G100-G102-Chassis-Manual #2

AUTOMATIC TRANSMISSION
15. Installation of the 2nd brake piston

( 1 ) Install the "0" ring and washer to the piston rod.
NOTE:
Prior to the installation, apply grease to the "0" ring.
(2) Insert the spring and rod to the piston. Secure it with @@-
the "En ring. 9
NOTE:
Prior to the installation, apply the automatic fluid to the
inserting section of the rod.
Fig. 4-159 WR-04202A
(3) Install the two "0" rings to the piston.
NOTE 1:
Be careful not to damage the " 0 " rings.
NOTE 2:
Do not expand the " 0 " rings excessively.
NOTE 1:
Apply the automatic fluid to the inserting section of the
piston rod.
NOTE 2:
Care must be exercised to ensure that the "0" rir
not be damaged or pinched.
NOTE 3:
&?$g
Fig. 4-160
La b\
/
WR-04203
Make sure that the forward end of the rod is aligned with
the metal fitting of the brake band.
(5) Install two "0"rings to the piston cover.
NOTE:
Prior to the installation, apply the automatic fluid to the "0"
I
rings.
(6) Insert the piston cover into the transmission case.

NOTE:
Care must be exercised to ensure that the " 0 " ring may
I I
Fig. 4-161 WR-04204
--
(7) With the piston cover pushed to the inside, attach the
snap ring in position.
(8) Through the side cover hole, check to see if the 0
forward end of the rod is in contact with the metal
fitting of the brake band at its specified position.
0 /
Fig. 4-162 WR-04205

(9) Perform the 2nd brake piston stroke check in the same
way as with the disassembly. WR-04206
(10) Install the transmission case side cover and its gasket.
Tighten them by means of the four bolts.
Tightening Torque: 0.7 - 0.9 kg-m (5.5 - 6.5 ft-lb)
16. Installation of the neutral start switch and the manual valve
outer lever.
(1) Install the neutral start switch.
@Set the manual shaft to the "N" position.
@Insert the switch into the control shaft.
@Temporarily secure the switch bolt (nominal length:
35 mm).
@Align the scribe lines on the control rod and switch
with each other.
@Securely tighten the bolt which has been secured
temporarily in the step @ above.
Tightening Torque: 1.6 - 2.3 kg-m (12 - 17 ft-lb)
@Ensure that the switch is functioning properly
(2) Pass the upper washer and then the shift lever through
the manual shift shaft which protrudes above the
transmission upper section. Then, secure them by
means of double nuts.
NOTE:
The following shows the tightening sequence of double
nuts.
OTighten the lower nut.
Tightening Torque: 0.9 - 1.7 kg-m (6.5 - 12 ft-lb)
@Tighten the upper nut.
@With the upper nut locked, tighten the lower nut in the
reverse direction.
-
Tightening Torque: 0.9 - 1.7 kg-m (6.5 12 ft-lb)
(3) Check to see if the shaft rotates smoothly.

17. Installation of the accumulator piston

(1) Install the "0"ring on the piston.
NOTE:
Prior to the installation, apply the automatic fluid to the
piston and "0" ring.
(2) Insert the spring into the piston.

(3) Insert the piston into the transmission case.
NOTE 1:
Number of Spring length Spring outer diameter
"0" ring mm (inch) mm (inch)
52 10.0
B1 2 (2.05) (0.394)
64.1 15.0
c1 1 (2.52) (0.591)
NOTE 2:
Care must be exercised to ensure that the "0" ring may -.
18. Installation of the valve body assembly
(1) Place the valve body assembly on the transmission
case.
(2) Install the pin of the manual lever in the manual valve.
(3) Temporarily tighten the two bolts indicated in the
figure.
Fig. 4-167 wR-04209
(4) Install the throttle cable to the throttle cam.

NOTE:
Do not pull the cable more than 40 mm (1.57 inches). I Throttle \I I
Fig. 4-168
(5) Tighten all bolts.
(6) Install the oil tubes.

NOTE 1:
First insert the oil tube's end having no stopper (1 in the
right figure) about 2 mm (0.079 inch). Then, insert the end
having a stopper (2 in the right figure).
NOTE 2:
To prevent the tube from being deformed, lightly tap the
tube using a plastic hammer.
NOTE3: Fig. 4-170 WR-04212

Positively insert the tube, until the stopper of the tube
comes into contact with the case.
NOTE 4:
Install the tubes in parallel with the valve body.
(7) Connect the solenoid connector.

NOTE:
The wire harness differs in length to prevent wrong I
No.% -
Direct clutch
solenoid (black)
2nd brake
solenoid (white) I
connections. Therefore, do not pull it forcibly.
I I
Fia. 4-171 WR-04213
(8) lnstall the oil strainer. At the same time, clamp the two
solenoid connectors. Tighten them all together.
1 I
Fig. 4-172 WR-04214
4-67
19. Installation of the oil pan

(1) Set the gasket on the transmission case.
NOTE:
Make sure that the bolt holes of the gasket are aligned with
those in the transmission case.
(2) Place the magnet on the oil pan. Oil pan Magnet
NOTE:
It is advisable to place the magnet at the position indicated \ /
in the figure.
I I
Fig. 4-173 WR-04215
(3) Tighten the oil pan by means of the bolts (13 pieces)
and screws (two pieces). Cross recessed
NOTE 1:
Apply the sealant to the two screws indicated in the figure.
NOTE 2:
Make sure that the tube and oil pan do not interfere with
each other.
g. 4-174 WR-04216
(4) Tighten the drain plug.
WR-04217
Installation of the oil filler tube

(1) Install the "0" ring to the oil filler tube. Insert the oil
fjiler tube into the transmipi~qcase.
NO?E 1:
Apply the automatic fluid to the " 0 " ring.
NOTE 2:
Insert the oil filler tube up to the flange position.
(2) Secure the oil filler tube by means of the bolt.

21. lnstallation of the test plug at the detecting hole

(1) Install the "0" ring and tighten the plug.
NOTE:
Apply the automatic fluid to the "0" ring.
L I
Fig. 4-176 WR-04220
4-68
?3. Installation of the torque converter Torque

(1) Install the torque converter. Check to see if the converter
attaching dimension indicated in the right figure com-
plies with the specification.
NOTE 1:
Be careful not to damage the oil seal.
Flange nut
NOTE 2:
Make sure that the torque converter rotates lightly. Transaxle case A: More than
housing 27.2 mm (1.07 in)
NOTE 3: Fig. 4-177 WR-04221
Apply grease to the point indicated in the figure.
APPENDIX
S H l n LEVER CONSTRUCTION
r I
@ Indicator lamp
@ Shift lever knob
r3 @ Position indicator housing
@ Shift & rod
Detent lever assembly
I
Fig. 4-1 78 WR-04222
Control cable components
I
Fig. 4-181 WR-04223A
4-71
ASSEMBLING POSITION AND DIRECTION OF THRUST BEARING
Inner Outer I
POSI- Thick- 1 Remarks
Part diameter diameter Flange ness I
tion mm (~nch) mrn (inch)
A
a Race
@ Bearing
22.15 (0.872)
24 (0.94)
37.5 (1.47)
37.5 (1.47)
lnner diameter flange
-
@ Race 24 (0.94) 37.5 (1.47) Inner diameter flange
@ Bearing 30 (1.18) 45 (1.77) -

@ Race 28 (1 .I
0) 45 (1.77) Inner diameter flange
c
8 HEHng
@ Race
19 (0.75)
2 2 3 (088)
22 (0.87)
23 (0.91)
35 (1.38)
36 (1.42)
37.9 (1.49)
35.8 (1.41)
Inner diameter flange
-
Outer diameter flange
Outer diameter flange
D . @ Bearing 22.3 (0.88) 36 (1.42) - Shared ~ncommon with C @
@ Race 22 (0.87) 37.9 (1.49) Outer diameter flange Shared ~ncommon with C @
I
@ Race 27.1 (1.07) 42 (1.65) lnner diameter flange

@ Bearing 30 (1.18) 42 (1.65) -
@ Race 30.5 (1.20) 43 (1.69) Not provided 0.8 Option
@ Race 30.5 (1.20) 43 (1.69) Not provided 1.4 : Option
I Fig. 4-182
i
WR-04224
4-72
LIST OF SPRINGS
Free length
lnstalling position Color Coil
diameter
outer
(Refgsce) mm (inch)
mm (inch)
Primary regulator valve Red 10 (0.39)
P
- Orifice control valve Yellowlgreen 8.5 (0.33)
9 Throttle valve White 9.2 (0.36)
T
a,
g I Throttle valve (Gasoline turbo,
diesel turbo )
Purple
Light blue
lnner diameter 6.0 (0.24)
lnner diameter 6.0 (0.24)
I
2
Throttle valve cam - lnner diameter 14 (0.55)

Yellow 7.4 (0.29)
-a
- Secondary regulator valve (Same as above) Brown 7.4 (0.29)
> 2 - 3 shift valve Pink 10.5 (0.413)
1 - 2 shift valve Pink 10.5 (0.413)
g
-I
B2 control valve Blue 7.9 (0.31)
Cooler bypass Orange 11.O (0.433)
- -
B1 accumulator -
5 C1 accumulator -
2 lnner -
%
Outer -
m' - --
6 For forward clutch (18 pieces) -

' Shaft parking pawl
1 -
-
1 lnner diameter
10.25 (0.4035)
(NOTE)
1. Figures in ( ) in the column of "Coil outer diameter" represent the inner diameter.
2. Figures in ( ) in the column of "lnstalling point" represent the number of the part.
3. This list does not post those springs which are incorporated in assemblies.
LIST OF "0"RINGS
lnner diameter lnner diameter
Installing point lnstalling point mm (inch)
mm (inch)
Oil pump body 200 (7.87) B2 brake 135 (5.31)
Direct clutch drum, inner 75.9 (3.00) B1 servo rod 8.8 (0.35)
C2piston, outer 117 (4.61) C1, B1 accumulators 23.47 (0.9240)

Bl servo cover 59.6 (2.35) Bl accumulator 15.4 (0.606)
C1 piston, inner 46.52 (1.831) Filler tube 9.6 (0.38)
C1 piston, outer 117 (4.61) Speedometer 19.7 (0.776)

B2 brake 94.1 (3.70)
Cl: Forward clutch
CP: Direct clutch
B1: 2nd brake
B2: 1st & reverse brake
LIST OF BOLTS USED (I)
1 /1Num- Stand- Tightening Nominal

Installing point ard torque
kg-m (ft-ib)
Housing x case 1 1 M8 1 1.6-2.3 (12- 16) / 35 B, WNV

Rear cover x case
Rear cover x case 2 M8 0.5 (3.6) 9/16 B, S
Rear cover x case 2 M8 1.1-1.5(8.0-10) - N
Rear cover x case
Oil pump assembly x case 5 M8 1.8 - 2.7 (14 - 19) 28 B, F
Stater shaft x Oil pump body 11 M6 0.8 - 1.2 (6.0 - 8.5) 1 17 B, WNV
Case side cover x case
Counter shaft x counter driver gear 1 M22 11-15(80-108) - 1 N
Differential gear x differential ring gear 10 M I0 8.0 - 1.0 (58 - 72) - I B,F
Manual shift shaft x Manual valve outer lever
--
1 2 I M8 1 0.9 - 1 7 (6.5 - 12) I - 1 N
Detent x case 1 M6 0.8 - 1.2 (6.0 - 8.5) 16.5 B, WNV
-
Detent x case 1 M6 0.2 (1.4) '78 B, S
Detent x case
- - - - - - - - -
Detent x case 1 66 - - W
Valve body assembly x case 7 M6 0.8 - 1.2 (6.0 - 8.5) 36 B, F
Valve body assembly x case
Upper valve body x lower valve body 6 M5 0.5 - 0.6 (3.6 - 4.3) 29.5 8, F
Upper valve body x lower valve body 6 M5 0.5 - 0.6 (3.6 - 4.3) 38 8, F
Upper valve body x lower valve body
Upper valve body x lower valve body 2 M5 0.5 - 0.6 (3.6 - 4.3) 29.5 8, F
---
Lower cover x lower valve body 6 M5 0.5 - 0.6 (3.6 - 4.3) B, F
Strainer x lower valve body
- - - - - - -
Solenoid x lower valve body 2 M6 0.64 - 0.96 (4.6 - 6.9) 10 B, WNV

Throttle cam x lower valve body 1 M6 0.6 - 0.9 (4.3 - 6.5) 28 B, F
Oil pan x case 13 M6 0.4 - 0.6 (3.0 - 4.3) 16 B, WNV
Drain plug x oil pan 1 MI0 1.8-2.3(13-17) 8.3 P
Wire-to-solenoid x case
Wire-to-solenoid x case 1 M6 0.5 - 0.6 (3.6 - 4.3) - N
Wire-to-solenoid x case 1 66 - - W
LIST OF BOLTS USED (11)
Installing point
Speedometer x housing
1 1 Nurn- Stand-
ard
Tightening
torque
kg-m(ft-lb)
Nominal
--
Filler tube x case 1 M8 0.3 - 0.7 (2.4 - 5.6) 20 B, WNV

Test plug x case 1 2,5~& 0.6 - 0.9 (4.3 - 6.5) 9.5 P
* Oil pan x case 2 M6 0.4 - 0.6 (3.0 - 4.3) 16 S, WNV
* Housing x case 3 M8 1.6 - 2.3 (12 - 16) 35 B, WNV
Housing x case I 1 1 M8 11.6-2.3(12-16) / 50 1 B,WNV
Speedometer sleeve plate lock x case 1 M6 0.6 - 0.9 (4.3 - 6.5) 12 6, WAN
Throttle cable clamp x case 1 M6 0.6 - 0.9 (4.3 - 6.5) 12 B, WNV
O/P assembly x case I 1 1 MI0 11.8-2.7(14-19)l 28 1 6.F
Neutral start switch x case 1 M8 1.6-2.3(12-16) 35 B, WNV
Clamp x case 1 M8 0.9 - 1.7 (6.5 - 12) 20 B, WNV
Mount bracket x case / 3(5) / MI0 13.0-4.5(22-33) 1 25 1 B,WW
*: Apply sealant to the bolt bearing the "*" mark. case: Transmission case WR-04228
Explanation of shape
B, WNV : Bolt with washer
B, S : Stud bolt
N : Nut
W : Washer
B, F : Bolt flange
P : Plug
S, WNV : Screw with washer
Chassis
SECTION 5
FRONT AXLE & SUSPENSION
FRONT AXLE...................................................5- 2 DRIVE SHAFT ................................................... 5-22

SECTIONAL VIEW ......................................... 5- 2 DRIVE SHAFT-RELATED PARTS ...................5-22
COMPONENTS ........................................... 5- 2 OPERATION PRIOR TO REMOVAL .............. 5-23
REMOVAL.....................................................5- 3 REMOVAL ..................................................... 5-23
INSPECTION ................................................ 5- 5 INSPECTION ................................................. 5-25
INSTALLATION ............................................. 5- 6 COMPONENTS ............................................. 5-26
FRONT SUSPENSION ..................................... 5- 9 DISASSEMBLY .............................................. 5-27
SECTIONAL VIEW .........................................5- 9 INSPECTION ................................................. 5-28
FRONT SHOCK ABSORBER .......................... 5-10 ASSEMBLY .................................................... 5-28
COMPONENTS ............................................. 5-10 INSTALLATION ............................................ 5-29
REMOVAL.....................................................5-10 FRONT DRIVE BEARING SHAFT ................... 5-32
DISASSEMBLY .............................................. 5-1 1 COMPONENTS ............................................. 5-32
INSPECTION ................................................. 5-12 INSPECTION .................................................5-32
ASSEMBLY.................................................... 5-13 DISASSEMBLY .............................................. 5-33
INSTALLATION ..........................................5-14 INSPECTION ................................................. 5-35
FRONT STABILIZER BAR ............................... 5- 15 ASSEMBLY .................................................... 5-35
COMPONENTS ........................................... 5-15 WHEEL ALIGNMENT (FRONT AND REAR) ... 5-38
REMOVAL..................................................... 5-15 CHECKS PRIOR TO WHEEL ALIGNMENT
INSPECTION ................................................. 5-16 MEASUREMENT ......................................... 5-38
INSTALLATION .............................................5-16 CHECKS AND ADJUSTMENT OF FRONT
LOWER ARM .............................................. 5-17 WHEEL ALIGNMENT ..................................5-39
COMPONENTS ......................................... 5-17 CHECK AND ADJUSTMENT OF REAR
REMOVAL..................................................... 5-18 ......................................................... 5-44
TOE-IN
INSPECTION ................................................. 5-19
INSTALLATION ............................................. 5-20
FRONT AXLE
SECTIONAL VIEW
I I
COMPONENTS
I I
@ Disc brake caliper Ay

@ Front disc
@ Cotter pin
@ Front wheel adjusting lock cap
@ Castle nut
@ Plate washer
0 Front axle hub S/A
@ Cotter pin
@ Nut
@ Tie rod end SIA
@ Bolt
@ Nut
@ Steering knuckle
@ Hole snap ring
@ Radial ball bearing
@ Disc brake dust cover
Radial ball bearing inner race
T : Tightening torque
Unit: kg-m (ft-lb)
* : Non-reusable parts
Fig. 5-2 WR-05003

