134 6 38MB
English Pages 324 Year 1996
VISSy.\\
Y N N U S Oct 1986 to Mar 1991
ae F -& £« }# (D to H registration) Petrol
Haynes Service and Repair Manual
7
é
a,
:
&
pe
Telecel ia anit: eure MOT Test Check Sections /
4
PEUGEOT 405
‘Excellent value for money, beginners and experts should find it equally useful...’ Motor
[5
1988 to 1996 (E to N registration) Potro}
1962 to 1980 Roadster ..GT Coupe -:1798 cc
Haynes Service and Repair Manual
There is almost certainly a Haynes Manual to cover your specific vehicle, whatever its age. Each manual features clear, easy-tofollow text linked to hundreds of step-bystep photos that guide you through each task. From the simplest service to a major rebuild, Haynes shows you how and saves
(Ub)
Roadside Repairs at MOT Tost Checks
you money.
TechBooks
AUTOMOTIVE
f
ELECTRICAL [=
Written for the DlYer, good enough for the professional! Each of these vehicle system or technique specific manuals is packed with practical information supported by step-by-step photo sequences and diagrams.
tinal
AUTOMOTIVE
WELDING
|pMANUAL
AUTOMOTIVE
AUTOMOTIVE
TOOLS MANUAL
BRAKE a UAL
TECHBOOK —_
Car Books This comprehensive range of fully illustrated books are packed with clear, practical advice and information on a wide variety of motoring or car related topics.
ill wi DAVE
POLLA)
‘These Manuals are essential reading for any biker tackling his own
servicing. ..
Motor Cycle News
Over 100 titles cover popular European, American and Japanese bikes. Written from hands-on experience, Haynes Motorcycle Manuals give you all the information you need to service and repair your motorcycle.
City Of esas
Coventry_
PS113567
W
‘Thoroughly recommended’
cycling Plus
Following the success of The Bike Book, a comprehensive, fully illustrated guide to bicycle maintenance, Haynes has published a number of bicycle titles. These include Mountain Biking, the popular Ride Your Bike series of regional ride guides and the pocket-sized Fix Your Bike.
ies Coventry Librar on and Informati Services
cil “Coventry City Coun
seme 00613
AE %
EF
SSN
&F
8996
;
% Nj
4
Nissan Sunny service and Repair Manual | M Coomber Models
(1378-320-1Y6)
covered
All Nissan Sunny models with petrol engines; Hatchback and Saloon/Pulsar (N13), Coupé and Estate (B12), including ZX models and special/limited editions 1270 cc, 1392 cc, 1597 cc, 1598 cc and 1809 cc Does not cover Diesel engine models
A
© Haynes Publishing 1996
)
Printed by J H Haynes & Co. Ltd, Sparkford, Nr Yeovil,
Somerset BA22 7JJ
P
A book in the Haynes Service and Repair Manual Series
All rights reserved. No part of this book may be reproduced or transmitted in any form
or by any
means,
electronic
or mechanical,
including
photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.
| Haynes Publishing Sparkford, Nr Yeovil, Somerset BA22 7JJ, England Haynes North America, Inc 861 Lawrence Drive, Newbury Park, California 91320, USA
ISBN 1 85960 186 3
British Library Cataloguing in Publication Data
Editions Haynes S.A.
A catalogue record for this book is available from the British Library.
147/149, rue Saint Honoré, 75001 PARIS, France
Contents LIVING WITH YOUR NISSAN SUNNY Introduction
Page
094
Safety First!
Page
0O*5
Dimensions, weights and capacities
Page
0°6
Identifying leaks
Page
097
Jacking, wheel changing and towing
Page
08
Jump starting
Page
0e10
Routine maintenance (also see Chapter 13)
Page
Oe11
Buying spare parts and vehicle identification numbers
Page
00e14
Tyre checks
Page
0e15
Lubricants and fluids
Page
0e*16
Roadside Repairs
Routine Maintenance
f\aby: Adan Y 62%, » ge “ti > at
TgBs kay Ap ep \
i,
4 4s,
Ps 2
we 7
a
‘S, Y %
r
E
>
ae Y) to, °
My, SHER wr : a
Oc
Contents REPAIRS & OVERHAUL Engine and Associated Systems Engine (also see Chapter 13)
Page
11
Cooling and heating systems (also see Chapter 13) Fuel, exhaust and emission control systems (also see Chapter 13) Ignition system (also see Chapter 13)
Page
2e1
Page
3e1
Page
4e1
Clutch (also see Chapter 13)
Page
5e1
Manual transmission (also see Chapter 13)
Page
66¢1
Automatic transmission (also see Chapter 13) Driveshafts (also see Chapter 13)
Page
7e1
Page
8e1
Page
9Qe1
Page
10e1
Page
11¢1
Page
12e¢1
Supplement: Revisions and information on later models
Page
13¢1
Wiring Diagrams
Page
1401
Transmission
Brakes Braking system (also see Chapter 13)
Suspension Suspension and steering (also see Chapter 13)
Body Equipment Bodywork and fittings (also see Chapter 13)
Electrical Electrical system (also see Chapter 13)
Additional Information
REFERENCE MOT Test Checks Checks carried out from the driver’s seat
Page
REFe1
Checks carried out with the vehicle on the ground
Page
REFe2
Checks carried out with the vehicle raised
Page
REFe3
Page
REFe4
Tools and Working Facilities
Checks carried out on your vehicle’s exhaust emission system
Page
REFe5
General Repair Procedures
Page
REFe8
Fault Finding
Page
REFe9
Conversion factors
Page
REFe12
Glossary of Technical Terms
Page
REFe13
Index
Page
REFe17
o4
Introduction.
Introduction to the Nissan Sunny The new Nissan Sunny range was introduced in October 1986. Mechanically
similar to the previous series of the Sunny. most of the changes made for the ‘new’ series are cosmetic. The engine and the transmission are of the same basic design of the earlier models. The engine is watercooled, has an overhead camshaft, and the crankshaft runs in five main bearings. The manual or automatic transmission (as applicable), is attached to the rear end of the engine, the two being transversely mounted at the front of the car. Drive is to the front roadwheels via driveshafts which are connected to the differential within the transmission at their inboard ends, and the wheel hubs at their outboard ends. Four distinct body types are produced; the 2-door or 4-door Saloon, the 3-door or 5-door Hatchback, the 5-door Estate and the 3-door Coupe. The level of standard equipment is high, but a range of optional extras for each is available. All models in the Sunny range are conventional in design and are therefore easy to maintain and repair.
Acknowledgements Thanks are due to Champion Spark Plug, who supplied the illustrations showing spark plug conditions. Certain other illustrations are the copyright of the Nissan Motor Company Limited of Japan and are used with their permission. Thanks are also due to SykesPickavant, who provided some of the workshop tools. Finally, thanks are due to all the staff at Sparkford who helped in the production of this manual. We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by errors in, or omissions from, the information given.
Project vehicle The vehicle used in the preparation of this manual, and appearing in many of the photographic sequences, was a Nissan
Sunny SGX Hatchback.
Nissan Sunny Coupe
Safety First! Working on your car can be dangerous. This page shows just some of the potential risks and hazards, with the aim of creating a safety-conscious attitude.
General hazards
® Mains voltage is also dangerous. Make sure that any mains-operated equipment is correctly earthed. Mains power points should be protected by a residual current device (RCD) circuit breaker.
Fume or gas intoxication
Scalding ¢ Don’t remove the radiator or expansion
tank cap while the engine is hot. ¢ Engine oil, automatic transmission fluid or power steering fluid may also be dangerously hot if the engine has recently been running.
Burning ° Beware of burns from the.exhaust system and from any part of the engine. Brake discs and drums can also be extremely hot immediately after use.
e Exhaust fumes are poisonous; they often contain carbon
a
° When working under or near a raised vehicle,
:
monoxide, which is
rapidly fatal if inhaled. Never run the engine ina confined space such as a garage with the doors shut. e Fuel vapour is also poisonous, as are the vapours from some
Poisonous or irritant substances
@f=3
a
-
under a car which is only supported by a jack. e Take care if loosening or tightening hightorque nuts when the vehicle is on stands. Initial loosening and final tightening should be done with the wheels on the ground.
e Avoid skin contact with battery acid and with any fuel, fluid or lubricant, especially antifreeze, brake hydraulic fluid and Diesel fuel. Don’t syphon them by mouth. If such a substance is swallowed or gets into the eyes, seek medical advice. e Prolonged contact with used engine oil can cause skin cancer. Wear gloves or use a barrier cream if necessary. Change out of oilsoaked clothes and do not keep oily rags in your pocket. e Air conditioning refrigerant forms a poisonous gas if exposed to a naked flame (including a cigarette). It can also cause skin burns on contact.
Fire
Asbestos
e Fuel is highly flammable; fuel vapour is explosive. ¢ Don’t let fuel spill onto a hot engine. ¢ Do not smoke or allow naked lights (including pilot lights) anywhere near a vehicle being worked on. Also beware of creating sparks (electrically or by use of tools). ¢ Fuel vapour is heavier than air, so don’t work on the fuel system with the vehicle over an inspection pit. e Another cause of fire is an electrical overload or short-circuit. Take care when repairing or modifying the vehicle wiring.
e Asbestos dust can cause cancer if inhaled or swallowed. Asbestos may be found in gaskets and in brake and clutch linings. When dealing with such components it is safest to assume that they contain asbestos.
always
WN ti, LEENR S_GFS
y
supplement the jack with axle
stands, or use
fae
drive-on ramps.
ae VEN
mr
ay
(ese @ Reames 6 se, }
Never
xa
venture
ae
WEDS
e Keep a fire extinguisher handy, of a type
suitable for use on fuel and electrical fires.
Electric shock
a
e Ignition HT voltage canbe
dangerous, especially to people with heart
ooh “Sf
oy
ay“~~
problems or a Lip pacemaker. Don’t a work on or near the ignition system with the engine running or the ignition switched on.
rf
Special hazards Hydrofluoric acid e This extremely corrosive acid is formed when certain types of synthetic rubber, found in some O-rings, oil seals, fuel hoses etc, are
cleaning solvents and paint thinners.
Crushing
0e5
exposed to temperatures above 400°C. The rubber changes into a charred or sticky substance containing the acid. Once formed, the acid remains dangerous for years. If it gets onto the skin, it may be necessary to amputate the limb concerned. e When dealing with a vehicle which has suffered a fire, or with components salvaged
from such a vehicle, wear protective gloves and discard them after use.
The battery e Batteries contain sulphuric acid, which attacks clothing, eyes and skin. Take care when topping-up or carrying the battery. e The hydrogen gas given off by the battery is highly explosive. Never cause a spark or
allow a naked light nearby. Be careful when connecting and disconnecting battery chargers or jump leads.
Air bags e Air bags can cause injury if they go off accidentally. Take care when removing the steering wheel and/or facia. Special storage Instructions may apply.
Diesel injection equipment e Diesel injection pumps supply fuel at very high pressure. Take care when working on the fuel injectors and fuel pipes. Warning: Never expose the hands, face or any other part of the body to injector spray; the fuel can penetrate the skin with potentially fatal results.
Remembenr... DO e Do use eye protection when using power tools, and when working under the vehicle.
e Do wear gloves or use barrier cream to protect your hands when necessary. * Do get someone to check periodically that all is well when working alone on the vehicle. ¢ Do keep loose clothing and long hair well out of the way of moving mechanical parts.
¢ Do remove rings, wristwatch etc, before working on the vehicle — especially the electrical system. ¢ Do ensure that any lifting or jacking equipment has a safe working load rating adequate for the job.
