WORKSHOP MANUAL DAIHATSU CHARADE Chassis FOREWORD “This workshop manual contains essential information regarding the construction, Gisassemblyreassembly procedures and servicing methods of the power tain, Suspension, brake system, steering system, body and electrical system of the DAIHATSU CHARADE. We hope that this. workshop manual i consulted to the fullest extent, in Combination with the workshop manual ofthe Type CB Engine. Type CL Engine, fad Trouble shooting for Engina contro! system of Type C8-80 Engine so that ‘Quality servicing may be assured at al imes. Furthermore, due i contnuing improvements in the design, contents end speciicatons in this workshop manual may be parly revised without advance notice and without incuring any obligation to us. Published in April, 1987 DAIHATSU MOTOR CO., LTD.SECTION INDEX NAME SECTIOL GENERAL INFORMATION CLUTCH | MANUAL TRANSMISSION Coote NOES COLe INS j_— | AUTOMATIC TRANSMISSION [eee | FRONT AXLE & SUSPENSION REAR AXLE & SUSPENSION ‘STEERING BRAKES BODY | BODY ELECTRICAL ar) ‘APPENDIXDAIHATSU CHARADE Chassis SECTION 1 GENERAL INFORMATION HOW TO READ THIS BOOK (CONTENTS OF EXPLANATION 1 Schematic Diagram of Ce 2 Servicing Procedure 4. Trouble Shooting 1 Table of SSTs Used 5 Table of Service Speciications 6: Table of Tightening Torque 7 Wing Diagrams DEFINITIONS OF TERMS ABBREVIATION CODES. ‘SERVICING OPERATIONS. {JACKING POINTS AND SUPPORTING POINTS OF SAFETY STANDS ‘SUPPORTING POINTS OF TWGENERAL INFORMATION HOW TO READ THIS BOOK CONTENTS OF EXPLANATION 4. Schematic Diagram of Components (f) The schematic diagram of components that appears atthe beginning of each secon describes the nomenclature and installed conditions o each component. Futhermare, the tightening torque is posted in the foure (2) Those parts whose reuse isnot permitted bear a “k* mark for an identfication purpose, Be certin to replace these parts with new ones during the assembly (Example) By: pemrgroe oe Neon parts 8 = Rese cap soacee @Rewewor suprragn {@ Seach operating tose Bilan ojan sor se Samp = Serose ODeme, Seat => 29 a Sanne e0¢e it eying reat i aoe 2. Servicing Procedure (@) Inprincible, the servicing procedure is described inthe folowing sequence given below: Removal —+ Inspection “> Insialation, and Disassembly — Inspection —» Assembly. (2) The explanation covers detaled servicing methods, spectfiations and notes. (@) The main pont of each item explains the servicng section and senicing procedure, using llustations. (example) What do Howiodot [aaeaoiniaten Ci 7 3. Brake tube ination (G) Insta the rake tube fo the wheel cinder temporary by hands. (2) Rohn the brake tube tothe wheel cylinder, using he folowing SST. , ST. 09751-2601 1-000 one ~ hi Min.(GENERAL INFORMATION cnet eae (@) The inspection section inthis manual deseribes only checking operation. Therefor, if you find any ‘uitnetion race any detective parts with new ones. 3, Trouble Shooting {ty At for the three-speed automatic ransmission, the trouble shoating table is provided in this book 80 that you may reacily locate causes of troubles, 4, Table of SSTs Used (1) The SSTs appearing in tis book are listed in the appendix of the book 5. Table of Service Specitications (iy The service specifications necessary forthe service are summarizes in the appendix of his book 6, Table of Tightening Torque {i As for hose sections wher thet tightening torque must be controled during the service, the tightening torque is speciad inthe appendix of tis Book. 7. Wiring Diagrams. {Gy The vehicle winng diagrams are posted inthe appendix ofthis book separately for Type CB and Type CL engines. DEFINITIONS OF TERMS Specified Value .. A value which represents the allowable range during the inspection and adjustment. Limit ‘A maximum or 8 minimum Imit which the value should not exceed or fal! beow. Nowe ‘an item which requires special alertion or an tem which is prohibited curing the(GENERAL INFORMATION {ABBREVIATION CODES The ebro coon he ope te wen mara etre lois pect Aobregeton Original word i ‘Meaning st Laat oe Bp oe —— [sc rie reread [tan er eee ELS (ana ELSA RET ITARRERSe eee aT eR aI os ows ERaip ea eae ceamencen ‘She at pa may oe Siswo ure agus “Over Sued pars ance ose sain brotindaceeecta ose Terenas mats corer pe (aromas us| ose Sie eee aver oe oars Sapna eae ce nee alee | RRS RAT a, magw te in ‘Sone of ‘Rese daagatinmurbarhane Coos sfc by Sosy errs oka ESSreaere sea eee nares see Sige ea uae ean mea snae Ger Ene naue esas ieee DiS ERR aaa ea ce Epeily secre pocwecmemcmsh oe ein \nhbrees engine ale wr Gove ens ae Casslid es CC, CO and 80.08 Seaton oer nv errs ct er restos Seon ma eer 2 vemety ‘else ial or suse to extn fof a sie compere. eee SESE perer ereweronetir ror tare eaT ww ere ae koing parle ac of [Sra at in a sear ae co | Seth ers an convene one Sides | RSE ‘The abbreviation codes that appear in the figure stand forthe following, respectively. @ | Bot © | Sew @ [rs << hi Iti. a(GENERAL INFORMATION Ee ee SERVICING OPERATIONS 11. Jacking up iy When ony the front section o rear section of the vehicle is jacked up, be sure to place checks at the wheels 60 as to insure safe operations, (@) When tne vehicle nas baen jacked up, be sure to support the vehicle at the specified sectons using safety stands. 2. In the case of repairs on the electrical system or the removal/nstallation of the engine, first disconnect the negative © terminal of the battery. Then, proceed to the operations. (On ‘lock-equipped vehicles, set the time of the clock after the negative ©) terminal of the battery is connected.) {3 Repairing fuel system of Type CB-80 engine ‘Type €8-80 engine employs a high fuel pressure. Therefore, the folowing notes should be observed UF When the union bois removed, take a measure to prevent the fuel fom splashing with a cloth a the like, Siacken the union bolt gradual (@) Tiahten each connecting section to the speciied torque. (6) Atach the specified clip fo each connecting section. 4. For increased work efficiency and improved accuracy, be sure to utilize the SSTs (Special ‘Service Tools) effectively. ‘5, Removal and disassembly (1) When disassembling complicated components, put stamped marks or mating marks on those sections vanere such marks do not affect ther functions so that the assembling operation may be performed easily (@) Each time a partis removed, check the par for the assembied condition, delormation, breakage, roughness and scratches. {@) Arrange the cisessembied parts In he disassembling order, In addition, separate and arrange those paits to be replaced and those parts to be reused. (4) Thoroughly clean anc wash those pars tobe reused, (6) inspection and measurement of part . PPetiorm thorough inspection and measurement on those parts to be reused, as required 6. Installation and assombly (i) Assemble those satstactory part, folowing the proper procedure and specified standards (acjusing ‘values anc’ tightening torque, et). {g) knsure tnat seal packings an grease we apotied 1 those sections where such spplictionis noodod, {@) Be sure fo use new packings, Gaskets, cater pins and 80 for {@) Encure thatthe spectieg bolts and ruts ony be used, Moreover, where specified, make sure to employ a torque wrench fo lighien bots and nuts to the specified toraus. Make sure to use only genuine parts for every replacement 77._Adjustment and operation chock ‘Adjust he reassembled or replaced components to the servicing specifications, using gauges and testers, as require. 8. Handling of hose, etc. (G) Connect ve! hoses and water hoses, etc. securely so that they exhibit no leakage. {@) When disconnecting fue! noses, make sure thet no ful is splashed around the hose. (Special care must be exercised as to the engine mount rubber, etc, for here isa possibilty thatthe rubber is deteriorated by the pettolbased tquid)GENERAL INFORMATION 8. Touch-up painting i paint fins surfaces ofthe body and bolts should be scratched when Bots, ete. are removes during the ‘ody alignment, ete. touch up the seratch with @ paint ving the same color as that of the Body. JACKING POINTS AND SUPPORTING POINTS OF SAFETY STANDS ‘© Jacking point Front side. Engine mounting canter member (Place the jack below the member, exercsing ‘care ofthe exhaust pipe) Rear side .... Center of rear floor cress member Engi mounting cetarmerer Peer ar rose rember oxen" ener Spgtea sit Baeyeee ‘© Supporting points of safety stands Four supporting points are located atthe right and left sides. (The supporting points have been strengthened by spotweiding reinforcements. Never support the vehicle at points ether than the spectiod pons) nansoomse, . Frntandrearon oor moet 322 /pgar on 3-dor mes rer cd SUPPORTING POINTS OF TWO-POST LIFT [Align the supporting pads ofa two-post it with the suoporing points of safety stands, as indicated in the figure above, a as Mt, “DAIHATSU CHARADE Chassis SECTION 2 CLUTCH DESCRIPTION "TROUBLE SHOOTING : CLUTCH PEDAL ADJUSTNENT ‘CLUTCH PEDAL AND ‘CLUTCH RELEASE ‘COMPONENTS REMOVAL vom INSPECTION INSTALLATIONCLUTCH DESCRIPTION TROUBLE SHOOTING a = = = Gennes |; Eaaeor miniere™ |: Gage [= cea TEgeeas mmr” |: aaa iaeaae 1 SERRA cit nin | «Fas ais n PERC be et a ms seems Term aaeigeiatanta | us angers | 59 a Semenmaeman™ | faiscana a Eero Se. st BREE oey | RBar cs! a ‘Grabbing and challering | © Wom or oly cich dacinngs. | © Check auch dee and replace, as | 2-8 oa mae ¢ Fetvesenreote 1 Selene o TEER ony |] RES zt ibaa | RRS. St Soar fs croeaie fos ear TOERETSERGRE wom SREB | 27 {Bei ecmtmoonenna | ropa enue Tn ed WES | BRE Si + FEES capregn sa. o° | « Fennec = ‘wom tp end ot spr, CLUTCH PEDAL ADJUSTMENT 1. Check the clutch pedi forthe installation height Pedal instalation Peight (Cistance between pedal pad upper surface’s center and ‘dash pane) LHD. vehicle 189.5 - 194.5 mm (7.46 - 7.68 inch) LHD. vehicle 181.5 - 186.5 mm (7-15 - 7.34 inch) 2. Adjust the pega! nstation nelght, as required (2) Slacken the lock nut. Turn the stopper bot unl the Installation height contocms to the specification (@) Tighten the lock nut ed neigh Pi tes. 19¢5 am 749- T35inen) CHD ters. tease (716.73¢mnen)CLUTCH 3. Clutch cable adjustment (G1) Pulthe outer cable ight with a force of 2-5 kg (8.4 411.0 1b). Check the clearance. (2) Ensure that the stopper (protruding portion) is fted securely in the adjusting groove. (@) Adjusting postion of clutch outer cable 3-6 mm (0.12 - 0:24 Inch) 4, Adjust the clutch pedal ree travel. (1) Depress the clutch pedal gradually unt you fee! a resistance ftom tne clutch. Measure the depressing tance upto this point. Pedal Free Travel: 15 ~90 mm (0.59 - 1.18 inch) 5, Adjust the clearance between the cistch pedal and the floor with the pedal fully depressed. (Minimum clearance ‘betwen the dash panel and the pedal arm) Vehicles mounted with Type CB-80 engine: not less than 20 mm (0.79 inch) Vehicle other than those mounted with Type CB-60 ‘engine: not less than 25 mm (0.88 inch 3G mm (012-024 ch) ensure nat stopcerxouldieg pin Jetted imacutong rg soo 5.200 (058-1 ety Clarnce Beean SoeCLUTCH CLUTCH PEDAL AND CLUTCH RELEASE CABLE COMPONENTS: pee Lary een seamen oe = = Ex BE aneeane ras REMOVAL Toone oe py (Oy LHD hn Sen page 8-7) 2. Fits Bo rt wet tts tan See ee cee anna aaa! 2. Faro tng baRemove the bot with washer. Remove the cable brackel attaching bolt. Remove the clutch cable. Remove the clutch pedal assembly. Remove the soring, ‘bush and spacer. INSPECTION Inspect the folowing pats. 1 2 3 4 6 ‘Bush for wear or damage. Pedal spacer for wear or damage. Pedal for damage or deformation, Pedal pad for wear or damage. ‘Spring for flattened conditon. Each section of clutch cableCLUTCH INSTALLATION 1 ‘Apply MP grease tothe following points () Insie of bush and spacer (@) Connecting section of clutch pedal and release cable Install the spring, bush and spacer to the clutch pedal assembly. Then, stall the assembly tothe pedal bracket Inetal the bolt with washer In poston, Insta both ends of the elutch cable, Tighten the bracket withthe bots. “Tightening Torque: 0.4 - 0.7 kg-m (2.95.1 b) Install the adjusting bot. Tighten the nut Tightening Torque: 1.5 - 22 kg-m (11 - 16 b) Depress the clutch pedal to or three times. Proceed to agjst the chitch peda, folowing the procedure at page 2-2. instal the brake pedal Ay. (Only for LH.D. vehicies. See page 8-8) hi Nis. ad Jo Ts-220m (dos 59%)CLUTCH UNIT COMPONENTS: yas gas se — : = on page ) ‘SEE Se Soren 2. Release the lock plate. Proceed to remove the lock pate along with the Bot.CLUTCH 3. Pull out the clutch release fork lover. Remove the bush felease lover yoke, spring, release Deering cip and release bearing hub. 44, Remove the cluich cover from the flywheel. Take out the clutch disc. INSPECTION 4. Check the pressure plate and flywheel surtace for scores, cracks and discoloration. 2 Check the diaphragm spring tips for wear, rust and breakage. 3. Check the clutch disc for wear and runout ‘Allowable Wear Limit (vet Depth): (08 mm (0.012 inch) Hin. ad i 4CLUTCH ee 4 ‘Alowable Limit of Lateral Runout: 1.34 mm (0.0528 inch) NOTE: Measure the lateral runout with the clutch disc assembled ‘onto a new input shaft Check to see if the release bearing rotates smoothly: Rotate the release bearing by your hand, while appiying a pressure to the beating ina thrust direction. Check to see IFthe Dearing rotates without any abnormal feeling oF binging CCheck the release bearing hub, clp-contacting surlace ‘and hub-teshousing siding section for damage and wear Check to see if the lip has the configuration as show in the figure in its hotzontal pian cus de -Asccelcoiguraion~ reise ‘one Sens SeCLUTCH INSTALLATION 1. Install the clutch aise and cluich cover, using the following SST. ‘SST:_09901-87202.000 Bol Tightening Torque: 1.5 - 2.2 kgm (11 - 16 fb) NOTE: (1) Assemble the clutch disc in the direction as shown in the figure, (2) Tighten the bolts evenly, staring with those bots provided near the locating pin, (2 Arp log le chasis reset the dich dic spines 2. Check the clutch cover diaphragm spring ti fr variation in height. Adjust the ciaphragm spring tips, as required. ‘Check ‘Allowable Limit of Variation in Height (0.7 mm (0.028 inch) SST: 09302-$4701-000 Ben. ‘Adjustment ‘Align the diaphragm spring tips at such a height that ‘makes the number of ps to be adjusted at a minimum umber. SST: 09893-00011-000 3, Assemble the clutch release bearing hub and release ‘beating lip to the clutch release lever yoke (1) Bing the cut-out section of the release lever yoke in contact withthe cp. Under the concltion described in (1), assemble the lever yoke by turning t 180 degrees. NoTE: ‘Apply iong-lte chassis grease to the yokeo- hub sling ‘ection and bearing-to-housing case siding secon, bin, = 1 e® 1 a & rosewood oor erkea00 10° ing (reste aptying ports4. Assemble the bush, dust seal, torsion spring and clutch release lever in positon. 5, Assemble the ott with washer, wih the lock plate interposed Tightening Torque: 3.0 - 4.0 kgem (22 - 29 tb) 6. Check the release hub and yoke for proper operation. ‘Operate the clutch release lever about 50 times. Chack the section A of the clip. f the cip exhibits excessive spread and there is a Ikelinood that the clio may be tached, replace it with # new clo. 7. Install he trenemission assembly to te vehicle (See page 3-7.)DAIHATSU CHARADE Chassis SECTION 3 MANUAL TRANSMISSION ‘SECTIONAL VIEW .. a2 MANUAL TRANSMISSION ASSEMBLY ~.. 3-9 PEMOVAL a3 INSTALLATION 3-7 F DISASSEMBLY, INSPECTION AND ASSEMBLY OF "TRANSMISSION HOUSING, CASE S/A AND CASE COVER ‘COMPONENTS DISASSEMBLY REPLACEMENT INSPECTION ASSEMBLY . ‘APPLICATION POINTS OF GREASE & BOND [AND APPLICATION PROCEDURE woe 3-22 DISASSEMBLY, INSPECTION AND ASSEMBLY ‘OF INPUT SHAFT 3-28 ‘COMPONENTS DISASSEMBLY INSPECTION. ASSEMBLY DISASSEMBLY, INSPECTION AND ASSEMBLY ‘OF OUTPUT SHAFT ‘COMPONENTS DISASSEMBLY INSPECTION .. ASSEMBLY DISASSEMBLY, INSPECTION AND ASSEMBLY OF STH GEAR... 3-38 (COMPONENTS 9-38 DISASSEMBLY = 3-38 INSPECTION "3-40 ASSEMBLY 3-42 DISASSEMBLY, INSPECTION AND ASSEMBLY OF DIFFERENTIAL CASE nee BA COMPONENTS aa DISASSEMBLY 3-45 INSPECTION .. 3-48 SEMBLY . 3-87 DISASSEMBLY, INSPECTION AND ASSEMBLY OF ‘CONTROL LINKAGE-RELATED PARTS... 9-50 3-50 382 3-58 ASSEMBLY . 3-55 SHIFT LEVER & SELECTING ROD encwsccu- 9-59 ‘COMPONENTS 3-59 3-60 361 261 INSPECTION .. 3-63 ‘ASSEMBLY 3-68 INSTALLATION 3-65 i :MANUAL TRANSMISSION SECTIONAL VIEW rT Ta (\ = anMANUAL TRANSMISSION fiity Keng 4-speed ‘S-speed [Eran ure aa ca an [once] oa | Trnemision PS Fomard gears Conan eh Ree guar. Slave idea | 1st gear 3.080 Gait) | 3090;Gar1) | S090 (ANT) | 3.090 (3411) | 209 (94711) [rdgcer | ate Gena | reese | 1e@Gsi9) | 1a@esNO) | 175 (520 Ges Tageer [100 e226) | 1200 as) | 150 6x28) | 1200008 | 120 e220 (fen, [am ocer | wae euen- | once aaa | ase s2an | occa czar | cove eae hee} caravan | overeat | ovorcoa| are) | sep [5142 GOTH 9142 ra) [48 aBONA) S42 aN) | Bee A078) | Bagration gear son ore) | asco rane) | aaxecvans) | aea(esns) | aose(esra Numeral pasa | . — saree es se ee [owe | ons CX Par ek bok BER [die | “aa Gans ei kr esi epereains SEB FAY ISEB SiS Stash pecans SHIRE Wena hs ane _ MANUAL TRANSMISSION ASSEMBLY REMOVAL 1. Remove the engine hood assembly. 