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1 QUICK REFERENCE INDEX

FOREWORD

This service manual has been prepared to


provide SUBARU service personnel with the
necessary information and data for the
correct maintenance and repair of SUBARU
vehicle.
This manual include the procedures for
maintenance disassembling, reassembling,
inspection and adjustment of components
and troubleshooting for guidance of both the
fully qualified and the less-experienced
mechanics.
Please peruse and utilize this manual fully to
ensure complete repair work for satisfying our
customers by keeping their vehicle in
optimum condition. When replacement of
parts during repair work is needed, be sure to
use SUBARU genuine parts.
Please use the following publications
available in addition to this manual.

Manual Name Pub. No.


TECHNICAL DESCRIPTION
NEW CAR FEATURES U611GE
MECHANISM AND FUNCTION W611GE

SERVICE MANUAL
GENERAL INFORMATION SECTION
G611GE1
TROUBLESHOOTINGSECTION G611GE3
WIRING DIAGRAM SECTION G611GE4

All information, illustration and specifications


contained in this manual are based on the
latest product information available at the time
of publication approval.

FUJI HEAVY INDUSTRIES LTD.


How to use this manual

This Service Manual is divided into four volumes by section so that it can be used with ease at
work. Refer to the Table of Contents select and use the necessary section

GENERAL INFORMATION SECTION


REPAIR SECTION
TROUBLESHOOTING SECTION

Each chapter in the manual is basically made of the following four types of areas

S Specifications and Service data


C Component parts
W Service procedure
(X Service procedure)
(Y Service procedure)
T Troubleshooting

The description of each area is provided with four types of titles different in size as shown below.
The Title No or Symbol prefixes each title in order that the construction of the article and the flow
of explanation can be easily understood

[Example of each title]


Area title: W. Services procedure (one of the four types of areas)
Large title (Heading): 1. Oil Pump (to denote the main item of explanation)
Medium title (Section): A. REMOVAL (to denote the type of work in principle)
Small title (Sub-section): 1. INNER ROTATOR (to denote a derivative item of explanation)
The Title Index No. is indicated on the top left (or right) side of the page as the book is opened. This is
useful for retrieving the necessary portion.

(Example of usage)
In this manual, the following Symbols are used.

: Selective part

: Replacement part

: Should be lubricated with oil.

: Should be lubricated with grease.

: Sealing point

: Tightening torque

WARNING. CAUTION. NOTE

WARNING: Indicates the item which must be observed precisely during performance of maintenance
services in order to avoid injury to the mechanics and other persons.
CAUTION: Indicates the item which must be followed precisely during performance of maintenance
services so as to avoid damage and breakage to the vehicle and its parts and
components.
NOTE: Indicates the hints. knacks. etc. which make the maintenance job easier.

SPECIAL TOOLS
When any special tool is required to perform the job. it is identified by "ST" in the applicable illustration
and its part number is shown in the manual.
TABLE OF CONTENTS
2-1 *************************
2-2 On-Car Services
2-3 Engine
2-4 Engine Lubrication System
2-5 Engine Cooling System
ENGINE SECTION 2-6 *************************
2-7 Fuel Injection System
2-8 Fuel System
2-9 Exhaust System
2-10 Clutch
2-11 Engine and Transmission Mounting System
3-1 Manual Transmission and Differential

TRANSMISSION AND 3-2 **************************


DIFFERENTIAL SECTION 3-3 Transmission Control System
3-4 4WD System
4-1 Suspension
4-2 Wheels and Axles

MECHANICAL COMPONENTS 4-3....Steering System


SECTION 4-4 Brakes
4-5 Pedal System and Control System
4-6 Heater and Ventilator
5-1 Body and Exterior
5-2 Doors and Windows
BODY SECTION 5-3 Seats, Seat Belts, and Interior
5-4 Instrument Panel
5-5 *************************
6-1 Engine Electrical System
ELECTRICAL SECTION
6-2 Body Electrical System
2 ENGINE SECTION

********** 2.1
ON-CAR SERVICES 2.2
ENGINE 2.3
ENGINE LUBRICATION SYSTEM 2.4
ENGINE COOLING SYSTEM 2.5

2.1 **********
2.2 ON-CAR SERVICES
Page
W SERVICE PROCEDURE......................................................................................................... 2
1. Foreword............................................................................................................................. 2
2. Ignition Timing..................................................................................................................... 2
3. Engine Idle Speed...............................................................................................................3
4. Engine Compression...........................................................................................................4
6. Valve Clearance.................................................................................................................. 6
2.2 SERVICE PROCEDURE
1. Foreword 2. Ignition Timing

1. Foreword

This chapter describes major inspection and service


procedures for the engine mounted on the body. For
procedures not found in this chapter, refer to the
service procedure section in the applicable chapter.

2. Ignition Timing
A: INSPECTION
1) Warm up the engine.
2) Confirm that the idle switch is ON. (Throttle pedal
OFF).
3) Turn ignition switch to OFF.
4) Connect test mode connector (2).
5) Remove engine room cover.

6) Check ignition timing when unloaded (with headlight,


heater fan, rear deffoger, radiator fan: OFF).

7) Connect a timing light to #1 cylinder spark plug cord,


and illuminate the timing mark with the timing light.

Ignition Timing (BTDC / rpm):


5 3/ 850
8) Disconnect test mode connector.

NOTE:

Ignition timing can be observed using select monitor.


(Function mode "F07")

2
SERVICE PROCEDURE 2.2
2.Ignition Timing 3. Engine Idle Speed.

B: ADJUSTMENT
1) Loosen the 8 mm bolt securing distributor.
2) Turn the distributor housing. The timing is advanced
when the distributor housing is turned clockwise and is
retarded when turned counterclockwise.
3) Tighten the bolts and make sure that the timing is
correct.
4) After adjusting ignition timing, adjust the engine idle
speed.
Tightening torque:
14.2 - 17.2 Nm (1.45 - 1.75 kg-m, 10.5 - 12.7ft-lb)

3. Engine Idle Speed


A: INSPECTION
1) Before checking idle speed, check the following:
(1) Ensure that air cleaner element is free from clog-
ging, ignition timing is correct, spark plugs are in
good condition, and that hoses are connected
properly.
(2) Ensure that CHECK ENGINE light is OFF.
2) Warm up the engine.

3) Turn ignition switch to OFF.


4) Connect read memory connector (1) and test
mode connector (2).
5)

5) Disconnect connector from ignition coil, and connect


ST between ignition coil and rear harness.
ST 498055900 ADAPTOR
6) Attach the pickup sensor on tachometer to ST.
7) Check idle speed when unloaded (with headlights,
heater fan, rear deffoger, radiator fan: OFF).
Engine Idle Speed (rpm):
850 50

3
2.2 SERVICE PROCEDURE
3, Engine Idle Speed 4. Engine Compression

8) Turn ignition switch to OFF.


9) Disconnect read memory connector and test mode
connector.
NOTE:
Engine speed can be observed using select monitor
(Function mode "F04").

B: ADJUSTMENT
Adjust engine idle speed outside specification by
rotating idle adjusting screw on throttle body.

4. Engine Compression
A: MEASUREMENT
1) After Warming up the engine, turn ignition switch to
OFF.
2) Make sure that the battery is fully charged.
3) Remove all spark plugs.
4) Disconnect connectors from all fuel injectors.
5) Fully open the throttle valve.
6) Check the starter motor for satisfactory performance
and operation.
7) Crank the engine by means of the starter motor, and
read the maximum value on the gauge When the
pointer is steady.
Hold the compression gauge tight against the spark
plug hole.
8) Perform at least two measurements per cylinder, and
make sure that the values are correct.

Engine Compression:
1373 - 1520 kPa (14-15.5kg/cm, 199-220 psi)
/300 rpm

4
SERVICE PROCEDURE 2.2
5. Intake Manifold Vacuum

5. Intake Manifold Vacuum


A: MEASUREMENT

1) Warm up the engine.


2) Attach the vacuum gauge to collector chamber.
3) Keep the engine at idle speed and read the vacuum
gauge indication.

Intake manifold vacuum at idle:


-62.7 to -69.3 kPa
(-470 to -520 mmHg,
-18.5 to -20.5 inHg)
NOTE:
Up to about 1,000 km (625 miles), vacuum gauge
indication may occasionally be lower than above
values.
5) If the needle deflects out of the normal value range,
adjust according to the following table.

vacuum gauge indication and defective points.


Vacuum gauge Vacuum gauge
Defective point Defective point
indication indication

Leakage from intake manifold gasket Needle points at


Advanced ignition timing
and carburetor gasket value greater than
Excessive valve clearance
Needle point Retarded ignition timing and narrow value
at value smaller valve clearance
than standard Excessive valve guide clearance Needle deflects up Defects in ignition system
value. Leakage from valve seat and down from Engine idle speed
Improper adjustment of engine idle normal value improperly adjusted
speed

5
2.2 SERVICE PROCEDURE
6. Valse Clearence

6. Valve Clearance
NOTE:
Inspection and adjustment should be performed while
engine is cold.
A: INSPECTION
1) Disconnect blow by hose from rocker cover.
2) Remove rocker cover.

3) Set piston of #1 cylinder to compression top dead


center by rotating crank pulley, and measure valve
clearance by using thickness gauge.

4) In the next, set piston of #1 cylinder to exhaust top


dead center, and measure valve clearance.
Valve lash (Clearance)
Intake:
0.13-0.17 mm (0.0051 - 0.0067 in)
Exhaust:
0.23 - 0.27mm (0.0091 0.0106 in)
0.24

NOTE:
The valves marked "o" in the table can be measured
fore valve clearance.

B: ADJUSTMENT
1) Loosen adjusting screw locknut.
2) Adjust valve clearance to specified value by using
ST.
ST 498767000 VALVE CLEARANCE ADJUSTER
3) Tighten locknut.

Tightening torque:
17-23 N m (1.7 2.3 kg-m, 12-17 ft-lb)

6
2.3 ENGINE
S SPECIFICATION AND SERVICE DATA...................................................................................2
1.Engine.................................................................................................................................. 2
C COMPONENT PARTS............................................................................................................. 6
1. Crankcase and Cylinder Head.............................................................................................6
2. Valve System...................................................................................................................... 7
3. Lubrication and Cooling Equipment.....................................................................................8
4. Crankshaft and Balancer Shaft............................................................................................9
W SERVICE PROCEDURE.......................................................................................................10
1. General Precautions.......................................................................................................... 10
2. Timing Belt......................................................................................................................... 11
3. Valve Rocker Assembly.....................................................................................................17
4. Camshaft........................................................................................................................... 20
5. Cylinder Head................................................................................................................... 28
6. Cylinder Block................................................................................................................... 41
T TROUBLESHOOTING........................................................................................................... 62
1. Engine Trouble in General.................................................................................................62
2. Engine Noise..................................................................................................................... 65
2.3 SPECIFICATION AND SERVICE DATA
1.Engine

1.Engine
A: SPECIFICATIONS

Model EMPi
Type In-line, 3-cylinder, with balancer shaft
Valve arrangement Belt driven, single over-head camshaft
Bore x Stroke 78.0 x 83.0 mm (3.07 x 3.27 in)
Piston displacement 1,189 cm3 (1,189cc, 72.55 cu in)
Compression ratio 9.1
Open (BTDC) 19 \
Intake valve timing
Close (ABDC) 53
Open (BBDC) 70
Exhaust valve timing
Close (ATDC) 12
Intake 0.13 0.17 mm (0.0051 0.0067 in)
Valve lash (Clearance)
Exhaust 0.23 - 0 27 mm (0.0091 - 0.0106 in)
Idling speed [At neutral position] 850 50 rpm
Firing order 1->3->2
Ignition timing BTDC 5 3 |
Ignition timing control Electric controlled advance

2
SPECIFICATION AND SERVICE DATA 2.3
1.Engine

B: SERVICE DATA
Valve rocker Rocker arm inner diameter STD 18 0 - 18.023 mm (0.7087 - 0.7096 in)
shaft runout 17.984 - 17.966 mm (0.7080 - 07073 In)
Rocker shaft outer diameter STD
Clearance between shaft and arm STD 0.016 - 0.057 mm (0.0006 - 0.0022 in)
Camshaft Camshaft runout Limit 0.020 mm (0.0079 in)
Camshaft bend Limit 0.025 mm (0.0010 in)
Front 38.940 - 38.965 mm (1.5331 - 1.5341 in)
Camshaft journal outer diameter STD Center 45.940 - 45.965 mm (1.8087 - 1.8096 in)
Rear 46.940 - 46.965 mm (1.8480 - 1.8490 in)
Front 39.000 - 39.025 mm (1.5354 - 1.536 in)
Journal bore diameter STD Center 46.000 - 46.025 mm (1.8110-1.8120 in)
Rear 47.000 - 47.025 mm (1.8504 - 1.8514 in)
STD 0.035 - 0.085mm (0.0014 - 0.0033 in)
Camshaft journal clearance
Limit 0.10 mm (0.0039 in)
IN 38.489 - 38.589 mm (1.5153-1.5192 in)
STD
EX 38.071 -39.071 mm (1.4989- 1.5382 in)
Cam height
IN 38.189 mm (1.5035 in)
Limit
EX 37.771 mm (1.4870 in)
STD 0.03-0.38 mm (0.0012-0.0150 in)
Thrust clearance
Limit 0.50 mm (0.020 in)
Valve STD 51.55 mm (2.030 in) 1
spring Free length
Limit 50.50 mm (1.988 in) |
Outer
Tension/maximum spring height STD 432 N (44.0 kg, 97 lb)/31.5 mm (1.24 in)
Out-of-squareness Limit 2.5, 1.8 mm (0.07 in) |
STD 45.08 mm (1.775 in) |
Free length
Limit 44.00 mm (1.732 in) j
Inner
Tension/maximum spring height STD 289 N (29.5 kg, 65.0 lb)/30.5 mm (1.20 in)
Out-of-squareness Limit 2.5, 1.8 mm (0.07 in)
Intake valve seat contact width STD 1.00 mm (0.039 in)
Valve seat
Exhaust valve seat contact width STD 1.40 mm (0.055 in)
Intake and STD 1.00 mm (0.039 in)
exhaust valves Intake valve head thickness 0.50 mm (0.020 in)
Limit
Catalyst STD 1.30 mm (0.051 in)
Exhaust valvemodel Limit 0.80 mm (0.031 in)
head thickness Non-Catalyst j STD 1.00 mm (0.039 in)
model Limit 0.50 mm (0.020 in)
Cylinder head Flatness of gasketed surface_ Limit 0.05 mm (0.0020 in)
Allowance of (gasketed surface) 0.20 mm (0.0079 in)
Limit
regrinding
[ Cylinder head height STD 100.0 mm (3.94 in) |

Cylinder block | Flatness of gasketed surface_ Limit 0.05 mm (0.0020 in)


Allowance of regrinding Limit 0.20 mm (0.0079 in)
Cylinder bore diameter STD 78.000 - 78.024 mm (3.0709 - 3.0718 in)

3
2.3 SPECIFICATION AND SERVICE DATA
1.Engine

Taper Limit 0.050 mm (0.0020 in)


Out-of-roundness Limit 0.050 mm (0.0020 in)
Allowance of cylinder reboring Limit 79.024 mm (3.1112 in)
STD 77.950-77.974 mm (3.0689 - 3.0698 in)
Piston skirt outer
0.5 mm (0.020 in) OS 78.450-78.474 mm (3.0886 - 3.0895 in)
diameter at 20C (68F)
1.0 mm (0.039 in) OS 78.950-78.974 mm (3.1083 - 3.1092 in)
STD 0.013-0.037 mm (6.0005 - 0.0015 in)
Piston-to-cylinder clearance at 20C (68F)
Limit 0.060 mm (0.0024 in)
Piston pin-to-piston bore clearance at 20C STD 0.004-0.008 mm (0.0002-0.0003 in)
(68F) Limit 0.015 mm (0.0006 in)
STD 0.035- 0.075 mm (0.0014 - 0.0030 in)
Top ring
Limit 0.15 mm (0.0059 in)
Piston Ring groove clearance at STD 0.025 - 0.065 mm (0.0010 - 0.0026 in)
Second ring
20C (68 F) Limit 0.15 mm (0.0059 in)
STD 0010- 0.037 mm (0.0004 - 0.0015 in)
Oil ring
Limit
STD 0.20 -0.35 mm (0.0079 - 0.0138 in)
Top ring
Limit 0.8 mm (0.031 in)
STD 0.35 -0.50 mm (0.0138-0.0197 in)
Piston ring end gap Second ring
Limit 0.8 mm (0.031 in)
STD 0.2-0.7 mm (0.0079-0.0276 in)
Oil ring
Limit 1.0 mm (0.089 in)
STD 0.07 -0.30 mm (0.0028 - 0.0118 in)
Side clearance
Limit 0.35 mm (0.0138 in)
Limit of bend or twist per 100 mm (3.94 in) 0.10 mm (0.0039 in)
STD 0.019-0.053 mm (0.0007 - 0.0021 in)
Rod bearing clearance
Connecting rod Limit 0.065 mm (0.0026 in)
STD 1.487 - 1.491 mm (0.0585 - 0.0587 in)
Rod bearing center
0.05 mm (0.0020 in) US 1.512 - 1.520 mm (0.0595 - 0.0598 in)
thickness
0.25 mm (0.0098 in) US 1.612-1.620 mm (0.0635 - 0.0638 in)
Rod small end bore clearance STD 0005- 0.021 mm (0.0002 - 0.0008 in)

4
SPECIFICATION AND SERVICE DATA 2.3
1.Engine

Crankshaft Crankshaft runout Limit 0.030 mm (0.0012 in)


Out-of-roundnes STD 0.030 mm (0.0012 in)
Taper Limit 0.020 mm (0.0008 in)
Crankpin and crank journal
Allowance on
Limit 0.25 mm (0.0098 in)
regrinding
STD 41.989 - 42.000 mm (1.6531 - 1.6535 in)
Crank pin outer diameter 0.05 mm (0.0020 in) US 41.939 - 41.950 mm (1.6511 - 1.6516 in)
0.25 mm (0.0098 in) US 41.739 _ 41.750 mm (1.6433 - 1.6437 in)
STD 41.974 - 41.985 mm (1.6525 - 1.6529 in)
Crank journal Outer 0.05 mm (0.0020 in) US 41.924 41.935 mm (1.6505- 1.6510 in)
diameter 0.25 mm ''3BK. (0.0098
41.724 - 41.735 mm (1.6427 - 1.6431 in)
in) US
Crankshaft thrust STD 0.08 - 0.177 mm (0.0031 - 0.0070 in)
clearance Limit 0.30 mm (0.012 in)
Crankshaft Bearing clearance STD 0.014 - 0.037 mm (0.0006 - 0.0015 in)
main Limit 0.060 mm (0.0024 in)
bearing
Thickness at center #1 1.505 - 1.508 mm (0.0593 - 0.0594 in)
#2 1.508 - 1.511 mm (0.0594 - 0.0595 in)
STD
#3 1.511 - 1.514 mm (0.0595 - 0.0596 in)
#4 1.514 - 1.517 mm (0.0596 - 0.0597 in)
0.05 mm (0.0020 in) US 1.527 - 1.535 mm (0.0601 - 0.0604 in)
0.25 mm (0.0098 in) US 1.627 - 1.635 mm (0.0641 - 0.0644 in)

STD: Standard OS: Oversize US: Undersize

5
2.3 COMPONENT PARTS
1. Crankcase and Cylinder Head

1. Crankcase and Cylinder Head

(1) Pitching stopper bracket (8)Main bearing cap 3 (17)Crankcase (26) Exhaust valve oil seal
(RWD model) (9)Main bearing cap 2 (18) Oil pump sprocket shaft (27) Exhaust valve guide
(2) Crankcase stiffener (10)Main bearing cap (19) Cylinder head gasket (28) Plug
(4WD model) (11)Crankshaft bearing 4 (20) Valve spring retainer key (29) Cylinder head
(3) Plug (12)Crankshaft bearing 3 (21) Valve spring retainer (30) Exhaust valve
(4) Balancer shaft bearing 2 (13)Crankshaft bearing 2 (22) Valve spring, outer (31) Intake valve
(5) Balancer shaft bearing (14)Crankshaft bearing (23) Valve spring, inner (32) Oil seal
(6) Bearing cap seal (15) Coolant drain plug (24) Intake valve oil seal
(7) Main bearing cap 4 (16) Plug (25) Intake valve guide

6
COMPONENT PARTS 2.3
2. Valve System

2. Valve System

(1) Camshaft (9) Washer (18.3x24x1) (17) Bolt (25) Timing belt cover 2
(2) Snap ring (10) Rocker shaft spring (18) Belt cover mount (26) Belt cover plug
(3) Spring washer (11) oil filler cap (19) Spacer (27) Tensioner springdamper
(4) Valve rocker shaft (12) oil filler gasket (20) Timing beIt (28) Tensioner spring
(5) Valve rocker screw (13) Valve rocker cover (21) Camshaft driven pulley (29) Timing belt tensioner
(6) Valve rocker nut 1 (14) Valve rocker cover gasket (22) Distributor cord stay
(7) Valve rocker arm 1 (15) Timing belt cover (23) Timing belt cover plate
(8) Valve rocker arm 2 (16) Spacer (24) BeIt cover sealing

7
2.3 COMPONENT PARTS
3. Lubrication and Cooling Equipment

3. Lubrication and Cooling Equipment

(1) Flywheel housing (9) Oil relief valve (17) Impeller (25) oil pump inner rotor
(2) Rubber plate (10) Relief valve spring (18) Gasket (26) Oil pump outer rotor
(3) Rubber plate 2 (11) Oil pump relief plug (19) Water pump cover (27) O-ring
(4) Oil pan (12) Oil level gauge guide (20) O-ring (28) Oil pump cover
(5) Oil drain plug (13) Oil strainer (21) Oil seal (29) Oil cooler
(6) Gasket (14) Mechanical seal (22) Oil pressure switch (30) Oil filter
(7) Oil seal (15) Plate (23) Shaft pin
(8) Crankcase cover (16) O-ring (24) Oil pump shaft

8
COMPONENT PARTS 2.3
4. Crankshaft and
Balancer Shaft

4. Crankshaft and Balancer Shaft

(1) Flywheel (9) Chain guide (17) Piston


(2) Oil seal (10) Camshaft drive plate (18) Piston pin
(3) Balancer shaft (11) Camshaft drive pulley 19) Connecting rod
(4) Crankshaft (12) V-belt (20) Connecting rod bolt
(5) Balancer shaft sprocket (13) Crankshaft pulley (21) Connecting rod bearing
(6) Balancer chain (14) Piston ring 1 (22) Connecting rod cap
(7) Crankshaft sprocket (15) Piston ring 2
(8) Oil pump sprocket (16) Oil ring

9
2.3 SERVICE PROCEDURE
4. Crankshaft and Balancer Shaft

1. General Precautions
CAUTION:
All parts should be thoroughly cleaned, paying
special attention to the engine oil passages,
pistons and bearings.
Rotating parts and sliding parts such as piston
bearing and gear should be coated with oil prior to
assembly.
Be careful not to let oil, grease or coolant contact
the timing belt, clutch disc and flywheel.
All removed parts, if to be reused, should be
reinstalled in the original positions and directions.
Gaskets and lock washers must be replaced with
new ones. Sealant should be used where specified
to prevent leakage.
Bolts, nuts and washers should be replaced with
new ones as required.
Even if necessary inspections have been made in
advance, proceed with assembly work while making
rechecks.
Coat the oil seal lips with clean engine oil before
reassembling.
Confirm the clearance of each portion during
assembling.

1) Before disassembling engine, install on ENGINE


STAND.
ST 499815500 ENGINE STAND

10
SERVICE PROCEDURE 2.3
1. General Precautions

2) Drain engine oil into a suitable container.

2. Timing Belt
A: REMOVAL
1) Loosen generator installation bolts and remove V-
belt.

2) Lock up crankshaft using ST onto flywheel.


ST 498275600 FLYWHEEL STOPPER

3) Remove crankshaft pulley.

4) Remove timing belt outside cover.

11
2.3 SERVICE PROCEDURE
2. Timing Belt

5) Mark the arrow indicating the rotating direction the


timing belt if it is reused.

6) Rotate crankshaft and align the timing pointers with


the TDC ( Top Dead Center) of No.1 Cylinder indicators
CAUTION:
Do not rotate crankshaft (timing belt) in the reverse
direction. This causes tooth skipping and
damaging.

7) Loosen tensioner retaining bolt. Pry the tensioner


away from timing belt, and tighten temporarily the
retaining bolt.

CAUTION:
Do not bend or twist the timing belt sharply.
[The bending radius must be greater than 60 mm
(2.40 in).]

9) Remove tensioner retaining bolt to detach tension


after removing timing belt.
CAUTION:
Do not attempt to remove tensioner spring only.

12
SERVICE PROCEDURE 2.3
2. Timing Belt

10) Remove camshaft sprocket with ST.


ST 499205500 CRANK AND CAMSHAFT PULLEY
WRENCH
11) Remove plate and crankshaft sprocket.

NOTE:
If crankshaft sprocket can not be removed by hand, use
ST1, ST2 and bolts (M6 x 20) to detach it from
crankshaft.
ST1 899521421 PULLER
ST2 399520802 BOLT

B: INSPECTION
1. TIMING BELT
1) Check timing belt teeth for breaks, cracks, and wear.
If any fault is found, replace belt.
2) Check the condition of back side of belt; if any crack
is found, replace belt.
CAUTION:
Be careful not to let oil, grease or coolant contact
the belt. Remove quickly and thoroughly if this
happens.
Do not bend the belt sharply.
[The bending radius must be greater than 60 mm
(2.40 in).]
When timing belt teeth are skipped, replace the
timing belt.

2. TIMING BELT TENSIONER


1) Check tensioner roller for smooth rotation. Replace
tensioner if noise or excessive play is noted.
2) Check sprocket of belt tensioner for wear. If
defective, replace the belt tensioner.
3) Check spring for a free length. If it is longer than 33
mm (1.3 in), replace the spring.

13
2.3 SERVICE PROCEDURE
2. Timing Belt

3. SPROCKET
check sprocket for wear. If defective, replace the
sprocket.

C: INSTALLATION
CAUTION:
Be careful not to apply oil and coolant to each
sprocket on timing belt.
Do not bend or twist the timing belt sharply.
[The bending radius must be greater than 60 mm
(2.40 in).]

1) Install crankshaft sprocket by hand.

2) Install camshaft sprocket and tighten the bolt with ST.


ST 499205500 CRANK AND CAMSHAFT
PULLEYWRENCH
Tightening torque:
11.3-12.3 N m (1.15 - 1.25 kg-m, 8.3 - 9.0
ft-lb)

3) Install timing belt tensioner and spring.


4) Tighten timing belt tensioner retaining bolts while
lifting up it.

14
SERVICE PROCEDURE 2.3
2. Timing Belt

5) Align the TDC marks on timing belt between timing


pointers and TDC indicators.

6) Install timing belt.


CAUTION:
If the timing belt is reused, make sure that the belt
rotates in the same direction as before disassem-
bling.

7) First with the belt tensioner bolt loosened, then


secure the tensioner bolt.
Tightening torque:
18 - 22 N.m (1.8 - 2.2 kg-m, 13 16 ft-lb)
8) Set and tighten tensioner in place. Check the belt
rotation and tension by driving crankshaft sprocket two
or three turns with ST.
ST 499205500 CRANK AND CAMSHAFT PULLEY
WRENCH
9) Install plate onto crankshaft sprocket.

15
2.3 SERVICE PROCEDURE
2. Timing Belt

10) Install timing belt outside cover.

11) Using ST, lock up crankshaft onto flywheel.


ST 498275600 FLYWHEEL STOPPER

12) Install crankshaft pulley.


13) Tighten crankshaft pulley bolt.
Tightening torque:
64 - 74 Nm (6.5 - 7.5 kg-m, 47 - 54 ft-lb)

14) Install V-belt between crankshaft pulley and


generator pulley.
15) Check and adjust v-belt tension.
V-belt tension:
Reused: 11-13 mm (0.43 0.51 in)
/ 98 N (10 kg, 22 lb)
Replaced: 9-11 mm (0.35 - 0.43 in)
/ 98 N (10 kg, 22 lb)
Tightening torque:
17.2-20.1 Nm (1.75-2.05kg-m, 12.7- 14.8 ft-lb

16
SERVICE PROCEDURE 2.3
2. Timing Belt

3. Valve Rocker Assembly


A: REMOVAL
1) Remove valve rocker cover.

2) Loosen adjusting screws of valve clearance after


loosening lock nuts.

3) Remove clips from both end of the rocker shaft, and


slide out the rocker shaft.
4) Remove rocker arms and rocker shaft springs.
CAUTION:
There are two types of shape in valve rocker
arms.
When disassembling the rocker arm assembly, be
sure to place the removed arm, washer, wave
spring, etc. in the order of disassembly. This will
help the parts to be installed in the proper order.

(1) Washer
(2) Spring washer
(3) Rocker shaft
(4) Valve rocker arm 2
(5) Rocker shaft spring
(6) Valve rocker arm 1

17
2.3 SERVICE PROCEDURE
3. Valve Rocker Assembly

B: INSPECTION
1. ROCKER ARM
1) Make a visual inspection to ascertain that the arm
can be operated freely. Replace the arm if defective.
2) Check the wear on the inside diameter of the rocker
arm and the outside diameter of the rocker shaft. Then
calculate the clearance between rocker arm inside
diameter and rocker shaft outside diameter if the limit is
exceeded, replace.
Specification:
(1) Rocker arm inside diameter
Standard: 18.000- 18.023 mm (0.7087- 0.7096in)
(2) Rocker shaft outside diameter
Standard: 17.984- 17.966mm (0.7080- 0.7073in)
(3) Clearance between (1) and (2)
Standard: 0.016 - 0.057mm (0.0006 - 0.0022 in)
3) Check the cam-riding face of arm for cracks and
wear. Repair or replace the arm if defective.
4) Check the tip of adjusting screw for wear.
Replace the adjusting screw if defective.
5)
2. ROCKER SHAFT
1) Check the runout of rocker shaft for cracks and wear.
Repair or replace the rocker shaft if defective.
2) Check the oil passage for clogging. Clean the oil
passage if defective.
3)

C: INSTALLATION
1) Position rocker arms and rocker shaft springs, and
then insert the rocker shaft in position.
2) Install spring washer, washer, and snap ring on each
end of the rocker shaft.
(1) Washer (4) Valve rocker arm 2
(2) Spring washer (5) Rocker shaft spring
(3) Rocker shaft (6) Valve rocker arm 1

3) Turn the crankshaft and set the #1 cylinder at TDC of


compression stroke.
CAUTION:
Do not rotate crankshaft using the crankshaft bolt
Use ST if required.
ST 498715410 CAM TIMING ADJUSTER

18
SERVICE PROCEDURE 2.3
3. Valve Rocker Assembly

4) Adjust the valve clearance.


(1) Loosen locknut.
(2) Turn the adjusting screw to adjust the valve
clearance of #1 intake and exhaust valve to the
specification with the ST or a thickness gauge.
ST 498767000 VALVE CLEARANCE ADJUSTER Valve
clearance:
Intake: 0.13-0.17 mm (0.0051 0.0067 in)
Exhaust: 0.23 -0.27 mm (0.0091 - 0.0106 in)

(3) After adjusting the valve clearance, tighten


locknut.
Tightening torque:
17-23 Nm (1.7-2.3 kg-m, 12-17ft-lb)
CAUTION:
In this time, the valves that is marked "o" in the
table can be adjusted the valve clearance.

#1 cylinder #2 cylinder #3 cylinder


IN EX IN EX IN EX
o o o o

(4) Rotate crankshaft 360 and set the #1 cylinder


at the TDC of exhaust stroke.
(5) Adjust the valve clearance.
CAUTION:
In this time, the valves that is marked "o" in the
table can be adjusted the valve clearance.

#1 cylinder #2 cylinder #3 cylinder


IN EX IN EX IN EX
o o o o

5) Install valve rocker cover.


Tightening torque:
6.9 - 7.8 N m (0.7-0.8 kg-m, 5.1 - 5.8 ft-lb)

19
2.3 SERVICE PROCEDURE
3. Valve Rocker Assembly

4. Camshaft
A: REMOVAL
1) Loosen generator installation bolts and remove
belt.
2)

2) Lock up crankshaft using ST onto flywheel.


ST 498275600 FLYWHEEL STOPPER

3) Remove crankshaft pulley.

4) Remove timing belt outside cover.

5) Mark the arrow indicating the rotating direction the


timing belt if it is reused.

20
SERVICE PROCEDURE 2.3
4. Camshaft

6) Rotate cranshaft an align the timing pointers with the


TDC (Top Dead Center) of #1 Cylinder indicators.
CAUTION:
Do not rotate crankshaft (timing belt) in the reverse
direction. This causes tooth skipping and
damaging.

7) Loosen tensioner retaining bolt. Pry the tensioner


away from timing belt, and tighten temporarily the
retaining bolt.
8) Remove timing belt.

CAUTION:
Do not bend or twist the timing belt sharply.
[The bending radius must be greater than 60 mm
(2.40 in).]

9) Remove camshaft sprocket With ST.


ST 499205500 CRANK AND CAMSHAFT PULLEN
WRENCH

21
2.3 SERVICE PROCEDURE
4. Camshaft

10) Remove valve rocker cover.

11) Loosen adjusting screws of valve clearance after


loosening lock nuts.

12) Remove clips from both end of the rocker shaft, and
slide out the rocker shaft.
13) Remove rocker arms and rocker shaft springs.
CAUTION:
There are two types of shape in valve rocker arms.
When disassembling the rocker arm assembly, be
sure to place the removed arm, washer, wave
spring, etc. in the order of disassembly. This will
help the parts to be installed in the proper order.

(1) Washer
(2) Spring washer
(3) Rocker shaft
(4) Valve rocker arm 2
(5) Rocker shaft spring
(6) Valve rocker arm 1

14) Remove distributor from cylinder head.

22
SERVICE PROCEDURE 2.3
4. Camshaft

15) Remove camshaft.


CAUTION:
When removing the camshaft, use care not to
damage the bearing.
16) Remove camshaft oil seal from cylinder head.
CAUTION:
Do not remove oil seal unless necessary.

B: INSPECTION
1. CAMSHAFT RUNOUT AND BEND

1) Flush place camshaft between V-blocks.


2) Check runout and bend by using dial gauge.
Service Limit:
Camshaft runout: 0.020 mm (0.0008 in)
Camshaft bend: 0.025 mm (0.0010 in)

2. CAMSHAFT JOURNAL AND JOURNAL BORE


DIAMETERS
Measure the camshaft journal diameter at seven points
by using micrometer, and measure the journal bore
diameter at two points by using cylinder gauge.

Camshaft journal diameter:


Front 38.940 - 38.965 mm (1.5331 - 1.5341 in)
Center 45.940 - 45.965 mm (1.8087 - 1.8096 in)
Rear 46.940 46.965 mm (1.8480 1.8490 in)
Journal bore diameter:
Front 39.000 - 39.025 mm (1.5354 - 1.5364 in)
Center 46.000 - 46.025 mm (1.8110 - 1.8120 in)
Rear 47.000 - 47.025 mm (1.8504 - 1.8514 in)
Journal clearance:
Standard: 0.035 - 0.085 mm (0.0014 - 0.0033 in)
Limit: 0.10 mm (0.0039 in)

23
2.3 SERVICE PROCEDURE
4. Camshaft

3. CAM HEIGHT
Check cam face condition; remove minor faults by
grinding With oil stone. Measure the height of lobe.
Replace if the limit is exceeded.
Cam height: H
Standard: IN: 38.489-38.589 mm (1.5153-1.5192 in)
EX: 38.071-39.071 mm (1.4989-1.5382 in)
Limit: IN: 38.189 mm (1.5035 in)
EX: 37.771 mm (1.4870 in)

4. THRUST CLEARANCE

1) When inspect this clearance, install camshaft and


distributor onto the cylinder head.
2) Measure thrust clearance of camshaft with dial
gauge. If the limit is exceeded, replace camshaft or
cylinder head.
Thrust clearance:
Standard: 0.03 0.38 mm (0.0012 0.0150 in)
Limit: 0.50 mm (0.0200 in)

C: INSTALLATION
1) Apply a coat of engine oil to camshaft journals and
install camshaft into the cylinder head.
2) Apply engine oil to the oil seal lip, and install
camshaft oil seal into cylinder head.

3) Install distributor onto cylinder head.


Tightening torque:
14.2- 17.2 Nm (1.451.75 kg-m, 10.512.7 ft-lb)

4) Position rocker arms and rocker shaft springs, and


then insert the rocker shaft in position.
5) Install spring washer, Washer, and snap ring on each
end of the rocker shaft.

(1) Washer (4) valve rocker arm 2


(2) Spring Washer (5) Rocker shaft spring
(3) Rocker shaft (6) Valve rocker arm 1

24
SERVICE PROCEDURE 2.3
4. Camshaft

6) Install camshaft sprocket and tighten the bolt with ST.


ST 499205500 CRANK AND CAMSHAFT PULLEY
WRENCH
Tightening torque:
11.3 - 12.3 Nm (1.15 - 1.25 kg-m, 8.3 - 9.0 ft-lb)
11.4

7) Align the TDC marks on timing belt between timing


pointers and TDC indicators.

8) Install timing belt.


CAUTION:
If the tinning belt is reused, make sure that the belt
rotates in the same direction as before
disassembling.

9) First with the belt tensioner bolt loosened, then


secure the tensioner bolt.
Tightening torque:
18 - 22 Nm (1.8 - 2.2 kg-m, 13 - 16 ft-lb)
10) Set and tighten tensioner in place. Check the belt
rotation and tension by driving crankshaft sprocket two
or three turns with ST.
ST 499205500 CRANK AND CAMSHAFT PULLEY
WRENCH

25
2.3 SERVICE PROCEDURE
4. Camshaft

11) Turn the crankshaft and set the #1 cylinder at TDC


of compression Stroke.
CAUTION:
Do not rotate crankshaft using the crankshaft bolt.
Use ST if required.
ST 498715410 CAM TIMING ADJUSTER

12) Adjust the valve clearance.


(1) Loosen locknut.
(2) Turn the adjusting screw to adjust the valve
clearance of #1 intake and exhaust valve to the
specification With the ST or a thickness gauge.
ST 498767000 VALVE CLEARANCE ADJUSTER
Valve clearance:
Intake: 0.13-0.17 mm (0.0051 - 0.0067 in)
Exhaust: 0.23 - 0.27 mm (0.0091 - 0.0106 in)

(3) After adjusting the valve clearance, tighten lock-


nut.
Tightening torque:
17-23 Nm (1.7-2.3 kg-m, 12-17 ft-lb)

CAUTION:
In this time, the valves that is marked "o" in the
table can be adjusted the valve clearance.

#1 cylinder #2 cylinder #3 cylinder


IN EX IN EX IN EX
o o o o

(4) Rotate crankshaft 360 and set the #1 cylinder at


the TDC of exhaust stroke.
(5) Adjust the valve clearance.
CAUTION:
In this time, the valves that is marked "o" in the
table can be adjusted the valve clearance.

#1 cylinder #2 cylinder #3 cylinder


IN EX IN EX IN EX
o o o o

26
SERVICE PROCEDURE 2.3
4. Camshaft

13) Install valve rocker cover.


Tightening torque:
6.9- 7.8 Nm (0.7 - 0.8 kg-m, 5.1- 5.8 ft-lb)

14) Install tinning belt outside cover.

15) Using ST, lock up crankshaft onto flywheel.


ST 498275600 FLYWHEEL STOPPER

16) Install crankshaft pulley.


17) Tighten crankshaft pulley bolt.
Tightening torque:
64 - 74 Nm (6.5 - 7.5 kg-m, 47- 54 ft-lb)

18) Install V-belt between crankshaft pulley and gener-


ator pulley.
19) Check and adjust V-belt tension.
V-belt tension:
Reused: 11-13 mm (0.43 - 0.51 in)/98 N (10 kg, 22 lb)
Replaced: 9-11 mm (0.35- 0.43in) /98N(10kg, 22lb)
Tightening torque:
17.2 -20.1 N m (1.75- 2.05 kg-m, 12.7- 14.8 ft-lb)

27
2.3 SERVICE PROCEDURE
4. Camshaft

5. Cylinder Head
A: REMOVAL
1) Loosen generator installation bolts and remove v-belt

2) Lock up crankshaft using ST onto flywheel.


ST 498275600 FLYWHEEL STOPPER

3) Remove crankshaft pulley.

4) Remove timing belt outside cover.

5) Mark the arrow indicating the rotating direction on


the timing belt if it is reused.

28
SERVICE PROCEDURE 2.3
5. Cylinder Head

6) Rotate crankshaft and align the timing pointers with


the TDC (Top Dead Center) of #1 Cylinder indicators.
CAUTION:
Do not rotate crankshaft (timing belt) in the reverse
direction. This causes tooth skipping and
damaging.

7) Loosen tensioner retaining bolt. Pry tensioner away


from timing belt, and tighten temporarily the retaining
bolt.
8) Remove timing belt.

CAUTION:
Do not bend or twist the timing belt sharply.
[The bending radius must be greater than 60 mm
(2.40 in).]

9) Remove camshaft sprocket with ST.


ST 499205500 CRANK AND CAMSHAFT PULLEY
WRENCH

29
2.3 SERVICE PROCEDURE
5. Cylinder Head

10) Remove distributor from cylinder head.

11) Remove valve rocker cover.

12) Remove cylinder head and gasket.

CAUTION:
When removing the bolts which install cylinder
head onto cylinder block, loosen all bolts two-three
times in numerical order shown in figure.

B: DISASSEMBLY
1) Loosen adjusting screws of valve clearance after
loosening lock nuts.

2) Remove clips from both end of the rocker shaft, and


slide out the rocker shaft.
3) Remove rocker arms and rocker shaft springs.
CAUTION:
There are two types of shape in valve rocker arms.
When disassembling the rocker arm assembly, be sure
to place the removed arm, washer, wave spring, etc. in
the order of disassembly. This will help the parts to be
installed in the proper order.

30
SERVICE PROCEDURE 2.3
5. Cylinder Head

(1) Washer
(2) Spring Washer
(3) Rocker shaft
(4) valve rocker arm 2
(5) Rocker shaft spring
(6) Valve rocker arm 1

4) Remove camshaft.
CAUTION:
When removing camshaft, use care not to damage
the bearing.

5) Compress valve spring With ST 1 and 2, and remove


valve spring retainer key.
ST1 899724100 VALVE SPRING PRESS ASSY
ST2 399722100 VALVE SPRING PRESS

6) Remove each valve spring seat, valve spring, and

C: INSPECTION
1. VALVE SPRING
1) Check valve springs for damage, free length, and
preload length. Replace the valve spring if the
specification is exceeded.
Free length (Standard)
Outer: 51.55 mm (2.030 in)
Inner: 45.08 mm (1.775 in)

31
2.3 SERVICE PROCEDURE
5. Cylinder Head

2) fo measure the squareness of the valve spring, stand


the spring on a surface plate and measure it deflection
at the top using a try square.
Out-of-squareness:
Limit: 1.8 mm (0.071 in) or below 2.5

2. VALVE SEAT
1) Inspect intake and exhaust valve seats, and repare
the seating contact face by cutting and regrinding. And
lap the valve face with compound if required.
CAUTION:
Be careful not to enter the compound into the valve
stem and guide.
Valve seat contact width: W
intake
Standard: 1.00 mm (0.039 in)
Exhaust
Standard: 1.40 mm (0.055 in)

2) Insert intake and exhaust valves into valve guide and


contact With valve seats. Measure valve stem
assembled height. If the limit is exceeded, replace valve
or cylinder head.
CAUTION:
Recheck valve stem assembled height if the valve
replaced.
Valve stem assembled height: H
intake
Standard:44.0 mm (1.732 in)
Limit: 43.5 mm (1.713 in)
Exhaust
Standard:44.0 mm (1.732 in)
Limit: 43.5 mm (1.713 in)

32
SERVICE PROCEDURE 2.3
5. Cylinder Head

3. VALVE GUIDE
1) Measure the clearance: W between the valve guide
and valve stem for intake and exhaust valves with a dial
gauge. If the limit is exceeded, replace valve or valve
guide.
Valve stem diameter: d
Intake
Standard: 6.965 - 6.980 mm
(0.2742 - 0.2748 in)
Exhaust
Standard: 6.945 - 6.960 mm
(0.2734 - 0.2740 in)
Valve guide inner diameter: D
Standard: 7.000 7.015 mm
(0.2756 - 0.2762 in)
Valve guide to valve stem clearance: w = D - d
Intake
Standard: 0.020 0.050 mm
(0.0008 - 0.0020 in)
Limit: 0.130 mm (0.0051 in)
Exhaust
Standard: 0.040 0.070 mm
(0.0016 0.0028 in)
Limit: 0.150 mm (0.0059 in)

2) Replacement of valve guide


(1) Place cylinder head on ST1 With the combustion
chamber upward so that valve guide enters the hole
of ST1.
(2) Insert ST2 into valve guide and press it down to
remove valve guide.
ST1 399762111 CYLINDER HEAD TABLE
ST2 399762103 VALVE GUIDE REMOVER

(3) Before installing new valve guide, make sure


that neither scratches nor damages exist on the
inside surface of the valve guide holes in cylinder
head.
(4) Place cylinder head on ST1 with the combustion
chamber downward. Fix special tool and valve
guide in cylinder head so that the valve guide upper
end is flush with the upper surface of ST3.
ST1 399762111 CYLINDER HEAD TABLE
ST3 399762102 VALVE GUIDE ADJUSTER

33
2.3 SERVICE PROCEDURE
5. Cylinder Head

(5) Ream the inside of valve guide With ST. Gently


rotate the reamer clockwise While pressing it lightly
into valve guide, and return it also rotating
clockwise. After reaming, clean valve guide to
remove chips.
ST 399762104 VALVE GUIDE REAMER
CAUTION:
Apply engine oil to the reamer when reaming.
If the inner surface of the valve guide is worn, the
edge of the reamer should be slightly ground with
an oil stone.
If the inner surface of the valve guide becomes
lustrous and the reamer does not chip, use a new
reamer or remedy the reamer.

(6) Recheck the contact condition between valve


and valve seat after replacing valve guide.

4. VALVE STEM OIL SEAL


Check the inside of valve stem oil seal for Wear,
interference, crack, and being fallen free of spring.
Replace the valve stem oil seal by using ST.
ST 398852100 OIL SEAL INSTALLER
Valve stem height: H
Standard: IN: 13.0 mm (0.512 in)
EX: 10.8 mm (0.425 in)

5. INTAKE AND EXHAUST VALVE


1) Inspect the flange and stem of valve, and replace if
damaged, worn, or deformed, or if "H" is less than the
specified limit.
Valve head thickness: H
Intake:
Standard: 1.00 mm (0.0390 in)
Limit: 0.50 mm (0.0200 in)

34
SERVICE PROCEDURE 2.3
5. Cylinder Head

Exhaust: Catalyst model


Standard: 1.30 mm (0.0510 in)
Limit: 0.80 mm (0.0310 in)
Exhaust: Non-Catalyst model
Standard: 1.00 mm (0.0390 in)
Limit: 0.50 mm (0.0200 in)
2) Put a small amount of grinding compound on the
seat surface and lap the valve and seat surface.

6. CYLINDER HEAD
1) Check the gasket and gasketed surface for leakage
of combustion gas.
2) Check the cylinder head for crack or other damage.
CAUTION:
Do not scratch or nick the surface of cylinder
head. Gas leakage and other damages may result.
Do not scratch or nick the gasketed surface. Gas
leakage may result.
NOTE:
Remove carbon from combustion chamber.
Clean sealant of the mating surface by using scraper.

3) Check the flatness of gasketed surface by using a


straight-edge and thickness gauge. If the limit is
exceeded, regrind the surface.
Flatness of gasketed surface:
Limit: 0.05 mm (0.0020 in)
Allowance of gasketed surface regrinding:
Limit: 0.20 mm (0.0079 in)
Cylinder head height:
Standard: 100.0 mm (3.94 in)

35
2.3 SERVICE PROCEDURE
5. Cylinder Head

D: ASSEMBLY
1) Installation of valve spring and valve.
(1) Coat stem of each valve with engine oil and
insert valve into valve guide.
(2) Install valve spring and retainer.
CAUTION:
When inserting the valve into valve guide, use
special care not to damage the oil seal lip.
Be sure to install the vaIve springs with their
closecoiled end facing the seat on the cylinder
head.

(3) Compress valve spring and fit valve spring


retainer key by using ST1 and ST2.
ST1 899724100 VALVE SPRING PRESS ASSY
ST2 399722100 VALVE SPRING PRESS
(4) After installing, tap valve spring retainers lightly
with Wooden hammer for better seating.

2) Apply a coat of engine oil to camshaft journals install


camshaft at TDC.

3) Position rocker arms and rocker shaft springs then


insert the rocker shaft in position.
4) Install spring Washer, Washer, and snap ring each
end of the rocker shaft.

(1) Washer (4) Valve rocker arm


(2) Spring Washer (5) Rocker shaft spring
(3) Rocker shaft (6) valve rocker arm

36
SERVICE PROCEDURE 2.3
5. Cylinder Head

E: INSTALLATION
1) Install cylinder head gasket and cylinder head on
cylinder block.
CAUTION:
Clean the mating faces before installing the
cylinder head on the cylinder block.
Use a new cylinder head gasket.

2) Tighten cylinder head bolts.


CAUTION:
When tightening the cylinder head bolts, use the
following procedure according to the sequence of
the numbers in the diagram.
(1) Apply a coat of engine oil to Washers and bolt
threads.
(2) Tighten all bolts in two or three steps in the order
shown in Figure.
Tightening torque:
70 - 77 Nm (7.1 - 7.9 kg-m, 51 - 57 Mb)

3) Install distributor onto cylinder head.


Tightening torque:
14.2- 17.2 N m (1.45- 1.75 kg-m, 10.5- 12.7 Mb)

4) Install camshaft sprocket and tighten the bolt with ST.


ST 499205500 CRANK AND CAMSHAFT PULLE'
WRENCH
Tightening torque:
11.3 - 12.3 N m (1.15 - 1.25 kg-m, 8.3 - 9.0 Mb)

37
2.3 SERVICE PROCEDURE
5. Cylinder Head

5) Align the TDC marks on timing belt between timing


pointers and TDC indicators.

6) Install timing belt.


CAUTION:
If the tinning belt is reused, make sure that the belt
rotates in the same direction as before
disassembling.

7) First with the belt tensioner bolt loosened, then


secure the tensioner bolt.
Tightening torque:
18 - 22 N m (1.8 - 2.2 kg-m, 13 - 16 ft-lb)
8) Set and tighten tensioner in place. Check the belt
rotation and tension by driving crankshaft sprocket two
or three turns with ST.
ST 499205500 CRANK AND CAMSHAFT PULLEY
WRENCH

9) Turn the crankshaft and set the #1 cylinder at TDC of


compression stroke.
CAUTION:
Do not rotate crankshaft using the crankshaft bolt.
Use ST if required.
ST 498715410 CAM TIMING ADJUSTER Jl

38
SERVICE PROCEDURE 2.3
5. Cylinder Head

10) Adjust the valve clearance.


(1) Loosen locknut.
(2) Turn the adjusting screw to adjust the valve
clearance of #1 intake and exhaust valve to the
specification with the ST or a thickness gauge.
ST 498767000 VALVE CLEARANCE ADJUSTER Valve
clearance:
Intake: 0.13-0.17 mm (0.0051 0.0067 in)
Exhaust: 0.23 -0.27 mm (0.0091 0.0106 in)
(3) After adjusting the valve clearance, tighten lock-
nut.
Tightening torque:
17-23 Nm(1.7-2.3 kg-m, 12-17ft-lb)
CAUTION:
In this time, the valves that is marked "o" in the
table can be adjusted the valve clearance.

#1 cylinder #2 cylinder #3 cylinder


IN EX IN EX IN EX
o o o o

(4) Rotate crankshaft 360 and set the #1 cylinder at


the TDC of exhaust stroke.
(5) Adjust the valve clearance.
CAUTION:
In this time, the valves that is marked "o" in the
table can be adjusted the valve clearance.

#1 cylinder #2 cylinder #3 cylinder


IN EX IN EX IN EX
o o o o

11) Install valve rocker cover.


Tightening torque:
6.9 - 7.8 N m (0.7- 0.8 kg-m, 5.1 - 5.8 ft-lb)

39
2.3 SERVICE PROCEDURE
5. Cylinder Head

12) Install timing belt outside cover. a

13) Using ST, lock up crankshaft onto flywheel.


ST 498275600 FLYWHEEL STOPPER

14) Install crankshaft pulley.


15) Tighten crankshaft pulley bolt.
Tightening torque:
64 - 74 Nm (6.5 - 7.5 kg-m, 47- 54 ft-lb)

16) Install V-belt between crankshaft pulley and


generator pulley.
17) Check and adjust v-belt tension.
V-belt tension:
Reused: 11- 13 mm (0.43 0.51 in)
/ 98 N (10 kg, 22 lb)
Replaced: 9-11 mm (0.35 0.43 in)
/ 98 N (10 kg, 22 ib)
Tightening torque:
17.2-20.1 Nm (1.75-2.05kg-m, 12.7-14.8 ft-lb)

40
SERVICE PROCEDURE 2.3
5. Cylinder Head

6. Cylinder Block
A: DISASSEMBLY
1) Lock up crankshaft by using ST onto flywheel.
ST 498275600 FLYWHEEL STOPPER

2) Remove timing belt. <Ref. to 2-3 [W2A0]>


3) Remove cylinder head. <Ref. to 2-3 [W5A0]>

4) Remove clutch cover and clutch disc.


