Mechanical Components Section

4-1 SPECIFICATIONS AND SERVICE DATA
1. Suspension
1. Suspension
A: SPECIFICATIONS
1. STABILIZER
Bar dia. mm (in)
Model
Front Rear
2200 cc 19 (0.75) 15 (0.59)
Sedan
2500 cc 20 (0.79) 16 (0.63)
2200 cc 19 (0.75) 15 (0.59)
Wagon
2500 cc 20 (0.79) 16 (0.63)
2200 cc 20 (0.79) 18 (0.71)
OUTBACK
2500 cc 20 (0.79) 18 (0.71)
B: WHEEL ALIGNMENT
Sedan Wagon OUTBACK
FWD AWD FWD AWD AWD
Camber
−0°05′ −0°05′ −0°05′ −0°05′ 0°20′
(tolerance: ±0°30′)
Caster
3°05′ 3°05′ 3°05′ 3°05′ 2°50′
(tolerance: ±1°)
Front
Toe-in mm (in) 0±3 (0±0.12) Total toe angle: 0°±20′
Kingpin angle (tolerance: ±1°) 14°15′ 14°15′ 14°15′ 14°15′ 13°30′
Wheel arch height
385 (15.16) 385 (15.16) 385 (15.16) 385 (15.16) 420 (16.54)
[tolerance: −+12 +0.47
24 mm (− 0.94 in)] mm (in)
Camber
−0°55′ −1° −0°45′ −0°55′ −0°35′
(tolerance: ±0°45′)
Toe-in mm (in) 0±3 (0±0.12) Total toe angle: 0°±20′
Rear
Wheel arch height
369 (14.53) 369 (14.53) 379 (14.92) 379 (14.92) 419 (16.50)
[tolerance: −+12 +0.47
24 mm (− 0.94 in)] mm (in)
Thrust angle 0°±20′
2
SPECIFICATIONS AND SERVICE DATA 4-1
1. Suspension
NOTE:
쐌 Front and rear toe-ins and front camber can be adjusted.
If toe-in or front camber tolerance exceeds specifications,
adjust toe-in and camber to the specification.
쐌 The other items indicated in the specification table can-
not be adjusted. If the other items exceeds specifications,
check suspension parts and joint portions of body suspen-
sion parts for deformities; and replace with new ones as
required.
B4M0182A
3
4-1 COMPONENT PARTS
1. Conventional Suspension
1. FRONT SUSPENSION
B4M1148A
쎻
1 Front crossmember 쎻
20 Upper spring seat Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Bolt ASSY 쎻
21 Rubber seat T1: 18±5 (1.8±0.5, 13.0±3.6)
쎻
3 Housing 쎻
22 Dust cover T2: 20±6 (2.0±0.6, 14.5±4.3)
쎻
4 Washer 쎻
23 Helper T3: 25±4 (2.5±0.4, 18.1±2.9)
쎻
5 Stopper rubber (Rear) 쎻
24 Coil spring T4: 29±5 (3.0±0.5, 21.7±3.6)
쎻
6 Rear bushing 쎻
25 Damper strut T5: 39 (4, 29)
쎻
7 Stopper rubber (Front) 쎻
26 Adjusting bolt T6: 44±6 (4.5±0.6, 32.5±4.3)
쎻
8 Ball joint 쎻
27 Castle nut T7: 49±10 (5.0±1.0, 36±7)
쎻
9 Transverse link 쎻
28 Self-locking nut T8: 54±5 (5.5±0.5, 39.8±3.6)
쎻
10 Cotter pin 쎻
29 Adapter front crossmember T9: 98±15 (10.0±1.5, 72±11)
쎻
11 Front bushing (OUTBACK model) T10:152±20 (15.5±2.0, 112±14)
쎻
12 Stabilizer link 쎻
30 Clip (OUTBACK model) T11:186±10 (19.0±1.0, 137±7)
쎻
13 Clamp (2200 cc model) 쎻
31 Bushing (2500 cc model) T12:245±49 (25.0±5.0, 181±36)
쎻
14 Bushing (2200 cc model) 쎻
32 Clamp (2500 cc model)
쎻
15 Stabilizer 쎻
33 Dynamic damper
쎻
16 Jack-up plate (2500 cc MT model)
(Except 2500 cc MT model) 쎻
34 Jack-up plate (2500 cc MT model)
쎻
17 Dust seal
쎻
18 Strut mount
쎻
19 Spacer
4
COMPONENT PARTS 4-1
2. REAR SUSPENSION (AWD MODEL)
B4M0766A
쎻
1 Stabilizer 쎻
16 Trailing link bracket Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Stabilizer bracket 쎻
17 Cap (Protection) T1: 20±6 (2.0±0.6, 14.5±4.3)
쎻
3 Stabilizer bushing 쎻
18 Washer T2: 25±7 (2.5±0.7, 18.1±5.1)
쎻
4 Clamp 쎻
19 Rear crossmember T3: 44±6 (4.5±0.6, 32.5±4.3)
쎻
5 Floating bushing 쎻
20 Strut mount cap T4: 59±10 (6.0±1.0, 43±7)
쎻
6 Stopper 쎻
21 Strut mount T5: 98±15 (10.0±1.5, 72±11)
쎻
22 Rubber seat upper
T6: 98±20 (10.0±2.0, 72±14)
쎻 Rear lateral link T7: 113±15 (11.5±1.5, 83±11)
8
쎻
23 Dust cover T8: 127±20 (13.0±2.0, 94±14)
쎻
9 Bushing (C) 쎻 Coil spring
24 T9: 137±20 (14.0±2.0, 101±14)
쎻
10 Bushing (A)
쎻
25 Helper +39
T10:196−10 +4.0
(20.0−1.0 +29
, 145−7 )
쎻
11 Front lateral link
쎻
26 Rubber seat lower
쎻
12 Bushing (B)
쎻
27 Damper strut
쎻
13 Trailing link rear bushing
쎻
28 Self-locking nut
쎻
14 Trailing link
쎻
15 Trailing link front bushing 쎻
29 Crossmember reinforcement
lower (Sedan model)
쎻
30 Adapter rear crossmember (OUT-
BACK model)
5
4-1 COMPONENT PARTS
3. REAR SUSPENSION (FWD MODEL)
B4M0185A
쎻
1 Stabilizer 쎻
15 Trailing link rear bushing Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Stabilizer bracket 쎻
16 Trailing link T1: 20±6 (2.0±0.6, 14.5±4.3)
쎻
3 Stabilizer bushing 쎻
17 Trailing link front bushing T2: 25±7 (2.5±0.7, 18.1±5.1)
쎻
4 Clamp 쎻
18 Trailing link bracket T3: 44±6 (4.5±0.6, 32.5±4.3)
쎻
19 Crossmember T4: 59±10 (6.0±1.0, 43±7)
쎻
6 Adjusting bolt 쎻
20 Strut mount cap T5: 98±20 (10.0±2.0, 72±14)
쎻
7 Adjusting wheel 쎻
21 Strut mount
T6: 113±15 (11.5±1.5, 83±11)
쎻 Rear lateral link T7: 127±20 (13.0±2.0, 94±14)
8
쎻
22 Rubber seat upper T8: 137±20 (14.0±2.0, 101±14)
쎻
9 Bushing (D) 쎻 Dust cover +39 +4.0 +29
23 T9: 196−10 (20.0−1.0, 145−7 )
쎻
10 Bushing (A)
쎻
24 Coil spring
쎻
쎻
25 Helper
쎻
12 Self-locking nut
쎻
26 Rubber seat lower
쎻
13 Washer
쎻
27 Damper strut
쎻
14 Cap (Protection)
6
SERVICE PROCEDURE 4-1
1. On-car Services
1. On-car Services
A: WHEEL ALIGNMENT
Check, adjust and/or measure wheel alignment in accor-
dance with procedures indicated below:
1. Wheel arch height (Front and rear)
왔
2. Camber (Front and rear)
왔
3. Caster (Front)
왔
4. Front toe-in
왔
5. Rear toe-in
왔
6. Thrust angle (Rear)
왔
7. Wheel steering angle
7
4-1 SERVICE PROCEDURE
1. On-car Services
1. WHEEL ARCH HEIGHT

1) Adjust tire pressure to specifications.
2) Set vehicle under “curb weight” conditions. (Empty lug-
gage compartment, install spare tire, jack, service tools,
and top up fuel tank.)
3) Set steering wheel in a wheel-forward position.
4) Suspend thread from wheel arch (point “A” in figure
below) to determine a point directly above center of
spindle.
5) Measure distance between measuring point and center
of spindle.
B4M0566A
Specified wheel arch height mm (in)

Vehicles
Front Rear
FWD 385+12 +0.47

−24 (15.16 −0.94) 369+12 +0.47
−24 (14.53 −0.94)
Sedan
AWD 385+12 +0.47
−24 (15.16 −0.94) 369+12 +0.47
−24 (14.53 −0.94)
FWD 385+12 +0.47

−24 (15.16 −0.94) 379+12 +0.47
−24 (14.92 −0.94)
Wagon
AWD 385+12 +0.47
−24 (15.16 −0.94) 379+12 +0.47
−24 (14.92 −0.94)
OUTBACK AWD 420+12 +0.47

−24 (16.54 −0.94) 419+12 +0.47
−24 (16.50 −0.94)
8
1. On-car Services
2. CAMBER AND CASTER

쐌 Inspection
1) Place front wheel on turning radius gauge. Make sure
ground contacting surfaces of front and rear wheels are set
at the same height.
2) Set ST into the center of the wheel, and then install the
wheel alignment gauge.
ST 927380000 ADAPTER
NOTE:
B4M0567A
Refer to the “SPECIFICATIONS AND SERVICE DATA” for
the camber and caster values.
쐌 Front camber adjustment
1) Loosen two self-locking nuts located at lower front por-
tion of strut.
CAUTION:
쐌 When adjusting bolt needs to be loosened or
tightened, hold its head with a wrench and turn self-
locking nut.
쐌 Discard loosened self-locking nut and replace with a
new one.
2) Turn camber adjusting bolt so that camber is set at the

specification.
NOTE:
Moving the adjusting bolt by one scale graduation changes
camber by approximately 0°10′.
B4M0189A
9
1. On-car Services
Left side Right side
Rotate
Camber is increased. Rotate clockwise.
counterclockwise.
B4M0190 B4M0350
Rotate
Camber is decreased. Rotate clockwise.
counterclockwise.
B4M0350 B4M0190
3) Tighten the two self-locking nuts.

Tightening torque:
152±20 N⋅m (15.5±2.0 kg-m, 112±14 ft-lb)
3. FRONT WHEEL TOE-IN

쐌 Inspection
1) Using a toe gauge, measure front wheel toe-in.
Toe-in: 0±3 mm (0±0.12 in)
2) Mark rear sides of left and right tires at height corre-
sponding to center of spindles and measure distance “B”
between marks.
3) Move vehicle forward so that marks line up with front
sides at height corresponding to center of spindles.
M4A0059
4) Measure distance “A” between left and right marks.
Toe-in can then be obtained by the following equation:
B − A = Toe-in
10
1. On-car Services
쐌 Adjustment
1) Loosen the left and right side steering tie-rods lock nuts.
2) Turn the left and right tie rods equal amounts until the
toe-in is at the specification.
Both the left and right tie-rods are right-hand threaded. To
increase toe-in, turn both tie-rods clockwise equal amounts
(as viewed from the inside of the vehicle).
3) Tighten tie-rod lock nut.
Tightening torque:
G4M0482
83±5 N⋅m (8.5±0.5 kg-m, 61.5±3.6 ft-lb)
CAUTION:
Correct tie-rod boot, if it is twisted.
NOTE:
Check the left and right wheel steering angle is within
specifications.
4. REAR WHEEL TOE-IN (FWD MODEL)

쐌 Inspection
1) Using a toe-in gauge, measure rear wheel toe-in.
Toe-in: 0±3 mm (0±0.12 in)
between marks.
M4A0059
B − A = Toe-in
쐌 Adjustment
1) Remove cap from lateral link and loosen self-locking
nut.
CAUTION:
쐌 When loosening or tightening adjusting bolt, hold
the bolt head and loosen self-locking nut.
쐌 Replace self-locking nut with a new one.
2) Using two wrenches, turn adjusting wheel and adjusting
bolt equally in opposite directions so that toe-in is at the
G4M0483
specification.
11
1. On-car Services
Turn adjusting
Turn adjusting
wheel
Toe-in is wheel clockwise
counterclockwise
increased. and adjusting bolt
and adjusting bolt
counterclockwise.
clockwise.
B4M0191A B4M0351A
Turn adjusting
Turn adjusting
wheel
Toe-in is wheel clockwise
counterclockwise
decreased. and adjusting bolt
and adjusting bolt
counterclockwise.
clockwise.
B4M0351A B4M0191A
NOTE:
쐌 When left and right wheels are adjusted for toe-in at the
same time, moving one scale graduation changes toe-in by
approximately 4 mm (0.16 in).
쐌 Turn adjusting wheel and adjusting bolt equally in oppo-
site directions so that same scale graduations are posi-
tioned directly above center of the adjusting bolt.
3) Tighten self-locking nut.
Tightening torque:
G4M0485
137±20 N⋅m (14±2 kg-m, 101±14 ft-lb)
5. REAR WHEEL TOE-IN (AWD MODEL)
쐌 Inspection
1) Using a toe-in gauge, measure rear wheel toe-in.
Toe-in: 0±3 mm (0±0.12 in)
between marks.
M4A0059
B − A = Toe-in
12
1. On-car Services
쐌 Adjustment
1) Loosen self-locking nut on inner side of rear lateral link.
CAUTION:
쐌 When loosening or tightening adjusting bolt, hold
bolt head and turn self-locking nut.
new one.
2) Turn adjusting bolt head until toe-in is at the specifica-
tion.
G4M0486
Rotate
Toe-in is increased. Rotate clockwise.
counterclockwise.
B4M0192 B4M0352
Rotate
Toe-in is decreased. Rotate clockwise.
counterclockwise.
B4M0352 B4M0192
NOTE:
When left and right wheels are adjusted for toe-in at the
same time, the movement of one scale graduation changes
toe-in by approximately 3 mm (0.12 in).
Tightening torque:
98±15 N⋅m (10±1.5 kg-m, 72±11 ft-lb)
13
1. On-car Services
6. THRUST ANGLE
쐌 Inspection
1) Position vehicle on a level surface.
2) Move vehicle 3 to 4 meters directly forward.
3) Determine locus of both front and rear axles.
4) Measure distance “L” between center line of loci of the
axles.
<For reference>
• Thrust angle is less than 20’ when “L” is equal to or less
than 15 mm (0.59 in).

쐌 Adjustment
Make thrust angle adjustments by turning toe-in adjusting
bolts of rear suspension equally in the same direction.
NOTE:
On FWD models, turn adjusting wheels one by one, by the
some amount in the opposite direction of the adjusting
bolts.
<For reference>
• When one rear wheel is adjusted in a toe-in direction,
adjust the other rear wheel equally in toe-out direction, in

G4M0488 order to make thrust angle adjustment.
• When left and right adjusting bolts are turned incremen-
tally by one graduation in the same direction, the thrust

angle of the AWD model will change approximately 10’ [“L”
is almost equal to 7.5 mm (0.295 in)] and the thrust angle
of the FWD model will change approximately 12’ [“L” is
almost equal to 9 mm (0.35 in)].
Thrust angle:
0°±20′
NOTE:
Thrust angle refers to a mean value of left and right rear
wheel toe angles in relation to vehicle body center line.
Vehicle is driven straight in the thrust angle direction while
swinging in the oblique direction depending on the degree
of the mean thrust angle.
B4M0193A
Thrust angle: r
α−β
r=
2
α: Right rear wheel toe angle
β: Left rear wheel toe angle
NOTE:
Here, use only positive toe-in values from each wheel to
substitute for α and β in the equation.
B4M0194A
14
1. On-car Services
7. STEERING ANGLE
쐌 Inspection
1) Place vehicle on a turning radius gauge.
2) While depressing brake pedal, turn steering wheel fully
to the left and right. With steering wheel held at each fully
turned position, measure both the inner and outer wheel
steering angle.
Steering angle:
Inner wheel 37.6°±1.5°
Outer wheel 32.6°±1.5°
쐌 Adjustment
Turn tie-rod to adjust steering angle of both inner and outer
wheels.
CAUTION:
쐌 Check toe-in.
쐌 Correct boot if it is twisted.
G4M0482
15
2. Front Transverse Link

A: REMOVAL
G4M0490
쎻
1 Front crossmember Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Transverse link T1: 29±5 (3.0±0.5, 21.7±3.6)
쎻
3 Stabilizer link T2: 44±6 (4.5±0.6, 32.5±4.3)
쎻
4 Front stabilizer T3: 98±15 (10.0±1.5, 72±11)
쎻
5 Self-locking nut T4: 186±10 (19.0±1.0, 137±7)
T5: 245±49 (25.0±5.0, 181±36)
1) Disconnect stabilizer link from transverse link.

2) Remove bolt securing ball joint of transverse link to
housing.
G4M0491
16
3) Remove nut (do not remove bolt.) securing transverse

link to crossmember.
4) Remove two bolts securing bushing bracket of trans-
verse link to vehicle body at rear bushing location.
G4M0492
5) Extract ball joint from housing.

6) Remove bolt securing transverse link to crossmember
and extract transverse link from crossmember.
G4M0493
B: DISASSEMBLY
1. FRONT BUSHING
Using ST, press front bushing out of place.
ST 927680000 INSTALLER & REMOVER SET
G4M0494
2. REAR BUSHING
1) Scribe an aligning mark on transverse link and rear
bushing.
2) Loosen nut and remove rear bushing.
G4M0495
C: INSPECTION
1) Check transverse link for wear, damage and cracks,
and correct or replace if defective.
2) Check bushings for cracks, wear,damage and creeping.
3) Check rear bushing for oil leaks.
4) If defective, replace with new one.
17
D: ASSEMBLY
1. FRONT BUSHING
To reassemble, reverse disassembly procedures.
CAUTION:
Install front bushing in correct direction, as shown in
figure.
G4M0496
2. REAR BUSHING
1) Install rear bushing to transverse link and align aligning
marks scribed on the two.
CAUTION:
new one.
쐌 While holding rear bushing so as not to change
position of aligning marks, tighten self-locking nut.
Tightening torque:
186±10 N⋅m (19.0±1.0 kg-m, 137±7 ft-lb)
E: INSTALLATION
1) Temporarily tighten the two bolts used to secure rear
bushing of the transverse link to body.
NOTE:
These bolts should be tightened to such an extent that they
can still move back and forth in the oblong shaped hole in
the bracket (which holds the bushing).
2) Install bolts used to connect transverse link to cross-
member and temporarily tighten with nut.
CAUTION:
Discard loosened self-locking nut and replace with a
new one.
3) Insert ball joint into housing.
18
4) Connect stabilizer link to transverse link, and tempo-

rarily tighten bolts.
CAUTION:
Discard loosened self-locking nut and replace with a
new one.
5) Tighten the following points in the order shown below
when wheels are in full contact with the ground and vehicle
is at curb weight condition.
(1) Transverse link and stabilizer link
G4M0497
Tightening torque:
29±5 N⋅m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
(2) Transverse link and crossmember
Tightening torque:
98±15 N⋅m (10.0±1.5 kg-m, 72±11 ft-lb)
(3) Transverse link rear bushing and body

Tightening torque:
245±49 N⋅m (25±5 kg-m, 181±36 ft-lb)
NOTE:
쐌 Move rear bushing back and forth until transverse link-
to-rear bushing clearance is established (as indicated in
figure.) before tightening.
쐌 Check wheel alignment and adjust if necessary.
G4M0928
19
3. Front Ball Joint
3. Front Ball Joint

A: REMOVAL
1) Remove the wheel.
2) Pull out the cotter pin from the ball stud, remove the
castle nut, and extract the ball stud from the transverse
link.
3) Remove the bolt securing the ball joint to the housing.
4) Extract the ball joint from the housing.
G4M0499
B: INSPECTION
1) Measure play of ball joint by the following procedures.
Replace with a new one when the play exceeds the speci-
fied value.
(1) With 686 N (70 kg, 154 lb) loaded in the direction
shown in the figure, measure dimension 1.
G4M0500
(2) With 686 N (70 kg, 154 lb) loaded in the opposite
direction shown in the figure, measure dimension 2.
(3) Calculate plays from the following formula.
S= 2 − 1
(4) When plays are larger than the following value,
replace with a new one.
FRONT BALL JOINT
Specified play for replacement: S
Less than 0.3 mm (0.012 in)
G4M0501
2) When play is smaller than the specified value, visually
inspect the dust cover.
3) If the dust cover is damaged, replace with the new ball
joint.
4) Check ball joint for damage and cracks. If defective,
replace with new one.
C: INSTALLATION
1) Install ball joint onto housing.
Torque (Bolt):
49±10 N⋅m (5.0±1.0 kg-m, 36±7 ft-lb)
CAUTION:
Do not apply grease to tapered portion of ball stud.
2) Connect ball joint to transverse link.
Torque (Castle nut):
39 N⋅m (4.0 kg-m, 29 ft-lb)
3) Retighten castle nut further within 60° until a slot in
castle nut is aligned with the hole of ball stud end, then
insert new cotter pin and bend it around castle nut.
4) Install front wheel.
20
4. Front Strut
4. Front Strut
A: REMOVAL
G4M0502
쎻
1 Dust seal 쎻
7 Helper Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Strut mount 쎻
8 Coil spring T1: 20±6 (2.0±0.6, 14.5±4.3)
쎻
3 Spacer 쎻
9 Damper strut T2: 54±5 (5.5±0.5, 39.8±3.6)
쎻
4 Upper spring seat 쎻
10 Adjusting bolt T3: 152±20 (15.5±2.0, 112±14)
쎻
5 Rubber seat 쎻
11 Self-locking nut
쎻
6 Dust cover
1) Remove wheel.
2) Depress brake pedal and hold it down using a wooden
block etc.
3) Remove union bolts from caliper.
CAUTION:
Use brake hose cap to prevent brake fluid from escap-
ing.
G4M0503
21
4. Front Strut
4) Remove brake hose clamp and disconnect brake hose

from strut. Attach brake hose to body using gum tape.
5) Scribe an alignment mark on the camber adjusting bolt
which secures strut to housing.
6) Remove bolt securing the A.B.S. sensor harness.
(A.B.S. equipped models.)
G4M0504
7) Remove two bolts securing housing to strut.

CAUTION:
While holding head of adjusting bolt, loosen self-lock-
ing nut.
8) Remove the three nuts securing strut mount to body.
G4M0505
B: DISASSEMBLY
1) Using a coil spring compressor, compress coil spring.
G4M0506
2) Using ST, remove self-locking nut.

ST 927760000 STRUT MOUNT SOCKET
3) Remove strut mount, upper spring seat and rubber seat
from strut.
4) Gradually decreasing compression force of spring
compressor, and remove coil spring.
5) Remove dust cover and helper.
G4M0507
22
4. Front Strut
C: INSPECTION
Check the disassembled parts for cracks, damage and
wear, and replace with new parts if defective.
1. DAMPER STRUT
1) Check for oil leakage.
2) Move the piston rod up and down to check its operates
smoothly without any binding.
3) Play of piston rod
Measure the play as follows:
Fix outer shell and fully extend the rod. Set a dial gauge at
the end of the rod: L [10 mm (0.39 in)], then apply a force
of W [20 N (2 kg, 4 lb)] to threaded portion. With the force
G4M0508 of 20 N (2 kg, 4 lb) applied, read dial gauge indication: P1.
Apply a force of 20 N (2 kg, 4 lb) in the opposite direction
of “W”, then read dial gauge indication: P2. The free play
is determined by the following equation:
Play = P1, P2
Limit of play:
If the play is greater, replace the strut with new one.
2. STRUT MOUNT
Check rubber part for wear, cracks and deterioration, and
replace it with new one if defective.
3. DUST COVER
If any cracks or damage are found, replace it with new one.
4. COIL SPRING
When vehicle posture is uneven, although there are no
considerable reasons like tire puncture, uneven loading,
etc., check coil spring and spring seats for cracks,
deformation, etc., and replace it with a new one if defective.
5. HELPER
Replace it with new one if cracked or damaged.
23
4. Front Strut
D: ASSEMBLY
1) Before installing coil spring, strut mount, etc., on the
strut, check for the presence of air in the dampening force
generating mechanism of the strut since air prevents
proper dampening force from being produced.
2) Checking for the presence of air
(1) Place the strut vertically with the piston rod facing
upward.
(2) Move the piston rod to the center of its entire
stroke.
(3) While holding the piston rod end with finger-tips,
move the rod up and down.
(4) If the piston rod moves at least 10 mm (0.39 in) in
step (3), purge air from the strut.
3) Air purging procedure
(1) Place the strut vertically with the piston rod facing
upward.
(2) Fully extend the piston rod.
(3) With the piston rod fully extended, place the piston
rod side down. The strut must stand vertically.
(4) Fully contract the piston rod.
(5) Repeat 3 or 4 times steps (1) through (4) above.
NOTE:
After completely purging air from the strut, be sure to place
the strut with the piston rod facing upward. If it is laid down,
check for entry of air in the strut as outlined under item 2)
above.
4) Using a coil spring compressor, compress the coil

spring.
NOTE:
Make sure that the vertical installing direction of coil spring
is as shown in figure.
B4M0568A
5) Set the coil spring correctly so that its end face fits well
into the spring seat as shown.
6) Install helper and dust cover to the piston rod.
G4M0510
24
4. Front Strut
7) Pull the piston rod fully upward, and install rubber seat
and spring seat.
NOTE:
Ensure that upper spring seat is positioned with “OUT”
mark facing outward.
8) Install strut mount to the piston rod, and tighten the
self-locking nut temporarily.
CAUTION:
Be sure to use a new self-locking nut.
G4M0511
9) Using hexagon wrench to prevent strut rod from turning,

tighten self-locking nut with ST.
Tightening torque:
54±5 N⋅m (5.5±0.5 kg-m, 39.8±3.6 ft-lb)
ST 927760000 STRUT MOUNT SOCKET
10) Loosen the coil spring carefully.
G4M0507
E: INSTALLATION
1) Install strut mount at upper side of strut to body and
tighten with nuts.
Tightening torque:
20±6 N⋅m (2.0±0.6 kg-m, 14.5±4.3 ft-lb)
2) Connect housing to lower side of strut.
3) Position aligning mark on camber adjusting bolt with
aligning mark on lower side bracket of strut.
CAUTION:
쐌 While holding head of adjusting bolt, tighten self-
locking nut.
쐌 Be sure to use new self-locking nut.
Tightening torque:
152±20 N⋅m (15.5±2.0 kg-m, 112±14 ft-lb)
4) Install A.B.S. sensor harness to strut. (A.B.S. equipped
models.)
Tightening torque:
152±20 N⋅m (15.5±2.0 kg-m, 112±14 ft-lb)
5) Install brake hose at lower side of strut with clamp.
6) Install union bolts which secure brake caliper to brake

hose.
Tightening torque:
18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
CAUTION:
Be sure to bleed air from brake system.
7) Install wheels.
NOTE:
Check wheel alignment and adjust if necessary.
G4M0503
25
5. Front Stabilizer
5. Front Stabilizer
A: REMOVAL
G4M0514
쎻
1 Front crossmember Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Transverse link T1: 25±4 (2.5±0.4, 18.1±2.9)
쎻
3 Jack-up plate T2: 29±5 (3.0±0.5, 21.7±3.6)
쎻
4 Stabilizer link T3: 18±5 (1.8±0.5, 13.0±3.6)
쎻
5 Front stabilizer T4: 44±6 (4.5±0.6, 32.5±4.3)
쎻
6 Self-locking nut
1) Jack-up the front part of the vehicle, support it with

safety stand (rigid racks).
2) Remove bolts which secure stabilizer to crossmember.
G4M0515
26
5. Front Stabilizer
3) Remove bolts which secure stabilizer link to front trans-

verse link.
4) Remove jack-up plate from lower part of crossmember.
G4M0516
B: INSPECTION
1) Check bushing for cracks, fatigue or damage.
2) Check stabilizer link for deformities, cracks, or damage,
and bushing for protrusions from the hole of stabilizer link
and its play.
C: INSTALLATION
1) To install, reverse the removal procedure.
NOTE:
쐌 Install bushing (on front crossmember side) while align-
ing it with paint mark on stabilizer.
쐌 Ensure that bushing and stabilizer have the same iden-
tification colors when installing.
G4M0519
2) Always tighten rubber bushing location when wheels

are in full contact with the ground and vehicle is at curb
weight condition.
Tightening torque:
Jack-up plate to crossmember:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
Stabilizer link to front transverse link:
29±5 N⋅m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
Stabilizer to crossmember:
25±4 N⋅m (2.5±0.4 kg-m, 18.1±2.9 ft-lb)
27
6. Front Crossmember
6. Front Crossmember
A: REMOVAL
1) Disconnect ground cable from battery.
2) Loosen front wheel nuts.
3) Lift-up vehicle, and remove front tires and wheels.
4) Remove both stabilizer and jack-up plate.
5) Disconnect tie-rod end from housing.
6) Remove front exhaust pipe.
G4M0520
7) Remove front transverse link from front crossmember

and body.
8) Remove nuts attaching engine mount cushion rubber to
crossmember.
9) Remove self-locking nuts connecting steering U/J and
pinion shaft.
10) Lift engine by approx. 10 mm (0.39 in) by using chain
block.
11) Support crossmember with a jack, remove nuts secur-
G4M0521
ing crossmember to body and lower crossmember gradu-
ally along with steering gearbox.
CAUTION:
When removing crossmember downward, be careful
that tie-rod end does not interfere with DOJ boot.
B: INSTALLATION
1) Installation is in the reverse order of removal proce-
dures.
CAUTION:
Always tighten rubber bushing when wheels are in full
contact with the ground and vehicle is at curb weight
condition.
Tightening torque:
Transverse link bushing to crossmember:
98±15 N⋅m (10.0±1.5 kg-m, 72±11 ft-lb)
Stabilizer to bushing:
25±4 N⋅m (2.5±0.4 kg-m, 18.1±2.9 ft-lb)
Tie-rod end to housing:
27.0±2.5 N⋅m (2.75±0.25 kg-m, 19.9±1.8 ft-lb)
Front cushion rubber to crossmember:
69±15 N⋅m (7.0±1.5 kg-m, 51±11 ft-lb)
Universal joint to pinion shaft:
24±3 N⋅m (2.4±0.3 kg-m, 17.4±2.2 ft-lb)
Crossmember to body:
98±15 N⋅m (10.0±1.5 kg-m, 72±11 ft-lb)
2) Purge air from power steering system.
NOTE:
28
7. Rear Trailing Link

A: REMOVAL
B4M0569A
쎻
1 Trailing link Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Front bushing T1: 98±20 (10.0±2.0, 72±14)
쎻
3 Rear bushing T2: 113±15 (11.5±1.5, 83±11)
쎻
4 Bracket
쎻
5 Housing
쎻
6 Self-locking nut
1) Loosen rear wheel nuts.

2) Lift-up vehicle, support it with safety stands (rigid racks)
and remove rear wheels.
3) Remove both rear parking brake clamp and A.B.S. sen-
sor harness. (A.B.S. equipped models.)
4) Remove bolt which secure trailing link to trailing link

bracket.
5) Remove bolt which secure trailing link to rear housing.
B4M0570A
29
B: DISASSEMBLY
1. FRONT BUSHING
Using ST, press front bushing out of place.
G4M0524
2. REAR BUSHING
1) Remove housing. Refer to “4-2 WHEELS AND AXLES”
for removal procedures.
2) Using ST, press rear bushing out of place.
G4M0525
C: INSPECTION
Check trailing links for bends, corrosion or damage.
30
D: ASSEMBLY
To assemble, reverse above disassembly procedures.
1. FRONT BUSHING
Using ST, press bushing into trailing link.
CAUTION:
When installing bushing, turn ST plunger upside down
and press it until plunger end surface contacts trailing
link end surface.
B4M0226A
CAUTION:
Install front bushing in the proper direction, as shown
in figure.
G4M0924
31
2. REAR BUSHING
1) Using ST, press bushing into trailing link.
NOTE:
If it is difficult to press bushing into trailing link, apply water-
diluted TIRE LUBE to the inner surface of ST as a lubricant.
Specified lubricant:
TIRE LUBE : water = 1 : 3
B4M0224A
2) Press ST plunger until bushing flange protrudes beyond

trailing link.
B4M0195A
32
3) Turn trailing link upside down. Press ST plunger in the

direction opposite that outlined in step 2) until bushing is
correctly positioned in trailing link.
B4M0196A
E: INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Always tighten rubber bushing location when wheels
are in full contact with the ground and vehicle is at
curb weight condition.
NOTE:
33
8. Lateral Link
8. Lateral Link
A: REMOVAL
B4M0644A
쎻
1 Crossmember 쎻
8 Bushing (B) Tightening torque: N⋅m (kg-m, ft-lb)
쎻
9 Washer T1: 44±6 (4.5±0.6, 32.5±4.3)
쎻
10 Cap (Protection) T2: 98±15 (10.0±1.5, 72±11)
쎻
4 Rear lateral link 쎻
11 Bushing (D) T3: 113±15 (11.5±1.5, 83±11)
쎻
5 Bushing (C) 쎻
12 Trailing link T4: 137±20 (14.0±2.0, 101±14)
쎻
6 Bushing (A) 쎻
13 Self-locking nut
쎻
34
8. Lateral Link
1. FWD MODEL
1) Loosen wheel nuts. Lift-up vehicle and remove wheel.
2) Remove rear exhaust pipe and muffler.
3) Remove stabilizer link from rear lateral link.
4) Scribe an aligning mark on adjusting bolt, adjusting
wheel and crossmember.
5) Remove bolts securing lateral links to housing.
6) Turn cap (lateral link) counterclockwise until it contacts
stopper, then remove cap.
G4M0529 7) While holding adjusting bolt’s head with a wrench,
loosen self-locking nut.
CAUTION:
Always loosen self-locking nut before turning adjust-
ing bolt.
8) Lateral link removal
(1) Left lateral links
Remove adjusting bolt and front and rear lateral links.
(2) Right lateral links
Support crossmember with transmission jack.
Remove bolts securing crossmember to vehicle body.
Lower transmission jack until adjusting bolt can be
removed. Remove adjusting bolt, front and rear lateral
links.
2. AWD MODEL
1) Loosen wheel nuts. Lift-up vehicle and remove wheel.
2) Remove stabilizers link from lateral link.
3) Remove A.B.S. sensor harness from trailing link.
(A.B.S. equipped models.)
4) Remove bolt securing trailing link to housing.

5) Remove DOJ from differential. <Ref. to 4-2 [W4A2].>
6) Scribe an alignment mark on rear lateral link adjusting
bolt and crossmember.
7) Remove bolt securing lateral link to housing.
8) Remove bolts securing front and rear lateral links to
crossmember, detach lateral links.
CAUTION:
To loosen adjusting bolt, always loosen nut while hold-
B4M0573A ing the head of adjusting bolt.
35
8. Lateral Link
B: DISASSEMBLY
Using ST, press bushing out of place.
NOTE:
쐌 Using the following table as a guide, verify the type of
bushings.
쐌 Select ST according to the type of bushings used.
ST: INSTALLER & REMOVER
Bushing
SET
Bushing A 927700000
Bushing B 927690000
Bushing C 927700000
Bushing D 927710000
G4M0531
G4M0532
C: INSPECTION
Visually check lateral links for damage or bends.
36
8. Lateral Link
D: ASSEMBLY
1) Using ST, press bushing into place.
CAUTION:
Select ST according to the type of bushings used.
NOTE:
쐌 Use the same ST as that used during disassembly.
쐌 If it is difficult to press bushing into trailing link, apply
water-diluted TIRE LUBE to the inner surface of ST as a
lubricant.
Specified lubricant:
TIRE LUBE : water = 1 : 3
G4M0533
NOTE:
Pay attention to the direction of bushing “D” as shown in
figure.
B4M0571A
37
8. Lateral Link
2) Press ST plunger until bushing flange protrudes beyond

lateral link.
NOTE:
Use the same ST as that used during disassembly.
B4M0197A
3) Turn lateral link upside down. Press ST plunger in the

opposite direction that outlined in step 2) until bushing is
correctly positioned in trailing link.
NOTE:
Use the same ST as that used during disassembly.
B4M0198A
38
8. Lateral Link
E: INSTALLATION
To install, reverse removal procedures, reading the follow-
ing instructions.
CAUTION:
쐌 Always tighten rubber bushing when wheels are in
full contact with the ground and vehicle is at curb
weight condition.
쐌 Tighten nut when installing adjusting bolt.
쐌 Replace self-locking nut and DOJ circlip with new
ones.
NOTE:
쐌 Lateral link washers for FWD and AWD models can be
identified by colors, as follows:
Olive (FWD model)
Gold (AWD model)
쐌 Check wheel alignment and adjust if necessary.
39
9. Rear Strut
9. Rear Strut
A: REMOVAL
B4M0199A
쎻
1 Strut mount cap 쎻
6 Coil spring Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Self-locking nut 쎻
7 Helper T1: 20±6 (2.0±0.6, 14.5±4.3)
쎻
3 Strut mount 쎻
8 Rubber seat lower T2: 59±10 (6.0±1.0, 43±7)
+39 +4.0 +29
쎻
4 Rubber seat upper 쎻
9 Damper strut T3: 196−10 (20.0−1.0, 145−7 )
쎻
5 Dust cover
1) Depress brake pedal and secure it in that position using

a wooden block, etc.
2) Remove rear seat cushion and backrest. (Sedan)
B4M0200A
3) Remove strut cap of rear quarter trim. (Wagon)

4) Loosen rear wheel nuts.
5) Jack-up vehicle, support it with safety stands (rigid
racks) and remove rear wheels.
6) Remove brake hose clip.
B4M0201A
40
9. Rear Strut
7) Models equipped with rear disc brakes:

Remove union bolt from brake caliper.
8) Models equipped with rear drum brakes:
Disconnect brake hose from brake pipe from strut, and
disconnect brake pipe from dram brake.
G4M0538
9) Remove bolts which secure rear strut to housing.

10) Remove nuts securing strut mount to body.
11) Remove strut mount cap.
G4M0539
B: DISASSEMBLY
For disassembly of rear strut, refer to procedures outlined
under front strut as a guide.
<Ref. to 4-1 [W4B0].>
C: INSPECTION
Refer to Front Strut [W4C0] as a guide for inspection pro-
cedures.
D: ASSEMBLY
Refer to Front Strut [W4D0] as a guide for assembly pro-
cedures.
CAUTION:
쐌 Install rear strut with “FWD” or “4WD” mark on strut
mount facing outside of vehicle body.
쐌 Insert the protrusion of lower rubber seat into the
strut spring seat hole.
G4M0540
41
9. Rear Strut
E: INSTALLATION
1) Install strut mount cap.
2) Tighten self-locking nut used to secure strut mount to
vehicle body.
CAUTION:
Use a new self-locking nut.
NOTE:
Tighten strut mount and cap as a unit.
Tightening torque:
20±6 N⋅m (2.0±0.6 kg-m, 14.5±4.3 ft-lb)
3) Tighten bolts securing rear strut to housing.
Tightening torque:
196−+39 +4.0 +29
10 N⋅m (20.0− 1.0 kg-m, 145− 7 ft-lb)
CAUTION:
4) Models with rear disc brakes:
Tighten brake hose union bolt on brake caliper.
Tightening torque:
18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
Models with rear drum brakes:
Connect brake hose to brake pipe.
Tightening torque:
15−+32 N⋅m (1.5−+0.3
0.2 kg-m, 10.8−+2.2
1.4 ft-lb)
5) Insert brake hose clip between brake hose and lower
side of strut.
CAUTION:
쐌 Check that hose clip is positioned properly.
쐌 Check brake hose for twisting, or excessive tension.
쐌 Models equipped with A.B.S.:
Do not subject A.B.S. sensor harness to excessive ten-
sion.
6) Be sure to bleed air from brake system.
7) Lower vehicle and tighten wheel nut.
Tightening torque:
88±10 N⋅m (9±1 kg-m, 65±7 ft-lb)
8) Sedan:
Install rear seat backrest and rear seat cushion.
Wagon:
Install strut cap of rear quarter trim.
NOTE:
42
10. Rear Crossmember (FWD Model)

A: REMOVAL
G4M0541
쎻
1 Crossmember 쎻
6 Self-locking nut Tightening torque: N⋅m (kg-m, ft-lb)
쎻
7 Front lateral link T1: 44±6 (4.5±0.6, 32.5±4.3)
쎻
3 Adjusting wheel 쎻
8 Washer T2: 127±20 (13.0±2.0, 94±14)
쎻
9 Cap (Protection) T3: 137±20 (14.0±2.0, 101±14)
쎻
5 Rear lateral link
1) Disconnect lateral links from housing.

3) Remove heat-shield cover.
4) Remove four bolts securing crossmember to body.
G4M0542
B: INSPECTION
Check removed parts for wear, damage and cracks, and
correct or replace if defective.
43
C: INSTALLATION
Installation is in reverse order of removal procedure.
CAUTION:
new one.
쐌 Always tighten nut (not adjusting bolt), when tight-
ening adjusting bolt.
쐌 Always tighten rubber bushing when wheels are in
full contact with the ground and vehicle is at curb
weight condition.
NOTE:
44
11. Rear Crossmember (AWD Model)

A: REMOVAL
B4M0572A
쎻
1 Crossmember 쎻
8 Washer Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Floating bushing 쎻
9 Cap (Protection) T1: 25±7 (2.5±0.7, 18.1±5.1)
쎻
10 Trailing link T2: 44±6 (4.5±0.6, 32.5±4.3)
쎻
4 Stopper 쎻
11 Self-locking nut T3: 98±15 (10.0±1.5, 72±11)
쎻
12 Crossmember reinforcement T4: 113±15 (11.5±1.5, 83±11)
T5: 127±20 (13.0±2.0, 94±14)
쎻
6 Rear lateral link lower (Sedan model only) T6: 137±20 (14.0±2.0, 101±14)
쎻
CAUTION:
Do not subject A.B.S. sensor harness to excessive ten-
sion. (A.B.S. equipped models.)
1) Separate front exhaust pipe and rear exhaust pipe.
3) Remove crossmember reinforcement lower.
(Sedan model only)
4) Remove rear differential. <Ref. to 3-4 [W2B0].>
45
5) Place transmission jack under rear crossmember.
G4M0544
6) Remove bolts securing crossmember to vehicle body,

and remove crossmember.
G4M0545
7) Scribe an alignment mark on rear lateral link cam bolt

and crossmember.
8) Remove four bolts securing front and rear lateral links
to crossmember by loosening nuts.
B: INSPECTION
Check removed parts for damage and cracks, and correct
or replace if defective.
C: INSTALLATION
1) Install in reverse order of removal.
2) For installation and tightening torque of rear differential,
refer to 3-4 [W2F0].
CAUTION:
Always tighten rubber bushing when wheels are in full
contact with the ground and vehicle is at curb weight
condition.
NOTE:
46
DIAGNOSTICS 4-1
1. Suspension
1. Suspension
1. IMPROPER VEHICLE POSTURE OR IMPROPER
WHEEL ARCH HEIGHT
Possible causes Countermeasures
(1) Permanent distortion or breakage of coil spring Replace.
(2) Unsmooth operation of damper strut Replace.
(3) Installation of wrong strut Replace with proper parts.
(4) Installation of wrong coil spring Replace with proper parts.
2. POOR RIDE COMFORT

1) Large rebound shock
2) Rocking of vehicle continues too long after running over
bump and/or hump.
3) Large shock in bumping
(1) Breakage of coil spring Replace.
(2) Over-inflation pressure of tire Adjust.
(3) Improper wheel arch height Adjust or replace coil springs with new ones.
(4) Fault in operation of damper strut Replace.
(5) Damage or deformation of strut mount Replace.
(6) Unsuitability of maximum and/or minimum length of
Replace with proper parts.
damper strut
(7) Deformation or loss of bushing Replace.
(8) Deformation or damage of helper in strut assembly Replace.
(9) Oil leakage of damper strut Replace.
3. NOISE
(1) Wear or damage of damper strut component parts Replace.
(2) Loosening of suspension link installing bolt and/or nut Retighten to the specified torque.
(3) Deformation or loss of bushing Replace.
(4) Unsuitability of maximum and/or minimum length of
Replace with proper parts.
damper strut
(5) Breakage of coil spring Replace.
(6) Wear or damage of ball joint Replace.
(7) Deformation of stabilizer clamp Replace.
47
1. Wheels and Axles
1. Wheels and Axles

A: SPECIFICATIONS
1. TIRE AND WHEEL SIZE
G4M0208
Rim offset P.C.D.

Tire size Rim size
mm (in) mm (in)
L
BRIGHTON P185/70R14 87S 14 × 5 1/2JJ 55 (2.17)
Front and Rear POST
2200 cc model LS P195/60R15 87H 15 x 6JJ 55 (2.17)
FWD T125/70D15 15 x 4T 53 (2.09)
T-type tire
AWD T135/70D16 16 x 4T 50 (1.97)
100 (3.94) dia.
LSi P195/60R15 87H 15 x 6JJ 55 (2.17)
Front and Rear GT P205/55R16 89H 16 x 6 1/2JJ 55 (2.17)
OUTBACK P205/70R15 95S 15 x 6JJ 55 (2.17)
2500 cc model
LSi
T135/70D16 16 x 4T 50 (1.97)
T-type tire GT
OUTBACK T135/80D16 16 x 4T 50 (1.97)
NOTE: “T-type” tire for temporary use is supplied as a spare tire.
2. TIRE INFLATION PRESSURE

Tire inflation pressure kPa (kg/cm2, psi)
Tire size
Light load Full load Trailler towing
P185/70R14 87S
Ft: 220 (2.2, 32)
P195/60R15 87H —
Rr: 210 (2.1, 30)
Except OUTBACK model P205/55R16 89H
T125/70D15
420 (4.2, 60) —
T135/70D16
Ft: 200 (2.0, 29) Ft: 200 (2.0, 29)
P205/70R15 95S
OUTBACK model Rr: 190 (1.9, 28) Rr: 220 (2.2, 32)
T135/80D16 420 (4.2, 60) —
2
1. Wheels and Axles
3. FRONT DRIVE SHAFT ASSEMBLY

SHAFT DOJ FTJ
Type of drive shaft No. of

assembly identification No. of spline No. of spline
paddings on teeth teeth
shaft
BJ87L+DOJ82RPC-
1 (One) 25 —
F
BJ87L+FTJ87 0 (None) — 25
UFJ95+DOJ95 3 (Three) 25 —
B4M0772B
3
1. Wheels and Axles
4. REAR DRIVE SHAFT ASSEMBLY (AWD MODEL)

SHAFT
Type of drive shaft assembly
No. of identification paddings on shaft
79AC-RH 1 (One)
79AC-LH 1 (One)
B4M0547A
5. APPLICATION TABLE
Front drive shaft
Model Power unit Rear drive shaft
5MT 4AT
FWD 2200 cc UFJ95+DOJ95 BJ87L+DOJ82RPC-F —
AWD 2200 cc BJ87L+DOJ82RPC-F BJ87L+DOJ82RPC-F 79AC-RH, 79AC-LH
AWD 2500 cc BJ87L+DOJ82RPC-F BJ87L+FTJ87 79AC-RH, 79AC-LH
B: SERVICE DATA
Use specified grease.
Front:
UFJ, BJ — NTG2218 (Part No. 28093AA020)
DOJ (except 2200 cc FWD MT model)
— VU-3A702 (Yellow) (Part No. 23223GA050)
DOJ (2200 cc FWD MT model)
— Molylex No. 2 (Part No. 723223010)
or Sunlight TB2-A
FTJ — SSG 6003 (Part No. 28093TA010)
Rear:
BJ — Molylex No. 2 (Part No. 723223010)
or Sunlight TB2-A
DOJ — VU-3A702 (Yellow) (Part No. 23223GA050)
4
COMPONENT PARTS 4-2
1. Front Axle
1. Front Axle
1. 2200 cc
H4M0999A
쎻
1 Spring pin 쎻
10 Boot (DOJ) 쎻
19 Tone wheel
쎻
2 Baffle plate (DOJ) 쎻
11 Boot (UFJ) 쎻
20 Hub bolt
쎻
3 Outer race (DOJ) 쎻
12 UFJ ASSY 쎻
21 Hub
쎻
4 Snap ring 쎻
13 Baffle plate 쎻
22 Axle nut
쎻
5 Inner race (DOJ) 쎻
14 Oil seal (IN)
쎻
6 Ball 쎻
15 Snap ring Tightening torque: N⋅m (kg-m, ft-lb)
T1: 13±3 (1.3±0.3, 9.4±2.2)
쎻
7 Cage 쎻
16 Bearing
T2: 186±20 (19±2, 137±14)
쎻
8 Circlip 쎻
17 Housing
쎻
9 Boot band 쎻
18 Oil seal (OUT)
5
4-2 COMPONENT PARTS
1. Front Axle
2. 2500 cc
B4M0773A
쎻
1 O-ring 쎻
10 Boot (FTJ) 쎻
19 Tone wheel
쎻
2 Baffle plate (FTJ) 쎻
11 Boot (BJ) 쎻
20 Hub bolt
쎻
3 Spring pin 쎻
12 BJ ASSY 쎻
21 Hub
쎻
4 Outer race (FTJ) 쎻
13 Baffle plate 쎻
22 Axle nut
쎻
5 Snap ring 쎻
14 Oil seal (IN)
쎻
6 Trunnion 쎻
15 Snap ring Tightening torque: N⋅m (kg-m, ft-lb)
T1: 13±3 (1.3±0.3, 9.4±2.2)
쎻
7 Free ring 쎻
16 Bearing
T2: 186±20 (19±2, 137±14)
쎻
8 Circlip 쎻
17 Housing
쎻
9 Boot band 쎻
18 Oil seal (OUT)
6
COMPONENT PARTS 4-2
2. Rear Axle
2. Rear Axle
1. AWD MODEL
B4M0704A
쎻
1 Baffle plate (DOJ) 쎻
10 Boot (BJ) 쎻
19 Hub bolt
쎻
2 Outer race (DOJ) 쎻
11 BJ ASSY 쎻
20 Hub
쎻
3 Snap ring 쎻
12 Oil seal (IN. No. 2) 쎻
21 Axle nut
쎻
4 Inner race 쎻
13 Oil seal (IN. No. 3)
쎻
5 Ball 쎻
14 Housing Tightening torque: N⋅m (kg-m, ft-lb)
쎻
6 Cage 쎻
15 Bearing T1: 13±3 (1.3±0.3, 9.4±2.2)
쎻
7 Circlip 쎻
16 Snap ring T2: 186±20 (19±2, 137±14)
쎻
8 Boot band 쎻
17 Oil seal (OUT)
쎻
9 Boot (DOJ) 쎻
18 Tone wheel
7
4-2 COMPONENT PARTS
2. Rear Axle
2. FWD MODEL
G4M0213
쎻
1 Hub cap 쎻
5 Hub unit Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 O-ring 쎻
6 Spindle T: 186±20 (19±2, 137±14)
쎻
3 Axle nut
쎻
4 Washer
8
1. Front Axle
1. Front Axle
A: REMOVAL
2) Jack-up vehicle, support it with safety stands, and
remove front wheels.
3) Unlock axle nut.

4) Remove axle nut using a socket wrench.
CAUTION:
Be sure to loose and retighten axle nut after removing
wheel from vehicle. Failure to follow this rule may dam-
age wheel bearings.
G4M0214
5) Remove stabilizer link.
G4M0215
6) Remove DOJ from transmission spindle.