DON’T e Don’t attempt to lift a heavy component
which may be beyond your capability - get assistance. ¢ Don’t rush to finish a job, or take unverified short cuts.
© Don’t use ill-fitting tools which may slip and cause injury.
e Don’t leave tools or parts lying around where someone can trip over them. Mop up oil and fuel spills at once.
® Don’t allow children or pets to play in or near a vehicle being worked on.
o6
Dimensions, Weights & Capacities
Dimensions Overall length: I ALCHIDAGK mmr teette Stet tien pero rete ae LTRS td ial oak eesaoe Salon mnteate hen yet Meese R ene ants tidwk Cetin ah Ak edited | Chey a OUD CMemee Tactca tai tis! Ree ae ie ee ice ciamaia ats ouimeseenaueraens EState mete tree nity Stee a I Oe he Ah, osesi ns So WS nk Overall width: Breath aCK sme tiint5 cents ene nrc cee ete. aren ey duck ee ae ed SECC aks ates ee eReLe ole Ro MER aed mene: poe en ey tei Bice
Overall height: Imatehback@eenwe tame. a.s cae Mien te AE), Ao tee Ae coe Getaba SAlOOMER Men atte cheonce ve cece ols Men ve See (CLOUT ere Sayan yesc Cason ake SRR PN om: © Vk Mares Sept Uaterwte SSELO, Geta ener Ns hr of OE ee We On hye ane
4061 4215 4230 4270
mm mm mm mm
(159.9 (165.9 (166.5 (168.1
in) in) in) in)
1640 1640 1665 1640
mm (64.6 in) mm (64.6 in) mm (65.6 in) mm (64.6 in)
1379 mm (54.3 in ) 1379 mm ((64.3 in)
1323 mm (62.1 in) 1384 mm (64.5 in)
Weights Kerb weight (typical — add 20 kg/44 Ib for automatic transmission): FIALCID ACK wicayctSteutse a c.cdits saxeomals onde WyAevaisco RT ae Eo
Maximum towing weight - with brakes: brat Ch baCk sans. siesta et mA, 1ooh CsA. SAO OW ewaper area eslin accra eat eters A
COUR CTR Prater eeiecaissche aeRO RUN cere ESTALOM
Eas gePeg eth nD Us
rit cic eR
Pa tard authatcnche suc anchored Sie Rete oto Teaches baer Bbgg
Bee ata
ane ee
ORG
989 kg (2180 Ib) 991 kg (2185 Ib) 1019 kg (2246 Ib) 1034 kg (2280 Ib) 999 999 899 999
kg kg kg kg
( ) (2202 Ib) (1982 Ib) (2202 Ib)
Capacities PARANA TOMES) ee okctck ko SNe cane | ca. Cooling system: Pui aluininitun, Faglators aes akey see ee. Mahe lees Ach With COppemadiatOlme siniiise cameras oe aes Uae ete eee Came Beare Ol (WICH TIREr: CHANGE) iche sete tise csc 2c hee ee ee Manual transmission:
pe DOOG UD 10 VANUlAly A-SPECC MON) VanuUahy SFESCClUP OIE WEY 5-speed from January Automatic transmission Power steering fluid
OB Wsitie cs .ce ss ounce ene oe eee OG sees aren ite a. es ee ee IRE shounntonedouedaorocoeececatece. 1987
50 litres (11 gallons) 4.9 litres (8.62 pints) 5.5 litres (9.68 pints) 3.2 litres (5.63 pints) 2.3 2.4 2.7 2.8 6.3 0.9
litres (4.05 pints) litres (4.22 pints) litres (4.75 pints) litres (4.93 pints) litres (11.0 pints) litre (1.6 pints)
Roadside Repairs
i
Se
7
identifying leaks Puddles
obvious
on the garage floor or drive, or
wetness
under
the
bonnet
or
underneath the car, suggest a leak that needs
investigating. It can sometimes be difficult to decide where the leak is coming from, especially if the engine bay is very dirty already. Leaking oil or fluid can also be blown rearwards by the passage of air under the car, giving a false impression of where the problem lies.
Warning: Most automotive oils
and fluids are poisonous. Wash
Th
HAYNES
ll of. aflaid leaks
f = giles eles
ee
them off skin, and change out of
HINT fhe . pees y ale pe
contaminated clothing, without delay.
yea - apis poe sibel as 9 oy ) coloured. It may help to clean the car __ carefully and to park it over some clean g : ti oo by ah meyers ae el ing ihe setesteaed ek Led z Remember that some leaks may only
occur while the engine is running.
Sump oil ee oe
—s
Oil from filter
eS
Gearbox oil .
Engine oil may leak from the drain plug...
...or from the base of the oil filter. 7
Gearbox oil can leak from the seals at the inboard ends of the driveshafts.
Antifreeze
Brake fluid
Power steering fluid
Leaking antifreeze often leaves a crystalline deposit like this.
A leak occurring at a wheel is almost certainly brake fluid.
Power steering fluid may leak from the pipe connectors on the steering rack.
0°8
Roadside Repairs
Jacking, wheel changing and towing Jacking The jack supplied with the vehicle should only be used for emergency roadside wheel changing (photo). Chock the roadwheels on the side opposite to that from which the wheel is being removed. Engage the jack in one of the two cut-outs at the base of the sill, either front or rear according to which wheel is being removed. When carrying out overhaul or repair work | use a trolley jack or a hydraulic bottle or screw jack. Locate the jack under the vehicle only at the positions indicated and always supplement the jack with axle stands placed under the side-members.
To avoid repetition, the procedure for raising the vehicle in order to carry out work under it is not included before each operation described in this Manual. It is to be preferred, and is certainly recommended, that the vehicle is positioned over an inspection pit or raised on a lift. Where these facilities are not available, use ramps or jack up the vehicle and supplement with axle stands, as described earlier.
Wheel changing The removal and refitting of a roadwheel should be carried out in the following way. Carefully prise off the centre trim (where
fitted) from the roadwheel — the trim is easily broken, so do not use excessive force. Unscrew the roadwheel nuts just enough to release them, before raising the car. On roadwheels having a small plastic centre cap, twist it through a quarter-turn and remove it. Raise the roadwheel from the ground, remove the nuts completely, then lift the roadwheel from the studs (photo). Refit the roadwheel, tighten the nuts as tightly as possible while the wheel is held against rotation with the foot. Lower the vehicle and tighten the nuts fully. Fit the cap/trim to the centre of the roadwheel.
Towing
Jack stowage location in luggage area (Hatchback)
Standard (pantograph) type jack location points when raising the vehicle
Location for spare wheel and tools (Hatchback)
Loosen the roadwheel bolts...
The front and rear towing hooks may be used in an emergency. On vehicles with manual transmission, restrict the towing speed to below 50 mph (80 kph) and the distance towed to 50 miles (80 km). On vehicles with automatic transmission, restrict the speed to 20 mph (30 kph) and the distance towed to 20 miles (30 km). If the transmission has a fault, then the front wheels of the vehicle must be raised and placed on a dolly. Never tow a vehicle with automatic transmission by raising the rear wheels and leaving the front wheels in contact with the road.
. then raise the vehicle
Roadside Repairs
os
Front towing hook
ca pala AQ SN : SS SSS , See Fe el a
—
Location
an
points under vehicle for axle (safety) stands. Also shown are the front and rear towing eye locations. Locate wooden blocks for protection when lifting at points indicated
U
|
\
DO NOT use for towing Mites
(aes
Towing hook
Towing hook
ae
4
Front and rear tow
hook
locations
o10
Roadside Repairs
Jump starting When jump-starting a car using a booster battery, observe the following precautions:
v
Make sure that the booster battery is the same voltage as the discharged one in the vehicle.
v
Before connecting the booster battery, make sure that the ignition is switched off.
v
lf the battery is being jump-started
v
Ensure that all electrical equipment (lights, heater, wipers, etc) is switched off.
from the battery in another vehicle, the two vehcles MUST NOT TOUCH each other.
Make sure that the transmission is in neutral (or PARK, in the case of automatic transmission).
Jump starting will get you out peayties of trouble, but you. must correct HINT whatever made the battery go flat in the first place. There are three possibilities: The battery has been drained by
repeated attempts to start, or by leaving the lights on. The charging system is not working properly (alternator drivebelt slack or broken, alternator wiring fault or alternator itself faulty).
The battery itself is at fault (electrolyte low, or battery worn out).
¥
|
é
Connect one end of the red jump lead to the positive (+) terminal of the flat battery
2
Connect the other end of the red lead to the positive (+) terminal of the booster battery.
A
q I I i
to the negative (-) terminal of the booster battery
ory
4
Connect the other end of the black jump lead to a bolt or bracket on the engine block, well away from the battery, on the vehicle to be started. Make sure that the jump leads will not come into contact with the fan, drivebelts or other moving parts of the engine.
S| St ee
eee
|
Start the engine using the booster battery, then with the engine running at idle speed, disconnect the jump leads in the reverse order of connection.
Routine Maintenance © oe11
For information applicable to later models see Supplement at end of manual The routine maintenance instructions listed are basically those recommended by the vehicle manufacturer. They are sometimes supplemented by additional maintenance tasks proven to be necessary. The maintenance intervals recommended are those specified by the manufacturer. They are necessarily something of a compromise, since no two vehicles operate under identical conditions. The DIY mechanic,
Weekly, or before a long journey Check engine oil level (Chapter 1)
Check coolant level (Chapter 2) Check automatic transmission fluid level (Chapter 7) CILICI Check brake fluid level (Chapter 9) Check tyre pressures (cold). Include spare (Chapter 10) EeCheck operation of all lights and horn, and add a screen wash to the washer bottle reservoirs (Chapter 12) |_| Check battery test indicator colour (if applicable) (Chapter 12)
Every 9000 miles (15 000 km) or 6 months — whichever comes first [_] Renew erngine oil and filter (Chapter 1)* [|] Check cooling system drivebelt(s) condition and tension (Chapter 2) Check idle speed and mixture settings (Chapter 3) Check exhaust system for condition and security (Chapter 3)
Clean and regap spark plugs Check ignition timing ILI Check clutch adjustment (Chapter 5) Check manual gearbox oil level (Chapter 6) & Check driveshafts for condition and security(Chapter 8) (| Braking system (Chapter 9) Check braking system adjustment(s) (Chapter 9) Check front pads for wear (Chapter 9) [ ]Check braking system for leaks (Chapter 9) _] Check Suspension and steering for condition and security (Chapter 10) Check power steering fluid level (Chapter 10) Check tyres for wear (Chapter 10)
[] Lubricate hinges and locks (Chapter 11)
-] Check drain channels are clear (Chapter 11) *Nissan state that, if an oil filter which is not of Nissan Premium type
is used, the oil and filter should be renewed every 6000 miles
(10 000 km) or six months, whichever comes first
who does not have labour costs to consider, may wish to shorten the service intervals. Experience will show whether this is necessary. Where the vehicle is used under severe operating conditions (extremes of heat or cold, dusty conditions, or mainly stop-start driving), more frequent oil changes may be desirable. If in doubt consult your dealer.
