Tài liệu sửa chữa ford laser repair manual (2001MY)

CONTENTS Title Section General Information 2001 LASER Repair Manual Supplement Engine GI B3 B1 ZL, ZM B2 FP, FS B3 Lubrication System D Cooling System E Fuel and Emission Control Systems B3 F1 ZL, ZM F2 FP, FS F3 FOREWORD This is a supplement to the previous repair manuals and this covers only main service points of major parts modified from them As to the service points, important safety notice and general service instructions in service which are not covered by this supplement, please refer to the previous Manuals shown on the following page Engine Electrical System G Clutch H All information in this manual was the best available at the time of printing Vehicle specification and other information will be updated in Service Information Ford Japan Limited APPLICATION: This manual is applicable to vehicles beginning with the Vehicle ldentification Numbers (VIN), and related materials shown on the following page Manual Transaxle F25M-R J1 G15M-R J2 Automatic Transaxle K Front and Rear Axles M Steering System N Braking System P Suspension R Body S Body Electrical System T Heater and Air Conditioner Systems U Technical Data TD Special Tools ST Explanations are given only for blackened sections (ąą) 2001 Ford Japan Limited All rights reserved Reproduction by any means, electronic or mechamical including photocopying, recording or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Ford Japan Limited PRINTED IN AUSTRALIA, FEB 2001 F173-10-01B VEHICLE IDENTIFICATION NUMBERS (VIN) Australian specs JC0 AAAS#NL✽✽ JC0 AAAS#NM✽✽ JC0 AAAS#PL✽✽ JC0 AAAS#PM✽✽ JC0 AAAS#PN✽✽ 400001 Ċ 400001 Ċ 400001 Ċ 400001 Ċ 400001 Ċ General specs (R.H.D L.H.D.) JC6 AAAS#NJ✽✽ JC6 AAAS#NK✽✽ JC6 AAAS#NL✽✽ JC6 AAAS#PK✽✽ JC6 AAAS#PL✽✽ 400001 Ċ 400001 Ċ 400001 Ċ 400001 Ċ 400001 Ċ RELATED MATERIALS LASER TRAINING MANUAL (Australia, General (R.H.D L.H.D.)) LASER REPAIR MANUAL (Australia, General (R.H.D L.H.D.)) LASER REPAIR MANUAL SUPPLEMENT (Australia, General (L.H.D.)) LASER OVERHAUL MANUAL (Australia, General (R.H.D L.H.D.)) LASER OVERHAUL MANUAL (Australia, General (R.H.D L.H.D.)) EOBD TRAINING MANUAL (Australia, Genral (R.H.D L.H.D.)) LASER WIRING DIAGRAMS (Australia, General (R.H.D.)) LASER WIRING DIAGRAMS (General (L.H.D.)) LASER BODYSHOP MANUAL (Australia, R.H.D.) F328-10-98K F162-10-98K F164-10-99H F162-20-98K F173-20-01B F335-10-01B F173-30-01B F173-40-01D F329-10-98K GENERAL INFORMATION GI GI VIN CODE GI-2 VIN CODE GI-2 HOW TO USE THIS MANUAL GI-2 RANGE OF TOPICS GI-2 NEW STANDARDS GI-3 NEW STANDARDS TABLE GI-3 ABBREVIATIONS GI-5 ABBREVIATIONS TABLE GI-5 SCHEDULED MAINTENANCE GI-5 SCHEDULED MAINTENANCE TABLE GI-5 GI–1 VIN CODE , HOW TO USE THIS MANUAL VIN CODE VIN CODE Z4F200800021W01 Australia, General (L.H.D R.H.D.) Specs Z4F20080W01 End Of Sie HOW TO USE THIS MANUAL RANGE OF TOPICS Z4F201000001W01 • This manual indicates only changes/additions, as it is supplemental to the related materials Therefore it may not contain the necessary reference service procedures to perform the service indicated in this manual End Of Sie GI–2 NEW STANDARDS NEW STANDARDS GI NEW STANDARDS TABLE Z4F202800020W01 • Following is a comparison of the previous standard and the new standard New Standard Abbreviation AP ACL A/C BARO B+ — — CMP sensor CAC CLS CTP — CPP CIS CS sensor CKP sensor DLC DTM DTC DI DLI EI ECT EM — EVAP EGR FC FF 4GR — FSO solenoid GEN GND HO2S IAC — — — — IAT KS MIL MAP MAF sensor MFL OBD Name Accelerator Pedal Air Cleaner Air Conditioning Barometric Pressure Battery Positive Voltage Brake Switch Calibration Resistor Camshaft Position Sensor Charge Air Cooler Closed Loop System Closed Throttle Position Closed Throttle Position Switch Clutch Pedal Position Continuous Fuel Injection System Control Sleeve Sensor Crankshaft Position Sensor Data Link Connector Diagnostic Test Mode Diagnostic Trouble Code(s) Distributor Ignition Distributorless Ignition Electronic Ignition Engine Coolant Temperature Engine Modification Engine Speed Input Signal Evaporative Emission Exhaust Gas Recirculation Fan Control Flexible Fuel Fourth Gear Fuel Pump Relay Previous Standard Abbreviation — — — — VB — — — — — — — — EGI CSP sensor — — — — — — — — — — — — — — — — Name Remark Accelerator Pedal Air Cleaner Air Conditioning Atmospheric Pressure Battery Voltage Stoplight Switch