2. Remove the holgdown elame and bstlory 3. Remove the battery carir stay. 4. Disconnect the following harnesses: ) Hamass to staner © (@) Tranemission eart (@) Backup lamp hamess @MANUAL TRANSMISSION 5. Remove the intercocier assombly. (Wericles mounted with Type CB-80 engine ony) 6. Remove the stater assembly 7. Disconnect the speedometer cable 1. Detach the three harness clamps. 9. Disconnect the clutch cable. a440. Remave the two bali that directly attach the transmission ‘assembly fo the engine, 11.Jack up the vehicle. Remove the front res at the ight ang left sides ofthe vehicle. NOTE: Be sure to support the vehicle securely by means of safety stands. 42, Drain the transmission oll 48, Detach the engine undercover. (Type CL engine only) 14 Remove the lower suspension brace. (Types CB-61 and (CB-20 engines only) 15. Disconnect the font exhaust pipe at the bracket support ‘No.1 and manifold sides. 416, Disconnect the following contr! inkage-eated parts from the transmission housing (1) Shit & solect shat SA (@) Extension od SIA(MANUAL TRANSMISSION 17. Remeve the stabilizer bar (@) Remove the stabizer bar end mut and retainer. (@) Remove the stabiizer bar instaling nuts, 418. Discannect the lower arm atthe bracket side 49: Remove the drive shats atthe right and let sides, using the folowing SST. SST: 09648-87201-000 NOTE: 1LNo stopper is provided at the inboard side ofthe drive ‘shat, Hence, be sure to suppor the invoad joint section during the removal 2, Be very careful not to damage the lip section of the ol seal during the removal 3.8 for the right side of vehicles mounted with Type ‘CB-80 engine, insert a crowbar into between the prot- ruding section of the bearing shaft and the drive shaft ‘Then take out the font erive shat, being very careful not to deform the dust cover of the cive shat 20, Remove the trot drive bearing shaft assembly. (ericles mounted with Type G8-80 engine only) (41) Remove the two bolts and pull out the front criveshat bearing shall from the transmission assembly. raw21. Remove the transmission assembly attaching bots. NOTE: Bo sure to leave the one bolt located at the front central par. 22, Lighty supoor the lower part ofthe transmission, using jack. Then, remove the engine mounting lowerilet bracket attaching bots {Tum the engine mounting lowerfet insulator 90 degrees ‘20 that k may oiat upward. 28, Remove the one bolt located at the front central part ofthe transmission assembly. Siowiack down the ransmission ‘assembly and take it out from Qelow the vericle. cs INSTALLATION 4. Install the transmission assemoly fo the engine assemby a follows: (Gi) Ensure that the clutch disc is centered in postion, Using the SST given below. ‘SST: 09301-87702-000 (2) Install the transmission, making sure that the clutch disc _may not be pried. Temporafily tighten the stiaching bots, 3-7MANUAL TRANSMISSION 2. Tighien the transmission assembly attaching bots securely. ‘Tightening Torque: 5.0 -7.0 kgm (96 - 51 fb) 2, Install the engine mounting were insulator and engine rmeunting lowereh bracket Bracket Tightening Torque: ‘30 4.5 kgm (22 - 33 fb) Insulator Tightening Torave 75 = 10.5 kgm (64 - 76 fb) 4 Install the tront drive bearing shaft assembiy as follows: (Vehicles mounted with Type CB-60 engine only) (@) Slowly install the pearing shaft assembly to the di {erential case, making sure that no damage is made to the lip section ofthe oll sea. (2) Tighten the two attaching bots. Tightening Torque: 3.0 4.5 kg-m (22-38 fb) 5. Install he drive shalte atthe right and left sites. NOTE: ‘Slowly install the tive shaft tothe siferenial case, making sure that no damage is made to the lip section of te of eal, 6. Install the lower arm (at the bracket side). Temporary ‘ighten the ataching bots.7. Install the stabitzer bar. (() Temporarily tighten the stablizer bar end nut (@) Tighten the cushion end stabilzer bar bracket “Tightening Torque: 40 - 6.0 kgm (28 - 43 fib) 8, Install the fllowing contol inkage-related pars (4) Shit & select shat SIA ‘Tightening Torque: 1.0 - 1.6 kgm (7.2- 11.6 feb) (2) Exonsion od SIA Tightening Torque: 1.0 - 1.6 gem (7.2- 11.6 feb) ©. Install the maniloid sie of the font exhaust pioe. install the bracket support No: (1) Maniola sige Tightoning Torque: 2.0 - 5.0 kgm (22 - 96 fb) (2) Bracket support No.1 Tightening Torgue: 2.0 - 0 kg-m (14.5 - 22 fe) 10. nstal the lower suspension brace. (Wericles mounted wth Type CB-61 and CB-80 engines oniy) “Tightening Torque: 4.0 - 85 kg-m (29 - 40 feb) 1. Install the engine undercover. (Wehicles mounted with Type CL engine only) 12 Install the front wheels atthe right and left wheels. Jack down the vehicle, 18, Rock the vehicle in a up-and-down direction a few times 50 a8 t0 sate the suspension. ‘With the vehicle in an unloaded, tighten the nuts. (1) Staoitzer bar insaling nuts Tightening Torque: 75 - 11.0 kg-m (64 - 60 fe) (2) Lower arm (bracket side) Tightening Torque: 7.0 - 10.0 kg-m (6t - 72 fb) 3-8MANUAL TRANSMISSION 19. Fil the tansmission ofl Oi capacity: ‘speed transmission: 1.9 - 206 (U.7 - 18 Imp qs, 20-21 US. as) S-speed transmission: 21-222 (8-19 Imp ais, 22-23 US. ats) 14. Insta he clutch cable. (See page 2-3), 18, Attach the three harness clamps. 16 instal the speedometer cable. 17. Instal the starter assembly. “Tightening Torque: 5.0 - 7.0 kg-m (96 ~51 feb) 48. install he intercooler assombiy. (Weticles mounted with Type C3-80 engine only) Fre psp19, nsal the folowing hamesses: (i) Hamess to staner © (@) Transrrission ears @ {@) Backup lamp harness @ 20, Insal the battery carrier stay, battery, holc-down clamp and engine hood assembly.MANUAL TRANSMISSION DISASSEMBLY, INSPECTION AND ASSEMBLY OF TRANSMISSION HOUSING, CASE S/A AND CASE COVER: ‘COMPONENTS (PART 1) 1 Nonrousable parts. QWrsad svagr sew ua ie cise) Speoderetr sta sleeve SA Wnaod seat scrw aug rams) ears cnse co’ Suscae bac {8 Case coerce pcteabecte! Seen ow ite Sees S:dcorerosnon ng Bo =e Sve stn ay 8a Srenmason case Bie BS rce wap ens ea a2(MANUAL TRANSMISSION COMPONENTS (PART 2)MANUAL TRANSMISSION DISASSEMBLY 1. Remove the screw plugs (atthe drain and filer sides) 2. Remove the clutch cable bracket and engine mounting bracket, 3. Remove backup lamp switch assembly and bfeather plug, 4, Remove the lock plate and speedometer shaft sleeve subassembly. ‘5. Remove the ail seal, using the SST given below. SST: 09921-00010-000 6. Remove the wansmission case cover subassembly as follows: (1) To drive out the case cover subassembly, tap the flange section ighty in the axial drection, using a plastic hammer. NOTE: Never tap the case cover at its side.MANUAL TRANSMISSION 7. Remove the case cover oll pipe. 8. Remove the lock ball plate and gasket, Teke out the ‘compression spring and ball {inne case of he 6-epeed transmission, proceed to this ‘operation after the Sth Qear has been disassembled) 18. Remove the transmission case as folows: (G) With the hele snap ring for output shaft bearing use held in an expanded state by means of the SST. crop the shat ‘SST: 09908-00012-000 (2) To drive out the transmission case, tap the case rib with a piastic hammer. 430. Detach the hole snap ring 11, Remove the contr! linkage-elated pars (For the cisassemoly procedure for each part, see page 3-50)MANUAL TRANSMISSION 12, Remove the Input shaft bearing lock plate, 13, Remove the input shaft assembly and output shaft assem by atthe same time (3) Atemately pull out both shafts litle ata tine +4 Remove the selactor support assembly, siti bell crank and magnet. 15, Remove the diferenial case as follows (G) witha brass bar placed on the inner race of the side Dearing, lightly tap the bar so that the ciferential case ‘may be diven out from the transaxle case REPLACEMENT Inspect the folowing pars. (See page 3-18) Replace any pars that exhibit delects, folowing the procedure given below. 1. Qi geal for contol shaft use Disassembly: Remove the ol seal by pinching its ange section with piers ‘Assembly: "Drive the oil eeal into postion, unlit comes. into contact wih the axle case ‘SST: 09515-87201-000 a6 32. Oil seal for input shaft use Disassembly: Remove the oll seal with @ common ecrewtiver Assembly: Dive the cll seal info position, un it be- "comes fush ‘with the edge Surtace of the transaxle SST: 09606-87201-000 3. Neadie Raler Bearing Disassembly: Alter the outout shaft bearing lock plate nes been removed, remove the roler bearing, using the SST given below. SST: 09308-00010-000 ‘Assembly: (1) Assemble the roller bearing, using the SST given beow. SST: 09309-67201-000 NOTE: Visually check to see Ifthe output shatt cover exhibits severe distortion or clogging. (2) instal the beating lock pate. ‘Tightening Torque: 0.7 = 1.0 kgm (6.1 -72 ib) 4 Oil seal for aiferental use Disassembly: Remove the oll seal wih @ common sorencriver ‘Assembly: Drive the oll seal into postion, until it comes. “ito contact with te rip ofthe axle case ‘SST: 09517-67701-000 (Case sie) (09517-87702-000 (Housing side) INSPECTION 41. Check each bearing for wear or damage Pa Inspection crteria Wien the inne ace ie etated by yeur Beating _| fingers t shoul rotate sro wie outer nang 2. Check each oil seal for wear or damage, Par 1 Transction eerie ‘Vigsly inspect 0 s00fthe ip ton Lip section ofall seal_| Shots excessive camage of wear a7 ‘MANUAL TRANSIISSION ~~ _ : | 0 i i Mion sector Steers sceMANUAL TRANSMISSION 3. Check the speedometer shaft sleeve subassembly for wear or damage, me Tae |e renee | _ mia Den ee ret donee a I, costa tam | _ 63 ‘Satara bo i ots tay | _ ot Giese ry aoe ee lll e |e ASSEMBLY 1. Assemble the diferental case. (For the assembly procedure for each cart, see page 3-47) 2. Assemble the magnet and selecting & shiting bell crank ‘support assembly. (For the assembly procedure for each par, see page 3-57) Tightening Torque: 0.7 - 1.0 kg-m (6.1 -7.2 fb) 3, Assemble the input shaft assembly and output shaft ‘assembly altho same time, 4, Assemble the input shaft bearing lock plate. “Tightening Torque: 1.5 - 2.2 kgem (11 ~ 16 fb) Jes‘Assemble the contol inkage-related pars (For tne assembly procedure for each part, see page 3-57) Install the hole enap ring in the transmission case. ‘Assemble the transmission case as follows: (@) Apoy the Three Bond sealer 1216 to the mating ‘Surface ofthe housing, While the hole snap ring of the Dearing is held in an expanded slate, assemble the ttansmission case in the ale case, SST: 09005-00012-000 NOTE: Make ‘sure that the snap ring Is ited postvely in the bearing, by raising the output shat by your hand (2) Tighten the housing attaching bots. Tightening Torque: 1.5 -2.2 kgm (11-16 fib) ‘Assemble the ball and compression spring. ‘Assemble the lock bal plate and gasket as folows! (() Perform the assembling, using the bots. a9MANUAL TRANSMISSION Pemieillbediedeeat 410. natal he case cover ol pipe as follows: (Q) insert the ol pipe, until ils rb section comes. into Contact withthe case, NOTE: ‘The ol pipe for the 4-speed transmission difers from that for the ‘S-speed transmission in its overall length and ‘iprend shape. ‘Overall length: (Ol pipe for 4-speed transmission 126 mm (5.0 inch) (Ol pipe for 5-spoed transmission 167 mm (66 inch) 11. Assemble the transmission case cover as follows (1) Apply the liquid gasket sealer (Three Bond 1216) to the mating surtaces ofthe case, except for those hole areas. (See page 3-19.) Tightening Torque: 0.7 - 1.0 kg-m (6.1 -7.2 fb) 12, Assemble the ol sea for speedometer shaft sleeve, using the SST given below. SST: 08201-60011-000 43, Assemble the speedometer shat sieeve subassembly and lock plat. “Tightening Torgue: 0.7 - 1.0 kg-m (S:1-7.2 fb) 14. ntall he backup lamp switch and breather plug. “Tightening Torque Backup Lamp Switch: 3.0- 6.0 kg-m (22-96 fh) Breather Plug: 1.0 - 1.3 kgm (7.2 9.4 tab) Ot peo Cine s rosecon( _Sapeedanamasen Cana coer aoe SSpeectraemiesin speed vrwmissonbracket “Tightening Torques Clutch Cable Bracket: 1.5 - 2.2 kgm (11 - 16 fib) Engine Mounting Bracket: 30 -45 kom (22 - 93 tb) 16. Install he serew plugs (t the drain and filer sides). Tightening Torque: 3.0 ~ 6.0 kg-m (22 - 36 tb) 45. instal the clutch cable bracket and engine mountingMANUAL TRANSMISSION APPLICATION POINTS OF GREASE & BOND AND APPLICATION PROCEDURE ‘hepa tnd orp shat ‘ne nat tnd sepa we proton of case cover Sie sole adele) Soph gear alte he erro ‘rac of cach par rte parton of case (thvesond 121) ‘aly vareniason ole exch ct ger and Lipsacton etl a (green) rao ‘Application Procedure for Liquid Gasket Sealer (Three Bond 1216 .. Part No. 999-0480-8U90-00) 4. Cat the fist stage of the rozzle of the Dainatsu genuine ‘sealer (Tivee Bond 1216) that is furished in accessories, - | 2. Remove any remaining trace ofthe quid gasket that may tbe found on te housing oF the case wih thinner or @ seraper, Care must be exercised not 10 scraich the ‘surfaces during the cleaning.3. Apply the liquid sealer to the entire periphery of the housing ene case without any unappied spot, as ind cated inthe ilustation at the eight. NOTE: App. the liquid sealer to the inside of each hole excluding those bolls holes. 2.Be sure to perform the assembling within five minutes after the application ofthe quid sealer. 8, Make sure to aty the thinner completly NOTE: “ The liquid gasket stars to cure when it reacts withthe moisture in the atmosphere. Hence, upon completion of the work, be sure to expel any ar trapped in the tube ‘and tighten the tube cap securely. 2. Rs regards the storage place fr this quid gasket, avoid Such places where high Temperature or high humidity prevals or those exposed to Grect sunrays. Make sure fo store tin a dy, cold and dark place. {The allowable lit for use is approximately sh months.)MANUAL TRANSMISSION DISASSEMBLY, INSPECTION AND ASSEMBLY OF INPUT SHAFT COMPONENTS: 0B gon we 906 Locke @gyncrenizes tub Ay No.2 ria ane Brera ne 0, agen gear bush Shefterep roa ‘ah gest Syren rag Bineut Sat ees200 Fase ae 3-28MANUAL TRANSMISSION Operation Prior to Disassembly Ul out the input shaft andthe output shat at tne same tie from the vanemission cage, Proseed tothe next dsassembly persion. (See page $16) DISASSEMBLY +L. Remove the lock rut. (4speed transmission ony) (i) Clamp the 18t gear section of the input shaft in a vise, making sue that no scratch is made to the clamped section (@) Release the staked section ofthe lock nut, using a chisel {@) Remove the lock aut NOTE: For the 5-speed transmission, see page 3-99. 2. Remove the conical spring washer. Then, remove the Dearing, using the SST ajven below. ‘SST: 09602-87301-000 2. Remove the 4th gear and 4tn gear bush 4. Remove the synchronizer rng. Then, remove the syncho- rizr hub assembly No.2. (1) Detach the two synchromesh shiting springs and three eynohromesh siting keys. © Ore,MANUAL TRANSMISSION 5, Remove the synchronizer ring and Sra gear. 6 Detach the shaft snap ring, using two common screw: sve, NOTE: 1. Special care must be exercised as 10 the snap ring ‘which may jump out during the cisassembiy 2 Partcular anton should be paid to avoid scratching the shat. 17. Remove the bearing, using the SST given below. ‘SST: 09602-67301-000 INSPECTION 1. Cawck he th goar bush for wear of damage P| ES [Ut am eect @ 2 8 20 = © | tosses se) (0925) le Ouercaneer @| ne, = 29 Orerneea | cad i) rae =F Themes og 380%, ee BBR | ordi 2S a0 | ohoMANUAL TRANSMISSION 2. Check each gear for wear or damage. ; ——— Pat in aieaoet ate ee| | [2T oem | wee | mm | ma moa jit Bdta| ah | eh a | 93m As 05 | BT wa dao ls! 28h h_| —_ esrsecin | ee — set eo ae anata iblses "| toonced as mn tun ‘Type 6860 engine th gear) PUpRdbin creation and san of he hub and sleowe Sleeve a) ST ee een | Pa TRTESS |_ume omen ‘Shi fok groove 7088 | ig sEereer @ | ozwiin | win Thang sxion | Vu epect i oon ene ENBSS"" © | Garage wear ck or ounces one 4, Check the input shit for wear or damage. Pent [Spaced 22 | Umit mm neh) Quecdameirct | aszauz | age bushbore-coriact, | (ond shi) | O88) jeter) | _ “oom surfaces of | Visually nepect he euace fr excessive Searerd spine | Gamage, wear ick or rounded edge. 2. Gk he ch tu nd ar fre eh ot Sete pk 7 ‘Cluteh Hub \ mo] = Splined section © | a eS may age =| ee ue | ‘With the hub fitted into the sieeve, check for excessive looseness cnc eeMANUAL TRANSMISSION 55. Check the synehromesh shiting key and key spring for ‘wear or damage eae ave Tat Pat Serene rom (ch) Key 5 & 4h 5 43 pelrtimensony) | (a1e7 28%) oe) = © | Weare sea canage 66. Check the synchronizer rng for wear or damage. deal "Prem tne) _mm (inch) =e rmeeing spresed | 4th =: Bo | Seth | ction — [seer sea a Doras ne 7. Chwokne neg fr wear or ae Pan : Inspection efiteria as ete sri a ASSEMBLY — ss weaned — ' NOTE: i} ‘section A —.L—rt~—~—O_—=CizsORr Te ral ra hen ipo cares oar Sapo mocuiegn ima ead Tre | Overall ie Presence of “Without spline (speed) —— ae ae ec Sere rae ast 2 ves | ly We SSpeed (92.24) : oes(MANUAL TRANSMISSION 2, Assemble the bearing, using the SST given below. ‘SST: 09908-87201-000 3, Drive a new snap fing Into postion, using a common serewive, For easier installation, hold the snap ring with the SST siven below: ‘SST: 09900-87201-000 NOTE: ‘Be very careful not to scratch the shat. 4. Assemble the 8rd gear 5, Assemble the synchronizer ring and synchronizer hub ‘assembly No.2. (G) Assemble the clutch and sleeve. Ensure that both parte can side smoothly. (@) Besemiie the shifting koye end springs, 6. Aseemble the synchronizer ring and Ath gear. 7. Assembly the 4th gear bush 300 $7201-000 fant © ‘Srenoneeing & 4h go eanMANUAL TRANSMISSION 8. Assemle the bearing, using the SST given below. ‘SST: 09909-97201-000 NOTE: (On the 5-speed transmission, measure the end play of comeeeanone ‘each gear ater the bearing has been assembled (Gee page 3-43.) 