REMOVAL
1. Jack up the vehicle at the front side. Support the body
with safety stands.
2. Remove the front wheel.
3. Disc brake caliper removal

(1) Remove the attaching bolts of the disc brake caliper.
(2) Suspend the caliper.
4. Remove the disc rotor.
5. Front axle hub removal

(1) Remove the cotter pin and front wheel adjusting lock
cap.
(2) Remove the castle nut, using the following SST
SST: 0951 1 -87202-000
I I
Fig. 5-6 WR-05007
(3) Draw out the axle hub, using the following SST. I 1
NOTE:
Do not separate the axle hub from the steering knuckle
unless such separation is necessary.
SST: 09520-00031-000
I I
Fig. 5-7 WR-05008
6. Tie rod end separation

(1) Remove the cotter pin castle nut from the tie rod end.
(2) Separate the tie rod end from the steering knuckle,
using the following SST.
SST: 09611-87701-000
NOTE:
While using the SST, be very careful not to damage the
boot and threaded portion.
I
09611-87701-000
Fia. 5-8 WR-05009
7. Remove the lower ball joint attaching bolt and nut.
I
- I
Fia. 5-9 WR-05010
8. Steering knuckle separation
Remove the attaching nuts. Leave the bolts in their
inserted conditions.
9. Steering knuckle removal

(1) While supporting the steering knuckle, draw out the
attaching bolts of the shock absorber lower bracket.
(2) Disengage the axle hub from the drive shaft. Remove
the steering knuckle.
NOTE:
Protect the drive shaft boot with cloth or the like so that it
may not be damaged during the operation.
Wind a tape or the like on the drive shaft threaded
portion so that the oil seal may not be damaged.
I I
-Fia.
-a- 5
- 1- 1- WR-05012
10. Front axle bearing removal
(1) Remove the dust seal from the axle hub, using a
common screwdriver.
(2) Remove the bearing inner race (outer side) from the
axle hub, using the following SST.
SST: 09950-20014-000
09720-00010-000(Use the item No.3 that is
part of the set.)
Fig. 5-12 WR-05013

(3) Detach the snap ring, using snap ring pliers.
WR-05014
(4) Remove the bearing from the steering knuckle, using a
press in combination with the following SSTs.
SST: 09527-87301-000 09550-10012-000
09550-1001 2-000 (09554-1 0010-000, part of
the preceeding tool)
09527-87301-000
INSPECTION
Disc surface for damage

1. Disc brake cover replacement

(1) Separate the disc brake cover from the knuckle, using
a common screwdriver or the like.
NOTE:
Do not remove the disc brake cover unless its replacement
is required.
(2) Press the disc brake cover until it comes into close
contact with the knuckle, using the following SSTs.
SST: 09506-87302-000
09718-87701-000
I I
Fig. 5-17 WR-05018
INSTALLATION
1. Front axle bearing installation
I
(1) Press the bearing into position. using the following
SSTs.
SST: 09506-87302-000
09550-10012-000 (09554-10010-000, part of
09506-87302-000
Fig. 5-18 WR-05019
(2) Install a new snap ring, using snap ring pliers. I I I
(3) Press the front axle hub into position. using the
following SST.
SST: 09550-10012-000 (09554-10010-000, part of
2. Steering knuckle installation

(1) Insert the steering knuckle into the drive shaft.
NOTE:
Be careful not to allow the drive shaft to come into
contact with the oil seal at the knuckle side.
Pay utmost attention not to damage the ball joint dust
cover.
(2) Mount the steering knuckle on the lower ball joint.

(3) Mount the steering knuckle on the shock absorber
lower bracket. Tighten the bolts and nuts.
NOTE:
With the knuckle pushed against the lower side, tighten the
bolts and nuts.
(4) Install the lower ball joint. Tighten the bolt and nut.
I . . I
Fig. 5-22 WR-05023
(5) lnstall the washer. lnstall the nut temporarily. I I
NOTE:
Be sure to install the washer in the correct direction.
I I
Fig. 5-23 WR-05024
1
3. lnstall the disc rotor.
NOTE:
Care must be exercised to ensure that no foreign matter
lodge between the hub and the disc rotor.
Fig. 5-24 WR-05025

I
4. Disc brake caliper installation
(1) lnstall the pad guide plate to the steering knuckle.
(2) Tighten the attaching bolts of the disc brake caliper.
Fig. 5-25 WR-05026

5. Tightening of castle nut using the following SST.

(1) Tighten the castle nut.
SST: 09511-87202-000
(2) Install the front wheel adjust~nglock cap and a new

cotter pin.
Fig. 5-26 wR-05027

6. Tie rod end installation
(1) Attach the tie rod end to the steering knuckle and
tighten the castle nut.
-
Tightening Torque: 3.0 4.5 kg-m (22 - 32.5 ft-lb)
(2) Install a new cotter pin.
I
Fig. 5-27 WR-05028
7 . Install the wheel.

8. Front wheel alignment inspection and adjustment
(See page 5-38.)
FRONT SUSPENSION
FRONT SHOCK ABSORBER

COMPONENTS
Unit: kg-m (ft-lb)
Ir : Non-reusable parts
6J Bearing dust cover @ Front spring upper seat

@ Nut @ Coil spring
@ Front suspension support @ Spring bumper
@ Bear~ng @ Shock absorber
Fig. 5-29 WR-05031
REMOVAL
1 . Jack up the vehicle at the front side. Support the body
with safety stands.
3. Flexible hose removal

(1) Remove the clip at the shock absorber side.
(2) Disconnect the flexible hose at the shock absorber
bracket.
4. Shock absorber removal

(1) Remove the attaching bolts and nuts of the steering
knuckle. Separate the shock absorber from the steer-
ing knuckle.
NOTE:
Before removing the left shock absorber, remove the disc
brake caliper attaching bolt (upper side).
(2) Remove the two attaching nuts of the suspension

support located at the fender upper section. Remove
the shock absorber from the body.
NOTE:
Be sure to protect the drive shaft boot with cloth or the like
so that it may not be damaged.
I I
Fig. 5-33 WR-05035
I
DISASSEMBLY
1. Compress the coil spring, using the following SST
SST: 09727-87701-000
I I
2. Coil spring disassembly

(1) Clamp the front suspension support in a vice.
(2) Remove the bearing dust cover and loosen the nut.
NOTE:
Never remove the nut by applying impacts on it, using an
impact wrench or the like.
(3) Remove the following parts; the front suspension

support, bearing, front spring upper seat, coil spring
and spring bumper.
@-gearing
Front
upperspring*
seat
& Spring bumper
,Coil spring
Front shock-
absorber
I I
Fig. 5-36 WR-05038
INSPECTION
1. Inspect the following parts.
Rubber section for

deterioration
@- Bearing for wear
Deterioration,
deformation
0- Deterioration
Fig. 5-37 WR-05039

2. Shock absorber operation inspection

(1) Push or pull the piston rod of the shock absorber at a
constant speed. Ensure that the force required to
move the rod is uniform over the entire stroke.
However, when the piston rod is pulled strongly, the
pulling force may become slightly greater over the
stroke 30 mm (1.2 inches) toward the end of the
pulling stroke. It should be noted that this phe-
nomenon is not abnormal.
(2) Move the piston rod quickly in a up-and-down direc-
tion with a stroke of 5 - 10 mm (0.2 - 0.4 inch). Ensure WR-05040
that the force required to move the rod will not change.
(3) If any abnormal feeling or noise is encountered during
the inspection above, replace the shock absorber.
NOTE:
8 Perform this inspection after the piston rod has been
moved in a up-and-down direction three or four times.
8 When the gas filling type shock absorber is replaced,
previous to the disposal, be sure to release the gas from
the shock absorber.
ASSEMBLY
1. Assembly of coil spring
(1) Insert the spring bumper at a point below the cut-out
section of the piston rod.
(2) Compress the coil spring, using the following SST.
Install it to the shock absorber.
SST: 09727-87701-000
""
Spring bumper
I I I
J
Fig. 5-39 WR-05041
(3) Install the front spring upper seat and bearing.
L ' I
Fig.5-40 WR-05042
(4) Install the front suspension support.

NOTE:
Be sure to align the cut-out section of the front suspension
support with that of the piston rod during the assembly.
Cut sec
I
Fig. 5-41 wR-05043
(5) Clamp the front suspension support in a vice. Tighten

the suspension support, using a new nut.
(6) lnstall the bearing dust cover.

(7) Align the coil spring end with the recessed sections of
the upper and lower seats. Proceed to remove the
SST.
INSTALLATION
1. Installation of shock absorber upper section
(1) lnstall the suspension support on the fender apron.
(Use a new nut.)
2. Installation of steering knuckle section

(1) Mount the steering knuckle on the shock absorber
lower bracket.
(2) lnstall the bolt and nut in position and tighten them.
NOTE:
With the knuckle pushed against the lower side, tighten the
bolt and nut.
NOTE:
In the case of the removal/installation of the left shock
absorber, install the attaching bolt (upper side) of the disc
brake caliper after the steering knuckle section has been
installed.
3. lnstall the flexible hose, as follows:

(1) lnstall the flexible hose to the shock absorber bracket.
(2) lnstall the flexible hose clip.
4. lnstall the wheels. Jack down the vehicle.
5. Front wheel alignment inspection (See page 5-38.)

WR-05048
FRONT STABILIZER BAR

COMPONENTS
Unit: kg-m (ft-lb)
@ Front stabilizer bar @ Nut

@ Strut bar cushion a Stabilizer bush
@ Suspension lower arm SIA @ Stabilizer bracket
@ Strut bar cushion @ Steering knuckle
@ Retainer cushion @ Front stabilizer lower bracket
Fig. 5-47 wR-05049
REMOVAL
with safety stands.
2. Remove the engine under-cover. (Vehicles mounted with
Type CL-11 and CL-61 engines only)
3. Remove the stabilizer bar, as follows:
(1) Remove the stabilizer bar end nuts and retainer.
I I
WR-05050
(2) Remove the attaching bolts of the stabilizer bar

brackets.
Fig. 5-49 WR-05051

-
(3) Remove the stabilizer bar from the vehicle.

' NOTE:
If any difficulty in removing the stabilizer bar is encoun-
tered, remove the stabilizer bar by using a jack on the tire.
(4) Remove the bush from the stabilizer bar
I I
Fig. 5-50 WR-05052
INSPECTION
Inspect the following parts.
Deformatlon, cracks or rust
Q
-L~eterloration
g7Deterioraflon
Deformatlon or damage
Deformatlon or damage
-. - ,.,m **"P*
INSTALLATION Cushions I
1. Stabilizer bar installation
(1) Install the cushions to the stabilizer bar
I
Fig. 5-52 WR-05054
(2) Install the stabilizer bar to the lower arm. I 1
NOTE:
If the stabilizer bar end is not aligned with the lower arm
attaching hole, use a jack on the tire so as to align the
holes with each other.
I I
Fig. 5-53 wR-05055

(3) Install the cushion and stabilizer bar brackets.

(4) Install the cushions and retainers, while paying atten-

tion to the direction of the retainer. Tighten them
temporarily, using a new nuts.
(5) Rock the front section of the vehicle in an up-and-
down direction two or three times so as to settle the
suspension.
(6) With the vehicle in an unloaded state (the lower arm is
horizontal), tighten the nuts.
Tightening Torque: 7.5 - 11 kg-m (54 - 80 ft-lb)
NOTE:
If the nut is tightened at the rebound side, the cushion I I I I
Fig. 5-55 WR-05057
twisting angle will become large, resulting in reduced riding
comfort.
2. Install the engine under-cover. (Vehicles mounted with

Type CL-I I and CL-61 engines only)
LOWER ARM
1
Fig. 5-56 WR-05058
5-17
REMOVAL
with safety stands.
3. Lower arm removal.
(1) Remove the stabilizer bar end nut.
(2) Remove the attaching bolt and nut of the ball joint.
(3) Remove the attaching nut of the lower arm at the body
side.
L I
Fig. 5-58 WR-05060
. ,
(4) Remove the attaching bolts of lower suspension brace.
(TURBO and GTti grades only)
(5) Remove the lower arm bracket.
(6) Remove the lower arm.
lNSPECTlON
Lower ball joint dust cover replacement

(1) Remove the dust cover, using a common screwdriver.
NOTE: ' grease
Be very careful not to damage the socket section.
(2) When assembling the lower ball joint dust cover, apply 'Socket section
grease to the following sections.
I I
Fig. 5-61 wR-05063
(3) Press the dust cover into position, using a press in
combination with the following SST.
SST: 09618-87301-000
NOTE:
Make sure that no grease or oil gets to the socket section
(indicated by a "*" mark) during the press operation.
Fig. 5-62 wR-05064
5-19
2. Lower arm bush replacement

(1) Remove the bush, using the following SSTs.
SST: 09301-87701
,
lRemove, Install
09636-20010
(2) Press the bush into position, using a press in conjunc-

tion with the following SSTs.
SST: 09301-87701
09636-20010
I J
Fia. 5-63 wR-05065
INSTALLATION
1 . Lower arm installation
( 1 ) Temporarily tighten the lower arm ball joint section and
stabilizer bar end nut section.
1 , I
Fia. 5-64 WR-05066
(2) Tighten the bolt and nut of the ball joint section.
.. I
Fia. 5-65 WR-05067
(3) Install the lower arm bracket.
(4) Tighten the lower arm attaching nut temporarily
(5) Installation of lower suspension brace.

(TURBO and GTti grades only)
I I
Fig. 5-67 WR-05069
(6) Install the front wheel.

(7) Jack down the vehicle. Rock the front section of the
vehicle in an up-and-down direction two or three times
so as to settle the suspension.
(8) With the vehicle in an unloaded state (lower arm is
horizontal), tighten the nut.
(Stabilizer bar)
Tightening Torque:
7.5 - 11.O kg-m (54 - 80 ft-lb)
I
(Lower arm)
Tightening Torque:
7.0 - 10.0 kg-m (51 - 72 ft-lb)
Fig. 5 6 9 wR-05071
DRIVE SHAFT
DRIVE SHAFT-RELATED PARTS
+: Non-reusable parts
6) Cotter pin @ Extension rod S/A

Front wheel adjusting lock cap @ Lower suspension brace
O Nut (Vehicles mounted with Type CB-80 engine only)
@ Tie rod Ay @ Shift & select shaft S/A
@ Stabilizer bar @ Front
I drive shaft Ay
@ Lower arm Ay @ Bolt
@ Bolt @ Front drive bearing shaft Ay
(Vehicles mounted with Type CB-80 engine only)
OPERATION PRIOR TO REMOVAL

1 . Jack up the vehicle.
2. Drain the transmission fluid.
3. Remove the front wheels.
L . I
Fig. 5-71 WR-05073
REMOVAL
1. Pull out the cotter pin. Remove the front wheel adjusting
lock cap.
I I
Fig. 5-72 wR-05074
I I
2. Remove the nut, using the following SST.
SST: 09511-87202-000
I I
Fig. 5-73 WR-05075
3. Disconnect the tie rod, using the following SST
SST: 09611-87701-000
I I
4. Remove the stabilizer bar.
Fig. 5-75 WR-05077

5. Remove the lower arm. (Bracket side only)
I I
Fig. 5-76 WR-05078
6. Remove the bolts. Separate the extension rod subassem-
bly and shift & select shaft subassembly from the trans-
mission.
I I
Fig. 5-77 WR-05079
7. Pull out the front drive shaft, using the following SST.
SST: 09648-87201-000
NOTE:
1. As for the inboard side of the drive shaft, no stopper is
provided at the inside. Therefore, be sure to support the
inboard joint section by your hand during the removal.
2. As for the right side of vehicles mounted with Type

CB-80 engine, insert a crowbar into between the pro-
truding section of the bearing shaft and the drive shaft.
Then, take out the front drive shaft, being very careful
not to deform the dust cover of the drive shaft.
9. Remove the two bolts. Remove the front drive shaft

bearing shaft assembly. (Vehicles mounted with Type CB-
80 engine only)
I I
Fig. 5-80 wR-05082
'NSPECTION
~nspectthe following sections.
Oil seal-contacting-section
for damage or wear
Bands for breakage or deformation
/ Boots for rupture

Dust cover for deformation
Fig. 5-81 WR-05083

COMPONENTS
NOTE:
When replacing the parts of the drive shaft, each of the
boot, the inboard joint and the outboard joint (with the
front axle shaft) should be replaced only as a complete
unit.
+: Non-reusable parts
@ Boot band
@ Outboard joint S/A
@ Front axle inboard joint SIA
@ Shaft snap ring
0Inboard joint tripod Ay
@ Front axle joint boot
Fig. 5-82 WR-05084

DISASSEMBLY
1. Pry up the boot band clip with a common screwdriver
Detach the boot.
0
NOTE:
Be very careful not to damage the boot.
2. Put a mating mark on the inboard joint and shaft, as

shown in the figure. Remove the front axle inboard joint
subassembly.
NOTE:
Put mating marks by painting. (Never use a punch to put
mating marks.)
L I
Fig. 5-84 wR-05086
3. Detach the shaft snap ring, using a snap ring expander.
IFig. 5-85 WR;05087

I
4. Remove the inboard joint tripod assembly, as follows:
(1) Put a mating mark at the tip end of the tripod and
shaft, using a punch.
I I
Fig. 5-86 WR-05088
(2) Pull out the tripod from the shaft, using a brass bar. I I
NOTE:
Be sure to apply the brass bar to the tripod boss section,
not to the roller section.
5. Remove the front axle joint boot.
I I
Fig. 5-87 wR-05089
INSPECTION
Inspect the following sections.
I I
Deterioration or wear
Damage or wear \ 1
Damage or wear
Damage or wear
Fig. 5-88 WR-05090
ASSEMBLY
1. Assemble the front axle joint boot in position. Mating marks
2. Assemble the inboard joint tripod assembly, as follows:
(1) Face the non-splined side of the tripod toward the
outboard joint.
(2) Align the mating marks which were put during the
disassembly.
Fig. 5-89 WR-05091

(3) Drive the tripod assembly into the shaft lightly, using a
brass bar.
NOTE:
Be sure to apply the brass bar to the boss section of the
tripod, not to the roller section.
I I
Fig. 5-90 WR-05092
3. Attach the shaft snap ring in position, using a snap ring
expander.
I I
I
Fig. 5-91 wR-05093
5-28
4. Assemble the front axle inboard joint, as follows:

(1) Pack the inboard joint with joint grease.
NOTE:
Use the grease which has been provided in the boot kit of
the replacement parts.
L I
Fig. 5-92 WR-05094
(2) Install the inboard joint, aligning the mating marks
which were put during the disassembly.
9
I
I
Fig. 5-93
~ a t i n gmarks
I
WR-05095
5. Prior to assembling the boot of the front axle outboard
joint, pack the outboard joint with joint grease.
NOTE:
1. Use the grease which has been provided in the boot kit
of the replacement parts.
2. On vehicles other than those mounted with Type CB-80
engine, it should be noted that the grease to be used for
the inboard joint differs from that to be used for the
outboard joint.
Grease for inboard joint ... Yellow
Grease for outboard joint ... Black Fig. 5-94 WR-05096
6. Assemble a new boot band, as shown in the figure.
INSTALLATION
Grease applying points
1. Apply chassis grease to the whole serrated section of the
front axle hub installation section.
2. lnstall the front drive bearing shaft in position.

