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SAFETY NOTICE CAUTION

ALL SERVICE AND REBUILDING INSTRUCTIONS CONTAINED HEREIN ARE

APPLICABLE

TO,

AND

FOR

THE

CONVENIENCE

OF,

THE

AUTOMOTIVE

TRADE ONLY. All test and repair procedures on components or assemblies in

non-automotive applications should be repaired in accordance with instructions supplied by the manufacturer of the total product.

Proper service and repair is important to the safe, reliable, operation of all motor vehicles. The service procedures recommended and described in this publication were developed for professional servlTe personnel and are effective methods for performing vehicle repair. Following these procedures will help assure efficient economical vehicle performance and service reliability. Some of these service procedures require the use of special tools designed for specific procedures. These special tools should be used when recommended throughout this publication.

Special attention should be exercised when working with spring or tension loaded fasteners and devices such as E-Clips, Circlips, Snap rings, etc., as careless removal may cause personal injury. Always wear safety goggles whenever working on vehicles or vehicle components.

7

It is important to

These should be carefully read in order to minimize the risk of personal injury, or the possibility that, improper service methods may damage the vehicle or render it unsafe. It is important to note that these Cautions and Warnings cover only the situations and procedures Chrysler Motors has encountered and recommended. Chrysler Motors could not possibly know, evaluate, and advise the service trade of all conceivable ways that service may *be performed, or of the possible hazards of each. Consequently, Chrysler Motors has not undertaken any such broad service review. Accordingly, anyone who uses a service procedure, or tool, that is not recommended in this publication, must assure oneself thoroughly that neither personal safety, nor vehicle safety, be jeopardized by the service methods they select.

this publication contains various Cautions and Warnings .

note that

publication contains various Cautions and Warnings . note that WE SrjPPORT VOLUNTARY TECHNICIAN CERTIFICATION THROUGH
publication contains various Cautions and Warnings . note that WE SrjPPORT VOLUNTARY TECHNICIAN CERTIFICATION THROUGH

WE SrjPPORT VOLUNTARY TECHNICIAN CERTIFICATION THROUGH

publication contains various Cautions and Warnings . note that WE SrjPPORT VOLUNTARY TECHNICIAN CERTIFICATION THROUGH
publication contains various Cautions and Warnings . note that WE SrjPPORT VOLUNTARY TECHNICIAN CERTIFICATION THROUGH
publication contains various Cautions and Warnings . note that WE SrjPPORT VOLUNTARY TECHNICIAN CERTIFICATION THROUGH
TALON BACKUP TECHNICAL INFORMATION MANUAL FOREWORD This manual has been prepared as an introduction to

TALON

BACKUP

TECHNICAL

INFORMATION
INFORMATION

MANUAL

FOREWORD

This manual has been prepared as an introduction to the specifications, features, construction and func- tions of the newly developed TALON. Please read this manual carefully as it will be of assistance for service and sales activities Please note that the service manuals are also available and should be used in conjunction with this manual. All information, illustrations and product descrip- tions contained in this manual are current as at the time of publication. We, however, reserve the right to make changes at any time without prior notice or obligation.

make changes at any time without prior notice or obligation. This BACKUP DSM manual IS to

This BACKUP DSM manual IS to be used ONLY as a BACKUP. Please DO NOT REDISTRIBUTE

IS to be used ONLY as a BACKUP. Please DO NOT REDISTRIBUTE WHOLE SECTIONS. This a

WHOLE SECTIONS. This

a GENUINE DSM MANUAL. It CANNOT BE considered a REPLACEMENT (Unless your manual was lost or destroyed.)

BACKUP was sold to you under the fact that you do indeed OWN

original

sold to you under the fact that you do indeed OWN original Please See README.N or

Please

See README.N

or README.HTML for additional information
or README.HTML
for additional information
See README.N or README.HTML for additional information Thank you. G~mm~emymanual@hotma~l.com -- GROUP INDEX

Thank you. G~mm~emymanual@hotma~l.com

information Thank you. G~mm~emymanual@hotma~l.com -- GROUP INDEX ROSA. General Front Suspension Rear Axle
-- GROUP INDEX ROSA. General Front Suspension Rear Axle . Brakes - Eir$rii s Clutch
--
GROUP INDEX
ROSA.
General
Front Suspension
Rear Axle
.
Brakes - Eir$rii
s
Clutch
Cooling
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Electrical
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Engine
Intake and Exhaust
Fuel System
Propeller Shaft and Universal
Joint
Rear Suspension
l
m
Power steering
l
CD
Manual
Transaxle - Automatic
m
Body
m
A
Heaters and Air Conditioning
RI
Emission Control Systems

Chrysler Motors 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 PreViOUSlV manufactured.

to install them on its products PreViOUSlV manufactured. a * - a - . I .-1-L,.*

a *-a- .I

.-1-L,.*

#Q ^_^

l L.-

Orintul

in U.S.A.

-_-

1

-.

-_- 1 -. MODEL INDICATIONS The following abbreviations are used in this manual for classification of

MODEL INDICATIONS

The following abbreviations are used in this manual for classification of model types. M/T: Indicates the manual transaxle, or models equipped ‘with the manual transaxle.

A/T:

or models equipped ‘with the manual transaxle. A/T: Indicates the automatic transaxle, or models equipped with

Indicates the automatic transaxle, or models equipped with the automatic transaxle.

MPI: Indicates the multi-point injection, or engines equipped with the multi-point injection.

or engines equipped with the multi-point injection. DOHC: Indicates an engine with the double overhead

DOHC: Indicates an engine with the double overhead camshaft, or a model equipped with such an engine,

Turbo:

Non-Turbo: Indicates an engine without turbocharger, or a model equipped with such an engine.

2WD: Indicates the front wheel-drive vehicles. 4WD: Indicates the 4 wheel-drive vehicles.

Indicates an engine with turbocharger, or a model equipped with such an engine.

Indicates the 4 wheel-drive vehicles. Indicates an engine with turbocharger, or a model equipped with such
with turbocharger, or a model equipped with such an engine. HOW TO READ A CIRCUIT DIAGRAM

HOW TO READ A CIRCUIT DIAGRAM

Circuit diagrams are prepared as follows using these symbols:

NOTE For specific details concerning the interpretation of circuit diagrams, refer to the separately bound Service Manual.

The current flow at the i nition key positions “ACC” ”8N” and “ST” is shown
The current flow at the i nition
key positions “ACC” ”8N” and
“ST” is shown combined.
Be sure to trace the appropriate
circuit depending on the ignition
key position.
~
These symbols show the input to
and output from (direction of
current flow to and from) an
electronic control unit.
o&ficates that current flows
Input
and
1 Indicates
power
1
Input
Output
output
supply connection.
Connectors A : Female connector 9.1 Male connector \ I l-4’ Arrow indicates direction of
Connectors
A : Female connector
9.1 Male connector
\ I l-4’
Arrow indicates direction of

This symbol indicates connector for equipment (male connector is used as an intermediate connec- tor) viewed from in front of the

as an intermediate connec- tor) viewed from in front of the Connector for equip- ment with
as an intermediate connec- tor) viewed from in front of the Connector for equip- ment with
as an intermediate connec- tor) viewed from in front of the Connector for equip- ment with
Connector for equip- ment with attached har- ness Connector inserted
Connector for equip-
ment with attached har-
ness
Connector inserted

- --- -~- -------l

O-l

- --- -~- -------l O-l GENERAL CONTENTS G E N E R A L D A

GENERAL

- --- -~- -------l O-l GENERAL CONTENTS G E N E R A L D A

CONTENTS

GENERAL DATA AND SPECIFICATIONS

13

TECHNICAL FEATURES 4WD (Four-wheel Drive) PJT Safety-lock System Basic Construction

 

2

7

7

4

Engine

5

Exterior

2

Interior

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3

Theft-alarm System (Option for 4WD

Theft-alarm System (Option for 4WD

Vehicles)

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8

VEHICLE IDENTIFICATION Engine Model Stamping Vehicle Identification Code Chart Plate Vehicle Identification Number List Vehicle Identification Number Location Vehicle Information Code Plate Vehicle Safety Certification Label

9

12

9

10
10

9

1

12

1

I n f o r m a t i o n C o d e P
I n f o r m a t i o n C o d e P

o-2

GENERAL - Technical Features

TECHNICAL FEATURES

EXTERIOR
EXTERIOR

Low and wide profile for appearance sports car impression.