5) Remove flywheel.

6) Remove oil level gauge and level gauge guide.

7) Remove oil pan.


(1) Remove engine stand.
(2) Remove oil pan retaining bolts.
(3) Scrape off the fluid packing by inserting a oil-pan
cutter between oil pan-to-oil pan plate clearance to
disconnect oil pan and cylinder block (oil pan plate).
CAUTION:
Do not use a screwdriver or similar tool to scrape
off the fluid packing.

41
2.3 SERVICE PROCEDURE
6. Cylinder Block

8) Remove oil pan plate.

9) Remove oil strainer.

10) Remove Water pump cover, then remove water


pump impeller.
CAUTION:
When removing the water pump impeller, lock the
balancer shaft by inserting a screwdriver.

11) Remove oil filter and oil cooler.


12) Remove oil pump cover and pump rotor (inner and
outer).
13) Remove crankcase cover.
CAUTION:
Do not remove crankshaft and balance shaft oil
seals unless necessary.
Do not r
euse if it is removed.

14) Loosen connecting rod nuts to remove rod bearing


caps and shells.
CAUTION:
Arrange removed rod bearing caps and shells order
to prevent confusion.

42
SERVICE PROCEDURE 2.3
6. Cylinder Block

CAUTION:
To avoid damaging to crankshaft journal, install a
short piece of tube over the rod bolt thread as a
protector.

15) Remove pistons and connecting rods by pushing


out with suitable tool.
NOTE:
Put a number to the piston head to prevent
confusion.

16) Disassemble piston and connecting rod.


(1) Using a sharp-edged screwdriver, remove circlip
from piston.
(2) Push the piston pin out to disconnect piston and
connecting rod.
17) Remove piston rings (top, second, and oil ring).

18) Remove main bearings.


(1) Loosen main bearing cap bolts to remove main
bearing caps and lower bearings.
Remove rubber seals from the #4 main bearing cap.
(2) Detach lower thrust bearings from main bearing
center cap.
CAUTION:
Arrange removed main bearing caps, lower thrust
bearing and lower main bearings in order to prevent
confusion.

43
2.3 SERVICE PROCEDURE
6. Cylinder Block

19) Remove crankshaft from cylinder block.


20) Remove upper main bearings.
CAUTION:
Arrange removed upper main bearings in order to
prevent confusion.
Do not remove crankshaft rear oil seal unless
necessary.

21) Remove balancer chain and or pump sprocket.


22) Slightly pulls out the balancer shaft and remove
chain guide.

23) Remove balancer shaft.


CAUTION:
When removing the balancer shaft, use care not to
damage the bearings.

24) Set the crankshaft to a hydraulic press with ST.


ST 498517000 DRIVE PINION BEARING REPLACER
25) Press the end of the crankshaft and remove
crankshaft balancer chain sprocket.

26) Remove balancer shaft sprocket in the same


manner with crankshaft sprocket.
ST 498517000 DRIVE PINION BEARING REPLACER

44
SERVICE PROCEDURE 2.3
6. Cylinder Block

27) Remove balancer shaft bearing (front) With ST by


using a hydraulic press.
CAUTION:
Do not remove balancer shaft bearing unless
necessary.
SI 498835901 FRONT BALANCER METAL PRESS

28) Remove balancer shaft bearing 2 (rear).


CAUTION:
Do not remove balancer shaft bearing 2 unless
necessary.
(1) Remove the plug by tapping it from the rear side
of the cylinder block With an aluminum bar or similar
tool.
(2) Remove the balancer shaft bearing 2 With ST by
using a hydraulic press.
ST 498835801 REAR BALANCER METAL PRESS

B: INSPECTION
1. CYLINDER BLOCK
1) Clean the gasketed surface and the oil pump contact
surface.
CAUTION:
Do not scratch and nick the upper and lower
surfaces of cylinder block by using a sharp-edged
tool.
2) Remove carbon from cylinder bore.
CAUTION:
Do not scratch and nick the cylinder bore by using
a sharp-edged tool.
3) Visual inspection
(1) Check the cylinder block for crack and other
damage. Especially, check the oil pump and water
pump contact surfaces for crack and other damage.
(2) Check the oil passages for clogging.

45
2.3 SERVICE PROCEDURE
6. Cylinder Block

4) Flatness of gasket surface.


Cheek the gasket surface tor flatness by using straight-
edge and thickness gauge. If the limit exceeded,
correct the flatness.
Flatness of gasket surface:
Limit: 0.05 mm (0.0020 in)
Allowance of regrinding:
0.20 mm (0.0079 in)

5) Cylinder bore
Using a cylinder bore gauge, measure the cylinder bore
in axial and thrust directions at three points ((1) (2) (3)
in Figure.) If cylinder bore is Worn: the cylinder bore
diameter exceeds the specification, or measurement in
axial and thrust directions exceeds the taper limit on
out-of-roundness limit, perform reboring and horning to
the cylinder and use oversize piston.

(1) 8 mm (0.315 in) from top


(2) 43 mm (1.693 in) from top
(3) 78 mm (3.071 in) from top
(4) Axial direction
(5) Thrust direction

A. Top
B. Bottom
C. Exhaust port side
D. Crankshaft pulley side

46
SERVICE PROCEDURE 2.3
6. Cylinder Block

2. PISTON AND PISTON PIN


1) Remove carbon from piston head.
2) visually check the piston and pin for cracks, wear or
other damage. If the piston or pin is badly worn or
damaged, replace the piston or pin.
3) Measure the piston diameter at the height of 10.5
mm (0.413 in) from the piston skirt end by using a
micrometer.
Piston skirt standard outer diameter at 20C (68F)
Standard size:
77.950 - 77.974 mm (3.0689 - 3.0698 in)
Oversize;
0.5 mm (0.020 in);
78.450 - 78.474 mm (3.0886 - 3.0895 in)
1.0 mm (0.039 in);
78.950 - 78.974 mm (3.1083 - 3.1092 in)

4) Piston-to-cylinder clearance
Measure the cylinder bore diameter at the center of
cylinder and the piston diameter at the height of 10.5
mm (0.413 in) from the piston skirt end. The piston-to-
cylinder clearance is the difference between the
cylinder bore diameter and the piston diameter. If the
limit is exceeded, perform reboring and honing to the
cylinder and use oversize piston.
Piston-to-cylinder clearance:
Standard; 0.013 - 0.037 mm (0.0005 - 0.0015 in) Limit;
0.060 mm ( 0.0024 in)

5) Check the piston bore and its groove for burr. Repair
the piston bore such that the piston pin can be moved
by a finger push if defective.

47
2.3 SERVICE PROCEDURE
6. Cylinder Block

6) Check the piston pin-to-piston bore clearance. If the


limit is exceeded, replace the piston.
Piston pin-to-piston bore clearance at 20C (68F)
Standard; 0.004 - 0.008 mm (0.0002-0.0003 in)
Limit; 0.015 mm (0.0006 in)

7) Clean carbon from the piston ring grooves and check


the ring grooves for damage. Especially, make a visual
inspection to ascertain that no gas leakage has been
allowed.

3. PISTON RING
1) visual inspection
If piston ring is broken, damaged, or Worn, or if its
tension is insufficient, or When the piston is replaced,
replace piston ring With a new one of the same size as
the piston.
"R" or "2R" is marked on the end of the top and second
rings. When installing the rings to the piston, face this
mark upward.
CAUTION:
"R" or "2R" is marked on the end of the top and
second rings. When installing the rings to the
piston, face this mark upward.

48
SERVICE PROCEDURE 2.3
6. Cylinder Block

2) Ring groove clearance.


(1) Remove carbon from the piston ring groove and
piston ring.
(2) Measure the clearance between the ring groove
and the ring by using a thickness gauge. If the limit
is exceeded, replace the ring. If the limit is still
exceeded in spite of using a new ring, replace the
piston.
Ring groove clearance
Top ring:
Standard; 0.035-0.075 mm (0.0014-0.0030 in)
Limit; 0.15 mm (0.0059 in)
Second ring:
Standard; 0.025-0.065 mm (0.0010-0.0026 in)
Limit; 0.15 mm (0.0059 in)
Oil ring:
Standard; 0.010-0.037 mm (0.0004-0.0015 in)

3) Flush place piston ring in the top of cylinder bore to


measure the piston ring end gap with a thickness
gauge.
Piston ring end gap:
Top ring:
Standard; 0.20 - 0.35 mm (0.0079 - 0.0138 in)
Limit; 0.8 mm (0.0315 in)
Second ring:
Standard; 0.35 - 0.50 mm (0.0138 - 0.0197 in)
Limit; 0.8 mm (0.0315 in)
Oil ring:
Standard; 0.2 -0.7 mm (0.0079 - 0.0276 in)
Limit; 1.0 mm (0.0394 in)

4. CONNECTING BOD
1) Install connecting rod fitted with bearing to
crankshaft and measure the side clearance (thrust
clearance). Replace connecting rod if the side
clearance exceeds the limit.
Connecting rod side clearance:
Standard; 0.07- 0.30 mm (0.0028 - 0.0118 in)
Limit; 0.35 mm (0.0138 in)
2) Replace connecting rod, if the large or small end
thrust surface is damaged.

49
2.3 SERVICE PROCEDURE
6. Cylinder Block

3) Check for bend or twist using a connecting rod


aligner. Replace connecting rod if the bend or twist
exceeds the limit. .
Limit of bend or twist per 100 mm (3.94 in) in
length: 0.10 mm (0.0039 in)

4) Inspect connecting rod bearing for scar, peeling


seizure, melting, wear, etc.

5) Measure the rod bearing clearance on individual


connecting rod bearings by means of plastigauge.
(1) Before measuring the rod bearing clearance, clean
the bearing and the crankpin.
(2) Cut the plastigauge to the width of the bearing,
place it on the crankpin parallel with the crankshaft axis,
and install connecting rod.
Tightening torque:
39 - 45 N m (4.0 - 4.6 kg-m, 29 - 33 ft-lb)
CAUTION:
Do not turn the crankshaft with plastigauge
installed.

50
SERVICE PROCEDURE 2.3
6. Cylinder Block

(3) Remove connecting rod and measure the width of


the plastigauge with the scale printed on the
plastigauge case.
Connecting rod bearing clearance:
Standard; 0.019 - 0.053 mm (0.0007 0.0021 in) Limit;
0.065 mm (0.0026 in)
(4) If the rod bearing clearance exceeds the limit, use a
new standard size bearing and recheck the clearance.

(5) If the rod bearing clearance is not still within the


limit, regrind the crankpin and attempt to use a
undersize bearing to remeasure the clearance.

Bearing thickness Crankpin Outer diameter


1.487-1.491 mm 41.989-42.000 mm
Standard
(0.0585-0.0587 in) (1.6531-L6535 in)
0.05 mm
1.512-1.520 mm 41.939-41.950 mm
(0.0020 in)
(0.0595-0.0598 in) (1.6511-1.6516 in)
undersize
0.25 mm
1.612-1.620 mm 41.739-41.750 mm
(0.0098in)
(0.0635-0.0638 in) (1.6433-1.6437 in)
undersize

6) Check the connecting rod small end bore for wear or


other damage. Replace the connecting rod if required.
7) Connecting rod small end bore clearance. Measure
the clearance between the connecting rod small end
bore and the piston pin.
If the limit is exceeded, replace the connecting rod.
Connecting rod small end bore clearance:
Standard; 0.005 - 0.021 mm (0.0002 - 0.0008 in)

5. CRANKSHAFT
1) With crankshaft cleaned, check the crankshaft for
cracks or other damage.
2) Check crankshaft runout
Measure the runout at the crank journal center diameter
by using a dial gauge. If the limit is exceeded, replace
the crankshaft.
Crankshaft runout:
Limit: 0.030 mm (0.0012 in)

51
2.3 SERVICE PROCEDURE
6. Cylinder Block

3) Inspect the crank journal and crankpin for wear.If


not to specifications, replace bearing with an
undersize one, and replace or recondition crankshaft
as necessary. When grinding crank journal or
crankpin, finish them to the specified dimensions
according to the undersize bearing to be used.
Crankpin and crank journal:
Out-of-roundness:
0.030 mm (0.00120 in) or less
Taper limit:
0.020 mm (0.00080 in)
Allowance on regrinding limit:
0.25 mm (0.0098 in)

Unit: mm (in)

Crank journal Crankpin


41.974-41.985 41.989 42.000
Journal outer diameter
(1.6525 - 1.6529) (1.6531 - 1.6535)
Standard
Bearing size 1.505-1.517 1.487 1.491
(Thickness at center) (0.0593 - 0.0597) (0.0585 - 0.0587)
41.924 - 41.935 41.939 - 41.950
Journal outer diameter
0.05 mm (0.0020 in) (1.6505-1.6510) (1.6511 -1.6516)
undersize Bearing size 1.527 1.535 1.512-1.520
(Thickness at center) (0.0601 - 0.0604) (0.0595 - 0.0598)
41.724 41.735 41.739 41.750
Journal outer diameter
0.25 mm (0.0098 in) (1.6427-1.6431) (1.6433-1.6437)
undersize Bearing size 1.607 1.635 1.612-1.620
(Thickness at center) (0.0633 - 0.0644) (0.0635 - 0.0638)

4) Crankshaft-to-main bearing #4 Clearance-


Measure the clearance in axial direction of crankshaft
between the crankshaft end and the main bearing with
journal bearing caps installed.
Crankshaft end-side clearance:
Standard; 0.08 - 0.177 mm (0.0031 - 0.0070 in)
Limit; 0.30 mm (0.012 in)

52
SERVICE PROCEDURE 2.3
6. Cylinder Block

5) Check the main bearing for scar, peeling, seizure,


melting, and wear.
6) Measure the clearance on each crankshaft bearing
by using a plastigauge. If the limit is exceeded, replace
a new main bearing and remeasure the clearance. If
the measurement is still out of the specification, regrind
the crank journal and attempt to use a undersize
bearing to remeasure the clearance.
Main bearing clearance:
Standard: 0.014 - 0.037 mm (0.0006 - 0.0015 in)
Limit: 0.060 mm (0.0024 in)
CAUTION:
The undersize bearing clearances must be the
same as the above specification.

6. OIL PUMP SPROCKET


1) Check each portion of the oil pump sprocket for
damage and wear, and replace if it is faulty.
2) Measure the thrust clearance of the oil pump
sprocket. Replace the sprocket if any limit value is
exceeded.
Oil pump sprocket thrust clearance:
Standard: 0.05 - 0.25 mm (0.0020 - 0.0098 in)
Limit: 0.4 mm (0.016 in)
3) Check journals for wear or damage. If faulty, replace
the journal and sprocket as a unit.
Oil clearance:
Standard: 0.016 - 0.118 mm (0.0006 - 0.0046 in)
Limit: 0.15 mm (0.0059 in)
4) Check the journal of the oil pump sprocket shaft for
wear or damage. Repair or replace if it is faulty.
(1) When installing a new oil pump sprocket shaft,
align the hole in the shaft with that in the crankcase.
Press it until it is flush at point A as shown in Figure.

53
2.3 SERVICE PROCEDURE
6. Cylinder Block

(2) After installing the sprocket shaft, check the engine


oil flows to hole B When added through hole A.
(3) Ensure that engine oil does not run out of hole C.

54
SERVICE PROCEDURE 2.3
6. Cylinder Block

C: ASSEMBLY
1) Install balancer shaft bearing 2 (rear).
CAUTION:
When installing the bearing, ensure that the oil hole
of the bearing is properly aligned with the oil hole
of the crankcase.
(1) Install new balancer shaft bearing 2 with S'! 1
and ST2 by using a hydraulic press.
ST1 498835801 REAR BALANCER METAL PRESS
ST2 498835803 REAR BALANCER METAL SPACER
(2) Install plug by tapping it from the rear side of the
cylinder block with ST1.
ST 1 498835801 REAR BALANCER METAL PRESS

2) Install balancer shaft bearing (front) with ST by using


a hydraulic press.
ST 498835901 FRONT BALANCER METAL PRESS

3) Install crankshaft balancer chain sprocket with ST1


and ST2 by using a hydraulic press.
ST1 499715500 CRANKSHAFT REMOVER
ST2 499585400 CRANKSHAFT SPROCKET
INSTALLER
CAUTION:
Ensure the chain installation mark faces up before
pressing on the sprocket.

4) Install balancer shaft sprocket in the same manner


with the crankshaft sprocket by using ST2 and ST3.
ST2 499585400 CRANKSHAFT SPROCKET
INSTALLER
ST3 498517000 DRIVE PINION BEARING
REPLACER
CAUTION:
Ensure the chain installation mark faces up before
pressing on the sprocket.

55
2.3 SERVICE PROCEDURE
6. Cylinder Block

5) Install balancer shaft.


CAUTION:
Use care not to damage the bearings.

6) Install oil pump sprocket.


7) Temporarily install chain guide.

8) Install upper main bearings on cylinder block.


CAUTION:
Apply oil to the surface of bearings.

9) Install balancer chain on crankshaft sprocket and


balancer shaft sprocket.

10) Mount crankshaft to cylinder block so that the


alignment mark on the crankshaft sprocket is positioned
between the two gold-colored links.
11) Verify that the alignment marks on the sprockets are
positioned as shown in Figure.

56
SERVICE PROCEDURE 2.3
6. Cylinder Block

12) Install lower main bearings, thrust bearings and


bearing caps.
CAUTION:
Apply oil to the surface of bearings.
Be careful not to confuse the bearing contact sur-
faces.
Tightening torque:
Main bearing cap:
41 - 47 N m (4.2 - 4.8 kg-m, 30 - 35 ft-lb)

13) Install bearing cap seal. Apply sealant at the upper


part of the bearing cap seal and insert into the cylinder
block. Wipe off any excessive sealant after installing.
Sealant: THREE BOND #1105

14) Pull down the balancer chain at the arrow A


position, and press the chain guide until the guide
contacts the balancer chain at portion B.
15) Tighten chain guide bolts C and D.
Tightening torque:
6-7N m (0.6- 0.7kg-m, 4.3-5.1 ft-lb)

16) Assemble the connecting rod on the piston so that


"F" mark on the former and the arrow on the piston
head are positioned as shown in Figure.
CAUTION:
Apply oil to the piston, piston pin, and connecting
rod.

17) Install the piston pin and circlip to the piston and
connecting rod assembly.

57
2.3 SERVICE PROCEDURE
6. Cylinder Block

18) Installation of piston rings


(1) Install oil ring spacer, upper rail and lower rail in
this order by hand. Then, install second ring and top
ring with a piston ring expander.
(2) Position the gaps of the piston rings and oil ring
as shown in Figure.

19) Installation of piston and connecting rod.


(1) To avoid damaging to crankpin, install a piece of
tube to the connecting rod bolt thread as a pro-
tector.
(2) With special tool set, insert piston into cylinder
block by using ST.
NOTE:
Position each connecting rod with the side marked
"F" facing forward.

ST 498745500 PISTON GUIDE


CAUTION:
Be careful not to change the ring end gap
position.
Apply engine oil to the piston assembly.
Position each piston with the arrow on the piston
head facing forward.

20) Assembly of rod bearing cap


(1) Install rod bearing shell to rod bearing cap.
CAUTION:
Apply oil to the surface of bearing cap and shell.
(2) Connect rod bearing cap and connecting rod,
and tighten connecting rod bolt.
Tightening torque:
39 - 45 N m (4.0 - 4.6 kg-m, 29 - 33 ft-lb)
CAUTION:
Apply oil to the thread of connecting rod bolt.
21) Install rear oil seal to cylinder block by using ST.
CAUTION:
Do not reuse the oil seal, and be careful not to allow
oil seal lip turn inside out.
ST 498725500 OIL SEAL GUIDE
497725600 OIL SEAL GUIDE

58
SERVICE PROCEDURE 2.3
6. Cylinder Block

22) Install crankshaft front oil seal and balance shaft oil
seal.
CAUTION:
Do not reuse the oil seal, and be careful not to allow
oil seal lip turn inside out.

23) Install crankcase cover.

CAUTION:
Coincide the groove of the oil pump shaft.
Do not drop the O-ring for oil pump in mating
surface of crankcase cover and cylinder block.
Tightening torque:
14.2- 17.2 Nm(1.45- 1.75 kg-m, 12.7ft-ib)

24) Install oil pump rotor (inner and outer), and oil pump
cover.
25) Install oil cooler and oil filter.

26) Install water pump impeller into crankcase cover


and connect with the balancer shaft.
CAUTION:
Apply coolant to the end of the mechanical seal
and install the water pump impeller.
Insert the screwdriver, etc. into the gap between
balancer shaft weight and crankcase in order to fix
them when the impeller is tightened.
Refer to SEC. "ENGINE COOLING SYS." on the
measurement of tip-clearance.
Tightening torque:
9.3 - 10.3 N m (0.95 - 1.05 kg-m. 6.9 - 7.6 ft-Ib)

59
2.3 SERVICE PROCEDURE
6. Cylinder Block

27) Install Water pump cover. >

28) Install oil strainer.


Tightening torque:
6-8 Nm (0.6- 0.8kg-m, 4.3-5.8 ft-lb)

29) Apply fluid packing to the oil pan plate and install oil
pan plate to cylinder block.
Fluid packing: THREE BOND #1207C

30) Installation of oil pan.


(1) Apply fluid packing to oil pan as shown in Figure.
Fluid packing: THREE BOND #12070

(2) Install oil pan to cylinder block, and tighten oil


pan retaining bolts.
Tightening torque:
4.4 - 5.4 N m (0.45 - 0.55 kg-m, 3.3 - 4.0 ft-lb)

60
SERVICE PROCEDURE 2.3
6. Cylinder Block

31) Install engine to the engine stand.


ST 499815500 ENGINE STAND
32) Install oil level gauge guide and level gauge.

33) Install plate and flywheel onto cylinder block.


34) Set ST to lock up crankshaft.
ST 498275600 FLYWHEEL STOPPER

35) Tighten flywheel retaining bolts.


Tightening torque:
64 - 73 Nm (6.5 - 7.5 kg-m, 47 - 54 ft-lb)

36) Install clutch disc and clutch cover by using ST.


Tightening torque:
9.1 - 10.6 N m (0.93 - 1.08 kg-m, 6.7- 7.8 ft-lb)
ST 499745500 CLUTCH DISC GUIDE

37) Install cylinder head assembly, intake manifold,


exhaust manifold and valve rocker cover.
<Ref. to 2-3 [W5E0]>
38) Install timing belt.
<Ref. to 2-3 [W2C0]>

61
2.3 TROUBLESHOOTING
1. Engine Trouble in General

1. Engine Trouble in General

TROUBLE Priority of checking is in numerical order.


Engine Will not
start.
acceleration.Low output, hesitation and poor
Engine stalls after initial combustion

Excessive engine oil consumption.


Initial combustion does not occur.

Afterburning in exhaust system.


Engine does not return to idle.

Excessive fuel consumption.


Rough idle and engine stall.
Initial combustion Occurs.
Starter does not turn.

Dieseling (Run-on).

Knocking
Surging

1 2 3 4 5 6 7 8 9 10 11 12 13 POSSIBLE CAUSE '


STARTER '
2 Defective battery-to-starter harness.
3 Defective starter switch.
3 Defective inhibitor switch.
2 3 Defective starter.
BATTERY
1 1 Poor terminal connection.
1 Run-down battery.
2 Defective charging system.
1 1 1 1 1 1 1 1 1 1 1 1 ENGINE CONTROL SYSTEM
i IGNITION SYSTEM
2 2 2 1 1 1 1 1 1 1 1 Incorrect ignition system.
2 1 I 2 2 2 3 3 Disconnection of spark plug cord.
2 3 1 2 2 1 2 Defective distributor.
2 3 2 2 1 Defective ignition coil.
2 3 3 3 Defective cord or Wiring.
2 2 3 2 3 2 Leaking Of spark plug cord.
2 2 2 2 1 Defective spark plug.
2 2 2 1 2 1 3 2 2 Incorrect cam timing.
1 2 3 4 5 6 7 8 9 10 11 12 13

62
TROUBLESHOOTING 2.3
1. Engine Trouble in General

TROUBLE No.
POSSIBLE CAUSE
1 2 3 4 5 6 7 8 9 10 11 12 13
INTAKE SYSTEM
2 2 1 2 2 1 2 2 1 Improper idle adjustment.
3 1 1 1 3 1 1 Loosened or cracked blow-by hose.
3 1 2 1 1 2 1 Loosened or cracked vacuum hose.
2 2 2 2 2 1 Defective intake manifold gasket.
3 2 2 2 2 2 Defective PCV valve.
2 2 2 3 2 3 Loosened oil filler cap.
3 3 1 2 2 1 Dirty air cleaner element.
FUEL LINE
2 3 2 2 Defective fuel pump.
3 3 2 2 Clogged fuel line.
2 2 2 2 3 3 Lack of or insufficient fuel.
BELT
2 2 2 Defective.
2 2 2 3 2 2 2 2 2 Defective timing.
FRICTION
3 Seizure of crankshaft and connecting rod bearing.
3 Seized camshaft.
3 Seized or stuck piston and cylinder.
COMPRESSION
3 3 3 2 2 2 2 3 2 Incorrect valve clearance.
3 3 3 2 2 3 3 3 Loosened spark plugs or defective gasket.
3 3 3 2 2 3 3 3 Loosened cylinder head bolts or defective gasket.
3 3 3 2 2 3 2 2 Improper valve seating
3 3 3 3 3 3 3 1 3 Defective valve stem.
2 2 2 2 2 2 3 3 Worn or broken valve spring.
3 3 3 2 3 3 3 1 2 Worn or stuck piston rings, cylinder and piston.
2 2 2 1 1 1 1 2 2 Incorrect valve timing.
2 2 2 2 2 2 Improper engine oil (low viscosity).
1 2 3 4 5 6 7 8 9 10 11 12 13

63
2.3 TROUBLESHOOTING
1. Engine Trouble in General

TROUBLE No.
POSSIBLE CAUSE
1 2 3 4 5 6 7 8 9 10 11 12 13
LUBRICATION SYSTEM
2 2 3 3 Incorrect oil pressure.
2 Loosened oil pump attaching bolts.
2 Defective oil filter seal.
2 Defective crankshaft oil seal.
2 Defective rocker cover gasket.
2 Loosened oil drain plug.
2 Loosened oil pan bolts or defective oil pan.
COOLING SYSTEM
3 3 2 2 1 Overheating.
3 3 3 Over cooling.
OTHERS
Malfunction of Evaporative Emission Control System.
1 1 3 3
<Ref. to 2- 7>
2 1 Stuck or damaged throttle valve.
3 2 2 2 Accelerator cable out of adjustment.
1 2 3 4 5 6 7 8 9 10 11 12 13

64
TROUBLESHOOTING 2.3
2. Engine Noise

2. Engine Noise

Type of sound Condition Possible cause


Worn valve rocker.
Sound increases as engine
Regular clicking sound. Worn camshaft.
speed increases.
Broken valve spring.
Worn crankshaft main bearing.
Oil pressure is low.
Worn connecting rod bearing (big end).
Heavy and dull metallic knock.
Loose flywheel mounting bolts.
Oil pressure is normal.
Damaged engine mounting.
Ignition timing advanced. I
Accumulation of carbon inside combustion
High-pitched metallic knock. Sound is noticeable when
chamber.
(Engine knocking) accelerating with and overload.
Wrong spark plug.
Improper gasoline.
Metallic knock when engine Sound is reduced when spark Worn crankshaft main bearing I
speed Is medium (1,000 to plug in noisy cylinder is Worn bearing at crankshaft end of connecting
2,000 rprn). shortened out. rod.
Worn cylinder bore and piston ring.
Sound is reduced when spark
Broken or stuck piston ring.
plug in noisy cylinder is
Knocking sound when engine shortened out. Worn piston pin and hole at piston end of
is operating under idling speed connecting rod.
and engine is warm. Sound is not reduced if each
spark plug is shortened out in Worn camshaft journal bore in crankcase.
turn.
Squeaky sound. Insufficient alternator lubrication. I
Rubbing sound. Defective alternator brush and rotor contact.
Gear scream when starting Defective ignition starter switch.
engine Worn gear and starter pinion.
Sound like polishing glass with Loose timing belt.
a dry cloth. Defective water pump shaft.
Loss of compression.
Hissing sound. Air leakage in air intake system, hoses,
connections or manifolds.
Loose timing belt.
Timing belt noise.
Belt contacting case/adjacent part.

65
2.4 ENGINE LUBRICATION SYSTEM
Page
S SPECIFICATION AND SERVICE DATA...................................................................................2
1. Engine Lubrication System..................................................................................................2
C COMPONENT PARTS............................................................................................................. 3
1. Oil Pan and Oil Strainer.......................................................................................................3
2. Oil Pump............................................................................................................................. 4
W SERVICE PROCEDURE......................................................................................................... 5
1. Oil Pan and Oil Strainer.......................................................................................................5
2. Oil Pump............................................................................................................................. 7
3. Oil Cooler.......................................................................................................................... 10
4. Oil Pressure Switch........................................................................................................... 11
T TROUBLESHOOTING........................................................................................................... 12
1. Engine Lubrication System................................................................................................12
2.4 SPECIFICATION AND SERVICE DATA
1. Engine Lubrication System

1. Engine Lubrication System


A: SPECIFICATIONS

Forced lubrication
Lubrication method
Pump type Trochoid type
Inner rotor 4
Number of teeth Number
Outer rotor 5
Outer rotor diameter x thickness 40.56 x 14.7 mm (1.597 x 0.579
Oil pump - pressure 167 kPa (1.7 kg/cm*, 24 psi)
1,500 rpm Discharge
Capacity - quantity 6.7 L (7.1 US qt, 5.9 Imp qt)/min.
80C (176F) - pressure 324 kPa (3.3 kg/cm2, 47 psi)
3,000 rpm Discharge
- quantity 11 L (H.6 US gal, 9.7 Imp gal)/min.
Relief valve operation pressure I 294.2-318.7 kPa (3.0-3.25 kg/cm2, 42.7-46.2 psi)
Type Full-flow filter type
Filtration area 800 cm2 (124.0 sq in)

Oil filter By-pass valve Opening pressure 78.5 - 117.7 kPa (0.8 - 1.2 kg/cm2, 11.4-17.1 psi)
Outer diameter x width 68 x 65 mm (2.7 x 2.6 in)
Oil filter to engine thread size M 20 x 1,5p
Type Immersed contact point type
Working voltage Wattage 12 V - 3.4 W or less
Oil pressure
switch Warning light activation pressure 14.7 - 24.5 kPa (0.15 - 0.25 kg/cm2, 2.1 - 3.6 psi)
Proof pressure More than 981 kPa (10 kg/cm2,142 psi)
Oil capacity (at replacement) 3.5 L (3.7 US qt, 3.1 Imp qt)

B: SERVICE DATA
STD 0.02 - 0.12 mm (0.0008 - 0.0047 in)
Tip clearance between inner and outer rotor
LIM 0.2 mm (0.008 in)
Side clearance between inner rotor and crankcase STD 0.05 - 0.16 mm (0.002 - 0.0063 in)
cover LIM 0.18 mm (0.0071 in)
Case radial clearance between outer rotor and STD 0.15 - 0.21 mm (0.0059 - 0.0083 in)
crankcase cover LIM 0.25 mm (0.01 in)

ST: STANDARD
LIM : LIMIT

2
COMPONENT PARTS 2.4
1. Oil Pan and Oil
Strainer

1. Oil Pan and Oil Strainer

(1) Oil pan pIate


(2) Oil pan
(3) Oil strainer
(4) O-ring

3
2.4 COMPONENT PARTS
2. Oil Pump

2. Oil Pump

(1) Oil IeveI gauge (7) Oil pump cover (13) O-ring
(2) Oil level gauge guide (8) Gasket (14) Gasket
(3) O-ring (9) Oil pump outer rotor
(4) OiI filter (10) Oil pump inner rotor
(5) OiI cooler (11) Crankcase cover
(6) Gasket (12) OiI pump drive gear

4
SERVICE PROCEDURE 2.4
2. Oil Pump

1. Oil Pan and Oil Strainer


A: REMOVAL
1) Lift up the vehicle.
2) Remove drain plug and drain engine into container.
CAUTION:
Replace washer with a new one.

3) Remove diagonal member with rear under cover.


4) Separate right side rear axle shaft by using ST.
ST 28099PA100 DRIVE SHAFT REMOVER

5) Remove flywheel housing cover.

6) Remove oil pan from cylinder block.


CAUTION:
Set container under the oil pan.

7) Remove oil strainer.


CAUTION:
Replace O-ring with a new one.

5
2.4 SERVICE PROCEDURE
1. Oil Pan and Oil Strainer

8) Remove oil pan plate.

B: INSPECTION
Make sure not to damage oil pan and oil strainer by
visual check.

C: INSTALLATION
CAUTION:
Before installing oil pan, clean sealant from oil pan,
oil pan plate and engine block.
1) Apply fluid packing to mating surfaces of oil pan
plate.
Fluid packing:
THREE BOND 1207C
2) Install oil pan plate to cylinder block.

3) Install oil strainer onto cylinder block.


CAUTION:
Always use a new O-ring.
Tightening torque:
5.9 - 6.9 N m (0.6 - 0.7kg-m, 4.4 -5.1 ft-lb)

4) Apply fluid packing to mating surfaces of oil pan.

6
SERVICE PROCEDURE 2.4
1. Oil Pan and Oil Strainer

5) Install oil pan and tighten bolts Which install oil pan
onto engine block.
Tightening torque:
4.4 - 5.4 Nm (0.45 - 0.55 kg-m, 3.3 - 4.4 Mb)

6) Install flywheel cover.


Tightening torque:
5.9 - 6.9 N m (0.6 0.7kg-m, 4.4 5.1 ft-lb)

7) Install right rear axle shaft to transmission.


8) Install diagonal member with rear under cover.

2. Oil Pump
A: REMOVAL
1) Open rear gate and rear bumper.
2) Removal oil level gauge and oil level gauge guide.

3) Loosen alternator installing bolt, and remove v-belt.

7
2.4 SERVICE PROCEDURE
2. Oil Pump

4) Lift up the vehicle.


5) Drain engine oil into container.
CAUTION:
Replace aluminium gasket with a new one.

6) Remove engine room coner.


7) Remove crankshaft pulley by using ST.
ST 498715410 CAM TIMING ADJUSTING PLATE

8) Remove oil filter and oil cooler.

9) Remove oil pump cover.

10) Remove oil pump outer rotor and inner rotor.

8
SERVICE PROCEDURE 2.4
2. Oil Pump

B: INSPECTION
1. OIL PUMP SHAFT
Check oil pump shaft damage and wear.

2. OIL PUMP OUTER ROTOR AND INNER ROTOR


Check each rotor for damage and wear.
NOTE:
The inner rotor can be replaced by removing shaft pin.
Outer diameter:
Inner rotor:
29.70 - 29.74 mm (1.1693 - 1.1709 in)
Outer rotor:
40.53 - 40.56 mm (1.5957- 1.5968 in)

C: INSTALLATION
1) Install oil pump outer rotor and inner rotor.

2) Install oil pump cover.

3) Install oil cooler and oil filter.


Tightening torque:
22 - 27 N m (2.2 - 2.8 kg-m, 16 - 20 ft-lb)

9
2.4 SERVICE PROCEDURE
2. Oil Pump

4) Install crankshaft pulley by using ST.


ST 498715410 CAM TIMING ADJUSTER PLATE
CAUTION:
Install a washer as shown in figure. Be careful
about its installation direction.
Tightening torque:
65 - 75 N m (6.5 - 7.5 kg-m, 47 - 55 ft-lb)
5) Install engine room cover.

6) Install alternator v-belt and adjust its tension.


<Ref. to 1-5 [01A0]>
7) install oil level gauge guide and oil level gauge.
Be sure the timing belt is in the proper direction.
Do not reverse the rotating direction of belt.
This causes tooth skipping and damaging.

3. Oil Cooler
A: REMOVAL AND INSTALLATION
1) Open rear gate and rear bumper.
2) Remove oil level gauge and oil level gauge guide,
3) Loosen alternator installing bolt, and remove V-belt

4) Lift up the vehicle.


5) Remove rear right wheel.
6) Remove engine room cover.
7) Remove crankshaft pulley by using ST.
ST 498715410 CAM TIMING ADJUSTING PLATE

8) Remove oil filter.


9) Remove nut which install oil cooler.

10
SERVICE PROCEDURE 2.4
3. Oil Cooler

10) Disconnect oil cooler inlet and outlet hoses.

11) Installation is in the reverse order of removal


procedure.
Tightening torque:
22 - 27 Nm (2.2 - 2.8 kg-m, 16 - 20 ft-lb)

4. Oil Pressure Switch


A:REPLACEMENT
1) Lift up the vehicle.
2) Disconnect connector from oil pressure switch.

3) Remove oil pressure switch.


CAUTION:
Plug the oil pressure switch hole.

4) Installation is in the reverse order of removal.


CAUTION:
Before installing oil pressure switch, apply fluid
packing onto screw.
Tightening torque:
17-23 N m (1.7- 2.3 kg-m, 12 - 17 ft-lb)

11
2.4 TROUBLESHOOTING
1. Engine Lubrication
System

1. Engine Lubrication System


Before troubleshooting, make sure that the engine level

Trouble Possible cause corrective action


Cracked diaphragm or oil leakage within
1) Oil pressure switch switch Replace.
failure
Broken spring or seized contacts Replace.
clogged oil filter Replace.
Malfunction of oil by-pass valve of oil filter Clean or replace.
Malfunction of oil relief valve of oil pump Clean or replace.
Warning light remains 2) Low oil pressure
Clogged oil passage Clean.
on.
Excessive tip clearance and side clearance
Replace.
of oil pump rotors
Clogged oil strainer or broken pipe Clean or replace
Insufficient engine oil | Replenish.
3) No oil pressure Broken pipe of oil strainer Replace.
Stuck oil pump rotor I Replace.
1) Burn-out bulb Replace.
Warning light does not
2) Poor contact of switch contact points I Replace.
go on.
3) Disconnection of wiring Repair.
1) Poor contact at terminals Repair.
2) Defective wiring harness Repair.
Warning light flickers
momentarily. Check for the same
3) Low oil pressure possible causes as
listed in 1 .-2)

12
2.5 ENGINE COOLING SYSTEM
Page
S SPECIFICATIONS AND SERVICE DATA................................................................................2
1. Engine Cooling System.......................................................................................................2
C COMPONENT PARTS............................................................................................................. 2
1. Water Pump........................................................................................................................ 4
2. Thermostat.......................................................................................................................... 5
3. Radiator............................................................................................................................... 6
4. Cooling System...................................................................................................................7
W SERVICE PROCEDURE......................................................................................................... 2
1. Precaution........................................................................................................................... 8
2. Water Pump...................................................................................................................... 10
3. Thermostat........................................................................................................................ 17
4. Radiator............................................................................................................................. 18
T TROUBLESHOOTING........................................................................................................... 20
1. Engine Cooling System.....................................................................................................20
2.5 SPECIFICATION AND SERVICE DATA
1. Engine Cooling System

1. Engine Cooling System


A: SPECIFICATIONS

Cooling system Electric fan + Forced circulation water-cooled type


Type Centrifugal type
Discharge 1000 rpm Discharge rate 8 L /min (8.7 US qt/min, 7.0 Imp qt/min)
performance
(Water 4000 rpm Discharge rate 37 L /min (9.8 US qt/min, 8.1 Imp qt/min)
Water pump temperature)
Water temperature 85C (185F) '
Impeller Diameter x number of vanes 62 mm (2.4 in) x 8 " ~
Pulley ratio 1.00 ^
Type Wax pellet type
Operation Starts to open 85C (185F)
Thermostat
temperature Fully opens 100C (212F)
Valve lift 8 mm (0.3 in)
7,9 L (8.4 US qt, 6.9 Imp qt)
Total coolant capacity *
7.9 8.1 L (8.6 US qt, 7.1 Imp qt)**
Type Down flow, pressure type
Radiation capacity 30 KW/h (26,100 kcal/h, 103,565 BTU/h) '
Core dimensions
383 x 350 x 16 mm (15.1 x 13.8 x 0.63 in)
(width x height x thickness)
Radiator Fin type Corrugated fin type
Coolant capacity 0.9 t (0.95 US pt, 0.79 Imp pt)
Cap valve | 73.6 - 103 kPa (0.75 - 1.05 kg/cm2, 10.7 - 14.9
Positive pressure side
opening psi)
pressure Negative pressure side 4.90 kPa (0.05 kg/cm2, 0.71 psi)
Motor 120W
Radiator fan
Diameter 320 mm (12.6 in)
motor Fan
Number of blades 5
Radiator fan operating temperature ON : 93C (199F), OFF : 89C (192F)
Full level: 0.35 L (0.74 US pt, 0.61 Imp pt)
Reservoir tank Capacity
Total: 1.0 L (1.05 US pt, 0.88 Imp pt)

* : Include reservoir tank


** : With rear heater model

2
SPECIFICATION AND SERVICE DATA 2.5
1. Engine Cooling System

B: MAINTENANCE STANDARDS
Water pump Standard 0.3 0.9 mm (0.012 0.035 in)
Clearance between impeller and case
Limit 1.1 mm (0.043 in)
"Thrust" runout of impeller end 0.5 mm (0.020 in)

C: RECOMMENDED COOLANT
SUBARU Lowest anticipated atmospheric tempera-
Above -30C (-22 F) Above -10C (-14F)
Genuine ture
Coolant SUBARU coolant-to-water* ratio
Part No. 50% - 50% 30% - 70%
(Volume)
000016218
net 18 L Specific gravity at 10C (50F) 1.078 1.047
(4.8 US gal, at 20C (68 F) 1.074 1.044
4.0 Imp gal) at 30C (86 F) 1.069 1.041
at 40C (104 F) 1.063 1.036
at 50C (122F) 1.057 1.031
Freezing point -36C (-33F) -16C (-3F)
*: It is recommended that distilled water be used.

3
2.5 COMPONENT PARTS
1. Water Pump

1. Water Pump

(1) Balancer shaft (7) Plate


(2) Gasket (8) Impeller
(3) Oil seal (9) Gasket
(4) Crankcase cover (10) Water pump cover
(5) Mechanical seal (11) o-ring
(6) Ceramic plate

4
COMPONENT PARTS 2.5
2. Thermostat

2. Thermostat

(1) Thermostat Cover (5) Engine coolant temperature sensor


(2) Gasket (6) Gasket
(3) Thermostat (7) Thermo gauge
(4) Gasket (8) Thermostat case

5
2.5 COMPONENT PARTS
3. Radiator

3. Radiator

(1) Spacer (8) Radiator fan motor


(2) Cushion rubber (9) Radiator outlet hose
(3) Radiator mounting bracket LH (10) Lower mounting bracket RH
(4) Clamp (11) O-ring
(5) Radiator inlet hose (12) Drain cock
(6) Radiator fan (13) Lower mounting bracket LH
(7) Radiator fan shroud (14) Lower cushion rubber

6
COMPONENT PARTS 2.5
4. Cooling System

4. Cooling System

(1) Coolant filler pipe (9) Radiator inlet pipe (17)Air vent hose B
(2) Coolant filler cap (10) Radiator outlet pipe (18) Rear heater hose A
(3) coolant filler hose (11) Heater pipe (19) Rear heater hose B
(4) Air breather hose A (12) Engine inlet hose (20) Heater hose A
(5) Air breather hose B (13) Engine outlet hose (21) Heater hose B
(6) Reservoir tank hose (14) Heater hose (22) Heater inlet hose
(7) Reservoir tank (15) Air vent plug (23)Heater outlet hose
(8) Air breather pipe (16) Air vent hose A

7
2.5 SERVICE PROCEDURE
4. Cooling System

1. Precaution
A: DRAINING OF COOLANT
WARING:
The radiator is of the pressurized type, do not
attempt to open the radiator cap immediately after
the engine has been stopped.
1) Set heater lever to FULL.
2) Lift up the vehicle.
3) Fit vinyl tube to drain pipe on radiator.
4) Loosen drain cock, and drain coolant into container.
5) After draining coolant, tighten drain cock.

6) Disconnect radiator inlet hose and heater hose, and


drain coolant into container.
7) After draining coolant, reconnect the hoses.
(1) Radiator outlet hose
(2) Heater hose
(3) Radiator inlet hose
(4) Radiator assembly

8) Disconnect filler hose from coolant reservoir tank,


and drain coolant into container.
9) After draining coolant, reconnect the hose.

B: FILLING OF COOLANT
1) Remove spare tire.
2) Remove air vent plug from air vent hose.

8
SERVICE PROCEDURE 2.5
1. Precaution

3) Fill coolant to upper level of reservoir tank.

4) Slowly fill coolant through filler opening.

5) If draining coolant from air vent hose, install air vent


plug.
6) After installing air vent plug, fill coolant to level of
filler neck.
Coolant Capacity (FULL level)
with rear heater:
Approx. 8.1 L (8.6 US qt, 7.1 Imp qt)
without rear heater:
Approx. 7.9 L (8.4 US qt, 6.9 Imp qt)

CAUTION:
The SUBARU Genuine Coolant containing
antifreeze and-rust agents is especially made for
SUBARU engine, which has an aluminum
crankcase. Always use SUBARU Genuine Coolant,
since other coolant may cause corrosion.

7) Securely install coolant filler cap.


8) Run engine for more five minutes at idling.
9) Stop engine and wait until coolant temperature
lowers. Then open coolant filler cap to check coolant
level. If necessary, add coolant up to filler neck.
10) Check coolant level of coolant reservoir tank. If
necessary, and coolant up to upper level of it.
11) After adding coolant, securely install coolant filler
cap and coolant reservoir tank cap.

9
2.5 SERVICE PROCEDURE
1. Precaution

2. Water Pump
A: REMOVAL
1) Open rear gate and rear bumper.
2) Remove oil level gauge and oil level gauge guide.

3) Loosen alternator installing bolt, and remove V-belt.

4) Lift up the vehicle.


5) Fit vinyl tube to drain cock.
6) Loosen drain cock and drain coolant into container.

7) Drain engine oil into container.


CAUTION:
Replace aluminium gasket with a new one.

8) Remove diagonalmember With rear under cove


9) Separate rear right axle shaft by using ST.
ST 28099PA 100 DRIVE SHAFT REMOVER

10
SERVICE PROCEDURE 2.5
2. Water Pump

CAUTION:
Hold drive shaft onto transverse link with wire, etc.

10) Remove flywheel housing cover.


11) Remove oil pan from cylinder block.
CAUTION:
Set container under the oil pan.

12) Remove oil strainer.


CAUTION:
Replace O-ring with a new one.
13) Remove oil pan plate.

14) Remove engine room cover.


15) Remove crankshaft pulley by using ST.
ST 498715410 CAM TIMING ADJUSTING PLATE

16) Disconnect connector from oxygen sensor.


17) Remove timing belt outside cover.

11
2.5 SERVICE PROCEDURE
2. Water Pump

18) Loosen tensioner holding bolt and timing belt

19) Remove crankshaft sprocket.

20) Remove oil filter and oil cooler.

21) Remove Water pump cover.

22) Remove Water pump impeller While holding


balancer shaft by inserting a screwdriver.

12
SERVICE PROCEDURE 2.5
2. Water Pump

B: DISASSEMBLY
1) Remove crankcase cover.
2) Remove mechanical seal.
(1) Press mechanical seal by using ST1.
ST1 498835400 MECHANICAL SEAL PRESS
(2) Set ST3 onto water pump side of crankcase
cover.
(3) Pull out mechanical seal by using ST2.
ST2 499715400 MECHANICAL SLAL REMOVER
ST3 499685510 MECHANICAL SEAL REMOVER
PLATE

C: INSPECTION
Check all removed parts, and replace if defective.
1) Check water pump impeller and ceramic seal for
cracks.
2) Check the contact surface of mechanical seal and
ceramic seal for wear and damage.
3) Check water pump impeller for corrosion or damage.
4) Check oil seal lip for wear, damage or hardening.
5) Check all other parts for crack, wear or damage.

D: ASSEMBLY
1) Install mechanical seal.
Press mechanical seal into crankcase cover by using
ST1 and ST2.
ST1 498835400 MECHANICAL SEAL PRESS
ST2 499795400 MECHANICAL SEAL INSTALLER

13
2.5 SERVICE PROCEDURE
2. Water Pump

2) Install crankcase cover to cylinder block.


CAUTION:
Always using a new gasket.
Tightening torque:
14.2 - 17.2 Nm (1.45 - 1.75 kg-m, 10.5-12.7 ft-lb)

E: INSTALLATION
1) Manually press Water pump impeller to balance
shaft, and measure the tip clearance. \
CAUTION:
When installing new water pump impeller add one
or two spacers and measure tip clearance
Standard:
0.3 - 0.9 mm (0.012 - 0.035 in)
Service limit:
1.1 mm (0.043 in)

2) Install water pump impeller.


Tightening torque:
9.3 - 10.3 N m (0.95 - 1.05 kg-m, 6.9 - 7.6 ft-lb)

3) Install water pump cover.


CAUTION:
Always using a new gasket.
Tightening torque:
8 mm bolt:
14.2- 17.2 N m 1.45-1.75 kg-m, 10.5-12.7 ft-lb)
6 mm bolt:
6-7 Nm (0.6 -0.7 kg-m, 4.3 - 5.1 ft-lb)

14
SERVICE PROCEDURE 2.5
2. Water Pump

4) Install oil cooler and oil filter.


Tightening torque:
22 - 27 Nm (2.2 - 2.8 kg-m, 16 - 20 ft-lb)

5) Install oil pan.


CAUTION:
Before installing oil pan, clean fluid packing
from oil pan, oil pan plate and cylinder block.
(1) Apply fluid packing to mating surfaces of oil pan
plate and oil pan.
Fluid packing:
THREE BOND 1207C
(2) Install oil pan plate and oil strainer
CAUTION:
Always use a new O-ring.
Tightening torque:
4.4 7.0 Nm (0.45- 0.7kg-m, 3.3-5.1 ft-lb)

(3) Install oil pan.


Tightening torque:
4.4 - 5.4 N m (0.45 - 0.55 kg-m, 3.3 - 4.4 ft-lb)

(4) Install flywheel cover.


Tightening torque:
6-7 Nm (0.6 -0.7kg-m, 4.3 -5.1 ft-lb)

15
2.5 SERVICE PROCEDURE
2. Water Pump

6) Install rear right drive shaft.


7) Install diagonalmember With rear under cover.

8) Install crankshaft sprocket.

9) Install timing belt.


(1) Align the TDC marks between timing pointer and
TDC indicators.
CAUTION:
Be sure the timing belt is in the proper direction.
Do not reverse the rotating direction of belt..
This causes tooth skipping and damaging.

(2) Set belt tensioner and tighten retainer bolts.


(3) Install timing belt.
(4) First loosen belt tensioner bolts, then select the
tensioner bolts to specified torque.
Tightening torque:
18 - 22 N m (1.8 - 2.2 kg-m, 13 - 16 ft-lb)

16
SERVICE PROCEDURE 2.5
2. Water Pump

11) After setting crankshaft drive plate, install timing belt


outside cover.
CAUTION:
Install crankshaft drive plate as shown in figure.

12) Install crankshaft pulley by using ST.


ST 498715410 CAM TIMING ADJUSTER PLATE
13) Install engine room cover.
CAUTION:
Install a washer as shown in figure. Be careful
about its installation direction.
Tightening torque:
65 - 75 Nm (6.5 - 7.5 kg-m, 47 - 54 ft-lb)

CAUTION:
Install a washer as shown in figure. Be careful
about its installation direction.
Tightening torque:
65 -75 Nm (6.5 -7.5 kg-m, 47-54 ft-lb)

14) Install alternator V-belt and adjust its tension. <Ref.


to 1-5 [01 A0]>
15) Install oil level gauge guide and oil level gauge.

3. Thermostat
A: REMOVAL AND INSTALLATION
1) Disconnect Water hoses from thermostat cover

17
2.5 SERVICE PROCEDURE
3. Thermostat

2) Remove thermostat cover and thermostat.

3) installation is in the reverse order of remove


procedure.
Tightening torque:
14.2- 17.2 Nm (1.45- 1.75 kg-m, 10.5-12.7 ft-lb)
CAUTION:
Always using a new gasket.
(1) Thermostat cover
(2) Gasket
(3) Thermostat

4. Radiator
A: REMOVAL
1) Lift up the vehicle.
2) Attach vinyl tube to drain cock.
3) Loosen drain cock and drain coolant into container.

4) Remove propeller shaft.


<Ref. to 3-4>

18
SERVICE PROCEDURE 2.5
4. Radiator

5) Remove front differential assembly.


<Ref. to 3-4>

6) Disconnect radiator inlet hose (3) and outlet hose


(1).

7) Disconnect radiator fan motor connector.

