1993es300汽车维修手册英有电路automatic transmission

1、CL1CLUTCHCL2CLUTCH DESCRIPTIONDESCRIPTIONThe diaphragm spring turnover type clutch providing lighter release performance.CL00201CL3CLUTCHPREPARATIONPREPARATIONSST (SPECIAL SERVICE TOOLS)CL00303RECOMMENDED TOOLSCL00S01EQUIPMENTCL004 01CalipersDial indicatorTorque wrenchCL4CLUTCH TROUBLESHOOTINGTROUBL

2、ESHOOTINGCL00501You will find the cause of trouble more easily by properly using the table shown below. In this table, the numbers indicate the priority of the probable cause of trouble. Check each part in the order shown. If neces- sary, repair or replace the part.CL6 CL5 CL8CL11CL17 MX35 CL17 CL17

3、 CL17 CL17 CL17 CL17 CL17CL17 CL20CL17 CL19CL17CL5CLUTCH CLUTCH SYSTEM BLEEDINGCLUTCH SYSTEM BLEEDINGCL00602HINT: If any work is done on the clutch system or if air is sus- pected in the clutch lines, bleed the system of air.NOTICE: Do not let brake fluid remain on a painted sur- face. Wash it off i

4、mmediately.FILL CLUTCH RESERVOIR WITH BRAKE FLUIDCheck the reservoir frequently. Add fluid if necessary.CONNECT VINYL TUBE TO BLEEDER PLUG1.2.Insert the other end of the tube in a halffull container of brake fluid.BLEED CLUTCH LINESlowly pump the clutch pedal several times.While pressing on the peda

5、l, loosen the bleeder plug until the fluid starts to run out. Then close the bleeder plug.Repeat this procedure until there are no more air bubbles in the fluid.3.(a)(b)(c)CL6CLUTCH CLUTCH PEDALCLUTCH PEDALCLUTCH PEDAL CHECK AND ADJUSTMENTCL007031.CHECK THAT PEDAL HEIGHT IS CORRECTPedal height from

6、asphalt sheet: 164.7174.7 mm (6.486.88 in.)IF NECESSARY, ADJUST PEDAL HEIGHT2.Loosen the lock nut and turn the clutch switch until the height is correct. Tighten the lock nut.CHECK THAT PEDAL FREEPLAY AND PUSH ROD PLAY ARE CORRECT(Pedal freeplay)Push in on the pedal until the beginning of clutch is

7、felt.Pedal freeplay:5.015.0 mm (0.1970.591 in.)(Push rod play)Push in on the pedal with a finger softly until the begins to increase a little.Push rod play at pedal top:1.05.0 mm (0.0390.197 in.)3.4.IF NECESSARY, ADJUST PEDAL FREEPLAY AND PUSH ROD PLAYLoosen the lock nut and turn the push rod until

8、the freeplay and push rod play are correct.Tighten the lock nut.After adjusting the pedal freeplay, check the pedal height.(a)(b)(c)CL7CLUTCH CLUTCH PEDAL5.(a)(b)(c)INSPECT CLUTCH RELEASE POINTPull the parking brake lever and install wheel stopper. Start the engine and idle the engine.Without depres

9、sing the clutch pedal, slowly shift the shift lever into reverse position until the gears contact.Gradually depress the clutch pedal and measure the stroke distance from the point the gear noise stops (release point) up to the full stroke end position.Standard distance:25 mm (0.98 in.) or more(From

10、pedal stroke end position to release point)If the distance not as specified, perform the following opera- tion.(d)Inspect pedal height.Inspect push rod play and pedal freeplay. Bleed the clutch line.Inspect the clutch cover and disc.6.(a)CHECK CLUTCH START SYSTEMCheck that the engine does not start

11、when the clutch pedal is released.Check that the engine starts when the clutch pedal is fully depressed.If necessary, adjust or replace the clutch start switch.(b)7.(a)INSPECT CONTINUITY OF CLUTCH START SWITCHCheck that there is continuity between terminals when the switch is ON (pushed).Check that