ROOCAAB

OOA0190 2
OOA0190
2

7

OOA0189
OOA0189

I

1

No.

t

Features

1

Flush surface and low front high rear styling for outstanding aerodynamic performance

2

Pop up headlights of optical horn type

3

Hood bulge indicating DOHC engine

4

Futuristic glass upper body

5

Removable tilt up sunroof (option for all models)

6

Smooth integrated body lines giving a lean appearance

7

Wide tires and wide tread to emphasize power and stability

a
a

Bumpers made integral with the body

9

Wall to wall tail lamps for sporty image

I

f

I

1

i

I

i --
i
--
Y
Y

GENERAL -

Technical Features

o-3

INTERIOR
INTERIOR
Y GENERAL - Technical Features o-3 INTERIOR , I i ! ! I   \ /

,

I

i

!

!

I

 

\

/
/
OOAO162
OOAO162

No.

Features

1

Cock pit type instrument panel to give sporty image

2

Switches arranged around the driver seat for easy access and operation

 

3

Hi back seats with integral head rest for comfortable and firm holding

 

4

Integrally molded door trims with round and smooth transition to the instrument panel

 

5

Sporty double seat with firm holding

6

Rear quarter trims with built in dynamic speakers

7

Easy to use large capacity console box

o-4

GENERAL - Technical Features

BASIC CONSTRUCTION

The 4WD vehicles are equipped with 2.OL DOHC 16-valve turbocharged engine and incorporate new technologies such as full time 4WD of center differential type with viscous coupling differential limiting for excellent running stability and excellent

driving across bad roads, and $-wheel independent suspension for comfortable riding. Adopted on 2WD vehicles are 2.OL DOHC 16-valve engine, MacPherson strut type front suspension and torsion axle typ.e 3-link rear suspension.

Steering

l

l

Light weight and compact rack and pinion type for high steering response

Tilt steering mechanism to give optimum driving position \

Tilt steering mechanism to give optimum driving position \ Rear suspension l Self-aligning double wishbone type

Rear suspension

l

Self-aligning double wishbone type suspen- sion for comfortable ride (4WD)

l

Torsion axle type 3 link suspension for outstanding driving stability (2WD)

Negative chamber for outstanding steer- ability during high speed driving 0 Anti-lift geometry for high stability during braking

l

l Integral torsional bar type axle beam for optimum roll stiffness (2WD) \ Front propeller
l Integral torsional bar type axle beam for
optimum roll stiffness (2WD)
\
Front propeller shaft (3-piece 4-joint type)
(2WD) \ Front propeller shaft (3-piece 4-joint type) l Robro joint to absorb lengthwise and angular

l Robro joint to absorb lengthwise and angular change and prevent transmission of vibrations.

(4WD)
(4WD)
I Front suspension The front suspension of McPherson strut type independent suspension system Brakes
I
Front suspension
The front suspension of McPherson strut type
independent suspension system
Brakes

l

Under steer geometry for outstanding steering stability

Negative offset geometry for outstanding stabil- ity at braking 0 Offset coil springs for comfortable ride

l

at braking 0 Offset coil springs for comfortable ride l l Cross piping dual type proportioning
l Cross piping dual type proportioning valve that keeps balanced braking power even at failure
l
Cross piping dual type proportioning valve
that keeps balanced braking power even at
failure of the hydraulic system.
l
Four wheel disc brake system for high
braking power.
balanced braking power even at failure of the hydraulic system. l Four wheel disc brake system

GENERAL - Technical Features

o-5

ENGINE
ENGINE

The engines are the transverse-mounted engine especially for front-engine/front-wheeldrive or front-engine/4-wheel drive models, the 2.OL DOHC 16-valve engine with high-performance, silent-

2.OL DOHC 16-valve engine with high-performance, silent- SPECIFICATIONS operation, l o w - v i b

SPECIFICATIONS

operation, low-vibration, low-noise, low-fuel- consumption features, an engine that fully displays the most up-todate engine technology.

Engine model

Displacement

cc (cu.in.1

Displacement cc (cu.in.1

h$xo$put (SAE net)

h$xo$put (SAE net)
h$xo$put (SAE net)

Max. torque (SAE net) ft.Ibs./rpm

Max. torque (SAE net) ft.Ibs./rpm

4G63 Non-Turbo

1997

(122)

135/6000

125/5000

4663 Turbo

4663 Turbo

1997

(122)

195/6000

203/3000

FEATURES

High performance and low fuel consumption

The rocker arm reduces the valve-actuation torque as well as fuel consumption.

l

Air-intake efficiency improved through the adoption of the optimum air-intake system layout.

l

Improved response and fuel consumption has been achieved by electronic control multipoint fuel injection.

l

Water-cooled turbocharger. <Turbo>

l

Quiet

operation

Noise and vibration have been decreased by the adoption of roller rocker arms.

l

Noise generated by the valve mechanism has been decreased by the hydraulic auto lash adjusters.

l

l

Vibrations have been decreased by the adoption of bearing caps with beams which increase the rigidity of the crankshaft support points.

-

Serviceability

Complete self-diagnosis functions.

l

Enhanced reliability through the adoption of gold-plated connector terminals.

l

Use of an auto tensioner achieves maintenance-free, automatic adjustment of timing belt tension.

l

Use of the auto lash adjusters achieves maintenance-free, automatic adjustment of valve clearance

l

.o The 2coil The 2coil

ignition system without a distributor supplies sufficient ignition energy even during

high speed operation.

O-6
O-6

GENERAL - Technical Features

O-6 GENERAL - Technical Features Ignition system The 2coil ignition system without a distributor supplies
O-6 GENERAL - Technical Features Ignition system The 2coil ignition system without a distributor supplies

Ignition system

The 2coil ignition system without

a distributor supplies sufficient

ignition energy even in the high

speed operation.

ignition energy even in the high speed operation. 76-4 Crankshaft pu!ley The oullev orovrded with a
76-4 Crankshaft pu!ley The oullev orovrded with a torsion- al da’mper ieduces the transmis- sion
76-4 Crankshaft pu!ley
The oullev orovrded with a torsion-
al da’mper ieduces the transmis-
sion of vibrations.
EN0376
Valve mechanism
l
The roller rocker arms de-
crease losses.due to friction in
the valve system.
Auto tensioner
l
The auto lash adjusters elimin-
ate the need to adjust the valve
clearance.
The auto tensioner eliminates the
need to adjust the timing belt
tension.

I

Combustion

chamber

J
J

The combustion chamber is pro- vided with a squish area for high combustion efficiency. t

chamber is pro- vided with a squish area for high combustion efficiency. t ]I crankshaft has
]I crankshaft has five marn bearings
]I
crankshaft has five marn bearings

GENERAL

-

Technical

Features

o-7

4WD (Four-wheel
4WD (Four-wheel

drive)

The full time 4WD system adopts viscous coupling

as the differential limiting device for the

unit (VCU)

center

differential

of

4WD vehicle to achieve auto-

(VCU) center differential of 4WD vehicle to achieve auto- matic and ideal distribution of engine torque
(VCU) center differential of 4WD vehicle to achieve auto- matic and ideal distribution of engine torque

matic and ideal distribution of engine torque to the

front and rear wheels.

Viscous coupling

Viscous coupling
r_ Engine
r_
Engine
Viscous coupling (VCU) VP? limited slip differential (OptIOn) 00P0031
Viscous coupling
(VCU) VP?
limited slip differential (OptIOn)
00P0031

A/T SAFETY-LOCK SYSTEM

JT safety-lock system
JT safety-lock
system

interlock device) has been adopted to improve

safety*FN
safety*FN

Key interlock device

Ignition key cylinder

(shift lock device and key

device Ignition key cylinder (shift lock device and key Shift lock device Selector handle AIT control
device Ignition key cylinder (shift lock device and key Shift lock device Selector handle AIT control

Shift lock device

Selector handle AIT control cable S h i f t l o c k c

Selector handle

Selector handle AIT control cable S h i f t l o c k c a
Selector handle AIT control cable S h i f t l o c k c a

AIT control cable

Selector handle AIT control cable S h i f t l o c k c a

Shift lock cable

~

^.