8) Remove bolts which install radiator assembly onto


frame.
9) Remove radiator assembly.

B: INSTALLATION
Installation is in the reverse order of removal procedure.

19
2.5 TROUBLESHOOTING
1. Engine Cooling System

1. Engine Cooling System


Trouble Probable cause Remedy
Over a. Short of coolant Repair leakage points, then refill coolant.
heating b. Defective thermostat Replace.
c. Defective Water pump Repair or replace.
d. Clogged coolant passages Clean.
e. Improper ignition timing Adjust ignition timing or check advance mechanism.
f. Clogged radiator or coolant leakage Clean, repair or replace. 1
g. Deteriorated engine oil Replace.
h. Lean air-fuel ratio Check and repair fuel system.
i. Excessive back pressure in exhaust system Clean or replace exhaust system.
j. Improper valve clearance. Adjust.
k. Clutch slipping Repair or replace.
I. Brakes dragging Adjust.
m. Deteriorated transmission oil Replace.
n. Defective motor fan Replace.
o. Knocking due to use of improper Octane fuel Use proper Octane fuel.
p. Faulty or run-down battery Replace Or recharge.
q. Insufficient engine oil Add.
r. Improper rotation of radiator fan Repair or replace.
s. Harness open or poor contact Repair or replace.
t. High coolant density Adjust.
u. Defective radiator fan relay Replace.
Over- a. Excessively low outside temperature Cover part Of radiator front.
cooling b. Defective thermostat Replace.
c. Radiator Water temperature sensor Replace.
d. Defective radiator fan relay Replace.
Coolant a. Loose or damaged connectors Repair Or replace.
leak b. Leak from Water pump Repair Or replace.
c. Leak from intake manifold Repair Or replace.
d. Leak from cylinder head gasket Retighten cylinder head Or replace gasket-
e. Damaged or cracked cylinder and crankcase Repair Or replace.
f. Damaged thermostat case Repair Or replace.
g. Leak from radiator Repair Or replace.
Unusual a. Defective motor fan Replace.
noise b. Defective Water pump mechanical seal Replace mechanical seal.
c. Foreign matter in Water passage Remove foreign matter.
d. Coolant frozen Check and adjust coolant density.

20
2.7 FUEL INJECTION SYSTEM
C COMPONENT PARTS............................................................................................................. 2
1. Air Intake System................................................................................................................2
2. ThrottIe body....................................................................................................................... 3
W SERVICE PROCEDURE......................................................................................................... 4
1. Air Cleaner.......................................................................................................................... 4
2. Throttle Body....................................................................................................................... 4
3. Intake Manifold....................................................................................................................5
4.Intake Air Temperature Sensor.............................................................................................7
5. Water Temperature Sensor..................................................................................................7
6. Pressure Sensor.................................................................................................................7
7. Oxygen (O2) Sensor........................................................................................................... 7
8. Solenoid Valves................................................................................................................... 8
9. Fuel Injector........................................................................................................................ 9
10. Electric Control Unit.........................................................................................................10
11. Main Relay and Fuel Pump Relay ..................................................................................10
T TROUBLESHOOTING........................................................................................................... 12
1. General Troubleshooting Table..........................................................................................12
2.7 COMPONENT PARTS
1. Air Intake System

1. Air Intake System

(1) Throttle body (6) PCV valve (11) Intake air temperature sensor
(2) Fuel injector holder assembly (7) Grommet (12) Air filter
(3) Fuel return hose (8) Grommet
(4) FueI delivery hose (9) Collector chamber*:RWD model only
(5) Fuel pipe assembly (10) Gasket

2
COMPONENT PARTS 2.7
2. Throttle body

2. Throttle body

(1) Throttle body


(2) Gasket
(3) Engine coolant hose A
(4) Engine coolant hose B

3
2.7 SERVICE PROCEDURE
2. Throttle body

1. Air Cleaner
A: REMOVAL AND INSTALLATION
1) Remove bolts Which hold air cleaner case on rocker
cover bracket.
2) disconnect blow-by hose.
3) Remove bolt Which holds air intake duct on body

4) Remove air cleaner assembly and air intake duel,

5) Installation is in the reverse order of removal.

2. Throttle Body
A: REMOVAL AND INSTALLATION
1) Remove air cleaner assembly. <Ref. to 2-7 [W1A0]>

2) Disconnect throttle switch connector (1)


3) Disconnect evaporation hose (2).
4) Disconnect water hoses.

4
SERVICE PROCEDURE 2.7
2. Throttle Body

5) Disconnect throttle cable.

6) Remove throttle body from intake manifold.


7) Installation is in the reverse order of removal.
CAUTION:
Use a new gasket between throttle body and intake
manifold.
Tightening torque:
23 - 26 N m (2.3 - 2.7 kg-m, 17-20 ft-lb)

3. Intake Manifold
A: REMOVAL AND INSTALLATION
1) Release fuel pressure. <Ref. to C.2-8 [W1A0]>
2) Remove air cleaner assembly. <Ref. to 2-7 [W1A0]>

3) Disconnect throttle switch connector (1).


4) Disconnect evaporation hose (2).
5) Disconnect water hose.

6) Disconnect throttle cable.

5
2.7 SERVICE PROCEDURE
3. Intake Manifold

7) Disconnect hoses Tom intake manifold.


(1) 4WD solenoid hose (4WD model)
(2) idle up solenoid valve hose
(3) Brake booster hose
(4) Pressure regulator hose
(5) Pressure sensor hose
(6) PCV valve hose

8) Remove bolts and screw which install fuel delivery


pipe bracket onto collector chamber.

9) Remove nuts Which install fuel delivery pipe


assenbly with fuel injectors on intake manifold.

10) Remove bolts and nuts Which hold intake manifold


on cylinder head.

11) Installation is in the reverse order of removal.


CAUTION:
Use the new gaskets.
Tightening torque:
14.2 - 17.2 N m (1.45-10.5-12.7ft-lb)

6
SERVICE PROCEDURE 2.7
3. Intake Manifold

4.Intake Air Temperature Sensor


A: REMOVAL AND INSTALLATION
1) Disconnect connector from intake air temperature
sensor.
2) Remove intake air temperature sensor.
3) Installation is in the reverse order of removal.
Tightening torque:
31- 37 Nm (3.2 - 3.8 kg-m, 23 - 27 ft-lb)

5. Water Temperature Sensor


A: REMOVAL AND INSTALLATION
1) Disconnect connector from water temperature
sensor.
2) Remove water temperature sensor from thermostat
housing.
3) Installation is in the reverse order of removal.
Tightening torque:
16 - 20 N m (1.6 - 2.0 kg-m, 12 14 ft-lb)
6. Pressure Sensor
A: REMOVAL AND INSTALLATION
1) Disconnect vacuum hose from pressure sensor.
2) Disconnect connector from pressure sensor.
3) Remove pressure sensor.
4) Installation is in the reverse order of removal.

7. Oxygen (O2) Sensor


A: REMOVAL AND INSTALLATION
1) Disconnect oxygen sensor connector.

2) Apply SUBARU CRC 5-56 (Part No. 004301003) or


its equivalent to threaded portion of oxygen sensor, and
leave if for one minute or more.
3) Remove oxygen sensor from front exhaust pipe.
CAUTION:
When removing, do not force oxygen sensor
especially when exhaust pipe is cold, otherwise it
will damage exhaust pipe.

7
2.7 SERVICE PROCEDURE
7. Oxygen (O2) Sensor

B: INSTALLATION
1) Before installing oxygen sensor apply
compound only to threaded portion of oxygen sensor
to make the next removal easier.
Anti-seize compound:
SS-30 by JET LUBE Inc. or equivalent
CAUTION:
Never apply anti-seize compound to protect the
oxygen sensor.
Tightening torque:
25 - 34 N m (2.5 - 3.5 kg~m, 18 - 25 ft-lb)

2) Connect oxygen sensor connector.

8. Solenoid Valves
A: LOCATION
1) Turn ignition switch to OFF.
2) Remove bracket Which install each solenoid valve,
3) Disconnect hoses from each solenoid valve.
4) Disconnect connector from each solenoid valve.
5) Remove bolts Which install each solenoid valve.
6) Installation is in the reverse order of removal.

*: 4WD model only

8
SERVICE PROCEDURE 2.7
8. Solenoid Valves

9. Fuel Injector
WARNING:
Place "No fire" signs near the work area when
removing and installing fuel injector.
A: REMOVAL
1) Release the fuel pressure.
<Ref. to 2-8 [W1A0]>
2) Remove air cleaner assembly.
<Ref. to 2-7 [W1A01]>

3) Disconnect connectors from fuel injectors.


4) Remove fuel injector cover.

5) Remove fuel injector from fuel delivery pipe.

B: INSTALLATION
CAUTION:
Replace O-ring and seal with a new one.

1) After installing O-ring to fuel injector, install that fuel


injector into fuel delivery pipe.

2) After installing seal onto intake manifold, install fuel


injectors into intake manifold at straight with fuel
delivery pipe.

9
2.7 SERVICE PROCEDURE
9. Fuel Injector

3) Install fuel injector cover.


Tightening torque:
3.3 - 3.5 N m (0.34 - 0.36 kg-m, 2.5 2.6 ft-lb)
CAUTION:
Rotate fuel injector by hand to confirm o-ring is properly
engaged and the seal has no burrs.
4) Connect connectors to fuel injectors. rK

10. Electric Control Unit


CAUTION:
Make sure that battery ground terminal is
disconnected before removal and installation.
A: LOCATION

11. Main Relay and Fuel Pump Relay


CAUTION:
Make sure that battery ground terminal is discon-
nected before removal and installation.

A: LOCATION
(1) Main relay
(2) Fuel pump relay

B: INSPECTION
1) Check main relay.
(1) Measure resistance between main relay con-
nector terminals as following.
Terminals / Specified resistance
No.3 - No.5 / Above 1 M
No.4 - No.6 / Above 1 M

10
SERVICE PROCEDURE 2.7
11. Main Relay and Fuel Pump Relay

(2) Measure resistance between same terminals


while connecting battery between terminal No.1 and
No.2.
Terminals / Specified resistance
No.3 - No.5 / Below 10
No.4 - No.6 / Below 10

2) Check fuel pump relay.


(1) Measure resistance between fuel pump relay
connector terminal No.2 and No.4.
Terminals / Specified resistance
No.2 - No.4 / Above 1 M

(2) Measure resistance between same terminals


while connecting battery between terminal No.1 and
No.3.
Terminals / Specified resistance
No.2 - No.4 / Below 10

11
2.7 TROUBLESHOOTING
1. General Troubleshooting
Table

1. General Troubleshooting Table


Priority of parts to check is shown by figures (1, 2, 3...).

Connected test mode or road memory connector


Intake air temperature sensor

Idle air control solenoid valve

Air bleed of air intake system


Purge control solenoid valve
Water temperature sensor

Ignition switch ground


Vehicle speed sensor

Crank angle sensor

Lack of warming up
Electric load switch
ECU power supply

Pressure regulator

Engine idle speed


Blower fan switch

Accelerator cable
Thermo air valve
Pressure sensor

Valve clearance
Throttle switch

Fuel injector
Ignition coil

Spark plug
Fuel pump
O2 sensor
startFailure of engine to

Internal combustion does not occur. 1 3 2 3 2 2 3 3 3 2 1

InternaI combustion occur. 3 2 3 2 3 3 1 2 3

Engine stalls after internal 1 2 3 3 3 3 2 2 3


combustion

Engine staIIs 3 2 2 3 3 3 3 3 2 3 3 1 3
Rough idling 2 2 3 3 3 3 3 2 3 2 3 1 1 2 3 2
Hard to drive at constant speed 3 3 2 2 3
Poor acceIeration / deacceIeration 3 3 2 2 2 2 2 1
Poor return to idling 3 3 2 3 2 3 1 1 3 2
Back fire 3 3 3 2 1 1 3
Knocking 2 2 1
Excessive fuel consumption 2 1 2 2 1
Shocks while driving 2 2 1 2
Poor engine revving 2 2 2 2 2 2 1 2 2
Out of specifications for idle mixture 2 2 2 2 2
Remarks *1 *2 *2 *2 *2

*1 : Include ECU grounding circuit.


*2 : Check hoses.

12
2.8 FUEL SYSTEM
S SPECIFICATIONS AND SERVICE DATA................................................................................2
1. Fuel System........................................................................................................................ 2
C COMPONENT PARTS............................................................................................................. 3
1. Fuel Line............................................................................................................................. 3
2. Fuel Tank............................................................................................................................. 5
W SERVICE PROCEDURE......................................................................................................... 6
1. Precaution........................................................................................................................... 6
2. On Car Service....................................................................................................................7
3. Fuel Tank............................................................................................................................. 9
4. Fuel Filler Pipe.................................................................................................................. 10
5. Fuel Filter.......................................................................................................................... 10
6. Fuel Pump......................................................................................................................... 10
7. Fuel Delivery, Return and Evaporation Lines.....................................................................11
8. Roll Over Valve.................................................................................................................. 12
9. Canister............................................................................................................................. 13
2.8 SPECIFICATION AND SERVICE DATA
1. Fuel System

1. Fuel System
A: SPECIFICATIONS
EMPi model
Capacity 40 L (10.6 US gal, 8.8 Imp gal)
Fuel tank
Location Under rear floor
Type Impeller type
Fuel pump Discharge pressure 294.2 kPa (3.0 kg/cm2, 42.7 psi)
Discharge volume More than 45 L (11.9 US gal, 9.9 Imp gal)/h
Fuel filter Cartridge type

2
COMPONENT PARTS 2.8
1. Fuel Line

1. Fuel Line
1. WAGON MODEL

(1) Air bleeder hose (9) Fuel delivery hose B


(2) Canister holder bracket (10) Clamp
(3) Canister (11) Fuel return hose B
(4) Clip (12) Fuel pipe assembly
(5) Canister hose B (13) Fuel delivery hose A
(6) Roll over valve (14) Fuel return hose A
(7) Evaporation hose B (15) Evaporation hose A
(8) Canister hose A

3
2.8 COMPONENT PARTS
1. Fuel Line

2. VAN MODEL

(1) Air bleeder hose (10) Evaporation hose B


(2) Canister holder bracket (11) Fuel delivery hose B
(3) Canister (12) Clamp
(4) Clip (13) Fuel return hose B
(5) Canister hose B (14) Fuel pipe assembly
(6) Canister hose A (15) Fuel delivery hose A
(7) Roll over valve (16) Fuel return hose A
(8) Evaporation hose C (17) Evaporation hose A
(9) Check valve

4
COMPONENT PARTS 2.8
2. Fuel Tank

2. Fuel Tank

(1) Air vent hose (10) Fuel filter


(2) Clip (11) Fuel cap
(3) Fuel tank (12) Inner spacer
(4) Rubber packing (13) Outer grommet
(5) Fuel pump assembly (14) Inner grommet
(6) Fuel delivery hose A (15) Fuel filler pipe
(7) Fuel pump (16) Clamp
(8) Clamp (17) Fuel filler hose
(9) Fuel deliver hose B (18) Fuel tank valve

5
2.8 SERVICE PROCEDURE
2. Fuel Tank

WARNING:
Place "No fire" signs near the work area.
Be careful not to spill fuel on the ground.
Disconnect ground cable from battery.

1. Precaution
A: RELEASING OF FUEL PRESSURE
1) Lift up the vehicle.
2) Disconnect fuel pump connector.

3) Start engine, and run it until it stalls.


4) After engine has stalled, crank it for five more sec-
onds.
5) Turn ignition switch to "OFF".

B: DRAINING OF FUEL
1) Remove fuel filler cap.
2) Disconnect fuel filler hose (1) from pipe.

3) Drain fuel from fuel filler hose by using hand pump


WARNING:
Don't use a motor pump.

6
SERVICE PROCEDURE 2.8
1. Precaution

6) After draining fuel, connect fuel filler hose (1) to pipe.

2. On Car Service
A: MEASUREMENT OF FUEL PRESSURE
1) Release fuel pressure. <Ref. to 2-8 [W1A0]>
2) Connect fuel pump connector.

3) Disconnect fuel delivery hose (2) from pipe in engine


compartment, and connect fuel pressure gauge.

4) Start engine.
5) Measure fuel pressure while disconnecting pressure
regulator vacuum hose from intake manifold.
Fuel pressure:
294.1 kPa (3.0 kg/cm2, 42.7 PSI

6) After connecting pressure regulator vacuum hose,


measure fuel pressure.
Fuel pressure:
226 kPa (2.3 kg/cm2, 33 psi)
CAUTION:
If out of specification as measured at step 6),
replace pressure regulator.
Before removing fuel pressure gauge, release fuel
pressure.

7
2.8 SERVICE PROCEDURE
2. On Car Service

3. Fuel Tank
A: REMOVAL
1) Lift up the vehicle.

2) Disconnect connector from fuel pump.


3) Release fuel pressure.
<Ref. to 2-8 [W1A0]>

4) Drain fuel from fuel tank.


<Ref. to 2-8 [W1B0J>

5) Disconnect air vent hose (D from fuel tank.

6) Disconnect fuel delivery hose.

8
SERVICE PROCEDURE 2.8
3. Fuel Tank

7) Disconnect fuel return hose and evaporation hose.

8) While holding fuel tank, remove bolts which hold fuel


tank onto body.
WARNING:
Two men are required to perform step 8) above.
When lowering fuel tank, disconnect connector of
fuel meter unit from wiring harness.

B: INSTALLATION
1) Install fuel tank onto body.
WARNING:
Two men are required to perform step 1) above.
When raising up fuel tank, connect connector of
fuel meter unit.
Tightening torque:
18 - 32 N m (1.8 - 3.2 kg-m, 13 - 23 ft-lb)

2) Connect fuel return hose and evaporation hose to


fuel tank.

3) Lower the vehicle.


4) Connect fuel filler hose (1) and air vent hose (2) to
fuel filler pipe.

9
2.8 SERVICE PROCEDURE
3. Fuel Tank

4. Fuel Filler Pipe


A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
2) Disconnect fuel filler hose (1) and air vent hose (2)
from fuel filler pipe.

3) Remove bolts Which install bracket of fuel filler pipe


onto body.
4) Remove fuel filler pipe assembly.
5) Installation is in the reverse order of removal.

5. Fuel Filter
A: REMOVAL AND INSTALLATION
1) Lift up the vehicle.
2) Release fuel pressure.
<Ref. to 2-8 [W1A0]>

3) Disconnect fuel delivery hoses from fuel filter.


4) Remove bolts which hold fuel filter bracket on body
5) Installation is in the reverse order of removal.
Tightening torque:
5.5 9.5 N-m (0.55 0.95 kg-m, 4.0 6.9 ft-lb)

6. Fuel Pump
A: REMOVAL AND INSTALLATION
1) Release fuel pressure.
<Ref. to 2-8 [W1A0]>
2) Keep connector disconnected.

10
SERVICE PROCEDURE 2.8
6. Fuel Pump

3) Remove nuts which install fuel pump onto frame.


4) Disconnect fuel delivery hose.

5) Installation is in the reverse order of removal.


Tightening torque:
5.5 - 9.5 N m (0.55 - 0.95 kg-m, 4.0 - 6.9 ft-lb)

7. Fuel Delivery, Return and Evaporation


Lines
A: REMOVAL
1) Release fuel pressure. <Ref. to 2-8 [W1A0]>
2) Remove fuel delivery pipes and hoses, fuel return
pipes and hoses, and evaporation pipes and hoses.

(1) Roll over valve (4) Fuel filter (7) Fuel filter pipe
(2) Canister (5) Fuel pump
(3) Purge control solenoid valve (6)Fuel tank

11
2.8 SERVICE PROCEDURE
7. Fuel Delivery, Return and Evaporation
Lines

3) In engine compartment, detach fuel delivery hose


and fuel return hoses.

4) In engine compartment, detach evaporation hose


from canister.

B: INSTALLATION
Install in the reverse order of removal.
1) Connect delivery hose to delivery pipe as figure.
A : 1 - 4 mm (0.04 - 0.16 in)
B : 20 - 25 mm (0.79 - 0.98 in)

2) Connect delivery hoses and fuel return hose to ??


tank until they reach the base of each pipe.
3) Insert evaporation tube into evaporation pipe approx.
15 mm (0.59 in) and position a clip with approx. 8 mm
(0.31 in) from hose end.
4) Be sure to inspect hoses and their connections for
any leakage of fuel.

8. Roll Over Valve


A: REMOVAL
1) Lift up the vehicle.
2) Remove canister.
3) Remove roll over valve from bracket.
4) Disconnect hoses from roll over valve.

12
SERVICE PROCEDURE 2.8
8. Roll Over Valve

B: INSPECTION
1) Connect hose to valve as shown.
2) While blowing through open end of tube, tilt valve at
least 90 left and right from normal position.
3) Ensure that there is no air flow when tube is tilted
greater than 90.

C: INSTALLATION
Installation is in the reverse order of removal.
Observe the following:
1) Do not install top side of valve down.
2) Before installing bracket on body, securely fit
concave part of bracket to hole in body.

9. Canister
A: REMOVAL AND INSTALLATION
1) Lift up the vehicle.
2) Remove canister from bracket.
3) Disconnect canister hoses from evaporation pipes.
4) Installation is in the reverse order of removal.
CAUTION:
When installing canister, through air vent hose into
the frame.

13
2.9 exhaust system
C COMPONENT PARTS............................................................................................................. 2
1. Exhaust System.................................................................................................................. 2
W SERVICE PROCEDURE......................................................................................................... 3
1. Exhaust System.................................................................................................................. 3
2.9 COMPONENT PARTS
1. Exhaust System

1. Exhaust System

(1) Under heat shield cover (7) Seat (13) Mounting cushion RH
(2) Gasket (8) Washer (14) Muffler mounting rod
(3) Oxygen sensor (9) Catalyst converter (15) Mounting cushion LH
(4) Exaust pipe (10) Gasket (16) Muffler
(5) Gasket (11) Heat shield cover (17) Rear mounting cushion
(6) Holder (12) Mounting bracket RH

2
SERVICE PROCEDURE 2.9
1. Exhaust System

1. Exhaust System
A: REMOVAL
1) Disconnect battery terminal.
2) Remove rear bumper.

3) Disconnect connector from oxygen sensor.

4) Separate exhaust pipe from exhaust manifold.

5) Separate heat shield cover of exhaust pipe body


bracket.

6) Remove muffler mounting rod.

3
2.9 SERVICE PROCEDURE
1. Exhaust System

7) Remove bolt Which installs heat shield muffler to


cushion rubber.

8) Remove bolt Which installs heat shield


body.
9) Remove nuts Which installs muffler onto frame

10) Remove exhaust system components from from


the vehicle.
CAUTION:
Be careful not to drop exhaust system components

B: DISASSEMBLY AND ASSEMBLY


1) Remove heat shield cover of muffler.

2) Remove heat shield cover on underside of muffler.

4
SERVICE PROCEDURE 2.9
1. Exhaust System

3) Remove bolts which install under heat shield cover to


upper heat shield.
4) Separate upper heat shield cover and under shield
cover.

5) Separate catalyst converter from exhaust pipe.

6) Separate catalyst converter from muffler


7) Assembly is in the reverse order of removal
procedure.

C: INSTALLATION
1) Install exhaust system components onto the vehicle.

2) Tighten nut which installs muffler onto frame.


3) Tighten bolt which installs heat shield cover to body.

5
2.9 SERVICE PROCEDURE
1. Exhaust System

4) Tighten bolt Which installs heat shield cover of


muffler to cushion rubber.

5) Install muffler mounting rod.

6) Install heat shield cover of exhaust pipe to body


bracket.

7) Install exhaust pipe to exhaust manifold.

8) Connect connector to oxygen sensor.

6
SERVICE PROCEDURE 2.9
1. Exhaust System

9) Install rear bumper.

10) Connect battery terminal.

7
2.10 CLUTCH
Page
S SPECIFICATIONS AND SERVICE DATA................................................................................2
1. Clutch.................................................................................................................................. 2
C COMPONENT PARTS............................................................................................................. 3
1. Clutch.................................................................................................................................. 3
W SERVICE PROCEDURE......................................................................................................... 4
1. Clutch Release Lever & Fork...............................................................................................4
2. Clutch Disc.......................................................................................................................... 6
T TROUBLESHOOTING............................................................................................................. 9
1. Clutch.................................................................................................................................. 9
2.10 SPECIFICATION AND SERVICE DATA
1. Clutch

1. Clutch
A: SPECIFICATIONS
Type Dry single plate
Outer diameter x inner diameter x 180 x 125 x 3.5 mm
thickness (7.09 x 4.92 x 0.138 in]
Clutch disc
Facing Material Woven (asbestos-free) "
Compression thickness at setting 7.8 mm (0.307 in)
Tree thickness 8.3 mm (0.327 in)
Outer diameter 181 mm (7.13 in)
Inner diameter 117 mm (4.61 in)
Clutch Pressure
cover plate 2.47- 3.021 N
Setting load
(252- 308 kg, 556- 679 lb)
Diaphragm height at installation 27.5- 29.5 mm (1.08-1.16 in)

B: MAINTENANCE STANDARDS
Sinkage limit of rivet head 0.3 mm (0.012 in)
Clutch disc Deflection 0.5 mm (0.020 in) at 170 mm (6.7 in) diameter
Runout limit 0.5 mm (0.020 in)
Clutch free On cable center of clutch release fork
1 - 2 mm (0.04 - 0.08 in)
play adjusting portion

2
COMPONENT PARTS 2.10
1. Clutch

1. Clutch

(1) Clutch disc (6) Spring Pin


(2) Clutch cover (7)Holder Spring
(3) Spring washer (8) Release fork
(4) Release bearing sleeve (9) Release lever
(5) O-ring (10) Clutch housing

3
2.10 SERVICE PROCEDURE
1. Clutch

1. Clutch Release Lever & Fork


A: REMOVAL
1) Remove transmission from engine.

2) Remove holder spring and remove clutch release


bearing sleeve.
CAUTION:
When bearing holder spring is removed, use care
not to deform it.

3) Using ST, drive spring pin out until clutch release


lever can be removed.
ST 398791700 STRAIGHT PIN REMOVER 2

4) Remove clutch release fork and clutch release lever.

B: INSPECTION AND REPAIR


Check all removed parts and replace if defective.
1) Check if clutch release bearing sleeve operates
properly when pushed and turned in thrust direction. If it
does not or if it is damaged, replace.
NOTE:
Do not clean bearing because it is a permanent
grease-filled type.
Check bearing for smooth movement in radial
direction.

4
SERVICE PROCEDURE 2.10
1. Clutch Release Lever & Fork

2) If contacting surfaces of release bearing sleeve and


clutch release fork are badly worn, replace.
3) If nicking is evident on inside surface of release
bearing sleeve replace.

C: INSTALLATION
1) Apply grease to clutch release lever and install to
clutch housing to match pin hole of clutch release fork.

2) Using ST, drive spring pin into proper placement.


ST 398791700 STRAIGHT PIN REMOVER 2

CAUTION:
Slits of spring pins should be at 90 angles to
release lever shaft (portion) centerline.

3) Install clutch release bearing sleeve and install


holder spring.
4) Install transmission to engine.

5
2.10 SERVICE PROCEDURE
1. Clutch Release Lever & Fork

2. Clutch Disc
A: REMOVAL
1) Remove transmission.

2) Insert ST to prevent clutch disc from falling down ST


499745500 CLUTCH DISC GUIDE
Apply oil or grease to 10 mm (0.39 in) dia. portion of ST
end.
3) Loosen clutch cover attaching bolts evenly in several
steps and remove cover and clutch disc.
CAUTION:
Use care to prevent oil or grease from
contaminating disc facing.

B: INSPECTION
Check all removed parts and replace if defective.
1) Check diaphragm spring end and replace if
excessive wear is evident.
2) If clutch cover produces noise when swung up and
down or if damage to rivets is evident, replace.
3) Check disc compression surface of pressure plate
and replace if wear, distortion or damage is evident.

4) Check clutch disc facing and replace if worn beyond


limit. (Measure sinkage of rivets with calipers.)
Sinkage limit: 0.3 mm (0.012 in)

6
SERVICE PROCEDURE 2.10
2. Clutch Disc

5) Check torsion springs for damage and deterioration


and check the spline hub and rivets for looseness.
Replace if defective.

6) Using ST and dial gauge, measure the play of the


splines in the turning direction at the facing outside
circumference, and replace if the play exceeds the limit.
If the runout of the outside circumferences is beyond
the limit, replace.
Deflection limit (Limit of play in turning direction):
0.5 mm (0.020 in) on 7 mm (6.69 in) dia.
Runout limit:
0.5 mm (0.020 in)
ST 499745500 CLUTCH DISC GUIDE
7) If there is oil on the facing, replace the clutch disc.
CAUTION:
Do not wash the clutch disc.

C: INSTALLATION
Install all parts by reversing order of removal, while
paying attention to the following points.
1) Insert ST into clutch disc and install to flywheel.
ST 499745500 CLUTCH DISC GUIDE
2) Line up dowel pin hole of clutch cover with dowel pin
of flywheel, and secure clutch cover to flywheel with
bolts.
Tightening torque:
10 1.0 Nm (1.0 0.75 kg-m, 7.3 0.8 ft-lb)

7
2.10 SERVICE PROCEDURE
2. Clutch Disc

3) Install transmission.
CAUTION:
Tighten bolts in the numerical order shown in
Figure.
NOTE:
Before installing transmission, apply a coat of clutch
grease (FX2200) to splines of mainshaft. (Do not apply
too much grease.)

8
TROUBLESHOOTING 2.10
1. Clutch

1. Clutch
DIAGNOSTIC DIAGRAM OF CLUTCH DRAGS

Test (1)

Test (2)

Test (3)

Judgment

Cause:
Cracked clutch disc
Broken or Worn clutch cover
Faulty clutch release mechanism
Insufficient amount Of clutch release
Excessive free play Of clutch pedal

9
2.10 TROUBLESHOOTING
1. Clutch

Symptom 1) CLUTCH SLIPPING


If any of the following symptoms are noticed, the clutch is slipping.
(a) Engine tends to rev up While shifting gears.
(b) Car speed does not increase or quickly respond to engine rpms during acceleration.
(c) Car lacks power during upgrade driving and clutch facing smells charred.
* Test method
With the transmission in top gear and the engine at full-throttle, quickly disengage and engage
the clutch while the car is being driven in the 40 to 50 km/h (25 to 31 MPH), range and
determine Whether or not the clutch's "slip" time is short or long. If it is long, the clutch is
evidently slipping.
Probable cause Remedy
(1) NO free play Of clutch pedal Adjust
(2) NO free play at end of release lever I (3) Oil on clutch facing Adjust
(4) Worn clutch facing Replace
(5) Weak diaphragm spring Replace
(6) Warped or broken pressure plate/flywheel Replace
(7) Inoperative release bearing sleeve Repair or replace Repair or
(8) Faulty clutch control system replace Repair or replace
Symptom 2) FAILURE OF CLUTCH TO DISENGAGE
This condition is evidenced by hard shifting (= high shift effort), particularly into low gears.
Probable cause Remedy
(1) Excessive free play of clutch pedal Adjust
(2) Excessive free play at end of release lever I (3) Cracked clutch disc facing Adjust
(4) Wear or rust on clutch disc hub's splines ; Replace
(5) Surface runout of clutch disc facing Remove rust, apply grease or
(6) Clutch disc jamming (oil or water stuck to disc) replace
(7) Faulty clutch control system Repair or replace
Replace
Repair or replace
Symptom 3) CLUTCH CHATTERS
This symptom is noticed by unwanted vibration of the entire car body When the car starts to move
With the clutch partially engaged.
Probable cause Remedy
(1) Loose engine mounting Tighten or replace
(2) Clutch cable not properly laid out Repair
(3) Oil on clutch disc facing Replace
(4) Broken or weak torsion spring Replace
(5) Improper contact of clutch facing or clutch disc runout Replace
(6) Warped pressure plate/flywheel Repair or replace Replace
(7) Loose clutch disc rivet

10
TROUBLESHOOTING 2.10
1. Clutch

Symptom 4) NOISY CLUTCH.


Noise Occurs:
(a) When clutch is disengaged
(b) When clutch is partially engaged Determine which One causes noise.
(c) When clutch is engaged
Probable cause Remedy
(1) Release bearing broken, Worn Or improperly lubricated Replace
(2) Loose clutch disc hub Replace
(3) Loose retainer (torsion spring) Replace
(4) Broken Or Weak torsion spring Replace
Symptom 5) CLUTCH GRABS
Even though the clutch is partially engaged, the clutch is actually engaged completely,
causing the car to surge forward.
Probable cause Remedy
(1) Oil or grease on clutch facing Replace
(2) Weak cushioning spring Replace
(3) Broken or weak torsion spring Replace
(4) Wear or rust on splines of clutch disc/main shaft Remove rust, apply grease or replace
(5) Loose engine mounting Tighten Or replace
(6) Weak diaphragm spring Replace

11
2.11 ENGINE AND TRANSMISSION
MOUNTING SYSTEM
Page
C COMPONENT PARTS............................................................................................................. 2
1. Engine and Transmission Mounting....................................................................................2
W SERVICE PROCEDURE......................................................................................................... 3
1. Engine and Transmission....................................................................................................3
2.11 COMPONENT PARTS
1. Engine and Transmission Mouting

1. Engine and Transmission Mouting

Tightening torque: N m (kg-m, ft-lb)


T1:5.4 - 9.3 (0.55 - 0.95, 4.0 - 6.9) T5: 58 - 68 (5.8 - 6.8, 42 - 49)
T2:23 43(2.3 - 4.3, 17 - 31) T6:57 - 72(5.7-7.2,41-52)
T3: 43 - 55 (4.3 - 5.5, 31 - 40) T7:55 - 75 (5.5 - 7.5, 40 - 54)
T4:45 - 65 (4.5 - 6.5, 33 - 47) T8: 80 - 10018.0-10.0. 58 72)

(1) Front mount Cushion (6) Front engine mount Cushion


(2) Front mount bracket (7) Engine mount Crossmember
(3) Transmission mount cushion (8) Rear protector
(4) Transmission mount bracket (9) Transmission protector
(5) Rear engine mount bracket

2
SERVICE PROCEDURE 2.11
1. Engine and Transmission

1. Engine and Transmission


A: REMOVAL

1. Set the vehicle on lift arms.


2. Release fuel pressure.
3. Disconnect battery cable from battery.
4. Remove air cleaner assembly.
5. Remove rear bumper.
6. Drain exhaust system.


7. Disconnect cables, connectors and hoses.


8. Drain coolant from radiator.


9. Remove diagonalmember and rear under guard.


10. Remove rear drive shaft from transmission.
11. Remove propeller shaft. (4WD model only).


12. Disconnect clutch cable.
13. Disconnect water hose from pipes.


14. Set two transmission jacks under engine and transmission.


15. Remove front engine mounting bracket.
16. Remove bolts which install engine mounting crossmember to frame.


25. Remove engine and transmission from vehicle.

3
2.11 SERVICE PROCEDURE
1. Engine and Transmission

1) Set the vehicle on lift arms. >

2) Release fuel pressure.


(1) Lift up the vehicle.
(2) Disconnect fuel pump connector.
(3) Start the engine, and run until It stalls.
(4) After the engine stalls, crank it for five second
more.
(5) Turn ignition switch to "OFF".
<Ref. to 2-8 [W101]>

3) Disconnect battery cable from battery.

4) Remove air cleaner assembly.


CAUTION:
Cover intake port of throttle body with clean cloth to
prevent ingesting dust.

5) Remove rear bumper.

4
SERVICE PROCEDURE 2.11
1. Engine and Transmission

6) Remove exhaust system.


(1) Disconnect connector from oxygen sensor.

(2) Separate exhaust pipe from exhaust manifold.

(3) Separate heat shield cover of exhaust from body


bracket.

(4) Remove muffler mounting rod.

(5) Remove bolts which install heat shield cover of


muffler to body.

5
2.11 SERVICE PROCEDURE
1. Engine and Transmission

(6) Remove bolt and nut which Install muffler onto


frame.

(7) Remove exhaust system components from the


vehicle.
CAUTION:
Be careful not to drop exhaust system components.

6
SERVICE PROCEDURE 2.11
1. Engine and Transmission

MEMO:

7
2.11 SERVICE PROCEDURE
1. Engine and Transmission

7) Disconnect cables, connectors and hoses,


(1) Disconnect following cables:
(2) Accelerator cable
(3) Speedometer cable
(4) Shift control cables

8
SERVICE PROCEDURE 2.11
1. Engine and Transmission

9
2.11 SERVICE PROCEDURE
1. Engine and Transmission

(2) Disconnect following connectors;


(1)4WD indicator light switch connector (4WD
model only)
(2) Back up light switch connector
(3)Starter connector
(4) Starter terminal
(5) Engine harness connector
(6) Alternator connector
(7) Alternator terminal
(8) Transmission ground cable
(9) Distributor connector

10
SERVICE PROCEDURE 2.11
1. Engine and Transmission

11
2.11 SERVICE PROCEDURE
1. Engine and Transmission

(3) Disconnect following hoses;


(1) Evaporation hose (From purge control
solenoid valve)
(2) Blow-by hose (To PCV valve)
(3) 4WD Solenoid valve hose (4WD model only)
(4) Idle Speed control Solenoid valve hose
(5) Brake booster hose
(6) Fuel hoses
(7) Pressure Sensor hose

12
SERVICE PROCEDURE 2.11
1. Engine and Transmission

13
2.11 SERVICE PROCEDURE
1. Engine and Transmission

8) Drain coolant.
(1) Lift up the vehicle.
(2) Fit vinyl tube to drain cock of radiator.

(3) Drain coolant into container from radiator.

(4) Disconnect radiator inlet (3) and outlet (1)


hoses from pipes, and drain coolant into container.

9) Remove diagonalmember and rear under guard.

10) Remove rear drive shaft from transmission by


using ST.
ST 28099PA 100 DRIVE SHAFT REMOVER

14
SERVICE PROCEDURE 2.11
1. Engine and Transmission

11) Remove propeller shaft. (4WD model only)


(1) Separate propeller shaft from differential.

(2) Remove propeller shaft from transmission.

CAUTION:
Be sure to use an empty container to each oil
flowing out when removing propeller shaft.
Be sure not to damage oil seal and frictional
surface of sleeve yoke.
Be sure to plug the opening in transmission after
removal of propeller shaft.

12) Disconnect clutch cable-

13) Disconnect water hoses from pipes.

15
2.11 SERVICE PROCEDURE
1. Engine and Transmission

14) Set two transmission jacks under engine and


transmission.

15) Remove front engine mounting bracket.

16) Remove bolts Which install engine mounting cross


member to frame.

17) Remove engine and transmission from the vehicle.

16
SERVICE PROCEDURE 2.11
1. Engine and Transmission

B: INSTALLATION

1. Install engine and transmission Onto the vehicle.


2. Tighten bolts Which install engine mounting crossmember to frame.
3. Install front engine mounting bracket.


4. Remove transmission jacks.


5. Connect Water hoses to pipes.
6. Connect clutch cable.


7. Connect Connector to fuel pump.


8. Install rear drive shafts to transmission.
9. Install propeller shaft. (4WD model Only)


10. Install diagonalmember and rear under guard.


11. Connect cables, connectors and hoses.


12. Install exhaust system.
13. Install rear bumper.
14. Install air cleaner assembly.
15. Connect battery cable.
16. Fill coolant.

17
2.11 SERVICE PROCEDURE
1. Engine and Transmission

1) Install engine and transmission onto the vehicle.

2) Install engine mounting crossmember to frame.

3) Install front engine mounting bracket.

4) Remove transmission jacks.

5) Connect water hoses to pipes.

18
SERVICE PROCEDURE 2.11
1. Engine and Transmission

6) Connect clutch cable.

7) Connect connector to fuel pump.

8) Install rear drive shafts to transmission.

9) Install propeller shaft. (4WD model only)

10) Install diagonalmember and rear under guard.

19
2.11 SERVICE PROCEDURE
1. Engine and Transmission

11) Connect connectors, hoses and cables.


(1) Lower the vehicle, and connect following con-
nectors and terminals;
Engine harness connector
Alternator connector
Alternator terminal
Distributor connector
Starter connector
Starter terminal
Back up light switch
4WD indicator light switch connector (4WD model
only)
Transmission ground terminal
(2) Connect following hoses;
Pressure sensor hose
Evaporation hose (From purge control solenoid
valve)
Blow-by hose (To PCV valve)
Brake booster hose
Idle air control solenoid valve hose
4WD solenoid valve hoses
Fuel hoses
(3) Connect following cables;
Shift control cables
Speedometer cable
Accelerator cable

12) Install exhaust system.


(1) Install exhaust system components onto the
vehicle.
CAUTION:
Be careful not to confuse attaching position of bolts
and nuts for installing exhaust pipe or heat shield
cover.

(2) Install muffler onto frame.

20
SERVICE PROCEDURE 2.11
1. Engine and Transmission

(3) Tighten bolts which install heat shield cover of


muffler to body.

(4) Install muffler mounting rod.

(5) Install heat shield cover of exhaust pipe to body


bracket.

(6) Install exhaust pipe to exhaust manifold.

(7) Connect connector to oxygen sensor.

21
2.11 SERVICE PROCEDURE
1. Engine and Transmission

13) Install rear bumper.

14) Install air cleaner assembly

15) Connect battery cable.

16) Fill coolant. <Ref. to 2-5 [W1B0]>

22
3 TRANSMISSION AND DIFFERENTIAL SECTION

MANUAL TRANSMISSION AND DIFFERENTIAL 3-1


TRANSMISSIONCONTROL SYSTEM 3-3
4WD SYSTEM 3-4
3.1 MANUAL TRANSMISSION AND
DIFFERENTIAL
Page
S SPECIFICATIONS AND SERVICE DATA................................................................................2
1. Manual Transmission and Differential..................................................................................2
C COMPONENT PARTS............................................................................................................. 5
1. Transmission Case..............................................................................................................5
2. Gear Shift Control Component Parts...................................................................................7
3. Gear Component Parts.......................................................................................................8
4. Differential Gear..................................................................................................................9
5. Extension & Transfer Gear................................................................................................10
W SERVICE PROCEDURE.......................................................................................................11
1. Preparations...................................................................................................................... 11
2. Transmission Side Cover...................................................................................................11
3. speedometer Driven Gear.................................................................................................17
4. Gear Shifter & Selector Assembly.....................................................................................18
5. Transmission Main case....................................................................................................21
6. Clutch Housing.................................................................................................................. 27
7. Drive Pinion Assembly.......................................................................................................29
8. Main Shaft Assembly.........................................................................................................32
9. Differential Assembly.........................................................................................................33
10. Arms and Forks............................................................................................................... 34
11. Other Parts...................................................................................................................... 35
12. 4WD Mechanism............................................................................................................. 36
T TROUBLESHOOTING........................................................................................................... 53
1. Manual Transmission and Differential................................................................................53
3.1 SPECIFICATION AND SERVICE DATA
MANUAL TRANSMISSION AND
DIFFERENTIAL

1. Manual Transmission and


Differential
A: SPECIFICATIONS
Model 4WD RWD
Type 5 forward speeds with synchromesh and 1 reverse
1st 3.166
2nd 1.809
3rd 1.161
Transmission gear ratio
4th 0.810
5th 0.658
Reverse 3.285
Type of gear Hypoid
Final
Gear ratio 3.900
Front Type of gear Helical
Transfer
reduction
(In transmission) Gear ratio 1.666
gears
Final Type of gear Bevel
(In transmission) Gear ratio 0.947
Rear Type of gear Helical
reduction Final
gear Gear ratio 6.166
Front differential Type of gear Bevel
Rear differential Type of gear Bevel
Transmission oil capacity 2.0 L
2.1 L
(2.1 US qt, 1.8 Imp
(2.2 US qt, 1.8 Imp qt)
qt)
0.8 L
Front differential gear oil capacity
(0.8 US qt, 0.7 Imp qt)

2
SPECIFICATION AND SERVICE DATA 3.1
1. Manual Transmission and
Differential

B: MAINTENANCE STANDARDS

Thrust clearance (side clearance) Of gear


1 st 0.10-0.53 mm (0.0039 - 0.0209 in)
2nd 0.11-0.43 mm (0.0043 - 0.0169 in)
3rd 0.11-0.43 mm (0.0043-0.0169 in)
4th 0.05 - 0.30 mm (0.0020 - 0.0118 in)
5th 0.10 - 0.25 mm (0.0039 - 0.0098 in)
Clearance between synchronizer ring and cone
STD 1.2mm (0.047 in)
Limit 0.5 mm (0.020 in)
Main shaft side (thrust) clearance 0 0.2 mm (0 0.008 in)
Washer [46 x 55.2 x 0.2 mm Part No. 803046020 0.2 mm (0.008 in)
(1.81 x 2.17x0.008 in)] 0 to 2 pieces to be used
Differential side gear backlash 0.05 - 0.15 mm (0.0020 - 0.0059 in)
Washer [27.1 x 42 x t mm Part NO. 803027041 1.000 mm (0.0394 in)
(1.067 x 1.654 x t in)) thickness 803027042 1.050 mm (0.0413 in)
803027043 1.100mm (0.0433 in)
Differential side bearing side clearance 0 - 0.2 mm (0 - 0.008 in)
Washer [61 x 71 x 0.2 mm Part NO. 803061020 0.2 mm (0.008 in)
(2.40 x 2.80 x 0.008 in)) 0 to 2 pieces to be used
Driven bevel gear bearing preload Adjusting method Adjusted by collapsible spacer
Preload value At bearing case hole:
9.32-18.63 N (0.95 - 1.90 kg, 2.09 -4.19 lb)
Starting Torque:
0.39-0.78 N-m
(4.0 - 8.0 kg-cm, 3.5 7.0 in-lb)
Bevel gear height Adjusting method Adjusted by shim
Bevel gear height adjusting shim thickness Part No. 31 89KA000 0.150 mm (0.0059 in)
33189KA010 0.175 mm (0.0069 in)
33189KA020 0.200 mm (0.0079 in)
33189KA030 0.225 mm (0.0089 in)
33189KA040 0.250 mm (0.0098 in)
33189KA050 0.275 mm (0.0108 in)
33189KA060 0.300 mm (0.0118 in)
33189KA070 0.500 mm (0.0197 in)
Bevel gear backlash .. 0.1 - 0.15 mm (0.0039 - 0.0059 in)
Drive pinion shim thickness part No. 841968602 0.150 mm (0.0059 in)
841968603 0.200 mm (0.0079 in)
841968604 0.250 mm (0.0098 in)
841968605 0.300 mm (0.0118 in)
841968606 0.500 mm (0.0197 in)
841968607 0.175 mm (0.0069 in)
841968608 0.225 mm (0.0089 in)
0.275 mm (0.0108 in)
'

3
3.1 SPECIFICATION AND SERVICE DATA
1. Manual Transmission and Differential

Transfer shaft Washer side clearance 0 - 0.05 mm (0 - 0.0020 in)


Outer snap ring (20) thickness Part No.805020041 2.51 mm (0.0988 In)
805020042 2.57 mm (0.1012 In)
805020043 2.63 mm (0.1035 In)
805020044 2.69 mm (0.1059 in)

4
COMPONENT PARTS 3.1
1. Transmission Case

1. Transmission Case
1. RWD MODEL

(1)Transmission main ease (8) Ball bearing (15) Back lamp switch (22) Oil seal
(2) Oil seal (9) Oil seal (16) Gasket (23) Snap ring
(3) Oil drain plug (10) Needle bearing (17) Hanger (24) Snap ring
(4) Oil filter plug (11) Oil seal (18) Speedometer shaft (25) Air cleaner stay
(5) Washer (12) Oil guide (19) Speedometer guide (26)Band clip
(6) Clutch housing (13) CIutch housing retainer (20) Washer
(7) Straight pin (14) Transmission side case (21) Washer

5
3.1 COMPONENT PARTS
1. Transmission Case

2. 4WD MODEL

(1) Transmission main Case (9) Back lamp switch (17) Washer (25) Oil reservoir plate
(2) Ball bearing (10) Gasket (18) Snap ring (26) Clutch housing retainer
(3) Oil seal (11) Hanger (19) Clutch housing (27) Straight pin
(4) Oil drain plug (12) Speedometer Shaft (20) Ball bearing (28) Air cleaner stay
(5) Washer (13) Oil seal (21) Oil seal (29) Band clip
(6) Clip (14) Washer (22) Oil seal
(7) Oil ffIler plug (15) Snap ring (23) Oil seal
(8) Transmission side case (16) Speedometer gear (24) Oil guide

6
COMPONENT PARTS 3.1
2. Gear Shift Control

2. Gear Shift Control Component Parts

(1) Transmission cover (15) Plunger (29) 5th shifter fork


(2)verse checking cam (16) Checking ball (30) Selector shaft
(3) Reverse checking spring (17) Snap ring (31) Selector lever
(4) Air breather pipe (18) Shifter shaft (32) Shifter lever
(5) Clip (19) Shifter arm (33) Reverse shifter lever
(6) 1st-2nd shifter fork (20) Interlock plate (34) Snap pin
(7) 1st-2nd shifter rail (21) Checking spring (35) Checking ball plug
(8) Spring pin (22) Spring retainer (36) Checking ball spring
(9) 3rd-4th shifter fork (23) Reverse return spring (37) Interlock bolt
(10) 3rd-4th shifter rail (24) Checking ball (38) Bracket
(11)-Reverse shifter rail (25) Snap ring (39)
(12) Reverse shifter arm (26) O-ring (40) Clevis pin
(13) Reverse shifter arm 2 (27) Washer (41) Washer
(14) Reverse shifter arm spring (28) Collar (42) Shift sealing

7
3.1 COMPONENT PARTS
3. Gear Component Parts

3. Gear Component Parts

(1) Reverse idler gear (16) Synchronizer hub (31) Synchronizer ring
(2) Reverse idler gear shaft (17) Synchronizer hub insert (32) Gear thrust spacer key 3
(3) Roller bearing (18) Synchronizer spring (33) Gear thrust spacer key 2
(4) Spring pin (19):Synchronizer hub sleeve (34) Bushing
(5) Bushing (20) Synchronizer hub (35) 5th gear thrust washer
(6) Snap ring (21)Synchronizer hub insert (36) Thrust washer
(7) Main shaft (22) Synchronizer spring (37) Ball bearing
(8) Ball bearing (23) Gear thrust spacer key (38) Synchronizer hub
(9) 5th drive gear (24) Gear thrust spacer key (39) 5th driven gear
(10) Washer (25) Gear thrust spacer (40) Insert stopper plate
(11) Lock washer (26) 1 st driven gear (41) Bearing retainer plate
(12) Lock nut (27) 2nd driven gear
(13)Dnve pinion shaft (28) 3rd driven gear
(14) Washer (29) 4th driven gear
(15) Reverse driven gear & sleeve (30)Synchronizer ring

8
COMPONENT PARTS 3.1
4. Differential Gear

4. Differential Gear

(1) Final gear (6) Oil seal


(2) Differential case (7) Washer
(3) Differential pinion shaft (8) Straight pin
(4) Differential pinion (9) Ball bearing
(5) Differential side gear (10) Washer

9
3.1 COMPONENT PARTS
5. Extension & Transfer Gear

5. Extension & Transfer Gear

(1) Transfer case cover (15) Extension (29) O-ring


(2) Gasket (16) Extension bushing (30) Drive pinion shim
(3) Transfer shifter spring (17) Oil seal (31) Ballbearing
(4) Ball (18) Snap ring (32) Lock washer
(5) 4WD indicator light switch (19) Washer (33) Lock nut
(6) Gasket (20) Transfer gear bushing (34) Gasket
(7) Bevel driven gear (21) Transfer driven gear (35) Transfer sealing
(8) Roller bearinq (22) Synchronizer hub (36) Knock pipe
(9) Collapsible spacer (23) Transfer shaft (37) Transfer side cover
(10)Bevel gear height shim (24) Woodruff key (38) Oil seal
(11) Transfer bearing case (25) Bevel drive gear (39) Transmission case stiffener
(12) Roller bearing (26) Spring pin (40) Transfer diaphragm
(13) Lock washer (27) Transfer shifter fork (41) Diaphragm cover
(14) Lock nut (28) Synchronizer sleeve

10
SERVICE PROCEDURE 3.1
5. Extension & Transfer Gear

1. Preparations
1) Before disassembling the transmission
CAUTION:
Wrap vinyl tape around spline at end of both dif-
ferential side gears (to prevent damage to oil seal).
Disassembled parts should be washed clean first
and then inspected carefully.
When oil seal is removed, replace it with a new
one.
When oil seal is washed or replaced, apply gear
oil to lips.
Use care to prevent damage to switch leads and
air breather pipes.
NOTE;
Clean oil, grease, dirt and dust from transmission.
Before cleaning, cap vacuum pipe with vinyl tape to
prevent entry of dust (4WD model).
Bearing should be replaced if burns, wear, noise,
unsmooth rotation, etc. are evident.
To check for noise and unsmooth rotation, apply gear
oil and check bearings by turning.
2) Drain oil by removing drain plug. After draining,
retighten plug as before. <Ref. to 1-5 [014A1]>
CAUTION:
Replace gasket with a new one.
Tightening torque:
34 4 N m (3.5 0.4 kg-m, 25 3 ft-lb)

3) Install ST1 to transmission clutch housing.


