GI-1
GENERAL INFORMATION
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CONTENTS
GENERAL INFORMATION
SERVICE INFORMATION .. ..........................2
PRECAUTIONS .............................................. .....2
Description .......................................................... ......2
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ...................................................................
2
Precaution Necessary for Steering Wheel Rota-
tion After Battery Disconnect .....................................
2
Precaution for Procedure without Cowl Top Cover ......3
General Precaution ...................................................3
Precaution for Three Way Catalyst ...........................4
Precaution for Fuel (Unleaded Premium Gasoline
Recommended) .........................................................
5
Precaution for Fuel (Unleaded Premium Gasoline
Required) ..................................................................
5
Precaution for Multiport Fuel Injection System or
Engine Control System .............................................
5
Precaution for Hoses .................................................5
Precaution for Engine Oils ........................................6
Precaution for the Environment .................................7
Precaution for Air Conditioning .................................7
HOW TO USE THIS MANUAL ............................8
Description .......................................................... ......8
Terms ........................................................................8
Units ..........................................................................8
Contents ....................................................................8
Component ................................................................8
How to Follow Trouble Diagnosis ..............................9
How to Read Wiring Diagram ..................................13
Abbreviations ..........................................................20
SERVICE INFORMATION FOR ELECTRICAL
INCIDENT ...........................................................
22
How to Check Terminal ....................................... ....22
How to Perform Efficient Diagnosis for an Electri-
cal Incident .......................................................... ....
25
Control Units and Electrical Parts ............................32
CONSULT-III/GST CHECKING SYSTEM .........34
Description ...............................................................34
CONSULT-III Function and System Application*1 ....34
CONSULT-III/GST Data Link Connector (DLC)
Circuit ......................................................................
35
Wiring Diagram - CONSULT-III/GST CHECKING
SYSTEM - ................................................................
36
LIFTING POINT .................................................37
Commercial Service Tool ........................................37
Garage Jack and Safety Stand ................................37
2-Pole Lift ................................................................38
Board-On Lift ...........................................................38
TOW TRUCK TOWING .....................................40
Tow Truck Towing ...................................................40
Vehicle Recovery (Freeing a Stuck Vehicle) ...........41
TIGHTENING TORQUE OF STANDARD
BOLTS ...............................................................
43
Tightening Torque Table .........................................43
RECOMMENDED CHEMICAL PRODUCTS
AND SEALANTS ...............................................
44
Recommended Chemical Product and Sealant .......44
IDENTIFICATION INFORMATION ....................45
Model Variation ........................................................45
Dimensions ..............................................................47
Wheels & Tires ........................................................47
TERMINOLOGY ................................................48
SAE J1930 Terminology List ...................................48
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MA-34
< SERVICE INFORMATION >
CHASSIS AND BODY MAINTENANCE
Check lines for improper attachment, leaks, cracks, damage,loose connections, chaf ing and deterioration.
Check rack boots for accumulati on of power steering fluid.
Axle and Suspension PartsINFOID:0000000001328934
Check front and rear axle and suspension parts for excessive play,
cracks, wear or other damage.
Shake each wheel to check for excessive play.
Check wheel bearings for smooth operation.
Check axle and suspension nuts and bolts for looseness.
Check strut (shock absorber) for oil leakage or other damage.
Check suspension ball joint for grease leakage and ball joint dust
cover for cracks or other damage.
Drive ShaftINFOID:0000000001328935
Check boot and drive shaft for cracks, wear, damage and grease
leakage.
SST851C
SMA525A
SFA392B
SFA108A
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STEERING WHEELPS-9
< SERVICE INFORMATION >
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STEERING WHEEL
On-Vehicle Inspection and ServiceINFOID:0000000001327712
CHECKING CONDITION OF INSTALLATION
Check installation condition of steering gear assemb ly, front suspension, axle and steering column.
Check if movement exists when steering wheel is mo ved up and down, to the left and right and to the axial
direction.