7) Remove front drive shaft assembly from hub. If it is hard
to remove, use STs.
ST1 926470000 AXLE SHAFT PULLER
ST2 927140000 PLATE
CAUTION:
쐌 Be careful not to damage oil seal lip when removing
front drive shaft.
쐌 When replacing front drive shaft, also replace inner
G4M0216
oil seal.
8) Remove disc brake caliper from housing, and suspend
it from strut using a wire.
9
1. Front Axle
9) Remove disc rotor from hub.

If disc rotor seizes up within hub, drive disc rotor out by
installing an 8-mm bolt in screw hole on the rotor.
G4M0217
10) Remove cotter pin and castle nut which secure tie-rod
end to housing knuckle arm.
G4M0218
11) Using a puller, remove tie-rod ball joint from knuckle

arm.
G4M0219
12) On A.B.S. equipped models, remove A.B.S. sensor

assembly and harness in advance.
CAUTION:
Be sure to use soft jaws (such as aluminum plates)
when placing the mating surfaces of housing and strut
in a vise.
G4M0220
13) Remove transverse link ball joint from housing.
G4M0221
10
1. Front Axle
14) After scribing an alignment mark on camber adjusting

bolt head, remove bolts which connect housing and strut,
and disconnect housing from strut.
G4M0222
B: DISASSEMBLY
1) Using ST1, support housing and hub securely.
2) Attach ST2 to housing and drive hub out.
ST1 927080000 HUB STAND
ST2 927060000 HUB REMOVER
G4M0223
If inner bearing race remains in the hub, remove it with a

suitable tool (commercially available).
CAUTION:
쐌 Be careful not to scratch polished area of hub.
쐌 Be sure to install inner race on the side of outer race
from which it was removed.
G4M0224
3) Remove disc cover from housing.

4) Using a standard screwdriver, remove outer and inner
oil seals.
CAUTION:
Do not use old oil seals.
G4M0225
11
1. Front Axle
5) Using flat bladed screwdriver, remove snap ring.
H4M1001
6) Using ST1, support housing securely.

7) Using ST2, press inner race to drive out outer bearing.
ST1 927400000 HOUSING STAND
ST2 927100000 BEARING REMOVER
CAUTION:
쐌 Do not remove outer race unless it is faulty.
쐌 Discard outer race after removal.
쐌 Do not replace inner or outer race separately;
always replace as a unit.
G4M0227
8) Loosen bolts which secure tone wheel to hub. Remove
tone wheel (only vehicle equipped with A.B.S.).
9) Using ST and a hydraulic press, drive hub bolts out.

ST 927080000 HUB STAND
CAUTION:
Be careful not to hammer hub bolts. This may deform
hub.
G4M0228
C: INSPECTION
Check the removed parts for wear and damage. If
defective, replace with new ones.
CAUTION:
쐌 If bearing is faulty, replace it as a bearing set.
쐌 Be sure to replace oil seal at every overhaul.
H4M1002A
12
1. Front Axle
D: ASSEMBLY
1) Attach hub to ST securely.
2) Using a hydraulic press, press new hub bolts into place.
CAUTION:
Be sure to press hub bolts until their seating surfaces
contact the hub.
NOTE:
G4M0230 Use 12 mm (0.47 in) dia. holes in HUB STAND to prevent
bolts from tilting.
3) Remove foreign particles (dust, rust, etc.) from mating

surfaces of hub and tone wheel, and install tone wheel to
hub (only vehicle equipped with A.B.S.).
CAUTION:
Be careful not to damage tone wheel teeth.
NOTE:
Ensure tone wheel closely contacts hub.
4) Clean dust or foreign particles from inside the housing.
G4M0231
5) Using ST1 and ST2, press a new bearing into place.

CAUTION:
쐌 Always press outer race when installing bearing.
쐌 Be careful not to remove plastic lock from inner race
when installing bearing.
쐌 Charge bearing with new grease when outer race is
not removed.
G4M0232
6) Install snap ring in its groove.
NOTE:
Make sure to install it firmly to groove.
13
1. Front Axle
7) Using ST1 and ST2, press outer oil seal until it contacts
the bottom of housing.
ST1 927410000 OIL SEAL INSTALLER
G4M0233
8) Using ST1 and ST2, press inner oil seal until it contacts
circlip.
G4M0234
9) Invert ST and housing.

ST 927400000 HOUSING STAND
10) Apply sufficient grease to oil seal lip.
Specified grease:
SHELL 6459N
CAUTION:
쐌 If specified grease is not available, remove bearing
grease and apply Auto Rex A instead.
쐌 Do not mix different types of grease.
11) Install disc cover to housing the three bolts.
Tightening torque:
14±4 N⋅m (1.4±0.4 kg-m, 10.1±2.9 ft-lb)
12) Attach hub to ST1 securely.

13) Clean dust or foreign particles from the polished sur-
face of hub.
14) Using ST2, press bearing into hub by driving inner
race.
ST2 927120000 HUB INSTALLER
G4M0235
14
1. Front Axle
E: INSTALLATION
1) Install transverse link ball joint to housing.
Tightening torque:
44±6 N⋅m (4.5±0.6 kg-m, 32.5±4.3 ft-lb)
2) While aligning alignment mark on camber adjusting bolt
head, connect housing and strut.
CAUTION:
Tightening torque:
147±15 N⋅m (15±1.5 kg-m, 108±11 ft-lb)
3) Install speed sensor and harness on housing (only
vehicle equipped with A.B.S.).
4) Install disc rotor on hub.
5) Install disc brake caliper on housing.
Tightening torque:
59±10 N⋅m (6±1 kg-m, 43±7 ft-lb)
6) Install front drive shaft. <Ref. to 4-2 [W4E1].>
7) Connect stabilizer link.
8) Install tie-rod end ball joint on housing knuckle arm.

Tightening torque:
27.0±2.5 N⋅m (2.75±0.25 kg-m, 19.9±1.8 ft-lb)
G4M0236
9) While depressing brake pedal, tighten axle nut and lock

it securely.
Tightening torque:
186±20 N⋅m (19±2 kg-m, 137±14 ft-lb)
CAUTION:
쐌 Use a new axle nut.
쐌 Always tighten axle nut before installing wheel on
vehicle. If wheel is installed and comes in contact with
ground when axle nut is loose, wheel bearings may be
G4M0237
damaged.
쐌 Be sure to tighten axle nut to specified torque. Do
not overtighten it as this may damage wheel bearing.
15
1. Front Axle - 2. Rear Axle (AWD Model)
10) After tightening axle nut, lock it securely.

11) Install wheel and tighten wheel nuts to specified
torque.
Tightening torque:
88±10 N⋅m (9±1 kg-m, 65±7 ft-lb)
G4M0238
2. Rear Axle (AWD Model)

A: REMOVAL
2) Jack-up vehicle, and remove rear wheel cap and
wheels.
CAUTION:
Be sure to loosen and retighten axle nut after remov-
ing wheel from vehicle. Failure to follow this rule may
damage wheel bearings.
3) Unlock axle nut.
5) Return parking brake lever and loosen adjusting nut.

(1) Disc brake: Perform steps 6) and 7).
(2) Drum brake: Perform steps 8) through 10).
B4M0050A
6) Remove disc brake caliper from back plate, and sus-

pend it from strut using a piece of wire.
NOTE:
If disc rotor seizes up within hub, drive it out by installing
an 8-mm bolt into bolt hole in disc rotor.
G4M0240
16
1. Front Axle - 2. Rear Axle (AWD Model)

torque.
Tightening torque:
88±10 N⋅m (9±1 kg-m, 65±7 ft-lb)
G4M0238

A: REMOVAL
wheels.
CAUTION:
3) Unlock axle nut.

(1) Disc brake: Perform steps 6) and 7).
B4M0050A
6) Remove disc brake caliper from back plate, and sus-

pend it from strut using a piece of wire.
NOTE:
an 8-mm bolt into bolt hole in disc rotor.
G4M0240
16
8) Remove brake drum from hub.
9) If it is difficult to remove brake drum, remove adjusting

hole cover from back plate, and then turn adjusting screw
using a slot-type screwdriver until brake shoe separates
from the drum.
G4M0242
NOTE:
If brake drum is difficult to remove, drive it out by installing
an 8-mm bolt into bolt hole in brake drum.
G4M0243
10) Using a flare-nut wrench, disconnect brake pipe from

wheel cylinder.
CAUTION:
Cover open end of wheel cylinder to prevent entry of
foreign particles.
G4M0244
11) Disconnect parking brake cable end.
G4M0241
17
12) Remove bolts which secure trailing link assembly to

rear housing.
CAUTION:
Discard old self-locking nut. Replace with a new one.
G4M0246
13) Remove bolts which secure lateral link assembly to

rear housing.
CAUTION:
G4M0245
14) Disengage BJ from housing splines, and remove rear

drive shaft assembly. If it is hard to remove, use STs.
ST2 927140000 PLATE
CAUTION:
rear drive shaft.
쐌 When rear drive shaft is to be replaced, also replace
inner oil seal with a new one.
G4M0247
15) Remove rear A.B.S. sensor from back plate (only

vehicle equipped with A.B.S.).
G4M0248
16) Remove bolts which secure rear housing to strut, and

separate the two.
G4M0249
18
B: DISASSEMBLY
1) Using ST1 and ST2, remove hub from rear housing.
ST2 927420000 HUB REMOVER
2) Remove back plate from rear housing.
3) Using a standard screwdriver, remove outer and inner
oil seals.
CAUTION:
G4M0250
Use new oil seals.
4) Using flat bladed screwdriver, remove snap ring.
H4M1003
5) Using ST1 and ST2, remove bearing by pressing inner

race.
CAUTION:
쐌 Do not remove bearing unless damaged.
쐌 Do not re-use bearing after removal.
6) Remove tone wheel bolts and remove tone wheel from
G4M0252
7) Using ST, press hub bolts out.

CAUTION:
Be careful not to hammer hub bolts. This may deform
hub.
G4M0228
C: INSPECTION
Check the removed parts for wear and damage. If
defective, replace with new ones.
CAUTION:
쐌 If a bearing is faulty, replace it as a bearing set.
쐌 Be sure to replace oil seal at every overhaul.
H4M1002A
19
D: ASSEMBLY
1) Using ST, press new hub bolt into place.
CAUTION:
쐌 Ensure hub bolt closely contacts hub.
쐌 Use a 12 mm (0.47 in) hole in the ST to prevent hub
bolt from tilting during installation.
G4M0230
2) Remove foreign particles (dust, rust, etc.) from mating

surfaces of hub and tone wheel, and install tone wheel to
CAUTION:
쐌 Ensure tone wheel closely contacts hub.
쐌 Be careful not to damage tone wheel teeth.
G4M0231
3) Clean housing interior completely. Using ST1 and ST2,

press bearing into housing.
CAUTION:
쐌 Always press outer race when installing bearing.
쐌 Be careful not to remove plastic lock from inner race
when installing bearing.
쐌 Charge bearing with new grease when outer race is
G4M0257
not removed.
4) Install snap ring.
CAUTION:
Ensure snap ring fits in groove properly.
G4M0251
5) Using ST1 and ST2, press outer oil seal until it comes
in contact with snap ring.
G4M0258
20
6) Invert both ST1 and housing.

7) Using ST2, press inner oil seal into housing until it
touches bottom.
G4M0259
8) Using ST1 and ST2, press sub seal into place.

G4M0260
9) Apply sufficient grease to oil seal lip.

Specified grease:
SHELL 6459N
CAUTION:
쐌 If specified grease is not available, remove bearing
grease and apply Auto Rex A instead.
쐌 Do not mix different types of grease.
10) Install back plate to rear housing.

Tightening torque:
52±6 N⋅m (5.3±0.6 kg-m, 38.3±4.3 ft-lb)
G4M0261
11) Using ST1 and ST2, press bearing into hub.

ST2 927450000 HUB INSTALLER
G4M0262
21
E: INSTALLATION
1) Connect rear housing assembly and strut assembly.
CAUTION:
Tightening torque:
147±15 N⋅m (15±1.5 kg-m, 108±11 ft-lb)
2) Fit BJ (bell joint) to rear housing splines.
CAUTION:
Be careful not to damage inner oil seal lip.
3) Connect rear housing assembly to lateral link assembly.

CAUTION:
Tightening torque:
137±20 N⋅m (14±2 kg-m, 101±14 ft-lb)
G4M0245
4) Connect rear housing assembly to trailing link assem-

bly.
CAUTION:
Tightening torque:
98 — 127 N⋅m (10 — 13 kg-m, 72 — 94 ft-lb)
5) Connect parking brake cable to parking brake.
Disc brake: Perform steps 6) through 8).
G4M0246 6) Install disc rotor on rear housing assembly.
7) Install disc brake caliper on back plate.

Tightening torque:
52±6 N⋅m (5.3±0.6 kg-m, 38.3±4.3 ft-lb)
G4M0240
8) Install rear speed sensor to back plate (only vehicle

equipped with A.B.S.).
G4M0266
22
2. Rear Axle (AWD Model) - 3. Rear Axle (FWD Model)
Drum brake: Perform steps 9) through 11).

9) Clean brake pipe connection. Using a flare-nut wrench,
connect brake pipe to wheel cylinder.
10) Connect parking brake cable to lever.
11) Install brake drum on rear housing assembly.
12) Bleed air from brake system. <Ref. to 4-4 [W11B0].>
13) Adjust parking brake lever stroke by turning adjuster.
14) Move brake lever back to apply brakes. While
depressing brake pedal, tighten axle nut using a socket
wrench. Lock axle nut after tightening.
Tightening torque:
186±20 N⋅m (19±2 kg-m, 137±14 ft-lb)
CAUTION:
damaged.
torque.
Tightening torque:
88±10 N⋅m (9±1 kg-m, 65±7 ft-lb)
3. Rear Axle (FWD Model)

A: REMOVAL
wheels.
CAUTION:
3) Pry hub cap off with a screwdriver placed between it
and hub.
4) Unlock axle nut.
5) Remove axle nut using a socket wrench. Remove
washer.
CAUTION:
Do not re-use old axle nut. Replace with a new one.
NOTE:
Temporarily tighten axle nut to hold hub in place.
23
2. Rear Axle (AWD Model) - 3. Rear Axle (FWD Model)

9) Clean brake pipe connection. Using a flare-nut wrench,
connect brake pipe to wheel cylinder.
11) Install brake drum on rear housing assembly.
13) Adjust parking brake lever stroke by turning adjuster.
14) Move brake lever back to apply brakes. While
depressing brake pedal, tighten axle nut using a socket
wrench. Lock axle nut after tightening.
Tightening torque:
186±20 N⋅m (19±2 kg-m, 137±14 ft-lb)
CAUTION:
damaged.
torque.
Tightening torque:
88±10 N⋅m (9±1 kg-m, 65±7 ft-lb)

A: REMOVAL
wheels.
CAUTION:
3) Pry hub cap off with a screwdriver placed between it
and hub.
4) Unlock axle nut.
5) Remove axle nut using a socket wrench. Remove
washer.
CAUTION:
Do not re-use old axle nut. Replace with a new one.
NOTE:
Temporarily tighten axle nut to hold hub in place.
23

(1) Disc brake: Perform steps 7) through 9).
B4M0050A
7) Remove disc brake assembly from back plate. Suspend

disc brake assembly from strut using a wire.
G4M0268

an 8-mm bolt in bolt hole on disc rotor.
9) Disconnect end of parking brake cable.
G4M0269
10) Remove brake drum from hub.
11) If it is difficult to remove brake drum, remove adjusting

hole cover from back plate, and then turn adjusting screw
using a slot-type screwdriver until brake shoe separates
from the drum.
G4M0242
24
NOTE:
If brake drum seizes up within hub, drive it out by installing
an 8-mm bolt in bolt hole on brake drum.
12) Disconnect end of parking brake cable.
13) Using a flare-nut wrench, disconnect brake pipe from
wheel cylinder.
CAUTION:
Cover brake pipe connection to prevent entry of for-
eign particles.
G4M0271

rear spindle.
CAUTION:
G4M0273
15) Remove bolts which secure lateral link assembly to

rear spindle.
CAUTION:
G4M0272
16) Remove bolts which secure strut assembly to rear

spindle.
Remove rear spindle, back plate and hub as a unit.
G4M0249
B: DISASSEMBLY
1) Remove hub from rear spindle.
G4M0275
25
2) Remove back plate from rear spindle.
G4M0276
3) Using ST, press hub bolts out.

CAUTION:
Do not hammer hub bolt since this may deform hub.
G4M0277
C: INSPECTION
Clean the removed parts and check them for wear, dam-
age and corrosion. If faulty, replace.
CAUTION:
Hub unit cannot be disassembled. If faulty, replace it
as a unit.
D: ASSEMBLY
1) Using ST, press new hub bolts into place.
NOTE:
쐌 Use a 12 mm (0.47 in) hole in ST to prevent hub bolt
from tilting during installation.
쐌 Ensure hub bolt closely contacts hub.
G4M0278
2) Completely clean dust or dirt from the mating/polished

surface of rear spindle back plate.
3) Install back plate to rear spindle.
Tightening torque:
52±6 N⋅m (5.3±0.6 kg-m, 38.3±4.3 ft-lb)
4) Charge oil seal located on the rear of hub with grease.
Specified grease:
SHELL 6459N
26
5) Install hub on rear spindle. Temporarily tighten axle nut

and washer to hold hub in place.
CAUTION:
Discard old axle nut. Replace with a new one.
G4M0275
E: INSTALLATION
1) Connect rear spindle assembly to strut assembly.
Tightening torque:
147±15 N⋅m (15±1.5 kg-m, 108±11 ft-lb)
CAUTION:
2) Connect rear spindle assembly to lateral link assembly.

Tightening torque:
137±20 N⋅m (14±2 kg-m, 101±14 ft-lb)
CAUTION:
Use new self-locking nut.
G4M0272
3) Connect rear spindle assembly to trailing link assembly.

Tightening torque:
113±15 N⋅m (11.5±1.5 kg-m, 83±11 ft-lb)
CAUTION:
Disc brake: Perform steps 4) through 6).
4) Connect end of parking brake cable.
5) Install disc rotor to hub unit.
6) Install disc brake assembly to back plate.
Tightening torque:
52±6 N⋅m (5.3±0.6 kg-m, 38.3±4.3 ft-lb)
7) Completely clean brake pipe connection. Using a flare-
nut wrench, connect brake pipe to wheel cylinder.
9) Install brake drum on hub unit.
11) Tighten axle nut using a socket wrench, and lock
securely.
27
3. Rear Axle (FWD) - 4. Front and Rear Drive Shafts
Tightening torque:
186±20 N⋅m (19±2 kg-m, 137±14 ft-lb)
CAUTION:
damaged.
12) Install O-ring to hub cap flange, and install hub cap by
lightly tapping it with a plastic-faced hammer.
torque.
Tightening torque (Wheel nut):
88±10 N⋅m (9±1 kg-m, 65±7 ft-lb)
4. Front and Rear Drive Shafts

A: REMOVAL
1. FRONT DRIVE SHAFT
racks), and remove front wheel cap and wheels.
3) Unlock axle nut.
4) While depressing brake pedal, remove axle nut using a
socket wrench.
CAUTION:
5) Disconnect stabilizer link from transverse link.
6) Disconnect transverse link from housing.
7) Remove spring pin which secures transmission spindle

to DOJ.
CAUTION:
Use a new spring pin.
G4M0279
28
8) Remove front drive shaft assembly. If it is hard to

remove, use ST1 and ST2.
ST2 927140000 PLATE
CAUTION:
front drive shaft.
쐌 When front drive shaft is to be replaced, also replace
inner oil seal.
G4M0216
2. REAR DRIVE SHAFT

2) Lift-up vehicle, and remove rear wheel cap and wheels.
CAUTION:
3) Unlock axle nut.
4) Loosen axle nut using a socket wrench.
CAUTION:
Do not remove axle nut.
5) Remove A.B.S. sensor clamps and parking brake cable
bracket.
6) Remove bolts which secure lateral link assembly to rear
housing.
CAUTION:
rear housing.
CAUTION:
8) Remove crossmember reinforcement lower from cross-
member (4 door model only).
9) Remove DOJ from rear differential using ST.

ST 28099PA100 DRIVE SHAFT REMOVER
CAUTION:
Do not remove circlip attached to inside of differential.
G4M0994
29
CAUTION:
Be careful not to damage side bearing retainer. Always
use bolt as shown in figure, as supporting point for ST
during removal.
G4M0995
10) Remove axle nut and drive shaft. If it is hard to

remove, use ST1 and ST2.
ST2 927140000 PLATE
CAUTION:
rear drive shaft.
쐌 When rear drive shaft is to be replaced, also replace
inner oil seal with a new one.
G4M0247
B: DISASSEMBLY
1. AWD MODEL
1) Straighten bent claw of larger end of DOJ boot.
2) Loosen band by means of screwdriver or pliers with
care of not damaging boot.
3) Remove boot band on the small end of DOJ boot in the
same manner.
4) Remove the larger end of DOJ boot from DOJ outer
race.
G4M0281
5) Pry and remove round circlip located at the neck of DOJ

outer race with a screwdriver.
G4M0282
6) Take out DOJ outer race from shaft assembly.

7) Wipe off grease and take out balls.
CAUTION:
The grease is a special grease (grease for constant
velocity joint). Do not confuse with other greases.
NOTE:
Disassemble exercising care not to lose balls (6 pcs).
쎻1 Outer race
쎻2 Grease
B4M0227A
30
8) To remove the cage from the inner race, turn the cage
by a half pitch to the track groove of the inner race and shift
the cage.
9) Remove snap ring, which fixes inner race to shaft, by
using pliers.
10) Take out DOJ inner race.
11) Take off DOJ cage from shaft and remove DOJ boot.
CAUTION:
Be sure to wrap shaft splines with vinyl tape to prevent
boot from scratches.
12) Remove UFJ/BJ boot in the same procedure as steps
1) to 3).
13) Thus, disassembly of axle is completed, but UFJ/BJ is
unable to be disassembled.
2. FWD MODEL
1) Remove both DOJ boot bands.
2) Loosen band by means of screwdriver or pliers taking
care to not damage the boot.
3) Remove the larger end of DOJ boot from DOJ outer
race.
G4M0281
4) Pry and remove round circlip located at the neck of DOJ

outer race with a screwdriver.
5) Take out DOJ outer race from shaft assembly.

G4M0282
6) Wipe off grease and take out balls.
CAUTION:
The grease is a special grease (grease for constant
velocity joint). Do not confuse with other greases.
NOTE:
Disassemble exercising care not to lose balls (6 pcs).
쎻1 Outer race
쎻2 Grease
NOTE:
Clean all parts as necessary.
B4M0227A
31
7) To remove the cage from the inner race, turn the cage
by a half pitch to the track groove of the inner race and shift
the cage.
8) Remove snap ring, which holds the inner race to shaft,
by using pliers.
9) Take out DOJ inner race.
10) Take off DOJ cage from shaft and remove DOJ boot.
CAUTION:
Be sure to wrap shaft splines with vinyl tape to protect
the boot from scratches.
11) Place drive shaft in a vise between wooden blocks.
CAUTION:
Do not place drive shaft directly in the vise; use
wooden block.
12) Raise boot band claws by means of screwdriver and

hammer.
B4M0689A
13) Cut and remove the boot.

CAUTION:
The boot must be replaced with a new one whenever
it is removed.
14) Thus, disassembly of axle is completed, but UFJ can-
not be disassembled.
B4M0690
32
3. FTJ (Free-ring Tripod Joint)

1) Place alignment marks on shaft and outer race.
B4M0774
2) Remove FTJ boot band and boot.

CAUTION:
Be careful not to damage boot.
B4M0775A
3) Remove circlip from FTJ outer race using screwdriver.

4) Remove FTJ outer race from shaft assembly.
5) Wipe off grease.
CAUTION:
The grease is a special grease. Do not confuse with
other greases.
B4M0776
6) Place alignment mark on free ring and trunnion.

7) Remove free ring from trunnion.
B4M0777
33
8) Place alignment mark on trunnion and shaft.
B4M0778
9) Remove snap ring and trunnion.

CAUTION:
10) Remove FTJ boot.
11) Remove BJ boot band and boot.
B4M0779
C: INSPECTION
Check the removed parts for damage, wear, corrosion and
etc. If faulty, repair or replace.
1) DOJ (Double Offset Joint)
Check seizure, corrosion, damage, wear and excessive
play.
2) Shaft
Check excessive bending, twisting, damage and wear.
3) UFJ (Under cut Free Joint)
Check seizure, corrosion, damage and excessive play.
4) Boot
Check for wear, warping, breakage or scratches.
5) Grease
Check for discoloration or fluidity.
34
D: ASSEMBLY
1. AWD MODEL
UFJ/BJ side:
UFJ (Front) — NTG2218 (Part No. 28093AA020)
BJ (Rear) — Molylex No. 2 (Part No. 723223010) or
Sunlight TB2-A
DOJ side:
AT model (Front and Rear) and MT model (Rear)
— VU-3A702 (Yellow)
(Part No. 23223GA050)
MT model (Front) — Molylex No. 2 (Part No.
723223010) or Sunlight TB2-A
1) Install BJ boot in specified position, and fill it with 60 to
70 g (2.12 to 2.47 oz) of specified grease.
2) Place DOJ boot at the center of shaft.
CAUTION:
3) Insert DOJ cage onto shaft.

NOTE:
Insert the cage with the cut-out portion facing the shaft end,
since the cage has an orientation.
G4M0284
4) Install DOJ inner race on shaft and fit snap ring with
pliers.
NOTE:
Confirm that the snap ring is completely fitted in the shaft
groove.
G4M0285
5) Install cage, which was previously fitted, to inner race

fixed upon shaft.
NOTE:
Fit the cage with the protruded part aligned with the track
on the inner race and then turn by a half pitch.
쎻1 Inner race
쎻2 Cage
B4M0228A
35
6) Fill 80 to 90 g (2.82 to 3.17 oz) of specified grease into

the interior of DOJ outer race.
7) Apply a coat of specified grease to the cage pocket and
six balls.
8) Insert six balls into the cage pocket.
9) Align the outer race track and ball positions and place
in the part where shaft, inner race, cage and balls are pre-
viously installed, and then fit outer race.
쎻1 Outer race
B4M0227A 쎻2 Grease
10) Install circlip in the groove on DOJ outer race.

NOTE:
쐌 Assure that the balls, cage and inner race are com-
pletely fitted in the outer race of DOJ.
쐌 Exercise care not to place the matched position of circlip
in the ball groove of outer race.
쐌 Pull the shaft lightly and assure that the circlip is com-
pletely fitted in the groove.
G4M0282
11) Apply an even coat of the specified grease [20 to 30 g

(0.71 to 1.06 oz)] to the entire inner surface of boot. Also
apply grease to shaft.
12) Install DOJ boot taking care not to twist it.
NOTE:
쐌 The inside of the larger end of DOJ boot and the boot
groove shall be cleaned so as to be free from grease and
other substances.
쐌 When installing DOJ boot, position outer race of DOJ at
center of its travel.
13) Put a band through the clip and wind twice in align-
ment with band groove of boot.
CAUTION:
Use a new band.
14) Pinch the end of band with pliers. Hold the clip and
tighten securely.
NOTE:
When tightening boot, exercise care so that the air within
the boot is appropriate.
15) Tighten band by using ST.

ST 925091000 BAND TIGHTENING TOOL
NOTE:
Tighten band until it cannot be moved by hand.
G4M0289
36
16) Tap on the clip with the punch provided at the end of
ST.
CAUTION:
Tap to an extent that the boot underneath is not dam-
aged.
G4M0290
17) Cut off band with an allowance of about 10 mm (0.39

in) left from the clip and bend this allowance over the clip.
CAUTION:
Be careful so that the end of the band is in close con-
tact with clip.
18) Fix up boot on BJ and UFJ in the same manner.
NOTE:
Extend and retract DOJ to provide equal grease coating.
2. FWD MODEL
UFJ side:
UFJ (Front) — NTG2218 (Part No. 28093AA020)
DOJ side:
AT model (Front) — VU-3A702 (Yellow) (Part No.
23223GA050)
MT model (Front) — Molylex No. 2 (Part No.
723223010) or Sunlight TB2-A
1) Place UFJ boot and small boot band on UFJ side of
shaft.
CAUTION:
2) Place drive shaft in a vise.
CAUTION:
Do not place drive shaft directly in the vise; use
wooden blocks.
3) Apply a coat of specified grease [60 to 70 g (2.12 to
2.47 oz)] to UFJ.
4) Apply an even coat of specified grease [20 to 30 g (0.71
to 1.06 oz)] to the entire inner surface of boot. Also apply
grease to shaft.
NOTE:
The inside of the larger end of UFJ boot and the boot
other substances.
37
5) Install boot projecting portion to UFJ groove.

쎻1 UFJ
쎻2 Large boot band
쎻3 Boot
6) Set large boot band in place.
B4M0691A
7) Align the boot end of the smaller diameter with the 3rd
groove in the drive shaft as shown in the figure.
쎻1 Boot
쎻2 Small boot band
쎻3 Shaft
B4M0692A
8) Tighten boot bands using ST, torque wrench and socket

flex handle.
ST 28099AC000 BOOT BAND PLIER
쎻1 Large boot band
쎻2 Boot
쎻3 Torque wrench
쎻4 Socket flex handle
쎻5 UFJ
B4M0693A
Tightening torque:
Large boot band
152 N⋅m (16.0 kg-m, 116 ft-lb) or more
Small boot band
133 N⋅m (13.6 kg-m, 98 ft-lb) or more
9) Place DOJ boot at the center of shaft.
10) Insert DOJ cage onto shaft.

NOTE:
Insert the cage with the cut-out portion facing the shaft end,
since the cage is directional.
G4M0284
38
11) Install DOJ inner race on shaft and fit snap ring with
pliers.
NOTE:
Confirm that the snap ring is completely fitted in the shaft
groove.
G4M0285
12) Install cage, which was previously fitted, to inner race

fixed upon shaft.
NOTE:
Fit the cage with the protruded part aligned with the track
on the inner race and then turn by a half pitch.
쎻1 Inner race
쎻2 Cage
B4M0228A
13) Put 80 to 90 g (2.82 to 3.17 oz) of specified grease into

the interior of DOJ outer race.
14) Apply a coat of specified grease to the cage pocket
and six balls.
15) Insert six balls into the cage pocket.
16) Align the outer race track and ball positions and place
in the part where shaft, inner race, cage and balls are pre-
viously installed, and then fit outer race.
쎻1 Outer race
B4M0227A 쎻2 Grease
17) Install circlip in the groove on DOJ outer race.

NOTE:
쐌 Assure that the balls, cage and inner race are com-
pletely fitted in the outer race of DOJ.
쐌 Exercise care not to match the open end of circlip in the
ball groove of outer race.
쐌 Pull the shaft lightly and assure that the circlip is com-
G4M0282
18) Apply an even coat of specified grease [20 to 30 g

(0.71 to 1.06 oz)] to the entire inner surface of boot. Also
apply grease to shaft.
19) Install DOJ boot taking care not to twist it.
NOTE:
쐌 The inside of the larger end of DOJ boot and the boot
other substances.
쐌 When installing DOJ boot, position outer race of DOJ at
center of its travel.
39
CAUTION:
Use a new band.
tighten securely.
NOTE:

NOTE:
G4M0289
ST.
CAUTION:
Tap only to the extent that the boot underneath is not
damaged.
G4M0290

CAUTION:
Be careful so that the end of the band is in close con-
tact with clip.
25) Fix up boot on UFJ in the same manner.
NOTE:
Extend and retract DOJ to provide equal grease coating.
40
3. FTJ
CAUTION:
BJ side:
NTG2218 (Part No. 28093AA020)
FTJ side:
SSG 6003
CAUTION:
1) Install BJ boot in specified position and fill it with 60 to
70 g (2.12 to 2.47 oz) of specified grease.
CAUTION:
The inside of the larger end of BJ boot and the boot
groove must be cleaned so as to be free from grease
and other substances.
2) Place FTJ boot at the center of shaft.
3) Align alignment marks and install trunnion on shaft.

4) Install snap ring to shaft.
CAUTION:
Confirm that the snap ring is completely fitted in the
shaft groove.
5) Fill 100 to 110 g (3.53 to 3.88 oz) of specified grease
into the interior of FTJ outer race.
6) Apply a coat of specified grease to free ring and trun-
nion.
B4M0778
7) Align alignment marks on free ring and trunnion and

install free ring.
B4M0777
41
8) Align alignment marks on shaft and outer race, and

install outer race.
9) Install circlip in the groove on FTJ outer race.
CAUTION:
Pull the shaft lightly and assure that the circlip is com-
10) Apply an even coat of the specified grease 30 to 40 g
(1.06 to 1.41 oz) to the entire inner surface of boot.
11) Install FTJ boot taking care not to twist it.
B4M0774
CAUTION:
쐌 The inside of the larger end of FTJ boot and the boot
groove shall be cleaned so as to be free from grease
and other substances.
쐌 When installing FTJ boot, position outer race of DOJ
at center of its travel.
CAUTION:
Use a new band.
tighten securely.
NOTE:

NOTE:
G4M0289
ST.
CAUTION:
Tap to an extent that the boot underneath is not dam-
aged.
G4M0290
42

CAUTION:
Be careful to that the end of the band is in close con-
tact with clip.
17) Fix up boot on BJ in the same manner.
NOTE:
Extend and retract FTJ to provide equal grease coating.
E: INSTALLATION
1. FRONT DRIVE SHAFT
1) Insert UFJ (Under cut Free Joint) into hub splines.
CAUTION:
2) Using ST1 and ST2, pull drive shaft into place.
ST1 922431000 AXLE SHAFT INSTALLER
ST2 927390000 ADAPTER
G4M0291 CAUTION:
Do not hammer drive shaft when installing it.
3) Tighten axle nut temporarily.
4) Install DOJ on transmission spindle and drive spring pin

into place.
CAUTION:
Always use a new spring pin.
G4M0279
43
5) Connect transverse link to housing.

Tightening torque (self-locking nut):
49±10 N⋅m (5.0±1.0 kg-m, 36±7 ft-lb)
CAUTION:
6) Install stabilizer bracket.
7) While depressing brake pedal, tighten axle nut to the
specified torque.
Tightening torque:
186±20 N⋅m (19±2 kg-m, 137±14 ft-lb)
CAUTION:
damaged.
2. REAR DRIVE SHAFT

1) Insert BJ into rear housing splines.
CAUTION:
2) Using ST1 and ST2, pull drive shaft into place.
ST1 922431000 AXLE SHAFT INSTALLER
ST2 927390000 ADAPTER
CAUTION:
Do not hammer drive shaft when installing it.
G4M0293
3) Tighten axle nut temporarily.
4) Using ST, install DOJ into differential.
ST 28099PA090 SIDE OIL SEAL PROTECTOR
B4M0549A
5) Insert DOJ spline end into bore of side oil seal, and
remove ST.
CAUTION:
Do not allow DOJ splines to damage side oil seal.
B4M0550A
44
6) Align DOJ and differential splines.

7) Push housing to insert DOJ into differential.
NOTE:
Make sure DOJ is inserted properly.
G3M0050
8) Connect crossmember reinforcement lower to cross-

9) Connect rear housing assembly to trailing link
assembly, and tighten self-locking nut.
Tightening torque:
113±15 N⋅m (11.5±1.5 kg-m, 83±11 ft-lb)
10) Connect rear housing assembly to lateral link
Tightening torque:
137±20 N⋅m (14±2 kg-m, 101±14 ft-lb)
11) Install stabilizer bracket.
12) While depressing brake pedal, tighten axle nut using
a socket wrench.
Tightening torque:
186±20 N⋅m (19±2 kg-m, 137±14 ft-lb)
CAUTION:
damaged.
45
5. Replacement of Front DOJ and UFJ Boots
5. Replacement of Front DOJ and UFJ

Boots
A: REMOVAL
rocks), and remove front wheel cap and wheels.
NOTE:

to DOJ.
CAUTION:
6) Remove DOJ and UFJ boot from drive shaft.
<Ref. to 4-2 [W4B0].>
G4M0279
B: INSTALLATION
1) Install DOJ and UFJ boots to drive shaft.
<Ref. to 4-2 [W4D0].>
2) Install DOJ on transmission spindle and drive spring pin

into place.
CAUTION:
4) Install stabilizer link.
G4M0279
46
6. Replacement of Rear DOJ and BJ Boots
6. Replacement of Rear DOJ and BJ

Boots
A: REMOVAL
2) Lift-up vehicle, and remove rear wheel cap and wheels.
NOTE:
Axle nut need not be removed.
3) Remove A.B.S. sensor clamps and parking brake cable
bracket.
4) Disconnect stabilizer link from lateral link.
5) Remove bolts which secure lateral link assembly to rear
housing.
rear housing.
7) Remove crossmember reinforcement lower from cross-
8) Remove DOJ from rear differential using ST.

NOTE:
The side spline shaft circlip comes out together with the
shaft.
G4M0994
CAUTION:
Be careful not to damage side bearing retainer. Always
use bolt as shown in figure, as supporting point for ST
during removal.
G4M0995
B: INSTALLATION
1) Install DOJ and BJ boots to drive shaft.
<Ref. to 4-2 [W4D0].>
47
6. Replacement of Rear DOJ and BJ Boots
2) Using ST, install DOJ into differential.

B4M0549A
3) Insert DOJ spline end into bore of side oil seal, and
remove ST.
CAUTION:
Do not allow DOJ splines to damage side oil seal.
B4M0550A
4) Align DOJ and differential splines.

5) Push housing to insert DOJ into differential.
NOTE:
Make sure DOJ is inserted properly.
G3M0050
CAUTION:
6) Connect rear housing assembly to trailing link
7) Connect rear housing assembly to lateral link assembly,
and tighten self-locking nut.
8) Connect stabilizer link to lateral link.
9) Install crossmember reinforcement lower to crossmem-
ber (4 door model only).
10) Install A.B.S. sensor clamps and parking brake cable
bracket.
48
7. Full Wheel Cap - 8. Steel Wheel and Tire
7. Full Wheel Cap

A: REMOVAL
Pry off the full wheel cap with a wheel cap remover inserted
between openings in the cap.
B4M0051
B: INSTALLATION
Align the valve hole in the wheel cap with the valve on the
wheel and secure the wheel cap by tapping four points by
hand.
8. Steel Wheel and Tire

1) Deformation or damage on the rim can cause air leak-
age. Check the rim flange for deformation, crack, or
damage, and repair or replace as necessary.
2) Take stone, glass, nail etc. off the tread groove.
3) Replace tire:
쐌 when large crack on side wall, damage or crack on
tread is found.
쐌 when the “tread wear indicator” appears as a solid
band across the tread.
CAUTION:
쐌 When replacing a tire, make sure to use only the
same size, construction and load range as originally
installed.
G4M0297
쐌 Avoid mixing radial, belted bias or bias tires on the
vehicle.
49
7. Full Wheel Cap - 8. Steel Wheel and Tire
7. Full Wheel Cap

A: REMOVAL
Pry off the full wheel cap with a wheel cap remover inserted
between openings in the cap.
B4M0051
B: INSTALLATION
Align the valve hole in the wheel cap with the valve on the
wheel and secure the wheel cap by tapping four points by
hand.
8. Steel Wheel and Tire

1) Deformation or damage on the rim can cause air leak-
age. Check the rim flange for deformation, crack, or
damage, and repair or replace as necessary.
2) Take stone, glass, nail etc. off the tread groove.
3) Replace tire:
쐌 when large crack on side wall, damage or crack on
tread is found.
쐌 when the “tread wear indicator” appears as a solid
band across the tread.
CAUTION:
쐌 When replacing a tire, make sure to use only the
same size, construction and load range as originally
installed.
G4M0297
쐌 Avoid mixing radial, belted bias or bias tires on the
vehicle.
49
8. Steel Wheel and Tire - 9. Aluminum Wheel
A: INSPECTION OF WHEEL RUNOUT

1) Jack-up vehicle until wheels clear the floor.
2) Slowly rotate wheel to check rim “runout” using a dial
gauge.
G4M0298
Axial runout limit Radial runout limit
Steel wheel 1.5 mm (0.059 in)
Aluminum wheel 1.0 mm (0.039 in)
3) If rim runout exceeds specifications, remove tire from

rim and check runout while attaching dial gauge to posi-
tions shown in figure.
4) If measured runout still exceeds specifications, replace
the wheel.
G4M0299
9. Aluminum Wheel
A: INSPECTION
Inspection for aluminum wheels is basically the same as
the one for steel wheels. However, check the rim flange for
cracks or damage, and replace (not repair) aluminum
wheel if air leakage is found.
B: PRECAUTIONS
Aluminum wheels are easily scratched. To maintain their
appearance and safety, do the following:
1) Do not damage aluminum wheels during removal,
disassembly, installation, wheel balancing, etc. After
removing aluminum wheels, place them on a rubber mat,
etc.
2) While vehicle is being driven, be careful not to ride over
sharp obstacles or allow aluminum wheels to contact the
shoulder of the road.
3) When installing tire chain, be sure to install it properly
not to have a slack; otherwise it may hit wheel while driv-
ing.
4) When washing aluminum wheel, use neutral synthetic
detergent and water. Avoid using the cleanser including
abrasive, hard brushes or an automatic car washer.
50
8. Steel Wheel and Tire - 9. Aluminum Wheel
A: INSPECTION OF WHEEL RUNOUT

1) Jack-up vehicle until wheels clear the floor.
2) Slowly rotate wheel to check rim “runout” using a dial
gauge.
G4M0298
Axial runout limit Radial runout limit
Steel wheel 1.5 mm (0.059 in)
Aluminum wheel 1.0 mm (0.039 in)
3) If rim runout exceeds specifications, remove tire from

rim and check runout while attaching dial gauge to posi-
tions shown in figure.
4) If measured runout still exceeds specifications, replace
the wheel.
G4M0299
9. Aluminum Wheel
A: INSPECTION
Inspection for aluminum wheels is basically the same as
the one for steel wheels. However, check the rim flange for
cracks or damage, and replace (not repair) aluminum
wheel if air leakage is found.
B: PRECAUTIONS
Aluminum wheels are easily scratched. To maintain their
appearance and safety, do the following:
1) Do not damage aluminum wheels during removal,
disassembly, installation, wheel balancing, etc. After
removing aluminum wheels, place them on a rubber mat,
etc.
2) While vehicle is being driven, be careful not to ride over
sharp obstacles or allow aluminum wheels to contact the
shoulder of the road.
3) When installing tire chain, be sure to install it properly
not to have a slack; otherwise it may hit wheel while driv-
ing.
4) When washing aluminum wheel, use neutral synthetic
detergent and water. Avoid using the cleanser including
abrasive, hard brushes or an automatic car washer.
50
10. Wheel Balancing - 11. Installation of Wheel Assembly to Vehicle
10. Wheel Balancing

1) Proper wheel balance may be lost if the tire is repaired
or if it wears. Check the tire for dynamic balance, and repair
as necessary.
2) To check for dynamic balance, use a dynamic balancer.
Drive in the balance weight on both the top and rear sides
of the rim.
3) Some types of balancer can cause damage to the
wheel. Use an appropriate balancer when adjusting the
wheel balance.
4) Use genuine balance weights.
Service limit: A
Weight for steel wheel;
1.6 — 2.0 mm (0.063 — 0.079 in)
Weight for aluminum wheel;
4.6 — 5.4 mm (0.181 — 0.213 in)
CAUTION:
쐌 55 g (1.94 oz) weight used with aluminum wheel is
not available.
쐌 Balance weights are available for use with any of 14-
B4M0053A
to 15-inch wheels.
11. Installation of Wheel Assembly to

Vehicle
1) Attach the wheel to the hub by aligning the wheel bolt
hole with the hub bolt.
2) Temporarily attach the wheel nuts to the hub bolts. (In
the case of aluminum wheel, use SUBARU genuine wheel
nut for aluminum wheel.)
3) Manually tighten the nuts making sure the wheel hub
hole is aligned correctly to the guide portion of hub.
4) Tighten the wheel nuts in a diagonal selection to the
specified torque. Use a wheel nut wrench.
Wheel nut tightening torque:
88±10 N⋅m (9±1 kg-m, 65±7 ft-lb)
CAUTION:
쐌 Tighten the wheel nuts in two or three steps by
gradually increasing the torque and working
diagonally, until the specified torque is reached. For
drum brake models, excess tightening of wheel nuts
may cause wheels to “judder”.
쐌 Do not depress the wrench with a foot; Always use
both hands when tightening.
쐌 Make sure the bolt, nut and the nut seating surface
of the wheel are free from oils.
5) If a wheel is removed for replacement or for repair of a
puncture, retighten the wheel nuts to the specified torque
after running 1,000 km (600 miles).
51
10. Wheel Balancing - 11. Installation of Wheel Assembly to Vehicle
10. Wheel Balancing

1) Proper wheel balance may be lost if the tire is repaired
or if it wears. Check the tire for dynamic balance, and repair
as necessary.
2) To check for dynamic balance, use a dynamic balancer.
Drive in the balance weight on both the top and rear sides
of the rim.
3) Some types of balancer can cause damage to the
wheel. Use an appropriate balancer when adjusting the
wheel balance.
4) Use genuine balance weights.
Service limit: A
Weight for steel wheel;
1.6 — 2.0 mm (0.063 — 0.079 in)
Weight for aluminum wheel;
4.6 — 5.4 mm (0.181 — 0.213 in)
CAUTION:
쐌 55 g (1.94 oz) weight used with aluminum wheel is
not available.
쐌 Balance weights are available for use with any of 14-
B4M0053A
to 15-inch wheels.
11. Installation of Wheel Assembly to

Vehicle
1) Attach the wheel to the hub by aligning the wheel bolt
hole with the hub bolt.
2) Temporarily attach the wheel nuts to the hub bolts. (In
the case of aluminum wheel, use SUBARU genuine wheel
nut for aluminum wheel.)
3) Manually tighten the nuts making sure the wheel hub
hole is aligned correctly to the guide portion of hub.
4) Tighten the wheel nuts in a diagonal selection to the
specified torque. Use a wheel nut wrench.
Wheel nut tightening torque:
88±10 N⋅m (9±1 kg-m, 65±7 ft-lb)
CAUTION:
쐌 Tighten the wheel nuts in two or three steps by
gradually increasing the torque and working
diagonally, until the specified torque is reached. For
drum brake models, excess tightening of wheel nuts
may cause wheels to “judder”.
쐌 Do not depress the wrench with a foot; Always use
both hands when tightening.
쐌 Make sure the bolt, nut and the nut seating surface
of the wheel are free from oils.
5) If a wheel is removed for replacement or for repair of a
puncture, retighten the wheel nuts to the specified torque
after running 1,000 km (600 miles).
51
12. Tire Rotation - 13. “T-type” Tire
12. Tire Rotation

If tires are maintained at the same positions for a long
period of time, uneven wear results. Therefore, they should
be periodically rotated.
This lengthens service life of tires.
CAUTION:
When rotating tires, replace unevenly worn or dam-
aged tires with new ones.
G4M0301
13. “T-type” Tire

“T-type” tire for temporary use is prepared as a spare tire.
CAUTION:
쐌 Keep the inflation pressure at 420 kPa (4.2 kg/cm2,
60 psi) at all times.
쐌 When the wear indicator appears on the tread
surface, replace the tire with a new one.
쐌 Do not use a tire chain with the “T-type” tire.
Because of the smaller tire size, a tire chain will not fit
properly and will result in damage to the vehicle and
the tire.
쐌 Do not drive at a speed greater than 80 km/h (50
MPH).
쐌 Drive as slowly as possible and avoid passing over
bumps.
쐌 Replace with a conventional tire as soon as possible
since this “T-type” tire is only for temporary use.
52
12. Tire Rotation - 13. “T-type” Tire
12. Tire Rotation

If tires are maintained at the same positions for a long
period of time, uneven wear results. Therefore, they should
be periodically rotated.
This lengthens service life of tires.
CAUTION:
When rotating tires, replace unevenly worn or dam-
aged tires with new ones.
G4M0301
13. “T-type” Tire

“T-type” tire for temporary use is prepared as a spare tire.
CAUTION:
쐌 Keep the inflation pressure at 420 kPa (4.2 kg/cm2,
60 psi) at all times.
쐌 When the wear indicator appears on the tread
surface, replace the tire with a new one.
쐌 Do not use a tire chain with the “T-type” tire.
Because of the smaller tire size, a tire chain will not fit
properly and will result in damage to the vehicle and
the tire.
쐌 Do not drive at a speed greater than 80 km/h (50
MPH).
쐌 Drive as slowly as possible and avoid passing over
bumps.
쐌 Replace with a conventional tire as soon as possible
since this “T-type” tire is only for temporary use.
52
14. Replacement of Front FTJ and BJ Boots
14. Replacement of Front FTJ and BJ

Boots
A: REMOVAL
rocks), and remove front wheel cap and wheels.
NOTE:

to FTJ.
CAUTION:
6) Remove FTJ and BJ boot from drive shaft.
<Ref. to 4-2 [W4B3].>
G4M0279
B: INSTALLATION
1) Install FTJ and BJ boots to drive shaft.
<Ref. to 4-2 [W4D3].>
2) Install FTJ on transmission spindle and drive spring pin

into place.
CAUTION:
4) Install stabilizer link.
G4M0279
53
1. Steering System
1. Steering System
A: SPECIFICATIONS
Except OUTBACK model OUTBACK model
Minimum turning radius m (ft) 5.3 (17.4) 5.6 (18.4)
Steering angle (Inside-Outside) 37.6° — 32.6° 34.4° — 30.2°
Whole system
Steering wheel diameter mm (in) 385 (15.16)
Overall gear ratio (Turns, lock to lock) 16.5 (3.2) 19 (3.4)
Type Rack and pinion, Integral
Gearbox Backlash 0 (Automatically adjustable)
Valve (Power steering system) Rotary valve
Type Vane pump
Oil tank Installed on pump
3
Output cm (cu in)/rev. 7.2 (0.439)
2
Relief pressure kPa (kg/cm , psi) 7,355 (75, 1,067)
Pump (Power steering Dropping in response to increased engine
system) Hydraulic fluid control
revolutions
1,000 rpm: 7 (7.4, 6.2)
Hydraulic fluid (US qt, Imp qt)
3,000 rpm: 5 (5.3, 4.4)
Range of revolution rpm 500 — 7,500
Revolving direction Clockwise
Name ATF DEXRON II, IIE or III
Working fluid (Power
steering system) Capacity Oil tank (US qt, Imp qt) 0.35 (0.4, 0.3)
Total 0.7 (0.7, 0.6)
2
1. Steering System
B: SERVICE DATA
Except OUTBACK model OUTBACK model
Steering wheel Free play mm (in) 17 (0.67)
Inner tire & wheel 37.6° 34.4°
Turning angle
Outer tire & wheel 32.6° 30.2°
Clearance between steering
Steering shaft wheel and column cover 3.0 (0.118)
mm (in)
Sliding resistance N (kg, lb) 240.3 (24.5, 54.0) or less
Rack shaft play in radial direc-
0.15 (0.0059) or less
tion
mm (in)
Right-turn steering Horizontal movement: 0.3 (0.012) or less
Steering gearbox Left-turn steering Vertical movement: 0.15 (0.0059) or less
(Power steering system) Input shaft play mm (in)
In radial direction 0.18 (0.0071) or less
In axial direction 0.1 (0.004) or less
Within 30 mm (1.18 in) from rack center in straight ahead
Turning resistance N (kg, lb) position: Less than 11.18 (1.14, 2.51)
Maximum allowable value: 12.7 (1.3, 2.9)
Pulley shaft mm (in)
Radial play 0.4 (0.016) or less
Axial play 0.9 (0.035) or less
Pulley
Ditch deflection mm (in)
Oil pump (Power steering sys- 1.0 (0.039) or less
Resistance to rotation
tem) 9.22 (0.94, 2.07) or less
N (kg, lb)
Regular pressure
981 (10, 142) or less
kPa (kg/cm2, psi)
Relief pressure
7,355 (75, 1,067)
kPa (kg/cm2, psi)
At standstill with engine
idling on a concrete road 31.4 (3.2, 7.1) or less
Steering wheel effort N (kg, lb)
(Power steering system) At standstill with engine
stalled on a concrete road 147 (15, 33) or less
N (kg, lb)
C: RECOMMENDED POWER STEERING