8, Assemile the conical spring washer and lock nut (speed transmission) (G) instal the conical spring in such a way that its expanded sice may face foward the shat se. (2) Clamp the reduction gear section in a vise, making Sure that no scratch may be made tothe section. estate cons eptog (@) Tighten the lock nut ivi oxperced se Tightening Torque: 10.0- 14.0 kg-m (72 - 101 fo) facing ova 10. Upon completion of the assembly, measure the end play Y ‘of each part ofthe input shat Spacted ae Tat cs | FPrmiech) smn (ch) ardger _@| 1-028 os & ‘thgear @ | (00089-30001) (ote) a NOTE! If the end play does not comply with the specification, ® check the gear, bush and cuich hub sliding section. sar “sama Replace any parts which exhibit defects 11. Stake the lock nut, using a chisel NOTE: Be sure to stake the central part of the look nut so as to ° ‘avoid dislocation or cracks. OOCOMPONENTS: MANUAL TRANSMISSION DISASSEMBLY, INSPECTION AND ASSEMBLY OF OUTPUT SHAFT (SCout ena Fane 31MANUAL TRANSMISSION Operation Prior to Disassembly Pullout the output shaft and the input shaft atthe same time from the tensmission case. Proceed tothe next disassembly operation. (See page 3-53) DISASSEMBLY 1. Remove the lock nut. (4-speed transmission ony) (1) Clamp the reduction gear section ofthe output shat in 4 vise, making sure that no scratch fs made to the clamped section (2) Release the staked section of the lock nut, using @ chisel (@) Remove the lock nut NOTE: For the 5-speed transmission, see page 9-99. 2. Remove the conical spring washer. Then, remove the bearing, using the SST given below. ‘SST; 09602-87301-000 8, Remove the output 4th gear, speedometer drive gear and output 3rd gear 4, Remove the 2nd gear assembly (() Detach the shaft snap fing, using the SST given below. SST: 09905-00012-000 (@) Remove the 2nd suogear. {@) Ramove the conical spring washer. aog=<=Qjp eo) 06g,MANUAL TRANSMISSION Remove the 2nd gear bush and synchronizer ring No.8 Remove the synchronizer hub assembly No.2. (G) Remove the two synchromesh shiting key springs and thee synchromesh shiting keys. emave the synchronizer ring No.3 Remove the 1st gear assembly (() Detach the shaft snap fing, using the SST given below. ‘SST: 09905-00012-000 (@) Remove the 1st subgear. {G) Remove the conical spring washer. Remove the spacer and needle roller bearing,MANUAL TRANSMISSION INSPECTION 1. Chack the 2nd gear bush for wear or damage. Seated ae oa Pa Peete | many 23-81 28.84 hail ©! cserribien ES) a7 Es 288, ower cemaer @| sry i824) overatiengh @| «AAS 903, sar fei) 2. Check each gear for wear ar damage. | Seecteg value en fren) |Link mm (ret) toe © | Yeah @ | Ove | @ wich [a HH | ios | 2 aes ome) jy asar gto zr ee eee) | (ae 7 Pat ards) mane 9| See, 8 [roc Yapcremntrecnoncesies Eisen mo Treen g erence wowtom maaan ieee Check the clutch hub forthe tst & 2nd gears and reverse (ear for wear or damage. ‘Clute Hub Pa a ‘Spined secon @ E o_O | igsaty inspect he section oro ‘Synchrameshsrfing Wey | sesevé Gamage o ea fing groove @ ‘Wit the rub fied into the sleave, check for excessive looseness. ‘i Edown drecton and San af he hub ar sleeve Reverse Gear Sates ane | oa Pat | SPramtindh) © | rm nen) 70 2838 73 Shittorkaroove wien ®| ware see) | 0287) Fring eactonwit gear @ | Visually inspect he section fr ex Senin oes _@ | ecive cage, wear, ick or Poewagearomastace © | reseed edge Ted Forte ira gear Revere oatMANUAL TRANSMISSION 4. Check the output shaft for wear or damage. ra Specieg ane | Tine | SPrrn‘ines) © | ew tinct) ‘ol, Bie 23.86 tar cameter of te (1817 Faced) | P785) ‘esate rll Bosh ‘ontac'secton lol, 2, ae [2508 =F) | (2580) Toot sulases of gear ond | Vaxaly speci ste reese Sine ‘raga wes horace 5. Check the synehrernesh shifting Key and key sexing for ‘wear oF damage. ‘Samage or distoron packers | UaT Past [Seimtecl) | mm tnem ghey iesoaoes | 612 Ot a7 GRR APHOM® otha Occse) 0185) a a (ex insect te sping for 6 Check the Ist and 2nd subgears and conical spring washer for damage or wear. (Except fr vehicles mounted with Type C8-80 engine) Spates ae | Un Pan PSS | _ men ech) (peter soe ears Borecisuogear | cuaspesge™) | (870) Subpsaricoic| spina Vly spestne sce fr stacker icing sonar "%@ | Gamage o corn, Fear 7. Check the synchronizer rng for wear or damage. aaa] Oe J a amo) men (inch) SSRN |S” oSE- Mn | atk mee |2ig., (oes 0571 | (ozo) pane Damage ane sao | guatygpacn ecto ore — esse Sarace Damage at ptne 8, Check the bearing for wear or damage. Pat Trenection oetie ‘inen the ner 08 ated by your Beaing Inger grou Yotae smeery wihout ary econ,(MANUAL TRANSMISSION ‘ASSEMBLY NOTE: ‘Apply gear oil to the entre surface ofthe rotary or sliding section of each gear ofthe output shalt. 1. Assemble the needie roller bearing and spacer 2. Aseemble the tst gear assembly (1) Install the conical spring in such a way that is expanded side may face toward the subgear side, (2) Assemble the 1st subgear {@) Assemble @ new snap ring, using the SST given blow. ‘SST: 09905-00012-000 3. Assemble the synchronizer ring No, 44. Assemble the synchronizer hub assembly (1) Assemble the hub clutch and reverse gear. Ensure that both parts can slide smoothiy. (2) Assemble the shifing keys anc springs. 5, Assemble the synchronizer ring No’ and 2nd gear bush 6, Assemble the 2nd gear assembly. (3) instal the conical spring in such a way that its ‘expanded side may face toward the subgear side. (2) Assemble the and subgear. {@) Assemble @ new enap ring, using the SST given below. SST: 09905-00012-000 5) %9 reerMANUAL TRANSMISSION 7. Assemble the output Src gear, speedometer drive gear ‘and output 4th gear. NOTE: ‘The umber of the speedometer crive gear teeth clflers depending upon the gear reduction ratio. Hence, care must be exerosed as to the number of gear teeth during the assombly. (See page 3-3.) Apply gear ol to the entre surface of the rotary or sing seation of each gear 8, Assemble the bearing, using the SST given below, ‘SST: 08908-87201-000 8. Assemble the corical spring washer and lock nut (@-spoed transmission) (4) instal the conical spring in such a way that its ‘expanded side may face toward the gear side. (@) Clamp the reduction gear section in a vise, making sure that ao soraich may be made tothe section, (2) Tighten the lock rut Tightening Torque: 10.0- 14.0 kg-m (72-101 ft eon 720-000, MK Inga ne cei sprog white excances se eho warns 5 a 10.Upon complation ofthe assembly, measure the end pay of each part of the outout shat Part ]_Specineg yao | Limit rm inch) 1 weer | gto | 8 Ht sage @) Ootie-bauH | ten NOTE | Ihthe end play doos not comply wih the specication, chock the gear, bush and. cutch hub siding section. S | Replace ary pars which exhibit defect, 11. Stake the lock nut, using a chs om ° NOTE ~ 2 Be sure to stake the cerival part of the lock nut so as to : _void dislocation or cracks j x & rae aeMANUAL TRANSMISSION DISASSEMBLY, INSPECTION AND ASSEMBLY OF 5TH GEAR ‘COMPONENTS: Stew r Sica sng water iraeon aS poe raramason ctch No3 hab Ay oeMANUAL TRANSMISSION DISASSEMBLY 1. Remove the slotted spring pin 2. Remove the lock nut (() Lock the input shat, using the recommenced too! for this application. (See page 9-66) (@) Release tne staked lock nu, using a chisel. NOTE: Be very careful not to damage the threaded portion of the Input shat {@) Remove the lock nut atthe input shaft, using a socket whose width across flats is 32 mm. (4) Set the sieeve for Sth gear to te Sth gear poston, {6) Remove the lock nut at the output shaft side, 3. Remove the conical spring washer atthe input shaft side land transmission hub sleeve stopoer. 4. Remove the Sth shift fork and transmission clutch hub assembly No. (() Remove the Sth shift fork and transmission cutch hub assembly No. at the same time, mam(MANUAL TRANSMISSION 5. Remove the synchronizer ring and Sth gear. 6. Remove the Sth gear bush, 7. Remove the conical spring washer at the output shaft side, Remove the output 5h gear. INSPECTION ig 3140. waa 1. Check the bush wear or damage. ® Fen] ER | it ord q re sunsce ©! se 3) eile ee: ee) J omnia 8 | stn | __ ah ar 5 BERS, ©| ott l Bron | ety 2. Check he Sh aero west or rage | Species valve am fren) Lint neh 2 bed [i | Bed | en hice Bar Bae |nctatm| CS | ce | | S| @ Gaeo & err _| Voda cn boca cag = _ out GEREN capita ieee py, chr ce ee 3-4043. Check the clutch hub and sleeve forthe Sth gear for wear or damage. ‘Clutch Hub Pat T rat ‘Spined secon o| ee army | Mat ogptie eee ro Sector shina er (we damage oF wear L iting groove “Wh the pub ite ito the sleav. cack or excess ocseness IRE Grocton and sant he hub an sleeve Sleeve rad Specterae | Un | mentncr) | mminch) | 7 [70% 73 By 73, sriiocomoewan @| 20h) | Bn 7 ieuly inspect he section fox (esi damage, wear nicer Fring ection wit gsr © founds jecge. 4. Check the synchromesh shiting key and key soting for wear or damage, 7 SERS TE Par | tom (inch) mmm (inch) eine ce i Bese [ov@atem | otk ora o | Seamer 5, Check the synchronizer ring for wear or damage, Damage at pine = Spectea as | _Ua Pa Perm inch) | mm inn) Gap when aynehronier | 05-245 Os. fngisprectedtogeer | (0083-0087) | __ (Oe) Damage stinner tapered | sector ‘sual ingpect he section ore esewe damage. {6 Check the shit fork forthe Sth gear for damage or wes 7 Tpachec yas | UR Pa [Sfiincy) | mm tren) Typressarsosectonct | 70026) | 830025 at Ff), HeMANUAL TRANSMISSION ASSEMBLY NOTE: ‘Apply gear oll to the entre surace of the rotary or sicing section of each gear of the output shat. 1. Assemble the output Sth gear and the conical spring washer for the output shaft NOTE: Tighten @ new lock nut temporary. 2. Assemble the Sth gear bush, 3. Assemble the Sth gear and synchronizer rng, 4. Assemble the transmission clutch hub assembly. (3) Assemble the cutch and sleeve. Ensure that both pars can sie smoothly (2) Assemiole the shiting keys and springs. NOTE 1. The hub assembly for the &1¢ and 4th gear use difers from the hub assembly for the Sth gear use only in the Inner lameter of the clutch hub. Other parts are shared in common. 2.The sleeve and dutch do not have any instaling rection to be observed during thelr assembly. 5, Assemble the vansmission cluich hub assembly and the Sth gear shit fark atthe sarne tie. 6. Assemble the transmission hub sleeve stopper 77. Assemile the conical spring washer (@) instal the conical spring in such a way that ts ‘expanded side may face toward the transmission side, 1 was expanded meteon eae ears8. Insta anew look nut (7) Lock the input shat. using the recommended too for this application. (See page 3-66.) (2) Tighten the lock nut at the input shat to the specitied torque, using 2 cocket whose wiath across fas is $2 Tightening Torque: 10.0 - 14.0 kg-m (72 - 101 feb) (@) Set the transmission to the Sth gear poston. (@) Tighten the lock nut at he output shat fo the specited rorque, Tightening Torque: 10.0- 14.0 kg-m (72 - 101 feb) (6) Before the lock rut is staked, measure the end play of the Sth goat ‘Spectied Value: 0.1 - 0.28 mm (0.004 - 0,009 ineh) Unt: 0.4 mm (0.016 inch) (@)Stake the lock nut, using @ chisel NOTE: Be sure to stake the central part ofthe lock nut so as to ‘avoid dislocation or cracks. ‘9 Drive the slated spring pin into poston, uni it becomes flash vith the edge sutace ofthe shift fork. 43 rome aa‘MANUAL TRANSMISSION [hee ee DISASSEMBLY, INSPECTION AND ASSEMBLY OF DIFFERENTIAL CASE COMPONENTS: Fe aEDISASSEMBLY 1. Remove the radial ball bearing. (1) Remove the Dearing at the engine side, using the SST given below, ‘SST: 09602-87301-000 (2) Remove the bearing athe transmission side, using te SST given below SST: 09906-87302-000 NOTE: Grinding off the interfering section ofthe SST witl make the operation easier. 2. Remove the differential ring gear. (1) Clamp the diferent case In 2 vise. Remove the attaching bots, (2) Remove the siferential ring gear IWany diffeuly Ia removing the ring gear is encoun tered, evenly tap the perinheral section of the ring gear, using a plastic hammer 3. Drive out the slated spring in, using punch pin‘MANUAL TRANSMISSION 4. Pullout the diferential pinion shat. 5, Remove the diferental pinion, diferential side gear and ‘i Ai fe 2 os Evauaton | Pion rediengih | __Wertiicaton mark ‘Too short [121.3 men (4.77 inches) | ‘Not provided 2 [oolong [1227 mm (669 rhea) | Provided (See fgu below) ‘ra iano psn oa Giron fare Securely tighten four bots marked with @. NOTE: [At the same time, securely tghten the bolts which were temporarily tightoned instep © “Tightening Torque: 05-018 kg-m (86-43 th) Inet the manual valve into the upper valve body. ASSEMBLY OF TRANSMISSION INSTRUCTIONS ON ASSEMBLY 1 2 ‘Be sure to replace the folowing pasts with new ones: gaske's, lock nut, “O° rings, cl seals, sel rings of teach piston, seal washers of te ol purnp 88 Dal, oi deflector and test plug. When replacing the low brake band and cluich cisc with new ones, immerse the new parts in the automatic fui fora least two nours preceding the assembly. Be sure o apply the automatic thid tothe sliding sections ofthe parts ‘Thoroughly clean the bats or threaded holes, to which a sealing agent has been applied. Prior othe assembly, ensure that air continuity exists in each ol passage by applying comexessed air into each ol passage Be careful not to damage each gaske: surace of the transmission case, rear cover, oll pump. valve body and housing. Tighten the bolls and nuts tothe specified torque. Install the bearing and race In thal cortect postions and directions. In order to prevent foreign matters, such as dust or aif. fom geting into the transmission case, clean ‘each part by applying compressed air prior tothe instalation, ‘When applying grease, use the specified MP (multipurpose) type ner Inetalation of the manual shit shaft and parking lock pawl (j) festa the lower washer and parking rod to the manual shit shat. (2) Insert the marusl shit shaft into the transmission case. NOTE: When the manual shit shaft passes through the oll se be careful not to damage the lip section of the oil seal (@) Lock the shift shaft by the washer and the “E* ring{@) Instal the manual detent spring subassembly, (4) instal the pin and snap ring tothe parking lock paw sleeve, Install the sieeve in the transmission case in such a way thatthe rod may get into the sleeve. (6) instalation of parking lock pawi and parking lock pawi shat ‘Oinsial the paw in the correct postion, {@Pass she shalt through the spring. Install them tothe paw, as shown inthe right figure, @Snit the manual shift lever 10 the B] range. Ensure ‘that the earking lock paw moves smoothly: Installation of the 1st & reverse brake piston G1) Apply the automatic fuid tothe “O" rings (both inner land outer) Then, install them to he piston, (@) Insert the piston into the transmission case in the direction ingicated in the Nght gure. NOTE: Be careful not to twist the “O" rings or not to have them ‘caught by other parts. 451AUTOMATIC TRANSMISSION (@) Install he return spring subassembly in such a way that it fited! into the round groove of the piston. Compress the spring @s shown in the right figure Using tne folowing SST. Then, atlach the reium spring snap ting ‘SST: 08380-87702-000 NOTE 1 neue thatthe snap ring i attached to four grooves ofthe spring seat, NoTE 2 Do not compress the return spring beyond its compression allowance (dllection allowance). (4) Install the folowing parts in tis order. Cushion plate @Paate Disc @Plate Total umber of piates: 4 @Disc Total numberof discs. 