O-8

GENERAL - Technical Features

THEFT-ALARM 4WD VEHICLES)

To make the vehicle theftproof, this system is so designed that the headlights go on and off and the horn is sounded intermittently for ‘about three

for

SYSTEM

(OPTION

minutes when the locked door, hood or liftgate has been forced open without using a key. Furthermore, the starter circuit is interrupted so that the engine may not be operated, making the vehicle theftproof.

4uthorized

4uthorized I About 20 seconds after all doors are closed and locked, the rear hatch is

I

About 20 seconds after all doors are closed and locked, the rear hatch is closed, and the hood is closed---t SYSTEM ARMED Unauthorized

and the hood is closed---t SYSTEM ARMED Unauthorized A door, rf!ar hatch or hood is broken
and the hood is closed---t SYSTEM ARMED Unauthorized A door, rf!ar hatch or hood is broken
and the hood is closed---t SYSTEM ARMED Unauthorized A door, rf!ar hatch or hood is broken

A door, rf!ar hatch or hood is broken

to open +

ALARM ACTIVATED Engine is disabled to start.

+ A L A R M ACTIVATED Engine is disabled to start. t I Driver opens
t
t

I

Driver opens door with the keyA L A R M ACTIVATED Engine is disabled to start. t I 0 1 SYSTEM

is disabled to start. t I Driver opens door with the key 0 1 SYSTEM DISARMED
0
0

1

SYSTEM DISARMED

I
I

Normal 1 starting-1

or rear hatch with the -
or rear hatch with the
-
the key 0 1 SYSTEM DISARMED I Normal 1 starting-1 or rear hatch with the -

ALARM DEACTIVATED

DISARMED)

(SYSTEM

16Y3575
16Y3575

/

GENERAL - Vehicle Identification

019

VEHICLE IDENTIFICATION RooDAiA VEHICLE IDENTIFICATION NUMBER LOCATIO N The vehicle identification number (V.I.N.) is
VEHICLE
IDENTIFICATION
RooDAiA
VEHICLE IDENTIFICATION NUMBER
LOCATIO N
The vehicle identification number (V.I.N.) is located on a plate
attached to the left top side of the instrument panel.

VEHICLE

IDENTIFICATION CODE CHART PLATE

All vehicle identification numbers contain 17 digits. The vehicle number is a code which tells country, make, vehicle type, etc.

is a code which tells country, make, vehicle type, etc. / I I \ \ 12th
is a code which tells country, make, vehicle type, etc. / I I \ \ 12th
/ I I \ \ 12th to 1st 2nd 3rd 4th 5th 6th 7th 6th
/
I
I
\ \
12th to
1st
2nd
3rd
4th
5th
6th
7th
6th
9th
10th
11th
---l--
Digit
Digit
Digit
Digit
Digit
Digit
Digit
Digit
Digit
Digit
Digit
17th
Digits
Country
Make
Vehicle
Others
Line
Price
Model
Plant
Serial
Sody
Engine
*Check
number
tvw
I
I
class
digits
year
4-
4-
R-
1
L-
E-
000001
1
I-
E-
3 -
6 -
S-
USA
Eagle
Passenger
Manual
Talon
High
Bdoor
2.0
liters
:
1990
DSM
6-
Hatch-
/;gHE.in.)
year
99%99
car
seat belt
IZWDI
C-
T-
Premrum
back
Automatic
Talon
6
MPI]
seat belt
(4WD)
Special
U-
2.0
liters
1
/;gHF.in.)
MPI-Turbo]
:
9
X

NOTE l “Check digit” means a single number or letter X used to verify the accuracy of transcriptron of vehicle identification number.

means a single number or letter X used to verify the accuracy of transcriptron of vehicle

r -.--

r -.-- O - 1 0 GENERAL - Vehicle Identification

O-10

GENERAL - Vehicle Identification

VEHICLE IDENTIFICATION

VEHICLES FOR FEDERAL

NUMBER LIST

V.I.N. (except sequence number)

Brand

Engine

displacement

Models Code

 

4E3CT44RClLE

Eagle TalonQWD)

2.0

liter (122 cu,in.)

D22AMNHML4E
D22AMNHML4E
 

[DOHC-MPI]

 

D22AMRHML4E

 

4E3CT54UClLE

2.0 liter (122 cu.in.) [DOHC-MPI-Turbo]

D22AMNPFL4E
D22AMNPFL4E
 

4E3CT64UOLE

Eagle Talon (4WD)

D27AMNGFL4E

 

VEHICLES FOR CALIFORNIA (Can also be sold in Federal States.)

 

1 V.I.N. (except sequence number)

( Brand

1 Engine

displacement

I

Models Code

 

4E3CT44tKILE

Eagle Talon (2WD)

2.0

liter (122 cu.in.)

D22AMNHMLSE

 

[DOHC-MPI]

 

D22AMRHMLSE

4E3CT54UOLE

2.0

2.0 liter (122 cu.in.1

liter (122 cu.in.1

D22AMNPFLSE

4E3CT64UOLE

Eagle Talon (4WD)

[DOHC-MPI-Turbo]

D27AMNGFLSE

VEHICLES FOR CANADA

 

1 V.I.N. (except sequence number)

1 Brand

Engine

displacement

Models Code

 

4E3BT44ROLE

4E3BT44ROLE 2.0 liter (122 cu.in.) D22AMNHML5E  

2.0

liter (122 cu.in.)

D22AMNHML5E
D22AMNHML5E
 

[DOHC-MPI]

 
D22AMRHML5E
D22AMRHML5E
 

4E3BT54UOLE

 

2.0

liter (122 cu.in.)

4E3BT54UOLE   2.0 liter (122 cu.in.)

4E3BT64UOLE

Eagle Talon (4WD)

[DOHC-MPI-Turbo]

G E N E R A L - Vehicle Identification o-11

GENERAL - Vehicle Identification

o-11
o-11
/lb------ I OOAO164 J HODEL ENGINE TNANS 3 coLoK E 4 OOAO163
/lb------
I
OOAO164
J
HODEL
ENGINE
TNANS
3
coLoK E
4
OOAO163

VEHlCLE

J HODEL ENGINE TNANS 3 coLoK E 4 OOAO163 VEHlCLE INFORMATION CODE PLATE Vehicle information code

INFORMATION CODE PLATE

TNANS 3 coLoK E 4 OOAO163 VEHlCLE INFORMATION CODE PLATE Vehicle information code plate the The

Vehicle information code plate

the

The plate shows model and body color code.

is riveted onto the bulkhead in

engine

compartment.

code. is riveted onto the bulkhead in engine compartment. code. engine model, transaxle model, 1. MODEL

code. engine model, transaxle model,

1.

MODEL

2.

ENGINE

3.

TRANSAXLE

4.

COLOR,

TRIM OPT

ENGINE 3. TRANSAXLE 4. COLOR, TRIM OPT SF bll~~l~~~e, 4663 F5!Vl33 I Engine model (Transaxle
ENGINE 3. TRANSAXLE 4. COLOR, TRIM OPT SF bll~~l~~~e, 4663 F5!Vl33 I Engine model (Transaxle

SF bll~~l~~~e,

4663 F5!Vl33
4663
F5!Vl33

I Engine model

(Transaxle model

H18

)
)

Monotone exterior color code

BODY COLOR CODE

Exterior code

Body color

H18

Light Gray (M) Red Dark-Red Turquoise Blue (M) Dark Blue (M) White Black

Light Gray (M) Red Dark-Red Turquoise Blue (M) Dark Blue (M) White Black

Light Gray (M) Red Dark-Red Turquoise Blue (M) Dark Blue (M) White Black
Rll
Rll

R16

T13 T-81 w12 x13
T13
T-81
w12
x13

o-12

GENERAL - Vehicle Identification

VEHICLE SAFETY CERTI,FICATION LABEL 1. The vehicle safety certification label is attached to the face
VEHICLE SAFETY CERTI,FICATION LABEL 1. The vehicle safety certification label is attached to the face
VEHICLE SAFETY CERTI,FICATION LABEL 1. The vehicle safety certification label is attached to the face
VEHICLE SAFETY CERTI,FICATION LABEL 1. The vehicle safety certification label is attached to the face
VEHICLE SAFETY CERTI,FICATION LABEL 1. The vehicle safety certification label is attached to the face
VEHICLE SAFETY CERTI,FICATION LABEL 1. The vehicle safety certification label is attached to the face
VEHICLE SAFETY CERTI,FICATION LABEL 1. The vehicle safety certification label is attached to the face
VEHICLE SAFETY CERTI,FICATION LABEL 1. The vehicle safety certification label is attached to the face
VEHICLE SAFETY CERTI,FICATION LABEL 1. The vehicle safety certification label is attached to the face
VEHICLE SAFETY CERTI,FICATION LABEL 1. The vehicle safety certification label is attached to the face
VEHICLE SAFETY CERTI,FICATION LABEL 1. The vehicle safety certification label is attached to the face