12、there is no continuity between terminals when the switch is OFF (free).If continuity is not as specified, replace the switch.(b)CL8CLUTCH CLUTCH MASTER CYLINDERCLUTCH MASTER CYLINDERCOMPONENTSCL00802MASTER CYLINDER REMOVALCL009021.2.DRAW OUT FLUID WITH SYRINGE DISCONNECT CLUTCH LINE TUBEUsing SST, d

13、isconnect the tube. Use a container to catch the brake fluid.SST 0902300100REMOVE CLIP AND CLEVIS PINREMOVE MOUNTING NUTS AND PULL OUT MASTER CYLINDER3.4.CL9CLUTCH CLUTCH MASTER CYLINDERMASTER CYLINDER DISASSEMBLYCL00A021.(a)REMOVE RESERVOIR TANKUsing a pin punch and a hammer, drive out the slotted

14、spring pin.Remove the reservoir tank and grommet.(b)2.REMOVE PUSH RODPull back the boot, and using snap ring pliers, remove the snap ring.REMOVE PISTON3.MASTER CYLINDER INSPECTIONCL00B01HINT: Clean the disassembled parts with compressed air. INSPECT MASTER CYLINDER BORE FOR SCORING OR CORROSIONIf a

15、problem is found, clean or replace the cylinder. INSPECT PISTON AND CUPS FOR WEAR, SCORING, CRACKS OR SWELLINGIf either one requires replacement, use the parts from the cyl- inder kit.INSPECT PUSH ROD FOR WEAR OR DAMAGEIf necessary, replace the push rod.1.2.3.MASTER CYLINDER ASSEMBLYCL00C02COAT PART

16、S WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWNINSERT PISTON INTO CYLINDERINSTALL PUSH ROD ASSEMBLY WITH SNAP RING1.2.3.CL10CLUTCH CLUTCH MASTER CYLINDER4.(a)(b)INSTALL RESERVOIR TANKInstall the reservoir tank and new grommet.Using a pin punch and a hammer, drive in the slotted spring pin.MASTER CY

17、LINDER INSTALLATIONCL00D031.INSTALL MASTER CYLINDERInstall the mounting nuts, and torque them. Torque: 7.8 Nm (80 kgfcm, 58 inlbf) CONNECT CLUTCH LINE UNIONUsing SST, connect the union. SST 0902300100Torque: 15 Nm (155 kgfcm, 11 ftlbf)CONNECT PUSH ROD AND INSTALL PINInstall the clip in the push rod

18、pin.BLEED SYSTEM AND ADJUST CLUTCH PEDAL2.3.4.CL11CLUTCH CLUTCH RELEASE CYLINDERCLUTCH RELEASE CYLINDERCOMPONENTSCL00E02RELEASE CYLINDER REMOVALCL00F021.DISCONNECT CLUTCH LINE TUBEUsing SST, disconnect the tube. Use a container to catch the brake fluid.SST 0902300100REMOVE TWO BOLTS AND PULL OUT REL

19、EASE CYLINDER2.RELEASE CYLINDER DISASSEMBLYCL00T011.REMOVE UNION FROM RELEASE CYLINDERRemove the union bolt, two gaskets and union from the re- lease cylinder.CL12CLUTCH CLUTCH RELEASE CYLINDER2.3.PULL OUT BOOT WITH PUSH ROD REMOVE PISTONUsing compressed air, remove the piston with the spring from t

20、he cylinder.RELEASE CYLINDER INSPECTIONCL00U01HINT: Clean the disassembled parts with compressed air. INSPECT RELEASE CYLINDER BORE FOR SCORING OR CORROSIONIf a problem is found, clean or replace the cylinder. INSPECT PISTON AND CUPS FOR WEAR, SCORING, CRACKS OR SWELLINGIf either one requires replac

21、ement, use the parts from the cyl- inder kit.INSPECT PUSH ROD FOR WEAR OR DAMAGEIf necessary, replace the push rod.1.2.3.RELEASE CYLINDER ASSEMBLYCL00V01COAT PISTON WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWNINSTALL PISTON WITH SPRING INTO CYLINDER INSTALL BOOT WITH PUSH ROD TO CYLINDER1.2.3.4.(a

