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رد: رابطة مالكى الاكسل
كتالوج اكسيل
HYUNDAI 1 9 9 1 CONTENTS Shop Manual FOREWORD This shop manual is intended for use by service technicians of authorized Hyundai dealers to help them provide efficient and correct service and maintenance on Hyundai vehicles. To ensure customer satisfaction with Hyundai products, proper service and maintenance by Hyundai technicians is essential. Consequently, it is important that service personnel fully understand the contents of this manual, which should be kept in a handy place for quick and easy reference. All the contents of this manual, including photographs, drawings, and specifications, are the latest available at the time of printing. As modifications affecting service occur, dealers will be provided technical service bulletins or supplementary volumes. This manual should be kept carefully up-to-date upon receipt of the new information. Hyundai Motor Company reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products previously manufactured. This book may not be reproduced or copied, as a whole or as a part, without the written permission of publisher. APR. 1990, Printed in Korea TITLE SECTION General Information Lubrication and Maintenance Engine Cooling System Engine Electrical System Intake & Exhaust System Emission Control System Fuel System Clutch (Hydraulic type) Clutch (Cable type) Manual Transaxle Automatic Transaxle Drive Shaft and Front Axle Front Suspension Rear Suspension 00 10 20 25 27 28 29 31 41 41A 43 45 49 54 55 Steering System (Manual and Power) 56 Brake System 58 Body (Interior and Exterior) 60 Body Electrical System Air Conditioning System Appendix (Electrical Wiring System) 90 97 WS GENERAL INFORMATION GENERAL INFORMATION GENERAL INFORMATION HOW TO USE THIS MANUAL This manual is divided into 20 sections. This first page of each section is marked with a black tab at the edge of the page. You can quickly find the first page of each section without looking through a full table of contents. Each section includes the essential removal, installation, adjustment and maintenance procedures for servicing all body styles. This information is current as of time of publication. An INDEX is provided on the first page of each section to guide you to the item to be replaced. TROUBLESHOOTING tables are included for each system to help you diagnose the system problem and find the cause. The repair for each possible cause is referenced in the remedy column to quickly lead you to the solution. DEFINITION OF TERMS Standard Value Indicates the value use as the standard for judging the quality of a part or assembly on inspection or the value to which the part or assembly is corrected and adjusted. It is given by a tolerance. Limit Shows the standard for judging the quality of a part or assembly on inspection and means the maximum or minimum value within which the part or assembly must be kept functionally or in strength. It is a value established outside the range of standard value. NOTE, WARNING AND CAUTION NOTE A point of information. WARNING Information about an activity that could cause damage to the vehicle. CAUTION Information about an activity that could cause injury or damage to the driver, occupants or repair personnel. ABBREVIATIONS MPI: Indicates Multi Point Fuel Injection system. FBC: Indicates Feedback Carburetor system. 0 0 - 2 GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER LOCATION The vehicle identification number (V.I.N.) is stamped on the upper right side of the cowl top front panel. 1. World manufacturer’s identifier code KMH - Hyundai Motor Co., Korea 2HM- - Bromont Assembly Plant, Canada 2. Drive line type V - For LHD (EXCEL) U - For RHD (EXCEL) 3. Body Type A - 5 Door sedan F - 4 Door sedan D - 3 Door sedan 4. Body style & version 1 - Standard 2 - Deluxe (GL) 3 - Super deluxe (GLS) 5. Restraint type 1 - Active system 2 - Passive system 6. Engine type M - 1298 cc J - 1468 cc 7. Check digit Mathematically determined to validate frame numbers 8. Model year L - 1990 N - 1992 R - 1994 M - 1991 P - 1993 9. Plant code U - Ulsan plant B - Bromont plant 10. Serial number 000001 through 999999 0 0 - 3 GENERAL INFORMATION ENGINE IDENTIFICATION PLATE The engine identification plate is stamped at the right front side on the top edge of the cylinder block. ENGINE IDENTIFICATION NUMBER Engine identification number consists of 10 digits. 1. Engine fuel G : Gasoline 2. Engine range 4 : In line 4 cycle 4 cylinder 3. Engine development order A-Z : 4. Engine capacity J : 1468 cc M : 1298 cc 5. Product year 6. Engine production sequence number 000001-999999 0 0 - 4 PROTECTION OF THE VEHICLE Always be sure to cover fenders, seats, and floor areas before starting work. CAUTION: The support rod must be inserted into the hole near the edge of the hood whenever you inspect the engine compartment to prevent the hood from falling and possibly injuring you. Assure that the support rod has been released prior to closing the hood. Always double check to be sure the hood is firmly latched before driving away. A WORD ABOUT SAFETY The following precautions must be followed when jacking up the vehicle. 1. Block wheels. 2. Use only specified jacking positions. 3. Support vehicle with safety stands (jack stands) Refer to the page 00-10. 4. Start the engine only after making certain the engine compartment is clear of tools and people. 0 0 - 5 GENERAL INFORMATION PREPARATION OF TOOLS AND MEASURING EQUIPMENT Be sure that all necessary tools and measuring equipment are available before starting work activity. SPECIAL TOOLS Use special tools when they are required. REMOVAL OF PARTS First find the cause of trouble and then make sure whether removing or disassembling is required before starting the job. DISASSEMBLY If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in a way that will not affect their performance or external appearance and be identified so that reassembly can be performed efficiently. 1. Inspection of parts Each part when removed should be carefully inspected for wear, deformation, damage, and other problems. I 0 0 - 6 GENERAL INFORMATION 2. Arrangement of parts All disassembled parts should be carefully arranged for reassembly. Be sure to separate or otherwise identify the parts to be replaced from those that will be reused. 3. Cleaning parts for reuse All parts to be reused should be carefully and thoroughly cleaned by the appropriated method. PARTS When replacing parts, use HYUNDAI genuine parts. REASSEMBLY Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. If removed, these parts should be replaced with new ones. 1. Oil seals 2. Gaskets 3. O-rings 4. Lock washers 5. Cotter pins (split pins) 6. Nylon nuts 0 0 - 7 GENERAL INFORMATION Depending on where they are; 1. Sealant should be applied to gaskets. 2. Oil should be applied to moving components of parts. 3. Specified oil or grease should be applied at the prescribed locations (oil seals, etc.) before assembly. ADJUSTMENTS Use gauges and testers to correct adjustments to standard values. ELECTRICAL SYSTEM 1. Be sure to disconnect the battery cable from the negative (-) terminal of the battery. 2. Never pull on the wiring when disconnecting connectors. 3. Locking connectors will click when the connector is secure. 4. Handle sensors and relays carefully. Be careful not to drop them or hit them against other parts. RUBBER PARTS AND TUBING Always prevent gasoline or oil from touching rubber parts or tubing. 0 0 - 8 GENERAL INFORMATION PRECAUTIONS FOR A CATALYTIC CONVERTER CAUTION: If large amounts of unburned gasoline flow into the converter, it may overheat and create a fire hazard. To prevent this, observe the following precautions and explain them to your customer. 1. Use unleaded gasoline only. 2. Avoid prolonged idling. 3. 4. 