Every 18 000 miles (30 000 km) or 12 months — whichever comes first In addition to the 9000 mile (15 000 km) maintenance requirements Check valve clearances (Chapter 1) Clean positive crankcase ventilation system hoses and check operation (Chapter 1)
Check cooling system hoses for condition and security _ (Chapter 2) |_| Renew fuel filter (Chapter 3) __]| Check vacuum hoses for condition and security (Chapter 3) Check automatic temperature control operation (Chapter 3) Renew spark plugs (Chapter 4) Renew manual gearbox oil (if used in adverse conditions) (Chapter 6) Renew automatic transmission fluid (if used in adverse conditions) (Chapter 7) Renew brake fluid (Chapter 9) _ |Check rear shoes for wear (Chapter 9) |_|] Check front wheel alignment (Chapter 10) Check seat belts for condition and security (Chapter 11)
Every 36 000 miles (60 000 km) or 2 years — whichever comes first In addition to the 18 000 mile (80 000 km) maintenance requirements
(_] Renew coolant (Chapter 2) _] Check fuel lines for condition and security (Chapter 3) Renew air cleaner element (Chapter 3) Check ignition system wiring for condition and security (Chapter 4) [_] Check servo and vacuum hoses for condition and security (Chapter 9)
Every 60 000 miles (100 000 km) Renew timing belt (Chapter 1)
0°12
Routine Maintenance
Under bonnet view - 1.6 engine
1 Engine oil dipstick 2 Coolant filler cap 3 Power steering pump reservoir 4 5 6 7
Wiper/washer fluid filler/reservoir Engine oil filler cap Brake master cylinder and fluid reservoir Alternator
8 9 10 11 12 13 14
Carburettor (air cleaner removed) Heater coolant hoses Fuel filter Windscreen wiper motor Headlight dim-dip switch unit Front suspension strut upper mounting Ignition coil
15 16 17 18 19 20 21
Starter motor Ignition distributor Battery Clutch release lever Cooling fan Coolant thermostat Exhaust manifold
Routine Maintenance
013
View of front underside of vehicle 1.6 engine with manual gearbox
Radiator drain plug Gearbox drain plug and level/filler plug Driveshaft and gaiter Brake caliper unit Transverse link arm Gear selector control rod Stabilizer (anti-roll) bar Exhaust system — front ODOANDAAWNH™= Steering tie-rod
Steering gear unit Sump drain plug
Oil filter
View of rear underside of vehicle 1.6 Hatchback
Hydraulic brake lines and fuel lines Fuel tank drain plug Fuel check valve Front and rear parallel links Rear towing eye Fuel filler pipe Exhaust system — rear Rear strut Radius rod Handbrake cable ~~SOANDaAAWNH-
0014
Routine Maintenance
Buying spare parts and vehicle identification numbers Buying spare parts Spare parts are available from many sources, for example: Nissan garages, other garages and accessory shops, and motor factors. Our advice regarding spare part sources is as follows: Official appointed Nissan garages - This is the best source of parts which are peculiar to your vehicle and are otherwise not generally available (eg, complete cylinder heads, internal gearbox components, badges, interior trim, etc). It is also the only place at which you should buy parts if your vehicle is still under warranty non-standard components may invalidate the warranty. To be sure of obtaining the correct parts it will always be necessary to give the stores person your vehicle’s engine and chassis number, and if possible, to take the ‘old’ parts along for positive identification. Remember that some parts are available on a factory
exchange scheme - any parts returned should always be clean! It obviously makes good sense to go straight to the specialists on your vehicle for this type of part for they are best equipped to supply you. Other garages and accessory shops — These are often very good places to buy materials and components needed for the maintenance of your vehicle (eg, spark plugs, bulbs, drivebelts, oils and greases, touch-up paint, filler paste, etc). They also sell general accessories, usually have convenient opening hours, charge lower prices and can often be found not far from home. Motor factors — Good factors will stock all of the more important components which wear out relatively quickly (eg clutch components, pistons, valves, . exhaust systems, brake cylinders/pipes/hoses/seals
shoes and pads etc). Motor factors will often provide new or reconditioned components on a part exchange basis —- this can save a considerable amount of money.
Vehicle identification numbers The chassis number is located on a plate in the rear corner of the engine compartment. The number is repeated on the bulkhead upper panel in which it is stamped. The engine number is stamped into a machined inclined surface on the crankcase just below the distributor mounting (photo). The manual transmission serial number is located on the clutch release arm, and the automatic transmission serial number on the upper casing surface.
Vehicle identification number
(Chassis number) Vehicle identification plate
Tyre
Engine number location
pressure chart
Vehicle identification number and tyre pressure chart locations
On RHD models, tyre pressure chart is on driver’s pillar
Manual transaxle number
RN4F30A and RS5F30A rs
A
Automatic transaxle
V2
number
7
Se a
RNY KK
Engine number locatoin (shaded)
Transmission number locations
plate
Routine Maintenance
0°15
Tyre conditon and pressure It is very important that tyres are in good condition, and at the correct pressure - having a tyre failure at any speed is highly dangerous. Tyre wear is influenced by driving style - harsh braking and acceleration, or fast cornering, will all produce more rapid tyre wear. As a general rule, the front tyres wear out faster than the rears. Interchanging the tyres from front to rear ("rotating" the tyres) may result in more even wear. However, if this is completely effective, you may have the expense of replacing all four tyres at once! Remove any nails or stones embedded in the tread before they penetrate the tyre to cause deflation. If removal of a nail does reveal that
the tyre has been punctured, refit the nail so that its point of penetration is marked. Then immediately change the wheel, and have the tyre repaired by a tyre dealer. Regularly check the tyres for damage in the form of cuts or bulges, especially in the sidewalls. Periodically remove the wheels, and clean any dirt or mud from the inside and outside surfaces. Examine the wheel rims for signs of rusting, corrosion or other damage. Light alloy wheels are easily damaged by "kerbing" whilst parking; steel wheels may also become dented or buckled. A new wheel is very often the only way to overcome severe damage.
New tyres should be balanced when they are fitted, but it may become necessary to rebalance them as they wear, or if the balance weights fitted to the wheel rim should fall off. Unbalanced tyres will wear more quickly, as will the steering and suspension components. Wheel imbalance is normally signified by vibration,
particularly
at a certain
speed
(typically around 50 mph). If this vibration is felt only through the steering, then it is likely that just the front wheels need balancing. If, however, the vibration is felt through the whole car, the rear wheels could be out of balance. Wheel balancing should be carried out by a tyre dealer or garage.
GIS bic, BS OI SIR tech ica ene A ec ee (CAI SLUIGIUGT Giese cor AIR ca EO olieatre Ei AEE ease evlolstanikamumyecscrc ri tecesp at My ae et te lata NA a Sap A eectcsc:ses aheeen eee Se
13 to 16 6 to 7 26 to 36
Buel taniKctilenpl PeitOIDOdy 2 astaie. =o cone oars cecil ans aeeeralers Exhalisthidownpipe tOnmantOldi acs: cta slncyemseala aeeeretens cuereeere tet e troree
3.4 to 4.2 28 to 33
10 to 12 4to5 19 to 27 2.5 to: 3.1 20 to 24
1 General description
Air temperature bimetal
Cold air
‘Temperature sensor
The fuel system is the same on all models in the range, comprising a rear mounted fuel tank, a mechanical diaphragm fuel pump, and a dual barrel downdraught carburettor with an automatic choke. The fuel pump is operated by a cam on the engine jackshaft. The carburettor air cleaner has a dry paper element and the unit also contains an air temperature control in the intake. By regulating the air temperature in the unit, the carburettor is able to operate more efficiently, the warm-up period is reduced and there is an
overall increase in efficiency to improve emission control. When working on, or disconnecting any part of the system, particular care must be taken to guard against the risk of fire (see Safety First for general guidelines at the start of this manual).
Unleaded fuel Vacuum
motor
LAE Air bleed valve
tte intake manifold
Temperature sensor
Fig. 3.1 Air cleaner unit showing the air temperature control components (Sec 1)
It is likely that Nissan Sunny models can be run on unleaded fuel following suitable modifications. No adjustment information was available at the time of writing so refer to your dealer for guidance.
Fuel, exhaust and emission control systems
3¢3
3.2A Air cleaner cover wing nut. Note cover alignment arrows
3.2B Removing the air cleaner element
3.4A Air cleaner case retaining bolts to rocker cover
3.4B Air cleaner intake duct retaining bolts to front panel
3.5A Identify the hose connections...
3.5B ... then lift the air cleaner from the carburettor...
2 Routine maintenance
clean and dry before fitting the new element into position, then refit the cover; aligning the arrows on the cover and case (see photo
WOK)3.2A).
The following maintenance procedures must be made at the intervals given in Routine Maintenance at the start of this manual. 1 Check and if necessary adjust the engine ‘idle speed and mixture settings (Section 11). 2 Check the condition and security of the fuel lines. Repair or renew as necessary. 3 Renew the air cleaner element at the specified intervals, or before if the vehicle is used in adverse conditions (city traffic or a dusty environment) (Section 3). 4 Renew the in-line fuel filter (Section 5). 5 Check the air temperature control valve for satisfactory operation (Section 4). 6 Inspect the exhaust system for any signs of leaks and/or damage and, if required, make the necessary repairs (Section 16).
3 Air cleaner servicing, removal and refitting
x
EN N
1 The air cleaner fitted to all models in the range contains a dry paper type element ‘which must be renewed at the specified intervals given at the start of this manual (see Routine Maintenance). 2 To renew the element, unscrew the wing nut and lift the air cleaner cover away. Lift out the air cleaner element (photos). 3 Wipe out the air cleaner casing so that it is
4 To remove the air cleaner casing, remove the cover and element as_ previously described, then undo the casing and intake duct retaining bolts (photos). 5 Carefully lift the air cleaner away from the carburettor and detach the vacuum hoses and the flexible hot air hose from the manifold (photos). Also detach the throttle cable from its retaining clip on the top of the intake duct as the casing is removed. 6 Refitting is a reversal of the removal procedure.
3.5C ... and the hot air hose from the exhaust manifold cowl
that warm
4 Air temperature control (ATC) system - checking 4 Check the condition and security of the vacuum hoses and repair or renew any which are perished or cracked. 2 Detach the extension duct from the air cleaner intake duct. 3 Detach the vacuum hose from the
air is drawn from the hot air intake
port on the underside of the air cleaner duct. As the engine warms up, the valve opens to allow cooler air through, and the hot air intake
is closed off. This can be observed by holding a mirror at the end of the duct (Fig. 3.2). Vacuum
Carburetor
temperature sensor on the air cleaner duct.
Start the engine from cold, allow it to idle and check that there is a strong vacuum through the hose. If not, check the hose for blockage or a leak, and repair as necessary. Reconnect the vacuum hose. 4 When the engine is cold, the valve in the intake duct will be in the closed position so
Hot air
Fig. 3.2 Warm air flow circuit with the intake duct valve shut (Sec 4)
3e4
Fuel, exhaust and emission control systems t
Air cleaner
Orifice
Idle compensator
To intake |manifold
ae
Fig. 3.3 Sectional view of the idle compensator (Sec 4)
Fig. 3.4 Testing the idle compensator (Sec 4)
5 If the valve operates in a satisfactory manner, reconnect the extension duct. If the valve is defective, the air cleaner unit complete will probably be in need of replacement, but first check the idle compensator. 6 The idle compensator device is fitted in the air cleaner body. The compensator is operated by a bi-metal strip in accordance
dryer whilst checking the temperature with a thermometer. The engine should be at its normal operating temperature for this test, the air cleaner cover removed and the warm air directed at the device whilst the compensator temperature is checked with the thermometer, held as close as possible to the compensator
with the intake air temperature. At temperatures below 55°C (131°F) the air valve is shut, but as the air temperature rises above intermediate temperatures, the valve can be
8 If the compensator is in good condition, it should be open allowing air to pass through it and this will be obvious by the hissing sound. During this check take care not to damage the compensator bi-metal strip.
open or closed (Fig. 3.3).
9 If defective, renew the air cleaner unit.
65°C (149°F), the valve should open fully. At
ay
7 The
operation
of
this
device
can
be
checked by warming it with hot air from a hair
Except E16i engine model and E16S engine with A/T model Lock ey aes)
(Fig. 3.4).
