Installation: Hint: After Installation, Fill AFT and Check The Fluid Level (See Page)

AX-18
AUTOMATIC TRANSAXLE (A242L) - VALVE BODY ASSEMBLY

AX0RY-01
INSTALLATION
Installation is in the reverse order of the previous steps.
HINT:
After installation, fill AFT and check the fluid level (See page AX-27 ).
1996 TERCEL (RM440U)

AX-19
AUTOMATIC TRANSAXLE (A242L) - THROTTLE CABLE
THROTTLE CABLE AX0RZ-01
ON-VEHICLE REPAIR
1. DISCONNECT THROTTLE CABLE FROM ENGINE
Disconnect the cable from the throttle linkage.
2. REMOVE PARK/NEUTRAL POSITION SWITCH

(a) Disconnect the transaxle control cable from the transaxle
control shaft lever.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
(b) Remove the nut and transaxle control shaft lever.
(c) Using a screwdriver, pry off the nut stopper.
(d) Remove the nut and nut stopper.
Q06565 Torque: 6.9 N·m (70 kgf·cm, 61 in.·lbf)
(e) Remove the 2 bolts and park/neutral position switch.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
3. REMOVE VALVE BODY (See page AX-16 )
4. REMOVE THROTTLE CABLE

(a) Remove the retaining bolt and plate.
(b) Pull out the cable from the transaxle case.
N00513
HINT:
New cable does not have a staked cable stopper
0.8 - 1.5 mm (c) Bend the cable so that there is a radius of about 200 mm
(7.87 in.).
(d) Pull the inner cable lightly until a slight resistance is felt,
200 mm
and hold it there.
(e) Stake the stopper so that the distance from the end of out-
er cable to the stopper is 0.8 - 1.5 mm (0.031 - 0.059 in.).
N00515
Author: Date: 801

AX-20
AUTOMATIC TRANSAXLE (A242L) - THROTTLE CABLE
AX0S0-01
INSTALLATION
HINT:
After installation, adjust the throttle cable (See page AX-2 ).
Test drive the vehicle.

AX-21
AUTOMATIC TRANSAXLE (A242L) - GOVERNOR VALVE
GOVERNOR VALVE AX0S1-01
ON-VEHICLE REPAIR
1. DISCONNECT SPEEDOMETER CABLE
2. REMOVE GOVERNOR COVER WITH O-RING

HINT:
Replace the used O-ring with a new one.
AT2848
3. REMOVE GOVERNOR BODY WITH THRUST WASHER

4. REMOVE GOVERNOR BODY ADAPTOR
5. REMOVE GASKET
HINT:
Replace the used gasket with a new one.
AT3318
Author: Date: 803

AX-22
AUTOMATIC TRANSAXLE (A242L) - GOVERNOR VALVE
AX0S2-01
INSTALLATION
HINT:
After installation, fill AFT and check fluid level.

AX-23
AUTOMATIC TRANSAXLE (A242L) - DIFFERENTIAL OIL SEAL
DIFFERENTIAL OIL SEAL AX0S3-01
ON-VEHICLE REPAIR
1. DRAIN TRANSAXLE FLUID
2. REMOVE ENGINE UNDER COVER
3. REMOVE LH AND RH DRIVE SHAFTS
(See page SA-18 )
SST 4. REMOVE SIDE OIL SEAL

Using SST, drive out the oil seals on both sides.
SST 09308-00010
Q02133
Author: Date: 805

AX-24
AUTOMATIC TRANSAXLE (A242L) - DIFFERENTIAL OIL SEAL
AX0S4-01
LH Side INSTALLATION
1. INSTALL SIDE OIL SEALS
(a) Using SST, drive in a new oil seal until its surface is flush
with the case surface.
SST 09350-32014 (09351-32150, 09351-32130)
Oil seal drive in depth:
SST
LH side: 5.3 ± 0.5 mm (0.209 ± 0.020 in.)
RH side: 3.1 ± 0.5 mm (0.122 ± 0.020 in.)
(b) Coat the lip of the oil seal with MP grease.
RH Side 2. INSTALL LH AND RH DRIVE SHAFTS
SST (See page SA-23 )
3. INSTALL ENGINE UNDER COVER
4. FILL AND CHECK FLUID LEVEL
(See page AX-2 )
D01627

AX-25
AUTOMATIC TRANSAXLE (A242L) - SPEEDOMETER DRIVEN GEAR OIL SEAL
SST
SPEEDOMETER DRIVEN GEAR
OIL SEAL AX0S5-01
ON-VEHICLE REPAIR
REMOVE SPEEDOMETER DRIVEN GEAR OIL SEAL
Using SST, pull out the oil seal.
SST 09921-00010
Q06598
Author: Date: 807

AX-26
AUTOMATIC TRANSAXLE (A242L) - SPEEDOMETER DRIVEN GEAR OIL SEAL
AX0S6-01
INSTALLATION
INSTALL SPEEDOMETER DRIVEN GEAR OIL SEAL
SST SST 09201-10000 (09201-01080)
Drive in depth: 25 mm (0.98 in.)
Q06599

AX-27
AUTOMATIC TRANSAXLE (A242L) - SHIFT LOCK SYSTEM
SHIFT LOCK SYSTEM

AX084-01
LOCATION
Key Interlock Solenoid
Shift Lock
Stop Light Switch
Override Button
Shift Lock Control

Unit Assembly
WIRING DIAGRAM
Ignition Switch
CIG
ACC
IG
ECU-IG
Stop IG ACC
Shift Lock
ALT Stop Light Control ECU
Switch
MAIN STP
FL Key Interlock Solenoid
KLS+
Stop
Battery Light
D01645
Author: Date: 809

AX-28
AUTOMATIC TRANSAXLE (A242L) - SHIFT LOCK SYSTEM
AX085-01
INSPECTION
IG
1. INSPECT SHIFT LOCK CONTROL ECU
ACC
Using a voltmeter, measure the voltage at each terminal.
HINT:
Do not disconnect the ECU connector.
KLS+ E STP
Wire Harness Side

Z16063
Terminal Measuring Condition Voltage (V)

ACC - E Ignition switch ACC 10 - 14
IG - E Ignition switch ON 10 - 14
STP - E Depressing brake pedal 10 - 14
1 Ignition switch ACC and P position 0
KLS+ - E 2 Ignition switch ACC and except P position 10 - 14
3 (After approx 1 second) 6-9
2. INSPECT KEY INTERLOCK SOLENOID

(a) Disconnect the solenoid connector.
(b) Using an ohmmeter, measure the resistance between ter-
minals.
Standard resistance: 12.5 - 16.5 Ω
If the resistance is not as specified, replace the solenoid.
AT8748
(c) Apply battery positive voltage between terminals. Check

that the solenoid operation sound is heard.
If the operation is not as specified, replace the solenoid.
AT8749

AX-29
AUTOMATIC TRANSAXLE (A242L) - AUTOMATIC TRANSAXLE UNIT
AUTOMATIC TRANSAXLE UNIT

AX086-04
COMPONENTS
Air Cleaner
Starter Assembly
RH Drive Shaft
Snap Speedometer Cable

Ring Rear Engine Mounting Insulator
x6
Hole Plug
Plug for Governor

Torque Converter Pressure Test
Clutch Tie Rod End
Snap Ring
Clip
LH Drive Shaft
Control
Cable
Gasket
Clamp
Plug for Line Pressure Test O/D Solenoid
Connector
Oxygen Sensor
Gasket
Nut Cap
Cotter Pin
Front Exhaust Pipe
Compression Spring
Engine Under Cover
Non-reusable part
Q07636
Author: Date: 811

AX-30
AX087-03
REMOVAL
1. REMOVE BATTERY
2. REMOVE AIR CLEANER ASSEMBLY
3. REMOVE THROTTLE CABLE
4. REMOVE GROUND CABLES
5. REMOVE UPPER SIDE MOUNTING BOLTS

(a) Remove the 2 upper side mounting bolts.
(b) Remove the upper side starter bolt.
Q06569
6. INSTALL ENGINE SUPPORT FIXTURE

7. RAISE VEHICLE
8. REMOVE UNDER COVER
9. REMOVE LH AND RH DRIVE SHAFTS
(See page SA-18 )
10. DISCONNECT SPEEDOMETER CABLE
Q06548
11. DISCONNECT CONTROL CABLE

(a) Remove the clip from the control cable.
(b) Disconnect the control cable from the lever.
12. DISCONNECT PARK/NEUTRAL POSITION SWITCH
CONNECTOR
13. DISCONNECT O/D SOLENOID CONNECTOR
14. DISCONNECT OIL COOLER HOSE FROM PIPE
Q06571
15. REMOVE STARTER

(a) Disconnect the cable and connector.
(b) Remove the starter with the bolt.
Q06572

AX-31
16. REMOVE FRONT EXHAUST PIPE

(a) Disconnect the oxygen sensor.
(b) Remove the bolts and springs from the exhaust manifold
and front exhaust pipe.
(c) Remove the clamp.
Q08079 (d) Remove the front exhaust pipe and gaskets.
HINT:
Replace the used gaskets with new ones.
17. REMOVE TORQUE CONVERTER CLUTCH MOUNT-

ING BOLTS
(a) Remove the converter cover.
(b) Turn the crankshaft to gain access and remove the 6 bolts
with holding the crankshaft pulley set bolt a wrench.
Q08081
18. SUPPORT TRANSAXLE WITH A TRANSMISSION

JACK
19. DISCONNECT LH ENGINE MOUNTING BRACKET
Remove the 2 mounting bolts.
Q07892
20. REMOVE ENGINE REAR MOUNTING

(a) Remove the rear mounting insulator through bolt.
(b) Remove the 5 bolts and rear mounting insulator.
Torque:
Bolt A: 80 N·m (800 kgf·cm, 59 in·lbf)
Bolt B: 92 N·m (920 kgf·cm, 69 ft·lbf)
A
A B
Q08080

AX-32
C 21. REMOVE TRANSAXLE MOUNTING BOLT

Torque:
B Bolt A: 7.4 N·m (75 kgf·cm, 65 in·lbf)
Bolt C: 46 N·m (470 kgf·cm, 34 ft·lbf)
A
Q06573

AX-33
AX088-04
INSTALLATION
1. TORQUE CONVERTER CLUTCH
Using calipers and a straight edge, measure the distance from
the installed surface to the front surface of the transaxle hous-
ing.
Correct distance: More than 13.0 mm (0.512 in.)
2. TRANSAXLE INSTALLATION
Installation is in the reverse order of removal.
AT0943
HINT:
After installation, adjust the shift cable and park/neutral
position switch (See page AX-2 ).
Fill ATF and check fluid level (See page AX-2 ).
Test drive the vehicle.

AX-34
AUTOMATIC TRANSAXLE (A242L) - TORQUE CONVERTER CLUTCH AND DRIVE PLATE
TORQUE CONVERTER CLUTCH

SST
AND DRIVE PLATE AX0S7-01
INSPECTION
1. INSPECT ONE-WAY CLUTCH
(a) Install SST in the inner race of the one-way clutch.
SST 09350-32014 (09351-32010)
AT0952
(b) Install SST so that it fits in the notch of the converter clutch
hub and outer race of the one-way clutch.
SST 09350-32014 (09351-32020)
AT0953
(c) With the torque converter clutch held upright, inspect the
clutch locks when turned counterclockwise, and rotates
Hold
freely and smoothly clockwise.
If necessary, clean the converter and retest the clutch. Replace
Lock the converter clutch if the clutch still fails the test.
Turn Free
AT3306
2. MEASURE DRIVE PLATE RUNOUT AND INSPECT

RING GEAR
Set up a dial indicator, and measure the drive plate runout.
Maximum runout: 0.20 mm (0.0079 in.)
If the runout is not within the specification, replace the drive
plate.
AT2821
3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE

RUNOUT
Temporarily mount the torque converter clutch to the drive
plate. Set up a dial indicator.
If the runout is not within the specification, try to correct by reori-
enting the installation of the converter.
HINT:
AT2820 Mark the position of the converter clutch to ensure the correst
installation.
Author: Date: 816

SA-1
SUSPENSION AND AXLE - TROUBLESHOOTING
TROUBLESHOOTING
SA10Z-04
PROBLEM SYMPTOMS TABLE

Use the table to help you find the cause of the problem. The numbers indicate the priority of the likely case
of the problem. Check each part in order. If necessary, replace these parts.
Symptom Suspect Area See page
1. Tire (Worn or improperly inflated) SA-2
2. Wheel alignment (Incorrect) SA-4
SA-8
3. Steering linkage (Loosen or worn) -
Wander/pulls 4. Hub bearings (Worn) SA-10
SA-39
5. Steering gear (Out of adjustment or broken) SR-34
SR-46
6. Suspension parts (Worn) -
1. Vehicle (Overloaded) -
2. Spring (Weak) SA-24
Bottoming SA-44
3. Shock absorber (Worn) SA-24
SA-44
2. Stabilizer bar (Rear axle beam) SA-54
Sways/pitches
SA-44

2. Wheels (Out of balance) SA-2
Front wheel shimmy 5. Ball joint (Worn) SA-34
6. Hub bearing (Worn) SA-10
7. Steering linkage (Loosen or worn) -
8. Steering gear (Out of adjustment or broken) SR-34
SR-46
SA-8
Abnormal tire wear
3. Suspension parts (Worn) -
SA-44
Author: Date: 817

SA-2
SUSPENSION AND AXLE - TIRE AND WHEEL
TIRE AND WHEEL SA110-03
INSPECTION
1. INSPECT TIRE
(a) Check the tires for wear and for the proper inflation pres-
sure.
Cold inflation pressure
Front Rear
Tire size
kPa (kgf/cm2, psi) kPa (kgf/cm2, psi)
155SR13 AS 240 (2.4, 34) 225 (2.25, 32)
(b) Check the tire runout.

Tire runout: 1.4 mm (0.055 in.) or less
R03031
Front 2. ROTATING TIRES

HINT:
See the illustration for where to rotate each tire.
R15157
3. INSPECT WHEEL BALANCE

(a) Check and adjust the Off-the-car balance.
(b) If necessary, check and adjust the On-the-car balance.
Unbalance after adjustment: 8.0 g (0.018 lb) or less
R07928
Author: Date: 818

SA-3
SUSPENSION AND AXLE - TIRE AND WHEEL
4. CHECK WHEEL BEARING LOOSENESS

(a) Check the backlash in bearing shaft direction.
Maximum: 0.05 mm (0.0020 in.)
(b) Check the axle hub deviation.
Maximum: 0.05 mm (0.0020 in.)
5. CHECK FRONT SUSPENSION FOR LOOSENESS
6. CHECK STEERING LINKAGE FOR LOOSENESS
7. CHECK BALL JOINT FOR LOOSENESS
R11682 8. CHECK SHOCK ABSORBER WORKS PROPERLY
Check for oil leaks
Check mounting bushings for wear
Bounce front and rear of the vehicle
Author: Date: 819

SA-4
SUSPENSION AND AXLE - FRONT WHEEL ALIGNMENT
Front FRONT WHEEL ALIGNMENT SA23E-01
INSPECTION
1. MEASURE VEHICLE HEIGHT
Tire size Front Rear
155SR13 187.9 mm (7.40 in.) 253.2 mm (9.97 in.)
Front measuring point:

Measure from the ground to the center of the lower suspension
arm front mounting bolt.
Rear Rear measuring point:
Measure from the ground to the center of the axle beam mount-
ing bolt.
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle
height to the specification.
If the vehicle height is not the specification, try to adjust it by
pushing down on or lifting the body.
R11681
R11753 F02280
2. INSTALL CAMBER-CASTER-KINGPIN GAUGE OR

ONTO WHEEL ALIGNMENT TESTER
Follow the specific instruction of the equipment manufacturer.
3. INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION
Camber -0 °20’ ± 45’
Left-right error 45’ (0.75°) or less
Caster 1°20’ ± 45
Z03382 Left-right error 45’ (0.75°) or less
Steering axis inclination 12°10’ ± 45’

HINT:
If the caster and steering axis inclination are not within the spec-
ification, after the camber has been correctly adjusted, recheck
the suspension parts for damaged and/or worn out parts.
4. INSPECT TOE-IN
A B
D Toe-in A + B: 0.1° ± 0.2°
Front (total) C - D: 1 ± 2 mm (0.04 ± 0.08 in.)
If the toe-in is not within the specification, adjust by the tie rod
end.
C
SA3213
Author: Date: 820

SA-5
5. ADJUST CAMBER
NOTICE:
After the camber has been adjusted, inspect the toe-in.
(a) Remove the front wheels.
(b) Remove the 2 nuts on the lower side of the shock absorb-
er.
(c) Coat the threads of the nuts with engine oil.
F03984
(d) Temporarily install the 2 nuts.

(e) Adjust the camber by pushing or pulling the lower side of
the shock absorber in the direction in which the camber
adjustment is required.
Adjusting value: 0°06’ - 0°30’
(f) Tighten the nuts.
Torque: 245 N·m (2,500 kgf·cm, 181 ft·lbf)
(g) Install the front wheels.
R15511 Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
(h) Check the camber.
Camber -0 °20’ ± 45’
HINT:
Try to adjust the camber to the center value.
Adjusting value for the set bolts is 6’ - 30’ (0.1° - 0.5°).
Author: Date: 821

SA-6
If the camber is not within the specification, using the table be-
low, estimate of how much additional camber adjustment will be
required, and select the camber adjusting bolt.
Set Bolt Adjusting Bolt

Bolt
90105-15001 90105-15004 90105-15005 90105-15006
1 Dot 2 Dots 3 Dots
Adjusting
Value
1 2 1 2 1 2 1 2
15’
30’
45’
1°00’
1°15’
1°30’
F01195
(i) Follow the above mentioned steps again. Between step

(b) and (c), exchange 1 or 2 selected bolts.
HINT:
When exchanging the 2 bolts, exchange 1 bolt for each time.
6. ADJUST TOE-IN
(a) Remove the boot clamps.
(b) Loosen the tie rod end lock nuts.
(c) Turn the left and right rack ends an equal amount to adjust
the toe-in.
Toe-in A + B: 0.1° ± 0.2°
(total) C - D: 1 ± 2 mm (0.04 ± 0.08 in.)
HINT:
W00533 Try to adjust the toe-in to the center value.
Make sure that the lengths of the left and right rack ends
are the same.
Tie rod end length difference: 1.5 mm (0.059 in.) or
less
(d) Torque the tie rod end lock nuts.
(e) Place the boots on the seat and install the clamps to them.
HINT:
W00533 Make sure that the boots are not twisted.
Author: Date: 822

SA-7
7. INSPECT WHEEL ANGLE

A B B A
Turn the steering wheel fully, and measure the turning angle.
Front Inside wheel 35°55’ ± 2°
Reference: Outside wheel 32°10’
If the wheel angles differ from the standard specifications, in-
spect the toe-in.
A: Inside
B: Outside
SA0028
Author: Date: 823

SA-8
SUSPENSION AND AXLE - REAR WHEEL ALIGNMENT
REAR WHEEL ALIGNMENT SA112-04
INSPECTION
1. MEASURE VEHICLE HEIGHT (See page SA-4 )
NOTICE:
Before inspecting the weel alignment, adjust the vehicle
height to the specitication.
2. INSPECT CAMBER
Camber -0 °30’ ± 45’
HINT:
Camber is not adjustable, if the measurement is not within the
specification, inspect and replace the suspension parts as nec-
essary.
A B 3. INSPECT TOE-IN
D
Toe-in A + B: 0.3° ± 0.3°
Front (total) C - D: 3 ± 3 mm (0.12 ± 0.12 in.)
HINT:
Toe-in is not adjustable, if the measurement is not within the
specification, inspect and replace the suspension parts as nec-
essary.
C
SA3213
Author: Date: 824

SA-9
SUSPENSION AND AXLE - FRONT AXLE HUB
FRONT AXLE HUB

SA113-04
COMPONENTS
Author: Date: 825

SA-10
SA114-03
REMOVAL
1. REMOVE FRONT WHEEL
2. w/ ABS
REMOVE BOLT AND ABS SPEED SENSOR
3. REMOVE FRONT BRAKE CALIPER AND DISC
(a) Remove the 2 bolts and brake caliper from the steering
knuckle.
Torque: 88 N·m (900 kgf·cm, 65 in.·lbf)
(b) Support the brake caliper securely.
(c) Remove the disc.
4. CHECK BACKLASH IN BEARING SHAFT DIRECTION

Using a dial indicator, check the backlash near the center of the
axle hub, and check the backlash in the bearing shaft direction.
Maximum: 0.05 mm (0.0020 in.)
If the backlash exceeds the maximum, replace the bearing.
5. CHECK AXLE HUB DEVIATION
Using a dial indicator, check the deviation at the surface of the
axle hub outside the hub bolt.
R11682 Maximum: 0.05 mm (0.0020 in.)
If the deviation exceeds the maximum, replace the axle hub.
6. REMOVE DRIVE SHAFT LOCK NUT
(a) Install the brake disc and caliper.
(b) Remove the cotter pin and lock cap.
(c) With applying the brakes, remove the nut.
(d) Remove the brake caliper and disc.
F03986
7. LOOSEN 2 NUTS ON LOWER SIDE OF SHOCK AB-

SORBER
HINT:
Do not remove the 2 bolts.
Coat the nut’s thread with engine oil.
F03987

SA-1 1
8. DISCONNECT TIE ROD END FROM STEERING

KNUCKLE
(a) Remove the cotter pin and nut.
(b) Using SST, disconnect the tie rod end from the steering
knuckle.
SST
SST 09628-6201 1
W00656
9. DISCONNECT LOWER BALL JOINT FROM LOWER

SUSPENSION ARM
Remove the 2 nuts and bolt.
10. REMOVE STEERING KNUCKLE WITH AXLE HUB
(a) Remove the 2 nuts and bolts on lower side of the shock
absorber.
(b) Remove the steering knuckle with the axle hub.
R11683 NOTICE:
Be careful not to damage the oil seal with the drive shaft.