5. Avoid running the engine at fast idle speed for more than 10 minutes and at idle speed for more than 20 minutes. Avoid spark jump test. Spark jump only when absolutely necessary. Perform this test as rapidly as possible and, while testing, never race the engine. Avoid prolonged engine compression measurement. Engine compression tests must be made as rapidly as possible. Do not run engine when fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter. 6. 7. Avoid coasting with ignition turned off and prolonged braking. Do not dispose of used catalyst along with parts contaminated with gasoline or oil. CATALYTIC CONVERTER INSPECTION Inspect for damage, cracking or deterioration. Replace if faulty. CAUTION The catalytic converters require the use of unleaded gasoline only. Leaded gasoline will destroy the effectiveness of the catalysts as an emission control device. Under normal operating conditions, the catalytic converters will not require maintenance. However, it is important to keep the engine properly tuned. Engine misfiring may cause overheating of the catalysts. This may cause heat damage to the converters or vehicle components. This situation can also occur during diagnostic testing if any spark plug cables are removed and the engine is allowed to idle for a prolonged period of time. 0 0 - 9 GENERAL INFORMATION JACK POINT When using a single-post lift When using a free wheel type auto lift When using double-post lift GENERAL INFORMATION JACK POINT When using a floor jack When using the jack provided with the vehicle (for reference) NOTE Do not support car at locations other than the specified support points. This will cause damage etc. to the body. 0 0 - 1 1 GENERAL INFORMATION STANDARD PARTS TIGHTENING TORQUE TABLE Bolt nominal diameter (mm) M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 NOTES Pitch (mm) Head Mark 4 Torque Nm (kg.cm, lb.ft) 0.8 3-4 (30-40, 2.2-2.9) Head Mark 7 5-6 (50-60, 3.6-4.3) 1.0 5-6 (50-60, 3.6-4.3) 9-11 (90-110, 6.5-8.0) 1.25 12-15 (120-150, 9-11) 20-25 (200-250, 14.5-18.0) 1.25 25-30 (250-300, 18-22) 30-49 (400-500, 29-36) 1.25 34-44 (350-450, 25-32) 59-78 (600-800, 43-58) 1.5 74-83 (750-850, 55-60) 120-135 (1,200-1,400, 85-100) 1.5 110-125 (1,100-1,300, 80-95) 180-200 (1,800-2,100, 130-150) 1.5 155-175 (1,600-1,800, 115-130) 260-290 (2,600-3,000, 190-215) 1.5 220-240 (2,200-2,500, 160-180) 350-410 (3,600-4,200, 260-300) 1.5 290-320 (2,900-3,300, 210-240) 470-540 (4,800-5,500, 350-400) 1.5 360-410 (3,700-4,200, 270-300) 600-680 (6,100-7,000, 440-505) 1. The torques shown in the table are standard values applicable to tightening performed under the following conditions: 1) Nuts and bolts are made of steel bar, and galvanized. 2) Galvanized plain steel washers are inserted. 3) All nuts, bolts, and plain washers are dry. 2. The torques shown in the table are not applicable: 1) Spring washers, toothed washers and the like are inserted. 2) If plastic parts are fastened. 3) If self-tapping screws or self-locking nuts are used. 4) If threads and surface are coated with oil. 3. It should be standard practice to reduce the torques given in the table to the percentage indicated below: 1) If spring washers are used. 85% 2) If threads and bearing surfaces are stained with oil 85% 0 0 - 1 2 |
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رد: رابطة مالكى الاكسل
BODY ELECTRICAL SYSTEM Return To Main Table of Contents GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ELECTRICAL COMPONENT LOCATION . . . . . . . . . . . . . . . . 7 FUSIBLE LINKS AND FUSES . . . . . . . . . . . . . . . . . . . . . . . . . 16 IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 MULTIFUNCTION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 INSTRUMENTS AND WARNING SYSTEM . . . . . . . . . . . . 22 LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 AUDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 WINDSHIELD WIPER AND WASHER . . . . . . . . . . . . . . . . . . 55 CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 ClGARETTE LIGHTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 SUN ROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 TIME AND ALARM CONTROL UNIT . . . . . . . . . . . . . . . . . . 68 TAIL GATE OPENER (TRUNK LID OPENER) . . . . . . . . . . 73 A/T AND KEY LOCK CONTROL SYSTEM . . . . . . . . . . . . . . . 75 GENERAL GENERAL SERVICING THE ELECTRICAL SYSTEM 1. Prior to servicing the electrical system, be sure to turn off the ignition switch and disconnect the battery ground cable. NOTE: On the course of MPI or ELC system diagnosis, when the battery cable is removed, any diagnostic code retained by the computer will be cleared. Therefore, if necessary. read the diagnostic codes before removing the battery cable. 2. Secure the wiring harnesses by using clamps so that there is no slack. However, for any harness which passes to the engine or other vibrating parts of the vehicle, allow some slack within a range that does not allow the engine vibrations to cause the harness to come into contact with any of the surrounding parts, and then secure the harness by using a clamp. 3. If any section of a wiring harness interferes with the edge of a part, or a corner, wrap the section of the harness with tape or something similar in order to protect it from damage. 4. When installing any of the vehicle parts, be careful not to pinch or damage any of the wiring harnesses. 9 0 - 2 GENERAL 5. The sensors, relays, etc, must never be subjected to strong shocks. Do not allow them to fall and do not throw them when handling. 6. The electronic parts used in the computer, relays, etc. are readily damaged by heat. If there is a need for service operations that may cause the temperature to exceed 80°C (176°F). remove the electronic parts beforehand. 7. Loose connectors could be troubled. Make sure that connectors are connected securely. 8. When removing a connector, be sure to pull only the connector, not the harness. 9 0 - 3 GENERAL 9. Remove connectors which have catches by pressing in the direction indicated by the arrows in the illustration. 10. Connect connectors which have catches by inserting the connectors until a “snap” noise is heard. 11. When using a circuit tester to perform continuity or voltage checks on connector terminals, insert the test probe from the harness side. If the connector is a seales connector, insert the test probe in through the hole in the rubber cap for the electrical wires, being careful not to damage the insulation of the wires; continue to insert the test probe until it contacts the terminal. 12. In order to avoid overloading the wiring, take the electrical current load of the optional equipment into consideration, and determine the appropriate wire size. Test probe Connector 9 0 - 4 GENERAL CHECKING CABLES AND WIRES 1. 2. 3. 4. 5. 6. 7. 8. 9. Checking the terminal for tightness. Check terminals and wires for corrosion by battery electrolyte, etc. Check terminals and wires for open circuit or impending open circuit. Check wire insulation and coating for damage, cracks and degrading. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. Check for incorrect wiring. Check that wirings are so clamped as to prevent contact with sharp corners of the vehicle body, etc. or hot parts (exhaust manifold, pipe, etc.). Check that wirings are clamped firmly to secure enough clearance from the fan pulley, fan belt and other rotating or moving parts. 10. Check that the wirings between the fixed parts such as the vehicle body and the vibrating parts such as the engine are made with adequate allowance for vibrations. 9 0 - 5 GENERAL INSTALLATION OF RADIO EQUIPMENT The computers of the electronic control system has been designed so that external radio waves will not interfere with their operation. However, if antenna or cable of amateur transceiver etc. is routed near the computers, it may affect the operation of the computers, even if the output of the transceiver is no more than 25W. To protect each of the computers from interference by transmitter (hum, transceiver, etc.) the following should be observed. 