POWER STEERING GEAR AND LINKAGE
PS-17
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6. Remove steering outer socket from steering knuckle so as not to
damage ball joint boot using the ball joint remover (suitable tool).
CAUTION:
Temporarily tighten the nut to prevent damage to threads
and to prevent the ball joint remover (suitable tool) from
suddenly coming off.
7. Remove high-pressure piping and low-pressure hose of hydrau-
lic piping, and then drain power steering fluid. Refer to PS-37,
"HYDRAULIC LINE" .
8. Remove the power steering tube bracket mounting bolts and
nuts, and then remove power steering tube bracket from steer-
ing gear assembly.
9. Tilt steering gear assembly to prevent any contact with other
parts and then remove it from right side of vehicle.
INSTALLATION
Installation in the reverse order of the removal. For tightening torque, refer to PS-16, "COMPONENT" .
When installing lower shaft to steering gear, follow the procedure listed below.
–Set rack of steering gear in the neutral position.
NOTE:
To get the neutral position of rack, turn gear sub assembly and measure the distance of inner socket, and
then measure the intermediate position of the distance.
–Align rear cover cap projection with the projection of gear sub assembly.
–Align slit part of lower shaft with the projection of rear cover cap.
And then install it onto rear cover cap of steering gear assembly.
Make sure that the slit part of lower shaft is aligned with both the
projection of rear cover cap and the marking position of gear sub
assembly.
–After installation, bleed air from the steering hydraulic system.
Refer to PS-6, "
Air Bleeding Hydraulic System" .
–Perform final tightening of nuts and bolts on each part under
unladen conditions with tyres on level ground when removing
steering gear assembly. Check wheel alignment. Refer to FSU-
6, "Wheel Alignment" .
–Adjust neutral position of steering angle sensor after checking
wheel alignment. Refer to BRC-52, "
Adjustment of Steering Angle Sensor Neutral Position" .
SGIA1164E
SGIA0912E
SGIA0910E
SRS-48
COLLISION DIAGNOSIS
COLLISION DIAGNOSISPFP:00015
For Frontal CollisionEHS000DF
To repair the SRS, perform the following steps.
WHEN SRS (EXCEPT THE FRONT SIDE AIR BAG) IS ACTIVATED IN A COLLISION:
1. Replace the diagnosis sensor unit.
2. Remove the air bag modules (except the front side air bag module), bracket and seat belt pre-tensioner
assemblies.
3. Check the SRS components using the table shown below:
–Replace any SRS components showing visible signs of damage (dents, cracks and deformation).
4. Install new air bag modules (except the front side air bag module) and seat belt pre-tensioner assemblies.
5. Conduct self-diagnosis using CONSULT-II or “AIR BAG” warning lamp. Refer to SRS-17, "
SRS Operation
Check" for details. Ensure entire SRS operation properly.
WHEN SRS IS NOT ACTIVATED IN A COLLISION:
1. Check the SRS components using the table shown below:
–Replace any SRS components showing visible signs of damage (dents, cracks and deformation).
2. Conduct self-diagnosis using CONSULT-II or “AIR BAG” warning lamp. Refer to SRS-17, "
SRS Operation
Check" for details. Ensure entire SRS operation properly.
SRS INSPECTION (FOR FRONTAL COLLISION)
Part SRS is activated SRS is NOT activated
Air bag module
(driver or front pas-
senger air bag mod-
ule)Replace
Install with new bolts.1. Remove air bag module. Check harness cover and connectors for damage, termi-
nals for deformities, and harness for binding.
2.
–Install driver air bag module into the steering wheel to check fit and alignment with
the wheel.
–Install passenger air bag module into the instrument panel to check fit with the
instrument panel.
3. No damage found, reinstall with new bolts.
4. If damaged—Replace. Install air bag modules with new special bolts
Air bag must be deployed before discarding.
Seat belt pre-ten-
sioner assemblyReplace
Install seat belt pre-
tensioner with new
bolts.1. Remove seat belt pre-tensioners.
Check harness cover and connectors for damage, terminals for deformities, and
harness for binding.
