Replace any of these parts as necessary. Do not use old or used brake fluid, or one taken from unsealed container. Change brake fluid as follows. Drain existing fluid from brake system completely, fill system with above recommended fluid and carry out air purge operation. Replace cable if it is in deteriorated condition.
If any damage or wear is found, replace parking lever. If defective, replace. Wear indicator. A disc in badly damaged condition must be replaced. Repair or replace defective parts, if any. Front axle housing 7. Ball joint. REAR 1 Check shock absorber 1 for damage, deformation, oil leakage and operation. Replace any parts found defective in steps 1 to 5.
Spring seat. If rattle is found, replace defective part with a new one. Repair leaky point if any. Oil level can be checked roughly by means of level plug hole.
That is, if oil flows out of level plug hole or if oil level is found up to hole when level plug is removed, oil is properly filled. If oil is found insufficient, pour specified amount of specified oil. Repair leaky point, if any. If fluid level is low, replenish specified fluid. Dipstick 2. Drain plug. Drain plug Apply sealant. If rattle or damage is found, replace defective part with a new one. Repair or replace defective part, if any. If leakage is found, check oil level in gear box.
If damage is found, replace defective boot with new one. If necessary, have belt adjusted or replaced. If any malfunction is found, lubricate hinge and latch or repair door lock system. Also check that hood opens and closes smoothly and properly and hood locks securely when closed. If any malfunction is found, lubricate hinge and latch, or repair hood lock system. Check hood latch bolt for tightness. Also check that reclining mechanism of front seat back allows it to be locked at any angle.
Check that seat belt is securely locked. If battery is equipped with built-in indicator, check battery condition by the indicator. Then, firmly apply both the parking brake and the regular brakes. Do not use the accelerator pedal. If the engine starts, be ready to turn off the ignition promptly. Take these precautions because the vehicle could move without warning and possibly cause personal injury or property damage.
On automatic transmission vehicles, try to start the engine in each select lever position. With automatic transmission equipped vehicle, also check that shift indicator indicates properly according to which position selector lever is shifted to.
Parking Brake Check that lever has proper travel. WARNING: With vehicle parked on a fairly steep slope, make sure nothing is in the way downhill to avoid any personal injury or property damage. Be prepared to apply regular brake quickly even if vehicle should start to move. Check to ensure that parking brake is fully effective when the vehicle is stopped on the safe slope and brake lever is pulled all the way. Clutch linkage pivot points Steering knuckle seal Door hinges Hood latch assembly Key lock cylinder.
Either or these two conditions may result in severe injury. Diagnosis Table Wiring Circuit On Vehicle Service Heater Blower Motor Heater Blower Resistor Heater Control Lever Assembly Heater Blower Fan Switch General Description The heater, an in and out air selectable-type hot water heater, is so constructed that it is possible to assure an agreeable ventilation at all times by providing the ventilator air outlets at the center and both sides right and left of the instrument panel, the hot air outlet at a place close to the feet of front passengers, and the defroster air outlets at places, right and left, along the windshield glass.
The heater and ventilation consist of following parts. Possible Cause Blower fuse blown Blower resistor faulty Blower fan switch faulty Blower motor faulty Wiring or grounding faulty Control cables broken or binding Temperature control lever faulty Control cable clamp position is faulty Air damper broken Air ducts clogged Heater radiator leaking or clogged Heater hoses leaking or clogged Control cable broken or binding Mode control lever faulty Control cable clamp position is faulty Air damper broken Air ducts leaking on clogged.
Correction Replace fuse to check for short. Check resistor. Check blower fan switch. Replace motor. Repair as necessary. Check cables. Check control lever. Check and adjustment. Repair damper. Repair air ducts. Replace radiator. Replace hoses. Check cable. If check results are continuity, proceed to next operation check, If not replace. Heater unit 2. Blower motor. Heater blower resistor resistance Me-Lo: approx.
Heater control lever assembly. NOTE: After installing control cables, be sure that control levers move smoothly and stop at proper position. Air inlet box 3.