1. 2. 3. 4. 5. Install the antenna on the roof or rear bumper. Because radio waves are emitted from the coaxial cable of the antenna, keep it 200 mm (8 in.) away from the computers and the wiring harness, route it so that it runs at right angles to the wiring harness. The antenna and the cable should be well matched, and the standing-wave ratio* should be kept low. A transmitter having a large output should not be installed in the vehicle. After installation of transmitter, run the engine at idle, emit radio waves from the transmitter and make sure that the engine is not affected. * STANDING-WAVE RATIO If an antenna and a cable having different impedances and connected, the input impedance Zi will vary in accordance with the length of the cable and the frequency of the transmitter, and the voltage distribution will also vary in accordance with the location. The ratio between this maximum voltage and minimum voltage is called the standing-wave ratio. It can also be represented by the ratio between the impedances of the antenna and the cable. The amount of radio waves emitted from the cable increases as the standing-wave ratio increases, and this increases the possibility of the electronic components being adversely affected. 9 0 - 6 ELECTRICAL COMPONENT LOCATION ELECTRICAL COMPONENT LOCATION RELAY A. Fender apron outer panel B. Decker member (cowl cross upper member) C. Dash panel D. Cowl cross lower member A. Relay box (Engine compartment) 8. Relay box (Passenger compartment) C. Resistor with diode D. Control relay 9 0 - 7 ELECTRICAL COMPONENT LOCATION CONTROL UNIT A. ECU C. D.R.L. unit (Canada only) B. TCU 9 0 - 8 ELECTRICAL COMPONENT LOCATION FUSIBLE LINK & FUSE A. Main fusible link C. Relay box B. Sub-fusible link 9 0 - 9 ELECTRICAL COMPONENT LOCATION SWITCH ES Multifunction switch Overdrive switch/Normal economy switch Seat belt switch (without passive seat belt) Crash pad mounting switch Ignition switch Kick down switch Seat belt switch (with passive seat belt) Lap belt switch (with passive seat belt) 9 0 - 1 0 Parking brake switch ELECTRICAL COMPONENT LOCATION P/position switch (with A/T) Luggage lamp switch Power steering switch Back-up lamp switch Ignition lock switch (with M/T) Oil pressure switch Pressure switch (with A/C) 9 0 - 1 1 ELECTRICAL COMPONENT LOCATION Inhibitor switch (with A/T) Door switch Door warning switch Blower switch (Level type) Accelerator switch (with A/T) Stop switch Blower switch (Rotary type) 9 0 - 1 2 ELECTRICAL COMPONENT LOCATION SENSORS A. Brake fluid sensor 8. Fuel sender C. Oil temperature sensor (with KM176-5) D. Water temperature sender *For the more accurate location of sensors such as Water Temperature Sensor, Throttle Position Sensor, Crank Angle Sensor, Motor Position Sensor, Engine Speed Sensor, Air Flow Sensor, EGR Temp. Sensor (USA, California only), O 2 Sensor, refer to Group “ENGINE”. 9 0 - 1 3 ELECTRICAL COMPONENT LOCATION GROUND POINTS G01 (Multi) GO2 G03-1 (Multi), G03-2 9 0 - 1 4 ELECTRICAL COMPONENT LOCATION GO6 (Multi) GO7 GO9 (Multi) G11 G10 (4 Door) 9 0 - 1 5 FUSIBLE LINKS AND FUSES FUSIBLE LINKS & FUSES FUSIBLE LINK SPECIFICATIONS Item Main fusible link Type Ampere rating Housing color Sub-fusible link Type Ampere rating & circuit, housing color Specification Screw-up type 50A (Charging circuit) 30A (Radiator & Condenser fan circuit) 50A-Red 30A-Pink Located in engine compartment relay box Connector type Circuit Fuse Item box MPI Head lamp IGN Ampere rating 50A 20A 30A 30A Housing color Red Blue Pink Pink INSPECTION 1 . Check for a burnt fusible link with an ohmmeter. (fusible link must be removed from holder prior to testing) 2. If a fusible link burns out, there is a short or some other problem in the circuit. Carefully determine the cause and correct it before replacing the fusible link. NOTE The fusible link will burn out within 15 seconds if a higher current than specified flows through the circuit. 9 0 - 1 6 FUSIBLE LINKS AND FUSES FUSES INSPECTION When a fuse is blown, there are two probable causes as follows. Which of the two causes is responsible can be easily determined by visual check after removing the fuses. 1. Fuse blown due to over-current. Prior to replacing the fuse with a new one has check the circuit for short and check the related parts for abnormal condition. Only after the correction of such short or abnormal parts, fuse with same ampere rating should be used as a replacement. 2. Fuse blown due to repeated current on-off. Normally, this type of problem occurs after fairly long period of use and hence is less frequent than the above type. In this case, you may simply replace with a new fuse of the same capacity. CAUTION A blade type fuses are identified by the numbered value in amperes. If the fuse is burnt-out, be sure to replace a fuse with the same ampere rating. If a fuse of higher capacity than specified is used parts may be damaged and the danger of fire also exists. 9 0 - 1 7 IGNITION SWITCH IGNITION SWITCH (WITH KEY WARNING SWITCH) INSPECTION 1. Remove the connector located under the steering column. 2. Check for continuity between terminals. NOTE : indicates that there is a continuity between terminals. RO : Round the locking bar, RE : Return the locking bar, R : Removed, I : Inserted 9 0 - 1 8 MULTIFUNCTION SWITCH MULTIFUNCTION SWITCH COMPONENT 9 0 - 1 9 MULTIFUNCTION SWITCH REMOVAL AND INSTALLATION 1. Disconnect the battery ground cable. 2. Remove the steering wheel. 3. Remove the steering column shroud. 4. Disconnect the harness connector. 5. Remove 3 straps. 6. Remove the multifunction switch ass’y by loosening 4 screws. 7. Installation is the reverse order of the removal procedure. INSPECTION With the multifunction switch in each position, make sure that continuity exists between terminals below. Lighting switch (Connector No.: M16-1) Dimmer and passing switch (Connector No.: M16-2) 9 0 - 2 0 MULTIFUNCTION SWITCH Turn signal and hazard warning switch (Connector No.: M 1 6 - 1 ) L : Left position N : Neutral position R : Right position Wiper switch (Connector No.: M16-1) Washer switch (Connector No.: Ml 6-1) NOTE m: indicates that there is continuity between terminals. 9 0 - 2 1 INSTRUMENTS AND WARNING SYSTEM INSTRUMENTS AND WARNING SYSTEM SPECIFICATIONS Instrument cluster Type Illumination lamps Illumination color Indicator and warning lamps Battery charge Oil pressure Door ajar Check engine Brake warning Low fuel Direction indicator (LH, RH) Low beam High beam Seat belt warning Hazard Tail gate (Trunk lid) open Over-drive OFF Rear heated Package type (flexible P.C.B. with push connection) 12V 3.4W x 4, 1.2W x 1 Milky white Bulb wattage Illumination color 1.2 Red 1.2 Red 1.2 Red 1.2 Amber 1.2 Red 3.0 Amber 1.2 Green 1.2 Green 3.0 Blue 1.2 Red 1.2 Red 1.2 Red 1.2 Amber 1.2 Amber 9 0 - 2 2 INSTRUMENTS AND WARNING SYSTEM SERVICE SPECIFICATIONS Item Speedometer Type Indication tolerance Specification Vortex ampere push connection type Speed (MPH) 10 20 40 55 75 100 Tolerance (MPH) ±1.5 ±1.5 ±1.5 ±1.5 ±1.5 ±1.5 Speed (km/h) 20 40 60 80 100 120 140 160 Tolerance (km/h) +4 +3 +4 +5 +5 +5.5 +5.5 +5.5 0 0 0 0 0 +0.5 +0.5 +0.5 Tachometer Type Indication tolerance Electronic type Standard (RPM) Tolerance (RPM) 1,000 2,000 3,000 4,000 5,000 6,000 7,000 ±100 ±125 ±150 ±150 ±150 ±180 ±210 Fuel gauge Type Indication Bimetal (built-in voltage regulator) type Fuel level E (Empty) 1/2 Scale angle -30° 0° Tolerance ±2°24’ ±4° Tolerance when assem- 0° bled with fuel sender - 5 . 