Install ST2 to front mount bracket boss of transmission.
ST1 499295600 TRANSMISSION STAND
ST2 499935400 TRANSMISSION STAND

2. Transmission Side Cover


A: DISASSEMBLY
1) Remove bolts, and lightly tap side cover off with
plastic hammer.

11
3.1 SERVICE PROCEDURE
2. Transmission Side Cover

2) Operate shifter lever and selector lever to shift gears


to 1st forward speed condition in mesh.

3) Install ST to splined part of mainshaft in alignment


with groove in housing.
ST 398781600 MAIN SHAFT STOPPER
NOTE:
Turn transmission on its side.
Support transmission with wood blocks as ded to
avoid damaging transmission case.

4) Cut and pry out lock nut stopper tabs away from
drive pinion shaft.
CAUTION:
Use care not to damage drive pinion shaft.
Do not reuse lock nut.

5) Remove lock nut, then remove lock washer from


drive pinion.

6) Drive out spring pin from reverse shifter rail using ST.
ST 398791600 STRAIGHT PIN REMOVER 2

12
SERVICE PROCEDURE 3.1
2. Transmission Side Cover

7) Remove 5th hub and sleeve together with 5th shifter


fork.
8) Remove synchronizer and 5th driven gear from
drive pinion.

9) Straighten lock nut of main shaft at staked portion,


and then remove the lock nut.
10) Remove lock washer and 5th drive gear from main
shaft.

11) Remove ST from main shaft, and wrap vinyl tape


around splined part of main shaft (to prevent damage to
oil seal).
ST 398781600 MAIN SHAFT STOPPER

12) Remove bearing retainer plate.

13) Remove snap ring of drive pinion ASSY bearing.

13
3.1 SERVICE PROCEDURE
2. Transmission Side Cover

14) Remove snap ring from reverse shifter rail.

B: ASSEMBLY
1. ASSEMBLY SNAP RING (OUTER 50)
1) Place ST1 on drive pinion center ball bearing [22 x
50 x 14 mm (0.87 x 1.97 x 0.55 in)], and install snap
ring (outer 50) on guide taper.
2) Shift gears to 2nd to allow ball bearing groove to be
raised over main case end face, operating shifter and
selector levers.
Then, press snap ring (outer 50) into bearing groove
with ST2.
ST1 499755501 SNAP RING GUIDE
ST2 499755502 SNAP RING PRESS

2. ADJUST MAIN SHAFT THRUST CLEARANCE (LH)


Measure depth L of ball bearing [#63/22N] with ST to
determine the number of Washers according to Table
given below.
ST 498147001 DEPTH GAUGE

Washer 46 x 55.2 x 0.2 mm


L (1.81 x 2.17 x 0.008 in)
Part NO- 803046020
0.2 mm (0.008 in) or less None
Over 0.2 mm (0.008 in) and
Use one
less than 0.4 mm (0.016 in)
0.4 mm (0.016 in) or more Use two

14
SERVICE PROCEDURE 3.1
2. Transmission Side Cover

3. ASSEMBLY SIDE COVER


1) Attach thrust clearance adjusting washer to main
shaft bearing (left) and install bearing retainer plate to
main case with bolts.
Tightening torque:
T: 25 2 Nm (2.5 0.2 kg-m, 18 1 ft-lb)

2) Remove vinyl tape from main shaft splines (left), and


install ST by maintaining alignment with housing
groove.
ST 398781600 MAIN SHAFT STOPPER

3) Install 5th drive gear and lock washer onto main


shaft spline (left), and tighten lock nut.
Apply gear oil to lock nut.
Tightening torque:
78 6 N m (8.0 0.6 kg-m, 58 4 ft-lb)

4) Stake lock nut at two locations.


CAUTION:
Use new lock nut.

5) Install 5th driven gear and synchronizer ring onto


bushing on drive pinion assembly.

15
3.1 SERVICE PROCEDURE
2. Transmission Side Cover

6) Assembling 5th hub assembly


(a) Install synchronizer sleeve and synchronizer
insert to synchronizer hub.
(b) Install synchronizer springs with ends of a
spring shifted 120 With respect to that on the
opposite side.
7) Mount insert stopper plate.

8) Place 5th shifter fork in synchronizer sleeve groove


and, while aligning 5th shifter fork hole with reverse
shifter rail, install hub assembly onto drive pinion.
NOTE:
Operate shifter lever and selector lever to shift gears to
1 st forward speed condition in mesh.

9) Install lock washer and lock nut to drive pinion.


Tighten lock nut, and then stake it at two portion.
Tightening torque:
78 6 N m (8.0 0.6 kg-m, 58 4 ft-lb)

10) Drive spring pin in 5th shifter fork and shifter rail.
ST 398791600 STRAIGHT PIN REMOVER 2
CAUTION:
Install spring pin so that slit of spring pin is
aligned with shifter rail centerline.
Do not reuse spring pin.

11) Degrease mating surfaces of transmission main


case and transmission side cover, apply liquid gasket
and secure with bolts,
CAUTION:
Speedometer gear is made of nylon, use care not to
deform it at assembly.
Tightening torque:
25 2 N m (2.5 0.2 kg-m. 18+1 ft-lb)

16
SERVICE PROCEDURE 3.1
2. Transmission Side Cover

3. speedometer Driven Gear


A: DISASSEMBLY
1) Using ST, remove snap ring from inside side cover
ASSY. And remove washer and speedometer driven
gear.
ST 899471410 SNAP RING EXPANDER

2) Remove oil seal and speedometer shaft from


speedometer cable attaching side.
NOTE:
Washer and snap ring are installed to shaft. Remove
snap ring of speedometer shaft in opposite direction to
oil seal attaching side (to prevent oil seal sliding portion
of shaft from damaging).
CAUTION:
Do not reuse oil seal.

B: ASSEMBLY
1) Install snap ring onto speedometer shaft from
speedometer driven gear side.
CAUTION:
Be sure not to install snap ring from oil seal sliding
portion side.

2) Put washer on speedometer shaft under snap ring.


Then insert speedometer shaft into side cover.
3) Install speedometer driven gear and washer to
speedometer shaft and secure with snap ring. Use ST
to install snap ring.
ST 899471410 SNAP RING EXPANDER

4) Install oil seal, using ST.


Apply grease to oil seal lips.
ST 499827000 SPEEDOMETER OIL SEAL PRESS

17
3.1 SERVICE PROCEDURE
3. speedometer Driven Gear

4. Gear Shifter & Selector Assembly


A: DISASSEMBLY
1) Place transmission so transmission coyer side is up.
And shift gears in neutral by operating shift and selector
lever.

2) Drive spring pin out from shifter shaft and lever


connecting portion by using ST.
ST 398791600 STRAIGHT PIN REMOVER 2
3) Remove shifter lever and shift sealing.
NOTE:
When necessary, drive spring pin out from selector
shaft and lever connecting portion by using ST.

4) Remove bolts and lightly strike transmission cover


attaching portion.
5) Remove transmission cover.

6) Loosen interlock bolt.

7) Remove gear shifter & selector ASSY from


transmission main case by operating selector lever.
CAUTION:
Use care not to damage O-ring of shifter shaft.

18
SERVICE PROCEDURE 3.1
4. Gear Shifter & Selector Assembly

8) Remove collar from transmission main case.


NOTE:
When necessary, remove selector shaft after separating
main case and clutch housing.
CAUTION:
Use care not to damage O-ring of shifter shaft.

B: ASSEMBLY
1) Place transmission so transmission cover side is up.
And shift gears in neutral.
2) Install collar into transmission main case.

3) Carefully install gear shifter & selector ASSY into


transmission main case, by operating selector lever.
CAUTION:
Mesh arm of selector shaft with groove of shifter
arm.

4) Tighten interlock bolt.


Tightening torque:
20.0 1.5 Nm (2.0 0.15 kg-m, 14 1.1 ft-lb)

5) Apply liquid gasket to outside transmission cover and


bolt hole pattern of transmission main case.
6) Using screwdriver not to touch reverse checking cam
with liquid gasket, install transmission cover to
transmission main case.
Tightening torque:
10.0 0.7Nm (1.0 0.075kg-m, 7.0 0.5 ft-lb)

19
3.1 SERVICE PROCEDURE
4. Gear Shifter & Selector Assembly

7) Install shifter lever to shifter shaft, and then drive


new spring pin into shifter lever and shaft connecting
portion.
ST 398791600 STRAIGHT PIN REMOVER

NOTE:
If installing selector shaft, tighten selector shaft bolt,
aligning its edge to groove on selector shaft.
Tightening torque:
10.0 0.7 Nm (1.0 0.075 kg-m, 7.0 0.5ty,

CAUTION:
Install spring pin so that slit of spring pin is
aligned with shifter shaft centerline.
Do not reuse spring pin.
Check to ensure that O-rings is in proper direction
as shown in Figure.

8) Check gear shifter & selector ASSY for smooth


operation.

20
SERVICE PROCEDURE 3.1
4. Gear Shifter & Selector Assembly

5. Transmission Main case


A: DISASSEMBLY
1) Remove side cover and related parts.
<Ref. to 3-1 [W2A0]>
2) Remove gear shifter and selector ASSY.
<Ref. to 3-1 [W4A0]>

3) Remove shifter rail spring plug and aluminum gasket.


and take out shifter fork spring and ball[6.350 mm
(0.2500 in)] from plug mounting hole at three locations.
CAUTION:
Be careful not to confuse shifter fork springs.

4) Remove snap rings and dust seals from differential


side gears.
CAUTION:
Do not reuse snap ring and dust seal.
Be careful not to forget to remove snap ring and
dust seal at clutch housing side (opposite side in
Figure) one.

5) Wrap vinyl tape around both splined portions of


differential side gears.
CAUTION:
Be careful not to forget to wrap vinyl tape around
clutch housing side (opposite side in Figure) one.

6) Remove bolts. While striking main case bolt


mounting sections and protrusions on the periphery of
mating surface with a plastic hammer, separate main
case from clutch housing.

21
3.1 SERVICE PROCEDURE
5. Transmission Main case

7) Remove thrust clearance adjusting washers from


differential side bearing.
CAUTION:
Do not hammer main case outer wall, side cover
mating surface rib, and shift connecting rod
prevent deformation and damage.
Be careful not to lose differential side bearing
adjusting washer which may be adhering to main
case.

8) Remove snap pin from clevis pin of reverse shifter


lever and remove clevis pin.

9) Remove reverse shifter rail from clutch housing.


CAUTION:
Be careful not to lose plunger in shifter rail
connecting parts.

10) Pull out reverse idler shaft together with reverse


idler gear and remove reverse shifter lever.

11) Remove reverse shifter rail by moving it upward.


12) Carefully pull out main shaft assembly and drive
pinion assembly together with arm, shifter rail, and
related parts. (Parts such as fork and arm are fastened
to rail with spring pin.)

22
SERVICE PROCEDURE 3.1
5. Transmission Main case

13) Pull out differential assembly.

B: ASSEMBLY
CAUTION:
Always use a new gasket.
When disassembling oil seal, replace it with a new
one.
When replacing oil seal, apply grease to lip.
Apply gear oil to bearing and gear.

1. ASSEMBLING MAIN CASE


1) If removing differential gear oil seal L [27 x 45 x 9
mm (1.06 x 1.77 x 0.35 in)], replace with new
differential gear oil seal L by using ST.
ST 498175600 OIL SEAL INSTALLER
CAUTION:
Oil seal with mark L must be used, and gear oil
must be applied to lips. If oil seal with mark R is
used, oil leakage will result.
NOTE:
Press oil seal into place until ST rests evenly against
main case.

2) Press ball bearing [#6304] of transfer shaft into


place. (4WD Model only)

23
3.1 SERVICE PROCEDURE
5. Transmission Main case

2. INSTALLING GEAR ALLIED PARTS


1) Install differential assembly into clutch housing
Wrap vinyl tape around splines at end of both
differential side gears.
During installation, ensure that oil seal lip is not
separated. Install with differential case facing downward

2) Assemble drive pinion assembly and main shaft


assembly together with 1 st-2nd fork and 3rd-4th fork.
CAUTION:
Wrap vinyl tape around main shaft splines.
Coat sliding surfaces of fork and sleeve with
sufficient amount of gear oil.

3) Install reverse shifter lever to straight pin of clutch


housing.
4) Install plunger [5.26 x 11.1 mm (0.2071 x 0.4370 in)]
into reverse shifter arm 2 of reverse shifter rail, Then
mount reverse shifter rail into housing.
Apply grease to plunger to prevent it from coming off.
Assemble reverse shifter lever with reverse shifter arm
2. Then install clevis pin, and insert snap pin.

5) Assemble reverse idler shaft with spring pin [4x12


mm (0.16 x 0.47 in)] attached, together with reverse
idler gear, into housing.
Spring pin height:
5-6 mm (0.20 0.24 in)

6) Mesh reverse shifter lever of gear shifter arm ASSY


with reverse idler gear.

24
SERVICE PROCEDURE 3.1
5. Transmission Main case

7) Adjusting thrust clearance of differential assembly


(a) Pace ST3 on main case mating surface and put
ST1 on ST3, and measure depth (h2) of outer race
of ball bearing [#6207] with ST2.
(b) Measure depth (h1) of ball bearing in main case
CP.
(c) Make calculation using following equations to
select washer so that clearance may be adjusted to
0 to 0.2 mm (0 to 0.008 in)
ST1 499575400 BEARING HEIGHT GAUGE
ST2 498147001 DEPTH GAUGE
ST3 498285400 BEARING HEIGHT BLOCK

C = hi - (20.5-h2) (mm)
C = hi - (0.807-h2) (in)
Washer 61 x 71 x 0.2 mm
C (2.40 x 2.80 x 0.008 in)
Part No. 803061020
0.2 mm (0.008 in) or less None
Over 0.2 mm (0.008 in) and less
Use one
than 0.4 mm (0.016 in)
0.4 mm (0.016 in) or more Use two

C = Thrust clearance [0 to 0.2 mm (0 to 0.008 in)]


h1 = Depth at main case side
h2 = Bearing outer race height

8) Install washer [61 x 71 x 0.2 mm (2.40 x 2.80 x 0.008


in)] on main case side.
Apply grease to washer to prevent it from coming off.

3. MOUNTING MAIN CASE


1) Assemble washers on main case.

25
3.1 SERVICE PROCEDURE
5. Transmission Main case

2) Wipe off grease, oil and dust on the mating surfaces


of transmission case with white gasoline, and apply
liquid gasket.
Liquid gasket:
Part No. 004403007

3) Install main case onto clutch housing with main shaft,


drive pinion and differential side gear bearing, transfer
shaft (4WD model) and shifter rail holes aligned.
CAUTION:
Apply sufficient amount of gear oil to bearing
journals and rails.

4) Fasten housing to main case with bolts. Tighten bolts


in order shown in figure.
Tightening torque:
25+ 2 N m (2.5 0.2 kg-m, 181 ft-lb)

5) Install dust seal to differential side bearing hole,


pushing dust seal onto differential side gear
CAUTION:
Do not reuse dust seal.

26
SERVICE PROCEDURE 3.1
5. Transmission Main case

6) Install snap ring to snap ring groove of differential


side gear splined portion, pushing firmly by finger but
not to deform snap ring.
CAUTION:
Do not reuse dust seal.

7) Put ball [6.350 mm (2.5000 in)], shifter fork rail spring


and aluminum gasket into main case at rail end, and
tighten shifter rail spring plug.
Tightening torque:
20.0 1.5 Nm (2.0 0.15 kg-m, 14 1.1 ft-lb)
NOTE:
Install shifter rail spring as per table given below.
ID color: White (1 - 2)
Gold (3 4, 5 Reverse)

8) Install snap ring (outer 50) into drive pinion center


ball bearing groove with ST1 and ST2.
ST1 499755501 SNAP RING GUIDE
ST2 499755502 SNAP RING PRESS
<Ref. to 3-1 [W2B1]>
9) Adjust main shaft thrust clearance (LH).
<Ref. to 3-1 [W2B1]>
10) Install bearing retainer plate.
<Ref. to 3-1 [W2B3]>

6. Clutch Housing
A: DISASSEMBLY
1) Remove side cover and related parts.
<Ref. to 3-1 [W2A0]>
2) Remove main case and related parts.
<Ref. to 3-1 [W5A0]>

3) Loosen bolts, and remove clutch housing retainer


and needle bearing and oil guide from drive pinion
installing portion.
CAUTION:
Do not disassemble bearing and oil seal except
that it damaged.
Replace with new bearing and oil seal if required.

27
3.1 SERVICE PROCEDURE
6. Clutch Housing

4) Remove bearing and oil seal from differential ASSY


installing portion, bearing by using ST and oiI seal from
mainshaft installing portion.
ST 499705401 BEARING OUTER RACE PULLER

B: ASSEMBLY
1) When oil seal [19.8 x 35x7 mm (0.780 x 1.378 x
0.276 in)] is installed to main shaft front, check to
ensure that grease has been applied to lips and install
oil seal with dust lip downward.

2) Install ball bearing to main shaft front. Ball bearing


should be installed with stamped side up.

3) Press oil seal R [27 x 45 x 9 mm (1.06 x 1.77 x 0.35


in)] into place until installer rest evenly against clutch
housing by using ST.
CAUTION:
Check to ensure that gear oil has been applied to
lips and install oil seal with mark up.
Oil seal with mark R must be used. If oil seal with
mark L is used, oil leakage will result.
ST 498175700 OIL SEAL INSTALLER

4) Install driven pinion oil guide, needle bearing [25x 37


x 17 mm (0.98 x 1.46 x 0.67 in)], and drive pinion rear
retainer at the right side of drive pinion by tightening
bolts.
Tightening torque:
10.0 0.7 N m (1.00 0.075 kg-m,
7.0 0.5 ft-lb)

28
SERVICE PROCEDURE 3.1
6. Clutch Housing

7. Drive Pinion Assembly


A: DISASSEMBLY
1. DRIVE PINION ASSEMBLY
1) Using ST1 and ST2, remove ball bearing (1), 5th
drive gear thrust washer (2), bushing (3) and thrust
washer (4), all together.
NOTE:
Insert ST1 between 4th driven gear and washer.
Be careful in removing as bearing is hard to come off.

ST1 498515500 DRIVE PINION BEARING REPLACER


ST2 899864100 MAIN SHAFT REMOVER

2) Remove 4th driven gear (5), synchronizer ring (6)


and 3rd-4th hub assembly (7).
3) After pull out gear thrust spacer key (8), remove gear
thrust spacer 2 (9), synchronizer ring (15), 3rd driven
gear gear thrust spacer (11), 2nd driven gear and gear
thrust spacer (13).
4) After pull out gear thrust spacer key 2 (14), remove
reverse driven gear (1st-2nd hub assembly) (16),
synchronizer ring (15), and 1st driven gear (17).
CAUTION:
Not disassemble washer (18) and bushing (19)
except that it damaged.

2. HUB ASSEMBLY
1) Disassemble reverse driven gear (1st-2nd hub
assembly) (16).
Remove synchronizer spring (1), and pull out
synchronizer hub insert (2). Then separate reverse
driven gear
(3) and synchronizer hub (4).
2) Disassemble 3rd-4th hub assembly (7).
Remove synchronizer spring (5), and pull out
synchronizer hub insert (6). Then separate
synchronizer hub (7) and synchronizer hub sleeve (8).

29
3.1 SERVICE PROCEDURE
7. Drive Pinion Assembly

B: INSPECTION
1. GEAR
1) Check the gear tooth surface for abnormal wear,
damage, and replace if defective.
2) Replace if cone located at synchronizer ring is seized
or damaged.
3) Replace if inner wall at bearing location or end face
is excessively worn or damaged.
4) Replace if spacer end faces and bushing are
excessively worn or damaged.
5) Thrust clearance of gear (side clearance).
NOTE:
When inspecting clearance, see to <Ref. to 3-1
[S1B0]>.

2. SYNCHRONIZER RING
1) Check the inside surface and, tooth surface of
synchronizer ring for damage or abnormal wear, and
replace if defective.
2) Check the clearance between synchronizer ring and
cone. Press the ring against the cone and measure the
clearance C between the interfaces of the ring and
cone.
Standard value of C: 1.2 mm (0.047 in)
Limit of C: 0.5 mm (0.020 in)

3) Replace if synchronizer hub insert mating surface is


excessively worn.

3. SYNCHRONIZER HUB INSERT


Check the synchronizer hub insert for excessive wear
and other defects and replace if defective.

30
SERVICE PROCEDURE 3.1
7. Drive Pinion Assembly

C: ASSEMBLY
1) Assemble reverse driven gear (1st-2nd hub
assembly) (16).
(1) After setting synchronizer insert onto
synchronizer hub, insert synchronizer hub into
reverse driven gear.
(2) Install synchronizer spring.
2) Assemble 3rd-4th hub assembly (7).
(1) After setting synchronizer insert onto
synchronizer hub, insert synchronizer hub into
synchronizer hub assembly.
(2) Install synchronizer spring.
CAUTION:
if disassembling washer (18) and bushing (19),
replace it with new one.
NOTE:
When installing synchronizer spring, set it by offsetting
inside diameter of one spring 120 with respect to that
of the other spring, and check to ensure that insert is in
position.

3) Install 1st driven gear (17) and synchronizer ring


(15).
4) Install reverse driven gear (1st-2nd hub assembly)
(16) so that portion of synchronizer hub that has no
angular spline tooth will be positioned away from oil
hole of drive pinion shaft.

5) After insert gear thrust spacer key 2 (14), install


thrust spacer (13).
NOTE:
When install gear thrust spacer be careful for gear
thrust spacer key installing position.
6) Install synchronizer ring (15), 2nd driven gear (12),
gear thrust spacer 2 (11), 3rd driven gear (10). gear
thrust spacer 2 (9), and synchronizer ring (7).

7) As for gear thrust spacer 2 (9) face end of notched


groove [6.6 mm (0.260 in) wide, 1.5 mm (0.059 in)
deep] toward 4th driven gear, make a turn to match
toothless portion of splines, and insert gear thrust
spacer key (8) into notched groove.
NOTE:
Confirm that each gear thrust spacer key is exactly
positioned in its correct location.

31
3.1 SERVICE PROCEDURE
7. Drive Pinion Assembly

8) Install synchronizer ring (7).

9) Install 3rd-4th hub assembly (7) so that portion of


synchronizer hub that has no angular spline tooth will
be positioned away from oil hole of driven pinion shaft.
10) Install synchronizer ring (6).
11) Install 4th driven gear (5) and Washer (4),
NOTE:
When installing Washer (4) to 4th driven gear, face oil
groove surface of Washer toward 4th driven gear.

12) Install ball bearing (1) With stamped mark toward


spline shaft, using ST.
ST1 899754112 SNAP RING PRESS
ST2 899754102 SNAP RING PRESS

13) Mount 5th driven gear thrust plate (2), and press-fit
5th driven gear bushing (3) using ST.
ST 899754112 SNAP RING PRESS

8. Main Shaft Assembly


A: DISASSEMBLY
Press out main shaft ball bearing using ST1 and ST2.
ST1 498515500 DRIVE PINION BEARING REPL-
ACER
ST2 899864100 MAIN SHAFT REMOVER

B: ASSEMBLY
Press ball bearing [22 x 56 x 16 mm (0.87 x 2.20 x 0.63
in)] onto main shaft, using ST.
ST1 899754112 SNAP RING PRESS
ST2 498515500 DRIVE PINION BEARING REPL-
ACER

32
SERVICE PROCEDURE 3.1
8. Main Shaft Assembly

9. Differential Assembly
A: DISASSEMBLY
1) Remove bolls, and take out final gear.

2) Remove differential side gear adjusting washer from


final gear side.

3) Remove straight pin from differential case, and take


out differential pinion shaft. Then remove differential
pinions, differential side gears, and adjusting washer.
CAUTION:
Be careful not to damage differential side gear
ground portion which is a sliding surface for oil
seal.
NOTE:
Place removed adjusting washer for final gear side
separately from those for differential case side.

4) Using ST1 and ST2, pull out ball bearing from


differential case.
ST1 399520105 DIFFERENTIAL BEARING PUL-
LER SEAT
ST2 399703600 PULLER ASSEMBLY
CAUTION:
Do not remove differential side bearing (#6207)
except when necessary.
When bearing to be replaced, use new one.

B: INSPECTION
1) Replace final gear if tooth face is damaged or shows
excessive wear.
2) Replace if pinion gear, bevel gear, washer [27.1 x 42
x t mm (1.067 x 1.654 x t in)] and differential shaft are
worn, seized or damaged.
3) Replace if case is cracked or otherwise damaged.

33
3.1 SERVICE PROCEDURE
9. Differential Assembly

C: ASSEMBLY
1) Replace if roiling surface of needle bearing (at drive
pinion shaft) or sliding surface of hexagonal splines ( at
gear) shows excessive wear.
2) Assemble ball bearing (#6207) onto final gear,using
ST.
3) Assemble ball bearing (#6207) using ST.
ST 899580100 BEARING INSTALLER

3) Assemble pinion, washer [27.1 x 42 x t mm (1.067 x


1.654 x t in)] , side gear, pinion shaft, and straight pin [4
x 35 mm (0.16 x 1.38 in)] on differential case side and
washer [27.1 x 42 x t mm (1.067 x 1.654 x t in)] and
side gear on final gear side. Then, install differential
case to final gear with tightening torque specified
below, and measure backlash. Vary washer to obtain
backlash in the range between 0.05 mm (0.0020 in)
and 0.15 mm (0.0059 in).
After assembling check to ensure that gears turn
smoothly. Install adjusting washers with chamfered side
of inside diameter toward differential side gear.
Tightening torque:
62 5 N m (6.3 0.5 kg-m, 46 4 ft-lb)
Adjusting Washers
27.1 x 42 x t mm (1.067 x 1.654 x t in)
Part No. Standard Thickness mm (in)
803027041 1.000 (0.0394)
803027042 1.050 (0.0413)
803027043 1.100 (0.0433)
10. Arms and Forks
A: DISASSEMBLY
Drive out spring pin with ST to remove it from rail. Then,
separate fork and arm from rail.
ST 398791600 STRAIGHT PIN REMOVER 2

B: INSPECTION
1) Check to ensure that clearance between shifted fork
and groove in synchronizer sleeve is within
specifications.
Standard value:
0.4 - 0.6 mm (0.016- 0.024 in)

34
SERVICE PROCEDURE 3.1
10. Arms and Forks

2) Replace if lock ball [6.350 mm (0.25000 in) or spring


is excessively worn or deformed.
3) Replace if lock ball groove ridgeline in rail is worn.
4) Replace other faulty parts if excessively worn, bent
or damaged.

C: ASSEMBLY
1) Fasten fork and arm onto rail with spring pin [5 x 22
mm (0,20 x 0.87 in)].
CAUTION:
Always use a new spring pin.
NOTE:
Install spring pin with its slit facing toward rail axial
direction.
2) Fasten reverse shifter arm (2) to reverse shifter rail
(1) with spring pin. With spring (3) and ball [5.556 mm
(0.21874 in)] (5), install in reverse shifter arm 2 (4),
insert rail into arm 2 (4) while holding ball (5) in position
with a screwdriver.
Then using ST, put snap rings into lower two ones of
three undercuts on reverse shifter rail.
ST 899471410 SNAP RING EXPANDER
NOTE:
Install ball (5) into reverse shifter arm 2 after applying
grease on ball (5).

11. Other Parts


A: INSPECTION
1. BEARING
Bearing should be replaced if burns, wear, noise,
unsmooth rotation, etc. are evident.
To check for noise and unsmooth rotation, supply gear
oil and check the bearings by turning.

35
3.1 SERVICE PROCEDURE
11. Other Parts

Location Bearing mm(in)


[Ball bearing] 20 x 52 x 15
Main shaft (engine side)
(0.79 x 2.05 x 0.59)
Main shaft (4th gear side) 22 x 56 x 16 (0.87 x 2.20 x 0.63)
[Needle bearing]
Drive pinion (engine side)
24.7 x 44 x 23 (0.97 x 1.73 x 0.91)
Drive pinion (4th gear side) 22 x 56 x 16 (0.87 x 2.20 x 0.63)
[Ball bearing] 35 x 72 x 17
Differential (right)
(1.38 x 2.83 x 0.67)
[Ball bearing] 35 x 72 x 17
Differential (left)
(1.38 x 2.83 x 0.67)

2.OIL SEAL
Check the oil seal lips for deformation, hardening, wear,
etc. and check the outside periphery of the oil seal for
damage and replace if defective.

Location Oil seal mm (in)


Oil seal
Main shaft (engine side) 19.8x35x7
(0.780x1.38x0.28)
Oil seal (RH)
Differential (right) 27 x 45 x 9
(1.06x1.77x0.35)
Oil seal (LH)
Differential (left) 27 x 45 x 9
(1.06 x 1.77 x 0.35)

12. 4WD Mechanism


NOTE:
Following description deals with operating procedures
necessary for 4WD model only.
Before disassembly of 4WD mechanism, remove side
cover, main case and related parts. <Ref. to 3-1 [W2A0]
and 3-1 [W5A0]>

A: DISASSEMBLY
1. EXTENSION
1) Remove bolts, and separate extension from clutch
housing.

36
SERVICE PROCEDURE 3.1
12. 4WD Mechanism

2. BEARING CASE ASSEMBLY


Remove bolts, and separate bearing case assembly
and height adjusting shim from clutch housing.

3. TRANSFER SHAFT ASSEMBLY AND DIAPHRAGM


1) Remove bolts, and take out transfer cover and
gasket from transfer coven

2) Remove spring and ball [6.350 mm (2.5000 in)] from


inside clutch housing.

3) Remove spring pin from transfer shifter rail to free


transfer shifter fork with synchronizer hub sleeve.
ST 899904100 STRAIGHT PIN REMOVER

4) Remove oil reservoir plate attaching bolt.


Lightly take transfer shifter fork with synchronizer hub
sleeve up, and remove oil reservoir plate.

37
3.1 SERVICE PROCEDURE
12. 4WD Mechanism

5) Remove bolts from transfer Side cover, and take out


diaphragm cover and transfer diaphragm.

6) Remove bolts from clutch housing to take out


transfer side cover together With gasket.

7) Remove transfer shaft ASSY from transmission main


case side by lightly striking with a plastic hammer.

4. TRANSFER SHAFT ASSEMBLY


NOTE:
4WD transfer shaft ball bearing [25 x 70 x 30 mm
(0.98 x 2.76 x 1.18 in)] should be checked for rotation
before disassembly.
In this case, bearing will feel somewhat heavy
because of application of preload.

1) Remove caulking strip, and take out lock nut and


lock Washer in order, using ST1 and ST2.
ST1 499885400 BEVEL GEAR HOLDER
ST2 499985500 SOCKET WRENCH ASSEMBLY

38
SERVICE PROCEDURE 3.1
12. 4WD Mechanism

2) Using ST1, ST2 and a press, remove bevel drive


gear, transfer shaft collar, and ball bearing. Be careful
not to damage key in bevel drive gear.
ST1 899/14110 REMOVER
ST2 899864100 MAIN SHAFT REMOVER

3) Remove snap ring using ST arid then remove


washer, transfer gear.
ST 899474100 SNAP RING EXPANDER

4) Remove synchronizer hub by using ST1 and ST2.


ST1 899714110 REMOVER
ST2 899864100 MAIN SHAFT REMOVER
5) Remove key from transfer shaft.

5 TRANSFER DAMPER ASSEMBLY


1) Remove snap ring.

2) Disassemble damper ASSY.

39
3.1 SERVICE PROCEDURE
12. 4WD Mechanism

6. BEARING CASE ASSEMBLY


1) Remove caulking strip and take out lock nut, lock
washer in order, using ST.
ST 498405400 BEVEL GEAR STAND

2) Remove bevel driven gear using ST1, ST2 and a


press.
ST1 899714110 REMOVER
ST2 899864100 MAIN SHAFT REMOVER

3) Remove rear bearing cone.

4) Remove front bearing cone from bevel driven gear,


using ST 1, ST2 and a press.
ST1 498515400 BEVEL GEAR REPLACER
ST2 899864100 MAIN SHAFT REMOVER

5) Press out bearing races from bearing case, using ST.


ST 398527700 OIL SEAL & OUTER RACE
PULLER ASSEMBLY

40
SERVICE PROCEDURE 3.1
12. 4WD Mechanism

B: ASSEMBLY
This sub-section describes assembly work required for
4WD model only.
Reassemble all parts by reversing order of
disassembly, while paying attention to the following
points.
1) Check bevel gear for damage, burns, abnormal
wear, etc. and replace if defective.
Drive gear and driven gear should be replaced as a set.
2) Whenever oil seals are removed from extension,
speedometer gear, gear shifter, main shaft, and
differential, they must be replaced with a new one.
3) When oil seals are replaced or washed, apply grease
to their lips.
4) Use a new lock nut for bearing case assembly and
transfer shaft assembly.
5) There must be no oil or dust on diaphragm.
6) When gaskets irrespective of paper and aluminum
one are disassembled, replace them all with a new one.
7) Coat sliding surfaces of bearings and gears with
gear oil.

1. TRANSFER SHAFT ASSEMBLY


1) Handle drive and driven gears of bevel gears as a
set.

41
3.1 SERVICE PROCEDURE
12. 4WD Mechanism

2) Transfer damper assembly


(1) Assemble damper ASSY.
CAUTION:
Insert dampers into transfer drive hub so that 4
dampers evenly deflect in transfer drive hub

(2) Install washer and snap ring so that clearance is


less than 0.07 mm (0.0028 in).
Transfer damper washer to snap ring clearance:
0 - 0.07 mm (0- 0.0028 in)
NOTE:
Attach snap ring outer 35 as per table given below
Snap ring thickness H:
Snap ring outer 35
Thickness mm Thickness mm
Part Number Part Number
(in) (in)
805035020 0.47 (0.0059) 805035060 1.59 (0.0197)
805035030 1.72 (0.0079) 805035070 1.655 (0.0069)
805035050 1.53 (0.0098) 805035080 1.78 (0.0089)

3) After installing synchronizer hub onto transfer shaft,


force bushing onto transfer shaft using ST. Make sure
that bushing is forced in correct direction and gear oil is
applied to bushing beforehand.
ST 899754102 SNAP RING PRESS

42
SERVICE PROCEDURE 3.1
12. 4WD Mechanism

4) Choose snap ring to adjust clearance between snap


ring and washer to 0 to 0.05 mm (0 to 0.020 in) and
install snap ring onto transfer shaft, using ST2 and ST3.
ST1 499966900 THICKNESS GAUGE
ST2 899754100 SNAP RING PRESS
ST3 899754121 SNAP RING GUIDE

5) Fit key into a keyway in transfer shaft, press bevel


gear onto transfer with ST.
ST 899580100 BEARING INSTALLER

6) Press-fit ball bearing [25 x 70 x 30 mm (0.98 x 2.76 x


1.18 in)] with ST.
ST 899580100 BEARING INSTALLER

7) Mount lock washer and lock nut to transfer shaft, and


then stake in one place. Make sure that new lock nut is
always used.
Tightening torque:
78 6 N m (8.0 0.6 kg-m, 58 4 ft-lb)

43
3.1 SERVICE PROCEDURE
12. 4WD Mechanism

2. BEARING CASE
Adjustment of bevel gear height (selection of bevel
gear height adjusting shims)
1) Install front and rear bearing races into bearing case,
using ST 1, ST2 and ST3.
ST1 398477701 DRIVE PINION OUTER RACE
DRIFT HANDLE
ST2 398477702 BEARING OUTER RACE DRIFT
ST3 498215402 DIFFERENTIAL CARRIER
STAND

2) After installing rear bearing cone onto ST, insert it


into bearing case.
With front bearing cone and lock washer installed onto
dummy shaft, tighten new lock nut finger-tight. Apply oil
to bearing.
ST 498505402 BEVEL GEAR DUMMY SHAFT

3) Use ST to tighten lock nut. Do not tighten lock nut all


the way. While confirming the following item 4), tighten
lock nut in two or three steps.
Use care that preload is not increased excessively.
Avoid tightening lock nut to the extent that dummy shaft
cannot be turned by hand.
ST1 499985500 SOCKET WRENCH ASSEMBLY
ST2 498505402 BEVEL GEAR DUMMY SHAFT

4) For load measurement, turn bearing case several


times, install a spring balance in bolt hole in bearing
case, and measure load at the time it starts moving.
ST 499985500 SOCKET WRENCH ASSEMBLY
Load:
9.32 - 18.63 N (0.95 - 1.90 kg, 2.09 - 4.19 lb)
Starting torque:
0.39 - 0.78 N m (4.0 - 8.0 kg-cm, 3.5- 7.0 in-lb)

5) Install ST through transfer shaft hole in clutch


housing and tighten bolts [8 x 20 mm (0.31 x 0.79 in)] at
four locations.
ST 498505700 BEVEL GEAR GAUGE ASSEMBLY
Tightening torque:
25 3 N m (2.0 0.2 kg-m, 18 2 ft-lb)

44
SERVICE PROCEDURE 3.1
12. 4WD Mechanism

6) Install bearing case, with dummy shaft assembled


into it, into clutch housing and tighten bolts [8 x 20 mm
(0.31 x 0.79 in)] at four locations.
7) Measure space between gauge and dummy shaft
top with ST.
The shim thickness is obtained by subtracting gauge
from 1 mm (0-039 in).
ST 499667000 THICKNESS GAUGE

Bevel gear height shim


Thickness
Part Number Part Number Thickness mm (in)
mm (in)
33189KA000 0-150 (0.0Q59) 33189KA040 0,250 (0.0098)
33189KA010 0-175 (0.006m 33189KA050 0.275 (0.0108)
33189KA020 0.200 (0,0079) 33189KA060 0.300 (0.0118)
33189KA030 0-225 (0,0089) 33189KA070 0.500 (0.0197)
8) Remove bearing case assembled bevel gear dummy
shaft and ST from housing.

Installing bevel driven gear in place of dummy shaft


1) Press-fit rear bearing cone onto bevel driven gear,
using ST1 and ST2.
ST1 498175400 BEVEL GEAR BEARING INSTALLER
ST2 899864100 MAIN SHAFT REMOVER

2) Install bevel driven gear, with collapsible spacer


attached on it, into bearing case.
Before installing, apply gear oil to bearing. See to <Ref.
to 3-1 [S1B0]>.

3) Press-fit front bearing cone into bearing case, using


ST1 and ST2.
At that time, apply gear oil to bearing. See to <Ref. to 3-
1 [S1B0]>.
ST1 498175400 BEVEL GEAR BEARING INSTALLER
ST2 899864100 MAIN SHAFT REMOVER

45
3.1 SERVICE PROCEDURE
12. 4WD Mechanism

4) Install lock washer and nut. Using ST, tigten lock nut
until there is no play in bearing case and bevel driven
gear, then hook a spring balance into bolt hole of bearing
case to measure starting torque, if preload is insufficient,
retighten lock nut another 5 to 10. Do not perform
caulking until tooth contact pattern check is completed.
If preload is excessive, replace spacer.
ST 498405400 BEVEL GEAR STAND
Load:
9.32 - 18.63 N (0.95 - 1.90 kg, 2.09 - 4.19 lb)
Starting torque:
0.39 - 0.78 Nm (4.0 - 8.0 kg-cm, 3.5- 7.0 in lb)
5) Loosen and retighten lock nut, and stake at two
portions.
Tightening torque:
78 - 128 N m (8 13 kg-m, 58 - 94 ft-lb)

46
SERVICE PROCEDURE 3.1
12. 4WD Mechanism

3. TRANSFER SHAFT ASSEMBLY AND BEARING-


CASE ASSEMBLY
Selection of bevel gear backlash adjusting shims
1) Install transfer shaft assembly into clutch housing.
Do not assemble synchronizer sleeve, O-ring, and
shim.
NOTE:
Clutch housing end face and ball bearing [25 x 70 x 30
mm (0.98 x 2.76 x 1.18 in) ] should be spaced a few
mm apart.
2) With bevel gear height shim, selected through height
adjustment, attached to bearing case assembly, install
bearing case to clutch housing with 4 bolts [8 x 20 mm
(0.31 x 0.79 in)].
Tightening torque:
29 3 N m (3.00.3 kg-m, 22 2 ft-lb)

3) Fasten ST3 to clutch housing with bolt [8 x 20 mm


(0.31 x 0.79 in)], and mount ST1 and ST2.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
ST3 498247400 MAGNET BASE PLATE

4) Insert dial gauge probe through backlash adjusting


hole and set it on bevel driven gear.

5) Gradually pull transfer shaft assembly until bevel


gear backlash become 0. Then, measure clearance
between clutch housing end face and ball bearing [25 x
70 x 30 mm (0.98 x 2.76 x 1.18 in)] flange with ST.
ST 499667000 THICKNESS GAUGE

6) Pull out bearing case assembly and transfer shaft


assembly.

47
3.1 SERVICE PROCEDURE
12. 4WD Mechanism

7) Attach to transfer shaft assembly shim with a


thickness of clearance measured in 5) minus about 0.2
mm (0.008 in). Then, fasten transfer shaft assembly to
clutch housing with 2 bolts [8 x 20 mm (0.31 x 0.79 in)]
ST 499667000 THICKNESS GAUGE
Shim (drive pinion)
Thickness Thickness
Part Number Part Number
mm (in) mm (in)
841968601 0.150 (0.0059) 841968605 0.500 (0.0197)
841968602 0.200 (0.0079) 841968606 0.175 (0.0069)
841968603 0.250 (0.0098) 841968607 0.225 (0.0089)
841968604 0.300(0.0118) 841968608 0.275 (0.0108)

8) Install transfer shaft assembly shim to bearing case


ASSY, and tighten 4 bolts [8 x 28 mm (0.31 x 1-10 in) to
fasten transfer shaft assembly to clutch housing.

9) Hold transfer shaft assembly in position, and measure


backlash by moving bevel driven gear.
Backlash specification:
0.1 -0.15 mm (0.0039 - 0.0059 in)

10) if the specified backlash is not obtained vary


transfer shaft assembly shim.
ST 498247100 DIAL GAUGE

11) Pull out bearing case assembly and transfer shaft


assembly.

Installing transfer shaft assembly and bearing case


assembly
1) Insert transfer shaft assembly into main case with
drive pinion shim and O-ring attached. Then, tighten
bolts to the specification to secure transfer shaft
assembly.
Tightening torque:
20 2 N m (2.0 0.2 kg-m, 14 1 ft-lb)

48
SERVICE PROCEDURE 3.1
12. 4WD Mechanism

2) Apply a thin even coat of red-lead to bevel driven


gear teeth surface. Then, tighten bolts to fasten bearing
case assembly together with bevel gear height shim.
Tightening torque:
29+3 N m (3.0 0.3 kg-m, 22 2 ft-lb)

3) Check backlash.
Backlash specification:
0.10 - 0.15 mm (0.0039 - 0.0059 in)
ST 498247100 DIAL GAUGE

Checking bevel gear tooth contact


1) Mount ST1 onto lock nut of transfer shaft assembly,
and tighten screw to eliminate looseness.
2) Mount ST2 onto ST1.
Hold bevel driven gear splines in position by way of
waste cloth, and rotate ST2 several complete turns.
Then, judge contact condition by contact pattern
obtained.
ST1 499985500 SOCKET WRENCH ASSEMBLY
ST2 499925400 HANDLE

49
3.1 SERVICE PROCEDURE
12. 4WD Mechanism

3) Readjust if proper backlash or contact pattern is not


obtained.

Bevel Driven Gear Tooth Contact (Drive Side Shown)


Check Condition Adjustment
Correct tooth contact

Face contact Replace bevel gear height shim


with thick one and replace drive
Occurs when bevel gear height
shim is thin or when backlash is pinion shim with thin one.
large.

Flank contact Replace bevel gear height shim


with thin one and replace drive
Occurs when bevel gear height
shim is thick or when backlash is pinion shim with thick one.
small.

On bevel driven gear, convex side is drive side, wherea concave side is coast side.

4. EXTENSION ASSEMBLY
1) Press oil seal into extension case, using ST.
ST 498415700 OIL SEAL DRIFT
2) Apply liquid gasket to bolt hole pattern of extension
case.

3) Install extension together with extension gasket to


clutch housing by tightening bolts. (No plain washer
involved)
Tightening torque:
25 2 N m (2.5 0.2 kg-m, 18 1 ft lb)

50
SERVICE PROCEDURE 3.1
12. 4WD Mechanism

5. TRANSFER SIDE COVER CP ASSEMBLY


1) Press oil seal [13 x 26 x 9 mm (0.51 x 1.02 x 0.35
in)] and knock pipe.
NOTE:
Oil seal must first be press-fitted before knock pipe.
Knock pipe height 10-11 mm (0.39 - 0.43 in)

2) After inserting transfer sealing to knock pipe, install


transfer side cover to clutch housing together with
adjusting shim, transfer shaft bearing and gasket. At
same time, adjust knock pipe to transfer rail hole in
clutch housing.

3) Install transfer side cover by tightening bolts.


Tightening torque:
20 2 Nm (2.0 0.2 kg-m, 14 1 ft-lb)

6. ASSEMBLY OF DIAPHRAGM AND RELATED-


PARTS
1) Insert transfer diaphragm from housing side, and
install transfer shifter fork and synchronizer sleeve onto
transfer diaphragm rail from main case side.
Tightening torque:
T: 6.4 0.5 Nm (1.0 0.15 kg-m, 4.7 0.4 ft-lb)

2) Lightly take transfer shifter fork and synchronizer hub


sleeve up, and tighten oil reservoir plate attaching
bolts.

51
3.1 SERVICE PROCEDURE
12. 4WD Mechanism

2) Using ST, drive spring pin in shifter form transfer


cove: mounting hole in clutch housing.
ST 899904100 STRAIGHT PIN REMOVER

3) Install transfer side cover to clutch housing


Tightening torque:
T 6.4 0.5 Nm (1 0.075 kg-m, 4.7 0.4 ft-lb)

3) Install spring and ball [6.350 mm (0.25000 in)]


to inside clutch housing.

4) Install transfer cover, together with gasket, to clutch


housing by tightening bolts.
Tightening torque:
10.0 0.7Nm (1.00 0.075kg-m, 0.5ft-lb)

5) Tighten 4WD switch to specified torque.


Tightening torque:
18 2 N m (1.8 0.2 kg-m, 13 1 ft-lb)

52
TROUBLESHOOTING 3.1
1. Manual Transmission and
Differential

1. Manual Transmission and Differential


Symptom and Probable cause Remedy
1. Hard gearshiftting
The conditions that cause hard gear-shifting can be due to a malfunction of the
change cable or transmission.
However, if shift lever operates heavily and gear-shifting is difficult, it can also be
due to "Improper clutch disengagement." Therefore, first inspect to see if clutch
functions properly and then check change cable and transmission.

(1) Loose or separated change cable joints Adjust or replace


(2) Internal splines of reverse driven gear and sleeve worn, damaged, or rough Replace
(3) Splines of each gear worn, damaged, or rough Replace
(4) Lack of working stroke due to worn or loose sliding parts Repair or replace
(5) improper contact of synchronizer ring with gear cone, or their wear Replace
2. Gear disengagement during operation
Generally, gear disengagement occurs:
(1) When vehicle is running on rough roads without depressing accelerator pedal, or
(2) When accelerator pedal is depressed

(1) Improper adjustment of pitching stopper Adjust


(2) Loose engine mounting Adjust
(3) Worn shifter fork and/or worn or broken shifter fork rail spring f Replace
(4) Worn locking ball cut in shifter rail Replace
(5) Excessive Clearance between splines of synchronizer hub and synchronizer sleeve Replace
(6) Worn splines of each gear Replace
3. Transmission noise
If a noise occurs when engine is idling and does not when clutch is disengaged, if can
be judged to be transmission noise.

(1) Low lubricating oil or use of improper oil Add or change with genuine
(2) Worn or broken gears or bearings gear oil Replace
A high roar comes out only at high speed if tooth surfaces are worn. However,
knocks Comes out periodically even at low speed if broken.
(3) Worn splines of each gear Replace
14. Breakage of differential (case, gear, bearing, etc.)
Unusual noise comes out and chips caught among components hinder rotation, making
it impossible to drive vehicle.

(1) Low oil or use of improper oil Disassemble differential, check


(2) Use of vehicle in severe conditions such as under excessive loads, faulty clutch parts, and replace defective
operation, etc. ones. Adjust gear backlash.
(3) Excessive backlash between final gear and drive pinion Add genuine gear oil as
(4) Excessive backlash due to worn differential side gear, washer, and differential pinion specified and avoid using
(5) Loose final gear clamping bolts vehicle in severe conditions.

53
3.1 TROUBLESHOOTING
1. Manual Transmission and
Differential

Symptom and Probable cause Remedy


5. Noisy differential and final gear
Noise from differential and final gear indicate trouble in those components.
However, care must be exercised in their diagnosis, because the noises are apt to
be mistaken for engine noise, exhaust noise, muffler's vibrating noise, tire noise,
bearing noise, and body noise. Especially, be careful because final gear noise can
easily be taken for Other gear noises. Noises can roughly be divided into following
types:
(1) Noises at starting Or speed change
When noise increases as vehicle catches up speed, it is caused by lack Of gear
Oil, improper gear engagement, Or broken gears.
(2) Bearing noise during driving Or cruising
Bearing noises comes mostly from cracked or damaged bearings.
(3) Noises during turning
Noises caused by differential side gear, differential pinion, differential pinion I
shaft, etc.

(1) LOW oil Add Oil up to specified level


(2) Excessive backlash between differential side gear and differential side pinion Replace gear or washer
(3) Worn teeth Of final gear and drive pinion Replace as a set
(4) Broken differential pinion shaft Replace
(5) Bearings seized Or damaged Replace
() Worn washer (27.1 x 42 x t) and differential pinion shaft Replace
6. Breakage of transfer (case, gear, bearing, etc.)
Unusual noise comes Out and chips caught among components hinder rotation,
making it impossible to drive vehicle.

(1) Low Oil Or use Of improper Oil Disassemble transfer, check pans
(2) Use Of vehicle in severe conditions such as under excessive loads, faulty clutch and replace defective parts.
Operation, etc. Properly adjust bearing preload
(3) Improper adjustment Of taper roller bearings aim gear backlash. Add genuine
(4) Improper adjustment Of bevel gear height j oil up to specified level and avoid
(5) Excessive backlash due to worn bevel gear spacer Using vehicle in severe
(6) Loose bolts conditions.
7. Noisy transfer and bevel gear
Noises from transfer and bevel gear indicate troubles in those components.
However, care must be exercised in their diagnosis, because the noises are apt to
be mistaken for engine noise, exhaust noise, muffler's vibrating noise, tire noise,
bearing noise, and body noise.
Especially, be careful because noise can easily be taken for Other gear noises.
Noises can roughly be divided into following types:
(1) Gear noises during acceleration
When noise Increases as vehicle catches up speed, it is caused by lack of gear
Oil, improper gear engagement, Or broken gears.
(2) Gear noises during cruising
Gear noises come from damaged gears due to improper adjustment Of
bearings Or shims.
(3) Bearing noises during acceleration Or cruising
Bearing noises are caused by cracked Or damaged bearings.

(1) LOW Oil Add Oil


(2) Improper adjustment Of bearing preload Of bevel driven gear Check tooth contact
(3) Worn teeth bevel drive gear and driven gear Replace as a set
(4) Loose taper roller bearings Adjust bearing preload; adjust
back-lash and tooth contact
between bevel drive and driven
gear.
(5) Deformation Of case, gears, etc. Replace

54
TROUBLESHOOTING 3.1
1. Manual Transmission and
Differential

3.3 TRANSMISSION CONTROL SYSTEM


Page
C COMPONENT PARTS.................................................................................................................... 2
1. Gear Shift Lever......................................................................................................................... 2
2. selective 4WD System................................................................................................................ 3
W SERVICE PROCEDURE................................................................................................................ 4
1. Gear Shift Lever......................................................................................................................... 4

55
3.3 COMPONENT PARTS
1. Gear Shift Lever

1. Gear Shift Lever

(1) Knob (RWD) (7) Clip (13) Bush (19) Shift lever (RWD)
(2) Boot (8) Bracket (14) Lever COMPL (20) Bail block
(3) 4wD/RwD selector switch (9) Shift control cable (15) Bush (21) Spacer
(4) Knob (4wD) (10) Snap pin (16) spring
(5) Connector (11) Select control cable (17) Spring seat
(6) Shift lever (4WD) (12) Select shaft (18) Bush

2
COMPONENT PARTS 3.3
2. selective 4WD
System

2. selective 4WD System

(1) Bracket
(2) 4WD/RWD solenoid valve

3
3.3 SERVICE PROCEDURE
2. selective 4WD System

1. Gear Shift Lever ^


A. REMOVAL
1) Disconnect the battery ground cable.
2) Remove console box. <Ref to 5-4 [W2A0] >

3) Remove snap pins and then disconnect cables

4) Remove wire clips.

5) Remove bolts and then remove gear shift lever


ASSY.

6) Remove trap door and air cleaner case.

4
SERVICE PROCEDURE 3.3
1. Gear Shift Lever ^

7) Remove snap pin (1) and clip (2) and then discon-
nect shift control cable from transmission.

8) Lift up vehicle.
9) Remove snap pin (1) and clip (2) and then
disconnect select control cable from transmission.