Mode control cable 4. Temperature control cable 5. Fresh air control cable. Be sure to check which refrigerant is used before any service work including inspection and maintenance. Use of incorrect one will result in leakage of refrigerant, damage in parts or other faulty condition. Major Components and Location Refrigerant Circulation Refrigerant Type General Diagnosis Table Abnormal Noise Diagnosis Abnormal noise from compressor Abnormal noise from magnetic clutch Abnormal noise from tubing Abnormal noise from condenser Abnormal noise from crankshaft pulley Abnormal noise from tension pulley Abnormal noise from blower fan motor Quick Checking of Refrigerant Charge Performance Diagnosis Performance diagnosis table Compressor Drive Belt Electronical Diagnosis Wiring Diagram Refrigerant Recovery, Evacuating and Charging Operation Procedure for Refrigerant Charging Replenishing Compressor Oil Evacuating procedure Charging procedure Removing Manifold Gauge Set Leak Test On-Vehicle Service Service Precaution Refrigerant line Handling refrigerant HFCa Ra Condenser Assembly Condenser Cooling Fan Assembly Cooling Unit Evaporator Also, it can be checked by the shape of the service charge valve 2.
Correction Perform recover, evacuation and charging. Check fuses in main and circuit fuse boxes, and check short circuit to ground. Check blower fan switch referring to Section 1A. Dual pressure switch faulty Check dual pressure switch. Wiring or grounding faulty Repair as necessary. Compressor drive belt loosen or broken Adjust or replace drive belt. Compressor faulty Check compressor. Blower fan switch faulty Check blower fan switch referring to Section 1A. Blower fan motor faulty Check blower fan motor referring to Section 1A.
Correction Check charge of refrigerant and system for leaks. Check condenser. Expansion valve faulty Check expansion valve. Magnetic clutch faulty Check magnetic clutch. Air leaking from cooling unit or air duct Repair as necessary. Heater and ventilation system faulty Check air inlet box cooling unit , heater control lever assembly and heater unit referring to Section 1A. Excessive charge of refrigerant Check charge of refrigerant.
Thermal switch faulty Check thermal switch. Abnormal Noise Diagnosis There are various types of noise, ranging from those produced in the engine compartment to those from the passenger compartment, also from rumbling noises to whistling noises. Abnormal noise from compressor Condition During compressor operation, a rumbling noise is heard proportional to engine revolutions. A loud noise is heard at a certain rpm, disproportionately to engine revolution.
A loud rattle is heard at low engine rpm. Retighten clutch plate bolt. Replace compressor if it was operated in this condition for a long time. Abnormal noise from magnetic clutch Condition A rumbling noise is heard when compressor is not operating. A chattering noise is heard when compressor is engaged. Faulty clutch clearance excessive.
Worn clutch friction surface. Compressor oil leaked from lip type seal. Contaminating the friction surface. Adjust clutch clearance. Replace magnet clutch assembly. Replace lip type seal.
Replace compressor body assembly. Abnormal noise from tubing Condition A droning noise is heard inside vehicle, but not particularly noticeable in engine compartment. Correction Reposition clamps or increase the number of clamps. Resonance caused by pulsation from variations Attach a silencer to tubing, or modin refrigerant pressure. Abnormal noise from crankshaft pulley Condition Possible Cause A large rattling noise Loosen crankshaft pulley bolt.
Abnormal noise from tension pulley Condition Clattering noise is heard from pulley. Pulley cranks upon contact. Correction At times, slightly decreasing refrigerant volume may stop this noise. Inspect expansion valve and replace if faulty. Abnormal noise from blower fan motor Condition Blower fan motor emits a chirping sound in proportion to its speed of rotation.
Fluttering noise or large droning noise is heard from blower fan motor. Leaves or other debris introduced from fresh air Remove debris and make sure that inlet to blower fan motor. Charge of refrigerant condition Insufficient charge of refrigerant in system No or insufficient charge of refrigerant in system Empty or nearly empty system. Correction Check system for leaks with a leak tester. Refer to the items 3 and 4. Evacuate and charge system and then check it for leaks with a leak tester.
Refer to the items 5 and 6. Proper or too much charge of refrigerant in system Too much charge of refrigerant in Discharge excess refrigerant in system order to obtain a specified charge. Proper charge of refrigerant in system. Performance Diagnosis 1 Confirm that vehicle and environmental conditions are as follows. When a hissing sound is heard, immediately tighten nut.
Radiator cooling fan should not be working when checking pressure and temperature. Keep all windows, doors and engine food open. Performance diagnosis condition Ambient temperature Engine rpm Blower fan motor switch Temperature control Air outlet control Vehicle doors Air inlet door position.