VEHICLE

SAFETY CERTI,FICATION

LABEL
LABEL

1. The vehicle safety certification label is attached to the face of left door pillar.

2. This label indicates the month and year of manufacture, Gross Vehicle Weight Rating (G.V.W.R.), Gross Axle Weight Rating (G.A.W.R.) front, rear and Vehicle identification Number (V.I.N.).

front, rear and Vehicle identification Number (V.I.N.). ENGINE MODEL STAMPING 1. The engine model number is

ENGINE

ENGINE MODEL STAMPING 1. The engine model number is stamped at the front side on the

MODEL STAMPING

1. The engine model number is stamped at the front side on the top edge of the cylinder block as shown in the following.

Engine model

Engine displacement

4663
4663

2.0 liter (122 cu.in.) [DOHC-MPI] or [DOHC-MPI-Turbo1

2.

The engine serial number is stamped near the engine model number, and the serial number cycles, as shown below.

  Engine serial number   Number cycling   AA0201 t o Y Y 9 9
 

Engine serial number

 

Number cycling

 
AA0201
AA0201

toYY9999

-

AAo201--------hAA
AAo201--------hAA
 
LAB0001 --------+ AY9999

LAB0001 --------+ AY9999

L BAOOOl-------+ YY9999

L BAOOOl-------+ YY9999

GENERAL - General Data and Specifications o - 1 3

GENERAL -

General Data and Specifications

o-13

GENERAL DATA AND SPECIFICATIONS

M M

o - 1 3 GENERAL DATA AND SPECIFICATIONS M OOAO159 Items Vehicle dimensions Overall length Overall
OOAO159
OOAO159
Items Vehicle dimensions Overall length Overall width Overall height Wheel base Tread mm (in.) 1
Items
Vehicle dimensions
Overall length
Overall width
Overall height
Wheel base
Tread
mm (in.)
1
4,330 (170.5)
4,350 (171.3)
4,380 (172.4)
2
1,690 (66.5)
1,700 (66.9)
1,700 (66.9)
3
1,306 (51.4)
1,306 (51.4)
1,321 (52.0)
4
2,470 (97.2)
2,470 (97.2)
2,470 (97.2)
Front
5
1,465 (57.7)
1,465 (57.7)
1,465 (57.7)
Rear
6
1,450 (57.1)
‘1,450 (57.1)
1,455 (57.3)
Overhang
Front
7
950
(37.4)
960
(37.8)
960
(37.8)
Rear
8
910
(35.8)
920
(36.2)
950
(37.4)
Minimum running ground
clearance
9
lsO(6.3)
160
(6.3)
158
(6.2)
Angle of approach
Angle of departure
10
16.5”
13.8”
1’4.7”
.
11
19”
17”
18.4”
Vehicle’weight
kg (Ibs.)
Curb weights
M/T
1,215 (2,679)
1.245.(2,745)
1,245 (2,745)
Al-r
1,240 (2,734)
-
Gross vehicle weight rating
Gross axle weight rating
1,620 (3,571)
1,620 (3,571)
1,782 (3,929)
Front
930
(2.050)
930
(2,050)
979
(2,158)
Rear
690
(1,521)
690(1,521)
803
(1,770)
Seating capacity
4
4
4
Engine
Model No.
4663 (2.OL)
4663 (2.OL)
4663 (2.OL)
Transaxle
Model No.
Manual transaxle
Automatic transaxle
F5M22
F5M33
W5M33
-
-
F4A22
Clutch
Type
Dry-single disc &
diaphragm spnng
Dry-single disc &
diaphragm spring
Dry-single disc &
diaphragm spring

o-14

GENERAL - General Data and Specifications

tiems Chassis Tire P205/55HR16 or P205/55VR 16 or P205155VR16 or 205l55VR 16 205155VR16 205155VR16 Front
tiems
Chassis
Tire
P205/55HR16 or
P205/55VR 16 or
P205155VR16 or
205l55VR 16
205155VR16
205155VR16
Front suspension
Type
Independent strut
Independent strut
Independent strut
Rear
suspension
Type
3-Link
3-Link
Double wishbone
Torsion axle
Torsion axle
Brake
Type
Front
Disc
Disc
Disc
Rear
Disc
Disc
Disc
Steering
Gear type
Gear ratio
Fuel tank
Capacity liters (gals.)
Rack and pinion
Rack and pinion
Rack and pinion
m
00
co
60 (16)
60 (16)
60 (16)

ENGINE SPECIFICATIONS

Items

4G63 (2.OL)

Non-Turbo

1 4 6 6 3 ( 2 . O L )

14663 (2.OL)

Turbo

 
Type Number of cylinders

Type Number of cylinders

 

In-line DOHC

~In-line DOHC

4

‘4

Bore

mm (in.)

85.0

(3.35)

85.0 (3.35)

Stroke

mm (in.)

88.0

(3.46)

88.0 (3.46)

Piston displacement

cm3 (cu.in.)

cm3 (cu.in.)

1,997 (122)

 

1,997 (122)

Compression ratio Firing order

9.0

7.8

l-3-4-2

 

l-3-4-2

TRANSAXLE

SPECIFICATIONS

Items

F5M22
F5M22
F5M33
F5M33
W5M33
W5M33
F4A22
F4A22
Type
Type

5-speed M/T

5-speed M/T

&speed ArF 3.083
&speed ArF
3.083
4-speed AiT

4-speed AiT

Gear ratio

1st

3.363

3.038

2.846

2nd

1.947

1.833

1.684

1.581

3rd

1.285

1.217

1.115

1 .ooo

1 .ooo

4th

0.939
0.939

0.888

0.833

0.686

5th

0.756

0.741

0.666

 
 
 

Reverse

3.083

3.166

3.166

2.176

Transfer gear

ratio

-

1.090

Final

drive gear

ratio

3.941

3.437

3.866

3.562

it?
it?
2-1
2-1
it? 2-1

‘FRONT

SUSPENSION

it? 2-1 ‘FRONT SUSPENSION ANTI-DIVE GEOMETRY F R O N T A X L E Drive

ANTI-DIVE GEOMETRY

FRONT AXLE Drive Shaft Hub and Knuckle

F R O N T A X L E Drive Shaft Hub and Knuckle GENERAL INFORMATlON

GENERAL INFORMATlON Construction Diagram Specifications

CONTENTS

no2&--

5

LOWER ARM

LOWER ARM

7

8

NEGATIVE-OFFSET GEOMETRY

5

8

OFFSET SPRING

6

9

 

STABILIZER

7

2

2

3

T R Y 5 8 O F F S E T S P R I N
T R Y 5 8 O F F S E T S P R I N
T R Y 5 8 O F F S E T S P R I N
T R Y 5 8 O F F S E T S P R I N
T R Y 5 8 O F F S E T S P R I N
T R Y 5 8 O F F S E T S P R I N
T R Y 5 8 O F F S E T S P R I N
T R Y 5 8 O F F S E T S P R I N
T R Y 5 8 O F F S E T S P R I N
T R Y 5 8 O F F S E T S P R I N

2-2

FRONT SUSPENSION - General Information

2 - 2 FRONT SUSPENSION - General Information . GENERAL INFORMATION The front suspension has a

.

GENERAL INFORMATION

The front suspension has a simple construction, the McPherson strut type independent suspension featuring light unsprung weight.

The front Suspension has the

the

following features:

thanks

to

l

Excellent

driving

stability,

“antidive” geometry.

