FRONT WHEEL TURNING ANGLE
1. Set wheels in straight-ahead position. Then move vehicle
forward until front wheels rest properly on turning radius
gauge.
2. Rotate steering wheel all the way right and left; measure
turning angle.
lOn power steering models, turn steering wheel to full lock
and apply force (at circumference of steering wheel) of 98 to
147 N (10 to 15 kg, 22 to 33 lb) with engine at idle.
lDo not hold the steering wheel at full lock for more than
15 seconds.
Wheel turning angle (Full turn):
Refer to SDS, FA-36.
3. Adjust stopper bolt if necessary.
Standard length ``L
1'' (2WD):
20 mm (0.79 in)
Stopper bolt lock nut:
: 39 - 49 N´m (4.0 - 5.0 kg-m, 29 - 36 ft-lb)
Standard length ``L
2'' (4WD):
26.5 mm (1.043 in)
Stopper bolt lock nut:
: 76 - 98 N´m (7.8 - 10.0 kg-m, 56 - 72 ft-lb)
Drive Shaft
lCheck for grease leakage and damage.
SFA439BA
SFA915B
SFA916B
SFA901
ON-VEHICLE SERVICE
Front Wheel Alignment (Cont'd)
FA-11
GENERAL INFORMATION
SECTION
GI
CONTENTS
PRECAUTIONS......................................................... 1
Precautions for Supplemental Restraint
System (SRS) ``AIR BAG'' (4WD models)............. 1
Precautions for Supplemental Restraint
System (SRS) ``AIR BAG'' (2WD models)............. 1
Precautions for NATS ............................................ 2
General Precautions .............................................. 2
Precautions for Multiport Fuel Injection System
or ECCS Engine .................................................... 4
Precautions for Three Way Catalyst
(If so equipped) ...................................................... 4
Precautions for Engine Oils ................................... 4
Precautions for Fuel............................................... 5
Precautions for Air Conditioning ............................ 6
HOW TO USE THIS MANUAL.................................. 7
HOW TO READ WIRING DIAGRAMS...................... 9
Sample/Wiring Diagram - EXAMPL - .................... 9
Description ........................................................... 11
HOW TO CHECK TERMINAL................................. 18
How to Probe Connectors ................................... 18
How to Check Enlarged Contact Spring of
Terminal ............................................................... 19
Waterproof Connector Inspection ........................ 20
Terminal Lock Inspection ..................................... 20
HOW TO PERFORM EFFICIENT DIAGNOSIS
FOR AN ELECTRICAL INCIDENT......................... 21
Work Flow ............................................................ 21HOW TO PERFORM EFFICIENT DIAGNOSIS...... 22
Incident Simulation Tests..................................... 22
Circuit Inspection ................................................. 25
HOW TO FOLLOW FLOW CHART IN
TROUBLE DIAGNOSES......................................... 31
How to Follow This Flow Chart ........................... 32
CONSULT CHECKING SYSTEM............................ 34
Function and System Application ........................ 34
Lithium Battery Replacement............................... 34
Checking Equipment ............................................ 35
Loading Procedure............................................... 36
CONSULT Data Link Connector (DLC) Circuit ... 36
IDENTIFICATION INFORMATION.......................... 37
Model Variation .................................................... 37
Identification Number ........................................... 40
Dimensions .......................................................... 44
Wheels and Tires ................................................. 46
LIFTING POINTS AND TOW TRUCK TOWING..... 47
Pantograph Jack .................................................. 47
Screw Jack........................................................... 48
Garage Jack and Safety Stand ........................... 49
2-pole Lift ............................................................. 50
Tow Truck Towing ............................................... 51
Towing Point ........................................................ 53
TIGHTENING TORQUE OF STANDARD BOLTS.. 54
SAE J1930 TERMINOLOGY LIST.......................... 55
SAE J1930 Terminology List ............................... 55
GI
lAfter disconnecting vacuum or air hoses, attach a tag to
indicate the proper connection.
lUse only the fluids and lubricants specified in this manual.
lUse approved bonding agent, sealants or their equivalents
when required.
lUse tools and recommended special tools where specified
for safe and efficient service repairs.
lWhen repairing the fuel, oil, water, vacuum or exhaust
systems, check all affected lines for leaks.
lDispose of drained oil or the solvent used for cleaning parts
in an appropriate manner.
WARNING:
To prevent ECM from storing the diagnostic trouble codes,
do not carelessly disconnect the harness connectors which
are related to the ECCS system and TCM (Transmission
Control Module) system. The connectors should be discon-
nected only when working according to the WORK FLOW of
TROUBLE DIAGNOSES in EC section.
Precautions for Multiport Fuel Injection
System or ECCS Engine
lBefore connecting or disconnecting any harness connector
for the multiport fuel injection system or ECM (Engine Con-
trol Module):
Turn ignition switch to ``OFF'' position.
Disconnect negative battery terminal.
