MA-4
PREPARATION
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PREPARATIONPFP:00002
Special Service ToolsELS001BG
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Commercial Service ToolELS001PF
Tool number
(Kent-Moore No.)
Tool nameDescription
KV10115801
(J-38956)
Oil filter cap wrench Removing and installing oil filter
a: 64.3 mm (2.531 in)
KV991J0010
(J-23688)
Engine coolant refractometer Checking concentration of ethylene glycol in
engine coolant
KV991J0070
(J-45695)
Coolant refill tool Filling cooling system
NT375
WBIA0539E
LMA053
(Kent-Moore No.)
Tool name
Description
Power tool Loosening bolts and nuts
Spark plug wrench Removing and installing spark plug
PBIC0190E
S-NT047
ENGINE MAINTENANCEMA-13
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Checking Drive BeltsELS001PG
WARNING:
Be sure to perform when the engine is stopped.
1. Remove air duct and resonator assembly (inlet) when inspecting drive belt.
2. Make sure that indicator (single line notch) of each auto tensioner is within the allowable working range
“A” (between three line notches) as shown.
NOTE:
Check the auto tensioner indication when the engine is cold.
When the new drive belt is installed, the range should be “A” as shown.
The indicator notch is located on the moving side of the auto tensioner.
3. Visually check entire belt for wear, damage or cracks.
4. If the indicator is out of allowable working range or belt is damaged, replace the belt. Refer to EM-13,
"DRIVE BELTS" .
DRIVE BELT TENSION
There is no manual drive belt tension adjustment. The drive belt tension is automatically adjusted by the auto
tensioner.
Changing Engine CoolantELS001PH
WARNING:
To avoid being scalded, never change the coolant when the engine is hot.
Wrap a thick cloth around the cap to carefully remove the cap. First, turn the cap a quarter of a
turn to release any built-up pressure, then push down and turn the cap all the way to remove it.
DRAINING ENGINE COOLANT
1. Turn ignition switch ON and set temperature control lever all the way to HOT position or the highest tem-
perature position. Wait 10 seconds and turn ignition switch OFF.
2. Remove the engine front undercover using power tool.
1. Drive belt 2. Power steering oil pump pulley 3. Generator pulley
4. Crankshaft pulley 5. A/C compressor6. Idler pulley
7. Cooling fan pulley 8. Water pump pulley9. Drive belt tensioner
LBIA0391E
ENGINE MAINTENANCEMA-19
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REMOVAL
1. Remove the ignition coil. Refer to EM-28, "IGNITION COIL" .
2. Remove the spark plug(s) using a suitable tool.
INSPECTION AFTER REMOVAL
Do not use a wire brush for cleaning.
If the spark plug tip is covered with carbon, a spark plug cleaner may be used.
Checking and adjusting the spark plug gap is not required
between change intervals.
INSTALLATION
Installation is in the reverse order of removal.
Use standard type spark plug for normal condition.
The hot type spark plug is suitable when fouling occurs with the standard type spark plug under conditions
such as:
–Frequent engine starts
–Low ambient temperatures
The cold type spark plug is suitable when spark knock occurs with the standard type spark plug under
conditions such as:
–Extended highway driving
–Frequent high engine revolution
SEM294A
SMA773C
Cleaner air pressure : Less than 588 kPa (5.9 bar, 6 kg/cm2 , 85 psi)
Cleaning time : Less than 20 seconds
SMA806CA
MA-24
CHASSIS AND BODY MAINTENANCE
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If the ATF contains frictional material (clutches, bands, etc.), replace the radiator and flush the transmis-
sion cooler lines using cleaning solvent and compressed air after repairing the transmission.
9. Install the ATF level gauge in the ATF charging pipe and install the level gauge bolt.
10. Tighten the level gauge bolt to specification.
Changing Automatic Transmission Fluid (ATF)ELS001PR
1. Drive the vehicle to warm up the ATF to 80 ° C (176 ° F).
2. Stop the engine.
3. Remove the ATF level gauge bolt.
4. Drain the ATF from the drain plug hole and then install the drain plug with a new gasket. Refill the transmission with new ATF.
Always refill with the same volume as the drained ATF. Use the
ATF level gauge to check the ATF level as shown. Add ATF as
necessary.
To flush out the old ATF from the coolers, pour new ATF into the charging pipe with the engine idling
and at the same time drain the old ATF from the auxiliary transmission oil cooler hose return line.
