Page 3143 of 3502

POWER STEERING OIL PUMP
PS-29
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POWER STEERING OIL PUMPPFP:49110
On-Vehicle Inspection and ServiceBGS0003Y
CHECKING RELIEF OIL PRESSURE
CAUTION:
Make sure that belt tension is normal before starting the following procedure.
1. Connect the hydraulic pressure gauge [SST] between oil pump
discharge connector and high-pressure hose. Bleed air from the
hydraulic circuit while opening valve fully. Refer to PS-7, "
Air
Bleeding Hydraulic System" .
2. Start engine. Run engine until oil temperature reaches 50 to
80°C (122 to 176°F).
CAUTION:
Leave the valve of the hydraulic pressure gauge [SST]
fully open while starting and running engine. If engine is
started with the valve closed, the hydraulic pressure in
oil pump goes up to the relief pressure along with
unusual increase of oil temperature.
Be sure to keep hose clear of belts and other parts when engine is started.
3. Fully close the hydraulic pressure gauge [SST] valve with
engine at idle and measure the relief oil pressure.
CAUTION:
Never keep valve closed for 10 seconds or longer.
4. Open the valve slowly after measuring. Repair oil pump if the
relief oil pressure is outside the standard. Refer to PS-31, "
Dis-
assembly and Assembly (Except for QR20DE Models)" , PS-35,
"Disassembly and Assembly (QR20DE Models)" .
5. After inspection, disconnect the hydraulic pressure gauge [SST]
from hydraulic circuit, then add fluid and bleed air. Refer to PS-
7, "Air Bleeding Hydraulic System" .
Relief oil pressure
Except for QR20DE models8,000 - 8,800 kPa
(80 – 88 bar, 81.6 – 89.8 kg/cm
2 , 1,160 – 1,276 psi)
QR20DE models9,000 – 9,800 kPa
(90 – 98 bar, 91.8 – 100 kg/cm
2 , 1,305 – 1,421 psi)
SGIA0364E
SGIA0726E
Page 3168 of 3502

RF-4
SQUEAK AND RATTLE TROUBLE DIAGNOSES
SQUEAK AND RATTLE TROUBLE DIAGNOSESPFP:00000
Work FlowBIS001TK
CUSTOMER INTERVIEW
Interview the customer if possible, to determine the conditions that exist when the noise occurs. Use the Diag-
nostic Worksheet during the interview to document the facts and conditions when the noise occurs and any
customer's comments; refer to RF-8, "
Diagnostic Worksheet" . This information is necessary to duplicate the
conditions that exist when the noise occurs.
The customer may not be able to provide a detailed description or the location of the noise. Attempt to
obtain all the facts and conditions that exist when the noise occurs (or does not occur).
If there is more than one noise in the vehicle, be sure to diagnose and repair the noise that the customer
is concerned about. This can be accomplished by test driving the vehicle with the customer.
After identifying the type of noise, isolate the noise in terms of its characteristics. The noise characteristics
are provided so the customer, service adviser and technician are all speaking the same language when
defining the noise.
Squeak —(Like tennis shoes on a clean floor)
Squeak characteristics include the light contact/fast movement/brought on by road conditions/hard sur-
faces=higher pitch noise/softer surfaces=lower pitch noises/edge to surface=chirping
Creak—(Like walking on an old wooden floor)
Creak characteristics include firm contact/slow movement/twisting with a rotational movement/pitch
dependent on materials/often brought on by activity.
Rattle—(Like shaking a baby rattle)
Rattle characteristics include the fast repeated contact/vibration or similar movement/loose parts/missing
clip or fastener/incorrect clearance.
Knock —(Like a knock on a door)
Knock characteristics include hollow sounding/sometimes repeating/often brought on by driver action.
Tick—(Like a clock second hand)
Tick characteristics include gentle contacting of light materials/loose components/can be caused by driver
action or road conditions.
Thump—(Heavy, muffled knock noise)
Thump characteristics include softer knock/dead sound often brought on by activity.
Buzz—(Like a bumble bee)
Buzz characteristics include high frequency rattle/firm contact.
Often the degree of acceptable noise level will vary depending upon the person. A noise that you may
judge as acceptable may be very irritating to the customer.
Weather conditions, especially humidity and temperature, may have a great effect on noise level.
SBT842
Page 3223 of 3502