22、)INSTALL UNION TO RELEASE CYLINDERAdjust the center line of the union is in parallel with the release cylinder.Install the union bolt.Torque: 25 Nm (250 kgfcm, 18 ftlbf)(b)CL13CLUTCH CLUTCH RELEASE CYLINDERRELEASE CYLINDER INSTALLATIONCL00J031.INSTALL RELEASE CYLINDER WITH TWO BOLTSTorque: 13 Nm (13

23、0 kgfcm, 9 ftlbf)CONNECT CLUTCH LINE TUBEUsing SST, connect the tube. SST 0902300100Torque: 15 Nm (155 kgfcm, 11 ftlbf)2.3.FILL CLUTCH RESERVOIR WITH BRAKE FLUID AND BLEED CLUTCH SYSTEMCHECK FOR LEAKS4.CL14CLUTCH CLUTCH ACCUMULATORCLUTCH ACCUMULATORCOMPONENTSCL00Z01CLUTCH ACCUMULATOR REMOVALCL00X021

24、.(a)REMOVE CRUISE CONTROL ACTUATORRemove the two bolts and actuator cover.(b)Remove the three nuts and actuator.CL15CLUTCH CLUTCH ACCUMULATOR2.(a)(b)REMOVE STARTERDisconnect the connector and wire from the starter. Remove the two bolts and starter.3.(a)(b)REMOVE CLUTCH ACCUMULATOR WITH BRACKETRemove

25、 the bolt and clamp.Using SST, disconnect the clutch line unions from the clutch accumulator.SST 0902300100(c)Remove the two bolts and clutch accumulator.CLUTCH ACCUMULATOR INSTALLATIONCL00Y02INSTALL CLUTCH ACCUMULATOR WITH BRACKETInstall the clutch accumulator with the two bolts.Torque: 21 Nm (210

26、kgfcm, 15 ftlbf)1.(a)(b)Using SST, connect the clutch line unions to the clutch accumulator.Torque: 15 Nm (155 kgfcm, 11 ftlbf)SST 0902300100Install the clamp with the bolt.Torque: 7.4 Nm (75 kgfcm, 66 inlbf)(c)CL16CLUTCH CLUTCH ACCUMULATOR2.(a)INSTALL STARTERInstall the starter with the two bolts.T

27、orque: 39 Nm (400 kgfcm, 29 ftlbf)Connect the connector and wire harness to the starter.(b)3.(a)INSTALL CRUISE CONTROL ACTUATORInstall the actuator with the three nuts.(b)4.Install the actuator cover with the two bolts.FILL CLUTCH RESERVOIR WITH BRAKE FLUID AND BLEED CLUTCH SYSTEMCHECK FOR LEAKS5.CL

28、17CLUTCH CLUTCH UNITCLUTCH UNITCOMPONENTSCL00K02CLUTCH UNIT REMOVALCL00L021.REMOVE TRANSAXLE FROM ENGINE(See MX section)2.(a)(b)REMOVE CLUTCH COVER AND DISCPlace matchmarks on the flywheel and clutch cover. Loosen each set bolt one turn at a time until spring tension is released.Remove the set bolts

29、, and pull off the clutch cover with the clutch disc.NOTICE: Do not drop the clutch disc.(c)CL18CLUTCH CLUTCH UNIT3.REMOVE RELEASE BEARING AND FORK FROM TRANSAXLERemove the release bearing together with the fork and then separate them.Remove the boot.(a)(b)CLUTCH PARTS INSPECTIONCL00M021.INSPECT CLU

30、TCH DISC FOR WEAR OR DAMAGEUsing calipers, measure the rivet head depth.Minimum rivet depth: 0.3 mm (0.012in.)If a problem is found, replace the clutch disc.2.INSPECT CLUTCH DISC RUNOUTUsing a dial indicator, check the disc runout.um runout:0.8 mm (0.031 in.)If runout is excessive, replace the clutc

31、h disc.3.INSPECT FLYWHEEL RUNOUTUsing a dial indicator, check the flywheel runout.um runout:0.1 mm (0.004 in.)If runout is excessive, replace the flywheel.4.INSPECT DIAPHRAGM SPRING FOR WEARUsing calipers, measure the diaphragm spring for depth and width of wear.um:Depth0.6 mm (0.024 in.)Width5.0 mm