10 On completion. refit the air cleaner or its cover, as the case may be.
E16S engine with A/T model (see Supplement)
‘)
5.1 In-line fuel filter
5 Fuel filter—renewal
KCC
1 An in-line type of fuel filter is used (photo). 2 Disconnect the hoses from the filter, and remove the unit from the clip. 3 Fit the new filter then start the engine and check for leaks.
6 Fuel tank -
\
removal. repair and refitting
x
1 Disconnect the battery earth lead. 2 Position a suitable container under the fuel tank drain plug, undo the plug and drain the fuel from the tank. Store the fuel in a safe place. 3 Jack up the rear of the car and support it on axle stands. 4 Undo the retaining nut and remove the handbrake cable support bracket from the forward edge of the fuel tank. 5 Undo the retaining clips and detach the fuel
filler hose and the vent hose (photo). Fuel tank gauge unit
6 Disconnect the hoses and wiring from the fuel transmitter as described in the following Section. 7 Support the tank and then unscrew the mounting bolts from floor. Carefully lower the
Fuel
: O-ring
tank
pump assembly
and
manoeuvre
it clear.
It may
be
necessary to remove or partially disconnect the exhaust system and/or the rear radius rod to allow the tank to be removed. 8 Serious damage to the fuel tank will
Fuel check valve
Fig. 3.5 Fuel tank and associated fittings (Sec 6)
6.5 Fuel filler and vent hoses
Fuel, exhaust and emission control systems
6.10 Fuel filler pipe flange nuts
6.11 Fuel check valve
necessitate its renewal. Although minor damage or leaks may be repairable, such tasks must be entrusted to a specialist. Consult a Nissan dealer for advice if in doubt. 9 The removal of sediment or sludge can be carried out after first having removed the tank transmitter unit. Pour in some paraffin, or petrol, and shake the tank vigorously. Empty the tank and repeat the operations as many times as is necessary to clean it and then give a final rinse with clean fuel. 10 The fuel filter and vent hoses can be removed if required by undoing the four retaining nuts from the top flange, then lowering them from the car (photo). 11 If required, the fuel check valve hose can be removed by detaching the hose and withdrawing the unit from the bracket on the fuel tank. This valve must be renewed if it is suspected of malfunction (photo). 12 Refitting is a reversal of the removal procedure. Top up the fuel tank on completion and check for any signs of leakage from the tank and hose connections.
loosen the retaining clips and detach the hoses from the transmitter (photo). 4 Untwist the transmitter unit by locating a screwdriver or a suitable flat piece of metal
7 Fuel level transmitter and
gauge - removal and refitting
VU x
1 Disconnect the battery earth lead. 2 Tilt the rear seat squab forward, then fold back the floor covering to gain access to the transmitter cover plate. Remove the cover plate, then disconnect the transmitter wires at their in-line connector. 3 Mark the hoses for identification, then
7.3 Fuel level transmitter and hose connections
FFuel-vapor separator
@ >. 7
across the top of the unit between castellated sections and unscrew it. Withdraw the transmitter unit with care as it is easily damaged. 5 The fuel gauge can be removed after withdrawing
the
instrument
panel,
ao
Return (To fuel tank)
‘_
as
described in Chapter 12. 6 Refitting is a reversal of the removal procedure. Renew the transmitter O-ring seal and ensure that all connections are securely made.
8 Fuel pump -
removal and refitting
XS
Fig. 3.6 Fuel pump and connections (Sec 8)
x
1 The mechanically-operated fuel pump is of rocker arm type, actuated by an eccentric cam on the jackshaft (photo). 2 Disconnect the fuel hoses from the pump, and plug them to prevent loss of fuel. 3 Unscrew and remove the pump mounting nuts and washers and lift the pump from the crankcase. Discard the joint gaskets, but retain the insulator, if fitted (photo). 4 The fuel pump is of sealed type and, if clogged or faulty, will have to be renewed; cleaning and repair is not possible. 5 Clean the pump and crankcase mating faces, use new joint gaskets and bolt the pump into position. 6 Reconnect the fuel hoses, run the engine and test for leaks.
9 Carburettor - description 1 The carburettor fitted on all models is a dual barrel downdraught type with an automatic choke system. The calibration details of the carburettor are dependent on the engine and gearbox type used. The main components are as follows (photo).
9.1 General view of the carburettor
8.1 Fuel pump location beneath the inlet manifold
3¢5
8.3 Fuel pump removal
A B C D E
Automatic choke unit Choke unloader device Vacuum break diaphragm Secondary throttle vacuum diaphragm Fuel inlet union
3°6
Fuel, exhaust and emission control systems
10 Carburettor - check and adjustments (general) Vacuum break diaphragrm
WEY
The following checks and adjustments should only be necessary if a malfunction or drop in performance and/or economy are noted.
Automatic choke heater bimetal cover
Float level check awwsll Diaphragm for secondary system
Fuel needle valv (en geo,
;
Secondary oe jet
8
Primary main air mal Secondary main air bleed
“Primary main jet
Secondary small venturi
Secondary slow jet +.
y a
Secondary slow air bleed
Be
4
oe
i
Injection isweight
\i
y >t
:
Primary
—~ slow jet Accelerating pump piston
small venturi
Primary slow air bleed
INE
oy
UIA
|
Fuel cut solenoid valve
Throttle opener adjusting screw
_ 09
2)
&
ia oeOe
Lock lever
Throttle adjusting aa Idle aes
beea idle adjusting screw
Fig. 3.7 Exploded view of the carburettor fitted to the E13 engine models (Sec 9)
Automatic choke
Dashpot
2 This is of bi-metal spring type, the heating being carried out electrically. A relay is located within the engine compartment for operating the automatic choke.
5 On certain models a dashpot is fitted to the carburettor to prevent the engine stalling during sudden braking or quick release of the accelerator pedal.
Fuel cut-off solenoid valve
Choke unloader
3 The purpose of this valve is to prevent the engine running on when the ignition is switched off. This is done by cutting off the fuel supply to the idle circuit.
6 This device opens the choke valve plate slightly when increasing the engine speed during the warm-up period to provide a suitable fuel/air mixture which would otherwise be too rich.
Secondary throttle vacuum diaphragm 4 This is actuated by vacuum conditions in the carburettor venturi. The diaphragm is linked to the secondary throttle in order to open it after the primary throttle valve plate has opened through an angle of 48°.
Vacuum break diaphragm 7 This is a double-acting type diaphragm which opens the choke valve plate immediately after cold starting to create a suitable fuel/air mixture in accordance with the prevailing engine vacuum conditions.
1 The float level can be easily checked with the carburettor in situ through the sight glass in the side wall of the float chamber. The vehicle must be standing level when making this check (Fig. 3.9). 2 The fuel level must be maintained at the level indicator index mark on the window. If adjustment is necessary, remove the top cover from the carburettor and adjust the float as described in Section 13.
Automatic choke 3 To make this check. the engine must be fully cold. Do not start the engine. Remove the air cleaner unit (Section 3). 4 Open the throttle valve to its full extent and check that the choke valve shuts properly. Operate the choke valve by pressing it with your finger and ensure that the valve has a smooth action. 5 Ensure that the index marks on the automatic choke cover and housing are in alignment (photo). Check that the automatic choke heater wires are securely connected, then start the engine and warm it up to its normal operating temperature, at which point
check that the choke valve has fully opened. If it hasn’t,
then
check
the automatic
choke
heater wiring for continuity using an ohmmeter as shown (Figs. 3.10 and 3.11). 6 If the automatic choke wiring system is in order, the system relay is most probably at fault. Have the relay checked by a Nissan dealer and renew it, if necessary, ensuring that the replacement is of the correct type (Fig. 3.12).
Fast idle (automatic choke) 7 Bring the temperature.
engine to normal operating Remove the choke housing
cover. 8 Set the fast idle lever on the second step of the fast idle cam (photo) . 9 Check that the fast idle engine speed is as given in the Specifications. If it is not, turn the fast idle screw as necessary, then refit the choke cover (photo).
Vacuum break 10 With the engine cold, remove the air cleaner and close the choke valve plate. 11 Using a vacuum pump as shown, apply vacuum to the vacuum break diaphragm and give a light push on the piston rod to shut the choke valve. Now check that the clearance shown at R11 (Fig. 3.13) is as specified. 12 Now push the piston rod back towards the vacuum break diaphragm and check
Fuel, exhaust and emission control systems
3¢7
Vacuum break diaphragm
~
Top cover
ee
:
Fuel level should be maintained in 2
Automatic choke heater
Accelerating pump
Oy}
ys
Ye
?
@
——~ lever
%@
a
Accelerating pump piston
a Bee
a0
Accelerating pump
connecting rod
R
a
Secondary main air bleed.
Fig. 3.9 Carburettor float chamber sight glass and level mark (Sec 10)
;
6
| Power jet
his mark.
Diaphragm for secondary system
BW
Fuel needle valve—{ & Primary main air bleed
t
)
SS
Secondary slow jet. J ‘
BZ
|
g
°
§
©, oa
Outlet
i
L
Sgr
e
y
&
»\
aoe
\
Eh
WED ONS =
Ik OIE
:
7
6
aot
@®
99
: oO ®
ox
circuit (Sec 10)
1 Alternator “L” terminal
5 Bimetal switch
2 Automatic choke relay
6 PTC heater (B)
3 Automatic choke cover
7 Bi-metal strip
4 PTC heater (A)
8 Choke valve
Lock lever
DS =
Fig. 3.10 Automatic choke unit electrical
>)
suitable for expert DIY NS or professional x
Specifications General ESVSCOM VIG mre mare Meme CIC TOLCCIamnen emetic
sere asa enter Ree Estey csie tessleeinrn ARI A® Ba eal ae fe crete eteyore ate etl clowtilssewiles elas evra seid 8g
Electronic, with breakerless distributor 1-3-4-2 (No 1 at timing belt end)
Spark plugs (8-valve engine)* 1.3 and 1.6 Electrode gap
Champion RN9YCC or RN9YC 0.8 mm (0.032 in)
HT leads (8-valve engine) 1.3 and 1.6
Champion LS-08, boxed set
Ignition timing (8-valve engine) At idle with vacuum hose detached and plugged:
2° + 2° BIDC 4° + 2° BTDC
Distributor Direction of rotation
Anticlockwise
Air gap
0.3 to 0.5 mm (0.012 to 0.020 in) 10 mm (0.39 in) minimum Manual transmission Hitachi D4R83-30 Hitachi D4R83-36
Carbon brush wear limit
Type number: WE
2 As onal phe cee otkot Globo CO
DIR EOL
RoR
Iona
ee
ge
Automatic transmission
Hitachi D4R83-36 Hitachi D4R83-31
Coil Type number Primary resistance at 20°C (68°F) Secondary resistance at 20°C (68°F)
Hanshin STC-143 1.0 to 1.3 ohm 8.4 to 12.6 ohm
Torque wrench setting
Nm
Ibf ft
Spark plugs
20 to 29
15 to 21
“Information on spark plug types and electrode gaps is as recommended by Champion Spark Plug. Where alternative types are used, refer to the manufacturer’s recommendations
4e2
Ignition system
1 General description 1 A transistorised ignition system is fitted to all models. With this system the circuit is switched by an electronic unit (located in the distributor) incorporating a magnetic stator, reluctor and transistor control . 2 In order that the engine can run correctly, it is necessary for an electrical spark to ignite the fuel/air mixture in the combustion chamber at exactly the right moment in relation to engine speed and load. The ignition system is based on feeding low tension voltage from the battery to the coil where it is converted to high tension voltage. The high tension voltage is powerful enough to jump the spark plug gap in the cylinders many times a second under high compression,
providing that the system is in good condition
is cold,
and that all adjustments are correct. 3 The system is divided into two circuits: the low tension and high tension circuits. Low tension voltage is changed in the coil to high tension voltage by the alternate switching on and off of the primary circuit. The high tension voltage is fed to the relevant spark plug via the distributor cap and rotor arm. The ignition is advanced and retarded automatically to ensure that the spark occurs at the correct instant in relation to the engine speed and load. 4 Centrifugal weights in the distributor advance the ignition timing in relation to engine speed, and a vacuum unit on the side of the distributor controls the timing in relation to engine load.
vacuum valve are incorporated into the vacuum line between the carburettor and distributor (Fig. 4.2 and photo). 6 When working on electronic ignition systems remember that the high tension voltage can be considerably higher than a conventional system and in_ certain circumstances could prove fatal.