NOTE: Pressure registered on gauge varies with ambient temperature. Therefore, use graph when determining if pressures are normal or not. Engine overheat. Correction Recharge Check expansion valve Clean or replace Check condenser cooling fan Clean or repair Check compressor Check engine cooling system referring to Section 6B.
Check for leakage, repair if necessary and recharge Check expansion valve. Correction Check expansion valve Check compressor Check for leakage, repair if necessary and recharge Check expansion valve Repair or replace. Correction Check refrigerant pressure Clean or repair Repair or replace Repair or replace Check compressor Check blower motor and fan Check compressor. Normal condition The low pressure side reads a negative pressure, and the high pressure side reads an extremely low pressure.
Also high pressure side reading fluctuates between the abnormal and normal pressure. Dust particles or water droplets are either stuck or frozen inside expansion valve, preventing the refrigerant from flowing. Clean expansion valve. Replace it if it cannot be cleaned. Expansion valve is frozen due to moisture in the system, and temporarily shuts off the refrigeration cycle.
Replace expansion valve. Both low and high pres- Insufficient refrigerant in sure sides indicate low system. Refrigerant leaking Continuous air bubbles are visible through sight glass. Output air is slightly cold. Pressure on low pressure side is high. Pressure on high pressure side is low. Pressure on both low and high pressure sides is high. Air bubbles are not visible even when engine rpm is lowered. Low pressure side tubing is not cold when touched.
Air bubbles are visible through sight glass. Large amount of frost or dew on the low pressure side tubing. Using leak detector, check for leaks and repair as necessary. Recharge refrigerant to a specified amount. If the pressure reading is almost 0 when the manifold gauges are attached, check for any leaks, repair them, and evacuate the system. Internal leak in compres- Inspect compressor and sor. Faulty condenser cooling operation.
Faulty condenser cooling fan operation. Improperly evacuated. Inspect and repair condenser cooling fan. Inspect quantity of compressor oil and presence of contaminants in oil. Evacuate system and recharge with fresh refrigerant. If belt tension is out of above specification, adjust belt tension according to the following procedures. NOTE: Because each terminal voltage is affected by the battery voltage, confirm that the battery voltage is 11 V or more when ignition switch is ON.
A [B] : Fig. Normal value 10 — 14 volt 0 — 1 volts 10 — 14 volts 10 — 14 volts 0. Engine coolant temperature at 0. Should liquid HFCa Ra get into your eyes, it may cause a serious injury.
To protect your eyes against such accident, it is necessary to always wear goggles. Should it occur that HFCa Ra strikes your eyes s , consult a doctor immediately. Instead, use quantities of fresh cold water to splash it over the affected area to gradually raise temperature of such area above freezing point. It should never be stored where a high temperature is anticipated, e. Such fumes may be hazardous to health.
Replenish compressor oil Start evacuating 15 minutes — mmHg Stop evacuating Wait 10 mintues Check system for pressure tightness. Discharging refrigerant HFCa Ra into atmosphere would cause adverse effect to environments. Replenishing Compressor Oil It is necessary to replenishing specified amount of compressor oil to compressor 1 from compressor suction side hole 2 before evacuating and charging refrigerant.
Compressor oil D0. Therefore, when using a new compressor for replacement, drain oil from new compressor by the amount calculated as follows. New compressor 2. Removed compressor. Amount of compressor oil to be replenished Replaced part. NOTE: Do not evacuate before recovering refrigerant and replenishing compressor oil.
If there is no blockage in the system, there will be an indication on high pressure gauge 9. In this case, open the other side valve Lo 10 of the set and repair the system. In this case, repair the system before continuing its evacuation. Disconnect center charging hose 6 from pump inlet. Now, the system is ready for charging refrigerant.
Reversing in direction causes liquid refrigerant to enter compressor, causing troubles, such as compression of liquid refrigerant and the like. Described here is a method to charge the air conditioning system with refrigerant from the refrigerant service container.
And next, this method must be followed by charging from the low pressure side with the engine running. Thus open refrigerant container valve 4 to purge the charging line. Then, operate air conditioning. At this time, refrigerant container should be held upright. When using refrigerant container tap valve 4 , use the following procedure for replacement. The high pressure side valve is closed continuously during the process of charging. This operation must be performed rapidly.