6 ° ±7.5° F (Full) +30° ±2°24 +7.1° 0° Temperature gauge Type Indication Resistance (a) Bimetal type 9 0 - 2 3 INSTRUMENTS AND WARNING SYSTEM TROUBLESHOOTING Problem Probable cause Remedy Speedometer does not operate No.17 fuse (10A) blown Check for short and replace fuse Speedometer faulty Check speedometer Reed switch faulty Check the switch located within the speedometer Wiring faulty Repair if necessary Tachometer does not operate No.17 fuse (10A) blown Check for short and replace fuse Tachometer faulty Check tachometer Wiring Faulty Repair if necessary Fuel gauge does not operate No.17 fuse (10A) blown Check for short and replace fuse Fuel gauge faulty Check gauge Fuel sender faulty Check fuel sender Wiring faulty Repair if necessary Low fuel warning lamp does No.17 fuse (10A) blown Check for short and replace fuse not light Bulb burned out Replace bulb Fuel level sensor faulty Check switch Wiring or ground faulty Repair as necessary Water temperature gauge does No. 17 (10A) fuse blown Check for short and replace fuse not operate Water temperature gauge faulty Check gauge Water temperature sender faulty Check sender Wiring or ground faulty Repair if necessary Oil pressure warning lamp NO. 17 (10A) fuse blown Check for short and replace fuse does not light Bulb burned out Replace bulb Oil pressure sender faulty Check sender Wiring or ground faulty Repair if necessary Low brake fluid warning lamp NO. 17 (10A) fuse blown Check for short and replace fuse does not light Bulb burned out Replace bulb Brake fluid level warning switch faulty Check switch Parking brake switch faulty Check switch Wiring or ground faulty Repair if necessary Open door warning lamp does NO. 5 (10A) fuse blown Check for short and replace fuse not light Bulb burned out Replace bulb Door switch faulty Check switch Wiring or ground faulty Repair if necessary 9 0 - 2 4 INSTRUMENTS AND WARNING SYSTEM INSTRUMENT CLUSTER COMPONENTS REMOVAL AND INSTALLATION 1. 2. 3. 4. 5 . Disconnect the battery ground cable. Remove three retaining screws at the facia panel and pull panel rearward. Remove four screws retaining cluster and carefully pull rearward enough to disengage speedometer cable. Carefully pull cluster away from instrument panel and disconnect the cluster wiring from the printed circuit board. Installation is the reverse order of removal. 9 0 - 2 5 INSTRUMENTS AND WARNING SYSTEM PRINTED CIRCUIT BOARD CIRCUIT DIAGRAM 9 0 - 2 6 INSTRUMENTS AND WARNING SYSTEMS SPEEDOMETER AND SPEEDOMETER CABLE Speedometer inspection (under in-vehicle) 1. Using a speedometer tester, ensure that any indication error is within tolerance limits. NOTE It should be noted that the excessive tire wear and tire over or under-inflation will cause indication errors. Speed (MPH) 10 20 40 55 75 100 Tolerance (MPH) ±1.5 ±1.5 ±1.5 ±1.5 ±1.5 ±1.5 Speed (km/h) 20 40 60 80 100 120 140 160 Tolerance (km/h) +4 +3 +4 +5 +5 +5.5 +5.5 +5.5 0 0 0 0 0 +0.5 +0.5 +0.5 2. Check the speedometer for pointer fluctuation and abnormal noise. NOTE Pointer fluctuations can be caused by a faulty speedometer cable. 3. Check to see if the odometer is functioning properly. Speedometer cable inspection 1. Check the cable for kinks, bents or damages in routing. If the conditions are severe, replace cable. 2. After disconnecting cable, check the core for kinks, burrs or bent tips. NOTE When installing a cable, it is necessary that extra care should be taken to verify that the stopper of the cable is fitted properly into the speedometer groove and the cable is routed properly to eliminate any kinks. Reed switch inspection 1. Remove the instrument cluster. 2. Use an ohmmeter to check circuit repeats on-off between terminals while the speedometer drive shaft completes a turn. 9 0 - 2 7 INSTRUMENTS AND WARNING SYSTEMS TACHOMETER On-vehicle inspection 1. Connect the multi-use tester to the diagnosis connector in the fuse box, or install a tachometer for the tune-up test. 2. With engine starting, compare the readings of the tester with that of the tachometer. If the multi-use tester is used, press code No.22 and read the rpm. Replace tachometer if difference is excessive. Standard (RPM) 1,000 2,000 3,000 4,000 5,000 6,000 7,000 Tolerance (RPM) ±100 ±125 ±150 ±150 ±150 ±180 ±210 FUEL GAUGE AND FUEL SENDER Fuel gauge operation check (in-vehicle) 1. Raise the vehicle and disconnect the fuel sender connector from fuel sender. 2. Ground the harness side connector (terminal 2) via 12V, 3.4 W bulb. 3. Turn the ignition switch to the ON position. 4. Check to be sure that the test bulb flashes and that the indicator moves graually to the “F” position. Fuel gauge inspection 1. Remove the instrument cluster. 2. Measure the resistance between terminals. Standard resistance : 550 NOTE If the resistance value is extremely low, there may be a short in the coil; if it is extremely high, there may a broken wire or some other problems in the coil. 9 0 - 2 8 INSTRUMENTS AND WARNING SYSTEMS Fuel sender inspection 1. Remove the luggage covering carpet and spare tire. 2. Remove the fuel tank cover retaining screws. 3. Remove the fuel sender assembly. 4. Using an ohmmeter, measure the resistance between terminals 2 and 3 at each float level. Float position E 1/2 F Resistance R 110±7 32.5±4 3±2 5. Check that resistance changes smoothly when the float is moved to “E” or “F”. Low fuel lebel sensor inspection 1. Connect the sender with a test lamp (12V, 3.4W) to the battery and immerse it in the water. 2. The lamp should be off while thermistor is beneath the water, and should illuminate when the sender is taken out of the water. NOTE If there is a malfunction, replace the fuel sender as an assembly. CAUTION After completing this test, wipe the sender dry and install it in the fuel tank. WATER TEMPERATURE GAUGE AND SENDER Water temperature gauge operation check (in-vehicle) 1. Remove the harness connector from water temperature sender located in engine compartment. 2. Ground the harness side connector via 12V, 3.4W bulb. 3. Turn the ignition switch to ON position. 4. Check to be sure that the test bulb flashes and that the indicator moves. 9 0 - 2 9 INSTRUMENTS AND WARNING SYSTEMS Water temperature sender inspection Using on ohmmeter, measure the resistance between terminal and ground. If the resistance is out of specification, replace the sender. Temperature 50 60 70 115 120 122 °C (°F) (112) (140) (158) (239) (248) (252) Resistance R 230 155 104±13.5 23.8±2.5 21 19.5 OIL PRESSURE SWITCH AND WARNING LAMP Oil pressure switch inspection 1. Pull out the connector from the oil pressure switch located at the cylinder block. 2. Ensure that there is continuity between switch terminal and ground under condition of pressure below. Switch ON pressure ......................... ......................... ................... 0.3 ± 0.1 kg/cm 2 (29.4 ± 9.8 kPa, 4.3 ± 1.4 psi) Oil pressure warning lamp inspection 1. Pull out the connector from the oil pressure switch. 2. Ground the harness side connector. 3. Ensure that the oil pressure warning lamp lights when the ignition switch is turned ON. BRAKE FLUID LEVEL WARNING SWITCH AND LAMP Brake fluid level warning switch inspection 1. Remove the connector from the switch located at brake fluid reservoir. 2. Ensure that the continuity exists between switch terminals 1 and 2 while pressing down the switch (float) with a rod. 9 0 - 3 0 INSTRUMENTS AND WARNING SYSTEMS Brake fluid level warning lamp inspection 1. 2. 3. 4. 5. Start the engine. Release the parking brake lever to the original position. Disconnect the connector of the brake fluid level warning switch. Ground the connector at the harness side. Ensure that the warning lamp lights. Parking brake switch inspection 1. Remove the rear console assembly. 2. 3. Disconnect the connector of parking brake switch. Check continuity between terminal and body ground. SEAT BELT WARNING SWITCH AND Seat belt switch inspection 1. Disconnect the connector from the switch. 