5 To assist ignition timing control, and improve engine performance when the engine
(NorFfacc[ony sry |-
A
a vacuum delay valve and a thermal
2 Routine maintenance At the intervals given in Routine Maintenance at the start of this manual, carry out the following operations on the ignition system.
1 Remove the spark plugs as described in Section 6. Renew all four plugs if any are found to be in poor condition. 2 Renew the spark plugs at the specified intervals, even if they appear to be still in good condition.
3 Check
the HT
leads for condition
and
security. Renew if necessary. Wipe clean the inside and outside of the distributor cap, also
the top of the ignition coil. 4 Check the condition and security of all wiring and leads and their connections associated with the ignition system. Ensure that no chafing is occurring on any of the wires. 5 Check and if necessary adjust the ignition timing as described in Section 5.
3 Distributor removal and refitting Condenser
Spark plugs
: L.H. drive model : R.H. drive model
Fig. 4.1 Ignition system wiring diagram (Sec 1)
.
WEG
1 The distributor is driven by the camshaft; the distributor drive dog engaging with a lug on the rear end face of the camshaft. The distributor is mounted in a combined distributor/thermostat housing which is bolted to the rear end of the cylinder head. 2 Each plug lead fitted during manufacture is numbered for identification (although later replacements may not be).
Distributor
To throttle and intake manifold port
Below 50°C (122°F) CLOSED Above 50°C (122°F) PEN
Therma’ vacuum valve cei
Fig. 4.2 Thermo-vacuum ignition timing control system (Sec 1)
1.5 View showing vacuum delay valve (A) and thermal vacuum valve (B)
Ignition system
3.4A Undoing the distributor cap retaining
3.4B Disconnecting the LT leads from the distributor
screws
3.6A Undo the distributor retaining nut
3.6B Distributor drive dog showing off-set slot
3 To remove the distributor, first unclip and remove the insulator cover from the distributor cap (photo). 4 Either undo the retaining screws and
remove the distributor cap and then detach the LT leads (photos), or disconnect the LT ‘leads and the HT lead at the ignition coil if the cap and leads are to be removed
3.8 Refitting the rubber rim seal
Cap.
Carbon brush
ee @—_—__—Rotor
f
Rotor shaft Reluctor
distributor. 5 Make a mark on the slotted flange of the distributor body in line with the mounting stud so that the ignition timing can be reset approximately when the distributor is refitted.
shaft
adjusting screw
Rotor head
with the
Governor spring Governor weight
6 The distributor shaft incorporates an offset slot so there is no need to note the position of
the rotor arm. Simply disconnect the vacuum hose, then unscrew the mounting nut and withdraw the distributor from the cylinder head (photos). 7 Refitting is a reversal of removal, but align the offset slot with the dog on the camshaft before inserting the distributor. Turn the rotor arm if necessary until the slot engages. If the ignition timing setting has been lost, it can be reset approximately by aligning the crankshaft timing marks (Section 5) with No 1 piston on compression, then turning the distributor within the adjustment slot until the reluctor peak is aligned with the stator post. 8 When the LT leads are reconnected, refit the rubber rim seal (photo) . 9 After refitting the distributor, check and adjust the ignition timing as described in Section 5.
4¢3
Breaker plate
Vacuum controller
| Sal
Roll ak Fig. 4.3 Exploded view of the distributor (Sec 4)
4e4
Ignition system
Reluctor
4.19 Top view of reassembled distributor A B C D
Rotor shaft cutout
Fig. 4.5 Correct relation of the rotor shaft to the driveshaft (Sec 4)
:
4 Distributor — overhaul
N
w
1 With the distributor removed from the engine (Section 3), clean away the external dirt. 2 If not already removed, undo the retaining screws and remove the distributor cap, then disconnect the LT leads at the distributor (see photos in previous Section). 3 Pull the rotor head from the shaft. 4 Extract the fixing screws and remove the vacuum advance unit. 5 Using two screwdrivers as levers, prise free the reluctor from the shaft and recover the roll pin. Take care when levering the reluctor not
Breakerplate alignment notch mark LT wire (black and white is positive) Felt lubrication pad Reluctor roll pin
to damage its teeth (Fig. 4.4). 6 Extract the fixing screws and remove the breaker plate. 7 Undo the retaining screws and remove the IC ignition unit and spacers. 8 Remove the magnet, stator and spacers from the breaker plate. 9 Mount the shaft collar in a vice, then drive out the roll pin and remove the collar and washer from the bottom end of the shaft. 10 Withdraw the shaft from the distributor body. 11 Extract the felt lubrication pad from the recess in the top of the shaft and remove the screw now exposed. Separate the rotor shaft from the mainshaft. 12 If necessary, disconnect the springs and remove the counterweights, but mark the location of the springs with a dab of quickdrying paint. 13 Clean and inspect all components. The reluctor and stator should be unscratched and not distorted, otherwise renew them. If the carbon brush is worn down to its specified minimum length, renew the cap. 14 Apply grease to all friction and bearing surfaces as work proceeds. 15 Reassembly is a reversal of dismantling, but observe the following points. 16 When reconnecting the counterweight springs, fit the smaller diameter spring first.
4.22 Reluctor air gap check using feeler gauge blade of specified thickness. Stator
setscrews are arrowed 17 Set the relative position of the rotor shaft cut-out to the mainshaft offset groove as shown in Fig. 4.5. 18 Use a new roll pin to fix the drive collar to the shaft. 19 When fitting the breakerplate, make sure that its mark is in alignment with the one on the distributor body (photo). 20 Fit a new roll pin to the reluctor. 21 Make sure that the wiring harness spade terminals are correctly located. 22 Finally, set the reluctor air gap (reluctor peak to stator prong edge) to the specified dimension using a feeler blade (photo). Adjustment is made by loosening the screws and repositioning the stator.
5 Ignition timing — checking and adjustment
S x
1 Run the engine to normal operating temperature then switch it off and connect a | stroboscopic timing light in accordance with the manufacturer’s instructions. 2 Disconnect and plug the vacuum advance hose at the distributor. 3 With the engine idling, point the timing light at the index above the crankshaft pulley. The notch in the pulley rim should be in alignment |
with the mark on the index which applies to your particular vehicle (see Specifications). | 4 Any difficulty experienced in seeing the — timing marks clearly can be overcome by |
tt
No. 1 cylinder at T.D.C. Fig. 4.6 Ignition timing marks and crankshaft pulley timing index mark (set at TDC) (Sec 5)
Fig. 4.7 Distributor rotor arm at TDC (No 1 cylinder) (Sec 5)
Fig. 4.8 Ignition timing adjustment (Sec 5)
Ignition system
6.12 Fitting a spark plug
6.14 Plug leads are numerically marked for identification
applying a spot of white paint to the pulley notch and the specified timing mark on the index. 5 If the marks are not in alignment, release the distributor clamp nut and turn the distributor in either direction as necessary to align the marks. 6 Tighten the nut, switch off the engine, reconnect the vacuum hose, and remove the timing light.
4 Unscrew the spark plugs with a deep socket or a box spanner. Do not allow the tool to tilt, otherwise the ceramic insulator may be cracked or broken. 5 Examination of the spark plugs will give a
6 Spark plugs, HT leads and distributor cap — general
good indication of the condition of the engine. 6 If the insulator nose of the spark plug is clean and white, with no deposits, this is indicative of a weak mixture, or too hot a plug (a hot plug transfers heat away from the electrode slowly, a cold plug transfers heat away quickly). 7 If the top and insulator nose are covered with hard black-looking deposits, then this is
HUGHindicative
4¢5
adjusting tools are available from most motor accessory stores. 12 Screw each plug in by hand. This will make sure that there is no chance of crossthreading (photo). 13 Tighten to the specified torque. If a torque wrench is not available, just nip up each plug. It is better to slightly undertighten rather than overdo it and strip the threads from the light alloy cylinder head. 14 When reconnecting the spark plug leads, make sure that they are refitted in their correct order, 1-3-4-2, No 1 cylinder being at the timing belt end of the engine. The original leads are numerically marked for identification (photo). 15 The plug leads require no routine attention other than being kept clean and wiped over regularly. At intervals, however, pull each lead
off the plug in turn and remove it from the distributor. Water can seep down into the joints giving rise to a white corrosive deposit which must be carefully removed from the end of each cable. A smear of petroleum jelly applied to the end fitting of the cable will help to eliminate this problem. 16 Whenever the distributor cap is removed wipe it clean and check for thin lines between the electrodes. If evident, renew the cap as the lines are the result of tracking. eS
rarely necessary and should not be attempted unless specialised equipment is available as damage can easily be caused to the firing ends. 2 To remove the plugs, first open the bonnet, and pull off the HT leads. Grip the rubber end fitting, not the lead, otherwise the lead connection may be fractured. 3 Brush out any accumulated dirt or grit from the spark plug recess in the cylinder head otherwise it may drop into the combustion chamber when the plug is removed.
that the mixture is too rich. Should the plug be black and oily, then it is likely that the engine is fairly worn, as well as the mixture being too rich. 8 If the insulator nose is covered with light tan to greyish brown deposits, then the mixture is correct and it is likely that the engine is in good condition. 9 The spark plug gap is of considerable importance, as, if it is too large or too small, the size of the spark and its efficiency will be seriously impaired. For the best results the spark plug gap should be set in accordance with the Specifications at the beginning of this Chapter. 10 To set it, measure the gap with a feeler gauge, and then bend open, or close, the outer electrode until the correct gap is achieved. The centre electrode should never be bent as this may crack the insulation and cause plug failure if nothing worse. 11 Special spark plug electrode gap
1 The coil is located on the left-hand side of the engine compartment. It should be kept clean at all times to prevent possible arcing across the high tension tower (photo). 2 To ensure the correct HT polarity at the spark plugs, the LT coil leads must always be connected correctly. Refer to the wiring diagram (Section 1) for the lead colour coding. 3 The coil may be tested by using an ohmmeter. Connect the ohmmeter across the two LT terminals on the coil to check the primary winding resistance, and across the negative LT terminal and central HT tower to check the secondary winding resistance If the readings are not as_ given in the Specifications, renew the coil. All wiring should be disconnected while checking the coil (Figs. 4.9 and 4.10).