FLUID
Recommended power steering fluid Manufacturer
B.P.
CALTEX
ATF DEXRON II, ATF DEXRON IIE or ATF CASTROL
DEXRON III MOBIL
SHELL
TEXACO
3
4-3 COMPONENT PARTS
1. Steering Wheel and Column (Tilt)
1. Steering Wheel and Column (Tilt)

1. WITH AIRBAG MODEL
B4M0551A
쎻
1 Bushing Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Column shaft T1: 25±5 (2.5±0.5, 18.1±3.6)
쎻
3 Steering roll connector T2: 34±5 (3.5±0.5, 25.3±3.6)
쎻
4 Column cover
쎻
5 Steering wheel
쎻
6 Airbag module
4
COMPONENT PARTS 4-3
2. Power Steering System

1. LHD MODEL
B4M1149A
Tightening torque: N⋅m (kg-m, ft-lb) T10: 24±3 (2.4±0.3, 17.4±2.2)

T1: 5.4±1.5 (0.55±0.15, 4.0±1.1) T11: 24.5±2.0 (2.50±0.2, 18.07±1.48)
T2: 7.4±2.0 (0.75±0.20, 5.4±1.4) T12: 25±5 (2.5±0.5, 18.1±3.6)
T3: 8±2 (0.8±0.2, 5.8±1.4) T13: 27.0±2.5 (2.75±0.25, 19.92±1.84)
T4: 13±3 (1.3±0.3, 9.4±2.2) T14: 59±12 (6.0±1.2, 43±9)
T5: 15±5 (1.5±0.5, 10.8±3.6) T15: 60.8±6.9 (6.2±0.7, 44.8±5.1)
T6: 15.7±2.4 (1.60±0.24, 11.58±1.77) T16: 78±10 (8.0±1.0, 58±7)
T7: 18.1±2.5 (1.85±0.25, 13.35±1.84) T17: 83±5 (8.5±0.5, 61.5±3.6)
T8: 20.1±2.5 (2.05±0.25, 14.8±1.8) T18: 6.35±1.0 (0.65±0.1, 4.7±0.7)
T9: 22±2 (2.2±0.2, 15.9±1.4) T19: 15.7±2.5 (1.6±0.25, 11.6±1.8)
T20: 34±5 (3.5±0.5, 25.3±3.6)
5
4-3 COMPONENT PARTS
쎻
1 Clamp 쎻
32 Lock nut
쎻
2 Adapter 쎻
33 Adjusting screw
쎻
3 Hose bracket 쎻
34 Spring
쎻
4 Pipe C 쎻
35 Sleeve
쎻
5 Pipe D 쎻
36 Adapter
쎻
6 Clamp E 쎻
37 Clamp
쎻
7 Cap 쎻
38 Cotter pin
쎻
8 Strainer 쎻
39 Castle nut
쎻
9 Seal washer 쎻
40 Dust seal
쎻
10 Tank 쎻
41 Clip
쎻
11 O-ring 쎻
42 Tie-rod end
쎻
12 Oil pump 쎻
43 Small clip
쎻
13 Pulley 쎻
44 Boot
쎻
14 Bracket 쎻
45 Large clip
쎻
15 Bush 쎻
46 Tie-rod
쎻
16 Belt cover 쎻
47 Lock washer
쎻
17 Clamp plate 쎻
48 Pipe B
쎻
18 Pipe F 쎻
49 Pipe A
쎻
19 Pipe E 쎻
50 Housing ASSY
쎻
20 Universal joint 쎻
51 Back-up washer
쎻
21 Dust seal 쎻
52 Oil seal
쎻
22 C-ring 쎻
53 Piston ring
쎻
23 Oil seal 쎻
54 Rack
쎻
24 Valve housing 쎻
55 O-ring
쎻
25 Packing 쎻
56 Rack bushing
쎻
26 Seal ring 쎻
57 Oil seal
쎻
27 Pinion and valve ASSY 쎻
58 Rack stopper
쎻
28 Oil seal 쎻
59 Circlip
쎻
29 Back-up washer 쎻
60 Spacer
쎻
30 Ball bearing 쎻
61 Stay (2500 cc model only)
쎻
31 Snap ring 쎻
62 Gasket
6
COMPONENT PARTS 4-3
2. RHD MODEL
B4M1150A
Tightening torque: N⋅m (kg-m, ft-lb) T10: 24±3 (2.4±0.3, 17.4±2.2)

T1: 7.4±2.0 (0.75±0.2, 5.4±1.4) T11: 24.5±2.0 (2.50±0.20, 18.07±1.48)
T2: 8±2 (0.8±0.2, 5.8±1.4) T12: 25±5 (2.5±0.5, 18.1±3.6)
T3: 13±3 (1.3±0.3, 9.4±2.2) T13: 27.0±2.5 (2.75±0.26, 19.92±1.84)
T4: 15±5 (1.5±0.5, 10.8±3.6) T14: 59±12 (6.0±1.2, 43±9)
T5: 15.7±2.4 (1.60±0.24, 11.58±1.77) T15: 61±7 (6.2±0.7, 44.8±5.1)
T6: 18.1±2.5 (1.85±0.26, 13.35±1.84) T16: 64±10 (6.5±1.0, 47±7)
T7: 20±4 (2.0±0.4, 14±2.9) T17: 78±10 (8.0±1.0, 58±7)
T8: 20.1±2.5 (2.05±0.25, 14.8±1.8) T18: 83±5 (8.5±0.5, 61.5±3.6)
T9: 22±2 (2.2±0.2, 15.9±1.4) T19: 34±5 (3.5±0.5, 25.3±3.6)
7
4-3 COMPONENT PARTS
쎻
1 Clamp 쎻
27 Castle nut
쎻
2 Adapter 쎻
28 Cotter pin
쎻
3 Hose bracket 쎻
29 Dust seal
쎻
4 Pipe C 쎻
30 Clip
쎻
5 Pipe D 쎻
31 Tie-rod end
쎻
6 Clamp E 쎻
32 Clip
쎻
7 Cap 쎻
33 Boot
쎻
8 Strainer 쎻
34 Wire
쎻
9 Seal washer 쎻
35 Tie-rod
쎻
10 Tank 쎻
36 Lock washer
쎻
11 O-ring 쎻
37 Holder
쎻
12 Oil pump 쎻
38 Bush
쎻
13 Pulley 쎻
39 Y-packing
쎻
14 Bracket 쎻
40 Oil seal
쎻
15 Bush 쎻
41 O-ring
쎻
16 Belt cover 쎻
42 Rack
쎻
17 Universal joint 쎻
43 Oil seal
쎻
18 Dust cover 쎻
44 Back-up washer
쎻
19 Valve housing 쎻
45 Housing ASSY
쎻
20 Y-packing 쎻
46 Pipe A
쎻
21 Ball bearing 쎻
47 Pipe B
쎻
22 Spacer 쎻
48 Lock nut
쎻
23 Pinion 쎻
49 Adjusting screw
쎻
24 Shim 쎻
50 Spring
쎻
25 Adapter 쎻
51 Sleeve
쎻
26 Clamp 쎻
52 Gasket
8
COMPONENT PARTS 4-3
3. Power Steering Oil Pump
3. Power Steering Oil Pump
B4M0123A
쎻
1 Pulley 쎻
9 Spring 쎻
17 Side plate
쎻
2 Snap ring 쎻
10 Front casing
쎻
3 Bearing 쎻
11 Rear cover Tightening torque: N⋅m (kg-m, ft-lb)
쎻
4 Oil seal 쎻
12 Gasket T1: 16±2 (1.6±0.2, 11.6±1.4)
T2: 61±7 (6.2±0.7, 44.8±5.1)
쎻
5 Shaft 쎻
13 Knock pin
T3: 74±5 (7.5±0.5, 54.2±3.6)
쎻
6 Connector 쎻
14 Cam ring
쎻
7 O-ring 쎻
15 Vane
쎻
8 Spool valve 쎻
16 Rotor
9
1. Supplemental Restraint System “Airbag” - 2. Tilt Steering Column
1. Supplemental Restraint System

“Airbag”
Airbag system wiring harness is routed near the steering
wheel, steering shaft and column.
WARNING:
쐌 All Airbag system wiring harness and connectors
are colored yellow. Do not use electrical test equip-
ment on these circuit.
쐌 Be careful not to damage Airbag system wiring har-
ness when servicing the steering wheel, steering shaft
and column.
2. Tilt Steering Column
B4M0554A
Tightening torque: N⋅m (kg-m, ft-lb)

T1: 24±3 (2.4±0.3, 17.4±2.2)
T2: 25±5 (2.5±0.5, 18.1±3.6)
A: REMOVAL
1) Disconnect battery minus terminal.
2) Lift-up vehicle.
3) Remove airbag module. (with airbag model) <Ref. to
5-5 [W3A1].>
WARNING:
Always refer to “5-5 Supplemental Restraint System”
before performing airbag module service (if so
equipped).
10
1. Supplemental Restraint System “Airbag” - 2. Tilt Steering Column

“Airbag”
Airbag system wiring harness is routed near the steering
wheel, steering shaft and column.
WARNING:
ness when servicing the steering wheel, steering shaft
and column.
B4M0554A

T1: 24±3 (2.4±0.3, 17.4±2.2)
T2: 25±5 (2.5±0.5, 18.1±3.6)
A: REMOVAL
2) Lift-up vehicle.
3) Remove airbag module. (with airbag model) <Ref. to
5-5 [W3A1].>
WARNING:
Always refer to “5-5 Supplemental Restraint System”
before performing airbag module service (if so
equipped).
10
4) Remove steering wheel nut, then draw out steering

wheel from shaft using steering puller.
G5M0332
5) Remove universal joint bolts and then remove universal

joint.
CAUTION:
Scribe alignment marks on universal joint so that it can
be reassembled at the original serration.
6) Remove trim panel under instrument panel.
7) Disconnect connectors for ignition switch and combina-
tion switch wiring harness under instrument panel.
G4M0086
8) Remove the two bolts under instrument panel securing

steering shaft.
9) Pull out steering shaft assembly from hole on toe board.
CAUTION:
Be sure to remove universal joint before removing
steering shaft assembly installing bolts when remov-
ing steering shaft assembly or when lowering it for
servicing of other parts.
B4M0127A
B: DISASSEMBLY
Remove the four screws securing upper and lower steer-
ing column covers, and the two screws securing combina-
tion switch, then remove related parts.
NOTE:
Steering column assembly can not to be disassembled.
B4M0555
11
C: INSPECTION
1. BASIC INSPECTION
Clean the disassembled parts with a cloth, and check for
wear, damage, or any other faults. If necessary, repair or
replace faulty parts.
Part name Inspection Corrective action
쐌 Free play
쐌 Swinging torque
쐌 Yawing torque
looseness
Universal joint Replace if faulty.
G4M0089
Standard value of universal joint free play: 0 mm (0 in)
Max. value of universal joint swinging torque:
0.3 N⋅m (0.03 kg-m, 0.2 ft-lb)
쐌 Overall length of steering column
Measure overall length of steering column.
Standard overall length of steering column:
Replace steering column

Steering column
assembly.
B4M0129C
12
D: ASSEMBLY
1) Insert combination switch to upper column shaft, and
install lower column cover with tilt lever held in the lowered
position. Then route ignition key harness and combination
switch harness between column cover mounting bosses.
2) Fit upper column cover to lower column cover, and
tighten combination switch and column cover.
Tightening torque:
1.2±0.2 N⋅m (0.12±0.02 kg-m, 0.9±0.1 ft-lb)
B4M0555
CAUTION:
Don’t overtorque screw.
E: INSTALLATION
1) Insert end of steering shaft into toe board grommet.
2) Tighten steering shaft mounting bolts under instrument
panel.
Tightening torque:
25±5 N⋅m (2.5±0.5 kg-m, 18.1±3.6 ft-lb)
3) Connect ignition and combination switch connectors
under instrument panel.
4) Connect airbag system connector at harness spool.
NOTE:
Make sure to apply double lock.
5) Install universal joint.
(1) Align bolt hole on the long yoke side of universal
joint with the cutout at the serrated section of shaft end,
and insert universal joint.
(2) Align bolt hole on the short yoke side of universal
joint with the cutout at the serrated section of gearbox
assembly. Lower universal joint completely.
(3) Temporarily tighten bolt on the short yoke side.
Raise universal joint to make sure the bolt is properly
passing through the cutout at the serrated section.
(4) Tighten bolt on the long yoke side, then that on the
short yoke side.
Tightening torque:
24±3 N⋅m (2.4±0.3 kg-m, 17.4±2.2 ft-lb)
CAUTION:
쐌 Make sure that universal joint bolts is tightened
through notch in shaft serration.
쐌 Excessively large tightening torque of universal
joint bolts may lead to heavy steering wheel operation.
Standard clearance between gearbox to DOJ:
Over 15 mm (0.59 in)
13
6) Align center of roll connector. (with airbag model)

<Ref. to 5-5 [W7B1].>
CAUTION:
Ensure that front wheels are set in straight-forward
direction.
7) Set steering wheel to neutral and install it onto steering
shaft.
Tightening torque:
34±5 N⋅m (3.5±0.5 kg-m, 25.3±3.6 ft-lb)
G5M0328
Column cover-to-steering wheel clearance:
2 — 4 mm (0.08 — 0.16 in)
CAUTION:
Insert roll connector guide pin into guide hole on lower
end of surface of steering wheel to prevent damage.
Draw out airbag system connector, horn connector
and cruise control connectors from guide hole of
steering wheel lower end. (with airbag model)
8) Install airbag module to steering wheel. (with airbag
model)
WARNING:
Always refer to 5-5 [W7B1] before performing the ser-
vice operation.
14
3. Steering Gearbox (Power Steering System) [LHD model]
3. Steering Gearbox (Power Steering

System) [LHD model]
NOTE:
For disassembly and assembly of gearbox unit, refer to
section Control Valve (Power Steering Gearbox).
B4M0131A
쎻
1 Cotter pin 쎻
16 O-ring 쎻
31 Valve housing
쎻
2 Castle nut 쎻
17 Rack 쎻
32 Dust seal
쎻
3 Dust cover 쎻
18 Back-up washer 쎻
33 Universal joint
쎻
4 Clip 쎻
19 Rack housing 쎻
34 Spring washer
쎻
5 Tie-rod end 쎻
20 Adapter
쎻
6 Clip 쎻
21 Clamp T1: 13±3 (1.3±0.3, 9.4±2.2)
쎻
7 Boot 쎻
22 Lock nut T2: 24±3 (2.4±0.3, 17.4±2.2)
쎻
8 Clip 쎻
23 Adjusting screw T3: 25±5 (2.5±0.5, 18.1±3.6)
쎻
9 Spacer 쎻
24 Spring T4: 27.0±2.5
쎻
10 Tie-rod 쎻
25 Sleeve (2.75±0.25, 19.9±1.8)
쎻
11 Lock washer 쎻
26 C-ring T5: 39±10 (4.0±1.0, 29±7)
쎻
12 Circlip 쎻
27 Ball bearing T6: 59±12 (6.0±1.2, 43±9)
T7: 78±10 (8.0±1.0, 58±7)
쎻
13 Rack stopper 쎻
28 Valve
T8: 83±5 (8.5±0.5, 61.5±3.6)
쎻
14 Oil seal 쎻
29 Seal ring
쎻
15 Rack bushing 쎻
30 Packing
15
A: REMOVAL
2) Loosen front wheel nut.
3) Lift vehicle and remove front wheels.
4) Remove front exhaust pipe assembly.
WARNING:
Be careful, exhaust pipe is hot.
5) Using a puller, remove tie-rod end from knuckle arm

after pulling off cotter pin and removing castle nut.
G4M0097
6) Remove jack-up plate and front stabilizer.
G4M0098
7) Remove one pipe joint at the center of gearbox, and

connect vinyl hose to pipe and joint. Discharge fluid by
turning steering wheel fully clockwise and counterclock-
wise. Discharge fluid similarly from the other pipe.
G4M0099
8) Remove lower side bolt of universal joint, then remove

upper side bolt and lift the joint upward.
NOTE:
Place a mark on the joint and mating serration so that they
can be re-installed at the original position.
G4M0086
16
9) Disconnect pipes C and D from pipe of gearbox.

CAUTION:
Be careful not to damage these pipes.
NOTE:
Disconnect upper pipe D first, and lower pipe C second.
G4M0101
10) Remove clamp bolts securing gearbox to

crossmember, and remove gearbox.
G4M0102
B: DISASSEMBLY
1) Disconnect four pipes from gearbox.
2) Secure gearbox removed from vehicle in vice using ST.
ST 926200000 STAND
CAUTION:
Secure the gearbox in a vice using the ST as shown.
Do not attempt to secure it without this ST.
3) Remove tie-rod end and lock nut from gearbox.
B4M0132A
4) Remove small clip from boot using pliers, and move

boot to tie-rod end side.
G4M0104
5) Remove boot together with large clips.
G4M0105
17
6) Straighten lock washer under ball joint.

CAUTION:
쐌 Be extremely careful not to hit surface of right hand
rack; otherwise, oil leakage may result.
쐌 Tie-rod lock washer must be replaced with a new
one whenever it is removed.
G4M0106
7) Loosen ball joint using ST and spanner and remove

tie-rod from rack.
NOTE:
When loosening ball joint, securely fix the rack using ST.
ST 925700000 WRENCH
G4M0107
8) Loosen lock nut using ST, and remove adjusting screw.

ST 926230000 SPANNER
9) Remove spring and sleeve.
10) Remove dust seal.
CAUTION:
Be careful not to damage housing and input shaft, or
to allow foreign matters to get inside when removing
dust seal.
G4M0108
18
C: INSPECTION
1) Clean all disassembled parts, and check for wear,
damage, or any other faults, then repair or replace as nec-
essary.
2) When disassembling, check inside of gearbox for water.
If any water is found, carefully check boot for damage,
input shaft dust seal, adjusting screw and boot clips for
poor sealing. If faulty, replace with new parts.
No. Parts Inspection Corrective action
(1) Bend of input shaft If bend or damage is excessive, replace
1 Input shaft
(2) Damage on serration entire gearbox.
(1) Crack or damage If outer wall slips, lip is worn out or
2 Dust seal
(2) Wear damage is found, replace it with new one.
(1) Adjust backlash properly.
By measuring turning torque of
gearbox and sliding resistance of rack,
check if rack and pinion engage
uniformly and smoothly with each
other.
3 Rack and pinion Poor mating of rack with pinion
(Refer to “Service limit”.)
(2) Keeping rack pulled out all the way so
that all teeth emerge, check teeth for
damage.
Even if abnormality is found in either
(1) or (2), replace entire gearbox.
(1) Bend of rack shaft
(2) Bend of cylinder portion Replace gearbox with new one.
(3) Crack or damage on cast iron portion
If free play of rack shaft in radial direction
is out of the specified range, replace
(4) Wear or damage on rack bush
4 Gearbox unit gearbox with new one. (Refer to “Service
limit”.)
If free plays of input shaft in radial and
axial directions are out of the specified
(5) Wear on input shaft bearing
ranges, replace gearbox with new one.
5 Boot Crack, damage or deterioration Replace.
(1) Looseness of ball joint
6 Tie-rod Replace.
(2) Bend of tie-rod
7 Tie-rod end Damage or deterioration on dust seal Replace.
8 Adjusting screw spring Deterioration Replace.
9 Boot clip Deterioration Replace.
10 Sleeve Damage Replace.
(1) Damage to flared surface
(2) Damage to flare nut
11 Pipes Replace.
(3) Damage to pipe
(4) Damage to O-ring
19
1. SERVICE LIMIT
Make a measurement as shown in the figures. If it exceeds
the specified service limit, adjust or replace.
NOTE:
When making a measurement, vise gearbox by using ST.
Never vise gearbox by inserting aluminum plates, etc.
between vise and gearbox.
ST 926200000 STAND
Sliding resistance of rack shaft:
G4M0109
Service limit
240.3 N (24.5 kg, 54.0 lb) or less
G4M0110
2. RACK SHAFT PLAY IN RADIAL DIRECTION

Right-turn steering:
Service limit
0.15 mm (0.0059 in) or less
On condition
L: 5 mm (0.20 in)
P: 98 N (10 kg, 22 lb)
G4M0111
Left-turn steering:
Service limit
Direction
0.3 mm (0.012 in) or less
Direction
0.15 mm (0.0059 in) or less
On condition
L: 5 mm (0.20 in)
P: 98 N (10 kg, 22 lb)
G4M0887
3. INPUT SHAFT PLAY

In radial direction:
Service limit
0.18 mm (0.0071 in) or less
On condition
P: 98 N (10 kg, 22 lb)
G4M0113
20
In axial direction:
Service limit
On condition
P: 20 — 49 N (2 — 5 kg, 4 — 11 lb)
G4M0114
4. TURNING RESISTANCE OF GEARBOX

Using ST, measure gearbox turning resistance.
Service limit:
Straight-ahead position within 30 mm (1.18 in)
from rack center
Less than 11.18 N (1.14 kg, 2.51 lb)
Maximum allowable resistance
12.7 N (1.3 kg, 2.9 lb)
G4M0115
D: ASSEMBLY
CAUTION:
Use only SUBARU genuine grease for gearbox.
Specified grease for gearbox:
VALIANT GREASE M2 (Part No. 003608001)
1) Apply grease to teeth of rack so that grease applied is
about as high as teeth, and also apply a thin film of grease
to sliding portion of rack shaft.
CAUTION:
쐌 When moving rack to stroke end without tie-rod
attached, prevent shocks from being applied at the
end.
쐌 Do not apply grease to threaded portion at end of
rack shaft.
쐌 Move rack shaft to stroke end two or three times to
squeeze grease which accumulates on both ends.
Remove grease to prevent it from choking air passage
hole.
2) Apply grease to sleeve insertion hole.
3) Apply grease to dust seal insertion hole.
CAUTION:
Apply clean grease with clean hands. If material hav-
ing a sharp edge is used for applying grease, oil seal
at the inside might be damaged.
21
4) Press-fit dust seal into gearbox housing while tapping it

via a spanner or the like so that stepping between gearbox
and dust seal is normally 2 mm (0.08 in).
G4M0116
Depth: A
2 mm (0.08 in)
G4M0117
5) Apply grease to sliding surface of sleeve and spring

seat, then insert sleeve into pinion housing. Fit spring into
sleeve screw, pack grease inside of screw, then install the
screw.
쎻1 Sleeve
쎻2 Spring
쎻3 Adjusting screw
G4M0118
6) Fit new lock washer on screwed portion of rack end.

Aligning cut portion of rack and nail of washer, screw in and
tighten ball joint by using ST and spanner.
ST 925700000 WRENCH
Tightening torque (Ball joint):
78±10 N⋅m (8.0±1.0 kg-m, 58±7 ft-lb)
CAUTION:
Pay attention to prevent rack surface on the right side
from being damaged by a tool or the like, otherwise oil
G4M0107
leakage might be caused.
NOTE:
While tightening ball joint, hold rack with ST to prevent it
from revolving.
22
7) Bend lock washer using a chisel.

CAUTION:
Be careful not to scratch rack when bending lock
washer.
G4M0120
8) Rack and pinion backlash adjustment

(1) Loosen adjusting screw.
(2) Rotate input shaft so that rack is in the straight
ahead direction.
(3) Apply grease to sleeve.
쎻1 Sleeve
쎻2 Spring
쎻3 Lock nut
G4M0122
(4) Tighten adjusting screw by two threads.
G4M0121
(5) Apply liquid packing to at least 1/3 of entire perim-

eter of adjusting screw thread.
Liquid packing:
THREE BOND 1141
G4M0662
(6) Tighten adjusting screw to 15 N⋅m (1.5 kg-m, 11

ft-lb) and back off 26°.
(7) Install lock nut. While holding adjusting screw with
a wrench, tighten lock nut using ST.
Tightening torque (Lock nut):
39±10 N⋅m (4.0±1.0 kg-m, 29±7 ft-lb)
NOTE:
쐌 Hold adjusting screw with a wrench to prevent it from
turning while tightening lock nut.
23
쐌 Make adjustment so that steering wheel can be rotated

fully from lock to lock without binding.
9) Check for service limit as per article of “Service limit”.
<Ref. to 4-3 [W3C1].> Make replacement and adjustment
if necessary.
10) Install boot and mounting rubber to housing.
NOTE:
Apply grease through small hole in boot.
11) Fit clip (large) to boot, and then install boot to gearbox
while holding boot flange.
After installing boot, fold back boot flange to the extent that
large clip can not be seen.
NOTE:
쐌 Before installing boot, be sure to apply grease to the
groove of tie-rod.
쐌 Install fitting portions of boots to the following portions in
both sides of assembled steering gearbox.
G4M0123 1. The groove on gearbox
2. The groove on the rod
쐌 Make sure that boot is installed without unusual inflation
or deflation.
12) Turn boot until it seats well on gearbox and rubber

mounting, then bend boot flange back.
G4M0124
13) Fix boot end with clip (small).

CAUTION:
Use screwdriver with blunted tip to prevent boot from
damage, when installing.
NOTE:
After installing, check boot end is positioned into groove on
tie-rod.
G4M0125
24
14) If tie-rod end was removed, screw in lock nut and tie-
rod end to screwed portion of tie-rod, and tighten lock nut
temporarily in a position as shown in figure.
Installed tie-rod length: L
15 mm (0.59 in)
NOTE:
Pay attention to difference between right and left tie-rod
ends.
G4M0126
15) Inspect gearbox as follows:

A. Holding tie-rod end, repeat lock to lock two or three
times as quickly as possible.
B. Holding tie-rod end, turn it slowly at a radius one or two
times as large as possible.
After all, make sure that boot is installed in the specified
position without deflation.
G4M0127
16) Remove gearbox from ST.

ST 926200000 STAND
17) Install four pipes on gearbox.
(1) Connect pipes A and B to four pipe joints of gear-
box. Connect upper pipe B first, and lower pipe A.
Tightening torque:
13±3 N⋅m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
(2) Connect pipes C and D to gearbox.

Connect lower pipe C first, and upper pipe D second.
Tightening torque:
15±5 N⋅m (1.5±0.5 kg-m, 10.8±3.6 ft-lb)
G4M0101
E: INSTALLATION
1) Insert gearbox into crossmember, being careful not to
damage gearbox boot.
2) Tighten gearbox to crossmember bracket via clamp with
bolt to the specified torque.
Tightening torque:
59±12 N⋅m (6.0±1.2 kg-m, 43±9 ft-lb)
G4M0102
25
3) How to install the joint.

(1) Push the long yoke of the joint, all the way into the
serrated portion of the steering shaft, setting the bolt
hole in the cutout.
(2) Then pull the short yoke all way out of the serrated
portion of the gearbox, setting the bolt hole in the cut-
out.
(3) Insert the bolt through the short yoke, pull the joint
and confirm that the bolt is on cutout of the gearbox.
(4) Fasten the short yoke side with a spring washer

and bolt, then fasten the long yoke side.
Tightening torque:
24±3 N⋅m (2.4±0.3 kg-m, 17.4±2.2 ft-lb)
G4M0086
4) Connect tie-rod end and knuckle arm, and tighten with

castle nut. Fit cotter pin into the nut and bend the pin to
lock.
Castle nut tightening torque:
Tighten to 27.0±2.5 N⋅m (2.75±0.25 kg-m,
19.9±1.8 ft-lb), and tighten further within 60° until
cotter pin hole is aligned with a slot in the nut.
CAUTION:
When connecting, do not hit cap at the bottom of tie-
G4M0097
rod end with hammer.
5) Install front stabilizer to vehicle.
6) Install front exhaust pipe assembly.
<Ref. to 2-9 [W1B0].>
7) Install tires.
8) Tighten wheel nuts to the specified torque.
Tightening torque:
88±10 N⋅m (9.0±1.0 kg-m, 65±7 ft-lb)
9) Connect ground cable to battery.
10) Pour fluid into oil tank, and bleed air. <Ref. to 4-3
[W9A0].>
11) Check for fluid leaks.
12) Install jack-up plate.
WARNING:
Be careful, exhaust manifold is hot.
13) Lower vehicle.
14) Check fluid level in oil tank.
26
15) After adjusting toe-in and steering angle, tighten lock

nut on tie-rod end.
Tightening torque:
83±5 N⋅m (8.5±0.5 kg-m, 61.5±3.6 ft-lb)
CAUTION:
When adjusting toe-in, hold boot as shown to prevent
it from being rotated or twisted. If twisted, straighten it.
G4M0132
F: ADJUSTMENT
1) Adjust front toe.
Standard of front toe:
IN 3 — OUT 3 mm (IN 0.12 — OUT 0.12 in)
2) Adjust steering angle of wheels.
Inner wheel: 37.6°±1.5
Outer wheel: 32.6°±1.5
G4M0133
3) If steering wheel spokes are not horizontal when wheels

are set in the straight ahead position, and error is more
than 5° on the periphery of steering wheel, correctly re-in-
stall the steering wheel.
B4M0133A
4) If steering wheel spokes are not horizontal with vehicle

set in the straight ahead position after this adjustment,
correct it by turning the right and left tie-rods in the same
direction by the same turns.
G4M0135
27
4. Steering Gearbox (Power Steering System) [RHD model]
4. Steering Gearbox (Power Steering

System) [RHD model]
NOTE:
For disassembly and assembly of gearbox unit, refer to
section Control Valve (Power Steering Gearbox).
B4M0666A

T1: 20±4 (2.0±0.4, 14.5±2.9)
T2: 25±5 (2.5±0.5, 18.1±3.6)
T3: 39±10 (4.0±1.0, 29±7)
T4: 64±10 (6.5±1.0, 47±7)
T5: 78±10 (8.0±1.0, 58±7)
T6: 83±5 (8.5±0.5, 61.5±3.6)
28
쎻
1 Dust cover 쎻
17 Spring
쎻
2 Valve housing 쎻
18 Adjusting screw
쎻
3 Y-packing 쎻
19 Lock nut
쎻
4 Ball-bearing 쎻
20 Pipe A
쎻
5 Spacer 쎻
21 Pipe B
쎻
6 Pinion 쎻
22 Adapter
쎻
7 Shim 쎻
23 Housing ASSY
쎻
8 Dust seal 쎻
24 Back-up washer
쎻
9 Clip 쎻
25 Oil seal
쎻
10 Tie-rod end 쎻
26 Rack
쎻
11 Clip 쎻
27 O-ring
쎻
12 Boot 쎻
28 Oil seal
쎻
13 Wire 쎻
29 Y-packing
쎻
14 Tie-rod RH 쎻
30 Bush
쎻
15 Lock washer 쎻
31 Holder
쎻
16 Sleeve 쎻
32 Tie-rod LH
29
A: REMOVAL
1) Disconnect battery negative terminal.
2) Disconnect both oxygen sensor and exhaust gas tem-
perature warning sensor connectors from front exhaust
pipe assembly.
WARNING:
Be careful as exhaust pipe is hot.
3) Raise vehicle with a jack and remove front wheel.
4) Disconnect front exhaust pipe assembly.
5) Remove cotter pin and castle nut. Using a puller,

remove tie-rod end from knuckle arm.
G4M0097
6) Remove jack-up plate and stabilizer.
G4M0098
7) Disconnect one pipe joint A from center of gearbox

assembly, and connect a vinyl hose to it. While turning
steering wheel to the left and right, drain fluid through the
hose. Similarly, drain fluid from the other pipe joint B.
G4M0786
8) Remove lower and upper bolts from universal joint, and

remove universal joint in the upward direction.
NOTE:
Scribe alignment marks on universal joint so that it can be
reassembled at the original serration.
G4M0787
30
9) Remove flare nuts from control valve of gearbox

assembly, and disconnect upper and lower hoses B and A.
CAUTION:
쐌 Always disconnect hoses B and A in that order.
쐌 Be careful not to damage the hoses during removal.
10) Remove bolts securing gearbox to crossmember, and
detach gearbox.
B: DISASSEMBLY
1) Disconnect four pipes from gearbox.
2) Secure gearbox removed from vehicle in vice using ST.
ST 926200000 STAND
CAUTION:
Secure the gearbox assembly in a vice using the ST as
shown. Do not attempt to secure it without this ST.
G4M0788
3) Pry off clip from outer end of boot, and slide boot toward
tie-rod end.
G4M0789
4) Using ST, remove lock wire from inner end of boot, and
remove boot.
ST 927590000 WRENCH
G4M0790
5) Extend rack approximately 40 mm (1.57 in) out. Unlock

lock wire at lock washer on each side of tie-rod end using
a standard screwdriver.
CAUTION:
Be careful not to scratch rack surface as oil leaks may
result.
G4M0791
31
6) Using ST, loosen lock nut.

G4M0792
7) Tighten adjusting screw until it no longer tightens.
G4M0793
8) Using a wrench [32 mm (1.26 in) width across flats] or

adjustable wrench, remove tie-rod.
CAUTION:
쐌 Check ball joint for free play, and tie-rod for bends.
Replace if necessary.
쐌 Check dust seals used with tie-rod end ball joint for
damage or deterioration. Replace if necessary.
G4M0794
9) Loosen adjusting screw and remove spring and sleeve.

CAUTION:
Replace spring and/or sleeve if damaged.
10) Disconnect pipes A and B from steering body and con-

trol valve housing.
CAUTION:
Replace pipes and/or flare nuts if damaged.
G4M0795
32
C: INSPECTION
1) Clean all disassembled parts, and check for wear,
damage, or any other faults, then repair or replace as nec-
essary.
2) When disassembling, check inside of gearbox for water.
If any water is found, carefully check boot for damage,
input shaft dust seal, adjusting screw and boot clips for
poor sealing. If faulty, replace with new parts.

(1) Bend of input shaft If bend or damage is excessive, replace
1 Input shaft
(2) Damage on serration entire gearbox.
(1) Crack or damage If outer wall slips, lip is worn out or damage
2 Dust seal
(2) Wear is found, replace it with new one.
(1) Adjust backlash properly.
By measuring turning torque of
gearbox and sliding resistance of rack,
check if rack and pinion engage
uniformly and smoothly with each
other.
3 Rack and pinion Poor mating of rack with pinion
(2) Keeping rack pulled out all the way so
that all teeth emerge, check teeth for
damage.
Even if abnormality is found in either
(1) or (2), replace entire gearbox.
(1) Bend of rack shaft
(2) Bend of cylinder portion Replace gearbox with new one.
(3) Crack or damage on cast iron portion
If free play of rack shaft in radial direction is
(4) Wear or damage on rack bush out of the specified range, replace gearbox
4 Gearbox unit
with new one. (Refer to “Service limit”.)
If free plays of input shaft in radial and axial
directions are out of the specified ranges,
(5) Wear on input shaft bearing
replace gearbox with new one.
5 Boot Crack, damage or deterioration Replace.
(1) Looseness of ball joint
6 Tie-rod Replace.
(2) Bend of tie-rod
7 Tie-rod end Damage or deterioration on dust seal Replace.
8 Adjusting screw spring Deterioration Replace.
9 Boot clip Deterioration Replace.
10 Sleeve Damage Replace.
(1) Damage to flared surface
(2) Damage to flare nut
11 Pipes Replace.
(3) Damage to pipe
(4) Damage to O-ring
33
1. SERVICE LIMIT
Make a measurement as shown in the figures. If it exceeds
the specified service limit, adjust or replace.
NOTE:
When making a measurement, vise gearbox by using ST.
Never vise gearbox by inserting aluminum plates, etc.
between vise and gearbox.
ST 926200000 STAND
Sliding resistance of rack shaft:
G4M0796
Service limit
304 N (31 kg, 68 lb) or less
Difference between left and right sliding resistance
Less than 20%
G4M0797
2. RACK SHAFT PLAY IN RADIAL DIRECTION

Right-turn steering:
Service limit
Less than 0.4 mm (0.016 in) (direction )
Less than 0.6 mm (0.024 in) (direction )
On condition
L: 5 mm (0.20 in)
P: 98 N (10 kg, 22 lb)
G4M0798
Left-turn steering:
Service limit
(direction and )
On condition
L: 5 mm (0.20 in)
P: 98 N (10 kg, 22 lb)
G4M0799
3. INPUT SHAFT PLAY

In radial direction:
Service limit
0.18 mm (0.0071 in) or less
On condition
P: 98 N (10 kg, 22 lb)
G4M0800
34
In axial direction:
Service limit
0.27 mm (0.0106 in) or less
On condition
P: 20 — 49 N (2 — 5 kg, 4 — 11 lb)
G4M0801
4. TURNING RESISTANCE OF GEARBOX

Using ST, measure gearbox turning resistance.
Service limit:
from rack center
Less than 11.18 N (1.14 kg, 2.51 lb)
Maximum allowable resistance
15.79 N (1.61 kg, 3.55 lb) or less
G4M0802
Difference between left and right sliding resistance:
Less than 20%
D: ASSEMBLY
CAUTION:
Use only SUBARU genuine grease for gearbox.
Specified grease for gearbox:
1) Clean all parts and tools before reassembling.
2) Move rack shaft fully to the left and right two or three
times to lubricate shaft ends with grease. Remove excess
grease, being careful not to block air vent hole.
CAUTION:
쐌 When rack is fully moved to its stroke ends with tie-
rod removed, be careful not to bump rack ends.
쐌 Ensure that screw located at end of rack shaft is free
from grease.
3) Apply grease to bore wall which accommodates sleeve.
CAUTION:
Ensure that hands are clean when applying grease.
35
4) Apply a coat of grease to sliding surface of sleeve and

seating surface of spring, and insert sleeve into steering
body. Charge adjusting screw with grease, insert spring
into adjusting screw and install on steering body.
쎻1 Sleeve
쎻2 Seat
쎻3 Spring
쎻5 Lock nut
G4M0803
5) Installation of tie-rod
(1) Tighten adjusting screw until it will no longer
tighten.
(2) Install lock washers and tighten left and right tie-
rods into rack ends.
On condition
L: Approximately 40 mm (1.57 in)
Tightening torque:
78±10 N⋅m (8.0±1.0 kg-m, 58±7 ft-lb)
G4M0804
(3) The left and right tie-rod differ as indicated in the

table below.
Right tie-rod Grooved.
No air vent hole provided.
(pinion side) (for identification)
Left tie-rod Not grooved.
Air vent hole provided.
(cylinder side) (for identification)
G4M0805
6) Using a chisel and hammer, bend lock washers (at two

places).
CAUTION:
Be careful not to scratch rack.
G4M0806
7) Rack and pinion backlash adjustment

(1) Loosen adjusting screw three to four turns.
(2) Rotate input shaft so that rack is in the straight
ahead direction. [Ensure that distance between rack
end and stopper is 70.8 mm (2.787 in).]
(3) Tighten adjusting screw by two threads.
G4M0807
36
(4) Turn adjusting screw so that the entire thread area

is coated with liquid packing.
Liquid packing:
THREE BOND 1102 or equivalent
NOTE:
쐌 Apply liquid packing of approximately 1.5 grams (0.053
oz) to adjusting screw thread area.
쐌 Also turn plug to ensure that its entire contact area is
coated with liquid packing.
G4M0662
(5) Tighten adjusting plug to 5 N⋅m (0.5 kg-m, 3.6 ft-lb)

and loosen, then tighten to 5 N⋅m (0.5 kg-m, 3.6 ft-lb)
and loosen, and finally tighten to 5 N⋅m (0.5 kg-m, 3.6
ft-lb) and loosen 26°.
(6) While holding adjusting plug using a closed
wrench, tighten lock nut using ST.
Tightening torque:
39±10 N⋅m (4±1 kg-m, 29±7 ft-lb)
G4M0808
CAUTION:
쐌 Do not allow liquid packing to come in contact with
sleeve.
쐌 While rotating input shaft to fully move rack shaft to
the left and right, ensure that rack moves smoothly
without binding, and that rotating torque is constant.
8) Installation of boot
(1) Apply a coat of grease to inner wall of boot small
end.
(2) Position boot large end in rubber mount groove and
gearbox, and small end in groove of tie-rod.
CAUTION:
쐌 Ensure that both ends of boot are properly situated
in grooves.
쐌 Ensure that boot is free from abnormal swelling or
dents.
9) Attach lock wire to boot large end, and twist it while

pulling it upward with a force of approximately 39±10 N
(4±1 kg, 9±2 lb).
ST 927590000 WRENCH
CAUTION:
Ensure that lock wire is not loose.
G4M0790
37
10) Then bend wire end along boot as shown.
G4M0810
11) Install clip using pliers.

CAUTION:
After installing clip, ensure that boot’s small end is
properly positioned in groove on tie-rod.
G4M0812
12) Install pipes A and B.

Tightening torque:
20±4 N⋅m (2.0±0.4 kg-m, 14.5±2.9 ft-lb)
E: INSTALLATION
Do the following:
CAUTION:
When adjusting toe-in, hold boot as shown to prevent
it from being rotated or twisted. If twisted, straighten it.
G4M0132
F: ADJUSTMENT
1) Adjust front toe.
Standard of front toe:
IN 3 — OUT 3 mm (IN 0.12 — OUT 0.12 in)
G4M0133
38
2) Adjust steering angle of wheels.

Standard of steering angle:
Inner wheel 37.6°±1.5°
Outer wheel 32.6°±1.5°
3) If steering wheel spokes are not horizontal when wheels

are set in the straight ahead position, and error is more
than 5° on the periphery of steering wheel, correctly re-in-
stall the steering wheel.
B4M0133A
4) If steering wheel spokes are not horizontal with vehicle

set in the straight ahead position after this adjustment,
correct it by turning the right and left tie-rods in the same
direction by the same amount.
G4M0135
39
5. Control Valve (Power Steering Gearbox) [LHD model]
5. Control Valve (Power Steering

Gearbox) [LHD model]
NOTE:
This section focuses on the disassembly and reassembly
of control valve. For the inspection and adjustment and the
service procedures for associated parts, refer to “Steering
Gearbox”.
G4M0136
쎻
1 Power cylinder 쎻
6 Torsion bar 쎻
10 Pipe B
쎻
2 Cylinder 쎻
7 Valve housing 쎻
11 Pipe A
쎻
3 Rack piston 쎻
8 Valve body 쎻
12 Pinion
쎻
4 Rack axle 쎻
9 Control valve 쎻
13 Pinion axle
쎻
5 Input shaft
A: CHECKING OIL LEAKING POINTS
1. OIL LEAKING POINTS
1) If leak point is other than a, b, c, or d, perform check
step 5) in 4-3 [W5A2] before dismounting gearbox from
vehicle. If gearbox is dismounted without confirming where
the leak is, it must be mounted again to locate the leak
point.
2) Even if the location of the leak can be easily found by
observing the leaking condition, it is necessary to thor-
oughly remove the oil from the suspected portion and turn
the steering wheel from lock to lock about 30 to 40 times
with engine running, then make comparison of the sus-
pected portion between immediately after and several
hours after this operation.
3) Before starting oil leak repair work, be sure to clean the
gearbox, hoses, pipes, and surrounding parts. After com-
pleting repair work, clean these areas again.
40
2. OIL LEAK CHECK PROCEDURE AND

REPLACEMENT PARTS
NOTE:
Parts requiring replacement are described in the smallest
unit of spare parts including damaged parts and spare
parts damaged. In actual disassembly work, accidental
damage as well as inevitable damage to some related
parts must be taken into account, and spare parts for them
must also be prepared. However, it is essential to pinpoint
the cause of trouble, and limit the number of replacement
parts as much as possible.
1) Leakage from “a”
The oil seal is damaged. Replace valve assembly with a
new one.
2) Leakage from “b”
The torsion bar O-ring is damaged. Replace valve assem-
bly with a new one.
3) Leakage from “c”
new one.
4) Leakage from “d”
The pipe is damaged. Replace the faulty pipe or O-ring.
5) If leak is other than a, b, c, or d, and if oil is leaking from
the gearbox, move the right and left boots toward tie-rod
end side, respectively, with the gearbox mounted to the
vehicle, and remove oil from the surrounding portions.
Then, turn the steering wheel from lock to lock 30 to 40
times with the engine running, then make comparison of
the leaked portion immediately after and several hours
after this operation.
6) Leakage from “e”
The cylinder seal is damaged. Replace rack bush with a
new one.
7) Leakage from “f”
There are two possible causes. Take following step first.
Remove the pipe assembly B from the valve housing, and
close the circuit with ST.
ST 926420000 PLUG
Turn the steering wheel from lock to lock 30 to 40 times
with the engine running, then make comparison of the
leaked portion between immediately after and several
CAUTION:
쐌 If leakage from “f” is noted again:
The oil seal of pinion and valve assembly is damaged.
Replace pinion and valve assembly with a new one. Or
replace the oil seal and the parts that are damaged
during disassembly with new ones.
쐌 If oil stops leaking from “f”:
The oil seal of rack housing is damaged.
Replace the oil seal and the parts that are damaged
41
B: DISASSEMBLY
1. VALVE ASSEMBLY
1) Loosen two bolts securing valve assembly.
G4M0137
2) Carefully draw out input shaft and remove valve assem-

bly.
G4M0138
3) Draw out pinion and valve assembly from valve

housing, as necessary, using pipe of I.D. 44 to 46 mm (1.73
to 1.81 in) and a press.
G4M0139
2. RACK ASSEMBLY
1) Slide mounting rubber to expose slit.
G4M0140
2) Rotate rack stopper in the direction of arrow using ST

until the end of circlip comes out of stopper, then rotate it
in the opposite direction, and pull out circlip.
ST 926340001 WRENCH
G4M0141
42
NOTE:
If ST is used, grind area (shown in figure) by 1 mm (0.04
in) in advance.
ST 926340000 WRENCH
G4M0142
3) Pull rack assembly from cylinder side, and draw out

rack bushing and rack stopper together with rack assem-
bly.
CAUTION:
Be careful not to contact rack to inner wall of cylinder
when drawing out. Any scratch on cylinder inner wall
will cause oil leakage.
4) Remove rack bushing and rack stopper from rack
assembly.
G4M0143
CAUTION:
Do not reuse removed rack bushing and circlip.
C: REPLACEMENT OF SEAL AND PACKING

1. VALVE HOUSING OIL SEAL
쐌 Removal
1) Pry off dust seal using screwdriver.
2) Remove snap ring using snap ring pliers.
G4M0144
3) Pry off oil seal using screwdriver.

CAUTION:
After removing, check inside surface of valve housing
for damage. If oil seal contacting surface is damaged,
replace valve housing with a new one.
G4M0145
43
쐌 Installation
1) Press-fit oil seal into valve housing using ST and press.
ST 927610000 INSTALLER
NOTE:
Before fitting, coat oil seal fully with ATF DEXRON II.
G4M0146
2) Fit snap ring in snap ring groove using snap ring pliers.
CAUTION:
Be careful not to scratch oil seal with snap ring pliers.
NOTE:
Rotate snap ring to check for proper installation.
2. PINION AND VALVE ASSEMBLY

쐌 Removal
1) Remove snap ring using snap ring pliers.
CAUTION:
쐌 Do not reuse removed snap ring.
쐌 Be careful not to scratch pinion and valve assembly.
G4M0147
2) Press out bearing together with backing washer using

pipe of I.D. 38.5 to 39.5 mm (1.516 to 1.555 in) and press.
CAUTION:
Do not reuse removed bearing.
3) Remove oil seal.
CAUTION:
Do not reuse removed oil seal.
G4M0148
44
쐌 Installation
1) Fit pinion and valve assembly into valve housing.
NOTE:
Apply ATF DEXRON II to outer diameter surface of input
shaft and outer surface of valve body seal ring, and pay
special attention not to damage seal when inserting pinion
and valve assembly.
2) Secure valve assembly to ST1 and ST2.

3) Put ST3 over pinion, and insert oil seal, then force-fit oil
seal into housing using ST4.
NOTE:
쐌 Apply ATF DEXRON II to oil seal and ST3, being care-
ful not to damage oil seal lip.
쐌 Push oil seal until ST3 contacts housing end face.
4) Remove ST3, and fit backing washer.
ST1 926370000 INSTALLER A
ST2 927630000 STAND BASE
ST4 927620000 INSTALLER B
G4M0149
5) Force-fit ball bearing using ST3.

ST2 927630000 STAND BASE
ST3 927640000 INSTALLER B
NOTE:
Be careful not to tilt ball bearing during installation.
6) Install snap ring using snap ring pliers.
NOTE:
G4M0150 Rotate snap ring to check for proper installation.
3. RACK HOUSING OIL SEAL AND BACK-UP

WASHER
쐌 Removal
Insert a round rod [26 — 27 mm (1.02 — 1.06 in) dia.] from
pinion housing side and remove oil seal and back-up
washer by hammering the rod.
NOTE:
쐌 Discard removed oil seal and back-up washer.
쐌 Apply the unchamfered end of remover to back-up
G4M0151 washer.
45
쐌 Installation
Force-fit oil seal and back-up washer using ST.
ST 927650000 INSTALLER
CAUTION:
Be careful not to damage or scratch cylinder inner
wall.
NOTE:
쐌 Apply ATF DEXRON II to oil seal.
G4M0152 쐌 Pay special attention not to install back-up washer and
oil seal in wrong direction.
쐌 Push oil seal until the stepped portion of A contacts end
face of B.
D: ASSEMBLY
1. RACK ASSEMBLY
1) Fixing rack housing
Fix rack housing in vice using ST.
ST 926200000 STAND
CAUTION:
쐌 When fixing rack housing in vice, be sure to use this
special tool. Do not fix rack housing in vice using pad
B4M0134A such as aluminum plates, etc.
쐌 When using old rack housing, be sure to clean and
remove rust before assembling. Check pinion housing
bushing carefully.
2) Fit ST over toothed portion of rack assembly, and check

for binding or unsmooth insertion. If any deformation is
noted on flats at the end of rack, shape by using file, and
wash with cleaning fluid.
3) Apply genuine grease to teeth of thoroughly washed
rack assembly, and fit ST over the toothed portion.
ST 926390001 COVER & REMOVER
NOTE:
쐌 Be careful not to block air passage with grease. Remove
G4M0154
excessive grease.
46
쐌 After fitting cover, check air passage hole for clogging.