Corrected Resistance Crank Angle Sensor Intercooler Feedback System Fully Closed Idle Switch Clutch position Electronic Gasoline Injection System Control Sleeve Position Sensor Crank Angle Sensor Diagnosis Connector Test Mode Service Code(s) Spark Ignition Direct Ignition Electronic Spark Ignition Water Thermo Engine Modification Engine RPM Signal Evaporative Emission Exhaust Gas Recirculation Fan Control Flexible Fuel Overdrive Circuit Opening Relay #6 #6 #1 #2 #3 Fuel Shut Off Solenoid FCV Fuel Cut Valve #6 Generator Ground Heated Oxygen Sensor Idle Air Control IDM Relay Incorrect Gear Ratio Injection Pump Input/Turbine Speed Sensor Intake Air Temperature Knock Sensor Malfunction Indicator Lamp Manifold Absolute Pressure Mass Air Flow Sensor Multiport Fuel Injection On-Board Diagnostic — — — — — — FIP — — — — — — — — Alternator Ground/Earth Oxygen Sensor Idle Speed Control Spill Valve Relay With heater — Fuel Injection Pump Pulse Generator Intake Air Thermo Knock Sensor Malfunction Indicator Light Intake Air Pressure Airflow Sensor Multiport Fuel Injection Diagnosis/Self Diagnosis #6 #6 GI–3 NEW STANDARDS New Standard Previous Standard Abbreviation OL — OC O2S PNP — PSP PCM — Open Loop Output Speed Sensor Oxidation Catalytic Converter Oxygen Sensor Park/Neutral Position PCM Control Relay Power Steering Pressure Powertrain Control Module Pressure Control Solenoid Abbreviation — — — — — — — ECU — PAIR Pulsed Secondary Air Injection — Secondary Air Injection System Pump Speed Sensor — NE Sensor Secondary Air Injection — Secondary Air Injection System — AIR SAPV SFI Name Secondary Air Pulse Valve Sequential Multipoint Fuel Injection — Shift Solenoid A — Shift Solenoid B — 3GR TWC TB TP sensor TCV TCC Shift Solenoid C Third Gear Three Way Catalytic Converter Throttle Body Throttle Position Sensor Timer Control Valve Torque Converter Clutch Transmission (Transaxle) Control TCM Module Transmission (Transaxle) Fluid — Temperature Sensor TR Transmission (Transaxle) Range TC Turbocharger VSS Vehicle Speed Sensor VR Voltage Regulator VAF sensor Volume Air Flow Sensor Warm Up Three Way Catalytic WU-TWC Converter WOT Wide Open Throttle — — — — — — — — — — — TCV — Name Open Loop Vehicle Speed Sensor Catalytic Converter Oxygen Sensor Park/Neutral Range Main Relay Power Steering Pressure Engine Control Unit Line Pressure Solenoid Valve Reed Valve Sequential Fuel Injection 1-2 Shift Solenoid Valve Shift A Solenoid Valve 2-3 Shift Solenoid Valve Shift B Solenoid Valve 3-4 Shift Solenoid Valve 3rd Gear Catalytic Converter Throttle Body Throttle Sensor Timing Control Valve Lockup Position — EC-AT Control Unit — ATF Thermosensor — — — — — Inhibitor Position Turbocharger Vehicle Speed Sensor IC Regulator Air Flow Meter — Catalytic Converter — Fully Open Remark #6 #4 Pulsed injection #6 Injection with air pump #6 #5 #1 : Diagnostic trouble codes depend on the diagnostic test mode #2 : Controlled by the PCM #3 : In some models, there is a fuel pump relay that controls pump speed That relay is now called the fuel pump relay (speed) #4 : Device that controls engine and powertrain #5 : Directly connected to exhaust manifold #6 : Part name of diesel engine End Of Sie GI–4 ABBREVIATIONS , SCHEDULED MAINTENANCE ABBREVIATIONS GI ABBREVIATIONS TABLE AAS ABDC ABS ACC ATDC ATF ATX BBDC BTDC CM E/L EBD ELR HI HU IG LCD LED LH L.H.D LO Z4F203000011W01 Air adjusting screw After bottom dead center Antilock brake system Accessories After top dead center Automatic transaxle fluid Automatic transaxle Before bottom dead center Before top dead center Control module Electric load Electronic brakeforce distribution Emergency locking retractor High Hydraulic unit Ignition Liquid crystal display Light emitting diode Left hand Left hand drive Low M MTX OFF ON P/S P/W CM PCV PRC RH R.H.D SAS SST SW TAS TCS TFT TNS VICS WDS 4SD 5HB Motor Manual transaxle Switch off Switch on Power steering Power window control module Positive crankcase ventilation Pressure regulator control Right hand Right hand drive Sophisticated air bag sensor Special service tool Switch Throttle adjusting screw Traction control system Transaxle fluid temperature Tail number side lights Variable inertia charging system World wide diagnostic system Door Sedan Door Hatchback End Of Sie SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE TABLE Z4F203400013W01 