7.1 Ignition coil
Fig. 4.9 Ignition coil primary circuit test method (Sec 7)
Fig. 4.10 Ignition coil secondary circuit test method (Sec 7)
1 The correct functioning of the spark plugs is vital for the correct running and efficiency of the engine. It is essential that the plugs fitted are appropriate for the engine, and the suitable type is specified at the beginning of this chapter. If this type is used and the engine is in good condition, the spark plugs should not need attention between scheduled
_ replacement intervals. Spark plug cleaning is
7 Coil - description and testing
MNx Ry
4°6 Ignition system
Fault finding — ignition system Starter turns but engine will not start Faulty or disconnected leads
_] Faulty spark plug Air gap incorrect Fault in ignition coil eyeFault in pick-up/starter unit
Engine starts but runs erratically O Incorrect timing [_] Fouled spark plug Incorrectly connected HT leads [] Crack in distributor cap or rotor O Poor battery, engine and earth connections
O
5e1
Chapter 5 Clutch For modifications, and information applicable to later models, see Supplement at end of manual
Contents Clutch — adjustment Peedi ye Y 8 eee Mowenten taniatera Oras” cha set guste, oitd ClUtChsinSpeCtlOn pe rserccin ete riers 6 haere easton oa cau SIC CHSStittinG ween cant eye omic tte ce tiore cass Ae chic so whe (FUG SIGINT OVEN 5 chess ostien,EYEPre vehccCNeNTS Gece ncaa toycartRei OREN era Clutchicable —trenewalils msec ta weetery eee cores atta cece Mera aes
Easy, suitable for novice with little experience
xR S
Fairly easy, suitable for beginner with some experience
x SN a
3 7 OP 6> A>
-Gluteh)pedal/=removalland| refitting” yrs. ee sper sere eet 5 Clutch release bearing - removal, inspection and refitting ....... 8 eFaultitincingl!clutchin nna ces seve center grar tiem iew ere See end of chapter General\description®
voneuiuny| ‘asued!7
un jOs2U09 1461) aw1Aeg ‘leas Gules};
eran
JOUSeM PUe JOdIM 1U0I4
Aw13u AYOSS39D9V
[Nofoovj 11s poToToT {oTot zi] =] wothOnl Oz ae al Die Oks 4jen “B4OYD-OINY 10UQIYUI Agjas ‘BAjeA P1OUgOS 31ND $022U09 dwund jany
A wa" NOILINO!
NOILLINO!HOLIMS 40199UUOD YD@YD : ‘jeubis wn f ‘due, dn-yeg g ‘sezzNg ‘sdwe| Buiusey ‘abned ‘se1ey
430) |
Wiring diagrams 14¢11
14e¢12 Wiring diagrams IGNITION SWITCH
RJorF]acclon]ST]
(Main harness)
@® @ @w
©HH] (Engine harness)
s
© : L.H. drive model ® : R.H. drive model
IGNITION SWITCH
Nore ]acclon |s 7]
(Main harness)
FUSE BLOCK
(Refer to “Power Supply Routing.)
© : LH. drive model
® : R.H. drive model CED : E16i engine model
EX :
(Engine harness)
Except E16i engine modd
g B/P
INHIBITOR
€D scyr
EX) G/R STARTER
MOTOR
BODY GROUND
i 6) =
8
i ENGINE = GROUND
& Starting system wiring diagram - B12 automatic transmission models
SWITCH 4
any © \LH O
Wiring diagrams
IGNITION SWITCH ON or START INHIBITOR RELAY
(Main harness)
FUSIBLE LINK
é)
@)
HOLDER
fa
tg
(Refer to ‘Power Supply Routing’.)
©O
@
oy
@Hm
fe 4
(Engine harness)
FUSE BLOCK
co £& Be)
FA
6 o
©
—: LH. drive model
®:
: R.H. drive model
®)
: E16i engine model
& CEP)
: Except
g B/R
E16i engine model
INHIBITOR @)
©
mateo]
~*~’
(P)
GY/R
EP) G/R
SWITCH
—
BATTERY ry,
4
|STARTER
este]
[meron
g
BODY
S
GROUND =
:ENGINE
B
ea
= GROUND
GE)
SEL3881
Starting system wiring diagram - N13 automatic transmission models
B/R
IGNITION SWITCH
‘Lew | Ea Net ccfonTs
aay on CB
£o
FUSIBLE LINK HOLDER
aa
idee cy dee
=
|
g
ij
DISTRIBUTOR
BATTERY
=
ok Pal oes) mm
otOD
Des
ea:
soe
_
oe '
CONDENSER © : L.H. drive model
=
%
SPARK PLUG
@® : R.H. drive model
Ignition system wiring diagram - all models
14°13
=
YHOLVNYH3ILIY
—OH9o
YOLVNYSLIV
|
A¥31LLV8
OO
4032U18})\7) (ssausey
@)
W908)
az
=" ep» =o
auibu5) (ssausey
mo—e—=o+m
SS
co
378ISN4a NIN Y3010H
sts me YUAA 49BWOYIE? INOYrIM BWOYIEI 4d
aurBua lapow
weibeip — 21g
1913
BulbseyDwajshs Bum
:
: :
: :
® ecefG@
jasaig auibua lapow
auiBbua Japow
“H"7 BALIp J@POW "Hy BALIP J@Pow
1913
auljosesauibua japow
sjepow
1d39xa
we) (ssausey
:
:
(0)
TW'S
=
2° al
SINE ND3ZHD AV13uY
JSNOHDT-OLNY
quownansuy) (ssausey
Aiddng
104844) 03 ;
zz
as
(,,,Bunnoy
ont
horas
re
Sto——@y—
oy £
3OYVHO
rere
o—@—r
NOILVNIGWOD H3.L3W
NOILINSIHOILIMS LYV1LS
soovaeing 49MOd,,
NO 49
3Z9OYVHO
39YVHO
Av13uY
14°14 Wiring diagrams
4Y3010H =
JHOHDTOLNV
jy) euUs3a sO}
ii —
(ssausey
=
318ISNs NIN
ect:
au!6u3) (ssausey aAUp
aap
Japow
y/M
aD 30010
A
OOO
YHOLVNYH3L1V
YHOLVNY31L1V
8 M——————-
ee
M {JO
3
Le3
=~
oy
|
oO {ayg3
06988 ee oe
Sots“Ganm—
{Ts
em earl
1daox3 (Y)
:
lapow
japow 40}
GuibseyDweysAs Bum
“H"7] aap
:
adoiNy
sjepow
aul6ua
waisAs
WaysAs Idaoxa1913
yUawWNJIsU}) (ssausey
yNOYIUM awiyAep 1461;
awNZAep 2461)
wesbeip — LN¢
1daoxg(qq) japous
japoWYIM
*}"7] aAlIp
:
:
YIP, JaJAWOYIC INOYLIAA JaIBWOYIEI yring awiAep 1461) waysAs InoYyr\A awiyAep 1461) wiaysdAs auljoseyauibua japow Jdadxa 404 1913 jasaig suibua pue 19,3 aulGua japow
HO.LIMS
: : : : : :
auljosesauibua japow jasaig auibua japouw
"HY
: : :
*H"7
:
ai
Japow
43
y/M
oppem ea 90)
za
NOILINSI
A
Gs0)
‘TWwSs
4°NO LYVLS
AY31LLVE
AV13y NOSHD 81N
AV13Y
a
4JOMOd,,
92
(x4
49018
©
3DYVYHO Le
© JOYVHO
(',,6bunnoy Ajddns
494844) 0}
vz
Y3LAW NOILVNISGWOD
ASNA
Wiring diagrams 14¢15
39DYVHO
GNNOYD
AGos
GNnNOYydD ies)
@» © SeWS)
(aves) -
= (203)
AGo#
@io)
o
(,,,Burnnoy Aiddng 48M0q,, 03 485844) 90718 3SsN4
dn
OMD
: OMY
:
4819WOYIE? INOYIUM japoWw BAIIP*H'Y
48OWOYIEI YIM jBPOW BALIP "HY
4918WOYIe) INOYIM jepoW BALIP “HT:
jepow eAlIp*H'7
[epow BALIP "HY
:
:
@)
®
49\BWOYDEI YIM j@POW BALIP "HH" :
AY¥31LLVS
dNW10V3H ‘H'Y
Sjepow (ssausey }UGWNASUI)
:
wesbeip — Z1.g
.
Yu
9/u 8/Y
wey) (ssousey
sdwejpeepy Burm
a
ONILHSITHOLI
14°16 Wiring diagrams
g
o
8wW
GNNOYD AGOoa
ao
@) 3deox3 japow :
Ja{@WOYIE? YUM [BPOW BALIP “HY
:
481@WOYIE. INOYUM [EPOW BAP “H{"7] :
jepow euiBue 1913 : 4@Y@WOYIE} INOYIUM jEPOW BALIP "HY :
006 B86
:
:[@POW “HY BALIP
49J@WOYIE} YUM jePOW BALIP “"}H"7] :
fepouw BALIP “HT
dNVWI0V3H “H1
GNNOYSD Agog
@§
pak
em 8 FB @ a
uley) (ssausey
wesbeip — ELN 69
HE
sdwe|pesy Bulim
é4ne
sjepow
@D ___ Gap g
Riis 184844) 4aMOd,, a0}
ca+-91m@ oim-t ae cae oer
A¥3LLV8
dNWVIGV3H “HY
| Tt| ONILHOIT HOLIMS
OUUGGUE ololglelol
NOILVNISWOD Y313W
14°17 Wiring diagrams
S| 19|Le 8|6 04) it 2a
png
(Instrument harness)
ASN "9018 484844) O21 JOMOd,, Ajddng Bunnoy (,,
A¥31LVE
(ssausey uleyW)
JONVHV3STS
dNVT ‘HY
B= 3)
6-2) “2
dWV1 “H1 JONVHV319
o
Joua}xysdwe| Bum
wesbeip — 71g
quawinsysul)
(ssausey
sjepow
GNNOwD
@):
@):
HO
AGO
Sa §@ ®OULI®
‘HY
aauip
"Hy aap
“Hy
wa
3SN39I7 dWV71
YV3HY dNV1 ‘HY
Wiring diagrams japow
japow
VWVL dO1s
MVWL dO1ls
NOILVYNISWODS
dO1s Tv
GNNOuD
ONILHSITHOLIMS
dOLS Tv
Agog
5@ @LBE
T@®
dO1s dWV71 HOLIMS
14°18
a
Yv3Y NOILVNISWOD
lol| olLiglol
$F) ED ste
3SsNs 39018 434344) OF 4aMOd,, Ajddng (",,Bunnoy
tt izu elololelolol SORE
}9)|
annou dog
Is. | {Oo} lOfofolo}
plalv{olelvlolaly
(ssausey (ssausey dWV7 "HY 3SN3017 a/9 9/9
g/9
ulew) Apog)
8/91
g/9
Fan @H
9/971
dWNV1
HO.LIMS
dOLS
=
ree_ —
G
a/9
JONVHV3TO
FS) ath dWV7 "HT
annous Agoa
LG/B
@se)
Garpere ee uepes : 6)
Lanz YV3u
H4 aac G2
(ssausey
ps
Y¥V3u dWV7 ‘H1
8
NOILVNISWOO
GQNnouD
a/9
(Guba
NOILWNISWOO
Agog
aes =a:
qosceaiert eta)
[Fas His B
co
O
g
ist |
OGpar res)
3SN3917
ONILHONTHOLIMS
Qn
He g
330 |
Be
HI dWv7 3aSN3a9I7
[S)
@-H
t [# 53
‘Gwar @-Y Be?