SA-12
SA115-01
DISASSEMBLY
1. REMOVE LOWER BALL JOINT
(a) Remove the clip and nut.
(b) Using SST, remove the lower ball joint.

SST SST 09628-6201 1
2. REMOVE INNER OIL SEAL
Using a screwdriver, remove the inner oil seal.
3. REMOVE DUST COVER SET BOLTS
Using a torx wrench (T30), remove the 3 bolts.
SA3121
4. REMOVE AXLE HUB AND DUST COVER

(a) Using SST, remove the axle hub from the steering
knuckle.
SST 09520-00031
(b) Remove the dust cover.
SST
R11685
5. REMOVE INNER RACE (OUTSIDE) FROM AXLE HUB

SST
Using SST and a press, remove the inner race from the axle
hub.
SST 09631-12040, 09950-00020
R11686
6. REMOVE OUTER OIL SEAL

Using SST, remove the outer oil seal.
SST
SST 09308-00010
7. REMOVE BEARING FROM STEERING KNUCKLE
(a) Using snap ring pliers, remove the snap ring.
(b) Place the inner race on the outside of the bearing.
N00182

SA-13
(c) Using SST and a press, remove the bearing from the
steering knuckle.
SST SST 09223- 15020, 09950- 60010 (09951- 00650),
09950-70010 (09951-07150)
SST
R11687

SA-14
SA116-01
REASSEMBLY
1. INSTALL BEARING
SST (a) Using SST and a press, install a new bearing to the steer-
ing knuckle.
SST 09608-10010
NOTICE:
If the inner race and balls come loose from the bearing out-
er race, be sure to install them on the same side as before.
N00185
(b) Using snap ring pliers, install the snap ring.
2. INSTALL OUTER OIL SEAL

(a) Using SST and a hammer, install a new outer oil seal.
SST SST 09608-10010
(b) Coat the oil seal lip with MP grease.
3. INSTALL DUST COVER
(a) Place the dust cover on the steering knuckle.
(b) Using a torx wrench (T30), tighten the 3 bolts.
SA3199
4. INSTALL AXLE HUB

SST
Using SST and a press, install the axle hub.
SST 09608-10010, 09950-60010 (09951-00610)
5. INSTALL LOWER BALL JOINT
(a) Install the lower ball joint and tighten the nut.
(b) Install a new clip.
SST SA3200
6. INSTALL INNER OIL SEAL

(a) Using SST and a hammer, install a new inner oil seal.
SST SST 09608-10010
(b) Coat the oil seal lip with MP grease.
SA3201

SA-15
SA117-02
INSTALLATION
Installation is in the reverse order of removal (See page SA-10 ).
HINT:
After installation, check ABS speed sensor signal (See page DI-1 11 and SA-4 ).

SA-16
SUSPENSION AND AXLE - FRONT WHEEL HUB BOLT
FRONT WHEEL HUB BOLT SA118-03
REPLACEMENT
2. REMOVE BRAKE CALIPER AND DISC
(See page SA-10 )
3. REMOVE HUB BOLT

SST Using SST, remove the hub bolt.
SST 09628-1001 1
N00187
Washer 4. INSTALL HUB BOLT

Install washer and nut to the hub bolt, as shown in the illustra-
tion, and install the hub bolt with torquing the nut.
5. INSTALL DISC AND BRAKE CALIPER
(See page SA-10 )
6. INSTALL FRONT WHEEL
N00188
Author: Date: 832

SA-17
SUSPENSION AND AXLE - FRONT DRIVE SHAFT
FRONT DRIVE SHAFT

SA127-03
COMPONENTS
Author: Date: 833

SA-18
SA128-02
REMOVAL
NOTICE:
The hub bearing could be damaged if it is subjected
to the vehicle weight, such as when moving the ve-
SST hicle with the drive shaft removed. Therefore, if it is
absolutely necessary to place the vehicle weight on
the hub bearing, first support it with SST.
SST 09608-16042 (09608-02021, 09608-02041)
FA1535
w/ ABS:
After disconnecting the drive shaft from the axle hub,
work carefully so as not to damage the sensor rotor
serrations on the drive shaft.
2. M/T:
REMOVE LH ENGINE UNDER COVER
3. DRAIN TRANSAXLE OIL (M/T) OR ATF (A/T)
4. w/ ABS:
REMOVE BOLT AND ABS SPEED SENSOR
5. REMOVE DRIVE SHAFT LOCK NUT

(a) Remove the cotter pin and lock cap.
(b) While applying the brakes, remove the nut.
6. DISCONNECT TIE ROD END FROM STEERING
KNUCKLE (See page SA-10 )
7. DISCONNECT LOWER BALL JOINT FROM LOWER
SUSPENSION ARM (See page SA-10 )
F03986 8. DISCONNECT DRIVE SHAFT FROM AXLE HUB
NOTICE:
Be careful not to damage the drive shaft boot and inner oil
seal.

SA-19
LH Drive Shaft: 9. LH drive shaft:

M/T A/T REMOVE DRIVE SHAFT
(a) M/T:
Using a hammer, remove the drive shaft.
(b) A/T:
Using a hammer and hub nut wrench or an equivalent, re-
move the drive shaft.
Z18939
RH Drive Shaft: 10. RH drive shaft:

REMOVE DRIVE SHAFT
Using a brass bar and hammer, remove the drive shaft.
11. REMOVE SNAP RING
Using a screwdriver, remove the snap ring from the inboard joint
shaft.
Z18938

SA-20
SA129-06
DISASSEMBLY
1. CHECK DRIVE SHAFT
(a) Check to see that there is no play in the outboard joint.
(b) Check to see that the inboard joint slides smoothly in the
thrust direction.
(c) Check to see that there is no remarkable play in the radial
direction of the inboard joint.
2. REMOVE INBOARD JOINT TULIP
N00191
(a) Using a screwdriver, remove the 2 boot clamps.
(b) Place matchmarks on the inboard joint tulip and tripod.

(c) Remove the inboard joint tulip from the drive shaft.
3. REMOVE TRIPOD
(a) Using a snap ring expander, remove the snap ring.
Matchmarks
R11817
(b) Place matchmarks on the shaft and tripod.

(c) Using a brass bar and hammer, remove the tripod joint
from the drive shaft.
4. REMOVE INBOARD JOINT BOOT AND 2 BOOT
CLAMPS
5. RH DRIVE SHAFT:
REMOVE DYNAMIC DAMPER
Matchmarks (a) Using a screwdriver, remove the damper clamp.
N00194 (b) Remove the damper from the drive shaft.
6. REMOVE OUTBOARD JOINT BOOT
(a) Using a screwdriver, remove the 2 boot clamps.
(b) Remove the boot and 2 boot clamp from the outboard
joint.
NOTICE:
Do not disassemble the outboard joint.
7. REMOVE DUST COVER

Using SST and a press, remove the dust cover from the inboard
SST
joint tulip.
SST 09950-00020
8. w/o ABS:
REMOVE NO.2 DUST DEFLECTOR
(a) Mount the outboard joint in a soft jaw vise.
(b) Using a screwdriver, remove the No.2 dust deflector.
R09716

SA-21
SA12A-05
REASSEMBLY
1. w/o ABS:
SST INSTALL DUST DEFLECTOR NO.2
Using SST and a press, install a new dust deflector No.2.
SST 09309-36010, 09316-20011
R11822
2. INSTALL DUST COVER

Using a press, install a new dust cover to the inboard joint tulip.
SA1459
3. TEMPORARILY INSTALL BOOTS, CLAMPS AND

Inboard Joint Boot Outboard Joint Boot
DAMPER (RH DRIVE SHAFT)
HINT:
Before installing the boots, wrap vinyl tape around the spline of
the drive shaft to prevent damaging the boot.
(a) Temporarily install a new outboard joint boot.
(b) RH drive shaft:
Temporarily install the damper.
R09694 (c) Temporarily install a new inboard joint boot.
4. INSTALL TRIPOD
(a) Place the beveled side of the tripod axial spline toward the
outboard joint.
(b) Align the matchmarks before removal.
(c) Using a brass bar and hammer, tap in the tripod to the
drive joint shaft.
NOTICE:
Do not tap the roller.
(d) Using a snap ring expander, install a new snap ring.
5. INSTALL BOOT TO OUTBOARD JOINT
Before assembling the boot, pack the outboard joint and boot
with grease in the boot kit.
Grease capacity: 65 - 75 g (2.3 - 2.6 oz.)
6. INSTALL INBOARD JOINT TO FRONT DRIVE SHAFT
(a) Pack the inboard tulip and boot with grease in the boot kit.
Grease capacity: 112 - 122 g (4.0 - 4.3 oz.)
(b) Align the matchmarks as they were placed before disas-
sembly
(c) Install the inboard joint tulip to the drive shaft.
(d) Temporarily install the boot to the inboard joint shaft.

SA-22
7. ASSEMBLE BOOT CLAMPS TO BOTH BOOTS

(a) Make sure the boot are on the shaft groove.
(b) Set the drive shaft length to the standard.

RH
Standard length
RH 785.1 ± 5.0 mm (30.909 ± 0.197 in.)
LH 544.9 ± 5.0 mm (21.421 ± 0.197 in.)
LH (c) Place the 4 new boot clamps to the boots.

(d) Bend the band, and lock it with a screwdriver.
Z12938
8. RH DRIVE SHAFT:
ASSEMBLE DYNAMIC DAMPER CLAMP
(a) Be sure the damper is on the shaft groove.
(b) Set the distance, as shown.
Distance: 361.4 ± 5.0 mm (14.335 ± 0.197 in.)
(c) Place a new damper clamp to the damper.
(d) Bend the band and lock it in the same procedure for the
boot clamp assembly.
R09908 9. INSTALL SNAP RING
Using a snap ring expander, install a new snap ring to the in-
board joint shaft.
10. CHECK DRIVE SHAFT (See page SA-20 )

SA-23
SA12B-02
INSTALLATION
HINT:
After installation, check ABS speed sensor signal and front wheel alignment (See page DI-1 11 and
SA-4 ).

SA-24
SUSPENSION AND AXLE - FRONT SHOCK ABSORBER
FRONT SHOCK ABSORBER

SA119-05
COMPONENTS
Author: Date: 840

SA-25
SA1W8-02
REMOVAL
2. REMOVE FLEXIBLE HOSE
Remove the bolt and disconnect the flexible hose from the shock absorber.
3. w/ ABS:
DISCONNECT ABS SPEED SENSOR WIRE HARNESS
Remove the bolt and disconnect the ABS speed sensor wire harness from the shock absorber.
4. DISCONNECT SHOCK ABSORBER FROM STEERING KNUCKLE
Remove the 2 nuts and bolts and disconnect the shock absorber from steering knuckle,
HINT:
Coat the nut’s threads with engine oil.
5. REMOVE SHOCK ABSORBER AND COIL SPRING
(a) Remove the 3/4 nuts on the upper side of the shock absorber.
(b) Remove the shock absorber with the coil spring.

SA-26
SA1W9-01
DISASSEMBLY
REMOVE COIL SPRING
(a) Using SST, compress the coil spring.
SST 09727-30021
NOTICE:
Do not use an impact wrench. It will damage the SST.
SST (b) Install 2 nuts and bolt to the bracket at the lower part of
the shock absorber and secure it in a vise.
F02799
(c) Using SST, to hold the spring seat, remove the nut.
SST SST 09729-22031
(d) Remove these parts:
Suspension support.
Dust seal.
Spring seat.
Upper insulator.
Coil spring.
W03398 Spring bumper.
Lower insulator.

SA-27
SA11C-02
INSPECTION
INSPECT SHOCK ABSORBER
Compress and extend the shock absorber rod and check that
there is no abnormal resistance or unusual operation sound.
If there is any abnormality, replace the shock absorber with a
new one.
NOTICE:
When disposing of the shock absorber, use the following
R11754
procedure.

SA-28
SA11D-02
DISPOSAL
1. FULLY EXTEND SHOCK ABSORBER ROD
2. DRILL HOLE TO REMOVE GAS FROM CYLINDER
Using a drill, make a hole in the cylinder, as shown to remove
the gas inside.
CAUTION:
The gas coming out is harmless, but be careful of chips
which may fly up when drilling.
R11755

SA-29
SA1WA-01
REASSEMBLY
SST 1. INSTALL LOWER INSULATOR ONTO SHOCK AB-
SORBER
2. INSTALL COIL SPRING AND SUSPENSION SUPPORT
(a) Using SST, compress the coil spring.
SST 09727-30021
NOTICE:
Do not use an impact wrench. It will damage the SST.
W03399
(b) Install the spring bumper to the piston rod.
(c) Install the coil spring to the shock absorber.
HINT:
Fit the lower end of the coil spring into the gap of the spring seat
of shock absorber.
(d) Install the spring seat with the upper insulator.
(e) Install the dust seal and suspension support.
MP Grease (f) Using SST, to hold the spring seat, install a new nut.
SST 09729-22031
SST (g) Remove the SST.
(h) Pack the suspension support with MP grease.
(i) Install the cap.
W03400

SA-30
SA11F-02
INSTALLATION
HINT:
After installation, check front wheel alignment (See page SA-2 ).

SA-31
SUSPENSION AND AXLE - FRONT LOWER SUSPENSION ARM
FRONT LOWER SUSPENSION ARM

SA11G-04
COMPONENTS
Author: Date: 847

SA-32
SA11H-04
REMOVAL
2. DISCONNECT LOWER SUSPENSION ARM FROM

LOWER BALL JOINT
Remove the 2 nuts and bolt.
R11688
3. REMOVE LOWER SUSPENSION ARM

Remove the 3 bolts, lower suspension arm.
Torque:
A: 142 N·m (1,450 kgf·cm, 105 ft·lbf)
B: 74 N·m (750 kgf·cm, 55 ft·lbf)
HINT:
After stabilizing the suspension, torque the bolts.
Z14904

SA-33
SA11I-02
INSTALLATION
HINT:
After installation, check front wheel alignment (See page SA-4 ).

SA-34
SUSPENSION AND AXLE - FRONT LOWER BALL JOINT
FRONT LOWER BALL JOINT

SA11J-05
COMPONENTS
Author: Date: 850

SA-35
SA11K-01
REMOVAL
SST
1. REMOVE STEERING KNUCKLE WITH AXLE HUB
(See page SA-10 )
2. REMOVE LOWER BALL JOINT
(a) Remove the clip and nut.
(b) Using SST, remove the lower ball joint.
SST 09628-6201 1
SA3121

SA-36
SA11L-05
INSPECTION
INSPECT LOWER BALL JOINT FOR ROTATION CONDI-
TION
(a) As shown flip the ball joint stud back and forth 5 times, be-
fore installing the nut.
(b) Using a torque wrench, turn the nut continuously one turn
per 2 - 4 seconds and take the torque reading on the 5th
turn.
N00208
Turning torque:
0.78 - 2.45 N·m (8 - 25 kgf·cm, 7.0 - 22.0 in.·lbf)

BR-1
BRAKE - BRAKE SYSTEM
BRAKE SYSTEM
BR0R8-01
PRECAUTION
Care must be taken to replace each part properly as it could affect the performance of the brake
system and result in a driving hazard. Replace the parts with parts having the same part number
or equivalent.
It is very important to keep parts and the area clean when repairing the brake system.
If the vehicle is equipped with a mobile communication system, refer to the precaution in the
IN section.
Author: Date: 875

BR-2
BRAKE - TROUBLESHOOTING
TROUBLESHOOTING
BR0R9-06

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
1. Brake system (Fluid leaks) DI-145
2. Brake system (Air in) BR-4
3. Piston seals (Worn or damaged) BR-23
Lower pedal or spongy pedal
4. Rear brake shoe clearance (Out of adjustment) BR-33
5. Master cylinder (Faulty) BR-9
6. Booster push rod (Out of adjustment) BR-18
1. Brake pedal freeplay (Minimal) BR-6

2. Parking brake lever travel (Out of adjustment) BR-8
3. Parking brake wire (Sticking) -
5. Pad or lining (Cracked or distorted) BR-20
BR-29
Brake drag
6. Piston (Stuck) BR-23
7. Piston (Frozen) BR-23
8. Anchor or return spring (Faulty) BR-29
10. Booster system (Vacuum leaks) BR-16
11. Master cylinder (Faulty) BR-9
1. Piston (Stuck) BR-23
2. Pad or lining (Oily) BR-20
BR-29
Brake pull 3. Piston (Frozen) BR-23
4. Disc (Scored) BR-23
BR-29
1. Brake system (Fluid leaks) DI-145
2. Brake system (Air in) BR-4
3. Pad or lining (Worn) BR-20
BR-29
BR-29
Hard pedal but brake inefficient
6. Pad or lining (Oily) BR-20
BR-29
7. Pad or lining (Glazed) BR-20
BR-29
10. Booster system (Vacuum leaks) BR-9
Author: Date: 876

BR-3
BRAKE - TROUBLESHOOTING

BR-29
2. Installation bolt (Loosen) BR-23
4. Pad support plate (Loosen) BR-23
5. Sliding pin (Worn) BR-23
Noise from brake 6. Pad or lining (Dirty) BR-20
BR-29
7. Pad or lining (Glazed) BR-23
BR-29
8. Anchor or return spring (Faulty) BR-29
9. Anti-squeal shim (Damage) BR-20
10. Hold-down spring (Damage) BR-29
Author: Date: 877

