARTS
Steering Column
21 Snap ring
1 Pipe ASSY 22 Washer
2 Shaft ASSY 23 Dust seal
3 Fix bracket CP 24 Spacer
4 Inner bracket CP 25 Memory pin ASSY
5 Tilt lever 26 Bolt
6 Bolt 27 Bolt
7 Tilt adjusting screw 28 Telescopic lever
8 Bearing 29 Nut
9 Washer 30 Column pipe CP
10 Bolt 31 Pin ASSY
12 Wing bracket ASSY 33 Tilt spring
13 Telescopic shaft 34 Boss
14 Telescopic lock shaft 35 Bolt
15 Rod 36 Lock washer
16 Telescopic lock key 37 Telescopic bush
17 Snap ring 38 Bearing bush
19 Telescopic adjusting 39 Bearing
screw 40 Telescopic guide
20 Nut 41 Steering shaft CP
42 Snap ring
43 Washer
44 Shaft spring
45 Washer
46 Bearing
47 Bearing bush
48 Housing
49 Pin CP
50 Bearing
51 Clip
52 Stopper
53 Toe board bush
54 Lower cover ASSY
55 Pop-up cable ASSY
56 Dress nut
57 Knob
58 Cap
59 Lower column cover
60 Upper column cover
61 Combination switch
ASSY
62 Steering wheel ASSY
63 Washer
64 Spring washer
65 Nut
66 Spring washer
67 Pad ASSY
68 Protector
69 Pad
70 Steering sensor
71 Screw ASSY
72 Clip
73 Pad CP (Knee)
74 Washer
75 Spring washer
76 Screw
Fig. 12 L4-1408
13
4-3 STEERING SYSTEM
CD
A
1 Steering gearbox ASSY ®

2 Tie-rod end ASSY (LH)
3 Tie-rod and ASSY (RH)
4 Dust seal
5 Clip
6 Clip
7 Rack boot
8 Clip
9 Tie-rod CP
10 Lock washer
11 Pinion dust cover
12 Oil seal
13 Snap ring
14 Pinion ASSY
15 Lock nut
16 Adjusting screw
17 O-ring
18 Sleeve spring
19 Sleeve /"1
20 Gearbox unit
/' I
,/,/ I
21 Adapter B ,/ I
,/
22 Bushing A /' I
/
23 Retainer I
24 Clip /'
./ I
25 Adapter A ,/
I
,/ I
26 Rack ,/
/'
I
,/
/' I
./
,/
./ )
.-'
,/
/'
,/
,/
/'
,/
,/
/'
,/
./
./
,/
./
./
./ 9
/'
./
/'
® ®
I
v
Fig. 13 Steering gearbox L4-1158
14
STEERING SYSTEM '4-3
Power Steering System (Except for XT6)

1 Tie-rod end ASSY, R H
2 Tie-rod end ASSY, LH
3 Dust seal
4 Snap ring
5 Nut
6 Clip (small)
7 Boot
8 Clip (large)
9 Tie-rod CP
10 Lock washer
11 Dust cover
12 Clip (medium)
14 Sleeve
15 Spring
16 O-ring (sleeve)
17 Adjusting screw
18 Lock nut
19 Rack ASSY
20 Adapter (cylinder)
21 Steering body ASSY
22 Seal holder ASSY
23 V-packing (seal holder!
24 O-ring (seal holder)
*25 Snap ring (seal holder!
*26 Oil seal (pinion housing)
27 Backup ring
30 Adapter (gear)
31 O-ring (pinion)
32 Seal ring (pinion)
33 Valve housing ASSY
34 Snap ring (pinion)
35 Backup ring
*36 V-packing (valve housing)
37 Ball bearing (valve housing)
38 Pinion & valve ASSY
39 O-ring (valve)
40 Seal ring (valve)
41 O-ring (rack piston)
42 Seal ring (rack piston)
*43 Dust seal
44 Oil seal (pinion)
45 Spacer
46 Valve ASSY
47 Shim
49 Pipe ASSY A (Long)
Tightening torque N·m (kg-m, ft-Ib) Pipe ASSY B (Short)
50
T1: 42 - 62(4.3 - 6.3, 31 - 46) 51 Bolt
T2: 20 - 29 (2.0 - 3.0, 14 - 22) 53 Seal kit
T3: 18 - 22 (1.8 - 2.2, 13 - 16) Consists of all * marked
T4: 29 - 49 (3.0 - 5.0, 22 - 36) parts for one vehicle.
55 Tank ASSY
T5: 20 - 24 (2.0 - 2.4, 14 - 17) 56 Cap
T6: 5 - 8 (0.5 - 0.8, 3.6 - 5.8) 57 Strainer
T7: 10 - 16 (1.0 - 1.6, 7 - 12) 58 O-ring
T8: 10 - 20 (1.0 - 2.0, 7 - 14) 59 Pipe ASSY E
60 Bracket
T9: 2 - 3 (0.2 - 0.3, 1.4 - 2.2)
61 Pulley
62 Pump ASSY
63 Hose A
NOTE: 64 Hose B
a.0 shows availability as replacement part. 65 Pipe C
b. * can not be supplied singularly. These parts are supplied as 66 Pipe 0
®.
..ts,available 8S seal kit 67
68
Clamp A
Clamp B
Fig. 14 69 Clamp C
L4-693
15
4-3· STEERI~NG~S~Y.:::.ST..:....:E_M___ _
1 Rear body
2 Seal washer
3 Pin
4 Rotor
5 Vane
6 Cam ring
7 Pressure plate
8 a-ring
9 Front body ..- --
" ..- --
10 Oil sea~ . ..- --
11 Retainmg nng '" ................... ./
..-"-
12 Shaft ................. .".
13 Bearin~ '",
14 Snap nng
15 Pulley
16 Spring
17 Spool valve ®
18 Connector
ing torque N· m (kg-m, 22ft-Ib)

_ 29)
Tighten
T 39 (3.0 - 4.0, 3)
1: 29 - 6 0 36 _ 4
T2: 49- 59 (5.0 - . ,
- 15 Oil pump
Fig. L4-1222
16
STEERING SYSTEM 4-3
Power Steering System for XT6 19 Rack ASSY

20 Adapter (cylinder)
21 Steering body ASSY
1 Tie-rod end ASSY, RH 22 Seal holder ASSY
2 Tie-rod end ASSY, LH 23 V-packing (seal holder)
3 Dust seal
@
24 O-ring (seal holder)
4
5
Snap ring
Nut G *25
*26
Snap ring (seal holder)
Oil seal (pinion housing)
I~i
6 Clip (small) 27 Backup ring
7 Boot 30 Adapter (gear)
8 Clip (large) 31 O-ring (pinion)
9 Tie-rod CP ~, : 32 Seal ring (pinion)
10
11
12
Lock washer
Dust cover
Clip (medium)
[23]' 4 33
34
35
Valve housing ASSY
Snap ring (pinion)
Backup ring
~
14 Sleeve *36 V-packing (valve housing)
15 Spring
16 O-ring (sleeve) ® ®
I
"-
37 Ball bearing (valve housing)
17 Adjusting screw
i ;..,..,/ I ............... ' ; ; r-®
18 Lock nut J ,/®
~~
~ / ~
19-~@ /;/
>/ < ~®
~ ~ ~~/>/ @ ~ ~':~-"Y
~ /~®@, X
® -~~\ @* 1m
~~@ ~
~~ ®
~
~~rfim @
*@ ®~ ~\ \~
I / ~ @@ ® 38 Pinion & valve ASSY
~~?1\~ w
/ \ , ff2r\@43090-ring(VaIVe)
.._.If
.. /
~ .@ Seal ring (valve)
~'\o ~~/
O-ri ng (rack piston) :~
t
Seal ring (rack piston)
-@~ T ~/ .!@f ® ® *:~ g~~e:~aipiniOn)

0~~0-©_ ~
Ii I
~ • ~~'\~ ~, (L~ /8 (J) ~~il:

c U I· / /@®45spacer
46 ASSY
~
?7~ 0 ~ \\~
18
®®® ®
~®((Dl:~
I/ ~ Pipe ASSY A (Long)
((Dl roP~
(J) / ~ i
:
I 0
I (; /
d@~~}@
/ e@l
50 Pipe ASSY B (Short)
:~ ~~~ kit
Consists of all * marked
® ~~/ -j§\J ~ 55 parts for one vehicle.
~ / Motor pump ASSY
® 56 Cap
'@' 57 Strainer
58 Mounting rubber
59 Motor pump spacer
61 Spacer bushing
62 Bracket bushing
63 Hose A
64 Hose B
65 Pipe C
66 Pipe 0
67 Clamp A
68 Clamp B
69 Power controller
70 Motor pump bracket
71 Bracket bushing
72 Motor pump bolt
a. 0
shows availability as replacement part.
b. * can not be supplied singularly. These parts are supplied as
Fig. 16 sets, available as seal kit ®_ L4-1409
17
4-3 STEERING SYSTEM
SERVICE PROCEDURE
11) Remove steering column mounting bolts under instrument
Steering Column panel.
REMOVAL
1) Disconnect ground (-) battery cable.

2) Remove universal joint.
Not only when removing steering shaft/column but when

removing steering column for servicing of other parts, be sure
to remove universal joint. Steering column must not be
lowered with only column mounting bolts loosened.
3) Remove lower cover under instrument panel.

4) Remove ventilation duct under steering column.
5) Remove protector by taking off the screw and clip.
Fig. 18
I
12) Pull out steering shaft ASSY from toe board toward
Fig. 17
6) Through the opening in toeboard, disconnec the steering

sensor wiring harness at the bottom of steering column shaft.
7) Disconnect wiring harness connectors for ignition switch,
combination switch, control wing switch, and combination
meter. Then, remove screws securing harness under column
bracket. Fig. 19
8) Remove meter cable.
9) Pull knob to pop up steering wheel. Then, remove cable,
push down steering wheel and relock it. a. Be careful not to damage sensor steering and its wiring
10) After setting steering wheel to lowest position, fasten tilt harness.
lock bolt [8 mm in dia. and 16 mm (0.63 in) in length] from b. Because combination meter is removed with shaft assembly,.
below column bracket. be careful not to damage meter and instrument panel surface.
a. Temporarily tighten bolt until its bearing surface touches.

b. This step may be omitted when entire steering column
ASSY is to be disassembled.
18
'.
STEERING SYSTEM 4-3
DISASSEMBLY
sr Remove upper and lower steering column covers by
loosening four screws.
1) Remove pad ASSY from steering wheel as follows. Loosen 6) Remove control wing ASSY and combination switch
telescopic lever. With your hand, hold pad's concave portion ASSY.
containing lever and pull it toward you.
2) Loosen nut on top of steering shaft, and remove tele-
scopic lever.
_'_I
L4-785
Fig. 23
Telescopic lever
L4-700 7) Remove two screws which secure steering sensor to
Fig. 20 column and remove steering sensor.
3) Loosen nut securing steering wheel, and remove steering
wheel from shaft using a steering wheel puller.
TELESCOPIC PORTION
(Telescopic portion can be disassembled without removing
column ASSY from vehicle.)
Fig. 21
4) Loosen nut on meter bracket of steering column, and

remove combination meter ASSY.
L4-702
Fig. 24
1) Remove nut ® and adjusting screw @ in underside of

wing bracket ASSY @' Then, remove bracket @ and
telescopic shaft @ as a unit. .
2) Remove snap ring @ and then shaft @ from bracket @.
3) From shaft @, remove lock key (telescopic) @, lock
Fig. 22 shaft (telescopic) (jJ) and rod @.
19
4-3 STEERING SYSTEM
BRACKET COMPLETE
1) Mount column ASSY on STAND (926740000) and @
®
secure with a vise.
Fig. 27
STAND
(926740000)
4) Align the flange of bolt @ with round part of guide
L4·703
groove in bracket CP (fix) @, and simultaneously remove
bolt @ and bearing ®.
Fig. 25
2) Remove memory pin ASSY @ from bracket CP (fix) @

by loosening bolts.
L4·706
Fig. 28
5) After removing column ASSY from STAND, remove pipe

ASSY CD from bracket @ while turning the former.
6) Insert a screwdriver between inner bracket CP @ and
pipe ASSY CD. Release the fit of protrusion, and remove
bracket while swinging it sideways.
)~ L4·704
Fig. 26 Be careful not to damage either tilt sliding surface.
3) Turn bolt ® clockwise to remove. Remove washer ®.

Next, push tilt lever @ down and loosen adjusting screw
(tilt) (J). Then, remove adjusting screw (J), bearing @, and
washer ® while pushing column in direction of arrow.
Tilt lever adjusting screw and bolt have left·hand threads.

L4·708
Fig. 29
20
STEERING SYSTEM 4-3
SHAFT ASSEMBLY 4) Remove snap ring @. Then remove washers @ and @ ,

spring @, and housing @.
1) Remove wing bracket ASSY @ and telescopic shaft
5) Remove bearing· @ from housing @. Remove bushing
@' (Refer to "Disassembly of telescopic portion.")
@ from housing @ by prying with a screwdriver, etc.
2) Remove dust seal @ by piercing with a sharply·pointed
tool such as a scribing punch.
a. Do not reuse bushing.
Do not pry off dust seal with a screwdriver, etc. Also, do not b. Be careful not to scratch inside of housing.
reuse dust seal when assembling shaft ASSY.
PIPE ASSEMBLY
1) After removing bearing @ and bushing (telescopic) ®,
remove bushing (bearing) @ by prying with a screwdriver, etc.
CD
Be careful not to scratch inside of pipe. Also, do not reuse
bushing (bearing).
® ® @
Sensor plate
~;;l;=k
L4-1410
L4-711
Fig. 30
3) With pipe ASS,Y CD pushed in direction of arrow, remove Fig. 32
snap ring ® and washer @. Next, remove bolt @, washer
@, and spacer ®, and remove shaft ASSY ®by pulling
downward (in direction of arrow).
2) Remove guide @ from pipe by inserting screwdriver into
them.
1
I
rn
~
I
) r @
,
I
I
I
FF=
1 L4-712
Fig. 33
I
L4-71D
Fig. 31
Be careful not to damage sensor plate when removing shaft

ASSY ®. Sensor plate is pressed into place.
21
4-3 STEERING SYSTEM
3) While pushing INSTALLER (926730000) in direction of
arrow, remove bolt @ . And take out boss @ and spring @.
Align pin ASSY ® with direction of long hole in pipe and
remove from hole.
Engage protrusion at INSTALLER's end with notched portion

of boss @.
) )
L4·714
Fig. 35
4) Remove clip ® from pin ASSY ® and pullout needle

bearing ®.
L4·713
Fig. 34
22
STEERING SYSTEM 4-3
INSPECTION
Clean the disassembled parts with a cloth, and check for wear, damage, or any other faults. If necessary, repair or replace faulty
parts.
No. Part Name Inspection Corrective action
1 Shell ball bearings

(upper, lower)
• Wear and damage
Replace if faulty.
* With bearing installed to steering shaft, check for axial and
and ball bearing radial play.
2 Collapsible shaft
CP
• Shaft length
Shaft runout Replace
Unit: mm (in)
CD ® @@
-
I
r - 3 (0.12)
---+ ---+-+++-
? 10 (0.39)
Itt-+1-t::=-- -~-++- -
J-i~--==f 10 (0.39)
r-
LStaked portion
20 (0.79)- ~f-- 10 (0.39)- I--
Support Support
(Lower bearing portion) (Upper bearing port ion)-
Fig. 36 Shaft length L4-715
Shaft length:
751.7 ± 1 mm (29.59 ± 0.04 in)
CDShaft lower end:
Runout: 1.2 mm (0.047 in) or less
® Elliptical press portion:
Rotating dia.: 32.6 mm (1.283 in) or less
@ Collar portion:
@ Telescopic pipe
• Looseness in staked portion

• Scratches on inside of telescopic pipe
-- • Damage on whole shaft
• Damaged sensor plate Repair or replace

shaft ASSY
• Dirty sensor plate Clean
3 Telescopic shaft Scratches on telescopic sliding surface Replace

Scratches in keyway
4 Key (telescopic) Scratches on key surface Replace
5 Bushing (telescopic) Scratches on surface Replace
6 Wi ng bracket Scratches on telescopic sliding surface Replace
7 Snap ring Deformation and expansion Replace
8 Tilt spring Deterioration Replace
9 Needle bearing Wear and damage Replace
23
4-3 STEERING SYSTEM
10 Bracket CP (fix) Scratches on inner bracket sliding surface Replace

Scores on needle bearing rolling surface
Looseness of sliding plate
11 Inner bracket Scratches on sliding surfaces with bracket CP (fix) and tilt bracket Replace
Scratches and deformation on memory pin's engaged portion
12 Memory pi n ASSY Smooth pin slide Replace

Scratches on pin surface
Deterioration of spring
13 Universal joint • Free play of universal joint Replace

ASSY • Swinging torque
Looseness
Fig. 37 L4-380
Universal joint free play (standard):

o mm (0 in)
Universal joint swinging torque (maximum):
0.6 N·m (0.06 kg-m, 0.4 ft-Ib)
14 Pipe CP Looseness of staked rivets Replace
c
-o
Fig. 38 L4-717
24
STEERING SYSTEM 4-3
4) Apply adhesive (Cemedine 5430) to outer periphery of
ASSEMBLY bushing (bearing) @. Combine bushing @ and bearing
@ , and insert them in the pipe up to the end. Leave a gap of
Grease: 2 to 3 mm (0.08 to 0.12 in) at end of pipe by prying only
a. To telescopic sliding portion and memory bearing with a screwdriver.
pin ASSY; VALIANT M2 (PIN 003608001)
b. To other portion; SUNLIGHT 2 a. Be careful not to allow adhesive to overflow.
(PIN 003602010) b. Apply grease to bearing.
5) Fit guide (telescopic) @ in long hole of pipe @. Then,

PIPE ASSEMBLY stretch bushing (telescopic) (@ and insert it securely between
1) Insert pin ASSY ® into column pipe CP @ from its long end of pipe and bearing.
hole. Apply small amount of grease to spring @, add insert
spring @ and boss @ into pipe so that the notched portion The guide @ should be installed with short-flanged side down.
of boss faces upwards.
Apply adhesive
INSTALLER
Note (926730000) ®
@-~~s-----t-1'liI
@
® o
Grease
L4-719
Fig. 40
SHAFT ASSEMBLY
1) Apply adhesive (Cemedine 5430) to outer periphery of
bushing (bearing) @ and fit it into housing @ together with
I
bearing @. Install housing @, washer @, spring @ and

washer @ on shaft CP @ and lock them with snap ring @.
I
a. Do not apply grease to the sensor plate slit.

L4-718 b. Be careful not to damage sensor plate.
Fig. 39
®
I
2) Insert INSTALLER (926730000) in pipe and engage I I I I I I I t
INSTALLER's protrusion with notched portion of boss @. @@@@@)@@@

/ Sensor plate
Then, align 5 mm screw hole in boss @ with 9 mm (0.35 in)
dia. hole in pipe by turning boss while compressing spring
@. Fix with bolt @ from outside. (Align so notched portion
of INSTALLER faces the vertical direction of steering.)
Tightening torque:
2.5 - 4.4 N·m (0.25 - 0.45 kg-m, 1.8 - 3.3 ft·lb)
3) Apply small amount of grease to bearing periphery of pin L4·1411

ASSY.
Fig. 41
25
4-3 STEERING SYSTEM
2) After installing spacer ® on pipe ASSY CD,
put shaft
ASSY ® into CD, align screw hole of housing with holes of
pipe and spacer, and lock with bolt @ and lock washer @.
I
mil
~
1
Tightening torque:
7.4 - 12.3 N·m (0.75 - 1.25 kg-m, 5.4 - 9.0 ft-Ib) 1 ~
I!
,
I
I
I
F=~
CD
I
L4-710
L4-1412 Fig. 44
Fig. 42
Put shaft ASSY ® into CD with notch of housing aligned 4) Install dust seal @ in place.
with pipe seam.
After installation, ensure shaft rotates smoothly without
rubbing and dragging.
Pipe seam
L4·722
Fig. 43
L4-1413
Fig. 45
3) Support lower end of shaft ASSY ®. While compressing

pipe ASSY CD in direction of arrow, install washer @ and
lock with snap ring ® .
TELESCOPIC PORTION
I. Do not apply more force to pipe ASSY thIn necessary 1) Fit lock key (telescopic) @l into keyway on shaft
[about 294 N (30 kg, 66Ib)]. (telescopic) @. Put shaft @ and shaft ASSY ® together
b. Install washer with its tapered side facing the bearing. with lock key @l fitted in keyway on ®. Fit snap ring @
c. Be sure to fit snap ring snugly into undercut on shaft. in undercut on key side of shaft @ in advance. Apply grease
d. After assembling, there must not be any axial or radial to key @l, sliding portion of shaft @, and inner wall of
play of shaft. shaft ASSY ®.
26
STEERING SYSTEM 4-3
(If telescopic portion only was disassembled, proceed to item,
"Adjustment of operating effort for telescoping" when
reassembly has reached this stage.)
BRACKET COMPLETE
1) After assembling bracket CP (inner) @ with pipe ASSY
G), insert pin ASSY @ of pipe ASSY G) through arc groove
in the bracket ®. With the above state, mount them on
STAND (926740000). Then fix it in a vise. Apply grease to
L4-724
sliding surfaces of brackets ® and @ and pipe ASSY G)
Fig. 46
(where G), ® and @ are in contact).
2) Apply grease to outer periphery of bushing (telescopic)

@ , bearing portion of wing bracket ASSY @ , and concavitY
of guide (telescopic) @. Then, install bracket @ and lock
with snap ring @.
Make sure that snap ring fits snugly in undercut.
'-STAND~
L4-727
Fig. 49
2) Align bolt hole in lower bracket of shaft ASSY G) with

L4·725
guide grooves in brackets ® and @. Insert bolt @, to which
Fig. 47
bearing ® and clip ® have been installed, through bolt hole
to opposite side.
3) Align 14 mm screw hole (protrusion portion) of bracket
@ with slit in bushing @. Then, install adjusting screw
(telescopic) @) and nut ~. (Temporary tightening is
enough.) Apply grease to tapered part of adjusting screw @)
before installing.
Fig. 50
'---_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _L_4-_72_6..... a. Fit lock on flange of bolt@lintoguidegrooveinbracket

Fig 48 @.
27
4-3 STEERING SYSTEM
CLAMP
Rotation lock (926720000)
STAND
L4-729
Fig. 51 Fig. 53
Move upper side of column ASSV in this condition up and

b. Apply grease to bearing ® and guide grooves in brackets down several times to see if it moves smoothly.
@ and @.
3) Install washer ®, bearing ® and adjusting screw (tilt)

(j) to bolt @.
ADJUSTMENT OF TILT TIGHTENING FORCE
Apply grease to washer ® and bearing ® . 1) Adjust engagement of lever (tilt) @ so that lever knob is
parallel with column center line when adjusting screw (tilt)
is tightened with lever @.
Adjusting screw tightening torque:

8 - 10 N·m (0.8 - 1.0 kg·m, 5.8 -7.2 ft-Ib)
After adjustment, install washer ® and bolt @.

Bolt tightening torque:
12 - 16 N·m t1.2 - 1.6 kg-m, 9 - 12 ft-Ib)
L4-730
Fig. 52
Parallel
4) Force down lower side of column ASSY and hold it on

STAND with CLAMP (926720000). Then, align 20 mm
(0.79 in) dia. hole in bracket @ and tapered hole in bracket
@
L4-732
@. Install memory pin ASSY @.
Fig. 54
Lock and unlock tilt function several times repeatedly to

check that lever operates smoothly.
28
STEERING SYSTEM 4-3
2) Ensure that steering column pops up and locks normally.

To do this with tilt function locked, pull memory pin ASSY
lever c@ in direction of arrow to allow column to pop up and
then push column down to original position. Repeat several
times.
Tilt function must be securely locked.
~t:::::~:J--@ L4-735
Fig. 57
@
c@ 2) Apply a small amount of grease to rod @. Install rod

@ and lock shaft (telescopic) @ to telescopic shaft @ .
Then, tighten with telescopic lever @. (This tightening may
be performed after mounting steering column ASSY on
L4-733 vehicle.)
Fig. 55
Tightening torque:
5 - 6 N·m (0.5 - 0.6 kg-m, 3.6 - 4.3 ft-Ib)
3) After adjustment, move column ASSY to lowest tilt
position, lock tilt lever, and tighten lock bolt from below
column bracket.
L4-736
Fig. 58
Fig. 56
COLUMN ASSEMBLY
1) Install control wing ASSY and combination switch ASSY
ADJUSTMENT OF OPERATING EFFORT to steering column ASSY.
FOR TELESCOPING
1) Turn adjusting screw @ until it makes contact, then Apply grease to sliding portion of combination switch and
back off 20 to 30 degrees. Tighten nut @ while holding shaft.
adjusting screw @ stationary.
2) Next, with telescopic shaft fully extended, install column
Tightening torque: cover, lower cover ASSY, and combination meter ASSY.
12 - 16 N·m (1.2 - 1.6 kg-m, 9 - 12 ft-Ib)
Nut tightening torque:
Confirm that wing bracket has no play in rotational direction 10 - 18 N·m (1.0 - 1.8 kg-m, 7 - 13 ft-Ib)
and little operating effort for telescoping is required. Readjust
if necessary. Harness should be routed as shown below.
29
4-3 STEERING SYSTEM
L4-737
Fig. 59
3) I nstall steering sensor @ using two screw sets ~.
Tightening torque:
1.3 - 1.7 N·m (0.13 - 0.17 kg-m, 0.9 - 1.2 ft-Ib)
a. Adjust sensor plate through the access hole so that it is

situated in the center of photo couplers. After installation,
turn shaft to check that sensor plate does not come into
contact with photo couplers.
b. Do not apply grease to photo couplers.
4) Route harness through steering sensor clip ®. Insert it

into hole in column pipe and then secure it. L4-1414
Fig. 60
a. Always use new clips and fasten harness securely.
b. Be careful not to damage harness.
30
STEERING SYSTEM 4-3
10) Connect harness of pad ASSY and install pad ASSY to

INSTALLATION steering wheel.
11) Install universal joint.
1) Insert lower end of shaft ASSY pipe into toe board
bushing, and temporarily tighten three bolts. Tightening torque:
2) Remove lock bolt fastening column pipe and bracket 21 - 26 N·m (2.1 - 2.7 kg-m, 15 - 20 ft-Ib)
(fix). Loosen tilt lever, move shaft up and down several times,
and tighten tilt lever. a. Ensure that each coupling bolt passes through the cutout at
3) Tighten mounting bolts to specified torque. the serrated section of steering shaft or the one of gearbox
pinion.
Tightening torque: b. Install long yoke side to steering shaft and short yoke side
20 - 29 N·m (2.0 - 3.0 kg-m, 14 - 22 ft-Ib) to pinion.
4) Operate lever of memory pin ASSY to check if shaft
pops up. Also, check that shaft locks when it is pushed down.
5) Connect meter cable, harness and pop-up cable.
6) Install steering wheel.
Tightening torque:
29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-Ib)
Clearance between column cover and steering wheel:

2 - 4 mm (0.08 - 0.16 in)
7) Install telescopic lever so that its knob is parallel with

steering wheel spoke. Tighten nut temporarily.
Steering Gearbox (Manual

Steering System)
REMOVAL
1) Remove ground cable from battery.

3) Loosen front wheel nuts, jack up vehicle, and support on
a rigid rack.
4) Release parking brake lever.
5) Remove front wheel.
6) Pull out tie-rod end cotter pin, remove castle nut and
Fig. 61
tie-rod end from knuckle arm by using a puller.
7) Remove pinch bolt from torque rod universal joint.
Never attempt to remove gearbox ASSY or crossmember with

8) Confirm that telescoping is performed smoothly when the pinch bolt fitted to torque rod universal joint.
telescopic lever lock is released. Also, check that telescoping
is locked securely when telescopic lever is locked. 8) Loosen exhaust manifold tightening nuts, and lower
9) Tighten nut to specified torque. exhaust pipe.
9) Remove gearbox mounting bolts (four places).
10) Draw out gearbox ASSY toward pinion.
Tightening torque:
As pinion shaft comes off torque rod, rotate gearbox rearward
12 - 16 N·m (1.2 - 1.6 kg-m, 9 - 12 ft-Ib)
and draw out toward pinion.
Tighten nut while holding telescopic lever stationary.

Be careful not to damage gearbox boot.
31
4-3 STEERING SYSTEM
7) Loosen ball joint, and remove tie-rod CP from rack.
DISASSEMBLY
Be sure to fix the rack with adjustable wrench to prevent it
Before starting disassembly operation, measure the pinion from rotating.
rotating torque and backlash (adjust screw tightening angle) at
the neutral position for reference during reassembling opera-
tion.
1) Secure gearbox ASSY in a vice using pad or a cloth for
protection.
Fig. 64
8) Loosen adjust screw lock nut, and remove adjust screw.
Fig. 62
2) Loosen tie-rod end lock nut, and remove tie-rod end and
lock nut.
3) Remove quick-type clip from small end of boot using
pliers.
L4·267
Quick-type clip
Fig. 65
9) Remove spring and sleeve.

10) Pullout pinion oil seal using screwdriver.
Be sure to replace oil seal with a new one.
L4·265
Fig. 63
4) Loosen big and boot clip screw with screwdriver, and

remove clip.
5) Remove boot from gearbox.
Be careful not to damage boot.

L4-268
6) Straighten ball joint lock washer using chisel or screw-
Fig. 66 VG R gearbox
driver.
32
STEERING SYSTEM 4-3
11) Remove snap ring, and pullout pinion. 13) Removal of bushing A.
Using press and REMOVER (926540000), press out outer
Be careful not to damage the inside surface of housing with retainer and bushing A from gearbox unit.
snap ring or pliers..
Be sure to replace bushing A and retainer with new ones.
INSPECTION
1) Clean all disassembled parts, and check for wear, damage,

or any other fault, and repair or replace if necessary.
2) When diassembling, check the gearbox for water. If water
is found, carefully check pinion oil seal, boot, and adjusting
screw D-ring for sealing, and replace if faulty.
L4-270
Fig. 67
12) Remove rack.
Be sure to pull the toothed side of rack outward so that

bushing will not be damaged by the rack teeth.
L4-271
Fig. 68
33
4-3 STEERING SYSTEM
1 Rack • Faults on tooth face: Dent, wear, cracks, and other damages. } Replace rack and pinion
• Bend in rack shaft ASSY as a unit.
~~
rl ~
I
u
C
t
~
~
c
.>
Fig. 69
A18·068
Limit:
0.2 mm (0.008 in) (runout)
2 Pinion ASSY • Faults on pinion tooth face: Dent, wear, cracks, and other Replace pinion ASSY
and rack as a unit.
•
damages.
Ball bearing: Free play, noise, binding When replacing, be sure I
to use SUBARU genuine
parts.
• Snap ring: Deformation Replace.

3 Oil seal Always replace when oil
seal is removed.
4 Snap ring
(Big)
• Deformation Be sure to use SUBARU
genuine parts.
5 Gearbox unit • Cracks or other damage in aluminium die-cast
• Cracks, bend, or deformation in pipe } Replace gearbox unit.
• Displaced needle bearing roller
• Wear or damage on bushing A Replace.
• Wear or deterioration of adapters A and B Replace.
6 Boot • Cracks, damage, or deterioration Replace.
7 Tie-rod CP • Free play in ball joint

. Replace.
• Bend in tie-rod Replace .
8 Lock washer Always replace when

it is removed.
9 Tie-rod end • Damage or deterioration in dust seal Replace.
10 Sleeve spring • Fatigue Replace.
Free length (standard):

20.3 mm (0.799 in)
34
STEERING SYSTEM 4-3
11 O-ring • Damage Replace.
12 Sleeve • Interference with rack Replace.
• Damage
ASSEMBLY
Use only SUBARU genuine grease for gearbox.
Specified grease for gearbox
VALIANT GREASE M2
[Parts No. 003608001, net 0.5 kg (l.llb)]
1) Install bushing A.
L4-279
(1) Insert bushing A, and push it into pipe using
INSTALLER (926530000). Fig. 71
Be careful not to damage inside surface of bushing.
(2) Insert retainer into pipe using INSTALLER

(926530000) until INSTALLER contacts pipe end face. a. Do not use any grease other than that recommended. Use
of improper grease may result in poor lubrication, deteriorated
Press or corroded parts, or other faults.
b. Be sure to insert rack from the pinion side (aluminum
~ die-cast side), being careful not to damage bushing.
3) Apply grease to sliding surface and root of pinion ASSY

INSTALLER (926530000) teeth, and also to ball bearing, then insert pinion ASSY into
Retainer gearbox.
Bush A
Retainer
L4-277
Fig. 70
2) Apply grease to sliding portions of both bushing A and

pinion bushing inside gearbox unit. And also apply grease to
L4-280
the sliding portion and teeth portion of rack, then insert rack
into gearbox unit. Fig. 72
35
4-3 STEERING SYSTEM
4) Fit snap ring into snap ring groove of case to secure ball
bearing.
After inserting snap ring, confirm that snap ring turns

Clearance 0.9 mm (0.035 in) or less
smoothly for checking of proper installation.
A18-072
Fig. 75
Snap ring
7) Install sleeve CD and spring ®, in that order, into
gearbox, and screw in adjusting screw @.
A1B-070
Pack grease abundantly into sleeve.
Fig. 73
5) Measure axial play of pinion using dial gauge.
Limit of axial play:

0.3 mm (0.012 in)
1 Sleeve
2 Spring
3 Adjusting screw
4 a-ring
A18-073
Fig. 76
Tightening torque (Lock nut):

29 - 49 N'm (3.0 - 5.0 kg-m, 22 - 36 ft-Ib)
Hold the adjusting screw with a wrench to prevent it from

turning while tightening the lock nut.
L4-28l
Fig. 74
® L-----@
@---+--t
®
6) Press-fit oil seal.
1 Sleeve
2 Spring
Excessively large clearance between oil seal flange and gearbox 3 a-ring
may be attributable to an incorrectly fit snap ring. Pull out 4 Lock nut
oil seal, and check installation of snap ring. 5 Adjusting screw
6 Apply grease L4-948
Fig. 77
36
STEERING SYSTEM 4-3
8) Tighten adjusting screw to 7.4 N·m (0.75 kg-m, 5.4 ft-Ib)
and then loosen it. Repeat this operation twice. Finally tighten
adjusting screw to 7.4 N·m (0.75 kg-m, 5.4 ft-Ib) and back off
25°.
9) Check the engaging condition of rack and pinion by
turning the pinion with hand. If turning is unusually heavy or
harsh, readjust backlash. Put the rack and pinion in straight-
ahead drive position, paint marking on the pinion shaft and
oil seal.
Unit: mm (in)
Apply grease
n
L4-284
76.0 (2.992) 76.0 (2.992)
rl
f'E-.Q]] <:)
Fig. 80
Hold the rack with a wrench to prevent it from turning while

tightening the ball joint.
L4-1228 11) Stake lock washer so that tie-rod CP socket will not
Fig. 78 become loose with respect to rack.
Stake lock washer against recess of tie-rod socket. (Two
places each)
Do not leave sharp edges on the corner after staking, or allow

CD any portion of lock washer to protrude from the socket.
~--@
1 Marking of straight ahead drive condition

2 Oil seal
3 Pinion shaft
A18-076
Fig. 79
10) Fit the lock washer on the screwed portion of the rack
Fig. 81
end.
Aligning the cut portion of rack and the nail of washer, screw
in and tighten ball joint ASSY.
Tightening torque (Ball joint):

78 N·m (8.0 kg-m, 58 ft-Ib)
37
4-3 STEERING SYSTEM
12) Apply grease to the specified portion of the boot and Pay attention to the difference between the right and left
then install it to gearbox. ti e-rod ends.
After installing, confirm that the whole of boot turns
smoothly. Right one RH
Identification mark
Left one LH
Quick-type clip
16) Confirm the operation of the pinion by turning round it.
(screw-type clip
Pinion rotating torque:
Straight-ahead position within ±30 mm (1.18 in)
from rack center
Less than 0.9 N·m (0.09 kg-m, 0.7 ft-Ib)
Maximum allowable torque
1.4 N'm (0.14 kg-m, 1..0 ft-Ib)
a. If rack and pinion have been replaced, move rack back and
L4-286 forth several strokes by holding tie:J'.od to ensure smooth
Fig. 82 movement.
b. If pinion rotating torque exceeds the specified valu@l back
off the adjusting screw within the range of 20° fro., its fully
tightened position, and adjust the backlash again. .. .,
a. Before installation of boots, draw out rack until maximum c. While rotating the pinion, also check the boot, and make
turning position and then apply grease again to the teeth and sure the gearbox is properly ventilated.
the sliding portion of rack for both sides.
b. Install the fitting portions of boots to the following
portions in both sides of assembled steering gearbox.
• The gro.ove on gearbox or the groove on adaptor.
• The groove on tie-rod.
c. Check boot is installed without unusual inflation or defla-
tion. INSTALLATION
13) Tighten screw-type clip on big end of boot.
1) Insert gearbox into crossmember from driver's seat side,
14) Attach quick-type clip to small end of boot using pliers.
and insert pinion shaft into torque rod universal joint.
15) Screw in the lock nut and tie-rod end to the screwed
portion of tie-rod and tighten the lock nut temporarily in a
Be careful not to damage gearbox boot.
position shown in figure.
2) Fit gearbox to crossmember bracket, and tighten clamp
with bolts.
Tightening torque:
A 23 mm 10.91 ;nl
47 -71 N·m (4.8 - 7.2 kg-m, 35 - 52 ft-Ib)
~ -ffE 6l: @?l-

Be sure to tighten the clamp from the pinion side.
A18-080
Fig. 83
38
STEERING SYSTEM 4-3
3) Insert pinch bolt into torque rod universal joint, and

tighten to the specified torque.
Tie-rod end
Castle nut
L4-1415
Fig. 85
5) Tighten exhaust manifold.

6) Install tires, and lower front body of vehicle.
7) Tighten wheel nuts to the specified torque.
8) Connect ground cable to battery.
ADJUSTMENT OF TOE, AND CHECK

L4-288 AND ADJUSTMENT OF BACKLASH
Fig. 84
TOE ADJUSTMENT
Tightening torque: 1) Set gearbox rack at the center position by turning steering
21 - 26 N'm (2.1 - 2.7 kg-m, 15 - 20 ft-Ib) wheel until white paint marks on gearbox and pinion are
aligned correctly.
a. Be sure to use SUBARU genuine pinch bolt (7T).
b. Never attempt to remove gearbox ASSV or crossmember a. To adjust wheel alignment, be sure to place the vehicle on
with pinch bolt fitted to universal joint. a level surface.
b. The front suspension and steering system must be in their
normal states, and wheel runout and tire inflation pressure
4) Connect tie-rod end and knuckle arm, and tighten castle must be kept within the specifications.
nut, then insert cotter pin and bend to lock the nut.
2) Under above conditions, loosen tie-rod lock nut, and turn
Tie-rod end castle nut tightening torque: tie-rod to adjust front toe.
Tighten to 25 - 29 N·m (2.5 - 3.0 kg-m,
18 - 22 ft-Ib), then tighten further within 60° until
Standard of front toe
cotter pin hole is aligned with a slot in the nut.
2WD:
OUT 1 - IN 1 mm (OUT 0.04 - IN 0.04 in)
Do not hit the cap at the bottom of tie-rod end with a hammer
4WD:
when connecting knuckle arm.
IN 1 - IN 3 mm (IN 0.04 -IN 0.12 in)
One rotation of both tie-rods:

Change in toe: Approx. 12 mm (0.47 in)
39
4-3 STEERING SYSTEM
a. Both the left and right tie·rods are right·hand threaded. 5) After completing the above-mentioned adjustment, check
To increase toe, turn both tie-rods counterclockwise equal whether the steering wheel spokes are in the horizontal
amounts (as viewed from the outside of the vehicle). position with wheels set in the straight-ahead position. If the
spokes are inclined more than 5° [approx. 17 mm (0.67 in) on
the outer periphery of steering wheell, re-install the steering
wheel to the horizontal position.
6) If the steering wheel position is unsatisfactory even after
the wheel has been reinstalled, make correction by turning the
right and left tie-rods in the same direction by the same
amount.
A 1/4 turn of tie-rod corresponds to approx. 10 mm

(0.39 in) on the steering wheel outer periphery.
L4-861 INSPECTION AND ADJUSTMENT OF

Fig. 86 BACKLASH
Inspection and adjustment procedures of gear backlash with
the steering .gearbox mounted on vehicle are as follows:
b. When adjusting toe, hold the boot or remove its small end
clip so that the boot will be twisted. Inspecting backlash
1) Get into vehicle with tires placed on ground.
3) Check and adjust steering angle of wheels. 2) Quickly turn steering wheel back and forth by a small
amount.
Steering angle
0 0
Inner wheel: 38 ± 1.5 About 30°
0 0
Outer wheel: 34.5 ± 1.5
4) After completing adjustment of toe and steering angle,

tighten lock nut on tie-rod end.
Lock nut tightening torque:

69 - 88 N'm (7.0 - 9.0 kg-m, 51 - 65 ft-Ib)
a. When tightening lock nut, be sure to hold tie·rod end

socket. L4-1241
b. Straighten boot if twisted, and correctly install the clip.
Fig. 88
3) While turning steering wheel, listen for backlash noise that

may be generated from the engaged portion of gears.
4) Jack up the vehicle, and support on rigid racks.
5) Holding pinion side tie-rod from underside, move it up
and down by force, and check for excessive play.
If excessive loud noise or large play is noticed, adjust gear
backlash, proceeding as follows.
Adjusting backlash
1) Set steering wheel in the straight-ahead position.
2) Loosen lock nut using LOCK NUT WRENCH
Fig. 87 (925640000) .
40
STEERING SYSTEM 4-3
3) Turn adjusting screw to adjust gear backlash.

After adjustment, tighten lock nut.
Steering Gearbox (Power
Steering System)
3 Tighten lock nut.
(Reference)
Tightening torque: For disassembly and assembly of gearbox unit, refer to section
29-49N·m Control Valve (Power Steering Gearbox).
(3.0 - 5.0 kg-m,
22 - 36 ft-Ib)
Be careful not to change

the adjusting screw
position when tightening
lock nut.
REMOVAL
1 ) Disconnect thermo sensor connector.

2) Lift up vehicle.
3) Remove front wheels.
4) Remove front exhaust pipe ASSY.
(Refer to "EXHAUST SYSTEM".)
5) Using a puller, remove tie-rod end from knuckle arm after
Back off adjusting
screw by (25±5)O from pulling off cotter pin and removing castle nut.
the position in
step 1.
Tighten the adjusting screw Tie-rod end

to 7.4 N·m (0.75 kg-m,
5.4 ft-Ib) and then loosen it.
Repeat th is operation twice
and finally tighten to 7.4 N·m Castle nut
(0.75 kg-m, 5.4 ft-Ib). L4-295
Fig. 89 Knuckle arm
4) Check backlash by repeating procedure as specified in L4-1415

"Inspecting backlash" above to ensure proper adjustment. Fig. 90
After completing backlash adjustment, turn steering wheel to

the extreme right and left positions to check for proper
steering feel with the vehicle jacked up. If unsmooth move-
6) Remove jack-up plate and clamp A.
ment or binding is felt, it may be attributable to improperly
adjusted backlash; repeat backlash adjustment.
Fig. 91
41
4-3 STEERING SYSTEM
7) Remove one pipe joint at the center of gearbox ASSY,

and connect vinyl hose to pipe and joint. Discharge fluid by
turning steering wheel fully clockwise and counterclockwise.
Discharge fluid similarly from the other pipe.
Fig. 94
10) Disconnect pipes A and B from lower side of control valve

of gearbox ASSY.
a. Disconnect lower pipe A first, and upper pipe Bsecond.

Fig. 92 b. Be careful not to damage pipes.
11) Remove bolts securing gearbox ASSY to crossmember,

and remove gearbox ASSY.
8) Remove lower side bolt of universal joint ASSY, then
remove upper side bolt and lift the joint ASSY upward.
DISASSEMBLY
Place a mark on the joint and mating serration so that it can
be reinstalled at the original position. 1) Secure gearbox removed from vehicle in vice using
STAND (926200000).
Secure the gearbox ASSV in a vice using the special tool as

shown. Do not attempt to secure it without this special tool.
Use two ~ieces of manual steering gearbox clamp B
(31026GA240).
STAND (926200000)
Fig. 93
L4-949
Fig. 95
9) Disconnect pipes C and D from control valve of gearbox 2) Remove clip from boot, and move boot to tie-rod end
ASSY. side.
a. Disconnect upper pipe 0 first, and lower pipe C second. Remove clip from boot using screwdriver, being careful not to
b. Be careful not to damage these pipes. damage the boot and clip.
42
STEERING SYSTEM 4-3
6) Loosen lock nut using SPANNER (926230000), and

remove adjusting screw.
Fig. 96
3) Remove boot together with big clips.
Fig. 99
7) Remove spring and sleeve.

8) Remove dust seal or dust cover.
Be careful not to damage housing and input shaft or to allow.

entry of foreign matter when removing dust cover.
L4-867 INSPECTION
Fig. 97
4) Push rack fully into gearbox, and straighten tie-rod lock 1) Clean all disassembled parts, and check for wear, damage,
washer using ch isel. or any other faults, then repair or replace as necessary.
2) When disassembling, check inside of gearbox for water.
Be extremely careful not to hit the surface of right-hand rack; If any water is found, carefully check boot for damage, input
otherwise, oil leakage may result. shaft dust seal, adjusting screw G-ring, and boot clips for poor
sealing. If faulty, replace with new parts.
5) Loosen ball joint using WRENCH (925700000) and
SPANNER (926230000), and remove tie-rod CP from rack.
When loosening ball joint, securely fix the rack using special
tool.
WRENCH (925700000)
L4-868
Fig. 98
43
4-3 STEERING SYSTEM
1 Input shaft (1) Bend of input shaft If bend or damage is excessive, replace entire
(2) Damage on serration gearbox ASSY.
2 Dust cover (1 ) Crack or damage If outer wall slips, inner wall slips, lip is
(2) Wear worn out or damage is found, replace it with
new one.
3 Rack and pinion Poor mating of rack with pinion (1 ) Adjust backlash properly.
By measuring turning torque of gearbox
and sliding resistance of rack, check if
rack and pinion engage uniformly and
smoothly with each other.
(Refer to "Service limit".)
(2) Keeping rack pulled out all the way so
that all teeth emerge, check teeth for
damage.
Even if abnormality is found in either (1)
or (2), replace entire gearbox ASSY.
4 Gearbox unit (1 ) Bend of rack shaft Replace gearbox ASSY with new one.
(2) Bend of cylinder portion
(3) Crack or damage on

aluminum alloy portion
(4) Wear or damage on rack bush If free play of rack shaft in radial direction is
out of the specified range, replace gearbox
ASSY with new one. (Refer to "Service
limit".)
(5) Wear on input shaft bearing If free plays of input shaft in radial and axial
directions are out of the specified ranges,
replace gearbox ASSY with new one.
(Refer to "Service I im it".)
5 Boot Crack, damage or deterioration Replace.
6 Tie-rod CP (1) Looseness of ball joint Replace.

(2) Bend of tie-rod
7 Tie-rod end Damage or deterioration on dust seal Replace.
S Adjusting screw spring Deterioration Replace.
9 Boot clip Deterioration Replace.
10 D-ring of adjusting Crack, damage or deterioration Replace.

screw
11 Sleeve Damage Replace.
12 Pipes (1) Damage to flared surface Replace.

(2) Damage to flare nut
(3) Damage to pipe
44
STEERING SYSTEM 4-3
SERVICE LIMIT
Make a measurement as follows. If it exceeds the specified
service limit, adjust or replace.
When making a measurement, vise gearbox by using special
,~
tool (STAN D; 926200000). Never vise gearbox with inserting
aluminum plates etc. between vise and gearbox.
~
Sliding resistance of rack shaft ~
98 N
Service limit: (10 kg, 22 Ib)
245 N (25 kg, 55 Ib) or less
Fig. 102
• Left-turn steering
Service limit:
Direction . . .
Direction ¢:::::>
0.15 mm (0.0059 in) or less
Fig. 100 Right-turn steering
L4-311
Fig. 103
L4-309
Input shaft play
Fig. 101 Left-turn steering
• In radial direction
Service limit:
Rack shaft play in radial direction 0.18 mm (0.0071 in) or less
• Right-turn steering
Service limit:
0.15 mm (0.0059 in) or less
45
4-3 STEERING SYSTEM
SPANNER
(926230000)
L4-314
Fig. 104 Fig_ 106
• In axial direction
Service limit: ASSEMBLY

Use only SUBARU genuine grease for gearbox.
Specified grease for gearbox
VALIANT GREASE M2
[Parts No. 003608001, net 0.5 kg (1.1 Ib)]
1) Apply grease to teeth of rack so that grease applied is

about as high as teeth, and also apply a thin film of grease to
sliding portion of rack shaft.
a. When moving rack to stroke end without tie-rod attached,

prevent shocks from being applied at the end.
b. Do not apply grease to threaded portion at end of rack
L4-313
shaft.
Fig. 105 e. Move rack shaft to stroke end two (2) or three (3) times to
squeeze grease which accumulates on both ends. Remove
grease to prevent it from choking air passage hole.
2) Apply grease to sleeve insertion hole.

3) Apply grease to dust seal or dust cover insertion hole.
Turning resistance of gearbox Apply clean grease with clean hands. If material having a
sharp edge is used for applying grease, oil seal at the inside
Service limit: might be damaged.
Straight-ahead position within 30 mm (1.18 in)
from rack center 4) Grease up dust cover and install it on input shaft until it
Less than 7.85 N (0.80 kg, 1.76 Ib) reaches stepped section.
Maximum allowable resistance
10.10 N (1.03 kg, 2.27 Ib)
46
STEERING SYSTEM 4-3
Be sure to adjust the lip of dust cover so that it comes into a. Hold adjusting screw with a wrench to prevent it from
contact with housing end [approximately 0 to 0.5 mm (0 to turning while tightening lock nut.
0.020 in)]. If contact is too hard, steering wheel will not b. Make adjustment so that steering wheel can be rotated fully
return smoothly; if clearance exists, dust or dirt will get in. from lock to lock without binding.
@
@--
®---l~~i~
CO-{j:
1 Sleeve
2 Spring
3 D-ring
4 Lock nut
5 Adjusting screw
L4-423 A18-l79
Fig. 107 Fig. 109
7) Check for service limit as per article of "INSPECTION,

5) Apply grease to sliding surface of sleeve and spring seat, Service limit". Make replacement and adjustment if necessary.
then insert sleeve into pinion housing ASSY. Fit spring into 8) Fit new lock washer on screwed portion of rack end.
sleeve screw, pack grease inside of screw, then install the screw. Aligning cut portion of rack and nail of washer, screw in and
tighten ball joint by using WRENCH (925700000) and
SPANNER (926230000).
Torque (Ball joint):

78 N·m (8.0 kg-m, 58 ft-Ib)
WRENCH (925700000)
1 Sleeve
2 Spring
3 Adjusting screw
4 D-ring
A18-073
Fig. 108
6) Adjust backlash of rack and pinion in the following

L4-868
manner.
Fig. 110
(1) To make sure that sleeve is in contact with rack,
tighten adjusting screw to 5 N·m (0.5 kg-m, 3.6 ft-Ib) and
return it about half a rotation.
(2) Turn adjusting screw until turning torque increases
0
steeply, and then turn it back approx. 1/12 turn (30 ).
Lock adjusting screw by lock nut. a. While tightening ball joint, hold rack with special tool
(WRENCH; 925700000) to prevent it from revolving.
Torque (Lock nut): b. Pay attention to prevent rack surface on the right side from
29 - 49 N·m (3 - 5 kg-m, 22 - 36 ft-Ib) being damaged by a tool or the like, otherwise oil leakage
might be caused.
47
4-3 STEERING SYSTEM
9) Bend lock washer toward plain surface of ball joint, after
removing gearbox ASSY from stand.
Apply grease
When bending lock washer, always put ball joint on plain
block. Do not leave sharp edge on bent lock washer.
Reverse after installing
L4-1418
Fig. 113
11) Fix boot end with clip (small).
A18-128
Fig. 111
Clip (small)
10) Fit clips (large and middle) to boot, and then install boot
to gearbox while holding boot flange.
After installing boot, fold back boot flange to the extent that
large clip can not be seen_
a. Before installing boot, be sure to apply grease to the groove L4-1419
of tie-rod. Fig. 114

b. Install fitting portions of boots to the following portions in
both sides of assembled steering gearbox. a. Use screwdriver with blunted tip to prevent boot from
• The groove on gearbox damage, when installing.
• The groove on ball joint b. After installing, check boot end is positioned into groove
• The groove on the rod on tie-rod.
c. Make sure that boot is installed without unusual inflation
or deflation. 12) If tie-rod end was removed, screw in lock nut and tie-rod
end to screwed portion of tie-rod, and tighten lock nut
temporarily in a position as shown in the illustration.
Clip (middle)
L4-318
Fig. 112
AlB-aBO
Fig. 115
48
STEERING SYSTEM 4-3
Pay attention to difference between right and left tie-rod ends.
Right one RH
Identification mark
left one lH
13) I nspect gearbox ASSY as follows.
Fig. 117
4) Connect pipes C and 0 to gearbox ASSY.

Connect lower pipe C first, and upper pipe 0 second.
L4-320
Fig. 116
Tightening torque:
10 - 20 N·m (1.0 - 2.0 kg-m, 7 - 14 ft-Ib)
A. Holding tie-rod end, repeat lock to lock two (2) or three

(3) times as quickly as possible.
B. Holding tie-rod end, turn ASSY slowly at a radius one (1)
or two (2) times as large as possible.
After all, make sure that boot is installed in the specified
position without deflation.
14) Remove gearbox ASSY from STAND (926200000).
INSTALLATION
Fig. 118
1) Insert gearbox ASSY into crossmember, being careful not
to damage gearbox boot.
2) Tighten gearbox ASSY to crossmember bracket via clamp
with bolt.
5) Install joint ASSY, proceeding as follows:
Tightening torque: (1) Align bolt hole of long yoke with the notch in
47 -71 N·m (4.8 -7.2 kg-m, 35 - 52 ft-Ib) serration of column ASSY, and push in joint fully.
(2) Align bolt hole of short yoke with the notch in input
3) Connect pipes A and B to four pipe joints of gearbox shaft serration of gearbox, and lower joint fully.
ASSY. Connect upper pipe B first, and lower pipe A second. (3) Fit bolt to short yoke, and raise the joint, then check
that the bolt on short yoke side is correctly fitted in the
Tightening torque: serration notch.
10 - 16 N·m (1.0 - 1.6 kg-m, 7 - 12 ft-Ib) (4) Tighten long yoke side bolt, then tighten joint side
bolt.
Tightening torque:
22 - 25 N·m (2.2 - 2.6 kg-m, 16 - 19 ft-Ib)
49
4-3 STEERING SYSTEM
12) Pour fluid into oil tank, and bleed air. Refer to section
"Air bleeding procedure".
13) Check for fluid leaks.
14) Install jack-up plate and clamp A.
Be careful, exhaust manifold is hot.
15) Lower vehicle.

16) Check fluid level in oil tank.
17) After adjusting toe-in and steering angle, tighten lock nut
on tie-rod end.
Tightening torque:
78 - 88 N·m (8.0 - 9.0 kg-m, 58 - 65 ft·lb)
Fig. 119
When adjusting toe-in, hold boot as shown to prevent it from

being rotated or twisted. If twisted, straighten it.
6) Connect tie-rod end and knuckle arm, and tighten with
castle nut. Fit cotter pin into the nut and bend the pin to
lock.
Castle nut tightening torque:

Tighten to 25 - 29 N·m (2.5 - 3.0 kg·m,
18 - 22 ft·lb), and tighten further within 60° until
cotter pin hole is aligned with a slot in the nut.
When connecting, do not hit cap at the bottom of tie·rod end

I
with hammer.
L4-322
Tie-rod end
Fig. 121
Castle nut
L4-1415
Fig. 120
7) Install front exhaust pipe ASSY.

(Refer to "EXHAUST SYSTEM".) Fig. 122
8) Install tires.
9) Tighten wheel nuts to the specified torque.
Tightening torque:
78 - 98 N·m (8.0 - 10.0 kg·m, 58 - 72 ft·lb)
10) Install thermo sensor connector.

50
STEERING SYSTEM 4-3
If steering wheel spokes are not horizontal with vehicle set in

ADJUSTMENT the straight ahead position after this adjustment, correct it by
turning the right and left tie-rods in the same direction by the
1) Adjust front toe. same amount.
Standard of front toe
FWD:
OUT 1 - IN 1 mm (OUT 0.04 - IN 0.04 in)
4WD:
IN 1 - IN 3 mm (IN 0.04 -IN 0.12 in)
2) Adjust steering angle of wheels. Adjust to the same direction and same turns
!
Inner wheel:
Except XT6: 36°30' - 39°30'
XT6: 34°30' - 37°30'
Outer wheel:
Except XT6: 33° - 36°
XT6: 30°30' - 33°30'
1/4turn
9 mm (0.35 in!~
3) If steering wheel spokes are not horizontal when wheels
fA
are set in the straight ahead position, and error is more than
-(-+==.~S>
~D
5° on the periphery of steering wheel, correctly reinstall the
steering wheel.
1/4 turn
~~
17 mm (0.67 in)
L4-741
Fig. 124
L4-740
Fig. 123
51
4-3 STEERING SYSTEM
Control Valve
(Power Steering Gearbox)
a. This section focuses on the disassembly and reassembly of
control valve. For the inspection and adjustment and the
service procedures for associated parts, refer to "Steering
Gearbox (Power Steering System)".
b. The number following a parts name in the text refers to the
key No. in the component parts illustration.
CHECKING OIL LEAKING POINTS AND

REPLACEMENT PARTS
01 L LEAKING POINTS
Control valve b
Cylinder
Power cylinder Rack piston
1
Rack axle
d d Pinion housing
Pipe ASSY A Pipe ASSY B
L4-742
Fig. 125
a. If leak point is other than a, b, c, or d, perform check steering wheel from lock to lock about 30 to 40 times with
(5) in 2) before dismounting gearbox ASSY from vehicle. If engine running, then make comparison of the suspected
gearbox ASSY is dismounted without confirming where the portion between immediately after and several hours after this
leak is, it must be mounted again to locate the leak point. operation.
b. Even if the location of the leak can be easily found by c. Before starting oil leak repair work, be sure to clean the
observing the leaking condition, it is necessary to thoroughly gearbox ASSY, hoses, pipes, and surrounding parts. After
remove the oil from the suspected portion and turn the completing repair work, clean these areas again.
52
STEERING SYSTEM 4-3
OIL LEAK CHECK PROCEDURE AND into account, and spare parts for them must also be prepared.
REPLACEMENT PARTS H01Never, it is essential to pinpoint the cause of trouble, and
limit the number of replacement parts as much as possible.
a. Parts requiring replacement are described in the smallest b. Disassembly and parts to be replaced.
unit of spare parts including damaged parts and spare parts c. To locate cause of trouble, disassemble steering system as
damaged. In actual disassembly work, accidental damage as indicated below.
well as inevitable damage to some related parts must be taken
Disassembling Parts to be replaced
Disassembling the steering body ASSY Lock washer ®

Seal kit ®
(Backup ring ® should be replaced depending on amount of damage,
wear.)
Steering grease (PIN 003608001)
Bond C (PIN 004403004)
Disassembling the valve ASSY Seal kit ®

Steering grease (PIN 003608001 )
Bond C (PIN 004403004)
Parts to discard after disassembling Lock washer ®

Parts included in seal kit ®
(Backup ring ®
and Backup ring ® should be replaced depending
on amount of damage, deformation.)
1) Leak from "a" (1) Leak from "e"

Since the V-packing @ is damaged, replace valve housing V-packing @ is damaged, so replace seal holder ASSY®
ASSY ® with a new one. Or replace the damaged parts and with new one.
parts damaged during disassembly with new ones. (2) Leak from "f"
2) Leak from "b" Leakage from "f" may have two causes.
a-ring (torsion bar) is damaged, so replace pinion & valve Determine the exact cause by the following procedure.
ASSY ® with a new one. Finding the leak
3) Leak from "c" Remove the pipe ASSY B ® from the valve housing and
Oil seal @ is damaged, so replace pinion & valve ASSY ® substitute the cap with the special tool (PLUG: 926420000).
with a new one. Start the engine, and then check if it leaks immediately after
4) Leak from ltd" the about 30 to 40 lock-to-Iock operations of the steering
Pipe ASSY @ or ® is damaged, so replace the damaged pipe wheel and after a few hours later.
ASSY with a new one. Result of test and remedial action
5) Leak from "e" or "f" • Leak continues from "f"
Slide both boots to the tie-rod end with the gearbox ASSY on Oil seal @ is damaged, so replace the pinion & valve ASSY
the vehicle, and then wipe any oil around them. Start the ® with a new one.
engine, and make sure of the following items immediately • No further leak from "f"
after about 30 to 40 lock-to-Iock operations of the steering Oil seal ® is damaged, so replace the oil seal and all parts
wheel and again a few hours later. Then replace faulty parts. damaged during disassembly with new ones.
53
4-3 STEERING SYSTEM
2) Removal of rack ASSY

DISASSEMBLY Push on rack from the valve side of steering body ASSY and
extract it from the opposite side.
REMOVAL OF VALVE ASSEMBLY
1) Remove two bolts which hold valve housing ASSY. a. Do not allow rack to contact the inner wall of cylinder when
2) Extract valve housing ASSY and pinion & valve ASSY as a removing it. Scratches on the wall may cause oil leakage.
unit. b. Holder ASSY can be removed with rack ASSY.
a. If the pinIOn part is pulled out from valve ASSY, pinion

dust seal may easily be damaged. Therefore, pull out valve
Holder ASSY
ASSY while grasping valve housing and input shaft simul-
taneously.
i to 'li» ~_
L Rack ASSY t:§...L-.---------;-
L4-432
Fig. 128
3) Removal of high-pressure seal

Push backup ring and oil seal out by inserting REMOVER
L4-747 (926330000) from the valve side.
Fig. 126
REMOVER (926330000)
b. For easier assembly, remember the tooth position between
the rack and the pinion.
3) Extract pinion & valve ASSY from valve housing ASSY, if

necessary.
DISASSEMBLY OF RACK ASSEMBLY

1) Removal of seal holder snap ring
Attach REMOVER (926260000) to snap ring through the hole
L4-433
in boot groove on the cylinder side of steering body ASSY, and
Fig. 129
lightly tap REMOVER with a hammer to drive snap ring out.
Seal holder snap ring
DISASSEMBLY OF VALVE ASSEMBLY
1) After removing dust cover, push pinion & valve ASSY

out of valve housing.
a. Do not allow the serrated edges of input shaft to contact

V-packing.
L-____________________________________L4-431 ~~
b. If pinion & valve ASSY is hard to remove, push out using
Fig. 127 a press.
54
STEERING SYSTEM 4-3
ASSEMBLY OF VALVE ASSEMBLY
1) Apply a coat of grease to valve housing as shown in the
figure, as well as to back-up ring and V-packing (valve
housing).
Grease
L4-748
Fig. 130
Valve
housing
2) Drive dust seal, back-up ring, V-packing and ball bearing
L4-450
out of valve housing REMOVE R (926290000) and a press_
Fig. 132
Use side A of REMOVER an,d do not apply load to the face of

2) Drive dust seal into place using INSTALLER
valve housing.
(926300000) and a press.
a. Face dust seal in the direction shown in the figure.

B side-- b. Apply a coat of grease to the mating surface of INSTALLER
with dust seal to avoid damaging the dust seal.
REMOVER
(926290000)
INSTALLER
(926300000)
A side Dust seal

Backup ring
V-packing Dust seal
F-i!'~~+----Ball bearing
L4-451
L4-749
Fig- 133
Fig. 131
3) Drive valve housing V-packing and backup ring with
a. Pay attention to the direction of Y·packing and the order of

installation as shown in the figure. Otherwise, oil leakage may
result.
ASSEMBLY b. Apply a coat of grease to the mating surface of INSTALLER
with Y·packing to avoid damaging the Y·packing.
a. Before operation, clean all parts to be assembled and tools. c. To facilitate installation, attach Y·packing and backup ring
b. Use only genuine SUBARU steering grease. to INSTALLER and insert into valve housing before using a
c. Do not use the parts to be replaced, as shown in NOTE b. of press.
2) of "CHECKING OIL LEAKING POINTS AND REPLACE·
MENT PARTS".
55
4-3 STEERING SYSTEM
6) Apply a coat of grease to the su rface of G U I DE
(926310000) and place GUIDE over end of input shaft. Also
apply grease to input shaft.
INSTALLER
(926300000) Insert pinion & valve ASSY into valve housing until the lip of
pinion oil seal touches valve housing.
Be sure GUIDE is free from scratches which would damage y.

packing.
y·packing
GUIDE (926310000)
1'r':l~1---- Backup ring
Grease::;=;
............ ----- Ix. xx..
r---fF:=l1
L4·452
Fig. 134
4) Drive ball bearing into place with REMOVER

(926290000) and a press. Use side 8 of REMOVER.
To facilitate installation, attach ball bearing to REMOVER and

insert into valve housing before using a press.
Fig. 137
REMOVER
(926290000)
7) Push valve housing until it accommodates pinion & valve
ASSY.
Ball bearing
L4-453
Fig. 135
5) Fill dust seal with grease.
L4-456
Fig. 138
8) Apply a coat of grease to the lip of dust cover and insert

l4-454 dust cover until it butts up to the "graded" section of input
Fig. 136 shaft.
56
STEERING SYSTEM 4-3
,--- - ---~.--"'--
INSTALLER ~~~NSTALLER A
L Oil seal
-=ll--~-=
1
Rack ASSy '-INSTALLER A
A18-537 L4-459
Fig. 139 Fig. 141
3) Install back-up ring to rack ASSY from the gear side, as

a. Adjust so that the lip touches the end of housing [0 to 0.5 shown.
mm (0 to 0.020 in)] . If contact is too hard, steering wheel will
not return smoothly; if clearance exists, dirt or dust will get in. Ensure backup ring is installed in the proper direction.
b. Be sure pinion & valve ASSY is properly inserted into valve
housing prior to adjustment
ASSEMBLY OF RACK ASSEMBLY

1) Securely attach steering body ASSY to STAND
(926200000) as shown in the figure, and grease to needle
bearing.
ST AN D (926200000) Rack ASSY
Steering body ASSY

L4-460
Fig. 142
(I
4) Apply a coat of grease to rack teeth grooves, sleeve's
sliding portion, and piston's sealing surface. Then insert rack
ASSY into the cylinder side of steering body ASSY.
a. Be sure to apply sufficient grease to rack tooth sections to

'--_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _L_4_-7_5--J4 the extent that the entire tooth section is covered with grease.
Fig. 140 b. Do not allow grease to enter vent hole in rack.
a. Always use the special tool when holding steering body

ASSY.
b. Whenever steering body ASSY is removed from the vehicle,
remove any rust and clean the unit.
c. Make sure that none of the needle rollers of needle bearing - ---------------
are missing or bent. If defective, replace steering body ASSV
with a new one.
Rack ASSY
2) Using special tools [shown by Band C (926240000) in
the figure], attach oil seal to special tool [shown by A
(926240000)] . L Steering body ASSY
Insert special tool A with oil seal into rack ASSY from gear
side. Remove oil seal near the piston, and then extract special L4-461
tool from rack ASSY. Fig. 143
57
4-3 STEERING SYSTEM
Sid"
5) Attach GUIDE (926250000) to rack ASSY which
protrudes beyond the cylinder side, and apply a thin coat of
grease uniformly to the surfaces of rack ASSY and GU IDE.
'"'P no~,--___
r GU I DE (926250000)
lb lEa)
---- - ---- - ------ - - - - - -
*--~~- - -~--- - -~~ - - - - - - - ----- - --- I~__

: '--L-LrJj_
'X 'X )( , )( 'X )( " 'X ')( X " X 'X "
~'-----_/
I L4-464
~ Grease
Fig. 146
L4-462 8) Attach INSTALLER (926320000) to the cylinder side of

Fig. 144 rack ASSY and drive back·up ring and oil seal into place on
steering body ASSY using a pressing tool.
6) Apply coat of grease to the inner surface of holder ASSY

Be sure to push INSTALLER until its groove reaches the end
surface of holder ASSY.
and a-ring, insert into rack ASSY, and attach holder ASSY to
steering body ASSY.
a. Be sure GUIDE is free from scratches which would damage

V-packing. Steering body ASSY
Backup ring
b. Be careful not to damage the lip section of Y-packing when
installing holder ASSY.
----+--I--~ ---- - ----+--.
Rack ASSY
L4·465
Fig. 147
-+---------------------- INSTALLATION OF VALVE ASSEMBLY

1) Clean all traces of sealer, oil, rust, etc. from the mating
surface of valve housing and steering body ASSY.
2) Attach shim(s) to the stepped lip of steering body ASSY's
pinion housing, and apply sealer (Fuji Bond C: 004403004)
uniformly to the lip side end surface of pinion housing.
L4-463
Fig. 145
a. Use the same number of shims as before if previopsly re-
moved steering body ASSY, valve housing and valve ASSY are
reassem bled.
b. If any of the above units are replaced with new ones, add a
number of shims, install valve ASSY to pinion housing, and
tighten two socket bolts to the specified torque of 20 to 29 N·m
7) Apply a coat of grease to snap ring and insert it into (2 to 3 kg-m, 14 to 22 ft-Ib). Next, measure the clearance at the
groove to secure holder ASSY. mating surface of steering body ASSY and valve housing with
a thickness gauge. Remove the number of shim(s) which
Be sure one end of snap ring is close to pin hole. correspond to the clearance.
58
STEERING SYSTEM 4-3
13 mm
Fuji Bond C (0.51 in)
(004403004 )
L4·755 L4·758
Fig. 148 Fig. 151
3) Extract rack ASSY until it protrudes 77 mm (3.03 in)

beyond the housing end face of pinion side. 6) With rack and pinion teeth positioned as in step (5) above,
push valve ASSY in.
Valve ASSY
~
( 1---.....-,
77 mm (3.03 in)
.,.".'
L4·756
Fig. 149 L4·759
Fig. 152
4) Apply grease to pinion gear teeth grooves and ball bearing.

5) Position input shaft so that the cutout section faces
toward the sleeve boss.
77mm
(3.03 in) 7) Position rack ASSY again, as outlined in step (3), and
gradually tighten socket bolts alternetely after confirming that
the direction of the cutout secion of input shaft is correct.
a. If the direction of cutout section is incorrect, it means rack

and pinion are displaced by one pitch. Repeat steps (3) to (6)
above.
b. If valve ASSY needs to be reinstalled due to improper
positioning, check the condition of sealer and reapply if re-
quired.
L4·757 c. When shim(s) binds or when needle bearing is not in proper
Fig. 150 condition, valve ASSY cannot be properly installed. Replace
faulty parts, as needed.
If the top of pinion tooth is in the center position when pinion
tooth is viewed from the sleeve side, input shaft is positioned
Tightening torque
correctly. If the bottom of tooth is in the center, turn input
20 - 29 N·m (2 - 3 kg-m, 14 - 22 ft-Ib)
shaft 1800 •
59
4-3 STEERING SYSTEM
4) Loosen pulley belt(s).

5) Remove the nut and detach oil pump pulley.
6) Disconnect hose A from pipe 1;. Disconnect hose B from
oil tank.
L4-760
Fig. 153
Oil Pump (Power Steering

System) Fig. 156
REMOVAL

2) Drain the working fluid about 0.3 Q (0.6 US pt, 0.5 Imp a. When disconnecting hose A, use two wrenches to prevent
pt) from oil tank. pipe E from twisting.
b. Do not allow fluid from the hose end to come into contact
with pulley belt.
c. To prevent foreign matter from entering the hose and pipe,
cover the open ends of them with a clean cloth.
7) Remove clamp which secures pipe E to oil tank.
Fig. 154 /,
/
Clamp~
3) Loosen (do not remove) oil pump pulley nut_
Pipe E~
Oil tank stay
Bracket
L4-764
Fig. 157
8) Loosen bolt which secures oil tank stay to bracket_

9) Loosen bolts A and B located on the upper surface of oil
Fig. 155 tank.
60
STEERING SYSTEM 4-3
a. Complete loosening of bolts causes the fluid to run out of 12) Place oil pump in a vise, remove two bolts from the upper
tank. To minimize the amount of fluid lost, remove bolts side of oil tank and detach oil tank.
while oil tank is pressed against oil pump and then quickly
detach oil tank. Do not place oil pump directly in the vise; use soft pads and
Wipe off any oil which has spilled on any part. hold oil pump lightly to protect the pump
b. Except when only oil tank needs to be inspected, detach
oil tank and oil pump as a unit. Then separate one from the 13) Disconnect pipe E from oil pump if necessary.
other on a work bench to prevent oil from spilling on any part
of the engine.
10) Remove three bolts from the front side of oil pump and
detach the pump.
Fig. 159
Use two wrenches, one on the pump side and the other on the
pipe side, to offset any torque being imposed on the pump.
Fig. 158
11) Remove three bolts from the lower side of bracket and
detach the bracket.
The bracket does not need to be removed unless it is damaged.
61
4-3 STEERING SYSTEM
CHECK
• In accordance with the following table, check all removed parts for wear and damage, and maKe repair or replacement if
necessary.
1 Oil pump (Outside) (1) Crack, damage or oil leakage Replace oil pump ASSY with a new one.
(2) Play of pulley shaft Measure radial play and axial play.
If any of these exceeds the service limit,
replace oil pump ASSY with a new one.
(R efer to "Service I im it".)
2 Pulley (1) Damage Replace it with a new one.
(2) Bend Measure V d itch deflection.

If it exceeds the service limit, replace pulley
with a new one. (Refer to "Service limit".)
3 Cap Crack or damage Replace it with a new one.
4 Strainer (1 ) Clogging with dirt Wash it.
(2) Breakage Replace it with a hew one.
5 Oil pump (Interior) (1 ) Defect or burning of vane pump Check resistance to rotation of pulley.
If it is past the service limit, replace oil pump
ASSY with a new one.
(Refer to "Service limit".)
(2) Bend in the shaft or damage to Oil pump emits a noise that is markedly
bearing different in tone and loudness from a sound
of a new oil pump when turning with a string
put around its pulley, replace oil pump ASSY
with a new one.
6 O-ring Crack or deterioration Replace it with a new one.
7 Oil tank Crack, damage or oil leakage Replace it with a new one.
S Bracket Crack Replace it with a new one.
SERVICE LIMIT Play of pu lIey shaft

Make a measurement as follows. If it exceeds the specified
Service limit:
service limit, replace the parts with a new one.
Radial play (Direction I )
a. Fix oil pump ASSV on a vise to make a measurement. At
Axial play (Direction ~)
this time, hold oil pump ASSV with the least possible force
between two wood pieces.
b. Do not set outside of flow control valve or pulley on a vise;
otherwise outside or pulley might be deformed. Select
properly sized wood pieces.
62
STEERING SYSTEM 4-3
Resistance to rotation of pulley
Dial i nd icator
Service limit:
Maximum load; 9.22 N (0.94 kg, 2.07 Ib) or less
L4-357
Fig. 160 Radial play
L4-360
Fig. 163
A rather higher value may be indicated when pulley starts

turning.
Measure the load during rotation and make a judgement.
10 N (1 kg, 2 Ib)
L4-358
Fig. 161 Axial play
Ditch deflection of pulley
Service limit:
L4-359
Fig. 162
Read the value for one surface of V ditch, and then the value
for another off the dial.
63
4-3 STEERING SYSTEM
01 L LEAKING POINTS
/
Connector
Rear body L4-960
Fig. 164
a. Even when a possible oil leaking point is identified, chances

are the oil comes from other parts. To make it doubly certain,
proceed as follows: With the leaked oil wiped off, turn steering
wheel 30 to 40 times fully clockwise and counterclockwise
(with the engine kept running). Check for oil leaks immediate-
ly, and in several hours, after this operation.
b. Before attempting to repair oil leaks, clean the pump &
tank ASSY, hoses, and surrounding parts. Clean also after
completing the repair work.
1) Oil leaking from "a"

It is because the oil seal is damaged. Replace the oil seal and
other parts that have been damaged during disassembly with L4-1238
new ones. Fig. 165
2) Oil leaking from "b"
The bolt is either damaged or left loose. If damaged, replace it
with a new one. If left loose, tighten four bolts evenly to (2) With front body tilted, remove spool valve and spring.
specified torque. If neither of above is responsible for leak, 0-
ring or seal washer is probably damaged. Replace the damaged Use care not to drop spool valve and spring causing damage.
part with a new one.
3) Oil leaking from "c"
The connector is either damaged or left loose. If damaged,
replace it with a new one; if loose, tighten to specified torque.
If neither is responsible for leak, a-ring is damaged. Replace it
with a new one.
DISASSEMBLY
When securing the pump with a vise, apply wood pieces to

protect pump from damage.
L4-1239
1) Spool valve ASSY
(1) Remove connector and separate a-ring. Fig. 166
64
STEERING SYSTEM 4-3
2) Rear body 5) Front body

(1) With front body clamped in vise, remove four bolts to (1) Remove retammg ring from inner groove on the
separate rear body. pulley side of front body. Remove drive shaft by tapping
(2) Remove gasket. the end (on the cartridge side) with a plastic hammer.
(2) Remove oil seal using a standard screwdriver.
Front body
a. If shaft is hard to remove, tap it with a plastic hammer.
b. Use care to prevent damaging or denting front body end
face or front body internal surface which is sealed.
c. Note that bearing is non-reusable.
Fig. 167
Rear body
Gasket
L4-1230
o
3) Cartridge ASSY
(1) Remove cartridge ASSY from front body. L4-1233
(2) Cartridge ASSY consists of a rotor, ten vanes and a
Fig. 169
cam.
6) Oil seal
Using a screwdriver. pry off oil seal fitted into front body.
~Vane Use care to prevent damage to front body internal surfaces.
0
0
.~~~~
0
B~ 00
Pressure plate 0 0 .
Cam rmg
L4-1231
Fig. 168
4) Pressure plate
L4-1234
(1) Remove pressure plate and a-ring.
(2) Remove pin from pressure plate. Fig. 170
65
4-3 STEERING SYSTEM
INSPECTION
Perform following inspection procedures and repair or replace defective parts.
No. Part name Description Remedy
1. Front body 1) Damage on body surfaces Replace with a new one together with
2) Excessive wear on hole into which control control valve as selective fit is made.
valve is inserted.
3) Wear and damage on cartridge ASSY mounting
surface
4) Wear and damage on surfaces in contact with
shaft and oil seal
5) Wear or damage to ball bearing or bushing
2. Rear body 1) Damage on body surfaces Replace with a new one.

2) Wear and damage on sliding surfaces
3. Shaft 1) Shaft bend Replace with a new one.

2) Wear and damage on surfaces in contact with
bushing and oil seal
3) Wear and damage on rotor mounting surfaces
4. Pressure plate Wear and damage on sliding surfaces Replace with a new one.
5. Cam case 1) Damage on inner surfaces Replace with a new one.

2) Damage on O-ring fitting grooves
6. Cam ring Ridge wear on sliding surfaces i

7. Vane Excessive wear on nose radius and side surfaces
If damage is serious, replace with a new
8. Rotor 1) Wear and damage on sliding surfaces cartridge ASSY.
2) Ridge wear on vane sliding grooves (If light
leaks with vane in slit against light source)
3) Damage resulting from snap ring removal Correct with oil stone. If damage is
serious, replace with a new cartridge
ASSY.
9. Control valve Damage or burrs on sliding surface periphery Replace with a new one together
with front body as selective fit is
made.
10. Connector Damage on threads Replace with a new one.
11. Spring Damage Replace with a new one.
12. Bolts and nuts Damage on threads Replace with a new one.
(3) Reassembly procedure must be performed in clean

ASSEMBLY place. Ensure that parts are kept away from waste threads
or other dust particles.
(4) Cleaning oil tends to stay inside the front body.
1) Reassembly precautions
Remove it completely by blowing compressed air.
(1) Whenever O-rings, oi I seals, and snap rings are re-
(5) Ensure that parts are free from rust. (Use specified
moved, they must be replaced with new ones.
hydraulic oil for rust prevention after cleaning and dry-
(2) Thoroughly wash parts and allow to dry. They must
ing.)
be kept free from cleaning oil and dust.
66
STEERING SYSTEM 4-3
2) Shaft 3) Cartridge ASSY

(1) Apply grease to oil seal and front body internal (1) Install cam, rotor and vanes, in that order.
surfaces. (2) Insert pin into hole in cam, and insert cartridge ASSY
into pressure plate.
Make sure that the front body internal surfaces are free from
damage. a. Make sure vanes are installed with R marks facing the cam.
b. Check that vanes move smoothly.
(2) Using INSTALLER (926970000), press-fit oil seal c. Apply a coat of DEXRON ATF to vanes.
into front body.
a. Orient oil seal toward correct direction.

b. When press-fitting, use care to prevent damage to surface
mating with rear body_
Press
{}
INSTALLER
(926770000)
Vane
Oil seal
Front body
L4-1236
Fig. 173
, Fig. 171
L4-1235
4) Rear body
(1) Align pin with hole in rear body using a gasket, and
install rear body.
(2) First tighten all bolts in a criss-cross fashion to one-
(3) Using GUIDE (926980000), install bearing onto
half of specified torque, then to the specified torque.
shaft.
Install retaining ring on oil seal. Insert shaft & bearing
Tightening torque:
ASSY into place, and lock with retaining ring.
(4) With pulley side of front body facing down, install 49, - 59 N·m (5.0 - 6.0 kg-m, 36 - 43 ft-Ib)
two types of O-rings, pressure plate and shaft on front
body, in that order.
Always use new O-rings.
After installation, make sure that shaft is inserted flush with

GUIDE (926830000) end face.
GUIDE
(926980000)
Shaft &
bearing ASSY
Front body Fig. 174
a. After tightening the rear body, make sure shaft turns

L4-1242 smoothly by hand.
Fig. 172 b. Always use new O-rings.
67
4-3 STEERING SYSTEM
5) Spool Valve ASSY (2) Check followings by referring to "CHECK" article.

(1) Install spring into front body. Then, with spool valve • Excessive play in pulley shaft
ASSY dipped in specified hydraulic oil, install it into the • Ditch deflection of pulley
front body. • Resistance to rotation of pulley
• Measurement of generated oil pressure
INSTALLATION
L4-1239
1) Install bracket on engine.
Fig. 175
Tightening torque:
18 - 22 N·m (1.8 - 2.2 kg-m, 13 - 16 ft-Ib)
(2) Using a 5-mm-dia. round bar, ensure that valve moves
smoothly. 2) Install oil pump on oil tank as follows outside the vehicle:
(3) Set O-ring, with grease applied to it, onto connector
and secure connector to front body. Prior to installation, make sure that all oil is removed from oil
pump, oil tank and pipe.
Tightening torque:
29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-Ib) (1) Connect pipe E to oil pump.
Tightening torque:
a. Use care to prevent damage to D·ring at installation. 10 - 20 N·m (1.0 - 2.0 kg-m, 7 - 14 ft·lb)
b. When tightening connector, ensure that D'ring does not
protrude or get caught. Use two wrenches, one on the pump side and the other on
pipe E, to tighten the pipe at the specified degrees to the
center line of the pump shaft.
L4-1238
Fig. 176
L4·361
Fig. 177
6) Check
(1) When reassembly procedures have been completed,
turn shaft by hand to ensure it turns smoothly. If it binds
or other unusual conditions are evident, disassemble again
and check for foreign matter trapped on sliding surfaces
and improper installation. Eliminate the cause of trouble.
68
STEERING SYSTEM 4-3
(2) Install an O-ring on the oil passage located at the 3) Install oil pump, previously assembled to oil tank, on
bottom of oil tank. bracket.
Tightening torque:
29 - 49 N·m (3 - 5 kg-m, 22 - 36 ft-Ib)
L4-881
Fig. 178
a. Be sure to insert O-ring gradually. Otherwise, it will not

remain in position. Fig. 181
b. Be careful not to allow foreign matter to enter the passage.
(3) Insert the oil flow passage of oil tank into the center
hole on the upper side of oil pump and temporarily
tighten bolts. 4) Secure oil tank stay to bracket.
Tightening torque:
20 - 24 N·m (2.0 - 2.4 kg-m, 14 - 17 ft-Ib)
5) Place oil pump pulley and tighten nut temporarily.

6) Tighten bolts on the upper surface of oil tank.
Tightening torque:
20 - 29 N·m (2.0 - 3.0 kg-m, 14 - 22 ft-Ib)
L..-_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _L4_-3_6___
3 7) Secure pipe E to oil tank by clamp.
Fig. 179
Tightening torque:
5 - 8 N·m (0.5 - 0.8 kg-m, 3.6 - 5.8 ft-Ib)
8) I nterconnect hoses A and B.
Tightening torque:
Hose clip
2 - 3 N'm (0.2 - 0.3 kg-m, 1.4 - 2.2 ft-Ib)
Joint nut
10 - 20 N'm (1.0 - 2.0 kg-m, 7 - 14 ft-Ib)
L4-1240
Fig. 180
69
4-3 STEERING SYSTEM
5) Remove jack-up plate and clamp A.
6) Disconnect pipe joint at the center of gearbox ASSY, and
connect vinyl hoses to pipe and joint. Discharge fluid by
turning steering wheel to the right and left. Discharge fluid in
the same way from the other pipe.
Fig. 182
If a hose is twisted at this step, the hose may come into

contact with some other parts.
9) Adjust pulley belt tension. (For details, refer to 1. Drive

Belt(s) [Except Camshaft] in Chapters 1-5.) Fig. 183
And then tighten oil pump pulley nut to the specified torque.
Tightening torque:
42 - 62 N·m (4.3 - 6.3 kg-m, 31 - 46 ft-Ib)
10) Connect minus terminal of battery.