32、 (0.197 in.)If necessary, replace the clutch cover.CL19CLUTCH CLUTCH UNIT5.INSPECT RELEASE BEARINGTurn the bearing by hand while applying force in the axial direction.HINT: The bearing is permanently lubricated and requires no cleaning or lubrication.If a problem is found, replace the bearing.CLUTCH

33、 UNIT INSTALLATIONCL00W02INSTALL CLUTCH DISC AND CLUTCH COVER ON FLYWHEELInsert the SST in the clutch disc, and then set them and the clutch cover in position.SST 09301002201.(a)(b)(c)Align the matchmarks on the clutch cover and flywheel. Temporarily tighten the topmost bolt from the three near the

34、knock pins.HINT: Temporarily tighten the No.3 bolt.Torque the bolts on the clutch cover in the order shown.Torque: 19 Nm (195 kgfcm, 14 ftlbf)(d)2.CHECK DIAPHRAGM SPRING TIP ALIGNMENTUsing a dial indicator with roller instrument, check the dia- phragm spring tip alignment.um nonalignment:0.5 mm (0.0

35、20 in.)If alignment is not as specified, using SST, adjust the dia- phragm spring tip alignment.SST 0933300013CL20CLUTCH CLUTCH UNIT3.APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE GREASE (NLGI NO.2) TO FOLLOWING PARTSRelease fork and hub contact point Release fork and push rod contact point Release fork

36、pivot pointClutch disc spline4.INSTALLRELEASEBEARINGANDFORKTO TRANSAXLEInstall the bearing to the release fork, and then install them to the transaxle.5.INSTALL TRANSAXLE TO ENGINE(See MX section)CL21CLUTCH SERVICE SPECIFICATIONSSERVICE SPECIFICATIONSSERVICE DATACL00P06TORQUE SPECIFICATIONSCL00Q05Pa

37、rt tightenedN mkgf cmft lbfMaster cylinder installation nut7.88058 inlbfRelease cylinder installation bolt131309Union bolt2525018Clutch line union1515511Bleeder plug8.38574 in lbfClutch accumulat r installation bolt2121015Release fork support4748035Clutch co erFlywheel1919514Flywheel set bolt8890065

38、Pedal height from asphalt sheet164 7174 7 mm (6.486.88in.)Push rod play at pedal top1 05 0mm (0 0390 197in )Pedal freeplay5 015 0mm (0 1970.591 in )Clutch release point from pedal full stroke end position25 mm (0.98in.) or moreDisc rivet head depth (Minimum)0 3mm (0 012in )Disc runout (um)0 8mm (0.0

39、31in.)Diaphragm spring tip nonalignment (um)0 5mm (0.020in.)Diaphragm spring finger wear (um depth)0 6mm (0 024in )Diaphragm spring finger wear (um width)5 0mm (0.197in.)Flywheel runout (um)0.1mm (0.004in.)MX1MANUAL TRANSAXLEMX2MANUAL TRANSAXLE DESCRIPTIONDESCRIPTIONPRECAUTIONSWhen working with FIPG

40、 materials, you must be observe the following.MX01Q01 Using a razor blade and gasket scraper, remove all the old sealant(FIPG) material from the gasket surfaces. Thoroughly clean all components to remove all the loose material. Clean both sealing surfaces with a nonresidue solvent. Apply the sealant

41、 in approx. 1 mm (0.04 in.) bead along the sealing surface. Part must be assembled within 10 minutes of application. Otherwise, the sealant (FIPG) material must be removed and reapplied.DESCRIPTIONMX01R01 The gear and shaft layout is the same as the E52 manual transaxle. A triplecone type synchromes

42、h mechanism is used in the second gear and a doublecone type synchromesh mechanism is used in the third gear to improve the shift feeling characteristics. This helps to reduce the shifting effort, provide smoothly shifting. A reverse synchromesh mechanism is used to suppress gear engagement noise in

