Page 1359 of 1865
ENGINE SPEED SENSING POWER STEERING 1 0
86u10x-167
86u10x-168
86u10x-169
Snap ring
Install the snap ring.
Note
Verify that the snap ring is correctly seated
in the ring groove of the housing.
Locknut
1. Temporarily install the tie-rod on the tube side of
the rack.
2. Install the locknut and turn it until the tie-rod con-
tacts the tube.
3. Tighten the locknut.
Tightening torque:
39—49 N
m
(4.0—5.0 m-kg, 29—36 ft-lb)
Housing cover
1. Apply thread sealant to the housing cover threads.
2. Install the housing cover.
Tightening torque:
44—54 N-m (4.5—5.5 m-kg, 33—40 ft-lb)
3. Stake between the rack housing and housing cover
at two points with a center punch.
86U10X-170
10—71
Page 1360 of 1865
1 0 ENGINE SPEED SENSING POWER STEERING
Pressure pad
1. Secure the gear housing in a vise so that the pres-
sure pad position faces upward.
2. Apply grease (lithium base NLGI No. 2) to the rack
sliding surface of the pressure pad; then install it
in the housing.
3. Install the pressure pad.
86U1OX-171
Adjust cover
1. Set the rack in the center position.
2. Tighten the adjust cover to 9.8 N-m (100 cm-
kg, 7.2 ft-lb) then loosen it.
3. Tighten again to 4.9 ± 0.5 N-m (50 ± 5 cm-
kg, 3.6 ± 0.4 ft-lb), and then return it 45°.
4. Apply thread sealant to the exposed threads of ad-
just cover.
86U10X-172
5. Install and tighten the locknut.
Tightening torque:
49—59 N-m (5.0—6.0 m-kg, 36—43 ft-lb)
86U10X-173
Tie-rod
1. Secure the rack in a vise.
2. Install the tie rod on the rack.
Tightening torque:
123—143 N-m
(12.5—14.5 m-kg, 90.6—105 ft-lb)
86U10X-174
10-72
Page 1363 of 1865
ELECTRONICALLY-CONTROLLED POWER STEERING 1 0
ELECTRONICALLY-CONTROLLED POWER STEERING
DISASSEMBLY
Disassemble in the sequence shown in the figure, referring to the disassembly note for specially marked
parts.
Caution
a) Because adjustment of the spool valve is not possible, do not disassemble the gear box
for spool valve repairs. If repairs are necessary, replace the gear box assembly.
b) In order to prevent the entrance of dirt, all disassembly and assembly should be done
in a clean area.
c) Before disassembly, plug the openings of all pipe installation fittings; then thoroughly
clean the steering gear and linkage.
86U10X-180
1. Pipe
2. Solenoid valve
3. Tie-rod end
4. Tie-rod end locknut
5. Spring clip
6. Boot wire
7. Boot
8. Tie-rod
9. Adjust cover locknut
10. Adjust cover
11. Spring
12. Pressure pad
13. Outer box assembly
14. Oil seal
15. Mounting bracket
16. Mounting rubber
10—75
Page 1365 of 1865
ELECTRONICALLY-CONTROLLED POWER STEERING 1 0
/
I I
86U10X-185
63U10X-127
86U10X-186
Tie-rods
1. Uncrimp the washer as shown in the figure.
2. Remove the tie-rod from the rack.
Locknut and adjust cover
Loosen the locknut and remove the adjust cover,
spring, and pressure pad.
Outer box
Protect the outer box with cloth and remove it with
a pipe wrench.
86U10X-187
10—77
Page 1369 of 1865
ELECTRONICALLY-CONTROLLED POWER STEERING 1 0
86U10X-197
86U10X-198
86U10X-199
6. Apply thread sealant to the threads of the adjust
cover.
7. Install the adjust cover to the gear housing and
tighten it as specified; then loosen it 35°.
Tightening torque:
4.5—5.5 Nm
(45—55 cm-kg, 39—48 in-lb)
8. Measure the pinion torque with the SST.
Pull scale: 1,000—1,400 g (35.3—49.4 oz)
9. If the pinion torque is not within specification, read-
just the adjust cover.
10. Lock the adjust cover with the locknut.
Tightening torque:
40—50
N
m
(4—5 m-kg, 29—36 ft-lb)
11. Set the rack in a vise and install the washer. Tight-
en the tie-rod.
Tightening torque:
60—80 N-m
(6—8 m-kg, 43—58 ft-lb)
Caution
Insert protective material (such as copper
plates) in the jaws of the vise.
76G10X-040
10—81
Page 1376 of 1865
1 0 ELECTRICAL COMPONENTS OF ELECTRONICALLY-CONTROLLED POWER STEERING (ECPS)
76G10X-020
76G10X-021
Checking Condition
Condition A
1. Turn the ignition switch OFF.
2. Start the engine and let it idle.
3. Turn the steering wheel to the straight-ahead po-
sition, and check the output pattern.
Refer to page 10—89 for other patterns and indi-
cated failure points.
Condition B
1. Turn the ignition switch OFF.
2. Start the engine and let it idle.
3. Turn the steering wheel 45° left and right from the
center, and check the output pattern.
Refer to page 10—89 for other patterns and indi-
cated failure points.
Condition C
1. Turn the ignition switch OFF.
2. Place the vehicle on a chassis roller tester. Block
the rear wheels, and secure it with chains.