7) After discharging fluid, disconnect pipes A and B from
11) Feed the specified fluid and discharge air. (For details,
gearbox ASSY.
refer to the section regarding fluid line.)
a. Be careful not to bend pipes.
Never start the engine before feeding the fluid; otherwise vane b. Do not allow dirt and other foreign matter to come in
pump might be seized up. contact with pipe seal, joint, and threaded hole of gearbox
pipe joint.
8) Remove pipes C and D from control valve of gearbox

ASSY.
Fluid Line (Power Steering a. Disconnect upper pipe 0 first, then disconnect lower pipe
System) C.
b. Be careful not to damage pipe end face.
REMOVAL
Improper removal and installation of parts often causes fluid

leak trouble. To prevent this, disassembling of connectors and
joints must be kept to a minimum, clean the surrounding
portions before disassembly and reassembly, and pay special
attention to keep dirt and other foreign matter from mating
surfaces.

2) Disconnect thermo sensor connector.
3) Lift up vehicle.
4) Remove front exhaust pipe ASSY. Refer to "EXHAUST
Fig. 184
SYSTEM".
70
STEERING SYSTEM 4-3
9) Remove flange bolt securing hoses A and B in position. 12) Disconnect hose A from pipe E. Disconnect hose B from
oil tank.
Hose B
Hose A
Crossmember
Flange bolt
Bracket
Pipe C L4-365
Fig. 185
Fig. 186
10) Disconnect hose A from pipe C, hose B from pipe D.

11) Remove pipes C and D through the clearance between a. When disconnecting hose A, use two wrenches to prevent
crossmember and oil pan. pipe E from twisting.
b. Be sure to use wrenches having square and undeformed
a. Be careful not to bend pipes. jaws; otherwise, flats on joint may be damaged.
b. Do not allow dirt and other foreign matter to come in c. Do not allow fluid from the hose end to come into contact
with pulley belt.
contact with pipe seal, joint, and threaded hole of gearbox
pipe joint. d. To prevent foreign matter from entering the hose and pipe,
cover the open ends of them with a clean cloth.
13) Remove flange bolt of clamp B.

14) Remove flange bolt of clamp C.
15) Remove hoses A and B.
16) Disconnect pipe E from oil pump. Refer to "Removal
and installation of oil pipe".
71
4-3 STEERING SYSTEM
INSPECTION
Inspect all removed parts for wear and damage, replace them if necessary.
1 Pipes (1 ) Damage to flared surface Replace the pipe with a new one.
(3) Damage to pipe
2 Clamp A Deterioration of the hold on pipe Replace the clamp with a new one.
3 Clamp B Deterioration of the hold on hose Replace the clamp with a new one.
Clamp C
4 Hoses (1) Damage to flared surface

(3) Crack on hose surface
Replace the hose with a new one.
(4) Swollen hose
(5) Wear of hose surface

(6) Damage to adapter
(7) Damage to hose cI ip Replace it with a new one.
2) Connect hose A to pipe E and hose B to oil tank. Refer to

INSTALLATION
"Removal and installation of oil pump".
3) Install hose A to pipe C and hose B to pipe D.
1) Connect pipe E to oil pump.
Tightening torque:
Tightening torque: 10 - 20 N·m (1.0 - 2.0 kg·m, 7 - 14 ft·lb)
10 - 20 N·m (1.0 - 2.0 kg-m, 7 - 14 ft·lb)
Tighten hose A first, and hose B second.
a. Attach pipe E so that it forms the specified angle to the oil
pump axis. 4) Fix hoses A and B to bracket on crossmember by tighten-
b. Be careful not to damage oil pump pulley and oil tank. ing flange bolt.
If proper tool is unavailable, remove oil tank and oil pump
pulley before disconnecting pipes. a. Place hose A stay on hose B stay.
b. Install hoses A and B in vertical position.
L4-361
Fig. 187
72
STEERING SYSTEM 4-3
7) Install clamp B to hoses A and B, and tighten with flange
Hose B
Hose A
bolt.
Flange bolt
Bracket
Pipe C
L4-365
Fig. 188
5) Install pipes C and 0 to gearbox ASSY.

Fig. 191
Tightening torque:
10 - 20 N·m (1.0 - 2.0 kg·m, 7 - 14 ft·lb)
Tighten pipe C first, and pipe D second.

8) Connect pipes A and B to four joints of gearbox ASSY.
Tighten upper pipe B first, and lower pipe A second.
Tightening torque:
10 - 16 N'm (1.0 - 1.6 kg·m, 7 - 12 ft·lb)
Fig. 189
6) Install clamp C to hoses A and B, and tighten with flange

bolt.
Fig. 192
9) Install jack-up plate and clamp A.

10) Install front exhaust pipe ASSY.
Refer to "EXHAUST SYSTEM".
11) Install exhaust sensor connector.
13) With vehicle raised, feed the specified fluid and discharge
air as follows.
Fig. 190
73
4-3 STEERING SYSTEM
15) Inspect fluid level on flat and level surface with engine
Recommended fluid (ATF DEXRON II) "OFF" by indicator of filler cap.
B.P. B.P. Autran DX If the level is at lower point or below, add fluid to keep the
level in the specified range of the indicator. If at upper point
CAlTEX Texamatic fluid 6673 Dexron or above, drain fluid by using a syringe or the like.
CASTROl CASTROl TO Dexron

Fluid capacity: _
MOBil MOBil ATF 220 0.7 Q (1.5 US pt, 1.2 Imp pt)
SHELL SHELL ATF Dexron (1) Check at temperature 21°C (70°F) on reservoir
surface of oil pump.
TEXACO Texamatic fluid 6673 Dexron
(1) Feed the specified fluid with its level being about
4 cm (1.6 in) lower than the mouth of tank.
(2) Continue to turn steering wheel slowly from lock to
lock until bubbles stop appearing in the tank while
keeping the fluid at that level.
In case air is absorbed to deliver bubbles into piping because

the fluid level is lower, leave it about half an hour and then do
the step (2) all over again.
(3) Start, and idle the engine.

(4) Continue to turn steering wheel slowly from lock to A3-285
lock again until bubbles stop appearing in the tank while
Fig. 193
keeping the fluid at that level.
It is normal that bubbles stop appearing after three times
turning of steering wheel.
(2) Check at temperature 60°C (140°F) on reservoir
In case bubbles do not stop appearing in the tank, leave it surface of oil pump.
about half an hour and then do the step (4) all over again.
(5) Stop the engine, and take out safety stands after
jacking up vehicle again.
Then lower the vehicle, and idle the engine.
(6) Continue to turn steering wheel from lock to lock
until bubbles stop appearing and change of the fluid level
is within 3 mm (0.12 in).
In case the following happens, leave it about half an hour and

then do step (6) again.
a. The fluid level changes over 3 mm (0.12 in).
b. Bubbles remain on the upper surface of the fluid. A3·286
c. Grinding noise is generated from oil pump. Fig. 194
14) Check the fluid leakage at flare nuts after turning steering
wheel from lock to lock with engine running.
a. Before checking, wipe off any fluid on flare nuts and

piping.
b. In case the fluid leaks from flare nut, it is caused by dust
(or the like) and/or damage between flare and tapered seat in
piping.
So remove the flare nut, tighten again it to the specified
torque after cleaning flare and tapered seat. If flare or tapered
seat is damaged, replace it with a new one.
74
STEERING SYSTEM 4-3
Motor Pump & 4) Disconnect harnesses and ground lead.
Power Controller
REMOVAL

2) Disconnect connectors between power controller and
battery.
Fig. 197
5) Remove at least 0.3 Q (0.6 US pt, 0.5 Imp pt) of fluid

from reservoir.
Fig. 195
3) Remove bolts which secure power controller, and remove

controller ASSY.
Fig. 198
6) Remove bolts and hoses from motor ASSY.
Fig. 196
Fig. 199
7) Remove motor ASSY.
When disconnecting hoses, be careful not to spill fluid on any

part of car body. Plug open ends of hoses with a rag to prevent
dirt from entering.
75
4-3 STEERING SYSTEM
5) Remove pressure plate.

DISASSEMBLY 6) Cartridge ASSY
(1) Remove cam ring.
Select a clean place free from dirt and dust before disassembly.
Be careful not to scratch or damage disassembled parts.
1) Securely place STAND (927020000) in a vise and place

motor ASSY on STAN D.
L4-1428
Fig. 202
STAND (927020000)
L4-1426
Fig. 200 (2) Remove two straight (locating) pins.

(3) Remove ten vanes.
2) Disconnect connector from discharge port. (4) Remove rotor.
Do not place motor ASSV directly in a vise as damage to The cartridge ASSV is the heart of motor pump. Be extremely
magnet may resu It. careful not to scratch or damage it.
3) Remove cap. Lightly tap area around fluid filler with a 7) Front body ASSY
plastic hammer and remove reservoir. (1) Extract front body while holding motor section
horizontal.
Always remove motor pump while holding it horizontally.
Otherwise, fluid may spill on motor.
4) Rear body ASSY

(1) Completely drain fluid from motor pump. Remove
bolts from pump body with rear body facing up. Remove
rear body ASSY.
(2) Remove Q'ring from rear body ASSY.
Fig. 203
(2) Remove Q'ring from groove at outer periphery of

front body.
Be careful not to damage the frictional surface of front body

Fig. 201 rotor.
76
STEERING SYSTEM 4-3
8) Using a screwdriver, drive oil seal out of front body.

INSPECTION
Perform following inspection procedures and repair or replace

defective parts.
L4-1430
Fig. 204
Pressure plate
~ 1111[011
~ 11(0110
~ (fillOIl
L:
~Q
[," O"ring
Oil seal
L4-1441
Fig. 205
No. Part Name Description Remedy
1) Damage on body surfaces

1. Front body Replace with a new one.

2. Rotor 2) Ridge wear on vane sliding grooves (If light leaks
with vane in slit against light source) If damage is serious, replace with
3. Vane Excessive wear on nose radius and side surfaces a new cartr idge ASSY.
4. Cam ring Ridge wear on sliding surfaces
5. Pressure plate Wear and damage on sliding surfaces Replace with a new one.
1) Damage on body surfaces

6. Rear body Replace with a new one.
Wear or damage on contact surfaces of oil seal and

7. Motor Replace with a new one.
shaft
77
4-3 STEERING SYSTEM
ASSEMBLY
Motor Front body
1) Oil seal assembly
(1) Apply a coat of grease to outer periophery of oil seal
and press oil seal into front body until it is flush with the
surface.
Always use a new oil seal, and be sure to assemble.
Press
Air inlet
L4-1432
INSTALLER
Fig. 207
Cam Pin hole

Rotor
Front body
L4-1431
Fig. 206
2) Front body
(1) Install O-ring in groove at outer periphery of front
body. Projection Mark Rounded sides faCing cam
(Plate side)
(2) I nstall front body with the bottom facing down when
motor is installed. I nsert motor shaft into place on the L4-1433
protrusion side of cover. . Fig. 208
Always use a new O-ring, and be sure to assemble.
3) Cartridge ASSY
(1) Install rotor by aligning it with shaft splines. 4) Install pressu re plate.
(2) I nsert two straight (locating) pins into front body. 5) Rear body ASSY
(3) I nstall cam ring. (1) First tighten all bolts in a criss-cross fashion to one-
(4) Install 10 vanes into slits in rotor with the rounded half of specified torque, then to the specified torque.
sides facing cam.
Tightening torque:
a. Always use new rubber parts. Be careful not to allow these 20 - 29 N·m (2.0 - 3.0 kg-m, 14 - 22 ft-Ib)
parts to be pinched or dislocated.
b. Apply a coat of specified grease to frictional surfaces of
parts.
c. Check that front body and rotor vanes face in the proper
direction.
Specified fluid
SPECIAL POWER STEERING FLUID

[Part No. K0209A0080)
Specified grease for motor pump
VALIANT GREASE M2 L4-1434

[Part No. 003608001, net 0.5 kg (1.1 Ib))
Fig. 209
78
STEERING SYSTEM 4-3
6) Install reservoir ASSY.
7) Connect connectors. Gauge
Motor yoke
Always use new O-rings, and be sure to assemble.
Tightening torque:
49 - 59 N.m (5.0 - 6.0 kg-m, 36 - 43 ft-Ib)
8) I nstall cap, oil strainer and cap ASSY.

9) I nstall harness.
Tightening torque: L4-1436

3.9 - 5.1 N·m (0.40 - 0.52 kg-m, 2.9 - 3.8 ft-Ib)
Fig. 211
REMOVAL
1) Remove two bolts from motor cover.
Motor Brush
INSPECTION
1) Remove screws from outer periphery of yoke.

2) Insert a 2.5 to 3 mm (0.098 to 0.118 in) dia. gauge (insu-
lated) vertically to yoke surface.
3) Measure dimension "H" from yoke surface. Replace
brushes if "H" is within the 13.5 to 14 mm (0.531 to 0.551
in) range.
L4-1437
Standard (new) 7.85 mm (0.0391 in)
Replacement standard 13.85 mm (0.5453 in) Fig. 212
Service limit 15.85 mm (0.6240 in)
4) Install screws on periphery of yoke. 2) Remove motor cover by prying its two grooves.
L4-1438
Fig. 210 Fig. 213
79
4-3 STEERING SYSTEM
3) Remove nuts and washers from brush lead terminals.
L4-1443
Fig. 217
L4-1443
3) I nstall washers and nuts to stud bolts and tighten.
Fig. 214
4) Remove brushes while lifting brush springs. Tightening torque:

3.9 - 5.1 N·m (0.40 - 0.52 kg-m, 2.9 - 3.8 ft-Ib)
4) Secure harnesses with washers and nuts.
Tightening torque:
3.9 - 5.1 N·m (0.40 - 0.52 kg-m, 2.9 - 3.8 ft-Ib)
a. Check that brushes face in the correct direction.
Tightening torque:
1.2 - 1.5 N.m (0.12 - 0.15 kg-m, 0.9 - 1.1 ft-Ib)
b. Be careful to install brushes properly because of their

L4-1440
polarity.
Fig. 215 c. Always replace brushes (positive and negative sides) as a
Always replace both brushes (positive and negative sides) as a unit.
unit
INSTALLATION
1) Secure pump ASSY to bracket above front bulkhead with
ASSEMBLY bolts, and connect high and low pressure hoses.
1) Lift brush springs and install new brushes.
Tightening torque:
23 - 42 N·m (2.3 - 4.3 kg-m, 17 - 31 ft-Ib)
~!
~ ~ -~
~.~~~~
L4-1442
Fig. 216
2) Install new brush terminals to stud bolts and tighten with L4-1444
washers and nuts. Fig. 218
80
STEERING SYSTEM 4-3
2) Connect harnesses as shown in Figure 219. 5) Replenish specified oil and bleed air.
Tightening torque: N.m (kg-m, ft-Ib'

9.5 - 12.3 (O.97 - 1.25, 7.0 - 9.0)
3.9 - 5.1 (0.40 - 0.52,2.9 - 3.8)
Positive terminal
Fig. 221
Negative terminal
Blue line from
power contra lIer
L4-1445
Specified oil for motor pump
Fig. 219
SPECIAL POWER STEERING FLUID
[Part No. K0209A0080]
Oil quantity:
3) I nstall power controller. All systems .... . . 0.65 £ (1.4 US pt, 1.1 Imp pt)
Oil tank ........ 0.25 £ (0.5 US pt, 0.4 Imp pt)
Tightening torque: (1) Replenish specified fluid to 4 cm (1.6 in) below reser-
4.4 - 7.4 N·m (0.45 - 0.75 kg-m, 3.3 - 5.4 ft-Ib) voir filler opening.
(2) Raise car with ignition switch OFF. Turn steering
wheel from lock to lock until air bubbles disappear, as
follows:
a. Turn steering wheel slowly from lock to lock at least ten

times.
b. Thereafter, turn steering wheel from lock to lock by
gradually increasing turning speed. Repeat ten times. Be care-
ful not to allow fluid to overflow from filler opening.
(3) Idle engine with car raised.

(4) Slowly turn steering wheel fully to the left and then
to the right until no air bubbles appear. (Turning steering
wheel from lock to lock three times causes air bubbles to
disappear.) During turning, oil level falls. Add fluid as
Fig_ 220
required to maintain a constant level of oil.
(5) Lower the car to ground with engine running at idle.
(6) Slowly turn steering wheel fully to the left and then
to the right to check that no air bubbles appear in fluid,
4) Connect ground leads to power controller, motor pump and that change in oil level is within 3 mm (0.12 in).
and engine.
If oil level changes excessively or oil is whitish (contaminated)
Be sure to securely tighten ground lead between engine and and if oil pump emits gear noise, air is not bled completely.
power controller because high current flows through it. Leave car unattended for 30 minutes and start to bleed air
again.
Tightening torque:
4.4 - 7.4 N·m (0.45 - 0.75 kg-m, 3.3 - 5.4 ft-Ib' 6) Lower car to ground.
81
4-3 STEERING SYSTEM
7) Check fluid leakage.

After completely bleeding air, check pipe couplings for
leakage.
a. Do not confuse spilled oil with leakage.

b. Wipe oil off parts before checking for leakage.
8) Check and adjust fluid level.

Oil level is correct if it is between arrow marke on the COLD
side of gauge rod when reservoir surface temperature is ap-
proximately 20°C (68°F) (engine cold).
A3-285
Fig. 222
Remove excess oil using a clean syringe.

I
82
STEERING SYSTEM 4-3
TROUBLESHOOTING
Manual Steering
I STEERING TROUBLES I
I
I Hard steering I Car pulls to one Steering wheel I I Shock loads to Poor return of
side during
driving
shimmy steering wheel I steering wheel
Steering is hard
even when car is
Steering is light
when car is
Excessive play in
steering system
I~ nsuffi~ient
In
play
steering system
I
jacked up. jacked up.
Faulty steering Improper tire inflation pressure

shaft bearing
Poor lubrication
Worn tires I Uneven wear on tires I Fau Ity steering
shaft bearing
Deformed I Loose hub nut I

Damaged boot knuckle arm
Improper back-
lash of rack and
Distorted
crossmember
I Runout or un-
balance of tire or
Improper back-
lash of rack and
J pinion wheel pinion
Seized or dam- Improper front wheel alignment Seized or dam-

aged ball joint aged ball joint
I Worn or damaged wheel bearing

Deformed tie-rod Improper front
wheel alignment
Deformed or improperly installed suspension arm
I Loose tie-rod connection
Damaged or worn in steering gearbox components
Shock absorber malfunction 1
Unequal left and

right wheelbase
83
4-3 STEERING SYSTEM
Power Steering
A1) STEERING CONDITION
( 1) Except XT6
Heavy steering Heavy steering Steering wheel Vehicle leads to Poor return of
effort in all effort at stand surges when one side or the steering wheel
ranges still turning other to center
I T I I r r
•
Pulley belt •
Fluid line
NG
Reform orl
1 . Unequal length of pulley belts 1. Folded hose replace
2. Adhesion of oil and grease 2. Flattened pipe
3. Loose or damage of pulley
belt
4. Poor uniformity of pulley belt
cross section.
NG Adjust or
replace
I
Tire and rim
GOOD
5. Pulley belt touches to Pulley

bottom 1. Flat tire
6. Poor revolution of pulleys 2. Mix use of different tires NG Fix or
except oil pump pulley 3. Mix use of different rims
replace
7. Poor revolution of oil pump 4. Abnormal wear of tire
pulley 5. Unbalance of remained grooves
6. Unbalance of tire pressure
~ GOOD
Tire and rim
1. Imp'op" t;,,, out Of) NG

I GOOD
Front alignment
specification Replace or NG Adjust or
2. Improper rims out of
*1 1 reinflate 1. Improper or unbalance caster
retighten
2. Improper or unbalance toe-in
specification
3. Loose connection of suspension
3. Tires not properly inflated
I GOOD
i
Others
GOOD
Replace,
Fluid
Refill, NG Adjust or
1. Damaged joint ASSY
1. Low fluid level NG bleed air, instruct
2. Unbalance of height
2. Aeration replace or customer
3. One-sided weight
3. Dust mix instruct
~
4. Deterioration of fluid customer
GOOD
5. Poor warming up of fluid *2
l GOOD Measure steering effort.
Idling speed
1. Lower idling speed NG Adjust or

instruct
2. Excessive drop of idling speed
at start or at turning steering customer
wheel *3
*1 If tires andlor rims are wider, the load to power steering system is the more.
1 GOOD Accordingly, in a condition, for example before fluid warms up, relief valve may
work before maximum turning angle. In this case, steering effort may be he avy.
Measure hydraulic pressure. When measured hydraulic pressure is normal, there is no abnormal thing.
I GOOD
*2 In cold weather, steering effort may be heavy due to increased flow resistance
of cold fluid. After warming up engine, turn steering wheel from stop to stop
several times to warm up fluid. Then if steering effort reduces normally, the re is
Measure steering effort. no abnormal thing.
I *3 In cold weather or with insufficient warm up of en gine steerin g effort ma y be
heavy due to excessive drop of idling speed when turning steering wheel. In this
case, it is recommended to start the vehicle with increasing engine speed than
usual. Then if steering effort reduces normally, there is no abnormal thing.
84
STEERING SYSTEM 4-3
(2) XT6 Heavy steering Heavy steer I ng Steering wheel Veh icle leads to Poor return of
effort in all effort at stand surges when one side or the steering wheel
ranges std I turning other to center
I I I I I I
1
Fluid line
GOOD Warning lamp comes NG Reform or
on after engine starts 1. Folded hose replace
2. Flattened pipe
Malfunctioning part(s) of Tire and rim

NG
!
Tire and rim
GOOD
electrical system * 4
1. Harness
1. Im",op" I;".
specification
0", Of) NG Replace or
1.
2.
Flat tire
Mix use of different tires
*1 reinflate NG Fix or
2. Engine signal system 2. Improper rims out of 3. Mix use of different rims
3. Motor pump power specification replace
4. Abnormal wear of tire
controller 3. Tires not properly inflated 5. Unbalance of remained grooves
4. Power supply
5. Signal controller ! 6. Unbalance of tire pressure
~
GOOD
GOOD
Fluid
Refill,
Front alignment
1. Low fluid level bleed air,
Locate problem in self·check NG NG
2. Aeration Adjust or
mocle replace or 1. Improper or unbalance caster
3. Dust mix retighten
Instruct 2. Improper or unbalance toe·in
4. Deterioration of fluid customer 3. Loose connection of suspension
5. Poor warming up of fluid *2
t GOOD 1Others
GOOD
Replace,
Idling speed NG Adjust or
1. Damaged 10lnt ASSY
NG Adjust or instruct
1. Lower idling speed 2. Unbalance of height
instruct customer
2. Excessive drop of idl ing speed 3. One-sided weight
at start or at turning steering customer
wheel *3
! GOOD
~ GOOD
Measure steering effort
t GOOD
Malfunctioning part(s) of
electrical system * 4
*1 If tires and/or rims are wider, the load to po wer
steering system is the more. Accordingly, in a
1. Harness condition, for example before fluid warms up,
2. Engine signal system
3. Motor pump Repair
relief valve may work before maximum tur ning
4. Power controller
NG
or angle. In this case, steering effort may be heavy.
5. Power supply replace When measured hydraulic pressure is nor mal,
6. Signal controller
7. Car-speed sensor
there is no abnormal thing.
8. Steering sensor *2 In cold weather, steering effort may be he avy
9. Poor grounding due to increased flow resistance of cold fl uid.
GOOD
After warming up engine, turn steering wheel
t from stop to stop several times to warm up fl uid.
Measure hydroulic pressure Then .f steermg effort reduces normally, there is
no abnormal thing.
*3 In cold weather or with insufficient warm up of
engine, steering effort may be heavy due to
excessive drop of idling speed when turning
steering wheel. In this case, it is recommended to
start the vehicle with increasing engine speed
than usual. Then if steering effort reduces
normally, there is no abnormal thing.
*4 Most problems that occur in electrical system can
be isolated as to what system line or part is
malfunctioning.
85
4-3 STEERING SYSTEM
Considerable effort is required to turn Considerable effort is required to turn

steering wheel fully. particularly when steering wheel when air conditioning
speed is below 10 km/h (6 MPH) epprox. system in ON or when radiator sub-fan is
operating
Faulty steering sensor line
Chack in self-check mode NO Faulty sub·fan control function
See 6·3 chapter.
86
STEERING SYSTEM 4-3
A2) MEASUREMENT OF STEERING EFFORT
*5
Measure steering efforts in standstill

with engine idling on concrete road. NG
Result: 31.4 N (3.2 kg, 7.1Ib)
or less in both directions
I Adjust backlash
I
*5 When turning steering more quickly than n8Ceuary

GOOD from a direction to the other direction at an engine
speed over 2,000 rpm, steering effo rt may be heavy.
This is caused by flow characteristic of oil pump and
Remove joint ASSY is no problem.
Measure steering wheel effort.

Result: Maximum force is 2.26 N
NG
(0.23 kg, 0.51 Ib) or less in J
both direction. I
Check, readjust, replace if necessary
I
Fluctuation width is 1.08 N
(0.11 kg. 0.24 Ib) or less.
GOOD
Measure folding torque of the joint

ASSY.
Result: 5.49 N (0.56 kg, 1.23 Ib) NG
or less for long yoke.
I Replace with a new one
I I
8.43 N (0.86 kg, 1.90 Ib)
or less for short yoke.
GOOD
Check front wheels for unsteady

revolution or rattling and brake for
NG I Inspect, readjust, replace if necessary
l
I
dragging.
GOOD
Remove tie-rod ends
(To be continued)
87
4-3 STEERING SYSTEM
Check tie-rod ends, tie-rods and ball NG

joints of suspension for unsteady I Inspect, replace if necessary
I
revolution or rattling.
GOOD
Measure rotating and sliding

resistance of gearbox ASSY.
Result: Rotati!19 resistance is 7.85 N
(0.80 kg, 1.76 Ib) or less
around center position and
10.10 N (1.03 kg, 2.27 Ib)
or less in all positions within NG Readjust backlash, if ineffective
20% difference between replace bad parts
clockwise and counter-
clockwise.
Sliding resistance is 245 N
(25 kg, 55 Ib) or less with
20% difference between
left and right directions.
Measurement of steering effort Measurement of folding torques of joint assembly
Long yoke
5.49 N (0.56 kg, 1.23 Ibl or less
Spring balance
L4-372
Long yoke
5.49 N (0.56 kg, 1.23 Ibl or less
L4-373 L4-884
Fig. 223 Fig. 224
88
STEERING SYSTEM 4-3
A3) MEASUREMENT OF HYDRAULIC PRESSURE
Be sure to complete all items aforementioned in article 1), prior to measuring hydraulic pressure. Otherwise, pressure can not
be measured correctly.
~ Flattened pipes or hoses I

Replace bad parts
Measure regular pressure at I

~ Leakage of fluid line I Replace
idling with valve opened.
Obstacle in fluid line I Replace fluid or com-

ponent of fluid line
GOOD
~ Poor work of relief valve
Measure relief pressure at Fluid leakage inside oil

.3 Replace oil pump ASSY
idling with valve closed.'
~PumpASSY
Excessive wear of vane

GOOD pump mechanism
Measure work ing pressure of

control valve at idling with NG Replace valve ASSY or
J Poor work of control valve I
valve opened, turning steering pinion & valve ASSY
wheel from stop to stop.
a. 00 not leave the valve of pressure gauge closed or hold the steering wheel at stop end for 5 seconds or more in any case, as
the oil pump may be damaged due to long keep of these conditions.
b. Put cotton cloth waste at a place where fluid drops before pressure gauge is installed. Wipe off spilt fluid thoroughly after the
measurement
c. Keep engine idling during the measurement.
89
4-3 STEERING SYSTEM
Regular pressure:
981 kPa (10 kg/cml, 142 psi) or less
Fig. 227
PRESSURE GAUGE (925711000)
Fig. 225
PRESSURE GAUGE (925711000)
ADAPTER B (926220000)
ADAPTER A (926210000)
L4-1450
Fig. 228
ADAPTE R B (926220000)
ADAPTE R A (926210000)
L4-1449
Fig. 226
Working pressure:
5,884 - 7,355 kPa
(60 - 75 kg/cm 2 , 853 - 1,067 psi)
Relief pressure:
3,923 - 5,394 kPa
(40 - 55 kg/cm 1 , 569 - 782 psi)
5,884 - 7,355 kPa A18·225
(60 - 75 kg/cml, 853 - 1,067 psi)
Fig. 229
90
STEERING SYSTEM 4-3
Sliding resistance:
Right-turn steering
245 N (25 kg, 55 Ib) or less
Left-turn steering
8.43 N (0.86 kg. 1.90 Ib) or less
245 N (25 kg, 55 Ib) or less
8.43 N (0.86 kg. 1.90 Ib) or less

Short yoke
I L4-886
Fig. 230
Measurement of resistances of gearbox assembly
L4-309
Rotating resistance:
Straight-ahead position within 30 mm (1.18 in)
Fig. 232
from rack center
Less than 7.85 N (0.80 kg. 1.76Ib)
Maximum allowable torque
10.10 N (1.03 kg. 2.27 Ib)
Fig. 231
91
4-3 STEERING SYSTEM
A4) FLUID LEAKAGE

( 1) Except XT6
It is likely that although one judges fluid leakage, there is actually no leakage. This is because the fluid spilt during the last
maintenance was not completely wiped off. Be sure to wipe off spilt fluid thoroughly after maintenance.
Leakage from connecting Insufficient tightening of Loosen and retighten, if
portions of pipes and hoses, flare nut, catching dirt or ineffective, replace
numbered with CD thru ® the like, damage to flare or
in figure flare nut
Poor insertion of hose, poor I Retighten or replace clamp

clamping
., Damaged a-ring Replace a-ring pipe or hose

with new one, if ineffective,
I Leakage from hose @> and I
,............ I Crack or damage in hose replace gearbox ASSY also
<!J) in figure
Crack or damage in hose ~----....j Replace with a new one
hardware
Leakage from surrounding

Damaged a-ring, @
of casted iron portion of
Replace oil pump ASSY
oil pump ASSY' @ and
@ in figure Damaged oil seal, @
Crack in oil tank, ® 1-------1 Replace oil tank

Leakage from oil tank,
® and @ in figure
Damaged a-ring, @ 1---------1-1 Replace a-ring
~---------~
Damaged cap packing 1-------1 Replace cap

~---------------~ ~------------~
Leakage from filler neck @ ~-----t~ Crack in root of filler neck ~-------I'" Replace oil tank ASSY
High fluid level *6 1-------1-.1 Adjust fluid level

of power cylinder of gear- I-------t~ Damaged Y -shaped packing
box ASSY, @ in figure
Damaged Y -shaped packing
Leakage from control valve

or oil seal I Replace bad parts
of gearbox ASSY, @ and
@ in figure
Damage in control valve
*6 Fluid level is specified at optimum position (range) for ordinary use. Accordingly, if the car is used often under hard
conditions such as on very rough roads or in mountainous areas, fluid may bleed out from cap air vent hole. This is not a
problem. If a customer complains strongly and is not likely to be satisfied with the leakage, lower the fluid level to the
extent that fluid will not bleed out under the conditions described, and have the customer check the fluid level and its
quality more frequently than usual.
92
STEERING SYSTEM 4-3
(2) XT6
It is likely that although one judges fluid leakage, there is actually no leakage. This is because the fluid spilt during the last
maintenance was not completely wiped off. Be sure to wipe off spilt fluid thoroughly after maintenance.
Leakage from connecting Insufficient tightening of r Loosen and retighten, if

1ineffective, replace
~
portions of pipes and hoses, flare nut, catching dirt or
numbered with CD thru @ the like, damage to flare or
in figure flare nut
~
Poor insertion of hose, poor Retighten or replace clamp

clamping
Damaged C-ring Replace C-ring pipe or hose

with new one, if ineffective,
Leakage from hose ® and replace gearbox ASSY also
Crack or damage in hose
@ in figure
Crack or damage in hose Replace with a new one
hardware
I Fatigued C-ring '(j]) at

I pressure port ~
I Fatigued oil seal @ ~
Fluid leakage from motor
pump ASSY i Replace faulty part. I
Parts (j]), @, @ and @
: Cracked reservoir @ r-
I Reservoir C-ring @ fatigued
Damaged cap packing ~------I Replace cap

~---------~ ~---------~
Leakage from filler neck @ ~----~ Crack in root of filler neck I - - - - -__~ Replace oil tank ASSY
I--H_ig_h_f_1u_i_d_le_v_e_1_ _ _ _*_6---l1--------t.~1 Adjust fluid level

of power cylinder of gear- 1 - - - - - - . . . . , Damaged Y -shaped packing
box ASSY, @ in figure
Damaged Y -shaped packing ~

l-0_r_oi_l_se_a_I_ _ _ _ _ _-....Jr----- :-1 Replace bad parts
Leakage from control valve
of gearbox ASSY, @ and
@ in figure
Damage in control valve
*6 Fluid level is specified at optimum position (range) for ordinary use. Accordingly, if the car is used often under hard
conditions such as on very rough roads or in mountainous areas, fluid may bleed out from cap air vent hole. This is not a
problem. If a customer complains strongly and is not likely to be satisfied with the leakage, lower the fluid level to the
extent that fluid will not bleed out under the conditions described, and have the customer check the fluid level and its
quality more frequently than usual.
93
4-3 STEERING SYSTEM
L4·775
Fig. 233
l4-1451
Fig. 234
94
STEERING SYSTEM 4-3
A5) NOISE AND VIBRATION
*7
Hiss noise (continuous) Relief Generates at
Normal (Don't keep this
While engine is running with valve max. turning
condition over 5 seconds.)
maximum turning angle sound angle
Generates
Defective.
without steering
Replace oil pump ASSY.
operation
Check clearance.
Rattling noise Interference with adjacent
[Refer to next article 6)]
(interm ittent) parts
Correct if necessary
While engine is running
Loosened installation of
Oil pump ASSY, Oil tank,
Retighten
Pump bracket, Gearbox
ASSY or Crossmember
Loosened installation of
Oil pump pulley or other i Retighten
pulley(s)
Loosened linkage or play of

steering sys. or suspension.
I Retighten or replace
Loosened tightening of
joint ASSY or Column sys.
Sound generates from the

inside of gearbox ASSY or I Replace the ASSY
oil pump ASSY
Knocking Excessive backlash

When turning steering wheel Loosened Lock nut for I Adjust and retighten I
in both directions with adjusting backlash
small angle repeatedly at
engine ON or OFF Loosened tightening or play
of Tie-rod, Tie-rod end
I Retighten or replace I
*7 Don't keep the relief valve operated over 5 sec. at any time or inner parts of the oil pump may ba damaged due to rapid
increase of fluid tamperature.
95
4-3 STEERING SYSTEM
*8
Grinding noise L Vane pump aeration Inspect and retighten fluid
I
(continuous) line connection.
While engine is running Refill fluid and vent air.
Vane pump seizing I
J Replace Oil pump ASSY

Pulley bearing seizing of
Oil pump ASSY or Motor
pump ASSY
Folded hose, flat pipe

I
I
I Replace I
Squeal, squeak. Maladjustment of pulley Adjust or replace
(intermittent or continuous) belt (Replace two belts as a set)
While engine is running Damaged or charged pulley
belt
Unequal length of pulley
belts
Run out or soilage of

V-groove surface of Oil
pump pulley
Clean or replace I
I
Sizzling noise I Fluid aeration Fix wrong part causing
(continuous) aeration.
While engine is running Replace fluid and vent air
Damaged pipe of Gearbox

Replace pipe
ASSY
Abnormal inside of hose or

pipe. Rectify or replace
Flat hose or pipe
I Abnormal inside of oil tank I : Replace

or motor pump ASSY
Removed oil tank cap or

I oil reservoir cap I : Install cap
Whistle Abnormal pipe of Gearbox Replace

(conti nuous) ASSY or abnormal inside Bad parts of Gearbox ASSY
While engine is running of Hose or Hose
*8 Grinding noise may be heard immediately after the engine start in extremely cold condition.
In this case, if the noise goes off during warm up there is no abnormal function in the system.
This is due to the fluid characteristic in extremely cold condition.
96
STEERING SYSTEM 4-3
Whine or growl Loosened installation of

(continuous or intermittent) Oil pump ASSY, Oil pump I Retighten
While engine is running bracket, Motor pump ASSY
with/without steering or Motor pump bracket
turned
*9
Abnormal inside of Oil
pump ASSY, Hose or Replace Oil pump ASSY,
Motor pump ASSY, Hose Hose, if the noise can be
heard when running as well
as standsti II
Torque converter growl
Remove power steering
Air conditioner compres-
pulley belt and confirm
sion growl
Motor (of motor pump

ASSY) whines while car is Replace brushes
being driven
I f noise still persists,

replace motor pump ASSY
Faulty floating unit of

I Repair or replace
motor pump ASSY
Faulty floating unit at

hose clamp of upper strut Repair or replace
mount
97
4-3 STEERING SYSTEM
Creaking noise Abnormal inside of Gear- Replace bad parts of Gear-

(intermittent) box ASSY box ASSY
While engine is running
with steering turned Abnormal bearing for
I Apply grease or replace
Steering shaft
*10
Generates when turning
If the noise goes off when
steering wheel with brake
brake is released, normal
(service or parking) applied
*11
Vibration Too low engine speed at Adjust and Instruct
While engine is running start customers
with/without steering
turned I V ane pump aeration
. I Fix wrong part.
Vent air
Damaged valve in Oil pump Replace Oil pump ASSY,

ASSY, Gearbox ASSY or bad parts of Gearbox ASSY
Motor pump ASSY or Motor pump ASSY
"
..
Looseness of play of
Retighten
.
(
Steering, Suspension parts to
L
v
3
*9 Oil pump or Motor pump makes whine or growl noise slightly due to its mechanism. Even if the noise can be heard when
steering wheel is turned at standstill there is no abnormal function in the system provided that the noise eliminates when the
car is running.
*10 When stopping with service brake and/or parking brake applied, power steering can be operated easily due to its light
steering effort. If doing so, the disk rotates slightly and makes creaking noise. The noise is generated by creaking between
the disk and pads. If the noise goes off when the brake is released, there is no abnormal function in the system.
*11 There may be a little vibration around the steering devices when turning steering wheel at standstill, even though the
component parts are properly adjusted and have no defects.
, Hydraulic systems are likely to generate this kind of vibration as well as working noise and fluid noise because of combined
conditions, i.e.,
Road surface and tire surface, Engine speed and turning speed of steering wheel, Fluid temperature and braking condition.
This phenomena does not indicate there is some abnormal function in the system.
The vibration can be known when steering wheel is turned repeatedly at various speeds from slow to rapid step by step
with parking brake applied on concrete road and in "0" range for automatic transmission vehicle.
98
STEERING SYSTEM 4-3
A6) CLEARANCE TABLE
This table lists various clearances that must be correctly adjusted to ensure normal vehicle driving without interfering noise or
any other faults.
(1) Except XT6
Minimum Minimum
Location allowance Location allowance
mm (in) mm (in)
CD High tension cord - Oil tank 5 (0.20) (]) Exhaust pipe - Gearbox boot 15 (0.59)
CV DOJ - Shaft or Joint ASSY 14 (0.55) @ Side frame - Hoses A and B 15 (0.59)
@ DOJ - Valve housing 11 (0.43) ® TURBO lubricating pipe - Hoses A and B 8 (0.31)
@ Pipe - Pipe @ Radiator hose - Hoses A and B 13(0.51)

2 (0.08)
Pipe - Crossmember (jJ) Oil pan - Pipe 10 (0.39)
@ Stabilizer - Pipe 5 (0.20) @ Thermostat - Hoses A and B 2 (0.08)
® Exhaust pipe - Pipe 15 (0.59) @ AT cooling hose - Joint ASSY 20 (0.79)
AT cooling hose
High-tension cord
L4-776
Fig. 235
99
4-3 STEERING SYSTEM
(2) XT6
Minimum Minimum
Location allowance Location allowance
mm (in) mm (in)
CD Motor pump to bracket 3 (0.12) (j) Exhaust pipe to gear box boot 14 (0.55)
@ DOJ joint to shaft/joint ASSY 14 (0.55) @ Power cylinder to starter ring gear 12 (0.47)
@ DOJ to valve housing 14 (0.55) ® Brake booster to pipe 5 (0.20)
® Pipe to pipe/crossmember 2 (0.08) @ Engine intake duct to hoses A and B 10 (0.39)
@ Stabilizer to pipe 5 (0.20) (j]) Brake master cylinder to hoses A and B 10 (0.39)
@ Exhaust pipe to pipe 15 (0.59) @ Accelerator cable to power controller 5 (0.20)
Accelerator cable
® Brake booster
@ @ @
L4-1452
Fig. 236
100
STEERING SYSTEM 4-3
A7) BREAKAGE OF HOSES
Pressure hose burst Excessive holding time of

Instruct customers
rei ief status
~_ _ _ _--I Replace Oil pump ASSY

Malfunction of relief valve
or Motor pump ASSY
Poor cold characteristic of

Replace fluid
fluid
Forced out Return hose Poor connection 1---------1 Correct
Poor holding of clip 1---------1 Retighten
Poor cold characteristic of

1---------1 Replace fluid
fluid
Fluid bleeding out of hose Wrong layout, tensioned l Replace hose I

slightly
Excessive play of engine due
to deterioration of engine i Replace defective parts I
mounting rubber
Inproper stop position of

pitching stopper
I Replace defective parts I
*12
I Crack on hose I
I
Excessive holding time of Replace
rei ief status Instruct customer
Excessive tightening torque

Replace
for return hose cI ip
Power steering fluid, brake Replace

fluid, engine oil, electrolyte Pay attention on service
adhere on the hose surface work
Too many times use in Replace

extremely cold weather I nstruct customers
I
*12 Although surface layer materials of rubber hoses have excellent weathering resistance, heat resistance and resistance for low
temperature brittleness, they are likely to be damaged chemically by brake fluid, battery electrolyte, engine oil and
automatic transmission fluid and their service lives are to be very shortened. It is very important to keep the hoses free
from before-mentioned fluids and to wipe out immediately when the hoses are adhered with the fluids.
Since resistances for heat or low temperature brittleness are gradually declining according to time accumulation of hot or
cold conditions for the hoses and their service lives are shortening accordingly, it is necessary to perform careful inspection
frequently when the car is used in hot weather areas, cold weather areas and/or a driving condition in which many times
steerings are required in short time. Particularly continuous work of relief valve over 5 seconds causes to reduce service
lives of the hoses, the oil pump ASSY, the fluid, etc. due to over heat.
So, avoid to keep this kind of condition when servicing as well as driving.
101
BRAKES
Page
SUBARU MECHANISM AND FUNCTION.... . . . . . • . . . . . . . . . • . . . . . • . . ..

Disc Brake .•....•..........••.........•.........•....•
2
2
Master Cylinder ..•..•.•••••.•.•••...••.•••....•..•.•.•. 2
1988 Brake Booster ...•.•••••.•••••..••••.••.••..••••••••.•. 5

Proportioning Valve ..••.••••••••••••...••.•••••..••.••••
Hill-Holder •.....•........••...••...••••..•.•.•.•.•.•• 7
SPECIFICATIONS AND SERVICE DATA .......•••••••••••••••. 10
SPECIFICATIONS ...•...••.•••••••••••..••••••••.•••••• 10
SERVICE DATA .•••••.•••.•••••••••..•••...•••....•.. 11
5
-
RECOMMENDED BRAKE FLUiD •.•...•......•....•...•... 11
COMPONENT PARTS ..•....•....•.....•.....•........•... 12
SERVICE PROCEDURE .................••....•..... / ....•. 20
Front Disc Brake ........•...........••.........••..•.•. 20
Rear Disc Brake ....•....••....•............•....•...•.. 30
Rear Drum Brake ...•...........................••...•.. 33
Master Cylinder •...•..........•................•••.•... 36
Brake Booster •....••••••.....•...................••... 37
Brake Hose .•.•••.•.......•.••.•••.•..••.....•••••.•.• 40
Proportioning Valve ..•...............•.....•....•....•.. 41
Hill-Holder .•.....•.....•...........•..........•....•. 42
Parking (Hand) Brake .•....•....•...........••....•....•. 44
Brake Fluid Level Indicator ..•...........•....•.....•...•.. 45
Air Bleeding •..•.••..••.••...•.........•.••...•...•..• 45
Replacement of Brake Fluid . • . . • • . • . . • • • • . . . • • . • • . • • • . • • • .. 46
TROUBLESHOOTING •................•....•..........•... 48
Entire Brake System ................•.....•..........•... 48
Hill-Holder .....••....•.....•....•.........•.....••... 50
4-4 BRAKES

Disc Brake
PAD WEAR INDICATOR
A wear indicator is provided on disc brake pad. If the front Wear indicator
pad wears down to 1.5 mm (0.059 in) or the rear pad wears
down to 3 mm (0.12 in), the tip of the wear indicator comes
into contact with the disc rotor, and it makes a squeaking
sound as the wheel rotates, indicating that the pad needs to
be replaced. (XT6)
If the pad wears down to 1.5 mm (0.059 in), the tip of the
wear indicator comes into contact with the disc rotor, and it
makes a squeaking sound as the wheel rotates, indicating that
the pad needs to be replaced. (Except XT6)
/ /
Disc rotor
New pad
Wear indicator
/ /
Disc rotor
Worn pad L4-002
Fig. 2 Rear disc brake
Disc rotor New pad
Master Cylinder (Except XT6)

>7TJe;;/J/4w,,7a
Disc rotor 1.5 mm (0.059 in)
1) The fast-fill mechanism is adopted to improve the pedal
operating feel.
Worn pad L4-910
2) The sealed reservoir tank is adopted to extend the service
Fig. 1 Front disc brake life of brake fluid.
3) The fluid leveler is built into the reservoir tank for easy
and correct monitoring of the fluid level when adding brake
fluid.
2
BRAKES 4-4
The ball valve is opened when fluid pressure in chamber F
exceeds the preset pressure level. The notch in the supply
valve keeps the valve always in a partially opened state, so that
no fluid pressure will be left in chambers P and F when the
system is not operating.
Operation of fast-fill valve

1) Low fluid pressure period
During the low fluid pressure period which begins immediately
after starting the piston and ends when the ball valve in the
FFV releases, the fluid pressure generated in chamber F is
higher than the one in chamber P; the fluid pressure difference
causes fluid to flow from chamber F to chamber P. The
amount of fluid flow shortens the brake pedal stroke, i.e.
brake fluid is pushed out of the master cylinder through the
sectional area of chamber F.
Large diameter side

hydraulic chamber
Primary hydraulic chamber (Chamber P) (Chamber F)
L4-OO9
Fig. 3
~ Piston movement
OPERATION OF FAST-FILL MECHANISM

L4-011
When compared to a conventional master cylinder, the one
with the fast-fill mechanism has the following two unique Fig. 5
structural features: 2) High fluid pressure period
1) It has a large diameter chamber (chamber F) on the inlet During the high fluid pressure period after releasing fluid from
side of the master cylinder, and small diameter chambers the ball valve, the pressure in chamber P is higher than the
(chambers P and S) on the inner side. The primary piston is pressure in chamber F, and flow of fluid is made stationary by
of a stepped construction with those two diameters. primary cup's sealing the passage. As the fluid pressure in
2) A check valve, which is called the fast-fill valve (FFV), is chamber F drops thereafter, the operating pressure is generated
installed between chambers P & F and the reservoir. by the pedal depressing force and the sectional area of
This FFV controls the flow of brake fluid from chamber F to chamber P.
reservoir, and vice versa, by ball valve and supply valve, An orifice is provided in the passage between chamber F and
respectively. the reservoir for smooth pedal feel.
Notch
Supply valve-- ¢:l Piston movement
L4-010
L-____________________________________________ ~
L4-012
~4 ~6
3
4-4 BRAKES
3) When slackening pedal depression Fast·fill effect

Brake fluid is supplied from the reservoir through the supply
The pedal stroke on the primary side is shortened because
valve by negative pressure generated in chamber F. Fluid is
brake fluid flows from chamber F. The secondary side pedal
also supplied to chamber P through chamber F.
stroke is also shortened since a large amount of flu id fed from
chamber F to chamber P separates the primary piston and
secondary piston.
Primary piston and ,-Brake fluid is flowed

secondary piston ~ ~
are separated. ~ _ ~
¢ Piston movement
[ rs::=:: :Jt:CE '-
-t-----+tt+-
L4-013
Fig. 7
L4-015
Fig. 9
With the FFV provided, the piston stroke can be made shorter
4) When pedal is released
than that of the conventional master cylinder through the
When the brake pedal is released, a residual pressure is
above-mentioned process. That is, the brake pedal stroke is
generated by the amount of fluid oversupplied to chamber F
shortened, and brake pedal feel is improved.
while the pedal is being released, the amount of fluid moved
from chamber F to chamber P during low pressure period, and
the amount of fluid supplied from the reservoir. This exces-
sive amount of fluid in both chambers is returned to the
reservoir through the notch mentioned previously until the
pressure becomes zero.
BRAKE FLUID LEVEL INDICATOR
,
Max. level line
Approx. 25 mm (0.98 in)

Float
Reservoir
tank
Warning light
actuation point Magnet L4-911
L4-014
Fig. 8 Fig. 10
4
BRAKES 4-4
Proportioning Valve
Warning light
The proportioning vain for dual piping systems is adopted for

r------ a _ _ _ _ _ ... _ _ _ _ _ .. ,
controlling the braking force.

I
I
Reed :
switch : To rear wheel cylinder (RH) To rear wheel cylinder (LH)
.,.
: : o o Stopper
~
:
rI~ i I
Permanent:
I
magnet :
_____________________ J
A17-154
Fig. 11
Under normal conditions, the float remains above the reed

switch, and the line of the magnetic force from the permanent
piston
From master cylinder

o
From master cvlinder
magnet in the float is unable to activate the reed switch. (Secondary) (Primary) L4-913
Therefore, the circuit is kept open, and the warning light Fig. 13 Construction
remains off. The float lowers as the brake fluid level lowers,
and if it falls below the specified fluid level [approx. 25 mm Incase of failure /
(0.98 in) below the MAX level line], the reed switch will be in one circuit 'y
activated by the permanent magnet to close the circuit. In 7,846 (80, 1. 138)1
this event, the warning light comes on and warns the driver of
Rear wheel 5,884 (60. 853)
a reduction of the brake fluid level. cylinder flUid
However, the lamp may be lighted momentarily even when the pressure 3,923 (40. 569)-+-----,~
brake fluid surface is still above the specified level, if the
vehicle body tilts or swings largely. 1,961 (20. 284) When both circuits
kPa (kg/cm 1 , psi)
0(0,0)
1,961 3,923 5.884 7.846
(20, (40, (60. (80.
284) 569) 853) 1.138)
Master cylinder fluid pressure kPa (kg/em 1 , psi)
In case of split point 3,923 kPa (40 kg/em'. 569 psi)
Brake Booster 7.846 (80. 1,138)
CHECK VALVE Rear wheel 5,884 (60, 853)
The check valve is built into the vacuum hose. Its orientation cylinder fluid
pressure 3,923 (40. 569)
is indicated on the label attached to the vacuum hose.
1,961 (20,284) When both circuits
1-----, l
kPa (kg/cm , psi)
: <ENGINE
_ _ _ _ _ _ --l1 (Stamp) I 1,961 3,923 5,884 7.846
(20. (40, (60, (80,
284) 569) 853) 1,138)
)/-1
- I , I)
Master cylinder fluid pressure kPa
Fig. 14 Characteristic curve

(kg/cm 1 , psi)
In case of split point 4,413 kPa (45 kg/cm 2 • 640 psi) L4-019
~'~_
~~
J-- __ '1
r:::IIl _•
[ . \ To engine" -
c.cr To brake
booster I
\~-~II L4-1227
Fig. 12
5
4-4 BRAKES
OPERATION IN CASE OF CIRCUIT FAILURE

OPERATION
1. Failure of primary circuit
OPERATION DURING NORMAL CONDITIONS If the primary circuit fails, the fail·safe piston and balance
1. Prior to valve operation (Before split point) piston are moved rightward by the fluid pressure in the master
cylinder in the secondary circuit until the piston contacts the
When the fluid pressure in the master cylinder is low (the
plug. In th is case, the balance piston remains off the seal (2),
fluid pressure before the split point), the piston is pressed by
and no split point is created in the graph. That is, the flu id
the spring load and the valve remains inoperative. As a result,
pressure in the secondary side rear wheel cylinder is equal to
the fluid pressure in the master cylinder is held equal to the
the fluid pressure in the master cylinder.
fluid pressure in the rear wheel cylinder.
To rear wheel cylinder

2. After valve operation (~fter split point) To rear wheel cylinder
1) When the master cylinder fluid pressure rises, the piston in

o o (inoperative)
the primary circuit is moved rightward against the spring load,

and brought into contact with the seal (1) (as shown in the
figure). The master cylinder fluid pressure chamber (chamber
A) is therefore cut off from the rear wheel cylinder fluid
pressure chamber (chamber 8), and the fluid pressure to the
rear wheel cylinder is thus controlled. (The pressure at this
Seal (2)
moment is the split point pressure.) Plug j,
If the fiuid pressure in chamber A rises further, the piston is
moved leftward, off the seal (1 L and this causes the fluid
o
From master cylinder
OFrom master cylinder
(Primary)
(Secondary)
pressure in chamber B to rise. The piston is then moved right· (inoperative) L4.915
ward, and brought into contact with the seal (1) again. After
Fig. 16
this, the piston repeats this contact with the seal (1) in this
way, thereby controlling the fluid pressure in the rear wheel
cylinder.
2) When the fluid pressure in chamber B is controlled in the 2. Failure of secondary circuit
secondary circuit, the balance piston is moved rightward by
If the secondary circuit fails, the balance piston is moved
the fluid pressure difference between chamber B and chamber
leftward by the fluid pressure in chamber B until the end of
C, and brought into contact with the seal (2), and the fluid
the piston contacts the stopper. Since sectional area A 1 is
pressure in chamber 0 is controlled. Since sectional areas A 1
greater than A2, the piston remains unmoved even after the
and A2 are equal, the balance piston is pushed by equal forces
master cylinder fluid pressure has reached the split point, and
from the right and left. If the fluid pressure rises in chamber
the piston is kept off the seal (1). Hence, no split point is
B, the balance piston performs control to equalize the fluid
created in the graph, and the rear wheel cylinder fluid pressure
pressure in chamber 0 and chamber B by repeating open·close
of the primary circuit is kept equal to the master cylinder
operation with the seal (2).
fluid pressure.
To rear wheel cylinder To rear wheel cylinder To rear wheel cylinder To rear wheel cylinder
o Balance {) Seal (1) linoperativeb Chamber B
Stopper
A2
piston
{) Chamber (B) 0 From master

cylinder
From master cylinder (Secondary) From master cylinder
From master cylinder (Secondary) (Primary) L4·914 (i noperative) (Primary) L4·916
Fig. 15 Fig. 17
6
BRAKES 4-4
Hill- Holder
OUTLINE depressed in order to start the vehicle on an uphill road, this
device holds the brake temporarily upon taking your foot off
Hill-holder is a device to make starting on an uphill road easily
the brake pedal (until the clutch pedal is released). Therefore,
and permits even a driver not yet familiarized with starting by
smooth starting is enabled by usual engagement of the clutch
use of parking brake to start the veh icle smoothly.
wh ile depressing the accelerator pedal.
When pressing down the clutch pedal with the brake pedal
Clutch release fork
Master cylinder
PHV cable Brake

Brake pedal
Clutch pedal
cable
Proportioning valve
L4·023
Fig. 18 Outline of hill-holder
PRESSURE HOLD VALVE (PHV) When stopping the vehicle on an uphill road by depressing
both brake and clutch pedals, the ball rolls toward the rear
PHV (Pressure Hold Valve) is connected to one of the service
and, at the same time, the push rod retracts to close the valve,
brake pipes and pushrod (8) is pushed in andlor pulled out by
so that hydraulic pressure is maintained. Even when taking
cam shaft (2) interlinked with the clutch pedal to change the
your foot off the brake pedal, the hydraulic pressure is
clearance between ball (3) and seal (5), thereby opening andl
maintained so far as the clutch pedal is kept depressed. In this
or closing the hydraulic circuit. Normally, on a flat road,
status, when engaging the clutch ordinarily While depressing
ball (3) is located at the front and the valve is kept opened
the accelerator pedal,' the maintained hydraulic pressure is
regardless of the position of the pushrod. (This status is the
released simultaneously with the generation of driving force to
same as on a downhill road.)
permit smooth starting.
7
4-4 BRAKES
• Inactive status
This accessory is not activated in any status other than the
above.
1) While driving
(1) During acceleration or usual driving
@
@
@
Front ¢:J -----1....;::::,.I---+__ -tE':::::=::HIt---:-- -++---+-H==c3- *" ..
®
...
To rear LH ® @ ®
brake
A17-265
Fig. 21
1 Body 8 Push rod

2 Camshaft 9 Spring
3 Ball 10 Boot
4 Ball guide 11 Collar
5 Seal 12 Lever
Since the clutch pedal is not depressed, the pushrod is
6 Plate spring 13 O-ring
7 Cap 14 O-ring located outside the port. In this status, hydraulic pressure
L4-917 cannot be maintained.
(2) During deceleration
Fig. 19 Pressure hold valve
• Activating condition
This device is activated only when depressing the clutch and
brake pedals with the vehicle stopped on an uphill road.
A 17·266
Fig. 22
A 17-264 Even when depressing the clutch pedal, the ball is kept at
Fig. 20 the front by decelerating force. In this status, hydraulic
pressure is not maintained.
When stopping the vehicle on an uphill road, the ball rolls

toward the rear to seal the port and therefore the hydraulic
pressure is maintained even by releasing the brake pedal.
8
BRAKES 4-4
2) When stopping This device is not designed to operate on a flat road, except
for reversing.
OPERATIONAL PRECAUTIONS
1) Hill-holder is a device used to facilitate starting on an
uphill road. For stoppage on the uphill road. therefore. you
must keep the brake pedal depressed or pull the parking brake.
2) H ill-holder may not be activated on a slope of an
extremely small inclination.
3) If the brake is not held sufficiently upon releasing the
brake pedal with the clutch pedal depressed. press down the
brake pedal a little strongly once again.
4) If depressing the clutch pedal again in the course of
A17-267 starting operation, the brake may be released. In this case.
'-----------------------~ depress the brake pedal again. (Because the brake is released
Fig. 23 when returning the clutch pedal halfway.) (For example.
when interrupting starting operation or shifting gear from
other than LOW because of misoperation.)
Even when stopping on an uphill road, hydraulic pressure is 5) Before you leave the driver's seat, be sure to pull the
not maintained unless the clutch pedal is depressed. parking lever and confirm that the vehicle is kept stopped
3) On a flat road upon releasing the clutch pedal.
6) When reversing the vehicle on a flat road, the following
phenomena may be felt. These phenomena are caused by the
activation of the hill holder. which does not constitute
abnormality.
(1) Brake effect remains even after releasing the brake
pedal if depressing the clutch and brake pedals when
reversing the vehicle.
(2) A slight shock is given to the vehicle when starting
the vehicle after stopping the reverse movement.
A17-215
Fig. 24
9
4-4 BRAKES

SPECIFICATIONS
~
Engine 1800 cc 2700 cc
Driving system FWD 4WD FWD

I 4WD
Type Disc (AD type, ventilated)
Effective disc diameter mm (in) 192 (7.56) 212 (8.35)
Disc thickness x outer diameter mm (in) 18 x 242 (0.71 x 9.53) 22 x 262 (0.87 x 10.31)
Front
brake Effective cylinder diameter mm (in) 53.97 (2.1248)
Pad dimensions
mm (in) 118 x 45.5 x 12 (4.65 x 1.791 x 0.47)
(length x width x th ickness)
Clearance adjustment Automatic adjustment
Drum
Type (Leading- Disc (Colette)
Trailing)
Effective drum or disc diameter mm (in) 180 (7.09) 190 (7.48) 220 (8.66)
10 x 226
Disc thickness x outer diameter mm (in) - (0.39 x 8.90)
10 x 256 (0.39 x 10.08)
Rear
brake Effective cylinder diameter mm (in) 17.46 (11/16) 30.23 (1.1902)
172 x 30 x 4.5
Lining or pad dimensions 71 x 36 x 10
mm (in) (6.77 x 1.18
(length x width x thickness) (2.80 x 1.42 x 0.39)
x 0.177)
Manual
Clearance adjustment Automatic adjustment
adjustment
Type Tandem (with fast fill mechanism) Tandem
Master 20.64 (13/16) (Small)

Effective diameter mm (in) 23.81 (15/16)
cylinder 25.40 (1) (Large)
Reservoir Sealed type
Type Vacuum suspended Vacuum suspended (Tandem)

Brake
booster Effective diameter mm (in) 205 (8.07) 180 (7.09)+205 (8.07)
Propor- Split point kPa (kg/cm 2 , psi) 3,923 (40,569) 4,413 (45, 640) 3,923 (40, 569) 14,413 (45,640)
tioning
valve Reducing ratio 0.3
Brake line Dual circuit system
Brake fluid reservoir capacity cm 3 (cc, cu in) 160 (160,9.76)
Parking brake Mechanical on front brakes
Hill-holder -
I Equipped
10
BRAKES 4-4
SERVICE DATA
ITEM STANDARD SERVICE LIMIT
Front brake Pad thickness (including back metal) 18 mm (0.71 in) 7.5 mm (0.295 in)
(Disc type)
Disc thickness Ventilated disc Except XT6 18 mm (0.71 in) 16.0 mm (0.630 in)
XT6 22 mm (0.87 in) 20.0 mm (0.787 in)
Disc run-out 0.10 mm (0.0039 in)
Rear brake Inside diameter 180 mm (7.09 in) 182 mm (7.17 in)
(Drum type)
Lining thickness 4.5 mm (0.177 in) 1.5 mm (0.059 in)
Rear brake Pad thickness (including back metal) Except XT6 6.5 mm (0.256 in)
15 mm (0.59 in)
(Disc type) XT6 8.0 mm (0.315 in)
Disc thickness 10 mm (0.39 in) 8.5 mm (0.335 in)
Disc run-out 0.10 mm (0.0039 in)
Brake booster Brake fluid pressure without engine running At brake pedal force 147 N (15 kg, 33 Ib):
392 kPa (4 kg/cm l , 57 psi)
At brake pedal force 294 N (30 kg, 66 Ib):
2,452 kPa (25 kg/cm l , 356 psi) (Except XT6)
1,569 kPa (16 kg/cml, 228 psi) (XT6)
Brake fluid pressure with engine running and At brake pedal force 147 N (15 kg, 33Ib):
vacuum at 66.7 kPa (500 mmHg, 19.69 inHg) 4,904 kPa (50 kg/cm 2 , 711 psi) (Except XT6)
5,394 kPa (55 kg/cml, 782 psi) (XT6)
At brake pedal force 294 N (30 kg, 66 Ib):
6,375 kPa (65 kg/cml, 924 psi) (Except XT6)
9,317 kPa (95 kg/cml, 1,351 psi) (XT6)
Parking brake Lever stroke 3 to 4 notches1245 N (25 kg, 55 Ib)
Hill-holder Adjusting shim Thickness 0.6 mm (0.024 in)

(One shim increases an angle of approx. 0.5°.)
Part Number 725807000
RECOMMENDED BRAKE FLUID
FMVSS No. 116, fresh DOT3 or 4 brake fluid
a. Avoid mixing brake fluid of different brands to prevent the fluid performance from degrading.
b. When brake fluid is supplemented, be careful not to allow any dust into the reservoir.
c. Use fresh DOT3 or 4 brake fluid when replacing or refilling the fluid.
11
4-4 BRAKES
COMPONENT PARTS
Front Disc Brake
Guide pin boot

2 Piston
3 Air bleeder cap
~ 4
5
Air bleeder screw
Lever & spindle t.
~---;>,~r-:;>'79-----@ 6 Spindle
(
t
7 Connecting link ?
8 Return spring C
9 Lever cap (upper)
10 Garter spring
'(
11 Lever cap ~
,j
12 Retainer (
t
13 Boot ring !
14
15
Piston boot
Piston seal
.
(
16 Lock pin boot t
t
17 Lock pin sleeve
18 Caliper body ~
19 Retaining spring S
20 Spring pin
21
22
Cone spring
Lock pin I
23 Bolt ASSY ~
I"
24 Bracket
25 O-ring
26 Pad clip
27 Shim
28 Outer pad
29 Support
30 Inner pad
31 Guide pin sleeve
32 Guide pin
33 Needle bearing

T1: 7 - 9 (0.7 - 0.9, 5.1 - 6.5)
T2: 31 - 41 (3.2 - 4.2, 23 - 30)
T3: 44 - 54 (4.5 - 5.5, 33 - 40)
T4: 49 - 69 (5.0 -7.0, 36 - 51)
Fig. 25
L4·1327
12
BRAKES 4-4
Rear DiSC~B~ra~k~e~~~~~~~~~~~~~~_
Tightening torque N·m09

(kg-m,
5.1 ft·lb)
_ 6.5)
T1: 7 - 9 (0.7 - . , 2 16 _ 23)
T2: 22 - 31 (2.2 - 3'9' 34 _ 43)
T3: 46 - 58 (4.7 - 5. ,
1 Outer pad
2 Inner pad
3 Pad spring
4 Support
5 Pin boot
6 Pin
7 Piston
8 Piston boot
9 Piston seal
10 Caliper body
11 Air bleeder screw
12 Shim
Fig. 26
13
4-4 BRAKES
Rear Drum Brake (FWD) 1 Boot

2 Shoe hold d own'
Back pi pm
43 ate
Adjuster
~ Brake, shoe
Shoe hold d
7 Upper sh own spring
8 oe return .
Lower sh spnng
oe retur .
Air bleed n spring
9 er cap
11 Airbl
10 B eeder screw
oot
12 Cup
13 Piston
14 Wheel cylinder body
<.
...
Tightening torque N
T1: 46 _ 58 (4;m (kg-m, ft·lb)
T2: 12.3 -152 - 5.9, 34 - 43)
T3': 8 _ 10 (DB _(1.25
1 0 -155" 9.0 - 11.21
T4. 7 _ 9 (07 . ,5.8 - 72)
. - 0.9, 5.1 - 6.5)
L4·920
Fig. 27
14
BRAKES 4-4
Master Cylinder (Except XT6)
9 10 8
@----+-~
@----r--
@---+--I
(})----+--
1 Cap
@-----' 2 Reserve tank
3 Float
4 Seal
5 Valve
6 Coring
@ 7 O-ring
8 Cylinder body
9 Secondary piston
10 Primary piston
11 Coring
12 Bolt
Fig. 28 L4·1214
15
4-4 BRAKES
Master Cylinder for XT6
1 Cap
2 Reserve tank
3 Float
4 Seal
5 Cylinder body
6 Secondary piston
7 Primary piston
8 Coring
9 Bolt
I
I
®-_:--@ (j)
I
I
I
I
I
I
L4-1328
Fig. 29
16
BRAKES 4-4
Brake Booster
1 Front shell
2 Rear shell
3 Diaphragm plate
4 Diaphragm
5 Valve body
6 Retainer
7 Bearing
8 Seal
9 Valve body guard
10 Filter
11 Retainer
12 Push rod
13 Retainer
14 Plate & seal ASSY
15 Return spring
16 Reaction disc
17 Key
18 Silencer
19 Operating rod
20 Clevis
21 Nut
22 Retainer
23 Stopper
L4-921
Fig. 30 Except XT6

1 Clevis
2 Nut
3 Operating rod
4 Valve body guard
5 Valve body
6 Retainer
7 Filter
8 Silencer
9 Rear shell
® 10 Front shell
11 Seal valve body
@
12 Bearing
@ 13 Retainer
14 Key
@-c=BE~=H-II=~~wrn=f
15 Stopper
16 Retainer
17 O-ring
18 Center body
19 a-ring
20 Diaphragm plate
21 Diaphragm
22 Return spring
23 Push rod
24 Push rod seal
25 Retainer
L4-1329
Fig. 31 XT6
17
4-4 BRAKES
Hill-Holder
Clutch release fork
1 PHV (Pressure hold valve)
(For 2WD Non-TURBO ®® @ 2 Support
vehicle) Clutch cable
(For 2WD Non-TURBO vehicle) 3 Hook (spring)
4 Stay (PHV)
Clutch release fork Return spring
5
6 Pin
(For 2WD Non- ®. Clutch cable
7 Snap pin
TURBO vehicle) 8 PHV cable
9 Adjusting nut
10 Bracket (cable)
11 Clamp
(For 2WD, 4WD MPFI
12 Clip
TURBO vehicle and
13 Lock nut
4WD MPFI Non-TURBO
vehicle)
(j})
(For 2WD MPFI ® -® (For 2WD, 4WD MPFI TURBO @
Non-TURBO vehicle and 4WD MPFI
vehicle)
Non-TURBO vehicle)
®,-~~
(For MPFI vehicle) ®
/
Water pipe-~
Side frame
L4-1215
Fig. 32 Component parts of hill-holder (Except XT6)
Clutch release fork
1 PHV (Pressure hold valve)

Clutch cable Support
2
3 Hook (spring)
4 Stay (PHV)
5 Return spring
6 Pin
7 Snap pin
8 PHV cable
9 Adjusting nut
(For FWD, 4WD MPFI 10 Bracket (cable)
TURBO vehicle and 11 Clamp
4WD MPFI Non-TURBO
12 Clamp
vehicle)
13 Lock nut
14 Bolt
Side frame L4-1330

Fig. 33 Component parts of hill-holder for XT6
18
BRAKES 4-4
Parking (Hand) Brake
\
)/ @
\
)/
\ \
\
1 Hand brake lever button

2 Hand brake lever grip
3 Hand brake lever spring
4 Hand brake switch
5 Hand brake lever
6 Hand brake adjuster
7 Hand brake spring
8 Equalizer
9 Hand brake pin
10 Hand brake rod
11 Cotter pin
Tightening torque N·m (kg-m, ft-lb)
12 Clevis pin
13 Clamp
T1: 4A - 7.4 (0.45 - 0.75, 3.3 - 5.4)
,~ 14 Hand brake cable R H T2: 10 - 18 (1.0 - 1.8, 7 - 13)
15 Clamp T3: 10 -16 (1.0 -1.6,7 -12)
16 Hand brake cable LH
Fig. 34
L4-1216
19
4-4 BRAKES
SERVICE PROCEDURE
Front Disc Brake
Grease Application
N NIGLUBE RX·2 GREASE (003606000 or 725191040)
S SILICON COMPOUND (003606010 or 725191050)
P PBC GREASE (003603000 or 725191060)
N: On the face of caliper body coming

N: In lever cap fitting groove at the rear
into contact with cone springs
of caliper body
S: Around sealing section of caliper N: I n the space between cone springs

body
N: Inner wall of needle bearing on caliper

N: I n the groove after install ing piston body and around lever & spindle
into caliper body
N: Sufficiently around lever & spindle
so as to fill inside of lever cap after
N: In groove of caliper body before fitting it
fitting piston boot
N: On the head of spindle ASSY
s: Around piston seal S: Around O·ring
Sliding surface of
pad and pad clip
S: Around sleeve before

fitting boot
In guide pin fitting

hole of caliper body
Around guide pin before inserting

it into the hole
N: Around lever cap ring

N: In groove of lever & spindle to be
fitted to lever cap
L4·1331
Fig. 35
20
BRAKES 4-4
Replacement of Pad 4) Spin caliper body ASSY on guide pin.
REMOVAL
1) Return hand brake lever completely.

2) Remove inner cable end from lever, draw out outer cable
clamp, then disconnect hand brake cable from caliper body
ASSY.
Fig. 38
5) Remove pads from support.
L4-1332
Fig. 36
3) Remove lock pin.
L4-1334
Fig. 39
a. Do not touch the brake pedal after the pads have been
removed.
b. Do not disconnect hose.
c. When replacing the pad, do not remove the caliper body,
but just turn it enough for removal and installation.
Lock pin
L4-1333
Fig. 37
21
4-4 BRAKES
INSPECTION INSTALLATION
1) Pad
1) It is necessary to push back piston into cylinder, since
Check the pad thickness through the inspection hole and
piston protrudes from cylinder in proportion to the amount of
replace pads if not within specification.
pad wear, and the gap where pads are to be inserted is narrow.
Rotate piston clockwise with WRENCH (926430000) and
SPACER (926440000) to force in piston to caliper body, and
set the piston notch to the specified position.
When using WRENCH, fix SPACER as shown with 6 mm dia.
bolts [length: less than 15 mm (0.59 in)].
WRENCH (9264300001
SPACER (926440000)
6 mm dia. bolt
;.'
Fig. 40 When using former WRENCH (925590000),

bore 7 mm (0.28 in) dia. holes at interval
of 75 mm (2.95 in).
(Difference between 926430000 and
Pad thickness including back metal: 925590000 is whether or not 7 mm 10.28 in)
dia. holes are providecU
Standard L4-040
18 mm (0.71 in)
Fig. 41
Usable limit
7.5 mm (0.295 in)
a. Always replace the pads for both the left and right wheels
at the same time.
b. A wear indicator is provided on the disc brake pad. If the
pad wears down to such an extent that the end of the wear
indicator contacts the disc rotor, a squeaking sound is pro-
duced as the wheel rotates. If this sound is heard, replace the
pad.
2) Disc rotor
Check for wear and damage, and correct or replace if
abnormal.
Fig. 42 Pushing back piston
Disc rotor thickness:
Ventilated disc
Standard
Except XT6: 18 mm (0.71 in)
XT6: 22 mm (0.87 in)
Usable limit
Except XT6: 16 mm (0.63 in)
XT6: 20 mm (0.79 in)
3) Disc rotor runout
Disc rotor runout:

Limit
L4-1338
0.10 mm (0.0039 in)
Fig. 43 Specified position of piston notch
22
BRAKES 4-4
After pushing back piston, check piston boot for twist. If (1) If wheel bearing is worn or disc rotor is not exactly
twisted, correct twist using ~ strip driver. perpendicular to the counterpart, the surface of disc rotor
runs out in the axial direction during rotation. This causes
a. Do not disconnect hose. disc rotor to be pressed against lining, and rotational
b. Always return the piston to that point which allows only resistance increases.
a minimum clearance for the pad to be inserted. When such trouble occurs, measure the disc rotor runout.
c. Be sure to use the special tool when pushing in the piston If the runout exceeds the limit, change the tightening
to the caliper body. If the piston is pushed into the caliper position of rotor on hub or the meshing position of hub
body with a vice and without rotating it, the spindle {5-thread} to axle shaft serration. If this does not correct the run-
may be buckled. To prevent this, the piston should be rotated out, replace rotor.
clockwise when pushed into the caliper body.
Disc rotor runout:
2) Remove rust and foreign materials from the contact area Limit
of support with the sliding part of pad. Then, install a new 0.10 mm (0.0039 in)
genuine SUBARU pad. Make sure that pad clips are in normal
operating condition before installing new pad.
Measure the disc rotor runout at a point less than 5 mm
a. Securely attach all pads to the frictional surfaces of their (0.20 in) from the outer periphery of the rotor.
supports.
b. Apply thin coat of PBe GREASE (725191060 or
003603000) to the frictional portion between pad and pad
clip.
c. Do not install shim on inner pad.
d. When replacing the pad, replace pads of the right and left
wheels at the same time.
L4-1339
Fig. 45
(2) If the rotational resistance is over the specified value

due to the other causes, recheck disc brake ASSY and
Pad must be installed repair or replace it if necessary.
with the clip of pad facing
lower side of vehicle. L4-043
Fig. 44
3) Remove foreign materials from lock pin.

Tighten lock pin to the specified torque.
Torque (Lock pin):

31 - 41 N'm (3.2 - 4.2 kg-m, 23 - 30 ft-Ib) Caliper Assembly
4) Upon completion of installing the brake system, confirm
that the pad dowel (rise on pad back metal) fits into the piston REMOVAL AND DISASSEMBLY
notch.
Depress brake pedal several times.
5) Confirm that tire can be rotated with a force of less than 1) Remove union bolt and disconnect brake hose from
39 N (4 kg, 9 Ib) at the outside diameter of tire. caliper body ASSY.
23
4-4 BRAKES
o~
~
... :'
.," "j,'
" :::::';<- ,: . Sleeve
Lock pin boot
L4.1340 A17·308
Fig. 46 Fig. 48
2) Remove hand brake cable and pad in accordance with the 7) Remove boot ring by using a strip driver with taking care
removing procedure of pad. so as not to scratch piston boot. Then, remove piston boot.
3) Remove caliper body ASSY by pulling it out of support.
Do not remove guide pin unless it is.clamaged.
4) Remove support from housing.
The support should be removed only when the disc rotor or

the support is replaced, and should not be removed when
performing the maintenance of the caliper body ASSY.
Fig. 49
If the strip driver is not available, use a screwdriver after the

tip of the screwdriver is rounded off, and burrs are thoroughly
eliminated.
8) Draw out piston from cylinder by applying a compressed

L4·1341 air or pressurized liquid gradually from the brake fluid inlet of
Fig. 47 caliper body ASSY,
Do not apply an excessively high pressure, since such careless-

5) Remove sludge and dirt from support and caliper body ness may cause the piston to spring out of the cylinder.
ASSY.
Take special care to prevent dirt from entering through the

brake fluid inlet
6) Remove sleeve, then remove lock pin boot, taking care

not to scratch it.
24
BRAKES 4-4
L4·1343 L4·1345
Fig. 50 Fig. 53
9) Remove piston seal by using a strip driver with taking The lever cap may only be pulled out of the groove in the
special care so as not to scratch the inner wall of cylinder. caliper body.
A17·121
Fig. 51 Fig. 54
10) Remove guide pin boot from caliper body. 12) Press spring washer (coned disc spring) with PULLER
(925471000) to eliminate a load applied to lever & spindle
through spring washer, pull out lever & spindle.
Detach PULLER, and then remove connecting link and return
spring.
Fig. 52
Replace the removed boot with • new one.

A17·309
11) Remove retainer and lever cap, then remove retaining
Fig. 55
spring from lever & spindle.
25
4-4 BRAKES
INSPECTION
Inspect the disassembled parts, correct or replace if defective.

1) Caliper body
Uneven wear, damage or rust.
2) Piston
Uneven wear, damage or rust.
3) Rubber parts
Deformation, wear, damage, deterioration or coat of mineral
oil.
4) Pad clip
Deformation, wear, damage or rust. A17·125
5) Spindle and cone spring Fig. 57
Damage or rust.
6) Lever & spindle
Damage or rust. 3) Upon completion of inserting piston into cylinder, apply
7) Support NIGLUBE RX-2 GREASE (725191040 or 003606000) into
Wear, damage or rust. the grooves provided in cylinder and along the circumference
8) Other parts of piston head. Then fit boot into the grooves. After con-
Deformation, wear, damage or rust. firming that boot is not twisted, attach boot ring.
If the rubber parts are scratched or coated with mineral oil, When attaching the boot ring, refer to the figure.
replace it with a new one.
1) Clean the inner part of caliper body (cylinder) with brake

fluid. Apply a thin coat of SILICON COMPOUND
(725191050 or 003606010) to piston seal, and fit the seal to
the groove provided in the cylinder with hand.
Pay special attention to prevent the seal from twisting.
L4-1347
Fig. 58 Fitting piston boot and boot ring
4) Apply NIGLUBE RX-2 GREASE (725191040 or

(03606000) to the cone springs fitting section of spindle, into
the space between cone springs after fitting them, and onto
the face of caliper body coming into contact with cone
springs.
Apply a thin coat of SILICON COMPOUND (725191050 or
L4·1346
003606010) to the sealing section of caliper body coming into
Fig. 56 contact with O-ring of spindle ASSY.
Then, insert spindle ASSY into cylinder by turning clockwise
2) Insert piston into cylinder. from the opening at the bottom of caliper body.
Be sure to insert the piston into the cylinder with hand. Never fail to apply the specified grease or compound to the
Do not use a vice when inserting the piston. proper sections.
26
BRAKES 4-4
ADAPTER
(925600000)
A17-027 A17-310
Fig. 61 Fitting O-ring
Niglube RX-2
5) Apply N IGLUBE RX-2 GREASE (725191040 or
003606000) to the head of spindle ASSY and onto the inner
wall of needle bearings on caliper body in which lever &
spindle is to be fitted. After setting connecting link and
return spring, press a set of cone springs by PU LLER
CD
@ (925471000).
Apply NIGLUBE RX-2 GREASE (725191040 or 003606000)
1 Caliper body to grooves of lever & spindle in which lever cap and connecting
2 Cone spring link are to be fitted. Then, fit connecting link into the groove
3 Spindle
at the head of spindle. Insert lever & spindle provided with
A17-223 lever cap and garter spring. Be sure to force in the hooked
portion of return spring to the groove of lever & spindle as
Fig. 59 Spindle ASSY and grease application
shown. Then, remove PULLER (925471000).
a. When the cone spring is replaced due to scratch, be sure to
replace the a-ring with a new one. Also, attach a new cone
spring before fitting the O·ring. NIGLUBE RX-2
Six cone springs are incorporated. The assembling combination
is as follows. "'.
NA
--_._- A 17·224
WJ
Lever & spindle
A 17-029 Niglube RX.2-A---_-=~~~r____4

Fig. 60
b. After attaching cone springs, apply thin coat of SILICON

COMPOUND (725191050 or 003606010) to the a-ring, and
insert it with ADAPTER (925600000) with taking care to
L4-049
prevent the a-ring from being damaged.
Fig. 62 Grease application
27
4-4 BRAKES
Apply sufficient amount of NIGLUBE RX-2 GREASE
(725191040 or 003606000) to the space around connecting
link and lever & spindle so as to fill inside of lever cap after
fitting it.
Fit lever cap properly into the groove at the rear of caliper
body.
Attach retainer onto lever cap.
Be careful not to damage the lever cap by the edge of the

retainer.
Garter spring
L4-050
Fig. 63 Lever & spindle, lever cap and garter spring in ASSY
Retaining
Niglube
spring
RX-2
C.,iper
PULLER body
(925471000)
A 17·237
Fig. 66 Grease application
A17-311
Fig. 64 Inserting lever & spindle
@ @ @ ® CD
I
A17-121
Fig. 67
1 Spindle 4 Return spring
2 Connecting link 5 Hooked portion of return spring
3 Lever & spindle
A17-198
Fig. 65
When inserting the lever & spindle, make sure that the needle
bearing of caliper body is clean and free from any foreign
. matter.
6) Fit retaining spring into the groove of lever & spindle.