4 @Piste @Disc @Picte @Dise ‘Flange NOTE 1 ‘Make sure thatthe cushion plate is installed inthe correct Instaling drecton, (instal tin such a way thet, as viewed from above, the floated side may come tothe center, whereas the recessed side may come tothe outside.) NOTE 2: Immerse the discs in the automatic fud for at least two hous preceding the installation. NoTE 3 Care must be exercised as to the assemping sequence land the numberof the discs and plates. (5) instal the snap tng (6) Measure the clearance indicated In the right Agure, using @ thickness gauge Specified Value: 0.58 - 1.92 mm (0.023 - 0.075 inch) NOTE: Hf the measure value does not comply with the spect: tion, check the installing condition of the clutch cises and the plates. ——————— onssp 97702000 ap(7) Apply compressed a int the ol hole indicated in the right fgure ana cheek 1o See the piston moves freely Intalaion of the counter shat, reduction gear and rear (G) Press the bal bear's int “ne output shat, using the following SST. SST: 09350-87702-000 NOTE: Prior to the press-fiting, apoly the automatic fis to the inner race and outer rac. (2) Drive the bal bearing int the transmission case, using ‘a hammer in combination withthe folowing SST ‘SST: 09606-30017-000, NOTE: Prior to the press-iting, apply the automatic fud to the Inner race and outer rac. (3) Press the output shat into the transmission case using the folowing SST, es incicated in the figure. ‘SST: 09350-87702-000 (4) Press the roller bearing from the differential gear side of the courter shaft case, using the folowing SST. ‘Thon, attach the snap fing SST! 09608-30011-000, NOTE: Prior tothe press-fting ofthe bearing, apply the automatic ‘ud to the Inner race and outer race. AUTOMATIC TRANSWISSION Tren fi cssso.er72.000 eaaze sr7ce 805 |AUTOMATIC TRANSWI (6) in advance, put the spacer on the counter shaft case. (6) Press the ball Dearing from the reduction gear side of the.countet shaft case, using the folowing SST. SST: 09606-30011-000 NOTE: Prior tothe prese-iting ofthe bearing, apply the automatic fluid tothe inner race and outer race. (7) Install the bearing packing plate along the groove ‘tach the snap ring (@) White the inner race of the ball bearing is being sustained, pase the spacer through the counter shat {and press the counter snaft into poston. ‘SST 09950-87702-000 (9) Install the reduction driven gear to the counter shat. Tighten the lock nut. ‘Tightening Torque: 11 «15 kg-m (80 - 108 fib) (10) Stake the lock nut, using a chisel NOTE: Be careful not to apply excessive forces to the counter shat. eae(11) Install the gasket, making sure that itis aligned with the straight pin ofthe case. Install the rear cove, NOTE 1 Be sure that the bearing smoothly gets into the bearing hole of the rear cover. NOTE 2 CCheck to s2e if the shaft emits any abnormal gear sound, while rotating the shat vont (12) Secure the rear cover by tightening the ten boits and ‘wo nuts Tightening Torque: Bolt 1.6 - 23 kg-m (12-16 th) Nut 1.1 1.5 kg-m (8.0 » 10 feb) NOTE: ‘As for the arrow-headed bolt in the right figure, use this bolt to secure the solenoid wire harness in common. (13) Werking from te inside of tne case, push the bearing ‘outer face against the rear cover side, using the Tolowing SST SST: 09350-87702-000 NOTE 1 For this operation, use the four cut-out sections of the transmission case. ‘Pushing Foree: 500 kg (1100 Io) 4 Instalaton ofthe rear planetary gear and one-way clutch (7) Install the tear planetary rng gear, making sure that it Is alignes win the spline of the oviput shat. AUTOMATIC TRANSMISSIONAUTOMATIC TRANSMISSION (2) Insta the bearing races (both sides) and thst needle roller bearing (@) Fittne one-way clutch race snap ring to the groove at the 1st reverse brake side ofthe transmission case. (4) Install the thrust washers on each of the front and rear sections of the planetary gear assembly. NOTE 1 ‘Apply grease to the washers. NOTE 2 Fite recessed sections ofthe gear assembly with the two protruding sections corect. (6) While turing the one-way clich assembiy counter- clockwise, instal ito the planetary gear assembly. NOTE: ‘After completion of the installaton, be sure that the planetary gear sosemly fraly eotaas clackwisn whan tha ‘one-way clutch outer race is secured. (© Insert the planetary gear assembly filed wits the one- \way clutch assembly into the transmission case, while Tolating the planetary gear assembly. NOTE 1: For easier iseron, align the pavls of he brake dc a NoTE 2: HF the shit lever is shited to the (F) range, the shaft is locked, thus making it easier to align the cutout sections with each other. 456 owt areacs. ust wastes SesorelyNOTES ‘ter completion ofthe insertion, check the one-way clutch operation. ‘Clockwise rotaion: Free ‘Counterclockwise rotation; Locked (7) attach the one-way clutch race snap ring to secure the ‘one-way cluich assembly. Installation ofthe planetary sun gear assembly (G) instal the cushion pate and the snap lng (sheet type) ta the sun gear NOTE: Be sure to instal the cushion plate in the correct direction, (2) Insert the sun gear into the sun gear input rum, (@) Temoorary lock the sun gear input crum with another ‘snap fing (vie type) “srAUTOMATIC TRANSMISSION (4) Insta the snap ring (wie type) inthe correct positon by pressing the cushion iat. (6) insert the etraght pin into the sun gear. (6) instal the waahor In such a way tat the staan pin ‘gets into the cutout section of the planetary thrust washer NOTE: Prior to the installation, apply grease to the washer to prevent it rom dropping (7) While meshing the sun gear assembly with the rear planetary gear, inser the sun gear assembly into the NOTE 1: Be carcful not to damage the bush provided inside of the ‘sun gear. Note 2 Be certain that the flange section of the thrust bearing ace, which was installed in the previous step, has been Installed positively into the sun gear bore. Installation ofthe front planetary gear (3) Piace the thrust needle roller Bearing and beating race fn the eun gear Note: Be sure 10 piace the bearing ray ir te cones dection fn the sun gear (2) White rotating the kent planetary gear assembly, he pinion gear inthe sun gear NOTE: ‘Care must be exercised to ensure that the thrust bearing oF the race may not be displaced from the correct position,(@) Place the folowing paris on the front planetary gear ‘assembly in this order. @Bearng race @Thrust needle rler bearing @Bearng race NOTE: ‘Be sure to place the bearing races in the correct direction (on the front planetary gear assembly. (4) instal the front planetary fing gear to the thrust Deering which was installed in the preceding ste. (6) instal the “O° ring at the forward end of the output shaft NOTE: Do not expane the “O" ring excessively during the instal tin. Installation ofthe 2nd brake band (jp instal the brake 2nd band in the transmission case. NOTE: ‘Be sure to instal the brake band in the corct rection Installation ofthe forward clutch and direct clutch (4) Wen the “O° ring of te input shalt is replaced, apoly forease fo the input shaft side before instaling the new “O-ring NOTE 1 ‘Be sure to install the “O" rng tothe comect groove. NoTE2 (Do not expand the “O” ring excessively during the instala- tion 4-69 oeAUTOMATIC TRANSMISSION (2) Apaly grease to the thrust bearing race and thrust feedle role’ Deering a& well as to thelr installing ‘Sections at the forward clutch, Then, instal these oars into postions NOTE: ‘Be certain to instal the bearing race in the correct rection (2) instal the thrust washer, with the side having no fgroove facing toward the direct clutch. For easier instalation, apply grease to the side of the cirect cutcn, NOTE: ‘Be sure to instal the thrust washer in the correct direction (4) instal the creo cluch tothe forward clutch NOTE 1 For easier insertion, align the pawls ofthe clutch dise prior {o the installation. NoTE 2 Be carelul not to drop the thrust washer which was imetalle Inthe preceding step. (6) Appi grease on the front planetary ring gear in the transmission case, Install he thrust beating race anc thrust needle roles bearing in postion NOTE: Care rust Ue exerceed a8 to the inataling direction and sequence. (6) Wie holding the input shaft of the forward clutch. install the forward cluteh fited with the direct clutch to the transmission NOTE 1: For easier insertion, align the pawls ofthe forward clutch ‘se prior fo the installation NOTE 2: Be careful not to drop the thrust bearing which was intaled in the preceding step. Notes Be very careful not to damage the oll seal of the output shat 4-60 Fea ranAUTOMATIC TRANSMISSION 10. (7) Secure the 2nd brake band by passing the straight pin ‘trough the transmission ease and the hole of the 2nd brake band. NOTE: Prior to the installation, apply the automatic fd tothe pin. Inetalation ofthe dlferentat asserly (4) Place the tarsmission case, wih is rear cover side facing downward. Wile meshing the pinion gear of ‘the counter shaft with the teeth ofthe differential ring ‘gear, insal the ciferential assembly. NOTE 1 Be carol not to damage the tooth of the gear during the Installation NoTE2 ‘The counter shaft pinion gear and the diferent ring gear have been sat as a pair. Hence, be careful not to mix these parts wih other pars Instaiaion ofthe torque converter housing (1) Install te gasket. NOTE: Make sute that the gasket isnot protruding to the inside. (@) Wie aligning the canter of the citferental gear Deering and the locating pin positon, instal the rousing In he transmission case. (9) Tighten the housing attaching bots indicated in the right figure. ‘Tightening Torque: 1.6 - 28 kg-m (12 - 16 fe) NOTE: ‘Apply the sealant to the entvo threaded portion of each bolt which bears a star mark (indicated by an arrow mark In the figure). Instaiaion ofthe oil pump assamoly (1) Apaly grease to the thst bearing race and thrust ‘needle roller bearing, Instl ther tothe input shat. NOTE 1 ‘Be sure 10 instal the bearing race inthe corect direction Note 2 Make sure that the bearing race and bearing are ited positively a =F \ ‘atin laden goat dn those Boel sareAUTOMATIC TRANSMISSION (2) Install the thrust bearing race, attr coating the oi pump side with grease. (2) Attach the clutch drum thrust washer tothe oil pump. NOTE 1: ‘Align the flange of the washer with the cutout section of ‘the pump, NOTE 2: Prior to the installation, apply grease to retain the thrust washer. (4) When the ol sea! is replaced, apply grease tothe cil 26! prio to the instalation, NOTE 1: Do not expand the ol sel excessively during the instala- tion NoTE 2: Be certain to instal the ol seal to the correct groove, (6) Install the “Oring tothe periphery ofthe oil pum. NOTE 1 Prior othe installation, apply grease to the “O” ring Note e: Use a new "0" rng NoTEs: ‘Make sure thatthe “0” ring isnot twisted or displaced from the groove on the periphery of the oll pump. (6) instal the oll pump assembly in the transmission case, NOTE: ‘Care must be exercised to ensure that the “O” ring ofthe input shaft and the “0” rings provided inside or outside of the pump may not be pinched or damaged. rene12, 13 14 (7) Tighten the six ange bots. ‘Tightening Torque: 1.8 -2.7 kgm (14 - 19 tb) NOTE: Note that only the bot indicated by the © mark in the figure is a M10 bok. Check ofthe input shatt end play (G) Measure the play inthe axel rection by applying the plunger of dial gauge fo the end surface ofthe input shat. Specified Value: 0.3 - 0.9 mm (0.012 - 0.085 inch) (2) the measured value does nat comply with the ‘specification, select a proper one from the folowing ‘Wo thrust bearing races having ciferent thicknesses. ‘Then, replace the race which was installed in Step 42:Q) at page 00 with the newiyselected bearing “Thrust bearing race thickness “Too large end play — 1.4 mm (0.055 inch) ‘Too small end play — 0.8 mm (0.031 inch) (@) Ater the ‘einstallaton, ensure that the input shaft rotates smoothly. Installation ofthe solenoid wire harness (3) Fit the lock pate into the groove ofthe solencid wire ‘grommet. Install the solenoic wite to the stud bolt of {he transmission case. (@) Atach the waehor fo the stud hot and tight i with the nut (@) Ciamp the wire harness at two points ofthe rear cover. Instalaion ofthe throttle cable (G) inser the trate cable inio the hole of the transmis- sion case, NOTE 1 ‘Apply the automatic fluid to the “O° ring, NoTE 2: Care must be exercised to ensure thatthe "“O” ring may ‘ot be damaged or pinched. Fi al ekAUTOMATIC TRANSMISSION 415, Installation of the 2nd brake piston {ip instal the “Oring ane washer tothe piston rod NOTE: Prior othe installation, apply grease tothe “O" ring (2) Insert the spring and rod to the piston. Secure it with the E" rng. NOTE: Prior to the instalation, apply the automatic uid t0 the inserting section ofthe rod (3) Install the two “0° rings to the piston. NOTE Be careful not to damage the “O° rings. NOTE 2: Do not expand the *O" rings excessively. (4) Put the spring in the transmission case. Insert the piston assembly into the case. NOTE ‘Apply the automatic uid to the inserting section of the piston rod. NoTE2 Care must be exercised to ensure thatthe "0" ring may ‘ot be damaged or pinches, NOTES Make sure thatthe forward end of the rod is aligned with the metal fiting of the brake band. (6) Install two °O™ rings tothe piston cover NOTE: Prior tothe instalation, apply the automatic id to the ings. (©) Insert the piston caver into the transmission case NOTE: Gare must be exercised to ensure that the “O" ring may not be damaged or pinched. (7) With the piston cover pushed to the inside, attach the snap ring in psiion (@) Through the side cover hole, check to see it the forward end of fhe rod is in contact with the metal fiting of te brake band a ts speced postion. reneAUTOMATIC TRANSMISSION (@) Perform the 2nd brake piston stoke checkin he same way as withthe disassembly woot 10) Instl the transmission case side cover and its gasket. Tighten them y means of the four bots Tightening Torque: 0.7 - 0.9 kgm (65-65 tb) 16. Installation ofthe neutral start itch and the manual valve (4) instal the neutral start swt. {Set the manual shatt o the "N" poston. insert the switch into the contol shalt. Temporary secure the swten bot. (nominal length 35 mm) @Aign the serie lines on the contol rod and switch ‘wih each other. Securely tighten the bolt which has been secures temporal in the step @ above Tightening Torque: 1.6 - 2:3 kg-m (12 - 17 feb) @Ensure that the switch Is functioning propery (2) Pass the upper washer and then the shit lever through the manual shit shaft which protrudes above the ttancmssion upper section, Then, secure them by means of double nuts. NOTE: The following shows the tightening sequence ot double ruts. DTighton the lower nut. “Fightening Torque: 0.9 - 1.7 kgm (65 - 12 fH) @Tighten the upper nut ‘Tightening Torque: 0.0. 1.7 kgm (65 - 12 feb) @Wi the upper nut locked, tighton the lower nut in the reverse creation. “Tightening Torque: 0.9 - 1.7 kg-m (65 12 tb) (9) Check 10 sae ifthe shaft rotates smoothly. FearAUTOMATIC TRANSMISSION 17. Installation ofthe accumator piston By, (3) instal the "Oring on the piston NOTE: Prior to the installation, apply the automatic fuid to the piston and *O" rng, (2) insert the spring into the piston (3) Insert the piston ito the transmission case. NOTES ‘Number of |” Spring length ‘Spring outer diameter Lonsdale ime] Semaees” | ert roa ms 32. T 70.0, Es | 8 T S41 35.0. Gj} ot | ese oe) NoTE 2 Coro must bo exercised to ensure thatthe “O" rng may fot be damages or pinched 48, Installation of the valve body assembly (() Place the valve body assembly on the transmission (2) Insal the pin ofthe manual lever in the manual valve {@) Temporeriy tighten the two bots indicated in the figure. (4 Instal the throttle cable to the trot cam. NOTE: Bo not pull the cable mare than 0 mm (1.57 inches), 66(6) Tighten al bots =] mara fe] *ee asst] MEERER* [tome ear anne ee | mt | km Ge) fo) we [se (ain| oe). 1200-65] 7 | Deeprecese [| Ws (47 (2a80)| 000. 120(60-65)| + _|Deeprecess [we [es o2m0ono-ran 60-08)| | Nemainene f@| Ne [seranoloeo-120(60-85)| 1 | nomalecss (6) instal the ol tubes. NOTE ¢ First insert the oil tube's end having no stopper (tin the right figure) about 2 mm (0.079 inch). Then, insert the end having @ stopper (2 inthe right figure). NOTE 2 To prevent the tube from being deformed, bghty tap the tube using a plastic hammer. Notes. Positively inser the tubo, unt the stopper of the tube ‘comes into contact withthe case, NOTE 4: Install he tubes in paral withthe valve body. (7) Connect the solenoid connector. NOTE: ‘The wire hamess ifers in length to prevent. wrong connections. Therefore, do not pul it forcibly (©) instal te oil strainer. At the same time, clamp the two solenoid comectors. Tighten them al together Tightening Torque: 0.4 - 0.6 kgm (8.0 4.0) 467 e = oes tian pane ‘leno ck) noe wa)AUTOMATIC TRANSMISSION 19. 