B. DISASSEMBLY
1) Remove select shaft.

2) Remove bolts and then remove ball block.

C. ASSEMBLY
Assembly is in the reverse order of disassembly.

5
3.3 SERVICE PROCEDURE
1. Gear Shift Lever ^

NOTE:
When assembling the ball block to the bracket, check
the alignment of the locater (1).
Assemble without trapping the spring between the
lever CP and the spring seat.
When the bracket and ball block are separated make
adjustments in the vertical direction of the lever
a: Temporarily close the coupling bolt of the bracket
and ball block.
b: Attach the gear shift control lever assembly to
the vehicle, couple the shift and selector cable
c: With the lever in the upright position, move the
ball block forwards and backwards.
d: After adjusting, take out the gear shift control
lever assembly, close the coupling bolts to the stip-
ulated torque and fit the lever assembly to the
vehicle.

When the lever is in the vertical position, the length


from the clevis pin of the select control cable and gear
shift control lever assembly to the clip attachment
section is 195.7 mm (7.71 in).
If the length is different, move the ball block in the for-
wards/backwards direction and make adjustment.

D. INSTALLATION
Installation is in the reverse order of removal.
NOTE:
After properly installing parts ensure that lever moves
smoothly with reasonable force.

6
3.4 4WD system
Page
S SPECIFICATIONS AND SERVICE DATA................................................................................2
1. 4WD System....................................................................................................................... 2
C COMPONENT PARTS............................................................................................................. 4
1. Front Differential and Propeller Shaft..................................................................................4
2. Front Differential Mounting..................................................................................................5
W SERVICE PROCEDURE......................................................................................................... 6
1. Propeller Shaft.................................................................................................................... 6
2. Front Differential ................................................................................................................. 8
T TROUBLESHOOTING........................................................................................................... 26
1. Front Differential................................................................................................................ 26
2. Propeller Shaft.................................................................................................................. 27
3.4 SPECIFICATION AND SERVICE DATA
1. 4WD System

1. 4WD System
A: SPECIFICATIONS
Gear ratio 3.900
Reduction gear
Tooth number of gear 39/10
Front differential Tooth number of pinion 13
Differential gear
Tooth number of side gear 18
Fluid capacity 0.8 t (0.8 US qt, 0.7 Imp qt)
Type 2-joint type
Propeller shaft Distance between joints 1,182.5 mm (46.56 in)
Tube outer diameter x tube thickness 63.5 x 1.6 mm (2.5 x 0.063 in)

B: MAINTENANCE STANDARDS
DIFFERENTIAL
Differential gear backlash 0.05 - 0.15 mm (0.0020 - 0.0059 in)
Washer (35.1 x 45 x t mm) thickness Part No. 803135011 0.950 mm (0.0374 in)
803135012 0.975 mm (0.0384 in)
803135013 1.000 mm (0.0394 in)
803135014 1.025 mm (0.0404 in)
803135015 1.050 mm (0.0413 in)
Drive pinion bearing preload Rotating torque:
0.39 - 0.98 N-m
(4.0 - 10.0 kg-cm, 2.6 - 8.7 in-lb)
Force at companion flange hole:
11.8 - 28.4 N (1.2 - 2.9 kg, 2.6 - 6.4 lb)
Drive pinion shim thickness for height adjustment Part No. 442185401 0.150 mm (0.0059 in)
442185402 0.175 mm (0.0069 in)
442185403 0.200 mm (0.0079 in)
442185404 0.225 mm (0.0089 in)
442185405 0.250 mm (0.0098 in)
442185406 0.275 mm (0.0108 in)
442185407 0.300 mm (0.0118 in)
442185408 0.500 mm (0.0197 in)
Side clearance between axle shaft and pinion shaft 0 - 0.2 mm (0 - 0.008 in)
Snap ring thickness Part No. 805026010 1.05 mm (0.0413 in)
031526000 1.2 mm (0.047 in)
Drive pinion (hypoid gear) backlash 0.1 -0.18 mm (0.0039 - 0.0071 in)
Differential side bearing preload Tighten axle shaft holder by 1/2 notch.
PROPELLER SHAFT
Runout limit 0.6 mm (0.024 in)
Joint bending resistance 0.3 -1.5 N-m
(0.03 - 0.15 kg-m, 0.2 - 1.1 ft-lb)
Axial play of journal 0 mm (0 in)

2
SPECIFICATION AND SERVICE DATA 3.4
1. 4WD System

C: ADJUSTING POINTS

D: RECOMMENDED GEAR OIL

3
3.4 COMPONENT PARTS
1. Front Differential and Propeller Shaft

1. Front Differential and Propeller Shaft

(1) Propeller shaft (11) Oil seal (21) Differential drive pinion shaft
(2) Lock nut (12) Gasket (22) Differential ease
(3) Washer (13) Drive pinion spacer (23) Washer
(4) Companion flange (14) Roller bearing (24) Differential gear
(5) Oil seal (15) Drive pinion shim (25) Snap ring
(6) Roller bearing (16) Pinion gear (26) Differential pinion
(7) Differential carrier (17) Crown gear (27) Air breather pipe
(8) Lock plate (18) Axle drive shaft (28) Air breather nipple
(9) O-ring (19) Roller bearing (29) Differential carrier cover
(10)Axle shaft oil seal holder (20) Straight pin (30) Oil drain plug

4
COMPONENT PARTS 3.4
2. Front Differential
Mounting

2. Front Differential Mounting

(1) Front mounting bracket


(2) Rear mounting bracket

5
3.4 SERVICE PROCEDURE
2. Front Differential Mounting

1. Propeller Shaft
A: ON-CAR SERVICE
Check the following points with propeller shaft installed
in vehicle.
1) Joints and connections
Check for any looseness of yoke flange connecting
bolts.

2) Splines and bearing locations


Turn propeller shaft by hand to see if abnormal free
play exists at splines. Also move yokes to see if abnor-
mal free play exists at spiders and bearings.

3) Runout of propeller shaft


Turn rear wheels by hand to check for "runout' of pro-
peller shaft.
Run out:
Limit 0.6 mm (0.024 in)
NOTE:
Measure runout with a dial gauge at the propeller shat
tube.

B: REMOVAL
NOTE:
Before removing propeller shaft, wrap metal parts with
a cloth or rubbered material.
1) Remove bolts attaching propeller shaft to front dif-
ferential.

2) Pull out propeller shaft from transmission. At the


time, ready oil basin and cap to accommodate oil flow-
ing out of transmission.
CAUTION:
When removing propeller shaft, be carets vent
damage to oil seal of transmission.

6
SERVICE PROCEDURE 3.4
1. Propeller Shaft

C: INSPECTION
Check the following items and replace if detective.
1) Dents or cracks on shaft pipe.
2) Twist or abnormal wear of splines.
3) Shaft deflection
Propeller shaft runout limit:
0.6 mm (0.024 in)
Measure deflection of front and rear shafts at their cen-
ter with a dial gauge.
4) Unsmooth operation of joints and unusual noise
developed in joints.
5) Abnormally worn or damaged oil seal,

D: INSTALLATION
1) Apply gear oil to splined portion and outside
periphery of sleeve york.

2) Remove cap from transmission, and install propeller


shaft sleeve yoke into transmission.

3) Join propeller shaft flange yoke to front differential.


Tightening torque:
25 7 N m (2.5 0.7 kg-m, 185 ft-lb)

7
3.4 SERVICE PROCEDURE
1. Propeller Shaft

2. Front Differential
A: ON-CAR SERVICE
1. GEAR OIL LEAKAGE AND LEVEL
1) Check for oil leakage around engaging, face of dif-
ferential, oil shield, dram plug, filler plug, etc.

2) Remove filler plug and check. Oil should be maint-


ained at bottom of filler hole.

2. REPLACEMENT OF GEAR OIL


1) Remove drain plug to drain gear oil. After all gear oil
is expelled, tighten drain plug as it was.
Tightening torque:
34 4 N m (3.5 0.4 kg-m, 253 ft-lb)
CAUTION:
Remove any particles attached to magnetic sec-
tion of drain plug.
Use only new gasket.

2) Remove filler plug and fill with gear oil.

Oil capacity (at replacement):


0.7 i (0.7 US qt, 0.6 Imp qt)
NOTE:
At on-car service, oil replacement quantity is smaller by
approximately 0.1 L (0.11 US qt, 0.09 Imp qt).

3) Check oil level. Oil should be maintained at bottom of


filler hole.

8
SERVICE PROCEDURE 3.4
2. Front Differential

4) Tighten filler plug together with aluminum gasket.

Tightening torque:
34 4 N m (3.5 0.4 kg-m, 25 3 ft-lb)

B: REMOVAL
1) Remove propeller shaft.
(1) Remove bolts attaching propeller shaft to front
differential.

(2) Pull out propeller shaft from transmission.


CAUTION:
When removing propeller shaft, pay attention not to
damage the sliding surfaces of rear drive shaft
(extension) spline, oil seal and sleeve yoke.
NOTE:
Prepare an oil can and cap since the transmission oil
flows out from the extension at removing propeller
shaft.
(3) Install cap into transmission.
NOTE:
Insert the cap into the extension to prevent
transmission oil from flowing out immediately after
removing the propeller shaft.

2) Remove DOJ from differential using ST; making use


of leverage by attaching screwdriver to carrier main
body.
ST 28099PA100 DRIVE SHAFT REMOVER
CAUTION:
Do not attach screwdriver to axle shaft holder.
Do not deform DOJ baffle plate.
Snap ring attached to axle drive shaft cannot be
reused.

9
3.4 SERVICE PROCEDURE
2. Front Differential

3) After removal of stabilizer link, remove ball joint por-


tion of transverse link from housing.

4) Remove tie-rod end ball joint portion from housing


knuckle arm using puller.

5) Pull out axle shaft from front differential.


NOTE:
Secure front drive shaft to front crossmember using
wire.

6) Support front differential with transmission jack.


7) Remove self-locking nuts which connect front differ-
ential to front crossmember.

8) While slowly lowering transmission jack, move front


differential forward and remove bolts from front cross-
member.
9) Disconnect air breather pipe.
10) Remove front differential from body.

10
SERVICE PROCEDURE 3.4
2. Front Differential

C: DISASSEMBLY
To detect real cause of trouble. inspect the following
items before disassembling. <Ref. to 3-4 [W2E0|>
Tooth contact of hypoid drive gear and pinion, and
backlash.
Runout of drive gear at its back surface
Turning resistance of drive pinion

1) Install ST to front differential.


ST 498215500 CARRIER ATTACHMENT

2) Remove drain plug and drain gear oil. After draining,


install drain plug and tighten to specified torque.
CAUTION:
Clean drain plug magnet before installing.
Be sure to replace gasket with a new one.
Tightening torque:
34 4 N m (3.5 0.4 kg-m, 25 3 ft-lb)

3) Remove the circlip from axle drive shaft.


CAUTION:
Be sure to replace circlip with a new one.

4) Loosen lock nut after uncaulking and remove it from


drive pinion shaft.
ST 398427700 COMPANION FLANGE WRENCH
5) Remove washer and companion flange.

11
3.4 SERVICE PROCEDURE
2. Front Differential

6) Remove oil seal. Do not reuse oil seal.


ST 398527700 OIL SEAL & OUTER RACE PULLER
ASSY

7) Remove cover.
8) Wrap vinyl tape around splined portion of each axle
drive shaft.
9) Remove right and left lock plates.

10) Remove snap rings with ST.


ST 899471410 SNAP RING EXPANDER

11) Loosen right and left holder, and remove their


together with respective axle drive shafts.
ST 399780111 OIL SEAL HOLDER WRENCH

12) Remove differential assembly from differential


carrier, with differential case so set that two flat sides of
case are vertical.

12
SERVICE PROCEDURE 3.4
2. Front Differential

13) Remove drive pinion and rear bearing cone from


differential carrier
ST 899864100 MAIN SHAFT REMOVER

14) Remove front bearing race from differential carrier


using hub shocker.

15) Remove rear bearing race from differential carrier


using hub shocker, ST1 and ST2.
ST1 398477701 DRIVE PINION OUTER RACE DRIFT
HANDLE
ST2 498215402 DIFFERENTIAL CARRIER STAND

16) Disassemble differential assembly by the following


procedure.
(1) Remove differential side bearing cone using
ST1 and ST2.
ST1 399520105 DIFFERENTIAL BEARING PULLER
SEAT
ST2 899524100 DIFFERENTIAL BEARING PULLER
SET
CAUTION:
Do not reuse bearing cone.
(2) Remove crown gear.

13
3.4 SERVICE PROCEDURE
2. Front Differential

(3) Remove straight pin out of crown gear side.


ST 899904100 STRAIGHT PIN REMOVER
CAUTION:
Straight pin hole edge on differential case side is
caulked. Do not use excessive force when driving
out pin.

(4) Remove differential drive pinion shaft differen-


tial pinion, differential gears and washer [35,1 x 45
x t mm]

17) Remove bearing race from right and left holder with
ST1 and ST2,
ST1 499705401 BEARING OUTER RACE PULLER
ASSY
ST2 499705404 OUTER RACE PULLER SEAT

18) Remove oil seal from right and left holder with ST.
ST 498107000 BUSHING REPLACER

19) Remove drive pinion bearing cone.


ST1 498515500 BEARING REPLACER
ST2 899864100 MAIN SHAFT REMOVER

14
SERVICE PROCEDURE 3.4
2. Front Differential

D: INSPECTION
Wash all the disassembled parts clean, and examine
them for wear, damage, or other defects. Repair or
replace defective parts as necessary.
1) Crown gear and drive pinion
(1) If abnormal tooth contact is evident, find out the
cause and adjust to give correct tooth contact at
assembly. Replace as a set if excessively worn or
incapable of adjustment.
eg h crack, score, or seizure is evident, replace as a
set. Slight damage of tooth can be corrected by oil
stone or the like.
2) Side gear and pinion gear
(1) Replace if crack, score, or other defects are evident
on tooth surface.
(2) Replace if thrust washer contacting surface is worn
or seized. Slight damage of the surface can be
corrected by oil stone or the like.

3) Bearing
Replace if seizure, peeling, wear, rust, dragging during
rotation, abnormal noise or other defect is evident.
4) Differential case
Replace if its sliding surfaces are worn or cracked.

5) Thrust washers of side gear


Replace if seizure, flaw, abnormal wear or other defect
is evident.

6) Oil seal
Replace if deformed or damaged, and at every
disassembling.
7) Differential carrier
Replace if the bearing bores are worn or damaged.
8) Companion flange
Replace if the oil seal lip contacting surfaces have
flaws.

15
3.4 SERVICE PROCEDURE
2. Front Differential

E: ASSEMBLY
1) Precautions for assembling
(1) Assemble in the reverse order of disassem-
bling. Check and adjust each part during assembly.
(2) Keep the shims and washers in order, so that
they are not misinstalled.
(3) Thoroughly clean the surfaces on which the
shims, washers and bearings are to be installed
(4) Apply gear oil when installing the bearings and
thrust washers.
(5) Replace removed oil seal, gasket, lock nut and
differential side bearing with new ones.

(6) Replace the oil seal with new one at every dis-
assembly. Apply chassis grease between the lips
when installing the oil seal of differential carrier
side.
CAUTION:
Apply gear oil to oil seal lip of axle shaft oil seal
holder.
Do not reuse drive pinion spacer. Use new one.

2) Assemble differential.

(1) Install differential gears and differential pinions


with washers and drive pinion shaft, into differential
case.

16
SERVICE PROCEDURE 3.4
2. Front Differential

(2) To measure backlash, place one pinion tooth in


contact with adjacent differential gear teeth, and
measure movement of gear.
If backlash is improper, select a washer of proper
thickness 35.1 x 45 x t mm.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
Standard backlash:
0.05 - 0.15 mm (0.0020 - 0.0059 in)

Washer 35.1 x 45 x t mm
Part No. Thickness mm (in)
803135011 0.950 (0.0374)
803135012 0.975 (0.0384)
803135013 1.000 (0.0394)
803135014 1.025 (0.0404)
803135015 1.050 (0.0413)

(3) Install straight pin from the crown gear side and
stake.
ST 899904100 STRAIGHT PIN REMOVER

(4) Mount crown gear and tighten bolt to specified


torque.
Tightening torque:
62 5 N m (6.3 0.5 kg-m, 46 4 ft-lb)

(5) Press-fit differential bearing cone,


ST1 498475403 BEARING OUTER RACE DRIFT
ST2 498485400 SIDE BEARING DRIFT

17
3.4 SERVICE PROCEDURE
2. Front Differential

3) Assemble holder
(1) Do not confuse right if side oil seal with left side
oil seal. Do not disturb combination of bearing race
and bearing cone.
ST 399790110 AXLE SHAFT OIL SEAL INSTALLER

(2) Use care not to confuse bearing race with front


bearing race of differential carrier.
ST 398477702 BEARING OUTER RACE DRIFT

4) Press-fit front and rear bearing races to differential


carrier.
ST1 398477701 DRIVE PINION OUTER RACE DRIFT
HANDLE
ST2 398477702 BEARING OUTER RACE DRIFT
ST3 498215402 DIFFERENTIAL CARRIER STAND
ST4 498475403 BEARING OUTER RACE DRIFT

5) Adjust preload of drive pinion bearing.


(1) Install front bearing cone to ST. Install ST into
differential carrier, and install rear bearing cone
companion flange and washer. Then tighten lock
nut temporarily.

18
SERVICE PROCEDURE 3.4
2. Front Differential

CAUTION:
Do not install drive pinion spacer and height
adjusting shim.
Apply gear oil to bearing. Use a new lock nut.
ST 498505502 DRIVE PINION DUMMY SHAFT

(2) Do not tighten lock nut all the way at a time.


While confirming the following item (3), tighten lock
nut in two or three steps until specified preload is
obtained.
If preload is increased to extent that dummy shaft
cannot be turned by hand, damage to bearing will
result.
ST 398427700 OMPANION FLANGE WRENCH

(3) Attach a spring balance to bolt hole of


companion flange, turn dummy shaft several turns,
and measure load at which shaft begins to rotate.
Load:
11.8 - 28.4 N (1.2 - 2.9 kg, 2.6 - 6.4 lb)
Starting torque:
0.39 - 0.98 N m (4.0 - 10.0 kg-cm,
2.6-8.7 in-lb)

(4) Insert ST1 through side hole of differential


carrier, and measure clearance between ST1 and
ST2 using ST3.
(5) The value measured by thickness gauge is
thickness of shim to be used.
ST1 498505501 DIFFERENTIAL CARRIER GAUGE
ST2 498505502 DRIVE PINION DUMMY SHAFT
ST3 499667000 THICKNESS GAUGE
Drive pinion shim
Thickness Thickness
Part No. Part No.
mm (in) mm (in)
442185401 0.150 (0.0059) 442185405 0.250 (0.0098)
442185402 0.175 (0.0069) 442185406 0.275 (0.0108)
442185403 0.200 (0.0079) 442185407 0.300 (0.0118)
442185404 0.225 (0.0089) 442185408 0.500 (0.0197)

19
3.4 SERVICE PROCEDURE
2. Front Differential

6) Assemble drive pinion to differential in place of ST1.


(1) Fit drive pinion shim to the drive pinion, and
press-fit front bearing cone.
ST 1 498505502 DRIVE PINION DUMMY SHAFT
ST2 498175500 BEARING INSTALLER
ST3 899864100 MAIN SHAFT REMOVER

(2) Fit drive pinion spacer to the drive pinion, and


insert drive pinion into front differential. n ^
CAUTION:
Apply gear oil to the bearing beforehand.

(3) Insert or press-fit rear bearing cone.


ST1 399780104 AXLE SHAFT OIL SEAL HOLDER
WEIGHT
ST2 899754102 SNAP RING PRESS
ST3 899864100 MAIN SHAFT REMOVER

(4) Press-fit oil seal.


ST1 399780104 AXLE SHAFT OIL SEAL HOLDER
WEIGHT
ST2 498415400 OIL SEAL DRIFT j

(5) Fit companion flange and washer, and tighten


lock nut with ST.
ST 398427700 COMPANION FLANGE WRENCH

20
SERVICE PROCEDURE 3.4
2. Front Differential

7) Tighten lock until there is no play in companion


flange and front differential and measure preload. If
preload is insufficient, retighten lock nut another 5 to
10 . Do not perform caulking until tooth contact pattern
check is completed.
Load:
11.8 - 28.4 N (1.2 - 2.9 kg, 2.6 - 6.4 lb)
Starting torque:
0.39-0.98Nm (4.0-10.0kg-cm, 3.5-8.7in-lb)

8) Before differential assembly is inserted into differen-


tial carrier, coat differential side bearing with gear oil.
9) Do not confuse right axle shaft with left axle shaft.
Wrap vinyl tape around splined portion that engages
with DOJ.

21
3.4 SERVICE PROCEDURE
2. Front Differential

10) Select a proper snap ring so that a clearance


between axle shaft end and pinion shaft is 0 to 0.2 mm
(0 to 0.008 in).
SI 499667000 THICKNESS GAUGE

Snap ring
Part No. Thickness mm (in)
805026010 L05 (0.0413)
031526000 1.2(0.047)

11) Ensure that, in the holder, oil seal with R mark is


on right side and one with "L" mark is on left.
Do not install O-ring at this stage of operation
ST 399780111 OIL SEAL HOLDER WRENCH

12) Perform adjustment of backlash of hypoid gear and


adjustment of preload of differential side bearing.
(1) Turn drive pinion for better fitting of differential
side bearing.
ST 499925400 HANDLE

(2) Screw in crown gear-side (right-side) holder


until light contact is made with ST.
(3) Screw in left-side holder until light contact is
made.
(4) Back off crown gear-side holder approx. 1 1/2
teeth of holder, and tighten left-side holder by
approximately 2 teeth (approx. 1 1/2 + 1/2 teeth)
[Back off amount of crown gear-side holder + 1/2
tooth]. This + 1/2 tooth gives preload.
ST 399780111 OIL SEAL HOLDER WRENCH

(5) Temporarily tighten lock plate.


Turn over lock plate to displace holder 1/2 tooth.

22
SERVICE PROCEDURE 3.4
2. Front Differential

(6) Measure backlash:


Set ST1 on differential carrier. Place contact point
of ST2 on tooth face of crown gear, and move
crown gear with drive pinion fixed. Read value
indicated on dial gauge,
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
Standard backlash:
0.1-0.18 mm (0.0039 - 0.0071 in)

(7) If measured backlash is not within specified


range, repeat items (1) thru (6).
13) Scribe a matching mark on both differential carrier
and holder. Remove holder one side at a time. Replace
in the original position after inserting an O-ring and
applying grease to threaded portion.

14) Tighten bolt of lock plate to specified torque and


measure backlash.
Tightening torque:
25 3 N m (2.5 0.3 kg-m, 18 2 ft-lb)
Standard backlash:
0.1-0.18 mm (0.0039 - 0.0071 in)
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE

15) Check tooth contact.


(1) Apply a thin coat of red lead evenly on 3 or 4
teeth of the crown gear.
(2) Holding right and left axle shafts by hand,
rotate drive pinion a few turns by using ST.
(3) Check tooth contact as follows:
(4) If proper tooth contact is not obtained, perform
drive pinion height adjustment mentioned in 9) and
hypoid gear backlash adjustment and differential
side bearing preload adjustment mentioned in 15)
again.
ST 499925400 HANDLE

23
3.4 SERVICE PROCEDURE
2. Front Differential

Tooth contact between crown gear and drive pinion


Condition Contact pattern Adjustment
Proper contact

Backlash is too large. Reduce the backlash.

Backlash is too small. Increase the backlash.

Adjusting shim (drive pinion shim) Increase the thickness of drive


thickness is too small. pinion shim.

Adjusting shim (drive pinion shim) Reduce the thickness of drive pinion
thickness is too large. shim.

M3A0274

16) Caulk drive pinion lock nut.


17) install cover. Tighten bolt to specified torque.
Tightening torque:
25 2 N m (2.5 0.2 kg-m,
18 2 ft-lb)

24
SERVICE PROCEDURE 3.4
2. Front Differential

18) Remove plug located on left side of carrier, and fill


with gear oil up to threaded hole.
CAUTION:
Use a new aluminum gasket when installing the
Plug.
Tightening torque:
34 4 Nm (3.5 0.4 kg-m, 25 3 ft-lb)
Oil capacity:
0.8 L (0.8 US qt, 0.7Imp qt)

F: REMOUNTING
Remount by reversing order of dismounting while pay-
ing attention to the following points.
1) When mounting stoppers, do not confuse upper with
lower one.
2) Use a new self-locking nut to tighten bracket.
3) Ensure sufficient clearance between air breather
pipe and axle shaft.
4) insert air breather pipe end that is cut slantwise into
a hole in body frame.
Ensure that hose end bottoms on frame wall.
5) Use new circlips to connect differential assembly to
rear axle shafts.
Tightening torque:
T1:79 5 N m (8.0 0.5 kg-m, 58 4 ft-lb)
T2:58 10 N m (5.9 1.0 kg-m, 43 8 ft-lb)
T3:58 9 N m (6.0 1.0 kg-m ,44 8 ft-lb)
NOTE'
. Match DOJ spline to rear differential spline, press rear
housing to DOJ.
Confirm that DOJ is firmly pressed.

25
3.4 TROUBLESHOOTING
1. Front Differential

1. Front Differential

Symptom and possible cause Remedy


1. Oil leakage
(1) Worn, scratched, or incorrectly seated oil seals.
Scored, battered, or excessively worn sliding surface of Repair or replace. n
companion flange.
(2) Clogged or damaged air breather. Clean, repair or replace.
(3) Loose bolts or missing lock plate, or incorrectly fitted Install lock plate. Tighten bolts to specified torque.
O-ring. Replace O-ring.
(4) Loose rear cover attaching bolts or damaged gasket. Tighten bolts to specified torque. Replace gasket
(5) Loose oil filler or drain pIug. Retighten.
(6) Wear, damage or incorrectly fitting for spindle, side
Repair or replace.
retainer and oil seal.
2. Seizure
Seized or damaged parts should be replaced, and also
other parts should be thoroughly checked for any defect
and should be repaired or replaced as required.
(1) Insufficient backlash for hypoid gear. Readjust or replace.
(2) Excessive preload for side, rear, or front bearing. Readjust or replace.
(3) Insufficient or improper oil used. Replace seized part and fill with specified oil to
specified level.
3. Damage
Damaged parts should be replaced, and also other parts
should be thoroughly checked for any defect and should
be repaired or replaced as required.
(1) Improper backlash for hypoid gear. I Replace.
(2) Insufficient or excessive preload for bearings on drive
Readjust or replace.
pinion.
(3) Excessive backlash for differential gear. Replace gear or thrust Washer.
(4) Loose bolts and nuts such as crown gear bolt. Retighten.
(5) Damage due to overloading. Replace.
4. Noises when starting or shifting gears
Noises may be caused by differential assembly, universal
joint, wheel bearing, etc. Find out what is actually making
noise before disassembly.
(1) Excessive backlash for hypoid gear. Readjust.
(2) Excessive backlash for differential gear. Replace gear or thrust Washer.
(3) Insufficient preload for bearings on drive pinion. Readjust.
(4) Loose drive pinion nut. Tighten to specified torque.

26
TROUBLESHOOTING 3.4
1. Front Differential

Symptom and possible cause Remedy


5, Noises when cornering
(1) Darnage differential gear, Replace.
(2) Excessive wear or damage of thrust washer. Replace.
(3) Broken drive pinion shaft. Replace.
(4) Seized or damaged side bearing. ' Replace.
6, Gear noises
Since noises from engine, muffler, transmission, propeller shaft,
wheel bearings, tires, and body are sometimes mistaken for noises
from differential assembly, be careful in checking them. Inspection
methods to locate noises include coasting, accelerating, cruising,
and jacking up all four wheels. Perform these inspections according
to condition of trouble. When listening to noises, shift gears into four
wheel drive and fourth speed position, trying to pick up only
differential noise.
(1) Improper tooth contact of hypoid gear. Readjust or replace hypoid gear set.
(2) Improper backlash for hypoid gear. Readjust.
(3) Scored or chipped teeth of hypoid gear. Replace hypoid gear set
(4) Seized hypoid gear. Replace hypoid gear set.
(5) Improper preload for front or rear bearings. Readjust.
(6) Seized, scored, or chipped front or rear bearing. Replace
(7) Seized, scored, or chipped holder bearing. Replace
(8) Vibrating differential carrier. Replace
2. Propeller Shaft
Symptom and possible cause [ Remedy I
1 Vibration of propeller shaft I
Vibration is caused by propeller shaft during operation and
is transferred to vehicle body. Generally vibration increase
in proportion to vehicle speed.
(1) Worn or damaged universal joint. Replace.
(2) Unbalanced propeller shaft due to bend or dent. Replace.
(3) Loose installation of propeller shaft. Retighten.
2.Tapping when starting and noise while cruising,
caused by propeller shaft.
(1) Worn or damaged universal joint. Replace
(2) Worn spline of sleeve yoke. Replace
(3) Loose installation of propeller shaft. Retighten
(4) Loose installation of joint. Replace.

Note:
Vibration while cruising may be caused by an unbalanced tire, improper inflation pressure, improper
wheel alignment, etc.

27
4 MECHANICAL COMPONENTS SECTION

SUSPENSION 4.1
WHEELS AND AXLES 4.2
STEERING SYSTEM 4.3
BRAKES 4.4
PEDAL SYSTEM AND CONTROL CABLES 4.5
HEATER AND VENTILATOR 4.6
4.1 SUSPENSION

S SPECIFICATIONS AND SERVICE DATA................................................................................2


1. Suspension......................................................................................................................... 2
C COMPONENT PARTS............................................................................................................. 3
1. Front Suspension................................................................................................................3
2. Rear Suspension................................................................................................................. 4
W SERVICE PROCEDURE......................................................................................................... 5
1. On-car Services.................................................................................................................. 5
2- Transverse Link Assembly...................................................................................................9
3. Front Ball Joint.................................................................................................................. 10
4. Front Strut Assembly.........................................................................................................11
5. Front Stabilizer.................................................................................................................. 16
6. Front Crossmember.......................................................................................................... 17
7. Trailing Arm Assembly.......................................................................................................18
8. Rear Shock Absorber........................................................................................................ 20
9. Coil Spring and Helper......................................................................................................21
T TROUBLESHOOTING........................................................................................................... 23
1. Suspension....................................................................................................................... 23
4.1 SPECIFICATION AND SERVICE DATA
1. Suspension

1. Suspension
A: SPECIFICATIONS
Camber 1 45'
Caster 350' 1
Toe angle Per wheel : 0 018'
Front foe-in mm (in) 03 (00.12)
when toe-in is 0 3 (0 0.12)
King pin angle 1310'
+12 +0.47
Chassis reference point height mm (in) 339 -20 (13.35 -0.79 )
Camber -050 45'
Toe angle Per wheel : 003' 009'
Toe-in mm (in) 1 3 (0.040.12)
when toe-in is 1 3 (0.04 0.12)
Rear
+12 +0.47
Chassis reference point height mm (in) 298 -20 (11.73 -0.79 )
Thrust angle 0 20'

Toe-in
B - A = Positive
= Toe angle (per Wheel)

2
COMPONENT PARTS 4.1
1. Front Suspension

1. Front Suspension

(1) Front crossmember (12) Cap


(2) Housing (13) Strut mount
(3) Ball joint (14) Thrust bearing
(4) Cotter pin (15) Spring seat
(5) Front bushing (16) Dust cover
(6) Transverse link (17) Coil spring
(7) Rear bushing (18) Helper
(8) Stabilizer link (19 ) Damper strut
(9) Stabilizer
(10) Stabilizer bushing
(11) Stabilizer clamp

3
4.1 COMPONENT PARTS
2. Rear Suspension

2. Rear Suspension

(1) Rubber seat (7) Adjusting bolt


(2) Helper (8) Outer bushing
(3) Coil spring (9) Trailing arm
(4) Spring seat (10) Under bushing
(5) Cam washer (11) Shock absor
(6) Inner bushing

4
SERVICE PROCEDURE 4.1
2. Rear Suspension

1. On-car Services
A. WHEEL ALIGNMENT
Check adjust and/or measure wheel alignment in
accordance wit procedures indicated below:

1. CHASSIS REFERENCE POINT HEIGHT


1) Inflate tire pressure to specifications.
2) Set vehicle under "curb weight" conditions. (Empty
luggage compartment, install spare tire, jack, service
tools, and top up fuel tank).
3) Set steering wheel in a wheel-forward position.

Unit: mm (in)
Specified chassis reference point height
Front Rear
+12 +0.47 +12 +0.47
339 -80 (13.35 -0.79 ) 298 -80 (17.73 -0.79 )

2. CAMBER AND CASTER


1) Place wheel to be measured on turning radius
gauge. Make sure ground contacting surfaces of front
and rear wheels are set at the same height.
2) Set ST into the center of the wheel, and then install
the wheel alignment gauge.
ST 922640000 CAMBER GAUGE ADAPTOR

5
4.1 SERVICE PROCEDURE
1. On-car Services

Camber: 1 45'
Caster : 3 50' 1
Measure when vehicle is not loaded.

2) If measured value of camber or caster is out of the


specification, check suspension mounting portion of
body, crossmember, transverse link, and other related
parts for damage or deformation. Repair or replace
faulty parts, if any.

3. REAR WHEEL TOE-IN


Inspection
Toe-in: 1 3 mm (0.04 0.12 in)
Adjustment
1) Loosen self-locking nut on trailing arm inner.
CAUTION:
Replace self-locking nut with a new one.
NOTE:
When loosening or tightening adjusting bolt, hold bolt
head and turn self-locking nut.
2) Turn adjusting bolts head until toe-in and -out are
within specifications.
Rotatory direction of adjusting bolt
Left wheel Right wheel

Toe-in is increased

Toe-in is decreased

6
SERVICE PROCEDURE 4.1
1. On-car Services

NOTE:
When both the left and right wheel bolts are turned
equally in the same direction which increases the toe-
in, the toe-in increases approx. 3mm (0.12in).
3) Tighten self-locking nut.
Tightening torque:
59 10 N m (6.0 1.0 kg-m, 43 7.0 ft-lb)

4. THRUST ANGLE
Inspection
1) Position vehicle on a level surface.
2) Move vehicle 3 to 4 meters directly forward.
3) Determine centers of the front and rear axle loci.
4) Measure difference "L" between center lines of the
axle loci.
(For reference)
Thrust angle is less than 20' when "L" is less than 11
mm (0.43 in).
Adjustment
Make thrust angle adjustments for left and right rear
wheels by turning toe-in adjusting bolts equally in the
same direction.
(For reference)
When one rear wheel is adjusted in a toe-in direction,
adjust the other rear wheel equally in toe-out direction,
in order to make thrust angle adjustment.
When left and right adjustment bolts are turned
incrementally by one scale mark in the same direction,
the thrust angle will change approximately 9' ["L" is
nearly equal to 5 mm (0.20 in)].
Standard thrust angle:
Less than 10'

5. FRONT WHEEL TOE-IN


Inspection
Using a toe gauge, measure front wheel toe-in or toe-
out.
1) Make a mark on the rear of the tires at the height of
the center of the wheel.
(2) Using the toe-in gauge, measure dimension B of the
left and right tire marks.
(3) Move the vehicle forward to rotate the tire marks
180.

7
4.1 SERVICE PROCEDURE
1. On-car Services

(4) Using the toe-in gauge, measure dimension A of the


displaced tire marks.
(5) Calculate the toe-in as B - A.
Toe-in: 0 3 mm (0 0.12 in)
Adjustment
1) Loosen the inside and outside tie rod lock nuts.
2) Turn the left and: right tie rods equal amounts until
the toe-in is within the specified range.
Both the left and right tie-rods are right-hand threaded
To increase toe-in, turn both tie-rods clockwise equal
amounts (as viewed from the inside of the vehicle.
3) Tighten tie-rod lock nut.
Tightening torque:
69 10 N m (7.0 1.0 kg-m, 51 7.0 ft-lb)
CAUTION:
Correct tie-rod boot if twisted.
NOTE:
Check that left and right wheel steering angle is within
specifications.

6. STEERING ANGLE
Inspection
1) Place vehicles on a turning radius gauge.
2) While depressing brake pedal, turn steering wheel
fully to the left and right. With steering wheel held at
each fully turned position, measure both the inner and
outer wheel steering angle.
Steering angle:
+130'
Inner wheel : 32.9 -230'
+130'
Outer wheel : 30.4 -230'

Adjustment
Turn tie-rod to adjust steering angle of both inner and
outer wheels.
NOTE:
Check toe-in.

8
SERVICE PROCEDURE 4.1
1. On-car Services

2- Transverse Link Assembly


A: REMOVAL
1) Remove bolt securing transverse link to stabilizer
link.
2) Remove bolt securing housing to ball joint.
3) Extract ball joint from housing.
NOTE:
When removing ball joint from housing, cover ball joint
boots with wiping cloth to protect from damage.
4) Loosen bolt securing transverse link to
crossmember.
NOTE:
Do not remove bolts.

5) Remove two bolts securing rear of transverse link to


car body at bushing location.
6) Remove bolts securing transverse link to
crossmember and remove transverse link from
crossmember.

B: DISASSEMBLY
1) Scribe an aligning mark on transverse link and rear
bushing.
2) Loosen nut and remove rear bushing.

C: INSPECTION
1) Check transverse link for wear, damage and cracks,
and correct or replace if defective.
2) Check bushings for cracks, fatigue or damage.
3) Check rear bushing for oil leaks.

9
4.1 SERVICE PROCEDURE
2- Transverse Link Assembly

D: ASSEMBLY
1) Install rear bushing to transverse link an align
aligning marks scribed on the two.
2) Tighten self-locking nut.
CAUTION:
Discard loosened self-locking nut and replace
with a new one.
While holding rear bushing do not change
position of aligning marks, tighten self-locking nut.
E: INSTALLATION
1) Temporarily tighten two bolts located behind the
transverse link at bushing location.
CAUTION:
Discard loosened self-locking nut and replace with
new one
2) Install bolts used to connect transverse link and
crossmember are temporarily tighten with nuts.
3) Insert ball joint into housing.
4) Insert bolt used to connect transverse link and
housing and temporarily tighten.
NOTE:
Confirm that bolts pass through concave portion in the
ball joint stud section.
5) Tighten the following points in the order shown below
when vehicle is empty and wheels are firmly on the
ground.
6) Check and adjust wheel alignment.

3. Front Ball Joint


A: REMOVAL
1) Remove the wheels.
2) Disconnect the stabilizer from the transverse link.
3) Puli out the cotter pin from the ball stud, remove the
castle nut, and extract the ball stud from the transverse
link
4) Remove the bolt securing the ball joint to the
housing.
5) Extract the ball joint from the housing.
B: INSPECTION
1) Measure play of ball joint by the following proce-
dures. Replace with a new one when the play exceeds
the specified value.
(1) With 686 N (70 kg, 154 lb) loaded in the
direction shown in the figure, measure dimension
L1.

10
SERVICE PROCEDURE 4.1
3. Front Ball Joint

(2) With 686 N (70 kg, 154 lb) loaded in the


direction shown in the figure, measure dimension
L2.
(3) Calculate plays from the following formula.
S=L1 - L2.
(4) When plays is larger than the figure, replace
with a new one.
FRONT BALL JOINT:
Specified play for replacement: S
Less than 0.4 mm (0.016 in)
2) When play is smaller than the specified value,
visually inspect the dust cover.
3) The ball joint and cover that have been removed
must be checked for wear, damage or cracks, and any
defective part must be replaced.
4) If the dust cover is damaged, replace with the new
ball joint.

C: INSTALLATION
1) Connect ball joint to transverse link.
Torque (Castle nut):
39 N m (4.0 kg-m, 29 ft-lb)
2) Retighten castle nut further within 60 until a slot in
castle nut is aligned with the hole in ball stud end, then
insert new cotter pin and bend it around castle nut.
3) Install ball joint onto housing.
CAUTION:
Do not apply grease to tapered portion of ball stud.
4) Install front wheels.
5) Check and adjust wheel alignment.

4. Front Strut Assembly


A: REMOVAL
1) Remove wheel.
2) Disconnect brake hose from strut.

11
4.1 SERVICE PROCEDURE
4. Front Strut Assembly

3) Remove bolt securing housing to strut.


4) Put the tip of a standard screwdriver into the slit of
the housing and pull off the strut.

5) Remove the two nuts connecting the strut mount and


the frame, and carefully extract the strut assembly
downward.

B: DISASSEMBLY
1) Mount Coil Spring Compressor to a vice.

2) Set the strut assembly to Coil Spring Compressor


CAUTION:
Be sure to use Coil Spring Compressor in order to
avoid an accident.
Set the projections of Coil spring Compressor to
the inner diameter side of coil spring.

3) Compress the coil spring by carefully turning the coil


spring compressor handle.
(Compress the spring until it comes off the strut upper
seat surface.)

12
SERVICE PROCEDURE 4.1
4. Front Strut Assembly

4) Loosen the nut that connect the strut mount and the
rod. Fit a hexagonal wrench key into the end of the strut
rod, and loosen the nut using a box wrench.
( Hexagonal wrench key: 6 mm)

5) Remove the strut mount and other minor parts.


6) Return carefully the coil spring compressor handle to
the original position, and take out the coil spring from
strut after making sure that the spring has been
stretched fully
CAUTION:
Take out the coil spring, using care not to cause the
spring to contact the strut rod.

C: INSPECTION
Check the disassembled parts for cracks, damage and
wear, and replace with new parts if defective.
1. DAMPER STRUT
1) Check for oil leakage.
2) Move the piston rod up and down to check its
operates smoothly without any binding.

3) Deflection of piston rod Measure the deflection as


follows:
Fix the outer shell and fully extend the rod. Set a dial
gauge at the end of the rod, and apply a weight of 20
N (2 kg, 4 lb) to the threaded portion. Read the dial
gauge indication. Assess the deflection of the rod by
the difference in the values of the tire gauge readings
for when the applied load is + 20 N (+ 2 Kg, + 4
lb) and - 20 N(-2 Kg,-4 lb).
Limit of defection:
Less than 0.8 mm (0.031 in)
if the deflection is greater, replace the strut.

13
4.1 SERVICE PROCEDURE
4. Front Strut Assembly

2. STRUT MOUNT
1) Check rubber part for creep, cracks and deteriora-
tion, and replace it with new one if defective
2) If distortion is found on its connecting surface to
body, replace it with a new one.
3. DUST COVER
If any cracks or damage are found, replace it with a
new one.
4. COIL SPRING
One having permanent strain should be replaced with a
new one. When vehicle posture is uneven, although
there are no considerable reasons like tire puncture,
uneven loading, etc., check coil spring for
its cracks etc., and replace it with a new one if
defective.
5. HELPER
Replace it with new one if cracked or damaged.

D: ASSEMBLY
1) Before installing coil spring, strut mount, etc., on the
strut, check for the presence of air in the dampening
force generating mechanism of the strut since air
prevents proper dampening force from being produced
2) Checking for the presence of air
(1) Place the strut vertically with the piston rod facing
up.
(2) Move the piston rod to the center of its entire
stroke.
(3) While holding the piston rod end with fingertips,
move the rod up and down.
(4) If the piston rod moves at least 10 mm (0.39 in)
in step (3), purge air from the strut.
3) Air purging procedure
(1) Place the strut vertically with the piston rod
facing up.
(2) Fully extend the piston rod.
(3) With the piston rod fully extended, place the pis-
ton rod side down. The strut must stand vertically'
(4) Fully contact the piston rod.
(5) Repeat steps (1) through (4) above 3 or 4 times.
N0TE:
After completely purging air from the strut, be sure to
place the strut with the piston rod facing up. If it is laid
down, check for entry of air in the strut as outlined
under item 2) above.

14
SERVICE PROCEDURE 4.1
4. Front Strut Assembly

4) Clean the strut rod.

5) Compress the coil spring with Coil Spring


Compressor.

6) Install the helper to the piston rod.


7) Pull the piston rod fully upward, and install the dust
cover and upper spring seat.

8) Arrange in a straight line the notched mark on the


upper spring seat with the protruding mark on the dust
cover and the paint mark on the coil spring of the
damper strut.

9) Install the thrust bearing.


10) Install the strut mount to the piston rod.
11) Install the washer (mount) to the piston rod, and
tighten the self-lock nut temporarily.

Be sure to use a new self-lock nut.

15
4.1 SERVICE PROCEDURE
4. Front Strut Assembly

12) Loosen Coil Spring Compressor carefully.


13) While fixing the rod with a hexagonal wrench key,
tighten the self-lock nut with a box wrench.

14) After assembling, fit the cap above the self locking
nut.

E: INSTALLATION
1) Install the strut assembly in the reverse order of
removal procedures.
CAUTION:
Use a new self-locking nut.
2) Check and adjust wheel alignment.

5. Front Stabilizer
A: REMOVAL
1) Jack up the front part of the vehicle.
2) Remove bolts which secure clamp to chassis.

3) Remove bolts which secure stabilizer link to


transverse link.

16
SERVICE PROCEDURE 4.1
5. Front Stabilizer

B: INSPECTION
1) Check bushing for cracks, fatigue or damage.
g) Check stabilizer links for deformities, cracks, or
damage, and bushing for protrusions beyond eye
portion of stabilizer links.

C: INSTALLATION
1) To install, reverse the removal procedure.
2) Always tighten rubber bushing location when
wheels are in full contact with the ground and vehicle is
curb weight.

6. Front Crossmember
A: REMOVAL
1) Disconnect ground cable from battery.
2) Loosen front wheel nuts.
3) Jack up vehicle, support it with safety stands (rigid
racks), and remove front tires and wheels.

4) Remove the bolts securing the transverse link to


crossmember.

5) Remove the nuts and take away the bolts attaching


the steering center lever to the front crossmember.
6) Support the front differential with a transmission
jack.

17
4.1 SERVICE PROCEDURE
6. Front Crossmember

7) Remove the bolts attaching the fronts differential


bracket to the front crossmember.
8) Remove the radiator bracket which is attached to the
front crossmember.
9) Remove the bolts attaching the crossmember to the
frame and detach the crossmember.

B: INSTALLATION
1) To install, reverse the removal procedure.
2) Always tighten rubber bushing location when wheels
are in full contact with the ground and vehicle is curb
weight.
3) Check and adjust wheel alignment.

7. Trailing Arm Assembly


A: REMOVAL
1) Lift up vehicle and remove rear wheels.
2) Remove brake pipe clamp from trailing arm,
3) Remove rear brake assembly from trailing arm.
<Ref. to 4-4 [W2A0]>
NOTE:
Detach the brake pipe from the rear brake.

4) Remove diagonal member.

5) Temporarily tighten castle nut.


6) Remove TJ from transmission using ST and driver.
Put a large screwdriver against the transmission case.
Using this screwdriver as a fulcrum, detach TJ with ST.
ST 28099PA 100 DRIVE SHAFT REMOVer
7) Remove castle nut.

18
SERVICE PROCEDURE 4.1
7. Trailing Arm Assembly

8) Disengage BJ from trailing arm, and remove rear


drive shaft assembly. If it is hard to remove, use a ST.
ST1 921122000 BRAKE DRUM REMOVER (PULLER)
ST2 922493001 BRAKE DRUM REMOVER (PLATE)
CAUTION:
Do not do this work except when exchanging the
bearing which is fitted inside the housing of the
trailing arm.

9) Mark the rear toe-in adjustment bolt.


10) Loosen the nuts securing the trailing arm to the
chassis frame.
CAUTION:
Do not remove the nuts completely.

11) Support the trailing arm by raising with a jack, and


then remove the bolt from the bottom of the shock
absorber.
12) While lowering the jack little by little, remove the coil
spring and rubber seat.
13) Remove the trailing arm from the chassis frame.

B: INSPECTION
Check the removed parts as follows, and if a fault is
defected on any parts, replace with a new one.
1) Check for wear, damage, deformation, or cracks.
2) Check the threads of bolts, nuts, and mating parts for
deformation or damage.

C: INSTALLATION
1) To install, reverse the removal procedure.
Refer to "COMPONENT PARTS" for the tightening
torque of the suspension parts.
CAUTION:
Use a new self-locking nuts.
Tighten nut when installing adjusting bolt.

19
4.1 SERVICE PROCEDURE
7. Trailing Arm Assembly

2) When installing the coil spring, fit the end of the coil
spring in the coil spring seat mounting recess of the
trailing arm.
3) Always tighten trailing arm when wheels are in full
contact with the ground and vehicle is curb weight.

4) Check and adjust rear wheel toe-in and thrust angle.

8. Rear Shock Absorber


A: REMOVAL
1) Raise the vehicle and remove the rear wheel
2) Support the trailing arm by raising with a jack, and
remove the shock absorber.
CAUTION:
Do not remove the jack from under the trailing arm.

B: INSPECTION
1) Check the rubber bush for distortion of damage
2) Check the smooth operation of the shock absorber

3) Shock absorber leakage, damage.


NOTE:
An oil leak in the shock absorber is defined by the
standard for when L is greater than 1/3 of L

20
SERVICE PROCEDURE 4.1
8. Rear Shock Absorber

C: INSTALLATION
Install the shock absorber in the reverse order of
removal procedure.
CAUTION:
Use a new self-locking nut.

9. Coil Spring and Helper


A: REMOVAL
1) Lift up the vehicle and remove rear wheels.
2) Remove diagonal member.

3) Remove TJ from transmission using ST and driver.


Put a large screwdriver against the transmission case.
Using this screwdriver as a fulcrum, detach TJ with ST.
ST 28099PA100 DRIVE SHAFT REMOVER

4) Support the trailing arm by raising with a jack, and


remove the shock absorber.
5) While lowering the jack little by little, remove the coil
spring and rubber seat.
6) Remove the helper.

B: INSPECTION
Check the disassembled parts for cracks, damage and
wear, and replace with new parts if defective.

21
4.1 SERVICE PROCEDURE
9. Coil Spring and Helper

1. COIL SPRING
One having permanent strain should be replaced with a
new one. When vehicle posture is uneven, although
there are no considerable reasons like tire puncture
uneven loading, etc., check coil spring for its free
length, cracks, etc., referring to specifications, and
replace it with a new one if defective.

2. RUBBER SEAT
If any cracks or damage are found, replace it with a
new one.

3. HELPER
Replace it with new one if cracked or damaged
Measure the helper height.
Specified height:
H = 55 mm (2.17 in) or more.
If the height is less than specified, replace the helper.

C: INSTALLATION
1) To install, reverse the removal procedure.
Refer to "COMPONENT PARTS" for the tightening
torque of the suspension parts.
CAUTION:
Use a new self-lock nuts.
2) Always tighten trailing arm when wheels are in full
contact with the ground and vehicle is curb weight.
3) Notes on installation.
When installing the coil spring, fit the lower rubber
seat and the end of the coil spring in the coil spring
seat mounting recess of trailing arm.
4) Check and adjust rear wheel toe-in and thrust angle.

22
TROUBLESHOOTING 4.1
1. Suspension

1. Suspension
1. IMPROPER VEHICLE POSTURE OR IMPROPER
CHASSIS REFERENCE POINT HEIGHT

Possible causes Countermeasures


(1) Permanent distortion or breakage of coil spring Replace.
(2) Unsmooth operation of damper strut Replace.
(3) Installation of wrong transverse link and trailing arm Replace with proper parts.
(4) Deformation of transverse link and trailing arm Replace.

2. POOR RIDE COMFORT


1) Large rebound shock.
2) Rocking of vehicle continues too long after running
over bump and/or hump.
3) Large shock in bumping.

Possible causes Countermeasures


(1) Breakage of coil spring Replace.
(2) Overinfiation pressure of tire Adjust.
3) improper chassis reference point height Adjust or replace coil springs With new ones.
4) Fault in operation of damper strut and shock absorber Replace.
(5) Damage or deformation of damper strut lower end bushing and
Replace.
shock absorber
(6) Unsuitability of maximum and/or minimum length of damper strut
Replace With proper parts.
and shock absorber
(7) Deformation or loss of bushing Replace.
(8) Deformation or damage of helper assembly Replace.

23
4.1 TROUBLESHOOTING
1. Suspension

3. NOISE

Possible causes Countermeasures


(1) Wear Or damage of damper strut and shock absorber component
Replace.
parts
(2) Damage Or deformation Of damper strut and shock absorber lower
Replace.
end bushing
(3) Loosening Of transverse link installing bolt Retighten to the specified torque.
(4) Deformation Or loss Of bushing Replace.
(5) Loosening Of trailing arm installing bolt to crossmember bracket Retighten to the specified torque.
(6) Unsuitability Of maximum and/or minimum length Of damper strut
Replace with proper parts.
and shock absorber
(7) Breakage Of coil spring Replace.
(8) Loosening Of each bolt and/or nut Retighten to the specified torque.