Otherwise, there may be damage to ECM.
lBefore disconnecting pressurized fuel line from fuel pump to
injectors, be sure to release fuel pressure.
lBe careful not to jar components such as ECM and mass air
flow sensor.
Precautions for Three Way Catalyst
(If so equipped)
If a large amount of unburned fuel flows into the catalyst, the
catalyst temperature will be excessively high. To prevent this,
follow the instructions below:
lUse unleaded gasoline only. Leaded gasoline will seriously
damage the three way catalyst.
lWhen checking for ignition spark or measuring engine
compression, make tests quickly and only when necessary.
lDo not run engine when the fuel tank level is low, otherwise
the engine may misfire causing damage to the catalyst.
Do not place the vehicle on flammable material. Keep flammable
material off the exhaust pipe and the three way catalyst.
Precautions for Engine Oils
Prolonged and repeated contact with used engine oil may cause
skin cancer. Try to avoid direct skin contact with used oil.
SGI787
PRECAUTIONS
General Precautions (Cont'd)
GI-4
If skin contact is made, wash thoroughly with soap or hand
cleaner as soon as possible.
HEALTH PROTECTION PRECAUTIONS
lAvoid prolonged and repeated contact with oils, particularly
used engine oils.
lWear protective clothing, including impervious gloves where
practicable.
lDo not put oily rags in pockets.
lAvoid contaminating clothes, particularly underpants, with oil.
lHeavily soiled clothing and oil-impregnated footwear should
not be worn. Overalls must be cleaned regularly.
lFirst Aid treatment should be obtained immediately for open
cuts and wounds.
lUse barrier creams, applying them before each work period,
to help the removal of oil from the skin.
lWash with soap and water to ensure all oil is removed (skin
cleansers and nail brushes will help). Preparations contain-
ing lanolin replace the natural skin oils which have been
removed.
lDo not use gasoline, kerosine, diesel fuel, gas oil, thinners
or solvents for cleaning skin.
lIf skin disorders develop, obtain medical advice without
delay.
lWhere practicable, degrease components prior to handling.
lWhere there is a risk of eye contact, eye protection should
be worn, for example, chemical goggles or face shields; in
addition an eye wash facility should be provided.
ENVIRONMENTAL PROTECTION PRECAUTIONS
Burning used engine oil in small space heaters or boilers can be
recommended only for units of approved design. The heating
system must meet the requirements of HM Inspectorate of Pol-
lution for small burners of less than 0.4 MW. If in doubt check
with the appropriate local authority and/or manufacturer of the
approved appliance.
Dispose of used oil and used oil filters through authorized waste
disposal contractors to licensed waste disposal sites, or to the
waste oil reclamation trade. If in doubt, contact the local author-
ity for advice on disposal facilities.
It is illegal to pour used oil on to the ground, down sewers or
drains, or into water courses.
The regulations concerning the pollution of the environment
will vary from country to country.
Precautions for Fuel
GASOLINE ENGINE:
Three way catalyst equipped models ... unleaded gasoline of at
least 91 octane (RON)
CAUTION:
Do not use leaded gasoline. Using leaded gasoline will dam-
age the three way catalyst.
Except for the above models ... unleaded or leaded gasoline of
above 88 octane (RON)
Use unleaded fuel if instructed on the fuel filler lid.
PRECAUTIONS
Precautions for Engine Oils (Cont'd)
GI-5
lThe followingSYMBOLS AND ABBREVIATIONSare used:
,: Tightening torque
: Should be lubricated with grease.
Unless otherwise indicated, use
recommended multi-purpose
grease.
: Should be lubricated with oil.
: Sealing point
: Checking point
: Always replace after every disas-
sembly.
VP: Apply petroleum jelly.
: Apply ATF.
.: Select with proper thickness.
>: Adjustment is required.
SDS : Service Data and Specifications
LH, RH : Left-Hand, Right-Hand
FR, RR : Front, Rear
M/T : Manual Transaxle/Transmission
A/T : Automatic Transaxle/Transmission
,
4WD : 4-Wheel Drive
2WD : 2-Wheel Drive
A/C : Air Conditioner
P/S : Power Steering
SST : Special Service Tools
SAE : Society of Automotive Engineers,
Inc.
ATF : Automatic Transmission Fluid
D
1: Drive range 1st gear
D
2: Drive range 2nd gear
D
3: Drive range 3rd gear
D
4: Drive range 4th gear
OD : Overdrive
2
2: 2nd range 2nd gear
2
1: 2nd range 1st gear
1
2: 1st range 2nd gear
1
1: 1st range 1st gear
lTheUNITSgiven in this manual are primarily expressed as the SI UNIT (International System of Unit),
and alternatively expressed in the metric system and in the yard/pound system.
``Example''
Tightening torque:
59 - 78 N´m (6.0 - 8.0 kg-m, 43 - 58 ft-lb)
lTROUBLE DIAGNOSESare included in sections dealing with complicated components.
lSERVICE DATA AND SPECIFICATIONSare contained at the end of each section for quick reference
of data.
lThe captionsWARNINGandCAUTIONwarn you of steps that must be followed to prevent personal
injury and/or damage to some part of the vehicle.
