رابطة مالكى الاكسل

[toto_hoho82]

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

[toto_hoho82]

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.
2. 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.

9 0 - 7 9

[Good09]

المشاركة الأصلية كتبت بواسطة toto_hoho82 اريد تفسييير للاهمية منذ اسبوعين غيرت زيت الماتور واستبدلتة بزيت موبيل 1 سوبر 1000 hxp يتغير بعد3000ومقياس الزيت بين العلامتين ويميل اقرب الى علامة F المهم بعد استهلاك حوالى 300 كيلو خطر ببالى القى نظرة على مقياس الزيت وجدت مفاجأه مذهلة وهى ان مقياس الزيت يشير الى اقل من العلامة L ذهبت الى الميكانيكى لاخبرة لاحتمال يكون فية تسرب للزيت من اى مكان اخبرنى انة لا يوجد اى تسريب من اى مكان ولا شنبر ولا جوانات وذهبت لمركز الخدمة المعتمد اخبرتة بالموضوع ظل يبحث عن اى عيب بالسيارة ورفع السيارة على المجره وكشف من تحت وقرر انزال الزيت فى جركن فوجدة ينقص 2 كيلو بعد مشاورات فتح جركن جديد واضاف الناقص وقال لى اختبر المقياس كل فترة واخبرة بالنتائج هل معنى هذا ان الزيت موبيل 1 سوبر 1000 hxp زيت سئ ام انة مغشوش ام انة يتطاير اريد تفسير لاطمئن

هل كان فى دخنة من الشكمان ؟
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

[toto_hoho82]

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

[Good09]

المشاركة الأصلية كتبت بواسطة toto_hoho82 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

لو زى مابتقول يبقى الزيت مضروب او كان متخزن غلط

المرة الجاية استخدم شل الاصفر و قولنا ايه الاخبار
بس ضرورى لازم تتابع الزيت لانه روح العربية