Apply NIGLUBE RX-2 GREASE (725191040 or 003606000)
A17·133
to the groove of caliper body in which lever cap is to be fitted
and to retaining spring. Fig. 68
28
BRAKES 4-4
7) Remove any foreign matter from the guide pin portion in 9) Rotate piston until the notch at the head of piston is set
caliper body. Fit guide pin boot. (Be careful not to scratch to the specified position, and make sure that all parts are
boot itself.) properly attached.
After fitting, make sure that boot is not damaged. (For pushing back piston, refer to step 1) in "INSTALLA·
TlON" of "Replacement of Pad").
Once the guide pin boot is removed, always replace it with a 10) Install support to housing.
new one.
Torque (Support bolt):
49 - 69 N'm (5.0 - 7.0 kg-m, 36 - 51 ft-Ib)
L4-048
Fig. 69
L4-1341
Fig. 72
8) Install lock pin boot to caliper body. Apply SILICON
COMPOUND (725191050 or 003606010) to the inside (the
sliding surface) of lock pin boot and to the boot-fitting 11) Install pad clips properly.
grooves of sleeve. Then insert sleeve into lock pin boot. 12) Install outer pad and inner pad properly.
Use new lock pin boot.
, Outer pad
Shim
Pad clip
A17-313
Pad must be installed
Fig. 70 with the clip of pad facing
lower side of vehicle. L4·043
Fig. 73
13) Make sure that caliper body and support are properly
coated with grease. Insert the support guide pin into the
A3·266 fitting hole in caliper body. Tighten lock pin to the specified
Fig. 71 Grease application to lock pin portion torque.
29
4-4 BRAKES
L4-1224
Fig. 74 Grease application to guide pin portion Fig. 75
Torque (Lock pin):

31 - 41 N'm (3.2 - 4.2 kg-m, 23 - 30 ft·lb)
L Use only SILICON COMPOUND (125191050 or

003606010) grease for the guide pin and lock pin portions.
b. After assembling, make sure that boots are properly fitted
in the grooves on the caliper body, guide pin sleeve and lock
pin sleeve.
e. If the boot contains too much air and is expanded, press it REMOVAL
to purge out some air.
14) Make sure that all parts are properly attached, then 1) Remove the lower of the two bolts securing the caliper
connect brake hose and hand brake cable. body to the support. (The upper bolt does not need to be
removed.)
Torque (Union bold:
15 - 21 N'm (1.5 - 2.1 kg·m, 11 - 15 ft·lb)
Replace brake hose gaskets with new ones.
15) Bleed air from the brake system.
Torque (Air bleeder screw):

7 - 9 N·m (0.7 - 0.9 kg·m, 5.1 - 6.5 ft-Ib)
L4-894
Fig. 76
Rear Disc Brake 2) Remove the pad and pad spring by turning up the caliper
body using the upper pin as the pivot.
Replacement of Pad
a. The brake pedal must not be depressed Vllhen the pad has
been removed.
The thickness of the pad can be visually inspected from the b. When replacing the pad, do not remove the caliper body,
inspection hole of the caliper body. but just turn it enough for removal and installation.
30
BRAKES 4-4
3) Turn the caliper body back to the original position, and
INSPECTION tighten the lower bolt.
1) Inspection of pad
Check the pad thickness through the inspection hole and Tightening torque:
replace pads if not with in specification. 22 - 31 N'm (2.2 - 3.2 kg·m, 18 - 23 ft·lb)
Thickness of pad (including back metal): 4) Depress the brake pedal several times with usual braking
Standard value effort to adjust the relative position between the pad and
15.0 mm (0.591 in) rotor. Also, make sure that the pedal has a proper stroke.
Service limit 5) Put back tires and rotate them several times. Then, wind a
Except XT6: 6.5 mm (0.256 in) rope around the circumference of tire, and confirm that tire
XT6: 8.0 mm (0.315 in) can be rotated with a force of less than 39 N (4 kg, 9 Ib) at the
outside diameter of tire.
If wheel bearing is worn or disc rotor is not exactly perpen·
Replace the pads of the right and left wheels at the same time.
dicular to the counterpart, the surface of disc rotor runs out in
Also, replace the pad spring if deformed or strained.
the axial direction during rotation. This causes disc rotor to be
pressed against lining, and rotational resistance increases.
2) Inspection of rotor
When such trouble occurs, remove tire and measure the disc
Check the rotor for wear and damage, and repair or replace if
rotor runout. If the runout exceeds the limit, check the
defective.
bearing and replace it if defective. If this does not correct the
runout, replace rotor.
Thickness of rotor:
Standard value
Disc rotor runout:
10.0 mm (0.394 in)
Limit
Service limit
0.10 mm (0.0039 in)
8.5 mm (0.335 in)
Measure the disc rotor run out at a point less than 5 mm
(0.20 in) from the outer periphery of the rotor.
INSTALLATION
1) Clean the cal iper body and piston end face, and push the
piston in the caliper body.
Caliper Assembly
When the piston is difficult to put in place, loosen the air
bleeder, then push into place. REMOVAL
2) Install the pad spring taking care of its upper and lower
sides. Then install the pad. 1) Disconnect the brake hose from the caliper body.
Fig. 77 Fig. 78
31
4-4 BRAKES
2) Remove the caliper ASSY from trailing arm by loosening
ASSEMBLY
the mounting bolts.
a. When replacing piston seal, make sure of the sizes of piston

DISASSEMBLY and seal.
b. When replacing piston boot, make sure of the sizes of
1) Drain the brake fluid from the caliper body. piston and boot.
2) Remove the bolts and separate the support from the
caliper body.
3) Pull out the pads and remove the pad springs.
Piston Piston boot Seal
4) Pull out the piston by blowing air into the caliper body.
Blow in air little by little to prevent the piston from jumping

out.
Effective
cylinder
diameter
mm (in)
30.23
(1.1902)
rn
30.2 mm
11
(1.189 in) dia.
m 41.5 mm
(1.634 in) dia.
111
30.2 mm
(1.189 in) dia.
L4-1125
Fig. 80
1) Wash the inner wall of the cylinder with brake fluid. Then
apply a small amount of SILICON COMPOUND (725191050
or 003606010) to the piston seal and fit it into the seal groove
L4-059
of the cylinder by hand.
Fig. 79
Be careful not to twist the seal when fitting.
5) After the piston has been removed, remove the boot and
seal. 2) Apply brake fluid to piston.
6) Remove the pins and boots from the support. 3) Apply NIGlUBE RX-2 GREASE (725191040 or
003606000) to the inner surface of piston boot.
4) Install the piston and piston boot to the caliper body.
INSPECTION When doing this work, put the piston boot on the piston end
in advance and fit the boot into the boot groove of the caliper
Check all disassembled parts and replace if defective. body, as shown in figure.
1) Check the inner wall of the cylinder for wear, rust and
damage.
2) Check the support for wear, rust, cracks and other
Boot
damage.
Rust and foreign material may be removed with a fine sand-

paper. However, if they are excessive, replace the support.
3) Check the piston for wear, rust and damage.
Do not use sandpaper to clean the piston's surface, because it

is plated.
4) Check the pin and pin boot for damage. K14-044
Fig. 81
Be sure to replace the piston seal and piston boot each time
the caliper ASSV is disassembled.
32
BRAKES 4-4
5) Slowly put the piston into the caliper body, and fit the 2) Connect the brake hose and bleed out air.
piston boot into the undercut of the piston just before the
piston is completely inserted. Tightening torque:
Brake hose
16 - 20 N'm (1.6 - 2.0 kg-m, 12 - 14 ft·.b)
Bleeder screw
7 - 9 N'm (0.7 - 0.9 kg·m, 5.1 - 6.5 ft·lb)
The brake hose must be connected without any twist
3) After the installation is completed, depress the brake

pedal several times to see that the braking system is not
leaking any fluid.
K14-045
Fig. 82
6) Uniformly apply NIGLUBE RX-2 GREASE (725191040

or 003606000) to the whole sliding surface of the pin, and
boot-fitting undercuts of the pin and the support. Then install
the boot and pin to the support. Rear Drum Brake
(1800 cc FWD model)
REMOVAL
Apply NIGLUBE RX-2 GREASE
1) Remove brake drum. referring to chapter "WHEELS AND

AXLES".
2) Unscrew brake pipe flare nut and disconnect brake pipe.
L4..Q61
Fig. 83
7) Install the pad, and pad spring to the support. (Refer to

SUb-section, "Replacement of pad.")
After installing the pad, make sure that the pad is held down
by spring force.
8) Install the support to caliper body. Fig. 84
INSTALLATION
1) Install caliper ASSY to trailing arm with bolts.

3) Unscrew back plate installing bolts and remove brake
ASSY. Take care so that spindle shaft and bearing are free
46 - 58 N·m (4.7 - 5.9 kg-m, 34 - 43 ft-Ib) from dust.
33
4-4 BRAKES
7) Strut ASSY (4WD only)
(1) Improper operation (due to worn meshing tooth
surface or rust etc.) or damage.
(2) Wear on brake shoe contacting portion.
Never disassemble strut ASSY.
1 Back plate
2 Back plate install ing bolt
3 Adjuster A17-351
Fig. 85
4) Remove shoe hold down spring with pliers.

5) Pull out shoe on anchor side.
6) Pull out shoe on cylinder side.
INSTALLATION (FWD)
1) Clean back plate and wheel cylinder.

INSPECTION 2) Assemble shoe ASSY with springs. Pay attention to the
shape and installing position of springs.
Check the disassembled parts. Correct or replace if defective. Upper Lower

1) If the inside surface of brake drum is streaked, correct the
Wire diameter Thin Thick
surface. If it is unevenly worn, taperingly streaked, or the
outside surface of brake drum is damaged, correct or replace it. On wheel cylin- On anchor and
Installing
der and brake brake drum
Drum inner diameter: position
drum side. side.
Standard
180 mm (7.09 in)
Service limit
182 mm (7.17 in)
2) Measure the lining thickness. If it exceeds the limit,

replace shoe ASSY.
Lining thickness:
Standard
4.5 mm (0.177 in)
Service limit
1.5 mm (0.059 in)
1 Upper return spring
Replace the leading and trailing shoes on the right and left 2 Lower return spring
A17·352
brake ASSV at the same time.
Fig. 86
3) If the deformation or wear of back plate, shoe, etc. are
notable, replace them.
4) When the shoe return spring tension is excessively 3) Apply brake grease to the portions shown by arrows in
weakened, replace it, taking ,care to identify upper and lower figure.
springs.
5) If grease has leaked from brake drum, replace oil seal or Brake grease:
drum. Dow Corning Molykote No. 7439 (PIN 725191460)
6) If drum bearing is abnormal or loose, replace it.
34
BRAKES 4-4
Torque (Air bleeder screw):

7 - 9 N·m (0.7 - 0.9 kg-m, 5.1 - 6.5 ft-Ib)
L4-063 CLEARANCE ADJUSTMENT (FWD)

Fig. 87
The adjusting mechanism for the brake lining clearance is of
a manual type.
4) Fit shoe ASSY first to wheel cylinder, then to anchor, and Follow the undermentioned procedure.
secure both shoes with shoe hold down springs. 1) Jack up vehicle body to release wheel from the ground.
5) Adjust the shoe diameter to about 179.8 mm (7.08 in) by 2) Tighten the wedge fully until wheel ceases to rotate.
turning the wedge. Measure the shoe diameter at three Screwing up the wedge forces anchor to expand on either side
positions, upper, middle, and lower position. by the wedge action and consequently shoes stick to drum.
0
6) Tighten temporarily brake pipe flare nut. 3) Turn back the wedge for 180 , and the shoe clearance
7) Fit spacer (seal) onto spindle and install back plate. In will be 0.1 to 0.15 mm (0.004 to 0.0059 in).
this case, center by using the outer circumference of spacer as 4) Be sure that tire and wheel can be rotated easily by hand.
a faucet joint. Insert three bolts from the back plate side.
Torque (Back plate):

46 - 58 N'm (4.7 - 5.9 kg-m, 34 - 43 ft-Ib)
1 Wedge
2 Anchor
3 Brake shoe
4 Adjuster
5 Back plate L4·926
Fig. 89 Adjusting mechanism
1 Back plate
2 Spacer
A 17-044
Fig. 88
Do not allow foreign matters to enter the brake ASSV.
8) Tighten brake pipe flare nut to the specified torque.
Torque:
13 -18 N·m (1.3 -1.8 kg-m, 9 -13 ft-Ib)
9) Install brake drum in parallel with brake ASSY. A3·229

Fig. 90 Adjusting shoe clearance
35
4-4 BRAKES
Wheel Cylinder 2) Apply rubber grease to the boot inside as shown in figure.
DISASSEMBLY NIGlUBE RX-2 GREASE (PIN 003606000)
1) Remove boot from cylinder. Never use brake grease.

2) Take out piston, which is piston ASSY with cup.
a. Wheel cylinder can be disassembled and inspected with it

mounted on the back plate. Therefore it should not be
removed except replacing the wheel cylinder ASSY etc.
b. When removing the cup from piston, be careful not to
damage piston. And be sure to use the new cup.
INSPECTION
*; Apply NIGLUBE RX-2 L4-927
Inspect each parts after washing them with brake fluid, and Fig. 91
replace if the following defects are found.
Do not use any cleaning solvent other than brake fluid.
1) Cup: Damage, fatigue or wear.

2) Cylinder and piston frictional surfaces: damage, uneven
wear, corrosion or rust. Master Cylinder
3) Spring: Rust or damage.
4) Boot: Damage.
REMOVAL
1) Thoroughly drain brake fluid from reservoir tank.

2) Disconnect fluid level indicator harness connector.
3) Remove brake pipes from master cylinder.
ASSEMBLY 4) Remove master cylinder mounting nuts, and take out
master cyl inder from brake booster.
1) Assembly is the reverse order of disassembly.
Do not let brake fluid remain on a painted surface. Wash off
a. When installing the cup, use the special tool ADAPTER, it immediately.
apply brake fluid to the frictional surface for smooth installa-
tion and pay attention to cup direction.
b. When replacing the repair kit, make sure that the sizes of
cylinder and cup are the same as those which were replaced. DISASSEMBLY
c. Special tools (ADAPTE Rs) are available in different sizes.
Use only the tool of the correct size.
PRECAUTIONS FOR DISASSEMBLY
ADAPTER 1) Remove mud and dirt from the surface of brake master
cylinder.
Part No. Applicable size
2) Prepare tools necessary for disassembly operation, and
925460000 17.46 mm (11/16 in) arrange them neatly on work bench.
3) Clean work bench.
4) Tools for disassembly operation:
d. While assembling, be careful to prevent any metal chip, dust • Phillips screwdriver
or dirt from entering the wheel cylinder. • C-ring pliers
36
BRAKES 4-4
DISASSEMBLY PROCEDURE
ASSEMBLY
1) Remove Coring with Coring pliers pushing in primary
piston slightly.
PRECAUTIONS FOR ASSEMBLING
Piston may jump out from master cylinder. 1) When assembl ing, be sure to use recommended brake
fluid.
2) Ensure that the inside wall of cylinder, pistons, and piston
cups are free from dirt when assembling.
3) Be extremely careful not to damage, scratch, or dent
Primary piston cylinder inside wall, pistons, and piston cups.
4) Do not drop parts. Never attempt to use any part that has
been dropped accidentally.
ASSEMBLING OPERATION
1) Assembling piston CP:
Apply recommended brake fluid to inside wall of cylinder, and
to outer surface of piston CP, and install piston CPs carefully
into cylinder.
Push in primary piston slightly. L4-835 2) Assembling Coring:
~--------------------~~----------~
Fig. 92 With primary piston pushed in slightly, attach Coring by using
Coring pliers.
After assembling, ensure that the Coring is fitted securely in

the ring groove.
2) Extract primary piston CP and secondary piston CPo
I. Do not disassemble the piston CP; otherwise, the spring set INSTALLATION
value may be changed.
b. Use brake fluid or methanol to wash inside wall of cylinder,
To install the master cylinder to the body, reverse the
pistons and piston cups. Be careful not to damage parts when
sequence of removal procedure.
washing. If methanol is used for washing, do not dip rubber
parts, such as piston cups, in it for more than 30 seconds;
Tightening torque:
otherwise, they may become swelled.
Master cylinder mounting nut
10 - 18 N·m (1.0 - 1.8 kg-m, 7 - 13 ft-Ib)
Piping flare nut
13 - 18 N'm (1.3 - 1.8 kg-m, 9 - 13 ft-Ib)
Be sure to use recommended brake fluid.

INSPECTION
If any damage, deformation, wear, swelling, rust, and other
faults are found on the primary piston CP, secondary piston
Brake Booster
CP, secondary piston stopper, or gasket, replace the faulty
part.
REMOVAL
a. The primary and secondary pistons must be replaced as
complete assemblies. 1) Remove the following parts at engine compartment.
b. The service limit of the clearance between each piston and (1) Disconnect connector for brake fluid level indicator.
the master cylinder inner dia. is 0.11 mm (0.0043 in). (2) Remove brake pipes from master cylinder.
c. When handling parts, be extremely careful not to damage or (3) Remove master cylinder installing nuts.
scratch the parts, or let any foreign matter get on them. (4) Disconnect vacuum hose from brake booster.
2) Remove the following parts from the pedal bracket.
(1) Snap pin and clevis pin.
(2) Four brake booster installing nuts.
3) Remove brake booster while shunning brake pipes.
37
4-4 BRAKES
6) Connect electric connector for brake fluid level indicator.
INSTALLATION 7) Adjust operating rod of brake booster as follows:
1) Mount brake booster in position.
booster.)
(2) There should be play between brake booster clevis
Torque (Brake booster to toe board):
13 - 23 N'm (1.3 - 2.3 kg-m, 9 - 17 ft-Ib) (Depress brake pedal pad with a force of less than 10 N
[1 kg, 2 Ib] to a stroke of 0.5 to 2.5 mm [0.020 to 0.098
2) Connect operating rod to brake pedal with clevis pin'and
in] .)
snap pin.
Pin (Clevis)
Clevis (M/V)
Play of pin
A17-318
Fig. 93
L4-1124
Fig. 95
3) Connect vacuum hose to brake booster.
4) Mount master cylinder onto brake booster.
(3) Depress the surface of brake pad by hand.
Torque (Nut): (4) If there is no free play between clevis pin and clevis,
10 - 18 N'm (1.0 - 1.8 kg-m, 7 - 13 ft-Ib) loosen lock nut for operating rod and adjust operating
rod by turning in the direction that shortens it.
5) Connect brake pipes to master cylinder.
Torque (Brake pipe flare nut):

13 - 18 N·m (1.3 - 1.8 kg-m, 9 - 13 ft-Ib)
A16-251
Fig. 96 Tightening lock nut on operating rod ASS Y
8) Bleed air from brake system.
Torque (Air bleeder screw':

7 - 9 N'm (0.7 - 0.9 kg-m, 5.1 - 6.5 ft-Ib'
Fig. 94
38
BRAKES 4-4
9) Conduct road tests to ensure brakes do not drag.
OPERATION CHECK
When checking operation, be sure to securely apply the hand

brake.
CHECKING WITHOUT USING GAUGES

This method cannot determine the exact portion which has
failed, but it can provide a rough understanding of the nature
L4-1351
of the failure if checking is conducted in accordance with the
following procedure. Fig. 97
Air tightness check

Start engine, and run it for 1 to 2 minutes, then turn it off.
Depress brake pedal sever'!l times applying the same pedal
force as that used in ordinary braking operations. The pedal Air tightness check
stroke should be greatest on the 1st depression, and it should 1) Start engine and keep it running until a vacuum of
become smaller with each successive depression. If no change 66.7 kPa (500 mmHg, 19.69 inHg) is indicated on vacuum
occurs in the pedal height while in a depressed state, brake gauge. Do not depress brake pedal.
booster is faulty.
2) Stop engine and watch the gauge. If the vacuum drop
range is less than 3.3 kPa (25 mmHg, 0.98 inHg) within 15
In the event of defective operation, inspect the condition of seconds after stopping engine, brake booster is functioning
the check valve and vacuum hose. Replace them if faulty and properly.
conduct the test again. If no improvement is observed, check If defective, the cause may be one of those listed below.
precisely with gauges. • Check valve malfunction
• Leak from vacuum hose
Operation check • Leak from the shell jointed portion or stud bolt welded
1) With engine off, depress brake pedal several times apply- portion
ing the same pedal force and make sure that the pedal height • Damaged diaphragm
does not vary with each depression of the pedal. • Leak from valve body seal and bearing portion
2) With brake pedal depressed, start engine. • Leak from plate & seal ASSY portion
3) As engine starts, brake pedal should move slightly toward • Leak from poppet valve ASSY portion
the floor. If no change occurs in the pedal height, brake
booster is faulty. Loaded air tightness check
1) Start engine and depress brake pedal with pedal force of
If faulty, check precisely with gauges. 196 N (20 kg, 44 Ib). Keep engine running until a vacuum of
66.7 kPa (500 mmHg, 19.69 inHg) is indicated on vacuum
Loaded air tightness check gauge while the pedal is still depressed.
Depress brake pedal while engine is running, and turn off 2) Stop engine and watch vacuum gauge.
engine while the pedal is still depressed. Keep the pedal If the vacuum drop range is less than 3.3 kPa (25 mm Hg,
depressed for 30 seconds; if no change occurs in the pedal 0.98 inHg) within 15 seconds after stopping engine, brake
height, brake booster is functioning normally; if the pedal booster is functioning properly.
height increases, it is faulty. If defective, refer to "Air tightness check" described above.
If faulty, check precisely with gauges. Lack of boosting action check

Turn off engine, and set the vacuum gauge reading at "0".
CHECKING WITH GAUGES Then, check the fluid pressure when brake pedal is depressed.
Connect gauges as shown in figure. After bleeding air from The pressure must be greater than the standard value listed
pressure gauges, proceed to each check. below.
39
4-4 BRAKES
2) Be careful not to drop brake booster. Brake booster
Pedal force Fluid pressure
should be discarded if it has been dropped.
N (kg, Ib) kPa (kg/cm 2 , psi)
3) Use special care when handling operating rod.
147 (15, 33) 392 (4,57) If excessive force is applied to operating rod, sufficient to
cause a change in the angle in excess of ± 3°, it may result in
Except XT6: 2,452 (25, 356) damage to the power piston cylinder.
294 (30,66)
XT6: 1,569 (16,228) 4) Use care when placing brake booster on the floor.
Boosting action check

Set the vacuum gauge reading at 66.7 kPa (500 mmHg, 19.69 ~orce { } If external force is applied from
inHg) by running engine. Then, check the fluid pressure when above when brake booster is
placed in this position, the resin
brake pedal is depressed. The pressure must be greater than the
portion as indicated by "P", may
standard value listed below. be damaged.
Pedal force Fluid pressure

N (kg, Ib) kPa (kg/cm 2 , psi)
Except XT6: 4,904 (50, 711)

147 (15,33)
XT6: 5,394 (55, 782)
Except XT6: 6,375 (65,924)

294 (30,66) L4-1353
XT6: 9,317 (95,1,351)
Fig. 99 Handling precaution
HANDLING PRECAUTIONS
1) After protector has been removed from push-rod, do not

turn the master cylinder side of brake booster downwards.
(1) If the master cylinder side is turned downwards,
push-rod may come loose by virtue of its own weight, and Brake Hose
reaction disc may drop into brake booster.
(2) Whether or not reaction disc has dropped can be
determined by measuring the dimension fll". REMOVAL
The projected amount ilL" of pushrod should be as
follows: 1) Separate brake pipe from brake hose.
(Always use flare nut wrench and be careful not to deform
Standard (Correct): L = 9.3
mm (0.366 in) (Except XT6)
10.0 mm (0.394 in) (XT6) flare nut.)
Incorrect: L = 4.8 mm (0.189 in) (Except XT6)
4.4 mm (0.173 in) (XT6) Brake hose
L4-1352
Fig. 98 Push rod projection
Fig. 100 Separating brake pipe
(3) If protector is fitted correctly, reaction disc will not

fall out. 2) Pullout clamp to remove brake hose.
40
BRAKES 4-4
3) In case of front disc brake, remove clamp at strut and
union bolt.
A17-157
Fig. 102 Tightening flare nut

L4-1340
Fig. 101 Removing front brake hose
INSTALLATION
Front brake hose

1) Route end of brake hose (on caliper side) through hole in
brake hose bracket at strut location.
2) Tighten end of brake hose at caliper using a union bolt. Proportioning Valve
Torque (Union bolt):
_;;:;:=::;=:::::::::::::::::::::::::::::::~P~ro:portioning valve
15 - 21 N·m (1.5 - 2.1 kg-m, 11 - 15 ft-Ib)
3) Secure middle fitting of brake hose to bracket at strut

location using a clamp.
4) Position disc in straight-forward direction and route
brake hose through hole in bracket on wheel apron side.
Be sure brake hose is not twisted.
5) Temporarily tighten flare nut to connect brake pipe and
hose.
6) Fix brake hose with clamp at wheel apron bracket. Tightening torque
7) While holding hexagonal part of brake hose fitting with a 18 - 31 N·m
wrench, tighten flare nut to the specified torque. 11.8 - 3.2 kg-m, 13 - 23 ft-Ibl L4-899
Fig. 103
Torque (Brake pipe flare nut):
13 - 18 N·m (1.3 - 1.8 kg-m, 9 - 13 ft-Ib)

INSPECTION
1) Install the oil pressure gauges to measure the master

Rear brake hose cylinder fluid pressure (front wheel brake fluid pressure) and
rear wheel cylinder fluid pressure.
1) Pass brake hose through the hole of bracket, and lightly
2) Bleed air from the oil pressure gauges.
tighten flare nut to connect brake pipe.
2) Insert clamp upward to fix brake hose. 3) Check the master cylinder fluid pressure and rear wheel
3) Perform the same procedures as beforementioned in steps cylinder fluid pressure.
7) and 8). The standard values are shown in figure.
41
4-4 BRAKES
Hill-Holder
7.846 (80. 1.138)
Rear wheel 5.884 (60. 853)

cylinder fluid
pressure
3.923 (40. 569) - I - - -__~
kPa (kg/cm]. 1.961 (20.284)

psi)
1.9613.9235.8847.846
(20. (40. (60. (80.
284) 569) 853) 1.138)
Master cylinder fluid pressure kPa (kg/cm] , psi)
In case of split point 3.923 kPa (40 kg/em] .569 psi)
7.846 (80,1,138)
Rear wheel Fig. 105
cylinder fluid 5.884 (60. 853)
pressure
3,923 (40, 569)
kPa (kg/em",
psi) 1.961 (20, 284)
REMOVAL
o 1.9613.9235.884 7.846
(20. (40, (60. (80, 1) Drain brake fluid from reservoir on primary side of master
284) 569) 853) 1,138}
Master cylinder fluid pressure kPa (kg/em] • psi)
cylinder.
In case of split point 4,413 kPa (45 kg/em 2 • 640 psi) 2) Remove adjusting nut and cable clamp, and disconnect
L4·079
PHV cable from cable bracket on engine.
Fig. 104 3) Detach PHV cable from clips.
4) Remove cable clamp, and disconnect PHV cable from
PHV stay.
REMOVAL Carefully protect boots and inner cable from damage when
disconnecting PHV cable.
1) Remove brake pipe from proportioning valve at four
5) Disconnect brake pipes from PHV.
places.
2) Remove proportioning valve from its bracket.
a. Pay attention not to drop brake fluid onto body painting
Do not disassemble or adjust the proportioning valve. (The since it may dissolve paint.
proportioning valve must be replaced as an assembly.) b. Pay attention not to damage hexagonal head of flare nut
by using pipe wrench without fail.
6) Detach PHV along with support from side frame.
INSTALLATION Exercise utmost care to prevent foreign matter from entering

into PHV when removing it.
1) Install proportioning valve to bracket.
2) Connect brake pipes correctly to proportioning valve.
3) Bleed air, then check each joint of brake pipe for oil leaks.
Tightening torque:
INSPECTION
Proportioning valve to brake pipe flare nut
13 - 18 N·m (1.3 - 1.8 kg-m. 9 - 13 ft-Ib)
Proportioning valve to bracket Check up removed parts as follows, and replace defective ones.
20.1 - 28.9 N'm 1) Check if boots of PHV cable are damaged or degraded,
(2.05 - 2.95 kg-m, 14.8 - 21.3 ft-Ib) and if inner cable is damaged or corroded.
2) Check if return spring is worn out, damaged or corroded.
42
BRAKES 4-4
3) Confirm that rolling sound of ball is heard with PHV
, ADJUSTMENTS
inclined and lever rotates smoothly.
1) Inspect free play of clutch pedal by depressing the pedal
CAUTION: by hand. If it is out of the specified value, adjust it by turning
Never disassemble PHV. Replace entire PHV ASSV if adjusting nut on engine side end of clutch cable at release fork.
necessary.
Standard of free play:
At clutch pedal
INSTALLATION 10 - 20 mm (0.39 - 0.79 in)
At center of cable on clutch release fork:
2WD: 2 - 3 mm (0.08 - 0.12 in)
1) Assemble bracket with support of PHV.
4WD: 3 - 4 mm (0.12 - 0.16 in)
Torque:
7 - 13 N'm (0.7 - 1.3 kg-m, 5.1 - 9.4 ft-Ib)
Torque:
Lock nut of clutch cable
2) Install PHV onto side frame. 5.4 - 9.3 N·m (0.55 - 0.95 kg-m, 4.0 - 6.9 ft-Ib)
Lock nut of PHV cable
Torque: 2.5 - 4.4 N'm (0.25 - 0.45 kg-m. 1.8 - 3.3 ft-Ib)
7 - 13 N·m (0.7 - 1.3 kg-m, 5.1 - 9.4 ft-Ib)
2) Confirm stopping and starting performances by activating
hill-holder on an uphill road of 3° or higher inclination.
3) Connect brake pipes to PHV. (1) If vehicle does not stop;
Tighten adjust nut of PHV cable.
Torque: (2) If vehicle does not start properly;
13 - 18 N'm (1.3 - 1.8 kg-m. 9 - 13 ft-Ib) • Case A - When hill-holder is released later than engage-
ment of clutch pedal (Engine tends to stalL):
Loosen adjust nut gradually until smooth starting is
Confirm that brake pipes are not deformed andlor damaged. enabled.
Replace them with new ones if necessary. • Case B - When hill·holder is released earlier than
4) Install PHV cable to PHV stay. engagement of clutch pedal (Vehicle slips down
slightlY·):
If cable clamp (and clips) is damaged, replace it with a new Tighten adjust nut so that hill-holder is released later
one. than engagement of clutch pedal (status in Case A).
Then make adjustment the same as in Case A.
5) Connect PHV cable with clips.
CAUTION:
Avoid sharp bending of PHV cable as it may cause breakage. Whenever turning adjust nut, prevent PHV cable from revolv-
ing as shown in following figure.
6) Install PHV cable onto cable bracket on engine.
7) Apply grease to the following points.

• Hook portion of return spring
• Cable end portion of lever
• Cable end portion of clutch release fork
Grease:
SUN LIGHT 2 (PIN 003602010)
8) Be sure to bleed air from the system.
After replacing PHV cable or clutch cable with new one,

operate clutch pedal about 30 times as a running-in operation L1470
prior to adjustment. Fig. 106 Turning adjust nut for PHV cable
43
4-4 BRAKES
Parking (Hand) Brake

...----_=Adjuster
Parking (Hand) Brake Lever -~~-\_----L 11-_____
REPLACEMENT
1) Remove parking brake cover.

2) Disconnect electric connector for parking brake switch.
Parking brake lever

. 4·1219
Fig. 108
6) Pull out parking brake cable clamp from caliper, and

disconnect cable end.
L
L4·1218
Fig. 107
3) Loosen parking brake adjuster, and remove inner cable ,

t
end from equalizer. !
4) Remove parking brake lever.
5) Install parking brake lever in the reverse order of removal.
Torque (Lever installing bold:

Fig. 109
10 - 18 N'm (1.0 - 1.8 kg-m, 7 - 13 ft-Ib)
6) Adjust parking brake.

brake".)
(See "Adjustment of parking 7)
8)
Remove bolt and bracket from transverse link.
Remove bolt and clamp from leading bracket.
I
\
Parking brake cable
Parking (Hand) Brake Cable
REPLACEMENT

2) Jack up vehicle, and support it with safety stands (rigid
racks). Fig. 110
3) Remove front tires and wheels.
4) Remove parking brake cover.
5) Loosen parking brake adjuster, then remove inner cable 9) Detach parking brake cable from cable guide at rear
end from equalizer, and detach clamps. crossmember.
44
BRAKES 4-4
10) Remove cable ASSY from cabin by forcibly pulling it
forward. Torque (Adjuster lock nut):
11) Install (new) parking brake ASSY in the reverse order of 4.4 -7.4 N·m (0.45 - 0.75 kg-m, 3.3 - 5.4 ft·lb'
removal.
Ensure that front brake is not dragging.
a. Be sure to pass cable through cable guide inside the tunnel.
b. Be sure to adjust the lever stroke.
c. Do not twist boot when attaching inner cable to lever of
caliper body ASSY.
d. Be careful not to damage boot when driving clamp in.
Brake Fluid Level Indicator
Torque (Rear crossmember cable clamp): INSPECTION
10 - 16 N·m (1.0 - 1.6 kg-m,7 - 12 ft-Ib)
Torque (Bracket to transverse link):
10 - 16 N'm (1.0 - 1.6 kg-m, 7 - 12 ft-Ib) 1) Ensure that warning light will come on if brake fluid in
reserve tank reduces to the following quantity.
(Check fluid level after starting engine.)
Adjustment of Parking (Hand) Brake
Reserve tank with level indicator:
Before adjusting the hand brake, check the depressed height of
Residual fluid quantity at light ON
brake pedal. Approx. 80 cm 3 (80 ee, 4.88 cu in'
Make sure that the distance above is as specified, then perform Tank capacity
the following operations. 160 cm3 (160 ee, 9.76 cu in'
Bleed air completely from the brake system before attempting 2) Check float, etc. for deformation, and replace if necessary.
the following operations.
1) Forcibly pull hand brake lever 3 to 5 times.

2) Adjust hand brake lever by turning adjuster until the play
at the A portion is set at 0 to 0.5 mm (0 to 0.020 in), then Air Bleeding
confirm that the lever stroke is as specified.
Bleed air out the front and rear brakes in the following
manner.
General Rules for the Effective Bleeding

1) Start with the brakes (wheels) connecting to the second-
ary chamber of the master cylinder.
2) The time interval between two brake pedal operations
(from the time when the pedal is released to the time when
it is depressed another time) shall be approximately 3 seconds.
3) The air bleeder on each brake shall be released for 1 to 2
seconds.
Recommended Brake Fluid

Fig. 111
Bleeding Procedure
I. The FMVSS No. 116, fresh DOT3 or 4 brake fluid must be
used.
Lever stroke: b. During bleeding operation, keep the brake reserve tank
3 to 4 notches when pulled filled with brake fluid to eliminate entry of air.
with a force of 245 N (25 kg, 55 Ib' c. Ensure also that the linings and pads are free from brake
fluid.
45
4-4 BRAKES
1) Make sure that there is no leak from joints and connec-
tions of the brake system.
Replacement of Brake Fluid
2) Fit one end of vinyl tube into the air bleeder and put the
other end into a brake fluid container. To always maintain the brake fluid characteristics, replace the
3) Slowly depress the brake pedal and keep it depressed. brake fluid according to maintenance schedule or earlier than
Then, open the air bleeder to discharge air together with the that when used in severe condition.
fluid.
Release air bleeder for 1 to 2 seconds.
Next, with the bleeder closed, slowly release the brake pedal.
Repeat these steps until there are no more air bubbles in the
vinyl tube.
Allow 3 to 4 seconds between two brake pedal operations. REPLACEMENT
1) Either jack up the front end of vehicle and place a safety

a. Brake pedal operation must be very slow. stand under it, or drive vehicle onto the pit and then jack up
b. Cover bleeder with waste cloth, when loosening it, to the front end.
prevent brake fluid from being splashed over surrounding 2) Remove both left and right front wheels.
parts. 3) Remove filler cap from brake fluid tank.
Install one end of a vinyl tube onto the air bleeder of front
4) Tighten air bleeder securely when no air bubbles are brake and insert the other end of the tube into a container to
visible.
collect the brake fluid.
To drain fluid into container, open the air bleeder and
Air bleeder tightening torque:
repeatedly depress and release the brake pedal until a small
7 - 9 N·m (0.7 - 0.9 kg-m, 5.1 - 6.5 ft-Ib)
amount of fluid remains in the reservoir tank.
Then tighten the bleeder screw.
5) Perform these steps for the brakes connecting to the
secondary chamber of master cylinder, first, and then for
the ones connecting to primary chamber. With all procedures
completed, fully depress the brake pedal and keep it in that
position for approximately 20 seconds to make sure that
there is no leak evident in the entire system.
Bleeding sequence CD ® -+
-+ @ -+ @
Front right Rear right
--.-- ®
Primary
Fig. 113
@
'----
Front left Rear left a. The brake piping consists of a dual system, cross design.
L4-1011 The piping on the primary side connects the right front brake
and the rear left brake and the piping on the secondary side
Fig. 112
connects the left front brake and rear right brake.
b. For convenience and safety, it is advisable to have two men
6) If the pedal action is soft and spongy, or pedal travels
working.
excessively, the system must be bled of air again.
c. Be careful not to spill brake fluid onto the painted surface.
7) Add brake fluid to the required level (MAX level) of
d. Discard the drained brake fluid and do not reuse it.
reserve tank.
4) Refill reservoir tank with recommended brake fluid.
8) As a final step, test run the vehicle at low speed and apply
brakes relatively hard 2 to 3 times to ensure that brakes
Recommended brake fluid:
provide normal braking action on all four wheels without
dragging and uneven braking.
46
BRAKES 4-4
a. Avoid mixing different brands of brake fluid to prevent 9) Bleed air from each wheel cylinder using the same pro-
degrading the quality of the fluid. cedures as described in steps 5) through 8) above.
b. Be careful not to allow dirt or dust to get into the reservoir
tank.
c. Use fresh 00T3 or 4 brake fluid when replacing or refilling
the fluid.
d. Always check to be sure a small amount of brake fluid is
in the tank while changing brake fluid.
e. The amount of brake fluid required is approximately
270 mQ (9.1 US fl oz, 9.5 Imp fl oz) for total brake system.
f. Bleed air according to illustrated sequence.
Bleeding sequence CD ® ... ® -

-+ @
Front right Rear right
L4-1358
Fig. 115
Primary
10) Depress brake pedal with a force of approximately 294 N

(30 kg, 66 Ib) and hold it there for approximately 20 seconds.
CD At this time check pedal to see if it shows any unusual move-
Front left Rear left
L4.1011 ment.
L - -_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _-----' Visually inspect bleeder screws and brake pipe joints to make
Fig. 114 sure that there is no fluid leakage.
11) Install wheels, and drive car for a short distance between
2 to 3 km (1 to 2 miles) to make sure that brakes are operating
properly.
5) Instruct your co-worker to depress the brake pedal slowly

two or three times and then hold it depressed.
6) Loosen bleeder screw approx imately 1/4 turn until a small
amount of brake fluid drains into container, and then quickly
tighten screw.
7) Repeat steps 5) and 6) above until there are no air bubbles
in drained brake fluid and new fluid flows through vinyl tube.
Add brake fluid as necessary while performing the air bleed

operation, in order to prevent the tank from running short of
brake fluid.
8) After completing the bleeding operation, hold brake pedal

depressed and tighten screw and install bleeder cap.
Tightening torque (Bleeder screw):

7 - 9 N·m (0.7 - 0.9 kg-m, 5.1 - 6.5 tt-Ib)
47
4-4 BRAKES
TROUBLESHOOTING
Entire Brake System
1. Insufficient braking
(1 ) Oil leakage from the hydraulic mechanism Repair or replace (cup, piston seal, piston boot, master
cylinder piston kit, pipe or hose).
(2) Entry of air into the hydraulic mechanism Bleed the air.
(3) Excessively wide shoe clearance Adjust the clearance.
(4) Wear, deteriorated surface material, adhering Replace, grind or clean.
water or oil on the lining
(5) Improper operation of master cylinder, wheel Correct or replace.
cylinder, disc caliper, brake booster or check valve
2. Unstable or uneven braking
(1) Oil on the lining, drum Eliminate cause of oil leakage, clean, or replace.
(2) Oil on the pad, rotor Eliminate cause of oil leakage, clean, or replace.
(3) Drum or rotor eccentricity Correct or replace the drum or rotor.
(4) Worn brake drum, or damage to the drum caused Correct by grinding, or replace.
by sand
(5) Improper lining or pad contact, deteriorated surface Correct by grinding, or replace.
material, improper inferior material, or wear
(6) Deformed back plate Correct or replace.
(7) Loosened back plate or the support installing bolts Retighten.
(8) Loosened rear wheel bearing Retighten to normal tightening torque or replace.
(9) Trouble in the hydraulic system Replace the cylinder, brake pipe or hose.
(10) Uneven effect of the hand brake Check,. adjust, or replace the front brake and cable system.
3. Excessive pedal stroke
(1) Entry of air into the hydraulic mechanism Bleed the air.
(2) Excessive play in the master cylinder push rod Adjust.
(3) Oil leakage from the hydraulic mechanism Repair or replace (cup, piston seal, piston boot, master
cylinder piston kit, pipe or hose).
(4) Improperly adjusted shoe clearance Adjust.
(5) Improper lining contact or worn lining Correct or replace.
(6) Improper pad contact or worn pad Correct or replace.
48
BRAKES 4-4
4. Brake dragging or improper brake return
(1 ) Insufficient pedal play Adjust play.

(2) Improper master cylinder return Clean or replace the cylinder.
(3) Clogged hydraulic system Replace.
(4) Improper return or adjustment of hand brake Correct or adjust.
(5) Weakened spring tension or breakage of shoe Replace the spring.

return spring
(6) Excessively narrow shoe clearance Adjust the clearance.
(7) Improper wheel cylinder operation Correct or replace.
(8) Improperly adjusted rear wheel bearing Adjust or replace.
5. Brake noise (1) (creak sound)
(1 ) Hardened or deteriorated lining or pad Replace the shoe ASSY or pad.

(2) Worn lining or pad Replace the shoe ASSY or pad.
(3) Loosened back plate or the support installing bolts Retighten.
(4) Loose rear wheel bearing Retighten to normal tightening torque.
(5) Dirty drum or rotor Clean the drum or rotor, or clean and replace the brake
ASSY.
6. Brake noise (2) (hissing sound)
(1 ) Worn lining or pad Replace the shoe ASSY or pad.

(2) Improperly installed shoe or pad Correct or replace the shoe ASSY or pad.
(3) Loose or bent drum or rotor Retighten or replace.
7. Brake noise (3) (click sound)
In the case of the disc brake.

(1) Excessively worn pad or the support Replace the pad or the support.
In the case of the drum brake.

(1 ) Excessively worn shoe ridge Replace the back plate.
(2) Excessively worn wheel cylinder piston Replace the wheel cylinder ASSY.
(3) Lack of oil on the shoe ridge surface and anchor Add more grease.
49
4-4 BRAKES
Hill .. Holder
1. Counterforce of clutch pedal is too strong
(1 ) PHV cable is damaged or does not operate properly Repair or replace.

(2) Lever of PHV is defective Replace entire PHV ASSY.
(3) Clutch system is anomalous Refer to "Clutch and pedal cable system".
0
2. Vehicle does not stop on uphill road of 3 or higher inclination
(1 ) Front side of vehicle is lowered Refer to "Suspension".

(2) PHV cable is broken Replace.
(3) Play of clutch is excessive Adjust.
(4) PHV cable is elongated Adjust.
(5) Sealing of PHV is poor Replace entire PHV ASSY.
3. Shock is felt when starting
(1 ) Poor adjustment of starting performance Adjust.

(2) When depressing the brake pedal strongly: (The stronger brake pedal depressing force, the later hill
holder releasing.)
(3) When starting on flat road after stopping reverse (Because hill holder is activated.)
movement:
4. Vehicle slips down when starting
(1 ) PHV cable is elongated Adjust.

(2) Clutch facing is worn out Adjust or replace.
(3) Bracket (cable) or stay (PHV) is deformed Repair or replace.
5. Vehicle cannot start after stoppage
(1 ) Return spring is fatigued or broken Replace.

(2) PHV lever won't return Replace entire PHV ASSY.
(3) When intentionally depressing brake pedal strongly: [When the brake pedal is depressed by a force of 1,177 N
(120 kg, 265 Ib) or more.]
6. Abnormal sound is generated upon releasing brake pedal when stopping
Rotor and pad, drum and lining matched with each (Abnormal sound is not generated when depressing brake
other due to inadequate depressing force to brake pedal pedal a little stronger.)
50
BRAKES 4-4
7. Abnormal sound is generated when operating clutch pedal
(1 ) Grease is inadequate for the hook of return spring Apply grease.

and sliding portion of PHV cable end
(2) When releasing after maintaining high fluid (Flowing sound of fluid when releasing high fluid
pressure: pressure.)
(3) Clutch system is anomalous Refer to "Clutch and pedal cable system".
CAUTION:
•• Description in parentheses is a characteristic of hill-holder and does not indicate abnormality.
Depressing force required for clutch pedal equipped to hill-holder specifications is 20 to 29 N (2 to 3 kg, 4 to 71b) larger than
the conventional specifications, which does not constitute abnormality.
b. When vehicle cannot travel (brake cannot be released) because return spring is broken, remove adjust nut, disconnect clutch
and PHV, and then return PHV lever to release the brake. (Be sure to apply the parking brake before starting this operation.)
c. The hill-holder may not be activated on a slope of an extremely small inclination. If you want to correct it, insert a shim in
between the side frame and support, thereby raising the front of PHV.
When inserting a shim, be sure to confirm stopping status on a slope whenever inserting a single shim. It is recommendable to
avoid raising front of PHV excessively. Never insert 2 or more shims at a time.
Part Number Part Name
725807000 Shim
[Thickness of shim is 0.6 mm (0.024 in), and one shim

increases an angle of 0.5°.J
Front ~
·lP.him~/
L4-091
Fig. 116 Inserting shim
51
PEDAL SYSTEM AND
CONTROL CABLES
Page
BUBARU MECHANISM AND FUNCTION . . . . . . . . . . . . . . . . . • . . . . . • • . • • .• 2

Pedal Effort Reducing Mechanism (2700 cc model) . . . • • • . . . • • • . • • •• 2
SPECIFICATIONS AND SERVICE DATA....... . . . • . . . . . . • • . . .. 3
1988 COMPONENT PARTS. . • . . . . . . . . . . . . . . . . . . . . . . . . . . . • • . • . .. 4

Pedal (Manual Transmission) . . . . . • . . . . . • . . . . . • . . . • . • • . • . • . .• 4
Pedal (Automatic Transmission) ..............•....••..•...•• 5
SERVICE PROCEDURE ..........•..........•.....•.•.•... 6.
Pedal .. . . . . . . . . . . . . . . . . . . . . • . . . . . • . . . . . • . . . . • . • . • . .. 6
Cable. . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . • . • . .. 10
4-5 PEDAL SYSTEM AND CONTROL CABLES

Pedal Effort Reducing Mechanism (2700 cc model)
A. CONSTRUCTION B. OPERATION
Two arms are welded on the clutch pedal. One end of each When the clutch pedal is depressed, the two arms also move
arm is equipped with a spring. and spring hooks change position. When the arms move past
the line (between the stationary position of the hook and the
centerline of shaft), the effort required to depress the clutch
pedal is reduced.
L4-1382
Fig. 1
2
PEDAL SYSTEM AND CONTROL CABLES 4-5

MAINTENANCE STANDARDS
Brake pedal Free play 0.5 - 2.5 mm (0.020 - 0.098 in)

Reserve distance (Remaining clearance) More than 120 mm (4.72 in)/294 N (30 kg, 66 Ib)
Clutch pedal Free play At clutch pedal pad 10 - 20 mm (0.39 - 0.79 in)
At center of cable on 4WD: 3 - 4 mm (0.12 - 0.16 in)
clutch release fork FWD: 2 - 3 mm (0.08 - 0.12 in)
Full stroke At center of cable on 4WD: 25.5 - 27 mm (1.004 - 1.063 in)
clutch release fork FWD: 17 - 18 mm (0.67 - 0.71 in)
Accelerator Free play At pedal pad 0-4 mm (0 - 0.16 in)

pedal Stroke At pedal pad 46 - 50 mm (1.81 -1.97 in)
At cable end 33 - 38 mm (1.30 - 1.50 in)
3
COMPONENT PARTS
Pedal (Manual Transmission)
T1: 23 - 36 (2.3 - 3.7,17 - 27)
T2: 6 - 9 (0.6 - 0.9, 4.3 - 6.6)
T3: 13 - 23 (1.3 - 2.3,9 - 17)
1 Accelerator pedal CP
2 Accelerator pedal pad
3 CUp
4 Stopper
5 Spring (accelerator pedal pad)
6 Spring (accelerator pedal)
7 Bracket CP
8 Stopper
9 Spacer
10 Spring (brake'
11 Bushing
12 Stopper
13 Snap pin
14 Clevis pin
15 Brake pedal
16 Pad
17 Spring (clutch)
18 Spacer
19 Clevis pin
20 CUp
21 Bushing
22 Clutch cable
23 Clamp
24 Clutch pedal
25 Stopper
26 Bracket
27 Spring washer
28 Clamp
29 Stop lamp switch
30 Footrest
31 Washer
32 Bushing
33 Spring
34 Spring
35 Stop & brake switch (cruise)
Fig. 2 L4·1384
4
Pedal (Automatic Transmission)
1 Accelerator pedal CP
2 Accelerator pedal pad
3 Clip
4 Stopper
5 Spring (accelerator pedal pad)
6 Spring (accelerator pedal)
7 Bracket
8 Spacer
®I 9 Spring (brake)
10 Bushing
@ 11 Stopper
12 Snap pin
® 13 Clevis pin
14 Brake pedal
15 Pad
16 Plug toe board
17 Kick down switch
18 Stop lamp switch
19 Stop & brake switch (cruise)
20 Washer
21 Foot rest
L4-1226
Fig. 3
5
SERVICE PROCEDURE
Pedal Lock nut tightening torque:
5.4 - 9.3 N·m (0.55 - 0.95 kg·m, 4.0 - 6.9 ft·lb)
ON-CAR SERVICE
1) BRAKE PEDAL
1} Check position of pedal pad.
If it is not within specified value, adjust it by adjusting brake
booster operating rod length.
Reserve distance (Remaining clearance):

More than 120 mm (4.72 in)/294 N (30 kg, 66 Ib)
Check free play by operating pedal by hand.

If it is not within specified value, adjust it by adjusting posi-
tion of stop lamp switch. Pedal play:
10- 20 mm (0.39 - 0.79 in) L 1.060
Be careful not to rotate stop lamp switch. Fig. 5
Full stroke
Brake pedal free play: Free play 4WD:
0.5 - 2.5 mm (0.020 - 0.098 in) 4WD: 25.5 - 27 mm (1.004 - 1.063 in)
3-4mm FWD:
(0.12 - 0.16 in) 17 - 18 mm (0.67 - 0.71 in)
Unit: mm (in) FWD:
2-3mm
Stop lamp switch (O.OS - 0.12 in)
Floor mat
Stop & brake switch
(for cruise) 1 Lock nut
2 Adjusting nut
3 Release fork A20.Q51
Fig. 6
Stroke
128.5 - 139.5
Remaining ---.'l.:!aR_~~;:,;;;:;~;;_ (5.06 - 5.49)
clearance ""
120(4.72) L4.1192
2) Apply grease to connecting portion of clutch pedal and
Fig. 4
clutch cable and contact point of clutch release fork and
clutch cable nut.
2} Apply grease to operating rod connecting pin to prevent
it from wearing.
2) CLUTCH PEDAL 3) ACCELERATOR PEDAL

1) Check clutch pedal free play by operating pedal by hand. Check pedal stroke and free play by operating accelerator
If it is not within specified value, adjust it by turning adjusting pedal by hand.
nut on engine side end of clutch cable. If it is not within specified value, adjust it by turning nut con-
necting accelerator cable to throttle body.
Free play:
at clutch pedal pad Free play at pedal pad:
10 - 20 mm (0.39 - 0.79 in) 0-4 mm (0 - 0.16 in)
at center of cable on clutch release fork Stroke:
FWD: 2 - 3 mm (0.08 - 0.12 in) at pedal pad 46 - 50 mm (1.81 - 1.97 in)
4WD: 3-4mm(0.12-0.16in) at cable end 33 - 38 mm (1.30 - 1.50 in)
6
2) Inspect play between bushing and shaft; replace bushing
CD and/or shaft with new one if defective.
1 Stroke at cable end

2 Pedal bracket
3 Accelerator pedal
4 Stroke at pedal pad
5 Pin
6 Toe board
7 Accelerator cable L4-680
Fig. 7
A20·040
Fig. 8
REMOVAL AND DISASSEMBLY

2) Disconnect accelerator cable from throttle body.
3) Disconnect/detach clutch cable from the following parts.
( 1) Clutch release fork
(2) Clamp on transmission case
(3) Grommet of toe board
4) Detach trim panel and lower steering column.
5) Disconnect the following parts from pedal bracket.
(1) Operating rod of brake booster
(2) Electrical connectors (for stop light switch. etc.)
(3) Accelerator cable
A20-D41
Be careful not to kink accelerator cable. Fig. 9
6) Remove pedal bracket ASSY along with clutch cable

while supporting brake booster in engine room.
7) Detach following parts from pedal bracket ASSY.
(1) Accelerator pedal return spring
(2) Accelerator pedal 2) ACCELERATOR PEDAL
(3) Clutch cable Clean all parts and inspect for wear and damage.
(4) Brake pedal return spring Replace it with new one if defective.
(5) Clutch pedal return spring (vehicle with Hill-Holder)
(6) Circlip retaining pedal shaft
(7) Clutch pedal and brake pedal
(8) Stop light switch
INSPECTION
1) PEDAL SHAFT AND BUSHING

L4·211
1) Clean off grease and dust. and inspect for wear and
damage. Fig. 10
7
3) STOP LIGHT SWITCH
Torque (Lock nut):
Inspect switch stroke and operation. 5.4 - 9.3 N·m (0.55 - 0.95 kg-m, 4.0 - 6.9 ft-Ib)
If operation is not smooth and/or stroke is not with in specified
value, replace it with new one. 6) Connect clutch cable to clutch pedal by using clevis pin
and clip.
Clamp bolt torque:

5.9 - 8.8 N·m (0.60 - 0.90 kg-m, 4.3 - 6.5 ft-Ib)
1.8 - 3.3 mm (0.071 - 0.130 inl
PuSh. , .. -
For connection of clutch cable of 2700 cc model, see the topic
"Clutch Cable".
A20-OO9
Fig. 11
INSTALLATION
1) Insert clutch cable into hole on toe board, and set pedal
bracket above steering column.
ASSEMBLY
Be careful not to bend clutch cable too much.
1) Attach stop light switch, etc. to pedal bracket temporarily. 2) Insert bolts of brake booster into holes on toe board,
2) Clean inside of bores of clutch pedal and brake pedal, support it from engine room, and fit holes of pedal bracket
apply grease, and set bushings into bores.
onto the bolts.
3) Align bores of pedal bracket, clutch pedal and brake At this time, operating rod of brake booster should be engaged
pedal, attach brake pedal return spring and clutch pedal return
with brake pedal.
spring (vehicle with Hill·Holder), and then install pedal shaft 3) While pushing pedal bracket upward firmly, tighten 4 nuts
completely to prevent it from rotating.
and 2 bolts at its upper surface.
Clean inside of bushes and apply grease before installing shaft.
4) Clean and apply grease to shaft and inside of bore of

accelerator pedal. Install accelerator pedal onto pedal bracket.
Tightening torque:
13 - 23 N'm (1.3 - 2.3 kg-m, 9 -17 ft-Ib) I
5) Set brake pedal position by adjusting position of stop 4) Connect operating rod of brake booster to brake pedal
light switch. using clevis pin and snap pin.
1 Clevis pin
2 Snap pin
3 Operating rod A20-Q83
A20-Q53
Fig. 12 Fig. 13
8
5) Pull out accelerator inner cable to its maximum stroke, Make sure to check operation of accelerator cable by operating
and attach it to accelerator pedal. accelerator pedal by hand.
Pull accelerator cable from throttle body side.
9) Attach clutch cable grommet to toe board, and then
Be careful not to kink accelerator cable. connect clutch cable to clutch release fork.
6) Connect electrical connectors for stop light switch, etc. Never fail to cover outer cable end with boot.
7) Install steering column as before.
8) Connect accelerator cable to throttle body.
,I
9
Cable
1. Clutch Cable Release fork
* Apply
To clutch release fork
~-- ..
•
FWD
Stroke
Free play FWD
FWD 2 - 3 mm (O.OB - 0.12 in) 17 - 18 mm (0.67 - 0.71 in)
4WD 3 - 4 mm (0.12 - 0.16 in) 4WD
25.5 - 27 mm (1.004 - 1.063 in)
1 Lock nut
2 Clutch cable adjusting nut
3 Clutch cable ASSY
4 Clamp
5 Boot
Tightening torque: N·m (kg""" ft-Ib)

T: 5.4 - 9.3 (0.55 - 0.95, 4.0 - 6.9)
I
I~"---~
1_ ~ I--J..-=-...j...------.-r----..+---l----',r---~;::;:::::=r"
I
[For 1800 ccl [For 2700 cel
L4-1385
Fig. 14
10
CLUTCH CABLE (2700 cc)

1) Removal
(1) Disconnect clutch cable on transmission side. Push
grommet into passenger compartment.
(2) Remove trim panel located under pedal shaft.
(3) Remove a nut at pedal shaft and two bolts which
hold clamp with bracket, and detach clamp.
o
Clutch pedal
L4-682
Fig. 15
(4) Remove clip from clevis pin which holds clutch cable L4-1387
to clutch pedal. Remove clevis pin and clutch cable.
Fig. 17
(5) Remove spring-hook from bushing.

(6) Remove two bolts which hold pedal switch stopper,
and detach stopper.
(7) Remove clutch pedal.
2) Installation
(1) Apply a coat of grease to frictional/movable sections
of spring bushing and install spring.
(2) Hold clutch pedal to lever.
(3) Install pedal switch stopper.
(4) Connect clutch cable. (Apply a coat of grease to
clevis pin location.)
L4·1386 (5) Install spring.
Fig. 16 (6) Align hole at clutch cable end with clamp hole, and
install clamp.
(7) Install trim panel.
(8) Connect clutch cable on transmission side.
(9) Adjust free play of clutch pedal to 10 to 20 mm
(0.39 to 0.79 in).
11
2. Accelerator Cable
1800 cc
Pitching stopper
Accelerator cable
I,
I
o~1.....qj~ Clip--~
"'-" \ " View ®
~
~Hl---o To accelerator pedal
L4-685
Fig. 18
2700 cc
To throttle body
L4-1388
Fig. 19
12
3. Speedometer Cable
MT vehicle
Pedal bracket View @
Be sure to insert the tongue

of cable end into the groove
of speedometer shaft.
To speedometer
Brake booster
AT vehicle
View@
L4·1389
Fig. 20
13
HEATER AND VENTILATOR
Page
BUBARU MECHANISM AND FUNCTION... . . . . . . . . . . . . . . . . . . . . . . . . . .. 2

Outline ............................................. . 2
Control Lever and Switch ............•................•.... 4
Mode Selector Switch and Flow of Air ........................ . 6
1988 Electrical System .....•..•..•.... . • • . • . . . . . . . . . . . . . . . . . . B
SPECIFICATIONS AND SERVICE DATA ...................... . 8
COMPONENT PARTS .............................•....... 9
SERVICE PROCEDURE .•..........•....................... 10
Heater Unit .......................................... . 10
Blower Assembly ......................•................ 10
Heater Control (Control Wing, Temperature Control Lever
and Fan Switch Lever) .......••...•.....•..•....•......... 11
-
............................................................................
.~
4-6 HEATER AND VENTILATOR

Outline
1) Configuration 3) Heating system
The heating and ventilating systems consist of a control unit A high performance heater system is adopted. All models are
at wing installed on steering column, heater unit, blower equipped with the front side window defroster.
ASSY, heater duct, and heater hoses.
2) Ventilation system
Fresh outside air is introduced into the compartment through
the center and side ventilator grilles when the ventilator fan is
operated.
Defroster
OD Side defroster
Heater
Heater (Foot level outlet)
(Foot level outlet)
L4-1206
Fig. 1
2
HEATER AND VENTILATOR 4-6
Front
defroster
F,on,,;d<
windowdefroster~ "
~ '\ \ -V
??r/
r------"
lHf
{}
Driver side outlet Center outlet Passenger side
outlet
L4-586
Fig. 2
3
Control Lever and Switch
1 DEF switch
2 HEAT switch
3 BI-LEV switch
4 Ale· Ale MAX switch
(For Ale equipped model)
VENT switch
(For Ale not equipped model)
5 OFF switch
6 Temperature control lever
7 Fan switch lever
L4·1207
Fig. 3
4
A. Mode selector switch C. Fan switch lever
Air is directed to the windshield, and

front side windows.
(Part of air is directed to foot level.)
Air flow can be controlled in four
steps.
Air is directed to foot level. Position 1 ... Smallest air flow
(Part of air is also directed to defros- l.
Position 4 ... Largest air flow
ters.)
If mode switch is OFF, blower is

Air is sent out at neck to breast level also OFF irrespective of fan switch
and also at foot level. dial position.
L4-590
Air is sent out at neck to breast level.
~: 1st position for AIC Fig. 6
(air conditioner)
.c.: 2nd position for AIC MAX.
In this position, air is circulated.
Pressing the button changes 1st and
2nd positions alternately.
With vehicles having no Ale, this

switch serves as (V ENT) (one
position only).
Blower is OF F, and no air is sent out

to the compartment.
L4-588
Fig. 4
8. Temperature control lever
Air temperature can be

variably controlled from
COLD to HOT. HOT
position provides maxi-
mum heating.
L4-589
Fig. 5
5
Mode Selector Switch and Flow of Air

Mode selector Position of other
Flow of air
switch position· levers and switches
• Temperature con-
trollever
HOT
DEF • Fan switch lever
1st to 4th position
I-.-.-~-.-.--I
1---------
Fig. 7 L4-591
trol lever
HEAT HOT
• Fan switch lever
1st to 4th position
Fig. 8
.........r-I- - - - - - , I ............n. . . . . . . jr"- - - - - - - - - - - - . 1 .... -1 L4-592
BI-LEV.
trol lever
COLD to HOT
i ,----,
1st to 4th position
r:
, ,II ----~I
,,1
n",
'" 'I- - - - - - - - - - III'
~
Fig. 9' •• • L4-593
trollever
..K. AIC COLD to HOT
1st to 4th position
Fig. 10 •
t• •
..--'~-II-=========~I ,t r-II----------~,
• L4-594
Mode selector Position of other

Flow of air
switch position levers and switches
trol lever
COLD
J;l, AIC
1st to 4 th position
MAX
r--,r--t-I=~-=-~-------~-----------~I
•
Fig. 11
•• • L4-595
trol lever
COLD
OFF • Fan switch lever
Blower is OF F
irrespective of
level position_
Fig. 12 L4-596
VENT trollever
(Model without COLD to HOT
~
A/C) • Fan switch lever
~~------.~~J~'~I~----------~~~
1st to 4th position
n
fill - - - - - 1 1 II III '-1- - - - - - - - - - - I II I
Fig. 13 • •• • L4-597
7
Electrical System
An electrical system is adopted in the heater control, and is
used to open or close the mode selector shutter and internal/
external air selector shutter by util izing an electrical motor.

SPECIFICATIONS
Item Specifications Condition
• Temperature difference between hot

water and inlet air: 65°C (149°F)
Heating capacity' 4.536 kW (3,900 kcal/h, 15,475 BTU/h) • Hot water flowing volume:
360Q/h (95.1 US gal/h,
79.2 Imp gal/h)
Air flow volume 330 m 3 /h (11,700 cu ft/h) -

Fan
I diameter x width 140 x 65 mm (5.51 x 2.56 in) -
Fan motor 200W at 12.8 V magnet motor
Heater core size

200 x 159.5 x 32 x 2.0 mm
(length x width x th ickness
(7.87 x 6.28 x 1.26 x 0.08 in)
-
x fin pitch)
I
8
COMPONENT PARTS
@ @ ®
CD
1\
I
-
I
1 Heater unit
2 Blower ASSY
I 3 Heater duct
I
4 Heater inlet hose
\
5 Heater outlet hose
6 Heater grommet
7 Grommet plate
8 Hose clamp
,, 9 Actuator
10 Actuator harness
~
11 Pipe plug
12 Hose plug
Fig. 14 L4-598
9
SERVICE PROCEDURE
Heater Unit
REMOVAL
1) Remove heater hoses (inlet, outlet) in engine compart·

ment.
Fig. 17
INSTALLATION
I nstallation is in the reverse order of removal procedures.
a. Fitting length of heater hose to pipe is 20 to 25 mm (0.79

Fig. 15 to 0.98 in).
b. Heater unit mounting bolt tightening torque: 5.4 to
9.3 N·m (0.55 to 0.95 kg-m, 4.0 to 6.9 ft·lb).
Drain as much coolant from heater unit as possible, and plug

heater pipes with cloth. Blower Assembly
2) Remove . instrument panel. (Refer to chapter "INSTRU· REMOVAL
MENT PANEL".)
3) Disconnect connector of harness coming from motor 1) Remove lower cover on passenger's side.
and temperature control cable. (Refer to chapter "INSTRUMENT PANEL".)
2) Remove pocket.
(Refer to chapter "INSTRUMENT PANEL".)
3) Remove heater duct (or separate evaporator from blower
ASSY for air conditioner equipped vehicle).
4) Disconnect motor harness and resistor harness.
I
Fig. 16
4) Remove heater unit.

Fig. 18
5) Remove blower ASSY.
10
INSTALLATION INSTALLATION
Installation is in the reverse order of removal procedures. To install. reverse removal procedures.
Blower ASSY mounting bolt and nuts tightening torque: a. Be sure harnesses are not forcibly pulled or caught in parts.
5.4 to 9.3 N·m (0.55 to 0.95 kg·m, 4.0 to 6.9 ft-lb). b. After installing parts, check to be sure both tilt and
telescopic mechanisms operate properly.
Temperature Control Lever and Fan

Heater Control (Control Switch Lever (Both parts are installed on
Wing, Temperature Control the same base.)
Lever and Fan Switch Lever) REMOVAL
Control Wing , ) Remove console box.

(Refer to "Removal" of console box.)
REMOVAL 2) Remove each knob of "Temperature Control Lever and
Fan Switch Lever" respectively.
, ) Remove screws wh ich hold lower instrument cover. 3) Remove screws to take out "Temperature Control Lever
2) Remove screws which hold column cover. and Fan Switch Lever" as a unit.
3) Remove screws which hold combination switch to control
wing bracket.
Fig. 20
~o
L4-599
Fig. 19
4) Remove clips which hold harness to lower section of INSTALLATION

meter.
5) Remove holddown band which holds harness to steering Reverse the order of "Removal".
column.
6) Remove bolts which hold control wing. and detach Temperature control cable is preset at factory. Do not remove
control wing. it from base.
'1
AIR CONDITIONING SYSTEM
Page
BUBARU MECHANISM AND FUNCTION... . . . . . . • . • . . . . . . • • . . . . • • . . .. 2

Electrical System ...................................... . 2
F.I.C.D ..........................•..............•..•. 4
1988 Belt Protection System ..•.........••.••.•.•••••.....•.••• 4

SPECIFICATIONS ......••................•....•.......... 5
COMPONENT PARTS ..........................•.......... 7
Air Conditioner System .............................•..... 7
Evaporator .................................•..•••••.• 8
Compressor, Fan and Belt ...••••••...••....••.•..•..•••••.
Compressor Components ..••.•..•..•.••••••.•..•.•.•••••.•
SERVICE PROCEDURE ................................... .
On-Car Service ....••.... _.....•..... _.... _.....••...••.
Compressor ......•.....•.................•....•...•...
9
10
11
11
23
•
Condenser ......................................•..••. 35
Receiver Drier ............•......................•....• 36
Evaporator .....................................•..... 37
Condenser Fan Assembly ................................. . 38
Flexible Hose ......................................... . 38
Relay and Fuse ....................................•... 39
Pressure Switch ........................•............•.. 40
Microswitch .................................. _.... _.. . 40
Pulser Amplifier ....................................... . 41
TROUBLESHOOTING .................................... . 42
REMARKS:
The description for air-conditioning system in this chapter pertains only to
the SUBARU AIR-CONDITIONING SYSTEM that is installed as original
equipment by the manufacturer (FUJI HEAVY INDUSTRIES, LTD.).
4-7 AIR CONDITIONING SYSTEM