BR-4
BRAKE - BRAKE FLUID
BRAKE FLUID BR0RA-07
BLEEDING
HINT:
If any work is done on the brake system or air in the brake lines
is suspected, bleed the system of air.
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
1. FILL BRAKE RESERVOIR WITH BRAKE FLUID

Fluid: SAEJ1703 or FMVSS No.116 DOT3
BR5038
2. BLEED MASTER CYLINDER

HINT:
If the master cylinder has been disassembled or the reservoir
becomes empty, bleed the master cylinder.
(a) Disconnect the brake lines from the master cylinder.
(b) Slowly depress the brake pedal and hold it.
BR5040
(c) Block off the outer holes with your finger and release the
brake pedal.
(d) Repeat (b) and (c) 3 or 4 times.
BR5039
3. BLEED BRAKE LINE

(a) Connect the vinyl tube to the brake caliper.
(b) Depress the brake pedal several times, then loosen the
bleeder plug with the pedal held down.
(c) At the point when fluid stops coming out, tighten the
bleeder plug, then release the brake pedal.
(d) Repeat (b) and (c) until all the air in the fluid has been bled
out.
BR3885 (e) Repeat the above procedure to bleed the air out of the
brake line for each wheel.
Author: Date: 878

BR-5
BRAKE - BRAKE FLUID
4. CHECK FLUID LEVEL IN RESERVOIR

Check the fluid level and add fluid if necessary.
Fluid: SAEJ1703 or FMVSS No.116 DOT3
Author: Date: 879

BR-6
BRAKE - BRAKE PEDAL
Stop Light Switch BRAKE PEDAL BR1DT-01
Push Rod ON-VEHICLE INSPECTION

1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
EZ Grade:
143.0 - 153.0 mm (5.630 - 6.024 in.)
Except EZ Grade:
140.0 - 150.0 mm (5.512 - 5.906 in.)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Disconnect the connector from the stop light switch.
(b) Loosen the stop light switch lock nut and remove the stop
light switch.
(c) Loosen the push rod lock nut.
(d) Adjust the pedal height by turning the pedal push rod.
(e) Tighten the push rod lock nut.
Pedal Height
R12354
(f) Install the stop light switch and turn it until it lightly con-
tacts the pedal stopper.
(g) Turn the stop light switch back one turn.
A
(h) Check the clearance (A) between stop light switch and
pedal.
Clearance: 0.5 - 2.4 mm (0.020 - 0.094 in.)
(i) Tighten the stop light switch lock nut.
(j) Connect the connector to the stop light switch.
(k) Check the stop lights come on when the brake pedal is de-
pressed, and go off when the brake pedal is released.
BR4980
(l) After adjusting the pedal height, check the pedal freeplay.
HINT:
If clearance (A) between the stop light switch and the brack ped-
al stopper has been adjusted correctly, the pedal freeplay will
meet the specifications.
Author: Date: 880

BR-7
BRAKE - BRAKE PEDAL
3. CHECK PEDAL FREEPLAY

(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the booster.
(b) Push in the pedal by hand until the resistance begins to
be felt, then measure the distance, as shown.
Pedal freeplay: 1 - 6 mm (0.04 - 0.24 in.)
If incorrect, check the stop light switch clearance. If the clear-
ance is OK, then troubleshoot the brake system.
Pedal Freeplay
R12355
4. CHECK PEDAL RESERVE DISTANCE

(a) Release the parking brake.
Pedal Reserve Distance (b) With the engine running, depress the pedal and measure
the pedal reserve distance.
Pedal reserve distance from asphalt sheet at 490 N
(50 kgf, 110.2 lbf):
w/o ABS: More than 60 mm (2.36 in.)
w/ ABS: More than 55 mm (2.17 in.)
BR4228 If the reserve distance is incorrect, troubleshoot the brake sys-
tem.
Author: Date: 881

BR-8
BRAKE - PARKING BRAKE LEVER
PARKING BRAKE LEVER BR0RC-06
ON-VEHICLE INSPECTION
1. CHECK PARKING BRAKE LEVER TRAVEL
Pull the parking brake lever all the way up, and count the num-
ber of clicks.
Parking brake lever travel at 196 N (20 kgf, 44.1 lbf):
5 - 8 clicks
BR0786
2. IF NECESSARY, ADJUST PARKING BRAKE

HINT:
Before adjusting the parking brake, make sure that the rear
brake shoe clearance has been adjusted.
For shoe clearance adjustment, see step 2 on page BR-33 .
(a) Remove the console box.
(b) Loosen the lock nut and turn the adjusting nut until the le-
ver travel is correct.
BR5045 (c) Tighten the lock nut.
(d) Install the console box.
Author: Date: 882

BR-9
BRAKE - BRAKE MASTER CYLINDER
BRAKE MASTER CYLINDER

BR0RD-06
COMPONENTS
Air Cleaner Assembly
Brake Booster
w/o ABS:
Clamp
w/ ABS: Gasket
2-way Master Cylinder
w/o ABS:
w/ ABS:
Cap Cap
Stariner
Stariner
Reservoir
No.1 Piston and Spring No.1 Piston and Spring
Reservoir Snap Ring
Grommet Grommet
Snap Ring
No.2 Piston and Spring
No.2 Piston and Spring
Reservoir Set Screw
Master Cylinder Body
Reservoir Gasket
Master Cylinder Body Gasket
Set Screw
Piston Stopper Bolt
Non-reusable part
Lithium soap base glycol grease
F04745
Author: Date: 883

BR-10
BR0RE-01
REMOVAL
1. REMOVE AIR CLEANER ASSEMBLY
2. DISCONNECT LEVEL WARNING SWITCH CONNEC-
TOR
3. DRAW OUT FLUID WITH SYRINGE
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
4. DISCONNECT BRAKE LINES

Using SST, disconnect the brake lines from the master cylinder.
SST 09751-3601 1
SST
BR5042
5. REMOVE MASTER CYLINDER

(a) w/o ABS:
Remove the 2 mounting nuts, clamp and pull out the mas-
ter cylinder and gasket.
(b) w/ ABS:
Remove the 2 mounting nuts, 2-way and pull out the
master cylinder and gasket.
BR5041 Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)

BR-1 1
BR0RF-06
DISASSEMBLY
1. REMOVE RESERVOIR
(a) Remove the set screw and pull out the reservoir.
Torque: 1.7 N·m (17.5 kgf·cm, 15.2 in.·lbf)
(b) Remove the cap and strainer from the reservoir.
2. REMOVE 2 GROMMETS
3. PLACE CYLINDER IN VISE
4. REMOVE PISTON STOPPER BOLT

Soft Jaws
Using a screwdriver, push the pistons in all the way and remove
the piston stopper bolt and gasket.
HINT:
Tape the screwdriver tip before use.
BR5036
Soft Jaws 5. REMOVE PISTONS

(a) Push in the piston with a screwdriver and remove the
snap ring with snap ring pliers.
(b) Remove the No.1 piston and spring by hand, pulling
straight out, not at an angle.
NOTICE:
If pulled out and installed at an angle, there is a possi-
bility that the cylinder bore could be damaged.
BR5037 Be careful not to damage the rubber lips on the pis-
tons.
(c) Place a rag and 2 wooden blocks on the work table and
lightly tap the cylinder flange against the block edges until
the No.2 piston drops out of the cylinder.
HINT:
Make sure the distance (A) from the rag to the top of the blocks
is at least 100 mm (3.94 in.).
R12236

BR-12
BR0RG-01
INSPECTION
HINT:
Clean the disassembled parts with compressed air.
1. INSPECT CYLINDER BORE FOR RUST OR SCORING
2. INSPECT CYLINDER FOR WEAR OR DAMAGE
If necessary, clean or replace the cylinder.

BR-13
BR0RH-02
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR-1 1).
NOTICE:
Apply lithium soap base glycol grease to the rubber parts indicated by arrows (See page BR-9 ).

BR-14
BR0RI-05
INSTALLATION
Installation is in the reverse order of removal (See page BR-10 ).
1. BEFORE INSTALLATION, ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD (See page
BR-18 )
2. AFTER INSTALLATION, FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE
SYSTEM (See page BR-4 )
3. CHECK FOR LEAKS, CHECK AND ADJUST BRAKE PEDAL (See page BR-6 )

BR-15
BRAKE - BRAKE BOOSTER ASSEMBLY
BRAKE BOOSTER ASSEMBLY BR0RJ-01
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine off
and check that there is no change in the pedal reserve
distance.
(b) Depress the brake pedal and start the engine. If the pedal
BR2237
goes down slightly, operation is normal.
2. AIR TIGHTNESS CHECK

GOOD NO GOOD (a) Start the engine and stop it after 1 or 2 minutes. Depress
the brake pedal several times slowly.
If the pedal goes down farthest the 1st time, but gradually rises
after the 2nd or 3rd time, the booster is air tight.
(b) Depress the brake pedal while the engine is running, and
3rd stop the engine with the pedal depressed. If there is no
2nd change in the pedal reserve travel after holding the pedal
1st
BR2238 for 30 seconds, the booster is air tight.
Author: Date: 889

BR-16
BR0RK-06
COMPONENTS
Air Cleaner Assembly
Vacuum Hose
Gasket
Clip
w/o ABS: Gasket Pin
Clamp Clip
Clevis
w/ ABS:
2-way
Master Cylinder
Brake Booster
Non-reusable part R12151

BR-17
BR0RL-01
REMOVAL
1. REMOVE MASTER CYLINDER (See page BR-10 )
2. DISCONNECT VACUUM HOSE FROM BRAKE
BOOSTER
3. REMOVE PEDAL RETURN SPRING
4. REMOVE CLIP AND CLEVIS PIN
5. REMOVE BRAKE BOOSTER

(a) Remove the No.1 brake line clamp.
F05027
(b) Remove the No.2 brake line clamp.
BR5055
(c) Remove the 4 nuts and clevis.

(d) Pull out the brake booster and gasket.
R04651

BR-18
BR0RM-04
INSTALLATION
1. INSTALL BRAKE BOOSTER
(a) Install the booster and a new gasket.
(b) Install the clevis to the operating rod.
(c) Install and torque the booster installation nuts.
(d) Insert the clevis pin into the clevis and brake pedal, and
install the clip to the clevis pin.
(e) Install the pedal return spring.
(f) Install the No.1 brake line clamp to the body.
(g) Install the No.2 brake line clamp to the body.
2. ADJUST LENGTH OF BOOSTER PUSH ROD

(a) Install the gasket on the master cylinder.
SST (b) Set SST on the gasket, and lower the pin until its tip slight-
ly touches the piston.
Gasket SST 09737-00010
F03521
(c) Turn SST upside down, and set it on the booster.

SST SST 09737-00010
(d) Measure the clearance between the booster push rod
and pin head (SST).
Clearance: 0 mm (0 in.)
(e) Adjust the booster push rod length until the push rod
slightly touches the pin head.
HINT:
BR1728 BR0021 N00744 When loosening the push rod nut, depress the brake pedal
enough so that the push rod sticks out.
3. INSTALL MASTER CYLINDER
4. CONNECT VACUUM HOSE TO BRAKE BOOSTER
5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See page BR-4 )
6. CHECK FOR LEAKS

BR-19
7. CHECK AND ADJUST BRAKE PEDAL

(See page BR-6 )
Check and adjust the brake pedal, then tighten the clevis lock
nut.
8. DO OPERATIONAL CHECK
(See page BR-15 )

BR-20
BRAKE - FRONT BRAKE PAD
FRONT BRAKE PAD

BR0RN-05
COMPONENTS
Author: Date: 894

BR-21
BR0RO-03
REPLACEMENT
Remove the wheel and temporarily fasten the disc with hub
nuts.
2. INSPECT PAD LINING THICKNESS

Check the pad thickness through the caliper inspection hole
and replace the pads if they are not within the specification.
Minimum thickness: 1.0 mm (0.039 in.)
BR4213
3. REMOVE CALIPER
(a) Remove the 2 installation bolts from the torque plate.
(b) Remove the caliper and suspend it securely.
HINT:
Do not disconnect the flexible hose.
4. REMOVE THESE PARTS:
(a) 2 brake pads
(b) 3 anti-squeal shims
BR4214 (c) Pad wear indicator plate
(d) 4 pad support plates
NOTICE:
The support plates can be used again provided that they
have sufficient rebound, no deformation, cracks or wear,
and have had all rust, dirt and foreign particles cleaned off.
5. CHECK DISC THICKNESS AND RUNOUT
(See page BR-26 )
6. INSTALL 4 PAD SUPPORT PLATES
7. INSTALL NEW PADS

NOTICE:
When replacing worn pads, the anti-squeal shims and
wear indicator plates must be replaced together with the
pads.
(a) Install a pad wear indicator plate on the inner pad.
(b) Apply disc brake grease to the anti-squeal shims (See
page BR-23 ).
BR0272 (c) Install the 2 anti-squeal shims on the outer pad.
(d) Install the anti-squeal shim on the inner pad
BR-22
(e) Install inner pad with the pad wear indicator plate facing
upward.
(f) Install outer pad.
NOTICE:
There should be no oil or grease adhering to the friction
surfaces of the pads or the disc.
8. INSTALL CALIPER
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in the piston with a hammer handle or an equiva-
lent.
HINT:
If the piston is difficult to push in, loosen the bleeder plug and
push in the piston while letting some brake fluid escape.
(c) Install the caliper.
N00746 (d) Install and torque the 2 installation bolts.
9. INSTALL FRONT WHEEL
10. CHECK THAT FLUID LEVEL IS AT MAX LINE

BR-23
BRAKE - FRONT BRAKE CALIPER
FRONT BRAKE CALIPER

BR0RP-06
COMPONENTS
Author: Date: 897

BR-24
BR0RQ-05
REMOVAL
1. DISCONNECT FLEXIBLE HOSE
(a) Remove the union bolt and 2 gaskets from the caliper,
then disconnect the flexible hose from the caliper.
HINT:
Install the flexible hose lock securely in the lock hole in the cali-
per.
BR4220
(b) Use a container to catch the brake fluid as it drains out.
2. REMOVE CALIPER
Remove the 2 installation bolts, and caliper.
(a) 2 brake pads with anti-squeal shims.
(b) 4 pad support plates.

BR-25
BR0RR-03
DISASSEMBLY
(a) 2 sliding bushings.
(b) 4 dust boots.
BR3964 BR3965 N00747
2. REMOVE CYLINDER BOOT SET RING AND CYL-

INDER BOOT
Using a screwdriver, remove the cylinder boot set ring and cylin-
der boot from the caliper.
BR3966
3. REMOVE PISTON
(a) Place a piece of cloth or similar, between the piston and
the caliper.
(b) Use compressed air to remove the piston from the cylin-
der.
CAUTION:
Do not place your fingers in front of the piston when using
compressed air.
BR3968
4. REMOVE PISTON SEAL

Using a screwdriver, remove the piston seal from the cylinder.
BR3969

BR-26
BR0RS-07
INSPECTION
1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness: 10.0 mm (0.394 in.)
Replace the pad if the pad’s thickness is at the minimum thick-
ness or less, or if the pad has severe and uneven wear.
BR4362
2. MEASURE DISC THICKNESS

Using a micrometer, measure the disc thickness.
Replace the disc if the disc’s thickness is at the minimum thick-
ness or less. Replace the disc or grind it on a lathe if it is badly
scored or worn unevenly.
BR4237
3. MEASURE DISC RUNOUT

Using a dial indicator, measure disc runout 10 mm (0.39 in.)
away from the outer.
Maximum disc runout: 0.07 mm (0.0028 in.)
If the disc’s runout is the maximum value or greater, check the
bearing play is in the axial direction and check the axle hub run-
out (See page SA-10 ). If the bearing play and axle hub runout
are not abnormal, adjust the disc runout or grind it on a ”On-car”
BR4238 brake late.
4. IF NECESSARY, ADJUST DISC RUNOUT

(a) Remove the torque plate from the knuckle.
(b) Remove the hub nuts and the disc. Reinstall the disc in
the position turned 1/4 from its original position on the
hub. Install and torque the hub nuts.
Remeasure the disc runout. Make a note of the runout and the
disc’s position on the hub.
BR4221 (c) Repeat (b) until the disc has been installed on the 2 re-
maining hub positions.
(d) If the minimum runout recorded in (b) and (c) is less than
0.07 mm (0.0028 in.), install the disc in that position.
(e) If the minimum runout recorded in (b) and (c) is greater
than 0.07 mm (0.0028 in.), replace the disc and repeat
step 3.
(f) Install the torque plate and fighten the 2 bolts.

BR-27
BR0RT-04
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR-25 ).
NOTICE:
Apply lithium soap base glycol grease to the parts indicated by arrows (See page BR-23 ).

BR-28
BR0RU-04
INSTALLATION
1. AFTER INSTALLATION, FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE
SYSTEM (See page BR-4 )
2. CHECK FOR LEAKS

BR-29
BRAKE - REAR DRUM BRAKE
REAR DRUM BRAKE

BR0RV-04
COMPONENTS
Author: Date: 903

BR-30
BR0RW-03
REMOVAL
1. INSPECT SHOE LINING THICKNESS
Remove the inspection hole plug, and check the shoe lining
thickness through the hole.
If less than minimum, replace the shoes.
2. REMOVE REAR WHEEL
BR4239
3. REMOVE BRAKE DRUM (See page SA-39 )

HINT:
If the brake drum cannot be removed easily, do the following
steps.
(a) Insert a screwdriver through the hole in the backing plate,
and hold the automatic adjusting lever away from the ad-
juster.
(b) Using another screwdriver, reduce the brake shoe adjust-
BR4240 er by turning the adjusting wheel.
4. REMOVE FRONT SHOE

(a) Using, remove the return spring and calmp.
BR0405 BR0406 N00750
(b) Using SST, remove the shoe hold-down spring, cups and
pin.
SST 09718-00010
(c) Disconnect the anchor spring from the front shoe and re-
SST move the front shoe.
(d) Remove the anchor spring from the rear shoe.
5. REMOVE REAR SHOE
(a) Using SST, remove the shoe hold-down spring, cups and
BR4241 pin.
SST 09718-00010
(b) Using pliers, remove the adjusting lever spring.
(c) Remove the adjuster.

BR-31
(d) Using pliers, disconnect the parking brake cable from the
parking brake lever and remove the rear shoe.
6. REMOVE AUTOMATIC ADJUSTING LEVER AND
PARKING BRAKE LEVER
(a) Remove the E-ring.
(b) Remove the automatic adjusting lever.
(c) Remove the C-washer.
(d) Remove the parking brake lever.
BR4387
7. REMOVE WHEEL CYLINDER

(a) Using SST, disconnect the brake line. Use a container to
SST catch the brake fluid.
SST 09751-3601 1
(b) Remove the 2 bolts and the wheel cylinder.
BR3027
8. DISASSEMBLE WHEEL CYLINDER

Remove the these parts from the wheel cylinder.
2 boots
2 pistons
2 piston cups
Spring
BR0370

BR-32
BR0RX-01
INSPECTION
1. INSPECT DISASSEMBLED PARTS
Inspect the disassembled parts for wear, rust or damage.
2. MEASURE BRAKE SHOE LINING THICKNESS

Using a ruler, measure the shoe lining thickness.
If the thickness is less than the minimum or shoe lining shows
signs of uneven wear, replace the brake shoes.
HINT:
If a brake shoes needs replacing, the brake shoes must be re-
BR4081 placed as a set
3. MEASURE BRAKE DRUM INSIDE DIAMETER

Using a vernier calipers, measure the inside diameter of the
drum.
Standard inside diameter: 180.0 mm (7.087 in.)
Maximum inside diameter: 181.0 mm (7.126 in.)
If the drum is scored or worn, the brake drum may be lathed to
the maximum inside diameter.
BR0394
4. INSPECT REAR BRAKE LINING AND DRUM FOR

PROPER CONTACT
If the contact between the brake lining and drum is improper, re-
pair the lining with a brake shoe grinder, or replace the brake
shoe assembly.
BR0395

BR-33
BR0RY-04
INSTALLATION
Installation is in the reverse order of removal (See page
BR-30 ).
1. AFTER INSTALLATION, FILL BRAKE RESERVOIR
WITH BRAKE FLUID, BRAKE SYSTEM
NOTICE:
Apply lithium soap base glycol grease and high tempera-
ture grease to the parts indicated by the arrows (See page
BR-29 ).
2. CHECK OPERATION OF AUTOMATIC ADJUSTING

MECHANISM
(a) Move the parking brake lever of the rear shoe back and
forth. Check that the adjuster turns.
If the adjuster does not turn, check for incorrect installation of
the rear brake.
(b) Adjust the adjuster length to the as short as possible.
BR4247
(c) Install the brake drum.