So, care must be used to protect your eyes and skin. Leak Test Whenever a refrigerant leak is suspected in the system or any service operation has been performed which may result in disturbing lines or connections, it is advisable to test for leaks. Common sense should be used in performing any refrigerant leak test, since the need and extent of any such test will, in general, depend upon the nature of a complaint and the type of a service performed on the system. By merely applying the solution to the area in question with a swab, such as attached to the cap of a vial, bubbles will form within seconds if there is a leak.
For confined areas, such as sections of the evaporator and condenser, an electronic refrigerant leak detector 1 is more practical for determining leaks. On-Vehicle Service Service Precaution When servicing air conditioning system, note the following instructions. When bending a pipe, try to make its bending radius as slight as possible.
When disconnecting any line from system, install a blind plug or cap to the fitting immediately. Instead, use quantities of fresh cold water to splash it over affected area to thus gradually raise its temperature above the freezing point.
Should liquid refrigerant HFCa Ra get on your skin, such affected part should be treated in the same manner as when skin is frostbitten or frozen. Always wear goggles to protect your eyes.
Avoid you direct contact to liquid refrigerant. Do not discharge refrigerant into atmosphere. Do not allow liquid refrigerant to touch bright metals. Refrigerant combined with moisture is corrosive and will tarnish surfaces of bright metals including chrome.
If condenser fin is bent, straighten it by using flat head screwdriver or pair of pliers. If, any clogs are found, condenser fins should be washed with water, and should be dried with compressed air. If any defects are found, repair or replace condenser. NOTE: The amount of removed compressor oil must be measured for replenishing compressor oil.
If condenser fin is bent, straighten condenser fin by using flat head screwdriver or pair of pliers. If check results are no continuity, replace condenser cooling fan motor. Reference current of condenser cooling fan motor approximately 7.
If check results are as not specified, replace thermistor. In each of these cases, switch should show proper continuity. A : Approximately kPa 1.
Check if indicator lamp lights. If there is continuity, replace relay. If there is no continuity, replace relay. After that stop the engine. NOTE: Cap open fittings immediately to keep moisture out of system. NOTE: If compressor is replaced, drain oil from removed compressor. And then, measure its amount. If measured resistance is not within tolerance, replace magnet clutch coil. Magnet Clutch coil resistance : 3.
If it is no continuity, replace thermal switch. Special tool A : Special tool A : 5 Remove magnet clutch lead wire clamp screw, and disconnect magnet clutch lead wire. Special tool A : 8 Remove magnet clutch coil 2 from compressor body assembly 3. Ensure that edge rests only on inner race of bearing.
Front head. NOTE: Be careful not to remove cylinder 3 from compressor body assembly 4. Refrigerant 12 mm pipe 0. Refrigerant Dual pressure switch Clutch plate bolt Front head bolt 5 mm Front head bolt 8 mm. Wear Indicators General Diagnosis Since the problems in steering, suspension, wheels and tires involve several systems, they must all be considered when diagnosing a complaint.
To avoid using the wrong symptom, always road test the vehicle first. Proceed with the following preliminary inspections and correct any defects which are found. Possible Cause Mismatched or uneven tires Tires not adequately inflated Broken or sagging springs Radial tire lateral force Disturbed front wheel alignment Disturbed rear wheel alignment Brake dragging in one road wheel Loose, bent or broken front or rear suspension parts Sagging or broken springs Tire out of balance Disturbed front wheel alignment Faulty shock absorber Hard driving Overloaded vehicle Not rotating tire Worn or loose road wheel bearings Wobbly wheel or tires Tires not adequately inflated Blister or bump on tire Improper shock absorber action.
Correction Replace tire. Adjust tire pressure. Replace spring. Replace tire. Check and adjust wheel alignment. Repair front brake. Tighten or replace suspension part. Adjust balance or replace tire. Check wheel alignment. Replace shock absorber.
Replace or rotate tire. Replace wheel bearing. Replace wheel or tire. Adjust the pressure. Replace tie rod end. Replace tire or wheel. Check and adjust front wheel alignment.
Loose or worn steering linkage Tighten or replace steering linkage. Loose steering gear box bolts Tighten box bolts. Worn steering knuckle oil seal Replace.
Bind in tie rod end ball studs or king pin bearReplace tie rod end or king pin ings bearing. Disturbed front wheel alignment Check and adjust front wheel alignment.