ELECTRICAL SYSTEM
1) When the mode control switch is set at "A/C. MAX",
"A/C", or "DEF", the air conditioner switch (microswitch)
will be turned on. In this condition, when the blower switch
is turned on, the blower relay and air conditioner relay will
activate. This in turn causes the blower motor, fast idle sole-
noid (FICO) and compressor clutch to activate.
2) In addition, activating the pressure switch (main fan
control) or the thermo switch will cause the main fan to
activate.
3) When either the triple switch or the thermostat acti-
vates, all air conditioner circuits except the blower motor
wilt deactivate. In this condition, however, when the tem-
perature of the coolant in the radiator is high enough and
the thermo switch turns on, the radiator fan (main fan) will
activate.
4) When refrigerant pressure exceeds the specified value with
the A/C switch to ON, the main fan will activate to help cool
the condenser.
5) Electrical system is also used to open or close the mode
selector shutter and internal/external air selector shutter by
utilizing the electrical motor.
2
AIR CONDITIONING SYSTEM 4-7
Wiring Harness Installation and Electrical Device
$®
YW
~~~~~~~~~~~~~~=ffi~~T~~ W
o
Battery <§)Y B~
LY~(@
o
~@
Triple switch . -
LB YW
Main fan control LR~W
pressure switch
High-low
rn L LR
pressure switch ,.
Pulser coil
Compressor A/Crelay~ r-~;;{::.+=::; ~
TO~/G~~Aj ~~. . . .Y)±(

T LRL ~""'YW
Main fan
control relay LW
®
LR Sub fan control
relay
YW LY
9~--"'~®
@
Mode control
switch I Blower
L LW
YL @ GW motor
~ ~llln@,~~~IJ
I
LW LB LW \ LR GY YR RY
B LG L LgB YG
AIC cut relay (AT only)
Micro switch
Blower switch ~
LY L MPFI unit RY RY
D
~L RB
~@ LB
II [III1III@
L4-1520
Fig. 1
3
F.I.C.D.
x 1,000 rpm
F.I.C.D. is of the solenoid valve type incorporated into throttle
7 Normal rpm
body. It operates when the air conditioner switch is turned
E 6
on. Idle speed need not be adjusted. e-
5 5
'"'"
Q) 4
Idle speed with F.I.C.D. in operation:
9-..: 3
850 ± 50 rpm 0
()
2
BE L T PROTECTION SYSTEM 2 345 6 7

General x 1,000 rpm
Engine rpm
Whenever the compressor rpm drops below the specified value, A26·138
the belt protection system quickly turns off the magnet clutch
Fig.3 Characteristic curves of "lock" detection
of compressor and operations of alternator, water pump and
power steering oil pump are kept normal. Disengagement of
the clutch causes the compressor pulley to rotate freely so that
belt is not broken.
Operation
In the system as shown in figure, while compressor is operat-
ing, the ratio of compressor rpm to engine rpm is monitored
by a pulser amplifier. When compressor rpm drops more than
20 to 25% below the normal rpm, the system judges as if
compressor is "locked" and turns off the magnet clutch of
compressor.
Once the system defects a "Iocked" compressor, the magnet

clutch remains off until the air conditioner switch is turned
off and turned on again.
Battery
A/C max. unit
Ignition
switch
Micro switch
Triple
switch
MT
MPFI
co ntro I ----+.
Ignition coil unit
(to detect
engine rpm)
-
Blower switch
A/C cut unit (AT only)
L4-1252
Fig. 2
4
SPECIFICATIONS
Type of air conditioner Reheat air mix type
Standard cooling efficiency (lMACA) 5,001 kW (4,300 kcal/h, 17,062 BTU/h)
Refrigerant R-12 (CCL 2 F 2 ) [0.74 -0.79kg (1.63 -1.74Ib)]
Type Swash plate type MJS170-60Y
Compressor Discharge 170 cm 3 (170 cc, 10.37 cu in)/rev.
Max. permissible speed 7,500 rpm
Type Dry, single-disc type PMC140-1 PJ
Power consumption 40W
Magnet clutch Type of belt Poly V type
Pulley dia. (effective dia.) 122 mm (4.80 in)
Pulley ratio 1.11
Type Corrugated fin type
Front area 0.142 m2 (1.53 sq ftl

Condenser
Core thickness 26 mm (1.02 in)
Radiation area 3.43 m2 (36.9 sq ft)
Receiver dryer Effective inner capacity 420 cm 3 (420 cc, 25.63 cu in)
Expansion valve Type Automatic temperature control, internal pressure-balance type
Type Corrugated fin type

Evaporator
Dimensions (W x H x T) 101.3 x 170 x 230 mm (3.99 x 6.69 x 9.06 in)
Fan type Sirocco fan type
Blower fan Outer diameter x Width 140 x 65 mm (5.51 x 2.56 in)
Power consumption 230 W at 12 V
Motor type Magnet type

Condenser fan
Power consumption 140Wat 12 V
(Sub fan)
Fan outer diameter 280 mm (11.02 in)
Motor type Magnet type

Radiator fan
Power consumption 140 W at 12 V
(Main fan)
Fan outer diameter 340 mm (13.39 in)
Idling speed with F .I.C.O. in operation 850 ± 50 rpm
196 ± 20 kPa (2.0 ± 0.2 kg/cm 2, 28 ± 2.8 psi) ON ~ OFF

Low-pressure-switch working pressure
206 ± 29 kPa (2.1 ± 0.3 kg/cm2, 30 ± 4 psi) OFF~ON
5
2,648 ± 196 kPa (27.0 ± 2.0 kg/cm2, 384 ± 28 psi)

High-pressure-switch working pressure ON -+ OFF
DI FF 588 ± 196 kPa (6 ± 2 kg/cm 2, 85 ± 28 psi)
1,569 ± 127 kPa (16.0 ± 1.3 kg/cm2 , 228 ± 18 psi)

OFF -+ ON
Pressure switch (Main fan control)
1,275 ± 147 kPa (13.0 ± 1.5 kg/cm 2 , 185 ± 21 psi)
ON -+ OFF
6
COMPONENT PARTS
Air Conditioner System
t-~
I
I
CD I
t- 0
'f-G
I
[22]'1 I
I
I
I
I
I
®
I
L.. ............
............. _,
I
I
1 AIC fuse
2 Radiator fan relay
3 AIC relay
®
4 Clamp
5 Bracket A
6 Bracket B
1 Pipe CP
8 Flexible hose ASSY (Ps)
9 Flexible hose ASSY (Pd)
Pressure switch
10
11 Bracket (RH) T1: 10 - 20 (1.0 - 2.0,7 -14)
12 Bracket (LH) T2: 15 - 25 (1.5 - 2.5,11 - 18)
13 Rubber cushion T3: 5 -10 (0.5 -1.0, 3.6 - 7.2)
14 Condenser
T4: 3 - 6 (0.3 - 0.6, 2.2 - 4.3)
15 Pipe CP
16 Bracket
T5: 20 - 29 (2.0 - 3.0, 14 - 22)
11 Receiver drier T6: 5.4 - 8.3 (0.55 - 0.85, 4.0 - 6.1)
18 Condenser fan relay T7: 15 - 18 (1.5 - 1.8,11 - 13)
L4-1522
Fig. 4
7
Evaporator
t----®
I
I
~ @
1 Pulser amplifier
2 Evaporator
3 Heater band ASSY Tightening torque: N·m (kg-m, ft-Ib)
4 Blower band ASSY
5 Bracket
T1: 5 - 10 (0.5 - 1.0,3.6 -7.2)
6 Drain hose T2: 3 - 6 (0.3 - 0.6, 2.2 - 4.3)
7 Grommet (PsI
8 Grommet (Pdl
L4-1523
Fig. 5
8
Compressor, Fan and Belt

~
[\gCD
~--!J I
I
I
I
cb
1 Bracket
2 Pulser ASSY
3 Compressor CP
4 V-ribbed belt
5 Washer
6 Rubber cushion
7 Spacer
8 Fan motor ASSY
9 Shroud

Tl: 34 - 44 (3.5 - 4.5, 25 - 33)
T2: 15 - 25 (1.5 - 2.5,11 - 18)
T3: 5 - 10 (0.5 - 1.0, 3.6 - 7.2)
@
L4-1524
Fig. 6
9
Compressor Components
® ® ®
l
I ®
No. Part name Bolt type Tightening torque

Tl Cover end (A) bolt 10 mm x 25 mm socket head bolt 19 - 21 N·m (1.9 - 2.1 kg-m. 14 - 15 ft-Ib)
T2 Clutch ASSY nut 8 mm nut 19 - 21 N·m (1.9 - 2.1 kg-m. 14 - 15 ft-Ib)
T3 Wire clamping bolt 5 mm x 8 mm screw 2.7 - 3.3 N·m (0.28 - 0.34 kg-m. 2.0 - 2.5 ft-Ib)
T4 Seal cover bolt 8 mm x 12 mm flange head bolt 5 - 6 N'm (0.5 - 0.6 kg-m. 3.6 - 4.3 ft-Ib)
T5 Hub nut 24 mm x 7.5 mm nut 19 - 21 N·m (1.9 - 2.1 kg-m, 14 - 15 ft-Ib)
Nut (8 mm) 10 Key 19 Shell 28 O-ring (12 mm. gas pipe)

2 Hub nut 11 Snap ring (32 mm) 20 Shell gasket 29 Compressor cylinder
3 Spacer 12 Shaft seal ASSY 21 Cover end (F) 30 Cylinder head (R)
4 Clutch ASSY 13 O-ring (28 mm) 22 O-ring (Cylinder head IN) 31 O-ring (Cover end Al
5 Armature 14 Cover plate 23 O-ring (Cylinder head OUT) 32 Cover end (A)
6 Wedge ring (40 mm) 15. Seal ring 24 Cylinder head (F) 33 Seal cover set (Delivery)
7 Rotor 16 Shaft seal 25 Suction valve plate 34 Seal cover set (Suction)
8 Wedge ring (50 mm) 17 Wire clamp 26 Key 35 Wave washer
9 Stator 18 Screw 27 Knock pin 36 Socket bolt (10 mm)
Fig, 7 L4-1525
10
SERVICE PROCEDURE
conditioner to operate normally in the next season.
On-Car Service
1 ) Keep the entire system free from refrigerant leakage by
periodically checking for refrigerant gas leak even out of
REFRIGERANT R-12 season.
2) Turn the compressor for 10 minutes at least once a month
The refrigerant used in the air conditioner is generally called
by running the engine at 1,500 rpm.
"Refrigerant-12 {R-12)". No other refrigerant than the above
refrigerant should be used. This refrigerant is usually available
GENERAL SERVICE INSTRUCTION
in a small can or a cylinder. In either case, it is liquefied
under high pressure in the container. The servicing of the air conditioner should be carried out
Refrigerant evaporates easily (has a low evaporation point) only by well-trained servicemen. This chapter describes
and, moreover, since the latent heat of the refrigerant is large, essential points of servicing.
it can absorb a large amount of heat when evaporating. Ex- • If a large amount of dirt and sand ,enter the system, they
treme care must be exercised when handling the refrigerant. will be carried with refrigerant and may clog the system
or scratch rotating parts. This points out the need for
COMPRESSOR 01 L care in servicing the system. That is, disconnecting joints
should be carried out in a clean place.
The "SUN ISO 5GS" refrigeration lubrication should be used
• Water should not be allowed to get inside the system. The
to assure the successful compressor operation. Use of oils
refrigerant does not readily mix with water. However, the
other than recommended or mixing of the oil with other
presence of even a minute amount of water will cause a
oils would cause chemical reaction or lead to lowered viscosi-
chemical reaction at high temperature which will in turn
ty or deficient lubrication.
produce hydrochloric acid (HC1). Since hydrochloric acid
The oil absorbs moisture as it contacts the air. This points out
is highly corrosive to metals, the aluminum and copper
the need for care not to expose it to atmosphere for an ex-
piping, etc. will become corroded and the refrigeration
tended period of time.
system will become clogged.
a. The oil should not be transfused from a container into • Water in the system will ice the orifice when the high
another, as the failure will possibly cause moisture to mix pressure refrigerant is changed to low pressure refrigerant
with the oil. by expansion valve, etc., and will obstruct the refrigerant
b. The used oil should not be returned into a container. flow.
c. The oil should not be used if its state of preselVation is not
clear enough. SAFETY PRECAUTIONS
1) Since direct contact of the liquid refrigerant with your
skin will cause frostbite, always be careful when handling the
MAINTENANCE refrigerant. Wear gloves or wrap a piece of cloth around service
Periodical maintenance and season-in inspection valve to protect your fingers against frostbite by refrigerant.
If any of the refrigerant should get into your eyes when
Both periodical maintenance and season-in inspection are
charging the refrigerant. splash your eyes with cool water to
most essential to enable the air conditioner to give full per-
raise the temperature gradually. Apply a protective film to
formance.
the eye to avoid infection. Do not rub your eyes. Consult
Perform the following checks.
an eye special ist. Always wear goggles or glasses to protect
1) Start engine and check refrigerant level through sight glass
your eyes when working around the system. Should refrigerant
on receiver drier. For details, refer to relative topics under
strike your body, splash on cool water and apply a protective
"Refrigerant Level Check".
film.
2) Check the entire system for sign of refrigerant leaks.
2) The refrigerant service container has a safe strength. How-
Refer to relative topics under "Checking for Leaks" and
"Refrigerant Leaks". ever, if\handled incorrectly, it will explode. Therefore, always
If any trace of oil is noted at and around connection fittings, follow the instructions on the label. In particular, never
it is a sure indication that refrigerant is .leaking. This con- store it in a hot location [above 52°e (126°F)] or drop it
dition can be corrected easily by retightening the joints. If from a high height.
any joint on line is suspected of small amount of leakage, use 3) The refrigerant gas is odorless and colorless and breathing
a leak detector to locate leaking points. may become difficult due to the lack of oxygen. Since the
3) Check compressor drive belts for proper deflection. refrigerant gas is heavier than air and will lay close to the floor.
be especially careful when handling it in small, confined
Season-off spaces.
Observe the following maintenance tips to allow the air 4) The refrigerant itself is nonflammable. However, a toxic
11
gas (phosgene gas) is produced when it contacts fire and (Connection to service valve)
special care is therefore required when checking for leaks in
the system with a halide torch. 1) Fully close both valves of manifold gauge. Connect
5) Do not steam clean on the system, especially condenser high· and low-pressure charging hoses to manifold gauge.
since excessively high pressure will build up in the system, 2) Remove caps from service valves. Connect high· and low·
resulting in explosion of the system. pressure charging hoses to service valves in system. The
The above precautions are essential in handling of Refrigerant- refrigerant gas will be discharged since check valve is open
12, and their strict observation requires sufficient training. when pressing charging hose onto service valve.
Therefore, it is of first importance that any other personnel 3) Next, loosen the connection fitting of charging hose at
than a well-trained serviceman should not be allowed to handle manifold gauge side for 2 to 3 seconds to purge any air inside
the retrigerant. charging hose by the pressurized gas in system.
EVACUATING AND CHARGING SYSTEM (Disconnection from service valve)

During servicing, use caution to keep air from getting into
refrigerant. When air enters the system, all refrigerant must 1) Fully close both valves of manifold gauge.
be evacuated from system prior to charging new refrigerant. 2) Disconnect two charging hoses from service valves. At
Air in refrigerant has the following deleterious effects: this time, the gas will be discharged until check valve is closed.
1) Since the condensation temperature of the air is ex· Therefore, disconnect hose quickly.
tremely low, the air will not be condensed when refrigerant
gas is condensed in the condenser, and the air will thus remain CAUTION:
in gaseous form. Consequently, the effective thermal trans· When working with refrigerant, protect your fingers against
mission area of condenser for refrigerant gas will be reduced frostbite by using gloves or other cloth material.
and refrigerant gas to be condensed· will be reduced. The
pressure rise will become proportional to the volume of the air Handling service valve
in system. An automatic check valve is built into service valve. When this
2) When air and refrigerant are mixed in system, a chemical valve presses against the connection fitting, that is, when
reaction will be produced and hydrochloric acid which will charging hose is connected to service valve. the valve is open.
adversely affect the aluminum, copper, iron, and other When charging hose is disconnected, the valve is closed auto·
materials in system may be generated. matically. Always observe the following usage precautions:
1) Always install valve cap after using service valve.
Handling manifold gauge
When high speed operation is performed without valve cap. a
The pressure at the high· and low-sides of system should be negative pressure will gradually build up at the low pressure
measured when evacuating and charging refrigerant and side of system and air may be sucked in. In addition, dirt and
when diagnosing trouble in the system. The manifold gauge dust will easily enter the valve resulting in foreign matter
is used for these purposes. A manifold gauge has two pressure entering the system.
gauges; a low pressure gauge and a high pressure gauge. 2) Check valve will be half opened during connection and
These gauges are connected to the high· and low-side service disconnection of charging hoses and refrigerant will be
valves of system through flexible charging hoses. The con· forcefully discharged. Therefore, connect and disconnect
struction of manifold gauge is shown in Figure. charging hoses quickly while pressing flare nut of charging
When valve stem is fully screwed, the valve is front·seated and hose against service valve.
valve path and the center path are blocked. When valve stem is
backed off, the paths are opened.
CAUTION:
When working with refrigerant, protect your fingers against
frostbite by using gloves or other cloth material.
3) Since close contact between the thread of valve cap and
the thread of service valve will prevent gas leakage, keep these
sections clean and free of scratches and damage.
Back-seated 4) Since packing of charging hose will be lost during long
(Full counter· use, always check packing prior to installing charging hose.
clockwise)
To low-side To vacuum To high-side

. I pump or service valve
service va ve refrigerant can
A26-Q28
Fig. 8
12
CD
Cap
® 2 Service valve
3 Charging hose
4 Packing Purging air
2
5 Check valve
R-12
Close
A26-029 A26{)31
Fig. 9 Fig. 11
Discharging system
Handling can tap The pressurized refrigerant gas inside system must be dis-
A wide variety of can taps are available. The following pro- charged to a pressure approaching atmospheric pressure prior
cedures apply to conventional can taps. to evacuating refrigerant inside system. This operation should
For the correct usage, refer to the manufacturer's instruc- be made to permit safe removal when replacing system com-
tions. ponents.
1) Close high- and low-pressure valves of manifold gauge
CAUTION: fully.
Use can tap of good quality. 2) Connect two charging hoses of manifold gauge to their
respective service valves.
1) Connect charging hose to the center fitting of manifold 3) Open both manifold gauge valves slightly and slowly
gauge. At this time, confirm that both stems are fully turned discharge refrigerant from system.
in (front-seated).
2) Turn can tap handle fully counterclockwise so that the Do not allow refrigerant to rush out Otherwise, compressor
needle is pulled up. oil will be discharged along with refrigerant.
3) Attach can tap to refrigerant can firmly.
4) Turn can tap handle fully clockwise to make a hole in
refrigerant can.
5) Turn the handle fully counterclockwise to raise the
needle. Refrigerant gas will flow up to the center fitting of
manifold gauge.
6) Loosen the connection at the center fitting of manifold
gauge for a few seconds to purge air inside charging hose.
(Clockwise) (Counterclockwise)
n n
L4491
Fig. 12
CAUTION:
When connecting the charging hose to the service valve or
® disconnecting it therefrom, protect your fingers against frost-
Can tap handle
- bite by using gloves or other cloth material.
2 Charging hose
3 Needle Evacuating system
4 Refrigerant can A26{) 30 1) Connect high- and low-pressure charging hoses of mani-
Fig. 10 fold gauge to their respective service valves of system and
13
discharge refrigerant from system. Refer to "Discharge Repair any leakages found. Refer to "Checking for Leaks"
System". and "Refrigerant Leaks".
2) When refrigerant has been discharged to a pressure ap- (6) Confirm that both valves of manifold gauge are fully
proaching atmospheric pressure, connect center charging hose closed and then change center charging hose from can tap
to a vacuum pump. to vacuum pump.
3) Close both valves of manifold gauge fully. Then start (7) Open high- and low-pressure valves and operate
vacuum pump. vacuum pump to such refrigerant from system. When the
4) Open low-pressure valve and suck old refrigerant from pressure in system has dropped to 94.6 kPa (710 mmHg,
system. 27.95 inHgl, fully close both valves of manifold gauge.
5) When low-pressure gauge reading has reached to ap- 7) The above operation completes evacuation of system.
Next, charge refrigerant. Refer to "Charging Refrigerant".
proximately 66.7 kPa (500 mmHg, 19.69 inHg), slowly open
high-pressure valve.
6) When pressure inside system has dropped to 94.6 kPa Evacuating system - First step
•
(710 mmHg, 27.95 inHg). fully close both valves of mani-
fold gauge and stop vacuum pump. Let it stand for 5 to 10
minutes in this state and confirm that the reading does not
rise.
a. The low-pressure gauge reads lower by 3.3 kPa (25 mmHg,

0.98 inHg) per a 300 m (1,000 ft) elevation. Perform evacua- •
tion according to the following table.
Elevation Vacuum of system

m (ft) kPa (mm Hg, in Hg)
L4-492
0 (0) 94.6 (710,27.95)
Fig. 13
300 (1,000) 91.3 (685,26.97)
600 (2,000) 88.0 (660, 25.98) Evacuating system - Second step
900 (3,000) 84.6 (635, 25.00)
NOTE:
Values show readings of the low-pressure gauge.
b. The rate of ascension of the low-pressure gauge should be

less than 3.3 kPa (25 mmHg, 0.98 inHg) in five minutes.
If the pressure rises or the specified negative pressure can

not be obtained, there is a leak in the system. In this case,
immediately charge system with refrigerant and repair the leak
I
described in the followings.
L4-493
(1) Confirm that both valves of manifold gauge are fully
closed and then disconnect center charging hose from Fig. 14
vacuum pump.
(2) Connect center hose to can tap in place of vacuum
pump. Attach refrigerant can to can tap and pass Charging refrigerant
refrigerant to manifold gauge. 1) Install manifold gauge to system. Refer to "Handling
(3) Loosen the connection of center fitting of manifold Manifold Gauge".
gauge to purge air from center hose.
(4) Open low-pressure valve of manifold gauge and charge a. Be sure to purge air from the high- and low-pressure
refrigerant into system. After one can [about 0.4 kg (0.9 charging hoses.
Ib)] of refrigerant has been charged into system, close b. If air is mixed with refrigerant gas in system, evacuation
low-pressure valve. of system should be performed. Refer to "Evacuating
(5) Check for refrigerant leakage with a leak detector. System".
14
2) Attach center charging hose of manifold gauge to refriger-
ant can through can tap. Break seal of refrigerant can to allow
refrigerant to enter manifold gauge. Loosen charging hose at
the center fitting of manifold gauge and purge air from inside
charging hose. Refer to "Handling Can Tap".
3) Open high- and low-pressure valves of manifold gauge and
charge refrigerant into system.
•
L4495
t t
Fig. 17
4) If refrigerant charging speed slows down, charge it while

L4494 running the compressor for ease of charging. After having
taken the steps up to 3) above, proceed with charging in the
Fig. 15
following order.
(1) Shut off high pressure valve of manifold gauge.
a. When refrigerant charging speed is slow, immerse refriger-
ant can in water heated to a temperature of about 40° C CAUTION:
(104°F). However, note that this is dangerous when water is Never charge refrigerant through high pressure side of system
hot. since this will force refrigerant back into refrigerant can and
can may explode.
(2) Run the engine at idling speed.

(3) Set temperature control lever and fan switch at
maximum cool and maximum speed respectively.
(4) Charge refrigerant while controlling low-pressure
gauge reading at 275 kPa (2.8 kg/cm2, 40 psi) or less by
Immerse in water turning in or out low-pressure valve of manifold gauge.
heated to about
40°C 1104°FI.
~zz:zzzz:z:zzz:z:z:z::r:z:P Note th a t hot Repeat from 3) when difference of pressure between low and
, water is
dangerous.
high pressure gauges does not appear after one minute opera-
tion. It is not possible to charge refrigerant without pressure
difference between low- and high-pressure gauges.
A26-o36
Fig. 16
CAUTION:
a. Under any circumstances the refrigerant can must not
be warmed in water heated to a temperature of over 52°C
(126°F).
b. A blow torch or stove must never be used to warm up
the can.
c. When charging liquefied refrigerant into the system with
the can turned upside down to reduce charging time, charge
it only through high pressure valve, but not through low·
pressu re valve.
L4496
After completion of charging, the compressor should always
be turned several times manually. Fig. 18
15
5) When refrigerant can is empty, fully close both valves of Oi I separator
manifold gauge and replace refrigerant can with a new one.
The Oil Separator Kit is used to efficiently withdraw the oil
Before opening manifold gauge valve to charge refrigerant
in the refrigeration system (that is, to separate oil and refriger·
from new can, be sure to purge air from inside charging hose.
ant). If an excessive quantity of oil is charged in the system, or
6) Charge the specified amount of refrigerant into system by
if the quantity of oil in the system is unknown, adjust the
weighing charged refrigerant with scale. Overcharging will
quantity of oil in the system to specification, proceeding as
cause discharge pressure to rise.
follows:
1) Discharge air conditioning system. (Refer to "Discharging
Measure the amount of charged refrigerant with a scale. System".)
Make a note of the amount charged from can. 2) Using two special flexible hoses and double union in Oil
Separator Kit connect oil separator between compressor dis·
charge side and condenser, as shown.
3) Evacuate and charge system. (Refer to "Evacuating and
Charging System.")
4) Fully open all windows or all doors of car.
5) Operate compressor at engine idling with air conditioner
set for maximum cooling and high fan speed.
Never allow engine speed to exceed idling speed.
6) Observe oil separator oil level gauge. If rise of oil level has
stopped, immediately stop compressor operation. (This indi·
A26"()39 cates that oil has been withdrawn.)
Fig. 19
a. Do not continue oil withdrawal operation more than 10
minutes.
b. In some cases, fluid refrigerant may be mixed with oil,
causing unusual rise of oil level. In such a case, stop com-
pressor operation after ten minutes of withdrawal operation.
Refrigerant capacity
Unit· kg (lb) 7) Discharge system. (Refer to "Discharging System.")
8) Disconnect oil separator, two flexible hoses and double
Refrigerant Minimum Maximum union from system.
9) Connect refrigerant lines to original positions.
R-12 0.74 (1.63) 0.79 (1.74)
10) Disconnect low flexible hose from compressor suction
valve.
11) Add 120 ml (4.1 US fl OZ, 4.2 Imp fl ozl of new com·
The presence of bubbles in sight glass of receiver drier is an
pressor oil from compressor suction valve.
unsuitable method of checking the amount of refrigerant
After charging, rotate compressor clutch with hand 5 to 10
charged in system. The state of the bubbles in sight glass
turns.
should only be used for checking whether the amount of
12) Connect low flexible hose to compressor suction valve.
charged refrigerant is small or not. The amount of charged
Evacuate and charge system. (Refer to "Evacuating System
refrigerant can be correctly judged by means of discharge
and Charging Refrigerant".)
pressure. Refer to "Refrigerant Level Check".
13) Conduct leak test and performance test.
14) Gradually loosen drain cap of oil separator to release
7) After the specified amount of refrigerant has been charged
residual pressu reo Remove cap and drain oil.
into system, close manifold gauge valves. Then detach charging
15) To prevent formation of rust and intrusion of moisture
hoses from service valves of system. Be sure to install valve cap
or dust, perform the following before placing oil separator
to service valve.
8) Confirm that there are no leaks in system by checking kit into storage.
(1 I Cap each opening of two flexible hoses and double
with a leak detector.
Refer to "Checking for Leaks". union securely.
(2) Cap oil separator, evacuate it from service valve, and
Conducting a performance test prior to removing manifold charge refrigerant.
gauge is a good service operation. Refer to "Performance
Test".
16
•
1 Oil separator
2 Double union Propane type Butane type
3 Flexible hose [1.5 m (4.9 ft)]
Connector pipe NO LEAK Greenish blue Pale blue
SMALL LEAK Yellow Bright blue
LARGE LEAK Purple Vivid green
1) Discharge refrigerant in one or two seconds to ascertain

that system has sufficient pressure needed for leak detection.
Charge with 0.4 kg (0.9 Ib) of refrigerant, if necessary.
L4497
2) Light leak detector. Adjust the height of the flame be-
Fig. 20 tween flame adjusting lines at the top and bottom of com-
bustion tube. A reaction plate will immediately become red
hot.
3) Place the end of sampling tube near the point of the sus-
CHECKING FOR LEAKS pected leak in system.
Conduct a leak test whenever leakage of refrigerant is sus-
pected and when conducting service operations which are a. Since refrigerant gas is heavier than air, small leaks can be
accompanied by disassembly or loosening of connection easily detected by placing sampling tube directly below the
fittings. check point.
Refrigerant is a colorless, odorless gas and leakage from b. Suitable ventilation is required. If refrigerant gas is mixed
system is difficult to detect. Accordingly, the use of a leak with the surrounding air, leak detector will always indicate a
detector facilitates check for leaks. Two methods of checking response and detection of the actual leak will be difficult
are available; one employs a halide leak detector which burns c. Never hold leak detector at an angle.
propane gas or butane gas and the other is an electric type leak
detector. CAUTION:
a. Never inhale the fumes produced by combustion of refriger-
ant gas since they are toxic.
Halide leak detector b. Never use halide torch in a place where combustible or ex·
Since the propane leak detector and butane leak detector are plosive gas is present.
the same in respect to their operation. this section describes
the operation of the propane leak detector. 4) The flame will be almost colorless when there is no re-
The copper screen is heated by the burning of propane. frigerant gas being burned. When there is a small refrigerant gas
Refrigerant gas decomposes to color the flame when it con- leak. the flame will be green or yellowgreen. When refrigerant
tacts the heated screen. The gas to be checked is drawn into gas leakage is large, the flame will be brilliant blue or purple.
the sampling tube and sent out to the burner. A refrigerant Since the color of the flame will be yellow when dust is
leak can clearly be detected by variations in the color of the being burned or there is aging scale on copper reaction plate,
flame. always keep the strainer of sampling tube and reaction plate
clean.
5) Major check points
(1) Compressor
• Compressor shaft seal (rotate the compressor by
hand)
1 Copper reaction plate
2 Flame adjusting lines • Oil filler plug
3 Burner • Flexible hose connections
4 Sampling tube • Rear cover and side cover gaskets
5 Strainer • Service valve
6 Gas bomb
(2) Condenser
5 7 Flame adjuster
• Condenser pipe fitting
• Condenser inlet and outlet pipe connections
@ (3) Piping
A26-Q41
• O-ring section of high pressure and low pressure
Fig. 21 flexible hose.
17
•
• Pipe connections REFR IGERANT LEVEL CHECK

• Service valve Sight glass
(4) Evaporator housing
• Inlet and outlet pipe connections Sight glass is provided at the top of receiver drier. One guide
• Expansion valve for whether there is enough refrigerant in system is given by
observing refrigerant flow through sight glass. However, this
method is unsu itable for judging the amount of refrigerant.
Electric leak detector The correct refrigerant level can be judged by measuring the
For the operational procedures, refer to the instructions system pressures in accordance with the procedures as de-
furnished with each electric leak detector. scribed "Performance Test".
1) Start the engine and hold engine speed at 1,500 rpm.
2) Turn on AIC switch. -
3) Set blower to maximum speed.
4) Check sight glass after the lapse of about five minutes.
Judge according to the following table.
Almost no refrigerant Insufficient Suitable Too much refrigerant
Temperature of high pressure Almost no difference High pressure side is High pressure side is High pressure side is
and low pressure pipes. between. high pressure warm and low pressure hot and low pressure abnormally hot.
and low pressure side side is fairly cold. side is cold.
temperature.
State in sight glass. Bubbles flow continu- The bubbles are seen Almost transparent. No bubbles can be seen.
ously. Bubbla will at intervals of 1 - 2 Bubbles may appear
disappear and seconds. when engine speed is
something like mist raised and lowered.
will flow when
refrigerant is nearly No clear difference exists between these two
gone. conditions.
A26~42 A2~3 A26-044

Fig. 22 Fig. 23 Fig. 24
Pressure of system. High pressure side is Both pressure on high Both pressures on high Both pressures on high
abnormally low. and low pressure sides and low pressure sides and low pressure sides
are slightly low. are normal. are abnormally high.
Repair. Stop compressor and Check for gas leakage, Discharge refrigerant
conduct an overall repair as required, from service valve of
check. replenish and charge low pressure side.
system.
18
•

a. The bubbles seen through the sight glass are influenced 1) Operate compressor at engine speed from 1,000 rpm to
by the ambient temperature. Since the bubbles are hard to 1,500 rpm with controls set for maximum cooling and high
show up in comparatively low temperatures below 20 e 0
blower speed for about 10 minutes in order to return com-
(68° F), it is possible that a slightly larger amount of refriger- pressor oil to compressor.
ant would be filled, if supplied according to the sight glass. Be 2) Stop the engine and discharge refrigerant of system and
sure to recheck the amount when it exceeds 20 e (68°F). In
0
then remove compressor from the car.
higher temperature the bubbles are easy to show up. 3) When exchanging the compressor for new one which
b. When the screen in the receiver drier is clogged, the bubbles contains 150 cm 3 (150 cc, 9.15 cu in) oil, drain 80 cm 3
will appear even if the amount of refrigerant is normal. In (80 cc, 4.88 cu in) oil from it respectively or adjust the
this case, the outlet side pipe of the receiver drier becomes amount of oil to the same of the removed compressor.
considerably cold. 4) If the oil separator is not available, control the quantity
of oil in accordance with the following table, when charging
Performance test compressor oil into the system from suction port of com-
Check for the amount of refrigerant in the system can be madp pressor by using funnel as below picture.
by measuring pressure on discharge side.
The correct amount of refrigerant is in the system. if pressure
on the discharge side is within the specified range. For details,
refer to "Performance Test" described later.
Overcharging will show up in higher pressure on discharge side.
COMPRESSOR OIL LEVEL CHECK

The oil used to lubricate compressor circulates into system
with refrigerant gas while compressor is operating. If a con-
siderable amount of leakage of refrigerant gas happens. the
leakage of compressor oil is also considered. There will be no
compressor oil leakage from a completely sealed system. When
system operates under satisfying condition. the compressor oil
level check is unnecessary. L4498
When checking the level of compressor oil or when replacing Fig. 25
any component part of the system, use the following service
procedure. This facilitates to return oil to compressor.
19
•
OIL CHARGE TABLE
Amount of oil to be added

Condition Proper charging method
m£ (US fl OZ, Imp fl oz)
Remove all oil from new compressor *

Replacement of compressor and charge it with amount of oil shown 70 (2.4, 2.5)
in right column.
Add amount of oil shown in right

Replacement of evaporator 70 (2.4, 2.5)
column.
Replacement of receiver drier

Oil need not be added. -
(I iqu id tank)
There is no sign of oil

leakage from condenser.
Replacement
of condenser There is evidence of a
large amount of oil 50 (1.7, 1.8)
column.
leakage from condenser.

Replacement Oil need not be added. -
leakage.
of flexible
hose or There is evidence of a
copper tube large amount of oil 50 (1.7, 1.8)
column.
leakage.

leakage.
Gas leakage
There is evidence of a
large amount of oi I 50 (1.7, 1.8)
column.
leakage.
* Remove compressor oil as follows: - Example-

1. With the compressor upside down, completely drain the When replacing the evaporator and compressor, drain all oil
oil through the suction port (cast-out letter "s" mark side). out of the new compressor and then charge the compressor
Be sure to use a clean container to receive the oil. with the total amount of 140 m£ (4.7 US fl OZ, 4.9 Imp fl ozl
2. When the oil stops flowing out, rotate the clutch hub (com- oil [70 m£ (2.4 US fl OZ, 2.5 Imp fl OZ) for the evaporator and
pressor shaft) two or three times to completely drain the 70 m£ (2.4 US fl oz, 2.5 Imp fl ozl for compressorl.
oil.
CAUTION:
When replacing two or more of the parts indicated in the a. The oil should not be transfused from a container into
above chart, follow each instruction under the proper charging another, as the failure will possibly cause moisture to mix with
method column for the proper amount of oil to be added. the oil.
b. The used oil should not be returned into a container.
c. The oil should not be used if its state of preservation is not
clear enough.,
If compressor is inoperative due to defective compressor or

heavy loss of refrigerant, exchange the compressor through the
procedure from 2 to 5.
20
PERFORMANCE TEST REFRIGERANT LEAKS

The cooling performance of the air conditioner changes con- If leaks are noticeable, leaky parts should be repaired. Then
siderably with changes in surrounding conditions. Testing must system should be filled with refrigerant. Do not operate com-
be performed using the correct method. This test is used to pressor with refrigerant level excessively low.
judge whether system is operating correctly and can also be If this caution is neglected, a burnt compressor will result
used as a guide in checking for problems. sinGe heavy loss of refrigerant usually indicates heavy loss of
1) Park the car indoors or in the shade. compressor oil.
2) Open all the windows of the car fully. However, close the If system has been exposed to atmosphere for an extended
doors. period of time, receiver drier must be replaced. If leaks are
3) Open the hood. slight and no air is present in system, add refrigerant as
4) Connect manifold gauge to high· and low·side service necessary. To detect leaks, refer to relative topics under
valves of the system. Refer to "Handling Manifold Gauge". "Checking for Leaks". Here is how leaks are stopped.
5) Set mode switch to AIC MAX position. 1) Check torque on the connection fitting and, if too loose,
6) Set temperature control lever to COLD position. tighten to the proper torque. Check for gas leakage with a leak
7) Start the engine and hold engine speed at 1,500 rpm. detector.
8) After the air conditioner has been operated for about 10 2) If leakage continues even after the fitting has been re-
minutes, measure system pressures at high-pressure (discharge) tightened, discharge refrigerant from system, disconnect the
side and low-pressure (suction) side. fittings, and check its seating face for damage. Always reo
9) Measure the temperatures of inlet air to blower and outlet place even if damage is sl ight.
air at the grilles. 3) Check compressor oil and add oil if required.
10) Measure the temperature and humidity of the ambient air 4) Charge refrigerant and recheck for gas leaks. If leaks are
at a point 1 m (3.3 tt) front of condenser. However, a dry found, evacuate and charge system.
bulb and wet bulb must not be placed in direct sunlight.
11) Check for any abnormalities by comparing the test
results with standard pressure in "Performance Chart".
a. The pressure will change in the following manner with

changes in conditions:
• When blower speed is low, discharge pressure will drop.
• When the relative humidity of intake air is low, discharge
pressure will drop.
b. The temperature will change in the following manner
with changes in conditions:
When the ambient air temperature is low, the outlet air
temperature will become low.
If the test reveals that there is any abnormality in system

pressure, isolate the cause and repair by reference to "Trouble-
shooting".
21
•
PERFORMANCE CHART
Conditions
Engine rotating speed: 1,500 rpm
Sunshine.: No
Doors: Close
Door windows: Open
Engine hood: Open
Front wind velocity; 2 m/sec (7 ft/sec) or less
2,158 Air humidity of front window: 50 to 80 percents
(22,313) Mode switch position: CIRe - AIC MAX
Fan switch position: Highest
1,961
(20,284)
1,765
(18,256)
~
~
III
III
(I>
1,569
Q.
(II
116, 228)
~
n:I
~ 1,373
~ (14,199)
'5
.0..
(II
1,177
Q. (12, 171)
E 70
0
u 981
(10,142) 20
785
(8,1141
60
15
50 10
392
III (4,571
......:;
III 294
Q. (3,43)
c
.2 5
t; 196 40
9al
~
III (2,28)
0
III
III
III
Q.
E 11, :4)
0
u
(0,0)
o
15 20 25
60 70 80
Unit inlet air temperature

Fig. 26 A26'()79
22
Compressor 4) High-pressure hose (Flexible hose Pd)
The MJS-170 compressor employs an oil-mist jet system in Plug the opening to prevent foreign matter from getting in.
which some lubricant is mixed in the refrigerant and the mix-
ture is sprayed directly to the sliding portions from the com- 5) Low-pressure hose (Flexible hose PsI
pressor suction side.
Plug the opening to prevent foreign matter from getting in.
COMPRESSOR CLUTCH 6) V-belt (Refer to Chapter 2-2 "Oil Pump Assembly.")

7) Remove compressor and compressor upper bracket.
The most likely source of problem is clutch slippage_ Factors
are listed here. Exercise ample care.
1) Clearance between clutch hub and pulley should be within
specifications at all peripheral points.
Clearance: mm (in)
0.5 - 0.8 (0.020 - 0.031)
2) Make sure that there is no oil or dirt on friction surfaces

of clutch disc (clutch hub) and pulley. Remove any oil or dirt
with a dry rag.
3) Make sure that terminal voltage at magnetic coil is above
10.5 V.
Fig. 28
INSTALLATION
REMOVAL
1 ) Compressor
• Tighten compressor mounting bolts in numerical sequence, as
1) Battery negative terminal
2) Pulser (pulser and compressor connector) shown in figure below, to specified torque.
3) Discharge refrigerant using manifold gauge
(1) Fully close low-pressure valve of manifold gauge.
(2) Connect low-pressure charging hose of manifold
gauge to low-pressure service valve.
(3) Slightly open low-pressure manifold gauge valve and
slowly discharge refrigerant from system.
Do not allow refrigerant to rush out. Otherwise, compressor

oil will be discharged along with refrigerant.
L4-1528
Fig. 29
*1:
Tighten this bolt with your fingers until it stops go. Tighten all
other bolts and then this bolt to specified torque.
When tightening this bolt, be careful because it has a coarse·
thread pitch.
Tightening torque:
Compressor mounting bolt:
34 - 44 N·m (3.5 - 4.5 kg-m, 25 - 33 ft-Ib)
Fig. 27
23
•
2) V-belt
(1) Loosen belt tension pulley lock nut.
(2) Turn adjusting bolt to adjust belt tension. The belt
tightens when the bolt is turned clockwise and vice versa.
98 N 110 kg. 22 Ib)

Lock nut
!C
Adjusting bolt
-tWrong Connect Wrong
L4-1530
Tensioner Fig. 31 Confirming pulley alignment

pulley
a. The V-belt should not be too tight or too loose.

L4-1529
A belt which is too tight may break bearing or cause gas to
Fig. 30 leak from the shaft seal. A belt which is too loose slips, there-
by causing the belt cut.
b. After completing the compressor installation and testing
~
H: mm (in)/98 N Tension: the system operation, check and adjust the tension of both
(10 kg, 22 Ib) N (kg, Ib) V-belts again.
5.5 - 6.5 637 - 736 3) Low-pressure hose (Flexible hose PsI

New belt
(0.217 - 0.256) (65 -75,143 -165) Connect low-pressure hose with compressor.
4) High-pressure hose (Flexible hose Pd)
6.5 - 1'.s 441 - 637
Existing belt Connect high-pressure hose with compressor.
(0.256 - 0.295) (45 - 65, 99 - 143)
Tightening torque:
(3) Tighten lock nut. Low- and High-pressure hoses:
15 - 25 N'm (1.5 - 2.5 kg-m, 11 - 18 ft-Ib)
Tightening torque:
34 - 44 N'm (3.5 - 4.5 kg-m, 25 - 33 ft-Ib)
(4) After adjusting belt tension, turn adjusting bolt

counterclockwise to lock.
Tightening torque:
4 - 6 N·m (0.4 - 0.6 kg-m, 2.9 - 4.3 ft-Ib)
B. When replacing belt with a new one, adjust its tension to

the specification, then readjust it to the same specification
after running engine for 5 minutes in consideration of its
initial expansion.
b. Ensure that the V-belt is aligned correctly. If it is not, Fig. 32
check for loose bolts.
Be sure to apply compressor oil to the periphery of O-ring.
5) Pulser
(1) Install pulser onto the compressor.
Tightening torque:
15 - 25 N·m (1.5 - 2.5 kg-m, 11 - 18 ft-Ib)
24
Be sure to provide a specified clearance between the pulser's
sending portion and compressor clutch.
n
L4·1534
Pulser
@J Fig. 35
I
L4·1532 If the compressor has been removed from the vehicle, measure
Fig. 33
the amount of oil discharged.
(2) Connect pulser and compressor connector.
3) Removing clutch ASSY
(1) Remove the 8 mm nut and hub nut using CLUTCH
TIGHTENER (925770000) and 13 mm socket.
CLUTCH
TIGHTENER
Fig. 34
6) Battery negative terminal L4·1535
7) Charging refrigerant (Refer to 4-7 "On·Car Service.")
Fig. 36
DISASSEMBLY
Fix the CLUTCH TIGHTENER securely when turning the
1) Discharging refrigerant socket wrench.
(1) When removing the compressor from the vehicle
using manifold gauge, gradually discharge the refrigerant (2) Remove the clutch armature using CLUTCH ARMA·
. from the low pressure side. TURE REMOVER (926130000).
Do not suddenly discharge· the refrigerant, otherwise oil will
also be discharged with the refrigerant.
(2) When using the compressor which has been stored, reo
move the seal cover from the inlet and outlet ports of the
high pressure and low pressure sides.
a. Insert the INJECTOR NEEDLE (926190000) into the hole

in the seal cover, and gradually discharge the high pressure gas.
b. After discharging, remove the seal cover.
2) Discharging oil
Hold the compressor upside down, and discharge the oil from
the refrigerant inlet port [approx. 20 to 50 mQ (0.7 to 1.7 L4-1536
US fl OZ, 0.7 to 1.8 Imp fl oz)]. Fig. 37
25
(3) Remove the spacer ASSY. (7) Remove the 50 mm wedge ring using snap ring pliers.
..
Retain the parts for reassembly.
(4) Remove the 40 mm wedge ring using snap ring pliers.
Snap ring pliers

Snap ring pliers
L4·556
Fig. 41
L4·1537
Fig. 38 Do not reuse the removed part.
Do not reuse the removed part. (8) Remove the stator.
(5) Remove the rotor.
Stator
Rotor
40 mm wedge ring
£t~ ~Key
'to ~ 50 mm wedge ring L4·1540
L4·1538 Fig. 42
Fig. 39
(6) Remove the 5 mm screw fixing the lead wire clamp

using standard screwdriver. Check the terminal for damage.
Do not damage the terminal when storing.
/ (9) Remove the key.
Do not reuse the removed part.
L4·1539
Fig. 40
26
4) Removing shaft seal 5) Removing cover end (R)
(1) Remove the 32 mm snap ring using snap ring pliers. (1) Attach FRONT COVER TIGHTENER (926170000).
32 mm snap
ring
L4-1542
Fig. 45
Fig. 43
Do not damage the cover end (F). Remove dirt and other foreign matter from the tapered surface
at the end of the cover end (F).
(2) Remove cover plate using refrigerant, charging hose,
charging valve and INJECTOR NEEDLE (926190000). (2) Remove the 10 mm socket bolt using 8 mm hexa-
gon wrench or 8 mm HEXAGON SOCKET WRENCH
(926180000).
L4-1541
Fig. 44
L4-1543
a. Attach the seal cover to the inlet and outlet ports, and Fig. 46
apply pressure to the low pressure side.
b. Using waste cloth on the shaft portion receive the cover
plate pushed out
c. Do not use air pressure for pressurizing. Water in the air
will cause rust to be formed inside the compressor. a. Loosen each bolt one turn in diagonal selection, then
d. Be sure to cover the shaft portion with cloth since the cover loosen bolts off.
plate will be ejected suddenly. b. Check the thread and neck portion of each bolt for
e. If it does not eject, push it back, and then press it again. deformation.
f. Do not reuse the removed part
(3) Remove the seal ring using SHAFT SEAL INSTALL·

ER (926120000).
a. Using the SHAFT SEAL INSTALLER, push the ring while

rotating it slowly in either direction, then carefully withdraw
it.
b. Do not reuse the removed parts.
27
(3) Remove the cover end (R) using plastic hammer. (2) Remove the shell packing.
a. Clean the packing surface of the shell using a knife or the

like.
b. Replace the shell packing with a new one.
(3) Remove the cover end (F).
Cover end (F)

Cover end (R)
L4·1544 Cylinder
head (Fl
Fig. 47
Slowly withdraw by holding with a hand. If hard to remove,

tap the flange portion lightly by diagonal selection with a
plastic hammer.
Fig. 49
(4) Remove the Q·rings.
115 mm, 110 mm I 63 m m
Do not reuse the removed D·rings. (4) Remove the a·rings.

115 mm, 110 mm, 63 mm
(5) Remove the cylinder head (R) and SV plate.
Replace the D·rings with new ones.
a. Do not damage the seat surface.
(5) Remove the cylinder head (F) and SV plate.
b. Do not deform the SV plate when removing.
a. Do not damage the seat surface.
6) Removing cover end (F) b. Do not deform the SV plate when removing.
(1) Remove the shell using plastic hammer.
INSPECTION
Shell
a. After washing the parts, dry them naturally; avoid use of
compressed air for drying, because water in the air may be
trapped inside the compressor.
b. Check each part visually to see whether it can be used
again by referring to "Disassembled Parts Check List".
L4·1545
Fig. 48
a. Place the shell with its clutch side facing up, and pull it off
upward while tapping the flange portion with a plastic
hammer.
b. Use a stand (90 mm cylinder) to facilitate removal of shell.
28
Parts Check List
Part name Check point
Armature (1 ) Rotor contacting surface for uneven wear or sign of uneven contact.
(2) Plate spri ng for permanent set, deformation, cracks, or breakage.
(3) Key groove for deformation.
(4) Shaft fitting surface for seizure or fretting.
(5) Disk and hub for offset.
(6) Stopper rubber for hardening or missing.
Rotor (1 ) Armature contacting surface for uneven wear or sign of uneven contact.
(2) Pulley for deformation or crack.
(3) Bearing for seizure, damage, or leakage of grease.
(4) Bearing for slackening or noise in rotation.
Stator (1 ) Resin and coil portion for burn or projected coil.

(2) Harness for disconnection, or broken coating.
Shell (1 ) Inlet port sealing surface for damage.

(2) Threaded portion for deformation or damage.
(3) Cylinder contacting surface (inside) for dents or deformation.
Shaft seal (1) Seal ring seating surface for damage or sign of uneven contact.
(2) Seal ring for crack, break, or abnormal wear.
(3) O-ring for hardening, deformation, or crack.
(4) Spring for permanent set.
(5) Case for deformation or crack.
Cover plate (1 I Sealing surface for damage, roughness, sign of uneven contact, or abnormal wear.
(2) O-ring groove for damage.
Cover end (F) (11 Shell packing surface for damage, or deformation.
(2) Beari ngfitti ng surface for abnormal wear.
(3) Cylinder head fitting surface for damage, or deformation.
(4) Cracks, deformation, or breakage.
Cylinder head (1 ) Valve for floating up. (Any floating up of a valve is unpermissible.)
(2) Valve for damage, cracks, deformation, or rust.
(3) Plate for rust.
(4) Valve seating surface for flaws, deformation, or sign of uneven contact.
(5) Discoloration by temperature rise.
SV plate (1 ) Damage, crack, deformation, or rust.
Cylinder (1 ) Whether the cylinder rotates smoothly when the shaft is manually turned.
(2) Cylinder shaft for axial play, or noise in rotation.
(3) Cylinder for crack or damage.
(4) Swash plate slipper sliding surface for flaws, abnormal wear, or seizure.
(5) Shaft for deformation, damage, abnormal wear; key groove for damage; 8 mm bolt for
damage; armature fitting surface for excessive fretting.
Cover end (R) (1 ) Cylinder head (Rl contacting surface for flaws, or deformation.
(2) Separator for incorrect positioning, cracks, or deformation.
(3) Cracks, deformation, or damage.
29
ASSEMBLY Cylinder head (F) Cylinder head (R)
When reassembling, wash each part in clean washing fluid

(trichlene or gasoline) and left dry, then check for damage or
any other faults.
Do not reuse the packings, a·rings keys and snap rings, reo
place them with new ones when reassembling.
1) Assembling cover end (F)

(1) Fit the knock pins in the knock pin holes of the
cylinder ASSY. Gas pipe position L4·567
(2) Assemble the 12 mm a'ring, SV plate, and cyl inder
Fig. 52
head (F) in this order.
12 mm O-ring b. Coat the a·ring with oil when assembling.

c. Carefully assemble the SV plate into correct position.
* (Two knock pin holes will not fit if the plate is incorrectly
positioned. Make sure the valve of the SV plate fits with
the valve seat of the cylinder.)
(3) Assemble the a·ring (110 mm, 63 mm) and seal ring
using SHAFT SEAL INSTALLER (926120000).
L4·666
Fig. 50
110 mm a·rlng
Co
C
to
L
L4·668
Fig. 53
I
...
L4·566 "
Fig. 51
a. Coat the O·ring and seal ring with oil when assembling.
b. Insert the seal ring by aligning the cut portion of the ring
with the cut portion in the shaft.
c. Do not damage the a·ring of the seal ring with the sharp
a. Be careful not to confuse cylinder head (F) with cylinder end of the key groove. Be sure not to damage the sliding
head (R). surface.
(Assemble it so that the gas pipe is aligned with the 12 mm
hole.) (4) Install the cover end (F).
30
Cover end (F)
L4-569 L4-1546
Fig. 54 Fig. 56
Install the cover end (F) so that the terminal, when installed b. After installing the shell, turn the assembly upside down by
the coil, will face the same side as the shell inlet port. holding the shaft.
2) Assembling cover end (R)
(5) Attach the front cover tightener using FRONT
(1) Fit the knock pin into the knock pin hole of the
COVER TIGHTENER (926170000).
cylinder ASSY.
(2) Install the 12 mm O-ring, SV plate and cylinder head
Remove dirt and other foreign matter from the tapered surface (R) in this order.
at the end of the cover end (F).
(6) Install the shell packing.
a. Coat the packing with oil.

b. If the packing is protruded, re-adiust its position.
(7) Insert the shell.
Fig. 57
Shell
i Fig. 55
L4-1545
a. Install the shell so the oil reservoir of the cylinder will be L4-1548
at the lower portion. Fig. 58
31
a. Coat the Q-ring with oil when assembling.

b. Carefully install the SV plate into correct position.
(3) Install the O-rings.

110 mm, 63 mm
HEXAGON SOCKET
WRENCH
L4-1551
Fig. 61
Tighten bolts lightly by diagonal selection, and finally tighten

to the torque of 19 to 21 N·m (1.9 to 2.1 kg-m, 14 to 15
ft-Ib).
L4-1549
Fig. 59 3) Installing shaft seal
(1) Install the cover plate fitted in advance with the 28
mm O-ring in its outer groove into the cover end (F) using
SHAFT SEAL INSTALLER (926120000).
Coat the Q-rings with oil when assembling.
a. Check the Q·ring for damage.
(4) Install the 115 mm O-ring. b. Apply oil to the O-ring.
Coat the Q-ring with oil when assembling. (2) Install 32 mm snap ring using snap ring pliers.
(5) Install the cover end (R).
Cover end (R)
32 mm snap
ring
L4-558
L4-1550 Fig. 62
Fig. 60
Make sure the snap ring is fitted correctly into the groove.
4} Installing clutch ASSY

(6) Tighten the 10-mm hexagon socket head bolts togeth· (1) After installing the stator, install 50 mm wedge ring
er with the wave washers using hexagon wrench, torque using snap ring pliers.
wrench and 5-mm hexagon socket wrench.
32
a. Thoroughly wipe off dirt and oir from the clamp mounting
surface on the compressor side.
b. Do not damage the lead and earth wires.
c. Avoid interference of the lead and earth wires with the
pulley.
(3) Carefully install the rotor while rotating it by a hand.
Remove dirt and oil from the armature contacting surface.
(4) Install the 40 mm wedge ring using snap ring pliers.
L4-1552
Snap ring pliers
Fig. 63
/
Snap ring pliers
L4-1537
Fig. 66
Install the wedge ring with its tapered surface facing up.
L4-1553
Fig. 64 (5) Install the key to the key groove in the shaft.
a. Do not damage the coil bearing portion.

b. Install the wedge ring with its tapered surface facing up.
(2) Tighten 5 mm x 8 screws to secure the clamp using

Ph illips-head screwdriver and torque driver.
Tightening torque:
2.7 - 3.3 N·m (0.28 - 0.34 kg-m, 2.0 - 2.5 ft-Ib)
Torque driver
L4-1555
Clamp
Fig. 67
Make sure the key is free from burrs or any other damage.
(6) Install the spacer ASSY using thickness gauge.
Spacer sizes:
L4-1554 Thickness 0.1 mm (0.004 in), 0.3 mm (0.012 in),
Fig. 65 0.8 mm (0.031 in)
33
Spacer ASSY
L4-1556 L4-1558
Fig. 68 Fig. 70
Adjust the spacer ASSY so that the gap between the pulley Measure 150 mQ (5.1 US fl oz, 5.3 Imp fl oz) of oil using a
and armature (armature gap) is within 0.5 to 0.8 mm (0.020 measuring cylinder, and charge oil from the inlet port using a
to 0.031 in). plastic oiler. [If some oil is already charged in the cycle of the
cycle carrier, adjust the amount of new oil to be charged so
(7) Install the armature while aligning it with the groove. that the total amount will be 150 mQ (5.1 US fl oz, 5.3
Imp fl oz) in the cycle.]
Remove dirt and oil from the rotor contacting surface.
(2) Run the compressor on the cycle carrier for checking
(8) Install the 8 mm nut and hub nut using CLUTCH DV leakage, and also for checking compressor perform-
TIGHTENER (925770000), torque wrench and 13 mm ance.
socket.
Before starting the operation, be sure to evacuate the refriger-
Tightening torque: ant cycle to avoid air trapped inside.
19 - 21 N·m (1.9 - 2.1 kg-m, 14 - 16 ft-Ib)
(3) Charge refrigerant using INJECTOR NEEDLE
(926190000).
a. Charging pressure 98 to 147 kPa (1.0 to 1.6 kg/cm l , 14 to

21 psi).
b. Refer to "Charging Refrigerant" in manual.
CLUTCH
TIGHTENER TEST
L4-t557
NOISE TEST
Fig. 69 Open the compressor outlet and inlet ports, and rotate the
armature. No abnormal noises nor irregular rotation must be
noted inside the compressor and magnet clutch.
COMPRESSION TEST
Close the compressor outlet or inlet port with a finger, and
5) Charging oil and refrigerant rotate the armature, and check for normal compression or
(1) Charge oil using measuring cylinder and plastic oiler. suction.
34
GAS LEAKAGE TEST Condenser
Charge R-12 into the compressor and pressurize (to the
saturation pressure). Then check the gas leakage by using an REMOVAL AND INSTALLATION
electric leak detector.
1) Immediately direct air to the shaft seal portion before 1) Disconnect battery negative terminal.
measurement in order to blow off any gas from around the 2) Discharge refrigerant from low pressure side.
sea. 3) Remove horn ASSY, stay, hood lock ASSY and front
In this state, the deflection of the needle must be less than hood cable cover.
1 x 10-4 mmHg-Q/sec (20 gr/year).
2) For other portions, deflection of needle must be less than
0.6 x 10-4 mmHg·Q/sec (12 gr/year).
CLUTCH ASSEMBLY OPERATION TEST

1) Rotate the rotor with a hand. No abnormal noise nor play
must be noted. /;
2) Apply a voltage of 12V (battery voltage) across the coil
terminals. The clutch plate must be attracted. e 1,. V,.-
Hood cable cover
~ ~L4.'559
3) Make sure the armature gap is 0.5 to 0.8 mm (0.020 to
0.031 in).
BREAK·IN TEST
--=====lU : :i i i! ! : !:il~ ~~~

After completing the above-mentioned tests, install the com-
pressor to the refrigerant cycle unit (if unavailable, actual
vehicle). and perform break-in operation for 30 minutes under
the following conditions:
Stay
Conditions:
Rotating speed: ',800 rpm
High pressure: 1,324 ± 98 kPa
(13.5 ± , kg/cm 2, 192 ± 14 psi)
Low pressure: 147 - 196 kPa
(1.5 - 2 kg/cm2, 21 - 28 psi)
L4-1560
Fig. 71
DV LEAKAGE TEST
Stop the compressor when the pressure difference between the
2
outlet side and inlet side is 686 kPa (7 kg/cm , 100 psi). 4) Disconnect pipe connections.
Pressure rise in the inlet side must be less than 490 kPa
(5 kg/cm2, 71 psi) within five minutes.
- , \ ) - - r - - - - - - - . - - c - - - - - - - - ; " " " ' / " - Pipe bracket -

'--1 U U
L4-1561
Fig. 72
35
5) Remove two upper bolts and then take out the con- Receiver Drier
denser.

1) Disconnect battery negative terminal.
2) Discharge refrigerant.
3} Remove canister and place it on the engine.
4) Disconnect two pipes from receiver drier.
Fig. 73
6) The condenser should be installed in the reverse order in

which it was removed.
When installing the condenser, pay attention to the following:
Before connecting the pipe, be sure to apply oil to the Fig. 74

periphery of O-ring.
Tightening torque: 5) Remove receiver drier by removing mounting bolts.

Left-hand piping nut
15 - 25 N·m (1.5 - 2.5 kg-m, 11 - 18 ft-Ib)
Right-hand piping nut
10 - 20 N·m (1.0 - 2.0 kg-m, 7 - 14 ft-Ib)
Bracket bolt
5 - 10 N·m (0.5 - 1.0 kg-m, 3.6 - 7.2 ft-Ib)
Upper bolts
15 - 25 N·m (1.5 - 2.5 kg-m, 11 - 18 ft-Ib)
Fig. 75
INSPECTION
1) Make sure the condenser fins are free from dust and The receiver drier contains a desiccant. Be sure to put a
insects. If the fins are clogged, clean by blowing air or water blind plug in the detached receiver drier to protect it from
through them. moisture.
To prevent dust and water from getting into the condenser, 6) Install the receiver drier in the reverse order of removal.
this work must be done when the condenser is installed in
Tightening torque:
an actual vehicle.
Mounting bolt
2} Check all of the condenser's parts to see if they show any 5 - 10 N·m (0.5 - 1.0 kg-m, 3.6 - 7.2 ft-Ib)
Pipe nut
sign of oil seepage. Should oil ooze or gas leak from a particu-
lar part, replace it with a new one.
10 - 20 N·m (1.0 - 2.0 kg-m, 7 - 14 ft-Ib)
36
Evaporator 2) Remove lower case from evaporator.

3) Remove the component parts from evaporator.
(1) Thermostat
(2) Disconnect the connection between the expansion
valve and pipe from receiver drier.
1) Disconnect battery negative terminal. (3) Remove the expansion valve from the header pipe.
3) Disconnect discharge pipe, suction pipe and grommets.
Expansion valve
/ ~
L4-524
~ Discharge pipe
~ (high-pressure) \ Fig. 78
Fig. 76
4) Remove under cover trim.

5) Remove pocket ASSY.
6) Disconnect wiring harness from evaporator thermostat.
7) After removing two bands, remove evaporator.
8) Install the evaporator in the reverse order of removal.
4) Check to see if the evaporator fins are clogged. If they
When installing the evaporator in the car body, make sure the are, clean them with compressed air.
wiring harness and vacuum hose do not get caught between the
body parts. Water must never be used to clean the evaporator.
5) Check parts that have been removed for cracks or

scratches, and repair or replace them with new ones, if neces-
DISASSEMBLY & ASSEMBLY sary.
6) Reassemble the evaporator in the reverse order of dis-
1) Using a flat-bladed screwdriver, remove the eight clamps assembly. Observe the following points during the reassembly
and the evaporator upper case. process:
(1) Confirm that the O-ring is inserted in the specified
position.
(2) Tightening torque
Tightening torque:
Expansion valve's mounting nut
2.5 - 4.4 N·m (0.25 - 0.45 kg-m, 1.8 - 3.3 ft-Ib)
Discharger pipe union nut
10 - 20 N'm (1.0 - 2.0 kg-m, 7 - 14 ft-Ib)
Nut on discharge side
10 - 20 N·m (1.0 - 2.0 kg-m, 7 - 14 ft-Ib)
Nut on suction side
L4-523
20 - 29 N'm (2.0 - 3.0 kg-m, 14 - 22 ft-Ib)
Fig. 77
37
Condenser Fan Assembly INSTALLATION

REMOVAL AND DISASSEMBLY Installation is in the reverse order of removal.
2) Remove pulser. Tightening torque:
3) Remove the bolts from upper side of fan shroud. Fan motor ASSY to shroud:
5 - 10 N·m (0.5 - 1.0 kg-m, 3.6 - 7.2 ft-Ib)
Condenser fan shroud to body:
5 - 10 N·m (0.5 -1.0 kg-m, 3.6 -7.2 ft-Ib)
I
Il L4-1566
Fig. 79 Flexible Hose
With the following cautions, replace flexible hoses with new
ones if they are damaged or swollen.
(1) The flexible hoses should be free from twists and
tension after they have been connected.
(2) The flexible hoses must not be bent forcibly.
4) Raise the car.
5) Disconnect the fan motor connector, and remove the bolt
from lower side of fan shroud.
REMOVAL

3) Remove low pressure hose.
(1) Remove hose attaching bolts from compressor side.
(2) Disconnect the connector at evaporator unit.

Sub fan shroud
Main fan shroud
L4-1567
Fig. 80
6) Lower car to the floor.

7) Remove condenser fan assembly.
8) Remove fan motor and fan from shroud.
Fan and fan motor are balanced and must not be separated. Fig. 81
38
(3) Unclamp the hose. Relay and Fuse
4) Remove high-pressure hose. The air conditioner relay, main fan control relay, and air
(1) Remove hose attaching bolts from compressor side. conditioner fuse are installed as shown in the figures below.
(2) Remove bolt holding pipe to condenser.

IQII
Radiator fan relaj I
(3) Disconnect the pipe connection at condenser. (Main fan) 6 '1-1r
L4-1570
Fig. 83
Fig. 82
INSPECTION
Check conduction with a circuit tester (ohm range) according

to the following table .
• Ale relay, Fan control relay, Condenser fan relay
INSTALLATION
Installation is in the reverse order of removal.

Tightening torque for flexible hose connections:
Tightening torque:
Low-pressure pipe to evaporator unit:
20 - 29 N·m (2.0 - 3.0 kg-m, 14 - 22 ft-Ib)
High-pressure pipe to condenser:
15 - 25 N·m (1.5 - 2.5 kg-m, 11 - 18 ft-Ib)
Pipe (high and low) to compressor:
15 - 25 N·m (1.5 - 2.5 kg-m, 11 -18 ft-Ib)
About 80n between
Pipe holding bolt (condenser side):
@ and @
5 - 10 N·m (0.5 - 1.0 kg-m, 3.6 - 7.2 ft-Ib)
oon between CD and ® L4-1571

Be sure to clamp and clip the hose. Fig. 84
39
Pressure switch Microswitch

The pressure switch is provided with a main fan control switch REMOVAL AND INSTALLATION
and a high/low-pressure switch.
1) Select "Heat" mode on control wing.

2) Lift up a steering wheel.
RW} High/Low pressure switch 3) Remove driver's side lower cover.
BW
4) Remove side ventilation duct.
5) Disconnect harness couplers.
6) To facilitate the work, push up the harness coming from
meter ASSY into steering column lower cover.
LW l Fan control 7) Remove microswitch.
LR r switch 8) Installation is in the reverse order of removal.
L4-1572
Fig. 85
1) Disconnect battery negative terminal. L4·1288

2) Discharge refrigerant. Fig. 87
3) Remove canister and place it on the engine.
4) Disconnect pressure switch connector and remove pres-
sure switch.
Fig. 86
5) Install pressure switch in the order of its removal.
Coat O-ring of pressure switch with compressor oil before

installing pressure switch.
Tightening torque:
15 -18 N·m (1.5 -1.8 kg-m, 11 -13 ft-Ib)
40
Pulser Amplifier REMOVAL AND INSTALLATION
FUNCTION 1} Remove instrument panel lid and pocket.

2} Remove front shelf.
3} Disconnect body harness (6-pole connector) from ampli·
fier.
o
4} Loosen the bolt installing evaporator and remove pulser
o amplifier.
L4-539
Fig. 88
Fig. 89
5) Install in the reverse order of removal.
Terminal
Description
No. Cable color Destination
Supplies current to the pulser amplifier through the air conditioner

1 RY Power supply switch and triple (low-pressure) switch for the purpose of acti-
vating accessories.
2 y Ignition coil (-) Transmits engine rpms to the pulser amplifier in pulse form.
Transmits compressor rpms to the pulser amplifier for comparison

3 R Pulse sensor (-)
with ignition pulses.
When compressor rpms drop below 75 to 80% of engine rpms, the
4 G Pulse sensor (+)
RB's grounding circuit will open.
When the thermostat activates to close the ground circuit with the
Magnetic clutch air conditioner switch "ON", the clutch will engage.
5 RB
drive relay coil When compressor is locked, the thermostat activates to open the
ground circuit, disengaging the clutch.
The thermostat opens and closes the ground circuit, depending on

6 LB Ground
the temperature of the evaporator.
41
TROUBLESHOOTING
Air Conditioning System Diagnosis
Follow this chart first when following trouble. occur.
Insufficient Cooling, Noisy

Operation
Check Compressor Belt Tension.

- Refer to SOA Information
No. 10-41-85.
I I
Insufficient Belt Tension Normal Belt Tension
I
Check Gap between Clutch
Face and Pulser Sensor.
Check Belt.
[Normal Gap is 3 ± 1 mm
(0.12 ± 0.04 in)]
I I
I I I I
Belt is Broken. Belt is Norma1. Gap is not Norma1. Gap is Normal.
1
Replace Faulty Belt
I
Adjust Belt Tension to
I
Adjust Gap to 3±1 mm
I
Check Other Items.
with Genuine Belt. 314 to 432 N (32 to (0.12 ± 0.04 in).
44 kg, 71 to 97 Ib).
42
I I I
Noisy
I Insufficient cooling I I
I I Blower does not Compressor
rotate. does not run.
I 1 I I
I Compressor OFF ICompressor ON I Bubbles in sight glass I No bubbles in sight glass I Refer to "Blower Refer to "Com-
I Motor pressor
I
Blower makes Compressor
I
When engine
I
Check refrigeration line
I
With manifold gauge, check system pressures.
Diagnoses". Diagnoses".
noise. itself makes rpm is changed, for gas leaks, and repair Measure temperature of discharge air.
Repair or re- noise. there are reso- leaks if any. Charge Refer to "Performance Test".
place blower. Repair or nant sounds. refrigerant to correct
replace com- Retighten com- level. In case of too Temperature of
pressor. pressor bracket many leaks, stop com- outside air 21 (70) 26.5 (SO) 32 (90) J8 (100)
I bolts.
Piping is resc-
pressor, discharge the
system, evacuate and
°c (OF)
Bearings of com pres-
sor clutch or idler
pulley make noise.
I
I
Belt is loose.
nating. Add
cramp.
recharge the system.
As necessary, replace
receiver drier.
Suction pressure
kPa (kg/cm 2, psi)
1,961 - 2,746
(20 - 28,
284 - 398)
2,256 - 3,236
(23 -33,
327 - 469)
2,746 - 3,727
128-38,
398 - 540)
3,629 - 4,707
(37 - 48,
526- 683)
»
JJ
Repair.
Adjust belt. 13,534 - 16,476 14,907 -18,143 17,162 - 20,497 19,712 - 23,046
Air in system may Head pressure ()
cau. bubbles in sight kPa (kg/cm2~ psi)
(138-168, (152 - 185, (175 - 209, (201 - 235,
o
glass.\
1,962 - 2,389) 2,161 - 2,631) 2,489 - 2,972) 2,858 - 3,342)
z
Temperature
difference (Outside 10 - 13.5 10.5 -14.5 13 -17 15 - 19.5 o
air - discharge air!
°c (OF)
(50 - 56) (51 - 58) (55- 63) (59-67) --I
,JIo.
w •
o
Engine speed : 1,500 rpm Z
• Fan switch : Highest position
Z
• Mode switch : AlC MAX (USA model)
G)
en
-<
en
--I
System pressure and temperature of discharge air are Temperature of discharge
m
abnormal. Refer to "Performance Test Diagnoses"
for detail.
air is abnormal, but system
pressure is normal. s:
I I
I
Suction pressure is low.
I
I
I
Suction pres-
sure is high.
~ Head pressure is
high.
I I
Suction pressure is
high, while head is
Check air flow system.
Refer to "4-6 HEATER
I
Check grommets on car's dash panel
for air leaks; check other seals of
I I I I low. AND VENTILATOR". car.
Pipe at receiver Fin and tube of Expansion valve is Overcharge of refrigerant.
drier outlet has
low temperature.
Receiver drier is
evaporator have
some dents.
Replace or repair
open excessively,
or expansion
O-ring is damaged.
Discharge some of refrig-
erant to correct level. I
Valve or gasket of
Air is mixed in. Discharge
restricted. Replace evaporator. Replace expansion compressor is dam-
system, and replace drier.
raceiver drier. valve. aged.
I Evacuate and recharge
Repair or replace
Expansion valve is system.
compressor.
close excessively, Condenser's fin is dented
or gas leakage from or clogged with dust.
thermo bulb. Clean exterior surface
Replace expansion with_ter. ~
I
valve.
.....
Performance Test Diagnoses As to the method of a performance test, refer to the item of
Of various conditions caused to the air conditioning system, "Performance Test".
Each shaded area on the following tables indicates a reading of
the characteristics revealed on manifold gauge reading are
the normal system when the temperature of outside air is
shown in the following.
32.5°C (91°F).
Condition Probable cause Corrective action
I INSUFFICIENT REFRIGERANT CHARGE I

Insufficient cooling. Refrigerant is small, or 1. Lea k test.
Low·pressure Bubbles appear in sight leaki ng a little. 2. Repair leak.
gauge glass.
3. Charge system.
Evacuate, as necessary, and

recharge system.
Fig. 90 A26-069
Stop compressor immedi-

I ALMOST NO REFRIGERANT I ately.
Low-pressure No cooling action. Serious refrigerant leak. 1. Leak test.
gauge In sight glass appear a lot 2. Discharge system.
of bubbles or something
3. Repair leak(s).
4. Replace receiver drier if
like mist.
necessary.
5. Check oi.! level.
6. Evacuate and recharge
system.
A26-070
Fig. 91
FAULTY EXPANSION VALVE
Slight cooling. Expansion valve restricts If valve inlet reveals sweat

Low-pressure
refrigerant flow. or frost:
gauge Sweating or frosted expan-
• Expansion valve is clog- 1. Discharge system.
sion valve inlet.
ged. 2. Remove valve and clean
• Expansion valve is in- it. Replace it if neces-
operative. sary.
Valve stuck closed. 3. Evacuate system.
Thermal bulb has 4. Charge system.
lost charge. If valve does not operate:
1. Discharge system.
A26-Q71 2. Replace valve.
3. Evacuate and charge
Fig. 92 system.
44
Insufficient cooling. Expansion valve allows too Check valve for operation.
Low-pressure much refrigerant through If suction side does not
Sweated suction line.
gauge evaporator. show a pressure decrease,
replace valve.
Fig. 93 A26-072
No cooling. Faulty seal of O-ring in 1. Discharge system.
Low-pressure Sweating or frosted suc- expansion valve. 2. Remove expansion
gauge tion line. valve and replace 0-
ring.
3. Evacuate and replace
system.
A2S-073
Fig. 94
I AIR IN SYSTEM I
Insufficient cooling. Air mixed with refrigerant 1. Discharge system.
Low-pressure
Sight glass shows occasion- in system. 2. Replace receiver drier.
gauge
al bubbles. 3. Evacuate and charge
system.
A26-074
Fig. 95
IMOISTURE IN SYSTEM I
After operation for a Drier is saturated with 1. Discharge system.
Low-pressure while, pressure on suction moisture. Moisture has 2. Replace receiver drier
gauge side may show vacuum frozen at expansion valve. (twice if necessary).
pressure reading. During Refrigerant flow is restrict- 3. Evacuate system com-
this condition, discharge ed. pletely. (Repeat 30-
air will be warm. As warn- minute evacuating three
ing of this, reading shows times.)
39 kPa (0.4 kg/cm 2 , 6 psi) 4. Recharge system.
vibration.
A2S-Q75
Fig. 96
45
IFAULTV CONDENSER I
No cooling action: engine Condenser is often found • Check condenser cool-
may overheat. not functioning well. ing fan.
L ow-pressu re
Bubbles appear in sight • Check condenser for
gauge glass of drier. dirt accumulation.
Suction line is • Check engine cooling
very hot. system for overheat.
• Check for refrigerant
overcharge.
If pressure remains high in

spite of all above actions
taken, remove and inspect
A26-076 the condenser for possible
oil clogging.
Fig. 97
IHIGH PRESSURE LINE BLOCKED I

Low-pressure Insufficient cooling. Drier clogged, or restric- 1. Discharge system.
gauge Frosted high pressure tion in high pressure line. 2. Remove receiver drier
liquid line. or strainer and replace
it.
system.
A2S-077
Fig. 98
IFAULTV COMPRESSOR I
Low-pressure Insufficient cooling. Internal problem in com- 1. Discharge system.
gauge pressor, or damaged gasket 2. Remove and check
and valve. compressor.
3. Repair or replace com-
pressor. I
4. Check oil level.
5. Replace receiver drier.
system.
Fig. 99 A26-078
46
Blower Motor Diagnoses
Blower motor inoperative

I I
I Check two 15A fuses for blower relay. I
Fuse OK
Fuse blown
I I
Locate short-circuited spot and repair or replace Ground one of lead wires, blue (4 speed), blue/white
faulty parts. (3 speed)' blue/yellow (2 speed), yellow/white (1 speed)
leading to blower switch.
Blower runs.
I I Blower does not run.
Check ground circuit connection and lead wire con· Ground blue wire of blower motor.
nection. When no problem is found, replace blower
speed switch.
Blower runs.
I l Blower does not run.
Check connection of resistor. When no problem is Connect 12-volt test light to green/white wire lead-
found, replace resistor. ing of blower motor.
Light ON
I I Light OFF
I Check lead wire connection. When no problem is

found, replace blower motor.
(Ctd.)
47
I
Connect 12·volt test I ight to blue wire leading to
relay.
I
I I
I Light ON
I 1
Light OFF
~
I I
Check lead wire connection. Check connector and check fuse holder, too.
When no problem is found, replace relay. Repair or replace damaged parts, if any.
Fuse Relay
Battery -
Resistor Blower
speed
switch
L6·386
Fig. 100
48
oo
I I I
..
3
'a
CI)
en
Compressor clutch is
not engaged.
I
I J 1
I Compressor clutch ;5 engaged, but
compressor does not run.
I
I I
Compressor oil leaking
I
..c
en
o
Lead wire of com- Compressor clutch Clutch slipping. Belt slipping. Seizured com- Air-blow on spot where oil leak evidence is 5"
pressor clutch is coil has voltage pressor. found. Then check for refrigerant leaks ea
dead. decreased to less t'-' l 1 using leak detector. :::J
I
I I
I
10.5V.
I
I • Check and re- Internal problem I
I I 1.
I
Check belt ten-
Refer to "Compr-es- adjust gap of sion and adjust it. in compressor Refrigerant leak- No refrigerant
sor Clutch Diag- clutch. If belt is worn cylinder. ,ng. leaking.
noses". Ground terminal of • Clean oil or out or damaged, Check system.
I I I 1
coil is poor at con- dust on con-- replace it. Repair or replace
nection.
Repair connection.
tact surface of
clutch.
if necessary.
Repair or replace Wipe - clean oil »
Refer to "Pulser If slipping coo-
compressor. with rag.
JJ
and Related Cir· I tinoes, replace
o
cuits Diagnoses".
In case dutch is not
engaged yet, replace
compressor
clutch. oz
compressor clutch.
o
--4
~
I High torque I o
Z
I I z
Overcharge of refrigerant Air in refrigeration system G>
I en
Discharge refrigerant gas to an extent that Discharge system from service
-<
en
sight glass of receiver drier has only a few va~ on discharge side.
--4
bubbles.
Engine speed: 1,500 rpm
Evacuate and recharge the sys-
tern.
m
~
I I I
When torque is still great,
Check for dis- Discharge pres-
repair or replace cOlllpnrssor.
charge pressure. sure is not re-
OK if discharge duced.
pressure is
reduced.
I
~
I
""
Compressor Clutch Diagnoses
I Compressor clutch is not engaged. I

I
I Check both 15A fuses for blower relay.'
I Fuse blown. I l Fuse OK I

I I
Locate short-circuit spot, and repair or replace dam·
aged parts.
Check AIC relay fuse 15A in engine compartment.
1
I
I Fuse blown.
I
I
I Locate cause of problem and repair.
I
I
I Fuse O.K.
I
I
Connect 12-volt test light to L wire of AIC relay. I
I Ground the other end of test light.
I I
I Light ON
I I Light OF F
I
I I
Check lead wire and ground wire of compressor clutch Connect 12-volt test light to LR wire of relay.
for connection. When there is nothing wrong with
them, replace compressor clutch.
I Ground the other end of test light.
I
I
I I
1~ _______L_ig_htrO
__N______ ~1 l Light OFF
I
I
Replace air conditioner relay. I I
I
I Ground AIC relay RG lead wire. I
I I
Clutch is ergaged (ON). I Clutch is not engaged (OFF).
I
I I
Short G and R lead wires (of body harness) running
to pu Iser ampl ifier.
l Replace AIC relay. [
I I
Clutch is engaged (ON). I Clutch is not engaged (OFF).
I
I I
Replace pulser or amplifier to determine which is
faulty.
I Ground LB lead wire running to thermostat.
I
I
II
Clutch is engaged (ON). I Clutch is not engaged (OFF).
I
I I
Check ground circu it of mode selector switch. I Replace thermostat.
I
50
Radiator Fan (Main Fan) Diagnoses
I Radiator fan (main fan) will not operate. I
I Check 20A fuse for red iator fan (main fan). J
l Fuse is blown. I I Fuse is normal. I
Locate short-circuited spot, and repair or re- Connect one end of a 12-volt test light to main
place damaged parts. fan relay LR wire, and ground the other end.
I light ON
I l light OFF
I
Turn AIC switch ON. Check wire discontinuity on the side of electric
Short LB and YW lead wires running to triple power source.
switch connector.
Fan does not turn.

I Fan turn
I I J
Check lead wire connections. Connect one end of a 12-volt test light to
When no problem is found, replace triple switch. radiator fan (main fan) motor LW wire and
ground the other end.
light ON light OFF

I I I I
Check rediator fan (main fan) motor connector. Check lead wire connections.
If the connector is in good condition, replace When no problem is found, replace radiator
rediator fan (main fan) motor. fan (main fan) relay.
51
Condenser Fan (Sub Fan) Diagnoses
I Condenser fan (sub fan) will not operate.

J
I
I Check 20A fuse for condenser fan (sub fan).
I
I
I
Fuse is blown. Fuse is normal.
I I I I
I
Locate short·circuited spot, and repair or replace Disconnect ground terminal from battery and turn
damaged parts. fan with your hand.
J
I
I Fan turns smoothly.
I l Fan does not turn smoothly. I
I
Check if fan turns when fan motor lead is Replace fan motor ASSY* 1.
connected directly to battery terminal.
I
[ Fan turns. I I Fan does not turn. I
I
Check condenser fan (sub fan) relay. Replace fan motor ASSY* 1.
I No
Yes
l Faulty relay
I
I
Disconnect connector from relay (A/C, radiator
Replace condenser fan (sub fan) relay.
fan, condenser fan) and check for continuity. *2
Yes I No
[ Normal I Check diode inside fender and replace if faulty.
1
Connect battery ground terminal. Check if 12

volts are produced at LW lead of condenser fan
relay connector when ignition key is turned ON.
I No
Yes
Check power harness and repair or replace if
faulty.
,r
OK
52
*1: Replace fan and fan motor as a unit because they are balanced.
*2: Connect tester leads to LR leads of condenser fan relay connector, YW lead of radiator fan relay connector and L lead of
AIC relay connector. Check for continuity, as shown in Table below.
Tester lead
Positive (+) Negative (-)

I
LR L
No continuity
LR YW
L LR
Continuity
YW LR
53
Pulser and Related Circuits Diagnoses
Set A/C switch, Blower switch, High/Low

pressure switch to ON.
Disconnect 2-pin (pole) connector from

pulser plot to check if magnetic clutch turns
off.
I Yes
I Normal I Conduct continuity test of wiring from
amplifier to negative side (-) of ignition
coil. Does continuity exist?
I
Yes INo
Disconnect ground wire of AIC relay ex-
citing coil, leading to amplifier, to see if
I Faulty wiring
I
magnetic clutch turns OFF.
I Yes I No
t Faulty amplifier
J I Faulty relay
I
54
Set A/C switch, Blower switch, High/Low

pressure switch to ON positions.
I Does magnet clutch turn ON? I
INo I Yes
Turn A/C switch OFF and then ON to check if l Normal J

magnet clutch turns ON.
J No I Yes
Is 12-volt power is applied to positive side (+) I Normal I
of A/C relay exciting coil?
INo J Yes
I Check wiring. Measure resistance between pulser's plot termi-

nals to see if it is in the 600 to aoon
range.
IYes I No
Check gap between pawl (protrusion) of clutch Replace pulser plot.
and pulser plot (on clutch side) to see if it is
below 4 mm (0.16 in).
INo I Yes
Adjust gap to 2 to 4 mm (o.oa to 0.16 in). Check to see if 12-volt power is appl ied to
power terminal (+) of amplifier (through wiring
from High/Low pressure switch).
IYes INo
I Faulty amplifier Faulty wiring or switches J
55
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·,
BODY AND EXTERIOR
Page
SUBARU MECHANISM AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Body Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . .. 2
Cross-sectional Structure of Body ............................ 3
1988 Quietness ............................................ 4

Body Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .•.. . 9
Exterior ............................................ . 9
SERVICE DATA ........................................ . 10
Body Datum Points ..................................... . 10
COMPONENT pARTS .................................... . 16
Body Construction ..................................... . 16
Front Hood and Hood Lock ................. '..... '......... . 17
Trunk Lid and Fuel Flap ................................. . 18
Front Bumper ................•..........•............. 19
Rear Bumper ......................................... . 20
Body Parts .......................................... . 21
Cover and Molding ..............................•....... 22
•
Sunroof ................................ ".........•... 23
SERVICE PROCEDURE ................................... . 24
Hood ............................................... . 24
Trunk Lid and Fuel Flap .. "............................... . 25
',' Bumper ............................................ . 26
Body Parts ..................... ; .................... . 36
Outer Accessories ...................................... . 37
Cover and Molding ............. .' ....................... . 38
5-1 BODY AND EXTERIOR

Body Construction
The vehicle body is of monocoque construction built with high tensile strength steel sheets for light weight and rigidity. Corro-
sion preventive steel sheets are utilized where necessary to protect the body against corrosion.
2700 cc
["i\t:;:'}] High tensi Ie strength steel sheet

W. Corrosion preventive steel sheet ~Galvanized steel sheet ... etc.)
_ Galvanized high tensile strength steel sheet
L5-737
Fig. 1
2
BODY AND EXTERIOR
Cross-sectional Structure of Body
.c>
0- \)\. ~ ~
~
A-A
8-8 C-C
0-0 E-E
{1 ~
F-F
J-J H-H I-I
G-G
LS-691
Fig. 2
3
Quietness
Silencers, dual-wall panels, sound-absorbing materials, etc. are utilized in conjunction with a high-rigidity and vibration/noise-
proof body structure in order to provide a quiet passenger compartment.
1) Silencers
They (= asphalt sheets) minimize the transmission of noise/vibration into the passenger compartment.
L5-692
Fig. 3
2) Dual-wall toeboard
The toeboard is a dual-wall design consisting of an asphalt sheet placed between two steel panels to reduce the transmission
of noise and vibration from the engine compartment to the passenger compartment.
_---I
.. /
F ront wJndshlel~y--
-~f _ {'n,,,ument pane'

Silencer
~s;p.n.'
" _-_-==~:====\
Toe-board
L5-693
Fig. 4
3) Sound-absorbing materials
A unit construction type insulator is used respectively for the toeboard, floor, trunk, roof and rear bulkhead section to improve
the sound-absorbing effect and even thicker sound-absorbing material is used in the floor for 2700 cc.
Roof insulator
(2700 ee) Sub-trunk insulator
Trunk insulator and mat
Rear apron insulator
Floor insulator and mat
Front pillar insulator

Toe-board insulator L5-738
Fig. 5
4
BODY ANID (EXTERIOR, 5-1
Body Sealing
1) Sections sealed against entry of water/dust
L5-461
Fig. 6
(1) Detail (1) - Cross-sectional view of sealed sections
RoOf'panel
Seal SECTION "8"

SECTION "A"
Seal
Outer panel,
Seal
SECTION "0"
L5-4S2
Fig. 7
5
5-1 BODY AND, EXTERIOR
(2) Detail (2) - Cross sectional views of sealed sections
Seal -~--.wu..4
SeCTION "e" SECTION "F"
Front pillar
SECTION N~"
SECTION "H"
Fig. 8 L5-463
6
BODY·.i AND EXTERIOR 5-1
(3) Detail (3) - Cross sectional views of sealed sections
VIEW"J"
VIEW"K"
LS-464
Fig. 9
(4) Detail (4) - Engine compartment
L5-465
Fig. 10
7
r
5-1 BODY AND E~XTERIOR
2) Sealed parts
All gauge holes and other holes used during the body manufacturing process are plugged to prevent entry of water and dust.
Anytime the vehicle body has been repaired, etc., the affected holes should be properly plugged with the use of the specified
plugs as shown below.
Unit{ mm (in)
1 Plug 40 (1.57) dia.
2 Plug 28 (1.10) die.
3 Plug 12 (0.47) die.
4 Plug 20 (0.79) die.
6 Plug 36 (1.38) die.
6 Plug 10 (0.39) die.
7 Plug 23 (0.91) die.
8 Plug 10 (0.39) die.
9 Plug 15 (0.59) die.
CD
Section -C
-R: ®
Section -A Section - B
L5-694
Fig. 11
8
t
r BO~ANO EXTERIOR 5-1
~
t
t
,..
Ventilation
r
~
t
f
r
r
r
r
r
r
Front windshield
f
t
r
(
r
r
r
r
From door Rear quarter outer panel
r
r Fresh air inlet port A - (Air outlet)
f
L6·739
J
Fig. 12
r
f
'"
Exterior
Bumper Fuel Flap Opener
The front and rear bumpers are basically composed of a back The fuel flap opener, which can open fuel flap from the
beam with a resin covering. Some of them are painted the driver's compartment, is standard equipment on all models.
sama color as the car body.
Aero-Parts
Rearvlew Mirror Aero-parts are installed on some models for improved aero-
The rearview mirror is aerodynamically designed to reduce dynamic performance during high-speed operation.
wind noise and resistance.
9 /
r 5-1 BODY AND EXlER10R ~...,. • • "L
SERVICE DATA
BODY DATUM POINTS
CENTER STRUCTURE
• Measuring point
Measure dimensions with mounted parts removed.

Unit: mm (in)
Front bumper M12 rear crossmember mounting bolt hole

mounting bolt hole
9.S (0.374) dia. front suspension mounting bolt hole
M6,front bumper mounting
bolt hole M12 rear suspension mounting bolt hole
11 (0.43) dia. front
crossmember mounting
bolt hole
LS-740
Fig. 13
• Alignment - 1
Unit: mm (in)
2700 cc
LS-741
Fig. 14
10
IBODY~~ANDEXTERIOR 5-1
• Alignment - 2
Unit: mm (in)
141 167
(5.55) (6.61)
460 278 282 302
570 (22".44) 161 (6.34) (18.111 . (~.94) 530 (20.87) 111.101 (11.89)
t----~-"""'i-'......---~- 995 (39.171--.foO---t---t
•
r
r
r 12 (0.47) dia.
t, 2700 cc 11 (0.43) dia.
gauge hole
( bolt hole
I
r
t
r
f
r M~
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vIt)
( ........
2700 cc
J
L5-742
I Fig. 15
Tracking gauge
.L All dimensions ,rafer tathe distance between the centers of
hOles when melSured in. ~lIight'line.
':b~1.eft and right dimensio'ns are all symmetrical to each other.
t ~ 'Use a tram tracking gauge to measure all dimensions. If a
r ,_ .
measuring: tape: is used, be extremely careful because it tends
to deflect 01 twist which results in a false reading.
r
L5-136
Fig. 16
11
FRONT STRUCTURE
• Measuring points '
A suffix character "R" or "L"

refers to the right or the left.
AA. AL - Fender mOUntlnghola ~ Front [Bmm (0.31 in) dia., symmetrical]

BR. at tr,RlICliator mountiogpinhotes (16.4 mm (0.646 in) dia., not symmetrical]
CR. CL ~ Radiator mpynting hole, (19 mm (0.15 in) dia •• not symmetrical]
, OR, 0L - Radiator panelatay mounting holes (10 mm (0.39 in) die., symmetrical]
ER, EL - Frbnt crosStneMber mounting holes - Front [11 mm (0.43 in) dia., symmetrical]
FR, FL - Front cl'Otlmembir mounting holes - Rear [11 mm (0.43 in) dia., symmetrical)
GR, GL - StNt mount mountihg hol.1 [9.5 mm (0.374 in) dia., symmetrical]
HR, H L - Fender mou nting hole - Rear [10 mm (0.39 in) dia., $'fmmetrlcal]
I - Wiper motor mounting hole - Center [B mm (0.31 in) dia.]
L5-743
Fig. 17
12
BODY AND EXTERIOR 5-1
• Datum dimensions
, ','"
Unit: mm (in)
AR-HR AR-HL BR -CL

AR -AL HR -HL BR -BL . ~-CL
AL-HL AL-HR BL-CR
560 560 665

1,001 1,360 1,364 1,690 (22.05) (22.05) (26.18)
(39.4" (53.54) (63.70) (66.54) 513· 513· 624·
(20.20) (20.20) (24.57)
DR-HR FR-GL
GR .... GL ER-I EL-I GR - I GL-I
DL-HL FL-GR
1,242 660 550

(48.90) 974 1.028 (25.98) (21.65) 628 479
1,306· (38.35) (40.47) 614· 565· (24.72) (18.86)
(51.42' (26.54' (22.241
·2700 cc
All dimensions refer to the distance between the canten of holes m...red in a
Fig. 18 streight fine. L5-144
13
5-1 BODYe ANOEXTERIOR
DOOR
Unit: mm (in)
L, L2 L3
1,140.4 1,444.0 1,468.0

(44.90) (56.85) (57.80)
~------L,----~--~
Weatherstrip mounting hole

5.5 mm (0.217 in) dia.
A-
L5·302
Fig. 19
14
BODY AND· EXTERIOR 5-1
FRONT WINDSHIELD AND REAR WINDOW
----Datum for measurement

(on the joggle line)
center
line
Section A Section·B
Front
Front window
.. glass
Rear
Rea' wi~ gllll
Unit: mm (in)
f"< Front ·.Aear
a 784.5 (30.891 697.1 (27.44)

b 777.1 (30.59) 696.5 (27;42)
c 1.180.6 (46:481 1.186.4 (46.71)
d 1,395.2 (54.93) 1,377.0 (54.21)
e 73.8 ( 2.911 138.4 ( 5.45)
f 548.4 (21.591 453.0 (17.~3t
9 981.8 (38.65) 919.3 (36.19)
h 1,368.4 (53.87) 1,316.3 (51J!2)
L5·303
Fig. 20
15
COMPONENT PARTS
Body Construction
1 Front rail CP
2 Rear rail CP
3 Front brace
4 Rear brace
5 Roof panel
6 Roof panel (Sunroof)
7 CowHide panel
~
8 Front pillar (inner)
9 Side rail (inned
~
10 Rear quarter (inner)
11 Rear panel gunet
12 Reinforcemant (Rear pillar)
13 A.r arch (inner)
@ 14 Reinforcement (Side sill rear)
15 Reinforcefn'nt (Side sill center)
16 Reinforcement (Side sill front)
17 Front bulk head
18 Reer bulk CP
19 Front pillar (outer)
20 Side rail (outer)
21 Rear quarter (outer)
22 Roof drip rail
23 Side sill (outar)
24 Wheel apron ASSY
25 Front sida frame
26 Rear side frame
27 Radiator panel
28 Toe board
29 Front floor
30 Reer wheel apron ASSY
.a1 Raar floor
32 Rear skirt
® 33 Rear panel ASSY
34 Frama side (upper)
L5·745
Fig. 21
16
BODY:ANO EXTERIOR 5-1
, Front Hood and Hood Lock

l
r
r
r
r
r
r DETAIL "A"
r
r
r
r
r DETAIL "c"
f
r
f.. B
DETAIL liE"
f
f
I
f
J
f,
DETAIL "F" 1 Front hood cable ASSY
i
r 2 Front panel 1881
3 Front hood CP
4 Clip
f 5 Clemp
f 6 Grommet, .
r,[ 7 Front hood stay
8 Clamp
DETAIL "G" 9 Front hood cover
10 Hood buffer ASSY
r 11 Buffer
12 Grommet
if 2700 cc
13 Striker ASSY
14 Hood lock ASSY
11 15 Clamp
~
16 F. hood cover cable
17 Hinge CP
18 Stopper hood
19 Hood grille ASSY
IT 20 Duct
DETAIL "0"
L5·746
Fig. 22
17
I
;J
f
5..1 B1DlI)'Y~ANOE)(tERIOR;
t~ . Z
Trunk Lid and Fuel Flap .
CD
DE"tAll "B" .
Detail "A"
DETAIL. "e"" ,
1 Trunk lid CP 7 Knob

2 Weather strip 8 Pull hWndle
3 Hinge 9 CableASSY
4 Torsion bar 10 Lock ASSY
5 Torsion bar 11 Key lock ASSY
6 Stopper 12 Striker
L5·747
Fig. 23
18
BODY AND EXTERIOIR 5-1
Front Bumper
r-----@
L..........:..------@
1 Upper side hOlder lRj·l)

2 Uppet'l1old&r (F)
3 Upper'side holder (LH)
4 Beam ASSY (F)
5 E/A foam (F)
6 Bumper face (F)'
7 Side bracket
8 Cover bracket' (fogl (1800 ee)
9 Cover (fog lamp) 11800 eel
10 Lower holder (F)
11 Lower duct (F) (1800 eel
12 Screw grommet
13 Fog lamp CP (2700 ee)
L5·748
Fig. 24
19
5-1 eODY'ANDEXTERIOR
Rear Bumper
CD
~
I
..r---_@
t---------@
14iiiP---_ _ _ @
i""'~z...----(i)
1 Holder (upper)
2 Rear bumP4H' ~pporter
3 Licanse light ASSY
4 Beam CPI
5 E/A foam (R), "
6 Bumper face (Ri
7 Lower holder A
8 Lower holder B
9 Spacer stay
10 ,Rear bumper ASSY nut
11 Washer
12 Screw gromf11lt
L5-749
Fig. 25
20
BODV AND ,EXTERIOR 5-1
Body Parts
1 Front fender
2 Bracket
3 Fender stay
4 Under cover
5 Mud guard
6 Exhaust cover
7. Mud guard A
L5·750
Fig. 26
21
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21 '» co; 5~
1 Front lower moulding

2 Front pillar cover
3 Drip moulding
4 Center pillar cover
5 Rear quarter moulding
6 Rear pillar cover
7 Side upper moulding
8 Side lower moulding
9 Rear upper moulding
I;; 10 Rear lower moulding
~ 11 Screw rivet
w
BO~yj AND EXTERIOR 5-1
SERVICE PR;QCEDlJRE:
Hood INSTALLATION
HoOct.~:. Installation is in the reverse order 'of removal.
The hood lock has a dual locking design. which con~i&ts of a

a. Align the cen1lr of striker Nth lock during installation.
main lock and a safety lock mechanism. Whentha release
Make aue safety lever is properly caught by striker under the
knob located at the front pillar on the driver's side is pulled
hood's own weight
back, the main lock is released through the cable attached to
b. Rou1l hood lock release cable and hold with damps.
the knob. When the hood lock must be opened, lift the lever
Co Adjust height of buffer on each side so that height of hood
protruding to the front to release the safety lock.
is aligned with fender.
REMOVAL
1) Open hood and remove striker ASSY.

2) Remove cable cover.
Fig. 30
Fig. 28
ADJUSTMENT
3) Remove lock· ASSY'and disconllect cable. 1) Fore-aft and left-right adjustments

Loosen striker mounting bolts and adjust fore-and-aft position
of striker.
Do not adjust striker position using the lock. Doing so may

result in a misaligned front grille.
2) Up-down adjustment
Make up-and-down adjustment of lock only when hood does
not properly contact buffer or hood is not flush with fender.
or when release cable does not properly operate. Adjustment
can be made by adjusting the position of lock ASSY.
Fig. 29
23
r
5-1
POINTS TO CHECK
11~\"~tif:~~~~£~"<·'; ~. ;',ff'~1~~ . " Trunk ·Lid

2) Clinched section of safety lever for rust formation and
balky movement of safety lever due to improper sta~ng. REMOVAL
3) Other levers and spring for rust formation and unsmooth
movement. Open trunk lid. Remove trunk' lid Motlntingbolts and detach
trunk lict1rom·hingeS.
Hood Lock Release Cable
REMOVAL
1) Remove clamp fro,nlqck ASSY and disconnect cable end

from lever. .
2) Remove clips from radiator panel and cable from clips.
3) Remove cable clamps from engine compartment.
4) Remove lower trim panel from instrument panel. Refer to Fig. 31
the "Instrument panel lower trim panel" section.
5) Remove tapping screws which hold cable bracket to front
pillar. and detach bracket.
INSTALLATION
ADJUSTMEN r
1) To adjust left-right lid positioning, loosen bolts which
hold trunk lid to hinges.
2) To adjust up-down lid alignment, place washer(s' between
trunk lid'andhinges or meve trunk,lock'ASSY,upor dowri.
Torsion Bar
REMOVAL
1) Open trunk tid. Remove torsion bars from hinge' links

using REMOVER (926661000) ..
2) Remove the torsion bar fr~ .bracket using REMOVER
(926661000). "',;' ,/
CAUTION:
8. cmful baCIUJI tomon bar 'quicldy_nas back when
ral...d.
24
5-1
3) Remove the left and right torsion bars.
Bumper
CAUTION: _
Be careful because trunk lid drops under its ~W'UAlligbt when Front Bumper
torsion ban lie "rem0¥8d. " .
REMOVAL
1) Position vehicle on a lift.

INSTALLATION 2) Set headlights to upper beam.
3) Remove battery.
1) Installation is in the reverse order of removal. 4) Raise vehicle.
2) Apply a coat of grease to the rotary section of hinges and 5) Remove mud guards.
contact surfaces of torsion bars.
a. When installing hinge link to the end of torsion bar, move

trunk lid in the "close" direction so that jil can be easily
disengaged from torsion bar. ~Do not move trunk lid in that
direction if hinge link is hard to install. Otherwise, tonion bar
may suddenly disengage.
b. After installing new torsion bar, cheCk tim trunk lid opens
and closes smoothly.
L5·706
Trunk Lid Lock Assembly and Key Cylinder
Fig. 32
REMOVAL
1 ) Remove rod of lock ASSY from rod holder Qf kev "lock

ASSY.
2) Disconnect trunk opener cable by' removing the screw fl) Remove undercover and air dam skirt.
from the rear skirt section.
3) Remove bolts which ~old lock ASSYand remove lock
ASSY.
" '.' , ' ", .,i,'~';'
a. Alweys remcive-reir:-skirt tnM.1f8nel beforehand, if so
equipped. .
b. Be careful not to r.nd opener calt•. -; .
4) Remove drain connector from key cylinder.

5) Remove clip and detach key cylinder from rear skirt.
Always remove rear garnish beforehand, if so equipped.
Fig. 33
INSTALLATION
26
7) Remove bolts which secure lower duct. 11) Lower vehicle.
8) Remove bolts which secure side bumpers. 12) Remove washer tank.
(1) Disconnect hose from check valve on the back of
frOnt bumper.
(2) Remove bolts and washers which hold air cleaner.
(3) Remove clamp from boot (B) ASSY.
(4) Remove air cleaner and then remove conical nuts
which, hold, washer tank.
'.:;,.~~""~~:.. >,~ :·-'''-~fi.~ ,
Fig. 34 Step@
9) Remove bolts which secure lower side of side duct.

L5-310
Fig. 31
Be ana to turn mering wheel completely to the left before

. . .Idq . . . .~.....
". ~ '-r, ~ 0" • . ,.
. ,00,
13) Remove bolts which secure upper side of side duct, and
remove side duct.
L5-709
Fig. 35
10) Remove bolts from the back of bumper stays.
'----L> Irr~,
Fig. 38
14) Extract front bumper with help of co-worker.
Fig. 36 Ba careful not to damage harness.
26
rr
f
BQI)YAND EXTERIOR c 5-1
15) Disconnect front combination light harness connector. Rear Bumper
REMOVAL
I'
1) Open trunk lid.
2) Remove trunk lid trim.
3) Disconnect license light harness connector, remove'
grommet from body and transfer connector outside trunk.
j
L5·712
Fig. 39
16) Remove front bumper.

7"-.... ""----..~
=
j L6-713
.I
Fig. 40
4) Remove bolts which secure sides of rear bumper.

5) Remove nuts which secure bumper stays.
6) Remove rear bumper.
1f To ins~all, feverse removal procedures.

B. aU8 to adjust cl.arancas between bump.r and rear com-
bination liglrt and "tMan bump.r and tail light to 8 mm
(0.31 in).
27
Service Instructions for Resin IIuIIIper:
f'R~~st!M;'
~ ~ ( ,'!f ~;" .. :. • •• - '.~'" '<
Process
Process name Job contents
No.
Set bumper on paint worktable if

required. Use paint worktable
conforming to inner shape of
Bumpermounting bumper when possible.
L5-168
Fig. 41 Set bumper section
2 Masking
Mask specified part (black base.
with masking tape. Use masking tape for resin
(example, Nichiban No. 533, etc.). For details, see the following figures.
t. Clean all parts to be painted with white gasoline, normal alcohol, etc. to remove dirt,
3 Degreasing, cleaning
oil, fat, etc.
4 Primer paint APhly prim,r one to all parts to be painted, using air gun. Use wi~er (clear).
Dry at normal temperature [10 to 15 min. at 20°C (6SoF)).

5 Drying In half-dried condition. Resin primer paint is dissolved by solvent e.g. thinner, etc.
Therefore, if dust, dirt must be removed, use ordinary alcohol, etc.
Solid color Metallic color
Use section (block) paint for top coat .

• , Paint In1lJJ8 (for each color) • Paint in use (for each color)
. (;; i SoUd paint~' Metallic paint
·Hardener PS Hardener PB
6 Top coat paint Thinner T-301 Thinner T-306
• Mixing ratio: fy'Iain agent vs. • Mixing ratio: Main agent vs.
hardener = 4 : 1 hardener = 10 : 1
.V~~\y~1.p",,,,1~ sec/20°C (6SoF) • Viscosity: 10 - 13 sec/20°C (6SoF)
i.c'r:ifri1°~~~;4_ - 45tL
• Spraying ple'ssure: 245 - 343 kPa
• Film thickness: 15 - 20tL
• Spraying pressure: 245 - 343 kPa
(2.5 ~ 3.5kg/em 2, 36 - 50 psi) (2.5 - 3.5 kg/cm2, 36 -50 psi)
Dry at normal temperature [10 min. or

more at 20°C (6SoF)).
7 " Drying. . Noueq~~d.
In half-dried condition, avoid dust,
dirt.
Apply clear to parts with top coat (I),

three times at 5 - 7 minute intervals.
• Paint in use
Metallic paint
Hardener PB
Thinner T-301
S Top coat (II) Not required.
• Mixing ratio: Clear vs. hardener
= 6: 1
• Viscosity: 14 - 16 sec/20°C (6SoF)
• Film thickness: 25 - 30tL
(2.5 - 3.5 kg/cm 2 , 36 - 50 psi)
28
5-1
Process
No. .'
60°C (140°F), 60 min. or BOoC (17~~F), 30 min;

9 Drying If higher than BO°C (176°F), PP mavibe deformecL Keep maximum temperature of
SOoC ( 1 7 S O F ) . '
.-" .....
_
·1
10 Inspection Paint chec~.
.. ~ '':'7'-d:'
11 Masking removal Remove masking in process-No. 2~:

v
Basic paint method
[ Lower StJ rflIceJ

Do not paint. (Maskl
Paint area Emboss for parting

Paint area
Color A 0.5 (O.~O)
~
parting position
>" "">
Two-tone [oRecess portion
~--=--' 0.6
((J;020)-~~ 0; 0 - -, ' Section C-C
cOfor only
o
O.!
(Partil'lg position of no-paint
section)]
R
Color B Paint up to end (0020)
. ~~ss portion
Section 0-0
Section B-B
Section A-A $
Embossed line for parting

Unit: mm (in)
L5-751
Fig. 42 Front bumper masking and painting positions
29
5 ..1
Paint up to end
Parting Color A
Color A
position
::~~7:n+ ~lC...~
-.-.- - . .. Color B Colo.r B
Section 0
Section c-c
Section B-B Section A-A
Basic
paint method
Emboss line for parting
0.5mm
(0.020 in)
L5·752
Fig. 43 Rear bumper masking and painting posi(iDf,s .
. :.
30
BODY lANlI) 'EXTERIOR 5-1
Repair Instructions for Colored Realn Bu.,."...

All resin bumpers are provided with grained surface; and if the surface is damaged, it cannot normally be restored to its former
condition. Damage limited to' shallow scratches that cause only :achange in the lustre of the base material or·coating, can be
almost fully restored. Before repairing a damaged area, explain this point to the customer and get an understanding about the
matter.
Repair methods are outlhied below; based on a classification of the extent of dam~age.
(1) Minor damage causing only a change in the lustre of the bumper due to a light touch
Almost restorable.
. "
Process
No.
1 Cleaning Clean the area to be repaired usiAttwater.
2 Sanding Grind the repairing area with #50(fsa~dpaper in a "featherig" motion.
Resin section Coated section
Repeatedly apply wax to the affected

irea using a soft ciotti (such' as 1Iann81,. ' Perform either the same operation as for
Recommended wax: N'lfttfKAS!f the resin sactin or process No. 18 and
3 Finish
Soft ~9 TI RE WAX BLACK, or , ... bsequent operations in the "(3)" sec-
equivalent. tion, depending on the degree and
Polish the waxed area with a clean nature of damage.
cloth after 5 to 10 minutes.
(2' Deep damage caused by scratching fences, etc.

Adent cannot be repaired but. whitened or sw.lledt)8rtcan be removed.
"
T<!',
Process
No.
Process name
~ i.:. \ '
,.: .~~~. c,o,:,~ef'lts
.,~ . [:
1 Cle,,,ing Clean damaged He~ ,~irt~~,t'~._
.'
~
", , .• i.' ';,.i -,- ,_... 1,
~ ;
Removal of dam~ged
2 Cut off protruding area, if any, due to collision, using a putty knife.
area
--
3 Sanding " _ :Grind the affected area with #100 to #500 sandpaper.
Resin section Coated section
4 Finish Same as Process NO.3 in the "(1)" Perform Process No. 12 and subsequent
section. operations in the "(3)" section.
~~-< •
'~ -. ~', '.
r
5-1
(3) Deep damage such as a break or hole that requires ......'tuB fi!8SR b010fo:) ~~)~ ;; :~:.):'~'.;, '~>:~1! '.
Much -Of; 1he' ~raf..gr,aiBaO(Jurfaoe 'must ~t._ori'ficed ,for: :repai~,' and the 'dagrft<lof; rlltStorati0F11 i.· not .real.lv WCJIIth, ttte ex":
pense",.:(Thestll!face, bowever,.,wift betome aknbstflushwitntlldjaoent areas,). . ',): ,<,' ',! f _0
,·Recammendechepeir.kit: 'fWstnfart:Repair-Kit (NRM)' ':,~ ," ".,.
Process
No.
Process name
. . Job contents
Bumper removal Remove bumper as required.
.. Pi;lrt remQvaL Remo.v,eparts builtJnto. bumper.as requjred.
P1aCI!!bumper on a paint worktable as re-

quired.
It is recbml'1llendeO'thlt contoot ,of worktable
3 Bumper' placement accommodate internal shape of bumper.
• • ; I ,:" , \ - ~. ~ • ~; '. ~. i \ • .' ;-
L5-168
Fig. 44 Set bumper section
, • , ,~ .... ' • ..r
Remove ~~f~,,~ilr. ~W. frop1are'~}9 ~~ ~~'n.:td and surrounding areas, using a

4 . Surface preparation
~Litable ~~ .~~~. ~9 ~H:JG"P9! .l/V".ite gasoline, or alcoho~):
,:," l·tfnatureofdarifage:is··'etabkVb¥;~bi~s: clit " 20-30(0.79-1.18) Unit: mm(in)
, 8 guLde sl!t of 2Q to_~O mm (0.79to"""l H Paintsurface
~f;t.18. in) in I~ "IQ.,.RQ..~~.,:~r~.~~.Q.!lIl.PIe" ,i ..',.' m?~~~

up to the bumper'sJ~~'MW~f::e. Then." ~/ /d'h_
5 Cutting
bav8l..or_~~vee..ou1~:.the..affectedarea · T ---. ..-- . ' .. .~ ..
using a knife or grinder. 3 (0.12)
Resin base
surface
c:l,: ':3:J{k,filJn~:'fb ';;' ,/.-1 r~W~! "\f;'>',( " :..rL+p~r .!
6 Sanding (I) Grind beveled surface with sandpaper (#4a to f60)to·sm()G)thfini.sb~