If clogged, open by removing grease from the hole.
쐌 Check rack shaft for damage.
쐌 Apply ATF DEXRON II to this ST and surface of piston
ring to prevent seal from being damaged.
4) Insert rack assembly into rack housing from cylinder

side, and remove ST after it has passed completely
through oil seal.
NOTE:
Before inserting rack assembly, apply a coat of ATF
DEXRON II to surfaces of ST and rack piston.
ST 926390001 COVER & REMOVER
G4M0155
5) Fit ST1 and ST2 over the end of rack, and install rack
bushing.
ST1 926400000 GUIDE
ST2 927660000 GUIDE
CAUTION:
쐌 If burrs, or nicks are found on this guide and rack
shaft portion, remove by filing.
쐌 Dip rack bushing in ATF DEXRON II before installing,
and pay attention not to damage O-ring and oil seal.
G4M0156
6) Insert rack stopper into cylinder tube until internal

groove (on cylinder side) is aligned with external groove
(on rack stopper). Turn rack stopper with ST so that rack
stopper hole is seen through cylinder slits.
7) Insert rack stopper into rack housing, and wrap circlip
using ST to secure rack stopper in position.
ST 926340001 WRENCH
CAUTION:
Be careful not to scratch rack while winding circlip.
G4M0157
NOTE:
Rotate wrench another 90 to 180° after the end of circlip
has been wrapped in.
8) Fit mounting rubber onto rack housing.
47
2. VALVE ASSEMBLY
1) Apply genuine grease to pinion gear and bearing of
valve assembly.
G4M0158
2) Install packing on valve assembly. Insert valve assem-

bly into place while facing rack teeth toward pinion.
CAUTION:
Be sure to use a new packing.
NOTE:
Do not allow packing to be caught when installing valve
assembly.
3) Tighten bolts alternately to secure valve assembly.
B4M0135 Tightening torque:
25±5 N⋅m (2.5±0.5 kg-m, 18.1±3.6 ft-lb)
CAUTION:
Be sure to alternately tighten bolts.
48
6. Control Valve (Power Steering Gearbox) [RHD model]
6. Control Valve (Power Steering

Gearbox) [RHD model]
NOTE:
This section focuses on the disassembly and reassembly
of control valve. For the inspection and adjustment and the
service procedures for associated parts, refer to “Steering
Gearbox”.
B4M0668A
A: CHECKING OIL LEAKING POINTS

1. OIL LEAKING POINTS
1) If leak point is other than a, b, c, or d, perform check
step 5) in 4-3 [W6A2] before dismounting gearbox from
vehicle. If gearbox is dismounted without confirming where
the leak is, it must be mounted again to locate the leak
point.
2) Even if the location of the leak can be easily found by
observing the leaking condition, it is necessary to thor-
oughly remove the oil from the suspected portion and turn
the steering wheel from lock to lock about 30 to 40 times
with engine running, then make comparison of the sus-
pected portion between immediately after and several
3) Before starting oil leak repair work, be sure to clean the
gearbox, hoses, pipes, and surrounding parts. After com-
pleting repair work, clean these areas again.
49
2. OIL LEAK CHECK PROCEDURE AND

REPLACEMENT PARTS
NOTE:
Parts requiring replacement are described in the smallest
unit of spare parts including damaged parts and spare
parts damaged. In actual disassembly work, accidental
damage as well as inevitable damage to some related
parts must be taken into account, and spare parts for them
must also be prepared. However, it is essential to pinpoint
the cause of trouble, and limit the number of replacement
parts as much as possible.
1) Leakage from “a”
new one.
2) Leakage from “b”
The torsion bar O-ring is damaged. Replace valve assem-
bly with a new one.
3) Leakage from “c”
new one.
4) Leakage from “d”
The pipe is damaged. Replace the faulty pipe or O-ring.
5) If leak is other than a, b, c, or d, and if oil is leaking from
the gearbox, move the right and left boots toward tie-rod
end side, respectively, with the gearbox mounted to the
vehicle, and remove oil from the surrounding portions.
Then, turn the steering wheel from lock to lock 30 to 40
times with the engine running, then make comparison of
the leaked portion immediately after and several hours
after this operation.
6) Leakage from “e”
There are two possible causes. Take following step first.
Remove the pipe assembly B from the valve housing, and
close the circuit with ST.
ST 926420000 PLUG
Turn the steering wheel from lock to lock 30 to 40 times
with the engine running, then make comparison of the
leaked portion between immediately after and several
CAUTION:
쐌 If leakage from “e” is noted again:
The oil seal of pinion and valve assembly is damaged.
Replace pinion and valve assembly with a new one. Or
replace the oil seal and the parts that are damaged
쐌 If oil stops leaking from “e”:
The oil seal of rack housing is damaged.
Replace the oil seal and the parts that are damaged
50
B: DISASSEMBLY
1. VALVE ASSEMBLY
1) Slide dust cover out.
CAUTION:
쐌 Be careful not to scratch housing or input shaft dur-
ing dust cover removal. Also do not allow foreign mat-
ter to enter housing interior.
쐌 Replace dust cover with a new one if its inside bore
or lips are worn or damaged.
G4M0817
2) Remove the two bolts securing valve housing.
G4M0818
3) Remove valve housing, pinion and valve as a unit.
G4M0819
2. RACK ASSEMBLY
1) Remove holder using a 32 mm (1.26 in) wrench or
adjustable wrench.
CAUTION:
Discard old holder and replace with new one.
G4M0820
51
2) Install ST on valve side of rack and press outer side oil

seal out.
ST 34099FA030 INSTALLER & REMOVER
CAUTION:
쐌 Block pipe connection of steering body to prevent
fluid from flowing out.
쐌 Do not allow rack to come in contact with inner wall
of cylinder. Otherwise, cylinder wall may be scratched,
resulting in oil leaks.
쐌 Remove holder and rack as a unit.
쐌 Check rack and steering body for bends or cracks
and replace as required.
쐌 Discard oil seal after removal and replace with new
ones.
G4M0821
3) Insert ST from valve side and press back-up ring and oil
seal out.
CAUTION:
Discard back-up ring and oil seal after removal and
replace with new ones.
ST 927580000 REMOVER
G4M0822
52
4) Using ST1 and ST2, repair cylinder’s clinched sections.

ST1 34099FA080 PUNCH
ST2 34099FA070 BASE
G4M0823
5) If cylinder edge is deformed in a convex shape, repair

using an oil stone.
G4M0889
C: REPLACEMENT OF SEAL AND PACKING

1. VALVE HOUSING OIL SEAL
쐌 Removal
1) After removing dust cover, extract pinion and valve from
valve housing.
CAUTION:
쐌 If pinion and valve is difficult to remove, use a press.
쐌 Discard Y-packing after removal and replace with a
G4M0824 new one.
쐌 Check rotor for bends and serrations for damage
and replace as required.
53
2) Using ST and press, remove dust seal, back-up washer,

Y-packing and ball bearing from valve housing.
CAUTION:
쐌 Use the “A” end of remover.
쐌 Do not apply a force to end surface of valve hous-
ing.
쐌 Do not reuse Y-packing after removal.
G4M0825
쐌 Installation
Specified steering grease:
1) Apply a coat of grease to inner wall of valve housing,
Y-packing and outer perimeter of dust seal.
G4M0836
2) Using ST and press, install Y-packing in valve housing.

(1) Face Y-packing in the direction shown in figure
when installing.
(2) To avoid scratching Y-packing, apply a coat of
grease to contact surface of installer and Y-packing.
(3) To facilitate installation, attach Y-packing to installer
and position in valve housing before pressing into
place.
G4M0838
3) Attach ST2 to ST1, and press ball bearing into place

using a press.
NOTE:
쐌 To facilitate installation, attach ball bearing to remover
and position in valve housing before pressing it into place.
쐌 Use the “B” end of remover.
ST1 34099FA000 INSTALLER & REMOVER
ST2 34099FA050 SPACER
G4M0839
4) Charge Y-packing with specified steering grease.
G4M0840
54
5) Apply a coat of specified steering grease to ST surface,

and install ST onto end of input shaft. Insert pinion and
valve until “A” of oil seal contacts “B” of valve housing. The
ST is used to prevent scratching Y-packing.
ST 34099FA020 GUIDE
G4M0841
6) While supporting pinion and valve, push end of pinion

until bearing contacts brazed end of valve housing.
CAUTION:
Do not allow spacer to extend beyond brazed end.
Otherwise, pinion cannot be inserted properly.
G4M0842
7) Apply a coat of grease to sealing lips of dust cover, and

insert dust cover until it contacts staged portion of input
shaft.
8) Adjust sealing lip-to-housing end clearance to 0 to 0.5
mm (0 to 0.020 in). If sealing lip is too close to housing end,
steering wheel will not return smoothly; if it is too far from
housing end, dust or dirt will enter the clearance.
NOTE:
Ensure that pinion and valve is properly positioned in valve
G4M0843 housing before adjustment.
2. PINION AND VALVE ASSEMBLY
쐌 Removal
1) Remove snap ring securing valve sleeve to pinion and
valve, and remove valve sleeve.
CAUTION:
Be careful not to scratch pinion and valve when remov-
ing snap ring.
G4M0826
2) Remove oil seal and spacer.

3) Using a long rod, remove seal ring and O-ring from
pinion.
CAUTION:
Be careful not to scratch outer surface and seal ring
groove of input shaft. If scratched, sealing effect will
be lost, resulting in a malfunctioning valve.
G4M0827
55
쐌 Installation
1) Wash and clean pinion & valve and valve housing.
2) Attach ST to pinion, and apply grease to outer perimeter
of the cover and mating surface of oil seal.
ST 926270000 COVER
G4M0828
3) Apply a coat of grease to spacer and sealing lips of oil

seal, and install spacer and oil seal.
CAUTION:
쐌 Face chamfered side of spacer toward oil seal.
쐌 Face oil seal in correct direction.
G4M0829
4) Install ST to input shaft, and apply a coat of grease to

the cover surface. Install O-ring and seal ring.
CAUTION:
Do not expand O-ring and seal ring more than neces-
sary.
ST 926450000 COVER
G4M0830
5) Apply a coat of grease to inner wall of ST, and secure

seal ring assembled in step 4) as shown. Leave seal ring
unattended for approximately 10 minutes until it settles
down.
ST 926280000 FORMER
G4M0831
6) While aligning valve sleeve pin with groove on pinion,

secure with snap ring.
CAUTION:
쐌 Be careful not to damage inner wall of valve sleeve
and contact surface of pinion.
쐌 Before assembling valve sleeve and pinion, clean in
kerosene and dry with compressed air.
G4M0832
56
3. RACK PISTON SEAL RING AND O-RING

쐌 Removal
Using a sharp-edged, long rod, remove seal ring and
O-ring from rack piston.
CAUTION:
Be careful not to scratch outer surface of rack piston
and seal ring groove. A scratch may reduce the seal-
ing effect, resulting in faulty piston operation.
G4M0833
쐌 Installation
1) Wash clean rack piston.
2) Install O-ring and seal ring in groove on rack piston.
CAUTION:
쐌 Do not expand O-ring and seal ring more than nec-
essary.
쐌 To facilitate installation of seal ring, first position
one half of entire seal ring in groove. Then slowly posi-
tion the second half using a spatula, as shown.
G4M0834
3) Apply a coat of grease to inner surface of ST and insert

rack piston into it. Leave ST at least 10 minutes until seal
ring settles down in place.
CAUTION:
Be careful not to scratch rack, piston and seal ring
during installation.
ST 927600000 FORMER
G4M0835
57
D: ASSEMBLY
1. RACK ASSEMBLY
Specified steering grease:
1) Attach steering body to ST as shown. Apply a coat of
grease to needle bearing.
ST 926200000 STAND
CAUTION:
G4M0844 쐌 Use a ST to support steering body.
쐌 Ensure that needle bearing is free from defects. If it
is faulty, replace steering body with a new one.
NOTE:
If steering body is removed from vehicle, be sure to remove
rust and clean.
2) Using ST⋅B and ST⋅C, attach oil seal to ST⋅A. Insert

ST⋅A into rack from gear side. Remove oil seal from ST⋅A
when it approaches piston and remove STs from rack.
ST 927490000 INSTALLER; A⋅B⋅C
NOTE:
Face oil seal in the direction shown in figure.
G4M0845
3) Install back-up ring from gear side of rack.
G4M0846
4) Install ST on rack and equally apply a thin coat of

grease to rack and ST, then install oil seal.
CAUTION:
Be careful not to scratch oil seal lips with piston’s
knurl section.
ST 926250000 GUIDE
G4M0890
58
5) Apply a coat of grease to grooves in rack, sliding sur-

face of sleeve and sealing surface of piston. Install ST on
the end of steering body cylinder. Then insert rack into
steering body from cylinder side.
CAUTION:
쐌 Be sure to apply grease so that it covers the entire
surface of rack gear teeth.
쐌 Do not allow grease to block air vent hole on rack.
ST 34099FA010 GUIDE (Oil seal)
G4M0891
6) Slowly press inner side oil seal until distance between

ST and end of rack is 65 mm (2.56 in).
CAUTION:
Ensure ST’s inner wall is free of scratches. Otherwise,
it may damage oil seal during installation.
ST 34099FA010 GUIDE (Oil seal)
G4M0892
7) Pass ST2 and pipe through rack and press outer side
oil seal until ST1 is in contact with ST2.
ST1 34099FA010 GUIDE (Oil seal)
ST2 34099FA040 INSTALLER (Oil seal)
G4M0893
8) Install holder from cylinder side of steering body.

Tightening torque:
64±5 N⋅m (6.5±0.5 kg-m, 47.0±3.6 ft-lb)
G4M0820
59
9) Attach ST to rack cylinder. Using a press, install

back-up ring and oil seal.
NOTE:
Press ST until its groove is aligned with end of holder.
G4M0850
10) Using ST, clinch steering body cylinder at a point less

than 3 mm (0.12 in) from holder.
CAUTION:
Be careful not to deform holder.
ST 34099FA060 PUNCH HOLDER
G4M0967
60
2. VALVE ASSEMBLY
1) Remove traces of sealer, oil, rust, etc., from mating
surfaces of valve housing and steering body.
2) Position a shim in graded portion of steering body pin-
ion housing, and apply an even coat of sealer (Fuji Bond
C: 004403004 or three bond 1105 (00440310) or equiva-
lent) to end of pinion housing.
3) Use the same number of shims as that used when
steering body was removed.
B4M0669A 4) If steering body, valve housing or pinion and valve is
replaced with a new one, add two or three shims, install
valve on pinion housing and tighten with two bolts to 25±5
N⋅m (2.5±0.5 kg-m, 18.1±3.6 ft-lb). Then, measure clear-
ance between steering body and valve housing using a
thickness gauge. Remove shims so that the clearance is
zero.
5) Extend rack “L” beyond pinion side of steering body.

L: 70.8 mm (2.787 in)
B4M0670A
6) Apply grease to pinion gear teeth and ball bearing.

Insert valve into place.
7) Alternately and slowly tighten socket bolts.
NOTE:
Replace faulty parts before installing valve. Otherwise,
valve may not be installed properly.
Tightening torque:
25±5 N⋅m (2.5±0.5 kg-m, 18.1±3.6 ft-lb)
G4M0853
61
7. Pipe Assembly (Power Steering System)
7. Pipe Assembly (Power Steering

System)
A: REMOVAL
1. LHD MODEL
G4M0098
2) Lift vehicle and remove jack-up plate.

CAUTION:
Improper removal and installation of parts often
causes fluid leak trouble. To prevent this, clean the
surrounding portions before disassembly and
G4M0099 reassembly, and pay special attention to keep dirt and
other foreign matter from mating surfaces.
4) Remove clamp E from pipes C and D.
G4M0162
62
5) Disconnect pipe C⋅D from pipe (on the gearbox side).

CAUTION:
쐌 When disconnecting pipe C⋅D, use two wrenches to
prevent deformities.
쐌 Be careful to keep pipe connections free from for-
eign matter.
G4M0101
6) Remove bolt A.
Disconnect pipe C from oil pump. Disconnect pipe D from
oil tank.
CAUTION:
쐌 Do not allow fluid from the hose end to come into
contact with pulley belt.
쐌 To prevent foreign matter from entering the hose
and pipe, cover the open ends of them with a clean
cloth.
B4M1159A
2. RHD MODEL
G4M0098
2) Lift vehicle and remove jack-up plate.

CAUTION:
Improper removal and installation of parts often
causes fluid leak trouble. To prevent this, clean the
surrounding portions before disassembly and
B4M0671A reassembly, and pay special attention to keep dirt and
other foreign matter from mating surfaces.
63
4) Remove clamp E from pipes C and D.
B4M0672A
5) Remove flare nuts from control valve of gearbox

assembly, and then disconnect pipe C⋅D.
CAUTION:
쐌 When disconnecting pipe C⋅D, use two wrenches to
prevent deformities.
쐌 Be careful to keep pipe connections free from for-
eign matter.
6) Remove bolt A.
Disconnect pipe C from oil pump. Disconnect pipe D from
oil tank.
CAUTION:
cloth.
B4M1159A
B: CHECK
Check all disassembled parts for wear, damage or other
abnormalities. Repair or replace faulty parts as required.
Part name Inspection Remedy
Pipe 쐌 O-ring fitting surface for
damage
Replace with new one.
쐌 Nut for damage
쐌 Pipe for damage
Clamp 쐌 Clamps for weak
Clamp E clamping force
Hose 쐌 Flared surface for

damage
쐌 Flare nut for damage
쐌 Outer surface for cracks
쐌 Outer surface for wear
쐌 Clip for damage
쐌 End coupling or adapter
for degradation
64
C: ASSEMBLY
1. LHD MODEL
1) Interconnect pipes C and D.
Tightening torque:
Joint nut
15±5 N⋅m (1.5±0.5 kg-m, 10.8±3.6 ft-lb)
CAUTION:
Visually check that hose between tank and pipe D is
B4M1159A free from bending or twisting.
2) Connect pipe D from oil tank.
3) Connect pipe C from oil pump.
CAUTION:
Use a new gasket.
Tightening torque:
34±5 N⋅m (3.5±0.5 kg-m, 25.3±3.6 ft-lb)
4) Tighten bolt A.
Tightening torque:
13±3 N⋅m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
5) Temporarily connect pipes C and D to pipes (on the

gearbox side).
G4M0165
65
6) Temporarily install clamp E on pipes C and D.

CAUTION:
Ensure that the letter “8” on each clamp side are
diagonally opposite each other as shown in the figure.
7) Tighten clamp E firmly.
Tightening torque:
7.4±2.0 N⋅m (0.75±0.20 kg-m, 5.4±1.4 ft-lb)
8) Tighten joint nut.
B4M0557A Tightening torque:
15±5 N⋅m (1.5±0.5 kg-m, 10.8±3.6 ft-lb)
9) Connect pipes A and B to four pipe joints of gearbox.

Connect upper pipe B first, and lower pipe A second.
Tightening torque:
13±3 N⋅m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
G4M0099

11) Connect battery minus terminal.
12) Feed the specified fluid and discharge air.
NOTE:
Never start the engine before feeding the fluid; otherwise
vane pump might be seized up.
66
G4M0167
13) Finally check clearance between pipes and/or hoses,

as shown above.
If clearance between cruise control pump and power steer-
ing hose is less than 10 mm (0.39 in), proceed as follows:
(1) Move clamped section 쎻 A (refer to figure above.)
down to a point where pipe is close to crossmember.
Pipe-to-crossmember clearance:
10 mm (0.39 in), min.
(2) Check that clearance between cruise control pump
and power steering hose is at least 10 mm (0.39 in). If
it is not, bend section 쎻
B down until a clearance of at
least 10 mm (0.39 in) is obtained.
2. RHD MODEL
Tightening torque:
Joint nut
15±5 N⋅m (1.5±0.5 kg-m, 10.8±3.6 ft-lb)
CAUTION:
Visually check that hose between tank and pipe D is
free from bending or twisting.
B4M1159A
67

CAUTION:
Use a new gasket.
Tightening torque:
34±5 N⋅m (3.5±0.5 kg-m, 25.3±3.6 ft-lb)
4) Tighten bolt A.
Tightening torque:
13±3 N⋅m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
5) Temporarily connect pipes C and D to control valve of

gearbox.
B4M0673A
6) Temporarily install clamp E on pipes C and D.

CAUTION:
Ensure that the letter “8” side of clamp E is on the pipe
C side as shown in the figure.
7) Tighten clamp E firmly.
Tightening torque:
7.4±2.0 N⋅m (0.75±0.20 kg-m, 5.4±1.4 ft-lb)
8) Tighten joint nut.
15±5 N⋅m (1.5±0.5 kg-m, 10.8±3.6 ft-lb)
9) Connect pipes A and B to four pipe joints of gearbox.

Connect upper pipe A first, and lower pipe B second.
Tightening torque:
13±3 N⋅m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
B4M0671A
68

11) Connect battery negative terminal.
NOTE:
B4M0674A
69
8. Oil Pump (Power Steering System)

A: REMOVAL
1) Remove ground cable from battery.
2) Drain the working fluid about 0.35 (0.4 US qt, 0.3 Imp
qt) from oil tank.
3) Remove pulley belt cover bracket.
B4M1160
4) Loosen oil pump pulley nut, then remove bolts which

secure alternator.
5) Loosen pulley belt(s).
6) Remove the nut and detach oil pump pulley.
B4M1161A
7) Remove bolt A. Disconnect pipe C from oil pump. Dis-

connect pipe D from oil tank.
CAUTION:
cloth.
쐌 Except when only oil tank needs to be inspected,
B4M1159A detach oil tank and oil pump as a unit. Then separate
one from the other on a work bench to prevent oil from
spilling on any part of the engine.
8) Remove three bolts from the front side of oil pump and
detach the pump.
9) Remove three bolts from the lower side of bracket and
detach the bracket.
CAUTION:
The bracket does not need to be removed unless it is
damaged.
B4M0560
70
10) Place oil pump in a vise, remove two bolts from oil tank
and detach oil tank.
CAUTION:
Do not place oil pump directly in the vise; use soft
pads and hold oil pump lightly to protect the pump.
11) Remove O-ring from oil pump.
12) Remove stay from oil pump. (2500 cc model only)
B4M0561A
B: CHECK
In accordance with the following table, check all removed
parts for wear and damage, and make repair or replace-
ment if necessary.
(1) Crack, damage or oil leakage Replace oil pump with a new one.
Measure radial play and axial play.
1 Oil pump (Exterior) If any of these exceeds the service limit,
(2) Play of pulley shaft
replace oil pump with a new one. <Ref. to
4-3 [W8B1].>
(1) Damage Replace it with a new one.
Measure V ditch deflection.
2 Pulley If it exceeds the service limit, replace
(2) Bend
pulley with a new one. <Ref. to 4-3
[W8B1].>
3 Cap Crack or damage Replace it with a new one.
(1) Clogging with dirt Wash it.
4 Strainer
(2) Breakage Replace it with a new one.
Check resistance to rotation of pulley.
If it is past the service limit, replace oil
(1) Defect or burning of vane pump
pump with a new one. <Ref. to 4-3
[W8B1].>
5 Oil pump (Interior) Oil pump emits a noise that is markedly
different in tone and loudness from a
(2) Bend in the shaft or damage to
sound of a new oil pump when turning with
bearing
a string put around its pulley, replace oil
pump with a new one.
6 O-ring Crack or deterioration Replace it with a new one.
7 Oil tank Crack, damage or oil leakage Replace it with a new one.
8 Bracket Crack or damage Replace it with a new one.
71
1. SERVICE LIMIT
Make a measurement as follows. If it exceeds the specified
service limit, replace the parts with new ones.
CAUTION:
쐌 Fix oil pump on a vise to make a measurement. At
this time, hold oil pump with the least possible force
between two wood pieces.
쐌 Do not set outside of flow control valve or pulley on
a vise; otherwise outside or pulley might be deformed.
G4M0172 Select properly sized wood pieces.
Play of pulley shaft

Service limit:
Radial play (Direction )
Axial play (Direction )
On condition:
P: 9.8 N (1.0 kg, 2.2 lb)
G4M0173
Ditch deflection of pulley

Service limit:
NOTE:
Read the value for one surface of V ditch, and then the
value for another off the dial.
G4M0174
Resistance to rotation of pulley

Service limit:
Maximum load; 9.22 N (0.94 kg, 2.07 lb) or less
NOTE:
쐌 A rather higher value may be indicated when pulley
starts turning.
쐌 Measure the load during rotation and make a judgment.
G4M0175
72
C: DISASSEMBLY
B4M0142A
쎻
1 Pulley 쎻
9 Spring 쎻
17 Side plate
쎻
2 Snap ring 쎻
10 Front casing
쎻
3 Bearing 쎻
11 Rear cover Tightening torque: N⋅m (kg-m, ft-lb)
쎻
4 Oil seal 쎻
12 Knock pin T1: 16±2 (1.6±0.2, 11.6±1.4)
T2: 61±7 (6.2±0.7, 45.0±5.2)
쎻
5 Shaft 쎻
13 Seal washer
T3: 74±5 (7.5±0.5, 54.2±3.6)
쎻
6 Connector 쎻
14 Cam ring
쎻
7 O-ring 쎻
15 Vane
쎻
8 Spool valve 쎻
16 Rotor
1) Oil pump body

(1) Place oil pump in a vise, and remove two bolts
which secure tank.
CAUTION:
Do not place oil pump directly in vise; use soft pads
and hold oil pump lightly to protect it.
B4M0561A
73
(2) Remove four bolts which secure rear cover.
G4M0178
(3) Remove the following parts from front casing.

쎻
1 Seal washer
쎻
2 Knock pin ...............................................................2 ea.
쎻
3 Cam ring
쎻
4 Rotor
쎻
5 Vane .....................................................................10 ea.
쎻
6 Side plate
쎻
7 O-ring .....................................................................2 ea.
CAUTION:
G4M0923
Discard old seal washer; replace with a new one.
2) Control valve
Slightly loosen outlet connector, and remove connector.
Remove the following parts for pump casing.
쐌 Spool valve assembly
쐌 Flow control spring
쐌 Connector
쐌 O-ring
G4M0180
3) Shaft
(1) Remove snap ring from front casing.
G4M0181
74
(2) Remove shaft using a hand press.

CAUTION:
쐌 Discard old drive shaft assembly; replace with a new
one.
쐌 Be careful not to scratch or dent casing’s surface
which serves as a seal.
G4M0182
(3) Pry oil seal off using a screwdriver.

CAUTION:
Be careful not to scratch inner surface of casing.
4) Remove pressure switch.
G4M0183
D: INSPECTION
Perform the following inspection procedures and repair or
replace defective parts.
Part name Description Remedy
1) Damage on body surfaces
2) Excessive wear on hole, into which spool valve
is inserted.
Replace with a new one together with spool valve
1. Front casing 3) Wear and damage on cartridge assembly mount-
as selective fit is made.
ing surface
4) Wear and damage on surfaces in contact with
shaft and oil seal
1) Damage on body surfaces
2. Rear cover Replace with a new one.
2) Wear and damage on sliding surfaces
1) Shaft bend
2) Wear and damage on surfaces in contact with
3. Shaft bushing and oil seal Replace with a new one.
3) Wear and damage on rotor mounting surfaces
4) Bearing damage
4. Side plate Wear and damage on sliding surfaces Replace with a new one.
5. Cam ring Ridge wear on sliding surfaces
6. Vane Excessive wear on nose radius and side surfaces
If damage is serious, replace with a new cartridge
1) Wear and damage on sliding surfaces assembly.
2) Ridge wear on vane sliding grooves (If light
7. Rotor leaks with vane in slit against light source)
Correct with oil stone. If damage is serious, replace
3) Damage resulting from snap ring removal
with a new cartridge assembly.
Replace with a new one together with front casing
8. Spool valve Damage or burrs on sliding surface periphery
as selective fit is made.
9. Connector Damage on threads Replace with a new one.
10. Spring Damage Replace with a new one.
11. Bolts and nuts Damage on threads Replace with a new one.
75
E: ASSEMBLY
1) Reassembly precautions
(1) Whenever O-rings, oil seals, and snap rings are
removed, they must be replaced with new ones.
(2) Thoroughly wash parts and allow to dry. They must
be kept free from cleaning oil and dust.
(3) Reassembly procedure must be performed in clean
place. Ensure that parts are kept away from waste
threads or other dust particles.
(4) Cleaning oil tends to stay inside the front casing.
Remove it completely by blowing compressed air.
(5) Ensure that parts are free from rust. (Use specified
hydraulic oil for rust prevention after cleaning and dry-
ing.)
(6) Reverse the sequence of disassembly procedures.
2) Shaft
(1) Apply grease to oil seal and inner surface of front
casing (at bearing location).
CAUTION:
Make sure that the front body internal surfaces are free
from damage.
(2) Using ST, press-fit oil seal into front body.

ST 340099AA000 INSTALLER
CAUTION:
When press-fitting, use care to prevent damage to sur-
face mating with rear body.
NOTE:
Orient oil seal toward correct direction.
G4M0184
(3) Using ST, press-fit shaft assembly into front body

and mount snap ring.
ST 340099AA020 INSTALLER
NOTE:
Turn snap ring to ensure that it fits right into the groove.
G4M0185
76
3) Cartridge assembly
(1) Apply specified hydraulic oil to O-rings and fit them
into front casing.
(2) Install side plate to front casing.
CAUTION:
Use care not to let side plate gall.
G4M0186
(3) Mount rotor onto shaft.

(4) Install 10 vanes into rotor with their nose radius
facing toward cam ring.
(5) Install cam ring to front casing, securing with knock
pins.
CAUTION:
Do not use hammer to fit knock pins in position.
G4M0187
4) Rear cover
(1) Mount seal washer on front casing.
(2) With knock pin positions aligned, install rear cover.
Tightening torque:
16±2 N⋅m (1.6±0.2 kg-m, 11.6±1.4 ft-lb)
CAUTION:
Loosely tighten bolts in the sequence 쎻 1 , 쎻
3 , 쎻2 , and 쎻4
shown in figure. Then, tighten in the same sequence.
G4M0188
5) Spool Valve
(1) Install spring into front casing. Then, with spool
valve dipped in specified hydraulic oil, install it into the
front casing.
G4M0189
(2) Using a 5-mm dia. round bar, ensure that valve

moves smoothly.
(3) Set O-ring, with grease applied to it, onto connec-
tor and secure connector to front casing.
Tightening torque:
74±5 N⋅m (7.5±0.5 kg-m, 54.2±3.6 ft-lb)
CAUTION:
쐌 Use care to prevent damage to O-ring at installation.
쐌 When tightening connector, ensure that O-ring does
not protrude or get caught.
77
6) Check
(1) When reassembly procedures have been
completed, turn shaft by hand to ensure it turns
smoothly. If it binds or other unusual conditions are
evident, disassemble again and check for foreign mat-
ter trapped on sliding surfaces and improper installa-
tion. Eliminate the cause of trouble.
(2) Check followings by referring to “CHECK” article.
쐌 Excessive play in pulley shaft
쐌 Ditch deflection of pulley
쐌 Resistance to rotation of pulley
쐌 Measurement of generated oil pressure
F: INSTALLATION
1) Install bracket on engine.
Tightening torque:
22±2 N⋅m (2.2±0.2 kg-m, 15.9±1.4 ft-lb)
2) Install oil pump on oil tank as follows outside the
vehicle:
NOTE:
Prior to installation, make sure that all oil is removed from
oil pump, oil tank and pipe.
3) Place oil pump in vise.

CAUTION:
Do not place oil pump directly in vise; use soft pads
and hold oil pump lightly to protect it.
4) Install O-ring on oil pump.
CAUTION:
Discard old O-ring and replace with a new one.
5) Install oil tank on oil pump.
Bolt C: 15.7±2.4 N⋅m
(1.60±0.24 kg-m, 11.58±1.77 ft-lb)
Bolt D: 18.1±2.5 N⋅m
(1.85±0.25 kg-m, 13.35±1.84 ft-lb)
CAUTION:
Discard old seal washer and replace with a new one.
78
6) Install stay to oil pump. (2500 cc model only)

Tightening torque:
15.7±2.5 N⋅m (1.6±0.25 kg-m, 11.6±1.8 ft-lb)
B4M1163A
7) Install oil pump, previously assembled to oil tank, on

bracket.
Tightening torque:
20.1±2.5 N⋅m (2.05±0.25 kg-m, 14.8±1.8 ft-lb)
8) Place oil pump pulley and tighten pulley nut temporarily.
B4M0560

Tightening torque:
Joint nut
15±5 N⋅m (1.5±0.5 kg-m, 10.8±3.6 ft-lb)
CAUTION:
If a hose is twisted at this step, the hose may come into
contact with some other parts.
B4M1159A
CAUTION:
Use a new gasket.
Tightening torque:
34±5 N⋅m (3.5±0.5 kg-m, 25.3±3.6 ft-lb)
12) Tighten bolt A.
Tightening torque:
13±3 N⋅m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
13) Install pulley belt to oil pump.
14) Tighten oil pump pulley nut to the specified torque.
Tightening torque:
61±7 N⋅m (6.2±0.7 kg-m, 44.8±5.1 ft-lb)
15) Adjust pulley belt tension. <Ref. to 1-5 [01A0].>
16) Tighten bolt belt tension.
Tightening torque:
8±2 N⋅m (0.8±0.2 kg-m, 5.8±1.4 ft-lb)
17) Install pulley belt cover bracket.
18) Connect minus terminal of battery.
NOTE:
79
9. Power Steering Fluid

A: RECOMMENDED AIR BLEEDING AND
POWER STEERING FLUID
Recommended power steering fluid Manufacturer
B.P.
CALTEX
CASTROL
ATF DEXRON II or ATF DEXRON IIE
MOBIL
SHELL
TEXACO
1) Feed the specified fluid with its level being about 5 cm

(2.0 in) lower than the mouth of tank.
2) Continue to turn steering wheel slowly from lock to lock
until bubbles stop appearing in the tank while keeping the
fluid at that level.
3) In case air is absorbed to deliver bubbles into piping
because the fluid level is lower, leave it about half an hour
and then do the step 2) all over again.
4) Start, and idle the engine.
5) Continue to turn steering wheel slowly from lock to lock
again until bubbles stop appearing in the tank while keep-
ing the fluid at that level.
It is normal that bubbles stop appearing after three times
turning of steering wheel.
6) In case bubbles do not stop appearing in the tank, leave
it about half an hour and then do the step 5) all over again.
7) Stop the engine, and take out safety stands after jack-
ing up vehicle again.
Then lower the vehicle, and idle the engine.
8) Continue to turn steering wheel from lock to lock until
bubbles stop appearing and change of the fluid level is
within 3 mm (0.12 in).
9) In case the following happens, leave it about half an
hour and then do step 8) again.
(1) The fluid level changes over 3 mm (0.12 in).
(2) Bubbles remain on the upper surface of the fluid.
(3) Grinding noise is generated from oil pump.
10) Check the fluid leakage at flare nuts after turning
steering wheel from lock to lock with engine running.
CAUTION:
쐌 Before checking, wipe off any fluid on flare nuts and
piping.
쐌 In case the fluid leaks from flare nut, it is caused by
dust (or the like) and/or damage between flare and
tapered seat in piping.
쐌 So remove the flare nut, tighten again it to the speci-
fied torque after cleaning flare and tapered seat. If flare
or tapered seat is damaged, replace it with a new one.
11) Inspect fluid level on flat and level surface with engine
“OFF” by indicator of filler cap.
80
If the level is at lower point or below, add fluid to keep the

level in the specified range of the indicator. If at upper point
or above, drain fluid by using a syringe or the like.
Fluid capacity:
0.7 (0.7 US qt, 0.6 Imp qt)
(1) Check at temperature 21°C (70°F) on reservoir sur-

face of oil pump.
(2) Check at temperature 60°C (140°F) on reservoir
surface of oil pump.
B4M0563
81
4-3 DIAGNOSTICS
1. Power Steering
1. Power Steering
1. STEERING CONDITION
Heavy steering Heavy steering Steering wheel Vehicle leads to Poor return of
effort in all range effort at stand still surges when turn- one side or the steering wheel to
ing. other. center
왔 왔
Pulley belt NOT GOOD Fluid line Reform or
1. Unequal length of pulley 왘 Adjust or replace. 1. Folded hose 왘 replace.
NOT
belts 2. Flattened pipe
GOOD
2. Adhesion of oil and
GOOD
grease 왔
3. Loose or damage of pul-
Tire and rim
ley belt 왘 Fix or replace.
1. Flat tire
4. Poor uniformity of pulley NOT
2. Mix use of different tires
belt cross section GOOD
3. Mix use of different rims
5. Pulley belt touches to
4. Abnormal wear of tire
pulley bottom
5. Unbalance of remained
6. Poor revolution of pulleys
grooves
except oil pump pulley
6. Unbalance of tire pres-
7. Poor revolution of oil
sure
pump pulley
GOOD
왔 GOOD 왔
Tire and rim NOT GOOD Front alignment Adjust or
1. Improper tires out of 왘 Replace or reinflate. 1. Improper or unbalance 왘 retighten.
NOT
specification caster
GOOD
2. Improper rims out of 2. Improper or unbalance
specification toe-in
3. Tires not properly 3. Loose connection of sus-
inflated*1 pension
왔 GOOD 왔 GOOD
Fluid NOT GOOD Refill, bleed air, replace or Others Replace, adjust or
1. Low fluid level 왘 instruct customer. 1. Damaged joint assembly 왘 instruct customer.
NOT
2. Aeration 2. Unbalanced height
GOOD
3. Dust mix 3. One-sided weight
4. Deterioration of fluid
왔
GOOD
5. Poor warming-up of fluid
*2 Measure steering effort.
왔 GOOD
Idling speed NOT GOOD
1. Lower idling speed 왘 Adjust or instruct customer.
2. Excessive drop of
idling speed at start
or at turning steering
wheel *3 *1 If tires and/or rims are wider, the load to power steering system is the more. Accordingly, in a
GOOD condition, for example before fluid warms-up, relief valve may work before maximum turning angle.
왔 In this case, steering effort may be heavy. When measured hydraulic pressure is normal, there is
no abnormal thing.
Measure hydraulic pressure. *2 In cold weather, steering effort may be heavy due to increased flow resistance of cold fluid. After
GOOD warming up engine, turn steering wheel from stop to stop several times to warm up fluid. Then if
steering effort reduces normally, there is no abnormal thing.
왔
*3 In cold weather or with insufficient warm-up of engine, steering effort may be heavy due to exces-
Measure steering effort. sive drop of idling when turning steering wheel. In this case, it is recommended to start the vehicle
with increasing engine speed than usual. Then if steering effort reduces normally, there is no
abnormal thing.
82
DIAGNOSTICS 4-3
1. Power Steering
2. MEASUREMENT OF HYDRAULIC PRESSURE

CAUTION:
Be sure to complete all items aforementioned in
“STEERING CONDITION” 4-3 [K101], prior to measur-
ing hydraulic pressure. Otherwise, pressure can not be
measured correctly.
Measure regular pressure at NOT GOOD Flattened pipes or hoses Replace bad parts.
왘 왘
idling with valve opened.
NOT GOOD Leakage of fluid line Replace.

왘 왘
NOT GOOD Obstacle in fluid line Replace fluid or component of

왘 왘
fluid line.
GOOD
왔
Measure relief pressure at NOT GOOD
왘
Poor work of relief valve 왘
Replace oil pump.
idling with valve closed.
NOT GOOD
왘
Fluid leakage inside oil pump 왘
NOT GOOD
왘
Excessive wear of vane pump 왘
mechanism
GOOD
왔
NOT GOOD
Measure working pressure of 왘
Poor work of control valve 왘
Replace valve assembly or
control valve at idling with pinion and valve assembly.
valve opened, turning steering
wheel from stop to stop.
CAUTION:
쐌 Do not leave the valve of pressure gauge closed or
hold the steering wheel at stop end for 5 seconds or
more in any case, as the oil pump may be damaged
due to long keep of these conditions.
쐌 Put cotton cloth waste at a place where fluid drops
before pressure gauge is installed. Wipe off split fluid
thoroughly after the measurement.
NOTE:
Keep engine idling during the measurement.
83
4-3 DIAGNOSTICS
1. Power Steering
1) Install STs to power steering pump.

(1) Drain the power steering fluid about 0.35 (0.4 US
qt, 0.3 Imp qt) from oil tank.
(2) Remove two bolts securing power steering pipes to
engine.
(3) Install ST1, 2 and 3 between power steering pump
and pipes using gasket (Part No. 34621AC020) and
bolt (Part No. 34620AC010).
ST1 925711000 PRESSURE GAUGE
B4M1193A
ST2 34099AC020 ADAPTER B
ST3 34099AC010 ADAPTER A
(4) Replenish power steering fluid up to specified level.
2) Using STs, measure regulator pressure.
Regulator pressure:
981 kPa (10 kg/cm2, 142 psi) or less
3) Using STs, measure relief pressure.

Relief pressure:
7,159 — 7,748 kPa
(73 — 79 kg/cm2, 1,038 — 1,123 psi)
B4M1162A
84
DIAGNOSTICS 4-3
1. Power Steering
3. MEASUREMENT OF STEERING EFFORT

*4
Measure steering efforts in stand still with engine idling on NOT GOOD Adjust backlash.
왘
concrete road.
Result: 29.4 N (3.0 kg, 6.6 lb) or less in both directions
GOOD
왔
*4 When turning steering more
Measure steering efforts in stand still with engine stalled on
quickly than necessary from
concrete road.
a direction to the other direc-
Result: 294.2 N (30.0 kg, 66.2 lb) or less in both directions
tion at an engine speed over
NOT GOOD GOOD 2,000 rpm, steering effort
may be heavy. This is caused
by flow characteristic of oil
pump and is not a problem.
왔
Adjust backlash.
왔
Remove universal joint.
왔
Measure steering wheel effort. NOT GOOD
왘
Check, readjust, replace if
Result: Maximum force is 2.26 N (0.23 kg, 0.51 lb) or less in necessary.
both directions.
Fluctuation width is 1.08 N (0.11 kg, 0.24 lb) or less.
GOOD
왔
Measure folding torque of the joint. NOT GOOD
왘
Replace with a new one.
Result: 5.49 N (0.56 kg, 1.23 lb) or less for long yoke
8.43 N (0.86 kg, 1.90 lb) or less for short yoke
GOOD
왔
Check front wheels for unsteady revolution or rattling and brake NOT GOOD
왘
Inspect, readjust, replace if
for dragging. necessary.
GOOD
왔
Remove tie-rod ends.
왔
(To be continued.)
85
4-3 DIAGNOSTICS
1. Power Steering
NOT GOOD
Check tie-rod ends, tie-rods and ball 왘
Inspect, replace if necessary.
joints of suspension for unsteady
revolution or rattling.
GOOD
왔
NOT GOOD
Measure rotating and sliding resistance 왘
Readjust backlash, if ineffective replace
of gearbox. bad parts.
Result: Rotating resistance is 11.18 N
(1.14 kg, 2.51 lb) or less around
center position and 15.79 N
(1.61 kg, 3.55 lb) or less in all
positions within 20% difference
between clockwise and
counterclockwise.
Sliding resistance is 304 N (31
kg, 68 lb) or less with 20%
difference between left and right
directions.
쐌 Measurement of steering effort is as shown in the fig-

ures.
B4M0146
B4M0147
86
DIAGNOSTICS 4-3
1. Power Steering
쐌 Measurement of folding torque of universal joint is as

shown in the figures.
G4M0199
G4M0200
G4M0201
G4M0202
NOTE:
Using ST, measure resistances of gearbox.
Rotating resistance:
from rack center
Less than 11.18 N (1.14 kg, 2.51 lb)
Maximum allowable torque
15.7 N (1.6 kg, 3.5 lb)
G4M0203
87
4-3 DIAGNOSTICS
1. Power Steering
Sliding resistance:
Right-turn steering
304 N (31 kg, 68 lb) or less
Left-turn steering
304 N (31 kg, 68 lb) or less
G4M0204
G4M0205
88
DIAGNOSTICS 4-3
1. Power Steering
4. FLUID LEAKAGE (LHD MODEL)

CAUTION:
It is likely that although one judges fluid leakage, there
is actually no leakage. This is because the fluid spilt
during the last maintenance was not completely wiped
off. Be sure to wipe off spilt fluid thoroughly after
maintenance.
Leakage from connecting portions of 왘
Insufficient tightening of flare nut, 왘
Loosen and retighten, if ineffective,
pipes and hoses, numbered with 쎻1 catching dirt or the like, damage to replace.
thru 쎻
9 in figure flare or flare nut
왘
Poor insertion of hose, poor clamp- 왘
Retighten or replace clamp.
ing
왘
Damaged O-ring 왘
Replace O-ring pipe or hose with
new one, if ineffective, replace gear-
box also.
Leakage from hose 쎻

10 and 쎻
11 in 왘
Crack or damage in hose 왘
figure
왘
Crack or damage in hose hardware 왘
Leakage from surrounding of cast 왘

Damaged oil seal 왘
Replace oil seal.
iron portion of oil pump 쎻
12 and 쎻
13 in
figure
왘
Leakage from oil tank, 쎻

14 and 쎻
15
왘
Crack in oil tank, 쎻
14
왘
Replace oil tank.
in figure
왘
Damaged O-ring, 쎻
15
왘
Replace O-ring.
Leakage from filler neck 쎻

16
왘
Damaged cap packing 왘
Replace cap.
왘
Crack in root of filler neck 왘
Replace oil tank.
왘
High fluid level *5 왘
Adjust fluid level.
Leakage from surrounding of power 왘

Replace bad parts.
cylinder of gearbox, 쎻
17 in figure
Leakage from control valve of 왘

Damaged packing or oil seal 왘
gearbox, 쎻
18 and 쎻
19 in figure
왘
Damage in control valve 왘
*5 Fluid level is specified at optimum position (range) for ordinary use. Accordingly, if the vehicle is used often under hard con-
ditions such as on very rough roads or in mountainous areas, fluid may bleed out from cap air vent hole. This is not a prob-
lem. If a customer complains strongly and is not likely to be satisfied with the leakage, lower the fluid level to the extent that
fluid will not bleed out under the conditions described, and have the customer check the fluid level and its quality more fre-
quency than usual.
89
4-3 DIAGNOSTICS
1. Power Steering
B4M0564A
90
DIAGNOSTICS 4-3
1. Power Steering
5. FLUID LEAKAGE (RHD MODEL)

CAUTION:
It is likely that although one judges fluid leakage, there
is actually no leakage. This is because the fluid spilt
during the last maintenance was not completely wiped
off. Be sure to wipe off spilt fluid thoroughly after
maintenance.
Leakage from connecting portions of 왘
Insufficient tightening of flare nut, 왘
Loosen and retighten, if ineffective,
pipes and hoses, numbered with 쎻1 catching dirt or the like, damage to replace.
thru 쎻
9 in figure flare or flare nut
왘
Poor insertion of hose, poor clamp- 왘
Retighten or replace clamp.
ing
왘
Damaged O-ring 왘
Replace O-ring pipe or hose with
new one, if ineffective, replace gear-
box also.
Leakage from hose 쎻

10 and 쎻
11 in 왘
Crack or damage in hose 왘
figure
왘
Crack or damage in hose hardware 왘
Leakage from surrounding of cast 왘

Replace oil seal.
iron portion of oil pump 쎻
12 and 쎻
13 in
figure
왘
Leakage from oil tank, 쎻

14 and 쎻
15
왘
Crack in oil tank, 쎻
14
왘
Replace oil tank.
in figure
왘
Damaged O-ring, 쎻
15
왘
Replace O-ring.
Leakage from filler neck 쎻

16
왘
Damaged cap packing 왘
Replace cap.
왘
Crack in root of filler neck 왘
Replace oil tank.
왘
High fluid level *5 왘
Adjust fluid level.
Leakage from surrounding of power 왘

Replace bad parts.
cylinder of gearbox, 쎻
17 in figure
Leakage from control valve of 왘

Damaged packing or oil seal 왘
gearbox, 쎻
18 and 쎻
19 in figure
왘
Damage in control valve 왘
*5 Fluid level is specified at optimum position (range) for ordinary use. Accordingly, if the vehicle is used often under hard con-
ditions such as on very rough roads or in mountainous areas, fluid may bleed out from cap air vent hole. This is not a prob-
lem. If a customer complains strongly and is not likely to be satisfied with the leakage, lower the fluid level to the extent that
fluid will not bleed out under the conditions described, and have the customer check the fluid level and its quality more fre-
quency than usual.
91
4-3 DIAGNOSTICS
1. Power Steering
B4M0675A
92
DIAGNOSTICS 4-3
1. Power Steering
6. NOISE AND VIBRATION

*6
Hiss noise (continu- Relief valve sound Generates at max. Normal (Don’t keep
ous) turning angle. this condition over 5
While engine is run- seconds.)
ning with maximum
turning angle. Generates without Defective
steering operation. Replace oil pump.
Rattling noise Interference with adjacent parts Check clearance.

(intermittent) [Refer to next article
While engine is run- 6.]
ning. Correct if necessary.
Loosened installation of oil pump, oil tank, pump bracket, Retighten.

gearbox or crossmember.
Loosened installation of oil pump pulley or other pulley(s). Retighten.
Loosened linkage or play of steering or suspension. Retighten or replace.

Loosened tightening of joint or steering column.
Sound generates from the inside of gearbox or oil pump. Replace the gearbox
or oil pump.
Knocking Excessive backlash Adjust and retighten.

When turning steer- Loosened lock nut for adjusting backlash.
ing wheel in both
direction with small
angle repeatedly at Loosened tightening or play of tie-rod, tie-rod end. Retighten or replace.
engine ON or OFF.
*6 Don’t keep the relief valve operated over 5 sec. at any time or inner parts of the oil pump may be damaged due to rapid increase
of fluid temperature.
93
4-3 DIAGNOSTICS
1. Power Steering
*7
Grinding noise (continuous) Vane pump aeration Inspect and retighten fluid line
While engine is running. connection.
Refill fluid and vent air.
Vane pump seizing Replace oil pump.
Pulley bearing seizing of oil pump
Folded hose, flat pipe Replace.
Squeal, squeak Maladjustment of pulley belt Adjust or replace.

(intermittent or continuous) Damaged or charged pulley belt (Replace two belts as a set.)
While engine is running. Unequal length of pulley belts
Run out or soilage of V-groove Clean or replace.

surface of oil pump pulley
Sizzling noise (continuous) Fluid aeration Fix wrong part causing aeration.
While engine is running. Replace fluid and vent air.
Damaged pipe of gearbox Replace pipe.
Abnormal inside of hose or pipe Rectify or replace.