20. a. ‘netalation ofthe ol pan (2) Set the gasket on the transmission case. NOTE: ‘Make sure thatthe bolt holes ofthe gasket are aligned with ‘hose in the transmission case. (2) Place the magnet onthe oil pan. NOTE: It is advisable to pace the magnet at the poston inicated In the figure. (@) Tiohten the all pan by means of the bots (13 pieces) and screws (two pieces). Tightening Torque: 0.4 - 0.6 kg-m (3.0 - 40 fib) NOTE? ‘Apply the sealant tothe two screws incicated in the Agu. NOTE 2 Make sure that the tube and oll pan do not interere with ‘each other. (@) Tighten the drain plug Tightening Torque: 1.8 - 23 kg-m (13.5- 16.5 fb) Installation ofthe ol fer tube (4) Install the "O° sng to the ol fle tube, Insert the oil filer tube into the ransmissigg case. NOTE 1 ‘Apply the automatic fd to the “O° ing NoTe 2: Insert the ol filer tube upto the flange poston. (2) Secure the ai filer tube by means ofthe bot Tightening Torque: 0.3 - 0.7 kg-m (24 -5.6 fb) Inetalaton ofthe test plug atthe detecting hole (3) tnstal the “O° ring ana tighten the plu. Tightening Torque: 0.6 - 0.9 kg-m (43-65 t NOTE: Apply the automatic tid tothe “O" rngAUTOMATIC TRANSMISSION 2 Installation ofthe torque converter (G) instal the torque converter. Check to see if the attaching dimension indicated in the eight figure com- plies wih the specication, NOTE t ‘Be careful not to damage the ol seal. NoTE2 Make sure thatthe torque converter rotates igh. Notes ‘Apply grease to the point indicated in the figure. Tose 2, a Rossrg Bm oriAUTOMATIC TRANSMISSION APPENDIX SHIFT LEVER CONSTRUCTION - : ; Sa we y 4 I ay ; ES PEER ne —‘CONTROL CABLE CONSTRUCTION FeeAUTOMATIC TRANSMISSION ASSEMBLING POSITION AND DIRECTION OF THRUST BEARING fares | Sungei cath Pio ger oe et utr sat (eter cme gear m=] ee SE | ae | Tp aie, RES] BEL [er sores | |G Bohn A) HE = [BR ) 221883 | 375604) [inner ameter targe |_| Sie BR | SCR =a see?) 2118) | 48077 _| ne tarts tonge Ty pace | core) | 350138 | rer lamar tage | | |B Senin) seh | Sete) | dss Face | “2e(0er) | 3791.48) | Outer diameter fangs [is | eee ee ee ee i Tp pice) Boon aig [Overaenwertowe| > |G Bigra| Baws, | Ste) = | gat nae 1B Ber] SES | SiN, lower aamentange| | Saesneanron nn Tome) ican) eres [ime aaneertere| | e |B Signo! lg? | BES = Ber] B.0 | BUS | wecovoes | 08 gun ec | 88s | hiss | NRBeueS | 2 | Bbien eee ee ee oo aot “7AUTOMATIC TRANSMISSION ‘UST OF SPRINGS ] T Feeerg® | Cot ouer Instaling postion Color | (Reference | ‘Samete _ rm (ee ual @ | Primary equator vane Fea | s25205) 10058 § | Ortes conte vane Yetowigreen | 343 (338) 85105) § | Twetievave Winte (2225 (08760)| 82038) g Gasoline wb, Purle_ [318111 250) | iver darter 60 (024 B ) Trew vane (Sesertabo uprBe | 51:54 (1283) | fre sant 0 (0d Tc wae cam eS OE | ee rte 4 (088) | Yelow | 314 1.38 7a ‘Secondary regu vave Gare as above) Yee giattzg, | 74ea 8 |2-senitvave Pink | S86(156) | 105 (0419) B | 1-250 vave Prk | sy | 105 (0419 bcontolvave fue | aarti) | 73103) Cooer bypass. orange | foo (b7a | 110,048) @ | 8 eccumaiace =| s0@05) | 1000s) & |. accumulator =| ares) | isos 2 [ver ; = | em | aes loo = | SR | Bee | Forfoward atte (18 ices) = [aso 08860) 771030) ‘haf parking paw - | - | eee OH P Foe 3 same creas caves pe tate 3 HBSURIRSAE retires immanent ns LIST OF “O” RINGS intling port emer | Trang pore Ig dato Ole boay 200767) || Babrake on Diesel mere {79 200) || Bs senovea 28039 Gxpiten oer 77 (eet) |) 0 acum | a7 (09280) B, sen cover '$98.6(256) || 8, accumulator [154 (@.608) spin er 7532 (1859) || Fterabe 90005) _| Cyto. oer T7460 || Seeecoreie 7870778) B.be mi e70 & Biman” & dubs 8: See tevre orate woesAUTOMATIC TRANSMISSION LIST OF BOLTS USED (1) Tigsenra | Nominal Intaling oie Sage | Sang | ee | eee | ace Housing x case _ 1” we | 16-23(12-16) | 35 8, WW Fear cover x case yo | Me | 16-23(2-16 | 35 | BWW Fear cover cate 2 [we | oseH | % | 88 Fear cover ca66 2 [Me [t4-18@0-7 | — N Rear cover x case 2 | 68 = = Ot pp asemby case 3 [Me pear | | ar | Sater nat x Oi puro body | we [oe-12(60-85)] 7 | Swar Case ide cover % case [we [o7-08@s-65| 1 | awa ‘Courter sha court aiver oar 1) wee [115 00-108) | — N Differential gear x differential ring gear 70 | mio | a0-1068-72)| — | BF ‘Manual ait halt x Manval valve outer lover we [os-1765-12| — N Deter x ase + [we [oa-12(60-65)/ 165 | wan Bete x ase Lor fe [20a | | 8s Detent x case 1 08-12(60-85)| — | N Detent x case 7 1 6 = - | w Valve body assembly x case 7 [Me [oe-1260-05/ 96) BF Vatve body asserly x case 1 [Me [oe-12060-05)) 7 | BF ‘Valve body assembly x case: 2 | M6 [0a-1260-85)| 25 BF ‘Valve body assembly x case 1 we jos-12(60-85)| 2 | BF Upper vae body x lower vave Body @ | ws [es-05e-49| as | AF npr vate body x lower vate Body [ws [os-ose-a9) «8 | 8F Upper vaive body » lower value body: 2 MS [05-06(36-43)) 44 BF ‘User valve Boy x verve Body 2 | ws [es-o8@e-4a| 205 | BF ona cover% lve valve Boey © | ws joscs@s-aa| | BF ‘Strainer x lower valve body 6 | M5 (05-0666-43)) 14 BF Solenoid owe vate boy 2 | me per-osae-cs| 10 | 8 ww “rote cam x ower ve boy 1 [sé [es-oous-65) 2 | BF Olipan x cate [Ls [we [oa-05(00-«3)) 16 | BWA Daln pig ota 7 [ime [ae-zanam{ es [| P Weeto-soerad x cane 1 LM | oan] | 8S vive eomeid x cae as-056-49| =| N Wire o-soerad x cate WwAUTOMATIC TRANSMISSION LIST OF BOLTS USED (1) um saa] Teiewe | Nema ting sore veg [eap| Tere® |S] ace Seeecorsier x hang 7 [we [av-s0i-7a] | awa Filertibe x case 1 [we [oa-07@a-sa)| 2 | aww “Test plug x case 7 | aie (06-09%43-65)| 95 | Pp * Oil pan x case, = 2 MG [04-06@0-43)) 16 WW “Housing x eae 2 | we [46-20(02-16 | 35 | wir Housing x case 7 1 wg | 16-23(12-16) | 50 aww | ‘Speedometer sleeve plate lock x case 1 [| ms [os-o9s-65)) 12 | eww Tote abe clamp = ease 1 [owe fos-00a-es)| 2) ewan OF asso case 1 [wo [1e-2704-19 | | OF ‘Neutral start switch x case 1 ma | 16-23(12-16) | 35 eww | Cae x coe 1 [we [ost7@s-] 2 | eww oun cha ose 3@ | wo | 30-45 ¢@2-6 | 25 | Eww “TRopy sairio he botbearroihe™ mark case Taerisson case a Explanation of shape 3, WW Botan washer Bam: Sater Be > gatfonge S wave ebm wacoeDAIHATSU CHARADE Chassis SECTION 5 FRONT AXLE & SUSPENSION FRONT AXLE sm 5-2 DRIVE SHAFT. 22 ‘SECTIONAL VIEW “5-2 DRIVE SHAFTAELATED PARTS 5-22 COMPONENTS . 5-2 OPERATION PRIOR TO REMOVAL wee S=23 REMOVAL . 5-3 REMOVAL S523 INSPECTION 5-5 INSPECTION 5-25 INSTALLATION 5-6 COMPONENTS ~ 5-26 FRONT SUSPENSION 5-9 DISASSEMBLY o S27 ‘SECTIONAL VIEW «.- “5-9 INSPECTION .. = 5% FRONT SHOCK ABSORBER 5-10 ASSEMBLY . 5-28 ‘COMPONENTS: 5-10 _ INSTALLATION 52 REMOVAL .. 5-10 FRONT DRIVE BEARING SHAFT 5-32 DISASSEMBLY 5-11 COMPONENTS .. 5-3 INSPECTION 5-12 INSPECTION 5-32 ASSEMBLY 5-13 DISASSEMBLY 5-33 INSTALLATION 5-14 INSPECTION .. 5-35 FRONT STABILIZER BAR 5-18 ASSEMBLY . 5-35 ‘COMPONENTS "5-18 WHEEL ALIGNMENT (FRONT AND REAR) .. 5-38 PEMOVAL won 5-15 CHECKS PRIOR TO WHEEL ALIGNMENT INSPECTION 5-16 EASUREMENT sn 38 INSTALLATION 5-16 CHECKS AND ADJUSTMENT OF FRONT LOWER ARM 5-17 WHEEL ALIGNMENT . 5-39 ‘COMPONENTS 5-17 CHECK AND ADJUSTMENT OF REAR REWOVAL 5-18 TOBIN. san 4 INSPECTION 5-19 INSTALLATION 5-20FRONT AXLE & SUSPENSION FRONT AXLE SECTIONAL VIEW Fr = COMPONENTS ““eER Ore gee ee) 2a ea etemc tte Greases , somo S eros SA = ae Tra 5 (68-78) 19 Serna knucke Bie seme (@ Racal bat boxing Dib dat mr Racin Slbearhg mre aceREMOVAL 41. dack up the vehicle at the front side. Support the body with safety stands, 2. Femove tho front whee! 3, Disc brake caliper removal (1) Remove the ataching bots ofthe disc brake caliper. (2) Suspend the caliper. 4. Remove the aise rotor. 5, Front axe hub removal (1) Remeve the cotter pin and front whee! adjusting lock cap. (2) Remove the caste nut, using the folowing SST. ‘SST: 09611-87202-000 (3) Draw out the axle hub, using the folowing SST. NOTE: Do not separate the axle hub from the steering knuckle unless such separation is nocessary ‘SST: 09520-00081-000 rar waeFRONT AXLE & SUSPENSION 6. Tie rod end separation (3) Remove the cotter pin caste nut trom the te rod end. (2) Separate the tis rod and trom the steering knucke, using the folowing SST. SST: 09611-87701-000 NOTE: While using the SST, be very careful not to damage the ‘boot and threaded portion. 7. Remove the lower bal joint ataching bot and nut 8. Steering knuckle separation Remove the attaching nuts. Leave the bots in their inserted conattions. 8, Steering knuckie removal @) While supporting the steering knuckle, draw out the sttacting bolts of the shock absorber lower bracket (@) Disengage the axle hub from the dive shat Remove the string kre, NOTE: «Protec the drive sha boot wih cloth or the like so that it ‘may not be damaged during the operation. ‘© Wind'a tape or the lke on the drive shaft threaded ‘portion so that the ol seal may not be damaged. 410, Front axle bearing removal (@) Remove the dust seal from the axle hub, using @ ‘common sorewariver. (@) Remove the beating inner race (outer side) from the axle hub, using the following SST. SST: 09950-20014-000 (09720-00010-000 (Use the item No. that is part ofthe set.) aw(@) Detach the snap ring, using snap rng pliers. (4) Remove the bearing from the steering knuckle, using a press in combination withthe folowng SSTs, ‘SST: 09527-87301-000 (08550-10012-000 (09554-10010-000, part of ‘the preceeding tool) INSPECTION Inspect the folowing pats innate See suoe cage | } . orderage spear \ courte Steraon Spe seeton or aoe aa 8-6FRONT AXLE & SUSPENSION 1. ise brake cover replacement (1) Separate the dso brake cover Irom the knuckle, using a common screwdriver or te ike NOTE: Do nol remove the dise brake cover unless its replacement is require. (2) Press the disc brake cover unt it comes into close Contact win tne kruckle, using the folowing SSTS SST: 09506-87202-000 09718-87701-000 INSTALLATION 1. Front axle bearing instalation (G) Press the bearing into postion, using the following sts SST: 09506-87302-000 (08550-10012-000 (09554-10010-000, part of the preceoding tool) {@) instal a new snap Fg, using snap ring pier. (3) Press the. font axe hub info postion, using the {allowing SST. SST. 09550-10012-000 (08554-10010-000, part of the preceeding toa) 2, Steering knuckie installation {Insert the steering keke into the drive shat NOTE ‘8 Be careful not to allow the dtive shat to. come into ‘contact with the ol seal atthe knuckle side, ‘© Pay utmost attention not to damage the ball jint dust cose raz cassq10012.000(2) Maunt the steering knuckle on the lower bal joint, {@) Mount the steering knuckle on the shock absorber lower bracket. Tighten the bots end nuts Tightening Torque: 8.0 - 13.0 kgm (65 - 94 fib) NOTE: With the knuckle pushed agains! the lower side, tighten the bolts and nuts. (4) instal the lower ball joint. Tighten the bot and nut. Tightening Torque: 8.0 - 10.5 kgvm (58 - 76 fib) (6) instal the washer. Install the nut temporary NOTE: ‘Be sure to install the washer in the coroct direction. Install the disc rotor. NOTE: Care must be exercised to ensure that no foreign matter lodge between the hub and the cic rotor. Dise brake caliper installation () Install the aaa guide plate to the storing knuckle {@) Tighten the ateching bots of the cise brake caliper. Tightening Torque: 3.2 42 kg-m (23-90 fib) FRONT AXLE & SUSPENSIONFRONT AXLE & SUSPENSION 5. Tightening of casio nut using the following SST (4) Tighten the caste nut SST: 09511-87202-000 Tightening Torque: 18.0 - 23.0 kg-m (100 - 160 fe) {@) Insta the front wheel adjusting lock cap and @ new cater pin Tie od end instalation (1) Attach the te rod end to the steering knuckle anc tighten the caste nut Tightening Torque: 3.0 - 4. kg-m (22 - 32.5 feb) (@) Install a new cotter pin Install the whee. Front whee! alignment inspection and adjustment (Gee page 5~38)FRONT AXLE & SUSPENSION FRONT SUSPENSION ‘SECTIONAL VIEW Fao o9FRONT AXLE & SUSPENSION FRONT SHOCK ABSORBER COMPONENTS: 1: Tightening true (es 34) Q seeing duster Frortsexng upper eat gna Calera frre suspension suppor ® Sping ounce: Beare (B Stove shower oa REMOVAL 1. dack up the vehicle at the front side. Support the body wi safely stands. 2, Remove the front whee! 2, Flexbie hose removal (1) Remove the lp atthe shock absorber side. {2) Disconnect the flexible hose at the shock absorber bracket4. Shock absorber removal (1) Remove the atacring bots and nuts of the steering knuckle. Separate the shack absorber from the sleet- ing krack NOTE: Belore removing the left shock absorber, remove the cise ‘brake caliper attaching bok (upper side). (2) Remove the two attaching nuts of the suspension support located a the fender upper section. Remove the shock absorber from the body. NOTE: ‘Be sure to protect the drive shaft boot with cloth or the tke 0 that it may not be damaged, DISASSEMBLY 1. Compress the col spring, using the following SST. ‘SST: 09727-87701-000 2. Cal soring disassembly (7) Camp the front euspension suppor in a vice (2) Remove the bearing dust cover and loosen the nut NOTE: Never remove the nut hy anniving impacts oni, using an impact wrench or the IkeFRONT AXLE & SUSPENSION @) Remove the folowing parts; the front suspension support, bearing, front spring upper seat, col sorin Font sunens jpport, beating, front spring upper . Sowa S— Beare ‘and spring bumper. INSPECTION 1. Inspect the following parts 2 sure cn Bewing or wear o—: Deterioration - 5-122. Shock absorber operation inspection (1) Push oF pul the piston roc ofthe shock absorber at a constant speed. Ensure that the force requied 10 ave the fod is uniform over the entire stroke. However, when the piston rod ie pulles strongly, the puling force may become slightly greater over the Stoke 30 mm (1.2 inches) toward the end of the puling stoke. It should be noted that this pho fomenon isnot abaotmal (@) Move the piston rod auicky in a up-and-down direc- tion witha stoke of 5 ~ 10 men (0.2 - 0.4 inch). Ensure that the force required to move the roa wil net change. (9) I'any abnormal fling or noise is encountered curing the ingpection above, replace the shock absorber NOTE: «© Perform this inspection ater the piston rod has been moved in @ up-and-down direction three or four times. ‘© When the gas filing type shock absorber is replaced, previous to the disposal, be sure to release the gas from {the shock absorber. ASSEMBLY 1. Assembly of coll spxing (G) Insert the spring bumper at a point below the cut-out section ofthe piston rod (2) Compress the call soring, using the folowing SST. Install i to tha shock absorber SST: 09727-87701-000 (@) lasal he front spring upper seat and besting (4) instal the front suspension suppor. NOTE Be sure to align the cutout section of the front suspension ‘Support with that ofthe piston rod during the assembly. FRONT AXLE & SUSPENSION caleaang Ft para /'soer stFRONT AXLE & SUSPENSION (6) Clamp the front suspension support in vice. Tighten the suspension suppor, using @ new nut Tightening Torque: 3.5 -5.5 kgm (25 ~ 40 tb) (©) Install the bearing dust cover. (3) Align the col spring and wit the recessed sections of the upper and lower seats. Proceed 10 remove the ss INSTALLATION 1. Installation of shock absorber unper section (G) instal tre suspension suppor on the fender apron. (Use a new nut) Tightening Torque: 2.0 - 9.0 kg-m (14.8 - 22 eb) 2, Instalation of steering knuckle section (2) Mount the steering kruckle on the shack absorber lower bracket {@) Install the bol anc nut in postion and tighten them. Tightening Torque: 9.0 13.0 kg-m (65 ~ 94 feo) NOTE: ‘With the knuckle pushed against the lower side, tighten the bolt and nut NOTE: In the case of the removalinstallation of the left shock absorber, install the attaching bolt (upper side) ofthe disc brake caliper after the steering knuckle section has been instal. Tightening Torque: 3.2 -42 kgem (23 - 90 feb) 3. Intal the flexible hose, as follows: (G) instal the flenible nose to the shock absorber bracket. (2) Instal te fexile hose clip. 4 Ital the wheels. Jack down the vehicle. 5, Front wheel alignment inspection (See page 5-38.)FRONT AXLE & SUSPENSION FRONT STABILIZER BAR COMPONENTS. “T: Tigheningtorque ‘nat kgm ‘F Noneeusatle pats “Dea = G4 mS ra Tae) fara] #8 @ Feontsaaer bse BSecoe eutner |B Suspension lonerarn SA Srurber cue Petra sion sear REMOVAL 41. dack up the vehicle at the front side. Support the body ‘with seety stands. 2, Remove the engine under-cover. (Vehicles mounted with Type CLT? and CL! engines only) 8. Remove the stabilize bar, as (olows: (G) Remove the stabitzer bar end nuts and retainer. (2) Remove the attaching bots of the stabilizer bar bracketsFRONT AXLE & SUSPENSION (@) Remove the stabilizer bar ror the vehicle NOTE: If any difcuty in removing the stabilzer bar is encoun. tered, remove the stablizer bar by using @ jack onthe tre. (4) Remove the bush trom the stabizer bar INSPECTION Ingpeet the folowing parts Defamation, crackers \ ¥ Cy-pwrection f if 4a Detometen or damage greeter arage 6 Samay 8 omen a Tear INSTALLATION 1. Stabilize: bar installation (7) lastal the custions to the stabizer bar. (2) Insal the stabilizer bar tothe ower arm, NOTE: IW the stabilzer bar end fs not abgned withthe lower arm attaching hole, use a lack on the Ure so as to align the holes with each other. —(@) Install he cushion and stabilzer bar bracke's Tightening Torque: 4.0 - 6.0 kg-m (28 - 48 fb) (4) Install the custions and retainers, white paying atten- tion to he direction of the retainer. Tighten them temporarily, using a new nuts (6) Rock the front section of the vehicle in an up-and down cirecton two o” thee times 50 as 10 salle the suspension. (6) With the vehicle in an unloaded state (tne lower am is horizonta), tighten the nuts Tightening Torque: 75-11 kgim (64 80 feb) NOTE! IW the nut is tightened at the rebound side, the cushion twisting ange wil come large, resulting in reduced riding ‘comfort. 