Steering gear box adjustment Check and adjust steering gear box. Tire not adequately inflated Inflate tires to proper pressure. Bind in steering column Repair or replace. Low fluid level, loose drive belt or malfunction of Check and correct. Steering gear box attachments loose Tighten or repair. Steering gear box adjustments Check and adjust steering gear box. Worn steering shaft joints Replace joint. Worn tie rod ends drug rod ball joints Replace tie rod end.
Bind in tie rod end ball studs Replace tie rod end. Bind in king pin bearings Replace king pin bearing. Steering gear box needing lubricant Check, repair or lubricate steering gear box.
Steering gear box not properly adjusted Check and adjust steering gear box torque. Tires not adequately inflated Adjust pressure. Loose bolts and nuts Retighten. Broken or otherwise damaged wheel bearings Replace wheel bearing. Worn or sticky tie rod ends Replace tire rod end. Linkage joints needing grease Lubricate or replace. Possible Cause Worn, sticky or loose tie rod ends, drug rod ball joints, king pin bearings or axle shaft joints Damaged shock absorbers or mountings Worn leading arm bushings Worn stabilizer bar bushings Worn Iateral rod bushings Loose stabilizer bar Loose wheel nuts Loose suspension bolts or nuts Broken or otherwise damaged wheel bearings Broken suspension springs Mismatched or uneven tires Loose king pin bearings and tie rod ends Faulty shock absorbers or mounting Loose stabilizer bar Broken or sagging springs Steering gear box not properly adjusted Front wheel alignment.
Worn wheel bearings Broken or sagging springs Leaking wheel cylinder or caliper Warped discs Badly worn brake linings Drum is out of round in some brakes Wheel tires are inflated unequally Defective wheel cylinders Disturbed front wheel alignment Faulty shock absorber Overloaded Faulty shocks absorber Incorrect, broken or sagging springs Loose stabilizer bar Faulty shocks absorbers or mounting. Broken or sagging springs Overloaded Worn wheel bearings Excessive tire or wheel run-out Tire out of balance.
Correction Replace tie rod end, king pin bearing or axle shaft joint. Replace or repair. Tighten bolts or replace bushes. Tighten wheel nuts. Tighten suspension bolts or nuts. Replace tire or inflate tires to proper pressure.
Replace king pin bearing or tie rod end. Replace absorber or repair mounting. Tighten or replace stabilizer bar or bushes. Check or adjust steering gear box torque. Repair or replace wheel cylinder or caliper. Replace brake disc. Replace brake shoe lining. Replace brake drum. Inflate tires to proper pressure.
Replace or repair wheel cylinder. Check front wheel alignment Replace shock absorber. Check loading. Tighten stabilizer bar bolts or replace bushes.
Replace shock absorber or tighten mounting. Replace tire or wheel disc. Adjust tire balance. Some of them are: incorrect inflation pressures lack of tire rotation, driving habits, improper alignment.
Wear Indicators The original equipment tires have built-in tread wear indicators to show when tires need replacement. These indicators will appear as 12 mm 0. When the indicators appear in 3 or more grooves at 6 locations, tire replacement is recommended. It is caused by the steel belt not being straight within the tire. It is most noticeable at low speed, 5 to 30 mph.
It is possible to road test a vehicle and tell on which end of the vehicle the faulty tire is located. If the faulty tire is on the front, the waddle is more visual. The front sheet metal appears to be moving back and forth and the driver feels as though he is at the pivot point in the vehicle.
If wadding end cannot be identified, substitute rear ones. If improvement is noted, reinstall originals one at a time till waddle causal tire is found. If no improvement is noted, install known good tires in place of all four.
Then reinstall originals in the same manner as above. Lead is usually caused by: 1 Incorrect alignment. The way in which a tire is built can produce lead in a vehicle. An example of this is placement of the belt. Off center belts on radial tires can cause the tire to develop a side force while rolling straight down the road. If one side of the tire has a little larger diameter than the other, the tire will tend to roll to one side.
This will develop a side force which can produce vehicle lead. The procedure in above figure Lead Diagnosis should be used to make sure that front alignment is not mistaken for tire lead. If a medium to high mileage tire is moved to the other side of the vehicle, be sure to check that ride roughness has not developed.