Flat hose or pipe
Abnormal inside of oil tank Replace.
Removed oil tank cap Install cap.
Whistle (continuous) Abnormal pipe of gearbox or Replace bad parts of gearbox

While engine is running. abnormal inside of hose or hose.
*7 Grinding noise may be heard immediately after the engine start in extremely cold condition. In this case, if the noise goes off
during warm-up there is no abnormal function in the system. This is due to the fluid characteristic in extremely cold condi-
tion.
94
DIAGNOSTICS 4-3
1. Power Steering
Whine or growl (continuous or Loosened installation of oil pump, Retighten.

intermittent) oil pump bracket
While engine is running with/
without steering turned. *8
Abnormal inside of oil pump, hose Replace oil pump, hose, if the
noise can be heard when running
as well as stand still.
Torque converter growl Remove power steering pulley

air conditioner compression growl belt and confirm.
Creaking noise (intermittent) Abnormal inside of gearbox Replace bad parts of gearbox.
While engine is running with
steering turned. Abnormal bearing for steering Apply grease or replace.
shaft
*9
Generates when turning steering If the noise goes off when brake
wheel with brake (service or park- is released, it is normal.
ing) applied.
*10
Vibration Too low engine speed at start Adjust and instruct customers.
While engine is running with/
without steering turned. Vane pump aeration Fix wrong part.
Vent air.
Damaged valve in oil pump, gear- Replace oil pump, bad parts of
box gearbox.
Looseness of play of steering, Retighten.

suspension parts
*8 Oil pump makes whine or growl noise slightly due to its mechanism. Even if the noise can be heard when steering wheel
is turned at stand still there is no abnormal function in the system provided that the noise eliminates when the vehicle is
running.
*9 When stopping with service brake and/or parking brake applied, power steering can be operated easily due to its light
steering effort. If doing so, the disk rotates slightly and makes creaking noise. The noise is generated by creaking between
the disk and pads. If the noise goes off when the brake is released, there is no abnormal function in the system.
*10 There may be a little vibration around the steering devices when turning steering wheel at standstill, even though the com-
ponent parts are properly adjusted and have no defects.
Hydraulic systems are likely to generate this kind of vibration as well as working noise and fluid noise because of com-
bined conditions, i.e., road surface and tire surface, engine speed and turning speed of steering wheel, fluid temperature
and braking condition.
This phenomena does not indicate there is some abnormal function in the system.
The vibration can be known when steering wheel is turned repeatedly at various speeds from slow to rapid step by step
with parking brake applied on concrete road and in “D” range for automatic transmission vehicle.
95
4-3 DIAGNOSTICS
1. Power Steering
7. CLEARANCE TABLE (LHD MODEL)

CAUTION:
This table lists various clearances that must be cor-
rectly adjusted to ensure normal vehicle driving with-
out interfering noise, or any other faults.
Minimum Minimum
Location allowance Location allowance
mm (in) mm (in)
쎻
1 Crossmember — Pipe 5 (0.20) 쎻
6 Exhaust pipe — Pipe 15 (0.59)
쎻
2 DOJ — Shaft or joint 14 (0.55) 쎻
7 Exhaust pipe — Gearbox bolt 15 (0.59)
쎻
3 DOJ — Valve housing 11 (0.43) 쎻
8 Side frame — Hose A and B 15 (0.59)
쎻
4 Pipe — Pipe 쎻
9 Cruise control pump — Hose A and B 15 (0.59)
2 (0.08) 1.5
Pipe — Crossmember 쎻
10 Pipe portion of hose A — Pipe portion of hose B
(0.059)
쎻
5 Stabilizer — Pipe 5 (0.20) 쎻
11 AT cooling hose — Joint 20 (0.79)
B4M0565A
96
DIAGNOSTICS 4-3
1. Power Steering
8. CLEARANCE TABLE (RHD MODEL)

CAUTION:
This table lists various clearances that must be cor-
rectly adjusted to ensure normal vehicle driving with-
out interfering noise, or any other faults.
Minimum Minimum
Location allowance Location allowance
mm (in) mm (in)
쎻
1 Crossmember — Pipe 5 (0.20) 쎻
5 Stabilizer — Pipe 5 (0.20)
쎻
2 DOJ — Shaft or joint 14 (0.55) 쎻
6 Exhaust pipe — Pipe 15 (0.59)
쎻
3 DOJ — Valve housing 11 (0.43) 쎻
7 Exhaust pipe — Gearbox boot 15 (0.59)
쎻
4 Pipe — Pipe 쎻
8 Side frame — Hose A and B 15 (0.59)
2 (0.08) 1.5
Pipe — Crossmember 쎻
9 Pipe portion of hose A — Pipe portion of hose B
(0.059)
B4M0676A
97
4-3 DIAGNOSTICS
1. Power Steering
9. BREAKAGE OF HOSES
Pressure hose burst Excessive holding time of relief Instruct customers.
status
Malfunction of relief valve Replace oil pump.
Poor cold characteristic of fluid Replace fluid.
Forced out return hose Poor connection Correct.
Poor holding of clip Retighten.
Poor cold characteristic of fluid Replace fluid.
Fluid bleeding out of hose slightly Wrong layout, tensioned Replace hose.
Excessive play of engine due to Replace defective parts.

deterioration of engine mounting
rubber
Improper stop position of pitching Replace defective parts.

stopper
*11
Crack on hose Excessive holding time of relief Replace.
status Instruct customer.
Excessive tightening torque for Replace.

return hose clip
Power steering fluid, brake fluid, Replace.

engine oil, electrolyte adhere on Pay attention on service work.
the hose surface
Too many times use in extremely Replace.

cold weather Instruct customers.
*11 Although surface layer materials of rubber hoses have excellent weathering resistance, heat resistance and resistance for
low temperature brittleness, they are likely to be damaged chemically by brake fluid, battery electrolyte, engine oil and
automatic transmission fluid and their service lives are to be very shortened. It is very important to keep the hoses free
from before mentioned fluids and to wipe out immediately when the hoses are adhered with the fluids.
Since resistances for heat or low temperature brittleness are gradually declining according to time accumulation of hot or
cold conditions for the hoses and their service lives are shortening accordingly, it is necessary to perform careful inspec-
tion frequently when the vehicle is used in hot weather areas, cold weather area and/or a driving condition in which many
steering operations are required in short time. Particularly continuous work of relief valve over 5 seconds causes to reduce
service lives of the hoses, the oil pump, the fluid, etc. due to over heat.
So, avoid to keep this kind of condition when servicing as well as driving.
98
1. Brakes
1. Brakes
A: SPECIFICATIONS
1. MODELS WITH ABS OR ABS/TCS
Model Sedan Wagon
Engine (cc) 2200 2200
Driving system FWD AWD FWD AWD
L L LS L L LS
Type Disc (Floating type, ventilated)
Effective disc diameter
210 (8.27)
mm (in)
Disc thickness x Outer diameter
24 x 260 (0.94 x 10.24)
mm (in)
Front
brake Effective cylinder diameter
57.2 (2.252)
mm (in)
Pad dimensions
(length x width x thickness) 112.4 x 44.3 x 11.0 (4.43 x 1.744 x 0.433)
mm (in)
Clearance adjustment Automatic adjustment
Type Disc (Floating type)
230 (9.06)
mm (in)
10 x 266 (0.39 x 10.47)
mm (in)
Rear
34.9 (1.374) 38.1 (1.500)
mm (in)
Pad dimensions
mm (in)
3
1. Brakes
Model 4 Door Sedan Wagon

Engine (cc) 2200 2200
L L LS L L LS
Hill holder — ★ — — ★ —
Type Mechanical on rear brakes, drum in disc
Effective drum diameter
170 (6.69)
mm (in)
Parking
brake Lining dimensions
mm (in)
Clearance adjustment Manual adjustment
Type Tandem
Effective diameter
26.99 (1-1/16)
Master mm (in)
cylinder Reservoir type Sealed type
Brake fluid reservoir capacity
190 (11.59)
cm3 (cu in)
Type Vacuum suspended
Brake
booster Effective diameter
205 + 230 (8.07 + 9.06)
mm (in)
Split point
Proportioning 2,942 (30.0, 427)
kPa (kg/cm2, psi)
valve
Reducing ratio 0.3
Brake line Dual circuit system
ABS — OP STD — OP STD
ABS/TCS OP — OP —
★: Equipped on manual transmission vehicle. (Except TCS model)
4
1. Brakes
2. MODELS WITHOUT ABS OR ABS/TCS

Model Sedan Wagon
Engine (cc) 2200
L L L POST BRIGHTON L
210 (8.27)
mm (in)
24 x 260 (0.94 x 10.24)
mm (in)
Front
57.2 (2.252)
mm (in)
Pad dimensions
mm (in)
Type Drum (Leading-Trailing type)
228.6 (9)
mm (in)
Effective cylinder diameter
Rear 17.4 (0.685) 19.0 (0.748)
mm (in)
brake
Lining dimensions
mm (in)
5
1. Brakes
Model Sedan Wagon

Engine (cc) 2200
L L L POST BRIGHTON L
Hill holder ★ ★ — — — ★
228.6 (9)
mm (in)
Parking
mm (in)
Type Tandem
Effective diameter
23.81 (15/16)
Master mm (in)
190 (11.59)
cm3 (cu in)
Brake
230 (9.06)
mm (in)
Split point
kPa (kg/cm2, psi)
valve
Reducing ratio 0.3
★: Equipped on manual transmission vehicle.
6
1. Brakes
3. 2500 cc MODEL
Model Sedan Wagon
Engine (cc) 2500
Driving system AWD
GT LSi GT LSi OUTBACK
228 (8.98)
mm (in)
24 x 277 (0.94 x 10.91)
mm (in)
Front
42.8 (1.687) x 2
mm (in)
Pad dimensions
mm (in)
Type Disc (Floating type)
230 (9.06)
mm (in)
10 x 266 (0.39 x 10.47)
mm (in)
Rear
38.1 (1.500)
mm (in)
Pad dimensions
mm (in)
7
1. Brakes
Model Sedan Wagon

Engine (cc) 2500
Driving system AWD
GT LSi GT LSi OUTBACK
Hill holder — — — — —
170 (6.69)
mm (in)
Parking
mm (in)
Clearance adjustment Manual adjustment
Type Tandem
Effective diameter
26.99 (1-1/16)
Master mm (in)
190 (11.59)
cm3 (cu in)
Brake
205 + 230 (8.07 + 9.06)
mm (in)
Split point
kPa (kg/cm2, psi)
valve
Reducing ratio 0.3
ABS STD
8
1. Brakes
B: SERVICE DATA
ITEM STANDARD SERVICE LIMIT
Pad thickness
17 mm (0.67 in) 7.5 mm (0.295 in)
(including back metal)
Front brake
Disc thickness 24 mm (0.94 in) 22 mm (0.87 in)
Disc runout — 0.075 mm (0.0030 in)
Pad thickness
15 mm (0.59 in) 6.5 mm (0.256 in)
Rear brake (Disc type)
Disc thickness 10 mm (0.39 in) 8.5 mm (0.335 in)
Disc runout — 0.10 mm (0.0039 in)
Inside diameter 228.6 mm (9 in) 230.6 mm (9.08 in)
Rear brake (Drum type)
Lining thickness 4.1 mm (0.161 in) 1.5 mm (0.059 in)
Rear brake (Disc type Inside diameter 170 mm (6.69 in) 171 mm (6.73 in)
parking) Lining thickness 3.2 mm (0.126 in) 1.5 mm (0.059 in)
Parking brake Lever stroke 7 to 8 notches/196N (20 kg, 44 lb)
Without ABS and TCS With ABS and TCS

Brake pedal force Fluid pressure
147 N 785 kPa 588 kPa
Brake fluid pressure (15 kg, 33 lb) (8 kg/cm2, 114 psi) (6 kg/cm2, 85 psi)
without engine running 294 N 2,158 kPa 1,667 kPa
Brake booster (30kg, 66 lb) (22 kg/cm2, 313 psi) (17 kg/cm2, 242 psi)
Brake fluid pressure with 147 N 5,492 kPa 5,394 kPa

engine running and (15 kg, 33 lb) (56 kg/cm2, 796 psi) (55 kg/cm2, 782 psi)
vacuum at 66.7 kPa (500 294 N 8,434 kPa 10,003 kPa
mmHg, 19.69 inHg) (30kg, 66 lb) (86 kg/cm2, 1,223 psi) (102 kg/cm2, 1,450 psi)
C: RECOMMENDED BRAKE FLUID

FMVSS No. 116, fresh DOT3 or 4 brake fluid
CAUTION:
쐌 Avoid mixing brake fluid of different brands to pre-
vent the fluid performance from degrading.
쐌 When brake fluid is supplemented, be careful not to
allow any dust into the reservoir.
쐌 Use fresh DOT3 or 4 brake fluid when replacing or
refilling the fluid.
D: BRAKE FLUID LEVEL INDICATOR

Reserve tank with level indicator:
Residual fluid quantity at light ON
Approx. 80 cm3 (4.88 cu in)
Tank capacity
190 cm3 (11.59 cu in)
9
4-4 COMPONENT PARTS
1. Front Disc Brake
1. Front Disc Brake

1. EXCEPT 2500 cc MODEL
B4M1152A
쎻
1 Caliper body 쎻
9 Support Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Air bleeder screw 쎻
10 Pad clip T1: 8±1 (0.8±0.1, 5.8±0.7)
쎻
3 Guide pin (Green) 쎻
11 Outer shim T2: 18±5 (1.8±0.5, 13.0±3.6)
쎻
4 Pin boot 쎻
12 Inner shim T3: 37±5 (3.8±0.5, 27.5±3.6)
쎻
5 Piston seal 쎻
13 Pad (Outside) T4: 78±10 (8.0±1.0, 58±7)
쎻
6 Piston 쎻
14 Pad (Inside)
쎻
7 Piston boot 쎻
15 Disc rotor
쎻
8 Lock pin (Yellow) 쎻
16 Disc cover
10
COMPONENT PARTS 4-4
1. Front Disc Brake
2. 2500 cc MODEL
B4M1151A
쎻
1 Caliper body 쎻
쎻
11 Pad clip T1: 8±1 (0.8±0.1, 5.8±0.7)
쎻
12 Outer shim T2: 18±5 (1.8±0.5, 13.0±3.6)
쎻
4 Pin boot 쎻
13 Inner shim T3: 37±5 (3.8±0.5, 27.5±3.6)
쎻
5 Piston seal 쎻
14 Pad (Outside) T4: 78±10 (8.0±1.0, 58±7)
쎻
6 Piston 쎻
15 Pad (Inside)
쎻
7 Piston boot 쎻
16 Disc rotor
쎻
8 Boot ring 쎻
17 Disc cover
쎻
9 Lock pin (Yellow)
11
4-4 COMPONENT PARTS
2. Rear Disc Brake
2. Rear Disc Brake
B4M0066A
쎻
1 Lock pin 쎻
16 Pad clip 쎻
29 Strut shoe spring
쎻
2 Lock pin sleeve 쎻
17 Outer pad 쎻
30 Shoe guide plate
쎻
3 Lock pin boot 쎻
18 Outer shim 쎻
31 Secondary shoe return spring
쎻
19 Shoe hold-down pin 쎻
32 Primary shoe return spring
쎻
5 Caliper body 쎻
20 Cover 쎻
33 Adjuster
쎻
6 Guide pin 쎻
21 Back plate 쎻
34 Shoe hold-down cup
쎻
7 Guide pin boot 쎻
22 Retainer 쎻
35 Shoe hold-down spring
쎻
8 Piston seal 쎻
23 Spring washer 쎻
36 Disc rotor
쎻
9 Piston 쎻
24 Parking brake lever
쎻
10 Piston boot 쎻
25 Parking brake shoe Tightening torque: N⋅m (kg-m, ft-lb)
쎻
11 Boot ring (Secondary) T1: 8±1 (0.8±0.1, 5.8±0.7)
쎻
12 Support 쎻
26 Parking brake shoe T2: 20±4 (2.0±0.4, 14.5±2.9)
T3: 26±5 (2.7±0.5, 19.5±3.6)
쎻
13 Shim (Primary)
T4: 52±6 (5.3±0.6, 38.3±4.3)
쎻
14 Inner shim 쎻
27 Adjusting spring
쎻
15 Inner pad 쎻
28 Strut
12
COMPONENT PARTS 4-4
3. Rear Drum Brake
3. Rear Drum Brake
G4M0910
쎻
1 Air bleeder cap 쎻
11 Upper shoe return spring 쎻
21 Lower shoe return spring
쎻
12 Retainer 쎻
22 Adjusting spring
쎻
3 Boot 쎻
13 Washer 쎻
23 Drum
쎻
4 Piston 쎻
14 Parking brake lever 쎻
24 Plug
쎻
5 Cup 쎻
15 Brake shoe (Trailing)
쎻
6 Spring 쎻
16 Brake shoe (Leading) Tightening torque: N⋅m (kg-m, ft-lb)
쎻
7 Wheel cylinder body 쎻
17 Shoe hold-down spring T1: 8±1 (0.8±0.1, 5.8±0.7)
T2: 10±2 (1.0±0.2, 7.2±1.4)
쎻
8 Pin 쎻
18 Cup
T3: 52±6 (5.3±0.6, 38.3±4.3)
쎻
9 Plug 쎻
19 Adjusting lever
쎻
10 Back plate 쎻
20 Adjuster
13
4-4 COMPONENT PARTS
4. Master Cylinder
4. Master Cylinder
1. WITHOUT TCS
B4M0067A
쎻
1 Cap 쎻
7 C-ring Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Reserve tank 쎻
8 Level indicator ASSY T1: 2.2±0.7
쎻
3 Seal 쎻
9 Supply valve stopper (0.225±0.075, 1.6±0.5)
쎻
4 Cylinder body (With ABS) T2: 14±4 (1.4±0.4, 10.1±2.9)
쎻
5 Secondary piston 쎻
10 Gasket (With ABS)
쎻
6 Primary piston 쎻
11 Reservoir stopper bolt
2. WITH TCS
B4M0613A
쎻
1 Cylinder pin 쎻
5 Spring 쎻
9 Bush
쎻
2 Seal 쎻
6 Secondary piston 쎻
10 Stop washer B
쎻
3 Filter 쎻
7 Primary piston 쎻
11 C-ring
쎻
4 Cylinder body 쎻
8 Stop washer A
14
COMPONENT PARTS 4-4
4. Master Cylinder
3. RHD MODEL
B4M1199A
쎻
1 Cap 쎻
7 Secondary piston Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Filter 쎻
8 Cylinder body T1: 14±4 (1.4±0.4, 10.1±2.9)
쎻
3 Reservoir tank 쎻
9 Seal
쎻
4 Bracket 쎻
10 Pin
쎻
5 Piston retainer
쎻
6 Primary piston
15
4-4 COMPONENT PARTS
5. Brake Booster
5. Brake Booster
1. MODELS WITH ABS AND TCS
G4M0355
쎻
1 Push rod 쎻
5 Filter 쎻
9 Valve body
쎻
2 Return spring 쎻
6 Silencer 쎻
10 Plunger valve
쎻
3 Reaction disc 쎻
7 Operating rod 쎻
11 Diaphragm plate
쎻
4 Key 쎻
8 Poppet valve 쎻
12 Valve return spring
2. MODELS WITHOUT ABS AND TCS
G4M0356
쎻
1 Push rod 쎻
5 Plunger valve 쎻
9 Operating rod
쎻
2 Return spring 쎻
6 Key 쎻
10 Silencer
쎻
3 Diaphragm plate 쎻
7 Poppet valve 쎻
11 Filter
쎻
4 Reaction disc 쎻
8 Valve return spring 쎻
12 Valve body
16
COMPONENT PARTS 4-4
6. ABS System (Except ABS 5.3i Type)

1. SENSOR AND CONTROL MODULE (EXCEPT ABS
5.3 TYPE)
B4M0068A
쎻
1 G sensor (AWD MT only) 쎻
6 ABS control module Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Rear ABS sensor RH 쎻
7 Front ABS sensor LH T1: 5.9±1.5 (0.60±0.15, 4.3±1.1)
쎻
3 ABS spacer 쎻
8 Front ABS sensor RH T2: 7.4±2.0 (0.75±0.2, 5.4±1.4)
쎻
4 Rear ABS sensor LH T3: 32±10 (3.3±1.0, 24±7)
쎻
5 Bracket
17
4-4 COMPONENT PARTS
2. HYDRAULIC CONTROL UNIT (EXCEPT ABS 5.3

TYPE)
B4M0069A
쎻
1 Connector 쎻
9 Front-LH outlet Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Cap 쎻
10 Primary inlet T1: 1.2±0.2
쎻
3 Motor relay 쎻
11 Secondary inlet (0.125±0.025, 0.9±0.2)
쎻
4 Valve relay 쎻
12 Bracket T2: 18±5 (1.8±0.5, 13.0±3.6)
쎻
5 Hydraulic control unit T3: 29±7 (3.0±0.7, 21.7±5.1)
쎻
6 Front-RH outlet T4: 32±10 (3.3±1.0, 24±7)
쎻
7 Rear-LH outlet
쎻
8 Rear-RH outlet
18
COMPONENT PARTS 4-4
3. SENSOR AND CONTROL MODULE (ABS 5.3 TYPE)
B4M1044A
쎻
1 G sensor (AWD only) 쎻
5 Bracket Tightening torque: N⋅m (kg-m, ft-lb)
쎻
6 ABS control module T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
쎻
3 ABS spacer 쎻
7 Front ABS sensor LH T2: 32±10 (3.3±1.0, 24±7)
쎻
4 Rear ABS sensor LH 쎻
8 Front ABS sensor RH
19
4-4 COMPONENT PARTS
4. HYDRAULIC CONTROL UNIT (ABS 5.3 TYPE)
B4M0994A
쎻
1 Hydraulic control unit 쎻
8 Front-LH outlet 쎻
15 Cap
쎻
2 Damper 쎻
9 Front-RH outlet 쎻
16 Connector bracket
쎻
3 Stud bolt 쎻
10 Cable clip
쎻
4 Rear-RH outlet 쎻
11 Bracket
T1: 18±5 (1.8±0.5, 13.0±3.6)
쎻
5 Rear-LH outlet 쎻
12 Relay box T2: 29±7 (3.0±0.7, 21.7±5.1)
쎻
6 Secondary inlet 쎻
13 Motor relay T3: 32±10 (3.3±1.0, 24±7)
쎻
7 Primary inlet 쎻
14 Valve relay
20
COMPONENT PARTS 4-4
7. Hill Holder
7. Hill Holder
G4M0359
쎻
1 PHV cable 쎻
7 Adjusting nut Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Clamp 쎻
8 Snap pin T1: 3.4±1.0 (0.35±0.10, 2.5±0.7)
쎻
3 Bracket A 쎻
9 Clip T2: 18±5 (1.8±0.5, 13.0±3.6)
쎻
4 Pin 쎻
10 PHV (Pressure hold valve) T3: 33±4 (3.4±0.4, 24.6±2.9)
쎻
5 Bushing 쎻
11 Bracket
쎻
6 Release fork
21
4-4 COMPONENT PARTS
8. Parking (Hand) Brake
8. Parking (Hand) Brake
B4M0705A
쎻
7 Clamp Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Parking brake switch 쎻
8 Parking brake cable RH T1: 5.9±1.5 (0.60±0.15, 4.3±1.1)
쎻
3 Lock nut 쎻
9 Cable guide T2: 18±5 (1.8±0.5, 13.0±3.6)
쎻
4 Adjusting nut 쎻
10 Clamp T3: 32±10 (3.3±1.0, 24±7)
쎻
5 Equalizer (Rear disc brake model only)
쎻
6 Bracket 쎻
11 Parking brake cable LH
22
COMPONENT PARTS 4-4
9. ABS/TCS System
9. ABS/TCS System
1. SENSOR AND CONTROL MODULE
B4M0706A
쎻
4 ABS/TCS control module Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 ABS spacer 쎻
5 Front ABS sensor LH T1: 32±10 (3.3±1.0, 24±7)
쎻
3 Rear ABS sensor LH 쎻
6 Front ABS sensor RH
23
4-4 COMPONENT PARTS
9. ABS/TCS System
2. HYDRAULIC UNIT
B4M0707A
쎻
1 ABS/TCS Hydraulic 쎻
8 Secondary suction line Tightening torque: N⋅m (kg-m, ft-lb)
control unit 쎻
9 Primary suction line T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
쎻
10 Bumper T2: 29±7 (3.0±0.7, 21.7±5.1)
쎻
11 Bracket T3: 32±10 (3.3±1.0, 24±7)
쎻
12 Pressure switch T4: 38±10 (3.8±1.0, 27±7)
쎻
5 Rear-LH outlet T5: 3.1±1 (0.32±0.1, 2.3±0.7)
쎻
13 Valve relay
쎻
6 Secondary inlet
쎻
14 Motor relay
쎻
7 Primary inlet
24
COMPONENT PARTS 4-4
10. ABS System (ABS 5.3i Type)

1. SENSOR
B4M1219A
쎻
1 G sensor (AWD only) 쎻
4 Rear ABS sensor LH Tightening torque: N⋅m (kg-m, ft-lb)
쎻
5 Front ABS sensor LH T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
쎻
3 ABS spacer 쎻
6 Front ABS sensor RH T2: 32±10 (3.3±1.0, 24±7)
25
4-4 COMPONENT PARTS
2. ABS CONTROL MODULE AND HYDRAULIC

CONTROL UNIT (ABSCM&H/U)
B4M1220A
쎻
1 Stud bolt 쎻
6 Front-RH outlet Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Damper 쎻
7 Primary inlet T1: 18±5 (1.8±0.5, 13.0±3.6)
쎻
3 ABS control module and hydraulic 쎻
8 Rear-LH outlet T2: 29±7 (3.0±0.7, 21.7±5.1)
control unit 쎻
9 Rear-RH outlet T3: 32±10 (3.3±1.0, 24±7)
쎻
10 Bracket
쎻
5 Secondary inlet
26
1. Front Disc Brake
1. Front Disc Brake
B4M0065B
쎻
10 Lock pin 쎻
19 Disc rotor
쎻
2 Guide pin 쎻
11 Housing 쎻
20 Disc cover
쎻
12 Support
쎻
4 Piston 쎻
13 Pad clip Tightening torque: N⋅m (kg-m, ft-lb)
쎻
5 Piston seal 쎻
14 Outer shim T1: 8±1 (0.8±0.1, 5.8±0.7)
T2: 18±5 (1.8±0.5, 13.0±3.6)
쎻
6 Piston boot 쎻
15 Outer pad
T3: 39±5 (4±0.5, 28.9±3.6)
쎻
7 Lock pin boot 쎻
16 Inner pad T4: 78±10 (8.0±1.0, 58±7)
쎻
17 Inner shim
쎻
9 Caliper body 쎻
18 Shim
27
1. Front Disc Brake
A: ON-CAR SERVICE
1. PAD
1) Remove lock pin.
2) Raise caliper body.
3) Remove pad.
B4M1167
4) Check pad thickness A.

Pad thickness Standard value 17 (0.67)
mm (in) Wear limit 7.5 (0.295)
CAUTION:
쐌 Always replace the pads for both the left and right
wheels at the same time. Also replace pad clips if they
are twisted or worn.
쐌 A wear indicator is provided on the inner disc brake
B4M1168A
pad. If the pad wears down to such an extent that the
end of the wear indicator contacts the disc rotor, a
squeaking sound is produced as the wheel rotates. If
this sound is heard, replace the pad.
쐌 Replace pad if there is oil or grease on it.
5) Apply thin coat of PBC GREASE (Part No. 003607000)

to the frictional portion between pad and pad clip.
6) Install pads on support.
7) Install caliper body on support.
NOTE:
If it is difficult to push piston during pad replacement,
loosen air bleeder to facilitate work.
B4M1169A
2. DISC ROTOR
1) Install disc rotor by tightening the five wheel nuts.
2) Set a dial gauge on the disc rotor. Turn disc rotor to
check runout.
NOTE:
Make sure that dial gauge is set 5 mm (0.20 in) inward of
rotor outer perimeter.
Disc rotor runout limit:
0.075 mm (0.0030 in)
G4M0364
28
1. Front Disc Brake
3) Measure disc rotor thickness.

NOTE:
Make sure that micrometer is set 5 mm (0.20 in) inward of
Standard Service
Disc outer dia.
Disc rotor thickness A value limit
mm (in) 24.0 22.0 260
(0.945) (0.866) (10.24)
G4M0365
B: REMOVAL
1) Remove union bolt and disconnect brake hose from
caliper body assembly.
B4M1170
2) Remove bolt securing lock pin to caliper body.

3) Raise caliper body and move it toward vehicle center to
separate it from support.
B4M1171
4) Remove support from housing.

NOTE:
Remove support only when replacing it or the rotor. It need
not be removed when servicing caliper body assembly.
B4M1192A

NOTE:
If disc rotor seizes up within hub, drive disc rotor out by
installing an 8-mm bolt in holes B on the rotor.
6) Clean mud and foreign particles from caliper body
assembly and support.
G4M0365
29
1. Front Disc Brake
C: DISASSEMBLY
B4M1152B
쎻
1 Caliper body 쎻
쎻
10 Pad clip T1: 8±1 (0.8±0.1, 5.8±0.7)
쎻
11 Outer shim T2: 18±5 (1.8±0.5, 13.0±3.6)
쎻
4 Pin boot 쎻
12 Inner shim T3: 37±5 (3.8±0.5, 27.5±3.6)
쎻
5 Piston seal 쎻
13 Pad (Outside) T4: 78±10 (8.0±1.0, 58±7)
쎻
6 Piston 쎻
14 Pad (Inside)
쎻
7 Piston boot 쎻
15 Disc rotor
쎻
8 Lock pin (Yellow) 쎻
16 Disc cover
30
1. Front Disc Brake

CAUTION:
Be careful not to allow foreign particles to enter inlet
(at brake hose connector).
2) Gradually supply compressed air via caliper body brake

hose to force piston out.
CAUTION:
쐌 Place a wooden block as shown in Figure to prevent
damage to piston.
쐌 Do not apply excessively high-pressure.
3) Remove piston boot.
B4M1174A
4) Remove piston seal from caliper body cylinder.

5) Remove guide pin and boot from caliper body.
B4M1173A
31
1. Front Disc Brake
2. 2500 cc MODEL
B4M1151B
쎻
1 Caliper body 쎻
쎻
11 Pad clip T1: 8±1 (0.8±0.1, 5.8±0.7)
쎻
12 Outer shim T2: 18±5 (1.8±0.5, 13.0±3.6)
쎻
4 Pin boot 쎻
13 Inner shim T3: 37±5 (3.8±0.5, 27.5±3.6)
쎻
5 Piston seal 쎻
14 Pad (Outside) T4: 78±10 (8.0±1.0, 58±7)
쎻
6 Piston 쎻
15 Pad (Inside)
쎻
7 Piston boot 쎻
16 Disc rotor
쎻
8 Boot ring 쎻
17 Disc cover
쎻
9 Lock pin (Yellow)
32
1. Front Disc Brake

CAUTION:
2) Using a standard screwdriver, remove boot ring from

piston.
3) Remove boot from piston end.
B4M1164A
4) Gradually supply compressed air via caliper body brake

hose to force piston out.
CAUTION:
Place a wooden block as shown in Figure to prevent
damage to piston.
B4M1165A

6) Remove lock pin boot and guide pin boot.
B4M1172A
D: INSPECTION
1) Repair or replace faulty parts.
2) Check caliper body and piston for uneven wear, dam-
age or rust.
3) Check rubber parts for damage or deterioration.
33
1. Front Disc Brake
E: ASSEMBLY
1) Clean caliper body interior using brake fluid.
2) Apply a coat of brake fluid to piston seal and fit piston
seal in groove on caliper body.
3) Apply a coat of brake fluid to the entire inner surface of
cylinder and outer surface of piston.
4) Apply a coat of specified grease to boot and fit in groove
on ends of cylinder and install piston boot onto cylinder.
Grease:
NIGLUBE RX-2 (Part No. 003606000)
5) Insert piston into cylinder.

CAUTION:
Do not force piston into cylinder.
B4M1175A
6) Position boot in grooves on cylinder and piston.
B4M0072A
7) Apply a coat of specified grease to lock pin and guide

pin outer surface, cylinder inner surface, and boot grooves.
Grease:
8) Install lock and guide pin boot on support.
B4M1176A
34
1. Front Disc Brake
2. 2500 cc MODEL

CAUTION:
B4M0771A

on ends of cylinder and piston.
Grease:
To facilitate installation, fit boot starting with piston end.
6) Position boot in grooves on cylinder and piston.
7) Install boot ring. Be careful not scratch boot.
G4M0373
8) Apply a coat of specified grease to lock pin and guide

pin, outer surface, cylinder inner surface, and boot
grooves.
Grease:
9) Install lock pin boot and guide pin boot on support.
B4M1176A
35
1. Front Disc Brake
F: INSTALLATION
2) Install support on housing.
Tightening torque:
78±10 N⋅m (8±1 kg-m, 58±7 ft-lb)
CAUTION:
쐌 When replacing the pad, replace pads of the right
and left wheels at the same time.

4) Install pads, rubber coated shim and stainless shim on
support.
Tightening torque:
39±5 N⋅m (4±0.5 kg-m, 28.9±3.6 ft-lb)
6) Connect brake hose.
Tightening torque:
B4M1169A
18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
CAUTION:
Replace brake hose gaskets with new ones.
7) Bleed air from brake system.
36
2. Rear Disc Brake
2. Rear Disc Brake
G4M0912
쎻
1 Guide pin 쎻
10 Piston boot 쎻
19 Disc rotor
쎻
2 Lock pin 쎻
11 Boot ring
쎻
3 Lock pin boot 쎻
12 Pad clip Tightening torque: N⋅m (kg-m, ft-lb)
쎻
13 Shim T1: 8±1 (0.8±0.1, 5.8±0.7)
T2: 20±4 (2.0±0.4, 14.5±2.9)
쎻
14 Inner shim
T3: 26±5 (2.7±0.5, 19.5±3.6)
쎻
15 Inner pad T4: 52±6 (5.3±0.6, 38.3±4.3)
쎻
7 Caliper body 쎻
16 Outer pad
쎻
8 Piston seal 쎻
17 Support
쎻
9 Piston 쎻
18 Outer shim
A: ON-CAR SERVICE
1. PAD
1) Remove lock pin.
G4M0378
37
2. Rear Disc Brake
2) Raise caliper body.

3) Remove pad from support.
G4M0379
4) Check pad thickness (including back metal).

Pad thickness: A
Standard value 15.0 mm (0.591 in)
Wear limit 6.5 mm (0.256 in)
CAUTION:
G4M0362
쐌 Replace pad if there is oil or grease on it.

6) Install pad on support.
G4M0363

Tightening torque:
20±4 N⋅m (2.0±0.4 kg-m, 14.5±2.9 ft-lb)
NOTE:
If it is difficult to push piston during pad replacement,
loosen air bleeder to facilitate work.
38
2. Rear Disc Brake
2. DISC ROTOR
1) Install disc rotor by tightening the five wheel nuts.
2) Set a dial gauge on the disc rotor. Turn disc rotor to
check runout.
NOTE:
Make sure that dial gauge is set 5 mm (0.20 in) inward of
Disc rotor runout limit:
0.1 mm (0.004 in)
G4M0382
3) Measure disc rotor thickness.

NOTE:
Make sure that micrometer is set 5 mm (0.20 in) inward of
Disc rotor thickness: A
Standard value 10 mm (0.39 in)
Service limit 8.5 mm (0.335 in)
NOTE:
When removing disc rotor, refer to instructions under Park-
G4M0383
ing Brake 4-4 [W4A0].
B: REMOVAL
1) Lift-up vehicle and remove wheels.
2) Disconnect brake hose from caliper body assembly.
CAUTION:
Do not allow brake fluid to come in contact with vehicle
body; wipe off completely if spilled.
3) Remove lock pin.
4) Raise caliper body and move it toward vehicle center to
separate it from support.
G4M0384
5) Remove support from back plate.
NOTE:
Remove support only when replacing it or the rotor. It need
not be removed when servicing caliper body assembly.
CAUTION:
39
2. Rear Disc Brake
C: DISASSEMBLY
1) Remove the boot ring.
G4M0370
2) Remove the piston boot.
G4M0474
3) Gradually supply compressed air via inlet of caliper

body to force piston out.
CAUTION:
쐌 Place a wooden block as shown in Figure to prevent
damage to piston.
쐌 Do not apply excessively high-pressure.
G4M0371

5) Remove lock pin sleeve and boot from caliper body.
6) Remove guide pin boot.
G4M0388
D: INSPECTION
1) Repair or replace faulty parts.
2) Check caliper body and piston for uneven wear, dam-
age or rust.
3) Check rubber parts for damage or deterioration.
40
2. Rear Disc Brake
E: ASSEMBLY
CAUTION:
on ends of cylinder and piston.
Grease:
6) Install the piston boot to the caliper body, and attach

boot ring.
G4M0373
7) Apply a coat of specified grease to guide pin, outer

surface, sleeve outer surface, cylinder inner surface, and
boot grooves.
Grease:
8) Install guide pin boot on caliper body.
9) Install lock pin boot on caliper body and insert lock pin
sleeve into place.
G4M0390
G4M0375
41
2. Rear Disc Brake
F: INSTALLATION
2) Install support on back plate.
Tightening torque:
52±6 N⋅m (5.3±0.6 kg-m, 38.3±4.3 ft-lb)
CAUTION:
쐌 Replace pads if there is oil or grease on them.
4) Install pads on support.
G4M0363

Tightening torque:
20±4 N⋅m (2.0±0.4 kg-m, 14.5±2.9 ft-lb)
6) Connect brake hose.
Tightening torque:
18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
CAUTION:
쐌 The brake hose must be connected without any
twist.
쐌 Replace brake hose gaskets with new ones.
42
3. Rear Drum Brake
3. Rear Drum Brake
B4M0075A
쎻
1 Air bleeder cap 쎻
11 Upper shoe return spring 쎻
쎻
12 Retainer 쎻
22 Adjusting spring
쎻
3 Boot 쎻
13 Washer 쎻
23 Plug
쎻
4 Piston 쎻
14 Parking brake lever
쎻
5 Cup 쎻
15 Brake shoe (Trailing) Tightening torque: N⋅m (kg-m, ft-lb)
쎻
6 Spring 쎻
16 Brake shoe (Leading) T1: 8±1 (0.8±0.1, 5.8±0.7)
쎻
7 Wheel cylinder body 쎻
17 Shoe hold-down spring T2: 10±2 (1.0±0.2, 7.2±1.4)
T3: 52±6 (5.3±0.6, 38.3±4.3)
쎻
8 Pin 쎻
18 Cup
쎻
9 Plug 쎻
19 Adjusting lever
쎻
10 Back plate 쎻
20 Adjuster
43
3. Rear Drum Brake
A: REMOVAL
1. BRAKE DRUM AND SHOE
1) Loosen wheel nuts, jack-up vehicle, support it with rigid
racks, and remove wheel.
2) Release parking brake.
3) Remove brake drum from brake assembly.
G4M0393
NOTE:
If it is difficult to remove brake drum, remove adjusting hole
cover from back plate, and then, turn adjuster assembly
pawls using a slot-type screwdriver until brake shoe sepa-
rates from the drum.
G4M0242
4) Hold hold-down pin by securing rear of back plate with

your hand.
5) Disconnect hold-down cup from hold-down pin by rotat-
ing hold-down cup.
G4M0395
6) Disconnect lower shoe return spring from shoes.
G4M0396
7) Remove shoes one by one from back plate with

adjuster.
CAUTION:
Be careful not to bend parking brake cable excessively
when removing brake shoes.
8) Disconnect parking brake cable from parking lever.
G4M0397
44
3. Rear Drum Brake
9) Remove the following:

쎻1 Retainer
쎻2 Washer
쎻3 Parking lever
쎻4 Upper shoe return spring
쎻5 Trailing shoe
쎻6 Leading shoe
쎻7 Shoe hold-down spring
쎻8 Shoe hold-down cup
G4M0398 쎻9 Adjusting lever
쎻
10 Adjusting spring
쎻
11 Adjuster
쎻
2. BRAKE ASSEMBLY
1) Remove wheel.
2) Remove axle nut.
3) Remove brake drum
4) Unscrew the brake pipe flare nut and disconnect brake
pipe.
5) Remove hub. <Ref. to 4-2 [W2A0].>
G4M0399
6) Remove the bolts installing back plate, and then,

remove brake assembly.
G4M0400
3. WHEEL CYLINDER
1) Remove brake drum and shoes.
2) Unscrew brake pipe flare nut; and disconnect brake
pipe.
3) Remove the bolts installing wheel cylinder on back
plate, and remove it.
G4M0401
45
3. Rear Drum Brake
B: DISASSEMBLY
1. WHEEL CYLINDER
1) Remove right and left dust boots from wheel cylinder.
2) Remove piston, cup, spring and air bleeder screw and
cap.
쎻1 Bleeder cap
쎻2 Bleeder screw
쎻3 Spring
쎻4 Cylinder
G4M0402
쎻5 Cup
쎻6 Piston
쎻7 Boot
C: INSPECTION
1) If the inside surface of brake drum is streaked, correct
the surface. And, if it is unevenly worn, taperingly streaked,
or the outside surface of brake drum is damaged, correct
or replace it.
2) Measure the drum inner diameter.
Drum inner diameter: “L”
Standard 228.6 mm (9 in)
G4M0403
3) Measure the lining thickness.
Lining thickness:
Standard 4.1 mm (0.161 in)
4) If the deformation or wear of back plate, shoe, etc. are
notable, replace them.
5) When the shoe return spring tension is excessively
weakened, replace it, taking care to identify upper and
lower springs.
46
3. Rear Drum Brake
D: ASSEMBLY
1. WHEEL CYLINDER
Clean all parts in brake fluid. Check and replace faulty
parts.
쐌 Cup and boot for damage or fatigue
쐌 Cylinder, piston and spring or damage or rust formation
1) Assembly is the reverse order of disassembly.
(1) When installing the cup, use ST, apply brake fluid
to the frictional surface for smooth installation and pay
attention to cup direction.
(2) STs are available in different sizes.
CAUTION:
쐌 When replacing the repair kit, make sure that the
sizes of cylinder and cup are the same as those which
were replaced.
쐌 Use only the tool of the correct size.
ST: ADAPTER
Applicable size Part No.
17.46 mm (11/16 in) 925460000
19.05 mm (3/4 in) 926460000
CAUTION:
While assembling, be careful to prevent any metal
chip, dust or dirt from entering the wheel cylinder.
G4M0404
2) Apply rubber grease to the boot inside as shown in

Figure.
Grease:
CAUTION:
Never use brake grease.
G4M0405
E: INSTALLATION
1. WHEEL CYLINDER
Install wheel cylinder on back plate, and tighten bolts.
Tightening torque:
10±2 N⋅m (1.0±0.2 kg-m, 7.2±1.4 ft-lb)
G4M0401
47
3. Rear Drum Brake
2. BRAKE DRUM AND SHOE

1) Clean back plate and wheel cylinder.
2) Apply grease to portions indicated by arrows in Figure.
Brake grease:
Dow Corning Molykote No. 7439 (Part No.
725191460)
G4M0407
3) Apply grease to adjusting screw and both ends of

adjuster.
Brake grease:
725191460)
4) Connect upper shoe return spring to shoes.
G4M0408
5) While positioning shoes (one at a time) in groove on

wheel cylinder, secure shoes.
6) Connect lower shoe return spring.
7) Fix shoes by connecting hold-down cup to hold-down
pin.
G4M0409
3. BRAKE ASSEMBLY
1) Install brake assembly on housing, and tighten bolts to
install back plate.
Tightening torque:
52±6 N⋅m (5.3±0.6 kg-m, 38.3±4.3 ft-lb)
G4M0400
2) Install hub. <Ref. to 4-2 [W2E0].>

3) Connect brake pipe, and tighten brake pipe flange nut.
Tightening torque:
+3 +0.3 +2.2
15−2 N⋅m (1.5−0.2 kg-m, 10.8−1.4 ft-lb)
4) Set the outside diameter of brake shoes less than 0.5
to 0.8 mm (0.020 to 0.031 in) in comparison with the inside
diameter of brake drum.
5) Install brake drum.
6) After installing brake assembly, bleed air from brake
line.
48
4. Parking Brake (Rear Disc Brake)
G4M0411
쎻
1 Back plate 쎻
8 Strut 쎻
15 Shoe hold down spring
쎻
2 Retainer 쎻
9 Shoe guide plate 쎻
16 Shoe hold down pin
쎻
3 Spring washer 쎻
10 Primary return spring 쎻
17 Adjusting hole cover
쎻
4 Lever 쎻
11 Secondary return spring
쎻
5 Parking brake shoe (Primary) 쎻
12 Adjusting spring
T: 52±6 (5.3±0.6, 38.3±4.3)
쎻
6 Parking brake show (Secondary) 쎻
13 Adjuster
쎻
7 Strut spring 쎻
14 Shoe hold-down cup
A: REMOVAL
1) Remove the two mounting bolts to the disc brake
assembly and remove the disc brake assembly.
2) Suspend the disc brake assembly so that the hose is
not stretched.
3) Remove the disc rotor.
4) Remove shoe return spring from parking brake assem-
bly.
5) Remove front shoe hold down spring and pin with pli-
G4M0412 ers.
6) Remove strut and strut spring.
7) Remove adjuster assembly from parking brake assem-
bly.
8) Remove brake shoe.
9) Remove rear shoe hold-down spring and pin with pliers.
49
10) Remove parking cable from parking lever.

11) Using a standard screwdriver, raise retainer. Remove
parking lever and washer from brake shoe.
G4M0413
B: INSPECTION
1) Measure brake disc inside diameter. If the disc is scored
or worn, replace the brake disc.
Disc inside diameter:
Standard
170 mm (6.69 in)
Service limit
171 mm (6.73 in)
2) Measure the lining thickness. If it exceeds the limit,
replace shoe assembly.
Lining thickness:
Standard
3.2 mm (0.126 in)
Service limit
1.5 mm (0.059 in)
CAUTION:
Replace the brake shoes on the right and left brake
assembly at the same time.
C: INSTALLATION
CAUTION:
Be sure lining surface is free from oil contamination.
Brake grease:
725191460)
1) Apply brake grease to the following places.
쐌 Six contact surfaces of shoe rim and back plate
packing
쐌 Contact surface of shoe wave and anchor pin
쐌 Contact surface of lever and strut
쐌 Contact surface of shoe wave and adjuster assem-
bly
쐌 Contact surface of shoe wave and strut
쐌 Contact surface of lever and shoe wave
50
2) Installation is in reverse order of removal.

CAUTION:
쐌 Use new retainers and clinch them when installing
brake shoes to levers.
쐌 Ensure that parking lever moves smoothly.
쐌 Do not confuse left parking lever with right one.
쐌 Do not confuse left strut with right one.
NOTE:
Ensure that adjuster assembly is securely installed with
screw in the left side, facing vehicle front.
G4M0414
NOTE:
Ensure that shoe return spring is installed as shown in
Figure.
G4M0415
3) Adjust parking brakes. <Ref. to 4-4 [W4D1].>

CAUTION:
After replacing parking brake lining, be sure to drive
vehicle for “break-in” purposes.
(1) Drive the vehicle about 35 km/h (22 MPH).
(2) With the parking brake release button pushed in,
pull the parking brake lever gently, pulling with a force
of approximately 147 N (15 kg, 33 lb).
(3) Drive the vehicle for about 200 m (0.12 mile) in this
condition.
(4) Wait 5 to 10 minutes for the parking brake to cool
down. Repeat this procedure once more.
(5) After breaking-in, re-adjust parking brakes.
51
4. Parking Brake (Rear Disc Brake) - 5. Master Cylinder
D: PARKING BRAKE ADJUSTMENT

1. SHOE CLEARANCE ADJUSTMENT
1) Remove adjusting hole cover from back plate.
2) Turn adjusting screw using a slot-type screwdriver until
brake shoe is in close contact with disc rotor.
3) Turn back (downward) adjusting screw 3 or 4 notches.
4) Install adjusting hole cover to back plate.
G4M0416
2. LEVER STROKE ADJUSTMENT

1) Remove console box lid.
2) Forcibly pull parking brake lever 3 to 5 times.
3) Adjust parking brake lever by turning adjusting nut until
parking brake lever stroke is set at 6 notches with operat-
ing force of 196 N (20 kg, 44 lb).
4) Tighten lock nut.
5) Install console box lid.
Lever stroke:
B4M0050A 7 to 8 notches when pulled
with a force of 196 N (20 kg, 44 lb)
5.9±1.5 N⋅m (0.60±0.15 kg-m, 4.3±1.1 ft-lb)
5. Master Cylinder
A: REMOVAL
1) Thoroughly drain brake fluid from reservoir tank.
2) Disconnect fluid level indicator harness connector.
3) Remove brake pipes from master cylinder.
4) Remove master cylinder mounting nuts, and take out
master cylinder from brake booster.
CAUTION:
Be extremely careful not to spill brake fluid. Brake fluid
spilt on the vehicle body will harm the painted surface;
wipe it off quickly if spilt.
52
4. Parking Brake (Rear Disc Brake) - 5. Master Cylinder
D: PARKING BRAKE ADJUSTMENT

1. SHOE CLEARANCE ADJUSTMENT
1) Remove adjusting hole cover from back plate.
2) Turn adjusting screw using a slot-type screwdriver until
brake shoe is in close contact with disc rotor.
3) Turn back (downward) adjusting screw 3 or 4 notches.
4) Install adjusting hole cover to back plate.
G4M0416
2. LEVER STROKE ADJUSTMENT

1) Remove console box lid.
2) Forcibly pull parking brake lever 3 to 5 times.
parking brake lever stroke is set at 6 notches with operat-
ing force of 196 N (20 kg, 44 lb).
5) Install console box lid.
Lever stroke:
B4M0050A 7 to 8 notches when pulled
with a force of 196 N (20 kg, 44 lb)
5.9±1.5 N⋅m (0.60±0.15 kg-m, 4.3±1.1 ft-lb)
5. Master Cylinder
A: REMOVAL
1) Thoroughly drain brake fluid from reservoir tank.
2) Disconnect fluid level indicator harness connector.
3) Remove brake pipes from master cylinder.
4) Remove master cylinder mounting nuts, and take out
master cylinder from brake booster.
CAUTION:
Be extremely careful not to spill brake fluid. Brake fluid
spilt on the vehicle body will harm the painted surface;
wipe it off quickly if spilt.
52
5. Master Cylinder
B: DISASSEMBLY
1. PRECAUTIONS FOR DISASSEMBLING
1) Remove mud and dirt from the surface of brake master
cylinder.
2) Prepare tools necessary for disassembly operation, and
arrange them neatly on work bench.
3) Clean work bench.
4) Tools for disassembly operation:
쐌 1 Phillips screwdriver
쐌 1 C-ring pliers
2. DISASSEMBLING PROCEDURE
1) Remove reserve tank.
2) Remove supply valve stopper. (only vehicle equipped
with ABS)
3) Remove filter and cylinder pin. (only vehicle equipped
with TCS)
4) Remove C-ring with C-ring pliers pushing in primary
piston slightly.
NOTE:
G4M0418 Piston may jump out from master cylinder.
5) Extract primary piston assembly and secondary piston
assembly.
CAUTION:
쐌 Do not disassemble the piston assembly; otherwise,
the spring set value may be changed.
쐌 Use brake fluid or methanol to wash inside wall of
cylinder, pistons and piston cups. Be careful not to
damage parts when washing. If methanol is used for
washing, do not dip rubber parts, such as piston cups,
in it for more than 30 seconds; otherwise, they may
become swelled.
C: INSPECTION
If any damage, deformation, wear, swelling, rust, and other
faults are found on the primary piston assembly, second-
ary piston assembly, supply valve stopper, or gasket,
replace the faulty part.
CAUTION:
쐌 The primary and secondary pistons must be
replaced as complete assemblies.
쐌 The service limit of the clearance between each pis-
ton and the master cylinder inner dia. is 0.11 mm
(0.0043 in).
쐌 When handling parts, be extremely careful not to
damage or scratch the parts, or let any foreign matter
get on them.
53
5. Master Cylinder
D: ASSEMBLY
1. PRECAUTIONS FOR ASSEMBLING
1) When assembling, be sure to use recommended brake
fluid.
2) Ensure that the inside wall of cylinder, pistons, and pis-
ton cups are free from dirt when assembling.
3) Be extremely careful not to damage, scratch, or dent
cylinder inside wall, pistons, and piston cups.
4) Do not drop parts. Never attempt to use any part that
has been dropped accidentally.
2. ASSEMBLING OPERATION
1) Assembling piston assembly:
Apply recommended brake fluid to inside wall of cylinder,
and to outer surface of piston assembly, and install piston
assemblies carefully into cylinder.
2) Assembling supply valve stopper or cylinder pin:
After installing piston into cylinder, push primary piston in
about 10 mm (0.39 in), using a rod, such as push rod then
assemble gasket and supply valve stopper or cylinder pin.
Tightening torque:
2.2±0.7 N⋅m (0.225±0.075 kg-m, 1.6±0.5 ft-lb)
CAUTION:
If the gasket and supply valve stopper are assembled
without pushing in the primary piston, scratches may
be caused on the secondary piston, and no pressure
may be built up in the secondary side. To avoid such
an error, be sure to push in the primary piston before
assembling these parts.
3) Assembling C-ring:
With primary piston pushed in slightly, attach C-ring by
using C-ring pliers.
NOTE:
After assembling, ensure that the C-ring is fitted securely
in the ring groove.
E: INSTALLATION
To install the master cylinder to the body, reverse the
sequence of removal procedure.
Tightening torque:
Master cylinder mounting nut
14±4 N⋅m (1.4±0.4 kg-m, 10.1±2.9 ft-lb)
Piping flare nut
+3 +0.3 +2.2
15−2 N⋅m (1.5−0.2 kg-m, 10.8−1.4 ft-lb)
CAUTION:
Be sure to use recommended brake fluid.
54
6. Brake Booster
6. Brake Booster
A: REMOVAL
1) Remove or disconnect the following parts at engine
compartment.
(1) Disconnect connector for brake fluid level indicator.
(2) Remove brake pipes from master cylinder.
(3) Remove master cylinder installing nuts.
(4) Disconnect vacuum hose from brake booster.
2) Remove the following parts from the pedal bracket.
(1) Snap pin and clevis pin
(2) Four brake booster installing nuts
3) Remove brake booster while shunning brake pipes.
B: INSTALLATION
1) Mount brake booster in position.
2) Connect operating rod to brake pedal with clevis pin
and snap pin.
쎻1 Clevis pin
쎻2 Snap pin
쎻3 Operating rod
B4M0117A
3) Connect vacuum hose to brake booster.