2. Install the engine under-cover. (Vehicies mounted with Type CL-11 and CL-61 engines only) 3, Front wheel alignment inspection (See page 5-38.) LOWER ARM COMPONENTS Nehring rave on kee ON rar 3 Nemec parts liver Srrbanter sa Fron aaa! Siutoer enon Suspension: am 8 etter sues Bisrer amen rae adFRONT AXLE & SUSPENSION REMOVAL 1 2 3 ‘Jack up the vehicle at the front side. Support the body vith safety sends Remove the front whee. Lower arm removal (1) Remove tne stabizer ber end nut (2) Flemove the atlachng bot and nut of the bal jit. (@) Remove the attaching nut of the lower arm atthe body se (4) Remove the attaching bolts of lower suspension brace. (TUARO and GTi grades only) (5) Remove the lower arm bracket (6) Remove the lower arm.FRONT AXLE & SUSPENSION INSPECTION Inspect the folowing parts. san‘ cxeeten EY Damage races ese aoe 1. Lower ball joint dust cover replacement (1) Remove the dust cover, using @ common screwesiver. NOTE: Be very careful not to damage the socket section, ce (2) When assembling the lower bal jint dust cover, apply Soca secon ‘rease to tne folowing sections oo =e {@) Press the dust cover into positon, using a. press In eRe ‘combination with the following SST. SST: 09618-87301-000 NOTE: Make sure that no grease or ol gots to the socket section (incited by 2 "*" mark) curing the press operation here aFRONT AXLE & SUSPENSION 2. Lower erm bush replacement Renae (7) Remove the bush, using the folowing SST. SST: 09901-8701 (09636-20010 90187707. 000 (2) Press the bush inte position, using a press in conjunc: tion with the folowing SST. SST: 09901-8701 (09636-20010 INSTALLATION 1. Lower arm instalation (1) Temporary tighten the lower atm ll oint section anc stablizer bar end nut section. (2) Tighten the bott end nut ofthe ball joint section. Tightening Torque: 8.0 - 10.5 kg-m (58 - 76 tb) (@) Insta the lower arm bracket Tightening Torque: 75 ~ 10.5 kg-m (54-76 tb) (4) Tighten the lower arm attaching nut temporaty. (6) Instalation of lower suspension brace. (TURBO and GTi grades only) Tightening Torque: 4.0 ~ 5.5 kg-m (29 - 40 fb)(6) instal he font whee! (7) dack down the vehicts, Rock the front section of the ‘ehile in an Up-and-down direction two or three tines 50 a8 to Sate the suspension. (8) With the venicle in_an unloaded state (lower arm is horizontal tighten the rut (Stabilizer bar) “Tightening Torque: 75 = 11.0 kgm (54 - 80 fe) (Lower arm “Tightening Torque: 7.0 - 10.0 kgm (51 = 72 fb) 2, Front wheel alignment inspection (See page 5-38.)FRONT AXLE & SUSPENSION DRIVE SHAFT DRIVE SHAFT-RELATED PARTS 1 Noneusable parts eno ee gic ssnes ce EE coe meneos Bien gbeimeren se Site giana {B Fort cnvebeming shy (oss neue wt Type C880 erne an) be ras a a2OPERATION PRIOR TO REMOVAL 1. Jack up the vehicle 2. Drain tne transmission fa. 3. Remove the front whee's. REMOVAL 41, Pul out the cotter pin, Remove the front wheel adjusting lock cap, 2. Remave the nut, using the folowing SST. ‘SST: 09511-87202-000, 3, Disconnect the tie 10d, using the folowing SST. ‘SST: 09611-87701-000, 4. Remove the stablizer barFRONT AXLE & SUSPENSION 5, Remove the lower arm, (Bracket side only) 6, Remove the bolts. Separate the extension rod subassem bly and shift & select shaft subassembly from the trans 7. Pul out the front dive shat, using the following SST. SST: 09648-87201-000 NOTE: 1.AS forthe inboard sido of the crive shaft, no stopper is. provided atthe inside. Therefore, be sure to support the Inboard joint section by your hand during the removal 2.As for the right sige of vehicles mounted with Type (CB-80 engine, insert a crowbar into between the pro- trusing section ofthe bearing shaft andthe drive shaft ‘Then, take out the font drive shalt, being very careful ‘nt 1 deform the dust cova ofthe drive ena. 9, Remove the two bolts. Remove the front drive shaft bearing shat assembly, (Vehicles mounted with Type CB- £80 engine ony) ==FRONT AXLE & SUSPENSION EE 'NSPECTION inepect the folowing sections ands for brakage ce de'eraton a ( sxatcomactng secon i st ever stration Boots pte FeetFRONT AXLE & SUSPENSION disaillimcbchetataine COMPONENTS we pacar ne ‘MRosestcn he pa ote shat cat Nor Wibaed send eran ene ‘et sat sud be reced ont a compte ‘+: Non reusabo farts Stare ibook Grefacenecon sn 8 recs repos Ay B Free ort boo! Fase eam 5-28FRONT AXLE & SUSPENSION DISASSEMBLY 1. Pry up the Boot band clip with a common screwdriver. Detach the boat NOTE: Be very careful not to damage the boot. 2, Put a mating matk on the inboard joint and shaft, as shown in the figure, Remave the lront axe inboars joint subassembly, NOTE: Put mating marks by painting. (Never use a punch to put mating marks.) 2. Detach the shatt snap ring, using @ snap ring expander. 4. Remove the inboard jin tipod assembly, as follows: (1) Put_a mating mark at the tip end of the tipod and ‘Shaft, using @ punch. (2) Pullout the tripad from the shat, using a brass bar. NOTE: ‘Be sure to apoly the brass bar to the tripod boss section, ‘not othe roller section, 5. Remove the front axle jint Boot ac ae rar =eFRONT AXLE & SUSPENSION INSPECTION Inspect te following sections, “9 'FO0 KO) ——o— Densgdorwear Damage or wea ‘amg or wear Fao ASSEMBLY 1. Assemble the front axe joint boot in pasion. | 2. Assemble the mboard joint tipo assembly, as flows: 1) Face the non-epined side of the tipod toward the ‘outboard joint (@) Align the mating marks which were put curing the sleaseombly (@) Drive the triped assembly nto the shat light, using a brass bar NOTE: Be sure to apply the brass bar tothe boss section of the {rpod, not tothe roller section. 3, Attach the shaft snap ing in positon, using a snap ring expanderFRONT AXLE & SUSPENSION 4, Assemble the front axle inboard join, as folows: (3) Pack the inboars joint with joint grease NOTE: Use the grease which has been provided inthe boot Kt of the replacement parts. (2) Install the inboard joint, aligning the mating marks ‘which were aut uring the Gisessembly 5. Prior to assembling the boot ofthe front axle outboarc Joint. pack the outboard joint with joint grease NOTE: 1, Use the grease which has been provided in the Boot kit ‘ofthe replacement parts. 2, On vehices other than those mounted with Type CB-€0 engine, it shouldbe noted thatthe grease to be used for the Inboard joint cifers from that to be used for the outboard joint {Grease for inboard joint. Yellow {Grease for outboard joint. Black 6. Assemble a new boot band. as shown in the figure INSTALLATION Grease applying points 11 Apply chassis ease to the whole serrated secton ofthe front axle hub instalation section.FRONT AXLE & SUSPENSION 2. Install the tront drive bearing shaft in position (Wericies mounted with Type CB-80 engine only) “Tightening Torque: 30-45 kgm (22 - 3 fb) {3 Install the front drive bearing shalt in poston, NOTE: Be very careful not to damage the olf seal during the Instaliaton 4, instal the sit & select shaft subassembly and extension ‘08 subassembly in poston. ‘Tightening Torque: 1.0 = 1.6 kg-m (7.2- 11.6 feo) 5. instal the bracket side of the lower arm assembly in postion “Tightening Torque: 7.0 - 10.0 kgm (St - 72 tb) 6, Install the stabilizer bar to tne lower arm assembly, “Tightening Torque: 7.5 - 11.0 kg-m (54 - 80 fb) 7. Insal the stablizes lover bracket tothe Body. Tightening Torque 4.0 = 60 km (29 - 43 fb) rasaFRONT AXLE & SUSPENSION 8. install he tietod assembly tothe steering knuckle Tightening Torque: 3.0 - 4.8 kgm (22 - 39 fib) 9. Insal the drive shaft othe front axe nub, Secure the axle ub, using the folowing SST. ‘SST: 09511-87202-000 10. Tighten the nut Tighisning Torque 8.0 = 23.0 Kgrm (130 - 166 fe) Nore: {When this nut fs tightened to the speciied torque, the specied preload of the front whee s attained. 2.Assemble the spring washer in such a way that its recassed side comes tothe hub side. 41 Install the front whee! aajusting lock cap tothe nut 12. Install the cotter pin, as shown in the right figure Frees! asin locks reste aaFRONT AXLE & SUSPENSION FRONT DRIVE BEARING SHAFT (Vehicles Mounted with Type CB-80 Engine Only) ‘COMPONENTS: + Nonusable ports B foe ara aro ‘Uses fin yore Sh (@ Radia bai boeing Fase aoe INSPECTION Inspect the folowing parts Damage or wos Delemetnerdemsge —Darage . ( et mramarecn 8] EE | _ Fe sar ae 5-32FRONT AXLE & SUSPENSION DISASSEMBLY 41. Remove the oll sea, using @ common screweriver 2. Detach the shaft snap ring, using a snap ring expander Remove the drive shatt bearing bracket, using the folow- ing SST SST: 09934-87201-000 SST: 09608-8750"-000 4, Remove the another cl seal, using a cornmon screwetiver 5. Detach the hole snap ring. using a snap ring expander. 6, Flemove the radial ball bearing, using the folowing SSTs. ‘SST; 09547-97301-000 SST: 09608-87501-000 7. Remove the dust defector, using a brass bar and a hammer. Be catetll not to damage the dust detector ‘uring the removal cose 7601-00 oxse7a7301-000FRONT AXLE & SUSPENSION 8. Puta mating mark on the yoke and universal yoke. 8. Detach tne hole snap ring. using @ snap ring expander, 10, Remove the universal joint spider subassembly, following the procedure given below, (1) Push off the spider bearing cap, using a vice in ‘comoination with @ 19 mm socket and the folowing Sst SST: 09628-10020-000 (2) Clamp the pushed-out cap in a vice. Remove the ‘bearng cap trom the yoke No2 by tapping we yore No2 lightly {@) Tao the spider trom the side of the cap removed, thus pushing out the another cap (4) Clamp the cap in a vies. Remove the cap by tapoing the yoke No? igh, Separate the yoke No. from tne Universal joint yoke subassembly. (6) Remove the remaining caps, following the same pro: couure, +1. Disconneet the universal oiet No.2 yoke from the universal Joint yoke subassembly. | fe ceFRONT AXLE & SUSPENSION 'NSPECTION inspect the following sections Damage o deesion Damtge, wesc attortion ontonnceih Damage or deematon Damage Wea orasnape Sarge or cetemeton a mae eee ie oo ea Grease applying points Siscaap ssc, ‘Apply MP grease to the points shown in the right figure. ol ot pier (Greve pee 1. Assemble the universal joint yoke spider subassembly, following the procedure given Delow. (4) Assemble the pide to the unversal join yoke sub- ‘assembly. Push them in vce ftom both sides unt the Deering ean haramas fush withthe end surface of the yoke subassembly (@) Using 2 19 mm socket, push the spider cap ina vice nil the snap ring ean 0¢ inserted in postion. (@) Install the universal joint yoke No.2 to the spider Assemble i in the sequence (1) and (2) described aboveFRONT AXLE & SUSPENSION 2, Assemble the hale snag rng, using @ snap ring expancer, in accordance with the prosedure given below. (1) Selecta proper enag ring so that the play ofthe spider inthe axial diection will not exceed 0.05 mm (0.002 Inch) ang the thickness ofthe snap ring becomes the same at both sides. Reference: Snap Ring Availability Pant number I Thickness '90045-21046-000 7148 enm (0.087 inch) e0045-21047-000 | 150m (0058 Tren) ‘0085 27048-000 7155 mm (0061 neh) (2) Assemble the selected snap ring, (3) Check the spider bearing for excessive looseness. 3, Install the dust deflector, using the following SST. ‘SST: 09547-87501-000 4, Assemble the radial ball bearing, using the following S5Ts. SST: 09647-87301-000 SST: 09606-87501-000 = seca s7s01000 oaser 7901-00FRONT AXLE & SUSPENSION ‘5 Altach the hole enap ring, using a snap ring expander. 6, {ntal the ol sel, using the following SST. ‘SST: 09606-87501-000 860687501000 7. Install the drive shaft bearing bracket, using the folowing SSTs, ‘SST: 09506-90011-000 ‘SST: 08606-87501-000 {8 Altach the shaft snap ring, using a snap ring expander. ‘9, Assemble the ol se, using the folowing SST. ‘SST: 09608-87501-000, , chee 8750-000 5-37FRONT AXLE & SUSPENSION WHEEL ALIGNMENT (FRONT AND REAR) TOOLS AND INSTRUMENTS. ‘Shape I Nmenclaure T Use T Gok pune converses | Aizen or canbe: caster Sex ‘na kongen gauge Sppied by Banzal, Lia ‘Brake pusher hexagon wrench Key (with acres ats & mm) inavueria | Turing racus gauge, te pressure gauge, camber, case, Kingpin gauge and cial gauge CHECKS PRIOR TO WHEEL ALIGNMENT MEASUREMENT 1. Checking Tres for Wear 2. Checking Ties for Alr Pressure Pian pssure Spe a [soos 1927) seon1a 7, TSS 20.20 | sicoRra 7a5 eS5R19 2009) fss0Rs3 Tas 657055 20) ae aaS soon 76 feseonsa ax Pia) 3, Checking Ties for Runout (Up-ang-down and right-andtiet crections) ‘Maximum Limit: 3.0 mm (0.12 inch) ut mn 4. Cheoking Botts of Related Sections for Tightened Condi- tion ear =a 5, Checking Helates Sections for Excessive Play G)dack up the vehicle. Altemstely push and pull the Upper and lower parts of each tre. Ensure that the tre extibis no excessive vay: @) the tre exniots an excessive play, perform the following check while the brake pedal is being de- pressed «The excessive play aisappears: ‘This indicates that te front whee! bearing is loose. 19 The excessive play stl persists: “Ins indicates that the knuckle section, axle carter section or suspension Is loose.(3) ifthe whee! bearing is udged as being loose, proceed to check the play in the axial diction, using the folowing SST. SST: 09510-87501-000 (Front and rear whee! bearings) Specified Value: Not to exceed 0.2 mm (0.008 inch) Maximum Lents 0,05 ren (0.002 inch) CHECKS AND ADJUSTMENT OF FRONT WHEEL ALIGNMENT 4, Tuming Radius Gauge Set (1) Set tne turning radius gauge tothe zor point. Proceed to lock the gauge. (2) Place the vehicle on the gauge in such a way that the center of the tieo-loor contact surface may be Signed withthe center ef the fuming radius gauge NOTE: '* Perform the check on a level foo. ‘When a portable ype turning radius gauge fs employed, fa plate having the Same thickness as thal of the gauge ‘Should be placed under the rear wheel so that the Vehicle leveiness may be maintained. ‘¢ Make sure that the wheels are in their staightabead ‘conctions, ‘= Keep the vehicle in an unloaded stale. In order to prevent the venice from moving during the check, be Sure to apply the foot brake, using a brake pedal pusher or the tke ‘© Remove the stop lamp fuse so 3s to prevent the stop lamp from glowing. esto 707.000 ee aoeFRONT AXLE & SUSPENSION 2. Checking Wheel Turing Angle @) Measure the wheel turing angle, using a tuming radius gauge. Spectied Value: Taner ae weeae Outer side Dare oe (2) tthe wheel turning angie diflers between the right anc let sides, correct the turning angle. 3, Correction Wheel Turing Angle (@) Stecken the lock ruts ofthe te rod ends, (@) Make the length indicated in the right gure equal bbatween the night and left sides, NOTE: (© Make sure that the boot is not twisted during the ‘correction. ‘¢ Make sure thatthe te rods atthe right and let sides are ‘ured by the same amount. 14. Checking Camber, Caster and Kingpin Angies (G) Inthe case of steel wheels, perform the measurement, using the folowing SST (atachment) SST: 09722-87702-000 (2) inthe case of aluminum wheels, perform the measure- ‘ment, using the CCK (Camber, Caster, Kingpin) gauge ‘compensator (avaiable In the market). NOTE: ‘The CCK gauge compenostor can be used for the measurement on stoel wneols, too. {@) Installation procedure for the CCK gauge compensa: tor, and the camber. caster and kingpin gauge reo cod cao ma | oA cores it ! ree a‘© Jack up the vehicie. 1 Before instaling the CCK gauge to the wheel, set the CCK gauge compensator to the mechanical zara line by turing the compensating dal of the ‘compensator. © while turing the clamp dial of the CCK gauge ‘compensator, nook the four pawls to the whoel ledges securely. While pusting the compensator, Took the compensator postively by tuning the clamp dial NOTE: In order to prevent the wheel edges trom being scratched, affix tapes oF the Ike on the wheel edge sections to which the four pavis ofthe compensator are hooked. Set the camber caster and kingpin gauge to the installation plate of the CCK gauge compensator. AM this poin, align the set lines on the gauge and ‘compensate with each other. f© Turn the wheel so that the level air bubble in the ‘gauge may come tothe central poston. [At this postion, tum the caster adjusting screw of the gauge 0 that the caster air bubble may be [lgned withthe graduation zor postion, ‘* Turn the whee! 180 degrees so that the gauge may be turned over. Proceed to align the set ines on the (gauge and compensator with each other. Next, tum the wheel so that the level air bubble in the gauge may come fo the certral positon. eee ame ras eaeFRONT AXLE & SUSPENSION "= Record the caster reading of the gauge. Tum the ‘compensating dil ofthe compensator so that t may be aligned with the 1/2 cf the recorded caster reading NOTE: ‘Be sure not to tamper the caster adjusting sorew of the gauge. ‘ Repeat the steps described in Fig 686 and Fig. 587 Ensure that the air bubble of the caster gaut registers the same reading when the whee! i tuned {60 degrees in a normal drecton and ina reversed direction ‘Jack down the wheel on the turning radius gauge. Fock the vehicle in an up-and-down diection 80 as to sett the suspension (2) Camber check fe Ensure that the wheels ar in thelr streight-ahead conditions « Aign the lave ar bubble with the central position. «Take tne camber reading ofthe gauge. Speciied Value: 2041" or}o' rhe" -29 \ Zl 2 Tt roeFRONT AXLE & SUSPENSION (6) Checking caste (ight wnee) '8 Tum the steering whee! to the right side, unl the right front tte comes at @ point where the turning racius gauge registers 20 degrees. '* Tum each of the caster and kingpin adjusting screws so thatthe respective air bubble may be aligned withthe 2610 pot. «Tum the steering whee! tothe left sie, unl the right font tre comes ata point where the turing rads gauge registers 20 degrees. «Take the gauge readings of the caster and kingpin angles. ‘Specified Value: Caster Best" Kingpin angle nnn 12890" (Left wnee) ' Perform the check, folowing the same procedure as withthe right wheel. However, the turning rection ofthe stering wheel must be reversed nd kingpin angles Fao aa Agra bt with 5. Toedn Measurement (2) Rook the vehicle 0 that the vehicle eight may stable, (@) Move the vehicle forward about five meters so thatthe front wheels may become in their straight-ahead ‘conditions NOTE: Do not move the vehicle backward during the measure- = ment (@) Align the height ofthe toein gauge pointers with the ‘conte height ofthe front wneets. (8) Puta mark on the tread center of each front wnee! tre atthe rear side, Measure the distance between the two ‘marks (Dimension A) inthe figure. 