(Vehicles mounted with Type CB-80 engine only)
3. lnstall the front drive bearing shaft in position.

NOTE:
Be very careful not to damage the oil seal during the
installation.
4. lnstall the shift & select shaft subassembly and extension

rod subassembly in position.
5. lnstall the bracket side of the lower arm assembly in

position.
6. lnstall the stabilizer bar to the lower arm assembly.

7. lnstall the stabilizer lower bracket to the body.

FRONT AXLE, & SUSPENSION
9. Install the tierod assembly to the steering knuckle.

I I
Fig. 5-102 WR-05104
I
Install the drive shaft to the front axle hub. Secure the axle
hub, using the following SST.
SST: 0951 1-87202-000
10. Tighten the nut.

Tightening Torque:
18.0 - 23.0 kg-m (130 - 166 ft-lb)
NOTE:
1. When this nut is tightened to the specified torque, the
specified preload of the front wheel is attained.
2. Assemble the spring washer in such a way that its
recessed side comes to the hub side.
11. lnstall the front wheel adjusting lock cap to the nut.
12. Install the cotter pin, as shown in the right figure.
Front wheel adjusting lock cap

Fig. 5-1 05 WR-05107
FRONT DRIVE BEARING SHAFT

(Vehicles Mounted with Type CB-80 Engine Only)
COMPONENTS
Ir: Non-reusable parts
Oil seal @
Dust deflector
@ Shaft snap ring @
Hole snap ring
@ Drive shaft bearing bracket @
Universal joint spider S/A
@ Oil seal @
Universal joint No.2 yoke
@ Hole snap ring Universal
@ I joint yoke S/A
@ Radial ball bearing
Fig. 5-106
I
WR-05108
INSPECTION
Damage or wear Deformation or damage Damage
Excessive looseness
in round direction
Fig. 5-107 WR-05109

DISASSEMBLY
1. Remove the oil seal, using a common screwdriver.
2. Detach the shaft snap ring, using a snap ring expander
I I
Fig. 5-108 WR-05110
3. Remove the drive shaft bearing bracket, using the follow-
ing SSTs.
SST: 09334-87201-000
SST: 09608-87501-000
09334-87201-000
09608-87501-000
i7 -s
I I
Fig. 5-109 WR-05111
4. Remove the another oil seal, using a common screwdriver. I
5. Detach the hole snap ring. using a snap ring expander. I I
I I
Fig. 5-110 WR-05112
6. Remove the radial ball bearing, using the following SSTs.
SST: 09547-87301-000
SST: 09608-87501-000
09608-87501-0
47-87301-000
I I
Fig. 5-111 wR-05113
I
Remove the dust deflector, using a brass bar and a
hammer. Be careful not to damage the dust deflector
during the removal.
I I
Fig. 5-112 wR-05114
5-33
Put a mating mark on the yoke and universal yoke.

Detach the hole snap ring, using a snap ring expander
I I
Fig. 5-113 wR-05115
10. Remove the universal joint spider subassembly, following
Socket (19mm)
the procedure given below.
(1) Push off the spider bearing cap, using a vice in
combination with a 19 mm socket and the following
SST.
SST: 09628-10020-000
I I
Fig. 5-114 WR-05116
(2) Clamp the pushed-out cap in a vice. Remove the
bearing cap from the yoke No.2 by tapping the yoke
No.2 lightly.
(3) Tap the spider from the side of the cap removed, thus
pushing out the another cap.
I I
Fig. 5-115 WR-05117
(4) Clamp the cap in a vice. Remove the cap by tapping
the yoke No.2 lightly. Separate the yoke No.2 from the
universal joint yoke subassembly.
(5) Remove the remaining caps, following the same pro-
cedure.
I I
Fig. 5-116 WR-05118
11. Disconnect the universal joint No.2 yoke from the universal
joint yoke subassembly.
LFig. 5-1 17 WR-05119I

INSPECTION
Inspect the following sections.
Damage or deformation
\ Damage, wear or deterioration
\
\ \ Damage or deformation \
Damage Wear or damage Damage or deformation
I Fig. 5-118 WR-05120
ASSEMBLY Inside of oil seal

Grease applying points Oil seal lip section,
Apply MP grease to the points shown in the right figure.
Inside of spider ( ~ r e a s enipple)
I
Fin. 5-119 wR-0.5121
1. Assemble the universal joint yoke spider subassembly,
following the procedure given below.
(1) Assemble the spider to the universal joint yoke sub-
assembly. Push them in a vice from both sides until the
bearing cap becomes flush with the end surface of the
yoke subassembly.
I I
Fia. 5-120 wR-05122
(2) Using a 19 mm socket, push the spider cap in a vice
until the snap ring can be inserted in position.
(3) Install the universal joint yoke No.2 to the spider.
Assemble it in the sequence (1) and (2) described
above.
I A
Fig. 5-121 WR-05123
2. Assemble the hole snap ring, using a snap ring expander, 1

in accordance with the procedure given below.
(1) Select a proper snap ring so that the play of the spider
in the axial direction will not exceed 0.05 mm (0.002
inch) and the thickness of the snap ring becomes the
same at both sides.
Reference: Snap Ring Availability

Part number Thickness
I I
90045-21046-000 1.45 mm (0.057 inch) Fig. 5-122 WR-05124
90045-21047-000 1.50 mm (0.059 inch)

90045-21048-000 1.55 mm (0.061 inch)
(2) Assemble the selected snap ring

(3) Check the spider bearing for excessive looseness.
Fia. 5-123 WR-05125

3. Install the dust deflector, using the following SST.
SST: 09547-87501-000
I I
Fig. 5-124 WR-05126
4. Assemble the radial ball bearing, using the following
SSTs.
SST: 09547-87301-000
SST: 09608-87501-000 09608-87501-000
09547-87301-000
Fig. 5-125 wR-05127

5. Attach the hole snap ring, using a snap ring expander.
6. Install the oil seal, using the following SST.

SST: 09608-87501-000
09608-87501-000
Fig. 5-127 WR-05129

7. Install the drive shaft bearing bracket, using the following
SSTs.
SST: 09506-30011-000 09506-30011-000 09608-87501-000
SST: 09608-87501-000
Fig. 5-128 WR-05130

8. Attach the shaft snap ring, using a snap ring expander.
9. Assemble the oil seal, using the following SST.
SST: 09608-87501-000
/
09608-87501-000
Fig. 5-129 WR-05131
WHEEL ALIGNMENT (FRONT AND REAR)

TOOLS AND INSTRUMENTS
CHECKS PRIOR TO WHEEL ALIGNMENT

MEASUREMENT
1. Checking Tires for Wear
2. Checking Tires for Air Pressure
Air inflation pressure kg/cm2(psi)
Tire
G- 100 G-101
I 1
Fig. 5130 'NR-05133
(185160R14 82H (Pirelli) 1.8 (26) I

3. Checking Tires for Runout
(Up-and-down and right-and-left directions)
Maximum Limit: 3.0 mm (0.12 inch)
2.Ivle
4. Checking Bolts of Related Sections for Tightened Condi-
tion
I i
Fig. 5-131 WR-05134
I 1
5. Checking Related Sections for Excessive Play
(1) Jack up the vehicle. Alternately push and pull the
upper and lower parts of each tire. Ensure that the tire
exhibits no excessive play.
(2) If the tire exhibits an excessive play, perform the
following check while the brake pedal is being de-
pressed.
The excessive play disappears:
This indicates that the front wheel bearing is
loose. 5
The excessive play still persists: Fig. 5-132 WR-05135
This indicates that the knuckle section, axle
carrier section or suspension is loose.
(3) If the wheel bearing is judged as being loose, proceed

to check the play in the axial direction, using the
following SST.
SST: 09510-87301-000
(Front and rear wheel bearings)
Specified Value: Not to exceed 0.2 mm (0.008 inch)
I (Drum brake) (Disc brake)

I
09510-87301-000
Fig. 5-134 wR-05137
CHECKS AND ADJUSTMENT OF FRONT WHEEL I I I

ALIGNMENT
1. Turning Radius Gauge Set
(1) Set the turning radius gauge to the zero point. Proceed
to lock the gauge.
(2) Place the vehicle on the gauge in such a way that the
center of the tire-to-floor contact surface may be
aligned with the center of the turning radius gauge.
NOTE:
Perform the check on a level floor. I I
Fig. 5-135 WR-05138

When a portable type turning radius gauge is employed,
a plate having the same thickness as that of the gauge
should be placed under the rear wheel so that the
vehicle levelness may be maintained.
Make sure that the wheels are in their straightahead
conditions.
Keep the vehicle in an unloaded state. In order to
prevent the vehicle from moving during the check, be
sure to apply the foot brake, using a brake pedal pusher
or the like.
Remove the stop lamp fuse so as to prevent the stop I I
lamp from glowing. Fig. 5-136 WR-05139

2. Checking Wheel Turning Angle

(1) Measure the wheel turning angle, using a turning
radius gauge.
Specified Value:
Inner side 39"55'+2"
Outer side 7 s * 3&" 4 5 2 "
(2) If the wheel turning angle differs between the right and
left sides, correct the turning angle.
Fig. 5-137 wR-05140
3. Correction Wheel Turning Angle
(1) Slacken the lock nuts of the tie rod ends.
(2) Make the length indicated in the right figure equal
between the right and left sides.
NOTE:
Make sure that the boot is not twisted during the
correction.
Make sure that the tie rods at the right and left sides are
turned by the same amount.
4. Checking Camber, Caster and Kingpin Angles

(1) In the case of steel wheels, perform the measurement,
using the following SST (attachment).
SST: 09722-87702-000
I I
Fig. 5-139 wR-05142

(2) In the case of aluminum wheels, perform the measure-
ment, using the CCK (Camber, Caster, Kingpin) gauge
compensator (available in the market).
NOTE:
The CCK gauge compensator can be used for the
measurement on steel wheels, too.
I I
Fig. 5-140 WR-05143
(3) Installation procedure for the CCK gauge compensa-
tor, and the camber, caster and kingpin gauge.
) CCK gauge I
Clamp dial
zero
installatio
plate
compensating dial
I I
Fig. 5-141 WR-0.5144
5-40
Jack up the vehicle.
Before installing the CCK gauge to the wheel, set
the CCK gauge compensator to the mechanical
zero line by turning the compensating dial of the
compensator.
While turning the clamp dial of the CCK gauge

I
I
':"
Fig. 5142
r
Mechanical zero line I
WR-05145
compensator, hook the four pawls to the wheel

edges securely. While pushing the compensator,
lock the compensator positively by turning the
clamp dial.
NOTE:
In order to prevent the wheel edges from being scratched,
affix tapes or the like on the wheel edge sections to which
the four pawls of the compensator are hooked.
I pawl /,
Fig. 5-143 WR-05146
Set the camber caster and kingpin gauge to the r
installation plate of the CCK gauge compensator.

At this point, align the set lines on the gauge and
compensator with each other.
I 1
Fig. 5144 WR-05147
Turn the wheel so that the level air bubble in the I 1
gauge may come to the central position.
At this position, turn the caster adjusting screw of
the gauge so that the caster air bubble may be
aligned with the graduation zero position.
Fig. 5-145 wR-05148

Turn the wheel 180 degrees so that the gauge may
be turned over. Proceed to align the set lines on the
gauge and compensator with each other.
Next, turn the wheel so that the level air bubble in
the gauge may come to the ceritral position.
Fig. 5-146 WR-05149

Record the caster reading of the gauge. Turn the
compensating dial of the compensator so that it may
be aligned with the 112 of the recorded caster
reading.
NOTE:
Be sure not to tamper the caster adjusting screw of the
gauge.
Repeat the steps described in Fig 5-86 and Fig.
5-87. dial
Ensure that the air bubble of the caster gauge
I I
registers the same reading when the wheel is turned Fig. 5-147 WR-05150
180 degrees in a normal direction and in a reversed
direction.
Jack down the wheel on the turning radius gauge.

Rock the vehicle in an up-and-down direction so as
to settle the suspension.
IFig. 5-148 WR-05151

I
(4) Camber check
Ensure that the wheels are in their straight-ahead
conditions.
I Level air bubble I
Align the level air bubble with the central position.
Take the camber reading of the gauge.
Specified Value: m0 Camber caster and
kingpin gauge
Banzai, ~ i r n i t e t j B 1 1
Set alr bubble at central posillon

when ~nslalled
1 I
Fig. 5-149 WR-05152

(5) Checking caster and kingpin angles

(Right wheel)
Turn the steering wheel to the right side, until the right front tire comes at a point where the
turning radius gauge registers 20 degrees.
8 Turn each of the caster and kingpin adjusting screws so that the respective air bubble may be
aligned with the zero point.
8 Turn the steering wheel to the left side, until the right front tire comes at a point where the turning
radius gauge registers 20 degrees.
8 Take the gauge readings of the caster and kingpin angles.
+
Specified Value: Caster.. ................................ 2'55' 1" .
Kingpin angle ....................... 12"+30f
(Left wheel)
8 Perform the check, following the same procedure as with the right wheel. However, the turning
direction of the steering wheel must be reversed.
Kingpin Kingpin
(6
t
\
Align air bubble with Measurement value

zero position.
/
Caster
5. Toe-In Measurement
(I) Rock the vehicle so that the vehicle height may
stabilize.
(2) Move the vehicle forward about five meters so that the
front wheels may become in their straight-ahead
conditions.
NOTE:
Do not move the vehicle backward during the measure-
ment.
(3) Align the height of the toe-in gauge pointers with the
center height of the front wheels. Fig. 5-151 WR-05154
(4) Put a mark on the tread center of each front wheel tire
at the rear side. Measure the distance between the two
marks (Dimension A) in the figure.
t
(5) Slowly move the vehicle forward by pushing the
vehicle, until the wheels turn 180 degrees. I
I I
Fia. 5-152 WR-05155
r
- -
(6) Measure the distance (Dimension 9) between the two I

pp
-- Front
marks which were put in the preceding step. This
measurement is performed at the front side of the
vehicle.
Calculate the amount of toe-in, i.e. (Dimension A -
Dimension 9).
Specified Value: -1 - +3 mm (-0.04 - +0.12 inch)
I I
Fig. 5-153 WR-05156
6. Toe-In Adjustment
(1) Slacken the lock nuts of the tie rod ends.
(2) Perform the toe-in adjustment by turning the tie rod
ends.
NOTE:
Care must be exercised to ensure that the boot is not
twisted during the adjustment.
When adjusting the toe-in, the tie rods at the right and
left sides should be turned by the same amount.
The length indicated in the right figure must be the same
amount. I
Fig. 5-154
I
WR-05 157
(If the length differs between the right and left sides, a
difference occurs in the wheel turning angle between the
right and left sides.)
7. Sideslip Check
Check the sideslip, using a sideslip tester.
Specified Value: =4-+3am (-0.12 - +0.12 inch) -4 -- C$
Per 1 meter (3.28 ft) WR-05158
CHECK AND ADJUSTMENT OF REAR TOE-IN