"HY dW 3SN30I7
N
=O
Wiring diagrams 14°19
ELN sjepow 10198}x4 sdwe| Bum wesbeip —
JONVHV319 a/9
|H
A
G
ot os
Wed)
emerseeree Sal vm
soreusarjy) (ssausey
©
Ege e
yuo14
& ne
@d) Md
na
DED
eH
cE)
@2
sdwej6o} Burm
O> CJ nd
hw
(ssausey
7a
wesbeip — jje
@) :
nd
8a
va
43 y/M
A
SD)
« 2 @() sjepow
aaiip“*Hja@pow
na @-
0s)
H
aui6u3) (ssausey
oe
at@®
pet:
uleW)
SaaS
a/m $2) A
ae aS
Gd)
xD : @D : ORD ID : ©) @ MD
:
: :
‘>
HOLVNH31L1V
HOLVNH3L1V
@
=
AGOS
|
a7 =
GNNOYS
‘HY dW
904 LNOwSA
58) wad
See ie Pee SE
LNOYS904 dWvI‘HT
Fee
eae DREAD aA) eae
(ssausey Apog)
een
AW13¥Y dWVT
HS) wed
ee
a=wam | ==
(sseusey queWNAISU})
OON Sesey hee Se
Seai=) OSG2
73
aA
AV134Y dWV71 9043 LNOYS
NOILINS! HO.LIMS Luvis
dn
qj
oH
Gains
BAP
awiyAep 3461,
®)
i
©
YNOYYUNM
UUAA
mopuim
48BWOYIEY
4928WOYIE?
ydaox3 Jjamod
wayshs
waysAs
paddinbs [apow
auijoseyauiBua [e@pow jasaig auiBua |apow Jamodg mopuim paddinba japow
awiiAep 146i)
inoyum
japowyim
[SPOW
dWv71
(,Bunnoy
49M0q,,
49078
HOLIMS
ee ALIS feral =e
Aiddng
183944) 03
3SN4
aa
LNOYS 904
*H" aAlip
*H-7
q
TE
Au3LLv8
aSYVHO
¥313W NOILVNISWOOD
=
0
ONILHSI1 HOLIMS
wa
AaWILAVG LHS
LYVLS 49 NO HOLIMS NOILINS!
¥V3H 904
14°20 Wiring diagrams
: : : :
|
usey)
1deoxg 10) soUesy pus PUus}JaZIIMS 104 euesy pue PueyJeZzUuMsg japoyyYIM swNAEp 1461) weasds japoy, InoYyIM aWNAEp 3461) Waishs
(,Bunnoy A\ddng
[onz aTs]v}olelvlolelv| OOOUE S28 EOSEE -Tel_t_ts Tete ]
03 19584) 3ASN4
(ssousey
seay
AGO
sdwej6oy Bum
GNNOYS
wesbeip — 21g
Sjepow
42eg) Joop
HOLIMS
yvay 904 dNV1
(ssewey
a/y
yvaH 904 | ¥V3Y 904
ONINYYM&dWV1
uv3ay 904
Atk: @-
dwv1
¥v3y dW “H1
NO!ILVNISWOS
‘HY dNVT NOILVNISWODS Y¥V3u
48MO0d,, D078
Wiring diagrams 14°21
9078 3sN4
(, Bunnoy Aiddng
02 18424) 4aMOg,,
: :wia3sAs YUMA eulzAep 2461 : : : :
QSQCOGE 88
:
BALIP “H’Y eAUP“H'Y ALP “HT AUP "HT
AY3LLVE
SALIP"H'y jepOwWpue 19,3
ONILHOITHILIMS
X77 “7 *X1S XJ] “7 ‘X1S
waysAs 3461) awizAep NoYyUM
aulBue japow
ice
TST
sjepow sjepOW XOS sjapow sjapow XOS
wei Se
ae dWVT
sesy
aNnous ¥V3uY904 dWvT AW134y
Agog AV134
ie)
wiaisdAs 461 auAep INOYIM japoOW eALIP “H] = japow eulBue 19,3 Wdeoxe japowW BALIP “HH:
¥V3Y 904
sdwe)6oj Butim ¥V3Y 904
Wesbeip — ELN dWV7
HOLIMS
SjJepow
AGO
Apog) (sseusey ¥V3u 904
NOILVNIGWOOD ¥3L3W
¥v3u 9043
Eee
(Main harness)
a
Y¥V3u
YV3Y
bey) [EE
dWV1 ‘H"1 ¥Vv3uy 904
Qnnows
es LY 904 4¥V3Y
of
NOILYNISGWOS
NOILVNIGWOOS
Wiring diagrams 14°22
Wiring diagrams IGNITION SWITCH
: For Europe
ON or START
: Except for Europe REAR COMBINATION
: A/T model : M/T model
rae grag ate -H.
FUSE BLOCK (Refer to “Power Supply Routing.)
(Main harness)
(Back door harness)
BAS LAMP R.H. R/B s—tp—_®
BACK-UP LAMP L.H.
°c tp—®
R/B
BACK-UP LAMP
ee GROUND
BACK-UP LAMP
INHIBITOR
SWITCH
SWITCH
R/B 8 cl tih—®
Reversing lights wiring diagram - B12 models IGNITION SWITCH ON or START
ve fiFis) BACK-UP 8B LAMP R.H.
R/8 B
FUSE BLOCK
BACK-UP LAMP L.H.
R/B
LAMP R.H.
8 nett
BACK-UP LAMP L.H.
(Refer to ‘Power Supply Routing’’.)
REAR COMBINATION BACK-UP LAMP SWITCH
@ (Main harness) (Engine harness No. 2)
“AE ® R/B
INHIBITOR
SWITCH
R/B
a —a
: A/T model
: M/T model REAR COMBINATION
LAMP L.H.
: Sedan
: Hatchback : For Europe : Except for Europe
aa? es BODY GROUND
Reversing lights wiring diagram - N13 models
14¢23
3aISs
‘HY
IVNOIS
TVNOIS
dWV1
NYNL
NHNL
NYNL
Asauive [
Aiding
2o
> ~c
TYNOIS
°HE-®
w/AD
dWwY7 “H'Y
30IS NYNL TYNOISdWNW1“HT
(.,Bunnoy
3SN4 49078 BL eee
¥O/9
|
-
=
NOILINSIHOLIMS LHVLS
NOILWNISWOO NYNL TWNOIS
y3HSW14
LINN
e01Ipuj 10} pue
puezey
Burusems}4y6y Guim
WweIsAs
Bury6) O4
NO 4O
wes6elp — 71g
NOILVNIGWOOD ¥3L3W
sjepow
:
: :
: : :
:
Yv3u
Hv3y
104
J9BWIOYIE} 49BWOYIE}
adoing }daoxy 105 adoin3
uobeny YIIAA NOY
adnog
uepas
NOILWNIBWOO
NOILWNIGWOS
14e¢24 Wiring diagrams
dW “Hy
GONNOYS
“HT dWV1 IWNOIS NYNL LNOYS
“WI
NYNL 3GIS IVWNOIS dWV1
AGOS
QNNOUYS
WS
y/AD
AGO
ONNOYS
ams Sen
Gs 2ks SEER
8@
ye @q
sjepow ¢4.N — wes6eip Guim s}Yy6i) Buiusem puezey pue 10}e9!pu|
VAS
NOILINSIHOLIMS
AGO
VAS
aed E—-6)
(a ee ae
(,,Bunnoy Ajddng
“HY dWV7 TVNOIS NYNL LNOYS
AY3LLVE
JaIBWOYIE. INOYIUA : OND Jal@WOYde} YIM : WD
0} 48384) 3SN4
NuYNL‘HY 3a0Is
Y/AD
ieee
IVNOIS
ONO
ssouse
cian
NOILLWNISWOO DDC
4aMOd,, 490718
dWV71 LHVLS
B
ie
|fel ol
[{{_Jofz] HoLims 1inn— uaHswi4 = fOT_«*[é]ir] TWNOIS
R/L
y/AD
S PCS)
“HY NYNL
R/B
Of
GNNOWS
ptawrd
Y3L3W NOILVNISWOD
rW'S
Buliybiy sds wa
8Vv3¥y
¥V3u
14025 NOILYNISWOO
NOILVNISWOO
iring d iagrams
14°26 Wiring diagrams
INTERIOR
LAMP
(Room lamp harness)
LUGGAGE ROOM LAMP SWITCH
TRUNK OR LUGGAGE ROOM LAMP TRUNK OR LUGGAGE ROOM LAMP SWITCH
FUSE BLOCK
(Refer to “Power Supply Routing.’’) BATTERY
F
(Back door
harness)
R,
{Main harness)
(Body harness)
GROUND
@o 1®@ : Sedan : Coupe
O°
@)
nanY GROUNO
}
: Wagon
: SLX, SR and SGX models
: Land LX @Q®DO@
FRONT
ORIVER
models
a
FRONT
REAR L.H.
ASSIST
REAR R.H.
DOOR SWITCH
Interior and luggage compartment lights wiring diagram - B12 models
INTERIOR LAMP
(Room lamp harness) FUSE BLOCK
8
8
R
B
B
(Reter to “Power
8
TRUNK OR LUGGAGE
whee
TRUNK ROOM LAMP SWITCH
y/rput)
“Eee
: SLX and SGX models : Sedan
: Hatchback
: Sedan and 5-door Hatchback
2
°°°Y SROUN©
é 7
53
>
5
& >
9
: SLX and SGX models and
R.H. drive 5-door Hatchback
LX model except Europe
: Except » a)
oc
(q
ore
;
@ model
FRONT
DRIVER
ASSIST
REAR
LH.
DOOR SWITCH
Interior and luggage compartment lights wiring diagram - N13 models
REAR
RH.
>NVL 13N4
Hh
LINN 39NVO
13n4
a9nv9
Y3LYM “dW31 39nv9o
>NVL 13N4
LINN 39NVS
3OVLIOA
yOLV1ND3y
¥yOoLV1ND3y 3OVLIOA
39Nv9 13N4
39nvo
Y3LVM “dW31
(a4
Y¥3L3IW NOILVNISWOD
| Y3LIWOHOVL
o—
japow auibua jasvig
: (©)
@
>: GND
: GND >: GD
: CAD
:
Jeyawoyse? yum
Jayawoyoer INOyUM
jepow suibua euijosegy
(A
screeZe
.
sjepow z1g — wesbeip Bum sabneb oinjesodwi} 10}eM pue jany ‘JayawWOYyoe |
roca
Ss duund jan 914398]8 NOY duund jan; 914398)8 YUM
annou9
5D
re) alia 08)
109 Netuncs
iauling OVA
:
7
Q
Fi é AQos
€ a
3
YOSN3S
ir
TWwwuaHL pounsonas
Ya LLINSNVEL
LYVLS 40 NO HOLIMS NOILINS!
90798 3sN4
(,.,Bunnoy Aiding
184944) 19MOd,, 02
14°27 iring diagrams
+
-
(,Bunnoy
48MOd,,
49018
NOILINS! HOLIMS LHVLS
A+]
Y3BLLINSNVHL
vwH3sHl
YOSN3S
ANIONS NOILNTOASY
|
1109
(Engine harness No. 2)
“ayowWOYyoR jeny pue
49}eM
¥OLSISSY ZZ) (G4
ts
ead “
AG
>
©E
@e2)
a
©
Apog)
-
wes6eip E}N
GNNOXD
(ssausey
quaWNAIsUy)
(ssausey
RS os)
oinjyesodwia} saebneb Guim
Sez
U]co) Se © i= Agoa
@&D3
143909 janj } duind NOUN o1.90a) janj a duwind yy 4aawOyse} AA NOYI 4928W0YIe}
aurjosenauibua lapous jasaiq auibua lapow YIM
(ssausey
: :
:
:
: :
NOILINO!
uieyy)
oofSbe
| “ale
Aiddng
18484) 02
3SN4
NO 4°
SJ@pow
+8 el {|[
39NV9
39NVS
39NVD LINN
13N4 ANVIL
TANS ANVIL 3ONVSLINN
Y3LVM “dW31L aonv9s
13N4
JOVLIOA yO1LV1NO3Y
Y3LVM “dN31 a9nv9o
13N4
NOILVNIGWOO Y¥31L3W
14°28 Wiring diagrams
13N3 A>NVL 39NVSLINN
YOSN3S dOLS
(edoin3 duund
4105 3da9x3)
InNoyuM
: OND
Apog)
vmoc> Ofgeati vo ofseait Ell
(Rear R.H.)