Chart symbols: I : Inspect and clean, repair, or replace if necessary (Inspect, and if necessary replace air cleaner element only.) A : Adjust: Examination resulting in adjustment or replacement R : Replace T : Tighten Remarks: • To ensure efficient operation of the engine and all systems related to emission control, the ignition and fuel systems must be serviced regularly It is strongly recommended that all servicing related to these systems be done by an authorized Ford Dealer • After 150,000 km {90,000 miles} or 90 months, continue to follow the described maintenance at the recommended intervals • Refer below for a description of items marked* in the maintenance chart *1: If the vehicle is operated under any of the following conditions, change the engine oil and oil filter more often than recommended intervals a Driving in dusty conditions b Extended periods of idling or low speed operation c Driving for long periods in cold temperatures or driving regularly at short distances only d Towing a heavy trailer, caravan or carrying high roof rack loads continuously.(only for Australia) e Driving less than 10,000 km in 12 months.(only for Australia) *2: Replacement of the timing belt is required at every 100,000 km {60,000 miles} Failure to replace the timing belt may result in damage to the engine *3: If the vehicle is operated in very dusty or sandy areas, inspect and, if necessary, replace the air cleaner element more often than the recommended intervals *4: Also adjust and inspect the power steering and air conditioner drive belts, if equipped *5: If the brakes are used extensively (for example, continuous hard driving or mountain driving) or if the vehicle is operated in extremely humid climates, change the brake fluid annually GI–5 SCHEDULED MAINTENANCE Maintenance Interval Maintenance Item Number of months or km (miles), whichever comes first Months ×1000 km ×1000 miles 0.6 10 12 20 12 18 30 18 24 40 24 30 50 30 36 60 36 42 70 42 48 80 48 54 90 54 I I I I I I I I I 60 66 72 78 84 90 100 110 120 130 140 150 60 66 72 78 84 90 ENGINE Engine valve clearance Engine timing belt for B3 for ZL, ZM, FP (leaded fuel) for ZL, ZM, FP, FS (unleaded fuel) (except for Australia)*2 (for Australia)*2 (except for Australia)*4 I I I I I I I I I I Replace every 100,000 km (60,000 miles) R I I I I I I I I I I I I I I I (for Australia)*4 I I I I I I I I I I I I I I I Engine oil *1 R R R R R R R R R R R R R R R Oil filter *1 R R R R R R R R R R R R R R R Drive belts A COOLING SYSTEM Cooling system (except for Australia) Engine coolant (for Australia) FUEL SYSTEM Idle speed Idle mixture (leaded fuel) (except for Air cleaner Australia)*3 element (for Australia)*3 (except for Australia) Fuel filter (for Australia) Fuel lines & hoses IGNITION SYSTEM Initial ignition (for Australia) timing (except for Australia) I Spark plugs (for Australia) EVAPOLATIVE EMISSION CONTROL SYSTEM Evaporative emission control system ELECTRICAL SYSTEM Battery (except for Australia) I electrolyte level & specific (for Australia) I gravity CHASSIS & BODY Brake & clutch pedals I Brake lines, hoses & connections Brake fluid level (for Australia) I (except for I Australia)*5 Brake fluid (for Australia)*5 Clutch fluid level (for Australia) (except for Australia, Malaysia) Clutch fluid (for Australia, Malaysia) Parking brake GI–6 I I I I I I Replace every years Replace every 25 months regardless of distance travelled I I I I I I I I I I I I I I I I R I R I R I R R R R R I I I R I I I I I I R R I R R I I I I I I I I R I I I I I I I I I I I I I I I I I I I I R I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I R I I I R I I I R I I I Replace every 24 months regardless of distance travelled I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I R I I I R I I I R I I I I I I I I I I I I I I I I I I SCHEDULED MAINTENANCE Maintenance Interval Number of months or km (miles), whichever comes first Months ×1000 km ×1000 miles 0.6 Power brake unit & hoses Disc brakes (except for Malaysia) Drum brakes (for Malaysia) (except for Australia) I Power steering fluid & lines (for Australia) Steering operation & gear housing Steering linkages, tie rod ends & arms (except for Australia, Malaysia) Manual transaxle oil (for Malaysia) (for Australia) (except for Australia, Automatic Malaysia) transaxle fluid (for Australia, level Malaysia) Wheel