1. Toe-In Check
(1) Rock the vehicle so that the vehicle height may
stabilize.
(2) Move the vehicle forward about five meters so that the
front wheels may become in their straight-ahead
conditions.
(3) Align the height of the toe-in gauge pointers with the
center height of the rear wheels.
(4) Put a mark on the tread center of each rear wheel tire I 1
at the rear side. Measure the distance between the two Fig. 5-155 WR-05159
marks (Dimension A) in the figure.
(5) Slowly move the vehicle forward by pushing the

vehicle, until the wheels turn 180 degrees.
L I
Fig. 5-156 WR-05160
(6) Measure the distance (Dimension B) between the two
marks which were put in the preceding step. This
Front 1
measurement is performed at the front side of the rear
wheels.
(7) Calculate the amount of toe-in, i.e. (Dimension A -
Dimension B).
Specified Value: +4 - +8 mm (+0.16 - +0.31)
I
. .=. - .-'
I
Fin ZL157 WR-05161
2. Toe-In Adjustment I
(1) slacken the set bolt of the toe adjusting cam.
I
I I
WR-05162
(2) Insert a hexagon wrench key into the hexagonal hole
provided at the back side of the tow adjusting cam.
Turn the hexagon wrench key.
(Inside: IN, Outside: OUT)
(Reference)
When each of the adjusting cams provided at both sides is
turned by one graduation, the toe-in will change approx-
imately 5 mm (0.20 inch).
3. Sideslip Check
Check the sideslip, using a sideslip tester. Fig. 5-159 WR-05163
Specified Value: 1 - 7 mm (-0.04 - 0.28 inch)
Per 1 meter (3.28 ft)
Chassis
SECTION 6
REAR AXLE & SUSPENSION
REAR AXLE......................................................6- 2 SUSPENSION ARM ........................................6-18

SECTIONAL VIEW .........................................6- 2 COMPONENTS ............................................. 6-18
COMPONENTS ............................................. 6- 3 REMOVAL ..................................................... 6-18
REMOVAL .....................................................6- 4 INSPECTION .................................................6-20
INSPECTION ................................................ 6- 7 INSTALLATION ........................................ 6-20
INSTALLATION .............................................6- 8 STRUT ROD.....................................................6-22
REAR SUSPENSION ........................................ 6-1 1 REMOVAL ..................................................... 6-22
SECTIONAL VIEW ......................................... 6-1 1 INSPECTION ................................................. 6-22
REAR SHOCK ABSORBER .............................6-1 1 INSTALLATION ............................................. 6-22
COMPONENTS ............................................. 6-1 1 STABILIZER BAR ............................................ 6-23
REMOVAL ....................................................6-12 COMPONENTS ........................................6-23
DISASSEMBLY ............................................. 6-13 REMOVAL .................................................. 6-23
, I INSPECTION ................................................ 6-14 INSPECTION ................................................. 6-24
ASSEMBLY ................................................... 6-15 INSTALLATION ............................................ 6-25
INSTALLATION ............................................6-16
REAR AXLE
T : Tightening toque
Unit: kg-m (ft-lb)
* : Nowreusable parts
@ Radial ball bearing @ Bolt

@ Rear axle bearing outer retainer @ Rear brake Ay
@ Radial ball bearing 0Rear brake drum
@ Rear axle carrier S/A @ Plate washer
@ Rear axle bearing inner retainer @ Castle nut
@ NutI @ Cotter pin
@ Bolt @ Grease retainer cap
@ Bolt
REMOVAL
1. Jack up the vehicle at the rear side. Support the body with
safety stands.
2. Remove the rear wheel.
3. Backing plate removal

(Drum brake equipped vehicle)
(1) Remove the grease retainer cap.
(2) Remove the cotter pin, castle nut and plate washer.
I I I
Fig. 6-4 WR-06005
(3) Remove the brake drum, using the following SST. I
Remove the bearing inner retainer.
SST: 09510-87301-000
I t
Fig. 6-5 wR-06006
(4) Disconnect the brake tube from the wheel cylinder, I I
SST: 09751-36011-000
(5) Remove the backing plate with the brake shoe in-
stalled.
(Disc brake equipped vehicle)

(1) Remove the parking cable guide.
(2) Remove the anti-rattle spring.
(3) Remove the caliper.

NOTE:
Suspend the caliper as shown in the right figure.
(4) Remove the caliper support.
(5) Remove the grease retainer cap.

(6) Remove the cotter pin, castle nut and plate washer.
1 I I
WR-06012.
(7) Remove the disc rotor and bearing inner retainer.
Fig. 6-12 WR-06013

(8) Remove the backing plate.
1 I
Fia. 6-13 WR-06014

Axle carrier removal
(1) Remove the attaching bolt and nut of the axle carrier
from the strut rod.
from the suspension arm No.1.
from the suspension arm No.2.
(4) Remove the attaching bolts and nuts of the axle carrier
from the shock absorber. Remove the axle carrier.
5. Hub bearing removal

(1) Drive out the inner bearing, using a brass bar. At the
same time, drive out the bearing outer retainer, too.
(2) Drive out the outer bearing, using a brass bar.
Fig. 6-1 9 WR-06020
INSPECTION
Brake drum for wear or damage

Specified inner diameter: 180 mm (7.09 inches)
imlt: 181.5 mm (7.15 inches)
Bearing for wear and damage
Both ends for Deformation

wear or damage
Hub and bolt for fitting

condition threaded portion for
damage
Disc surface for damage and wear

Specified thickness: 10 mm (0.39 inch)
Minimum Limit: 9 mm (0.35 inch)
Fig. 6-20 WR-06021

INSTALLATION Brake
1. Hub bearing installation
Pack the hub and bearing with grease. Then, press the
outer bearing, outer retainer and inner bearing, in this
order, using a press in conjunction with the following SST.
SST: 09608-12010-000
(For the outer bearing, use No. 13 of the SST set.)
(For the inner bearing, use No. 5 of the SST set.)
:ig. 6-21 WR-06022

I D~SCrotor
I
Fig. 6-22 WR-06023

Axle carrier installation I I
NOTE:
As for those suspension-related bolts and nuts on which a
friction stabilizing agent has been coated, be certain not to
reuse them if they have been once removed
(1) Mount the axle carrier to the shock absorber. Friction stabilizing
(2) Install the attaching bolts and new nuts of the axle agent coated
carrier. Proceed to tighten them.
NOTE:
Tighten the bolts and nuts while pushing the axle carrier to 1
Fig. 6-23
the lower side (positive side). I 4
I I 1
Fia. 6-24 WR-06024
(3) Mount the axle carrier on the suspension arm No.1.
Tighten the new bolt and nut temporarily.
Temporarily tighten the new bolt and nut.
5. Hub bearing removal

(1) Drive out the inner bearing, using a brass bar. At the
same time, drive out the bearing outer retainer, too.
(2) Drive out the outer bearing, using a brass bar.
Fig. 6-18
Disc rotor
.
WR-06019
Fig. 6-19 WR-06020
INSPECTION
I-
Brake drum for wear or damage
imit: 181.5 mm (7.15 inches)
Both ends for Deformation

wear or damage
Hub and bolt for fitting

condition threaded portion for
damage
Disc surface for damage and wear

Specified thickness: 10 mm (0.39 inch)
Fig. 6-20 WR-06021

INSTALLATION
1. Hub bearing installation
Pack the hub and bearing with grease. Then, press the
outer bearing, outer retainer and inner bearing, in this
order, using a press in conjunction with the following SST.
SST: 09608-12010-000
(For the outer bearing, use No. 13 of the SST set.)
(For the inner bearing, use No. 5 of the SST set.)
Fig. 6-21 WR-06022

~ D ~ Srotor
C I
I I
Fig. 6-22 wR-06023
2. Axle carrier installation I I
NOTE:
As for those suspension-related bolts and nuts on which a
friction stabilizing agent has been coated, be certain not to
reuse them if they have been once removed
(1) Mount the axle carrier to the shock absorber. Friction stabilizing
(2) Install the attaching bolts and new nuts of the axle agent coated
carrier. Proceed to tighten them.
NOTE:
Tighten the bolts and nuts while pushing the axle carrier to Fig. 6-23
the lower side (positive side). 1

Tighten the new bolt and nut temporarily.
Temporarily tighten the new bolt and nut.
Fig. 6-25 WR-06025

(5) Mount the axle carrier on the strut rod. Tighten the new
bolt and nut temporarily.
Fia. 6-26 WR-06026

Installation of brake drum or disc rotor
(Drum brake equipped vehicle)
(1) lnstall the backing plate.
NOTE:
Be sure to apply DAIHATSU Bond No.4 (999-6304-6323-
00) to the mating surface between the rear brake and the
axle carrier. During this sealer application, be very careful
not to restrict the 5 mm (0.20 inch) dia. grease releasing
hole.
(2) lnstall the brake tube to the backing plate.

(3) lnstall the bearing inner retainer, brake drum, plate
washer and castle nut.
(5) lnstall a new cotter pin. lnstall the grease retainer cap.
(6) Perform air bleeding for the brake system. (See page
8-5.)
(Disc brake equipped vehicle)

(1) lnstall the backing plate.
(2) lnstall the bearing inner retainer, disc rotor, plate

(4) lnstall a new cotter pin. lnstall the grease retainer cap.
I Inside
-.-- 1 p d e 1
Fig. 6-30 wR-06030
(5) lnstall the caliper support.

(6) lnstall the caliper.
(7) lnstall the anti-rattle spring.

(8) lnstall the parking cable guide.
4. Tightening of axle carrier attaching bolts

(1) lnstall the tires.
(2) With the vehicle in an unloaded state, jack down the
vehicle. Rock the vehicle in an up-and-down direction
several times to settle the suspensions.
(3) With the vehicle weight being applied to the suspen-

sions, tighten the bolt and nut of each section.
5. Rear wheel alignment inspection

(See Fig. 5-38)
REAR SUSPENSiBN
SECTIONAL VIEW
Fig. 6-36 WR-06036
REAR SHOCK ABSORBER

COMPONENTS
*@I T : Tightening torque

Unit: kg-m (ft-lb)
r---\ i * : Non-reusable parts
\
\
\
\
0 \
\
\
\
@ Rear shock absorber Ay

. 0 Clip
@ Rear axle carrier S/A
@ Coil spring
@ Spring bumper
I
.
\
I
I
@ Rear corl sprrng rnsulator
aRear suspensron support
\ I @ Rear shock absorber cushron
<
I
Fig. 6-37 WR-06037
REMOVAL
1. Jack up the vehicle at the rear section. Support the body
with safety stands.
2. Remove the wheel.
3. Removal of brake tube and flexible hose I Drum brake equipped vehicle I
(1) Disconnect the brake tube from the flexible hose.
SST: 09751-36011-000
(2) Detach the clip. Disconnect the flexible hose from the
shock absorber.
4. Remove the nuts attaching the shock absorber to the axle

carrier. Leave the bolts in an inserted condition.
I I
Fig. 6-41 WR-06041
5. Trim removal
(1) Remove the package tray.
(2) Remove the package tray side trim.
I \
Fig. 6-42 wR-06042
'i. Slacken the nut attaching the shock absorber to the

suspension support.
NOTE:
Do not remove the nut.
7. Remove the nuts attaching the suspension support to the

body.
8. Remove the attaching bolts of the axle carrier and shock
absorber. Remove the shock absorber from the body.
DISASSEMBLY
1. Coil spring removal
SST: 09727-87701-000
(2) Remove the nut.
Fig. 6-46 WR-06046

(3) Remove the rear shock absorber cushion, rear sus- Rear shock absorber
pension support, rear coil spring insulator, spring
bumper and coil spring. Rear suspension+&cusho
in
support
Rear coil
spring insulator
Spring bumper
Coil spring
INSPECTION
Rubber section for Flattened condition

deterioration
Deterioration,
deformation
Rubber section for

deterioration
oil leakage
2. Shock absorber operation inspection

(1) Push or pull the piston rod of the shock absorber at a
constant speed. Ensure that the force required to
move the rod is uniform over the entire stroke.
However, when the piston rod is pulled strongly, the
pulling force may become slightly greater over the
stroke 30 mm (1.2 inches) toward the end of the
pulling stroke. It should be noted that this phe-
nomenon is not abnormal.
(2) Move the piston rod quickly in a up-and-down direc-
I I
tion with a stroke of 5 - 10 mm (0.2 - 0.4 inch). Ensure Fig. 6-49 WR-06049
that the force required to move the rod will not change.
(3) If any abnormal feeling or noise is encountered during
the inspection above, replace the shock absorber.
NOTE:
Perform this inspection after the piston rod has been
moved in a up-and-down direction three or four times.
When the gas filling type shock absorber is replaced,
previous to the disposal, be sure to release the gas from
the shock absorber.
ASSEMBLY
1. Assembly of coil spring
( I ) lnstall the spring bumper at a point below the cut-out
section of the piston rod.
lnstall it to the shock absorber.
SST: 09727-87701-000
Fia. 6-50 wR-06050

(3) lnstall the rear shock absorber cushion to the rear
suspension support.
(4) lnstall the rear coil spring insulator io the rear suspen-
sion support.
NOTE:
Be sure to align the cut-out section of the rear coil spring
insulator with the stud bolt section of the rear suspension
support during the assembly.
L / I I
Fig. 6-51 WR-06051
(5) lnstall the rear suspension support. I I
NOTE:
Be sure to align the cut-out section of the rear suspen-
sion support with that of the piston rod during the
assembly.
Align the rear suspension support on the shock absorber
lower bracket, as shown in Fig. 6-53.
(6) Fit the suspension support. Tighten it temporarily,

using a new nut.
I J
Fig. 6-52 WR-06052
6-15
I I
Fig. 6-53 WR-06053
1
(7) Align the coil spring end with the recessed sections of
the upper and lower seats. Proceed to remove the
SST.
INSTALLATION
1. Install the suspension support to the body, using a new
nuts.
Tightening Torque: 1.O - 1.6 kg-rn (7.2 - 11.6 ft-lb)
I I
Fig. 6-55 WR-06055
2. Mount the axle carrier on the shock absorber. Fit the bolts
and new nuts in position and tighten them.
NOTE:
The steering carrier attaching nuts are special nuts on
which a friction stabilizing agent has been coated.
Hence, be certain not to reuse them.
Tighten the bolts and nuts while pushing the axle carrier
to the lower side (positive side).
I I I
Fig. 6-56 WR-06056
Install the flexible hose and brake tube, as follows: I (Drum brake equipped vehicle) I 1
(1) Install the flexible hose to the shock absorber. Secure

I
it with the clip.
(2) Install the brake tube to the flexible hose.
SST: 09751-36011-000
4. Tighten the suspension support attaching nut.

I I
Fig. 6-59 WR-06059
1
5. Trim installation
(1) Install the package tray side trim.
(2) Install the package tray.
Bolts
I
Fig. 660 WR-06060
6. Perform air bleeding for the brake system. (See page
8-5.)
7. Install the wheels. Jack down the vehicle.
8. Check the rear wheel alignment. (See page 5-38.)
WR-06061
SUSPENSION ARM
COMPONENTS
Unit: kg-m (ft-lb)
@ Suspension arm No. 1

@ Suspension arm No. 2
@ Rear axle carrier SIA
@ Strut rod
@ Toe adjust cam SIA
@ Toe adjust plate
1 Fig. 6-61
I
WR-06062
REMOVAL
1. Jack up the vehicle.
(1) Jack up the vehicle and support the body with safety
stands.
(2) Remove the wheel.
2. Removal of suspension arm No.2

(1) Remove the attaching bolt and nut of the stabilizer link.
(2) Remove the attaching bolt and nut of the suspension

arm at the axle carrier side.
Fig. 6-63 wR-06064

--
(3) Remove the attaching bolt of the suspension arm and

cam at the body side. Then, remove the suspension
arm.
NOTE:
Put a mate mark on the body bracket and the toe adjusting
cam so that the mark may be used as guide during the
installation.
Marks Hexagon wrench
(Width a c r 0 9
flats 8 mm)
Fig. 6-64 wR-06065
I
(4) Remove the rear stabilizer bar bracket from the
suspension arm.
I I
Fig. 6-65 WR-06066
Removal of suspension arm No.1 I 1
arm at the axle carrier side.
I I
Fig. 6-66 WR-06067
arm at the body side. Then, remove the suspension
arm.
I I
Fig. 6-67 WR-06068
INSPECTION
Suspension arm No.2
Inspect the parts as right figure.
I
Suspension arm No.1
INSTALLATION
NOTE:
The suspension arm attaching bolts are special bolts on
which a friction stabilizing agent has been coated. Hence,
be certain not to reuse them.
1. Installation of suspension arm No.1
(1) Tighten the suspension arm to the body temporarily
with the new bolt and nut.
(2) Tighten the suspension arm to the axle carrier tempo-
rarily with the new bolt and nut.
2. Installation of suspension arm No.2

(1) Install the rear stabilizer bar bracket to the suspension
arm.
I I
(2) Mount the suspension arm on the body.