2. Check for continuity between terminals. Seat belt condition Continuity Fastened Non-conductive (MI) Non fastened Conductive (On) 9 0 - 3 1 INSTRUMENTS AND WARNING SYSTEMS Passive seat belt switch inspection 1. Disconnect the connector from the switch. 2. Check for continuity between terminals. Seat belt condition Continuity Fastened Non-conductive (man) Non fastened Conductive (On) Lap belt switch inspection (with passive seat) 1. Remove the connector from the switch. 2. Check for continuity between terminals. Seat belt condition Continuity Fastened Non-conductive (~0) Non fastened Conductive (On) Seat belt warning lamp inspection With the ignition switch turned ON, ensure that the lamp glows. Seat belt condition Warning lamp Fastened Not fastened Off Glows for about six seconds 9 0 - 3 2 LIGHTING SYSTEM LIGHTING SYSTEM SPECIFICATION Lamps Headlamp Front turn signal lamp (located in headlamp) Front side marker and reflex reflector lamp Rear combination lamp Tail and stop lamp Back-up lamp Rear turn signal lamp Rear side marker and reflex reflector (common with tail and stop lamp) Licence plate lamp Luggage lamp High mounted stop lamp Overhead console lamp (with sunroof) Courtesy lamp (with sunroof) Flasher unit Turn signal blinking frequency Hazard warning blinking frequency 65/45 W 28/8 W 4 W 27/8 W 27 W 27 W 27/8 W 8 W 5 W 17 W 10 W 10 W 85 ± 10 C/M at 12.8V 80 ± 12 C/M at 12.8V 9 0 - 3 3 LIGHTING SYSTEM TROUBLESHOOTING Problem Possible cause Remedy One lamp only does not light Bulb burnt out Replace bulb (all exterior) Socket, wire or ground faulty Repair as necessary No headlamps light Sub-fusible link (30A) blown Replace sub-fusible link Headlamp relay faulty Check relay Lighting switch faulty Check switch Wiring or ground faulty Repair as necessary Tail, parking and licence lamp Tail fuse blown (No.13 and/or No.14) Replace fuse and check for short do not light Fusible link blown (30A) Replace fusible link Taillamp relay faulty Check relay Lighting switch faulty Check switch Wiring or ground faulty Repair as necessary Stop lamps do not light Stop fuse (No.4) blown Replace fuse and check for short Stop lamp switch faulty Adjust or replace switch Wiring or ground faulty Repair as necessary Stop lamps stay on Stop lamp switch faulty Adjust or replace switch Instrument lamps do not light Lamp control rheostat faulty Check rheostat (taillamps light) Wiring or ground faulty Repair as necessary Turn signal does not flash on Bulb burnt-out Replace bulb one side Turn signal switch faulty Check switch Wiring or ground faulty Repair as necessary Turn signal does not operate Turn signal fuse (No.17) blown Replace fuse and check for short Turn signal flasher faulty Check flasher Turn signal switch faulty Check switch Wiring or ground faulty Repair as necessary Hazard warning lamps do not Sub-fusible link (50A) blown Replace fusible link operate Hazard fuse (No.3) blown Replace fuse and check for short Turn signal flasher faulty Check flasher Hazard switch faulty Check switch Wiring or ground faulty Repair as necessary Flasher rate too slow or too fast Lamps are of a wattage smaller or Replace lamps larger than is specified for use Defective flasher unit Replace unit Backup lamps do not light Back up fuse (No.17) blown Check for short, replace fuse Back up lamp switch faulty Check switch Damaged wiring or poor grounding Repair as necessary 9 0 - 3 4 LIGHTING SYSTEM HEADLAMP AIMING PRE-AIMING INSTRUCTIONS 1. 2. 3. 4. 5. 6. 7. 8. 9. Test dimmer switch operation. Observe operation of high beam indicator light mounted in the instrument cluster. Inspect for badly rusted of faulty headlamp assemblies. These conditions must be corrected before a satisfactory adjustment can be made. Place the vehicle on a level floor. Bounce the front suspension through three (3) oscillations by applying body weight to hood or bumper. Check and correct tire inflation pressures. Rock vehicle sideways to allow vehicle to assume its normal position. If the fuel tank is not full, place a weight in the trunk of the vehicle to simulate the weight of a full tank. There should be no other load in the vehicle other than driver or substituted weight of approximately 75 kg (165 Ibs.) placed in driver’s position. 10. Thoroughly clean the headlamp lenses. COMPENSATING THE AIMERS FOR FLOOR SLOPE The floor level offset dial must coincide with the floor slope for accurate aiming. Calibration fixtures are included with the aimers. 1. 2. 3. 4. 5. 6. Attach one calibration fixture to each aimer. Fixtures will easily snap into position on the aimer when properly positioned. Place aimers at the center line of each wheel on one side of vehicle. Unit A must be placed at the rear wheel with the target facing forward. Unit B must be placed at the front wheel with the target facing rearward. Adjust the thumb screw on each calibration fixture by turning either clockwise or counter-clockwise until the level vial bubble registers in a centered, level position. Look into the top port hole of Unit A. Turn horizontal knob until split image is aligned. Transfer the plus of minus reading indicated on the horizontal dial to floor level offset dial on each aimer. Press floor level dial inward to set reading. Remove the calibration fixtures from both units. 9 0 - 3 5 LIGHTING SYSTEM TIMING AIMER CALIBRATION 1. Turn the thumb adjusting screw on each calibration fixture until it is approximately the same distance as the supporting posts. 2. Attach the calibration fixtures to each unit with level vials 3. 4. 5. on top. Locate the true vertical plate glass window or smooth surgace and secure aimers three to five feet apart so split image targets can be located in the viewing ports. Set the floor level dial to zero. 6. Rotate thumb adjusting screws on each calibration fixture until level vials on fixtures are centered. With both calibration level vials centered, turn vertical dial knobs on each aimer until aimer level vials are centered. If aimer vertical dial pointers read between 1/2 up and 1/2 down, aimers are within allowable vertical tolerance, Recalibrate units if beyond these limits. Vertical dial pointer reading (on each aimer)1/2 up to 1/2 down 7. Adjust horizontal dial knob on each aimer until split image targets align. If aimer horizontal dial pointers read between 1 left and 1 right, the aimers are within allowable tolerance limits. Recalibrate units if beyond these limits. The aimer calibration may be off due to extended use. Calibration fixtures used in conjunction with the aimers can be used to check and adjust the aimer. Horizontal dial pointer reading (on each aimer) 1 left to 1 right MOUNTING AIMERS Adjustable rod 1. Remove the calibration fixture from the each unit. 2. As shown in the figure, install the articulating vacuum cup assembly (A), vacuum extension plate (B) and small universal adapter (C) to each unit. 3. Marke the length of the adjustable rod as shown in the figure. (A) Articulating vacuum cap assembly 9 0 - 3 6 LIGHTING SYSTEM 4. Position the aimers on the headlamps pushing the piston handle forward, engaging the rubber suction cup. Immediately pull back the piston handle until it locks in place. NOTE Steel inserts are molded into position on the adapter to insure accuracy. These inserts must be in contact with the three guide points on the lamps when the aimers are properly positioned. HORIZONTAL ADJUSTMENT 1. Set the horizontal dial to zero. 2. Check to see that the split image target lines are visible in the viewing port. If necessary, rotate each aimer slightly to locate the target. 3. Turn the horizontal screw on the side of the headlamp until the split image of target line appears in the mirrors as one solid line. To remove “backlash”, make the final adjustment by turning adjusting screw in a clockwise direction. 