Check if the mounting bolts for steering gear assembly are loose or not. Refer to PS-17
.
CHECKING STEERING WHEEL PLAY
1. Set tires to the straight ahead, start engine, then turn steering wheel to the left and right lightly, and mea-
sure steering wheel movement on the outer circumfe rence when steering wheel is turned up to the point
where tires start moving.
CHECKING NEUTRAL POSITION ON STEERING WHEEL
Check neutral position on steering wheel after confirming that front wheel alignment is correct. Refer to FSU-5,
"Wheel Alignment Inspection".
1. Set vehicle to the straight direction, chec k if steering wheel is in the neutral position.
2. If it is not in the neutral position, remo ve steering wheel and reinstall it correctly.
3. If the neutral position cannot adjust in the two teeth of steering gear assembly, loosen outer socket lock
nuts of steering outer sockets, then adjust outer so cket by the same amount in the opposite direction.
CHECKING STEERING WHEEL TURNING FORCE
1. Park vehicle on a level and dry surface, set parking brake.
2. Start engine.
3. Bring power steering fluid up to adequate operating te mperature. [Make sure temperature of fluid is
approximately 50 to 80 °C (122 to 176 °F).]
NOTE:
Tires need to be inflated normal pressure.
4. Check steering wheel turning force when steering wheel has been turned 360 ° from neutral position.
NOTE:
Multiply the distance L from the hook of spring balance to the
center of steering wheel by the measurement value with a spring
balance.
5. If steering wheel turning force is out of the specification, check
rack sliding force and relief hydraulic pressure of oil pump.
Regarding relief hydraulic pressure of oil pump, refer to PS-27, "
On-Vehicle Inspection and Service".
End play of the axle direction for steering wheel : 0 mm (0 in)
SGIA0546E
Steering wheel play on the
outer circumference : 0 − 35 mm (0 − 1.38 in)
Steering wheel turning force : Less than 7.45 N·m (0.76 kg-m, 66 in-lb)
SGIA1136E
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PS-18
< SERVICE INFORMATION >
POWER STEERING GEAR AND LINKAGE
7. Remove oil pipings (high pressure side and low pressure side)from steering gear assembly, then drain fluid from pipings.
8. Remove mounting bolt of steering hydraulic piping bracket from steering gear assembly.
9. Remove mounting bolt (lower side) of lower joint.
10. Remove mounting bolts of steering gear assembly with power tool, and then remove steering gear assembly from vehicle.
INSTALLATION
Refer to "Removal and Installation" for tightening torque. Install in the reverse order of removal.
NOTE:
Refer to component parts location and do not reuse non-reusable parts.
After removing/installing or replacing steering components, check wheel alignment. Refer to FSU-5, "
Wheel
Alignment Inspection".
After adjusting wheel alignment, adjust neutral position of steering angle sensor. Refer to BRC-8, "
Adjust-
ment of Steering Angle Sensor Neutral Position".
SGIA0541E
SGIA0545E
SGIA0542E
SGIA0546E
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RAX-6
< SERVICE INFORMATION >
REAR WHEEL HUB AND KNUCKLE
REAR WHEEL HUB AND KNUCKLE
On-Vehicle InspectionINFOID:0000000001327526
Make sure the mounting conditions (looseness, back lash) of each component and component status (wear,
damage) are normal.
WHEEL BEARING INSPECTION
With the vehicle raised, inspect the following.
Move wheel hub in the axial direction by hand. Che ck that there is no looseness of front wheel bearing.
Rotate wheel hub and make sure there is no unusual noi se or other irregular conditions. If there are any
irregular conditions, replace wheel hub and bearing assembly.
Removal and InstallationINFOID:0000000001327527
COMPONENTS
REMOVAL
1. Remove tires from vehicle with power tool.
2. Remove cotter pin. Then remove lock nut from drive shaft.
3. Remove brake caliper with power tool. Hang it in a place where it will not interfere with work. Refer to BR-
25, "Removal and Installation of Brake Caliper Assembly".