SD
@ &
(Rear L.H.)
>
4
plese
eS
T3N4
z
Hl
an
a
©) wi fy Hw
oO
t
ous eet @) CIS) jasaiq suibua Xs X1s lapow sjapow pue : (Alternator harness)
a
ONNOUYS
@
c/a
AGOS
©
je Si
©
3asns 490718 10}044) 03 48M0q,, Ayddng (..,Bunnoy
NOILINS!HOLIMS LYVLS NO 40
eleiaids
(0)
"a
a
3MOLVNUaLIY HOLVNY3LIV S31 =OPEN: ea10 able 3=«= ONDed =annoys aaoa : anvua ape =Vv GD Renan apa1s39918 YM jany >duund
Buimseyqsdwe; Bum
(fl©
;
(ssousey
HOLINS
wesbeip — 71g
sjepow
@ (6) 104: adoun3 auljoses auibua japow :
©
aaa ap >
q
914393819
um
quewnsisuy) (ssousey
is)
wind
(1105)
TOHLNOD LINN MOTD ¥31115
jany
37
:
@ 6) SR
|
:
ri, carl
adnog uepes:
3xOHTOLNV
14¢29
dO1s GNv VVL dAVT
TWVL'®
ONINYYMS-dWV7
¥311I4
¥31L3W NOILVNISWOD
39YVHO
13NS XINVL 39NVvVSLINN
Wiring diagrams
NOILIND!HOLIMS LWVLS
:
See sci
2
(0)
@)
6)
JOMOd,,
(,,Bunnoy
9078
with Aer
@)
“EE
Y/M
a/o7 a/O7
Qisav
Ww
qUNssaud 10
HOLIMS
wesbeip — ELN
(ssousey
Buiweyysdwe; Bum
Ee
Apog)
Hl
Agog 1)
@) (Engine harness)
HOLVNYSITV
QO .
og
@)
=) sl
aE
(Alternator harness)
HOLVNH3aLIVY
02 Aiddng 195244) 3SN4
“at
§@8
H+ Rei pee
f
fared
eau
VM
ne
30010
HOLIMS ONINEHYM ==WnnoWwA axvUa
:
TO¥LNOD LINN
|
JUeWINJISUj)
HOLIMS 13A37) GiINd4 3xVv4a
NO 40
y3LMy MO19D
YOSN3S
%93HD any
AW13u4
e1N8
(sseusey
GQNNOY¥S AGog
AW1a¥
SJepOwW
13N4 ANVIL
39NVSAINA
ONIIuWd axvue HO.LIMS
e O
GNNOYD Agog
3HOHD
BE
§© @
a
:@
:
(©) :: 3) : GD : GD :
JOYVHO
431714
480) (H™
Cfesho
480u) (Hd
suibua jeapow
auijoseysuibua japow UepESpue 1O0P-G IEQUIIeY yy d1n9a}8 jany duund InoYdAM 314399]8 jany duund
jasaig
anu eho Ti
Nd/ACo
Nala sho Ufe
MO
13N4
NOILYNIGW ¥313W OO
DOOR SWITCH
]
aD
@ §©
OLny
juos4) (4eaup (381888 2u0J4)
Py
és
14°30 Wiring diagrams
edimsysem Bum Y¥V3Y
AGoa
GNNOYS
J@Pow BAIJp “Hy Pue edosng 10) Weoxe jepow BALIP “H}"] : HT] = edosng 10; jepow eALIPdate
:
(.,,Burinoy Ayddng
ednog
43384)) 3SNs
03
Jseay
wes6eip — 71g
sjepow Apog)
(ssausey
Yad Y3dIM yOLOW
AGOSs
48MOdg,,
(ssousey uley))
79018
NOILINS!HO.LIMS 9940 NO
I
(ssousey quaWNJysU})
YSHSVM HOLIMS
GNNOYS
YV3u H3adIM yOLOW
I
H3dIM
14¢31 Wiring diagrams
(ssausey
4100p
49eg)
ONV
14°32
Wiring diagrams IGNITION SWITCH ACC or ON
REAR WIPER MOTOR REAR WIPER AND WASHER SWITCH
Na
Eset te {Tory {9 f4TO OT OTLoo}
FUSE BLOCK (Refer to '‘Power Supply Routing”’.)
(Back door harness)
(Main harness)
(Instrument harness)
GOO >.
G GD >!
BODY GROUND @®) : E16i engine model CEP) : Except (P) model
(Body harness)
wt
dibybaal
Rear wash/wipe wiring diagram — N13models
FUSE BLOCK inetarcore
supe mouting
WIPER SWITCH
Ri daa
NJorF[int[co [Ht was
WIPER MOTOR
seo|
8
INTERMITTENT WIPER VOLUME
aL
We
AMPLIFIER
8
@ WASHER MOTOR
1 @ iE
[B12] yp) Gsw [e12] oO © if BODY GROUND
Front wash/wipe wiring diagram - all models
©
: L.H. drive model
® : R.H. drive model WD : Variable intermittent wiper
Wiring diagrams
14°33
IGNITION SWITCH ACC or ON
uP
HEADLAMP WASHER MOTOR
HEADLAMP WIPER AND WASHER SWITCH
go
Ee
FUSE BLOCK
HEADLAMP WIPER
(Refer to “Power
MOTOR
Supply Routing.’’)
RH.
L/OR L/R A
(Main harness)
le L/Y W/L
@ @ (Fotdout poe). OND[81]
[212] Gap SM. (Ref
HEADLAMP WIPER MOTOR L.H.
|
u/R ® vy @ vs LW
L/R
(Instrument harness)
@ :
| B12
BODY GROUND
®
:
N13
BODY GROUND
Headlamp wash/wipe wiring diagram - all models
vao-forpoo REAR DEFOGGER
Gd (Main harness)
a 71@©
(Body harness)
Q) FUSE BLOCK
(EERE Cis) OH
(Refer to “Power Supply Routing.”’)
A
: Gs
= = ew
o
5
ds
SMa. oo
DGD
ee
REAR DEFOGGER
o
Cw GD
BODY
GROUND
(Back door
once] ofwtane
4
5;
VU
1 val So
fe)
ar an twepaos Leantra
(Instrument harness)
tse
REAR DEFOGGER
Ps
Gs)= F Gres ee (_[2ea) BEeaD
20—@)—__03 REAR DEF. WARNING
REAR DEF.
REAR DEFOGGER
SWITCH
© : Sedan ©
: Coupe
WW
: Wagon
© ® (WD EX
: : : :
LH. drive model R.H. drive model Power window equipped model Except power window equipped model
LAMP-A
Heated rear window wiring diagram - B12 models
:
yoequoiey MopuiM
Jamog
0
peddinba japow
6
¥V3sy
:
43990430
“HD i
‘7P aap
x7
japow 3sN4
Rel),(RR
LLO—"Wy '
9019
payeoy Jee 02 ay
YV3u
japow Gid>3da0x3
uepas
:
:
:
adosng 404 :
adoing 103 }daoxg
lapow XOS *X1S @UP “HY :
Ceanneg Aades OPM XOS Ws SNe THT japow X7 “7 ap “HY : ease ann
::
|
eS ie
sd) a (ssausey
wesbelp — ¢1N NOILVNISWOD ¥31L4W
MopuIMBum €O—
43990430
Setalees wil ha
wleW)
Ot —
TW'S
YV3H
a
Tees 8 aD
LYVLS 4° NO HOLIMS NOLLINOS!
dfn
BEGoooehe
43990430
©
6 6 @
af
yO
EU | @
Sjepow lO
H¥V3uY
|
Os
¥3990430
498g) 4oop
LtO——@y—0 8%
©
¥V3Y MOGNIM
H3990430 HOLIMS
tae
To lighting system
eet
soofw}-o
2
= ¥399033¢0 MOGNIM ¥V3Y
43990330 MOONIM 3V3Y
@3—8
14°34 Wiring diagrams
AGOSB
SYNLVYSdW3L
HALYM
3YuNSS3Yd 110 HOLIMS
GNNOYS
39018 3aSsNa
8/M
bredM abed vas sjapow §1.N 404
ueW)
AD sot
Na
Ha)
5
WA
2)
508) Gm
GS)
(ssousey
sjapow z1.g — wesbelp Bum souyo9]2 oulbug
2S aaa Sa
(8) 8/M Aldi 8/M
Ajddngs (,,Burnoy Mas ociaieicl
Y3LVSH SYNLXIW
GION310S
> @Dz
AGOS
aay
(ane eer Ee
AY3LLVS
3NOHOD Y3LV3H
@
Poo
GNNOYS
omer nd
8 M/Nd
meine aE TET RG eT
s
7ans 41nd
Coo UleW)
Hd Cow y/M
(sseusey
Ados
aNNowd
Ss See ci 30010
LINN 1OHLNOD dWNd 13N4
: intel
See
Aga” ta ee
aaa
inate cea
Hl“(6
HOLIMS
LHYV.LS 49 NO HO.LIMS NOILINSI
NO D99V 49
ies
SYNLXINW ¥31LV3H
VAS 5J
Y3SLVNY3LIV
see a ae
NOILINS!
te ye AW14y
AW1348 3yOHD OLNV
AS
14°35 iring diagrams
14°36 Wiring diagrams
POWER
-
WINDOW
AMP..Front driver side door (Behind trim)
=
7
N
a
ra
IGNITION SWITCH | gw
CIRCUIT CONNECTIONS
ONcnsD
REMARKS
‘
Power source (IGN.)—Via ignition relay-Il
BATTERY via Fusible Link-Brown
Ignition switch condition
From ignition switch ON or ST
For detecting AUTO signal
To front driver side power window switch—
For detecting UP signal
To front driver side power window switch— @>
Mi
®
®
'
CIRCUIT
:
Y
For detecting DOWN signal
To front driver side power window switch— @)
BREAKER
tpve
Window upward power source
To/From
front driver side power window regulator
(White)
Window downwerd power source
To/From
front driver side power window regulator
(Beside steering column bracket
:
a
©®@
)
©
IGNITION RELAY-II {
(Beside steering
-_——_———
+ eee
i (White)
ray ——
-
-—
Soe > |O>00
OG
®
ea BE (Blue)
TES eaae
main
Ua
RIN
[+
Ra)
=e!
yoge
iiaces WA a
8 (Steering column x ‘HOO
bracket)
~
©:
|@+: Go
L/R
——_——
oe Ben
'en
nif
©: ®:
S18
©: &® ® j Gan)
8 ©: GD (Assist side Kjom) dash side panel)
L/R
||
|_|
@ + Gow
B
[Front driver side
door harness)
cH
fall
Bw
©:
(Blue)
Ay
g> *LEr2E0 |9>G06
Mes Y/8
column bracket)
(White) Lae
:
rie Es keel
611M)
neat
Baia
pet
DSaaeee
ees
[it G/BWw
(Black)
.
(White)
ce
CIRCUIT
eG
Power
(©s@|'©s®
Manuel | er
LH. side | RH. side
ee pnt
en
ae
BREAKER
CONNECTIONS
|
ee
Puyo fuln]ojonforrlu[nyT ofu[nyo lun] o | | epi nf | Ee ef a Ff ef |e | |RH] | ror powerspindows7A MEX@) eR
inti 1 7319] tet Se ae |
aim
PST | é| | Fete
ce oa |es
Has fro]|
i