43、 reverse gearshifting while providinoothly shifting.MX3MANUAL TRANSAXLE OPERATIONOPERATION The illustrations below show the engagements of transaxle gears.MX00E02MX4MANUAL TRANSAXLE PREPARATIONPREPARATIONSST (SPECIAL SERVICE TOOLS)MX01S01MX5MANUAL TRANSAXLE PREPARATIONMX6MANUAL TRANSAXLEPREPARATIONR

44、ECOMMENDED TOOLSMX01T01EQUIPMENTMX01U01LUBRICANTMX013 01ItemCapacityClassificationManual transaxle oil (w/Differential oil)4.2 liters (4.4 US qts, Imp. qts)API GL4 or GL5 SAE 75W90 or 80W90Dial indicator with magnetic baseFeeler gaugeMicrometerStraight edgeTorque wrenchMX7MANUAL TRANSAXLE PREPARATIO

45、NSSM(SPECIAL SERVICE MATERIALS)MX01V010882600090Seal Packing 1281,Three bond 1281 or equivalentTransaxle case X Case coverTransmission case X Transaxle caseTransmission case X Case cover0883300080Adhesive 1344THREE BOND 1344,LOCTITE 242 or equivalentTransaxle case cover boltStraight screw plug Contr

46、ol shaft cover boltMX8MANUAL TRANSAXLE TROUBLESHOOTINGTROUBLESHOOTINGMX00D01You will find the troubles easier using the table well shown below. In this table, each number shows the priority of causes in troubles. Check each part in order. If necessary, replace these parts.MX2MX23MX23MX23MX89MX23MX23

47、MX23MX23MX40, 46MX40, 46MX9MANUAL TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATIONASSEMBLY REMOVAL AND INSTALLATIONRemoval and installation the parts as shown below.MX01W01MX10MANUAL TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATIONRemoval and installation the parts as shown below.MX11MANUAL TRANSAXLE ASSEMBLY

48、 REMOVAL AND INSTALLATIONTRANSAXLE REMOVALMX01X011.2.REMOVE NEGATIVE BATTERY CABLEREMOVE AIR CLEANER CASE ASSEMBLY WITH AIR HOSEREMOVE CRUISE CONTROL ACTUATORRemove the cruise control actuator cover. Disconnect the connector.3.(a)(b)(c)Remove the three bolts and cruise control actuator bracket.with4

49、.REMOVE CLUTCH RELEASE CYLINDER5.(a)(b)REMOVE STARTERDisconnect the connector and wire from the starter. Remove the two bolts and starter.6.(a)(b)REMOVE CLUTCH ACCUMLATOR AND TUBE CLAMPRemove the two bolts and clutch accumlator with bracket. Remove the bolt and clutch tube clamp.7.DISCONNECT BACKUP

50、LIGHT SWITCH CONNECTORMX12MANUAL TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION8.DISCONNECT WIRES CLAMPS9.REMOVE CLUTCH RELEASE CYLINDER BRACKET10.REMOVE EARTH CABLES11.(a)(b)DISCONNECT CONTROL CABLESRemove the clips and washers. Remove the retainer from the cables.12.REMOVE TRANSAXLE MOUNTING TRANSAXL

51、E CASE UPPER SIDETHREE BOLTSOFMX13MANUAL TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION13.DISCONNECT SPEED SENSOR CONNECTOR14.15.REMOVE FRONT WHEEL RAISE VEHICLENOTICE: Be sure the vehicle is securely supported. REMOVE UNDER COVERS AND SIDE COVERS DRAIN TRANSAXLE OILREMOVE EXHAUST FRONT PIPERemove the

52、four nuts.16.17.18.(a)(b)Remove the two bolts and front pipe support.(c)(d)Remove the two bolts and nuts. Remove the front pipe.MX14MANUAL TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION19.REMOVE DRIVE SHAFT(See page SA20)20.DISCONNECT STEERINGGEARHOUSING FROMFRONT SUSPENSION MEMBERRemove the four bolts.Remove the stabilizer bar bushing bracket.(a)(b)(c)(d)Remove the two set bolts and nuts.Disconnect the steeling gear housing from the front suspension member.HINT: Suspend the steering gear housing with cord.21.REMOVE STIFFENER PLATEMX15MANUAL TRANSAXLE ASSEMBLY REM