5-43FRONT AXLE & SUSPENSION (6) Sowly move the vehicle foward by pushing the vehicle, unt the wheels turn 180 degrees. (6) Measure the distance (Dimension 8) between the two ‘marks which were put in the preceding step. This measurement le performed at the front side of the vehicle Calculate the amount of toein, Le. (Dimension A = Dimension 8). Specified Value: —1 - +3 mm (-004 - +0.12 inch) 6, Toe-n Adjustment (1) Slacken the lock nus ofthe te rod ends, (2) Pertorn the toe-n adustment by turning the tle ros ends. NOTE: 1 Care must be exercised to ensure thatthe boot is not twisted during the adjustment. ‘© When adjusting the toesn, the te rods atthe Fight and left sides should be turned by the same arnaunt. ‘¢ The length Inicatod inthe right figure must be the same amount {ifthe length dtfers between the right and let sides, a ditference occurs inthe wheel turing angle between the tight and let sides.) 7. Sisal Check Geax te siestp, using a sides tester. Spectied Velie: ~@-—3-em (0.12 -+0.12 inch) Perimeter (9261) wens CHECK AND ADJUSTMENT OF REAR TOE-IN 4. Toe-in Check (1) Rock the vehicle so that the vehicle height may salize. (2) Move the vehicle forward about five meters so that the front’ wheels may become in their straight-ahead ‘conations. (@) Align the neight ofthe toein gauge pointers with the center height ofthe rear wheels (4) Put a mark onthe tread center of each rear wheel tre al the rear side, Measure the distance between the two marks (Dimension A) inthe figure. aFRONT AXLE & SUSPENSION (6) Sowly move the vehicle forward by pushing the ‘ericle, until the wheels tum 180 degrees (6) Measure the distance (Dimersion B) between the two marks which were put in the preceding step. This measurement is performed al tne front side of the ear wheels (7) Caleuiate the amount of toon, 1e. (Dimension A ~ Dimension 8) Specified Value: +4- +8 mm (+0.16- +03) 2. Toon Adjustment (1) Siacken the sat bot ofthe toe adjusting cam. (2) Insert a hexagon wrench key into the nexagonal hole provided al the back side of the tow adjusting car, “Turn the hexagon wrench key. (Inside: IN, Outside: OUT) (Reference) ‘When each ofthe adjusting cams provided at both sides is tumed by one graduation, the toein will change approx- imately 5 men (0-20 inch, 3. Sidesip Chock Check ine sidestp, using a sidesio tester. ‘Speciied Value: 1 - 7 mm (0.04 - 0.28 inch) Per t meter (8.28 t)DAIHATSU CHARADE Chassis SECTION 6 REAR AXLE & SUSPENSION REAR AXLE .. 2 SUSPENSION ARM . 6-18 ‘SECTIONAL 2 COMPONENTS 618 COMPONENTS 3 REMOVAL 618 REMOVAL 4 INSPECTION INSPECTION 7 _INSTALLATION INSTALLATION re a REAR SUSPENSION SECTIONAL VIEW REAR SHOCK ABSOI 8-11 __INSTALLATION a ‘COMPONENTS 6-11 STABILZERBAR BESSSRRRNSS REMOVAL 6-12 COMPONENTS - DISASSENE! 6-13 REMOVAL . INSPECTION 6-14 INSPECTION’. = ASSEMBLY INSTALLATION - INSTALLATIONREAR AXLE & SUSPENSION ‘COMPONENTS: “eo. (@ Rac ba bea et BR ate bear outer retsner esr rake Ay iat, ear nee carer , Ren oveSecanginnr ane Scenone na SS on oon {8 Grease ean cap Ban | Feet oeREAR AXLE & SUSPENSION REMOVAL 1. Jack up the vehicle atthe rear side. Support the body with Safety stands 2, Remove the rear whee! 12. Backing plate removal (Drum brake equipoed vehicle) (1) Remove the grease retainer cap. (2) Remove the cotter pin, castle nut and plate washer. (2) Remove the brake drum, using the following SST. Remove the bearing inner retainer ‘SST: 09510-87301-000 (2) Disconnect the brake tube fom the wheel cylinder, Using the folowing SST. SST: 09751-36011-000 (6) Remove the backing plate with the brake shoe in stalled reer(Disc brake equipped vehicle) o the parking cable guide, (@) Ramove the antattle spring {@) Remove the caliper. NOTE: ‘Suspend the caliper as shown in the right flgure. (4) Remove the caliper suppor. (5)Remove the grease retainer cap. (G)Remove the cotter pin, castie nut and plate washer. (7) Remove the dise rotor and bearing inner retainer. cera rer raeREAR AXLE & SUSPENSION (6) Remove the backing plate. ‘Axle carter removal (1) Remove tne atacting bolt and nut ofthe axe carr from the stu ro. ree aa (@) Remove the ataching bo! and nut of the axle carter fom the suspension arm No.1 () Remove the attaching bolt and nut ofthe axle cari: from the suspension arm No2. (4) Remove the attaching bolts and nuts ofthe axle cater from the shock absorber. Remove the axle carter tor a 6REAR AXLE & SUSPENSION 5. Hub beating removal rake rom (1) Drive out te inner bearing, using a brass bar. At he same time, ctive out te bearing outer retainer, to. (2) Drive out the outer Dearing, using @ brass bar reer ue S lene oe INSPECTION Ingpect the folowing parts “Teves pasion Brake rm x woo damage Spin for damage po Epochediner arelen "abn 7 9irches) Ccracis.or damage seeing teweera: Mocrumbint. 1BtSrm(r ‘Beran \ - oe Beating fr woe and damage ab /f- anes ter damage ee aoe fox boar \ ‘tear carage ‘bamee ff ‘Hub and bot for fiting fj Hert ae Dac aus canege na os ied tocar Som 039 re) Meus 5 ren ree e7REAR AXLE & SUSPENSION INSTALLATION 1 Hub bearing installation Pack the hub and bearing with grease. Then, oress the ‘outer Bearing, outer retainer and inner bearing, in tis ‘order, using @ press in conjunction wih the following SST. ‘SST: 09608-12010-000 (Fer he cer bearing, use No. 19 ofthe SST set) (Forte inner boarig, use No. 5 ofthe SST set) Ade cartier instalation NOTE: {As for those suspension-elated bolts and nuts on which a friction stabilzing agent has boon coated, be certain not to rouse them If ey Rave been once removed (1) Mount the axe cari to te shock absorber. (2) instal the attaching ols and new nuts of the axle Carrer, Proceed to bohten them. ‘Tightening Torque: 9.0 - 12.0 kg-m (65 - 87 fb) NoTE: “Tighten the bots and nuts while pushing the axe cater to the lower side (postive side). (@) Mount the axle carrier on the suspension arm Not Tighten the new bolt and nut temporal. (4) Mount the axie carter on the suspension arm No2. Temporal tighten the new bot and ut Fes sang SoestREAR AXLE & SUSPENSION 5. Hub bearing removal ‘Brake arom, (1) Drive out the inner bearing, using a brass ber. At the ‘same time, ative out the beating outer retainer, to. (2) Drive out the outer bearing, using a brass bar £e INSPECTION Inepect the folowing pars letor damage Teaded parton ‘rae rr or wea damege Soratefordamage praarge ‘Sacto nner deerter 1mm 7.09!rches) Seusingtorwear or‘ Masimum Lint 1645 (18 nos) Hoan bot esting Eraton rene pron or aarage ic sutaos or caage nd non Sieceea micinaer 0 un (0.39 ch) Momo it arm (035i) e7REAR AXLE & SUSPENSION INSTALLATION 1 Hib bearing installation Pack the hub and Dearing with grease. Then, press the ‘outer bearing, outer retainer and inner bearing. in this ftder, using a press in conjunction withthe folowing SST. ‘SST: 09608-120t0-000 (ox the outor bearing, use No. 19 ofthe SST set) (For the lane: bearing, use No. 5 ofthe SST sot) ‘Axle cartier intallation NOTE: {A for those suspension-elated bolts and nuts on which @ friction stebzing agent has been coated, be certain not to reuse them i they have been once removed (G) Mount the axio carie tothe shock absorber (@) Insta the attaching ots and new nuts of the axle ‘cartier. Proceed to tighten them, Tightening Torque: 9.0 - 120 kg-m (65 - 87 fb) NOTE: Tighten the bots and nuts while pushing the axle carrer to the lower side (postive side). (@) Mount the axle carrier on the suspension arm No.1 Tighten the new bot and nut tempor (4) Mount the axle carrer on the suspension arm No2 “Temporary tighten the new bolt an nut roto ebiing(6) Mount the axle carie onthe stu od, Tighten the new bolt and nut temporary Installation of brake crum or dsc rotor (Drum brake equipped vehicle) (7) Install the backng plate Tightening Torque: 4.0 - 5.5 kg-m (29 - 40 ft) Be sure to apply DAIHATSU Bond No.4 (899-6304-6323- (00) tothe mating surface between the rear brake and the ‘axe carer. Dunng tis sealer application, be very caretl ot to restrict the 5 mm (0.20 inch) dia. grease releasing hole. (2) Install tne brake tube tothe backing plate Tightening Torque: 1.8 - 1.8 kg-m (8.4 - 18.0 fb) the Dearing inner retainer, brake ckum, plate (4) Tighten the caste nut Tightening Torque: 6.0 - 10.0 kg-m (@3 - 72 fb) (6) Install anew cotter pin. install the grease retainer cap, (6) Pertoum air bleeding for tne brake system. (See page 8-5) (Disc brake equipped vericle) (7) tal the backing plate Tightening Torque: 4.0 ~ 55 kg-m (29 - 40 4b) (2) instal the bearing inner retainer, disc rotor, plate washer and caste ut (5) Tighten the caste nut “Tightening Torque: 6.0 - 10.0 kg-m (43 -72 fb) (4) Install a new cote pin Install the grease retainer cap.REAR AXLE & SUSPENSION (6) tnstat the caliger suppor. Tightening Torque: 4.0 - 5.5 kgm (29 - 40 feb) (6) instal the caliper. (7) Install the anticate spring {@) instal the parking cable guide. 4. Tightening of axle carr attaching bots (2) lastal te tres. (@) With tne vehicle in an unloaded state, jack down the vehicle. Rock the veticle in an up-and-down diction Several times fo setle the suspensions. (@) With the vehicle weight being applied to the suspen- sions, tighten the bolt and nut of each section Tightening Torque: 7.5 ~ 10.5 kg-m (54 ~ 76 fob) 5. Rear whee! alignment inspection (See Fig. 5-38) e109REAR AXLE & SUSPENSION REAR SUSPENSION ‘SECTIONAL VIEW REAR SHOCK ABSORBER ‘COMPONENTS: 1: Ttenng tongue ot: fem 8 Nemroueable parts 8 Fear urpenaon neo, |B fer noth sbeober coin wT aa etREAR AXLE & SUSPENSION REMOVAL 4. dack up the vehicle at the rear section. Support the body ‘with safety stan. 2. Remove the wheel 3, Removal of brake tube and flexible hos (1) Disconnect the brake tube trom th ‘SST: 09751-36011-000 jaxible hose (2) Detach the clip. Disconnect the flexible hose from the shock absorber. 4. Remove the nuts attaching the shock absorber tothe axle cartier Leave the bolts in an inserted condition, 5. Tem removal (1) Remove the package tay. (2) Remove the package tray side tim eaREAR AXLE & SUSPENSION 4. Slacken the nut atlaching the sheck absorber to the DISASSEMBLY 1 suspension suppor. NOTE: Do not remove the nut. Remove the nuts atlaching the suspension support tothe body. Remove the attaching bots ofthe axle carrier and shock absorber. Remove the shock absorber from the body, Coil soring removal (4) Comaress the coll spring, using the folowing SST. SST: 09727-87701-000 onfers770.000 (@) Remove the nutREAR AXLE & SUSPENSION (@) Remove the rear shock absorber cushion, reer sus- pension suppor. reer coll spring insulator, spring bumper and eal spring. INSPECTION 1. Inspect the following pars. Fear stocr abso] anion fet scanner <> Be es ost eB Col sere Roar sock Sonos estometor Deteraton rea ea esseREAR AXLE & SUSPENSION 2. Shock absorber operation inspection (G7) Push or pul the piston 10d ofthe shock absorber at a ‘constant speed. Ensure that the force required 10 ‘move the rod is urorm over the entire stroke, However, when the piston rod is pulled strongly, the paling force may become sightly greater over the Stroke 30mm (1.2 inches) toward the end of the pauling stoke. It should be noted that this phe- omenon isnot absorml (2) Move the piston rod quicky in a up-and-down direc- tion with a stroke of § ~ 10 mm (0.2 - 0.4 inch). Ensure that he foree required to move the rod wll not change. (@) Itany abnormal feaing or nose is encountered curing the Ingpection above, replace the shock absorber. NOTE: © Perform this inspection ater the piston rod has been moved in @ up-and-down direction three or four times. ‘© When the gas fling type shock absorber is replaced, previous to the dsposal, Be sure to release the gas from the shock absorber ‘ASSEMBLY 1. Assembly of col spring (7) instal the spring bumper at a point below the cut-out ‘section of the piston rod (@) Compress the call spring, using the following SST. Ital i t0 the shock absorber. ‘SST: 09727-87701-000 (@) install the tear shock absorber cushion to the rear ‘suspension suppor. (4) instal the rear col spring insulator tothe rear suspen- sion support Nore: Be sure to align the cutout section ofthe rear coll spring ‘euiator with the stud Bott section of the rear suspension ‘support during the assembly (6) Insta the rear suspension suppor NOTE: '* Be sure to align the cut-out section ofthe rear suspen- sion suppor with that of the piston rod during the assembly «# Aign the rear suspension support on the shock absorber lower bracket, es shown in Fig. 653. (6) Fit the suspension suppor. Tighten it temporary, Using @ new nut 6-15 oorerer70-00REAR AXLE & SUSPENSION (7) Align the eal spring end with the recessed sections of the upper and lower seats. Proceed to remove the Sst INSTALLATION 1. Inetall the suspension support to the body, using @ new “Tightening Torque: 1.0 1.6 kgm (7.2- 11.6 feb) 2, Mount te axle eartier onthe shock absorber. Ft the bots ‘and new aus in postion and tighten them, weoTanening True 80 20 kom (5-7 tb) 1 The steering carer attaching nuts are special nuts on ‘whieh a fetion stabilizing “agent has been coated. Henoe, be certain not to reuse them. ‘8 Tighten the bolis and nuts while pushing the axe carer to the lower side (postive side). 2, Insta the flexible hose and brake tube, as follows: (1) install the flexioie hose tothe shock absorber. Secure ‘twith te clip. (@) instal the brake tube to te flexible hose. SST: 08751-96011-0004, Tighten the suspension suppor attaching nut Tightening Torque: 3.5~ 5.5 kovm (25 - 40 fab) ‘5. Tem inetalavon (1) install the package tray side trim, (2) instal the package tray. 6. Perform air bleeding for the brake system. (See page 8-5) 7. Install the wheels. Jack down the vehicle 18 Check the rear wheel aignment. (See page 5~8.)REAR AXLE & SUSPENSION ‘SUSPENSION ARM ‘COMPONENTS: rae + @ Neg usprsion ame. Sueperson am Ne? me. J @ Bea ate carers @ Satter ° {@ Tow adust cam sa G Tevacust ste Feet ae REMOVAL 1. dack up the veicte. (G1) Jack up the vehicle and suppor the body with safety ‘sands. (2) Remove the wheel 2. Removal of suspension arm No.2 (G) Remove the attaching bolt and nut ofthe stabilizer ink (2) Remove the attaching bolt and nut of the suspension fam a the axle cartier side oeREAR AXLE & SUSPENSION (@) Remove the attaching bolt ofthe suspension arm and cam at the Body side. Then, remove the suspension NOTE: uta mate mark onthe body bracket and the toe adjusting ‘cam 20 that the mark may be used as guide duting the installation (4) Remove the rear stablizer bar bracket trom the ‘suspension arm. 3, Removal of suspension arm No.t (1) Remove the ataching bolt and nut of the suspension arm atthe axle carrer side (2) Remove the attaching bolt and nut ofthe suspension farm atthe body side. Then, remove the suspension am, 0 wt agen wench ace wee ear bia ba oracie, 7e ly (BAZREAR AXLE & SUSPENSION INSPECTION Inepect the pars as right gure INSTALLATION NOTE: ‘The suspension arm attaching bolts are special bolts on which a friction stabilzing agent has been coated. Hence, be certain not to reuse thom. 1. Installation of suspension arm No.1 (3) Tighten the suspension arm to the body temporary withthe new bof and nut (2) Tighten the suspension arm to the axe cariertempo- ratly wth the new Bot and nut 2, Installation of suspension arm No.2 (7) Insal the rear staviizer bar bracket tothe suspension ‘Tightening Torque: 1.0 - 1.6 kgm (7.2- 11.6 fb) (2) Mount the suspension arm cn the body. {@) Tighten the euspension aim to the body temporatiy withthe new bolt and cam. (4) Prior to secure tightening, align the mate marks on the toe adjuster cam and body with each other. 6-20 Sespension arm No: Deformation cage —— hie(5) Tighten the euspension arm to the axle cari tempo: raniy withthe new bok and ut (6) Tighten the ataching bot and nut of the stabilizer link to the spectied torque, Tightening Torque: 1.9 - 3.1 kg-m (14 = 22 feb) Tightening of suspension arm attaching bot (1) instal the wheel. {2} With the vehicle in an unloaded state, jack down the vehicle. Rock the vehicle in an up-and-down direction 2 few times $0 as to sete the suspension. (@) With the vehicle weight applied to the suspension. tighten the bots and nuts {Suspension arm No.1] (Aue cartier side) Tightening Torque: 7.5 - 10.5 kgm (54 - 78 fb) (Body side) Tightening Torque: 7.5 - 10.5 kgm (54 - 76 fib) [Suspension arm No.2] (Ate carter side) Tightening Torque: 7.5 - 10.5 kg-m (64-76 fb) (Bocy sie) “Tighiening Torque: 7.1 - 88 kgm (51 - 64 Reb) ‘Check the rear whee! alignment (See page 5-28.) 