WARNINGindicates the possibility of personal injury if instructions are not followed.
CAUTIONindicates the possibility of component damage if instructions are not followed.
BOLD TYPED STATEMENTSexceptWARNINGandCAUTIONgive you helpful information.
HOW TO USE THIS MANUAL
GI-8
Work Flow
STEP DESCRIPTION
STEP 1 Get detailed information about the conditions and the environment when the incident occurred.
The following are key pieces of information required to make a good analysis:
WHATVehicle Model, Engine, Transmission and the System (i.e. Radio).
WHENDate, Time of Day, Weather Conditions, Frequency.
WHERERoad Conditions, Altitude and Traffic Situation.
HOWSystem Symptoms, Operating Conditions (Other Components Interaction).
Service History and if any After Market Accessories have been installed.
STEP 2 Operate the system, road test if necessary.
Verify the parameter of the incident.
If the problem can not be duplicated, refer to ``Incident Simulation Tests'' next page.
STEP 3 Get the proper diagnosis materials together including:
POWER SUPPLY ROUTING
System Operation Descriptions
Applicable Service Manual Sections
Check for any Service Bulletin.
Identify where to begin diagnosis based upon your knowledge of the system operation and the customer comments.
STEP 4 Inspect the system for mechanical binding, loose connectors or wiring damage.
Determine which circuits and components are involved and diagnose using the Power Supply Routing and Harness
Layouts.
STEP 5 Repair or replace the incident circuit or component.
STEP 6 Operate the system in all modes. Verify the system works properly under all conditions. Make sure you have not inad-
vertently created a new incident during your diagnosis or repair steps.
SGI838
HOW TO PERFORM EFFICIENT DIAGNOSIS
FOR AN ELECTRICAL INCIDENT
GI-21
Incident Simulation Tests
INTRODUCTION
Sometimes the symptom is not present when the vehicle is brought in for service. If possible, re-create the
conditions present at the time of the incident. Doing so may help avoid a No Trouble Found Diagnosis. The
following section illustrates ways to simulate the conditions/environment under which the owner experiences
an electrical incident.
The section is broken into the six following topics:
lVehicle vibration
lHeat sensitive
lFreezing
lWater intrusion
lElectrical load
lCold or hot start up
Get a thorough description of the incident from the customer. It is important for simulating the conditions of
the problem.
VEHICLE VIBRATION
The problem may occur or become worse while driving on a rough road or when engine is vibrating (idle
with A/C on). In such a case, you will want to check for a vibration related condition. Refer to the illustra-
tion below.
Connectors & harness
Determine which connectors and wiring harness would affect the electrical system you are inspecting.Gen-
tlyshake each connector and harness while monitoring the system for the incident you are trying to dupli-
cate. This test may indicate a loose or poor electrical connection.
Hint
Connectors can be exposed to moisture. It is possible to get a thin film of corrosion on the connector ter-
minals. A visual inspection may not reveal this without disconnecting the connector. If the problem occurs
intermittently, perhaps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean
the terminals on related connectors in the system.
Sensors & relays
Gentlyapply a slight vibration to sensors and relays in the system you are inspecting.
This test may indicate a loose or poorly mounted sensor or relay.
SGI839
HOW TO PERFORM EFFICIENT DIAGNOSIS
FOR AN ELECTRICAL INCIDENT
GI-22
Engine compartment
There are several reasons a vehicle or engine vibration could
cause an electrical complaint. Some of the things to check for
are:
lConnectors not fully seated.
lWiring harness not long enough and is being stressed due
to engine vibrations or rocking.
lWires laying across brackets or moving components.
lLoose, dirty or corroded ground wires.
lWires routed too close to hot components.
To inspect components under the hood, start by verifying the
integrity of ground connections. (Refer to GROUND INSPEC-
TION described later.) First check that the system is properly
grounded. Then check for loose connection bygently shaking
the wiring or components as previously explained. Using the
wiring diagrams inspect the wiring for continuity.
Behind the instrument panel
An improperly routed or improperly clamped harness can
become pinched during accessory installation. Vehicle vibration
can aggravate a harness which is routed along a bracket or near
a screw.
Under seating areas
An unclamped or loose harness can cause wiring to be pinched
by seat components (such as slide guides) during vehicle vibra-
tion. If the wiring runs under seating areas, inspect wire routing
for possible damage or pinching.
HEAT SENSITIVE
The owner's problem may occur during hot weather or after car
has sat for a short time. In such cases you will want to check for
a heat sensitive condition.
To determine if an electrical component is heat sensitive, heat
the component with a heat gun or equivalent.
Do not heat components above 60ÉC (140ÉF).If incident
occurs while heating the unit, either replace or properly insulate
the component.
SGI842
HOW TO PERFORM EFFICIENT DIAGNOSIS
FOR AN ELECTRICAL INCIDENT
Incident Simulation Tests (Cont'd)
GI-23