(d) Pull the parking brake lever all the way up until a clicking
sound can no longer be heard.
3. CHECK CLEARANCE BETWEEN BRAKE SHOES AND
DRUM
(a) Remove the brake drum (See page SA-39 ).
BR0376 BR0412 N00755
(b) Measure the brake drum inside diameter and diameter of

the brake shoes. Check that the difference between the
diameters is the correct shoe clearance.
Shoe clearance: 0.6 mm (0.024 in.)
If incorrect, check the parking brake system.
(c) Install the brake drum (See page SA-42 ).
BR0394 BR0413 N00756

BR-34
BRAKE - PROPORTIONING VALVE (P VALVE)
PROPORTIONING VALVE (P VALVE)

BR0RZ-06
1. INSTALL LSPV GAUGE (SST)
SST 09709-29018
SST
SST
R04666
2. BLEED AIR FROM FLUID PRESSURE GAUGE

3. RAISE FRONT BRAKE CALIPER PRESSURE AND CHECK REAR WHEEL CYLINDER PRES-
SURE
w/o ABS
Front brake caliper pressure Rear wheel cylinder pressure
2,452 kPa (25 kgf/cm2, 356 psi) 2,452 kPa (25 kgf/cm2, 356 psi)
7,845 kPa (80 kgf/cm2, 1,138 psi) 3,805 kPa (38.8 kgf/cm2, 552 psi)
w/ ABS
Front brake caliper pressure Rear wheel cylinder pressure
2,942 kPa (30 kgf/cm2, 427 psi) 2,942 kPa (30 kgf/cm2, 427 psi)
7,845 kPa (80 kgf/cm2, 1,138 psi) 4,168 kPa (42.5 kgf/cm2, 604 psi)
When inspecting the fluid pressure, inspect the left front and right rear together, and the right front and left
rear together.
If the rear wheel cylinder pressure is incorrect, replace the P valve assembly.
4. BLEED BRAKE SYSTEM (See page BR-4 )
5. CHECK FOR LEAKS
Author: Date: 908

BR-35
BRAKE - ABS ACTUATOR
ABS ACTUATOR BR1DU-01
1. INSPECT BATTERY POSITIVE VOLTAGE
Battery positive voltage: 10 - 14 V
2. DISCONNECT CONNECTORS
(a) Disconnect the 2 connectors from the control relay.
(b) Disconnect the connector from the actuator.
3. CONNECT ACTUATOR CHECKER (SST) TO ACTUA-

TOR
(a) Connect the actuator checker (SST) to the actuator, con-
trol relay and body side wire harnesses through the sub-
wire harnesses C and I (SST), as shown.
SST 09990-00150, 09990-00200, 09990-00300
(b) Connect the red cable of the checker to the battery posi-
tive (+) terminal and black cable to the negative (-) termi-
F04750 nal. Connect the black cable of the sub-wire harnesses
to the battery negative (-) terminal or body ground.
(c) Place the ”SHEET A” (SST) on the actuator checker.
SST 09990-00163
Sub-Wire Harness C (SST)

(SST)
Control Relay
To Body
To Body
ABS
Actuator Sub-Wire Harness I (SST)
R04103
Author: Date: 909

BR-36
4. INSPECT BRAKE ACTUATOR OPERATION

(a) Start the engine, and run it at idle.
(b) Turn the selector switch of the actuator checker to
”FRONT RH” position.
(c) Push and hold in the MOTOR switch for a few seconds.
Make sure that you can hear the motor running.
(d) Depress the brake pedal and hold it for about 15 seconds,
and check that the brake pedal dose not go down.
F04746
(e) With your foot still applied onto the brake pedal, push the
MOTOR switch and check the brake pedal does not pul-
sate.
R00326
(f) Depress the brake pedal and hold it. As you hold the ped-
al down, push and hold in the POWER SWITCH for a few
seconds. Check the pedal does not go down.
(g) With your foot still applied onto the brake pedal, release
the POWER SWITCH and check that the pedal goes
down.
R00324
(h) With your foot still applied on the brake pedal, push the
MOTOR switch and check the brake pedal returns.
(i) Release the brake pedal.
R00325
5. INSPECT FOR OHTER WHEELS

(a) Turn the selector switch to ”FRONT LH” position.
(b) Repeat (c) to (i) of step 4, check the actuator operation as
before.
(c) Similarly, inspect ”REAR RH” and ”REAR LH” position.
HINT:
When inspecting ”REAR LH” position, push the REAR LH
switch instead of the POWER SWITCH, and you can inspect in
BR1813 any selector switch position.
Author: Date: 910

BR-37
6. PUSH MOTOR SWITCH

(a) Push and hold in the MOTOR switch for a few seconds.
(b) Stop the engine.
7. DISCONNECT ACTUATOR CHECKER (SST)
Remove the ”SHEET A” (SST) and disconnect the actuator
checker (SST) and sub-wire harness (SST) from the actuator,
control relay and body side wire harness.
8. CONNECT CONNECTORS
(a) Connect the connector to the actuator.
(b) Connect the 2 connectors to the control relay.
9. CLEAR DTC (See page DI-1 11)
Author: Date: 911

BR-38
BR0S1-08
COMPONENTS

BR-39
BR0S2-07
REMOVAL
1. DISCONNECT CONNECTORS
(a) Disconnect the 2 connectors from the control relay.
(b) Disconnect the 2 connectors from the ABS actuator.
(c) Remove the control relay from the clamp.
2. DISCONNECT BRAKE LINES
Using SST, disconnect the 6 brake lines from the ABS actuator
assembly.
SST 09023-00100
3. REMOVE ABS ACTUATOR ASSEMBLY
(a) Remove the RH front fender linner.
(b) Remove the 2 bolts, nut and ABS actuator assembly.
4. REMOVE ABS ACTUATOR
(a) Remove the bolt and No.3 bracket from the ABS actuator
assembly.
Torque: 19 N·m (195 kgf·cm, 14 in.·lbf)
(b) Remove the 3 nuts and actuator from the bracket assem-
bly.
(c) Remove the 3 holders and cushions from the ABS actua-
tor.

BR-40
BR0S3-06
INSTALLATION
AFTER INSTALLATION, FILL BRAKE RESERVOIR WITH BRAKE FLUID, BLEED BRAKE SYSTEM (See
page BR-4 ) AND CHECK FOR LEAKS

BR-41
BRAKE - FRONT SPEED SENSOR
FRONT SPEED SENSOR

BR0S4-05
COMPONENTS
Fender Liner
Front Speed
Sensor
Sensor Rotor
R15521
Author: Date: 915

BR-42
BR0S5-06
REMOVAL
1. DISCONNECT SPEED SENSOR CONNECTOR
(a) Remove the fender liner.
(b) Disconnect the speed sensor connector.

2. REMOVE SPEED SENSOR
(a) Remove the 2 clamp bolts and a clip holding the sensor
harness to the body and shock absorber.
R04569
(b) Remove the bolt and speed sensor from the steering
knuckle.
R04570

BR-43
BR0S6-06
INSTALLATION
AFTER INSTALLATION, CHECK SPEED SENSOR SIGNAL (See page DI-1 11)

BR-44
BRAKE - REAR SPEED SENSOR
REAR SPEED SENSOR

BR0S7-06
COMPONENTS
Sensor Rotor
Brake Drum
Outer Bearing
Rear Speed Sensor Nut Lock

Claw Washer
Cotter Pin Grease Cap
Non-reusable part R15522
Author: Date: 918

BR-45
BR0S8-06
REMOVAL
1. DISCONNECT SPEED SENSOR CONNECTOR
(a) Remove the rear seat cushion.
(b) Disconnect the speed sensor connector, and pull out the
sensor wire harness with the grommet.
(c) Remove the 3 clamp bolts holding the sensor wire har-
ness to the suspension arm.
R04572
2. REMOVE SPEED SENSOR

Remove the bolt and speed sensor from the axle beam.
R04573

BR-46
BR0S9-03
INSTALLATION
AFTER INSTALLATION, CHECK SPEED SENSOR SIGNAL (See page DI-1 11)

SR-1
STEERING - STEERING SYSTEM
STEERING SYSTEM
SR05M-03
PRECAUTION
Care must be taken to replace parts properly because they could affect the performance of the
steering system and result in a driving hazard.
The TERCEL is equipped with SRS (Supplemental Restraint System) such as the driver airbag
and front passenger airbag. Failure to carry out service operation in the correct sequence could
cause the SRS to unexpectedly deployed during servicing, possibly leading to a serious acci-
dent. Before servicing (including removal or installation of parts, inspection or replacement),
be sure to read the precautionary notices in the RS section.
Author: Date: 921

SR-2
STEERING - TROUBLESHOOTING
TROUBLESHOOTING
SR05N-06

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in the order shown. If necessary, repair or replace these parts.
1. Tires (Improperly inflated) SA-2
2. Power steering fluid level (Low) SR-6
3. Drive belt (Loose) SR-3
4. Front wheel alignment (Incorrect) SA-4
Hard steering
5. Steering system joints (Worn) -
6. Suspension arm ball joints (Worn) SA-36
7. Steering column (Binding) -
8. Power steering gear SR-46
1. Tires (Improperly inflated) SA-2
2. Front wheel alignment (Incorrect) SA-4
Poor return
3. Steering column (Binding) -
1. Steering system joints (Worn) -

2. Suspension arm ball joints (Worn) SA-36
Excessive play 3. Intermediate shaft, Sliding yoke (Worn) -
4. Front wheel bearing (Worn) SA-10
1. Power steering fluid level (Low) SR-6
Abnormal noise 2. Steering system joints (Worn) -
Author: Date: 922

SR-3
STEERING - DRIVE BELT
DENSO Borroughs DRIVE BELT SR1F5-01
INSPECTION
1. CHECK DRIVE BELT TENSION
Using a belt tension gauge, measure the belt tension.
Belt tension gauge:
DENSO BTG-20 (95506-00020) or
Borroughs No. BT-33-73F
Z00038 Drive belt tension:
New belt: 140 - 180 lbf
Used belt: 80 - 120 lbf
NOTICE:
After installing the belt, check that it fits properly in the
ribbed grooves.
HINT:
”New belt” refers to a belt which has been used less than
5 minutes on a running engine.
”Used belt” refers to a belt which has been used on a run-
ning engine for 5 minutes or more.
CORRECT WRONG WRONG
CH0087
2. VEHICLES WITH BELT TENSION ADJUSTING BOLT:

ADJUST DRIVE BELT TENSION
(a) Loosen the bolts A and B.
(b) Loosen the lock nuts D and E.
(c) Adjust adjusting bolt F so that its protrusion above nut C
is ± 0 mm (0 in.).
(d) Fix nut C using lock nut D.
(e) Push up the PS pump body so that there is no free play

in the belt. Turn adjusting bolt F to obtain the play in the
PS Vane correct belt tension as specified above.
Pump
NOTICE:
C Ensure that the pump body and nut C are positioned cor-
D rectly, as shown before turning bolt F to adjust the bet ten-
E
sion.
F (f) Torque the bolt A.
CORRECT WRONG
R11541 Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
Author: Date: 923

SR-4
STEERING - DRIVE BELT
(g) Torque the bolt B.

(h) Loosen adjusting bolt F by 4 or 5 turns.
NOTICE:
Check that there is a gap of 5 mm (0.20 in.) or more between
the tip of nut C and the pump body.
(i) Fix adjusting bolt F with lock nut E.
(j) Recheck the belt tension.
Author: Date: 924

SR-5
STEERING - POWER STEERING FLUID
POWER STEERING FLUID SR05P-15
BLEEDING
1. CHECK FLUID LEVEL (See page SR-6 )
2. JACK UP FRONT OF VEHICLE AND SUPPORT IT
WITH STANDS
3. TURN STEERING WHEEL
With the engine stopped, turn the wheel slowly from lock to lock
several times.
4. LOWER VEHICLE
5. START ENGINE
Run the engine at idle for a few minutes.
6. TURN STEERING WHEEL
(a) With the engine idling, turn the wheel to left or right full
lock position and keep it there for 2-3 seconds, then turn
the wheel to the opposite full lock position and keep it
there for 2-3 seconds.
(b) Repeat (a) several times.
7. STOP ENGINE
8. CHECK FOR FOAMING OR EMULSIFICATION

Normal Abnormal If the system has to be bled twice specifically because of foam-
ing or emulsification, check for fluid leaks in the system.
9. CHECK FLUID LEVEL (See page SR-6 )
R07281
Author: Date: 925

SR-6
SR05Q-17
INSPECTION
1. CHECK FLUID LEVEL
(a) Keep the vehicle level.
(b) With the engine stopped, check the fluid level in the oil
reservoir.
If necessary, add fluid.
Fluid: ATF DEXRON® II or III
HINT:
Check that the fluid level is within the HOT LEVEL range on the
reservoir cap dipstick. If the fluid is cold, check that it is within
the COLD LEVEL range.
(c) Start the engine and run it at idle.
(d) Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80°C (176°F)
(e) Check for foaming or emulsification.

Normal Abnormal
If there is foaming or emulsification, bleed power steering sys-
tem. (See page SR-5 )
R11229
(f) With the engine idling, measure the fluid level in the oil
5 mm (0.20 in.)
or less reservoir.
(g) Stop the engine.
(h) Wait a few minutes and remeasure the fluid level in the oil
reservoir.
Maximum fluid level rise: 5 mm (0.20 in.)
If a problem is found, bleed power steering system.
(See page SR-5 )
Engine Idling Engine Stopped (i) Check the fluid level.
R11025

SR-7
2. CHECK STEERING FLUID PRESSURE

(a) Disconnect the pressure feed tube from the PS vane
pump. (See page SR-24 )
(b) Connect SST, as shown in the illustration below.
SST 09640-10010 (09641-01010, 09641-01030,
09641-01060)
NOTICE:
Check that the valve of the SST is in the open position.
Attachment
Attachment
SST
OUT
Pressure Feed Tube IN
PS Vane Pump
Q10145
(c) Bleed the power steering system.

(d) Start the engine and run it at idle.
(e) Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80 °C (176 °F)
(f) With the engine idling, close the valve of the SST and ob-
Oil serve the reading on the SST.
Reservoir Minimum fluid pressure:
6,374 kPa (65 kgf/cm2, 925 psi)
PS Gear NOTICE:
Closed
Do not keep the valve closed for more than 10 se-
PS Vane conds.
Pump Do not let the fluid temperature become too high.
SST
Z15498

SR-8
(g) With the engine idling, open the valve fully.

Oil (h) Measure the fluid pressure at engine speeds of 1,000 rpm
Reservoir and 3,000 rpm.
Difference fluid pressure:
PS Gear 490 kPa (5 kgf/cm2, 71 psi) or less
Open
NOTICE:
PS Vane Do not turn the steering wheel.
Pump
SST
Z15499
(i) With the engine idling and valve fully opened, turn the
Oil steering wheel to full lock position.
Reservoir Minimum fluid pressure:
Lock Position 6,374 kPa (65 kgf/cm2, 925 psi)
PS Gear NOTICE:
Open
Do not maintain lock position for more than 10 se-
PS Vane conds.
Pump Do not let the fluid temperature become too high.
SST
Z15500 (j) Disconnect the SST.
(k) Connect the pressure feed tube (See page SR-33 ).
(l) Bleed the power steering system.

SR-9
STEERING - AIR CONTROL VALVE
AIR CONTROL VALVE SR0KE-01
INSPECTION
1. TURN AIR CONDITIONING SWITCH OFF
2. CHECK IDLE-UP
(a) Start the engine and run it at idle.
Vacuum Hose (b) Fully turn the steering wheel.
(c) Check that the engine rpm decreases when the vacuum
hose is pinched.
(d) Check that the engine rpm increases when the hose is re-
leased.
R14423
Author: Date: 929

SR-10
STEERING - STEERING WHEEL
Maximum
STEERING WHEEL SR05R-11
Freeplay INSPECTION
1. CHECK STEERING WHEEL FREEPLAY
With the vehicle stopped and tires pointed straight ahead, rock
the steering wheel gently back and forth with light finger pres-
30 mm (1.18 in.) sure.
Freeplay should not exceed the maximum.
SR4208
Maximum freeplay: 30 mm (1.18 in.)
2. CHECK STEERING EFFORT

(a) Center the steering wheel.
(b) Remove the steering wheel pad (See page SR-13 ).
(c) Start the engine and run it at idle.
(d) Measure the steering effort in both directions.
Reference: 7.8 N·m (80 kgf·cm, 69 in.·lbf)
HINT:
Be sure to consider the tire type, pressure and contact surface
R12030 before making your diagnosis.
(e) Torque the steering wheel set nut.
(f) Install the steering wheel pad (See page SR-20 ).
Author: Date: 930

SR-1 1
STEERING - NON-TIL T STEERING COLUMN
NON-TIL T STEERING COLUMN

SR17Z-02
COMPONENTS
Author: Date: 931

SR-12
Author: Date: 932

SR-13
SR17R-02
Torx Screw Screw Case

REMOVAL
1. w/ Airbag:
REMOVE STEERING WHEEL PAD
NOTICE:
If the airbag connector is disconnected with the igni-
tion switch at ON or ACC, DTCs will be recorded.
Never use airbag parts from another vehicle. When
replacing parts, replace with new ones.
R12031
(a) Place the front wheels facing straight ahead.
(b) Using a torx socket wrench, loosen the 2 torx screws.
HINT:
Loosen the 2 screws until the groove along the screw circumfer-
ence catches on the screw case.
(c) Pull the wheel pad from the steering wheel and discon-
nect the airbag connector.
CAUTION:
When storing the wheel pad, keep the upper surface
of the pad facing upward.
Never disassemble the wheel pad.
NOTICE:
When removing the wheel pad, take care not to pull the air-
bag wire harness.
Airbag 2. w/o Airbag:
Connector
REMOVE STEERING WHEEL PAD
Correct Wrong (a) Remove the screw.
(b) Remove the 3 clips.
R11976
Matchmarks 3. REMOVE STEERING WHEEL

(a) Disconnect the connector.
(b) Remove the steering wheel set nut.
(c) Place matchmarks on the steering wheel and main shaft
assembly.
(d) Using SST, remove the wheel.
SST 09950-50010 (09951-05010, 09952-05010,
SST 09953-05020, 09954-05020)
R11977

SR-14
4. REMOVE CENTER UPPER INSTRUMENT CLUSTER

FINISH PANEL
(a) Remove the screw.
(b) Remove the 3 clips.
5. REMOVE UPPER AND LOWER COLUMN COVERS

Remove the 6 screws.
6. REMOVE FRONT DOOR SCUFF PLATE AND COWL
SIDE TRIM
Remove the clip and trim.
7. REMOVE LOWER INSTRUMENT COVER AND
INSTRUMENT PANEL LOWER PAD INSERT
(a) Remove the 2 opening covers from the instrument cover.
(b) Remove the 2 screws and disconnect the hood lock re-
lease lever from the instrument cover.
(c) Remove the 4 panel cover set bolts.
(d) Remove the lower pad insert from the instrument cover.
8. REMOVE NO.2 HEATER TO REGISTER DUCT
(a) Disconnect the junction block No.1 with the 3 screws.
(b) Remove the clip.
9. REMOVE COMBINATION SWITCH WITH SPIRAL
CABLE
(a) Disconnect the 3 connectors.
(b) w/ Airbag:
Disconnect the airbag connector.
(c) w/ Airbag:
Remove the 3 screws.
10. REMOVE SPIRAL CABLE (See page BE-14 )
NOTICE:
Do not disassemble the cable or apply oil to it.
11. REMOVE COLUMN HOLE COVER
Remove the 4 nuts.
Manual Steering: 12. DISCONNECT SLIDING YOKE

(a) Place matchmarks on the yoke and steering pinion shaft/
A control valve shaft.
B (b) Loosen bolt A and remove bolt B.
Matchmarks R12213

SR-15
13. REMOVE STEERING COLUMN ASSEMBLY

(a) Disconnect the connector.
A (b) Remove the 4 column assembly set nuts.
B
Matchmarks R12213

SR-16
SR17S-01
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. REMOVE SLIDING YOKE
Remove the bolt.
2. REMOVE COLUMN UPPER BRACKET AND COLUMN
UPPER CLAMP
(a) Using a centering punch, mark the center of the 2 ta-
pered-head bolts.
(b) Using a 3 - 4 mm (0.12 - 0.16 in.) drill, drill into the 2 bolts.
(c) Using a screw extractor, remove the 2 bolts.