When the color of the ATF coming out of the auxiliary transmission oil cooler hose return line is about
the same as the color of the new ATF, flushing out the old ATF is complete. The amount of new trans-
mission ATF used for flushing should be 30% to 50% of the specified capacity.
CAUTION:
Use only the specified ATF. Do not mix with other fluids.
Using an ATF other than the specified ATF will cause deterioration in driveability and automatic
transmission durability, and may damage the automatic transmission, which is not covered by
the warranty.
When filling the transmission with ATF, do not spill the ATF on any heat generating parts such
as the exhaust manifold.
Do not reuse the drain plug gasket.
5. Install the ATF level gauge in the ATF charging pipe and tighten the level gauge bolt to specification.
6. Drive the vehicle to warm up the ATF to 80 ° C (176 ° F).
7. Check the ATF level and condition. Refer to MA-22, "
Checking Automatic Transmission Fluid (ATF)" . If
the ATF is still dirty, repeat steps 2 through 5.
Changing Transfer FluidELS001H0
DRAINING
1. Stop the engine. Level gauge bolt: : Refer to
AT- 2 5 0 , "
Components" .
Drain plug : Refer to AT- 2 5 0 , "
Components" .
WLIA0014E
ATF type and capacity : Refer to MA-11, "Fluids and Lubricants" .
Drain plug : Refer to AT- 2 5 0 , "
Components" .
Level gauge bolt : Refer to AT- 2 5 0 , "
Components" .
CHASSIS AND BODY MAINTENANCEMA-25
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2. Remove the drain plug and gasket to drain the transfer fluid as
shown.
3. Install the new gasket on the drain plug and install the drain plug in the transfer. Tighten the drain plug to specification.
CAUTION:
Do not reuse the gasket.
FILLING
1. Remove the filler plug and gasket.
2. Fill with new specified fluid until the fluid level reaches the spec-ified limit near the filler plug mounting hole as shown.
CAUTION:
Carefully fill the transfer with fluid. Filling should take
approximately three minutes.
3. Leave the vehicle for three minutes and then check the fluid level again as shown.
4. Install the new gasket on the filler plug and install the filler plug in the transfer. Tighten the filler plug to specification.
CAUTION:
Do not reuse the gasket.
Checking Transfer FluidELS001H1
FLUID LEAKAGE AND FLUID LEVEL
1. Check for any fluid leaks from the transfer assembly or around it and correct as necessary.
2. Remove the filler plug to check the fluid level at the filler plugmounting hole as shown.
CAUTION:
Do not start the engine while checking the fluid level.
3. Install the new gasket on the filler plug and install the filler plug in the transfer. Tighten the filler plug to specification.
CAUTION:
Do not reuse the gasket.
Checking Propeller ShaftELS001C5
Check the front and rear propeller shafts for damage, dents, and cracks. Check the joints for looseness and
any damage. Repair or replace as necessary.
Checking Final Drive OilELS001H3
1. Remove the filler plug. Drain plug : Refer to
TF-146, "
COMPONENTS" .
SMA444B
Fluid capacity and grade : Refer to MA-11, "Fluids
and Lubricants" .
Filler plug : Refer to TF-146, "
COMPONENTS" .
SMA439B
Filler plug : Refer to TF-146, "COMPONENTS" .
SMA439B
CHASSIS AND BODY MAINTENANCEMA-29
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CALIPER
Check the caliper for any leaks, repair as necessary.
PA D
Check the pads for wear or damage. Refer to BR-32, "Front Disc
Brake" , BR-33, "Rear Disc Brake" .
Checking Steering Gear and LinkageELS001CD
STEERING GEAR
Check the steering gear housing for looseness, damage and oil
leakage as shown.
Check the steering column connections for looseness.
STEERING LINKAGE
Check the ball joint, dust cover and other component parts for looseness, wear, damage, and grease leak-
age.
Checking Power Steering Fluid and LinesELS001CE
CHECKING FLUID LEVEL
Check the power steering fluid level with the engine off.
Check fluid level on reservoir. Use “HOT ” range at fluid tempera-
tures of 50 ° to 80 °C (122 ° to 176 °F). Use “COLD” range at fluid
temperatures of 0 ° to 30 °C (32 ° to 86 °F).
CAUTION:
Do not overfill.
Refer to MA-11, "Fluids and Lubricants" .
