Front Axle and Front Suspension Parts
Check front axle and front suspension parts for excessive play,
cracks, wear and other damage.
+Shake each front wheel to check for excessive play.
+Make sure that cotter pin is inserted.
+Retighten all axle and suspensions nuts and bolts to the speci-
®ed torque.
Tightening torque:
Refer to FRONT SUSPENSION (FA-24).
+Check front axle and front suspension parts for wear, cracks
and other damage.
+Check shock absorber for oil leakage and other damage.
+Check knuckle ¯ange for grease leakage and knuckle ¯ange
grease seal for cracks and other damage.
Front Wheel Bearing
+Check that wheel bearings operate smoothly.
+Check axial end play.
Axial end play:
0mm(0in)
+Adjust wheel bearing preload if there is any axial end play or
wheel bearing does not turn smoothly.
SMA525A
SFA851B
SFA852B
SFA413A
ON-VEHICLE SERVICE
FA-5
19. Pack drive ¯ange groove with grease, apply grease to O-ring
and mating surface of drive ¯ange, and install ¯ange.
20. Place snap ring in drive shaft groove. Choose snap ring so that
the gap between groove and snap ring is 0.4 mm (0.016 in) or
less.
Refer to SDS for selection of snap ring.
Front Wheel Alignment
Before checking front wheel alignment, be sure to make a prelimi-
nary inspection (Unladen*).
*: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand
tools and mats in designated positions.
PRELIMINARY INSPECTION
1. Check tires for wear and improper in¯ation.
2. Check wheel runout on outside and inside.
Wheel runout average
[(Outside runout value + Inside runout value) x 0.5]:
Refer to SDS (FA-27).
3. Check front wheel bearings for looseness.
4. Check front suspension for looseness.
5. Check steering linkage for looseness.
6. Check that shock absorbers work properly.
7. Check vehicle posture (Unladen).
CAMBER, CASTER AND KINGPIN INCLINATION
Camber, caster and kingpin inclination are preset at factory
and cannot be adjusted.
1. Measure camber, caster and kingpin inclination of both right
and left wheels with a suitable alignment gauge.
Camber, Caster and Kingpin inclination:
Refer to SDS (FA-27).
2. If camber, caster or kingpin inclination is not within
speci®cation, inspect front suspension parts. Replace damaged
or worn out parts.
SFA417A
SFA418AA
SFA356B
SFA894
ON-VEHICLE SERVICE
Front Wheel Bearing (Cont'd)
FA-8
SFA889B
FRONT SUSPENSION
FA-24
Shock Absorber
REMOVAL AND INSTALLATION
1. Support front axle case with jack.
2. Remove both upper and lower sides ®xing nuts.
INSPECTION
Except for nonmetallic parts, clean all parts with suitable solvent
and dry with compressed air.
Use compressed air to blow dirt and dust off of nonmetallic parts.
+Check for oil leakage and cracks. Replace if necessary.
+Check piston rod for cracks, deformation and other damage.
Replace if necessary.
+Check rubber parts for wear, cracks, damage and deformation.
Replace if necessary.
Stabilizer Bar
REMOVAL
+Remove stabilizer bar connecting bolts and clamp bolts.
INSPECTION
+Check stabilizer bar for twist and deformation.
Replace if necessary.
+Check rubber bushing for cracks, wear and deterioration.
Replace if necessary.
INSTALLATION
+Install stabilizer bar with ball joint socket properly placed.
Coil Spring
INSPECTION
Visually check for cracks or damage. If faulty, replace.
Ensure that springs are installed correctly. Incorrect installa-
tion will cause vehicle not set in horizontal posture.
SFA890B
SFA891B
SFA896B
SFA897B
FRONT SUSPENSION
FA-25
Leading Arm
INSPECTION
Check for cracks, bends or damage. Also check bushing.
If bushing is faulty, replace it using suitable tool.
When installing bushing, make sure that it is positioned as shown.
Panhard Rod
INSPECTION
+Check for cracks or other damage. Replace if necessary.