4) Mount master cylinder onto brake booster.
5) Connect brake pipes to master cylinder.
6) Connect electric connector for brake fluid level indica-
tor.
G4M0420
55
6. Brake Booster
7) Adjust operating rod of brake booster.

Standard: L
145.3 mm (5.72 in)
If it is not in specified value, adjust it by adjusting brake
booster operating rod.
8) Measure the clearance between threaded end of stop
light switch and stopper.
If it is not in specified value, adjust it by adjusting position
of stop light switch.
B4M0616A
쎻1 Stop light switch
쎻2 Stopper
쎻3 Brake pedal
CAUTION:
Be careful not to rotate stop light switch.
Stop light switch clearance: A
0.3 mm (0.012 in)
9) Apply grease to operating rod connecting pin to prevent
it from wearing.
B4M0617A
Tightening torque (Air bleeder screw):
8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
11) Conduct road tests to ensure brakes do not drag.
C: OPERATION CHECK
CAUTION:
When checking operation, be sure to securely apply
the hand brake.
1. CHECKING WITHOUT USING GAUGES
This method cannot determine the exact portion which has
failed, but it can provide a rough understanding of the
nature of the failure if checking is conducted in accordance
with the following procedures.
56
6. Brake Booster
2. AIR TIGHTNESS CHECK

Start engine, and run it for 1 to 2 minutes, then turn it off.
Depress brake pedal several times applying the same
pedal force as that used in ordinary braking operations.
The pedal stroke should be greatest on the 1st depression,
and it should become smaller with each successive
depression. If no change occurs in the pedal height while
in a depressed state, brake booster is faulty.
NOTE:
G4M0744 쐌 In the event of defective operation, inspect the condition
of the check valve and vacuum hose.
쐌 Replace them if faulty and conduct the test again.
쐌 If no improvement is observed, check precisely with
gauges.
3. OPERATION CHECK
1) With engine off, depress brake pedal several times
applying the same pedal force and make sure that the
pedal height does not vary with each depression of the
pedal.
2) With brake pedal depressed, start engine.
3) As engine starts, brake pedal should move slightly
toward the floor. If no change occurs in the pedal height,
brake booster is faulty.
G4M0914 NOTE:
If faulty, check precisely with gauges.
4. LOADED AIR TIGHTNESS CHECK

Depress brake pedal while engine is running, and turn off
engine while the pedal is still depressed. Keep the pedal
depressed for 30 seconds; if no change occurs in the pedal
height, brake booster is functioning normally; if the pedal
height increases, it is faulty.
NOTE:
If faulty, check precisely with gauges.
57
6. Brake Booster
5. CHECKING WITH GAUGES

Connect gauges as shown in Figure. After bleeding air from
pressure gauges, proceed to each check.
G4M0423
6. AIR TIGHTNESS CHECK

1) Start engine and keep it running until a vacuum of 66.7
kPa (500 mmHg, 19.69 inHg) = point A is indicated on
vacuum gauge. Do not depress brake pedal.
2) Stop engine and watch the gauge. If the vacuum drop
range is less than 3.3 kPa (25 mmHg, 0.98 inHg) within 15
seconds after stopping engine, brake booster is functioning
properly.
If defective, the cause may be one of those listed below.
G4M0746 쐌 Check valve malfunction
쐌 Leak from vacuum hose
쐌 Leak from the shell jointed portion or stud bolt welded
portion
쐌 Damaged diaphragm
쐌 Leak from valve body seal and bearing portion
쐌 Leak from plate and seal assembly portion
쐌 Leak from poppet valve assembly portion
7. LOADED AIR TIGHTNESS CHECK

1) Start engine and depress brake pedal with pedal force
of 196 N (20 kg, 44 lb). Keep engine running until a vacuum
of 66.7 kPa (500 mmHg, 19.69 inHg) = point B is indicated
on vacuum gauge while the pedal is still depressed.
2) Stop engine and watch vacuum gauge.
If the vacuum drop range is less than 3.3 kPa (25 mmHg,
0.98 inHg) within 15 seconds after stopping engine, brake
booster is functioning properly.
G4M0747 If defective, refer to “AIR TIGHTNESS CHECK” described
above.
58
6. Brake Booster
8. LACK OF BOOSTING ACTION CHECK

Turn off engine, and set the vacuum gauge reading at “0”.
Then, check the fluid pressure when brake pedal is
depressed. The pressure must be greater than the stan-
dard value listed below.
Brake pedal force 147 N (15 kg, 33 lb) 294 N (30 kg, 66 lb)
Models without ABS and 785 kPa 2,158 kPa
TCS (8 kg/cm2, 114 psi) (22 kg/cm2, 313 psi)
Models with ABS and 588 kPa 1,667 kPa
TCS (6 kg/cm2, 85 psi) (17 kg/cm2, 242 psi)
9. BOOSTING ACTION CHECK

Set the vacuum gauge reading at 66.7 kPa (500 mmHg,
19.69 inHg) by running engine. Then, check the fluid pres-
sure when brake pedal is depressed. The pressure must
be greater than the standard value listed below.
Brake pedal force 147 N (15 kg, 33 lb) 294 N (30 kg, 66 lb)
Models without ABS and 5,492 kPa 8,434 kPa
TCS (56 kg/cm2, 796 psi) (86 kg/cm2, 1,223 psi)
10,003 kPa
Models with ABS and 5,394 kPa
(102 kg/cm2, 1,450
TCS (55 kg/cm2, 782 psi)
psi)
D: HANDLING PRECAUTIONS
1) Be careful not to drop brake booster. Brake booster
should be discarded if it has been dropped.
2) Use special care when handling operating rod.
If excessive force is applied to operating rod, sufficient to
cause a change in the angle in excess of ±3°, it may result
in damage to the power piston cylinder.
59
6. Brake Booster
3) Use care when placing brake booster on the floor.

CAUTION:
If external force is applied from above when brake
booster is placed in this position, the resin portion as
indicated by “P”, may be damaged.
G4M0425
4) Do not change the push rod length. If it has been

changed, reset the projected length “L” to the standard
length.
Standard:
L = 10 mm (0.39 in)
G4M0424
60
7. Brake Hose
7. Brake Hose
A: REMOVAL
1) Separate brake pipe from brake hose.
(Always use flare nut wrench and be careful not to deform
flare nut.)
2) Pull out clamp to remove brake hose.
3) Remove clamp at strut and union bolt.
G4M0426
B: INSTALLATION
1. FRONT BRAKE HOSE
1) Route end of brake hose (on caliper side) through hole
in brake hose bracket at strut location.
2) Tighten end of brake hose at caliper using a union bolt.
Tightening torque (Union bolt):
18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
G4M0427
3) Secure middle fitting of brake hose to bracket at strut

location using a clamp.
4) Position disc in straight-forward direction and route
brake hose through hole in bracket on wheel apron side.
CAUTION:
Be sure brake hose is not twisted.
5) Temporarily tighten flare nut to connect brake pipe and
hose.
6) Fix brake hose with clamp at wheel apron bracket.
7) While holding hexagonal part of brake hose fitting with
a wrench, tighten flare nut to the specified torque.
Tightening torque (Brake pipe flare nut):
+3 +0.3 +2.2
15−2 N⋅m (1.5−0.2 kg-m, 10.8−1.4 ft-lb)
8) Bleed air from the brake system.
2. REAR BRAKE HOSE

1) Pass brake hose through the hole of bracket, and lightly
tighten flare nut to connect brake pipe.
2) Insert clamp upward to fix brake hose.
3) Perform the same procedures as before mentioned in
steps 7) and 8).
61
8. Hill Holder
8. Hill Holder
A: REMOVAL
1) Drain brake fluid from reservoir of master cylinder.
2) Remove adjusting nut and cable clamp, and disconnect
PHV cable from cable bracket on engine.
3) Detach PHV cable from clips.
4) Remove cable clamp, and disconnect PHV cable from
PHV stay.
G4M0428 CAUTION:
Carefully protect boots and inner cable from damage
when disconnecting PHV cable.
5) Disconnect brake pipes from PHV.
CAUTION:
쐌 Pay attention not to drop brake fluid onto body
painting since it may dissolve paint.
쐌 Pay attention not to damage hexagonal head of flare
nut by using pipe wrench without fail.
6) Detach PHV along with support from side frame.
CAUTION:
Exercise utmost care to prevent foreign matter from
entering into PHV when removing it.
B: INSPECTION
Check up removed parts as follows, and replace defective
ones.
1) Check if boots of PHV cable are damaged or degraded,
and if inner cable is damaged or corroded.
2) Check if return spring is worn out, damaged or cor-
roded.
3) Confirm that rolling sound of ball is heard with PHV
inclined and lever rotates smoothly.
CAUTION:
Never disassemble PHV. Replace entire PHV assembly
if necessary.
62
8. Hill Holder
C: INSTALLATION
1) Install PHV onto side frame.
Tightening torque:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
2) Connect brake pipes to PHV.
Tightening torque:
+3 +0.3 +2.2
15−2 N⋅m (1.5−0.2 kg-m, 10.8−1.4 ft-lb)
CAUTION:
Confirm that brake pipes are not deformed and/or dam-
aged. Replace them with new ones if necessary.
3) Install PHV cable to PHV stay.
CAUTION:
If cable clamp (and clips) is damaged, replace it with a
new one.
4) Connect PHV cable with clips.
NOTE:
Avoid sharp bending of PHV cable as it may cause break-
age.
5) Install PHV cable onto cable bracket on engine.
6) Apply grease to the following points.
쐌 Hook portion of return spring
쐌 Cable end portion of lever
Grease:
SUNLIGHT 2 (Part No. 003602010)
7) Be sure to bleed air from the system.
CAUTION:
After replacing PHV cable or clutch cable with new
one, operate clutch pedal about 30 times as a run-
ning-in operation prior to adjustment.
D: ADJUSTMENTS
Confirm stopping and starting performances by activating
hill holder on an uphill road of 3° or higher inclination.
(1) If vehicle does not stop;
Tighten adjusting nut of PHV cable.
(2) If vehicle does not start properly;
쐌 Case A — When hill holder is released later than
engagement of clutch pedal (Engine tends to stall.):
Loosen adjusting nut gradually until smooth starting
is enabled.
쐌 Case B — When hill holder is released earlier than
engagement of clutch pedal (Vehicle slips down
slightly.):
Tighten adjusting nut so that hill holder is released
later than engagement of clutch pedal (status in Case
A). Then make adjustment the same as in Case A.
63
8. Hill Holder - 9. Parking Brake Lever
NOTE:
Whenever turning adjusting nut, prevent PHV cable from
revolving as shown in Figure.
G4M0429
9. Parking Brake Lever

A: REPLACEMENT
1) Remove console box from front floor.
2) Disconnect electric connector for parking brake switch.
3) Loosen parking brake adjuster, and remove inner cable
end from equalizer.
4) Remove parking brake lever.
5) Install parking brake lever in the reverse order of
removal.
Tightening torque (Lever installing bolt and nut):
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)

parking brake lever stroke is set at 7 to 8 notches with
operating force of 196 N (20 kg, 44 lb).
5.9±1.5 N⋅m (0.60±0.15 kg-m, 4.3±1.1 ft-lb)
B4M0050A
64
8. Hill Holder - 9. Parking Brake Lever
NOTE:
Whenever turning adjusting nut, prevent PHV cable from
revolving as shown in Figure.
G4M0429
9. Parking Brake Lever

A: REPLACEMENT
2) Disconnect electric connector for parking brake switch.
3) Loosen parking brake adjuster, and remove inner cable
end from equalizer.
4) Remove parking brake lever.
5) Install parking brake lever in the reverse order of
removal.
Tightening torque (Lever installing bolt and nut):
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)

parking brake lever stroke is set at 7 to 8 notches with
operating force of 196 N (20 kg, 44 lb).
5.9±1.5 N⋅m (0.60±0.15 kg-m, 4.3±1.1 ft-lb)
B4M0050A
64
10. Parking Brake Cable
B4M0070A
쎻
7 Clamp Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Parking brake switch 쎻
8 Parking brake cable RH T1: 5.9±1.5 (0.60±0.15, 4.3±1.1)
쎻
3 Lock nut 쎻
9 Cable guide T2: 18±5 (1.8±0.5, 13.0±3.6)
쎻
4 Adjusting nut 쎻
10 Clamp T3: 32±10 (3.3±1.0, 24±7)
쎻
5 Equalizer (Rear disc brake model only)
쎻
6 Bracket 쎻
11 Parking brake cable LH
A: REPLACEMENT
1) Lift-up vehicle.
2) Remove rear wheels.
3) Remove rear cushion.
5) Loosen parking cable adjusting nut.
65
6) Roll up floor mat and remove clamps.
B4M0077A
7) Remove inner cable end from equalizer.
B4M0078A
8) Pull out parking brake cable from parking brake assem-

bly. <Ref. to 4-4 [W4A0].>
9) Pull out clamp from parking brake assembly.
10) Remove bolt and bracket from trailing link bracket.
11) Remove bolt and clamp from rear floor.

12) Detach grommet from rear floor.
13) Remove cable assembly from cabin by forcibly pulling
it backward.
G4M0433
14) Detach parking brake cable from cable guide at rear

trailing link.
15) Install (new) parking brake assembly in the reverse
order of removal.
NOTE:
쐌 Be sure to pass cable through cable guide inside the
tunnel.
쐌 Be sure to adjust the lever stroke. <Refer to 4-4
[W4D1].>
66
11. Air Bleeding (Without TCS model)

A: GENERAL RULES FOR EFFECTIVE
BLEEDING
1) Start with the brakes (wheels) connecting to the sec-
ondary chamber of the master cylinder.
2) The time interval between two brake pedal operations
(from the time when the pedal is released to the time when
it is depressed another time) shall be approximately 3 sec-
onds.
3) The air bleeder on each brake shall be released for 1
to 2 seconds.
B: BLEEDING PROCEDURE
CAUTION:
쐌 The FMVSS No. 116, fresh DOT3 or 4 brake fluid
must be used.
쐌 Cover bleeder with waste cloth, when loosening it,
to prevent brake fluid from being splashed over sur-
rounding parts.
쐌 Avoid mixing different brands of brake fluid to pre-
vent degrading the quality of the fluid.
쐌 Be careful not to allow dirt or dust to get into the
reservoir tank.
NOTE:
쐌 During bleeding operation, keep the brake reserve tank
filled with brake fluid to eliminate entry of air.
쐌 Brake pedal operating must be very slow.
쐌 For convenience and safety, it is advisable to have two
man working.
1) Make sure that there is no leak from joints and connec-

tions of the brake system.
2) Fit one end of vinyl tube into the air bleeder and put the
other end into a brake fluid container.
3) Slowly depress the brake pedal and keep it depressed.
Then, open the air bleeder to discharge air together with
the fluid.
Release air bleeder for 1 to 2 seconds.
Next, with the bleeder closed, slowly release the brake
G4M0434 pedal.
Repeat these steps until there are no more air bubbles in
the vinyl tube.
Allow 3 to 4 seconds between two brake pedal operations.
CAUTION:
Cover bleeder with waste cloth, when loosening it, to
prevent brake fluid from being splashed over sur-
rounding parts.
NOTE:
Brake pedal operating must be very slow.
4) Tighten air bleeder securely when no air bubbles are
G4M0435
visible.
67
Air bleeder tightening torque:

8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
5) Perform these steps for the brakes connecting to the
secondary chamber of master cylinder, first, and then for
the ones connecting to primary chamber. With all proce-
dures completed, fully depress the brake pedal and keep
it in that position for approximately 20 seconds to make
sure that there is no leak evident in the entire system.
6) Perform sequence control. (With ABS model) <Ref. to

4-4 [W15C1].>
7) Check the pedal stroke.
While the engine is idling, depress the brake pedal with a
490 N (50 kg, 110 lb) load and measure the distance
between the brake pedal and steering wheel. With the
brake pedal released, measure the distance between the
pedal and steering wheel again. The difference between
the two measurements must be more than specified.
G4M0436 Specified pedal stroke:
Without ABS
90 mm (3.54 in)
With ABS
95 mm (3.74 in)
When depressing brake pedal with a 490 N (50 kg,
110 lb) load.
(1) Models without ABS
If the distance is more than specifications, there is a
possibility that air is in the brake line. Bleed air from the
brake line.
(2) Models with ABS
possibility air is in the inside of the hydraulic unit.
Therefore, air must be bled from the inside of the
hydraulic unit to the brake pipes in accordance with the
bleeding sequence control. <Ref. to 4-4 [W15C1].>
8) Add brake fluid to the required level (MAX. level) of

reserve tank.
9) As a final step, test run the vehicle at low speed and
apply brakes relatively hard 2 to 3 times to ensure that
brakes provide normal braking action on all four wheels
without dragging and uneven braking.
68
12. Brake Fluid Replacement

NOTE:
To always maintain the brake fluid characteristics, replace
the brake fluid according to maintenance schedule or ear-
lier than that when used in severe condition.
A: REPLACEMENT
CAUTION:
must be used.
rounding parts.
reservoir tank.
NOTE:
쐌 During bleeding operation, keep the brake reserve tank
filled with brake fluid to eliminate entry of air.
man working.
쐌 The amount of brake fluid required is approximately 500
m (16.9 US fl oz, 17.6 Imp fl oz) for total brake system.
1) Either jack-up vehicle and place a safety stand under it,
or lift-up vehicle.
2) Remove both front and rear wheels.
3) Draw out the brake fluid from reserve tank with syringe.
4) Refill reservoir tank with recommended brake fluid.
Recommended brake fluid:
FMVSS No. 116, fresh DOT3 or 4 brake fluid
69
5) Install one end of a vinyl tube onto the air bleeder of and
insert the other end of the tube into a container to collect
the brake fluid.
6) Instruct your co-worker to depress the brake pedal
slowly two or three times and then hold it depressed.
7) Loosen bleeder screw approximately 1/4 turn until a
small amount of brake fluid drains into container, and then
quickly tighten screw.
8) Repeat steps 6) and 7) above until there are no air
G4M0434
bubbles in drained brake fluid and new fluid flows through
vinyl tube.
CAUTION:
Add brake fluid as necessary while performing the air
bleed operation, in order to prevent the tank from run-
ning short of brake fluid.
9) After completing the bleeding operation, hold brake
pedal depressed and tighten screw and install bleeder cap.
Tightening torque (Bleeder screw):
8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
10) Bleed air from each wheel cylinder using the same
G4M0438
procedures as described in steps 6) through 7) above.
11) Depress brake pedal with a force of approximately 294
N (30 kg, 66 lb) and hold it there for approximately 20 sec-
onds. At this time check pedal to see if it shows any
unusual movement.
Visually inspect bleeder screws and brake pipe joints to
make sure that there is no fluid leakage.
12) Install wheels, and drive vehicle for a short distance
between 2 to 3 km (1 to 2 miles) to make sure that brakes
are operating properly.
G4M0435
70
13. Proportioning Valve
13. Proportioning Valve
B4M1177A
B4M1197A
A: INSPECTION
1) Install the oil pressure gauges to measure the master
cylinder fluid pressure (front wheel brake fluid pressure)
and rear wheel cylinder fluid pressure.
2) Bleed air from the oil pressure gauges.
3) Check the master cylinder fluid pressure and rear wheel
cylinder fluid pressure.
The standard values are shown in Figure.
4) For the oil pressure in case of split point, refer to A:
B4M1198A
SPECIFICATIONS 4-4 [S1A0].
B: REMOVAL
1) Remove brake pipe from proportioning valve at four
places.
2) Remove proportioning valve from its bracket.
CAUTION:
Do not disassemble or adjust the proportioning valve.
(The proportioning valve must be replaced as an
assembly.)
C: INSTALLATION
1) Install proportioning valve to bracket.
2) Connect brake pipes correctly to proportioning valve.
3) Bleed air, then check each joint of brake pipe for oil
leaks.
Tightening torque:
Proportioning valve to brake pipe flare nut:
+3 +0.3 +2.2
15−2 N⋅m (1.5−0.2 kg-m, 10.8−1.4 ft-lb)
Proportioning valve to bracket:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
71
14. ABS Sensor
14. ABS Sensor

A: REMOVAL
1. FRONT ABS SENSOR
1) Disconnect front ABS sensor connector located in
engine compartment.
2) Remove bolts which secure sensor harness to strut.
B4M0079A
3) Remove bolts which secure sensor harness to body.
G4M0451
4) Remove bolts which secure front ABS sensor to

housing, and remove front ABS sensor.
CAUTION:
쐌 Be careful not to damage pole piece located at tip of
the sensor and teeth faces during removal.
쐌 Do not pull sensor harness during removal.
5) Remove front disc brake caliper and disc rotor from
housing after removing front tire.
6) Remove front drive shaft and housing and hub assem-
G4M0443
bly. <Ref. to 4-2 [W1A0].>
72
14. ABS Sensor
7) Remove tone wheel while removing hub from housing

and hub assembly. <Ref. to 4-2 [W1B0].>
CAUTION:
Be careful not to damage teeth faces of tone wheel
during removal.
G4M0444
2. REAR ABS SENSOR

1) Remove rear seat and disconnect rear ABS sensor con-
nector.
2) Remove rear sensor harness bracket from rear trailing
link and bracket.
3) Remove rear ABS sensor from rear back plate.

4) Remove rear tone wheel while removing hub from
housing and hub assembly. <Ref. to 4-2 [W2A0].>
CAUTION:
쐌 Be careful not to damage pole piece located at tip of
the sensor and teeth faces during removal.
쐌 Do not pull sensor harness during removal.
G4M0445
B: INSPECTION
1. ABS SENSOR
1) Check pole piece of ABS sensor for foreign particles or
damage. If necessary, clean pole piece or replace ABS
sensor.
73
14. ABS Sensor
2) Measure ABS sensor resistance.

ABS sensor Terminal No. Standard
Front - LH 1 and 2
Front - RH 1 and 2
1.0±0.2 kΩ
Rear - LH 1 and 2
Rear - RH 1 and 2
CAUTION:
If resistance is outside the standard value, replace
B4M0248 ABS sensor with new one.
NOTE:
Check ABS sensor cable for discontinuity. If necessary,
replace with a new one.
2. TONE WHEEL
1) Check tone wheel’s teeth (44 pieces) for cracks or
dents. If necessary, replace tone wheel with a new one.
2) Clearances (sensor gaps) should be measured one by
one to ensure tone wheel and speed sensor are installed
correctly.
ABS sensor clearance:
Front
0.9 — 1.4 mm (0.035 — 0.055 in)
G4M0448 Rear
0.7 — 1.2 mm (0.028 — 0.047 in)
NOTE:
쐌 If clearance is narrow, adjust by using spacer (Part No.
26755AA000).
쐌 If clearance is wide, check the outputted voltage then
replace ABS sensor or tone wheel if the outputted voltage
is outside the specification.
74
14. ABS Sensor
3. OUTPUT VOLTAGE
Output voltage can be checked by the following method.
Install resistor and condenser, then rotate wheel about 2.75
km/h (2 MPH) or equivalent.
NOTE:
Regarding terminal No., please refer to item 1. ABS SEN-
SOR.
B4M0118B
C: INSTALLATION
1. FRONT ABS SENSOR
1) Install tone wheel on hub, then install housing on hub
assembly. <Ref. to 4-2 [W1D0].>
2) Temporarily install front ABS sensor on housing.

CAUTION:
Be careful not to strike ABS sensor’s pole piece and
tone wheel’s teeth against adjacent metal parts during
installation.
G4M0443
3) Install front drive shaft to hub spline. <Ref. to 4-2

[W1E0].>
75
14. ABS Sensor
4) Install front ABS sensor on strut and wheel apron

bracket.
Tightening torque:
32±10 N⋅m (3.3±1.0 kg-m, 24±7 ft-lb)
G4M0451
5) Place a thickness gauge between ABS sensor’s pole

piece and tone wheel’s tooth face. After standard clearance
is obtained over the entire perimeter, tighten ABS sensor
on housing to specified torque.
ABS sensor standard clearance:
0.9 — 1.4 mm (0.035 — 0.055 in)
Tightening torque:
32±10 N⋅m (3.3±1.0 kg-m, 24±7 ft-lb)
CAUTION:
Check the marks on the harness to make sure that no
distortion exists. (RH: white, LH: yellow)
NOTE:
If the clearance is outside specifications, readjust.
2. REAR ABS SENSOR

1) Install rear tone wheel on hub, then rear housing on
hub. <Ref. to 4-2 [W2D0].>
2) Temporarily install rear ABS sensor on back plate.

CAUTION:
Be careful not to strike ABS sensor’s pole piece and
tone wheel’s teeth against adjacent metal parts during
installation.
G4M0445
76
14. ABS Sensor
3) Install rear drive shaft to rear housing and rear differen-

tial spindle. <Ref. to 4-2 [W2E0].>
4) Install rear sensor harness on rear trailing link.

Tightening torque:
32±10 N⋅m (3.3±1.0 kg-m, 24±7 ft-lb)
G4M0453
5) Place a thickness gauge between ABS sensor’s pole

piece and tone wheel’s tooth face. After standard clearance
is obtained over the entire perimeter, tighten ABS sensor
on back plate to specified torque.
ABS sensor standard clearance:
0.7 — 1.2 mm (0.028 — 0.047 in)
Tightening torque:
32±10 N⋅m (3.3±1.0 kg-m, 24±7 ft-lb)
CAUTION:
Check the marks on the harness to make sure that no
distortion exists. (RH: white, LH: yellow)
NOTE:
If the clearance is outside specifications, readjust.
77
15. Hydraulic Unit for ABS System (ABS 5.3 Type)
15. Hydraulic Unit for ABS System

(ABS 5.3 Type)
B4M0994A
쎻
1 Hydraulic control unit 쎻
15 Cap
쎻
2 Damper 쎻
16 Connector bracket
쎻
3 Stud bolt 쎻
10 Cable clip
쎻
11 Bracket
T1: 18±5 (1.8±0.5, 13.0±3.6)
쎻
5 Rear-LH outlet 쎻
12 Relay box T2: 29±7 (3.0±0.7, 21.7±5.1)
쎻
6 Secondary inlet 쎻
13 Motor relay T3: 32±10 (3.3±1.0, 24±7)
쎻
7 Primary inlet 쎻
14 Valve relay
A: REMOVAL
1. HYDRAULIC UNIT
2) Remove air intake duct and canister from engine com-
partment to facilitate removal of hydraulic unit.
3) Disconnect connector from hydraulic unit.
4) Unlock cable clip.
5) Disconnect brake pipes from hydraulic unit.
CAUTION:
Wrap brake pipes with vinyl bag to avoid spilling brake
fluid on vehicle body.
78
6) Remove nuts and bolt which secure hydraulic unit

bracket, and remove hydraulic unit from engine compart-
ment.
CAUTION:
쐌 Hydraulic unit cannot be disassembled. Do not
attempt to loosen bolts and nuts.
쐌 Do not drop or bump hydraulic unit.
쐌 Do not turn the hydraulic unit upside down or place
it on its side.
B4M0996 쐌 Be careful to prevent foreign particles from getting
into hydraulic unit.
쐌 When a new hydraulic unit is installed, apply a coat
of rust-preventive wax (Nippeco LT or GB) to bracket
attaching bolt after tightening.
쐌 Do not pull harness disconnecting harness connec-
tor.
2. RELAY BOX
2) Remove air intake duct and canister from engine com-
partment to facilitate removal of relay box.
3) Disconnect connector from relay box.

5) Remove nuts which secure relay box, and remove relay
box and connector bracket.
CAUTION:
Do not drop or bump relay box.
B4M1029
79
B: INSPECTION
1) Check connected and fixed condition of connector.
2) Check valve relay and motor relay for discontinuity or
short circuits.
Condition Terminal number Standard Diagram Terminal location
85 — 86 103±10 Ω
Turning off
30 — 87a less than 0.5 Ω
electricity.
30 — 87 less than 1 MΩ
Valve relay
Turning on 30 — 87a more than 1 MΩ
electricity between
85 and 86.
(DC 12 V) 30 — 87 less than 0.5 Ω G4M0457
G4M0456
85 — 86 80±8 Ω
Turning off
electricity.
30 — 87 more than 1 MΩ
Motor relay
Turning on
electricity between
30 — 87 less than 0.5 Ω
85 and 86.
(DC 12 V) G4M0458 G4M0459
C: CHECKING THE HYDRAULIC UNIT ABS

OPERATION
1. CHECKING THE HYDRAULIC UNIT ABS
OPERATION BY PRESSURE GAUGE
2) Disconnect the air bleeder screws from the FL and FR
caliper bodies.
3) Connect two pressure gauges to the FL and FR caliper

bodies.
CAUTION:
쐌 Pressure gauges used exclusively for brake fluid
must be used.
쐌 Do not employ pressure gauge previously used for
transmission since the piston seal is expanded which
may lead to malfunction of the brake.
NOTE:
B4M0633A
Wrap sealing tape around the pressure gauge.
80
4) Bleed air from the pressure gauges.

5) Perform ABS sequence control.
<Ref. to 4-4 [W15D0].>
6) When the hydraulic unit begins to work, and first the FL
side performs decompression, holding, and compression ,
and then the FR side performs decompression, holding,
and compression.
7) Rear values indicated on the pressure gauge and check
if the fluctuation of the values between decompression and
compression meets the standard values. Also check if any
irregular brake pedal tightness is felt.
Initial value When decompressed When compressed
2
490 kPa (5 kg/cm , 71 psi) 3,432 kPa (35 kg/cm2, 498 psi)
Front wheel 3,432 kPa (35 kg/cm2, 498 psi)
or less or more
490 kPa (5 kg/cm2, 71 psi) 3,432 kPa (35 kg/cm2, 498 psi)
Rear wheel 3,432 kPa (35 kg/cm2, 498 psi)
or less or more
8) Remove pressure gauges from FL and FR caliper bod-
ies.
9) Remove air bleeder screws from the RL and RR caliper
bodies.
10) Connect the air bleeder screws to the FL and FR cali-
per bodies.
11) Connect tow pressure gauges to the RL and RR cali-
per bodies.
12) Bleed air from the pressure gauges and the FL and FR
caliper bodies.
<Ref. to 4-4 [W15D0].>
14) When the hydraulic unit begins to work, at first the RR
side performs decompression, holding, and compression,
and then the RL side performs decompression, holding,
and compression.
15) Rear values indicated on the pressure gauges and
check if they meet the standard value.
16) After checking, remove the pressure gauges from cali-
per bodies.
17) Connect the air bleeder screws to RL and RR caliper
bodies.
18) Bleed air from brake line.
81

OPERATION WITH BRAKE TESTER
1) In the case of AWD AT vehicles, install a spare fuse with
the FWD connector in the engine compartment to simulate
FWD vehicles.
2) Prepare for operationing ABS sequence control. <Ref.
to 4-4 [W15D1] or 4-4 [W15D2].>
G4M0462
3) Set the front wheels or rear wheels on the brake tester

and set the select lever’s position at “neutral”.
4) Operate the brake tester.
5) Perform ABS sequence control. <Ref. to 4-4 [W15D1]
step 1 or 4-4 [W15D2] step 1.>
6) Hydraulic unit begins to work; and check the following
working sequence.
(1) The FL wheel performs decompression, holding,
and compression in sequence, and subsequently the
G4M0464
FR wheel repeats the cycle.
(2) The RR wheel performs decompression, holding,
RL wheel repeats the cycle.
7) Read values indicated on the brake tester and check if
the fluctuation of values, when decompressed and
compressed, meet the standard values.
Unit: N (kg, lb)

Front wheel 981 (100, 221) 490 (50, 110) or less 981 (100, 221) or more
Rear wheel 981 (100, 221) 490 (50, 110) or less 981 (100, 221) or more
8) After checking, also check if any irregular brake pedal
tightness is felt.
82
D: ABS SEQUENCE CONTROL

1) Under the ABS sequence control, after the hydraulic
unit solenoid valve is driven, the operation of the hydraulic
unit can be checked by means of the brake tester or pres-
sure gauge.
2) ABS sequence control can be started by diagnosis con-
nector or select monitor.
1. OPERATIONAL GUIDELINES OF THE ABS

SEQUENCE CONTROL WITH DIAGNOSIS
CONNECTOR
1) Connect diagnosis terminals to terminals No. 3 and No.
6 of the diagnosis connector beside driver’s seat heater
unit.
2) Set the speed of all wheels at 4 km/h (2 MPH) or less.
3) Turn ignition switch OFF.
4) Within 0.5 seconds after the ABS warning light goes
B4M0082D
out, depress the brake pedal and hold it immediately after
ignition switch is turned to ON.
CAUTION:
Do not depress the clutch pedal.
NOTE:
쐌 When the ignition switch is set to on, the brake pedal
must not be depressed.
쐌 Engine must not operate.
5) After completion of ABS sequence control, turn ignition
switch OFF.

SEQUENCE CONTROL WITH SELECT MONITOR
1) Connect select monitor to data link connector beside
driver’s seat heater unit.
2) Turn ignition switch ON.
3) Put select monitor to ABS mode.
4) Press F D 1 ENT key.
B4M0635
83
5) The message shown in the figure is displayed.
B4M0997
6) The message shown in the figure is displayed as fol-

lows:
(1) When using the brake tester, depress brake pedal
with braking force of 981 N (100 kg, 221 lb).
(2) When using the pressure gauge, depress brake
pedal so as to make the pressure gauge indicate 3,432
kPa (35 kg/cm2, 498 psi).
CAUTION:
B4M0998
7) When the message shown in the figure is displayed,

press ENT key.
8) Check points will be displayed on select monitor.
B4M0999
9) When ABS sequence control cannot be started (by sys-

tem malfunction, etc.), the message shown in the figure will
be displayed.
NOTE:
Read the trouble codes. Repair faulty parts.
B4M1000

switch OFF.
B4M1030
84
3. CONDITIONS FOR COMPLETION OF ABS

SEQUENCE CONTROL
When the following conditions develop, the ABS sequence
control stops and ABS operation is returned to the normal
control mode.
1) When the speed of at least one wheel reaches 10 km/h
(6 MPH).
2) When terminal No. 3 or No. 6 are separated from diag-
nosis terminals. (When select monitor is not used.)
3) When the brake pedal is released during sequence con-
trol and the braking lamp switch is set to off.
4) When brake pedal is depressed after ignition key is
turned to ON, and before ABS warning light goes out.
(When select monitor is not used.)
5) When brake pedal is not depressed after ignition key is
turned to ON, and within 0.5 seconds after ABS warning
light goes out. (When select monitor is not used.)
6) After completion of the sequence control.
7) When malfunction is detected. (When select monitor is
used.)
85
4. CONDITIONS FOR ABS SEQUENCE CONTROL
B4M1001A
NOTE:
쐌 When select monitor is used, control operation starts at
point A. The patterns from IGN key ON to the point A show
that operation is started by diagnosis connector.
쐌 HIGH means high voltage.
쐌 LOW means low voltage.
86
E: INSTALLATION
1. HYDRAULIC UNIT
1) Install hydraulic unit.
Tightening torque:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
2) Connect hydraulic unit ground cable to body.
Tightening torque:
32±10 N⋅m (3.3±1.0 kg-m, 24±7 ft-lb)
B4M0996 3) Connect brake pipes to their correct hydraulic unit con-
nections. <Ref. to 4-4 [W18A4].>
4) Secure hydraulic unit connector to connector bracket.

CAUTION:
Align connector wit mating receptacle.
5) Using cable clip, secure hydraulic unit harness to relay
box harness.
CAUTION:
Make sure hydraulic unit harness band is secured
beneath cable clip.
B4M1031A 6) Connect connector to hydraulic unit.
7) Install canister.
8) Install air intake duct.
2. RELAY BOX
1) Install relay box and connector bracket.
Tightening torque:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
B4M1029
87
15. Hydraulic Unit for ABS System (ABS 5.3 Type) - 16. ABS Control Module (ABS 5.3 Type)
2) Secure relay box connector to connector bracket.

CAUTION:
box harness.
CAUTION:
beneath cable clip.
B4M1031A 4) Connect connector to relay box.
16. ABS Control Module (ABS 5.3 Type)

A: REMOVAL
1. LHD MODEL
1) Turn ignition switch to OFF.
2) Remove front pillar lower trim.
3) Remove glove box.
4) Remove glove box bracket.
B4M1002
5) Remove pocket back panel.
B4M1003
6) Remove bolt from bracket.
B4M1004
88
15. Hydraulic Unit for ABS System (ABS 5.3 Type) - 16. ABS Control Module (ABS 5.3 Type)
2) Secure relay box connector to connector bracket.

CAUTION:
box harness.
CAUTION:
beneath cable clip.
B4M1031A 4) Connect connector to relay box.

A: REMOVAL
1. LHD MODEL
2) Remove front pillar lower trim.
3) Remove glove box.
4) Remove glove box bracket.
B4M1002
5) Remove pocket back panel.
B4M1003
6) Remove bolt from bracket.
B4M1004
88
7) Remove bolt cover and bolt.
B4M1005
8) Remove ABSCM upper mounting bolt.
B4M1006
9) Pull the lower part of the instrument panel rearward 5

cm (1.97 in).
CAUTION:
When pulled more than 6 cm (2.4 in), the instrument
panel may be deformed.
NOTE:
At this time, instrument panel securing clips can be
removed.
B4M1045A
10) Remove two ABSCM lower mounting bolts from the

lower part of the instrument panel.
B4M1008
11) While holding the lower part of instrument panel rear-

ward 5 cm (1.97 in) remove the ABSCM.
CAUTION:
When pulled more than 6 cm (2.4 in), the instrument
panel may be deformed.
12) Disconnect connector from ABSCM.
CAUTION:
Do not drop or bump ABSCM.
B4M1009A
89
16. ABS Control Module (ABS 5.3 Type) - 17. G Sensor for ABS System (ABS 5.3 Type)
B: INSPECTION
Check that connector is connected correctly and that con-
nector terminal sliding resistance is correct.
C: INSTALLATION
To install, reverse the removal procedure.
17. G Sensor for ABS System (ABS 5.3

Type)
A: REMOVAL AND INSTALLATION
2) Remove console box. <Ref. to 5-4 [W1A0].>
3) Disconnect connector form G sensor.
4) Remove G sensor from body.

CAUTION:
Do not drop or bump G sensor.
B4M1011
B: INSPECTION
1. USING CIRCUIT TESTER
2) Remove G sensor from vehicle.
3) Connect connector to G sensor.
4) Turn ignition switch to ON.
5) Measure voltage between G sensor connector termi-
nals.
B4M0915
: Connector & terminal
(P9) No. 2 (+) — No. 1 (−)
Is voltage 2.3±0.2 V when G sensor is hori-
zontal?
: Go to next .
: Replace G sensor.
90
16. ABS Control Module (ABS 5.3 Type) - 17. G Sensor for ABS System (ABS 5.3 Type)
B: INSPECTION
C: INSTALLATION
To install, reverse the removal procedure.
17. G Sensor for ABS System (ABS 5.3

Type)
2) Remove console box. <Ref. to 5-4 [W1A0].>
3) Disconnect connector form G sensor.
4) Remove G sensor from body.

CAUTION:
Do not drop or bump G sensor.
B4M1011
B: INSPECTION
1. USING CIRCUIT TESTER
2) Remove G sensor from vehicle.
3) Connect connector to G sensor.
4) Turn ignition switch to ON.
5) Measure voltage between G sensor connector termi-
nals.
B4M0915
(P9) No. 2 (+) — No. 1 (−)
Is voltage 2.3±0.2 V when G sensor is hori-
zontal?
: Go to next .
: Replace G sensor.
90
17. G Sensor for ABS System (ABS 5.3 Type)

(P9) No. 2 (+) — No. 1 (−)
Is voltage 3.9±0.2 V when G sensor is
inclined forwards to 90°?
: Go to next .
: Replace G sensor.
B4M0917A

(P9) No. 2 (+) — No. 1 (−)
Is voltage 0.7±0.2 V when G sensor is
inclined backwards to 90°?
: G sensor is normal.
: Replace G sensor.
B4M0918A
2. USING SELECT MONITOR

2) Connect select monitor connector to data link connec-
tor.
3) Turn select monitor into ABS mode.
4) Press F , 1 and 0 on the select monitor.

5) Rear the select monitor display.
: Is the indicated reading 2.3±0.2 V when the
vehicle is in horizontal position?
: Go to next step 6).
: Replace G sensor.
6) Remove console box.
7) Remove G sensor from vehicle. (Do not disconnect
B4M0927 connector.)
8) Read the select monitor display.

: Is the indicated reading 3.9±0.2 V when G
sensor is inclined forwards to 90°?
: Go to next .
: Replace G sensor.
B4M0917A
91
17. G Sensor for ABS System (ABS 5.3 Type)
: Is the indicated reading 0.7±0.2 V when G

sensor is inclined backwards to 90°?
: G sensor is normal.
: Replace G sensor.
B4M0918A
92
18. Brake Hose and Pipe

SUPPLEMENTAL RESTRAINT SYSTEM “AIRBAG”
Airbag system wiring harness is routed near the center
brake pipe.
CAUTION:
ness when servicing the center brake pipe.

CAUTION:
쐌 When removing and installing the brake pipe, make
sure that it is not bent.
쐌 After installing the brake pipe and hose, bleed the
air.
쐌 After installing the brake hose, make sure that it
does not touch the tire or suspension assembly, etc.
1. MODELS WITHOUT ABS
G4M0472
쎻
1 Union bolt 쎻
8 Center brake pipe ASSY Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Front brake hose RH 쎻
9 Connector bracket T1: 13±3 (1.3±0.3, 9.4±2.2)
쎻
3 Proportioning valve 쎻
10 Two-way connector +3
T2: 15−2 +0.3
(1.5−0.2 +2.2
, 10.8−1.4 )
쎻
4 Front brake pipe 쎻
11 Rear brake pipe RH T3: 18±3 (1.8±0.3, 13.0±2.2)
쎻
5 Front adapter pipe (UPPER) 쎻
12 Rear brake hose drum T4: 18±5 (1.8±0.5, 13.0±3.6)
쎻
6 Front adapter pipe (LOWER) 쎻
13 Rear brake pipe ASSY
쎻
7 Front brake hose LH 쎻
14 Rear brake pipe LH
93
2. MODELS WITH ABS (EXCEPT ABS 5.3 TYPE)
B4M0708A
쎻
1 Union bolt 쎻
8 Two-way connector Tightening torque: N⋅m (kg-m, ft-lb)
쎻
9 Connector bracket T1: 13±3 (1.3±0.3, 9.4±2.2)
쎻
3 Valve bracket 쎻
10 Rear brake hose RH +3
T2: 15−2 +0.3
(1.5−0.2 +2.2
, 10.8−1.4 )
쎻
11 Rear brake pipe ASSY T3: 18±3 (1.8±0.3, 13.0±2.2)
쎻
5 Front brake pipe ASSY 쎻
12 Rear brake hose LH T4: 18±5 (1.8±0.5, 13.0±3.6)
쎻
6 Front adapter pipe
쎻
13 Center brake pipe ASSY
쎻
7 Front brake hose LH
94
3. MODELS WITH TCS
B4M0709A
쎻
1 Union bolt 쎻
8 Connector bracket Tightening torque: N⋅m (kg-m, ft-lb)
쎻
9 Rear brake hose RH T1: 13±3 (1.3±0.3, 9.4±2.2)
쎻
3 Valve bracket 쎻
10 Rear brake pipe ASSY +3
T2: 15−2 +0.3
(1.5−0.2 +2.2
, 10.8−1.4 )
쎻
쎻
12 Center brake pipe ASSY T4: 18±5 (1.8±0.5, 13.0±3.6)
쎻
6 Front brake hose LH T5: 19±4 (1.9±0.4, 13.7±2.9)
쎻
7 Two-way connector
95
4. MODELS WITH ABS (ABS 5.3 TYPE)
B4M0995A
쎻
1 Union bolt 쎻
9 Connector bolt Tightening torque: N⋅m (kg-m, ft-lb)
쎻
쎻
3 Valve bracket 쎻
T2: 15−2 +0.3
(1.5−0.2 +2.2
, 10.8−1.4 )
쎻
쎻
쎻
6 Front adapter pipe
쎻
쎻
8 Two-way connector
96
5. MODELS WITH ABS (ABS 5.3i TYPE)
B4M1221A
쎻
1 Union bolt 쎻
9 Connector bracket Tightening torque: N⋅m (kg-m, ft-lb)
쎻
쎻
3 Clip 쎻
T2: 15−2 +0.3
(1.5−0.2 +2.2
, 10.8−1.4 )
쎻
4 Valve bracket 쎻
쎻
쎻
6 Front brake pipe ASSY
쎻
쎻
8 Two-way connector
97
19. Air Bleeding (With TCS model)

A: RULES FOR EFFECTIVE BLEEDING
1) Pressure is not applied to suction pipe by depressing
brake pedal. When any of the following are performed,
bleed air from suction pipe by air bleeding control opera-
tion.
NOTE:
For TCS vehicle, suction pipe is installed between master
cylinder and hydraulic unit to allow flow of brake fluid
between them during ABS and TCS operation.
(1) When brake pipe is disconnected from master cyl-
inder.
(2) When brake pipe between hydraulic unit and mas-
ter cylinder is disconnected.
(3) When fluid is emptied from reservoir tank.
2) The time interval between two brake pedal operations
(from the time when the pedal is released to the time when
it is depressed another time) shall be approximately 3 sec-
onds.
3) The air bleeder on each brake shall be released for 1
to 2 seconds.
B: BLEEDING PROCEDURE WITH AIR

BLEEDING CONTROL
1. BLEEDING PROCEDURE
CAUTION:
must be used.
rounding parts.
reservoir tank.
쐌 During bleeding operation, keep the brake reserve
tank filled with brake fluid to eliminate entry of air.
NOTE:
man working.
1) Start air bleeding control operation. <Ref. to 4-4

[W19C0] or 4-4 [W19D0].>
2) Make sure that there is no leak from joints and connec-
tions of the brake system.
3) Bleed air through front RH caliper by operating brake
pedal.
(1) Fit one end of vinyl tube into the air bleeder and put
the other end into a brake fluid container.
G4M0434
98
(2) Slowly depress the brake pedal and keep it

depressed. Then, open the air bleeder to discharge air
together with the fluid.
Release air bleeder for 1 to 2 seconds.
Next, with the bleeder closed, slowly release the brake
pedal.
Repeat these steps until there are no more air bubbles
in the vinyl tube.
Allow 3 to 4 seconds between two brake pedal opera-
tions.
CAUTION:
Cover bleeder with waste cloth, when loosening it, to
prevent brake fluid from being splashed over sur-
rounding parts.
NOTE:
Brake pedal operating must be very slow.
4) Bleed air from suction pipe through front RH caliper.
(1) Open the air bleeder.
(2) Keep pressing TCS OFF switch for 20 seconds or
more.
NOTE:
Ensure no air comes out from air bleeder.
(3) Close the air bleeder.
5) Bleed air through front LH caliper by operating brake
pedal. This is the same procedure as step 3).
6) Bleed air from suction pipe through front LH caliper.
This is the same procedure as step 4).
7) Bleed air through front RH and LH calipers by operat-
ing brake pedal. This is the same procedure as step 3).
Repeat steps 3) to 7) until air does no longer comes out.
8) Tighten air bleeders securely when bubbles are visible.
8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
9) Bleed air through rear LH and RH caliper by operating
brake pedal. This is the same procedure as step 3).
10) Tighten air bleeders securely when bubbles are vis-
ible.
8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
99
11) Operate FRO (Front Right Outlet) valve and RLO

(Rear Left Outlet) valve to bleed air from hydraulic unit
outlet circuit.
(1) Press TCS OFF switch while depressing brake
pedal.
(2) Make sure ABS warning light illuminates.
(3) Repeatedly depress and release brake pedal 10
times or more while pressing TCS OFF switch.
NOTE:
쐌 Air comes out from reservoir tank.
12) Operate FLO (Front Left Outlet) valve and RRO (Rear
Right Outlet) valve to bleed air from hydraulic unit outlet
circuit.
(1) Press TCS OFF switch while depressing brake
pedal.
(2) Make sure TCS warning light illuminates.
(3) Repeatedly depress and release brake pedal 10
times or more while pressing TCS OFF switch.
NOTE:
쐌 Air comes out from reservoir tank.
쐌 The operations in steps 11) and 12) above can be
switched with each other by operating brake pedal (stop
light switch) while pressing TCS OFF switch.
쐌 Repeat procedures 11) and 12) until air no longer comes
out of reservoir tank.
13) Perform these steps for the brakes connecting to the
secondary chamber of master cylinder, first, and then for
the ones connecting to primary chamber. With all proce-
dures completed, fully depress the brake pedal and keep
it in that position for approximately 20 seconds to make
sure that there is no leak evident in the entire system.
15) Perform TCS sequence control. <Ref. to 4-4
[W20F0].>
100
16) Check the pedal stroke.

While the engine is idling, depress the brake pedal with a
490 N (50 kg, 110 lb) load and measure the distance
between the brake pedal and steering wheel. With the
brake pedal released, measure the distance between the
pedal and steering wheel again. The difference between
the two measurements must be less than specified.
Specified pedal stroke:
With TCS
G4M0436 95 mm (3.74 in)
When depressing brake pedal with a 490 N (50 kg,
110 lb) load.
possibility that air is in the brake line. Bleed air from the
brake line. <Ref. to 4-4 [W19B1].>
18) Disconnect select monitor or diagnosis terminal.
19) Add brake fluid to the required level (MAX. level) of
reserve tank.
20) As a final step, test run the vehicle at low speed and
apply brakes relatively hard 2 to 3 times to ensure that
brakes provide normal braking action on all four wheels
without dragging and uneven braking.
2. CONDITIONS FOR AIR BLEEDING CONTROL

TCS
ABS TCS
Stop light TCS OFF Pump TCS FRO FLO operating
warning warning
switch switch motor valve RLO RRO indicator
light light
light
OFF ON ON Close Close Close ON ON ON
Air
bleeding ON ON OFF Open Open Close ON ON OFF
control is ON ON OFF Open Close Open ON OFF ON
operating.
ON or OFF OFF OFF Open Close Close ON OFF OFF
Stops tem-
— — OFF Open Close Close OFF OFF OFF
porarily.*
Prohibited. — — OFF Open Close Close OFF ON ON
*: When brake fluid level switch detects brake fluid in LOW level, control operation stops temporarily. After refilling brake fluid, operation
re-starts.
101
3. CONDITIONS FOR COMPLETION OF AIR

BLEEDING CONTROL
When any of the following conditions occurs, ABS and TCS
warning lights illuminate. Air bleeding control stops, while
the ABS and TCS function will then stop. The brake sys-
tem functions as a conventional brake system.
(6 MPH).
2) When terminal No. 4 is separated from diagnosis termi-
nal. (When select monitor is not used.)
3) When pump motor remains ON for two minutes.
4) When TCS valve remains open for two minutes.
5) When outlet valve remains closed for two minutes.
6) When malfunction is detected.
NOTE:
When a malfunction is detected the air bleeding operation
stops and the trouble codes are stored in memory.
C: AIR BLEEDING CONTROL WITH

DIAGNOSIS CONNECTOR
1) Connect diagnosis terminals to terminal No. 4 of the
diagnosis connector beside driver’s seat heater unit.
B4M0082C
2) Start the engine while pushing TCS OFF switch.