bearings smooth rotation/ (for Australia) end play Tyre damage/ (for Australia) condition Driveshaft dust (except for Malaysia) boots (for Malaysia) Front suspension ball joints Exhaust system (except for Australia) heat shields (for Australia) Bolts & nuts on (except for Australia) T chassis & body (for Australia) Maintenance Item 10 I I I I 12 20 12 I I I I I I I 18 30 18 I I I I I 24 40 24 I I I I I I I 30 50 30 I I I I I 36 60 36 I I I I I I I 42 70 42 I I I I I 48 80 48 I I I I I I I 54 90 54 I I I I I I 60 66 72 78 84 90 100 110 120 130 140 150 60 66 72 78 84 90 I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I R I I I I I I I I I I I I I R I I I I R I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I T I I I I T T I T I I I I T T T I I I I I T T T End Of Sie GI–7 GI ENGINE (FP, FS) B3 FEATURES B3 OUTLINE B3-2 OUTLINE OF CONSTRUCTION B3-2 FEATURES B3-2 SPECIFICATIONS B3-2 ENGINE MOUNT B3-3 ENGINE MOUNT DESCRIPTION B3-3 CAMSHAFT B3-5 CAMSHAFT DESCRIPTION B3-5 ENGINE B3-5 CRANKSHAFT DESCRIPSION B3-5 SERVICE OUTLINE B3-6 SUPPLEMENTAL SERVICE INFORMATION B3-6 COMPRESSION PRESSURE B3-6 COMPRESSION INSPECTION B3-6 ENGINE B3-7 ENGINE REMOVAL/INSTALLATION B3-7 B3–1 CONTROL SYSTEM A/C AMPLIFIER INSPECTION Z4F854061790W01 Remove the glove compartment Pull out the A/C amplifier with the connector still connected Turn the ignition switch to ON position Measure the voltage at each A/C amplifier terminal or climate control unit terminal and refer to the terminal voltage list • If not as specified, inspect the parts listed under “Action” and the related wiring harness • If there is no malfunction under “Action”, replace the A/C amplifier Terminal Voltage List (Reference) Y3E8540W024 Terminal Signal A IG2 B A/C signal Connected to A/C 15 A fuse Refrigerant pressure switch Test condition Ignition switch at ON position Ignition switch at LOCK position Fan switch at 1st position, A/C switch ON Fan switch OFF Voltage (V) B+ Below 1.0 0.6 12 C A/C switch A/C switch Fan switch OFF 11.5 Fan switch at 1st position, A/C switch ON 0.6 D E F End Of Sie U–16 — — — — — — — — — — — — Action • Inspect for continuity or short circuit (Fuse —A/C amplifier:A/C 15 A fuse —A) • Inspect A/C 15 A fuse • Inspect related harness • Inspect for continuity or short circuit (PCM— Refrigerant pressure switch:1P (B3,ZL,ZM,FP),4F (FS)—B) (Refrigerant pressure switch—A/C amplifier:A (Australian, Genaral (L.H.D.) specs.),C (General (R.H.D.)specs.)— B) • Inspect terminal voltage of A/C amplifier (C) • Inspect refrigerant pressure switch • Inspect PCM (See F1–20 PCM INSPECTION) (See F2–19 PCM INSPECTION) (See F3–57 PCM INSPECTION (FS)) • Inspect related harness • Inspect for short circuit (A/C amplifier—Climate control unit: C—B) • Inspect terminal voltage of A/C amplifier (A) • Inspect for continuity or short circuit (A/C amplifier— Climate control unit: C—B) (Climate control unit—Fan switch:A—C) • Inspect A/C switch • Inspect fan switch — — — TROUBLESHOOTING TROUBLESHOOTING FOREWORD Z4F858001038W01 • The areas for inspection (steps) are given according to various circuit malfunctions Use the chart below to verify the symptoms of the trouble in order to diagnose the appropriate area End Of Sie TROUBLESHOOTING INDEX No Z4F858001038W02 TROUBLESHOOTING ITEM DESCRIPTION • Magnetic clutch does not operate No cool air End Of NO.1 NOSie COOL AIR DESCRIPTION POSSIBLE CAUSE Z4F858001038W03 No cool air • Magnetic clutch does not operate • A/C switch system malfunction (Step 3) • PCM A/C cut-off control system, coolant system malfunction (Step 17) • A/C amplifier, A/C switch, potentiometer malfunction (Steps 5—10) • PCM (A/C signal) system malfunction (Steps 11, 12) • Refrigerant pressure switch, refrigerant system malfunction (Steps 5, 13, 14) • PCM (IG1 signal) system malfunction (Steps 15, 16) • A/C compressor system malfunction (Step 18) • A/C relay system malfunction (Steps 19—21) • When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while doing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions If there is a problem, check to make sure connectors, terminals and wiring harnesses are connected correctly and undamaged Diagnostic procedure STEP INSPECTION • Does cool air blow out? • Start engine • Turn both A/C switch and fan switch on • Does A/C compressor operate? • Are any DTCs displayed? *4 • Turn both