BATTERY
SC-5
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CHECKING ELECTROLYTE LEVEL
WARNING:
Never allow battery fluid to come in contact with skin, eyes, fabrics, or painted surfaces. After touch-
ing a battery, never touch or rub your eyes until you have thoroughly washed your hands. If acid con-
tacts eyes, skin or clothing, immediately flush with water for 15 minutes and seek medical attention.
Remove the cell plug using a suitable tool.
Add distilled water up to the MAX level.
Sulphation
A battery will be completely discharged if it is left unattended
for a long time and the specific gravity will become less than
1.100. This may result in sulphation on the cell plates.
To determine if a battery has been “sulphated”, note its voltage
and current when charging it. As shown in the figure, less cur-
rent and higher voltage are observed in the initial stage of
charging sulphated batteries.
A sulphated battery may sometimes be brought back into ser-
vice by means of a long, slow charge, 12 hours or more, fol-
lowed by a battery capacity test.
SPECIFIC GRAVITY CHECK
1. Read hydrometer and thermometer indications at eye level.
2. Convert into specific gravity at 20°C (68°F).
Example:
When electrolyte temperature is 35°C (95°F) and specific gravity
of electrolyte is 1.230, converted specific gravity at 20°C (68°F)
is 1.240.
When electrolyte temperature is 0°C (32°F) and specific gravity
of electrolyte is 1.210, converted specific gravity at 20°C (68°F)
is 1.196.
MEL043F
PKIA2353E
MEL042FA
Page 3228 of 3502

SC-10
BATTERY
Fig. 3 Additional Charge (Slow Charge)
CAUTION:
Set charging current to specified value in Fig. 2. If charger is not capable of producing specified
current value, set its charging current as close to that value as possible.
Keep battery away from open flame while it is being charged.
When connecting charger, connect leads first, then turn on charger. Never turn on charger first, as
this may cause a spark.
If battery temperature rises above 55°C (131°F), stop charging. Always charge battery when its
temperature is below 55°C (131°F).
B: STANDARD CHARGE
Fig. 4 Initial Charging Current Setting (Standard Charge)
*:SC-8, "CHART II"
SEL757W
*1:SC-5, "SPECIFIC GRAVITY
CHECK"
*2:SC-8, "CHART II"
SEL758W
CONVERTED
SPECIFIC
GRAVITYBATTERY TYPE
28B19R(L)
34B19R(L)
46B24R(L)
55B24R(L)
50D23R(L)
55D23R(L)
025 YUASA type code
027 YUASA type code
65D26R(L)
80D23R(L)
80D26R(L)
067 YUASA type code
096 YUASA type code
75D31R(L)
95D31R(L)
115D31R(L)
110D26R(L)
95E41R(L)
130E41R(L)
1.100 - 1.130 4.0 (A) 5.0 (A) 6.0 (A) 7.0 (A)8.0
(A)9.0 (A)13.0
(A)
1.130 - 1.160 3.0 (A) 4.0 (A) 5.0 (A) 6.0 (A)7.0
(A)8.0 (A)11 . 0
(A)
Page 3229 of 3502

BATTERY
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Check battery type and determine the specified current using the table shown above.
After starting charging, adjustment of charging current is not necessary.
Fig. 5 Additional Charge (Standard Charge)
CAUTION:
Never use standard charge method on a battery whose specific gravity is less than 1.100.
Set charging current to specified value in Fig. 4. If charger is not capable of producing specified
current value, set its charging current as close to that value as possible.
Keep battery away from open flame while it is being charged.
When connecting charger, connect leads first, then turn on charger. Never turn on charger first, as
this may cause a spark.
If battery temperature rises above 55°C (131°F), stop charging. Always charge battery when its
temperature is below 55°C (131°F).
1.160 - 1.190 2.0 (A) 3.0 (A) 4.0 (A) 5.0 (A)6.0
(A)7.0 (A)9.0
(A)
1.190 - 1.220 2.0 (A) 2.0 (A) 3.0 (A) 4.0 (A)5.0
(A)5.0 (A)7.0
(A) CONVERTED
SPECIFIC
GRAVITYBATTERY TYPE
28B19R(L)
34B19R(L)
46B24R(L)
55B24R(L)
50D23R(L)
55D23R(L)
025 YUASA type code
027 YUASA type code
65D26R(L)
80D23R(L)
80D26R(L)
067 YUASA type code
096 YUASA type code
75D31R(L)
95D31R(L)
115D31R(L)
110D26R(L)
95E41R(L)
130E41R(L)
*:SC-8, "CHART II"
SEL759W
Page 3230 of 3502