CONSTRUCTION

DIAGRAM driving stability, “antidive” geometry. CONSTRUCTION l Excellent braking stability, thanks to the

stability, “antidive” geometry. CONSTRUCTION DIAGRAM l Excellent braking stability, thanks to the

l Excellent braking stability, thanks to the negative-offset geometry. l Greatly improved riding comfort, thanks to the offset arrangement of the coil springs.

t
t
<2WD>
<2WD>
/ lshing
/
lshing
<2WD> / lshing Rubber insulator Coil spring ,Strut assembly I ,Rubber bushing Stabili Centermember Lowecarm

Rubber insulator

Coil spring

,Strut assembly

/ lshing Rubber insulator Coil spring ,Strut assembly I ,Rubber bushing Stabili Centermember Lowecarm

I ,Rubber

bushing

insulator Coil spring ,Strut assembly I ,Rubber bushing Stabili Centermember Lowecarm <4WD> Rubber

Stabili

Centermember Lowecarm <4WD>
Centermember
Lowecarm
<4WD>
bushing Stabili Centermember Lowecarm <4WD> Rubber insulator Stabilizer bar No.1 Crokmember - -

Rubber insulator

Stabilizer bar
Stabilizer
bar
No.1 Crokmember
No.1 Crokmember
- - 12AOO25
-
- 12AOO25

Lower arm

FRONT SUSPENSION - General Information 2 - 3

FRONT SUSPENSION - General Information

2-3

SPECIFICATIONS

<2WD>

terns Non-Turbo Turbo With a manual transaxle With an automatic transaxle With a manual transaxle
terns
Non-Turbo
Turbo
With a manual
transaxle
With an automatic
transaxle
With a manual
transaxle
Suspension system
McPherson strut with coil spring and compression rod type
Camber
5’
z!z
30’
Caster
2”24’ 31
30 ’
Toe-in
mm (in.)
0
It
3
(0
*
.12)
Coil spring
Wire dia. x O.D. x free length
mm (in.)
13.7x173.7x314
13.9x173.9x321.5
Coil spring identification color
Spring constant
N/mm (IbsAn.)
(.54 x 6.84 x 12.4)
Light blue x 1
24 (134)
l.55 x 6.85 x 12.7)
Light blue x 2
24 (134)
Shock absorber
Hydraulic, cylindrical double-acting type
Type
Max. length
mm (in.)
483
(19.02)
Min. length. mm (in.)
330
(12.99)
Stroke
mm (in.)
153 (6.02)
Damping force [at 0.3. m/set. (.984 ft./sec.)l
Expansion N (Ibs.)
Contraction N (Ibs.)
1,000 (220)
300 (66)
FRONT SUSPENSION - General Information
FRONT SUSPENSION - General Information

FRONT SUSPENSION - General Information

c4WD>

Items

 

Specifications

 

Suspension system

 

McPherson strut with coil spring and compression rod type

Camber

 
10’ +- 30’ 2”18’ + zk 3 (0
10’
+-
30’
2”18’ +
zk
3
(0

30 ’

f .l2)

 

Caster

Toe-in

mm (in.)

 

0

Coil spring Wire dia. x O.D. x free length

Coil spring identification color

mm (in.)

14.0

x 174.0

x 174.0 x 326.5 Pink (.55 x 6.85 x 1 x

x 326.5

Pink

(.55 x 6.85 x 1

x 174.0 x 326.5 Pink (.55 x 6.85 x 1 x

x

12.9)

Spring constant

N/mm (Ibs./in.)

 

26 (146)

Shock absorber

   
Type
Type

Hydraulic, cylindrical double-acting type

Max. length

mm (in.)

   

489

(19.25)

Min. length

mm (in.)

340

(13.39)

Stroke

Damping force [at 0.3 m/set. (.984 ft./set.)] Expansion N (Ibs.) Contraction N (Ibs.)

mm (in.)

S t r o k e Damping force [at 0.3 m/set. (.984 ft./set.)] Expansion N (Ibs.)

149 (5.87)

1,000 (220)

300 (66)

 
FRONT SUSPENSION - Anti-dive Geometry / Negative-offset Geometry 2-5

FRONT SUSPENSION - Anti-dive Geometry / Negative-offset Geometry

2-5

- Anti-dive Geometry / Negative-offset Geometry 2-5 ANTI-DIVE GEOMETRY RO2cAAA Ordinarily, when the brakes are

ANTI-DIVE GEOMETRY

RO2cAAA
RO2cAAA

Ordinarily, when the brakes are applied, the load is moved toward the front of the vehicle as the result of inertial force, and this causes the phenomenon known as “nose dive”, in which the front of the vehicle is caused to tilt forward and downward. For this front suspension, however, the suspension link design -which has a high “anti-dive” effect- is such that the lower arm is tilted forward in order to counteract the “nose dive” phenomenon. In other words, braking force F is divided into force compo- nents F, and F2; of these, F1 acts in the direction that expands the front spring, with an effect that reduces the “nose dive” phenomenon.

with an effect that reduces the “nose dive” phenomenon. NEGATIVE-OFFSET GEOMETRY For negative-offset geometry. the
with an effect that reduces the “nose dive” phenomenon. NEGATIVE-OFFSET GEOMETRY For negative-offset geometry. the
with an effect that reduces the “nose dive” phenomenon. NEGATIVE-OFFSET GEOMETRY For negative-offset geometry. the
with an effect that reduces the “nose dive” phenomenon. NEGATIVE-OFFSET GEOMETRY For negative-offset geometry. the
with an effect that reduces the “nose dive” phenomenon. NEGATIVE-OFFSET GEOMETRY For negative-offset geometry. the

NEGATIVE-OFFSET GEOMETRY

For negative-offset geometry. the king pin offset angle is outside the center point of tire-to-ground contact. Thus, for example, if a tire on the right side is punctured during driving, or if the brakes are applied while the left tires are on a slippery surface (ice, etc.), the vehicle would be inclined to swerve to the side (in this case the right side) of greater road surface resistance to the tires, but, because of the negative-offset geometry construction, a certain force would be generated to cause rotation in direction C, employing point A as the fulcrum point. At the same time, there would be generated at the tires on the opposite side a corresponding force to cause rotation in direction D, also employing point A as the fulcrum point, but, because that force is Centre ooint of strut Pati

AOZDAAA
AOZDAAA

greater in direction C (where road surface resistance is greater), the tires themselves will tend to turn in the left direction. As a result,. because t.he tires automatically countersteer in the left direction, even though the force applied to the vehicle by the road surface resistance is to the right, the system thus functions to maintain the vehicle on a relatively straight-ahead course. NOTE The king pin offset is the distance from the center point of tire-to-ground contact when a line (ex- tended to the road surface) is drawn to connect the ball joint center point and the center point of the strut upper installation part.

and the center point of the strut upper installation part. Direction of travel Direction of tire
and the center point of the strut upper installation part. Direction of travel Direction of tire
Direction of travel Direction of tire - - Direction of > movement tendency ;’ vehicle
Direction
of travel
Direction of tire
- -
Direction of
>
movement
tendency
;’
vehicle move-
f
*J
ment tendency
:’
4
,
Ball joint
L
centre
point <B<\r
t
Point A
Icy surface
12AOO30
12AO548

----

2-6

FRONT SUSPENSION -

Offset Spring

OFFSET SPRING

Ro2EMA
Ro2EMA

Because struts are installed at an angle, the road surface reaction force (RI) applied to the tyres tends to act vertically upon the tyre centre, and that force tries to bend the strut toward the inside of the vehicle. When this happens, the force trying to bend the strut toward the inside of the vetiicle acts upon the strut bearing component as bending moment reaction force FL (because the upper part of the strut is fixed in place), thus increasing the friction of the bearing, and, as a result of the bending of the strut, amplifying the moving resistance of the shock absorber.

amplifying the moving resistance of the shock absorber. Then, because the coil spring is installed so
amplifying the moving resistance of the shock absorber. Then, because the coil spring is installed so

Then, because the coil spring is installed so that its centre is greatly offset (toward the outside of the vehicle) from the centre of the strut, the counterac- tive force for the spring tends to become great toward the outside of the vehicle, thus resulting in the generation of bending force FL opposite to the bending of the strut, and thereby decreasing the friction applied to the strut bearing. As a result, the shock absorber’s internal movement friction is reduced, thereby improving riding comfort as well as the durability of components.