6-21REAR AXLE & SUSPENSION ‘STRUT ROD REMOVAL, 1 Jack up the vehicle, (1) Jack up the vehicle. Suppor the body with safely stands. (2) Remove the whee! 2. Strut rod removal (1) Remove the attaching bot and nut of the strut rod at the axle carrier sie. (@) Remove the attaching bolt and nut ofthe sttut rod at the body side. Then, remove the strut rod INSPECTION Inspect the parts as right figure. INSTALLATION 1. Strut rod instalation (3) Tighten the sit rod to the body temporarily wih the ‘ew got and nut (@) Tighten the strut rod 0 the axle cartier temporary with the new bolt and nut NOTE: ‘The stut rod attaching bolts aro special bots on which @ fftion stabllzing. agent has been coated. Hence, be certain not to reuse them. 2, Tightening of strut rod ataching bott (1) Intal the whee (@) With the vehisle in an unloaded state, jack down the vehicle, Rock the vehicle in an up-and-down direction 2 few times so as to satle the suspension. reer waa Danage Delomation, soe om =e(@) With the vehicle weight applied to the suspension, tighten the bolt and nut Tightening Torque: 7.5 - 10.5 kgm (64-76 fib) 3. Check the ear wheel alignment. (See page 5-38.) STABILIZER BAR ‘Tiamtening torgve a) oar abuser REMOVAL 1, Jack up the vehicle. Suppor the body with salety stands, 2 Stabilizer bar removal (1) Remove the stabiizer bar attaching nuts from the stabilizer lnk e238REAR AXLE & SUSPENSION (@) Remove the stabizer bar ataching bots at the body ide. Remove the stablizer bar (2) Revove te atacing bets and as to size IC Ranote earn ay fe | : / 4) Remove the rer stablizer bar bracket attaching bots. Proveed to remove the stablzer bar bracket. INSPECTION Inspect te fllowing parts Delematin, cansoe Deterioration: 8 -? / eR J \ V \ ———berraon Deloration, samage ournten carage ofemston can ad Deformation camage Foor a e-24REAR AXLE & SUSPENSION INSTALLATION 1. Stabilzer bar installation (1) Insta he rear stabitzer bar bracket to the suspension arm No.2. Tightening Torque: 1.0 - 1.6 kg-m (7. =11.6 feb) (@) Tighten the stabilizer link to the rear stabilizer bar bracket tempocarly withthe Bolts and nus. (3) Fit temporary the bush, bracket and stabilzer bar to the body, (4) Fit the etablizer bar tothe stablizer tink. Tighten the ruts temporarily NOTE: ‘Assemble the bush and bracket, as shown in the right ‘gure. 2. Tightening of bolts and nuts (1) Totten the nuts attaching the stablizer bar to the stabilizer link Tightening Torque: 1.0 1.6 kg-m (7.2- 11.6 feb) \ : (ie Z aeREAR AXLE & SUSPENSION {@) Tighten the stablizer bar attaching bolts at the body sie. Tightening Torque: 1.0 - 1.6 kgm (7:2 11.8 feb) (@) Tighten the attaching bolts and nuts of the stabilizer link “Tightening Torque: 1.9 - 3.1 kgm (14 - 22 fb)DAIHATSU CHARADE Chassis SECTION 7 STEERING STEERING se SCHEMATIC VIEW STEERING WHEEL COMPONENTS . REMOVAL . INSTALLATION ~~ ENGINE KEY CYLINDER REMOVAL. ws INSTALLATION ‘STEERING COLUMN ‘COMPONENTS: REMOVAL . DISASSEMAL INSPECTION ASEEMBLY INSTALLATION STEERING GEAR ASSEMBLY ‘COMPONENTS: REMOVAL wwnnrar ‘STEERING GEAR HOUSING ‘SECTIONAL VIEW COMPONENTS DISASSEMBLY INSPECTION. ASSEMBLY « INSTALLATION vnSTEERING STEERING ‘SCHEMATIC VIEW 7-2‘STEERING WHEEL COMPONENTS: Resin pe Uretane pe © Ser wes! @ hom comactestng (@ Hor btn contact ng ot plete @ Stuteg wheal pad at png (G Stowrrg weal pad SA © S0%ng west @ Sern wheel boss ower eave @ Hom baton core te @ Hom cose seg (© Hom cote sig sepa ( searng wheal over IR (Hom conact ng REMOVAL 1. Disconnect the battery negative (—) termina. 2. Hold the steering wheel pad at its lower end by your fingers. Then, detach the steering wheel pad by puling it towers your side. 3. Remove the steering whee! lock nut4, Remove the steering wheel, using the folowing SST. ‘SST: 09608-20011-000 INSTALLATION 1. Fite steering wheel and tighten the lock nut Tightening Torque: 3.5 = 5.5 kg-m (25 - 40 fb) 2. Install the steering wheel pad 3. Connect the battery negative (~) terminal 1-4ENGINE KEY CYLINDER REMOVAL, 1. Loosen six serews and remove the steering column lower 2. Engine key oylinder removal (7) Fabricate @ rod as shown in the right foure, by bencing an approx. 2 mm (0.08 inch) lamer 103 (2) Set the engine key tothe (ACC] postion (3) While pushing the stop pin by means of the rod, draw cout the cylinder. INSTALLATION 1. Engine key oylinder installation (1) inser @ common screwdriver into the paw groove of the lock eylinder. Set ihe paw! groove to the [ACC] position. (2) Set te engine key tothe [ACC] postion. Insert the key fyinder Eneure that the stop pin is locked to the lock ylinder. 2. Instal the steering column lower cover Siem fo eBirem)) aap roc im (HO FEN G38 a7STEERING STEERING COLUMN COMPONENTS: “Ts Tightening ore ne gem ) Nereus pats © Setngcouna upper wow achat (© Sterg coun vope cove 1 Sturng cour lowe over @ raping {© Sowing ater upper ‘tachment pte (© Serna mae Set Ay (@ Seerag coun Ay (B Sewing stat rst sogpes (@ Pate washer (8 Step ing | Unveran ie €@ Seong col nls (2): 80 & EEC and AustalonSpectstions @ Man ans owe disco mca ad REMOVAL 41, Disconnect the battery negative (—) terminal. 2. Remove the steering wheel. (See page 7-3.) 3, Detach the instrument lower finish panel and steering ‘column lower cover.4, Remove the instrument panel iower reinforcement 5. Remove the connectors for the mull-use lever switch anc engine key switch, 6. Remove the bot of the univereal joint, 7. Steering column assembly removal (1) Remove three bots and two nuts. (2) Remove the steering column assembly from the body. 8. Remeve the steering column upper cover and mulse aver switch rom the steering column assembly. DISASSEMBLY 1. Detach the snap ring and plate washer located at the lower sie of the steering main shat‘STEERING 2 Detach the snap ring located at the upper side of the steenng main shat. 3. Steering main shat subassembly removal (i) Remove the steering man shalt subassembly by tapoing the main shaft ightly win a piastc hammer. NOTE: Never tap the main shaft strongly the main shaft shouls be tapoed strongly th resin pin ofthe steering main shat may be damaged. (ECE & EEC and Australan spectica- tions) (2) Remove the stopper from the steering main shat. (@) Detach the snap ring from the steering main shat(NSPECTION :nspect the following pars Searing tr wearer rising caraton senso darae Sen eae “: EOE REC and Australian speticatons Spe end yt for singin or derage a a ASSEMBLY 1. Assembly of steering main shett (1) Fita new snap tng tothe steering main shat (@) Place the stopper on the bearing 2. Insert the main shaft (with the bearing) into the stesring| column, using & plug wrench‘STEERING 8, Fit the new snao ring to the upper side of the steering main shaft 4. Insal he plate washer and snap ring 5. instal the muitiuse lever switch tothe stering column, INSTALLATION 1. Steering column assembiy instalation G) Insta te steering column upper cover to the steering (2) Tighten the attaching pot of the universal joint Tightening Torque: 25 -3.5 kgm (18 - 25 fb) {@) Insta the steering column with the three bolts and two ute Tightening Torque Bolt 15-22 Nut 25-35 kg-m (18 - 25 feb) 7-10 ‘Sap ingInstall the connector forthe muit-use lever and engine key wich. Install the instrument pane! lower reinforcement. Install tle insttument lower finish panel and steering Coluran lower cover Install the steering whee! (See page 7-4.) Install the battery negative (—) terminaSTEERING STEERING GEAR ASSEMBLY ‘COMPONENTS: @ corer in @casions € Steeng ack navi No bracket 1: Tightening rave @ seetna gee Ay @ Bap (@ Lnvesal ont Fare REMOVAL 1. Jack uo the vehicle atthe front side. Suppor the body ‘ith safety stands. 2, Remove the wheel 3, Steering universal joint removal (1) Remove the bot. (2) Remove the universal joint.‘STEERING 4, Tie rod end removal (1) Remove the cotter pins and caste nuts. {2} Remove the tie rod end fom the knuckle arm, using the folowing SST. SST: 09641-87701-000 5. Steering gear assembly removal (1) Remove the four pisces of steering rack housing bracket set bots, (2) Remove the steering gear assembly from the vehicle,STEERING STEERING GEAR HOUSING SECTIONAL VIEW Seecrarak Sting rackrousng ins smoromh re aa specications Taxi te Fon bo ok 1 3a oe Seeing pon on nano caro ack tooth number T Fy‘COMPONENTS. kgm oo "Reece © Sera eto gent comets ing Orenwaeasn Shackouce One Senge ding vxivara Ne Soren {© Sowing oe entre @ Srapre0 {© Sponge et Sato o { Seera axes rac ee nvrg Srucren po Seer pn Ghowgenne Sheed teen {Bhaccguce ing cap 8 Sewing wextouare SA 718‘STEERING DISASSEMBLY 1 ‘Clamp the mounting section ofthe steering rack housing Ina vice with copper sheets or aluminum sheets inter- posed. Te rod end removal (1) Before the steering Ue rod end is removed, put a mark (onthe rack end section in order that this mark may be used as guide to ensure easier toe-in adjustment uting the reassembly. (2) Slacken the lock nut. Remove the tle rod end trom the rack end Remove the boot band No.2 and rack boot band. Remove the rack boot Stoaring rack end removal (1) Slacken the rack end plug, using the flat sections of the steering rack (width across flats: 19 mm) and the flat sections of the rack end pug (with across flats: 26 mm), (2) Remove the string rack end from the steering rack. (G) Remove the cack end plug from the steering rack end! Remove the lock nut (hexagon nut), using the folowing ssr. SST: 09617-22080-000 Rack guide spting cap removal (@) Remove the rack Quide spring cap, using @ simple spinner, ‘Simple Spinner (Wieth across flats: 17 mm) (@) Remove the comoression spring and rack guide from the steering rack housing Teresens ack end Wish serosa: yian arcs tt Sm Bae ‘Sierng ck ena Sterna ack accord nog ee = el 1 —— Eee Bares x races fa?7. Remove the steering rack NOTE: 1 Be sure fo raw out the rack toward the housing side so thal the rack Bush may not be damaged by the rack twoth surface. ‘© Draw out the rack straight, not allowing the rack t rotate 8. Remove the oil sea, using a common screwdriver ofthe Ike. Be caretul nat to damage the housing during the ‘9. Detach the snap ring, using a snap ring expander, 40. Remove the steering pinion, together with the bearing, from the steering rack housing. 11, Racial bal beating removal (@) Detach the shaft snap ring, using @ snap ring ex: ‘pander (2) Remove the bearing, using the following SST. 887: 09060 2014-000 opaso zecn0|STEERING INSPECTION Inspect the folowing pars tenator cage. SB _eaing tor wear operation Scena fackerdtaliont Sn suze wes or davage ‘or excessive looseness: 7 sees = Tae ig eet: cameoe ont fo: eceaseaosenose cone oma sucwecersmee Sones Ce, io Lee, FRack bush for wear or damage e 2 ca can ot ttt anager @ cnet coh Sai a = ASSEMBLY 1. Apply grease to the following sections.>. Racial bal bearing installation (4) Install the eating to the steering pinion, using the following SST SST: 09612-10061-000 (2) Atach the shaft snap ring, using a snap ring ex pander 3. Steering pinion installation (7) neta he steering pinion tothe steering rack housing, Using the folowing SST. SST: 09608-87102-000 (@) Attach the snap rng, using a snap ting expander. 3. Insial the oil sea! to the steering rack housing, using the folowng 8ST ‘SST: 08309-87201-000 4, Assembly of steering rack (1) Apply EP grease to the tooth sutface and whole peripheral portion ofthe steering rack (2) Assemble the steering rack, paying attention not to damage the rack bush EIR CRET rere aSTEERING '5. Assemble the rack guide, compression spring anc rack ‘ude spring can tothe etering rack housing, 6. Rank preload adjustment (1) Tighten the rack guide spring cap, using @ simple spinner. Tightening Torque: 0.7 kg-m (5.1 hb) (2) Move the steering rack back and for about 15 times 0 a8 {0 sete the steering rack. Then, proceed to ‘Uohten the rack guide spring cap again. Tightening Torque: 1.25 kg-m (0.9 fib} (@) Back off the rack guide spring cap 45°37, using @ simple spinner (8) Measure the rack preload, using the following SST. SST: 09616-87701-000 Specified Value (Staring Torque: ‘3-6 kgom (26-52 inchb) (6) Ifthe preload does not comply with tne specification, repeat the operations (1) through (4). 7. Hexagon nut (lack nut) instalation (() Tighten the foek nut using the SST, while holding the rack guide sering cap with a simple spinner so as to prevent the rack guide spring cap from turning during the tightening, ‘SST: 09617-22030-000 Tightening Torque: 2.6 - 4.6 kgum (25.5 - 92.5 Rab) NOTE: “The actual reading ofthe torque wrench will be a product that i obtained by mulipiying the figure above by the following figure alven below: ‘of torque wrench “amare a So (2) Check the pinion stating torque again. SST: 09616-87701-000 Specified Value [Staring Torque): ‘3-6 kgm (26-52 inctrb) Bove Own 9.4, Steering rack end instalation (7) Serew inthe rack end plug into the rack end. (Get the rack end plug in such a way that the side having a larger lange comes to the rack end side.) (@) Under the condition described in (1), tighten the rack ns to the steering rack, (6) Secure the staring rack. Tighten the rack end plug. Tightening Torque: 5.0 = 6 kgrm (96 - 47 fb) 9, Install the steering rack boot. Install the boot band No.2 ‘and rack boot band. 10. Tle fod end instalation (1) Serew inthe lock nut and tle rod end into the rack end Up to the mating mark. Tighten the lock nut tempo- rariy. @) Tighten the lock rut securly after the toe-in check and adjustment have been carried cut. INSTALLATION 1. Steering rack assembiy installation (G) Insta the grommet fo the steering rack assembly ‘Then, insert it tothe vehicle NOTE, Be very careful not to damage the steering rack boot uring the inseron. (2) Insalthe steering universal joint othe steering pinion. Tighten the bolt temporal. (@) Install the steering rack assembly to the body. Tightening Torque: 4.0 55 kg-m (29 ~ 40 feb) 721 Steoingrack ——Rackend afd oa ote Leck Teresene Fackend‘STEERING 2, Tighten the attaching bot of the steering universal joint, Tightening Torque: 2.5 - 85 kg-m (18 - 25 te) Note: When tightening the bolt, be sure to imi the protruding length ofthe serraion sections ofthe universal jint anc pinion fo 5 ram (0.20 inch). 8, Tie od end instalation (1) ttl the tie roc end to the knuckle, Tighten the castle nuts Tightening Torque: 3.0 - 45 kg-m (22 - 92.5 fb) (2) Install @ new cotter pins, Insta the wheel Jack down the vehicle Check tne steering whee! pay. Berform the toe-n anjustment. (See page S~44.) Conf the stiaight-2nead postion of steering wheel 7-22DAIHATS! CHARADE Chassis SECTION 8 BRAKES BRAKE PEDAL CHECKS AND ‘ADJUSTMENT BRAKE BOOSTE: AIR BLEEDING OF BRAKE SYSTEM SCHEMATIC VIEW BRAKE PEDAL .. ‘COMPONENTS, REMOVAL INSPECTION INSTALLATION BRAKE MASTER CYLINDER AND 'BRAKE BOOSTER .. ‘SECTIONAL VIEW ASTER CYLINDER ‘COMPONENTS, FEMOVAL DISASSEMBLY INSEECTION ASSEMBLY . INSTALLATION BRAKE BOOSTER (Geinch Booster) COMPONENTS .. REMOVAL .. DISASSEMBLY INSPECTION ASSEMBLY (neh Booster) COMPONENTS DISASSEMBLY . INSPECTION ASSEMBLY INSTALLATION FRONT BRAKE ‘SECTIONAL VIEW COMPONENTS. DISC BRAKE PAD DISC BRAKE FRONT CALIPER REAR ORUM BRAKE .. SECTIONAL VIEW COMPONENTS REWOVAL INSPECTION INSTALLATION REAR DISC BRAKE SECTIONAL VIEW COMPONENTS DISC BRAKE Pad DISC BRAKE REAR CYLINOEF PARKING BRAKE. PARKING BRAKE LEVER PARKING BRAKE CAI SSSeseseyee ean eaesssaatBRAKES BRAKE PEDAL CHECKS AND ADJUSTMENTS 1. Pedal height check ‘Measure the brake pedal height (the dimension from the ‘center ofthe pedal applying surface to the dash pane). ‘Spectiod Value: 176 - 181 mm (6.93 - 7.13 inch) 2. Pedal height adjustment (1) Disconnect the connector trom the stop lamp switch Slacken the aut @ and tum the switch, until the pedal has a tee travel (2) Siacken the nut @. Tum the push rod @ so as to adjust the pedal height. Lock the nut @. (@) Tum the Switch, until the pedal cushion comes in contact with the edge of the threaded portion of the stop lamp switch. Lock the nut ®. (4) Connect the connector of the stop lamp switch. (6) Upon completion of the pedal height adjustment, ‘ensure thatthe pedal free travel is proper and the stop lamp functions propery 3. Pedal fre travel check ‘ter stopping the engine, depress the brake pedal ‘sttongly several tes eo that no vacuum may remain the Drake booster. Measure the brake pedal free travel by pushing the brake pedal ighty oy fingers. Here, tne pedal fee travel means the cistance from a point where the brake pedal is free fo a pont where you begin to feel 2 resistance, ‘Specified Value: ‘inch Booster 3-7 mm (0.12 - 0.28 inch) inch Booster 0.5 - 2 mm (0.02 ~ 0.08 inch) 4. Pedal tree travel adjustment (1) Saoken the nut @. Tum the push rod @ so as to adjust the pedal free travel, (2) Upon completion of the adjustment, eneure that the ‘pedal height is proper and the stop lamp functions propery 5. Pedal reserve travel check ‘withthe engine running at the idling speed and with the parking brake lever in fis returned state, depress the brake pedal wth a pedal applying force of 30 kg (66 Ib). Measure the gap between the postion where the depress- 26 pedal stops anc the floor panel ‘Specified Value: 102 mm (4.0 inches) or more ae