3. REMOVE MAIN SHAFT ASSEMBLY AND MAIN SHAFT
BUSHING
(a) Using snap ring expander, remove the snap ring from the
shaft assembly.
(b) Using a plastic hammer, tap out the shaft assembly from
the column tube.
(c) Using snap ring expander, remove the snap ring from the
shaft assembly.
4. REMOVE STEERING SUPPORT
(a) Remove the set bolt and nut.
(b) Remove the 2 steering support No.1 collars.

SR-17
SR17T-02
INSPECTION
NOTICE:
When using a vise do not overtighten it.
1. INSPECT STEERING LOCK OPERATION
Check that the steering lock mechanism operates properly.
2. IF NECESSARY, REPLACE KEY CYLINDER

(a) Place the ignition key at the ACC position.
(b) Push down the stop pin with a thin rod, and pull out the
key cylinder.
(c) Install a new cylinder.
HINT:
Make sure the ignition key is at the ACC position.
3. INSPECT IGNITION SWITCH (See page BE-1 1)
4. IF NECESSARY, REPLACE IGNITION SWITCH
(a) Remove the 2 screws.
(b) Install a new ignition switch with the 2 screws.
5. INSPECT KEY UNLOCK WARNING SWITCH
(See page BE-1 1)
6. IF NECESSARY, REPLACE KEY UNLOCK WARNING
SWITCH
(b) Install a new switch with the 2 screws.
7. A/T:
INSPECT KEY INTERLOCK SOLENOID
A132L A/T: (See page AX-24)
A242L A/T: (See page AX-28)
8. A/T:
IF NECESSARY, REPLACE KEY INTERLOCK SOLE-
NOID
(b) Install a new solenoid with the 2 screws.
9. INSPECT BEARING
Check the bearing rotation condition and check for abnormal
noise.
If the bearing is worn or damaged, replace the column tube.

SR-18
10. IF NECESSARY, REPLACE BUSHING

(a) Using a screwdriver, depress the projections on the bush-
ing to release the bushing, then remove the bushing from
the column tube.
(b) Coat the inside of new bushing with molybdenum disul-
fide lithium base grease.
(c) Align the projections on the bushing with the holes in the
column tube. Install the bushing until the projections are
firmly engaged in the holes in the column tube.

SR-19
SR17U-01
REASSEMBLY
NOTICE:
1. INSTALL STEERING SUPPORT
(a) Install the 2 steering support No.1 collars.
(b) Torque the set bolt and nut.
Torque: 5.4 N·m (55 kgf·cm, 48 ft·lbf)
2. INSTALL MAIN SHAFT ASSEMBLY
(a) Using snap ring expander, install a new snap ring to the
shaft assembly.
(b) Install the shaft assembly to the column tube.
(c) Using snap ring expander, install a new snap ring to the
shaft assembly.
3. INSTALL COLUMN UPPER BRACKET AND COLUMN

UPPER CLAMP
Tighten the 2 new tapered-head bolts until the bolts head break
off.
4. INSTALL SLIDING YOKE
Temporarily tighten the bolt.
R11676

SR-20
SR17V-02
INSTALLATION
1. INSTALL STEERING COLUMN ASSEMBLY
(a) Torque the 4 column assembly set nuts.
(b) Connect the connector.
Manual Steering: 2. CONNECT SLIDING YOKE

(a) Align the matchmarks on the sliding yoke and steering
A pinion shaft/control valve shaft.
B (b) Torque the bolt B.
(c) Torque the bolt A.
3. INSTALL COLUMN HOLE COVER
Matchmarks R12213 Torque the 4 nuts.
4. w/ Airbag:
INSTALL SPIRAL CABLE (See page BE-14 )
5. INSTALL COMBINATION SWITCH WITH SPIRAL
CABLE
(a) Tighten the 3 screws.
(b) w/ Airbag:
Connect the airbag connector.
(c) Connect the 3 connectors.
6. INSTALL NO.2 HEATER TO REGISTER DUCT
(a) Install the clip.
(b) Connect the junction block No.1 with the 3 screws.
7. INSTALL LOWER INSTRUMENT COVER AND
INSTRUMENT PANEL LOWER PAD INSERT
(a) Install the pad insert to cover.
(b) Tighten the 4 panel set bolts.
(c) Connect the hood lock release lever with the 2 screws.
(d) Install the 2 opening covers.
8. INSTALL FRONT DOOR SCUFF PLATE AND COWL
SIDE TRIM
Install the clip and trim.
9. INSTALL UPPER AND LOWER COLUMN COVERS
Tighten the 6 screws.
10. INSTALL CENTER UPPER INSTRUMENT CLUSTER
FINISH PANEL
(a) Connect the connector.
(b) Tighten screw.

SR-21
11. CENTER SPIRAL CABLE

(a) Check that the front wheels are facing straight ahead.
(b) Turn the cable counterclockwise by hand until it becomes
harder to turn the cable.
(c) Then rotate the cable clockwise about 2.5 turns to align
the green marks.
HINT:
The spiral cable turns clockwise about 2.5 turns to either left or
right of the center.
12. INSTALL STEERING WHEEL
(a) Align the matchmarks on the steering wheel and main
shaft assembly.
(b) Torque the steering wheel set nut.
(c) Connect the connector.
13. w/ Airbag:
INSTALL STEERING WHEEL PAD
NOTICE:
Make sure the wheel pad is installed with the speci-
fied torque.
If the wheel pad has been dropped, or there are
cracks, dents or other defects in the case or connec-
tor, replace the wheel pad with a new one.
When installing the wheel pad, take care that the wir-
ings do not interfere with other parts and that they are
not pinched between other parts.
(a) Connect the airbag connector.
(b) Install the wheel pad after confirming that the circumfer-
Torx Screw Screw Case
ence groove of the torx screws are caught on the screw
case.
(c) Using a torx socket wrench, torque the 2 screws.
14. w/o Airbag:
INSTALL STEERING WHEEL PAD
15. CHECK STEERING WHEEL CENTER POINT
W01455

SR-22
STEERING - POWER STEERING VANE PUMP
POWER STEERING VANE PUMP

SR0KL-03
COMPONENTS
Author: Date: 942

SR-23
Author: Date: 943

SR-24
SR0KM-03
REMOVAL
1. DISCONNECT RETURN HOSE
NOTICE:
Take care not to spill fluid on the drive belt.
2. DISCONNECT PRESSURE FEED TUBE
Remove the union bolt and gasket.
3. REMOVE DRIVE BELT

Loosen the 2 pump assembly set bolts.
4. REMOVE PS VANE PUMP ASSEMBLY
Remove the 2 pump assembly set bolts.

SR-25
SR1EY-01
DISASSEMBLY
NOTICE:
1. MEASURE PS VANE PUMP ROTATING TORQUE
(a) Check that the pump rotates smoothly without abnormal
noise.
(b) Using a torque wrench, check the pump rotating torque.

Rotating torque:
0.3 N·m (2.8 kgf·cm, 2.4 in.·lbf) or less
2. REMOVE VANE PUMP PULLEY

Using SST, stop the pulley rotating and remove the nut.
SST SST 09960-10010 (09962-01000, 09963-01000)
3. REMOVE SUCTION PORT UNION
(a) Remove the 2 bolts.
(b) Remove the O-ring from the union.
4. REMOVE PRESSURE PORT UNION, FLOW CONTROL
VALVE AND COMPRESSION SPRING
Remove the O-ring from the union.
5. REMOVE REAR HOUSING AND WAVE WASHER

(a) Using 2 screwdrivers, remove the snap ring.
NOTICE:
Be careful not to damage the front and rear housing.
Z13628
(b) Wind vinyl tape on the pump shaft.

(c) Using a plastic hammer, tap the pump shaft end.
6. REMOVE SIDE REAR PLATE
Remove the O-ring from the rear plate.
7. REMOVE CAM RING, 10 VANE PLATES
NOTICE:
Be careful not to drop the plate.
8. REMOVE VANE PUMP SHAFT WITH VANE PUMP RO-
TOR AND SIDE FRONT PLATE
9. REMOVE LOWER STRAIGHT PINS
SR-26
Using pliers, remove the pin from the front housing.

10. REMOVE ROTOR AND SIDE FRONT PLATE
(a) Using snap ring pliers, remove the snap ring from the
vane pump shaft.
(b) Remove the 2 O-rings and shorter straight pin from the
plate.

SR-27
SR1EZ-01
INSPECTION
NOTICE:
1. MEASURE OIL CLEARANCE BETWEEN VANE PUMP
SHAFT AND BUSHING
Using a micrometer and a caliper gauge, measure the oil clear-
ance.
Standard clearance:
0.01 - 0.03 mm (0.0004 - 0.0012 in.)
Maximum clearance: 0.07 mm (0.0028 in.)
If it is more than the maximum, replace the front housing and
vane pump shaft.
Thickness 2. INSPECT VANE PUMP ROTOR AND VANE PLATES

(a) Using a micrometer, measure the height, thickness and
Height length of the 10 plates.
Minimum height: 8.0 mm (0.315 in.)
Minimum length: 14.97 mm (0.5894 in.)
Length
Z13631
(b) Using a feeler gauge, measure the clearance between

the rotor groove and plate.
Feeler Gauge
R10282
If it is more than the maximum, replace the plate and/or rotor

with the one having the same mark stamped on the cam ring.
Inscribed mark: 1, 2, 3, 4 or None
Inscribed Mark
R13897

SR-28
HINT:
There are 5 vane plate lengths with the following rotor and cam
ring marks:
Rotor and Vane plate Vane plate length
cam ring mark part number mm (in.)
14.996 - 14.998
None 44345-12010
(0.59039 - 0.59047)
14.994 - 14.996
1 44345-12020
(0.59032 - 0.59032)
14.992 - 14.994
2 44345-12030
(0.59024 - 0.59032)
14.990 - 14.992
3 44345-12040
(0.59016 - 0.59024)
14.988 - 14.990
4 44345-12050
(0.59008 - 0.59016)
3. INSPECT FLOW CONTROL VALVE

(a) Coat the valve with power steering fluid and check that it
falls smoothly into the valve hole by its own weight.
Z13632
(b) Check the flow control valve for leakage. Close one of the
Compressed Air holes and apply 392 - 490 kPa (4 - 5 kgf/cm2, 57 - 71 psi)
of compressed air into the opposite side hole, and confirm
that air does not come out from the end holes.
R07591
If necessary, replace the valve with the one having the same let-
ter as inscribed on the front housing.
Inscribed mark: A, B, C, D, E or F

SR-29
4. INSPECT COMPRESSION SPRING

Using calipers, measure the free length of the spring.
Minimum length: 36 - 38 mm (1.42 - 1.49 in.)
If it is not within the specification, replace the spring.
Calipers
R08702
5. IF NECESSARY, REPLACE OIL SEAL

(a) Using a screwdriver, pry out the oil seal.
NOTICE:
Place the shop rag, as shown, be careful not to damage the
bushing of the front housing.
(b) Coat a new oil seal lip with power steering fluid.
(c) Using a socket wrench (24 mm), press in the oil seal.
NOTICE:
Make sure you install the oil seal facing the correct direc-
tion.

SR-30
SR1F0-01
REASSEMBLY
NOTICE:
1. COAT WITH POWER STEERING FLUID
(See page SR-22 )
2. INSTALL LONGER STRAIGHT PIN
Using a plastic hammer, tap in a new pin to the front housing.
NOTICE:
Be careful not to damage the pin.
3. INSTALL SIDE FRONT PLATE AND VANE PUMP RO-

Mark TOR
(a) Coat 2 new O-rings with power steering fluid, and install
them to the plate.
(b) Install the plate to the vane pump shaft.
NOTICE:
Make sure you install the plate facing the correct direction.
(c) Install the rotor to the pump shaft with the inscribed mark
Z13635 on the rotor facing outward.
(d) Using snap ring pliers, install a new snap ring to the vane
pump shaft.
(e) Install a new shorter straight pin to the plate.
NOTICE:
Be careful not to damage the pin.
4. INSTALL VANE PUMP SHAFT WITH VANE PUMP RO-

Vinyl Tape
TOR ANd SIDE FRONT PLATE
(a) To prevent oil seal lip damage, wind vinyl tape on the
pump shaft.
(b) Align the hole of the front plate and longer straight pin.
(c) Tap in the pump shaft with a plastic hammer.
NOTICE:
Be careful not to damage the oil seal and O-rings.
R11542
5. INSTALL CAM RING

Align the holes of the ring and straight pins, and install the ring
with the inscribed mark facing outward.

SR-31
Round End 6. INSTALL VANE PLATES

Install the 10 plates with the round end facing outward.
7. INSTALL SIDE REAR PLATe
(a) Coat a new O-ring with power steering fluid, and install
it to the plate.
(b) Align the holes of the plate and straight pins.
R11071
8. INSTALL WAVE WASHER

Install the washer so that its protrusions fit into the slots in the
side rear plate.
R12361
9. INSTALL REAR HOUSING

(a) Coat a new O-ring with power steering fluid and install it
to the rear housing.
(b) Install the rear housing and use a press to push down on
the wave washer hard enough to compress it.
NOTICE:
Do not apply too much pressure.
Be careful not to damage the O-ring.
R12362 10. INSTALL SPRING, FLOW CONTROL VALVE AND
PRESSURE PORT UNION
(a) Install the valve facing the correct direction.
(See page SR-22 )
(b) Coat a new O-ring with power steering fluid, and install
it to the union.
(c) Torque the union.
11. INSTALL SUCTION PORT UNION
(a) Coat a new O-ring with power steering fluid, and install
it to the union.
(b) Torque the 2 bolts.

SR-32
12. INSTALL VANE PUMP PULLEY

(a) Install the woodruff key to the vane pump shaft.
(b) Using SST to stop the pulley rotating, torque the pulley set
nut.
SST 09960-10010 (09962-01000, 09963-01000)
13. MEASURE PS VANE PUMP ROTATING TORQUE
(See page SR-25 )

SR-33
SR0KQ-03
INSTALLATION
1. INSTALL PS VANE PUMP ASSEMBLY
Temporarily tighten the 2 bolts (A and B).
2. INSTALL DRIVE BELT
(a) Adjust drive belt tension (See page SR-3 ).
(b) Torque the A bolt.
(c) Torque the B bolt.
3. CONNECT PRESSURE FEED TUBE
Torque the union bolt over a new gasket.
4. CONNECT RETURN HOSE
5. BLEED POWER STEERING SYSTEM
(See page SR-5 )

SR-34
STEERING - MANUAL STEERING GEAR
MANUAL STEERING GEAR

SR0KR-02
COMPONENTS
Column Hole Cover
Sliding Yoke
Cotter Pin
Bracket
Grommet
Manual Steering
Gear Assembly
Grommet
Bracket
Cotter Pin
Non-reusable part
R12816
Author: Date: 954

SR-35
Pinion Bearing Adjusting

Screw Lock Nut
Oil Seal
Pinion Bearing Adjusting Screw
Rack Guide Spring Cap
Bearing
Rack Guide Spring
Steering Pinion Cap Lock Nut
Bearing
Clip Rack Guide Spring

Rack Boot Rack Guide
Clamp
Bushing
Rack Housing
Clamp
Clip
Rack Boot
Tie Rod End Claw Washer
Lock Nut
Rack End
Rack End
Claw Washer Lock Nut

Tie Rod End
Steering Rack
Non-reusable part
Precoated part
Molybdenum disulfide lithium base grease
Z19009
Author: Date: 955

SR-36
SR0KS-01
REMOVAL
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. REMOVE STEERING WHEEL PAD
(See page SR-13 )
3. REMOVE STEERING WHEEL
(See page SR-13 )
4. DISCONNECT RH AND LH TIE ROD ENDS
(See page SA-10 )
Remove the 4 nuts.
6. DISCONNECT SLIDING YOKE
(See page SR-13 )
7. REMOVE 2 BRACKETS AND GROMMETS
Remove the 2 bolts and nuts.
8. REMOVE MANUAL STEERING GEAR ASSEMBLY
Remove the gear assembly from the LH side of the vehicle.

SR-37
SR0KT-01
DISASSEMBLY
NOTICE:
1. SECURE MANUAL STEERING GEAR IN VISE
Using SST, secure the gear assembly in a vise.
SST
SST 09612-00012
N00249
2. REMOVE RH AND LH TIE ROD ENDS AND LOCK

Matchmarks NUTS
Place matchmarks on the tie rod end and rack end.
3. REMOVE RH AND LH CLIPS, RACK BOOTS AND
CLAMPS
Remove the clamp screw from the boot.
NOTICE:
Be careful not to damage the boot.
N00250 Mark the RH and LH boots.
4. REMOVE RH AND LH RACK ENDS AND CLAW

WASHERS
(a) Using a screwdriver and hammer, unstake the washer.
NOTICE:
Avoid any impact on the steering rack.
N00251
(b) Using a spanner, hold the steering rack steadily and using
SST SST, remove the rack end.
SST 09922-10010
NOTICE:
Use SST 09922-10010 in the direction shown in the il-
lustration.
Mark the RH and LH rack ends.
R12034
5. REMOVE RACK GUIDE SPRING CAP LOCK NUT

Using SST, remove the nut.
SST 09922-10010
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
SST 6. REMOVE RACK GUIDE SPRING CAP, RACK GUIDE
SPRING AND RACK GUIDE
R12035 Using a hexagon wrench (19 mm), remove the cap.

SR-38
7. REMOVE PINION BEARING ADJUSTING SCREW

SST LOCK NUT
SST 09922-10010
NOTICE:
tion.
R12036
8. REMOVE PINION BEARING ADJUSTING SCREW

Vinyl Tape
(a) To prevent oil seal lip damage, wind vinyl tape on the ser-
rated part of the steering pinion.
(b) Using SST, remove the screw.
SST 09612-24014 (09616-10020)
SST
R15598
9. REMOVE STEERING PINION WITH BEARING

Fully pull the steering rack from the steering pinion side of the
Cutout Portion rack housing and align the rack cutout portion with the pinion.
NOTICE:
Be careful not to damage the serrations.
10. REMOVE STEERING RACK
NOTICE:
To avoid damaging the bushing, remove the rack from the
R13864 steering pinion housing side of the rack housing without
revolving it.