24
4.2 WHEELS AND AXLES

Page
S SPECIFICATIONS AND SERVICE DATA................................................................................2
1. Steering System..................................................................................................................2
C COMPONENT PARTS............................................................................................................. 3
1. Steering Wheel and Column................................................................................................3
2. Steering System..................................................................................................................4
3. Steering Gear Box...............................................................................................................5
W SERVICE PROCEDURE......................................................................................................... 6
1. Steering Column.................................................................................................................6
2. Steering Gear Box...............................................................................................................9
3. Center Lever & Drag Link Assembly..................................................................................17
4. Tie-rod Assembly............................................................................................................... 19
T TROUBLESHOOTING........................................................................................................... 21
1. Steering............................................................................................................................. 21
4.2 SPECIFICATION AND SERVICE DATA
1. Wheels and Axles

1. Wheels and Axles


A: SPECIFICATIONS
1. TIRE & WHEEL SIZE

Front and Rear


Rim offset PCD Spare
Tire size Rim size
mm (in) mm (in)
155R13C- 44.5 100 Same as front and rear
13x4.50B
6PR (1.75) (3.94) tires and rims

2. TIRE INFLATION PRESSURE

Tire inflation pressure kPa (kg/cm2,psi)


Tire size
Light load Full load
Ft: 200 (2.0, 29) Ft: 220 (2.2, 32)
155R13C-6PR
Rt: 250 (2.5, 36) Rt: 300 (3.0, 44)

3. FRONT DRIVE SHAFT ASSEMBLY

Distance between Diameter


Model inner and outer boots (D)
(L) mm (in) mm (in)
RH 426.1 (16.78) 21 (0.83)
4WD
LH 364.3 (14.34) 21 (0.83)'

4. REAR DRIVE SHAFT ASSEMBLY

Distance between Diameter


Model inner and outer boots (D)
(L) mm (in) mm (in)
RH 430.5 (16.95) 21.2 (0.835)
All model
LH 305.3 (12.02) 21.2 (0.835)

2
SPECIFICATION AND SERVICE DATA 4.2
1. Wheels and Axles

B: SERVICE Data
Wheel balancing Standard Service Limit
Dynamic unbalance Less than 10 g (0.35 Oz)

Balance weight part number


For steel wheel Weight g (oz)
723141290 5 (0.18)
723141300 10(0.35)
723141310 15 (0.53)
723141320 20 (0.71)
723141330 25 (0.88)
723141340 30 (1.06)
723141350 35 (1.23)
723141360 40 (1.41)
723141370 45 (1.59)
723141380 50 (1.76)

3
4.2 COMPONENT PARTS
1. Front Axle

1. Front Axle
1. 4WD model

(1) Axle nut (8) Housing (15) DOJ boot


(2) Disk rotor (9) Bearing (16) Circlip
(3) Hub bolt (10) Oil seal (inner) (17) Snap ring
(4) Hub (11) BJ (18) DOJ
(5) Oil seal (outer) (12) Boot band (large) (19) Buckle plate
(6) Snap ring (13) BJ boot (20) Circlip
(7) Disk cover (14)Boot band (small) (21) Dust seal

4
COMPONENT PARTS 4.2
1. Front Axle

2. RWD model

(1) Hub cap (6) Hub unit


(2) Axle nut (7) Disk Cover
(3) Axle nut (8) Spindle assembly
(4) Disk rotor
(5) Hub bolt

5
4.2 COMPONENT PARTS
1. Front Axle

2. Rear Axle

(1) Cotter pin (9) BJ & shaft assembly (17) Circlip


(2) Castle nut (10) Boot band (large) (18) Dust seal
(3) Conical spring (11) BJ boo (19) Oil seal (in)
(4) Center piece (12) Boot band (small) (20) Bearing (in)
(5) Wheel nut (13) TJ boot (21) Spacer
(6) Hub bolt (14) Snap ring (22) Bearing (out)
(7) Brake drum (15) TJ assembly (23) Oil seal (out)
(8) Oil seal B (16) Baffle plate (24) Trailing arm

6
SERVICE PROCEDURE 4.2
1. Front Axle

1. front Axle
A: REMOVAL AND INSTALLATION
1) Jack up vehicle, support it with safety stands, and
remove front wheels.

2) Unlock axle nut.

3) Depress brake pedal to stop drive shaft rotation.


Remove axle nut with socket wrench.
CAUTION:
Be sure to loose and retighten axle nut after
removing wheel from vehicle. Failure to follow this
rule may damage wheel bearings.

4) Remove disc brake caliper from nousing, and


suspend it from strut using a wire.

5) Remove disc rotor from hub.


If disc rotor seizes up within hub, drive disc rotor ou by
installing 8-mm bolts in screw holes on the rotor.

7
4.2 SERVICE PROCEDURE
1. front Axle

6) Disconnect stabilizer from transverse link.


7) Disconnect transverse link from housing.
CAUTION:
Protect ball joint using cloth to prevent damage.

8) Remove front drive shaft assembly from hub. If it is


hard to remove, use the ST. (4WD model only)
CAUTION:
Be careful not to damage oil seal lip when
removing front drive shaft.
When replacing front drive shaft, also replace
inner oil seal.
ST1 921122000 BRAKE DRUM REMOVER (PULLER).
ST2 922493001 BRAKE DRUM REMOVER (PLATE)
9) Remove cotter pin and castle nut which secure tierod
end to housing knuckle arm.
10) Using a puller, remove tie rod ball joint from knuckle
arm.

11) Remove bolt that connects housing to strut.


12) Remove housing assembly.
13) Install in reverse order of removal. For installation
and tightening torque of suspension parts, refer to 4-1
[W2E0].
For installation and tightening torque of brake parts,
refer to 4-4 [W1F0].
CAUTION:
Be careful not to damage inner oil seal lip.
Use a new self-locking nut.
Use a new axle nut.

8
SERVICE PROCEDURE 4.2
1. front Axle

Always tighten axle nut before installing wheel on


vehicle. If wheel is installed and comes in contact
with ground when axle nut is loose, wheel bearings
may be damaged.
Be sure to tighten axle nut to specified torque. Do
not overtiqhten it as this may damage wheel
bearing.
14) After tightening axle nut, caulk it securely.

B: DISASSEMBLY
1. 4WD model
1) Using ST, support housing and hub securely.
2) Attach ST to housing and drive hub out.
ST1 927080000 HUB STAND
ST2 922590000 HUB PULLER
ST3 28099KC040 BUSH

If inner bearing race remains in the hub, remove it with


a suitable tool (commercially available).
NOTE:
Be careful not to scratch polished area of hub.
Be sure to install inner race on the side of outer race
from which it was removed.

4) Using a standard screwdriver, remove outer and


inner oil seals.
CAUTION:
Do not use old oil seals.

5) Using pliers remove snap ring.

9
4.2 SERVICE PROCEDURE
1. front Axle

6) Using ST 1, support housing securely


7) Using ST2, press inner race to drive out outer
bearing.
ST 1 922620000 HOUSING STAND
ST 2 922610000 BEARING PULLER
CAUTION:
Do not remove outer race unless it is faulty.
Discard outer race after removal.
Do not replace inner or outer race separately;
always replace as a unit.

8) Using ST and a hydraulic press, drive hub bolts out.


ST 927080000 HUB STAND
CAUTION:
Be careful not to hammer hub bolts. This may
deform hub.

2. RWD model
1) Remove hub from spindle.
2) Remove back plate from spindle.

3) Using ST, press hub bolts out.


CAUTION:
Do not hammer hub bolt since this may deform hub.
ST 927080000 HUB STAND

10
SERVICE PROCEDURE 4.2
1. front Axle

C: INSPECTION
Check the removed parts tor wear and damage. If
defective, replace with a new one.
CAUTION:
If a bearing is faulty, replace it as the bearing set.
Be sure to replace oil seal at every overhaul.

D: ASSEMBLY
1. 4WD model
1) Attach hub to ST1, ST2 securely.
ST1 927080000 HUB STAND ST2 922630000
SPACER
2) Using a hydraulic press, press new hub bolts into
place until their seating surfaces contact the hub.
NOTE:
Use 12 mm (0.47 in) dia. holes in ST (HUB STAND) to
prevent bolts from tilting.

3) Clean dust or foreign particles from inside the


housing.
4) Using ST, press a new bearing into place.
ST1 922620000 HOUSING STAND
ST2 922610000 BEARING PULLER
CAUTION:
Always press outer race when installing bearing.
Be careful not to remove plastic lock from inner
race when installing bearing.
Charge bearing with new grease when outer race
is not removed.

5) Apply sufficient grease to bearing.


Sufficed grease:
SHELL 6459N
6) Install snap ring in its groove.
NOTE:
Make sure to install it firmly to groove.

11
4.2 SERVICE PROCEDURE
1. front Axle

7) Using ST, press a new outer oil seal until it contacts


the circlip.
ST1 922600000 HUB INSTALLER
ST2 922620000 HOUSING STAND

8) Invert housing and ST2.


9) Using ST1, press a new inner oil seal until it contacts
the bottom of housing.
ST1 922600000 HUB INSTALLER
ST2 922620000 HOUSING STAND

10) Apply sufficient grease to oil seal lip.


Specified grease:
SHELL 6459N
CAUTION:
If specified grease is not available, remove bea-
ring grease and apply Auto Rex A instead.
Do not mix different types of grease.

11) Install disc cover to housing the three bolts.

12) Attach hub assembly to ST1 and ST2 securely.


ST1 92708000 HUB STAND
ST2 922630000 SPACER
13) Clean dust or foreign particles from the polished
surface of hub.
14) Using ST3, press bearing into hub by driving inner
race.
ST3 922600000 HUB INSTALLER

12
SERVICE PROCEDURE 4.2
1. front Axle

2. RWD model
1) Using ST1 and ST2, press new hub bolts into place.
NOTE:
Use a 12 mm (0.47 in) hole in ST to prevent hub bolt
from tilting during installation.
Ensure hub bolt closely contacts hub.
ST1 92708000 HUB STAND
ST2 922630000 SPACER

2) Completely clean dust or dirt from the mating /


polished surface of spindle back plate.
3) Install back plate to spindle.
4) Charge oil seal located on the front of hub with
grease.
Specified grease:
SHELL 6459N

5) Install hub on spindle. Temporarily tighten axle nut to


hold hub in place.
CAUTION:
Discard old axle nut. Replace with a new one.

2. Front Drive Shaft


A: REMOVAL
1) Refer to step 8 of the procedure for installing and
removing the front axle.
Refer to 4-2 [WIA0]

2) Temporarily tighten castle nut.


3) Remove DOJ from front differential using ST and
driver. Put a large screwdriver against the transmission
case. Using this screwdriver as a fulcrum, detach
TJ with ST.
ST 28099PA 100 DRIVE SHAFT REMOVER
CAUTION:
Do not apply screwdriver on differential holder.
4) Remove castle nut and axle shafts.

13
4.2 SERVICE PROCEDURE
2. Front Drive Shaft

B: DISASSEMBLY
1) Straighten bent claw of DOJ boot.
2) Loosen band by means of screwdriver or pliers with
care of not damaging boot.
3) Remove the larger end of DOJ boot from DOJ outer
race.

4) Pry and remove round circlip located et the neck of


DOJ outer race with a screwdriver.

5) Take out DOJ outer race from shaft assembly.


6) Wipe off grease and take out balls.
CAUTION:
The grease Is a special grease (grease for constant
velocity joint). Do not confuse with other greases.
NOTE:
Disassemble exercising care not to lose balls (6 pcs.)

7) To remove the cage from the inner race, turn the


cage by a half pitch to the track groove of the inner race
and shift the cage.

14
SERVICE PROCEDURE 4.2
2. Front Drive Shaft

8) Remove snap ring, which fixes inner race to shaft, by


using snap ring pliers.

9) Take out DOJ inner race.


10) Take off DOJ cage from shaft and remove DOJ
boot.
NOTE:
Be sure to wrap shaft splines with vinyltape to prevent
boot from scratches.
11) Remove BJ boot in the same procedure as steps
1)to 2).
12) Thus, disassembly of axle is completed, but BJ is
unable to be disassembled.

C: INSPECTION
Check the removed parts for damage, wear, corrosion
and etc. If faulty, repair or replace.
1) DOJ (Double Offset Joint)
Check seizure, corrosion, damage, wear and excessive
play.
2) Shaft
Check excessive bending, twisting, damage and wear.
3) BJ (Bell Joint)
Check seizure, corrosion, damage and excessive play.
4) Boot
Check for wear, warping, breakage or scratches.
5) Grease
Check for discoloration or fluidity.

D: ASSEMBLY
Specified grease:
DOJ and BJ side - Molylex No. 2
or Sunlight TB2-A
1) Install BJ boot in specified position, ad fill it with 60 to
70 g (2.12 to 2.47 oz) of specified grease.
2) Place DOJ boot at the center of shaft.
NOTE:
Be sure to wrap shaft splines with vinyltape to prevent
boot from scratches.

15
4.2 SERVICE PROCEDURE
2. Front Drive Shaft

3) Insert DOJ cage onto shaft.


NOTE:
Insert the cage with the cut-out side facing the shaft
end, since the cage has an orientation.

4) Install DOJ inner race on shaft and fit snap ring with
snap ring pliers.
NOTE:
Confirm that the snap ring is completely shaft groove.

5) Install cage, which was previously fitted, to inner race


fixed upon shaft.
NOTE:
Fit the cage with the protruded part aligned with the
track on the inner race and then turn by a half pitch.

6) Fill 20 to 30 g (0.71 to 1.06 oz) of specified grease


into the interior of DOJ outer race.
7) Apply a coat of specified grease to the cage pocket
and six balls.
8) Insert six balls into the cage pocket.

9) Align the outer race track and ball position and place
in the part where shaft, inner race, cage and balls are
previously installed, and then fit outer race.

16
SERVICE PROCEDURE 4.2
2. Front Drive Shaft

10) Install circlip in the groove on DOJ outer race.


NOTE:
Assure that the bails, cage and inner race are
completely fitted in the outer race of DOJ.
Exercise care not to place the matched position of
circlip in the ball groove of outer race.
Pull the shaft lightly and assure that the circlip is
completely fitted in the groove.
11) Apply an even coat of the specified grease [20 to 30
g (0.71 to 1.06 oz)] to the entire inner surface of boot.
Also apply grease to shaft.
12) Install DOJ boot taking care not to twist it.
CAUTION
Use a new band.
NOTE:
The inside of the larger end of DOJ boot and the boot
groove shall be cleaned so as to be free from grease
and other substances.
When installing DOJ boot, position outer race of DOJ
at center of its travel.
13) Put a band through the clip and wind twice in
alignment with band groove of boot.

14) Adjust distance between A and B of DOJ boot band


to specification and tighten boot band.
Specified distance between A and B: L
73 mm (2.87 in)
15) Pinch the end of band with pliers. Hold the clip and
tighten securely.
NOTE:
When tightening boot, exercise care so that the air
within the boot is appropriate.

17
4.2 SERVICE PROCEDURE
2. Front Drive Shaft

16) Tighten band by using ST.


ST 925091000 BAND TIGHTENING TOOL
NOTE:
Tighten band until it cannot be moved by hand

17) Tap on the clip with the punch provided at the end
of ST.
ST 925091000 BAND TIGHTENING TOOL
CAUTION:
Tap to an extent that the boot underneath is not
damaged.
18) Cut off band with an allowance of about 10 mm
(0.39 in) left from the clip and bend this allowance over
the clip.
CAUTION:
Be careful so that the end of band is in close
contact with clip.
19) Fix up boot on BJ in the same manner.
NOTE:
Extend and retract DOJ to provide equal grease
coaling.

E: INSTALLATION
1) Replace circlip from differential splines with new one.
2) Insert BJ into hub splines,
CAUTION:
Be careful not to damage inner oil seal lip.
3) Temporarily tighten axle nut.
4) Install dust seal onto differential splines.
5) Install DOJ onto differential.

6) Align DOJ and differential splines.


7) Push DOJ to insert DOJ into differential by the hand.
NOTE:
Make sure DOJ is inserted properly.
8) Install remaining parts in reverse order of removal.
9) For installation and tightening torque of suspension
parts, refer to 4-1 [W1E0].
For installation and tightening torque of brake parts,
refer to 4-4 [W1F0].

18
SERVICE PROCEDURE 4.2
2. Front Drive Shaft

CAUTlON:
Use a new self-lock nut.
Always tighten axle nut before installing wheel on
vehicle. If wheel is installed and comes in contact with
ground when axle nut is loose, wheel may be damaged.
Be sure to tighten axle nut to specified torque. Do not
overtighten it as this may damage wheel bearing.

10) After tightening axle nut, lock it securely.

3. Rear AxIe
A: REMOVAL
1) Set parking brake
2) Lift up vehicle and remove rear wheel.

3) Remove cotter pin from castle nut.

4) Remove axle nut using a socket wrench


CAUTION:
Be sure to loosen and retighten axle nut after
removing wheel from vehicle. Failure to follow this
rule may damage wheel bearings.
5) Remove conical spring.

19
4.2 SERVICE PROCEDURE
3. Rear AxIe

6) Remove center piece by lightly tapping with


screwdriver.
7) Remove brake shoe.
Refer to 4-4 [W2A0]

8) Remove brake pipe clamp from trailing arm.

9) Remove rear brake assembly from trailing arm.


Suspend rear brake assembly from frame using a wire.
NOTE:
Do not remove the brake pipe.

10) Temporarily tighten castle nut.


11) Remove TJ from rear differential using ST and
driver. Put a large screwdriver against the transmission
case. Using this screwdriver as a fulcrum, detach TJ
with ST.
ST 28099PA100 DRIVE SHAFT REMOVER
CAUTION:
Be careful not to damage baffle plate.
12) Remove castle nut.

13) Disengage BJ from housing splines, and remove


rear drive shaft assembly. If it is hard to remove, us ST
ST1 921122000 BRAKE DRUM REMOVER (PULLER)
ST2 922493001 BRAKE DRUM REMOVER (PLATE)
14) Remove trailing arm from frame.
Refer to 4-1 [W7A0]

20
SERVICE PROCEDURE 4.2
3. Rear AxIe

B: DISASSEMBLY
1) Using the press, hub bolt out from brake drum.
CAUTION:
Be careful not to hammer hub bolts. This may
deform brake drum.

2) Move the spacer in a radial direction with a finger.


3) Apply a brass bar to the inner race of the bearing.
Tap the bar with a hammer to drive out the bearing and
oil seal from the housing.

CAUTION:
a. Do not reuse the bearing which has been
removed by tapping the inner race. Such a bearing
can cause noise in operation.
b. Do not reuse the oil seal once removed.
c. Evenly tap all periphery of the inner race when
removing the bearing.

4) Remove the spacer.


5) Apply a brass bar to the outer race of the bearing.
Lightly tap the bar with a hammer to drive out the
bearing and oil seal.

CAUTION:
a. Evenly tap all periphery of the outer race of the
bearing.
b. Do not reuse the oil seal once removed.

6) If the bearing has been removed together with the


axle shaft, move the oil seal away from the bearing,
and place a puller between the bearing and oil seal.
Then remove the bearing.

21
4.2 SERVICE PROCEDURE
3. Rear AxIe

C: INSPECTION
Check the following parts:
1) Bearing
Clean and check the inner race and outer race for
cracks or damage. Turn the outer race slowly while
holding the inner race, and check for binding in rotation.
2) Spacer
Clean the spacer and check for damage or
deformation.
3) Hub
Wipe the inner surface with a clean cloth, and check for
cracks or damage.

D: ASSEMBLY
1) Using the press, press new hub bolts into place.
CAUTION:
Insert the hub bolt until the seating surface is tight
against the drum.

2) Pack grease to the outer bearing.


Support the trailing arm on ST1, and set ST2 and ST3
to the bearing. Force-fit the bearing using a press.
ST1 922441000 STAND
ST2 922470000 INSTALLER
ST3 498477000 HANDLE

3) Fully coat the oil seal with grease, and set the oil
seal on the outer bearing side. Force-fit the oil seal by
using a 65 mm (2.56 in) dia. bar or block.
ST1 922441000 STAND
CAUTION:
Do not excessively pack grease, otherwise, it may
leak out from the outer bearing to the inside of
brake drum, causing the brake to slip.

22
SERVICE PROCEDURE 4.2
3. Rear AxIe

4) Pack approx. 32 g (1.13 oz) of grease into the hub.


Install the spacer in the hub.
5) Pack grease to the inner bearing.
Set ST 1 and ST2 to the inner bearing, and force-fit the
bearing.
ST1 922470000 INSTALLER
ST2 498477000 HANDLE

6) Fully coat the oil seal with grease, and set the oil
seal to the hub. Set the 30 mm (1.18 in) dia. side of ST
to the oil seal, and force-fit the oil seal until the oil seal
contacts the end face of the bearing.
ST 921350000 HUB BEARING INSTALLER

CAUTION:
The oil seal must be correctly fitted. If fitted
improperly and there is a clearance at A, a change
may occur in the interference of the oil seal lip
causing the oil seal lip to wear.

E: INSTALLATION
1) Install the trailing arm to the vehicle body.
Refer to 4-1 [W7C0]

23
4.2 SERVICE PROCEDURE
3. Rear AxIe

2) Insert BJ into rear trailing arm splines.


CAUTION:
Be careful not to damage inner oil seal lip.
3) Using ST1 and ST2, pull drive shaft into place.
CAUTION:
a. Do not hammer drive shaft when installing it.
b. The right-hand axle shaft and left-hand axle shaft
are different in length. Install each axle shaft to its
correct position.
c. Be careful not to damage the boot.
NOTE:
Holding the two flat faces of the ST1 with a 41 mm
(1.61 in) wrench, turn the handle to force-fit axle the
shaft.
ST1 922431000 AXLE SHAFT INSTALLER
ST2 927130000 EXTENSION AXLE SHAFT
INSTALLER
4) Temporarily tighten castle nut,

5) Align TJ and transmission splines.


6) Push TJ to insert TJ into transmission by the hand.
NOTE:
Make sure TJ is inserted properly.
7) Install remaining parts in reverse order of removal.
8) For installation and tightening torque of suspension
parts, refer to 4-1 [W7C0].
For installation and tightening torque of brake parts,
refer to 4-4 [W2E0].
CAUTION:
use a new self-lock nut.
Always tighten axle nut before installing wheel on
vehicle. If wheel is installed and comes in contact
with ground when axle nut is loose, wheel bearings
may be damaged.
Be sure to tighten axle nut to specified torque. Do
not overtighten it as this may damage wheel
bearing.

24
SERVICE PROCEDURE 4.2
3. Rear AxIe

9) Check for "OUT" mark on conical spring; install con-


ical spring with "OUT" mark on nut side.
10) Tighten castle nut and insert cotter pin into its
holes.
Tightening torque:
235 N m (24 kg-m, 174 ft-lb)
After tightening nut, retighten it within 30 to
align nut slot with cotter pin hole.

CAUTION:
Always use new cotter pin, and bend it after
insertion.
Ensure that cotter pin does not contact brake
drum.

4. Rear Drive Shafts


A: REMOVAL
1) Remove the rear axle according to step 13 of the
procedure for removing the rear axle.
Refer to 4-2 [W3A0]

B: DISASSEMBLY
1) Straighten bent claw of TJ boot.
2) Loosen band by means of screwdriver or pliers with
care of not damaging boot.
3) Remove the larger end of TJ boot from TJ outer
race.

4) Place alignment marks on shaft and TJ outer race.

25
4.2 SERVICE PROCEDURE
4. Rear Drive Shafts

5) Take out TJ outer race from shaft assembly


6) Wipe off grease.
CAUTION:
The grease is a special grease (grease for tJ). Do
not confuse with other greases.

7) Place alignment marks on shaft and trunnion by


punch.

8) Remove snap ring, which fixes inner race to shaft, by


using snap ring pliers.
9) Take out trunnion.
NOTE:
Be sure to wrap shaft splines with vinyltape to prevent
boot from scratches.
10) Remove TJ boot.
11) Remove BJ boot in the same procedure as steps 1)
to 2).
12) Thus, disassembly of axle is completed, but BJ is
unable to be disassembled.

26
SERVICE PROCEDURE 4.2
4. Rear Drive Shafts

C: INSPECTION
Check the removed parts for damage, wear, corrosion
and etc. If faulty, repair or replace.
1) TJ (Tripod Joint)
Check seizure, Corrosion, damage, wear and excessive
play.
2) Shaft
Check excessive bending, twisting, damage and wear.
3) BJ (Bell Joint)
Check seizure, corrosion, damage and excessive play.
4) Boot
Check for wear, warping, breakage or scratches.
5) Grease
Check for discoloration or fluidity.

D: ASSEMBLY
Specified grease:
TJ side - SSG - 6003
BJ side - Molylex No. 2 or
Sunlight TB2-A

1) Install BJ boot in specified position, ad fill it with 75 g


(2.65 oz) of specified grease.
CAUTION:
Be sure to wrap shaft splines with vinyltape to
prevent boot from scratches.
2) Place TJ boot at the center of shaft.

3) Align alignment marks and install trunnion on shaft.


CAUTION:
Be sure to install the trunnion in the correct
direction using the alignment marks.

4) Fit snap ring on shaft with snap ring pliers.


NOTE:
Confirm that the snap ring is completely fitted in the
shaft groove.

27
4.2 SERVICE PROCEDURE
4. Rear Drive Shafts

5) Fill 60 g (2.12 oz) of specified grease into the interior


of TJ outer race.
NOTE:
Coat evenly with grease, avoiding partiality to a
particular area.

6) Align alignment marks on shaft and outer race, and


install outer race.

7) Install TJ boot taking care not to twist it.


CAUTION
Use a new band.
NOTE:
The inside of the larger end of TJ boot and the boot
groove shall be cleaned so as to be free from grease
and other substances.
When installing TJ boot, position outer race of TJ at
center of its travel.
8) Put a band through the clip and wind twice in
alignment with band groove of boot.

9) Adjust distance between A and B of TJ boot banc to


specification and tighten boot band.
Specified distance between A and B: L
85.2 mm (3.354 in)
10) Pinch the end of band with pliers. Hold the clip and
tighten securely.
NOTE:
When tightening boot, exercise care so that the air
within the boot is appropriate.

28
SERVICE PROCEDURE 4.2
4. Rear Drive Shafts

11) Tighten band by using ST.


ST 925091000 BAND TIGHTENING TOO
NOTE:
Tighten band until it cannot be moved by hand.

12) Tap on the clip with the puncj provided at the end of
ST.
ST 925091000 BAND TIGHTENING TOOL
CAUTION:
Tap to an extent that the boot underneath is not
damaged.
13) Cut off band with an allowance of about 10 mm
(0.39 in) left from the clip and bend this allowance over
the clip.
CAUTION:
Be careful so that the end of band is in close
contact with clip.
14) Fix up boot on BJ in the same manner.
NOTE:
Extend and retract TJ to provide equal grease coating.

E: INSTALLATION
Install the rear axle according to steps 2-10 of the
procedure for installing the rear axle.
Refer to 4-2 [W3E0]

29
4.2 SERVICE PROCEDURE
4. Rear Drive Shafts

5. SteeI Wheel and Tire


1) Deformation or damage on the rim can cause air
leakage. Check the rim flange for deformation, crack or
damage, and repair or replace as necessary.
2) Take stone, glass, nail etc. off the tread groove.
3) Replace tire:
When large crack on side wall, damage or crack on
tread is found.
When the "tread wear indicator" appears as a solid
band across the tread.
CAUTION:
When replacing a tire, make sure to use only the
same size, construction and load range as original-
ly installed. Avoid mixing radial, belted bias or bias
tires on the vehicle.

A: INSPECTION OF WHEEL RUNOUT


1) Jack up vehicle until wheels clear the floor.
2) Slowly rotate wheel to check rim "runout" usings a
dial gauge.

Axial runout limit Radial runout limit


Steel wheel 1.5 mm (0.059 in)

3) If rim runout exceeds specifications, remove tire from


rim and check runout while attaching dial gauge to
positions shown in the figure.
Rim runout limit: A: 7 mm (0.276 in)
B: 7 mm (0.276 in)
C: 7 mm (0.276 in)
CAUTION:
If measured runout still exceeds specifications
replace the wheel.

30
SERVICE PROCEDURE 4.2
5. SteeI Wheel and Tire

6. Wheel Balancing
1) Proper wheel balance may be lost if the tire is
moaned or if it wears. Check the tire for dynamic
balance, and repair as necessary.
2) To check for dynamic balance, use a dynamic
balancer. Drive in the balance weight on both the top
and rear sides of the rim.
3) Some types of balancer can cause damage to the
wheel. Use an appropriate balancer when adjusting the
wheel balance.
4) Use genuine balance weights.
Standard clearance: A
Weight for steel wheel
1.6 - 2.0 mm (0.063 - 0.079 in)

7. InstaIIation of Wheel Assembly to


Vehicle
1) Attach the wheel to the hub by aligning the wheel
bolt hole with the hub bolt.
2) Temporarily attach the wheel nuts to the hub bolts.
3) Manually tighten the nuts making sure the whee
hub hole is aligned correctly to the hub.
4) Tighten the wheel nuts in a diagonal selection to the
specified torque. Use a wheel nut wrench.
Wheel nut tightening torque:
88 10 N m (9 1 kg-m, 65 7 ft-lb)
CAUTION:
Tighten the wheel nuts in two or three steps by
gradually increasing the torque and working
diagonally, until the specified torque is reached.
Do not depress the wrench with a foot: Always
use both hands when tightening.
Make sure the bolt, nut and the nut seating
surface of the wheel are free from oils.
5) If a wheel was removed for replacement or for repair
of a puncture, retighten the wheel nuts to the specified
torque after running 1,000 km (600 miles).

31
4.2 SERVICE PROCEDURE
7. InstaIIation of Wheel Assembly to Vehicle

8. Tire Rotation '


If tires are maintained at the same positions for a long
period of time, uneven Wear results. Therefore, they
should be periodically rotated.
This lengthens service life of tires.
NOTE:
When rotating tires, replace unevenly worn or damaged
tires with new ones.

32
4.3 STEERING SYSTEM

Page
S SPECIFICATIONS AND SERVICE DATA................................................................................2
1. Steering System..................................................................................................................2
C COMPONENT PARTS............................................................................................................. 3
1. Steering Wheel and Column................................................................................................3
2. Steering System..................................................................................................................4
3. Steering Gear Box...............................................................................................................5
W SERVICE PROCEDURE......................................................................................................... 6
1. Steering Column.................................................................................................................6
2. Steering Gear Box...............................................................................................................9
3. Center Lever & Drag Link Assembly..................................................................................17
4. Tie-rod Assembly............................................................................................................... 19
T TROUBLESHOOTING........................................................................................................... 21
1. Steering............................................................................................................................. 21
4.3 SPECIFICATION AND SERVICE DATA
1. Steering System

1. Steering System
A: SPECIFICATIONS
Type Rack and pinion
Minimum turning radius 4.2 m (13.8 ft)
Inside 32.9
Steering angle
Outside 30.4
Steering wheel diameter 370 mm (14.57 in) \
Turns, lock to lock 4.1
Steering lock Provided
Shock absorbing shaft Provided
Overall gear ratio 23

B: SERVICE DATA
Steering wheel Free play 0 - 25 mm (0 - 0.98 in)
Inner tire & wheel 30.4-34.4
Turning angle
Outer tire & wheel 27.9 - 31.9
Looseness 0 mm (0 in)
Universal joint
Maximum yawing torque 0.29 N-m (0.03 kg-m, 0.22 ft-lb)
Gearbox rack Bending limit (Runout) 0.25 mm (0.01 in)

2
COMPONENT PARTS 4.3
1. Steering Wheel and
Column

1. Steering Wheel and Column

(1) Column cover (8) Stopper


(2) Key cylinder cover (9) Snap ring
(3) Combination switch (10) Floor cover
(4) Steering wheel (11) Universal joint
(5) Steering shaft (12) Universal joint cover
(6) Bearing (13) Column
(7) Spring washer (14) Horn brush

3
4.3 COMPONENT PARTS
2. Steering System

2. Steering System

(1) Snap pin (7) Drag link bushing (13) Center lever bushing (18) Clamp
(2) Castle nut (8) Drag link (14) Adjusting cap (19) Air vent tube
(3) Dust seal (9) Clip (15) Boot cover (20) Rubber coupling
(4) Tie_rod end (outer) (10) Center lever (16) Steering gear box (21) Torque rod
(5) Tie_rod (11) Rubber cap assembly
(6) Tie rod end (inner) (12) Center lever pin (17) Cover cliD

4
COMPONENT PARTS 4.3
3. Steering Gear Box

3. Steering Gear Box

(1) Yoke (7) Rake (13) Gear box


(2) Scraper (8) Pinion (14) Lock nut
(3) Clip (9) Oil seal (15) Adjusting screw
(4) Inner boot (10) Snap ring (large) (16) Spring
(5) Boot Clip (11) Ball bearing (17) Sleeve
(6) StopperPper (12) Snap ring (small) (18) Outer boot

5
4.3 SERVICE PROCEDURE
3. Steering Gear Box

1. Steering Column
A: REMOVAL AND DISASSEMBLY
1) Disconnect harness from battery ground terminal.

2) Hook your fingers in the space between wheel and


pad, then pull to release the pad.

3) Remove steering wheel mounting nut.

4) Attach steering wheel puller to steering wheel, and


remove steering wheel from shaft.

5) Remove universal joint cover to column coupling clip


and remove universal joint cover from colurnn.

6
SERVICE PROCEDURE 4.3
1. Steering Column

6) Remove universal joint and gearbox pinion coupling


bolt.
7) Remove harness connectors for ignition switch and
combination light switch.

8) Remove column to body coupling bolt and remove


column from gearbox pinion.

9) Remove universal joint from column.

10) Remove combination switch.

11) Remove snap ring


12) Pull steering shaft from column assembly.

7
4.3 SERVICE PROCEDURE
1. Steering Column

B: INSPECTION
1) Clean the disassembled parts with a cloth.
(1) Check shaft distort, damage.
(2) Check bearing wave washer wear makes
unusual noise, does not rotate freely.
(3) Check earth brush wear, distort.
(4) Check snap ring distort.
(5) Check universal joint damage, wear.

1. UNIVERSAL JOINT ASSEMBLY


1) Free play.
2) Swing torque, yawing torque, looseness.
Standard value of universal joint free play:
0 mm (0 in)
Max. value of universal joint swing torque:
0.3 N m (0.03 kg-m, 0.2 ft-lb)

C: INSTALLATION AND ASSEMBLY


1) Install and assembly in reverse order of removal.
2) Apply a coat of specified greases to bearing and
wave washer.
Specified greases:
Showa Shell Sekiyu SUNLIGHT 2
Idemitsu AUTOLEX A

NOTE:
Confirm that universal joint mounting bolt passes cut-
off portion of pinion serration.
If shaft friction is excessive, loosen each mounting
bolt, rotate shaft right and left several times, then
tighten bolts securely.
Refer to "Steering shaft component parts" for
tightening torque.

D: ADJUSTMENT
1) If steering wheel spokes are not horizontal whet1
wheels are set in the straight ahead position, and error
is more than 5 on the periphery of steering wheel,
correctly re-install the steering wheel.
Specified Length: L (On steering wheel)
0 - 25 mm (0 - 0.98 in)

8
SERVICE PROCEDURE 4.3
1. Steering Column

2) If steering wheel spokes are not horizontal with


vehicle set in the straight ahead position after this
adjustment, correct it by turning the right and left tie-
rods in the same direction by the same amount.

2. Steering Gear Box


A: REMOVAL AND DISASSEMBLY
1) Set the vehicle over a pit or on an inspection stand.
2) Remove the floor cover.

3) Remove the rubber coupling from the gearbox.


4) Remove the under cover.

5) Remove the bolt connecting the yoke and drag link.

6) Remove air vent tube from gearbox.

9
4.3 SERVICE PROCEDURE
2. Steering Gear Box

7) Remove gearbox to body coupling bolts while using


care not to damage the adjacent cables and brake
piping. Then remove the gearbox.

B: DISASSEMBLY
1) Secure the yoke of the gearbox in a vice, loosen the
self-locking nut, and remove the yoke.
2) Remove the clips from the boots. Remove the boots
from the gearbox while using care not to give damage
to them.

3) Hold the rack in a vice and remove the stopper.

4) Remove lock nut, adjusting screw, spring and sleeve.

5) Remove the oil seal from the steering gearbox with a


screwdriver.

10
SERVICE PROCEDURE 4.3
2. Steering Gear Box

6) Remove the snap ring.


7) Pull the pinion ASSY.
8) Remove the rack.

9) Remove the snap ring (small) from the pinion.

10) Then, using a press, remove the ball bearing


making sure that the pressing load is always supported
by the inner race of the bearing.
11) Remove the oil seal and snap ring (Large).

C: INSPECTION
1) Wash the disassembled parts, check for wear,
damage and other defects, and repair or replace if
necessary.
2) During disassembly, check to see if water has leaked
into the gearbox. If there is a trace of water, it may be
due to a poor pinion oil seal, broken boot, or defective
Sealant (adjusting screw). Check those parts carefully
and replace if defective.

11
4.3 SERVICE PROCEDURE
2. Steering Gear Box

No Part name Checking item Correction


1 Rubber
Wear and cracks. Replace if excessively worn or cracked
coupling
2 Defects on pinion tooth surface such as
Replace rack and pinion together if defective.
scores. Wear, cracks, etc.
Always use repair parts (NSK6003 DDu2-oc)
Ball bearing.
When replacing.
Pinion ASSY Rattle and smooth rotation.
Replace.
Snap ring.
Always use repair parts.
Deformation.
Replace each time it is removed.
Oil seal.
3 Defects on tooth surface such as scores,
Rack Replace together with pinion ASSY.
wear, cracks, etc.
4 Damage such as cracks in aluminum
die casting. Replace gearbox unit.
Gearbox unit
Wear and damage of bush.
Wear and deterioration adaptor. Replace.
5 Boot Cracks, damage and deterioration. Replace.
6 Sleeve Damage. Replace.
7 Stopper Deformation. Replace.
8 Yoke Cracks and deformation. Replace.

D : ASSEMBLY AND INSTALLATION


Assemble and install the parts by reversing the order of
disassembly and removal, while paying attention to the
following points.

Specified greases:
Kyodo Yushi ONE-L UBE SG
Showa Shell Sekiyu VALIANT M2

1) Apply grease to bushing A and pinion bushing of the


gearbox unit.

12
SERVICE PROCEDURE 4.3
2. Steering Gear Box

2) Apply grease to the tooth roots of the pinion ASSY


and the sliding portions and tooth roots of the rack.

3) After adjusting the rack position to straightahead


driving condition, mesh the pinion with rack at the
specified direction as shown in figure.
Rack position

Pinion position

4) After securing the pinion with the snap ring, measure


the axial play of the pinion with a dial gauge. To
measure, move the pinion up and down by applying a
force of approximately 98 N (10 kg, 22lb)
Max axial play: A
0.3 mm (0.012 in)

5) Install the oil seal into the gearbox. If there is a large


misalignment between the seal top surface and
gearbox, remove the oil seal and reconfirm that the
snap ring is in place.
Be sure to replace the oil seal each time it is
disassembled.

13
4.3 SERVICE PROCEDURE
2. Steering Gear Box

6) Apply grease to oil seal lips and inner portion.


7) Install sleeve and spring in that order into gearbox.
NOTE:
Pack grease abundantly.
(1) Sleeve
(2) Spring
(3) Adjusting screw
(4) O-ring

8) Tighten adjusting screw by two threads.


9) Apply sealant to three or more ridges in thread
portion of adjusting screw.
Sealant: Three Bond 1102 (P/N 004403006)

10) Adjust rack to pinion backlash.


Tighten adjusting screw two or three times by
increacing torque, and finally tighten to specified
torque. After this, loosen adjusting screw by 20 from
that position, and tighten lock nut using ST.
ST 926230000 LOCK NUT WRENCH
Tightening torque:
Adjusting screw
4 0.5 N-m (0.4 0.05 kg-m, 0.4 ft-lb)
Lock nut
39 10 N m (4.0 1.0 kg-m, 29 7 ft-lb)
NOTE:
When tightening lock nut, fix adjusting screw, using
Wrench or similar tool so that it will not be rotated.

11) Install the stopper to the end of the rack.

14
SERVICE PROCEDURE 4.3
2. Steering Gear Box

12) Before install the stopper to the rack, apply sealant


to three or more ridges in the end portion of stopper.
Sealant:
THREE BOND 1102 (P/N 004403006)
Tightening torque:
74 20 N m (7.5 2.0 kg-m, 54 14 ft-lb)

13) Before the boot is installed, reapply specified


grease to the boot inside surface and rack.
(1) After installing the boot, check for abnormal
swelling or depressions.

(2) Clamp the wire (gathering wire) at the large


end of the boot. Anchor the end of the wire to the
hook and pull upwards to a force of about 39
10N-m (4 1 kg,9 2lb), secure.
After, wrap the protruding end of the wire around
the boot.
ST 927590000 WRENCH
CAUTION:
Ensure there is no slack in the wire.

(3) Rotate the pinion, and make sure that the


inner boot is ventilated at air vent nipple.

15
4.3 SERVICE PROCEDURE
2. Steering Gear Box

14) Install the scraper and yoke to the rack.


NOTE:
Align both surfaces of the yoke to the both notches of
the rack.
15) Temporarily tighten self-locking nut.
CAUTION:
Be sure to use a new self-locking nut.

16) Hold the yoke in a vise and tighten self-locking nut.


Tightening torque:
52 10 Nm ( 5.3 1.0 kg-m, 38 7 ft-lb)

17) After assembly, turn the pinion to see if it rotates


smoothly.
Check ventilation in the gear box by carefully observing
how the boot behaves while the pinion is turning.
Pinion turning torque:
In the range of about 60p from the center of rack:
1 N m (0.1 kg-m, 0.7 ft-lb) or less
Maximum torque in the entire operating range:
1.5 N m (0.15 kg-m, 1.1 ft-lb) or less

18) When tightening the bolts, use care not to damage


the adjacent cable and brake piping.
Tightening torque:
59 10 N m ( 6.0 1.0 kg-m, 43 7 ft-lb)
19) When the yoke and drag link are coupled, make
sure that the bolt is tightened with the vehicle in the
straightahead drive condition.
Tightening torque:
49 10 Nm ( 5.0 1.0 kg-m, 36 7 ft-lb)

16
SERVICE PROCEDURE 4.3
2. Steering Gear Box

20) Connect the lower shaft and gearbox pinion via the
rubber coupling. Place all the coupling-pinion nuts on
the upper side of the coupling.
Tightening torque:
17 3 Nm (1.7 0.3 kg- 12 2.2 ft-lb)
(1) Lower shaft
(2) Gearbox
(3) Confirm that the bushing is fitted to each hole of the
rubber coupling.

21) Before installing the floor cover, apply grease to the


dust seal lip.
When tightening, be sure to install the seat between the
floor cover and floor.
Tightening torque:
2 0.5 Nm ( 0.2 0.05 kg-m, 1.4 0.4 ft-lb)
22) Install the under cover.

3. Center Lever & Drag Link Assembly


A: REMOVAL
1) Lift up the vehicle.
2) Remove the boot cover of steering gearbox.
3) Remove the drag link from the yoke.

4) Using a puller, remove the tie-rod end (inner) and


drag link from center lever.

5) Remove the center lever from the cross member.

17
4.3 SERVICE PROCEDURE
3. Center Lever & Drag Link Assembly

B: INSPECTION
Check all removed parts and replace if defective.
1) Check the center lever for damage and deformation.
2) Check the bushing for wear and damage.
3) Secure the center lever bushing in a vice as shown
and check for smooth operation.
Oscillating force:
P Standard value
20 N (2.0 kg, 4.4 lb)
(Reading of spring balance)
This measurement must be taken after oscillating the
center lever two or three times.

C: INSTALLATION
Install the parts by reversing the order of removal, while
paying attention to the following points.
1) After the center lever has been installed to the
chassis frame, make sure that the cotter pin is
positively bent.
CAUTION:
Use a new cotter pin.
Tightening torque:
Tighten to 113 9.8 N m ( 11.5 1.0kg-m,
25 2.2 ft-lb); then tighten further until
the cotter pin hole is aligned within a
+60 range.
2) Install the tie-rod end (inner) and drag link.
CAUTION:
Use a new cotter pin.
Tightening torque:
Tighten to 27 2.5 N m (2.75 0.25kg-m,
20 1.8 ft-lb) ; then tighten further until
the cotter pin hole is aligned within a
+60 range.
3) Connect the yoke and drag link.
Tightening torque:
49 10 N m (5.0 1.0 kg-m, 36 7 ft-lb)

18
SERVICE PROCEDURE 4.3
3. Center Lever & Drag Link Assembly

4. Tie-rod Assembly
A: REMOVAL
1) Lift up fie vehicle and remove the front wheels.
2) Remove the under cover.
3) Using a puller, remove the inner and outer tie-rod
ends from the center lever and knuckle arm.

B: INSPECTION
Check ail removed parts and replace if defective.
1) Check the dust seals at the tie-rod ends for damage
and wear.
2) Check the ball studs at the tie-rod ends for rattle.
3) Check the tie-rod ends for grease leakage.
4) Check the bend of the tie rods.
CAUTION:
The tie-rod ends are non-disassembly type. All of
them should be replaced as an assembly.

C: INSTALLATION
Install the parts by reversing the order of removal, while
paying attention to the following points.
1) Install the tie-rod by adjusting the distance between
ball studs so that the threaded portions at both ends of
tie-rod will be equal in length.
NOTE:
Tighten so that A and B portion maybe equal in length.
Installed tie-rod length : L
345.6 mm (13.61 in)

19
4.3 SERVICE PROCEDURE
4. Tie-rod Assembly

2) Install the inner and outer tie-rod ends to the center


lever and knuckle arms.
CAUTION:
Use a new cotter pin.
Tightening torque:
After tightening to 27 2.5 Nrn (2.75
0.25 kg-m, 20 1.8 ft-lb) adjust cotter
pin holes by turning within +60.
(1) Outer tie-rod end (right-hand thread)
(2) Inner tie-rod end (left-hand thread)
(3) The side having flat faces for attaching wrench is
the outer side.
3) After installation, check front toe-in and steering
angle.

20
TROUBLESHOOTING 4.3
1. Steering

1. Steering
Trouble and probable cause Correction
1. Steering wheel operation is heavy.
jack up the fronf end of fhe vehicIe so that the front wheels are lifted off the ground, then separate the tie-rod ends
and turn the steering Wheel.
(A) Tight steering wheel: Tire air pressure or defects in suspension.
(1) Tire air pressure too low. Adjust to proper pressure.
(2) improper front-wheel alignment. Adjust (toe-in).
(3) Worn tires. Replace.
(B) Heavy steering wheel: Defects in steering system.
(1) Center lever bushing damaged. Replace.
(2) Steering gear box damaged. Replace.
(3) Insufficient lubrication. Lubricate.
(4) Excessive friction at tie-rod ends. Replace.
(5) improper rack and pinion backlash Adjust
2. Steering wheel vibration.
(1) Improper tire air pressure. Adjust to proper pressure
(2) improper front-wheel alignment. Adjust (toe-in).
(3) Wheel nuts loose. Tighten to specified torque
(4) Deformed wheel. Repair or replace.
(5) Wheel bearing damaged or worn. Replace.
(6) Suspension arm deformed or damaged. Repair or replace.
(7) Wear or looseness at tie-rod end. Adjust or replace.
(8) Worn center lever bushing. Replace.
(9) Improper front-wheel balance. Adjust.
3. Steering wheel pulls to one side.
(1) Improper tire air pressure. Adjust to proper pressure.
(2) Improper front-wheel alignment. Adjust
(3) Wheel bearing improperly adjusted or worn. Adjust or replace.
(4) Malfunctioning shock absorber. Replace.
(5) Suspension arm deformed or broken. Repair or replace.
(6) Loose drag link bush. Tighten to specified torque.
(7) Improper backlash of rack and pinion. Adjust.
(8) Excessive friction at tie-rod ends and drag link Replace.
4. Shock is transmitted to steering wheel.
(1) Tire air pressure is too high. Adjust to proper pressure.
5. Play or steering wneel is more than 25 mm (0.98 in)
(1) Worn rack and pinion. Replace.
(2) Damaged or worn steering shaft and serration of torque rod. Retighten or replace.
(3) Loose steering-wheel nut. Tighten to specified torque.
(4) Joint clamping bolt loose. Tighten to specified torque.
(5) Worn front-wheel bearing. Adjust or replace.
(6) Insufficient tightening of each joint. Tighten to specified torque or replace.
(7) Worn center lever bushing. Replace.
(8)Improper rack and pinion back lash. Adjust.
(9) Worn drag link bushing Replace.

21
4.4 BRAKES

Page
S SPECIFICATIONS AND SERVICE DATA................................................................................2
1. Brakes................................................................................................................................. 2
C COMPONENT PARTS............................................................................................................. 4
1. Front Disc Brake.................................................................................................................4
2. Rear Drum Brake................................................................................................................ 5
3. Master Cylinder and Brake Booster.....................................................................................6
4. Parking Brake...................................................................................................................... 7
W SERVICE PROCEDURE......................................................................................................... 8
1. Front Disc Brake.................................................................................................................8
2. Rear Drum Brake............................................................................................................... 11
3. Master Cylinder................................................................................................................. 17
4. Brake Booster................................................................................................................... 20
5. Parking Brake Cable......................................................................................................... 24
6. Parking Brake Lever.......................................................................................................... 25
7. Air Bleeding....................................................................................................................... 26
8. Brake Fluid Replacement..................................................................................................28
9. Dual Proportioning valve (DPV).........................................................................................31
10. Brake Hose and Pipe......................................................................................................32
T TROUBLESHOOTING........................................................................................................... 33
1. Entire Brake System.......................................................................................................... 33
4.4 SPECIFICATION AND SERVICE DATA
1. Brakes

1. Brakes
A: SPECIFICATIONS
type Supportless ventilated disc brake
Effective diameter 184 mm (7.24 in)
Front Effective cylinder diameter 51 mm (2.0 in)
brake 92 x 36 x 7 mm
Lining dimensions (Width x length x thickness)
(3.62 x 1.42 x 0.35 in)
Clearance adjustment Automatic adjustment
Type Leading-trailing drum brake
Effective diameter 180 mm (7.09 in)
Rear Effective cylinder diameter 17.46 mm (7/10 in)
brake 172.4 x 30 x 4.4 mm
Lining dimensions (Width x length x thickness)
(6.79 x 1.18 x 0.173 in)
Clearance adjustment Automatic adjustment
Master Type Tandem type
cylinder | Effective diameter 19.05 mm (3/4 in)
Brake Type Vacuum suspended type
booster r Effective diameter 177.8 mm (7 in)
Brake line Dual circuit system
Brake fluid tank capacity 123 cma (123 cc, 7.51 cu in)
Parking brake Mechanical on rear brakes
DPV Split point 1,961 kPa (20 kg/cm2, 284 psi)
(Dual Proportioning Valve) Reducing ratio 0.3

2
SPECIFICATION AND SERVICE DATA 4.4
1. Brakes

B: SERVICE DATA
ITEM STANDARD SERVICE LIMIT
Pad thickness
15 mm (0.59 in)
(including back metal) 8 mm (0.315 in)
Front brake
Disc thickness 18.0 mm (0.709 in) 16.5 mm (0.650 in)
Disc run-out 0.10 mm (0.0039 in)
Inside diameter 180 mm (7.09 in) 182 mm (7.17 in)
Rear brake
Lining thickness 4.4 mm (0.173 in) 1.7 mm (0.070 in)
Parking brake Lever stroke 7 to 9 notches/196 N (20 kg, 44 lb)

Brake pedal force Fluid pressure


Brake fluid pressure without engine 147 N (15 kg, 33 lb) 1274.9 kPa (13 kgf/cmz, 184.9 psi)
running 294 N (30 kg, 66 lb) 3432.5 kPa (35 kgf/cmz, 497.7 psi)
Brake booster
Brake fluid pressure with engine 147 N (15 kg, 33 lb) 5001.6 kPa (51 kgf/crm, 725.2 psi)
running and vacuum at 66.7 kPa
(500 mrnHg, 19.69 in Hg) 294 N (30 kg, 66 ib) 9414.7 kPa (96 kgf/cnm, 1365.1 psi)

C: RECOMMENDED BRAKE FLUID


Specified brake fluid:
FMVSS No. 116, DOT3 or 4 brake fluid
CAUTION:
Avoid mixing brake fluid of different brands to
prevent the fluid performance from degrading.
When replenishing brake fluid, be careful not to
allow any dust into the brake fluid tank.
Use fresh DOT3 or 4 brake fluid when replacing or
refilling the fluid.

D: BRAKE FLUID LEVEL INDICATOR


Reserve tank with level indicator:
Residual fluid quantity at light ON
Approx. 54 cm3 (54 cc, 3.30 cu in)
Tank capacity
123 cm3 (123 cc, 7.51 cu in)

3
4.4 COMPONENT PARTS
1. Front Disc Brake

1. Front Disc Brake

(1) Disk rotor (8) Bleeder (15)Inner sleeve boot


(2) Key (9)Look pinbolt (16) Oil seal
(3) Key spring (10) Caliper cover (17) Piston
(4) Outer pad (11) Outer sleeve boot (18) Piston boot
(5) Pad cover (12) Sleeve (19) Boot stopper
(6) Inner pad (13) O-ring
(7) Cap (14) Caliper

4
COMPONENT PARTS 4.4
2. Rear Drum Brake

2. Rear Drum Brake

(1) Hold down pin (6) Brake shoe (Leading) (11) Parking brake lever
(2) Bake plate (7) Upper shoe spring (12) Spring washer
(3) Packing (8) Lower shoe spring (13) Spring
(4) Wheel cylinder (9) Hold down spring
(5) Adjuster (10) Brake shoe (Trailing)

5
4.4 COMPONENT PARTS
3. Master Cylinder and Brake Booster

3. Master Cylinder and Brake Booster

(1) Master cylinder


(2) Brake booster

(1) Piston stopper (4)Secondary piston


(2) Gasket (5)Primary piston CP
(3) Piston spring

6
COMPONENT PARTS 4.4
4. Parking Brake

4. Parking Brake

(1) Adjusting screw (6) Equalizer


(2) Pin B (7) Parking brake cable RH
(3) Grip (8) Parking brake cable LH
(4) Spring
(5) Pin A

7
4.4 SERVICE PROCEDURE

1. Front Disc Brake


A: ON-CAR SERVICE
1. PAD
1) Remove pad cover
2) Remove key spring.
3) Remove key.
4) Remove pad.