(3) Tighten the suspension arm to the body temporarily
with the new bolt and cam.
(4) Prior to secure tightening, align the mate marks on the
toe adjuster cam and body with each other.
(5) Tighten the suspension arm to the axle carrier tempo-

rarily with the new bolt and nut.
(6) Tighten the attaching bolt and nut of the stabilizer link
to the specified torque.
Tightening Torque: 1.9 - 3.1 kg-rn (14 - 22 ft-lb)
3. Tightening of suspension arm attaching bolt

(1) Install the wheel.
a few times so as to settle the suspension.
Fig. 6-74 wR-06075

(3) With the vehicle weight applied to the suspension,
tighten the bolts and nuts.
[Suspension arm No.1]
(Axle carrier side)
(Body side)
[Suspension arm No.21

(Axle carrier side)
(Body side)
4. Check the rear wheel alignment.

(See page 5-38.)
STRUT ROD
REMOVAL
1. Jack up the vehicle.
(1) Jack up the vehicle. Support the body with safety stands.
(2) Remove the wheel.
2. Strut rod removal

(1) Remove the attaching bolt and nut of the strut rod at
the axle carrier side.
(2) Remove the attaching bolt and nut of the strut rod at
the body side. Then, remove the strut rod.
Fig. 6-77 WR-06079
INSPECTION
Inspect the parts as right figure.
INSTALLATION
1. Strut rod installation
(1) Tighten the strut rod to the body temporarily with the
new bolt and nut.
(2) Tighten the strut rod to the axle carrier temporarily with
the new bolt and nut.
NOTE:
The strut rod attaching bolts are special bolts on which a
friction stabilizing agent has been coated. Hence, be
certain not to reuse them.
Fig. 6-79 WR-06081
i
2. Tightening of strut rod attaching bolt
(1) Install the wheel.
a few times so as to settle the suspension.
Fig. 6-80 WR-06082

(3) With the vehicle weight applied to the suspension,

tighten the bolt and nut.
Check the rear wheel alignment. (See page 5-38.)
STABILIZER BAR
@ Nut
@ Washer
@ Bush
@ Bush
@ Washer
@ Stabilizer link S/A
@ Rear stabilizer bar bracket
@ Bush
Stabilizer bracket
@ Rear stabilizer
REMOVAL
1. Jack up the vehicle. Support the body with safety stands.
2. Stabilizer bar removal
(1) Remove the stabilizer bar attaching nuts from the
stabilizer link.
(2) Remove the stabilizer bar attaching bolts at the body

side. Remove the stabilizer bar.
(3) Remove the attaching bolts and nuts of the stabilizer

link. Remove the stabilizer link.
r i ,
(4) Remove the rear stabilizer bar bracket attaching bolts.

Proceed to remove the stabilizer bar bracket.
INSPECTION
I -
Deformation, damage
Deformation, damage
Deterioration
Deformation, damage Deformation, damage

Deformation, damage
Deformation, damage
Deformation, damage
I Fig. 6-87
I
WR-06088
1. Stabilizer bar installation

(1) Install the rear stabilizer bar bracket to the suspension
arm No.2.
Tightening Torque: 1.O - 1.6 kg-m (7.2 - 11.6 ft-lb)
(2) Tighten the stabilizer link to the rear. stabilizer bar

bracket temporarily with the bolts and nuts.
(3) Fit temporarily the bush, bracket and stabilizer bar to

the body.
(4) Fit the stabilizer bar to the stabilizer link. Tighten the
nuts temporarily.
NOTE:
Assemble the bush and bracket, as shown in the right
figure.
Tightening of bolts and nuts

(1) Tighten the nuts attaching the stabilizer bar to the
stabilizer link.
Tightening Torque: 1.O - 1.6 kg-m (7.2 - 11.6 ft-lb)
I I
Fig. 6-92 wR-06093
(2) Tighten the stabilizer bar attaching bolts at the body

side.
-
Tightening Torque: 1.0 1.6 kg-m (7.2- 11.6 ft-lb)
(3) Tighten the attaching bolts and nuts of the stabilizer

link.
I . - 1
Fig. 6-94 wR-06095
DAIHATSU
Chassis
SECTION 7
STEERING
STEERING.............................................................7- 2
SCHEMATIC VIEW ............................................ 7- 2
STEERING WHEEL .............................................7- 3
COMPONENTS ................................................. 7- 3
REMOVAL ......................................................... 7- 3
INSTALLATION ................................................. 7- 4
ENGINE KEY CYLINDER ...................................... 7- 5
REMOVAL ......................................................... 7- 5
INSTALLATION ................................................. 7- 5
STEERING COLUMN ........................................7- 6
COMPONENTS .................................................7- 6
REMOVAL .........................................................7- 6
DISASSEMBLY ...................................................7- 7
INSPECTION .......................................................7- 9
ASSEMBLY .......................................................7- 9
INSTALLATION ................................................. 7-1 0
STEERING GEAR ASSEMBLY ............................ 7-12
COMPONENTS ................................................. 7-12
REMOVAL ........................................................7-12
STEERING GEAR HOUSING ................................7-14
SECTIONAL VIEW ..............................................7-14
COMPONENTS ................................................. 7-1 5
DISASSEMBLY ..................................................7-16
INSPECTION ....................................................... 7-18
ASSEMBLY ....................................................... 7-18
INSTALLATION .................................................7-21
STEERING
STEERING
STEERING
STEERING WHEEL
COMPONENTS
Resin type
@) Steering wheel
0 Horn contact spring
0 @ Horn button contact ring or plate
@ Steering wheel pad set spring
@ Steering wheel pad SIA
Urethane type
0
@) Steering wheel
0 Steering wheel boss lower cover
@ Horn button contact plate
@ Horn contact spring
@ Horn contact spring set plate
@ Steering wheel cover SIA
@ Horn contact rlng
Fig. 7-2 WR-07003
REMOVAL
1. Disconnect the battery negative (-) terminal.
?. Hold the steering wheel pad at its lower end by your
fingers. Then, detach the steering wheel pad by pulling it
toward your side.
I I
Fig. 7-3 WR-07004
3. Remove the steering wheel lock nut. I I
L I
Fig. 7-4 WR-07005
STEERING
4. Remove the steering wheel, using the following SST.
SST: 09609-20011-000 09609-20011-000
INSTALLATION
1. Fit the steering wheel and tighten the lock nut.
2. Install the steering wheel pad.

3. Connect the battery negative (-) terminal.
L I
Fig. 7-7 WR-07008
STEERING
ENGINE KEY CYLINDER

REMOVAL
1. Loosen six screws and remove the steering column lower
cover.
Fia. 7-8 WR-07009

2. Engine key cylinder removal
(1) Fabricate a rod as shown in the right figure, by
bending an approx. 2 mm (0.08 inch) diameter rod.
(2) Set the engine key to the [ACC] position.
I I
Fia. 7-9 WR-07010
(3) While pushing the stop pin by means of the rod, draw
out the cylinder.
L I
Fia. 7-10
INSTALLATION 0 WR-07011
1. Engine key cylinder installation

(1) Insert a common screwdriver into the pawl groove of
the lock cylinder. Set the pawl groove to the [ACC]
position.
(2) Set the engine key to the [ACC] position. Insert the key
cylinder. Ensure that the stop pin is locked to the lock
cylinder.
groove I I
2. Install the steering column lower cover.
Fig. 7-11 WR-07012
STEERING
STEERING COLUMN
COMPONENTS
I
Unit: kg-m (ft-lb)
@ Steering column upper wlswitch

bracket
@ Steering column upper cover
@ Steering column lower cover
@ Snap ring
@ Steer~ngcolumn upper
attachment plate
@ Steering main shaft Ay
@ Steering column Ay
@ Steering shaft thrust stopper
@ Plate washer
@ Snap ring
@I Universal joint
@ Steering column hole cover
C-:] : ECE & EEC and Australian Specifications @ Main shaft lower dust cover
Fig. 7-12 WR-07013
REMOVAL
1. Disconnect the battery negative (-) terminal.
2. Remove the steering wheel. (See page 7-3.)
3. Detach the instrument lower finish panel and steering

column lower cover.
1 I
Fig. 7-14 WR-07015
STEERING
4. Remove the instrument panel lower reinforcement.

5. Remove the connectors for the multi-use lever switch and
engine key switch.
6. Remove the bolt of the universal joint.
7. Steering column assembly removal

(1) Remove three bolts and two nuts.
(2) Remove the steering column assembly from the body.
8. Remove the steering column upper cover and multi-use

lever switch from the steering column assembly.
DISASSEMBLY
1. Detach the snap ring and plate washer located at the
lower side of the steering main shaft.
Fig. 7-19 WR-07020

STEERING
2. Detach the snap ring located at the upper side of the

steering main shaft.
I I
WR-a7021
3. Steering main shaft subassembly removal
(1) Remove the steering main shaft subassembly by
tapping the main shaft lightly with a plastic hammer.
NOTE:
Never tap the main shaft strongly. If the main shaft should
be tapped strongly, the resin pin of the steering main shaft
may be damaged. (ECE & EEC and Australian specifica-
tions)
(2) Remove the stopper from the steering main shaft.
(3) Detach the snap ring from the steering main shaft.
Fig. 7-22
STEERING
-
lNSPECTlON
,nspect the following parts.
Damage or deformatton Bearing for wear or

rotating condlt~on
Damage or deformat~on
*' Resin pins for damage Bend or damage
Bearlng for wear or
k
Spider and yoke for
excesslve looseness
@&Stopper for breakage
f
&
Boots for breakage
3: *'Resin pln for damage
*': ECE & EEC and Australian specifications
Fig. 7-23 WR-07024
ASSEMBLY
1. Assembly of steering main shaft
\ (1) Fit a new snap ring to the steering main shaft.
(2) Place the stopper on the bearing.
2. Insert the main shaft (with the bearing) into the steering
column, using a plug wrench.
Fig. 7-25 WR-07026

STEERING
I/
3. Fit the new snap ring to the upper side of the steering
main shaft.
4. Install the plate washer and snap ring.
5. Install the multi-use lever switch to the steering column.
INSTALLATION
1. Steering column assembly installation
(1) Install the steering column upper cover to the steering
column.
(2) Tighten the attaching bolt of the universal joint.
( 3 ) lnstall the steering column with the three bolts and two
nuts.
Tightening Torque:
Bolt 1.5 - 2.2 kg-m (11 - 16 ft-lb)
Nut 2.5 - 3.5 kg-m (18 - 25 ft-lb)
STEERING
2. lnstall the connector for the multi-use lever and engine key
switch.
3. lnstall the instrument panel lower reinforcement.
4, lnstall the instrument lower finish panel and steering
column lower cover.
5. lnstall the steering wheel.
(See page 7-4.)
6. lnstall the battery negative (-) terminal.
. ..
I I
Fig. 7-31 WR-07032
STEERING
STEERING GEAR ASSEMBLY

COMPONENTS
1
Unit: kg-m (ft-lb)
@ Cotter pin @ Steering gear Ay

@ Castle nut @ Ball joint
@ Steering rack housing No.1 bracket @ Universal joint
I Fig. 7-32 WR-070
REMOVAL
1 . Jack up the vehicle at the front side. Support the body
with safety stands.
2. Remove the wheel.
3. Steering universal joint removal

(1) Remove the bolt.
(2) Remove the universal joint.
L I
Fig. 7-34 WR-07035
STEERING
4. Tie rod end removal
(1) Remove the cotter pins and castle nuts.
(2) Remove the tie rod end from the knuckle arm, using
the following SST.
SST: 09611-87701-000
5. Steering gear assembly removal

(1) Remove the four pieces of steering rack housing
bracket set bolts.
(2) Remove the steering gear assembly from the vehicle.
Fig. 7-37 WR-07038

STEERING
STEERING GEAR HOUSING

SECTIONAL VIEW
Steer~ngrack
F- Steering rack hous~ng
Steering rack
Fig. 7-38 WR-07039
Specifications
Maximum turns from lock to lock 3.82
Rack stroke mm (inch) 141.5 (5.571)

-
ti
Steering pinion tooth number
Rack tooth number 26
WR-07040
STEERING
@ Steering rack housing grommet @ Compression spring

@ Tie rod end S/A @ Rack
I guide
@ Nut @ Steering rack
@ Steering boot band No.2 @ Oil seal
@ Steering rack boot band @ Snap ring
@ Steering rack boot @ Shaft snap ring
a Steering rack end Radial ball bearing
@ Rack end plug @ Steering pinion
@ Hexagon nut @ Needle roller bearing
@ Rack guide spring cap @ Steering rack housing SIA
STEERING
DISASSEMBLY
1. Clamp the mounting section of the steering rack housing
in a vice with copper sheets or aluminum sheets inter-
posed.
or aluminum
I I
Fig. 7-40 WR-07042
2. Tie rod end removal I 1
(1) Before the steering tie rod end is removed, put a mark I ~ o c knut I
on the rack end section in order that this mark may be
used as guide to ensure easier toe-in adjustment
I Tie rod end \ Rackend I
during the reassembly.
(2) Slacken the lock nut. Remove the tie rod end from the
rack end.
3. Remove the boot band No.2 and rack boot band. Remove
the rack boot.
IFig. 7-41 I
WR-07043
I 1
4. Steering rack end removal
(1) Slacken the rack end plug, using the flat sections of
the steering rack (width across flats: 19 mm) and the Width across flats: Width across flats:
flat sections of the rack end plug (width across
flats: 26 mm).
(2) Remove the steering rack end from the steering rack.
(3) Remove the rack end plug from the steering rack end:
I 1
Fig. 7-42 WR-07044
5. Remove the lock nut (hexagon nut), using the following I I
SST.
SST: 09617-22030-000
I I
Fin- 743 WR-07045
6. Rack guide spring cap removal
(1) Remove the rack guide spring cap, using a simple
spinner.
Simple Spinner (Width across flats: 17 mm)
(2) Remove the compression spring and rack guide from
the steering rack housing.
STEERING
7. Remove the steering rack. 1 I

NOTE:
Be sure to draw out the rack toward the housing side so
that the rack bush may not be damaged by the rack
tooth surface.
Draw out the rack straight, not allowing the rack to
rotate.
<
IFia. 7-45 WR-07047

I
8. Remove the oil seal, using a common screwdriver or the
like. Be careful not to damage the housing during the
removal.
I I
Fia. 7-46 WR-07048
9. Detach the snap ring, using a snap ring expander
10. Remove the steering pinion, together with the bearing,

from the steering rack housing.
I I
Fig. 7-47 WR-07049
11. Radial ball bearing removal
(1) Detach the shaft snap ring, using a snap ring ex-
pander.
(2) Remove the bearing, using the following SST.
SST: 09950-20014-000
Fig. 7-48 WR-07050

STEERING
INSPECTION
Oil seal for damage
Steering rack
1. Tooth surface for wear
or damage
2. Bend
Ball loint for excessive looseness
Dust cover for wear, damage or .
deterioration
Rack bush for wear or damage
Crack, damage or evidence of deterioration
Damage or evidence of deterioration
Crack, damage or d~stortion
Fig. 7-49 WR-07051
ASSEMBLY
1. Apply grease to the following sections.
Oil seal lip section

*@
Ga
o Inside of bearing
ek
Boot retaining section
Whole portion of bush inside
1 Fig. 7-50 WR-07052

I
STEERING
'. Radial ball bearing installation
I
09612-10061-000
(1) Install the bearing to the steering pinion, using the
following SST.
SST: 09612-10061-000
(2) Attach the shaft snap ring, using a snap ring ex-
pander.
Fig. 7-51 wR-07053

3. Steering pinion installation
(1) Install the steering pinion to the steering rack housing,
SST: 09309-87102-000
09309-87102-000
(2) Attach the snap ring, using a snap ring expander.
I I
Fig. 7-53 WR-07055
3. Install the oil seal to the steering rack housing, using the
following SST.
SST: 09309-87201-000
Fig. 7-54
4. Assembly of steering rack
- WR-07056
(1) Apply EP grease to the tooth surface and whole

peripheral portion of the steering rack.
(2) Assemble the steering rack, paying attention not to
damage the rack bush.
1 I
Fig. 7-55 WR-07057
STEERING
5. Assemble the rack guide, compression spring and rack

guide spring cap to the steering rack housing.
Rack guide spring cap
6. Rack preload adjustment

(1) Tighten the rack guide spring cap, using a simple
spinner.
Tightening Torque: 0.7 kg-m (5.1 ft-lb)
Simple
(2) Move the steering rack back and forth about 15 times
so as to settle the steering rack. Then, proceed to
tighten the rack guide spring cap again.
Tightening Torque: 1.25 kg-m (0.9 ft-lb)
(3) Back off the rack guide spring cap 45"?;r, using a L I
Fig. 7-57 WR-07059
simple spinner.
(4) Measure the rack preload, using the following SST.
SST: 09616-87701-000
Specified Value [Starting Torque]:
3 - 6 kg-cm (2.6 - 5.2 inch-lb)
(5) If the preload does not comply with the specification,

repeat the operations (1) through (4).
7 . Hexagon nut (lock nut) installation

(1) Tighten the lock nut using the SST, while holding the
rack guide spring cap with a simple spinner so as to
prevent the rack guide spring cap from turning during
the tightening.
SST: 09617-22030-000
NOTE:
The actual reading of the torque wrench will be a product
that is obtained by multiplying the figure above by the
I I
following figure given below: Fig. 7-58 WR-07060
Length of torque wrench
+
Length of torque wrench 6 cm
(2) Check the pinion starting torque again.