SR-39
SR0KU-02
INSPECTION
Dial Indicator NOTICE:
1. INSPECT STEERING RACK
(a) Using a dial indicator, check the rack for runout and for
teeth wear and damage.
(b) Check the back surface for wear and damage.
R13855
2. IF NECESSARY, REPLACE BEARING

(a) Using SST, remove the bearing.
SST 09950-40010 (09951-04010, 09952-04010,
09953-04020, 09954-04010, 09955-04050,
09957-04010, 09958-04010)
NOTICE:
SST Be careful not to damage the pinion.
(b) Coat a new bearing with molybdenum disulfide lithium
R14424 base grease.
(c) Using SST, press in the bearing.

SST 09612-24014 (09612-10061)
SST NOTICE:
Make sure to install the bearing facing the correct direc-
tion.
F05533
3. IF NECESSARY, REPLACE BEARING

(a) Heat the rack housing to above 80°C (176°F).
(b) Using a plastic hammer, tap out the bearing from the rack
housing.
N00343
(c) Heat the rack housing to above 80°C (176°F).

(d) Coat a new bearing with molybdenum disulfide lithium
SST base grease.
SST (e) Using SST, press in the bearing.
SST 09950-60010 (09951-00340),
09950-70010 (09951-07150)
Bearing R15525

SR-40
4. IF NECESSARY, REPLACE BUSHING

(a) Using a screwdriver, depress the projections on the bush-
ing to release the bushing, then remove the bushing from
the rack housing.
SR4254
(b) Ensure that the hole of the rack housing is not clogged
with grease.
HINT:
If the hole is clogged, the pressure inside the boot will change
after it is assembled and the steering wheel is turned.
(c) Coat inside a new bushing with molybdenum disulfide lith-
ium base grease.
(d) Install the bushing into the rack housing, making sure to
N00345 align into the 3 holes.
5. IF NECESSARY, REPLACE OIL SEAL

(a) Using SST, press out the oil seal from the pinion bearing
adjusting screw.
SST 09950-60010 (09951-00240),
SST
09950-70010 (09951-07100)
Oil Seal
R14426
(b) Coat a new oil seal lip with molybdenum disulfide lithium
base grease.
(c) Using SST, press in the oil seal with it is protruding 5 mm
SST (0.21 in.).
SST 09950-60010 (09951-00240),
5 mm 09950-70010 (09951-07100)
NOTICE:
Oil Seal Make sure to install the oil seal facing the correct direction.
W04041

SR-41
SR0KV-01
REASSEMBLY
NOTICE:
1. COAT WITH MOLYBDENUM DISULFIDE LITHIUM
BASE GREASE
(See page SR-34 )
2. INSTALL STEERING RACK
Install the rack into the rack housing.
NOTICE:
To avoid damaging the bushing, install the rack from the
steering pinion side of the rack housing without revolving
it.
3. INSTALL STEERING PINION

Steering (a) Set the steering rack notched side so that the pinion can
Pinion Steering be positioned inside.
Rack (b) Line up the cutout portion of the rack with the pinion.
(c) Ensure that the pinion end is securely located in the bear-
ing.
NOTICE:
Do not engage the pinion teeth with the rack teeth.
Cutout Portion R13860
4. INSTALL PINION BEARING ADJUSTING SCREW

Vinyl Tape
(a) To prevent oil seal lip damage, wind vinyl tape on the ser-
rated part of the steering pinion.
(b) Apply sealant to 2 or 3 threads of the screw.
Sealant:
SST Part No.08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Using SST, temporarily install the screw.
R15598 SST 09612-24014 (09616-10020)
5. ADJUST PINION PRELOAD

NOTICE:
SST Do not engage the pinion teeth with the rack teeth.
(a) Using SST and a torque wrench, tighten the pinion bear-
ing adjusting screw until the preload matches the specifi-
cation.
SST 09612-24014 (09616-10010, 09616-10020)
Preload (turning):
SR4258 0.4 N·m (3.7 kgf·cm, 3.2 in.·lbf)

SR-42
(b) Using SST and a torque wrench, loosen the screw until
the preload is within specification.
SST 09612-24014 (09616-10010, 09616-10020)
Preload (turning):
0.23 - 0.32 N·m (2.3 - 3.3 kgf·cm, 2.0 - 2.9 in.·lbf)
6. INSTALL PINION BEARING ADJUSTING SCREW
LOCK NUT
(a) Apply sealant to 2 or 3 threads of the nut.
Sealant:
Part No.08833-00080, THREE BOND 1344,
(b) Using SST, stop the pinion bearing adjusting screw rotat-
ing and using another SST, torque the nut.
SST 09612-24014 (09616-10020), 09922-10010
Fulcrum Length Torque: 85 N·m (871 kgf·cm, 63 ft·lbf)
NOTICE:
SST tion.
HINT:
R12038 Use a torque wrench with a fulcrum length of 380 mm (14.96
in.).
(c) Recheck the pinion preload.
Preload (turning):
0.23 - 0.32 N·m (2.3 - 3.3 kgf·cm, 2.0 - 2.9 in.·lbf)
7. INSTALL RACK GUIDE, RACK GUIDE SPRING AND
RACK GUIDE SPRING CAP
(a) Apply sealant to 2 or 3 threads of the cap.
Sealant:
(b) Temporarily install the cap.

SR-43
8. ADJUST TOTAL PRELOAD

(a) To prevent the steering rack teeth from damaging the oil
seal lip, temporarily install the RH and LH rack ends.
(b) Using a hexagon wrench (19 mm), torque the rack guide
spring cap.
12° Torque: 14.7 N·m (150 kgf·cm, 10.8 ft·lbf)
(c) Using a hexagon wrench (19 mm), return the cap 12°.
Hexagon Wrench
R12818
(d) Using SST, turn the pinion shaft right and left 1 or 2 times.
SST 09612-24014 (09616-10010)
(e) Using a hexagon wrench (19 mm), loosen the cap until the
SST rack guide spring is not functioning.
R15481
(f) Using SST, a torque wrench and hexagon wrench (19

mm), tighten the cap until the preload is within specifica-
SST
tion.
SST 09612-24014 (09616-10010)
Preload (turning):
0.6 - 1.2 N·m (6 - 12 kgf·cm, 5.2 - 10.4 in.·lbf)
Hexagon Wrench
Z14313
9. INSTALL RACK GUIDE SPRING CAP LOCK NUT

SST
(a) Apply sealant to 2 or 3 threads of the nut.
Sealant:
(b) Using a hexagon wrench (19 mm), hold the rack guide
spring cap rotating and using SST, torque the nut.
Hexagon
Fulcrum SST 09922-10010
Wrench
Length
NOTICE:
tion.
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
(c) Recheck the total preload.
Preload (turning):
0.6 - 1.2 N·m (6 - 12 kgf·cm, 5.2 - 10.4 in.·lbf)
(d) Remove the RH and LH rack ends.

SR-44
10. INSTALL RH AND LH CLAW WASHERS AND RACK

ENDS
SST
(a) Install a new washer, and temporarily tighten the rack
end.
HINT:
Align the claws of the washer with the steering rack grooves.
Fulcrum
Length SST, torque the rack end.
R12040 SST 09922-10010
NOTICE:
tion.
HINT:
in.).
(c) Using a brass bar and hammer, stake the washer.

NOTICE:
Avoid any impact on the rack.
N00349
11. INSTALL RH AND LH BOOTS, CLAMPS AND CLIPS

(a) Install the rack boot.
NOTICE:
Be careful not to damage or twist the boot.
(b) Install the clamp screw, as shown in the illustration.
0 mm
6 mm
(0.24 in.)
R15520
(c) Install the clip.

HINT:
Face the open ends of the clips outward/upward as shown in
the illustration, to avoid damage to the boot.
12. INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS
(a) Screw the lock nut and tie rod end onto the rack end until
the matchmarks are aligned.
(b) After adjusting toe-in, torque the nut.
R15519 (See page SA-4 )
SR-45
SR0KW-02
INSTALLATION
1. INSTALL MANUAL STEERING GEAR ASSEMBLY
Install the gear assembly from the LH of the vehicle.
2. INSTALL 2 GROMMETS AND BRACKETS
Torque the 2 bolts and nuts.
3. CONNECT SLIDING YOKE (See page SR-20 )
Torque the 4 nuts.
5. CONNECT RH AND LH TIE ROD ENDS (See page SA-10 )
HINT:
Do it with the front of the vehicle jacked up.
7. w/ Airbag:
CENTER SPIRAL CABLE (See page SR-20 )
8. INSTALL STEERING WHEEL
(a) Install the wheel at straight-ahead position.
(b) Temporarily tighten the wheel set nut.
10. w/ Airbag:
TORQUE STEERING WHEEL SET NUT
11. w/ Airbag:
INSTALL STEERING WHEEL PAD (See page SR-20 )
12. CHECK FRONT WHEEL ALIGNMENT (See page SA-4 )

SR-46
STEERING - POWER STEERING GEAR
POWER STEERING GEAR

SR0KX-04
COMPONENTS
Author: Date: 966

SR-47
Author: Date: 967

SR-48
Union Seat
Author: Date: 968

SR-49
SR0KY-02
REMOVAL
2. w/ Airbag:
REMOVE STEERING WHEEL PAD (See page SR-13 )
3. w/ Airbag:
REMOVE STEERING WHEEL (See page SR-13 )
4. DISCONNECT RH AND LH TIE ROD ENDS (See page
SA-10 )
Remove the 2 bolts and nut.
6. DISCONNECT SLIDING YOKE (See page SR-13 )
7. REMOVE OXYGEN SENSOR
8. REMOVE FRONT EXHAUST PIPE
(a) Remove the 2 bolts, compression springs and gasket.
(b) Remove the bolt, clamp and gasket.
(c) Disconnect the 2 rings.
9. REMOVE ENGINE REAR MOUNT INSULATOR
Remove the 6 bolts.
10. REMOVE ENGINE REAR MOUNT BRACKET
Remove the 2 bolts.
11. DISCONNECT 2 VACUUM HOSES
12. M/T:
DISCONNECT CONTROL CABLES
(a) Remove the 2 clips and washers.
(b) Remove the 2 clips from the cables.
(c) Disconnect the 2 cables from the control lever housing
support bracket.
13. DISCONNECT PRESSURE FEED AND RETURN

TUBES
SST Using SST, disconnect the tube.
SST 09631-22020
14. DISCONNECT TUBE CLAMP
Remove the bolt.
15. REMOVE 2 BRACKETS AND GROMMETS
Remove the 2 bolts and nuts.
R11074
16. REMOVE PS GEAR ASSEMBLY

(a) Slide the gear assembly to the RH side of the vehicle.
(b) Slide the gear assembly to the LH side and pull it out.
SR4244

SR-50
SR17W-02
DISASSEMBLY
NOTICE:
1. SECURE PS GEAR ASSEMBLY IN VISE
Using SST, secure the gear assembly in a vise.
SST SST 09612-00012
R11026
2. REMOVE 2 TURN PRESSURE TUBES

(a) Using SST, remove the tube.
SST 09633-00020
(b) Remove the 2 union seats from the rack housing.
3. REMOVE AIR CONTROL VALVE
4. REMOVE RH AND LH TIE ROD ENDS AND LOCK
SST
NUTS (See page SR-37 )
R11027
5. REMOVE RH AND LH CLIPS, RACK BOOTS AND

CLAMPS
Using a screwdriver, loosen the clamp.
NOTICE:
Be careful not to damage the boot.
Mark the RH and LH boots.
6. REMOVE RH AND LH RACK ENDS AND CLAW WASH-
ERS (See page SR-37 )
R13122
7. REMOVE RACK GUIDE SPRING CAP LOCK NUT

SST 09922-10010
NOTICE:
tion.
SST 8. REMOVE RACK GUIDE SPRING CAP
Using a hexagon wrench (21 mm), remove the cap.
R11029 9. REMOVE RACK GUIDE SPRING, RACK GUIDE AND
RACK GUIDE SEAT
Remove the seat from the guide.
10. REMOVE RACK HOUSING CAP

SR-51
11. REMOVE SELF-LOCKING NUT

SST Using SST, stop the control valve rotating and remove the nut.
SST 09616-00010
SR4297
12. REMOVE CONTROL VALVE ASSEMBLY WITH OIL

SEAL AND BEARING
SST (a) Using snap ring pliers, remove the snap ring from the rack
housing.
(b) Using SST, remove the valve assembly with the oil seal
Pin and bearing.
SST 09613-12010
NOTICE:
Pin R06217 Never attempt to tap out the control valve as this would
damage it.
(c) Remove the oil seal from the valve assembly.
(d) Using SST, remove the bearing from the valve assembly.
SST SST 09950-40010 (09951-04010, 09952-04010,
09953-04020, 09954-04010, 09955-04050,
09957-04010, 09958-04010)
13. REMOVE BEARING
Using a brass bar and hammer, tap out the bearing from the
rack housing.
R11075
14. REMOVE CYLINDER END STOPPER AND BUSHING

SST Using SST, remove the stopper and bushing.
SST 09631-20090
R11056

SR-52
15. REMOVE STEERING RACK WITH OIL SEAL

SST (a) Using SST, press out the rack with the oil seal.
SST 09612-24014 (09612-10061)
NOTICE:
Take care not to drop the rack.
(b) Remove the oil seal from the rack.
SR4282
16. REMOVE SPACER AND OIL SEAL

Using SST and a hammer, drive out the spacer and oil seal.
SST 09950-60010 (09951-00220),
09950-70010 (09951-07360)
NOTICE:
Do not damage the rack housing.

SR-53
SR0L0-02
INSPECTION
Dial Indicator NOTICE:
1. INSPECT STEERING RACK
Using a dial indicator, check the rack for runout and teeth wear
and damage.
R10072
2. MEASURE OIL CLEARANCE BETWEEN CONTROL

Cylinder Gauge VALVE ASSEMBLY AND BUSHING
Using a micrometer and a cylinder gauge, measure the oil clear-
ance.
Standard clearance:
Micrometer 0.050 - 0.083 mm (0.00197 - 0.00327 in.)
Bushing
R11358
3. IF NECESSARY, REPLACE BUSHING AND OIL SEAL

Steel (a) Using SST and 2 steel plates, remove the bushing from
Plate the rack housing.
SST 09612-65014 (09612-01030)
SST NOTICE:
As shown, from the opposite side of SST confirm that
its claw is firmly caught on the bushing.
Bushing Be careful not to damage the rack housing.
R11357
(b) Using a brass bar and a hammer, remove the oil seal from
Brass Bar the rack housing.
NOTICE:
Be careful not to damage the rack housing.
Oil Seal
R11359
(c) Coat a new oil seal lip with power steering fluid.
(d) Using a socket wrench (24 mm), extension bar and ham-
mer, press in the oil seal.
NOTICE:
Make sure to install the oil seal facing the correct direction.

SR-54
(e) Using a socket wrench (24 mm) and a extension bar, care-
fully press in a new bushing to a depth of 73 mm (2.87 in.).
NOTICE:
If the bushing is pushed in too far, it will cause deformation
of the rack housing. If it is not pushed in far enough, it will
interfere with the control valve assembly. Therefore, al-
ways use a press and install the bushing to the proper
depth. Then, install the control valve assembly and ensure
that it rotates smoothly.
4. IF NECESSARY, REPLACE TEFLON RING AND

O-RING
(a) Using a screwdriver, remove the teflon ring and O-ring
from the steering rack.
NOTICE:
Be careful not to damage the groove for the teflon ring.
(b) Coat a new O-ring with power steering fluid and install it.
R10955
(c) Expand a new teflon ring with your fingers.

NOTICE:
Be careful not to overexpand the ring.
R06172
(d) Coat the ring with power steering fluid.

(e) Install the ring to the steering rack and settle it down with
your fingers.
Z06082
5. IF NECESSARY, REPLACE TEFLON RINGS

(a) Using a screwdriver, remove the 4 rings from the control
valve assembly.
NOTICE:
Be careful not to damage the grooves for the ring.
(b) Expand 4 new teflon rings with your fingers.
NOTICE:
Be careful not to overexpand the ring.
Z01716

SR-55
(c) Coat the rings with power steering fluid and install them
to the control valve, and settle them down with your fin-
gers.
(d) Carefully slide the tapered end of SST over the rings until
SST the rings fit to the control valve assembly.
SST 09631-20081
NOTICE:
Be careful not to damage the rings.
F05317

SR-56
SR1F1-01
REASSEMBLY
NOTICE:
1. COAT WITH POWER STEERING FLUID OR
MOLYBDENUM DISULFIDE LITHIUM BASE GREASE
(See page SR-46 )
2. INSTALL OIL SEAL AND SPACER

(a) Coat a new oil seal lip with power steering fluid.
(b) Install the oil seal and spacer to SST, and drive in them
with a plastic hammer.
SST 09950-60010 (09951-00220, 09951-00380,
09952-06010), 09951-70010 (09951-07360)
NOTICE:
Make sure to install the oil seal facing the correct
R14429 direction.
Take care that the oil seal does not get reversed as
you install it.
3. INSTALL STEERING RACK

(a) Install SST to the rack.
SST 09631-10041
HINT:
If necessary, scrape the burrs off the rack teeth end and bur-
nish.
(b) Coat SST with power steering fluid.
Rack Teeth End (c) Insert the rack into the rack housing.
NOTICE:
Be careful not to damage the oil seal.
(d) Remove the SST.
SST
W02101

SR-57
4. INSTALL OIL SEAL

Vinyl Tape (a) Coat a new oil seal lip with power steering fluid.
(b) To prevent oil seal lip damage, wind vinyl tape on the
steering rack end, and apply power steering fluid.
(c) Install the oil seal by pushing it into the rack housing, with-
out tilting.
NOTICE:
Z03128
5. INSTALL BUSHING AND CYLINDER END STOPPER

SST
(a) Install a new bushing to the stopper.
(b) Using SST, torque the stopper.
SST 09631-20090
R11057
(c) Using a punch and a hammer, stake the stopper and rack
housing.
6. AIR TIGHTNESS TEST

(a) Install SST to the rack housing.
SST 09631-12071
NOTICE:
SST Do not install union seats.
(b) Apply 53 kPa (400 mmHg, 15.75 in.Hg) of vacuum for
about 30 seconds.
(c) Check that there is no change in the vacuum.
SR4264 If there is change in the vacuum, check the installation of the oil
seals.
7. INSTALL CONTROL VALVE ASSEMBLY
(a) Coat the teflon rings with power steering fluid.
(b) Push the valve assembly into the rack housing.

SR-58
8. INSTALL BEARING
Using SST, press in a new bearing.
SST SST 09612-2201 1
Bearing
Z13779
9. INSTALL OIL SEAL

Press
(a) Coat a new oil seal lip with power steering fluid.
SST (b) Using SST, press in the oil seal until it contacts the bear-
Oil Seal ing.
SST 09612-2201 1
Bearing NOTICE:
(c) Using snap ring pliers, install a new snap ring to the rack
W04072 housing.
10. INSTALL SELF-LOCKING NUT

(a) Coat a new bearing with molybdenum disulfide lithium
base grease and install it to the control valve shaft.
SST
(b) Using SST, stop the control valve shaft rotating and
torque a new nut.
SST 09616-00010
SR4281
11. INSTALL RACK HOUSING CAP

Punch (a) Apply sealant to 2 or 3 threads of the cap.
Sealant: Part No.08833-00080, THREE BOND 1344,
(b) Torque the cap.
(c) Using a punch and a hammer, stake the cap at 2 places.
12. INSTALL RACK GUIDE SEAT, RACK GUIDE, RACK
Z13781 GUIDE SPRING, AND RACK GUIDE SPRING CAP
(a) Install the seat to the guide.
(b) Install the guide to the rack housing.
(c) Apply sealant to 2 or 3 threads of the spring cap.
(d) Temporarily install the cap.