SMA922A
LMA051
SGIA0506E
LGIA0021E
MA-30
CHASSIS AND BODY MAINTENANCE
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CHECKING LINES
Check lines for improper attachment, leaks, cracks, damage,
loose connections, chafing, and deterioration.
Checking Axle and Suspension PartsELS001CF
FRONT AND REAR AXLE AND SUSPENSION PARTS
Check front and rear axle and suspension parts for excessive play, cracks, wear or other damage.
Shake each wheel to check for excessive play.
Rotate each wheel to check for abnormal noise.
Check the axle and suspension nuts and bolts for looseness.
Check the strut and shock absorber for oil leakage or other damage.
Check the suspension ball joints for grease leakage and ball joint dust cover for cracks or other damage.
DRIVE SHAFT
Check the boots and drive shaft for cracks, wear, damage, and
grease leakage.
SGIA0506E
SMA525A
SFA901
PS-1
POWER STEERING SYSTEM
G STEERING
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PRECAUTIONS .....................................................
..... 2
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” ............................................................. ..... 2
Precautions for Steering System ......................... ..... 2
PREPARATION ...................................................... ..... 3
Special Service Tools (SST) ................................ ..... 3
Commercial Service Tools ................................... ..... 4
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ........................................... ..... 5
NVH Troubleshooting Chart ................................ ..... 5
POWER STEERING FLUID ................................... ..... 6
Checking Fluid Level ........................................... ..... 6
Checking Fluid Leakage ...................................... ..... 6
Air Bleeding Hydraulic System ............................ ..... 6
STEERING WHEEL .................................................... 7 On-Vehicle Inspection and Service ..................... ..... 7
CHECKING CONDITION OF INSTALLATION . ..... 7
CHECKING STEERING WHEEL PLAY ........... ..... 7
CHECKING NEUTRAL POSITION ON STEER-
ING WHEEL ..................................................... ..... 7
CHECKING STEERING WHEEL TURNING
FORCE ............................................................. ..... 7
CHECKING FRONT WHEEL TURNING ANGLE ..... 8
Removal and Installation ..................................... ..... 8
REMOVAL ........................................................ ..... 8
INSTALLATION ................................................ ..... 8
TILT SYSTEM ............................................................. 9 Removal and Installation ..................................... ..... 9
TILT MOTOR AND TILT SENSOR ................... ..... 9
STEERING COLUMN ............................................ ... 10
Removal and Installation ..................................... ... 10
REMOVAL ........................................................ ... 10
INSPECTION AFTER REMOVAL .................... .... 11
INSTALLATION ................................................ .... 11INSPECTION AFTER INSTALLATION .............
... 12
Disassembly and Assembly ................................. ... 13
DISASSEMBLY ................................................ ... 13
ASSEMBLY ...................................................... ... 14
INSPECTION AFTER ASSEMBLY ................... ... 14
POWER STEERING GEAR AND LINKAGE ......... ... 15
Removal and Installation ..................................... ... 15
REMOVAL ........................................................ ... 15
INSTALLATION ................................................ ... 16
INSPECTION AFTER INSTALLATION ............. ... 17
Disassembly and Assembly ................................. ... 17
DISASSEMBLY ................................................ ... 17
INSPECTION AFTER DISASSEMBLY ............. ... 18
ASSEMBLY ...................................................... ... 19
POWER STEERING OIL PUMP ............................ ... 21
On-Vehicle Inspection and Service ...................... ... 21
CHECKING RELIEF OIL PRESSURE ............. ... 21
Removal and Installation ..................................... ... 21
REMOVAL ........................................................ ... 21
INSTALLATION ................................................ ... 21
Disassembly and Assembly ................................. ... 22
INSPECTION BEFORE DISASSEMBLY .......... ... 22
DISASSEMBLY ................................................ ... 22
INSPECTION AFTER DISASSEMBLY ............. ... 22
ASSEMBLY ...................................................... ... 22
HYDRAULIC LINE ................................................. ... 23
Removal and Installation ..................................... ... 23
SERVICE DATA AND SPECIFICATIONS (SDS) ... ... 25
Steering Wheel .................................................... ... 25
Steering Column .................................................. ... 25
Steering Outer Socket and Inner Socket ............. ... 26
Steering Gear ...................................................... ... 27
Oil Pump ................................................................. 27
Steering Fluid .......................................................... 27