2. Check belts for damage and anchors for loose mounting.
3. Check retractor for smooth operation.
4. If no damage is found, reinstall seat belt pre-tensioner assembly.
5. If damaged—Replace. Install the seat belt pre-tensioners with new bolts.
Seat belt pre-tensioners must be deployed before discarding.
Diagnosis sensor unit Replace
Install with new bolts.1. Check case for dents, cracks or deformities.
2. Check connectors for damage, and terminals for deformities.
3. If no damage is found, reinstall with new bolts and ground bolt.
4. If damaged—Replace. Install diagnosis sensor unit with new bolts and ground bolt.
Steering wheel 1. Visually check steering wheel for deformities.
2. Check harness (built into steering wheel) and connectors for damage, and terminals for deformities.
3. Install air bag module to check fit or alignment with steering wheel.
4. Check steering wheel for excessive free play.
5. If no damage is found, reinstall with bolts.
6. If damaged—Replace.
MA-4
DESCRIPTION
DESCRIPTIONPFP:00000
Pre-Delivery Inspection ItemsELS000Y5
Shown below are Pre-delivery Inspection Items required for the new vehicle. It is recommended that
necessary items other than those listed here be added, paying due regard to the conditions in each
country.
Perform applicable items on each model. Consult text of this section for specifications.
Install vehicle protection kit
Fit all accessories ordered (if applicable) (e.g. towbar, audio, navigation, air conditioner, styling kit)
UNDER HOOD — engine off
Check coolant level and cooling system for leaks
Charge battery and check terminals for condition
Check drive belts tension (diesel only)
Check fuel filter for water or dust (diesel only) and fuel system for leaks
Check engine oil level and for oil leaks
Check brake and clutch fluid levels and fluid lines for leaks
Check and top up washer reservoirs
Check power steering fluid level and fluid lines for leaks (if applicable)
Check air conditioning system for gas leaks (if applicable)
ON INSIDE AND OUTSIDE
Install transit fuse if removed for vehicle storage
Check instruments, gauges, lamps, horn and accessories for operation
Check wipers and washers for operation and adjustment
Check interior and door mirrors and sun visors for operation
Set radio code and set clock
Check parking brake adjustment
Check clutch pedal adjustment
Check steering lock operation
Check seat adjusters and seat belts for operation
Check all windows for operation and alignment
Check mouldings, trim and fittings for fit and alignment
Check weatherstrips for fit and adhesion
Check hood, trunk lid, door panels and fuel lid for fit and alignment
Check latches, keys, remote key, door locks and remote trunk lid and fuel lid release for operation
Check wheel nut torques
Check tyre pressure (incl. spare tyre)
Check tool kit and jack for operation
Check automatic transmission/transaxle starter inhibitor (if applicable)
Check sunroof for operation and alignment (if applicable)
UNDER BODY
Check manual transmission/transaxle, differential and transfer box for oil level and oil leaks
Tighten bolts and nuts steering linkage and gear box, axle/suspension parts, propeller and exhaust system
Check brake and clutch lines, and oil/fluid reservoirs for leaks
Remove front suspension spacer blocks (if applicable)
Check body mounting torque (if applicable)
DESCRIPTION
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ROAD TEST
Check clutch operation
Check foot brake operation
Check parking brake operation
Check steering operation, self-centering and steering wheel alignment
Check engine performance
Check for squeaks, rattles and noise from interior, suspension and brakes
Check heating, ventilation and air conditioning operation
Check radio, cassette and CD player operation
Check odometer and trip meter operation and cancelling
Check instruments for operation
Check automatic transmission/transaxle shift pattern and kickdown operation (if applicable)
Check cruise control and navigation system operation (if applicable)
ENGINE OPERATING AND HOT
Check idle speed
Check automatic transmission/transaxle oil level (if applicable)
FINAL INSPECTION
Remove vehicle protection kit
Fit interior mats and wheel covers
Check for interior and exterior metal and paint damage
Wash, clean interior and exterior
: Not applicable to this model
MA-8
PERIODIC MAINTENANCE
CHASSIS AND BODY MAINTENANCE (QR20DE AND QR25DE PETROL ENGINE)
(Annual Mileage <30,000 Km/year)
Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, L = Lubricate.