SR-59
13. ADJUST TOTAL PRELOAD

Hexagon
(a) To prevent the steering rack teeth from damaging the oil
Wrench
12° seal lip, temporarily install the RH and LH rack ends.
(b) Using a hexagon wrench (21 mm), torque the rack guide
spring cap.
(c) Using a hexagon wrench (21 mm), return the cap 12°.
W04432
(d) Using SST, turn the control valve shaft right and left 1 or
2 times.
SST SST 09616-00010
(e) Using a hexagon wrench (21 mm), loosen the cap until the
rack guide spring is not functioning.
W00840
(f) Using SST, a torque wrench and hexagon wrench (21

SST mm), tighten the cap until the preload is within the specifi-
cation.
SST 09616-00010
Preload (turning):
Hexagon 0.8 - 1.4 N·m (8 - 14 kgf·cm, 6.9 - 12.2 in.·lbf)
Wrench
W00841
Fulcrum 14. INSTALL RACK GUIDE SPRING CAP LOCK NUT

Length Hexagon (a) Apply sealant to 2 or 3 threads of the nut.
Wrench
(b) Using a hexagon wrench (21 mm), hold the rack guide
spring cap and using SST, torque the nut.
SST 09922-10010
SST W01203 NOTICE:
tion.
HINT:
in.).
(c) Recheck the total preload.
Preload (turning):
0.8 - 1.4 N·m (8 - 14 kgf·cm, 6.9 - 12.2 in.·lbf)
(d) Remove the RH and LH rack end.

SR-60
15. INSTALL RH AND LH CLAW WASHERS AND RACK

Rack Groove ENDS
(a) Install a new washer, and temporarily tighten the rack
end.
HINT:
Align the claws of the washer with the steering rack grooves.
R07337
SST, torque the rack end.
SST 09922-10010
SST Torque: 51 N·m (520 kgf·cm, 18 ft·lbf)
NOTICE:
Fulcrum
Length tion.
HINT:
R11031 Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
(c) Using a brass bar and a hammer, stake the washer.
Brass NOTICE:
Bar Avoid any impact on the rack.
R10934
16. INSTALL RH AND LH RACK BOOTS, CLAMPS AND

CLIPS
(a) Ensure that the steering rack hole is not clogged with
grease.
HINT:
If the hole is clogged, the pressure inside the boot will change
after it is assembled and the steering wheel is turned.
(b) Install the boot.
F05319 NOTICE:
Be careful not to damage or twist the boots.
0 - 3 mm (c) Tighten a new clamp, as shown in the illustration.
(0 - 0.12 in.)
SR4273

SR-61
(d) Install the clip.

HINT:
Face the open ends of the clip outward/upward, as shown.
17. INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS
(a) Screw the lock nut and tie rod end onto the rack end until
the matchmarks are aligned.
(b) After adjusting toe-in, torque the nut
(See page SA-4 ).
18. INSTALL AIR CONTROL VALVE
Torque the valve.
19. INSTALL 2 TURN PRESSURE TUBES

(a) Install 2 new union seats.
(b) Using SST, install the tube.
SST 09633-00020
SST Torque: 20 N·m (203 kgf·cm, 15 ft·lbf)
HINT:
Fulcrum Use a torque wrench with a fulcrum length of 300 mm
Length
(11.81 in.).
R11032 This torque value is effective in case that SST is parallel
to a torque wrench.

SR-62
SR0L2-03
INSTALLATION
1. INSTALL PS GEAR ASSEMBLY
Install the gear assembly from the LH of the vehicle.
NOTICE:
Do not damage the turn pressure tubes.
2. INSTALL 2 GROMMETS AND BRACKETS
Torque the 2 bolts and nuts.
R11193
3. CONNECT PRESSURE FEED AND RETURN TUBES

Fulcrum
Using SST, connect the tube.
Length SST 09631-22020
HINT:
Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).
SST
This torque value is effective in case that SST is parallel
R13112 to a torque wrench.
4. CONNECT TUBE CLAMP
Torque the bolt.
5. M/T:
CONNECT CONTROL CABLES
(a) Connect the 2 cables to the control lever housing.
(b) Install the 2 clips to the cables.
(c) Install the 2 clips and washers.
6. CONNECT 2 VACUUM HOSES
7. INSTALL ENGINE REAR MOUNT BRACKET
Torque the 2 bolts.
8. INSTALL ENGINE REAR MOUNT INSULATOR

Torque the 6 bolts.
A Torque:
Bolt A: 64 N·m (650 kgf·cm, 47 ft·lbf)
B B
B B
B Z14367

SR-63
9. INSTALL FRONT EXHAUST PIPE

(a) Connect the 2 rings.
(b) Install the bolt and clamp over a new gasket.
(c) Install the 2 bolts and compression springs over a new
gasket.
10. INSTALL OXYGEN SENSOR
Install the sensor.
11. CONNECT SLIDING YOKE (See page SR-20 )
Torque the 2 bolts and nut.
13. CONNECT RH AND LH TIE ROD ENDS
(See page SA-10 )
HINT:
Do it with the front of the vehicle jacked up.
15. w/ Airbag:
CENTER SPIRAL CABLE (See page SR-20 )
16. w/ Airbag:
INSTALL STEERING WHEEL
(a) Install the wheel at straight-ahead position.
(b) Temporarily tighten the wheel set nut.
17. BLEED POWER STEERING SYSTEM
(See page SR-5 )
19. w/ Airbag:
TORQUE STEERING WHEEL SET NUT
20. w/ Airbag:
INSTALL STEERING WHEEL PAD (See page SR-20 )
21. CHECK FRONT WHEEL ALIGNMENT
(See page SA-4 )

RS-1
SUPPLEMENTAL RESTRAINT SYSTEM - SRS AIRBAG
SRS AIRBAG
RS02V-04
PRECAUTION
NOTICE:
The TERCEL is equipped with an SRS, which comprises a driver airbag and front passenger
airbag. Failure to carry out service operations in the correct sequence could cause the SRS to
unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mis-
take is made in servicing the SRS, it is possible the SRS may fail to operate when required. Be-
fore performing servicing (including removal or installation of parts, inspection or replace-
ment), be sure to read the following items carefully, then follow the correct procedure described
in the repair manual.
Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most impor-
tant source of information when troubleshooting the SRS, always inspect the DTCs before dis-
connecting the battery.
Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front
passenger airbag assembly and airbag sensor assembly should be inspected.
(See page RS-9 , RS-22 , RS-34 )
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
Never disassemble and repair the steering wheel pad, front passenger airbag assembly or air-
bag sensor assembly in order to reuse it.
If the steering wheel pad, front passenger airbag assembly or airbag sensor assembly has been
dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace
them with new ones.
Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting the system’s
electrical circuits.
Information labels are attached to the periphery of the SRS components. Follow the instruction
on the notices.
After work on the SRS is completed, check the SRS warning light. (See page DI-148 )
If the vehicle is equipped with a mobile communication system, refer to the precaution in the
IN section.
CAUTION:
Work must be started 90 seconds after the ignition switch is turned to the ”LOCK” position and
the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a
back-up power source so that if work is started within 90 seconds of disconnecting the nega-
tive (-) terminal cable of the battery, the SRS may be deployed.)
When the negative (-) terminal cable is disconnected from the battery, the memory of the clock
and audio system will be canceled. So before starting work, make a record of the contents mem-
orized in the audio memory system. When work is finished, reset the audio systems as before
and adjust the clock. To avoid erasing the memory of each memory system, never use a back-
up power supply from outside the vehicle.
Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.
Do not expose the steering wheel pad, front passenger airbag assembly or airbag sensor as-
sembly directly to hot air or flames.
Author: Date: 984

RS-2
RS0Q8-02
OPERATION
1. STEERING WHEEL PAD (with AIRBAG)
The inflater and bag of the SRS are stored in the steering wheel
pad and cannot be disassembled. The inflater contains a squib,
igniter charge, gas generant, etc., and inflates the bag when
instructed by the airbag sensor assembly.
N12248
2. SPIRAL CABLE (in COMBINATION SWITCH)

A spiral cable is used as an electrical joint from the vehicle body
side to the steering wheel.
Spiral Cable
R09725
3. FRONT PASSENGER AIRBAG ASSEMBLY

The inflater and bag of the SRS are stored in the front passen-
ger airbag assembly and cannot be disassembled. The inflater
contains a squib, igniter charge and gas generant, etc., and in-
flates the bag when instructed by the airbag sensor assembly.
H05490
4. SRS WARNING LIGHT

The SRS warning light is located on the cluster finish panel. It
goes on to alert the driver of trouble in the system when a mal-
function is detected in the airbag sensor assembly. In normal
operating conditions when the ignition switch is turned to the
ACC or ON position, the light goes on for about 6 seconds and
then goes off.
N12151
5. AIRBAG SENSOR ASSEMBLY

The airbag sensor assembly is mounted on the floor inside the
console box. The airbag sensor assembly consists of airbag
sensor, safing sensor, diagnosis circuit, ignition control and
drive circuit, etc. It receives signals from the airbag sensor and
judges whether the SRS must be activated or not.

RS-3
6. SRS CONNECTORS
No. Item Application

(1) Terminal Twin-Lock Mechanism Connectors 1, 2, 3, 4, 5, 6, 7
(2) Airbag Activation Prevention Mechanism Connectors 2, 3, 4
(3) Electrical Connection Check Mechanism Connectors 1
(4) Connector Twin-Lock Mechanism Connectors 2, 3, 4
(a) All connectors in the SRS are colored in yellow to distin-

guish them from other connectors. Connectors having
special functions and specifically designed for SRS are
used in the locations shown above to ensure high reliabil-
ity. These connectors use durable gold-plated terminals.
(1) Terminal Twin-Lock Mechanism

Spacer
Each connector has a two-piece construction con-
sisting of a housing and a spacer. This secures the
Housing
locking of the terminal by two locking devices (the
spacer and the lance) to prevent terminals from
coming out.
Female Male
Z05953

RS-4
(2) Airbag Activation Prevention Mechanism

Each connector contains a short spring plate. When
the connector is disconnected, the short spring
plate automatically connects the power source and
grounding terminals of the squib.
When Connector is Connected When Connector is Disconnected
Short Spring Plate

Short Spring Plate
Contacting Male Terminal
Housing
Housing
Terminal Short Spring Plate ON
Squib Squib
Connectors Short Spring Plate Closed Circuit
R10587
HINT:
The illustratration shows connectors ”2”, ”3” and ”4”. Connector
1 has short spring plates on the female terminal side.

RS-5
(3) Electrical Connection Check Mechanism

This mechanism is designed to electrically check if
connectors are connected correctly and complete-
ly. The electrical connection check mechanism is
designed so that the connection detection pin con-
nects with the diagnosis terminals when the con-
nector housing lock is in the locked condition.
Half Connection Complete Connection
Terminal for Terminal for

Diagnosis Diagnosis
Disconnection Detection Pin

R13061
(4)Connector Twin-Lock Mechanism

With this mechanism connectors (male and female
connectors) are locked by two locking devices to in-
crease connection reliability.
If the primary lock is incomplete, ribs interfere and prevent the
secondary lock.
Secondary Lock
Primary Lock Lock Lock
Primary Lock Incomplete Primary Lock Complete Twin-Lock Completed

(Secondary Lock Prevented) (Secondary Lock Permitted)
Z05490

RS-6
(b) When the vehicle is involved in a frontal collision in the

hatched area (Fig. 1) and the shock is larger than the pre-
determined level, the SRS is activated automatically. A
safing sensor is designed to go on at a smaller decelera-
tion rate than the airbag sensors. As illustrated in Fig. 2,
ignition is caused when a safing sensor and the decelera-
tion sensor go on simultaneously. When a deceleration
Fig.1
force acts on the sensors, two squibs in the driver airbag
and front passenger airbag ignite and generate gas. The
Power Source
gas discharging into the driver and front passenger air-
bags rapidly increases the pressure inside the bags
breaking open the steering wheel pad and instrument
panel door. Bag inflation then ends, and the bags deflate
Safing
Sensor as the gas is discharged through discharge holes at the
Squibs
bag’s rear or side.
Fig.2
Deceleration
Sensor Z14034

RS-7
SUPPLEMENTAL RESTRAINT SYSTEM - STEERING WHEEL PAD AND SPIRAL CABLE
STEERING WHEEL PAD AND SPIRAL CABLE

RS02X-13
COMPONENTS
Author: Date: 990

RS-8
RS02Y-09
REMOVAL
(See page SR-13 )

RS-9
RS0QB-03
INSPECTION
1. VEHICLE NOT INVOLVED IN COLLISION
(a) Do a diagnostic system check (See page DI-148 ).
(b) Do a visual check which includes the following items with
the steering wheel pad (with airbag) installed in the ve-
hicle.
Check for cuts, minute cracks or marked discoloration of
the steering wheel pad top surface and grooved portion.
2. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS

NOT DEPLOYED
the steering wheel pad (with airbag) installed in the ve-
hicle.
Check for cuts and cracks in, or marked discolor-
ation of the steering wheel pad top surface and
H17548 grooved portion.
Check for cuts and cracks in wire harnesses, and for
chipping in connectors.
Check for deformation of the horn button contact

Horn Button Contact Plate plate of the steering wheel.
H14642
HINT:
If the horn button contact plate of the steering wheel is de-
formed, never repair it. Always replace the steering wheel
assembly with a new one.
There should be no interference between the steering
wheel pad and the steering wheel, and the clearance
should be uniform all the way around when the new steer-
ing wheel pad is installed on the steering wheel.
N12248

RS-10
CAUTION:
For removal and installation of the steering wheel pad, see
page SR-13 and SR-20 , and be sure to follow the correct
procedure.
DEPLOYED
(a) Do diagnostic system check (See page DI-148 ).
the steering wheel pad (with airbag) removed from the ve-
hicle.
Check for deformation of the horn button contact
plate of the steering wheel.
Check for damage to the spiral cable connector and
wire harness.
HINT:
If the horn button contact plate of the steering wheel is de-
formed, never repair it. Always replace the steering wheel
assembly with a new one.
There should be no interference between the steering
wheel pad and the steering wheel, and the clearance
should be uniform all the way around when the new steer-
ing wheel pad is installed on the steering wheel.

RS-1 1
RS0QC-02
DISPOSAL
HINT:
When scrapping vehicle equipped with an SRS or disposing of
a steering wheel pad, always first deploy the airbag in accor-
dance with the procedure described below. If any abnormality
occurs with the airbag deployment, contact the SERVICE
DEPT. of TOYOTA MOTOR SALES, U.S.A., INC.
When disposing of a steering wheel pad with an airbag
deployed in a collision, follow the same procedure given in step
1-(d) in ”DISPOSAL”.
CAUTION:
Never dispose of a steering wheel pad which has an
undeployed airbag.
The airbag produces a sizeable exploding sound
SST when it deploys, so perform the operation out-of-
doors and where it will not create a nuisance to
nearby residents.
When deploying the airbag, always use the specified
AB0152 SST (SRS Airbag Deployment Tool). Carry out opera-
tion in a place away from electrical noise.
SST 09082-00700
When deploying an airbag, do it at least 10 m (33 ft)
away from the steering wheel pad.
The steering wheel pad is very hot when the airbag is
deployed, so leave it alone for at least 30 minutes af-
ter deployment.
Use gloves and safety glasses when handling a steer-
ing wheel pad with a deployed airbag.
Do not apply water, etc. to a steering wheel pad with
a deployed airbag.
Always wash your hands with water after completing
the operation.

RS-12
1. AIRBAG DEPLOYMENT WHEN SCRAPPING VE-

HICLE
HINT:
Battery
Have a battery ready as the power source to deploy the airbag.
SST
AB0158
(a) Check functioning of the SST.

CAUTION:
When deploying the airbag, always use the specified SST:
SRS Airbag Deployment Tool.
SST SST 09082-00700
AB0152
(1) Connect the SST to battery.

Connect the red clip of the SST to the battery posi-
tive (+) terminal and the black clip to the battery neg-
Battery ative (-) terminal.
HINT:
Do not connect the yellow connector which connects with the
SST SRS.
AB0158
(2) Check functioning of the SST.

Press the SST activation switch, and confirm the
SST LED of the SST activation switch lights up.
CAUTION:
If the LED lights up when the activation switch is not being
pressed, SST malfunction is probable, so definitely do not
use the SST.
H01580
(b) Disconnect the airbag connector.

(1) Remove the No.1 under cover.
(2) Disconnect the airbag connector of the spiral cable.
N12265

RS-13
(c) Install the SST.

(1) Connect the SST connector to the airbag connec-
tor.
SST 09082-00700
NOTICE:
To avoid damaging the SST connector and wire harness,
do not lock the secondary lock of the twin lock.
H14726
(2) Move the SST to at least 10 m (33 ft) away from the
front of the vehicle.
(3) Close all the doors and windows of the vehicle.
NOTICE:
Take care not to damage the SST wire harness.
(4) Connect the SST red clip to the battery positive (+)
terminal and the black clip to the negative (+) termi-
10 m (33 ft) or more nal.
← →
R13455
(d) Deploy the airbag.

(1) Confirm that no-one is inside the vehicle or within
10 m (33 ft) of the vehicle.
(2) Press the SST activation switch and deploy the air-
bag.
HINT:
The airbag deploys simultaneously as the LED of the SST ac-
tivation switch lights up.
(e) Dispose of the steering wheel pad.
CAUTION:
ter deployment.
a deployed airbag.
the operation.
(f) When scrapping a vehicle, deploy the airbag and scrap
the vehicle with the steering wheel pad still installed.
2. DEPLOYMENT WHEN DISPOSING OF STEERING
WHEEL PAD ONLY
NOTICE:
When disposing of the steering wheel pad only, never use
the customers vehicle to deploy the airbag.
HINT:
(a) Remove the steering wheel pad.

RS-14
CAUTION:
When storing the steering wheel pad, keep the deployment
direction facing up.
(b) Fix the steering wheel pad.

Wire Harness (1) Using a service-purpose wire harness for the ve-
Diameter
hicle tie down the steering wheel pad to the disc
wheel
Wire harness: Stripped wire harness section
1.25 mm2 or more (0.0019 in.2 or more).
CAUTION:
Stripped Wire Harness Section If a wire harness which is too thin or some other thing is
AB0163 used to tie down the steering wheel pad, it may be snapped
by the shock when the airbag is deployed. This is highly
dangerous. Always use a wire harness for vehicle use
which is at least 1.25 mm2 (0.0019 in.2).
HINT:
To calculate the square of the stripped wire harness section:
Square = 3.14 X (Diameter)2 divided by 4
(2) Remove the connector on the steering wheel pad
rear surface from the inflater cover.
(3) Install the bolts and washers in the 3 bolt holes in

the steering wheel pad.
Bolt:
L: 35.0 mm (1.387 in.)
M: 6.0 mm (0.236 in.)
Pitch: 1.0 mm (0.039 in.)
NOTICE:
Tighten the bolts by hand until the bolts become diffi-
cult to turn.
Do not tighten the bolts too much.