3. Start the engine. Put the transmission in gear and
operate the vehicle at more than 10 km/h (6.2
mph).
4.Check the output pattern.
76G10X-022
Normal pattern
4 4V
Normal pattern Normal pattern
uV
Refer to page 10—90 for other patterns and indi-
cated failure points.
Note
For vehicles equipped with ABS, the ABS
warning light may come on. This is not a fail-
ure. The light will go off when turning the ig-
nition switch OFF and back ON.
86U10X-213
10—88
Page 1384 of 1865
1 0 ELECTRICAL COMPONENTS OF 4-WHEEL STEERING
Condition B
1. Place the vehicle on a chassis roller tester. Block
the rear wheels, and secure it with chains.
2. Turn the ignition switch OFF.
3. Start the engine after the ignition switch has been
OFF for at least 10 seconds. Put the transmission
in gear and operate the vehicle at more than 40
km/h (25 mph).
4. Check if the 4WS warning light flashes or il-
luminates within 60 seconds.
5.
If
flashing or illumination occurs, inspect the circuit
by referring to the table below.
76G10X045
Diagnosis Output Pattern
Warning light output pattern
0.5 sec —i 2.5 sec
Malfunction
Normal operation, control unit or wir-ing harness
Speed sensors or
wiring harness
Flow chart
No.
4WS—0
4WS—1
Rear steering gear
assembly
Solenoid valve or wiring harness
Stepper motor or wiring harness
Rear-to-front steer-ing ratio sensor or wiring harness
4WS—2
4WS—3
4WS—4
4WS—5
86U10X-225
10-96
Page 1393 of 1865
11
BRAKING SYSTEM
OUTLINE 11—2
STRUCTURAL VIEW 11—2
SPECIFICATIONS 11— 4
TROUBLESHOOTING GUIDE 11— 5
ON-VEHICLE MAINTENANCE 11—6
BRAKE FLUID LEVEL IN MASTER
CYLINDER RESERVOIR 11— 6
BRAKE HYDRAULIC LINE 11—6
STRUCTURAL VIEW 11—6
ON-VEHICLE INSPECTION OF
BRAKE LINES 11— 8
REMOVAL AND INSTALLATION OF
BRAKE LINES 11— 9
REPLACEMENT OF BRAKE
FLUID 11— 9
AIR BLEEDING 11— 9
BRAKE PEDAL 11—11
ON-VEHICLE INSPECTION 11—11
REMOVAL 11—12
INSPECTION 11—13
INSTALLATION 11—13
MASTER CYLINDER 11—14
REMOVAL 11—15
DISASSEMBLY AND ASSEMBLY
(EXCEPT RHD DOHC TURBO).... 11—14
INSPECTION 11—17
DISASSEMBLY AND ASSEMBLY
(RHD DOHC TURBO) 11—18
INSPECTION 11—21
INSTALLATION 11—22
POWER BRAKE UNIT 11—27
FUNCTION CHECK 11—27
INSPECTION OF CHECK VALVE... 11—29
REMOVAL 11—29
DISASSEMBLY AND ASSEMBLY... 11—30
INSPECTION 11—32
INSTALLATION 11—33
VACUUM PUMP 11—35
ON-VEHICLE INSPECTION 11—35
REMOVAL AND INSTALLATION.... 11—35
DISASSEMBLY AND ASSEMBLY... 11—36
INSPECTION 11—37
DUAL PROPORTIONING VALVE 11—38
FUNCTION CHECK 11—38
REMOVAL AND INSTALLATION.... 11—39
FRONT DISC BRAKE 11—40
SIMPLE INSPECTION OF DISC
PAD WEAR 11—40
REPLACEMENT OF DISC PAD 11—40
REMOVAL 11—42
DISASSEMBLY AND ASSEMBLY... 11—43
INSPECTION 11—44
INSTALLATION 11—45
REAR DISC BRAKE 11—46
SIMPLE INSPECTION OF DISC
PAD WEAR 11—46
REPLACEMENT OF DISC PAD 11—46
REMOVAL 11—49
DISASSEMBLY AND ASSEMBLY... 11—50
INSPECTION 11—54
INSTALLATION 11—55
REAR DRUM BRAKE 11—56
REMOVAL 11—56
DISASSEMBLY AND ASSEMBLY
OF WHEEL CYLINDER 11—59
INSPECTION 11—60
INSTALLATION 11—61
PARKING BRAKE 11—65
ON-VEHICLE MAINTENANCE 11—65
REMOVAL AND INSTALLATION
OF PARKING BRAKE LEVER 11—66
REMOVAL OF PARKING BRAKE
CABLE 11—68
INSTALLATION OF PARKING
BRAKE CABLE 11—69
ANTI-LOCK BRAKE SYSTEM
(ABS) 11—71
STRUCTURAL VIEW 11—71
WIRING DIAGRAM 11—72
TROUBLESHOOTING 11—73
DIAGNOSIS INDICATION MODE ... 11—86
MEMORY CANCEL 11—86
ABS WARNING LIGHT 11—87
RELAY BOX 11—87
WHEEL SPEED SENSOR 11—87
SENSOR ROTOR 11—90
HYDRAULIC UNIT FLUID 11—94
HYDRAULIC UNIT 11—94
CONTROL UNIT CIRCUIT 11—99
76G11X-001