A/C switch and fan switch off • Test voltage at climate control unit terminal A (A/C signal) • Is voltage approximately B+? • Turn ignition switch to ON position • Set fan switch at 1st speed • Test voltage at following terminal of refrigerant pressure switch connector (on wiring harness side) — Australian, General (L.H.D.) specs Terminal A (A/C signal) — General (R.H.D.) specs Terminal C (A/C signal) • Is voltage approximately B+ when A/C switch is off and V when it is on? • Start engine • Turn both A/C switch and fan switch on • When A/C amplifier connector terminal B is shorted, does cool air blow out? • Turn ignition switch to ON position • Test voltage at A/C amplifier connector terminal A (IG2 signal) • Is voltage approximately B+ ? *5 *6 *7 Yes No Yes No Yes No Yes No ACTION Go to next step Go to Step of troubleshooting indexes No.1, (See LASER Repair Manual (material No F162-10-98K) Section U) Go to Step of troubleshooting index No.6 (See LASER Repair Manual (material No F162-10-98K) Section U) Go to next step Go to appropriate inspection procedure Go to next step Go to next step Repair wiring harness between climate control unit and fan switch, then go to Step 23 Yes No Go to Step 16 Reconnect refrigerant pressure switch connector, then go to next step Yes No Undo short, then go to next step Undo short, then go to Step 12 Yes No Go to next step Repair wiring harness between fuse block and A/C amplifier, then go to Step 23 U–17 U TROUBLESHOOTING STEP *8 *9 INSPECTION • Turn A/C switch off • Test voltage at climate control unit connector terminal C (A/C switch signal) • Is voltage approximately B+? • Turn ignition switch to ON position • Test voltage at A/C amplifier connector terminal C (A/C switch signal) • Is voltage approximately B+? 10 • Inspect potentiometer • Is it okay? 11 • Inspect A/C amplifier • Is it okay? *12 *13 14 15 *16 *17 *18 *19 20 *21 U–18 • Test voltage at refrigerant pressure switch connector terminal B (A/C signal) • Is voltage approximately B+? • Test voltage at the A/C signal terminal of PCM • Is voltage approximately B+? • When following refrigerant pressure switch connector terminals are shorted, does cool air blow out? — Australian, General (L.H.D.) specs Terminals A—B (A/C signal) — General (R.H.D.) specs Terminals B—C (A/C signal) • Inspect refrigerant pressure switch • Is it okay? • Does magnetic clutch operate when terminal E (IG1 signal) of A/C relay connector is grounded? • Turn A/C switch off • Test voltage at the IG1 signal terminal of PCM • Is voltage approximately B+? • Inspect the PCM’s A/C cut off control input signal components • Is it okay? (A/C compressor type A) • Test voltage at magnetic clutch’s thermal protector terminal A (A/C control signal) (A/C compressor type B) • Test voltage at magnetic clutch’s stator and thermal protector terminal A (A/C control signal) • Is voltage approximately B+? • Are A/C relay power supply fuses okay? • Turn ignition switch to ON position • Test voltage at the following A/C relay connector terminals — Terminal A (IG1 signal) — Terminal C (A/C control signal) • Is voltage approximately B+? Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No ACTION Replace climate control unit, then go to Step 23 Go to next step Inspect wiring harness between A/C amplifier and climate control unit, then go to Step 23 (With heater core) Inspect A/C amplifier, then go to Step 23 (Without heater core) Go to next step Go to next step Replace potentiometer, then go to Step 23 Repair wiring harness between A/C amplifier and potentiometer, then go to Step 23 Replace A/C amplifier, then go to Step 23 Go to Step 14 Go to next step Repair wiring harness between PCM and refrigerant pressure switch, then go to Step 23 Inspect PCM, then go to Step 23 Go to next step Inspect wiring harness between refrigerant pressure switch and A/C amplifier, then go to Step 23 Use the vacuum pump for more than 30 minutes to remove the moisture in the refrigerant lines Add refrigerant to refrigerant line to the specified level, then go to Step 22 Replace refrigerant pressure switch, then go to Step 23 Undo short, then go to next step Go to Step 19 Yes No Go to next step Repair wiring harness between A/C relay and PCM, then go to Step 23 Yes No Inspect PCM, then go to Step 23 Replace input signal components, then go to Step 23 Yes No Inspect