NOTE:
Keep the TCS OFF switch depressed even after the engine
has started.
B4M0621A
3) After ABS and TCS warning lights go out, depress

brake pedal within 0.5 seconds.
4) After ensuring TCS ON indicator illuminates, release
TCS OFF switch and brake pedal.
5) Air bleeding control operation starts.
102
D: AIR BLEEDING CONTROL WITH SELECT

MONITOR
driver’s seat instrument panel lower.
쎻1 Data link connector (for Subaru select monitor and
OBD-II general scan tool)
쎻2 Data link connector (for Subaru select monitor)
NOTE:
When using data link connector 쎻 1 above, use ST.
B4M0622A
ST 498357200 ADAPTER CABLE
2) Start the engine.
3) Change select monitor to TCS mode by pressing the
function key.
4) Press FD3 ENT key.
B4M0623

press ENT key.
B4M0624
6) Air bleeding control operation starts.
B4M0625
103
7) Select monitor indicates that air bleeding control is now

operating.
B4M0626
8) When air bleeding control cannot be started (by system

malfunction, etc.), the message shown in the figure will be
displayed.
NOTE:
B4M0627
104
20. Hydraulic Unit for ABS/TCS System
B4M0707A
쎻
1 ABS/TCS hydraulic 쎻
8 Secondary suction line Tightening torque: N⋅m (kg-m, ft-lb)
control unit 쎻
9 Primary suction line T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
쎻
10 Bumper T2: 29±7 (3.0±0.7, 21.7±5.1)
쎻
11 Bracket T3: 32±10 (3.3±1.0, 24±7)
쎻
12 Pressure switch T4: 38±10 (3.8±1.0, 27±7)
쎻
5 Rear-LH outlet T5: 3.1±1 (0.32±0.1, 2.3±0.7)
쎻
13 Valve relay
쎻
6 Secondary inlet
쎻
14 Motor relay
쎻
7 Primary inlet
A: REMOVAL
2) Remove canister, air intake and air cleaner case duct
from engine compartment to facilitate removal of hydraulic
unit.
3) Disconnect brake pipes from hydraulic unit.
CAUTION:
4) Disconnect connector from hydraulic unit.
105
5) Remove bolts which secure hydraulic unit bracket, and

remove hydraulic unit from engine compartment.
CAUTION:
쐌 Hydraulic unit cannot be disassembled. Do not
쐌 Do not drop or bump hydraulic unit.
쐌 Do not turn the hydraulic unit upside down or place
it on its side.
쐌 Be careful to prevent foreign particles from getting
B4M0628 into hydraulic unit.
tor.
B: INSPECTION
2) Check for discontinuity or short circuits.
Condition Terminal number Standard Diagram Terminal location
A—B 90 Ω
Turning off
C—F 0Ω
electricity.
C—E
Valve relay
Turning on C—F
electricity between
A and B.
(DC 12 V) C—E 0Ω
B4M0629A B4M0630
a — b* 57 Ω
Turning off
electricity.
c—d
Motor relay
Turning on
electricity between
c—d 0Ω
a and b.
(DC 12 V) B4M0631A B4M0632
*: Attach circuit tester positive probe to terminal “a” and its negative probe to terminal “b” and measure the circuit resistance.
106

OPERATION
caliper bodies.

bodies.
CAUTION:
must be used.
NOTE:
B4M0633A
5) Perform ABS sequence control. <Ref. to 4-4 [W20D0].>
and compression.
7) Read values indicated on the pressure gauge and
check if the fluctuation of the values between decompres-
sion and compression meets the standard values. Also
check if any irregular brake pedal tightness is felt.
2
490 kPa (5 kg/cm , 71 psi) 981 kPa (10 kg/cm2, 142 psi)
or less or more
490 kPa (5 kg/cm2, 71 psi) 981 kPa (10 kg/cm2, 142 psi)
or less or more
8) Remove pressure gauges and air bleeder screws from

the RL and RR caliper bodies.
9) Connect the air bleeder screws hose to the FL and FR
caliper bodies.
10) Connect two pressure gauges to the RL and RR cali-
per bodies.
caliper bodies.
12) Perform ABS sequence control. <Ref. to 4-4
[W20D0].>
and compression.
14) Read values indicated on the pressure gauges and
107

per bodies.
bodies.

1) Prepare for operating ABS sequence control. <Ref. to
4-4 [W20D1] or 4-4 [W20D2].>

working sequence.
(1) The front left wheel performs decompression,
holding, and compression in sequence, and subse-
G4M0464 quently the front right wheel repeats the cycle.
(2) The rear right wheel performs decompression,
holding, and compression in sequence, and subse-
quently the rear left wheel repeats the cycle.
Unit: N (kg, lb)

981 — 1,471
Front wheel 245 (25, 55) or less 588 (60, 132) or more
(100 — 150, 221 — 331)
981 — 1,471
Rear wheel 245 (25, 55) or less 588 (60, 132) or more
(100 — 150, 221 — 331)

tightness is felt.
108

sure gauge.

CONNECTOR
diagnosis connector beside driver’s seat heater unit.
2) Ignition switch is turned to ON.
3) Make sure only the start code (code 11) is shown in
normal condition. <Ref. to 4-4b [T6D1].>
NOTE:
B4M0082C When trouble codes are stored in memory, repair the faulty
parts.
6) Within 0.5 seconds after the ABS and TCS warning
lights go out, depress the brake pedal and hold it immedi-
ately after engine starts.
NOTE:
쐌 Engine must operate.
쐌 If brake pedal is not depressed within 0.5 seconds after
ABS and TCS warning lights go out, the trouble code mode
comes on.
switch OFF.

driver’s seat heater unit. <Ref. to 4-4 [W19D0] step 1).>
2) Engine starts.
3) Put select monitor to TCS mode.
4) put select monitor to FBI mode. Make sure code 11 is
indicated.
NOTE:
When trouble codes are stored in memory, repair the faulty
parts.
109
B4M0635

lows:
with braking force of 981 to 1,471 N (100 to 150 kg, 221
to 331 lb).
kPa (35 kg/cm2, 498 psi)
B4M0634

press ENT key.
7) Checked portions will be displayed on select monitor.
B4M0624

be displayed.
NOTE:
B4M0627

switch OFF.
110

SEQUENCE CONTROL
control stops and ABS and TCS warning lights come on
while the ABS and TCS function will then stop. The brake
system functions as a conventional brake system.
(6 MPH).
2) When terminal No.4 is separated from ground. (When
select monitor is not used.)
NOTE:
When malfunction has been detected and the ABS
sequence control operation has stopped, the trouble codes
are stored in memory.
111
B4M0637A
NOTE:
When select monitor is used, control operation starts at
point A. It is not required to operate brake lamp switch for
starting ABS sequence control operation. The patterns
from IGN key ON to the point A show that operation is
started by diagnosis connector.
112
E: CHECKING THE HYDRAULIC UNIT TCS

OPERATION
1. CHECKING THE HYDRAULIC UNIT TCS
caliper bodies.

bodies.
CAUTION:
must be used.
NOTE:
B4M0633A
5) Perform sequence control. <Ref. to 4-4 [W20F0].>
side performs compression, holding, and decompression,
and then the FR side performs compression, holding, and
decompression.
check if the fluctuation of the values between compression
and decompression meets the standard values. Also check
if any irregular brake pedal tightness is felt.
Initial value When compressed When decompressed
2 2
490 kPa (5 kg/cm , 71 psi) 1,471 kPa (15 kg/cm , 213 psi) 490 kPa (5 kg/cm2, 71 psi)
Front left wheel
or less or more or less
490 kPa (5 kg/cm2, 71 psi) 1,471 kPa (15 kg/cm2, 213 psi) 490 kPa (5 kg/cm2, 71 psi)
Front right wheel
or less or more or less
8) After checking, remove the pressure gauges from the

caliper bodies.
per bodies.
113
2. CHECKING THE HYDRAULIC UNIT TCS

1) Prepare for operating TCS sequence control. <Ref. to
4-4 [W20F1] step 1 or 4-4 [W20F2] step 1.>
2) Set the front wheels on the brake tester and set the
select lever’s position at “neutral”.
B4M0638

4) Perform sequence control. <Ref. to 4-4 [W20F1] or 4-4
[W20F2].>
working sequence.
The front left wheel performs compression, holding,
and decompression in sequence, and subsequently the
front right wheel repeats the cycle.
When compressed When decompressed
Front left wheel 981 — 1,471 N (100 — 150 kg, 221 — 331 lb) 245 N (25 kg, 55 lb) or less
Front right wheel 981 — 1,471 N (100 — 150 kg, 221 — 331 lb) 245 N (25 kg, 55 lb) or less
114
F: TCS SEQUENCE CONTROL

1) Under the TCS sequence control, after the hydraulic
sure gauge.
2) TCS sequence control can be started by diagnosis con-
1. OPERATIONAL GUIDELINES OF THE TCS

CONNECTOR
diagnosis connector beside driver seat heater unit.
2) Ignition switch is turned to ON.
3) Make sure only the start code (code 11) is shown in
normal condition. <Ref. to 4-4b [T6D1].>
NOTE:
B4M0082C When trouble codes are stored in memory, repair the faulty
parts.
6) Start engine, and within 0.5 seconds after the ABS
warning light and TCS warning light go out, press TCS OFF
switch. Within 1.0 second thereafter, release and press the
switch again. Then, keep the switch pressed.
NOTE:
쐌 When the TCS sequence control is set to on, the brake
pedal must not be depressed.
쐌 Engine must operate.
쐌 When TCS OFF switch is not depressed within 0.5 sec-
onds after ABS and TCS warning lights turn off, the trouble
code mode comes on.
7) After completion of TCS sequence control, turn ignition
switch OFF.
115
2. OPERATIONAL GUIDELINES OF THE TCS

driver’s seat heater unit. <Ref. to 4-4 [W19D0] step 1).>
2) Engine starts.
3) Put select monitor to TCS mode.
4) Put select monitor to FBI mode. Make sure code 11 is
indicated.
NOTE:
When trouble codes are stored in memory, repair the faulty
parts.
B4M0639

press ENT key.
7) Checked portions will be displayed on select monitor.
B4M0624
8) When TCS sequence control cannot be started (by sys-

be displayed.
NOTE:
B4M0627
116
3. CONDITIONS FOR COMPLETION OF TCS

SEQUENCE CONTROL
When the following conditions develop, the TCS sequence
control stops and ABS and TCS warning lights come on
while the ABS and TCS function will then stop. The brake
system functions as a conventional brake system.
(6 MPH).
2) When terminal No. 4 is separated from ground. (When
select monitor is not used.)
3) When the brake pedal is depressed during sequence
control and the braking lamp switch is set to ON.
4) When TCS OFF switch is released. (When select moni-
tor is not used.)
5) After completion of the TCS sequence control.
6) When output signal to break TCS control is emitted from
ECM.
NOTE:
When malfunction has been detected and the TCS
sequence control operation has stopped, the trouble codes
are stored in memory.
117
4. CONDITIONS FOR TCS SEQUENCE CONTROL
B4M0642A
NOTE:
When select monitor is used, control operation starts at
point A. It is not required to operate TCS OFF switch for
starting control operation. The patterns from IGN key ON
to point A show operation is started by diagnosis connec-
tor.
118
20. Hydraulic Unit for ABS/TCS System - 21. ABS/TCS Control Module
G: INSTALLATION
1) Install hydraulic unit and bracket.
Tightening torque:
32±7 N⋅m (3.3±0.7 kg-m, 23.9±5.1 ft-lb)
2) Connect brake pipes to their correct hydraulic unit con-
3) Connect connector to hydraulic unit.
5) Install air cleaner case.
B4M0628
CAUTION:
Cover relay securely with rubber boot.
21. ABS/TCS Control Module

A: REMOVAL
2) Remove floor mat located under lower right side of front
seat.
3) Remove screw which secure ABS/TCS control module

from the body.
4) Disconnect connector from ABS/TCS control module.
B4M0643A
B: INSPECTION
119
20. Hydraulic Unit for ABS/TCS System - 21. ABS/TCS Control Module
G: INSTALLATION
1) Install hydraulic unit and bracket.
Tightening torque:
32±7 N⋅m (3.3±0.7 kg-m, 23.9±5.1 ft-lb)
2) Connect brake pipes to their correct hydraulic unit con-
3) Connect connector to hydraulic unit.
5) Install air cleaner case.
B4M0628
CAUTION:
Cover relay securely with rubber boot.

A: REMOVAL
2) Remove floor mat located under lower right side of front
seat.
3) Remove screw which secure ABS/TCS control module

from the body.
4) Disconnect connector from ABS/TCS control module.
B4M0643A
B: INSPECTION
119
C: INSTALLATION
1) Connect connector to ABS/TCS control module.
2) Install ABS/TCS control module on the body.
CAUTION:
쐌 When installing seat rail, be careful no to have the
harness caught in the rail.
쐌 Cover the connector completely with rubber boot.
120
22. ABS Control Module and Hydraulic Control Unit (ABSCM&H/U) (ABS 5.3i Type)
22. ABS Control Module and Hydraulic

Control Unit (ABSCM&H/U) (ABS 5.3i
Type)
B4M1220A
쎻
1 Stud bolt 쎻
6 Front-RH outlet Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Damper 쎻
7 Primary inlet T1: 18±5 (1.8±0.5, 13.0±3.6)
쎻
3 ABS control module and hydraulic 쎻
8 Rear-LH outlet T2: 29±7 (3.0±0.7, 21.7±5.1)
control unit 쎻
9 Rear-RH outlet T3: 32±10 (3.3±1.0, 24±7)
쎻
10 Bracket
쎻
5 Secondary inlet
121
A: REMOVAL
2) Remove air intake duct from engine compartment to
facilitate removal of ABSCM&H/U.
3) Use an air-gun to get rid of water around the
ABSCM&H/U.
CAUTION:
The contact will be insufficient if the terminal gets wet.
4) Pull on the lock of the ABSCM&H/U connector to

remove it.
5) Disconnect connector from ABSCM&H/U.
CAUTION:
Be careful not to let water or other foreign matter con-
tact the ABSCM&H/U terminal.
7) Disconnect brake pipes from ABSCM&H/U.
CAUTION:
B4M1224A
8) Remove ABSCM&H/U from engine compartment.

CAUTION:
쐌 ABSCM&H/U cannot be disassembled. Do not
쐌 Do not drop or bump ABSCM&H/U.
쐌 Do not turn the ABSCM&H/U upside down or place
it on its side.
쐌 Be careful to prevent foreign particles from getting
into ABSCM&H/U.
B4M1222 쐌 Apply a coat of rust-preventive wax (Nippeco LT or
GB) to bracket attaching bolt after tightening.
tor.
122
B: INSPECTION
2) Check specifications of the mark with ABSCM&H/U.

Mark Model
C3 AWD AT
C4 AWD MT
B4M1248A

OPERATION
caliper bodies.

bodies.
CAUTION:
must be used.
NOTE:
B4M0633A
123

<Ref. to 4-4 [W22D0].>
and compression.
check if the fluctuation of the values between decompres-
sion and compression meets the standard values. Also
check if any irregular brake pedal tightness is felt.
or less or more
or less or more
8) Remove pressure gauges from FL and FR caliper bod-

ies.
9) Remove air bleeder screws from the RL and RR caliper
bodies.
per bodies.
11) Connect two pressure gauges to the RL and RR cali-
per bodies.
caliper bodies.
<Ref. to 4-4 [W22D0].>
and compression.
15) Read values indicated on the pressure gauges and
per bodies.
bodies.
124

1) In the case of AWD AT vehicles, install a spare fuse with
the FWD connector in the engine compartment to simulate
FWD vehicles.
2) Prepare for operating ABS sequence control. <Ref. to
4-4 [W22D1] or 4-4 [W22D2].>
G4M0462

working sequence.
(1) The FL wheel performs decompression, holding,
G4M0464 FR wheel repeats the cycle.
(2) The RR wheel performs decompression, holding,
RL wheel repeats the cycle.
Unit: N (kg, lb)

Front wheel 981 (100, 221) 490 (50, 110) or less 981 (100, 221) or more
Rear wheel 981 (100, 221) 490 (50, 110) or less 981 (100, 221) or more

tightness is felt.
125

sure gauge.

CONNECTOR
1) Connect diagnosis terminals to terminals No. 3 and No.
6 of the diagnosis connector beside driver’s seat heater
unit.
4) Within 0.5 seconds after the ABS warning light goes
B4M0082D out, depress the brake pedal and hold it immediately after
ignition switch is turned to ON.
CAUTION:
NOTE:
쐌 Engine must not operate.
switch OFF.

NOTE:
In the event of any trouble, the sequence control may not
be operative. In such a case, activate the sequence
control, referring to “OPERATIONAL GUIDELINES OF
THE ABS SEQUENCE CONTROL WITH DIAGNOSIS
CONNECTOR ”. <Ref. to 4-4 [W22D1].>
driver’s seat heater unit.
2) Turn ignition switch ON.
3) Put select monitor to ABS mode.
126
4) Press F D 1 ENT key.
B4M0635
5) The message shown in the figure is displayed.
B4M0997

lows:
with braking force of 981 N (100 kg, 221 lb).
kPa (35 kg/cm2, 498 psi).
CAUTION:
B4M0998

press ENT key.
8) Check points will be displayed on select monitor.
B4M0999

be displayed.
NOTE:
B4M1000
127
10) After completion of ABS sequence control.
B4M1030
11) Press 0 key to start ABS sequence control again and

press 1 key to end.
H4M1144

SEQUENCE CONTROL
control stops and ABS operation is returned to the normal
control mode.
(6 MPH).
2) When terminal No. 3 or No. 6 are separated from diag-
nosis terminals. (When select monitor is not used.)
4) When brake pedal is depressed after ignition key is
turned to ON, and before ABS warning light goes out.
(When select monitor is not used.)
5) When brake pedal is not depressed after ignition key is
turned to ON, and within 0.5 seconds after ABS warning
light goes out. (When select monitor is not used.)
7) When malfunction is detected. (When select monitor is
used.)
128
B4M1001A
NOTE:
쐌 When select monitor is used, control operation starts at
point A. The patterns from IGN key ON to the point A show
that operation is started by diagnosis connector.
쐌 HIGH means high voltage.
쐌 LOW means low voltage.
129
22. ABS Control Module and Hydraulic Control Unit (ABSCM&H/U) (ABS 5.3i Type) - 24. G Sensor (ABS 5.3i Type)
E: INSTALLATION
1) Install ABSCM&H/U.
CAUTION:
Confirm that the specifications of the ABSCM&H/U
conforms to the vehicle specifications.
Tightening torque:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
2) Connect brake pipes to their correct ABSCM&H/U con-
B4M1222
3) Using cable clip, secure ABSCM&H/U harness to

bracket.
4) Connect connector to ABSCM&H/U.
CAUTION:
쐌 Be sure to remove all foreign matter from inside the
connector before connecting.
쐌 Ensure that the ABSCM&H/U connector is securely
locked.
23. ABS Sensor (ABS 5.3i Type)

<Ref. to 4-4 [W1400].>
24. G Sensor (ABS 5.3i Type)

<Ref. to 4-4 [W1700].>
130
E: INSTALLATION
CAUTION:
Tightening torque:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
B4M1222

bracket.
CAUTION:
locked.

<Ref. to 4-4 [W1400].>

<Ref. to 4-4 [W1700].>
130
E: INSTALLATION
CAUTION:
Tightening torque:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
B4M1222

bracket.
CAUTION:
locked.

<Ref. to 4-4 [W1400].>

<Ref. to 4-4 [W1700].>
130
DIAGNOSTICS 4-4
1. Entire Brake System

Trouble and possible cause Corrective action
1. Insufficient braking
Repair or replace (cup, piston seal, piston boot, master cylinder
(1) Fluid leakage from the hydraulic mechanism
piston kit, pipe or hose).
(2) Entry of air into the hydraulic mechanism Bleed the air.
(3) Excessively wide shoe clearance Adjust the clearance.
(4) Wear, deteriorated surface material, adhering water or fluid
Replace, grind or clean.
on the lining
(5) Improper operation of master cylinder, disc caliper, brake
Correct or replace.
booster or check valve
2. Unstable or uneven braking
(1) Fluid on the lining, drum or rotor Eliminate cause of fluid leakage, clean, or replace.
(2) Drum or rotor eccentricity Correct or replace the drum or rotor.
(3) Worn brake drum, or damage to the drum caused by sand Correct by grinding, or replace.
(4) Improper lining contact, deteriorated surface material,
Correct by grinding, or replace.
improper inferior material, or wear
(5) Deformed back plate Correct or replace.
(6) Improper tire inflation Inflate to correct pressure.
(7) Disordered wheel alignment Adjust alignment.
(8) Loosened back plate or the support installing bolts Retighten.
(9) Loosened wheel bearing Retighten to normal tightening torque or replace.
(10) Trouble in the hydraulic system Replace the cylinder, brake pipe or hose.
(11) Uneven effect of the parking brake Check, adjust, or replace the rear brake and cable system.
3. Excessive pedal stroke
(1) Entry of air into the hydraulic mechanism Bleed the air.
(2) Excessive play in the master cylinder push rod Adjust.
Repair or replace (cup, piston seal, piston boot, master cylinder
(3) Fluid leakage from the hydraulic mechanism
piston kit, pipe or hose).
(4) Improperly adjusted shoe clearance Adjust.
(5) Improper lining contact or worn lining Correct or replace.
131
4-4 DIAGNOSTICS

4. Brake dragging or improper brake return
(1) Insufficient pedal play Adjust play.
(2) Improper master cylinder return Clean or replace the cylinder.
(3) Clogged hydraulic system Replace.
(4) Improper return or adjustment of parking brake Correct or adjust.
(5) Weakened spring tension or breakage of shoe return spring Replace the spring.
(6) Excessively narrow shoe clearance Adjust the clearance.
(7) Improper disc caliper operation Correct or replace.
(8) Improper adjusted wheel bearing Adjust or replace.
5. Brake noise (1) (creak sound)
(1) Hardened or deteriorated lining Replace the shoe assembly or pad.
(2) Worn lining Replace the shoe assembly or pad.
(3) Loosened back plate or the support installing bolts Retighten.
(4) Loose wheel bearing Retighten to normal tightening torque.
(5) Dirty drum or rotor Clean the drum or rotor, or clean and replace the brake assembly.
6. Brake noise (2) (hissing sound)
(1) Worn lining Replace the shoe assembly or pad.
(2) Improper installed shoe or pad Correct or replace the shoe assembly or pad.
(3) Loose or bent drum or rotor Retighten or replace.
7. Brake noise (3) (click sound)
In the case of the disc brake:
(1) Excessively worn pad or the support Replace the pad or the support.
In the case of the drum brake:
(1) Excessively worn shoe ridge Replace the back plate.
(2) Lack of oil on the shoe ridge surface and anchor Add more grease.
132
DIAGNOSTICS 4-4
2. Hill Holder
2. Hill Holder
1. Counterforce of clutch pedal is too strong.
(1) PHV cable is damaged or does not operate properly. Repair or replace.
(2) Lever of PHV is defective. Replace entire PHV assembly.
(3) Clutch system is anomalous. Refer to “Clutch and pedal cable system”.
2. Vehicle does not stop on uphill road of 3° or higher inclination.
(1) Front side of vehicle is lowered. Refer to “Suspension”.
(2) PHV cable is broken. Replace.
(3) Play of clutch is excessive. Adjust.
(4) PHV cable is elongated. Adjust.
(5) Sealing of PHV is poor. Replace entire PHV assembly.
3. Shock is felt when starting.
(1) Poor adjustment of starting performance: Adjust.
(The stronger brake pedal depressing force, the later hill holder
(2) When depressing the brake pedal strongly:
releases.)
(3) When starting on flat road after stopping reverse movement: (Because hill holder is activated.)
4. Vehicle slips down when starting.
(1) PHV cable is elongated. Adjust.
(2) Clutch facing is worn out. Adjust or replace.
(3) Bracket (cable) or stay (PHV) is deformed. Repair or replace.
5. Vehicle cannot start after stoppage.
(1) Return spring is fatigued or broken. Replace.
(2) PHV lever won’t return. Replace entire PHV assembly.
[When the brake pedal is depressed by a force of 1,177 N (120
(3) When intentionally depressing brake pedal strongly:
kg, 265 lb) or more.]
6. Abnormal sound is generated upon releasing brake pedal when stopping.
(1) Rotor and pad matched with each other due to inadequate (Abnormal sound is not generated when depressing brake pedal a
depressing force to brake pedal. little stronger.)
7. Abnormal sound is generated when operating clutch pedal.
(1) Grease is inadequate for the hook of return spring and slid-
Apply grease.
ing portion of PHV cable end.
(2) When releasing after maintaining high fluid pressure: (Flowing sound of fluid when releasing high fluid pressure.)
(3) Clutch system is anomalous. Refer to “Clutch and pedal cable system”.
CAUTION:
쐌 Description in parentheses is a characteristic of hill holder and does not indicate abnormality.
Depressing force required for clutch pedal equipped to hill holder specifications is 20 to 29 N (2 to 3 kg, 4 to 7 lb) larger than
the conventional specifications, which does not constitute abnormality.
쐌 When vehicle cannot travel (brake cannot be released) because return spring is broken, remove adjusting nut, disconnect
clutch and PHV, and then return PHV lever to release the brake. (Be sure to apply the parking brake before starting this opera-
tion.)
쐌 The hill holder may not be activated on a slope of an extremely small inclination.
133
1. Pedal System
1. Pedal System
A: SERVICE DATA
1 — 3 mm (0.04 — 0.12 in)
Brake pedal Free play [Depress brake pedal pad with a force of less than
10 N (1 kg, 2 lb).]
Free play At clutch pedal pad 10 — 20 mm (0.39 — 0.79 in)
Clutch pedal
Full stroke At clutch pedal pad 140 — 145 mm (5.51 — 5.71 in)
Free play At pedal pad 1 — 4 mm (0.04 — 0.16 in)
Accelerator pedal
Stroke At pedal pad 50 — 55 mm (1.97 — 2.17 in)
2
COMPONENT PARTS 4-5
1. Pedal (MT Model)
1. Pedal (MT Model)

1. 2200 cc MODEL
B4M0737A
쎻
1 Accelerator pedal 쎻
14 Pedal bracket 쎻
26 Spring assist
쎻
2 Bushing 쎻
15 Stop light switch (Without T.C.S.) / 쎻
27 Clutch cable clamp
쎻
3 Holder stroke sensor (With T.C.S.) 쎻
28 Clutch cable
쎻
4 Accelerator bracket 쎻
16 Brake pedal 쎻
29 Mass damper
쎻
5 Stopper 쎻
17 Spacer 쎻
30 Clutch switch (Starter interlock)
쎻
6 Clip 쎻
18 Snap pin 쎻
31 Clutch switch (With cruise control)
쎻
7 Accelerator spring 쎻
19 Brake pedal pad
쎻
8 Accelerator pedal spring 쎻
20 Clevis pin Tightening torque: N⋅m (kg-m, ft-lb)
쎻
9 Spring pin 쎻
21 Brake pedal spring T1: 5.9±1.5 (0.60±0.15, 4.3±1.1)
쎻
10 Accelerator pedal pad 쎻
22 Washer T2: 8±2 (0.8±0.2, 5.8±1.4)
T3: 18±5 (1.8±0.5, 13.0±3.6)
쎻
11 Accelerator stopper 쎻
23 Clutch pedal pad
T4: 29±7 (3.0±0.7, 21.7±5.1)
쎻
12 Clip 쎻
24 Clutch pedal
쎻
13 Accelerator plate 쎻
25 Bushing assist
3
4-5 COMPONENT PARTS
1. Pedal (MT Model)
2. 2500 cc MODEL
B4M1158A
쎻
1 Holder 쎻
15 Clevis pin 쎻
29 Pedal bracket
쎻
16 Brake pedal spring 쎻
30 Stop light switch
쎻
3 Stopper 쎻
17 Bracket shaft 쎻
31 Wave washer
쎻
4 Clip 쎻
18 Clutch pedal pad 쎻
32 Lever
쎻
5 Bushing 쎻
19 Clutch pedal 쎻
33 Clutch switch (Starter interlock)
쎻
6 Accelerator spring 쎻
20 Bushing C 쎻
34 Clutch switch (With cruise control)
쎻
21 Clip
쎻
22 Clutch clevis pin Tightening torque: N⋅m (kg-m, ft-lb)
쎻
9 Spring pin 쎻
23 Assist rod T1: 2.2±0.5 (0.22±0.05, 1.6±0.4)
쎻
24 Assist plate A T2: 8±2 (0.8±0.2, 5.8±1.4)
쎻
25 Assist spring A T3: 18±5 (1.8±0.5, 13.0±3.6)
T4: 29±7 (3.0±0.7, 21.7±5.1)
쎻
12 Snap pin 쎻
26 Assist spring B
쎻
13 Brake pedal pad 쎻
27 Assist bushing
쎻
14 Brake pedal 쎻
28 Assist plate ASSY
4
COMPONENT PARTS 4-5
2. Pedal (AT Model)
2. Pedal (AT Model)

1. LHD MODEL
B4M0738A
쎻
20 Brake pedal pad
쎻
2 Bushing 쎻
12 Clip 쎻
21 Brake pedal
쎻
3 Holder 쎻
13 Accelerator plate 쎻
22 Clevis pin
쎻
14 Plug 쎻
23 Brake pedal spring
쎻
5 Stopper 쎻
15 Pedal bracket
쎻
6 Clip 쎻
16 Stop light switch (Without T.C.S.) / Tightening torque: N⋅m (kg-m, ft-lb)
쎻
7 Accelerator spring stroke sensor (With T.C.S.) T1: 8±2 (0.8±0.2, 5.8±1.4)
T2: 18±5 (1.8±0.5, 13.0±3.6)
쎻
17 Spacer
T3: 29±7 (3.0±0.7, 21.7±5.1)
쎻
9 Spring pin 쎻
18 Stopper
쎻
19 Snap pin
5
4-5 COMPONENT PARTS
2. Pedal (AT Model)
2. RHD MODEL
B4M0677A
쎻
9 Clip 쎻
17 Snap pin
쎻
10 Stop light switch 쎻
18 Bushing
쎻
3 Spring pin 쎻
11 Accelerator spring
쎻
12 Brake pedal spring Tightening torque: N⋅m (kg-m, ft-lb)
쎻
5 Stopper 쎻
13 Brake pedal T1: 8±2 (0.8±0.2, 5.8±1.4)
T2: 18±5 (1.8±0.5, 13.0±3.6)
쎻
6 Bushing 쎻
14 Spacer
T3: 29±7 (3.0±0.7, 21.7±5.1)
쎻
7 Holder 쎻
15 Clevis pin
쎻
8 Pedal bracket 쎻
16 Brake pedal pad
6
1. Pedal
1. Pedal
A: ON-CAR SERVICE
1. BRAKE PEDAL
1) Check position of pedal pad.
쎻1 Stop light switch
쎻2 Mat
쎻3 Toe board
쎻4 Brake booster operating rod
B4M0366A
Pedal height: L
148 mm (5.83 in)
If it is not in specified value, adjust it by adjusting brake
booster operating rod length.
2) Check free play by operating pedal by hand.
If it is not in specified value, adjust it by adjusting position
of stop light switch.
CAUTION:
Be careful not to rotate stop light switch.
Brake pedal free play: A
1 — 3 mm (0.04 — 0.12 in)
[Depress brake pedal pad with a force of less than
10 N (1 kg, 2 lb).]
Stop light switch lock nut tightening torque:
8±2 N⋅m (0.8±0.2 kg-m, 5.8±1.4 ft-lb)
3) Apply grease to operating rod connecting pin to prevent
it from wearing.
2. CLUTCH PEDAL (2200 cc MODEL)

1) Check clutch pedal free play by operating pedal by
hand.
Free play: L (At clutch pedal pad)
10 — 20 mm (0.39 — 0.79 in)
G4M0318
Pedal height: Y
158 mm (6.22 in)
Pedal stroke: A
140 — 145 mm (5.51 — 5.71 in)
쎻1 Toe board
쎻2 Mat
B4M0367A
7
1. Pedal
2) If it is not in specified value, adjust it by turning adjust-

ing nut on engine side end of clutch cable.
Free play: L
3 — 4 mm (0.12 — 0.16 in)
Full stroke: A
25.5 — 27 mm (1.004 — 1.063 in)
3) Apply grease to connecting portion of clutch pedal and
clutch cable.
G4M0319 쎻1 Lock nut
쎻2 Adjusting nut
쎻3 Release fork
Lock nut tightening torque:
5.9±1.5 N⋅m (0.60±0.15 kg-m, 4.3±1.1 ft-lb)
3. ACCELERATOR PEDAL
Check pedal stroke and free play by operating accelerator
pedal by hand.
If it is not within specified value, adjust it by turning nut
connecting accelerator cable to throttle body.
Free play at pedal pad: L
1 — 4 mm (0.04 — 0.16 in)
Stroke at pedal pad: A
50 — 55 mm (1.97 — 2.17 in)
쎻1 Accelerator pedal
쎻2 Toe board
쎻3 Accelerator cable
Accelerator cable lock nut tightening torque:
14±4 N⋅m (1.4±0.4 kg-m, 10.1±2.9 ft-lb)
G4M0320
8
1. Pedal

1) Push release fork until operating cylinder push rod
retracts. Check that clutch fluid level in reservoir tank
increases.
2) If clutch fluid level increases, hydraulic clutch play is
correct.
3) If clutch fluid level does not increase or push rod does
not retract, clutch pedal must be adjusted. <Ref. to 4-5
[W1F1].>
B4M1191A 4) Check the fluid level on the outside of the clutch mas-
ter cylinder tank. If the level is below “MIN”, add clutch fluid
to bring it up to “MAX”.
Recommended clutch fluid:
FMVSS No. 116, fresh DOT 3 or DOT 4 brake fluid
B: REMOVAL
1. ACCELERATOR PEDAL (LHD MODEL)
2) Disconnect accelerator cable from throttle body.
CAUTION:
Be careful not to kink accelerator cable.
3) Remove instrument panel lower cover from instrument
panel, and connector.
4) Disconnect accelerator cable from accelerator pedal

lever.
G4M0322
5) Working inside engine compartment, remove casing

cap out of the toe board by turning it clockwise.
6) Pull out the cable from the toe board hole.
G4M0335
9
1. Pedal
7) Remove accelerator pedal connecting bolt from accel-

erator pedal bracket.
G4M0321
2. BRAKE AND CLUTCH PEDAL (LHD EXCEPT 2500

cc MODEL)
2) Disconnect clutch cable from release lever.
panel.
4) Disconnect the following parts from pedal bracket.
(1) Operating rod of brake booster
(2) Electrical connectors (for stop light switch, etc.)
5) Remove clevis pin which secures pedal to push rod.
6) Remove bolts and nuts which secure brake and clutch
pedals, and remove pedal bracket and clutch cable as a
unit.
CAUTION:
Before removing clutch cable from toe board, remove
grommet. Slowly remove clutch cable, being careful
not to scratch it.
7) Depress clutch pedal, disconnect clutch cable from
clutch pedal.
B4M0154A
3. BRAKE PEDAL (LHD MODEL)

panel.
3) Remove clevis pin which secures brake pedal to brake
booster operating rod. Also disconnect stop light switch
connector.
4) Remove two bolts and four nuts which secure brake
pedal to pedal.
G4M0324
10
1. Pedal
4. ACCELERATOR AND BRAKE PEDAL (RHD

MODEL)
1) Disconnect negative cable from battery.
2) Disconnect accelerator cable from throttle body.
CAUTION:
Be careful not to kink accelerator cable.
panel.
4) Remove clevis pin which secures brake pedal to brake
booster operating rod. Also disconnect electrical connec-
tors (for stop light switch, etc.).
5) Disconnect accelerator cable from accelerator pedal

lever.
G4M0322
6) Remove the casing cap out of the toe board by turning

it clockwise.
B4M0156A
11
1. Pedal
8) Remove nuts and bolts which secure pedal bracket.
B4M0157A
5. BRAKE AND CLUTCH PEDAL (2500 cc MODEL)

1) Remove steering bolts.
2) Raise vehicle on hoist and remove the two bolts which
secure steering unit to underside of body.
3) Lower vehicle to floor.
panel.
5) Disconnect the following parts from pedal bracket.
쐌 Operating rod of brake booster
쐌 Electrical connectors (for stop light switch, etc.)
6) Remove clevis pin which secures lever to push rod.
7) Remove nut which secures clutch master cylinder.
8) Remove steering assembly.
9) Remove bolts and nuts which secure brake and clutch
pedals, and remove pedal assembly.
12
1. Pedal
C: INSPECTION
1. BRAKE AND CLUTCH PEDALS
Move brake and clutch pedal pads in the lateral direction
with a force of approximately 10 N (1 kg, 2 lb) to ensure
pedal deflection is in specified range.
Deflection of brake and clutch pedal:
Service limit
G4M0325 CAUTION:
If excessive deflection is noted, replace bushings with
new ones.
G4M0326
Lightly move pedal pad in lateral the direction to ensure
pedal deflection is in specified range.
Deflection of accelerator pedal:
Service limit
CAUTION:
If excessive deflection is noted, replace bushing and
clip with new ones.
G4M0333
3. STOP LIGHT SWITCH

If stop light switch does not operate properly (or if it does
not stop at the specified position), replace with a new one.
Specified position: L
2.8+1.5
0 mm (0.110 +0.059
0 in)
G4M0327
13
1. Pedal
D: ASSEMBLY
1. BRAKE AND CLUTCH PEDAL
1) Attach stop light switch, etc. to pedal bracket tempo-
rarily.
2) Clean inside of bores of clutch pedal and brake pedal,
apply grease, and set bushings into bores.
3) Align bores of pedal bracket, clutch pedal and brake
pedal, attach brake pedal return spring and clutch pedal
effort reducing spring (vehicle with hill holder), and then
install pedal bolt.
Tightening torque:
T2: 29±7 N⋅m (3.0±0.7 kg-m, 21.7±5.1 ft-lb)
NOTE:
Clean up inside of bushings and apply grease before
installing spacer.
4) Set brake pedal position by adjusting position of stop
light switch.
Pedal position: L
125.9 mm (4.96 in)
G4M0329
Tightening torque:
T1: 8±2 N⋅m (0.8±0.2 kg-m, 5.8±1.4 ft-lb)
Clean and apply grease to spacer and inside bore of accel-
erator pedal. Install accelerator pedal onto pedal bracket.
14
1. Pedal
E: INSTALLATION
dures.
CAUTION:
쐌 Be careful not to bend clutch cable too much.
쐌 Never fail to cover outer cable end with boot.
쐌 Be careful not to kink accelerator cable.
2) Adjustment after pedal installation. <Ref. to 4-5
[W1A1].>
G4M0330
1) Make sure that holder and casing cap are securely con-
nected.
쎻1 Casing cap
쎻3 Toe board
쎻4 Accelerator pedal bracket
쎻5 Holder
2) Adjustment after pedal installation. <Ref. to 4-5
B4M0159A
[W1A1].>
1) Set pedal bracket above steering column.
2) Insert bolts of brake booster into holes on toe board,
support it from engine room, and fit holes of pedal bracket
onto the bolts.
At this time, operating rod of brake booster should be
engaged with brake pedal.
3) While pushing pedal bracket upward firmly, tighten 4
nuts and 2 bolts at its upper surface.
4) Connect operating rod of brake booster to brake pedal

using clevis pin and snap pin.
5) Connect electrical connectors for stop light switch, etc.
6) Install steering column or steering assembly as before.
7) Install nut which secures clutch master cylinder.
8) Install clevis pin which secures lever to push rod.
9) Check brake pedal free play.
<Ref. to 4-5 [W1A1].>
10) Adjust clutch pedal.
B4M1189A <Ref. to 4-5 [W1F1].>
15
1. Pedal
F: ADJUSTMENT
1) Turn cruise control clutch switch lock nuts until clutch
pedal full stroke length is within specifications.
CAUTION:
Do not attempt to turn clutch switch to adjust clutch
pedal full stroke length.
NOTE:
B4M1190A If lock nuts cannot adjust clutch pedal full stroke length to
specifications, turn master cylinder push rod to adjust it.
Specified clutch pedal full stroke: A
145 — 150 mm (5.71 — 5.91 in)
Tightening torque (Clutch switch lock nut):
8±2 N⋅m (0.8±0.2 kg-m, 5.8±1.4 ft-lb)
2) Turn master cylinder push rod so that clevis pin moves

to the left and then to the right. Clevis pin must move with-
out resistance while it is rattling.
Tightening torque (Push rod lock nut):
8±2 N⋅m (0.8±0.2 kg-m, 5.8±1.4 ft-lb)
B4M1189A
3) Depress and release clutch pedal 2 to 3 times to ensure

that clutch pedal and release fork operate smoothly. If
clutch pedal and release fork do not operate smoothly,
bleed air from clutch hydraulic system. <Ref. to 2-10
[W202].>
4) Measure clutch pedal full stroke length again to ensure

that it is within specifications. If it is not, repeat adjustment
procedures again from the beginning.
Specified clutch pedal full stroke:
145 — 150 mm (5.71 — 5.91 in)
16
1. Pedal - 2. Clutch Cable
5) Move clevis pin to the left and then to the right. It should
move without resistance while it is rattling. If resistance is
felt, repeat adjustment procedures again from the begin-
ning.
6) Push release lever until operating cylinder push rod

retracts. Ensure that clutch fluid level in reservoir tank
increases. If clutch fluid level increases, hydraulic clutch is
properly adjusted; if fluid level does not increase or push
rod does not retract, replace master cylinder with new one.
<Ref. to 2-10 [W600].>
B4M1191A
2. Clutch Cable
A: REMOVAL
2) Depress clutch pedal to the floor.

3) Remove clutch cable clamp from pedal bracket.
4) Disconnect clutch cable from pedal bracket and pedal
end.
5) Remove clutch cable from body.
CAUTION:
not to scratch it.
B4M0160A
B: INSTALLATION
1) Clean clutch pedal fitting hole, and apply grease. Con-
nect clutch cable to clutch pedal.
2) Fit clutch pedal to pedal bolt, and connect clutch cable
to bracket with clamp.
3) Connect clutch cable end to pedal end.
4) Connect clutch cable from release lever.
5) Install grommet to toe board.
6) Adjustment after cable installation.
G4M0332 <Ref. to 4-5 [W1A2].>
17
1. Pedal - 2. Clutch Cable
5) Move clevis pin to the left and then to the right. It should
move without resistance while it is rattling. If resistance is
felt, repeat adjustment procedures again from the begin-
ning.
6) Push release lever until operating cylinder push rod

retracts. Ensure that clutch fluid level in reservoir tank
increases. If clutch fluid level increases, hydraulic clutch is
properly adjusted; if fluid level does not increase or push
rod does not retract, replace master cylinder with new one.
<Ref. to 2-10 [W600].>
B4M1191A
2. Clutch Cable
A: REMOVAL
2) Depress clutch pedal to the floor.

3) Remove clutch cable clamp from pedal bracket.
4) Disconnect clutch cable from pedal bracket and pedal
end.
5) Remove clutch cable from body.
CAUTION:
not to scratch it.
B4M0160A
B: INSTALLATION
1) Clean clutch pedal fitting hole, and apply grease. Con-
nect clutch cable to clutch pedal.
2) Fit clutch pedal to pedal bolt, and connect clutch cable
to bracket with clamp.
3) Connect clutch cable end to pedal end.
4) Connect clutch cable from release lever.
5) Install grommet to toe board.
G4M0332 <Ref. to 4-5 [W1A2].>
17
3. Accelerator Cable
1. LHD MODEL
B4M0768A
2. RHD MODEL
B4M1157A
18
A: REMOVAL
1) Disconnect accelerator cable from connector inside
engine compartment first.
2) Remove lock nut from accelerator cable bracket.

3) Separate accelerator cable 쎻
1 from bracket, then unlock
inner cable.
4) Remove cable end from throttle cam using your finger-
tips.
CAUTION:
Be careful not to bend inner cable.
5) Disconnect cable end from accelerator cable bracket
inside driver compartment.
G2M0280
6) Remove clip inside engine compartment.
7) Working inside engine compartment, remove the casing
cap out of the toe board by turning it clockwise.
G4M0335
B: INSTALLATION
dures.
CAUTION:
쐌 Be careful not to kink accelerator cable.
쐌 Make sure that holder and casing cap are securely
connected.
쎻1 Casing cap
쎻3 Toe board
쎻4 Accelerator pedal bracket
쎻5 Holder
<Ref. to 4-5 [W1A3].>
B4M0159A
19
4-5 DIAGNOSTICS
1. Pedal System and Control Cables
1. Pedal System and Control Cables

Trouble Corrective action
Excessively worn brake pedal pad Replace.
Failure of clutch and/or accelerator pedals to operate Connect cables correctly.
Stop light switch does not light up. Adjust position of stop light switch.
Stop light switch is not smooth and/or stroke is not correct. Replace.
Insufficient pedal play Adjust pedal play.
Clutch and/or brake pedal free play insufficient Adjust pedal free play.
Maladjustment of brake pedal or booster push rod Inspect and adjust.
Excessively worn and damaged pedal shaft and/or bushing Replace bushing and/or shaft with new one.
20
1. Heater System
1. Heater System
A: SPECIFICATIONS
Item Specifications Condition
쐌 Mode
selector : HEAT
switch
쐌 Temp.
: FULL HOT
control lever
4.652 kW (4,000 kcal/h, 15,872 BTU/h) or more ... 쐌 Temperature

Heating capacity difference
When 300 m3 (10,593 cu ft)/h
between hot : 65°C (149°F)
water and
inlet air
: 360 (95.1
쐌 Hot water
US gal, 79.2
flow rate
Imp gal)/h
Heat mode (FRESH), FULL
Air flow rate 300 m3 (10,593 cu ft)/h
HOT at 12.5 V
쐌 Temperature
: FULL COLD
control lever
쐌 Blower fan
: 4th position
Max air flow rate 510 m3 (18,008 cu ft)/h speed
쐌 RECIRC
switch : RECIRC
position
Heater core size
193.5 x 152.0 x 25.0 x 0.9 mm
(height x length x width x —
(7.62 x 5.98 x 0.984 x 0.035 in)
thickness)
Type Magnet motor 230 W or less at 12 V
Blower
motor Fan type and size Sirocco fan type
—
(diameter x width) 150 x 75 mm (5.91 x 2.95 in)
2
COMPONENT PARTS 4-6
1. Heater System
1. Heater System
B4M0368A
쎻
1 Intake unit 쎻
9 Rear heater duct
쎻
2 Grommet 쎻
10 Resistor
쎻
3 Hose (Inlet)
쎻
4 Hose (Outlet) Tightening torque: N⋅m (kg-m, ft-lb)
쎻
5 Heater duct T: 7.35±1.96 (0.750±0.200, 5.421±1.446)
쎻
6 Clamp
쎻
7 Grommet
쎻
8 Heater unit
3
4-6 COMPONENT PARTS
2. Heater Unit
2. Heater Unit
G4M0551
쎻
1 Vent lever 쎻
9 Mix rod 쎻
17 Vent door
쎻
2 Side link 쎻
10 Mix link 쎻
18 DEF. door
쎻
3 DEF. lever 쎻
11 Mix lever 쎻
19 Foot lever upper
쎻
4 Heater case upper 쎻
12 Foot duct (RH)
쎻
5 Heater grommet 쎻
13 Foot duct (CTR) Tightening torque: N⋅m (kg-m, ft-lb)
T: 7.35±1.96
쎻
6 Heater core 쎻
14 Foot duct (LH)
(0.750±0.200, 5.421±1.446)
쎻
7 Mix door 쎻
15 Foot lever lower
쎻
8 Heater case lower 쎻
16 Foot door
4
COMPONENT PARTS 4-6
3. Intake Unit
3. Intake Unit
G4M0920
쎻
1 Intake unit case upper 쎻
7 Blower motor ASSY Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Lever (A) 쎻
8 Hose T: 7.35±1.96
쎻
3 Link 쎻
9 Actuator rod (0.750±0.200, 5.421±1.446)
쎻
4 Door (A) 쎻
10 Actuator motor
쎻
5 Bell mouth-intake 쎻
11 Actuator bracket
쎻
6 Intake unit case lower
5
4-6 COMPONENT PARTS
4. Control Unit
4. Control Unit
B4M0369A
쎻
1 Back plate 쎻
9 A/C switch
쎻
2 Bulb 쎻
10 Temp. switch knob
쎻
3 Fan switch ASSY 쎻
11 Mode switch
쎻
4 Illumi. plate 쎻
12 Temp. lever ASSY
쎻
5 Switch base 쎻
13 Base plate
쎻
6 Control panel 쎻
14 Control amp.
쎻
7 Fan switch knob 쎻
15 Temp. control cable
쎻
8 RECIRC switch
6
1. Supplemental Restraint System “Airbag” - 2. Heater Unit

“Airbag”
Airbag system wiring harness is routed near the instrument
panel, heater unit, blower motor and control unit.
CAUTION:
ness when servicing the instrument panel, heater unit,
blower motor and control unit.
2. Heater Unit
1) Disconnect GND cable from battery.
2) Remove heater hoses (inlet, outlet) in engine compart-
ment.
NOTE:
Drain as much coolant from heater unit as possible, and
plug disconnected hose with cloth.
<Ref. to 2-5 [W1A0].>
3) Remove instrument panel.
<Ref. to 5-4 [W1A0].>
4) Remove steering support beam.
<Ref. to 5-1 [C700].>
5) Remove evaporator. (With A/C model)
<Ref. to 4-7 [W14A0].>
6) Remove heater unit.
G4M0554
7
1. Supplemental Restraint System “Airbag” - 2. Heater Unit

“Airbag”
Airbag system wiring harness is routed near the instrument
panel, heater unit, blower motor and control unit.
CAUTION:
ness when servicing the instrument panel, heater unit,
blower motor and control unit.
2. Heater Unit
2) Remove heater hoses (inlet, outlet) in engine compart-
ment.
NOTE:
Drain as much coolant from heater unit as possible, and
plug disconnected hose with cloth.
<Ref. to 2-5 [W1A0].>
3) Remove instrument panel.
<Ref. to 5-4 [W1A0].>
4) Remove steering support beam.
<Ref. to 5-1 [C700].>
5) Remove evaporator. (With A/C model)
<Ref. to 4-7 [W14A0].>
6) Remove heater unit.
G4M0554
7
2. Heater Unit - 3. Blower Motor Assembly
7) Installation is in the reverse order of removal.

Fitted length of heater hose over pipe:
25 — 30 mm (0.98 — 1.18 in)
8) Pour coolant. <Ref. to 2-5 [W1B0].>
3. Blower Motor Assembly

2) Remove glove box and pocket back panel. <Ref. to 5-4
[W1A0].>
3) Disconnect blower motor harness connector.
B5M0025
4) Disconnect aspirator pipe 쎻 1 .

5) Remove blower motor mounting screw.
6) Remove blower motor assembly.
G4M0555
8
2. Heater Unit - 3. Blower Motor Assembly

Fitted length of heater hose over pipe:
25 — 30 mm (0.98 — 1.18 in)
8) Pour coolant. <Ref. to 2-5 [W1B0].>
3. Blower Motor Assembly

[W1A0].>
3) Disconnect blower motor harness connector.
B5M0025
4) Disconnect aspirator pipe 쎻 1 .

5) Remove blower motor mounting screw.
6) Remove blower motor assembly.
G4M0555
8
4. Control Unit
4. Control Unit
A: REMOVAL
2) Set temperature control lever to “FULL COLD” position.
3) Remove temperature control cable from heater unit.
NOTE:
Do not attempt to move link of heater unit during installa-
tion.
B5M0027
4) Remove cup holder.