SST: 09616-87701-000
Specified Value [Starting Torque]:
3 - 6 kg-cm (2.6 - 5.2 inch-lb)
STEERING
S. Steering rack end installation

(1) Screw in the rack end plug into the rack end.
(Set the rack end plug in such a way that the side , Steering rack Rack end
having a larger flange comes to the rack end side.)
(2) Under the condition described in (I), tighten the rack
end to the steering rack.
(3) Secure the steering rack. Tighten the rack end plug.
Tightening Torque: 5.0 - 6.5 kg-m (36- 47 ft-lb)
Rack end plug
9. lnstall the steering rack boot. lnstall the boot band No.2
and rack boot band.
I I
10. Tie rod end installation Fig. 7-60 WR-07062
(1) Screw in the lock nut and tie rod end into the rack end
up to the mating mark. Tighten the lock nut tempo-
rarily.
I Lock ?ut 1
(2) Tighten the lock nut securely after the toe-in check
and adjustment have been carried out.
I I
Fig. 7-61 WR-07063
INSTALLATION I I / I
1. Steering rack assembly installation
(1) lnstall the grommet to the steering rack assembly.
Then, insert it to the vehicle.
NOTE:
Be very careful not to damage the steering rack boot
during the insertion.
(2) lnstall the steering universal joint to the steering pinion.

Tighten the bolt temporarily. I I
Fia. 7-62 wR-07064
(3) lnstall the steering rack assembly to the body.
-
Tightening Torque: 4.0 - 5.5 kg-m (29 40 ft-lb)
Fig. 7-63 WR-07065

STEERING
2. Tighten the attaching bolt of the steering universal joint.

Tightening Torque: 2.5 - 3.5 kg-m (18- 25 ft-lb)
NOTE:
When tightening the bolt, be sure to limit the protruding
length of the serration sections of the universal joint and
pinion to 5 rnm (0.20 inch).
3. Tie rod end installation

(1) Install the tie rod end to the knuckle. Tighten the castle
nuts.
Tightening Torque: 3.0 - 4.5 kg-m (22 - 32.5 ft-lb)
(2) Install a new cotter pins.
I I
Fig. 7-65 WR-07067
4. Install the wheel. Jack down the vehicle.
5. Check the steering wheel play.
6. Perform the toe-in adjustment. (See page 5-44.)
7. Confirm the straight-ahead position of steering wheel.
WR-07068
Chassis
SECTION 8
BRAKES
BRAKE PEDAL CHECKS AND (7-inch Booster)

ADJUSTMENT ................................................ 8- 2 COMPONENTS .............................................8-21
BRAKE BOOSTER OPERATION CHECK ...... 8- 3 DISASSEMBLY ......................................... 8-22
;
AIR BLEEDING OF BRAKE SYSTEM ............. 8- 5 INSPECTION ................................................. 8-23

SCHEMATIC VIEW ........................................... 8- 6 ASSEMBLY ....................................................8-23
BRAKE PEDAL ...............................................8- 7 INSTALLATION .............................................8-26
COMPONENTS .............................................8- 7 FRONT BRAKE ................................................8-28
REMOVAL....................................................8- 7 SECTIONAL VIEW ........................................ 8-28
INSPECTION .................................................. 8- 8 COMPONENTS ............................................8-29
INSTALLATION .............................................8- 8 DISC BRAKE PAD .........................................8-30
BRAKE MASTER CYLINDER AND DISC BRAKE FRONT CALIPER ..................... 8-31
BRAKE BOOSTER ......................................... 8-1 0 REAR DRUM BRAKE ...................................... 8-37
SECTIONALVIEW .........................................8-10 SECTIONAL VIEW .........................................8-37
.
IASTER CYLINDER ........................................8-1 1 COMPONENTS .............................................8-37
COMPONENTS .............................................8-1 1 REMOVAL .....................................................8-38
REMOVAL..................................................... 8-12 INSPECTION .................................................. 8-40
DISASSEMBLY .............................................8-12 INSTALLATION .............................................8-41
INSPECTION ..................................................8-13 REAR DISC BRAKE ......................................... 8-45
ASSEMBLY...................................................8-13 SECTIONAL VIEW ......................................... 8-45
INSTALLATION .............................................8-14 COMPONENTS .............................................8-46
BRAKE BOOSTER ...........................................8-15 DISC BRAKE PAD .........................................8-47
(6-inch Booster) DISC BRAKE REAR CYLINDER .....................8-49
COMPONENTS .............................................8-15 PARKING BRAKE ............................................8-56
REMOVAL....................................................8-1 6 PARKING BRAKE LEVER ..............................8-56
DISASSEMBLY .............................................. 8-16 PARKING BRAKE CABLE .............................. 8-58
INSPECTION ..................................................8-17
ASSEMBLY....................................................8-18
BRAKES
BRAKE PEDAL CHECKS AND

ADJUSTMENTS
s
1. Pedal height check
Measure the brake pedal height (the dimension from the
center of the pedal applying surface to the dash panel).
Specified Value: 176 - 181 mm (6.93 - 7.13 inch)
Pedal height adjustment

(1) Disconnect the connector from the stop lamp switch.
Slacken the nut @) and turn the switch, until the pedal
has a free travel.
(2) Slacken the nut 0. Turn the push rod @ so as to
adjust the pedal height. Lock the nut 0.
(3) Turn the switch, until the pedal cushion comes in
contact with the edge of the threaded portion of the
stop lamp switch. Lock the nut 0.
(4) Connect the connector of the stop lamp switch.
(5) Upon completion of the pedal height adjustment,
ensure that the pedal free travel is proper and the stop
lamp functions properly.
3. Pedal free travel check

After stopping the engine, depress the brake pedal
strongly several times so that no vacuum may remain the
brake booster. Measure the brake pedal free travel by
pushing the brake pedal lightly by fingers. Here, the pedal
free travel means the distance from a point where the
brake pedal is free to a point where you begin to feel a.
resistance.
Specified Value:
6-inch Booster 3 - 7 mm (0.12 - 0.28 inch) Free travel
7-inch Booster 0.5 - 2 mm (0.02 - 0.08 inch)
4. Pedal free travel adjustment

(1) Slacken the nut 0. Turn the push rod @ so as to \ .
adjust the pedal free travel.

(2) Upon completion of the adjustment, ensure that the
pedal height is proper and the stop lamp functions
properly.
5. Pedal reserve travel check

With the engine running at the idling speed and with the
parking brake lever in its returned state, depress the
brake pedal with a pedal applying force of 30 kg (66 Ib).
Measure the gap between the position where the depress-
ed pedal stops and the floor panel. Pedal applying
Specified Value: 102 mm (4.0 inches) or more
G/ Pedal reserve travel

I I
Fig. 8-3 WR-08004
BRAKES
BRAKE BOOSTER OPERATION CHECK
b
1. SIMPLE CHECK
(1) Booster air-tight performance check
Start the engine. After running the engine for one to
two minutes, stop the engine. Depress the brake pedal 3r2 application
several times, applying a force which will be used
during normal brake applications. If the position of the \ 2nd appl~cat~on
brake pedal rises progressively at the second and \
third applications and so on, it indicates the brake Ist application
booster is functioning properly. Fig. 8-4 WR-08005
NOTE:
Intervals between the first and second applications as well
as between the second and third applications should be at
least five seconds.
(2) Booster air-tight performance check under loaded
condition
With the engine running, depress the brake pedal.
While maintaining this condition, stop the engine. If the
brake pedal height remains at the same level at least
30 seconds, it indicates that the booster is functioning
properly.
(3) Booster operation check

With the engine stopped, depress the brake pedal
several times, applying the same force at each brake
application. Ensure that the brake pedal height will not
vary at each brake application. Then, start the engine
while depressing the brake pedal. If the brake pedal
moves in slightly, it indicates that the booster is
functioning properly.
I I
Fig. 8-6 WR-08007
2. CHECK EMPLOYING PORTABLE BRAKE BOOSTER TESTER

(1) Connection of portable brake booster tester
Connect the portable booster tester. Carry out air bleeding for the booster tester.
I
BRAKES
(2) Booster air-tight performance check

Start the engine. When the negative pressure exceeds
500 mmHg, stop the engine. Proceed to measure the
negative pressure. Ensure that the negative pressure
will not drop for a period of 15 seconds following the
stoppage of the engine.
Negative pressure
I I
Fig. 8-8 WR-08009
(3) Booster air-tight performance check under loaded 25 m m ~ g
condition
With the engine running, depress the brake pedal with
a pedal applying force of 20 kg (44 lb). Stop the
4
engine when the negative pressure exceeds 500 mm
Hg, stop the engine. Proceed to measure the negative
pressure. Ensure that the negative pressure will not
drop more than 25 mmHg for a period of 15 seconds
following the stoppage of the engine.
f7)@ rpm xw
mrn H~
7
Engine running Negative pressure

Fig. 8-9 WR-08010
(4) No-boosting operation check

With the engine stopped, set the reading of the negative pressure gauge to zero. Under this
condition, check the relationship between the pedal applying force and the hydraulic pressure.
Specified Value:
I Pedahfp&$g force Hydraulic pressure

6-inch
kg/cm2 (Psi)
7-inch
WR-08011
(5) Boosting operation check

With the engine running, set the reading of the negative pressure gauge to 500 mmHg. After
stopping the engine, depress the brake pedal. Check the relationship between the pedal applying
force and the hydraulic pressure.
Specified Value:
Hydraulic pressure kg/cm2 (Psi)
Pedal applying force
kg (Ib) 6-inch 7-inch
5 (11) 18.4 (262) 13.6 (193)

10 (22) 46.4 (660) 34.2 (487)
15 (33) 56.0 (797) 54.8 (779)
20 (44) 63.9 (909) 67.2 (955)
BRAKES
AIR BLEEDING OF BRAKE SYSTEM ,
1. Filling brake fluid

Fill the brake master cylinder reservoir with the brake fluid.
NOTE:
If the brake fluid is spilled inadvertently over the paint-finish Loosen
surface of the vehicle, quickly wipe off the brake fluid.
1 I I
Fig. 8-10 WR-08013
2. Connection of vinyl hose to bleeder plug of wheel I 1
cylinder
(1) Submerge one end of a vinyl hose in a container filled
with the brake fluid. Connect the other end of the vinyl
hose to the wheel cylinder bleeder plug of the vehicle.
(2) Start this air bleeding operation at the wheel cylinder
which is located at the farthermost point from the
master cylinder.
3. Air bleeding
(1) Perform the operation by two persons. One person
should depress the brake pedal slowly and hold it in a
depressed state.
(2) The other person slackens the bleeder plug 113
through 112 turn at a time. Be sure to tighten the
bleeder plug before the hydraulic pressure ceases to
exist in the cylinder.
(3) Repeat the steps (1) and (2) above , until you no
longer observe bubbles in the fluid.
4. Checking of brake fluid leakage

Depress the brake pedal and ensure that each section of
the pipe line exhibits no fluid leakage.
WR-08016
BRAKES
I I
Fig. 8-13 wR-08017
BRAKES
BRAKE PEDAL
COMPONENTS
Manual Transmission Automatic Transmission
Unit: kg-m (ft-lb)
@) Brake pedal @ Bolt

@ Brake pedal pad @ Nut
Cushion @ With-hole pin
@ Spacer @ Clip
@ Spring @ Brake
I pedal bracket
REMOVAL
1. Detach the clamp of the stop lamp switch wiring.
2. Remove the clip and the with-hole pin from the connecting
section of the master cylinder push rod with the brake
pedal.
BRAKES
3. Remove the brake pedal attaching bolt and nut.

4. Remove the brake pedal from the brake pedal bracket.
Brake pedal bracket Brake pedal

I I
Fig. 8-16 WR-08020
5. Remove the spring, bush, spacer, brake pedal pad and
cushion from the brake pedal.
Spacer
Bush-@
I Spring
~rake'pedalpad
Fig. 8-17 WR-08021-
INSTALLATION
1, Install the cushion, brake pedal pad, spacer, bush and
spring on the brake pedal.
1 I
Fig. 8-19 wR-08023
BRAKES
2. Install the brake pedal on the brake pad brake.

3. Install the brake pedal attaching bolt and nut.
4. Install the with-hole pin and the clip on the connecting

section of the master cylinder push rod with the brake
pedal.
5. Attach the clamp of the stop lamp switch wiring.
6. Perform the check and adjustment of the brake pedal.
(See page 8-2.)
. .
I
Fig. 8-21 wR-08025
BRAKES
BRAKE MASTER CYLINDER AND BRAKE BOOSTER

BRAKES
MASTER CYLINDER
COMPONENTS
6 inch
Unit: kg-m(ft-lb)
@ Brake master cylinder Ay @ Master cylinder reservoir Ay

Reservoir filler cap @ Clamp
@ Reservoir cap spacer @ Set bolt
@ Reservoir diaphragm @ Gasket
@ Master cylinder reservoir float 0 Gasket
@ Tandem master cylinder repair kit
BRAKES
REMOVAL
1. Remove the level switch connector.
2. Drain the brake fluid.
3. Disconnect the three brake tubes, using the following SST.
SST: 09751-36011-000
NOTE:
If the brake fluid is spilled inadvertently over the paint-finish
surface of the vehicle, quickly wipe off the brake fluid.
4. Remove the two attaching nuts of the master cylinder

Remove the master cylinder and gasket from the brake
booster.
DISASSEMBLY
Reservoir filler
1. Clamp the flange section of the master cylinder in a vise, cap
IIilJU
-Reservoir cap
with jaw plates or the like interposed. Reservoir diaphragm- Spacer
NOTE: Master cylinder
Be sure not to clamp the cylinder portion of the master
cylinder in a vise. Failure to observe this caution will cause
reservoir Ay
cylinder distortion.
-Clamp
2. Remove the reservoir filler cap, reservoir diaphragm,
reservoir cap spacer, master cylinder reservoir float,
clamp and master cylinder reservoir assembly from the Fig. 8-26 WR-08030
master cylinder. I
3. Remove the set bolt and gasket while the pistons are
being pushed fully by means of a cross point screwdriver.
NOTE:
During the removal, be sure to push the piston slowly so as
to prevent the brake fluid from splashing.
4. Detach the snap ring.

Using a snap ring, detach the snap ring while the pistons
are being pushed by means of a screwdriver.
5. Remove the pistons No.1 and No.2 from the master
cylinder.
1
Fig. 8-28 WR-08032
8-12
BRAKES

1 I
Damage
Damage
Deterioration or
deformation
%-- Cylinder bore for uneven wear,

damage or corrosion
I
Fig. 8-29 wR-08033
ASSEMBLY
1. Assemble a new tandem master cylinder repair kit (comprising the pistons No.1 and No.2) in the master
cylinder.
NOTE:
Apply rubber grease to those points indicated by arrow heads in the figure below.
I Fig. 8-30
I
WR-08034
2. Install the snap ring.

With the pistons in their fully pushed-in state, install a new
snap ring.
I I
Fig. 8-31 WR-08035
BRAKES
3. While pushing the pistons fully by means of a cross point

screwdriver, assemble the set bolt with a new gasket
interposed.
4. Install the clamp, master cylinder reservoir assembly,

master cylinder reservoir float, reservoir cap spacer,
reservoir diaphragm and reservoir filler cap.
Fig. 8-32
cap
+d
Reservoir filler
Reservoir
diaphragm
-
a
Reservoir cap
spacer
Master cylinder
reservoir float
I
wR-08036
1
Master cylinder
reservoir Ay
Clamp
0 1 I
I I
Fia. 8-33 WR-08037
INSTALLATION
1. Adjust the clearance of the brake booster push rod.
&inch Booster: See page 8-20.
7-inch Booster: See page 8-26.
2. With a new gasket interposed, install the master cylinder,
using the two nuts.
NOTE:
The master cylinder's attaching nut at the right side, as
viewed toward the vehicle, should be used to tighten the
bracket, too.
3. Connect the brake tubes.