1". ··7· . .... €-feefting C~an -the sanded'suf"fattwiththe ume--sotvent-as used in Process -No. 4-;
G'rind't~;'side just opposite the beveled area with sandpap'er (#4b'to:#60) and clear
using a solvent.
Temporarily $Pot4N~lcf~ile 'si'cfe~ USiWg'a'" Welded spot (Ulle' heater gun
and resin welding rod)
resin welding rod and heater gun.
""
8 Temporary welding' '" Resin base surl~Ce
. ""
, 0',' ~ ~ ~ J" L5-173
•. Do-riot meff weidlngi-ad uniil it flOWs out 'This'iiSUits fii reduced strength.
b. leave the welded spot unattended until it cools completely.
Process
No.
. Using:1 Mater gunisnd resin·wetdin,.rod,:~ the beveled spot while melting the
rod and damaged area. ., " i:' f
,-
9 Welding
fig. 47 ,,:1 ,!"',

LS-174
a. Melt the sections indicatICI.,y ha1l:lJed,.,.. ,',

b. Do not melt welding rod until it flows out, in order to provide strength. .,
c. Always keep the hHter itUt " t02cm (0.4 to 0.8 in) away from the welding spot
d. Leaye the weldecJ spotunattend~~ ~nti~j~ cools completely.
Remove excess part of weld ...vlth a puttY~nife. If a drill or disc wheel is used
instead of the knife, operate it at a rate lower than 1500 rpm and grind the excess
part little by little. Pi. higher rpm will' caJse the resin substrate to melt from the heat.
10 Sanding (II)
:)(: .' t;:,t
Fig. 48r,'-l)' (:~£ .. 2:';:; ,,,'..' V",,' ..... ' ,";

L5-175
Sand the w~~pOtttmobth With:~#24b~andpaper.
',,'. Mask the black substrate section (as indicated in .the figure), using masking tape .
11 Masking. • :Becommended masking tape: Nichiban No. 533 or equivalent
For details, see the figures showing the masking portions.
Completely clean the entire coat~.,:e:af ~'"" solvent~fs~QtM~W~~ in Process

12 Clean ina/degreasi ng
• ~''''~.''''~.' ,~"i. ',~ ~~,! .~;,:, .No.4 .
•. :~pply a coat of primer to the repaired surface and its surrounding areas. Mask these
.areas, if necessary.
,'Recommended primer: No. 364 PP Primer
13 Primer coating
., Ie sure to apply one coat of primer at a spraying pressure of 245 to 343 kPa (2.5 to
3.5 kg/cm2, 36 to 50 psi) with a spray gun. ;
Leave the repaired area unattended at 20°C (68~F) for 10 to 15 minutes until
wimer is half-dry. " .,~ . " ,;
14 Leave unattended
If dirt or dust comes into contact with the coated area, wipe off with a cloth
dampened with alcohol. (Do not use thinner since the coated area tends to melt)
33
Process
No.
Apply a coat of primer surfacer to the repaired area two or three times at an interval
of 3 to 5 minutes.
Recommended surfacer: • UPS 300 Flex Primer
Primer surfacer • No. 303 UPS 300 Exclusive hardener
15
coating • NPS 725 Exclusive Reducer (thinner)
• Mixing ratio: 2: 1 (USP3oo : No. 303)
• Coated film thickness: 40 - 5010'
Allow the coated surface to dry for 60 minutes at 20°C (6SoF) [or 30 minutes at
16 Drying
60°C (140°F)].
17 Sanding (III) Sand the coated surface and its surrounding areas using #400 sandpaper and water.
1S Cleaning/degreasing Same. Process No. 12.

Solid colOr Metallic color
Use a ''block'' coating method. ; +-

• Recommended paint: +-
Suncryl(SC)
No. 3Q7 Flex t-tardaner
>
19 Topcoating (I) SC Reducer (thinner)

• Mixing ratio: 3: 1 +-
JiWacryl : No. 307),
• ~sity: 11 - t3 sec/20° C (68° F) +-
• Coated film thickness: 40 - 5010' • Coated film thickness: 20 - 3010'
• Spraying thickness: 245 - 343 kPa +-
. (2~6-.3.6 kg/cm 2 , 36 - 50 psi)
leave unattended at 20°C (6SoF) for

at least 10 minutes until the topcoated
area is half-dry.
20 Leaving unattended Not required.
Be careful to keep dust or dirt from
coming into contact with the affected
.ro.
Apply a coat of clear three times at an
interval of 3 to 5 minutes.
". Recommended paint:
SC710 Overlay Clear
No. 307 Flex Hardener
SC Reducer (thinner)
21 Topeoating (II) Not required.
• Mixing ratio: 3 : 1
(SC710: No. 307)
• Coated film thickness: 20 - 3010'
(2.5 - 3.5 kg/cm 2 , 36 - 50 psi)
34
, BODY AND EXTERIOR 5-1
,
Process
No. ""; , .,"; -~- ,..: ,'''' ."
'''~
"
,
,"
""', ""',, "l;,~!;: ' >"",' "
BOoC(14dt~t_,30' ,
',", '
AnoW the CoItetflurface at _... , ,',,:'

minutes.
22 Drying j ~
Do not tHow the temperature to exned· 800 C (1760 F) since this is the sur. way of
deforming the resin subltrl1L
23 Inspection ~~ef~lIl c~~ck,the ~ondition of' the repaired area.
24 .. ' .,'
removal:'"' . -~
" ,4;, .~
, 'Masking,tape applied in Process Nos. 11 and 13.
25 Parts installation Install parts on but:nper in reverse order of removal.
26 Bumper installation Install bumper.
Body, "Parts '

Front Fender
REMOVAL
1) Remove mud guard.

2) Remove air dam skirt.
3) Remove front bumper. ~; " :,;:
4) Remove front combination lamps.
5) Remove bolts which hold fenders and detach fenders.
L6-716
Ba careful not to scratch body panals wiUt,fendar ad,.s whlln Fig. 49 Gap bBtWIIM front 'hood and fender
removing it.
INSTALLATION
CHECKS AFTER INSTALLATION
Check for alignment of front fender with hoQd and front door
with front fender at all points. Adjust, if necessary. Fig. 50 Gap between front door and fender
35
&1 BODY:1AND ',mXl"BRIOR
MuaGuari:l Exhaust 'Cover'
REMOVAL REMOVAL
1) Raise front end of vehicle with a jack and remove wheels. 1) Disconnect muffler and exhaust pipe.
:2) Remove screws. and cliPs (exCept :Jt'tGidl~~d:: into :2):< ReJnUfllirexhaustcover.
'fender flange) which hold mud guard. Move mud guard toward!::;,. ; . , : - ~'I""i',,l.;
the center of car body and remove mud guard and c1ips (from
:flange) as a unit. ' . ";(1')' '~:' " . ):..... .
INSTALLATION
'Installation is In the reverse ordet of removal.

Be sure to adjust clearances between exhaust cover and
adjacenfbart$ as equally as pOssible'befc,re finally tightening
bolts.
If exhaust cover is deformed or damaged, causing unequal

dearances between it and muffler or exhaust pipe, repair or
replace exhaust cover.
Clip
~Rivet screw
L5-718 .
Outer Accessories
Fig. 51
Rearview Mirror
INSTALLATION REMOVAL

ELECTRICALL V-CONTROLLED TYPE
Only use new nIts and clips.
2) Remove three screws.

,MUd Guard R 3) Withdraw harness with connector frorn hole in car body.
. '" ~ -. ;-:
REMOVAL
Do not withdraw harness forcibly.
1) Raise rear end of vehicle with a jack and remove wheels.
2) Remove screws and clips (except those inserted into rear 4) Disdihnec'tcohneetors.
quarter outer fl.ange) which hold mud gUilrd.Mo'le mud.guard:
toward the bottom of car body.,:)themrernove mud, . . . and Dlttu,t.'fiSHy:cb'nnector baCk \thrb~ltflh'hole. .
clips (from flange) as a unit.
,
\
~
L5-753
Fig. 52 Fig. 53
36
f
BODY AND EXTERIOR 5-1
Cover and Molding INSTALLATION
REMOVAL 1) Front lower molding

(1) Install clips on front lower molding securely on the
glass side.
1) Front lower molding
(2) Align the clips with holes in car body on the glass
(1) Remove wiper arm ASSY, wheel ASSY and front
side and push them in forcibly.
panel seat.
(3) Place the front end of molding under front panel
(2) Remove front screw rivets.
seal, and secure with clips and screw rivets.
(3) Remove molding from clips by pushing it up along
(4) Install wiper and associated parts.
glass surface.
2) Center and rear pillar covers
(4) Remove clips from car body.
(1) Use only new clips when installing covers.
2) Front pillar cover
(2) Insert clips into holes in car body by hammering.
(1) Break clips.
3) Front pillar cover
3) Drip molding
Use same procedures as in 2) above.
(1) Use same procedures as for 4·door series.
4) Top rail molding
4) Upper and lower side moldings
(1) To install, reverse removal procedures.
(1) Break clips.
5) Rear quarter molding
(2) On lower side molding, remove screw from the back.
5) Rear quarter molding
6) Rear upper molding
(1) Break clips.
(1) Replace clips if broken or deformed.
6) Center pillar and rear pillar cover
(2) Place pawl section of molding on clips and, while
(1) Break clips.
lightly holding the end of molding on glass side, insert
7) Rear upper molding
clips into holes by hammering.
(1) Detach rear upper molding by pulling it from clips
7) Rear lower molding
horizontally (if upper side molding has already been
(1) Align holes in molding with screw grommets on the
removed).
side of car.
(2) If upper side molding has not been removed, break
(2) Tighten screws, starting with the center one and
the clip at the extreme end and lift the end of molding to
moving toward the end.
disengage all the clips.
8) Side upper molding
B) Rear lower molding
(1) Open trunk lid.
9) Side lower molding
(2) Remove screws which hold molding.
(1) Replace clips if broken or damaged.
(2) Align clips with holes in body and insert them into
holes by hammering.
(3) Tighten the screw at the extreme rear end.
Where necessary, some moldings and covers should be over-

lapped.
!
r
37
DOORS AND WINDOWS
Page
SUBARU MECHANISM AND FUNCTION....... . . . . . • . . . . . . • . . . . . . . . ..

Door ..•............................................
2
2
Window Glass .......................................... 2
1988 SERVICE DATA. . . . . . . . . . . . . . . . . . . • . . . . • . . . . . • . . . . . • . . •.

Door Alignment . . . . . . • . . . . . • . . . . . • . . . . . . • . . . • . . . . . . . . .•
3
3
COMPONENT PARTS . . . . • • • • • • . • • • • • • • • • • • • • • • • • • • • • • • • •• 4
Door. . . . . . . . . . . . . . • . . . . • . . . . . . . . . . • . . . . . . • . . . . . • • .. 4
Window Glass ........................•.....••.•.•...... 5
SERVICE PROCEDURE. . . . • • . . . . . . . . . • . • . • • . . . . . . . . . • . • . .• 6
Door Assembly ........................................ 6
Door Glass ........................................... 15
Window Glass .............................••••..•••••. 19
TROUBLESHOOTING •.•.••••••.••••••..••••••••••••••.••• 25
Door Glass ......•.•..•.••...•••..••••••••...•......•. 25
Door Lock System .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. 28 _
I,
rI.:.:
~.
5-2 DOORS AND WINDOWS

Door 2) Usable time
Although the time during which the adhesive is usable varies
with the environmentaltempet'lt~re, make it a standard
Door Hinge practice to finish attaching the glass within thirty minutes
A two-stage arm checker is used to insure that the door opens after a cartridge is opened for use.
and closes in two steps and the checker arm operates with 3) Hardening time
weak friction over the entire opening range of the door. This Leave the vehicle alone a whole day after attaching the glass.
arrangement allows the door to stop easily in any position and In addition, high-speed or off-road driving should be avoided
improves the overall ease of door opening and closing. for three days to allow the adhesive to harden completely.
4) Primer
The job of a primer is to increase the effect of adhesion.
Degree of opening 1st stage 34°
Therefore, it should be appl ied to the contact surfaces of the
of door hinge 2nd stage glass and body without fail.
5) Precautions in handling adhesive and primer
(1) The adhesive and primer quality deteriorate about six
months after manufacture. Thus, adhesive and primer
Door Lock System which are more than six months old must not be used.
(The date of manufacture is indicated on the adhesive
The surface where the lock contacts the striker is covered with package.)
a soundproof resin which provides excellent wear resistance. (2' Keep the adhesive and primer in a cool, dark place.
This lessens the striker's shock noise and improves the closing . (3. the adhesive and primer harden through a reaction
sound of the door. with water content in the air. Therefore, remove the seals
right before use and do not use any remains.
(4) Shake primer well before using.
Door Glass
The moulding around the glass uses a flush mount to reduce
The radius of curvature of the glass is 1,250 mm (49.21 in). the difference in height between the glass and moulding,
This, together with flush surfaces, improves aerodynamic thereby improving the aerodynamic characteristic and reduc-
characteristics. ing wind noise.
Automatic Door Lock

Pressing the driver-seat door lock knob (or key plate) permits
Dam rubber
the locking and unlocking of all doors with one touch.
Glass
Ceramic print
Window Glass LS-064
Fig. 1
An adhesive is used to attach the following.
Windshield, rear quarter glass and rear window glass
ADHESIVE
1) General
A single-liquid urethane adhesive hardens into a gum elastic
body at room temperature through a chemical reaction with
water content in the air.
2
DOORS AND WINDOWS 5-2
SERVICE DATA
Unit: mm ~in'
Door Alignment
Rear Quarter panel
Fender
J \ ~~.............
5 (0.20H
CD-CD
Step (Rear Quarter base)

13.5 t 2
(O~531 t 0.079' ::~.5 (..:8.0591
DoOrpaneJ
@-@
Step (Fender base) ~~.5 f:8.ose l ® _@
12 (0.41,)
8 t 1.5
~O.31)
~
@-@
,#
~ ~'.
_.
. 12.3 (0.484)
(0.315 ± 0.0591
Fig. 2 @-@ L5-260
3
COMPONENT PARTS
Door
@
1Jt/ 14
14
15
16
17
Lower hinge
Drain cover
Front sash
Power regulator (Option)
18 Inner remote ASSY
1 Glass stopper 19 Clip
2 Weatherstrip (Roof) 20 Regulator
3 Glass ASSY 21 Clip
4 Door weatherstrip 22 Auto-c!oor lock (actuator switch)
5 Upper stopper 23 Stopper
6 Handle bracket 24 Striker
7 Rivet washer 25 Latch 32 Gusset cover
8 Upper hinge 26 Outer handle 33 Door trim
9 Gusset ASSY 27 Inner weatherstrip 34 Pull handle
10 Stabilizer 28 Inner stabilizer 35 Sealing cover
11 Upper stopper 29 Outer stabilizer 36 Escutcheon
12 Outer weatherstrip 30 Glass holder 37 Door trim bracket
Fig. 3 13 Checker 31 Sash 38 Regulator handle
4
Window Glass
Windshield Glass
1 Glass
2 Dam rubber
3 Spacer
4 Stopper
5 Molding
6 Dam rubber
L5·725
Fig. 4
Rear window Glass
1 Dam rubber
-?
2 Spacer
3 Moulding side upper (LH)
4 Cover rear pillar (LHI
5 Moulding side lower (LH)
·,6 Cower rear pillar (AH)
7 Stopp8f'
e Aear lower moulding
9 Moulding side lower (AH)
10 Glass
11 Rear upper moulding
12 Moulding aide upper (RH)
L6-268
Fig. 5
Rear Quarter Glass
1 Drip moulding
2 Moulding Iide upper
3 Spicer
4 Stopper
6 Center pillar cover (LH)
8 Dim rubber
7 Moulding (R.O)
8 Moulding lidelower
9 Cover r..r pillar
10 Gla ..
L6-269
Fig. 6
6
SERVICE PROCEDURE
Door Assembly
Procedure Chart for Removing and Installing Door and Related Parts
I I
I I
,
Door Door lock system Door regulator Door glass
f
Remove door trim parts,
etc.
~
Remove front and rear
upper stoppers and
stabilizer linner)
REMOVAL
~
I Remove door
I Disconnect joints Separate door glass from j
between latch, outer regulator
handle, key lock and
remote ASSV
Remove regulator rail

I Remove door glass
I
Remove door lock system Remove regulator
-
I I nltall door
I Install door lock system Install regulator
Install regulator rail

I Insert door glass
I
t
I Adjust door alignment I Adjust door lock system Mount door glass on
regulator
j
INSTALLATION
AND
I Adjust striker I Link latch, outer handle,
key lock and remote
Install front and rear
upper stoppers and
ADJUSTMENT ASSV together stabilizer (inner)
~
Adjust glall position
I
•
I nstall door trim parts,
etc.
J
t
Confirm
This flowchart shows the main procedures for removing and installing the door and its related parts. For details, refer to the
text.
6
Door and Hinge ADJUSTMENT

The method described below involves removing and installing
only the front door itself. There is another method of removal 1) Using DOOR HINGE WRENCH (925610000), loosen
and installation in which the front fender is first removed. bolts securing upper and lower hinges to body, and adjust
The hinges may be removed and installed with the front fender fore-and-aft and vertical alignment of door.
removed. But the method of removal and installation is
described below and should be performed after removing the
door itself.
REMOVAL
1) Place a cloth or a wood block under door to prevent

damage, and support door with a jack.
2) Remove checker pin by driving it upward. Be careful not
to damage door and body.
A24-463
Fig. 8
2) Loosen door striker and adjust opening/closing direction

Checker pin of door.
Hinge tightening torque (body side):

25 - 34 N'm (2.5 - 3.5 kg-m, 18 - 25 ft-Ib)
Hinge tightening torque (door side):
20 - 29 N'm (2.0 - 3.0 kg-m, 14 ..... 22 ft-Ib)
~-O70 Trim Panel

Fig. 7
REMOVAL
1) Remove screws which hold gusset cover, and detach cover.

3) Remove bolts (MB) securing upper and lower hinges to 2) Remove screws which hold pull handle and other screws
door, then remove door itself from hinges. located further inside.
4) Remove hinges by loosening hinge mounting bolts (MB) 3) First remove retainer spring and then regulator handle.
off body. Use a wire bent at one end, as shown below, for easier removal
of retainer spring.
a. Work carefully to avoid damaging door_

b. If equipped with power window regulator, disconnect
harness first.
INSTALLATION
1) Fasten hinges to body with bolts kept after removal.

2) Install door itself to hinges.
Retainer spring
3) Install checker pin.
L5-071
Apply grease to moving parts of door hinges. Fig. 9
7
4) Remove remote handle cover. Be careful because cover may break if sealer is removed
5) Remove clip attached to trim panel using CLIP PULLE R forcefully.
(925580000). Then remove trim panel. Be careful not to
break clip by applying undue force.
INSTALLATION
1) Confirm that sealer is properly applied without breaks.
Then install sealing cover.
2) When repairing or replacing sealing cover, use "Cemedine
5430L" as sealer. It may be overlaid on existing sealer.
Any breaks in sealer applied can cause water leakage or entry

of air and dust. Be sure scaler is applied in a continuous line.
Fig. 10
INSTALLATION

Checker
a. When installing trim panel, check clip, hold the clip section
down by hand, and push into place. REMOVAL
b. Adjust so that remote cover and trim panel do not overlap,
and install remote cover clip to remote ASSY. 1) Remove trim panel.
2) Remove speaker ASSY.
Sealing Cover 3) Remove sealing cover.
4) Apply a cloth to door and body to prevent damaging
REMOVAL them and remove checker pin by driving it upward.
1 ) Remove trim panel. Be careful not to damage door and body.

2) Disconnect harness connectors for remote control rear-
view mirror and power window (optional). 5) Completely close door glass.
3) Loosen screws which hold speaker, and remove speaker 6) Loosen two nuts securing checker, and take out checker
and harness connector as a unit. through access hole in underside.
4) Remove remote ASSY.
6) Remove remote clip. Remove carefully to avoid damaging checker cover.
6) Remove door trim bracket.
7) Remove sealer with a spatula.
INSTALLATION
Tightening torque:
6.4 - 9.3 N'm (0.66 - 0.96 kg-m, 4.0 - 6.9 ft-Ib)
L5-263
Fig. 11
8
Inner Remote Assembly
REMOVAL
1) Remove trim panel.

2) Remove sealing cover
3) Disconnect joints of two rods with latch.
4) Remove screws holding remote ASSY. Then remove rods
from remote clip by pulling them out.
L5..Q76
Fig. 13
INSPECTION
Inner remote ASSY
1) Check operation of each part.

2) Check each sliding part for proper lubrication.
L5-262
Fig. 12 After installation, be sure lock mechanism operates normally.
Tightening torque (screw):

4.4 -7.4 N·m (0.45 - 0.75 kg-m, 3.3 - 5.4 ft-Ib)
INSTALLATION
1) Pass two rods through remote clips and rod holes in

sealing cover, and install remote ASSY on instrument panel.
2) With door locked, hold upper rod to door latch connector
with screws.
3) Attach lower rod to door latch connector with screws.
Do not pull connector to make this attachment. Key Lock
Tightening torque (screw): REMOVAL
4.4 - 7.4 N'm (OA6 - 0.76 kg·m, 3.3 - 6.4 ft·lb)
2) Remove sealing cover.
3) Completely close door glass.
Door Latch 4) Remove key lock from door latch rod.
5) Disengage outer handle from door latch rod.
REMOVAL 6) Remove outer handle.
7) Remove key lock from outer handle.
2) Remove seal ing cover.
3) Completely close door glass.
4) Remove remote ASSY from latch.
5) Turn rod holder to disconnect joint between key lock INSTALLATION
ASSY and rod.
6) Using a flat-head screwdriver, disconnect joint between Installation is in the reverse order of removal.
outer handle and adjusting nut.
7) Loosen three screws securing latch, and remove latch Install so that key slot in key lock comes to center of hole in
through service hole in bottom. outer handle.
9
Outer Handle Door Weatherstrip
REMOVAL REMOVAL
1) Remove trim panel. 1) Remove trim panel.

2) Remove sealing cover. 2) Remove rearview mirror from door.
3) Completely close window. 3) Remove speaker.
4) Separate outer handle, key lock and door latch rod. 4) Completely close window.
5) Loosen two nuts which hold outer handle, and remove 5} Remove sealing cover.
outer handle from outside and handle bracket from inside. 6) Remove weatherstrip at the hook section on the lower
end of gusset and slanted section.
7) Extract weatherstrip mounting clips from panel.
L5-264
Lower hook
Fig. 14
L5-273
Fig. 16
INSTALLATION
Always install handle bracket with arrow mark facing upward.

Outer Weatherstrip
Tightening torque:
5.4 - 9.3 N·m (0.55 - 0.95 kg·m, 4.0 - 6.9 ft·lb) REMOVAL

L Adjust escutcheon to panel properly so that there is no gap. 2) Remove rearview mirror from door.
b. Adjust play between outer handle rod and door latch lever 3) Remove end of body weatherstrip.
to 0.5 to 1 mm (0.020 to 0.039 in) with adjusting nut pro· 4) Remove rivet washer securing rear of outer weatherstrip.
vided. 5) Put a flat-bladed screwdriver in between outer weather-
strip and door panel, and remove weatherstrip by pulling it
Play upward. (Be careful not to damage door panel.)
0.5 - 1 mm (0.020 - 0.039 in)
INSTALLATION
L5{)77
Fig. 15
10
Roof Weatherstrip Stabilizer
REMOVAL REMOVAL
1) Remove clips holding end of roof weatherstrip from 1) Remove trim panel.
panel. 2) Remove rearview mirror from door.
2) Remove roof weatherstrip from retainer. 3) Remove sealing cover.
4) Remove outer weatherstrip.
5) Loosen bolt securing inner stabilizer,and remove stabilizer
through access hole.
Fig. 17
~
. / L5-079
Fig. 19
6) Loosen screw securing outer stabilizer, and remove
stabi I izer from top of door.
Fig. 18
Outer stabilizer
L5-080
Fig. 20
INSTALLATION
INSTALLATION
1) Install ends of roof weatherstrip.
2) Put straight portion into retainer using a roller or spatula. Installation is in the reverse order of removal.
a. When weatherstrip is dirty or dusty, clean it with water a. To prevent roller stabilizer and glass from chattering, fix
silicone. This will make weatherstrip as lustrous as a new one. inner stabilizer while pressing glass outward.
b. If door glass and weatherstrip are in tight contact with b. Be careful to keep roller stabilizer clean.
installed power window, apply water silicone to weatherstrip. c. Install inner stabilizer so that roller stabilizer is parallel to
It will increase the wear resistance of weatherstrip. glass surface.
c. Use a cloth soaked with water silicone (oil must not be
used), and apply two or three times to roof weatherstrip. Tightening torque:
Allow several hours for silicone to dry and deliver vehicle only 5.4 - 9.3 N'm (0.55 - 0.95 kg-m, 4.0 - 6.9 ft-Ib)
after weatherstrip has dried completely.
11
Door Glass Window Regulator
REMOVAL REMOVAL
1) Remove trim panel. 1) Remove trim panel.

2} Remove remote ASSY. 2) Remove remote ASSY.
3} Remove sealing cover. 3) Remove sealing cover.
4) Remove rearview mirror from door. 4) Remove rearview mirror from door.
5} Remove outer weatherstrip. 5) Remove outer weatherstrip.
6) Remove inner stabilizer. 6) Remove inner stabilizer.
7) Remove front and rear upper stoppers from door.
For details of above six items, refer to respective descriptions. 8) Remove door glass.
9) Remove wire clip (manual type only).
7) Loosen upper stopper bolt from the front of door and 10) Remove regulator base plate and regulator rail.
glass stoppers, and move door glass. Then, remove upper
stopper from the rear of door. Remove two bolts which hold
glass holder to regulator slider.
Bolts attaching glass holder

to regulator slider
I
Fig. 22
L5-274
11) Take out regulator ASSY through service hole in under-
Fig. 21
side of door.
a. When removing bolts on regulator slider, move glass to
position where bolts can be seen through service hole.
b. Mark position and tightening allowance of upper stopper INSPECTION
bolts before removal. This will make adjustment after installa-
Make following checks and replace parts if defective.
tion easy.
1) Worn gears.
B) Open door, hold door glass with both hands and pull it 2) Broken springs.
straight up from door panel. 3) Damage and wear on other component parts.
4) Lubrication of sliding parts.
Do not turn regulator in direction th8t closes window after
door glass has been removed. This will dislocate slider and
slider will scratch corner roller.
INSTALLATION
Tightening torque:
Joining regulator slider
5.4 - 9.3 N·m (0.55 - 0.95 kg-m, 4.0 - 6.9 ft-Ib)
L5-276
Put bottom of glass holder on regulator slider properly. Fig. 23
12
INSTALLATION Door Sash

REMOVAL
First, fasten base plate with three bolts, and then fasten
regulator rail with three bolts. 1) Remove trim panel.
Tightening torque: 3) Remove glass.
Base plate mounting bolt 4) Remove the nut and bolt which hold door sash.
5.4 - 9.3 N·m (0.55 - 0.95 kg-m, 4.0 - 6.9 ft-Ib)
Rail mounting nut
10 - 18 N'm (1.0 - 1.8 kg-m, 7 - 13 ft-Ib)
Gusset
REMOVAL

2) Remove speaker.
3) Remove rearview mirror from door. L5-277
4) Remove outer weatherstrip. Fig. 25
6) Close window completely.
7) Remove three screws and nut which hold gusset. Swing 5) lift door sash out.
gusset back with lower adjusting bolt used as a pivot and
extract it from access hole.
INSTALLATION
~screw 0 Gusset Installation is in the reverse order of removal.
~ 0
~ Tightening torque:
~,~~, :::'~
00
Upper nut
10 - 18 N'm (1.0 - 1.8 kg·m, 7 - 13 ft·lb)
Lower bolt
~
5.4 - 9.3 N'm (0.55 - 0.95 kg-m, 4.0 - 6.9 ft-Ib)
N"
Glass Stopper
L5-631
Fig_ 24 REMOVAL
1} Remove weatherstrip from roof at the retainer location.

2) Remove screws which hold stopper, and detach stopper.
INSTALLATION
Installation is in reverse order of removal. INSTALLATION
Tightening torque: Installation is in the reverse order of removal.

Screw Be sure to tighten glass stopper together with retainer.
5.4 - 9.3 N'm (0.55 - 0.95 kg-m, 4.0 - 6.9 ft·lb)
Nut Tightening torque:
10 - 18 N'm (1.0 -1.8 kg-m, 7 - 13 ft-Ib) 1.7 - 2.6 N·m (0.17 - 0.27 kg·m, 1.2 - 2.0 ft·lb)
13
Auto-Door Lock Switch Door Striker
REMOVAL REMOVAL
1) Remove trim panel. Remove door striker by loosening two screws.

3) Remove remote ASSY.
4) Close window completely.
5) Remove clip from latch. Remove two screws which hold
auto-door lock switch, and remove harness clip, The switch
can then be extracted through lower access hole.
/
/--- L5·633
Fig. 27
Tightening torque:
L5-632 10 - 18 N'm (1.0 - 1.8 kg-m, 7 -13 ft-Ib)
Fig. 26
6} Disconnect switch from harness.

ADJUSTMENT
Be careful not to damage harness when extracting switch
ASSY.
When door does not fit well or close well at rear end, move
striker sideways.
INSTALLATION
Installation is in reverse order of removal.

Door
Rear quarter
Tightening torque:
5.4 - 9.3 N·m (0.55 - 0.95 kg-m, 4.0 - 6.9 ft-Ib)
+
'+
Auto-Door Lock Actuator
L5-278
INSTALLATION AND REMOVAL Fig. 28
Use the same procedures as for auto-door lock switch.
14
Door Glass
Construction ...... Adjusting Position and Value
200081
~1!=,===~~~~~~S"b~;':~:N.
I\~GI."I
Unit: mm (in)
LS-279
Fig. 29
Door Window Alignment 3) Raise window near the fully-closed position. With the
window held in that position, apply a force of approximately
Before adjusting door window alignment, raise window until
20 N (2 kg, 4 Ib) to the upper edge of glass from the inside,
weatherstrip at the end of gusset and glass edges are aligned
contact stabilizer on glass and hold it securely.
with each otheL
Adjusting bolts used for stabilizer, upper stoppers, sashes, etc.,
should be loosened before window alignment.
1) Temporarily tighten bolt located at the lower end of
regulator rear sash in the center of oblong hole on panel.
2) Temporarily tighten one of two bolts used to hold upper
end of regulator rear sash at the center of oblong hole on
panel. (The other bolt should be loose.)
Bolts used to hold upper and lower ends of front sash should
be tight.
No clearance
L5-281
Fig. 31
Be sure there is no clearance between glass and stabilizer.

Do not press stabilizer against glass too hard. This will increase
the effort required to operate regulator.
Temporarily tighten
(Center of oblong hole) LS-280
Fig. 30
15
Up-down and Fore-aft Adjustment

1) Determine upward travel of window glass. Close door and
raise window until glass fits into lips of weatherstrips.
Iips of weatherstrips.
(A-) L5-282
Fig. 32
2) Determine clearances between window glass and body

weatherstrips in the fore-and-aft direction.
(1) Move regulator rear sash in either fore or aft direction
until glass edge is aligned with weatherstrip on the center
pillar side.
IN
Center pillar
4 9 mm (0.35 in)
OUT (A-)
L5-726
Fig. 33
(2) If it is not aligned properly. proceed to step 3) below.
. .. ':.
Wide --II--Narrow
- - 1 1 - - Narrow
--....:::::::::=t==========iiiiiiiiiii;;:===;;;~:~- Wide
~i=======~======53'
t
Secure Secure
L5-284
Fig. 34
16
3) If al ignment is not made properly by means of upper
adjuster alone, move lower adjuster as required.
Wide Narrow Wide
Adjuster under
sash
L5-285
Fig. 35
4) When any of the following problems (shown in figure

below) occur even when glass edge is parallel to weatherstrip,
move regulator sash forward or backward until alignment is
correct.
•
IN
:::: Wide or narrow
Loosen upper and lower

adjusters fully, and move
regulator rear sash
foreward or rearward.
OUT
L5-727
Fig. 36
5) After proper alignment, check to be sure glass edge fits
correctly into roof weatherstrip on the front pillar side.
Be sure glass edge fits correctly

into roof weatherstrip.
L5-287
Fig. 37
6) Tighten upper stoppers.
17
Glass Contact Adjustment

1 ) Loosen one of two upper adjusting bolts which hold
regulator rear sash and adjust glass contact pressure as
indicated in figure below. Tighten bolt.
- IN
Center
pillar
Adjusting bolt
4.8
(2 pes)
(0.189)
Unit: mm (in)
L5-288
Fig. 38
2) Adjust front sash, using step 1) above as a guide.
Adjustment amount of front and rear sashes is basically the

same; however, it may differ slightly due to the way the door
is aligned.
It is advisable to adjust both sash bolts as close to the center
of holes as possible.
18
Window Glass
Removal and Installation of Adhesion Type Glass
Procedures of removal and installation
Removal of moulding
~
I Removal of glass
I
,
Body
,
Glass
,
Finishing and cleaning of adhesion Cleaning of adhesion surface
surface
I I
Pasting of spacer
I
Appl ication of primer
I I
t +
Application of primer
I Application of adhesive
I
I I
I Installation of glass
I
I Installation of moulding
I
Removal of excess adhesive

I I
Check for water leakage
19
Materials required for application

Protective tape
Description Remarks
Repair adhesive set Putty knife

• Cartridge of single-liquid Sunstar No. 580 or Essex
urethane adhesive Chemical Corp's Urethane E
• Primer for glass and body Sunstar No. 435-580
Windshield knife For cutting windshield
Sealant gun For applying adhesive
Suction cups For holding glass L5-436
For finishing adhesion surface Fig. 39

Putty knife
and cutting spacer
(4) Cut adhesive layer as shown using putty knife.
Sponge For applying sponge
Gauze or cloth For cleaning
Alcohol or white gasoline For clean i ng adhesi on surface
For preventing damage to

Tape
painted surface
Fig. 40
(5) Remove stopper and spacer (glass).
(6) Put windshield knife into layer of adhesive.
(7) Hold part "a" in one hand, and cut by pulling part
"b" parallel to glass whi Ie holding knife edge at right angle
to glass.
Windshield
REMOVAL
a. Keep knife edge along glass surface and end face.
USING WINDSHIELD KNIFE: b. When first putting knife into layer of adhesive, select point
The following procedure for the front windshield can also be
with wide gap between body and glass.
appl ied to other windsh ields.
USING PIANO WI RE:
The windshield knife cannot be used on the rear window of 1) Remove wiper arm.
the sedan without damaging the surrounding grille. If the 2) Remove joints and moulding.
grille is not to be damaged, the windshield must be removed Refer to "USING WINDSHIELD KNIFE".
by using piano wire. 3) Remove glass.
(1) Put protective tape on body to prevent damage.
1) Remove wiper arm. (2) Using drill or putty knife, make through hole (one
2) Remove moulding. place) in adhesive agent.

(3) Pass piano wire through the hole from inside the
3) Remove glass.
compartment. and connect both ends of wire securely to
(1) Put protective tape on body to prevent damage.
(2) Apply soapy water to the surface of the adhesive wooden blocks.
agent so the knife blade slides smoothly. (4) Cut adhesive layer with the wire by pulling it back
(3) Cut off excess adhesive agent. and forth.
20
(2) Clean body wall surface and upper surface of layer
of adhesive with a solvent such as alcohol or white
gasoline.
4) Pasting spacer stopper.
Put new spacer stopper at places where it was removed.
Spacer Spacer
L5-438
Fig. 41
When ma.king through-hole into adhesive layer and cutting

the adheSive, be careful not to damage interior and exterior Stopper
parts. L5-224
Fig. 43
INSTALLATION
Remove tack paper from back of spacer stopper and stick it to
1) Removing gum rubber and spacer stopper.
body positively.
(1) After cutting layer of adhesive, remove remaining
5) Positioning glass.
gum rubber on body.
(1) Mount glass on body.
(2) Remove remaining spacer stopper. At this time, also
(2) Adjust position of glass so that gap between body and
remove two-sided tape from spacer stopper completely.
glass is uniform on all sides.
2) Finishing adhesion surface on body side.
(3) Put matching mark on body and glass in several
Using a cutter knife, etc., cut layer of adhesive sticking to
places.
body and finish it into a smooth surface of about 2 mm
6) Cleaning glass.
(0.08 in) in thickness.
(1) Dismount glass from body.
(2) Clean surface of glass to be adhered with alcohol or
white gasoline.
7) Application of primer.
(1) Using a sponge, apply primer to part of glass to be
adhered.
(2) Apply primer to part of body to be adhered.
2 mm (0.08 in)
L5-223
Fig. 42
Take extra care not to cause damage to body paint. Glass side Body side
3) Cleaning body surface.

L5-225
(1) Thoroughly remove chips, dirt and dust from body
surface. Fig. 44
21
a. Primer is hard to wipe off body paint, instrument panel, 10) Installation of moulding.
inner trim, etc. if dropped on them. So put masking on them. (1) Remove adhesive overflowing outside of glass until it
b. After application, 1st primer will dry spontaneously for becomes level with outer height of glass. Then, add
about 10 minutes. adhesive to portions that need it.
c. Do not touch primer-coated surface under any circum-
stances.
8) Application of adhesive.
(1) Cut nozzle tip of cartridge as shown in figure below.
(2) Open cartridge and put it into a gun with nozzle
attached.
(3) Apply adhesive uniformly to all sides of adhesion
surface while operating gun along glass end face.
Apply adh.esive
while building it up
~ 10.47 to 0.591.
L5·228
Fig. 47
(2) Insert mouldings into corner parts, and then put them
10 (0.39) into slits in body.
A-~
(3) Press·fit mouldings.
(4) Remove overflowing adhesive with a spatula, and
~ 15 (0.59)
Unit: mm (in) clean with alcohol or white gasoline.
Cut off nozzle tip
L5·226 a. Install mouldings with proper facing_
Fig. 45
9) Installation of glass.
(1) Hold glass with rubber suction cups.
(2) Mount glass on body with matching marks aligned.
(3) Stick them fast by pressing all sides lightly.
Glassend • • Body end
L5-729
Fig. 49
b. Do not open and close door after mouldings have been

installed. When opening and closing door for unavoidable
reason, lower door glass and gently move door.
L5·227
Fig. 46
22
11) Water leakage test. Rear Quarter Glass

Test for water leakage about one hour after installation.
a. Move vehicle very gently. REMOVAL

b. Do not squirt strong hose stream on vehicle.
1) Remove upper side moulding.
12) Spontaneous drying. 2) Remove lower side moulding.
After completing all operations, leave vehicle alone for 24 3) Remove drip moulding.
hours. 4) Remove rear quarter moulding.
5) Remove center pillar cover.
When delivering vehicle to user, ,tell him that vehicle should 6) Remove rear pillar cover.
not be sUbjected to heavy shocks for at least three days. 7) Remove rear quarter glass in same manner as for wind-
shield.
13) Install wiper arm.
INSTALLATION
1) Removal of spacer, etc.

After cutting layer of adhesive, remove remaining spacers and
two-sided tape securing them to body.
2) Finishing layer surface of adhesive on body.
Using a cutter knife, etc., cut layer of adhesive stuck firmly
to body and finish all sides of layer into plain surface of about
1 mm (0.04 in) in thickness.
Rear Window Glass
REMOVAL 1 mm (0.04 inl
1) Remove side upper moulding.

2) Remove side lower moulding.
3) Remove rear pillar cover.
4) Remove upper rear moulding.
5) Remove lower rear moulding.
6) Disconnect terminals of heating wire print.
7) Remove glass in same manner as for windshield.
L5-234
Fig. 50
Work carefully to avoid damaging body coating.

INSTALLATION
3) Temporary installation of glass.
(1) Apply new spacer and rear quarter glass to see if they
1) Install glass in same manner as for windshield.
can be put in as before.
2) Install lower rear moulding.
(2) If they cannot be, this is because there is an over-
3) Install upper rear moulding.
lapping portion. So cut that portion with a putty knife,
4) Install rear pillar cover.
5) Install lower side moulding. etc.
6) Install upper side moulding. 4) Cleaning of body surface.
(1) Remove chips, dirt and dust from body surface.
7) After installation, test for water leakage after about one
(2) Clean body wall surface and upper surface of layer of
hour and leave vehicle alone for 24 hours.
adhesive with a solvent such as alcohol or white gasoline.
8) Make heating wire print connections.
5) Cleaning of glass.
(1) Remove dirt and dust from surface of glass to be
Always install mouldings and cover immediately after install-
ing window glass. adhered.
23
(2) Clean surface of glass to be adhered with alcohol or 9) Installation of glass.
white gasoline. (1) Hold glass with rubber suction cups.
6) Pasting of spacer. (2) Mount glass on body.
Put new spacer at places where it was removed. (3) Stick them firmly together by lightly pressing down.
7) Application of primer. 10) Water leakage test.
(1) Using a sponge, apply primer to surface of glass to be After installing glass, test for water leakage after about one
adhered. hour.
(2) Likewise, apply primer to area of body to be adhered.
a. Move vehicle gently.
b. When opening and closing door, lower door glass and move
door gently.
c. Do not squirt strong hose stream on vehicle.
10 mm (0.39 in)
11) Spontaneous drying.
After completing all operations, leave vehicle alone for 24
hours.
When delivering vehicle to user, tell him that vehicle should

not be su bjected to large shocks for at least three days.
12) Install rear pillar cover.

13) Install center pillar cover.
L5·235
14) Install rear quarter moulding.
Fig. 51
15) Install drip moulding.
16) Install lower side mOUlding.
B. If primer has dropped onto body finish, it is hard to wipe 17) Install upper side moulding.
off. So protect with masking.
b. Primer must not project from black frame of glaa. Always install mouldings and covers immediately after install·
c. After applying primer, I.t it dry spontaneously for about ing window glass.
10 minutes.
d. Do not touch primer·coated surface under any circum·
stances.
8) Application of adhesive.
(1) Cut nozzle tip as shown in figure below.
(2) Open cartridge and put it into a gun with nozzle
attached.
(3) Apply adhesive uniformly to all sides of adhesion
surface while operating gun along glass end face.
10 (0.39)
10 (0.39)
o 15
(0.591
10
(0.391
Unit: mm (in)
L5·236
Fig. 52
24
TROUBLESHOOTING
Door Glass
Condition Apparent cause/Correction
Window in (1) When applying hand pressure to window glass • Window is too low in relation to roof
fully-closed from inside, glass runs out of weatherstrip, weatherstrip. (TDC of window glass
position especially at upper center pillar location. not properly adjusted.)
• Adjust so upper edge of window glass
properly fits into weatherstrip lips.
Fig. 53 L5-289
* Wind noise occurs during high-speed operation

if window glass is not properly adjusted. * Do not allow window glass to ride over
lips when door is opened or closed.
Door in fully (1) Window glass rides over weatherstrip lip. • Window glass is too high in relation to
closed/open roof weatherstrip. (TDC of window
position glass not properly adjusted.)
• Adjust so upper edge of window glass
properly fits into weatherstrip. Also
adjust fore·aft clearances of glass in
relation to body weatherstrips.
* Window glass should not be lowered to
Fig. 54 L5.290 the point that it does not contact
* Wind noise occurs or water leaks if window weatherstrip.
glass is not properly adjusted.
(2) Window glass rides over edges of weatherstrip (on • Window glass clearances in the fore-aft
the center pillar side) when door is opened or direction are not adjusted equally.
closed. It also should not contact retainer. • Move window glass forward, as
required.
* Do not allow front edge of window
glass to ride over weatherstrip.
Fig. 55 L5·291
* Wind noise occurs or water leaks if window

glass is not properly adjusted.
When window (2) Regulator does not move smoothly. • Stabilizer pressure against window
is raised or glass is excessive or regulator is preset
lowered improperly.
• Adjust so there is no clearance between
window glass and stabilizer.
• Reduce contact pressure.
25
I'
Door Lock System

No. Trouble Possible cause Remedy
Door cannot be opened Excessive play of outer Adjust play of rod to 0.5 to
by outer handle or handle rod. 1 mm (0.020 to 0.039 in) by
outer handle flap does turning adjusting nut in or
not return to its original Excessive play out.
position
(Door can be opened by
inner handle)
Fig. 56 L5-237
2 Door cannot be opened a. Joint of lower rod is loose. Retighten firmly.

by inner handle Functionally normal.
(Door can be opened by
outer handle)
3 Door does not open a. Joint of upper rod is disconnected. Loosen screw linking upper
when outer or inner rod, pull forward connector
handle is operated with with latch, and install rod with
inner lock knob set to lock knob butting against
unlock position stopper (red label cannot be
seen).
(See Fig. 58.)
Connector (upper: white)

Locked
\ Push
-to 31111100 + E'4? ) Bracket
~
"~(EC33=;)~\~1 --
Pull
Lock knob
Rod (lower)
Connector (lower: yellow)
LS-293
Fig. 57
b. Lock is not released due to improper adjustment Positively link joint in above
of upper rod (red can be seen large in locked manner.
state). (See Fig. 58.)
26
No. Trouble Possible cause Remedy
3 Door does not open c. Lock is not released due to outer handle rod
when outer or inner pressing down lever.
handle is operated with
inner lock knob set to Rod pushes leller too far downward.
unlock position
Standard lock position
Link pin rides on

outer handle leller and
Lock will be reteased. lock cannot be released.
Fig. 58 L5·239
4 Door opens even when a. Upper rod joint is separated. Same as a in No.3.
inner lock knob is set (See Fig. 58.)
to lock position b. Door;s not locked due to improper adjustment. Same as b in No.3.
(Keyless locking is
(See Fig. 58.)
impossible)
5 locking and unlocking Contact of lock knob with inner remote mounting Eliminate contact by bending
of inner remote is not bracket. bracket or applying oil.
smooth.
Check for proper contact
Check for proper

contact
L5-294
Fig. 59
6 Inner handle stops Contact of inner handle with inner remote Apply oil or replace faulty
halfway mounting bracket. part.
27
SEATS, SEAT BELTS, AND
INTERIOR
Page
BUBARU MECHANISM AND FUNCTION.. . . . . . . . . . . . • . . . . . . . . . . . . . . •. 2

Front Seat ........................................... 2
Rear Seat ..... . . . . . . • . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . .. 4
1988 Seat Belts ... . . . . . . . . . . . . . . . . . . . . . . . • . . . . . • . . . . • . . . . .. 5

Inner Trim .........................•................. 8
COMPONENT PARTS . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . .. 9
Front Seat ....................•....•..........•...... 9
Rear Seat ..................... . . . . . . . . . . . • . . . . . • . • . •. 9
Seat Belts ..• . . • . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . • • . . . •. 10
Inner Accessories . . . . . . • . . . . • . • . . . . . . . • . . . . . • . . . . . . • • . •. 11
Inner Trim ..........•..............•................. 11
SERVICE PROCEDURE ......................•.....•...••. 12
Front Seat ..•.......•.........................•...•.. 12
Rear Seat ...........•••........•..............•....•. 12
Trim Cushion And Trim Back . . . . . . . . . . . . . . . . . . . • . . . . . . . . . .. 13
Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14 _
Console Box .......................................... 18
Inner Trim .......•......................•....•....... 19
TROUBLESHOOTING ............•........................ 24
5-3 SEATS, SEAT BELTS, AND INTERIOR

All seats are designed for improved riding comfort. The
driver's seat can be precisely adjusted to provide the optimum
driving position.
Rear link
Front Seat Brake mechanism
Front link
L5-640
SEAT SLIDING
Fig. 2
When the slide adjuster lever is turned, the slide rail lock is
released. The front seat can then be moved 190 mm (7.48 in)
in the fore-and-aft direction [13 positions at a pitch of 16 mm
(0.63 in)].
Mechanism
When the adjustment lever is extended and moved up. the
Standard position pinion. interconnected with the lever. will move in direction A.
(4th position) This causes the sector gear to rotate in direction B. so that the
55.4
0 front link is lifted in direction C. The rear link also is lifted.
(Approx. along with the front link, in direction D. As a result, the entire
0
204.75 mm 2.5 x 22 seat cushion moves up. The brake lock mechanism, which is
(8.0610 in) positions)
[15.75 mm built into the rotary shaft section of the adjustment lever, has
(0.6201 in) the same design as the window regulator in order to securely
c:::1:'->,.1n_9_...>.-
x 13 positions) R I' .
hold the cushion in place.
Side adjuster lever

L5-639
Fig. 1
Lifter lever
LS-003
SEAT RECLINING
Fig. 3
When the reclining lever is moved UP. the reclining hinge lock
is released. The seat backrest can be adjusted every 2°30', and
also folded fully forward.
SEAT LI FTE R LUMBAR SUPPORT

When the lifter adjustment lever is extended and rotated, the The lumbar support adjustment lever can set the loin support-
lifter brake is released. The seat can be precisely adjusted to fng section of the seatback to any of four positions in the
the desired height within a range of 40 mm (1.57 in). fore-and-aft direction.
2
SEATS, SEAT BELTS, AND INTERIOR 5-3
WALK·IN SYSTEM REMOVAL AND INSTALLATION OF

When getting in or out of rear seat, front seat can be moved to HEADREST (Exc. XT·6 model)
the forwardmost position as follows: To remove the headrest, lightly turn lock release knob
Depress pedal or lift reclining hinge lever to tilt backrest (counterclockwise) located on the upper left side of the seat
forward. Wire cable connecting reclining hinge will then release backrest and lift out headrest.
slide rail lock so that seat moves forward by helper spring. To install, align headrest stays with the holes in the backrest
and push headrest in firmly.
When turning lock release knob, be careful not to damage the

seat cover.
Back rest
Reclining lever
L5-641
Fig. 4
HEADREST FORE·AND·AFT ADJUSTMENT

(XT -6 model only)
To adjust the headrest, hold it with both hands. Move it
t .\.--_J~
in the fore-and-aft direction and release it at the desired
position. The headrest will lock in that position.
L5-643
Fig. 6
L5-642
Fig. 5
3
(XT-6 model) Rear Seat

To remove the headrest, lightly turn lock release knob
(counterclockwise) located on the upper left side of the seat FOLDABLE BENCH SEAT
backrest and lift out headrest. The lock release knob is able to
be seen after lifting the left bellows (as viewed from the rear
of the car).
To install the headrest, align headrest stays with the hole
and push headrest in firmly.
When turning lock release knob, be careful not to damage the

seat cover.
(Unlock)
8
(Lock)
L5-645
Fig. 8
Operation
L5-644 1) Unlock key located under strap and pull strap. Backrest
~----------------------------------~~~
Fig. 7 will then tilt forward.
4
Seat Belts
Front Seat Belt
Rail & motor ASSY

2 ELR ASSY
3 Belt guide
4 Knee panel
5 Outer belt ASSY
(Manual lap belt)
6 Inner belt ASSY
(Manual lap belt)
7 Shoulder anchor
8 Emergency release buckle
9 Rail
10 Locking device
11 Tube
12 Motor
13 Belt holder
14 ELR ASSY
(Manual lap belt)
15 Caution label
16 Shoulder belt
L5-646
Fig. 9
Features 2) -E LR (Emergency Locking Retractor) ASSY

The ELR's used on the driver and passenger seats are com-
The front seat is equipped with an automatic shoulder belt bined. They are located on the upper side of the floor tunnel
system and a manual lap belt. in front of the rear seat cushion. The belts extracted from the
ELR's turn at the belt guide and latch on the ERB (Emergency
AUTOMATIC SHOULDER BELT SYSTEM Release Buckle). These belts are used as shoulder belts.
1) Rail & motor ASSY 3) Belt guide'
This system consists of a shoulder anchor, guide rail and motor The belt guide is secured to the slide rail between the driver
ASSY. and passenger seats, on the floor tunnel. The belt extracted
(1) Shoulder anchor from the ELR turns at the belt guide and restrains the upper
The shoulder anchor is united with an E RB (Emergency body of the driver or passenger at a fixed position, regardless
Release Buckle). It is securely latched to the shoulder belt of physique and seating position.
tongue and allows the tongue to move along the guide
rail.
The shoulder belt fits the occupant when pulled to the center
(2) Guide rail
pillar although it appears to be twisted when moved to the
The guide rail allows the shoulder anchor to move along
center pillar.
the track on the front pillar, side rail and center pillar.
(3) Motor ASSY MANUAL LAP BELT
The motor ASSY winds or unwinds the wire moving along 1) Outer belt ASSY
the guide rail which moves the shoulder anchor. The belt extracted from the ELR (located below the center
pillar) is secured by the belt holder close to the seat hinge
cover. It is within easy reach, regardless of the seating position.
5
2) Inner belt ASSY 2) Submarine-preventing material (incorporated in passenger
The inner belt ASSY is parallel to the belt guide. Its buckle is seat cushion)
secured in a fixed position, regardless of physique and seating Unlike the driver's seat, the position of the passenger seat can
position. be optionally selected. (In other words, the passenger is less
restrained than the driver.) As a result, the distance between
Others the passenger's knee and knee panel is not constant. For this
1) Knee panel
reason, submarine-preventing material is incorporated in the
The knee panel is located below the instrument panel. front edge of the passenger seat cushion to help increase the
It restrains the lower body of the driver and passenger in a effect of the knee panel.
front-end collision.
Operation
Front limit switch

2 Rear limit switch
3 Warning switch
4 Door latch switch
5 Motor
6 Control unit
7 Buckle switch
L5-647
Fig. 10
The automatic shoulder belts (for the driver and passenger)

Contro~ unit
are controlled by a control unit located behind the motor
ASSY under the lower part of the right hand side rear quarter
section.
These belts operate in response to the opening/closing of
the corresponding doors.
I
CirCUIt
When the door is closed, the shoulder anchor moves to the brea-ker
extreme end of the center pillar guide rail. It stops and locks I
there (Fig. 11). When the door is opened, the door lock switch
turns from CLOSED to OPEN, turning relay L 1 ON. I :,~~-
_____
L2.
- L ----~
L5-648
Fig. 11
6
The motor then rotates so that the shoulder anchor moves If the door is closed before the shoulder anchor reaches the
to the front (Fig. 12). When the shoulder anchor reaches the front end or if the door is opened before the anchor reaches
front end, the front limit switch turns from CLOSED to the rear end, the door lock switch turns from OPEN to
OPEN, turning relay L 1 OFF and stopping the motor (Fig. CLOSED or from CLOSED to OPEN. This alternately turns
13). relays L1 and L2 ON and OFF, moving the shoulder anchor in
the corresponding direction. Time required for the shoulder
anchor to move from one end to the other is approximately
2 seconds.
Motor & Wire Protection Circuit

A circuit breaker and timer are used to protect the automatic
SWitch -=- shoulder belt system circuit from damage.
L5-649 If the shoulder anchor sticks for more than 13 seconds,
current flowing to the motor will be interrupted. However, it
Fig. 12
can be corrected by opening and closing the door. If the motor
When the door is closed, the door lock switch turns from overloads, the circuit breaker activates immediately to inter-
OPEN to CLOSED, turning relay L2 ON. rupt the current, protecting the motor against damage.
The circuit breaker automatically resets as soon the overload
Control unit is eliminated. Basically, the timer activates before the circuit
breaker does.
GUide rai~
Rear Seat Belt

Two rear seat belts are installed. These seat belts are 2-point
hitch type and equipped with an ALR (Automatic Locking
L5-650 Retractor).
~--------------------------------------------~
Fig. 13
The motor then rotates so that the shoulder anchor moves to

the rear (Fig. 14). When the shoulder anchor reaches the rear,
the rear limit switch turns from CLOSED to OPEN, turning
relay L2 OFF and stopping the motor (Fig. 11).
L5-652
Fig. 15
L5-651
Fig. 14
7
Inner Trim 3) Urethane material is installed around the rear surface to

prevent booming noise and entrance of dust and dirt. An
Door Trim insulator is also used, depending on the specifications.
4) The covering material used for the roof trim is tricot to
The front and rear door trims are made up of formed core
provide a good outward appearance.
materials at the window shoulder location with soft formed
covering materials pasted over the core material. Trims used in
other areas consist of a board, cushion and covering material
pasted. The covering material used with trims is either chloride Floor Mat
vinyl, tricot or moquett, depending on the specifications.
Some lower trims are equipped with carpets. The front and rear floor mats are a one-piece, wall-to-wall
type, which have a noise and heat-insulator on the back side.
Foamed chloride vinyl mat, needle punch carpet, and cut-pile
carpet are also available for installation, depending on the
Trim Panel and Side Sill Cover specifications.
1) The trim panel and side sill cover is a polypropylene,

injection-molded type to provide a fresh appearance.
2} A sealing material is installed on the front and rear pillars
to improve noise-proofing.
~ tdm
Sealing material Pillar trim
L5-653
Fig. 16
8
COMPONENT PARTS
Front Seat 2
1 Headrest
Backrest
11 Seat lifter lever
12 Lifter lever cover
CD
3 Lumbar support knob 13 Belt guide
4 Reclining lever 14 Inner belt ASSY
5 Hinge cover 15 Hinge protector ® @
6 SI ide rail ASSY 16 Belt holder ® ~
7 Bolt cover 17 Belt holder cap ~ ~~,fo
8 Rail cap 18 Belt stopper .-' ,~
9 Hinge ASSY 19 Seat anchor cover ® . /JJJ~ J
10 Cushion
~
1/'" _~
'it'
'.
/j"
@
®
0@ II 'it'/~-;;~~ [~'~~'~~-::::-!r(
~1
~@
\t1~@~®
~~ ': {:
r.c...-_-.F
___-_I,
1 ~';,6/~
1:
: ~ ... ·1"
/1:
/u ®
~@
~
1 1
I 1
I
Rear Seat
[Seat lifter equipped model)

T1: 20 - 39 (2.0 - 4.0,14 - 29)
T2: 15 - 34 (1.5 - 3.5,11 - 25)
T3: 25 - 34 (2.5 - 3.5,18 - 25)
T4: 6 - 18 (0.6 - 1.8,4.3 - 13.0)
1 Striker T5: 18 - 27 (1.8 - 2.8,13 - 20)
2 Backrest
3 Hinge
4 Center bracket
Fig. 17 5 Cushion L5·654
9
Seat Belts
1 Rail & motor ASSY

2 ELR ASSY
3 Belt guide
4 Inner belt ASSY
5 Outer belt ASSY
6 Rear outer belt ASSY
7 Rear inner belt ASSY
Tightening torque: N·m (kg-m, ft·lb)

T1: 25 - 34 (2.5 - 3.5, 18 - 25)
T2: 6 - 9 (0.6 - 0.9,4.3 - 6.5)
L5-655
Fig. 18
10
SEATS, SEAT BELTS AND INTERIOR 5-3
Inner Accessories
1 Sun visor ASSY

2 Rear view mirror ASSY
3 Rear view mirror cup
4 Coat hanger
5 Assist rail
6 Ash tray
7 Console boot
8 Console cover ASSY
9 Pocket lid CP
10 Console box (upper)
11 Tray CP
12 Console base
13 Console bracket CP
14 Console bracket (8)
15 Console bracket (A)
16 Console box bracket
17 ELR cover
L5-656
Fig. 19
Inner Trim
Front pillar trim panel

2 Front pillar center trim panel
3 Front pillar lower trim panel
4 Rear bul k trim panel
5 Rear quarter upper trim panel
6 Rear quarter bracket
7 Side cover plate
8 Side sill cover
9 Rear quarter pocket
10 Rear quarter strip
11 Rear quarter lower trim panel
12 Rear shelf trim panel
L5-657
Fig. 20
11
SERVICE PROCEDURE
Front Seat INSTALLATION
REMOVAL 1) Fold backrest forward.

2) Move lower slide rails forward so that front seat is
positioned all the way back.
1) Move front seat all the way back using slide adjuster lever.
3) Position front seat and align mounting holes.
2) Remove bolts which hold front section of seat.
4) Tighten bolt which holds front section of seat on tunnel
3) Move front seat all the way forward.
side (at reference hole).
4) Remove bolt cover from rear end of slide rail on door side.
5) Tighten bolts which hold front section of seat on door
side.
6) Move front seat all the way forward.
7) Tighten bolts which hold rear section of seat on tunnel
side.
8) Similarly, tighten bolts on door side.
9) Tighten anchor bolt.
10) Install bolt cover at rear seat on door side and seat anchor
cover at rear of seat on tunnel side.
11) After properly installing seat, move it back and forth to
make sure slide rails function properly without binding.

20 - 39 N·m (2.0 - 4.0 kg-m, 14 - 29 ft-Ib)
L5-658
Anchor bolt (pinch) tightening torque:
Fig. 21 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-Ib)
Tighten bolts in the order designated.
5) Remove seat anchor cover from rear end of slide rail on

tunnel side.
Rear Seat
~CO",OlebO' REMOVAL
r - - - - _ __
1) Remove bolts which hold front of rear cushion to floor.
2) Slightly raise front side of rear seat cushion and push
center rear section down. With seat cushion held in that
position, move it forward until it is unhooked.
L5-659
Fig. 22
6) Remove bolts which hold rear section of front seat and

anchor bolt.
L2-298
Fig. 23
12
3) Pass rear seat belt through slit at rear section of rear
cushion. INSTALLATION
Trim Cushion And Trim Back

(1800cc DL model)
\\,--'-""~---
'--_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _=L2:..:-2:.:9:::..J9 1)
REMOVAL
Remove bolts which hold front of trim cushion to floor.

Fig. 24 2) Slightly raise front side of trim cushion and push center
rear section down. With trim cushion held in that position,
move it forward unti I it is unhooked.
4) Fold seat back rest forward and remove bolts which hold 3) Remove caps from upper section of trim back, using a
hinge to the right side of backrest. standard screwdriver, and remove screws.
4) Lift trim back up and remove.
Trim back
Hook
Trim cushion
Fig. 25
L5·379
Fig. 27
5) Tilt rear seat backrest [approx. 400 mm 115.75 in)] for·
ward and slide it toward the right until it can be detached
from the left bracket.
INSTALLATION
t'\
About 400 mm (15.75 in)
"I
\'.\
\'\,
Fig. 26
~ L5-378
13
5) Remove M6-bolts which hold side rail and motor ASSY.

Seat Belts
Front Seat Belts (Automatic Shoulder Belt)
Rail & Motor Assembly
In case the connector to the automatic shoulder belt has been
disconnected for repairs of the automatic shoulder belt or
related parts or for repairs of other parts, be sure to disconnect
the battery and reset the control unit.
If the connector of the automatic shoulder belt control unit or
the connector of the front or rear limit switch has been dis-
connected once during repairs, the control unit can enter the
failure mode when the connector is reconnected, making the
automatic shoulder belt inoperative. L5-662
Fig. 30
REMOVAL
1) Push emergency release button on the shoulder anchor

and remove belt.
Fig. 31
Fig. 28
2) Remove rear seat cushion and backrest. DISASSEMBLY

3) Remove front pillar trim panel, rear quarter trim panel
(upper and lower) and roof trim.
FRONT LIMIT SWITCH
4) Disconnect the connector of the front limit switch, rear
limit switch and motor. 1) Remove screw and slide it in direction of the arrow.
Front limit switch

bracket
L5-661 L5-664
Fig. 29 Fig. 32
14
LOCKING DEVICE (REAR LIMIT SWITCH,
WARNING SWITCH)
1) Remove E-clip which fixies pin of the rail and tube and Shoulder anchor Rail
pull out the pin. (Emergency
release buckle)
Locking device
Pin Wire
L5·665
Fig. 33
·c."'"
2)
3)
Remove tube in the rail.
Pull out locking device by sliding. A
'I:' . "•.• .
Section-C
Section-A Section-B
L5-667
Locking device Fig. 35
b. Do not remove grease from wire.

c. Do not bend or twist wire too sharply.
L5-666 INSTALLATION
Fig. 34
Installation is the reverse order of removal.
Use M5·bolts length 12 mm (0.47 in) (901010001) or equiv·

alent when installing assist rails.
SHOULDER ANCHOR (EMERGENCY RELEASE
BUCKLE) & MOTOR ASSY
1) Remove locking device.
2) Remove motor ASSY wire and shoulder anchor as a unit
from guide rail.
OPERATION CHECK
Perform operation checks after replacing parts.

ASSEMBLY
RAI L & MOTOR ASSY
Assembly is the reverse order of disassembly. While latching shoulder belt on shoulder anchor (emergency
release buckle). open and close the door to check that
a. Assemble plastic part and shoulder anchor to wire end, as shoulder anchor moves smoothly without binding, free play.
shown in Figure 35, and insert into guide rails. etc.
15
EMERGENCY RELEASE BUCKLE

DISASSEMBLY
Check that tongue properly releases when emergency release
button is pressed. Also check that click is heard to indicate
Remove M6-bolts which mount base of ELR.
proper latching when tongue is inserted into emergency release
buckle.
ELR Assembly
REMOVAL

and remove belt.
2) Remove belt stopper. Withdraw shoulder belt from belt
guide and wind on shoulder belt until the end reaches outlet
Fig. 38
hole on console box.
Reverse the removal and disassembly procedures.
OPERATION CHECK
L5-668
Perform operation checks before installing new parts.
Fig. 36
1) Align point of ELR ASSY with floor tunnel and tempo·
rarily install E LR ASSY. Check that shoulder belt winds and
unwinds properly.
2) GraduaJly tilt E LR ASSY. Check that ELR locks so that
3) Remove front seat. belt cannot be withdrawn when ELR is tilted 45° or more in
4) Remove console box. relation to standard installation angle, and that ELR unlocks
5) Remove anchor bolts which hold ELR ASSY. when it is tilted within 15°.
Standard installation angle L5·733
Fig. 37 Fig. 39
16
Manual Lap Belt Inner Belt Assembly
Outer Belt Assembly
REMOVAL
REMOVAL
and remove belt.
1) Remove belt holder cap and remove either front or rear 2) Remove belt stopper. Remove shoulder belt from belt
screw from belt holder. guide and reel it until its end reaches outlet hole in console
box.
3) Remove front seats. (Disconnect belt warning connector
located under driver seat.)
L5-672
Fig. 40
Fig. 42
2) Remove tongue from belt and reel the entire belt into 4) Remove anchor nut and inner slide rail as a unit. (On
ELR. driver seat, also remove tape which secures harness.)
3) Move front seat to the extreme front position and remove
anchor bolt and screw.
Fig. 43
L5-673
Fig. 41
INSTALLATION
a. The left and right ELR's are not mutually interchangeable

INSTALLATION because different sensors are used.
b. On inner belts, be sure to insert pin into position-limit
I nstallation is in the reverse order of removal. guide hole.
17
OPERATION CHECK
h
Must be installed with installing
surface facing downward.
Perform operation checks before installing new parts. (Align with rotating stopper
.Q stepped portion.)
'-
1) Temporarily install ELR ASSY under center pillar. Check
that lap belt reels in and out properly. ~~
W·.
2) Gradually tilt ELR ASSY. Check that ELR locks so that Must be installed parallel
to vehicle center line
lap belt cannot be withdrawn when ELR is tilted 45° or more with installing surface
in relation to standard installation angle, and that E LR
~ng downw"d
unlocks when it is tilted within 15°.
LS-30S
Fig. 45
L5-734
Fig. 44 Console Box
REMOVAL
1) Remove front seats.

Rear Seat Belt 2) Apply hand brake lever.
3) Remove console cover and disconnect connector of
REMOVAL cigarette lighter.
4) Remove clips from tray and detach tray.
OUTER BELT
1) Remove rear cushion and rear back rest.
2) Remove rear quarter upper and lower trim panel.
3) Remove outer anchor bolt and outer belt.
INNER BELT
1) Remove rear cushion.
2) Remove inner anchor bolt and inner belt.
Tray
INSTALLATION L5·306
Fig. 46
a. Remove anchor bolts, washers, spacers, etc. as a unit.

b. Be careful not to twist belts during installation.
c. Do not confuse outer and center buckles during installa·
tion. Although they look alike, they are not interchangeable.
18
5) Remove caps from the side of console box. Rear Luggage Shelf
6) Open console box lid and remove screws from bottom
of console box.
REMOVAL
1) Remove rear seat cushion and backrest.

2) Remove rear pillar upper trim panel.
3) Disconnect harness connector for "H igh·mount stop
lamp".
4) Remove eight clips which hold rear luggage shelf, and
detach rear luggage shelf.
[If equipped with mat, use CLIP PULLER (925580000) to
remove eight clips.)
INSTALLATION
Fig. 47
7) Remove screws from the side of console box.

8) Disconnect switch harness connectors, and move console
box back and up.
Inner Trim
Front Pillar Upper Trim Panel
REMOVAL
1) Remove assist rail from passenger seat side.

2) Pull trim panel down at side rail location, and remove
resin clips.
Front pillar upper

trim panel
Fig. 48
INSTALLATION
I nstallation is in the reverse order of removal.

Fig. 49
Do not allow wiring harnesses to get caught in console box
when installing.
3) Pull trim panel at front pillar location, and remove the
sheet metal clip from car body.
4) Slide trim panel back and remove.
19
I'"
I
/ /
INSTALLATION .~1rimpanel
/ -
1) Be sure clips are securely installed on trim panel.
2) Align clips with holes in front pillar, and tap trim panel
until clips are fitted into body.
3) Align clips with holes at side rail location, and tap trim
panel until clips are fitted into car body.
4) Install assist rail on passenger seat side.
Use H5-bolts length 12 mm (0.47 in) (901010001) or equiv-

I
..:-
alent when installing assist rails.
I .
L5·681
Fig. 50
5) Remove clips (6 places) which hold trim panel to car

Front Pillar Center Trim Panel body, using CLIP PULLER (925580000).
6) Disengage pawls from body flange at front section of trim
panel.
REMOVAL 7) Slide trim panel forward and remove.
Pull trim back and remove.

INSTALLATION
INSTALLATION Installation is in the reverse order of removal.
Insert lower side of center trim panel into lower trim panel
Be sure pawls are securely attached to body flange at front
and push it against body flange. section of trim panel.
Rear Quarter Lower Trim Panel
Front Pillar Lower Trim Panel REMOVAL
1) Remove rear back rest and cushion.

REMOVAL
(On D L models, remove trim cushion and trim back instead.)
2) Remove rear quarter upper trim panel.
1) Remove clip which holds the right lower cover.
3} Remove clips (6 places) which hold lower trim panel to
2) Pull trim panel back and remove.
car body, using CLIP PULLER (925580000).
Rear Quarter Upper Trim Panel
REMOVAL
1) Fold rear back rest forward. (On D L models, remove trim

back.)
2) Remove shoulder anchor bolt of seat belt.
3) Remove belt cover at outer belt outlet portion and
remove screw.
4) Remove clip from rear section of trim panel. Fig. 51
20
4) Slide lower trim panel forward and remove.
INSTALLATION
Rear Bulk Trim Panel Installation is in the reverse order of removal.
Do not allow harnesses and piping to get caught betlllJeen side

REMOVAL sill cover and car body during installation.
1) Fold rear back rest forward. (On DL models, remove trim

back.)
2) Remove rear sides of rear quarter upper trim panel and
lower tri m panel.
3) Remove bolts which hold striker.
4) Remove clips (4 places) and stoppers (2 places) which
hold rear bulk trim panel to car body, using CLIP PULLER
(925580000) .
Trunk Mat
Rear bulk trim panel REMOVAL
1) Fold rear back rest forward. (On DL models, remove trim

cushion.)
2) Remove spare tire supporter and holder.
L5-312
Fig. 52
5) Remove rear bulk trim panel from car body.
L6-683
INSTALLATION Fig. 53
3) Remove clips which hold front side of trunk mat, and

Be sure upper section of rear bulk trim panel is placed betMen
detach trunk mat.
rear luggage shelf and car body.
,.
Side Sill Cover
REMOVAL Rear Luggage Shelf
1) Remove rear seat cushion. (On DL models, remove trim REMOVAL

cushion).
2) Remove E LR unit of the manual lap belt. 1) Fold rear back rest forward. (On DL models, remove trim
3) Remove side cover plate. back.)
4) Remove clips from side sill cover. 2) Remove rear quarter upper trim panel.
5) Remove tapping screws from side sill cover, and detach 3) Remove clips (10 places) which hold rear luggage shelf to
side sill cover from car body. car body, using CLIP PULLER (925580000).
21
Trunk Rear Trim Panel Roof Trim
REMOVAL REMOVAL
1} Remove clips (7 places) which hold trim panel to car 1) Completely open doors and lower windows all the way.
body. 2) Fold front seat back rest rearward.
2} Remove trim panel from trunk while deflecting it. 3) Remove sun roof escutcheon, (sun roof models).
4) Remove clips (4 places) which hold rear trim rai I, using
CLIP PULLER (925580000).
Fig. 54 / L5-316
Fig. 56
5) Remove rear quarter upper trim panel.

6) Remove assist rail caps using a standard screwdriver, and
remove screws which hold assist rai I.
7) Remove front pillar upper trim panel.
Trunk Side Trim Panel
8} Remove rearview mirror cap.
Straighten tongues which engage with rearview mirror stay in
REMOVAL advance.
1} Remove rear seat cushion and back rest. (On DL models,

remove trim cushion and trim back.)
2) Remove rear quarter lower trim panel.
3) Remove center clip.
4) Detach adhesive tape which holds front and upper rear
sections of trim panel to car body, and remove trim panel.
Fig. 57
9) Remove spot & room lamp, and disconnect harness

connector.
Trun k side trim panel 10) Remove rearview mirror.
11) Turn roof clip on passenger side counterclockwise and
Fig. 55 remove.
22
12) Remove coat hanger on driver's side. Floor Mat
13) Remove sun visor and hook.
REMOVAL
1) Remove front seat.

2) Remove rear seat cushion. (On DL models, remove trim
cushion.)
3) Remove E LR unit of the manual lap belt.
4) Remove console box.
5) Remove front pillar lower trim panel.
6) Remove clips (3 places) from rear section of floor mat.
7) Remove side cover plate.
Fig. 58
14) Remove clips A which hold trim to roof, using CLIP

PU LLER (925580000) (7 places on sun roof models and
place on all other models).
15) Remove roof trim from car body. L5-684
Fig. 60
Do not fold edge section of room trim Vllhen removing.
8) Undo mat hooks.

9) Detach velcro tape of front apron section.
10) Straighten hooks at toeboard location and detach mat.
11) Detach mat from hooks at lower section of heater unit.
12) Remove mat, without disturbing hand brake lever, etc.
INSTALLATION
a. Be sure floor mat is held with hooks and velcro tape.

Fig. 59 b. Be sure side cover plate is held with clips.
23
5-3 SEATS, SEAT BELTS AND INTERIOR
TROUBLESHOOTING
Automatic Shoulder Belt
If the automatic shoulder belt fails to operate, be sure to troubleshoot before disconnecting the battery.
CAUTION:
Even if the automatic shoulder belt does not have faulty parts, it can become inoperative if the shoulder belt anchor is forced
down or the front or rear limit switch is operated manually. In such a case, if you disconnect the battery, the trouble will be
corrected automatically, without giving you the chance to determine its cause.
@ ®
®@ ®
@@
@
®
®QD
®
CD(§)(!)@
@
~
1 Driver's seat side front limit switch 13 GND wire, BATT wire
2 Passenger's seat side front limit switch 14 Passenger's seat side lap belt
3 Passenger's seat side rail & motor ASSY 15 Driver's seat side shoulder belt
4 Driver's seat side rail & motor ASSY 16 Passenger's seat side door cord
5 Passenger's seat side shoulder belt 17 Key switch
6 Passenger's seat side rear limit switch 18 IG.SW.
7 Passenger's seat side ERB switch 19 Warning lamp (built in meter)
8 Driver's seat side rear limit switch 20 Chime
9 Driver's seat side ERB switch 21 Driver's seat side cord
10 Passenger's seat side door switch 22 Driver's seat side door switch
" Control unit 23 Driver's seat side lap belt switch
,2 Wiring harness 24 Driver's seat side lap belt
L5-735
Fig. 61
24
Indication Symptom when

Timing of Operation leading
Location Probable cause when IG. SW. belt anchor Fault reset
occurrence to occurrence
is ON is faulty
A Only when IG. Faulty operation of Front limit switch is Flashing at Belt anchor a
SW. is ON front limit switch pressed or held down 0.3/0.3 sec. remains stationary
when belt anchor is at at reverse end
reverse end
F Always Shorted front limit Door operated 32 times Battery - OFF *1

switch circuit at intervals
Open front limit Belt anchor moved to a

switch circuit reverse end with door
closed
B Only when IG. Disconnection or Connector disconnected Battery - 0 F F

SW. is ON connection of or connected when belt
connector anchor is at reverse end
Always Disconnected Belt anchor moved to c

connector reverse end with door
closed
J Only when IG. Disconnection or Connector disconnected Battery - OFF

SW. is ON connection of or connected when belt
connector anchor is at reverse end
Always Disconnected Belt anchor moved to c

connector reverse end with
battery connected
M Always Disconnected Belt anchor moved to OFF Belt anchor b

connector reverse end when IG. remains stationary
SW. is OFF at reverse end
H Always Open circuit in door Belt anchor moved to b

switch circuit (@l), reverse end
(@**
Only when IG. Open circuit in door IG. SW. is ON Depends on Remains where IG.SW. is
SW. is ON switch circuit (([VI, anchor it was when IG. OFF *1
(@) ** location SW. was turned
ON
Only when IG. Belt anchor moved to OFF Remains stationary a

SW. is OFF forward end when at forward end
Shorted door switch battery is connected
circuit
Only when IG. Belt anchor moved to Flashing at Belt anchor a
SW. is ON reverse end when I G. 0.3/0.3 sec. remains stationary
SW. isON at reverse end
Only when IG. Shorted door switch Belt anchor moved to IG. SW. is
SW. is ON circuit (®) - (@), reverse end when I G. OFF *2
(@l-(@l ** SW. isON
G Only when IG. Faulty operation of Belt anchor arrived at Normal operation IG. SW. is
SW. is ON ERB switch forward end with (lamp flash only) OFF *1
E RB switch held down
K Always Shorted rear limit Door operated 32 times Belt anchor Battery - OFF *1
switch at intervals remains stationary
at reverse end
Open circuit in rear Belt anchor moved to Remains station- c

limit switch forward limit when ary at forward
door is opened end
25
5-3 SEATS, SEAT BELTS AND INTERIOR

isON is faulty
0 Only when IG. Disconnection or Connector disconnected Note Battery - OFF

SW. is ON connection of and connected when belt
connector anchor is at forward end
Flashing at
Always Disconnected Belt anchor moved to 0.3/0.3 sec. Remains station- c
connector forward limit when door ary at forward
is opened end
E Always Incorrect operation ON Belt anchor re- Battery - OFF

of microcomputer mains stationary
at reverse end
I Only when IG. Disconnection or Connector inserted when Flashing at Belt anchor re- Battery - OFF
SW. is ON connection of belt anchor is at reverse 0.3/0.3 sec. mains stationary
connector or forward end at reverse end
N Always Disconnected Door operation OFF No movement b

connector at all
P Always Disconnected Door operation b

connector
0 Always Open circuit in Door operation b

motor circuit
Shorted motor Battery connection Fuse blo......s b

circuit
L Only when IG. Shorted lap buckle IG. SW. is ON when Flashing at Chime does not b
SW. is ON switch circuit tongue is not inserted 0.5/0.7 sec. sound even with-
in lap belt buckle out tongue
Only when IG. Disconnected IG. SW. is ON when Chime sounds b

SW. is ON connector tongue is inserted in even with tongue
lap belt buckle
Q Only when key Disconnected Driver side door OFF Normal operation b
SW. is ON * connector opened with key in (key 1118rning
position chime does not
operate)
R When IG. SW. Disconnected IG. SW. is ON OFF Normal operation b

is ON connector (lamp does not
come ON, key
When IG. SW. Terminal (@) shorted IG. SW. is ON warning chime b
is ON to GND (open to 12V) operates, etc.)
T Always Power failure, blown No motion at all OFF No motion at all b

fuse
U Only when IG. Disconnected IG. SW. is ON OFF Normal operation b

SW. is ON connector (lamp) (lamp does not
come ON)
Short circuit in lamp IG. SW. is ON Deteriorated or Replace control

circuit broken lamp unit
circuit in control
unit. Belt
operates normal-
ly
26

is ON is faulty
V When KEY SW. Disconnected connector Drive door opened with OFF Normal operation b
is ON * and IG. (chime) KEY SW. ON* (key warning
SW. is ON chime does not
operate)
Short circuit in chime Drive door opened with Normal operation, Replace control
circuit KEY SW. ON* but deterioration unit
or breakage in
control unit
chime circu it
S Always Floated GN Dwire No motion at ali - No motion at atl a
H When IG. SW. Shorted door SW. Cause generated at belt - Remains at re- b
is OFF circuit {~ - ((Ul), anchor reverse end verse end (lamp
(@)-( 1)** and chime
operate)
*: With key insterted

**: Control unit side connector terminal No.
Operation at belt anchor failure depends on the interval from removal to reconnection of the connector.
Reconnected within 13 sec .... Belt anchor moves from forward end toward reverse end and stops after 13 sec.
Reconnected after 13 sec. or more ... Remains stationary at forward end.
In either case, it moves to reverse end and stops there if IG. SW. is turned ON, then OFF and again ON.
Fault reset
a: Reset to normal when battery is reconnected after removal of the cause.
b: Reset to normal when cause is removed.
Battery OFF is reset to normal by its reconnection.
Battery OFF*1 occurs again as it has not been corrected actually.
IG. SW. OFF is reset to normal when IG. SW. is set from ON to OFF.
IG. SW. OFF*2 occurs again as it has not been corrected actually.
c: a when IG. SW. is ON and b when IG. SW. is OFF.
"
27
i
INSTRUMENT PANEL
Page
SUBARU COMPONENT PARTS •.•.••..•.•.....•..................... 2

SERVICE PROCEDURE ......•••..••...........•.....•...... 4
Instrument Panel ........................................ 4
Pocket ............................................... 5
1988
•
5-4 INSTRUMENT PANEL
COMPONENT PARTS
Upper panel
2 Instrument panel
3 Grille pad RH
4 Grille pad LH
5 Reinforcement A
6 Meter visor bracket
7 Meter visor spring
8 Meter visor
9 Meter visor hinge
10 Visor and clock bracket
11 Visor A bracket
12 Visor A spring
27 Fuse box label

28 Driver side center lower panel
29 Passenger side center lower panel
30 Passenger side lower cover
31 Passenger side lower cover bracket
32 Passenger side lower panel
33 Instrument insulator weatherstrip
34 Instrument panel side garnish
35 I nstrument panel side bracket
(With automatic shoulder belt)
36 Driver side lower cover bracket LH
(Except automatic shoulder belt)
37 Driver side lower cover bracket RH
38 Cluster clip
L5-730
Fig. 1
2
INSTRUMENT PANEL 5-4
1 Driver side defroster duct
2 Front defroster nozzle
3 Passenger side defroster duct
4 Side vent duct
5 Side vent duct
6 Side vent duct
7 Side vent duct
8 Center vent duct
9 D-A duct
10 Passenger side center vent duct
11 Passenger side center vent duct
~ 12 Front defroster center bracket
,~ ~@13 Front defroster bracket LH

14 Reinforcement B
"" 15 Reinforcement C
16 Side pocket bracket B
I (With automatic shoulder belt)
~
;';' 17 Pocket frame COMPL
;' .,. /' 18 Side pocket bracket A
/' ./ /" (With automatic shoulder belt)
(" 19 Side pocket bracket
I (With automatic shoulder belt)
I
I
I 20 Front defroster bracket RH
I
I
I 21 Pocket hinge
l...
' .... -----.-~
I
r-_._.
I 22 Pocket bracket
- .... J
(With automatic shoulder belt)
23 Pocket ASSY
24 Striker
25 Instrument panel LH
26 Reinforcement DCP
27 Radio bracket LH
28 Radio bracket RH
29 Side pocket bracket B
30 Side pocket bracket A
I
8 L5-731
Fig. 2
3
5-4 INSTRUMENT PANEL
SERVICE PROCEDURE
Instrument Panel 4) Remove lower cover on passenger's side.
REMOVAL
1) Remove lower cover on driver's side.
j
,,of'"
L5-638
Fig. 6
5) Remove instrument panel upper cover by prying it with a
standard screwdriver at three points (both sides and middle
section).
L5-637
Fig. 3
2) Remove side ventilation duct.
/~~~- L5-270
Fig. 7
6) Remove console box.
L5-732 7) Remove steering shaft ASSY, combination meter and
~----------------------------------------~
Fig. 4 control wing as a unit.
8) Disconnect harness connectors from radio and other parts.
3) Open fuse box lid. Remove screws which hold fuse box, 9) Remove eight bolts which hold instrument panel. and
and detach fuse box from instrument panel. detach instrument panel.
~------------~--------~----~--------~-,
L5-268 L5-685
Fig. 5 Fig. 8
4
INSTRUMENT PANEL 5-4
INSTALLATION

1) Two persons should install instrument panel in vehicle.
Be careful not to strike it against adjacent parts during installa·
tion.
2) While setting instrument panel in position, be careful not
to obstruct air outlets of heater and blower with harness
connectors.
Also, do not allow them to be caught between bracket and
instrument panel.
Fig. 9
3) Disengage lock from striker, remove pocket from instru·

Pocket ment panel.
REMOVAL
1) Remove lower cover on passenger's side. INSTALLATION

2) Remove screws which hold hinge located at the lower
section of pocket. Installation is in the reverse order of removal.
5
-'\
- i--
f'\
r'\
1\
1\
1\
.
1'\
1'\
1\
~
t~
1\
f'..
'\.
J.-'
f\
T\
1\
[\
1\
1\
1\
~ ~
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\ 1\
\ 1\
\ 1\
...-
\ 1'\
.
. \ 1\
\ 1'\
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'\ 1\
I
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l'
Publication No. G 140BE ~
Issued: July 1987 A
Printed in Japan M-4.2
~-----------FOREWORD------------~
FUJI HEAVY INDUSTRIES LTD.
r - - - - - - - - - - - - - - - - How to use this manual
This service manual is divided into four volumes. Each volume consists of Section 1, Section 2. 3, Section 4. 5.
Each chapter, beginning with the Engine section, is basically made up of the fol~owing five areas.
3. Component parts
4. Service pr'ocedure
5. Trouble-shooting
This service manual applies to SUBARU XT, and explains all e.quipments including factory options. Therefore,
SUBARU, -8- and fi are registered trademarks of FUJI HEAVY INDUSTRIES LTD.
© Copyright 1987 FUJI HEAVY INDUSTRIES LTD. All rights reserved.
Not to be reptodl,lced in whole or in part without the prior written permission

TABLE OF CONTENTS
6-1 Engine Electrical System

[§] ELECTRICAL SECTION 6-2 Body Electrical System
~.
I
t
[§] ELECTRICAL SECTION

ENGINE ELECTRICAL SYSTEM 6-1
SUBARU BODY ELECTRICAL SYSTEM 6-2
WIRING DIAGRAM AND TROUBLESHOOTING 6-3
1988
SlERV~CIE
MANUAIL
ABBREVIATION LIST
AIC pulley Air Conditioner Pulley GND Ground
AID converter AnaloglDigital converter IC Integrated Circuit
ALT Alternator IGN Ignition
AIS Air Suspension INT Intermittent
ASSY Assembly liP Idler Pulley
ASV Air Suction Valve LCD Liquide-Crystal Display
AT Automatic Transmission LED Light Emitting Diode
ATF Automatic Transmission Fluid LH Left-Hand
AVG speed Engine Average speed LSI Large Scale Integrated Circuit
BAT Battery MPFI Multi Point Fuel Injection
Cal California MPS Motor Power Steering
CP Complete (Electronic-Controlled Motor Drive
CIP Crankshaft Pulley Power Steering)
DIFF. LOCK Differential Lock MT Manual Transmission
ECM Electronic Control Module 00 Outer Diameter
ECS Electric Control System PIS pulley Power Steering Pulley
ECU Electronic Control Unit REV sensor Revolution sensor
EIG Engine RH Right-Hand
EGR Exhaust Gas Recirculation RL Rear Left
ETR Electronic Tuning Radio RR Rear Right
FCV Float Chamber Ventilation Sir Single-range
FICO Fast Idle Control Device SW Switch
FL Front Left VLC Vacuum Line Control
FLT Fluorescent WIP pulley Water Pump Pulley
FR Front Right
\. .
INDEX
Alternator ..... ... ...... ...... .............. .... ....... ........ ...... ... .... 6-1- 14 Instrument Panel Wiring Harness ........................ 6-3- 14
Analogue Meter ... ... ......... ... ..... .... ... .... ... ... ... .... ........ 6-2- 21 Lighting System ... ... ........... ... ... ... ......... ... .... ......... .... 6-3- 60
Antenna ..................................................................... 6-2- 45 Mode Selector ......................................................... 6-3-138
Automatic Shoulder Belt and Key Warning Parking Brake System .......... ... ... ...... ......... .... .... ..... 6-3-105
Chime ........................................................................ 6-2- 61 Pneumatic Suspension System ............................ 6-3-140
Automatic Transmission Control System ............ 6-3-109 Power Supply Routing ........................................... 6-3- 36
Back-up Light .......................................................... 6-3- 71 Power Window ......................................................... 6-2- 56
Battery ....................................................................... 6-2- 12 Power Window ......................................................... 6-3-126
Blower Motor ........................................................... 6-3-139 Power Window Main Harness and Door
Brake Fluid Level Warning System ..................... 6-3-106 Cord ........................................................................... 6-3- 24
Clock ......................................................................... 6-3-121 Radio ......................................................................... 6·2- 44
Combination Meter ................................................. 6-2- 18 Radio and Auto Antenna ...................................... 6-3-115.,
Combination Meter ................................................. 6-3- 43 Rear Window Defogger .......................................... 6-2- 47
Combination Switch ................ ................................ 6-2- 35 Rear Window Defogger .......................................... 6-3-122
Common Grounding ....... .... ...... ...................... ........ 6-3- 26 Rear Wiring Harness .............................................. 6-3- 18
Control Wing .. ...... ... .......... ........... ...... ......... ......... .... 6-2- 36 Remote Controlled Rearview Mirror .................... 6-2- 58
Cruise Control ......................................................... 6-2- 48 Remote Controlled Rearview Mirror .................... 6-3-124
Cruise Control System ... ......... ..... .... .............. ........ 6-3-133 Retractable Headlight ............................................. 6-2- 40
Differential Lock Switch ......................................... 6-2- 59 Room Light and Door Switch .............................. 6-3- 74
Digital Clock ............................................................. 6-2- 47 Seat Belt and Key Warning Chime ..................... 6-2- 62
Distributor ................................................................. 6-1- 24 Seat Belt and Key Warning System ................... 6-3- 78
Door Lock System .................................................. 6-3-130 Spark Plug ................................................................ 6-1- 26
Electronic-Controlled Motor Drive Speed Alarm ............................................................ 6-3-131.
Power Steering Systrem ........................................ 6-3- 91 Speed Warning Buzzer .......................................... 6-2- 60
Engine Electrical System ....................................... 6-3- 39 Starter ........................................................................ 6-1- 10
Engine Wiring Harness .......................................... 6-3- 12 Stop Light ................................................................. 6-3- 72
First Hold Switch .................................................... 6-2- 59 Telltale (Graphic Monitor) ...................................... ,6-2- 20
Fog Light Switch ..................................................... 6-2- 60 Trip Computer .......................................................... 6-2- 24
Front Fog Lamp ...................................................... 6-3- 66 Trip Computer .......................................................... 6-3- 57 4
Front Wiring Harness ............................................. 6-3- 8 Trunk Room Light .. ... .............. ................................ 6-3- 77 .
Fuse ........................................................................... 6-2- 13 Turn Signal and Hazard Warning Light .............. 6-3- 67
Headlight Washer .................................................... 6-3-114 Windshield Wiper & Washer ................................. 6-3-113
Horn ........................................................................... 6-2- 47 Wiper and Washer ....................... .................. ......... 6-2- 42
Horn and Cigarette Lighter ................................... 6-3-118 Wiper Intermittent Control System ...................... 6-2- 43
Ignition Coil .............................................................. 6-1- 25 4WD-MT System ...................................................... 6-3-107
Ignition Switch ......................................................... 6-2- 34
li'l
ENGINE ELECTRICAL SYSTEM
Page _
SUBARU MECHANISM AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator (lC Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
2
2
SPECIFICATIONS AND SERVICE DATA. . . . . . . . . . . . . . . . • . . . . .• 3
1988 COMPONENT PARTS . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . ..

Starter ..............................................
5
5
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6
Distributor ...................................•....... 8
SERVICE PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . .. 10
Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14
Distributor ........................................... 24
Ignition Coil .......................................... 25
Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 26
Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 28
6-1 ENGINE ELECTRICAL SYSTEM

Alternator (Ie Regulator)
The internal circuitry of the IC regulator is very complicated.
It consists of the following circuits.
(f(---r---------
I l
I Y
I
I (f)
I
I T
I I
I I BAT
I
coil -1-
e
It(~-
, I Field
31III
coil
' (,-
t1:
I
: t~ t )I
-~~__~ -~~
IC regulator
'b
I
~--- -- _ _ _I
IC alternator ~ - - - - - - - 2)
1)
- - . - - - 3)
L6-1650
Fig. 1
1) Ignition switch ON (When engine is stopped) transistor Trt is off. Therefore, the power transistor is on,
When the ignition switch is turned "ON", the charge light allowing field current to flow.
comes on and electric current (less than 0.5A) flows through Even in this condition, if the voltage at terminal @ exceeds
the field coil. battery voltage, charging current flows to the battery.
If the charge light does not come on when the switch is turned 3) When the IC alternator produces voltage (above regulation
"ON", it may be due to a burned-out charge I ight, a break in voltage)
the field coil, a defective Ie regulator, or improper contact As the condition in 2) continues, voltage at terminal ©
or wear of the brushes. builds up. Therefore, voltage at connection (a) increases. When
2) When the Ie alternator produces voltage (below regulation this voltage exceeds the voltage at which the Zener diode Dz
voltage) conducts, current flows through Dz and the transistor Trl'
When the Ie alternator starts to generate, the charge light The voltage at terminal <!) at this time is called regulation
goes out because the voltage at both ends of the light is equal. voltage (14.0 to 15.0V). In this condition, the power transistor
On the other hand, field current is supplied from the diode. is off because Trt is on.
When voltage at connection (a) of Rv·R t (the voltage-dividing 4) The alternator supplies electric current, repeating oper-
resistors which divide the voltage at the voltage detection ations 2) and 3) to stabilize the voltage.
terminal <!)) is low, no current flows in Zener diode Dz and
!
.
\
\.
2

SPECIFICATIONS
Item 1800 cc model 2700 cc model
Type Reduction type
[MT) [AT) [MT) [AT)

Model
MIT70381 MIT74081 MIT70381 MIT74081
Manufactu rer MITSUBISHI
Voltage and Output 12V-1.0kW 12V - 1.4 kW 12V -1.0 kW 12V - 1.4 kW
Direction of rotation Counterclockwise (when observed from pinion)
Number of pinion teeth 8 9 8 9
Voltage 11V
No-load
Current 90A or less
characteristics
~
t: Rotating speed 3,000 rpm or more 2,900 rpm or more 3,000 rpm or more 2,900 rpm or more
cc
ci5
Voltage 8V
Current 280A or less 370A or less 280A or less 370A or less

Load
characteristics 8.5 N·m 14 N'm 8.5 N·m 14 N·m
Torque
(0.87 kg-m, 6.3 ft-Ib) (1.4 kg-m, 10 ft-Ib) (0.87 kg-m, 6.3 ft-Ib) (1.4 kg-m, 10 ft-Ib)
Rotating speed 980 rpm or more 880 rpm or more 980 rpm or more 880 rpm or more
Voltage 4V
Lock Current 780A or less 980A or less 780A or less 980A or less
characteristics
18 N·m (1.8 kg-m, 25 N'm (2.6 kg-m, 18 N·m (1.8 kg-m, 25 N·m (2.6 kg-m,
Torque
13 ft-Ib) or more 19 ft-Ib) or more 13 ft-Ib) or more 19 ft-Ib) or more
Type Rotating-field three-phase type, Voltage regulator built-in type
Model LR165-704 A3T01691
Regu lator type TR12-219 A866X06272
Ma nufactu rer HITACHI MITSUBISHI
Voltage and Output 12V - 65A 12V -90A
....(;cc Polarity on ground side Negative

E Rotating direction Clockwise (when observed from pulley side)
....
Q)
<i:
Armature connection 3-phase V-type
Rectifying system Full wave rectification by eight self-contained silicone diodes
1,600 rpm - 22A or more 1,500 rpm - 27 A or more

Output current 3,000 rpm - 53A or more 2,500 rpm - 62A or more
6,000 rpm - 63A or more 5,000 rpm - 83A or more
Regulated voltage 14.1 - 14.8V [20°C (68°F)) 14.2 - 14.8V [20°C (68°F))
3
Item 1800 cc model

1 2700 cc model
Type Breakerless type with control unit
Model D4P8&03
I D6P8&02
Manufacturer HITACHI
6
:;
,Q
...
1;;
F iring order 1-3-2-4
I 1-&3-2-5-4
i5 Rotating direction Cou ntercl ockwise
CaP insulation resistance More than 50 Mn
Rotor head insulation resistance More than 50 Mn
Type E12-113
Manufactu rer HITACHI

'0
u
c: Primary coil resistance n 0.84 - 1.02
.2
...
c: Secondary coil resistance n 8,000 - 12,000
!!!
Insulation resistance between
More than 10 Mn
primary terminal and case
(BPA6ES.11 10, BPA5ES·11, BPA7ES·11) .•••..•. NGK

For U.S.A.: W20EPR-U11 (or W16EPR-U11, W22EPR-U11) ... Nippondenso
Cl Type and Manufacturer
:l RN9YC-4 (or RN11 YC-4) .................... Champion
Q. For Canada: RN9YC-4 (or RN11 YC-4) .................... Champion
~
III
fJi Thread size mm 14, P = 1.25
Spark gap mm (In) 1.0 - 1.1 (0.039 - 0.043)
I 4
l
COMPONENT PARTS
Starter
MT: MIT70381 @ @
AT: MIT74081
_- "1
I
I
I
I
I
I
I
I
I
._--J
8
---- -
-- - --
-
r
I
I
- e$
I
I
I 1 Lever set
I 2 Switch ASSY
I 3 Ball
I 4 Packing
I 6 Sleeve bearing
6 Front bracket
I 7 Stopper set
I
I 8 Overrunning clutch
9 Internal gear ASSY
10 Gear shaft ASSY
11 Washer set
12 Gear ASSY
13 Through bolt
14 Yoke
15 Armature
16 Bearing
17 Conical spring washer
18 Brush ASSY
19 Brush set spring
20 Brush holder
21 Rear bracket
Fig. 2
L6·1466
6
Alternator
1800cc model
Tightening torque N'm (kg-m, ft-Ib):

T: 39 - 59 (4.0 - 6.0, 29 - 43)
1 Pulley
(J) 2 Front cover
3 Ball bearing
4 Bearing retainer
5 Rotor
6 Stator
7 Fan guide
8 Bolt
9 I C regulator
10 Brush
11 Diode ASSY
12 Condenser
13 Rear cover
L6-359
Fig. 3
6
2700cc model
/'1
~--""'-~/ :
I
I
I
I
I
I
I
I
)
/
/
./
./
./
./
./
./
./
./
./
/'
./
./
./
./
,/
./
./
./
./"
/'
./
./
./
./"
/'
./"
CD ./
,/
./
./
./
./
./"
./
./
./
./
/
r
I ® ./
I ./
/
./
®
I
I
1 Pulley
2 Front cover
3 Ball bearing
4 Bearing retainer
5 Rotor
6 Stator
7 Brush
8 Regulator ASSY
9 Rear cover
L6·1651
Fig. 4
7
Distributor
•
1800cc model
1 Cap ASSY
2 Carbon point ASSY
3 Aotor head
4 Packing
6 Bush
6 Q'ring
7 Pinion set
n--nII~---@
FIg. 5
L6·1467
s
2700cc model
~~-®--
I
I
t-----@
1 Cap ASSY
2 Carbon point ASSY
3 Rotor head
4 Packing
5 O-ring
6 Pinion set
d) @
~<~~~ ~ L6·1652
Fig. 6
9
SERVICE PROCEDURE
Starter
TEST
SWITCH ASSEMBLY OPERATION

1) Connect terminal S of switch ASSY to positive terminal
of battery with a lead wire, and starter body to ground
terminal of battery. Pinion should be forced endwise on shaft.
~Stop~,
Pinion
With pinion forced endwise on shaft, starter motor can some-
times rotate because current flows, through pull-in coil, to L6-361
motor. This is not a problem. Fig. 8
2) Disconnect connector from terminal M, and connect

positive terminal of battery and terminal M using a lead wire
If motor is running with the pinion forced endwise on the
and ground terminal to starter body.
shaft, disconnect connector from terminal M of switch ASSY
In this test setup, pinion should return to its original position
and connect terminal M to ground terminal (-) of battery
even when it is pulled out with a screwdriver.
with a lead wire. Next, gently push pinion back with your
fingertips and measure pinion gap.
2) If pinion gap is outside specified range, remove or add
number of adjustment washers used on the mounting surface
M of switch ASSY until correct pinion gap is obtained.
PERFORMANCE TEST
The starter should be submitted to performance tests
whenever it has been overhauled, to assure its satisfactory
performance when installed on the engine.
Three performance tests, no-load test, load test, and lock test,
are presented here; however, if the load test and lock test
L6-360 cannot be performed, carry out at least the no-load test.
Fig. 7 For these performance tests, use the circuit shown in figure.
Switc
PINION GAP
1) With pinion forced endwise on shaft, as outlined in step 1)
above, measure pinion gap.
Pinion gap:
0.5 - 2.0 mm (0.020 - 0.079 in)
Voltmeter Ammeter
Ammeter AS-050
Fig. 9
10
1) No-load test
With switch on, adjust the variable resistance to obtain 11 V,
take the ammeter reading and measure the starter speed.
Compare these values with the specifications.
No-load test (Standard):

Voltage/Current
11V/90A max
Rotating speed
MT 3,000 rpm min
AT 2,900 rpm min
Switch ASSY
2) Load test L6-362
Apply the specified braking torque to starter. The condition
Fig. 10
is satisfactory if the current draw and starter speed are within
specifications.
Load test (Standard): 3) Remove both through-bolts and brush holder screws,
Vo Itage/Load and detach rear bracket and brush holder.
MT aV/8.S N·m (0.87 kg-m, 6.3 ft·lb)
AT aV/14 N·m (1.4 kg-m, 10 ft·lb)
Brush holder
Cu rrent/Speed
MT 2aOA max/9aO rpm min
AT 370A max/aaO rpm min
3) Lock test
With starter stalled, or not rotating, measure the torque
developed and current draw when the voltage is adjusted to
the specified voltage.
Lock test (Standard):

Voltage/Current
LS-363
MT 4V/780A max
AT 4V/980A max Fig. 11
Torque
MT 18 N·m (1.8 kg-m, 13 ft-Ib) min
AT 2S N·m (2.6 kg-m, 19 ft-Ib) min 4) Remove armature and yoke. Ball used as a bearing will
then be removed from the end of armature.
Be sure to mark an alignment mark on yoke and front bracket

before removing yoke.
DISASSEMBLY
Armature
1) Loosen nut which holds terminal M of switch ASSY, and
disconnect connector.
2) Remove bolts which hold switch ASSY, and remove
switch ASSY, plunger and plunger spring from starter as a
unit.
Front bracket
Be careful because pinion gap adjustment washer may some-
times be used on the mounting surface of switch ASSV.
L6-364
Fig. 12
11
5) Remove packing A, three planetary gears, packing Band
plate. INSPECTION
ARMATURE
1) Check commutator for any sign of burns of rough surfaces
or stepped wear. If wear is of a minor nature, correct it by
Planetary using sandpaper.
gear
2) Run-out test
Check the commutator run-out and replace if it exceeds the
limit.
Commutator run-out:
Standard
0.05 mm (0.0020 in)
L6·365 Service limit
Fig. 13 Less than 0.10 mm (0.0039 in)
6) Remove shaft ASSY and overrunning clutch as a unit.

Dial gauge
Record the direction of lever before removing.
L6-1458
Fig. 16
L6·366
Fig. 14
3) Depth of segment mold
Check the depth of segment mold.
7) Remove overrunning clutch from shaft ASSY as follows:
(1) Remove stopper from ring by lightly tapping a jig Depth of segment mold
placed on stopper. 0.5 - 0.8 mm (0.020 - 0.031 in)
(2) Remove ring, stopper and clutch from shaft.
Jig
Segment
Mold
Stopper Ring
Shaft
L6-367 A9{)24
Fig. 15 Fig. 17
12
4) Armature short circuit test BRUSH AND BRUSH HOLDER
Check armature for short circuit by placing it on growler
1) Brush length
tester. Hold a hacksaw blade against armature core while
Measure the brush length and replace if it exceeds the service
slowly rotating armature. A short-circuited armature will
limit.
cause the blade to vibrate and to be attracted to core. If the
Replace if abnormal wear or cracks are noticed.
hacksaw blade is attracted or vibrates, the armature, which is
short-circuited, must be replaced or repaired.
Brush length:
MIT 70381
MIT 74081
I Growler tester
LS-14S9
Fig. 18
,
5) Armature ground test I ':-I!-I~_ _.L...-+-I--Wear limit line
I II ,
Using circuit tester, touch one probe to the commutator I I, I
I II I
segment and the other to shaft. There should be no continuity. ~ II ,
If there is a continuity, armature is grounded. '-J..L---~.JBrUSh
Replace armature if it is grounded.
L6-1461
Fig. 20
2) Brush movement
Be sure brush moves smoothly inside brush holder.
3) Insulation resistance of brush holder
Be sure there is no continuity between brush holder and its
plate.
Fig. 19
YOKE
Make sure pole is set in position.
OVERRUNNING CLUTCH
Inspect teeth of pinion for wear and damage. Replace it if
damaged. Rotate pinion in direction of rotation (clockwise).
It should rotate smoothly. But in opposite direction, it should
be locked.
L6-1462
Do not clean overrunning clutch with oil to prevent grease
from flowing out. Fig. 21
13
4) Brush spring force • Gear shaft spl ines
Measure brush spring force with a spring scale. If it is less than • Mating surface of lever and clutch
the service limit, replace brush spring. • Ba II at the armature shaft end
• Internal and planetary gears
Brush spring force: 3) After assembling parts correctly. check to be sure starter
Standard operates properly.
18.6 N (1.9 kg, 4.2 Ib) (when new)
Service limit
6.9 N (0.7 kg, 1.5 Ib)
SWITCH ASSEMBLY
Be sure there is continuity between terminals Sand M, and
between terminal S and body ground. Use a circuit tester (set
in "ohm").
Also check to be sure there is no continuity between terminal
M and B.
Terminal Alternator·
S -M Continuity
S - Body ground Continuity 1800cc model
M -B No continuity
TEST
Notes on alternator test:

a) The lead wires between alternator terminal B and battery
positive terminal, and between alternator terminal Land
battery negative terminal must be less than 2.5 m (8.2 ft) in
Circuit tester length and greater than 8 mm 2 (0.012 sq in) in section area.
b) The switch used in the circuit must have as small a contact
resistance as possible.
0.25n
Starter
Resistor
body DC ammeter
(0-100A) Connect when
_, / battery is
L6-1463 k:l;p;Q~,/ r-----,<I,=-"'--r---rl-'~-
__
'+-,,' discharged
Fig. 22
Variable
resistor
(O-0.25nl
ASSEMBLY
DC voltmeter o position
(O-30V or 0-75V) L6·369
Assembly is in the reverse order of disassembly procedures.
Observe the following: Fig. 23
1) Carefully assemble all parts in the order of assembly and
occasionally inspect nothing has been overlooked.
Measuring regulated voltage
2) Apply grease to the following parts during assembly.
• Front bracket sleeve bearing Open switch SW1 and close switch SW2 in the circuit shown
• Armature shaft gear above to raise the alternator speed to the rated speed of
• Outer periphery of plunger 6,000 rpm, and measure the voltage on the voltmeter.
• Mating surface of plunger and lever The regulated voltage must be 14.1 to 14.8 V.
14
Measuring output current 3) Remove the screws securing the bearing retainer, and
remove the bearing retainer, ball bearing and front cover.
Set the variable resistor to the on
position, and close switches
SW1 and SW2 to raise the alternator speed to the rated rpm.
At this rpm, adjust the variable resistor so that the voltmeter
reads 13.5 V, and read the indication on the ammeter.
1,600 rpm 22 A or more

DISASSEMBLY L6-1465
Fig. 26
1) Remove the through-bolt. Pressing the tip of a standard
screwdriver into the clearance between the front cover and
stator core, pry the alternator into two parts; front side (front
cover and rotor) and rear side (rear cover and stator). 4) Remove the nuts securing the BAT terminal, diode and
brush holder. Separate the rear cover from the stator.
Use care not to damage the stator coil with the screwdriver.
IIIIIII!=====:ID
~~~
:iII,:,Ii:' A9-303
L6-1464 Fig. 27
Fig. 24
2) Secure the rotor in a vise, and remove the pulley nut.