Panhard rod bushing
Removal
+Using a press and suitable tool as shown in ®gure at left,
remove bushing from vehicle side.
+Using a ¯at-bladed screwdriver, pry bushing out of axle case.
Installation
+Using suitable tool shown in ®gure at left, gradually press bush-
ing into place.
Always install new bushing. Do not tap end face of bushing
directly with a hammer. Apply soap water to outer wall of bush-
ing before installation.
SFA460A
SFA892B
SFA462A
SRA030A
SFA893B
FRONT SUSPENSION
FA-26
General Speci®cations
Suspension typeRigid axle, leading arm and panhard rod with
coil spring
Strut type Double-acting hydraulic
Stabilizer bar Standard equipment
Inspection and Adjustment
WHEEL ALIGNMENT (Unladen*1)
Applied modelWagon Hardtop
Camber Minimum 0É (0.00É)
Degree minute
(Decimal degree)Nominal 0É30¢(0.50É)
Maximum 1É00¢(1.00É)
Left and right difference 45¢(0.75É) or less
Caster Minimum 3É00¢(3.00É) 3É20¢(3.33É)
Degree minute
(Decimal degree)Nominal 3É30¢(3.50É) 3É50¢(3.83É)
Maximum 4É00¢(4.00É) 4É20¢(4.33É)
Left and right difference 45¢(0.75É) or less
Kingpin inclination Minimum 13É45¢(13.75É)
Degree minute
(Decimal degree)Nominal 14É30¢(14.50É)
Maximum 15É15¢(15.25É)
Total toe-in Minimum 0 (0)
Distance (A þ B)
mm (in)Nominal 1 (0.04)
Maximum 2 (0.08)
Angle (left plus right)
Degree minute
(Decimal degree)Minimum 0¢(0.00É)
Nominal 5¢(0.08É)
Maximum 10¢(0.17É)
Wheel turning angle Minimum 33É00¢(33.00É)
Full turn*2Inside
Degree minute
(Decimal degree)Nominal 35É00¢(35.00É)
Maximum 35É00¢(35.00É)
Outside
Degree minute
(Decimal degree)Minimum 29É00¢(29.00É)
Nominal 31É00¢(31.00É)
Maximum 31É00¢(31.00É)
*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
*2: On power steering models, wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 lb) with engine idle.
WHEEL RUNOUT AVERAGE*
Wheel typeSteel Aluminum
6JJ-16 8JJ-16 6JJ-16 8JJ-16
Radial runout limit
mm (in)1.2
(0.047)0.8
(0.031)0.3
(0.012)0.3
(0.012)
Lateral runout limit
mm (in)1.2
(0.047)0.8
(0.031)0.3
(0.012)0.3
(0.012)
*: Wheel runout average = (Outside runout value + Inside runout value) x 0.5
SERVICE DATA AND SPECIFICATIONS (SDS)
FA-27
Front drive shaft (Transfer) .............................TF-11
Front ®nal drive disassembly (4WD) ..............PD-14
Front ®nal drive removal and installa-
tion (4WD)...................................................PD-11
Front passenger air bag.............................RS-8, 14
Front seat belt ..................................................RS-2
Front seat ........................................................BT-32
Front suspension ............................................FA-24
Front washer .................................................EL-141
Front wiper ....................................................EL-141
Fuel cut control (at no load & high
engine speed) .............................................EC-20
Fuel cut solenoid valve ................................EC-129
Fuel ®ller lid.......................................................BT-6
Fuel ®lter replacement ...................................MA-16
Fuel gauge ....................................................EL-102
Fuel injection system......................................EC-15
Fuel line inspection ........................................MA-17
Fuel precautions ................................................GI-5
Fuel temperature sensor ..............................EC-134
Fuse block.....................................................EL-319
Fuse ................................................................EL-14
Fusible link ......................................................EL-14
G
GLOW - Wiring diagram...............................EC-150
GOVNR - Wiring diagram ..............................EC-95
Garage jack and safety stand .........................GI-39
Gauges..........................................................EL-102
Gear components (M/T) .................................MT-10
Glass .................................................................BT-9
Glow plug .............................................EC-150, 154
Glow relay ............................................EC-150, 154
Grease .............................................................MA-9
Ground distribution..........................................EL-15
H
H/AIM - Wiring diagram ..................................EL-71
H/LAMP - Wiring diagram ...............................EL-61
HEAT UP - Wiring diagram ..........................EC-182
HFC134a (R134a) system service
procedure ..................................................HA-112
HLC - Wiring diagram ...................................EL-153
HORN - Wiring diagram................................EL-155
Harness connector inspection .........................GI-17
Harness connector ............................................EL-2
Harness layout ..............................................EL-275
Headlamp aiming control ................................EL-70
Headlamp leveler - See Headlamp
aiming control ..............................................EL-70
Headlamp wiper ............................................EL-153