(1) Temporarily connect the three brake tubes to the
master cylinder by hands.
(2) Tighten the brake tube, using the following SST.
SST: 09751-36011 -000
I I
Fig. 8-35 WR-08039
4. Connect the level switch connector.
5. Fill the brake fluid.
6. Perform air bleeding for the brake system.
(See page 8-5.)
7. Check the brake system for brake fluid leakage.
8. Perform the checks and adjustments for the brake pedal.
(See page 8-2.)
BRAKES
BRAKE BOOSTER
COMPONENTS
(6-inch Booster)
Unit: kg-m (ft-lb)
+ : Non-reusable parts
@ Master cylinder push rod clevis @ Element

@ Nut @ Spring seat
@ Booster body @ Valve spring
@ Booster spring @ Poppet spring
@ Output rod @ Valve stopper
@ Rod seal @ Poppet valve
0Boot @ Booster housing
@ Rod stopper Q Push rod Wtvalve
@ Reaction ring Q Bush stopper
@ Reaction rubber @ Bush
@ Reaction plate @ Piston seal
@ Snap ring @ Diaphragm
@ "Enring @ Booster piston
@ Plate washer
I
Fig. 8-36 WR-08041
8-15
BRAKES
- --
REMOVAL - . Front suspension upper brace'

1. Remove the master cylinder. (See page 8-12.)
2. Disconnect the vacuum hose.
3. Remove the front suspension upper brace subassembly.
(RHD TURBO and GTtl grades only)
4. Remove the clutch cable and ignition coil.
(LHD TURBO and GT,, grades only)
5. Working from the passenger room side, remove the clip
and the with-hole pin. Separate the master cylinder push
rod clevis and from the brake pedal. (See Fig. 8-15.)
Fia. 8-37 WR-08042
6. Remove the brake booster assembly.
(1) Remove the four attaching nuts of the brake booster,
using a long socket wrench (having a width across flat
of 12 mm), as indicated in Fig. 8-38.
I Long socket wrench
I 11
(2) Remove the brake booster assembly and gasket from
the vehicle.
(6-inch Booster)
DISASSEMBLY
1. Remove the master cylinder pushrod clevis and lock nut.
2. Separate the booster housing from the booster body as
follows:
(1) Put mate marks on the booster body and booster
housing.
Fig. 8-40 WR-08045

(2) Secure the brake booster on the following SST.
SST: 09753-87701-000
NOTE:
Be certain to evenly tighten the SST nuts at the right and
left sides. Also, be very careful not to tighten the SST nuts
excessively.
(3) Turn the SST screw clockwise so as to disengage the

booster housing from the booster body.
(4) Detach the brake booster from the SST.
I I
Fig. 8-41 WR-08046
8-16
BRAKES
(5) Disassemble the brake booster.
Reaction rubber
INSPECTION
I I
Bend Damage
V
Damage or deformation
9-QOQ
Bend
ama age or deformation
I
Fig. 8-43 WR-08048
BRAKES
ASSEMBLY
1. Application of silicon grease
Apply silicon grease to those points indicated by arrow heads in the figure below.
I Fig. 8-44
I
WR-08049
2. Assemble the following parts in the booster piston.

(1) lnstall the diaphragm in position.
(2) Assemble the push rod with valve. Retain it with the
snap ring.
(3) lnstall the reaction plate, reaction rubber and reaction

ring.
(4) Install the rod stopper.
3. Assemble the following parts in the booster housing.

(1) Install the piston seal, bush and bush stopper.
(2) lnstall the booster piston.
Fig. 8-47 WR-08052

BRAKES
(3) Assemble the poppet valve to the valve stopper. Then, &-Spring
install them in the booster housing. seat
(4) Install the poppet spring, valve spring and spring seat Valve
spring
in place.
8-poppet
Fia. 8-48 wR-08053

(5) lnstall the element, plate washer and "E" ring.
(6) Install the boot.
I I I
Fig. 8-49 wR-08054
4. Assemble the booster body and booster housing as
~OIIOWS: 09753-87701-000
(1) Place the booster body and booster spring in the
following SST.
SST: 09753-87701-000
Fia. 8-50 WR-08055

(2) lac el the booster housing in the following SST.
SST: 09753-87701-000
NOTE:
excessively.
Furthermore, care must be exercised to ensure that the
diaphragm will not be pinched.
Fia. 8-51 WR-08056

(3) Turn the SST screw counterclockwise so that the
mating marks may be lined up.
If the force required for turning is great, apply a small
amount of silicon grease to the portion where the
booster body is making contact with the booster
housing.
(4) Remove the brake booster from the SST.
I I
Fig. 8-52 WR-08057
BRAKES
5. Install the output rod and rod seal in the brake booster.
6. Temporarily install the master cylinder push rod clevis and
nut.
Fig. 8-53 WR-08058

7. Adjust the brake booster push rod clearance as follows:
09737-22011-000
(1) Set the SST in such a way that the SST rod makes a
light contact with the piston of the master cylinder, as
indicated in Fig. 8-54.
SST: 09737-22011-000
NOTE:
Be sure to carry out this adjustment with the gasket
attached in position.
II ~ a s t k cylinder
r I
I
Fig. 8-54 WR-08059
(2) Connect a MityVac to the union of the brake booster. Booster body
Apply a negative pressure of 500 mmHg.
(3) Set the SST as indicated in Fig. 8-55. Adjust the push
rod so that the push rod clearance may become zero.
Fig. 8-55
/
Push rod
WR-08060
I
(4) Perform the adjustment of the push rod clearance by
turning the nut provided at the tip end of the push rod.
I
Fig. 8-56 WR-08061
BRAKES
COMPONENTS
(7-inch Booster)
Unit: kg-m (ft-lb)
( i
Jcylinder push rod clevis
Master @ Adjuster nut
@ Nut @ Element B
@ Rod seal @ "E" ring
@ Booster body @ Element A
@ Retainer spring @ Control valve spring retainer
@ Booster spring @ Piston return spring retainer
a Booster piston rod @ Valve spring
@ Reaction disc Q Control valve spring
@ Reaction plate @ Air valve spring retainer
@ Booster housing @ Poppet valve
@I Booster push rod seal retainer Q Booster with rod, valve SIA
@ Valve ring Q Set cover
@ Piston seal Q Valve body
@ Nut @ Diaphragm
@ Booster plate
Fig. 8-57
8-21
BRAKES
(7-inch Booster)
DISASSEMBLY
1. Remove the master cylinder push rod clevis and lock nut.
2. Remove the rod seal.
3. Separate the booster housing from the booster body as
follows:
(1) Put mate marks on the booster body and booster
housing.
I I
Fig. 8-58 WR-08063
t
(2) Secure the brake booster on the following SST.
SST: 09753-87701-000
NOTE:
excessively.
(3) Turn the SST screw clockwise so as to disengage the

booster housing from the booster body.
1 I
Fig. 8-59 WR-08064
4. Disassemble the brake booster.
I 1
Element B
\ Piston seal
Adjusting nut Booster push rod

seal retainer /
Booster housing
I Fig. 8-60
I
WR-08065
BRAKES
'NSPECTION
I I
Fig. 8-61 WR-08066
ASSEMBLY
1. Application of silicorl grease
Apply silicon grease to those points indicated by arrow heads in the figure below.
I 1
I
Fig. 8-62 WR-08067
8-23
BRAKES
2. Assemble the following parts in the booster valve sub-

assembly with rod.
(1) lnstall the poppet valve in the air valve spring retainer.
lnstall them in the booster valve subassembly with rod.
(2) lnstall the control valve spring, valve spring, control
valve spring retainer, element and "Enring.
Air valve sprlng retainer
3. lnstall the booster valve subassembly with rod and the

piston return spring retainer in the valve body.
1
Fig. 8-63 wR-08068
4. lnstall the element, adjusting nut and nut in place.
Element
Adlusting nut I
I
Fig. 8-64 WR-08069
1
Assemble the following parts in the booster plate.
Booster plate
(1) lnstall the diaphragm. Booster piston rod
(2) lnstall the valve body, reaction plate, reaction disc and <
booster piston rod.
I \
Set cover
Fig. 8-65
I
deaction plate
I
WR-08070
I
(3) lnstall the set cover as follows:
a Temporarily install the set cover on the booster
plate.
a Assemble the set cover by pinching the joint section
of the booster plate with the claw section of the set
cover, using pliers.
a Slide the claw section of the set cover using a
common screwdriver, until it is no longer possible to
move the claw section.
I I I
Fig. 8-66 WR-08071
8-24
BRAKES
5. Install the piston seal, valve ring and booster push rod
seal retainer in the booster housing.
I I
Fig. 867 WR-08072
7. Assemble the booster housing and booster plate.
1 I
Fig. 868 WR-08073
Assemble the booster body and booster housing as
0?753-87701-000
follows:
(1) Place the booster body, spring retainer and booster
spring in the following SST.
SST: 09753-87701-000
I I
Fig. 8-69 WR-08074

(2) Place the booster housing in the following SST. 09753-87701-000
SST: 09753-87701-000
NOTE:
excessively.
Furthermore, care must be exercised to ensure that the
diaphragm will not be pinched.
I ' I
I
Fig. 8-70 WR-08075
(3) Turn the SST screw counterclockwise so that the
mating marks may be lined up.
If the force required for turning is great, apply a small
amount of silicon grease to the portion where the
booster body is making contact with the booster
housing.
I I
Fig. 8-71 WR-08076
8-25
BRAKES
9. Install the rod seal in the brake booster.

10. Temporarily install the master cylinder push rod clevis and
nut.
11. Adjust the brake booster push rod clearance as follows:

(1) Set the SST in such a way that the SST rod makes a
light contact with the piston of the master cylinder, as
indicated in Fig. 8-73.
SST: 09737-87001-000
NOTE:
Be sure to carry out this adjustment with the gasket
attached in position.
(2) Set the SST as indicated in Fig. 8-74. Adjust the push
rod so that the push rod clearance may become zero.
(3) Perform the adjustment of the push rod clearance by

turning the nut provided at the tip end of the push rod.
INSTALLATION
1. Install the brake booster on the body with a new gasket
interposed, using the four nuts.
2. Attach the master cylinder push rod clevis to the brake
pedal by means of the with-hole pin and clip.
BRAKES
3. Attach the vacuum hose. Front suspension upper brace

[I I
4. Install the front suspension upper brace subassembly. 1
(RHD TURBO and GTti grades only)

5. Install the clutch cable and ignition coil.
(LHD TURBO and GT,, grades only)
6. Install the master cylinder. (See page 8-14.)
BRAKES
FRONT BRAKE
BRAKES
COMPONENTS
Unit: kg-m (ft-lb)
* : on-reusable parts
' GTti grade I I

1 General specifications except forI TURBO, '
@ Disc brake front caliper Ay @ Piston boot

@ Bolt @ Bush retainer
@ "Enring @ Cylinder slide bush
@ Tube clamp @ Anti-rattle spring No. 2
@ Flexible hose @ Set ring
@ Screw @ Cylinder boot
Front disc @$ Front disc brake piston
@ Disc brake pad @ Piston seal
@ Anti-rattle spring No. 1 @ Bleeder plug cap
@ Pad wear indicator plate Q Bleeder plug
0 Bush dust boot @ Disc brake pad guide plate
@! Bush retainer Q Anti-squeal sihm No. 1
@ Cylinder slide bush Q Anti-squeal sihm No. 2
I
Fig. 8-79 wR-08084
BRAKES
DISC BRAKE PAD

REMOVAL
1. Jack up the front end of the vehicle. Support the body with
safety stands. Remove the front wheel.
2. Inspect the brake pad thickness through the inspection
hole provided in the disc brake front caliper.
General specifications
except for Others
TURBO, GTti grade
Specified Thickness 10 mm (0.39 inch) 9 mm (0.35 inch)
Minimum Limit 1 mm (0.04 inch) 1 mm (0.04 inch)
3. Remove the two attaching bolts of the disc brake front

cylinder assembly.
4. Remove the disc brake pad and anti-squeal shim.

5. Detach the disc brake pad guide plate.
6. Check the front disc thickness. (See Fig. 8-98.)
except for Others
TURBO, GTti grade
7. Drain a small amount of brake fluid from the master

cylinder reservoir. Push in the piston with the handle of a
hammer or the like.
NOTE:
Be sure to carry out the pad replacement operation for one
wheel at a time, for there is a possibility that the piston at
the opposite side may be jumped out.
I I
Fig. 8-83 WR-08088
INSTALLATION
I . Install a new disc brake pad guide plate on the knuckle.
Fig. 8-84 WR-08089

BRAKES
2. Assemble a new anti-squeal shim at a new disc brake pad

(outboard side). Then, install them on the disc brake front I General specificationsexcept
for TURBO. GT. arade Other specifications I
caliper.
I . -- I
Fia. 8-85 WR-08090
3. Install the disc brake front caliper assembly on the
knuckle.
NOTE:
Care must be exercised so that the caliper boot may not be
pinched during the installation.
I. Install the front wheel.

5. Fill the brake fluid up to the "MAX" reference line of the
master cylinder reservoir.
DISC BRAKE FRONT CALIPER

REMOVAL
1. Jack up the front end of the vehicle. Support the body with
safety stands. Remove the front wheel.
2. Disconnect the flexible hose as follows:
(Body side)
(1) Separate the flexible hose from the brake tube, using
the following SST.
SST: 09751-36011-000
(2) Detach the clip. I I I
Fia. 8-87 WR-08092
(Shock absorber side)
(3) Detach the clip.
(4) Disconnect the flexible hose from the shock absorber
bracket.
(5) Disconnect the flexible hose from the disc brake front
1
caliper, using the following SST.
SST: 09751-36011-000
Fig.
BRAKES
3. Remove the caliper from the vehicle by removing the two
attaching bolts of the disc brake front caliper.
4. Detach the disc brake pad from the disc brake front
caliper.
I I
WR-08095
DISASSEMBLY
1. Remove the following parts from the disc brake front
caliper.
(1) General specifications except for TURBO, GT,, grade
.boot
Bush dust
(Bush dust boot, bush retainer, cylinder slide bush,

bleeder plug and plug cap)
(2) Other specifications

(Piston boot, bush dust boot, bush retainer, cylinder
slide bush, bleeder plug and plug cap)
.BUS^ dust bootbush ]

I
Fig. 8-92
Bleeder plug
WR-08097
2. Detach the cylinder boot set ring and cylinder boot, using 1
a common screwdriver.
1Fig. 8-93 WR-08098

I
3. With a wooden piece or a cloth placed at the end of the I I
disc cylinder, as indicated in the right figure, drive out the

piston by applying compressed air.
NOTE:
Special caution must be exercised so that no brake fluid
may be splashed. Also, be very careful not to allow your
finger be pinched.
I I
Fig. 8-94 WR-08099
8-32
BRAKES
- - -
4. Detach the piston seal, using a common screwdriver.
Fia. 8-95 WR-08100

INSPECTION Cylinder for distortion or cracks
1. Inspect each part of the disc brake front caliper assembly. Cylinder bore for uneven wear
Be sure to replace them
with new ones (kit parts).
Piston for uneven

wear or damage
Damage or deterioration
Fia. 8-96 WR-08101
2. Measurement of pad thickness
except for Others
TURBO, GTti grade
I I
Fig. 8-97 WR-08102
3. Checking of disc thickness I 1
GT,, grade
I I
Fig. 8-98 WR-08103
4. Replace the front disc.
Fig. 8-99 wR-08105

BRAKES
ASSEMBLY
1. Apply rubber grease to those points indicated by arrow heads in the figure below.
I
I (7) General specifications except for TURBO, GTI grade (8) Other specifications I
I Fig. 8-100
I
WR-08106
2. Assemble the piston seal and piston.

(1) Assemble the piston seal in the disc brake front
caliper.
I I
WR-08107
(2) Insert the piston into the disc brake front caliper,
making sure that the piston is not tilted during the
installation.
I I
Fig. 8-102 WR-08107A
3. Assemble the cylinder boot in the disc brake front caliper.
NOTE:
Make sure that the boot is fitted securely in the groove.
4. Assemble the cylinder boot set ring, making sure that no

scratch is made to the boot.
I I
Fig. 8-103 wR-08108
8-34
BRAKES
5. Assemble those parts indicated in the figure below in the disc brake front caliper.
I
General specifications except for TURBO, GT,, grade Other specifications
Bush retainer
Bush retainer
Bush dust boot Cylinder slide bush linder slide bush
Bush dust boot
Cylinder slide bush

Bush dust boot
~ u s dust
h boot Cylinder slide bush
Fig. 8-1 04 wR-08109
INSTALLATION General specifications except

for TURBO, GT, grade Other specifications
1. Install the disc brake pad guide plate on the knuckle. (See
Fig. 8-84.)
2. Install the anti-squeal shim at the disc brake pad (out-
board side). Then, install them on the disc brake front
caliper.
3. Install the disc brake front caliper assembly on the

knuckle.
NOTE:
Care must be exercised so that the caliper boot may not be
pinched during the installation.
1 I
Fig. 8-106 WR-08111
I
4. lnstall the flexible hose.
(1) Attach the flexible hose to the disc brake front caliper,
SST: 09751-36011-000
(2) Attach the flexible hose to the bracket section at the
shock absorber side, using the clip.
BRAKES
(3) Temporarily install the flexible hose and brake tube by

hands.
(4) Tighten the flexible hose and brake tube.
NOTE:
1
Make sure that the flexible hose is not twisted or stretched
excessively.
(5) Attach the clip at the bracket section at the body side.
NOTE:
After completion of the installation, turn the steering wheel
Fig.
from lock to lock position. Make sure that the flexible hose
is not interfering with any part of the body.
5. Perform air bleeding for the brake system.

(See page 8-5.)
6. Check the brake system for brake fluid leakage.
(See page 8-5.)
BRAKES
REAR DRUM BRAKE

SECTIONAL VIEW
. Fig. 8-109 WR-08115
COMPONENTS
@ Grease cap @ Automatic adjusting latch @ Bolt

@ Cotter pin @ Torsion spring @ Compression spring
@ Castle nut @ Automatic adjusting lever pin @ Cylinder cup
@ Plate washer @ Tension spring @ Wheel brake cylinder piston
@ Brake drum Ay @ Parking brake shoe strut Q Wheel cylinder boot
@ Bolt @ Tension spring @ Bolt
@ Shoe hold-down spring @ Tension spring @ Shoe hold-down pin
@ Brake shoe @ Parking brake shoe lever S/A @ Rear brake backing plate S/A
@ "C" ring @ Rear wheel brake cylinder Ay @ Hole
i)plug
@ Automatic adjusting lever S/A @ Bleeder plug
Washer Q Bleeder plug cap
Fig. 8-110 WR-08116
BRAKES
REMOVAL
1. Jack up the rear section of the vehicle. Support the body
with safety stands. Remove the rear wheel. Castle nut
2. Remove the grease cap, cotter pin, castle nut and plate
washer. / Cotter pin
platewasher
I cap
~rease I
3. Remove the brake drum, using the following SST.
SST: 09510-87301-000
4. Remove the tension spring, using the following SST.