4. Repeat the last three steps on the apposite headlamp. VERTICAL ADJUSTMENT 1. The vertical dial should be set at zero. (For passenger vehicles, “0” setting is generally required. For special settings, consult local state laws. 2. Turn the vertical adjusting screw until the level bubble is centered between the lines. 3. Repeat the last two steps on the opposite headlamp. 4. Re-check the target alignment on both aimers and readjust the horizontal aim if necessary. 5. Remove aimers by pressing “vacuum release” button located on the piston handle. 9 0 - 3 7 LIGHTING SYSTEM AIMING WITH SCREEN Headlamp aiming preparation Place the vehicle on a level floor, 7.6 m (25 feet) from the aiming screen or a light-colored wall. 1. Position a vertical place of tape so that it is aligned with the vehicle center line. 2. Position a horizontal tape with reference to the center line of the headlamp. 3. Position a vertical piece of tape on the screw for vertical adjustment, adjust side screw for horizontal adjustment. Visual headlamp adjustment 1. A properly aimed low beam will appear on the aiming screen 7.6 m (25 feet) in front of the vehicle. The shaded area as shown in the illustration indicates a high intensity zone. 2. Adjust the low beam headlamps to match the low beam pattern of the right and left headlamps. NOTE If the visual headlamp adjustment at low beam is made, the adjustment at high beam is not necessary. 9 0 - 3 8 LIGHTING SYSTEM HEADLAMP Removal and installation 1. Remove the radiator grille. 2. Remove the side marker and reflex reflector lamp ass’y. 3. Disconnect the headlamp connector. 4. Remove the headlamp assembly with transverse filler. 5. Disconnect the head lamp from transverse filler. 6. Installation is the reverse order of removal procedure. Tightening torque Radiator grill mounting 2-3 N.m (20-30 kg.cm, 1.5-2.2 Ib.ft) Head lamp mounting 3-5 N.m (30-50 kg.cm, 2.2-3.6 Ib.ft) REAR COMBINATION LAMP Removal and installation 1. Remove the trunk inner trim. 2. Disconnect the harness connector. 3. Remove the rear combination lamp assembly by loosening the 4 nuts. 4. Installation is the reverse order of removal procedure. Tightening torque Rear combination lamp mounting 2.0-2.5 Nm (20-25 kg.cm, 1.4-1.8 Ib.ft) 9 0 - 3 9 LIGHTING SYSTEM RELAY Inspection 1. Remove the headlamp relay and taillamp relay. 2. Check for continuity between the terminals. NOTE 1. indicates that there is continuity between the terminals. 2. indicates power supply connection. TURN SIGNAL FLASHER UNIT Inspection 1. Connect the positive (+) lead from the battery to terminal B and the negative (-) lead to terminal E. 2. Connect the two turn signal lamps parallel to each other to terminal L and E, check that the bulbs turn on and off. NOTE The turn signal lamps should flash 75 to 95 times per minute. If one of the front or rear turn signal lamps has an open circuit, the number of flashes will be more than 120 per minute. If operation is not as specified, replace the flasher unit. 9 0 - 4 0 LIGHTING SYSTEM STOP LAMP SWITCH Inspection 1. Remove the stop lamp switch connector located at brake pedal bracket. 2. Make sure that there is a continuity between terminals 1 and 2 when the brake pedal is depressed. 3. Ensure that no continuity exists between the terminals when the pedal is released. BACK UP LAMP SWITCH (M/T) Inspection 1. 2. Remove the back up lamp switch connector. Check for continuity between terminals. LUGGAGE COMPARTMENT LAMP SWITCH Inspection 1. Remove the luggage compartment lamp switch connector. 2. Check for continuity between terminal and ground. Tail gate (trunk lid) condition Continuity Opened 0fi Closed Ml 9 0 - 4 1 AUDIO AUDIO SPECIFICATIONS BASE GRADE Items Radio Receiving band Tuning type Memory (AM/FM) Frequency range AMP Output power Volume type Tape player Deck type Reproducing type MEDIUM GRADE Items Radio Receiving band Tuning type Memory (AM/FM) Frequency range AMP Output power Volume type Tape player Deck type Eject type Reproducing type SPEAKER C-320 H - 5 1 0 AM/FM E.T.R. 6 / 6 AM : 530-1,610 KHz FM : 87.9-107.9 MHz MAX. 18W x 2CH Rotary Mechanical Auto reverse H-455 AM/FM1/FM2 E.T.R. 6/12 AM : 531-1,602 KHz FM : 87.5-108 MHz Max. 25W x 2CH Rotary Full logic Key off release Auto reverse AM/FM1/FM2 6/12 AM : 530-1,620 KHz FM : 87.9-108 MHz MAX. 20W x 2CH Full logic H - 5 5 0 AM : 530-1,710 KHz FM : 87.9-107.9 MHz Items Specifications Front speaker Input power Rated impedance Distortion Size Rear speaker input power Rated impedance Frequency response NOM. 20W RMS (MAX. 40W RMS) 4 ± 0.6fl (at 400 Hz, 1V) MAX. 5% (at 400 Hz, 8W) 10 cm (4 in.) NOM. 20W RMS (MAX. 40W RMS) 4.0R 60-20,000 Hz 9 0 - 4 2 AUDIO TROUBLESHOOTING There are 5 areas where a problem can occur: the wiring harness, radio, cassette tape deck, speaker, and the antenna. Your job in troubleshooting is to isolate the problem to a particular area. 9 0 - 4 3 AUDIO CHART 1 9 0 - 4 4 AUDIO CHART 2 9 0 - 4 5 AUDIO CHART 3 9 0 - 4 6 AUDIO CHART 4 1. RADIO 9 0 - 4 7 AUDIO CHART 4 (Continued) 2. TAPE CHART 5 9 0 - 4 8 AUDIO CHART 6 CHART 7 9 0 - 4 9 AUDIO CHART 8 9 0 - 5 0 AUDIO STRUCTURAL VIEW (BASE GRADE) -FRONT SIDEC- 320 C-510 -BACK SIDE- 6 5 4 3 2 1 13P Connector (M20) 90-51 AUDIO STRUCTURAL VIEW (MEDIUM GRADE) -FRONT SIDEH- 4 5 5 H - 5 5 0 -BACK SIDE Antenna jack 9 0 - 5 2 AUDIO REMOVAL AND INSTALLATION 1. Remove the ash tray. 2. Remove the mounting screws. (2 EA). 3. Remove the center lower crash pad facia panel. 4. Remove the mounting screws. 5. Remove the radio unit from the mounting bracket. 6. Replace in reverse order of preceding steps. SPEAKER FRONT SPEAKER 1. Remove the front speaker grille. 2. Remove the speaker mounting bolts. 3. Remove the speaker assembly. 4. Replace in reverse order of the preceding steps. REAR SPEAKER 1. Remove the rear speaker grille. 2. Remove the speaker mounting bolts. 3. Remove the speaker assembly. 4. Replace in reverse order of the preceding steps. 9 0 - 5 3 AUDIO SERVICE ADJUSTMENT PROCEDURES FUSE REPLACEMENT Make sure of using the specified fuse when marking a replacement. Audio unit Permissible current BASE GRADE 3A (ACC) MEDIUM GRADE 5A (ACC) & 3A (B+) CAUTION Substituting with a higher capacity fuse or connection without a fuse may result in damage to the unit. TAPE HEAD AND CAPSTAN CLEANING 1. To obtain optimum performance, clean the head and capstan as often as necessary, depending upon frequency of use and tape cleanliness. 2. To clean the tape head and capstan, use a cotton swab dipped in ordinary rubbing alcohol. Wipe the head and capstan. SPEAKER CHECKING 1. Check the speaker by using an ohmmeter. If an ohmmeter indicates the impedance of the speaker when checking between speaker (+) and speaker (-) of the same channel, the speaker is ok. 2. If clicking sound is emitted from the speaker when the ohmmeter plugs touch the speaker terminals, the speaker is ok. Ohmmeter 9 0 - 5 4 WINDSHIELD WIPER AND WASHER WINDSHIELD WIPER SPECIFICATIONS Items Front wiper motor Specification Speed/current when 10 kg.cm, load test (1.0 Nm, 0.7 Ib.ft) Speed/current when 40 kg.cm, load test (3.9 Nm, 2.9 Ib.ft) Current when locking Rear wiper motor Speed/current when no load test Speed/current when 10 kg.cm, load test (1.0 Nm, 0.7 Ib.ft) Current when locking Wiper arm and blade Arm spring type Arm pressure Blade type Blade rubber length (when flat) Blade height (when flat) Wiping angle Low : 48 ± 5 rpm/2.5A or less High : 68 ± 8 rpm/3.5A or less Low : 32 rpm or more/4.5A or less High : 44 rpm or more/6A or less 18A or less 48 rpm/1.2A or less 40 ± 6 rpm/2.5A or less 9A or less Tension type Front : 680 g or less Rear : 510 ± 50 g or less Tournament Front : 455 mm (17.9 in.) Rear : 405 mm (15.9 in.) Front : 31 mm (1.2 in.) or less Rear : 32 mm (1.3 in.) or less Driver side : 78.5° ± 1 o Passenger side : 97.1° ± 1° Rear side : 108° ± 3° TROUBLESHOOTING Problem Possible cause Wipers do not operate or return to off position Wiper fuse blown Wiper motor faulty Wiper switch faulty Wiring or ground faulty Wipers do not operate in INT position Intermittent relay faulty Wiper switch faulty Wiper motor faulty Wiring or ground faulty Remedy Replace fuse and check for short Check motor Check switch Repair as necessary Check intermittent relay Check switch Check motor Repair as necessary 9 0 - 5 5 WINDSHIELD WIPER AND WASHER FRONT WIPER COMPONENTS TORQUE : Nm (kg.cm, Ib.ft) 9 0 - 5 6 WINDSHIELD WIPER AND WASHER REMOVAL AND INSTALLATION OF FRONT WIPER Removal 1. With opening the wiper arm head cap, remove the nut. NOTE Care must be taken not to scratch in the engine hood. 2. Remove wiper arm and blade assembly. 