riding comfort as well as the durability of components. RI : Road surface reaction force R2:

RI : Road surface reaction force R2: Strut axial-reaction force

surface reaction force R2: Strut axial-reaction force R3: Strut bend direction reaction force R4: Strut bending

R3: Strut bend direction reaction force R4: Strut bending force (by spring offset)

Spring counteractive force

R3: Strut bend direction reaction force R4: Strut bending force (by spring offset) Spring counteractive force
R3: Strut bend direction reaction force R4: Strut bending force (by spring offset) Spring counteractive force
R3: Strut bend direction reaction force R4: Strut bending force (by spring offset) Spring counteractive force
F R O N T S U S P E N S I O N
F R O N T S U S P E N S I O N

FRONT SUSPENSION - Lower Arm /

Stabilizer

2-7

LOWER ARM

The lower arm is an A-type arm, and is connected, via a rubber bushing, to the crossmember. The rod bushing is optimum tuned, including the spring constant of the arm bushing, to provide “soft” characteristics relative to the front and rear

“soft” characteristics relative to the front and rear ROZGAAA and “hard” characteristics relative to the left
ROZGAAA
ROZGAAA

and “hard” characteristics relative to the left and right, so that road surface impacts during travel are alleviated, and also so that changes of alignment caused by lateral forces are reduced, thus assuring excellent I driving stability.

I d r i v i n g s t a b i l i t
Rod bushing Arm bushing ,m
Rod bushing
Arm bushing
,m

STABILIZER

The stabilizer mounting uses *pillow balls. The adoption of a stabilizer link with a pillow ball on each end increases the link stiffness and ensures the effective operation of the stabilizer bar even when a

the effective operation of the stabilizer bar even when a small rolling motion occurs, NOTE *

small rolling motion occurs, NOTE * Pillow ball: Ball joint not preloaded.

rolling motion occurs, NOTE * Pillow ball: Ball joint not preloaded. Pillow ball ROZHAAB Stabilizer bar

Pillow ball

ROZHAAB
ROZHAAB

Stabilizer bar

Stabilizer bar 12AOOOS
Stabilizer bar 12AOOOS

12AOOOS

4--
4--

2-8

FRONT SUSPENSION - Front Axle

FRONT AXLE

The drive shaft is of the Bit-field joint (B.J.)-tripod joint (T.J.) type. This type features high power transmission efficiency and low vibration and noise.

ROPKAAA
ROPKAAA
transmission efficiency and low vibration and noise. ROPKAAA The knuckle has the wheel bearing assembled a@

The knuckle has the wheel bearing assembled a@ the hub press-fitted. The drive shaft and hub are spline-coupled.

T.J.: Tripod Joint B.J.: Birfield Joint Hub

T.J.: Tripod Joint B.J.: Birfield Joint

T.J.: Tripod Joint B.J.: Birfield Joint Hub

Hub

DRIVE SHAFT

constant velocity joint combination main-T.J.: Tripod Joint B.J.: Birfield Joint Hub DRIVE SHAFT tains speed completely even when flexed, can

tains speed completely even when flexed, can

withstand heavy loads and shock and offer high

fea-

power

tures are outlined below.

B.J. 0 Large operating angle Compact size and decreased space require- me&

transmission

efficiency.

Their

special

require- me& transmission efficiency. Their special l T.J. l Axially slidable Smaller sliding resistance Taking

l

require- me& transmission efficiency. Their special l T.J. l Axially slidable Smaller sliding resistance Taking
require- me& transmission efficiency. Their special l T.J. l Axially slidable Smaller sliding resistance Taking

T.J.

l

me& transmission efficiency. Their special l T.J. l Axially slidable Smaller sliding resistance Taking these

Axially slidable

Smaller sliding resistance Taking these characteristics into account, B.J. is adopted on the wheel side of the shaft, as it can make large deflections when the tire is steered and T.J. is adopted on the transmission side, as it can slide axiallv to absorb the chanae in the distance between joints caused by motionWof the suspension.

l

to absorb the chanae in the distance between joints caused by motionWof the suspension. l B.J.
to absorb the chanae in the distance between joints caused by motionWof the suspension. l B.J.

B.J.

T.J.
T.J.
llA0123
llA0123
FRONT SUSPENSION - Front Axle 2 - 9

FRONT SUSPENSION - Front Axle

2-9

HUB AND KNUCKLE

The construction of the hub and knuckle consists of the wheel bearing assembled to the knuckle and the hub pressed in; the drive shaft and hub are coupled

The wheel bearing is the double-row, angular- contact ball bearing type to withstand the lateral (thrust) load. The installation of the brake disc and

by &rations. hub are the outer disc configuration, thus improving

hub are the outer disc configuration, thus improving serviceability and also reducing rotation unbalance. Hub

serviceability and also reducing rotation unbalance.

Hub Wheel bearing Oil seal Dust shi&d II I I llA0053 Oil seal / Hub
Hub
Wheel bearing
Oil seal
Dust shi&d
II
I
I
llA0053
Oil seal
/
Hub
Braie disc
11 A0295

~

--

-

-

~

-

3-1
3-1
3-1

REAR AXLE

CONTENTS

AXLE SHAFT

4

DIFFERENTIAL

5

DIFFERENTIAL SUPPORT MEMBER

9

DRIVE SHAFT

4

SUPPORT MEMBER 9 D R I V E S H A F T 4 G E

GENERAL INFORMATION Construction Diagram Specifications

I

N Construction D i a g r a m Specifications I VICOUS COUPLING TYPE LIMITED S

VICOUS COUPLING TYPE LIMITED SLIP DEFFERhlTlAL

LIMITED S L I P D E F F E R h l T l A

Construction Functions and features Operation

.v:

3-2

-

-.-

.

.v: 3 - 2 - -.- . REAR AXLE - General Information GENERAL INFORMATION RO3BAAA T

REAR AXLE - General Information

GENERAL INFORMATION

RO3BAAA
RO3BAAA

T

The differential carrier and axle housing have been separated from each other, and D.O.J. and B.J. drive shafts arranged in between, They are driven by the axle shaft. The axle shaft is supported by ball bearings (inner

CONSTRUCTION DIAGRAM
CONSTRUCTION
DIAGRAM

and outer) in the axle housing and are coupled with the drive shaft with the companion flange in* between. The front of the rear suspension, and the rear side of the differential carrier is mounted via the differential support member to the body.

A Crossmember

A Crossmember Differential support member llA0339

Differential support member

A Crossmember Differential support member llA0339

llA0339

Differential carrier 12AO616
Differential carrier
12AO616
support member to the body. A Crossmember Differential support member llA0339 Differential carrier 12AO616
support member to the body. A Crossmember Differential support member llA0339 Differential carrier 12AO616
M E H M n n l L - ueneral mrormation J - J SPECIFICATIONS

MEHM

nnlL -

ueneral mrormation

J-J

SPECIFICATIONS
SPECIFICATIONS

Items

Conventional

Viscous coupling type limited slip defferential (option)

differential

Axle shaft

   
Type Shaft dimensions Outer bearing portion dia. m m ( i n . ) Inner

Type Shaft dimensions Outer bearing portion dia. mm (in.) Inner bearing portion dia. mm (in.)

Semi-floating type

Semi-floating type

 

35

(1.38)

35f1.38)

28t1.10)

28t1.10)

Center portion dia.

mm (in.)

 

34.5 (1.36)

34.5 (1.36)

Overall length mm (in.)

 

214.9 (8.46)

214.9 (8.46)

Bearing O.D. x I.D.

Outer

mm

(in.)

72

x 35 (2.83 x 1.38)

72 x 35 (2.83 x 1.38)

72

x 35 (2.83 x 1.38)

Inner

mm (in.)

58x28(2.28x 1.10)

58x28(2.28x1.10)

 

Drive shaft

 

Joint type

Outer

D.O.J. B.J. 397 x 24 (15.6 x .94)

D.O.J. B.J. 397 x 24 (15.6 x .94)

D.O.J. B.J. 397 x 24 (15.6 x .94)

 

Inner Length (joint to joint) x diameter

Differential Reduction gear type Reduction ratio Differential gear type and configuration Side gear Pinion gear

mm (in.)