5) Remove center panel and then disconnect connector.
B4M0370
6) Remove control unit assembly and disconnect connec-

tor.
B4M0059
B: INSPECTION
1. FAN SWITCH
Check continuity between terminals at each switch posi-
tion.
Switch Terminals
position 1 2 3 4 5 6
1 쎻 쎻 쎻
2 쎻 쎻 쎻
B4M0060A
3 쎻 쎻 쎻
4 쎻 쎻 쎻
GND IGN
9
4. Control Unit
2. CONTROL UNIT
Check circuit continuity between each terminal, when push
control switch is turned ON.
Mode selector switch RECIRC switch
Terminal A/C Illumi.
No. DEF/ switch
VENT BI-LEV HEAT DEF RECIRC FRESH
HEAT
3 쎻
B4M0061A
4
5 쎻
6 쎻 쎻
7 쎻 쎻
8 쎻 쎻 쎻 쎻 쎻 쎻 쎻
9 쎻
10 쎻
11 쎻
12 쎻 쎻 쎻 쎻 쎻
13
14 쎻 쎻
15 쎻 쎻
16 쎻
17 쎻
18 쎻
19 쎻
C: ADJUSTMENT
1) Operate temperature control lever to “FULL COLD”
position.
2) Install control cable to lever 쎻1 . While pushing outer
cable, secure control cable with clip 쎻2 .
B4M0062A
D: INSTALLATION
NOTE:
Before control unit installation, set temperature control
lever to “FULL COLD” position.
10
5. Intake Door Motor

A: REMOVAL
[W1A0].>
3) Remove heater duct or evaporator. (With A/C model).
<Ref. to 4-7 [W14A0].>
B5M0025
4) Remove intake unit from the vehicle.
G4M0561
5) Remove screws which secure intake door motor to

intake unit.
NOTE:
Ensure that RECIRC switch is set to “ON”.
B4M1428A
B4M1429A
11
B: INSPECTION
1) When approx. 12 V is applied to the intake door motor
terminals, intake door motor operates as follows:
Intake Terminal
door motor Intake door motor operation
position 䊝䊞
2*
FRESH Door motor moved to FRESH position.
3* 1**
B4M0294A
2** 1*
RECIRC Door motor moved to RECIRC position.
3**
*: LHD model
**: RHD model
2) Connect harness to intake door motor.

3) Turn ignition switch to “ACC” and RECIRC switch to
“ON” then, set to “RECIRC”.
NOTE:
Ensure that intake door motor is set in the “RECIRC” mode.
4) Install intake door motor on intake unit.
5) Secure rod holder to link, and install link to intake unit.
6) Manually set rod in the “RECIRC” mode, and secure to
rod holder.
B4M1430A
7) Operate mode selector switch to ensure that system
changes from intake air to “RECIRC” and from “RECIRC”
to intake air in full-stroke range.
B4M1431A
C: INSTALLATION
12
6. Mode Door Motor
6. Mode Door Motor

A: REMOVAL
1) Remove instrument panel. <Ref. to 5-4 [W1A0].>
2) Remove mode door motor.
B4M0063
B: INSPECTION
1) When approx. 12 V is applied to the mode door motor
terminals, mode door motor operates as follows:
Terminal No.
Mode door motor
2 1
Polarity of power supply Mode door motor Direction of linkage
terminals operation rotation
− + VENT,DEF Clockwise
+ − DEF,VENT Counterclockwise
B4M0064A
2) Check mode door motor position switch.

When the mode door motor is moved to each mode posi-
tion by using the mode selector switch, check if continuity
exists between each terminal as follows:
Mode selector switch
Terminal No.
positions
VENT 8 or 7
BI-LEV 6 or 7
HEAT 5 or 6 9 (GND)
DEF/HEAT 4 or 5
DEF 3 or 4
C: INSTALLATION
13
4-7 SPECIFICATIONS
1. Air Conditioning System

A: SPECIFICATIONS
Item Specifications
Type of air conditioner Reheat air-mix type
Cooling capacity (IMACA) 4.885 kW
(4,200 kcal/h, 16,666 BTU/h)
HFC-134a (CH2FCF3)
Refrigerant [0.55 — 0.65 kg
(1.21 — 1.43 lb)]
Type 5-vane rotary, fix volume (DKV-14D)
Compressor Discharge 140 cm3 (8.54 cu in)/rev
Max. permissible speed 7,000 rpm
Type Dry, single-disc type
Power consumption 45 W
Magnet clutch Type of belt V-Ribbed 4 PK
Pulley dia. (effective dia.) 125 mm (4.92 in)
Pulley ratio 1.064
Type Corrugated fin (Multi-flow)
Core face area 0.215 m2 (2.31 sq ft)
Condenser
Core thickness 19 mm (0.75 in)
Radiation area 4.7 m2 (51 sq ft)
Receiver drier Effective inner capacity 290 cm3 (17.70 cu in)
Expansion valve Type Internal equalizing
Type A-laminate
Evaporator 74 x 224 x 235 mm
Dimensions (W x H x T) (2.91 x 8.82 x 9.25 in)
Fan type Sirocco fan
Blower fan Outer diameter x width 150 x 75 mm (5.91 x 2.95 in)
Power consumption 230 W at 12 V
Motor type Magnet
Condenser fan Power consumption 120 W at 12 V
(Sub fan)
Fan outer diameter 320 mm (12.60 in)
Motor type Magnet
Radiator fan Power consumption 120 W at 12 V
(Main fan)
Fan outer diameter 320 mm (12.60 in)
Idling speed with MPFI model 850±100 rpm (700±100 rpm “D” range in AT model)
F.I.C.D. in operation
Dual switch
(Pressure switch)
High-pressure line
B4M0755A
Compressor relief valve

blow-out pressure
B4M0084A
Thermo control
amplifier working
temperature
(Evaporator outlet air)
B4M0756A
2
COMPONENT PARTS 4-7

1. LHD MODEL
B4M0757A
쎻
1 Receiver drier bracket Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Pipe (Receiver drier — Evaporator module) T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
쎻
3 Receiver drier T3: 15±5 (1.5±0.5, 10.8±3.6)
쎻
4 Evaporator unit T3: 15±3 (1.5±0.3, 10.8±2.2)
쎻
5 Hose (Low-pressure) T4: 25±5 (2.5±0.5, 18.1±3.6)
쎻
6 A/C relay
쎻
7 Fuse
쎻
8 Hose (High-pressure)
쎻
9 Compressor
쎻
10 Condenser
쎻
11 Pipe (Condenser — Receiver drier)
3
4-7 COMPONENT PARTS
2. RHD MODEL
B4M0683A
쎻
1 Receiver drier Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Pipe (Receiver drier — Evaporator module) T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
쎻
3 Evaporator unit T2: 15±3 (1.5±0.3, 10.8±2.2)
쎻
4 Hose (Low-pressure) T3: 15±5 (1.5±0.5, 10.8±3.6)
쎻
5 A/C relay T4: 25±5 (2.5±0.5, 18.1±3.6)
쎻
6 Fuse
쎻
7 Hose (High-pressure)
쎻
8 Compressor
쎻
9 Condenser
쎻
10 Pipe (Condenser — Receiver drier)
4
COMPONENT PARTS 4-7
2. Evaporator Unit
2. Evaporator Unit
1. LHD MODEL
B4M0086A
쎻
1 Thermo control amplifier Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Case upper T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
쎻
3 Cooling unit T2: 10±3 (1.0±0.3, 7.2±2.2)
쎻
4 Pipe T3: 15±5 (1.5±0.5, 10.8±3.6)
쎻
5 Seat T4: 20±5 (2.0±0.5, 14.5±3.6)
쎻
6 Expansion valve
쎻
7 Drain hose
쎻
8 Case lower
쎻
9 Resistor
쎻
10 Resistor bracket
5
4-7 COMPONENT PARTS
2. Evaporator Unit
2. RHD MODEL
B4M0684A
쎻
1 Thermo control amplifier
쎻
2 Case upper
쎻
3 Cooling unit
쎻
4 Pipe
쎻
5 Expansion valve
쎻
6 Drain hose
쎻
7 Case lower
쎻
8 Resistor
6
COMPONENT PARTS 4-7
3. Compressor
3. Compressor
1. LHD MODEL
B4M0758A
쎻
1 Alternator bracket Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Alternator T1: 23.0±4.4 (2.35±0.45, 17.0±3.3)
쎻
3 Alternator bracket nut T2: 29±4 (3.0±0.4, 21.7±2.9)
쎻
4 Bracket T3: 35±4 (3.6±0.4, 26.0±2.9)
쎻
5 Compressor bracket lower
쎻
6 Compressor
쎻
7 Idler pulley ASSY
쎻
8 Compressor bracket upper
7
4-7 COMPONENT PARTS
3. Compressor
2. RHD MODEL
B4M0685A
쎻
1 Alternator bracket Tightening torque: N⋅m (kg-m, ft-lb)
쎻
2 Alternator T1: 23±4 (2.3±0.4, 16.6±2.9)
쎻
3 Alternator bracket nut T2: 35±5 (3.6±0.5, 26.0±3.6)
쎻
4 Bracket T3: 43±6 (4.4±0.6, 31.8±4.3)
쎻
5 Compressor bracket lower
쎻
6 Compressor
쎻
7 Idler pulley ASSY
쎻
8 Compressor bracket upper
8
1. Safety Precautions
1. HFC-134a AIR CONDITIONING SYSTEM
Component parts of the cooling system, refrigerant, com-
pressor oil, and other parts are not the same for the HFC-
134a system and the older CFC-12 system. Do not inter-
change parts or liquid.
Vehicles with HFC-134a air conditioning systems, use only
HFC-134a parts that are indicated on a label attached to
the vehicle. Before performing any maintenance, verify the
type of air conditioning system installed in the vehicle.
B4M0780
2. COMPRESSOR OIL
Do not use any compressor oil that is not specifically des-
ignated for the HFC-134a air conditioning system; only use
ZXL200PG. Also, do not use HFC-134a compressor oil in
the CFC-12 air conditioning system. If compression oils are
mixed, poor lubrication will result and the compressor itself
may be damaged.
Because HFC-134a compressor oil is very hygroscopic
(easily absorbs moisture), when parts of the air condition-
ing system are being removed, quickly install a blind plug
to prevent contact with the outside air. Also, always make
sure that the service container for compressor oil is tightly
closed except when in use. Store compressor oil in a tightly
closed steel container.
9
3. REFRIGERANT
Do not put CFC-12 refrigerant into a HFC-134a air condi-
tioning system. Also, do not put HFC-134a refrigerant into
a CFC-12 air conditioning system. If the wrong refrigerant
is used, poor lubrication will result and the compressor
itself may be destroyed.
4. HANDLING OF REFRIGERANT
Because refrigerant boils at approx. −30°C (−22°F) at sea
level, it is cold enough to give you severe frostbite. Always
wear goggles to protect your eyes and gloves to protect
your hands. Also, even under the pressures normally found
in CFC-12 containers, refrigerant will boil with the addition
of heat. This could raise the pressure inside the container
to a dangerous level.
Never expose a can of HFC-134a to direct sunlight, or to
temperatures over 40°C (104°F). One more thing to
remember about HFC-134a is that when it is exposed to an
open flame or to hot metal, it forms phosgene, a deadly
gas. Do not discharge HFC-134a into the atmosphere on
purpose. Always read and follow the precautions on the
HFC-134a bottle.
G4M0979
10
2. Basic Information
2. Basic Information
1) The combination of moisture and refrigerant forms acid,
therefore, moisture should not be allowed to enter the
refrigerant.
2) Refrigerant oil readily absorbs moisture, therefore, keep
refrigerant oil containers tightly capped.
3) The process of evacuating the system is performed to
remove small amounts of moisture. This is accomplished
by lowering the pressure inside the system, which allows
the moisture to boil off, in much the same way that a pot
of water will boil away to nothing given enough time. The
evacuation process does not suck the moisture out of the
system.
4) A minimum level of vacuum must be reached to satis-
factorily evacuate the system. This minimum level of
vacuum depends on the temperature inside the system.
The chart below shows the level of vacuum required to boil
water at various temperatures.
Additionally, the vacuum level shown on a gauge will read
approx. 4 kPa (25 mmHg, 1 inHg) less for each 304.8 m
(1,000 ft) above sea level, due to the decrease in atmo-
spheric pressure at altitude.
Vacuum level required to boil water (at sea level)
Temperature °C (°F) Vacuum kPa (mmHg, inHg)
1.7 (35) 100.9 (757, 29.8)
7.2 (45) 100.6 (754, 29.7)
12.8 (55) 99.9 (749, 29.5)
18.3 (65) 99.2 (744, 29.3)
23.9 (75) 98.5 (739, 29.1)
29.4 (85) 97.2 (729, 28.7)
35 (95) 95.8 (719, 28.3)
11
3. Tools and Equipment

The following section provides information about the tools
and equipment that will be necessary to properly service
the A/C system.
Since equipment may vary slightly depending on the
manufacturer, it is important to always read and follow the
manufacturer’s instructions.
CAUTION:
When working on vehicles with the HFC-134a system,
only use HFC-134a specified tools and parts. Do not
mix with CFC-12 tools and parts. If HFC-134a and
CFC-12 refrigerant or compressor oil is mixed, poor
lubrication will result and the compressor itself may be
destroyed.
In order to help prevent mixing HFC-134a and CFC-12
parts and liquid, the tool and screw type and the type
of service valves used are different. The gas leak
detectors for the HFC-134a and CFC-12 systems must
also not be interchanged.
HFC-134a CFC-12
Tool & screw type Millimeter size Inch size
Valve type Quick joint type Screw-in type
Tools and Equipment Description

쐌 WRENCH
Various WRENCHES will be required to service any A/C

system. A 7 to 40 N⋅m (0.7 to 4.1 kg-m, 5 to 30 ft-lb) torque
wrench with various crowfoot wrenches will be needed. Open
end or flare nut wrenches will be needed for back-up on the
tube and hose fittings.
G4M0571
쐌 APPLICATOR BOTTLE
A small APPLICATOR BOTTLE is recommended to apply

refrigerant oil to the various parts. They can be obtained at a
hardware or drug store.
G4M0572
12

쐌 MANIFOLD GAUGE SET
A MANIFOLD GAUGE SET (with hoses) can be obtained

from either a commercial refrigeration supply house or from
an auto shop equipment supplier.
G4M0573
쐌 REFRIGERANT RECOVERY SYSTEM
A REFRIGERANT RECOVERY SYSTEM is used for the

recovery and reuse of A/C system refrigerant after
contaminants and moisture have been removed from the
refrigerant.
G4M0574
쐌 SYRINGE
A graduated plastic SYRINGE will be needed to add oil back

into the system. The syringe can be found at a pharmacy or
drug store.
G4M0575
쐌 VACUUM PUMP
A VACUUM PUMP (in good working condition) is necessary,

and may be obtained from either a commercial refrigeration
supply house or an automotive equipment supplier.
G4M0576
쐌 CAN TAP
A CAN TAP for the 397 g (14 oz) can is available from an
auto supply store.
G4M0577
13

쐌 THERMOMETER
Pocket THERMOMETERS are available from either industrial

hardware store or commercial refrigeration supply houses.
G4M0578
쐌 ELECTRONIC LEAK DETECTOR
An ELECTRONIC LEAK DETECTOR can be obtained from

either a specialty tool supply or an A/C equipment supplier.
G4M0579
쐌 WEIGHT SCALE
A WEIGHT SCALE such as an electronic charging scale or a

bathroom scale with digital display will be needed if a 13.6 kg
(30 lb) refrigerant container is used.
G4M0580
14
4. O-ring Connections
1. GENERAL
The following points should be kept in mind when assem-
bling O-ring connections.
1) Avoid unnecessary handling and contact of O-rings with
your hands, since even clean fingers contain body acids,
which can contaminate the O-ring surface.
2) Do not handle O-rings with gloves, shop towels, etc.,
since lint particles may cling to the O-ring, possibly caus-
ing a leak upon assembly.
3) Always lubricate O-rings before assembly to allow the
O-ring to seat itself properly.
4) Be certain to use torque wrenches when tightening
O-ring fittings, because overtightening can not only dam-
age the O-ring, but it can distort the tube end as well.
2. REMOVE PROTECTIVE SEALS

Just prior to making the connection, remove the protective
seals.
CAUTION:
If for any reason you have to stop before making a
connection, recap the tube, component or fitting.
G4M0581
Visually inspect the O-ring surface, the O-ring mating

surface, the threads and the connection points. If a defec-
tive part is found, replace it.
The O-ring must sit square against the tube bead. If
necessary, slide the O-ring into proper position with clean
hands.
G4M0582
15
3. LUBRICATE THE COMPONENTS

For lubrication of the components, use only refrigerant oil
as described in the appropriate service manual. Apply oil
from an oil squirt gun or other closed container. Do not use
your finger to spread the oil over the O-ring.
Apply a small amount of refrigerant oil to the top and sides
of the O-ring. The area covered by oil should include the
O-ring and the tube bead.
G4M0583
4. TORQUE THE FITTING

Using a back-up wrench in conjunction with a calibrated
torque wrench, torque the connection to the midrange of
the specification.
After completion of torquing, use a clean shop towel to
remove any excess oil from the connection or any oil that
may have dripped on the vehicle body or other parts.
CAUTION:
If a leak is suspected after torquing, do not retighten
G4M0584 or retorque the connection. Instead, disassemble the
connection, remove the O-ring, and inspect the O-ring,
threads, joints and seating surfaces.
16
5. Refrigerant Service Procedure
5. Refrigerant Service Procedure

1. WORK FLOW
17
6. Discharge the System
6. Discharge the System

CAUTION:
The following points should be kept in mind when dis-
charging the system.
쐌 Be certain that goggles and gloves are worn.
쐌 Connect refrigerant recovery system to manifold
gauge set and remove recycle refrigerant from A/C
system.
NOTE:
Refer to appropriate refrigerant recovery system instruction
manual for operation.
1. CONNECTING THE MANIFOLD GAUGE SET

1) Close the high and low side manifold valves.
G4M0585
2) Turn the A/C system ON and turn the IG switch OFF.

3) Attach the high- and low-pressure manifolds to the high
and low services port on the vehicle.
G4M0586
2. PREPARE FOR DISCHARGING

Connect the center manifold hose to the refrigerant recov-
ery system to recycle refrigerant.
18
7. Evacuating and Charging

The following points should be kept in mind when evacu-
ating and charging with a manifold gauge set.
1) Be certain that goggles and gloves are worn.
2) If bulk refrigerant [13.6 kg (30 lb) canister] is used, be
certain to weigh the charge amount carefully, using the
correct equipment, to avoid overcharging the system.
3) The charging procedure described in this section
begins by charging liquid refrigerant into the high- pres-
G4M0596 sure side of the system with the engine off. The proce-
dure is completed by charging refrigerant vapor into the
low-pressure side of the system with the engine running.
CAUTION:
Never open the high-pressure manifold valve when the
engine is running.
1. CONNECT THE GAUGE SET

1) Close the high- and low-pressure manifold valves.
2) Attach the low-pressure manifold hose to the low- pres-
sure service port on the vehicle. Check the low- pressure
gauge. If more than 68.6 kPa (0.70 kg/cm2, 10 psi) is
indicated, discharge the system prior to charging.
3) Attach the high-pressure manifold hose to the high-
pressure service port on the vehicle.
4) Connect the center hose from the manifold to the
G4M0597 vacuum pump.
5) Turn on the vacuum pump.
6) Slowly open the low-pressure manifold valve.
7) When the low-pressure gauge reaches approximately
66.43 kPa (498.3 mmHg, 19.62 inHg), slowly open the
high-pressure manifold valve.
8) Maintain a minimum vacuum level of 100.56 kPa (754.4

mmHg, 29.70 inHg) for a minimum of 15 minutes on a new
system or 30 minutes for an in-service system.
NOTE:
The gauge will read 4 kPa (25 mmHg, 1 inHg) less for
every 304.8 m (1,000 ft) above sea level.
G4M0598
19
2. PERFORM A VACUUM LEAK TEST

1) After 15 minutes (or more) of evacuation, close the
high-pressure manifold valve.
2) Close the low-pressure manifold valve.
3) Turn off the vacuum pump.
G4M0599
4) Note the low side gauge reading.

5) After 5 minutes, re-check the low-pressure gauge read-
ing.
If the vacuum level has changed more than 4 kPa (25
mmHg, 1 inHg), perform an HFC-134a leak test.
If the vacuum reading is about the same as noted in step
2-4), continue on to step 2-6).
G4M0600
6) Carefully attach the can tap to the refrigerant can by

following the can tap manufacturer’s instructions.
7) Disconnect the center manifold hose from the vacuum
pump and connect the hose to the tap valve.
G4M0980
8) If a 13.6 kg (30 lb) container of refrigerant is used a

weight scale will be needed. This scale is to determine the
amount of refrigerant that is used.
Connect the center hose from the manifold to the valve.
Place the 13.6 kg (30 lb) container on the scale, valve end
down.
G4M0981
3. PURGE THE CENTER HOSE

1) Verify that all three hose connections are tight at the
manifold gauge set.
2) Open the valve on the HFC-134a source.
3) With safety equipment in place (goggles and
gloves), use extreme caution and loosen the center hose
connection at the manifold and allow the HFC-134a to
escape for no more than two or three seconds, then quickly
retighten the hose fitting at the manifold.
G4M0603
20
4. INITIAL CHARGING THROUGH THE HIGH SIDE

1) Connect a tachometer to the engine.
2) With the engine off, start charging by slowly opening
the high-pressure manifold valve.
NOTE:
The initial charge rate can be increased by immersing the
can in lukewarm [Below 38°C (100°F)] water for a short
time.
G4M0604
5. CHECK THE GAUGE READINGS

When both the high- and low-pressure gauge readings are
about equal, or the HFC-134a source is empty, or the sys-
tem has been filled to specifications, close the high- pres-
sure manifold valve.
G4M0605
6. ADD ADDITIONAL CANS

If the HFC-134a source is exhausted, first close the high-
pressure manifold valve, second, close the can tap valve,
then slowly purge the refrigerant from the service hose by
loosening the fitting at the can tap. Repeat steps 15
through 19 as necessary.
7. COMPLETE CHARGING THROUGH THE LOW SIDE

1) Verify that the high-pressure manifold valve is closed
(should have already been closed).
2) Verify that the low-pressure manifold valve is closed
(should have already been closed).
G4M0606
3) With the A/C switch off and the windows rolled down,
start the engine and run at idle rpm.
4) Set the A/C controls on maximum cool and set the
blower speed on the highest setting.
5) Quickly turn the A/C switch on-off-on-off a few times to
prevent initial compressor damage due to “load shock.”
Finish this operation with the A/C switch in the ON position.
6) Raise engine rpm to approximately 1,500 rpm.
G4M0607
21
8. CHARGE THE SYSTEM

1) With the refrigerant source connected and the service
hose purged, slowly open the low-pressure manifold valve,
while checking the low-pressure gauge reading.
CAUTION:
The refrigerant source must be positioned for vapor
(valve up).
2) Keep the low side pressure below 276 kPa (2.81
kg/cm2, 40 psi) by using the low-pressure manifold valve to
G4M0608
regulate the flow of refrigerant into the system.
3) When the system is fully charged, close the low- pres-
sure manifold valve.
4) Close the valve at the refrigerant source.
쐌 Refrigerant capacity Unit: kg (lb)
Refrigerant Minimum Maximum
HFC-134a 0.55 (1.21) 0.65 (1.43)
9. COMPLETE ALL SYSTEM CHECKS

1) Evaluate the system performance (refer to performance
testing section).
2) Perform leak detection test.
CAUTION:
Always perform leak checking in an environment free
of refrigerant pollution.
Do not disconnect the high- or low-pressure hoses
from the vehicle before leak checking.
10. DISCONNECT THE MANIFOLD GAUGE SET

Remove the high- or low-pressure hoses from the service
ports and install the service port caps.
22
8. Leak Testing
8. Leak Testing
The following points should be kept in mind when conduct-
ing a refrigerant leak test.
1) The A/C system to be tested must have an adequate
refrigerant charge to begin with.
2) The area where the leak test is conducted must be free
of wind and drafts, with still air being the ideal condition.
3) The atmosphere where the leak test is conducted must
be free of refrigerant contamination.
4) Operate the A/C system for approx. 10 minutes, then
turn the engine off an begin the leak test.
5) Refrigerant gas is heavier than air, therefore always
hold the probe below the connection being tested.
6) When checking for a leak along a length of hose or
tube, the leak detector probe must be moved slowly,
approx. 25 mm (1 in) per second making sure probe does
not come in contact with the component being tested.
7) When checking for a leak at a certain point, the leak
detector probe must be held at that point for at least 5
seconds.
1. CHECK THE SYSTEM PRESSURE

With gauges connected to the A/C system, operate the A/C
and confirm that the high side pressure is above 690 kPa
(7.03 kg/cm2, 100 psi). If not, evacuate and charge the
system before leak checking (refer to evacuation and
charging sections).
G4M0609
2. CLEAN CONNECTIONS BEFORE TESTING

Before testing, use a clean shop towel to wipe off refriger-
ant oil, dirt, or foreign material from all of the connections
and components to be tested.
NOTE:
Since refrigerant oil absorbs refrigerant, excess oil on or
near a connection may falsely signal a leak.
3. CALIBRATE LEAK DETECTOR

Refer to the manufacturer’s instructions for the particular
type of detector used and calibrate the instrument.
CAUTION:
Always make sure that the probe tip filter is clean and
free of contamination.
B4M0089
23
8. Leak Testing
4. LEAK TEST — HIGH-PRESSURE SIDE

Operate the A/C system for approx. 10 minutes, then turn
the engine off and begin the leak test.
1) Begin at the connection of the high-pressure tube to the
evaporator, and work your way along the high- pressure
side of the system to the compressor. There are three
places to check on each tube connection.
2) Check the area.
(1) Check the area where the fitting joins the tube.
G4M0612
(2) Check the area where the two parts of the fitting
join each other.
G4M0613
(3) Check the area where the nut joins the tube.
G4M0614
3) Check the area of the sight glass and pressure switch

(dual switch), and also check the seams of the receiver
drier.
4) Check the connections of the tubes to the condenser,
and also check any welded joints on the condenser.
CAUTION:
An oily area on the fins of the condenser may indicate
a leak.
5) Check the area where the hoses attach to the compres-
sor.
6) Check around the machined portions of the compressor
(where the compressor sections join each other).
7) If equipped, check the thermal limiter on the compres-
sor housing.
8) Check the compressor shaft seal by probing near the
center of the compressor clutch pulley.
NOTE:
Some shaft seals have a very slight amount of normal
leakage [approximately 28 g (1.0 oz) per year].
24
8. Leak Testing
5. LEAK TEST — LOW-PRESSURE SIDE

1) Begin at the connection of the low-pressure tube to the
evaporator, and work your way along the low-pressure of
the system to the compressor. There are three places to
check on each tube connection.
2) Check the area.
(1) Check the area where the fitting joins the tube.
(2) Check the area where the two parts of the fitting
join each other.
G4M0615
(3) Check the area where the nut joins the tube.
G4M0616
6. CHECK THE FLEXIBLE HOSES

Visually inspect the rubber portions of the flexible hoses for
cracking. Probe the rubber section, including the ends of
any insulators or protectors which may cover sections of
the rubber hose, and near the ends where the rubber
meets the metal collar.
NOTE:
Be certain to move the probe slowly [approximately 25 mm
(1 in) per second] when probing along any length of hose
G4M0617 or tube.
7. CHECK THE EVAPORATOR ASSEMBLY
1) Use one or both of the following methods to check the
evaporator assembly.
2) Remove the drain hose from the case drain nipple. Hold
the probe at the end of the case drain nipple for at least 10
seconds. Be certain to reconnect the drain hose when fin-
ished.
3) With the ignition key in the “ACC” position, run the
blower on high speed for 1 minute, then turn the blower off.
G4M0618 Place the probe in the center instrument panel vent, an turn
the blower on low speed for 1 to 2 seconds, then turn the
blower off. Leave the probe in the vent for at least 10 sec-
onds.
25
8. Leak Testing - 9. Lubrication
8. CHECK THE SERVICE PORT CAPS

Visually inspect the inside of the service port caps. Make
sure the rubber seal is in place on the inside of the caps.
Disconnect the gauges from the vehicle and install the
service port caps.
G4M0619
9. Lubrication
1. SYSTEM OIL STABILIZATION
Prior to opening the refrigerant system for repairs (except
compressor seizure) the system must be stabilized for cor-
rect oil replenishment.
Follow these procedures:
1) Engine speed set to 1,500 rpm
2) A/C “ON”
3) Air source to recirculate
4) Blower in 4th or high speed position
쐌 Make sure the air entering the evaporator is above
26.7°C (80°F).
쐌 The discharge (high) side pressure must be above
588 kPa (6 kg/cm2, 85 psi).
5) Operate the A/C for 10 minutes.
2. SYSTEM DISCHARGE
Slowly, discharge the system starting with the high- pres-
sure side until the pressure drops below 345 kPa (3.52
kg/cm2, 50 psi), then open the low-pressure side.
26
8. Leak Testing - 9. Lubrication
8. CHECK THE SERVICE PORT CAPS

Visually inspect the inside of the service port caps. Make
sure the rubber seal is in place on the inside of the caps.
Disconnect the gauges from the vehicle and install the
service port caps.
G4M0619
9. Lubrication
1. SYSTEM OIL STABILIZATION
Prior to opening the refrigerant system for repairs (except
compressor seizure) the system must be stabilized for cor-
rect oil replenishment.
Follow these procedures:
1) Engine speed set to 1,500 rpm
2) A/C “ON”
3) Air source to recirculate
4) Blower in 4th or high speed position
쐌 Make sure the air entering the evaporator is above
26.7°C (80°F).
쐌 The discharge (high) side pressure must be above
588 kPa (6 kg/cm2, 85 psi).
5) Operate the A/C for 10 minutes.
2. SYSTEM DISCHARGE
Slowly, discharge the system starting with the high- pres-
sure side until the pressure drops below 345 kPa (3.52
kg/cm2, 50 psi), then open the low-pressure side.
26
9. Lubrication
3. OIL REPLACEMENT (RHD MODEL)

After stabilization and discharge, replace the component,
adding the appropriate amount of oil (ND-OIL9) to the new
component before installation.
Amount of oil to
Proper charging be added
Condition
method m (US fl oz,
lmp fl oz)
Remove all oil
from new
compressor and
Replacement of compressor charge it with 70 (2.4, 2.5)
amount of oil
shown in right
column.
Replacement of evaporator — 70 (2.4, 2.5)
Replacement of receiver drier Oil need not be
—
(Liquid tank) added.
There is no sign Oil need not be
—
of leakage. added.
Replacement of There is
condenser evidence of a
large amount of — 50 (1.7, 1.8)
oil leakage from
condenser.
—
of leakage. added.
Replacement of
flexible hose or There is
aluminum pipe evidence of a
— 50 (1.7, 1.8)
large amount of
oil leakage.
—
of leakage. added.
Gas leakage There is

evidence of a
— 50 (1.7, 1.8)
large amount of
oil leakage.
If the compressor is replaced (after stabilization):
1) Drain and measure the oil from the original compressor.
2) Drain the oil from the replacement compressor and refill
with the same amount that was drained from the original
[20 m (0.7 US fl oz, 0.7 Imp fl oz) minimum]. Always use
ND-OIL9 for the replacement oil.
27
10. Performance Test

1. VEHICLE SET UP
In order to obtain meaningful test results, the vehicle must
be set up to meet the following conditions:
1) Vehicle in shade
2) No wind
3) All vehicle doors closed
4) Front windows opened
5) Hood opened
6) Engine speed set at 1,500 rpm.
7) A/C ON
8) Temperature control lever — Maximum cold
9) Air source — Recirculation
10) Blower speed — 4th position (High)
11) Operate A/C for 10 minutes (Minimum) before taking
measurement.
2. MEASUREMENTS
After 10 minutes (Minimum) of A/C operation and using
accurate test equipment, take the following measurements
(in order):
1) Evaporator intake air temperature at recirculation door.
2) Evaporator discharge air temperature at center grill.
3) Condenser (Ambient) intake air temperature measured
0.9 m (3 ft) in front and in line with the center of the con-
denser.
4) Suction (Low) side pressure
5) Discharge (High) side pressure
NOTE:
If only one thermometer is available; 1) take the ambient
measurement first; then 2) the intake air; and 3) dis-
charge air temperature.
28
3. MEASUREMENT STANDARD BY VERSES

Compare temperature and pressure measurements with
the established standards shown in the following charts.
B4M0371A
29
11. Compressor
11. Compressor
Compressor is a swash plate type. When trouble occurs,
replace compressor as a single unit.
A: COMPRESSOR CLUTCH INSPECTION

Compressor clutch trouble is often caused by clutch slip-
page and noise. Check and take corrective measures, as
required.
1) Remove belt cover.
2) Check that clearance between drive plate and pulley
over the entire perimeter is within specifications.
Clearance:
B4M0090
0.3 — 0.6 mm (0.012 — 0.024 in)
3) Check that voltage applied to magnetic coil is at least

10.5 volts.
4) When noise is noted, check that it originates in either
compressor or pulley bearing.
B4M0091
B: REMOVAL
2) Discharge refrigerant using refrigerant recovery system.
<Ref. to 4-7 [W601].>
(1) Fully close low-pressure valve of manifold gauge.
(2) Connect low-pressure charging hose of manifold
gauge to low-pressure service valve.
(3) Open low-pressure manifold gauge valve slightly,
and slowly discharge refrigerant from system.
B4M0760A
CAUTION:
Do not allow refrigerant to rush out. Otherwise, com-
pressor oil will be discharged along with refrigerant.
30
11. Compressor
3) Remove low-pressure hose 쎻 1 (Flexible hose Ps) and

high-pressure hose 쎻
2 (Flexible hose Pd).
CAUTION:
쐌 Be careful not to lose O-ring of low-pressure hose.
쐌 Plug the opening to prevent foreign matter from
entering.
B4M0761A
4) Remove compressor belt cover and alternator belt

cover.
Remove bolts which secure belt covers.
G4M0624
5) Remove alternator V-belt.

Loosen lock bolt on alternator bracket. Turn adjusting bolt
and remove V-belt.
G4M0625
6) Remove compressor V-belt.

Loosen lock nut on idler pulley. Turn adjusting bolt and
remove V-belt.
G4M0626
7) Disconnect alternator harness.
G4M0627
31
11. Compressor
8) Disconnect compressor harness.

Disconnect compressor harness from body harness.
9) Lower bracket.
Remove bolts which secure lower compressor bracket.
G4M0628
10) Remove compressor.

Remove bolt which secure compressor. Remove compres-
sor from bracket.
G4M0629
C: INSTALLATION
1) Install compressor.
Install compressor on bracket.
G4M0630
2) Connect compressor harness.

3) Connect alternator harness.
4) Install compressor V-belt (Rear).
After adjusting belt tension, tighten tension pulley lock nut
securely.
5) Install alternator V-belt.

After adjusting V-belt tension, tighten alternator bracket
lock bolt securely.
6) Check drive belt tension and adjust it if necessary by
changing alternator position and/or idler pulley position.
G4M0632
32
11. Compressor
Pulley arrangement Tension mm (in)/98N (10 kg, 22 lb)
A B
*New belt: *New belt:

7.0 — 9.0 7.5 — 8.5
(0.276 — 0.354) (0.295 — 0.335)
Existing belt: Existing belt:
9.0 — 11.0 9.0 — 10.0
(0.354 — 0.433) (0.354 — 0.394)
G4M0939
* When replacing belts with new ones, adjust tensions to

specification and then readjust to the same specification
after running engine for 5 minutes.
Figures in table refer to the number of grooves in pulleys.
C/P : Crankshaft pulley
ALT : Alternator pulley
P/S : Power steering oil pump pulley
A/C : Air conditioner compressor pulley
I/P : Idler pulley
CAUTION:
쐌 Ensure that the V-belt is aligned correctly. If it is not,
check for loose bolts.
쐌 The V-belt should not be too tight or too loose.
A belt which is too tight may break bearing or cause
gas to leak from the shaft seal. A belt which is too
loose slips, thereby causing the belt cut.
쐌 After completing the compressor installation and
testing the system operation, check and adjust the ten-
G4M0634 sion of both V-belts again.
7) Install high-pressure hose 쎻

2 (Flexible hose Pd).
Connect high-pressure hose with compressor.
CAUTION:
Be sure to apply compressor oil to the periphery of
O-ring.
B4M0761A
8) Install low-pressure hose 쎻

1 (Flexible hose Ps).
Connect low-pressure hose with compressor.
CAUTION:
Be sure to apply compressor oil to the periphery of
O-ring.
33
B4M0761A
11. Compressor - 12. Condenser
9) Install belt cover.

10) Connect ground cable to negative terminal of battery.
11) Charge refrigerant. <Ref. to 4-7 [W708].>
12. Condenser
<Ref. to 4-7 [W601].>
3) Remove front grille.
B4M0095
4) Remove canister from bracket.

CAUTION:
쐌 Do not disconnect hose from canister.
쐌 Insert air vent hose of canister into the hole on body.
G2M0375
5) Remove the radiator upper bracket of both side.

6) Disconnect high-pressure hose 쎻1 and high-pressure
pipe 쎻
2 from condenser.
B4M0096A
7) Remove the two bolts which secure condenser. While

lifting condenser, remove it through space between radia-
tor and radiator panel.
B4M0097
34
11. Compressor - 12. Condenser
9) Install belt cover.

10) Connect ground cable to negative terminal of battery.
12. Condenser
<Ref. to 4-7 [W601].>
3) Remove front grille.
B4M0095
4) Remove canister from bracket.

CAUTION:
쐌 Do not disconnect hose from canister.
쐌 Insert air vent hose of canister into the hole on body.
G2M0375
5) Remove the radiator upper bracket of both side.

6) Disconnect high-pressure hose 쎻1 and high-pressure
pipe 쎻
2 from condenser.
B4M0096A
7) Remove the two bolts which secure condenser. While

lifting condenser, remove it through space between radia-
tor and radiator panel.
B4M0097
34
12. Condenser
8) The condenser should be installed in the reverse order

in which it was removed.
When installing the condenser, pay attention to the follow-
ing:
CAUTION:
Before connecting the pipe, be sure to apply oil to the
periphery of O-ring.
B4M0098A
NOTE:
After installing condenser, ensure that guide on lower side
of condenser is inserted into hole in radiator panel. Tighten
attaching bolts.
B: INSPECTION
1) Make sure the condenser fins are free from dust and
insects. If the fins are clogged, clean by blowing air or
water through them.
NOTE:
To prevent dust and water from getting into the condenser,
this work must be done when the condenser is installed in
an actual vehicle.
2) Check the condenser to see if it shows any sign of oil.
Should oil ooze or gas leak from the condenser replace it
with a new one.
35
13. Receiver Drier - 14. Evaporator Unit
13. Receiver Drier

<Ref. to 4-7 [W601].>
3) Disconnect pressure switch harness 쎻 1 .
4) Disconnect pipes 쎻 2 .
5) Remove mounting bolt 쎻 3 and remove receiver drier.
G4M0640 CAUTION:
The receiver drier contains a desiccant. Be sure to put
a blind plug in the detached receiver drier to protect it
from moisture.
6) Install the receiver drier in the reverse order of removal.
14. Evaporator Unit

<Ref. to 4-7 [W601].>
3) Disconnect discharge pipe, suction pipe and grommets.
G4M0641

[W1A0].>
B5M0025
5) Disconnect the harness connector from evaporator.

6) Disconnect drain hose.
7) Remove evaporator mounting bolt and nut.
8) Install the evaporator in the reverse order of removal.
G4M0642
36
13. Receiver Drier - 14. Evaporator Unit
13. Receiver Drier

<Ref. to 4-7 [W601].>
3) Disconnect pressure switch harness 쎻 1 .
4) Disconnect pipes 쎻 2 .
5) Remove mounting bolt 쎻 3 and remove receiver drier.
G4M0640 CAUTION:
The receiver drier contains a desiccant. Be sure to put
a blind plug in the detached receiver drier to protect it
from moisture.
6) Install the receiver drier in the reverse order of removal.
14. Evaporator Unit

<Ref. to 4-7 [W601].>
3) Disconnect discharge pipe, suction pipe and grommets.
G4M0641

[W1A0].>
B5M0025
5) Disconnect the harness connector from evaporator.

6) Disconnect drain hose.
7) Remove evaporator mounting bolt and nut.
8) Install the evaporator in the reverse order of removal.
G4M0642
36
14. Evaporator Unit
B: DISASSEMBLY AND ASSEMBLY

1) Remove resistor assembly 쎻
1 and remove six screws
from evaporator case.
B4M0099A
2) Remove thermostat 쎻 1 from upper case. (Thermistor 쎻 2

is inserted into specified evaporator fin position.) When
installing thermostat, be sure to insert thermistor into speci-
fied fin position.
B4M0100A
3) Disconnect the connection between the expansion

valve and pipe from receiver drier.
4) Remove the expansion valve from pipes.
5) To install expansion valve, reverse removal procedures.
Properly wrap capillary tube of expansion valve with seal.
6) Check to see if the evaporator fins are clogged. If they
are, clean them with compressed air.
CAUTION:
Water must never be used to clean the evaporator.
B4M0101A
7) Check parts that have been removed for cracks or
scratches, and repair or replace them with new ones, if
necessary.
8) Reassemble the evaporator in the reverse order of dis-
assembly.
NOTE:
Confirm that the O-ring is inserted in the specified position.
37
15. Condenser Fan Assembly - 16. Flexible Hose
15. Condenser Fan Assembly

2) Disconnect harness connector from fan motor.
3) Remove condenser fan bolt from radiator.
4) Pull condenser fan assembly.
5) Install the condenser fan assembly in the reverse order
of removal.
T: 7.4±2.0 N⋅m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
16. Flexible Hose

<Ref. to 4-7 [W601].>
3) Remove low-pressure hose.
(1) Remove hose attaching bolts.
CAUTION:
B4M0103 Plug the opening to prevent foreign matter from get-
ting in.
(2) Disconnect the connector at evaporator module.
4) Remove high-pressure hose.
(1) Disconnect hose attaching bolt (compressor side).
(2) Disconnect hose attaching bolt (condenser side).
CAUTION:
Plug the opening to prevent foreign matter from get-
ting in.
B4M0764 6) Charge refrigerant. <Ref. to 4-7 [W708].>
38
15. Condenser Fan Assembly - 16. Flexible Hose
15. Condenser Fan Assembly

2) Disconnect harness connector from fan motor.
3) Remove condenser fan bolt from radiator.
4) Pull condenser fan assembly.
5) Install the condenser fan assembly in the reverse order
of removal.
T: 7.4±2.0 N⋅m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
16. Flexible Hose

<Ref. to 4-7 [W601].>
3) Remove low-pressure hose.
(1) Remove hose attaching bolts.
CAUTION:
B4M0103 Plug the opening to prevent foreign matter from get-
ting in.
(2) Disconnect the connector at evaporator module.
4) Remove high-pressure hose.
(1) Disconnect hose attaching bolt (compressor side).
(2) Disconnect hose attaching bolt (condenser side).
CAUTION:
Plug the opening to prevent foreign matter from get-
ting in.
B4M0764 6) Charge refrigerant. <Ref. to 4-7 [W708].>
38
17. Relay and Fuse
17. Relay and Fuse

A: LOCATION
Relays used with A/C system are located as shown in fig-
ure.
1) A/C relay
2) Main fan (radiator fan) relay
3) Sub fan (condenser fan) relay
4) Sub fan (condenser fan) water temperature relay
G4M0649
5) Fuses (10 A and 20 A)
B: INSPECTION
1) Check conduction with a circuit tester (ohm range)
according to the following table in figure.
G4M0651
2) Replace relays which do not meet specifications.
B4M0105A
39
18. Pressure Switch (Dual Switch)
18. Pressure Switch (Dual Switch)

Pressure switch is attached to receiver dryer.
G4M0654
A: INSPECTION
1) Remove cap from high-pressure line service valve, and
connect gauge manifold to service valve.
2) Disconnect pressure switch harness connector, and
check pressure switch for proper ON-OFF operation. Use
a circuit tester.
High-pressure side line pressure
Terminal Operation
kPa (kg/cm2, psi)
Increasing to
2,648±196 (27±2, 384±28)
Turns OFF.
Decreasing to
High and low pressure 177±20 (1.8±0.2, 26±3)
1 — 쎻
쎻 2
switch Increasing to
186±29 (1.9±0.3, 27±4)
Turns ON.
Decreasing to
1,471+196 +2 +28
−98 (15−1, 213−14 )
40
DIAGNOSTICS 4-7
1. Air Conditioning System Diagnosis
1. Air Conditioning System Diagnosis
41
4-7 DIAGNOSTICS
2. Performance Test Diagnosis

If various conditions caused to other air conditioning
system, the characteristics revealed on manifold gauge
reading are shown in the following:
As to the method of a performance test, refer to the item
of “Performance Test”.
Each shaded area on the following tables indicates a read-
ing of the normal system when the temperature of outside
air is 32.5°C (91°F).
Condition Probable cause Corrective action
Insufficient cooling Refrigerant is small, or 1. Perform leak test.
INSUFFICIENT REFRIGERANT CHARGE
leaking a little. 2. Repair leak.
3. Charge system.
Evacuate, as
necessary, and
recharge system.
G4M0673
No cooling action Serious refrigerant leak. Stop compressor
ALMOST NO REFRIGERANT
immediately.
1. Perform leak test.
2. Discharge system.
3. Repair leak(s).
4. Replace receiver
drier if necessary.
5. Check oil level.
6. Evacuate and
recharge system.
G4M0674
Slight cooling; Expansion valve If valve inlet reveals
FAULTY EXPANSION VALVE
Sweating or frosted restricts refrigerant flow. sweat or frost:
expansion valve inlet. 쐌 Expansion valve is 1. Discharge system.
clogged. 2. Remove valve and
쐌 Expansion valve is clean it. Replace it if
inoperative. necessary.
Valve stuck closed. 3. Evacuate system.
Thermal bulb has lost 4. Charge system.
charge. If valve does not oper-
ate:
1. Discharge system.
2. Replace valve.
3. Evacuate and charge
system.
G4M0675
42
DIAGNOSTICS 4-7

Insufficient cooling; Expansion valve allows Check valve for opera-
Sweated suction line. too much refrigerant tion. If suction side does
No cooling; through evaporator. not show a pressure
Sweating or frosted suc- Faulty seal of O-ring in decrease, replace valve.
tion line. expansion valve. 1. Discharge system.
2. Remove expansion
valve and replace
O-ring.
3. Evacuate and
replace system.
G4M0676
G4M0677
Insufficient cooling Air mixed with refriger- 1. Discharge system.

AIR IN SYSTEM
ant in system. 2. Replace receiver
drier.
system.
G4M0678
After operation for a Drier is saturated with 1. Discharge system.

MOISTURE IN SYSTEM
while, pressure on suc- moisture. Moisture has 2. Replace receiver
tion side may show frozen at expansion drier (twice if neces-
vacuum pressure read- valve. Refrigerant flow sary).
ing. During this is restricted. 3. Evacuate system
condition, discharge air completely. (repeat
will be warm. As warn- 30-minute evacuating
ing of this, reading three times.)
shows 39 kPa (0.4 4. Recharge system.
kg/cm2, 6 psi) vibration.
G4M0679
43
4-7 DIAGNOSTICS

No cooling action; Condenser is often 쐌 Check condenser
FAULTY CONDENSER
Engine may overheat. found not functioning cooling fan.
Suction line is very hot. well. 쐌 Check condenser for
dirt accumulation.
쐌 Check engine cooling
system for overheat.
쐌 Check for refrigerant
overcharge.
If pressure remains
high in spite of all
above actions taken,
remove and inspect
the condenser for pos-
sible oil clogging.
G4M0680
Insufficient cooling; Drier is clogged, or 1. Discharge system.

HIGH-PRESSURE LINE BLOCKED
Frosted high-pressure restriction in high-pres- 2. Remove receiver
liquid line. sure line. drier or strainer and
replace it.
system.
G4M0681
Insufficient cooling Internal problem is in 1. Discharge system.

FAULTY COMPRESSOR
compressor, or dam- 2. Remove and check
aged gasket and valve. compressor.
3. Repair or replace
compressor.
4. Check oil level.
5. Replace receiver
drier.
system.
G4M0682
44
DIAGNOSTICS 4-7
3. Blower Motor Diagnosis
3. Blower Motor Diagnosis
45
4-7 DIAGNOSTICS
4. Compressor Diagnosis
4. Compressor Diagnosis
46
DIAGNOSTICS 4-7
5. Compressor Clutch Diagnosis
EPA0110
47
4-7 DIAGNOSTICS
EPA0111
48
DIAGNOSTICS 4-7
6. Radiator Fan (Main Fan) Diagnosis
6. Radiator Fan (Main Fan) Diagnosis
EPA0048
49
4-7 DIAGNOSTICS
7. Condenser Fan (Sub Fan) Diagnosis (I)
7. Condenser Fan (Sub Fan)

Diagnosis (I)
50
DIAGNOSTICS 4-7
8. Condenser Fan (Sub Fan) Diagnosis (II)
8. Condenser Fan (Sub Fan)

Diagnosis (II)
51

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4-1 SPECIFICATIONS AND SERVICE DATA

Thrust angle 0°±20′

2. REAR SUSPENSION (AWD MODEL)

3. REAR SUSPENSION (FWD MODEL)

1. WHEEL ARCH HEIGHT

Specified wheel arch height mm (in)

FWD 385+12 +0.47

FWD 385+12 +0.47

OUTBACK AWD 420+12 +0.47

2. CAMBER AND CASTER

2) Turn camber adjusting bolt so that camber is set at the

Left side Right side

3) Tighten the two self-locking nuts.

3. FRONT WHEEL TOE-IN

4. REAR WHEEL TOE-IN (FWD MODEL)

Left side Right side

Left side Right side

than 15 mm (0.59 in).

adjust the other rear wheel equally in toe-out direction, in

tally by one graduation in the same direction, the thrust

2. Front Transverse Link

1) Disconnect stabilizer link from transverse link.

3) Remove nut (do not remove bolt.) securing transverse

5) Extract ball joint from housing.

4) Connect stabilizer link to transverse link, and tempo-

(3) Transverse link rear bushing and body

3. Front Ball Joint

4) Remove brake hose clamp and disconnect brake hose

7) Remove two bolts securing housing to strut.

2) Using ST, remove self-locking nut.

4) Using a coil spring compressor, compress the coil

9) Using hexagon wrench to prevent strut rod from turning,

6) Install union bolts which secure brake caliper to brake

1) Jack-up the front part of the vehicle, support it with

3) Remove bolts which secure stabilizer link to front trans-

2) Always tighten rubber bushing location when wheels

7) Remove front transverse link from front crossmember

7. Rear Trailing Link

1) Loosen rear wheel nuts.

4) Remove bolt which secure trailing link to trailing link

2) Press ST plunger until bushing flange protrudes beyond

3) Turn trailing link upside down. Press ST plunger in the

4) Remove bolt securing trailing link to housing.

2) Press ST plunger until bushing flange protrudes beyond

3) Turn lateral link upside down. Press ST plunger in the

1) Depress brake pedal and secure it in that position using

3) Remove strut cap of rear quarter trim. (Wagon)

7) Models equipped with rear disc brakes:

9) Remove bolts which secure rear strut to housing.

10. Rear Crossmember (FWD Model)

1) Disconnect lateral links from housing.

11. Rear Crossmember (AWD Model)

5) Place transmission jack under rear crossmember.

6) Remove bolts securing crossmember to vehicle body,

7) Scribe an alignment mark on rear lateral link cam bolt

2. POOR RIDE COMFORT

1. Wheels and Axles

Rim offset P.C.D.

2. TIRE INFLATION PRESSURE

3. FRONT DRIVE SHAFT ASSEMBLY