The pulley, front cover and rotor can be separated. 5) Unsolder the diode ASSY and remove the stator.
E6-051 L6-370
Fig. 25 Fig. 28
15
6) Remove the nuts securing the fan guide, and remove the Checking negative side diodes
fan guide.
Terminal E (Negative side diode)
Diode ASSY
Tester lead Positive 'E Negative 8
U Positive -r
- Continuity
V
W Negative e No continuity -
Terminals from stator coil
u v w
I··--··~
; L I
Fan guide
L6-1466 ::::: side ---:___ ..J
Fig. 29 diode
7) (This procedure is unnecessary when the diode is normal.)

2 side
diode
Cut off rivet which holds diode ASSY to brush holder
-:- E
terminals with a dri II. Unsolder termi nal L and brush holder,
Direction of current flow
and remove brush holder and IC regulator from diode ASSY as
a unit. E6-057
Fig. 31
a) Brush holder and IC regulator are a one·piece type. Be
careful not to apply shocks or load to cooling fin.
b) Do not remove rivet unless diode is replaced.
The diode allows current to flow in only one direction as

shown in the figure. If continuity is noted when connecting
tester leads in the normal direction (for example, BAT and WI,
the diode is normal; if no continuity is noted, the diode is
faulty. On the contrary, if tester leads are connected in the
reverse direction, no continuity means a normal diode, while
continuity means a faulty diode.
If any diode is proven faulty in the above check, repoace the
diode assembly. The auxiliary diode have no terminals, and
must be checked for continuity by connecting tester leads to
both terminals of this diode.
L6-1467
Never use a megger or other high voltage insulation tester for
Fig. 30 this test; otherwise, diodes may be damaged.
INSPECTION AND REPAIR

ROTOR
DIODE 1) Slip ring wear limit
Measure the outer diameter of the slip ring. If worn more than
Checking positive side diodes.
1 mm (0.04 in) from the standard dimension, replace the rotor
assembly.
Terminal BAT (Positive side diode)
Outer diameter of slip ring:
Tester lead Positive CB Negative ~~,
Standard
Positive (-£ - No continuity 27.0 mm (1.063 in)
U
V Wear limit:
W Negative '8 Continuity - 26.0 mm (1.024 in)
16
2) Checking slip ring surface

Check the slip ring surface for roughness or contamination
with oil. If the surface is rough, smoothen with sandpaper
(#500 - #600). If contaminated with oil, wipe with clean
cloth moistened with alcohol.
3) Checking rotor coil for continuity
Check the rotor coil for continuity between slip rings using a
circuit tester. If no continuity is detected, replace the rotor.
E6-061
Fig. 34
STATOR
1) Checking stator coil for continuity
Check the stator coil for continuity between terminals using a
circuit tester. If no continuity is noted, it indicates that the
stator coil is disconnected, and the stator must be replaced.
Fig. 32
Lead wire
4) Checking rotor coil for proper insulation
Check for continuity between the slip ring and rotor core or
shaft using a circuit tester. If continuity is noted, the rotor coil
is shortcircuited, and the rotor must be replaced with a new
one.
T9-046H
Fig. 35
2) Checking stator coil for proper insulation

Connect the circuit tester between any terminal of the stator
coil and the stator core. If continuity is noted, it indicates that
the stator coil is shortcircuited inside, and the stator must be
replaced.
E6-060
Fig. 33
5) Check the rear side ball bearing.

If resistance is felt wh ile rotating, or if abnormal noise is
heard, replace the ball bearing.
After separating the rotor, be sure to replace the rear side ball T9-047H
bearing. Fig. 36
17
BRUSHES Ie REGULATOR
Measure the length of each brush. If wear exceeds the wear Connect a variable resistor, two 12·V batteries, a resistor and
limit, replace the brush. Each brush has the wear limit mark on voltmeter as shown below.
it.
Brush length:
Standard
18 mm (0.71 in)
Wear limit
6.0 mm (0.236 in)
If the brush pigtail (lead wire) is soldered, use a soldering iron

heated to 300 to 350°C (572 to 662°F) and paste without
oxygen.
Resistor (Rl):
10n/3W
Variable resistor (RV):
BAT2T
0-300n/12W
Battery (BATl & BAT2):
l2V
DC voltmeter:
0-50V
(measured Vl , V2,
V3 and V4)
L6·373
Fig. 37
L6·374
Fig. 38
Perform the following measurement:

1) Check V1 (voltage of BA T1). The voltage must be 10 to
13V.
2) Check V3 (voltage of BAT1 + BAT2). If a voltage of 20 to
26V is measured, both BAT1 and BAT2 are normal.
3) Measure V2 (voltage between terminals F and E) while
gradually moving the variable resistor away from O. Voltage
V2 should change from below 2.0V to voltage V1 measured in
step 1) above. If no change is observed, the regulator is faulty,
and must be replaced with a new one.
4) Measure V4 (voltage between the intermediate tap of
variable resistor and terminal E) with variable resistor RV
fixed to see whether the voltage is within the specified range.
If found within the range, the regulator is normal. If out of
range, replace the regulator with a new one.
18
(3) Insert a pin from outside the rear cover to push each
ASSEMBLY brush into the brush holder.
After completely reassembled, be sure to remove the pin.
To reassemble, reverse the disassembly procedure, noting the
following points.
1) Use a high temperature solder for soldering the diode and
stator coil leads, and the diode lead and brush holder.
Observe the following working conditions:
Soldering iron temperature 300 to 380°C (572 to 716° F)
Soldering time : Within 5 seconds
Solder : Pb-Sn (5-1) solder
2) Assembling of front side and rear side
(1) Whenever the alternator has been disassembled, be
sure to replace the rear side ball bearing.
(2) The rear side bearing has a ring inserted into the
offset groove of the outer race, and a part of the ring is
projected to the outside of the outer race. When reassem-
bling, rotate the ring so that this projection is minimized.
If any fault is found on the rear cover bearing portion,
replace the rear cover.
Ring Pin
L6-375
Fig. 40
Eccen tric groove
E6-066
Fig. 39
19
2700cc model
DISASSEMBLY
1) Heat the bearing box to 50 to 60°C (122 to 140°F) with

a 100 W-soldering iron and remove the three through bolts.
Then insert the tip of a flat-head screwdriver into the gap
between the stator core and front bracket. Pry then apart to
disassemble.
Be careful not to lose the spring fitted in the periphery of the Pulley
rear bearing.
L6-1655
Soldering iron (100 W) Fig. 43
Bearing box
3) Remove the nut and insulating bushing at terminal B.

Remove the screws fastening the rectifier and the brush
holders to separate the stator from the rear bracket.
L6·1653
Fig. 41
L6·1656
Fig. 44
4) Remove the IC regulator.
Fig. 42
2) Remove the pulley nut. The pulley rotor and front L6-1657
bracket can be separated. Fig. 45
20
5) Unsolder the rectifier and remove the stator.
Rectifier
L6-1658 Fig. 48
Fig. 46
2) Checking negative diode
Check for continuity between the negative side heat sink and
diode lead. The negative diode is in good condition if con-
6) Remove the brushes by unsoldering at the pigtails. tinuity exists only in the direction from the heat sink to the
diode lead.
Heat sink (Negative side)

fF==~
L6-1659
Fig. 47
Fig. 49
3) Checking trio diode

Check the trio diode using a circu it tester. It is in good con-
dition if continuity exists only in one direction.
INSPECTION AND REPAIR
DIODE
Never use a megger tester (measuring use for high voltage) or
any other similar measure for this test; otherwise, the diodes
may be damaged.
1) Checking positive diode

Check for continuity between the diode lead and the positive
side heat sink. The positive diode is in good condition if con-
tinuity exists only in the direction from the diode lead to the
heat sink. Fig. 50
21
ROTOR
1) Checking slip ring surface
Repair the slip ring surface, if rough, with a lathe or fine sand-
paper.
2) Checking rotor coil for continuity
Check the resistance between the slip rings with a circuit
tester. It should be somewhere between 3.0 and 3.Sn. If the
resistance is not within this range, replace rotor with a new
one.
/~ L6-1665
o Fig. 53
2) Replacing rear bearing

The rear bearing can be removed by using a common bearing
puller. When installing a new one, press-fit so that its peri-
pheral groove is on the slip ring side.
L6-1663
Fig. 51
3) Checking rotor coil for proper insulation
Check for continuity between the slip ring and rotor core
using a circuit tester. If continuity is noted, the rotor coil is
shortcircu ited, and the rotor must be replaced with a new one.
L6-1666
Fig. 54
STATOR
1) Checking stator coil for continuity
Check the stator coil for continuity between terminals using a
circuit tester. If no continuity is noted, it indicates that the
L6-1664 stator coil is disconnected, and the stator must be replaced.
Fig. 52
BEARING
Check front and rear ball bearings.
If resistance is felt while rotating, or if abnormal noise is Lead wire
heard, replace the ball bearing.
After separating the rotor, be sure to replace front and rear

ball bearings.
1) Replacing front bearing

Install closely fit jig on the bearing outer race. Press the
bearing down into place with a hand press or vise. A socket
wrench can serve as the jig. Fig. 55
22
2) Checking stator coil for proper insulation 2) Checking brush spring for proper pressure
Connect the circuit tester between any terminal of the stator Using a spring pressure indicator, push the brush into the
coil and the stator core. If continuity is noted, it indicates that brush holder until its tip protrudes 2 mm (0.08 in). Then
the stator coil is shortcircuited inside, and the stator must be measure the pressure of the brush spring. If the pressure is
replaced. less than 2.059 N (210 g, 7.41 oz), replace the brush spring
with a new one. The new spring must have a pressure of
2.942 to 3.923 N (300 to 400 g, 10.58 to 14.11 oz).
T9-047H
Fig. 56
L6-1669
Fig. 58
BRUSHES
1) Measure the length of each brush. If wear exceeds the
wear limit, replace the brush. Each brush has the wear limit
mark on it.
ASSEMBLY
Brush length:
Standard To reassemble, reverse the disassembly procedure, noting the
16.5 mm (0.650 in) following points.
Wear limit 1) The rear bearing has an eccentric groove on its periphery.
8.0 mm (0.31 in) Fit the lock spring into this groove so that the projecting part
is in the deepest portion of the groove. This will reduce spring
If the brush pigtail (lead wire) is soldered, use a soldering iron projection, making reassembly easy. Also, it assures greater
heated to 300 to 350°C (572 to 662°F) and paste without locking effect, since the spring will be free from undue force
oxygen. during reassembly. The deepest portion of the groove has
chamfered edges for easy identification.
Spring
.!:
E-
E~
cog
&
Wear limit lin e
EC
.-
E~
--
It)~
'0
co-
L6-1668 L6-1670
~------------------------------------------~
~~ ~~
23
2) Pulling up brush
Before assembling, press the brush down into the brush holder
Distributor
with your finger and secure in that position by passing a DESCRIPTION
[2 mm (0.08 in) dia. length 4 to 5 cm (1.6 to 2.0 in)] wire
through the hole shown in the figure. This distributor is equipped with a photoelectric crank-angle
sensor which trans.mits a crank-angle signal and a cylinder-
Be sure to remove the wire after reassembly. identification signal to the MPF I control unit.
Rotor head
L6-1671
Fig. 60
3) Heat the rear bracket [50 to 60°C (122 to 140° F)] and
press the rear bearing into the rear bracket. Then lubricate the
rear bracket.
4) After reassembly, turn the pulley by hand to check that L Rotor plate
the rotor turns smoothly. L6-146B

Fig. 61
A signal processing unit, which is built into the distributor

housing, consists of LED and a photodiode. The rotor plate,
located between the LED and the photodiode, is secured to
the rotor shaft.
The rotor plate has four slits along its periphery through which
90° signals (in terms of distributor angle) are transmitted for
cylinder detection. In addition, there are three hundred and
0
sixty slits through which 1 signals (in terms of distributor
angle) are transmitted for crank-angle detection. Directly
above the rotor plate is the LED and below it is the photo-
diode.
When th,e ignition switch is turned "ON", the LED emits light
to the photodiode. The rotor plate turns as the engine starts.
The light emitted from the LED is then repeatedly interrupted
and transmitted through the slits by rotation of the rotor plate.
The "on-off" light signals (for cylinder detection and crank-
angle detection) are then converted into output signals which
are transmitted to the MPF I control unit.
The MPFI control unit determines optimum ignition timing in
response to these output signals and engine operating condi-
tions and transmits an ignition signal to the ignition coil.
This type of distributor is not equipped with a centrifugal
advance angle and a vacuum advance angle device.
24
DISASSEMBLY Ignition Coil

1) Detach cap and dust cover as a unit. The E12·113 ignition coil is equipped with a power transistor
2) Remove carbon point from cap. igniter. The power transistor amplifies the ignition signal
3) Remove rotor head securing screw and detach rotor head transmitted from the MPF I control unit. The amplified signal
from rotor shaft. is used to make and break the current flowing through the
4) Remove O-ring from housing. primary winding of the ignition coil.
5) Drive roll pin out of shaft and pinion.
6) Remove pinion from shaft.
Further disassembly of parts is prohibited.
1) Disconnect battery negativ.e (-) terminals.
2) Disconnect wires from ignition coil.
INSPECTION 3) Remove ignition coil.
4) To install, reverse the order of removal.
1) Carbon point
Measure the length of carbon point in cap. Replace if it is less Be sure to connect wires to their proper positions. Failure to
than service limit. do so will damage unit.
Standard length:
12 mm (0.47 in)
INSPECTION
Service limit:
10 mm (0.39 in)
Using accurate tester, inspect the following items, and replace
if defective.
2) Cap and rotor head
1) Primary resistance
Measure insulation resistance using a megger. Replace if it is 2) Secondary coil resistance
less than the specified value.
If the resistance is extremely low, this indicates the presence ;.-~-
Insulation resistance:
of a short·circuit.
More than 50 MQ
3) Insulation between primary terminal and case: 10 MQ or
more.
ASSEMBLY 4) If engine does not run due to faulty ignition system,
check ignition system as follows:
ASSY is in the reverse order of disassembly. Observe the Check for cracked distributor rotor or cap and corroded
following: terminals.
1) Use new roll pin when installing pinion. Visually inspect high tension wire for condition. Check spark
2) Install pinion so that its alignment mark is aligned with plugs and adjust gaps as necessary. Replace spark plug which
the mark on the housing when the cutout section of rotor is not suitable for further use.
shaft faces the 1st cylinder mark on the cap. If the above checks cannot correct the problem, check entire
ignition system with oscilloscope or circuit tester in accord-
ance with the troubleshooting charts. (See chapter 6-3)
L6-080
Fig. 62
25
The above torque should be only applied to new spark plugs

Spark Plug without oil on their threads.
In case their threads are lubricated, the torque should be
DESCRIPTION reduced by approximately 1/3 of the specified torque in order
to avoid their over-stressing.
4) Connect spark plug cords.
INSPECTION
O1eck electrodes and inner and outer procelains of plugs,
noting the type of deposits and the degree of electrode
1.0 - 1.1 mm (0.039 - 0.043 in) erosion.
1) Normal
Brown to grayish-tan deposits and sl ight electrode wear
indicate correct spark plug heat range.
A9-163
Fig. 63
The spark plugs are project type, having 14 mm (0.551 in)

threads and 1.0 to 1.1 mm (0.039 to 0.043 in) gap.
All spark plugs installed on an engine, must be of the same

heat range.
Applicable model Spark plug
NGK:
A9·164
BPR6ES-11
(or BPR5ES-l1, BPR7ES-11) Fig. 64
NIPPONDENSO:
U.S.A.
W20EPR-U11
(or W16EPR-Ul1, W22EPR-U11)
2) Carbon fouled
CHAMPION:
RN9YC4 (or RN11YC4) Dry fluffy carbon deposits on insulator and electrode are
mostly caused by slow speed driving in city, weak ignition,
CHAMPION: too rich fuel mixture, dirty air cleaner, etc.
Canada
RN9YC-4 (or RN11YC-4) It is advisable to replace with plugs having hotter heat range.
1) Remove spark plug cords by pulling boot, not cord itself.

2) Remove spark plugs.
3) When installing spark plugs on cylinder head, use spark
pi ug wrench.
Tightening torque (Spark plug): A9-165

20 - 29 N'm (2 - 3 kg-m. 14 - 22 ft·lb)
Fig. 65
26
3) Oil fouled
Wet black deposits show excessive oil entrance into combus- CLEANING AND REGAPPING
tion chamber through worn rings and pistons or excessive
clearance between valve guides and stems. If same condition Clean spark plugs in a sand blast type cleaner.
remains after repair, use a hotter plug. Avoid excessive blasting. Clean and remove carbon or oxide
deposits, but do not wear away porcelain.
If deposits are too stubborn, discard plugs.
After cleaning spark plugs, recondition firing surface of
electrodes with file. Then correct the spark plug gap to 1.0 to
1.1 mm (0.039 to 0.043 in) using a gap gauge.
A9-166
Fig. 66
4) Overheating
White or light gray insulator with black or gray brown spots
and bluish burnt electrodes indicate engine overheating. More-
over, the appearance results from incorrect ignition timing,
loose spark plugs, wrong selection of fuel, hotter range plug,
etc. It is advisable to replace with plugs having colder heat
range.
A9-167
Fig. 67
27
TROUBLESHOOTING (ON THE CAR)

AL TERNATOR (2700 cc model)
1. Rotational speed refers to the number of engine revolutions.

2. General inspections such as belt tightness and connector contact should be completed before troubleshooting.
3. Replace the battery with a good one for accurate inspection.
BATTERY OVER-DISCHARGES
*1
IC alternator terminal-B voltage (at 2,000 rpm) is YES After idling 2 or 3 minutes (more than S minutes
higher than during idling when battery discharges), increase speed to 2,SOO
NO
rpm and check terminal-L voltage to see if it is
regulation voltage (14.0 to lS.0V)
I
Check IC alternator terminal-L voltage when 1 to 3V YES t NO
ignition switch is ON and engine stops
IC alternator defective
*2 Disassemble and check
Battery voltage
o to lV (10 to 12V) Check IC regulator O.S to 2V
terminal-F voltage '--
with ignition switch ON
and engine stopped
Check IC alternator terminal-L voltage with IC
1 to 3V Battery
alternator terminals Band IG shortcircuited with voltage
another lead wire (10 to 12V)
Faulty contact Replace

of wiring on positive
o to lV body side (+) diode
Disconnect IC alternator connector and check for NO

Replace IC regulatorl
continuity in the direction from IG to L o to O_SV
YES I Field coil broken

Faulty brush contact
NO
I Terminal-L grounded? I
I I Ground terminal-L I
OK
Disconnect wiring from IC alternator terminal B
I Replace I C regulator
1 63A or less and connect ammeter (SOA, min.). After starting
t engine, increase speed to 2,SOO to 3,000 rpm and
read maximum amperage with all electrical loads
I IC alternator defective I turned ON
63 to 81A I 81A or more

~
After discharging battery slightly, 81A or more
Normal
carry out previous operation I I
~ 81Aorless
Check IC alternator * 1, *2: See next page.
28
BATTERY OVERCHARGES
Check terminal-B voltage while increasing engine

speed from idle slowly; check if terminal-B voltage
builds up above 15.0V
*2
I YES
Terminal-F grounded?
OK Replace.IC regulator
NO NO
Ground terminal F
I Check if terminal-F voltage is higher at 3,000 rpm NO

Replace IC regulator
than at idle
YES
*1
After idling 2 or 3 minutes (more than 5 minutes
when battery is discharged), increase engine speed NO
I C alternator defective
to 2,500 rpm and check terminal-L voltage to see
if it is regulation voltage (14.0 to 15.0V)
YES
Normal
*1 When checking this, be sure to turn off the lights and all other electrical loads.
*2 To check the voltage at terminal F, insert the contact bar straight through the access hole. This will allow the contact bar
to hit only terminal F. Even if the bar comes into contact with the rear bracket during insertion, no damage will result
as long as it is released.
Fig. 68
29
BODY ELECTRICAL SYSTEM
Page
SUBARU SPECIFICATIONS AND SERVICE DATA......... . . . . . . . . . . . . .. 2 _

COMPONENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5
Combination Meter . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5
Switches .........•................................... 6
1988 Retractable Headlight . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7
Front Combination Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7
Fog Light ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8
Rear Combination Light •................................. 8
High-Mount Stop Light .................................. . 9
License Plate Light ........•.......................•..... 9
Room Light .......................................... . 9
Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9
Window Washer .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10
Headlight Washer ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10
Electrical Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12
Fuse ....••.•••....•................................. 13
Combination Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 18
Trip Computer (XT6 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 24
Ignition Switch ........................................ 34
Combination Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 35
Control Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 36
Retractable Headlight ........... . . . . . . . . • . . . . . . . . . . . . . . .. 40
Wiper and Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 42
Wiper Intermittent Control System ........................... 43
Radio ............................................... 44
Antenna .......•..................................... 45
Digital Clock .. • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 47
Horn ......•........................................ 47
Rear Window Defogger ...................•............•.. 47
Cruise Control . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 48
Power Window .•...•.•................................. 56
Remote Controlled Rearview Mirror. . . . . . . . . . . . . . . . . . . . . . . . . .. 58
First Hold Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 59
Differential Lock Switch ............ . . . . . . . . . . . . . . . . . . . . .. 59
Fog Light Switch ....................................... 60
Speed Warning Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 60
Automatic Shoulder Belt and Key Warning Chime
(Except Canada model) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 61
Seat Belt and Key Warning Chime (Canada model only) . . . . . . . . . . . . .. 62
6-2 BODY ELECTRICAL SYSTEM
Type
- 55D23R (MF)*1
XT6
75D23R (MF)*2 50D20R (MF)* 1

Others
65D23R (MF)*2
...>-
........
Q)
Reserve capacity 99 minutes 111 minutes 78 minutes 111 minutes
co Capacity
co
Cold cranking ampere 356 ampere 490 ampere 306 ampere 420 ampere
Fuses 15A : 17, 20A : 4 15A : 18, 20A : 2
Type Analogue meter
Speedometer Eddy current type
Temperature gauge Thermister-cross coil type
Fuel gauge Resistor-cross coil type
Tachometer Electric impulse type
Oil pressure gauge Bimetal-bimetal type
Voltmeter Cross coil type
Turn signal indicator light 12V-3W (x 2)
Low fuel indicator light 12V-3W
... Charge indicator light 12V-1.4W

.aQ)
E Oil pressure indicator light

c
- 12V-1.4W
[DL model only]
0
•.j:J
co
.5 CHECK ENGINE warning light 12V-1.4W
.0
E
0 High beam indicator light 12V-1.12W
u
Brake fluid level warning light 12V-1.4W
Door ajar warning light 12V-1.12W (x 2)
Seat belt warning light 12V-1.12W
Stop light warning light 12V-1.4W
Parking brake warning light 12V-1.12W
Four wheel drive indicator light

- 12V-l.12W (x 1 or x 2)
[Selective 4WD model only]
Front wheel drive indicator light

[4WD AT model only]
12V-1.12W -
12V -3.4W (x 2)
Meter illumination light
12V-3W (x 2)
*1: MT, *2: AT
2
BODY ELECTRICAL SYSTEM 6-2
XT6
I Others
Headlight 12V-65/55W (Halogen)
Turn signal light 12V-27W

Front combination light
Clearance light 12V-8W
Front fog light 12V-55W

1 -
Front 12V-3.8W
Side marker light
Rear 12V-3.8W
Stop and tail light 12V-27/8W
Rear combination light Turn signal light 12V-27W
Back-up light 12V-27W
License plate light 12V-3.8W (x 2)
High-mount stop light 12V-27W
Spot & room light 12V-8W (x 3)
Trunk room light 12V-5W
Glove box light 12V-3.4W
Front ash tray illumination light 12V-l.4W
Automatic transmission selector illumination light 12V-3.4W
Motor speed 2-speed with intermittent operation

Windshield wiper
Input 12V -50W or less
Pump type Centrifugal

Windshield washer
Input 12V-35W or less
AM/FM Mono, AM/FM Stereo

Type
Push-button station selection or ETR
Radio
Front doors (x 2)
Speaker position
Rear luggage shelf (x 2)
Horn 12V-420 Hz, 12V-350 Hz
Input 12V-120W
Cigarette lighter
Illumination light 12V-1.4W (x 2)
Input 12V-150W
Rear window defogger
Indicator light 12V-l.4W (x 2)
3
XT6 Others
I
Rated voltage 12V
Rated current 7Aorless
Rated revolutions 55 rpm
Rated load 2.4 N·m (24 kg-em, 21 in-Ib)
Stalling current 20A or less
Power window (Option) Stalling torque 8.3 N.m (85 kg-em, 74 in-Ib)
Working voltage 10V - 15V
Working temperature -25 to 80°C (-13 to 176°F)
Raising or lowering Approx. 3.5 seconds (varies depending on ambient temperature,

time work ing voltage and type of glass)
Approx. 196 N (20 kg, 44 Ib) (varies depending on ambient

Excess raising force
temperature, working voltage and type of glass)
Motor type Electromagnetic type

Heater fan
Motor type Electromagnetic type

Cooling fan
Input 12V-140W or less 12V-12OW or less
\
Fuel pump Input 12V-9.6W or less
Pump type Centrifugal

Headlight washer
4
COMPONENT PARTS
Combination Meter
1 Wire ASSY
2 Bulb and socket
3 Printed plate (Graphic monitor)
4 Bulb
5 Printed plate
6 Bulb and socket
7 Printed plate
8 Case
9 Printed plate (Seat belt timer)
10 Printed plate (Speed timer)
11 Lens
12 Tachometer
13 Temperature gauge and dial
14 Fuel gauge and dial
15 Speedometer
16 Window plate
17 Glass
18 Grommet
19 Knob
20 Clock ASSY
21 Bulb and socket
22 Printed plate
23 Warning unit
24 Printed plate
25 Warning unit
26 Wire ASSY
27 Visor
28 Buzzer
29 Trip computer circuit unit
30 Bracket
31 Trip computer control and display unit
L6-1756
Fig. 1
5
Switches
A Remote controlled rearview

mirror switch
2 Power window main switch
®I'
e.,,,, 3 Power window sub·switch
4 Fog light switch (XT6 only)
5 Boot
6 Door switch
7 Trunk room switch
8 Cigarette lighter
I
Power Window Main Switch
Power Window Sub·switch 9
DETAIL "E" 10
11
Rear defogger knob
Retractable headlight knob
Headlight washer knob
12 Cruise knob
DETAIL "Oil
Remote Controlled 13 Height knob
Mirror Switch 14 Lighting switch ASSY
~
DETAIL "C"
~
®
~.
cf
V
Trunk Room Switch
DETAIL "G"
15
16
17
18
19
20
Control wink clip
Case (LH·B)
Illumination volume
Illumination knob
Case (LH·A)
Illumination unit
,I Door Switch 21 Case (RH·A)
22 Intermittent volume
DETAIL "F"
~@ 23
24
Intermittent knob
Front defroster knob
25 Heat knob
Cigarette Lighter
26 Bilevel knob
Fog Light Switch DETAIL "H" 27 Vent or AIC knob
28 OFF knob
DETAIL "B"
29 Wiper switch ASSY
30 Case (RH·B)
DETAIL "A"
Fig. 2 L6-1469
6
Retractable Headlight
1 Lid
2 Cover
3 Cap
4 Retractable headl ight motor
5 Bracket
6 Adjusting screw
7 Mounting ring
B Screw grommet
9 Retaining ring
10 Sealed beam unit
11 Spring
12 Cord
13 Spring nut
@/rr 14 Protector
15 Stopper
16 Retractable headlight ASSY
®®
L6·1470
Fig. 3
Front Combination Light
1 Lens
2 Packing
3 Bulb
4 Bulb
5 Spring nut
6 Socket CP
7 Bulb
8 Spring
9 Front side marker light
lens and body
10 Front combination light ASSY
L6·1471
Fig. 4- CD
7
Fog Light
1 Cap
2 Socket CP
3 Bulb
4 Fog light ASSY
L6·1831
Fig. 4-@
Rear Combination Light
I
® ®
1 Rear side marker 9 Bulb

light ASSY 10 Socket
2 Lens and body 11 Bulb
3 Packing 12 Lens and body
4 Bulb 13 Packing
5 Socket 14 Back·up light ASSY
6 Flange nut 15 Tapping screw
7 Rear combination 16 Packing
light ASSY 17 Lens and body
8 Back cover 18 Socket L6·1472
Fig. 5
8
High- Mount Stop Light License Plate Light

1 High-mount
stop light ASSY
2 Cover
3 Bulb
4 Lens and body 1 Screw grommet
2 Screw
3 Blacket
4 Screw grommet
5 Bulb
6 Lens
7 Screw
8 License plate light ASSY
L6-1473 L6·1474
Fig. 6 Fig. 7
Room Light
1 Bulb
2 Glove box light ASSY
3 Screw
G love box light 4 Bulb
5 Bulb
6 Spot light lens
7 Spot light lens
8 Room light lens
9 Spot and room light ASSY
L6·1475
Fig. 8
Wiper
1 Wiper blade
2 Wiper arm
3 Wheel ASSY
4 Bracket
5 Rod
I
I 6 Sleeve unit
7 Wiper motor

Tl: 10 -18 (1.0 - 1.8,7 - 13)
T2: 4.4 -7.4 (0.45 - 0.75, 3.3 - 5.4)
T3: 6.4 - 9.3 (0.65 - 0.95,4.7 - 6.9)
T4: 22 - 29 (2.2 - 3.0,16 - 22)
L6·1476
Fig. 9 9
Window Washer
1 Hose
2 Washer nozzle ASSY
® 3 Screw grommet
4 T-joint
5 Hose
6 Joint
7 Hose
DETAIL "A"
8 Cap
9 Motor and pump ASSY
(j) 10 Grommet
11 Tank
12 Grommet
13 Clip
14 Hose
®
®
DETAIL "B"
L6-1477
Fig. 10
Headlight Washer
@
Headlight washer timer 10 Conical nut

2 Bracket 11 Hose
3 Clip 12 Nozzle
4 Hose 13 Clip
5 Motor and pump ASSY 14 Hose
I
I 6 Hose 15 Valve
I
7 Cap 16 Clip
A~ @ :
~~
8 Tank 17 Hose
9 Motor and pump ASSY 18 Clip
~ L6-1478
Fig. 11
10
BODY EL 6-2
Electrical Eq . ECTRICAL SYSTEM
Ulpment
@~/'
, LV
,
~/ ~
DETAIL "C"
®
~
DETAIL "E"
~
DETAIL "F"
DETAIL "G" DETAIL "H"
1 ~ear defogger relay

2 uel pump relay
Blower motor relay
Ignition relay
3 Wip
4 S er °Intermittent unit
peed alarm
5 Retractable head °
DETAIL "K" ~ Ugnt'.g relay "gnt tim.,
Headlight relay
: Hei~ht control unit
Cruise
10 0 °
co ntrol unit
11 Chime tem perature sensor
utslde
12 Auto matic seat belt

control unit
13 Headli gh t washer unit
14 AO O
Ir condOt
15 Horn I loner cut relay
17 Valve ~spsump ASSY

16 Vacuu
18 Y °
AIC M ( cr~lse
19 Actuator control)
DETAIL "M" ax Unit
L6·1757
Fig. 12
11
SERVICE PROCEDURE
Battery a. Electrolyte has toxicity; be careful handling the fluid.
b. Avoid contact with skin, eyes or clothing. Especially at
contact vvith eyes, blush with water for 15 minutes and get
REMOVAL AND INSTALLATION prompt medical attention.
c. Batteries produce explosive gasses. Keep sparks, flame,
1) Disconnect the positive (+) terminal after disconnecting cigarettes away.
the negative (-) terminal of battery. d. Ventilate when charging or using in enclosed space.
2) Remove flange nuts from battery rods and take off e. On the 75D23R battery, peel off the label along the cutting
battery holder. line, remove the cap and add distilled water.
3) Remove battery.
4) I nstallation should follow the removal procedure in the 3) Specific gravity
reverse order. Indicator is provided for checking the specific gravity and the
battery condition.
INDICATOR SIGN
Blue ()=:::> Blue
O.K. O.K.
White --© ©:> Red or white
CHARGING CHARGING
NECESSARY NECESSARY
Fig. 13 L6·1219
Fig. 14
a. Clean battery cable terminals and apply grease to retard the

formation of corrosion.
b. Connect the positive (+) terminal of battery and then the
negative (-) terminal of the battery. Charged condition
"OK"
Specific gravity> 1.15
The battery must be recharged when

"Charging
engine does not start.
necessary"
<
Specific gravity 1.15
INSPECTION 4) Voltage under high discharge

Charging (or discharging) the battery raises (or lowers) the
1) External parts voltage but after stopping the charging (or discharging) the
Check for the existence of dirt or cracks on the battery case, voltage gradually varies and finally settles at about 2 volts
top cover, vent plugs, and terminal posts. If necessary, clean per cell. Therefore, to check the real condition of the battery,
with water and wipe with a dry cloth. it is necessary to measure the voltage with the battery under
Apply a thin coat of grease on the terminal posts to prevent high discharge. A simple method is the use of a high-discharge
corrosion. battery tester.
2) Electrolyte level Check that the individual cell voltages are more than 1.5 volts
Check the electrolyte level in each cell. If the level is below and the voltage differences between the cells are within 0.1
MIN LEVEL, bring the level to MAX LEVEL by pouring volt when the measurements are made for 5 seconds per cell.
distilled water into the battery cell. Do not fill beyond MAX
LEVEL.
12
Since a large current flow raises electrolyte temperature, the
CHARGING battery is subject to damage if the large current is used for
prolonged time. For this reason, the quick charging must be
Measuring the specific gravity of the electrolyte in the battery carried out within a current range that will not increase the
will disclose the state of charge of the battery. The relation electrolyte temperature above 40°C (104°F).
between the specific gravity and the state of charge is as shown It should be also remembered that the quick charging is a
in figure. temporary means to bring battery voltage up to a fair value
and, as a rule, a battery should be charged slowly with a low
1.28
current.
u. 1.26
00
~ 1.24 a. Observe the items in NOTE in 1) Normal charging.
C,)
0
0 1.22 --------- b. The battery should not be charged with 1DA or more.
~
1.20
:=-
":;: 1.18
ct1
C,
u 1.16 I
:;:: -------~---------
"uCIl 1.14 I
0. I
C/") I
1.12
100% 75% 50% 22% 0%
Complete charge Charging condition (%)
Specific gravity and state of charge
Fuse
L6-913
Fig. 15 FUSE BOX
The fuse box is located underneath of the instrument panel:
The connection between each fuse and main electrical
1) Normal charging
units/devices is as shown in the following illustration. (Also
refer to the wiring diagram at the end of this manual.)
a. Do not bring an open flame close to the battery at this
time.
b. Prior to charging, corroded terminals should be cleaned FUSE BOX NO
with a brush and common baking soda solution. OIJ IT] CIJ
mJ [!QJ IT]
O!J [DJ OJ
~------+.(6)o @ I(20) I [ill IT]
@
()
@
[ill] [JIJ []]
@ [ill [IJ
@ Spare
L----".--KQ)O @ @] IT]
Battery
( ): XT6 only Catcher ~ITJ
L6-452
Fig. 17
A9-005
Fig. 16
a. When replacing fuse, be sure to use fuse of specified rating.

The battery must be charged when indicator shows "charging b. If fuse is blown, be sure to eliminate cause before installing
necessary" and also engine does not start. new fuse in position.
Perform charging for 5 hours or more with a constant current c. Poor contact of any fuse holder will often lead to voltage
of6A. drop or heating in the circuit or fuse holder and could result
At the condition of full charged, the charging current is O.5A in blown fuse, so be careful with holder contacting and clean
or less. metal parts if necessary.
2) Quick charging
Quick charging is a method in which the battery is charged in
a short period of time with a relatively large current by using
a quick charger.
13
4WD·FWD SELECT FUSE PRECAUTIONS WHEN INSTALLING OPTIONAL

[4WD·A T model only] UNITS/DEVICES
For changing from 4WD to the FWD drive mode during 1) If there is no designated spare terminals available. attach
servicing, insert a 15-ampere fuse into the FWD fuse holder. separate fuses and connect new wiring directly from the
The FWD pilot lamp on the combination meter will come on battery. Do not modify an existing wire harness.
2) Pay attention to the following points when connecting the
to indicate that the vehicle is set in the FWD drive mode.
new wiring.
(1) Determine the wire size according to the load of the
optional units/devices to be installed.
Allowable current (A)
Wire size Wiring through

engine Other
0.3
compartment
- 7
I
0.5 6 12
0.85 8 16
1.25 10 21
Fig. 18 2.0 14 28
3.0 19 38
(2) Always attach fuses to the new circuits. Determine

the fuse capacity so that the load of the units/devices to
be i nsta lied does not exceed 70% of the rated capacity.
(3) Route new harnesses as close as possible to the
existing ones and secure them with clamps.
14
XT 6
No.1 (15A) Heater fan motor
No.2 (15A) Heater fan motor
No.3 (15A) Stop light, High-mount stop light, Room light
No.4 (15A) Parking light
No.5 (15A) . Hazard warning, Horn, Clock, Trunk room light Connecting to fusible link
License plate light, Taillight, Clearance light, Grove box light,

No.6 (15A)
Illumination light (Combination meter) (Through lighting relay)
No.7 (15A) Headlight (LH)
No.8 (15A) Headlight (RH), Headlight beam indicator light

I No.9 (15A) Charge indicator light, Brake fluid level warning light Connecting to alternator
No. 10 (15A) Turn signal light, Back-up light, AT control unit
No.ll (15A) Ignition coil, EGI unit, Ignition relay, Fuel pump relay
Connecting to IG terminal of
Fuel gauge, Temperature gauge, Power window relay, ignition switch
No. 12 (15A)
Automatic shoulder belt control unit
No. 13 (15A) Power steering control unit
No. 14 (15A) Radio

Connecting to ACC terminal
No. 15 (15A) Cigarette lighter, Remote-controlled rear view mirror
of ignition switch
No. 16 (20A) Wiper and washer switch
No. 17 (20A) Rear window defogger

Connecting to fusible link
No. 18 (15A) Door lock switch, Pneumatic Suspension Solenoid
No. 19 (15A) Cruise control unit
ignition switch
No. 20 (20A) Condenser fan (sub fan) motor

Connecting to fusible link
No. 21 (20A) Radiator fan motor
15
Others
No.1 (15A) H eater fan motor
No.2 (15A) H eater fan motor
No.3 (15A) Stop light, High-mount stop light, Room light
No.4 (15A) Parking light
No.5 (15A) Hazard warning, Horn, Clock, Trunk room light Connecting to fusible I ink
License plate light, Taillight, Clearance light, Grove box light,

No.6 (15A)
Illumination light (Combination meter)
(Through lighting relay)
No.7 (15A) Headlight (LH)
No.8 (15A) Headlight (RH), Headlight beam indicator light
No.9 (15A) Charge indicator light, Brake fluid level warning light Connecting to alternator
Turn signal light, Back-up light, 4WD selector switch, AT control

No. 10 (15A)
unit
No.11 (15A) Ignition coil, EGI unit, Ignition relay, Fuel pump relay
ignition switch
Fuel gauge, Temperature gauge, Power window relay, Automatic
No. 12 (15A)
shoulder belt control unit
No. 13 (15A) Radio
No. 14 (15A) Cigarette lighter, Remote controlled rear view mirror Connecting to ACC term inal
of ignition switch
No. 15 (15A) Radiator fan motor /'
No. 16 (20A) Wiper and washer switch
No. 17 (20A) Rear window defogger
No. 18 (15A) Door lock switch Connecting to fusible link
No. 19 (15A) Air suspension solenoid valve
16
FUSIBLE LINK
4Wf&Hf
CD
1 Terminal
2 Rubber tube
3 Glass tube
4 Core wire
A25-550
Fig. 20
Fig. 19 Designation Appearance Quantity per vehicle
0.5 mm 2
If current increases beyond specified amperage, fusible metal Green 2
(0.0008 sq in)
melts and the circuit is broken, thus protecting cable and
electrical equipment from burning. 0.85 mm 2
Red 1
(0.00132 sq in)
1.25 mm 2
Black 1
(0.00194 sq in)
2.0mm 2
Blue 1
(0.0031 sq in)
a. When replacing fusible link, be sure to use one with the

specified rating.
b. Blown fusible link is caused by short circuit in the source of
electricity circuit or large amperage circuit, so certain check of
cause and/or repair is necessary.
Nominal gauge size of conductor

No. Item
0.5 mm 2 0.85 mm 2 1.25 mm 2 2.0 mm 2
(0.0008 sq in) (0.00132 sq in) (0.00194 sq in) (0.0031 sq in)
70mV 60mV 50mV 40mV

1 Voltage drop
Voltage drop across lug terminals should be less than the above value when a 10-ampere
current flows through fusible link at room temperature.
Fusible link should Fusible link should Fusible link should Fusible link should
Melting melt within 15 seconds melt within 15 seconds melt within 15 seconds melt within 15 seconds
2
Characteristics at a current flow of at a current flow of at a current flow of at a current flow of
80 amperes. 130 amperes. 190 amperes. 260 amperes.
17
Combination Meter
Warning and Indicator Lights
According to ignition switch position, each light will come on
and/or go off under normal conditions as follows:
Ignition switch position OFF ACC ON ST While engine is running
Raise * * * * *
Retractable headlight indicator light
Down * * * * *
AT oil temperature warning light OFF OFF ON ON OFF
Charge indicator light OFF OFF ON ON OFF
Oil pressure indicator light (DL model only) OFF OFF ON ON OFF
Stop light warning light OFF OFF ON ON OFF
Brake fluid level warning OFF OFF ON ON OFF
CHECK ENGINE warning light OFF OFF • • OFF
STEERING warning light (XT6 only) OFF OFF ON ON OFF
Symbols used: * Indicator light comes on while headlights are raised or lowered.
• Light comes on before engine starts, and stays off after engine stops.
LEFT HAND
AT Oil Temperature Warning Light
The warning light is provided for the purpose of preventing
(XT6 model)
overheating of torque converter fluid in case of repeated
(D ~~3~ ~ CHARGE
AIR SUS-
PENSION STEERING start·off operations in sand or on a snowy road, or when the
car is operated at very low speed (near the stall speed) con·
(DL model)
tinuously under heavily loaded conditions.
~ ~
I. tD ATOlL
TEMP
CHARGE OIL If the temperature of the fluid at the torque converter outlet
exceeds 150°C (302°F), the warning lamp "AT 01 L TEMP"
RIGHT HAND
will illuminate and warn the driver of high oil temperature.
STOP (<D) BRAKE CHECK In such a case, the driver need not stop the car, but should
LAMP FLUID ENGINE
avoid undue operation. The warning light will go out as the
fluid temperature drops.
L...-_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _------=L::6-~1:....:.7..:.5.:.J9 The thermoswitch is installed on the side of the extension
Fig. 21 case.
Charge Indicator Light

The light indicates the alternator and charging system operat·
ing condition.
If there is something wrong with the alternator and charging
Retractable Headlight Indicator Light
system, the light will come on while the engine is running.
This indicator light turns on only when the headlight raise/
down motor is in operation. I t comes on and lights for about Oil Pressure Indicator Light (DL model only)
one second when the headlights pop up or down.
Oil pressure indicator light indicates whether or not oil pump
is feeding oil under normal pressure to various parts of engine.
Indicator light is operated by oil pressure switch located in
lubricating system.
18
Stop Light Warning Light a. For checking if bulb of brake fluid level warning light is
The light is connected to the stop light checker. This checker burned out, make sure that the warning light glows when
consists of a reed switch and magnet coils CD and ®, as ignition switch is initially turned to "ON" and it goes out
shown in figure. Under normal conditions, the magnetic fields
when engine is running.
are generated in the magnet coils CD and ® by the current
b. If brake fluid reservoir is inclined or vibrated abnormally,
flowing through each light while the stop light switch is ON.
the warning light may be lighted momentarily even fluid level
These magnetic fields cancel each other because the coils turn
is above the specified limit.
in directions opposite to each other. As a result, the reed
4WD-AT
switch will remain OFF, and the warning light is OFF. If Ignition switch Fuse fluid
either the left or right hand side stop light fails, current will
flow through only one magnet coil, and the resultant magnetic AT oil Warning &
arking
field causes the reed switch to turn ON. Therefore, the Fusible link temp. indicator
warning light will remain lighted as long as the brake pedal is FL-2 '----+_-+_-+-_+----1r-----J1 i ghts
depressed.
The light will not come ON if both right and left lamp bulbs
burn out simultaneously. Battery
-
T i-~ Ie regulator Stop
Fuse Fuse
(15A) (15A) Stop light switch
I-=
I
':"4WD-AT flui'1
temperature -=
light
checker
I. 1_ 1_
Parking brake
switch
A ternator switch Brake fluid
level sensor A25-169
Fig. 23
1Bat"'v Stop
checker
I"J ~'
L.
Stop light CHECK ENGINE Warning Light
(Right)
A11-259 The warning light is provided for the purpose of indicating the
condition of the MPF I system. If the MPF I system is faulty,
Fig. 22
the warning light will come on while the engine is running.
For troubleshooting, refer to the chapter titled "2-7 Fuel
Injection System".
Brake Fluid Level Warning Light STEERING Warning Light

The light is connected to the brake fluid level sensor that is This light comes on when trouble occurs in electronic-
incorporated in brake fluid reserve tank. controlled motor drive power steering system while engine is
If brake fluid decreases to less than the specified volume in the running. It also functions as a monitor light when diagnosing
reservoi r, the sensor is actuated and the I ight comes on wh i Ie the steering system. For troubleshooting, refer to Chapter 4-3
the engine is running. "Steering System".
Total brake fluid volume in reservoir:

180 em 3 (180 ee, 10.98 eu in)
Remaining volume when brake fluid level warning Low Fuel Indicator Light
light glows:
The indicator light is operated by thermistor incorporated in
Approx. 90 em 3 (90 ee, 5.49 eu in)
fuel unit on fuel tank, and goes on when amount of gasoline
in fuel tank is less than the specified volume as shown below.
All models:
9 Q (2.4 US gal, 2.0 Imp gal)
19
Telltale (Graphic Monitor)

According to ignition switch position, each light will come on
and/or go off under normal conditions as follows:
While engine
Ignition switch position OFF ACC ON ST
is running
Lock OFF OFF ON ON ON

DIFF LOCK indicator light
Unlock OFF OFF OFF OFF OFF
1
FWD OFF OFF ON ON ON
Front wheel drive indicator light
4WD OFF OFF OFF OFF OFF
2 Fasten seat belt warning light OFF OFF 0 0 OFF
Engage OFF OFF ON ON ON

3 Parking brake warning light
Disengage OFF OFF ON ON OFF
High-beam OFF OFF ON ON ON

4 Headlight beam indicator light
Low-beam OFF OFF OFF OFF OFF
5 Power mode indicator light OFF OFF OFF OFF /}.
6 A T selector position indicator light OFF OFF ON ON ON
Engaged (Hold) OFF OFF 0 0 0

7 First hold indicator light Disengaged
OFF OFF OFF OFF OFF
(Not Hold)
Disengaged
OFF OFF OFF OFF OFF
Height control indicator light (Normal position)
8
(Canada model only)
Engaged
OFF OFF ON ON ON
(High position)
Lock OFF OFF OFF OFF OFF

9 Door lock indicator light
Unlock OFF OFF ON ON ON
Open OFF OFF' ON ON ON

10 Door ajar warning light
Shut OFF OFF OFF OFF OFF
Engage OFF OFF ON ON ON

11 Rear defogger indicator light
Disengage OFF OFF OFF OFF OFF
Symbols used: 0 Light comes on only for 6 seconds.

o When the first hold switch has been set to ON with the select lever in position "2", the indicator light is
illuminated.
/}. Immediately after engine starts, indicator light comes on. It soon goes out. It also comes on when the AT
power mode is selected.
20
OILP'~5
45
PSI
'
\ , II "
\'45 55 65 75 I I
85
95/
I, fi 18
12v
VOLTS
~ ~""1 x1000r/min ~ 105"_ ~E:!l
~~ ·d::::;4==O o 11~~: fiFUNL:~~~O

135 - Y2 FUEL ONLY
I!!lllIlU3 ,".::=0 il
CHECK
ENGINE
ceJ
[BJ
IN] PARK PARK
IC&l BRAKE DOOR LOCI 01 BRAKE DOOR LOCI
(]l] 1PO 1m 1
rn
[2J 11HOLoi
0
IHII
.'0. 11111
o
(U
IIIH
0
U
(U L1
e ~ o
~DOOR " 0"
Iiiil~LOCK
I awn
01
PARK
fULLTIME I' /
!iii]
§ " ~~' o 0
BmE~
(FWD AIT) (Full-Time 4WD AIT) (FWD MIT) (Selective 4WD MIT) (Full-Time 4WD MIT)
L6-1760
Fig. 24
Analogue Meter
For procedures used to remove and install meters, refer to

Chapter 4-3 "Steering System".
Be sure to disconnect earth cable from negative (minus)

[]
terminal of battery previously.
L6-862
Fig. 25
DISASSEMBLY & ASSEMBLY
1) Remove trip knob by pulling it out.