5) Check pad thickness A.


Pad thickness (including back metal): A
Standard: 15 mm (0.59 in)
Service limit: 8 mm (0.32 in)
CAUTION:
Always replace the pads for both the left and right
wheels at the same time. Also replace key spring if
they are twisted or worn.
Replace pad If there is oil or grease on it.

6) Install pads on caliper body.


7) Install key and key spring.
8) Install pad cover.
NOTE:
If It is difficult to push piston during pad replacement,
loosen air bleeder to facilitate work.

2. DISC ROTOR
1) Set a dial gauge on the disc rotor. Turn disc rotor to
check runout.
NOTE:
Make sure that dial gauge is set 5 mm (0.20 in) inward
of rotor outer perimeter.
Disc rotor runout limit:
0.1 mm (0.004 in)

2) Measure disc rotor thickness A.


[NOTE:
Make sure that micrometer is set 5 mm (0.20 in) inward
of rotor outer perimeter.
Disc rotor thickness: A
Standard: 18.0 mm (0.709 in)
Service limit: 16.5 mm (0.650 in)

8
SERVICE PROCEDURE 4.4
1. Front Disc Brake

B: REMOVAL
1) Remove pad cover.
2) Remove key spring and key.
3) Remove pad.

4) Remove union bolt from caliper body.


5) Remove lock pin bolt.

6) Remove disc rotor from hub.


NOTE:
If disc rotor seizes up within hub, drive disc rotor out by
installing an 8-mm bolt in holes B on the rotor.

C: DISASSEMBLY
1) Clean mud and foreign particles from caliper body
assembly.
CAUTION:
Be careful not to allow foreign particles to enter
inlet (at brake hose connector).
2) Using a standard screwdriver, remove boot stopper
from piston.
3) Remove boot from piston end.

4) Gradually supply compressed air via caliper body


brake hose to force piston out.
CAUTION:
Do not apply excessively high pressure.
Place a wooden block of 10 mm (0.39 in) wide as
shown in figure to prevent damage to piston.
5) Remove piston seal from caliper body cylinder.
6) Remove lock pin sleeve , boot and O-ring from
caliper body.

9
4.4 SERVICE PROCEDURE
1. Front Disc Brake

D: INSPECTION
1) Repair or replace faulty parts.
2) Check caliper body and piston for uneven wear,
damage or rust.
3) Check rubber parts for damage or deterioration.

E: ASSEMBLY
1) Clean caliper body interior using brake fluid.
2) Apply a coat of brake fluid to piston seal and fit
piston seal in groove on caliper body.
3) Apply a coat of brake fluid to the entire inner surface
of cylinder and outer surface of piston.
4) Insert piston seal into cylinder.

5) Insert piston into cylinder.


NOTE:
Do not force piston into cylinder.

6) Apply a coat of specified grease to the entire inner


surface of boot and fit in groove on ends of cylinder and
piston.
Grease:
Dow Coming Molykote M77.

To facilitate installation, fit boot starting with piston end.


7) Install boot stopper. Be careful not scratch boot.

8) Apply a coat of specified grease to sleeve outer


surface, cylinder inner surface, and O-ring grooves.
Grease:
Dow Corning Molykote M77
9) Attach the O-ring to the O-ring groove of the caliper
body.

10
SERVICE PROCEDURE 4.4
1. Front Disc Brake

10) Insert sleeve into caliper body.


11) Install boors on caliper body.

F: INSTALLATION
To install in reverse order of removal.
CAUTION:
When replacing the pad, replace pads of the right
and left wheels at the same time.
Replace brake hose gaskets with new ones.
Bleed air from brake system.
<Ref. to 4-4 [W7A0]>
NOTE;
For tightening torque, see Component Parts.

2. Rear Drum Brake


A: REMOVAL
1) Pull parking brake lever.
2) Jack up car and support with safety stands. Then,
remove wheel.
3) Remove hub cap and cotter pin.
4) Remove castle nut and washer.
5) Release parking brake lever, and loosen adjusting
screw at rear end of parking brake lever to slack off
cable tension.
6) Manually pul! brake drum off from axle shaft
assembly.
7) If brake drum is hard to remove due to "stepped"
wear, release brake shoe as follows:
(1) Remove the grommet from the working hole of
the back plate. Insert a screwdriver as shown below.
After rotating the fulcrum of the adjusting lever,
detach the back plate

11
4.4 SERVICE PROCEDURE
2. Rear Drum Brake

(2) Using ST, remove brake drum.


ST2 921122000 BRAKE DRUM REMOVER
(PULLER)
ST1 922493001 BRAKE DRUM REMOVER
(PLATE)

8) Remove lower shoe return spring.

9) Remove shoe hold down spring and shoe hold down


pin.

10) Remove brake shoe. Disconnect parking brake


cable from brake shoe.
11) Remove return spring from brake shoe.
12) Remove adjusting and parking brake levers from
brake shoe.
13) Loosen brake pipe flare nut to disconnect brake
pipe from wheel cylinder assembly.

14) Remove back plate attaching bolts to remove brake


assembly.
15) Remove wheel cylinder from back plate.

12
SERVICE PROCEDURE 4.4
2. Rear Drum Brake

B: DISASSEMBLE
1) Remove right and left dust boots from wheel cylinder.
2) Remove piston, cup, spring and air bleeder screw
and cap.

C: INSPECTION
1) If the inside surface of brake drum is streaked,
correct the surface. And, if it is unevenly worn,
taperingly streaked, or the outside surface of brake
drum is damaged, correct or replace it.

2) Measure the drum inner diameter.


Drum inner diameter: D
Standard: 180 mm (7.09 in)
Service limit: 182 mm (7.17 in)
3) Measure the lining thickness.
Lining thickness:
Standard: 4.4 mm (0.173 in)
Service limit: 1.7 mm (0.067 in)
4) If the deformation or wear of back plate, shoe, etc.
are notable, replace them.
5) When the shoe return spring tension is excessively
weakened, replace it, taking care to identify upper and
lower springs.

D: ASSEMBLY
1) Clean all parts in brake fluid. Check and replace
faulty parts.
Cup and boot for damage or fatigue.
Cylinder, piston and spring or damage or rust form-
ation.

13
4.4 SERVICE PROCEDURE
2. Rear Drum Brake

2) Using ST installing the cup, apply brake fluid to the


frictional surface for smooth installation and pay
attention to cup direction.
CAUTION:
When replacing the repair kit, make sure that the
sizes of cylinder and cup are the same as those
which were replaced.
ST (Special tools) are available in different
Use only the tool of the correct size.
ST 925460000 ADAPTER
3) Install spring and piston to cylinder.

4) Apply rubber grease to the boot inside, install boot to


cylinder.
Specified grease:
METAL RUBBER #20
CAUTION:
Never use brake grease.

E: INSTALLATION
NOTE:
For tightening torque, see Component Parts.
1) Install back plate on housing.
2) Install wheel cylinder assembly onto back plate.
3) Apply a proper amount of molybdenum grease to
trailing shoe pin. Install parking adjusting lever and
position clips in their pin grooves. Install parking lever
spring between parking lever and trailing shoe web.
Brake grease:
Dow Corning Molykote No.7439 (P/N 725191460 )

14
SERVICE PROCEDURE 4.4
2. Rear Drum Brake

4) Apply adequate amount of brake grease to


contacting surfaces of back plate With Wheel cylinder
piston, and anchor plate with shoe. Tight flare nut
loosely to back plate, install back plate assembly.
Brake grease:
NISSEKI BRAKE GREASE

5) Set strut assembly length to standard value by


rotating adjuster lever.
Strut assembly standard length: L
96 mm (3.78 in)
6) Attach the parking brake cable to the parking lever
on the trailing side.

7) Attach the strut retaining spring to the strut assembly,


and fix to the trailing shoe.
Attach the long hook and the short hook of the strut
retaining spring to the strut assembly and to the hole of
the trailing shoe respectively.

8) Insert the adjusting lever of the strut assembly into


the square opening of the leading shoe.
9) Installing upper return spring.

10) After attaching the leading and trailing shoes to the


wheel cylinder side, attach to the side of the
anchor.
11) Mount shoe hold-down pins and shoe hold-down
springs.

15
4.4 SERVICE PROCEDURE
2. Rear Drum Brake

12) Install lower shoe return-spring between trailing and


leading shoes.
13) Tighten brake pipe flare nut to fasten brake pipe to
wheel cylinder assembly.
14) Connect inner parking brake cable to parking brake
lever.
CAUTION:
Be sure to remove grease, if present on lining
surface and brake drum inner surface.

15) Install brake drum.


CAUTION:
Always tighten axle nut before installing wheel on
vehicle. If wheel is installed and comes in contact
with ground when axle nut is loose, wheel bearings
may be damaged.

16) Check installation directions before installing con-


ical spring.
NOTE:
Conical spring installer direction "OUT" mark on nut
side

17) Tighten castle nut and insert cotter pin into its
holes.
Tightening torque:
+20 +2 +14
196 -0 N.m (20 -0 kg-m, 145 -0 ft-lb)
:20 *. 104
After tightening castle nut, retighten it within 30' so
that cotter pin holes are aligned.
CAUTION:
Always use new cotter pin, and bend it after inser-
tion.
18) After installing brake assembly, bleed air-from brake
line. <Ref. to 4-4 [W7A0]>
19) Be sure to adjust the parking lever stroke.
<Ref. to 4-4 [W5B1]>

16
SERVICE PROCEDURE 4.4
2. Rear Drum Brake

3. Master Cylinder
CAUTION:
Be extremely careful not to spill brake fluid. Brake
fluid spilt on the vehicle body will harm the painted
surface; wipe it off quickly if spilt.

A: REMOVAL
1) Extract the brake fluid from the bleeder screw of the
front and rear brake assembly.
NOTE:
By the air bleed operating sequence, keep stepping on
the brake pedal until the fluid has gone from the inside
of the vinyl hose.
2) Remove steering column. <Ref. to 4-3 [W1 A0]>

3) Remove reservoir tank from instrument panel.


4) Disconnect fluid level indicator harness connector.

5) Disconnect reservoir hoses from reservoir tank.

6) Remove brake pipes from master cylinder.

17
4.4 SERVICE PROCEDURE
3. Master Cylinder

7) Remove master cylinder mounting nuts, and take out


master cylinder from brake booster.

B: DISASSEMBLY
1) Remove mud and dirt from the surface of break
master cylinder.
2) Clean Work bench.

3) Remove secondary piston stopper. Pushing in


primary piston slightly.
CAUTION:
Piston may Jump out from master cylinder.

4) Extract primary piston and secondary piston.


CAUTION:
Do not disassemble the piston; otherwise,the
spring set value may be changed.
Use brake fluid or methanol to wash inside wall of
cylinder, pistons and piston cups. Be careful not to
damage parts when washing. If methanol is used
for washing, do not dip rubber parts, such as piston
cups, in it for more than 30 seconds; otherwise they
may become swelled.

18
SERVICE PROCEDURE 4.4
3. Master Cylinder

C: INSPECTION
If any damage, deformation, wear, swelling, rust, and
other faults are found on the primary piston, secondary
piston, secondary piston stopper, or gasket, replace the
faulty part.
CAUTION:
The primary and secondary pistons must be
replaced as complete assemblies.
The service limit of the clearance between each
piston and the master cylinder inner dia. is 0.11 mm
(0.0043 in).
When handling parts, be extremely careful not to
damage or scratch the parts, or let any foreign
matter get on them.

D: ASSEMBLY
1) When assembling, be sure to use recommended
brake fluid.
2) Ensure that the inside wall of cylinder, pistons, and
piston cups are free from dirt when assembling.
3) Be extremely careful not to damage, scratch, or dent
cylinder inside wall, pistons, and piston cups.
4) Do not drop parts. Never attempt to use any part that
has been dropped accidentally.
5) Assembling piston:
Apply recommended brake fluid to inside wall of
cylinder, and to outer surface of piston, and install
piston carefully into cylinder.
6) Assembling secondary piston stopper:
After installing piston into cylinder, push primary piston
in about 10 mm (0.39 in), using a rod, such as push rod
then assemble gasket and secondary piston stopper.
CAUTION:
If the gasket and secondary piston stopper are
assembled without pushing in the primary piston,
scratches may be caused on the secondary piston,
and no pressure may be built up in the secondary
side. To avoid such an error, be sure to push in the
primary piston before assembling these parts.

19
4.4 SERVICE PROCEDURE
3. Master Cylinder

E: INSTALLATION
1) To install the master cylinder to the body, reverse the
sequence of removal procedure.
2) Be sure to use recommended brake fluid 3; Bleed air
from brake system.
4) For tightening torque, see Component Parts

4. Brake Booster
CAUTION:
Be extremely careful not to spill brake fluid. Brake
fluid spilt on the vehicle body will harm the painted
surface; wipe it off quickly if spilt.

A: REMOVAL
1) Remove pedal bracket. <Refer to 4-5 [W2A0]>
2) Remove snap pin and clevis pin.
3) Remove the bracket.

4) Remove brake booster fitting nut.


5) Remove brake booster.

B: INSTALLATION
1) To install in reverse order of removal.[W7A0]
2) Bleed air from brake system. <Ref. to 4-4[W7A0]>
3) For tightening torque, see Component Parts.
CAUTION:
Be sure to use recommended brake fluid.

20
SERVICE PROCEDURE 4.4
4. Brake Booster

C: CHECKING WITHOUT USING GAUGES


This method cannot determine the exact portion which
has failed, but it can provide a rough understanding of
the nature of the failure if checking is conducted in
accordance with the following procedure.
NOTE:
When checking operation, be sure to securely apply
the hand brake.
If faulty, check precisely with gauges.

1. AIR TIGHTNESS CHECK


Start engine, and run it for 1 to 2 minutes, then turn it
off. Depress brake pedal several times applying the
same pedal force as that used in ordinary braking
operations. The pedal stroke should be greatest on the
1st depression, and it should become smaller with each
successive depression. If no change occurs in the
pedal height while in a depressed state, brake booster
is faulty.
NOTE:
In the event of defective operation, inspect the condi-
tion of the check valve and vacuum hose. Replace
them if faulty and conduct the test again. If no improve-
ment is observed, check precisely with gauges.

2. OPERATION CHECK
1) With engine off, depress brake pedal several times
applying the same pedal force and make sure that the
pedal height does not vary with each depression of the
pedal.
2) With brake pedal depressed, start engine.
3) As engine starts, brake pedal should move slightly
toward the floor. If no change occurs in the pedal
height, brake booster is faulty.

D: CHECKING WITH GAUGES


Connect gauges as shown in figure. After bleeding air
from pressure gauges, proceed to each check.

21
4.4 SERVICE PROCEDURE
4. Brake Booster

1. AIR TIGHTNESS CHECK


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

2. LOADED AIR TIGHTNESS CHECK


1) Start engine and depress brake pedal with pedal
force of 196 N (20 kg, 44 lb). Keep engine running until
a vacuum of 66.7 kPa (500 mmHg, 19.69 inHg) = B
point is indicated on vacuum gauge while the pedal is
still depressed.
2) Stop engine and watch vacuum gauge.
If the vacuum drop range is less than 3.3 kPa (25
mmHg, 0.98 inHg) within 15 seconds after stopping
engine, brake booster is functioning properly.
If defective, refer to "Air tightness check" described
above.

3. LACK OF BOOSTING ACTION CHECK


Turn off engine, and set the vacuum gauge reading a
"0". Then, check the fluid pressure when brake pedal is
depressed. The pressure must be greater than tto
standard value listed below.

Pedal force gauge reading Pressure gauge reading


147 N (15 kg, 33 lb) 1,275 kPa (13 kg/cm2,185 psi)
294 N (30 kg, 66 lb) 3,432 kPa (35 kg/cm2, 498 psi)

22
SERVICE PROCEDURE 4.4
4. Brake Booster

4. BOOSTING ACTION CHECK


Set the vacuum gauge reading at 66.7 kPa (500
mmHg, 19.69 inHg) by running engine. Then, check
the fluid pressure when brake pedal is depressed. The
pressure must be greater than the standard value listed
below.

Pedal force gauge reading Pressure gauge reading


147 N (15 kg, 33 lb) 5,002 kPa (51 kg/cm2, 725 psi)
294 N (30 kg, 66 lb) 9,415 kPa (96 kg/cm2, 1,365 psi)

E: HANDLING PRECAUTIONS
1) After protector has been removed from push-rod, do
not turn the master cylinder side of brake booster
downwards.
(1) If the master cylinder side is turned downwards,
push-rod may come loose by virtue of its own
weight, and reaction disc may drop into brake
booster.

(2) Whether or not reaction disc has dropped can be


determined by measuring the dimension "L".
The projected amount "L" of pushrod should be as
follows:
Standard length:
L = 17.4 mm (0.685 in)

(3) If protector is fitted correctly, reaction disc will not


fall out.
2) Be careful not to drop brake booster. Brake booster
should be discarded if it has been dropped.

23
4.4 SERVICE PROCEDURE
4. Brake Booster

3) Use special care when handling operating rod.


If excessive force is applied to operating rod, sufficient
to cause a change in the angle in excess of +3, it may
result in damage to the power piston cylinder.
4) Use care when placing brake booster on the floor.
CAUTION:
If external force is applied from above when brake
booster is placed in this position, the resin portion
as indicated by "P", may be damaged.

5. Parking Brake Cable


A: REPLACEMENT
1) Lift up vehicle and remove rear wheels.
2) Remove rea;' console from front floor.

3) Loosen adjusting screw.

4) Remove inner cable end from equaliser.

5) Disconnect lever from parking brake cable.


<Ref. to 4-4 [W2A0]>
(1) Remove brake drum.
(2) Remove brake shoe.
(3) Disconnect lever from parking brake cable.

24
SERVICE PROCEDURE 4.4
5. Parking Brake Cable

6) Remove cable clamp.


7) Remove parking brake cable from vehicle.
8) Install (new) parking brake in the reverse order of
removal.
9) For tightening torque, see Component Parts
CAUTION:
Be sure to adjust the lever stroke.

B: ADJUSTMENT OF LEVER STROKE


1. PARKING BRAKE ADJUSTMENT
1) Pull parking brake lever 3 to 5 times.
2) Check lever stroke.
Lever stroke:
7-9 notches when pulled
with a force of 196 N (20 kg, 44 lb)

3) Return the parking brake lever.


4) Insert a screwdriver through the gap in the boot of
the rear console box, and rotate the adjusting screw to
the standard setting.
CAUTION:
Ensure that rear brake is not dragging.

6. Parking Brake Lever


A: REPLACEMENT
1) Remove console box from front floor.
2) Disconnect electric connector for parking brake
switch.

3) Loosen adjusting screw, and remove inner cable end


from equaliser.

25
4.4 SERVICE PROCEDURE
6. Parking Brake Lever

4) Remove parking brake lever.

5) Install parking brake lever in the reverse order of


removal.
Tightening torque (Lever installing bolt):
18 5 N m (1.8 0.5 kg-m, 13 4 ft-lb)
6) Adjust parking brake lever by turning adjusting screw
until parking brake lever stroke is set at 7 to 9 notches
with operating force of 196 N (20 kg 44 lb).

7. Air Bleeding
A: BLEEDING PROCEDURE
CAUTION:
The FMVSS No.116, fresh DOT3 or 4 brake fluid
must be used.
Cover bleeder with waste cloth, when loosening it,
to prevent brake fluid from being splashed over
surrounding parts.
Avoid mixing different brands of brake fluid to
prevent degrading the quality of the fluid.
Be careful not to allow dirt or dust to get into the
reservoir tank.
NOTE:
During bleeding operation, keep the brake reserve
tank filled with brake fluid to eliminate entry of air.
Brake pedal operating must be very slow.
For convenience and safety, it is advisable to have
two man working.

1) Make sure that there is no leak from joints and con


nections of the brake system.

26
SERVICE PROCEDURE 4.4
7. Air Bleeding

2) Fit one end of vinyl tube into the air bleeder and nut
the other end into a brake fluid container.
3) Slowly depress the brake pedal and keep it
depressed. Then, open the air bleeder to discharge air
together with the fluid.
Release air bleeder for 1 to 2 seconds.
Next, With the bleeder closed, slowly release the braKe
pedal.
Repeat these steps until tnere are no more air bubbles
in the vinyl tube.
Allow 3 to 4 seconds between two brake pedal
operations.
4) Tighten air bleeder securely When no air bubbles are
visible.
Tightening torque (Bieeder screw):
11 2Nm (1.0 0.2kg-m, 8 1 ft-lb)

5) Air Bleeding Sequence.


Perform these steps for the brake connecting to the
secondary chamber of master cylinder, first, and then
for the ones connecting to primary chamber.

Model Cross piping

Left-hand drive (1)(2)(3)(4)

6) If the pedal action is soft and spongy, or pedal travels


excessively, the system must be bled of air again.

27
4.4 SERVICE PROCEDURE
7. Air Bleeding

7) Check the pedal stroke.


While the engine is idling, depress the brake pedal with
a 294 N (30 kg. 66 lb) load and measure the distance
between the brake pedal (B) and Toe board (A).
Specified distance:
A to B = 90 mm (3.54 in) or more
If the distance is less than specified, there is a
possibility air is in the brake line.
8) Depress brake pedal with a force of approximately
294 N (30 kg, 66 lb) and hold it there for approximately
20 seconds. At this time check pedal to see if it shows
any unusual movement.
Visually inspect bleeder screws and brake pipe joints to
make sure that there is no fluid leakage.
9) Add brake fluid to the required level (MAX level) of
reserve tank.
10) Install wheels, and drive car for a short distance
between 2 to 3 km (1 to 2 miles) to make sure that
brakes are operating properly.

8. Brake Fluid Replacement


To always maintain the brake fluid characteristics,
replace the brake fluid according to maintenance
schedule or earlier than that when used in severe
condition.

A: REPLACEMENT
CAUTION:
The FMVSS No.116, fresh DOT3 or 4 brake fluid
must be used.
Cover bleeder with waste cloth, when loosening it
to prevent brake fluid from being splashed over
surrounding parts.
Avoid mixing different brands of brake prevent
degrading the quality of the fluid.
Be careful not to allow dirt or dust to get into the
reservoir tank.

NOTE:
During bleeding operation, keep the brake reservoir
tank filled with brake fluid to eliminate entry of air.
Brake pedal operating must be very slow.
For convenience and safety, it is advisable to have
two man working.
The amount of brake fluid required is approximatively
300 ml (10.1 US fl oz, 10.6 Imp fl oz) for total brake
system.

28
SERVICE PROCEDURE 4.4
8. Brake Fluid Replacement

1) Either jack up vehicle and place a safety stand under


it, or left up vehicle.
2) Remove both front and rear wheels.

3) Draw out the brake fluid from reservoir tank with


syringe.
4) Refill reservoir tank with recommended brake fluid.
Recommended brake fluid:
FMVSS No. 116, fresh DOT3 or 4 brake fluid.

5) Install one end of a vinyl tube onto the air bleeder of


and insert the other end of the tube into a container to
collect the brake fluid.

6) Brake fluid replacement sequence.

Model Cross piping

Left-hand drive (1)(2)(3)(4)

29
4.4 SERVICE PROCEDURE
8. Brake Fluid Replacement

7) Instruct your co-worker to depress the brake pedal


slowly two or three times and then hold it depressed.
8) Loosen bleeder screw approximately 1 /4 turn until a
small amount of brake fluid drains into contained then
quickly tighten screw.
9) Repeat steps 6) and 7) above until there are no air
bubbles in drained brake fluid and new fluid flows
through vinyl tube.
NOTE:
Add brake fluid as necessary while performing the air
bleed operation, in order to prevent the tank from
running short of brake fluid.

10) After completing the bleeding operation, hold brake


pedal depressed and tighten screw and install bleeder
cap.
Tightening torque (Bleeder screw):
11 2 N m (1.0 0.2 kg-m, 8 1 ft-lb)
11) Bleed air from each wheel cylinder using the same
procedures as described in steps 6) through 7) above.
12) Depress brake pedal with a force of approximately
294 N (30 kg, 66 lb) and hold it there for approximately
20 seconds. At this time check pedal to see if it shows
any unusual movement.
Visually inspect bleeder screws and brake pipe joints to
make sure that there is no fluid leakage.
13) Install wheels, and drive car for a short distance
between 2 to 3 km (1 to 2 miles) to make sure that
brakes are operating properly.

30
SERVICE PROCEDURE 4.4
8. Brake Fluid Replacement

9. Dual Proportioning valve (DPV)


CAUTION:
Be extremely careful not to spill brake fluid. Brake
fluid spilt on the vehicle body will harm the painted
surface; wipe it off quickly if spilt.

A: CHECK
Check brake pipe connections for oil leaks. If leakage is
found, retighten or replace.

B: REMOVAL AND INSTALLATION


1) Loosen brake pipe flare nuts at four locations.

2) Remove attaching bolt take out DPV and bracket.


CAUTION:
Do not disassemble or readjust DPV.

3) Install DPV.
NOTE:
Before installation, insert valve attaching bracket
protrusion into hole for securing valve body.
Tightening torque:
5.9 2 N m (1.8 0.5 kg-m, 4.35 1.1 ft-lb)
4) Tighten brake pipe flare nuts.
Tightening torque:
+3 +0.3 +2.2
15 -2 N m (1.5 -0.2 kg-m, 11 -1.4 ft-lb)
CAUTION:
Be sure to use recommended brake fluid.
4) Bleed air from brake system. <Ref. to 4-4 [W7A0]>

31
4.4 SERVICE PROCEDURE
10. Brake Hose and Pipe

10. Brake Hose and Pipe


A: REMOVAL AND INSTALLATION
CAUTION:
When removing and installing the brake pie, make
sure that it is not bent.
After installing the brake pipe and hose, bleed the
air from brake system.
After installing the brake hose, make sure that it
does not touch the tire or suspension etc.

32
TROUBLESHOOTING 4.4
1. Entire Brake System

1. Entire Brake System

Trouble and possible cause Corrective action


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

33
4.4 TROUBLESHOOTING
1. Entire Brake System

Trouble and possible cause Corrective action


4. Brake dragging or improper brake return
(1) Insufficient pedal play Adjust play.
(2) Improper master cylinder return Clean or replace the cylinder.
(3) Clogged hydraulic system Replace.
(4) Improper return Or adjustment of parking brake Correct or adjust.
(5) Weakened spring tension Or breakage of shoe return Replace the spring.
spring
(6) Excessively narrow shoe clearance Repair or replace.
(7) Improper disc caliper operation Correct or replace.
(8) Improper adjusted wheel bearing Adjust or replace.
5. Brake noise (creak sound)
(1) Hardened Or deteriorated lining Replace the shoe assembly or pad.
(2) Worn lining Replace the shoe assembly or pad.
(3) Loosened back plate or the support installing bolts Retighten.
(4) Loose wheel bearing Retighten to normal tightening torque.
(5) Dirty drum or rotor Clean the drum or rotor, or clean and replace the brake
assembly.
6. Brake noise (hissing sound)
(1) Worn lining Replace the shoe assembly or pad.
(2) Improper installed shoe or pad Correct or replace the shoe assembly or pad.
(3) Loose or bent drum or rotor Retighten or replace.
7. Brake noise (click sound)
In the case Of the disc brake.
(1) Excessively worn pad Or the support Replace the pad Or the support.
In the case Of the drum brake.
(1) Excessively worn shoe ridge Replace the back plate.
(2) Lack Of Oil On the shoe ridge surface and anchor Add more grease.
(3) Excessively worn wheel cylinder piston Replace the Wheel cylinder assembly.

34
4.5 PEDAL SYSTEM AND CONTROL
CABLES

Page
S SPECIFICATIONS AND SERVICE DATA................................................................................2
1. Pedal System and Control CabIes......................................................................................2
C COMPONENT PARTS............................................................................................................. 3
1. Pedal................................................................................................................................... 3
W SERVICE PROCEDURE......................................................................................................... 4
1. ON-CAR Service.................................................................................................................4
2. Brake and Clutch Pedal.......................................................................................................6
3. Accelerator Pedal................................................................................................................8
4. Installation of Each Cable..................................................................................................10
5. Accelerator Cable.............................................................................................................. 10
6. Clutch Cable...................................................................................................................... 12
7. Speedometer Cable.......................................................................................................... 13
T TROUBLESHOUTING........................................................................................................... 14
1. Pedal System and Control Cables.....................................................................................14
4.5 SPECIFICATION AND SERVICE DATA
1. Pedal System and Control CabIes

1. Pedal System and Control CabIes


A: SERVICE DATA

1-3 mm (0.04-0.12 in)


Brake pedal Free play [Depress brake pedal pad With a force of less than
10 N (1 kg, 2 lb)]
Free play At clutch pedal pad 10-25 mm (0.39-0.98 in)
Clutch pedal
Full stroke At clutch pedal pad 130-140 mm (5.12-5.51 in)
Free play At pedal pad 1 - 4 mm (0.04 - 0.16 in)
Accelerator 45 mm (1.77 in)
pedal Stroke At pedal pad (Measure at a point 120mm from the rotation center
of the pedal pad.)

2
COMPONENT PARTS 4.5
1. Pedal

1. Pedal

(1) Clip (8) PedaI bracket (15) Brake pedal pad


(2) Washer (9) Bracket (16) Accelerator pedal
(3) Bushing (10) Stop light switch (17) Insulator
(4) Clutch pedal nad (11) Brake pedal spring (18) Cover
(5) Clutch peda pad (12) Clevis pin (19) Plate
(6) Cluth pedal spring (13) Snap ring
(7) Stopper (14) Brake pedal

3
4.5 SERVICE PROCEDURE

1. ON-CAR Service
A: ADJUSTMENT

1. BRAKE PEDAL FREE PLAY


1) Check for play of the brake booster operating rod.
Brake pedal free play: L
1-3 mm (0.04 - 0.12 in) at pedal pad center
2) Adjust the play of the operating rod by loosening the
two bolts mounting the stopper bracket. If necessary,
relocate the stop light switch.

2. CLUTCH PEDAL FREE PLAY


1) Check for play of the clutch pedal by lightly pressing
the pedal pad With finger.
Clutch pedal free play: L
10-25 mm (0.39 - 0.98 in) at pedal pad center

2) The adjustment should be made by turning the


adjusting screw (Wing nut) in the clutch-cable-attache
part at the lower position of the engine.
CAUTION:
If properly adjusted, the play of the clutch releaf
lever pin will be about 2 mm(0.08in).

4
SERVICE PROCEDURE 4.5
1. ON-CAR Service

3. CLUTCH PEDAL STROKE


Check for stroke of clutch pedal.
Clutch pedal stroke: L
135 - 140 mm (5.31 - 5.51 in)

4. ACCELERATOR PEDAL
1) Check pedal stroke and free play by operating
accelerator pedal by hand.
If it is not within specified value, adjust it by turning nut
connecting accelerator cable to throttle body.
Free play at pedal pad: L
1-4mm (0.04-0.16in)

2) If it is not in specified value adjust it by turning


adjusting nut on engine side end of throttle body.
Free play at inner cable: L
1-8mm (0.04-0.31 in)

3) Apply grease to inner end of accelerator cable to


prevent uneven wear.
Tightening torque (Lock nut):
14 4 N m (1.4 0.4 kg-m, 10 3 ft-lb)

5
4.5 SERVICE PROCEDURE
1. ON-CAR Service

2. Brake and Clutch Pedal


A: REMOVAL
1) Remove steering column. Ref. to 4-3[W1A0]
2) Remove master cylinder. Ref. to 4-4[W3A0]
3) Loosen the adjusting screw (wing nut) of the clutch
cable at the side of the engine.

4) Remove the clamp from the clutch cable connected


on the pedal side so that the cable may be passed
through the bracket.

5) Remove the clutch cable from the clutch pedal.


6) Remove brake switch connecter.

7) Remove vacuum hose.


8) Remove fuse box from pedal bracket.

9) Loosen the bolt below the instrument panel, the nuts


below the front panel, and Pull out the pedal bracket by
moving it toward the rear.

6
SERVICE PROCEDURE 4.5
2. Brake and Clutch Pedal

B: DISASSEMBLY
1. CLUTCH PEDAL
1) Remove the clip and washer at the shaft end.
2) Remove the clutch pedal, return spring and bushes
together from the shaft.

2. BRAKE PEDAL
1) Remove the clevis pin linking the brake booster and
pedal lever.
2) Remove brake booster.
3) Remove clip and washer at shaft end.
4) Remove bracket, brake pedal, return spring and
bushing.

C: INSPECTION
Check all removed parts and replace if deformed,
damaged, or worn.

D: ASSEMBLY
1) Apply sufficient grease to the bush and insert it into
the pedal boss.
2) To assembly in reverse order of disassembly.

7
4.5 SERVICE PROCEDURE
2. Brake and Clutch Pedal

E: INSTALLATION
1) Installation procedure is in the reverse order of
removal.
2) Adjust free play of fork lever using wing nut located
at inner end of clutch cable in engine compartement.
3) Apply a coat of grease to fork lever.
Fork lever free play: L
1-2 mm (0.04 - 0.08 in)

4) Bleed air from brake system Ref. to 4-4[W7A0]


5) Check brake pedal free play and stroke.
Ref. to ON-CAR SERVICE 4-5 [W1A1].

3. Accelerator Pedal
A: REMOVAL

1) Remove the nut securing accelerator pedal to body


on inside.
2) Remove the mud guard.

3) Remove nuts from the plate holding down the pedal


cover, and remove the plate and pedal cover.

8
SERVICE PROCEDURE 4.5
3. Accelerator Pedal

4) Remove the outer end of the accelerator cable from


the pedal bracket by loosening the nut.
5) Remove the inner cable from the pedal lever
6) Take out the entire accelerator pedal by moving it
toward the compartment.

B: INSPECTION
Check all removed parts and replace if deformed,
damaged, or worn.

C: INSTALLATION
1) Coat the end of the accelerator cable With grease.
2) Installation is in the reverse order of removal.
3) Check pedal free play and stroke.
Ref .to ON-CAR SERVICE 4-5[W1 A4]

9
4.5 SERVICE PROCEDURE
4. Installation of Each Cable

4. Installation of Each Cable

(1) Accelerator cable (4) Band


(2) Speedometer cable (5) Clamp
(3) Clutch cable (6) Clip

5. Accelerator Cable
A: REMOVAL
1) Remove the nut securing accelerator pedal to body
on inside.
2) Remove the mud guard.
3) Remove the nut securing accelerator pedal to body
on outside.
4) Remove the accelerator pedal cover.

5) Remove the outer end of the accelerator cable from


the pedal bracket.
6) Remove the inner end of the accelerator cable from
the pedal lever.

10
SERVICE PROCEDURE 4.5
5. Accelerator Cable

7) open the trap door of the engine compartment.


8) Disconnect accelerator cable from throttle body.

9) Remove the clips and bands and pull out the cable.

B: INSPECTION
Check the removed cable and replace if damaged,
rusty, or malfunctioning.
1) Check for smooth operation of the cable (damage
and a short stroke).
2) Check the inner cable for damage and rust.
3) Check the outer cable for damage, bends, and
cracks.
4) Check the boot for damage, cracks, and deteriora-
tion.
C: INSTALLATION
1) Arrange the cable Ref. to Installation of each
cable.4-5[W400]
2) Apply grease to the front and rear ends of the inner
cable.
3) Installation is in the reverse order of removal.
a. Arrange the cable without making sharp bends
and twisting.
b. Fix each clip securely along the curve of the
cable so that the cable is not bent.
4) Check pedal free play.
Ref To ON-CAR SERVICE 4-5[W1 A4]

11
4.5 SERVICE PROCEDURE
5. Accelerator Cable

6. Clutch Cable
A: REMOVAL
1) Loosen the wing nut on the inner cable end at the
transmission side.

2) Remove the clamp in the outer cable end joint at the


side of the pedal, and then remove the cable from the
pedal bracket.
3) Remove the inner cable end from the clutch pedal.
4) Remove the cable by loosening the clips and bands.

5) Remove the undercover in the engine compartment.


6) Remove the clamp on the transmission.
7) Remove the clutch cable from the clutch release
lever.
8) Remove the grommet in the cab floor, and pull out
the cable from below the floor and toward the rear.

B: INSPECTION
Replace if defective.
1) Check for smooth operation of the clutch cable
(looseness and interference).
2) Check the inner cable for damage and rust.
3) Check the outer cable for damage.
4) Check the boot for dislocation and damage.

C: INSTALLATION
1) Installation is in the reverse order of removal.
2) Check pedal free play.
Ref To ON-CAR SERVICE 4-5[W1A2]

12
SERVICE PROCEDURE 4.5
6. Clutch Cable

7. Speedometer Cable
A: REMOVAL
1) Disconnect Speedometer cable from transmission.
2) Remove combination meter.

3) Disconnect speedometer cable from combination


meter.
4) Remove the clips and bands and pull out the cable.

B: INSTALLATION
1) Installation is in the reverse order of removal.
2) Turn the socket by hand as far as it goes in, then
tighten 45 to 90 degrees farther With a Wrench.

13
4.5 TROUBLESHOOTING
1. Pedal System and Control
Cables.

1. Pedal System and Control Cables.

Trouble Corrective action


Excessively Worn brake pedal pad Replace
Failure of clutch and/or accelerator pedals to operate Connect cables correctly
Speedometer does not Work Connect speedometer cable correctly
Stop light switch does not light up Adjust position of stop light switch
Stop light switch is not smooth and/or stroke is not correct Replace
Insufficient pedal play Adjust pedal play
Clutch and/or brake pedal free play insufficient j Adjust pedal free play
Maladjustment of brake pedal or booster push rod Inspect and adjust
Excessively Worn and damaged pedal shaft and/or bushing Replace bushing and/or shaft With new one

14
4.6 HEATER AND VENTILATOR

Page
C COMPONENT PARTS............................................................................................................. 2
1. Heater System.................................................................................................................... 2
2. Heater Unit.......................................................................................................................... 3
3. Heater Control..................................................................................................................... 4
4. Rear Heater Unit.................................................................................................................5
W SERVICE PROCEDURE......................................................................................................... 6
1. Heater Unit.......................................................................................................................... 6
2. Rear Heater Unit.................................................................................................................7
4.6 COMPONENT PARTS
1. Heater System

1. Heater System

(1) Front defroster duct (LH) (5) Intake shutter box


(2) Heater unit (6) Drain hose
(3) Front defroster duct (RH) (7) Cover
(4) Intake duct

2
COMPONENT PARTS 4.6
2. Heater Unit

2. Heater Unit

(1) Vent door lever (5) Mix door (9) Heater core
(2) Resister (6) DEF, heat door (10) Blower fan assembly
(3) Case (LH) (7) Case (RH) (11) DEF, heat door lever
(4) Vent door (8) Mix door link

3
4.6 COMPONENT PARTS
3. Heater Control

3. Heater Control

(1) VaIve socket (5) Recirc Iever


(2) Heater control assembly (6) Knob
(3) Control cable (7) Mode control lever
(4) Temperature lever

4
COMPONENT PARTS 4.6
4. Rear Heater Unit

4. Rear Heater Unit

(1) Rear heater (5) Motor assembly


(2) Case a 9 (6) Seal
(3) Plate (7) Case B
(4) Fan (8) Core

5
4.6 SERVICE PROCEDURE
4. Rear Heater Unit

1. Heater Unit
A. REMOVAL
1) Disconnect battery ground cable
2) Remove instrument panel <Ref to 5-4 [W1A0]>.
3) Remove heater hose cover.
4) Drain coolant from radiator by drain cock.
b) Remove two hose clamps, then disconnect outlet
and inlet heater hoses.
NOTE:
When removing heater unit, close opening of pipes with
cloth to prevent coolant from spilling.

6) Disconnect connectors from heater unit.


7) Remove bolts and then remove heater unit.
NOTE:
While storing the heater unit, take care to prevent
bending outlet and inlet pipes.

B. DISASSEMBLY
1) Remove blower motor ASSY.
2) Remove heater core.
3) Remove resistor.
4) Remove four clips and six screws and separate
heater unit into two sections.

C. ASSEMBLY
Installation is in the reverse order of disassembly.

6
SERVICE PROCEDURE 4.6
1. Heater Unit

D: INSTALLATION
1) Installation is in the reverse order of removal.
2) Connect inlet hose to resin pipe and connect outlet
hose to other pipe, and clamp heater hose securely.
Fitted length of heater hose over pipe:
20 - 30 mm (0.8 - 1.2 in)
3) Pour coolant. <Ref. to 2-5 [W1B0]>

2. Rear Heater Unit


A. REMOVAL
1) Disconnect battery ground cable.
2) Drain coolant from radiator by drain cock.
3) Remove rear heater grilles and then remove four
screws from rear heater unit.

4) Lift up drivers seat and then remove bolt.

5) Lift up vehicle.
6) Remove front wheel of left.
7) Remove hose clamps and then disconnect outlet and
inlet heater hoses.
NOTE:
When disconnect heater hoses, catch coolant by
vessel, and then close opening of pipes with cloth to
prevent coolant from spilling.
8) Disconnect harness connector.

7
4.6 SERVICE PROCEDURE
2. Rear Heater Unit

9) Remove fuel filler pipe.


10) Remove rear neater unit.

B. INSTALLATION
1) Installation is in the reverse order of removal.
2) Pour coolant. <Ref. to 2-5 [W1B0]>

8
5 BODY SECTION

BODY AND EXTERIOR 5.1

DOORS AND WINDOWS 5.2

SEATS, SEATBELTS, AND INTERIOR 5.3

INSTRUMENT PANEL 5.4


5.1 BODY AND EXTERIOR

S SPECIFICATIONS AND SERVICE DATA................................................................................2


1. Datum Points And Dimensions............................................................................................2
2. Sun Roof............................................................................................................................. 4
C COMPONENT PARTS............................................................................................................. 5
1. Front Bumper...................................................................................................................... 5
2. Rear Bumper....................................................................................................................... 5
3. Sun Roof............................................................................................................................. 6
4. Body Parts........................................................................................................................... 7
W SERVICE PROCEDURE......................................................................................................... 8
1. Front Bumper...................................................................................................................... 8
2. Rear Bumper....................................................................................................................... 9
3. Coating Method for PP bumper.........................................................................................10
4- Repair Instructions for Colored PP Bumper.......................................................................11
5. Front Sun Roof.................................................................................................................. 15
6. Rear Sun Roof.................................................................................................................. 15
5.1 SPECIFICATION AND SERVICE DATA
1. Datum Points And Dimensions

1. Datum Points And Dimensions


1. MEASURE DATUM DIMENSIONS
Use a tram tracking gauge to measure all dimensions. If
a measuring tape is used, be extremely careful because
it tends to deflect or twist, which results in a false
reading.
NOTE:
All dimensions refer to the distance between the
centers of holes measured ina straight line.
Each dimension indicates a projected dimension
between hole centers.

2. BODY

2
SPECIFICATION AND SERVICE DATA 5.1
1. Datum Points And
Dimensions

3. CHASSIS FRAME

3
5.1 SPECIFICATION AND SERVICE DATA
2. Sun Roof

2. Sun Roof

4
COMPONENT PARTS 5.1
1. Front Bumper

1. Front Bumper

(1) Guard bar (3) Clip A lower (5) Beam upper (7) Bumper face
(2) Clip A upper (4) Clip B (6) Beam (8) Cover

2. Rear Bumper

(1) Insulator (6) Cover bumper side RH (11) Bumper side LH


(2) Cover insulator (7) Bumper side RH
(3) Latch (8) Cover handle
(4) Striker (9) Bumper face
(5) Cover bumper (10) Cover bumper side LH

5
5.1 COMPONENT PARTS
3. Sun Roof

3. Sun Roof

(1) Front glass lid (7) Rear rail ASSY (13) Front rail ASSY
(2) Lock handle ASSY (8) Rear rail Cover (14) Roller bracket and wire ASSY
(3) Spring ASSY (9) Control unit (15) Sun shade ASSY
(4) Hinge (10) Guide pipe ASSY (16) Bracket
(5) Rear glass lid (11) Motor ASSY
(6) Roller bracket (12) Handle

6
COMPONENT PARTS 5.1
4. Body Parts

4. Body Parts

(1) Clip
(2) Filler lid
(3) Key
(4) Gusset cover
(5) Outer mirror

7
5.1 SERVICE PROCEDURE
4. Body Parts

1. Front Bumper
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
2) Remove Front trun signal lights of both side.
CAUTION:
Be sure to hold socket section when disconn
not harness.

3) Disconnect washer tank nozzle from front bumper.

4) Remove attaching bolts of both side.

5) Carefully disconnect front bumper clips (1) by pulling


it forward and then disconnect horn and head light
Washer hose.
6) To install, reverse order of removal.
CAUTION:
When installing is avoid jamming of wire harness.

8
SERVICE PROCEDURE 5.1
1. Front Bumper

2. Rear Bumper
A: REMOVAL AND INSTALLATION
1. REAR BUMPER CENTER
1) Open rear bumper center
2) Remove four nuts and then remove rear bumper
center.
3) To install, reverse order of removal.

2. REAR BUMPER SIDE


1) Remove rear bumper center. <Ref to [W2A 1]>
2) Remove bolt and then disconnect three clips from
body Side.
3) Remove rear bumper side.
4) To install, reverse order of removal.

9
5.1 SERVICE PROCEDURE
3. Coating Method for PP
bumper

3. Coating Method for PP bumper


1. PROCESS STEPS
Process
Process name Job contents
No.

Set bumper on paint worktable if required. Use


1 Bumper mounting paint worktable conforming to inner shape of
bumper When possible.

Mask specified part (black base) With masking tape. Use masking tape for PP (example
2 Masking
Nichiban No, 533. etc.) For details, see the following figures.
Degreasing. Clean all parts to be painted With White gasoline, normal alcohol, etc. to remove dirt, oil fat
3
cleaning etc.
4 Primer paint Apply primer one to all parts to be painted, using air gun. Use primer (clear).
Dry at normal temperature [10 to 15 min. at 20C (68F)]. "" 1 In half-dried condition, PP
5 Drying primer paint is dissolved by solvent, e.g. thinner, etc.
Therefore, if dust or dirt must be removed, use ordinary alcohol, etc.
Solid color Metallic color
Use section (block) paint for top coat.
Paint in use (for each color)
Paint use (for each color)
Metallic paint
Solid paint
Hardener PB
Hardener PB
Thinner T-306
6 Top coat paint Thinner T-301
Mixing ratio:
Mixing ratio:
Main agent vs. hardener = 10:1
Main agent vs. hardener = 4:1
Viscosity: 10-13 sec/20C (68F)
Viscosity: 10-13 sec/20C (68F)
Film thickness: 15 - 20fi
Film thickness: 35 - 45p
Spraying pressure: 245 - 343 kPa
Spraying pressure: 245 - 343 kPa
(2.5 - 3.5 kg/cm2, 36 - 50 psi)
(2.5 3.5 kg/cm2, 36 - 50 psi)
Dry at normal temperature [10 min. or more
7 Drying Not required at 20C (68F)].
In half-dried condition, avoid dust, dirt.
Apply a clear coat to parts with top coat (I),
three times, at 5 - 7 minute intervals.
Paint in use
Metallic paint
Hardener PB
8 Top coat (II) Not required. Thinner T-306
Mixing ratio: Clear vs. hardener = 6:1
Viscosity: 14-16 sec/20C (68F)
Film thickness: 25 - 30p
Spraying pressure: 245 - 343 kPa
(2.5 - 3.5 kg/cm2, 36 - 50 psi) _^
60C (140F), 60 min. or 80C (176F), 30 min.
9 Drying If higher than 80C (176F), PP may be deformed. Keep maximum temperature of 80C
(176F)
10 Inspection Paint check.
11 Masking removal Remove masking in process No. 2.

10
SERVICE PROCEDURE 5.1
4- Repair Instructions for
Colored PP Bumper

4- Repair Instructions for Colored PP


Bumper
All PP bumper are Provided with a grained surface,
and if the surface is damaged, it cannot normally be
restored to its former condition. Damage limited to
shallolw scratches that cause only a change in the lus-
tre of the base material or coating, can be almost fully
restored. Before repairing a damaged area, explain his
point to the customer and get an understanding vabout
the matter.
Repair methods are outlined below, based on a classifi-
cation of the extent of damage.
1. MINOR DAMAGE CAUSING ONLY A CHANGE IN
THE LUSTRE OF THE BUMPER DUE TO A LIGHT
TOUCH
Almost restorable.
Process
Process name Job content
No.
1 Cleaning Clean the area to be repaired using water.
2 Sanding Grind the area with #500 sandpaper in a feathering motion
Resin section Coated section
Repeatedly apply wax to the affected area
using a soft cloth (such as flannel). Perform either the same operation as for the
3 Finish
Recommended wax: NITTO KASEI Soft 99 resin section or process No.18 and subs-
TIRE WAX BLACK, or equivalent. equent operations in the "(3)" section- depend-
ing on the degree and nature of damage.
Polish the waxed area clean cloth after
2. DEEP DAMAGE CAUSED BY SCRATCHING
FENCES, ETC.
A dent cannot be repaired but a whitened or swellec part
can be removed.

Process
Process name Job contents
No.
1 Cleaning Clean damaged area With Water.
Removal of damaged
2 Cut off protruding area, if any, due to collision, using a putty knife.
area
3 Sanding Grind the affected area With #100 to #500 sandpaper.
Resin section Coated section
4 Finish Perform Process No. 12 and subsequent oper-
Same as Process No.3 in the "(1)" section.
ations in the "(3)" section.

11
5.1 SERVICE PROCEDURE
4- Repair Instructions for
Colored PP Bumper

3. DEEP DAMAGE SUCH AS A BREAK OR HOLE


THAT REQUIRES FILLING
Much of the peripheral grained surface must be sacrif-
ficed for repair, and the degree of restoration is not
really worth the expense. (The surface, however, will
become almost flush with adjacent areas.).
Recommended epair kit: PP Part Repair Kit (NRM)

Process
Process name Job contents
No.
1 Bumper removal Remove bumper as required;
2 Part removal Remove parts built into bumper as required.

Place bumper on a paint worktable as required.


3 Bumper placement It is recommended that contour of worktable
accommodate internal shape of bumper.

Surface Remove dust, oil, etc. from areas to be repaired and surrounding areas, using a suitable
4
preparation solvent (NRM No. 900 Precleno, white gasoline, or alcohol).

If nature of damage is cracks or holes, cut a


guide slit of 20 to 30 mm (0.79 to 1,18 in) in
length along the crack or hole up to the
5 Cutting
bumper's base surface.
Then, bevel or "vee-out" the affected area
using a knife or grinder.

6 Sanding (I) Grind beveled surface with sandpaper (#40 to #60) to smooth finish.
17 Cleaning Clean the sanded surface with the same solvent as used in Process No. 4.
Grind the side just opposite the beveled area With sandpaper (#40 to #60) and clean using a
solvent. Temporarily spot-weld the side, using a PP Welding rod and heater gun.

Temporary
8
Welding

M5A0141
Do not melt welding rod until it flows out. This results in reduced strength.
Leave the welded spot unattended until it cools completely.

12
SERVICE PROCEDURE 5.1
4- Repair Instructions for
Colored PP Bumper

Process
Process name Job contents
No.
Using a heater gur and PP welding rod, weld the beveled spot while melting the rod and damaged
area.

9 Welding

Melt the sections indicated by hatched area.


Do not melt welding rod until it flows out, in order to provide strength.
Always keep the heater gun 1 to 2 cm (0.4 to 0.8 in) away from the welding spot.
Leave the welded spot unattended until it cools completely.
Remove excess part of weld with a putty knife. If a drill or disc wheel is used instead of the knife,
operate it at a rate lower than 1,500 rpm and grind the excess part little by little. A higher rprn will
cause the PP substrate to melt from the heat.

10 Sanding (II)

Sand the Welded spot smooth With #240 sandpaper.