Headlamp ........................................................EL-61
Headlining - See Roof trim .............................BT-20
Heat up switch..............................................EC-182
Heated seat.....................................................BT-34Hood..................................................................BT-4
Horn ..............................................................EL-155
How to erase DTC for ECCS OBD
system ........................................................EC-30
I
IATS - Wiring diagram ..................................EC-121
IC/FAN - Wiring diagram ..............................EC-177
ILL - Wiring diagram .......................................EL-87
INT/L - Wiring diagram..................................EL-101
Identi®cation plate............................................GI-37
Idle speed inspection .....................................MA-19
Idle speed .......................................................EC-46
Illumination ......................................................EL-86
In vehicle sensor ..........................................HA-105
Injection nozzle inspection .............................MA-18
Injection nozzle...............................................EC-22
Injection timing control valve ........................EC-100
Instrument panel .............................................BT-11
Intake door control linkage adjustment ..........HA-84
Intake door motor ...........................................HA-25
Intake sensor ................................................HA-111
Interior lamp ....................................................EL-93
Interior .............................................................BT-14
J
Jacking points ..................................................GI-39
Joint connector (J/C).....................................EL-322
Journal bearing assembly (propeller
shaft) .............................................................PD-8
Journal bearing disassembly (propeller
shaft) .............................................................PD-7
Junction box (J/B) .........................................EL-319
L
LSV (Load sensing valve) ................................BR-6
Lifting points ....................................................GI-40
Limited slip diff. adjustment............................PD-23
Limited slip diff. assembly ..............................PD-24
Limited slip diff. disassembly .........................PD-21
Limited slip diff. inspection .............................PD-21
Location of electrical units ............................EL-269
Lock, door .........................................................BT-9
Lubricant (R134a) A/C ..................................HA-114
Lubricants.........................................................MA-9
Lubrication circuit (engine) ...............................LC-3
Lubrication-locks, hinges and hood
latches ........................................................MA-27
Luggage compartment trim .............................BT-14
Luggage room lamp ........................................EL-93
ALPHABETICAL INDEX
IDX-4
ROOM/L - Wiring diagram ..............................EL-95
Radiator ..........................................................LC-14
Radio - See Audio.........................................EL-168
Rear axle (disc brake type) ..............................RA-6
Rear bumper .....................................................BT-6
Rear case (Transfer) .......................................TF-10
Rear combination lamp removal and
installation ...................................................BT-26
Rear cover packing replacement diff..............PD-11
Rear disc brake ..............................................BR-24
Rear door ........................................................BT-10
Rear fog lamp .................................................EL-80
Rear heater - Wiring diagram ........................HA-14
Rear seat belt ...................................................RS-5
Rear seat ........................................................BT-35
Rear side window ...........................................BT-44
Rear suspension ............................................RA-12
Rear washer..................................................EL-145
Rear window defogger ..................................EL-158
Rear window ...................................................BT-42
Rear wiper.....................................................EL-145
Refrigerant connection precaution ...................HA-2
Refrigerant discharging evacuating
charging ....................................................HA-113
Refrigerant general precaution.........................HA-2
Refrigerant lines ...........................................HA-117
Refrigeration cycle ..........................................HA-11
Release bearing (clutch) .................................CL-11
Removal and installation (Transfer) ..................TF-8
Reverse idler shaft (M/T) ...............................MT-10
Reverse lamp switch (M/T) - See
Back-up lamp switch (M/T)...........................MT-4
Reverse main gear (M/T) ...............................MT-10