Vibration Diagnosis Wheel unbalance causes most of the highway speed vibration problems. If a vibration remains after dynamic balancing, its possible causes are as follows. If TPD is not available, alternative method of substituting known good tire and wheel assemblies on the problem vehicle can be used, although it takes a longer time.
Toe Adjustment General Description Front alignment refers to the angular relationship between the front wheels, the front suspension attaching parts and the ground. Generally, the only adjustment required for front wheel alignment is toe setting. Therefore, should camber or caster be out of specification due to the damage caused by hazardous road conditions or collision, whether the damage is in body or in suspension should be determined.
If the body is damaged, it should be repaired and if suspension is damaged, it should be replaced. Toe Setting Toe is the turning in or out of the front wheels.
The purpose of a toe specification is to ensure parallel rolling of the front wheels Excessive toe-in or toe-out may increase tire wear. NOTE: Toe-in value was measured by using a toe-in gauge. Camber Camber is the tilting of the front wheels from the vertical, as viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive.
When the wheels tilt inward at the top, the camber is negative. The amount of tilt is measured in degrees. An additional item to be checked is the possibility of tire lead due to worn or improperly manufactured tires. Section 3 of this manual contains a procedure for determining the presence of a tire lead problem. Before making any adjustment affecting toe setting, the following checks and inspections should be made to ensure correctness of alignment readings and alignment adjustments: 1 Check all tires for proper inflation pressures and approximately the same tread wear.
Check tie rod ends; if excessive looseness is noted, it must be corrected before adjusting. If this excess load is normally carried in vehicle, it should remain in vehicle during alignment checks. Toe Adjustment Toe is adjusted by changing tie rod length. Loosen right and left tie rod end lock nuts first and then rotate tie rod to align toe-in to specification. After adjustment, tighten lock nuts to specified torque.
Camber And Caster Check And Adjustment Should camber or caster be found out of specifications upon inspection, locate its cause first.
If it is in damaged, loose, bent, dented or worn suspension parts and axle housing, they should be replaced.
If it is in vehicle body, repair it so as to attain specifications. NOTE: To prevent possible incorrect reading of camber or caster, vehicle front end must be moved up and down a few times before inspection. Steering Angle Check And Adjustment When tie rod 2 or tie rod end 3 was replaced, check toe and then also steering angle with turning radius gauge 1.
NOTE: If tie rod lengths were changed to adjust steering angle, reinspect toe-in. Side Slip Reference For inspecting front wheel side slip with side slip tester: If side slip exceeds limit, toe or front wheel alignment may out not be correct.
They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of lesser quality or substitute design.
Torque values must be used as specified during reassembly to assure proper retention of these parts. Steering Wheel Play Check Adjustment of Worm Shaft Starting Torque. Steering Wheel Play Check Check steering wheel for play and rattle, holding vehicle in straight forward condition on ground.
If play is not within specification, inspect for the following. If found defective, replace. If even a small tear is noted, replace with new one. If not, add prescribed gear oil, SAE Apply sealant to thread parts of breathing plug and tighten breathing plug to specified torque.
Adjustment of Worm Shaft Starting Torque Steering gear box has adjusting bolt 1 which gives preload to sector shaft. With pitman arm 2 in this position, front wheels are in straightforward state. Adjusting bolt. If measured torque is not within specification, carry out adjustment with adjusting bolt 1 to meet specification and check to confirm it again. Lock nut. Tighten joint bolt to specified torque. NOTE: Align flat part 3 of sector shaft with bolt hole of lower shaft joint as shown.
Then insert sector shaft into lower shaft joint. Tighten nuts and bolt to specified torque. Steering gear box. Tighten new drag rod end nut to specified torque. Then tighten new nut to specified torque. Then loosen lock nut 2 and remove tie rod end 1 from tie rod.
Align lock nut with mark 3 on tie rod thread. Tighten new nut 1 to specified torque. Then tighten new nut 1 to specified torque. Adjust tie rod 2 and drag rod length as required, if necessary.
Tightening Torque Specifications Fastening part Steering gear box oil plug Steering gear box adjusting bolt lock nut Pitman arm mounting nut Steering shaft joint bolt Steering gear box nuts and bolt Tie rod end nut and drag rod end nut knuckle side Wheel nut Tie rod end lock nut Drag rod end nut pitman arm side. Air Bleeding Procedure It is an integral type with the mechanical gear unit, hydraulic pressure cylinder unit and control valve unit all housed in the gear box.