NOTE:
Avoid depressing brake pedal while brake caliper is removed.
4. Remove disc rotor. Refer to BR-25, "
Removal and Installation of Brake Caliper Assembly".
5. Remove parking cable and parking shoe from back plate. Refer to PB-4, "
Removal and Installation".
6. Remove wheel sensor from axle. Refer to BRC-52
.
CAUTION:
Do not pull on wheel sensor harness.
7. Separate drive shaft from wheel hub and bearing assembly by lightly tapping the end with a suitable ham- mer and wood block. If it is hard to separate, use a suitable puller.
8. Remove fixing bolts of wheel hub and bearing assembly with power tool, then remove wheel hub and bearing assembly from axle.Axial end play : 0.05 mm (0.002 in) or less
1. Drive shaft 2. Bushing 3. Axle
4. Back plate 5. Anchor block 6. Wheel bearing
7. Wheel hub 8. Cotter pin
SDIA1481E
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REAR WHEEL HUB AND KNUCKLERAX-7
< SERVICE INFORMATION >
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9. Remove parking brake cable and parking brake shoe from back plate. Refer to PB-6 and PB-4.
10. Remove fixing nuts of anchor block with power tool , then remove anchor block and back plate from axle.
11. Loosen fixing bolts and nuts of front lower link, radius rod, and rear lower link in side of suspension mem-
ber.
12. Set jack under rear lower link. Then remove fixing bolt in front lower link side of shock absorber with power tool.
13. Remove bolt and nut in axle side of rear lower link with power tool. Then remove coil spring. Refer to RSU-15
.
14. Remove fixing bolts and nuts in axle side of fr ont lower link, radius rod with power tool.
15. Remove suspension arm and cotter pin at axle, then loosen mounting nut.
16. Use a ball joint remover (suitable tool) to remove suspension arm from axle. Be careful not to damage ball joint boot.
CAUTION:
Tighten temporarily mounting nu t to prevent damage to threads and to prevent ball joint remover
(suitable tool) from coming off.
17. Remove axle from vehicle.
INSPECTION AFTER REMOVAL
Check for deformity, cracks and damage on each parts, replace if necessary.
Ball Joint Inspection
Check for boot breakage, axial looseness, and tor que of suspension arm ball joint. Refer to RSU-11, "Removal
and Installation".
INSTALLATION
Refer to "Removal and Installation" for tightening torque. Install in the reverse order of removal.
NOTE:
Refer to component parts location and do not reuse non-reusable parts.
Perform final tightening of installation position of suspension links (rubber bushing) under unladen conditions
with tires on level ground, Check wheel alignment. Refer to RSU-5, "
Wheel AlignmentInspection".
After adjusting wheel alignment, adjust neutral position of steering angle sensor. Refer to BRC-8, "
Adjust-
ment of Steering Angle Sensor Neutral Position".
Disassembly and AssemblyINFOID:0000000001327528
DISASSEMBLY
Wheel Bearing
CAUTION:
Do not disassemble if wheel bearing has no trouble.
1. Remove wheel bearing fixing bolts and anchor block fixing nuts, and remove wheel hub and bearing assembly, back plate and anchor block from axle.
2. Using a drift (SST) and a puller (suitable tool), press wheel hub out to remove from wheel bearing.
SDIA1482E
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RSU-8
< SERVICE INFORMATION >
REAR SUSPENSION ASSEMBLY
REMOVAL
1. Remove tires from vehicle with power tool.
2. Remove brake caliper with power tool. Hang it in a place where it will not interfere with work. Refer to BR-
24.
NOTE:
Avoid depressing brake pedal while brake caliper is removed.
3. Remove wheel sensor from rear final drive, t hen remove wheel sensor harness from rear suspension
member.
4. Remove height sensor harness from rear suspension member (if equipped).
5. Remove center muffler and main muffler. Refer to EX-3, "
Component".
6. Remove stabilizer bar. Refer to RSU-16, "
Removal and Installation".