Hypoid gear

Hypoid gear

3.545

3.545

Straight bevel gear x 2 Straight bevel gear x 2

Straight bevel gear x 2” Straight bevel gear x 4

Straight bevel gear x 2” Straight bevel gear x 4

Number of teeth Drive gear Drive pinion Side gear Pinion gear Bearing O.D. x I.D.

 

39

39

11

11

14

16

10

10

Side mm (in.)

72

x 35 (2.83 x 1.38)

72 x 35 (2.83 x 1.38)

72

x 35 (2.83 x 1.38)

 

Front

mm (in.)

62

x 25 (2.44 x .98)

62 x 25 (2.44 x .98)

62

x 25 (2.44 x .98)

Rear

mm (in.)

72

x 35 (2.83 x 1.38)

72

x 35 (2.83 x 1.38)

i
i

Note *: Denotes the gear (L.H.) which. is in a single body with the viscous coupling.

72 x 35 (2.83 x 1.38) i Note *: Denotes the gear (L.H.) which. is in

3-4

REAR AXLE - Axle Shaft / Drive Shaft

AXLE SHAFT

The axle shaft is a semi-floating type supported by ball bearings (outer and inner) in the housing.

R03cAAA
R03cAAA

To prevent mud that may be deposited around the bearing (outer), a dust cover has been provided.

I

D.O.J.

Companion flange

I

G
G

? ust cover

been provided. I D.O.J. Companion flange I G ? ust cover Trailing arm llA0013 DRIVE SHAFT
Trailing arm
Trailing arm

llA0013

DRIVE SHAFT

Birfield type constant velocity ball joints have been provided for the drive shaft. On the axle shaft side, the D.O.J. type has been adopted to absorb the change in distance between the joints that may be caused by the movement of the suspension. On the differential carrier side, the B.J. type has been adopted which allows considerable flection in keeping with the movement of the suspension.

flection in keeping with the movement of the suspension. RO3OAAA On the axle shaft side, they
RO3OAAA
RO3OAAA

On the axle shaft side, they are coupled with the axle shaft with the companion flange in between. On the differential side, they are spline coupled with the side gears. On vehicles with a viscous coupling type limited slip differential, the right and left drive shafts are different in length. In addition, the B.J. side of the drive shaft (R.H.) is two-stage serration coupled.

Drive shaft and B.J.

Drive shaft and B.J. D.O.J. Boot _ D&e shaft (R.H.) two-sta e serration (ECLIPS!: Viscous coupling
D.O.J. Boot _ D&e shaft (R.H.) two-sta e serration (ECLIPS!: Viscous coupling type limited slip
D.O.J. Boot
_
D&e shaft (R.H.)
two-sta e serration
(ECLIPS!: Viscous coupling type
limited slip differential equipped
vehicles)
D.O.J. Inner I
D.O.J. Outer race

llA0338

R E A R A X L E - Viscous Coupling Type Limited Slip Differential

REAR AXLE - Viscous Coupling Type Limited Slip Differential

3-a
3-a

DIFFERENTIAL

The differential uses lower torque bearings and lower torque oil seals to improve power perform- ante and fuel consumption. For faster differential cooling and higher reliability during high speed operation, a differential carrier with cooling fins has been adopted.

ROlEAM

For better serviceability, spacers for adjustment of final drive gear backlash have been inserted be- tween the side bearing outer race and gear carrier. A speed difference responsive type viscous cou- pling type limited slip differential which provides outstanding performance during operation on a

s t a n d i n g performance during operation on a Side bearing space
s t a n d i n g performance during operation on a Side bearing space
s t a n d i n g performance during operation on a Side bearing space

Side bearing space

Differential cover Q Pinion gear Side gear . / \
Differential cover
Q
Pinion gear
Side gear
.
/
\
ifferential case
ifferential case

VISCOUS COUPLING TYPE LIMITED SLIP DIFFERENTIAL

RWEBAA

While the conventional mechanical type limited slip differential uses a cam (differential pinion shaft) and disc equipment compo.sed of a friction plate, disc and spring seat in limiting the differential, the

viscous coupling type limited slip differential limits the differential by use of a viscous coupling equip- ment consisting of outer and inner plates and silicone oil.

ment consisting of outer and inner plates and silicone oil. Front wheel Rear wheel Center differential
Front wheel Rear wheel Center differential ’ (viscous coupling) ,I Limited slip differential assembly Front
Front wheel
Rear wheel
Center differential
(viscous coupling)
,I
Limited slip differential
assembly
Front differential
Differential
T
Differential limiting section
(viscous coupling)
11KmI66
L.-
3-6
3-6

REAR AXLE - Viscous Coupling Type Limited Slip Differential

I

I

s

Side gear (L.H.) Side gear (R.H.) 1 Differential case B Pinion shaft 3r Thrust washer
Side gear (L.H.)
Side gear (R.H.)
1
Differential case B
Pinion shaft
3r
Thrust washer
Viscous cokpling

Side gear U3.H.)

shaft 3r Thrust washer Viscous cokpling Side gear U3.H.) , , , Differential cover I Differential
shaft 3r Thrust washer Viscous cokpling Side gear U3.H.) , , , Differential cover I Differential

,

,,

Differential cover

I Differential case B ‘Gear cagier Pir , Drive pinion front bearing Driv& pinion Drive
I
Differential case B
‘Gear cagier
Pir
,
Drive pinion
front bearing
Driv& pinion
Drive gear
rear bearing
Bearing cap
Driv& pinion Drive gear rear bearing Bearing cap Cokpanion flange llAo337 Normal operating range H u

Cokpanion flange

llAo337

Normal operating range

Hump region

Normal operating range H u m p r e g i o n Difference in rotating

Difference in rotating speed between right and left wheels (rpm)

Remarks

l A hump occurs when there is a large difference

in rotatin

speed between the right and left .! lnce the large difference causes .! lnce the large difference causes

7.
7.

wheels.

violent shearing of the silicone oil in the

viscous couplin

ture rises (the SI Icone 011 expands), and the

torque abruptly rises. If the hump occurs, the

by the plates, the oil tempera-

inner and outer plates enter a directly coupled

(differential locked) state.

llAOO5r
llAOO5r

FUNCTIONS

AND FEATURES
AND FEATURES

(1) The viscous coupling type limited-slip differential is functionally the same as the conventional mechanical type which reduces slipping of the rear wheels for better performance when travel- ing on a rough road or when getting out of a snowy or muddy surface. (2) The viscous coupling type limited slip differential responds to a difference in rotating speed and has outstanding characteristics for use in an on-road 4WD vehicle, as it has no difference in characteristics in the normal operating range between when power is ON and when it is OFF, and provides better straight ahead stability and running performance. (3) When a single wheel is slipping, a hump could cause the differential to approach a locked state. Provision is therefore made to provide a better ability to get out even in cases of one in a million

is therefore made to provide a better ability to get out even in cases of one
is therefore made to provide a better ability to get out even in cases of one

such as a stuck state.

REAR AXLE - Viscous

Coupling Type Limited Slip Differential

3-7
3-7

CONSTRUCTION

El Drive pinion Rear drive / shaft (L.H.) Rear drive shaft (R.H.1 Serration coupled 11Po070
El
Drive pinion
Rear drive /
shaft (L.H.)
Rear drive
shaft (R.H.1
Serration coupled
11Po070

The viscous coupling type limited differential is a “shaft-shaft” type consisting of the right and left rear drive shafts and viscous coupling directly coupled. The viscous coupling is a unit filled with silicone oil and consists of the outer plates @ coupled with the case @ , the inner plates @ coupled with the viscous coupling hub (j) , and the spacer rings @ arranged alternately to hold one plate and angther with only a small spacing in between. The X-rings @ are provided to prevent

spacing in between. The X-rings @ are provided to prevent entry of the differential oil into
spacing in between. The X-rings @ are provided to prevent entry of the differential oil into
spacing in between. The X-rings @ are provided to prevent entry of the differential oil into
spacing in between. The X-rings @ are provided to prevent entry of the differential oil into
spacing in between. The X-rings @ are provided to prevent entry of the differential oil into
spacing in between. The X-rings @ are provided to prevent entry of the differential oil into

entry of the differential oil into the viscous coupling. The rear drive shaft (L.H.) is serration coupled with the viscous coupling case @ and coupled ,via the case with the side gear (L.H.) @which is in a single body with the-viscous coupling case. The rear drive shaft (R.H.) is serration coupled with the side gear (R.H.) and its end serration coupled with the viscous coupling hub 0) . The viscous coupling must not be disassembled.