NOTE:
(1) Inspect once per year.
Maintenance items with “ ” should be performed more frequently according to “Maintenance Under Severe Driving
Conditions”.
*: For 4WD models only. MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page Perform on a kilometer basis, but on an
annual basis when driving less than
15,000 km (9,000 miles) per yearkm x 1,000
(Miles x
1,000)
Months15
(9)
1230
(18)
2445
(27)
3660
(36)
4875
(45)
6090
(54)
72105
(63)
84120
(72)
96
Underhood and under vehicle
Headlamp aiming IIIIIIIILT- 3 5
Brake & clutch, systems and fluid (For
level & leaks)IIIIIIIIMA-39,
MA-44
Brake fluidRRRRMA-44
Brake booster vacuum hoses, connec-
tions & check valveIIIIBR-25
Power steering fluid & lines (For level &
leaks)IIIIIIIIMA-45
Manual transaxle gear oil (For leaks) I I I I I I I IMA-39
Automatic transaxle fluid (For level &
leaks)IIIIIIIIMA-40
Transfer gear oil (For level & leaks) I I I I I I I IMA-41
Differential gear oil (For level & leaks or
replace)IIIIIIIIMA-43
Steering gear & linkage, axle & suspen-
sion parts, propeller shaft, front drive
shafts & exhaust systemI*II*II*II*IMA-45,
MA-46
,
MA-42
,
MA-46
,
MA-39
Wheel alignment (If necessary, rotate &
balance wheels)IIIIIIIIFSU-6,
MA-43
Brake pads, rotors & other brake compo-
nentsIIIIIIIIMA-45,
MA-45
,
MA-44
Foot brake, parking brake & clutch (For
free play, stroke & operation)IIIIIIIIBR-6,
PB-3
,
CL-5
Air conditioner filterRRRRAT C - 1 3 0
Body corrosionSee
NOTE (1)MA-48
MA-10
PERIODIC MAINTENANCE
NOTE:
(1) Inspect once per year.
Maintenance items with “ ” should be performed more frequently according to “Maintenance Under Severe Driving
Conditions”.
*: For 4WD models only.
MAINTENANCE UNDER SEVERE DRIVING CONDITIONS
(Annual Mileage <30,000 Km/year)
The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle is
mainly operated under severe driving conditions as shown below, more frequent maintenance must be per-
formed on the following items as shown in the table.
Severe driving conditions
A — Driving in dusty conditions
B — Repeatedly driving short distances
C — Towing a trailer or caravan
D — Extensive idling
E — Driving in extremely adverse weather conditions or in areas where ambient temperatures are either
extremely low or extremely high
F — Driving in high humidity or mountainous areas
G — Driving in areas using salt or other corrosive materials
H — Driving on rough and/or muddy roads or in the desert
I — Driving with frequent use of braking or in mountainous areas
J — Frequent off road use or driving in water
K —Sustained high speed driving
L — For models without Euro-OBD system
Differential gear oil (For level & leaks or
replace)IIIIIIMA-43
Steering gear & linkage, axle & suspension
parts, propeller shaft, front drive shafts &
exhaust systemI* I I* I I* IMA-45,
MA-46
,
MA-42
,
MA-46
,
MA-39
Wheel alignment (If necessary, rotate & bal-
ance wheels)IIIIIIFSU-6,
MA-43
Brake pads, rotors & other brake compo-
nentsIIIIIIMA-45,
MA-44
,
MA-45
Foot brake, parking brake & clutch (For free
play, stroke & operation)IIIIIIBR-6,
PB-3
,
CL-5
Air conditioner filterRRRRRRATC-130
Body corrosionSee
NOTE (1)MA-48
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page Perform on a kilometer basis, but on an annual
basis when driving less than 20,000 km
(12,000 miles) per yearkm x 1,000
(Miles x 1,000)
Months20
(12)
1240
(24)
2460
(36)
3680
(48)
48100
(60)
60120
(72)
72
PERIODIC MAINTENANCE
MA-13
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CHASSIS AND BODY MAINTENANCE (QR20DE AND QR25DE PETROL ENGINE)
(Annual Mileage >30,000 Km/year)
Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, L = Lubricate.