3. Remove the cowl top sealing cap. 4. Remove the cowl top cover. 5. Remove the wiper motor connector. 6. Remove the wiper motor mounting bolt. 7. Disconnect the motor from the link, then remove the motor assembly. NOTE When removing the wiper motor only, it can be done by steps 5 to 7. 8. Remove the wiper link mounting bolt. 9. Take out the wiper link assembly from the cowl top panel. 9 0 - 5 7 WINDSHIELD WIPER AND WASHER Installation 1. Install the windshield wiper link assembly. 2. Connect the wiper motor to the link securely, then install the motor assembly. 3. Install the cowl top cover. 4. Install the cowl top sealing cap to the drive shaft. 5. Connect the wiper arm and blade assembly to the wiper pivot housing. 6. Position the wiper arm and blade assembly at the distance of 30 mm from the windshield glass moulding endline. 7. Tighten the wiper arm and blade mounting nut. 9 0 - 5 8 WINDSHIELD WIPER AND WASHER REAR WIPER COMPONENTS REMOVAL AND INSTALLATION OF REAR WIPER Removal 1. Remove the rear wiper arm assembly. 2. Remove the tailgate trim. 3. Remove the rear wiper motor from the tailgate. 9 0 - 5 9 WINDSHIELD WIPER AND WASHER INSPECTION FRONT WIPER MOTOR Speed operation check 1. Remove the connector from front wiper motor. 2. Attach the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 5. 3. Check that the motor operates at low speed. 4. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2. 5. Check that the motor operates at high speed. Automatic stop operation check Motor side 1. Operate the motor at low speed. 2. Stop motor operation anywhere except at the off position by disconnecting terminal 5. 3. Connect terminals 5 and 6. 4. Connect the positive (+) lead from the battery to terminal 1. 5. Check that the motor stops running at the off position after the motor operates again. REAR WIPER MOTOR Speed operation check 1. Remove the connector from the rear wiper motor. 2. Attach the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 4. 3. Check that the motor operates. Motor side 9 0 - 6 0 WINDSHIELD WIPER AND WASHER WINDSHIELD WASHER SPECIFICATIONS Items Washer motor Motor type Pump type Rated voltage Current Discharge pressure Flow rate Over load capacity (continuous operation) With water Racing Specifications DC ferrate magnet type (M.P.I.) DC solenoid type (F.B.C.) Centrifugal type DC. 12V MAX. 3.8A (MPI) MAX. 3.5A (FBC) MIN. 1.2 kg/cm 2 MIN. 1,320 cc/min. MAX. 60 sec. MAX. 20 sec. COMPONENTS (FRONT WASHER) 9 0 - 6 1 WINDSHIELD WIPER AND WASHER COMPONENTS (REAR WASHER) FBC hose route 5 door route 3 door route MPI hose route 3 door route INSPECTION WASHER MOTOR 1. With the washer motor installed to the washer tank, fill the washer tank with washer fluid. 2. Attach the positive (+) lead from the battery to terminal 2, and negative (-) lead to the ground. 3. Check that the washer motor runs and washer fluid is ejected. SERVICE ADJUSTMENT PROCEDURES 1. Check the washer fluid contact point. 2. Adjust the washer fluid contact point by using a metal wire to move the washer nozzle ball. 3. If the amount of washer fluid ejected is too small, check for clogged, bent or crushed washer piping. Check the clipped points too, because the tube might be crushed. (COMPONENT SIDE) 9 0 - 6 2 CLOCK CLOCK SPECIFICATIONS Items Specifications Rated voltage Operating voltage range Operating temperature range Current consumption (with DC. 13V) DC. 12V DC. 6 - 16V -30 ~ +80°C (-22 - +176°F) MAX. 6 mA (with display) MAX. 150 mA (with display illuminated) REMOVAL 1. Remove the digital clock by using a flat type screwdriver. 2. Remove the wiring connector. 3. Remove the digital clock assembly CAUTION The clock is composed of delicate electronic components containing a crystal oscillator, transistor, etc. and should be handled with care. Specialized technical skill is needed to repair the internal mechanism of this clock. Do not attempt to disassemble it. If the clock itself is malfunctioning, replace the entire assembly. 9 0 - 6 3 CIGARETTE LIGHTER CIGARETTE LIGHTER SPECIFICATIONS Items Specifications Rated voltage DC. 12V Return time 13 ± 5 sec. Insulation resistance MIN. 5Mfi (with 500V megger) 9 0 - 6 4 SUN ROOF SUN ROOF SPECIFICATIONS Items Sun roof motor Rated voltage Operating voltage Testing voltage No load rotation and electric current Restriction torque and electric current Clutch quality for output shaft Early days torque 10,000 cycle test Dissociation resistance Sun roof switch R a t e d v o l t a g e Operating force Max. load ampere Operating temperature range Insulated resistance Specifications DC 12 V DC 9 ~ 15V DC 13 ± 0.2V MAX. 180 rpm, MAX. 6A MIN. 50 kg.cm, MAX. 35A 30 ~ 40 kg.cm 25 ~ 50 kg.cm MIN. 5Mfl (with 500 megger) DC 12V 0.5 ~ 1.0 kg 15A (Motor load) -40°C ~ +80°C (40°F - +176°F) MIN. 100Ma (with 500V megger) INSPECTION MOTOR 1. Remove the motor connector. 2. Attach the positive (+) lead from the battery to terminal 2 and negative (-) lead to terminal 1. 3. Check that the motor operates clockwise. 4. Attach the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2. 5. Check that the motor operates counter-clockwise. 9 0 - 6 5 SUN ROOF SWITCH Use an ohmmeter to check the continuity of the switch. If the continuity is not as specified, replace the switch. 9 0 - 6 6 HORN HORN SPECIFICATIONS Items Type Rated voltage Power consumption Sound level Horn effective voltage Operating temperature range Insulation resistance Fundamental frequency Low pitch High pitch Specifications Flat DC. 12V MAX. 3.5A (at DC 12V) 110 ± 5 dB (at DC 12V, 2m) DC 10V ~ DC 14.5V - 4 0 ° C ~ +80°C (-40°F - +176°F) MIN. 1Mfi (By 500V megger) 350 ± 20 Hz 415 ± 20 Hz REMOVAL 1. Disconnect the negative cable of battery. 2. Remove the radiator grille and head lamp. 3. Remove the horn attaching bolt. (on the radiator support panel). 4. Remove the horn connector. 5. Remove the horn. NOTE Check horn adjusting screw for looseness. ADJUSTMENT Operate the horn, and adjust the tone to a suitable level. (by turning the adjusting screw to the right “down” or the left “up”) CAUTION After adjusting, apply a small amount paint around the screw to prevent the adjusting screw from becoming loose. 9 0 - 6 7 TIME AND ALARM CONTROL UNIT TIME AND ALARM CONTROL UNIT (T.A.C.U.) SPECIFICATIONS Items Rated voltage Operating voltage range Operating temperature range Insulation resistance Rated load Variable intermittent wiper Rear defogger (heated) timer Seat belt warning Door warning Specifications DC. 12V DC. 9 ~ 16V -30° ~ +80°C (-22°F ~ +176°F) MIN. 100 Ma (with 500V megger) MAX. 5A (Inductance load) DC. 14.3V, 200W (Resistance load) DC. 12V, 1.2W (Lamp load) DC. 13.5V, 350mA (Inductance load) DC. 13.5V, 350mA (Inductance load) REMOVAL 1. Remove the front LH seat. (4 bolts) 2. Remove the T.A.C.U. cover. (2 tapping screws) 3. Remove the T.A.C.U. from the floor. (2 bolts) 4. Remove the connector. 