(R.H.) and its end serration coupled with the viscous coupling hub 0) . The viscous coupling
(R.H.) and its end serration coupled with the viscous coupling hub 0) . The viscous coupling
(R.H.) and its end serration coupled with the viscous coupling hub 0) . The viscous coupling
w
w
3-8
3-8

REAR AXLE - Viscous

Coupling Type Limited Slip Differential

OPERATION

I Drive force smaller ( S l i p p i n g s i
I
I
I Drive force smaller ( S l i p p i n g s i d

Drive force smaller (Slipping side)

Drive force larger (Grippina side)
Drive force larger
(Grippina side)
i n g s i d e ) Drive force larger (Grippina side) Rear drive shaft

Rear drive shaft

Rear drive shaft

larger (Grippina side) Rear drive shaft Rear drive shaft ( L . H . 1 (

(L.H.1 (Left wheel) resistance smaller)

(R.H.1 (Right
(R.H.1 (Right

wheel)

drive shaft ( L . H . 1 ( L e f t w h e
drive shaft ( L . H . 1 ( L e f t w h e

11 PO071

If a difference in rotating speed occurs between the right and left wheels, the viscous coupling case @ and viscous coupling hub @ relatively rotate with the same difference in rotating speed as the rear drive shafts. As a result a differential limiting torque is generated by the shear resistance of silicone oil and helps suppress the differential (slipping).

silicone oil and helps suppress the differential (slipping). For example, assume that the right wheel rotates
silicone oil and helps suppress the differential (slipping). For example, assume that the right wheel rotates

For example, assume that the right wheel rotates at 20 rpm due to the road surface resistance, whereas the left wheel rotates at 30 rpm. The difference in rotating speed between the right and left wheels is 10 rpm. Since the viscous coupling is provided between the right and left wheels, a differential limiting torque compensating for the difference of 10 rpm in rotating speed is transmitted from the left wheel to the right one. Therefore, a larger drive force is transmitted to the right wheel rotating at the lower speed.

wheel to the right one. Therefore, a larger drive force is transmitted to the right wheel

REAR AXLE - Differential Support Member

3-9

DIFFERENTIAL SUPPORT MEMBER

ROJFAAA

The differential support member supports the rear side of the differential carrier. That end of the member which is mounted to the body is elastically supported by use of rubber bushings.

Section A-A

Section A-A Differential support member llA0297

Differential support

member

llA0297
llA0297

c

Differential

support member

Section A-A Differential support member llA0297 c Differential support member \ Differential carrier

\

Differential carrier

Section A-A Differential support member llA0297 c Differential support member \ Differential carrier
Section A-A Differential support member llA0297 c Differential support member \ Differential carrier
BRAKES SERVICE AND PARKING 0 CONTENTS G E N E R A L I N
BRAKES SERVICE AND PARKING 0 CONTENTS G E N E R A L I N
BRAKES SERVICE AND PARKING 0 CONTENTS G E N E R A L I N
BRAKES SERVICE AND PARKING 0 CONTENTS G E N E R A L I N
BRAKES SERVICE AND PARKING 0 CONTENTS G E N E R A L I N
BRAKES SERVICE AND PARKING 0 CONTENTS G E N E R A L I N

BRAKES

BRAKES SERVICE AND PARKING 0 CONTENTS G E N E R A L I N F

SERVICE AND PARKING 0

CONTENTS

GENERAL INFORMATION Construction Diagram Features

Specifications

PARKING BRAKE Construction Diagram

2

SERVICE BRAKES

2

Front Disc Brake

2

Rear Disc Brake

2

Specifications

7

X Arrangement of Brake Lines

7

i s c B r a k e 2 S p e c i f i
i s c B r a k e 2 S p e c i f i

5-2

BRAKES - General Information

GENERAL INFORMATION

The service brakes are a brake system featuring excellent braking force and a high level of reliability and durability.

All models are equipped with four-wheel disc brake

SPECIFICATIONS

are equipped with four-wheel disc brake SPECIFICATIONS system as a brake system matching the vehicle superb
are equipped with four-wheel disc brake SPECIFICATIONS system as a brake system matching the vehicle superb

system as a brake system matching the vehicle superb driving performance. Models with turbochar- ger are equipped with a 7 + 8 inch tandem brake booster for lower brake pedal depression efforts.

brake booster for lower brake pedal depression efforts. Items Specifications Service brake Front

Items

Specifications

Service brake

Front

Ventilated disc

Rear

Solid disc

w

Parking brake

Mechanical rear wheel braking type

FEATURES

Improved

braking

performance

wheel braking type FEATURES Improved braking performance 1. Adoption of 4-wheel disc brake on all models.

1. Adoption of 4-wheel

disc brake on all models.

CONSTRUCTION DIAGRAM

Improved

1. Adoption of an outer disc system on the rear brake discs of all models.

2. Adoption of a white reserve tank cap for the master cylinder.

serviceability

Proportioning valv

Proportioning valv Front disc brake
Proportioning valv Front disc brake

Front disc brake

BRAKES - Service Brakes

5-3

SERVICE BRAKES

CPECIFICATIONS

BRAKES - Service Brakes 5-3 SERVICE BRAKES CPECIFICATIONS Items Non-Turbo Turbo Master cylinder $e . .

Items

Non-Turbo

Turbo

Master cylinder

$e . .
$e
.
.

mm (in.)

Tandem (with level sensor)

Tandem (with level sensor)

22.2

(718)
(718)

23.8

(15/l 6)

(15/l 6)

Brake booster

T Y p e Effective dia. of powmermc&;der

TYpe Effective dia. of powmermc&;der

T Y p e Effective dia. of powmermc&;der
y3tt$;ivacuum-boost
y3tt$;ivacuum-boost

type

Multiple-vacuum-boost type Front side: 180 (7.0) Rear side: 205 (8.0)

Proportioning

valve

Type Split point kPa (psi) Decompression ratio

Dual type

Dual type

c

 
4,200 (597)

4,200 (597)

4,200 (597)

0.3

0.3 or 0.4”

Front brakes

Type
Type

M-R44V

M-R44V 53.9 (2%)
M-R44V
53.9
(2%)
 
cyhnxLy.
cyhnxLy.
53.9 (2’/8)

53.9 (2’/8)

Clearance

Automatic

Automati c

adjustment

 

Rear disc brakes

I Type
I Type
Cyl~itl;.~.
Cyl~itl;.~.
AD30P
AD30P
AD30P 30.1 (13/16)
AD30P
30.1
(13/16)
 

30.1

(13/16)

 

Clearance

Automatic

Automatic

 

adjustment

 

NOTE

*:4WD
*:4WD
X ARRANGEMENT
X ARRANGEMENT

OF BRAKE LINES

The X arrangement of brake lines is the arrange- ment by which the right front and left rear and the left front and right rear are connected, so that the

braking force will be applied at the front’ and rear wheels even in the unlikely event of a mulfunction of failure of one system.

front’ and rear wheels even in the unlikely event of a mulfunction of failure of one

Master cylinder

Master cylinder 14AO454

14AO454

5-4
5-4

BRAKES -

Service

Brakes

FRONT DISC BRAKE The front brake is the M-R44V type featuring highly efficient heat dissipation, quick recovery of braking force when wet, and highly stabilized braking force.

braking force when wet, and highly stabilized braking force. Section A-A Braki disc 14A0531 14AO533 Piston

Section A-A

Braki disc 14A0531
Braki disc 14A0531
14AO533
14AO533

Piston seal

Braki disc 14A0531 14AO533 Piston seal 14AO530 ,ad Shim 0 14A0532
Braki disc 14A0531 14AO533 Piston seal 14AO530 ,ad Shim 0 14A0532

14AO530

,ad Shim 0 14A0532
,ad Shim
0
14A0532

<Brake disc installation xoss-section>

Disc wheel

<Brake disc installation xoss-section> Disc wheel

In addition, disc removal and installation is made easy by the outer disc system, in which the brake disc is installed to the disc wheel by the hub nuts.

.
.

7-.