Ring gear diff. inspection ...............................PD-19
Road wheel size ..............................................GI-38
Roof trim .........................................................BT-20
Room lamp - See Interior lamp ......................EL-93
Rotor disc (front) .............................................FA-14
S
S/LOCK - Wiring diagram .............................EL-215
S/SIG - Wiring diagram ................................EC-162
SAE J1930 terminology list .............................GI-43
SEAT - Wiring diagram .................................EL-190
SMJ (super multiple junction) .......................EL-317
SROOF - Wiring diagram .............................EL-186
SRS - See Supplemental Restraint
System ..........................................................RS-8
SRS Trouble diagnoses .................................RS-22
STAB - Wiring diagram ..................................RA-18
START - Wiring diagram .................................EL-45
Screw jack .......................................................GI-39
Seal - See Exterior .........................................BT-26
Seat belt inspection .......................................MA-27
Seat belt pre-tensioner disposal ....................RS-17
Seat belt pre-tensioner ...................................RS-12
Seat belt, front ..................................................RS-2
Seat belt, rear...................................................RS-5Seat, front .......................................................BT-32
Seat, rear ........................................................BT-35
Seat, second (2nd) .........................................BT-35
Seat, third (3rd) ...............................................BT-37
Second (2nd) seat ..........................................BT-35
Self-diagnostic results ....................................EC-31
Shift control (Transfer) ....................................TF-12
Shift control components (M/T) ......................MT-12
Shift fork (M/T) ...............................................MT-12
Shift lever .......................................................MT-12
Shock absorber (front) ....................................FA-25
Shock absorber (rear) ....................................RA-14
Side bearing preload (front ®nal drive
4WD)...........................................................PD-27
Side bearing preload diff. ...............................PD-27
Side trim ..........................................................BT-14
Side window - See Rear side window ............BT-44
Speedometer.................................................EL-102
Spiral cable.....................................................RS-13
Stabilizer bar (front) ........................................FA-25
Stabilizer bar (rear) ........................................RA-15
Stabilizer release device - Wiring
diagram .......................................................RA-18
Stabilizer release device ................................RA-16
Standardized relay ............................................EL-3
Start signal ...................................................EC-162
Starter .............................................................EL-51
Starting system ...............................................EL-45
Steering gear and linkage inspection ............MA-26
Steering linkage ..............................................ST-19
Steering switch................................................EL-59
Steering wheel and column ..............................ST-8
Steering wheel play ..........................................ST-4
Steering wheel turning force .............................ST-6
Striking rod (M/T) ...........................................MT-12
Sub-gear (M/T) ...............................................MT-10
Sunload sensor ............................................HA-107
Sunroof, electric ............................................EL-186
Sunroof............................................................BT-39
Super lock .....................................................EL-211
Supplemental Restraint System .......................RS-8
Supplemental restraint system - Wiring
diagram .......................................................RS-27
Symbols and abbreviations ...............................GI-7
Synchronizer (M/T) .........................................MT-10
T
TCV - Wiring diagram ..................................EC-100
Tachometer ...................................................EL-102
Thermometer .................................................EL-116
Thermostat ......................................................LC-12
Third (3rd) seat ...............................................BT-37
Three way catalyst precautions.........................GI-4
Throttle control solenoid valve .....................EC-155
Throttle control solenoid valve .....................EC-161
Throwout bearing - See Clutch release
bearing ........................................................CL-11
Thrust washer selection diff. ..........................PD-27
ALPHABETICAL INDEX
IDX-6