Mask the black substrate section (as indicated in the figure), using masking tape. Recommended
11 Masking masking tape: Nichiban No. 533 or equivalent For details, see the figures showing the masking
portions.
Cleaning/
12 Completely clean the entire coated area, using solvent similar to that used in Process No. 4.
degreasing
Apply a coat of primer to the repaired surface and its surrounding areas. Mask these areas, if
necessary.
13 Primer coating Recommended primer: No. 364 PP Primer
Be sure to apply one coat of primer at a spraying pressure of 245 to 343 kPa (2.5 to 3.5
kg/cm2, 36 to 50 psi) with a spray gun.
Leave the repaired area unattended at 20C (68F) for 10 to 15 minutes until primer is half-dry.
Leave
14 If dirt or dust comes in contact with the coated area, wipe it off with a cloth dampened with
unattended
alcohol. (Do not use thinner since the coated area tends to melt.)
Apply a coat of primer surface to the repaired area two or three times at an interval of 3 to 5
minutes.
Recommended surfacer:
UPS 300 Flex Primer
Primer surfacer
15 No. 303 UPS 300 Exclusive hardener
coating
NPS 725 Exclusive Reducer (thinner)
Mixing ratio: 2 : 1 (UPS 300: No. 303)
Viscosity: 12-14 sec/20C (68F)
Coated film thickness: 40 - 50p

13
5.1 SERVICE PROCEDURE
4- Repair Instructions for
Colored PP Bumper

Process
Process name Job contents
NO.
16 Drying Allow the coated surface to dry for 60 minutes at 20C (68F) [or 30 minutes at 60C (140F)
17 Sanding (III) Sand the coated surface and its surrounding areas using #400 sandpaper and water.
Cleaning/
18 Same as Process No. 12.
degreasing
Solid color Metallic color
Use a "block" coating method.
Recommended paint:
Suncryl (SC)
No. 307 Flex Hardener
19 Top coat (I) SC Reducer (thinner)
Mixing ratio: 3 :1
(Suncryl: No. 307)
Viscosity: 11-13 sec/20C (68F)
Coated film thickness: 40 - 50ju. Coated film thickness: 20 30fi
Spraying thickness: 245 - 343 kPa
(2.5 - 3.5 kg/cm2, 36 - 50 psi)
Leave unattended at 20C (68F) for at least] 10
Leave minutes until the topcoated area is half-dry.
20 Not required
unattended Be careful to keep dust or dirt from coming I in
contact with the affected area.
Apply a clear coat three times at an interval of 3 to 5
minutes.
Recommended paint:
SC710 Overlay Clear
No. 307 Flex Hardener
21 Top coat (II) Not required SC Reducer (thinner)
Mixing ratio; 3 :1 (SC710: No. 307)
Viscosity: 10-13 sec/20C (68F)
Coated film thickness: 20 - 30fi
Spraying pressure: 245 - 343 kPa
(2.5 - 3.5 kg/cm2, 36 - 50 psi)
Allow the coated surface to dry at 20C (68F) for two hours or 60C (140F) for 30 minutes.
22 Drying i Do not allow the temperature to exceed 80C (176F) since this will deform the PP
substrate.
23 Inspection Carefully check the condition of the repaired area.
24 Masking removal Remove masking tape applied in Process No. 11 and 13.
25 Parts installation Install parts on bumper in reverse order of removal.
Bumper
26 Install bumper.
installation

14
SERVICE PROCEDURE 5.1
4- Repair Instructions for Colored PP
Bumper

5. Front Sun Roof


A: REMOVAL AND INSTALLATION
1) Remove front roof trim.
2) Remove sun shade ASSY,
3) Remove hinge nuts (1), spring ASSY bolts (2D and
lock handle ASSY bolts (3).
4) Carefully remove glass lid from body.

CAUTION:
Be careful not to scratch coated by cloth at body
when removing glass lid from vehicle.
5) To install, reverse order of removal.

B. INSPECTION
In the weather strip, there should be no creases,
kinks, turned up edges or worn corners etc..
Check when fully closed, fully opened partition,
looseness and interference etc., make adjustments.
Check that the tilt-lock handle operates smoothly.

Operation force : N m (kg-m, ft-lb)


Push up force: 29 (3,22) or less
Pull down force: 39 (4, 29) or less

There should be no water leakage on the inside when


the sun-roof is fully closed.

6. Rear Sun Roof


A: REMOVAL
1) Disconnect ground cable from battery.
2) Remove front roof trim and rear roof trim.
3) Remove sun shade ASSY.

15
5.1 SERVICE PROCEDURE
6. Rear Sun Roof

4) Open glass lid at half position.

5) Remove bracket from glass lid.

6) Remove rear rail nuts.


7) Full open glass lid.
8) Floating rear end of rear rail and then moving glass
lid to back and remove it from rear rail.
CAUTION:
Be careful not to scratch coated by cloth at surface
of body when removing glass lid from vehicle.
9) Remove rear rail.

10) Remove motor ASSY.

11) Remove front rail with guide pipe ASSY.


CAUTION:
Be careful not to bend or break guide pipe ASSY
when removing it from vehicle.

16
SERVICE PROCEDURE 5.1
6. Rear Sun Roof

B: INSTALLATION
1) Installing front rail and guide pipe ASSY.
2) Measure clearance between front rail left side and
right side.

Difference of Measure "A" and Measure B :


2mm (0.08 in) or less

3) Installing reai rail to body and then setting glass lid to


rear rail.
CAUTION:
Always apply sealer to bolt hole of rear rail.
Be careful not to scratch coated by cloth at
surface of body when installing glass lid to vehicle.

4) With the left/right wires at the same length, set the


roller bracket assembly and assemble the glass lid.
5) Check that when the glass lid is fully closed there is
a clearance between the front rail end stopper and the
roller, and that the roller meets the cushion at the end
of the rear rail.

6) Installing motor ASSY.


7) Trun the handle about 20 times to ensure the gear
and cable mesh.
8) Installing sun shade and roof trim.
NOTE:
Check the roof-trim attachment after completing.

C: ADJUSTMENT
Insert the shim in between the bracket of the glass
lid and the roller bracket of the front rail, and adjust any
height difference in the side of the body and glass.
The holes for the bolts of the roller bracket of the front
rail are elongated (slot-type), adjust any height
difference by moving the bracket up or down.

17
5.1 SERVICE PROCEDURE
6. Rear Sun Roof

D: INSPECTION
The operation from fully open to fully closed takes
about 7-9 secs.
At about 250rmn before fully closed, stop and again
switch ON the CLOSE switch to operate.
In the weather strip, there should be no creasses
kinks, turned up edges or worn corners etc..'
During operation, the movement should be smooth
with no strange noises or catching.
The sun shade should move smoothly without con-
flicting with the harness.
There should be no water leakage on the inside when
the sun-roof is fully closed.

18
5.2 DOORS AND WINDOWS

Page
S SPECIFICATIONS AND SERVICE DATA................................................................................2
1. Door Alignment....................................................................................................................2
C COMPONENT PARTS............................................................................................................. 3
1. Front Door........................................................................................................................... 3
2. Slide Door........................................................................................................................... 4
2. Rear Gate............................................................................................................................ 5
4. Window Glass and Weather Strip........................................................................................6
W SERVICE PROCEDURE......................................................................................................... 7
1. Front Door........................................................................................................................... 7
2. Slide Doors........................................................................................................................ 10
3. Rear Gate.......................................................................................................................... 14
4. Windshield......................................................................................................................... 15
5. Rear Window Glass........................................................................................................... 17
6. Rear Quarter Window Glass..............................................................................................17
5.2 SPECIFICATION AND SERVICE DATA
1. Door Alignment

1. Door Alignment

2
COMPONENT PARTS 5.2
1. Front Door

1. Front Door

(1) Shoulder molding (8) Striker (15) Escutcheon (22) Upper hinge (29) Inner handle
(2) Run channel (9) Outer handle (16) Door latch (23) Lower hinge (30) Trim bracket
(3) Inner weather strip (10) Outer handle protector(17) Remote rod (24)Front door panel (31) Trim panel
(4) Rear sash (11) Key cylinder clip (18) Regulator handle (25) Buffer
(5) Regulator (12) Sealing cover (19) Retainer spring (26) Protector
(6) Safety knob (13) Inner handle (20) Esculcheon (27) Checker pin
(7) Safety knob cover (14) Retainer spring (21) Front sash (28) Checker spring

3
5.2 COMPONENT PARTS
2. Slide Door

2. Slide Door

(1) Suspender (8) Outer handle (15) Latch (22)Escutcheon (29) Run Channel
(2) striker (9) Link (16) Striker (23) Knob (30) Lower arm
(3) Hook (10) Outer handle protector (17) Inner handle (24) Sealing Cover (31)Center rail
(4) Catcher (11) safety knob (18) Escutcheon (25) Weather strip (32) Center arm
(5) Upper arm (12) Remote ASSY (19) Slide door glass (26) Lower sash (33) Ornament
(6) Slide door (13) Pad (20) Regulator ASSY (27) Inner weather strip (34) checker
(7) Stopper (14) Remote rod (21) Regulator handle (28) Door shoulder molding

4
COMPONENT PARTS 5.2
2. Rear Gate

2. Rear Gate

(1) Hinge (8) Key cylinder Clip


(2) Cover (9) Trim Par|el
(3) Rear gate panel (10) Gas stay
(4) Buffer
(5) Rear gate latch
(6) Spacer
(7) Rear gate striker

5
5.2 COMPONENT PARTS
4. Window Glass and Weather Strip.

4. Window Glass and Weather Strip.

(1) Wind shield glass


(2) Weather strip
(3) Rear quarter window glass
(4) Rear window glass

6
SERVICE PROCEDURE 5.2
4. Window Glass and Weather Strip.

1. Front Door
A. REMOVAL
1) Place o rag on door or body to prevent scratches
and drive out checker pin (1) with a hammer.
NOTE:
When detaching the door from tho vehicle body remove
the door trim while keeping a wire connected to the
head of the checker spring to stop from dropping inside
the door.

2) Support the door with a jack (1). He sure to place a


rag or wooden block (2) on supporting point to prevent
scratching door.
3) Remove the door hinge bolt.

B. DISASSEMBLY
1) Lowering the front door glass and then remove the
retainer spring (1) and then regulator handle (2) and
inner handle.
Use a wire bent at one end, as shown figure, for easier
removal of retainer spring.

2) Remove tapping screw and inner handle.


3) Using ST (1), disengage the clip and then remove
door trim panel (2).
ST 925580000 PULLER

3) Remove trim bracket (1) and then tear off sealing


cover (2).
NOTE:
Be careful not to break sealing cover because it may
break if sealer is removed force fully.

7
5.2 SERVICE PROCEDURE
1. Front Door

4) Remove inner weather strip. (Blind van model ).


5) Remove door shoulder molding CT) from inside.
CAUTION:
Be careful not to scratch coated by cloth at body
when removing door shoulder molding.

6) Raise the front window glass and then remove rear


sash (1)

7) Lower the front door glass and then move the front
window glass forwarding motion so that remove regula-
tor roller (1) from glass holder (2).

8) Lowering front edge of front window glass and then


remove it to upward.

9) Remove regulator bolts, and remove regulat0


ASSY through access hole.

8
SERVICE PROCEDURE 5.2
1. Front Door

10) Disconnect connecting rod from outer handle and


inner remote.
11) Remove safety knob from safety rod.
12) Remove latch screws, and remove latch through
access hole.

C. ASSEMBLY
Assembly is in the reverse order of disassembly.
NOTE:
Attach the inner handle upward and inclined to the
front.
With the window fully shut, attach the regulator 45 up
and forward.
On the reverse side of the escutcheon there are
projections for determining the position, therefore,
attach carefully to the back.

D. INSTALLATION
Installation is in the reverse order of removal.

E. ADJUSTMENT
1. DOOR GLASS
1) Adjust the attitude of the glass with respect to the
sash by the installation bolts (1) of the guide channel.
2) Raise and lower window to check that it is properly
aligned.

2. DOOR STRIKER
1) If door does not fit tightly in the rear end or if it does
not close lightly, move striker (1) laterally by striking
with plastic hammer.

9
5.2 SERVICE PROCEDURE
1. Front Door

2. Slide Doors.
A. REMOVAL
1) Remove rear combination light (1) and ornament (2).

2) Remove floor edge (1).

3) Remove checker (1) from lower rail.

4) Half open the door and then remove upper arm (1)
from door.

5) Draw out the lower arm (1) from rear end of lower
rail.

10
SERVICE PROCEDURE 5.2
2. Slide Doors.

6) Extract center arm slider (1) from rear end of center


rail.
CAUTION:
Be careful not to scratch at body when removing
slide door from lower rail.

B. DISASSEMBLY
1) Remove the door trim. <Ref. to 5-2 [W1 B0]>
2) Remove the sealing cover. <Ref. to 5-2 [W1B0]>
3) Remove lower sash (1).

4) Lower window glass completely and then remove run


channel (1) from door panel.
5) Raise the window glass until appear glass holder (2)
at access hole and then disconnect glass holder from
wire bracket (3).

6) Lowering front edge of window glass and then


remove it to upward.

7) Remove five bolts (1) and remove regulator and wire


ASSY through access hole.

11
5.2 SERVICE PROCEDURE
2. Slide Doors.

8) Disconnect connecting rod from inner remote.


9) Remove three bolts and remove latch ASSY through
access hole.

10) Remove center arm.

C. ASSEMBLY
Assembly is in the reverse order of disassembly
NOTE:
Attach the inner handle upward and inclined to the
front.
With the window fully shut, attach the regulator 45 up
and forward.
On the reverse side of the escutcheon there are pro-
jections for determining the position, therefore, attach
carefully to the back.

D. INSTALLATION
Installation is in the reverse order of removal.

E. UP AND DOWN ADJUSTMENT


1. FRONT SIDE
1) Adjust the lower 0 arm attaching portion so that the
sliding door outer panel bead will have the same height
as the body outer panel bead.
NOTE:
Prior to lower arm adjustment, temporarily tighten the
body side suspender.

12
SERVICE PROCEDURE 5.2
2. Slide Doors.

2) Tighten the lower arm to specification, close the


door- and locate and tighten the suspender (1).

2. REAR SIDE
Make vertical adjustment of the striker (1) attaching
portion.
NOTE:
Prior to striker adjustment, temporarily tighten the cen-
ter arm.

F. SLIDE DOOR AND BODY OUTER PANEL


HEIGHT ADJUSTMENT
1. FRONT SIDE
1) Adjust the top side at the upper arm (1) attaching
portion.
NOTE:
Prior to upper arm adjustment, temporarily tighten the
body side suspender.
2) Tighten the upper arm to specification, close the
door, and locate and locate and tighten the suspender.

3) Adjust the bottom side by adding or reducing spacers


between the lower arm (1) and panel.
NOTE:
Prior to adjustment, temporarily tighten the body side
suspender.
4) Tighten the lower arm to specification, close the
door, and locate and tighten the suspender.

13
5.2 SERVICE PROCEDURE
2. Slide Doors.

2. REAR SIDE
Adjust to right and left at the striker (i) attaching portion,
and tighten.

G. FORWARD AND BACKWARD ADJUST-


MENT
Temporarily tighten the center arm (1) close the door so
that the body-to-slide door clearances at the front will
be equal to that at the rear, and tighten the center arm
to specification.

3. Rear Gate
A. REMOVAL
1) Disconnect the battery ground cable.
2) Remove trim panel. <Ref to 5-2 [W1B0]>
3) Remove cover, and disconnect the vinyl hose (1) in a
access hole.
4) Disconnect the rear wiper motor and rear defogger
connectors.
NOTE:
If rear gate is to be reused, tie string to connector end
and remove harness and related parts from top of rear
gate.
Leave string undetached in side rear gate for use as a
guide for harness,etc.
During reinstallation.
5) Extract the harness from the rear gate.
NOTE:
The following work steps must be done with great care
by at least two persons working together.

14
SERVICE PROCEDURE 5.2
3. Rear Gate

6) Remove gas stay bolts.


7) Remove roof trim until appear rear gate bolt.
8) Remove the rear gate bolt and rear gate.
CAUTION:
Be careful not to scratch to body when removing
rear gate.

NOTE:
Before discarding gas stay, place it at a slight angle
with the cylinder body side facing up and drill a 2 to 3
mm (0.08 to 0.12 in) dia. hole to completely discharge
the content. (Gas is odorless, colorless and harmless;
however, metal power may come out of the hole.)
It is good practice to place a vinyl cover over it before
drilling the hole because oil may spurt out. Be careful to
prevent vinyl cover from becoming entangled on the
drill.
B. INSTALLATION
1) Apply sealer to body and rear gate at mating sur-
faces of hinges.
2) Installation is in the reverse order of removal.

C. ADJUSTMENT
1. REAR GATE STRIKER
1) Loosen striker bolts.
2) For lateral adjustment align striker and latch at their
centers.

4. Windshield
A. REMOVAL
1) Lift up wiper arms.
2) Pry the lip of indoor weatherstrip at the top center
with a spatula (0 or the iike and push to outside of the
body flange.

15
5.2 SERVICE PROCEDURE
4. Windshield

3) Apply pressure evenly to the glass from indoors,


push the portion near the weatherstrip, and force the
glass out together with weatherstrip.
NOTE:
If the weatherstrip is not to be reused, cut the weather-
strip with a knife, and take out the glass.

B. INSTALLATION
1) Clean sealant from the glass and weatherstrip,
using white gasoline.
2) Fit the weatherstrip (1) onto the glass. Then, fit cord
(2) around the weatherstrip, and overlap the ends of the
ends of the cord at the bottom of the glass.
After the cord has been installed to the weatherstrip,
apply white gasoline to the entire periphery.
3) Place the glass correctly with respect to the window
frame of the body from outside the body and put the
cord inside the body.

4) Apply white gasoline to all around the lip of


weatherstrip.
5) Pull the ends of cord to right and left from the center
of the glass. Pull the cord ends at such angles that the
cord will get over the body flange, and strike the glass
with hands from outside (do not strike the molding
surface) to seat the weatherstrip in position with respect
to the body.

6) Press a spatula (1) or the like along the outside


periphery of weatherstrip to seat the weatherstrip on
the body and strike the entire glass with the palm of
hand or a rubber hammer from outside to set it on the
body.

16
SERVICE PROCEDURE 5.2
4. Windshield

5. Rear Window Glass


A. REMOVAL AND INSTALLATION
1) Disconnect the battery ground cable.
2) Remove the rear wiper arm.
3) Disconnect the rear defogger connector.
4) Remove and install the rear window glass (1) same
manner as in Wind shield.
5) Install the rear Wiper arm and connect the rear
defogger connector.

6. Rear Quarter Window Glass


A. REMOVAL AND INSTALLATION
1) Remove guard bar (1).
2) Remove and install rear quarter Window glass in
same manner as in wind shield.
3) Install guard bar.

17
5.3 SEATS, SEATBELTS, AND
INTERIOR

C COMPONENT PARTS............................................................................................................. 2
1. Front Seat........................................................................................................................... 2
2. Second Seat........................................................................................................................ 4
3. Third Seat............................................................................................................................ 5
4. Seat Belt.............................................................................................................................. 6
5. Inner Trim............................................................................................................................ 7
6. Inner Accessary and Floor Mat............................................................................................8
7. Roof Trim............................................................................................................................. 9
W SERVICE PROCEDURE.......................................................................................................10
1. Front Seat......................................................................................................................... 10
2. Second Seat...................................................................................................................... 10
3. Third Seat.......................................................................................................................... 10
4. Front Seat Belt................................................................................................................... 11
5. Second Seat Belt............................................................................................................... 12
6. Third Seat Belt................................................................................................................... 12
7. Roof Trim........................................................................................................................... 13
5.3 COMPONENT PARTS
1. Front Seat

1. Front Seat
1. SWIVEL TYPE

(1) Reclining knob (7) Headrest bushing (13) Outer rail LH (19) Slider C
(2) Cover (8) Slider B (14) Lower frame COMPL (20) Slider A
(3) Reclining hinge (9) Cover rear (15) Lock (21) Arm front edge
(4) Hinge cover (10) Base assembly (16) Lock plate (22) Cover front edge
(5) Backrest assembly (11) Plate B (17) Outer rail RH (23) Cushion front edge
(6) Headrest (12) Inner rail LH (18) inner rail RH (24) Cushion assembly

2
COMPONENT PARTS 5.3
1. Front Seat

2- FIXED TYPE

(1) Reclining knob (6) Headrest (11) Lock


(2) Cover (7) Headrest bushing (12) Lock plate
(3) Reclining hinqe (8) lnner rail LH (13) Outer rail RH
(4) Hinge cover (9) Outer rail LH (14) Inner rail RH
(5) Backrest assembly (10) Lower frame COMPL (15) Cushion assembly

3
5.3 COMPONENT PARTS
2. Second Seat

2. Second Seat

(1) Arm rest (7) Headrest bushing Torsion bar B (13) Link assembly
(2) Cover (8) Headrest (Q) Hinge cover upper LH (14) Lower cover
(3) Bracket (9) Board Reclining hinge LH (15) Lever knob
(4) Hinge cover upper RH (10) Shaft Hinge cover lower LH (16) Hinge cover lower RH
(5) Reclining hinge RH (11) Flat board Link base cover
(6) Backrest assembly (12) Hook plate Torsion bar A

4
COMPONENT PARTS 5.3
3. Third Seat

3. Third Seat

(1) Hinge Cover lower RH (6) Headrest TT (11) Striker


(2) Hinge Cover upper RH (7) Strap (12) Hinge
(3) Reclining hinge RH (8) Hinge cover upper LH (13) Mat
(4) Backrest assembly (9) Hinge cover lower LH (14) Cushion assembly
(5) Headrest bushing (10) Reclining hinge LH

5
5.3 COMPONENT PARTS
4. Seat Belt

4. Seat Belt
1. FRONT SEAT BELT

(1) Adjust anchor (4) Grommet sheet (7) Outer belt assembly
(2) Adjuster Cover (5) Inner belt assembly(LH)
(3) ELR Cover(Blind van) (6) Inner belt assembly(RH)

2. SECOND SEAT BELT

(1) Outer belt assembiy(RH) (4) Outer belt assembly(LH)


(2) Inner belt assembly(RH) (5) ELR cover
(3) Inner belt assembly(LH)

6
COMPONENT PARTS 5.3
4. Seat Belt

3. THIRD SEAT BELT

(1) Outlet belt assembly(RH) (4) ELR Cover(LH)


(2) ELR cover(RH) (5) Inner belt assembiy(LH)
(3) Outer beii assembly(LH) (6) Inner belt assembly(RH)

5. Inner Trim

(1) A pillar trirn (2) "Dpillar trim (7) Pocket


(2) "Bpillar upper trim (3) Rear quarter trim(SDX) (8) B pillar lower trim
(3) C pillar trirn (4) Rear quarter trim(Panel van)

7
5.3 COMPONENT PARTS
6. Inner Accessary and Floor Mat

6. Inner Accessary and Floor Mat

(1) Sun visor (5) Assist grip bracket (9) Deck edge (13) Cab ftoor mat
(2) Hook (6) Front assist grip (10) Rear shelf mat
(3) Rear view mirror (7) Cab floor edge (11) Deck mat
(4) Rear assist grip (8) Center floor edge (12) Center floor mat

8
COMPONENT PARTS 5.3
7. Roof Trim

7. Roof Trim

(1) Edge (5) Rear sunroof garnish


(2) Roof bow (6) Front sunroof garnish
(3) Roof trim sheet (7) Front roof trim
(4) Rear roof trim

9
5.3 SERVICE PROCEDURE
7. Roof Trim

1. Front Seat
A: REMOVAL
1) Turn over floor mat
2) Release front seat lock of driver side
3) Remove bolts and then securing remove front

CAUTION:
Be careful not to scratch car body when removih
front seat from the vehicle.
NOTE:
Do not touch the slide adjuster lever until the front seat
is completely reinstalled in the car body.

B: INSTALLATION
Installation is in the reverse order of removal.
2. Second Seat
A: REMOVAL
1) Fold the backrest onto the seat cushion.
2) Remove bolts and then securing remove second
seat.
CAUTION:
Be careful not to scratch car body when removing
from the vehicle.

B: INSTALLATION
Installation is in the reverse order of removal.

3. Third Seat
A: REMOVAL
1) Fold the backrest onto the seat cushion.
2) Remove bolts and then securing remove third seat.
CAUTION:
Be careful not to scratch car body when removing
third seat from the vehicle.

10
SERVICE PROCEDURE 5.3
3. Third Seat

B: INSTALLATION
Installation is in the reverse order of removal.

4. Front Seat Belt


A: REMOVAL
1. OUTER BELT
1) Remove cab floor edge (1).
2) Remove door look trim (2) and B-piNar trim lower (3).

3) Remove outer belt.

4) Remove the adjust anchor.

2.INNER BELT
1) Remove console box <Ref to 5-4[W2A0]>.
2) Turn over floor mat.
3) Remove bolt and remove inner belt of right side.
4) Remove grommet sheet and then remove bolt and
inner belt of left side.

11
5.3 SERVICE PROCEDURE
4. Front Seat Belt

B: INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Be careful not to twist belts during installation

5. Second Seat Belt


A: REMOVAL
1) Remove ELR cover.
2) Remove outer belt.

3) Remove inner belt.

B: INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Be careful not to twist belts during installation.

6. Third Seat Belt


A: REMOVAL
1) Remove ELR cover.
2) Remove outer belt.

12
SERVICE PROCEDURE 5.3
6. Third Seat Belt

3) Turn over rear shelf mat. d) Remove inner belt.

B: INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Be careful not to twist belts during installation.

7. Roof Trim
A: REMOVAL
1. WITH SUNROOF MODEL
1) Remove sunroof garnish, sunvisor, rearview
mirror,assist grip and roomlight.
2) Using ST remove clips(ST 92558CG00 PULLER and
then remove screws.
3) Detach roof trim.
CAUTION:
When removing clip,use great care to prevent
damaging the roof trim.

2. WITH OUT SUNROOF MODEL


1) Remove wind shield and weather strip of rear gate.
2) Remove rear view mirror,sunvisor and roomlight.
3) Remove roof trim from body.
4) Remove all roof bows from stoppers (D and then
remove roof trim.
5) Remove traces of two sided tape from body.

13
5.3 SERVICE PROCEDURE
7. Roof Trim

B: INSTALLATION
1. WITH SUNROOF MODEL
Installation is in the reverse order of removal.

2. WITHOUT SUNROOF MODEL


CAUTION:
Do not reuse old roof trim,
1) Be sure affix two sided tape to body flange and
side rail (f).
2) Warm roof trim by infrared rays light.
3) Attach each side end of roof bows to its respective
stopper hole in the side rail.
4) Turn roof bows to up and then attach roof insulator.
5) Pull one side of the roof trim sheet toward rear gate
and temporarily secure it.
6) Pull other side of the roof trim sheet toward
windshield and temporarily secure that side.
7) Removing wrinkle of roof trim sheet and then attach
roof trim sheet to side rail.
8) Catch claw of side rail to roof trim sheet.
9) Install trim rail.
10) Drill holes in roof trim and install interior parts.
CAUTION:
Carefully wiring harness when drilling holes in roof
trim.

14
5.4 INSTRUMENT PANEL

Page
C COMPONENT PARTS............................................................................................................. 2
1. Instrument Panel................................................................................................................. 2
2. Console Box........................................................................................................................ 3
W SERVICE PROCEDURE......................................................................................................... 4
1. instrument Panel................................................................................................................. 4
2. Console Box........................................................................................................................ 5
5.4 COMPONENT PARTS
1. Instrument Panel

1. Instrument Panel

(1) Instrument panel (7) Center reinforce (13) Radio BRKT (LH) (19) Radio cover
(2) Ventilator grill (Center) (8) Cover (14) Heater reinforce (20) Speaker grill (LH)
(3) Ventilator grill (RH) (9) Pocket (15) Ash tray (21) Meter visor
(4) Speaker grill (RH) (10) Striker (16) Lower cover (D) (22) Brake reservoir tank lid
(5) Lower cover (P) (11) Pocket cover (17) Lower cover (D) BRKT (23) Ventilation grill (LH)
(6) Lower cover (P) BRKT (12) Radio BRKT (RH) (18) Cigar lighter protector

2
COMPONENT PARTS 5.4
2. Console Box

2. Console Box

(1) Front lid (5) Cap


(2) Console box (6) Rear lid
(3) Console cover (7) Ash tray
(4) Rear heater switch

3
5.4 SERVICE PROCEDURE
2. Console Box

1. instrument Panel
A. REMOVAL
1) Disconnect ground cable from battery.
2) Remove lower covers.

3) Remove four bolts and lower steering column.

4) Remove brake reservoir tank lid and two screws.

5) Set Air inlet control lever (1), Air outlet control lever
(2), and Temperature control lever (3) to positions
according to diagram.
NOTE:
Do not move three levers from those positions until
completion of reinstallation of instrument panel.

6) Remove air inlet control cable.


NOTE:
Do not move levers until completion of reinstallation of
control cable.

4
SERVICE PROCEDURE 5.4
1. instrument Panel

7) Remove air outlet control cable and temperature


control cable .
NOTE:
Do not move Lever until completion of reinstallation ol
control cable.

8) Remove six bolts and then disconnect connectors


((1):18 poles/white, (2):7 poles/black)and the meter
cable.
CAUTION:
Be sure to hold socket section when disconnecting,
not harness.

B. INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Avoid jamming of any wire harness when installing
instrument panel.

2. Console Box
A. REMOVAL
1) Disconnect ground cable from battery.
2) Remove console box lid and then disconnect main
fuse box from console box front lid.

3) Remove shift boot and console cover.

5
5.4 SERVICE PROCEDURE
2. Console Box

4) Remove five screws


5) Remove console box and then disconnect conn
CAUTION:
Be sure to hold socket section when disconnects
not harness.

B. INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Avoid jamming of any wire harness when installing
console box.

6
6 ELECTRICAL SECTION

ENGINE ELECTRICAL SYSTEM 6.1

BODY ELECTRICAL SYSTEM 6.2


6.1 ENGINE ELECTRICAL SYSTEM
Page
S SPECIFICATIONS AND SERVICE DATA................................................................................2
1. Engine Electrical System.....................................................................................................2
W SERVICE PROCEDURE......................................................................................................... 2
1. Starter................................................................................................................................. 4
2. Alternator........................................................................................................................... 10
3. Distributor.......................................................................................................................... 16
4. Ignition Coil....................................................................................................................... 16
5. Spark Plug......................................................................................................................... 17
6.1 SPECIFICATION AND SERVICE DATA
1. Engine Electrical System

1. Engine Electrical System


A: SPECIFICATIONS

1. STARTER
Type Magnetic switch type
Model 128000-2530
Manufacturer NIPPON DENSO
Voltage and output 12 V-0.8 kW
Rotating direction Clockwise (when observed from pinion)
Number of pinion teeth 8
Hour rating 30 seconds
Non-load Voltage 11 V
characteristics Current 50 A or less
Rotating speed 5,000 rpm or more

2. ALTERNATOR
Type Rotating-field three-phase type with IC regulator
Model __ A1T06471
Manufacturer _ MITSUBISHI
Voltage and output 12 V-60 A
Polarity on ground side Negative
Rotating direction Clockwise (when observed from pulley side
Output current at 13.5 V, 20C (68F) 5,000 rpm - 57 A or more
Regulated voltage 14.2-14.8 V

3. DISTRIBUTOR
Model 229100 - 9620
Manufacturer NIPPON DENSO
Firing order 1-3-2
Rotating direction Counterclockwise (when observed from cover side)
Air gap 0.2 mm (0.008 in)

2
SPECIFICATION AND SERVICE DATA 6.1
1. Engine Electrical System

4. IGNITION COIL
Model F-740
Manufacturer DIAMOND
Primary coil resistance 1.35-1.65
Secondary coil resistance 22.1 -29.9 k

5. SPARK PLUG
Manufacturer NGK: BPR6ES-11
Spark plug gap 1 -0 - 1.1 mm (0,039 0.043 in)

3
6.1 SERVICE PROCEDURE
1. Engine Electrical System

1. Starter
A: REMOVAL AND INSTALLATION
1) Remove battery from the vehicle.
2) Disconnect connector and terminals from sta
3) Remove bolts which install starter on transm^
case, and remove starter. Ssin

4) Installation is in the reverse order of removal.


Tightening torque:
41.2 - 47.0 N m (4.2 - 4.8 kg-m, 30 - 35 ft-lb)

B: PERFORMANCE TEST
CAUTION:
If starter does not rotate smoothly, the starter is
required a performance test before disassembly.
To prevent the coil from burning, a performance
test must be completed within 5 seconds.

1. NO-LOAD TEST
1) With starter clamped on test bench, set up system as
shown in figure.
2) Close switch and check that starter rotates smoothly
and freely at the specified current and voltage.

B: Battery terminal
M: Motor terminal
S : Magnetic switch terminal

Specified current and voltage:


50 A or less/11 V

4
SERVICE PROCEDURE 6.1
1. Starter

C: DISASSEMBLY
1) Disconnect the lead wire from the magnet switch.

2) Remove the magnet switch mounting nut.

3) Remove the magnet switch.

4) Remove the rear end cover. Remove the two screws


from the rear end cover.

5) Remove the lock plate, brake spring and rubber seal.

5
6.1 SERVICE PROCEDURE
1. Starter

6) Remove the through-bolts '

7) Remove the rear end frame

8) Remove each brush while lifting up its brush spring


with a long nose radio pliers.
CAUTION:
Use care not to damage the brushes and commuta-
tor.

9) Remove the yoke.

10) Remove the drive lever and armature.

6
SERVICE PROCEDURE 6.1
1. Starter

11) Pit the pipe as shown in the illustration over the


armature shaft, and press down the stop collar.

12) Remove the snap ring and remove the stop collar
and clutch.

D: INSPECTION AND REPAIR


1. ARMATURE
CAUTION:
Before performing the test, thoroughly remove
carbon powder, etc. from around the commutator.
1) Layer test
Check armature coil for short circuit between layers by
using growler tester.

CAUTION:
If any short-circuit exists in armature coil,
circulating current is generated by alternating flux
of growler tester, and the affected portion of the
armature core is magnetized.
If an iron piece is brought close to that portion, it
will vibrate, locating the short-circuit.

2) Insulation test
Check insulation between commutator and armature
core using 500 V megger.
Insulation resistance should be 0.1 M or larger.

7
6.1 SERVICE PROCEDURE
1. Starter

2. MAGNETIC SWITCH
CAUTION:
Ensure that lead wire is disconnected from terminal
M of magnetic switch before beginning tests.
1) Checking pull-in coil
Connect one test lead between ground terminal of
battery and terminal M of magnetic switch and the other
between positive terminal and terminal S.
Check that plunger is forcefully pulled in when at least 8
volts, dc. is applied across terminals M and S. If not,
replace magnetic switch.

2) Checking hold-in coil


Using test setup in step 1), disconnect test lead from
terminal M and connect to starter body to ensure that
plunger is held in. If plunger is not, replace magnetic
switch.

3. YOKE
Testing field coil for open circuit
Check field coil for continuity using circuit tester.
Continuity should exist.

4. BRUSH
1) Checking carbon brush
If carbon brush length has been reduced by more than
1/3 the original length, or if brush contact area has
been reduced largely due to brush breakage, replace
carbon brush.
Brush length:
Standard : 16mm (0.63 in)
Limit : 10.5 mm (0.41 in)

8
SERVICE PROCEDURE 6.1
1. Starter

2) Brush replacement
(1) Using a nipper, cut off brush lead wire.

(2) File away traces of lead soldering wire,


CAUTION:
Be careful not to scratch field coil because of limited
space.

(3) Place a new brush plate onto portion where


solder residue was removed. Secure contact by
pressing with pliers.
CAUTION:
Align new brush with the side on which lead wire
was cut off.

(4) Solder pressed portion of brush.


CAUTION:
Pre-heat pressed portion and solder quickly. Do
not allow solder to flow into brush lead wire.
Ensure that enough solder is deposited at edges
of brush plate.

5. CLUTCH
Check that pinion can be rotated in normal direction
only.
Check pinion gear for wear, damage, rusting, or binding
during rotation.

9
6.1 SERVICE PROCEDURE
1. Starter

6. BEARING
Check bearing portions of gear case and rear cover for
excessive play or damage.

E: ASSEMBLY
1) Assembly is in the reverse order of disassembly.
CAUTION:
When installing through bolts, be careful not to
cause a short by contacting brush,
Check for proper operation as required while
assembling parts.
Apply grease and engine oil, refer to "COMPO-
NENT PARTS".

2) After assembling, check pinion gap.


Connect battery (+) terminal to terminal S and (-) to
terminal M.
Then, with switch turned ON, measure pinion traveling
dimension "L" in thrust direction.
Pinion gap L:
Standard: 0.1 - 0.4 mm (0.004 - 0.016 in)

CAUTION:
When taking measurement, push pinion lightly in
the direction of arrow.
If dimension L" is out of specification, insert or
remove dust cover to obtain correct dimension.

2. Alternator
A: REMOVAL AND INSTALLATION
1) Disconnect connector and terminal from alternator.
2) Remove bolts which install alternator to bracket.
3) Remove V-belt and alternator.

10
SERVICE PROCEDURE 6.1
2. Alternator

4) Installation is in the reverse order of removal.


Tightening torque:
T1:3.4 - 5.0 Nm (0.35 - 0.5 kg-m, 2.5 -3.6 ft-lb)
T2:17.2 - 20.0 N m (1.75 2.0 kg-m, 12.7- 14.0
ft-l lb)
CAUTION:
After installing alternator and V-belt, check and
adjust V-belt tension. <Ref. to 1-5 [0100]>

B: DISASSEMBLY
1) Remove pulley from alternator by using ST.
ST 499985900 SOCKET WRENCH

2) Remove bolts which install front cover

3) Remove rotor.

4) Remove wires of stator coil from diode plate by using


soldering iron.

11
6.1 SERVICE PROCEDURE
2. Alternator

5) Remove nut of battery terminal.


6) Remove bolts which install diode plate assembly 0r
rear cover, and remove it. 1

7) Remove bearing from rotor by using puller.

8) Remove bearing retainer from front cover.

9) Remove bearing from front cover by using a press


and a rod.

C. INSPECTION
1.ROTOR
1) Slip ring surface
Inspect slip rings for contamination or any roughness of
the sliding surface.
Clean or polish with #500 to #600 emery paper if
defective.

12
SERVICE PROCEDURE 6.1
2. Alternator

2) Slip ring outside diameter


Measure slip ring outside diameter. If slip ring is worn
replace rotor assembly.

3) Check resistance between slip rings.


Specified resistance: Approx. 2.9

4) Check insulation resistance between slip ring and


core plate.
NOTE:
Use the 500 V megger tester.
Specified resistance: 0.1 k. or more

2. DIODE
Check that diode has a continuity only in one direction
by using "k" range of circuit tester.
CAUTION:
Do not use the 500 V megger tester.

3. BRUSH
Measure brush length protruding from brush holder.
Brush length: L
Standard: 21.5 mm (0.846 in)
Limit: 8 mm (0.315 in)
Lower length: L'
13.5 mm (0.531 in)
CAUTION:
If brush is worn, replace brush holder assembly.

13
6.1 SERVICE PROCEDURE
2. Alternator

D. INSTALLAT ON
1) Install bearing to rotor by using a press and a pipe

2) Install bearing to front cover by using a press and a


rod.

3) Install bearing retainer onto front cover.

4) Push up brush and hold with the pin.

5) Install diode plate assembly on rear cover.

14
SERVICE PROCEDURE 6.1
2. Alternator

6) Install stator coil to front cover.


NOTE:
Pay attention to location of wires connecting diode plate
to matching through bolt holes during installation of
alternator component in engine.
7) Install diode plate assembly to stator coil, and solder
wires of stator coil at connecting portion.

8) Install rotator.

9) Install front cover.

10) Remove the pin which holding brush.

11) Install pulley by using ST.


ST 499985900 SOCKET WRENCH
Tightening torque:
78 - 137 N m (8.0 - 14 kg-m, 58 - 101 ft-lb)

15
6.1 SERVICE PROCEDURE
2. Alternator

3. Distributor
A: REMOVAL AND INSTALLATION
1) Disconnect distributor connector.
2) Disconnect high tension cord and spark plug cords.
3) Remove bolts which install distributor onto cylinder
head.

4) Installation is in the reverse order of removal.


Tightening torque:
14.2 - 17.2 Nm (1.45 - 1.75 kg-m, 10.5- 12.7ft-lb)
5) After installing distributor, check and adjust ignition
timing.
<Ref. to 2-2 [0200]>

B: INSPECTION
Check and adjust the air gap between pick-up coil and
pick-up cams.
Air gap: W
0.2 mm (0.008 in)

4. Ignition Coil
A: REMOVAL AND INSTALLATION
1) Disconnect connectors and high tension cord.
2) Remove ignition coil from body with bracket.
3) Installation is in the reverse order of removal.

B: INSPECTION
1) Continuity of primary coil.
Measure resistance between the battery (+) terminal
and the distributor (-) terminal.
Specified resistance: 1.35 - 1.65

16
SERVICE PROCEDURE 6.1
4. Ignition Coil

2) Continuity of secondary coil


Measure resistance between the battery (+) terminal
and the secondary terminal.
Specified resistance: 22.1 -29.9 k
NOTE:
If the measured resistance value is too small, a short
circuit is indicated.

3) Insulation between primary terminal and case.


Measure resistance between the battery (+) terminal
and the body of ignition coil.
Specified resistance:

5. Spark Plug
A: REMOVAL AND INSTALLATION
1) Remove spark plug cords and dust cover.
2) Remove spark plugs.

3) When installing spark plugs on cylinder head use


spark plug wrench.
Tightening torque:
18 - 24 N m (1.8 - 2.4 kg-m, 13-17 ft-lb)
CAUTION:
The above torque should be only applied to new
spark plugs without oil on their threads.
In case their threads are lubricated, the torque
should be reduced by approximately 1/3 of
specified torque in order to avoid their over-
stressing.

4) Install dust cover and connect spark plug cords.

17
6.1 SERVICE PROCEDURE
5. Spark Plug

B: INSPECTION
1) Normal
Brown to grayish-tan deposits and slight electrode wear
indicate correct spark plug heat range.

2) Carbon fouled
Dry fluffy carbon deposits on insulator and electrode
are mostly caused by slow speed driving in city, weak
ignition, too rich fuel mixture, dirty air cleaner, etc.
It is advisable to replace with plugs having hotter heat
range.

3) Oil fouled
Wet black deposits show excessive oil entrance into
combustion chamber through worn rings and pistons or
excessive clearance between valve guides and stems.
If same condition remains after repair, use a hotter
plug.

4) Overheating
While or light gray insulator with black or gray brown
spots and bluish burnt electrodes indicate engine
overheating. Moreover, the appearance results from
incorrect ignition timing, loose spark plugs, wrong
selection of fuel, hotter range plug, etc. It is advisable to
replace with plugs having colder heat range.

5) Spark plug gap


After cleaning spark plugs, recondition firing surface of
electrodes with file. Then correct the spark plug gap
using a gap gauge.
Spark plug gap: L
1.0 -1.1 mm (0.039 - 0.043 in)

18
6.2 BODY ELECTRICAL SYSTEM
Page
W SERVICE PROCEDURE......................................................................................................... 2
1. Battery................................................................................................................................. 2
2. Fuse.................................................................................................................................... 5
3. Combination Meter..............................................................................................................6
4. Combination Switch.............................................................................................................6
5. Headlight............................................................................................................................. 7
6. Front Wiper......................................................................................................................... 8
7. Washer................................................................................................................................ 9
8. Rear Wiper........................................................................................................................ 10
9. Rear Window Defogger.....................................................................................................10
6.26.2 SERVICE PROCEDURE
BODY ELECTRICAL SYSTEM

1. Battery
A: PRECAUTION IN HANDLING
1) To prevent a short, first connect the plus-terminal
When making cable connections, and disconnect the
minus-terminal cable first when disconnecting.
2) When charging the battery, use a current input of
about one tenth the battery capacity.
3) Adjust the charging current so that the temperature
of the electrolyte will not rise over 45C (113F) during
charging.
4) During quick charging, the charging current should
be less than a rate expressed in a battery capacity of 5-
hour rate (5 HR).
5) When quick charging the battery while mounted on
the vehicle, be sure to disconnect the plus and minus
cables from the battery terminals to protect the
alternator diode.

B: INSPECTION
1) External parts
Check for the existence of dirt or cracks on the battery
case, top cover, vent plugs, and terminal posts. If
necessary, clean With water and wipe with a dry cloth.
Apply a thin coat of grease on the terminal posts to
prevent corrosion.
2) Electrolyte level
Check the electrolyte level in each cell. If the level is
below MIN LEVEL, bring the level to MAX LEVEL by
pouring distilled water into the battery cell. Do not
beyond MAX LEVEL.

WARNING:
Electrolyte has toxicity: be careful handling the
fluid.
Avoid contact with skin, eyes or clothing.
Especially at contact with eyes, blush with water for
15 minutes and get prompt medical attention.
Battery generates explosive gas. Keep spark,
flame, cigarette away.
ventilate when charging or using In enclosec
space.

2
SERVICE PROCEDURE 6.2
1. Battery

3) Specific gravity
Serviceable specific gravity:
1.220 - 1.280 at 20C (68F)
The specific gravity of electrolyte can be measured with
a hydrometer. Holding the glass tube vertically, slowly
draw the liquid into the tube. Take the reading on the
float scale at the highest point of the liquid.
When reading, the eye should be level with the surface
of the liquid.
If the specific gravity reading is below L220 at 20 TJ
(68F), the battery must be recharged and, if necessary,
the specific gravity of the electrolyte must be adjusted.
I fie specific gravity changes according to temperature.
The standard temperature is considered to be 20C
(68F).
When measuring the specific gravity, calculate as
follows:

S = St + 0.007 (t 20)

S = Specific gravity corrected for 20C (68F)


St = Measured specific gravity at tC
t = Electrolyte temperature on centigrade scale (C)
0.0007 = Temperature coefficient
EXAMPLE:
A hydrometer reading of 1.273 at 30C (86F) is cor-
rected to 1.280 at 20C (68F), indicating that the
battery is fully charged. On the other hand, a reading of
1.251 at 10C (14F) is corrected to 1.230 at 20C
(68F), indicating that the battery is partially charged.

C: CHARGING
Measuring the specific gravity of the electrolyte in the
battery will disclose the state of charge of the battery.
The relation between the specific gravity and the state
of charge is as shown in figure.

3
6.2 SERVICE PROCEDURE
1. Battery

1. NORMAL CHARGING (
If the specific gravity is below 1.220 at 20C (68R
normal charging must be made as soon as possible
Connect a charger to the battery as shown in the figure
and send a contact current of 6A until the voltage and
specific gravity reach the values for complete charge
Usually the charging is considered to be completed if
there is no further rise in specific gravity measured
every 30 minutes successively.
CAUTION:
Remove all the vent plugs since electrolyte
generates gas toward the end of charging.
Do not bring an open flame close to the battery at
this time.
Prior to charging, corroded terminals should be
cleaned with a brush and common baking soda
solution.

2. QUICK CHARGING
Quick charging is a method in Which the battery is
charged in a short period of time with a relatively large
current by using a quick charger.
Since a large current flow raises electrolyte
temperature, the battery is subject to damage if the
large current is used for prolonged time. For this
reason, the quick charging must be carried out within a
current range that Will not increase the electrolyte
temperature above 45C (113F).
It should be also remembered that the quick charging is
a temporary means to bring battery voltage up to a fair
value and, as a rule, a battery should be charged slowly
With a low current.
CAUTION:
Observe the items in NOTE in 1) Normal charging-
The battery should not be charged with 10A or
more.

4
SERVICE PROCEDURE 6.2
2. Fuse

2. Fuse
1. FUSE BOX
The fuse box is located underneath of the instrument
panel driver side.
The connection between each fuse and main electrical
units/devices is as shown in the "Wiring Diagram".
CAUTION:
When replacing fuse, be sure to use fuse of
specified rating.
If fuse is blown, be sure to eliminate cause before
installing new fuse in position.
Poor contact of any fuse holder will often lead to
voltage drop or heating in the circuit or fuse holder
and could result in blown fuse, so be careful with
holder contact, and clean metal parts if necessary.

2. MAIN FUSE BOX


The main fuse is located in the console box and all
current except for starter motor will flow through in this
main fuse. If current increases beyond specified
amperage, fusible metal melts and the circuit is broken,
thus protecting cable and electrical equipment from
burning.
CAUTION:
When replacing main fuse, be sure to use specified
rating one.
Blown main fuse is caused by short circuit in the
source of electricity circuit or large amperage
circuit, so certain check of cause and/or repair is
necessary.

Designation
Item
30A 40A 60A
100 mV or less 100 mV or less 100 mV or less
Voltage Voltage drop across terminals Voltage drop across terminals
Voltage drop across terminals
drop should be less than the above should be less than the above
should be less than the above value
value when a 15 A current value when a 20 A current
when a 30 A current flows.
flows. flows.
Melting Fusible metal should melt Fusible metal should melt Fusible metal should melt Within 15
charac- within 15 seconds at a current within 15 seconds at a current seconds at a current flow of 180
teristics flow of 90 amperes. flow of 120 amperes. amperes.
Case
Pink Green Yellow
Color

5
6.2 SERVICE PROCEDURE
2. Fuse

3. Combination Meter
A: REMOVAL AND INSTALLATION
1) Remove the steering wheel.
2) Remove the visor by taking off the tapping screws

3) Remove the tapping screws, separate the


speedometer cable and electrical connectors from the
back of the combination meter.
4) Take out the combination meter.
Installation should be made in the reverse order of
removal. Be careful of the following items.
Insert the electrical connector and speedometer cable
correctly.
Install the visor and instrument panel in such a way
that a uniform gap exists between them.
After the installation is completed, check for the
operation of the gauges and indicators.

4. Combination Switch
1) Remove the steering wheel.
2) Remove the column cover.

3) Disconnect combination switch connect from body


harness.
4) Remove combination switch from steering shaft by
taking out screws.
Installation should be made in the reverse order of
removal paying attention to the following points.
Make sure that harness is not caught between column
covers.
Harness connector must be correctly connected.
Check for proper operation.

6
SERVICE PROCEDURE 6.2
4. Combination Switch

5. Headlight
1. Light Bulb Replacement
1) Remove the protector.
2) Disconnect the connector.
3) Remove boots.
4) Remove the light bulb retaining spring to remove the
bulb.
5) Replace the bulb with a new one and hook the
spring.
Install in the reverse order of removal.
CAUTION:
Since the tungsten halogen bulb operates at high
temperature, dirt and oil on the bulb surface
decreases the bulb's useful life. When replacing the
bulb, hold the flange portion and do not touch the
glass portion.

Attach the rubber cover with letters TOP on the


top so that the drain hole will be on the lower side.
To keep water out, correctly engage the groove
portion of the rubber cover.

A: REMOVAL AND INSTALLATION


1) Remove the protector.
2) Disconnect headlight connector.
3) Remove the front combination light.
4) Remove bolts which ecure headlight, and remove
headlight.
Install in the reverse order of removal.

B: ADJUSTMENT
1) Adjust by turning the adjustment screw with a
screwdriver.

7
6.2 SERVICE PROCEDURE
5. Headlight

6. Front Wiper
A: REMOVAL AND INSTALLATION
1. BLADE
1) Pull out blade from arm while pushing up clip

2. ARM
1) Remove the arm cover.
2) Remove the arm by loosening the fitting nut.

3. WIPER MOTOR AND LINK


1) Remove the glove box and intake shutter box.

2) Remove wiper motor mounting bolt.

3) Separate wiper link from ball joint.


CAUTION:
Be careful not to snap the locking pin of the joint by
forcibly removing the wiper link.

8
SERVICE PROCEDURE 6.2
6. Front Wiper

4) Disconnect wiper motor connector and take out wiper


motor.

Install in the reverse order of removal.

B: ADJUSTMENT
1) Adjust blade in original position as shown in figure.
Original position: A
25 5 mm (0.98 0.20 in)

7. Washer
A: ADJUSTMENT
1) Adjust washer ejecting point on windshield glass as
shown in figure.
Ejecting point:
A 150 mm (5.91 in)
B 300 mm (11.8 in)
C 275 mm (10.8 in)
D 200 mm (7.87 in)
E 175 mm (6.89 in)

9
6.2 SERVICE PROCEDURE
7. Washer

8. Rear Wiper
A: REMOVAL AND INSTALLATION
1) Pull out the blade from the arm while pressing down
on the clip.
2) Remove the arm cover.
3) Loosen the arm fitting nut and remove the arm.
4) Remove the cap, nut and cushion.
5) Remove the rear gate trim from inside of the pas-
senger compartments
6) Disconnect the electrical connector, loosen the fitting
bolts, and take out the motor.
Install in reverse order of removal.

B: ADJUSTMENT
1) Adjust blade in original position as shown in figure.
Original position A:
A 15-20 mm (0.59 - 0.79 in)

9. Rear Window Defogger


A: INSPECTION
1) Start engine, and turn rear defogger switch on.
2) Check each heat wire at its center position for dis-
continuity by setting direct-current voltmeter.
3) If meter indicates 12 volts or 0 on specific wire that
line is broken. Normal indication is about 6 volts.
4) For rinding out broken position in the line, move
positive lead of voltmeter along the line until abrupt
variation in the meter indication is encountered.

10
SERVICE PROCEDURE 6.2
9. Rear Window Defogger

B: REPAIR
1) Clean broken wire and its surrounding area.
2) Cut off slit on thin film by 0.5 mm (0.020 in) width
area 10 mm (0.39 in) length.
3) Place the slit on glass along the broken wire, and
deposit conductive silver composition (DUPONT No.
4817) on the broken portion.

11