7. Remove rear propeller shaft. Refer to PR-9, "
Removal and Installation".
8. Separate attachments between parking brake cable and vehicle and rear suspension member.
9. Remove rear lower link and coil spring. Refer to RSU-14, "
Removal and Installation".
10. Remove fixing bolt in lower side of shock absorber with power tool.
11. Set jack under rear final drive.
12. Remove fixing bolts and nuts of tunnel stay and mem ber stay with power tool, then remove those parts
from vehicle.
13. Remove fixing bolts and nuts of rear pin stay with pow er tool and then remove rear pin stay from vehicle.
14. Gradually lowering jack, remove rear suspension assembly.
INSTALLATION
Refer to "Removal and installation" for tightening torque. Install in the reverse order of removal.
NOTE:
Refer to component parts location and do not reuse non-reusable parts.
Perform final tightening of installation position of links (rubber bushing) under unladen conditions with tires on level ground. Check wheel alignment. Refer to RSU-5, "
Wheel AlignmentInspection".
After adjusting wheel alignment, adjust neutral position of steering angle sensor. Refer to BRC-8, "
Adjust-
ment of Steering Angle Sensor Neutral Position".
19. Suspension arm 20. Stabilizer connecting rod mounting
bracket21. Stabilizer connecting rod
22. Rear pin stay 23. Rear suspension member 24. Stabilizer bar
25. Stabilizer bushing 26. Stabilizer clamp 27. Member stay
28. Tunnel stay A: With height sensor B: Without height sensor
Refer to GI-8, "
Component", for the symbols in the figure.
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REAR SUSPENSION MEMBERRSU-17
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REAR SUSPENSION MEMBER
Removal and InstallationINFOID:0000000001327562
REMOVAL
1. Remove tires from vehicle with power tool.
2. Remove brake caliper with power tool. Hang it in a place where it will not interfere with work. Refer to BR-
24.
NOTE:
Avoid depressing brake pedal while brake caliper is removed.
3. Remove wheel sensor from rear final drive, t hen remove wheel sensor harness from rear suspension
member. Refer to BRC-52
.
4. Remove height sensor harness from rear suspension member (if equipped).
5. Remove center muffler and main muffler. Refer to EX-3
.
6. Remove stabilizer bar. Refer to RSU-16, "
Removal and Installation".
7. Remove rear drive shaft. Refer to RAX-10
.
8. Remove propeller shaft. Refer to PR-7
.
9. Remove rear final drive. Refer to RFD-16, "
Removal and Installation".
10. Separate attachments between parking brake cable and vehicle and rear suspension member. Refer to PB-4
.
11. Remove rear lower link and coil spring. Refer to RSU-14, "
Removal and Installation".
12. Remove fixing bolt in lower side of shock absorber with power tool.
13. Set jack under rear suspension member.
14. Remove fixing bolts and nuts of tunnel stay and member stay with power tool, then remove those parts from vehicle and rear suspension member.
15. Remove fixing bolts and nuts of rear pin stay with pow er tool and then remove rear pin stay from vehicle
and rear suspension member.
16. Slowly lowering jack, then remove rear suspension me mber, suspension arm, radius rod, front lower link
and axle from vehicle as a unit.
17. Remove fixing bolts and nuts with power tool, then re move suspension arm, front lower link, and radius
rod from rear suspension member.
INSPECTION AFTER REMOVAL
Check rear suspension member for deformation, cracks, and other damage and replace if necessary.
INSTALLATION
Refer to RSU-6, "Removal and Installation", for tightening torque. Install in the reverse order of removal.
NOTE:
Refer to component parts location and do not reuse non-reusable parts.
Perform final tightening of installation position of links (rubber bushing) under unladen conditions with tires
on level ground. Check wheel alignment. Refer to RSU-5, "
Wheel AlignmentInspection".
After adjusting wheel alignment, adjust neutral position of steering angle sensor. Refer to BRC-8, "
Adjust-
ment of Steering Angle Sensor Neutral Position".
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