9 0 - 6 8 TIME AND ALARM CONTROL UNIT INSPECTION VARIABLE INTERMITTENT WIPER 1. Operating characteristic : Fig.1 2. T 1 : MAX. 0.5 sec. T2 : Time of wiper motor 1 rotation. T3 : 1.5 ± 0.7 sec. (VR=0 k0) ~ 10.5 ± 3 sec. (VR=50 kfl) 3. Variable resistance (VR) : 50 ± 10 kfI 4. Relay operating sound : MAX. 50 dB/20 cm WASHER 1. Operating characteristic : Fig.2 2. T 1 : 0.4 - 1.2 sec. T2 : 2.0 - 4.7 sec. 3. This function should be operated preferentially even though the variable intermittent wiper is operating. REAR DEFOGGER (HEATED) TIMER 1. Operating characteristic : Fig.3 2. T 1 : MAX. 0.5 sec. T2 : 10 ± 3 min. DOOR WARNING 1. Operating characteristic : Fig.4 2. T 1, T2 : 0.3 ± 0.1 sec. 9 0 - 6 9 TIME AND ALARM CONTROL UNIT SEAT BELT WARNING 1. Operating characteristic : Fig.5 2. T 1 : 6 ± 1 sec. T2 : MAX. 6 ± 1 sec. T3, T4 : 0.3 ± 0.1 sec. PASSIVE SEAT BELT WARNING 1. Operating characteristic : Fig. 6 2. T 1 : 6 ± 1 sec. T2 : 60 2” sec. T3, T4 : 0.3 ± 0.1 sec. LAP BELT WARNING 1. Operating characteristic : Fig. 7 2. T 1 : 6 ± 1 sec. T2 : MAX. 6 ± 1 sec. T3, T4 : 0.3 ± 0.1 sec. 3. It should be operated by the passive seat belt warning when both of passive seat belt warning and lap belt warning are operating simultaneously. CONTROL UNIT 1. After tracing the problem to the control unit, replace it with a new one. Check for proper operation. 2. If system operates properly, the original control unit is faulty. 9 0 - 7 0 TIME AND ALARM CONTROL UNIT REAR HEATED (DEFOGGER) GLASS PRINTED HEATER LINE CHECK CAUTION Wrap tin foil around the end of the voltmeter test lead to prevent damaging the heater line. Apply finger pressure on the tin foil, moving the tin foil along the grid line to check for open circuits. 1. Turn on the defogger switch and use a voltmeter to measure the voltage of each heater line at the glass center point. If a voltage of approximately 6V is indicated by the voltmeter, the heater line of the rear window is considered satisfactory. 2. If a heater line is burned out between the center point and (+) terminal, voltmeter indicates 12 volts. 3. If a heater line is burned out between the center point and (-) terminal, the voltmeter indicates 0 volts. 9 0 - 7 1 TIME AND ALARM CONTROL UNIT 4. To check for open circuits, slowly move the test lead in the direction that the open circuit seems to exist. Try to find a point where a voltage is generated or changes to 0V. The point where the voltage has changed is the open-circuited point. Defogger OFF 5. Use an ohmmeter to measure the resistance of each heater line between a terminal and the center of a grid line and between the same terminal and the center of one adjacent heater line after another. The section involving a broken heater line indicates resistance twice as that in other section. In the affected section, move the test lead to a position where resistance sharply changes. Repair Provide the following items: 1. Conductive paint 2 . P a i n t t h i n n e r 3. Masking tape 4. Silicone remover 5. Thin brush Wipe the glass adjacent to the broken heater line, clean with silicone remover and attach the masking tape as shown. Shake the conductive paint container well, and apply three coats with a brush at intervals of about 15 minutes apart. Remove the tape and allow sufficient time for drying before applying power. For a better finish, scrape away excess deposits with a knife after completely dried. (allow 24 hours) Masking tape CAUTION After repairing, clean the glass with a soft dry cloth or wipe along the grid line with a slightly moistened cloth. 9 0 - 7 2 TAIL GATE OPENER (TRUNK LID OPENER) TAIL GATE OPENER (3/5 DOOR) TRUNK LID OPENER (4 DOOR) SPECIFICATIONS Items Tail gate opener (trunk lid opener) Rated voltage Insulating resistance Operating temperature range Rated current Initial pulling torque Circuit braker (at 7.5A) Trip time Recovery time Tail gate opener switch (trunk lid opener switch) Type Rated voltage Insulating resistance Operating force Specifications DC 12V MIN. 1 D (with .500V megger) 40°C ~ +80°C (40°F - +176°F) MAX. 16A MIN. 3.6 kg (at DC 9V) MIN. 5 kg (at DC 13V) 4 - 9 sec. MAX. 5 sec. Auto return type DC 12V MIN. 100 Ma (with 500V megger) 0 . 4 - 1.0 kg COMPONENTS 9 0 - 7 3 TAIL GATE OPENER (TRUNK LID OPENER) INSPECTION TAILGATE OPENER SWITCH (TRUNK LID OPENER SWITCH) Remove the tail gate (trunk lid) opener switch and check continuity between the terminals. If the continuity is not as specified, replace the switch. TAIL GATE OPENER (TRUNK LID OPENER) Remove the tail gate (trunk lid) opener and check continuity between the terminal “a” and “b”. If there is no continuity, replace the opener assembly. 9 0 - 7 4 AUTOMATIC TRANSAXLE AND KEY LOCK CONTROL SYSTEM AUTOMATIC TRANSAXLE AND KEY LOCK CONTROL SYSTEM SPECIFICATION Items Control unit Rated voltage Operating voltage range Operating temperature range Rated load A/T solenoid Rated voltage Rated current Operating voltage range Operating temperature range Operating force Initial pull in force Spring force Holding force Key lock solenoid Operating voltage range Operating temperature range Exciting current Operating force Pull in force Holding force Parking position switch Rated load Operating force Operating temperature range Specifications DC 12V DC 9 ~ 16V -30°C ~ +80°C (-22°F - +176°F) MAX. 1A (A/T solenoid) MAX. 0.8A (Key lock solenoid) DC 12V 1A (MAX. 2A) DC 9 ~ 16V -30°C ~ +80°C (-22°F - +176°F) 0.4 kg.cm (at 12V, 20°C) 0.2 kg.cm (at 12V, 20°C) 1.5 kg.cm (at 12V, 20°C) DC 9 ~ 16V -30°C ~ +80°C (-22°F - +176°F) MAX. 0.9A MIN. 0.17 kg.cm (at DC 7.5 ± 0.1V) MIN. 0.25 kg.cm (at DC 6 ± 0.1V) 1A (resistance load, at DC 12V) 0.8 ± 0.2 kgf -30°C ~ +80°C (-22°F ~ +176°F) 9 0 - 7 5 AUTOMATIC TRANSAXLE AND KEY LOCK CONTROL SYSTEM COMPONENTS LAYOUT A. Cowl side panel B. Shift lever assembly C. Ignition key D. Shift lever assembly A. Control unit B. A/T solenoid C. Key lock solenoid D. P/position switch 9 0 - 7 6 AUTOMATIC TRANSAXLE AND KEY LOCK CONTROL SYSTEM SYSTEM CHECK KEY LOCK SYSTEM 1. Check that the ignition key cannot be turned to “LOCK (OFF)” position, when the position of the shift lever is not in “P” position. 2. Check that the ignition key turns to the “LOCK (OFF)” position, when the shift lever is set to the “P” position. SHIFT LOCK SYSTEM 1. Check that under the following conditions, the shift lever cannot be moved from the “P” position to any other position. IGNITION KEY POSITION : “ON” BRAKE PEDAL : NOT DEPRESSED BUTTON : PRESSED 2. Check that under the following conditions, the shift lever can be moved from the “P” position to other position. IGNITION KEY POSITION : “ON” BRAKE PEDAL : DEPRESSED BUTTON : PRESSED 9 0 - 7 7 AUTOMATIC TRANSAXLE AND KEY LOCK CONTROL SYSTEM INSPECTION TIMING CHART AUTOMATIC TRANSAXLE SOLENOID 1. Remove the solenoid connector. 2. Using an ohmmeter, measure the resistance between terminals. Standard resistance : 12-16fl 3. Attach the positive (+) lead from the battery to terminal 1. and the negative (-) lead to terminal 2. 4. Check that an operation noise can be heard from the solenoid. 9 0 - 7 8 AUTOMATIC TRANSAXLE AND KEY LOCK CONTROL SYSTEM KEY LOCK SOLENOID 1. Remove the solenoid connector. 9 0 - 7 92. Using an ohmmeter, measure the resistance between terminals. Standard resistance : 12.5-16.5;a 3. Attach the positive (+) lead from the battery to terminal 2. and the negative (-) lead to terminal 1. 4. Check that an operating noise can be heard from the solenoid. |
#723
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رد: رابطة مالكى الاكسل
ياريت تقيس كبس الموتور ؟ لو فى و الكبس قليل يبقى الموتور خفيف و ممكن تستخدم زيت شمبر مع زيت شل الاصفر و ابعد عن موبيل و غير لشل الاصفر لان ناس كتير بتشتكى من موبيل |
#724
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رد: رابطة مالكى الاكسل
الماتور كبسة كويس ومافيش دخنة فى الشكمان
كل الذى فعلة مركز الصيانة والذى قمت باستبدال الذيت عندة انة اضاف الناقص من الزيت واخبرنى ان احضر بعد شهر لاختبارة |
#725
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رد: رابطة مالكى الاكسل
المرة الجاية استخدم شل الاصفر و قولنا ايه الاخبار بس ضرورى لازم تتابع الزيت لانه روح العربية |
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