RS-15
(4) Using 3 wire harness, wrap the wire harness at least

2 times each around the bolts installed on the left
and right sides of the steering wheel pad.
CAUTION:
Tightly wind the wire harness around the bolts so that
there is no slack.
If there is slackness in the wire harness, the steering
wheel pad may come loose due to the shock when the
airbag is deployed. This is highly dangerous.
(5) Face the upper surface of the steering wheel pad

upward. Separately tie the left and right sides of the
steering wheel pad to the disc wheel through the
hub nut holes.
(6) Position the steering wheel pad connector so that
it hangs downward through a hub hole in the disc
wheel.
CAUTION:
R05751 Make sure that the wire harness is tight. It is very dan-
gerous if looseness in the wire harness results in the
steering wheel pad coming free through the shock of
the airbag deploying.
Always tie down the steering wheel pad with the pad
side facing upward. It is very dangerous if the steer-
ing wheel pad is tied down with the metal surface fac-
ing to the airbag deploying direction and the steering
wheel pad will be thrown into the air.
HINT:
The disc wheel will be marked by airbag deployment, so when
disposing of the airbag use a redundant disc wheel.
(c) Check functioning of the SST.
(See step 1)
SST 09082-00700
Battery
SST AB0158

RS-16
(d) Install the SST.

CAUTION:
SST Place the disc wheel on level ground.
Connect the SST connector to the steering wheel pad
connector.
SST 09082-00700
NOTICE:
R05752 do not lock the secondary lock of the twin lock. Also, pro-
vide some slack for the SST wire harness inside the disc
wheel.
(e) Cover the steering wheel pad with cardboard box or tires.
Covering method using cardboard box:
Cover the steering wheel pad with the cardboard
box and weight the cardboard box down in 4 places
with at least 190 N (20 kg, 44 lb).
Size of cardboard box:
Must exceed the following dimensions:
x= 460 mm (18.11 in.)
AB0164 When dimension y of the cardboard box exceeds the
diameter of the disc wheel with tire to which the steer-
ing wheel pad is tied -
x= 460 mm (18.11 in.) + width of tire
y= 650 mm (25.59 in.)
NOTICE:
If a cardboard box smaller than the specified size is used,
the cardboard box will be broken by the shock of the airbag
deployment.
Inner Diam. Covering method using tires:

Place at least 3 tires without disc wheel on top of the
Width disc wheel with tire to which the steering wheel pad
Tires is tied.
(3 or more) Tire size: Must exceed the following dimensions-
Width: 185 mm (7.28 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:
R04211 Do not use tires with disc wheels.

RS-17
NOTICE:
The tires may be marked by the airbag deployment, so use
redundant tires.
(f) Deploy the airbag.

terminal and the black clip to the battery negative
(-) terminal.
(2) Confirm that no-one is within 10 m (33 ft) area
around the disc wheel to which the steering wheel
pad is tied.
10 m (33 ft) or more
H00400 bag.
HINT:
(g) Dispose of the steering wheel pad (with airbag).

CAUTION:
ter deployment.
AB0166 deployed airbag.
the operation.
(1) Remove the steering wheel pad from the disc
wheel.
(2) Place the steering wheel pad in a vinyl bag, tie the
end tightly and dispose of it in the same way as oth-
er general parts.

RS-18
RS031-09
REPLACEMENT
REPLACEMENT REQUIREMENTS
In the following case, replace the steering wheel pad, steering wheel and spiral cable.
If the airbag has been deployed.
If the steering wheel pad and spiral cable has been found to be faulty in troubleshooting.
If the steering wheel pad, steering wheel and spiral cable has been found to be faulty during the
check in item (See page RS-9 ).
If the steering wheel pad and has been dropped.
CAUTION:
For remove and installation of the steering wheel pad See page SR-13 , RS-8 and RS-19 , and be sure
to follow the correct procedure.

RS-19
RS032-11
INSTALLATION
(See page SR-20 )

RS-20
SUPPLEMENTAL RESTRAINT SYSTEM - FRONT PASSENGER AIRBAG ASSEMBLY
FRONT PASSENGER AIRBAG ASSEMBLY

RS033-12
COMPONENTS
Author: Date: 1003

RS-21
RS0AZ-06
REMOVAL
NOTICE:
If the wiring connector of the SRS is disconnected
with the ignition switch at ON or ACC, diagnostic
trouble codes will be recorded.
Never use airbag parts from another vehicle. When
replacing parts, replace with new parts.
1. DISCONNECT AIRBAG CONNECTOR

(a) Remove the lower center finish panel.
(See page BO-38 )
NOTICE:
When handling the airbag connector, take care not to dam-
age the airbag wire harness.
2. REMOVE INSTRUMENT PANEL (See page BO-38 )
3. REMOVE FRONT PASSENGER AIRBAG ASSEMBLY

(a) Remove the 2 bolts, 2 nuts and front passenger airbag as-
sembly.
(b) Remove the airbag door.
CAUTION:
Do not store the front passenger airbag assembly
with the airbag deployment side facing down
Never disassemble the front passenger airbag as-
N12255 sembly.

RS-22
RS0QD-02
INSPECTION
1. VEHICLE NOT INVOLVED IN COLLISION

the front passenger airbag assembly installed in the ve-
hicle.
Check for cuts, minute cracks in or marked discoloration
of the front passenger airbag door.
NOT DEPLOYED
(a) Do a diagnostic system check (Seee page DI-148 ).
H05490 (b) Do a visual check which includes the following items with
the front passenger airbag assembly removed from the
vehicle.
Check for cuts and cracks in, or marked discolor-

ation of the front passenger airbag door.
Check for cuts and cracks in wire harnesses, and for
chipping in connectors.
H17547
Check for deformation of the instrument panel and

Intrument Panel Reinforcement instrument panel reinforcement.
H06090

RS-23
HINT:
If the instrument panel or instrument panel reinforcement
is deformed, never repair it. Always replace it with a new
one.
There should be no interference between the instrument
panel and front passenger airbag door, or the glove
compartment door and front passenger airbag door. The
clearance should be uniform all the way around when the
H05490 new airbag assembly is installed on the instrument panel.
CAUTION:
For removal and installation of the front passenger airbag
assembly, see page RS-21 and RS-31 , and be sure to fol-
low the correct procedure.
DEPLOYED
the airbag assembly removed from the vehicle.
Check for deformation of the instrument panel,
instrument panel reinforcement and glove compart-
ment door.
Check for damage to the connector and wire har-
ness.
HINT:
If the instrument panel or instrument panel reinforcement
is deformed, never repair it. Always replace it with a new
one.
There should be no interference between the instrument
panel and front passenger airbag door, or the glove
compartment and front passenger airbag door. The clear-
ance should be uniform all the way around when the new
airbag assembly is installed on the instrument panel.

RS-24
RS0T1-01
DISPOSAL
HINT:
When an scrapping vehicle equipped with an SRS or disposing
of a front passenger airbag assembly, always first deploy the
airbag in accordance with the procedure described below. If any
abnormality occurs with the airbag deployment, contact the
SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC.
When disposing of a front passenger airbag assembly with an
airbag deployed in a collision, follow the same procedure given
in step 1-(e) in ”DISPOSAL”.
CAUTION:
Never dispose of a front passenger airbag assembly
which has an undeployed airbag.
The airbag produces a sizeable exploding sound
SST
when it deploys, so perform the operation out-of-
doors and where it will not create a nuisance to
nearby residents.
When deploying the airbag, always use the specified
AB0152 SST (SRS Airbag Deployment Tool). Carry out opera-
tion in a place away from electrical noise.
SST 09082-00700
When deploying an airbag, do it at least 10 m (33 ft)
away from the front passenger airbag assembly.
The front passenger airbag assembly is very hot
when the airbag is deployed, so leave it alone for at
least 30 minutes after deployment.
Use gloves and safety glasses when handling a front
passenger airbag assembly with a deployed airbag.
Do not apply water, etc. to a front passenger airbag
assembly with a deployed airbag.
the operation.

RS-25
1. AIRBAG DEPLOYMENT WHEN SCRAPPING VE-

HICLE
HINT:
Battery Have a battery ready as the power source to deploy the airbag.
SST
AB0158
(a) Check functioning of the SST (See page RS-1 1).

SST 09082-00700
SST
AB0152

(1) Remove the lower finish panel
(See page BO-45 ).
(2) Disconnect the airbag connector.
NOTICE:
When handling the airbag connector, take care not to dam-
age the airbag wire harness.
(c) Install the SST.

(1) Connect the SST connector to the airbag connec-
tor.
SST 09082-00700
NOTICE:
do not lock the secondary lock of the twin lock.
H14927
(2) Move the SST to at least 10 m (33 ft) away from the
front of the vehicle.
(3) Close all the doors and windows of the vehicle.
NOTICE:
Take care not to damage the SST wire harness.
terminal and the black clip to the negative (+) termi-
10 m (33 ft) or more nal.
← →
R13455

RS-26
(d) Deploy the airbag.

(1) Confirm that no-one is inside the vehicle or within
10 m (33 ft) of the vehicle.
bag.
HINT:
R09686 (e) Dispose of the front passenger airbag assembly.
CAUTION:
assembly with a deployed airbag.
the operation.
When scrapping a vehicle, deploy the airbag and scrap
the vehicle with the front passenger airbag assembly still
installed.
2. DEPLOYMENT WHEN DISPOSING OF FRONT PAS-
SENGER AIRBAG ASSEMBLY ONLY
NOTICE:
When disposing of the front passenger airbag assembly
only, never use the customers vehicle to deploy the airbag.
HINT:
(a) Remove the front passenger airbag assembly.
CAUTION:
When storing the steering wheel pad, keep the deployment
direction facing up.
(b) Fix the front passenger airbag assembly.

Wire Harness (1) Using a service-purpose wire harness for the ve-
Diameter
hicle, tie down the front passenger airbag assembly
to the tire.
Wire harness: Stripped wire harness section
1.25 mm2 or more (0.0019 in.2 or more)
Stripped Wire Harness Section

AB0163

RS-27
CAUTION:
If the front passenger airbag assembly is tied down with
too thin wire harness, it may snap. This is highly danger-
ous. Always use a wire harness for vehicle use which is at
least 1.25 mm2 (0.0019 in.2).
HINT:
To calculate the square of the stripped wire harness section:
Square = 3.14 X (Diameter)2 divided by 4
(2) Wrap the wire harness around the tire, passing the
wire harness through the installation holes indi-
cated by arrows in the installation.
(3) Position the front passenger airbag assembly in-

Width side the tire with the airbag deployment side facing
inside.
Tire size: Must exceed the following dimensions-
Width: 185 mm (7.28 in.)
Inner
Diam.
Inner diameter: 360 mm (14.17 in.)
CAUTION:
Make sure that the wire harness is tight. It is very dan-
H04923 gerous if a loose wire harness results in the front pas-
senger airbag assembly coming free due to the shock
of the airbag deploying.
Always tie down the front passenger airbag assembly
with the airbag door facing inside.
NOTICE:
The tire will be marked by the airbag deployment, so when
disposing of the airbag use a redundant tire.
(c) Check functioning of the SST (See page RS-1 1).

SST 09082-00700
Battery
SST
AB0158

RS-28
(d) Install the SST.

(1) Place at least 2 tires under the tire to which the front
passenger airbag assembly is tied.
(2) Place at least 2 tires over the tire to which the front
Tires
passenger airbag assembly is tied. The top tire
(5 or more)
should have the wheel installed.
(3) Tie the tires together with 2 wire harnesses.
CAUTION:
R09689 Make sure that the wire harnesses are tight. It is very dan-
gerous if loose wire harnesses result in the tires coming
free due to the shock of the airbag deploying.
HINT:
Place the SST connector and wire harness inside tires. Provide
at least 1 m (3 ft) of slack for the wire harness.
R05403
(4) Connect the SST connector to the front passenger

airbag assembly connector.
SST 09082-00700
Battery NOTICE:
Front Passenger To avoid damaging the SST connector and wire harness,
SST
Airbag Assembly do not lock the secondary lock of the twin lock.
(e) Deploy the airbag.
10 mm (33 ft) or more
R09690 terminal and the black clip to the battery negative
(-) terminal.
(2) Confirm that no-one is within 10 m (33 ft) of the tires
covering the front passenger airbag assembly.
bag.
HINT:
(f) Dispose of the front passenger airbag assembly.

CAUTION:
R09687 assembly with a deployed airbag.

RS-29

the operation.
(1) Remove the front passenger airbag assembly from
the tire.
(2) Place the front passenger airbag assembly in a vi-
nyl bag, tie the end tightly and dispose of it in the
same way as other general parts.

RS-30
RS037-04
REPLACEMENT
In the following cases, replace the front passenger airbag assembly, instrument panel and instrument panel
reinforcement.
If the airbag has been deployed.
If the front passenger airbag assembly has been found to be faulty in troubleshooting.
If the instrument panel and instrument panel reinforcement has been found to be faulty during
the check in item (See page RS-22 ).
CAUTION:
For removal and installation of the front passenger airbag assembly, see page RS-21 and RS-31 re-
spectively. Be sure to follow the correct procedure.

RS-31
RS0QE-02
INSTALLATION
Front 1. INSTALL FRONT PASSENGER AIRBAG ASSEMBLY
Install the airbag door and front passenger airbag assembly to
the instrument panel.
CAUTION:
Make sure that no foreign objects are trapped between the
airbag bag, and within the module.
NOTICE:
N12255
If the front passenger airbag assembly has been dropped,
or there are cracks, dents or other defects in the case or
connector, replace the front passenger airbag assembly
with a new one.
2. INSTALL INSTRUMENT PANEL (See page BO-38 )
Install the 2 bolts to instrument panel reinforcement.
NOTICE:
Make sure the front passenger airbag assembly is
installed to the specified torque.
When installing the instrument panel, take care that
the airbag wire harness does not interfere with other
parts and is not pinched between other parts.
When installing the instrument panel box, carefully
pull out the airbag wire harness from the glove
compartment upper hole.
3. CONNECT AIRBAG CONNECTOR
(a) Connect the airbag connector.
(b) Install the lower finish panel (See page BO-45 ).

RS-32
SUPPLEMENTAL RESTRAINT SYSTEM - AIRBAG SENSOR ASSEMBLY
AIRBAG SENSOR ASSEMBLY

RS039-12
COMPONENTS
Author: Date: 1015

RS-33
RS03A-15
REMOVAL
NOTICE:
Do not open the cover or the case of the ECU and various
computers unless absolutely necessary.
If the IC terminals are touched, the IC may be destroyed by stat-
ic electricity.
2. REMOVE CONSOLE BOX
3. REMOVE CENTER CLUSTER FINISH PANEL
4. REMOVE LOWER CENTER FINISH PANEL
5. REMOVE REAR AIR DUCT NO.3
6. REMOVE AIRBAG SENSOR ASSEMBLY

(a) Disconnect the connectors.
NOTICE:
Remove of the connector is done with the sensor assembly
installed.
(b) Using a torx wrench remove the 3 screws and the airbag
sensor assembly.
Torx wrench: T40 (Part No. 09042- 00020 or locally
manufactured tool)

RS-34
RS08W-02
INSPECTION
1. VEHICLES NOT INVOLVED IN COLLISION
Do a diagnostic system check. (See page DI-148 )
2. VEHICLES INVOLVED IN COLLISION AND SRS IS NOT DEPLOYED
3. VEHICLES INVOLVED IN COLLISION AND SRS IS DEPLOYED
Replace the airbag sensor assembly.

RS-35
RS01J-16
REPLACEMENT
In the following cases, replace the airbag sensor assembly.
If the SRS has been deployed in a collision.
If the airbag sensor assembly has been found to be faulty in troubleshooting.
If the airbag sensor assembly has been dropped.
CAUTION:
For removal and installation of the airbag sensor assembly, see page RS-33 and RS-36 . Be sure to
follow the correct procedure.

RS-36
RS03C-13
INSTALLATION
NOTICE:
Never use SRS parts from another vehicle. When re-
placing parts, replace with new parts.
Never reuse the airbag sensor assembly involved in
a collision when the airbag has deployed.
Never repair a sensor in order to reuse it.
1. INSTALL AIRBAG SENSOR ASSEMBLY

(a) Using a torx wrench, install the airbag sensor assembly
with the 3 screws.
Torx wrench: T40 (Part No. 09042- 00020 or locally
manufactured tool)
(b) Connect the connector.
NOTICE:
Installation of the connector is done after the sensor
assembly has been installed.
Make sure the sensor assembly is installed to the
specified torque.
If the sensor assembly has been dropped, or there are
cracks, dents or other defects in the case, bracket or
connector, replace the sensor assembly with a new
one.
When installing the airbag sensor assembly, take
care that the SRS wiring does not interfere with other
parts and is not pinched between other parts.
After installation, shake the sensor assembly to
check that there is no looseness.
2. INSTALL THE REMOVED PARTS

RS-37
SUPPLEMENTAL RESTRAINT SYSTEM - WIRE HARNESS AND CONNECTOR
WIRE HARNESS AND CONNECTOR

RS03D-14
LOCATION
N12264
Author: Date: 1020

RS-38
SUPPLEMENTAL RESTRAINT SYSTEM - WIRE HARNESS AND CONNECTOR
RS03E-02
INSPECTION
HINT:
The SRS wire harness is integrated with the cowl wire harness assembly. The wires for the SRS wire harness
are encased in a yellow corrugated tube and all the connectors in the system are a standard yellow color.
1. VEHICLES NOT INVOLVED IN COLLISION
2. VEHICLES INVOLVED IN COLLISION
(a) Do a diagnostic system check. (See page DI-148 )
(b) Check for breaks in all wires of the SRS wire harness, and for exposed conductors.
(c) Check to see if the SRS wire harness connectors are cracked or chipped.

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AX-18

AUTOMATIC TRANSAXLE (A242L) - VALVE BODY ASSEMBLY

1996 TERCEL (RM440U)

THROTTLE CABLE AX0RZ-01

2. REMOVE PARK/NEUTRAL POSITION SWITCH

4. REMOVE THROTTLE CABLE

1996 TERCEL (RM440U)

Author: Date: 801

1996 TERCEL (RM440U)

GOVERNOR VALVE AX0S1-01

2. REMOVE GOVERNOR COVER WITH O-RING

3. REMOVE GOVERNOR BODY WITH THRUST WASHER

1996 TERCEL (RM440U)

Author: Date: 803

1996 TERCEL (RM440U)

DIFFERENTIAL OIL SEAL AX0S3-01

SST 4. REMOVE SIDE OIL SEAL

1996 TERCEL (RM440U)

Author: Date: 805

1996 TERCEL (RM440U)

1996 TERCEL (RM440U)

Author: Date: 807

1996 TERCEL (RM440U)

SHIFT LOCK SYSTEM

Key Interlock Solenoid

Shift Lock Control

1996 TERCEL (RM440U)

Author: Date: 809

Wire Harness Side

Terminal Measuring Condition Voltage (V)

2. INSPECT KEY INTERLOCK SOLENOID

(c) Apply battery positive voltage between terminals. Check

1996 TERCEL (RM440U)

AUTOMATIC TRANSAXLE UNIT

Snap Speedometer Cable

Plug for Governor

Front Exhaust Pipe

Engine Under Cover

1996 TERCEL (RM440U)

Author: Date: 811

5. REMOVE UPPER SIDE MOUNTING BOLTS

6. INSTALL ENGINE SUPPORT FIXTURE

11. DISCONNECT CONTROL CABLE

15. REMOVE STARTER

1996 TERCEL (RM440U)

16. REMOVE FRONT EXHAUST PIPE

17. REMOVE TORQUE CONVERTER CLUTCH MOUNT-

18. SUPPORT TRANSAXLE WITH A TRANSMISSION

20. REMOVE ENGINE REAR MOUNTING

1996 TERCEL (RM440U)

C 21. REMOVE TRANSAXLE MOUNTING BOLT

1996 TERCEL (RM440U)

1996 TERCEL (RM440U)

TORQUE CONVERTER CLUTCH

2. MEASURE DRIVE PLATE RUNOUT AND INSPECT

3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE

Author: Date: 816

PROBLEM SYMPTOMS TABLE

1. Tire (Worn or improperly inflated) SA-2