NOTE:
(1) Inspect once per year.
Maintenance items with “ ” should be performed more frequently according to “Maintenance Under Severe Driving
Conditions”.
*: For 4WD models only. MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page Perform at number of kilometers (miles)
basis only.km x 1,000
(Miles x
1,000)15
(9)30
(18)45
(27)60
(36)75
(45)90
(54)105
(63)120
(72)
Underhood and under vehicle
Headlamp aiming I I I ILT- 3 5
Brake & clutch, systems and fluid (For
level & leaks)IIIIMA-39,
MA-44
Brake fluidRRMA-44
Brake booster vacuum hoses, connec-
tions & check valveIIBR-25
Power steering fluid & lines (For level &
leaks)IIIIMA-45
Manual transaxle gear oil (For leaks) I I I IMA-39
Automatic transaxle fluid (For level &
leaks)IIIIMA-40
Transfer gear oil (For level & leaks) I I I IMA-41
Differential gear oil (For level & leaks or
replace)IIIIMA-43
Steering gear & linkage, axle & suspen-
sion parts, propeller shaft, front drive
shafts & exhaust systemI* I I* IMA-45,
MA-46
,
MA-42
,
MA-46
,
MA-39
Wheel alignment (If necessary, rotate &
balance wheels)IIIIFSU-6,
MA-43
Brake pads, rotors & other brake compo-
nentsIIIIMA-45,
MA-45
,
MA-44
Foot brake, parking brake & clutch (For
free play, stroke & operation)IIIIBR-6,
PB-3
CL-5
Air conditioner filterRRRRAT C - 1 3 0
Body corrosionSee
NOTE (1)MA-48
PERIODIC MAINTENANCE
MA-15
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NOTE:
(1) Inspect once per year.
Maintenance items with “ ” should be performed more frequently according to “Maintenance Under Severe Driving
Conditions”.
MAINTENANCE UNDER SEVERE DRIVING CONDITIONS
(Annual Mileage >30,000 Km/year)
The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle is
mainly operated under severe driving conditions as shown below, more frequent maintenance must be per-
formed on the following items as shown in the table.
Severe driving conditions
A — Driving in dusty conditions
B — Repeatedly driving short distances
C — Towing a trailer or caravan
D — Extensive idling
E — Driving in extremely adverse weather conditions or in areas where ambient temperatures are either
extremely low or extremely high
F — Driving in high humidity or mountainous areas
G — Driving in areas using salt or other corrosive materials
H — Driving on rough and/or muddy roads or in the desert
I — Driving with frequent use of braking or in mountainous areas
J — Frequent off road use or driving in water
K —Sustained high speed driving
L — For models without Euro-OBD system
Maintenance operation: Check = Check and correct or replace as necessary. Steering gear & linkage, axle & suspension parts,
propeller shaft, front drive shafts & exhaust systemIIMA-45
,
MA-46
,
MA-42
,
MA-46
,
MA-39
Wheel alignment (If necessary, rotate & balance
wheels)IIIFSU-6,
MA-43
Brake pads, rotors & other brake componentsIIIIIIMA-45
,
MA-44
,
MA-45
Foot brake, parking brake & clutch (For free play,
stroke & operation)IIIIIIBR-6,
PB-3
CL-5
Air conditioner filterRRRRRRATC-130
Body corrosionSee
NOTE (1)MA-48
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page
Perform at number of kilometers (miles) basis only.km x 1,000
(Miles x
1,000)20
(12)40
(24)60
(36)80
(48)100
(60)120
(72)
Driving conditionMaintenance itemMainte-
nance
opera-
tionMaintenance intervalRefer-
ence
page
A
...........Air cleaner filterPetrol models ReplaceEvery 30,000 km
(18,000 miles) MA-24
Diesel models ReplaceEvery 30,000 km
(18,000 miles) MA-35