magnetic clutch, then go to Step 23 Go to next step Yes No Go to next step Inspect for short to ground on blown fuse’s circuit Repair or replace as necessary Install appropriate amperage fuse Go to next step Repair wiring harness between fuse block and A/C relay, then go to Step 23 Yes No TROUBLESHOOTING STEP *22 INSPECTION • Test voltage at A/C relay terminal D (A/C control signal) • Is voltage approximately B+? Yes 23 • Does cool air blow out? (Is refrigerant system performance test result correct?) No Yes No ACTION (A/C compressor type A) Repair wiring harness between A/C relay and thermal protector, then go to next step (A/C compressor type B) Repair wiring harness between A/C relay and stator and thermal protector, then go to next step Inspect A/C relay, then go to next step Troubleshooting completed Explain repairs to customer Recheck malfunction symptoms, then repeat from Step if malfunction recurs End Of Sie U U–19 TECHNICAL DATA TD TECHNICAL DATA TD-2 ENGINE TD-2 LUBRICATION SYSTEM TD-2 COOLING SYSTEM TD-2 FUEL AND EMISSION CONTROL SYSTEMS TD-3 ENGINE ELECTRICAL SYSTEM TD-3 CLUTCH TD-4 MANUAL TRANSAXLE TD-5 AUTOMATIC TRANSAXLE TD-5 FRONT AND REAR AXLE TD-5 BRAKING SYSTEM TD-5 SUSPENSION TD-6 TD TD–1 TECHNICAL DATA TECHNICAL DATA ENGINE Z4F931001001W01 Item Standard Compression pressure (kPa {kgf/cm2, psi}) Minimum Maximum difference between cylinders Specification FP 1,373 {14.0, 199} [300 rpm] 1,079 {11.0, 156} [300 rpm] FS 1,471 {15.0, 213} [300 rpm] 1,030 {10.5, 149} [300 rpm] 196 {2.0, 28} End Of Sie LUBRICATION SYSTEM Item Oil pressure (kPa {kgf/cm2, psi} [rpm] ) Oil capacity (Approximate quantity) Total (dry engine) (L {US qt, lmp qt}) Oil replacement (L {US qt, lmp qt}) Oil and oil filter replacement (L {US qt, lmp qt}) Engine oil Viscosity Above 30°C {86°F} 0°C—40°C {32°F—104°C} –10°C—20°C {14°F—68°F} –25°C—30°C {–13°F—86°F} Above –25°C {–13°F} Above –10°C {14°F} –30°C—37°C {–22°F—98°F} –15°C—40°C {5°F—104°F} Below 10°C {50°F} Z4F931001001W02 Specification FS 393—490 {4.0—5.0, 57—71} [3,000] 3.7 {3.9, 3.3} 3.3 {3.5, 2.9} 3.5 {3.7, 3.1} API service SG, SH, SJ SAE 40 SAE 30 SAE 20W—20 SAE 10W—30 SAE 10W—40, 10W—50 SAE 20W—40, 20W—50 SAE 5W—20, 5W—30 — — End Of SieSYSTEM COOLING Z4F931001001W03 Item Cooling capacity (L {US qt, lmp qt}) (Approximate quantity) Cap valve opening pressure Radiator (kPa {kgf/cm2, psi}) Initial-opening pressure (°C {°F}) Thermostat Full-open temperature (°C {°F}) Full-open lift (mm {in}) Outer diameter (mm {in}) Blade Number Cooling fan Motor Current (A) *1 *2 : MTX : ATX End Of Sie TD–2 Specification FS 7.5 {7.9, 6.6} 94—122 {0.95—1.25, 13.5—17.7} 80.0—84.0 {176—183} 95 {203} 8.5 {0.33} 300 {11.8} 2.4—4.4*1 5.2—7.2*2 TECHNICAL DATA FUEL AND EMISSION CONTROL SYSTEMS Z4F931001001W04 Gasoline-Powerd Vehicle Specification FS Item ENGINE TUNE-UP Idle speed Ignition timing Idle-up speed*1 E/L ON*2 (rpm) 650—750 (700 ± 50) 7—9 (8 ± 1)/700 (rpm) (BTDC°/rpm) 30A—40A 650—750 (700 ± 50) Above 40A*2 A/C ON*3 700—800 (750 ± 50) P/S operating*4 CO concentration HC concentration Fuel pressure Within the regulation Within the regulation More than 340 {3.5, 50} Hold pressure 2, (kPa {kgf/cm psi}) Fuel pump maximum pressure Fuel leakage (drop/2 min) Fuel injector Injection volume (ml {cc, fl oz}/15 s) Resistance (ohms) [20°C {68°F}] Pressure regulator Fuel pressure (at vacuum ON) 450—630 {4.5—6.5, 64—92} (kPa {kgf/cm2, psi}) Fuel pressure (at vacuum OFF) 270—310 {2.7—3.2, 39—45} *1 *2 *3 *4 Less than 68—75 {68—75, 2.3—2.5} 14.2—14.8 210—250 {2.1—2.6, 30—36} : Excludes temporary idle speed drop just after the electrical loads (E/L, A/C, P/S) are turned on : Headlights are on, fan switch is above 1st, cooling fan is operating, rear window defroster is on : A/C switch and fan switch are turned on : Steering wheel fully turned End Of Sie ENGINE ELECTRICAL SYSTEM Z4F931001001W05 Gasoline-powered vehicle Specification FS 1.27—1.29 Item Electrolyte gravity Battery Back-up current*1 Test load chart Battery type 50D20L (A) Slow charge Battery type 50D20L (40) (A) (5-hour rate) Quick Battery type charge 50D20L (40) (5-hour rate) (A/30 min) Rotor resistance (Between slip rings) Standard Brush length Minimum Brush spring Standard force Minimum Generator Standard voltage (V) Ignition switch ON Terminal Idle [20 °C {68 °F}] Terminal Generated current*4 Engine (Reference) speed (A) (rpm) (mA) Max 20 150 4.0—5.0 25 (Ohms) (mm {in}) (mm {in}) (N {kgf, lbf}) (N {kgf, lbf}) B P D B P D TD 2.5—2.9 18.5 {0.73} 5.0 {0.20} 4.8—6.0 {0.48—0.62, 1.06—1.36} 2.2 {0.22, 0.48} B+ Approx B+ 14.1—14.7 13—14 * 1,000 Approx 0—63 2,000 Approx 0—81 TD–3 TECHNICAL DATA Item Ignition coil Resistance [20 °C {68 °F}] Secondary coil Insulation resistance of case (Kilohms) (Megohms) NGK Type DENSO (mm {in}) NGK Resistance (Kilohms) DENSO Tightening torque (N·m {kgf·m, ft·lbf}) No.1 lead No.2 lead High-tension Resistance (Kilohms/m) [20°C {68 °F}] lead No.3 lead No.4 lead Standard (mm {in}) Commutator diameter Minimum (mm {in}) Standard (mm {in}) Brush length Minimum (mm {in}) Starter Standard (N {kgf, lbf}) Brush spring force Minimum (N {kgf, lbf}) Pinion gap (mm {in}) Voltage (V) No load test Current (A) Spark plug Plug gap Specification FS 8—14 10 ZFR5F-11*2 ZFR6F-11*3 KJ16CR 11*2 KJ20CR-11*3 1.0—1.1 {0.039—0.043} 3.0—7.5 15—22 {1.5—2.3, 11—16} 2.3—3.6 2.2—3.3 1.6—2.4 1.5—2.2 29.4 {1.16} 28.8 {1.14} 12.3 {0.48} 7.0 {0.28} 180—243 {18.3—24.8, 40.3—54.5} 57.7 {5.88, 12.9} 3.0 {0.118} 11 Below 90 *1 : Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the ignition switch is OFF and with the ignition key removed *2 : Standard plug *3 : Cold type plug *4 : Must not be A * : Turn the following electrical loads on and verify that the voltage reading increases • Headlights • Blower motor • Rear window defroster End Of Sie CLUTCH Z4F931016003W01 Item Clutch pedal Clutch cover Clutch disc Flywheel End Of Sie TD–4 Full stroke (mm {in}) Height (with carpet) (mm {in}) Free play (mm {in}) (mm {in}) (mm {in}) Specification 130—140 {5.12—5.51} L.H.D.:204—209 {8.03—8.22} R.H.D.:199—204 {7.84—8.03} 0.7—3.5 {0.02—0.13} 0.6 {0.024} 0.6 {0.024} (mm {in}) 0.5 {0.020} (mm {in}) (mm {in}) (mm {in}) 0.3 {0.012} 0.700 {0.028} 0.200 {0.008} Depth Diaphragm spring fingers Misalignment Maximum clearance of flatness of the pressure plate Minimum thickness Runout limit Runout limit TECHNICAL DATA MANUAL TRANSAXLE Z4F931001024W01 Specification G15M-R Item Transaxle oil Grade API service GL-4 or GL-5 SAE 75W-90 SAE 80W-90 All-season Above 10 °C {50 °F} Viscosity Capacity (approximate quantity) (L {US qt, lmp qt}) 2.7 {2.9, 2.4} End Of Sie TRANSAXLE AUTOMATIC Z4F931001024W02 Item ZL Automatic transaxle type Idle D, S, L range Line pressure (kPa {kgf/cm2, psi}) R position Engine stall speed D, S, L range (rpm) R position N→D Time lag (second) N→R Stall 1,070—1,230 {10.9—12.5, 155—178} Idle Stall 2,150—2,450 2,150—2,450 Specification FP FS FN4A-EL 330—470 {3.4—4.8, 48—66} 1,200—1,360 1,140—1,300 1,160—1,320 {12.2—13.9, {11.6—13.3, 165— {11.8—13.5, 167— 174—197} 189} 191} 490—710 {5.0—7.2, 71—102} 1,470—1,690 {15.0—17.2, 214—245} 2,300—2,600 2,350—2,650 2,200—2,500 2,300—2,600 2,350—2,650 2,200—2,500 0.4—0.7 0.4—0.7 ZM End Of AND Sie REAR AXLE FRONT Z4F931001018W01 Specification FS Item Shaft length (Air in boot at Left side Drive shaft atmospheric pressure) (mm {in}) Right side MTX ATX 641.0—651.0 {25.24—25.62} 627.9—637.9 {24.73—25.11} 604.6—614.6 {23.81—24.19} 608.9—618.9 {23.98—24.36} End Of SieSYSTEM BRAKING Z4F931001020W01 Item Power brake unit B3, ZL ZM FP, FS 650 {6.6, 94} (Rear drum brake), At kPa {0 600 {6.1, 87} 650 {6.6, 94} 600 {6.1, 87} mmHg, inHg} (Rear disc brake) Fluid pressure 6,500 {66, 940} (kPa {kgf/cm , At 66.7 kPa {500 (Rear drum brake), psi}) 5,600 {57, 810} 6,500 {66, 940} mmHg, 19.7 inHg} 5,600 {57, 810} (Rear disc brake) End Of Sie TD–5 TD TECHNICAL DATA SUSPENSION Z4F931001013W01 Suspension Item Empty (mm {in}) (degree) Total toe-in Front wheel alignment (Unloaded*1) Inner Maximum steering angle Outer Caster angle*2 (reference value) 1°46′ ± SAI 1°48′ ± 1°51′ ± 1°53′ ± –0°48′ ± Camber angle*2 *3 Fuel gauge indication 1/2 3/4 Full ± {0.08 ± 0.16} 0°12′ ± 24′ 13 inch wheel: 41° ± 2°, Except 13 inch wheel: 37° ± 2° 13 inch wheel: 35° ± 2°, Except 13 inch wheel: 33° ± 2° 1/4 12°34′ (reference value) 1°56′ ± –0°49′ ± 12°35′ 12°36′ *1 : Fuel tank full Engine coolant and engine oil are at specified level Spare tire, jack and tools are in designated position *2 : Difference between left and right must not exeed 1°30′ *3 : SAI: Steering axis inclination Wheels and Tires Australian specs Item Size Air pressure Tire Wheel 175/65 R14 82T Front (kPa {kgf/cm2, psi}) Rear Standard tire (mm {in}) Remainig tread Snow tire Size Material Offset (mm {in}) Pitch circle diameter (mm {in}) Runout limit Unbalance limit (at rim edge) Wheel nut tightening torque (mm {in}) Horizontal Vertical (g {oz}) (N·m {kgf·m, ft·lbf}) Specification 185/65 R14 86H 210 {2.1, 30} 195/50 R16 84V 210 {2.1, 30} 1.6 {0.063} 50% of tread 14 x 1/2JJ 16 x 6JJ Steel or aluminum alloy Aluminum alloy 45 {1.77} 50 {1.97} 100 {3.94} 114.3 {4.50} Steel wheel: 2.5 {0.098} Aluminum wheel: 2.0 {0.079} 1.5 {0.059} 10 {0.35} max {0.28} 89—117 {9—12, 66—86} • One balance weight: max 60 g {2.1 oz} • If the total weight exceeds 100 g {3.5 oz} on one side, rebalance after moving the tire around on the rim • Do not use more than two balance weights on the inner or outer side of the wheel TD–6 TECHNICAL DATA General (L.H.D R.H.D.) specs Item 155/80 R13 79S Size Up to persons Air pressure ~ Full load Up to (kPa {kgf/cm2, psi}) persons Rear ~ Full load Standard tire (mm {in}) Remainig tread Snow tire Size Material Offset (mm {in}) Pitch circle diameter (mm {in}) Front Tire Wheel Runout limit (mm {in}) Horizontal Vertical Unbalance limit (at rim edge) Wheel nut tightening torque (g {oz}) (N·m {kgf·m, ft·lbf}) Specification 185/65 R14 175/65 R14 86H, 185/65 82T R14 86T 210 {2.1, 30} 210 {2.1, 30} 220 {2.2, 32} 230 {2.3, 33} 210 {2.1, 30} 210 {2.1, 30} 280 {2.8, 41} 13 x 5J Steel 195/55 R15 85V 310 {3.2, 45} 1.6 {0.063} 50% of tread 14 x 1/2JJ Steel or aluminum alloy 45 {1.77} 100 {3.94} Steel wheel: 2.5 {0.098} Aluminum wheel: 2.0 {0.079} 1.5 {0.059} 10 {0.35} max 89—117 {9—12, 66—86} 290 {3.0, 43} 15 x 6JJ Aluminum alloy • One balance weight: max 60 g {2.1 oz} • If the total weight exceeds 100 g {3.5 oz} on one side, rebalance after moving the tire around on the rim • Do not use more than two balance weights on the inner or outer side of the wheel End Of Sie TD TD–7 SPECIAL TOOLS ST SPECIAL TOOLS ST-2 FUEL AND EMISSION CONTROL SYSTEMS ST-2 MANUAL TRANSAXLE ST-2 AUTOMATIC TRANSAXLE ST-2 FRONT AND REAR AXLE ST-3 BRAKING SYSTEM ST-4 BODY ELECTRICAL SYSTEM ST-4 HEATER AND AIR CONDITIONER SYSTEMS.ST-4 ST ST–1 SPECIAL TOOLS SPECIAL TOOLS FUEL AND EMISSION CONTROL SYSTEMS Z4F941001001W01 49 B019 901B 49 N013 101A 49 N013 102A Oil Pressure Gauge Body Adapter Hose WDS 49 B019 9A0 System selector — End Of Sie MANUAL TRANSAXLE Z4F941001024W01 49 E017 5A0 49 B001 795 Engine support set Oil seal installer — End Of Sie TRANSAXLE AUTOMATIC Z4F941001024W02 49 0378 400C 49 B019 901B 49 H019 002 Oil pressure gauge set Oil pressure gauge Adapter 49 E017 5A0 WDS Engine support set End Of Sie ST–2 — SPECIAL TOOLS FRONT AND REAR AXLE Z4F941001018W01 49 B026 103 49 G026 105 49 B025 006A Sensor rotor installer Sensor rotor installer Sensor rotor installer 49 B025 009A 49 F026 102 49 H034 201 Installer attachment Bearing installer Support block 49 H027 002 49 G030 797 49 B025 004 Bearing remover Handle Dust seal installer 49 W027 003 49 T025 001 49 B027 006 Bearing installer Boot clamp crimpers Diff side gear holder (MTX) 49 G030 455 49 F027 005 Diff side gear holder (ATX) Attachment 62 — End Of Sie ST ST–3 SPECIAL TOOLS BRAKING SYSTEM Z4F941001020W01 49 0259 770B 49 G066 001 49 U043 0A0A Flare nut wrench Adapter harness Oil pressure gauge set 49 U043 004A 49 U043 005 49 U043 006 Oil pressure gauge (Part of 49 U043 0A0A) Joint (Part of 49 U043 0A0A) Hose (Part of 49 U043 0A0A) WDS — — End OfELECTRICAL Sie BODY SYSTEM Z4F941001047W01 49 D066 003 49 D066 801A 49 H066 002 Adapter harness Removing Tool Deployment tool 49 N088 0A0 49 0839 285 Fuel and thermometer checker (new) Fuel and thermometer checker (old) — End Of Sie HEATER AND AIR CONDITIONER SYSTEMS 49 C061 0A0B 49 B061 014 Manifold gauge set (R-134a) Spring lock coupling disconnect tool End Of Sie ST–4 Z4F941001038W01 — ... RELATED MATERIALS LASER TRAINING MANUAL (Australia, General (R.H.D L.H.D.)) LASER REPAIR MANUAL (Australia, General (R.H.D L.H.D.)) LASER REPAIR MANUAL SUPPLEMENT... essentially carried over from that of the current LASER , except for the following features (See LASER TRAINING MANUAL F328-10-98K.) (See LASER REPAIR MANUAL SUPPLEMENT F164-10-99H.) End Of Sie FEATURES... changes and/or additions have been made since publication of the LASER REPAIR MANUAL VOLUME1 (F162-10-98K) and the LASER REPAIR MANUAL SUPPLEMENT (F164-10-99H) Ignition timing • Inspection procedure