SC-12
BATTERY
C: QUICK CHARGE
Fig. 6 Initial Charging Current Setting and Charging Time (Quick Charge)
Check battery type and determine the specified current using the table shown above.
After starting charging, adjustment of charging current is not necessary.
CAUTION:
Never use quick charge method on a battery whose specific gravity is less than 1.100.
Set initial charging current to specified value in Fig. 6. If charger is not capable of producing spec-
ified current value, set its charging current as close to that value as possible.
Keep battery away from open flame while it is being charged.
When connecting charger, connect leads first, then turn on charger. Never turn on charger first, as
this may cause a spark.
Be careful of a rise in battery temperature because a large current flow is required during quick-
charge operation.
If battery temperature rises above 55°C (131°F), stop charging. Always charge battery when its
temperature is below 55°C (131°F).
Never exceed the charging time specified in Fig. 6, because charging battery over the charging
time can cause deterioration of the battery.
*:SC-8, "CHART II"
SEL760W
BATTERY TYPE
28B19R(L)
34B19R(L)
46B24R(L)
55B24R(L)
50D23R(L)
55D23R(L)
65D26R(L)
80D23R(L)
80D26R(L)
025 [YUASA type code]
027 [YUASA type code]
067 [YUASA type code]
096 [YUASA type code]
75D31R(L)
95D31R(L)
115D31R(L)
110D26R(L)
95E41R(L)
130E41R(L)
CURRENT [A] 10 (A) 15 (A) 20 (A) 25 (A) 30 (A)40
(A)
CONVERTED SPECIFIC GRAVITY
1.100 -
1.1302.5 hours
1.130 -
1.1602.0 hours
1.160 -
1.1901.5 hours
1.190 -
1.2201.0 hours
Above
1.2200.75 hours (45 min.)
Page 3239 of 3502
STARTING SYSTEM
SC-21
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VQ35DE MODELS
SKIB6768E
1. Magnetic switch assembly 2. Plate 3. Packing
4. Plate 5. Shift lever 6. Front bracket assembly
7. Pinion spring 8. Pinion assembly 9. Pinion stopper
10. Stopper ring 11. Brush holder assembly 12. Metal
13. Rear cover 14. Through-bolt 15. Armature assembly
16. Yoke assembly 17. Packing 18. Ball
19. Gear assembly 20. Gear shaft 21. Internal gear assembly
22. Clutch gear assembly
: N·m (kg-m, in-lb)
(H): High-temperature grease point
Page 3244 of 3502
SC-26
STARTING SYSTEM
ASSEMBLY
Apply high-temperature grease to lubricate the bearing, gears and frictional surface when assembling the
starter.
Carefully observe the following instructions.
Pinion Protrusion Length Adjustment
CLEARANCE (VQ23DE AND VQ35DE MODELS)
With pinion driven out by magnetic switch, push pinion back to
remove slack and measure clearance “L” between the front
edge of the pinion and the pinion stopper.
Not in the specified value... Adjust by adjusting plate.
MOVEMENT (QR20DE MODELS)
Compare movement “L” in height of pinion when it is pushed out
with magnetic switch energized and when it is pulled out by
hand until it touches stopper.
Not in the specified value... Adjust by adjusting plate.Clearance “L” : Refer to SDS. SC-38, "
Starter" .
SKIB0229E
SEL633BA
Movement “L” : Refer to SDS. SC-38, "Starter" .
SKIB0230E
SEL633BA