2) Disconnect wire harness connector from back of meter 4) Remove screws and detach meter visor, meter glass and
ASSY. window plate.
3) Remove screws and detach telltale graphic monitor. 5) Remove screws. and detach meters and gauges.
21
Table 2
Speedometer should point Meter drive shaft speed
60 km/h 637.5 rpm
60 MPH 1,020 rpm
L6-863 TEMPERATURE GAUGE

Fig. 26 Temperature gauge (cross coil type) is operated by thermistor
incorporated in temperature sending unit installed in intake
manifold.
6) Remove indicator & warning unit from meter visor. Since thermistor resistance changes with voltage, voltage
regulator is provided to prevent error in gauge indication due
to voltage fluctuation.
Temperature gauge
Ignition
Fuse switch
A (15A)
Voltage regulator Fusible

link
r::r::B-o B
Indicator & warning unit
Battery :
L6-864
Fig. 27
Temperature sending
unit (Thermistor)
L6-105
1
Fig. 28
7) To assemble, reverse disassembly procedures.
INSPECTION
It is normal if the readings of temperature gauge are within the
tolerances of engine coolant temperature as shown in the
SPEEDOMETER following table against the standard resistance between point
It is normal if the readings of speedometer are within the A and B indicated in the wiring diagram when ignition
tolerances shown in the table 1, against the standard indicated switch is "ON".
speeds on the speedometer tester.
Besides, speedometer should point as shown in the table 2. Standard Temperature of
Readings of
Table 1 temperature gauge resistance engine coolant
Standard indicated 34 - 62°C

20 40 60 80 50°C (122°F) 153.90
speed (km/h or MPH) (93 - 144°F)
17.9 - 38.3 - 56.1 - 75.6 -
(km/h) 116 -123°C
Readings 20.9 40.3 60.2 79.6 120°C (248°F) (16.10)
of speed- (241 - 253°F)
ometer 17.9 - 38.3 - 56.1 - 75.6-
(MPH)
20.9 40.3 60.2 79.6
Besides, standard resistance of temperature gauge is 450.
22
L
FUEL GAUGE TACHOMETER
Needle of fuel gauge remains indicating the amount of fuel in It is normal if readings of tachometer are within the tolerances
fuel tank after turning igniton switch to OFF position. as shown in the following table, against the standard indicated
speeds on tachometer tester.
Also, tachometer should point 5,000 rpm when distributor
speed is 2,500 rpm.
Fusible Standard indi-

1,000 2,000 3,000 4,000 5,000 6,000
cated speed (rpm)
~~.~~~,~~ Fuel~u~
: A unit Tolerance (rpm) 940 1,955 2,970 3,980 4,990 6,000
l___ -------, ~
B
-20 to 60°C
0
(-4 to 140 F)
to
1,090
to
2,145
to
3,200
to
4,250
to
5,305
to
6,360
Fuel tank
OIL PRESSURE GAUGE
Oil pressure gauge (bimetal type) is operated by oil pressure
A25·568
unit (bimetal type) located in lubricating system.
Fig. 29 It is normal if the readings of oil pressure gauge are within the
tolerances as shown in the following table, against the standard
indicated pressure values on oil pressure gauge.
It is normal if the readings of fuel gauge are within the Input OmA 75 mA
tolerances of all length between "E" and "F" as shown in the
following table, against the standard resistance between point
Standard indication o psi 45 psi
A and B indicated in the wiring diagram when ignition switch Indication tolerance +1.5°: -3.5° +4.5°, -5.5°
"ON".
Reading of Standard
VOLTMETER
Tolerance of fuel gauge
fuel gauge resistance It is normal if the readings of voltmeter are within the
tolerances as shown in the following table, against the standard
+1/12 to -1/24 of all length indicated values on voltmeter.
E 7.0!l
between "E" and "F"
Standard i nd icated
1/2 (32.5!l) - Voltmeter values (V)
8 12 16
+1/24 to -1/12 of all length Tolerance (V) 7-8 11.4 - 12.6 15 -17
F 95!l
between "E" and "F"
23
Trip Computer (XT6 Only) Connector

Connection
The trip computer essentially consists of three units - control Terminal Color
unit, display unit and circuit unit. (On XT models, the control
1 White Battery
unit and the display unit are unitized.)
The control unit contains the "CLOCK", "ALARM", "OUT 2 Red Ignition switch
TEMP", "TRIP", "ARRIVE" and "AVG. SPEED" push-
buttons. It also contains a "self-diagnosis" function. Pressing a 3 Black Grounding
pushbutton will display a computed result of its corresponding
4 Yellow Car speed pu Ise
function on the display unit.
5 Red/Black Out temperature 8
All information ("TRIP", "ARRIVE" and "AVG. SPEED")
concerning traveling distance appears on the display in Miles 6 - -
for US models and kilometers for Canada models.
7 Green Illumination grounding
8 Brown Power source (Illumination light)
9 Blue Ou t tem pe ratu re ®
CD
o ®
® ®
(j)
@
o o TO@ ®
Connecting to @
instrument
panel harness
rAn
~
(White)
R
(Green)
S
{B'ockl ~:}
Connecting to
control &
display unit
L6-1761
Fig. 30
24
OPERATION AND FUNCTION
TRIP
ARRIVE
L6-1265
Fig. 31
Display The travelled distance is shown by four digits of the 7-segment figures. While distance is being
displayed, the TRIP button on the control unit is illuminated. "0" as a high-order digit is
indicated by a blank.
Display range
~ Unit Display range Interval displayed
Mile miles 0.0 - 999.9 0.1 mile
km km 0.0 - 999.9 0.1 km
Function • The travelled distance is displayed when the TRIP button is depressed.
• If the "RESET" switch is depressed for more than·l.2 seconds in the TR IP functions, dis-
play returns to "0.0", and clocking of distance starts again in units of 0.1.
• In case of overflow in the display, i.e., more than 999.9 is travelled the display returns to
"0.0", and then continues.
• While the ignition switch is turned to ON, counting is performed if an other function button
is depressed.
• The count increases by 1.0 km each time 637.5 x 4 pulses are applied.
• The count increases by 1.0 mile each time 1020 x 4 pulses are applied.
• "0.0" is displayed immediately after the battery is connected. (No memory is retained when
the battery is disconnected.)
25
ARRIVE
~~ D='
~~ 0.:,
D»~~ ARRIVE
L6·1266
Fig. 32
Display • The distance left to go is shown by four digits of the 7·segment figures. While the distance is
being displayed, the IAR R Ivel button on the control unit is illuminated. "0" as a high-order
digit is indicated by a blank, except when resetting.
Display range • Same as the display range of the TR IP function.
Function • The distance left to go is displayed when the ARRiVe button is depressed.
• After presetting, count down in units of 0.1 starts.
Display of ARRIVE • The IARR IVE I display illuminates for six minutes when "0.0" has been reached, then
extinguishes. The display also goes out when the ignition switch is turned to OFF; and will
not reilluminate when the switch is turned to ON again.
The I ARRIVE I display illuminates even if another function is being displayed. At the same
time, the buzzer turned to sounds for 3 seconds.
• While the ignition switch is turned to ON, counting continues if the other function button
is depressed.
• The count decreases by 1.0 km each time 637.5 x 4 pulses are applied.
• The count decreases by 1.0 mile each time lQ20 x 4 pulses are applied.
• The indication immediately after connecting the battery is undefined.
Resetting 1) The resetting function is attained when "100", "10", "1" or "0.1" switches are depressed
while the ARRiVe function is selected. This mode is cancelled 10 seconds after operating
these switches, or when the AR RIVE button is depressed.
2) No counting of ARRIVE function is performed during the resetting mode.
3) When resetting, counted contents less than 0.1 are cleared.
4) The "100", "10", "1" or "0.1" switches function independently, and no carrying over is
made at any digit position.
5-6---9-0-1-2------
L T h e upper digit remains unchanged.
5) When the "100", "10", "1" or "0.1" switch is held in, the displayed number changes in
sequence for each 0.5 second for the first 1.5 second period, and for each 0.25 second
afterward. The number increases by one when the switch is depressed once.
26
CLOCK
ARRIVE
L6-1267
Fig. 33
Display • The current time is displayed by "AM", "PM", and four digits of the 7-segment figures.
While the time is displayed, the CLOCK button on the control unit is illuminated. When the
alarm time is being displayed, the ALARM button on the control unit is illuminated.
• "0" in the left digit of the "minute" position is displayed as "0", but the "0" in the left
digit of the "hour" position is displayed by a blank.
Example: AM 8 hours 3 minutes ..... AM 8 : 03
Display range
Display range Minimum display unit
AM
1 : 00 to 12 : 59 1 MINUTE
PM
Function • The time is displayed when the CLOCK button is depressed.

• The "AM" or "PM" display flashes once a second with the duty ratio of 50%.
• The time is counted continuously as long as the battery is connected, irrespective of the
display on the display unit.
• Immediately after connecting the battery, the display is "PM 1 : 00", which flashes once a
second with the duty ratio of 50%.
Time resetting 1) The "H", "10M", "M", and "SET" switches function only in the CLOCK function. This
mode is cancelled when the "SET" switch is depressed.
2) Time is being counted even during the time resetting operation.
3) When the "SET" switch is depressed, the CLOCK display is set to a time signal.
oto 29 second is rounded off (Ex. 10:00 29 -.10:0000 )
30 to 59 second is carried forward (Ex. 9:59 35 -.10:00 00 )
4) The "H", "10M", and "M" switches function independently and no carrying over is made
from the unit to tens place in the minute range, nor from minute nine to hour position.
5) If "12" is displayed when the "H" switch is depressed, "AM" changes to "PM", and "PM"
to "AM".
6) If "H", "10M", or "M" switch is held in, the displayed number changes for each 0.5 second
for the first 1.5 seconds, then for each 0.25 second afterward. The number increases by one
when the switch is depressed once.
27
ALARM
ARRIVE
If the ALARM is set, the mark" "») " illuminates even if

another function is being displayed, and flashes when the preset
alarm time is reached. L6-1268
Fig. 34
Time alarm 1) When the ALARM button on the control unit is depressed, it illuminates.
If the ALARM is presetted, the mark " .))~ " and alarm time are displayed. This state con-
tinues until the alarm is cancelled. Neither AM nor PM flashes.
2) When the preset alarm time is reached, the buzzer sounds for six minutes or until the alarm
is cancelled even if another function is displayed on the display unit. (The buzzer issues a
sound four times a second.) At the same time, the mark" .)~ " flashes once a second with
the duty ratio of 50% .
. . - - - - 1 Sec.
ON
OFF -
3) When the alarm time is being set, the mark II .»~" illuminates even if another function is
being displayed.
4) When the ALARM switch is pressed, alarm stops.
5) In the ALARM mode, pressing the RESET switch cancels the "set" time.
Alarm Time Resetting 1) With ALARM button depressed, the alarm time can be reset by pushing the "H", "10M",
and "M" switches. This resetting mode is cancelled 10 seconds after depressing these
switches, or when the "SET" switch is depressed. If other function button is depressed
within 10 seconds, this mode is cancelled after time setting.
2) If "12:" is displayed when the "H" switch is depressed, "AM" or "PM" changes as follows:
AM -+PM, PM -+AM.
3) If the "H", "10M", or "M" switch is helding the displayed number changes for each 0.5
second for the first 1.5 seconds, and for each 0.25 second afterward. When pushed once,
the displayed number changes by one.
28
OUT TEMP
t%~ D'==70
~~ 0::0
o»»~ ARRIVE ARRIVE
L6-1271 L6-1272
Fig. 35
Display • The outside air temperature is displayed by three digits of the 7-segment display.
• The outside air temperature indicator on the control panel illuminates when OUT TEMP is
displayed.
• The leading "0" in the tens or hundreds place is indicated by a blank.
Display range °c: -30 to 80

of: -24 to 176
°c indication OF indication
Display Display
temperature tC)
Resolution (oC)
temperature (0 F)
Resolution t F)
-30 to -16 2 -24 to 4 4
-16 to 30 4 to 88 2
30 to 80 2 88 to 176 4
Indication
°c
Temperature (oC) -20 20 60
Sensor resistance (kn) 50.53 6.244 1.244
Standard -20±4 20±3 62±4
of
Temperature tF) -4 68 140
Sensor resistance (kn) 50.53 6.244 1.224
Standard -4±8 68±6 144±8
29
Response time • When display temperature is decreasing: 4 seconds

(The minimum time for changing one display unit)
• When display temperature is increasing: 1 minute
Display after battery • Undefined (The value is within the display range.)
connection
30
AVG SPEED
ARRIVE
LS-1270
Fig. 36
Display • The AVG (SPEED) is displayed by four digits of the 7-segment figures.
• While this is being displayed, the AVG SPEED button on the control unit is illuminated.
"0" as a high-order digit is indicated as a blank.
Display range
~ Unit Display range Discrimination
mile MPH 0.0 - 150.0 0.1 MPH
km km/h 0.0 - 240.0 0.1 km/h
Display update time • 4.8 sec
Function • The average speed is displayed when the AVG SPEED button is depressed.
• The displayed contents are travelled distance/travelled time, and the distance and time
travelled after resetting the average car speed are used.
Display at overflow • If tt")e travelled time exceeds 100 hours, or the travelled distance exceeds 1000.0 display
unit [that is, 1000.0 km (625 mile), the previously displayed contents are displayed. In this
case, "km/h" or "MPH" display flashes.
Display immediately • If (AVG SPEED) function is selected directly after connecting the battery, or directly after
after resetting resetting, bars are displayed for 4.8 seconds, that is - - - km/h (MPH).
31
Self-d iagnosis
AM s~§
~M C§
~»»)
The hatched position and black-colored portion flash alternately,
in addition to the display of the 7-segment figures.
L6-1273
Fig. 37
Self-d iagnosis • The self-diagnosis function is attained when the CLOCK, ALARM and AR RIVE buttons are
depressed at the same time.
• In this function, all seven-segments light up for three seconds, then each digit changes from
a
9 to 8 to 7, ...• 2 to 1 to for 0.5 second each. During this period, ["AM"," .»» "," : ",
"Miles" "(km)"] and ["PM", "ARRIVE", ".", "MPH", "(/h)"] flash alternately.
• During this function, the buzzer sounds intermittently for a period of 0.5 second in syn-
chronization with the change of the displayed figure.
Return to function • The self-diagnosis function is cancelled when one complete cycle has ended, or when another
after self-diagnosis function button is depressed. Upon completion of the self-diagnosis cycle, display returns to
the CLOCK function.
Self-diagnosing of • The lamps are illuminated in the sequence of CLOCK, ALARM, OUT TEMP, TRIP, ARRIVE,
LED (pilot lamp) on AVG SPEED in synchronization with the change in the displayed figure. Each lamp illumi-
control unit nates for 0.5 seconds period.
(ON All digits and marks)
Display
~9 8 7 6 5 4 3 2 o ICLOCK I
Lamp
AVG
SPEED
In addition to the above, the following functions are also provided:
Display when • When the ignition switch is turned to ON, the function selected when the ignition switch
ignition switch is was turned to OFF is displayed again.
turned to ON
Multiple function • If two or more function inputs are made, except in the self-diagnosis, the function which is
input input first is displayed. The next input is accepted only after all functions are turned to OFF
once.
32
ALARM at ignition • If the preset alarm time is reached while the ignition switch is OF F and the ignition switch is
switch OFF turned to ON within 20 seconds after the alarm time, the buzzer sounds and the sign" "»)"
flashes till the 20-second period terminates.
ON
IGN OFF
ON , . . - - - - . . ,
Alarm I OFFI
I
I,_~
_ _- 20 seconds - - - - . :
I
I
Alarm time
Operation of function • When any of the function buttons are depressed, the buzzer sounds for 0.05 seconds,
button indicating that the signal has been accepted.
Operation of • If the "RESET" switch is kept ON for 1.2 second, the buzzer sounds for 0.05 seconds.
"R ESET" switch
(3) Disconnect the connector and take out the unit.

REMOVAL AND INSTALLATION (4) To replace bulbs, remove five screws on the back side
case.
1) Control & display unit
(1) Pry out the cover beside the unit and remove screw in
the opening.
(2) Using screwdriver, slightly pry the unit up, being
careful not to damage instrument panel.
~,--
[
__DDDDDD~
L~ ['__'Ii\..
L6-477
Fig. 39
L6-476
(5) Installation is in the reverse order of removal.
Fig. 38
33
2) Circuit unit
Ignition Switch
Ignition switch is installed on steering column and steering
lock mechanism is provided.
Key plate can be pulled out of ignition switch only in
"LOCK" position.
\
CONNECTION
Connection of ignition switch terminals is shown in the
following table.
View@ Make sure to securely connect electric connector to ignition

switch.
Buzzer
Circuit unit
IG
TO@
L6-1762
Fig. 40 L6-1763
Fig. 41
(1) Detach control & display unit.

(2) Remove radio fixing screws through the opening and Connector Switch operation
take out radio. Terminal LOCK ACC ON START
(3) Through the opening to be installed the radio, remove
~
~
three screws and detach the circuit unit from the bracket. 8 0
(4) Installation is in the reverse order of removal.
A
IG
34
Combination Switch
Combination switch is fitted on steering column and is com-
bined with headlight dimmer switch, turn-signal switch, hazard
warning light switch, parking light switch, and wiper & washer
switch. Transistorized turn & hazard unit is incorporated in
combination switch. Turn signal lever has clicks for lane
changing.
Wash
----Mist
L6-1764
Fig. 42
CONNECTION
Connection of each terminal is shown in the following table.
Turn
Parking Light Signal SW Turn Signal and Hazard
Hazard l-r--F----r--.--r------,.....--,--H---r---.
L M N SW G J 0
OFF
ON OFF ®
®
ON
Power
Dimmer and Passing Washer and Mist
Turn
o P Q signal
light
PASS (RI
DIM
MAIN
Power
L6-1765
Fig. 43
35
I'
1 ) Remove screws and detach lower cover.

2) Remove fixing screws and detach column covers (upper
and lower).
3) Take out steering wheel cover and remove nut using
Special Tool. Then, detach steering wheel.
4) Detach clip and band fitting harness to steering column,
and disconnect the connectors.
5) Remove screws fixing combination switch to control wing
bracket, and take out combination switch.
6) Installation is in reverse order of removal.
Control Wing
Lighting switch side Wiper switch side
ilmll TO
@
o E F G H
N 0 P Q R
TO@ TO@>
L6·1489
Fig. 44
36
Lighting switch
Connector Switch operation

Connection
Terminal Color OFF :([)<D= I([)
1 RL
? ? Power source
2 R 6 6 Combination meter and Combination switch
9 YW
? ?
10 YW 6 6
7 YR Timer
3 YB
9 Headlight beam switch and Retractable headlight switch
4 B
? ?I Grounding
IIllumination I
control unit -:::!::-
T I
8 RB 6 6 6 Combination meter
Wiper and washer switch
Connector Switch operation

Connection
Terminal Color OFF INT LO HO
D LW Wiper motor
~
E G 0 Wiper INT unit
~
F Y Wiper INT unit and wiper motor
G YL Wiper motor
H R Ignition switch (ACC)
I RB Wiper INT unit
K
YB
B I ~
Wiper INT unit
Grounding
N
BW
BY
I
Resistor
37
Heater & Ventilator Control
DEF
HEAT
GW
BILEV
GR
A/C(VENT)
RW
A/C(MAX)
OFF
L -_ _ --~ U ~-- ---~ v ~-- ------i w~-- ----- -----4

Br
LR LG RL LS-1492
Fig. 45
SUB SWITCH
Rear window defogger
GR@---o~Br
Retractable headlight
" " ' 0 - - - - - . . . . ( 15 Y
YL~
Headl ight washer
RY@---o~GW
Cruise control
:",W
23 Br
Height control
RY~~---'[-~RW
8 @RY
L6-1493
Fig. 46
38
Column cover (Upper)
Steering wheel Control wing
Combination switch
Column cover (Lower)

Steering lock
L6-1766
Fig. 47
1) Remove screws and detach lower cover.

2) Remove fixing screws and detach column covers (upper
and lower).
3) Take out steering wheel cover and steering wheel.
4) Detach clip and band fitting harness to steering column.
5) Remove screws and take out combination switch.
r-----!77-- Illumination control unit
6) Remove fixing bolts and detach control wing.
7) Remove screws and separate case A and case B from
control wing.
a. To remove switch knob, lightly push pawl inside it using a

pin and pull the knob out.
Case (AI
l6-498
Fig. 48
39
L6-499
Fig. 49 Fig. 51
a. If the headlights fail to retract or open, take emergency

action as follows:
b. When installing sliding switch knob and volume control, (1) Open hood and disconnect connector from retractable
place your finger on the rear surface of the control and mesh headlight motor.
the knob with the control. (2) Remove rubber cover from top of the motor.
(3) Turn manual control knob on top of the motor until
the headRjllts are open completely.
!! Knob
L6-1495
Fig. 50
Fig. 52
c. Do not allow harness to be caught in cases A and B or
pulled unnecessarily during ASSY.
(4) Install the rubber cover a~ before.

b. If foreign matter hampers movement of the headlights,
immediately repeat steps (1) through (3) in a. above, and
remove foreign matter.
Otherwise, current will continue to flow through the circuit,
reSUlting in a rundown battery. Whether or not current IS
Retractable Headlight flowing through the circuit can be determined by the indicator
light in the combination meter.
The retractable headlights are operated (opened or closed) by
the retractable headlight switch, lighting switch or flasher
switch.
An indicator light in the combination meter illuminates for
approximately one second to indicate that current is flowing
through the headlight motor during open-close operation.
40
1) Disconnect electric connectors for retractable headl ight

and motor.
2). Detach plastic cover.
3) Remove screws and take out lid.
Fig. 55
~
--~
L6-884
~:I~;): I
~
Screws::'
Fig. 53
4) Remove screws and take out headlight cover.
Fig. 56
6) Remove fixing bolts and separiie motor from retractable

headlight ASSY.
Fig. 54
L6-886
Fig. 57
5) Remove fixing bolts and take out retractable headlight
ASSY.
INSTALLATION
'\.". .
Install each part in the reverse order of removal with the

following cautions:
1 ) Tighten bolts and screws to the specifications.
41
2) Adjust washer ejecting point on windshield glass as shown
Tightening torque: in illustration when car stops.
Motor fixing bolts
13 - 23 N·m (1.3 - 2.3 kg-m, 9 - 17 ft-Ib) 450t50 (17.72t1.97)
Headlight cover fixing screws
3 - 6 N·m (0.3 - 0.6 kg-m, 2.2 - 4.3 ft-Ib)
2) Install retractable headlights so that the clearance between

lid, hood and fender is within the range indicated in the
following figure.
4.S(0.181)
1
I r Front fender
I
Unit: mm (in)
L6-179
Fig. 60
.-f.1----5.1 (0.201)
REMOVAL
J
BLADE
5.1 (0.201) (Engine hood)
Remove attaching screws and separate blade from wiper arm.
Unit: mm (in)
LS-512
Fig. 58
Blade
3) After adjusting the headlights, recheck them for proper
movement.
Wiper and Washer
ON-CAR SERVICES L6-181

Fig. 61
ADJUSTMENT
ARM
1) When wiper switch is in "OFF" position, adjust blades in
original position as shown in illustration by changing wiper With front hood opened, remove nut and take out wiper arm
arm installation. and arm cover.
Lifter
Section A-A
L6-539 LS-887
Fig. 59 Fig. 62
42
WIPER MOTOR ASSEMBLY
INSTALLATION
1) Detach plugs fitting moulding.
2) Disconnect electric connector.
Install each part in the reverse order of removal with the
3) Remove fixing bolts and detach wiper motor ASSY.
following cautions:
1) Tighten bolts and nuts to the specifications.
/
Tightening torque:
Wheel ASSY attaching bolts
6.4 - 9.3 N·m (0.65 - 0.95 kg-m, 4.7 - 6.9 ft-Ib)
Wiper motor to wheel ASSY attaching nut
22 - 29 N·m (2.2 - 3.0 kg-m, 16 - 22 ft-Ib)
Wiper motor ASSY fixing bolts
4.4 - 7.4 N·m (0.45 - 0.75 kg-m, 3.3 - 5.4 ft-Ib)
Wiper arm fixing bolts
10 - 18 N'm (1.0 - 1.8 kg-m, 7 - 13 ft-Ib)
Washer tank attaching nuts
3 - 6 N·m (0.3 - 0.6 kg-m, 2.2 - 4.3 ft-Ib)
Fig. 63
2) . After installation, make sure that the wiper and washer
are operated in the normal condition.
4) Remove bolts and nut, and separate wheel ASSY from

wiper motor ASSY.
Wiper Intermittent Control

WASHER TANK
1) With front right-hand side mud guard and air cleaner System
detached, disconnect electric connector and washer hose.
A microcomputer is used in the windshield wiper intermittent
2) Remove nuts in engine room, and take out washer tank
control circuit to provide a car-speed-sensing function.
along with washer pump.
The higher the car speed, the more rain on the windshield.
When the wiper switch is set to the INT position, the control
circuit automatically changes the time interval preset by the
intermittent control switch in response to car speed. In other
words, when the switch is in the INT position, the wiper
operates for one cycle and then stops. If speed increases to
20 km/h (12 MPH) before the next wiper cycle (during the
resting time), the wiper will complete another cycle during
that time.
Wiper intermittent control unit .connector

.--
Fig. 64
LS-890 '/8
17
7
16
6
15
5
14
n
13
4
12
3
11
2
10
1\
(Control unit side)
NOZZLE
To ®
1) Detach front lower moulding and net. LS-1497
2) Disconnect washer hose and pullout nozzle. Fig. 65
43
CONNECTION
Wiper intermittent control unit
Intermittent
Wiper motor
connector
o
_l~TO@
OFF
IN T
'@TO@)
--~
LOW
HIGH
Wiper motor
L6·1498
Fig. 66
Radio 2) Disconnect feeder cord connectors.

3) Take out clock.
4) Remove fitting screws, and slightly pull out radio along
REMOVAL AND INSTALLATION with bracket.
5) Disconnect electric connectors fr'om the back side of
RADIO BODY radio, and take out radio along with- antenna feeder cord and
bracket.
1) Take off floor mat of driver's side and draw out feeder
6) Remove screws and separate bracket from radio.
cord connectors from left side of center under portion of
instrument panel.
Feeder cord con nectar ADJUSTMENT
I 1) Setting push button .

• Other than ETR (Electronic tuning radio)
There are five push buttons, so five stations are selected as
follows.
. ' ',' .
. - ,',,'
(1) Select a station by turning the turning dial.
L6·1499 (2) Pull the push button and push it back, and then the
Fig. 67 push button is kept set at the station required.
44
(2) Push the manual or automatic tuner until the fre-
quency of the desired station appears on the digital
indicator panel.
(3) When desired preset button is pressed for more than
two seconds, the station now being received is memorized.
SW'VOLI SCAN FM/AM 1 2 3 4 5 VTUNE/'.
(0 tt:lt1IT1t]
1-Y.
0 en MTL
OM-l09l
Fig. 68 ------
FM/AM
a. Confirm the push button is set at the center of the channel, selector switch P b
otherwise the tone becomes bad according to an amount of reset utton
discrepancy from the center of the channel. L6-l767
b. For FMI AM radio, push the FM push button once before
selecting FM station. - Fig. 70
• ETR
2) Adjusting antenna trimmer (except ETR)
There are five pre-set buttons, so five stations each on AM and
Antenna trimmer is adjusted in order to make each radio
FM can be selected as follows.
sensitive in case the sensitivity is poor or abnormal noise exists
(1) Push the AM/FM selector switch to select the
(AM band only).
required band.
(1) Attach antenna rod in position.
(2) Push the manual or automatic tuner until the fre-
quency of the desired station appears on the digital (2) Select the channel of a weak station between
indicator panel. 1,400 kHz and 1,600 kHz.
(3) Push the memory button. "M" appears on the panel (3) Adjust antenna trimmer to make the sensitivity in
for five seconds. maximum.
Push one of the pre-set buttons while "M" appears on the
panel. The frequency on the panel is then pre-set for that Antenna trimming is available only for AM band.
button.
3) Prevention of abnormal noise
(1) Ignition system contacts, the alternator and motor
brush contact points are sources of abnormal noise in the
radio. In order to prevent this noise, the vehicle is
equipped with a high tension cord which contains
resistance, a condenser in the ignition coil harness and a
1-' AM,
Och FM Ie.
1-' D.C'
1-' I-' MH2
KHz M
ST.
grounding wire to the body from the engine.
(2) Antenna is grounded to body through antenna
installing bolts, when screws are not tightened securely, it
makes abnormal noise. So, tighten antenna installing bolts
securely.
OM-1528 Antenna
Fig. 69
REMOVAL
• ETR with auto-reverse cassette player 1) Remove antenna mounting nut and supporter.
There are five pre·set buttons, so five stations each on AM and 2) Remove two bolts which secure antenna to trunk.
FM can be selected as follows. Extract antenna and remove band clip.
(1) Push the AM/FM selector switch to select the 3) Disconnect feeder socket and harness connector.
required band. 4) Remove drain tube from grommet.
45
Supporter ~ Antenna mounting nut

~1' Antenna mounting
nut
Harness connector
Feeder socket
Taping
LS-899
Bracket
Fig. 72
Installing antenna rod
1) Insert centering pipe (furnished with an antenna rod of
genuine parts) into antenna housing until it bottoms.
Grommet
I
Tube protrusion:
approx. 20 mm (0.79 in)
L6-1502
Fig. 71
LS-900
INSTALLATION Fig. 73
2) Insert antenna rod rope into antenna housing via centering
1) Connect feeder socket and harness connector. pipe with its rack facing outward; at the same time, turn radio
2) Pass antenna rod through mounting hole. Temporarily power switch OFF.
tighten antenna bracket with two bolts. Install supporter and
tighten antenna mounting nut. Be sure antenna rod is vertical to antenna housing. This
3) Tighten two bolts to secure antenna bracket. prevents rack from sustaining damage and makes it easy to
4) Pass drain tube through grommet. Be sure tube protrudes insert rope.
approximately 20 mm (0.79 in).
3) Remove centering pipe from antenna housing and detach
it from rope.
REPLACEMENT
Rack
ANTENNA ROD
Removing antenna rod
1) Loosen antenna mounting nut enough so that it can be
removed with your fingers.
2) Turn radio power switch ON and extend antenna. Remove
antenna mounting nut.
3) Hold the lower section of antenna rod by hand and lift
antenna rod vertically. Extract inner pipe and rope from
antenna housing. L6-901
Fig. 74
46
4) Face inner pipe spring toward the center of car and insert
inner pipe into antenna housing. MBatt"Y~_I_in_k_ _ _ _----,
5) Temporarily tighten antenna mounting nut.
6) Turn radio switch ON and OFF to ensure antenna rod
extends and retracts properly.
Horn Fuse box
7) Tighten to secure antenna mounting nut. (Low)
jJ.,-SPdng Horn switch

Horn
(High)
L6-216
Fig. 77
For removal of high or low tone horn, disconnect electric

connector with front bumper removed and take out horn by
l...-_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ L_6_-9_0---l2 removing bolt.
Fig. 75 For installation, follow the removal procedure in reverse order.
Digital Clock After installing horn, connect electric wire with it by keeping
some slack to prevent wire from disconnecting by its vibration.
1) Pry out the cover beside the clock display and remove
screw in the opening.
2) Using screwdriver, slightly pry the clock up, being careful
not to damage instrument panel.
Rear Window Defogger
Rear window defogger is actuated when rear window defogger
switch is turned to "ON" with ignition switch "ON". Indicator
light glows when operating rear window defogger.
INSPECTION
1) Start engine, and turn rear defogger switch on.
2) Check ea~h heat wire at its center position for disconti-
nuity by setting direct-current voltmeter.
L6-556
Fig. 76
3) Disconnect the connector and take out the clock.

Fuse '-
Fusible link
Horn Rear window
defogger switch
All models are equipped with double horns which consists of : Battery
high tone and low tone horns.
Horn switch is incorporated in steering wheel. When horn
1 Voltmeter
button is pushed down to actuate horn switch regardless of A25-397
any position of ignition-starter switch, horn make a sound. Fig. 78
47
3) If meter indicates 12 volts or 0 on specific wire that line
is broken. Normal indication is about 6 volts.
Cruise Control
4) For finding out broken position in the line, move positive The cruise control automatically controls car speed and allows
lead of voltmeter along the line until abrupt variation in the the car to run at a constant speed without depressing the
meter indication is encountered. accelerator pedal. In operation, when the driver sets a desired
speed with the cruise control switch, the built-in micro-
computer compares the speed set in the memory with the
actual running speed detected by feedback signals from the
REPAIR speedometer. This feedback system operates the throttle to
correct the speed difference, thereby keeping the car at a con·
1) Clean broken wire and its surrounding area. stant speed.
2) Cut off slit on (used) thin film by 0.5 mm (0.020 in) The major components are as follows:
width and 10 mm (0.39 in) length. • Main switch ..... built in LH control wing
3) Place the slit on glass along the broken wire, and deposit • Cruise switch mounted on steering wheel
conductive silver composition (DUPONT No. 4817) on the • Control unit .... inside the instrument panel, above
broken portion. glove box (One end is inserted into
panel, and the other end is secured
Broken position with screws.)
• Vacuum pump and
Valve ASSY ..... mounted on RH strut in engine room
• Actuator . . . . . . . mounted on front bulkhead bracket in
engine room
• Clutch switch .... mounted on pedal bracket
• Stop & brake
switch mounted on pedal bracket
Masking thin
film
a. The cruise control must never be used in the following
driving conditions.
composition
A25-398 (1) When going up or coming down a steep slope
--7,-=-9------------------
'-:F:-:'ig.-. (2) On roads with poor traction, for example, snow-covered,
icy, or gravel roads
(3) When a strong wind is blowing
4) Dry out the deposited portion. (4) In congested traffic
5) Inspect the repaired wire for continuity. (5) On a road with many curves
b. Modification of this device must never be attempted.
c. The main switch of the cruise control must always be
turned off, except when in use.
Fig. 80
48
." m
~. r-
-
0)
m
o
-t
:D
o
Ignition switch o
:D
Fuse
o
Iif--bAswitch C
I ~. -t
~I ~---?~
Horn switch
OJ
Ignition Fuse
18 19 15 oo
switch
Cruise control unit -<
m
r
Battery
20
I
m
(')
Ignition
I
-i
1
coil
I
~
co I :0
Vacuum I Starter (')
r>
valve I
AT control
Set indicator
unit
(AIT)
L/ -rh
(AIT) Generator for check
CJ)
-<
Clutch
switch ~
m
(MIT) More than 11 V
~
OV~
Vacuum switch
Pump
r
cp
......... m
I
0)
co I\)
DETAILS OF CONNECTOR TERMINALS

Cruise control unit connector (Body harness side)
,/
CD ® @ @ (j) @ ® ®
@ @ @ @ @ @ @ ~
I
Terminal
Color code Name Description
No.
CD LY 4th range set indicator (AT) Voltage is av when set in the cruise control mode.
® Y Ignition coil (MT) When the engine is rotating, the ignition pulse signal is outputted.
@ YL Check This terminal is used for checking quality in production line.
If the main switch is turned ON when the ignition switch is ON, the
@ BrW Main switch battery voltage is outputted to th is term inal. If the main switch is
turned OFF, no voltage appears on this terminal.
If speedometer cable is rotated with ignition switch turned ON, the

(j) YR Speed sensor
ON-OFF signal (more than 5V and aV) is outputted repeatedly.
Manual transm ission model:

B(AT) This terminal is grounded unless clutch pedal is depressed.
@ Clutch switch
GY(MT) Automatic transmission model:
This terminal is normally grounded.
® WB Vent valve Signal is inputted to drive vent valve.
This terminal is normally grounded by the grounding wire of con-

@) B Ground
trol unit.
Voltage is OV when car speed is at least 5 km/h (3 MPH) below the

@ LG 4th range cancel (AT) speed set in the cruise control mode or when accelerating using the
resume switch.
This terminal is grounded when selector lever is set to N or P.

@ BW Inhibitor switch (AT)
It is not grounded if set in any other position.
Battery voltage is outputted from the control unit and fed to each
(i]l LW Valve common
valve while the cruise control is operating.
When the ignition switch is ON, the battery voltage is outputted.

@ BR B rake switch
If brake pedal is depressed, no voltage is outputted.
@ The battery voltage is outputted if the brake pedal is depressed.

GB Stop switch
If the brake pedal is released, the voltage is OV.
If the set button is depressed with the ignition switch not to ON,
@ WR Set switch the battery voltage is outputted. If the switch is released, the
voltage is av.
If the resume switch is turned when the ignition switch is ON, the
@ YB Resume switch battery voltage is outputted. If the switch is returned, no voltage
is outputted.
50
Terminal
Color code Name Description
No.
® G Vacuum valve The signal for activating the vacuum valve is inputted to this
terminal.
* The signals from terminals ®, ® and ® are not outputted unless the cruise control unit is connected to the harness and
actually operated.
(Adjust each terminal of the harness side connector of the cruise control unit according to the respective troubleshooting
procedure.
CONTROL AND OPERATION
Speed set range and If the set switch is turned ON when the car speed is in the range of 40~~ km/h to 250~g
engagement operation km/h (25 ~g MPH to 155~g MPH), the car speed is set, and automatically controlled.
When the set switch is kept in the ON position, the set car speed is updated every 0.4
second.
Resume/accelleration If the resume switch is set to ON within the set speed range, the car is accelerated up to the
operation memorized speed, and then automatically controlled at that speed.
If the resume switch is kept ON at a speed of over 40 km/h (25 MPH), acceleration is made
until the maximum engine output is reached.
If the resume switch is turned OFF after exceeding the set car speed, the car will continue at
the speed at the moment the switch was tu rned OF F.
If the resume switch is turned OFF without a set speed in memory, the entire system is
turned OFF.
Each time the set switch is pushed while the car is cruising, the set car speed is reduced by
approximately 1.6 km (1 MPH).
Coasting operation If the set switch is kept ON while the car is running at a constant speed, the car speed will
decrease as long as the switch is ON. If the set switch is turned OFF within the set speed
range, the car speed, at the time the switch is set to OF F, is memorized, and the car runs at
th is new set speed.
Each time the resume switch is pushed while the car is cruising, the car speed set in memory
increases by approximately 1.6 km (1 MPH).
Cancellation The cruise control function is cancelled by the following operations, or during the following
conditions.
* (a) When the main switch is set to OFF position.
* (b) When the ignition switch is set to ACC or OFF position.
(c) When either the brake switch, stop switch, clutch switch, or inhibitor switch is oper-
ated.
* (d) When the engine speed exceeds 6,000 ± 150 rpm.
(e) When the car speed is below 30 km/h (19 MPH).
* (f) When the car speed input change per second is greater than ±25 km/h (±16 MPH).
* (g) When both the resume switch and set switch are depressed at the same time.
The operation indicated by the asterisk mark" *" causes the set speed to be erased.
Cruise control unit compares the actual car speed detected This signal is transmitted to solenoid valves of valve ASSY
by feedback signals from speed sensor incorporated in speed- located in engine compartment. The movement of actuator
ometer with the speed set in the memory memorized when set operates throttle valve through accelerator pedal and cable,
switch was turned on. A signal is then transmitted according thereby keeping the car speed constant.
to the difference between the two speeds.
51
CONSTRUCTION OF VACUUM SYSTEM
Hose
Valve ASSY
To engine
throttle
Actuator
valve
Diaphragm
Eccentric
shaft
L6-566
Fig. 82
1) Pump The vacuum in the tank is consumed by the operation of the

The pump is controlled by the vacuum switch built into the vacuum valve. If the vacuum in the tank reaches -42.7 kPa
valve ASSY tank, and is used to supply vacuum to the tank. (-320 mmHg, -12.60 inHg) the vacuum switch is turned ON,
Power to the pump is fed when the vacuum switch is turned and the pump feeds the vacuum into the tank. When the
ON, and the diaphragm is moved up and down by the rotation vacuum in the tank reaches -50.7 kPa (-380 mmHg, -14.96
of the offset shaft fixed to the motor shaft. inHg) the vacuum switch turns OFF to stop the pump.
2) Valve ASSY
The vacuum valve, vent valve, and safety valve are provided, Signal from control unit and valve operation
and their open-close operation lead vacuum/atmospheric
pressure to actuator. Also to attached to this assembly is the Safety Vacuum Vent
tank for storing vacuum generated by the pump, and the valve valve valve
vacuum switch for controlling the pump to maintain a con- System OFF Open Close Open
stant vacuum level in the tank.
If the cruise control is turned on and a constant car speed Memory < actual
Close Close Open
is attained, the safety valve connected to the atmosphere is car speed
closed. Also, the vacuum valve connected to the tank and the System Memory = actual
Close Close Close
vent valve connected to the atmosphere operate to lead the ON car speed
atmosphere/vacuum to the actuator. When the cruise control
Memory > actual
is cancelled, the vacuum valve closes to shut off the tank car speed
Close Open Close
vacuum, and the safety valve opens to allow atmospheric
pressure to enter the actuator.
52
3) Actuator
The diaphragm is operated by vacuum or atmospheric pressure
led by each valve, and this diaphragm movement actuates the
wire cable via link ASSY to open or close the throttle valve.
With the cruise control set to OFF (system OFF state), no dia-
phragm operation occurs as the atmospheric pressure is kept
inside the actuator.
4) Engine throttle
The throttle body is equipped with two throttle cams. One
cam is used during acceleration and the other during cruising,
in order to open or close the throttle valve. These cams
operate independently of each other. In other words, while
one cam is operates, the other does not.
System OFF To accelerator pedal Atmospheric pressure

Accelerator cable
Cam (Accelerator)
Actuator cable
Throttle body
Cam (Cruise control)
System ON Accelerator cable To accelerator pedal
Cam (Accelerator)
.. -=-••
Actuator
~ Vacuum pump
Cam (Cruise control)

L6-1505
Fig. 83
53
Control Cable
ADJUSTMENT
a. Do not bend the control cable too sharply; otherwise, it

will not operate smoothly.
b. When installing the cam to the inner end of the control
cable, do not bend or crush the inner cable.
Cable inner
Cable outer end
Throttle cam Adjusting nut

[Tightening torque:
6.4 - 11.3 N·m
(0.65 -1.15 kg-m, 4.7 - 8.3 ft-Ib))
Cruise control actuator cable
When securing the cable outer end, adjust the clearance

Throttle lever
between the throttle cam and the lever to 0 to 2 mm
(0 to 0.08 in) using the adjusting nut. Ensure that there
is no free play between the throttle cam and the cable.
L6-1506
Fig. 84
Vacuum Pump and Valve 1) Removing air cleaner and air flow meter.
(1) Loosen hose clamp.
(2) Remove boot from air flow meter.
REMOVAL (3) Undo clips on air cleaner cover.
(4) Place air cleaner cover together with air flow meter
a. Ensure ignition switch is OFF. on the engine.
b. Be careful because exhaust system and turbocharger tem-
peratures are high while engine was operating.
c. Always keep air cleaner, vacuum hose, etc. free from dirt
and dust.
54
Clips
L6·1770
Fig. 85
2) Disconnect wiring harness connector and hose connector

of the vacuum pump ASSY.
3) Remove the vacuum pump ASSY and the valve ASSY as
unit.
L6·1510
Fig. 86
DISASSEMBLY
1) Disconnect harness connector of vacuum pump ASSY.

2) Remove screws which secure vacuum pump and valve
INSTALLATION
ASSY's to their brackets.
3) Disconnect hoses to separate vacuum pump and valve
ASSY's. To install, reverse removal procedures.
4) To reassemble, reverse the above disassembly procedures.
Tightening torque:
Be sure to connect hoses and connectors properly. M6 bolt:
5.4 - 9.3 N·m (0.55 - 0.95 kg-m, 4.0 - 6.9 ft·lb)
M5 Screw:
2.0 - 2.5 N·m (0.20 - 0.25 kg·m, 1.4 - 1.8 ft·lb)
a. Be sure hoses and connectors are connected properly.

b. Ensure pump issues sound to indicate proper operation
when ignition switch and cruise control switch are turned ON.
c. Also ensure pump sound automatically stops when vacuum
pressure is charged in tank.
55
Power Window SWITCH CONNECTOR AND CONNECTION
OPERATION
Main switch Main switch
Main switch consists of auto-switch knob for driver's window,
passenger's window switch knob and lock switch knob for
passenger's window.
Main switch has the following five positions:

AU and AD .... Driver's window can be opened or closed
fully by depressing this position for a
moment.
U and D ...... Driver's window can be opened or closed T1
while depressing this position.
N ............ OFF position.
Sub switch
Passenger's window is lowered or raised while sub switch is
operated with the lock switch in main switch is in OFF
Sub switch I
position.
Control unit
Control unit is installed under assistant seat. The control unit
consists of transistors, relay, transformer etc. and controls up
and down of driver's window in combination with auto switch.
L6-575
Relay and breaker Fig. 87
Relay and breaker are installed under assistant sheet. The relay
provides an ignition interlock to all switches so that windows
cannot be operated unless the ignition switch is in "ON"
position for safety.
When overcurrent flows, breaker cuts electric current to
components and electric wiring from damage and burn out.
Main switch
Electric motor
Auto
Electric motors are provided for window glass regulator of
each door to open and/or close the window glass.
Lock switch
Driver's side
switch
To ®V
LS-1511
Fig. 88
56
Passenger's side
Connector Driver's side window switch
window switch Connection
Terminal Color AU U N D AD U N D
1 WL (Motor Up)
) Sub switch
2 LB (Motor Down)
3 R <;:> 9 9
- <;:>
I I I I
4 Y
I
: 6 0 Control unit
I
I
I I
I I
6 6
~
5 G
6 RW Ignition switch
7 B (Lock switch) Grounding
Sub switch
L6·1512
Fig. 89
Connector Passenger's side window switch

Connection
Terminal Color U N D
1 R 0 Ignition switch
2 B
1Main switch
3
5
BW
YR
I
I I I Motor (Up)
Motor (Down)
57
Remote Controlled Rearvi.ew

Mirror
When adjacent two control knobs are pressed simultaneously,
the rearview mirror will move in an oblique direction. Select
\
Control knobs operation
knob
The remote controlled rearview mirror switch consists of a RIGHT LEFT

RH LH UP ON UP ON ON UP LH RH
left·right changeover select knob and a control knobs. The
switch is ready to function only when the ignition switch is in (R)
1 ) ) ) ) kf>
-l 2 ( <; ( I( I( 1<; (
(
[;k
"ACC" or "ON"'. Movement of the mirror is accomplished by
the motor in the mirror. '-~: V) C ) ) Ie ( ) )
v Ie rc
l01
::> ) ( (
I
3 ( ( )
SWITCH CONNECTOR AND CONNECTION
-:..-=::::;
4 ( ( ) (
I M)I
I I
~
5
6
)
)
LC0I
7
~
(
8
_..J
(L)
[=:=J
L I ij I I 1IIIIl A
TO@
L6-1514
L6·1513 Fig. 91
Fig. 90
Connector
Connection
Terminal Color REPLACEMENT
1 LB Ignition switch (ACC)
ELECTRIC WIRING
2 B Grounding
The wiring is routed from the instrument panel wiring harness
3 L connector to the rearview mirror via the front door cord and
LH & RH mirror motor
4 LW
) the rearview mirror cord. The front door cord can be removed
after detaching the grommet. The rearview mirror cord can be
detached by removing retaining clips.
5 W
6 y ) RH mirror motor
7 Br
8 G
1LH mirror motor
58
First Hold Switch Differential Lock Switch

SWITCH CONNECTOR AND CONNECTION The differential lock switch is located beside the parking lever
on the console box. When the switch is turned ON, the car is
set to "diff. lock driving"; when the switch is turned OFF,
First hold switch the car is set to the Jlfree-driving" mode. The DIFF. LOCK
indicator light in the combination meter comes on when the
car is set to the "diff. lock dri ving" mode.
Do not shift driving modes while the wheels are slipping or

while making a sharp turn.
L6-1515
Fig. 92
Differential lock switch

Connector
OFF ON Connection
Terminal Color
2 GY AT control unit
4 B I Grounding L6-1517
r~
1 R Lighting switch
Fig. 94
3 RG Illumination control
Connector
OFF ON Connection
Terminal Color
REPLACEMENT 1 BW Ignition switch
I
The fi rst hold switch is secured to the AT select lever indicator
from the rear with the two M4 tapping screws. Remove the
AT select lever indicator from body when replacing the hold
2
4
GY
R
L I Solenoid valve (UNLOCK)
Solenoid valve (LOCK)
Lighting switch
~ ~
switch.
\0> 5 RY Illumination control
Tapp;n, ,ecow7 \ ~
L6-1516
59
REPLACEMENT REPLACEMENT
The fog light switch is fitted in the console box. Using a small
The differential lock switch is fitted in the console box via
screwdriver, pry up the switch, being careful not to damage
the differential lock switch case.
the console box.
Fig. 95 Fig.97 .
Speed Warning Buzzer
Fog Light Switch

\..------
Fog light switch
lJ
11 L6-912
Fig. 98
When car speed exceeds 100 km/h (60 MPH), the speed
~TO@
warning switch built into the computer will turn on. If the
speed warning key switch has already been set to "ON", the
~ L6-1771 buzzer in the instrument panel will sound continuously.
~~
Fig. 96
[fCi-spee-d ----r?1
Connector \. warning I
OFF ON Connection J..switch
Terminal Color o Buzzer
1 W Fog light relay

3 RB b Lighting switch Combination
meter
2 - - Speed warning key switch
b
- -
[?= ~
4
Ignition
~
Illumination control
5 R U
~ ~
(Power supply) sWitch
L6-5S r
6 RG Illumination control
Fig. 99
60
Automatic Shoulder Belt and MOTOR DRIVE CIRCUIT

Operation
Key Warning Chime The door switch monitors the opening/closing of the door to
(Except Canada model) rotate the motor in the corresponding (standard or reverse)
direction.
A limit switch, situated at each end of the rail, monitors the
PRECAUTIONS front/rear limit position of the shoulder anchor.
a. In case the' connector related to the automatic shoulder belt When the door is opened, the motor activates so that the
has been disconnected for repairs of the automatic shoulder shoulder belt moves from the rear-limit position (fasten) to
belt or its related parts or for repairs of other parts, be sure to the front-limit position (release) and stops.
disconnect once the battery and reset the control unit. When the door is closed, the motor activates so that the
If the connector of the automatic shoulder belt control unit or shoulder belt moves from the front-limit position (release)
the connector of front or rear limit switch has once been dis- to the rear-limit position (fasten) and stops.
connected during repairs, the control unit can enter the failure
mode when the connector is reconnected, making the auto- Malfunction
matic shoulder belt inoperative. Motor output timer control
b. If the automatic shoulder belt fails to operate, be sure to
troubleshoot before disconnecting the battery. If the limit switch does not activate within 13 seconds after
Even if the automatic shoulder belt does not have faulty parts, the motor begins to run, the timer control activates to dis-
it can become inoperative when the shoulder belt anchor is connect the motor from its drive circuit.
forced down or the front or rear limit switch is operated
manually. In such case, if you disconnect the battery, the
trouble will be corrected automatically without giving you
the chance to determine its cause.
c. For troubleshooting electrical parts, refer ~ Chapter 6-3.
SEAT BELT WARNING SYSTEM

Warning chime Warning lamp
Used: 0 Duration of operation Duration of operation

No. Type of belt Priority Remarks
Not used: X
First 4 - 8 First 4 - 8
Thereafter Thereafter
seconds seconds
X Sounds OFF Blinks OFF Condition of lap belt "Not Used":

Driver's lap
1 1 Ignition switch ON and buckle
belt
0 OFF Blinks OFF switch ON*
Condition 1 OFF Illuminates 2 Condition of shoulder belt "Not

Driver's X Used":
2 Condition 2 Sounds OFF Blinks Illuminates 3
shoulder belt
Condition 1
0 OFF OFF - - Ignition switch ON and rear
limit switch ON *
Condition 1 OFF Illuminates 4
X Condition 2
Passenger's
3 Condition 2 Sounds OFF Blinks Illuminates 5 - Ignition switch ON, rear limit
shoulder belt switch OFF * and shoulder
0 OFF OFF - buckle switch ON *
The asterisk "*" refers to a normally-<:Iosed switch (normally-on typel.
a. The warning chime and warning light outputs are generated KEY WARNING CHIME
Only the driver's side.
from the same system. For this reason, a higher priority
output will preempt those of lower priority. No. Door Warning chime Remarks
b. The lap belt warning chime and warning light activate when Chime operating conditions:
the ignition switch is turned ON. HOV\lever, warning for the 1 Closed OFF
Key is inserted into ignition and
~houlder belts begins when condition 1 or 2 exists. turned to any position except
2 Open Sounds
ON or START.
61
CONNECTION
F.L.
20
[e
Front limit SW (D
15A 14
7 Ho~ Re 1 23
Key
2 -=- Door SW TO@
SW Chime Open (D) 456
11 Re-+ Ho
3 Closed Control unit side
10 Rear limit SW(D) -=-
~
15
15A
.t::
c
::J
"0
...
...c 17
":;'
7 8 9 10 n 11 12 13 14
9 15 16 17 18 19 20 21 22 23
0
()
22
8 Front limit SW (P)
18 Control unit side
Shoulder belt
Ignition
SW
buckle SW(D)
12
4 Ho~ Re
-::- TO@
~ Open
Closed a. Shoulder belt and lap belt are

16 5
~belt -=- fastened.
-T "::' buckle SW (D) 1~
Rearlimi~
: Battery ~ulderbelt
-=- buckle SW (P)
13
23 6 21
b. Shoulder anchor is rear limit
position. I
l ':'
'::" "::'
(D): Driver's side (P): Passenger's side Ho: Hold Re: Release
L6-1520
Fig, 100
Seat Belt and Key Warning

Chime (Canada model Only)
Seat belt & key warning chime participates in both seat belt
warning system and key warning system.
Seat belt warning system

Fasten seat belt warning light in combination meter turns on
for approx. six (6) seconds after turning ignition switch to
ON position.
Also, only when driver's seat belt is not fastened, the chime
will sound about four (4) times.
Key warning system

The chime will sound while door is opened with the key plate
inserted in ignition switch.
62
WIRING DIAGRAM AND
TROUBLESHOOTING
Page
BUBARU GENERAL DESCRIPTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2
-
ELECTRICAL WIRING HARNESS................. . . . . . . . . . .. 7
Front Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8
Engine Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12
1988 Instrument Panel Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14
Rear Wiring Harness ..................................... 18
Power Window Main Harness and Door Cord .... . . . . . . . . . . . . . . . .. 24
Common Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 26
ELECTRICAL UNIT LOCATION ............................. 28
WIRING DIAGRAM AND TROUBLESHOOTING .................. 36
Power Supply Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 36
Engine Electrical System ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 39
Combination Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 43
Trip Computer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 57
Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 60
Front Fog Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 66
Turn Signal and Hazard Warning Light . . . . . . . . . . . . . . . . . . . . . . . .. 67
Back·Up Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 71
Stop Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 72
Room Light and Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 74
Trunk Room Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 77
Seat Belt and Key Warning System. . . . . . . . . . . . . . . . . . . . . . . . . . .. 78
Electronic-Controlled Motor Drive Power Steering System . . . . . . . . . . .. 91
Parking Brake System _................................... 105
Brake Fluid Level Warning System ............................ 106
4WD-MT System ............ .' .......................... 107
Automatic Transmission Control System ........................ 109
Windshield Wiper & Washer ................................ 113
Headlight Washer ....................................... 114
Radio and Auto Antenna .................................. 115
Horn and Cigarette Lighter ................................. 118
Clock ............................................... 121
Rear Window Defogger ................................... 122
Remote Controlled Rearview Mirror. .......................... 124
Power Window ......................................... 126
Door Lock System ...................................... 130
Speed Alarm .......................................... 131
Cruise Control System .................................... 133
Mode Selector ......................................... 138
Blower Motor ......................................... 139
Pneumatic Suspension System ............................... 140
O~RALl WIRING DIAGRAM .............................. 000
6-3 WIRING DIAGRAM AND TROUBLESHOOTING
GENERAL DESCRIPTION
Contents of Manual and Its ~ isIndic,"" lock
included.
Usage
~
This manual consists primarily of the following four elements
W 8
with respect to the electrical system: R L R L
• WIRING HARNESS DIAGRAM
~ I ndicates a lock
• UNIT LOCATION DIAGRAM is included.
Indicates the number of
• WIRING DIAGRAM poles and the color of
• TROUBLESHOOTING CHART
WIRING HARNESS DIAGRAM

The wiring harness diagram shows the wiring routes of the
the wiring
Double frames indicate---.........

a male connector.
tilij
L R
A25·1098
main harness and illustrates the positions of the connectors.
Fig. 2
The connectors are numbered along with the number of poles,
external colors, and mating connections in the accompanying
list. The exterior color column has been left blank whenever
Indicates a lock
the general white connectors are referred to. In addition, the
earth position of the harness is clearly indicated by another
detailed illustration.
UNIT LOCATION DIAGRAM

The diagram clearly shows the major electric units and devices Indicates a lock
Double frames
and their connectors which are located in hard-to-see places.
indicate a male y:;::::::::::::;=~
connector.
WIRING DIAGRAM
The wiring diagram of each system is illustrated so that you W RB BR GY YR
can understand the path through which the electric current
A25·1099
flows from the battery.
Sketches and codes are used in the diagrams. They should read Fig. 3
as follows:
1) Each connector and its terminal position are indicated by 3) The following color codes are used to indicate the colors
of the wires used.
a sketch of the connector in a disconnected state which is
viewed from the front; as shown in figure.
Color code Color
L Blue
B Black
Y Yellow
G Green
R Red
W White
Br Brown
Viewed from this direction Lg light green
A25·1097 Gr Gray
(SB) (Sealed wire)
Fig. 1
4) The wire color code, which consists of two letters (or

2) The number of poles, male or female, presence of a lock, three letters including Br or Lg), indicates the standard color
and wire color of each terminal are indicated in the sketch of (base color of the wire covering) by its first letter and the
each connector. stripe marking by its second letter.
2
5) The wire diameter is indicated by the numeral of its 6) Each unit is directly grounded to the body or indirectly
nominal sectional area (mm 2 ) prefixed to the color code. grounded through a harness ground terminal. Different
However for a wire whose sectional area is 0.5 mm 2 the pre
I I symbols are used in the wiring diagram to identify the two
fix "0.5" is omitted. The table below lists the nominal sec- grounding systems.
tional areas and allowable currents of the wires.
Nominal Allowable
Outside diameter current
sectional No. of strands/
of finished wiring Amps/
1
area strand diameter 40°C
mm
mm 2 (104°F)
0.3 7/0.26 1.8 7

0.5 7/0.32 2.2 (or 2.0) 12
0.75 30/0.18 2.6 (or 2.4) Direct ground Indirect terminal
16
ground
0.85 11/0.32 2.4 (or 2.2) 16
1.25 16/0.32 2.7 (or 2.5) 21
L6-1138
2 26/0.32 3.1 (or 2.9) 28
Fig. 5
3 41/0.32 3.8 (or 3.6) 38
5 65/0.32 4.6 (or 4.4) 51
8 50/0.45 5.5 67
7) Relays are classified as normally-open or normally-closed.
The normally-closed relay has one or more contac~s.
a. The allowable current in the above table indicates the
The wiring diagram shows the relay mode when the energizing
tolerable amperage of each wire at an ambient temperature
circuit is OFF.
of 40°C (104°F).
b. The allowable current changes with ambient temperature.
Also, it changes if a bundle of more than two wires is used.
1.25
I! y.!!
t M"k;n.oolo"
Reference color:
'=t=l
Black=:=J
Yellow
()
Nominal sectional area of wire: 1.25 mm 3
A25-1100
Fig. 4
3
Relay type Energizing circuit OFF Energizing circuit ON
0 - - - -------..
4-pole
LdOI----f
Normally-open
6-pole
O~---4
0---------+
No~mally-closed 4-pole
L6·1139
Key to symbols:
0- - - ~: Current flows.
X---~: Current does not flow.
Fig. 6
8) The overall wiring diagram of the vehicle is provided at Working Precautions

the end of the manual.
Precautions when working with the parts mounted on

the vehicle
1) When working under a vehicle which is jacked up, always
be sure to use safety stands.
2) The parking brake must always be applied during working.
Also, in automatic transmission vehiclllS, keep the select lever
TROUBLESHOOTING CHART
set to the P (Parking) range.
The troubleshooting chart explains trouble diagnosis of each 3) Be sure the workshop is properly ventilated when running
system by using step-by-step procedures which are laid out so the engine. Further, be careful not to touch the belt or fan
that the steps can be followed by tracing the wiring diagram. while the engine is operating.
For locations of the connectors and those of the electric units 4) Be careful not to touch hot metal parts, especially the
and devices, refer to the wiring harness diagram and unit radiator and exhaust system immediately after the engine has
location diagram. been shut off.
4
Precautions in trouble diagnosis and repair of electric

parts
1) The battery cable must be disconnected from the
battery's (-) terminal, and the ignition-starter switch must be
set to the OF F position, unless otherwise required by the
troubleshooting chart.
2) Securely fasten the wiring harness with clamps and clips Wrong
so that the harness does not interfere with the body end parts
or edges and bolts or screws.
3) When installing parts, be careful not to catch them on the
wiring harness.
4) When disconnecting a connector, do not pull the wires,
but pull while holding the connector body. A25-1101
Fig. 7
5) To disconnect a lock type connector, press the lock

release lightly by hand. To connect, insert the connector until
it snaps and confirm that it is tightly connected.
5
m
r
m
\-"~,.
, ® n
\ ,,\\ \)I»'
® ~
CD ® @ :D
-
(")
»
r ~
:0
---
:D
Z
G)
o
»
Z G)
G> :0
»
I ~
»
:D
»
z
o
Z -f
m :0
CJ) oC
CJ) (D
r
m
(J)
I
o
o-f
21 Instrument panel wirin h
RH
wiring ha g arness Z
3 D rness G)
oor cord RH
~
--ro Room&S
E . pot light cord
ngiJle wiring h
6 Trunk arness
7 room cord
([j) Rear defo
8 Floor ..gger earth cord
f-l~~~J 9 D wlrtng harness
(ow"-'" to\ 10
oor cord LH
Console cord
HO-N'-es S 11
...,......12 Height
LH . control cord
13 E wlrtng harness
arth cord
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Connector Connecting to Connector Connecting to
No. 6lle Appearance No. Name No. Pole Appearance No. Name
l( I> F 1 '.<1- 2 Solenoid valve RH jxF49 2.)( Solenoid valve LH

I- (Air suspension) (Air suspension)
F4 6 Black Air flow meter k,F50 5~ Air suspension relay
F6 2 Resistor (AT control) F51 3 Black
} Front wiper motor
F7 4 Height sensor F52 4
(Air suspension) F53 4 Diff. lock solenoid valve
F8 4 Black Main fan relay F54 1 Black Starter motor
F9 4 Black Air-conditioner relay F55 2 Black Junction (AT)
FlO 4 Brown Fog lamp & AIC fuse F56 3 Black E21 Rear wheel speed sensor
Fl1 2 Front washer pump (4WD-AT)
F12 2 Black Outside temperature sensor F57 12 Black E17 Inhibitor switch (AT)
F13 3 LH wiring harness ....
RH wiring harness
4
~. Transmission cord
(Diff. lock/Back switch) (MT)
F14 6 Vacuum pump F58 12 Black E16 Transmission (AT control)
(Cruise control) 2 Black E16 Transmission cord
F15 2 Headlight washer pump (Neutral switch) tMT)
F16 2 LH wiring harness .... F59 1 Black 0l sensor
RH wiring harness F60 12 E8
} Engine wiring harness
F17 2 Side marker light !=IH F61 16 Black E7
F18 3 Headlight RH F62 11 Brown Check connector
F19 3 Front combination light RH F63 3 By-pass air control
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? Black
D~a~~,,~a~'A.i+~h (A/C)
-VVCllel
(A/C)
leI I I-'e I
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F64
F65
F66
4
4
3
Black
Sub-fan diode
Sub-fan relay
LH wiring harness ....
RH wiring harness
~I~ 2 13Tack Main fan mo~_ F67 2 Front fog lamp RH
~24 6 RetractaOllfneac:mgnt motor (?f'l'68" _.2
:--.. "a; '~
F25 2
RH
Horn RH
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;,)UD-ran moT®·
-Sub-fan condenser
F26 2 Horn LH F71 2 Front fog lamp LH
F27 3 Headlight LH F72 3 Green Power controller
IMPS he,te, ~el'y

F28 3 Front combination light LH F73 1
F29 2 Side marker light LH F74 1
F30 4 Compressor/Air discharge F75 2
solenoid valve F76 1 MPS fluid heater
(Air suspension) F77 2 MPS temperature sensor
F31 3 Pressure switch F78 1 MPS pump motor
(Air suspension)
F32 2 Air charge solenoid valve
(Air suspension)
F33 4 Height sensor
(Air suspension)
F34 6 Retractable headlight motor
LH
F35 1 Compressor (A/C)
F36 2 Black Pulser coil (A/C)
F37 2
} Alternator
F38 1x 2
F39 1 Battery
F40 1 Black Grounding (Condenser)
F41 4 Crank angle sensor
F42 2 Black Ignition coil
F43 Fusible link
F44 2 Brown FWD switch (Full-time 4WD
~:-
AT)
F46 2 Black Condenser
F47 3 Black Brake fluid level sensor
F48 17 Black Check connector
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Connector Connecting to Connector Connecting to
No. Pole Appearance No. Name No. Pole Appearance No. Name
F1 2 Solenoid valve RH F49 2 Solenoid valve LH

(Air suspension) (Air suspension)
F4 6 Black Air flow meter F50 5 Air suspension relay
F5 6 Black Dropping resistor F51 3 Black
} Front wiper motor
(Engine control) F52 4
F6 2 Resistor (AT control) F53 4 4WD/FWD solenoid valve
F7 4 Height sensor (MT)
(Air suspension) F54 1 Black Starter motor
F8 4 Black Radiator fan relay F55 2 Black Junction (AT)
F9 4 Black AirrConditioner relay F56 3 Black E21 Rear wheel speed sensor
F10 2 Black Air-conditioner fuse (4WD-AT)
F11 2 Front washer pump F57 12 Black E17 Inhibitor switch (AT)
F12 2 Black Outside temperature sensor 4 E17 Transmission cord (4WD or
F13 3 LH wiring harness ++ Ditt. lock/Back switch) (MT)
RH wiring harness F58 12 Black E16 Transmission (AT control)
F14 6 Vacuum pump 2 Black E16 Transmission cord
(Cruise control) (Neutral switch) (MT)
F16 2 LH wiring harness ++ F59 1 Black O2 sensor
RH wiring harness F60 16 E8
F17 2 Side marker light RH F61 16 Black E7
F18 3 Headlight RH F62 11 Brown Check connector
F19 3 Front combination light RH
F20 4 Pressure switch (A/C)
F21 2 Brown Water temperature cut switch
(A/C)
F22 2 Black Thermoswitch
F73 2 Radiator fan motor
RH
F25 2 Horn RH
F26 2 Horn LH
F27 3 Headl ight LH
F28 3 Front combination light LH
F29 2 Side marker light LH
F30 4 Compressor / Air discharge
solenoid valve
(Air suspension)
F31 3 Pressure switch
(Air suspension)
F32 2 Air charge solenoid valve
(Air suspension)
F33 4 Height sensor
(Air suspension)
LH
F35 1 Compressor (A/C)
F36 2 Black Pulser coil (A/C)
F37 2
} Alternator
F38 1
F39 1 Battery
F40 1 Black Gr9unding (Condenser)
F41 4 Crank angle sensor
F43 Fusible link
F44 2 Brown FWD switch (Full-time 4WD
AT)
F46 2 Black Condenser
F47 3 Black Brake fluid level sensor
F48 17 Black Check connector
11
Engine Wiring Harness

1800 engine model
\ @)
2700 engine model
Fig. 11 Engine room (2) L6-1698
12
[MT] [AT]
L6-1699
Fig. 12 Engine room (2)
Connector Connecting to
No. Pole Appearance No. Name
El 2 Black (No.1)
} Fuel injector
E2 2 Black (No.3)
E3 2 Sky blue Auxiliary air valve
E4 1 Black FICD solenoid valve
E5 4 Black Throttle sensor
E6 1 Knock sensor (2700)
E7 16 Black F61
E8 16 F60 ) Eng;no w;,;ng ""no" (1800)
12 F60 (2700)
E9 2 Temperature sensor
El0 2 Black. (No.4)
} Fuel injector
Ell 2 Black (No.2) .,
E12 2 Purge solenoid valve }.
E14 1 Thermometer
E15 1 Oil pressure switch or oil pressure gauge unit
E16 2 Black F58 (MT)
12 Black F58 (AT)
Engine wiring harness
E17 4 F57 (MT)
12 Black F57 (AT)
E18 2 4WD indicator switch or Diff. lock indicator switch
E19 2 Black Neutral switch
E20 2 Back-up light switch
E21 3 Black F56 Engine wiring harness (AT)
E22 2 Black (No.5)
} Fuel injector
E23 2 Black (No.6)
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i1 21 i68 LH wiring harness

i2 12 Black Warning unit
I
i3 21 Black iS9 LH wiring harness
i4 21 Blue
i5 21 Brown Comb;n";on m,W
i6 12
I
i7 8 Yellow Wiper select switch
i8 8 i 85
i9 9 Yellow i84 LH w;,;ng ha.,n,,,
3 i 84 (Canada model)
i 10 2 Blue (Warning alarm)
) Speed warning
i 11 2 (Warning switch)
i 12 2 Brown Clutch switch (MT with cruise control)
i 13 4 (With cruise control)
) Stop light switch
I
i 14 2
i 15 2 Blue
i 16 2 Green Opt;on oonnacto'
i 17 3
3 Black Cruise control sub-switch
i 18 3 Brown Switch box
i 19 2 Air-conditioner switch
i20 21 Switch box
i 21 21 Black Mode control unit
i22 9 Brown Air conditioner MAX. unit
i 23 4 Black Ignition relay
i 24 17 Blue Wiper intermittent unit
i 25 3 Cigarette lighter illumination light
i26 1 Black Cigarette lighter
i27 4 Brown Fuel pump relay
i28 4 Blue Rear defogger relay
i29 4 Blower motor relay
i30 9 Mode actuator
..... i31 ~-- -,.-----... ----,-~ _,_, 83 ·r-··-----··-----·-~··
0800 engill6 i1luderr- ~
- i32
20
21-- ---- - -
R3
.. Green -- ...... ----R2- -
:- .En.Qlrul..wiringbarnes.s-
(2700 engine model)
tt800~medett-....
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20 Black R2 (2700 engine model)
'-. i33 8 Blue R5
--,,«" i 34 _21 >- '-.-.~
-- '-'--
B~ack . R4- Floonwlffg M,no,. ('~-A:rmode~)
9 Brown R4 (2700 engine model)
~ i35 11 R7
9 R7
i 36 2 Diode (Air-conditioner)
__ i37 '6 Green R1 Engine wiring harness
i38 4 Diode (Air-conditioner/Ignition)
i39 6 Black Air conditioner amplifier
i40 5 FRESH/CIRC actuator
i41 2 Black Air conditioner thermoswitch
i42., .. 7 "'Y~IIO'1v Option connector
_i43 "-."f- 21 i 102
-- i44
i45 3
11 i 105
i 104
Instrument wiring harness
i46 2 i 103
.....
i47 3 Red P1 Power window main harness
_i48 2 Black Front limit switch RH (Automatic seat belt) (SOA)
- i49 4 Green P3 (Door lock)
- i50
~- i 51
3
2 Red
P4
P5
Door cord RH
(Door switch) (SOA)
(Speaker)
- i52 4 Blue P6 (Mirror)
... i53 2 Blower motor
-i54 4 Blower motor resistor
i 55 1x 2 Blue Junction (Automatic seat belt)
i 56 4 i 108 LH wiring harness
i 57 20 Black R39 Floor wiring harness (AT)
i58 4 Green Front fog lamp relay
i 59 2 Diode (Front fog lamp)
15
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i 61 3 P16 (Door switch-seat belt)

i 62 3 P19 (Door lock)
i 63 2 Red P20 Door cord LH (Speaker)
i64 4 P18 (Mirror)
i65 5 P17 (Mirror)
i66 2 Black Front limit switch LH
~67y.. 11 R11 Air suspension cord
_ i68 21 i1
} RH wiring harness
--i69 21 Black i3
i70 4 Blue Trail light relay
i 71 10 Diode box
i72 4 Lighting relay LH
i 73 4 Black Lighting relay RH
i 74 4 Retractable headlight relay LH
i 75 4 Green Retractable headlight relay RH
i 76 6 Yellow Retractable headlight timer
i77 2 (Option connector)
i78 2 Diode (Retractable heac;llight) (2WD)
i79 1 Black i80
} Junction
i80 1 Black i 79
i 81 1 i 82
} Junction (Clock)
i82 1 i 81
i83 2 Red Chime
i84 9 Yellow i9
3 i9 ) RH widn, h"n." (Canada model)
i85 8 i8
• i 86 4 Lighting switch
i87 21 Black Switch box
i88 2 Black Key warning switch
i89 6 Black Ignition switch
i90 8
} Combination switch
i 91 9
i 92 1 Option connector
i 93 13 Radio
i94 2 Stereo illumination light
i95 9 Yellow Trip computer unit
6 Clock
i96 2 Brown Glove box switch and light
i97 2 Diode
i98 20 Cruise control unit
i99 4 Speaker relay LH
i 100 4
. Speaker relay R H
i 102 21 i43
i 103 2 i46 ',f
RH wiring harness
i 104 3 i45
i 10~ 11 i44 ,
i 108 4 i56 RH wiring harness (2700 engine model)
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WIRtNG DIAGRAM AND TROUBLESHOOTING 6-3
R1 6 Green i37
R2 20 Black i32
R3 20 i 31 RH wiring harness
R4 9 Brown i 34
R5 8 Blue i33 .
R6 13 Green Floor wiring harness ..... Engine wiring harness
--R8 ~
2 Parking brake switch
.~~, _-zr 9f69.. AT indictor light
~ :-:4V 1 hold switch jAn
R11 11 i67 LH wiring harness \
""" ~12 ~ 21 Air suspension cord ..... RH Wiring harness
R13 16 Black
} Height control unit
R14 20 Black
R15 2 Lap bet switch
R16 5 (MT)
} Floor wiring harness ..... Console cord
R17 8
- R18 2 Door switch RH
- R19 A Green Room & spot light cord +-> .RH wiring harness
-- R20 4 Rear limit switch RH
- R21 2 Automatic seat belt motor RH
_ R22
'"",R23
6
17
IAuto~atic se~t belt control unit
.- R24 6 Blue Headlight washer unit
R25 4 Air conditioner cut relay
R26 2 Room & spot light
R27 2 Vanity mirror light
R28 1 Black Rear defogger
R29 2 Fuel pump
R30 5 Junction (AT)
R31 20
} AT control unit
R32 16
· .... R33 2 Automatic seat belt motor LH
- R34 4 Rear limit switch LH
-R35 2 Door switch LH
-R36 x: 2 Solenoid valve (Air suspension)
5 Height sensor (Air suspension)
- R37 '< Rear defogger
R38 1 Black
R39 20 Black i 57 RH wiring harness (AT)
1)40 3 Green Steering sensor
R41
R42
1
20
Brown
Brown
IFloor wiring harness ..... Engine wiring harness
(AT)
R43 6 Diff. lock switch (Full-time 4WD)
R44 6 Blower switch
R45 6 Brown Front fog lamp switch
R46 2 Switch illumination light
R47 6 Floor wiring harness ..... Console cord
R48 4 Junction
R49 17 MPS controller
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Rl 6 Green i37
R2 21 Green i 32
R4 21 Black i34 (AT)
R5 8 Blue i 33
R6 21 Floor wiring harness .... Engine wiring harness (AT)
R7 11 i35 RH wiring harness
R8 2 Parking brake switch
R9 2 Blue AT indicator light
Rl0 3 4WD selector switch (MT)
4 1 hold switch (AT)
Rl1 11 i67 LH wiring harness
R12 21 Air suspension cord ++ RH wiring harness
R13 16 Black
f Height control unit
R14 20 Black
R15 2 Lap bet switch
R17 8 Floor wiring harness -+ Console cord
R18 2 Door switch RH
R19 4 Green Room & spot light cord ++ RH wiring harness
R20 4 Rear limit switch RH
R21 2 Automatic seat belt motor RH
R22
R23
6
17
IAutomatic seat belt control unit
R25 4 Air conditioner cut relay

R26 2 Room & spot light
R29 2 Fuel pump
R30 5 Junction (AT)
R31
R32
20
16
IAT control unit
R33 2 Automatic seat belt motor LH

R34 4 Rear limit switch LH
R35 2 Door switch LH
R36 2 Solenoid valve (Air suspension)
R37 5 Height sensor (Air suspension)
R44 6 Blower switch
R46 2 Switch illumination light
R50 5 Floor wiring harness ++ Engine wiring harness (AT)
21
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T1 2 Black Speaker LH
T2 2 Brown High-mou nt stop light
T3 2 Truck room light
T4 2 Black Speaker RH
T5 2 Trunk room light switch
""- T6 17 Trunk room cord ++ RH wiring harness
T7 12
T8 16
MPF I control unit
T9 20
T10 15
T11 13 Check connector (Line end)
T12 9 (1800 engine model)
} Junction
8 (2700 engine model)
T13 2x2 Green (Test mode connector)
T14 1x2 Black (Read memory connector)
..-- T16 X. 5 Height sensor (Air suspension)
-T17 '7< 2 Solenoid valve RH (Air suspension)
""'" T18 4 Fuel gauge unit
_ T19 2 Black Side marker light RH
_ T20
2 Turn signal light RH
T21
T22
6
2
Rear combination light RH
Back-up light RH
,
T23 2 Black License light RH
T24 2 Back-up light LH
T25 6 Rear combination light LH
T26 2 Turn signal light LH
T27 2 Black Side marker light LH
T2S 3 Auto antenna unit
T29 2 License light LH
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P1 3 Pink i47 RH wiring harness

P2 3 Door cord RH ..... Power window main harness
P3 4 Green i49 (Door lock)
P4 3 i50 (Door switch-Seat belt)
RH wiring harness
P5 2 Pink i 51 (Speaker)
P6 4 Blue i 52 (Mirror)
P7 4 Remote controlled rearview mirror RH
P8 2 Door speaker RH
P9 2 Power window motor RH
P10 5 Power window sub-switch
P11 4 Door lock actuator RH
P12 3 Door switch (Seat belt)
P13 8 Power window control unit
P14 4 Power window relay
P15 2 Power window breaker
P16 3 i61 (Door switch-Seat belt)
P17 5 i65 (Motor)
P18 4 i64 LH wiring harness (Mirror)
P19 3 i62 (Door lock)
P20 2 Pink i63 (Speaker)
P21 7
} Power window main harness ..... Door cord LH
P22 2
P23 2 Door speaker RH
P24 4 Remote controlled rearview mirror LH
P25 2 Power window motor LH
P26 11 Remote controlled rearview mirror switch
P27 8 Power window main switch
P28
P29
4
3
., Door lock actuator LH
Door switch (Seat belt)
25
6-3 WIRING DIAGRAM AND TR
Common G r . OUBLESHOOTING
_ oundlng
L6-1413
Fig_ 19
Fig_ 20
26
Fig. 21-1 Fig. 21-5
~I
L6-1017
Fig. 21-6
cr--
Fig. 21-7
Fig. 21-4 Fig. 21-8
27
ELECTRICAL UNIT LOCATION

Air conditioner amplifier . . . . . . . . . . . . . . . . . . . . . , Inside of instrument panel (Fig. 25·2)
Air conditioner cut relay . . . . . . . . . . . . . . . . . . . . . . . Inside of RH quarter panel (Fig. 27·1)
Air conditioner fuse . . . . . . . . . . . . . . . . . . . . . . . . . Attached to RH wheel apron (1800 engine model) (Fig. 23·3)
Attached to RH wheel apron (2700 engine model) (Fig. 24-3)
Air conditioner MAX. unit . . . . . . . . . . . . . . . . . . . .. Inside of instrument panel (Fig. 25-6)
Air conditioner relay . . . . . . . . . . . . . . . . . . . . . . . . , Attached to RH wheel apron (1800 engine model) (Fig. 23-3)
Air flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On RH wheel apron (Fig. 23-3)
AT duty solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . , Inside of transmission case (Fig. 23-6)
AT fluid temperature sensor . . . . . . . . . . . . . . . . . . . , Inside of transmission case (Fig. 23·6)
AT shift solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside of transmission case (Fig. 23-6)
Automatic seat belt control unit .. . . . . . . . . . . . . . .. Inside of RH quarter panel (Fig. 27-1)
Automatic seat belt motor . . . . . . . . . . . . . . . . . . . .. Inside of each quarter panel (Fig. 27-1)
(Fig. 27-5)
Automatic transmission control unit . . . . . . . . . . . . . . Inside of LH quarter panel (Fig. 27·5)
Auxiliary air valve (1800 engine model) . . . . . . . . . . . . On intake manifold (Fig. 22-1)
Back·up light switch ....... . . . . . . . . . . . . . . . . . . Attached to transmission case
Blower motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Under instrument panel (Fig. 25-2)
Blower relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside of instrument panel (Fig. 25-6)
Brake fluid level sensor . . . . . . . . . . . . . . . . . . . . . . . Incorporated in brake fluid tank
By·pass air control (2700 engine model) . . . . . . . . . . . . Attached to intake manifold (Fig. 24-5)
Car·speed switch . . . . . . . . . . . . . . . . . . . . . . . . . . . , Incorporated in combination meter
Chime .. ~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , Inside of instrument panel (Fig. 264)
Clutch switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. On pedal bracket
Cruise control actuator . . . . . . . . . . . . . . . . . . . . . . . Attached to RH strut tower (1800 engine model) (Fig. 23-3)
Attached to toe board (2700 engine model) (Fig. 24-1)
Cruise control unit . . . . . . . . . . . . . . . . . . . . . . . . . , Inside of instrument panel (Fig. 25·1)
Cruise control vacuum pump . . . . . . . . . . . . . . . . . . . Attached to RH strut tower (Fig. 23-3)
Diff. lock solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . Attached to toe board (Fig. 23·2)
F ICD solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . Attached to throttle body on intake manifold (Fig. 224)
Front fog lamp fuse . . . . . . . . . . . . . . . . . . . . . . . . . Attached to R H wheel apron (Fig. 24-3)
Front fog lamp relay . . . . . . . . . . . . . . . . . . . . . . . .. Inside of instrument panel
FWD switch (4WD·A T) . . . . . . . . . . . . . . . . . . . . . . . Attached to LH strut tower (Fig. 22-8)
4WD/FWD solenoid valve (MT) . . . . . . . . . . . . . . . . . , Attached to toe board (Fig. 23-2)
Fuel gauge unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attached to fuel tank (Fig. 27-7)
Fuel injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On each side of cylinder head
Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Under body floor (Fig. 27-2)
Fuel pump relay . . . . . . . . . . . . . . . . . . . . . . . . . . . , Inside of instrument panel (Fig. 25-6)
Fusible link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , In front of LH strut tower (1800 engine model) (Fig. 22-8)
In front of LH strut tower (2700 engine model) (Fig. 24-7)
Headlight washer pump . . . . . . . . . . . . . . . . . . . . . . , Inside of RH wheel apron (Fig. 22-3)
Headlight washer unit . . . . . . . . . . . . . . . . . . . . . . . , Inside of RH quarter panel (Fig. 27-1)
Ignition coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , In front of LH strut tower (Fig. 22-8)
Ignition relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , Inside of instrument panel (Fig. 25-6)
Illumination control unit . . . . . . . . . . . . . . . . . . . . . , Incorporated in control wing (Fig. 26-1)
Inhibitor switch . . . . . . . . . . . . . . . . . . . . . . . . . . . , Attached to transmission case (Fig. 22·2)
Key warning switch . . . . . . . . . . . . . . . . . . . . . . . . . , Incorporated in ignition switch
Knock sensor (2700 engine model) . . . . . . . . . . . . . . . On rear end of engine (Fig. 22-1)
Lighting relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside of instrument panel (Fig. 25-4)
Main fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attached to radiator panel
Main fan relay .. , . . . . . . . . . . . . . . . . . . . . . . . . . . Attached to RH wheel apron (1800 engine model) (Fig. 23-3)
Mode control actuator . . . . . . . . . . . . . . . . . . . . . . . , Inside of instrument panel (Fig. 22-6)
28
Mode control unit. . . . . . . . . . . . . . . . . . . . . . . . . .. Inside of instrument panel (Fig. 26-3)
Motor pump ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . Attached to toe board (Fig. 24-2)
MPF I control unit. . . . . . . . . . . . . . . . . . . . . . . . . .. In the trunk room (Fig. 27-6)
MPS controller . . . . . . . . . . . . . . . . . . . . . . . . . . . " Attached to LH quarter panel (Fig. 27-5)
MPS heater relay . . . . . . . . . . . . . . . . . . . . . . . . . . . Attached to motor pump bracket (Fig. 24-2)
O 2 sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attached to exhaust pipe (Fig. 23-')
Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . Attached to oil pump
Oil pressure unit . . . . . . . . . . . . '/' . . . . . . . . . . . . . . Attached to oil pump (Fig. 22-6)
Outside temperature sensor . . . . . . . . . . . . . . . . . . . . Inside of RH wheel apron (Fig. 24-4)
Parking brake switch . . . . . . . . . . . . . . . . . . . . . . . .. Base of parking brake lever (Fig. 25-7)
Pneumatic suspension air charge solenoid . . . . . . . . . . . Inside of LH wheel apron (Fig. 23-7)
Pneumatic suspension compressor " . . . . . . . . . . . . .. Inside of LH wheel apron (Fig. 23-7)
Pneumatic suspension control unit. . . . . . . . . . . . . . .. Under driver's seat (Fig. 27-4)
Pneumatic suspension drier . . . . . . . . . . . . . . . . . . . . Inside of LH wheel apron (Fig. 23-7)
Pneumatic suspension pressure switch. . . . . . . . . . . . .. Inside of LH wheel apron (Fig. 23-7)
Pneumatic suspension relay . . . . . . . . . . . . . . . . . . . . Attached to LH strut tower (Fig. 23-8)
Pneumatic suspension solenoid valve . . . . . . . . . . . . . . Attached to each air suspension ASSY (Fig. 23-8)
Power controller (MPS) . . . . . . . . . . . . . . . . . . . . . . . Attached to toe board (Fig. 24-2)
Power window breaker . . . . . . . . . . . . . . . . . . . . . . . Under front passenger's seat (Fig. 27-3)
Power window control unit . . . . . . . . . . . . . . . . . . . . Under front passenger's seat (Fig. 27-3)
Power window relay . . . . . . . . . . . . . . . . . . . . . . . .. Under front passenger's seat (Fig. 27-3)
Pulser amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside of instrument panel
Pulser coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attached to compressor (A/C) (Fig. 23-5)
Rear defogger relay . . . . . . . . . . . . . . . . . . . . . . . . .. Inside of instrument panel (Fig. 25-6)
Rear revolution sensor (AT) . . . . . . . . . . . . . . . . . . .. Attached to transmission case (Fig. 22-7)
Resistor (AT control) . . . . . . . . . . . . . . . . . . . . . . . . Attached to R H strut tower
Resistor (Blower) . . . . . . . . . . . . . . . . . . . . . . . . . . . Attached to blower motor unit
Resistor (Engine control) . . . . . . . . . . . . . . . . . . . . . . Attached to RH strut tower
Retractable headlight motor . . . . . . . . . . . . . . . . . . . . Attached to radiator panel (Fig. 23-4)
Retractable headlight relay. . . . . . . . . . . . . . . . . . . .. Inside of instrument panel (Fig. 25-4)
Retractable headlight timer . . . . . . . . . . . . . . . . . . . . Inside of instrument panel (Fig. 25-5)
Seat belt timer . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Incorporated in combination meter
Speed warning buzzer .. . . . . . . . . . . . . . . . . . . . . .. Inside of instrument panel (Fig. 26-4)
Steering sensor . . . . . . . . . . . . . . . . . . . . . I ••••••• Attached to steering column (Fig. 26-5)
Stop light checker . . . . . . . . . . . . . . . . . . . . . . . . . . Incorporated in rear combination light (Fig. 27-8)
Sub-fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Attached to radiator panel (Fig. 24-6)
Sub-fan relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Attached to RH wheel apron (Fig. 24-3)
Tail light relay . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Inside of instrument panel (Fig. 25-4)
Temperature sensor (MPS) . . . . . . . . . . . . . . . . . . . .. Attached to toe board (Fig. 24-2)
Thermoswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attached to radiator (Fig. 22-5)
Throttle sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attached to throttle body (1800 engine model) (Fig. 22-4)
Attached to throttle body (2700 engine model) (Fig. 24-5)
Trip computer circuit unit ....... _ . . . . . . . . . . . .. Inside of instrument panel (Fig. 26-2)
Turn signal & hazard unit . . . . . . . . . . . . . . . . . . . . . Incorporated in combination switch
Windshield washer pump . . . . . . . . . . . . . . . . . . _ ... Inside of RH wheel apron (Fig_ 22-3)
Wiper intermittent unit . . . . . . . . . . . . . . . . . . . . . .. Inside of instrument panel (Fig. 26-7)
29
Fig. 22-1 Fig. 22-2
Fig. 22-3
L6-679
Fig. 22-6
Fig. 22-7 Fig. 22-8
30
"~ ~
L6-1426 L -_ _ _ _ _ _ _ _ _ _ _ _ ~.--------- __ --~
Fig_ 23-2
Fig. 23-4
L6-679
Fig. 23-6
Fig. 23-7 Fig. 23-8
31
6-3_ _ _ _~W~IR~IN\J(G----:-=-.:...::...:.~A~N~D~T~R~.~OUBLESHOOTI
DIAGRAM NG
32
Fig. 25·1
,-----------------------------,
L6·1025
Fig. 25·3
I~
Retractable
headlight relay
L6·1026
L6·685
Fig. 25·5
Fig. 25·6
33
\ "\ I ~\
I"~, >~~"~
\ '-,
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\
\
\ __ - \
- ~\
- I I,
\ -b\_\ ~ - '~\ 'I