Steering wheel feels heavy momentarily when turning it to the left or right. Air drawn in due to insufficient amount of fluid Slipping belt. Correction Change fluid. Correct or replace. Bleed air. Adjust belt tension or replace belt as necessary. Inflate tire. Adjust front wheel alignment.
Install steering wheel correctly. Add fluid and bleed air. Replace pressure switch terminal set. Pump vanes are sometimes hard to come out where temperature is low. Condition Possible Cause Steering wheel returns Dust or foreign object mixed in fluid slowly from turns. Steering column installed improperly Wheel alignment maladjusted Linkage or joints not operating smoothly Vehicle pulls to one Low or uneven tire inflation pressure side during straight Wheel alignment maladjusted driving.
Defective spool valve Steering wheel play is Loose steering shaft nut large and vehicle wan- Loose linkage or joint ders. Loose gear box fixing bolt Front wheel bearing worn Fluid leakage Loose joints of hydraulic pressure pipes and hoses Deformed or damaged pipes or hoses Gear box. Install correctly. Inflate tire s as necessary. Replace gear box assembly. Possible Cause Air drawn in due to insufficient fluid Air drawn in through pipe or hose joints Belt slipping loose Worn belt Loose steering linkage Loose gear box fixing bolt Loose pitman arm Pipes or hoses in contact with chassis Defective pump vane Malfunction of flow control valve Defective pump shaft bearing.
Correction Replenish fluid. Retighten or replace. Replace pump assembly. It is from operation of the valve in the gear box and indicates nothing abnormal. Move steering wheel to the right and left from its straight position and measure along its circumference how much it must be turned before tires start to move. It should be as specified below.
Steering Force Check 1 Place vehicle on level concreted road and set steering wheel at straight position. Steering force Less than 6. Power Steering Belt Tension Adjustment 1 Loosen tension pulley bolts 3 and set hexagon wrench to hexagon hole 5. Idle-Up System Check 1 Warm up engine to normal operating temperature. Engine idle speed drops a little momentarily when steering wheel is turned fully but returns to its specified level immediately.
If power steering pressure switch connector is connected, check the same with that connector disconnected. Momentary drop of engine idle speed should be less when it is connected than when disconnected.
Power Steering Fluid Leakage Check Start engine and turn steering wheel fully to the right and left so that maximum hydraulic pressure is applied to system. During this check, however, never keep steering wheel turned fully for longer than 10 seconds. Never operate steering system while servicing. Or Air Bleeding from gear box must be performed. Special tool A : 1. Steering gear box 2. Repeat this step a few times. Repeat this some times. Special tool B : 6 Perform Step 5 but with steering gear box in state [B] this time and then in state [C].
NOTE: As input shaft makes 4 full turns from lock to lock, neutral position is obtained by turning it till it locks and turning it back by 2 full turns. Vinyl tube See-through tube. Special tool A : B : 1. To gear box. Close valve 6 gradually while watching pressure increase indicated on gauge 4 and take reading of relief pressure maximum hydraulic pressure.
Then turn steering wheel to the left or right fully and take reading of relief pressure. Disconnect high pressure hose and low pressure hose. Disconnect pressure switch lead harness. If any defect is found, replace pump assembly. Pulley 2. Pump body. Side plate. Replace pump assembly if any defect is found. Clearance between rotor and vane Standard : 0.
Limit : 0. Replace pump assembly if any defective is found. Relief valve spring free length Standard : Limit : NOTE: Carefully align the dowel pins 3 on the side plate 2 at bolt hole 1 as shown in figure. NOTE: Never reuse the removed snap ring. The tapered end of cam ring 1 should face the side plate 2.
NOTE: After installing pump cover 1 , check to make sure that shaft can be turned by hand. Previous 1 2 template Next. Service Manuals , AM. Thank You Art. Last edited by boats. Regards Boats. Tags: None. I think this will be a great help Thanks for taking the time to post it Art.
Comment Post Cancel. These people seem to have some older service manuals. There are service manuals for sale on bonanza. The seller is legitimate. N2 Fishing. Originally posted by boats. The second link is working for me just now. Try again tomorrow and if still problems, please report the issue to a d m i n. Suzuki says the LE DFA manual should be available by second week of June, I will keep checking availability and let you know when they are available.
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