SST: 09703-30010-000
5. Detach the tension spring, using a common screwdriver.
1 I
Fig. 8-114 WR-08120
6. Removal of brake shoe (leading side) r 1
(1) Detach the shoe hold-down spring and pin.

(2) Remove the brake shoe, parking brake shoe strut and
tension spring at the leading side.
I I I I
Fig. 8-1 15 WR-08121
BRAKES
7. Brake shoe (trailing side) removal

(1) Remove the shoe hold-down spring and pin.
(2) Remove the parking brake cable from the parking
brake shoe lever, using pliers.
Fig. 8-116 wR-08122
8. Detach the "C" ring, using a common screwdriver. Remove the parking brake shoe lever and automatic
adjusting lever-related parts.
9. Wheel cylinder removal

(1) Disconnect the brake tube from the wheel cylinder,
SST: 09751-36011-000
(2) Remove the two attaching bolts of the wheel cylinder.

Proceed to remove the wheel cylinder from the back-
ing plate.
NOTE:
The wheel cylinder can be disassembled or checked with
I I
the wheel cylinder mounted on the backing plate. It is, Fig. 8-118 WR-08124
therefore, unnecessary to remove the wheel cylinder from
the backing plate except for cases where the wheel
cylinder assembly is replaced.
BRAKES
10. Remove the following parts from the wheel cylinder.

(1) Wheel cylinder boots (2 pieces)
(2) Wheel cylinder pistons (2 pieces)
(3) Wheel cylinder piston cups (2 pieces)
(4) Compression spring
Q
@Q@
Fig. 8-1 19 wR-08125
INSPECTION
Deformation
Brake shoe contacting surface for wear
Brake shoe and lining

@ Shoe for damage, deformation
wear
I
Fig. 8-120 WR-08126
1. Rear brake backing plate replacement I I

(1) Remove the four attaching bolts of the rear brake
backing plate.
(2) Apply Daihatsu Bond No.4 (999-6304-6323-00) to the
installation surface of the rear brake backing plate with
the rear axle carrier. At this time, do not plug the
grease releasing hole [5 mm (0.20 inch) dia.] with the
grease.
(3) Install the rear brake backing plate, using the four
bolts. 5 (0.20 inch) dia. hole
I I
Fig. 8-121 WR-08127
2. Brake drum replacement
(1) Apply Mp grease to the points indicated in the right
I Pack arease. (15 g)
figure.
I I
Fig. 8-122 WR-08128
BRAKES
(2) lnstall the outer bearing, using the following SST.

SST: 09608-12010-000 (No.13 in the set)
(3) lnstall the outer retainer.

(4) lnstall the inner bearing, using the following SST.
SST: 09608-1201 1-000 (No.5 in the set)
I I I
Fia. 8123 WR-08129
INSTALLATION
1. Assembly of wheel cylinder
(1) Apply rubber grease to the points indicated by arrows.
(2) Assemble the cup on the wheel cylinder piston.
NOTE:
@
4re
@
b: applyinggrease
points
Be sure to install the cup in the correct direction.
(3) lnstall the two pistons and compression spring to the ( WJ Rubbergrease
applying points
wheel cylinder.
(4) Assemble the two wheel cylinder boots.
Fia. 8-124 WR-08130
2. Wheel cylinder installation
(1) Apply liquid gasket to the installation section of the
rear brake backing plate with the wheel cylinder.
I Liquid gasket applying point
(Wheel cylinder installation surface)
(2) lnstall the wheel cylinder to the rear brake backing

plate, using the two bolts.
3. Brake tube installation

(1) Install the brake tube to the wheel cylinder temporarily
by hands.
(2) Tighten the brake tube to the wheel cylinder, using the
following SST.
SST: 09751-36011-000
1 I
Fig. 8-126 WR-08132
BRAKES
Apply brake grease to the contacting points of the rear

brake backing plate with the brake shoe.
NOTE:
Be careful not to allow lubricants, such as grease, to get to
the wheel cylinder boot.
Fig. 6-128
Assembly of brake shoe (trailing side)
(1) Assemble the parking brake cable to the parking
brake shoe lever, using pliers.
(2) Assemble the brake shoe on the rear brake backing
plate. Install the shoe hold-down spring and pin.
NOTE:
Apply liquid gasket to the installation section of the rear
brake backing plate with the shoe hold-down spring.
I I I
WR-08135
Fig. 8-129
BRAKES
I I
Shoe hold-down pin
surface of hole.
Fig. 8-130 wR-08136
7. Assemble the brake shoe (leading side) on the rear brake
backing plate. lnstall the shoe hold-down spring and pin.
I I I
Fig. 8-131 WR-08137
8. Install the tension spring, using a cross point screwdriver.
9. lnstall the tension spring, using'the following SST.

SST: 09703-30010-000
NOTE:
~6
the in#tion.
-
Be careful t to damaae the wheel cylinder boot during- I
Fig. 8-133 WR-08139

BRAKES
10. Ensure that the rear brake components have been assembled properly.
-
Front
- Front
Left Wheel Right Wheel
Fig. 8-134 WR-08140
11. Brake adjustment procedure

(1) Retract the shoe by moving the engagement of the
parking brake shoe strut, using a common screwdriver
or the like.
(2) Brake drum installation

(Bearing inner retainer, brake drum. plate washer,
castle nut, new cotter pin and grease cap)
(3) Perform air bleeding for the brake system. (See page
8-5.)
@//( Castle nut
Cotter pin
(4) Check the brake system for brake fluid leakage.

(5) Depress the brake pedal and ensure that the automa-
tic adjusting mechanism emits operating sound. Re-
peat this operation until you no longer hear the
Plate washer - Q Grease cap
WR-0814
operating sound.
(6) Adjust the working travel of the parking brake lever.
(See page 8-57.)
BRAKES
REAR DISC BRAKE
Adjuster sleeve
,
BRAKES
COMPONENTS
Unit: kg-m (ft-lb)
@ Grease cap 0 Clip

@ Cotter pin @ Parking brake clamp S/A
@ Castle nut @ Parking brake strut
@I Plate washer @ 011seal
@ Brake rear disc S/A @ Screw plug
@ Brake dust cover Q Gasket
@ Disc brake caliper Ay @ Bleeder plug cap
@ Hexagon socket head cap bolt @ Bleeder plug
@ Bush dust boot Q Set ring
@ Cylinder slide bush @ Cyllnder boot
@ Bolt Q Disc brake piston S/A
@ Cable support bracket @ P~stonseal
@ Anti-rattle spring @ Hole snap ring
@ Disc brake cylinder mounting @ "0"rlng
@ Disc brake pad @ Pad adjusting bolt
@ Torsion spring Q Disc brake rear cylinder
Fig. 8-138 WR-08144
BRAKES
DISC BRAKE PAD

REMOVAL Inspection
with safety stands. Remove the rear wheel.
2. Inspect the pad thickness through the inspection hole
provided in the disc brake caliper.
Specified Thickness: 9 mm (0.35 inch)
I -.. I
Fia. 8-139 WR-08145

3. Remove the parking cable guide.
4. Detach the anti-rattle spring.
5. Remove the screw plug.

6. Turn the adjusting gear counterclockwise as far as it will
go, using a hexagon wrench key, so that the piston may
be retracted.
NOTE:
It should be noted that the adjusting gear can not be
removed.
7. Remove the hexagon socket head cap bolts (2 pieces),

using a hexagon wrench key.
I I
Fig. 8142 WR-08148
8. Remove the disc brake pad. 1
I I
Fig. 8-143 WR-08149

BRAKES
INSTALLATION
1. Disc brake pad installation
(1) lnstall the inner disc brake pad to the disc brake
caliper.
(2) lnstall the outer disc brake pad to the disc brake
cylinder mounting.
NOTE:
Be careful not to allow oil, grease and other dirt to get to
the friction surfaces of the pad and brake disc.
Disc brake caliper assembly installation

(1) Tighten the hexagon socket head cap bolt, using a
hexagon wrench key. Assemble the disc brake caliper
assembly.
Turn the adjusting gear clockwise, using a hexagon

wrench key, until the disc brake pad is pressed against
the brake disc. Then, back off the adjusting gear about Plug
180 degrees counterclockwise.
lnstall the gasket and screw plug. Back off
180"
Gasket
I I
Fig. 8-146 wR-08152

lnstall the parking cable guide. 1
Depress the brake pedal about 40 times. (This operation

makes it possible to adjust the clearance between the
disc brake pad and the rear brake disc.)
Adjust the working travel of the parking brake lever. (See
Fig. 8-181 .)
lnstall the rear wheel. Jack down the vehicle.
WR-08154
BRAKES
DISC BRAKE REAR CYLINDER

REMOVAL
with safety stands. Remove the rear wheel.
2. Disconnect the brake hose from the disc brake rear
cylinder.
3. Detach the clip and torsion spring.
4. Parking brake cable removal

(1) Remove the parking brake cable guide.
(2) Remove the cable support bracket.
(3) Remove the parking brake cable from the disc brake
cylinder.
I I I
Fig. 8-149 wR-08156
1
5. Remove the anti-rattle spring.
6. Remove the hexagon socket head cap bolts (2 pieces),
using a hexagon wrench key.
7. Remove the disc brake rear cylinder from the vehicle.

Remove the disc brake pad.
DISASSEMBLY
1. Remove the set ring and cylinder boot from the disc brake
rear cylinder.
1
Fig. 8-152
. wR-08159
I
BRAKES
2. Disc brake piston assembly removal
(1) Remove the screw plug and gasket.
(2) Turn the adjusting gear clockwise, using a hexagon
wrench key, so that the adjusting screw may be
disengaged from the piston assembly. (Turn the ad-
justing gear, until it can be turned lightly.)
(3) With a wooden piece or a cloth placed at the end of
the disc brake cylinder, drive out the piston, using
compressed air.
NOTE:
I I I
During this operation, care must be exercised as to the Fig. E l 5 3 WR-08160
1
piston being jumped out from position.
3. Remove the piston seal.
4. Pad adjusting bolt removal

(1) Detach the hole snap ring, using the SST.
SST: 09905-87701-000
(2) Take out the pad adjusting bolt from the disc brake
cylinder. Remove the "0" ring from the pad adjusting
bolt.
Ir
I 'L
Disc byke cylinder
ring
"0"
r---
Hole snap ring

I'
Fig. E l 5 5
I
WR-08162
1
5. Remove the parking brake strut, parking brake clamp Parking brake
subassembly and oil seal from the disc brake cylinder. clamp SIA
Parking brake strut
Fig. 8156 WR-08163

BRAKES
6. Remove the bush dust boot and cylinder slide bush from
the disc brake cylinder. ~ g ~ r - - ,
I
I'
I I
Fig. 8-1 57 WR-08164
INSPECTION
Replace with new one.
Cylinder bore for uneven wear
Fig. 8-158 WR-08165
2. Pad thickness measurement

Fig. 8-159 wR-08166

3. Brake rear disc thickness check
Fig. 8160 WR-08167

BRAKES
4. Checking of brake rear disc for runout

(1) Before the brake rear disc is checked for runout,
ensure that the rear axle bearing exhibits no excessive
looseness.
(2) Measure the runout of the brake rear disc at the outer
edge surface.
5. Brake rear disc replacement

(1) Remove the disc brake cylinder mounting, grease
retainer cap, cotter pin, castle nut and brake rear disc.
(2) Check the brake dust cover for defects, such as
damage, cracks and deformation. Replace the brake
dust cover which exhibits any defect.
I
Fig. 8-162 WR-08169
(3) Install the outer bearing, outer retainer and inner I I I
bearing to the brake rear disc, using the following
SSTs.
(Outer bearing)
SST: 09608-12010-000 (N0.13)
(Inner bearing)
SST: 09608-12010-000 (No.5)
I I I
Fig. 8-163 WR-08170
1
(4) Apply chassis grease to the points indicated in the Pack arease. (15 a) I
right figure.
, .-, . -
L
Inside of bearing pack grease. I
I
Fig. 8-164 WR-08171

(5) Install the bearing inner retainer, brake rear disc, plate
(6) Install a new cotter pin. Attach the grease retainer cap.
(7) Install the disc brake cylinder mounting.
Plate washer i
Grease cap
I
I I
Fig. 8-165 WR-08172
BRAKES
9SSEMBLY
1. Apply rubber grease to the points indicated in the figure below.
Strut
Inside of boot
Push rod contacting section

\
Needle bearing section

Rubber grease applying point
Fig. 8-1 66 WR-08173
Install the oil seal, parking brake clamp subassembly and

parking brake stopper to the disc brake cylinder.
Parking brake
strut
L J
Fia. 8-167 WR-081.74
Pad adjusting bolt installation
(1) Install the "0"ring to the pad adjusting bolt. Assemble
the pad adjusting bolt to the disc brake cylinder.
(2) Attach the hole snap ring, using the following SST.
SST: 09905-87701-000
L
Fia.
" 8-168
- --
Installation of disc brake piston assembly
(1) Install the piston seal in the disc brake cylinder.
(2) Insert the piston into the caliper. With the piston
pushed lightly, turn the adjusting gear counterclock-
wise as far as it will go, using a hexagon wrench key.
Then, pull back the piston, until it is no longer possible
to turn the adjusting gear.
Fig. 8-169 WR-08 176

BRAKES
-
-
5. Install the cylinder boot and set ring to the disc brake
cylinder.
6. lnstall the bush dust boot and cylinder slide bush to the
disc brake cylinder.
INSTALLATION
1. Disc brake cylinder installation
(1) lnstall the disc brake cylinder to the disc brake
cylinder mounting, using a hexagon wrench key.
2. Parking brake cable installation

(1) Attach the tip end of the parking brake cable to the
parking brake clamp subassembly.
(2) lnstall the cable support bracket.
3. lnstall the parking brake guide.
4. lnstall the following parts to the disc brake cylinder

(1) lnstall the torsion spring and clip.
(2) Connect the brake hose.
(Use a new gasket.)
Fig. 8-174 WR-08181

G100-G102-Chassis-Manual #2

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AUTOMATIC TRANSMISSION

15. Installation of the 2nd brake piston

(6) Insert the piston cover into the transmission case.

Fig. 4-162 WR-04205

(3) Check to see if the shaft rotates smoothly.

17. Installation of the accumulator piston

(2) Insert the spring into the piston.

Fig. 4-167 wR-04209

(4) Install the throttle cable to the throttle cam.

(5) Tighten all bolts.

(6) Install the oil tubes.

NOTE3: Fig. 4-170 WR-04212

(7) Connect the solenoid connector.

19. Installation of the oil pan

Installation of the oil filler tube

(2) Secure the oil filler tube by means of the bolt.

21. lnstallation of the test plug at the detecting hole

?3. Installation of the torque converter Torque

Control cable components

ASSEMBLING POSITION AND DIRECTION OF THRUST BEARING

@ Bearing 30 (1.18) 45 (1.77) -

@ Race 27.1 (1.07) 42 (1.65) lnner diameter flange

Throttle valve cam - lnner diameter 14 (0.55)

6 For forward clutch (18 pieces) -

C2piston, outer 117 (4.61) C1, B1 accumulators 23.47 (0.9240)

C1 piston, inner 46.52 (1.831) Filler tube 9.6 (0.38)

C1 piston, outer 117 (4.61) Speedometer 19.7 (0.776)

LIST OF BOLTS USED (I)

1 /1Num- Stand- Tightening Nominal

Housing x case 1 1 M8 1 1.6-2.3 (12- 16) / 35 B, WNV

Solenoid x lower valve body 2 M6 0.64 - 0.96 (4.6 - 6.9) 10 B, WNV

LIST OF BOLTS USED (11)

Filler tube x case 1 M8 0.3 - 0.7 (2.4 - 5.6) 20 B, WNV

FRONT AXLE...................................................5- 2 DRIVE SHAFT ................................................... 5-22

@ Disc brake caliper Ay

Fig. 5-2 WR-05003

3. Disc brake caliper removal

4. Remove the disc rotor.

5. Front axle hub removal

6. Tie rod end separation

9. Steering knuckle removal

Fig. 5-12 WR-05013

(3) Detach the snap ring, using snap ring pliers.

Disc surface for damage

1. Disc brake cover replacement

2. Steering knuckle installation

(2) Mount the steering knuckle on the lower ball joint.

Fig. 5-24 WR-05025

Fig. 5-25 WR-05026

5. Tightening of castle nut using the following SST.

(2) Install the front wheel adjust~nglock cap and a new

Fig. 5-26 wR-05027

(2) Install a new cotter pin.

7 . Install the wheel.

FRONT SHOCK ABSORBER

6J Bearing dust cover @ Front spring upper seat

Fig. 5-29 WR-05031

3. Flexible hose removal

4. Shock absorber removal