\
\ -
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y /r1 I
(I f~;~
~\\~_ \ \
Illumination control unit~ \\)v~----
\ \1/ / (IA I ~~~
I : '\/ I #fl L6-1441
~--------~--------~
Fig. 26-1 Fig. 26-2
~------------------~
L6-685
Fig. 26-5
Fig. 26-6
34
\
Headlight washer unit
and/or Air conditioner
cut relay (AT)
'/Ii \ '\
m'
II .
6
j/
0
!
/
i ;' J
/ / /
\ r75'-"'----it'/ 1(' Automatic seat, ~ / );I'J

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\ '~ II
p/ -~
r/
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~\ .
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Automatic seat belt --;;:;c~~ \,\</ \"
motor RH ..////~ -~y" L6-1446 L6-1447
~-------------.----------~~
Fig. 27-1 Fig. 27-2
Fig. 27-3
Fig. 27-4
L6-692
Fig. 27-5
I~=== j'.b-- ~--~- 'I

L6-1452
Fig. 27-7 Fig. 27-8
35
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,--___+ __-"-0."'8S"R"G'--;. Parking light switch G>
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Height control unit, Hazard,
Trunk room light, Radio, Z ~
~
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~ ~ ~ i ~ ~ ~ ~ ! ~ C'l ~ ;;; ~
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Trip computer, Clock,
Automatic seat belt unit,
Key warning switch
lighting switch,
o »
z
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1 2 3 4 .: B,
,---"s.."w'-f-~_o=i~ob=~b=(~~~~~'r/c/Q ,-~--'GW"-;.:a:~_i:::~:~h,combination
Fog lamp switch
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Inhibitor switch,
~~f~~:~O!~i~~~
switch (Turn signal unit),
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~~~~';'ht "'oy
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r Trip computer, Diode box, r m
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Height control unit &. switch
Mode control unit &. switch, m
~
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L _ _ _ _ _ _ _ _ _~ To power window circuit breaker ~~~8 ~ "-l~
r--~
Rear defogger relay, Blower
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Speed warning key switch
Signal controller I o~
o
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C-I
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Starter motor 1 ~~:;, ~ >--____..:3c:W'-j ~3;.;w"----"c-_ _ To air conditioner power source
L-"-,·25",-,,LB~ Cigarette lighter, Clock,
Economy pressure switch,
o G>
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Air conditioner switch,
Air conditioner cut unit, Remote
1
- (Black) (MTI
@
3W-f"l---
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Of Ace ON ST
0·'0 Ignition
controlled rearview mirror switch
'--_-'c1.-"25'-'G~ Wiper motor, Washer motor,
-i
__\_'_M_TI_ _I~_ _ _ _ _ _ _2_B_W::-o-~~3~B"-W~--~~~~~~~~_-,,3~B!!W_-l-o-~~3~B.:..:W _____-__..:3j:ij~~ :: Intermittent wiper unit,
L---I switch
1.25LW Wiper switch Z
@IBIOO" ~~\ ¥B 3W~3L
3BW~3B
L-_---'-=:.:.:..;~
'--__---"'0"'8S"L"-';.
Rear defogger relay
Door lock switch,
Solenoid valve (Air suspension)
G>
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Pneumatic suspension relay.
Inhibitor (Black) Pneumatic suspension control unit,
switch
@ @ O.85LgR
AT control unit
tAfT only I
Cruise control main switch
2 BY 2BW L-_ _ _ _ _ -'3"'Lc;. Sub fan relay
3LR Radiator fan relay
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3B~3BW
B~38Y
38
B
m
@ tBluel
Jew
3BL
t-H--++---1---..-+-------+---".) To switch box
rT~E~~=E==tE=====jj==: ) ToTo switch box & warning unit

switch box ~
Fusible
To
To
headlight (RH)
headlight (LH)
:::0
~
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~
e ®
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headlight (LH) & warning light
switch box
Z
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rr~~~~~i~~1~~~~~~~~~~1~t~1~~~11It~~1j~~11~~~~JJj~j~i~~~~~+___
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Parking light switch
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r-_ _ +-___--"-GV!....,.
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Auto light switch,
antenna, Horn, Diode box, :::0
Key warning switch,
Trunk room light, »
Height control unit,
~
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~
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~
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~
m
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~
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b;-:O~X1-1-t-t-t-+=:t::t:::;---",O.c"'85~R:"L'-3> Lighting switch
~ Warning lights
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w
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r-__5_W+-<>='-'ob=ob=\:=1J 4WO selector switch, ,
I I I
@-mmr l!t~~~f~13!BW1l1~~~~~~~~~~:: 3BL switch (Turn signal unit) --i
@ 22W"@ ;:~ ~W AT :::0
@2RV$2RL v VR I Ignition
control
coil,unit,
Ignition
Combination
relay,
oC
w:
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B J8R 2WB RY VL G 2 WB 0.85 Fuel pump relay,
@ Lighting Aetractable
VB
Retractor
8
Retractor
RW RV MPFI control unit
relay (LH) headlight relay Warning light & unit,
motor tlHI timer
:,~t-- OJ
(LH)
5W Rear defogger relay, Blower
'~ relay, Diode box, Air conditioner
3BW 9( 1 1I( 12 1 14 1
r
Alternator
J~WR=--~H-+--------------------------------~~~-~-~3WR3~~W~(iiii~i!. ~~~~w_~&
switch, Mode control unit, m
~WR~
B- L -_ _ _ _ _ _ _ _ _.,. ( To automatic seat belt control unit ~ --~
Mode control switch
(j)
I
~
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t-__________________________________~__1_--~~~3~W+__b»
17
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Cigarette lighter,
o
2 WB
» » »
3B I
Remote controlled rearview
L. O.s.5~1":1____ mirror switch
------"..- Clock, Economy pressure switch,
Air conditioner switch,
o--i
<§) 3W-ID Air conditioner cut unit,
D.
CI S",n"
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Wiper motor, Washer motor.
Z
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1_
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fAce ON 51
1.25LW
Intermittent wiper unit,
Wiper switch
Rear defogger relay
- !Black) !MTJ
3L n • lQlQIo WL
<® 2BW 3BW
3
~1
1616- Ignition Door lock switch
H~
3 BWJL..3BW 3BW roswitch
"1..)" l- O.85Lg
"'" 3 B IG roro
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Solenoid valve (Air suspension),
Pneumatic suspension relay,
m
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@!BllICkJ
EFE
3aw
EGE30W 3WOO3L
3BW 3B
" Pneumatic suspension control unit,
AT control unit
®
Inhibitor ®!Gi~nJ @ !Black}
switch
(AfT only) @
2 BV 20W
0>
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c.v
Combination Meter
A. ANALOG TYPE
@ @ ®
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,"3 4 1#
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55 65
I,75 I I
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," 2 //
, " 35 95 .,- ~
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xl0QQrlmin 1010101010101O!
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101 pi pi 101
to ~~:J~L. G:ilCHARGE , ~~~s~g~- STEERING I

I
®
(Full-time (Selective (Full-time
(FWD-AT) 4WD-AT) (FWD-MT) 4WD-MT) 4WD-MT)
1 Temperature gauge
0::::( mum f0lml! OOOIIOC! lPll pm 2 Oil pressure gauge
...~" "'" "'" !Ill! OOOIlOC!
3 Tachometer
o 0 0 0 6 ~
~~~~~~ ~I~
4 Indicators
""'~O'~OOOR 5 Speedometer
:~\
6 Voltmeter
7 Fuel gauge
8 Warning lights
PARI
811l! 9 Low fuel warning light
A: Blue
®
0 0
0
00
§
y
<9
D eEl 9 B: Brown
0
@ 0 0
D: White
...
Fig. 32
~ L6-1720
43
(
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~
~
15
.....
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1'- ~.~.~ --I~
~ Ignition
switch
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light
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A: Blue B: Brown C: Black D: White
31 24 32 25
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50 51 52
30 37 38 39 33
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z I Carcpeed$witch I
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I.
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14WO Of Oiff. Jock ~ I 1..
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I L ________________________ '::/ ~
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: Chec.ong;ne= IS! -O-c>--
I'
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I Br'k.fLuld~ ~ :::----0---
I
s10P1i9nl~ ~ ..0--0--
00-- ~--
I
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1 r:I.tr.ctor~
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,
:riT ATFt.m~tr.tur.~ l' -o~
1
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Steer in, or Oil Pt'luure
I ::--.'"
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1
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Fig.34 Canada model L6-1722
45
1) Speedometer
II Speedometer trouble
I
f
r Speedometer pointer and/or odo· I •
Speedometer pointer deflects be- •
Speedometer pointer will not
meter will not operate.
I yond maximum point. return to zero nor exceed a
certain point.
j !
[ Determine whether speedometer INo I Oil rise
inner cable operates.
r
1 Yes
ISp,.dom"., cabl. impmp-l • Speedometer cable improperly

I Hair spring broken. I • Hair spring deformed.
erly connected. connected (on transm ission
side!.
• Pointer stopper de-
formed.
• Driven gear broken.
• Speedometer cable broken.
I
Foreign matter lodged in
magnet.
Replace driven gear or speedo-
meter cable.
,
I Replace speedometer. I
Speedometer pointer deflects er- Speedometer operates, but odo-

ratically. meter or tripmeter does not
operate.
Speedometer cable improperly Defective gear in speedometer.

routed.
No
Replace speedometer.
Speedometer cable near breaking
point.
Replace speedometer cable.
Correct speedometer cable route.
46
• 55-MPH speed alarm does not sound.
Check if warner sounds when speed

alarm switch is turned ON and terminal No
(@l of meter harness connector is -1J Faulty body harness.
grounded.
Yes
Faulty meter.
• 55-MPH speed alarm does not stop sounding.
Check if warner sounds when meter harness Yes I

12.P connector (white) is disconnected. f-------.tl Faulty body harness. I
No
Faulty meter.
47
2} Tachometer
Tachometer trouble
Tachometer pointer will not ope· Tachometer pointer deflects be· Tachometer pointer will not reo
rate. yond maximum point. turn to 0 nor exceed certain
point.
Hair spring is deformed.
Yes • Adjusting resistor value devia· • Pointer stopper deformed.

See if fuse is blown. tes. • Foreign matter interfering.
• Deteriorated capacity of filter • Pointer deformed.
No condenser.
I Fuse is blown.
I
I Replace fuse (15M.
I Replace tachometer. j
See if fuel gauge and temperature

No
gauge operate normally. (Sub· - Harness is defective.
stitutive check of power source
and grounding).
Yes
Repair or replace.
With ignition switch off. check

conduction between combination
No Signal wires (yellow) of instru·
ment panel and front harness
meter terminal and ignition coil
!tachometer) defective.
(-).
Yes
Tachometer is defective. Repair.
• Defective circuit.
• Hair spring or coil broken.
• Foreign matter caught in
movement.
Replace tachometer.
48
3) Temperature Gauge and Temperature Gauge Unit
~
Pointer will not operate.
Temperature gauge (thermome·
• It remains in high position.
ter) and temperature gauge unit
(thermo unit) are defective. • It remains in low position.
~============================~ ~_'n_a_c_c_u_ra_t_e_i_nd__
ic_a_ti_o_n_'__________- J
Determine whether thermometer

No
indicates below "C" when igni·
tion switch is turned off.
I Thermometer is defective.
I ·1 Replace thermometer.
I
Yes
Determine whether 12·volt
voltage appears at terminal
No I Harness is defective.
I
Turn on ignition switch.
No
on back of meter.
Yes y Repair. I
Yes
Determine whether fuel meter is
operat ing normally.
No
Check if fuse is blown. I"
"- /
Fuse blown.
I ./ Replace fuse.
I
Yes
Remove connector from thermo

unit. Connect resistor (42 n) to No Check if 7V* appears at
No Check if 7V* appears at f
YG wire on harness side and #26 terminal (YG or Gl)
thermo unit YG lead. '\",
ground to see if thermometer of 21·P connector (brown).

points to 86°C (187°F). Yes
Yes No
Yes
Thermo unit is defective. Thermometer defective.

(
l Thermometer is defective.
I
I Replace thermo unit.

I Replace thermometer. Y Replace. I
I
I
Defective harness wiring.
I
-I Re p air.
Note: *Mean value is 7V.
49
4) Oil Pressure Gauge
Pointer will not lower.

I I Pointer will not rise. I I Inaccurate indication. I
Check with
i
ignition switch I
off.
~
Oil pressure gauge is defec-
tive.
I Check with ignition switch
on.
~ NOI
Oil pressure gauge operates.
Replace.
I I
Replace fuse. J I Fuse is blown. I

I
Yes
I
See if fuse is blown.
No Yes
Remove oil pressure unit termi-

nal. Connect resistor (1400) to
Check if 12V appear at
-
Replace oil See if 12V is in RY lead
Yes oil pressure gauge lead terminal
pressure of 21-P connector of ~ #27 terminal of 21-P can-
on engine harness side and to
~
gauge. meter. nector (brown).

ground, to see if gauge points to
t
Ignition (+) power circuit
Yes
Defective harness between

392 kPa (4 kg/cml, 57 psi).
Yes
Oil pressure unit is defective.

of instrument panel is oil pressure gauge and oil
improperly conditioned. pressure unit.
~
Repair harness. Repair harness.
I Replace. I
I I
Oil pressure gauge is de-
fective.
l-
Replace.
50
5) Voltmeter
I Pointer will not lower with igni'l Pointer will not rise. l Inaccurate indication. I
tion switch turned off.
l
!
Voltmeter is defective. I . Check with ignition switch
turned on.
t
I Replace. I NOI
I
Voltmeter operates.
I
Yes
I Replace fuse. I
I
: Fuse is blown. f
Yes
No
Determine if voltmeter indicates

See if 12V is in RY lead of
I Repair. l l Voltmeter is defective. ~ Yes 21-P connector (blue) of
meter.
12±O.5V by letting load such as
headlamps, rear defogger, etc. and
connecting fully-charged battery.
No No
Defective ignition (+) har-

ness of instrument panel.
I Voltmeter is defective. I
r Repair harness·l I Replace voltmeter.

I
51
."
C
Fuse box !..
Ignition
Battery
switch
C)
C»
~Irrr~Tr
3W C
Ul
<D
3B RY
*: 2700 engine model

~
3w~(Black)
~3B
~R~~~~~
3B
rrr ~r~'Tt ~
::D
Z
G)
rrr~~21 o
»
G)
::D
»
~
»
z
Combination meter
o
-t
::D
RY
ac
RY (D
r
m
en
I
o
WY WY
o-t
BY BY Z
B G)
B
B
@
@ ® RY -= WWY
..
WY B BY
@
r
{ IIITIWI}
(Brown)B BY
~
"W
I\,)
6) Fuel Guage and Fuel Gauge Unit
Pointer will not operate.
• Pointer remains in high posi·
Fuel gauge (meter) and fuel gauge (meter) tion.
unit are not properly conditioned. • Pointer remains in low posi·
tion.
I naccurate indication.
No
Turn on ignition switch. Determine whether 12V
appears at terminal on
II Harness is defective.
I
back of meter.
No
Yes
Yes
Lr Re·'·"1
Check thermometer for normal No Determine if fuse in fuse I' J Replace fuse.
operation.
Yes
box is blown.
\,. r Fuse is blown. r
I I
Remove connector from fuel
Determine if 12V appears
gauge unit. Connect resistor (7nl Check if 12V appears at
No at fuel gauge unit BY lead No/,
to BY lead on harness side and to \" #24 terminal of 21·P con·
after disconnecting it from
ground. and see if meter points at nector (brown).
the unit.
1 (F).
Yes Yes Yes No
I
Fuel unit is defective. Fuel gauge is defective.
I
Thermometer is defective. I
Replace fuel unit.

-l Replace. J
Replace fuel gauge.
l Harness is defective.
I
"-----I Re p air.
53
7} Low Fuel Indicator Light
Lamp will not light up

even with fuel below speci-
fied level.
Yes
I
Fuse is blown.
J
J Replace.
No
Check with ignition switch

turned on.
Check operation of fuel RY lead between fuse Repair harness between

No
gauge and temperature and combination meter is fuse and combination
gauge operates. defective. meter.
Yes
Remove fuel gauge unit Check and repair WY lead

No WY lead connecting meter
connector. Ground WY J See if lamp bulb is broken. l No of 21-P harness or connec-
and fuel unit is defective.
lead to see if lamp lights. tor (brown) connection.
Yes
VII
Faulty contact of fuel

gauge unit connector.
I Lamp bulb is broken.
I I
Replace lamp.
J
Thermistor is improperly
grounded.
Repair or replace fuel

gauge unit.
54
8) AT Indicator
(1) AT indicator does not come on regardless of shift lever position.
Check if less than 1.5 volts is produced

across any of terminals @ through @ of No
meter harness connector and GND when I------~-i Faulty meter.
ignition switch is ON and shift lever is moved
to a "detent" position.
Yes
Faulty body harness.
(2 ) AT indicator display does not change to the position corresponding to that of gear sh ift lever.
Check if voltage across terminals @ through

@ of meter harness connector and GND Yes
a
changes within a range from to 5 volts Faulty meter.
when ignition switch is ON and shift lever is
moved to a "detent" position.
No
Terminal No. of
Shift position
connector
® 2
@ 3
@ 0
(3J) N
@ R
@ p
55
9) Power Indicator
Power indicator does not display.
Check if indicator displays when terminal @

I
of meter harness connector is grounded
Yes
r-------..I- Faulty body harness or AT control unit.
l
I
when ignition switch is ON.
No
Faulty meter.
10) Height Control Indicator (Canada model)

(1) "H I" indicator does not display when switch is turned ON. ("LO" indicator remains ON.)
Check if "HI" indicator displays when term i- No

nal@ofmeterharnessconnector is 1-------~-1 Faulty meter.
I
grounded with ignition switch set to ON.
Yes
(2) "HI" indicator remains on regardless of switch position.
Check if voltages across terminal @ of meter

harness connector and GND when ignition Yes
switch is ON are as follows: r------~1 Faulty meter.
1
o volts - height control switch ON
5 volts - height control switch OFF
56
-I
~
--
'0
RW
n
o
3
'0
RY C
<lID r+
Cl (1) ~
C3-G ~
~
Z
G)
® o
»
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~
(Blackl ® (Vellowl ~
_
VR B ~~5:V »z
GB
G
O.85R B
o
-I
JJ
Combination meter
Trip
oC
To lighting switch ____- . I
(See Fig. 38.1
computer
OJ
circuit unit
r
m
en
:J:
o
o-I
Z
G)
Control &
Displav unit
@)
@ E
G@-GB
(Blackl
Outside temperature
sensor
1) All Functions do not Operate (No LED's Glow)
Check if wiring is connected to Yes Faulty control & display unit or

+BAT and +IGN terminals. related circuit.
No
Faulty body harness (including

fuses).
2) Display (LCD) does not Glow or is Erroneous
Check if control & display unit

is connected to circuit unit.
Yes
- Faulty control & display or
circuit unit.
No
Connect harness properly.
3) Clock/Time Alarm Unit does not Operate

Circuit unit is faulty.
4) Tripmeter/Average Car Speed Unit does not Operate

I
I Check if speedometer operates. I Yes
I
Check if car speed signals are
emitted from combination meter.
Yes
II F l Circuit
au ty ' . Unit.
. I
No No
I Faulty meter.
I Faulty meter.
58
5) Buzzer does not Sound
Check if buzzer sounds when Yes

tachometer registers in the red
zone.
.. I Faulty circuit unit.
t No
Faulty buzzer (inside combina-

tion meter).
6) Meter Display does not Illuminate When Ignition Switch is Turned ON

Illumination lamp burned out or control & display unit faulty.
7) Meter Display does not Dim When Illumination Control Switch is Turned ON
Control & display unit may be faulty.
8) Control & Display Unit does not Illuminate When Illumination Control Switch is Turned ON
Illumination lamp may be burned out.
59
_.
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CC
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2AL
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2700 engine model Fuse boK
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Headlight
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Combination meter
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link
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r
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timer
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(LH! (RH)
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(LH)
... @F'i'1-VL
'9-2 YW 2YW
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r-~
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.:L-=t~~:~;j r--~l-2-
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d'odo
r
l2'-'YW"--_ _ _ _ --<t-L_ _
Tom"" '"um'''''o"
1m '".38.'
~ ~
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-
Front
sIde marker Aear side marker
Ioght ~RH) Ilgln fAHI
@) *: 2700 engine model

® B @ ~::; ~~~~matlon
B-ffi°~i F1TT1
~ R~
g:B58R (Blackl 0",0.85
'" 0
ill Fusible :tI 0.85RB
Front
il Imk Igmtlon switch
5W 0.8SRL
m 0.85 A
FFAC ON Sf 0.8SRB Tall
combmatlon 3BL OB5R light
lIght !RH)
0.85 R8
2B
~
r~Tli
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0.85 rffi-a @0.85AL ® :0

AB~ °85---1:Tft iFFFFFfrii
~ 8--tij 1t:tt:tt:nF=rF;=111="~ Z
3B R8
(Black)
® !Bleck)
G>
RB License o
@ (Black)
light !RH)
»
3B-m.3aw Parking
B-ffi-RB G>
~3BL ~~~-=--=-~~-'j switch
@) :0
a
(Blue)
»
~ ~
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RS O.85Ra
o
~
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{ 1,11111
OB5R (Blackl
f @"';
B-El3- RB
»
z
AT selector
@(BIaCkl
License
o
lever Illumination light
Glove box
~~O=.85",R'-I"- switch
light ILHI
-i
0.85 R
:0
RB
® MB
Glove bole
illumination oC
0.8::~® GO.85R light
(Brown)
(Blue)
+--t=====::!!:~'::Jereo illumination
~igarette lighter
light
OJ
Illumination light
0.8SR
r
0.85 R
®HB
Y-O.85 R
m
(j)
RadiO
illumination light
I
o
OB5 R
Tad
IigM
@t]nnan o-i
O.85A OBSR B
I·hold switch (ATI
@) RB
Diff.lock switch Ff;+O.85 A
o 8
B ~~;;i;tion light
~ CB--RB Trip computer/Clock
OB5A.-0
~
C§)
Illumination light Z
'" '" OBSR O.85R
@ G>
0.85R
FrFfIOB5R
(Black)
~~~ ~~~~0~.8~5~R~;=============lj~~R~B~ ®~ ~
RB
m
Blower switch
illumination light tOU\ ~ __ ~ 0.85R AB
0.85R
Front
(Yellowl R,,, ,;d. m"k"
side marker
fight !LH) ~ARB 0.85R \@!; OB5R~ ® O.85R B B hghtfLH)
O.85R1!J RB RB-ttt1j
RB .@IBlue) R
yanity mirror
Front fog lamp switch
Iliummation light* O.BSR Illumination light *
IB~Jijj @)Jijj @E
R-@-B
@l
RB O.8SR RB OB5R
0)
I
CAl
1) Headlights do not Open or Retract When Lighting Switch is Operated
I Ves
Check if fusible link is burned. I Replace fusible link.
I
No
Check if headlights open or No Check if voltage is applied to No Check and repair harness be-
retract when retractable head-
motor connector. tween fusible link and motor.
light switch is operated.
Yes i Yes
Check if resistance between No

ground terminal (black) of motor Repair harness.
and car body metal is zero ohms.
I Yes
Check if voltage is appl ied to R

terminal of motor connector
No Either motor or relay is faulty.
when retractable headlight relay
Replace.
(NC) is disconnected (and RV
terminal when headlights retract).
l ves
Repair harness between motor

and lighting switch/retractable
headlight switch.

power side of lighting switch and No
Replace lighting switch.
GN 0 is zero when lighting switch
is operated.
Ves
Repair harness between retract-

able headlight switch and lighting
switch or between lighting switch
and body (GND).
62
2) Headlights do not Open or Retract When Retractable Headlight Switch is Operated
Check if headl ights open or retract when No Refer to "Headlights do not open or retract
lighting switch is operated. when lighting switch is operated".
t Yes
Check if resistance between motor side of No
Replace retractable headlight switch.
retract switch and GND is zero ohms.
j Yes
Check if resistance between retract switch No

and timer and between timer and lighting Repair harness.
switch is zero ohms.
t Yes
Replace timer.
3) Headlights do not Open or Retract When Passing Switch is Operated
Check if headlights open or retract when No Refer to "Headl ights do not open or retract
Yes
Check if voltage is produced at power termi- No

nal of timer and if resistance between ground Repair harness.
terminal and body metal is zero.
Yes
Check if resistance at passing switch is zero No

Replace passing switch.
when switch is operated.
Yes
Repair harness between timer and passing

switch or between passing switch and body
metal.
63
4) Only One Headlight Opens and Retracts When Lighting Switch is Operated
l Only left headlight opens and retracts. 1

I
Repair shorted harness between motor and
lighting switch.
! Only right headlight opens and retracts. I Repair shorted harness between motor and
I I ighting switch/retractable headlight switch.
5) Headlights do not Come on When Lighting Switch is Operated
Check if headlights open or retract when No Refer to "Headlights do not open or retract
Yes
No
Check if fusible link and fuse are normal. Replace fusible link or fuse.
Yes
Check if voltage is applied to retractable No Repair harness between retractable headlight

headlight relay (NC). relay (NC) and battery.
Yes
Check if resistance between retractable No Repair harness between retractable headlight

headlight relay (NC) and motor (at RY
relay (NC) and motor.
terminal) is zero.
Yes
Check if continuity exists between contact-

point terminals of retractable headlight relay No
Replace retractable headligh~ relay (NC).
(NC) and between coil terminals,
respectively.
Yes
Check if voltage is applied to lighting relay No Repair harness between ignition switch and
coil when ignition switch is turned ON. lighting relay.
Yes
No
Check if voltage is applied to contact points
of lighting relay.
- Repair harness between fusible link to light-
ing"relay.
Yes ,
64
Check if resistance between ground terminal No Repair harness between lighting relay and
of lighting relay coil and body metal is zero. body metal.
Yes
Check if continuity exists between contact No

points of lighting relay when ignition switch Replace lighting relay.
is turned ON. I
Yes
Check if voltage is applied to passing switch No Repair harness between headlight(s) and
(high and low beams) when ignition switch is
passing switch.
turned ON.
Yes
Check if continuity exists between contact No

points corresponding to selected position of Replace passing switch.
passing switch (high-low beam).
Yes
No Repair harness between beam switch and

Check if voltage is applied to beam switch.
passing switch.
Yes
Check if resistance between lighting switch No Repair harness between lighting switch and
and beam switch is zero. beam switch.
Yes
Replace beam switch.
65
...
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o
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I
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(Blue) »
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(Brown) 2RB -i
Front fog JJ
lamp relay o
C
(l)
r
m
CJ)
I
®tfJ\ @ o
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OB5RW $ 2 R B
2RB~ (Green)
2RB
0.85RL
z
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Front
fog lamp
switch
E@
~OB5RL
0.85 :~-EIfD ®
OB5R
OB5RW
~R8
~(Brown)
$ O.85R
0.85RL
~
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aery Fusible
link
Ignltlon
..
"'-.., JoF IA<X

switch
Fuse box
0.85 RW,RW* ® _.
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* : 2700 engine model
(Black) t- HB
I I I 19
fOlblbla
z
3B Turn signal & :I: G')
Unit
Hazard switch D)
N 0
rl79~7' GL
t- LO
I~ I~
I
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GR
t- R 16 6 Q.
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Rear turn signal
light (RH) ~ »
--"<.I
B GL GL
_.
::l Z
<ID~ III ~1~1 G~~

@) ~
Front turn signal
::l 0
light (RH)
CC -i
Combination
meter
GL GR
_.
r-
CC
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Il :::T tIl
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r-@- I--
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GL
£@) r+ r
m
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Front turn signal light (LH)
@ ® GR
E @)
~~ { IIITIII} { ITIItlTII )
~ ear turn signal
~GL ght (LH)
B B GL
(Brown) (Blue) B~@
GL.:g
1) Turn Signal Switch and Turn Signal & Hazard Unit (With built-in combination switch)
Lamp flashes irregularly or re-

mains lighted.
Turn ignition switch to "ON".
No
Determine if lamp bulb is of
suitable wattage.
When bulb capacity is not suit-
able, it flashes too fast or too
J
I
Replace bulb with specified one.
I
slowly; when bulb is broken, it
flashes too fast.
Yes
No
Increase power voltage by running
engine, and see if lamp flashes
Battery voltage is too low. : Charge or replace battery.
I
regularly.
Yes
Determine if harness connection

No
.. Faulty contact of harness connec- .i Repair harness and connector. I
and grounded part of lamp are tion and grounded part.
in good condition.
Yes
I Combination switch is defective.
I I Replace combination switch
I
Only one lamp lights.
Check with ignition switch on.
No
Check conduction between com-
bination switch connector and
Faulty connector contact be-
tween combination switch can-
: Repair connector or harness.
I
turn signal lamp. nector and turn signal lamp, or
Conduction: O.5GR on RH side broken harness wire.
and O.5GL on LH side.
Yes
Faulty conduction of combina- I i Replace combination switch. I

tion switch.
68
Both right and left lamps fail

to light.
Turn on ignition switch.
. I Yes I Fuse is blown. I

See if
blown.
fuse (15A. TURN) IS
I J
I Replace fuse. I
No
No
See if voltage is 12V between GW Faulty contact of connector or J Repair connector or herness. J
of combinetion switch connector broken wire between fuse box
and ground. and combination switch connec·
tor.
Ves
Remove combination switch con-

nector from combination switch.
No
.
* Combination switch defective.
i Replace switch, or repair con·
nector or herness.
I
Faulty connector contact or
Connect GW on harness side and
broken wire between turn sig-
OR (RH side) or GL (LH side) to
nal switch connectors and turn
'" if lamp lights.
signal lamp. (In this case,
Ve. connect combination switch
connector and inspect with
hazard turned on.
. ] Faulty
switch.
contact of combination : Replace combination switch .
I
69
2) Hazard Warning Light Switch and Turn Signal & Hazard Unit (With built-in combination switch)
Hazard lamp does not light.
Yes
See if fuse (15A, HAZARD) is I Fuse is blown.
blown.
J I Replace fuse. I
No
Check voltage at RW of combina·

tion switch connector.
I No
Faulty connector connection be· I Repair connector or harness.
I
tween fuse box and combination
switch, or broken harness wire.
Yes
Remove combination switch con·

nector from switch. See if turn
No
*
*
Hazard unit defective.
Fau Ity contact or broken wire
l Replace unit or repair harness.
I
signal lamp lights by connecting in harness between hazard unit
GW and GR (RH) of connector connectors and combination
on harness side or GW and GL switch.
( LHI. * Fau Ity contact or broken wire
Yes between combination switch
connector and hazard lamp.
(Connect all turn signal cir-
cuits, and confirm by con·
trolling turn signals.)
1 Hazard switch defective. I Replace combination switch.

I
70
txJ
Q)
(')
;;1\
I
c:
Fusible
Battery
link "'C
e ~I ~5W.8W*
~
Ignition
switch ________________________________________r-~0~.8=5=G~~
Back-up
light (RH)
_.
r-
to
~ -----..-
f'..- OfF ACC ON ST 7-LJ 1)-
::T
E B Q Q
r+ :E
~~.85G
-::- ACC 6 Q
3B
ST I :n
@'-
I-- IG
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6 )
) @ z
G)
3Wffij ® * 0.85GW 0
I ~±rG
»G)
~
IIT II~
a
3B 000
"'00 I nhibitor switch (AT)
(Black) Gl'"
:;;Gl PRN032
:n
L-
r-
191<; »
Fuse box
oo
:..,~
~
"''''
GlGl »z
" ~ ~2 ~3
1 rrrrr :;;0
000
~~
Gl
:;;
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0.85G*.0.75G 16 19 16
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1 0.85GW~ 0.75GW UL....l.-L--'--L.....L-'
c
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r
3B
{II~IIII) (Black)
0.75GW
0.85GW* 0.75G
0.85G*
m
en
I
r~18z9rot Back-up light
0
0
switch (MT) -i
0.85G*.0.75G 0.85G 1----rl<J~
0.85GW*.0.75GW I r 0.85GW J II---_~
___- . . J Z
r I Back-up
G)
light (LH)
$ 0.75GW,
0.85GW*
0.85G*,
@
Y
0.85 G
0.85GW
B
0.85G
rg~.85G
0.75G
0')
I
W
en
r+
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c.v
0
Rear combination 'C
*; 2700 engine model
Stop light checker·
light (RH)
_.
r-
(,Q
0.85GB
YG
:::r
r+
8W'
5W 3W
~
B Stop light (RH)
3B
ST
IG
@) J)
@ B~0.85GB Z
~YG
G')
3W~
3B
(Black) 0
»
G')
J)
Alternator
® ® »
WR
~
0.85 GY m@)
(with cruise control)
0.85GB
O'~ @=.:'85GB
(Brown)
High
»
z
0
mounted
"""'14 ~ (without cruise control)

stop
light
-;
~ 0.85GB
J)
Stop light
sWitch
0.85GY 0
0.85GY C
0.85GB OJ
r
m
Combination E @) (J)
meter I
0
Br Rear combination
light (LH) 0
-;
Z
YG
Stop light (LHI G')
RY
Stop light checker
@
To AT control unit
(See Fig. 52. 53.)
J
.._----1
YG Ifl I ITI epBr
To cruise control unit
(See Fig. 64.)
(Black) RY
(1) Warning pilot will not light even when key switch is turned on (with brake pedal released)
I Turn on ignition switch. I
l See if fuse is blown.

I Yes
I
I Replace fuse.
I
No
l See if warning pilot bulb is broken.' Yes I Replace bulb. I

No
I See if voltage appears at ignition terminal of instru-

ment panel.
II No
Faulty connector connections from battery to meter
ignition, or break in harness. Repair connections or
harness.
Yes
Faulty connector connections from meter to voltage

regulator, or defective harness.
Repair connections or harness. Check voltage regula-
tor.
(2) Pilot lamp lights up during traveling (when brake pedal is depressed)
E'It her right

. I Yes
or left stop lamp is broken. 1 l Replace bulb. I
!No
Resistance between car body and connector grounding

terminal on harness side of right and left stop lamps is
No
I Faulty connector connections, or defective harness.
Repair connections or harness.
I
zero.
! Yes
When lamp checker connector is disconnected, resist-

ance between car body and yellow/green lead terminal
No
I Short circuit is present between meter and stop lamp
checker. Repair harness.
I
in meter junction block is infinite.
IYes
I Replace stop lamp checker. I
73
:D 0>
I
0 U>
0
@
3
Fuse box _.
r-
GY GY~BR
Room light 8. Spot light CQ
~1~2 ~~4~5~6~7~8 Spot RH
":j'
r+
3W
Q)
~
r
5W RY GY
3 B ::l
IG BR Q. JJ
~ ~A-L-L~~~I ~10r ~~13~14~15 ~16 Z
C G>
3WOO3B Spot LH 0
(Black) 3B -- 0 0
~ »
r~18z9r~21 @ en JJ G>
m
Gl til
-< :D
~
_. »
0
BR
GY
r+ ~
RY ®OB5GY :D til
-< -<
Gl Co :D (Green) (')
»
~IIIIII~
'"Gl ":j'
z
-<
:D
-<
0
Co
0
'"
Gl
@> --f
-< JJ
B-ffi-GB
GB
0
C
E- Door IJ)
switch (RH)
B r
m
(J)
I
0
0
--f
Z
G>
-
1) Doors Ajar Warning System
I
All lamps fail to light up. Some lamps fail to light up.
I ~I
See if fuse in fuse box is Yes
Fuse is blown. Replace.
blown.
I I
No
Throw room lamp switch for· Lead wire between fuse box
No
ward to see if room lamp
illuminates.
and room lamp is broken, or
connector has faulty contact.
I Repair.
I
Yes
f
See if 12V appears in con· Lead between room lamp and
No
nector on back side of com·
bination meter.
• meter is broken, or connector
has faulty contact.
I Repair .
I
Yes
No I
See if each bulb is normal.
Yes
I
I Lamp bulb is broken.
I I
Replace.
I
Remove hood of each door
Cord between door switch
switch and ground female ter· No
minal to see if lamp illumi·
nates.
and meter is broken or con·
nector has faulty contact.
I Repair.
I
I Yes
Door switch is defective. • Replace.
75
Dome lamp and door pilot

lamp do not light when door
is opened.
Set dome lamp switch to

door side, and check.
See if fuse (room) is blown, No

and if bulb is broken. f----~ Replace fuse or bulb.
Yes
.-----~-----~No
See if lamp lights by opening 1 - - - - - - - 1 Check door switch, harness • Unravel entangled door
other doors. connector and harness. switch cord.
• Repair harness connector.
Yes
Note: When ambient tem·
perature drops, switch
Determine if harness and con· may sometimes turn
nectors in dome lamp and on slowly.
door switch circuits are in
good condition.
Faulty contact of harness Repair harness connector or

connector, or break in har· harness.
ness.
Either dome lamp or door Broken bulb, faulty contact Repair connector or harness;
pilot lamp does not light. of harness connector, or replace bulb.
break in harness.
76
-I
~
C
:::l
Fuse box
r------.:...::.::::~~-----. RW
""
~
0
0
3
3BW
_.
r- ~
cc :D
::r zG)
r+
0
»G)
:D
»
~
»z
0
® -i
~~~5RW
:D
0
C
OJ
Trunk room r
B B light m
en
::J:
0
0
::j
BW z
G)
B
B~BW
@
"'rl
~. en 0>
I
CAl
CD
~ C»
r+
h
t::
8 Battery Fusible
O.85AW Shoulder belt buckle
switch RH and rear
aJ
-
Fuse box
~
...~ O.8SA 3 BW 1 :;~c,,:rnjng
.---
Fr~mt door
sWitch RH
Front limit
SW~H
limit switch RH
Limit LjShOUlder CD
3BW ~Irr?~~Ir AY l!l~W~ lTIir ,~ rtm~

Motor AH
@~lmJ ® r+
3Wr- Ul
~. Ignition switch
nto·!lG 2WB
~~CCOH
1~5W AY
M
~
ST
• D
...
III E
~ ~8W' 1 cc
-'LTQ
0 r6
RW 0.75
C»
I;)- ~ ST I
~ffi ~m ~
:l
...--
¥rrrr
<b
ro "':0'"
L ': :E RW
Gl
Q. :E
rrr~
U'1 0.85 Y ............... 0.75 0.75 r:D
® -< (Black) ~ ~ ~ RL Sr (Black)

*: 33~~
< r " J)
"
2700 engine model
(Black) 3B 2RBGA .5
~_-.:.2:..:A:j
<
CD Z
G>
r--.:=========~J
r -,-;~O.8:. . 5-+R: .:W ~ ~ ~ 085Y O.O.O.75AL~
I 1
@-2WB
AWRG 19'183 ~
CJ
_ _ _ _..L
5B,l LAB~
775AY] ffi0 :;:@ Fil »
~ "flllll'!} ~,q {Ill II II f @rft:" ~: ~
_ _ _-=..=J
2WB , 2WB
G>
_.
~
:l J)
'rR ~Y__IT--------+-t------------m ~
Combination meter
CD Automatic
»
~l
seat belt
control :l ~
CQ
~~O~.85-R~Y'----t~~~~~~~~~~~~;;;;;;;===~~;========~~~~~~~~~~~j~===~~~~~~~~~~~~=f=~==~==========t3~~~O~.8~5~A~Y
'''"''
unit
r---
.--- *-I §:e. " " »z
:,'tten~ = ,~ ,7 en
U
='"l.!TO.85RY r-::::======±t_t-___=++==~W~10 <(I) CJ
~--..:L:::W-"~. -'~~~---~-------~i==~====j=±==~LB~
p~~:~===jr========tf=t=====t±==~GY~
~ ® GY, GY OW '
LY,~~1611
r+ ~
I ________
(Blue)
LW CD J)
® 0Jil.I!I!! GY LW . 2B 6 3 0
c
® ~ LW B23 OJ
If Ifilii f
IYellow)
LB LV ----" r
IBIU.J
r
< '" '"
L.....L.....1
r
.., m
RY RY
'" (J)
® GW TOTO
~ ~
0
~ @E ::r:
111111~f
"'''''''
r r '"
< ::;; "
0
0
~
z
@
(Red)
..
o
"'Gl
@
B co ~
@)
BLA ",1' '" S;
G>
,...cS.<
~~
\ffil, L:,~rl
GY~
IBI~~) roo
v-t!f f---
0.85
.r M
~
switch LH
Fr~it
switch LH
Lap belt
switch LH Shoulde, ~-' .
Limit
Motor LH
Shoulder belt buckle

s.witch LH and rear
limit switch LH
General
Yes
Check if shoulder belt anchor moves pro- Go to Inspection Chart 1. (See page 80.)
perly.
No
~
Yes
Check if shoulder belt anchor stops midway Check if rail is fouled.
on rai I.
Yes
No
Clear the rail.
Recheck shoulder belt anchor for operation.
I Yes
Check if warning lamp comes on or blinks. Go to Inspection Chart 2. (See page 81.)
No
Yes
Check if fuse is blown. Check and repair cause of trouble; replace
fuse.
No
Motor is faulty. (See page 86.)

r-
After repairs, always disconnect battery cables and then reconnect them.
Otherwise, thuomputer will not function properly.
79
INSPECTION CHART 1
Check condition of warning light for 10

seconds after shoulder belt anchor reaches
the rear.
I Yes
Check if warning light continues to blink. Shoulder belt buckle switch is open.
I
(See page 82.)
No
Yes
Check if warning light remains on after Shoulder belt buckle switch is closed.
blinking for 4 to 8 seconds. (See page 82.)
No
Yes
Check if warning light remains on. Rear limit switch is closed. (See page 83.)
No
Check using ammeter.

Check
without using
ammeter.
Open door for 15 seconds and Measure current from battery
then close it for 15 seconds. while opening and closing
Repeat this procedure 35 door.
times.
No Yes
Check if shoulder belt anchor Check if front limit switch is Check if ammeter reading
moves smoothly. closed. increases when shoulder belt
anchor reaches front end.
Yes
No
O.K.
80
INSPECTION CHART 2
Check if warning light comes on or blinks.

I
Disconnect check connector (1-pole type) and check condition of warning light. I
Yes
Warning light goes out Door switch is closed.
quickly. (See page 85.)
No
Yes
Warning light blinks for 25 Front limit switch is closed.
seconds and then goes out. (See page 84.)
No
Yes
Warning light blinks for 10
seconds and then goes out.
No Yes
Check if shoulder belt anchor Rear limit switch is open.
is at front end. (See page 83.)
No
Front limit switch is open.

(See page 84.)
Yes
Warning light blinks Rear limit switch is closed.
continuously. (See page 83.)
No
Yes
Warning light remains on. Control unit is faulty.
(See page 85.)
No
Reconnect check connector.
81
Shoulder belt buckle switch is closed.
No JI Insert.
Check if tongue is inserted into shoulder belt
buckle.
I
Yes
Close the door.
No
Check if shoulder belt buckle pushes its 1 Shoulder belt buckle is faulty.
switch at anchor latch.
I
Yes
No
Check if shoulder belt buckle switch : Shoulder belt buckle switch is faulty.
connector terminals are open.
I
Yes
No
Check if circuit between body connector
terminal of control unit and ground terminal
: Wiring is shorted.
I
is open.
Yes
1 Control unit is faulty.

I
Shoulder belt buckle switch is open.
Open the door.
No
Check if shoulder belt buckle switch : Shoulder belt buckle switch is faulty.
connector terminals are open.
I
Yes
No
Check if there is continuity between body : Wiring is broken.
connector terminal of control unit and
I
ground terminal.
Yes
: Control unit is faulty.

I
82
Rear limit switch is closed.
Check if rear limit switch terminals are open

No
1 Rear limit switch is faulty.
I
when door is closed.
Yes
No II W··
Check if circuit between rear limit switch Iring .IS sh orte d .
terminal of body connector (at control unit)
I
and ground terminal is open.
Yes
: Motor is faulty. (See page 86.)

I
Rear limit switch is open.
No
Check if rear limit switch terminals are
closed.
: Rear limit switch is faulty.
I
Yes
Check if there is continuity between rear

No
1 Wiring is broken.
I
limit switch terminal of body connector
(on control unit) and ground terminal.
Yes
I Control unit is faulty. (See page 85.)

I
83
Front limit switch is close.
No
Check if front limit switch terminals open Front limit switch is faulty.
when front limit switch is pushed with a
screwdriver.
Yes
No
Disconnect and then reconnect battery Foreign matter caught in rail or insufficient
cables. Check if shoulder belt anchor moves stroke of rail ASSY.
to the front when door is opened.
Yes
No
Check if front limit switch connector Faulty front limit switch or insufficient
terminals are open. stroke of rail ASSY.
Yes
No
Check if front limit switch terminals of body I Wiring is shorted.
connector (on control unit side) and ground
termi nal are open.
Yes
Motor is faulty. (See page 86.)
Front limit switch is open.
No II
Check if front limit switch connector is
connected properly.
Connect.
I
Yes
No
: Front limit switch is faulty.
Check if front limit switch connector
terminals (on switch side) are closed.
I
Yes
No
Check if there is continuity between front
limit switch terminal of body connector
: Wiring is broken.
I
(on control unit side) and ground terminal.
Yes

I
84
Door switch is closed.
No
Check if door switch terminals switch i Door switch is faulty. I
properly when door is opened and closed.
Yes
No
Check if door switch terminals of body i Wiring is broken. I
connector (on control unit side) switch
properly and continuity exists between
respective terminals and ground terminal
when door is opened and closed.
Yes
: Control unit is faulty. (See below.)

J
Control unit is faulty.
Disconnect and then reconnect battery

cables.
No
Check if shoulder belt anchor moves over its
entire stroke when door is opened and
J
closed 5 to 6 times with ignition switch ON.
Yes
No
Check if shoulder belt anchor moves
properly when tested in accordance with
-[ Control unit is faulty.
J
Inspection Chart 1.
Yes
Control unit is O.K.
85
Motor is faulty.
Check if shoulder belt anchor moved

properly in previous checks.
No
~ Control unit is faulty.
l
Yes
-,I Connect.
No
Check if control unit's motor output
connector is connected properly.
I
Yes
No
: Wiring is incorrect or broken.
Check if voltage is produced between motor
terminals of control unit's body connector.
I
Yes
No
Check if voltage is produced across affected -f Control unit is faulty. 1
motor terminals when door is opened and
closed. (Conduct this test with connector
connected.)
Yes
No ,
Check if motor connector is connected
properly.
I Connect. I
Yes
Check if voltage is produced across motor

No rI W··iring .IS bro k en. 1
connector terminals when door is opened
and closed.
Yes
Check if motor pulley moves slightly when

door is opened and closed.
No
: Motor is faulty.
l
Yes
Rail ASSY is faulty.
86
Fuse box
*. 2700 engine model RW
Battery
Fusible link
e (f)j 0.B5~ 3BW 1 3BW
RY
~5B 5W, BW*
~
E
'------"-~
3 W"-- ' " PFFII>CC ON ST
I-- B O O ~ @(Red) ::n
3B
ACC
ST
0 Q
TIc 3B I-+GY
z
G)
) - IGOl( l:!f-RW
® ---' R 1< o
3 3 : m (Black)
r-----=::....:.~-II IChime 1 »G)
::n
»
~
»
z
Q)
...... Combination meter r -______________~R~Y ~R~Y------~ o
0.B5Y --I
@(Black)
::n
RY
~~~5Y oc
®~ RY (Black)
,---+-_ _....:.R,:,,:,W:..jr-1 ~
(D
r
~ r-________________________~0~.B~5.!.JY
0.B5Y
C/) ~------l
0.B5 Y
r--'------------l----~·~85~Y~
0 I'-' Key warning
switch m
~ GY - en
~ ~ _ _ _---l I.G~W~--------------------------~GYYJ rG~Y_ _ _ _ _ _~ I
o
1I
®~
;:+
§" I + - - - - - - l
®alrllll)
RY B RY (Blue)
~ Chime
switch
--o..~
t- BY
B
B
GY
i9 CD GY
@By-ffiGW
L -_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
GW ~~eat belt switch
~B~YjJ~
~~--~
~
o--I
Z
G)
.... 1-----------------t------------------------------------SG~;Jfr~oor switch (LH)
®{I ilI,lll)B (Brown)

@E
'"
a>
@E
'"a> B-ffiGY
@
(1) When chime does not sound and also fasten seat belt warning light does not turn on;
Turn ignition switch to ON

position while driver's seat
belt is not fastened. *1
No
Check if other devices in Inspect fuse, connector and
• Replace fuse if it is blown.
combination meter activate. wire between ignition switch
and timer.
• Repair
wire.
connector and
Yes
No
See if 12V is in RY lead of Poor connection between Repair connector or replace
21-P connector (blue) of timer and its connector, or timer.
meter. defective timer.
Yes
Replace timer circuit in com·

bination meter as timer cir-
cuit is faulty.
*1: Never leave the switch in ON position all the way.
88
(2) When chime does not sound, but fasten seat belt warning light turns on;
Turn ignition switch to ON Confirm that fasten seat belt

position while driver's seat
belt is not fastened. *, warning light in telltale turns
on for approx. 6 seconds.
Use circuit tester, and meas· Inspect connector and wire Repair connector and wire.
No
ure whether voltage at ter- between ignition switch and
minal of combination meter combination meter.
is '2V or not.
Yes
No
Poor connection between Repair connector, or replace
See if timer discharges inter-
timer and its connector, or timer.
mittently out-put voltage be-
defective timer.
tween its chime terminals.
Yes
No
Inspect earth and wire be-
tween combination meter and
Poor connection between
timer and its connector, or
I Repair connector, or wire. I
chime. open wire.
~fif discontinuity
Check for continuity between

terminal of combination
Poor connection or defection
between combination meter I Repair or replace.
I
meter and seat belt switch. and its connector, and be-
tween seat belt switch and
its connector.
Inspect earth wire between Poor connection between Repair connector, wire and
combination meter and combination meter and its driver's door switch.
driver's door switch. connector, or defective wire,
or defective driver's door
switch .
• ,: Never leave the switch in ON position all the way.
89
(3) When fasten seat belt warning light does not turn on, but chime sounds;
Turn ignition switch to ON 1-------0--1 Confirm that chime sounds

position.*, for 6 seconds, and then the
sound dies down.
No
Check if other pilots in com- Blown bulb of fasten seat belt 1-------. Replace bulb, and/or repair
bination meter activate. warning light, or defective connector and wire.
Yes wire, or poor connection.
Poor connection between 1-------0__1 Repair connector, or replace

combination meter and its timer circuit in combination
connector. meter.
*,: Never leave the switch in ON position all the way.
90
m
Temperature
sensor
-
CD
nr+
® @ ~
O.85BW~
17?iT I017 l
w
BV-Ej
o
~
(S.
n
0
/ "- V / "- V /
A
"- V / '" "- /

A
"- ~ ~
V
r+ ]J
A ~
Z
V
/
/ "-
"- /
/ "-
"- /
/ "-
" -
0
CD
G)
0
Check connector
c. »
____ ~G,'Vfj § (Brown)
OW ~ rtJiB-~v an~i-
G)
@
RB B
RS Tv aR ~St~~tne~
WB VB
3: ]J
GV sa ~
W 0
r+ »
s:
mount'"9 bolt)
B " (Green)
a 0
»z
A- A /
11 ~
/ "- / "- / "- / W
12
I "- / "- / "- / R
A
V
A- A A
V
/ W
C
_.
~ 0
-i
/
" V
/ "- / "- /
<
CD ]J
0
To MPFI
(See Fig. ~gJtrol unit ." C
Signal
0 (II
controller
r
~ m
CJ)
CD
~ I
0
en
la,~ h~-~~"'~::::~~ff;~=;:~~=~~~ r+ 0
-i
CD
O.85L
_.
CD
~
~
Z
G)
® (Blue)
CQ
{ ITIIIII ) @ en
B
<(I)
OB:~5j
va
® {lllrl'l} To main fan relay

r+
(Black) RY
To Ale compressor
CD
Sub-fan relay
3 (J)
I
VJ
~ SELF-DIAGNOSTIC PROCEDURE
Turn ignition switch OF F.
Connect terminal BR to terminal GY of

check connector.
Turn ignition switch ON. (engine running)
Drive car at least 10 m (33 tt).
Turn steering wheel at least 90° and wait for

15 seconds.
Disconnect terminal BR from terminal GY.
L No I No
Check if fail lamp blinks.
I I Fail lamp comes on. I : B·11 I
Yes Yes
Troubleshoot in accordance with Turn ignition switch OF F.

display presentation. (See next Check if continuity exists No
page.) between fail lamp and terminal -
YB of signal controller body
harness connector @ .
Yes
Check if battery voltage is
greater than 10 volts.
Yes I No I Repair connections or harness.

I
Replace signal controller.
l Faulty battery or charging circuit. I
92
§J DISPLAY PRESENTATION
Display presentation Cause Refer to
~ System operates properly. -
Lamp remains off. Signal is not emitted from MPFI control unit. B-ll
~ Faulty car-speed sensor circuit. B-3
~ Faulty steering sensor circuit. B-4
~ Faulty temperature sensor circuit. B-5
~ Faulty power steering fluid heater circuit. B-6
Faulty pump motor drive circuit. B-7
~ Faulty pump motor drive circuit. B-8
Faulty signal control power line voltage. B-l0
Faulty power controller control B-9
Example:
• All systems operate properly.
1 second Start pulse alone is emitted.
~ ..... Waveform pattern is repeated.

1 second 1 second
• Faulty car-speed pulse circuit.
. .... Waveform pattern is repeated.

Car-speed sensor
circuit is N.G.
• Both car-speed pulse circuit and pump motor circuits are faulty .
..... Waveform pattern is repeated.

Start
pulse Car-speed sensor Pump motor circuit
circuit is N.G. is faulty.
93
~ FAUL TV CAR-SPEED SENSOR CIRCUIT
No No
Check if speedometer operates properly Determine whether speedometer cable r--
when driving car at speed greater than operates.
10 km/h (6MPH).
Yes
Yes
Replace speedometer.
I Repair or replace
speedometer.
No
Check if continuity exists between car-speed
: Repair connections or harness.
I
sensor and terminal W of signal controller
body harness connector @.
Yes
No
Check if car-speed sensor operates properly. -I Replace speedometer.
I
Yes
94
~ FAUL TV STEERING SENSOR CIRCUIT
No
Check if continuity exists between steering
sensor and signal controller.
I
Yes
Connect positive lead of tester (set in V

range) to terminal B of signal controller
body harness connector @.
Connect negative lead to GND.
Check if tester alternately indicates 0 and

No
l Replace signal controller.
I
4.5 volts when steering wheel is turned
slowly.
Yes
No
I
Check if 4.5 volts are produced at terminal
W of signal controller body harness
I
I
connector CD.
Yes
Remove steering sensor.
No
Check if slit in column turns in response to
steering wheel operation.
: Repair slit or replace column shaft.
I
Yes
95
~ FAUL TV TEMPERATURE SENSOR CIRCUIT

I
No
Check if ambient temperature is above Conduct test in a place where ambient
-lO°C (14°F). temperature is above -lO°C (14°F).
Yes
No
Check if continuity exists between I Repair connections or harness.
temperature sensor and signal controller.
Yes
No
Check if resistance of temperature sensor is I Repair temperature sensor.
5,000 ± 150 n when ambient temperature is
25°C (noF).
Yes
96
~ FAULTY POWER STEERING FLUID HEATER CIRCUIT
No
Check if resistance of fluid sensor is O.5!1. : Replace heater.
J
Yes
I Yes
Check if fusible link is burned.
I
: Replace fusible link.
I
No
No
Check if 12 volts are produced at terminal
I
BW of heater relay body harness connector.
No
Check if 12 volts are produced at terminal W
of heater relay body harness connector.
J
Yes
Connect terminal BY of heater relay body

harness connector to ground.
No
Check if 12 volts are produced at terminal B I Replace heater relay. I
of heater relay body harness connector.
Yes
Disconnect terminal BY of heater relay

body harness connector from ground.
No
Check if continuity exists between BY and B -I Repair connections or harness.
I
terminals of heater relay and their
corresponding terminals of signal controller.
Yes
97
El FAUL TV PUMP MOTOR DRIVE CIRCUIT
Yes
Check if fusible link is burned.
I
: Replace fusible link.
I
No
No
Check if 12 volts are produced at terminal W
of pump motor.
I
Yes
No Yes
Check if 12 volts are produced at terminal L ~ Check if brushes are worn.
of pump motor.
No
Yes
I Replace motor pump ASSY. I I Replace brushes. I

No
II R ' connections
. or h arness.
(J) B, (jJ) Rand @ W terminals of signal
epalr
I
controller body harness connector and their
corresponding terminals of power controller.
Yes
No
Replace power controller.
Recheck if system operates properly when
: Replace signal controller.
I
tested in accordance with procedures under
[[D.
Yes
END
98
~ FAUL TV PUMP MOTOR DRIVE CIRCUIT

I
Connect terminals BR and GY of check

connector.
No
Check if at least 0.5 volts are produced at : Replace signal controller.
terminal W of signal controller body harness
J
connector @ for 10 seconds.
Yes
Replace motor pump ASSY.
99
~ FAULTY POWER CONTROLLER CONTROL
No
Check if continuity exists between terminal -I Repair connections or harness.
I
W of power controller body harness
connector and terminal W of signal con·
troller body harness connector @.
Yes
No
Check if 0.5 volts are produced between : Replace power controller.
terminals Wand B of power controller body
I
harness connector.
Yes
§] FAULTY SIGNAL CONTROLLER LINE VOLTAGE
No
Check if battery voltage is greater than : Faulty battery or charging circuit.
10 volts.
I
Yes

I
100
E FAIL LAMP DOES NOT COME ON
I Yes
Check if fuse is blown. : Check cause and replace fuse.
I
No
Disconnect terminals BR and GY of check

connector.
No
Check if fail lamp comes on. Disconnect signal controller connector.
Ground terminal YB of body harness
Yes connector @ of signal controller.
Yes
Connect signal
controller connector.
I Check if fail lamp comes on.
I
No
No
Start engine. Check if fail lamp power circuit operates f---
properly.
Yes
Replace fail lamp bulb.

I Repair connections or
harness.
No
Check if 12 volts are produced across Repair connections or harness.
terminals RL and B of signal controller body
harness connectors ® and ®.
Yes
No No
Check if 12 volts are produced at terminal Check if continuity exists between terminal f---
Br of signal controller harness connector Br of MPF I control unit harness connector
@. ® and terminal Br of signal controller @.
Yes Yes
Replace signal controller. Check if MPFI control Repair connections or

operates properly. harness.
101
~ FAULTY SUB-FAN CONTROL CIRCUIT - Part I
(The radiator sub-fan will not stop when the steering wheel is turned at least 250 deg/sec_ while the engne is off,
the air conditioner is ON and/or engine coolant temperature is so high the main fan operates_)
Yes Yes
Check if sub-fan operates when air condi- Check if sub-fan operates when terminal LR I---
tioner is OFF and if main fan stops when or YW on sub-fan relay energizing coil side
engine is cold_ is disconnected_
No No
Repair harness_
1 r Replace sub-fan_ J
No
Check if sub-fan control circuit operates Repair in accordance with procedures
properly if test is conducted in accordance described in [[IJ and subsequent steps_
with [[IJ.
Yes
102
~ FAULTY SUB-FAN CONTROL CIRCUIT - Part II

(The sub-fan will not operate when the main fan operates or when the air conditioner is ON.)
No
Check if fail lamp comes on.
I : 8-11 I
Yes
Start engine.
No
Check if fail lamp goes out.
I
JI 81-
I
Yes

LR of sub-fan relay body harness connector
No
1 Repair connections or harness.
I
when main fan operates and/or when air
conditioner is ON.
Yes
Check if 12 volts are produced at terminal L

of sub-fan relay body harness connector.
No
l Repair connections or harness.
I
Yes
Ground terminal YW of sub-fan relay

body harness connector.
No
L Y of sub-fan relay body harness connector
: Replace sub-fan relay.
J
when main fan operates and/or when air
conditioner is ON.
Yes
on
See if resistance is between terminal (8)
of sub-fan motor and vehicle body
No
l Repair harness.
I
(grounding).
Yes
103
No
Check if continuity exists between LY cl Repair connections or harness.
I
terminals of sub-fan relay body harness
connector and sub-fan motor.
Yes
No
Check if voltage is produced at terminal B of ~ Repair or replace sub-fan motor.
I
sub-fan motor body harness connector.
Yes
Disconnect terminal YW of sub-fan relay

body harness connector from ground.
No
Check if continuity exists between YW
terminal of sub-fan relay body harness
: Repair or replace sub-fan motor.
I
connector and signal controller body harness
connector ®.
Yes

I
104
Fusible Ignition
Battery link switch Fuse box
RY
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3W-hTTi JJ
3 B-t±!tj Z
(Black)
G)
Alternator 3B
o
WR
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Z
o
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Combination meter
OJ
r
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warning switch -I
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To lighting switch (
_-+--+--+_______~A!::..jB
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light switch
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link
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9
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Ignition switch
r'----.. OF F ACC
9 Q
6 ¢
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rrrrnT!i Wiper select switch
C.
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sensor
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I
eN
1) Radio
(1) Low sensitivity
Turn ignition switch to ACC.
Check radio for accurate tuning. Inaccurate tuning. Reset tuning knob.
Yes
Check antenna trimmer for prop- Trimmer out of adjustment. Readiust trimmer.
er adjustment.
Yes
~_R_a_d_i_o_i_s_d_e_fe_c_t_iv_e_. . - : - - - - - - - - - -...,..I Repair or replace radio.

No
Installing another antenna to see I-_ _ _ _...
if sensitivity increases.
Yes
Defective antenna grounding or Tighten screws securing antenna
insulation. or replace antenna.
(2) Noisy reception
Start up engine.
No
Check radio for noise while Crunching sound Fuel unit Repair connection at grounded
operating other electrical parts. Howling sound Wiper motor part, or replace condenser.
Yes Scratching sound Ignition coil

Whisling sound Alternator
No
Noise dies when antenna is re-
moved from radio.
Radio is defective.
I Repair or replace radio.
I
Yes
~I Loud noise from outside.

I -I Radio is in good condition.
I
Check antenna feeder and harness

for close arrangement.
I No
I Defective antenna grounding.
I -I Check and repair grounded part.
I
Yes
I Arrange feeder wiring apart from

harness.
116
2) Auto antenna
Turn radio on.

-- Turn radio off and con·
nect antenna harness.
t No
Check if terminal volt·
1st
replace·
Check if antenna har·
~ ~
Check if sound of mov· OK age of antenna harness ment
ness is connected pro· Replace radio.
ing antenna is heard. connector is at least 10
perly.
volts. If still NG
Yes
OK
Broken or shorted
Check if antenna fu Ily
No antenna harness.
extends and sound
Check and repair.
stops.
Yes
Replace antenna.
Install former radio.
1st
Turn radio off.
replace·
ment
Yes
Check if terminal volt·
~
Check if sound of mov· age of antenna harness No 1st replacement
Replace radio.
jng antenna is heard. connector is less than 1
volt. If still
Yes
NG
Repair shorted antenna
Check if antenna fully
harness (positive side).
extends and sound
stops.
Yes
No problem.
Details of antenna harness connector
----t--~
GrOUnd (0 volts)
Terminal
(Voltage produced here
should be at least 10
volts when radio is on
and less than 1 volt Battery terminal 8),
when radio is off.) 10 volts. min.
Female connector (body side)
It takes approximately eight seconds for antenna to extend completely.
117
0'>
I
CAl
*: 2700 engine model RW

@
E±m-1.25LB
Cigarette
lighter
Ignition switch
ST
3BW
1.25 LB _.
CC
C» ~
~
CD ~
IG
r+ Z
A (Black) r+ G>
3L CD
o
3W~3L
@
rnO. 85B
_.
r-
CC
»
G>
(Black) ~ ::rJ
@ r+
CD
»
~
~
»
z
00
o
Horn (RH)
-I
::rJ
Combination switch
oC
Horn switch CD
r
m
(J)
::r:
o
- - - - - 0.85GB
o-I
r--=~-+--------------~H
Horn (LH) 0.85 RW
r-------+----------------, Z
G>
0.85 RW ~ 0.85GB
@)
Diode box
1) Cigarette Lighter
Cigarette lighter plug does

not come out.
Check with ignition switch

turned to ACC.
Yes
See if fuse in cigarette lighter
circuit is blown.
1
Replace fuse if blown.
I
No
No
Check for voltage of 12V at Check and repair harness,
fuse box cigarette lighter connector, fusible link, and
circuit terminal. ignition switch.
Yes
No
Check for voltage of 12V at
cigarette lighter harness ter-
1
Defective cigarette lighter.
I- - - -..1 Replace plug or socket.
minal.
Yes
Defective groundin g. -----1.~ Repair grounding harness or

L..-_ _ _ _ _ _ _ _ _ _ _......I groundpart.
119
2) Horn
Horn will not sound.
I Yes I Fuse is blown.

See if horn circuit fuse in fuse I Replace fuse.
I
box is blown.
No
No
I Break in harness between bat- J Repair harness and connector.
Check for voltage of 12V be-
tery and horn.
tween horn connector (power
source) and ground (body).
Yes
No J
Determine if horn sounds by Horn is defective. I Replace horn.
L J
grounding horn terminal (ground-
ing side).
Yes
Ground wire in steering wheel to

see if horn sounds.
I No Break in harness between horn
grounding terminal and combina-
I Repair harness and connector.
I
tion switch.
Yes
I Repair faulty contact between

brush on combination switch side
and ring on steering wheel side.
Either horn switch or grounded J Repair horn switch or grounded

part of steering column is de-
fective.
part of steering column.
I
Horn has low volume or cracked
or vibrating tone.
!
! No
Check mounting bolts for loose- J Repair defective points.
ness, horn cord for proper ten-
sion, and horn for interference
with other parts.
tYes
Start engine (increase voltage to I J Low sound. I Loosen lock nut, and turn adjust-
normal level), and sound horn. ing screw counterclockwise at
pitch of about 20° .
(See Note'!
--t Cracked sound.

J
Loosen lock nut, and adjust by
turning adjusting screw clockwise
20 to 30°.
(See Note.)
Vibrating sound. Loosen lock nut, and adjust by

I turning right and/or left et pitch
of about 20° .
Note: Be sure to ti 9hten lock nut
firmly after adjustment. (See Note'!
120
0
-
0
n
Fusible ;:'
Battery
link
8 ~I
(J .-0.85 '!
3 BW ~r" Ignition switch Fuse box
RW
I ........t----I-o-'-_......("J:::H----'"
~_O ....,. ~ OF F ACC ON 5T I
~Ttt~~rrr
J
- 1.25 f)B~5_W...:..,_S_W_*-+-........
1 __ 3_W--1r- ~ 8 Q C 0
J ~lAcc 6 ()
E
3L ST c)
IG () () 3BW
~
® "- R () 0.S5 LR ( :0
3W$3L
rrrrrl'1~t
I
Z
G)
(Black) o
3L
»
G)
:0
® »
rrlT7'
G)
~G ~
?
~
»z
o
-
N
G)
--t
:0
@ 0.S5R ® o
c:
OB~:ffIIIIJI) OJ
r-
m
.__-----.---. 0.S5 LR T _________LR_f
" 0.S5 LR r-\-'-L=R-=---_ _~ j...L_R_ _ _ _ _ _ _ _---'
en
:J:
0.S5W I r 0.S5G o
~~~~---------~~ ~~~------------~
g
0.S5 R 0.S5 R To lighting switch z
Ci)
a.--=--------------------i ....--------\!.... (See Fig. 3S.)
®
i~I,II~lIlf
0.S5 R (Black)
0)
I
(,.)
CD
I
VJ
@
~
e
Battery
ffi+ ~
Fusible link
.......2'-'55~BD+
- 0,..._--+L..!l0'1
~ ~8W.
15;...;W~·,.....
r __
"
3W-1- f - B
~cc
Ignition switch
bFF~CON
0 (
6 (
ST 8aBGR
_.
:::J
c..
E
ST
::~o~~ o
~
~----~~-~--4~------~L- ~
*: C ;Q
2700 engine model (1) Z
Rear defogger
-It
G)
I ~_ _~~~
switch
o
GR
~----0-.8=5B-1J I~___~_~
~ I (Q
(Q
o
r
5>
[ 11,1'\1
@
~"l==T=1: ;: : ;: : :111 ]
...
(1) G)
:0
} \ »
0.85 B GR (Black)
~
»
z
o
~
@~ :0
I t::t:l!fj-1 .25 lW 1.25B
@ oC
~_ _ _ _ _ _ _ _ _ _ _ _ _ _ _G_RI ~G~R~________~
~1.25B CD
(Black) r
Combination meter m
(J)
1.25lW
~ III I I I) :I:
tr~
RY Rear o
Rear
defogger
~
defogger (Black) GR
Rear
o
GR GR relay
defogger ~
z
~
RY 1.25 B L - - L - - _......
J G)
RY
RY~1.25lW
GR~1.25B
@ RY ® @(Blue) @
~IIIITII)§mm
(Brown) GR RY (Blue) OJ
~0.85B
!=I (Black)
i}l
E @
(1) Meter pilot lamp does not come on.
~ Yes
I Replace.
Check if fuse is burned out.
t No
Check if 0 volts are produced

at GR lead wire then
No
Faulty switch or poor con-
nection or discontinuity be-
I Repair or replace.
I
defogger switch is ON and 12 tween switch and ground.
volts are produced when
switch is OFF.
1Yes
Check if pilot lamp is burned
Yes
I Replace. I
out.
INO
Discontinuity or poor con-
nection between meter and
J
I R ·
epalr. I
switch.
(2) Deffoger does not operate.
Check if connector is proper-

ly connected to printed heat-
No
I Connect securely. I
ing wire receptacle.
Yes
No
Check if 12 volts are present Discontinuity or poor con- Repair.
at printed wire harness connection between relay and
nector when switch is ON. printed wiring harness.
Yes
Discontinuity or poor con-

nection between printed
I Repair.
wiring harness and ground.
123
:D m
I
CD W
3
o
r+
Fuse box CD
Battery
8 ®
Fusible
link
1 3 W .-- t-- "B" OF F ACC
Ignition
switch o
o
..-
r-:-:;-:-l ON ST
().o+__~~<";";;rl2:>5-.J~Bo+..:5~W::.!.-=8,:,;,W:"'*~""-_-::-:--j
...... 0 Q
L..::-...=..J 3 L t-- lAce 6 Q 1.25LB
::l
r+
T ST
IG
J
0
1.25LB* ~
o ::IJ
@'-L...;.;..R-'---'----'--....L....::-I
3W~3L
t1lj (Black) 3 L
-
CD
Q.
Z
G)
:D o
»
._.
CD
m
<
G)
::IJ
»
® (Black)
CD ~
Q:- ~
®
~I)l
r
~ 0::1
®
rr.:+- ~ »
z
..s:_.
1.25 LB
0.75WR ~0.75L
o
..
Rearview ..-- rn-O.85 B
0.75LB -EJ:3.0.75 G
~ blr
LH0B=
mirror (RH)
.--- 0.75L r - ~_0.85Br
_ _ _~r- 0.85 Br 0::1
-i
f I-- 0::1
::IJ
M +RH
t---
0.75WR 0.85L O.85L
O.85LW
0.75 LB 0.75 L
EfpJ ~ ffTl~:;~ ~B
0.75B Remote controlled
rearview mirror o o
0.75G 0.85LW 0.75 W switch C
~,~
r--
0.75LB 0.85G 0.85G G WR r-~-r-r~-'-'--'-'--'-~~~-; (]]
~ ~ r
t--L.- L--
UP
@ O.75LD .H CH"' ON ••
m
0.85G~O.85L 0.75wB r 1.25LB .--- C/)
0.85 Br~0.85LW ~,...-,...-=-t-=->~ I--- 1 9
0.75 Y ~ ~ ~ ~ l..-_ _ _ _ _ _0_.7_5_B--1 r---1.-2"'*....
T19+H-I+I
9 -++H9f++-+++--'H+-H+-iH_-__t--::--, I
Rearview ® (Blue) 0.75L ~ ~~ ; ~C><~6::.'.J.+.I.I:-=+I6H-1-HII-H--+++-H+--H+-iH_r____t_t-, o
"'rx:~-.J.+.I.I_+==-I+~b:..j..=-+++-1F++~+-lH_r__H_t-+' o
=
mirror (LH) 0::1 I 0.75 L
LH'@ ~~~I~-------------------0-.~75~LB~ r__~J~O~)~~~~+-~~~~~~~~ -i
t M t RH
,------
---,~:~.~~5-L-------------------t--r-t-1111 0.75 W
0.75Y
~1_-:4__-+-_4_-+-____+-+-____+-+---+-+--+_+_-t-I Z
I r--~64-~~_+-4-+--4-4--+~-r~---1
r__
G)
t~
0.75LB WR 1
M tDN :== ~G~---------------------------------------G_;~r--~8~_L_L~~_~~_~~__~__~

UP '--
WR +=r.+0.75 L
0.75LB~G
@
Mirror will not move. I
Set ignition switch to "ACC".
Check if fuse is not blown.

I
Yes
I Replace fuse. I
No
No
Check if 12V appears in LB Repair wiring between fuse
wire of 11-pole connector for and switch.
switch wiring.
No
No
Check if 12V appears in each wire of 11-pole con- Check and repair wiring be-
nector for switch wiring at each switch position. tween motors inside mirror
and switch.
~
Changeover Wire Wire Wire Wire Wire Wire
switch L W Y LB WR G
Right OV 12V 1
Left 12V OV Check and repair motors
Right side inside mirror.
Up 12V OV
Down OV 12V
Right OV 12V
Left 12V OV
Left side
Up OV 12V
Down 12V OV
Yes
• Repair or replace switch .

• Check and repair ground
line (B wire) of 11-pole
connector.
125
0')
." "tJ
~.
o I
-
0)
Fuse box
~
...
CD
CAl
ST
RY
:E
3B RY ® JJ
Z
: (11111 j) G>
®> - (~--'I 0.75RB
-<
o
0.75RWaO.75R
'- !
~ ~ ',_.'
10.75L
Main switch
»
G>
075RB 0.75LB;;:'" Power window relay
:II r- '" B E CONTROL F. R JJ
"'r---'--'~:-:::ru--'~-::1~
0.75L
r- 0.75 RB
OJ ~ UNIT
.<>+-f-o
MOD
~@
r--
OJ
;; @ »
.. ~ fo7§L
0.75 LB ~~
~
u
r-t-C
i 0-
10:- ~
~2WB
@
""~
0.85RY~2W
s::
u
0
,
~ _ 1<1
..H'
...., 2WiT I - -
2W r-
..., " o o ...,
0.85B.f!l::!t 2 R »
z
bo
~
A
H
0
u
::; ::;
'"
:II
-<
OJ
:II
o
LOCK
~ 2WB~ -i
~ L---------------1-----~R~Y~·I 1100.~. 88~55~FR_Y____________~ JJ
I
0000
0.7~Y
0.75W
0.75WL
0.75LB
r
oC
@1-=+2WB
~ ~~ ~ O.7SG R y m (Red) OJ
-< ::; r;; ~ 1.25 B 1.25 R r
@@:1.25B m
CJ)
2 2R
1.25 R 2R 1.25R I
@~~
1.25 B 1.25 B 0.85B o
0.75R~'--"; ~ ~
0.75 W r- 0.B5 RL
0.75y 0.B5 y
0.85RL
0.85Y Control
o-i
unit
0.75G 0.85G 0.85G
0.75L I :
0.75 L 0.85L Z
'--' - 0.85 L
G>
0.75 R 0.85 RB 0.85RB
0.75 WL 0.85 LB 0.85RL
Power window (0 0 0.75 LB
~
0.85 RW
0.85G~0.85 RB
I
motor (LH) 0
0.85B~0.85Y
0.85L 1.25R
0.75 LB
0.75WL~0.75L
0.75W~0.75R
0.75Y 0.75G
(1) All motors do not operate.
Turn ignition switch "ON".
.. LYes
See if fuse in fuse box and fusible link are
blown.
Replace fuses and fusible link. I
No
No
See if lock switch in main switch panel is in Set lock switch to "OF F".
"OFF".
Yes I
No
See if voltage is approx. 12V at terminal (W)
of breaker.
I Repair connector or wiring.
I
Yes
Replace breaker or repair wiring between
See if voltage is approx. 12V at following ter·

(1) No I breaker and relay.
minals of relay.
(1) terminal (W)
(2) No
(2) terminal (RY) .1 Repair connector or wiring.
(3) terminal (R or B)
Yes
I (3) No
I Replace relay.
I
No
See if earth wiring (B) of relay is normal.
I
~ Repair wiring or fitting screw.
Yes
No
See if voltage is approx. 12V at connector (R)
of main switch.
I Repair connector or wiring.
I
Yes
See if earth wiring (B) of main switch is normal.

No
I Repair wiring or fitting screw.
I
Yes
Replace main switch.
127
(2) Passenger's window operation is defective.
See if passenger's window operation is normal

by means of main switch.
I--N_o_ _ _ _ _~Jl Replace motor or main-switch. I
Yes
Replace sub-switch, or wiring and connector.
128
,

(3) Driver's window operation is defective.
See if driver's window operation is normal by Refer to previous articles (1) and (2).
means of main switch.
I Yes No
No
See if resistance ison between terminal (8) of I Yes See if voltage is about 12V at terminal (Y or G)
control unit and vehicle body (grounding). of control unit while setting main switch to UP
No or DOWN position.
Yes
Repair wiring between control unit and vehicle
body, or connector. Replace control unit.
Turn ignition switch "OFF".
No
on
See if resistance is between following termi· I Repair wiring or connector.
nals and earth.
(1 ) terminal (8) of control unit
(2) terminal (8) of main switch.
Yes
No
on
See if resistance is between following termi· : Replace auto switch.
nals and earth.
(1 ) at raising; (G) and (W)
(2) at lowering; (Y) and (W)
Yes
No
See if resistance ison between wiring (R or Y Repair wiring between control unit and main
or G or RL) of control unit and wiring (R or Y switch, or connector.
or G or W) of main switch.
Yes
Turn ignition switch "OFF".
See if voltage is approx. 12V at terminal (R) of

control unit.
No
IRepair wiring. I
Yes
129
c 0)
I
o eN
Fusible Fuse box
o
~
Battery
link Ignition
8 <f?1 switch r-
0.5 G
~5W,8W*
2 WB
3 W
f"-., OFF ACC ON
r--_ B 00
5T
o(')
ACC 0 Q
ST I ~
3 B RY
0
<lID"-
- IG
LA,,-,--,----,----,,--,,--,
tn
<o ~
3WOO3B
r+ ::IJ
(Black) 3 B
WL,O.85Lg*
CD Z
3 G>
a
2 WB »
G>
::IJ
»
~
RY CIT) Jl
-< »z
....eN
o (111111) o Jl
-<
WL, 0.85 Lg*
r-
1-0:..:..7....:5....:W-'-_
.----
Y _ _ _ _ _O_.7_5_W_Y_j
0.75 B
~
pa I LOCK
Door lock
a
-I
- I
-A. I K switch (LH) ::IJ
1.25 R
1.25W
0.75 R
0.75W
O.75R
0.75W := oC
'- p ~ L-..l_ _ _ _--J
OJ
Combination meter ®
1.25 R
--
~ i»
U1
0.85 L g * m
WL
1.25 W ~25
....
U1@164
C%I
0.75WymO.75W
0.75 B 0.75 R
r
m
en
RY
RY
l'
J
{I 111 fI 1 11rJl~
1.25W
:" ~ til U1
@
T---<C%I
o
be> rnO.85B
U1 @ J:
o
o-I
(Black)
Jl ::;;
~Door
lock
1.~wrQThW
!@ QThW'----
Z
G>
~
YB
L----~1~.2=5~R~ ~0~.7....:5-R------~0~.7~5-R_j ~
: ~ LOCI<
Door lock
YB O.75Y 0.75Y 11
..",,00<1 actuator (RH)
L-_ _ _ _ _ _ _ _ _ _ _ _ _ _ _~~ ~~~-----~~~ r_ ~
_
® B L... 0.75B 0.75 B ~r-L1======~

1.25W~YBB 0.75B~0.75.Y
1 .25 R t!1:!l- 0.75 R rn 0.75 W
@ (Green) ®
CJ)
Fusible
link
"C
.------
2.0L
CD
0--.0 CD
O.85~
~
--v
Ignition switch
Fuse box
c.
:t>
~
~5!!...
~
8W
'-0+-----..---1
l' 3W
38
r--
-
~OFFACC
B
ACC
ST
Q (
0
ON
(
ST
~
(
-
Q)
~
, ---' I G
R
( (
(
RY
3
~
3W~
tl!E-3B :IJ
@(Black) 38 Z
G)
RY®
0
@(Blue)
:fi
-<
»
G)
:IJ
»
Combination meter ~~W ~
LW »
Co)
~
®~ I~ I II IJ Alarm I Lr-~_W _ _- - .
@ ~
I
Z
0
LW

1988 Subaru XT Service Manual

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1988 Subaru XT Service Manual

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II--t-------+--- § E C T rr 0 N Jl t----+--------+-+--+---+---+---+---+-----+---+-+--+--+---+-+--+-----+--+---t---J-----+----+-+-+-+-+--+--+---i

FUJI HEAVY INDUSTRIES LTD.

How to use this manual

"ALPHABETICAL INDEX" is also provided at the last page in each volume.

Not to be reptoduced in whole or in part without the prior written permission

[j] GENERAL SECTION

PERIODIC MAINTENANCE SERVICES 1 -5

!55i1..l~1==I1..I XT . ................................................. ~~ .....

MODEL FWD 4WD FWD 4WD

MPFI MPFI MPFI MPFI MPFI MPFI MPFI

Overall length mm (in) 4,510 (177.6)

Overall width mm (in) 1,690 (66.5)

*1 435 *2 455 *2 455 *2 510 *3 460 *3 510 *3 515

*1 1,085 *1 1,145 *1 1,170 *3 1,255 *3 1,290 *3 1,330

660 690 690 745 695 750 750

1,400 1,560 1,560 1,630 1,620 1,695 1,695

Seating capacity persons 2 4

*1: The weight of power steering is included.

1st 3.636 2.785 3.545 2.785 3.545 2.785

2nd 2.105 1.545 2.111 1.545 1.947 1.545

5th 0.885 - 0.871 - 0.780 -

Reduction gear Final Type of gear Hypoid

Transfer Type of gear - Helical - Helical -

*1: MacPherson strut type, Independent, Coil spring

Power steering fluid Q (US qt. Imp qt) - 0.7 (0.7,0.6)

General Precautions Precautions while working

8) Pneumatic suspension models w/height control .....

Precautions in handling a full-time 4WD vehicle 2) Testing Procedures

• Place the garage jack and safety stands in their

Fig. 7 Differential lock switch

(®) =:~ DOOR LOCK ((!!) ::e DOOfI LOCK

• For safety, start in second gear. Never make any

Since the speedometer detector is on the engine side of the

\ \ ..... _-,,: \'''' - ... ,/

• In order to prevent the vehicle from jumping off

• For safety, start in second gear. Never make any

• Chassis Dynamometer Test 2) Towing with Front Wheels Raised

a. In doing the testing, be sure to jack up both the left and

• Towing Towing distance within. Towing speed under

Fig. 16 Rope towing

a. Before towing, check transmission oil and differential oil

the car is left in the 4WD mode, it will surge abruptly

Vehicle Identification Numbers (V. I. N.)

DL (MPFI, 5MT) JF1AX422XJB 300001 and after

XT6 (MPFI,4AT) JF1AX842*1XJC 300001 and after

*1: For CANADA, "B" instead of "2"

~------ Sequential number

~--------------- Series and engine type

Identification Number and label locations

2. Engine Serial Number

Transmission serial number

Engine, transmission and vehicle identification numbers are

4. Safety Certification Plate 6. Vehicle Identification Number Plate

7. Color Code Label

5. Vehicle Emission Control

1. T.P. label and "R DOT" label

CD Front hood ® Rear quarter

(j) Trunk lid

@ Front bumper ® Transmission

Recommended Fuel, Lubricants, Sealants and Adhesives

1 435 2 455 2 455 2 510 3 460 3 510 *3 515

1 1,085 1 1,145 1 1,170 3 1,255 3 1,290 3 1,330